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2002 Subaru STI Factory Service Manual - Suba-Ghia

Contents

1. 11213 12 11213 8 9 1213 41516 11213 4 5 6 314 71819 10112 13114 7 8 9 01111211314 8134 BLACK 1 2 3 4 5 6 7 8 9 11213415 617 TEESE a ee 1121314 516 7 8 19 1121 1314151617 8 9 10 11 12113 1415 40 17 1213 14 15 16 17 18 10 11 1213114115 16 1617 181191202122 1920121 22 23 24 17118119 20 21 2223 24 11 GREEN 6137 112 314 1516171 818 1101112 1121 3 1 7 118 19 15 1611718 119120121122123124 25 26 27 2829 30 101112 1314 1516 1718 19120 21 2223 24125 26 27 28129130 13132 2223 24 25 26 27 28 29 30 si GR10 26B WI 65 ENGINE ELECTRICAL SYSTEM WIRING SYSTEM TO POWER SUPPLY ROUTING ST IGNITION SWITCH ST AT MODEL WR MT MODEL WB TA 01 A wey WR 11 G2 MAIN RELAY bam mg gd mmm bam mg OE STARTER MOTOR REF TO GND 07 oj B B
2. NOTE ae Perform the following procedures when m 41 rh Replacing the main shaft Be PS Replacing the 3rd to 6th drive gear and bush Replacing the 3rd to synchro ring assembly pa port E 1 Insert the main shaft assembly in adapter plate 5 ELI 2 Set the height gauge to adapter plate Lower the nii H indicator of height gauge to upper surface of snap pog E ring groove or the upper side of main rear bearing d nmi Then set to zero point P 18853AA000 HEIGHT GAUGE ALI gd pill i mi Hn Pie H 15 i Ke UL li ac 1 1 TRO867 TRO862 A 5th main gear A Ball bearing B 6th main gear 6MT 127 SHIFTER FORK AND ROD MANUAL TRANSMISSION AND DIFFERENTIAL 1 Shift the 5th 6th sleeve to 6th main gear side then press down to the stopper and mea sure D2 TRO868 A 6th main gear NOTE e Set the indicator of height gauge near measuring object then lock the dial 1 as shown in the figure Turn dial 2 to set the indicator to edge surface of sleeve side Perform the measuring procedure with two peo ple and measure the sleeve
3. q fl q I 1121345 67 172 31141151617 1123 4 56 71819 8 91 10 11 12 13 14 15 8911011 12 13 1415 116 1011 112 13 14 15 1617 18 19 1617 18 19 20 21 22 17 18 19 20 21 22 23 24 2012122 23 24 25 2612728 GR10 26A WI 64 ENGINE ELECTRICAL SYSTEM WIRING SYSTEM TO POWER SUPPLY ROUTING FB 17 F B FUSE NO 18 6 FB 36 F B FUSE NO 13 F2 9 GD aw SPEEDO 8 05 SC 2 TRANSMISSION CONTROL OIL PRESSURE WARNING LIGHT TEMPERATURE MALFUNCTION MODULE AT VEHICLE SPEED 7 SENSOR 2 01 9 Q E c RTB 05 sr STi TURBO ENGINE MODEL RTB NT NORMAL TURBO HEE 08 ENGINE MODEL BLACK ST BLACK A 110 GREEN c i12 GREEN n 4151617
4. Ess BLACK 11213 11516 112 3 4 EE STATS 617 51314516 778751 T 7 8 9110 11 12 5 67 8 9 10 11 12 13 14 15 16 10 11 12 13 14 15116 17 18 19 13 44 15 bein 91 17 18 19 20 21 22 23 24 20 21 22 23 24 25 26 27 28 c13 45 6 1718 19 20 GL10 26H WI 60 ENGINE ELECTRICAL SYSTEM WIRING SYSTEM 613 E ENGINE CONTROL MODULE E 5 9 p STi TURBO E G LTB 06 ENGINE MODEL NORMAL TURBO 02 ENGINE MODEL 5 17 m DD SE E pam Eq BI AVCS SOLENOID AVCS SOLENOID ENGINE COOLANT THROTTLE PRESSURE TGV ANGLE TGV ANGLE VALVE LH VALVE RH TEMPERATURE POSITION SENSOR SENSOR LH SENSOR RH STi TURBO STi TURBO SENSOR AND SENSOR NORMALTURBO NORMAL TURBO MODEL MODEL THERMOMETER MODEL MODEL Ces tueur GRAY E13 E fer BLack B 8135 BLUE Lad 112 112131415
5. 20A SUB SUB SWITCH SUB FAN tl F FAN FAN FAN 20A RELAY 2 RELAY 1 RELAY 2 RELAY 1 No 9 H L SBF 7 SBF Horn 8 SBF SBF 1 No 6 relay No 5 8 elay 5 6 No 4 RH 7 No 3 SBF 1 SBF 2 SBF 3 SBF 4 9 ed FUSE amp RELAY BOX F B 6 12 19 No 5 11 18 4 10 17 3 9 16 2 8 15 1 7 14 13 WI 11 WIRING SYSTEM P SUP R 01 GR01 21A POWER SUPPLY ROUTING WIRING SYSTEM BATTERY CURRENT BATTERY CURRENT FROM IGNITION SWITCH IG TERMINAL OTHER CURRENTS CURRENT FROM IGNITION SWITCH ACC TERMINAL MAIN FUSE BOX M B SBF 1 80A GENERATOR No 9 15A SBF HOLDER Ea C Q p sup r 05 a5 BLACK 26 GREEN BLACK 9 BLACK 11213 2 1 1121314 1121314 5678 2 alls 5161718 9 1011 12 13 14 15 16 17 18 01 218 WI 12 POWER SUPPLY ROUTING WIRING SYSTEM MAIN
6. _ 2_ REF TO GND 07 A 10 GREEN Git eracw R85 B99 RAD 1121814 namsmrenT5m 1 2 3 41516 1 2 3 4 6 7 8 9 0 516 7 8 7 8 9 0 1 12 13 14 1112 1311415 6 17 18192021 22 BLACK B 17 GREEN 1123456 71819 1011 12 3 4 516 17 8 9 10 2 13 114 12 13 14 1516 17 18 1920 21 22123 24 15 16 17118 19 20 21 22 23 24 25 26 27 28 29 30 WI 110 GG88 21
7. q D TEL fle aol zo s o 1213118161 Ies 8910112 13 14 15 116 10 11 112 13 14 15 16 17 18 19 17 18 19 20 21 2223124 2012122 23124252627 28 GL10 26A WI 53 ENGINE ELECTRICAL SYSTEM WIRING SYSTEM TO POWER SUPPLY ROUTING FB 36 FB 17 F B FUSE NO 13 F B FUSE NO 18 IG IG SPEEDO TACHO METER METER D E G LTB 05 COMBINATION METER TEMPERATURE OIL PRESSURE MALFUNCTION VEHICLE SPEED SENSOR fey 1 881 2 01 bel el E G LTB 05 E G LTB 09 ST STi TURBO 6 ENGINE MODEL NT NORMAL TURBO HERES ENGINE MODEL Sie 7 81 9110 11 12 13 14 8910112 18 14 15 8910011 12 13 14 15 116 16 17 18 19 20 21 22 17 18 19 20 21 22 23 24 BLACK 7 D
8. n 12 3 2 8294 213 112 314 1231416 1127374 1516 17 8 9 4516 314 5 11275 5 6 7 8 31415 6 ers enam H 11213 41516 5 6 7 8 111213 5116 7 7 8 9 10 11 12 13 14 1 2 3 415 6 7 8 Datt 12 8119 12 13146 9 10 11 12 13 14 15 16 17 11 2 6283 22 31 4 9 1415 16 19 24 2526 29 34 35 36 56 10 17 20 27 30 37 11112 13 18 21 22 23 28 31 32 33 38 112 314 5 67 8 9 10 12 s 4 8161718179 7118 1 2 3 415 6 7 8 9 1112 33 14 15 1637 1819120 1011 1211314 15 1617 1819 20 21 10 11 12 13 14115 16 17 18 22123 24 25 26 27 28 29 30 31 32 RELAY BLOCK BLACK GG04 22G WI 25 GROUND DISTRIBUTION WIRING SYSTEM REARVIEW MIRROR PASSENGER SIDE FUEL PUMP ASSEMBLY 4 1 SEAT BELT SWITCH REAR DOOR SWITCH LH 3 B FUEL PUMP CONTROLLER REAR DOOR SWITCH RH M
9. o 8 us 5 we 25 837 D gt lt D st 22 A i10 GREEN Cit Graco Cis CR c i12 GREEN 112131415 61718190 1 2 314 112134 11 12 13 14 15 16 17 18 19 20 21 22 5161718 1 2 3 41516 71819 1011112 1314 7 1 2 3 4 56 7189 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 3132 4 5 6 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 GR21 27A WI 84 CLEARANCE LIGHT AND ILLUMINATION LIGHT SYSTEM WIRING SYSTEM TO POWER SUPPLY ROUTING FB 36 F B FUSE NO 13 02 02 ILM RWI ILM RWI HAZARD SWITCH ILLUMI LIGHT 5 ____ 7 2 DIMMER DIMMERCIRCUT CIRCUIT aims DRIVER S 96 29999009S 4 INDICATOR LIGHT POWER MODE INDICATOR LIGHT HOLD MODE INDICATOR LIGHT OUT TEMP LCD BACK LIGHT ODO TRIP LCD BACK LIGHT 9 CYL B lo ect d n a
10. MECHANICAL Belt ten sion Protrusion of adjuster rod 5 2 6 2 mm 0 205 0 244 in adjuster Spacer O D 17 955 17 975 mm 0 7069 0 7077 in Tensioner bush I D 18 0 18 08 mm 0 7087 0 7118 in Belt ten STD 0 025 0 125 mm 0 0010 0 0049 in Clearance between spacer and bush sioner Limit 0 175 mm 0 0069 in STD 0 2 0 55 mm 0 0079 0 0217 in Side clearance of spacer Limit 0 81 mm 0 0319 in Bend limit 0 020 mm 0 0079 in STD 0 015 0 070 mm 0 0006 0 0028 in Thrust clearance Een Limit 0 10 mm 0 0039 Intake STD 45 25 45 35 mm 1 781 1 785 in Limit 45 15 mm 1 778 in Cam lobe height STD 45 60 45 70 mm 1 795 1 799 in Camshaft Exhaust Limit 45 50 mm 1 791 in Front 37 946 37 963 mm 1 4939 1 4946 in Journal O D STD 29 946 29 963 1 1790 1 1796 STD 0 037 0 072 mm 0 0015 0 0028 in Oil clearance HE Limit 0 10 mm 0 0039 in Surface warpage limit 0 05 mm 0 0020 in Cylinder head Surface grinding limit 0 1 mm 0 004 in Standard height 127 5 mm 5 02 in Refacing angle 90 STD 1 0 mm 0 039 in Intake m Valve seat Limit 1 7 mm 0 067 in Contacting width STD 1 5 mm 0 059 in Exhaust LAT i Limit 2 2 mm 0 087 in Inner diameter 6 000 6 012 mm 0 2362 0 2367 in Valve guide gt Protrusion above head 12 0
11. 211 1 314 4 3 296 q 1121314 5 6 112 3141516 7 1 2 3 45 6 71819 1112 311415 16117 18 9 71819 1011112 819 101 12 18 14 15 16 101112 18 1415 1617 18 19 10 1112 18 14 15 16 17 1819120 121 1311415 16 17 17 18 19 20 21 22 23 24 202122 23 24 25 26 27 28 22 23 24 25 26 27 28 29 30 31 GR10 26F WI 69 ENGINE ELECTRICAL SYSTEM WIRING SYSTEM l 5 a d 2 2 5 2 9 STi TURBO ENGINE MODEL KNOCK SENSOR CAMSHAFT POSITION SENSOR CRANKSHAFT POSITION SENSOR AVCS CAMSHAFT 112 3 415 6 POSITION SENSOR AVCS CAMSHAFT POSITION SENSOR LH STi TURBO MODEL STi TURBO MODEL LIGHT GRAY G20 LIGHT GRAY 9 8 7 23 24 25 26 27 28 1 2 3 4 5 6 10 11 12 13 14 15 16 17 18 19 20121122 16117 71819 1011112 1311415 314 2 1 GR10 26G WI 70 ENGINE ELECTRICAL SYSTEM WI
12. GL01 21D WI 7 POWER SUPPLY ROUTING WIRING SYSTEM AAE Cw T 2 w a E n HE AEK 1 P SUP L 03 AAH REF TO GND 02 sr G BLACK 872 BLUE 5 gt BLUE 21 8 BROWN E GRAY gt 4 ES GRAY 1 1 11 2 118 415 2 415 167 8 5 1 7 9 6 7 oho 314 14 5 6 7 6271 BLUE D D 15 1121314 5 6789 101 172 11213 415 12 1314 15 1617 1819202122 23 24 314 91 1415 16 19 124125126 29 34135136 6 7 8 9 10111112 516 10 17 20 27 30 37 11 12 13 18 21 22 23 28 3113233 38 7 8 RELAY HOLDER BLACK GLO01 21E WI 8 POWER SUPPLY ROUTING Load Air conditioning relay holder Combination meter Headlight RH Headlight LH Horn Cruise control sub switch Horn switch Hazard switch Key warning switch Transmission control module Diode With rear fog light model Lighting switch
13. WI 42 ANTI LOCK BRAKE SYSTEM WIRING SYSTEM TO POWER SUPPLY ROUTING STi MODEL EXCEPT STi MODEL CHECK CONNECTOR MEON 7 Brw 9 B B55 CB TRANSMISSION CONTROL MODULE DIAGNOSIS DIAGNOSIS CONNECTOR CONNECTOR GND 07 TM ONNECTOR EONA 5 REF TO GND 07 ee E SS ER d L AN ABS CONTROL MODULE BLACK GRAY BLACK 622 BROWN OJN Co 1 2 3141516 1 3 4 5 67 1211915181718 oj m Ao al BLACK B GRAY BLACK e 5 5 16117 ei TAS 5 EE 1011 12 13 14115 16 17 18 27128129130131 23 24 25 26 19 20 21 22 23 24 GR82 22B WI 43 ANTI LOCK BRAKE SYSTEM WIRING SYSTEM a 5 o z 2 o o o Ed lt SHIELD JOINT CONNECTOR 65 ol gt D
14. 4 Vehicle Speed E beoe 5 Transmission Mounting 6 Manual Transmission Assembly 7 Preparation for Overhaul neret fused nnns 8 Air Breather HOS gt e 10 Back up Light Switch cre Per Cer M Re er e 11 Neutral Position Switch rior ede Ped oa FER 12 Extension CASE orsi a A T p nd PER Van e 13 Reverse Checking 14 Transfer Drive Gear kom Lee nra ed De dE X a 15 Transfer Driven 16 Center Differential 17 OIl PUMP 18 Transmission Case D PRESE 195 Assembly s cones pereo rr a Suez a RE Ee as desees 20 Driven Gear 21 Reverse Idler Gear Assembly 22 Drive Pinion Shaft 2 4 44 23 Front Differential 12444411211 24 Speedometer ro eres cra Oe een 25 Shifter Fork and Bog i eid o ber ra br aee 26 HOUSING as
15. 4 93 0 1941 5 18 0 2039 ME STi 31 13228 6 Inspect all valves for clearance again at this stage If the valve clearance is not correct repeat the procedure over again from the first step 7 After inspection install the related parts in the reverse order of removal 5 65 0 2224 ENGINE ASSEMBLY MECHANICAL 9 Engine Assembly A REMOVAL 1 Set the vehicle on lift arms 2 Open the front hood fully and support with stay 3 Raise the rear seat and turn floor mat up 4 Release the fuel pressure 1 Disconnect the fuel pump relay connector 2 Start the engine and run until it stalls 3 After the engine stalls crank it for five sec onds more 4 Turn the ignition switch to OFF 5 Remove the filler cap 6 Disconnect the battery ground terminal G6M0095 7 Remove the radiator from vehicle Ref to CO 39 REMOVAL Radiator 8 Remove the coolant filler tank Ref to CO 53 REMOVAL Coolant Filler Tank 9 Collect the refrigerant and remove the pressure hoses 1 Place and connect the attachment hose to the refrigerant recycle system 2 Collect the refrigerant from A C system 3 Disconnect
16. ERR EUER E 5 Master Cylinder Clutch Pipe and Hose Clutch Fluid Clutch Fluid Air Bleeding Clutch Pedal Clutch Cable Clutch Switch General Diagnostic Table SEL Our sech sesch 5 STEM GENERAL DESCRIPTION 1 General Description A SPECIFICATIONS Model 1 6L 2 0 L NON TURBO 2 0 L TURBO 2 51 Push type Pull type Push type Diaphragm set load kgf Ib 450 992 830 1 830 550 1 213 Clutch disc Facing material Woven Non asbestos x x thickness mm in 225 x 150 x 3 5 8 86 x 5 91 x 0 138 230 x 150 x 3 5 9 06 x 5 91 x 0 138 228 6 x 155 x 6 6 9 00 x 6 10 x 0 260 Spline O D mm in 25 2 0 992 No of teeth 24 Clutch release lever ratio 1 6 1 7 1 6 Release bearing Grease packed self aligning Clutch pedal Full stroke mm in 130 135 5 12 5 31 mm 10 20 0 39 0 79 3 13 0 12 0 51 10 12 0 39 0 79 Clutch disc Model Stroke mm in 24 26 0 94 1 02 13 3 14 7 0 524 0 579 24 26 0 94 1 02 Play at release lever center mm in 8 4 0 12 0 16 3 4 0 12 0 16 Depth of rivet head mm in S
17. mm mm BLOWER MOTOR BR 1 ENGINE E CONTROL A 6133 MODULE B87 TURBO p 6137 ENGINE MODEL PRESSURE SWITCH 2 BrY 1 BY 2 FAN a 6134 CONTROL RL 1 8275 CONTROL 6135 MODULE NON TURBO B 4 ENGINE C GES MODEL gt f MAGNET CLUTCH AUTO A C A B282 B B283 CONTROL MODULE REF TO GND 03 COMPRESSOR E24 GRAY A 6282 GRAY 6283 GRAY n 5 1 112 11213 i 2 1 2 12 314 5 6 7 8 12 314 5 6 7 8 9 10 2 34 314 9 to 11 1213114 1516 11 1213114 15 16 1718 1920 11213 4151617 1123 415 1617 aeger shake e T 8 9 1011112 13 14 15 16 17 18 19 8 9 to t1 t2 13 14 15 16 17 19 20 819202122 2021 22123 24 25 26 27 28 21 22 03 24 25 26 27 28 29130 2 1 2 3 4 56 78 56 9 1314 17 2122 25 1112 hol asl Hal 26 AIST Siess 171819 9 1011 12 1311415 1611718 19120121122123 10 1112 1516 17118119120 21 3114 8 1112 16 19120 24 127128 30 252312425 26 27 28 29130131 24 25 26272829 30 31 32 33 34 35 RELAY HOLDER BLACK GL46 22A WI 30 AIR CONDITIONING SYSTEM WIRING SYSTEM VEHICLE SPEED TO POWER SUPPLY ROUTING SENSOR MT 856 8 9 27 17 TRANSMISSION M B FUSE NO 2 F B FUSE NO 2 F B FUSE NO 9 F B FUSE 18 CONTROL B
18. fl q fl q 1 2 3 4 5 6 7 1121314 5 6 71819 1112 3114151617 118 9 8 9 1011 12 13 14 15 101 112 18 14 15 16 17 18 19 1011 112 13 14 15 116 17118192021 1617 18 19 20 21 22 2012122 2324 25 2627 28 2223 242526 27 28 2913031 GL10 26D WI 56 ENGINE ELECTRICAL SYSTEM WIRING SYSTEM ENGINE CONTROL MODULE KAURA 5 8 S NEUTRAL POSITION SWITCH 03 1 IN UN 02 3 CERTAN E G LTB 02 8 IN 0 TEST MODE CONNECTOR m E 5 d gt E E 8 8 8 Gu E Ge 9 REF TO GND 02 CHECK CONNECTOR LINE END CONNECTOR LINE END CHECK DATA LINK CONNECTOR CONNECTOR GREEN 8128 8300 B79 GRAY GRAY 1 112 JAE id 5 2 3 4 4 5 6 11213 415 6 7 2 1121314 5 6 7 8 8 9 10411121 13146 9 10 11 12 1311415 116 n 1 2 3 4 5 67 8 9 10 11 12 13 14 15 1e iz 18 19 20 21122 GL10 26E WI 57 ENGINE ELECTRICAL SYSTEM WIRING SYSTEM 6135 136 6137 ENGINE CONTROL MODULE 81808 A 8688 T SHIELD
19. Fuel tank Q US gal Imp gal Engine Total Q US qt oil capacity Imp qt Engine 2 US qt oil Imp qt amount for refill Transmission US qt 3 5 gear oil Imp qt 3 7 3 1 4 0 4 2 3 5 1 Automatic trans 8 4 9 3 mission fluid 8 9 7 4 9 8 8 2 AT differential 1 2 1 2 gear oil 1 3 1 1 1 3 1 1 AWD rear differ ential gear oil Power steering fluid Engine coolant 50 13 2 11 0 50 13 2 11 0 60 15 9 13 2 4 0 4 2 3 5 4 5 4 8 4 0 4 0 4 2 3 5 Approx Approx 4 0 4 2 3 5 4 5 4 8 4 0 4 0 4 2 3 5 3 5 3 5 3 7 3 1 3 7 3 1 0 8 0 8 0 7 0 7 0 7 0 6 1 Dual range SPC 5 SPECIFICATIONS J WEIGHT 1 LHD VEHICLE Sedan Option code 1 IMPREZA Model Curb weight C W Front kgf Ib Rear kgf Ib Total kgf Ib Maximum permissible axle weight M P A W Front kgf Ib Rear kgf Ib Maximum permissible weight M P W Total kgf Ib Option Option codex1 Air conditioner Cruise control ABS Aluminium wheel Rear spoiler Spoiler pac Model Curb weight C W Front kgf Ib Rear kgf Ib Total kgf Ib Maximum permissible axle weight M P A W Front kgf Ib Rear kgf Ib Maximum permissible weigh
20. REF TO FOG L 01 R FOG L 01 NON TURBO ENGINE MODEL POWER amp HOLD MODE SWITCH ILLUMI LIGHT 6133 BOX ILLUMI LIGHT HEADLIGHT LEVELING OS TURBO ENGINE MODEL SWITCH ILLUMI LIGHT STi MODEL STi MODEL STi MODEL ete E E Cv _ 2 E ES EXCEPT STi MODEL 8299 REF TO GND 01 02 REF TO GND 02 SE e em e 112 112 DE 1 4 B160 GRAY 112 314 11213 1415 6 314 ala PER 5 6 7 8 9 10 7 8 9 121314 294 1 2 3 415 6 6283 GRAY A 134 c 6136 n 11213 415 6 7 1 2 3 4 5 6 7 8 524567188 8910 1112 13 14 15 16 17 1819 20 9 11112113 1415 16 17 21 22 23 24 25 26 27 28 29 30 GL21 24A WI 78 CLEARANCE LIGHT AND ILLUMINATION LIGHT SYSTEM WIRING SYSTEM TO POWER SUPPLY ROUTING FB 36 F B FUSE NO 13 IG HAZARD SWITCH ILLUMI LIGHT CEN Cen CIRCUIT DIMMERCIRCUT
21. GG04 221 WI 27 GROUND DISTRIBUTION WIRING SYSTEM REAR GATE LATCH SWITCH REAR DEFOGGER HIGH MOUNTED STOP LIGHT REAR SPOILER 2 HIGH MOUNTED STOP LIGHT REAR WIPER MOTOR 196 9 2 50 9 oia AJN GG04 22J WI 28 AIR CONDITIONING SYSTEM WIRING SYSTEM 7 Air Conditioning System A SCHEMATIC WI 29 AIR CONDITIONING SYSTEM WIRING SYSTEM 1 AUTO A C LHD MODEL T T TO POWER SUPPLY ROUTING 19 20 34 5 F B FUSE NO 17 F B FUSE NO 17 F B FUSE 1 5 lt IG F B FUSE NO 2 B lt lt TURBO ENGINE MODEL A NON TURBO ENGINE MODEL BLOWER MOTOR AIR CONDITIONING RELAY
22. S2M1230B ME STi 50 TIMING BELT ASSEMBLY MECHANICAL 6 Ensure the camshaft and crankshaft sprock ets are positioned properly CAUTION Intake and exhaust camshafts for this DOHC engine can be independently rotated with tim ing belts removed As can be seen from the fig ure if intake and exhaust valves are lifted simultaneously their heads will interfere with each other resulting in bent valves A Intake camshaft B Exhaust camshaft When the timing belts are not installed four camshafts are held at the zero lift position where all cams on camshafts do not push in take and exhaust valves down Under this con dition all valves remain unlifted When the camshafts are rotated to install tim ing belts 2 intake and 4 exhaust cam of left hand camshafts are held to push their corre sponding valves down Under this condition these valves are held lifted Right side cam shafts are held so that their cams do not push valves down Left hand camshafts must be rotated from the zero lift position to the position where timing belt is to be installed at as small an angle as possible in order to prevent mutual interfer ence of intake and exhaust valve heads Do not allow the camshafts to rotate in the di rection shown in the figure as this causes both intake and exhaust valves to lift simultaneous ly
23. 108 Rear Wiring Harness and Rear Gate Cord Intercooler Water Spray 110 WI 2 POWER SUPPLY ROUTING WIRING SYSTEM 4 Power Supply Routing A SCHEMATIC WI 3 WIRING SYSTEM 1 LHD MODEL P SUP L 01 POWER SUPPLY ROUTING MAIN FUSE BOX M B MAIN FAN ee re 20A SUB AC SUB MAIN MAIN sem SWITCH SUB FAN m RELAY FAN FAN FAN 20A RELAY 2 RELAY 1 RELAY 2 RELAY 1 No 9 0 SBF 7 SBF Horn 8 SBF SBF No 1 6 rela No 5 8 elay y RH 5 6 4 No 7 No 3 H L No 2 relay SBF 1 SBF 2 SBF 3 5 4 LH 2 FUSE amp RELAY BOX F B 13 14 No 7 1 15 8 No 2 16 9 17 10 4 18 11 No 5 19 12 6 L WI 4 P SUP L 01 GL01 21A POWER SUPPLY ROUTING WIRING SYSTEM BATTERY CURRENT BATTERY CURRENT FROM IGNITION SWITCH IG TERMINAL OTHER CU
24. Ud E amp B COMBINATION METER 4 ILLUMINATION LIGHT INDICATOR LIGHT Leg POWER MODE INDICATOR LIGHT HOLD MODE INDICATOR MAA OUT TEMP BACK LIGHT ODO TRIP LCD BACK LIGHT REF TO D R L 01 REF TO AT L 02 REF AT L 01 9 B 0 GREEN BLACK I 213 41516 1121314 5 6 78 9 10 11 9 10 11 12 13 14 12 13 14 15 16 17 18 19 20 21 22 23 24 A D 4 11213 1415 67 89 10 1 2 3 4 5 6 7 XX e 9 10 12 1314 2345 67 8 1e 18 ALS 16 1718 19 20 2122 2324 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 GL21 24B WI 79 CLEARANCE LIGHT AND ILLUMINATION LIGHT SYSTEM WIRING SYSTEM FRONT CLEARANCE LIGHT LH FRONT CLEARANCE LIGHT RH REAR COMBINATION LIGHT LH SEDAN REAR COMBINATION LIGHT RH SEDAN BLACK 21 TO POWER SUPPLY ROUTING FB 6 F B FUSE NO 5 FB 7 F B FUSE NO 5 TRAILER CONNECTOR LICENSE PLATE LIGHT Lik R
25. 8 9 20 21 5 6 7 8 9 10 18 19 20 21 22 5 16 17 lt 23 24 25 26 0157 Step Check Yes CHECK OUTPUT OF LATERAL SENSOR Is the lateral G sensor output Go to step 2 Go to step 5 USING SELECT MONITOR on monitor display between 2 3 1 Select Current data display amp Save on the and 2 7 V when lateral G sen select monitor sor is in horizontal position 2 Read the lateral G sensor output in select monitor data display ABS 20 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS Step Check Yes No CHECK POOR CONTACT IN CONNECTORS Is there poor contact in con nector between ABSCM amp H U and lateral G sensor Repair the con nector Go to step 3 CHECK ABSCM amp H U 1 Connect all connectors 2 Erase the memory 3 Perform the inspection mode 4 Read out the DTC Is the same DTC as in the cur rent diagnosis still being out put Replace the ABSCM amp H U lt Ref to ABS 4 ABS Control Mod ule and Hydraulic Control Unit ABSCM amp H U Go to step 4 CHECK ANY OTHER DIAGNOSTIC TROU BLE CODES DTCs APPEARANCE Are other DTCs being output Proceed with the diagnosis corre sponding to DTC A temporary poor contact CHECK INPUT VOLTAGE OF LATERAL G SENSOR 1 Turn the ignition switch to OFF 2
26. 20 Install the 6th baulk ring 24 Set the 6th bush to main shaft taking care not to overlap the 6th bush oil hole and main shaft oil hole A le TRO748 ager 21 Sufficiently apply gear to the main shaft 6th TRUM needle bearing and inner periphery of 6th drive gear A 6th bush oil hole 22 Install the 6th drive gear B Main shaft oil hole 25 Using the ST install the 6th bush 571 18651AA000 INSTALLER ST2 398177700 INSTALLER CAUTION Do not apply pressure in excess of 40 kN 4 0 ton 4 4 US ton 3 9 Imp ton TRO749 23 Install the 6th needle bearing d Leo TRO751 26 Make sure the 6th drive gear is smoothly turned by hand If not reassemble 27 Using the ST install the inner bearing inner TRO750 race 18651AA000 INSTALLER ST2 398177700 INSTALLER CAUTION Do not apply pressure in excess of 40 KN 4 0 ton 4 4 US ton 3 9 Imp ton TRO752 6MT 83 MAIN SHAFT ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 28 Using the ST install the retainer and outer bearing inner race 18651AA000 INSTALLER ST2 398177700 INSTALLER CAUTION Do not apply pressure in excess of 40 KN 4 0 ton 4 4 US ton 3 9 Imp ton NOTE Make sure to install the retainer in proper direc tion Press in until there is no backlash in retainer and where bearing is smoothly t
27. 3 5 5 5 5 3 8 5 3 8 e He oe REF TO GND 07 CHECK CONNECTOR LINE END CONNECTOR DATA LINK CONNECTOR LINE END CHECK CONNECTOR 875 GREEN B128 GRAY B300 GRAY BLACK A 134 T T T n 1 i 2 1213 1 2 3 4 5 6 7 8 1121345 67 2 314 SE D sf ah Se 9 10 11 12 1314115116 819 10111121314 15 1617 18 19 20 21 22 GR10 26E WI 68 ENGINE ELECTRICAL SYSTEM WIRING SYSTEM 6135 c 6136 6137 ENGINE CONTROL MODULE NTIS eT W B 8181016 850518 T SHIELD AND SENSOR GROUND JOINT CONNECTOR 1 mz 2 5 RW 4 3 B83 E G RTB 03 J es DW DM D E G RTB 09 1 03 K an em emm IN NN Ai dae 7 lt NORMAL TURBO ENGINE MODEL EJ S mi TH TELF WASTEGATE AIRFLOW EXHAUST GAS FRONT OXYGEN REAR OXYGEN SOLENOID SENSOR TEMPERATURE SENSOR A F SENSOR SENSOR NORMAL TURBO MODEL 12 213 4 YL 5 1 2 3 4 5 6
28. DR0033 16 Install the self lock nut Then tighten it with the ST ST 498427200 FRANGE WRENCH G3M1052 DI 26 REAR DIFFERENTIAL FOR DIFFERENTIALS 17 Install the crown gear on differential case NOTE Before installing the bolts apply Lock Tite to bolt threads Lock Tite THREE BOND 1324 or equivalent NOTE Tighten diagonally while tapping the bolt heads Tightening torque 105 N m 10 7 kgf m 77 4 ft lb 53 0509 18 Press fit the side bearing cone onto differential case with ST ST 398487700 DRIFT G3M0091 19 Assembling side retainer 1 Press fit the side bearing outer race with press and ST ST 398417700 DRIFT 050038 2 Install the seal lt Ref to 58 RE PLACEMENT Rear Differential Side Oil Seal gt 20 Adjusting 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 53 0533 3 Install the side retainer shims and O rings to the right and left retainers from which they were removed NOTE Replace the broken or cracked O ring with new one Replace the broken or corroded side retainer shim with a new one of same thickness Side bea
29. Wagon Turbo Wagon 2 0 L NA MT A B C D E F G H J L RH LH A B K ae 0 De CER lt gt NC 7 gt 7 G H 0 00 US E Y Sall gt 1 L1 04 0026 0 4 gt UJ EBJ82 DOJ82 Sedan RH EBJ82 DOJ82 Sedan LH BJ79 DOJ79 Sedan R160RH BJ79 DOJ79 Sedan R160LH GENERAL DESCRIPTION BJ79 DOJ79 Sedan R152R L BJ79 DOJ79 Wagon R152R L EBJ82 DOJ82 Wagon RH EBJ82 DOJ82 Wagon LH DS 5 DRIVE SHAFT SYSTEM BJ79 DOJ79 Wagon R160RH BJ79 DOJ79 Wagon R160LH Identification protrusion BJ87 DOJ87 R L GENERAL DESCRIPTION DRIVE SHAFT SYSTEM COMPONENT 1 PROPELLER SHAFT 080024 1 Propeller shaft Turbo model 3 Rear differential VA type Tightening torque N m kgf m ft Ib
30. 65 ER RE 73 Engine Trouble in Duk Te 92 Engine eld 97 GENERAL DESCRIPTION MECHANICAL 1 General Description A SPECIFICATIONS Type Horizontally opposed liquid cooled 4 cylinder 4 stroke gasoline engine Valve arrangement Belt driven double overhead camshaft 4 valve cylinder Bore x Stroke mm in 92 x 75 3 62 x 2 95 Piston displacement cm cu in 1 994 121 67 Compression ratio 8 0 Compression pressure at 200 300 rpm kPa psi 981 1 177 10 12 142 171 Number of piston rings Pressure ring 2 ring 1 Engine Opening Max retard ATDC 6 Min advance BTDC 29 Intake valve timing Closing Max retard ABDC 68 Min advance ABDC 33 Exhaust valve timing Opening 58 BBDC Closing 10 ATDC Intake Valve clearance 0 20 0 02 0 0079 0 0008 Exhaust 0 25 0 02 0 0098 0 0008 Idling speed At neutral position 700 50 No load 750 50 A C switch ON Firing order 13375254 Ignition timing BTDC rpm NOTE STD Standard Inner Diameter O D Outer Diameter 12 3 700 rpm OS Oversize US Undersize ME STi 2 GENERAL DESCRIPTION
31. ABS 27 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS AK DTC 73 ABNORMAL LATERAL SENSOR HIGH u OUTPUT DIAGNOSIS Faulty lateral G sensor output voltage TROUBLE SYMPTOM ABS does not operate WIRING DIAGRAM LHD MODEL ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT SHIELD JOINT CONNECTOR ST 7 n STi MODEL EXCEPT STi MODEL ABS G SENSOR JOINT CONNECTOR STi MODEL ABS LATERAL SENSOR GCSENSOB STi MODEL 3141516 1121314 Hepa 74 516171819 1 21 7 8 9 51678 Tekee 25 2 1 2 8 156 5 28 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS WIRING DIAGRAM RHD MODEL ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT SHIELD JOINT CONNECTOR lt 511 sti MODEL EXCEPT STi MODEL ABS G SENSOR JOINT CONNECTOR STi MODEL ABS LATERAL G SENSOR STi MODEL 5 16 17 11213141516 121318151 6 7 59 1213 517 5 6 7 8 pa uat 18 19 20 21 22 ie 7 18 19 20 21 22 26 Ex 1 21 3 0157 Step Check Yes CHECK OUTPUT OF LATERAL SENSOR Is the lateral G sensor output Go to step 2 Go to step 6 USING SELECT MON
32. 9NINHVM 1738 1V3S HOLIMS 1799 35 3 1ndOW Sav NOISSINSNVH L 1 116 Ld32X3 dIW3 L3IO LY TAGOW 116 1430 4 116 LUS SNINYVM AVHdS H31009H3 NI 7034405 NOISSIISNVH L 1 OW 115 13A31 AVHdS H31009H31NI HOLIMS YOlVYANAD Dri 2N HOLMS 13437 Zo LH9r1 5NINHVM 38nsS3ud VU 17 LHOTI 9NINHVM T3A31 AINT SNDIHVd 928 HOLIMS 9NDIHVd GG64 22B WI 46 WIRING SYSTEM COMBINATION METER LC 4 8 04 METER 04 DIMMER CIRCUIT ANE EN 0 90 DIMMER CIRCUIT gt O 9 HOLIMS YOLISIHNI 1H917 ONINYVM 9V8HIV 1OH1NOO 5vauiv E v 4 ien D A ie D 1 TVNOSIS NYNL HOLIMS TWNDIS X9 H7 YOLVOIGNI TVN9IS NYNL aoo gt HH AYAH WV38 IH eza gt HOLIMS METER 02 GG64 22C WI 47 COMBINATION METER WIRING SYSTEM BRIGHT SWITCH BATTERY Car AT MODEL EUROPE MODEL e Se Kia
33. TRO795 TRO792 A Needle bearin 7 Remove the outer baulk ring reverse synchro Ge S cone and inner baulk ring from reverse sleeve 9919 10 Remove the knock B C p e D bs e TRO935 A Reverse sleeve ET B Outer baulk ring 11 Remove the snap ring and friction plate from C Reverse synchro cone rEVErSS gear D Inner baulk ring 8 Remove the reverse idler gear No 2 TR0796 A Snap ring TR0794 B Friction plate 6MT 97 REVERSE IDLER GEAR ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 12 Remove the sub gear and spring TRO797 A Sub gear B Spring C Punch mark mark A D ASSEMBLY 1 Install the sub gear and spring NOTE Install the spring with white marking on hook part facing to sub gear side Install the sub gear with punch mark mark facing outside TRO797 A Sub gear B Spring C Punch mark mark A Install the spring and sub gear taking care to in stall the sub gear installation hole in proper direc tion A TRO951 Installation hole 2 Install the friction plate and snap ring NOTE Make sure to install the friction plate in proper di rection TRO798 A Friction plate B Snap ring C Snap ring side D Sub gear side 3 Sufficiently apply gear oil to the shaft needle bearing and inner periphery of reverse dr
34. BLUE LIGHT GRAY BLACK E BLACK B 8135 n BLUE D nh hod te d 112 BLACK 7 9 10 11 12 5 6 7 8 1011 12 1314 1516117 1819 hate heh 9 2012122 23124125 2612728 BLACK 13 1718 1920 12 3 GR10 26l WI 72 ENGINE ELECTRICAL SYSTEM WIRING SYSTEM A B134 6132 c 6139 E B84 ENGINE CONTROL MODULE P sae 9868 01 SH D dk H E E R d 9 B v c X Lol EL B gt 8 8 gt gt gt gt 5 5 H B E a 8 a m a COIL COIL COIL Geller COIL Gaon E 6136 8137 34 17218141516 2 7 1 2
35. FRONT CLEARANCE LIGHT LH TRAILER CONNECTOR LICENSE PLATE LIGHT FRONT CLEARANCE LIGHT RH 2 4 7 B REF GND 06 REAR COMBINATION REAR COMBINATION LIGHT LH SEDAN LIGHT LH WAGON Gz REAR COMBINATION REAR COMBINATION LIGHT RH SEDAN LIGHT RH WAGON EEC 4 8 ES REF GND 09 BLACK GRAY BLACK wG B99 Sr GRAY 50 R28 BLACK WG 11213145 1 2 3 4 5 6 7 8 9 8 617 81910 11 1213 14 15 16 17 18 19 20 21 2 11213 11213 2 1 56 61514 3 GR21 26C WI 83 CLEARANCE LIGHT AND ILLUMINATION LIGHT SYSTEM WIRING SYSTEM 3 RHD WITH ILLUMINATION CONTROL MODEL TO POWER SUPPLY ROUTING FB 36 F B FUSE 13 02 02 ILM RWI HAZARD SWITCH ILLUMI LIGHT 5 Cyt 2 DIMMER DIMMER gius DRIVER gt Iz 2 DHB d 8 8 BE COMBINATION METER 9 2 9 9 209 4 ILLUMINATION LIGHT INDICATOR LIGHT POWER MODE INDICATOR LIGHT HOLD MODE INDICATOR LIGHT OUT TEMP LCD BACK LIGHT ODO TRIP LCD BACK LIGHT AQ B hol 251 Ld
36. Washer Part No Thickness t mm in 803072030 0 15 0 0059 803072081 0 30 0 0118 803072032 0 45 0 0177 803072033 0 60 0 0236 6 95 REVERSE IDLER GEAR ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 21 Reverse Idler Gear Assembly A REMOVAL 1 Remove the manual transmission assembly from vehicle lt Ref to 6MT 37 REMOVAL Manual Transmission Assembly gt 2 Prepare the transmission for overhaul lt Ref to 6MT 42 Preparation for Overhaul gt 3 Remove the oil pipe neutral position switch back up light switch and harness lt Ref to 6MT 44 REMOVAL Oil Pipe gt lt Ref to 6MT 47 REMOV AL Neutral Position Switch Ref to 6MT 45 REMOVAL Back up Light Switch 4 Remove the extension case Ref to 6MT 49 REMOVAL Extension Case 5 Remove the transfer driven gear Ref to 6 60 REMOVAL Transfer Driven Gear 6 Remove the center differential Ref to 6 62 REMOVAL Center Differential 7 Remove the oil pump Ref to 6 64 RE MOVAL Oil Pump 8 Remove the transmission case Ref to 6MT 68 REMOVAL Transmission Case 9 Remove the reverse idler gear assembly Ref to 6MT 73 REMOVAL Main Shaft Assembly B INSTALLATION 1 Select the reverse fork rod Ref to 6MT 123 ADJUSTMENT Shifter Fork and Rod 2 Install the reverse idler gear assembly Ref to 6MT 74 INSTALLATION Main Shaft Assembly 3 Install the transmission ca
37. TRO720 3 Install the oil pan Tightening torque N 6 4 0 65 kgf m 4 7 ft lb TRO719 A Oil pan magnet Oil strainer TRO718 4 Install the relief valve relief valve spring and new washer 6MT 71 TRANSMISSION CASE MANUAL TRANSMISSION AND DIFFERENTIAL 5 Install the ball valve spring and new O ring Tightening torque T1 13 1 3 kgf m 9 6 ft lb 2 16 N m 1 6 kgf m 11 8 ft lb TRO721 O ring Relief valve spring Relief valve Valve spring Ball F Harness bracket E INSPECTION 1 Completely remove with shop cloth if sludge is adhered to the oil pan magnet 2 Make sure there is no clog on the oil strainer If clogged remove clog or replace the oil strainer 3 Make sure there is no damage on each parts Replace damaged parts with new parts 6 72 MAIN SHAFT ASSEMBLY 19 Main Shaft Assembly A REMOVAL 1 Remove the manual transmission assembly from vehicle lt Ref to 6MT 37 REMOVAL Manual Transmission Assembly gt 2 Prepare the transmission for overhaul lt Ref to 6MT 42 Preparation for Overhaul gt 3 Remove the oil pipe neutral position switch back up light switch and harness lt Ref to 6MT 44 REMOVAL Oil Pipe gt lt Ref to 6MT 47 REMOV AL Neutral Position Switch gt Ref to 6MT 45 REMOVAL
38. A Clutch hose B Operating cylinder 4 Remove the operating cylinder from transmis sion Non turbo model B2M1263 A Operating cylinder CL 5 OPERATING CYLINDER CLUTCH SYSTEM STi model R0982 A Operating cylinder B INSTALLATION 1 Install in the reverse order of removal NOTE Before installing the operating cylinder apply grease SUNLIGHT 2 P N 003602010 to contact point of the release lever and operating cylinder Non turbo model Tightening torque T1 18 N m 1 8 kgf m 13 0 ft Ib T2 37 N m 3 8 kgf m 27 5 ft Ib Turbo model except STi model Tightening torque T1 18 N m 1 8 kgf m 13 0 ft Ib T2 37 N m 3 8 kgf m 27 5 ft Ib STi model Tightening torque T1 18 N m 1 8 kgf m 13 0 ft Ib T2 41 N m 4 2 kgf m 30 2 ft Ib TRO983 NOTE Be sure to install the clutch hose with the mark side facing upward Be careful not to twist the clutch hose during in stallation H2M2666B Marking B Clutch hose C Operating cylinder 2 After bleeding air from the operating cylinder ensure that clutch operates properly lt Ref to CL 38 Clutch Fluid Air Bleeding gt C INSPECTION 1 Check the operating cylinder for damage If op erating cylinder is damaged replace it 2 Check the operating cylinder for fluid leakage o
39. Securely fix the disc rotor to hub 30 mm 326 mm 1 18 in 12 83 in B4M2353 NOTE Make sure that the dial gauge is set 5 mm 0 20 in inward of rotor outer perimeter f the disc rotor runout is above standard value inspect the play of hub bearing axial direction and runout of axle hub Ref to DS 23 INSPECTION Front Axle If the bearing and hub are normal re place 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 outside the standard value replace the disc rotor G4M0365 NOTE Make sure that a micrometer is set 5 mm 0 20 in inward of the rotor outer perimeter BR 9 FRONT DISC BRAKE ASSEMBLY BRAKE 4 Front Disc Brake Assembly A REMOVAL 3 17 INCH TYPE 1 Set the vehicle on a lift 2 Loosen the wheel nuts 3 Jack up the vehicle and then remove the front wheel 4 Remove the brake pads from caliper body lt Ref to BR 7 17 INCH TYPE REMOVAL Front Brake Pad gt 5 Remove the union bolt and brake hose from cal iper body assembly 6 Remove two installation bolts from housing 0149 1 Union bolt 2 Installation bolt 7 Clean mud and foreign particles from the caliper body assembly B INSTALLATION 3 17 INCH TYPE 1 Install the caliper body assembly on housing Tightening torque 155 N m 15 8 kgf m 114 3 ft Ib
40. 1 2 1125 2 112131415161718 1231415 6 7 9 10 1121 ala mm 3 9 10 1112 13 1415116 11 12 13 14 15 16 17 18 19 20 5X16 7 2 glach 3 1351415 x16 T 17 18 19 20 GR46 22D WI 37 ANTI LOCK BRAKE SYSTEM WIRING SYSTEM 8 Anti lock Brake System A SCHEMATIC WI 38 ANTI LOCK BRAKE SYSTEM WIRING SYSTEM 1 LHD MODEL TO POWER SUPPLY ROUTING FB 32 SBF 8 FB 17 FB 36 FB 31 F B FUSE 8 SBF HOLDER F B FUSE NO 18 F B FUSE NO 13 F B FUSE NO 16 B IG IG B ABS L 01 ABS L 01 STOP LIGHT SWITCH PARKING BRAKE WARNING ABS CONDENSER LIGHT ABS CONTROL MODULE amp GROUND SOLENOID FLINLET VALVE RELAY MOTOR RELAY 862 BLACK BLACK 8268 RED A 10 gt GREEN 4151617 9 n 112 8304 BLACK 12 314 11213 19 112 3145 617 9 314 5 6 7 8 12113 14 15 16 17 18 19 20 21 22 23 24 1 2 BLACK B 117 GREEN
41. 1121314 15 6 7 819 112 131415 67 89 1 1 112 3415 1617 1 sTo 1011 12 13114 1121 3456 7 8 9 12113 14115 16117 18 19120 21 22 23 24 12 18 14 15 16 17 18 19120121 22123 24 15 16 17 18 19 20 21 22123 24 25 26127 28 29 30 10111112113 14 15 16 17 18 19120121 22 23 24 25 26 27 28 29 30 31 GL10 26B WI 54 ENGINE ELECTRICAL SYSTEM WIRING SYSTEM TO POWER SUPPLY ROUTING MB 9 ST SBF 5 IGNITION SWITCH B ST E G LTB 01 GY MAIN RELAY 9 E G LTB 06 STARTER MOTOR REF TO GND 02 sel 5 8134 ENGINE CONTROL MODULE n n n n E 1121314 1 2 3 4 5 6 7 1121 1314151617 e 9 re 5161718 8 9 10111 12 1314115 10 11 12 1314115 16 17 18 19 20 21 1617 18 19 20 21 22 22 23 24 25 26 27 28 29 30 91 GL10 26C WI 55 ENGINE ELECTRICAL SYSTEM WIRING SYSTEM REF TO A C ALH 01 REF TO R F TB 01 REF TO IMB L 02 REF TO R DEF L 01 mol gt gt dk gt 5 5 a 134 8135 0 8137 ENGINE CONTROL MODULE
42. 3 6 kgf m 25 8 ft lb C INSPECTION Make sure there are no cracks or other damage ME STi 41 MECHANICAL PREPARATION FOR OVERHAUL MECHANICAL 11 Preparation for Overhaul A PROCEDURE 1 After removing the engine from the body secure in the ST shown below ST1 498457000 ENGINE STAND ADAPTER RH ST2 498457100 ENGINE STAND ADAPTER LH ST3 499817000 ENGINE STAND 2 In this section the procedures described under each index are all connected and stated in order It will be the complete procedure for overhauling of the engine itself when you go through all steps in the process Therefore in this section to conduct the particular procedure within the flow of a section you need to go back and conduct the procedure described pre viously in order to do that particular procedure ME STi 42 V BELT 12 V belt A REMOVAL 1 FRONT SIDE BELT NOTE Perform the following procedures 1 to 4 with the engine installed to the body 1 Remove the V belt cover 0048 2 Loosen the lock bolt A 3 Loosen the slider bolt B 4 Remove the front side belt C 2 REAR SIDE BELT 1 Loosen the lock nut A 2 Loosen the slider bolt B 3 Remove the rear side belt MECHANICAL 4 Remove the rear side belt tensioner 52 0113 INSTALLATION 1 FRONT SIDE BELT CAUTION Wipe off any oil or water on
43. 5 Calculate the clearance between cylinder and piston CAUTION Measurement should be performed at a temper ature of 20 C 68 F Cylinder to piston clearance at 20 C 68 F Standard 0 010 0 030 mm 0 0004 0 0012 in Limit 0 050 mm 0 0020 in 6 Boring and honing 1 If the value of taper out of roundness or cylinder to piston clearance measured exceeds the specified limit or if there is any damage on the cylinder wall rebore it to use an oversize pis ton CAUTION When any of the cylinders needs reboring all other cylinders must be bored at the same time and use oversize pistons Do not perform bor ing on one cylinder only nor use an oversize piston for one cylinder only 2 If the cylinder inner diameter exceeds the limit after boring and honing replace the crank case CAUTION Immediately after reboring the cylinder diame ter may differ from its real diameter due to tem perature rise Thus pay attention to this when measuring the cylinder diameter Limit of cylinder enlarging boring 0 5 mm 0 020 in 3 PISTON AND PISTON PIN 1 Check the pistons and piston pins for damage cracks and wear and the piston ring grooves for wear and damage Replace if defective 2 Measure the piston to cylinder clearance at each cylinder lt Ref to ME STi 85 CYLINDER AND PISTON INSPECTION Cylinder Block gt If any of the clearances is not within specification re place the piston or bo
44. Battery Type and capacity BHR For Europe and South America 12V 48AH 550231 12V 550231 AT 12V 52AH 65D23L MT 12V 48AH 55D23L 12V 52 75D23L 12V 48AH 550231 Others 12V 27AH 34B19L SPC 3 IMPREZA SPECIFICATIONS D TRANSMISSION Model 5 Non turbo 2 0 L Turbo 2 0 L 2 5L STi Transmission type 5MT 4AT 5MT 4AT 5MT 4AT 6MT Clutch type DSPD TCC DSPD TCC DSPD TCC DSPD Gear ratio 1st 3 454 3 454 2 785 3166 1 2nd 1 947 2 062 1 545 1 882 1 1 366 1 448 1 000 1 296 1 4th 1 088 0 694 0 972 0 694 1 088 0 694 1 346 5th 0 871 0 971 SE 0738 0 780 1 1 062 1 E 0 756 0 842 1 Reverse 3 545 Dual range Reduction 1st Type of gear Front reduction gear drive Gear ratio Final Type of reduction gear Gear 3 900 3 700 ratio 4 111 4 444 3 900 4 111 4 44441 4 111 4 11141 Reduction Transfer Type of gear Rear reduction gear drive Gear 1 100 1 100 ratio 1000 ER 1 0001 EE 1 0001 of reduction gear Gear 3 545 3 700 3 545 ratio KE 809 4 444 1 4 111 1 3 900 1 2 785 3 454 2 785 3 636 1 545 2 062 1 545 2 375 1 000 1 448 1 000 1 761 Helical Helical Helical Helical 1 000 1 000 1 000 1 000 Hypoid Hypoid Hypoid Hypoid Hypoid Hypoid Hypoid Hypoid Hypoid 4 111 3 900 Hel
45. F79 Gray A C pressure switch 94 Gray ABS front sensor LH F98 Black Headlight LH 4 Lights Hi F99 Black Headlight RH 4 Lights Hi Non colored WI 91 FRONT WIRING HARNESS WIRING SYSTEM BO0487 WI 92 FRONT WIRING HARNESS WIRING SYSTEM 2 RHD MODEL Connector Connecting to Pole Color 3 Gray Front clearance light RH and front turn signal light RH Black Horn Black Front fog light RH Headlight RH 2 Lights Black Headlight RH 4 Lights Lo Black Sub fan motor Non turbo model Black Sub fan motor Turbo model Black Radiator main fan motor Non turbo model Black Radiator main fan motor Turbo model Black Front fog light LH Gray Front clearance light LH and front turn signal light LH Headlight LH 2 Lights Black Headlight LH 4 Lights Lo Gray A C compressor Green Black A C fuse Relay holder Black A C sub fan relay 1 Relay holder Turbo model Black A C sub fan relay Relay holder Non turbo model Black A C sub fan relay 2 Relay holder Turbo model Black Radiator main fan relay 2 Relay holder Turbo model Black A C relay Relay holder Black SBF holder Black Black Gray F B Bulkhead wiring harness Bulkhead wiring harness Horn ABS control module Side turn signal light RH Headlight leveler LH Exce
46. Is the resistance between 6 and 12 Q EN TURBO 33 Repair the poor contact in ECM and variable valve timing solenoid valve Replace the vari able valve timing solenoid valve lt Ref to ME STi 59 Cam shaft DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC ENGINE DIAGNOSTICS DO DTC P1308 VARIABLE VALVE TIMING SOLENOID VALVE 2 CIRCUIT LOW INPUT LH DTC DETECTING CONDITION Two consecutive driving cycles with fault TROUBLE SYMPTOM Erroneous idling CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN TURBO 45 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN TURBO 42 Inspection Mode gt WIRING DIAGRAM ECM A a VARIABLE VALVE TIMING SOLENOID VALVE LH EN1531 EN TURBO 34 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC ENGINE DIAGNOSTICS Yes No CHECK HARNESS BETWEEN ECM AND VARIABLE VALVE TIMING SOLENOID VALVE 1 Turn the ignition switch to OFF 2 Disconnect the connector from ECM and variable valve timing solenoid valve 3 Measure the resistance between ECM and variable valve timing solenoid valve Connector amp terminal B84 17 E37 No 1 B84 No 16 E37 No 2 Is the resistance less than 1 Q Go to step 2 R
47. MODEL WITH AUTO A C MODEL METER 04 gt WITH ILLUMINATION CONTROL MODEL WITHOUT ILLUMINATION CONTROL MODEL IGNITION SWITCH O TAIL amp ILLUMINATION OH STE SE DRIVER TACHOMETER SPEEDOMETER LOW FUEL WARNING LIGHT ODO METER TRIP METER OUT TEMP REV INDICATOR STi MODEL WATER TEMPERATURE GAUGE ILLUMINATION CUSTOM CPU TRIP lt gt 2 o D TRIP ODO TRIPLCD OUTTEMP RESET SWITCH BACK LIGHT LCD BACK 9 LIGHT REV INDICATOR SET SWITCH STi MODEL STEET STEET Srp BEER ozzo 520 20 o 3548 FUEL GAUGE MODULE ENGINE CONTROL MODULE VEHICLE SPEED SENSOR AUTO A C CONTROL TRANSMISSION CONTROL MODULE MODULE um GG64 22D WI 48 CRUISE CONTROL SYSTEM WIRING SYSTEM 13 Cruise Control System A SCHEMATIC TO POWER SUPPLY ROUTING r3 F B FUSE NO 16 F B FUSE NO 18 HORN RELAY B IG 8 C C 01 C C 01 CRUISE CONTROL SUB SWITCH STOP LIGHT AND BRAKE SWITCH O O 2 SET 3 WB CT KSC RESUME CANCEL x1 AT YG MT YR CRUISE CONTROL MAIN SWITCH CLUTCH SWITCH MT 1 TYR 2 vo REF TO ILM RWI 01 Car
48. Make sure to install the reverse interlock arm and rod in proper direction Make sure to install the interlock arm and rod in proper direction REMOVER TRO856 Reverse interlock arm B Interlock arm C Spring pin 2 Install the reverse interlock block and interlock block to striking rod NOTE Make sure to install the reverse interlock block and interlock block in proper direction 0843 Reverse interlock block B Interlock block E INSPECTION 1 Check the shift shaft and shift rod for damage Replace if damaged 2 Repair or replace the gearshift mechanism if ex cessively worn bent or defective in any way 6MT 122 SHIFTER FORK AND ROD F ADJUSTMENT 1 SELECTION OF 1ST 2ND FORK ROD NOTE Perform the following procedures when Replacing the 1st 2nd driven gear Replacing the 1st 2nd synchro ring assembly Replacing the adapter plate Replacing the driven shaft 1 Insert the drive pinion assembly in adapter plate NOTE Make sure the thrust bearing outer race is not re moved and drive pinion is not lift up 2 Set the height gauge to adapter plate Lower the indicator of height gauge to mating surface of adapter plate and case then set to zero point ST 18853AA000HEIGHT GAUGE ZI NOTE Remove the remaining gasket on edge surface
49. TRO0648 5 Lower the vehicle and install the fixing bolt Tightening torque 50 N m 5 1 kgf m 36 9 ft Ib 2 2791 6 39 MANUAL TRANSMISSION ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 6 Make sure the release bearing is installed com pletely NOTE Push the release fork to operating cylinder side until you hear a click sound Pull the release fork to engine side Setting is completed if the release fork does not contact case Make sure the boot cover is firmly set 2 1818 7 Install the pitching stopper bracket and then in stall the pitching stopper Tightening torque T1 50 5 1 kgf m 36 9 ft lb T2 58 N m 5 9 kgf m 42 8 ft lb V a 8 Install the clutch operating cylinder Tightening torque 41 4 2 kgf m 30 2 ft lb NOTE Check that the clutch hose is routed properly TRO640 9 Install the starter assembly Tightening torque 50 5 1 kgf m 36 9 ft lb 10 Install the transmission and body ground cable TRO639 11 Connect the connector located on the upper side of transmission TRO637 A Vehicle speed sensor connector B Transmission connector 12 Lift up the vehicle and install the drive shaft 6MT 40 MANUAL TRANSMISSION ASSEMBLY 13 Using the ST install the spring pin of front drive ST 39
50. l O oF SENI oS 5 ug 5 gt lt D st 22 A i10 GREEN Git erac Cis C Q12 GREEN 112131415 617 9 112 314 142314 1 21514 519171819 10 11 2113 14 15 16117 18 19 20 2122 5161718 12 3 41516 71819 1011112 1314 7 GREEN gt 11213 4 56 7189 10 11 12 13 14 15 16 17 18 19 20 21 22123 24 25 26 27 28 29 30 3132 2 4 5 6 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 GR21 27B WI 85 CLEARANCE LIGHT AND ILLUMINATION LIGHT SYSTEM WIRING SYSTEM 03 TO POWER SUPPLY ROUTING FB 6 FB 7 F B FUSE NO 5 F B FUSE NO 5 03 oc z FRONT CLEARANCE LIGHT LH TRAILER CONNECTOR LICENSE PLATE LIGHT Sd TR Glas 8 FRONT CLEARANCE LIGHT RH REF TO GND 06 REAR COMBINATION REAR COMBINATION LIGHT LH SEDAN LIGHT LH WAGON Gz REAR COMBINATION REAR COMBINATION LIGHT RH SEDAN LIGHT RH WAGON EEC ERED ES REF GND 09 BLACK WG B99 BLACK WG 2 1 615 4 3 BLACK GRAY 1 2 3 99 BB m
51. 1121314 15 16 718 9 1011 12 4 5 6 sTo 112 12 13 14 15 16 17 18 19 201 21 22 23 24 15 16 17 18119 20 21 22 23 24 25 26 27 28 29 30 3 14 9 1411516 19 124125126 29 134135136 sme p o pp 37 1112 13 18 2122 231 28 31132133 38 112 314 5 6 7 8 9 101112130405 7118 RELAY HOLDER 16 17 18 19 20 21 22 T 26 27 28 29 30 31 GL82 22A WI 39 ANTI LOCK BRAKE SYSTEM WIRING SYSTEM TO POWER SUPPLY ROUTING TURBO ENGINE MODEL NON TURBO ENGINE MODEL STi MODEL EXCEPT STi MODEL TRANSMISSION CONTROL MODULE DIAGNOSIS DIAGNOSIS CONNECTOR CONNECTOR 892 CHECK CONNECTOR ABS L 01 A TE 7 9 DATA LINK REF TO GND 02 CONNECTOR SMJ gt a BR d ABS CONTROL MODULE OS BLACK GRAY GRAY BROWN 1 2 1121314 BROWN 3 4 5 6 5 6 7 8 1 2 3 4 5 6 7 8 9 10H 11 12 13 1415 9 1111213 14115116 1234 567 8 191101112 855 GRAY 13 14 1516
52. D R Dual range 1 For option code refer to ID section Ref to ID 5 Option code SPC 12 IMPREZA SPECIFICATIONS Option code 1 KA Model 2 0L 2 0 L Turbo AWD GX OUTBACK WRX D R 4AT D R 4AT 5MT 4AT Unladen mass U M Front kgf Ib 760 1 676 775 1 709 750 1 653 765 1 687 825 1 819 850 1 874 Rear kgf Ib 570 1 257 565 1 246 570 1 257 570 1 257 585 1 290 585 1 290 Total kgf Ib 1 330 1 340 1 320 1 335 1 410 1 435 2 932 2 954 2 910 2 943 3 109 3 164 Gross vehicle mass Front kgf Ib 920 2 028 920 2 028 920 2 028 920 2 028 970 2 138 970 2 138 G V M Rear kgf Ib 960 2 116 960 2 116 960 2 116 960 2 116 950 2 094 950 2 094 Total kgf Ib 1 800 1 800 1 800 1 800 1 860 1 860 3 968 3 968 3 968 3 968 4 101 4 101 Option Air conditioner Cruise control 5 Aluminium wheel mE Rear spoiler Option codex1 EK Model 2 0 L Turbo AWD WRX 5MT Curb weight C W Front 825 1 819 Rear 585 1 290 Total 1 410 8 109 Maximum permissible axle weight M P A W Front 970 2 138 Rear 950 2 094 Maximum permissible weight M P W Total 1 860 4
53. Diagnostics Chart with Diagnosis Connector gt Abnormal stop light switch lt Ref to ABS 84 DTC 54 ABNORMAL STOP LIGHT SWITCH Diagnostics Chart with Diagnosis Connector gt Abnormal G sensor output voltage lt Ref to ABS 11 DTC 56 ABNORMAL G SENSOR OUTPUT VOLTAGE Diagnostics Chart with Diagnosis Connector gt Abnormal lateral G sensor output voltage lt Ref to ABS 15 DTC 73 ABNORMAL LATERAL G SENSOR OUTPUT VOLTAGE Diagnostics Chart with Diagnosis Connec tor gt ABS 8 LIST OF DIAGNOSTICS TROUBLE CODE DTC Display screen 2 WITH SUBARU SELECT MONITOR Contents of diagnosis ABS DIAGNOSTICS Index No Communication for ini tializing impossible Select monitor commu nication failure lt Ref to ABS 92 COMMUNICATION FOR INITIALIZING IMPOSSI BLE Diagnostics Chart with Subaru Select Monitor gt No trouble code Although no trouble code appears on the select monitor display the ABS warning light remains on lt Ref to ABS 96 NO TROUBLE CODE Diagnostics Chart with Sub aru Select Monitor gt Open or short circuit in front right ABS sensor circuit Open or short circuit in front right ABS sensor circuit lt Ref to ABS 100 DTC 21 OPEN OR SHORT CIRCUIT IN FRONT RIGHT ABS SENSOR CIRCUIT Diagnostics Chart with Subaru Select Monitor gt Front right ABS sen sor abnormal signal Front right ABS sensor abno
54. baulk ring 392 40 0 289 11 4th gear 22 drive gear 6MT 9 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL 8 DRIVE PINION AND DRIVEN SHAFT ASSY TRO602 1 Drive pinion shaft 13 1st 2nd sleeve 25 Lock nut 2 Taper roller bearing 14 Shifting insert 26 Shim 3 Shim 15 1st 2nd hub 27 Collar 4 Washer 16 Outer baulk ring 5 Lock nut 17 Synchro cone 6 Thrust bearing 18 baulk ring Tightening torque N m kgf m ft lb 7 Needle bearing 19 2nd driven gear 1 285 29 1 210 8 Driven shaft 20 Needle bearing 265 27 0 195 9 Key 21 2nd bush T2 570 58 1 420 10 Needle bearing 22 3rd 4th driven gear 530 54 0 391 11 1st driven gear 23 5th 6th driven gear Tightening torque when ST used 12 1st synchro ring ASSY 24 Ball bearing 6MT 10 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL 9 REVERSE IDLER GEAR ASSY TRO603 1 Base COMPL 9 Reverse coupling sleeve 17 Reverse idler holder 2 Washer 10 Reverse idler gear 18 Spring pin 3 Reverse idler gear No 2 11 Spring 19 Knock pin 4 Needle bearing 12 Sub gear 20 Spring pin b Reverse idler synchro set 13 Friction plate 6 Reverse idler gear bush 14 Snap ring Tightening torque N m kgf m ft Ib 7 Needle bearing 15 Washer 25 2 5 18 1 8 Shifting insert 16 Snap ring 6 11 GE
55. 0 0598 05 0 25 mm 0 0098 1 615 1 619 mm 0 0636 0 0637 in US Connecting Clearance between piston pin and STD 0 0 022 mm 0 0 0009 in rod bushing bushing Limit 0 030 mm 0 0012 in Oil clearance ME STi 4 Crankshaft Bend limit GENERAL DESCRIPTION MECHANICAL 0 035 mm 0 0014 in Crank pin and crank jour nal Out of roundness 0 020 mm 0 0008 in or less Grinding limit 0 25 mm 0 0098 in Crank pin outer diameter STD 51 984 52 000 mm 2 0466 2 0472 in 0 03 mm 0 0012 in US 51 954 51 970 mm 2 0454 2 0461 in 0 05 mm 0 0020 in US 51 934 51 950 mm 2 0446 2 0453 in 0 25 mm 0 0098 in US 51 734 51 750 mm 2 0368 2 0374 in Crank journal outer diam eter STD 59 992 60 008 mm 2 3619 2 3625 in 0 03 mm 0 0012 in US 59 962 59 978 mm 2 3607 2 3613 in 0 05 mm 0 0020 in US 1 3 5 59 942 59 958 mm 2 3599 2 3605 in 0 25 mm 0 0098 in US 59 742 59 758 mm 2 3520 2 3527 in STD 59 992 60 008 mm 2 3619 2 3625 in 0 03 mm 0 0012 in US 59 962 59 978 mm 2 3607 2 3613 in 0 05 mm 0 0020 in US 59 942 59 958 mm 2 3599 2 3605 in 0 25 mm 0 0098 in US 59 742 59 758 mm 2 3520 2 3527 in Thrust clearance
56. 21814 i Lag 3l 1 2314 1516 17 819 to t1 t2 t3 14 15 16 17 1819 2012122 11 12 13 14 15 16 17 18 23 24 25 26 19 20 21 22 23 24 GL82 22B WI 40 ANTI LOCK BRAKE SYSTEM WIRING SYSTEM ABS CONTROL MODULE SHIELD JOINT CONNECTOR 5 o z N EXCEPT STi MODEL EXCEPT STi 2 STi VW EXCEPT STi ABS G SENSOR JOINT CONNECTOR STi MODEL ABS LATERAL G SENSOR ABS G SENSOR REAR ABS REAR ABS FRONT ABS FRONT ABS REF GND 03 STi MODEL GRAY 1121314 5678 SENSORLH SENSOR RH SENSOR RH SENSOR LH m 11 2 3 4 5 6 1 2 3 4 5 2 99 26 25 24 23 1 21 3 4 5 6 7 81 9110 11 12 13 14 15 16 17 18 19 20121 22 27 28 29 30 31 6171819 10 11 1 2 3 4 5 12 13 14 15 16 17 18 19 20 21 22 23 24 22 GL82 WI 41 ANTI LOCK BRAKE SYSTEM WIRING SYSTEM 2 RHD MODEL T TO POWER SUPPLY ROUTING T 32 F B FUSE NO 8 SBF HOLDER F B FUSE NO 16 0 4 STOP LIGHT SWITCH RELAY HOLDER WITH CRUISE CONTROL MODEL WITHOUT CRUISE CONTROL MOD
57. 498077610 REMOVER Used for removing speedometer drive gear B3M2015 398497701 Used for installing transfer drive gear ball bear ing B4M2397 6MT 22 ILLUSTRATION GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL TOOL NUMBER DESCRIPTION REMARKS TRO939 398437700 INSTALLER Used for installing front differential side bearing 4 2498 498745600 INSTALLER Used for installing oil pump drive gear TRO607 18632AA000 Newly adopted tool STAND ASSY Used for disassembling and assembling trans mission cg TRO608 18671AA000 Newly adopted tool OIL SEAL GUIDE 6MT 23 Used for installing oil seal to reverse check Used with INSTALLER 18657AA010 ILLUSTRATION GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL TOOL NUMBER DESCRIPTION REMARKS TRO610 18657AA010 Newly adopted tool INSTALLER Used for installing oil seal to reverse check Used with OIL SEAL GUIDE 18671AA000 TRO610 18657AA000 Newly adopted tool INSTALLER Used for installing oil seal to shift rod TRO611 18758AA000 Newly adopted tool PULLER Used for removing extension taper roller bearing outer race en TR0612 18831AA000 Newly adopted tool 6 24 Used for measuring extension taper roller bear ing ILLUSTRATION GENERAL DESCRIPTION MANUAL TRANSMISSIO
58. 51678 Tekee 25 2 1 2 8 156 ABS 15 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS WIRING DIAGRAM RHD MODEL ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT SHIELD JOINT CONNECTOR 50 STi MODEL EXCEPT STi MODEL ABS G SENSOR JOINT CONNECTOR STi MODEL ABS LATERAL G SENSOR STi MODEL 6 121314176 H 5 Ex 1 21 3 5 7 819 11213 14151617 8 1314115 18 19 20 21 22 6117 18 19 2021 5 16 17 23 24 25 26 lt 0157 Check Yes Have the wheels been turned The ABS is nor freely such as when the mal Erase the cle is lifted up or operated DTC a rolling road Step CHECK ALL FOUR WHEELS FOR FREE Go to step 2 TURNING ABS 16 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR Step Check Yes ABS DIAGNOSTICS No CHECK SPECIFICATIONS OF ABSCM amp H U Check the specifications mark on amp H U C9 MT STi model Does the vehicle specification ABSCM amp H U specifica tion match Go to step 3 Replace the ABSCM amp H U Ref to ABS 4 ABS Control Mod ule and Hydraulic Control Unit ABSCM amp H U CAUTION Be sure to turn the ignition Switch to OFF when removing ABSCM amp H U CHECK INP
59. Front washer motor Front wiper motor Front wiper switch License plate light Tail light LH Tail light RH Trailer connector Auto A C control module Radio Front accessory power supply socket Remote controlled rearview mirror switch Intercooler water spray timer STi Intercooler water spray switch STi WI 16 Rear fog light relay Load POWER SUPPLY ROUTING Mirror heater relay Stop light switch ABS control module Front fog light relay Blower motor relay Door lock timer Keyless entry control module Combination meter WI 17 WIRING SYSTEM GROUND DISTRIBUTION WIRING SYSTEM 5 Ground Distribution A SCHEMATIC WI 18 GROUND DISTRIBUTION WIRING SYSTEM 1 LHD MODEL GENERAL HEADLIGHT LO RH STi MODEL POWER WINDOW FRONT DOOR LOCK MAIN SWITCH ACUTUATOR DRIVER SIDE HEADLIGHT LO LH STi MODEL HEADLIGHT LEVELING SWITCH EXCEPT STi MODEL 3 19 LW MAIN FAN MOTOR TURBO ENGINE MODEL REARVIEW MIRROR DRIVER SIDE HEADLIGHT LEVELER RH EXCEPT STi MODEL HEADLIGHT LEVELER LH EXCEPT STi MODEL SUB FAN MOTOR TURBO ENGINE MODEL KEYLESS ENTRY CONTROL MODULE MAIN FAN MOTOR NON TURBO ENGINE MODEL FRONT CLEARANCE LIGHT LH POWER WINDOW RELAY SUB FAN MOTOR NON TURBO ENGINE MODEL FRONT CLEARANCE LIGHT RH DOOR LOCK TIMER
60. GUIDE CLIP Used for installing reverse idler gear snap ring KOR 18720 000 Newly adopted tool REMOVER 6MT 29 Used for disassembling main shaft ILLUSTRATION GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL TOOL NUMBER DESCRIPTION REMARKS TRO630 18654AA000 Newly adopted tool INSTALLER Used for assembling driven shaft 7 0631 18663AA000 Newly adopted tool SOCKET Used for installing and removing oil pump cover 18853AA000 Newly adopted tool HEIGHT GAUGE Used for selecting shift rod 0929 18760 000 Newly adopted tool 6MT 30 Used for removing front side retainer bearing outer race Used with PULLER ASSEMBLY 398527705 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL 2 GENERAL PURPOSE TOOLS TOOL NAME REMARKS Circuit Tester Used for measuring resistance voltage and ampere 6MT 31 TRANSMISSION GEAR OIL MANUAL TRANSMISSION AND DIFFERENTIAL 2 Transmission Gear Oil A INSPECTION 1 Park the vehicle on a level surface 2 Turn the ignition switch to OFF and wait until the engine cools 3 Remove the oil level gauge and wipe it clean 4 Reinsert the level gauge all the way Be sure that the level gauge is correctly inserted and in the proper direction 5 Pull out the oil level gauge again and check the oil level on it If it is below the lower level
61. Pad thickness including back metal Rear brake Drum type BR 3 GENERAL DESCRIPTION BRAKE Fluid pressure Brake pedal TS force WIhoutABS 2 686 kPa 686 kPa 147 N 588 kPa 7 kg cm 7 kg cm 15 kgf 33 Ib kg em Brake fluid pressure 100 psi 100 psi ithout i i without engine running 1 961 kPa 1 961 kPa 1 471 kPa 294 N 20 20 kg cm 30 kgf 66 Ib 2 30 kg J Saga Sep 284 psi 15 kg cm 213 psi booster 147 5 982 5 982 5 296 4 707 4 021 Se 667 868 psi 868 psi 768 psi 683 psi 583 psi kPa 500 mmHg 19 69 294 7 649 kPa 8 434 kPa 9 120 kPa 8 336 kPa inH 78 kg cm 86 kg cm 5 d 85 kg cm 9 30 kgf 66 Ib 1 109 psi 1 223 psi 93 kg cm 1 323 psi 1 209 psi Brake pedal 1 3 mm 0 04 0 12 in p Depress brake pedal pad with a force of less than 10 1 kgf 2 Ib BR 4 GENERAL DESCRIPTION BRAKE B COMPONENT 15 17 INCH TYPE BRO151 1 Housing 8 Piston boot 15 Disc cover 2 Caliper body 9 Piston 3 bleeder screw 10 Piston seal Tightening torque N m kgf m ft Ib 4 Guide plate 11 Pad shim T1 18 1 8 13 3 5 Cross spring 12 Pad Outside T2
62. Rear fog light relay Front wiring harness Headlight leveling switch Except STi Stop light switch Headlight leveling switch STi Steering roll connector Combination switch AT power mode amp hold mode switch Ignition switch Key warning switch Engine control module Test mode connector Immobilizer control module PM PM Mode actuator F B D Check connector Diagnosis terminal Ground Ignition relay Relay block F B Diagnosis connector Front fog light switch Shield amp sensor ground joint connec tor E G With OBD Air conditioning switch Manual A C Shield amp sensor ground joint connec tor E G Without OBD Blower fan switch Manual A C Mirror heated relay Keyless entry control module Engine control module Diode Rear fog light Joint connector Key less entry Blower fan resistor WI 100 Rear fog light switch BULKHEAD WIRING HARNESS COMPARTMENT WIRING SYSTEM Connector Connecting to No Pole Color 196 Diode Rear fog light Ground joint connec tor B208 Glove box light Front wiring harness 5 Ignition switch illumi nation B225 Fuse Relay box B256 Evaporator sensor ABS lateral G
63. d B2M4158 499207400 CAMSHAFT SPROCKET WRENCH ME STi 16 shaft sprocket Used for removing and installing exhaust cam ILLUSTRATION GENERAL DESCRIPTION TOOL NUMBER DESCRIPTION MECHANICAL REMARKS NM eg 499977500 Newly adopted tool CAMSHAFT SPROCKET WRENCH Used for removing and installing intake camshaft B2M3860 499587700 CAMSHAFT OIL SEAL INSTALLER Used for installing camshaft oil seal B2M3861 499587200 CRANKSHAFT OIL SEAL INSTALLER Used for installing crankshaft oil seal Used with CRANKSHAFT OIL SEAL GUIDE 499597100 Q 9 2 3863 499597100 CRANKSHAFT OIL SEAL GUIDE ME STi 17 Used for installing crankshaft oil seal Used with CRANKSHAFT OIL SEAL INSTALLER 499587200 MECHANICAL ILLUSTRATION GENERAL DESCRIPTION TOOL NUMBER DESCRIPTION REMARKS B2M3864 499718000 VALVE SPRING REMOVER Used for removing and installing valve spring B2M3865 498267700 VALVE GUIDE ADJUSTER Used for installing intake and exhaust valve guides B2M3867 499767200 VALVE GUIDE REMOVER Used for removing valve guides B2M3868 499767400 VALVE GUIDE REAMER ME STi 18 Used for reaming valve guides ILLUSTRATION GENERAL DESCRIPTION TOOL NUMBER DESCRIPTION MECHANICAL REMARKS B2M3869 499817000 ENGINE STAND Sta
64. A REMOVAL 1 Remove the V belt Ref to ME STi 43 RE MOVAL V belt gt 2 Remove the crankshaft pulley Ref to ME STi 45 REMOVAL Crankshaft Pulley gt 3 Remove the belt cover Ref to ME STi 46 REMOVAL Belt Cover gt 4 Remove the timing belt assembly lt Ref to ME STi 47 REMOVAL Timing Belt Assembly gt 5 Remove the camshaft sprocket Ref to ME STi 56 REMOVAL Camshaft Sprocket gt 6 Remove the intake manifold lt Ref to FU TUR BO 15 REMOVAL Intake Manifold gt 7 Remove the bolt which installs A C compressor bracket on cylinder head 8 Remove the camshaft Ref to ME STi 59 RE MOVAL Camshaft gt 9 Remove the cylinder head bolts in alphabetical sequence shown in the figure CAUTION Leave bolts A and D engaged by three or four threads to prevent the cylinder head from falling B2M1397C 10 While tapping the cylinder head with a plastic hammer separate it from cylinder block Remove bolts A and D to remove the cylinder head B2M1397C 11 Remove the cylinder head gasket CAUTION Do not scratch the mating surface of the cylin der head and cylinder block MECHANICAL 12 Similarly remove the right side cylinder head B INSTALLATION 1 Install the cylinder head and gaskets on cylinder block CAUTION Use new cylinder head gaskets Be careful not to scratch the mating surface of the cylinder head and cylinder blo
65. ER 5 cim oo GR21 27C WI 86 HEADLIGHT SYSTEM WIRING SYSTEM 27 Headlight System A SCHEMATIC WI 87 HEADLIGHT SYSTEM WIRING SYSTEM 3 LHD 4 LIGHTS MODEL TO POWER SUPPLY ROUTING MB 8 MB 2 MB 3 HEADLIGHT M B FUSE NO 9 M B FUSE NO 8 RELAY HEADLIGHT RH COMBINATION METER HI BEAM INDICATOR LIGHT ____ CR VO DIMMER amp PASSING REF TO GND 01 REF TO GND 02 B85 BROWN BLACK 1121 23 BROWN BLACK 1 2 3 4156 7 8 112 112 9 10 11 12 13 14 15 16 17 12345 7 8 9 10111 1213 1415 16 1711819120121122123124 GREEN 11213141516 7 8 9 1011121314 15 1611718 1912012122 23124125 26 27 28 29 30 GL19 22 WI 88 HEADLIGHT SYSTEM WIRING SYSTEM 4 RHD 4 LIGHTS MODEL TO POWER SUPPLY ROUTING MB 8 MB 2 MB 3 HEADLIGHT M B FUSE NO 9 M B FUSE 8 RELAY HEADLIGHT RH WITH REAR FOG LIGHT MODEL WITHOUT REAR FOG LIGHT MODEL FOR EUROPE MODEL RW OTHER MODEL FOR
66. GRAY 314 1213 141567 CT S271 BLUE 213 415 6789 10 112 9 14 15 16 19 24 25 26 291 134135 36 10 17 20 27 30 37 11 12 13 18 21 22 23 28 31 32 33 38 A RELAY BLOCK BLACK GRO1 21E WI 15 POWER SUPPLY ROUTING WIRING SYSTEM Load Air conditioning relay holder Combination meter Headlight RH Headlight LH Horn Cruise control sub switch Horn switch Hazard swtich Keyless entry control module Key warning switch Bright switch Combination meter Front fog light relay Front fog light switch Headlight leveling switch Illumination control module Illumination light Rear fog light relay Rear fog light switch Intercooler water spray switch STi Parking switch Transmission control module Diode With rear fog light model Lighting switch Engine control module Lighting switch Parking switch Data link connector Engine control module Fuel pump relay Immobilizer control module Main relay Mirror heater relay Rear defogger Rear defogger switch Auto A C Control module Combinatio
67. Remove the water pump 20 Remove the oil pump from cylinder block Use a flat bladed screwdriver as shown in the fig ure when removing oil pump CAUTION Be careful not to scratch the mating surface of cylinder block and oil pump 2 2 2 2 15 16 17 18 19 Flat bladed screwdriver G2M0162 ME STi 73 CYLINDER BLOCK MECHANICAL 0294 1 Service hole plug 3 Circlip 2 Gasket 4 Piston pin 21 Remove the service hole cover and service hole plugs using hexagon wrench 14 mm 0 55 in SS 2 alg a Ae EVA IN 5 2 2620 5 Service hole cover 6 O ring 22 Rotate the crankshaft to bring 1 and 2 pis tons to bottom dead center position then remove the piston circlip through service hole of 1 and 2 cylinders ST 499897200 PISTON CIRCLIP PLIER ME STi 74 CYLINDER BLOCK 23 Draw out the piston pin from 1 and 2 pistons using ST ST 499097700 PISTON PINREMOVER ASSY CAUTION Be careful not to confuse original combination of piston piston pin and cylinder G2M0166 MECHANICAL 24 Similarly remove the piston pins from 3 and 4 pistons 25 Remove the bolts which connect cylinder block on the side of 2 and 4 cylinders 26 Loosen the bolts which connect cylinder block on the side of 1 and 3 cylinders two or three turns 27 S
68. Replacing the 3rd 3rd to 6th drive gear and bush Replacing the 3rd 3rd to synchro assembly 1 Insert the main shaft assembly in adapter plate 2 Set the height gauge to adapter plate Lower the indicator of height gauge to upper surface of snap ring groove on the upper side of main rear bearing then set to zero point ST 18853AA000 HEIGHT GAUGE 0862 bearing Remove the remaining gasket edge surface with scraper since the height gauge is set on adapter plate during measurement Do not put the height gauge on shaded area the figure during the measurement TRO756 MANUAL TRANSMISSION AND DIFFERENTIAL 3 Using the height gauge measure C1 and C2 shown in the figure C1 T ail fay JM ms TRO863 A 3rd main gear B 4th main gear 1 Shift the 3rd 4th sleeve to 4th gear side then press down to the stopper and measure 4th main gear 6MT 125 SHIFTER FORK AND ROD MANUAL TRANSMISSION AND DIFFERENTIAL NOTE e Set the indicator of
69. TURBO 613 PRESSURE SWITCH MODEL ENGINE BW 2 A 134 CONTROL CDEN MODULE B 6138 NON TURBO GES MODEL d E SR CLUTCH AUTO 282 8 8283 CONTROL MODULE COMPRESSOR REF TO GND 08 F20 GRAY 6282 GRAY 6283 GRAY n n D 1 112 11213 1 2 112 112 314 56 7 8 11213 4151617 8 9 2 314 314 9 10 11 12 13 14 15 16 11 12 13 14 1516 1718 1920 Hehe 1 c 6136 RA D 112131415 1617 11213 45 617 1123 415 617 1172 516 9 3114 17 2122 25 os SEET 8 9 1011 12118114115 1617 18 19 8 9 10111213 1411516 17 18 19 20 77 Hol hsr Mel 23 126 Dez 1819120 21 221 2021 22123 24125126 27128 21 22 23124125 26127 28129130 3114
70. o z STi MODEL JOINT CONNECTOR ABS G SENSOR STi MODEL 8 DA 4 REAR REAR FRONT REF GND 06 BLACK B99 ABS LATERAL G SENSOR STi MODEL 6 7 8 9110 1 2 3 4 5 11 12 13 14 15 16 17 18 19 20 21 22 62 Gray 1121314 5 6 7 8 tt 29 85 lt o gt N 89 a E 98 D o m tc 59 lt 2 D o 89 42 o t lt lt lt 2 GIS 2 1 BLACK LO 1 0 IEN 2 lo N N N Ze c lt 2 bul r3 TID T7 oo Nolan FHN N 22C GR82 WI 44 COMBINATION METER WIRING SYSTEM 12 Combination Meter A SCHEMATIC T T m GG64 22A WI 45 WIRING SYSTEM A SE 04 YOLVOGNI H3ZITISOINWI 1OH1NOO H3ZITISOWWI HOLIMS HOOG 9NINHVM
71. 0 75 0 80 mm 0 0295 0 0315 in 383445202 0 80 0 85 mm 0 0315 0 0335 in 383445203 0 85 0 90 mm 0 0335 0 0354 in Side bearing standard width mm 20 00 0 7874 Side bearing retainer shim Part No Thickness 383475201 0 20 mm 0 0079 in 383475202 0 25 mm 0 0098 in 383475203 383475204 0 40 mm 0 0157 in 383475205 0 30 mm 0 0118 in 0 50 mm 0 0197 in Crown gear to drive pinion backlash in Crown gear runout on its back surface in STi model Front and rear bearing preload at com panion flange bolt hole N kgf Ib Limit 0 10 0 20 0 0039 0 0079 0 05 0 0020 31 1 59 5 3 17 6 07 7 0 13 4 Preload adjusting spacer Part No Length 31454AA130 52 2 mm 2 055 in 31454AA140 52 4 mm 2 063 in 31454AA150 52 6 mm 2 071 in 31454AA160 31454AA170 53 0 mm 2 087 in 31454AA180 DI 6 52 8 mm 2 079 in 53 2 mm 2 094 in Preload adjusting washer Part No GENERAL DESCRIPTION DIFFERENTIALS Length 383705200 2 59 mm 0 1020 in 383715200 2 57 mm 0 1012 in 383725200 2 55 mm 0 1004 in 383735200 2 53 mm 0 0996 in 383745200 2 51 mm 0 0988 in 383755200 2 49 mm 0 0980 in 383765200 2 47 mm 0 0972 in 383775200
72. 1 14 Waveform Fuelinjec 2 B136 10 13 1 14 Waveform tor 3 B136 10 13 1 14 Waveform 4 B136 10 13 1 14 Waveform Idle air control solenoid valve Signal B136 0 or 13 14 or 13 14 Waveform Fuel pump Signal 1 B134 controller Signal 2 B136 A C relay control B137 ON 0 5 or less OFF 10 13 ON 0 5 or less OFF 13 14 Radiator fan relay 1 control B137 ON 0 5 or less OFF 10 13 ON 0 5 or less OFF 13 14 Radiator fan relay 2 control B137 ON 0 5 or less OFF 10 13 ON 0 5 or less OFF 13 14 With A C vehicles only Malfunction indicator lamp B137 Light ON 1 or less Light OFF 10 14 Engine speed output B136 0 13 or more Waveform Purge control solenoid valve B137 ON 1 or less OFF 10 13 ON 1 or less OFF 13 14 Signal B135 1 7 2 4 1 1 1 6 Power Pressure supply sensor B135 5 5 GND sen sor B135 0 0 Fuel level sensor B135 0 12 4 75 0 12 4 75 Small light switch B134 ON 0 OFF 10 13 ON 0 OFF 13 14 Blower fan switch B134 ON 0 OFF 10 13 ON 0 OFF 13 14 Rear defogger switch B134 ON 0 OFF 10 13 ON 0 OFF 13 14 Power
73. 12 4 mm 0 472 0 488 in STD 1 2 mm 0 047 in Intake Limit 0 8 mm 0 031 in Head edge thickness STD 1 5 mm 0 059 in Exhaust een Limit 0 8 mm 0 031 in 4 Intake 5 962 5 970 mm 0 2347 0 2350 in Stem diameter Exhaust 5 945 5 960 mm 0 2341 0 2346 in STD Intake 0 030 0 050 mm 0 0012 0 0020 in Stem oil clearance Exhaust 0 040 0 050 mm 0 0016 0 0020 in Limit 0 15 mm 0 0059 Intak 104 4 4 1101 Overall length 2 Exhaust 104 7 mm 4 122 in Free length 43 89 mm 1 7279 in Valve Squareness 2 5 1 9 mm 0 075 in spring Set 220 7 15 7 22 5 1 6 kgf 49 6 3 5 Ib 36 0 mm 1 417 in Tension spring height Lift 582 29 59 3 3 0 kgf 130 8 6 5 16 24 65 mm 0 970 ME STi 3 GENERAL DESCRIPTION MECHANICAL Surface warpage limit mating with cylinder head 0 05 mm 0 0020 in Surface grinding limit 0 1 mm 0 004 in A 92 005 92 015 mm 3 6222 3 6226 in B 91 995 92 005 mm 3 6218 3 6222 in 0 015 mm 0 0006 in 0 050 mm 0 0020 in 0 010 mm 0 0004 in 0 050 mm 0 0020 in 0 010 0 030 mm 0 0004 0 0012 in 0 050 mm 0 0020 in Enlarging boring limit 0 5 mm 0 020 in A 91 985 91 995 mm 3 6214 3 6218 in B 91 975 91 985 mm 3 6211 3 6214 in 0 25 mm 0 0098 in 05 0 50 0 0197 OS Standard clearance between piston STD 0 004 0 008 mm 0 0002 0 0003 in pin
74. 2 Propeller shaft Non turbo model 4 Rear differential T type 31 3 2 23 1 STi model 5 Bush T2 52 5 3 38 3 DS 6 GENERAL DESCRIPTION DRIVE SHAFT SYSTEM 4 FRONT AXLE STI MODEL 080027 1 Baffle plate DOJ 10 Boot DOJ 19 Oil seal OUT 2 Spring pin 11 Boot BJ 20 Hub bolt 3 Outer 12 BJASSY 21 Hub 4 Snap ring 13 Tone wheel With ABS 22 Axle nut 5 Inner race 14 Baffle plate 6 Ball 15 Oil seal IN Tightening torque N m kgf m ft Ib 7 Cage 16 Snap ring T 186 19 137 8 Circlip 17 Bearing 9 Boot band 18 Housing DS 7 GENERAL DESCRIPTION DRIVE SHAFT SYSTEM 5 REAR AXLE STI MODEL DR0028 1 Circlip 10 Boot DOJ 19 Tone wheel With ABS 2 Baffle plate DOJ 11 Boot BJ 20 Hub bolt 3 Outer race 12 BJASSY 21 Hub 4 Snap ring 13 Baffle plate 22 Axle nut 5 14 Oil seal 6 Ball 15 Housing Tightening torque N m kgf m ft Ib 7 Cage 16 Bearing 1 13 1 3 9 4 8 Circlip 17 Snap ring T2 186 19 137 9 Boot band 18 Oil seal OUT DS 8 FRONT DRIVE SHAFT DRIVE SHAFT SYSTEM 5 Front Drive Shaft C DISASSEMBLY 2 STIMODEL Refer to Rear Drive Shaft as a guide for disassem bly procedures lt Ref to DS 40 DISASSEMBLY Rear Drive Shaft gt D ASSEMB
75. 5 Remove the transfer driven gear Ref to 6 60 REMOVAL Transfer Driven Gear 6 Remove the center differential Ref to 6 62 REMOVAL Center Differential 7 Remove the oil pump Ref to 6 64 RE MOVAL Oil Pump 8 Remove the transmission case Ref to 6MT 68 REMOVAL Transmission Case 9 Remove the driven gear assembly Ref to 6MT 73 REMOVAL Main Shaft Assembly 10 Remove the 1st needle bearing 11 Remove the thrust needle bearing B INSTALLATION 1 Adjust the main shaft snap ring Ref to 6MT 85 ADJUSTMENT Main Shaft Assembly 2 Adjust the 1st 2nd shifter rod Ref to 6 123 ADJUSTMENT Shifter Fork and Rod 3 Install the thrust needle bearing NOTE Make sure to install the thrust needle bearing in proper direction TRO760 4 Install the 1st needle bearing 5 Install the driven gear assembly lt Ref to 6MT 74 INSTALLATION Main Shaft Assembly gt 6 Install the transmission case lt Ref to 6 69 INSTALLATION Transmission Case gt 7 Adjust backlash at axial direction of driven gear assembly Ref to 6MT 95 ADJUSTMENT Driv en Gear Assembly 8 Install the oil pump Ref to 6MT 65 INSTAL LATION Oil Pump 9 Install the center differential Ref to 6MT 62 INSTALLATION Center Differential 10 Install the transfer driven gear Ref to 6MT 60 INSTALLATION Transfer Driven Gear 11 Install
76. AT MODEL Cur MT MODEL BLUE BLACK BLACK BROWN BLACK Es 112 m ipq2 1 2 3415 4 5 6 2345678 1121314 15 1617 1819120 GG71 22A WI 49 CRUISE CONTROL SYSTEM WIRING SYSTEM SUPPLY ROUTING POWER SUPPLY ROUTING MB 9 SBF 5 B CRUISE CONTROL MODULE 02 p Ze VEHICLE SPEED SENSOR MT TRANSMISSION CONTROL MODULE AT AT MODEL MT MODEL 4 D TURBO ENGINE MODEL NON TURBO ENGINE MODEL STi TURBO ENGINE MODEL AND NON TURBO ENGINE MODEL NORMAL TURBO ENGINE MODEL 3 3 B3 8 8 B 5 B E BER ZS BR 56 2 CHECK CONNECTOR GND 07 DATA LINK CONNECTOR Ge BLACK SN BLACK GRAY BROWN A M 11213 172 a 1121314 314 1 2 5 1617 4478 2 10112 113141516 BLACK BLACK 855 GRAY GREEN q q I 1721314151617 8 1 2 3 4 56 7 8 9 10 121314 516 7 8 9 1 2 8 4 516 7 8 9 111121131141511617118 19 20 101112113 halis
77. B ACC IG MODULE AT ENGINE MODEL a NON TURBO ENGINE MODEL STi TURBO ENGINE MODEL AND NON TURBO ENGINE MODEL NORMAL TURBO ENGINE MODEL 5 d tr CXE 817 822 A 8282 GRAY B 6283 GRAY 56 GREEN 1213 1 2 H BROWN 1 2 3 4 5 6 7 8 1 2 3 4 5 617 819110 1121314 1567 8 9 314 1121814 9 1011 12 18 14 15 116 12 1314 15 16 17 18 1920 1011213 14 15 16 17 18 5167 8 19120121 22 23 24 9 10 11 12 Jabel GL46 22B WI 31 AIR CONDITIONING SYSTEM WIRING SYSTEM A B282 B B283 AUTO A C CONTROL MODULE os 8 JHE e LCD OUT TEMP AMBIENT SENSOR EVAPORATION SUNLOAD B COMBINATION THERMO SWITCH SENSOR METER A GRAY B GRAY BLACK BLACK 2131415 1617 1231415 6 7 a o 12 3 415 6 7 o 1231415 6 7 8 9 10 11 Ce 9 10 11 12 13 14 15 16 1 12 13 1415116117 1819120 12 13 14
78. CAUTION Always replace the pads for both right and left 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 wear indicator contacts the disc rotor a squeaking sound is produced as the wheel rotates If this sound is heard replace the pad 2 Apply a thin coat of Molykote AS880N Part No 26298 000 to each pad side cim 146 Install the pads on caliper body Install the cross spring Install the pad pins Install the clip 7 Connect the brake hose 3 4 5 6 Tightening torque 18 1 8 kgf m 13 3 ft lb CAUTION The brake hose must be connected without any twist Replace the brake hose gaskets with new ones 8 Bleed air from the brake system C DISASSEMBLY 3 17 INCH 1 Clean mud and foreign particles from the caliper body assembly CAUTION Be careful not to allow foreign particles to enter inlet at brake hose connector 2 Remove the piston boots from each piston end BRO013 BR 10 FRONT DISC BRAKE ASSEMBLY 3 Gradually supply compressed air via inlet of the brake hose to force piston out CAUTION Place a wooden block as shown in the figure to prevent damage to piston BRO141 Place a 30 mm 1 18 in wide wood block here 4 Remove th
79. E37 No 1 Engine ground E37 No 2 Engine ground Is the resistance more than 1M Q Go to step 3 Repair the short circuit between ECM and variable valve timing sole noid valve connec tor CHECK VARIABLE VALVE TIMING SOLE NOID VALVE 1 Remove the variable valve timing solenoid valve 2 Measure the resistance between variable valve timing solenoid valve terminal EN TURBO 37 Is the resistance between 6 and 12 Q Repair the poor contact in ECM and variable valve timing solenoid valve Replace the vari able valve timing solenoid valve Ref to ME STi 59 Camshaft gt DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC ENGINE DIAGNOSTICS EN TURBO 38 2002 IMPREZA STi SERVICE MANUAL QUICK REFERENCE INDEX TRANSMISSION SECTION CONTROL SYSTEMS CS MANUAL TRANSMISSION AND MT 6MT DIFFERENTIAL CLUTCH SYSTEM CL 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
80. TRO658 5 Install the extension case Tightening torque 48 4 9 kgf m 35 4 ft lb TRO657 6 Install the manual transmission assembly to ve hicle lt Ref to 6MT 39 INSTALLATION Manual Transmission Assembly gt C DISASSEMBLY 1 Remove the transfer drive gear lt Ref to 6MT 58 REMOVAL Transfer Drive Gear gt 2 Remove the extension guide TRO659 TRO660 6MT 49 EXTENSION CASE MANUAL TRANSMISSION AND DIFFERENTIAL 4 Using the ST remove the bearing cone ST 18758AA000 PULLER TRO661 A Bearing cone 5 Remove the thrust washer and oil plate TRO662 A Thrust washer B Oil plate 6 Remove the shifter arm oil seal TRO941 A Oil seal 7 Remove the reverse checking system lt Ref to 6MT 55 REMOVAL Reverse Checking System gt 8 Remove the extension oil seal lt Ref to 6MT 33 REPLACEMENT Oil Seal gt D ASSEMBLY 1 Install the reverse checking system lt Ref to 6MT 56 INSTALLATION Reverse Checking Sys tem gt 2 Install the extension case oil seal lt Ref to 6MT 33 REPLACEMENT Oil Seal gt 3 Using the ST install the shifter arm oil seal 18657AA000 INSTALLER 572 18671AA000 OIL SEAL GUIDE TRO942 A Oil seal 4 Install the oil plate TRO663 5 Select the bearing thrust washer and then install to extension cas
81. lt Ref to IN TURBO 10 REMOVAL Intercooler gt 3 Disconnect the transmission harness and chas sis harness TRO654 Transmission connector 4 Measure the resistance between neutral posi tion switch terminals If it is not within specifica tions replace the neutral position switch Gear shift position Terminal No Specified resistance Neutral position 1 Less than 1 Q Other positions More than 1 TRO101 6MT 48 EXTENSION CASE MANUAL TRANSMISSION AND DIFFERENTIAL 12 Extension Case A REMOVAL 1 Remove the manual transmission assembly from vehicle Ref to 37 REMOVAL Manual Transmission Assembly 2 Prepare the transmission for overhaul Ref to 6MT 42 Preparation for Overhaul gt 3 Remove the extension case TRO657 4 Completely remove the remaining liquid gasket from the extension case and transmission case B INSTALLATION 1 Select the transfer driven gear thrust washer and then install to extension case lt Ref to 6MT 51 ADJUSTMENT Extension Case gt 2 Apply oil lightly to the outer periphery of bearing cone and then install to extension case 3 Select the thrust washer of transfer drive gear and then install to center differential 4 Apply liquid gasket to the transmission case Liquid gasket THREE BOND 1215
82. se Lr 3 4 5 6 7 112 4 5 6 7 1 21 45678 BLACK 2101112 819 1011 12 8 9 1011 12 1314115 8 o 10 11 12 13 14 15 16 10 11 12113 14 15 16 17 18 19 20 21 Ga erco 13114115 1617 1617 18 19 20 21 22 17 18 19 20 21 22 23 24 22 23 24 25 26 27 28 29 30 91 2 3h GR10 26J WI 73 ENGINE ELECTRICAL SYSTEM WIRING SYSTEM ENGINE CONTROL MODULE 2 FE 9 SCH PURGE CONTROL SOLENOID FUEL INJECTOR FUEL INJECTOR FUEL INJECTOR FUEL INJECTOR VALVE NO 1 NO 2 NO 3 NO 4 DARK GRAY G22 BROWN 8136 D 8137 CEs DARK GRAY 1121314 UE STATS 16 131 Jus 9 E16 DARK GRAY 5 6718 8 9 10 11 12 13 14 15 16 10 11 1213 14 15 16 17 18 19 20 21 91011112 17 18 19 20 21 22 23 24 22 23 24 25 26 2728 29 30 31 E17 DARK GRAY 13 14 15 16 4112 GR10 26K WI 74 HEADLIGHT BEAM LEVELER SYSTEM WIRING SYSTEM 20 Headlight Beam Leveler System A SCHEMATIC WI 75 HEADLIGHT BEAM LEVELER SYSTEM WIRING SYSTEM 2 STI MODEL TO POWER SUPPLY ROUTING FB 11 FB 18 TAIL amp ILLUMI FB FUSE NO 18 NATION RELAY gt 8 gt HEADLIGHT LEVELI
83. 0 079 0 118 in between the speedometer drive gear and roller bearing NOTE Be careful not to damage the differential case CTT di 9 mee A Speedometer drive gear B Roller bearing 6 Using the ST remove the roller bearing ST 498077000 REMOVER TRO825 6MT 110 FRONT DIFFERENTIAL ASSEMBLY 2 SIDE RETAINER 1 Remove the O ring from side retainer B3M2192 emove the oil seal from side retainer B3M2193 3 Remove the claw of ST1 and then install the claw of ST2 ST1 ST2 398527700 PULLER ASSY 18760AA000 CLAW TRO937 A Claw MANUAL TRANSMISSION AND DIFFERENTIAL 4 Remove the bearing outer race from side retain er 398527700 PULLER ASSY ST2 398527705 CLAW TRO938 6 111 Shaft Side retainer FRONT DIFFERENTIAL ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL D ASSEMBLY 1 DIFFERENTIAL CASE 1 Install the washer to bevel gear NOTE Face the chamfered side of washer toward gear 2 Install the bevel gear and bevel pinion gear washer to differential case and then insert the pin ion shaft 0823 Pinion shaft Bevel pinion gear Bevel gear Washer 3 Check the bevel pinion gear backlash lt Ref to 6MT 113 BEVEL PINION GEAR BACKLASH IN SPECTION Front Differential Assembly gt 4 Using the ST align the pinion shaft a
84. 0 2083 13228 AA360 4 94 0 1945 13228 AA860 5 31 0 2091 13228 AA370 4 95 0 1949 13228 AA870 5 33 0 2098 13228 AA380 4 96 0 1953 13228 AA880 5 35 0 2106 13228 AA390 4 97 0 1957 13228 AA890 5 37 0 2114 13228 AA400 4 98 0 1961 13228 AA900 5 39 0 2122 13228 AA410 4 99 0 1965 13228 910 5 41 0 2130 13228 AA420 5 00 0 1969 13228 AA920 5 43 0 2138 13228 AA430 5 01 0 1972 13228 AA930 5 45 0 2146 13228 AA440 5 02 0 1976 13228 AA940 5 47 0 2154 13228 AA450 5 03 0 1980 13228 950 5 49 0 2161 13228 460 5 04 0 1984 13228 960 5 51 0 2169 13228 470 5 05 0 1988 13228 970 5 53 0 2177 13228 480 5 06 0 1992 13228 980 5 55 0 2185 13228 490 5 07 0 1996 13228 990 5 57 0 2193 13228 500 5 08 0 2000 13228 000 5 59 0 2201 13228 510 5 09 0 2004 13228 010 5 61 0 2209 13228 520 5 10 0 2008 13228 020 5 63 0 2217 13228 AA530 5 11 0 2012 13228 540 5 12 0 2016 13228 AA550 5 13 0 2020 13228 560 5 14 0 2024 13228 570 5 15 0 2028 13228 AA580 5 16 0 2031 13228 AA590 5 17 0 2035 13228 600
85. 0157 Check Yes Have the wheels been turned The ABS is nor freely such as when the mal Erase the cle is lifted up or operated DTC a rolling road Step CHECK ALL FOUR WHEELS FOR FREE Go to step 2 TURNING ABS 12 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR Step Check Yes ABS DIAGNOSTICS No CHECK SPECIFICATIONS OF ABSCM amp H U Check the specifications mark on amp H U CM AT Rear disc brake CN MT Rear disc brake CC AT Rear drum brake CD MT Rear drum brake C9 MT STi model Does the vehicle specification ABSCM amp H U specifica tion match Go to step 3 Replace the ABSCM amp H U Ref to ABS 4 ABS Control Mod ule and Hydraulic Control Unit ABSCM amp H U CAUTION Be sure to turn the ignition switch to OFF when removing ABSCM amp H U CHECK INPUT VOLTAGE OF G SENSOR 1 Turn the ignition switch to OFF 2 Remove the console box 3 Remove the G sensor from vehicle 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 No 1 No 3 Is the voltag and 5 25 V e between 4 75 Go to step 4 Repair the har ness connector between G sensor and ABSCM amp H U CHECK OPEN CIRCUIT IN G SENSOR OUT PUT HARNESS AND GROUND HARNESS 1 Turn the ignition switch to OFF 2 Disconnect the connec
86. 1 For option code refer to ID section Ref to ID 5 Option code SPC 10 Option codex1 IMPREZA KA SPECIFICATIONS Model 2 0L Tu rbo AWD WRX 5MT 4AT Unladen mass U M Front kgf Ib 830 1 830 855 1 885 Rear kgf Ib 560 1 235 555 1 224 Total kgf Ib 1 390 3 065 1 410 3 109 Gross vehicle mass G V M Front kgf Ib 970 2 138 970 2 138 Rear kgf Ib 920 2 028 920 2 028 Total kgf Ib 1 850 1 850 Option code 1 Air conditioner Cruise control ABS Aluminium wheel Rear spoiler Spoiler pac Model 2 0 L Turbo AWD WRX STi 5MT 6MT Curb weight C W Front kgf Ib 830 1 830 895 1 973 Rear kgf Ib 560 1 235 575 1 268 Total kgf Ib 1 390 3 065 1 470 3 241 Maximum permissible axle weight M P A W Front kgf Ib 970 2 138 1 030 2 271 Rear kgf Ib 920 2 028 920 2 028 Maximum permissible weight M P W Total kgf Ib 1 850 4 079 1 880 4 145 Option Air conditioner O Cruise control ABS Aluminium wheel Rear spoiler Spoiler pac 1 For option code refer to ID section Ref to ID 5 Option code SPC 11 SPECIFICATIONS IMPREZA Wagon Optio
87. 2 129 2 132 0 0838 0 0839 1 615 1 619 0 0636 0 0637 O D Outer Diameter 4 Measure the thrust clearance of crankshaft at center bearing If the clearance exceeds the limit replace the bearing Crankshaft thrust clearance Standard 0 030 0 115 mm 0 0012 0 0045 in Limit 0 25 mm 0 0098 in EN0341 5 Inspect individual crankshaft bearings for signs of flaking seizure melting and wear 6 Measure the oil clearance on each crankshaft bearing by means of plastigauge If the measure ment is not within the specification replace the de fective bearing with an undersize one and replace or recondition the crankshaft as necessary Unit mm in Crankshaft oil clearance 0 010 0 030 0 0004 0 0012 Limit 0 040 0 0016 Standard ME STi 01 MECHANICAL ENGINE TROUBLE IN GENERAL 21 Engine Trouble in General A INSPECTION NOTE RANK shown in the chart refer to the possibility of reason for the trouble in order Very often to Rarely Trouble Problem Parts etc A Very often B Sometimes C Rarely Possible Cause Rank 1 Engine will not start 1 Starter does not turn Starter Defective battery to starter harness Defective starter switch Defective inhibitor switch or neutral switch Defective starter Battery Poor terminal connection Run down
88. 24 Washer T3 11 8 1 2 8 7 11 Spacer 25 Snap T4 18 1 8 13 0 12 Lock wire 26 Bracket T5 32 3 3 23 6 13 Snap ring 27 Cable plate 14 Washer 28 Joint CS 3 GENERAL DIAGNOSTIC CONTROL SYSTEMS 7 General Diagnostic A INSPECTION Symptom Possible cause Remedy 1 Select lever 1 Starter does not run Adjust the select cable and inhibitor switch or inspect circuit 2 Back up light does not light up Adjust the select cable and inhibitor switch or inspect circuit 2 MT Gear shift lever 1 Can not shift to reverse Adjust the reverse check cable 6MT 2 Can shift to reverse without pulling up the Adjust or replace the reverse check cable slider 3 Slider can not be pulled up or is stuck pulled up Check the reverse check system of transmis sion Adjust or replace the reverse check cable CS 4 GEAR SHIFT LEVER 8 6MT Gear Shift Lever A REMOVAL 1 Set the vehicle on a lift 2 Disconnect the ground cable from battery 3 Remove the gear shift knob 4 Remove the console box front lt Ref to El 40 REMOVAL Console Box gt 5 Remove the boot plate from body TRO953 6 Lift up the vehicle 7 Remove the under cover 8 Remove the rear exhaust pipe and muffer lt Ref to EX TURBO 13 REMOVAL Rear Exhaust Pipe gt lt Ref to EX TURBO 14 REMOVAL Muffer gt 9 Remove the crossmember lt Ref to 6MT 35 REM
89. 9 Snap pin 18 1 8 13 0 4 Bracket 10 Lever 4 37 3 8 27 5 5 11 Operating cylinder STi model T5 41 4 2 30 2 CL 3 GENERAL DESCRIPTION CLUTCH SYSTEM RHD MODEL TRO980 1 Operating cylinder Except STi 7 Clevis pin Tightening torque N m kgf m ft Ib model 8 Snap pin 1 7 5 0 76 5 53 2 Washer 9 Pedal T2 8 0 8 5 8 3 Clutch hose 10 Clamp 15 1 5 10 8 4 Bracket 11 Clutch pipe T4 18 1 8 13 0 5 12 Bracket 5 25 2 5 18 1 6 Master cylinder ASSY 13 Operating cylinder STi model 6 37 3 8 27 5 7 41 4 2 30 2 CL 4 OPERATING CYLINDER 5 Operating Cylinder A REMOVAL 1 Remove the air cleaner case and air intake duct Non turbo model lt Ref to IN 6 REMOVAL Air Cleaner Case gt and lt Ref to IN 7 REMOVAL Air Intake Duct gt 2 Remove the intercooler Turbo model lt Ref to IN TURBO 10 REMOVAL Intercooler gt 3 Remove the clutch hose from operating cylinder CAUTION Cover the hose joint to prevent clutch fluid from flowing out Non turbo model B2M1179J A Clutch hose B Operating cylinder Turbo model except STi model ANA BK SE cA Clutch hose B Operating cylinder CLUTCH SYSTEM STi model
90. B3M1902 498247001 MAGNET BASE Used for measuring backlash between side gear and pinion and hypoid gear Used with DIAL GAUGE 498247100 B3M1903 498247100 DIAL GAUGE Used measuring backlash between side gear and pinion hypoid gear Used with MAGNET BASE 498247001 B3M1904 398507704 DI 10 Used for adjusting pinion height and preload ILLUSTRATION GENERAL DESCRIPTION TOOL NUMBER DESCRIPTION DIFFERENTIALS REMARKS B3M1905 398177700 INSTALLER Used for installing rear bearing cone For T type 1906 398457700 Used for removing side bearing retainer For T type B3M1907 398477703 DRIFT2 Used for press fitting the bearing race rear of differential carrier For T type B3M1908 398437700 DI 11 Used for installing side oil seal For T type GENERAL DESCRIPTION DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 398507702 DUMMY SHAFT Used for adjusting pinion height and preload For T type B3M1909 398507703 DUMMY COLLAR Used for adjusting pinion height and preload For T type 1910 398517700 Used for removing rear bearing cone For T type B3M1911 398487700 Used for press fitting the side bearing cone For T type B3M1912 DI 12 ILLU
91. EN TURBO 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 G1841GE3 See eee FUEL INJECTION FUEL SYSTEMS FU TURBO e sch sch sch ch sch sch AKRANASGHNAAKONASOMNAARWYNAS PO Oe EOS Page General Description Throttle Body Intake Manifold Engine Coolant Temperature Sensor Crankshaft Position Sensor Camshaft Position Sensor Knock Sensor Throttle Position Sensor Mass Air Flow and Intake Air Temperature Sensor Pressure Sensor Idle Air Control Solenoid Valve Fuel Injector Tumble Generator Valve Assembly 2 Tumble Generator Valve Achuator 3 Wastegate Control Solenoid Valve Front Oxygen A F Sensor Rear Oxygen Sensor Exhaust Temperature Sensor 0 4 Engine Control Module Main Relay Fuel Pump Relay Fuel Pump Controller Fuel Fuel Tank Fuel Filler Pipe Fuel Pump Fuel Level Sensor Fuel Sub Level Sensor Fuel Filter Fuel Cut Valve Fuel Damper Valve Fuel Delivery Return and Evaporation Lines Fuel System Trouble in General Variable Valve Timing Camshaft Positon Sensor 5 Variable Valve Timing Solenoid Valve 6 TUMBLE GENERATOR VALVE ASSEMBLY FUEL INJECTION FUEL
92. FB 36 F B FUSE NO 13 02 02 ILM ROI 2 HAZARD SWITCH ILLUMI LIGHT 5 Cyt 2 DIMMER DIMMER DRIVER 96 pma 90 99990 o lel SS el B B p S S f d d d B bj 4 INDICATOR LIGHT ha POWER MODE INDICATOR LIGHT HOLD MODE INDICATOR LIGHT ex OUT TEMP LCD BACK LIGHT ODO TRIP LCD BACK LIGHT 10 E lt gt REF TO D R R 01 REF TO AT R 02 REF TO AT R 01 59 22 GREEN BLACK BLACK LII 4 1 2 3 4 5 6 71 8 9110 c 12 GREEN 2131445 6 8 1 2 3 41516 7 8 9 10 11 12 13 14 A N 10 A E 456 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 10 11 12 13 14 15 16 17 18 19 20 21 22123 24 25 26 27 28 29 30 3132 GR21 26B WI 82 CLEARANCE LIGHT AND ILLUMINATION LIGHT SYSTEM WIRING SYSTEM TO POWER SUPPLY ROUTING FB 6 FB 7 F B FUSE NO 5 F B FUSE NO 5 03 03 tc
93. Grounding line 26 1 Measure the I O signal voltage after removing the connector from the ABSCM amp H U terminal 2 Measure the I O signal voltage at connector 200 or 74 ABS 5 CONTROL MODULE I O SIGNAL ABS DIAGNOSTICS B SCHEMATIC H 8 lt 10 4 XJ 01 4 25 so 26 HERR 27 012 28 M 8 2 NJ 15 0155 1 Battery 10 Front right inlet solenoid valve 19 Brake warning light 2 IGN 11 Front right outlet solenoid valve 20 ABS warning light 3 ABS control module and hydrau 12 Rear left inlet solenoid valve 21 Stop light switch lic control unit ABSCM amp H U 13 Rear left outlet solenoid valve 22 Stop light 4 ABS control module area 14 Rear right inlet solenoid valve 23 G sensor 5 Valve relay 15 Rear right outlet solenoid valve 24 Lateral G sensor only STi model 6 Motor relay 16 Transmission control module only 25 Front left ABS sensor 7 Motor AT vehicle 26 Front right ABS sensor 8 Front left inlet solenoid valve 17 Diagnosis connector 27 Rear left ABS sensor 9 Front left outlet solenoid valve 18 Data link conn
94. Install with the liquid gasket remaining to prevent the mating surface of clutch housing and adapter plate from damaging Tightening torque 50 5 1 kgf m 36 9 ft lb 4 Using the ST rotate several times ST 18631AA000 HANDLE TRO817 6MT 105 MANUAL TRANSMISSION AND DIFFERENTIAL DRIVE PINION SHAFT ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 5 Remove the drive pinion shaft assembly and then check tooth contact If it is inaccurate adjust the back lash or thickness of shim Checking item Contact pattern Corrective action Tooth contact Tooth contact pattern is slightly shifted toward to under no load rotation When loaded contact pattern moves toward heel Toe side Heel side B3M0317A Face contact Backlash is too large This may cause noise and chipping at tooth ends B3M0319 Increase thickness of drive pinion height adjusting shim in order to bring drive pin ion close to crown gear 0323 Flank contact backlash is too small This may cause noise and stepped wear on surfaces 0320 Reduce thickness of drive pinion height adjusting shim in order to move drive pin ion away from crown gear 0324 Toe contact Inside end contact Contact areas is small This may cause chipping at toe SEA B3M0321 Adjust as for flank contact 0324 Heel contact outside end contact Contact ar
95. Needle vibrates above and below normal position in narrow range Defective ignition system or throttle chamber idle adjustment ME STi 25 ENGINE OIL PRESSURE MECHANICAL 6 Engine Oil Pressure A INSPECTION 1 Remove the oil pressure switch from engine cyl inder block lt Ref to LU 21 REMOVAL Oil Pres sure Switch gt 2 Connect the oil pressure gauge hose to cylinder block 3 Connect the battery ground cable G6M0095 4 Start the engine and measure the oil pressure 52 0242 Oil pressure 98 kPa 1 0 kg cm 14 psi or more at 800 rpm 294 kPa 3 0 kg cm 43 psi or more at 5 000 rpm CAUTION If the oil pressure is out of specification check oil pump oil filter and lubrication line Ref to LU 25 INSPECTION Engine Lubrica tion System Trouble in General f the oil pressure warning light is turned ON and oil pressure is in specification replace the oil pressure switch Ref to LU 25 INSPEC TION Engine Lubrication System Trouble in General NOTE The specified data is based on an engine oil tem perature of 80 C 176 F 5 After measuring the oil pressure install the oil pressure switch lt Ref to LU 21 INSTALLATION Oil Pressure Switch gt Tightening torque 25 2 5 kgf m 18 1 ft lb ME STi 26 FUEL PRESSURE 7 Fuel Pressure A INSPECTION WARNING Before removing the fuel pressure gauge re lease fuel pressure NOT
96. RH DTC DETECTING CONDITION Two consecutive driving cycles with fault e TROUBLE SYMPTOM e Erroneous idling CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode lt Ref to EN TURBO 45 OP ERATION Clear Memory Mode gt and Inspection Mode lt Ref to EN TURBO 42 Inspection Mode gt WIRING DIAGRAM ECM VARIABLE VALVE TIMING F5 SOLENOID VALVE RH EN1530 EN TURBO 30 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC ENGINE DIAGNOSTICS Yes No CHECK HARNESS BETWEEN ECM AND VARIABLE VALVE TIMING SOLENOID VALVE 1 Turn the ignition switch to OFF 2 Disconnect the connector from ECM and variable valve timing solenoid valve 3 Measure the resistance between ECM and variable valve timing solenoid valve Connector amp terminal B84 No 6 E38 No 1 B84 No 12 E38 No 2 Is the resistance less than 1 Q Go to step 2 Repair the open circuit in harness between ECM and variable valve tim ing solenoid valve connector NOTE In this case repair the following Open circuit in harness between ECM and variable valve timing sole noid valve connec tor Poor contact in coupling connec tor CHECK HARNESS BETWEEN ECM AND VARIABLE VALVE TIMING SOLENOID VALVE Measure the resistance betwe
97. Rear RH LH T3 10 1 0 7 9 Exhaust camshaft RH 21 Exhaust camshaft cap Rear LH 4 6 4 0 65 4 7 10 Cylinder head bolt 22 Rocker cover gasket LH T5 20 2 0 14 5 11 seal 23 Rocker cover LH 12 Cylinder head RH 24 filler cap ME STi 9 GENERAL DESCRIPTION MECHANICAL 3 CYLINDER HEAD AND VALVE ASSEMBLY heme ox 4 5 6 7 8 9 1194 1 Exhaust valve 5 Intake valve oil seal 9 Valve lifter 2 Intake valve 6 Valve spring 10 Exhaust valve oil seal 3 Cylinder head 7 Retainer 11 Intake valve guide 4 Valve spring seat 8 Retainer key 12 Exhaust valve guide ME STi 10 GENERAL DESCRIPTION MECHANICAL 4 CYLINDER BLOCK 0144 1 Oil pressure switch 15 Oil cooler Tightening torque kgf m ft lb 2 Cylinder block RH 16 Waster by pass pipe T1 5 0 5 3 6 3 Service hole plug 17 Connector T2 6 4 0 65 4 7 4 Gasket 18 Oil strainer 10 1 0 7 5 Oil separator cover 19 Gasket T4 25 2 5 18 1 6 Water by pass pipe 20 Oil pan T5 47 4 8 34 7 7 Oil pump 21 Drain plug T6 69 7 0 50 6 8 Front oil seal 22 Metal gasket T7 First 12 1 2 8 7 9 Rear oil seal 23 Oillevel gauge guide Second 12 1 2 8 7 10 O ring 24 Oil filter 16 1 6 11 6 11 Service hole cover 25 Gasket T9 44 4 5 33 12 Cylinder block LH 26 Water pump
98. Sensor CHECK LATERAL G SENSOR Measure the voltage between lateral G sensor connector terminals Connector amp terminal B257 No 2 No 3 Is the voltage between 3 3 and 3 7 V when lateral G sensor is inclined forwards to 9092 ABS 26 Go to step 20 Replace the lateral G sensor Ref to ABS 5 Lateral G Sensor DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS Step Check Yes No CHECK LATERAL G SENSOR Is the voltage between 1 3 and Go to step 21 Replace the lateral Measure the voltage between lateral G sensor 1 7 V when lateral G sensor is G sensor lt Ref to connector terminals inclined backwards to 90 ABS 5 Lateral G Connector amp terminal Sensor gt B257 No 2 No 3 CHECK POOR CONTACT IN CONNECTORS 15 there poor contact in con the con Go to step 22 Turn the ignition switch to OFF nector between ABSCM amp H U and lateral G sensor CHECK ABSCM amp H U Is the same DTC as in current Replace the Go to step 23 1 Connect all connectors diagnosis still being output ABSCM amp H U 2 Erase the memory Ref to ABS 4 3 Perform the inspection mode ABS Control Mod 4 Read out the DTC ule and Hydraulic Control Unit ABSCM amp H U CHECK ANY OTHER DIAGNOSTIC TROU v Are other DTCs being output Proceed with the A temporary poor BLE CODES DTCs APPEARANCE diagnosis corre contact sponding to DTC
99. TRO779 A 2nd needle bearing B 2nd driven gear C Protrusion portion of 2nd synchro cone 17 Install the key d TRO780 18 Using the ST install the 3rd 4th driven gear ST 18654AA000 INSTALLER CAUTION Do not apply pressure in excess of 40 KN 4 0 ton 4 4 US ton 3 9 Imp ton NOTE Make sure to install the 3rd 4th driven gear proper direction Align the groove of 3rd 4th driven gear with key TRO781 A 4th gear B 3rd gear C 2nd gear 19 Make sure the 2nd driven gear is smoothly turned by hand If not reassemble 20 Install the key TRO782 6MT 92 DRIVEN GEAR ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 21 Using the ST install the 5th 6th driven gear ST 18654AA000 INSTALLER CAUTION Do not apply pressure in excess of 40 KN 4 0 ton 4 4 US ton 3 9 Imp ton NOTE Make sure to install the 5th 6th driven gear proper direction Align the groove of 5th 6th driven gear with key TRO783 A 6th gear B 5th gear C 4th gear 22 Using the ST install the ball bearing ST 18654AA000 INSTALLER CAUTION Do not apply pressure in excess of 40 KN 4 0 ton 4 4 US ton 3 9 Imp ton NOTE Make sure to install the ball bearing in proper direc tion 23 Make sure the ball bearing is smoothly turned by hand If not reassemble 24 Install a new lock nut 25 I
100. The indicator is installed upside down compared to the setting procedure of zero point Add d1 fixing value 55 mm 2 17 in from the following figure to D1 to obtain measurement value of D1 TRO861 Lot No Mark M SFT M SFT M SFT T mm in Snap ring Snap ring Snap ring 805072010 805072011 805072012 t 1 65 mm t 1 95 mm t 2 25 mm 0 065 0 077 in 0 089 in SC 32945AA021 32945AA031 32945AA041 2 5362 mene 4 32945AA011 32945AA021 32945AA031 2 5480 1 28 2 om 32945AA001 32945AA011 32945AA021 2 5598 9 1 ene T Thickness 4 SELECTION OF REVERSE FORK ROD NOTE Perform the following procedures when Replacing the reverse idler gear Replacing the reverse idler gear No 2 Replacing the adapter plate Replacing the base 1 Insert the reverse idler gear assembly in adapter plate MANUAL TRANSMISSION AND DIFFERENTIAL 2 Tighten the base COMPL fixing bolt Tightening torque 25 2 5 kgf m 18 1 ft lb Yo 3 Set the height gauge to adapter plate Lower the indicator of height gauge to mating surface of adapter plate and case then set to zero point ST 18853AA000 HEIGHT GAUGE Uy T Ao ROSSI Remove the remaining gasket on edge surface with scr
101. Turn the crankshaft using ST ST 499987500 CRANKSHAFT SOCKET EN1197 12 Measure the 1 cylinder intake valve and 3 cylinder exhaust valve clearance by using thick ness gauge A CAUTION Insert the thickness gauge in direction as horizontal as possible with respect to the shim Measure the exhaust valve clearances while lifting up the vehicle Valve clearance Intake 0 20 0 02 mm 0 0079 0 0008 Exhaust 0 25 0 02 mm 0 0098 0 0008 in NOTE If the measured value is not within specification take notes of the value in order to adjust the valve clearance later on A B2M1234B 13 If necessary adjust the valve clearance lt Ref to ME STi 30 ADJUSTMENT Valve Clearance 14 Further turn the crankshaft pulley clockwise Using the same procedures described previously then measure the valve clearances again 1 Set the arrow mark on camshaft sprocket to position shown in the figure and measure 2 cylinder exhaust valve and 3 cylinder intake valve clearances EN1198 2 Set the arrow mark on camshaft sprocket to position shown in the figure and measure 2 cylinder intake valve and 4 cylinder exhaust valve clearances EN1199 ME STi 29 VALVE CLEARANCE MECHANICAL 3 Set the arrow mark on camshaft sprocket to position shown in the figure and measure 1 cylinder exhaust valve and 4 cyli
102. faces merely a high roaring noise will oc cur at high speeds but if any part is broken rhythmical knocking sound will be heard even at low speeds 6MT 133 Replace GENERAL DIAGNOSTIC TABLE MANUAL TRANSMISSION AND DIFFERENTIAL 2 DIFFERENTIAL Symptom Possible cause Remedy 1 Broken differential case gear bear ing etc NOTE Abnormal noise will develop and finally it will become impossible to continue to run due to broken pieces obstructing the gear revolution a Insufficient or improper oil Disassemble differential and replace bro ken components and at the same time check other components for any trouble and replace if necessary b Use of vehicle under severe condi tions such as excessive load and improper use of clutch Readjust bearing preload and backlash and face contact of gears c Improper adjustment of taper roller bearing Adjust d Improper adjustment of drive pinion and hypoid driven gear Adjust e Excessive backlash due to worn dif ferential side gear washer or differential pinion vehicle under severe operating conditions Add recommended oil to specified level Do not use vehicle under severe operat ing conditions f Loose hypoid driven gear clamping bolts Tighten 2 Differential and hypoid gear noises Troubles of the differential and hypoid gear always appear as noise problems Therefore noise is the first indicatio
103. 1 COMBINATION METER D e 2 314 AIR MIX ACTUATOR B 2 INTERCOOLER WATER SPRAY TIMER STi MODEL FUEL PUMP RELAY 4 46 MAIN RELAY B 1 MODE ACTUATOR B 2 0 0 4 STi MODEL ES EXCEPT STi MODEL 3 A 10 GREEN 4151617 12 3 11213 81910 1121314 6 7 8 9 10 15 6 7 8 879 141516 DESEN UE 3 4 4 h 9 12 6120 5161778 B283 5 6 7 8 9 10 213 415 6 7 1121314 5 6 7 8 9 8 9110 11 12 1314 1 2 41516 7 v e e to tt 12 13 14 1111211314 15 16 17 18 19 20 SCHER sue 16 gt GREEN 3114 e 1415161 19 24 25 26 29 34 35 36 10 20 _ 27 37 1 2 3 4 5 6 7 9 del 112 181451617114 eTo Tori ia EHS
104. 10 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS 12 Diagnostics Chart with Diagnosis Connector AA DTC 56 ABNORMAL G SENSOR OUTPUT VOLTAGE DIAGNOSIS Faulty sensor output voltage TROUBLE SYMPTOM ABS does not operate WIRING DIAGRAM LHD MODEL ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT SHIELD JOINT CONNECTOR 7 n lt STi MODEL EXCEPT STi MODEL ABS G SENSOR JOINT CONNECTOR STi MODEL LATERAL ABS G SENSOR G SENSOR STi MODEL 1121314 1516 1121314 11213141 1 213 4 5 6 7 1011121314 15 5 6 7 8 10 11 12 13 14 15 16 17 18 19 20 16 17 18 19 20 21 22 gt 272812930131 29224 11 29 26 156 ABS 11 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS WIRING DIAGRAM RHD MODEL ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT SHIELD JOINT CONNECTOR 50 STi MODEL EXCEPT STi MODEL ABS G SENSOR JOINT CONNECTOR STi MODEL ABS LATERAL G SENSOR STi MODEL 6 121314176 H 5 Ex 1 21 3 5 7 819 11213 14151617 8 1314115 18 19 20 21 22 6117 18 19 2021 5 16 17 23 24 25 26 lt
105. 12 Remove the pitching stopper and remove the pitching stopper bracket 13 Set the ST NOTE Also Part No 41099AA010 can be used ST 41099AA020 ENGINE SUPPORT TRO0641 14 Remove the center and rear exhaust pipe and muffler Ref to EX TURBO 8 REMOVAL Cen ter Exhaust Pipe gt Ref to EX TURBO 13 RE MOVAL Rear Exhaust gt lt Ref to EX TURBO 12 REMOVAL Joint Pipe 15 Remove the propeller shaft Ref to DS 15 REMOVAL Propeller Shaft 6 37 MANUAL TRANSMISSION ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 16 Remove the front stabilizer bolt TRO0090 17 Remove the ball joint of transverse link from housing 0642 18 Using the ST remove the spring of front drive shaft ST 398791700 NOTE Do not reuse the spring pin REMOVER G2M0325 19 Remove the front drive shaft 20 Set the transmission jack under the transmis sion then remove the front crossmember and rear crossmember TRO643 21 Move the transmission to right side then re move the joint COMPL stay bolt and reverse check cable NOTE If the transmission is not moved the joint COMPL and stay bolt will contact body and damage may occur TRO644 A Joint COMPL bolt B Stay bolt C Reverse check cable 6MT 38 MANUAL TRANSMISSION ASSEMBLY 22 Remove the fixing bolt of engine and
106. 13228 AA630 5 21 0 2051 13228 AA140 4 72 0 1858 13228 AA640 5 22 0 2055 13228 AA150 4 73 0 1862 13228 AA650 5 23 0 2059 13228 AA160 4 74 0 1866 13228 AA660 5 24 0 2063 13228 AA170 4 75 0 1870 13228 AA670 5 25 0 2067 13228 AA180 4 76 0 1874 13228 AA680 5 26 0 2071 13228 AA190 4 77 0 1878 13228 AA690 5 27 0 2075 13228 AA200 4 78 0 1882 13228 AA700 4 38 0 1724 13228 AA210 4 79 0 1886 13228 AA710 4 40 0 1732 13228 AA220 4 80 0 1890 13228 AA720 4 42 0 1740 13228 AA230 4 81 0 1894 13228 AA730 4 44 0 1748 13228 AA240 4 82 0 1898 13228 AA740 4 46 0 1756 13228 AA250 4 83 0 1902 13228 AA750 4 48 0 1764 13228 AA260 4 84 0 1906 13228 AA760 4 50 0 1772 13228 AA270 4 85 0 1909 13228 AA770 4 52 0 1780 13228 AA280 4 86 0 1913 13228 AA780 4 54 0 1787 13228 AA290 4 87 0 1917 13228 AA790 4 56 0 1795 13228 AA300 4 88 0 1921 13228 AA800 4 58 0 1803 13228 AA310 4 89 0 1925 13228 AA810 4 60 0 1811 13228 AA320 4 90 0 1929 13228 AA820 4 62 0 1819 13228 AA330 4 91 0 1933 13228 AA830 4 64 0 1827 13228 AA340 4 92 0 1937 13228 AA840 4 66 0 1835 13228 AA350 13228 AA850 5 29
107. 1516117 18 1920 21122123124 1213 14 1516117 18 19 20 21 22 23 24 1 2 B GREEN 12 314 56 71 8 o to t1 t2 13 14 15 16 17 18 1920 21 22 2324 2526127 2829130 GL46 22C WI 32 AIR CONDITIONING SYSTEM WIRING SYSTEM A B282 B B283 AUTO A C CONTROL MODULE SMJ AIR MIX ACTUATOR MODE ACTUATOR 90 OFF Dez moe FRESH RECIRC ACTUATOR REF TO GND 02 REF TO GND 02 LIGHT GRAY BLACK A B282 GRAY 283 GRAY rer BLACK 122 1121314 1 2 4 5 6 7 8 9 627 Gray 3 5 6 7 8 8 3141516 9 101 12 13 1415 116 12 1314 15 1617 1819120 d 2 314 GL46 22D WI 33 AIR CONDITIONING SYSTEM WIRING SYSTEM 2 AUTO A C RHD MODEL POWER SUPPLY ROUTING e FB 19 FB 20 FB 34 F B FUSE 17 F B FUSE 17 F B FUSE NO 1 tc lt IG IG F B FUSE NO 2 B lt lt TURBO ENGINE MODEL A NON TURBO ENGINE MODEL BLOWER MOTOR AIR CONDITIONING RELAY BLOWER MOTOR BR 1 ENGINE 2 CONTROL 8134 MODULE
108. 152 6 0 dia 2 160 6 3 dia Installation position R Rear Reduction gear ratio B 3 900 E 4 111 F 4 444 Rear differential 2 EG Specification differ ences J Case B Code Reduction gear ratio LSD EG 3 900 No ER 3 700 Viscous EM 4 444 SURETRAC EJ 4 111 Viscous EF 3 545 Viscous HG 3 500 SURETRAC HJ 3 545 SURETRAC ID 4 IDENTIFICATION IDENTIFICATION Option code ECPS Meaning Details Destination Main option of vehicle ID 5 IDENTIFICATION IDENTIFICATION ID 6 2002 IMPREZA STi SERVICE MANUAL QUICK REFERENCE INDEX ENGINE 2 SECTION FUEL INJECTION FUEL SYSTEMS FU TURBO EMISSION CONTROL EC TURBO AUX EMISSION CONTROL DEVICES INTAKE INDUCTION IN TURBO MECHANICAL ME STi 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 ENGINE DIAGNOSTICS
109. 2 Prepare the transmission for overhaul lt Ref to 6MT 42 Preparation for Overhaul gt 3 Remove the oil pipe neutral position switch back up light switch and harness lt Ref to 6MT 44 REMOVAL Oil Pipe gt lt Ref to 6MT 47 REMOV AL Neutral Position Switch Ref to 6MT 45 REMOVAL Back up Light Switch 4 Remove the extension case Ref to 6MT 49 REMOVAL Extension Case 5 Remove the transfer driven gear Ref to 6 60 REMOVAL Transfer Driven Gear 6 Remove the center differential Ref to 6 62 REMOVAL Center Differential 7 Remove the oil pump Ref to 6 64 RE MOVAL Oil Pump 8 Remove the transmission case Ref to 6MT 68 REMOVAL Transmission Case 9 Remove each gear assembly Ref to 6MT 73 REMOVAL Main Shaft Assembly 10 Remove the drive pinion shaft assembly Ref to 6MT 101 REMOVAL Drive Pinion Shaft As sembly gt 11 Remove the front differential assembly Ref to 6MT 107 REMOVAL Front Differential Assem bly gt 12 Remove the vehicle speed sensor lt Ref to 6MT 34 REMOVAL Vehicle Speed Sensor gt 13 Remove the speedometer gear lt Ref to 6MT 116 REMOVAL Speedometer Gear B INSTALLATION 1 Install the pitching stopper bracket Tightening torque 41 N m 4 2 kgf m 30 2 ft lb 2 Install the soeedometer gear lt Ref to 6MT 116 INSTALLATION Speedometer Gear gt 3 Install the vehicle speed sensor Ref to 6MT
110. 2 Inspect the variable valve timing system repair or replace if the following to operating angle and variable valve timing sole necessary clean the oil pas noid valve duty output using Subaru Select Engine oil sage Monitor and OBD II general scan tool amount con Replace the Specification tamination engine oil and idle Variable timing system operating angle Oil pipe clog the engine for 5 Approx 0 degree Variable minutes then Variable valve timing solenoid valve duty out valve timing replace the oil filter put Approx 10 solenoid valve engine oil NOTE clog or con Subaru Select Monitor tamination in oil For detailed operation procedure refer to the passage set READ CURRENT DATA FOR ENGINE tling at spring Ref to EN TURBO 34 Subaru Select Moni stuck at valve tor ntake cam OBD II general scan tool shaft sludge For detailed operation procedures refer to the damage at OBD II General Scan Tool Instruction Manual camshaft Timing belt timing mark aligning EN TURBO 19 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC ENGINE DIAGNOSTICS DJ DTC P0021 VARIABLE VALVE TIMING SYSTEM 2 LH DTC DETECTING CONDITION Immediately at fault recognition TROUBLE SYMPTOM Engine stalls Erroneous idling CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode lt Ref to EN TURBO 45 OP ERATION
111. 20 21 22 5 16 17 lt 23 24 25 26 0157 Step Check Yes CHECK OUTPUT OF LATERAL SENSOR Is the lateral G sensor output Go to step 2 Go to step 5 USING SELECT MONITOR on monitor display between 2 3 1 Select Current data display amp Save on the and 2 7 V when lateral G sen select monitor sor is in horizontal position 2 Read the lateral G sensor output in select monitor data display ABS 24 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS Step Check Yes No CHECK POOR CONTACT IN CONNECTORS Is there poor contact in con nector between ABSCM amp H U and lateral G sensor Repair the con nector Go to step 3 CHECK ABSCM amp H U 1 Connect all connectors 2 Erase the memory 3 Perform the inspection mode 4 Read out the DTC Is the same DTC as in current diagnosis still being output Replace the ABSCM amp H U lt Ref to ABS 4 ABS Control Mod ule and Hydraulic Control Unit ABSCM amp H U gt Go to step 4 CHECK ANY OTHER DIAGNOSTIC TROU BLE CODES DTCs APPEARANCE Are other DTCs being output Proceed with the diagnosis corre sponding to DTC A temporary poor contact CHECK FREEZE FRAME DATA 1 Select Freeze frame data on the select monitor 2 Read front right wheel speed on the select monitor display Is th
112. 22 79 584 22 99 638 25 12 643 25 32 584 22 99 Rear propeller shaft Joint to joint length Lo i 713 28 07 708 27 87 63 5 2 500 Outside diameter of tube 57 0 2 244 A A Di De s Y x y zl i 5 L1 L2 B B Di 9 2 5 E Ww JI f _ 4 080008 A UJ type DOJ type DS 2 GENERAL DESCRIPTION DRIVE SHAFT SYSTEM 2 FRONT DRIVE SHAFT ASSEMBLY SHAFT Shaft diameter Non turbo 26 mm 1 02 in Turbo 28 mm 1 10 in BJ92 DOJ87 28 mm 1 10 in Model Type of drive shaft assembly Except STi EBJ87 SFJ82 Y 1 040025 EBJ87 SFJ82 BJ924DOJ87 Measuring point DS 3 GENERAL DESCRIPTION DRIVE SHAFT SYSTEM 3 REAR DRIVE SHAFT ASSEMBLY No of identification protrusion on shaft EBJ82 DOJ82 Sedan RH 2 Two EBJ82 DOJ82 Sedan LH tree 1 One BJ79 DOJ79 Sedan R160RH 2 Two BJ79 DOJ79 Sedan R160LH 1 One BJ79 DOJ79 Sedan R152R L Sedan 1 6 L 2 0 L NA AT 3 Three BJ79 DOJ79 Wagon R152R L Wagon 1 6 L 2 0L NA AT None EBJ82 DOJ82 Wagon RH EBJ82 DOJ82 Wagon LH BJ79 DOJ79 Wagon R160RH BJ79 DOJ79 Wagon R160LH BJ87 DOJ87 R L STi model Size Model
113. 28 REAR LEFT ABNORMAL ABS SEN SOR SIGNAL Diagnostics Chart with Subaru Select Monitor gt Abnormal ABS sensor signal on any one of four sensor Abnormal ABS sensor signal on any one of four lt Ref to ABS 114 DTC 29 ABNORMAL ABS SENSOR SIGNAL ON ANY ONE OF FOUR SENSOR Diagnostics Chart with Sub aru Select Monitor gt Front right inlet valve malfunction Front right inlet valve malfunction lt Ref to ABS 118 DTC 31 FRONT RIGHT INLET VALVE MAL FUNCTION Diagnostics Chart with Subaru Select gt Front right outlet valve malfunction Front right outlet valve malfunction lt Ref to ABS 123 DTC 32 FRONT RIGHT OUTLET VALVE MAL FUNCTION Diagnostics Chart with Subaru Select gt Front left inlet valve malfunction Front left inlet valve malfunction lt Ref to ABS 118 DTC 33 FRONT LEFT INLET VALVE MAL FUNCTION Diagnostics Chart with Subaru Select Monitor gt Front left outlet valve malfunction Front left outlet valve malfunction lt Ref to ABS 123 DTC 34 FRONT LEFT OUTLET VALVE MAL FUNCTION Diagnostics Chart with Subaru Select Monitor Rear right inlet valve malfunction Rear right inlet valve malfunction Ref to ABS 118 DTC 35 REAR RIGHT INLET VALVE MAL FUNCTION Diagnostics Chart with Subaru Select Monitor Rear right outlet valve malfunction Rear right outlet valve malfun
114. 383785200 2 43 mm 0 0957 in 383795200 2 41 mm 0 0949 in 383805200 2 39 mm 0 0941 in 383815200 2 37 mm 0 0933 in 383825200 2 35 mm 0 0925 in 383835200 2 33 mm 0 0917 in 383845200 2 45 mm 0 0965 in 2 31 mm 0 0909 in Pinion height adjusting shim Part No Length 38336AA230 3 09 mm 0 1217 in 38336AA240 3 12 mm 0 1228 in 38336AA250 3 15 mm 0 1240 in 38336AA260 3 18 mm 0 1252 in 38336AA270 3 21 mm 0 1264 in 38336AA280 3 24 mm 0 1276 in 38336AA290 3 27 mm 0 1287 in 38336AA300 3 30 mm 0 1299 in 38336AA310 3 33 mm 0 1311 in 38336AA320 3 36 mm 0 1323 in 38336AA330 3 39 mm 0 1335 in 38336AA340 3 42 mm 0 1346 in 38336AA350 3 45 mm 0 1358 in 38336AA360 3 48 mm 0 1370 in 38336AA370 3 51 mm 0 1382 in 38336AA380 3 54 mm 0 1394 in 38336AA390 3 57 mm 0 1406 in 38336AA400 3 60 mm 0 1417 in 38336AA410 3 63 mm 0 1429 in 38336AA420 3 66 mm 0 1441 in Side bearing standard width 20 00 0 7874 Side bearing retainer shim Part No Thickness 383475201 0 20 mm 0 0079 in 383475202 0 25 mm 0 0098 in 383475203 383475204 0 40 mm 0 0157 in 383475205 0 30 mm 0 0118 in 0 50 mm 0 0197 in Crown
115. 475 151 02 1 994 121 67 Compression ratio 10 0 0 2 8 0 0 2 10 0 0 2 8 0 0 2 Firing order 1 3 2 4 Idle speed at Park Neutral position rpm 700 100 750 100 700 100 700 100 Maximum output kW HP rpm 70 94 5 200 123 5 600 92 160 215 5 600 112 150 5 600 195 261 6 000 Maximum torque N m kgf m ft Ib rpm 143 14 6 105 5 3 600 18 8 136 0 3 600 184 292 SPC 2 29 8 215 4 3 600 223 22 7 164 5 3 600 343 35 0 253 0 4 000 IMPREZA SPECIFICATIONS C ELECTRICAL Model 1 6L Non turbo 2 0 L Turbo 2 01 2 5L STi Ignition timing at idling speed BTDC rpm 5 10 700 10 10 700 12 10 750 10 10 700 15 10 700 12 10 700 Spark Type and plug manufacturer Without OBD NGK BKR6E without catalyst CHAMPION RC8YC4 with catalyst BKR6E 11 with catalyst NGK BKR6E without catalyst CHAMPION RC10YC4 with catalyst NGK BKR5E 11 with catalyst BKR6E with out catalyst CHAMPION RC10YCA with cat alyst NGK BKR5E 11 with catalyst With OBD CHAMPION RC8YCA CHAMPION 10 4 Alternate NGK BKR6E 11 Alternate NGK BKR5E 11 NGK PFR6G CHAMPION RC10YC4 Alternate NGK BKR6E 11 NGK PFR6G Generator 12V 75A
116. 7 ft lb CAUTION Be sure to use a new gasket When installing the water pump tighten bolts in two stages in alphabetical sequence as shown in the figure EN1521 25 Install the water by pass pipe for heater 26 Install the oil cooler Tightening torque T1 55 N m 5 5 kgf m 40 ft Ib T2 69 N m 7 0 kgf m 50 6 ft Ib F 20 O ring Oil cooler C Connector 27 Install the oil filter using ST ST 498547000 FILTER WRENCH 28 Install the water by pass pipe between oil cool er and water pump Tightening torque 6 4 N m 0 65 kgf m 4 72 ft Ib 29 Install the water pipe NOTE Always use a new O ring 30 Install the cylinder head assembly Ref to ME STi 65 INSTALLATION Cylinder Head As sembly gt 31 Install the oil level gauge guide and tighten at taching bolt left side only 32 Install the rocker cover 33 Install the crankshaft sprocket lt Ref to ME STi 58 INSTALLATION Crankshaft Sprock et gt 34 Install the camshaft sprocket Ref to ME STi 56 INSTALLATION Camshaft Sprock et gt 35 Install the timing belt assembly lt Ref to ME STi 49 INSTALLATION Timing Belt Assem bly 36 Install the belt cover Ref to ME STi 46 IN STALLATION Belt Cover 37 Install the crankshaft pulley Ref to ME STi 45 INSTALLATION Crankshaft Pulley gt 38 Install the generator and A C compre
117. A gear TRO738 A 3rd 4th sleeve 0741 3rd 4th shifting insert key fos ances Bening 7 Install the 3rd 4th sleeve to 3rd 4th hub B 4th drive gear NOTE 3rd 4th sleeve has a groove for identification Install the 3rd 4th sleeve with groove facing to 3rd drive gear side TRO739 A 3rd drive gear B Groove 1 for identification of 3rd 4th sleeve 6MT 80 MAIN SHAFT ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 11 Install the 5th bush 1 Set to the main shaft taking care not to overlap the main shaft oil hole and 5th bush oil hole A n ell AD D TRO986 A 5th bush B Main shaft oil hole C Main shaft D 5th bush oil hole E 4th drive gear 2 Using the ST press in the 5th bush 571 18651AA000 INSTALLER ST2 398177700 INSTALLER CAUTION Do not apply pressure in excess of 40 KN 4 0 ton 4 4 US ton 3 9 Imp ton ST1 SS TRO742 12 Make sure the 4th drive gear is smoothly turned by hand If not reassemble 13 Sufficiently apply gear oil to the main shaft 5th needle bearing and inner periphery of 5th drive gear 14 Install the 5th needle bearing and 5th drive gear TRO743 A 5th needle bearing B 5th drive gear 15 Install the 5th baulk ring TRO744 16 Install the 5th 6th hub 1 Set to the main shaft
118. AND SENSOR GROUND JOINT CONNECTOR EE 1g EE EE 1g EE EE igi EE EE 6 Abs Uu iL EE DU DH 5 EN EE 2 EE EE 1 EE B83 EE 1g 1 1 EE EE 1g 1 1 EE EE I if E G LTB 03 J n el 1 EE LTB san Mm E G LTB 03 vin E G LTB 11 4 7 7 47 NORMAL TURBO ENGINE MODEL SIG RSR imi TH TH WASTEGATE AIRFLOW EXHAUST GAS FRONT OXYGEN REAR OXYGEN SOLENOID SENSOR TEMPERATURE SENSOR A F SENSOR SENSOR NORMAL TURBO MODEL 112 112 112 112 314 314 1415165 q q n 1121314 5 6 112 311415 6 7 11234156 71819 2 3 141516 7118 9 7 81 9110 11 12 8910112 13 14 15 116 1011112 1314 1511617 18 19 1011 12 18 14 15 16 1718 1912021 1311415 1617 17 1
119. ASSY LEFT SIDE NOTE Screw in the right side retainer a bit further than left side 2 Install the drive pinion shaft assembly and then secure with four bolts NOTE Use the old gasket and washer to prevent the mat ing surface of housing from damaging Tightening torque 69 7 0 kgf m 50 9 ft Ib 3 Using the ST screw in the left side retainer until the drive pinion and hypoid driven gear contacts lightly Then loosen the right side retainer ST1 499787000 WRENCH ASSY RIGHT SIDE ST2 18630AA000 WRENCH ASSY LEFT SIDE 4 Using the ST rotate the drive pinion shaft sever al times ST 18631AA000 HANDLE 0817 5 Repeat step 3 and 4 until the left side retainer can not be rotated For the right side retainer screw in until the inner race and outer race contacts lightly This condition is 0 backlash 6 Mark an engagement point on the right and left side retainer and clutch housing TRO828 7 Return the left side retainer for three teeth and screw in the right side retainer for three teeth 6MT 114 FRONT DIFFERENTIAL ASSEMBLY 8 Using the ST secure the drive pinion shaft ST 18621AA000 ADAPTER WRENCH 9 After rotating the drive pinion shaft several times measure the hypoid gear backlash using the ST ST1 498255400 PLATE ST2 498247001 MAGNET BASE ST3 498247100 DIAL GAUGE Hypoid gear backlash 0 13 0 18 mm 0 0051 0 0071
120. C INSPECTION 3 17 INCH TYPE Check the pad thickness A 021 Pad thickness Standard value 13 5 mm 0 531 in including back metal CAUTION e Always replace the pads for both right and left wheels at the same time Also replace the pad clips if they are twisted or worn wear indicator is provided on the outer disc brake pad If the pad wears down to such an ex tent that the end of wear indicator contacts the disc rotor a squeaking sound is produced as the wheel rotates If this sound is heard replace the pad Replace the pad if there is oil or grease on it Wear limit 6 2 mm 0 244 in BR 12 REAR DISC ROTOR 6 Rear Disc Rotor C INSPECTION 1 Secure the disc rotor by tightening five wheel nuts 2 Set a dial gauge on the disc rotor Turn the disc rotor to check runout CAUTION Securely fix the disc rotor to hub B4M2353 NOTE Make sure that the dial gauge is set 5 mm 0 20 in inward of rotor outer perimeter f the disc rotor runout is above standard value inspect the play of hub bearing axial direction and runout of axle hub Ref to 05 31 INSPECTION Rear Axle If the bearing and hub are normal re place the disc rotor Disc rotor runout limit 0 070 mm 0 0028 in 3 Measure the disc rotor thickness If the thickness of disc rotor is outside the standard value replace the disc rotor G4M0383 NOTE Make sure
121. CAUTION Do not apply pressure in excess of 10 KN 1 ton 1 1 US ton 1 0 Imp ton B3M2139A A Roller bearing E INSPECTION 1 Bearings Replace the bearing in following cases Broken or rusty bearings Worn or damaged Bearings that fail to turn smoothly or make ab normal noise when turned after gear oil lubrication 2 Driven gear Replace the driven gear in following case f their tooth surfaces and shaft are excessively broken or damaged 6 61 CENTER DIFFERENTIAL MANUAL TRANSMISSION AND DIFFERENTIAL 16 Center Differential A REMOVAL 1 Remove the manual transmission case assem bly from vehicle Ref to 6MT 37 REMOVAL Manual Transmission Assembly 2 Prepare the transmission for overhaul Ref to 6MT 42 Preparation for Overhaul gt 3 Remove the extension case Ref to 6MT 49 REMOVAL Extension Case 4 Remove the transfer driven gear Ref to 6 60 REMOVAL Transfer Driven Gear 5 Remove the thrust washer and center differen tial 0694 A Thrust washer B Center differential 6 Remove the needle bearing ABE eae B INSTALLATION 1 Install the needle bearing TRO695 2 Install the thrust washer and center differential TRO694 A Thrust washer B Center differential 3 If replacing the center differential select the transfer drive gear and thrust washer
122. Compression Gauge Used for measuring compression Timing Light Used for measuring ignition timing E PROCEDURE It is possible to conduct the following service proce dures with engine on the vehicle however the pro cedures described in this section are based on the condition that the engine is removed from the vehi cle e V belt Timing Belt e Camshaft e Cylinder Head ME STi 21 COMPRESSION MECHANICAL 2 Compression A INSPECTION CAUTION After warming up engine becomes very hot Be careful not to burn yourself during measure ment 1 After warming up the engine turn the ignition switch to OFF 2 Make sure that the battery is fully charged 3 Release fuel pressure lt Ref to FU TURBO 53 RELEASING OF FUEL PRESSURE OPERA TION Fuel gt 4 Remove all the spark plugs Ref to IG TUR BO 4 REMOVAL Spark Plug gt 5 Fully open the throttle valve 6 Check the starter motor for satisfactory perfor mance and operation 7 Hold the compression gauge tight against the spark plug hole CAUTION When using a screw in type compression gauge the screw put into cylinder head spark plug hole should be less than 18 mm 0 71 in long 8 Crank the engine by means of the starter motor and read the maximum value on the gauge when the pointer is steady 0172 9 Perform at least two measurements per cylinder and make sure that the values are correct Compres
123. Data link connector Engine control module Fuel pump relay Immobilizer control module Main relay Power window circuit breaker Relay holder ABS control module Hazard switch Power window relay Engine control module Inhibitor switch AT Starter motor MT Hazard switch Rear turn signal light RH Trailer connector Turn signal switch Hazard switch Rear turn signal light LH Trailer connector Turn signal switch Parking switch Front turn signal light RH Side turn signal light RH Front turn signal light LH Side turn signal light LH Front clearance light LH Front clearance light RH Headlight leveler LH Except STi Headlight leveler RH Except STi License plate light Tail light LH Tail light RH Trailer connector Auto A C control module Combination meter Door lock timer Keyless entry control module Luggage room light Wagon Radio Room light Spot light Trunk room light Sedan WI 9 WIRING SYSTEM Bright switch Combination meter Front fog light relay Front fog light switch Headlight leveling switch Illumination light Rear fog light relay Rear fog light switch Intercooler water spray switch STi Parking switch Engine control module Lighting switch Parking switch Mirror heater relay Rear defogger Rear defogger switch Engine control module Rear defogger timer ABS relay Back up light switch MT Check
124. EN TURBO 2 Basic Diagnostic Procedure gt gt Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective intake manifold gasket Defective throttle body gasket Defective PCV valve Loosened oil filler cap Dirty air cleaner element Fuel line Defective fuel pump and relay Clogged fuel line Lack of or insufficient fuel Belt Defective timing Compression Incorrect valve clearance Loosened spark plugs or defective gasket Loosened cylinder head bolts or defective gasket Improper valve seating Defective valve stem Worn or broken valve spring Worn or stuck piston rings cylinder and piston Incorrect valve timing Improper engine oil low viscosity Lubrication system Incorrect oil pressure Cooling system Overheating Over cooling Others Malfunction of evaporative emission control system 4 Surging Engine control system Ref to EN TURBO 2 Basic Diagnostic Procedure Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective intake manifold gasket Defective throttle body gasket Defective PCV valve Loosened oil filler cap Dir
125. FUSE BOX M B No 7 20A 4 BLACK BLACK BLACK 11213 112 11213 1121314 3 4 4 5 6 GR01 21C WI 13 POWER SUPPLY ROUTING WIRING SYSTEM 8 03 03 5 03 J TRAILER CONNECTOR 10 LR kal 13 umm WM N NM d 5 t t H 5 gt A B51 BLUE F 8159 BROWN E GRAY GRAY 3 1 2 4 4 5 4567 8 5 6718 9 67 18 9 0 213 1 4 56 7 6271 BLUE 99 0 8152 112131415 617 8 19 23 112 13 14 15 1617 18119120121 22 45 7189101 12 GR01 21D WI 14 POWER SUPPLY ROUTING WIRING SYSTEM IGNITION SWITCH Jor aceon 03 03 AAH REF GND 07 FUSE amp RELAY sr G BLUE 2 851 1 2 3 F BROWN E GRAY 2 3 1112 31 4 5 4 5 6 7 8 5 6 7 8 9 6 7 8 9 10 zz
126. Imp qt Rear differential gear oil GL 5 GL 5 DI 2 GENERAL DESCRIPTION DIFFERENTIALS Identification Rear differential gear oil Recommended oil CAUTION Each oil manufacturer has its base oil and addi tives Thus do not mix two or more brands ITEM Rear differential gear oil API Classification 3 SAE Viscosity and Application Temperature 30 26 15 5 0 15 2530 F 22 15 5 23 32 59 77 86 080001 1272 1 SERVICE DATA Except STi 19 26 1 9 2 6 4 3 5 8 T type model Front and rear bearing preload at companion New bearing STi model 31 1 59 5 3 17 6 07 7 0 13 4 fl It hole N kgf Ib VA type 12 7 32 4 1 3 3 3 2 9 7 3 Used bearing T type 8 16 0 8 1 6 1 8 3 6 T type 0 10 0 20 0 0039 0 0079 VA type 0 05 0 15 0 0020 0 0059 Side gear backlash in Side bearing standard width mm 20 00 0 7874 T type 0 10 0 20 0 0039 0 0079 VA type 0 10 0 15 0 0039 0 0059 Crown gear runout on its back surface in Less than 0 05 0 0020 Crown gear to drive pinion backlash in DI 3 DIFFERENTIALS 2 ADJUSTING PARTS VA type Front and rear bearing preload at com panion flange bolt hole N kgf Ib GENERAL DESCRIPTION New bea
127. MAIN SHAFT ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 2 Set to the main shaft taking care not to overlap the main shaft oil hole and 4th bush oil hole A Ee D H C SL TRO985 A 4th bush 3rd 4th hub C 4th bush oil hole D Main shaft oil hole 3 Using the ST press in the 3rd 4th hub and Ath bush at once 571 18651AA000 INSTALLER ST2 398177700 INSTALLER CAUTION Do not apply pressure in excess of 40 KN 4 0 ton 4 4 US ton 3 9 Imp ton NOTE When pressing in 3rd 4th hub and 4th bush align the protrusion portion of outer baulk ring and cutout portion of 3rd 4th bush by moving the outer baulk ring LT T H 0736 3rd 4th hub Outer baulk ring Cutout portion of 3rd 4th hub Protrusion portion of outer baulk ring 4th bush gt annn lt In HD oco 5 Make sure the 3rd drive gear is smoothly turned by hand If not reassemble 6 79 MAIN SHAFT ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 6 Install the 3rd 4th shifting insert key in proper 8 Install the 4th baulk ring place of 3rd 4th sleeve NOTE Angle of each shifting insert key is 120 apart TRO740 9 Sufficiently apply gear oil to the main shaft 4th needle bearing and inner periphery of 4th drive gear 10 Install the 4th needle bearing and 4th drive
128. N m 1 0 kgf m 7 2 ft Ib Clearance g 1 0 0 5 mm 0 039 0 020 in op YT 2 1202 1204 ME STi 53 TIMING BELT ASSEMBLY MECHANICAL 0259 7 Install the belt cover Ref to ME STi 46 IN STALLATION Belt Cover 8 Install the crankshaft pulley Ref to ME STi 45 REMOVAL Crankshaft Pulley gt 9 Install the V belt lt Ref to ME STi 43 INSTAL LATION V belt gt C INSPECTION 1 TIMING BELT 1 Check the timing belt teeth for breaks cracks and wear If any fault is found replace the belt 2 Check the condition of back side of belt if any crack is found replace the belt CAUTION Be careful not to let oil grease or coolant contact the belt Remove quickly and thorough ly if this happens Do not bend the belt sharply Bending radius h 60 mm 2 36 in or more oa G2M0115 2 AUTOMATIC BELT TENSION ADJUST ER 1 Visually check oil seals for leaks and rod ends for abnormal wear or scratches If necessary re place the automatic belt tension adjuster assembly CAUTION Slight traces of oil at rod s oil seal does not in dicate a problem 2 Check that the adjuster rod does not move when a pressure of 294 30 kgf 66 Ib is applied to it This is to check adjuster rod stiffness 3 If the adjuster rod is not stiff and moves freely when applyi
129. NUMBER DESCRIPTION REMARKS 18722AA000 Newly adopted tool REMOVER Used for disassembling main shaft 18651AA000 Newly adopted tool INSTALLER Used for assembling main shaft 18852AA000 Newly adopted tool TORQUE WRENCH Used for tightening main shaft lock nut Used for tightening drive pinion shaft lock nut Used for tightening driven shaft lock nut 18668AA000 Newly adopted tool 6 27 Used for caulking main shaft lock nut GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 18669AA000 PUNCH Used for caulking driven shaft lock nut Newly adopted tool 18670AA000 Used for caulking drive pinion shaft lock nut Newly adopted tool 0624 0624 18620 000 ADAPTER Used for installing and removing driven gear Newly adopted tool WRENCH shaft lock nut TRO625 18621 AA000 ADAPTER Used for installing and removing drive pinion Newly adopted tool WRENCH shaft lock nut TRO625 6MT 28 ILLUSTRATION GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL TOOL NUMBER DESCRIPTION REMARKS ES 18723AA000 Newly adopted tool REMOVER Used for disassembling the driven shaft C 18630AA000 Newly adopted tool WRENCH ASSY Used for removing and installing differential side retainer left side TR0628 18672AA000 Newly adopted tool
130. OTHER DIAGNOSTIC TROU BLE CODES DTCs APPEARANCE Are other DTCs being output ABS 18 Proceed with the diagnosis corre sponding to DTC A temporary poor contact DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS 13 Diagnostics Chart with Subaru Select Monitor Al DTC 73 OPEN OR SHORT CIRCUIT IN LATERAL G SENSOR CIRCUIT DIAGNOSIS Faulty lateral sensor output voltage TROUBLE SYMPTOM ABS does not operate WIRING DIAGRAM LHD MODEL ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT SHIELD JOINT CONNECTOR 7 n lt STi MODEL EXCEPT STi MODEL ABS G SENSOR JOINT CONNECTOR STi MODEL LATERAL ABS G SENSOR G SENSOR STi MODEL 6171819 112131415 617 8 9 213114 15 8 1o 11 12 13 14 15 16 16 17 18 19 20 21122 4 25 26 27 28 29 30 31 156 ABS 19 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS WIRING DIAGRAM RHD MODEL ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT SHIELD JOINT CONNECTOR 50 STi MODEL EXCEPT STi MODEL ABS G SENSOR JOINT CONNECTOR STi MODEL ABS LATERAL G SENSOR STi MODEL 1213141578 1 5 Ex 1 21 3 112131415 6 7 8 9
131. Ref to EN TURBO 34 Subaru Select Moni tor gt OBD II scan tool For detailed operation procedures refer to the OBD II General Scan Tool Instruction Manual Does the ignition timing advance smoothly change according to engine output change Idling 2 2 degree Vehicle running 2 50 degree Repair the poor contact in connec tor NOTE In this case repair the following Poor contact in variable valve tim ing camshaft posi tion sensor Poor contact in ECM connector Go to step 2 CHECK HARNESS BETWEEN VARIABLE VALVE TIMING CAMSHAFT POSITION SEN SOR AND ECM CONNECTOR 1 Turn the ignition switch to OFF 2 Disconnect the connector from variable valve timing camshaft position sensor and ECM 3 Measure the resistance of harness between variable valve timing camshaft position sensor connector and engine ground Connector amp terminal E36 No 1 B84 No 2 E36 2 B84 3 Is the resistance less than 1 Q Go to step 3 Repair the har ness and connec tor NOTE In this case repair the following Open circuit in harness between variable valve tim ing camshaft posi tion sensor and ECM connector Poor contact in ECM connector Poor contact in coupling connector CHECK HARNESS BETWEEN VARIABLE VALVE TIMING CAMSHAFT POSITION SEN SOR AND ECM CONNECTOR Measure the resistance of harness between variable valve timing camshaft positi
132. Remove the console box 3 Remove the lateral G sensor from vehicle Do not disconnect the connector 4 Turn the ignition switch to ON 5 Measure the voltage between lateral G sen sor connector terminals Connector amp terminal B257 No 1 No 3 Is the voltage between 4 75 and 5 25 V Go to step 6 Repair the har ness connector between lateral G sensor and ABSCM amp H U CHECK OPEN CIRCUIT IN LATERAL G SEN SOR OUTPUT 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 LHD B301 No 29 No 28 RHD F49 No 29 No 28 Is the resistance between 5 0 and 5 6 Go to step 7 Repair the har ness connector between lateral G sensor and ABSCM amp H U CHECK GROUND SHORT IN LATERAL G SENSOR OUTPUT HARNESS 1 Disconnect the connector from lateral G sen sor 2 Measure the resistance between ABSCM amp H U connector and chassis ground Connector amp terminal LHD B301 No 29 Chassis ground RHD F49 No 29 Chassis ground Is the resistance more than 1 MQ Go to step 8 Repair the har ness between lat eral G sensor and ABSCM amp H U CHECK LATERAL G SENSOR 1 Connect the connector to lateral G sensor 2 Connect the connector to ABSCM amp H U 3 Turn the ignition switch to ON 4 Measure the voltage be
133. SIDE TURN SIGNA LIGHT LH r HEADLIGHT LEVELER RH STi MODEL NON TURBO ENGINE MODEL TURBO ENGINE MODEL STi MODEL B EXCEPT STi MODEL WL STi MODEL EXCEPT STi MODEL GRAY BLACK NA GRAY BLACK TE BROWN ST ED BLACK aD C22 GRAY ED BLACK TE 21 112 13 JAE ED BLACK 57 T EDE 572 GRAY 6169 GRAY GRAY d D aem 175 1 2 1 2 ese Gray ST 3 4 3141516 3141516 11213 5 6 7 8 D D DH D D 3 211 4151617 112131415 6 7 8 817161514 8 9 1011 1213 14 1516 11112 13 1
134. ST and align alignment marks on crankshaft sprocket left hand intake camshaft sprocket left hand ex haust camshaft sprocket right hand intake cam shaft sprocket and right hand exhaust camshaft sprocket with notches of belt cover and cylinder block ST 499987500 CRANKSHAFT SOCKET NS 2 gt 1202 Gen 0258 ME STi 47 TIMING BELT ASSEMBLY MECHANICAL 2 Using a white paint put alignment and or ar 7 Remove the timing belt row marks on timing belts in relation to the CAUTION sprockets After the timing belt has been removed never rotate intake and exhaust camshaft sprocket If the camshaft sprocket is rotated the intake and exhaust valve heads strike together and valve stems are bent 2 BELT IDLER AND AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY 1 Remove the belt idler B and C S NN MASA b 7 O DEN Ce 09 52 1226 21 54 5 tooth length 22 51 tooth length 23 28 tooth length 52 0411 3 Remove the automatic belt tension adjuster as sembly S2M1223A 6 Remove the belt idler A AOE See 2 52 0412 52 1226 ME STi 48 TIMING BELT ASSEMBLY B INSTALLATION 1 AUTOMATIC BELT TENSION ADJ
135. STI MODEL 1 Precautions for assembling Assemble in the reverse order of disassembling Check and adjust each part during assembly Keep the shims and washers in order so that they are not improperly installed Thoroughly clean the surfaces on which the shims washers and bearings are to be installed Apply gear oil when installing the bearings and thrust washers Be careful not to mix up the right and left hand races of the bearings Replace the oil seal with a new one at every dis assembly Apply chassis grease between the lips when installing the oil seal G3M0079 Adjust the bearing preload with spacer and washer between front and rear bearings Pinion height adjusting washer are not affected by this ad justment The adjustment must be carried out with out oil seal inserted DI 23 REAR DIFFERENTIAL FOR DIFFERENTIALS 2 Press fit the rear bearing race into differential NOTE carrier using ST If there is no punch mark it means 0 zero ST 398417700 DRIFT DR0037 DR0034 3 Obtain the thickness of pinion height adjust shim to be inserted from the following formula and replace the inserted shim with this one T1 T2 x 0 01 T3 x 0 01 Thickness of selected pinion height adjusting shim 3 Press fit the front bearing race into differential carrier using ST ST 398477702 DRIFT Thickness of inserted pin
136. STi Vehicle speed sensor MT Except STi Front oxygen A F sensor Rear oxygen sensor Engine wiring harness Wastegate control solenoid valve Transmission MT Exhaust temperature sensor ABS control module ABS motor ground Shield joint connector ABS Side turn signal light RH Front fog light RH B17 B18 B19 B20 B127 B128 B279 B301 B302 B303 B305 B306 Non colored BA A N AJN MO Co WI 96 BULKHEAD WIRING HARNESS ENGINE ROOM WIRING SYSTEM BO0470 WI 97 BULKHEAD WIRING HARNESS ENGINE ROOM WIRING SYSTEM 4 RHD TURBO ENGINE MODEL Connector Connecting to No Pole Color B3 5 Gray Mass airflow sensor B7 6 Black Cruise control actuator B8 5 Gray Front wiper motor B11 Black B12 White B14 Starter Magnet B16 Gray Brake fluid level switch Vehicle speed sensor MT STi Vehicle speed sensor MT Except STi Front oxygen A F sensor Oxygen sensor Engine wiring harness Transmission 17 18 19 20 21 22 127 128 B143 B144 B145 B146 B147 B148 B186 B255 B279 Non colored A A 1 Engine wiring harness Wastegate control solenoid valve Transmission MT Front washer
137. T5 41 4 2 30 2 7 Oil pipe 15 Plug 8 Harness bracket 16 Gasket 6MT 5 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL 4 OIL PAN AND OIL PUMP TRO598 1 Main case 8 Oil pan Tightening torque N m kgf m ft lb 2 Oil pump cover 9 1 6 4 0 65 4 7 3 Oil guide 10 Gasket T2 10 1 0 7 4 4 Oil pump driven gear ASSY 11 Oil guide 25 2 5 18 1 5 Oil pump rotor ASSY 12 Oil pipe T4 44 4 5 32 5 6 Strainer ASSY 13 O ring 7 Magnet 6MT 6 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL 5 EXTENSION CASE AND CENTER DIFFERENTIAL ye E 23 12 d zt S 25 E 2025 5 0 26 10 p 2i 2 AN 3 lt 33 Si 27 29 31 T2 32 6 7 0599 1 Taper roller bearing 15 Extension guide 29 Reverse check plug 2 Transfer driven gear 16 Extension case 30 Spring 3 Taper roller bearing 17 Oil seal 31 Gasket 4 Shim 18 seal 32 Plug 5 Oil plate 19 Dust cover 33 Plunger 6 Snap ring 20 Snap ring 7 Oil pump drive gear 21 Washer Tightening torque N m kgf m ft Ib 8 Center differential 22 Bush 1 25 2 5 18 1 9 Shim 23 Spring T2 41 4 2 30 2 10 Needle bearing 24 Reverse check shaft T3 48 4 9 35 4 11 Needle bearing 25 Ball bearing 12 Transfer dr
138. Yes No CHECK LATERAL G SENSOR Measure the voltage between lateral G sensor connector terminals Connector amp terminal B257 No 2 No 3 Is the voltage between 1 3 and 1 7 V when lateral G sensor is inclined backwards to 90 Go to step 12 Replace the lateral G sensor lt Ref to ABS 5 Lateral G Sensor gt 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 DTC Is the same DTC as in current diagnosis still being output Replace the ABSCM amp H U Ref to ABS 4 ABS Control Mod ule and Hydraulic Control Unit ABSCM amp H U Go to step 13 CHECK ANY OTHER DIAGNOSTIC TROU BLE CODES DTCs APPEARANCE Are other DTCs being output ABS 35 Proceed with the diagnosis corre sponding to DTC A temporary poor contact DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS ABS 36 N sch sch sch sch sch sch sch ch sch E EE General Description Front Brake Front Disc ROOP Front Disc Brake Assembly Rear Brake Rear Disc Rear Disc Brake Assembly Rear Drum Brake Shoe Rear Drum Brake Drum Rear
139. and gear cone or wear Correct or replace 2 Gear slips out Gear slips out when coasting on rough road Gear slips out during acceleration a Defective pitching stopper adjustment Adjust b Loose engine mounting bolts Tighten or replace ail spring Replace c Worn fork shifter broken shifter fork E d Worn or damaged ball bearing Replace e Excessive clearance between splines of synchronizer hub and synchronizer sleeve Replace f Worn tooth step of synchronizer hub responsible for slip out of 3rd gear Replace g Worn 1st driven gear needle bearing and race Replace h Worn 2nd driven gear needle bearing and race Replace i Worn 3rd drive gear and bushing Replace j Worn 4th drive gear and bushing Replace k Worn 5th drive gear and bushing Replace Replace m Worn reverse idler gear and bushing Replace 3 Unusual noise comes from transmis sion NOTE If an unusual noise is heard when the ve hicle is parked with its engine idling and if the noise ceases when the clutch is disen gaged it may be considered that the noise comes from the transmission Worn 6th drive gear and bushing a Insufficient or improper lubrication Lubricate or replace with specified oil b Worn or damaged gears and bearings NOTE If the trouble is only wear of the tooth sur
140. and hole in piston Limit 0 020 mm 0 0008 in Piston pin must be fitted into position with thumb at 20 C 68 F STD 0 20 0 25 mm 0 0079 0 0098 in Limit 1 0 mm 0 039 in Second STD 0 35 0 50 mm 0 0138 0 0197 in ring Limit 1 0 mm 0 039 in STD 0 20 0 50 mm 0 0079 0 0197 in Limit 1 5 mm 0 059 in STD 0 040 0 080 mm 0 0016 0 0031 in Limit 0 15 mm 0 0059 in Cylinder bore STD Cylinder Taper block Out of roundness Piston clearance STD Piston Outer diameter 92 225 92 235 mm 3 6309 3 6313 in 92 475 92 485 mm 3 6407 3 6411 in Piston pin Degree of fit Top ring Piston ring gap Piston ring Oil ring Clearance between pis ring ton ring and piston ring groove Second STD 0 030 0 070 mm 0 0012 0 0028 in ring Limit 0 15 mm 0 0059 in Bend twist per 100 mm 3 94 in in Connecting length 0 070 0 330 mm 0 0028 0 0130 in Limit 0 10 mm 0 0039 in Side clearance Limit 0 4 mm 0 016 in STD 0 020 0 046 mm 0 0008 0 0018 in Limit 0 05 mm 0 0020 in STD 1 486 1 498 mm 0 0585 0 0590 in 0 03 mm 0 0012 1 505 1 509 mm 0 0593 0 0594 in Connecting in US roa garing Thickness at center portion 0 05 mm 0 0020 1 515 1 519 0 0596
141. and install lt Ref to 6MT 51 ADJUSTMENT Extension Case gt 4 Install the transfer driven gear lt Ref to 6MT 60 INSTALLATION Transfer Driven Gear gt 5 Install the extension case lt Ref to 6MT 49 IN STALLATION Extension Case gt 6 Install the manual transmission case assembly to vehicle Ref to 6MT 39 INSTALLATION Man ual Transmission Assembly gt C DISASSEMBLY NOTE Do not disassemble the center differential because it is a non disassemble part 1 Remove the snap ring TRO696 6MT 62 CENTER DIFFERENTIAL 2 Using the ST remove the oil pump drive gear ST 498077610 REMOVER TRO697 D ASSEMBLY 1 Using the ST install the oil pump drive gear ST 498745600 INSTALLER CAUTION Do not apply pressure in excess of 20 KN 2 0 ton 2 2 US ton 2 0 Imp ton TRO698 2 Install the snap ring E INSPECTION 1 Make sure there is no damage on the center dif ferential Replace if damaged 2 Make sure there is no excessive damage or wear on the oil pump drive gear Replace if dam aged or worn 6MT 63 MANUAL TRANSMISSION AND DIFFERENTIAL OIL PUMP MANUAL TRANSMISSION AND DIFFERENTIAL 17 0il Pump A REMOVAL 1 Remove the manual transmission assembly from vehicle Ref to GMT 37 REMOVAL Manual Transmission Assembly 2 Prepare the transmission for overhaul Ref to 6MT 42 Preparation for Overhaul gt 3 Remove the exte
142. and pis ton 0150 1 Piston seal 2 Piston boot 3 Piston BR 15 BRAKE REAR DISC BRAKE ASSEMBLY BRAKE BR 16 PARKING BRAKE General DESCriPUON 2 Parking Brake Lever Parking Brake Cable Parking Brake Assembly Rear Disc Brake General Diagnostic Table pro OS GENERAL DESCRIPTION PARKING BRAKE 1 General Description A SPECIFICATIONS Rear disc brake Rear drum brake Rear disc brake STi model Mechanical on rear brakes Effective drum diameter mm in 228 6 9 170 6 69 190 7 48 Lining dimensions 218 8 x 35 0 x 4 1 162 6 x 30 0 x 3 2 182 3 x 30 0 x 3 2 length x width x thickness 8 61 x 1 378 x 0 161 6 40 x 1 181 x 0 126 7 18 x 1 181 x 0 126 Clearance adjustment Automatic adjustment Manual adjustment Lever stroke notches N kgf Ib 7 to 8 196 20 44 Type Mechanical on rear brakes drum in disc PB 2 2002 IMPREZA STi SERVICE MANUAL QUICK REFERENCE INDEX BODY SECTION LIGHTING SYSTEM LI INSTRUMENTATION DRIVER INFO EXTERIOR INTERIOR TRIM This service manual has been prepared to provide SUBARU service personnel with the necessary information and data for the correct maintenance and repair of SUBARU vehicles This manual includes the procedures for maintenance disassembling reas sembling inspection and adjustment of components and diagnostics for guid ance of experienced m
143. battery Defective charging system Friction Seizure of crankshaft and connecting rod bearing Seized camshaft Seized or stuck piston and cylinder 2 Initial combustion does not occur Starter Defective starter Engine control system Ref to 2 Basic Diagnostic Procedure Fuel line Defective fuel pump and relay Lack of or insufficient fuel Belt Defective Defective timing Compression Incorrect valve clearance Loosened spark plugs or defective gasket Loosened cylinder head bolts or defective gasket Improper valve seating Defective valve stem Worn or broken valve spring Worn or stuck piston rings cylinder and piston Incorrect valve timing Improper engine oil low viscosity 3 Initial combustion occur Engine control system lt Ref to EN TURBO 2 Basic Diagnostic Procedure gt Intake system Defective intake manifold gasket Defective throttle body gasket Fuel line Defective fuel pump and relay Clogged fuel line Lack of or insufficient fuel Belt Defective Defective timing Compression Incorrect valve clearance Loosened spark plugs or defective gasket Loosened cylinder head bolts or defective gasket Improper valve seating Defective valve st
144. be shifted to reverse when reverse check lever is in the following position SS TRO684 2 The plunger cannot be pushed or the gear cannot be shifted to reverse when reverse check lever is in the following position TRO685 5 not as specified reassemble the reverse check system 6MT 57 TRANSFER DRIVE GEAR MANUAL TRANSMISSION AND DIFFERENTIAL 14 Transfer Drive Gear A REMOVAL 1 Remove the manual transmission assembly from vehicle Ref to 6MT 37 REMOVAL Manual Transmission Assembly 2 Prepare the transmission for overhaul Ref to 6MT 42 Preparation for Overhaul gt 3 Remove the extension case Ref to 6MT 49 REMOVAL Extension Case 4 Remove the transfer drive gear TRO686 B INSTALLATION 1 Install the transfer drive gear Tightening torque 25 2 5 kgf m 18 1 ft lb TRO686 2 If the ball bearing transfer drive gear or snap ring is replaced select the transfer drive gear thrust washer lt Ref to 6MT 50 ASSEMBLY Extension Case gt 3 Install the extension case lt Ref to 6MT 49 IN STALLATION Extension Case gt 4 Install the manual transmission assembly to ve hicle lt Ref to 6MT 39 INSTALLATION Manual Transmission Assembly gt C DISASSEMBLY 1 Remove the snap ring TRO687 2 Using the ST remove the ball bearing ST 49987
145. bent or damaged Make sure that the cushion rubber is not stiff cracked or otherwise damaged 6MT 36 MANUAL TRANSMISSION ASSEMBLY 6 Manual Transmission As sembly A REMOVAL 1 Set the vehicle on a lift then open the front hood and support with hood stay NOTE Set the hood stay to its specified hole 2 Remove the front wheel 3 Disconnect the ground cable from battery 4 Remove the intercooler assembly lt Ref to IN TURBO 10 REMOVAL Intercooler gt 5 Lift up the vehicle and remove the under cover 6 Remove the steering universal joint lt Ref to PS 27 REMOVAL Universal Joint gt 7 Lower the vehicle and disconnect the connector located on upper side of transmission TRO637 A Vehicle speed sensor connector B Transmission connector 8 Disconnect the ground cable at upper side of transmission case and body MANUAL TRANSMISSION AND DIFFERENTIAL 9 Remove the starter assembly lt Ref to SC 5 REMOVAL Starter gt 10 Remove the clutch operating cylinder NOTE Hang the removed operating cylinder with wire TRO640 11 Remove the clutch release shaft 1 Remove the plug with hexagon wrench 2 Install a 6 mm 0 24 in bolt to the release shaft then pull out the release shaft 3 Lift up the release fork and then remove it from the release bearing claw Pull it to the en gine side and set it free
146. clearance Standard 0 070 0 330 mm 0 0028 0 0130 in Limit 0 4 mm 0 016 in 0335 ME STi 88 CYLINDER BLOCK MECHANICAL 4 Inspect the connecting rod bearing for scar peeling seizure melting wear etc 5 Measure the oil clearance on individual connect ing rod bearings by means of plastigauge If any oil clearance is not within specification replace the defective bearing with a new one of standard size or undersize as necessary See the table below Connecting rod oil clearance Standard 0 020 0 046 mm 0 0008 0 0018 in Limit 0 05 mm 0 0020 in Unit mm in Bearing Bearing size Thickness at cen ter Outer diameter of crank pin Standard 1 486 1 498 0 0585 0 0590 51 984 52 000 2 0466 2 0472 0 03 0 0012 undersize 1 505 1 509 0 0593 0 0594 51 954 51 970 2 0454 2 0461 0 05 0 0020 undersize 1 515 1 519 0 0596 0 0598 51 934 51 950 2 0446 2 0453 0 25 0 0098 undersize 1 615 1 619 0 0636 0 0637 51 734 51 750 2 0368 2 0374 2 0084 7 Replacement procedure is as follows 1 Remove the bushing from connecting rod with ST and press 2 Press the bushing with ST after applying oil on the periphery of bushing ST 499037100 CONNECTING ROD BUSH ING REMOVER AND IN STALLER ey 6 Inspect the
147. connector Cruise control actuator Cruise control main switch Cruise control module Inhibitor switch AT Seat belt timer Vehicle speed sensor MT Main relay Headlight leveler LH STi Headlight leveler RH STi Air conditioning relay Sub fan relay Thermal protector AUTO A C control module Blower motor relay Rear defogger timer Manual A C switch Engine control module Fuel pump relay Ignition coil and ignitor Immobilizer control module Transmission control module Airbag control module Airbag control module Rear washer motor Rear wiper intermittent module Rear wiper motor Front washer motor Front wiper motor Front wiper switch Auto A C control module Radio Front accessory power supply socket Remote controlled rearview mirror switch Intercooler water spray timer STi Intercooler water spray switch STi Rear fog light relay POWER SUPPLY ROUTING WIRING SYSTEM Load Mirror heater relay Stop light switch ABS control module Front fog light relay Blower motor relay Door lock timer Keyless entry control module Combination meter WI 10 POWER SUPPLY ROUTING 2 RHD MODEL P SUP R 01 MAIN FUSE BOX M B MAIN FAN
148. corre sponding to DTC Go to step 8 CHECK OPEN CIRCUIT IN LATERAL G SEN SOR OUTPUT 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 LHD B301 No 29 No 28 RHD F49 No 29 No 28 Is the resistance between 5 0 and 5 6 kQ Go to step 9 Repair the har ness connector between lateral G sensor and ABSCM amp H U CHECK LATERAL G SENSOR 1 Remove the console box 2 Remove the lateral G sensor from vehicle 3 Connect the connector to lateral G sensor 4 Connect the connector to ABSCM amp H U 5 Turn the ignition switch to ON 6 Measure the voltage between lateral G sen sor connector terminals Connector amp terminal B257 No 2 No 3 Is the voltage between 2 3 and 2 7 V when lateral G sensor is horizontal Go to step 10 Replace the lateral G sensor Ref to ABS 5 Lateral G Sensor CHECK LATERAL G SENSOR Measure the voltage between lateral G sensor connector terminals Connector amp terminal B257 No 2 No 3 Is the voltage between 3 3 and 3 7 V when lateral G sensor is inclined forwards to 90 ABS 34 Go to step 11 Replace the lateral G sensor lt Ref to ABS 5 Lateral G Sensor gt DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS Step Check
149. following table if clearance is out of specification Snap ring Parts No Thickness mm in 031319000 1 50 0 059 805019030 1 60 0 062 805019010 1 72 0 068 Inspect the clearance again after replacing snap ring 6MT 100 DRIVE PINION SHAFT ASSEMBLY 22 Drive Pinion Shaft Assembly A REMOVAL 1 Remove the manual transmission assembly from vehicle lt Ref to 6MT 37 REMOVAL Manual Transmission Assembly gt 2 Prepare the transmission for overhaul lt Ref to 6MT 42 Preparation for Overhaul gt 3 Remove the oil pipe neutral position switch back up light switch and harness lt Ref to 6MT 44 REMOVAL Oil Pipe gt lt Ref to 6MT 47 REMOV AL Neutral Position Switch Ref to 6MT 45 REMOVAL Back up Light Switch 4 Remove the extension case Ref to 6MT 49 REMOVAL Extension Case 5 Remove the transfer driven gear Ref to 6 60 REMOVAL Transfer Driven Gear 6 Remove the center differential Ref to 6 62 REMOVAL Center Differential 7 Remove the oil pump Ref to 6 64 RE MOVAL Oil Pump 8 Remove the transmission case Ref to 6MT 68 REMOVAL Transmission Case 9 Remove each gear assembly Ref to 6MT 73 REMOVAL Main Shaft Assembly 10 Remove the drive pinion shaft assembly TRO807 B INSTALLATION 1 Completely remove the remaining gasket on drive plate and clutch housing 2 Apply liquid gasket to the clutc
150. gasket THREE BOND 1215 TRO711 3 Install the transmission case MANUAL TRANSMISSION AND DIFFERENTIAL 4 Make sure the interlock block and reverse inter lock block are aligned in neutral position by inspect ing through the pilot bolt installation hole If not aligned remove the transmission case then shift each shifter fork and interlock block to neutral posi tion TRO712 A Interlock block B Reverse interlock block 5 Using a new gasket install the pilot bolts tempo rarily 6 Tighten the transmission case with bolts and nuts Tightening torque 50 5 1 kgf m 36 9 ft lb 7 Tighten the pilot bolts Tightening torque 34 3 5 kgf m 25 1 ft lb 8 Tighten the holder reverse bolt Tightening torque 25 2 5 kgf m 18 1 ft lb 6MT 69 TRANSMISSION CASE MANUAL TRANSMISSION AND DIFFERENTIAL 9 Install the snap ring washer and collar of driven gear assembly A Washer B Snap ring C Collar D Washer 10 Install the oil pump lt Ref to 6MT 65 INSTAL LATION Oil Pump gt 11 Install the center differential lt Ref to 6MT 62 INSTALLATION Center Differential gt 12 Install the transfer driven gear lt Ref to 6MT 60 INSTALLATION Transfer Driven Gear gt 13 Install the extension case lt Ref to 6
151. gear C Reverse gear 8 Install the thrust bearing of driven gear assem bly 9 Press each shifter fork main shaft assembly driven gear assembly and reverse idler gear as sembly then install to the adapter plate at once NOTE Two people should do the work 6MT 75 Tightening torque 37 3 8 kgf m 27 3 ft lb TRO727 Checking plug Gasket Checking spring Plunger MAIN SHAFT ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 11 Install the checking ball checking spring new gasket and checking plug Tightening torque 37 3 8 kgf m 27 3 ft lb TRO728 A Checking plug B Gasket C Checking spring D Checking ball 12 Install the bolt and new gasket Tightening torque 25 2 5 kgf m 18 1 ft lb 13 Using a screwdriver shift to 4th gear position 14 Install the reverse idler holder y N AN SIG K TRO723 A Reverse idler holder 15 Install the striking rod 16 Install the transmission case lt Ref to 6MT 69 INSTALLATION Transmission Case gt 17 Install the selected main shaft snap ring and washer 18 Install the oil pump lt Ref to 6 65 INSTAL LATION Oil Pump gt 19 Install the center differential lt Ref to 6MT 62 INSTALLATION Center Differential gt 20 Install the transfer driven gear lt Ref to 6MT 60 INSTA
152. holding it at base circle Tightening torque T1 10 N m 1 0 kgf m 7 ft lb T2 20 N m 2 0 kgf m 14 5 ft Ib EN1532 3 Camshaft oil seal installation Apply grease to new oil seal lips and press onto front end of camshaft by using ST1 and ST2 NOTE Use a new oil seal ST1 499587600 OIL SEAL GUIDE ST2 499597200 OIL SEAL GUIDE S2M1880A 4 Rocker cover installation 1 Install the gasket on rocker cover Install the peripheral gasket and ignition coil gasket 2 Apply fluid packing to four front open edges of peripheral gasket Fluid packing THREE BOND 1215 or equivalent 52 0300 ME STi 61 CAMSHAFT MECHANICAL 3 Install the rocker cover on cylinder head Ensure the gasket is properly positioned during installation 5 Install the oil pipe Tightening torque 30 3 1 kgf m 22 1 ft lb E 22 6 Connect the variable valve timing solenoid valve connector 7 Install the spark plug cord 8 Similarly install the parts on right hand side 9 Install the tensioner bracket Tightening torque 25 2 5 kgf m 18 1 ft lb J EX ES 10 Install the right hand belt cover No 2 Tightening torque 5 0 5 kgf m 3 6 ft lb B2M0738 11 Install the left hand belt cover No 2 Tightenin
153. in 10 If the backlash is out of specification adjust it by turning the right and left side retainers 11 Screw in the right side retainer for further 1 75 teeth 3 TOOTH CONTACT OF HYPOID GEAR Refer to the section of drive pinion shaft for check ing of tooth contact lt Ref to 6MT 113 TOOTH CONTACT OF HYPOID GEAR INSPECTION Front Differential Assembly gt 6MT 115 MANUAL TRANSMISSION AND DIFFERENTIAL SPEEDOMETER GEAR MANUAL TRANSMISSION AND DIFFERENTIAL 24 Speedometer Gear A REMOVAL 1 Remove the manual transmission assembly from vehicle lt Ref to 6MT 37 REMOVAL Manual Transmission Assembly gt 2 Prepare the transmission for overhaul lt Ref to 6MT 42 Preparation for Overhaul gt 3 Remove the oil pipe neutral position switch back up light switch and harness lt Ref to 6MT 44 REMOVAL Oil Pipe gt lt Ref to 6MT 47 REMOV AL Neutral Position Switch Ref to 6MT 45 REMOVAL Back up Light Switch 4 Remove the extension case Ref to 6MT 49 REMOVAL Extension Case 5 Remove the transfer driven gear Ref to 6 60 REMOVAL Transfer Driven Gear 6 Remove the center differential Ref to 6 62 REMOVAL Center Differential 7 Remove the oil pump Ref to 6MT 64 RE MOVAL Oil Pump 8 Remove the transmission case Ref to 6MT 68 REMOVAL Transmission Case 9 Remove each gear assembly Ref to 6MT 73 REMOVAL Ma
154. it in water and dispose of it in the same way that general steel materials are disposed of The disposal method is described in the following 1 Wearing rubber gloves remove the dam aged valve from the cylinder head 2 Prepare a large receptacle bucket or other container in a well ventilated location and fill the receptacle with water at least 10 liters 3 Immerse the damaged valve in the recepta cle CAUTION A severe reaction may occur so stand at least 2 3 m from the receptacle Because the reac tion will produce hydrogen gas moreover keep the receptacle away from sparks or flames ME STi 71 CYLINDER HEAD ASSEMBLY MECHANICAL 4 Once the reaction is completed about 4 5 hours have elapsed carefully remove the valve using large pincers so that the reaction liq uid does not contact your skin and dispose of it with other parts that are being disposed of b The reaction liquid is a strong alkaline solu tion so it must be disposed of in accordance with local regulations CAUTION Make sure the reaction liquid does not contact your skin If contact with skin occurs immedi ately wash the affected area with large quanti ties of water lt lt EN1495 ME STi 72 CYLINDER BLOCK 20 Cylinder Block A REMOVAL NOTE Before conducting this procedure drain the engine oil completely if applicable 1 Remove the intake manifold lt Ref to
155. leakage If there is oil leakage replace the gasket 6MT 44 BACK UP LIGHT SWITCH 10 Back up Light Switch A REMOVAL 1 Remove the manual transmission assembly from vehicle lt Ref to 6MT 37 REMOVAL Manual Transmission Assembly gt 2 Disconnect the back up light switch connector Back up light switch connector White Neutral position switch connector Black Clip 3 Remove the back up light switch gt 99 A Back up light switch B Neutral position switch MANUAL TRANSMISSION AND DIFFERENTIAL B INSTALLATION 1 Install the back up light switch Tightening torque 32 N m 3 3 kgf m 23 6 ft Ib ES A Back up light switch B Neutral position switch 2 Connect the back up light switch connector Back up light switch connector White B Neutral position switch connector Black C Clip 3 Install the manual transmission assembly to ve hicle Ref to 6MT 39 INSTALLATION Manual Transmission Assembly 6 45 BACK UP LIGHT SWITCH MANUAL TRANSMISSION AND DIFFERENTIAL C INSPECTION 1 Disconnect the ground cable from battery 2 Remove the intercooler lt Ref to IN TURBO 10 REMOVAL Intercooler gt 3 Disconnect the transmission harness and chas sis harness TRO654 A Transmission connector 4 Measure the resistance between back up light switch terminals If it is not w
156. lt 8134 ENGINE CONTROL MODULE ED rown Gis n n n JI 1 2 3 1 2 3 4 5 6 1 2 3 4 5 67 1 2 3 4 5 6 7 89 2 1 5 15161718 7 8 9 10 11 2 8 9 10 11 12 13 1415 10 11 12 1314 15 16 17 1920 21 9101112 16 17 18 19 20 21 22 22 23 24 25 26 27 28 29 30 31 GR10 26C WI 66 ENGINE ELECTRICAL SYSTEM WIRING SYSTEM REF TO IMB R 02 REF TO A C ARH 01 REF TO R F TB 01 T 2 lt o 01 j al 5 ____ 8134 8135 0 817 ENGINE CONTROL MODULE 8910112 18 14 15 1011 112 18 14 15 16 1718 19 101 112 13 14 15 1617181920121 1617 18 19 20 21 22 2012122 2324 25 2612728 2223124125126 27 28 29130131 GR10 26D WI 67 ENGINE ELECTRICAL SYSTEM WIRING SYSTEM ENGINE CONTROL MODULE N B fee 5 E 5 8 z n NEUTRAL POSITION SWITCH 02 9
157. make sure that neither scratches nor damages exist on the inside surface of the valve guide holes in cylinder head 5 Put new valve guide coated with sufficient oil in cylinder and insert ST1 into the valve guide Press in until the valve guide upper end is flush with the upper surface of ST2 ST1 499767200 VALVE GUIDE REMOVER ST2 498267700 VALVE GUIDE ADJUSTER S2M1883A 6 Check the valve guide protrusion Valve guide protrusion L 12 0 12 4 mm 0 472 0 488 in 7 Ream the inside of valve guide with ST Gently rotate the reamer clockwise while press ing it lightly into valve guide and return it also ro tating clockwise After reaming clean the valve guide to remove chips ST 499767400 VALVE GUIDE REAMER CAUTION Apply engine oil to the reamer when reaming f the inner surface of the valve guide is torn the edge of the reamer should be slightly ground with an oil stone f the inner surface of the valve guide be comes lustrous and the reamer does not chips use a new reamer or remedy the reamer ME STi 69 CYLINDER HEAD ASSEMBLY MECHANICAL 8 Recheck the contact condition between valve and valve seat after replacing the valve guide 4 INTAKE AND EXHAUST VALVE 1 Inspect the flange and stem of valve and re place if damaged worn or deformed or if H is less than the specified limit H Intake Standard 1 2 mm 0 047 Limit 0 8 0 031 in Exha
158. matching surfaces and install the oil pan Fluid packing THREE BOND 1215 or equivalent S2M1833A ME STi 80 CYLINDER BLOCK 20 Apply fluid packing to matching surfaces and install the oil separator cover Fluid packing THREE BOND 1215 or equivalent S2M1834A 21 Install the flywheel To lock the crankshaft use ST ST 498497100 CRANKSHAFT STOPPER Tightening torque 72 7 3 kgf m 52 8 ft lb 22 Install the housing cover 23 Installation of oil pump 1 Discard the front oil seal after removal Re place with a new one using ST ST 499587100 SEAL INSTALLER 52 0235 MECHANICAL 2 Apply fluid packing to matching surface of the oil pump Fluid packing THREE BOND 1215 or equivalent B2M0390B A O ring 3 Apply a coat of engine oil to the inside of the oil seal 52 0118 4 Install the pump on cylinder block Be careful not to damage the oil seal during instal lation Tightening torque 6 4 0 65 kgf m 4 7 ft lb CAUTION Do not forget to install the O ring and seal when installing the oil pump Align the flat surface of oil pump s inner rotor with crankshaft before installation ME STi 81 CYLINDER BLOCK MECHANICAL 24 Install the water pump and gasket Tightening torque First 12 1 2 kgf m 8 7 ft lb Second 12 1 2 kgf m 8
159. ne iro S tei eo uerba reor 2 Erant Grilles 2 e eee DE esee it A tag 3 Hood Grille 4 Front Under Cover 5 T 6 6 Rear Bumper 7 Mud Guard 8 Cowl Panel 9 Roof Spoiler 10 Rear Spoiler 11 Side Sill Spoiler 12 Front Door Trim 13 Rear Door Trim 14 Glove Box 15 Roof Rail 16 Console Box 17 Instrument Panel Assembly 18 Upper Inner Trim 19 Lower Inner Trim 20 Rear Quarter Trim 21 Sun Visor 22 Roof Trim 23 Rear Gate Trim 24 Rear Shelf Trim 25 Trunk Trim 26 Floor 27 Luggage Floor Mat Trunk Room Mat GENERAL DESCRIPTION EXTERIOR INTERIOR TRIM 1 General Description A COMPONENT 1 FRONT GRILLE STi model BO0510 1 Front grille 2 Front grille emblem 3 Clip 2 GENERAL DESCRIPTION EXTERIOR INTERIOR TRIM 4 FRONT BUMPER STi model 0511 1 Bumper face 4 Bumper energy absorber Tightening torque N m kgf m ft Ib 2 Bumper corner bracket 5 Bumper back beam Ti 32 3 3 24 3 License plate bracket T2 69 7 0 51 EI 3 GENERAL DESCRIPTION EXTERIOR INTERIOR TRIM 9 REAR SPOILER STi model 800512 1 Rear spoiler 4 Grommet Tightening torque N m kgf m ft lb 2 Protector 5 Seal only RH side T 7 4 0
160. on the re verse side for the top ring gap 9 Position the upper rail gap at C or D in the fig ure EN1516 10 Position the expander gap at 180 of the re verse side for the upper rail gap ME STi 77 CYLINDER BLOCK MECHANICAL 11 Position the lower rail gap at E or F in the fig ure CAUTION e Ensure the ring gaps do not face the same di rection Ensure the ring gaps are not within the piston skirt area EN1516 12 Install the circlip Install the circlips in piston holes located opposite service holes in cylinder block when positioning all pistons in the corresponding cylinders CAUTION Use new circlips 4 Front side 2 B2M1403A CAUTION Piston front mark faces towards the front of the engine EN1517 A Front mark B2M1322J 1 Piston 4 Gasket Tightening torque N m kgf m ft Ib 2 Piston pin b Service hole plug T 69 7 0 50 6 3 Circlip ME STi 78 CYLINDER BLOCK 13 Installing piston 1 Turn the cylinder block so that 1 and 2 cyl inders face upward 2 Using the ST1 turn the crankshaft so that 1 and 2 connecting rods are set at bottom dead center ST1 499987500 CRANKSHAFT SOCKET 3 Apply a coat of engine oil to the pistons and cylinders and insert pistons in their cylinders us ing ST2 ST2 398744300 PISTON GUIDE 52 0306 14
161. pipe lt Ref to EX TURBO 8 REMOVAL Center Exhaust Pipe gt 4 Remove the rear exhaust pipe and muffler 5 Remove the heat shield cover 6 Set the transmission jack under the transmission body CAUTION Always support the transmission case with a transmission jack 7 Remove the rear crossmember TRO643 8 Remove the rear cushion rubber OX AN 1 TRO086 2 Install the intercooler Ref to IN TURBO 11 INSTALLATION Inter cooler 3 Connect the battery ground cable to battery 2 CROSSMEMBER AND CUSHION RUB BER 1 Install the rear cushion rubber Tightening torque 35 N m 3 6 kgf m 25 8 ft Ib 2 Install the crossmember Tightening torque T1 70 N m 7 1 kgf m 51 6 ft Ib T2 140 N m 14 3 kgf m 103 ft Ib 0648 3 Remove the transmission jack 4 Install the center exhaust pipe lt Ref to EX TURBO 9 INSTALLATION Center Exhaust Pipe gt 5 Install the rear exhaust pipe and muffler 6MT 35 TRANSMISSION MOUNTING SYSTEM MANUAL TRANSMISSION AND DIFFERENTIAL C INSPECTION Repair or replace parts if the results of the inspec tion below are not satisfactory 1 PITCHING STOPPER Make sure that the pitching stopper is not bent or damaged Make sure that the rubber is not stiff cracked or otherwise damaged 2 CROSSMEMBER AND CUSHION RUB BER Make sure that the crossmember is not
162. pump bracket and tighten bolts Tightening torque 20 1 2 05 kgf m 14 8 ft lb H2M1954 3 Install the power steering pipe bracket on right side intake manifold and install the spark plug cords tor 0360 ME STi 38 ENGINE ASSEMBLY 5 Install the front side V belt and adjust it lt Ref to ME 44 FRONT SIDE BELT INSTAL LATION V belt gt 12 Tighten the nuts which hold lower side of trans mission to engine Tightening torque 50 5 1 kgf m 36 9 ft lb B2M2790 13 Tighten the nuts which install front cushion rub ber onto crossmember Tightening torque 85 8 7 kgf m 62 7 ft lb CAUTION Make sure the front cushion rubber mounting bolts A and locator B are securely installed B2M3880A 14 Install the center exhaust pipe lt Ref to EX TURBO 9 INSTALLATION Center Exhaust Pipe gt 15 Connect the following hoses 1 Fuel delivery hose return hose and evapo ration hose 2 Heater inlet and outlet hoses 3 Brake booster vacuum hose 16 Connect the following connectors and termi nals 1 2 3 4 Engine ground terminal Engine harness connectors Generator connector and terminal A C compressor connectors With A C MECHANICAL 17 Connect the following cables 1 Accelerator cable 2 Clutch release spring CAUTION After connecting each cable adjust
163. pump attaching bolts and defective gasket w gt gt 0 w gt gt U OU W 0 00 S O w w O w O O gt w w gt W gt gt Defective oil filter seal Defective crankshaft oil seal Defective rocker cover gasket Loosened oil drain plug or defective gasket Loosened oil pan fitting bolts or defective oil pan ME STi 95 wi w w w MECHANICAL Trouble ENGINE TROUBLE IN GENERAL Problem Parts etc Possible Cause 10 Excessive fuel consump tion Engine control system lt Ref to EN TURBO 2 Basic Diagnostic Procedure gt Intake system Dirty air cleaner element Belt Defective timing Compression Incorrect valve clearance Loosened spark plugs or defective gasket Loosened cylinder head bolts or defective gasket Improper valve seating Defective valve stem Worn or broken valve spring Worn or stuck piston rings cylinder and piston Incorrect valve timing Lubrication system Incorrect oil pressure Cooling system Over cooling Others Accelerator cable out of adjustment ME STi 96 w o o w w gt ENGINE NOISE MECHANICAL 22 Engine Noise A INSPECTION Type of sound Condition Possible cause Regular clicking sound Sound increases as engine speed increases Valve mechanis
164. resulting in interference with their heads Rotate direction Rotate direction S2M1231A ME STi 51 TIMING BELT ASSEMBLY MECHANICAL 3 Installation of timing belt N WA ES 52 0418 Align alignment mark on the timing belt with marks sprockets the alphabetical order shown in the figure While aligning marks position the timing belt properly CAUTION Disengagement of more than three timing belt teeth may result in interference between the valve and piston Ensure the belt s rotating direction is correct Arrow mark Timing belt SR OX 28 tooth n 54 5 tooth length 51 tooth length length I 4 Install it in the end 28 tooth length 52 1232 ME STi 52 TIMING BELT ASSEMBLY MECHANICAL 4 Install the belt idlers Tightening torque 39 4 0 kgf m 28 9 ft lb CAUTION Make sure that the marks on timing belt and sprockets are aligned 0255 5 After ensuring that the marks the timing belt and sprockets are aligned remove the stopper pin from tensioner adjuster 6 Install the timing belt guide 0256 1 Temporarily tighten the remaining bolts 3 Tighten the remaining bolts 2 Check and adjust clearance between the timing belt and timing belt guide Tightening torque 9 8
165. taking care of 5th 6th hub installing direction pee LJ n B 7180987 Main shaft 5th 6th hub C 5th drive gear 6MT 81 MAIN SHAFT ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 2 Using the ST press in the 5th 6th hub 571 18651AA000 INSTALLER ST2 398177700 INSTALLER CAUTION Do not apply pressure in excess of 40 KN 4 0 ton 4 4 US ton 3 9 Imp ton NOTE When pressing in 5th 6th hub align the protrusion portion of outer baulk ring and cutout portion of 5th 6th bush by moving the outer baulk ring Se 2 TRO745 D A 5th 6th hub B Outer baulk ring Cutout portion of 5th 6th hub D Protrusion portion of outer baulk ring 17 Make sure the 5th drive gear is smoothly turned by hand If not reassemble 18 Install the 5th 6th shifting insert key in proper place of 5th 6th sleeve NOTE Angle of each shifting insert key is 120 apart TRO738 A 5th 6th sleeve B Shifting insert key 19 Install the 5th 6th sleeve to 5th 6th hub NOTE 5th 6th sleeve has two grooves for identification Install the 5th 6th sleeve with the groove facing to 5th drive gear side TRO747 A 5th drive gear B Groove 2 for identification of 5th 6th sleeve 6 82 MAIN SHAFT ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL
166. that a micrometer is set 5 mm 0 20 in inward of the rotor outer perimeter BRAKE Standard Service Disc outer value limit dia 14 10 8 5 266 0 39 0 335 10 47 in Disc rotor 15 18 mm 16 mm 290 thickness 0 71 0 63 11 42 17 20 mm 18 mm 316 mm 0 79 in 0 71 in 12 44 in BR 13 REAR DISC BRAKE ASSEMBLY BRAKE 7 Rear Disc Brake Assembly A REMOVAL 3 17 INCH CAUTION Do not allow brake fluid to come in contact with vehicle body wipe off completely if spilled 1 Set the vehicle on a lift 2 Loosen the wheel nuts 3 Lift up the vehicle and then remove the wheels 4 Remove the brake pads from caliper body lt Ref to BR 12 17 INCH TYPE REMOVAL Rear Brake Pad gt 5 Disconnect the brake hose from caliper body 6 Remove the caliper body from housing 0063 7 Clean mud and foreign particles from the caliper body CAUTION Be careful not to allow foreign particles to enter inlet at brake hose connector B INSTALLATION 3 17 INCH TYPE 1 Install the caliper body on housing Tightening torque 65 6 6 kgf m 47 9 ft Ib CAUTION e Always replace the pads for both right and left wheels at the same time Also replace the pad clips if they are twisted or worn A wear indicator is provided on the outer disc brake pad If the pad wears down to such an ex tent that t
167. the extension case Ref to 6 49 IN STALLATION Extension Case 12 Install the oil pipe neutral position switch back up light switch and harness Ref to 6 44 INSTALLATION Oil Pipe gt Ref to 6 47 IN STALLATION Neutral Position Switch Ref to 6MT 45 INSTALLATION Back up Light Switch 13 Install the manual transmission assembly to ve hicle Ref to 6MT 39 INSTALLATION Manual Transmission Assembly 6MT 87 DRIVEN GEAR ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL DISASSEMBLY 5 Remove the driven gear key NOTE Each sleeve and hub engage at a specified point Mark an engagement point on the sleeve and hub before disassembly 1 Secure the ST on workbench ST 18664AA000 BASE 2 Lift the caulking of lock nut 3 Install the to lock nut set the driven gear as sembly on ST then remove the lock nut and wash er 18666AA000 HOLDER ST2 18664AA000 BASE 573 18620AA000 ADAPTER WRENCH TRO763 TRO764 TRO761 7 Remove the needle bearing and 1st 2nd sleeve 4 Install the ST1 to 4th gear then remove the ball bearing 5th 6th driven gear and 3rd 4th driven gear 511 18723AA000 REMOVER ST2 499877000 REMOVER TRO765 A Needle bearing B 1st 2nd sleeve TRO762 A Ball bearing B 5th 6th driven gear 41 driven gear 6MT 88 DRIVEN GEAR ASSEMBLY 8 Remove the outer ba
168. to 6MT 37 REMOVAL Manual Transmission Assembly 2 Prepare the transmission for overhaul Ref to 6MT 42 Preparation for Overhaul gt 3 Remove the extension case Ref to 6MT 49 REMOVAL Extension Case 4 Remove the transfer driven gear TRO691 B INSTALLATION 1 Install the transfer driven gear TRO691 2 If the bearing or transfer driven gear is replaced select the transfer driven thrust washer Ref to 6MT 51 ADJUSTMENT Extension Case 3 Install the extension case Ref to 6MT 49 IN STALLATION Extension Case 4 Install the manual transmission assembly to ve hicle Ref to 6MT 39 INSTALLATION Manual Transmission Assembly C DISASSEMBLY 1 Using the ST remove the roller bearing of exten sion case side ST 498515700 REMOVER TRO692 2 Using the ST remove the roller bearing of trans mission case side ST1 899858600 REMOVER ST2 899864100 REMOVER E TRO693 D ASSEMBLY 1 Using the ST install the roller bearing of exten sion case side ST1 398177700 INSTALLER ST2 899864100 REMOVER CAUTION Do not apply pressure in excess of 10 KN 1 ton 1 1 US ton 1 0 Imp ton ST2 A cs 2138 Roller bearing 6MT 60 TRANSFER DRIVEN GEAR MANUAL TRANSMISSION AND DIFFERENTIAL 2 Using the ST install the roller bearing of trans mission case side ST 499757002 INSTALLER
169. to sleeve edge when shifted to 3rd gear measurement value 55 mm 2 17 in C2 Length from main shaft rear bearing snap ring groove to sleeve edge when shifted to 4th gear NOTE The indicator is installed upside down compared to the setting procedure of zero point Add 1 fixing value 55 mm 2 17 in from the following figure to C1 to obtain measurement value of C1 TRO861 6MT 126 SHIFTER FORK AND ROD MANUAL TRANSMISSION AND DIFFERENTIAL Lot No Mark M SFT M SFT M SFT T mm in Snap ring Snap ring Snap ring 805072010 805072011 805072012 t 1 65 mm t 1 95 mm t 2 25 mm 0 065 in 0 077 in 0 089 in 137 22 137 52 32809AA171 32809AA181 32809AA191 5 4024 None 2 4 5 4142 137 52 137 82 32809AA161 32809AA171 32809AA181 5 4142 1 2 5 4260 137 82 138 12 32809 141 32809 161 32809 171 5 4260 3 1 5 4379 T Thickness 3 SELECTION OF 5TH 6TH FORK ROD NOTE Remove the remaining gasket on edge surface with scraper since the height gauge is set on adapter plate during measurement Do not place the height gauge on shaded area in the figure during the measurement TRO756 3 Using the height gauge measure D1 and D2 shown in the figure
170. valve 5 Tumble generator valve actuator valve STi model 3 Purge control solenoid valve Except STi model EN TURBO 10 ELECTRICAL COMPONENTS LOCATION ENGINE DIAGNOSTICS EN TURBO 11 ELECTRICAL COMPONENTS LOCATION ENGINE DIAGNOSTICS LHD model 1 4 bue EN1025 RHD model 1 4 E d 1026 1 Fuel pump 4 Fuel pump controller 7 Radiator sub fan relay 1 2 Main relay 5 Radiator main fan relay 1 8 Radiator sub fan relay 2 3 Fuel pump relay 6 Radiator main fan relay 2 9 Starter EN TURBO 12 ELECTRICAL COMPONENTS LOCATION ENGINE DIAGNOSTICS LHD model RHD model EN1028 0954 EN TURBO 13 ENGINE CONTROL MODULE ECM I O SIGNAL ENGINE DIAGNOSTICS 5 Engine Control Module ECM I O Signal A ELECTRICAL SPECIFICATION d 7 6 5 413 2 121111019 8 21 20 19 18 17 Boe 1514 22 21 955 Signal V Content rector ino anton SWON Engine ON Signal 135 0 7 7 Sensor output waveform shaft posi Signal B135 tion sensor Shield B135 Camshaft Signal B135 Sensor output waveform position Signal 135 sens
171. with MAGNET BASE 498247001 B3M1946 6MT 16 ILLUSTRATION GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL TOOL NUMBER DESCRIPTION REMARKS B3M1998 498077000 REMOVER Used for removing differential taper roller bear ing 2125 899858600 REMOVER Used for removing roller bearing B3M2129 399513600 INSTALLER Used for installing oil seal B3M1952 499757002 INSTALLER 6MT 17 Used for installing bearing cone of transfer driven gear extension core side GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499787000 WRENCH ASSY Used for removing and installing differential side retainer right side 1953 499827000 Used for installing speedometer oil seal when installing speedometer cable to transmission B3M1954 499877000 RACE 4 5 Used for disassembling driven shaft and transfer INSTALLER driven gear B3M1956 899864100 REMOVER Used for removing parts on transmission main shaft and drive pinion B3M1963 6MT 18 ILLUSTRATION GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL TOOL NUMBER DESCRIPTION REMARKS B3M1965 899904100 REMOVER Used for removing and installing straight pin B3M1969 899824100 Used for installing speedometer shaft oil seal B3M1972 498057300 INSTALLER Used for instal
172. 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 G1841GE4 CONTROL SYSTEMS Page 1 General Dest a er reor a Frei 2 2 Select Lever 3 Select Cable 4 Gear Shift Lever 5 Drive Select Lever 6 Drive Select Cable 7 General DIagnosllo cotes Set esc au aaa 4 8 GMT Gear Shift Lever nennen 5 9 BeverseCheckCable rennen nens 13 GENERAL DESCRIPTION CONTROL SYSTEMS 1 General Description B COMPONENT 4 6MT GEAR SHIFT LEVER TRO952 CS 2 GENERAL DESCRIPTION CONTROL SYSTEMS 1 Gear shift knob 15 Lever bush 29 Spring pin 2 Console box front 16 Spring pin 30 Shift rod 3 Boot plate 17 Bush 31 Reverse check lever 4 Slider 18 Boot 32 Band clip 5 Spring pin 19 Inner boot 33 Boss 6 Spring 20 Stay 7 Holder 21 Cushion rubber Tightening torque N m kgf m ft lb 8 Spring seat 22 Bush T1 1 3 0 13 0 96 9 Gear shift lever 23 Reverse check cable T2 7 5 0 76 5 5 10 Bush
173. 0 12 34 1727314 67 34 3141516 3141516 515 8 7 6 514 5 6 7 8 5678 15 16 1121314 516718 617181917 1 2 3 4 5 6 7 8 9110 814 11 12 13 14 15 16 17 18 11 12 13 14 15 16 17 18 19 20 5 6 7 8 9 H 12 1311415 1 2 BLACK Cas 161761819 314 9 1411516 19 24 25 26 29 34 35 36 20 21 2123124 25 77751 5186 9 7 2122 25 og 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 5 6 10 _ 17 _ 120 27 30 37 7 10 115 18 23 126 1617181920 21 22 11 12 13 18 21 22 23 28 31 32 33 38 3114 30 27 28 29 30 31 7118 8 1112 16 1917201 24 27128 RELAY BLOCK BLACK RELAY HOLDER BLACK GG04 22F WI 24 GROUND DISTRIBUTION WIRING SYSTEM HEADLIGHT LEVELING SWITCH INTERCOOLER WATER SPRAY STi MODEL SWITCH STi MODEL 5 2 iS 8294 COMBINATION METER DIAGNOSIS CONNECTOR 721 bet JC H CB REAR D
174. 1 Install the clutch release fork and bearing onto Before moving the engine away from transmis transmission sion check to be sure no work has been over 1 Remove the release bearing from clutch looked Doing this is very important in order to cover with flat type screw driver facilitate re installation and because transmis sion lowers under its own weight 52 1843 2 Install the release bearing on transmission 3 Install the release fork into release bearing 23 Separation of engine and transmission tab 1 Remove the starter lt Ref to SC 5 RE MOVAL Starter gt Se 2 Remove the bolt which holds right upper M DG side of transmission to engine 6 52 1928 52 1937 A Release fork B Release bearing B3M2044 24 Remove the engine from vehicle 1 Slightly raise the engine 2 Raise the transmission with garage jack 3 Move the engine horizontally until mainshaft is withdrawn from clutch cover 4 Slowly move the engine away from engine compartment CAUTION Be careful not to damage adjacent parts or body panels with crank pulley oil pressure gauge etc 25 Remove the front cushion rubbers ME STi 36 ENGINE ASSEMBLY 4 Apply grease to the specified points Spline FX2200 Shaft SUNLIGHT 2 52 1938 Spline FX2200 B Shaft SUNLIGHT 2 5 Insert the release for
175. 101 Option D R Dual range 1 For option code refer to ID section Ref to ID 5 Option code Air conditioner O Cruise control ABS Aluminium wheel Rear spoiler Spoiler pac SPC 13 IMPREZA SPECIFICATIONS SPC 14 IDENTIFICATION IDENTIFICATION IDENTIFICATION 1 Identification A IDENTIFICATION 2 MEANING OF The meaning of the VIN is as follows Europe Australia and General Except GCC JF1GD5LJ32G002001 The starting and ending brackets are stop marks Meaning Details Manufacturer body area JF1 Passenger car FHI made Car line IMPREZA Body type D 4 Door Sedan G Wagon Displacement 5 1 6 LAWD 9 2 0 L AWD 2 0 L AWD Turbo B 2 0 L AWD High power Turbo E 2 5L AWD Steering position K RHD Right hand drive L LHD Left hand drive Engine amp transmission SOHC MPI 4 speed J SOHC MPI Full time AWD 5 speed MT K SOHC MPI Full time AWD 5 speed MT Dual range D DOHC Turbo Full time AWD 5 speed MT H DOHC Turbo Full time AWD 6 speed MT P DOHC Turbo 4 speed AT Drive type 3 Full time AWD Single range 4 Full time AWD Dual range 5 AWD AT 10 Model year 2 2002MY 3 2003MY 11 G Factory location G FHI Gunma 12 10 17 002001 Serial number GCC countries Saudi Arabia etc JF1GD45MX2G002001 The starting and ending brackets are stop ma
176. 11112113 16 21223 28 31 82 33 10 11 12 tapa t 16 17 8 15116 17 18119 20 21 22 23 24 25 26 27 28 29 30 7 8 RELAY BLOCK BLACK GG04 22B WI 20 5 59 B GROUND DISTRIBUTION WIRING SYSTEM REARVIEW MIRROR FUEL PUMP ASSEMBLY PASSENGER SIDE 1 BW INTERCOOLER WATER SPRAY MOTOR AND LEVEL SENSOR STi MODEL ROOM LIGHT FRONT FOG LIGHT LH SEAT BELT SWITCH SIDE TURN SIGNAL LIGHT RH ABS CONTROL MODULE FAN CONTROL AMP 4 ABS CONDENSER HI MOUNTED STOP LIGHT SEDAN REAR DEFOGGER CHOKE COIL SEDAN BLOWER FAN SWITCH LS E gt o 5 a 1 2 1 1 11213 12 3415 2 1 2 3 BLACK 112 314 3 1 12 314 172 314 1516 7 8 9 10 11121314 15 61718 817161574 678 910 112 314 1617 18 19 20 21 22 1 2 3 5 6 7 8 9 27 28 29 a0 a1 23 24 25 26 4 5 6 1011
177. 12113145 79 Dv a GG04 22C WI 21 GROUND DISTRIBUTION WIRING SYSTEM RADIO RADIO SRS HARNESS REAR COMBINATION LIGHT RH WAGON TRAILER CONNECTOR REAR COMBINATION LIGHT LH WAGON TRUNK ROOM LIGHT SWITCH SEDAN REAR COMBINATION LIGHT RH SEDAN REAR WIPER INTERMITTENT MODULE WAGON REAR COMBINATION LIGHT LH SEDAN YELLOW lt 4 s 6 11213 12525441515 7 1213114 1516117 18 19 20 21 2 2324125 2612728 GG04 22D WI 22 GROUND DISTRIBUTION WIRING SYSTEM REAR DEFOGGER WITHOUT CHOKE COIL REAR GATE LATCH SWITCH HIGH MOUNTED STOP LIGHT HIGH MOUNTED STOP LIGHT REAR SPOILER 2 B REAR DEFOGGER WITH CHOKE COIL REAR WIPER MOTOR 4599 196 GG04 22E WI 23 GROUND DISTRIBUTION WIRING SYSTEM 2 RHD MODEL GENERAL HEADLIGHT LEVELER RH HEADLIGHT LEVELER LH STi MODEL STi MODEL POWER WINDOW FRONT DOOR LOCK MAIN SWITCH A
178. 16 17 18 101112113 balis 16 17 18 19 20 21 22 23 94 19 20 21 22 23 24 GG71 22B WI 50 CRUISE CONTROL SYSTEM WIRING SYSTEM CRUISE CONTROL MODULE dL gt 8 B Q o STARTER MOTOR C C 03 INHIBITOR SWITCH Ed 12 WB 11 REF TO GND 07 BLACK ay BLACK 1 21 3 12 314 112 3 4 5 6 172131215 617181911 41516 15161718 71819 10 11 12 11 12 13 1415 16 17 18 19 20 9 1011112 GG71 22C WI 51 ENGINE ELECTRICAL SYSTEM WIRING SYSTEM 16 Engine Electrical System A SCHEMATIC WI 52 ENGINE ELECTRICAL SYSTEM WIRING SYSTEM 3 LHD DOHC TURBO MODEL TO POWER SUPPLY ROUTING FB 21 F B FUSE NO 11 IG FUEL PUMP RELAY BETES REF TO GND 02 FUEL SUB LEVEL SENSOR mn CD want REF TO GND 03 112 112 1 2 WER 1121314 Sd ESEXETPTES terr 314 3456 41516 5161718 56 7 8910 9 1 11 12 13 14 15 16 17 18 19 20 21 22
179. 16 71819 E50 BLACK 71819401112 56 7 8 10112 13 14 1516 1718 19 13 14 15 1617 9 10 11412 20 21 22 23124125126127128 BLACK 31456 1718 1920 DER 9110 26 WI 61 ENGINE ELECTRICAL SYSTEM WIRING SYSTEM BLACK BLACK 1 2 Y c e E G LTB 01 5 B209 6139 8137 E Bed 84 ENGINE CONTROL MODULE N a gt gt bm tc gU d BE N CyB 3 2 og L Y 5 __ ____________ _ ____ __ ______ ome gt E dHR Ho D ng HE IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL NO 1 NO 2 NO 3 NO 4 BROWN E Wees 8136 6137 1121314 1 213 4 5 6 112 314 5 6 7 112 3145 121 81911 612 18 9 516 7 8 7 8 9 10 1 12 9 10 11 12 13 14 15 8 9110 11 1213 4 15 116 t0 t 12 t3 t4 15 16 17 18 19 20 21 m 9 n E 13 1415 Dei 1617 18 19 20 21 17 1819202 22 23 24 2 23 24 05 26 27 08 29130 31 GL10 26J WI 62 ENGINE ELECTRICAL SYSTEM W
180. 20 2 0 14 8 6 13 Pad Inside 155 15 8 114 3 7 Pad pin 14 Disc rotor BR 5 BRAKE GENERAL DESCRIPTION 16 REAR DISC BRAKE 17 INCH TYPE 42 25 23 Ee 2 4 20 26 E 27 28 BR0152 Caliper body Air bleeder screw Guide plate Cross spring Piston boot Piston Piston seal Clip Pad pin Pad shim Pad Outside Pad Inside AE C PER MA e JD D Jm E ob ve Shoe hold down 25 Cover 26 Back plate 27 Retainer 28 Spring washer 29 Parking brake lever 30 Primary shoe return spring Adjusting spring Adjuster Shoe hold down cup Shoe hold down spring Disc rotor Parking brake shoe Primary Strut Strut shoe spring Shoe guide plate 13 14 15 16 17 18 19 Parking brake shoe Secondary 20 21 22 23 24 Secondary shoe return spring BR 6 Tightening torque N m kgf m ft lb T1 20 2 0 14 8 2 52 5 3 38 3 T3 65 6 6 47 9 FRONT BRAKE PAD 2 Front Brake Pad A REMOVAL 3 17 INCH 1 Set the vehicle on a lift 2 Loosen the wheel nuts 3 Jack up the vehicle and then remove the front wheel 4 Remove the clip 0144 1 5 Remove the pad pins cross spring 0145 1 Pad pin 2 Cross spring 6 Use a wrench to expand the pads then
181. 34 INSTALLATION Vehicle Speed Sensor 4 Install the front differential assembly Ref to 6MT 108 INSTALLATION Front Differential As sembly gt 5 Install the drive pinion shaft assembly lt Ref to 6MT 101 INSTALLATION Drive Pinion Shaft As sembly gt 6 Install each gear assembly at once lt Ref to 6MT 74 INSTALLATION Main Shaft Assembly gt 7 Install the transmission case lt Ref to 6MT 69 INSTALLATION Transmission Case gt 8 Install the oil pump lt Ref to 6MT 65 INSTAL LATION Oil Pump gt 9 Install the center differential lt Ref to 6 62 INSTALLATION Center Differential gt 10 Install the transfer driven gear lt Ref to 6MT 60 INSTALLATION Transfer Driven Gear gt 11 Install the extension case lt Ref to 6MT 49 IN STALLATION Extension Case gt 12 Install the oil pipe neutral position switch back up light switch and harness lt Ref to 6MT 44 INSTALLATION Oil Pipe gt lt Ref to 6MT 47 IN STALLATION Neutral Position Switch gt lt Ref to 6MT 45 INSTALLATION Back up Light Switch gt 13 Install the manual transmission assembly to ve Ref to 6MT 39 INSTALLATION Manual Transmission Assembly gt C DISASSEMBLY 1 Remove the clutch release bearing guide 0872 2 Remove the oil seal ST 398527700 PULLER ASSY NOTE Do not reuse the oil seal 6MT 131 CLUTCH HOUSING MANUAL TRANSMISSION AND DIFF
182. 4 15 16 17 18 56 789 0 1011112 13 14 15 B42 16171819 20 21 22 23 24 25 7727 518 9 13114 17 21 22 25 Ge 7 nai 15 nai es 26 al nma hel zepa ad 578 80 3 4 9 14 15 16 19 24 25 26 29 3413536 sme __10 j 0 7 RELAY HOLDER BLACK 11 12 13 18 21 22 23 28 131132133 38 7118 GG04 22A WI 19 GROUND DISTRIBUTION WIRING SYSTEM INTERCOOLER WATER SPRAY SWITCH STi MODEL 2 HEADLIGHT LEVELING SWITCH STi MODEL 8 RADIO AT SELECT LEVER 7 8 13 FRONT DOOR SWITCH DRIVER SIDE B 1 3 TURN amp HAZARD MODULE COMBINATION SWITCH WIPER 2 COMBINATION SWITCH LIGHTING 16 B 12 REMOTE CONTROLLED FRONT ACCESSORY REARVIEW MIRROR SWITCH POWER SUPPLY SOCKET ESCH EnD ABS RELAY MIRROR HEATER RELAY 131 AUTO A C CONTROL MODULE CHECK CONNECTOR p 820 8 4812 SNOW MODE SWITCH IGNITION RELAY B KICK DOWN SWITCH SEAT BELT TIMER 1 B 3 B44 1 REAR DEFOGGER TIMER 1 FRONT WIPER MOTOR 4 B INHIBITOR SWITCH AT 4 B BRAKE FLUID LEVEL WARNING SWITCH GLOVE BOX ILLUMINATION LIGHT pif B FRONT DOOR SWITCH PASSENGER SIDE AWD LO SWITCH
183. 5200 2 53 mm 0 0996 in 383745200 2 51 mm 0 0988 in 383755200 2 49 mm 0 0980 in 383765200 2 47 mm 0 0972 in 383775200 2 45 mm 0 0965 in Preload adjusting washer 383785200 2 43 mm 0 0957 in 383795200 2 41 mm 0 0949 in 383805200 2 39 mm 0 0941 in 383815200 2 37 mm 0 0933 in 383825200 2 35 mm 0 0925 in 383835200 2 33 mm 0 0917 in 383845200 2 31 mm 0 0909 in DI 5 DIFFERENTIALS Pinion height adjusting shim GENERAL DESCRIPTION Part No Thickness 383495200 3 09 mm 0 1217 in 383505200 3 12 mm 0 1228 in 383515200 3 15 mm 0 1240 in 383525200 3 18 mm 0 1252 in 383535200 3 21 mm 0 1264 in 383545200 3 24 mm 0 1276 in 383555200 3 27 mm 0 1287 in 383565200 3 30 mm 0 1299 in 383575200 3 33 mm 0 1311 in 383585200 3 36 mm 0 1323 in 383595200 3 39 mm 0 1335 in 383605200 3 42 mm 0 1346 in 383615200 3 45 mm 0 1358 in 383625200 3 48 mm 0 1370 in 383635200 3 51 mm 0 1382 in 383645200 3 54 mm 0 1394 in 383655200 3 57 mm 0 1406 in 383665200 3 60 mm 0 1417 in 383675200 3 63 mm 0 1429 in 383685200 3 66 mm 0 1441 in Side gear backlash in 0 1 0 2 0 0039 0 0079 Side gear thrust washer Model without LSD Part No Thickness 383445201
184. 6AA110 1 775 mm 0 0699 in Pinion height adjusting shim Part No Thickness 32295AA200 0 150 mm 0 0059 in 32295AA210 0 175 mm 0 0069 in 32295AA220 0 200 mm 0 0079 in 32295AA230 32295AA240 0 250 mm 0 0098 in 32295AA250 0 225 mm 0 0089 0 275 mm 0 0108 in Side gear backlash 0 05 0 15 0 0020 0 0059 DI 4 GENERAL DESCRIPTION DIFFERENTIALS 0 925 0 950 mm 0 0364 0 0374 in 0 950 0 975 mm 0 0374 0 0384 in 0 975 1 000 mm 0 0384 0 0394 in 1 000 1 025 mm 0 0394 0 0404 in 1 025 1 050 mm 0 0404 0 0413 in 803135011 803135012 Side gear thrust washer 803135013 803135014 803135015 Crown gear to drive pinion backlash mm in Crown gear runout on its back surface mm in T type 0 10 0 15 0 0039 0 0059 0 05 0 0020 New bearin eee Front and rear bearing preload at com g 1 9 2 6 4 3 5 8 panion flange bolt kgf Ib Uisedibearind 5 Part Length 383695201 56 2 2 213 in 383695202 56 4 mm 2 220 in Preload adjusting spacer 383695203 56 6 mm 2 228 in 383695204 56 8 mm 2 236 in 383695205 57 0 mm 2 244 in 383695206 57 2 mm 2 252 in Part No Length 383705200 2 59 mm 0 1020 in 383715200 2 57 mm 0 1012 in 383725200 2 55 mm 0 1004 in 38373
185. 7000 RACE 4 5 INSTALLER NOTE Do not reuse the ball bearing TRO688 D ASSEMBLY 1 Using the ST install the ball bearing ST1 499247400 INSTALLER ST2 398497701 SEAT 0689 6 58 TRANSFER DRIVE GEAR MANUAL TRANSMISSION AND DIFFERENTIAL 2 Install the snap ring TRO687 3 Inspect the clearance between snap ring and ball bearing lt Ref to 6MT 59 INSPECTION Transfer Drive Gear gt E INSPECTION 1 Bearings Replace the bearings in the following cases Broken or rusty bearings Worn or damaged Bearings that fail to turn smoothly or make ab normal noise 2 Drive gear Replace the drive gear in the following cases f their tooth surface and shaft are excessively broken or damaged 3 Measure the clearance between snap ring and inner race of ball bearing with a thickness gauge Standard clearance between snap ring and in ner race 0 0 15 mm 0 0 0059 TRO690 4 If the measurement is not within specifications select suitable snap ring Thrust washer Part No Thickness mm in 805045050 1 76 0 069 805045060 1 88 0 074 805045070 2 00 0 079 After replacement of the snap ring inspect the clearance again 6 59 TRANSFER DRIVEN GEAR MANUAL TRANSMISSION AND DIFFERENTIAL 15 Transfer Driven Gear A REMOVAL 1 Remove the manual transmission assembly from vehicle Ref
186. 75 5 46 3 Cap 6 High mount stop lamp 4 FRONT GRILLE EXTERIOR INTERIOR TRIM 2 Front Grille A REMOVAL 2 STI MODEL 1 Open the hood 2 Remove the eight clips 5 EXTERIOR INTERIOR TRIM 5 Front Bumper A REMOVAL 2 STIMODEL CAUTION Handle the bumper carefully to avoid damage to bumper face Do not damage the body during removal or installation of bumper To avoid damage to bumper lay the removed bumper on sheet spread on the floor Do not lay it directly on the floor 1 Disconnect the ground cable from battery 2 Remove the front grille lt Ref to El 5 REMOV AL Front Grille gt 3 Loosen the three clips to remove the front grille side Except STi model 800057 4 Pull off the front side of front mud guard to re move clip 0058 5 Remove the clips and pull out the bumper slight ly EI 6 6 Disconnect the fog light connector to remove bumper 800059 7 Remove the E A FORM from bumper beam CAUTION E A FORM may easily break Do not apply ex cessive force to it during removal BO0060 8 Remove the bumper beam 0061 2002 IMPREZA STi SERVICE MANUAL QUICK REFERENCE INDEX WIRING SYSTEM SECTION This service manual has been prepared to provide SUBARU service p
187. 8 11112 16 19120 24 27128 30 RELAY HOLDER BLACK A E133 NA 112 3 4 Sie 7 8 1121 1314 5161718 9 10 11 12 13 14 15 16 17 18 1920 21122 23 10 1112 13 14 15 1617 1819120 21 22 23 24 25 26 2728 12930131 GR46 22A AIR CONDITIONING SYSTEM WIRING SYSTEM VEHICLE SPEED MB 10 FB 27 FB 17 SENSOR MT M B FUSE 2 F B FUSE NO 9 F B FUSE 18 856 IG TRANSMISSION CONTROL MODULE AT 1 WITH ILLUMINATION CONTROL MODEL YL WITHOUT ILLUMINATION CONTROL MODEL B SN STi TURBO ENGINE MODEL AND NON TURBO ENGINE MODEL REF TO ILM ROI 01 ILM RWI 01 NORMAL TURBO ENGINE MODEL E 5 282 B B283 AUTO A C CONTROL MODULE 17 eLack SN G17 Lack NT 822 Brown A GRAY B GRAY 11213 m q n 112 112134 1121314 516 7 8 1121314 516 7 8 9 to 34 516 78 12 1314 1516 11 1213114 15 1617 18 1920 101112 1811415 16 GREEN 11213141 56 71 8 9 10 11 12 13 1415 16 17 18 19 20 21 22 23 24 GR46 22B
188. 8 19 20 21 22 23 24 20 91 2 23124125126127128 22 23 24 25 26 27 28 29 30 31 GL10 26F WI 58 ENGINE ELECTRICAL SYSTEM WIRING SYSTEM B 8135 E ENGINE CONTROL MODULE STi TURBO ENGINE MODEL CAMSHAFT POSITION SENSOR CRANKSHAFT POSITION SENSOR AVCS CAMSHAFT 12 3 4 5 6 POSITION SENSOR RH AVCS CAMSHAFT POSITION SENSOR LH SENSOR STi TURBO MODEL STi TURBO MODEL LIGHT GRAY G20 LIGHT GRAY 9 8 T 23 24 25 26 27 28 1234 56 1011 12 13 14 15 1617 18 19 2012122 16 17 7 8 9101 12 1311415 2 26G GL10 WI 59 ENGINE ELECTRICAL SYSTEM WIRING SYSTEM B 6135 6136 B84 ENGINE CONTROL MODULE 48 535 E G LTB 02 G ENGINE MODEL OETA LY Ct T 1 1 Taw J 11 L CS 7 5 e Cw 2 R e TGV LH TGV RH IDLE AIR CONTROL NORMAL NORMAL SOLENOID VALVE OIL PRESSURE SWITCH POWER STEERING TURBO MODEL TURBO MODEL PRESSURE SWITCH BLACK D BLACK E BLACK B
189. 8791700 Align each chamfered part of front drive shaft axle drive shaft spring pin hole and assemble them Then insert the spring pin REMOVER G2M0325 14 Install the ball joint of transverse link to hous ing Tightening torque 50 5 1 kgf m 36 9 ft lb 0642 15 Install the stabilizer nut Tightening torque 45 4 6 kgf m 33 2 ft Ib NOTE Discard the loosened self locking nut and replace with a new one TRO0090 16 Install the propeller shaft Ref to DS 16 IN STALLATION Propeller Shaft MANUAL TRANSMISSION AND DIFFERENTIAL 17 Install the center exhaust pipe lt Ref to EX TURBO 9 INSTALLATION Center Exhaust Pipe 18 Install the rear exhaust pipe and muffler Ref to EX TURBO 13 INSTALLATION Rear Exhaust gt Ref to EX TURBO 12 INSTALLATION Joint Pipe 19 Install the universal joint Ref to PS 27 IN STALLATION Universal Joint 20 Install the under cover 21 Install the intercooler assembly Ref to IN TURBO 11 INSTALLATION Intercooler gt 22 Connect the battery ground cable to battery 6 41 PREPARATION FOR OVERHAUL MANUAL TRANSMISSION AND DIFFERENTIAL 7 Preparation for Overhaul A PROCEDURE 1 Clean oil grease dirt and dust from transmis sion 2 Remove the drain plug to drain oil After drain ing retighten it as before NOTE Replace the gasket
190. 9 1 21 7 8 9 51678 Tekee 25 2 1 2 8 156 ABS 32 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS WIRING DIAGRAM RHD MODEL ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT SHIELD JOINT CONNECTOR lt 511 sti MODEL EXCEPT STi MODEL ABS G SENSOR JOINT CONNECTOR STi MODEL ABS LATERAL G SENSOR STi MODEL 6 121314176 H 5 Ex 1 21 3 5 7 819 11213 14151617 8 1314115 18 19 20 21 22 6117 18 19 2021 5 16 17 23 24 25 26 lt 0157 Step CHECK ALL FOUR WHEELS FOR FREE Go to step 2 Have the wheels been turned The ABS is nor freely such as when vehicle 15 Erase the lifted up or operated on a roll ing road TURNING ABS 33 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS Step Check Yes No CHECK OUTPUT OF LATERAL G SENSOR USING SELECT MONITOR 1 Select Current data display amp Save on the select monitor 2 Read the select monitor display Is the lateral G sensor output on monitor display between 2 3 and 2 7 V when the vehicle is in horizontal position Go to step 3 Go to step 8 CHECK OUTPUT OF LATERAL G SENSOR USING SELECT MONITOR 1 Turn the ig
191. 9 ft lb 4 Install the belt idler Tightening torque 39 4 0 kgf m 28 9 ft lb EA 2 Q Es 0 ME STi 49 TIMING BELT ASSEMBLY MECHANICAL 2 TIMING BELT 1 Preparation for installation of automatic belt ten sion adjuster assembly Ref to ME STi 49 AU TOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER Timing Belt As sembly gt 2 Crankshaft and camshaft sprocket alignment 1 Align mark A on the crankshaft sprocket with mark on the oil pump cover at cylinder block 2 Align single line mark A on the right hand exhaust camshaft sprocket with notch B on belt cover 52 1227 3 Align single line mark the right hand intake camshaft sprocket with notch B on belt cover Ensure sure double lines C on the intake cam shaft and exhaust camshaft sprockets are aligned Fo S2M1228B 4 Align single line mark A on the left hand exhaust camshaft sprocket with notch B on belt cover by turning sprocket counterclockwise as viewed from front of engine A i S2M1229B 5b Align single line mark A on the left hand in take camshaft sprocket with notch B on belt cover by turning sprocket clockwise as viewed from front of engine Ensure double lines C on the intake and ex haust camshaft sprockets are aligned
192. ANUAL HI MOUNTED STOP A C SWITCH LIGHT SEDAN INTERCOOLER WATER SPRAY MOTOR AND LEVEL SENSOR STi MODEL FAN CONTROL AMP 8168 REAR DEFOGGER CHOKE COIL SEDAN g T ze sg 216 145 BLACK 1121314 2 415 6 56 7 8 112 1 2 3 3 4 4 5 6 5168 8122 BLACK 817654 112 314 12 34 5161718 19 5167189 10 101112113114 15 161789 2012122123 24 25 GG04 22H WI 26 GROUND DISTRIBUTION WIRING SYSTEM RADIO RADIO SRS HARNESS REAR COMBINATION LIGHT RH WAGON TRAILER CONNECTOR REAR COMBINATION LIGHT LH WAGON TRUNK ROOM LIGHT SWITCH SEDAN REAR COMBINATION LIGHT RH SEDAN REAR WIPER INTERMITTENT MODULE WAGON REAR COMBINATION LIGHT LH SEDAN YELLOW CTI 11213 456 112 3415 11213 41516 617 8 9 10 7 9 101 1213 14 7 8 9 1011121314 15 16 17 18 19 20 212212324125126127 28
193. ASH INSPECTION Front Differential Assembly gt 7 Check and adjust the tooth contact lt Ref to 6MT 105 ADJUSTMENT Drive Pinion Shaft As sembly gt 6MT 108 FRONT DIFFERENTIAL ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 8 Mark an engagement point on the right and left side retainer and clutch housing 0828 9 Remove the differential side retainer from both side NOTE Note the rotating number of time till removal when removing the side retainer 10 Install a new O ring to side retainer of both side 11 Install the differential side retainer to both side NOTE Install the side retainer by screwing in the same ro tating number of time till removal and then align the mark 12 Install the lock plate Tightening torque 25 2 5 kgf m 18 1 ft lb NOTE Be careful not to confuse right and left lock plate 0821 A Left Right 13 Completely remove the remaining gasket from the clutch housing and adapter plate 14 Apply liquid gasket to the clutch housing Liquid gasket THREE BOND 1215 TRO711 15 Install the drive pinion shaft assembly lt Ref to 6MT 101 INSTALLATION Drive Pinion Shaft As sembly gt 16 Install each gear assembly at once lt Ref to 6MT 74 INSTALLATION Main Shaft Assembly gt 17 Install the transmission case lt Ref to 6MT 69 INSTALLATION Transmission Case gt 18 Install the oil pump lt Ref
194. Back up Light Switch gt 4 Remove the extension case lt Ref to 6MT 49 REMOVAL Extension Case gt 5 Remove the transfer driven gear lt Ref to 6MT 60 REMOVAL Transfer Driven Gear gt 6 Remove the center differential Ref to 6MT 62 REMOVAL Center Differential gt 7 Remove the oil pump lt Ref to 6MT 64 RE MOVAL Oil Pump gt 8 Remove the transmission case lt Ref to 6MT 68 REMOVAL Transmission Case gt 9 Remove the striking rod 10 Using a screwdriver shift to 4th gear position TRO722 A 3rd 4th shift rod 11 Remove the reverse idler holder Ginn NW lt NN LC SES pc 1t TRO723 A Reverse idler holder MANUAL TRANSMISSION AND DIFFERENTIAL 12 Remove all checking plug gasket checking spring plunger and checking ball from adapter plate NOTE Do not reuse the gasket A B A TRO724 A Checking plug B Gasket C Checking spring D Plunger E Checking ball 13 Remove the bolt and gasket installing reverse idler shaft 9 2 P 14 Press the main shaft assembly driven gear as sembly reverse idler gear and each shifter fork then remove from the adapter plate at once NOTE Two people should do the work 6 73 MAIN SHAFT ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL B
195. CTUATOR DRIVER SIDE HEADLIGHT LEVELING SWITCH EXCEPT STi MODEL TURBO ENGINE MODEL REARVIEW MIRROR DRIVER SIDE HEADLIGHT LEVELER RH EXCEPT STi MODEL HEADLIGHT LEVELER LH EXCEPT STi MODEL SUB FAN MOTOR TURBO ENGINE MODEL CRUISE CONTROL MODULE KEYLESS ENTRY CONTROL MODULE MAIN FAN MOTOR NON TURBO ENGINE MODEL FRONT CLEARANCE LIGHT LH SUB FAN MOTOR NON TURBO ENGINE MODEL FRONT CLEARANCE LIGHT RH AIR MIX ACTUATOR HEADLIGHT LO RH STi MODEL FWD SWITCH NON TURBO ENGINE MODEL TURBO ENGINE MODEL STi MODEL EXCEPT STi MODEL BLACK 7 RA 5 NA Cr Gray C16 Lack TE Fs BLack ES 7 Cre Lack sr C17 NA Gray C7 eraco erac ES T 1213 2 1 2 h 2 3 m 112 1721314 1 2 1 2 Gray ST 3 2
196. Clear Memory Mode gt and Inspection Mode lt Ref to EN TURBO 42 Inspection Mode gt Step Check Yes No 1 CHECK ANY OTHER DIAGNOSTIC TROU 15 any other DTC displayed Inspect the rele to step 2 BLE CODE DTC ON DISPLAY vant DTC using List of Diagnostic Trouble Code DTC lt Ref to EN TURBO 18 List of Diagnostic Trouble Code DTC gt 2 CHECK CURRENT DATA Is the measured value largely Inspect the follow A temporary mal 1 Start the engine and let it idle out of specification ing items and function Conduct 2 Inspect the variable valve timing system repair or replace if the following to operating angle and variable valve timing sole necessary clean the oil pas noid valve duty output using Subaru Select Engine oil sage Monitor and OBD II general scan tool amount con Replace the Specification tamination engine oil and idle Variable valve timing system operating angle Oil pipe clog the engine for 5 Approx 0 degree Variable minutes then Variable valve timing solenoid valve duty out valve timing replace the oil filter put Approx 10 solenoid valve engine oil NOTE clog or con Subaru Select Monitor tamination in oil For detailed operation procedure refer to the passage set READ CURRENT DATA FOR ENGINE tling at spring Ref to EN TURBO 34 Subaru Select Moni stuck at valve tor ntake cam OBD II general scan tool shaft sludge For detailed operation pr
197. D TVUVACSCTDTMONouan EJ161RX3AA Digits Code Meaning Details 1 and 2 EJ Engine type EJ 4 cylinders 3 and 4 16 Displacement 16 1 6L 20 2 0L 25 2 5L 5 1 Fuel feed system 1 D MPI SOHC A 5 MPI Turbo 7 MPI High power Turbo 6 R Detailed specifications Used when ordering parts See the parts catalog for details 7 X Transmission W MT X AT 8 to 10 3AA Detailed specifications Used when ordering parts See the parts catalog for details ID 3 IDENTIFICATION IDENTIFICATION Transmission TY856WN2AA Meaning Details Transmission T Transmission Transmission type Y Full time AWD MT center differential V Full time AWD AT center differential Z Full time AWD AT MPT Classification 75 SMT 85 eMT 1B AT Series MT 4 5 6 6 AT 4 AT Transmission specifica tions V Full time AWD 5 speed MT with viscous coupling center dif ferential single range X Full time AWD 5 speed MT with viscous coupling center dif ferential dual range W Full time AWD 6 speed MT with viscous coupling center dif ferential single range Z Full time AWD 4 speed AT with MPT Y Full time AWD 4 speed AT with VTD Rear differential 1 VA1REJ Detailed specifications Meaning Used when ordering parts See the parts catalog for details Details For AWD V AWD Type A A type Hypoid gear diameter mm in 1
198. Drum Brake Assembly Master Cylinder Brake Booster Proportioning Valve Brake Fluid Air Bleeding Brake Hose Brake Pipe Hill Holder Brake Pedal Stop Light Switch General Diagnostics BRAKE GENERAL DESCRIPTION 1 General Description A SPECIFICATIONS Model TS GX RS OBK WRX STi Size 14 inch type 15 inch type 16 inch type 17 inch type Type Disc Floating type ventilated Disc Fixed type ventilated Effective disc diameter 210 mm 8 27 in 228 mm 8 98 in 255 mm 10 04 in 268 mm 10 55 in Disc thickness x Outer diameter 24 x 260 mm 0 94 x 10 24 in 24 277 0 94 x 10 91 in 24 x 294 mm 0 94 x 11 57 in 30 x 326 mm 1 18 x 12 83 in Effective cylinder diameter 57 2 mm 2 252 in 42 8 mm 1 685 in x 2 40 4 mm 1 591 in x 4 40 0 mm x 2 46 0 mm x 2 1 575 in x 2 1 811 in x 2 Pad dimensions length x width x thickness 112 4 x 44 3 x 11 0 mm 4 425 x 1 744 x 0 433 in 112 3 x 50 0 x 11 0 mm 4 421 x 1 969 x 0 433 in 116 0 x 48 3 x 10 0 mm 4 567 x 1 902 x 0 394 in 129 8 x 60 5 x 9 2 mm 5 110 x 2 382 x 0 362 in Clearance adjust ment Automatic adjustment Size 14 inch type 15 inch type 17 inch type Type Disc Floating type Disc Fixed type ventilated Effective disc diameter 230 mm 9 06 in 261 mm 10 28 in 268 mm 10 55 in D
199. E If out of specification check or replace the pressure regulator and pressure regulator vacuum hose 1 Release fuel pressure lt Ref to FU TURBO 53 RELEASING OF FUEL PRESSURE OPERA TION Fuel gt 2 Open the fuel flap lid and remove the fuel filler cap 2 2535 3 Disconnect the fuel delivery hoses from fuel fil ter and connect the fuel pressure gauge 52 0195 4 Connect the connector of fuel pump relay 5 Start the engine MECHANICAL 6 Measure the fuel pressure while disconnecting pressure regulator vacuum hose from intake fold Fuel pressure Standard 284 314 kPa 2 9 3 2 kg cm 41 46 psi S2M0554 7 After connecting the pressure regulator vacuum hose measure the fuel pressure Fuel pressure Standard 230 260 kPa 2 35 2 65 kg cm 33 38 psi S2M0554 NOTE The fuel pressure gauge registers 10 to 20 kPa 0 1 to 0 2 kg cm 1 to psi higher than standard val ues during high altitude operations ME STi 27 VALVE CLEARANCE MECHANICAL 8 Valve Clearance A INSPECTION CAUTION Inspection and adjustment of valve clearance should be performed while engine is cold 1 Set the vehicle on a lift 2 Disconnect the battery ground cable G6M0095 3 Remove the air intake duct Ref to IN TUR BO 8 REMOVAL Air Intake Duct 4 Remove one b
200. EF GND 01 REAR COMBINATION LIGHT LH WAGON at REAR COMBINATION LIGHT RH WAGON SEDAN WAGON d 22 Gray 28 50 28 WG 1 2 6171819 10 1 E 12 1314 15 16 17118 19 20 21 22 23 24 11213 11213 2 1 4 5 6 6151413 GL21 24C WI 80 CLEARANCE LIGHT AND ILLUMINATION LIGHT SYSTEM WIRING SYSTEM 2 RHD WITHOUT ILLUMINATION CONTROL MODEL TO POWER SUPPLY ROUTING FB 14 FB 12 FB 13 FB 3 FB 10 FB 11 F B FUSE 7 TAIL amp ILLUMI TAIL amp ILLUMI 8 NATION RELAY PP FUSE F B FUSE F B NATION RELAY m B 8 5 ILM ROI 01 ILM ROI 01 PARKING SWITCH ENGINE CONTROL MODULE NON TURBO AT SELECT LEVER FRONT ACCESSORY POWER A ILLUMI LIGHT SUPPLY SOCKET ILLUMI LIGHT ENGINE 1 v CONTROL MODULE Es TURBO 3 FRONT FOG LIGHT SWITCH ILLUMI LIGHT MODE CONTROL PANEL ILLUMI LIGHT MANUAL A C ERG Cv is 2 Cels B160 B168 REAR FOG LIGHT SWITCH AUTO A C ILLUMI LIGHT CONTROL MODULE 2 v Cv deis Ezo W HEADLIGHT LEVELING SWITCH ILLUMI LIGHT EI oe AMIGO POWER amp HOLD MODE SWITCH ILLUMI LIGHT ILM ROI 02 ES ST HE E 1 6 TURBO E
201. EFOGGER TIMER gt ENED RADIO AT SELECT LEVER B296 7 8 CB FRONT WIPER MOTOR 4 GN Gw oe COMBINATION SWITCH WIPER FRONT DOOR SWITCH DRIVER SIDE 2 B CRUISE CONTROL ACTUATOR COMBINATION SWITCH LIGHTING TURN amp HAZARD MODULE Lel ED SSES INTERCOOLER WATER SPRAY REMOTE CONTROLLED FRONT ACCESSORY INHIBITOR SWITCH TIMER STIIMODEE REARVIEW MIRROR SWITCH POWER SUPPLY SOCKET 418 218 emm 8 8256 8284 SSES BRAKE FLUID LEVEL WARNING SWITCH SIDE TURN SIGNAL LIGHT LH ABS RELAY MIRROR HEATER RELAY 218 LEIT s 14 6148 B264 GLOVE BOX nine Rie Soni DUCE ILLUMINATION LIGHT FUEL PUMP RELAY CHECK CONNECTOR 18 EDE p BE 8 B 1812 B208 46 283 FRONT DOOR SWITCH POWER MODE AND PASSENGER SIDE MAIN RELAY IGNITION RELAY SNOW MODE SWITCH B AWD LO SWITCH CTE KICK DOWN SWITCH PETA ROOM LIGHT STi MODEL ES EXCEPT STI MODEL Oo 6 ane Ome Om 112 1 2 1 2 er BROWN D 6133 ELVE 815 51 3 4 3 4 A 10 GREEN s 2
202. EL PARKING BRAKE WARNING LIGHT ABS RELAY ABS CONDENSER REF GND 07 tc REF GND 06 ABS MOTOR GROUND 862 BLACK BLACK 865 BLACK 8263 PINK A 10 GREEN 4151617 E SOLENOID VALVE OUTLET VALVE RELAY MOTOR RELAY 775 5 112 1 112 112 1234 11213 81910 5 3l4 3l4 51617 8 7 8 9 10 1 12 13 14 GREEN Fra BLACK 112 314 15 617 819 12 13 14 2 112131416 817781910 1516117 1819 20 21122123 24 25126127 28 29 30 12 112 1814115 1617 1819120 2122 3114 e 15 16 bal 4125126 29 34135136 BLACK 5 Te 29 je 7 11 12 13 18 21122123 28 31132133 38 1 213141516 718 9 112 314 516 7 8 STI 1617118 19120212 1011112113114 15116 17 18 19 20 32 27128 29 30 31 22 23 24 25 26 27 28129 30 91 GR82 22A
203. EMOVAL Back up Light Switch 4 Remove the extension case Ref to 6MT 49 REMOVAL Extension Case 5 Remove the transfer driven gear Ref to 6 60 REMOVAL Transfer Driven Gear 6 Remove the center differential Ref to 6 62 REMOVAL Center Differential 7 Remove the oil pump Ref to 6 64 RE MOVAL Oil Pump 8 Remove the shim and spacer of driven gear as sembly A Driven gear assembly 9 Remove the snap ring TRO706 10 Remove the pilot bolt TRO707 11 Remove the holder reverse bolt TRO708 12 Remove the transmission case NOTE If the oil guide catches on shift fork the transmis sion case may be difficult to be removed Move the oil guide right and left to remove Do not pull the transmission case by force TRO709 13 Completely remove the remaining liquid gasket on transmission case and adapter plate 6MT 68 TRANSMISSION CASE B INSTALLATION 1 Make sure that each shifter fork and interlock block is shifted to neutral position If not shift to neutral position Striking rod B Reverse interlock block C Interlock block 2 Apply liquid gasket to the adapter plate Liquid
204. ENT 1 CLUTCH HOUSING TR0595 1 Oil level gauge 9 Speedometer driven gear Tightening torque N m kgf m ft lb 2 Oil seal 10 Snap ring T1 6 4 0 65 4 7 3 Snap ring 11 Gasket T2 41 4 2 30 2 4 Washer 12 Oil seal 50 5 1 36 9 5 Speedometer gear shaft 13 Clutch release bearing guide T4 70 7 1 51 6 6 Pitching stopper bracket 7 8 Clutch housing 6MT 3 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL 2 ADAPTER PLATE TRO596 1 Breather hose 8 Gasket Tightening torque N m kgf m ft lb 2 Transmission harness stay 9 Spring T1 6 4 0 65 4 7 3 Plug 10 Ball T2 37 3 8 27 3 4 Gasket 11 Lubrication pipe 50 5 1 36 9 5 Spring 12 Adapter plate 6 Plunger 13 Oil chamber 7 Plug 6 4 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL 3 TRANSMISSION CASE r T N TRO597 1 Pilot bolt 9 Return spring Tightening torque N m kgf m ft Ib 2 Neutral switch 10 Pressure relief valve Ti 13 1 3 9 6 3 Back up light switch 11 Return spring T2 16 1 6 11 8 4 O ring 12 Ball 32 3 3 23 6 5 Adapter plate 13 Plunger 4 34 3 5 25 1 6 Transmission case 14 Spring
205. ERENTIAL D ASSEMBLY 1 Install the oil seal into clutch housing without damaging ST 399513600 INSTALLER 2 TRO874 2 Install the clutch release bearing guide Tightening torque 6 4 N m 0 65 kgf m 4 7 ft Ib TR0872 E INSPECTION 1 Make sure there is no damage or crack on the clutch housing Replace the clutch housing with a new one if there is excessive damage 2 Check the clutch housing for gear oil leakage If there is oil leakage repair or replace the leakage part 6MT 132 GENERAL DIAGNOSTIC TABLE MANUAL TRANSMISSION AND DIFFERENTIAL 27 General Diagnostic Table A INSPECTION 1 MANUAL TRANSMISSION Symptom Possible cause 1 Gears are difficult to intermesh NOTE The cause for difficulty in shifting gears can be classified into two kinds one is malfunction of the gear shift system and the other is malfunction of the transmis sion However if the operation is heavy and engagement of the gears is difficult defective clutch disengagement may also be responsible Check whether the clutch is correctly functioning before checking the gear shift system and transmission a Worn damaged or burred chamfer of internal spline of sleeve and reverse driven gear Replace b Worn damaged or burred chamfer of spline of gears Replace c Worn or scratched bushings Replace d Incorrect contact between synchro nizer ring
206. EUROPE MODEL OTHER MODEL COMBINATION METER HI BEAM INDICATOR LIGHT DIMMER amp PASSING SWITCH DIODE WITH REAR FOG LIGHT MODEL G 1 REF TO GND 07 BROWN BLACK FE 112 BROWN BLACK AE a N 12 1 3 14156 7 8 1 2 1314516 7 8 112 172 9 10 15 16 17 111121304516 17 B i11 GREEN 22 2 516 17 8 JABE 51617 819 911011112134151617 8 12 stes ahaa Oe f2tiat4 t5 16 17 18 19 20 21 22031 24 25 26 27 28 29 30 31 32 GR19 22 WI 89 FRONT WIRING HARNESS WIRING SYSTEM 45 Front Wiring Harness A LOCATION 1 LHD MODEL Connector Connecting to Pole Color 3 Gray Front clearance light RH and front turn signal light RH Black Horn Headlight RH 2 Lights Brown Headlight RH 4 Lights Lo Black Sub fan motor Non turbo model Black Sub fan motor Turbo model Black Radiator main fan motor Non turbo model Black Radiator main fan motor Turbo model Black Front fog light LH Gray Front clearance light LH and front turn signal light LH Head
207. FU TUR BO 15 REMOVAL Intake Manifold gt 2 Remove the V belt Ref to ME STi 43 RE MOVAL V belt gt 3 Remove the crankshaft pulley Ref to ME STi 45 REMOVAL Crankshaft Pulley gt 4 Remove the belt cover Ref to ME STi 46 REMOVAL Belt Cover gt 5 Remove the timing belt assembly lt Ref to ME STi 47 REMOVAL Timing Belt Assembly gt 6 Remove the camshaft sprocket lt Ref to ME STi 56 REMOVAL Camshaft Sprocket gt 7 Remove the crankshaft sprocket lt Ref to ME STi 58 REMOVAL Crankshaft Sprocket gt 8 Remove the generator and A C compressor with their brackets 9 Remove the cylinder head assembly lt Ref to ME STi 65 REMOVAL Cylinder Head Assem bly gt 10 Remove the clutch housing cover 11 Remove the flywheel Using the ST lock the crankshaft ST 498497100 CRANKSHAFT STOPPER G2M0776 12 Remove the oil separator cover 13 Remove the water by pass pipe for heater 14 Removal of oil pan 1 Turn the cylinder block with 2 and 4 piston sides facing upward 2 Remove the bolts which secure oil pan to cylinder block MECHANICAL 3 Insert a oil pan cutter blade between cylin der block to oil pan clearance and remove the oil pan CAUTION Do not use a screwdriver or similar tool in place of oil pan cutter G2M0163 emove the oil strainer stay emove the oil strainer emove the baffle plate emove the water pipes
208. G sen Battery short in G sen lt Ref to ABS 166 DTC 56 BATTERY SHORT IN G SENSOR sor circuit sor circuit CIRCUIT Diagnostics Chart with Subaru Select Monitor gt 56 Abnormal G sensor Abnormal G sensor Ref to ABS 171 56 ABNORMAL G SENSOR HIGH high output high output OUTPUT Diagnostics Chart with Subaru Select Monitor 56 Detection of G sensor Detection of G sensor Ref to ABS 175 DTC 56 DETECTION G SENSOR STICK Stick Stick Diagnostics Chart with Subaru Select Monitor Ref to ABS 19 DTC 73 OPEN SHORT CIRCUIT LAT Glas Gen sensor circuit ERAL G SENSOR CIRCUIT Diagnostics Chart with Subaru Select gt Battery short lateral Battey lateral G ot to ABS 23 DTC Toe TERY SHORT 73 G sensor circuit sensor SENSOR CIRCUIT Diagnostics Chart with Subaru Select tor gt Abnormal lateral G Abnormal lateral G lt Ref to ABS 28 DTC 73 ABNORMAL LATERAL G SENSOR 73 sensor outbi sensorhioh HIGH m OUTPUT Diagnostics Chart with Subaru Select Moni gh u outp gh u outp tor 73 Detection of lateralG Detection of lateral G Ref to ABS 32 DTC 73 DETECTION OF LATERAL SENSOR sensor stick sensor stick STICK Diagnostics Chart with Subaru Select Monitor NOTE High means high friction coefficient against road surface ABS
209. Glove Box Light LIGHTING SYSTEM GENERAL DESCRIPTION 1 General Description A SPECIFICATIONS Except STi model Headlight 12 V 55 W 60 W Halogen STi model High beam 12 V 55 W Halogen Low beam 12 V 60 W Halogen Front turn signal light 12V 21W Side turn signal light 12V 5W Parking light 12V 5W Front fog light 12V 55W Rear fog light 12V 21W Rear combination light Tail Stop light 12 5 21 W Turn signal light 12V 21W Back up light 12V 21W License plate light 12V 5W High mounted stop light Standard type 12V 21W Sedan Rear spoiler built in type 12V 1 2 W Wagon 12V 10W Room light 12V 8W Spot light 12V 8W Luggage room light 12 V 18W Trunk room light 12V 5W Glove box light LI 2 12V 1 4 HEADLIGHT BULB 12 Headlight Bulb A REMOVAL 2 STI MODEL CAUTION Because the tungsten halogen bulb operates at a high temperature dirt and oil on the bulb surface reduces the bulb s service life Hold the flange portion when replacing the bulb Never touch the glass portion Do not leave the headlight without a bulb for a long time Dust moisture etc entering the headlight may affect its performance 1 Disconnect the ground cable from battery 2 Remove the duct A when right si
210. H DIAGNOSIS CONNECTOR ABS DIAGNOSTICS Step Check Yes No CHECK GROUND SHORT OF HARNESS Measure the resistance between ABSCM amp H U connector and chassis ground Connector amp terminal LHD B301 No 28 Chassis ground RHD F49 No 28 Chassis ground Is the resistance more than 1 MQ Go to step 9 Repair the har ness between G sensor and ABSCM amp H U Replace the ABSCM amp H U Ref to 5 4 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 between G sensor con nector terminals Connector amp terminal B292 No 2 No 3 Is the voltage between 2 1 and 2 4 V when G sensor is hori zontal Go to step 10 Replace the G sensor lt Ref to ABS 22 G Sen sor gt 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 4 1 V when G sensor is inclined forwards to 90 Go to step 11 Replace the G sensor lt Ref to ABS 22 G Sen sor gt CHECK G SENSOR Measure the voltage between G sensor con nector terminals Connector amp terminal B292 No 2 No 3 Is the voltage betwee
211. IDE CAUTION Apply engine oil to the oil seal before force fitting Differentiate between intake valve oil seal and exhaust valve oil seal by noting their differ ence in color Color of rubber part Intake Black Exhaust Brown Color of spring part Intake Silver Exhaust Silver 52 1924 7 VALVE LIFTER 1 Check the valve lifter visually 2 Measure the outer diameter of valve lifter Outer diameter 34 965 34 975 mm 1 3766 1 3770 in EN1518 3 Measure the inner diameter of valve lifter mating part on cylinder head Inner diameter 34 994 35 016 mm 1 3777 1 3786 in B2M1400 CAUTION If difference between outer diameter of valve lifter and inner diameter of valve lifter mating part is over the limit replace the cylinder head Standard 0 019 0 051 mm 0 0007 0 0020 in Limit 0 100 mm 0 0039 in F DISPOSAL CAUTION Metallic sodium is enclosed in the exhaust valve Metallic sodium is extremely alkaline and may produce severe chemical reactions Full consideration must therefore be given to the following points when handing or disposing of the valve Since metallic sodium may cause blindness if contacted with the eyes burns if contacted with the skin and fire do not deliberately take the valve apart and remove the metallic sodium 1 If the valve is damaged remove the valve and neutralize it by immersing
212. INSTALLATION 1 Adjust the 3rd 4th and 5th 6th shifter fork rod lt Ref to 6MT 123 ADJUSTMENT Shifter Fork and Rod gt 2 Turn the sub gear counterclockwise for approx three teeth Align the sub gear and reverse idler gear hole then insert the ST ST 18757AA000 STRAIGHT PIN TRO726 A Sub gear B Reverse idler gear 3 Install the driven gear assembly to 1st 2nd shifter fork assembly TRO930 A 1st 2nd shifter fork B Driven gear assembly C 1st 2nd sleeve 4 Install the main shaft assembly to 3rd 4th shifter fork and then assemble to driven gear assembly 0931 3rd 4th shifter fork B 3rd 4th sleeve C Driven gear assembly D Main shaft assembly 5 Install the 5th 6th shifter fork assembly to main shaft assembly TRO932 A 5th 6th shifter fork B 5th 6th sleeve C Main shaft assembly 6MT 74 MAIN SHAFT ASSEMBLY 6 Install the reverse shifter fork assembly to re 10 Install the plunger checking spring new gasket MANUAL TRANSMISSION AND DIFFERENTIAL verse idler gear assembly and checking plug 1 LA LA C 933 Reverse idler gear assembly B Reverse shifter fork C Reverse sleeve 7 Install the reverse idler gear assembly TRO934 A Reverse idler gear assembly B 1st drive
213. ION Extension Case gt 15 Install the manual transmission assembly to ve hicle lt Ref to 6MT 39 INSTALLATION Manual Transmission Assembly gt C INSPECTION 1 Make sure there is no damage on the inner rotor and outer rotor Replace the inner rotor and outer rotor as assembly if damaged 2 Clearance at tip Install the inner rotor and outer rotor to transmis sion case Align tip of the inner rotor and outer ro tor then measure the clearance Replace the inner rotor and outer rotor as a set if clearance exceeds specification Specification of clearance at tip Less than 0 15 mm 0 0059 in 6MT 66 OIL PUMP MANUAL TRANSMISSION AND DIFFERENTIAL 3 Side clearance Measure to the transmission case and rotor Re place the inner rotor and outer rotor as a set if clear ance exceeds specification Specification of clearance at tip 0 03 0 10 mm 0 0012 0 0039 in TRO704 6MT 67 TRANSMISSION CASE MANUAL TRANSMISSION AND DIFFERENTIAL 18 Transmission Case A REMOVAL 1 Remove the manual transmission assembly from vehicle Ref to 6MT 37 REMOVAL Manual Transmission Assembly 2 Prepare the transmission for overhaul Ref to 6MT 42 Preparation for Overhaul gt 3 Remove the oil pipe neutral position switch back up light switch and harness Ref to 6 44 REMOVAL Oil Pipe Ref to 6MT 47 REMOV AL Neutral Position Switch gt Ref to 6MT 45 R
214. IRING SYSTEM ENGINE CONTROL MODULE 1 84 PB i5 PG 20 a 2 CD EECH 9 PEEK O FE H s PURGE CONTROL SOLENOID FUEL INJECTOR FUEL INJECTOR FUEL INJECTOR FUEL INJECTOR VALVE NO 1 NO 2 NO 3 BLACK Ces DARK GRAY BROWN 136 D DARK GRAY Oe 1 n n 2 314 1 4 112 345 11121 30456 78 E16 DARK GRAY 5 6 7 8 5161718 9 11 12 13 14 15 16 10 11 12 13 14 15 116 17 18 192021 19110111112 17 1811912021 22 23 24 22 23 124125126 27 08 29 3031 E17 DARK GRAY 13 14 15 16 4112 GL10 26K WI 63 ENGINE ELECTRICAL SYSTEM WIRING SYSTEM 6 RHD DOHC TURBO MODEL TO POWER SUPPLY ROUTING MB 9 21 SBF 5 F B FUSE NO 11 B IG FUEL PUMP RELAY 10 REF GND 07 FUEL PUMP ASSEMBLY FUEL PUMP LC Sep FUEL SUB LEVEL SENSOR REF TO GND 08 GREEN 15 BLACK 122 BLACK 112 112 1 2 1 2 3 11213 12 314 314 3141516 4516 5167 5161718 9
215. ITOR on monitor display between 1 Select Current data display amp Save on the 2 3 and 2 7 V when lateral G select monitor sensor is in horizontal posi 2 Read lateral G sensor output on the select tion monitor display ABS 29 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS Step Check Yes No CHECK POOR CONTACT IN CONNECTORS Turn the ignition switch to OFF Is there poor contact in con nector between ABSCM amp H U and lateral G sensor Repair the con nector Go to step 3 CHECK ABSCM amp H U 1 Connect all connectors 2 Erase the memory 3 Perform the inspection mode 4 Read out the DTC Is the same DTC as in current diagnosis still being output Replace the ABSCM amp H U Ref to ABS 4 ABS Control Mod ule and Hydraulic Control Unit ABSCM amp H U gt Go to step 4 CHECK ANY OTHER DIAGNOSTIC TROU BLE CODES DTCs APPEARANCE Are other DTCs being output Proceed with the diagnosis corre sponding to DTC Go to step 5 CHECK OPEN CIRCUIT IN LATERAL G SEN SOR OUTPUT 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 LHD B301 No 29 No 28 RHD F49 No 29 No 28 Is the resistance between 5 0 5 6 Go to step 6 Repair the har ness con
216. Installing piston pin 1 Insert ST3 into the service hole to align pis ton pin hole with connecting rod small end CAUTION Apply a coat of engine oil to ST3 before inser tion ST3 499017100 PISTON PIN GUIDE G2M0189 2 Apply a coat of engine oil to the piston pin and insert piston pin into piston and connecting rod through service hole MECHANICAL 3 Install the circlip using ST NOTE Use new circlips ST 499897200 PISTON CIRCLIP PLIER G2M0190 4 Apply fluid packing around the service hole plug Fluid packing THREE BOND 1215 or equivalent ZR B2M2625 5 Install the service hole plug and gasket CAUTION Use a new gasket trey Ge E Ve NS SI lt ME STi 79 CYLINDER BLOCK MECHANICAL B2M1323K 1 Piston 5 Service hole plug Tightening torque N m kgf m ft Ib 2 Piston pin 6 Service hole cover 1 6 4 0 65 4 7 3 Circlip 7 O ring T2 69 7 0 50 6 4 Gasket 6 Turn the cylinder block so that 3 and 4 cyl inders face upward Using the same procedures as used for 1 and 2 cylinders install the pis tons and piston pins 15 Install the water pipe 16 Install the baffle plate Tightening torque 6 4 N m 0 65 kgf m 4 7 ft lb 17 Install the oil strainer and O ring Tightening torque 10 N m 1 0 kgf m 7 ft lb 18 Install the oil strainer stay 19 Apply fluid packing to
217. L 15 Select the nearest thrust washer from the fol 19 Using the ST install the neutral set spring and lowing table according to the calculated value support 18756 000 CLAW Standard clearance between thrust washer 398663600 PLIERS taper roller bearing 0 04 0 11 mm T 0 0016 0 0043 NOTE T Tight Thrust washer 50 x 61 x t Part No Thickness t mm in 803050060 0 50 0 0197 803050062 0 60 0 0236 803050064 0 70 0 0276 803050066 0 80 0 0315 803050068 0 90 0 0354 803050070 1 00 803050072 1 10 0 0433 803050074 1 20 0 0472 803050076 1 30 0 0512 TRO666 20 Install the snap ring 21 Install the center differential 0 0394 803050078 1 40 0 0551 16 Install the selector arm No 2 and shifter arm TRO668 A Selector arm No 2 B Shifter arm 17 Install a new spring pin 18 Install the support to neutral set spring NOTE Make sure to install the support in proper direction TRO0671 6 53 EXTENSION CASE MANUAL TRANSMISSION AND DIFFERENTIAL 2 SELECTING THE TRANSFER DRIVE 4 Select the nearest thrust washer from the follow GEAR THRUST WASHER ing table according to the calculated value t 1 Measure the height Z between end of transmis Stand
218. LLATION Transfer Driven Gear gt 21 Install the extension case lt Ref to 6MT 49 IN STALLATION Extension Case gt 22 Install the oil pipe neutral position switch back up light switch and harness lt Ref to 6MT 44 INSTALLATION Oil Pipe gt lt Ref to 6MT 47 IN STALLATION Neutral Position Switch gt lt Ref to 6MT 45 INSTALLATION Back up Light Switch gt 23 Install the manual transmission assembly to ve Ref to 6MT 39 INSTALLATION Manual Transmission Assembly gt C DISASSEMBLY NOTE Each sleeve and hub engage at a specified point Mark an engagement point on the sleeve and hub before disassembly 1 Secure the ST on workbench ST 18664AA000 BASE 2 Lift the caulking of lock nut 6MT 76 MAIN SHAFT ASSEMBLY 3 Set the main shaft assembly on ST then remove the lock nut and washer 18665 000 HOLDER ST2 18664 000 BASE NOTE Use a 38 mm 1 50 in socket wrench TRO729 4 Remove the main shaft assembly from ST 5 Set the ST1 on 6th drive gear then remove the taper roller bearing bush and 6th drive gear using press 18722AA000 REMOVER ST2 899864100 REMOVER TRO730 gt Taper roller bearing Bush 6th drive gear 58 MANUAL TRANSMISSION AND DIFFERENTIAL 6 Remove the 5th 6th sleeve 6th needle bearing and 6th bau
219. LY 2 STI MODEL Refer to Rear Drive Shaft as a guide for assembly procedures Ref to DS 41 ASSEMBLY Rear Drive Shaft DS 9 FRONT DRIVE SHAFT DRIVE SHAFT SYSTEM DS 10 5 1 General Descriptions e tent RA 2 2 ABS Control Module and Hydraulic Control Unit ABSCM amp H U 4 3 ABS Sequence Control 4 Front ABS Sensor 5 Rear ABS Sensor 6 Front Tone Wheel 7 Rear Tone Wheel 8 Sensor 9 Lateral G Sensor series ect c c et iE E 5 5 GENERAL DESCRIPTION 1 General Description A SPECIFICATIONS Item Standard or remarks ABS sensor ABS sensor gap 0 3 0 8 mm 0 012 0 031 in 0 7 1 2 mm 0 028 0 047 in ABS sensor resistance 1 25 0 25 1 0 0 2 Marks of the harness White Yellow Light blue Brown G sensor G sensor voltage 2 3 0 2 V Lateral G sensor STi model only G sensor voltage 2 5 0 2 V ABS control module and hydraulic control unit ABSCM amp H U marks Rear drum brake model CC CD Rear disc brake model CM CN ABS 2 C9 GENERAL DESCRIPTION ABS B COMPONENT 1 SENSOR BRO111 1 G sensor 5 Front ABS sens
220. MT 4AT 5MT 4AT Curb weight C W Front kgf Ib 735 1 621 755 1 665 750 1 654 770 1 698 Rear 520 1 146 520 1 146 520 1 146 520 1 146 Total 1 255 2 767 1 275 2 811 1 270 2 800 1 290 2 844 Maximum permissible axle weight M P A W Front 890 1 962 890 1 962 890 1 962 890 1 962 Rear 890 1 962 890 1 962 890 1 962 890 1 962 Maximum permissible weight M P W Total 1 700 3 748 1 700 3 748 1 700 3 748 1 700 3 748 Option Option codex1 Air conditioner O Cruise control ABS Aluminium wheel Rear spoiler Spoiler pac Model 5MT 4AT 5MT 4AT Curb weight C W Front kgf Ib 765 1 687 790 1 742 770 1 698 795 1 753 Rear 535 1 179 530 1 168 535 1 179 530 1 168 Total 1 300 2 866 1 320 2 910 1 305 2 877 1 325 2 921 Maximum permissible axle weight M P A W Front 920 2 028 920 2 028 920 2 028 920 2 028 Rear 910 2 006 910 2 006 910 2 006 910 2 006 Maximum permissible weight M P W Total 1 760 3 880 1 760 3 880 1 760 3 880 1 760 3 880 Option Air conditioner O O Cruise control ABS Aluminium wheel Rear spoiler Spoiler pac
221. MT 49 IN STALLATION Extension Case gt 14 Install the oil pipe neutral position switch back up light switch and harness lt Ref to 6MT 44 INSTALLATION Oil Pipe gt lt Ref to 6MT 47 IN STALLATION Neutral Position Switch gt lt Ref to 6MT 45 INSTALLATION Back up Light Switch gt 15 Install the manual transmission assembly to ve hicle lt Ref to 6MT 39 INSTALLATION Manual Transmission Assembly gt C DISASSEMBLY 1 Remove the oil pipe and oil guide TRO714 A Oil pipe B Oil guide 2 Remove the bolt then remove the O ring relief spring and relief valve TRO715 A O ring B Relief valve spring C Relief valve 3 Remove the bolt then remove the O ring valve spring and ball e 8 TRO716 A O ring B Valve spring C Ball 6MT 70 TRANSMISSION CASE MANUAL TRANSMISSION AND DIFFERENTIAL 4 Remove the harness bracket D ASSEMBLY 1 Install the oil strainer and magnet Tightening torque 10 1 0 kgf m 7 4 ft lb TRO717 TRO719 Oil pan magnet B Oil strainer 2 Apply liquid gasket to the oil pan Liquid gasket THREE BOND 1215 TRO718 6 Completely remove the remaining liquid gasket on transmission case and oil pan 7 Remove the oil pan magnet then remove the oil strainer
222. N AND DIFFERENTIAL TOOL NUMBER DESCRIPTION REMARKS TRO613 18631 AA000 Newly adopted tool HANDLE Used for measuring front differential backlash TRO614 18756AA000 Newly adopted tool Used for installing and removing neutral set spring Used with INSTALLER 399893600 0615 18754 000 Newly adopted tool REMOVER Used for removing each parts of driven gear TRO616 18757AA000 Newly adopted tool STRAIGHT PIN REMOVER 6MT 25 Used for installing reverse idler gear ILLUSTRATION GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL TOOL NUMBER DESCRIPTION REMARKS G 18665AA000 Newly adopted tool HOLDER Used for installing and removing main shaft lock nut Used with BASE 18664AA000 p e 18666AA000 Newly adopted tool HOLDER Used for installing and removing driven shaft lock nut Used with BASE 18664AA000 18667 000 Newly adopted tool HOLDER Used for installing and removing drive pinion shaft lock nut Used with BASE 18664AA000 18664AA000 Newly adopted tool 6 26 Used for installing and removing main shaft lock nut Used for installing and removing drive pinion shaft lock nut Used for installing and removing driven shaft lock nut ILLUSTRATION GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL TOOL
223. NERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL 10 FRONT DIFFERENTIAL WITHOUT LSD TRO604 1 Drive pinion shaft 8 Roller bearing 15 Circlip 2 driven gear 9 Differential case 16 Speedometer drive gear 3 Pinion shaft 10 Oil seal 4 Straight pin 11 Differential side retainer Tightening torque N m kgf m ft Ib 5 Washer 12 O ring 1 25 2 5 18 1 6 Differential bevel gear 13 Axle drive shaft T2 69 7 0 50 9 7 Differential bevel pinion 14 Retainer lock plate 6MT 12 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL 11 FRONT DIFFERENTIAL WITH LSD EP TRO605 1 Drive pinion shaft 6 Differential side retainer 11 Speedometer drive gear 2 driven gear 7 O ring 3 Roller bearing 8 Axle drive shaft Tightening torque N m kgf m ft lb 4 Differential case ASSY 9 Retainer lock plate 1 25 2 5 18 1 5 Oil seal 10 Circlip T2 69 7 0 50 9 6 13 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL 12 TRANSMISSION MOUNTING TRO606 1 Pitching stopper 8 Center crossmember Except Tightening torque N m kgf m ft Ib 2 Spacer EUROPE model T1 7 5 0 76 5 5 3 Cushion C 9 Rear plate T2 35 3 6 25 8 4 Front plate 10 Front cross
224. NG SWITCH LHD MODEL REF GND 01 RHD MODEL REF TO GND 06 22 LHD MODEL REF GND 02 RHD MODEL REF TO GND 07 LHD MODEL RHD MODEL HEADLIGHT LEVELER LH HEADLIGHT LEVELER RH wry 2 COKE 359 GRAY 1121314 5 6 7 8 14 15 16 17 18 GG83 22 WI 76 CLEARANCE LIGHT AND ILLUMINATION LIGHT SYSTEM WIRING SYSTEM 25 Clearance Light and Illumination Light System A SCHEMATIC WI 77 CLEARANCE LIGHT AND ILLUMINATION LIGHT SYSTEM WIRING SYSTEM 1 LHD MODEL FB 14 B 9 PARKING SWITCH AT SELECT LEVER ILLUMI LIGHT FRONT FOG LIGHT SWITCH ILLUMI LIGHT 816 REAR FOG LIGHT SWITCH ILLUMI LIGHT HEADLIGHT LEVELING SWITCH ILLUMI LIGHT EXCEPT STi Y RADIO ILLUMI Cu INTERCOOLER WATER SPRAY SWITCH ILLUMI LIGHT F B FUSE 7 TO POWER SUPPLY ROUTING FB 12 TAIL amp ILLUMI NATION RELAY FB 13 TAIL amp ILLUMI NATION RELAY 5 FB 3 F B FUSE NO 5 F B FUSE NO 12 F B FUSE NO 12 ILM L 01 CONTROL MODULE NON TURBO FRONT ACCESSORY POWER SUPPLY SOCKET ILLUMI LIGHT ENGINE Cv 2 CONTROL MODULE TURBO MODE CONTROL PANEL ILLUMI LIGHT VEH 6168 AUTO A C ie MODULE B 8283
225. NGINE MODEL RADIO GLOVE BOX ILLUMI LIGHT ILLUMI LIGHT NON TURBO ENGINE MODEL ERR L7 FOR EUROPE MODEL EXCEPT FOR EUROPE MODEL INTERCOOLER WATER FOR EUROPE MODEL GRAY REF TO FOG RFE 01 EXCEPT FOR EUROPE MODEL FOG ROE 01 E BLACK SPRAY SWITCH ILLUMI LIGHT STi MODEL ERR RFOG FE 01 PM EEOGIDEEDT STi MODEL 2 B EXCEPT STi MODEL B294 REF TO GND 06 07 REF TO GND 07 1T2 1T2 1121314 160 1 TAE 772174 112 314 11213 456 314 4 56 7 8 9 10 7 8 9 1011 12 13 14 294 1 2 3 4 5 6 FE 283 GRAY D 1 1 2 3 415 67 N zi 5 3 11 12 13 14 15 116 17 18 19120 9 10 11 12 13 14 15 16 17 9 10 11 12 13 14115 16 17 17 18 18 20 83 T0 1112 130415 2122 23 24 25 26 27 28 29 30 GR21 26A WI 81 CLEARANCE LIGHT AND ILLUMINATION LIGHT SYSTEM WIRING SYSTEM TO POWER SUPPLY ROUTING
226. NSOR SIGNAL FRONT LH Diagnostics Chart with Diagnosis Connector Rear right ABS sensor Ref to ABS 46 DTC 26 ABNORMAL ABS SENSOR ABNOR MAL ABS SENSOR SIGNAL REAR RH Diagnostics Chart with Diagnosis Connector Rear left ABS sensor Ref to ABS 47 DTC 28 ABNORMAL ABS SENSOR ABNOR MAL ABS SENSOR SIGNAL REAR LH Diagnostics Chart with Diagnosis Connector Any one of four Ref to ABS 52 DTC 29 ABNORMAL ABS SENSOR ABNOR MAL ABS SENSOR SIGNAL ANY ONE OF FOUR Diagnostics Chart with Diagnosis Connector ABS 7 LIST OF DIAGNOSTICS TROUBLE CODE DTC ABS DIAGNOSTICS Contents of diagnosis Index No Abnormal solenoid valve circuit s in ABS control module and hydraulic unit Front right inlet valve lt Ref to ABS 57 DTC 31 ABNORMAL INLET SOLENOID VALVE CIRCUIT S INABSCM amp H U FRONT RH Diagnostics Chart with Diagnosis Connector gt Front right outlet valve lt Ref to ABS 61 DTC 32 ABNORMAL OUTLET SOLENOID VALVE CIRCUIT S INABSCM amp H U FRONT RH Diagnostics Chart with Diagnosis Connector gt Front left inlet valve Ref to ABS 57 DTC 33 ABNORMAL INLET SOLENOID VALVE CIRCUIT S INABSCM amp H U FRONT LH Diagnostics Chart with Diagnosis Connector gt Front left outlet valve lt Ref to ABS 61 DTC 34 ABNORMAL OUTLET SOLENOID VALVE CIRCUIT S INABSCM amp H U FRONT LH Diagnost
227. ODEL CAUTION Before handling gas filled struts be sure to wear goggles to protect eyes from gas oil and or filings Do disassemble the strut damper or place into a fire e Drill holes before disposing of gas filled struts 1 Place the gas filled strut on a flat and level sur face with damping tube fully extended 2 Using a 2 to 3 mm 0 08 to 0 12 in dia drill drill a hole in location 1 first and then drill a hole in lo cation 2 3 E e 500041 1 20 0 78 2 10 0 39 3 Strut 4 Damping tube FS 2 REAR SUSPENSION Page General Description Wheel Alignment Rear Stabilizer Rear Trailing Link E 2 Lateral link Rear Crossmember General Diagnostic Table SR ee REAR STRUT REAR SUSPENSION 5 Rear Strut F DISPOSAL 2 STI MODEL Refer to Front Strut as a guide for disposal proce dures Ref to FS 2 STI MODEL DISPOSAL Front Strut RS 2 WHEEL AND SYSTEM OG Ee General Descripsi DOR UR RE 2 Tire Steel Wheel Aluminum Wheel Wheel Balancing Tire Full Wheel Cap General Diagnostics Table GENERAL DESCRIPTION WHEEL AND TIRE SYSTEM 1 General Description A SPECIFICATIONS 1 2 S4M0367A 1 Offset 2 Tire size Rim size Rim offset mm in P C D mm in 185 70R14 88H 14 x 5 1 2JJ Ex
228. OUBLE CODE DTC ENGINE DIAGNOSTICS EN TURBO 25 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC ENGINE DIAGNOSTICS DL DTC P0390 VARIABLE VALVE TIMING CAMSHAFT POSITION SENSOR B CIRCUIT MALFUNCTION 2 LH e DTC DETECTING CONDITION Immediately at fault recognition TROUBLE SYMPTOM Engine stalls Failure of engine to start CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN TURBO 45 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN TURBO 42 Inspection Mode gt WIRING DIAGRAM VARIABLE VALVE TIMING CAMSHAFT POSITION SENSOR LH a 1 2 11211314 5 67 ER EN 1529 EN TURBO 26 Step Check DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC ENGINE DIAGNOSTICS Yes No CHECK CURRENT DATA 1 Start the engine 2 Measure the ignition timing advance using Subaru Select Monitor or OBD II general scan tool while running the vehicle at approx 30 km h 19 MPH NOTE Subaru Select Monitor For detailed operation procedure refer to the READ CURRENT DATA FOR ENGINE lt Ref to EN TURBO 34 Subaru Select Moni tor gt OBD II scan tool For detailed operation procedures refer to the OBD II General Scan Tool Instruction Manual Does the ignition timing advance smoothly cha
229. OVAL Transmission Mounting System gt 10 Remove the snap pin and washer and then re move the reverse check cable from reverse check lever TRO954 Snap Washer Reverse check cable CONTROL SYSTEMS 11 Move the transmission to right side and then remove the joint COMPL stay bolt and reverse check cable NOTE If the transmission is not moved the joint COMPL and stay bolt will contact body and damage may we Ad f TRO955 A Joint COMPL bolt B Stay bolt C Reverse check cable 12 Remove the cushion rubber from body TRO956 13 Lower the vehicle 14 Remove the gear shift lever CS 5 6MT GEAR SHIFT LEVER CONTROL SYSTEMS B INSTALLATION 1 Insert the gear shift lever from room side NOTE After inserting the rod and stay temporarily put them onto transmission mount 2 Mount the cushion rubber on body Tightening torque 18 1 8 kgf m 13 0 ft lb TRO956 3 Move the transmission to right side and then in stall the joint COMPL and stay Tightening torque T1 11 8 1 2 kgf m 8 7 ft lb T2 32 3 3 kgf m 23 6 ft lb 7180647 Reverse check cable 4 Install the crossmember lt Ref to 6MT 35 IN STALLATION Transmission Mounting System gt 5 Install the reverse check cable end wa
230. REMOVAL Center Differential gt 6 Remove the snap ring and support from selector arm part TRO665 A Snap ring B Support 6MT 51 EXTENSION CASE MANUAL TRANSMISSION AND DIFFERENTIAL 7 Using the ST remove the neutral set spring and support 18756AA000 CLAW ST2 398663600 PLIERS TRO667 Striking rod B Spring pin 9 Remove the selector arm No 2 and shifter arm TRO668 A Selector arm No 2 B Shifter arm 10 Install the bearing cone to transfer driven gear 11 Set the ST ST 18831AA000 GAUGE TRO669 12 Rotate the transfer driven gear approx ten times to get the bearing accustomed 13 Measure the depth Y between end of ST and bearing cone ST 18831AA000 GAUGE 5 z e e TRO670 14 Calculate the value 4 of transfer driven gear bearing thrust washer using the following equation 2 100 0 04 100 11 0 0016 to 0 0043 t Thickness of transfer driven gear mm in bearing thrust washer Y Depth from end of ST to bearing mm in cone Z Depth from end of extension case mm in to contact point of bearing cone 0 04 0 11 mm Standard clearance between thrust 0 0016 0 0043 washer and taper roller bearing in 100 mm 3 94 in Height of ST 6 52 EXTENSION CASE MANUAL TRANSMISSION AND DIFFERENTIA
231. RING SYSTEM 6136 E Bad B84 ENGINE CONTROL MODULE m NORMAL TURBO EL 14 CRY J 11 TEES Grp EE OECTA PECTIN DE lt RRG 2 KYL 1 2 GL TGV LH TGV RH IDLE AIR CONTROL NORMAL NORMAL SOLENOID VALVE OIL PRESSURE SWITCH POWER STEERING OIL TURBO MODEL TURBO MODEL PRESSURE SWITCH BLACK BROWN E B84 B84 BLACK n q Ess BLACK 1 11213141516 112 3 4 112 3 4 5 6 7 112131415 16 71819 819 10 11 12 5 617 8 9 10 11 12 13 1415 16 1011213 14 1516117 18 19 1311415 16 17 EIER 17 18 19 20 21 22 23 24 20 21 22 23 24125 26 27 28 131415 16 17 18 19 20 GR10 26H WI 71 ENGINE ELECTRICAL SYSTEM WIRING SYSTEM B 6138 E ENGINE CONTROL MODULE STi TURBO ENGINE MODEL NORMAL TURBO ENGINE MODEL AVCS SOLENOID AVCS SOLENOID ENGINE COOLANT THROTTLE PRESSURE TGV ANGLE TGV ANGLE VALVE LH VALVE RH TEMPERATURE POSITION SENSOR SENSOR LH SENSOR RH STi TURBO STi TURBO SENSOR AND SENSOR NORMAL TURBO NORMAL TURBO MODEL MODEL THERMOMETER MODEL MODEL
232. RRENTS CURRENT FROM IGNITION SWITCH ACC TERMINAL MAIN FUSE BOX 1 80 GENERATOR No 9 15A SBF HOLDER 5 x E BLACK GREEN BLACK BLACK T 123 2111 1121314 4113 2 4 GL01 21B WI 5 POWER SUPPLY ROUTING WIRING SYSTEM MAIN FUSE BOX M B H P SUP L 05 Oe cougar 59 1 04 KSE 1 59 1 04 BLACK BLACK BLACK 112 TAE 1 215 4 3 4 456 5678 GLO1 21C WI 6 POWER SUPPLY ROUTING WIRING SYSTEM ZL E FUSE amp RELAY BOX F B TRAILER CONNECTOR 10 Dn 13 LP le emm FB 4 FB 5 rez 8 FB 9 FB 10 11 17 18 c B52 Joe ol A B5T of E 6158 6158 8158 GRAY 21 31 1415 1 JACHU 55171815 6 7 H 8 910 6 9 5 gt 8 8271 BLUE B99 D 6162 HES 6 7 8 9 1011 3 415 12 1314 15 1617 18 19120121 22123124
233. Ref to 6MT 108 INSTALLATION Front Differential As sembly gt 6 Install the drive pinion shaft assembly lt Ref to 6MT 101 INSTALLATION Drive Pinion Shaft As sembly gt 7 Install each gear assembly at once lt Ref to 6MT 74 INSTALLATION Main Shaft Assembly gt 8 Install the transmission case lt Ref to 6 69 INSTALLATION Transmission Case gt 9 Install the oil pump lt Ref to 6 65 INSTAL LATION Oil Pump gt 10 Install the center differential lt Ref to 6MT 62 INSTALLATION Center Differential gt 11 Install the transfer driven gear lt Ref to 6MT 60 INSTALLATION Transfer Driven Gear gt 12 Install the extension case lt Ref to 6MT 49 IN STALLATION Extension Case gt 13 Install the oil pipe neutral position switch back up light switch and harness lt Ref to 6MT 44 INSTALLATION Oil Pipe gt lt Ref to 6MT 47 IN STALLATION Neutral Position Switch gt lt Ref to 6MT 45 INSTALLATION Back up Light Switch gt 14 Install the manual transmission assembly to ve Ref to 6MT 39 INSTALLATION Manual Transmission Assembly gt 6MT 117 MANUAL TRANSMISSION AND DIFFERENTIAL SHIFTER FORK AND ROD MANUAL TRANSMISSION AND DIFFERENTIAL 25 Shifter Fork and Rod A REMOVAL 1 Remove the manual transmission assembly from vehicle Ref to 37 REMOVAL Manual Transmission Assembly 2 Prepare the transmission for overhaul Ref to 6MT 42 Preparat
234. S 7 Disassemble the lock wire 11 Remove the snap ring from stay NOTE Do not reuse the lock wire e A A d TRO966 O 5 TRO964 A Snap ring 12 Separate the gear shift lever and stay A Lock wire 8 Remove the boss from rod D d A TROQ67 13 Remove the boot bush from gear shift le TRO991 ver A Rod B Boss 9 Remove the rod from lever A B TRO968 A Boot B Bush TRO965 A Rod B Lever C Stay 10 Separate the rod and inner boot CS 8 GEAR SHIFT LEVER 14 Remove the spring pin and then remove the bush washer and snap ring B 0969 Washer Snap ring 15 Remove the bush and spacer from boss e A O A Ox e A TROQ92 A Bush B Spacer 16 Remove the bush and cushion rubber from stay _ TRO970 A Bush B Stay C Cushion rubber D ASSEMBLY NOTE Clean all parts before assembly Apply NIGTIGHT LYW No 2 grease or equivalent to each parts CONTROL SYSTEMS 1 Mount the bush and cushion rubber on the stay A TRO970 Bush B Stay C Cushion rubber 2 Install the bush and spacer to boss e A B amp e e TRO0992 A Bush B Space
235. SCM amp H U Select Monitor 11 Stop light switch 2 Rear drum brake Proportioning 6 Transmission control module only 12 Master cylinder valve AT vehicle 13 Brake warning light Rear disc brake Joint connector 7 Tone wheel 14 sensor 3 Diagnosis connector 8 ABS sensor 4 ABS warning light 9 Wheel cylinder ABS 2 ELECTRICAL COMPONENTS LOCATION ABS DIAGNOSTICS B4M1226B 0120 4 0231 0033 0057 0058 ABS 3 CONTROL MODULE SIGNAL ABS DIAGNOSTICS 5 Control Module I O Signal A ELECTRICAL SPECIFICATION 11 2 314 5 6 7 8 910 1111211311415 16 17 18 19 20 21 22 r 277282015051 129 124 125 26 0121 1 ABS control module and hydraulic control unit ABSCM amp H U connector 2 Connector switch NOTE e The terminal numbers ABSCM amp H C connector are as shown in the figure When the connector is removed ABSCM amp H U the connector switch closes the circuit between ter minal No 22 and No 23 The ABS warning light illuminates ABS 4 CONTROL MODULE I O SIGNAL Contents Terminal No 0 ABS DIAGNOSTICS Input Output signal Measured value and measuring conditions Front left wheel 9 10 ABS sensor 2 Front right wheel 11 12 Wheel speed sensor Rear left wheel 7 8 Rear right wheel 14 15 0 12 1V When it is 20 Hz V
236. STD 0 030 0 115 mm 0 0012 0 0045 in Limit 0 25 mm 0 0098 in Oil clearance STD 0 010 0 030 mm 0 0004 0 0012 in Limit 0 040 mm 0 0016 in Crankshaft bearing Crankshaft bearing thick ness STD 1 998 2 011 mm 0 0787 0 0792 in 0 03 mm 0 0012 in US 2 017 2 020 mm 0 0794 0 0795 in 0 05 mm 0 0020 in US 2 027 2 030 mm 0 0798 0 0799 in 0 25 mm 0 0098 in US 2 127 2 130 mm 0 0837 0 0839 in STD 2 000 2 013 mm 0 0787 0 0793 in 0 03 mm 0 0012 in US 2 019 2 022 mm 0 0795 0 0796 in 0 05 mm 0 0020 in US 2 4 5 2 029 2 032 mm 0 0799 0 0800 in 0 25 mm 0 0098 in US ME STi 5 2 129 2 132 mm 0 0838 0 0839 in GENERAL DESCRIPTION MECHANICAL COMPONENT 1 TIMING BELT EN1192 1 Right hand belt cover No 2 9 Right hand intake camshaft 17 Right hand belt cover 2 belt guide sprocket 18 Crankshaft pulley 3 Crankshaft sprocket 10 Left hand intake camshaft 4 Left hand belt cover 2 sprocket Tightening torque N m kgf m ft lb 5 Tensioner bracket 11 Left hand exhaust cams
237. STRATION GENERAL DESCRIPTION TOOL NUMBER DESCRIPTION DIFFERENTIALS REMARKS 1913 398507701 DIFFERENTIAL CARRIER GAUGE Used for adjusting pinion height For T type B3M1914 398527700 PULLEY ASSY Used for removing front oil seal Used for removing side bearing cup T type B3M1915A 398527700 PULLER SET Used for extracting side bearing cone BOLT 899521412 PULLER 399527702 HOLDER 399527703 ADAPTER 398497701 BOLT 899520107 NUT 021008000 For T type 1916 398227700 WEIGHT DI 13 Used for installing side bearing For T type DIFFERENTIALS ILLUSTRATION GENERAL DESCRIPTION TOOL NUMBER DESCRIPTION REMARKS gt 1917 28099 090 OIL SEAL TOR Used for installing rear drive shaft into rear dif ferential For protecting oil seal 1918 398237700 Used for installing side bearing For T type 7 1919 28099 100 DRIVE SHAFT REMOVER Used for removing rear drive shaft from rear differential For T type B3M1920 498175500 INSTALLER DI 14 Used for installing rear bearing cone For VA type ILLUSTRATION GENERAL DESCRIPTION TOOL NUMBER DESCRIPTION DIFFERENTIALS REMARKS 1921 499785500 WRENCH ASSY Used for removing and installing s
238. SUBARU IMPREZA 2002 Model Year PDF Service Manual Supplement For STi Model GENERAL INFORMATION SECTION Pub No G1841GE1 ENGINE 2 SECTION Pub No G1841GE3 TRANSMISSION SECTION Pub No G1841GE4 CHASSIS SECTION Pub No G1841GE5 BODY SECTION Pub No G1841GE6 WIRING SYSTEM SECTION Pub No G1841GE7 2002 IMPREZA STi SERVICE MANUAL QUICK REFERENCE INDEX Fee GENERAL INFORMATION SECTION SPECIFICATIONS IDENTIFICATION This service manual has been prepared to provide SUBARU service personnel with the necessary information and data for the correct maintenance and repair of SUBARU vehicles This manual includes the procedures for maintenance disassembling reas 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 G1841GE1 c 25 22 6 SPECIFICATIONS SPECIFICATIONS 1 Impreza A DIMENSIONS Model IMPREZA Sedan Wagon OUTBACK STi O
239. SYSTEMS 13 Tumble Generator Valve As sembly A REMOVAL 2 STIMODEL NOTE Tumble generator valve actuator and sensor are not applied to STi model B INSTALLATION 2 STI MODEL NOTE Tumble generator valve actuator and sensor are not applied to STi model FU TURBO 2 TUMBLE GENERATOR VALVE ACTUATOR FUEL INJECTION FUEL SYSTEMS 14 Tumble Generator Valve Ac tuator A REMOVAL 3 STIMODEL NOTE Tumble generator valve actuator is not applied to STi model B INSTALLATION 3 STI MODEL NOTE Tumble generator valve actuator is not applied to STi model FU TURBO 3 EXHAUST TEMPERATURE SENSOR FUEL INJECTION FUEL SYSTEMS 18 Exhaust Temperature Sensor A REMOVAL 2 STI MODEL NOTE Exhaust temperature sensor is not applied to STi model B INSTALLATION 2 STI MODEL NOTE Exhaust temperature sensor is not applied to STi model FU TURBO 4 VARIABLE VALVE TIMING CAMSHAFT POSITON SENSOR FUEL INJECTION FUEL SYSTEMS 34 Variable Valve Timing Cam shaft Positon Sensor A REMOVAL 1 Disconnect the ground cable from battery 2 Remove the intercooler lt Ref to IN TURBO 10 REMOVAL Intercooler gt 3 Remove the intake manifold lt Ref to FU TUR BO 15 REMOVAL Intake Manifold gt 4 Disconnect the variable valve timing camshaft position sensor connector 5 Remove the variable valve timing camshaft posi tion sensor EN1533 i B INSTALLATION Install in the re
240. T IDLER 1 Check the idler for smooth rotation Replace if noise or excessive play is noted 2 Check the outer contacting surfaces of idler pul ley for abnormal wear and scratches 3 Check the idler for grease leakage ME STi 55 CAMSHAFT SPROCKET MECHANICAL 16 Camshaft Sprocket A REMOVAL 1 Remove the V belt Ref to ME STi 43 RE MOVAL V belt gt 2 Remove the crankshaft pulley Ref to ME STi 45 REMOVAL Crankshaft Pulley gt 3 Remove the belt cover Ref to ME STi 46 REMOVAL Belt Cover gt 4 Remove the timing belt assembly lt Ref to ME STi 47 REMOVAL Timing Belt Assembly gt 5 Remove the camshaft position sensor lt Ref to FU TURBO 31 REMOVAL Camshaft Position Sensor gt 6 Remove the camshaft sprockets To lock the camshaft use ST ST 499207400 CAMSHAFT SPROCKET WRENCH EN1213 CAMSHAFT SPROCKET WRENCH ST 499977500 EN1205 B INSTALLATION 1 Install the camshaft sprocket No 1 and No 2 To lock the camshaft use ST ST 499207400 CAMSHAFT SPROCKET WRENCH Tightening torque 98 10 kgf m 72 4 ft lb CAUTION Do not confuse right and left side camshaft sprockets during installation The camshaft sprocket No 2 is identified by a projection used to monitor camshaft position sensor EN1213 CAMSHAFT SPROCKET WRENCH ST 499977500 EN1205 2 Install the camshaft position senso
241. TH DIAGNOSTIC TROUBLE CODE DTC ENGINE DIAGNOSTICS Yes No CHECK HARNESS BETWEEN ECM AND VARIABLE VALVE TIMING SOLENOID VALVE 1 Turn the ignition switch to OFF 2 Disconnect the connector from ECM and variable valve timing solenoid valve 3 Measure the resistance between ECM and variable valve timing solenoid valve Connector amp terminal B84 No 6 E38 No 1 B84 No 12 E38 No 2 Is the resistance less than 1 Q Go to step 2 Repair the open circuit in harness between ECM and variable valve tim ing solenoid valve connector NOTE In this case repair the following Open circuit in harness between ECM and variable valve timing sole noid valve connec tor Poor contact in coupling connec tor CHECK HARNESS BETWEEN ECM AND VARIABLE VALVE TIMING SOLENOID VALVE 1 Turn the ignition switch to OFF 2 Disconnect the connector from ECM and variable valve timing solenoid valve 3 Measure the resistance between ECM and variable valve timing solenoid valve Connector amp terminal E38 No 1 Engine ground E38 No 2 Engine ground Is the resistance more than 1M Q Go to step 3 Repair the short circuit between ECM and variable valve timing sole noid valve connec tor CHECK VARIABLE VALVE TIMING SOLE NOID VALVE 1 Remove the variable valve timing solenoid valve 2 Measure the resistance between variable valve timing solenoid valve terminal
242. Ti model perature sensor EN TURBO 4 ELECTRICAL COMPONENTS LOCATION ENGINE DIAGNOSTICS EN TURBO 5 ELECTRICAL COMPONENTS LOCATION ENGINE DIAGNOSTICS 0948 1 Front oxygen A F sensor 3 Exhaust temperature sensor 4 Front catalytic converter 2 Precatalytic converter Except STi Except STi model 5 Rear oxygen sensor model 6 Rear catalytic converter EN TURBO 6 ELECTRICAL COMPONENTS LOCATION ENGINE DIAGNOSTICS EN1017 EN1018 0950 EN TURBO 7 ELECTRICAL COMPONENTS LOCATION ENGINE DIAGNOSTICS LHD model 1 EN1019 RHD model 1 mel 3 zT 1020 1 Fuel level sensor 2 Fuel sub level sensor EN1036 EN1037 EN TURBO 8 ELECTRICAL COMPONENTS LOCATION ENGINE DIAGNOSTICS EN TURBO 9 ELECTRICAL COMPONENTS LOCATION ENGINE DIAGNOSTICS Solenoid Valve Actuator Emission Control System Parts and Ignition System Parts 5 3 4 EN1526 1 Wastegate control solenoid valve 4 Ignition coil 6 Variable valve timing solenoid 2 Idle air control solenoid
243. UST ER ASSEMBLY AND BELT IDLER 1 Preparation for installation of automatic belt ten sion adjuster assembly CAUTION e Always use a vertical type pressing tool to move the adjuster rod down Do not use a lateral type vise Push the adjuster rod vertically Be sure slowly move the adjuster rod down applying a pressure of 294 30 kgf 66 Ib Press in the push adjuster rod gradually tak ing more than three minutes Do not allow press pressure to exceed 9 807 N 1 000 kgf 2 205 Ib Press the adjuster rod as far as the end sur face of the cylinder Do not press the adjuster rod into the cylinder Doing so may damage the cylinder Do not release press pressure until stopper pin is completely inserted 1 Attach the automatic belt tension adjuster assembly to the vertical pressing tool 2 Slowly move the adjuster rod down with a pressure of 294 30 kgf 66 Ib until the adjust er rod is aligned with the stopper pin hole in the cylinder H2M2382 3 With a 2 mm 0 08 dia stopper pin or a 2 m 0 08 in nominal dia hex bar wrench in serted into the stopper pin hole in the cylinder secure the adjuster rod H2M2383 MECHANICAL 2 Install the automatic belt tension adjuster as sembly Tightening torque 25 N m kgf m 18 1 ft lb 52 0416 3 Install the belt idler No 2 Tightening torque 39 4 0 kgf m 28
244. UT VOLTAGE OF LATERAL G SENSOR 1 Turn the ignition switch to OFF 2 Remove the console box 3 Remove the lateral G sensor from vehicle Do not disconnect the connector 4 Turn the ignition switch to ON 5 Measure the voltage between lateral G sen sor connector terminals Connector amp terminal B257 No 1 No 3 Is the voltage between 4 75 and 5 25 V Go to step 4 Repair the har ness connector between lateral G sensor and ABSCM amp H U CHECK OPEN CIRCUIT IN LATERAL G SEN SOR OUTPUT 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 LHD B301 No 29 No 28 RHD F49 No 29 No 28 Is the resistance between 5 0 and 5 6 Go to step 5 Repair the har ness connector between lateral G sensor and ABSCM amp H U CHECK GROUND SHORT IN LATERAL G SENSOR OUTPUT HARNESS 1 Disconnect the connector from lateral G sen sor 2 Measure the resistance between ABSCM amp H U connector and chassis ground Connector amp terminal LHD B301 No 29 Chassis ground RHD F49 No 29 Chassis ground Is the resistance more than 1 MQ Go to step 6 Repair the har ness between lat eral G sensor and ABSCM amp H U CHECK BATTERY SHORT OF HARNESS Measure the voltage between ABSCM amp H U connector and chassis grou
245. V belt Ref to ME STi 43 IN STALLATION V belt gt C DISASSEMBLY 1 Remove the valve lifters 2 Compress the valve spring and remove the valve spring retainer key Remove each valve and valve spring ST 498267600 CYLINDER HEAD TABLE ST 499718000 VALVE SPRING REMOVER CAUTION Metallic sodium is enclosed in the exhaust valve therefore use extreme care when han dling and discarding them Ref to ME STi 71 DISPOSAL Cylinder Head Assembly gt Keep the removed parts in order for re install ing in their original positions Mark each valve to prevent confusion Use extreme care not to damage the lips of the intake valve oil seals and exhaust valve oil seals 52 1881 ME STi 66 CYLINDER HEAD ASSEMBLY MECHANICAL D ASSEMBLY EN1194 1 Exhaust valve 5 Intake valve oil seal 9 Valve lifter 2 Intake valve 6 Valve spring 10 Exhaust valve oil seal 3 Cylinder head 7 Retainer 11 Intake valve guide 4 Valve spring seat 8 Retainer key 12 Exhaust valve guide ME STi 67 CYLINDER HEAD ASSEMBLY MECHANICAL 1 Installation of valve spring and valve 1 Coat the stem of each valve with engine oil and insert the valve into valve guide CAUTION When inserting the valve into valve guide use special care not to damage the oil seal lip 2 Set the cylinder head on ST1 3 Install the valve spring and retainer u
246. WI 35 AIR CONDITIONING SYSTEM WIRING SYSTEM A B282 B B283 AUTO A C CONTROL MODULE m oe e e LCD OUT TEMP AMBIENT SENSOR EVAPORATION SUNLOAD B COMBINATION THERMO SWITCH SENSOR METER BLACK 8282 GRAY B B283 GRAY B GREEN D 1 2 3 4 5 6 7 8 ILL 112 1314516 7 8 9 112 314 1516 171 amp o 9 10 11112 1314 1516 11 12 13 14 15 6 17 18 19 20 1516117 1819120 2122 12312425126127 2812030 10 11 12 18 14 15 16 17 18 19 2021 22 23 24 2526 27 2829130 3132 GR46 22C WI 36 AIR CONDITIONING SYSTEM WIRING SYSTEM 282 B B283 AUTO A C CONTROL MODULE AIR MIX ACTUATOR MODE ACTUATOR m TURBO ENGINE MODEL NON TURBO ENGINE MODEL FRESH RECIRC ACTUATOR es THERMOMETER BERT SNES TB BLACK LIGHT GRAY LACK A B282 GRAY B B283 GRAY 8282 8289 LIGAT GRAVI q
247. add oil through the oil level gauge hole to bring the level up to the upper level TRO633 A Oil level gauge B Upper level C Low level B REPLACEMENT 1 Pull out the oil level gauge 2 Lift up the vehicle 3 Remove the transmission under cover 4 Drain the transmission gear oil completely CAUTION Directly after the engine has been running the transmission gear oil is hot Be careful not to burn yourself NOTE Tighten the transmission gear oil drain plug after draining transmission gear oil Always use new gasket Tightening torque Oil pan side 44 4 5 kgf m 32 5 ft Ib Clutch housing side 70 N m 7 1 kgf m 51 6 ft lb TRO634 A Drain plug Oil pan side B Drain plug Clutch housing side 5 Lower the vehicle 6 Pour gear oil into the gauge hole Recommended gear oil Use GL 5 or equivalent Gear oil capacity 4 1 0 4 3 US qt 3 6 Imp qt 7 Check the level of the transmission gear oil CAUTION When inserting the level gauge into transmis sion gear align the protrusion on the side of the top part of the level gauge with the notch in the gauge hole NOTE The level should be within the specified range marked on the gauge 6MT 32 OIL SEAL MANUAL TRANSMISSION AND DIFFERENTIAL 3 Oil Seal A INSPECTION Inspect for oil leakage from the oil seal Replace the oil seal if the
248. ain the gear oil CAUTION Be careful not to burn your hands because gear oil becomes extremely hot after running 050003 A Filler plug B Drain plug 3 Tighten the oil drain plug NOTE Apply fluid packing to the drain plug for T type Use a new aluminum gasket for VA type Fluid packing THREE BOND 1105 or equivalent Tightening torque T type 49 N m 5 0 kgf m 36 2 ft Ib VA type 34 N m 3 5 kgf m 25 3 ft Ib per plug level NOTE Carefully refill oil while watching the level Excess or insufficient oil must be avoided Oil capacity Except STi model 0 8 0 0 8 US qt 0 7 Imp qt STi model 0 9 1 1 0 1 0 1 2 US qt 0 8 1 0 Imp qt A Filler plug B Drain plug 5 Install the filler plug NOTE Apply fluid packing to the filler plug for T type Use a new aluminum gasket for VA type Fluid packing THREE BOND 1105 or equivalent Tightening torque T type 49 N m 5 0 kgf m 36 2 ft Ib VA type 34 N m 3 5 kgf m 25 3 ft Ib DI 20 REAR DIFFERENTIAL FOR 4 Rear Differential for T type DISASSEMBLY 2 MODEL To detect the real cause of trouble inspect the fol lowing items before disassembling Tooth contact of crown gear and pinion and backlash Runout of crown gear at its back surface Turning resistance of drive pinion 1 Set the ST on vise and install the
249. alve relay power supply 24 23 10 15V Motor relay power supply 25 23 10 15V Power supply 30 28 4 75 5 25 2 Ground 28 AWD model only Output 6 28 2 3 0 2 V when vehicle is in horizontal position Lateral Power supply 30 28 4 75 5 25 V G sensor 2 Ground 28 STi model only Output 29 28 2 5 0 2 V when vehicle is in horizontal position Stop light switch 1 2 23 Less than 1 5 V when the stop light is OFF and 10 15 when the stop light is ON ABS warning light 2 22 23 Less than 1 5 V during 1 5 seconds when ignition switch is ON and 10 15 V after 1 5 seconds AT ABS signal 2 AT model only 31 23 Less than 1 5 V when the ABS control still operates and more than 5 5 V when ABS does not operate ABS operation signal monitor 2 3 23 Less than 1 5 V when the ABS control still operates and more than 5 5 V when ABS does not operate Data is received 20 23 Less than 1 5 V when no data is received Select monitor 2 Data is sent 5 23 4 75 5 25 V when no data is sent ABS diagnosis connec Terminal No 3 29 23 10 15 V when ignition switch is ON tor 2 Terminal No 6 4 23 10 15 V when ignition switch is ON Power supply 1 1 23 10 15 V when ignition switch is ON Grounding line 23
250. and reverse check cable NOTE If the transmission is not moved stay bolt will con tact body and damage may occur TRO976 A Stay B Stay bolt 7 Adjust the length between end of cable plate and reverse check cable to 84 mm 3 31 and then tighten the lock nut Tightening torque 6 0 6 kgf m 4 4 ft lb TRO973 84mm 3 31 8 Move the transmission to right side and then in Stall the stay Tightening torque 32 3 3 kgf m 23 6 ft lb A V A TRO977 A Stay CS 16 REVERSE CHECK CABLE CONTROL SYSTEMS 9 Install the crossmember lt Ref to 6 35 IN STALLATION Transmission Mounting System gt 10 Install the rear exhaust pipe and muffer lt Ref to EX TURBO 13 INSTALLATION Rear Exhaust Pipe gt lt Ref to EX TURBO 14 INSTALLATION Muffer gt 11 Install the reverse check cable end washer and snap pin to reverse check lever NOTE Take care to install the snap pin in proper direction TRO957 Reverse check cable Washer Snap pin Front side 12 Install the under cover CS 17 REVERSE CHECK CABLE CONTROL SYSTEMS CS 18 MANUAL TRANSMISSION AND DIFFERENTIAL 1 General eet teed tenon C Og 2 TRANSMISSION Gear Sal
251. ape around the spline part of axle shaft B3M2085A A Vinyl tape 13 Using the ST remove the axle shaft ST1 499247300 INSTALLER ST2 499095500 REMOVER ASSY NOTE Do not reuse the circlip Mark to identify the right and left axle shaft TRO819 6MT 107 FRONT DIFFERENTIAL ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 14 Using the ST remove the differential side re tainer on both side ST1 499787000 WRENCH ASSY RIGHT SIDE ST2 18630 000 WRENCH ASSY LEFT SIDE NOTE Be careful not to damage the part of clutch case where the retainer is to be installed B A Right side B Left side 15 Remove the front differential B INSTALLATION 1 Install the differential assembly into clutch hous ing 2 Apply oil to the threaded portion part of side re tainer 3 Remove the O ring from side retainer of both side 4 Using the ST install the differential side retainer to both side ST1 499787000 WRENCH ASSY RIGHT SIDE ST2 18630AA000 WRENCH ASSY LEFT SIDE NOTE Be careful not to damage the oil seal B A Right side B Left side 5 Install the axle shaft NOTE Replace the with a new one Be careful not to confuse right and left axle shaft Wrap vinyl tape around the spline part of axle shaft 6 Check and adjust the hypoid gear backlash lt Ref to 6MT 113 HYPOID GEAR BACKL
252. aper since the adapter plate is base point of measurement Do not place the height gauge on shaded area in the figure during measurement TRO756 6MT 129 SHIFTER FORK AND ROD MANUAL TRANSMISSION AND DIFFERENTIAL 4 Press the reverse sleeve to reverse side idler gear No 2 then measure T TRO870 A Reverse idler gear No 2 e Reverse idler gear No 2 NOTE e Set the indicator of height gauge near measuring object then lock the dial 1 as shown in the figure Turn dial 2 to set the indicator to edge surface of reverse sleeve side e Measure five points of the sleeve turning every approx 72 Round off each two upper and lower measurement value Use the remaining center val ue as measurement value TRO871 TRO758 5 According to measurement calculate the re verse sleeve neutral position Select the fork rod which applies to the calculated value from following equation Equation T 4 8 mm 0 189 in T 4 8 mm 0 189 in mm in Lot No Mark sanon 32816 130 None IECH T Thickness 6MT 130 CLUTCH HOUSING MANUAL TRANSMISSION AND DIFFERENTIAL 26 Clutch Housing A REMOVAL 1 Remove the manual transmission assembly from vehicle lt Ref to 6MT 37 REMOVAL Manual Transmission Assembly gt
253. ard clearance between thrust washer and Sion case and end of ST transfer drive gear ST 398643600 GAUGE 0 45 0 65 mm 0 018 0 026 in Thrust washer 36 3 x 52 x t Part No Thickness mm in AG 803036070 0 80 0 0315 803036071 0 95 0 0374 o 803036072 1 10 0 0433 C en 803036073 1 25 0 0492 2 803036074 1 40 0 0551 e ee 803036075 0 65 0 0256 TRO673 5 Install the selected thrust washer 2 Measure the depth Y between end of ST and transfer drive gear ST 398643600 GAUGE S 674 3 Calculate the value 4 transfer drive gear thrust washer using the following equation Y 15 mm 1 18 in Z 15 mm 1 18 in 0 45 to 0 65 mm 0 018 to 0 026 in t mm in Thickness of transfer drive gear thrust washer Y mm in Depth from end of ST to transfer drive gear 2 mm Height from end transmission case to the end of ST 0 45 0 65 mm 0 018 0 026 in Standard clearance between thrust washer and transfer drive gear 15 mm 1 18 in Thickness of ST 6MT 54 REVERSE CHECKING SYSTEM 13 Reverse Checking System A REMOVAL 1 Remove the manual transmission assembly from vehicle Ref to 6MT 37 REMOVAL Manual Transmission Assembly 2 Prepare the transmissio
254. aring race Used with SEAT 499705404 For VA type DIFFERENTIALS ILLUSTRATION GENERAL DESCRIPTION TOOL NUMBER DESCRIPTION REMARKS A 1931 899874100 INSTALLER Used for installing companion flange B3M1932A 899524100 PULLER SET Used for removing side bearing cone of differ ential For VA type 1 Puller 2 Cap 04 0029 18759 000 PULLER ASSY Newly adopted tool Used for removing side bearing cone of differ ential For T type STi model B3M2016 498937110 HOLDER DRIVE PINION This special tool is used for current automatic transmis sion DI 18 Used for installing pilot bearing For T type STi model ILLUSTRATION GENERAL DESCRIPTION TOOL NUMBER DESCRIPTION DIFFERENTIALS REMARKS B3M1905 18674 000 INSTALLER Used for installing rear bearing cone Newly adopted tool For T type STi model DR0030 398417700 DRIFT This special tool was prepared for the vehicles of 92MY and before DI 19 Used for installing side bearing race DIFFERENTIAL GEAR OIL DIFFERENTIALS 4 Fill the differential carrier with gear oil to the up 2 Differential Gear Oil B REPLACEMENT 1 Jack up the vehicle and support it with sturdy racks 2 Remove the oil drain plug and filler plug and dr
255. aru Select Monitor gt 44 ABS AT control Con ABS AT control Con lt Ref to ABS 138 DTC 44 ABS AT CONTROL CONTROLLED trolled trolled Diagnostics Chart with Subaru Select Monitor gt 51 Valve relay malfunc Valve relay malfunction lt Ref to ABS 141 DTC 51 VALVE RELAY MALFUNCTION tion y Diagnostics Chart with Subaru Select Monitor gt 5 lt Ref to ABS 145 DTC 51 VALVE RELAY ON FAILURE Diag 51 Valve relay ON failure Valve relay ON failure Chart with Subaru Select Monitor gt 52 Open circuit in motor Open circuit in motor lt Ref to ABS 149 DTC 52 OPEN CIRCUIT IN MOTOR RELAY relay circuit relay circuit CIRCUIT Diagnostics Chart with Subaru Select Monitor gt lt Ref to 5 153 52 MOTOR RELAY ON FAILURE E Ee EE Diagnostics Chart with Subaru Select Monitor gt 52 Mot Ifuncti Motor maltu nction lt Ref to ABS 157 DTC 52 MOTOR MALFUNCTION Diagnos tics Chart with Subaru Select Monitor gt Ston light switch sig Ston light switch lt Ref to ABS 160 DTC 54 STOP LIGHT SWITCH SIGNAL CIR 54 a p MEM gna GUIT MALFUNCTION Diagnostics Chart with Subaru Select Monitor Open or short circuit in Open or short circuit in lt Ref ip ABS 102 DTC Bo OPEN OR SHORT 56 G sensor circ it G sensor circ it SENSOR CIRCUIT Diagnostics Chart with Subaru Select Moni tor gt 56 Battery short in
256. ase TRO702 A Outer rotor B Inner rotor 2 Install the thrust washer to main shaft part 3 Install the oil pump cover assembly Tightening torque 25 N m 2 5 kgf m 18 1 ft Ib ST 18663AA000 SOCKET TRO701 4 Install the oil pump shaft assembly and plate Tightening torque 25 2 5 kgf m 18 1 ft lb ST 18663AA000 SOCKET A Oil pump shaft assembly B Plate 6MT 65 OIL PUMP MANUAL TRANSMISSION AND DIFFERENTIAL 5 If replacing the oil pump cover assembly select the transfer driven gear and thrust washer then in stall them to the extension case lt Ref to 6MT 51 ADJUSTMENT Extension Case gt 6 Install the selector arm No 2 and shifter arm A Selector arm No 2 B Shift arm 7 Install a new spring pin 8 Install the support to neutral set spring NOTE Make sure to install the support in proper direction TRO0671 9 Using the ST install the neutral set spring and support 5711 18756 000 CLAW ST2 398663600 PLIERS TRO666 10 Install the snap ring 11 Install the oil guide TRO699 A Oil guide 12 Install the center differential lt Ref to 6MT 62 INSTALLATION Center Differential gt 13 Install the transfer driven gear lt Ref to 6MT 60 INSTALLATION Transfer Driven Gear gt 14 Install the extension case lt Ref to 6MT 49 IN STALLAT
257. ases Gear teeth surfaces are broken or excessively worn Parts that contact the baulk ring is damaged The inner surface of gear is damaged 4 Baulk ring synchro cone Replace the baulk ring and synchro cone in the fol lowing case Worn rusted and damaged baulk ring 5 Shifting insert key Replace the shifting insert key if deformed exces sively worn or defective in any way 53 0189 6 94 DRIVEN GEAR ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL F ADJUSTMENT 1 Measure length which is from transmission case and oil pump cover mating surface to ball bearing edge TA TR0988 A Transmission case B Ball bearing C Driven gear assembly 2 Using the following equation calculate the washer thickness of driven gear assembly T H 5 8 0 05 mm 0 23 0 002 0 1 to 0 3 mm 0 0039 to 0 0118 in Thickness of washer Length from transmission case and oil pump cover mating surface to ball bearing edge 5 8 0 05 mm Thickness of collar 0 23 0 002 in 0 1 to 0 3 mm Backlash specification at axial direc 0 0039 to 0 0118 in tion of driven gear assembly 3 Select 0 to 3 washers from the following table to adjust backlash closest to specification Backlash specification at axial direction of driv en gear assembly 0 1 0 3 mm 0 0039 0 0118 in
258. ate and reverse check cable to 84 mm 3 31 in and then tighten the lock nut Tightening torque 6 0 6 kgf m 4 4 ft lb TRO973 84mm 3 31 2 Insert the reverse check cable to the hole of in ner boots from underneath the vehicle 3 Move the transmission to right side and then in stall the stay Tightening torque 32 3 3 kgf m 23 6 ft lb A Stay CS 14 REVERSE CHECK CABLE CONTROL SYSTEMS 4 Lower the vehicle 5 Insert the reverse check cable to the gear shift lever assembly then fix with the band clip NOTE Cut off the extra band clip Make sure that the reverse check cable is insert ed into gear shift lever assembly without any clear ance TRO978 6 Fix the slider and reverse check cable end with spring pin NOTE Apply grease to the sliding part of slider TRO958 Slider B Spring pin 7 Lift up the vehicle 8 Install the reverse check cable end washer and snap pin to reverse check lever NOTE Take care to install the snap pin in proper direction f 2 TRO957 A Reverse check cable B Washer C Snap pin D Front side 9 Fix the reverse check cable to clip of stay NOTE Install the reverse check cable to upper side of stay TRO974 A Reverse check cable B Clip 10 Install the rear
259. block 4 Rear oil seal Fluid packing THREE BOND 1215 or equivalent Tightening torque N m kgf m ft lb 1 25 2 5 18 1 2 47 4 8 34 7 CAUTION Do not allow fluid packing to jut into O ring grooves oil passages bearing grooves etc 1 52 1826 ME STi 76 CYLINDER BLOCK 3 Temporarily tighten the 10 mm cylinder block connecting bolts in alphabetical sequence shown in the figure L OA 42 Cape BEG Tai C AJCCEY mu B2M0088D 4 Tighten the 10 mm cylinder block connecting bolts in alphabetical sequence Tightening torque 47 N m 4 8 kgf m 34 7 ft Ib cape oY d T Va ey career ey tup S B2M0088D 5 Tighten the 8 mm and 6 mm cylinder block con necting bolts in alphabetical sequence shown in the figure Tightening torque A G 25 N m 2 5 kgf m 18 1 ft Ib H 6 4 N m 0 65 kgf m 4 7 ft Ib B2M0089F MECHANICAL 6 Install the rear oil seal using ST1 and ST2 ST1 499597100 CRANKSHAFT OIL SEAL GUIDE ST2 499587200 CRANKSHAFT OIL SEAL IN STALLER olt Rear oil seal Flywheel attaching b G2M0186 7 Position the top ring gap at A or B in the fig ure EN1515 8 Position the second ring gap at 180
260. bushing at connecting rod small end and replace if worn or damaged Also measure the piston pin clearance at the connecting rod small end G2M0177 3 Make two 3 mm 0 12 in holes in the bush ing Ream the inside of bushing 4 After completion of reaming clean the bush Clearance between piston pin and bushing Standard ing to remove chips 0 0 022 mm 0 0 0009 in Limit 0 030 mm 0 0012 in 2 0085 ME STi 89 CYLINDER BLOCK MECHANICAL 6 CRANKSHAFT AND CRANKSHAFT BEARING 1 Clean the crankshaft completely and check for cracks by means of red lead check etc and re place if defective 2 Measure the crankshaft bend and correct or re place if it exceeds the limit CAUTION If a suitable V block is not available install 1 and 5 crankshaft bearing on the cylinder block position the crankshaft on these bear ings and measure crankshaft bend using a dial gauge Crankshaft bend limit 0 035 mm 0 0014 in EN0339 3 Inspect the crank journal and crank pin for wear If they are not within the specifications replace the bearing with a suitable undersize one and re place or recondition the crankshaft as necessary When grinding the crank journal or crank pin finish them to the specified dimensions according to the undersize bearing to be used Crank pin and crank journal Out of roundness 0 020 mm 0 0008 in or less Tape
261. c Procedure gt ME STi 24 INTAKE MANIFOLD VACUUM MECHANICAL 5 Intake Manifold Vacuum A INSPECTION 1 Warm up the engine 2 Disconnect the brake vacuum hose and install the vacuum gauge to the hose fitting on the mani fold 3 Keep the engine at the idle speed and read the vacuum gauge indication By observing the gauge needle movement the in ternal condition of the engine can be diagnosed as described below Vacuum pressure at idling A C OFF Less than 64 0 kPa 480 mmHg 18 90 in Hg Diagnosis of engine condition by measurement of manifold vacuum Vacuum gauge indication Possible engine condition 1 Needle is steady but lower than normal position This ten dency becomes more evident as engine temperature rises Leakage around intake manifold gasket or disconnection or damaged vacuum hose 2 When engine speed is reduced slowly from higher speed needle stops temporarily when it is lowering or becomes steady above normal position Back pressure too high or exhaust system clogged 3 Needle intermittently drops to position lower than normal position Leakage around cylinder 4 Needle drops suddenly and intermittently from normal posi tion Sticky valves 5 When engine speed is gradually increased needle begins to vibrate rapidly at certain speed and then vibration increases as engine speed increases Weak or broken valve springs 6
262. cept 195 60R15 88H 15 x 6JJ OUTBACK 205 50 R16 87V 16 x 6 1 2JJ 55 2 17 215 45 R17 87W 17 x 7JJ OUTBACK P205 55 R16 89V 16 x 6 1 2JJ 100 3 94 dia STi 225 45 R17 90W 17 x 7 1 2JJ T125 70 D15 95M 15 T135 70 016 100M 16 x 4T T135 70 D17 102M 17 x 4T Front and rear Tire inflation pressure kPa kg cm psi Light load Full load Tire size 185 70 R14 88H Fr 220 2 2 32 Fr 220 2 2 32 Except 195 60 R15 88H Rr 200 2 0 29 Rr 220 2 2 32 OUTBACK 205 50 R16 87V Fr 220 2 2 32 Rr 200 2 0 29 215 45 R17 87W Fr 230 2 3 33 Rr 220 2 2 32 OUTBACK P205 55 R16 89V Fr 220 2 2 32 Rr 200 2 0 29 STi 225 45 R17 90W Fr 230 2 3 33 Rr 190 1 9 28 T125 70 D15 95M T135 70 D16 100M 420 4 2 60 T135 70 D17 102M Front and rear NOTE T type tire for temporary use is supplied as a spare tire At trailer towing rear inflation pressure is 250 kPa 2 5 kg cm 36 psi WT 2 DIFFERENTIALS General Descriptiohis Differential Geatr Oll idet e Front Differential Rear Differential for uix muto Rear Differential for VA type Rear Differential Front Oil Seal Rear Differential Side Oil Seal Rear Differential Member General Diagnostic Table MIU OMIT OI DIFFERENTIALS GENERAL DESCRIPTION 1 General Description A SPECIFICATIONS When replacing a rear
263. circuit in har ness between vari able valve timing camshaft position sensor and ECM connector NOTE The harness be tween both con nectors are shielded Repair the ground short circuit in harness together with shield CHECK CONDITION OF VARIABLE VALVE TIMING CAMSHAFT POSITION SENSOR Is the variable valve timing camshaft position sensor installation bolt tightened securely EN TURBO 27 Go to step 5 Tighten the vari able valve timing camshaft position sensor installation bolt securely DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC ENGINE DIAGNOSTICS Step Check Yes No 5 CHECK VARIABLE VALVE TIMING CAM SHAFT POSITION SENSOR 1 Remove the variable valve timing camshaft position sensor 2 Measure the resistance between connector terminals of variable valve timing camshaft position sensor Terminals No 1 No 2 EN TURBO 28 Is the resistance between 1 and 4 Check oil pres sure passage and stuck of oil vari able valve timing solenoid valve Replace the vari able valve timing camshaft position sensor lt Ref to FU TURBO 31 Variable Valve Timing Camshaft Position Sensor DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC ENGINE DIAGNOSTICS EN TURBO 29 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC ENGINE DIAGNOSTICS DM DTC P1306 VARIABLE VALVE TIMING SOLENOID VALVE 1 CIRCUIT LOW INPUT
264. ck 2 Tighten cylinder head bolts 1 Apply a coat of engine oil to washers and bolt threads 2 Tighten all bolts to 29 N m 3 0 kgf m 22 ft Ib in alphabetical sequence Then tighten all bolts to 69 N m 7 0 kgf m 51 ft Ib in alphabetical sequence 3 Loosen all bolts by 180 in reverse order and then loosen the bolts by 180 again 4 Tighten all bolts to 39 N m 4 0 kgf m 29 ft Ib in alphabetical sequence 5 Tighten all bolts by 80 to 90 in alphabetical sequence 6 Additionally tighten all bolts by 40 to 45 in alphabetical sequence CAUTION Do not tighten the bolts more than 452 7 Tighten bolts A B by 45 CAUTION Ensure that the total re tightening angle in the two previous step does not exceed 902 B2M1397D 3 Install the camshaft Ref to ME STi 60 IN STALLATION Camshaft gt 4 Install the A C compressor bracket on cylinder head 5 Install the intake manifold Ref to FU TURBO 18 INSTALLATION Intake Manifold gt 6 Install the camshaft sprocket Ref to ME STi 56 INSTALLATION Camshaft Sprocket gt 7 Install the timing belt assembly Ref to ME STi 49 INSTALLATION Timing Belt Assem bly 8 Install the belt cover Ref to ME STi 46 IN STALLATION Belt Cover ME STi 65 CYLINDER HEAD ASSEMBLY MECHANICAL 9 Install the crankshaft pulley Ref to ME STi 45 INSTALLATION Crankshaft Pulley gt 10 Install the
265. co oe p t tpe eco Pol reed 27 General Diagnostic GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL 1 General Description A SPECIFICATION 1 MANUAL TRANSMISSION AND FRONT DIFFERENTIAL STD OP 6 forward speeds and 1 reverse ist 3 636 2nd 2 375 3rd 1 761 Transmission gear ratio 4th 1 346 5th 0 971 1 062 6th 0 756 0 842 Reverse 3 545 Front reduc Type of gear Hypoid Final tion gear Gear ratio 3 900 Type of gear Helical Transfer Rear reduc Gear ratio 1 100 1 000 tion gear Type of gear Hypoid Final Gear ratio 3 545 3 900 Front differ ential Type and number of gear Straight bevel gear Bevel pinion 2 Bevel gear 2 SURETRAC Center differ ential Type and number of gear Straight bevel gear Bevel pinion 2 Bevel gear 2 and viscous coupling Transmission gear oil GL 5 Transmission gear oil capacity Australia model 2 TRANSMISSION GEAR OIL Recommended oil 4 1 2 4 3 US qt 3 6 Imp qt ITEM Transmission gear oil API Classification GL 5 SAE Viscosity No and Applicable Temperature C 30 26 15 5 0 15 2530 T T 22 15 5 23 32 59 7786 1 0024 6 2 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL COMPON
266. ction Ref to ABS 123 DTC 36 REAR RIGHT OUTLET VALVE MAL FUNCTION Diagnostics Chart with Subaru Select Monitor Rear left inlet valve malfunction Rear left inlet valve malfunction Ref to ABS 120 DTC 37 REAR LEFT INLET VALVE MAL FUNCTION Diagnostics Chart with Subaru Select Monitor Rear left outlet valve malfunction Rear left outlet valve malfunction Ref to ABS 124 DTC 38 REAR LEFT OUTLET VALVE MAL FUNCTION Diagnostics Chart with Subaru Select Monitor ABS control module malfunction ABS control module and hydraulic control unit malfunction Ref to ABS 128 DTC 41 ABS CONTROL MODULE MALFUNC TION Diagnostics Chart with Subaru Select Monitor Power supply voltage too low Power supply voltage too low Ref to ABS 130 DTC 42 POWER SUPPLY VOLTAGE TOO LOW Diagnostics Chart with Subaru Select Monitor Power supply voltage too high Power supply voltage too high Ref to ABS 132 DTC 42 POWER SUPPLY VOLTAGE TOO HIGH Diagnostics Chart with Subaru Select Monitor ABS 9 LIST OF DIAGNOSTICS TROUBLE CODE DTC ABS DIAGNOSTICS ring Display screen Contents of diagnosis Index No 44 ABS AT control ABS AT control Non lt Ref to ABS 136 DTC 44 ABS AT CONTROL NON CON Controlled Controlled TROLLED Diagnostics Chart with Sub
267. d baulk ring 5 Shifting insert key Replace the shifting insert key if deformed exces sively worn or defective in any way 53 0189 MANUAL TRANSMISSION AND DIFFERENTIAL F ADJUSTMENT 1 SELECTION OF MAIN SHAFT SNAP RING AND WASHER NOTE Perform the following procedures when Replacing the 1st to 6th driven gear Replacing the 1st and 2nd synchro ring assem bly Replacing the ball bearing Replacing the adapter plate Replacing the driven shaft 1 Insert the drive pinion assembly in adapter plate NOTE Make sure the thrust bearing outer race is not re moved and drive pinion is not lift up 2 Set the height gauge to adapter plate Lower the indicator of height gauge to mating surface of adapter plate and case then set to zero point ST 18853AA000 HEIGHT GAUGE NOTE Remove the remaining gasket on edge surface with scraper since the adapter plate is base point of measurement Do not place the height gauge on shaded area the figure during measurement TRO756 6MT 85 MAIN SHAFT ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 3 Measure the height to edge surface of ball bear ing height 1 TRO757 A Ball bearing NOTE Set the indicator of height gauge near measuring object then lock the dia
268. d intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective intake manifold gasket Defective throttle body gasket Defective PCV valve Loosened filler cap Dirty air cleaner element Fuel line Defective fuel pump and relay Clogged fuel line Lack of or insufficient fuel Belt Defective timing Compression Incorrect valve clearance Loosened spark plugs or defective gasket Loosened cylinder head bolts or defective gasket Improper valve seating Defective valve stem Worn or broken valve spring Worn or stuck piston rings cylinder and piston Incorrect valve timing Improper engine oil low viscosity Lubrication system Incorrect oil pressure Defective rocker cover gasket Cooling system Overheating Others Malfunction of evaporative emission control system Stuck or damaged throttle valve Accelerator cable out of adjustment ME STi 93 gt 0 0 DD gt w w O w w w w O W O w w gt gt gt gt O w O O O O O w w w O O w w O O W MECHANICAL Trouble ENGINE TROUBLE IN GENERAL Problem Parts etc Possible Cause 3 Low output hesitation and poor acceleration Engine control system lt Ref to
269. d valve LH STi AVCS solenoid valve RH STi TGV angle sensor LH Except STi TGV LH Except STi TGV angle sensor RH Except STi RH Except STi E2 20 Black E3 Brown E4 E5 E6 E7 E8 E10 E11 E13 E14 E15 E16 E17 E19 E21 E31 E32 E33 E34 E35 E36 E37 E38 E50 E51 E54 E55 Non colored PO GD PO PO PO GD o PO GW PO PO Connector Connecting to No Pole Color T3 12 Bulkhead wiring harness RHD model T4 Black Bulkhead wiring harness RHD model T9 Bulkhead wiring harness MT Except STi T9 Bulkhead wiring harness MT STi Non colored WI 106 ENGINE WIRING HARNESS AND TRANSMISSION CORD WIRING SYSTEM gt BO0484 WI 107 REAR WIRING HARNESS AND TRUNK LID CORD WIRING SYSTEM 52 Rear Wiring Harness and Trunk Lid Cord A LOCATION Connector Connecting to No Pole Color R16 Rear door switch RH R17 Black Rear defogger R19 High mounted stop light R20 Black Trunk room light R24 Trunk lid cord R26 Rear combination light RH R27 Trunk room light switch R28 Rear combination light LH R60 Rear wiring harness R63 License plate light R65 Rear defogger R66 High mounted stop light Rear spoiler R79 Trailer connector R122 Fuel pump cont
270. de headlight is removed BO0024 3 Disconnect the harness connector LOW BEAM BULB 4 Remove the bulb cover 0515 5 Remove the light bulb retaining spring to remove the bulb BO0516 LI 3 LIGHTING SYSTEM HIGH BEAM BULB 6 Remove the bulb by turning it counterclockwise BO0517 FRONT TURN SIGNAL LIGHT BULB LIGHTING SYSTEM 13 Front Turn Signal Light Bulb A REMOVAL 2 STI MODEL 1 Remove the headlight assembly Ref to LI 13 REMOVAL Headlight Assembly 2 Turn the socket A and remove the bulb BO0518 LI 4 CLEARANCE PARKING LIGHT BULB LIGHTING SYSTEM 14 Clearance Parking Light Bulb A REMOVAL 2 STI MODEL 1 Remove the headlight assembly Ref to LI 13 REMOVAL Headlight Assembly 2 Turn the socket A and remove the bulb 0519 LI 5 CLEARANCE PARKING LIGHT BULB LIGHTING SYSTEM LI 6 INSTRUMENTATION DRIVER INFO 1 General DescriptOni teed tannins LR NUR RR COEUR Cita 2 2 Combination Meter System 3 Combination Meter 3 4 Speedometer 5 Tachometer 6 Fuel Gauge 7 Water Temperature Gauge 8 Ambient Sensor GENERAL DESCRIPTION INSTRUMENTATION DRIVER INFO 1 General Description A SPECIFICATIONS 2 STI MODEL Combination meter Speedometer Electric
271. del for DTCs except following Item Index Variable valve timing system 1 RH Ref to EN TURBO 19 DTC P0011 VARIABLE VALVE TIMING SYS TEM 1 RH Diagnostic Procedure with Diagnostic Trouble Code DTC gt Variable valve timing system 2 LH Ref to EN TURBO 20 DTC P0021 VARIABLE VALVE TIMING SYS TEM 2 LH Diagnostic Procedure with Diagnostic Trouble Code DTC gt Variable valve timing camshaft posi tion sensor B circuit malfunction 1 RH Ref to EN TURBO 22 DTC P0365 VARIABLE VALVE TIMING CAM SHAFT POSITION SENSOR B CIRCUIT MALFUNCTION 1 RH Diag nostic Procedure with Diagnostic Trouble Code DTC gt Variable valve timing camshaft posi tion sensor B circuit malfunction 2 LH Ref to EN TURBO 26 DTC P0390 VARIABLE VALVE TIMING CAM SHAFT POSITION SENSOR B CIRCUIT MALFUNCTION 2 LH Diag nostic Procedure with Diagnostic Trouble Code DTC gt Variable valve timing solenoid valve 1 circuit low input RH Ref to 30 DTC P1306 VARIABLE VALVE TIMING SOLE NOID VALVE 1 CIRCUIT LOW INPUT RH Diagnostic Procedure with Diagnostic Trouble Code DTC gt Variable valve timing solenoid valve 1 circuit high input RH Ref to EN TURBO 32 DTC P1307 VARIABLE VALVE TIMING SOLE NOID VALVE 1 CIRCUIT HIGH INPUT RH Diagnostic Procedure with Diagnostic Trouble Code DTC gt Variable valve timin
272. differential as sembly to ST ST 398217700 ATTACHMENT SET G3M1031 2 Drain the gear oil by removing the plug 3 Remove the air breather cap NOTE Do not attempt to replace the air breather cap un less necessary S3M0530A A Air breather cap B Rear cover DIFFERENTIALS 4 Remove the rear cover by loosening the retain ing bolts 53 0531 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 NOTE Each shim which is installed to adjust the side bearing preload should be kept together with its mating retainer ST 398457700 ATTACHMENT T nmn 53 0532 6 Pull out the differential case assembly from dif ferential carrier NOTE Be careful not to hit the teeth against the case 53 0533 DI 21 REAR DIFFERENTIAL FOR DIFFERENTIALS 7 When replacing the side bearing pull the bear ing cup from side bearing retainer using ST ST 398527700 PULLER ASSY S3M0534A 8 Extract the bearing cone with ST NOTE Do not attempt to disassemble the parts unless necessary Set the puller so that its claws catch the edge of bearing cone Ne
273. differential assembly select the correct one according to the following table NOTE Using the different rear differential assembly causes the drive line and tires to drag or emit abnormal noise when AWD is selected MODEL 1 6L 2 0L AT MT MT Rear differential type VA type without LSD T type without LSD Identification XP XN EG Type of gear Hypoid gear Gear ratio Number of gear teeth 4 444 40 9 4 111 37 9 3 90 0 39 10 Oil capacity 0 8 0 0 8 US qt 0 7 Imp qt Rear differential gear oil MODEL 2 5L GL 5 2 0 L Turbo Except Australia AT Australia MT Except Australia Australia Rear differential type T type with LSD LSD type Viscous coupling SURETRAC Identification EJ ER EJ EF EM Type of gear Hypoid gear Gear ratio Number of gear teeth 4 111 37 9 3 700 37 10 4 111 37 9 3 545 39 11 4 444 40 9 Oil capacity 0 8 0 0 8 US qt 0 7 Imp qt Rear differential gear oil MODEL 2 0 L Turbo STi MT Except Australia Australia Rear differential type T type with LSD LSD type SURETRAC Identification HJ HG Type of gear Hypoid gear Gear ratio Number of gear teeth 3 545 39 11 3 900 39 10 Oil capacity 0 9 1 1 2 1 0 1 2 US qt 0 8 1 0
274. disconnect the connector 3 Read the select monitor display Is the indicated reading 3 5 0 2 V when lateral G sen sor is inclined forwards to 90 Go to step 7 Replace the lateral G sensor CHECK LATERAL G SENSOR Read the select monitor display Is the indicated reading 1 5 0 2 V when lateral G sen sor is inclined backwards to 90 ABS 6 Lateral G sensor is normal Replace the lateral G sensor ABS DIAGNOSTICS Page Basic Diagnostic Procedure Check List for Interview General Description Electrical Components Location 2 Control Module I O iier et rtp Re en 4 Subaru Select Monitor Read Diagnostic Trouble Code DTC Inspection Mode Clear Memory Mode ABS Warning Light Illumination Pattern List of Diagnostics Trouble Code 7 Diagnostics Chart with Diagnosis Connector 11 Diagnostics Chart with Subaru Select 19 General Diagnostics Table SC ONS h 2 II ELECTRICAL COMPONENTS LOCATION ABS DIAGNOSTICS 4 Electrical Components Location A LOCATION D ri V Sed IR Mi M4 4 71 d 4 8 BRO153 1 ABS control module and hydrau 5 Data link connector for Subaru 10 Lateral G sensor only STi model lic control unit AB
275. e lt Ref to 6MT 51 ADJUST MENT Extension Case gt 6 Apply oil lightly to the outer periphery of bearing cone and then install to extension case 7 Install the shift bracket Tightening torque 25 2 5 kgf m 18 1 ft lb TRO660 6MT 50 EXTENSION CASE 8 Install the extension guide and then install the transfer driven gear lt Ref to 6MT 58 INSTALLA TION Transfer Drive Gear gt E INSPECTION 1 Make sure there is no damage or crack on ex tension case If there is damage or crack replace the extension case 2 Check each oil seal and joint part of extension case and transmission case for oil leakage If there is oil leakage replace the oil seal and liquid gasket F ADJUSTMENT 1 TRANSFER DRIVEN GEAR BEARING THRUST WASHER ADJUSTMENT 1 Using the ST remove the bearing cone from ex tension case 18758AA000 PULLER TRO661 A Bearing cone 2 Remove the thrust washer MANUAL TRANSMISSION AND DIFFERENTIAL 3 Measure the depth 2 between end of extension case and contact point of bearing cone ST 398643600 GAUGE NOTE To measure the depth 7 subtract the thickness of ST 15 mm 0 59 in from the measured value 0664 15 0 59 4 Remove the transfer driven gear lt Ref to 6 60 REMOVAL Transfer Driven Gear gt 5 Remove the center differential lt Ref to 6MT 62
276. e before measurement Idle speed A C ON no load and gears in neu tral 750450 rpm CAUTION Never rotate the idle adjusting screw If the idle speed is out of specifications refer to General On board Diagnosis Table under Engine Con trol System lt Ref to EN TURBO 2 Basic Di agnostic Procedure gt ME STi 23 MECHANICAL IGNITION TIMING MECHANICAL 4 Ignition Timing A INSPECTION 1 Before checking ignition timing speed check the following 1 Ensure that air cleaner element is free from clogging spark plugs are in good condition and that hoses are connected properly 2 Ensure that malfunction indicator light CHECK ENGINE light does not illuminate 2 Warm up the engine 3 Stop the engine and turn the ignition switch to OFF 4 Insert the cartridge to SUBARU SELECT MONI TOR 5 Connect SUBARU SELECT MONITOR to the data link connector 6 Turn the ignition switch to ON and SUBARU SELECT MONITOR switch to ON 7 Select 2 Each System Check in Main Menu 8 Select Engine Control System in Selection Menu 9 Select 1 Current Data Display amp Save in En gine Control System Diagnosis 10 Select 1 12 Data Display in Data Display Menu 11 Start the engine at idle speed and check the ig nition timing Ignition timing BTDC rpm 12 3 700 If the timing is not correct check the ignition control system Refer to Engine Control System lt Ref to EN TURBO 2 Basic Diagnosti
277. e front right wheel speed on monitor display 0 km Go to step 6 Go to step 16 CHECK FREEZE FRAME DATA Read front left wheel speed on the select mon itor display Is the front left wheel speed on monitor display 0 km Go to step 7 Go to step 16 CHECK FREEZE FRAME DATA Read rear right wheel speed on the select monitor display Is the rear right wheel speed on monitor display 0 km Go to step 8 Go to step 16 CHECK FREEZE FRAME DATA Read rear left wheel speed on the select moni tor display Is the rear left wheel speed on monitor display 0 km Go to step 9 Go to step 16 CHECK FREEZE FRAME DATA Read lateral G sensor output on the select monitor display Is the lateral G sensor output on monitor display more than 3 65 V Go to step 10 Go to step 16 CHECK OPEN CIRCUIT IN LATERAL G SEN SOR OUTPUT 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 LHD B301 No 29 No 28 RHD F49 No 29 No 28 Is the resistance between 5 0 and 5 6 kQ Go to step 11 Repair the har ness connector between lateral G sensor and ABSCM amp H U CHECK BATTERY SHORT OF HARNESS 1 Turn the ignition switch to OFF 2 Remove the console box 3 Disconnect the connector from lateral G sen sor 4 Disconnect the con
278. e piston seal from caliper body cylin der 1 Piston seal BRAKE D ASSEMBLY 3 17 INCH TYPE 1 Clean the caliper body interior using brake fluid 2 Apply a coat of brake fluid to the piston seal and fit piston seal in groove on caliper body 3 Apply a coat of brake fluid to the entire inner sur face of cylinder and outer surface of piston 4 Apply a coat of specified grease to the boot and fit in to the groove on ends of cylinder and piston Grease NIGLUBE RX 2 Part No 003606000 5 Insert the piston into cylinder CAUTION Do not force the piston into cylinder 0016 6 Position the boot in grooves on cylinder pis ton 0150 1 Piston seal 2 Piston boot 3 Piston BR 11 REAR BRAKE PAD BRAKE 5 Rear Brake Pad A REMOVAL 3 17 INCH TYPE 1 Set the vehicle on a lift 2 Loosen the wheel nuts 3 Jack up the vehicle and then remove the front wheel 4 Remove the clip 0148 BR0019 1 Cross spring 2 Pad pin 6 Expand the pads and push piston back 7 Remove the pad BRO0020 1 Rear brake pad B INSTALLATION 3 17 INCH TYPE 1 Apply a thin coat of Molykote AS880N Part No 26298ACO000 to frictional portion between pad and pad inner shim 2 Install the pads on caliper body 3 Install the cross spring and pad pins 4 Install the Clip
279. ea is small This may cause chipping at heel ends 2 B3M0322 Adjust as for face contact B3M0323 up Adjusting direction of drive pinion gt Adjusting direction of crown gear 6MT 106 FRONT DIFFERENTIAL ASSEMBLY 23 Front Differential Assembly A REMOVAL 1 Remove the manual transmission assembly Ref to 6MT 37 REMOVAL Manual Transmis sion Assembly 2 Prepare the transmission for overhaul Ref to 6MT 42 Preparation for Overhaul gt 3 Remove the oil pipe neutral position switch back up light switch and harness Ref to 6 44 REMOVAL Oil Pipe Ref to 6MT 47 REMOV AL Neutral Position Switch Ref to 6MT 45 REMOVAL Back up Light Switch 4 Remove the extension case Ref to 6MT 49 REMOVAL Extension Case 5 Remove the transfer driven gear Ref to 6 60 REMOVAL Transfer Driven Gear 6 Remove the center differential Ref to 6 62 REMOVAL Center Differential 7 Remove the oil pump Ref to 6 64 RE MOVAL Oil Pump 8 Remove the transmission case Ref to 6MT 68 REMOVAL Transmission Case 9 Remove each gear assembly Ref to 6MT 73 REMOVAL Main Shaft Assembly 10 Remove the drive pinion shaft assembly Ref to 6MT 101 REMOVAL Drive Pinion Shaft As sembly gt 11 Remove the lock plates on both side TRO818 A Lock plate MANUAL TRANSMISSION AND DIFFERENTIAL 12 Wrap vinyl t
280. echanics 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 G1841GE6 24 LIGHTING SYSTEM sch a A A BA aaa 0 00 e CONS General Description iouis tili deae 2 Headlight and Tail Light System Front Fog Light System Rear Fog Light System Turn Signal and Hazard Light System Back up Light System Stop Light System Interior Light System Headlight Beam Leveler System Combination Switch Light Headlight Assembly Headlight Bulb ed E e ke 3 Front Turn Signal Light Bulb irri ere dre decer prets 4 Clearance Parking Light 5 Front Fog Light Assembly Front Fog Light Bulb Rear Combination Light Assembly Brake Tail Light Bulb Back up Light Bulb Rear Turn Signal Light Bulb Rear Fog Light Bulb License Plate Light High mounted Stop Light Side Turn Signal Light Spot Light Room Light Luggage Room Light Trunk Room Light
281. eck connector Rear fog light relay Diagnosis terminal Ground Headlight leveling switch Except STi Diagnosis connector WI 103 Headlight leveling switch STi AT power mode amp hold mode switch WIRING SYSTEM Connector Connecting to Pole Color Name Connector BULKHEAD WIRING HARNESS IN COMPARTMENT Connecting to 22 28 24 31 Engine control module No Pole Color Name B299 6 Shield joint connector AT Turbo model B300 6 Line end check con nector 14 Immobilizer control module 12 F B 4 Ignition relay Relay block F B F B Front fog light switch Cruise control sub switch Air conditioning switch Manual A C Blower fan switch Manual A C Mirror heated relay Keyless entry control module Joint connector Key less entry Rear fog light switch Diode Rear fog light Joint connection Ground Front wiring harness Glove box light Ignition switch illumi nation Fuse Relay box Evaporator sensor ABS lateral G sensor STi ABS G sensor joint connector STi ABS relay F B Fan control amp Auto A C control mod ule Remote control rear view mirror switch Intercooler water spray timer STi ABS s
282. ector for Subaru 28 Rear right ABS sensor Select Monitor ABS 6 LIST OF DIAGNOSTICS TROUBLE CODE DTC ABS DIAGNOSTICS 11 List of Diagnostics Trouble Code DTC A LIST 1 WITHOUT SUBARU SELECT MONITOR Contents of diagnosis Index No Start code DTC is shown after start code Only start code is shown in normal condition Abnormal ABS sensor Open circuit or input voltage too high Front right ABS sensor Ref to ABS 39 DTC 21 ABNORMAL ABS SENSOR OPEN CIRCUIT OR INPUT VOLTAGE TOO HIGH FRONT RH Diag nostics Chart with Diagnosis Connector Front left ABS sensor Ref to ABS 39 DTC 23 ABNORMAL ABS SENSOR OPEN CIRCUIT OR INPUT VOLTAGE TOO HIGH FRONT LH Diag nostics Chart with Diagnosis Connector Rear right ABS sensor Ref to ABS 39 DTC 25 ABNORMAL ABS SENSOR OPEN CIRCUIT OR INPUT VOLTAGE TOO HIGH REAR RH Diag nostics Chart with Diagnosis Connector Rear left ABS sensor Ref to ABS 40 DTC 27 ABNORMAL ABS SENSOR OPEN CIRCUIT OR INPUT VOLTAGE TOO HIGH REAR LH Diag nostics Chart with Diagnosis Connector Abnormal ABS sensor Abnormal ABS sen sor signal Front right ABS sensor Ref to ABS 46 DTC 22 ABNORMAL ABS SENSOR ABNOR MAL ABS SENSOR SIGNAL FRONT RH Diagnostics Chart with Diagnosis Connector Front left ABS sensor Ref to ABS 46 DTC 24 ABNORMAL ABS SENSOR ABNOR MAL ABS SE
283. el Gauge System 18 Full Time Dual Range System 19 Front Accessory Power Supply System 20 Headlight Beam Leveler 75 21 Horn System 22 Immobilizer System 23 Keyless Entry System 24 Back up Light System 25 Clearance Light and Illumination Light 77 26 Front Fog Light System 27 Headlight tria 87 28 Compartment Light System 29 Stop Light System 30 Turn Signal Light and Hazard Light System 31 Pressure Warning Light System 32 Outside Temperature Display System 33 Parking Brake and Brake Fluid Level Warning System 34 Power Window System 35 Radiator Fan System 36 Rear Fog Light System 37 Rear Window Defogger System 38 Remote Controlled Rearview Mirror System 39 Seat Belt Warning System 40 Starter System 41 Sunroof System 42 Wiper and Washer System Front 43 Wiper and Washer System Rear WIRING SYSTEM 44 45 46 47 48 49 50 51 52 53 54 Overall Systems Front Wiring uet e aed 90 Bulkhead Wiring Harness In Engine Room 96 Bulkhead Wiring Harness In Compartment 100 Engine Wiring Harness and Transmission 106 Instrument Panel Wiring Harness Rear Wiring Harness Bulkhead wiring Harness Roof Cord and Fuel Tank Cord Door Cord Rear Wiring Harness and Trunk Lid
284. em Worn or broken valve spring Worn or stuck piston rings cylinder and piston Incorrect valve timing Improper engine oil low viscosity ME STi 92 w w 0 0 w gt w Ol w S 0 O0O0 O0U 5 U0O0 O0Uu Trouble ENGINE TROUBLE IN GENERAL Problem Parts etc MECHANICAL Possible Cause 4 Engine stalls after initial combustion Engine control system lt Ref to EN TURBO 2 Basic Diagnostic Procedure gt gt Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective intake manifold gasket Defective throttle body gasket Dirty air cleaner element Fuel line Clogged fuel line Lack of or insufficient fuel Belt Defective Defective timing Compression Incorrect valve clearance Loosened spark plugs or defective gasket Loosened cylinder head bolts or defective gasket Improper valve seating Defective valve stem Worn or broken valve spring Worn or stuck piston rings cylinder and piston Incorrect valve timing Improper engine oil low viscosity 2 Rough idle and engine stall Engine control system Ref to EN TURBO 2 Basic Diagnostic Procedure Intake system Loosened or cracke
285. en ECM and variable valve timing solenoid valve Connector amp terminal E38 No 1 Engine ground E38 No 2 Engine ground Is the resistance more than 1M Q Go to step 3 Repair the short circuit between ECM and variable valve timing sole noid valve connec tor CHECK VARIABLE VALVE TIMING SOLE NOID VALVE 1 Remove the variable valve timing solenoid valve 2 Measure the resistance between variable valve timing solenoid valve terminal Is the resistance between 6 and 12 0 EN TURBO 31 Repair the poor contact in ECM and variable valve timing solenoid valve Replace the vari able valve timing solenoid valve Ref to ME STi 59 Camshaft gt DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC ENGINE DIAGNOSTICS DN DTC P1307 VARIABLE VALVE TIMING SOLENOID VALVE 1 CIRCUIT HIGH INPUT RH DTC DETECTING CONDITION Two consecutive driving cycles with fault TROUBLE SYMPTOM e Erroneous idling CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode lt Ref to EN TURBO 45 OP ERATION Clear Memory Mode gt and Inspection Mode lt Ref to EN TURBO 42 Inspection Mode gt WIRING DIAGRAM ECM VARIABLE VALVE TIMING F5 SOLENOID VALVE RH EN1530 EN TURBO 32 DIAGNOSTIC PROCEDURE WI
286. en set at position shown in the figure Left hand intake camshaft Rotate 80 clock wise Left hand exhaust camshaft Rotate 45 coun terclockwise EN1214 A Left side cylinder head Right side cylinder head a Intake camshaft b Exhaust camshaft ME STi 60 CAMSHAFT MECHANICAL 2 Camshaft cap and variable valve timing solenoid valve assembly installation 1 Apply fluid packing sparingly to cap mating surface CAUTION Do not apply fluid packing excessively Failure to do so may cause excess packing to come out and flow toward the oil seal resulting in oil leaks Fluid packing THREE BOND 1215 or equivalent EN1210 2 Apply engine oil to cap bearing surface and install the cap on camshaft as shown by identifi cation mark A 3 Gradually tighten the camshaft cap and oil control valve assembly in at least two stages in alphabetical sequence shown in the figure and then tighten to specified torque Tightening torque T1 10 N m 1 0 kgf m 7 ft lb T2 20 2 0 kgf m 14 5 ft lb M e B 9 io Vay 96 1211 4 Similarly tighten on the exhaust side After tightening cap ensure the camshaft ro tates only slightly while
287. ensor Air mix actuator Auto A C Intercooler water spray switch STi Rear defogger timer Non colored WI 104 BULKHEAD WIRING HARNESS COMPARTMENT WIRING SYSTEM WITHOUT OBD MODEL W9 wm opp MODEL BO0483 WI 105 ENGINE WIRING HARNESS AND TRANSMISSION CORD WIRING SYSTEM 48 Engine Wiring Harness and Transmission Cord A LOCATION 3 DOHC TURBO MODEL Connector Connecting to No Pole Color 1 10 Light gray Bulkhead wiring harness Front wiring harness LHD model Bulkhead wiring harness RHD model Front wiring harness LHD model Bulkhead wiring harness RHD model Black Purge control solenoid valve Dark gray Fuel injector No 1 Dark gray Fuel injector No 3 Black Idle air control solenoid valve Light gray Engine coolant temperature sensor and thermometer Light gray Crankshaft position sensor Oil pressure switch Black Throttle position sensor Gray Knock sensor Light gray Camshaft position sensor Dark gray Fuel injector No 2 Dark gray Fuel injector No 4 Power steering oil pressure switch Black Pressure sensor Ignition coil No 1 Ignition coil No 2 Ignition coil No 3 Ignition coil No 4 AVCS camshaft position sensor LH STi AVCS camshaft position sensor RH STi AVCS solenoi
288. epair the open circuit in harness between ECM and variable valve tim ing solenoid valve connector NOTE In this case repair the following Open circuit in harness between ECM and variable valve timing sole noid valve connec tor Poor contact in coupling connec tor CHECK HARNESS BETWEEN ECM AND VARIABLE VALVE TIMING SOLENOID VALVE Measure the resistance between ECM and variable valve timing solenoid valve Connector amp terminal E37 No 1 Engine ground E37 2 Engine ground Is the resistance more than 1M Q Go to step 3 Repair the short circuit between ECM and variable valve timing sole noid valve connec tor CHECK VARIABLE VALVE TIMING SOLE NOID VALVE 1 Remove the variable valve timing solenoid valve 2 Measure the resistance between variable valve timing solenoid valve terminal Is the resistance between 6 and 12 0 EN TURBO 35 Repair the poor contact in ECM and variable valve timing solenoid valve Replace the vari able valve timing solenoid valve lt Ref to ME STi 59 Cam shaft gt DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC ENGINE DIAGNOSTICS DP DTC P1309 VARIABLE VALVE TIMING SOLENOID VALVE 2 CIRCUIT HIGH INPUT LH DTC DETECTING CONDITION Two consecutive driving cycles with fault e TROUBLE SYMPTOM e Erroneous idling CAUTION After repair or replacement of faulty parts conduc
289. eplace deformed or otherwise damaged snap rings with new ones Before installing O rings or oil seals apply suffi cient amount of gear oil to avoid damage and defor mation Be careful not to incorrectly install or fail to install O rings snap rings and other such parts Before securing a part on a vise place cushion ing material such as wood blocks aluminum plate or shop cloth between the part and the vise Avoid damaging the mating surface of the case Before applying sealant completely remove the old seal REMARKS 398791700 B3M1938 REMOVER Used for removing and installing spring pin 6 mm 399527700 B3M1940A PULLER SET Used for removing and installing roller bearing Differential 1 BOLT 899521412 2 PULLER 399527702 3 HOLDER 399527703 4 ADAPTER 398497701 5 BOLT 899520107 6 NUT 021008000 6MT 15 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 498515700 REMOVER Used for removing roller bearing of drive pinion shaft B3M1942 498147000 DEPTH GAUGE Used for adjusting main shaft axial end play B3M1944 498247001 MAGNET BASE Used for measuring backlash between side gear and pinion and hypoid gear Used with DIAL GAUGE 498247100 B3M1945 498247100 DIAL GAUGE Used for measuring backlash between side gear and pinion and hypoid gear Used
290. equence shown in the figure and then tighten to specified torque Tightening torque T1 10 N m 1 0 kgf m 7 ft Ib T2 20 N m 2 0 kgf m 14 5 ft Ib 9 EN1211 CAUTION Do not turn the camshaft 5 Remove the bearing caps 6 Measure the widest point of the plastigauge on each journal If the oil clearance exceeds the limit replace the camshaft If necessary replace the camshaft caps and cylinder head as a set Standard 0 037 0 072 mm 0 0015 0 0028 in Limit 0 10 mm 0 0039 in B2M1216 7 Completely remove the plastigauge 5 Check cam face condition remove minor faults by grinding with oil stone Measure the cam height H replace if the limit has been exceeded Cam height H Standard Intake 45 25 45 35 mm 1 781 1 785 in Exhaust 45 60 45 70 mm 1 795 1 799 in Limit Intake 45 15 mm 1 778 in Exhaust 45 50 mm 1 791 in Cam base circle diameter A 37 0 mm 1 457 in B2M1209A ME STi 63 CAMSHAFT MECHANICAL 6 Measure the thrust clearance of camshaft with dial gauge If the clearance exceeds the limit re place caps and cylinder head as a set If necessary replace the camshaft Standard 0 015 0 070 mm 0 0006 0 0028 in Limit 0 1 mm 0 004 in B2M1217 ME STi 64 CYLINDER HEAD ASSEMBLY 19 Cylinder Head Assembly
291. ersonnel 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 WIRING SYSTEM WI G1841GE7 WIRING SYSTEM Page 1 Basic Diagnostics Procedure 2 Working Precautions 3 Super Multiple Junction SMJ 4 POWER Supply 3 55 Ground DISTHD UNION rate o een cae 18 6 Airbag System 7 Air Conditioning System 29 8 Anti lock Brake EE 38 9 A T Control System 10 Audio System 11 Charging System 12 Combination Meter iiie RR Keno PE Ra 45 13 Cruise Control System etre edo eee eds 49 14 Door Lock System 15 Engine Coolant Temperature Gauge System 16 Engine Electrical 52 17 Fu
292. et up the cylinder block so that 1 and 3 inders are on the upper side then remove the cyl inder block connecting bolts 28 Separate the right hand and left hand cylinder blocks CAUTION When separating the cylinder block do not al low the connecting rod to fall and damage the cylinder block 3 DY SN 0 2 2408 1 Cylinder block 3 2 Rear oil seal 4 29 Remove the rear oil seal 30 Remove the crankshaft together with connect ing rod Crankshaft Crankshaft bearing b Piston 31 Remove the crankshaft bearings from cylinder block using hammer handle CAUTION Do not confuse the combination of crankshaft bearings Press the bearing at the end opposite to locking lip ME STi 75 CYLINDER BLOCK MECHANICAL 32 Draw out each piston from the cylinder block using wooden bar or hammer handle CAUTION Do not confuse the combination of piston and cylinder B INSTALLATION 1 T M EVI B2M2407A 1 Crankshaft bearing 2 Crankshaft 3 Cylinder block CAUTION Remove oil in the mating surface of bearing and cylinder block before installation Also apply a coat of engine oil to the crankshaft pins 1 Position the crankshaft on the 2 and 4 cylinder block 2 Apply fluid packing to the mating surface of 1 and 3 cylinder block and position it on 2 and 4 cylinder
293. etween lateral G sen sor connector terminals Connector amp terminal B257 No 2 No 3 Is the voltage between 2 3 and 2 7 V when lateral G sensor is horizontal Go to step 10 Replace the lateral G sensor lt Ref to ABS 5 Lateral G Sensor gt CHECK LATERAL G SENSOR Measure the voltage between lateral G sensor connector terminals Connector amp terminal B257 No 2 No 3 Is the voltage between 3 3 and 3 7 V when lateral G sensor is inclined forwards to 90 Go to step 11 Replace the lateral G sensor lt Ref to ABS 5 Lateral G Sensor gt CHECK LATERAL G SENSOR Measure the voltage between lateral G sensor connector terminals Connector amp terminal B257 No 2 No 3 Is the voltage between 1 3 and 1 7 V when lateral G sensor is inclined backwards to 90 Go to step 12 Replace the lateral G sensor lt Ref to ABS 5 Lateral G Sensor gt CHECK POOR CONTACT IN CONNECTORS Is there poor contact in con nector between ABSCM amp H U and lateral G sensor Repair the con nector Go to step 13 CHECK ABSCM amp H U 1 Connect all connectors 2 Erase the memory 3 Perform inspection mode 4 Read out the DTC Is the same DTC as in the cur rent diagnosis still being out put Replace the ABSCM amp H U lt Ref to ABS 4 ABS Control Mod ule and Hydraulic Control Unit ABSCM amp H U Go to step 14 CHECK ANY
294. exhaust pipe and muffler lt Ref to EX TURBO 13 INSTALLATION Rear Exhaust Pipe gt lt Ref to EX TURBO 14 INSTALLATION Muffler gt 11 Install the console box lt Ref to El 40 INSTAL LATION Console Box gt CS 15 REVERSE CHECK CABLE CONTROL SYSTEMS C INSPECTION 1 Verify whether the slider moves smoothly If not adjust the reverse check cable or check damage of slider lt Ref to CS 16 ADJUSTMENT Reverse Check Cable gt 2 Check that the gear can be shift to reverse when the slider is pulled up If the gear can not be shift to reverse adjust the reverse check cable lt Ref to CS 16 ADJUSTMENT Reverse Check Cable gt 3 Check that the gear can not be shift to reverse when the slider is not pulled up If the gear can be shift to reverse adjust or replace the reverse check cable lt Ref to CS 16 ADJUSTMENT Reverse Check Cable gt 0 ADJUSTMENT 1 Set the vehicle on a lift 2 Remove the under cover 3 Remove the rear exhaust pipe and muffer lt Ref to EX TURBO 13 REMOVAL Rear Exhaust Pipe gt lt Ref to EX TURBO 14 REMOVAL Muf fler gt 4 Remove the crossmember lt Ref to 6MT 35 REMOVAL Transmission Mounting System gt 5 Remove the snap pin and washer and then sep arate the reverse check cable from reverse check lever TRO954 A Snap pin B Washer C Reverse check cable 6 Move the transmission to right side and then re move the stay bolt
295. from vehicle 3 Connect the connector to lateral G sensor 4 Turn the ignition switch to ON 5 Measure the voltage between lateral G sen sor connector terminals Connector amp terminal B257 No 2 No 3 Is the voltage 2 5 0 2 V when lateral G sensor is horizontal Go to step 3 Replace the lateral G sensor CHECK LATERAL G SENSOR Measure the voltage between lateral G sensor connector terminals Connector amp terminal B257 No 2 3 Is the voltage 3 5 0 2 V when lateral G sensor is inclined for wards to 90 Go to step 4 Replace the lateral G sensor CHECK LATERAL G SENSOR Measure the voltage between lateral G sensor connector terminals Connector amp terminal B257 No 2 3 Is the voltage 1 5 0 2 V when lateral G sensor is inclined backwards to 90 Lateral G sensor is normal Replace the lateral G sensor CHECK LATERAL 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 lateral G sensor output voltage Is the indicated reading 2 5 0 2 V when the vehicle is in horizontal position Go to step 6 Replace the lateral G sensor CHECK LATERAL G SENSOR 1 Remove the console box 2 Remove the lateral G sensor from vehicle Do not
296. g solenoid valve 2 circuit low input LH Ref to EN TURBO 34 DTC P1308 VARIABLE VALVE TIMING SOLE NOID VALVE 2 CIRCUIT LOW INPUT LH Diagnostic Procedure with Diagnostic Trouble Code DTC gt Variable valve timing solenoid valve 2 circuit high input LH Ref to EN TURBO 36 DTC P1309 VARIABLE VALVE TIMING SOLE NOID VALVE 2 CIRCUIT HIGH INPUT LH Diagnostic Procedure with Diagnostic Trouble Code DTC gt EN TURBO 18 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC ENGINE DIAGNOSTICS 18 Diagnostic Procedure with Diagnostic Trouble Code DTC DI DTC 0011 VARIABLE VALVE TIMING SYSTEM 1 RH DTC DETECTING CONDITION Immediately at fault recognition TROUBLE SYMPTOM Engine stalls Erroneous idling CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode lt Ref to EN TURBO 45 OP ERATION Clear Memory Mode gt and Inspection Mode lt Ref to EN TURBO 42 Inspection Mode gt Step Check Yes No CHECK ANY OTHER DIAGNOSTIC TROU 15 any other DTC displayed Inspect the rele to step 2 BLE CODE DTC ON DISPLAY vant DTC using List of Diagnostic Trouble Code DTC lt Ref to EN TURBO 18 List of Diagnostic Trouble Code DTC gt CHECK CURRENT DATA Is the measured value largely Inspect the follow temporary mal 1 Start the engine and let it idle out of specification ing items and function Conduct
297. g torque 5 0 5 kgf m 3 6 ft lb 52 1162 12 Install the crankshaft sprocket lt Ref to ME STi 56 INSTALLATION Camshaft Sprock et gt 13 Install the camshaft sprockets Ref to ME STi 56 INSTALLATION Camshaft Sprock et gt 14 Install the timing belt assembly lt Ref to ME STi 49 INSTALLATION Timing Belt Assem bly 15 Install the belt cover Ref to ME STi 46 IN STALLATION Belt Cover 16 Install the crankshaft pulley Ref to ME STi 45 INSTALLATION Crankshaft Pulley gt 17 Install the V belt Ref to ME STi 43 IN STALLATION V belt gt ME STi 62 CAMSHAFT MECHANICAL C INSPECTION 1 Measure the bend and repair or replace if nec essary Limit 0 020 mm 0 0008 in 2 Check the journal for damage and wear Re place if faulty 3 Measure the outside diameter of camshaft jour nal If the jounal diameter is not as specified check the oil clearance Camshaft journal Front Center rear 37 946 37 9635 mm 29 946 29 963 mm 1 4939 1 4946 1 1790 1 1796 in Standard 4 Measurement of the camshaft journal oil clear ance 1 Clean the bearing caps and camshaft jour nals 2 Place the camshafts on the cylinder head Without installing valve rocker 3 Place a plastigauge across each of the cam shaft jounals 4 Gradually tighten the cap in at least two stages in alphabetical s
298. gear to drive pinion backlash in Crown gear runout on its back surface in Limit DI 7 0 10 0 20 0 0039 0 0079 0 05 0 0020 DIFFERENTIALS GENERAL DESCRIPTION D PREPARATION TOOL 1 SPECIAL TOOLS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 1893 398477701 HANDLE Used for installing front and rear bearing cone B3M1894 398477702 Used press fitting the bearing cone of differential carrier rear B3M1895 398217700 ATTACHMENT SET Stand for rear differential carrier disassembly and assembly B3M1896 498447120 DI 8 Used for installing front oil seal ILLUSTRATION GENERAL DESCRIPTION TOOL NUMBER DESCRIPTION DIFFERENTIALS REMARKS B3M1897 498427200 FLANGE WRENCH Used for stopping rotation of companion flange when loosening and tightening self lock nut p B3M1898 398467700 Used for removing pinion pilot bearing and front bearing cone B3M1899 399780104 WEIGHT Used for installing front bearing cone pilot bear ing companion flange B3M1900 899580100 INSTALLER DI 9 Used for press fitting the front bearing cone pilot bearing DIFFERENTIALS ILLUSTRATION GENERAL DESCRIPTION TOOL NUMBER DESCRIPTION REMARKS B3M1901 899904100 STRAIGHT PIN REMOVER Used for driving out differential pinion shaft lock pin
299. h housing Liquid gasket THREE BOND 1215 TRO711 MANUAL TRANSMISSION AND DIFFERENTIAL 3 Install each gear assembly lt Ref to 6MT 74 IN STALLATION Main Shaft Assembly gt 4 Install the transmission case lt Ref to 6MT 69 INSTALLATION Transmission Case gt 5 Install the oil pump lt Ref to 6 65 INSTAL LATION Oil Pump gt 6 Install the center differential lt Ref to 6 62 INSTALLATION Center Differential gt 7 Install the transfer driven gear lt Ref to 6MT 60 INSTALLATION Transfer Driven Gear gt 8 Install the extension case lt Ref to 6MT 49 IN STALLATION Extension Case gt 9 Install the oil pipe neutral position switch baack up light switch and harness lt Ref to 6MT 44 INSTALLATION Oil Pipe gt lt Ref to 6MT 47 INSTALLATION Neutral Position Switch gt lt Ref to 6MT 45 INSTALLATION Back up Light Switch gt 10 Install the manual transmission assembly to ve Ref to 6MT 39 INSTALLATION Manual Transmission Assembly gt C DISASSEMBLY NOTE Replace the drive pinion shaft as a set with hypoid driven gear 1 Remove the pipe and oil chamber TRO808 A Pipe B Oil chamber 2 Remove the drive pinion shaft and shim from adapter plate TRO809 6MT 101 DRIVE PINION SHAFT ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 3 Secure the ST on workbench ST 18664AA000 BASE 4 Lift the caulk
300. haft Ti 5 0 5 3 6 6 Automatic belt tension adjuster sprocket T2 10 1 0 7 ASSY 12 Timing belt T3 25 2 5 18 1 7 idler 13 Belt idler No 2 T4 39 4 0 28 9 8 Right hand exhaust camshaft 14 Belt idler T5 98 10 72 4 sprocket 15 Left hand belt cover T6 ME STi 45 Installation 16 Front belt cover Crankshaft Pulley gt ME STi 6 GENERAL DESCRIPTION MECHANICAL ME STi 7 GENERAL DESCRIPTION MECHANICAL 2 CYLINDER HEAD AND CAMSHAFT T2 T2 EN1193 ME STi 8 GENERAL DESCRIPTION MECHANICAL 1 Rocker cover 13 Cylinder head gasket 25 Gasket 2 Rocker cover gasket RH 14 Cylinder head LH 26 Oil filler duct 3 Variable valve timing solenoid 15 Intake camshaft LH 27 O ring valve assembly RH 16 Exhaust camshaft LH 28 Stud bolt 4 Intake camshaft cap RH 17 Variable valve timing solenoid 5 Intake camshaft RH valve assembly LH Tightening torque N m kgf m ft lb 6 Exhaust camshaft cap Front RH 18 Intake camshaft cap LH ME STi 65 Installation 7 Exhaust camshaft cap Center 19 Exhaust camshaft cap Front LH Cylinder Head Assembly gt RH 20 Exhaust camshaft cap Center 2 5 0 5 3 6 8 Exhaust camshaft cap
301. he end of wear indicator contacts the disc rotor a squeaking sound is produced as the wheel rotates If this sound is heard replace the pad 2 Install the pads on caliper body 3 Connect the brake hose Tightening torque 18 N m 1 8 kgf m 13 3 ft lb CAUTION The brake hose must be connected without any twist Replace the brake hose gaskets with new ones 4 Bleed air from the brake system C DISASSEMBLY 3 17 INCH TYPE 1 Remove the piston boot from piston end 0064 2 Gradually supply compressed air via inlet of the brake hose to force piston out CAUTION Place a wooden block as shown in the figure to prevent damage to piston 0025 20 mm 0 79 wide wooden block here 3 Remove the piston seal from caliper body cylin der BROO65 BR 14 REAR DISC BRAKE ASSEMBLY D ASSEMBLY 3 17 INCH TYPE 1 Clean the caliper body interior using brake fluid 2 Apply a coat of brake fluid to the piston seal and fit piston seal in groove on caliper body 3 Apply a coat of brake fluid to the entire inner sur face of cylinder and outer surface of piston 4 Apply a coat of specified grease to the boot and fit in to the groove on ends of cylinder and piston Grease NIGLUBE RX 2 Part No 003606000 5 Insert the piston into cylinder CAUTION Do not force the piston into cylinder 6 Position the boot in grooves on cylinder
302. height gauge near measuring object then lock the dial 1 as shown in the figure Turn dial 2 to set the indicator to edge surface of sleeve 4th side Perform the measuring procedure with two peo ple and measure the sleeve lifted up straight Measure five points of the ball bearing turning every approx 72 Round off each two upper and lower measurement value Use the remaining cen ter value as measurement value TRO758 2 Set the height gauge indicator upside down P A Indicator TRO865 3 Shift the 3rd 4th sleeve to 3rd main gear side then press down to the stopper and mea sure C1 TRO866 A 3rd main gear NOTE e Set the indicator of height gauge near measuring object then lock the dial 1 as shown in the figure Turn dial 2 to set the indicator to edge surface of sleeve 3rd side Measure five points of the ball bearing turning every approx 72 Round off each two upper and lower measurement value Use the remaining cen ter value as measurement value TRO758 4 According to both measurements calculate the 3rd 4th sleeve neutral position Select the fork rod which applies to the calculated value from following equation Equation T C1 C2 2 3rd 4th sleeve center position C1 Length from main shaft rear bearing snap ring groove
303. hose 10 25 2 5 18 1 13 Water pump 27 Plug T11 55 5 5 40 14 Baffle plate ME STi 11 GENERAL DESCRIPTION MECHANICAL 5 CRANKSHAFT AND PISTON EN1519 1 Flywheel 8 Circlip 15 Crankshaft bearing 1 3 2 Ball bearing 9 Connecting rod bolt 16 Crankshaft bearing 2 4 3 ring 10 Connecting rod 17 Crankshaft bearing 5 4 Second ring 11 Connecting rod bearing 5 Oil ring 12 Connecting rod cap Tightening torque N m kgf m ft Ib 6 Piston 13 Crankshaft T1 52 5 3 38 4 7 Piston pin 14 Woodruff key T2 72 7 3 52 8 ME STi 12 GENERAL DESCRIPTION MECHANICAL 6 ENGINE MOUNTING 89 1 d gt S2M1783A 1 Heat shield cover 3 Front engine mounting bracket Tightening torque N m kgf m ft lb 2 Front cushion rubber T1 35 3 6 25 8 T2 42 4 3 30 9 T3 85 8 7 62 7 ME STi 13 GENERAL DESCRIPTION MECHANICAL C CAUTION Wear working clothing including a cap protec tive goggles and protective shoes during opera tion Remove contamination including dirt and corro sion before removal installation or disassembly Keep the disassembled parts in order and pro tect them from dust or dirt Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation di
304. hten with the ST and torque wrench straight lined T L1 0 1 L1 x285 T N m kgf m ft lb Setting value of torque wrench L1 m in Torque wrench length 0 1 m 3 94 in ST length 285 29 0 kgf m 210 ft lb Tightening torque of lock nut TRO786 A 0 1 m 3 94 in 6 Measure the starting torque lt Ref to 6MT 104 INSPECTION Drive Pinion Shaft Assembly gt MANUAL TRANSMISSION AND DIFFERENTIAL 7 Using the ST caulk two portions on the lock nut to obtain dimension A 37 0 5 mm 1 46 0 02 in ST 18670AA000 PUNCH CAUTION Do not crack the caulking part of lock nut 8 Using the ST measure dimension B of the drive pinion ST 398643600 TRO815 GAUGE B3M0590D 6MT 103 DRIVE PINION SHAFT ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 9 Calculate the following equation then select one or two pieces of drive pinion shim from the table be low 6 5 0 0625 mm B A 0 26 0 0025 in B A NOTE A Measured value from step 1 B Measured value from step 8 Drive pinion shim Thickness mm in 0 15 0 0059 0 175 0 0069 0 20 0 0079 0 225 0 0089 0 25 0 0098 0 275 0 0108 Part No 32295AA270 32295AA280 32295AA290 32295AA300 32295AA310 32295AA320 10 Apply gear oil to the side face of taper roller bearing then install the drive pinion shaft and se lected shim to adapter p
305. i 43 RE MOVAL V belt gt 2 Remove the crankshaft pulley bolt To lock the crankshaft use ST ST 499977300 CRANK PULLEY WRENCH H2M2393C 3 Remove the crankshaft pulley B INSTALLATION 1 Install the crankshaft pulley 2 Install the pulley bolt To lock the crankshaft use ST ST 499977300 CRANK PULLEY WRENCH 1 Clean the crankshaft pulley thread using an air gun 2 Apply engine oil to the crankshaft pulley bolt seat thread and washer 3 Tighten the bolts with tightening torque of 157 N m 16 0 kgf m 116 ft lb 4 Loosen the bolts by 180 5 Tighten the crankshaft pulley bolts Tightening torque 157 N m 16 kgf m 116 ft Ib H2M2393A MECHANICAL 3 Confirm that the tightening angle of the crank shaft pulley bolt is 45 or more If not conduct the following procedures 1 through 4 Replace the crankshaft pulley bolts and clean them CAUTION Conduct the tightening procedures by confirm ing the turning angle of the crankshaft pulley bolt referring to the gauge indicated on the belt cover 4 Install the rear side belt tensioner fS 52 0113 0226 Lock nut B Slider bolt C INSPECTION 1 Make sure the V belt is not worn or otherwise damaged 2 Check the tension of the belt Ref to ME STi 44 INSPECTION V belt gt ME STi 45 BELT COVER MECHANICAL 14 Belt Cover A REMOVAL 1 Remo
306. iagnosis corre sponding to DTC A temporary poor contact CHECK INPUT VOLTAGE OF LATERAL G SENSOR 1 Turn the ignition switch to OFF 2 Remove the console box 3 Remove the lateral G sensor from vehicle Do not disconnect the connector 4 Turn the ignition switch to ON 5 Measure the voltage between lateral G sen sor connector terminals Connector amp terminal B257 1 3 Is the voltage between 4 75 and 5 25 V Go to step 17 Repair the har ness connector between lateral G sensor and ABSCM amp H U CHECK OPEN CIRCUIT IN LATERAL G SEN SOR OUTPUT 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 LHD B301 29 28 RHD F49 No 29 No 28 Is the resistance between 5 0 and 5 6 Go to step 18 Repair the har ness connector between lateral G sensor and ABSCM amp H U CHECK LATERAL G SENSOR 1 Connect the connector to lateral G sensor 2 Connect the connector to ABSCM amp H U 3 Turn the ignition switch to ON 4 Measure the voltage between lateral G sen sor connector terminals Connector amp terminal B257 2 No 3 Is the voltage between 2 3 and 2 7 V when lateral G sensor is horizontal Go to step 19 Replace the lateral G sensor Ref to ABS 5 Lateral G
307. ical Helical Helical Helical Helical Hypoid Hypoid Hypoid Hypoid Hypoid 5MT 5 forward speeds with synchromesh and 1 reverse 4AT Electronically controlled fully automatic 4 forward speeds and 1 reverse 6MT 6 forward speeds with synchromesh and 1 reverse DSPD Dry Single Plate Diaphragm TCC Torque Converter Clutch 1 Australia spec vehicle E STEERING Model Turbo 2 0L 2 5L OUTBACK OTHERS Type Rack and Pinion Turns lock to lock RHD 2 7 LHD 3 0 Minimum turning circle m ft Curb to curb 11 0 36 1 10 8 35 4 10 4 34 1 Wall to wall 12 0 39 4 11 6 38 1 11 2 36 7 3 0 3 2 F SUSPENSION Front Macpherson strut type Independent Coil spring Rear Dual link type Independent Coil spring SPC 4 IMPREZA SPECIFICATIONS G BRAKE Model 1 6L Non turbo 2 01 2 51 Turbo 2 0 L STi Service brake system Dual circuit hydraulic with vacuum suspended power unit Front Ventilated disc brake Rear Drum brake Disc brake Ventilated disc brake Parking brake Mechanical on rear brakes H TIRE Rim size 14 x 5 5JJ 15x 6JJ 16 x 6 5JJ 17 x 7JJ 17 x 71 24 Tire size 175 70R14 84T 185 65R15 88H P205 55R16 89V 215 45R17 87W 225 45R17 90W 185 70R14 88H 195 60R15 88H 205 50R16 87V 215 45R17 87W Type Steel belted radial Tubeless I CAPACITY Model 1 6L Non turbo 2 0 L Turbo 2 0L 2 51 5MT 4AT 5MT 4AT 5MT 4AT 5MT
308. ics Chart with Diagnosis Connector gt Rear right inlet valve lt Ref to ABS 57 DTC 35 ABNORMAL INLET SOLENOID VALVE CIRCUIT S INABSCM amp H U REAR RH Diagnostics Chart with Diagnosis Connector gt Rear right outlet valve lt Ref to ABS 61 DTC 36 ABNORMAL OUTLET SOLENOID VALVE CIRCUIT S INABSCM amp H U REAR RH Diagnostics Chart with Diagnosis Connector gt Rear left inlet valve lt Ref to ABS 58 DTC 37 ABNORMAL INLET SOLENOID VALVE CIRCUIT S INABSCM amp H U REAR LH Diagnostics Chart with Diagnosis Connector gt Rear left outlet valve Ref to ABS 62 DTC 38 ABNORMAL OUTLET SOLENOID VALVE CIRCUIT S INABSCM amp H U REAR LH Diagnostics Chart with Diagnosis Connector gt Abnormal ABS control module lt Ref to ABS 66 DTC 41 ABNORMAL ABS CONTROL MOD ULE Diagnostics Chart with Diagnosis Connector gt Source voltage is abnormal lt Ref to ABS 68 DTC 42 SOURCE VOLTAGE IS ABNORMAL Diagnostics Chart with Diagnosis Connector gt A combination of AT control abnormal lt Ref to ABS 72 DTC 44 A COMBINATION OF AT CONTROL ABNORMAL Diagnostics Chart with Diagnosis Connector gt Abnormal valve relay lt Ref to ABS 75 DTC 51 ABNORMAL VALVE RELAY Diag nostics Chart with Diagnosis Connector gt Abnormal motor and or motor relay lt Ref to ABS 79 DTC 52 ABNORMAL MOTOR AND OR MOTOR RELAY
309. ide oil seal holder For VA type B3M1922 498447100 Used for installing oil seal For VA type 1923 399520105 Used for removing side bearing cone Used with PULLER SET 899524100 For VA type B3M1930 399703602 PULLEY ASSY DI 15 Used for removing companion flange DIFFERENTIALS ILLUSTRATION GENERAL DESCRIPTION TOOL NUMBER DESCRIPTION REMARKS B3M1924 498485400 DRIFT Used for installing side bearing cone For VA type B3M1925 498505501 DIFFERENTIAL CARRIER GAUGE Used for adjusting pinion height For VA type B3M1926 498447110 Used for press fitting the bearing race front of differential carrier For VA type B3M1927 498447150 DUMMY SHAFT DI 16 Used for adjusting pinion height and preload For VA type ILLUSTRATION GENERAL DESCRIPTION TOOL NUMBER DESCRIPTION DIFFERENTIALS REMARKS lt gt 1911 498515500 Used for removing rear bearing cone For VA type 1977 32285AA000 DUMMY COLLAR Used for adjusting pinion height and preload For VA type 1928 499705404 Used for removing side bearing race Used with PULLEY ASSY 499705401 For VA type B3M1930 499705401 PULLEY ASSY DI 17 Used for removing side be
310. in 3 Using the ST install the 3rd 4th shifter arm ST 398791700 REMOVER NOTE Make sure to install the 3rd 4th shifter arm and rod in proper direction TRO850 A 3rd 4th shifter rod B 3rd 4th shifter arm C Spring pin 4 Install the 3rd 4th fork rod into 1st 2nd shifter arm TRO851 5 Using the ST install the 3rd 4th shifter fork ST 398791700 REMOVER NOTE Make sure to install the 3rd 4th shifter fork in proper direction 3rd 4th shifter fork B Spring pin 3 5TH 6TH SHIFTER FORK 1 Using ST install the 5th 6th shifter arm ST 398791700 REMOVER NOTE Make sure to install the 5th 6th shifter arm and rod in proper direction TRO853 5th 6th shifter arm B 5th 6th shifter rod C Spring pin 6MT 121 SHIFTER FORK AND ROD MANUAL TRANSMISSION AND DIFFERENTIAL 2 Using the ST install the 5th 6th shifter fork ST 398791700 REMOVER NOTE Make sure to install the 5th 6th shifter fork and arm in proper direction 0854 5th 6th shifter fork B 5th 6th shifter arm C Spring pin 4 SHIFT ARM SHAFT Using the ST install the selector arm ST 398791700 REMOVER NOTE Make sure to install the selector arm and rod in proper direction TRO855 A Selector rod B Selector arm 5 STRIKING ROD 1 Using the ST install the reverse interlock arm and interlock arm ST 398791700 NOTE
311. in Shaft Assembly 10 Remove the drive pinion shaft assembly Ref to 6MT 101 REMOVAL Drive Pinion Shaft As sembly gt 11 Remove the front differential assembly Ref to 6MT 107 REMOVAL Front Differential Assem bly gt 12 Remove the vehicle speed sensor lt Ref to 6MT 34 REMOVAL Vehicle Speed Sensor gt 13 Remove the snap ring and then remove the gt PA ES A Snap ring B Speedometer driven gear 14 Remove the speedometer shaft from clutch housing 15 Remove the oil seal speedometer shaft and washer WR Nn B MIA M TRO832 A Washer B Snap ring C Oil seal 16 Remove the snap ring from speedometer shaft B INSTALLATION 1 Install the oil seal washer and snap ring to speedometer shaft 2 Insert the speedometer shaft Using the ST press the oil seal ST 899824100 or 499827000 PRESS TRO0833 NOTE Replace the oil seal with a new one Insert the oil seal approx 24 mm 0 94 in from the edge of clutch case 0834 A Approx 24 mm 0 94 B Oil seal C Speedometer shaft 6MT 116 SPEEDOMETER GEAR 3 Install the speedometer driven gear and snap TRO831 Snap ring B Speedometer driven gear 4 Install the vehicle speed sensor lt Ref to 6MT 34 INSTALLATION Vehicle Speed Sensor gt 5 Install the front differential assembly lt
312. ing of lock nut 5 Install the ST3 to lock nut then set drive pinion shaft to ST Remove the lock nut and washer 18667AA000 HOLDER ST2 18664AA000 BASE 573 18621AA000 ADAPTER WRENCH TRO810 6 Using the ST remove the taper roller bearing as sembly ST 18723AA000 REMOVER TRO811 D ASSEMBLY 1 Using the ST measure dimension A of drive pin ion NOTE Note dimension A for selection of drive pinion shim ST 398643600 GAUGE A B3M1176A 2 Install the inner bearing inner race to drive pinion shaft using ST and press ST 18723AA000 REMOVER CAUTION Do not apply pressure in excess of 40 kN 4 0 ton 4 4 US ton 3 9 Imp ton 3 Install the retainer and outer bearing inner race to drive pinion shaft using ST and press ST 18723AA000 REMOVER NOTE Press to the point where bearing is turned smoothly without slack A Retainer 4 Install the washer and new lock nut 6MT 102 DRIVE PINION SHAFT ASSEMBLY 5 Set the ST to drive pinion then tighten the lock nut 18667 000 HOLDER ST2 18664 000 BASE 573 18621AA000 ADAPTER WRENCH 574 18852AA000 TORQUE WRENCH NOTE Tighten with the ST and torque wrench straight lined Tightening torque 265 27 0 kgf m 195 ft lb TRO814 NOTE f torque wrench except ST4 is used calculate the following equation then tighten the lock nut e Tig
313. ion Switch Ref to 6MT 45 INSTALLATION Back up Light Switch 8 Install the manual transmission assembly to ve hicle Ref to 6MT 39 INSTALLATION Manual Transmission Assembly C DISASSEMBLY NOTE Discard the removed spring pin and replace with a new one 1 REVERSE SHIFTER FORK 1 Using the ST remove the reverse fork ST 398791700 REMOVER TRO835 2 Using the ST remove the reverse shifter arm ST 398791700 REMOVER TRO836 2 1ST 2ND 3RD 4TH SHIFTER FORK 1 Using the ST remove the 3rd 4th shifter fork ST 398791700 REMOVER TR0837 2 Using the ST remove the 3rd 4th shifter arm ST 398791700 REMOVER TRO0838 6MT 118 SHIFTER FORK AND ROD 3 Using the ST remove the 1st 2nd shifter arm and 1st 2nd shifter fork ST 398791700 REMOVER A B d TRO839 A 1st 2nd shifter arm B 1st 2nd shifter fork 3 5TH 6TH SHIFTER FORK 1 Using the ST remove the 5th 6th shifter fork ST 398791700 REMOVER TR0840 2 Using the ST remove the 5th 6th shifter arm ST 398791700 REMOVER 0841 MANUAL TRANSMISSION AND DIFFERENTIAL 4 SHIFT ARM SHAFT Using the ST remove the selector arm ST 398791700 REMOVER TR0842 5 STRIKING ROD 1 Remove the reverse interlock block and interlock block from striking rod 0843 Re
314. ion for Overhaul gt 3 Remove the oil pipe neutral position switch back up light switch and harness Ref to 6 44 REMOVAL Oil Pipe Ref to 6MT 47 REMOV AL Neutral Position Switch Ref to 6MT 45 REMOVAL Back up Light Switch 4 Remove the extension case Ref to 6MT 49 REMOVAL Extension Case 5 Remove the transfer driven gear Ref to 6 60 REMOVAL Transfer Driven Gear 6 Remove the center differential Ref to 6 62 REMOVAL Center Differential 7 Remove the oil pump Ref to 6 64 RE MOVAL Oil Pump 8 Remove the transmission case Ref to 6MT 68 REMOVAL Transmission Case 9 Remove each gear assembly Ref to 6MT 73 REMOVAL Main Shaft Assembly B INSTALLATION 1 Install each gear assembly at once Ref to 6MT 74 INSTALLATION Main Shaft Assembly 2 Install the transmission case Ref to 6MT 69 INSTALLATION Transmission Case 3 Install the oil pump Ref to 6MT 65 INSTAL LATION Oil Pump 4 Install the center differential Ref to 6 62 INSTALLATION Center Differential 5 Install the transfer driven gear Ref to 6MT 60 INSTALLATION Transfer Driven Gear 6 Install the extension case Ref to 6MT 49 IN STALLATION Extension Case 7 Install the oil pipe neutral position switch back up light switch and harness Ref to 6 44 IN STALLATION Oil Pipe Ref to 6MT 47 IN STALLATION Neutral Posit
315. ion height adjusting shim Punch mark number on installed drive pinion gear Punch mark number on new drive pinion gear Example of calculation T1 3 30 T2 2 1 T 3 30 2 x 0 01 1 x 0 01 3 33 Result Thickness 3 33 mm Therefore use the shim 38336AA310 050035 4 Pinion height adjusting shim selection 1 Measure the thickness of inserted pinion height adjusting shim Pinion height adjusting shim Part No Thickness T mm in RRR KN AC 050036 2 Read the punch mark of installed drive ion gear and new one 38336AA230 3 09 0 1217 38336AA240 3 12 0 1228 38336AA250 3 15 0 1240 38336AA260 3 18 0 1252 38336AA270 3 21 0 1264 38336AA280 3 24 0 1276 38336AA290 3 27 0 1287 38336AA300 3 30 0 1299 38336AA310 3 33 0 1311 38336AA320 3 36 0 1323 38336AA330 38336AA340 3 42 0 1346 38336AA350 3 45 0 1358 38336AA360 3 48 0 1370 38336AA370 3 51 0 1382 38336AA380 3 54 0 1394 38336AA390 3 57 0 1406 38336AA400 3 60 0 1417 38336AA410 3 63 0 1429 DI 24 38336AA420 3 39 0 1335 3 66 0 1441 REAR DIFFERENTIAL FOR 5 Install the selected pini
316. isc thickness x Outer diameter 10 x 266 mm 0 39 x 10 47 in 18 x 290 mm 0 71 x 11 42 in 20 x 316 mm 0 79 x 12 44 in Effective cylinder diameter 38 1 mm 1 500 in 36 0 mm 1 417 in Pad dimensions length x width x thickness 82 4 x 33 7 x 9 0 mm 3 244 x 1 327 x 0 354 in 71 8 x 35 0 x 11 5 mm 2 827 x 1 378 x 0 453 in 74 8 x 45 0 x 9 0 mm 2 945 x 1 772 x 0 354 in Clearance adjust ment Automatic adjustment Type Drum Leading Trailing type Effective drum diameter 228 6 mm 9 in Effective cylinder diameter 17 5 mm 0 689 in Lining dimensions length x width x thickness 218 8 x 35 0 x 4 1 mm 8 61 x 1 378 x 0 161 in Clearance adjust ment Automatic adjustment Master cylinder Type Tandem Effective diameter 23 81 mm 0 9374 in 25 4 mm 1 in 26 99 mm 1 1 16 in Reservoir type Sealed type Brake fluid reser voir capacity 205 cm 12 51 cu in Brake booster Type Vacuum suspended Effective diameter 230 mm 9 06 in 180 205 mm 7 09 8 07 in BR 2 205 230 mm 8 07 9 06 in GENERAL DESCRIPTION BRAKE Model TS GX RS OBK Propor nue 1 961 kPa lit t tioning Split goin 20 kg cm 285 psi valve Reducing ratio 0 4 0 3 Brake line Dual circuit system Brake fluid CAUTION Avoid mixing brake fluid of diffe
317. isconnect the water tank connector 5 Remove the hose between body and water tank then remove the water tank B INSTALLATION Install in the reverse order of removal Tightening torque 6 0 0 61 kgf m 4 4 ft lb C INSPECTION 1 Make sure the hose is not deformed damaged cracked or clogged 2 Make sure the water tank is not damaged or cracked IN TURBO 3 INTAKE INDUCTION INTERCOOLER WATER TANK INTAKE INDUCTION IN TURBO 4 MECHANICAL DCONOARON PP AH AH AH AH sch sch ch sch St Nort General Descripsi Je IER EE IMINO EEN Intake Manifold Vacuum Genie TR EE Fuel Pressure el EE en Une Engine Preparation for 000 42 43 Pulley 45 Ee ee 46 Timing Belt 47 ues opi eeneg ie 56 GCrankshaft SpIOCKOGL dedu decente pde doe 58 ch etu t cu Er EDS 59 Cylinder Head Assembly
318. ithin specifications re place the back up light switch Gear shift position Terminal No Specified resistance Back up position Less than 1 Q 2 and 4 Other positions More than 1 TRO655 6MT 46 NEUTRAL POSITION SWITCH 11 Neutral Position Switch A REMOVAL 1 Remove the manual transmission assembly from vehicle Ref to 37 REMOVAL Manual Transmission Assembly 2 Disconnect the neutral position switch connector and clip Back up light switch connector White Neutral position switch connector Black Clip 992 3 Remove the neutral position switch A Back up light switch B Neutral position switch MANUAL TRANSMISSION AND DIFFERENTIAL B INSTALLATION 1 Install the neutral position switch Tightening torque 32 N m 3 3 kgf m 23 6 ft Ib ETS A Back up light switch B Neutral position switch 2 Connect the neutral position switch connector and clip Back up light switch connector White B Neutral position switch connector Black C Clip 3 Install the manual transmission assembly to ve hicle Ref to 6MT 39 INSTALLATION Manual Transmission Assembly 6 47 NEUTRAL POSITION SWITCH MANUAL TRANSMISSION AND DIFFERENTIAL C INSPECTION 1 Disconnect the ground cable from battery 2 Remove the intercooler
319. ive gear 4 Install the knock pin TRO935 5 Install the washer and needle bearing NOTE Install the washer with groove facing to reverse idler gear TRO799 A Groove B Washer C Needle bearing 6MT 98 REVERSE IDLER GEAR ASSEMBLY 6 Install the reverse idler gear No 2 TRO936 7 Install the shifting insert key in proper place of reverse sleeve NOTE Angle of each shifting insert key is 120 apart A off TRO800 A Reverse sleeve B Shifting in sert key MANUAL TRANSMISSION AND DIFFERENTIAL 8 Install the reverse sleeve to reverse idler gear No 2 NOTE Make sure to install the reverse sleeve in proper di rection MQ ny 9 Sufficiently apply gear oil to the collar needle bearing and inner periphery of reverse drive gear 10 Install the outer baulk ring reverse synchro cone and inner baulk ring TRO801 TRO802 A Outer baulk ring B Reverse synchro cone C Inner baulk ring 11 Install the collar and needle bearing then in stall the knock pin TRO803 A Collar B Needle bearing C Knock pin 6MT 99 REVERSE IDLER GEAR ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 12 Align the protrusion portion of reverse synchro cone with reverse idler gear hole then install the reverse idler gear TRO804 A Protrusion portion of reverse synchr
320. ive gear 26 Oil seal 13 Ball bearing with flange 27 Reverse check lever COMPL 14 Snap ring 28 Straight pin 6MT 7 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL 6 SHIFTER FORK AND FORK ROD TRO600 1 Spring pin 9 Support 17 5 6 shifter arm 2 Interlock arm 10 Snap ring 18 fork COMPL 3 Interlock block 11 Reverse fork COMPL 19 Srd 4th fork rod 4 Reverse interlock block 12 Reverse shifter arm 20 3rd 4th shifter arm 5 Interlock arm 13 Reverse fork rod 21 1st 2nd shifter arm 6 Striking rod 14 Selector arm COMPL 22 3rd 4th fork COMPL 7 Selector arm No 2 15 Shifter arm shaft 23 1st 2nd fork rod 8 Neutral set spring 16 5th 6th fork rod 24 1st 2nd fork COMPL 6MT 8 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL 7 MAIN SHAFT ASSY A 18 23 14 16 7180601 1 Main shaft 12 4th bush 23 6th bush 2 Needle bearing 13 Needle bearing 24 bush 3 drive gear 14 5th bush 25 Taper roller bearing 4 Inner baulk ring 15 Needle bearing 26 Snap ring 5 Synchro cone 16 5th drive gear 27 Washer 6 Outer baulk ring 17 5th baulk ring 28 Washer 7 44 sleeve 18 sleeve 29 Lock nut 8 3rd 4th hub 19 5th 6th hub 9 Shifting insert 20 Shifting sleeve Tightening torque N m kgf m ft lb 10 4th baulk ring 21
321. k shaft into release fork CAUTION Be sure to fit groove on clutch release lever shaft into pin located at through hole S2M1845A A Release fork B Release shaft C Spring pin MECHANICAL 6 Tighten the plug Tightening torque 44 4 5 kgf m 32 5 ft lb 2 Install the front cushion rubbers to engine Tightening torque 34 N m 3 5 kgf m 25 3 ft lb 3 Install the engine onto transmission 1 Position the engine in engine compartment and align it with transmission CAUTION Be careful not to damage adjacent parts or body panels with crank pulley oil pressure gauge etc 2 Apply a small amount of grease to splines of mainshaft 4 Tighten the bolt which holds right upper side of transmission to engine Tightening torque 50 N m 5 1 kgf m 36 9 ft Ib 2 2791 5 Remove the lifting device and wire ropes ME STi 37 ENGINE ASSEMBLY MECHANICAL 6 Remove the garage jack Tightening torque T1 50 5 1 kgf m 37 ft lb T2 58 5 9 kgf m 43 ft lb Lp ARs 8 Install the starter lt Ref to 5 6 INSTALLA TION Starter gt 9 Push the clutch release lever to fit bearing into clutch cover 11 Install the power steering pump on bracket 1 Install the power steering tank on bracket 61 2 Install the power steering
322. l 1 as shown in the figure Turn dial 2 to set the indicator to edge surface of bearing TRO758 Measure five points of the ball bearing turning ev ery approx 120 Round off each two upper and lower measurement value Use the remaining cen ter value measurement value 4 According to measurement value select the snap ring and washer from the following table Snap ring A1 mm in Part No Thickness mm in 270 83 271 40 10 66 10 69 805072010 1 65 0 065 271 41 271 98 10 69 10 71 805072011 1 95 0 077 271 99 272 56 10 71 10 73 Washer 805072012 2 25 Thickness mm A1 mm in Part No in aA zi zen seem us 6 86 DRIVEN GEAR ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 20 Driven Gear Assembly A REMOVAL 1 Remove the manual transmission assembly from vehicle lt Ref to 6MT 37 REMOVAL Manual Transmission Assembly gt 2 Prepare the transmission for overhaul lt Ref to 6MT 42 Preparation for Overhaul gt 3 Remove the oil pipe neutral position switch back up light switch and harness lt Ref to 6MT 44 REMOVAL Oil Pipe gt lt Ref to 6MT 47 REMOV AL Neutral Position Switch Ref to 6MT 45 REMOVAL Back up Light Switch 4 Remove the extension case Ref to 6MT 49 REMOVAL Extension Case
323. late Tightening torque 54 N m 5 5 kgf m 40 ft lb TRO809 11 Install the oil chamber and pipe Tightening torque 6 4 N m 0 65 kgf m 4 7 ft Ib TRO808 A Pipe B Oil chamber E INSPECTION 1 Using the spring balancer measure the starting torque If the starting torque is out of specification replace the taper roller bearing Starting torque 0 0 95 N 0 0 097 kgf 0 0 21 Ib B3M0589 2 Gears Replace the gears in the following case Gear teeth surfaces are broken or excessively worn 3 Bearings Replace the bearings in the following cases Worn rusted and damaged bearing Bearings that fail to turn smoothly or make ab normal noise when turned 4 Adapter plate Replace the adapter plate in the following cases Worn rusted and damaged bearing Damaged adapter plate 5 Make sure the pipe and pipe chamber is not damaged or clogged Repair or replace if damaged or clogged 6MT 104 DRIVE PINION SHAFT ASSEMBLY F ADJUSTMENT 1 Inspect and adjust the backlash between hypoid driven gear and drive pinion lt Ref to 6 114 HYPOID GEAR BACKLASH ADJUSTMENT Front Differential Assembly gt 2 Apply a uniform thin coat of red lead on both teeth surfaces of three or four teeth of the hypoid driven gear TRO816 3 Install the drive pinion shaft assembly to clutch housing then tighten at least four bolts NOTE
324. lifted up straight Measure five points of the ball bearing turning every approx 72 Round off each two upper and lower measurement value Use the remaining cen ter value as measurement value TRO758 2 Set the height gauge indicator upside down Indicator TRO865 3 Shift the 5th 6th sleeve to 5th main gear side then press down to the stopper and mea sure D2 TRO869 A 5th main gear NOTE e Set the indicator of height gauge near measuring object then lock the dial 1 as shown in the figure Turn dial 2 to set the indicator to edge surface of sleeve 5th side Measure five points of the ball bearing turning every approx 72 Round off each two upper and lower measurement value Use the remaining cen ter value as measurement value TRO758 4 According to both measurements calculate the 5th 6th sleeve neutral position Select the fork rod which applies to the calculated value from following equation Equation T D1 D2 2 5th 6th sleeve center position D1 Length from the shaft rear bearing snap ring groove to sleeve groove edge when shifted to 5th gear measurement value 55 mm 2 17 in D2 Length from main shaft rear bearing snap ring groove to sleeve groove edge when shift ed to 6th gear 6MT 128 SHIFTER FORK AND ROD NOTE
325. light LH 2 Lights Brown Headlight LH 4 Lights Lo Gray A C compressor Green Black A C fuse Relay holder Black A C sub fan relay 1 Relay holder Turbo model Black A C sub fan relay Relay holder Non turbo model Black A C sub fan relay 2 Relay holder Turbo model Black Radiator main fan relay 2 Relay holder Turbo model Black A C relay Relay holder Green Front washer motor Rear washer motor Black SBF holder Black Black Black Brown Gray Bulkhead wiring harness Bulkhead wiring harness Bulkhead wiring harness Horn Side turn signal light LH Headlight leveler LH Except STi Headlight leveler LH Sti Headlight leveler RH Except STi Headlight leveler RH Sti Engine wiring harness Turbo model Engine wiring harness Turbo model Radiator main fan relay Relay holder Non turbo model Radiator main fan relay 1 Relay holder Turbo model FWD switch AWD AT model Generator F B 1 3 2 2 3 2 3 2 3 3 2 3 1 3 4 4 4 4 4 4 2 2 4 2 3 6 1 8 9 7 8 N A A WI 90 Connector FRONT WIRING HARNESS WIRING SYSTEM Connecting to No Pole Color Name F68 Black M B F76 Gray Bulkhead wiring harness 5 F78 Black Ambient sensor
326. ling extension oil seal B3M1973 498255400 6MT 19 Used for measuring backlash GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 41099AA010 ENGINE SUPPORT Used for supporting engine BRACKET F B3M1975 a 41099AA020 ENGINE SUPPORT Used for supporting engine B3M1976 398527700 PULLER ASSY Used for removing extension case oil seal and clutch housing oil seal B3M1977 398643600 Used for measuring total end play extension end play and drive pinion height B3M1978 6MT 20 ILLUSTRATION GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL TOOL NUMBER DESCRIPTION REMARKS B3M1905 398177700 INSTALLER Used for assembling main shaft 398663600 PLIERS Used for removing and installing neutral set spring Used with claw 18756AA000 B3M2007 499247300 INSTALLER Used for removing axle shaft Used with REMOVER ASSY 499095500 B3M2006 499095500 REMOVER ASSY 6MT 21 Used for removing axle shaft Used with INSTALLER 499247300 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499247400 INSTALLER Used for installing transfer drive gear ball bear ing B3M1999 499797000 OIL SEAL Used for installing differential side retainer oil INSTALLER seal B3M2197
327. lips is deformed hardened dam aged worn or defective if any B REPLACEMENT 1 Clean the transmission exterior 2 Drain the gear oil completely NOTE Tighten the drain plug after draining gear oil Always use new gasket Tightening torque Oil pan side 44 4 5 kgf m 32 5 ft Ib Clutch housing side 70 N m 7 1 kgf m 51 6 ft lb TRO634 A Drain plug Oil pan side B Drain plug Clutch housing side 3 Remove the rear exhaust pipe and muffler 4 Remove the propeller shaft lt Ref to DS 15 RE MOVAL Propeller Shaft gt 5 Using the ST remove the oil seal ST 398527700 PULLER ASSY B3M2135A A Oil seal 6 Using the ST install the oil seal ST 498057300 INSTALLER B3M1982 7 Install the propeller shaft lt Ref to DS 16 IN STALLATION Propeller Shaft gt 8 Install the rear exhaust pipe and muffler 9 Pour gear oil and check the oil level lt Ref to 6MT 32 REPLACEMENT Transmission Gear Oil gt 6MT 33 VEHICLE SPEED SENSOR MANUAL TRANSMISSION AND DIFFERENTIAL 4 Vehicle Speed Sensor A REMOVAL 1 Disconnect the ground cable from battery 2 Remove the intercooler lt Ref to IN TURBO 10 REMOVAL Intercooler gt 3 Disconnect the vehicle speed sensor connector PA TRO635 4 Remove the vehicle speed sensor B INSTALLATION 1 Align the tip end of vehicle speed sens
328. lk ring A Needle bearing B 6th baulk ring C 5th 6th sleeve 7 Set the ST on 3rd drive gear then remove each part using press ST 18720AA000 REMOVER TRO732 A 3rd drive gear B 3rd 4th sleeve 6MT 77 MAIN SHAFT ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL D ASSEMBLY NOTE Replace the following parts as a set Sleeve and hub Outer baulk ring 3rd synchro cone and inner baulk ring Taper roller bearing 1 Sufficiently apply gear oil to the main shaft 3rd needle bearing and inner periphery of 3rd drive gear 2 Install the 3rd needle bearing and 3rd drive gear to main shaft TRO733 A 3rd needle bearing B Srd drive gear 3 Install the inner baulk ring 3rd synchro cone and outer baulk ring TRO734 A Inner baulk ring B Outer baulk ring NOTE Install the 3rd synchro cone by aligning protrusion portions of the 3rd synchro cone with 3rd drive gear hole portion c gt TRO735 4 Install the 3rd 4th hub and 4th bush 1 Set to the main shaft taking care of 3rd 4th hub installing direction j n TRO984 A Main shaft 3rd 4th hub C 3rd drive gear 6 78
329. m is defective Incorrect valve clearance Worn valve rocker Worn camshaft Broken valve spring Heavy and dull clank Oil pressure is low Worn crankshaft main bearing Worn connecting rod bearing big end Oil pressure is normal Loose flywheel mounting bolts Damaged engine mounting High pitched clank Spark knock Sound is noticeable when accelerating with an overload Ignition timing advanced Accumulation of carbon inside combustion chamber Wrong spark plug Improper gasoline Clank when engine speed is medium 1 000 to 2 000 rpm Sound is reduced when fuel injector connector of noisy cyl inder is disconnected NOTE Worn crankshaft main bearing Worn bearing at crankshaft end of connecting rod Knocking sound when engine is operating under idling speed and engine is warm Sound is reduced when fuel injector connector of noisy cyl inder is disconnected NOTE Worn cylinder liner and piston ring Broken or stuck piston ring Worn piston pin and hole at piston end of connecting rod Sound is not reduced if each fuel injector connector is dis connected in turn NOTE Unusually worn valve lifter Worn cam gear Worn camshaft journal bore in crankcase Squeaky sound Insufficient generator lubrication Rubbing sound Defective generator brush and rotor contact Gear scream when starting engine Defective ignition starter switch Worn gear and starter pinion S
330. mbly and fix with band clip NOTE Cut off the extra band clip Make sure that the reverse check cable is insert ed into gear shift lever assembly without any clear ance TRO960 TRO972 A Spring B Spring seat 15 Adjust the length between end of cable plate and reverse check cable to 84 mm 3 31 in and then tighten the lock nut Tightening torque 6 0 6 kgf m 4 4 ft lb TRO973 A 84mm 3 31 in CS 11 GEAR SHIFT LEVER CONTROL SYSTEMS 16 Fix the slider and reverse check cable end with E INSPECTION spring pin 1 Check each part bushing cushion rubber spac NOTE er boot stay and rod etc for deformation dam Apply grease to the sliding part of slider age and wear Repair or replace any defective part Determine defective parts by comparing with new parts TRO958 Slider B Spring pin 17 Fix the reverse check cable to clip of stay NOTE Install the reverse check cable to upper side of stay TRO974 A Reverse check cable B Clip CS 12 TRO975 REVERSE CHECK CABLE 9 Reverse Check Cable A REMOVAL 1 Set the vehicle on a lift 2 Remove the gear shift knob 3 Remove the console box front lt Ref to El 40 REMOVAL Console Box gt 4 Remove the spring pin from slider TR0958 A Slider B Spring pin 5 Remove the slide
331. member 50 5 1 36 9 5 Rear cushion rubber 11 Center crossmember EUROPE T4 58 5 9 42 8 6 Rear crossmember model T5 70 7 1 51 6 7 Cushion D 12 Dynamic damper EUROPE 140 14 3 103 model 6 14 GENERAL DESCRIPTION MANUAL TRANSMISSION AND DIFFERENTIAL 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 and 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 When disassembling the case and other light al loy parts use a plastic hammer to force it apart Do not pry it apart with a screwdriver or other tool 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 D PREPARATION TOOL 1 SPECIAL TOOLS ILLUSTRATION TOOL NUMBER DESCRIPTION Be sure to tighten fasteners including bolts and nuts to the specified torque Place shop jacks or safety stands at the specified points Apply gear oil onto sliding or revolution surfaces before installation R
332. motor Rear washer motor Side turn signal light LH M B Front wiring harness With ABS Exhaust temperature sensor PO PO PO MD AJIN WI 98 BULKHEAD WIRING HARNESS ENGINE ROOM WIRING SYSTEM BO0478 WI 99 BULKHEAD WIRING HARNESS COMPARTMENT WIRING SYSTEM 47 Bulkhead Wiring Harness In Compartment A LOCATION 1 LHD MODEL Connector Connecting to Connector Connecting to Pole Color Name Pole Color Name Front door cord LH 2 Blower fan motor Yellow SRS Airbag harness Black Turn amp hazard module Brown Evaporator ther moswitch Black Instrument panel wir ing harness Roof cord Gray Data link connector FRESH RECIRC actuator Power window Door lock timer Power window Front door cord RH Seat belt warning module Front wiring harness Fuel pump relay Select lever illumina tion Main relay Front fog light Cigarette lighter Power Blower fan motor relay Radio 5 Oo Om gt F B Audio ground Shield joint connector AT Sensor ground joint connector Transmission control module Read memory con nector Kick down switch AT
333. move the spark plug cord 12 Remove the oil level gauge guide LH side only 13 Remove the rocker cover and gasket 14 Remove the oil pipe 1207 15 Loosen the variable valve timing solenoid valve assembly and intake camshaft cap bolts equally a little at a time in alphabetical sequence shown in the figure EN1208 16 Remove the oil control valve assembly intake camshaft cap and camshaft ME STi 59 CAMSHAFT MECHANICAL 17 Loosen the exhaust camshaft cap bolts equal ly a little at a time in alphabetical sequence shown in the figure EN1209 18 Remove the exhaust camshaft cap and cam CAUTION Arrange the camshaft caps in order so that they can be installed in their original positions 19 Similarly remove the right hand camshafts and related parts B INSTALLATION 1 Camshaft installation Apply engine oil to cylinder head at camshaft bear ing location before installing the camshaft Install the camshaft so that each valve is close to or in contact with base circle of cam lobe CAUTION When the camshafts are positioned as shown in the figure camshafts need to be rotated at a minimum to align with the timing belt during in stallation Right hand camshaft need not be rotated wh
334. n 0 5 and 0 9 V when G sensor is inclined backwards to 90 Go to step 12 Replace the G sensor lt Ref to ABS 22 G Sen sor gt CHECK POOR CONTACT IN CONNECTORS Is there poor contact in con nector between ABSCM amp H U and G sensor Repair the con nector Go to step 13 CHECK ABSCM amp H U 1 Connect all connectors 2 Erase the memory 3 Perform inspection mode 4 Read out the DTC Is the same DTC as in the cur rent diagnosis still being out put Replace the ABSCM amp H U lt Ref to ABS 4 ABS Control Mod ule and Hydraulic Control Unit ABSCM amp H U gt Go to step 14 CHECK ANY OTHER DIAGNOSTIC TROU BLE CODES DTCs APPEARANCE Are other DTCs being output ABS 14 Proceed with the diagnosis corre sponding to DTC A temporary poor contact DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS Al DTC 73 ABNORMAL LATERAL G SENSOR OUTPUT VOLTAGE DIAGNOSIS Faulty lateral G sensor output voltage TROUBLE SYMPTOM ABS does not operate WIRING DIAGRAM LHD MODEL ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT SHIELD JOINT CONNECTOR ST 7 n STi MODEL EXCEPT STi MODEL ABS G SENSOR JOINT CONNECTOR STi MODEL ABS LATERAL SENSOR GCSENSOB STi MODEL 3141516 1121314 Hepa 74 516171819 1 21 7 8 9
335. n codex1 Model D R 4AT D R 4AT Curb weight C W Front kgf Ib 740 1 631 755 1 664 755 1 664 770 1 698 Rear 545 1 202 545 1 202 545 1 202 545 1 202 Total 1 285 2 833 1 300 2 866 1 300 2 866 1 315 2 900 Maximum permissible Front 900 1 984 900 1 984 900 1 984 900 1 984 axle weight M P A W Rear 910 2 006 910 2 006 910 2 006 910 2 006 Maximum permissible Total weight M P W 1 730 3 814 1 730 3 814 1 730 3 814 1 730 3 814 Option Air conditioner Cruise control ABS Aluminium wheel Rear spoiler Spoiler pac Option 1 K1 Model 2 0L AWD GX D R 4AT D R 4AT Curb weight C W Front kgf Ib 775 1 709 790 1 742 780 1 720 795 1 753 Rear kgf Ib 570 1 257 565 1 246 570 1 257 565 1 246 Total kgf Ib 1 345 2 965 1 355 2 987 1 350 2 977 1 360 2 999 Maximum permissible Front kgf Ib 920 2 028 920 2 028 920 2 028 920 2 028 axle weight M P A W Rear kgf Ib 960 2 116 960 2 116 960 2 116 960 2 116 Maximum permissible kof Ib weight MPW gf Ib 1 800 3 968 1 800 3 968 1 800 3 968 1 800 3 968 Option Air conditioner Cruise control ABS Aluminium wheel Rear spoiler Spoiler pac
336. n for overhaul Ref to 6MT 42 Preparation for Overhaul gt 3 Remove the extension case Ref to 6MT 49 REMOVAL Extension Case 4 Remove the snap ring and washer from reverse check shaft TRO675 Snap ring B Washer 5 Remove the reverse check shaft and spring from the extension case MANUAL TRANSMISSION AND DIFFERENTIAL 6 Remove the spring pin then remove the reverse check lever and oil seal from reverse check shaft NOTE Do not reuse the oil seal TRO0677 A Spring pin B Reverse check lever C Oil seal 7 Remove the plug from extension case then re move the gasket spring and plunger NOTE Do not reuse the gasket A 0678 A Plug B Gasket C Spring D Plunger 8 Remove the reverse lock plunger m C NZ TRO679 A Reverse lock plunger 6 55 REVERSE CHECKING SYSTEM MANUAL TRANSMISSION AND DIFFERENTIAL B INSTALLATION 3 Install the spring and reverse check shaft to ex 1 Insert the reverse lock plunger tension case 2 Install in the order of reverse check plug spring NOTE gasket and plug Be sure the spring end aligns with the hole of re Tightening torque verse check shaft and cutout portion of extension case 41 4 2 kgf m 30 2 ft lb D B A TRO0678 A Plug B Gasket C Spring D Reve
337. n meter Door lock timer Keyless entry control module Luggage room light Wagon Radio Room light Spot light Trunk room light Sedan Engine control module Rear defogger timer Power window circuit breaker ABS relay Back up light switch MT Check connector Cruise control actuator Cruise control main switch Cruise control module Inhibitor switch AT Power window relay Rear defogger timer Vehicle speed sensor MT Relay holder ABS control module Hazard switch Main relay Headlight leveler LH STi Headlight leveler RH STi Engine control module Inhibitor switch AT Starter motor MT Air conditioning relay Pressure switch Sub fan relay Hazard switch Rear turn signal light RH Trailer connector Turn signal switch AUTO A C control module Blower motor relay Manual A C switch Hazard switch Rear turn signal light LH Side turn signal light LH Trailer connector Turn signal switch Engine control module Fuel pump relay Ignition coil and ignitor Immobilizer control module Transmission control module Airbag control module Parking switch Airbag control module Front turn signal light RH Side turn signal light RH Front turn signal light LH Rear washer motor Rear wiper intermittent module Rear wiper motor Front clearance light LH Front clearance light RH Headlight leveler LH Except STi Headlight leveler RH Except STi
338. n of the trouble However noises from the engine muffler tire exhaust gas bear ing body etc are easily mistaken for the differential noise Pay special attention to the hypoid gear noise because it is easily confused with other gear noises There are the following four kinds of noises Gear noise when driving If noise increases as the vehicle speed increases it may be due to insufficient gear oil incorrect gear engagement damaged gears etc Gear noise when coasting Damaged gears due to maladjusted bearings and incorrect shim adjustment Bearing noise when driving or when coasting Cracked broken or damaged bearings Noise which mainly occurs when turn ing Unusual noise from the differential side gear differential pinion differential pinion shaft etc a Insufficient oil Lubricate b Improper adjustment of hypoid driven gear and drive pinion Check tooth contact c Worn teeth of hypoid driven gear and drive pinion Replace as a set Readjust bearing preload d Loose roller bearing Readjust hypoid driven gear to drive pin ion backlash and check tooth contact e Distorted hypoid driven gear or differ ential case Replace f Worn washer and differential pinion shaft 6MT 134 Replace CLUTCH SYSTEM General DescriptOni costs Clutch Disc and Cover Flywheel Release Bearing and Lever
339. n the protrusion portion of outer baulk ring Piott siomportionofobter bakang and cutout portion of 1st 2nd hub then install esos EE 8 Using the ST install the 2nd hub ST 18654AA000 INSTALLER CAUTION Do not apply pressure in excess of 40 KN 4 0 ton 4 4 US ton 3 9 Imp ton TRO773 A 2nd bush 1st 2nd hub 9 Make sure the 1st drive gear is smoothly turned by hand If not reassemble 6MT 90 DRIVEN GEAR ASSEMBLY 10 Install the shifting insert key in proper place of 1st 2nd sleeve NOTE Angle of each shifting insert key is 120 apart TRO774 MANUAL TRANSMISSION AND DIFFERENTIAL 11 Install the 1st 2nd sleeve to 1st 2nd hub NOTE Make sure to install the 1st 2nd sleeve in proper di rection ES B C TRO775 A 1st driven gear B 1st 2nd sleeve C 1st driven gear side 12 Install the outer baulk ring TRO776 13 Install the 2nd synchro cone TRO777 6 91 DRIVEN GEAR ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 14 Install the inner baulk ring TRO778 15 Sufficiently apply gear oil to the bush 2nd nee dle bearing and inner periphery of 2nd drive gear 16 Install the 2nd needle bearing and 2nd driven gear NOTE Align the protrusion portion of 2nd synchro cone with 2nd driven gear hole then install
340. nd Connector amp terminal LHD B301 29 Chassis ground RHD F49 No 29 Chassis ground Is the voltage less than 1 V ABS 17 Go to step 7 Repair the har ness between lat eral G sensor and ABSCM amp H U DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS Step Check Yes No 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 LHD B301 29 Chassis ground RHD F49 No 29 Chassis ground Is the voltage less than 1 V Go to step 8 Repair the har ness between lat eral G sensor and ABSCM amp H U CHECK GROUND SHORT OF HARNESS Measure the resistance between ABSCM amp H U connector and chassis ground Connector amp terminal LHD B301 No 28 Chassis ground RHD F49 No 28 Chassis ground Is the resistance more than 1 MQ Go to step 9 Repair the har ness between lat eral G sensor and ABSCM amp H U Replace the ABSCM amp H U Ref to 5 4 ABS Control Mod ule and Hydraulic Control Unit ABSCM amp H U gt CHECK LATERAL G SENSOR 1 Turn the ignition switch to OFF 2 Remove the lateral G sensor from vehicle 3 Connect the connector to lateral G sensor 4 Connect the connector to ABSCM amp H U 5 Turn the ignition switch to ON 6 Measure the voltage b
341. nd differen tial case at their holes and drive straight pin into holes ST 899904100 REMOVER G3M0667 5 Using the ST install a new speedometer drive gear and right and left side bearing inner race to dif ferential case ST1 398437700 ST2 398497701 CAUTION Do not apply pressure in excess of 20 KN 2 0 ton 2 2 US ton 2 0 Imp ton INSTALLER SEAT NOTE Always replace the inner race and outer race as a set G3M0671 6 Install the hypoid driven gear to differential case Tightening torque 69 7 0 kgf m 50 9 ft Ib 0822 2 SIDE RETAINER 1 Using the ST install the oil seal ST 499797000 OIL SEAL INSTALLER A OY 99 di d i A d d 5 59 XX dai NM Xy t d G A d RRR B3M2196A 2 Install the bearing outer race to retainer on both side 3 Install the O ring to retainer on both side NOTE careful not to damage the O ring 6MT 112 FRONT DIFFERENTIAL ASSEMBLY E INSPECTION Repair or replace the front differential in following cases Each gear is damaged seized or excessively worn Sliding surfaces of the differential case is dam aged seized or excessively worn Bearings and bearings part is damaged rusted or worn Bearings that fail to turn smoothly or make ab normal noise when
342. nd left for several times 5 Remove the drive pinion shaft assembly and then check tooth contact If tooth contact is inaccu rate adjust it lt Ref to 6MT 105 ADJUSTMENT Drive Pinion Shaft Assembly gt Correct tooth contact NOTE Under no load tooth contacts 50 60 from center to toe side tooth contact shifts to heel side when driving A B la co TRO827 A Toe side B Heel side 6MT 113 FRONT DIFFERENTIAL ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL F ADJUSTMENT 1 BEVEL PINION GEAR BACKLASH 1 Measure the bevel pinion gear backlash lt Ref to 6 113 BEVEL PINION GEAR BACKLASH INSPECTION Front Differential Assembly gt 2 Disassemble the differential case lt Ref to 6MT 110 DIFFERENTIAL CASE DISASSEMBLY Front Differential Assembly gt 3 Select a washer from the following table and then assemble the differential case lt Ref to 6MT 112 DIFFERENTIAL CASE ASSEMBLY Front Differential Assembly gt TRO823 A Pinion shaft B Bevel pinion gear C Bevel gear D Washer NOTE If the backlash is excessive select a thicker shim If the backlash is insufficient select a thinner new shim Washer Part No Thickness mm in 08 080 803036022 0 0384 0 0394 uc 2 HYPOID GEAR BACKLASH 1 Install the right and left side retainer 499787000 WRENCH ASSY RIGHT SIDE ST2 18630AA000 WRENCH
343. nd used for engine disassembly and assem bly Used with ENGINE STAND ADAPTER RH 498457000 amp LH 498457100 B2M4157 499977300 CRANK PULLEY WRENCH Used for stopping rotation of crankshaft pulley when loosening and tightening crankshaft pulley bolts B2M3871 499987500 CRANKSHAFT SOCKET Used for rotating crankshaft 498547000 B2M3872 OIL FILTER WRENCH ME STi 19 Used for removing and installing oil filter MECHANICAL ILLUSTRATION GENERAL DESCRIPTION TOOL NUMBER DESCRIPTION REMARKS B2M3875 499587100 OIL SEAL INSTALLER Used for installing oil pump oil seal S1H0136 499587600 OIL SEAL GUIDE Used for installing camshaft oil seal 0168 499597200 OIL SEAL GUIDE Used for installing camshaft oil seal Used with OIL SEAL GUIDE 499587600 EN1196 499897200 PISTON CIR CLIP PLIER ME STi 20 Used for removing and installing piston pin GENERAL DESCRIPTION MECHANICAL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 24082AA190 CARTRIDGE Troubleshooting for electrical systems B2M3876 22771AA030 SELECT Troubleshooting for electrical systems TOR KIT English 22771AA030 Without printer German 22771AA070 Without printer French 22771AA080 Without printer Spanish 22771AA090 Without printer B2M3877 2 GENERAL PURPOSE TOOLS TOOL NAME REMARKS
344. nder intake valve clearances EN1200 15 After inspection install the related parts in the reverse order of removal Tightening torque 32 3 3 kgf m 24 ft lb 0191 ADJUSTMENT CAUTION Adjustment of valve clearance should be per formed while engine is cold 1 Measure all valve clearances lt Ref to ME STi 28 INSPECTION Valve Clearance gt NOTE Record each valve clearance after it has been measured B2M1234 2 Remove the camshaft Ref to ME STi 59 RE MOVAL Camshaft gt 3 Remove the valve lifter 4 Measure the thickness of valve lifter with mi crometer 55 525525056 i d 5 KAS 1049954944 ALRI 2224 TB lt 1201 5 Select valve lifter of suitable thickness using measured valve clearance and valve lifter thick ness by referring to the following table Unit mm Intake valve S V T 0 20 Exhaust valve S V T 0 25 S Valve lifter thickness to be used V Measured valve clearance T Removed valve lifter thickness ME STi 30 VALVE CLEARANCE Thickness mm in 13228 AA100 4 68 0 1843 Part No MECHANICAL Thickness mm in 13228 AA110 4 69 0 1846 13228 AA610 5 19 0 2043 13228 AA120 4 70 0 1850 13228 AA620 5 20 0 2047 13228 AA130 4 71 0 1854
345. necting rod nuts ap ply oil on the threads 4 Install the oil ring spacer upper rail and lower rail in this order by hand Then install the second ring and top ring with a piston ring expander 1 Connecting rod bearing 5 Second ring 2 Connecting rod 6 Top ring 3 Connecting rod cap 7 Circlip 4 Oil ring Tightening torque N m kgf m ft Ib T 52 5 3 38 4 E INSPECTION 1 CYLINDER BLOCK 1 Visually check for cracks and damage Especial ly inspect important parts by means of red lead check 2 Check the oil passages for clogging 3 Inspect crankcase surface that mates with cylin der head for warping by using a straight edge and correct by grinding if necessary Warping limit 0 05 mm 0 0020 in Grinding limit 0 1 mm 0 004 in Standard height of cylinder block 201 0 mm 7 91 in ME STi 84 CYLINDER BLOCK MECHANICAL 2 CYLINDER AND PISTON 1 The cylinder bore size is stamped on the cylinder block s front upper surface CAUTION Measurement should be performed at a temper ature of 20 C 68 F NOTE Standard sized pistons are classified into two grades and These grades should be used as a guide line in selecting a standard piston Standard diameter A 92 005 92 015 mm 3 6222 3 6226 in 91 995 92 005 mm 3 6218 3 6222 in H2M1732C Main journal size mark Cylinder block RH LH combination mark 1 cylinder bore
346. nector between lateral G sensor and ABSCM amp H U CHECK GROUND SHORT OF HARNESS Measure the resistance between ABSCM amp H U connector and chassis ground Connector amp terminal LHD B301 No 28 Chassis ground RHD F49 No 28 Chassis ground Is the resistance more than 1 MQ Go to step 7 Repair the har ness between lat eral G sensor and ABSCM amp H U Replace the ABSCM amp H U Ref to 5 4 ABS Control Mod ule and Hydraulic Control Unit ABSCM amp H U gt CHECK LATERAL G SENSOR 1 Remove the console box 2 Remove the lateral G sensor from vehicle 3 Connect the connector to lateral G sensor 4 Connect the connector to ABSCM amp H U 5 Turn the ignition switch to ON 6 Measure the voltage between lateral G sen sor connector terminals Connector amp terminal B257 No 2 No 3 Is the voltage between 2 3 and 2 7 V when lateral G sensor is horizontal Go to step 8 Replace the lateral G sensor lt Ref to ABS 5 Lateral G Sensor gt CHECK LATERAL G SENSOR Measure the voltage between lateral G sensor connector terminals Connector amp terminal B257 No 2 No 3 Is the voltage between 3 3 and 3 7 V when lateral G sensor is inclined forwards to 90 Go to step 9 Replace the lateral G sensor lt Ref to ABS 5 Lateral G Sensor gt CHECK LATERAL G SENSOR Measure the voltage between lateral G sensor connector terminals C
347. nector from ABSCM amp H U 5 Measure the voltage between ABSCM amp H U connector and chassis ground Connector amp terminal LHD B301 No 29 Chassis ground RHD F49 No 29 Chassis ground Is the voltage less than 1 V ABS 25 Go to step 12 Repair the har ness between lat eral G sensor and ABSCM amp H U DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS Step Check Yes No 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 LHD B301 No 29 Chassis ground RHD F49 No 29 Chassis ground Is the voltage less than 1 Go to step 13 Repair the har ness between lat eral G sensor and ABSCM amp H U CHECK POOR CONTACT IN CONNECTORS Is there poor contact in con nector between ABSCM amp H U and lateral G sensor Repair the con nector Go to step 14 CHECK ABSCM amp H U 1 Connect all connectors 2 Erase the memory 3 Perform the inspection mode 4 Read out the DTC Is the same DTC as in current diagnosis still being output Replace the ABSCM amp H U lt Ref to ABS 4 ABS Control Mod ule and Hydraulic Control Unit ABSCM amp H U gt Go to step 15 CHECK ANY OTHER DIAGNOSTIC TROU BLE CODES DTCs APPEARANCE Are other DTCs being output Proceed with the d
348. ng 294 N 30 kgf 66 Ib check it using the following procedures 1 Slowly press the adjuster rod down to the end surface of the cylinder Repeat this motion 2 or 3 times 2 With the adjuster rod moved all the way up apply a pressure of 294 N 30 kgf 66 Ib to it Check adjuster rod stiffness 3 If the adjuster rod is not stiff and moves down replace the automatic belt tension adjust er assembly with a new one CAUTION Always use a vertical type pressing tool to move the adjuster rod down Do notuse a lateral type vise Push the adjuster rod vertically Press in the push adjuster rod gradually tak ing more than three minutes Do not allow press pressure to exceed 9 807 N 1 000 kgf 2 205 Ib Press the adjuster rod as far as the end sur face of the cylinder Do not press the adjuster rod into the cylinder Doing so may damage the cylinder 4 Measure the extension of rod beyond the body If it is not within specifications replace with a new one Rod extension H 5 7 0 5 mm 0 224 0 020 in H2M2381A ME STi 54 TIMING BELT ASSEMBLY MECHANICAL 3 BELT TENSION PULLEY 1 Check the mating surfaces of timing belt and contact point of adjuster rod for abnormal wear or scratches Replace the belt tension pulley if faulty 2 Check the belt tension pulley for smooth rota tion Replace if noise or excessive play is noted 3 Check the belt tension pulley for grease leakage 4 BEL
349. nge according to engine output change Idling 2 2 degree Vehicle running 2 50 degree Repair the poor contact in connec tor NOTE In this case repair the following Poor contact in variable valve tim ing camshaft posi tion sensor Poor contact in ECM connector Go to step 2 CHECK HARNESS BETWEEN VARIABLE VALVE TIMING CAMSHAFT POSITION SEN SOR AND ECM CONNECTOR 1 Turn the ignition switch to OFF 2 Disconnect the connector from variable valve timing camshaft position sensor and ECM 3 Measure the resistance of harness between variable valve timing camshaft position sensor connector and engine ground Connector amp terminal E35 1 B84 9 E35 2 B84 15 Is the resistance less than 1 Q Go to step 3 Repair the har ness and connec tor NOTE In this case repair the following Open circuit in harness between variable valve tim ing camshaft posi tion sensor and ECM connector Poor contact in ECM connector Poor contact in coupling connector CHECK HARNESS BETWEEN VARIABLE VALVE TIMING CAMSHAFT POSITION SEN SOR AND ECM CONNECTOR Measure the resistance of harness between variable valve timing camshaft position sensor connector and engine ground Connector amp terminal E35 No 1 Engine ground E35 No 2 Engine ground Is the resistance more than 1M Q Go to step 4 Repair the ground short
350. nition switch to OFF 2 Remove the console box 3 Remove the lateral G sensor from vehicle Do not disconnect the 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 Is the lateral G sensor output on monitor display between 3 3 and 3 7 V when lateral G sen sor is inclined forwards to 90 Go to step 4 Replace the lateral G sensor lt Ref to ABS 5 Lateral G Sensor gt CHECK OUTPUT OF LATERAL G SENSOR USING SELECT MONITOR Read the select monitor display Is the lateral G sensor output on the monitor display between 1 3 and 1 7 V when lateral G sensor is inclined backwards to 90 Go to step 5 Replace the lateral G sensor lt Ref to ABS 5 Lateral G Sensor gt CHECK POOR CONTACT IN CONNECTORS Turn the ignition switch to OFF Is there poor contact in con nector between ABSCM amp H U and lateral G sensor Repair the con nector 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 DTC 15 the same DTC as in current diagnosis still being output Replace the ABSCM amp H U lt Ref to ABS 4 ABS Control Mod ule and Hydraulic Control Unit ABSCM amp H U gt Go to step 7 CHECK ANY OTHER DIAGNOSTIC TROU BLE CODES DTCs APPEARANCE Are other DTCs being output Proceed with the diagnosis
351. nsion case Ref to 6MT 49 REMOVAL Extension Case 4 Remove the transfer driven gear Ref to 6 60 REMOVAL Transfer Driven Gear 5 Remove the center differential Ref to 6 62 REMOVAL Center Differential 6 Remove the oil guide TRO699 A Oil guide 7 Remove the snap ring SSS A PF 7 TRO665 Snap ring B Support 8 Using the ST remove the neutral set spring and support 571 18756AA000 CLAW ST2 398663600 PLIERS TRO666 9 Raise the striking rod up then remove the spring pin TRO667 Striking rod B Spring pin 10 Remove the selector arm No 2 and shifter arm TRO668 A Selector arm No 2 B Shifter arm 6MT 64 OIL PUMP 11 Remove the pump shaft assembly and plate NOTE Remove the bolts using ST because tool may break if general tool is used ST 18663AA000 SOCKET A Oil pump shaft assembly B Plate 12 Remove the oil pump cover assembly NOTE Remove the bolts using ST because tool may break if general tool is used ST 18663AA000 SOCKET 13 Remove the thrust washer on main shaft part 14 Remove the oil pump rotor TRO702 A Outer rotor B Inner rotor MANUAL TRANSMISSION AND DIFFERENTIAL B INSTALLATION 1 Apply oil to the outer periphery of outer rotor then install to transmission c
352. nstall the ST3 to lock nut then install the ST to driven gear assembly and tighten lock nut 18666AA000 HOLDER ST2 18664AA000 BASE 573 18620AA000 ADAPTER WRENCH 574 18852AA000 TORQUE WRENCH Tightening torque 530 54 0 kgf m 391 ft Ib ST2 TRO785 NOTE If torque wrench except ST4 is used calculate the following equation then tighten the lock nut T L1 0 1 L1 x570 T N m kgf m ft lb Setting value of torque wrench L1 m in Torque wrench length 0 1 m 3 94 in ST length 570 N m 58 1 kgf m 420 ft lb Tightening torque of lock nut TRO786 A 0 1 m 3 94 in 6MT 93 DRIVEN GEAR ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 26 Using the ST caulk four portions on the lock nut to obtain dimension A 44 0 5 mm 1 73 0 02 in 18669AA000 PUNCH DRIVEN SHAFT CAUTION Do not crack the caulking part of lock nut TRO787 E INSPECTION Disassembled parts should be washed clean first and then inspected carefully 1 Bearing Replace the bearings in the following cases Worn rusted and damaged bearing Bearings that fail to turn smoothly or make ab normal noise when turned Bearings having other defects 2 Bushing each gear Replace the bushings in the following case When the sliding surface is damaged or abnor mally worn 3 Gears Replace the gears in the following c
353. o model Black Data link connector Power window circuit Black Power window relay Relay block Shield amp sensor ground joint connec tor E G Non turbo without OBD model Black Illumination control module gt N Engine control module Diode Rear fog light Green Fuel pump relay Blower fan resistor Main relay Blower fan motor Front fog light relay Relay block Evaporator ther moswitch Blower fan motor relay Roof cord F B FRESH RECIRC actu ator Shield joint connector AT Turbo model 0 M A gt Door lock timer Cruise control module Shield joint connector AT Non turbo model Front door cord LH Clutch switch Cruise control Transmission control module Select lever illumina tion light AT Front wiring harness Cigarette lighter Power Radio Stop light switch Audio ground Stop amp brake switch With cruise control Cruise control sub switch Read memory con nector With OBD model Combination switch Read memory con nector Without OBD model Ignition switch Read memory con nector With OBD model Key warning switch Test mode connector Read memory con nector Without OBD model Mode actuator Kick down switch AT Ch
354. o cone B Reverse idler gear hole 13 Install the washer with groove facing to reverse idler gear 14 Using the ST install the snap ring ST 18672AA000 GUIDE CLIP TRO805 15 Inspect and adjust the clearance between snap ring and washer Ref to 6MT 100 INSPECTION Reverse Idler Gear Assembly 16 Install a new spring pin E INSPECTION Disassembled parts should be washed clean first and then inspected carefully 1 Bearings Replace the bearings in the following cases Worn rusted and damaged bearing Bearings that fail to turn smoothly or make ab normal noise when turned Bearings having other defects 2 Bushing each gear Replace the bushings in the following case When the sliding surface is damaged or abnor mally worn 3 Gears Replace the gears in the following cases The gear teeth surfaces are broken or excessive ly worn The parts that contact the baulk ring is damaged The inner surface of gear is damaged 4 Baulk ring synchro cone Replace the baulk ring and synchro cone in the fol lowing case Worn rusted and damaged baulk ring 5 Shifting insert key Replace the shifting insert key if deformed exces sively worn or defective in any way 53 0189 6 Inspect the clearance between snap ring and washer Specification of clearance 0 1 0 3 mm 0 0039 0 01 18 in C TRO806 Select and replace the snap ring from the
355. ocedures refer to the damage at OBD II General Scan Tool Instruction Manual camshaft Timing belt timing mark aligning EN TURBO 20 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC ENGINE DIAGNOSTICS EN TURBO 21 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC ENGINE DIAGNOSTICS DK DTC P0365 VARIABLE VALVE TIMING CAMSHAFT POSITION SENSOR B CIRCUIT MALFUNCTION 1 RH e DTC DETECTING CONDITION Immediately at fault recognition TROUBLE SYMPTOM Engine stalls Failure of engine to start CAUTION After repair or replacement of faulty parts conduct Clear Memory Mode Ref to EN TURBO 45 OP ERATION Clear Memory Mode and Inspection Mode Ref to EN TURBO 42 Inspection Mode gt WIRING DIAGRAM VARIABLE VALVE TIMING CAMSHAFT POSITION SENSOR RH 30 5 X19 B84 1 2 3 4 5 6 8 9 10 11 12 1311415 16 17 1528 EN TURBO 22 Step Check DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC ENGINE DIAGNOSTICS Yes No CHECK CURRENT DATA 1 Start the engine 2 Measure the ignition timing advance using Subaru Select Monitor or OBD II general scan tool while running the vehicle at approx 30 km h 19 MPH NOTE Subaru Select Monitor For detailed operation procedure refer to the READ CURRENT DATA FOR ENGINE lt
356. ocket gt 3 Install the timing belt assembly lt Ref to ME STi 49 INSTALLATION Timing Belt Assem bly gt 4 Install the belt cover Ref to ME STi 46 IN STALLATION Belt Cover 5 Install the crankshaft pulley Ref to ME STi 45 INSTALLATION Crankshaft Pulley gt 6 Install the V belt Ref to ME STi 43 INSTAL LATION V belt gt C INSPECTION 1 Check the sprocket teeth for abnormal wear and scratches 2 Make sure there is no free play between the sprocket and key 3 Check the crankshaft sprocket notch for sensor for damage and contamination of foreign matter ME STi 58 CAMSHAFT 18 Camshaft A REMOVAL 1 Remove the V belt Ref to ME STi 43 IN STALLATION V belt gt 2 Remove the crankshaft pulley Ref to ME STi 45 REMOVAL Crankshaft Pulley gt 3 Remove the belt cover lt Ref to ME STi 46 REMOVAL Belt Cover gt 4 Remove the timing belt assembly lt Ref to ME STi 47 REMOVAL Timing Belt Assembly gt 5 Remove the camshaft sprocket lt Ref to ME STi 56 REMOVAL Camshaft Sprocket gt 6 Remove the crankshaft sprocket lt Ref to ME STi 58 REMOVAL Crankshaft Sprocket gt 7 Disconnect the variable valve timing solenoid valve assembly connector JA PATA BE Ke S2M1163 52 1162 MECHANICAL 10 Remove the right hand belt cover No 2 11 Re
357. od 4 Read out the DTC ule and Hydraulic Control Unit ABSCM amp H U CHECK ANY OTHER DIAGNOSTIC TROU v Are other DTCs being output Proceed with the A temporary poor BLE CODES DTCs APPEARANCE diagnosis corre contact sponding to DTC ABS 22 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS AJ DTC 73 BATTERY SHORT IN LATERAL G SENSOR CIRCUIT DIAGNOSIS Faulty lateral G sensor output voltage TROUBLE SYMPTOM ABS does not operate WIRING DIAGRAM LHD MODEL ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT SHIELD JOINT CONNECTOR ST 7 n STi MODEL EXCEPT STi MODEL ABS G SENSOR JOINT CONNECTOR STi MODEL ABS LATERAL SENSOR GCSENSOB STi MODEL 3141516 1121314 Hepa 74 516171819 1 21 7 8 9 51678 Tekee 25 2 1 2 8 156 ABS 23 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS WIRING DIAGRAM RHD MODEL ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT SHIELD JOINT CONNECTOR 50 STi MODEL EXCEPT STi MODEL ABS G SENSOR JOINT CONNECTOR STi MODEL ABS LATERAL G SENSOR STi MODEL 1213141578 1 5 Ex 1 21 3 112131415 6 7 8 9 8 9 20 21 5 6 7 8 9 10 18 19
358. olt which secures the timing belt cover RH 5 Lift up the vehicle 6 Remove the under cover 7 Loosen the remaining bolts which secure timing belt cover RH then remove the belt cover 8 Lower the vehicle 9 When inspecting 1 and 3 cylinders 1 Pull out the engine harness connector with bracket from air cleaner upper cover NY H2M1958 Remove the air cleaner case lt Ref to 2 IN TURBO 7 REMOVAL Air Cleaner 3 Disconnect the spark plug cords from spark plugs 1 and 3 cylinders RH 6 Remove the bolts then remove the rocker cover RH Place a suitable container under the vehicle Disconnect the PCV hose from rocker cover 10 When inspecting 2 and 4 cylinders 1 Disconnect the battery cables and then re move the battery and battery carrier H6M0426 2 Remove the bolt which secures engine har ness bracket onto body 6 0561 ME STi 28 VALVE CLEARANCE MECHANICAL 5 Move the washer tank upward 6 0431 6 Disconnect the spark plug cords from spark plugs 2 and 4 cylinders 7 Place a suitable container under the vehicle 8 Disconnect the PCV hose from rocker cover LH 9 Remove the bolts then remove the rocker cover LH 11 Turn the crankshaft pulley clockwise until arrow mark on camshaft sprocket is set to position shown in the figure NOTE
359. on height adjusting shim in order to move drive pinion away from crown gear G3M0098G Toe contact Contact area is small This may cause chipping at toe ends Eri MEN G3M0098D Adjust as for flank contact G3M0098G Heel contact Contact area is small mb Adjusting direction of drive pinion Adjusting direction of crown gear This may cause chipping at heel ends EET G3M0098bE 24 Remove the right and left side bearing retain ers 25 Install the new O ring to side bearing retainers DI 29 Adjust as for face contact G3M0098F REAR DIFFERENTIAL FOR DIFFERENTIALS 26 Tighten the side bearing retainer bolts NOTE Before tightening the two side bearing retainer bolts apply Lock Tite to bolt threads Lock Tite THREE BOND 1105 or equivalent Tightening torque 10 3 1 05 kgf m 7 6 ft lb 3M0173 27 Install the rear cover and tighten the bolts to specified torque Tightening torque 29 3 0 kgf m 21 7 ft lb G3M1050 DI 30 TRANSFER CASE Page 1 General Descriptio Ais ood tesa Eve LR RYE RR C EUN Cis 2 2 Transfer Case and Extension for MT 3 Transfer Clutch and Extension for AT Al ET 5 Transfer Drive Gear 6 Transfer Driven Gear de deet 7 Reduction Drive Gear with
360. on height adjusting shim on drive pinion and press fit the rear bearing cone into position with ST ST 18674AA000 INSTALLER S3M0519A 6 Insert the drive pinion into differential carrier in stall the previously selected bearing preload adjust ing spacer and washer A B3M0560B Drive pinion Bearing adjusting spacer Washer Differential carrier 7 Insert the spacer then press fit the pilot bearing with STs ST1 399780104 WEIGHT ST2 899580100 INSTALLER ST3 398507703 DUMMY COLLER ST4 498937110 HOLDER DRIVE PINION ST2 ST4 ST3 ST1 ST4 ST1 DRO032 DIFFERENTIALS 8 Press fit the companion flange with ST1 ST2 and ST3 NOTE Be careful not to damage the bearing 571 899874100 INSTALLER ST2 399780104 WEIGHT ST3 498937110 HOLDER DRIVE PINION ST1 A DR0033 9 Install the self locking nut Then tighten it with the ST ST 498427200 Tightening torque 181 18 5 kgf m 134 ft lb FLANGE WRENCH G3M1052 10 Rotate the drive pinion shaft more than ten times to accustom each taper roller bearing and then measure the preload Bearing preload 25 9 41 4 2 64 4 22 kgf 5 8 9 3 Ib B3M1935 DI 25 REAR DIFFERENTIAL FOR DIFFERENTIALS 11 bearing preload i
361. on sensor connector and engine ground Connector amp terminal E36 No 1 Engine ground E36 No 2 Engine ground Is the resistance more than 1M Q Go to step 4 Repair the ground short circuit in har ness between vari able valve timing camshaft position sensor and ECM connector NOTE The harness be tween both con nectors are shielded Repair the ground short circuit in harness together with shield CHECK CONDITION OF VARIABLE VALVE TIMING CAMSHAFT POSITION SENSOR Is the variable valve timing camshaft position sensor installation bolt tightened securely EN TURBO 23 Go to step 5 Tighten the vari able valve timing camshaft position sensor installation bolt securely DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC ENGINE DIAGNOSTICS Step Check Yes No 5 CHECK VARIABLE VALVE TIMING CAM SHAFT POSITION SENSOR 1 Remove the variable valve timing camshaft position sensor 2 Measure the resistance between connector terminals of variable valve timing camshaft position sensor Terminals No 1 No 2 EN TURBO 24 Is the resistance between 1 and 4 Check oil sure passage and stuck of variable valve timing sole noid valve Replace the vari able valve timing camshaft position sensor lt Ref to FU TURBO 31 Variable Valve Timing Camshaft Position Sensor DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TR
362. onnector amp terminal B257 No 2 No 3 Is the voltage between 1 3 and 1 7 V when lateral G sensor is inclined backwards to 90 ABS 30 Go to step 10 Replace the lateral G sensor lt Ref to ABS 5 Lateral G Sensor gt DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS Step Check Yes No CHECK ABSCM amp H U Is the same DTC as in current Replace the Go to step 11 1 Turn the ignition switch to OFF diagnosis still being output ABSCM amp H U 2 Connect all connectors Ref to 5 4 3 Erase the memory ABS Control Mod 4 Perform the inspection mode ule and Hydraulic 5 Read out the DTC Control Unit ABSCM amp H U CHECK ANY OTHER DIAGNOSTIC TROU v Are other DTCs being output Proceed with the A temporary poor BLE CODES DTCs APPEARANCE diagnosis corre contact sponding to DTC ABS 31 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS AL DTC 73 DETECTION OF LATERAL G SENSOR STICK DIAGNOSIS Faulty lateral G sensor output voltage TROUBLE SYMPTOM ABS does not operate WIRING DIAGRAM LHD MODEL ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT SHIELD JOINT CONNECTOR ST 7 n STi MODEL EXCEPT STi MODEL ABS G SENSOR JOINT CONNECTOR STi MODEL ABS LATERAL SENSOR GCSENSOB STi MODEL 3141516 1121314 Hepa 74 51617181
363. or LH Tightening torque N m kgf m ft Ib 2 Rear ABS sensor RH 6 Front ABS sensor RH T1 7 4 0 75 5 4 3 ABS spacer 7 Lateral G sensor STi model only T2 32 3 3 24 4 Rear ABS sensor LH ABS 3 ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT ABSCM amp H U ABS 2 ABS Control Module and Hy draulic Control Unit ABSCM amp H U C INSPECTION 1 Check the connected and fixed condition of con nector 2 Check specifications of the mark with ABSCM amp H U Model AT Rear drum brake MT Rear drum brake AT Rear disc brake MT Rear disc brake MT STi ABS 4 LATERAL G SENSOR 9 Lateral G Sensor A REMOVAL 1 Disconnect the ground cable from battery 2 Remove the console cover lt Ref to El 40 Console Box gt 3 Disconnect the connector from lateral G sensor 4 Remove the lateral G sensor from body CAUTION Do not drop or bump the lateral G sensor H tt 0143 INSTALLATION 1 Install the reverse order of removal CAUTION Do not drop or bump the lateral G sensor ABS 5 ABS LATERAL G SENSOR C INSPECTION Step Check Yes No CHECK SUBARU SELECT MONITOR Do you have a SUBARU SELECT MONITOR Go to step 5 Go to step 2 CHECK LATERAL G SENSOR 1 Turn the ignition switch to OFF 2 Remove the lateral G sensor
364. or Shield B135 Fully closed 0 2 1 0 Fully opened 4 2 4 7 Signal 135 Throttle Power position 135 5 sensor supply GND sen sor Signal B135 Shield B135 GND sen sor Front oxy Signal 1 B137 gen A F sensor Signal 2 B137 heater Rear oxygen sensor heater signal Engine Signal B135 1 1 After warm up the engine coolant tempera GND sen ture sen sor sor B135 Rear oxy gen sen sor B135 B136 mE B135 After warm up the engine 5 and 0 are repeatedly dis played when vehicle is driven Vehicle speed signal EN TURBO 14 ENGINE CONTROL MODULE ECM I O SIGNAL ENGINE DIAGNOSTICS Con Signal V Content nector Ignition SW ON Engine OFF Engine ON Idling Mass air Signal 884 0 3 4 5 flow sen Shield B84 0 0 sor GND B84 0 0 Intake air temperature sensor signal Variable valve timing B84 ON 0 ON 0 solenoid valve LH 1 OFF 10 13 OFF 10 13 Variable valve timing solenoid valve LH 1 Variable valve timing solenoid valve RH B84 1 Variable valve timing solenoid valve RH 1 Exhaust Signal t gas tem GND perature 2 sensor B135 B84 0 0 ON 0 ON 0 OFF 10 13 OFF 10 13 Signal Fully closed 0 2 1 0 Tumble 9 Fully o
365. or key with key groove on the end of speedometer shaft and then install Tightening torque 5 9 0 6 kgf m 4 4 ft lb NOTE Ensure the sensor mounting hole is clean and free of foreign matter Discard the vehicle speed sensor and after re moval replace with a new one TRO635 2 Connect the connector to vehicle speed sensor 3 Install the intercooler lt Ref to IN TURBO 11 INSTALLATION Intercoooler gt C INSPECTION Inspect that the speedometer is normally operated because vehicle speed sensor cannot be inspected as single part If it is not normally operated inspect the combination meter system lt Ref to IDI 5 IN SPECTION Combination Meter System gt 6MT 34 TRANSMISSION MOUNTING SYSTEM MANUAL TRANSMISSION AND DIFFERENTIAL 5 Transmission Mounting Sys tem A REMOVAL 1 PITCHING STOPPER 1 Disconnect the ground cable from battery 2 Remove the intercooler lt Ref to IN TURBO 10 REMOVAL Intercooler gt 3 Remove the pitching stopper B INSTALLATION 1 PITCHING STOPPER 1 Install the pitching stopper Tightening torque T1 50 5 1 kgf m 36 9 ft lb 2 58 N m 5 9 kgf m 42 8 ft lb OJN ee lt gt k 0072 2 CROSSMEMBER AND CUSHION RUB BER 1 Disconnect the ground cable from battery 2 Jack up the vehicle and support it with sturdy racks 3 Remove the center exhaust
366. otal kgf Ib Option Option 1 Air conditioner Cruise control ABS Aluminium wheel Rear spoiler Spoiler pac Model Curb weight C W Front kgf Ib Rear kgf Ib Total kgf Ib Maximum permissible axle weight M P A W Front kgf Ib Rear kgf Ib Maximum permissible weight M P W Total kgf Ib Option D R Dual range Air conditioner Cruise control ABS Aluminium wheel Rear spoiler Spoiler pac 1 For option code refer to ID section Ref to ID 5 Option code SPC 8 Option codex1 IMPREZA SPECIFICATIONS Model 2 0 L Turbo AWD WRX 5MT Curb weight C W Front 805 1 775 825 1 819 Rear 585 1 290 585 1 290 Total 1 390 3 065 1 410 3 109 Maximum permissible axle weight M P A W Front 970 2 138 970 2 138 Rear 950 2 094 950 2 094 Maximum permissible weight M P W Total 1 860 4 101 1 860 4 101 Option D R Dual range Air conditioner Cruise control ABS Aluminium wheel Rear spoiler Spoiler pac 1 For option code refer to ID section Ref to ID 5 Option code SPC 9 SPECIFICATIONS IMPREZA 2 RHD VEHICLE Sedan Option codex1 Model 5
367. ound like polishing glass with a dry cloth Loose drive belt Defective water pump shaft Hissing sound Loss of compression Air leakage in air intake system hoses connections or mani folds Timing belt noise Loose timing belt Belt contacting case adjacent part Valve tappet noise Incorrect valve clearance When disconnecting fuel injector connector Malfunction Indicator Light CHECK ENGINE light illuminates and trouble code is stored in ECM memory Therefore carry out the CLEAR MEMORY MODE lt Ref to EN TURBO 45 OPERATION Clear Memory Mode gt and INSPEC TION MODE lt Ref to EN TURBO 42 OPERATION Inspection Mode gt after connecting fuel injector connector ME STi 97 ENGINE NOISE MECHANICAL ME STi 98 ENGINE DIAGNOSTICS EN TURBO Page 1 Basic Diagnostic Procedure 2 Check List for Interview 3 General Description 4 Electrical Components Location 2 5 Engine Control Module ECM HO Signal 14 6 Engine Condition Data 7 Transmission Control Module TCM I O Signal 8 Data Link Connector 9 OBD II General Scan Tool 10 Subaru Select Monitor 11 Read Diagnostic Trouble Code 12 Inspection Mode 13 Clear Memory Mode 14 Compulsory Valve Operation Check Mode 15 Engine Malfunction Indicator Lamp MIL 16 Diagnostics for Engine Starting Failure 17 List of Diagnostic Trouble Code 18 18 Diagnostic Procedure wi
368. out VTD 8 Reduction Drive Gear with VTD 9 Reduction Driven Gear without VTD 10 Reduction Driven Gear with VTD 11 Center Differential 6 12 Transfer Clutch Pressure Test 13 Transfer Duty Solenoid and Valve Body 14 Extension Case for MT 7 GENERAL DESCRIPTION TRANSFER CASE 1 General Description A NOTE For general description refer to AUTOMATIC TRANSMISSION a separate publication Pub G0864ZE and AT MT or section AT model lt Ref to AT 2 General Description gt MT model lt Ref to MT 2 General Description gt 6MT model lt Ref to 6MT 2 General Description gt TC 2 OIL SEAL 4 Oil Seal A NOTE For removal installation and inspection work refer to AT MT or 6MT section AT model lt Ref to AT 27 Extension Case Oil Seal gt MT model lt Ref to MT 42 Oil Seal gt 6MT model lt Ref to 6 33 Oil Seal gt TC 3 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 MT model lt Ref to MT 52 Transfer Drive Gear gt 6MT model lt Ref to 6MT 58 Transfer Drive Gear gt TC 4 TRANSFER DRIVEN GEAR MT 6 Transfer Driven Gear MT A NOTE For removal installation and inspection work refer to MT section MT model lt Ref to MT 54 Tran
369. out on its back sur face and make sure that pinion and crown gear ro tate smoothly Limit of runout Less than 0 05 mm 0 0020 in D S GI 22 lt S3M0525 23 Checking and adjusting tooth contact of crown gear 1 Apply an even coat of red lead on both sides of three or four teeth on 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 just according to the instructions given in TOOTH CONTACT PATTERN NOTE Be sure to wipe off red lead completely after adjust ment is completed DI 28 REAR DIFFERENTIAL FOR TOOTH CONTACT PATTERN DIFFERENTIALS 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 A Heel side G3M0098A Face contact Backlash is too large This may cause noise and chipping at tooth ends elm G3M0098B Increase thickness of drive pinion height adjusting shim in order to bring drive pin ion closer to crown gear center G3MO0098F Flank contact Backlash is too small This may cause noise and stepped wear on surfaces es ee G3M0098C Reduce thickness of drive pini
370. pened 4 2 4 7 generator Power valve posi 5 5 tion sensor sensor Signal Fully closed 0 2 1 0 Tumble 9 Fully opened 4 2 4 7 generator Power valve posi sui 5 5 tion sensor sensor Tumble generator valve RH open 2 Tumble generator valve RH close 2 Tumble generator valve LH open 2 Tumble generator valve LH close 2 Wastegate control sole noid valve Starter switch 0 0 Cranking 8 14 ON 10 13 ON 13 14 NG SwWiteh OFF 0 OFF 0 Ignition switch 10 13 13 14 12 0 5 Switch is ON when gear is OFF 0 neutral position Test mode connector When connected 0 Knock Signal sensor Shield Back up power supply Ignition switch OFF 10 13 5 00 5 5 00 5 0 5 Oor5 Oor5 Oor5 10 13 13 14 Neutral position switch Control unit power sup ply EN TURBO 15 Content ENGINE CONTROL MODULE ECM I O SIGNAL ENGINE DIAGNOSTICS Con nector No Signal V Ignition SW ON Engine OFF Engine ON Idling Sensor power supply B135 5 5 Line end check 1 B134 0 1 B136 13 14 Waveform Ignition 2 136 13 14 Waveform control 3 B136 13 14 Waveform 4 B136 0 13 14 Waveform 1 B137 10 13
371. pt STi Headlight leveler LH Sti Headlight leveler RH Except STi Headlight leveler RH Sti Shield joint connector ABS Radiator main fan relay Relay holder Non turbo model Radiator main fan relay 1 Relay holder FWD switch AWD AT model ABS motor ground Bulkhead wiring harness ABS Ambient sensor A C pressure switch ABS front sensor LH ABS front sensor RH Bulkhead wiring harness ABS condenser Headlight LH 4 Lights Hi Generator M B 1 2 3 2 2 3 2 3 2 3 3 2 3 1 3 4 4 4 4 4 4 4 2 8 7 8 A N A BR CO WI 93 WIRING SYSTEM FRONT WIRING HARNESS Connector Connecting to No Pole Color Area No Name F99 2 Black B 1 Headlight RH 4 Lights Hi Non colored WI 94 FRONT WIRING HARNESS WIRING SYSTEM 5 BM BO0488 WI 95 BULKHEAD WIRING HARNESS ENGINE ROOM WIRING SYSTEM 46 Bulkhead Wiring Harness In Engine Room A LOCATION 2 LHD TURBO ENGINE MODEL Connector Connecting to No Pole Color B3 5 Gray Mass airflow sensor B8 Front wiper motor B14 Starter Magnet 15 Gray ABS front sensor RH B16 Gray Brake fluid level switch Vehicle speed sensor MT
372. pulse type Temperature gauge Thermistor cross coil type Fuel gauge Resistance cross coil type Tachometer Electric impulse type Turn signal indicator light 14 V 1 4W Charge indicator light LED Oil pressure indicator light LED ABS warning light LED CHECK ENGINE warning light Malfunction indicator light LED indicator light 14 V 1 4W Door open warning light LED Seat belt warning light LED Brake fluid and parking brake warning light LED AIRBAG warning light LED Meter illumination light 14V 3W 14V 2W Immobilizer indicator light LED Low fuel warning light LED LCD back light 14 V 1 4W Intercooler water spray warning light LED REV indicator light IDI 2 LED COMBINATION METER ASSEMBLY INSTRUMENTATION DRIVER INFO 3 Combination Meter Assem bly C DISASSEMBLY 2 BULB REPLACEMENT STI MODEL 4 5 6 3 2 A ERS mo 5 Je 6 Sm 1 ei 10 9 800509 1 Speedometer 2 Speedometer and tachometer 3 Turn RH 4 Hl beam 5 Tachometer 6 Turn LH 7 Fuel gauge 8 Temperature gauge 9 LCD Outside temperature indicator 10 LCD Odometer and tripmeter IDI 3 COMBINATION METER ASSEMBLY INSTRUMENTATION DRIVER INFO IDI 4 EXTERIOR INTERIOR TRIM d General DescriptiOnia
373. push the piston back 4 1370 BRAKE 7 Remove the pad H4M1371 B INSTALLATION 3 17 INCH TYPE 1 Apply a thin coat of Molykote AS880N Part No 26298ACO000 to each pad side 146 Install the pads on caliper body Install the cross spring Install the pad pins 2 3 4 5 Install the crip ass gt BR 7 FRONT BRAKE PAD BRAKE C INSPECTION 3 17 INCH Check the pad thickness A BRO147 Pad thickness Standard value 14 2 mm 0 559 in Wear limit 6 2 mm 0 244 in CAUTION e Always replace the pads for both right and left wheels at the same time Also replace the pad clips if they are twisted or worn A wear indicator is provided on the outer disc brake pad If the pad wears down to such an ex tent that the end of wear indicator contacts disc rotor a squeaking sound is produced as the wheel rotates If this sound is heard replace the pad Replace the if there is oil or grease on it BR 8 FRONT DISC ROTOR BRAKE 3 Front Disc Rotor Standard Disc outer C INSPECTION dio 24 mm 260 mm 1 Secure the disc rotor by tightening five wheel 0 94 in 10 24 in nuts e 24 mm 277 mm 2 Set a dial gauge on the disc rotor Turn the disc DIS TOTO 1 0 94 in 10 91 in rotor to check runout thickness A San 294 mm CAUTION 0 94 in 11 57 in
374. r 3 Install the snap ring and washer to gear shift le ver and then install the bush NOTE Apply grease to the bush o B ENSIS TRO969 A Bush B Washer C Snap ring CS 9 GEAR SHIFT LEVER CONTROL SYSTEMS 4 Apply grease to the bush and boot and then in stall to the gear shift lever TRO968 A Boot B Bush 5 Apply sufficient grease into the boss and then install the gear shift lever to stay TRO967 6 Install the washer and snap ring TRO966 Snap ring 7 Insert the gear shift lever and rod into boot hole 8 Install the rod Tightening torque 11 8 1 2 kgf m 8 7 ft lb TRO965 9 Install the boss to rod Tightening torque 11 8 1 2 kgf m 8 7 ft lb 0991 A Rod B Boss 10 Install a new lock wire 2 O 0964 Lock wire CS 10 GEAR SHIFT LEVER CONTROL SYSTEMS NOTE Install the lock wire to stay groove Bend the extra wire to same direction of lock wire winding TRO0971 A Inner boot B Wire C Stay 11 Install the holder Tightening torque 1 3 N m 0 13 kgf m 0 96 ft Ib A 222 TRO963 A Holder 12 Insert the reverse check cable into boot hole 13 Insert the reverse check cable into gear shift asse
375. r lt Ref to FU TURBO 31 INSTALLATION Camshaft Posi tion Sensor gt 3 Install the timing belt assembly lt Ref to ME STi 49 INSTALLATION Timing Belt Assem bly gt 4 Install the belt cover Ref to ME STi 46 IN STALLATION Belt Cover 5 Install the crankshaft pulley Ref to ME STi 45 INSTALLATION Crankshaft Pulley gt 6 Install the V belt Ref to ME STi 43 INSTAL LATION V belt gt ME STi 56 CAMSHAFT SPROCKET C INSPECTION 1 Check the sprocket teeth for abnormal wear and scratches 2 Make sure there is no free play between the sprocket and key 3 Check the crankshaft sprocket notch for sensor for damage and contamination of foreign matter ME STi 57 MECHANICAL CRANKSHAFT SPROCKET MECHANICAL 17 Crankshaft Sprocket A REMOVAL 1 Remove the V belt Ref to ME STi 43 RE MOVAL V belt gt 2 Remove the crankshaft pulley Ref to ME STi 45 REMOVAL Crankshaft Pulley gt 3 Remove the belt cover lt Ref to ME STi 46 REMOVAL Belt Cover gt 4 Remove the timing belt assembly lt Ref to ME STi 47 REMOVAL Timing Belt Assembly 5 Remove the camshaft sprocket Ref to ME STi 56 REMOVAL Camshaft Sprocket gt 6 Remove the crankshaft sprocket 0263 INSTALLATION 1 Install the crankshaft sprocket 0263 2 Install the camshaft sprocket Ref to ME STi 56 INSTALLATION Camshaft Spr
376. r damage on boot any leakage or damage is found replace the operating cylinder CL 6 2002 IMPREZA STi SERVICE MANUAL QUICK REFERENCE INDEX CHASSIS SECTION FRONT SUSPENSION REAR SUSPENSION WHEEL AND TIRE SYSTEM DIFFERENTIALS This service manual has been prepared to provide SUBARU service personnel with the necessary information and data for the correct maintenance and repair Geer DRIVE SHAFT SYSTEM This manual includes the procedures for maintenance disassembling reas sembling inspection and adjustment of 5 components and diagnostics for guid ance of experienced mechanics Please peruse and utilize this manual ABS DIAGNOSTICS fully to ensure complete repair work for satisfying our customers by keeping their vehicle optimum condition BRAKE When replacement of parts during repair work is needed be sure to use SUBARU genuine parts PARKING BRAKE TRANSFER CASE 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 G1841GE5 ELLA 2 25 22 24 ee FRONT SUSPENSION Page General Description Wheel Alignment Front Transverse Link Front Ball Joint EFODESIUL oS M 2 Front Stabilizer Front Crossmember Sub Frame General Diagnostic Table M SEO MD P OI FRONT STRUT FRONT SUSPENSION 5 Front Strut F DISPOSAL 2 STIM
377. r and spring TR0959 A Slider B Spring CONTROL SYSTEMS 6 Cut the band clip and then separate the reverse check cable from gear shift lever TRO960 7 Lift up the vehicle 8 Remove the under cover 9 Remove the rear exhaust pipe and muffer lt Ref to EX TURBO 13 REMOVAL Rear Exhaust Pipe gt lt Ref to EX TURBO 14 REMOVAL Muffer gt 10 Remove the crossmember lt Ref to 6MT 35 REMOVAL Transmission Mounting System gt 11 Remove the snap pin and washer and then separate the reverse check cable from reverse check lever d E A TR0954 A Snap pin B Washer C Reverse check cable CS 13 REVERSE CHECK CABLE CONTROL SYSTEMS 12 Move the transmission to right side and then remove the stay bolt and reverse check cable NOTE If the transmission is not moved stay bolt will con tact body and damage may occur TRO976 A Stay B Stay bolt 13 Raise the clip of stay and then separate the stay and reverse check cable TRO974 A Reverse check cable B Clip 14 Remove the reverse check cable by pulling from underneath the vehicle NOTE Take care not to damage the inner boot 15 Loosen the lock nut then remove the reverse check cable from cable plate TRO961 A Cable plate B Reverse check cable B INSTALLATION 1 Adjust the length between end of cable pl
378. r limit 0 07 mm 0 0028 in Grinding limit 0 250 mm 0 0098 in G2M0179 ME STi 90 CYLINDER BLOCK MECHANICAL Unit mm in Crank journal diameter 1 3 5 2 4 Crank pin diameter Standard Journal O D 59 992 60 008 2 3619 2 3625 59 992 60 008 2 3619 2 3625 51 984 52 000 2 0466 2 0472 Bearing size Thickness at cen ter 1 998 2 011 0 0787 0 0792 2 000 2 013 0 0787 0 0793 1 486 1 498 0 0585 0 0590 0 03 0 0012 undersize Journal O D 59 962 59 978 2 3607 2 3613 59 962 59 978 2 3607 2 3613 51 954 51 970 2 0454 2 0461 Bearing size Thickness at cen ter 2 017 2 020 0 0794 0 0795 2 019 2 022 0 0795 0 0796 1 505 1 509 0 0593 0 0594 0 05 0 0020 undersize Journal O D 59 942 59 958 2 3599 2 3605 59 942 59 958 2 3599 2 3605 51 934 51 950 2 0446 2 0453 Bearing size Thickness at cen ter 2 027 2 030 0 0798 0 0799 2 029 2 032 0 0799 0 0800 1 515 1 519 0 0596 0 0598 0 25 0 0098 undersize Journal O D 59 742 59 758 2 3520 2 3527 59 742 59 758 2 3520 2 3527 51 734 51 750 2 0368 2 0374 Bearing size Thickness at cen ter 2 127 2 130 0 0837 0 0839
379. rd 1 5 mm 0 059 Limit 2 2 mm 0 087 in G2M0761 ME STi 68 CYLINDER HEAD ASSEMBLY MECHANICAL 3 VALVE GUIDE 1 Check the clearance between valve guide and stem The clearance can be checked by measuring the outside diameter of valve stem and the inside diameter of valve guide with outside and inside mi crometers respectively Clearance between the valve guide and valve stem Standard Intake 0 030 0 050 mm 0 0012 0 0020 in Exhaust 0 040 0 050 mm 0 0016 0 0020 in Limit 0 15 mm 0 0059 in 2 If the clearance between valve guide and stem exceeds the limit replace the valve guide or valve itself whichever shows greater amount of wear See the following procedure for valve guide re placement Valve guide inner diameter 6 000 6 012 mm 0 2362 0 2367 in Valve stem outer diameters Intake 5 962 5 970 mm 0 2347 0 2350 Exhaust 5 952 5 960 mm 0 2343 0 2346 in 1 Place the cylinder head on ST1 with the combustion chamber upward so that valve guides enter the holes in ST1 2 Insert the ST2 into valve guide and press it down to remove the valve guide ST1 498267600 CYLINDER HEAD TABLE ST2 499767200 VALVE GUIDE REMOVER 52 1882 3 Turn the cylinder head upside down and place ST as shown in the figure ST 498267700 VALVE GUIDE ADJUSTER t G2M0763 4 Before installing the new valve guide
380. re the cylinder to use an over size piston ME STi 86 CYLINDER BLOCK MECHANICAL 3 Make sure that the piston pin can be inserted into the piston pin hole with a thumb at 20 C 68 F Replace if defective Standard clearance between piston pin and hole in piston Standard 0 004 0 008 mm 0 0002 0 0003 in Limit 0 020 mm 0 0008 in B2M1401 Micrometer B2M0084A 4 Check the circlip installation groove on the pis ton for burr A If necessary remove burr from the groove so that the piston pin can lightly move A B2M0420B 5 Check the piston pin circlip for distortion cracks and wear 4 PISTON RING 1 If the piston ring is broken damaged or worn or if its tension is insufficient or when the piston is re placed replace the piston ring with a new one of the same size as the piston CAUTION e N is marked on the end of the top and sec ond rings When installing the rings to the pis ton face this mark upward EN0330 The oil ring is a combined ring consisting of two rails and a spacer in between When install ing be careful to assemble correctly 02222 b CULL C EN0331 gt Top ring Second ring Oil ring Upper rail Spacer Lower rail eS OU RI MALI 22 ME STi 87 CYLINDER BLOCK MECHANICAL 2 Squarely place the pis
381. rent brands to pre vent the fluid performance from degrading When brake fluid is sup FMVSS 116 DOT3 or DOT4 plemented be careful not to allow any dust into the res ervoir Use fresh DOT3 4 brake fluid when replacing or refilling the fluid ABS equipped vehicle NOTE Refer to PB section for parking brake SPECIFICATIONS Ref to PB 2 SPECIFICATIONS General De scription gt ITEM STANDARD SERVICE LIMIT KSE 147 15 17 0 67 7 5 0 295 ad thickness 16 14 5 mm 0 571 in 6 0 mm 0 236 in including back metal 17 14 2 0 559 6 2 mm 0 244 Front brake Except 24 94 22 87 Disc thickness 17 0 94 0 87 17 30 mm 1 18 in 28 mm 1 10 in Disc runout 0 075 mm 0 0030 in 14 14 mm 0 55 in 6 5 mm 0 256 in 15 16 mm 0 63 in 6 0 mm 0 236 in 17 13 5 0 531 6 2 mm 0 244 in Rear brake Disc type 14 10 mm 0 39 8 5 mm 0 335 Disc thickness 15 18 mm 0 71 in 16 0 mm 0 63 in 17 20 mm 0 79 in 18 mm 0 71 in Disc runout 0 07 0 0028 Inside diameter 228 6 mm 9 in 230 6 mm 9 08 in Lining thickness 4 1 mm 0 161 in 1 5 mm 0 059 in Rear brake Disc type Inside diameter 170 mm 6 69 in 171 mm 6 73 in parking Lining thickness 3 2 mm 0 126 in 1 5 mm 0 059 in Parking brake Lever stroke 7 to 8 notches 196 N 20 kgf 44 Ib
382. ring 12 7 32 4 1 3 3 3 2 9 7 3 Preload adjusting spacer Part No Length 32288AA040 52 3 mm 2 059 in 32288AA050 52 5 mm 2 067 in 31454AA100 52 6 mm 2 071 in 32288AA060 52 7 mm 2 075 in 31454AA110 32288AA070 52 9 mm 2 083 in 31454AA120 53 0 mm 2 087 in 32288AA080 52 8 mm 2 079 in 53 1 mm 2 091 in 32288AA090 53 3 mm 2 098 in Preload adjusting washer Part No Thickness 38336AA000 1 500 mm 0 0591 in 38336AA120 1 513 mm 0 0596 in 38336AA010 1 525 mm 0 0600 in 38336AA130 1 538 mm 0 0606 in 38336AA020 1 550 mm 0 0610 in 38336AA140 1 563 mm 0 0615 in 38336AA030 1 575 mm 0 0620 in 38336AA150 1 588 mm 0 0625 in 38336AA040 1 600 mm 0 0630 in 38336AA160 1 613 mm 0 0635 in 38336AA050 1 625 mm 0 0640 in 38336AA170 38336AA060 1 650 mm 0 0650 in 38336AA180 1 663 mm 0 0655 in 38336AA070 1 675 mm 0 0659 in 38336AA190 1 688 mm 0 0665 in 38336AA080 1 700 mm 0 0669 in 38336AA200 1 713 mm 0 0674 in 38336AA090 1 725 mm 0 0679 in 38336AA210 1 738 mm 0 0684 in 38336AA100 1 750 mm 0 0689 in 38336AA220 1 638 mm 0 0645 in 1 763 mm 0 0694 in 3833
383. ring object then lock the dial 1 as shown in the figure Turn dial 2 to set the indicator to edge surface of sleeve 2nd side Perform the measuring procedure with two peo ple and measure the sleeve lifted up straight Measure five points of the ball bearing turning every approx 72 apart Round off each two upper and lower measurement value Use the remaining center value as measurement value TRO758 7 According to both measurements calculate the 1st 2nd sleeve neutral position Select the fork rod which applies to the calculated value from following equation Equation T B1 B2 2 T 1st 2nd sleeve center position B1 Height from adapter plate edge to sleeve edge when shifted to 1st gear B2 Height from adapter plate edge to sleeve edge when shifted to 2nd gear measurement value 55 mm 2 17 in NOTE The indicator is installed upside down compared to the setting procedure of zero point Add 1 fixing value 55 mm 2 17 in from the following figure to B2 to obtain measurement value of B2 TRO861 T mm in Lot No Mark 62 93 63 23 2 4776 2 4894 63 23 63 53 2 4894 2 5012 63 53 63 83 2 5012 2 5130 32801AA111 1 32801AA131 None 32801 141 2 6 124 SHIFTER FORK AND ROD 2 SELECTION OF 3RD 4TH FORK ROD NOTE Perform the following procedures when Replacing the main shaft
384. ring retainer shim Thickness mm in 0 20 0 0079 Part No 383475201 383475202 0 25 0 0098 383475203 0 30 0 0118 383475204 0 40 0 0157 383475205 0 50 0 0197 4 Align the arrow mark on differential carrier with the mark on side retainer during installation NOTE Be careful that side bearing outer race is not dam aged by bearing roller 3M0172B Arrow mark DI 27 REAR DIFFERENTIAL FOR DIFFERENTIALS 5 Tighten the side bearing retainer bolts Tightening torque 10 3 N m 1 05 kgf m 7 6 ft lb 53 0173 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 the crown gear while holding drive pinion still Read the value indicated on dial gauge Backlash 0 10 0 20 mm 0 0039 0 0079 in G3M1047 7 Atthe same time measure the turning resis tance of drive pinion Compared with the resis tance when differential case is not installed if the increase of the resistance is not within the specified range readjust side bearing retainer shims Turning resistance increase 31 1 59 5 3 17 6 07 kgf 7 0 13 4 Ib 21 Re check the crown gear to pinion backlash Backlash 0 10 0 20 mm 0 0039 0 0079 in G3M1047 22 Check the crown gear run
385. rks Digits Code Meaning Details 1to3 JF1 Manufacturer body area JF1 Passenger car FHI made 4 G Car line IMPREZA 5 D Body type D 4 Door Sedan G Wagon 6 4 Displacement 4 1 6 LAWD 8 2 0 LAWD 7 5 Grade 5 TS 7 GX 8 M Restraint M Manual belts dual airbag 9 Check digit 10 2 Model year 2 2002MY 3 2008MY 11 G Transmission type G Full time AWD 5 speed MT single range H Full time AWD 4 speed AT J Full time AWD 5 speed MT dual range 12 to 17 002001 Serial number ID 2 IDENTIFICATION IDENTIFICATION 3 MODEL NUMBER PLATE The model number plate indicates the applied model the option code the trim code the engine type the transmission type and the exterior color code This information is helpful when placing orders for parts GD9BL7R Meaning Details Series IMPREZA Body style D 4 Door Sedan G Wagon Engine displacement Drive system Suspension system 5 1 6 L AWD 9 2 0 AWD 2 0 L AWD Turbo B 2 0 L AWD High power Turbo 2 5 AWD Minor change 2002MY Destination K Right hand drive market Left hand drive market Grade TS GX RS OUTBACK WRX STi Transmission fuel feed system The engine and transmission type are as follows Engine SOHC MPI 4 speed AT SOHC MPI 5 speed MT AWD SOHC MPI 5 speed MT Dual range DOHC B MPI 4 speed AT DOHC B MPI 5 speed MT AWD DOHC B MPI 6 speed MT AW
386. rmal signal lt Ref to ABS 107 DTC 22 FRONT RIGHT ABNORMAL ABS SENSOR SIGNAL Diagnostics Chart with Subaru Select Moni tor gt Open or short circuit in front left ABS sensor circuit Open or short circuit in front left ABS sensor circuit lt Ref to ABS 100 DTC 23 OPEN OR SHORT CIRCUIT IN FRONT LEFT ABS SENSOR CIRCUIT Diagnostics Chart with Subaru Select Monitor gt Front left ABS sensor abnormal signal Front left ABS sensor abnormal signal lt Ref to ABS 107 DTC 24 FRONT LEFT ABNORMAL ABS SEN SOR SIGNAL Diagnostics Chart with Subaru Select Monitor gt Open or short circuit in rear right ABS sensor circuit Open or short circuit in rear right ABS sensor circuit lt Ref to ABS 100 DTC 25 OPEN OR SHORT CIRCUIT IN REAR RIGHT ABS SENSOR CIRCUIT Diagnostics Chart with Subaru Select Monitor gt Rear right ABS sensor abnormal signal Rear right ABS sensor abnormal signal lt Ref to ABS 107 DTC 26 REAR RIGHT ABNORMAL ABS SEN SOR SIGNAL Diagnostics Chart with Subaru Select Monitor gt Open or short circuit in rear left ABS sensor circuit Open or short circuit in rear left ABS sensor circuit lt Ref to ABS 101 DTC 27 OPEN OR SHORT CIRCUIT IN REAR LEFT ABS SENSOR CIRCUIT Diagnostics Chart with Subaru Select Monitor gt Rear left ABS sensor abnormal signal Rear left ABS sensor abnormal signal lt Ref to ABS 108 DTC
387. rol Turbo Model R130 Rear defogger choke coil Intercooler water spray motor and level sensor STi LHD Intercooler water spray motor and level sensor STi RHD R145 A Non colored WI 108 REAR WIRING HARNESS AND TRUNK LID CORD WIRING SYSTEM lt BO0485 WI 109 INTERCOOLER WATER SPRAY SYSTEM WIRING SYSTEM 54 Intercooler Water Spray System A SCHEMATIC TO POWER SUPPLY ROUTING 5 FB 36 FB 28 5 e 10 FB 11 e 1 F B FUSE NO 13 F B FUSE NO 4 i F B FUSE NO 12 F B FUSE NO 12 gt gt INTERCOOLER WATER SPRAY TIMER YR 4 uM 8286 INTERCOOLER WATER SPRAY SWITCH t INTERCOOLER WATER SPRAY WARNING LIGHT INTERCOOLER WATER 1 LHD MODEL REF TO GND 03 SPRAY MOTOR AND RHD MODEL REF TO GND 08 LEVEL SENSOR 2 3 5 lt LHD MODEL RHD MODEL LHD MODEL RHD MODEL LHD MODEL RHD MODEL LHD MODEL RHD MODEL LHD MODEL RHD MODEL LHD MODEL RHD MODEL REF TO GND 02 REF TO GND 07 145 BLACK 8294 8286 BLACK 1 2 415 6 112 4 B99 LHD 112 314 5 6 9 12 13114115 16 17118 1920 21 22 23 24
388. rossmember 9 8 0 4 2 den Cf See NG 17 Separate the clutch release fork from release bearing 52 1927 1 Remove the clutch operating cylinder from transmission 2 Remove the plug using 10 mm hexagon wrench 14 Remove the center exhaust pipe lt Ref to EX TURBO 8 REMOVAL Center Exhaust Pipe gt 15 Remove the nuts which hold lower side of transmission to engine B3M2047 ME STi 34 S2M1935 ENGINE ASSEMBLY 3 Screw 6 mm dia bolt into release fork shaft and remove it S2M1936A A Shaft B Bolt 4 Raise the release fork and unfasten release bearing tabs to free release fork CAUTION Step 4 is required to prevent interference with engine when removing the engine from trans mission 18 Remove the pitching stopper H3M1839 MECHANICAL 19 Disconnect the fuel delivery hose return hose and evaporation hose CAUTION Catch fuel from hose into container Disconnect the hose with its end wrapped with cloth to prevent fuel from splashing 21 Support the engine with a lifting device and wire ropes WZ G2M0297 ME STi 35 ENGINE ASSEMBLY MECHANICAL 22 Support the transmission with a garage jack B INSTALLATION CAUTION
389. rs to catch cool ant and oil wire ropes chain hoist transmission jacks etc Lift up or lower the vehicle when necessary Make sure to support the correct positions REMARKS 498267600 0147 CYLINDER HEAD TABLE Used for replacing valve guides Used for removing and installing valve springs 498457000 B2M3851 ENGINE STAND Used with ENGINE STAND 499817000 ADAPTER RH ME STi 14 ILLUSTRATION GENERAL DESCRIPTION TOOL NUMBER DESCRIPTION MECHANICAL REMARKS B2M3852 498457100 ENGINE STAND ADAPTER LH Used with ENGINE STAND 499817000 B2M3853 498497100 CRANKSHAFT STOPPER Used for stopping rotation of flywheel when loos ening and tightening crankshaft pulley bolt etc B2M3854 398744300 PISTON GUIDE Used for installing piston in cylinder B2M3855 498857100 VALVE OIL SEAL GUIDE ME STi 15 Used for press fitting of intake and exhaust valve guide oil seals MECHANICAL ILLUSTRATION GENERAL DESCRIPTION TOOL NUMBER DESCRIPTION REMARKS 2 3856 499017100 PISTON GUIDE ing rod Used for installing piston pin piston and connect SEN 2 3857 499037100 CONNECTING ROD BUSHING REMOVER amp INSTALLER bushing Used for removing and installing connecting rod a B2M3858 499097700 PISTON PIN REMOVER ASSY Used for removing piston pin
390. rse check plug TRO680 Reverse check shaft Spring Hole Cutout portion TR0675 A Snap ring B Washer 6 56 REVERSE CHECKING SYSTEM MANUAL TRANSMISSION AND DIFFERENTIAL 5 Set the ST1 to reverse check shaft Install a new oil seal then press with ST2 5711 18671AA000 OIL SEAL GUIDE ST2 18657AA010 INSTALLER TRO681 A Oil seal 6 Insert the reverse check lever then rotate the re verse check shaft until the plunger can be pushed in first 0682 Plunger Reverse check shaft 7 Align the hole of reverse check lever and reverse check shaft then install the spring pin E 46 74 WN A Reverse check shaft B Reverse check lever C Hole 8 Make sure the reverse check operates correctly lt Ref to 6MT 57 INSPECTION Reverse Checking System gt 9 Install the extension case lt Ref to 6MT 49 IN STALLATION Extension Case gt 10 Install the manual transmission assembly to ve hicle lt Ref to 6MT 39 INSTALLATION Manual Transmission Assembly gt C INSPECTION 1 Make sure there is no damage on each parts 2 Make sure the reverse check lever operates smoothly 3 Make sure there is no oil leakage on oil seal part of reverse check shaft If there is oil leakage re place the oil seal 4 Inspect the reverse check operation 1 The plunger can be pushed or the gear can
391. s out of specification adjust to specification by selecting preload adjusting washer and spacer from the following table 14 Fit a new oil seal with ST NOTE Press fit until the end of oil seal is 1 mm 0 04 in inward from end of carrier Part No Thickness mm in 383705200 2 59 0 1020 383715200 2 57 0 1012 383725200 2 55 0 1004 383735200 2 53 0 0996 383745200 2 51 0 0988 383755200 2 49 0 0980 Preload adjusting 383765200 2 47 0 0972 washer 383775200 2 45 0 0965 383785200 2 43 0 0957 383795200 2 41 0 0949 383805200 2 39 0 0941 383815200 2 37 0 0933 383825200 2 35 0 0925 383835200 2 33 0 0917 383845200 2 31 0 0909 Part No Length mm in 31454AA130 52 2 2 055 u 31454AA140 52 4 2 063 dung adjusting 1 454 150 52 6 2 071 31454 160 52 8 2 079 31454 170 53 0 2 087 31454 180 53 2 2 094 12 Hold the companion flange with ST and remove the self lock nut ST 498427200 Apply grease between the oil seal lips ST 498447120 DRIFT 6 15 Press fit the companion flange with ST1 5 2 and ST3 ST1 899874100 INSTALLER ST2 399780104 WEIGHT ST3 498937110 HOLDER DRIVE PINION NOTE Be careful not to damage the bearing FRANGE WRENCH G3M1052 13 Extract the companion flange with a puller S3M0511 ST1
392. sassembly 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 specified points Before disconnecting electrical connectors of sensors or units be sure to disconnect negative terminal from battery All parts should be thoroughly cleaned paying special attention to the engine oil passages pis tons and bearings D PREPARATION TOOL 1 SPECIAL TOOLS ILLUSTRATION TOOL NUMBER DESCRIPTION Rotating parts and sliding parts such as piston bearing and gear should be coated with oil prior to assembly Becareful not to let oil grease or coolant contact the timing belt clutch disc and flywheel All removed parts if to be reused should be re installed in the original positions and directions Bolts nuts and washers should be replaced with new ones as required Even if necessary inspections have been made in advance proceed with assembly work while making rechecks Remove or install engine in an area where chain hoists lifting devices etc are available for ready use Be sure not to damage coated surfaces of body panels with tools or stain seats and windows with coolant or oil Place a cover over fenders as re quired for protection Prior to starting work prepare the following Service tools clean cloth containe
393. se Ref to 6 69 INSTALLATION Transmission Case 4 Install the oil pump Ref to 6MT 65 INSTAL LATION Oil Pump 5 Install the center differential Ref to 6 62 INSTALLATION Center Differential 6 Install the transfer driven gear Ref to 6MT 60 INSTALLATION Transfer Driven Gear 7 Install the extension case Ref to 6 49 IN STALLATION Extension Case 8 Install the oil pipe neutral position switch back up light switch and harness Ref to 6 44 IN STALLATION Oil Pipe Ref to 6MT 47 IN STALLATION Neutral Position Switch Ref to 6MT 45 INSTALLATION Back up Light Switch 9 Install the manual transmission assembly to ve hicle Ref to 6MT 39 INSTALLATION Manual Transmission Assembly C DISASSEMBLY NOTE The sleeve and reverse gear engage at a specified point Mark an engagement point on the sleeve and hub before disassembly 1 Remove the spring pin TRO788 TRO789 3 Remove the washer and reverse idler gear TRO790 A Washer B Reverse idler gear 4 Remove the knock pin and reverse idler gear needle bearing TRO791 A Knock pin B Reverse idler gear needle bearing 6MT 96 REVERSE IDLER GEAR ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 5 Remove the collar 9 Remove the washer and needle bearing 6 Remove the reverse sleeve
394. sensor STi ABS G sensor joint connector STi B264 ABS relay B271 F B B275 Fan control amp B282 Auto A C control mod B283 ule Remote control rear view mirror switch Intercooler water spray timer STi B292 ABS G sensor Air mix actuator Auto A C Intercooler water spray switch STi B296 Rear defogger timer Line end check con nector B304 2 Black ABS condenser Non colored B198 B209 B224 B257 B261 B284 B286 B293 B294 B300 WI 101 BULKHEAD WIRING HARNESS COMPARTMENT WIRING SYSTEM ES el ST mm 5 2 ie Ee lt WO WITH OBD MODEL WITHOUT OBD MODEL 3 BO0482 WI 102 BULKHEAD WIRING HARNESS COMPARTMENT WIRING SYSTEM 2 RHD MODEL Connector Connecting to Connector Connecting to Pole Color Name Pole Color Name Front door cord RH Yel low SRS Airbag harness Black Turn amp hazard module Shield amp sensor ground joint connector E G Non turbo with OBD model Black Black Instrument panel wir ing harness Shield amp sensor ground joint connec tor E G Turb
395. sfer Driven Gear gt 6MT model lt Ref to 6MT 60 Transfer Driven Gear gt TC 5 TRANSFER CASE CENTER DIFFERENTIAL TRANSFER CASE 11 Center Differential A NOTE For removal installation and inspection work refer to MT section MT model lt Ref to MT 56 Center Differential gt 6MT model lt Ref to 6MT 62 Center Differential gt TC 6 EXTENSION CASE FOR 6 TRANSFER CASE 14 Extension Case for 6MT A NOTE For removal installation and inspection work refer to 6MT section lt Ref to 6MT 49 Extension Case gt TC 7 EXTENSION CASE FOR 6 TRANSFER CASE TC 8 DRIVE SHAFT SYSTEM pour pum Page General Description a scii rito teer costes EUR Dr Ra DOR UR KR OX EON Propeller Shaft Front Axle Rear Axle Brive Sliatts a RSEN E EM 9 Rear Drive Shaft General Diagnostic Table GENERAL DESCRIPTION DRIVE SHAFT SYSTEM 1 General Description A SPECIFICATIONS 1 PROPELLER SHAFT Model Turbo Non turbo STi Propeller shaft type type UJ type Front propeller shaft Joint to joint length 14 579
396. sher and snap pin to reverse check lever NOTE Take care to install the snap in proper direc tion e Conduct the adjustment of reverse check cable before installation lt Ref to CS 16 ADJUSTMENT Reverse Check Cable gt A TRO957 Reverse check cable B Washer Snap pin Front side 6 Install the rear exhaust pipe and muffer lt Ref to EX TURBO 13 INSTALLATION Rear Exhaust Pipe gt lt Ref to EX TURBO 14 INSTALLATION Muffer gt 7 Install the under cover 8 Install the boot plate NOTE Install the inner boot without any twist Tightening torque 7 5 0 76 kgf m 5 5 ft lb TRO953 9 Install the console box Ref to El 40 INSTAL LATION Console box 10 Check that the gear shift is correctly shifted to each gear CS 6 6MT GEAR SHIFT LEVER CONTROL SYSTEMS C DISASSEMBLY 4 Remove the reverse check cable from cable 1 Remove the spring pin from slider plate TRO958 0961 A Slider Cable plate B Spring pin B Reverse check cable 2 Remove the slider and spring 5 Remove the reverse check cable from gear shift assembly 0959 Slider 6 Remove the holder and spring seat B Spring 3 Cut the band clip TRO963 TRO960 A Holder CS 7 GEAR SHIFT LEVER CONTROL SYSTEM
397. sing ST2 ST1 498267600 CYLINDER HEAD TABLE ST2 499718000 VALVE SPRING REMOVER CAUTION Be sure to install the valve springs with their close coiled end facing the seat on the cylinder head S2M1881A 4 Compress the valve spring and fit valve spring retainer key 5 After installing tap the valve spring retainers lightly with wooden hammer for better seating 2 Apply oil to the surface of the valve lifter 3 Install the valve lifter E INSPECTION 1 CYLINDER HEAD 1 Make sure that no crack or other damage exists In addition to visual inspection inspect important areas by means of red check 2 Measure the warping of the cylinder head sur face that mates with crankcase by using a straight edge A and thickness gauge B If the warping exceeds 0 05 mm 0 0020 in re grind the surface with a surface grinder Warping limit 0 05 mm 0 0020 in Grinding limit 0 1 mm 0 004 in Standard height of cylinder head 127 5 mm 5 02 in CAUTION Uneven torque for the cylinder head nuts can cause warping When reassembling pay spe cial attention to the torque so as to tighten evenly 52 1840 2 VALVE SEAT Inspect intake and exhaust valve seats and correct the contact surfaces with valve seat cutter if they are defective or when valve guides are replaced Valve seat width W Intake Standard 1 0 mm 0 039 Limit 1 7 0 067 Standa
398. sion 350 rpm and fully open throttle Standard 951 1 147 kPa 9 7 11 7 kg cm 138 166 psi Limit 883 kPa 9 0 kg cm 128 psi Difference between cylinders 49 kPa 0 5 kg cm 7 psi ME STi 22 IDLE SPEED 3 Idle Speed A INSPECTION 1 Before checking idle speed check the following 1 Ensure that air cleaner element is free from clogging ignition timing is correct spark plugs are in good condition and that hoses are con nected properly 2 Ensure that malfunction indicator light CHECK ENGINE light does not illuminate 2 Warm up the engine 3 Stop the engine and turn the ignition switch to OFF 4 Insert the cartridge to SUBARU SELECT MONI TOR 5 Connect SUBARU SELECT MONITOR to the data link connector 6 Turn the ignition switch to ON and SUBARU SELECT MONITOR switch to ON 7 Select 2 Each System Check in Main Menu 8 Select Engine Control System in Selection Menu 9 Select 1 Current Data Display amp Save in En gine Control System Diagnosis 10 Select 1 12 Data Display in Data Display Menu 11 Start the engine and read engine idle speed 12 Check the idle speed when unloaded With headlights heater fan rear defroster radiator fan air conditioning etc OFF Idle speed No load and gears in neutral 700450 rpm 13 Check the idle speed when loaded Turn air conditioning switch to ON and operate compres sor for at least one minut
399. size mark 2 cylinder bore size mark 3 cylinder bore size mark 4 cylinder bore size mark 5 gt 2 How to measure the inner diameter of each inder Measure the inner diameter of each cylinder in both the thrust and piston pin directions at the heights shown in the figure using a cylinder bore gauge CAUTION Measurement should be performed at a temper ature of 20 C 68 F Taper Standard 0 015 mm 0 0006 in Limit 0 050 mm 0 0020 in Out of roundness Standard 0 010 mm 0 0004 in Limit 0 050 mm 0 0020 in AN Unit mm in S2M1821A A Piston pin direction B Thrust direction 3 When the piston is to be replaced due to general or cylinder wear determine a suitable sized piston by measuring the piston clearance ME STi 85 CYLINDER BLOCK MECHANICAL 4 How to measure the outer diameter of each pis ton Measure the outer diameter of each piston at the height shown in the figure Thrust direction CAUTION Measurement should be performed at a temper ature of 20 C 68 F Piston grade point H 37 0 mm 1 457 in Piston outer diameter Standard A 91 985 91 995 mm 3 6214 3 6218 in 91 975 91 985 3 6211 3 6214 in 0 25 mm 0 0098 in oversize 92 225 92 235 3 6309 3 6313 0 50 0 0197 oversize 92 475 92 485 3 6407 3 6411 B2M1305A
400. ssor brackets on cylinder head 39 Install the V belt Ref to ME STi 43 IN STALLATION V belt gt 40 Install the intake manifold Ref to FU TUR BO 15 REMOVAL Intake Manifold gt ME STi 82 CYLINDER BLOCK C DISASSEMBLY MECHANICAL EN1522 1 Connecting rod cap 3 ring 5 Oil ring 2 Connecting rod bearing 4 Second ring 6 Circlip 1 Remove the connecting rod cap 2 Remove the connecting rod bearing CAUTION Arrange removed connecting rod connecting rod cap and bearing in order to prevent confu sion 3 Remove the piston rings using the piston ring ex pander 4 Remove the oil ring by hand CAUTION Arrange the removed piston rings in good order to prevent confusion 5 Remove the circlip ME STi 83 CYLINDER BLOCK MECHANICAL D ASSEMBLY EN1523 1 Install the connecting rod bearings on connect ing rods and connecting rod caps CAUTION Apply oil to the surfaces of the connecting rod bearings 2 Install the connecting rod on crankshaft CAUTION Position each connecting rod with the side mark facing forward 3 Install the connecting rod cap with connecting rod nut Ensure the arrow on connecting rod cap faces the front during installation CAUTION Each connecting rod has its own mating cap Make sure that they are assembled correctly by checking their matching number When tightening the con
401. steering oil pres sure switch B135 10 13 ON 0 OFF 13 14 Front oxygen A F sen sor signal B137 2 8 3 2 2 8 3 2 Front oxygen A F sen sor signal B137 24 27 24 27 Front oxygen A F sen sor shield B136 0 0 SSM GST communica tion line B134 Less than 1 lt gt More than 4 Less than 1 lt gt More than 4 Torque control 1 signal B134 More than 4 More than 4 Torque control 2 signal B134 More than 4 More than 4 Torque control cut sig nal B136 8 8 EN TURBO 16 ENGINE CONTROL MODULE ECM I O SIGNAL ENGINE DIAGNOSTICS Gon Signal V Content nector Ignition SW ON Note A Engine OFF Engine ON Idling AT diagnosis input sig B135 Less than 1 lt gt More Less than 1 lt gt More Waveform nal 2 than 4 than 4 AT load signal 2 B135 4 3 4 4 0 9 1 4 GND sensors B135 GND injectors 136 GND ignition system 136 136 134 134 134 GND power supply GND control systems GND oxygen sensor heater 1 GND oxygen sensor heater 2 1 STi model 2 Except STi model B137 B137 EN TURBO 17 LIST OF DIAGNOSTIC TROUBLE CODE DTC ENGINE DIAGNOSTICS 17 List of Diagnostic Trouble Code DTC A LIST 2 STI MODEL Following DTCs are only for STi model Refer to normal turbo mo
402. t M P W Total kgf Ib Option Air conditioner Cruise control ABS Aluminium wheel Rear spoiler Spoiler pac 1 For option code refer to ID section Ref to ID 5 Option code SPC 6 Option codex1 IMPREZA SPECIFICATIONS Model 2 0 L Turbo WRX STi 5MT 4AT 5MT 6MT Curb weight C W Front kgf Ib 760 1 676 785 1 731 815 1 797 875 1 929 Rear 535 1 179 530 1 168 550 1 213 575 1 268 Total 1 295 2 855 1 315 2 899 1 365 3 009 1 450 3 197 Maximum permissible axle weight M P A W Front 930 2 050 930 2 050 970 2 138 1 030 2 271 Rear 910 2 006 910 2 006 920 2 028 920 2 028 Maximum permissible weight M P W Total 1 780 3 924 1 780 3 924 1 850 4 079 1 880 4 145 Option Air conditioner Cruise control ABS Aluminium wheel Rear spoiler Spoiler pac 1 For option code refer to ID section Ref to ID 5 Option code SPC 7 SPECIFICATIONS Wagon Option 1 IMPREZA Model Curb weight C W Front kgf Ib Rear kgf Ib Total kgf Ib Maximum permissible axle weight M P A W Front kgf Ib Rear kgf Ib Maximum permissible weight M P W T
403. t Clear Memory Mode lt Ref to EN TURBO 45 OP ERATION Clear Memory Mode gt and Inspection Mode lt Ref to EN TURBO 42 Inspection Mode gt WIRING DIAGRAM ECM A a VARIABLE VALVE TIMING SOLENOID VALVE LH EN1531 EN TURBO 36 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE DTC ENGINE DIAGNOSTICS Yes No CHECK HARNESS BETWEEN ECM AND VARIABLE VALVE TIMING SOLENOID VALVE 1 Turn the ignition switch to OFF 2 Disconnect the connector from ECM and variable valve timing solenoid valve 3 Measure the resistance between ECM and variable valve timing solenoid valve Connector amp terminal B84 17 E37 No 1 B84 No 16 E37 No 2 Is the resistance less than 1 Q Go to step 2 Repair the open circuit in harness between ECM and variable valve tim ing solenoid valve connector NOTE In this case repair the following Open circuit in harness between ECM and variable valve timing sole noid valve connec tor Poor contact in coupling connec tor CHECK HARNESS BETWEEN ECM AND VARIABLE VALVE TIMING SOLENOID VALVE 1 Turn the ignition switch to OFF 2 Disconnect the connector from ECM and variable valve timing solenoid valve 3 Measure the resistance between ECM and variable valve timing solenoid valve Connector amp terminal
404. tandard 1 3 1 9 0 051 0 075 Limit of sinking 0 3 0 012 Limit for deflection mm in 0 8 0 031 at 107 4 21 2 0 L TURBO STi 0 8 0 031 at R 110 4 33 Clutch cover Type Pull type Diaphragm set load kgf Ib 930 2 050 Clutch disc Facing material Woven Non asbestos O D x I D x thickness mm in 240 x 160 x 3 5 9 45 x 6 30 x 0 138 Spline O D mm in 25 2 0 992 No of teeth 24 Clutch release lever ratio 1 7 Release bear ing Grease packed self aligning Clutch pedal Full stroke 130 135 5 12 5 31 Free play 8 13 0 12 0 51 Clutch disc I D Inner d O D Outer Stroke 13 3 14 7 0 524 0 579 Play at release lever center Depth of rivet head mm in Standard 1 3 1 9 0 051 0 075 Limit of sinking 0 3 0 012 Limit for deflection iameter diameter mm in 0 8 0 031 at R 110 4 33 CL 2 1 0 0 039 at R 110 4 33 GENERAL DESCRIPTION CLUTCH SYSTEM COMPONENT 6 CLUTCH PIPE AND HOSE FOR TURBO MODEL LHD MODEL TRO979 1 Operating cylinder Except STi 6 Pipe Tightening torque N m kgf m ft Ib model 7 Master cylinder ASSY 8 0 8 5 8 2 Washer 8 Clevis pin T2 15 1 5 10 8 3 Clutch hose
405. th Diagnostic Trouble Code DTO 19 19 General Diagnostic Table ELECTRICAL COMPONENTS LOCATION ENGINE DIAGNOSTICS 4 Electrical Components Location A LOCATION 1 ENGINE Module LHD model 1 1423 RHD model Rss T p 1 1424 1 control module ECM 3 Test mode connector 2 CHECK ENGINE malfunction indi 4 Data link connector cator lamp MIL EN TURBO 2 ELECTRICAL COMPONENTS LOCATION ENGINE DIAGNOSTICS EN1425 EN TURBO 3 ELECTRICAL COMPONENTS LOCATION ENGINE DIAGNOSTICS Sensor ee c EA E En CZ oa E as AM AL 6 4 8 5 1524 1 Pressure sensor 4 Knock sensor 8 Tumble generator valve position 2 Engine coolant temperature sen 5 Camshaft position sensor sensor Except STi model Sor 6 Crankshaft position sensor 9 Variable valve timing camshaft 3 Throttle position sensor 7 Mass air flow and intake air tem position sensor S
406. the A C pressure hoses from A C compressor 52 1584 10 Remove the intercooler lt Ref to IN TURBO 10 REMOVAL Intercooler gt 11 Disconnect the following connectors and cable 1 Engine harness connector D ee gt 3 Engine harness connector 52 0731 52 1930 ME STi 32 ENGINE ASSEMBLY MECHANICAL 4 Generator connector terminal and A C 2 Heater inlet outlet hose compressor connectors 0205 13 Remove the power steering pump from brack et 1 Loosen the lock bolt and slider bolt and EE move the front side V belt Ref to ME STi 43 FRONT SIDE BELT REMOVAL V belt gt 2 Disconnect the power steering switch con nector A A C compressor connector B 0360 3 Remove the pipe with bracket from intake manifold 12 Disconnect the following hoses 1 Brake booster vacuum hose 0204 ME STi 33 MECHANICAL ENGINE ASSEMBLY 4 Remove the power steering pump from en gine ql quu eZ H2M1954 5 Remove the power steering tank from the bracket by pulling it upward 61 6 Place the power steering pump on the right side wheel apron 16 Remove the nuts which install front cushion rubber onto front c
407. the belt and pulley 1 Install the front side belt C and tighten the slid er bolt so as to obtain the specified belt tension Ref to ME STi 44 INSPECTION V belt gt 2 Tighten the lock bolt A 3 Tighten slider bolt B Tightening torque Lock bolt through bolt 25 2 5 kgf m 18 ft lb Slider bolt 8 0 8 kgf m 5 5 ft lb 0225 ME STi 43 V BELT MECHANICAL 2 REAR SIDE BELT 1 Install the rear side belt and tighten the slider bolt B so as to obtain the specified belt tension Ref to ME STi 44 INSPECTION V belt gt 2 Tighten the lock nut A Tightening torque Lock nut 22 6 N m 2 3 kgf m 16 6 ft Ib 0226 INSPECTION 1 Replace the belts if cracks fraying or wear is found 2 Check the drive belt tension and adjust it if nec essary by changing generator installing position and or idler pulley installing position Belt tension A replaced 7 9 mm 0 276 0 354 in reused 9 11 0 354 0 433 in B replaced 7 5 8 5 mm 0 295 0 335 in reused 9 0 10 0 mm 0 354 0 394 in With Air conditioner 98 N 10 kgf 22 Ib EN1520 C P Crankshaft pulley GEN Generator P S Power steering oil pump pulley Air conditioning compressor pulley Idler pulley ME STi 44 CRANKSHAFT PULLEY 13 Crankshaft Pulley A REMOVAL 1 Remove the V belt Ref to ME ST
408. them 18 Install the air intake system 1 Install the intercooler lt Ref to IN TURBO 11 INSTALLATION Intercooler gt 2 Install the air cleaner element and air clean er upper cover 3 Install the engine harness connector brack et 4 Install the filler hose to air cleaner case H2M1962B A Filler hose B Connector bracket 19 Install the A C pressure hoses With A C CAUTION Use new O rings Tightening torque 25 2 5 kgf m 18 1 ft lb 52 1584 20 Install the radiator lt Ref to CO 42 INSTALLA TION Radiator gt 21 Install the coolant filler tank lt Ref to CO 53 INSTALLATION Coolant Filler Tank gt 22 Install the window washer tank 23 Install the battery in vehicle and connect the cables 24 Fill coolant lt Ref to CO 26 FILLING OF EN GINE COOLANT REPLACEMENT Engine Cool ant gt ME STi 39 ENGINE ASSEMBLY MECHANICAL 25 Charge the A C system with refrigerant lt Ref to AC 22 OPERATION Refrigerant Charging Pro cedure gt 26 Remove the front hood stay and close the front hood 27 Take off the vehicle from lift arms ME STi 40 ENGINE MOUNTING 10 Engine Mounting A REMOVAL 1 Remove the engine assembly lt Ref to ME STi 32 REMOVAL Engine Assembly gt 2 Remove the engine mounting from engine as sembly B INSTALLATION Install in the reverse order of removal Tightening torque Engine mounting 35
409. to 6 65 INSTAL LATION Oil Pump gt 19 Install the center differential lt Ref to 6MT 62 INSTALLATION Center Differential gt 20 Install the transfer driven gear lt Ref to 6MT 60 INSTALLATION Transfer Driven Gear gt 21 Install the extension case lt Ref to 6MT 49 IN STALLATION Extension Case gt 22 Install the oil pipe neutral position switch back up light switch and harness lt Ref to 6 44 INSTALLATION Oil Pipe gt lt Ref to 6MT 47 IN STALLATION Neutral Position Switch gt lt Ref to 6MT 45 INSTALLATION Back up Light Switch gt 23 Install the manual transmission assembly to ve Ref to 6MT 39 INSTALLATION Manual Transmission Assembly gt 6MT 109 FRONT DIFFERENTIAL ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL C DISASSEMBLY 1 DIFFERENTIAL CASE 1 Secure the differential assembly on a vise then remove the hypoid driven gear 0822 2 Drive out straight pin from the differential assem bly toward hypoid driven gear Without LSD ST 899904100 REMOVER G3M0667 3 Pull out the pinion shaft and remove the bevel pinion gear and bevel gear and washer Without LSD 0823 Pinion shaft Bevel pinion gear Bevel gear Washer 4 Using the ST remove the hypoid driven gear side bearing ST 399527700 PULLER SET G3M0668 5 Using a screw driver make clearance of 2 3 mm
410. ton ring and oil ring in cyl inder and measure the piston ring gap with a thick ness gauge Unit mm in Standard Limit 0 20 0 25 0 0079 0 0098 0 35 0 50 1 0 0 039 Top ring Piston Second ring gap ring 0 0138 0 0197 Oil ring 0 20 0 50 rail 0 0079 0 0197 1 0 0 039 1 5 0 059 Thickness gauge 3 Measure the clearance between piston ring and piston ring groove with a thickness gauge CAUTION Before measuring the clearance clean the pis ton ring groove and piston ring Unit mm in Standard Limit 0 040 0 080 0 0016 0 0031 0 030 0 070 0 0012 0 0028 Clearance between pis ton ring and piston ring Second groove ring Top ring 0 15 0 0059 0 15 0 0059 Thickness gauge B2M1402A 5 CONNECTING ROD 1 Replace the connecting rod if the large or small end thrust surface is damaged 2 Check for bend or twist using a connecting rod aligner Replace the connecting rod if the bend or twist exceeds the limit Limit of bend or twist per 100 mm 3 94 in in length 0 10 mm 0 0039 in B2M1184B A Thickness gauge B Connecting rod 3 Install the connecting rod fitted with bearing to crankshaft and measure the side clearance thrust clearance Replace the connecting rod if the side clearance exceeds the specified limit Connecting rod side
411. tor from ABSCM amp H U 3 Measure the resistance between ABSCM amp H U connector terminals Connector amp terminal LHD B301 No 6 No 28 RHD F49 No 6 No 28 Is the resistance between 5 0 and 5 6 Go to step 5 Repair the har ness connector between G sensor and ABSCM amp H U 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 LHD B301 No 6 Chassis ground RHD F49 No 6 Chassis ground Is the resistance more than 1 MO Go to step 6 Repair the har ness between G sensor and ABSCM amp H U CHECK BATTERY SHORT OF HARNESS Measure the voltage between ABSCM amp H U connector and chassis ground Connector amp terminal LHD B301 No 6 Chassis ground RHD F49 No 6 Chassis ground Is the voltag e less than 1 V Go to step 7 Repair the har ness between G sensor and ABSCM amp H U 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 LHD B301 No 6 Chassis ground RHD F49 No 6 Chassis ground 5 Is the voltag e less than 1 V ABS 13 Go to step 8 Repair the har ness between G sensor and ABSCM amp H U DIAGNOSTICS CHART WIT
412. transmis sion then remove the transmission from vehicle NOTE Rotate the ST ENGINE SUPPORT ASSY counterclockwise to shorter the ST and lower the rear side of engine to facilitate removal Take not to contact the transmission with body when pulling backward to remove Remove carefully The clutch pipe and breather pipe may interfere each other TRO645 TRO646 B INSTALLATION 1 Set the release fork release bearing and release shaft to transmission lt Ref to CL 26 INSTALLA TION Release Bearing and Lever gt 2 Install the transmission NOTE Make sure the main shaft spline part is inserted completely Make sure the rear side of engine is lowered Tightening torque 50 5 1 kgf m 36 9 ft lb B2M2790 MANUAL TRANSMISSION AND DIFFERENTIAL 3 Move the transmission to the right side then in stall the joint COMPL bolt stay bolt and reverse check cable Tightening torque T1 11 8 N m 1 2 kgf m 8 7 ft lb 2 32 3 3 kgf m 23 6 ft lb TRO647 A Reverse check cable 4 Install the front crossmember and rear cross member NOTE Rotate the ST ENGINE SUPPORT ASSY turn buckle clockwise make longer the ST and lift up the rear side of engine to facilitate installation Tightening torque T1 70 N m 7 1 kgf m 51 6 ft lb T2 140 N m 14 3 kgf m 103 ft Ib
413. turned 1 BEVEL PINION GEAR BACKLASH Measure the bevel pinion gear backlash If it is not within specifications install a suitable washer to adjust it lt Ref to 6MT 114 ADJUSTMENT Front Differential Assembly gt NOTE Be sure the pinion gear teeth contacts adjacent gear teeth during measurement Before measuring the backlash rotate each gear to get each part accustomed ST1 498247001 MAGNET BASE ST2 498247100 DIAL GAUGE Standard backlash 0 13 0 18 0 0051 0 0071 YK 2 Check the hypoid gear backlash If it is not within specifications adjust it lt Ref to 6MT 114 HY POID GEAR BACKLASH Front Differential As sembly gt 3 TOOTH CONTACT OF HYPOID GEAR 1 Be sure the hypoid gear backlash is within spec ifications If it is not within specifications adjust it lt Ref to 6MT 114 HYPOID GEAR BACKLASH Front Differential Assembly gt G3M0670 MANUAL TRANSMISSION AND DIFFERENTIAL 2 Apply a uniform thin coat of red lead on both tooth surfaces of three or four teeth of the hypoid driven gear 7 3 Install the drive pinion shaft assembly and then secure with four bolts NOTE Use the old gasket and washer to prevent the mat ing surface of housing from damaging 0816 Tightening torque 69 7 0 kgf m 50 9 ft lb 4 Rotate the drive pinion shaft to right a
414. tween lateral G sen sor connector terminals Connector amp terminal B257 2 No 3 Is the voltage between 2 3 and 2 7 V when lateral G sensor is horizontal Go to step 9 Replace the lateral G sensor Ref to ABS 5 Lateral G Sensor CHECK LATERAL G SENSOR Measure the voltage between lateral G sensor connector terminals Connector amp terminal B257 No 2 No 3 Is the voltage between 3 3 and 3 7 V when lateral G sensor is inclined forwards to 9092 ABS 21 Go to step 10 Replace the lateral G sensor Ref to ABS 5 Lateral G Sensor DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS Step Check Yes No CHECK LATERAL G SENSOR Is the voltage between 1 3 and Go to step 11 Replace the lateral Measure the voltage between lateral G sensor 1 7 V when lateral G sensor is G sensor lt Ref to connector terminals inclined backwards to 90 ABS 5 Lateral G Connector amp terminal Sensor gt B257 No 2 No 3 CHECK POOR CONTACT IN CONNECTORS 15 there poor contact in con the con Go to step 12 Turn the ignition switch to OFF nector between ABSCM amp H U and lateral G sensor CHECK ABSCM amp H U Is the same DTC as in current Replace the Go to step 13 1 Connect all connectors diagnosis still being output ABSCM amp H U 2 Erase the memory Ref to ABS 4 3 Perform the inspection mode ABS Control M
415. ty air cleaner element Fuel line Defective fuel pump and relay Clogged fuel line Lack of or insufficient fuel Belt Defective timing Compression Incorrect valve clearance Loosened spark plugs or defective gasket Loosened cylinder head bolts or defective gasket Improper valve seating Defective valve stem Worn or broken valve spring Worn or stuck piston rings cylinder and piston Incorrect valve timing Improper engine oil low viscosity Cooling system Overheating Others Malfunction of evaporative emission control system ME STi 94 O U w gt 0010 09 O w w w w DW w W gt gt gt gt S O O 5 W gt O w W O W W gt 5 W W W W gt gt Trouble ENGINE TROUBLE IN GENERAL Problem Parts etc MECHANICAL Possible Cause 5 Engine does not return to idle Engine control system lt Ref to EN TURBO 2 Basic Diagnostic Procedure gt gt Intake system Loosened or cracked vacuum hose Others Stuck or damaged throttle valve Accelerator cable out of adjustment 6 Dieseling Run on Engine control system lt Ref to EN TURBO 2 Basic Diagnostic Procedure gt Cooling system Overheating Others Malfunction of evaporative emission control system 7 After b
416. ulk ring 2nd synchro cone and inner baulk ring C 8 2 TRO766 A Outer baulk ring B 2nd synchro cone C Inner baulk ring 9 Using the ST remove each parts ST 18754AA000 REMOVER B E C F dr DI i TRO767 2nd bush 1st 2nd hub Outer baulk ring 1st synchro cone Inner baulk ring 1st driven gear 1st needle bearing 5 gt 9 MANUAL TRANSMISSION AND DIFFERENTIAL D ASSEMBLY NOTE Replace the following parts as a set Sleeve and hub Outer baulk ring 1st synchro cone inner baulk ring Outer baulk ring 2nd synchro cone inner baulk ring 1 Sufficiently apply gear oil to the drive shaft 1st needle bearing and inner periphery of 1st driven gear 2 Install the 1st needle bearing TRO769 TRO770 6MT 89 DRIVEN GEAR ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 5 Align protrusion portions of the 1st synchro cone Make sure to install the 1st 2nd hub in proper di to the holes of 1st drive gear to install rection 6 Install the outer baulk ring MC TRO950 TRO772 7 Install the 1st 2nd hub a ii uter baulk ring NOTE Cutout portion 1st 2nd hub Alig
417. urned by hand TRO753 A Retainer B Outer bearing inner race 29 Make sure the taper roller bearing is smoothly turned by hand If not replace the taper roller bear ing as a set and reassemble 30 Install the lock washer and new lock nut 31 Set the main shaft assembly to ST then tighten the lock nut 18665AA000 HOLDER ST2 18664AA000 BASE Tightening torque 392 40 0 kgf m 289 ft lb TRO729 32 Using the ST caulk four portions on the lock nut to obtain dimension A 27 0 3 mm 1 06 0 01 in ST 18668AA000 PUNCH NOTE Do not crack the caulking part of lock nut TRO754 6MT 84 MAIN SHAFT ASSEMBLY E INSPECTION Disassembled parts should be washed clean first and then inspected carefully 1 Bearing Replace the bearings in the following cases Worn rusted and damaged bearing Bearings that fail to turn smoothly or make ab normal noise when turned Bearings having other defects 2 Bushing each gear Replace the bushings in the following case When the sliding surface is damaged or abnor mally worn 3 Gears Replace the gears in the following cases Gear teeth surfaces are broken or excessively worn Parts that contact the baulk ring is damaged The inner surface of gear is damaged 4 Baulk ring synchro cone Replace the baulk ring and synchro cone in the fol lowing case Worn rusted and damage
418. urning in exhaust system Engine control system lt Ref to EN TURBO 2 Basic Diagnostic Procedure gt Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective PCV Loosened oil filler cap Belt Defective timing Compression Incorrect valve clearance Loosened spark plugs or defective gasket Loosened cylinder head bolts or defective gasket Improper valve seating Defective valve stem Worn or broken valve spring Worn or stuck piston rings cylinder and piston Incorrect valve timing Lubrication system Incorrect oil pressure Cooling system Over cooling Others Malfunction of evaporative emission control system 8 Knocking Engine control system Ref to EN TURBO 2 Basic Diagnostic Procedure Intake system Loosened oil filler cap Belt Defective timing Compression Incorrect valve clearance Incorrect valve timing Cooling system Overheating 9 Excessive engine oil con sumption Intake system Loosened or cracked PCV hose Defective PCV valve Loosened oil filler cap Compression Defective valve stem Worn or stuck piston rings cylinder and piston Lubrication system Loosened oil
419. ust Standard 1 5 mm 0 059 in Limit 0 8 0 031 in Valve overall length Intake 104 4 mm 4 110 in Exhaust 104 7 mm 4 122 in 450 1 9 Ta 1 909 19 G2M0153 2 Puta small amount of grinding compound on the seat surface and lap the valve and seat surface In stall a new intake valve oil seal after lapping 5 VALVE SPRINGS 1 Check valve springs for damage free length and tension Replace the valve spring if it is not within the specifications presented in the table 2 To measure the squareness of the valve spring stand the spring on a surface plate and measure its deflection at the top using a try square Valve spring 44 67 mm 1 7587 in 220 7 15 7 22 5 1 6 kgf 49 6 3 5 36 0 mm 1 417 in Free length Tension spring height 582129 59 3 3 0 kgf 130 8 6 6 26 45 mm 1 041 in 2 5 1 9 mm 0 075 in Squareness G2M0154 ME STi 70 CYLINDER HEAD ASSEMBLY MECHANICAL 6 INTAKE AND EXHAUST VALVE OIL SEAL Replace the oil seal with new one if lip is damaged or spring out of place or when the surfaces of in take valve and valve seat are reconditioned or in take valve guide is replaced 1 Place the cylinder head on ST1 2 Press in oil seal to the specified dimension indi cated in the figure by using ST2 ST1 498267600 CYLINDER HEAD TABLE ST2 498857100 VALVE OIL SEAL GU
420. ve the V belt Ref to ME STi 43 RE MOVAL V belt gt 2 Remove the crankshaft pulley Ref to ME STi 45 REMOVAL Crankshaft Pulley gt 3 Remove the left hand belt cover A 4 Remove the right hand belt cover B 5 Remove the front belt cover C 52 1221 INSTALLATION 1 Install the front belt cover Tightening torque 5 0 5 kgf m 3 6 ft lb 2 Install the right hand belt cover B Tightening torque 5 0 5 kgf m 3 6 ft lb 3 Install the left hand belt cover A Tightening torque 5 0 5 kgf m 3 6 ft lb 52 1221 4 Install the crankshaft pulley Ref to ME STi 45 INSTALLATION Crankshaft Pulley gt 5 Install the V belt lt Ref to ME STi 43 INSTAL LATION V belt gt C INSPECTION Make sure the cover is not damaged ME STi 46 TIMING BELT ASSEMBLY MECHANICAL 15 Timing Belt Assembly A REMOVAL 1 TIMING BELT 1 Remove the V belt Ref to ME STi 43 RE MOVAL V belt gt 2 Remove the crankshaft pulley Ref to ME STi 45 REMOVAL Crankshaft Pulley gt 3 Remove the belt cover Ref to ME STi 46 REMOVAL Belt Cover 4 Remove the timing belt guides C EN0259 5 If the alignment mark and or arrow mark which indicates rotation direction on timing belt fade away put new marks before removing the timing belt as follows 1 Turn the crankshaft using
421. ver mix up the right and left hand bearing rac es and cones ST 18759AA000 PULLER ASSY ST 080031 9 Remove the crown gear by loosening the crown gear bolts NOTE Further disassembling is not allowed 53 0509 10 Hold the companion flange with ST and remove the drive pinion nut ST 498427200 FLANGE WRENCH G3M1052 11 lt Extract the companion flange with a puller S3M0511 12 Press fit the end of drive pinion shaft and ex tract it together with the rear bearing cone preload adjusting spacer and washer NOTE Hold the drive pinion so as not to drop it ST 398467700 DRIFT G3M0074 DI 22 REAR DIFFERENTIAL FOR DIFFERENTIALS 13 Remove the rear bearing cone from drive pin ion 050039 14 Remove the front oil seal from differential carri er using ST ST 398527700 PULLER ASSY 53 0513 15 Remove the pilot bearing together with front bearing cone using ST ST 398467700 DRIFT B A S3M0514A Pinion bearing B Front bearing C Rear bearing cup 16 When replacing the bearings tap the front bearing cup and rear bearing cup in this order out of case by using a brass bar S3M0515A A 2 cutouts along diagonal lines B Tap alternately with brass bar D ASSEMBLY 2
422. verall length 4 405 173 4 Overall width 1 730 68 1 1 695 66 7 1 710 67 3 1 730 68 1 Overall height at C W 1 440 56 7 1 465 57 7 1 485 58 5 4 1 475 58 1 1 495 58 9 4 1 440 56 7 Compartment Length 1 890 74 4 1 845 72 6 1 890 74 4 Width 1 380 54 3 Height 1 180 46 5 1 125 44 3 5 1 200 47 2 1 150 45 3 5 1 200 47 2 1 150 45 3 5 1 180 46 5 Wheelbase 2 525 99 4 Tread Front 1 485 58 5 1 460 57 5 1 1 465 57 7 1 460 57 5 1 490 58 7 Rear 1 475 58 1 1 480 58 3 3 1 450 57 1 1 1 455 57 3 1 455 57 3 1 480 58 3 Minimum road clearance Without catalytic converter 150 5 9 155 6 1 2 150 5 9 155 6 1 2 160 6 3 1 1 6L 2 2 0L 3 2 0 L Turbo x4 With roof rail x5 With sun roof B ENGINE Model With catalytic converter 150 5 9 155 6 1 3 Non Turbo 2 01 150 5 9 155 6 1 3 Turbo 2 0 L 160 6 3 155 6 1 Engine type Horizontally opposed liquid cooled 4 cylinder 4 stroke gasoline engine Valve arrangement Overhead camshaft type Bore x Stroke mm in 87 9 x 65 8 3 461 x 2 591 92 x 75 3 62 x 2 95 99 5 x 79 3 92 x 3 11 92 x 75 3 62 x 2 95 Displacement cm cu in 1 597 97 45 1 994 121 67 2
423. verse interlock block B Interlock block 2 Using the ST remove the reverse interlock arm ST 398791700 REMOVER aS A Reverse interlock arm B Interlock arm 0844 6 119 SHIFTER FORK AND ROD MANUAL TRANSMISSION AND DIFFERENTIAL 3 Using the ST remove the interlock arm ST 398791700 REMOVER TRO845 A Interlock arm D ASSEMBLY 1 REVERSE SHIFTER FORK 1 Using the ST install the reverse fork ST 398791700 REMOVER NOTE Make sure to install the reverse fork and rod in proper direction TRO846 A Reverse fork B Reverse rod C Spring pin 2 Using the ST install the reverse arm ST 398791700 REMOVER NOTE Make sure to install the reverse arm and rod in proper direction 0847 A Reverse arm B Reverse rod C Spring pin 2 1ST 2ND 3RD 4TH SHIFTER FORK 1 Using the ST install the 1st 2nd shifter fork ST 398791700 REMOVER NOTE Make sure to install the 1st 2nd shifter fork and rod in proper direction 0848 A 1st 2nd shifter fork B 1st 2nd shifter rod C Spring pin 6MT 120 SHIFTER FORK AND ROD MANUAL TRANSMISSION AND DIFFERENTIAL 2 Using the ST install the 1st 2nd shifter arm ST 398791700 REMOVER NOTE Make sure to install the 1st 2nd shifter arm and fork in proper direction TRO849 A 1st 2nd shifter fork B 1st 2nd shifter arm C Spring p
424. verse order of removal FU TURBO 5 VARIABLE VALVE TIMING SOLENOID VALVE FUEL INJECTION FUEL SYSTEMS 35 Variable Valve Timing Sole noid Valve A REMOVAL Refer to following procedure for removal lt Ref to ME STi 59 REMOVAL Camshaft gt B INSTALLATION Install in the reverse order of removal FU TURBO 6 EMISSION CONTROL AUX EMISSION CONTROL DEVICES EC TURBO 1 General Description 2 Front Catalytic Converter PRECATALYTIC CONVERTER EMISSION CONTROL AUX EMISSION CONTROL DEVICES 4 Precatalytic Converter A REMOVAL 2 STI MODEL NOTE Precatalytic converter is not applied to STi model B INSTALLATION 2 STI MODEL NOTE Precatalytic converter is not applied to STi model EC TURBO 2 INTAKE INDUCTION IN TURBO Resonator Chamber Intercooler Water Tank 1 General Description 2 Cleaner 3 Air Intake Duct 4 Intake Duct 5 Intercooler 6 Turbocharger 7 Air By pass Valve 8 9 GENERAL DESCRIPTION INTAKE INDUCTION 1 General Description A COMPONENT 5 INTERCOOLER WATER TANK EN1545 1 Water tank assembly 2 Water tank cap Tightening torque N m kgf m ft lb 6 0 0 61 4 4 IN TURBO 2 INTERCOOLER WATER TANK 9 Intercooler Water Tank A REMOVAL 1 Disconnect the ground cable from battery G6M0095 2 Remove the trunk trim Ref to El 52 REMOV AL Trunk Trim 3 D
425. with a new one Tightening torque Oil pan side 44 4 5 kgf m 32 5 ft Ib Clutch housing 70 7 1 kgf m 51 6 ft lb TRO634 A Drain plug Oil pan side B Drain plug Clutch housing side 3 Attach the transmission to ST ST 18632AA000 STAND ASSY TRO649 4 Rotating parts should be coated with oil prior to assembly 5 All disassembled parts if to be reused should be reinstalled in the original positions and direc tions 6 Gaskets lock washers and lock nut must be re placed with new ones 7 Liquid gasket should be used where specified to prevent leakage 6MT 42 AIR BREATHER HOSE MANUAL TRANSMISSION AND DIFFERENTIAL 8 Air Breather Hose A REMOVAL Disconnect the air breather hose TRO650 B INSTALLATION Install the air breather hose TRO650 C INSPECTION Make sure the hose is not cracked or clogged 6MT 43 OIL PIPE MANUAL TRANSMISSION AND DIFFERENTIAL 9 Oil Pipe A REMOVAL Remove the oil pipe NOTE Do not reuse the gasket TRO651 B INSTALLATION Install in the reverse order of removal NOTE Always use a new gasket Tightening torque 32 3 3 kgf m 23 6 ft lb TRO651 C INSPECTION 1 Make sure there is no damage on pipe If there is damage replace the pipe 2 Check the joint parts of pipe for oil
426. with scraper since the adapter plate is base point of measurement Do not place the height gauge on shaded area in the figure during measurement TRO756 3 Select the main shaft snap ring lt Ref to 6MT 85 ADJUSTMENT Main Shaft Assembly gt MANUAL TRANSMISSION AND DIFFERENTIAL 4 Shift the 1st 2nd sleeve to 1st driven gear side then press down to the stopper and measure B1 1st driven gear B 1st 2nd sleeve NOTE e Set the indicator of height gauge near measuring object then lock the dial 1 as shown in the figure Turn dial 2 to set the indicator to edge surface of sleeve 1st side Measure five points of the sleeve turning every approx 72 Round off each two upper and lower measurement value Use the remaining center val ue as measurement value TRO758 5 Set the height gauge indicator upside down WI Eel TRO859 Indicator 6MT 123 SHIFTER FORK AND ROD MANUAL TRANSMISSION AND DIFFERENTIAL 6 Shift the 1st 2nd sleeve to 2nd driven gear side then press down to the stopper and measure B2 cl _ TRO860 A 2nd driven gear B 1st 2nd sleeve NOTE e Set the indicator of height gauge near measu

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