2002 IMPREZA SERVICE MANUAL QUICK

I

2002

IMPREZA SERVICE MANUAL

~~

CHASSIS SECTION

QUICK REFERENCE INDEX

a

This service manual has been prepared to provide SUBARU service personnel with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.

This manual includes the procedures for maintenance, disassembling, reassembling, inspection and adjustment of components and diagnostics for 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 specifications contained in this manual are based on the latest product information available at the time of publication approval.

FUJI HEAVY INDUSTRIES LTD.

G18306E5

FRONT SUSPENSION

F S r

1

.

2

.

3

.

4

.

5

.

6

.

7

.

9

.

General Description

Wheel Alignment

Sub Frame

....................................................................................

.........................................................................................

2

8

................................................................................................

16

Front Transverse Link

...............................................................................

17

Front Ball Joint

..........................................................................................

19

Front Strut

.................................................................................................

20

Front Stabilizer

..........................................................................................

24

Front Crossmember

..................................................................................

25

General Diagnostic Table

..........................................................................

26

I

FRONT SUSPENSION

1. General Description

A: SPECIFICATIONS

1.

STABILIZER

GENERAL DESCRIPTION

Model

ALL MODEL

2.

WHEEL ALIGNMENT

Bar diameter.

20 mm (0.79 in)

Sedan Wagon

Model

Caster (common difference: f0'45')

Toe-in

I

Kingpin angle (tolerance: +0"45')

Wheel arch height

[tolerance: f 1 2 mm

(f0.47 in)]

3'35'

I

I

3'25'

I

3'35'

I

3'25'

I

I

I

I

0+3 mm (Of0.12 in)

Each toe anale: kO"O7'30

(Total toe anale: fO"15')

I

14"35'

I

14"20'

I

13"45'

I

13"30'

I

3'25'

13'20'

396 mm 406 mm 387 mm 397 mm

(15.59 in) (15.98 in) (15.24 in) (15.63 in)

AOTE:

Front and rear toe-ins and front camber can be adjusted. If the toe-in or camber tolerance exceeds specifications, adjust toe-in and camber to the middle value of specification.

The other items indicated in the specification table cannot be adjusted. If the other items exceeds specifications, check suspension parts and connections for deformities; replace with new ones as required.

402 mm

5.83 in)

B4M2250B

(1) Front

A

-

B

=

Positive: Toe-in, Negative: Toe-out

a

Each toe angle

FS-2

I


FRONT

SUSPENSION

FS-3

FRONT SUSPENSION

B: COMPONENT


FS-4


FRONT SUSPENSION

Front crossmember

Bolt ASSY

Housing

Washer

Stopper rubber (Rear)

Rear bushing

Stopper rubber (Front)

Ball joint

Transverse link

Cotter pin

Front bushing

Stabilizer link (Except sedan turbo model)

Clamp

Bushing

Stabilizer

Jack-up plate

Dust seal

Strut mount

Spacer

Tightening torque: N.m (kgf-m, ft-lb)

T I : ZO(2.0, 14.5)

T2: 25 (2.5, 18.1)

(20)

Upper spring seat

(21)

Rubber seat

(22)

Dust cover

(23)

Helper

(24)

Coil spring

(25)

Damper strut

(26)

Adjusting bolt

(27)

Castle nut

(28)

Self-locking nut

(29)

Sub frame

(30)

(31

1

Cover

Clip

(32)

T3: 30 (3.1,22)

T4: 34 (3.5,25)

T5: 40 (4.1, 30)

T6: 45 (4.6, 33)

T7: 50 (5.1, 37)

T8: 55 (5.6, 41)

T9: 71 (7.2, 52)

T10: 100 (10.2, 74)

T11: <Ref. to FS-17, INSPECTION,

Sub Frame.>

T12: 175 (17.8, 129)

T13: 190(19.4, 140)

Stabilizer link (Sedan turbo model) T14: 250 (25.5, 184)

1

.-

FS-5

I


FRONT SUSPENSION

C: CAUTION

Wear working clothing, including a cap, protective goggles, and protective shoes during operation.

Remove contamination including dirt and corrosion before removal, installation or disassembly.

Keep the disassembled parts in order and protect them from dust or dirt.

Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly, and replacement.

Use SUBARU genuine grease etc. or the equivalent. Do not mix grease etc. with that of another grade or from other manufacturers.

Be sure to tighten fasteners including bolts and nuts to the specified torque.

Place shop jacks or safety stands at the specified points.

Apply grease onto sliding or revolution surfaces before installation.

Before installing O-rings or snap rings, apply sufficient amount of grease to avoid damage and deformation.

Before securing a part on a vice, place cushion- ing material such as wood blocks, aluminum plate, or shop cloth between the part and the vice.

FS-6


D:

PREPARATION TOOL

1.

SPECIAL TOOLS

ILLUSTRATION

TOOL NUMBER

927380002

FRONT SUSPENSION

REMARKS sed as an adapter for camber & caster gauge

,hen measuring camber and caster.

I

) 281 99AC000 PLATE

2) 281 99AC010 BOLT

927680000

~

NSTALLER &

3EMOVER SET

Jsed for replacing transverse link bushing.

84M2385

927760000

STRUT MOUNT

SOCKET

Used for disassembling and assembling strut and shock mount.

2.

GENERAL PURPOSE

TOOLS

TOOL NAME

Alignment gauge

Turning radius gauge

Toe-in gauge

Dial gauge

REMARKS

Used for wheel alignment measurement.


Used for toe-in measurement.

Used for damper strut measurement.

FS-7

WHEEL ALIGNMENT

FRONT

SUSPENSION

2.

Wheel Alignment

A:

INSPECTION

Check, adjust and/or measure wheel alignment in accordance with procedures indicated in figure:

WHEEL ARCH HEIGHT (FRONT AND REAR)

1

CAMBER (FRONT AND REAR)

I

FRONT TOE-IN

REAR TOE-IN

THRUST ANGLE (REAR)

WHEEL STEERING ANGLE

B4M1 OBBA

FS-8

I

WHEEL ALIGNMENT

FRONT SUSPENSION

1. WHEEL ARCH HEIGHT

1) Adjust the tire pressure to specifications.

2) Set the vehicle under “curb weight” conditions. (Empty luggage compartment, install spare tire, jack, service tools, and top up fuel tank.)

3)

Set the steering wheel in a wheel-forward position.

4)

Suspend a thread from wheel arch (point “ A in figure below) to determine the point directly above center of spindle.

5 )

Measure the distance between measuring point “ A and center of spindle.

I

c

a,

.c

c

3

7

~

Sedan

Wagon

I

OUTBACK

Model

Front

Rear

Front

Rear

Front

Rear

I

t

.-

a,

c

2

m a, a,

c

5

L m a, a

E

.-

c

.c

2

-

f

End

of

spindle;,y//,/

Specified wheel arch height

Turbo mm

(1

~~

376k12

mm

(1

in) mm (1

5.24k0.47

376+12

mm

(1

in)

-

-

Non-turbo mm

(1

mm

(15.0k0.47

mm

(1 5.63k0.47

mm

(1

386k12

(1 suo009

FS-9

I

WHEEL ALIGNMENT

FRONT SUSPENSION

2. CAMBER

Inspection

1) Place the front wheel on turning radius gauge.

Make sure the ground contacting surfaces of front and rear wheels are set at the same height.

2) Set the ST into the center of the wheel, and then install the wheel alignment gauge.

ST 927380002 ADAPTER

2) Turn the camber adjusting bolt so that the camber is set at the specification.

NOTE:

Moving the adjusting bolt by one scale graduation changes the camber by approximately 0’10’.

(1) Alignment gauge

(2) Turning radius gauge

NOTE:

Refer to the ‘SPECIFICATIONS” for the camber va I u es.

Front: <Ref. to FS-2, SPECIFICATIONS, General

Description.>

Rear: <Ref. to RS-2, SPECIFICATIONS, General

Description.>

Front camber adjustment

1) Loosen the two self-locking nuts located at the lower front portion of strut.

CAUTION:

When the adjusting bolt needs to be loosened or tightened, hold its head with a wrench and turn the self-locking nut.

Discard the loosened self-locking nut and replace with a new one.

(1) Strut

(2) Adjusting bolt

(3) Housing

(4)

Outer

( 5 )

Inner

(6) Camber is increased.

(7) Camber is decreased.

J

FS-10

I

WHEEL ALIGNMENT

FRONT SUSPENSION

Camber is increased.

Left side

J

@)

;hte counterclock-

Right side

~

@

Rotate clockwise.

Camber is decreased. u

04M0190

@

Rotate clockwise.

B4M0350

3 )

Tighten the two self-locking nuts.

--

Tightening torque:

175 N.m (1 7.8 kgf-m, 129 ft-lb)

3. CASTER

Inspection

1)

Place the front wheel on turning radius gauge.

Make sure the ground contacting surfaces of front and rear wheels are set at the same height.

2) Set the ST into the center of the wheel, and then install the wheel alignment gauge.

ST 927380002 ADAPTER

B4M03Gn

‘

I

@

;?:e counterclock-

W

B4M0190

4.

FRONT WHEEL TOE-IN

Inspection

1) Using a toe gauge, measure the front wheel toe- in.

Toe-in:

Of3 mm

(OdU.

12 in)

2) Mark the rear sides of left and right tires at height corresponding to the center of spindles and measure distance

“ A

3) Move the vehicle forward so that the marks line up with front sides at height corresponding to the center of spindles.

4)

Measure the distance right marks. Toe-in can then be obtained by the following equation:

A

- B =

Toe-in

I

B

A

i i

(1) Alignment gauge

(2) Turning radius gauge

NOTE:

Refer to the ‘SPECIFICATIONS’ for the caster values. <Ref. to FS-2, SPECIFICATIONS, General

Description.>

Adjustment

1) Loosen the left and right side steering tie-rods lock nuts.

FS-11

I

WHEEL ALIGNMENT

FRONT SUSPENSION

2) Turn the left and right tie rods equal amounts until the toe-in is at the specification.

Both the left and right tie-rods are right-hand threaded. To increase toe-in, turn both tie-rods clockwise equal amounts (as viewed from the inside of the vehicle).

4)

Measure the distance “B” between left and right marks. Toe-in can then be obtained by the following equation:

A

-

B

=

Toe-in

I

-

S4M0348A

(1) Lock nut

3) Tighten the tie-rod lock nut.


N-m (8.5 61.5 ff-lb)

CAUTION:

Correct the tie-rod boot, if it is twisted.

NOTE:

Check that the left and right wheel steering angle is within specifications.

5.

REAR WHEEL

TOE-IN

Inspection

1) Using a toe-in gauge, measure the rear wheel toe-in.

Toe-in:

-132 mm

(-0.039fo.079 in)

2)

Mark the rear sides of left and right tires at height corresponding to the center of spindles and measure distance

“A”

between marks.

3) Move the vehicle forward so the that marks line up with front sides at height corresponding to the center of spindles.

Adjustment

1) Loosen the self-locking nut on inner side of link rear.

CAUTION:

When loosening or tightening the adjusting bolt, hold the bolt head and turn self-locking nut.


(1)

Adjusting

bolt

(2) Link rear

2) Turn the adjusting bolt head until toe-in is at the specification.

FS-12

WHEEL

ALIGNMENT

FRONT

SUSPENSION

NOTE:

When the left and right wheels are adjusted for toe-in at the same time, the movement

of

one scale graduation changes toe-in by approximately 1.5 mm (0.1 2 in).

Left

side Right side

~~

I

Toe-in is increased.

B4M0192

Rotate clockwise.

B4M0352

Rotate counterclockwise.

~~

c

Toe-in is decreased.

Rotate clockwise.

Rotate counterclockwise.

B4M0352

1)

Tighten the self-locking nut.


100 N-m (10.2 kgf-m,

74 ft-lb)

6.

STEERING ANGLE

Inspection

1) Place the vehicle on a turning radius gauge.

2) While depressing the brake pedal, turn the steering wheel fully to the left and right. With the steering wheel held at each fully turned position, measure both the inner and outer wheel steering angle.

Steering angle:

Model

Turbo, sedan and

OUTBACK

Others

Outerwheel

I

29"35"f1.5"

~~ I

31 "35Y1.5"

84M0192

Adjus ment

Turn the tie-rod to adjust the steering angle of both inner and outer wheels.

CAUTION:

Check the toe-in.

Correct the boot if it is twisted.

-

S4M0348A

(1) Locknut

FS-13

I

WHEEL ALIGNMENT

FRONT SUSPENSION

7.

THRUST ANGLE

Inspection

1) Position the vehicle on a level surface.

2) Move the vehicle 3 to 4 meters directly forward.

3) Determine the locus of both front and rear axles.

4) Measure the distance “L” between center line of loci of the axles.

Thrust angle:

Less than 20‘ when “L” is equal to or less than 15 mm (59 in).

3)

When the left and right adjusting bolts are turned incrementally by one graduation in the same direction, the thrust angle will change approximately 16’

Thrust angle:

O ” f 2 0 ’

T

S4M0350B

(1) Center line of loci (front axle)

(2)

Center line of loci (rear axle)

Adjustment

1) Make the thrust angle adjustments by turning toe-in adjusting bolts of rear suspension equally in the same direction.

2) When one rear wheel is adjusted in a toe-in direction, adjust the other rear wheel equally in toe- out direction, in order to make the thrust angle adjustment.

M

S4M0350B

(1)

Center line of loci (front axle)

(2) Center line of loci (rear axle)

NOTE:

Thrust angle refers to a mean value of left and right rear wheel toe angles in relation to the vehicle body center line. Vehicle is driven straight in the thrust angle direction while swinging in the oblique direction depending on the degree of the mean thrust angle.

( 1

1

t

FS-14

(1) Front

(2) Thrust angle

(3) Body center line

I

WHEEL ALIGNMENT

Thrust angle: r

= (a

a:

Right rear wheel toe-in angle p:

Left rear wheel toe-in angle

NOTE:

Here, use only positive toe-in values from each wheel to substitute for

a

and p in the equation.

FRONT SUSPENSION

I

(1) Front

(2)

Body center line

B4M01948

FS-15

FRONT SUSPENSION

3.

Sub Frame

A: REMOVAL

1) Lift-up the vehicle.

2) Remove the under cover.

3) Remove the bolt cover.

SUB FRAME

B: INSTALLATION

Install in the reverse order of removal.

NOTE:

Replace the M12 bolt with a new one.


T1: 34 N.m (3.5 kgf-m, 25 ff-lb)

T2: 55 N-m (5.6 kgf-m, 41 ff-lb)

T3: 71 N.m (7.2 kgf-m, 52 ff-lb)

T4: 105 N-m (10.7 kgf-m, 77 ff-lb)

4)

Remove the clip.

(1) M8 bolt

(2) M12 bolt (with max)

(3)

M12 bolt (with oil)

(4)

M10 bolt

5)

Remove the sub frame.

NOTE:

Loosen bolt (1) and leave a few threads caught, then remove the bolts in the order of

(2), (4),

(6).

FS-16

SUB FRAME

C: INSPECTION

1)

Check that there is no damage and distortion at the sub frame.

2)

Check that the bolts are tightened with the specified torque. If there is looseness, tighten to the specified torque.

NOTE:

The tightening torque differs by the color for bolt

(3).

Always verify the bolt color before checking tightening torque.


T I : 34 N-m (3.5 kgf-m, 25 ff-lb)

T2: 55 N.m (5.6 kgf-m, 41 ff-lb)

T3: 71 N-m (7.2 kgf-m, 52 ff-lb)

T4: Dark green bolt

T4: Except dark green bolt

55 N-m (5.6 kgf-m, 41 ff-lb)

FRONT SUSPENSION

FS-17

FRONT

SUSPENSION

3.

Sub Frame

A: REMOVAL



3) Remove the bolt cover.

SUB FRAME

B: INSTALLATION


NOTE:

Replace the M12 bolt with a new one.


T1: 34 N-m (3.5 kgf-my 25 ft-16)

T2: 55 N-m (5.6 kgf-my 41 ft-16)

T3: 71 N-m (7.2 kgf-my

52 ft-16)

4)

Remove the clip.

5 )

Remove the sub frame.

NOTE:

Loosen bolt (1) and leave a few threads caught, then remove the bolts in the order of

(2), (4),

and

(6).

(1) M8 bolt

(2)

M12 bolt

(3) MlO bolt

C: INSPECTION

Check that there is no damage and distortion at the sub frame.

FS-16

4.

FRONT TRANSVERSE LINK

Front Transverse Link

A: REMOVAL

1) Set the vehicle on the lift.

2) Disconnect the ground terminal from battery.

3) Lift-up the vehicle and remove the wheel.

4)

Remove the sub frame. <Ref. to FS-16, RE-

MOVAL, Sub Frame.>

5)

Disconnect the stabilizer link from transverse link.

6) Remove the bolt securing the ball joint of transverse link to housing.

FRONT SUSPENSION

B: INSTALLATION

1) Temporarily tighten the two bolts used to secure the rear bushing of the transverse link to body.

NOTE:

These bolts should be tightened to such an extent that they can still move back and forth in the oblong shaped hole in the bracket (which holds the bushing).

2) Install the bolts used to connect the transverse link to crossmember and temporarily tighten with nut.

CAUTION:


3)

Insert the ball joint into housing.

4)

Connect the stabilizer link to transverse link, and temporarily tighten bolts.

CAUTION:


S4MOO9(

7)

Remove the nut (do not remove bolt.) securing the transverse link to crossmember.

8)

Remove the two bolts securing the bushing bracket of transverse link to vehicle body at rear bushing location.

I

9) Extract the ball joint from housing.

10) Remove the bolt securing the transverse link to crossmember and extract the transverse link from crossmember.

5) Tighten the following points in the order shown below when the wheels are in full contact with the ground and vehicle is curb weight.

(1) Transverse link and stabilizer


Sedan Turbo model:

45 N.m (4.6 kgf-m, 33 ft-lb)

Except sedan Turbo model:

30 N m (3.1 kgf-m,

22 ft-lb)

(2)

Transverse link and crossmember

Tigh tening torque:

100 N-m (10.2 kgf-m, 74 ft-lb)

( 3 )

Transverse link rear bushing and body


250 N-m (25.5 kgf-m, 184 ff-16)

FS-17

I

FRONT TRANSVERSE LINK

FRONT SUSPENSION

NOTE:

Move the rear bushing back and forth until transverse link-to-rear bushing clearance is established

(as indicated in figure.) before tightening.

Unit: mm (in)

.059)

D: ASSEMBLY

1. FRONT BUSHING

To reassemble, reverse disassembly procedures.

CAUTION:

Install the front bushing in correct direction, as shown in the figure.

(1) Rear bushing

6) Install the sub frame. <Ref. to FS-16, INSTALLA-

TION, Sub Frame.>

7) Inspect the wheel alignment and adjust if necessary. <Ref. to FS-8, Wheel Alignment.>

C: DISASSEMBLY


Using ST, press the front bushing out of place.

ST 927680000 INSTALLER & REMOVER

SET

G4M0494

2. REAR

BUSHING

1) Scribe an aligning mark on the transverse link and rear bushing.

2)

Loosen the nut and remove the rear bushing.

S4M0351A

(1) Face bushing toward center of ball joint

(2) Ball joint

2. REAR

BUSHING

1) Install the rear bushing to transverse link and align the aligning marks scribed on the two.

2) Tighten the self-locking nut.

CAUTION:


While holding the rear bushing so as not to change position of aligning marks, tighten the self-locking nut.


190 N-m (19.4 kgf-m, 140 ff-lb)

E: INSPECTION

1) Check the transverse link for wear, damage and cracks, and correct or replace if defective.

2) Check the bushings for cracks, fatigue or damage.

3)

Check the rear bushing for oil leaks.

G4M0495

I

FS-18

5.

Front Ball Joint

FRONT BALL JOINT

A:

REMOVAL

1) Remove the front wheel.

2) Pull out the cotter pin from the ball stud, remove the castle nut, and extract the ball stud from the transverse link.

3) Remove the bolt securing the ball joint to the housing.

FRONT SUSPENSION

C: INSPECTION

1) Measure the play of ball joint by the following procedures. Replace with a new one when the play exceeds the specified value.

(1) With 686 N (70 kgf, 154 Ib) loaded in the direction shown in the figure, measure dimension

e

1 .

\

G4M0499

--

4)-€xtract the ball joint from the housing.

B: INSTALLATION

1) Install the ball joint onto the housing.

Torque (Bolt):

50 N-m

(5- kgf-m, 37 ft-lb)

CAUTION:

Do not apply grease to the tapered portion of ball stud.

2) Connect the ball joint to transverse link.

Torque (Castle nut):

Sedan turbo model:

30 N-m (3.7 kgf-m, 22ft-lb)

Except sedan turbo model:

45 N.m (4.6 kgf-m, 33ft-lb)

3) Retighten the castle nut further within 60" until a slot in castle nut is aligned with the hole in ball stud end, then insert the new cotter pin and bend it around castle nut.

4) Install the front wheel.

I

-

G4M0500

(2)

With 686 N (70 kgf, 154 Ib) loaded in the opposite direction shown in the figure, measure dimension e,.

4

G4M0501

(3) Calculate plays from the following formula.

S =

Q 2

- 0 1

(4) When plays are larger than the following value, replace with a new one.

FRONT BALL JOINT

Specified play for replacement: S

Less than 0.3 mm (0.012 in)

2)

When the play is smaller than the specified value, visually inspect the dust cover.

3)

The ball joint and cover that have been removed must be checked for wear, damage or cracks, and any defective part must be replaced.

4) If the dust cover is damaged, replace with a new ball joint.

I

FS-19

I

FRONT STRUT

FRONT SUSPENSION

6. Front Strut

A: REMOVAL

1) Remove the front wheel.

2) Remove the bolt securing brake hose from strut.

6) Remove the three nuts securing strut mount to body.

R4Mi78A

3)

Scribe an alignment mark on the camber adjusting bolt which secures strut to housing.

4)

Remove the bolt securing the ABS sensor harness. suo01

1

5 )

Remove the two bolts securing housing to strut.

CAUTION:

While holding the head of adjusting bolt, loosen self-locking nut.

FS-20

I

B: INSTALLATION

FRONT STRUT

1) Install the strut mount at upper side of strut to body and tighten with nuts.


20 N-m (2.0 kgf-m, 74.5 ft-lb)

2) Position the aligning mark on camber adjustment bolt with aligning mark on lower side of strut.

CAUTION:

While holding the head of adjusting bolt, tighten self-locking nut.

Be sure to use a new self-locking nut.


775 N-m (77.8 kgf-m, 729 ft-lb)

3 )

Install the ABS sensor harness to strut.


33 N.m (3.4 kgf-m, 24.3 ft-lb)

4)

Install bolts which secure the brake hose to strut.

FRONT SUSPENSION

C: DISASSEMBLY

1)

Using a coil spring compressor, compress the coil spring.

S4M0095

2) Using the ST, remove the self-locking nut.

ST 927760000 STRUT MOUNT SOCKET

33 N-m (3.4 kgf-m, 24.3 ft-lb)

5 )

Install the front wheels.

NOTE:

Check wheel alignment and adjust if necessary.

3) Remove the strut mount, upper spring seat and rubber seat from strut.

4)

Gradually decreasing the compression force, and remove the coil spring.

5 )

Remove the dust cover and helper spring.

I

FS-21

I

FRONT STRUT

FRONT SUSPENSION

D:

ASSEMBLY

1) Before installing the coil spring, strut mount, etc., on the strut, check for the presence of air in the dampening force generating mechanism of the strut since air prevents proper dampening force from being produced.

2)

Checking for the presence of air:

(1)

Place the strut vertically with the piston rod facing up.

(2)

Move the piston rod to the center of its entire stroke.

(3) While holding the piston rod end with finger- tips, move the rod up and down.

(4) If the piston rod moves at least 10 mm (0.39 in) in the former step, purge air from the strut.

3) Air purging procedure:

(1)

Place the strut vertically with the piston rod facing up.

(2) Fully extend the piston rod.

(3) With the piston rod fully extended, place the

--

-piston rod side down. The strut must stand vertically.

(4)

Fully contract the piston rod.

(5)

Repeat 3 or 4 times from the first step.

NOTE:

After completely purging air from the strut, be sure to place the strut with the piston rod facing up. If it is laid down, check for entry of air in the strut as outlined under “Checking for the presence of air”.

4)

Using a coil spring compressor, compress the coil spring.

NOTE:

Make sure that the vertical installing direction of coil spring is as shown in the figure.

( 2

5)

Set the coil spring correctly so that its end face fits well into the spring seat as shown.

I

4

( 1 )

S4M0353A

6)

Install the helper and dust cover to the piston rod.

7) Pull the piston rod fully upward, and install the rubber seat and spring seat.

NOTE:

Ensure the upper spring seat is positioned as shown in the figure.

S4M0097B

(1)

Outside of body

8)

Install the strut mount to the piston rod, and tighten the self-locking nut temporarily.

CAUTION:

Be sure to use a new self-locking nut.

9) Using a hexagon wrench to prevent strut rod from turning, tighten self-locking nut with ST.

ST 927760000 STRUT MOUNT SOCKET


55

N.m (5.6 kgf-m, 41 ft-lb)

I

B4M0568B

I

(1) Fiat (top side)

(2) identification paint

(3) inclined (bottom side)

FS-22

10)

Loosen the coil spring carefully.

E:

INSPECTION

Check the disassembled parts for cracks, damage and wear, and replace with new parts if defective.

1. DAMPER STRUT

1) Check for oil leakage.

2) Move the piston rod up and down to check that it operates smoothly without any binding.

3) Play of piston rod

Measure the play as follows:

Fix the outer shell and fully extend the rod. Set a dial gauge at the end of the rod: L [ l o mm (0.39 in)], then apply a force of W [20 N (2 kgf, 4 Ib)] to threaded portion. With the force of 20 N (2 kgf, 4 Ib) applied, read the dial gauge indication: PI. Apply a force of 20 N (2 kgf, 4 Ib) in the opposite direction of “W”, then read the dial gauge indication: P,.

FRONT STRUT

FRONT SUSPENSION

5.

HELPER

Replace it with a new one if cracked or damaged.

F: DISPOSAL

CAUTION:

On struts which have “GAS FILLED” marked on the outer housing under spring seat, completely discharge the gas before disposing, following the methods below.

Do not disassemble the strut damper or place into a fire.

Drill holes before disposing of gas filled struts.

Before handling gas filled struts, be sure to wear goggles to protect eyes from gas, oil and/ or filings.

GAS FILLED

DO NOT

OPEN

DO NOT HEAT

I

B4M1201

1)

Place the gas filled strut on a flat and level surface with piston rod fully extended.

2) Using a 2 to 3 mm (0.08 to 0.12 in) dia. drill, make holes in areas shown in the figure.

The free play is determined by the following equation:

Play

=

PI, P2

Limit of play:

Less than 0.8 mm (0.031 in)

If the play is greater, replace the strut.

2.

STRUT MOUNT

Check the rubber part for creep, cracks and deterioration, and replace it with a new one if defective.

3. DUSTCOVER

If any cracks or damage are found, replace it with a new one.

4.

COIL SPRING

One having permanent strain should be replaced with a new one. When the vehicle posture is uneven, although there are no considerable reasons like tire puncture, uneven loading, etc., check the coil spring for its free length referring to specifications, cracks, etc., and replace it with a new one if defective.

I

piston rod

M

(1.57 in)

,-Strut

B4M1202P

I

FS-23

I

FRONT STABILIZER

FRONT SUSPENSION

7. Front Stabilizer

A: REMOVAL

Jack-up the front part

Of the and it with safety stands (rigid racks).

2,

Remove the j a c k w plate from lower

Of crossmember.

3)

Remove the sub frame. <Ref. to

LbVAL, Sub Frame.>

4)

Remove the bolt and nut which secure the stabilizer to crossmember.

B: INSTALLATION

1) Install in the reverse order of removal.

NOTE:

Install the bushing (on front crossmember side) while aligning it with paint mark on stabilizer.

Ensure the bushing and stabilizer have the Same identification colors when installing.

5 )

Remove the bolts which Secure the stabilizer link to front transverse link.

(1)

Mark stamped on stabilizer

(2)

Bushing identification color

' ' suo012 wheels are in full contact with the ground and vehicle is curb weight.

Tightening torque (Sedan turbo model):

Jack-up plate to crossmember:

Stabilizer link to front transverse link:

45 N-m (4.6 kgf-m, 33 ft-lb)

Stabilizer to crossmember:

25 N.m (2.5 kgf-m, 18.1 ft-lb)

Tightening torque (Except sedan turbo model):

Jack-up plate to crossmember:

20 N.m (2.0 kgf-m, 14.5 ft-lb)

Stabilizer link to front transverse link:

30 N.m

(3.

kgf-m, 22 ft-lb)

Stabilizer to crossmember:

25 N-m (2.5 kgf-m, 18.1 ft-lb)

3)

Install the sub frame. <Ref. to FS-16, INSTALLA-

TION, Sub Frame.>

C: INSPECTION

1)

Check the bushing for cracks, fatigue or damage.

2) Check the stabilizer link for deformities, cracks or damage, and bushing for protrusions from the hole of stabilizer link.

FS-24

8.

Front Crossmember

FRONT CROSSMEMBER

A: REMOVAL


2) Lift-up the vehicle and remove the front tires and wheels.

3) Remove the sub frame. <Ref. to FS-16, RE-

MOVAL, Sub Frame.>

4) Remove both stabilizer and jack-up plate.

c.

(1) Front stabilizer

(2)

Front crossmember

5) Disconnect the tie-rod end from housing.

6) Remove the front exhaust pipe. (Non-turbo model) <Ref. to. EX(S0HC)-5, REMOVAL, Front Ex- haust Pipe.>

7 ) Remove the front transverse link from front crossmember and body.

FRONT SUSPENSION

12) Support the crossmember with a jack, remove the nuts securing crossmember to body and lower crossmember gradually along with the steering gearbox.

CAUTION:

When removing the crossmember downward, be careful that the tie-rod end does not inter- fere with SFJ boot.

13) Remove the steering gearbox from crossmember.

B: INSTALLATION


CAUTION:

Always tighten the rubber bushing when wheels are in full contact with the ground and vehicle is curb weight.


Transverse link bushing to crossmember:

100

N.m (10.2 kgf-m, 74 ft-lb)

Stabilizer to bushing:

25 N.m (2.5 kgf-m, 18.1 ft-lb)

Tie-rod end to housing:

27.0 N-m (2.75 kgf-m, 19.9 ft-lb)

Front cushion rubber to crossmember:

85 N.m (8.7 kgf-m, 62.7 ft-lb)

Universal joint to pinion shaft:

24 N-m (2.4 kgf-m, 17.4 ff-16)

Crossmember to body:

100 N-m (10.2 kgf-m, 74 ft-lb)

2) Purge air from the power steering system.

NOTE:

Check the wheel alignment and adjust if necessary.

C: INSPECTION

Check the crossmember for wear, damage and cracks, and correct or replace if defective.

8) Remove the nuts attaching engine mount cushion rubber to crossmember.

9) Remove the steering universal joint. <Ref. to PS-

26, REMOVAL, Steering Gearbox.>

10) Disconnect the power steering pipe from steering gear box.

11) Lift the engine by approx. 10 mm (0.39 in) by using a chain block.

FS-25

GENERAL DIAGNOSTIC TABLE

FRONT SUSPENSION

9.

General Diagnostic Table

A:

INSPECTION

1. IMPROPER VEHICLE POSTURE OR IMPROPER WHEEL ARCH HEIGHT

Possible causes Countermeasures

(2)

Unsmooth operation of damper strut and/or shock absorber

(3)

Installation of wrong strut and/or shock absorber

(4)

Installation of wrong coil spring

Replace.

Replace with proper parts.


1)

Large rebound shock ning over bump and/or hump.

3)

Large shock in bumping

(1)

Breakage of coil spring

(2) Overinflation pressure of tire

I

(3) Improper wheel arch height

(4)

Fault in operation of damper strut and/or shock absorber

I

Replace.

I

Adjust.

I

Adjust or replace coil springs with new ones.

I

Replace.

*(5) Damage or deformation of strut mount and/or shock absorber mount

Replace.

(6) Unsuitability of maximum and/or minimum length of damper strut and/or shock absorber

I

( 7 )

Deformation or loss of bushing

(8) Deformation or damage of helper

in

strut assembly and/or shock absorber


I

Replace.

Replace.

(9) Oil leakaae of damDer strut and/or shock absorber Replace.

I

I

Possible causes Countermeasures

(1 ) Wear or damage of damper strut and/or shock absorber component parts

(2) Loosenina of suspension link installing bolt

(3) Deformation or loss of bushing

(4)

Unsuitability of maximum and/or minimum length of damper strut and/or shock absorber

Replace.

I

Retighten to the specified torque.

1

Replace.


(5) Breakaae of coil sprina

I

(6)

Wear or damaae of ball ioint

I

(7)

Deformation of stabilizer clamp

Replace.

I

Replace.

I

Replace.

I

I

I

I

I

FS-26

REAR SUSPENSION

1

.

2

.

3

.

4

.

5

.

6

.

7

.

RS

.

a

Page

General Description

....................................................................................

2

Wheel Alignment

.........................................................................................

9

Rear Stabilizer

...........................................................................................

10

Rear Trailing Link

......................................................................................

11

Rear Strut

..................................................................................................

15

Lateral link

.................................................................................................

16

Rear Crossmember

...................................................................................

19


..........................................................................

20

I

REAR SUSPENSION

1.

General Description



I

Camber (tolerance:

Toe-in

Wheel arch height

Item fO"45')

[tolerance: k12 mm (k0.47 in)l

I

Thrust angle

Diameter of stabilizer

I

Turbo

Sedan

Wagon

I

Non-turbo

1

Turbo

1

Non-turbo

I

-1"30'

I

-1"25'

I

-1'20'

I

-1'15'

I

- I f 2 mm (-0.039k0.079 in)

OUTBACK

-1"10'

Each toe-in angle: fO"07'30 (Total toe-in angle 0"+1 5')

376

m m

381 mm 376

m m

381

m m

(14.80 in) (15.0 in) (14.80 in) (15.0 in)

386

m m

(15.20 in)

20 mm

(0.79 in)

1 3 mm

(0.51 in)

O"f20'

17 mm

(0.67 in)

13mm

(0.51 in)

NOTE:

Front and rear toe-ins and front camber can be adjusted. If the toe-in or camber tolerance exceeds specifications, adjust the toe-in and camber to the middle value of specification.

The other items indicated in the specification ta-

%le cannot be adjusted. If the other items exceeds specifications, check the suspension parts and connections for deformities; replace with new ones as required.

I

I

B4M2250C

(1) Front

A

-

=

Positive: Toe-in, Negative: Toe-out

a l , a2: Each toe-in angle

RS-2


REAR SUSPENSION

3

RS-3

I

REAR SUSPENSION

B: COMPONENT


I

P

I

SI

RS-4

c.

Stabilizer

Stabilizer bracket

Stabilizer bushing

Clamp

Floating bushing

Stopper

Stabilizer link

Rear lateral link

Bushing (C)

Bushing (A)

Front lateral link

Bushing (B)

Trailing link rear bushing

Trailing link

Trailing link front bushing


Trailing link bracket

Cap (Protection)

Washer

Rear crossmember

Strut mount cap

Strut mount

Rubber seat upper

Dust cover

Coil spring

Helper

Rubber seat lower

Damper strut

Self-locking nut

Rear differential member rear

REAR SUSPENSION

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

T1: 20(2.0, 14.5)

T2: 25 (2.5, 18.1)

T3: 45 (4.6, 33.2)

T4: 55 (5.6, 4 1)

T5: 70 (7.1, 52)

T6: 90 (9.2, 66)

T7: 100 (10.2, 74)

T8: 115(11.7, 85)

T9: 130 (13.3, 96)

TlO: 135(13.8, 100)

T11: 220(22.4, 162)

RS-5

I


REAR SUSPENSION

C: CAUTION









-0



Before disposing shock absorbers, be sure to bleed gas completely. Also, do not throw away in fire.

RS-6


I

D: PREPARATION TOOL

1. SPECIAL TOOLS

ILLUSTRATION

TOOL NUMBER

927380002 rDAPTER

REAR

SUSPENSION

REMARKS

Jsed as an adapter for camber & caster gauge vhen measuring camber and caster.

1) 28199ACOOO PLATE

2) 281 99AC010 BOLT

I

Jsed for replacing front bushing.

I suo01

4

927730000

NSTALLER &

3EMOVER

Used for replacing rear bushing.

I

SUOOI!

28099PA100 REMOVER

Used for removing DOJ.

RS-7

REAR SUSPENSION

ILLUSTRATION


TOOL NUMBER

92770000

DESCRIPTION

INSTALLER &

REMOVER

REMARKS

Used for replacing lateral link bushing.

I

SUO015

927690000 HELPER SOCKET

WRENCH

Used for replacing lateral link bushing.

SUO015

2.

GENERAL PURPOSE TOOLS

Alignment gauge

Turnina radius aauae

I

Transmission iack

I

Bearing puller

TOOL NAME

REMARKS


Used for wheel alianment measurement.

I

Used for toe-in measurement.

I

Used for suspension assembly/disassembly.

I

Used for removing bushings.

I

I

RS-8

WHEEL ALIGNMENT

2.

Wheel Alignment

A: INSPECTION

NOTE:

The front and rear wheel alignment must be measured and/or adjusted at once to obtain accuracy.

Measure and/or adjust the rear wheel alignment together with the front. Follow the procedure in "FS" section "Wheel Alignment" for measurement and/or adjustment of wheel alignment. <Ref. to FS-8, IN-

SPECTION, Wheel Alignment.>

REAR SUSPENSION

I

RS-9

I

REAR STABILIZER

REAR SUSPENSION

3. Rear Stabilizer

A: REMOVAL

1)

Jack-up the rear part of the vehicle, support it with safety stands (rigid racks).

2)

Remove the bolts which secure stabilizer link to rear lateral link.

B: INSTALLATION

1)


NOTE:

Install the bushing while aligning it with paint mark on stabilizer.

Ensure that the bushing and stabilizer have the same identification colors when installing.

3) Remove the bolt which secures stabilizer to stabilizer bracket.

(1)

Mark stamped on stabilizer

(2) Bushing identification color

2) Always tighten the rubber bushing location when wheels are in full contact with the ground and vehicle is curb weight.


Stabilizer link to rear lateral link

45 N-m (4.6 kgf-m, 33.2 ft-lb)

Stabilizer to stabilizer bracket

25 N.m (2.5 kgf-m, 18.1 ft-lb)

C: INSPECTION

1) Check the bushing for cracks, fatigue or damage.

2)

Check the stabilizer links for deformities, cracks, or damage, and bushing for protrusions from the hole of stabilizer link.

RS-10

4. Rear Trailing Link

A: REMOVAL

1)

Loosen the rear wheel nuts.

REAR TRAILING LINK

(rigid racks) and remove the rear wheels.

3) Remove both rear parking brake clamp and

ABS

sensor harness. (Models equipped with

ABS)

4)

R~~~~~ the bolt which Secures trailing link to trailing link bracket.

REAR SUSPENSION

B: INSTALLATION


CAUTION:

Always tighten the .rubber bushing location when wheels are in full contact with the ground and vehicle is at curb weight condition.

NOTE:


1

(1)

Trailing

link

5 )

Remove the bolt which secures trailing link to rear housing.

RS-11


REAR SUSPENSION

C:

DISASSEMBLY


Using ST, press the front bushing out of place.


SET

2. REAR

BUSHING

1)

Remove the housing. <Ref. to DS-23, REMOV-

AL, Rear Axle.>

2) Using ST, press the rear bushing out of place.

ST 927730000

INSTALLER &-REMOVER

SET

(1) Press

(2)

Trailing link

(1) Press

(2) Housing

RS-12

c-

D: ASSEMBLY


Using ST, press the bushing into trailing link.


SET

CAUTION:

When installing the bushing, turn ST plunger upside down and press it until plunger end surface contacts trailing link end surface.

‘ir


REAR

SUSPENSION

2. REAR BUSHING

1)

Using ST, press the bushing into trailing link.


SET

NOTE:

If it is difficult to press the bushing into trailing link, apply water-diluted TIRE LUBE to the inner surface of ST as a lubricant.

S

PE ClFlE

D lubricant:

TIRE

LUBE :

=

1

:

I

( 2 )

\

( 3 )

\

S4M0360E

(1) Press

(2) Front bushing

(3)

Trailing link

CAUTION:

Install the front bushing in proper direction, as shown in the figure.

(1) Press

I

(1) Front

RS-13


REAR SUSPENSION

2) Press the ST pluger until bushing flange pro- trudes beyond trailing link.

ST

927730000 INSTALLER & REMOVER

SET

3) Turn the trailing link upside down. Press the ST plunger in the direction opposite that outlines in the former procedure until bushing is correctly positioned in trailing link.

ST 927730060 INSTALLER

&

REMOVER

SET

r .

.

( 1 )

Plunger

(2)

Flange

( 1 )

(2)

Press

Plunger

4)

Install the housing. <Ref. to DS-26, INSTALLA-

TION, Rear Axle.>

E: INSPECTION

Check the trailing links for bends, corrosion or damage.

RS-14

I

5.

Rear

Strut

A: REMOVAL

1)

Remove the rear seat cushion and backrest.

(Sedan model)

2)

Remove the strut cap of quarter trim. (Wagon model)

3) Loosen the rear wheel nuts.

4) Jack-up the vehicle, support it with safety stands

(rigid racks) and remove the rear wheels.

5 )

Remove the brake hose clip and remove the brake hose from rear strut.

REAR STRUT

REAR SUSPENSION

B: INSTALLATION

1)

Tighten the self-locking nut used to secure strut mount to car body.

CAUTION:

Discard the loosened self-locking nut, and replace with a new one.


(1) Brake hose clip

(2) Brake hose

6) Remove -the bolts which secure rear strut to housing.

7)

Remove the nuts securing strut mount to body.

2)

Tighten the bolts which secure rear strut to housing.


220 N.m (22.4 kgf-m, 162 ft-lb)

CAUTION:

Discard the loosened self-locking nut, and replace with a new one.

3)

Install the brake hose to lower side of strut, then insert brake hose clip.

CAUTION:

Check that the hose clip is positioned properly-

Check the brake hose for twisting, or excessive tension.

(Model equipped with ABS)

Do not subject the ABS sensor harness to exces-sive tension.

4)

Lower the vehicle and tighten wheel nut.


90 N-m (9.2 kgf-m, 66 ft-lb)

5 )

Sedan model:

Install the rear seat backrest and rear seat cushion.

Wagon model:

Install the strut cap to rear quarter trim.

NOTE:

Check wheel alignment and adjust if necessary.

C: DISASSEMBLY

For disassembly of rear strut, refer to procedures outlined under front strut as a guide. <Ref. to FS-

21, DISASSEMBLY, Front Strut.>

D: ASSEMBLY

Refer to Front Strut as a guide for assembly procedures.

<Ref. to FS-22, ASSEMBLY, Front Strut.>

E: INSPECTION

Refer to Front Strut as a guide for inspection procedures.

<Ref. to FS-23, INSPECTION, Front Strut.>

F:

DISPOSAL

Refer to Front Strut as a guide for disposal procedures.<Ref. to FS-23, DISPOSAL, Front Strut.>

RS-15

I

LATERAL LINK

REAR SUSPENSION

6.

Lateral link

A: REMOVAL

1) Loosen the wheel nuts. Lift-up the vehicle and remove wheel.

2 )

Remove the stabilizers. (Turbo model)

3) Remove the ABS sensor harness from trailing link.

(Models eqipped with ABS)

4)

Remove the bolt securing trailing link to housing.

r .

(1) Rear housing

(2) Trailing link

5) Remove the bolts which secure lateral link assembly to rear housing.

6) Remove the DOJ from rear differential using ST.

ST 28099PA100 DRIVE SHAFT REMOVER

NOTE:

The side spline shaft circlip comes out together with the shaft.

Bushing

Bushing A

Bushina B

I

BushinaC

I

ST:INSTALLER & REMOVER SET

927700000

927690000

927700000

I

(1)

Bolt

(2) DOJ

CAUTION:

Be careful not to damage the side bearing retainer. Always use bolt shown in figure, as supporting point for ST during removal.

7) Scribe an alignment mark on the rear lateral link adjusting bolt and crossmember.

RS-16

(1)

Bushing

A

(2) Bushing B

(3) Bushing C

(4)

Front

( 5 )

Outside of body

S4MQIQQ

LATERAL LINK

REAR

SUSPENSION

D: ASSEMBLY

1)

Using ST, press the bushing into place.

CAUTION:

Select the ST according to the type of bushings used.

NOTE:

Use the same ST as that used during disassembly.

If it is difficult to press the bushing into trailing link, apply water-diluted TIRE LUBE to the inner surface of ST as a lubricant.

Specified lubricant:

TIRE

LUBE :

=

1

:

(1)

Press

(2) Bushing

(3) Lateral link

(1)

Press

(2) Lateral link

S4MQ365

RS-17

I

LATERAL LINK

REAR SUSPENSION

2) Press the ST plunger until bushing flange pro- trudes beyond lateral link.

NOTE:

Use the same ST as that used during disassembly.

3)

Turn the lateral link upside down. Press the ST plunger in the direction opposite that outlined in the former procedure until bushing is correctly positioned in trailing link.

NOTE:

Using the same ST as that used during dissassem- bly.

.

(1)

Press

(2)

Plunger

(3)

Lateral link

(4)

Flange

(1)

Press

(2) Plunger

(3)

Lateral link

E: INSPECTION

Visually check the lateral links for damage or bends.

RS-18

I

7. Rear Crossmember

REAR CROSSMEMBER

A: REMOVAL

CAUTION:

Do not subject the ABS sensor harness to excessive tension. (Models equipped with ABS)

1) Separate the front exhaust pipe and rear exhaust pipe.

2) Remove the rear exhaust pipe and muffler.

3) Remove the rear differential.

<Ref. to DI-19, REMOVAL, Rear Differential.>

4)

Place a transmission jack under rear crossmember.

REAR SUSPENSION

B:

INSTALLATION


2) For installation and tightning torque of rear differential:

<Ref. to DI-20, INSTALLATION, Rear Differential.>

3) Always tighten the rubber bushing when wheels are in full contact with the ground and vehicle is curb weight.

NOTE:


C: INSPECTION

Check the removed parts for wear, damage and cracks, and correct or replace if defective.

I

5)

Remove the bolts securing crossmember to vehicle body, and remove the crossmember.

6)

Scribe an alignment mark on the rear lateral link cam bolt and crossmember.

7) Remove the front and rear lateral links by loosening nuts.

RS-19


REAR SUSPENSION

8.


A: INSPECTION

1.

IMPROPER VEHICLE POSTURE

OR

IMPROPER WHEEL ARCH HEIGHT

Possible causes

(1)

Permanent distortion or breakage of coil spring

(2) Unsmooth operation of damper strut and/or shock absorber

I

(3) Installation of wrong strut and/or shock absorber

I

(4)

Installation of wrong coil spring

Countermeasures

Replace.

Replace.

I


I


2. POOR RIDE COMFORT

1)

Large rebound shock

2)

Rocking of vehicle continues too long after running over bump and/or hump.

3) Large shock in bumping

I

(1) Breakage of coil spring

I

(2)

Overinflation Dressure of tire

(3) Improper wheel arch height

44)

\ ,

Fault in operation of damper strut and/or shock absorber t(5)

Damaae or deformation of strut mount and/or shock absorber mount


I

Replace.

I

Adiust.

I

Adjust or replace coil springs with new ones.

I

I

Replace.

'

I

Replace.


(7) Deformation or loss of bushing

(8) Deformation or damage of helper in strut assembly and/or shock absorber

I

(9) Oil leakage of damper strut and/or shock absorber

Replace.

Replace.

1

Replace.

3. NOISE

Possible causes

(1)

Wear or damage of damper strut and/or shock absorber component parts

(2) Loosening of suspension link installing bolt

Replace.

Countermeasures

(3)

Deformation or loss of bushing


I

Retighten to the specified torque.

I

Replace.


( 6 )

Wear or damage of ball ioint

I

(7)

Deformation of stabilizer clamp

Replace.

I

Replace.

I

Replace.

I

I

I

I

I

I

I

RS-20

~~

WHEEL AND TIRE SYSTEM

~

WT

page

1

.

General Description

....................................................................................

2

2

.

Tire

..............................................................................................................

4

3

.

4

.

6

.

7

.

Steel Wheel

.................................................................................................

5

Aluminum Wheel

.........................................................................................

6

Wheel Balancing

.........................................................................................

7

“T-type” Tire

................................................................................................

8

Full Wheel Cap

............................................................................................

9

General Diagnostics Table

........................................................................

10

~

WHEEL AND TIRE SYSTEM

~

1.

General

Description



I

Front and rear

-*

.

T-Type tire

Front and rear

T-Type ti re

S4M0367A

I

P195/60R1587H

I

1 5 x 6 J J

I

P205/55 R16 89V 16 x 6 1/2JJ

21 5/45 R17 87W

T I 35/70 D16

1

17 x 7JJ

16 x

4T

Tire size

P I 95/60

R15

P205155 R16 89V

21 5/45 R17 87W

T135ffO D16 100M

55 (2.17)

50 (1.97)

I

100

(3.94) Dia.

Tire inflation pressure kPa

(kg/cm2,

psi)

Fr: 220 (2.2, 32)

Rr: 200 (2.0, 29)

Fr: 220 (2.2, 32) Fir: 200 (2.0, 29)

Fr: 230 (2.3, 33) Rr: 220 (2.2, 32)

420 (4.2, 60)

I

I

WT-2

I


WHEEL AND TIRE SYSTEM

1.

SERVICE DATA

~

I

Item

Steel wheel

Aluminum wheel

I

Axial runout

I

Radial runout

1.5 mm (0.059

in)

1

.O

mm (0.039 in)

2.

ADJUSTING PARTS

B: PREPARATION TOOL

1

1.


TOOL NAME

Air pressure gauge

Dial gauge

REMARKS

Used for measuring tire air pressure.

Used for measuring wheel runout.

I

Less than 5 g (0.1 8

02)

Balance weight part number

Weight

I

I

723141 320

7231 41 330

7231 41 350

I

20 g (0.71

02)

I

723241 380

723241 590


(For aluminum wheel)

231 41 GA462

231 41 GA482

Weight r

23141GA512

I

30 g (1.06

02)

I

I

231 41 GA522

-I

35 g (1.23

02)

I

231 41 GA532 40 g (1.41

02)

23141 GA552

-

45

" a (1 5 9

02)

>

50 g (I

02)

55 g (1.94

0 2 )

23141 GA572 60

g

(2.12

02)

WT-3

I


2.

Tire

A: INSPECTION

1) Take stone, glass, nail etc. off the tread groove.

2) Replace the tire:

CAUTION:

When replacing a tire, make sure to use only the same size, construction and load range as originally installed.

Avoid mixing radial, belted bias or bias tires on the vehicle.

(1) when large crack on side wall, damage or crack on tread is found.

(2) when the “tread wear indicator” appears as a solid band across the tread.

TIRE

-

r .

.

I

S4M0377A

(1 ) Tread wear indicator

(2)

Tire tread

1. TIRE ROTATION

If tires are maintained at the same positions for a long period of time, uneven wear results. There- fore, they should be periodically rotated.

This lengthens service life of tires.

CAUTION:

When rotating tires, replace unevenly worn or damaged tires with new ones.

WT-4

I

3.

Steel

Wheel

A: REMOVAL

1)

Apply the parking brake, and position select lever to “P” or “LOW”.

2)

Set the shop jacks or a lift to the specified point, and support the vehicle with its wheels slightly contacting the floor.

3)

Loosen the wheel nuts.

4)

Raise the vehicle until its wheels take off the ground using a jack or a lift.

5) Remove the wheel nuts and wheels.

NOTE:

While removing the wheels, prevent hub bolts from damage.

NOTE:

Place the wheels with their outer sides facing upward to prevent wheels from damage.

B: INSTALLATION

--

I ) Attach the wheel to the hub by aligning the wheel bolt hole with the hub bolt.

2)

Temporarily attach the wheel nuts to the hub bolts. (In the case of aluminum wheel, use SUBA-

RU genuine wheel nut for aluminum wheel.)

3)

Manually tighten the nuts making sure the wheel hub hole is aligned correctly to the guide portion of hub.

4)

Tighten the wheel nuts in a diagonal selection to the specified torque. Use a wheel nut wrench.

Wheel nut tightening torque:

90

N.m (9. I kgf-m, 65.7 ff-lb)

CAUTION:

Tighten the wheel nuts in two or three steps by gradually increasing the torque and working diagonally, until the specified torque is reached. For drum brake models, excess tightening of wheel nuts may cause wheels to “jud- der”.

Do not depress the wrench with a foot;

Al- ways use both hands when tightening.

Make sure the bolt, nut and the nut seating surface of the wheel are free from oils.

5) If a wheel is removed for replacement or for repair of a puncture, retighten the wheel nuts to the specified torque after running 1,000 km (600 miles).

STEEL WHEEL


C: INSPECTION

1)

Deformation or damage on the rim can cause air leakage. Check the rim flange for deformation, crack or damage, and repair or replace as necessary.

2) Jack-up the vehicle until wheels clear the floor.

3) Slowly rotate the wheel to check rim “runout” using a dial gauge.

APP

/

1.5 mm (0.059 in)

G4M029E

I

G4M0299

4)

If the rim runout exceeds specifications, remove the tire from rim and check runout while attaching dial gauge to positions shown in figure.

5) If the measured runout still exceeds specifications, replace the wheel.

I

WT-5

I

ALUMINUM WHEEL

WHEEL

AND

TIRE SYSTEM

4.

Aluminum Wheel

A: REMOVAL

Refer to Steel Wheel for removal procedure of a h - minum wheels. <Ref. to WT-5, REMOVAL, Steel

Wheel. >

B: INSTALLATION

Refer to Steel Wheel for installation procedure of aluminum wheels.cRef. to WT-5, INSTALLATION,

Steel Wheel.>

C: INSPECTION

Refer to Steel Wheel for inspection procedure of aluminum wheels. <Ref. to WT-5, INSPECTION,

Steel Wheel.>

Rim runout:

I

Axial runout limit

I

Radial runout limit

I

1

.O

mm (0.039 in)

D:

-CAUTION

Aluminum wheels are easily scratched. To maintain their appearance and safety, do the following:

1) Do not damage the aluminum wheels during removal, disassembly, installation, wheel balancing, etc. After removing the aluminum wheels, place them on a rubber mat, etc.

2)

While the vehicle is being driven, be careful not to ride over sharp obstacles or allow aluminum wheels to contact the shoulder of the road.

3) When installing a tire chain, be sure to install it properly not to have a slack; otherwise it may hit the wheel while driving.

4)

When washing the aluminum wheel, use neutral synthetic detergent and water. Avoid using the cleanser including abrasive, hard brushes or an automatic car washer.

WT-6

I

I

c-

~

5. Wheel

Balancing

I

I

A: REPLACEMENT

1)

Remove the balance weights.

2) Using the dynamic balancing, measure wheel balance.

3) Select a weight close to the value measured by dynamic balancing.


I

(For steel wheel)

7231 41 300

7231 41 31 0

7231 41 320

7231 41 330

723141 340

7231 41 350

723141360

7231 41 370

723241 380

723241 580

723241 590

I

I

I

I

Weight

10 g (0.35

02)

15 g (0.53

02)

20 g (0.71

02)

25 g (0.88

02)

30 g (1.06

02)

35

CI

(1.23 oz)

40

g

(1.41

02)

45 g (1.59

0 2 )

50 g (1.76

02)

55 g (1.94

02)

60 g (2.12

02)

WHEEL BALANCING

I

I


B: INSPECTION

1)

Proper wheel balance may be lost if the tire is repaired or if it wears. Check the tire for dynamic balance, and repair as necessary.

2) To check for dynamic balance, use a dynamic balancer. Drive in the balance weight on both the top and rear sides of the rim.

3)

Some types of balancer can cause damage to the wheel. Use an appropriate balancer when adjusting the wheel balance.

4)

Use genuine balance weights.

CAUTION:

55 g

(1.94

02)

weight used with aluminum wheel is not available.

Balance weights are available for use with any of 14- to 16-inch wheels.

I

I


(For aluminum wheel)

23 1 4 1 GA462

231 41 GA472

Weight

5

g (0.18

02).

10 a

(0.35

02)

I

I r -

231 41 GA492

I

20

CI

(0.71

02)

I

I

231 41 GA502

231 41 GA512

I

I

25 g (0.88

02)

30 g (1.06

02)

I

I

231 41 GA522

35 g (1.23

02)

231 41 GA532 40 g (1.41

02)

231 41 GA542

231 41 GA552

45 g (1.59

0 2 )

50

Q

(1.76

02)

-

231 41 GA572

I

55 g

(1.94

02)

60 g (2.12

02)

I

B4M0053B

(1) Weight for aluminum wheel

(2) Weight for steel wheel

Service limit: A

Weight for steel wheel;

2.16 mm (0.085 in)

Weight for aluminum wheel;

4.5 mm (0.177 in)

I

WT-7

I

“T-TY PE” TIRE


6.

“T-type” Tire

A: NOTE

“T-type” tire for temporary use is prepared as a spare tire.

CAUTION:

Do not use a tire chain with the “T-type” tire.

Because of the smaller tire size, a tire chain will not fit properly and will result in damage to the vehicle and the tire.

Do not drive at a speed greater than 80 km/h

(50 MPH).

Drive as slowly as possible and avoid passing over bumps.

B:

REPLACEMENT

Refer to Removal and Installation of Steel Wheel for removaVinstallation of “T-type” tires. <Ref. to

WT-5, Steel Wheel.>

CAUTION:

Tiepiace with a conventional tire as soon as possible since the “T-type” tire i s only for temporary use.

C: INSPECTION

1) Check the tire inflation pressure.

Specification:

420 kPa (4.2 kg/cn?, 60 psi)

2) Take the stones, glass, nails, etc. out of the tread groove

.

3)

Check the tires for deformation, cracks, partial wear, or wear.

CAUTION:

Replace the tire with a new one.

WT-8

FULL WHEEL CAP

7.

Full Wheel Cap

A: REMOVAL

Pry off the full wheel cap with a wheel cap remover inserted between openings in the cap.


I

B: INSTALLATION

Align the valve hole in the wheel cap with the valve on the wheel and secure the wheel cap by tapping

*.

-

.

C: INSPECTION

1)

Check the wheels for missing wheel caps.

2)

Check the pawls of wheel caps for damage or bend.

3) Check the wheel caps for cracks.

WT-9

GENERAL DIAGNOSTICS TABLE

WHEEL

AND

TIRE SYSTEM

8.

General Diagnostics Table

A:

INSPECTION

I

Front wheel shimmy

I

Abnormal tire wear

Sways/pitches

Wander/pulls

I

Worn or improperly inflated of tire.

I

Wheel is out of balance.

I

Improperly inflated of tire.



I

Replace

I

Adjustment

I

Replace

Replace

Replace

I

I

I

3

WT-10

DIFFERENTIALS

Dl

5.

6.

7.

8.

1.

2.

3.

4.

~~~~~~~~ ~

Page

General Description

....

. . ..

. .

...

. .

..

.

...

. ...

. .

...

. .. .

...

. .

..................................

. ..

.

..

.

..

..2

Differential Gear Oil

...................................................................................

17

Front Differential

........................................................................................

18

Rear Differential

........................................................................................

19

Rear Differential Front Oil Seal

......................................

....

. ...

.. .

.

...

.

... .

...

.

..

.35

Rear Differential Side Oil Seal

..................................................................

37

Rear Differential Member

..........................................................................

40


..........................................................................

41

E

DIFFERENTIALS

1.



I

I

MODEL

I

Waaon


Non-Turbo

Sedan Waaon Sedan

I

Type of gear

Gear ratio (Number of gear teeth)

Oil capacity

Rear differential gear oil

3.900 (39/10)

MT

Turbo

AT

4.1 11 (37/9)

Hypoid gear

4.444 (40/9) 3.545 (39/11) 4.1 11 (37/9)

0.8

0

(0.8 US qt, 0.7 Imp qt)

GL-5

I

I causes the drive line and tires to "drag" or emit abnormal noise when AWD is selected.

I \ I f=

DROOOI

1. SERVICE

DATA

Front and rear bearing preload at companion flange bolt hole N (kgf, Ib)

Side aear backlash mm (in)

I

Side bearina standard width mm (in)

I

Crown gear to drive pinion backlash mm (in)

I

Crown gear runout on its back surface mm (in)

New bearing

Used bearing

2.

ADJUSTING PARTS

I

I

I

ITEM

Rear differential gear oil

API

Classification tiL-5

SAE Viscosity No. and Application Temperature

("C) -30 -26

-15 -5 0 15

25

30

I

( O F )

-22 -15 5 23 32

I I I

L '

59 77 86

I

1 2

75W-90

I

I

I I I I

I

H3M1272A

19.6

- - -

8.34-16.67(0.85-1.7, 1.87-3.75)

0.10

-

-

20.00 (0.7874)

0.10 - 0.0079)

Less than 0.05 (0.0020)

Front and rear bearing preload at companion flange bolt hole

Preload adjusting spacer

I

I

New bearing

Used bearing

Part No.

383695201

383695202

383695203

383695204

383695205

383695206

I

I

19.6 -

(2.0

-

6.4 Ib)

8.34 -

(0.85

-

3.75 Ib)

Lenath

56.2 mm (2.21 3 in)

56.4 mm (2.220 in)

56.6 mm (2.228 in)

56.8 mm (2.236 in)

57.0 mm (2.244 in)

57.2 mm (2.252 in)

I

I

I

DI-2

I

Preload adjusting washer

I


Part No.

383705200

38371 5200

383725200

I

DIFFERENTIALS

Length

2.59 mm (0.1 020 in)

2.57 mm (0.1012 in)

2.55 mm (0.1 004 in)

I

. .

Pinion height adjusting shim

Side gear backlash

Side gear thrust washer

(Non-Turbo model)

Side bearina standard width

I

Side bearing retainer shim

&own gear to drive pinion backlash

Crown gear runout on its back sunface

I

1- t t

383575200

383585200

383595200

383605200

38361 5200

383625200

383635200

383645200

383655200

383665200

383675200

383685200

3.33 mm (0.1 31 1 in)

3.36 mm (0.1323 in)

3.39 mm (0.1 335 in)

3.42 mm (0.1 346 in)

3.45 mm (0.1 358 in)

3.48 mm (0.1 370 in)

3.51 mm (0.1382 in)

3.54 mm (0.1 394 in)

3.57 mm (0.1406 in)

3.60 mm (0.1 41 7 in)

3.63 mm (0.1 429 in)

3.66 mm (0.1441 in)

0.1

-

0.0079 in)

Part No.

383445201

383445202

I

0.75 -

Thickness

I

0.80 mm (0.0295

- in)

I

I

0.80

-

-

~

-

Part No.

383475201

383475202

383475203

383475204

383475205

Limit

I

I

20.00 mm (0.7874 in)

Thickness

0.20 mm (0.0079 in)

0.25 mm (0.0098 in)

0.30 mm (0.01 18 in)

0.40 mm (0.0157 in)

0.50 mm (0.01 97 in)

0.1 0

-

-

0.05 mm (0.0020 in)

I

I

DI-3

I


DIFFERENTIALS

B: COMPONENT

1. REAR DIFFERENTIAL WITHOUT LSD

I

(1) Pinion crown gear set (13) Side bearing

(2) Pinion height adjusting washer

(3) Rear bearing

(14) O-ring

(15) Side bearing retainer shim

(4) Bearing preload adjusting spacer (16) Side bearing retainer

(5) Bearing preload adjusting washer (17) Side oil seal

. , Differential carrier

(7) Front bearing

. , ..

(8) Spacer

(20) Pinion mate gear

(9) Pilot bearing

(21) Pinion mate gear washer

(IO)

Front oil seal

(22) Pinion shaft lock pin

(23) Circlip

(12) Self-locking nut

(24) Pinion mate shaft

DI-4

(25) Air breather cap

(26) Stud bolt

(27) Oil filler plug

(28) Oil drain plug

(29) Rear cover

\

(301 Differential case

I


T1: 10.3 (1.05, 7.6)

T2: 29.4 (3.00,21.7)

T3: 49.0 (5.0, 36.2)

T4: 103.0 (10.50, 75.9)

T5: 181.4 (18.50, 133.8)


2.

REAR DIFFERENTIAL WITH LSD

DIFFERENTIALS

I

(1 ) Pinion crown gear set

(2)


Rear bearing

Bearing preload adjusting spacer

Bearing preload adjusting washer

Differential carrier

Front bearing

Collar

Pilot bearing

Front oil seal

Companion flange

(12) Self-locking nut

(13) Side bearing

O-ring

Side bearing retainer shim

Side bearing retainer

Side oil seal

Gasket

Differential case

Rear cover

Air breather cap

Stud bolt

(23) Oil filler plug

(24)

Oil drain plug


T1: 10.3 (1.05, 7.6)

TZ: 29.4 (3.00,21.7)

T3: 49.0 (5.00, 36.2)

T4: 103.0 (10.50, 75.9)

T5: 181.4 (18.50, 133.8)

DI-5

I


DIFFERENTIALS

3.

REAR DIFFERENTIAL MOUNTING SYSTEM

I

(1)

Differential front member

(2)

Plate

(3) Crossmember

(4)

Differential rear member

(5)

Differential mount lower bracket

(TURBO model)

(6) Differential mount lower bracket

(Non-turbo model)

(7)

Stopper

( 8 )

Dynamic damper

(9)

Differential mount bracket

(1 0 ) Differential mount front cover

DR0002

Tightening torque: N-m (kgf-m, ft-I&)

T1: 20(2.0, 14.5)

T2: 33 (3.4, 24.3)

T3: 65 (6.6, 47.9)

T4: 70 (7.1, 51.6)

T5: 90 (9.2, 66.4)

T6: 100 (10.2, 73.8)

DI-6


C: CAUTION





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.



--a-

Apply gear oil onto sliding or revolution surfaces before installation.

Before installing O-rings or snap rings, apply sufficient amount of gear oil to avoid damage and deformation.


Avoid damaging the mating face of the case.

DIFFERENTIALS

DI-7

DIFFERENTIALS


1.

SPECIAL TOOLS


ILLUSTRATION

TOOL NUMBER

398477701

DESCRIPTION

HANDLE

REMARKS

Used for installing front and rear bearing cone.

B3M1893

398477702 DRIFT Used for press-fitting the bearing cone of differential carrier (rear).

B3M1894

39821 7700 ATTACHMENT SET Stand for rear differential carrier disassembly and assembly.

B3M1895

4984471 20 DRIFT Used for installing front oil seal.

B3M1896

DI-8

I

ILLUSTRATION


TOOL NUMBER

98427200

DIFFERENTIALS

DESCRIPTION

LANGE WRENCH

IEMARKS k e d for stopping rotation of companion flange vhen loosening and tightening self-lock nut.

B3M1897

I98467700

)RIFT Jsed for removing pinion, pilot bearing and front iearing cone.

B3M189e

VEIGHT

~

Used for installing front bearing cone, pilot bearing companion flange.

B3M189(

NSTALLER Used for press-fitting the front bearing cone, pilo bearing.

B3M190

DI-9

DIFFERENTIALS

ILLUSTRATION


TOOL NUMBER

8999041 00

DESCRIPTION

STRAIGHT PIN

REMOVER

REMARKS

Used for driving out differential pinion shaft lock

Din.

I

B3M1901

498247001 MAGNET BASE

1

Used for measuring backlash between side jear and pinion, and hypoid gear.

1

Used with DIAL GAUGE (498247100).

B3M1902

4982471 00 DIAL GAUGE

1

Used for measurng backlash between side gear and pinion, and hypoid gear.

1

Used with MAGNET BASE (498247001).

03M1903

398507704 BLOCK Jsed for adjusting pinion height and preload.

B3M1904

DI-I 0

I

ILLUSTRATION


TOOL NUMBER

%98177700

DESCRIPTION

VSTALLER

DIFFERENTIALS

3EMARKS

Used for installing rear bearing cone.

3

B3M1905

398457700

6=:p

B3M1906

3 8 7

]RIFT2

I

Used for removing side bearing retainer.

1

Used for press-fitting the bearing race (rear) of differential carrier.

B3M190i

398437700

DRIFT

Used for installing side oil seal.

B3M1901

DI-1 1

DIFFERENTIALS

I

ILLUSTRATION


TOOL NUMBER

398507702

DESCRIPTION

DUMMY SHAFT

REMARKS

Used for adjusting pinion height and preload.

398507703

3UMMY COLLAR Used for adjusting pinion height and preload.

I

B3M1910

3E PLACER

Used for removing rear bearing cone.

398487700

)RIFT

1

Used for press-fitting the side bearing cone.

DI-I 2

I

ILLUSTRATION


DIFFERENTIALS

TOOL NUMBER

398507701

DESCRIPTION

DIFFERENTIAL

CARRIER GAUGE

REMARKS

Used for adjusting pinion height.

I

B3M1913

398527700

PULLEY ASSY Used

for

removing front oil seal.

Used for removing side bearing cup. (T-type)

B3M1914

399527700

PULLER SET

Used for extracting side bearing cone.

BOLT

(899521412)

PULLER

(399527702)

HOLDER

(399527703)

(398497701)

BOLT

07)

NUT

(021

B3M1915A

398227700

WEIGHT

.

Used for installing side bearing.

B3M1916

DI-I 3

I

DIFFERENTIALS

ILLUSTRATION


TOOL NUMBER

28099PA090

DESCRIPTION

OIL SEAL PROTEC-

TOR

REMARKS

Used for installing rear drive shaft into rear differential.

For protecting oil seal.

B3M 191 7

398237700

GAUGE

Used for installing side bearing.

I

B3M1930

Used for removing rear drive shaft from rear differential.

399703602 WLLEY ASSY

Used for removing companion flange

DI-I 4

I

ILLUSTRATION


DIFFERENTIALS

TOOL NUMBER

3998741 00

DESCRIPTION

INSTALLER

1

3EMARKS

Used for installing companion flange.

I

B3M193

DI-I 5


DIFFERENTIALS

2. GENERAL PURPOSE TOOLS

I

TOOL NAME

I

Transmission jack

Puller

Thickness gauge

I

REMARKS

1

Used for assembly/disassembly of rear differential.

Used for removal of side bearing retainer.

Used for measuring clearance.

I

I

DI-16

I

2. Differential Gear Oil

DIFFERENTIAL GEAR OIL

A: INSPECTION

1) Take out the filler plug, and replace gear oil if it is contaminated or deteriorated. <Ref. to DI-17, RE-

PLACEMENT, Differential Gear Oil.>

2)

Check gear oil level is up to the bottom part of filler bolt. If the level is low, refill up to the bottom of filler bolt.

I

1

DIFFERENTIALS

5 )

Fill differential carrier with gear oil to the upper plug level.

CAUTION:

Carefully refill oil while watching the level. Ex- cess or insufficient oil must be avoided.

Oil capacity:

0.8 Q (0.8 US qf, 0.7 Imp qt)

1

1

I

(A) Filler plug

( 6 )

Drain plug

B: REPLACEMENT


2) Jack-up the vehicle and support it with sturdy racks.

3) Remove the oil drain plug and filler plug, and drain the gear oil.

CAUTION:

Be careful not to burn your hands, because gear oil becomes extremely hot after running.

. . ,

.

.

.

, I

I

(A) Filler plug

( 6 )

Drain plug

6) Install the filler plug.

NOTE:

Apply fluid packing to the filler plug.

Fluid packing:

THREE BOND 1105 or equivalent


49.0

N.m (5.0 kgf-m, 36.2 ff-lb)

I

(A) Filler plug

(B) Drain plug

4)

Tighten the oil drain plug.

NOTE:

Apply fluid packing to the drain plug.

Fluid packing:

THREE BOND

I105 or equivalent


49.0

N.m (5.0 kgf-m, 36.2 ff-lb)

DI-17

FRONT DIFFERENTIAL

DIFFERENTIALS

3.

Front Differential

A: NOTE

1. AT

MODEL

Refer to AUTOMATIC TRANSMISSION in separate publication “AUTOMATIC TRANSMISSION” for Front Differential. <Pub. No.

G0853ZE>

2.

MTMODEL

For front differential of manual transmission, refer to

“MT” section. <Ref. to MT-71, Front Differential

Assembly.>

DI-18

4.

Rear Differential

REAR DIFFERENTIAL

DIFFERENTIALS

14) Remove the DOJ of rear drive shaft from rear differential using ST. <Ref. to DI-37, REPLACE-

MENT, Rear Differential Side Oil Seal.>


A: REMOVAL


2 )

Disconnect the ground terminal from battery.

3) Move the select lever or gear shift lever to “N”.

4) Release the parking brake.

5) Loosen the wheel nuts.

6) Jack-up the vehicle and support it with sturdy racks.

7) Remove the wheels.


Non-turbo model:

<Ref. to EX(S0HC)-9, REMOVAL, Rear Exhaust

Pipe.> and <Ref. to EX(S0HC)-1 1 , REMOVAL,

Muffler.>

Turbo model:

<Ref. to EX(D0HC TURBO)-13, REMOVAL, Rear

(A) Bolt

15) Secure the rear drive shaft to rear crossmember using wire.

14, REMOVAL, Muffler.>

9) Remove the rear differential protector. (If equipped)

10) Remove the front cover of rear differential mount.

I

S3M0500

16) Remove the lower differential bracket.

11) Remove the propeller shaft. <Ref. to DS-14,

REMOVAL, Propeller Shaft.>

12) Remove the heat shield cover.

13) Remove the clamps and bracket of parking brake cable.

0

S3M0529

17) Support the rear differential with transmission jack.

DI-I

9

I


DIFFERENTIALS

18) Remove the self-locking nuts and bolts. 22) Remove the rear differential from front member, and remove rear member.

19) Remove the bolts which secure rear differential front member to body.

Loosen bolt A first, then remove bolts B.

NOTE:

Support the front member with the use of a helper to prevent it from dropping.

-

\

\

'

'B3M0657C

1

(A)

Bolt

A

(B)

Bolt

B

20) Remove bolt A.

21) While slowly lowering the transmission jack, move rear differential forward and remove front member and rear differential from body.

G3M1030

B: INSTALLATION

To install, reverse the removal sequence.

1) Install the air breather cap tapping with a plastic hammer.

CAUTION:

Be sure to install a new air breather cap.

2) Position the front member on body by passing it under parking brake cable and securing to rear differential.

NOTE:

When installing the rear differential front member, do not confuse the installation sequence of the upper and lower stoppers.

3) Install the DOJ of drive shaft into rear differential.<Ref. to DI-37, REPLACEMENT, Rear Differ- ential Side Oil Seal.>

ST 28099PA090 SIDE OIL SEAL PROTEC-

TOR

. .

I

4)


5 )

After installation, fill the differential carrier with gear oil to the filler plug level. <Ref. to DI-17, Differ- ential Gear Oil.>

DI-20


C: DISASSEMBLY

To detect the real cause of trouble, inspect the following 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 differential assembly to ST.

ST 39821 7700 ATTACHMENT

I

DIFFERENTIALS

4) Remove the rear cover by loosening retaining bolts.

I

2) Drain the gear oil by removing plug.

3) Remove the air breather cap.

NOTE:

Do not attempt to replace the air breather cap unless necessary.

(A) Rear cover

(B)

Differential carrier

5) Make right and left side bearing retainers in order to identify them at reassembly. Remove the side bearing retainer attaching bolts, set the ST to differential case, and extract right and left side bearing retainers with a puller.

CAUTION:

Each shim, which is installed to adjust the side bearing preload, should be kept together with its mating retainer.

ST 398457700 ATTACHMENT

(A) Air breather cap

(B)

Rear cover

)

S3M0530A

6) Pull out the differential case assembly from differential carrier.

CAUTION:

Be careful not to hit the teeth against the case.

S3M0533

DI-21

I


DIFFERENTIALS

7) When replacing the side bearing, pull the bearing cup from side bearing retainer using ST.

ST 398527700 PULLER ASSY

10)

Drive out the pinion shaft lock pin from crown gear side. (Without LSD)

NOTE:

The lock pin is staked at the pin hole end on the differential carrier; do not drive it out forcibly before unstaking it.

ST 899904100 STRAIGHT PIN REMOVER

I

,

S3M05341:

8) Extract the bearing cone with ST.

CAUTION:

Do not attempt to disassemble the parts unless necessary.

NOTE:

Set the puller so that its claws catch the edge of

+he bearing cone.

Never mix up the right and left hand bearing races and cones.

ST 398527700 PULLER SET

11) Draw out the pinion mate shaft and remove pinion mate gears, side gears and thrust washers.

(Without LSD)

NOTE:

The gears as well as thrust washers should be marked or kept separated right and left, and front and rear.

( C )

9) Remove the crown gear by loosening crown gear bolts.

CAUTION:

Further disassembling is not allowed.

(A)

Sidegear

(B)

Pinion mate gear

(C) Thrust washer

(D) Differential case

(E) Pinion mate shaft

S3M051 OP

S3M0509

DI-22

I


12) Hold the companion flange with ST and remove drive pinion nut.

ST 498427200 FLANGE WRENCH

DIFFERENTIALS

15) Remove the rear bearing cone from drive pinion by supporting cone with ST.

NOTE:

Place the replacer so that its center-recessed side faces the pinion gear.

ST 39851 7700 REPLACER

I

13) Extract the companion flange with a puller.

S3MOS

16) Remove the front oil seal from differential carrier using ST.


14) Press the end of drive pinion shaft and extract it together with rear bearing cone, preload adjusting spacer and washer.

NOTE:

Hold the drive pinion so as not to drop it.

ST 398467700 DRIFT

S3M0513

17) Remove the pilot bearing together with front bearing cone using ST.

ST 398467700 DRIFT

G3M0078

(A) Pinion bearing

(B) Front bearing

(C) Rear bearing cup

S3M0514A

DI-23

I


DIFFERENTIALS

18) When replacing the bearings, tap front bearing cup and rear bearing cup in this order out of case by using a brass bar.

D:

ASSEMBLY

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 misinstalled.

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 disassembly. Apply chassis grease between the lips when installing the oil seal.

(A) 2 cutouts along diagonal lines

I

DI-24

2) Adjusting preload for front and rear bearings:

Adjust the bearing preload with spacer and washer between front and rear bearings. Pinion height adjusting washer are not affected by this adjustment.

The adjustment must be carried out without oil seal inserted. carrier with STI and ST2.

ST1 398477701 HANDLE

ST2 398477703 DRIFT 2

(1) Press the rear bearing race into differential m

G3M1037

(2) Insert the ST1 into carrier with pinion height adjusting washer and rear bearing cone fitted onto it.

CAUTION:

Re-use the used washer if not deformed.

Use a new rear bearing cone.


(3) Then install the preload adjusting spacer and washer, front bearing cone, ST2, companion flange, and washer and drive pinion nut.

ST1 398507702 DUMMY SHAFT

ST2 398507703 DUMMY COLLAR

DIFFERENTIALS

Front and rear bearing preload

For new bearing:

N

- kgf,

- at companion flange bolt hole

For used bearing:

-

N

- kgf,

- at cotmanion flanae bolt hole

I

S3M0516A

(A)


(C) Preload adjusting washer

--

-

(4)

Turn the STI with hand to make it seated, and tighten the drive pinion nut while measuring the preload with spring balance. Select the preload adjusting washer and spacer so that the specified preload is obtained when nut is tightened to the specified torque.

CAUTION:

Use a new lock nut.

NOTE:

Be careful not to give excessive preload.

When tightening the drive pinion nut, lock ST1 with ST2 as shown in the figure.

ST1 398507704 BLOCK



181 N.m (18.5 kgf-m,

134 ft-lb)

1

Part

NO.

383705200

383725200

1

Thickyiy mm

I

. .

I

2.59 (0.1020)

[

2.57

I

2.55 (0.1004)

1

2.53 10.0996)

I

I

I

383735200

383755200

’reload adjusting

Masher

383775200

383785200

383795200

383805200

I

1

2.45

2.43 (0.0957)

f

2.41 (0.0949)

1

2.37 (0.0933)

383825200

r-

I

2.33

I

383845200

I

2.31 (0.0909)

I

I

Part No.

Preload adjusting spacer

383695202

383695203

383695204

383695205

383695206

1

57.0 (2.244)

I

57.2 (2.252)

U

G3M1038

DI-25

I


DIFFERENTIALS

3) Adjusting drive pinion height:

Adjust the drive pinion height with shim installed between rear bearing cone and the back of pinion gear.

(1) Install S T l , ST2 and ST3, as shown in the figure, and apply the specified preload on the bearings.

Front and rear bearing preload

For new bearing:

19.6

- - - at companion flange bolt hole

For used bearing:

8.34-l6.67N(0.85-l1.7kgf, 1.87-3.75Ib) at companion flange bolt hole

Adjusting preload for front and rear bearings:

NOTE:

At this time, install a pinion height adjusting shim which is temporarily selected or the same as that used before. Measure and record the thickness.


ST2 398507701 DIFFERENTIAL CARRIER

GAUGE


(2) Measure the clearance N between the end of ST2 and the end surface of STI by using a thickness gauge.

NOTE:

Make sure there is no clearance between the case and ST2.



GAUGE

-I

S3M0518B

H3M1309B

(3) Obtain the thickness of pinion height adjusting shim to be inserted from the following formula, and replace the temporarily installed shim with this one.

T

=

To

+

N

-

(H x 0.01)

-

0.20 mm (0.0079 in)

NOTE:

Use copies of this page.

T

Thickness of shim temporarily inserted mm (in)

To

N

H

Memo:

Thickness of pinion height adjusting

I shim mm (in)

I

I

Reading of thickness gauge mm (in)

I

I

Figure marked on drive pinion head

I

(A)


(Example of calculation)

To

=

2.20

+

1.20

=

3.40 mm

N

=

0.23 mm H

=

+

1,

T

=

3.40

+

0.23

-

0.01

-

0.20

=

3.42

Result: Thickness

=

3.42 mm

Therefore use the shim 383605200.

DI-26

I

I


383495200


i

DIFFERENTIALS

5) Insert the drive pinion into differential carrier, install the previously selected bearing preload adjusting spacer and washer.

I

383525200

3.15 (0.1240)

3.1 8 (0.1 252)

383545200

383555200

383565200

383575200

383585200

383595200

383605200

38361 5200

383625200

383635200

383645200

383655200

383665200

383675200

383685200

3.24 (0.1276)

3.27 (0.1 287)

3.30 (0.1 299)

3.33 (0.131 1)

3.36 (0.1 323)

3.39 (0.1 335)

3.42 (0.1 346)

3.45 (0.1 358)

3.48 (0.1 370)

3.51 (0.1 382)

3.54 (0.1 394)

3.57 (0.1 406)

3.60 (0.1 41 7)

3.63 (0.1429)

3.66 (0.1441)

(A)

Drive pinion

(B) Bearing adjusting spacer

(C) Washer

(D) Differential carrier

6) Press-fit the front bearing cone into case with

ST1, ST2 and ST3.


ST2 399780104 WEIGHT

ST3 8995801 00 INSTALLER

ST 3981 77700

INSTALLER

S3M0519A

7) Insert the spacer, then press-fit pilot bearing with

ST1 and ST2.

ST1 3997801 04 WEIGHT


DI-27

I


DIFFERENTIALS

8) Fit a new oil seal with ST.

NOTE:

Press-fit until end of oil seal is 1 mm (0.04 in) in- ward from end of carrier.

Apply grease between the oil seal lips.

ST 498447120 DRIFT

11) Assembling differential case:

Install the side gears and pinion mate gears, with their thrust washers and pinion mate shaft, into differential case. (Without

LSD)

CAUTION:

Apply gear oil on both sides of the washer and on the side gear shaft before installing.

Insert the pinion mate shaft into the differential case by aligning the lock pin holes.

9) Press-fit the companion flange with ST1 and

ST2.

GAUTION:

Be careful not to damage the bearing.


ST2 3997801 04 WEIGHT

S3M0521

A

10) Install the self-locking nut. Then tighten it with

ST.



181 N-m (18.5 kgf-m, 134 fWb)

G3M0089

(1) Measure the side gear backlash.

Side gear back clearance:

0.10

-

mm (0.0039

-

in)

DI-28


Part No.

I

383445201

I

0.75

Thickness mm (in)

383445202

383445203

I

DIFFERENTIALS

14) Adjusting the side bearing retainer shims:

(1)

The driven gear backlash and side bearing preload can be determined by the side bearing retainer shim thickness.

(2)

Install the differential case assembly into differential carrier in the reverse order of disassembly.

1

case with ST.

ST 398487700 DRIFT w

S3M0509

I

I

(3) Install the side retainer shims and O-rings to the left and right retainers from which they were removed.

NOTE:

Replace the broken or cracked O-ring with a new one.

Replace the broken or corroded side retainer shim with a new one of same thickness.

Part No.

383475201

383475202

383475203

383475204

3a3475205

I

Thickness mm (in)

I

01-29

(A) Arrow mark

I


DIFFERENTIALS

(5) Tighten the side bearing retainer bolts.

CAUTION:

Before tightening the two side bearing retainer bolts, apply Lock Tite to bolt threads.

+Lock Tite:

THREE BOND 1 105 or equivalent


10.3 N.m (1.05 kgf-m, 7.6 ft-16)

15) Recheck the crown gear-to-pinion backlash.

Backlash:

0.10

-

mm (0.0039

-

-

S3M0173

(6) Measure the crown gear-to-drive pinion backlash. Set the magnet base on differential carrier. Align the contact point of dial gauge with tooth face of crown gear, and move crown gear while holding drive pinion still. Read the value indicated on dial gauge.

Backlash:

0.10

-

-

G3M1047

16) Check the crown uear runout on its back surface, and make sure pinion and crown gear rotates smooth I y

.

Limit of runout:

Less than 0.05 mm (0.0020 in)

G3M1047

(7) At the same time, measure the turning resistance of drive pinion. Compared with the resistance 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:

2 . 9 - l 0 . 8 N ( 0 . 3 - l 1 . 1 kgf,O.7-2.4Ib)

1 1

4

S3M0525

17) Checking and adjusting the tooth contact of crown gear:

(1) Apply an even coat of red lead on both sides of three or four teeth on the the crown gear.

Check the contact pattern after rotating the crown gear several revolutions back and forth until a definite contact pattern appears on the crown gear.

(2) When the contact pattern is incorrect, readjust according to the instructions given in

“TOOTH CONTACT PATTERN”.

NOTE:

Be sure to wipe off red lead completely after adjustment is completed.

DI-30

I


18) If proper tooth contact is not obtained, once again adjust the drive pinion height changing RH and LH side bearing retainer shims and the hypoid

DIFFERENTIALS

Where:

T

=

Thickness of pinion height adjusting shim

(">

To = Thickness of shim temDorarilv inserted

(1) Drive pinion height

STl 398507702 DUMMY SHAFT


GAUGE

N

=

Reading of thickness gauge (mm)

H =

Figure marked on drive pinion head

(2)

Hyp6id gear backlash

Backlash:

0.10

-

mm (0.0039

-

in)

H3M13098

T

=

To

+

N

-

(H x 0.01)

-

0.20

(mm)

)

G3M104i

Face contact

Backlash is too large.

TOOTH CONTACT PATTERN

Contact pattern Adjustment Condition

Correct tooth contact

Tooth contact pattern slightly shifted towards toe under no load rotation.

(When loaded, contact pattern moves toward heel.)

Heel side

-

G3M0098A

This may cause noise and chipping at Increase thickness of drive pinion height tooth ends. adjusting shim in order to bring drive pinion closer to crown gear center.

Flank contact

Backlash is too small.

-

G3M0098B

This may cause noise and stepped wear

V

G3M0098F

Reduce thickness of drive pinion height on surfaces. adjusting shim in order to move drive pinion away from crown gear.

-

G3M0098C G3M0098G

DI-31

I

DIFFERENTIALS

Condition

Toe contact

Contact area is small.

Heel contact

Contact area is small.

: Adjusting direction of crown gear


TOOTH CONTACT PATTERN

Contact pattern rhis may cause chipping at toe ends.

Adjustment

Adjust as for flank contact.

G3M0098D rhis may cause chipping at heel ends. Adjust as for face contact.

I

I

G3M0098G

I

V

G3M0098F

G3M0098E

DI-32


19) Install the rear cover and tighten bolts to specified torque.

CAUTION:

Securely connect the ground terminal of rear differential temperature sensor.


29 N-m (3.0 kgf-m, 2 1.7 ff-lb)

DIFFERENTIALS

1. SIDE

GEAR BACKLASH

Using a dial gauge, check the backlash of the side gear.

Side gear backlash:

0.1

-

mm (0.004

-

in)

If the side gear backlash is not within the specification, adjust clearance as specified by selecting side gear thrust washer.

E:

INSPECTION

‘-Wash all the disassembled parts clean, and exam- ine them for wear, damage or other defects. Repair or replace defective parts as necessary.

1) Crown gear and drive pinion:

If abnormal tooth contact is evident, find out the cause and adjust to give correct tooth contact at assembly. Replace the gear if excessively worn or in- capable of adjustment.

If crack, score or seizure is evident, replace as a set. Slight damage of tooth can be corrected by oil stone or the like.

2) Side gear and pinion mate gear:

Replace if crack, score or other defects are evident on tooth surface.

Replace if thrust washer contacting surface is worn or seized. Slight damage of the surface can be corrected by oil stone or the like.

3)

Bearing:

Replace if seizure, peeling, wear, rust, dragging during rotation, abnormal noise or other defect is evident.

4) Thrust washers of side gear and pinion mate gear:

Replace if seizure, flaw, abnormal wear or other defect is evident.

5) Oil seal:

Replace if deformed or damaged, and at every disassembling.

6)

Differential carrier:

Replace if the bearing bores are worn or damaged.

7)

Differential case:

Replace if its sliding surfaces are worn or cracked.

8) Companion flange:

Replace if the oil seal lip contacting surfaces have flaws.

DI-33

1934

2. CROWN GEAR BACKLASH

Using a dial gauge, check the backlash of the crown gear.

Crown gear backlash:

0.1

-

mm (0.004

-

in)

If the crown gear backlash is not within the specification, adjust the side bearing preload or repair if necessary.

I

G3M 1047

I


DIFFERENTIALS

3. CROWN GEAR RUNOUT

Using a dial gauge, check the crown gear runout.

Crown gear runout:

Less than 0.05 mm (0.0020 in)

If the crown gear runout exceeds 0.05 mm (0.0020 in), replace the crown gear.

F: ADJUSTMENT

1. SIDE GEAR BACKLASH

Adjust the side gear backlash.

<Ref. to DI-24, ASSEMBLY, Rear Differential.>

2. CROWN GEAR BACKLASH

Adjust the crown gear backlash.


3. TOOTH CONTACT BETWEEN CROWN

GEAR AND DRIVE PINION

Adjust the tooth contact between crown gear and drive pinion gear.


4. TOTAL PRELOAD

Adjust the side bearing shim.


9

S3M0525

4. TOOTH CONTACT BETWEEN CROWN

GEAR AND DRIVE PINION

r .

Inspect the tooth contact between crown gear and driven pinion. <Ref. to DI-24, ASSEMBLY, Rear

Differential.>

5. TOTAL PRELOAD

Using a gauge, check the turning resistance increase.

Total preload:

2.9-l0.8N.m(0.3-l1.1 kgf,O.7-2.4Ib)

If the increase of the resistance is not within the specification, adjust the side bearing retainer shims.

B3M 1935

DI-34

REAR DIFFERENTIAL FRONT OIL SEAL

5.

Rear Differential Front Oil

Seal

A: INSPECTION

Make sure that there is no oil leakage from front oil seal.

If there is any oil leakage, replace the oil seal.

B: REPLACEMENT

1 )

Set the vehicle on the lift.




5) Remove the oil drain plug, and drain gear oil.

DIFFERENTIALS

11) Extract the companion flange using ST.

ST 399703602 PULLEY ASSY

.

12) Remove the oil seal using ST.


6448

I

--

-

.

DR0003

(A) Filler plug

(B)

Drain plug

6) Install the oil drain plug.

NOTE:

Apply fluid packing to drain plug.


49 N.m (5.0 kgf-m, 36.2 ft-lb)


8) Remove the rear differential protector. (If equipped)

9) Remove the propeller shaft from body. <Ref. to

DS-14, REMOVAL, Propeller Shaft.> panion flange with ST.


/ i:

13) Fit a new oil seal using ST

ST 498447120 DRIFT

B3M1609B

G3M0037

14) Install the companion flange.

NOTE:

Use a plastic hammer to install companion flange.

I

/ /

\ \

G3M0034

DI-35

I

REAR DIFFERENTIAL FRONT OIL SEAL

DIFFERENTIALS

15) Tighten the self-locking nut within the specified torque range so that the turning resistance of companion flange becomes the same as that before replacing oil seal.


NOTE:

Use a new self-locking nut.


181.4 N-m (18.50 kgf-m, 133.8 ff-lb)

\ \

G3M0034

r .

.

16) Reassembling procedure hereafter is the reverse of the disassembling.

17) Fill the differential carrier with gear oil to the filler plug level. <Ref. to DI-17, Differential Gear Oil.>

DI-36

6.

REAR DIFFERENTIAL SIDE OIL SEAL

Rear Differential Side Oil Seal

A: INSPECTION

Make sure that there is no oil leakage from side oil seal.

If there is any oil leakage, replace the oil seal.

B: REPLACEMENT

1 ) Disconnect the ground terminal from battery.



4) Loosen both wheel nuts.

5 )

Jack-up the vehicle and support it with rigid racks.



Non-turbo model:


Pipe.> and <Ref. to EX(S0HC)-11, REMOVAL,

Muffler.>

Turbo model:

*<Ref. to EX(D0HC TURBO)-13, REMOVAL, Rear

Exhaust Pipe.> and <Ref. to EX(D0HC TURBO)-


8) Remove the DOJ of rear drive shaft from rear differential.

(1) Remove the ABS sensor cable clamp and parking brake cable clamp from bracket.

DIFFERENTIALS

(3) Remove the ABS sensor cable clamp and parking brake cable guide from the trailing link.

(A) ABS

sensor cable clamp

(B)

Parking brake cable guide

(4) Remove the rear stabilizer link.

-

17

( 5 )

Remove the bolts which secure the trailing link to the housing.

1

(A) ABS

sensor cable clamp

(B)

Parking brake cable guide

(2) Remove the ABS sensor cable clamp from the trailing link.

\ \

G3M0042

(6) Remove the bolts which secure the front and rear lateral link to the rear housing.

DI-37

I


DIFFERENTIALS

(7) Remove the DOJ from the rear differential by using ST.

CAUTION:

When removing the DOJ from the rear differential, fit ST to the bolts as shown in figure so as not to damage the side bearing retainer.


10) Remove the nut of protector.


G3M1023

11) Drive in a new side oil seal with ST.

CAUTION:

Apply chassis grease between the oil seal lips.

ST 398437700 DRIFT

I

DR0006

(A) Bolt

9) Remove the rear drive shaft to rear crossmember using wire.

1024

12) Insert the DOJ into rear differential.

ST

,

(1) Install the ST to rear differential.

I

28099PA090 SIDE OIL SEAL PROTEC-

TOR

S3M050C

DI-38


_ _ _ ~

~

(2) Install the spline shaft until the spline portion is inside the side oil seal using ST.


TOR

DIFFERENTIALS

1

(3) Remove ST.


TOR

13) Hereafter, reassemble in the reverse order of disassembly. oil to the filler plug level. <Ref. to DI-17, Differential Gear Oil.>

DI-39

I

REAR DIFFERENTIAL MEMBER

DIFFERENTIALS

7. Rear Differential Member

A: REMOVAL



3) Move the selector lever or gear shift lever to “N”.


B: INSTALLATION

To install, reverse the removal sequence.

1) Position the front member

on

body by passing it under parking brake cable and securing to rear differential.

NOTE:

When installing the rear differential front member, do not confuse the installation seqence of the stopper.

6) Jack-up the vehicle and support it with study racks.



Non-turbo model:


Pipe.> and <Ref. to EX(S0HC)-1 1, REMOVAL,

Muffler.>

Turbo model:

<Ref. to EX(D0HC TURBO)-13, REMOVAL, Rear

Exhaust Pipe.> and <Ref. to EX(D0HC TURBO)-


Remove the rear differential protector. (If equipped)

10) Remove the rear differential front member.

NOTE:

When removing the rear differential front member, work the removal procedure as rear differential.

<Ref. to DI-19, REMOVAL, Rear Differential.>

11) Remove the differential rear member.

I

I

’

G3M1029

2) Insert the DOJ of rear drive shaft into rear differential.<Ref. to DI-37, REPLACEMENT, Rear Dif- ferential Side Oil Seal.>

CAUTION:

Before inserting, replace the differential side oil seal with a new one.

ST 28099PA090 SIDE OIL SEAL PROTEX-

TOR

1026

3) Installing procedure hereafter is in the reverse order of removal.

C: INSPECTION

1) Check the rear differential member for damage, bend or corrosion.

If damage, bend or corrosion is excessive, replace the rear differential member.

2) Check bushings of rear differential member for cracking, hardening or damage.

If cracking, hardening or damage is excessive, replace rear differential member.

DI-40

I


DIFFERENTIALS

8. General Diagnostic Table

A: INSPECTION

Symptom or trouble

1. Oil leakage

Possible cause

(1)

Worn, scratched, or incorrectly seated front or side oil seal. Scored, battered or excessively worn sliding surface

of

companion flange.

Remedy

Repair or replace.

(2) Clogged or damaged air breather.

(3)

Loose bolts on differential spindle or side retainer or incorrectlv fitted 0-rina.

(4)

Loose rear cover attaching bolts or damaged gasket.

( 5 )

Loose oil filler or drain plug.

(6) Wear, damage or incorrectly fitting for sDindle. side retainer and oil seal.

Clean, repair or replace.

Tighten bolts to specified torque. Replace

0-rina.

1

Tighten bolts to specified torque. Replace gasket and apply liquid packing.

Retighten and apply liquid packing.

Repair or replace.

2. Seizure

NOTE:

Seized or damaged parts should be replaced, and

Other parts should be thoroughly checked for any defect and should be repaired or replaced as required.

(1) Insufficient backlash for hypoid gear.

(2) Excessive preload for side, rear or front bearing,

(3) insufficient or improper oil used,

Readjust or replace.


Replace seized part and fill with specified oil to specified level.

Replace.

3. Damage

(1) Improper backlash for hypoid gear.

NOTE:

Damaged Parts should be replaced, and

Other parts should be thoroughly paired or replaced as required.

1

(2)

Insufficient or excessive preload for side. rear or front bearina.

(3)

Excessive backlash f& differential checked for any defect and should be re-

~~~"

ycai.

(4)

Loose bolts and nuts such as crown


Replace gear or thrust washer.

I

I

Retighten. gear bolt.

( 5 )

Damage due to overloading.

4. Noises when starting or shifting

(1) Excessive backlash for hypoid gear.

gears

NOTE:

Noises may be caused by differential

1

(2)

Excessive backlash for differential

near

a---..

(3) Insufficient preload for front or rear sembly, universal joint, wheel bearing,

cI

---:--

U ~ d l I l l y .

etc. Find out what is-actually making noise before disassemblv.

(4)

Loose drive pinion nut.

(5) Loose bolts and nuts such as side bearing retainer attaching bolt.

5. Noises when cornering

(1)

Damaged differential gear.

(2) Excessive wear or damage of thrust washer.

Replace.

Readjust.

Replace gear or thrust washer.

Readjust.

Tighten to specified torque.

Tighten to specified torque.

Replace.

Replace.

1

(4)

Seized or damaaed side bearing.

Redace.

I

Replace.

DI-41

I


DIFFERENTIALS

I

SvmDtom or trouble

6.

Gear noises

NOTE:

Since noises from engine, muffler, transmission, propeller shaft, wheel bearings, tires, and body are sometimes mistaken for noises from differential assembly, be careful in checking them. Inspection methods to locate noises include coast- ing, accelerating, cruising, and jacking-up all four wheels. Perform these inspections according to condition of trouble. When listening to noises, shift gears into four wheel drive and fourth speed position, try- ing to pick up only differential noise.

(1)

Improper tooth contact of hypoid gear.

(2) Improper backlash for hypoid gear.

(3) Scored or chipped teeth of hypoid gear.

(4)

Seized hypoid gear.

(5) Improper preload for front or rear bearings.

(6)

Seized, scored or chipped front or rear bearing

.

(7) Seized, scored or chipped side bearina.

(8)

Vibrating differential carrier.

I

I

Readjust or replace hypoid gear set.

I

Readiust.

Replace hypoid gear set.

Replace hypoid gear set.

Readjust.

Replace.

Replace.

Replace.

I

DI-42

TRANSFER CASE

TC

1

.

2

.

3

.

4

.

5

.

6

.

7

.

9

.

10

.

11

.

12 .

13 .

Page

General Description

....................................................................................

2

Transfer Case and Extension for MT

..........................................................

3

Transfer Clutch and Extension for AT

.........................................................

4

Oil Seal

........................................................................................................

5

Transfer Drive Gear (MT)

............................................................................

6

Transfer Driven Gear (MT)

..........................................................................

7

Reduction Drive Gear without VTD

.............................................................

8

Reduction Drive Gear with VTD

..................................................................

9

Reduction Driven Gear without VTD

.........................................................

10

Reduction Driven Gear with VTD

..............................................................

11

Center Differential

.....................................................................................

12

Transfer Clutch Pressure Test

..................................................................

13

Transfer Duty Solenoid and Valve Body

...................................................

14

I


TRANSFERCASE

1.


A: NOTE

For removal, installation and inspection work, refer to “AT” or “MT” section.

AT model:

<Ref. to AT-2, General Description.>

MT model:

<Ref. to MT-2, General Description.>

TC-2

TRANSFER CASE AND EXTENSION FOR MT

TRANSFERCASE

2.

Transfer Case and Extension

for

MT

A: NOTE

For removal, installation and inspection work, refer to “MT” section. <Ref. to MT-41, Transfer Case and

Extension Case Assembly.>

I

TC-3

TRANSFER CLUTCH AND EXTENSION FOR AT

TRANSFERCASE

3. Transfer Clutch and Exten- sion for AT

A: NOTE

For removal, installation and inspection work, refer to “AUTOMATIC TRANSMISSION’’ (a separate publication: Pub. No. G0853ZE).

I

TC-4

I

OIL SEAL

4.

Oil Seal

A: NOTE

For removal, installation and inspection work, refer to “AT” or “MT” section.

AT model:

<Ref. to AT-27, Extension Case Oil Seal.>

MT model:

<Ref. to MT-36, Oil Seal.>

TRANSFERCASE

TC-5

TRANSFER DRIVE GEAR

(MT)

TRANSFERCASE

5. Transfer Drive Gear (MT)

A: NOTE

For removal, installation and inspection work, refer to

“MT”

Gear.> section. <Ref. to MT-45, Transfer Drive

TC-6

I

TRANSFER DRIVEN GEAR (MT)

6. Transfer Driven

Gear

(MT)

A: NOTE

For removal, installation and inspection work, refer to "MT" section. <Ref. to MT-47, Transfer Driven

Gear.>

TRANSFERCASE

TC-7

I

REDUCTION DRIVE GEAR WITHOUT VTD

TRANSFERCASE

7.

Reduction Drive Gear without

VTD

A: NOTE

For removal, installation and inspection work, refer to “AUTOMATIC TRANSMISSION” (a separate publication:

Pub.

No. G0853ZE).

TC-8

I

REDUCTION DRIVE GEAR

WITH VTD

8. Reduction Drive Gear with

VTD

A: NOTE

For removal, installation and inspection work, refer to “AUTOMATIC TRANSMISSION’’ (a separate publication: Pub. No. G0853ZE)

TRANSFERCASE

TC-9

I

REDUCTION DRIVEN GEAR WITHOUT VTD

TRANSFERCASE

9. Reduction Driven Gear without VTD

A: NOTE

For removal, installation and inspection work, refer to “AUTOMATIC TRANSMISSION’’ (a separate publication: Pub. No. G0853ZE).

TC-10

I

REDUCTION DRIVEN GEAR WITH VTD

1O.Reduction Driven Gear with

VTD

A: NOTE

For removal, installation and inspection work, refer to “AUTOMATIC TRANSMISSION” (a separate publication: Pub. No.

G0853ZE)

TRANSFERCASE

TC-11

CENTER DIFFERENTIAL

TRANSFERCASE

11

.Center Differential

A: NOTE

For removal, installation and inspection work, refer to “AUTOMATIC TRANSMISSION’’ (a separate publication) or “MT” section.

AT model:

Pub No. G0853ZE

MT model:

<Ref. to MT-49, Center Differential.=.

TC-12

I

TRANSFERCLUTCHPRESSURETEST

12.Transfer Clutch Pressure

Test

A: NOTE

For inspection work, refer to “AT” section. <Ref. to

AT-1 8, Transfer Clutch Pressure Test.>

TRANSFERCASE

TC-13

I

TRANSFER DUTY SOLENOID AND VALVE BODY

TRANSFERCASE

13.Transfer Duty Solenoid and

Valve Body

A: NOTE

For removal, installation and inspection work, refer to “AUTOMATIC TRANSMISSION’’ (a separate publication: Pub. No. G0853ZE) or

“AT”

section.

<Ref. to AT-39, Shift Solenoids, Duty Solenoids and ATF Temperature Sensor.>

I

r .

.

TC-14

DRIVE

SHAFT SYSTEM

DS

1

.

2

.

4

.

6

.

7

.

General Description

Page

....................................................................................

2

Propeller Shaft

..........................................................................................

14

Front Axle

..................................................................................................

17

Rear Axle

..................................................................................................

23

Front Drive Shaft

.......................................................................................

32

Front Drive Shaft Boots

.............................................................................

38

Rear Drive Shaft

........................................................................................

39

Rear Drive Shaft Boots

.............................................................................

44


..........................................................................

46

DRIVE SHAFT SYSTEM

1.



1.

PROPELLER SHAFT


~ ~ ~~

I

[

Model

Propeller shaft type

Front propeller shaft Joint-to-joint length: L1 mm (in)

Rear propeller shaft Joint-to-joint length: L, mm (in)

Outside diameter of tube: mm (in)

AT

MT

D1

D2

Turbo

DOJ type

579 (22.79)

638 (25.12)

I

Non-turbo

UJ type

584 (22.99)

643 (25.32)

71 3 (28.07) 708 (27.87)

63.5 (2.500)

57.0 (2.244)

I

Di

D2

Di

Dz

(A)

UJtYPe

(B)

DOJ type

DS-2

DR0008


2.

FRONT DRIVE SHAFT ASSEMBLY

2 ,

EBJ87+SFJ82

Except turbo

MT model

Ttirbo MT model


a

26 mm (1.02 in)

28 mm (1.1 0 in)

(A)

EBJ87+SFJ82 (B) Measuring point

B4M2218l

DS-3


DRIVE SHAFT SYSTEM

3.

REAR DRIVE SHAFT ASSEMBLY

Type of drive shaft assembly

EBJ8WDOJ82 RH

EBJ8WDOJ82 LH

BJ79/DOJ79 RH

BJ79/DOJ79 LH

EBJ8WDOJ82 RH

EBJ82/DOJ82 LH

BJ79/DOJ79 RH

BJ79/DOJ79

LH

Model

Sedan Turbo

Sedan Non-turbo

Wagon Turbo

Wagon Non-turbo

I

No. of identification protrusion on shaft

2 (Two)

1 (One)

2 (Two)

1

.

,

2 (Two)

1

(One)

2 (Two)

1 (One)

(")

L1

363

353

368

358

353

343

358

348

+ D

(")

24

24

23

23

24

24

23

23

,

I

DR0013

11)

Identification protrusion

DS-4

B:

COMPONENT

1.

PROPELLER SHAFT


DRIVE SHAFT SYSTEM

(1)

Propeller shaft (Turbo model) (4) Bush

(2) Propeller shaft (Non-Turbo model) (5) Bush

(3) Rear differential

DROOlk


T I : 31 (3.2,23.1)

T2: 52 (5.3, 38.3)

DS-5

I

DRIVE SHAFT SYSTEM

2. FRONTAXLE


(1) Baffle plate (SFJ)

(2) Spring pin

(3) Outer race (SFJ)

(4)

Snap ring

( 5 )

Trunnion

(6) Free ring

(7) Circlip

(8) Boot band

(9) Boot (SFJ)

(1 0) Boot (EBJ)

(11) EBJASSY

(12) Tone wheel (With ABS)

(1 3) Baffle plate

(IN)

~I

(15) Snap ring

(16) Bearing

04M2213A

(17) Housing

(18) Oil seal (OUT)

(19) Hub bolt

(20) Hub

(21) Axle nut

Tightening torque: N-m (kgf-m,

.

-

ft-lb)

T: l S S ( 1 9 , 137)

DS-6

3. REARAXLE


DRIVE SHAFT SYSTEM

Baffle plate (DOJ)

Outer race (DOJ)

Snap ring

Inner race

Ball

Cage

Boot band

Boot (DOJ)

Boot (*)

Non-Turbo: BJ ASSY

Turbo: EBJ ASSY

Baffle plate

Oil seal (IN. No. 2)

Oil seal (IN. No. 3)

Housing

Bearing ASSY

Snap ring

Oil seal (OUT)

Tone wheel (With ABS)

Hub bolt

Hub

Axle nut


T1: 13 (1.3, 9.4)

12: lSS(19, 137)

*

Non-Turbo model: BJ

Turbo model: EBJ

DS-7



C: CAUTION












DS-8


DRIVE SHAFT SYSTEM


1.

SPECIAL TOOLS

ILLUSTRATION

TOOL NUMBER

122431

000

DESCRIPTION

4XLE SHAFT

NSTALLER

3EMARKS

1

1

Used for installing axle shaft into housing.

Used with ADAPTER (927390000).

B4M2386

325091

000

3ANDTIGHTENING r o o L

Used for tightening boot band. (Except front axle housing side)

(A) Jig for band

(B) Ratchet wrench

B4N2387P

326470000

AXLE SHAFT

PULLER

Used for removing axle shaft.

B4M238f

927060000

HUB REMOVER Used for removing front hub.

Used with HUB STAND (927080000).

B4M238!

DS-9

DRIVE SHAFT SYSTEM

ILLUSTRATION


TOOL NUMBER

927420000

DESCRIPTION

HUB REMOVER

REMARKS

Used for removing rear hub.

Used with HUB STAND (927080000).

H5M0981

927080000 HUB STAND Used for disassembling and assembling hub bolt in hub.

B4M2390

9271 00000 3EARING PULLER Used for disassembling and assembling front housing bearing.

Used with HOUSING STAND (927400000).

B4M2391

9271 40000 4XLE SHAFT

WLLER PLATE

Same as plate 2 included in AXLE SHAFT

PULLER (926470000).

B4M2392

DS-10

I


TOOL NUMBER

)27390000

ILLUSTRATION t

INSTALLER (922431 000).

DRIVE SHAFT SYSTEM

B4M2393

327400000 -1OUSING STAND

Used for disassembling and assembling front housing bearing.

Used with BEARING PULLER (927100000).

04M2394

32741 0000 OIL SEAL

INSTALLER

Used for installing oil seal into front housing.


B4M2395 r

Used for disasembling and assembling rear housing bearing.

Used with BEARING PULLER (927440000).

H5M098;

DS-11

I


I

ILLUSTRATION


TOOL NUMBER

9271 20000

DESCRIPTION

HUB INSTALLER

REMARKS

Used for installing hub.

927440000 BEARING

REMOVER

*

Used for disassembling and assembling rear housing bearing.


927460000 31L SEAL

NSTALLER

1

Used for installing outer bearing and sub bear-

1

ng into houding.


I

H5M0984

327450000

W B INSTALLER

1

Used for installing hub unit into hub ASSY.

1

Used with BEARING SPACER (28499AE000) md HUB STAND (927080000).

DS-12

ILLUSTRATION


DRIVE SHAFT SYSTEM

TOOL NUMBER

28OBPAO90

DESCRIPTION

OIL SEAL PROTEC-

TOR

REMARKS

Used for installing rear drive shaft into rear differential.

For potecting oil seal.

B4M2401

28099PA100

DRIVE SHAFT

REMOVER

Used for removing rear drive shaft from rear differential.

B4M2402

28099ACOOO BOOT BAND PLI-

ERS

Used for tightening front EBJ boot band. (Front axle housing side)

84M2403

2.

GENERAL PURPOSE

TOOLS

TOOL NAME

Puller

Dial aauae lSnaD riniiliers

~

REMERKS

Used for removing ball joint from knuckle arm.

Used for insDectinQ DroDeller shaft run-out.

I

Used for installing and removing snap ring.

I

DS-13

PROPELLER SHAFT


2. Propeller Shaft

A: REMOVAL

NOTE:

Before removing propeller shaft, wrap metal parts with a cloth or rubber material.

In case of DOJ type, before removing propeller shaft, wrap metal parts (installed at the rubber boot of center DOJ) with a cloth or rubber material, as shown in the figure. Rubber boot may be damaged due to interference with adjacent metal parts while bending the DOJ during removal.

9)

Remove the four bolts which hold propeller shaft to rear differential.

NOTE:

Put matching mark on affected parts before removal.

Remove all but one bolt. lt3“‘

S3M0030

1) Set the vehicle on a lift.



4)

Release the parking brake.

5) Jack-up the vehicle and support it with the safety stands. (rigid racks)


7) Remove the rear differential protector.

(If equipped)

8)

Remove the differential mount front cover.

(A) Matching mark

10) Remove the two bolts which hold center bearing to the vehicle body.

I

S3M0028

I

S3M0026

DS-14

PROPELLER SHAFT

11) Remove the propeller shaft from the transmission.

CAUTION: not to damage oil seals and frictional surface of sleeve yoke.

Cover the center exhaust pipe with a cloth to keep off any ATF or oil spilled from transmission when removing propeller shaft.

NOTE:

Be sure to use an empty oil can to catch oil flow- ing out when removing propeller shaft.

Be sure to plug the opening in transmission after removal of propeller shaft.

DRIVE

SHAFT SYSTEM

B: INSTALLATION

1) Insert the sleeve yoke into the transmission and attach center bearing to body.


52 N-m (5.3 kgf-m, 38.3 ff-lb)

,

.

'

S3M0028

2) Align the matching marks and connect the flange yoke and rear differential.


37 N-m (3.2 kgf-m, 23.7 ff-lb)

12)

Install the extension cap to transmission.

NOTE:

If extension cap is not available, place vinyl bag over opening and fasten with string to prevent gear oil or ATF from leaking.

(A)

Matching mark

3) Install the differential mount front cover.


88 N.m

(9.0

(A) Extension cap

S3MO026

4)

Install the rear differential protector. (If equipped)

5)

Install the rear exhaust pipe and muffler.

DS-15

PROPELLER SHAFT


C: INSPECTION

NOTE:

Do not disassemble propeller shaft. Check the following and replace if necessary.

1) Tube surfaces for dents or cracks

2) Splines for deformation or abnormal wear

3) Joints for non-smooth operation or abnormal noise

4)

Center bearing for free play, noise or non- smooth operation

5 )

Oil seals for abnormal wear or damage

6) Center bearing for breakage

Check the following points with propeller shaft installed in vehicle.

1. JOINTS AND CONNECTIONS

1)

Remove the rear exhaust pipes and muffler.

2) Remove the heat shield cover. (If equipped)

3)

Check for any looseness of yoke flange connecting bolts and center bearing retaining bolts.

2.

SPLINES AND BEARING LOCATIONS


2)

Remove the heat shield cover. (If equipped)

3)

Turn the propeller shaft by hand to see if abnormal free play exists at splines. Also move yokes to see if the abnormal free play exists at spiders and bearings.

3.

RUNOUT OF PROPELLER SHAFT



3) Turn the rear wheels by hand to check for

“runout” of propeller shaft.

NOTE:

Measure runout with a dial gauge at the center of front and rear propeller shaft tubes.

Runout:

Limit 0.6 mm (0.024 in)

(A)

Propeller shaft

(B) Dial gauge

4.

CENTER BEARING FREE PLAY



3) While holding propeller shaft near center bearing with your hand, move it up and down, and left and right to check for any abnormal bearing free play.

\

B3M1604

DS-16

3.

Front Axle

FRONT AXLE

A: REMOVAL

1) Disconnect the ground cable from battery.

2) Jack-up the vehicle, support it with safety stands, and remove the front wheels.

3) Unlock the axle nut.


7)

Remove the front drive shaft assembly from the hub. If it is hard to remove, use STs.

ST1 926470000 AXLE SHAFT PULLER


PLATE

CAUTION:

Be careful not to damage oil seal lip when removing front drive shaft.

When replacing front drive shaft, also replace inner oil seal.

14

4)

Remove the axle nut using a socket wrench.

CAUTION:

Be sure to loose and retighten axle nut after removing wheel from vehicle. Failure to follow this rule may damage wheel bearings.

5)

Remove the stabilizer link.

8)

Remove the disc rotor from the hub.

If disc rotor seizes up within hub, drive disc rotor out by installing an 8-mm bolt in screw hole on the rotor.

G4M0215

6) Remove the disc brake caliper from the housing, and suspend it from strut using a wire. u

B4M 1670

9) Remove the cotter pin and castle nut which secure tie-rod end to housing knuckle arm.

DS-17

(A)

Cotterpin

(B)

Castle nut

(C) Tie-rod

FRONT AXLE

DRIVE SHAFT SYSTEM

10) Using a puller, remove the tie-rod ball joint from the knuckle arm.

11)

On ABS equipped models, remove the ABS sensor assembly and harness in advance.

12)

Remove the transverse link ball joint from the housing.

B: INSTALLATION

1)

Install the transverse link ball joint to the housing.


49 N-m (5.0 kgf-m, 36 ft-lb)

2)

While aligning alignment mark on camber adjusting bolt head, connect the housing and strut.

CAUTION:

Use a new self-locking nut.


152 N-m (15.5 kgf-m, 112 ft-lb)

3) Install the ABS sensor on the housing (only vehicle equipped with ABS).


32 N-m (3.3 kgf-m, 24 ft-lb)

4 )

Install the disc rotor on the hub.

5) Install the disc brake caliper on the housing.


78 N.m (8 kgf-m, 57.9 ft-lb)

6)

Install the front drive shaft. <Ref. to DS-32, IN-

STALLATION, Front Drive Shaft.>

7)

Connect the stabilizer link.

8) Connect the tie-rod end ball joint and knuckle arm with a castle nut, and insert the cotter pin into the tie-rod end.

Castle nut tightening torque:

Tighten to 27.0 N-m (2.75 kgf-m, 19.9 ft-lb), and tighten further within 60" until cotter pin hole is aligned with a slot in the nut.

CAUTION:

When connecting, do not hit cap at the bottom of tie-rod end with hammer.

13) After scribing an alignment mark on camber adjusting bolt head, remove bolts which connect housing and strut, and disconnect the housing from the strut.

(A) Cotter pin

(B) Castle nut

(C) Tie-rod

DS-18

FRONT AXLE

9) While depressing brake pedal, tighten the axle nut and lock it securely.


186 N-m (19 kgf-m, 137 ft-lb)

CAUTION:

Use a new axle nut.

Always tighten axle nut before installing wheel on vehicle. If wheel is installed and comes in contact with ground when axle nut is loose, wheel bearings may be damaged.

Be sure to tighten axle nut to specified torque. Do not overtighten it as this may damage wheel bearing.

10) After tightening the axle nut, lock it securely.

I


C: DISASSEMBLY

1) Using ST1, support housing and hub securely.

2) Attach ST2 to housing and drive hub out.

ST1 927060000 HUB REMOVER

ST2 927080000 HUB STAND

1

I

G4M0238

1

11) Install the wheel and tighten the wheel nuts to specified torque.


90 N.m (9.2 kgf-m, 66.5 ft-lb)

v

G4M0223

If inner bearing race remains in the hub, remove it with a suitable tool (commercially available).

CAUTION:

Be careful not to scratch polished area of hub.

Be sure to install inner race on the side of outer race from which it was removed.

DS-19


3)

Remove the disc cover from the housing.

FRONT AXLE

8) Using ST and a hydraulic press, drive hub bolts out.

ST 927080000 HUB STAND

CAUTION:

Be careful not to hammer the hub bolts. This may deform hub.

Y

G4M0225

4) Using a standard screwdriver, remove the outer and inner oil seals.

CAUTION:

Do not use old oil seals.

5) Using flat bladed screwdriver, remove the snap ring.

CAUTION:

Be careful not to damage housing at removal.

G4M0228

H4M1001

6) Using STl

, support housing securely.

7) Using ST2, press inner race to drive out outer bearing.

ST1 927400000 HOUSING STAND

ST2 9271 00000 BEARING PULLER

CAUTION:

Do not remove outer race unless it is faulty.

Discard outer race after removal.

Do not replace inner or outer race separately; always replace as a unit.

DS-20

D: ASSEMBLY

1) Attach the hub to ST securely.


FRONT AXLE

DRIVE SHAFT SYSTEM

5) Using pliers, install the snap ring in its groove.

CAUTION:

Make sure t o install it firmly t o groove.

I

G4M0230

2) Using a hydraulic press, press the new hub bolts into place.

CAUTION:

Be sure to press hub bolts until their seating surfaces contact the hub.

NOTE:

Use 12 mm (0.47 in) dia. holes in HUB STAND to prevent bolts from tilting.

3) Clean the dust or foreign particles from inside the housing.

4) Using ST1 and ST2, press a new bearing into place.


ST2 9271 00000 BEARING PULLER

CAUTION:

Always press outer race when installing bearing.

Be careful not t o remove the plastic lock from inner race when installing bearing.

Charge bearing with new grease when outer race is not removed.

Do not apply pressure more than

30

kN

(3.1

ton,

2.8

US ton,

3.1

Imp ton).

Specified grease:

SHELL 6459N

6)

Using ST1 and ST2, press the outer oil seal until it contacts the bottom of housing.

ST1 927410000 OIL SEAL INSTALLER


CAUTION:


3.92

kN (0.4 ton, 0.4 US ton, 0.4 Imp ton).

7) Using ST1 and ST2, press the inner oil seal until it contacts circlip.



CAUTION:


3.92


G4M0234

8) Invert the ST and housing.

ST 927400000 HOUSING STAND

DS-21

FRONT AXLE

DRIVE SHAFT SYSTEM

9) Apply the sufficient grease to oil seal lip.

Specified grease

SHELL 6459N

CAUTION:

If specified grease is not available, remove bearing grease and apply Auto Rex

A instead.

Do not mix different types of grease.

10)

Install the disc cover to housing the three bolts.


18 N-m (1.8 kgf-m, 13.0 ft-lb)

11)

Attach the hub to ST1 securely.

12)

Clean the dust or foreign particles from the polished surface of hub.

13) Using ST2, press the bearing into hub by driving inner race.

STI 927080000 HUB STAND

ST2

927120000 HUB INSTALLER

CAUTION:

Do not apply pressure more than 25 kN (2.5 ton,

2.3 US ton, 2.5 Imp ton).

E: INSPECTION

1) Inspect the rattle of bearing, give the tires a shake with grasping both the upper and lower sides of the tire. And also inspect to rotate the wheel smoothly.

2)

Inspect the lean of axis direction using a dial gauge. Replace the hub bearing if the load range exceed the limitation.

Limit:

Maximum: 0.05" (0.0020in)

G4M0235

3) Inspect the removed parts for wear and damage.

If defective, replace with new ones.

CAUTION:

If bearing is faulty, replace it as the bearing set.

Be sure to replace oil seal at every overhaul.

DS-22

L

H4M1002C

Replace as a set.

(A)

REAR AXLE

DRIVE SHAFT

SYSTEM

8) Disconnect the parking brake cable end

4.

Rear Axle

A: REMOVAL

1. DISC BRAKE


2)

Jack-up the vehicle, and remove the rear wheel cap and wheels.

CAUTION:

Be sure to loosen and retighten the axle nut after removing wheel from vehicle. Failure to follow this rule may damage wheel bearings.

3)

Unlock the axle nut.

4)

Remove the axle nut using a socket wrench.

5) Return the parking brake lever and loosen the adjusting nut.

9)

Disconnect the rear stabilizer from rear lateral link.

10) Remove the bolts which secure trailing link assembly to the rear housing.

CAUTION:

Discard old self-locking nut. Relpace with a new one.

I

(1) Parking brake lever

(2) Lock nut

(3) Adjusting nut

6) Remove the disc brake caliper from the back plate, and suspend it from strut using a piece of wire.

S4M0109

11) Remove the bolts which secure lateral assembly to the rear housing.

CAUTION:

Discard old self-locking nut. Relpace with a new one.

7)

Remove the disc rotor from the hub.

NOTE:

If disc rotor seizes up within hub, drive it out by installing an 8-mm bolt into bolt hole in disc rotor.

DS-23

REAR AXLE


12) Disengage the BJ from the housing splines, and remove the rear drive shaft assembly.

If it is hard to remove, use STs.

STI 926470000 AXLE SHAFT PULLER


PLATE

CAUTION:

Be careful not to damage the oil seal lip when removing rear drive shaft.

When rear drive shaft is to be replaced, also replace inner oil seal with a new one.

I

2. DRUMBRAKE

1)

Disconnect the ground cable from battery.

2) Jack-up the vehicle, and remove the rear wheel cap and wheels.

CAUTION:

Be sure to loosen and retighten the axle nut after removing wheel from vehicle. Failure to follow this rule may damage wheel bearings.

3)

Unlock the axle nut.

4) Remove the axle nut using a socket wrench.

5) Return the parking brake lever and loosen the adjusting nut.

N

G4M0247

13) Remove the rear ABS sensor from the back plate (only vehicle equipped with ABS).


(2)

Locknut

(3)

Adjusting nut

6) Remove the brake drum from hub.

7) If it is difficult to remove brake drum, remove the adjusting hole cover from the back plate, and then turn the adjusting screw using a slot-type screwdriver until the brake shoe separates from the drum.

(1)

ABS sensor

14) Remove the bolts which secure rear housing to strut, and separate the two.

(1)

Back plate

(2) Wheel cylinder

(3) Adjuster ASSY pawls

(4)

Adjusting lever

(5)

Tightening direction

(6) Push

DS-24

REAR AXLE

NOTE:

If brake drum is difficult to remove, drive it out by installing an 8-mm bolt into bolt hole in brake drum.

I



CAUTION:

Discard old self-locking nut. Replace with a new one.

I

G4M0243

1

8) Using a flare-net wrench, disconnect the brake hose from the wheel cylinder.

CAUTION:

Cover open end of wheel cylinder to prevent entry of foreign particles.

S4M0109

I

12) Remove the bolts which secure lateral link assembly to the rear housing.

CAUTION:


9) Disconnect the parking brake cable end.

I \

(1) Cable end

10) Disconnect the rear stabilizer from the rear lateral link.

13) Disengage the BJ from the housing splines, and remove the rear drive shaft assembly.

If it is hard to remove, use STs.



PLATE

CAUTION:

Be careful not t o damage the oil seal lip when removing rear drive shaft.

When rear drive shaft i s to be replaced, also replace inner oil seal with a new one.

I

DS-25

I

//

U

G4M0247

I

REAR AXLE


14)

Remove the rear

ABS

sensor from the back plate (only vehicle equipped with

ABS).

(1) ABS sensor

15) Remove the bolts which secure rear housing to strut, and separate the two.

B:

INSTALLATION

1.

DISC BRAKE

1)

Connect the rear housing assembly and strut assembly.

CAUTION:



196

N-m (20 kgf-m, 145 ft-16)

2) Fit the BJ (bell joint) to the rear housing splines.

CAUTION:

Be careful not to damage inner oil seal lip.

3)

Connect the rear housing assembly to the lateral link assembly.

CAUTION:



137 N-m (14 kgf-m, 101 ft-16)

4)

Connect the rear housing assembly to the trailing link assembly.

CAUTION:



113

N-m (1 1.5 kgf-m, 83 ft-16)

S4M0109

5)

Connect the rear stabilizer to the rear lateral link.

CAUTION:



44 N-m (4.5 kgf-m, 32.5 ft-lb)

DS-26

6)

Connect the parking brake cable to the parking brake.

7)

Install the disc rotor on the rear housing assembly.

8) Install the disc brake caliper on the back plate.


52 N.m (5.3 kgf-m, 38.3 ft-lb)

9) Install the rear ABS sensor and brake cable bracket (only vehicle equipped with ABS).

(1)

ABS

sensor

10) Bleed air from brake system. <Ref. to BR-44,

REPLACEMENT, Brake FI u id. >

11) Adjust the parking brake lever stroke by turning adjuster.

12) Move the brake lever back to apply brakes.

While depressing brake pedal, tighten the axle nut using a socket wrench. Lock the axle nut after tightening.


786 N-m (79 kgf-m, 737 ft-lb)

CAUTION:

Use a new axle nut.

Always tighten axle nut before installing wheel on vehicle. If wheel is installed and comes in contact with ground when axle nut is loose, wheel bearings may be damaged.


REAR AXLE




88 N-m (9 kgf-m, 65 ft-lb)

2.

DRUMBRAKE

1) Connect the rear housing assembly and strut assembly.

CAUTION:



196 N-m (20 kgf-m, 745 ff-lb)

2)

Fit the BJ (bell joint) to rear housing splines.

CAUTION:

Be careful not to damage inner oil seal lip.

3) Connect the rear housing assembly to the lateral link assembly.

CAUTION:



137 N.m (74 kgf-m, 101 ff-lb)

I.

4) Connect the rear housing assembly to the trailing link assembly.

CAUTION:



173 N.m (1 7.5 kgf-m, 83 ff-lb)

S4M0109

DS-27

I

REAR AXLE


5) Connect the rear stabilizer to the rear lateral link.

CAUTION :



44 N-m (4.5 kgf-m, 32.5 ft-lb)

6) Connect the parking brake cable to the parking brake.

7) Clean the brake pipe connection. Using a flare- nut wrench, connect the brake pipe to the wheel cylinder.

8) Connect the rear ABS sensor to the back plate

(only vehicle equipped with ABS).

C: DISASSEMBLY

1) Using STI and ST2, remove the hub from the rear housing.


ST 927420000 HUB REMOVER

I I

(1)

ABS

sensor

9) Connect the parking brake cable to the lever.

IO)

Install the brake drum on the rear housing assembly.

11) Bleed air from brake system. <Ref. to BR-44,

REP LACEMENT, Brake

FI

uid. >

12) Adjust the parking brake lever stroke by turning adjuster.

13) Move the brake lever back to apply brakes.

While depressing brake pedal, tighten the axle nut using a socket wrench. Lock the axle nut after tightening.


186 N-m (19 kgf-m, 137 ft-lb)

CAUTION:

Use a new axle nut.

Always tighten axle nut before installing wheel o n vehicle. If wheel is installed and comes in contact with ground when axle nut is loose, wheel bearings may be damaged.

Be sure torque. Do to tighten axle nut to not overtighten it as this specified may damage wheel bearing.



90 Nom

G4M02501

2) Remove the back plate from the rear housing

3) Using a standard screwdriver, remove the outer and inner oil seals.

CAUTION:

Use new oil seals.

4)

Using flat bladed screwdriver, remove the snap ring.

CAUTION:

Be careful not t o damage housing at removal.

0

H4M1003

5 )

Using STI and ST2, remove the bearing by pressing inner race.

STI 927430000 HOUSING STAND

ST2 927440000 BEARING REMOVER

CAUTION:

Do

not remove bearing unless damaged.

Do not re-use bearing after removal.

U

G4M0252

DS-28

6) Remove the tone wheel bolts and remove the tone wheel from the hub (only vehicle equipped with ABS).

7 ) Using ST, press the hub bolt out.


CAUTION:

Be careful not to hammer the hub bolts. This may deform hub.

REAR AXLE

DRIVE SHAFT SYSTEM

D: ASSEMBLY

1) Using ST, press the new hub bolt into place.

CAUTION:

Ensure hub bolt closely contacts hub.

Use a 12 mm (0.47 in) hole in the ST to prevent hub bolt from tilting during installation.


G4M0221

2) Remove the foreign particles (dust, rust, etc.) from the mating surfaces of hub tone wheel, and install the tone wheel to hub (only vehicle equipped with ABS).

CAUTION:

Ensure tone wheel closely contacts hub.

Be careful not to damage tone wheel teeth.

( 1 )

(1) Tone wheel

S4M0370P

DS-29

REAR AXLE

DRIVE SHAFT

SYSTEM

3) Clean the housing interior completely. Using

STI and ST2, press the bearing into the housing.


ST2 927440000 BEARING REMOVER

CAUTION:

Always press iouter race when installing bearing.

Be careful not to remove plastic lock from inner race when installing bearing.

Charge bearing with new grease when outer race is not removed.


30

kN

(3.1

ton, 2.8 US ton, 3.1 Imp ton).

5)

Using ST1 and ST2, press the outer oil seal unit it comes in contact with snap ring.

STI 927430000 HOUSING STAND


CAUTION:


3.92


I

S4M0266A

4) Using plier, install the snap ring.

CAUTION:

Ensure snap ring fits in groove properly.

S4M0267E

(1) Snap ring

6) Invert both ST1 and housing.

7)

Using ST2, press the inner oil seal into the housing until it touches bottom.



CAUTION:


3.92

kN (0.4 ton, 0.4 US ton, 0.4

ImD ton).

(1) Plier

DS-30

REAR AXLE

8) Using ST1 and ST2, press the sub seal into place.



CAUTION:


3.92


DRIVE

SHAFT SYSTEM

E: INSPECTION

1) Inspect the rattle and lean of axis direction of the removed parts as the same procedure of Front Axle

<Ref. to DS-22, INSPECTION, Front Axle.>

The lean of axis direction

Maximum: 0.05" (0.0020in)

2) Inspect the removed parts for wear and damage.

If defective, replace with a new one.

CAUTION:

If a bearing is faulty, replace it as the bearing set.

Be sure to replace oil seal at every overhaul.

1

S4M0269A

9) Apply the sufficient grease to oil seal lip.

Specified grease:

SHELL 6459N

CAUTION:

If specification grease is not available, remove bearing grease and apply Auto Rex A stead. in-

Do not mix different types of grease.

10) Install back plate to rear housing.


52 N.m (5.3 kgf-m, 38 ft-16)

11) Using ST1 and ST2, press the baring into hub.

ST1 927080000 HUB STAND

ST2 927450000 HUB INSTALLER

CAUTION:


25

kN (2.5 ton,

2.3

US ton,

2.5

Imp ton).

(A)

Replace as a set.

H4M1002C

DS-31

FRONT DRIVE SHAFT


5.

Front Drive Shaft

A:

REMOVAL

1)



(rigid racks), and remove the front wheel cap and wheels.


4) Depress the brake pedal and remove the axle nut using a socket wrench.

CAUTION:

Be sure to loosen and retighten axle nut after removing wheel from vehicle. Failure to follow this rule may damage wheel bearings.

5 )

Remove the stabilizer link from the transverse link.

6) Disconnect the transverse link from the housing.

7) Remove the spring pin which secures transmission spindle to SFJ.

CAUTION:

Use a new spring pin.

6 :

INSTALLATION

1)

Insert the BJ into hub splines.

CAUTION:

Be careful not to damage inner oil seal lip and tone wheel.

2) Using STI and ST2, pull the drive shaft into place.

STI 922431 000 AXLE SHAFT INSTALLER

ST2 927390000 ADAPTER

CAUTION:

Do not hammer drive shaft when installing it.

3) Tighten the axle nut temporarily.

4) Install the SFJ on transmission spindle and drive spring pin into place.

CAUTION:

Always use a new spring pin.

8)

Remove the front drive shaft assembly. hard to remove, use STI and ST2.

If it is

STI 926470000 AXLE SHAFT PULLER


PLATE

CAUTION:

Be careful not t o damage the oil seal lip and tone wheel when removing front drive shaft.

When front drive shaft is to be replaced, also replace inner oil seal.

5 )

Connect the transverse link to the housing.

Tightening torque (self-locking nut):

49 N-m (5.0 kgf-m, 36 ft-lb)

CAUTION:


6) Install the stabilizer bracket.

DS-32


7)

While depressing brake pedal, tighten the axle nut to the specified torque.


186 N.m (1 9 kgf-m, 137 fi-lb)

CAUTION:

Use a new axle nut.

Always tighten axle nut before installing wheel o n vehicle. If wheel is installed and comes in contact with ground when axle nut is loose, wheel bearings may be damaged.

Be sure to tighten axle torque. Do nut to specified not overtighten it as this may damage wheel bearing.

8) After tightening axle nut, lock it securely.


C: DISASSEMBLY

-

/

1) Place alignment marks on the shaft and outer race.

04M0774

I

2) Remove the SFJ boot band and boot.

CAUTION:

Be careful not t o damage boot.

a

B4M0775

1

3) Remove the circlip from SFJ outer race using screwdriver.

04M0776

4)

Remove the SFJ outer race from shaft assembly.

5 )

Wipe off grease.

CAUTION:

The grease is a special grease. Do not confuse with other greases.

DS-33

I


DRIVE SHAFT SYSTEM

6) Place alignment mark on free ring and trunnion.

1 1 )

Place the drive shaft in a vise between wooden b I ocks.

CAUTION:

Do not place drive shaft directly in the vise; use wooden block.

driver and hammer

I

04M0777

7)

Remove the free ring from trunnion.

CAUTION:

Be careful with the free ring position.

8)

Place alignment mark on trunnion and shaft.

04M2220B

(A)

Boot band claws

CAUTION:

The boot must be replaced with a new one whenever it is removed.

9)

Remove the snap ring and trunnion.

04M0778

W

B4M0779

CAUTION:

Be sure to wrap shaft splines with vinyl tape to prevent boot from scratches.

14)

BJ cannot be disassembled.

DS-34


DRIVE SHAFT SYSTEM

7) Install the boot projecting portion to shaft groove.

D: ASSEMBLY

CAUTION:

Use specified grease.

EBJ side:

NTG2218 (Part No. 28093AA000)

SFJ side:

SSG6003 (Part No. 28093TAOOO)

1) Place the EBJ boot and small boot band on the

BJ side of shaft.

CAUTION:


2)

Place the drive shaft in a vise.

CAUTION:

Do not place drive shaft directly in the vise; use wooden blocks.

3) Apply a coat of specified grease [60 to 70 g (2.12 to 2.47 oz)] to

EBJ.

4)

Apply an even coat of specified grease [20 to 30 g (0.71 to 1.06 oz)] to the entire inner surface of boot. Also apply the grease to the shaft.

NOTE:

The inside of the larger end of BJ boot and the boot qroove shall be cleaned so as to be free from irease and other substances.

5) Install the boot projecting portion to the groove.

EBJ

N

(A) Boot

(6)

Small boot band

(C) Shaft

, C )

B4M

1297C

(A) EBJ

(6)

Lorge boot band

(C)

Boot

6) Set the large boot band in place.

DS-35

I



8) Tighten the boot bands using ST, torque wrench and socket flex handle.

ST

28099AC000 BOOT BAND PLlER

14) Align alignment marks on free ring and trunnion and install the free ring.

CAUTION:

Be careful with the free ring position.

(A)

Large boot band

(B) Boot

(C) Torque wrench

(D) Socket flex handle

(E)

BJ


Large boot band

157 N-m (16.0 kgf-m, 116 ff-lb) or more

Small boot band

733

N.m

(73.6 kgf-m, 98 ff-lb) or more

9) Place the SFJ boot at the center of shaft.

10) Align alignment marks and install the trunnion on the shaft.

84M0777

15) A g n alignment marks on shaft and outer race, and install outer race.

I

04M0778

I

11) Install the snap ring to the shaft.

CAUTION:

Confirm that the snap ring is completely fitted in the shaft groove.

12) Fill 100 to 11 0 g (3.53 to 3.88 oz) of specified grease into the interior of SFJ outer race.

13) Apply a coat of specified grease to the free ring and trunnion.

04MQ774

16) Install the circlip in the groove on the SFJ outer race.

CAUTION:

Pull the shaft lightly and assure that the circlip i s completely fitted in the groove.

17) Apply an even coat of the specified grease 30 to 40 g (1.06 to 1.41 oz) to the entire inner surface of boot.

18) Install the SFJ boot taking care not to twist it.

CAUTION:

The inside of the larger end of SFJ boot and the boot groove shall be cleaned so as to be free from grease and other substances.

When installing SFJ boot, position outer race of SFJ at center of its travel.

DS-36


19) Put a band through the clip and wind twice in alignment with band groove of boot.

CAUTION:

Use a new band.

20) Pinch the end of band with pliers. Hold the clip and tighten securely.

NOTE:

When tightening boot, exercise care so that the air within the boot is appropriate.

21) Tighten the band by using ST.

ST 925091000 BAND TIGHTENING TOOL

NOTE:

Tighten the band until it cannot be moved by hand.


E: INSPECTION

Check the removed parts for damage, wear, corrosion etc. If faulty, repair or replace.

1) SFJ (Shudder-less Freering tripod Joint)

Check seizure, corrosion, damage and excessive

Play.

2) Shaft

Check excessive bending, twisting, damage and wear.

3)

EBJ (Bell Joint)


Play.

4) Boot

Check for wear, warping, breakage or scratches.

5) Grease

Check for discoloration or fluidity.

22) Tap on the clip with the punch provided at the end of ST.

ST 925091 000 BAND TIGHTENING TOOL

CAUTION:

Tap to an extent that the boot underneath is not damaged.

G4M029C

23) Cut off band with an allowance of about 10 mm

(0.39 in) left from the clip and bend this allowance over the clip.

CAUTION:

Be careful so that the end of the band is in close contact with clip.

24) Fix up boot on the EBJ in the same manner.

NOTE:

Extend and retract the SFJ to provide equal grease coating.

DS-37

FRONT DRIVE SHAFT BOOTS

DRIVE SHAFT SYSTEM

6.

Front Drive Shaft Boots

A:

INSPECTION

Inspect the wear, warping, breakage or scratches for boot. If faulty, repair or replace.

B: REPLACEMENT

1

) Disconnect the ground terminal from battery.


(rigid racks), and remove the front wheel cap and wheels.

NOTE:

Do not remove the axle nut.

3) Remove the stabilizer link.

4)

Disconnect the transverse link from the housing.

5)

Remove the spring pin which secures transmission spindle to the SFJ.

CAUTION:

Use a new spring pin.

6) Remove the EBJ and SFJ boots from the drive shaft. <Ref. to DS-33, DISASSEMBLY, Front Drive

Shaft. >

7)

Install the EBJ and SFJ boots to the drive shaft.

<Ref. to DS-35, ASSEMBLY, Front Drive Shaft.>

8) Install the SFJ on transmission spindle and drive spring pin into the place.

CAUTION:

Always use a new spring pin.

9) Connect the transverse link to the housing.

10)

Install the stabilizer link.

DS-38

7. Rear Drive Shaft

REAR DRIVE SHAFT

A: REMOVAL


2) Lift-up the vehicle, and remove the rear wheel cap and wheels.

CAUTION:

Be sure to loosen and retighten axle nut after removing wheel from vehicle. Failure t o follow this rule may damage wheel bearings.


4)

Remove the DOJ from rear differential using ST.


NOTE:


DRIVE SHAFT SYSTEM

5)

Remove the axle nut and drive shaft. If it is hard to remove, use ST1 and ST2.



PLATE

CAUTION:

Be careful not t o damage tone wheel when removing rear drive shaft.

1

(1) Bolt

(2)

DOJ

CAUTION:

Be careful not to damage the side bearing retainer. Always use bolt as shown in figure, as supporting point for ST during removal.


(1)

Side bearing retainer

DS-39



B: INSTALLATION

1) Insert the BJ or EBJ into the rear hub splines.

CAUTION:

Be careful not to damage tone wheel.

2) Using ST1 and ST2, pull the drive shaft into the place.

ST1 922431 000 AXLE SHAFT INSTALLER

ST2 927390000 ADAPTER

CAUTION:

Do not hammer drive shaft when installing it.

6) Align the DOJ and differential splines.

7) Push the housing to insert DOJ into the differential.

NOTE:

Make sure the DOJ is inserted properly.

B4M1690A

3) Tighten the axle nut temporarily.

4)

Usina ST, install the DOJ into differential.


TOR

G3M0050

CAUTION:


8) While depressing brake pedal, tighten the axle nut using a socket wrench.


235 N-m (24 kgf-m, 174 ft-lb)

CAUTION:

Use a new axle nut for rear use only.

Always tighten axle wheel nut before installing on vehicle. If wheel is installed and comes in contact with ground when axle nut is loose, wheel bearings may be damaged.


9) After tightening axle nut, lock it securely.

5) Insert the DOJ spline end into the bore of side oil seal, and remove ST.

CAUTION:

Do not allow DOJ splines t o damage side oil seal.


TOR

DS-40

C: DISASSEMBLY


1) Straighten the bent claw of larger end of DOJ boot.

2) Loosen the band by means of screwdriver or pliers with care of not damaging boot.


7) Wipe off the grease and take out balls.

CAUTION:

The grease is a special grease (grease for constant velocity joint). Do not confuse with other greases.

NOTE:

Disassemble exercising care not to lose balls (6

PCS).

3) Remove the boot band on the small end of DOJ boot in the same manner.

4) Remove the larger end of DOJ boot from DOJ outer race.

5 )

Pry and remove the round circlip located at the neck of DOJ outer race with a screwdriver.

G4M0282

I

6) Take out the DOJ outer race from shaft assembly.

27E

(A)

Outer race

8) To remove the cage from the inner race, turn the cage by a half pitch to the track groove of the inner race and shift the cage.

9) Remove snap ring, which fixes inner race to shaft, by using pliers.

IO)

Take out the DOJ inner race.

11)

Take off the DOJ cage from shaft and remove

DOJ boot.

CAUTION:


12) Remove the BJ or EBJ boot in the same procedure as DOJ boot.

13) Thus, disassembly of axle is completed, but BJ or EBJ is unable to be disassembled.

DS-41


DRIVE SHAFT SYSTEM

D: ASSEMBLY

CAUTION

:

Use specified grease.

BJ side (Non-turbo model):

Molylex No. 2 (Part No. 723223010)

EBJ side (Turbo model):

NTG 2218 (Part No. 28093AA000)

DOJ side:

VU-3A702 (Yellow) (Part No. 23223GA050)

1) Install the BJ or EBJ boot in specified position, and fill it with 60 to 70 g (2.12 to 2.47 oz) of specified grease.

2) Place the DOJ boot at the center of shaft.

CAUTION:


3)

Insert the DOJ cage onto shaft.

NOTE:

Insert the cage with the cut-out portion facing the shaft end, since the cage has an orientation.

5) Install the cage, which was previously fitted, to inner race fixed upon shaft.

NOTE:

Fit the cage with the protruded part aligned with the track on the inner race and then turn by a half pitch.

B4M0228E

(A)

inner race

(B) Cage

6) Fill 80 to 90 g (2.82 to 3.17 oz) of specified grease into the interior of DOJ outer race.

7) Apply a coat of specified grease to the cage pocket and six balls.

8) Insert six balls into the cage pocket.

9) Align the outer race track and ball positions and place in the part where shaft, inner race, cage and balls are previously installed, and then fit outer race.

6 ,

S4M0376B

(A) Cage

(B)

Cut-out portion

~~~

-_

4) Install the DOJ inner race on shaft and fit snap ring with pliers.

NOTE:

Confirm that the snap ring is completely fitted in the shaft groove.

(A)

Outer race

(B) Grease

B4M0227E

I

I

G4M0285

DS-42


10) Install the circlip in the groove on the DOJ outer race.

NOTE:

Assure that the balls, cage and inner race are completely fitted in the outer race of DOJ.

Exercise care not to place the matched position of circlip in the ball groove of outer race.

Pull the shaft lightly and assure that the circlip is completely fitted in the groove.


16) Tap on the clip with the punch provided at the end of ST.


CAUTION:

Tap to an extent that the boot underneath is not damaged.

I

4

G4M0282

11) Apply an even coat of the specified grease [20 to 30 g (0.71 to 1.06 oz)] to the entire inner surface of boot. Also apply grease to shaft.

12) Install the DOJ boot taking care not to twist it.

NOTE:

The inside of the larger end of DOJ boot and the boot groove shall be cleaned so as to be free from grease and other substances.

When installing DOJ boot, position outer race of

DOJ at center of its travel.

13) Put a band through the clip and wind twice in alignment with band groove of boot.

CAUTION:

Use a new band.

14) Pinch the end of band with pliers. Hold the clip and tighten securely.

NOTE:

When tightening boot, exercise care so that the air within the boot is appropriate.

15) Tighten the band by using ST.


NOTE:

Tighten the band until it cannot be moved by hand.

G4M0290

17) Cut off the band with an allowance of about 10 mm (0.39 in) left from the clip and bend this allowance over the clip.

CAUTION:

Be careful so that the end of the band is in close contact with clip.

18) Fix up the boot on the BJ or EBJ in the same manner.

NOTE:

Extend and retract the DOJ to provide equal grease coating

.

E: INSPECTION

Check the removed parts for damage, wear, corrosion etc. If faulty, repair or replace.

1) DOJ (Double Offset Joint)

Check seizure, corrosion, damage, wear and excessive play.

2) Shaft

Check excessive bending, twisting, damage and wear.

3) BJ (Bell Joint) and EBJ (Eightball Bell Joint)


Play.

4) Boot

Check for wear, warping, breakage or scratches.

5) Grease

Check for discoloration or fluidity.

G4M0289


8.

Rear Drive Shaft

A: INSPECTION

REAR DRIVE SHAFT BOOTS

Boots

Inspect the wear, warping, breakage or scratches for boot. If faulty, repair or replace.

B: REPLACEMENT


2) Lift-up the vehicle, and remove the rear wheel cap and wheels.

NOTE:

Axle nut need not be removed.

3) Remove the ABS sensor clamps and parking brake cable bracket.

4)

Disconnect the stabilizer link from the lateral link.

5) Remove the bolts which secure lateral link assembly to the rear housing.


~

__

7) Remove the DOJ from rear differential using ST.


NOTE:


(1)

Bolt

(2)

DOJ

CAUTION:

Be careful not to damage the side bearing retainer. Always use bolt as shown in figure, as supporting point for

ST during removal.


(1) Side bearing retainer

8) Remove the DOJ and BJ or EBJ boots from the drive shaft. <Ref. to DS-41, DISASSEMBLY, Rear

Drive Shaft.>

9) Install the DOJ and BJ or EBJ boots to the drive shaft. <Ref. to DS-42, ASSEMBLY, Rear Drive

Shaft.>

DS-44

REAR DRIVE SHAFT BOOTS

10)

Using ST, install the DOJ into differential.


TOR

DRIVE SHAFT SYSTEM

14) Connect the rear housing assembly to the trailing link assembly, and tighten the self-locking nut.

15) Connect the rear housing assembly to the lat- era1 link assembly, and tighten the self-locking nut.

16) Connect the stabilizer link to the lateral link.

17) Install the ABS sensor clamps and parking brake cable bracket.

11) Insert the DOJ spline end into the bore of side oil seal, and remove ST.

CAUTION:

Do not allow DOJ splines to damage side oil seal.


TOR

12) Align the DOJ and differential splines.

13) Push the housing to insert DOJ into the differential.

NOTE:

Make sure the DOJ is inserted properly.

I

G3M005C

CAUTION:

Discard old self-locking nut. Replace with a new one.

DS-45



9. General Diagnostic Table

A:INSPECTION

NOTE:

Vibration while cruising may be caused by an unbalanced tire, improper tire inflation pressure, improper wheel alignment, etc.

Symptom

1. Vibration of propeller shaft

NOTE:

Vibration is caused by propeller shaft during operation and is transferred to vehicle body. Generally vibration increase in proportion to vehicle speed.

2. Tapping when starting and noise while cruising, Cawed by Propeller shaft.

3. Front wheel shimmy

4. Wander or pulling

Possible cause

(1) Worn or damaged universal joint.

(2) Unbalanced propeller shaft due to bend or dent,

(3)

of propeller shaft,

(4)

Worn or damaged center bearing and damaaed center mountina rubber.

I

"

(1) Worn or damaged universal joint.

(2) Worn spline of sleeve yoke.

(3)

Loose installation of propeller shaft.

(4)

Loose installation of joint.

(5)

Worn or damaged center bearing and damaged center mounting rubber.

(1)

Worn or damaged hub bearing

(1) Worn or damaged hub bearing

Replace.

Replace.

Retighten.

Replace.

Replace.

Replace.

Retighten.

Replace.

Replace.

Remedy

Repair or replace.

Repair or replace.

DS-46

ABS

ABS

1

.

General Description

Page

....................................................................................

2

2 . ABS Control Module and Hydraulic Control Unit (ABSCM&H/U)

................

3

.

ABS Sequence Control

.............................................................................

11

4

.

5

.

Front ABS Sensor

.....................................................................................

14

Rear ABS Sensor

......................................................................................

18

7

.

.

Front Tone Wheel

Rear Tone Wheel

.....................................................................................

21

......................................................................................

22

8

. G Sensor

...................................................................................................

23

ABS

1. General Description



Item

ABS sensor gap

ABS sensor

ABS sensor resistance

Marks

of

the harness

-

Front

Rear

Front

Rear

I

Front

I

Rear

RH

LH

RH

LH

I

I

0.3

Standard or remarks

-

2

- in)

0.7

- mm (0.028

- in)

1.25k0.25 kR

1 .Of0.2 k!2

White

Yellow

Light blue

Brown

ABS control module and hydraulic control unit (ABSCM&H/U) marks

AT

MT

cc

CD

I

I

ABS-2

B: COMPONENT

1. SENSOR


ABS

El

/-----Q

(1) G sensor

(2) Rear ABS sensor RH

(3) ABS spacer

(4) Rear ABS sensor LH

(5) Front ABS sensor LH

( 6 )

Front ABS sensor RH

BROOOl

Tightening torque: N.m (kgf-m, fi-lb)

T1: 7.4 (0.75, 5.4)

T2: 32 (3.3,24)

ABS-3

I


ABS

2.

ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U)

(1) Stud bolt

(2)

Damper

(4)

Front-LH outlet

(5)

Secondary inlet

(6) Front-RH outlet

(7) Primary inlet

(3) ABS control module and hydraulic (8) Rear-LH outlet control unit (9) Rear-RH outlet

(10) Bracket


N.m

(kgf-m, ft-lb)

T1: lS(1.8, 13.0)

T2: 29 (3.0, 21.7)

T3: 32 (3.3.24)

ABS-4


C: CAUTION





Be careful not to burn your hands, because each part in the vehicle is hot after running.



Before disconnecting electrical connectors of sensors or units, be sure to disconnect negative terminal from battery.

ABS

1

ABS-5

ABS


1.

SPECIAL

TOOLS


ILLUSTRATION TOOL NUMBER

24082AA150

(New apopted tool)

DESCRIPTION

;ARTRIDGE

REMARKS rroubleshooting for electrical systems.

02M3876

22771 AA030 SELECT MONITOR

<IT

Troubleshooting for electrical systems.

b

English: 22771 AA030 (Without printer)

German: 22771AA070 (Without printer)

French: 22771AA080 (Without printer)

Spanish: 22771 AA090 (Without printer)

02M3877

2.

GENERAL

PURPOSE TOOLS

TOOL NAME

Circuit tester

Pressure gauge

Oscilloscope

REMARKS

Used for measuring resistance, voltage and ampere.

Used for measuring oil pressure.

Used for measuring sensor.

ABS-6

I


ABS

2. ABS

draulic Control Unit

SCM

Control Module and Hy-

&H/U)

(AB-

A:

REMOVAL

1)


2) Remove the air intake duct from engine compartment to facilitate removal of ABSCM&H/U.

3) Use an air gun to get rid of water around the AB-

SCM&H/U.

CAUTION:

The contact will be insufficient if the terminal gets wet.

4)

Pull off the lock of the ABSCM&H/U connector to remove it.

8) Remove the ABSCM&H/U from engine compartment.

CAUTION:

ABSCM&H/U cannot be disassembled.

Do

not attempt to loosen the bolts and nuts.

Do

not drop or bump the ABSCM&H/U.

Do

not turn the ABSCM&H/U upside down or place it on its side.

Be careful to prevent foreign particles from getting into the ABSCM&H/U.

Apply a coat of rust-preventive wax (Nippeco

LT or

GB) to bracket attaching bolt after tightening.

Do not pull the harness when disconnecting connector.

ta

/ -

B4M1222

5) Disconnect the connector from ABSCM&H/U.

CAUTION:

Be careful not to let water or other foreign matter contact the ABSCM&H/U terminal.

6) Unlock the cable clip.

7) Disconnect the brake pipes from ABSCM&H/U.

CAUTION:

Wrap the brake pipes with vinyl bag to avoid spilling brake fluid on vehicle body.

ABS-7


ABS

B: INSTALLATION

1)

Install the ABSCM&H/U bracket.


32 N-m (3.3 kgf-m, 24 ff-16)

2)

Install the ABSCM&H/U.

CAUTION:

Confirm that the specifications of the AB-

SCM&H/U conforms t o the vehicle specifications.


18 N.m (1.8 kgf-m, 13.0 ff-16)

I

Mark

cc

CD

I

Model

AT

MT

I

I

/-

04M1222

3) Connect the brake pipes to their correct AB-

SCM&H/U connections.


15

N.m (1.5 kgf-m, 10.8 ft-lb)

4) Using cable clip, secure the ABSCM&H/U harness to bracket.

5 )

Connect the connector to the ABSCM&H/U.

CAUTION:

Be sure t o remove all foreign matter from inside the connector before connecting.

Ensure that the ABSCM&H/U connector i s securely locked.

6) Install the air intake duct.

Non-turbo model:

<Ref. to IN(S0HC)-7, INSTALLATION, Air Intake

Duct.>

Turbo model:

<Ref. to IN(D0HC TURBO)-8, INSTALLATION, Air

Intake Duct.>

7) Bleed air from the brake system. <Ref. to BR-46,

Air Bleeding.>

(1)

Mark

1. CHECKING THE HYDRAULIC UNIT ABS

OPERATION BY PRESSURE GAUGE

1) Lift-up the vehicle and remove wheels.

2)

Disconnect the air bleeder screws from the FL and FR caliper bodies.

3) Connect two pressure gauges to the FL and FR caliper bodies.

CAUTION:

Pressure gauges used exclusively for brake fluid must be used.

Do not employ the pressure gauge previously used for transmission since the piston seal is expanded and may lead t o malfunction of the brake.

NOTE:

Wrap a sealing tape around the pressure gauge.

I

R4M 1797

ABS-8


ABS

2.

CHECKING THE HYDRAULIC UNIT ABS

OPERATION

WITH

BRAKE TESTER

1)

In the case of AWD AT Non-turbo vehicles, install a spare fuse with the FWD connector in the main fuse box to simulate FWD vehicles.

I

Initial value

When decom- pressed

When compressed

Front wheel

3,432 kPa

(35 kgf/cm2, 498

Psi)

490 kPa

(5 kgf/cm2, 71 psi) or less

3,432 kPa

(35 kgf/cm2, 498

Psi) or more

Rear wheel

3,432 kPa

(35 kgf/cm2, 498

Psi)

490 kPa

(5 kgf/cm2, 71 psi) or less

3,432 kPa

(35 kgf/cm2, 498

Psi) or more

~

8) Remove the pressure gauges from FL and FR caliper bodies.

9 )

Remove the air bleeder screws from the RL and

RR caliper bodies.

10) Connect the air bleeder screws to the FL and

FR caliper bodies.

11) Connect two pressure gauges to the RL and

RR caliper bodies.

12) Bleed air from the pressure gauges and the FL and FR caliper bodies.

13) Perform the ABS sequence control.

<Ref. to ABS-I 1, ABS Sequence Control.>

14) When the hydraulic unit begins to work, at first the RR side performs decompression, holding, and compression, and then the RL side performs decompression, holding, and compression.

15) Read the values indicated on the pressure gauges and check if they meet the standard value.

16) After checking, remove the pressure gauges from caliper bodies.

17) Connect the air bleeder screws to RL and RR caliper bodies.

18) Bleed air from the brake line.

(1)

Main fuse box

(2) FWD connector

2) Prepare for operating the ABS sequence control.


3)

Set the front wheels or rear wheels on the brake tester and set the select lever’s position at “neu- t ral”.

(1)

Brake tester

4) Operate the brake tester.

5) Perform ABS sequence control.

<Ref. to ABS-1 1, ABS Sequence Control.>

ABS-9


ABS

6)

Hydraulic unit begins to work; and check the following working sequence.

(1)

The FL wheel performs decompression, holding, and compression in sequence, and subsequently the FR wheel repeats the cycle.

(2)

The

RR wheel performs decompression, holding, and compression in sequence, and subsequently the RL wheel repeats the cycle.

7) Read the values indicated on the brake tester and check if the fluctuation of values, when decom- pressed and compressed, meet the standard values.

Front wheel Rear wheel

Initial value

I

E m p r e s s e d or less

01yO or less

981 N 981 N

When

(100 kgf, 221 Ib)

1

(50 ~ ~ 0 l y O l b )

I

(50;:

(100 kgf, 221 Ib)

Ib)

(100 kgf, 221 Ib)

(100 kgf, 221 Ib) compressed

981 N 981 N or more or more

I

8 )

After checking, also check if any irregular brake pedal tightness is felt.

ABS-1 0

3.

ABS SEQUENCE CONTROL

ABS Sequence Control

A: OPERATION

1) Under the ABS sequence control, after the hydraulic unit solenoid valve is driven, the operation of the hydraulic unit can be checked by means of the brake tester or pressure gauge.

2) ABS sequence control can be started by diagnosis connector or select monitor.

1.

ABS

SEQUENCE CONTROL WITH

DIAG-

NOSIS CONNECTOR

1) Connect the diagnosis terminals to terminals No.

3 and No. 6 of the diagnosis connector beside driver’s seat heater unit.

&

BR0094

(1) Diagnosis connector

(2) Diagnosis terminals

’

(3) 3 terminal

(4)

6 terminal

2) Set the speed of all wheels at 4 km/h (2 MPH) or less.

3) Turn the ignition switch OFF.

4) Within 0.5 seconds after the ABS warning light goes out, depress the brake pedal and hold it immediately after the ignition switch is turned to ON.

CAUTION:

Do not depress the clutch pedal.

NOTE:

When the ignition switch is set to on, the brake pedal must not be depressed.

Engine must not operate.

5 )

After completion of ABS sequence control, turn the ignition switch OFF.

ABS

2. ABS

SEQUENCE CONTROL WITH SE-

LECT MONITOR

NOTE:

In the event of any trouble, the sequence control may not be operative. In such a case, activate the sequence control, referring to “ABS SEQUENCE

CONTROL WITH DIAGNOSIS CONNECTOR’’.

<Ref. to ABS-11, ABS SEQUENCE CONTROL

WITH DIAGNOSIS CONNECTOR, ABS Sequence

Control.>

When the diagnosis terminal is connected to the diagnosis connector, the sequence control will not operate.

1) Connect the select monitor to data link connector under the driver’s seat instrument panel lower cover.

2) Turn the ignition switch ON.

3) Turn the select monitor switch ON.

4)

Put the select monitor to “BRAKE CONTROL” mode.

5 )

When “Function check sequence’’ is selected,

‘ABS sequence control’ will start.

6) The message ’Press Brake Pedal Firmly’ is displayed as follows:

(1) When using the brake tester, depress the brake pedal with braking force of 981 N (100 kgf,

221 Ib).

(2) When using the pressure gauge, depress the brake pedal so as to make the pressure gauge indicate 3,432 kPa (35 kg/cm2, 498 psi).

CAUTION:

Do not depress the clutch pedal.

7)

When the message “Press YES’’ is displayed, press the YES key.

8) Operation points will be displayed on the select monitor.

m

ABS-1 1


ABS

3.

CONDITIONS

FOR ABS

SEQUENCE CONTROL

Operational guide line of sequence control

Operational pattern of sequence control

4 km/h

-

Speed of all wheels

Terminal No.3 and No.6

LOW

Ignition key switch

I I

ON

OFF

I

J

1.5

_ I A

j j 1.5

ABS warning light

Stop light switch

HIGH

LOW

AT ABS signal

I

'

I

I

W i t h i n m

; j

1

I I 1

I 1

I 1

I 1

1

I

1

FL inlet valve

FR outlet valve

FR inlet valve

OFF

ON

OFF

ON

OFF'

ON

I

I j j

!

RR outlet valve

RR inlet valve

ON

OFF

ON j

;

I

1

I

I

1

I

I 1

I 1

I 1

I 1

I 1

I 1

1

1

1

10 km/h (6 MPH) or less

I

I

I

I

!

1.4 i

1.0 i

1.4

Ljl

w - v

-1-

!

1

I

I

I

I

I 1

!

1

1

1

I

,

1

1 I

I

I

!

I

I

I

I

I

0.6

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

1

1

1

1

1

1

I

I

I

I

I

I

I

I l

I

. .

1

I 1 l

1

,

I

I

1

I

I 1

I 1

I 1

I

I

I

I

I

I

I

I

Unit: second

I

I

I

I

I

I

I

1 I

I

I

I

.

I

,

Point A

~

I

I *

I 1

I 1

I 1

n

I

I

1

I

I

I

I

1

1

1

I

1

1

1

I

I

I

I

I

I

I

I

I

I

I

.

.

1

1

1

1

I 1

I 1

I 1

I

I

I

I

I

I

I

I

I

I

I

I

I

I

Operational pressure of sequence control

Pressure of master cylinder

Pressure of FL wheel cylinder

Pressure of FR wheel cvlinder

Pressure of RR wheel c h d e r l

I

Pressure of RL wheel cilinderl j

L

!

I

!

!

!

I I

/ I

I

I

I

I

I 1

1 I

I I I

I

I

.

,

.

1

1

I

I

I

.

I

I

I 1

I ,

W

I

I i

I

B4M1001A

NOTE:

When the select monitor is used, control operation starts at point A. The patterns from IGN key ON to the point

A

show that operation is started by diagnosis connector.

HIGH means high voltage.

LOW means low voltage.

ABS-I 2


~~ ~

4.

CONDITIONS

FOR

COMPLETION

OF

ABS

SEQUENCE CONTROL

When the following conditions develop, the ABS sequence control stops and ABS operation is re- turned to the normal control mode.

1)

When the speed of at least one wheel reaches

10 km/h (6 MPH).

2) When terminal No. 3 or

No.

6 are separated from diagnosis terminals. (When the select monitor is not used.)

3) When the brake pedal is released during sequence control and the braking lamp switch is set to OFF.

4)

When the brake pedal is depressed after the ignition key is turned to

ON, and before ABS warning light goes out. (When the select monitor is not used.)

5 )

When the brake pedal is not depressed after the ignition key is turned to ON, and within 0.5 seconds after ABS warning light goes out. (When the select monitor is not used.)

6)

After completion of the sequence control.

7)

When malfunction is detected. (When the select monitor is used.)

ABS

ABS-1

3

FRONT ABS SENSOR

ABS

4. Front ABS

Sensor

A: REMOVAL

1)


2) Jack-up the vehicle, support it with rigid racks, and remove the wheel.

3) Disconnect the front ABS sensor connector located next to the front strut mounting house in engine compartment.

4) Remove the bolts which secure sensor harness to strut.

6) Remove the bolts which secure front ABS sensor to housing, and remove the front ABS sensor.

CAUTION:

Be careful not to damage the pole piece located at tip of the sensor and teeth faces during removal. ai.

Do not pull the sensor harness during remov-

B4M2209

5 )

Remove the bolts which secure sensor harness to body.

(1) To front

ABS

sensor connector

(2)

Bracket

ABS-1 4


B: INSTALLATION

1)

Temporarily install the front ABS sensor on housing.

CAUTION:

Be careful not to strike the ABS sensor's pole piece and tone wheel's teeth against adjacent metal parts during installation.

ABS

3) Place a thickness gauge between the ABS sensor's and tone wheel's tooth face. After standard clearance is obtained over the entire perimeter, tighten the ABS sensor on housing to specified torque.

ABS sensor standard clearance:

0.3

-

-


32 N-m (3.3 kgf-m, 24 ft-16)

1

1

84M220E

2) Install the front ABS sensor on strut and wheel apron bracket.


32 N-m (3.3 kgf-m, 24 ft-16)

CAUTION:

Check the marks on the harness to make sure that no distortion exists.

RH: White

LH: Yellow

NOTE:

If the clearance is outside specifications, readjust.

4)

After confirmation of the ABS sensor clearance, connect the connector to ABS sensor.

5) Install the wheel.

6) Connect the battery ground terminal to battery.

I

(1)

To front

ABS

sensor connector

(2)

Bracket

1728C

ABS-1

5


ABS

C: INSPECTION

1. ABS SENSOR

1)

Check the pole piece of the ABS sensor for foreign particles or damage. If necessary, clean the pole piece or replace the ABS sensor.

2) Measure the ABS sensor resistance.

2) Measure the distance “B” between the surface where front axle housing meets the ABS sensor, and the tone wheel.

NOTE:

Measure so that the gauge touches the tone wheel teeth top.

I

B

Terminal No.

1 and2

A

B4M0248

Standard

1.25f0.25 kQ

(1)

Axle housing

(2)

Tone wheel

3) Find the gap between the ABS sensor pole face and the surface of the tone wheel teeth by putting the measured values in the formula below and cal- culating.

ABS sensor clearance

=

B - A


0.3

-

mm

(0.012

-

NOTE:


A

B4M2482A

ABS-I 6


3. OUTPUT VOLTAGE

Output voltage can be checked by the following method. Install a resistor and condenser, then rotate the wheel about 2.75 km/h (2 MPH) or equivalent.

NOTE:

Regarding terminal No., please refer to item 1. ABS

SENSOR.

ABS

D: ADJUSTMENT

Adjust the gap using spacer (Part No. 26755A000).

+60 mV

-60

Standard output voltage:

0.12

-

1 v

(When it is 20 Hz)

1

Oscilloscope

1

LL

r

ABS-1 7

REAR ABS SENSOR

ABS

5.

Rear ABS Sensor

A: REMOVAL

1)


2)

Jack-up the vehicle, suppofl it with rigid racks, and remove the wheel.

3) Remove the rear seat and disconnect the rear

ABS

sensor connector.

4)

Remove the rear sensor harness bracket from rear trailing link and bracket.

5) Remove the rear

ABS

sensor from back plate.

B: INSTALLATION

1) Temporarily install the rear

ABS

sensor on back plate.

CAUTION:

Be careful not to strike the ABS sensor's pole piece and tone wheel's teeth against adjacent metal parts during installation.

(1 ) Rear ABS sensor

(1 ) Rear ABS sensor link.


32 N-m (3.3 kgf-m, 24 ff-lb)

(1 ) Rear sensor harness

(2)

Trailing link

ABS-I 8

REAR ABS SENSOR

3) Place a thickness gauge between the ABS sensor’s and tone wheel’s tooth face. After standard clearance is obtained over the entire perimeter, tighten the ABS sensor on rear arm to specified torque.


0.7- f.2mm(0.028-00.047in)


32 N.m (3.3 kgf-m, 24 ff-lb)

CAUTION:


RH: White

LH: Yellow

NOTE:


4)

After confirmation of the ABS sensor clearance, connect the connector to ABS sensor.

5) Connect the battery ground terminal to battery.

ABS

C: INSPECTION

1. ABS SENSOR

1) Check the pole piece of the ABS sensor for foreign particles or damage. If necessary, clean the pole piece or replace the ABS sensor.

2)

Measure the ABS sensor resistance.

I

Terminal No. Standard

~~~~ ~

CAUTION:

If resistance is outside the standard value, replace the ABS sensor with a new one.


RH: Light blue

LH: Brown

NOTE:

Check the ABS sensor cable for discontinuity. If necessary, replace with a new one.

ia

ABS-I 9

2.

SENSORGAP

Clearances (sensor gaps) should be measured one by one to ensure the tone wheel and speed sensor are installed correctly.

NOTE:

If clearance is narrow, adjust by using the spacer

(Part No. 26755AA000).

If clearance is wide, check the outputted voltage then replace the ABS sensor or tone wheel if the outputted voltage is outside the specification.

ABS sensor clearance:

0.7

-

mm

(0.028

-

in)

--E=

Tone wheel

REAR ABS SENSOR

3.

OUTPUT VOLTAGE

Output voltage can be checked by the following method. Install a resistor and condenser, then rotate the wheel about 2.75 km/h (2 MPH) or equivalent.

NOTE:

Regarding terminal No., please refer to item 1. ABS

SENSOR.

+60

mV

1

-60 mV

Standard output voltage:

0.12

-

1 v

(When it is 20 Hz)

Oscilloscope

%nsor

gap

BR0002 To terminal

To terminal

H4M1141 P

D: ADJUSTMENT

Adjust the gap using spacer (Part

26755AA000).

No.

ABS-20

FRONT TONE WHEEL

6.

Front Tone Wheel

A:

REMOVAL

Refer to Front Drive Shaft, because the front tone wheel is integrated with front drive shaft.

<Ref. to DS-32, REMOVAL, Front Drive Shaft.>

B: INSTALLATION

Refer to Front Drive Shaft, because the front tone wheel is integrated with front drive shaft.

<Ref. to DS-32, INSTALLATION, Front Drive

Shaft.>

C: INSPECTION

Visually check the tone wheels teeth (44 pieces) for cracks or dents. If necessary, replace the tone wheel with a new one.

NOTE:

Replace the BJ assembly with a new one as a single unit if there is any defect found on the tone wheel, since it is unitized with the BJ assembly of drive shaft.

ABS

PI

ABS-21

REAR TONE WHEEL

ABS

7.

Rear Tone Wheel

A: REMOVAL

Refer to Rear Drive Shaft, because the rear tone wheel is integrated with hub.

<Ref. to DS-23, REMOVAL, Rear Axle.>

B: INSTALLATION

Refer to Rear Drive Shaft, because the rear tone wheel is integrated with hub.

<Ref. to DS-26, INSTALLATION, Rear Axle.>

C: INSPECTION

Visually check the tone wheels teeth (44 pieces) for cracks or dents.

If necessary, replace the tone wheel with a new one.

ABS-22

G SENSOR

8.

GSensor

A: REMOVAL


B: INSTALLATION


CAUTION:

Do not drop or bump the G sensor.

Tightening torque (G sensor):

32 N.m (3.3 kgf-m, 24 ft-lb)

ABS

1

2) Remove the console cover.

<Ref. to El-41, Console

Box.>

3) Disconnect the connector from

G sensor.

4) Remove the G sensor from

body.

CAUTION:

Do not drop or bump the G sensor.

ABS-23

G SENSOR

ABS

C: INSPECTION

I

I

I

I

I

Step

CHECK SUBARU SELECT MONITOR.

Check

Do you have the SUBARU

SELECT MONITOR?

CHECK G SENSOR.

1)Turn the ignition switch to OFF.

2)Remove the G sensor from vehicle.

3)Connect the connector to G sensor.

4)Turn the ignition switch to ON.

5)Measure the voltage between G sensor con-

Is the voltage 2.3k0.2 V when

G sensor is horizontal? nector terminals.

Connector & terminal:

(8292) NO. 2

(+)

-

3

CHECK G SENSOR.

Measure the voltage between G sensor connector terminals.


(8292) NO. 2 (+)

-

Is the voltage 3.9k0.2 V when

G sensor is inclined forwards to go"?

CHECK G SENSOR.


Is the voltage 0.7f0.2 V when

G sensor is inclined backwards to go"?


(8292) NO. 2

(+)

-

CHECK G SENSOR.


2)Connect the select monitor connector to data

Is the indicated reading

2.3f0.2 V when the vehicle is in horizontal position? link connector.

3)Turn the select monitor into (BRAKE CON-

TROL} mode.

4)Set the display in the {Current Data Display

& Save} mode.

5)Read the G sensor output voltage.

CHECK G SENSOR.

1)Remove the console box.

2)Remove the G sensor from vehicle. (Do not disconnect connector.)

3)Read the select monitor display.

CHECK G SENSOR.

Read the select monitor display.


3.9f0.2 V when G sensor is inclined forwards to go"?


0.7k0.2 V when

G sensor is inclined backwards to go"?

Yes

30 to step 5.

30

to step

3.

30

to step 6.

3

sensor is nor- nal.

No

Go to step 2.

Replace G sensor.

Replace G sensor.

Replace G sensor.

ABS-24

ABS (DIAGNOSTICS)

ABS

5

.

6

.

7

.

8

.

9

.

10

.

11 .

12

.

13

.

14

.

1

.

2

.

3

.

4

.

Page

Basic Diagnostic Procedure

........................................................................

2

Check List for Interview

...............................................................................

6

General Description .................................................................................... 9

Electrical Components Location

................................................................

12

Control Module I/O Signal

.........................................................................

14

Subaru Select Monitor

...............................................................................

18

Read Diagnostic Trouble Code (DTC)

......................................................

20

Inspection Mode

........................................................................................

21

Clear Memory Mode

..................................................................................

22

ABS Warning Light Illumination Pattern

....................................................

23

List of Diagnostics Trouble Code (DTC)

...................................................

24

Diagnostics Chart with Diagnosis Connector

............................................

29

Diagnostics Chart with Subaru Select Monitor

..........................................

96

General Diagnostics Table

......................................................................

183

I

BASIC DIAGNOSTIC PROCEDURE


1.

Basic Diagnostic Procedure

A: PROCEDURE

1.

WITHOUT SUBARU SELECT MONITOR

CAUTION:

Remove foreign matter (dust, water, etc.) from the ABSCM&H/U connector during removal and installation.

NOTE:

To check harness for broken wires or short circuits, shake it while holding it or the connector.

When the ABS warning light illuminates, read and record the diagnostic trouble code (DTC) indicated by

ABS warning light.

I

!

Step

CHECK PRE-INSPECTION.

1)Ask the customer when and how the trouble occurred using interview checklist. <Ref. to

ABS-6, Check List for Interview.>

2)Before performing diagnosis, inspect the unit which might influence the ABS problem. <Ref. to ABS-9, INSPECTION, General Descrip- tion.>

Check

Is unit that might influence the

ABS problem normal?

CHECK INDICATION OF DIAGNOSTIC

TROUBLE CODE (DTC).

Calling up diagnostic trouble code (DTC).

<Ref. to ABS-20, Read Diagnostic Trouble

Code (DTC).>

Is the diagnostic trouble code

Yes

Go to step

2.

Go to step

3.

No

Repair or replace each unit.

I

Inspect using diag nostic chart for

ABS warning light failure.cRef. to

ABS-29, Diagnos- tics Chart with

Diagnosis Con- nector.>

NOTE:

Call up diagnostic trouble code (DTC] again after inspect. ing ABS warnins light. <Ref. to ABS.

20, Read Diagnos tic Trouble Code

(DTC).>

Go to step

5.

I

CHECK DIAGNOSTIC TROUBLE CODE

(DTC).

Is only the start code issued? Go to step

4.

NOTE:

Record all diagnostic trouble codes (DTC).

PERFORM THE GENERAL DIAGNOSTICS.

1 )Inspect using “General Diagnostics Table”.

<Ref. to ABS-I 83, General Diagnostics Table.>

Is only the start code issued? IComplete the diagnosis.

2)Perform the clear memory mode. <Ref. to

ABS-22, WITHOUT SUBARU SELECT MONI-

TOR, OPERATION, Clear Memory Mode.>

3)Perform the inspection mode. <Ref. to ABS-

21, Inspection Mode.>

Calling up the diagnostic trouble code (DTC).


Code (DTC).>

Go to step 5.

ABS-2

)


Step

PERFORM

THE DIAGNOSIS.

1)lnspect using “Diagnostics Chart with Diag- nostic Connectof.<Ref. to ABS-29, Diagnos- tics Chart with Diagnosis Connector.>

NOTE:

For diagnostic trouble code (DTC) list, refer tc

“List of Diagnostics Trouble Code (DTC)”.<Ref. to ABS-24, WITHOUT SUBARU SELECT

MONITOR, LIST, List of Diagnostics Trouble

Code (DTC).>

2)Repair the trouble cause.


ABS-22, WITHOUT SUBARU SELECT MONI-

TOR, OPERATION, Clear Memory Mode.>



5)Calling up the diagnostic trouble code (DTC).


Code (DTC).>

Check

Is only the start code issued?

Yes

2omplete the iiagnosis.

ABS (DIAGNOSTICS)

No

Inspect using

“Diagnostics Chart with Diagnostic

Connectof. <Ref. to ABS-29, Diag- nostics Chart with

Diagnosis Con- nector.>

I

I

ABS-3


ABS

(DIAGNOSTICS)

2. WITH SUBARU

SELECT

MONITOR

CAUTION:

Remove foreign matter (dust, water, etc.) from the ABSCM&H/U connector during removal and installation.

NOTE:

To check harness for broken wires or short circuits, shake it while holding it or the connector.

Check the list for interview. <Ref. to ABS-26, WITH SUBARU SELECT MONITOR, LIST, List of Diagnos- tics Trouble Code (DTC).>

Step

Check

CHECK PRE-INSPECTION.

1)Ask the customer when and how the trouble occurred using interview checklist. <Ref. to

ABS-6, Check List for Interview.>

2)Before performing diagnosis, inspect the unit which might influence the ABS problem. <Ref. to ABS-9, INSPECTION, General Descrip- tion.>

Is unit that might influence the

ABS problem normal?

CHECK INDICATION OF TROUBLE CODE

DISPLAY.


2)Connect the SUBARU SELECT MONITOR to data link connector.

3)Turn the ignition switch to ON and SUBARU

SELECT MONITOR to ON.

Is the corresponding trouble encoding?

NOTE:

If the communication function of the selec monitor cannot be executed normally, check the communication circuit. <Ref. to ABS-96

COMMUNICATION FOR INITIALIZING IM.

POSSIBLE, Diagnostics Chart with Subaru Se, lect Monitor.>

4)Read the diagnostic trouble code (DTC).

<Ref. to ABS-1 9, READ CURRENT DATA,

OPERATION, Subaru Select Monitor.>

5)Record all diagnostic trouble codes (DTC) and frame data.

PERFORM THE GENERAL DIAGNOSTICS.

1)lnspect using “General Diagnostics Table”.

I S

no diagnostic trouble code

:DTC) designated and ABS

<Ref. to ABS-1 83, General Diagnostics Table.> Narning light goes out after


ABS-19, CLEAR MEMORY MODE, OPERA-

:urning on?

TION, Subaru Select Monitor.>



4)Calling up the diagnostic trouble code (DTC).

<Ref. to ABS-I 8, READ DIAGNOSTIC TROU-

BLE CODE (DTC), OPERATION, Subaru

Select Monitor.>

Yes

;o to step 2.

30

to step

3.

2omplete the liagnosis.

No

lepair or replace

!ach unit.

;o to step 4.

;o to step 4.

ABS-4

I


Step

PERFORM THE DIAGNOSIS.

Check

Is no diagnostic trouble code

1)lnspect using “Diagnostics Chart with Sub- (DTC) designated and does aru Select Monitor”.<Ref. to ABS-96, Diagnos- ABS warning light go out after tics Chart with Subaru Select Monitor.> turning on?

NOTE:

Yes

Complete the diagnosis.


No

Inspect using

“Diagnostics Chart with Subaru Select

Monitor”. <Ref. to

ABS-96, Diagnos- tics Chart with

Subaru Select

Monitor.>

1

ABS-5

CHECK LIST FOR INTERVIEW


2. Check List for Interview

A:

CHECK

Check the following items about the vehicle's state.

1.

STATE

OF

ABS WARNING LIGHT

ABS warning light comes on.

Ignition key position

Timing

0

Always

CI

Sometimes

U Only once

CI

Does not come on

When / how long does it come on?:

CI

LOCK

CI

ACC

CI

ON

(before starting engine)

CI

START

CI

On after starting (Engine is running)

0 On after starting (Engine is stop)

CI

Immediately after ignition is

ON.

Q

Immediately after ignition starts.

CI

When advancing

0

While traveling at a constant speed

Q

When decelerating

Q

When turning to left

Steering time :

Steering angle :

1

Steering time : km/h

I km/h to

MPHto km/h to

MPHto

Parts name :

Operating condition : km/b

MPF

MPF

km/b

MPF sec deg sec

ABS-6



2. SYMPTOMS

4BS operating condition c1

Operates only when abruptly applying brakes.

*How to steD on brake pedal a) Operating time :

What kind of noise?

Vehicle speed : t

D Knock

D

Gong gong

D Bong

D

Buzz

D Gong gong buzz

D

Others :

Behavior of vehicle

D Stick

D

Press down once with a clunk c1 Press and released

D

Others :

a)

Directional stability cannot be obtained or steering arm refuses to work when applying brakes :

D Yes/ D No

When

:

I

D Vehicle turns to right km/h

MPH sec

When :

What :

What :

Where

What kind

: f) Occurrence of abnormal noise : P Yes /

D

No

Where

What kind :

a)

Occurrence of other Dhenomena : D Yes / D

No

What kind :

D Vehicle turns to right c1

Vehicle turns to left

CI

Spins

D

Others :

0

Braking distance is long

D Brakes lock or drag

D Pedal stroke is long c1 Pedal sticks

D

Others : c1 Fails to accelerate

D Engine stalls

D Others :

ABS-7



3. CONDITIONS UNDER WHICH TROUBLE OCCURS

:nvironment a) Weather

3

Fine

Ll Cloudy

CI

Rainy

U

Snowy

U

Various/Others : b) Ambient temperature c) Road

2ondition d) Road surface a) Brakes b) Accelerator c) Vehicle speed d) Tire inflation pressure e) Degree of wear

F u r b a n area

0

Suburbs

U

Highway

U

General road

U

Ascending slope

U

Descending slope

U

Paved road

U

Gravel road

U

Muddy road

U

Sandy place

U

Others :

U

Dry

CI

Wet

U

New-fallen snow

U

Compressed snow

U

Frozen slope

U

Others :

Deceleration :

U

Continuous /

U

Intermittent

Acceleration :

D Continuous / U Intermittent km/h

I

U

Advancing

U

Accelerating

U

Reducing speed

CI

Low speed

CI

Turning

U

Others :

Front RH tire :

Front LH tire :

Rear RH tire :

Rear LH tire :

Front RH tire

Front LH tire :

Rear RH tire :

Rear LH tire : f) Genuine parts are used. : 0 Yes /

U

No g) Chain is passed around tires. :

U

/

U

No h) T tire is used. :

U

Yes / Q No i) Condition of suspension alignment :

j)

Loading state : k) Repair parts are used. :

U

/

Q

No

What :

I)

Others :

OF ("C)

g

9

MPH kPa kPa kPa kPa

ABS-8

3.


A: CAUTION


1. SUPPLEMENTAL RESTRAINT SYSTEM

“AIR BAG”

The airbag system wiring harness is routed near the ABS sensor, ABS control module and hydraulic control unit.

CAUTION:

All Airbag system wiring harness and connectors are colored yellow. Do not use electrical test equipment on these circuit.

Be careful not to damage the Airbag system wiring harness when servicing the ABS sensor,

ABS control module and hydraulic control unit.


B: INSPECTION

Before performing diagnostics, check the following items which might affect ABS problems:

1. BATTERY

Measure the battery voltage and specific gravity of electrolyte.

Standard voltage: 12 V, or more

Specific gravity: Above 1.260

2.

BRAKE FLUID

1) Check the brake fluid level.

2) Check for brake fluid leakage.

3. HYDRAULIC UNIT

Check the hydraulic unit.

With brake tester <Ref. to ABS-9, CHECKING

THE HYDRAULIC UNIT ABS OPERATION WITH

BRAKE TESTER, INSPECTION, ABS Control

Module and Hydraulic Control Unit (ABSCM&H/

U).>

Without brake tester <Ref. to ABS-8, CHECK-

ING THE HYDRAULIC UNIT ABS OPERATION

BY PRESSURE GAUGE, INSPECTION, ABS

Control Module and Hydraulic Control Unit (AB-

SCM&H/U).>

4. BRAKEDRAG

Check for brake drag.

5.

BRAKE PAD AND

ROTOR

Check the brake pad and rotor.

Front <Ref. to BR-17, INSPECTION, Front

Brake Pad.> and <Ref. to BR-18, INSPECTION,

Front Disc Rotor.>

Rear <Ref. to BR-24, INSPECTION, Rear

Brake Pad.> and <Ref. to BR-26, INSPECTION,

Rear Disc Rotor.> or <Ref. to BR-31, INSPEC-

TION, Rear Drum Brake Shoe.> and <Ref. to BR-

32,

INSPECTION, Rear Drum Brake Drum.>

6. TIRE

Check the tire specifications, tire wear and air pressure. <Ref. to WT-2, SPECIFICATIONS, General

a

ABS

(DIAGNOSTICS)

C: PREPARATION TOOL



ILLUSTRATION

I

TOOL NUMBER

24082AA150

(Newly adopted tool)

DESCRIPTION

CARTRIDGE

REMARKS


B2M3876

22771 AA030 SELECT MONITOR

KIT


1

English: 22771 AA030 (Without printer)

1

1

1

German: 22771 AA070 (Without printer)

French: 22771 AA080 (Without printer)

Spanish: 22771AA090 (Without printer)

B2M3877

2.

GENERAL PURPOSE

TOOLS

I

Circuit tester

Oscilloscope

TOOL NAME

I

REMARKS

1

Used for measuring resistance, voltage and ampere.

I

Used for measuring sensor.

I

ABS-I 0



ABS-I 1

ELECTRICAL COMPONENTS LOCATION


4.

Electrical Components Location

A: LOCATION

(1)

ABS control module and hydraulic

(5)

Data link connector (for Subaru control unit (ABSCM&H/U)

(2) Proportioning valve


(4)

ABS warning light

(8)

ABS sensor select monitor)

(9)

Wheel cylinder

(6) Transmission control module (only (1 0) G sensor

AT vehicle)

(1 1)

Stop light switch

(7) Tone wheel (1 2) Master cylinder

ABS-1 2

ELECTRICAL COMPONENTS LOCATION

ABS IDIAGNOSTICS)

(4

BR0079

\ I

-

I

BR0056

64M1226B

REAR

( 7 )

ABS-I 3

CONTROL MODULE I/O SIGNAL


5. Control Module

I/O

Signal

A: ELECTRICAL SPECIFICATION

ABS control module and hydraulic control unit connector

I

Connector switch

B4M1220A

NOTE:

The terminal numbers in the ABS control module and hydraulic control unit connector are as shown in the figure.

When the connector is removed from the ABSCM&H/U, the connector switch closes the circuit between terminal No. 22 and No. 23. The ABS warning light illuminates.

ABS-1 4

Contents

ABS sensor*2

Front left wheel

Front right wheel

(Wheel speed sensor) Rear left wheel

I

Rear rightwheel

Valve relay power supply

Motor relay power supply

G sensor*2 power supply ground output

Stop light switch*l

ABS warning light*2

AT ABS signal*2

(AT model only)

ABS operation signal monitor*2

Select monitor*2

Data is received.

Data is sent.

ABS diagnosis connec- Terminal No.

3

tor*2 Terminal No.

6

Power supply*l

Grounding line

Grounding line


ABS

(DIAGNOSTICS)

Terminal

No.

(+)-(-)

9-1 0

11-12

7-8

14-1 5

24-23

25-23

30-28

28

6-28

2-23

22-23

31-23

3-23

20-23

5-23

29-23

4-23

1-23

23

26

InputlOutput signal

Measured value and measuring conditions

0.12- 1 v

(When it is 20 Hz.)

1 0 - 1 5 V

1 0 - 1 5 V

4.75

-

V

-

2.3f0.2 V when the vehicle is in horizontal position.

Less than 1.5 V when the stop light is OFF and, 10

-

V when the

. *

Less than 1.5 V during 1.5 seconds when ignition switch is ON, and 10

-

Less than 1.5 V when the ABS control still operates and more than 5.5 V when ABS does not operate.

Less than 1.5 V when the ABS control still operates and more than 5.5 V when ABS does not operate.

Less than 1.5 V when no data is received.

4.75

-

V when no data is sent.

10

-

V when the ignition switch is ON.

10

-

10

-

V when the ignition switch is

ON.

-

-

a

ABS-I 5

ABS

(DIAGNOSTICS)

B: SCHEMATIC


ABS control module and hydraulic control unit (ABSCM&H/U)

ABS control module area

Valve relay

Motor relay

Motor

Front left inlet solenoid valve

Front left outlet solenoid valve

Front right inlet solenoid valve

(9)

(11)

(1 3)

(14)

Front right outlet solenoid valve

Rear left inlet solenoid valve

AT model)

(1 5 )

(1

6)

Diagnosis connector

Data link connector

(1

7)

ABS warning light

(1

8)

Stop light switch

(19)

Stop light

Rear left outlet solenoid valve

Rear right inlet solenoid valve (20)

Rear right outlet solenoid valve

(21)

Transmission control module (only (22)

(23)

(24)

G sensor

Front left ABS sensor

Front right ABS sensor

Rear left ABS sensor

Rear right ABS sensor

BR0108

ABS-I 6

CONTROL MODULE

I/O

SIGNAL

C: WAVEFORM

ABS sensor

Terminal NO.

9

-

10

11 - 1 2

7 - 8

14

-

15

[VI

Standard output voltage at 20 Hz:

0.12

-

1 v

B4M2526A


ABS-I 7

SUBARU SELECT MONITOR


6.

Subaru Select Monitor

A: OPERATION

1.

READ DIAGNOSTIC TROUBLE CODE

W C )

1) Prepare the Subaru Select Monitor kit.

5) Turn the ignition switch to ON (engine OFF) and

Subaru Select Monitor switch to ON.

2) Connect the diagnosis cable to Subaru Select

Monitor.

3) Insert the cartridge into Subaru Select Monitor.

<Ref. to ABS-IO, SPECIAL TOOLS, PREPARA-

TION TOOL, General Description.>

4) Connect the Subaru Select Monitor to data link connector.

(1)

Data link connector is located in the lower portion of the instrument panel (on the driver’s side).

I

S2M0286

(1) Power switch

6) On the ((Main Menu)) display screen, select the

{Each System Check} and press the [YES] key.

7) On the ((System Selection Menu)) display screen, select the {Brake Control System} and press the [YES] key.

8) Press the [YES] key after displayed the information of engine type.

9) On the ((ABS Diagnosis)) display screen, select the {Diagnostic Code(s) Display} and press the

[YES] key.

10)

On the ((Diagnostic Code@) Display)) display screen, select the {Current Diagnostic Code(s)} or

{History Diagnostic Code(s)} and press the [YES] key.

NOTE:

For detailed operation procedure, refer to the

SUBARU SELECT MONITOR OPERATION MAN-

UAL.

For detailed concerning diagnostic trouble codes

(DTC), refer to the LIST OF DIAGNOSTICS TROU-

BLE CODE (DTC). <Ref. to ABS-24, List of Diag- nostics Trouble Code (DTC).>

(2)

Connect the diagnosis cable to data link connector.

ABS-1 8

FR Wheel Speed

FL Wheel Speed

RR Wheel Speed

RL Wheel Speed

Stop Light Switch

Stop Light Switch

G sensor output Signal

Wheel speed detected by the Front Right ABS sensor is displayed

Wheel speed detected by the Front Left ABS sensor is displayed

Wheel speed detected by the Rear Right ABS sensor is displayed

Wheel speed detected by the Rear Left ABS sensor is displayed

Stop light switch signal

Stop light switch monitor voltage is displayed.

Refers to vehicle acceleration detecting by the analog G sensor.

It appears

on

the select monitor display in volts. km/h or MPH km/h or MPH km/h or MPH km/h or MPH

ON or OFF

V

V

ON or OFF

Valve Relay Signal

Valve Relay Signal

1

Motor Relay Signal

I

ABS Signal to TCM

1

ABS operation signal from ABS control module to TCM

ABS Warning Lamp

Motor Relay Monitor

ON operation of the ABS warning light is displayed.

Operating condition of the motor relay is displayed.

ON or OFF

I

I

ON or OFF

ON or OFF

ON or OFF

ON or OFF

Valve Relay Monitor Operating condition of the valve relay is displayed.

ABS operation signal from ABS control module to TCM

I

ON or OFF

I

CCM Signal

I

NOTE:

For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.

1

3.

CLEAR MEMORY MODE

1)

On the ((Main Menu. display screen, select the {2. Each System Check} and press the ((YES)) key.

2 )

On the ((System Select Menu)) display screen, select {Brake System} and press the ((YES)) key.

3) Press the ((YES)) key after displayed the information of engine type.

4) On the (<Brake

5 )

When the “Done” and “turn ignition switch O F F are shown on the display screen, turn the Subaru Select

Monitor and ignition switch to OFF.

NOTE:

For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.

I

ABS-1 9

READ DIAGNOSTIC TROUBLE CODE (DTC)

ABS

(DIAGNOSTICS)

7. Read Diagnostic Trouble

Code (DTC)

A: OPERATION

1.


1) Take out the diagnosis connector from side of driver's seat heater unit.

BRO110

2) Turn the ignition switch OFF.

3) Connect the diagnosis connector terminal 6 to diagnosis terminal.

4) Turn the ignition switch ON.

5) ABS warning light is set in the diagnostic mode and blinks to identify diagnostic trouble code

(DTC).

6)

After the start code (1 1) is shown, the diagnostic trouble code (DTC) will be shown in order of the last information first.

These repeat for a maximum of 3 minutes.

NOTE:

When there are no diagnostic trouble code

(DTC) in memory, only the start code (1 1) is shown.

When on-board diagnosis of the ABS control module detects a problem, the information (up to a maximum of three) will be stored in the EEP ROM as a diagnostic trouble code (DTC). When there are more than three, the most recent three will be stored. (Stored codes will stay in memory until they are cleared.)

(1)

Diagnosis connector


(3) 3 terminal

(4)

6 terminal

Example of DTC indication

DTC: 21

^..

1 1 2 1

I

DTC: 22,31

1 1 k!-

0.3 sec 0.3 sec

DTC: 21

2

\L 0.3 sec

2

1 1

Start code

3

2 1

DTC: 21

1 1

1

Start code DTC: 22 DTC: 31 Start code

BR0081

2. WITH SUBARU SELECT MONITOR

Refer to SUBARU SELECT MONITOR for information about how to obtain and understand the diagnostic trouble code (DTC). <Ref. to ABS-18, Subaru Select Monitor.>

ABS-20

INSPECTION MODE

8.

Inspection Mode

A: OPERATION

Reproduce the condition under which the problem has occurred as much as possible.

Drive the vehicle at a speed more than 40 km/h (25

MPH) for at least one minute.


I

ABS-21

CLEAR MEMORY MODE


9. Clear Memory Mode

A: OPERATION

1.


1)

After calling up a diagnostic trouble code (DTC), disconnect the diagnosis connector terminal 6 from diagnosis terminal.



(3) 3 terminal

(4) 6 terminal

2) Repeat 3 times within approx. 12 seconds; connecting and disconnecting terminal 6 and diagnosis terminal for at least 0.2 seconds each time.

a

Memory erase mode

GND(Low level)

GND open (High level)

Terminal 8

0.2 sec or more

0.2 sec or more

12 sec or less

BR0082

NOTE:

After diagnostics is completed, make sure to clear memory. Make sure only start code (1 1) is shown after memory is cleared.

2.

WITH SUBARU SELECT MONITOR

Refer to SUBARU SELECT MONITOR for information about how to clear the diagnostic trouble code (DTC).

<Ref. to ABS-18, Subaru Select Monitor.>

ABS-22

ABS WARNING LIGHT ILLUMINATION PATTERN


1 O.ABS Warning Light Illumination Pattern

A: INSPECTION

START

Ignition

key switch

OFF

' I-

ABS warning light

Goes out.

1.5 s

Goes out.

1) When the ABS warning light does not illuminate in accordance with this illumination pattern, there must be an electrical malfunction.

2) When the ABS warning light remains constantly OFF, repair the ABS warning light circuit or diagnosis circuit. <Ref. to ABS-29, Diagnostics Chart with Diagnosis Connector.>

NOTE:

Even though the ABS warning light does not go out 1.5 seconds after it illuminates, the ABS system operates normally when the warning light goes out while driving at approximately 12 km/h (7 MPH). However, the Anti- lock brakes do not work while the ABS warning light is illuminated.

ABS-23


LIST OF DIAGNOSTICS TROUBLE CODE (DTC)

11

.List of Diagnostics Trouble Code (DTC)

A:

LIST

1.


~

3TC No

11

Contents of diagnosis

Start code

DTC is shown after start code.

Only start code is shown in normal condition.

21

23

25

27

22

24

26

Abnormal ABS sensor

(Open circuit or input voltage too high)

Abnormal ABS sensor

(Abnormal ABS sensor signal)

Index No.

-



Rear right ABS sensor


<Ref. to ABS-40, DTC 21 ABNORMAL ABS SENSOR (OPEN CIR-

CUIT OR INPUT VOLTAGE TOO HIGH) (FRONT RH), Diagnostics

Chart with Diagnosis Connector.>


CUIT OR INPUT VOLTAGE TOO HIGH) (FRONT LH), Diagnostics



CUIT OR INPUT VOLTAGE TOO HIGH) (REAR RH), Diagnostics



CUIT OR INPUT VOLTAGE TOO HIGH) (REAR LH), Diagnostics

Chart with Diaanosis Connector.>

s



Rear r'ght ABS

<Ref. to ABS-46, DTC 22 ABNORMAL ABS SENSOR (FRONT RH),

Diagnostics Chart with Diagnosis Connector.>

I

<Ref. to ABS-46, DTC 24 ABNORMAL ABS SENSOR (FRONT LH),

Diaanostics Chart with Diaanosis Connector.>

u

I

<Ref to ABS-46, DTC 26 ABNORMAL ABS SENSOR (REAR RH),

Diaanostics Chart with Diaanosis Connector.>

28

29

31

32

33

34

35

36

37

38

Abnormal solenoid valve circuit(s) in ABS control module and hydraulic unit


Any one of four

Front right inlet valve

Front right outlet valve

Front left inlet valve

Front left outlet valve

Rear right inlet valve

Rear right outlet valve

Rear left inlet valve

Rear left outlet valve

<Ref. to ABS-47, DTC 28 ABNORMAL ABS SENSOR (REAR LH),


<Ref. to ABS-53, DTC 29 ABNORMAL ABS SENSOR SIGNAL

(ANY ONE OF FOUR), Diagnostics Chart with Diagnosis Connec- tor.>

<Ref. to ABS-57, DTC 31 ABNORMAL INLET SOLENOID VALVE

ClRCUIT(S) IN ABSCM&H/U (FRONT RH), Diagnostics Chart with

Diagnosis Connector.>

<Ref. to ABS-61, DTC 32 ABNORMAL OUTLET SOLENOID VALVE

CIRCUIT(S) IN ABSCM&H/U (FRONT RH), Diagnostics Chart with



CIRCUIT(S) IN ABSCM&H/U (FRONT LH), Diagnostics Chart with


1


CIRCUIT(S) IN ABSCM&H/U (FRONT LH), Diagnostics Chart with



CIRCUIT(S) IN ABSCM&H/U (REAR RH), Diagnostics Chart with



CIRCUIT(S) IN ABSCM&H/U (REAR RH), Diagnostics Chart with



CIRCUIT(S) IN ABSCM&H/U (REAR LH), Diagnostics Chart with



ClRCUIT(S) IN ABSCM&H/U (REAR LH), Diagnostics Chart with


ABS-24


ABS

(DIAGNOSTICS)

DTC No.

41

Contents of diagnosis

Abnormal ABS control module

42 Source voltage is abnormal.

44 A combination of AT control abnormal

51 Abnormal valve relay

52 Abnormal motor and/or motor relay

54 Abnormal stop light switch

56

Abnormal G sensor output voltage

Index No.

<Ref. to ABS-66, DTC 41 ABNORMAL ABS CONTROL MODULE,


<Ref. to ABS-69, DTC 42 SOURCE VOLTAGE IS ABNORMAL.,


<Ref. to ABS-74, DTC 44 A COMBINATION

OF

AT CONTROL

ABNORMAL, Diagnostics Chart with Diagnosis Connector.>

<Ref. to ABS-77, DTC 51 ABNORMAL VALVE RELAY, Diagnostics


<Ref. to ABS-81, DTC 52 ABNORMAL MOTOR AND/OR MOTOR

RELAY, Diagnostics Chart with Diagnosis Connector.>

<Ref. to ABS-86, DTC 54 ABNORMAL STOP LIGHT SWITCH,


<Ref. to ABS-89, DTC 56 ABNORMAL G SENSOR OUTPUT VOLT-

AGE. Diaanostics Chart with Diaanosis Connector.>

ABS-25



2. WITH SUBARU SELECT MONITOR

21

22

23

24

25

26

27

28

29

31

32

33

34

35

36

37

38

1

i1

42

42

Display screen Contents of diagnosis Index No.

DTC

No.

-

-

Communication for ini- Select monitor commu- <Ref. to ABS-96, COMMUNICATION FOR INITIALIZING IMPOSSI- tializing impossible nication failure

Although no trouble

I

No trouble code code appears on the select monitor display, the ABS warning light

BLE, Diagnostics Chart with Subaru Select Monitor.>

<Ref. to ABS-101, NO TROUBLE CODE, Diagnostics Chart with

Subaru Select Monitor.> remains on.

Open or short circuit in Open or short circuit in <Ref. to ABS-104, DTC 21 OPEN OR SHORT CIRCUIT IN FRONT front right ABS sensor front right ABS sensor RIGHT ABS SENSOR CIRCUIT, Diagnostics Chart with Subaru circuit circuit Select Monitor.>

Front right ABS sensor Front right ABS sensor <Ref. to ABS-1 10, DTC 22 FRONT RIGHT ABNORMAL ABS SEN- abnormal signal abnormal signal SOR SIGNAL, Diagnostics Chart with Subaru Select Monitor.>

Open or short circuit in Open or short circuit in <Ref. to ABS-104, DTC 23 OPEN OR SHORT CIRCUIT IN FRONT front left ABS sensor front left ABS sensor LEFT ABS SENSOR CIRCUIT, Diagnostics Chart with Subaru Select circuit circuit Monitor.>

Front left ABS sensor Front left ABS sensor

<Ref. to ABS-1 10, DTC 24 FRONT LEFT ABNORMAL ABS SEN- abnormal signal abnormal signal SOR SIGNAL, Diagnostics Chart with Subaru Select Monitor.>

Open or short circuit in Open or short circuit in <Ref. to ABS-104, DTC 25 OPEN OR SHORT CIRCUIT IN REAR rear right ABS sensor rear right ABS sensor

RIGHT ABS SENSOR CIRCUIT, Diagnostics Chart with Subaru circuit circuit Select Monitor.>

Rear right ABS sensor Rear right ABS sensor <Ref. to ABS-1 10, DTC 26 REAR RIGHT ABNORMAL ABS SEN- abnormal signal abnormal signal SOR SIGNAL, Diagnostics Chart with Subaru Select Monitor.>

Open or short circuit in Open or short circuit in <Ref. to ABS-1 05, DTC 27 OPEN OR SHORT CIRCUIT IN REAR rear left ABS sensor rear left ABS sensor LEFT ABS SENSOR CIRCUIT, Diagnostics Chart with Subaru Select circuit circuit Monitor.>

Rear left ABS sensor Rear left ABS sensor <Ref. to ABS-1 11, DTC 28 REAR LEFT ABNORMAL ABS SENSOR abnormal signal abnormal signal SIGNAL, Diagnostics Chart with Subaru Select Monitor.>

Abnormal ABS sensor Abnormal ABS sensor <Ref. to ABS-1 17, DTC 29 ABNORMAL ABS SENSOR SIGNAL ON signal on any one of signal on any one of ANY ONE OF FOUR SENSOR, Diagnostics Chart with Subaru four sensor four Select Monitor.>

Front right inlet valve Front right inlet valve malfunction malfunction

<Ref. to ABS-121, DTC 31 FRONT RIGHT INLET VALVE MAL-

FUNCTION, Diagnostics Chart with Subaru Select Monitor.>

Front right outlet valve Front right outlet valve <Ref. to ABS-125, DTC 32 FRONT RIGHT OUTLET VALVE MAL- malfunction malfunction FUNCTION, Diagnostics Chart with Subaru Select Monitor.>

'

Front left inlet valve malfunction

Front left inlet valve malfunction

Front left outlet valve Front left outlet valve malfunction malfunction

<Ref. to ABS-121, DTC 33 FRONT LEFT INLET VALVE MALFUNC-

TION, Diagnostics Chart with Subaru Select Monitor.>

<Ref. to ABS-1 25, DTC 34 FRONT LEFT OUTLET VALVE MAL-


Rear right inlet valve malfunction

Rear right inlet valve malfunction

<Ref. to ABS-121, DTC 35 REAR RIGHT INLET VALVE MALFUNC-


Rear right outlet valve Rear right outlet valve <Ref. to ABS-1 25, DTC 36 REAR RIGHT OUTLET VALVE MAL- malfunction malfunction FUNCTION, Diagnostics Chart with Subaru Select Monitor.>

Rear left inlet valve malfunction

Rear left inlet valve malfunction

<Ref. to ABS-121, DTC 37 REAR LEFT INLET VALVE MALFUNC-


Rear left outlet valve malfunction

Rear left outlet valve malfunction

1

I

A D C

A--4"-l - - A . . l -

MPO l.UIIlIUI IIIUUUIG

I

ABS control and hydraulic control malfunction unit malfunction

Power supply voltage too low

Power supply voltage too high

Power supply voltage too low

Power supply voltage too high

<Ref. to ABS-125, DTC 38 REAR LEFT OUTLET VALVE MALFUNC-


I

I

. n - S

I-

A n m

Cnel.

LO

H D 3 - I d

0, DTC 41 ABS CONTROL MODULE MALFUNC-

TION, Diagnostic Chart with Subaru Select Monitor.>

<Ref. to ABS-1 32, DTC 42 POWER SUPPLY VOLTAGE TOO LOW,

Diagnostics Chart with Subaru Select Monitor.>

<Ref. to ABS-134, DTC 42 POWER SUPPLY VOLTAGE TOO HIGH,

Diagnostics Chart with Subaru Select Monitor.>

ABS-26



'

L'

No.

44

44

51

51

52

52

52

54

56

56

56

56

Display screen Contents of diagnosis Index No.

ABS-AT control (Non ABS-AT control (Non <Ref. to ABS-138, DTC 44 ABS-AT CONTROL (NON CON-

Controlled) Controlled) TROLLED), Diagnostics Chart with Subaru Select Monitor.>

ABS-AT control (Con- ABS-AT control (Con- <Ref. to ABS-I 40, DTC 44 ABS-AT CONTROL (CONTROLLED), trolled) trolled) Diagnostics Chart with Subaru Select Monitor.>

Valve relay malfunction Valve relay malfunction

I

Valve relay ON failure Valve relay ON failure

Open circuit in motor relay circuit

Motor relay ON failure

Motor malfunction

Open circuit in motor relay circuit

Motor relay ON failure

Motor malfunction

<Ref. to ABS-143, DTC 51 VALVE RELAY MALFUNCTION, Diag- nostics Chart with

Subaru Select Monitor,>

<Ref. to ABS-I 47, DTC 51 VALVE RELAY ON FAILURE, Diagnos- tics Chart with Subaru Select Monitor.>

<Ref. to ABS-151, DTC 52 OPEN CIRCUIT IN MOTOR RELAY CIR-

CUIT, Diagnostics Chart with Subaru Select Monitor.>

<Ref. to ABS-I 55, DTC 52 MOTOR RELAY ON FAILURE, Diagnos- tics Chart with

Subaru Select Monitor.r

<Ref. to ABS-159, DTC 52 MOTOR MALFUNCTION, Diagnostics

Chart with Subaru Select Monitor.>

Stop light switch signal Stop light switch signal <Ref. to ABS-162, DTC 54 STOP LIGHT SWITCH SIGNAL CIRCUIT circuit malfunction circuit malfunction MALFUNCTION, Diagnostics Chart with Subaru Select Monitor.>

Open or short circuit in Open or short circuit in

<Ref. to ABS-165, DTC 56 OPEN OR SHORT CIRCUIT IN G SEN-

G sensor circuit G sensor circuit SOR CIRCUIT, Diagnostics Chart with Subaru Select Monitor.>

Battery short in G sen- Battery short in

G sen- <Ref. to ABS-169, DTC 56 BATTERY SHORT IN G SENSOR CIR- sor circuit sor circuit CUIT, Diagnostics Chart with Subaru Select Monitor.>

Abnormal G sensor high output

Abnormal G sensor high

p

output

<Ref. to ABS-175, DTC 56 ABNORMAL G SENSOR HIGH

M

OUT-

PUT, Diagnostics Chart with Subaru Select Monitor.>

Detection of G sensor Detection of G sensor <Ref. to ABS-179, DTC 56 DETECTION OF G SENSOR STICK, stick stick Diagnostics Chart with Subaru Select Monitor.>

a

ABS-27

I



ABS-28

DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR


12.Diagnostics Chart with Diagnosis Connector

A: ABS WARNING LIGHT DOES NOT COME ON.

DIAGNOSIS:

ABS warning light circuit is open or shorted.

TROUBLE SYMPTOM:

When the ignition switch is turned ON (engine OFF), ABS warning light does not come on.

I

ABS-29


ABS

(DIAGNOSTICS)

WIRING DIAGRAM:

SBF-3 SBF-1

BATTERY

3 c

t

m

RELAY HOLDER

1

ABS-30

BROO83

I

2

3

S

5

6

7

8

9



Step

CHECK IF OTHER WARNING LIGHTS TURN

ON.

Turn the ignition switch to ON (engine OFF).

Check

)o

other warning lights turn

In?

Yes

io to step

2.

CHECK ABS WARNING LIGHT BULB.

1)Turn the ignition switch to

OFF.

2)Remove the combination meter.

3)Remove the ABS warning light bulb from combination meter.

CHECK BATTERY SHORT OF ABS WARN-

ING LIGHT HARNESS.

1)Disconnect the connector (B200) from connector (F74).

2)Measure the voltage between connector

(8200) and chassis ground.

Connector & terminal

(6200)

No. 19

(+)

-





(8200) and chassis ground.


(B200) No. 19

(+)

-

CHECK WIRING HARNESS.


2)lnstall the ABS warning light bulb from combination meter.

3)lnstall the combination meter.



(B200) and chassis ground.

Connector

&

terminal

(8200) No. 19

(+)





(F74) and chassis ground.


(F74) No. 19

(+)

-







(F74) No.

19 (+)

-

CHECK GROUND CIRCUIT OF ABSCM&HIU

Measure the resistance between ABSCM&HlU and chassis ground.

Connector

&

terminal

(F49) NO. 23

-


Measure the resistance between connector



(F74) No. 19

(+)

s

the ABS warning light bulb

IK?

s the voltage less than 3

V?

s the voltage less than 3 V? s the voltage between 10 and s the voltage less than 3 V? s the voltage less than 3

V?

s the resistance less than

0.5

2?

;o

to step 9. s the resistance less than

0.5

n?

i o to step

3.

;o

to step

4.

i o to step

5.

;o

to step 6.

;o

to step 7.

;o

to step 8.

20

to step 10.

ABS-31

No

3epair the combi- iation meter. cRef. to IDI-11,

Zombination

Weter Assembly.>

Replace the ABS

Narning light bulb.

<Ref. to IDI-11,

Zombination

Weter Assembly.>

Repair the warning light harness.

Repair the warning light harness.

Repair the wiring harness.



Repair the

ABSCM&HlU ground harness.

Repair the har- nesslconnector.



10

Step Check

CHECK POOR CONTACT IN CONNECTORS.

Is there poor contact in con-

Turn the ignition switch to OFF. nectors between combination meter and ABSCM&H/U?

Yes

Repair the connector.

No

Replace the

ABSCM&H/U.

<Ref. to ABS-7,

ABS Control Mod-

(ABSCM&H/U).>

ABS-32


ABS

(DIAGNOSTICS)

B: ABS WARNING LIGHT DOES NOT GO OFF.

DIAGNOSIS:

ABS

warning light circuit is open or shorted.


When starting the engine and while the

ABS

warning light is kept

ON.

ii

ABS-33



WIRING DIAGRAM:

SBF-3 SBF-1

BATTERY

C

r

I

m

RELAY HOLDER

ABS-34

BR0083

5

6

I

!

3

1

7

8



Step

CHECK INSTALLATION OF ABSCM&H/U

CONNECTOR.

Turn the ignition switch to OFF.

Check

;the ABSCM&H/U connector iserted into ABSCM until the lamp locks onto it?

CHECK DIAGNOSIS TERMINAL.

Measure the resistance between diagnosis terminals (B81) and chassis ground.

Terminals

Diagnosis terminal (A) ground:

Diagnosis terminal (B) ground:

CHECK DIAGNOSIS LINE.


2)Connect the diagnosis terminal (881) to diagnosis connector (B82) No. 6.

3)Disconnect the connector from ABSCM&

H/U.

4)Measure the resistance between

ABSCM&H/U connector and chassis ground.


(F49) No.

-

CHECK GENERATOR.

1)Start the engine.

2)ldle the engine.

3)Measure the voltage between generator and chassis ground.

Terminal

Generator B terminal

(+)

ground (-):

CHECK BAlTERY TERMINAL.


CHECK POWER SUPPLY OF ABSCM.


H/U.

2)Start the engine.

3)ldle the engine.

4)Measure the voltage between ABSCM&H/U connector and chassis ground.


(F49) No.

1

(+)

-


1)Disconnect the connector (F74) from connector (8200).


CHECK PROJECTION AT ABSCM&H/U.


2)Check for broken projection at the

ABSCM&H/U terminal.

;the resistance less than 0.5

I?

s the resistance less than 0.5

2?

s the voltage between 10 and

5

V? s there poor contact at battery erminal? s the voltage between 10 and

I5 V? loes the ABS warning light

,emain off?

9re the projection broken?

Yes io

to step 2. io to step

3.

YO

to step 4.

50

to step 5. i o to step 8. i o to step 9.

No

nsert ABSCM&H/

J connector into

4BSCM&H/U until he clamp locks into it.

3epalr the diagno-

;is terminal har- less. qepair harness

:onnector

Detween

\BSCM&H/U and jiagnosis connector.

Repair the genera tor. <Ref. to SC-

13. Generator.>

3epair the battery erminal.

Go to step 6.

;o to step 7.

Repair the

ABSCM&H/U power supply circuit.

Repair the front wiring harness.

Replace the

ABSCM&H/U.

<Ref. to ABS-7,

ABS Control Mod. ule and Hydraulic

Control Unit

(ABSCM&H/U).>

1

ABS-35



I

0

1

2

Step Check

CHECK ABSCM&H/U.

Measure the resistance between ABSCM&H/U

Is the resistance more than 1

MR? terminals.

Terminal

NO. 22

-

Yes

Go to step 10.

No

Replace the

ABSCM&H/U.

<Ref. to ABS-7,

ABS Control Mod- ule and Hydraulic

Control Unit

(ABSCM&H/U).>

Repair the harness.





(F74) No. 20

-


1)Connect the connector to ABSCM&H/U.

2)Measure the resistance between connector



-

CHECK POOR CONTACT IN ABSCM&H/U

CONNECTOR.

Is the resistance less than 0.5

Q?

Go to step 11.


MR?

Is there poor contact in

ABSCM&H/U connector?

Go to step 12.


I

I


Replace the

ABSCM&H/U.

<Ref. to ABS-7,


Control Unit

(ABSCM&H/U).>

ABS-36



C: DIAGNOSTIC TROUBLE CODE (DTC) DOES NOT APPEAR.

DIAGNOSIS:

Diagnosis circuit is open.


The ABS warning light turns on or off normally but the start code cannot be read out in t h e diagnostic mode.

ABS-37



WIRING DIAGRAM:

BATTERY

DIAGNOSIS

I m

RELAY HOLDER

ABS-38

BR0083

1

2

3



Step

CHECK DIAGNOSIS TERMINAL.


2)Measure the resistance between diagnosis terminals (881) and chassis ground.

Terminals

Diagnosis terminal

(A) ground:

Diagnosis terminal (B)

-

ground:

CHECK DIAGNOSIS LINE.


2)Connect the diagnosis terminal (B81) to diagnosis connector (B82) No. 6.


HIU.



Connector

&i

(F49) No. 4

-


CONNECTOR.

Check

Is the resistance less than 0.5 n?


Q?




Repair the diagnosis terminal harness. connector between

ABSCM&H/U and diagnosis connector.

Replace the

ABSCM&H/U.

<Ref. to ABS-7,


Control Unit

(ABSCM&H/U).>

ABS-39



D: DTC21

ABNORMAL ABS SENSOR (OPEN CIRCUIT OR INPUT VOLTAGE TOO

HIGH) (FRONT RH)

NOTE:

For the diagnostic procedure, refer to DTC 27. <Ref. to ABS-41, DTC 27 ABNORMAL ABS SENSOR (OPEN

CIRCUIT OR INPUT VOLTAGE TOO HIGH) (REAR LH), Diagnostics Chart with Diagnosis Connector.>

E: DTC23


HIGH) (FRONT LH)

NOTE:


CIRCUIT OR INPUT VOLTAGE TOO HIGH) (REAR LH), Diagnostics Chart with Diagnosis Connector.>

F: DTC25


HIGH) (REAR RH)

NOTE:


CIRCUIT

OR

INPUT VOLTAGE TOO HIGH) (REAR LH), Diagnostics Chart with Diagnosis Connector.>

1

ABS-40


ABS

(DIAGNOSTICS)

_ _ _ _ ~

G: DTC27


HIGH) (REAR LH)

DIAGNOSIS:

Faulty ABS sensor (Broken wire, input voltage too high)

Faulty harness connector


ABS does not operate.

fa

ABS41



WIRING DIAGRAM:

@

ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT

I

1.

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

5

I

I

I

I

I

I

I

I

I

I

I

I

I

!

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

@

I li

I

SENSOR LH

@

'i

~

I

FRONT

ABS

SENSOR RH

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

1.

I

I

I

I

5

1

I

I

I

I

I r

I

I

€

1.

I

I

I

I

5

I

REAR

ABS

SENSOR LH

REAR

ABS

SENSOR RH

I

I

I

SHIELD JOINT

CONNECTOR

BR0084

ABS-42

I

b

I



Step

Check

CHECK ABS SENSOR.


2)Disconnect the connector from ABS sensor.

3)Measure the resistance of ABS sensor connector terminals.

Terminal

Front RH

No.

1

-

2:

Front LH No. 1

-

2:

Rear RH

No.

1

-No.

2:

Rear LH No.

1

-

2:

s the resistance between 1 ind 1.5

kR?

CHECK BATTERY SHORT OF ABS SEN-

SOR.


H/U.

2)Measure the voltage between ABS sensor and chassis ground.

Terminal

Front RH No.

1

(+)


(+)

Rear RH No.

2 (+)

Rear LH

No. 2 (+)

-

-

-

-


s the voltage less than 1 V? s the voltage less than 1 V?

SOR.



Terminal

Front RH No. 1

(+)

Front LH No.

1

(+)

Rear RH No. 2

(+)

Rear LH No, 2 (+)

-

-

-

-

CHECK HARNESS/CONNECTOR BETWEEN

Is the resistance between 1

ABSCM&H/U AND ABS SENSOR.

1)Turn the ignition switch to OFF. and 1.5

kR?

2)Connect the connector to ABS sensor.


ABSCM&H/U connector terminals.

Connector

&

terminal

DTC 21

/

(F49) NO. 11

-

12:

DTC 23

/

(F49) NO. 9

-

10:

DTC 25

/

(F49) NO. 14

-

15:

DTC 27

/

NO. 7

-

8:

CHECK BAlTERY SHORT

OF

HARNESS.

Measure the voltage between ABSCM&H/U connector and chassis ground.

Connector i? terminal

DTC 21 / (F49)

No.

11

(+)

ground (-):

DTC 23 / (F49)

No.

ground (-):

DTC 25 / (F49)

No. 14

(+)

ground (-):

DTC 2 7 / (F49)

No.

7 (+)

ground

6):

Is the voltage less than 1 V?

Yes

20

to step 2.

20

to step

3.

30

to step 4.

20

to step

5.

No

3eplace the ABS sensor. Front:

:Ref. to ABS-I 4,

7ont ABS Sen-

;or.> Rear: <Ref.

:o

ABS-1 8, Rear

4BS Sensor.>

3eplace the ABS sensor. Front:

:Ref. to ABS-14,

3ont ABS Sen-

:or.> Rear: <Ref.

:o ABS-1 8, Rear

4BS Sensor.>

Replace the ABS sensor. Front:

<Ref. to ABS-14,

Front ABS Sen-

:or.> Rear: <Ref. to ABS-I 8, Rear

ABS Sensor.>

Repair harness/ connector between

ABSCM&H/U and

ABS sensor.

Repair harness between

ABSCM&H/U and

ABS sensor.

Is

ABS-43


ABS (DIAGNOSTICS) i r

$

Step

CHECK BAlTERY SHORT OF HARNESS.




DTC 21 /(F49) No. 11 (+)

ground (-):

DTC 23 / (F49) No. 9 (+)

ground (-):

DTC 25

/ (+)

ground (-):

DTC 2 7 / (F49) No. 7 (+)

ground (-):

CHECK INSTALLATION OF ABS SENSOR.



32

N.m (3.3 kgf-m, 24 ft-lb)

CHECK ABS SENSOR GAP.

Measure the tone wheel to ABS sensor piece gap over entire perimeter of the wheel.

Front wheel

0.3

-

mm (0.012

-

in)

Rear wheel

0.7

- -

in)

Check

s the voltage less than 1 V?

Yes

;o to step 7.

Are the ABS sensor installation

Iolts tightened securely?

20

to step 8. s the gap within the specifica- ions?

20

to step 9.

b

CHECK TONE WHEEL RUNOUT.

Measure the tone wheel runout.

0

CHECK GROUND SHORT OF ABS SENSOR.


2)Measure the resistance between ABS sensor and chassis ground.

Terminal


-

Front LH No.

1

-

Rear RH No. 1

-

Rear LH No. 1

- s the runout less than 0.05 nm (0.0020 in)? s the resistance more than 1

dR?

20

to step 10.

20

to step

11.

No


ABSCM&H/U and

ABS sensor.

Tighten the ABS sensor installation bolts securely.

Adjust the gap.

NOTE:

Adjust the gap u s ing spacers (Par

No. 26755AA000)

If spacers canno correct the gap, re. place worn sensoi or worn tone wheel.

Replace the tone wheel. Front:

<Ref. to ABS-21,

Front Tone

Wheel.> Rear:

<Ref. to ABS-22,

Rear Tone

Wheel.>

Replace the ABS sensor and

ABSCM&H/U.

Front: <Ref. to

ABS-1 4, Front

ABS Sensor.>

Rear: <Ref. to

ABS-18, Rear

ABS Sensor.> and <Ref. to

ABS-7, ABS Con- trol Module and

Hydraulic Control

Unit (ABSCM&H/

U).>

ABS-44

12

13

11

14



Step

CHECK GROUND SHORT OF HARNESS.

1)Turn the ignition switch to OFF:



ABSCM&H/U connector terminal and chassis ground.


DTC 21 / (F49) No. 11

-

DTC

23 / (F49) No. 9

DTC 25 / (F49) No. 14

-

-

DTC 27/(F49) No. 7

-


Is there poor contact in connectors between ABSCM&H/U and ABS sensor?


Is

the same diagnostic trouble

:ode as in the current diagnosis still being output?

2)Erase the memory.

3)Perform the inspection mode.

4)Read out the diagnostic trouble code.


Replace the

ABSCM&H/U.

<Ref. to ABS-7,


Control Unit

(ABSCM&H/U).>

CHECK ANY OTHER DIAGNOSTIC TROU-

BLE CODES APPEARANCE.

Check

Are other diagnostic trouble codes being output?

Proceed with the diagnosis corresponding to the diagnostic trouble code.

No


ABSCM&H/U and

ABS sensor.

Replace

ABSCM&H/U.

<Ref.

to

ABS-7,


Control Unit

(ABSCM&H/U).>

Go to step 13.

Go to step 14.

A temporary poor

NOTE:

Check harnes: and connector: between AB,

SCM&H/U anc

ABS sensor.

m

ABS-45

I



H: DTC22

ABNORMAL ABS SENSOR (FRONT RH)

NOTE:

For the diagnostic procedure, refer to DTC 28. <Ref. to ABS-47, DTC 28 ABNORMAL ABS SENSOR (REAR

LH), Diagnostics Chart with Diagnosis Connector.>

I: DTC24

ABNORMAL ABS SENSOR (FRONT LH)

NOTE:


LH), Diagnostics Chart with Diagnosis Connector.>

J: DTC26

ABNORMAL ABS SENSOR (REAR RH)

NOTE:


LH), Diagnostics Chart with Diagnosis Connector.> la

ABS-46



K: DTC28

ABNORMAL ABS SENSOR (REAR LH)

DIAGNOSIS:

Faulty

ABS

sensor signal (noise, irregular signal, etc.)

Faulty harnesskonnector


ABS

does not operate.

ia

ABS-47



WIRING DIAGRAM:


I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

5

I

FRONT

ABS

SENSOR LH

I

1,

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

1.

I

I

I

I

I

I

I

1.

I

I

I

I

5

e

I

I

I

1.

I

I

I

I I

I

I I

I

I I

I

I

I I

I

SHIELD JOINT

I

CONNECTOR

1

I

F

I

I

I

I

I I

I

I

I

@ i

I

FRONT

ABS

SENSOR RH

1.

I

I

I

I

5

I

I

I

I

I

I

I

I

I

I

I .

I

I

I

I

I

.

1

1

1 €

REAR

ABS

SENSOR LH

I

REAR

ABS

SENSOR RH

BR0084

ABS-48

I

I

I

i


ABS

(DIAGNOSTICS)

Step




32 N.m (3.3 kgf-m, 24 ft-lb)



Front wheel

0.3

-

mm (0.012

-

Check

Yes

Are the ABS sensor installation bolts tightened securely?

30

to step 2.

Is the gap within the specifications?

30 to step

3.

No

7ghten the ABS iensor installation lolts securely. idjust the gap.

JOTE: idjust the gap us

'lg spacer (Par do. 26755AA000) f spacers canno

:orrect the gap, re

)lace worn senso

)r worn tonc vheel.

io

to step 5.

20

to step 7.

PREPARE OSCILLOSCOPE.

Is an oscilloscope available?

CHECK ABS SENSOR SIGNAL.

1)Raise all four wheels off ground.

2)Turn the ignition switch OFF.

3)Connect the oscilloscope to the connector.

4)Turn the ignition switch

ON.

5)Rotate the wheels and measure voltage at specified frequency. <Ref. to ABS-1 7, WAVE-

FORM, Control Module I/O Signal.>

Is the oscilloscope pattern smooth, as shown in the figure?

30

to step 4.

30

to step 8.

NOTE:

When this inspection is completed, the ABS control module sometimes stores the DTC 29.


DTC 22 /

(F95) NO. 1

(+)

DTC 24

/

(F94) NO. 1

(+)

-

2

(-):

DTC26/

(699) NO. 9 (+)

-

10

(-):

DTC28/

(699) NO. 4 (+)

CHECK CONTAMINATION OF ABS SENSOR

OR TONE WHEEL.

Remove the disc rotor or drum from hub in accordance with diagnostic trouble code.

Is the ABS sensor piece or the tone wheel contaminated by dirt or other foreign matter?

CHECK DAMAGE OF ABS SENSOR OR

TONE WHEEL.

Are there broken or damaged in the ABS sensor piece or the tone wheel? rhoroughly

'emove dirt or ither foreign mat- e r.

3eplace the ABS sensor or tone

Nheel. Front: <Ref.

:o ABS-14, Front

4BS Sensor.>

3ear: <Ref. to

46s-18, Rear

4BS Sensor.> and

Front: <Ref. to

46s-21, Front

Tone Wheel.>

?ear: <Ref. to

465-22, Rear

Tone Wheel.>

io

to step 6.

30 to step

7. m

ABS-49



I

Step



Check

s the runout less than 0.05 nm (0.0020 in)?

~

~ _ _ _

~

Yes

So to step 8.

1

IO

I1

12

13

14

CHECK RESISTANCE OF ABS SENSOR.



3)Measure the resistance between ABS sensor connector terminals.

Terminal

Front

RH

No. 1

-

Front LH No. 1 -No.

2:

Rear RH No. 1

Rear LH No.

1

-

-

CHECK GROUND SHORT OF ABS SENSOR.

Measure the resistance between ABS sensor and chassis ground.

Terminal

Front RH No. 1

Front LH No. 1

Rear RH No. 1

-

-

-

Rear LH No. 1

-

CHECK HARNESWCONNECTOR BETWEEN

ABSCM&HIU AND ABS SENSOR.



H/U.

3)Measure the resistance at ABSCM&HIU connector terminals.

Connector

&

terminal

DTC 22

/ (F49) NO. 11

DTC 24

/ (F49) NO. 9

-

-

NO. 12:

NO. 10:

DTC 26 /(F49) NO. 14

-

DTC 28

/ (F49) NO.

7

-

NO. 15:

NO.

8:


Measure the resistance between ABSCM&H/U connector and chassis ground.

Connector

& terminal

DTC 22

/ (F49) No. 11

DTC 24

/ (F49) No. 9

-

-

Chassis ground:

Chassis ground:

DTC 26

/ (F49) No. 14

-

DTC

28

/ (F49) No.

7

-

Chassis ground:

Chassis ground:

CHECK GROUND CIRCUIT OF ABSCM&H/U.

Measure the resistance between ABSCM&H/U and chassis ground.

Connector

&

terminal

(F49) NO. 23

-


CHECK SOURCES

OF

SIGNAL NOISE.

s the resistance between 1 ind 1.5 kR? s the resistance more than 1

dR?

s the resistance between 1 md 1.5 kR? s the resistance more than 1

dQ?


2?

s

there poor contact in con- lectors between ABSCM&H/L md ABS sensor? s the car telephone or the vireless transmitter properly nstalled?

So to step 9.

So to step 10.

So

to step 11. i o to step 12.

So to step 13. lepair the con- lector.

So

to step 15.

~~

No


<Ref. to ABS-21,

Front Tone

Wheel.> Rear:

<Ref. to ABS-22,

Rear Tone

Wheel.>


<Ref. to ABS-14,

Front ABS Sen- sor.> Rear: <Ref. to ABS-1 8, Rear

ABS Sensor.>


<Ref. to ABS-1 4,


ABS Sensor.>

Repair harness1 connector between

ABSCM&H/U and

ABS sensor.

Repair harness/ connector between

ABSCM&H/U and

ABS sensor.

Repair the

ABSCM&H/U ground harness.

Go to step 14.

Properly install the car telephone or the wireless transmitter.

ABS-50

5

6

I7

18



Step

CHECK SOURCES OF SIGNAL NOISE.

CHECK SHIELD CIRCUIT.

1

)Connect all connectors.

2)Measure the resistance between shield con-

Is

the resistance less than 0.5

Q?

nector and chassis ground.

Connector

&

terminal

DTC 26

/

(6200)

No. 1

1

-

ground:

DTC 28

/

(6200) No. 3

-

NOTE:

For the DTC 22 and 24:

Go to step 17.


1)Connect all connectors.

2)Erase the memory.



Is the same diagnostic trouble code as in the current diagnosis still being output?



I

Check

Are noise sources (such as an antenna) installed near the sensor harness?

Yes

nstall the noise sources apart from he sensor har- less.

30

to step 17.


3eplace the

4BSCM&H/U.

:Ref. to ABS-7,

4BS Control Mod-

Jle and Hydraulic

Zontrol Unit

:ABSCM&H/U).>

Proceed with the jiagnosis corresponding to the

%agnostic trouble

:ode.

No

;o to step 16.

3epair the shield iarness.

20

to step 18.

4

temporary noise nterference.

a

ABS-51


ABS-52


ABS

(DIAGNOSTICS)

~~

L: DTC29

ABNORMAL ABS SENSOR SIGNAL (ANY ONE OF FOUR)

DIAGNOSIS:

Faulty ABS sensor signal (noise, irregular signal, etc.)

Faulty tone wheel

Wheels turning freely for a long time

TROUBLE

SYMPTOM:


ABS-53



WIRING DIAGRAM:

@


1.

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

5 ,

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

!

-

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

r.

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

-

@

[i i

FRONT

ABS

SENSOR LH

@

I

1

FRONT

ABS

SENSOR RH

IC

I

REAR

ABS

SENSOR LH

I

- i

I

5 -

I,

,

I

I

I

I-

,

.

-

I

3

I I

I

I

I I

I I

I

I

I

I

I

I

I

I

I I

I

@

I

I

I

_ .

- .

I

I

I

g

SHIELD JOINT

CONNECTOR

1

I

1.

F

I I

I

I

I

I

I

I

I

.

5

I

I

I

I

I

I

L

@

I v i

I

I

I

I

I

I

.

REAR

ABS

SENSOR RH

BR0084

ABS-54

!

1

I i

I



Step

CHECK IF THE WHEELS HAVE TURNED

FREELY FOR A LONG TIME.

CHECK TIRE SPECIFICATIONS.


CHECK WEAR OF TIRE.

CHECK TIRE PRESSURE.



32 N.m (3.3 kgf-m, 24 ft-lb)



Specifications

Front wheel

0.3

-

mm (0.012

-

Rear wheel

0.7

- -

in)



1)Raise all four wheels off ground.



4)Turn the ignition switch ON.

5)Rotate the wheels and measure voltage at specified frequency. <Ref. to ABS-17, WAVE-


Check Yes No

:heck if the wheels have been lThe ABS is nor- urned freely for more than one mal. Erase the ninute, such as when the vehi- diagnostic trouble

:le is jacked-up, under full-lock

:ornering or when tire is not in

:ontact with road surface. code.

NOTE:

When the wheels turn freely for a long time, such as when the vehicle is towed or jacked- up, or when steering wheel is contin- uously turned all the way, this trouble code may sometimes occur.

4re the tire specifications cor- ect?

Go to step

3.

Replace the tire. s the tire worn excessively? s the tire pressure correct?

Replace the tire.

Go to step

5.

Go to step

4.

Adjust the tire pressure.

4re the ABS sensor installation iolts tightened securely?

Go to step 6. Tighten the ABS sensor installation bolts securely. s the gap within the specifica- ions?

Go to step 7. Adjust the gap.

s s

an oscilloscope available? the oscilloscope pattern imooth, as shown in figure?

Go to step 8.

Go to ster, 12.

NOTE:

Adjust the gap us, ing spacer (Part

No. 26755AAOOO).

If spacers cannot correct the gap, replace worn sensor or worn tone wheel.

Go to step 9.

Go to step 9.

NOTE:

When this inspection is completed, the AB

SCM&H/U sometimes stores the DTC 29.


Front RH

(F95) NO. 1

(+)

Front

LH

-

2

(-):

(F94) NO.

1

(+)

-

2

(-):

Rear RH

(B99) NO. 9

(+)

Rear

LH

(B99) NO. 4

(+)

-

5

(-):

ABS55

~


ABS

(DIAGNOSTICS)

3

I O

I 1

12

13

Step

CHECK CONTAMINATION OF ABS SENSOR

OR TONE WHEEL.

Remove the disc rotor from hub.

CHECK DAMAGE OF ABS SENSOR

TONE WHEEL.



OR

Check

s the ABS sensor piece or the one wheel contaminated by lirt or other foreign matter?

4re there broken or damaged eeth in the ABS sensor piece

)r the tone wheel? s the runout less than 0.05 nm (0.0020 in)?

Yes

Thoroughly remove dirt or other foreign matter.

Replace the ABS sensor or tone wheel. Front: <Ref. to ABS-1 4, Front

ABS Sensor.>

Rear: <Ref. to

ABS-18, Rear

ABS Sensor.> and Front: <Ref. to ABS-21, Front

Tone Wheel.>

Rear: <Ref. to

ABS-22, Rear

Tone Wheel.>

Go to step 12.

CHECK ABSCM&H/U

.



3)Erase the memory.





s the same diagnostic trouble

;ode as in the current diagno-

;is still being output?

4re other diagnostic trouble

;odes being output?

30

to

No

step 11.

3eplace the tone

Nheel. Front:

:Ref. to ABS-21,

3ont Tone

Nhee1.z Rear:

:Ref. to ABS-22,

3ear Tone

N h e e b

30

to step 13. Replace the

ABSCM&H/U.

<Ref. to ABS-7,


Sontrol Unit

[ABSCM&H/U).>

Proceed with the diagnosis corresponding to the diagnostic trouble

:ode.

4

temporary poor

:ontact.

ABS-56



~~

M: DTC31

ABNORMAL INLET SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (FRONT

RH)

NOTE:

For the diagnostic procedure, refer to DTC 37. <Ref. to ABS-57, DTC 37 ABNORMAL INLET SOLENOID

VALVE CIRCUIT(S) IN ABSCM&H/U (REAR LH), Diagnostics Chart with Diagnosis Connector.>

N: DTC33

ABNORMAL INLET SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (FRONT

LH)

NOTE:



0: DTC35

ABNORMAL INLET SOLENOID VALVE ClRCUIT(S) IN ABSCM&H/U (REAR

RH)

NOTE:



P:

DTC37

ABNORMAL INLET SOLENOID VALVE ClRCUIT(S) IN ABSCM&H/U (REAR

LH)

DIAGNOSIS:

Faulty harness/connector

Faulty inlet solenoid valve in ABSCM&H/U



I

ABS-57



WIRING DIAGRAM:

BATTERY n

RELAY

HOLDER

ABS

RELAY

BR0005

ABS-58

I

2

3

4

5

6

7

0

9

10


ABS

(DIAGNOSTICS)

~

Step Check

Yes

CHECK INPUT VOLTAGE OF RELAY HOLD-

ER.


2)Remove the fuse.

3)Measure the voltage between ABS relay connector and chassis ground.


(8225)

No.

-

CHECK RELAY HOLDER.

s the voltage more than 10 V?

Is the fuse blown out?

Go to step

2.

I

Replace the fuse.

Is the voltage more than 10 V? Go to step

4.

CHECK INPUT VOLTAGE OF ABS RELAY.

1)lnstall the fuse.

2)Remove the ABS relay.




(8264) No.

2

(+)

-


Measure the voltage between ABS relay connector and chassis ground.

Connector

&

terminal

(8264)

No.

1 (+)

IS

the voltage more than 10 V? Go to step

5.

No

Repair open circuit in harness between battery m d Relay holder

Zonnector.

Go to step

3.

Repair open circuit in harness between battery and Relay holder connector. ignition switch and

ABS relay.

CHECK GROUND CIRCUIT OF ABS RELAY.


2)Measure the resistance between ABS relay connector and chassis ground.


(8264) No.

3 (+)

-

Is the resistance less than 5 Go to step 6. n?

CHECK the ABS RELAY.

1)Connect the battery to ABS relay terminal

No.

1 and 3.

2)Measure the resistance between ABS relay terminals.

Is the resistance less than 10 n?

Go to step

7.

15 V?

CHECK INPUT VOLTAGE

OF

ABSCM&H/U.


H/U.

2)Run the engine at idle.


Connector

&

terminal

(F49)

No.

1

(+)




Is

7 - j -

the resistance less than 0.5

Go to step 9.


Connector

&

terminal

(F49)

No.

23

-


Is there poor contact in connectors between generator, battery and ABSCM&H/U?



1 )Connect all connectors.

2)Erase the memory.



Is the same diagnositc trouble code as in the current diagnosis still being output?

Repair open circuit between ABS relay and chassis ground.

Replace the ABS relay.

Repair harness connector between ABS relay and

ABSCM&H/U.

Repair the


Go to step 10.

Replace the

ABSCM&H/U.

<Ref. to ABS-7,


Control Unit

(ABSCM&H/U).>

Go to step 11.

9

ABS-59



11

Step



Check

Are other diagnostic trouble codes being output? sponding to the diagnostic trouble code.

ABS-60



Q:

DTC32

ABNORMAL OUTLET SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U

(FRONT RH)

NOTE:

For the diagnostic procedure, refer to DTC 38. <Ref. to ABS-61, DTC 38 ABNORMAL OUTLET SOLENOID


R: DTC34


(FRONT LH)

NOTE:



S: DTC36


(REAR RH)

NOTE:



T: DTC38


(REAR LH)

DIAGNOSIS:

Faulty harnesdconnector

Faulty outlet solenoid valve in ABSCM&H/U



a

ABS-61



WIRING DIAGRAM:

BATTERY

RELAY

HOLDER

ABS

RELAY

I

@


I

I

1

ABS-62

2

3

~~

I

1

5

6 .

7

B

9

10



Step


ER.


2)Remove the fuse.



(8225) No. 5

(+)

-


Check j

the voltage more than 10

V?

Yes

Go to step

2.

s the fuse blown out? s the voltage more than 10

V?

Replace the fuse.

Go to step 4.


OF

ABS RELAY.

1)lnstall the fuse.





(8264) No. 2

(+)

-



Connector

&

terminal

(8264)

No. 1 (+)

-

(-):

CHECK GROUND CIRCUIT OF ABS RELAY,


OFF.


Connector

&

terminal

(8264) No. 3

(+)

-

CHECK ABS RELAY.


No. 1 and 3.

2)Measure the resistance between ABS relay terminals. s the voltage more than 10 V? Go to step

5.

s the resistance less than 5

2?


L?

Go to step 6.

Go to step 7. s the voltage between 10 and

15

V?

Go to step 8.

CHECK INPUT VOLTAGE OF ABSCM&H/U.


H/U.




(F49)

No. 1 (+)

-

(-):

CHECK GROUND CIRCUIT OF ABSCM&H/U




Connector

&

terminal

(F49) No. 23


l?

Go to step 9.

CHECK POOR CONTACT IN CONNECTORS

s there poor contact in con- lectors between generator,

Iattery and ABSCM&H/U?


CHECK ABSCM&HN.


2)Erase the memory.


4)Read out the diagnostic trouble code. s the same diagnostic trouble

:ode as in the current diagno-


No

3epair open circuit n harness

2etween battery

2nd Relay holder

:onnector.

30

3.

Repair open circuit n harness

Detween battery

2nd Relay holder

:onnector.

Repair harness

:onnector

Detween battery, ignition switch and

ABS relay.



Repair harness connector between battery, ignition switch and

ABSCM&H/U.

Repair the


Go to step 10.

Replace the

ABSCM&H/U.

<Ref. to ABS-7,


Control Unit

(ABSCM&H/U).>

Go to step 11.

m

ABS-63



11

Step



Check Yes No

Are other diagnostic trouble Proceed with the

A

temporary poor codes being output? diagnosis corresponding to the contact. diagnostic trouble code.

ABS-64



ABS-65



U: DTC41

ABNORMAL ABS CONTROL MODULE

DIAGNOSIS:

Faulty ABSCM&H/U.


ABS does

not operate.

WIRING DIAGRAM: a

@

ABS-66

B4M145i

I

I

I

5

!

i

3


ABS

(DIAGNOSTICS)

Step

Check Yes




H/U.


ABSCM&H/U and chassis ground.


(F49)

23

- s the resistance less than 0.5

2?


s there poor contact in con- lectors between battery, igni- ion switch and ABSCM&H/U?

I

I

Go to step 2.



s the car telephone or the vireless transmitter properly nstalled?

Go to step 4.




2) E rase the memory.





30

to

---i

:ar telephone or

>roperly install the

I

he wireless trans- nitter.

4re noise sources (such as an mtenna) installed near the

;ensor harness?

Install the noise sources apart from the sensor harness. s the same diagnostic trouble



Replace the

ABSCM&H/U.

<Ref. to ABS-7,


Control Unit

(ABSCM&H/U).>


:odes being output?


30

30

to step to step 6.

:ontact.

5.

ABS-67


ABS

(DIAGNOSTICS)

ABS-68



V: DTC42

SOURCE VOLTAGE IS ABNORMAL

DIAGNOSIS:

Power source voltage of the

ABSCM&H/U

is low or high.


ABS

does not operate.

ABS-69



WIRING DIAGRAM:

RELAY

HOLDER

ABS

RELAY

@


516171819

BR0085

ABS-70

1



Step

CHECKGENERATOR.

1)Start the engine.

2)ldling after warm-up.

3)Measure the voltage between generator B terminal and chassis ground.

Terminal

Generator 8 terminal

-

CHECK BATTERY TERMINAL.


Check s

the voltage between 10 and

7 V? ire the positive and negative battery terminals tightly ilamped?

s

the voltage more than 10 V?


ER.


2)Remove the fuse.



(8225) No.

(+)

-



OF

ABS RELAY.

1)lnstall the fuse.





(8264)

No.

(+)

-


OF

ABS RELAY.



(8264)

No.

1

(+)

-





(8264)

No.

- s the fuse blown out? s the voltage more than 10 V?

s


V?


2?



No. 1 and 3.




H/U.


3)Measure the voltage between ABSCM&H/U connector and chassis grou.nd.


(F49)

No.

(+)

-






(F49)

No.

- s the resistance less than 10

a?


I7

V? s the resistance less than 0.5

3?

Yes

30

to step

2.

30

to step

3.

30

to step

4.

3eplace the fuse.

30

to step

6.

30

step

7.

30

step 8.

So to step 10.

Go to step

11.

No

qepair the genera-

:or. <Ref. to SC-

13, Generator.>

Tighten the clamp

2f terminal.

Repair open circuit n harness

3etween battery and Relay holder

:onnector.

Go to step 5.

Repair open circuit in harness between battery and Relay holder connector.


ABS relay.




ABSCM&H/U.

Repair the


a

ABS-71

I



1

2

3

Step

Check





2)Erase the memory.




CHECK ANY OTHER DIAGNOSTIC TROW



Yes


No

Go to step 12.

Replace the

ABSCM&H/U.

<Ref. to ABS-7,


Control Unit

(ABSCM&H/U).>

Go to step 13.


A temporary poor contact.

ABS-72


ABS

(DIAGNOSTICS)

ABS-73

I



W: DTC44

A

COMBINATION OF AT CONTROL ABNORMAL

DIAGNOSIS:

Combination of AT control faults


ABS does not operate.

WIRING DIAGRAM:

I

@

A B S CONTROL MODULE AND

HYDRAULIC CONTROL UNIT

I

1 1

: TURBO ENGINE MODEL

I

6: 655 TCM

A : 8

BR0086

ABS-74

8

9

1

2

3

4

5

6

7



Step

CHECK SPECIFICATIONS OF THE AB-

SCM&H/U.

Check specifications of the mark to the

ABSCM&H/U.

CC: AT

Check

Is an ABSCM&H/U for AT model installed on a MT nodel?

Yes

3eplace the

4BSCM&H/U.

:Ref. to ABS-7,

9BS Control Mod- de and Hydraulic

2ontrol Unit

No

Go to step

2.



2)Disconnect two connectors from TCM.


H/U.



Connector

&

terminal

(F49) No. 3

-

CHECK BATTERY SHORT OF HARNESS.


Connector

& terminal

(F49) No.

3

(+)

-




Connector

&

terminal

(F49)

No,

3

(+)

-

(-):

CHECK TCM.


2)Connect all connectors to TCM.


4)Measure the voltage between TCM connector terminal and chassis ground.

Connector

&

terminal

NON-TURBO MODEL

(B54) No. 19

(+)

-

(-):

TURBO MODEL

(B55) No. 21 (+)

-

(-):

CHECK AT.


MQ?



Is the voltage between

10 and

15 V?

30

step

4.

30 5.

Go to step

7.

CHECK OPEN CIRCUIT

OF HARNESS.


Connector

&

terminal

(F49) No. 3

(+)

(F49) No.

31

(+)

-

-

(-):

(-):


Is the AT functioning normally? Replace the TCM.


15 V?

10 and

Go to step

8.

Is there poor contact in connectors between TCM and

ABSCM&H/U?





3)Erase the memory.




Repair harness between TCM and

ABSCM&H/U.


ABSCM&H/U.


ABSCM&H/U.

Go to step

6.

Repair the AT.

Repair harness/ connector between TCM and

ABSCM&H/U.

Go to step

9.

Replace the

ABSCM&H/U.

<Ref. to ABS-7,


Control Unit

(ABSCM&H/U).r

Go to step

10. ii

ABS-75


ABS (DIAGNOSTICS)

10

Step



codes being output? diagnosis corresponding to the diagnostic trouble code.

No

A

temporary poor contact.

ABS-76



X:

DTC51

ABNORMAL VALVE RELAY

DIAGNOSIS:

Faulty valve relay



ABS-??



WIRING DIAGRAM:

1

RELAY

I

I

I

1-1

11

ABS CONTROL MODULE AND

HYDRAULIC CONTROL UNIT

<

RELAY MOTOR RELAY

I

B

ABS-78

m

I r

3

a

'I

$

f

BR0087

!

I

?

5

3

~~~

I

i

I O



~

Step

Check


ER.


2)Remove the fuse.


Connector

&

terminal

(6225) No. 5

(+)

-

(-):




1)lnstall the fuse.




Connector

&

terminal

(6264)

No.

2

(+)

-

(-):



Connector

&

terminal

(6264)

No.

1

(+)

-

(-):




Connector

& terminal

(6264)

No.

3

(+)

-



No. 1 and 3.

2)Measure the resistance between ABS relay terminals. s the fuse blown out? s the voltage more than 10 V? s the voltage more than 10 V? s the resistance less than 5

2?


2?

CHECK INPUT VOLTAGE OF ABSCM&HIU.



H/U.



Connector

&

terminal

(F49) No.

1

(+)

(F49) No. 24

(+)

-

-

(-):

(-):





Connector

&

terminal

(F49) No. 23

-

CHECK VALVE RELAY IN ABSCM&H/U.

Measure the resistance between ABSCM&H/U and terminals.

Terminals

NO. 23

(+)

-

24

(-): s the voltage between 10 and

I5

V? s the resistance less than 0.5

;2? s the resistance more than 1

VlQ?

Yes

30

to step 2.

3eplace fuse.

30 to step 4.

30 5.

Go to step 9.

Go to step 10.


s there poor contact in con- lectors between generator, iattery and ABSCM&H/U?


No

Repair open circuit in harness between battery and relay holder

Connector.

Go to step

3.

Repair open circuit in harness between battery and relay holder connector.


ABS relay.



Repair harness connector between battery,

ABS relay and

ABSCM&H/U.

Repair the


Replace the

ABSCM&H/U.

<Ref. to ABS-7,


Control Unit

(ABSCM&H/U).>

Go to step 11.

ABS-79

m



I1

12

~ ~ ~~

Step



2)Erase the memory.





Check



Yes No

Replace the

ABSCM&H/U.

<Ref. to ABS-7,


Control Unit

(ABSCM&H/U).>

IGo to step 12.

Proceed with the A temporary poor diagnosis corre- contact. sponding to the diagnostic trouble code.

ABS-80

~~



~

Y: DTC 52

ABNORMAL MOTOR AND/OR MOTOR RELAY

DIAGNOSIS:

Faulty motor

Faulty motor relay




I

ABS-81



- I

~

WIRING DIAGRAM:

BATTERY

ABS RELAY 6 2 2 5

ZJ

h

VALVE RELAY

@

ABS-82

r

1

m

BR0088



Step




HIU.




(F49) No. 25

(+)

-

(-):

CHECK GROUND CIRCUIT OF MOTOR.





(F49)

No.

26

-

CHECK INPUT VOLTAGE OF RELAY HOLD,

ER.


2)Remove the fuse.



(8225)

No. 5 (+)

-

(-):

CHECKRELAYHOLDER.


1)lnstall the fuse.





(8264)

No.

2

(+)

-

(-):




(8264) No. 1

(+)

-

(-):

CHECK GROUND CIRCUIT

OF

ABS RELAY




(8264) No. 3

(+)

-



No. 1 and 3.






(F49)

No. 1 (+)

-

(-):

Check

the voltage between 10 and

5 V?

;the resistance less than

0.5

!?

Yes

;o to step

2.


30 4. s

the fuse blown out?

Replace the fuse.

j


Go to step

6.

the voltage more than

10

V?

j

the resistance less than 5

2?


2?

s the voltage between

10 and

I5

V?

30

to step

3.

30

to step

7 .

So to step

8.

Go to step

9.

Go to step

10.

No

Repair harness/ connector between battery and ABSCM&H/U and check fuse

SBF-holder.

Repair the

ABSCM&H/U ground harness. in harness between battery and Relay holder connector.

Go to step

5.

Repair open circui in harness between battery and Relay holder connector.


ABS relay.

Repair open circuP between ABS relay and chassis ground.

Replace the ABS relay. connector between battery, ignition switch an(

ABSCM&H/U.

II

ABS-83



IO

I1

12

13

14

Step Check






Connector

&

terminal

-

CHECK MOTOR OPERATION.

Operate the sequence control. <Ref. to ABS-

11, ABS Sequence Control.>

Can motor revolution noise

(buzz) be heard when carrying out the sequence control?

NOTE:

Use the diagnosis connector to operate the sequence control.

Yes

;o to step 11.

30

to step 12.

No

3epair the

4BSCM&H/U jround harness.

3eplace the

4BSCM&H/U.

:Ref. to ABS-7,

ABS Control Mod- de and Hydraulic

>ontrol Unit

ABSCM&H/U) .>

30

to step

13. CHECK POOR CONTACT IN CONNECTORS.


Turn the ignition switch to OFF. nector between generator, battery and ABSCM&H/U?



2)Erase the memory.






Are other diagnostic trouble

:odes being output? lepair the con- lector. leplace the

\BSCM&H/U.

:Ref. to ABS-7,

4BS Control Mod- ile and Hydraulic

:ontrol Unit

ABSCM&H/U).>

'roceed with the liagnosis corre- iponding to the liagnostic trouble

:ode.

30

to step 14.

4 temporary poor

:ontact.

ABS-84



ABS-85


ABS (DIAGNOSTICSI

2:

DTC54

ABNORMAL STOP LIGHT SWITCH

DIAGNOSIS:

Faulty stop light switch


ABS

does not operate.

WIRING DIAGRAM:

BATTERY n

STOP L I G H l

SWITCH

I

1

N



11

__

~ ~

2 7 1 2 8 1 2 9 1 3 0 1 3 1 1

23

I

24

I

25

I

26

m

: WITHOUT CRUISE

CONTROL m

: WITH CRUISE

CONTROL

BR0089

ABS-86

3

1

I

!

5



Step

CHECK STOP LIGHTS COME ON.

Depress the brake pedal.

Check

Do the stop lights come on?

CHECK OPEN CIRCUIT IN HARNESS.



H/U.

3)Depress the brake pedal.


10 and

15

V?


Connector

&

terminal

(F49)

No.

2

-

ground (-):


Is there poor contact in connector between stop light switch and ABSCM&H/U?

CHECK ABSCM&WU.


2)Erase the memory.







Yes

Go to step 2.

Go to step

3.

nector.

No

Repair the stop lights circuit.

Repair harness between stop light switch and

ABSCM&H/U.

Replace the

ABSCM&H/U.

<Ref. to

ABS-7,


Control Unit

(ABSCM&H/U).>

Go to step

5.



M

ABS-87



ABS-88



AA:DTC 56

ABNORMAL G SENSOR OUTPUT VOLTAGE

DIAGNOSIS:

Faulty G sensor output voltage


ABS

does not operate.

a

ABS-89



WIRING DIAGRAM:

SHIELD JOINT

CONNECTOR

7 -

$E

8200

L

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I t

1

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

:

,@

ABS

G SENSOR

BR0090

ABS-90


ABS

(DIAGNOSTICS)

CHECK ALL FOUR WHEELS FOR FREE

TURNING.

Step

CHECK SPECIFICATIONS OF ABSCM&H/U.


ABSCM&H/U.

CC: AT

CD: MT

Check

iave the wheels been turned reely such as when the vehicle s lifted up, or operated on a

,oiling road?

Ioes the vehicle specification

2nd the ABSCM&H/U specifi-

:ation match?

~

Yes

-he ABS is nor- nal. Erase the liagnostic trouble

:ode.

3eplace the

4BSCM&H/U.

:Ref. to ABS-7,


2ontrol Unit

ABSCM&H/U).>

2AUTION:

3e sure to turn ig- iition switch to

3FF when remov- ng ABSCM&H/U.

20

No

to step 2.

30

to step

3.

Repair harness/

:onnector

Detween G senso and ABSCM&H/U

CHECK INPUT VOLTAGE OF G SENSOR.



3)Disconnect the G sensor from body. (Do not disconnect the connector.)


5)Measure the voltage between G sensor connector terminals.


(6292) NO.

1

(+)

-

IS

the voltage between 4.75 and 5.25 V?

Is the resistance between 4.3 and 4.9

kR?

CHECK OPEN CIRCUIT IN G SENSOR OUT,

PUT HARNESS AND GROUND HARNESS.



H/U.




(F49) NO. 6

-


MR?

CHECK GROUND SHORT IN G SENSOR

OUTPUT HARNESS.

1)Disconnect the connector from G sensor.




(F49) No. 6

-





(F49) No. 6

(+)

-

(-):






(F49) No. 6

(+)

-

(-):

30

step 5.

Go to step 6.

Go to step 7.

Go to step 8.

Repair harness/ connector between G senso and ABSCM&H/U

Repair harness between G sensor and ABSCM&H/U.



9

ABS-91

I



I

I

0

1

2

3

4

Step Check




MR?


(F49) No.

-

CHECK G SENSOR.







Is the voltage between 2.1 and

2.4 V when G sensor is horizontal?


(B292) NO.

(+)

CHECK G SENSOR.

Measure the voltage between

G sensor connector terminals.


(B292)

NO.

(+)

-

3

CHECK G SENSOR.



(8292)

NO.

(+)


4.1 V when G sensor is inclined forwards to go"?


0.5

0.9

V'when G sensor is inclined backwards to 90°?


Is there poor contact in connector between ABSCM&H/U and G sensor?

CHECK ABSC M&H/U

.


2)Erase the memory.







Yes

30 to step 9.

30 to step 10.

;o to step 11.

;o to step 12.

No


Replace the

ABSCM&H/U.

<Ref. to ABS-7,


Control Unit

(ABSCM&H/U).>

Replace the G sensor. <Ref. to

ABS-23, G Sen- sor.>





3epair connector. Go to step 13.

3eplace the

4BSCM&H/U.

:Ref. to ABS-7,

4BS

Control Mod- ile and Hydraulic

:ontrol Unit

ABSCM&H/U).>

Go to step 14.

'roceed with the liagnosis corre- iponding to the liagnostic trouble

:ode.


ABS-92



AB :SELECT MO NIT0 R

Applicable cartridge of select monitor: <Ref. to

ABS-10, SPECIAL TOOLS, PREPARATION

TOOL, General Description.>

NOTE:

For basic handling of the select monitor, refer to its

Operation Manual.

AC:DIAGNOSTIC TROUBLE CODES

(DTC) ARE DISPLAYED.

A

maximum of 3 diagnostic trouble codes (DTC) are displayed in order of occurrence.

If a particular diagnostic trouble code (DTC) is not properly stored in memory (due to a drop in AB-

SCM&H/U power supply, etc.) when a problem occurs, the diagnostic trouble code (DTC), followed by a question mark

‘ I ? ” ,

appears on the select monitor display. This shows it may be an unreliable reading

.

AE:ANALOG DATA ARE DIS-

PLAYED.

DisDlav screen

I

FR wheel speed

Contents to be monitored

Wheel speed detected by the Front Right

ABS sensor is displayed in km/h or mile/ h.

1

FL wheel speed

RR

wheel speed

RL wheel speed

Stop light switch voltage

Output

Wheel speed detected by the Front Left


Wheel speed detected by the Rear Right


Wheel speed detected by the Rear Left


-

Stop light switch monitor voltage is displayed.

Refers to vehicle acceleration detecting by the analog

G

sensor. It appears on the select monitor display in volts.

21 Front Right ABS Sensor Circuit

Open or Shorted Battery

(*a*)/?

u

t t

S4M0076A

*a* refers to the troubles in order of occurrence

(Latest, Old, Older and Reference).

DisDlav screen

I

Latest


The most recent diagnostic trouble code

(DTC) appears on the select monitor dis-

Older

The second most recent diagnostic trouble code (DTC) appears on the select monitor display.

The third most recent diagnostic trouble code (DTC) appears on the select moni-

AF:ON/OFF DATA ARE DISPLAYED.

Display screen

Stop light switch

Valve relav siqnal



Motor relay signal

ABS signal to TCM

ABS warning light

Valve relay monitor

Motor relav monitor

CCM signal

Valve relay siqnal

1

I

Motor relay signal

ABS operation signal from ABS control module to TCM

ABS warning light

I

I

Valve relay operation monitor signal

Motor relay operation monitor signal

ABS operation signal from ABS control module to TCM

I

AG:ABS SEQUENCE CONTROL

1 I


I

IndexNo. sequence control

Reference diagnostic trouble code (DTC) appears

AD:CLEAR MEMORY

Display screen

Clear memory?


Function of clearing diagnostic trouble code (DTC) and freeze frame data.

ABS-93


ABS

(DIAGNOSTICS)

AH:FREEZE FRAME DATA

NOTE:

Data stored at the time of trouble occurrence is shown on display.

Each time trouble occurs, the latest information is stored in the freeze frame data in memory.

Freeze frame data will be memorized maximum to three.

If freeze frame data is not properly stored in memory (due to a drop in ABSCM power supply, etc.), a diagnostic trouble code (DTC), preceded by a question mark "?", appears on the select monitor display. This shows it may be an unreliable reading.

Display screen

FR wheel speed


Wheel speed detected by the Front Right


Wheel speed detected by the Front Left

Wheel speed detected by the Rear Right

Wheel speed detected by the Rear Left

ABS sensor is displayed in km/h or mile/ RL wheel speed

ABSCM power voltage

I

I h .

Power (in volts) supplied to ABSCM&H/U appears on the select monitor display.

Refers to vehicle acceleration detected

G sensor output by the analog G sensor. It appears on voltage

Motor relay mon- the select monitor disDlav in volts.

I

Motor relay operation monitor signal itor

Stop light switch

ABS signal to

TCM


ABS operation signal from ABS control module to

TCM

ABS-AT control

ABS 'peration module

to

TCM

I

ABS operation signal

ABS-94

\

I


ABS (DIAGNOSTICS)

ABS-95

DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR


13.Diagnostics Chart with Subaru Select Monitor

A: COMMUNICATION

FOR

INITIALIZING IMPOSSIBLE

DIAGNOSIS:


TROUBLE

SYMPTOM:

ABS warning light remains on.

WIRING DIAGRAM:

P

B

DATA LINK

CONNECTOR

RELAY

HOLDER

ABS

RELAY

+

@


I

ABS-96

m

BR0091


ABS

(DIAGNOSTICS)

,

Step

CHECK IGNITION SWITCH.

Check

Is the ignition switch ON?

Yes

30 2.

CHECK BATTERY.


2)Measure the battery voltage.

Is the voltage more than 11 V?

30 to step

3.

CHECK BAlTERY TERMINAL.

CHECK COMMUNICATION OF SELECT

MONITOR.


2)Using the select monitor, check whether communication to other system (such as engine, TCM, etc.) can be executed normally.


MONITOR.


€‘)Disconnect the ABSCM&H/U connector.

3)Check whether communication to other systems (such as TCM, engine etc.) can be executed normally.


MONITOR.


2)Connect the ABSCM&H/U connector.

3)Disconnect the ECM connector.

4)Check whether communication to other systems (such as TCM, engine etc.) can be executed normally.

Is there poor contact at battery terminal?

Are the name and year of the system displayed on the select monitor?


Repair or tighten the battery termi-

181.

So to step 10.

Go to step 10.


Inspect the ECM.


MONITOR.


2)Connect the ECM connector.

3)Disconnect the TCM connector.

4)Check whether communication to other systems (such as engine etc.) can be executed normally.


MONITOR.


2)Connect the TCM connector.

3)Disconnect the cruise control module connector.

4)Check whether communication to other systems (such as engine, TCM etc.) can be executed normally.


Inspect the TCM.


Inspect the cruise control module.

NOTE:

If the vehicle is not equipped with cruise control

-

Go to ster, 9.

No

Turn the ignition switch to ON, and select ABS mode using the select monitor.

Charge or replace bettery.

Go to step 4.

Go to step 5.

Go to step

6.

Go to step 7 .

Go to step 8.

Go to step 9.

3

ABS-97


ABS

(DIAGNOSTICS)

3

I O

I1

12

13

14

15

16

17

Step

CHECK HARNESS CONNECTOR BETWEEN

EACH CONTROL MODULE AND DATA LINK

CONNECTOR.


2)Disconnect the TCM, ECM, ABSCM&H/U, and, cruise control module connectors.




(840)

No.

5

-

(B40) No. 4

Chassis ground:

-

CHECK OUTPUT SIGNAL

FOR

ABSCM&H/

U.


2)Measure the voltage between ABSCM&H/U and chassis ground.


(840) No. 5

(+)

(840) No. 4

(+)

-

-

CHECK HARNESWCONNECTOR BETWEEN

ABSCM&H/U AND DATA LINK CONNEC-

TOR.

Measure the resistance between ABSCM&H/U connector and data link connector.


(F49) NO. 20

(F49) NO. 5

-

-

(840) NO. 5:

(840) NO. 4:

CHECK INSTALLATION OF ABSCM&HN

CONNECTOR.


Check


2?

s the voltage more than 1

V?


2?

s the ABSCM&H/U connector iserted into ABSCM&H/U until he clamp locks onto it? s the voltage more than 10

V? CHECK INPUT VOLTAGE OF RELAY HOLD-

ER.


2)Remove the fuse.


Connector

&

terminal

(8225) No. 5

(+)



OF

ABS RELAY.

1)lnstall the fuse.




Connector

&

terminal

(8264)

No.

2

(+)


OF

ABS RELAY.



(8264) No.

1

(+)

-


OF

ABS RELAY.


OFF.



(8264) No.

3

(+)

- s the fuse blown out?

s


V? s


V? s

the resistance less 5

R?

Yes

30

to step 10.

3epair harness and connector letween each con rol module and jata link connec- or.

20

to step 11.

3epair harness ind connector letween iBSCM&H/U and jata link connec- or.

20 to

step 13.

20

to step 14.

3eplace the fuse.

20 to

step 16.

20

to step 17.

20

to step 18.

No

3epair harness and connector letween each con,

:rol module and lata link connec-

:or.

30

to step 12. nsert ABSCM&H/

J connector into

4BSCM&H/U.

3epair open circuit n harness letween battery and Relay holder

:onnector.

20

to step

15.

3epair open circuit n harness letween battery md Relay holder

:onnector.

3epair harness

:onnector letween battery, gnition switch and

4BS relay.

3epair open circuit letween ABS

'elay and chassis ground.

ABS-98

8

9

!O

!1



Step



No. 1 and 3.


CHECK POWER SUPPLY CIRCUIT.


ON

(engine

OFF).

2)Measure the ignition power supply voltage

Check

Is the resistance less than 10

Q?

Is the voltage more than 10

V?

Go to

Yes

step 19.

Go to step 20.

No


Repair open circuit in harness between

ABSCM&H/U and battery.

CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1

ABSCM&H/U AND CHASSIS GROUND.

Q?


2)Disconnect the connector from ABSCM&H/U and transmission.

3)Measure the resistance of harness between


Connector

&

terminal

(F49) No. 23

-


Is there poor contact in control module power supply, ground line and data link connector?

Go to step 21.


Repair open circuit in harness between

ABSCM&H/U and inhibitor side connector, and poor contact in coupling connector.

Replace the

ABSCM&H/U.

<Ref. to ABS-7,


Control Unit

(ABSCM&H/U).>

ABS-99


ABS (DIAGNOSTICS)

ABS-I

00

I



B: NO TROUBLE CODE

DIAGNOSIS:

ABS warning light circuit is shorted.


ABS warning light remains on.

NO TROUBLE CODE displayed on the select monitor.

NOTE:

When the ABS warning light is OFF and “NO TROUBLE CODE” is displayed on the select monitor, the system is in normal condition.

I

ABS-I 01


ABS

(DIAGNOSTICS)

WIRING DIAGRAM:

SBF-3

SBF-1

BATTERY

3 c

U

IGNITION

SWITCH

?

z

F

RELAY HOLDER

ABS-1 02

BR0083

1

2

3

5

5

1


ABS

IDIAGNOSTICS)

Step



2)Disconnect the connector (F74) from connector (8200).


CHECK PROJECTION AT ABSCM&H/U.



H/U.

3)Check for broken projection at the

ABSCM&H/U terminal.

Check

Does the ABS warning light remain off?

Are the projection broken?

Yes

Go to step

2.

Go to step

3.


Measure the resistance between ABSCM&H/U terminals.

Terminals

NO. 22

-

23:

MR?

No

Repair the front wiring harness.

Replace the

ABSCM&H/U.

<Ref. to ABS-7,


Control Unit

(ABSCM&H/U).>

Replace the

ABSCM&H/U.

<Ref. to ABS-7,


Control Unit

(ABSCM&H/U).>






(F74) No. 19

-

ground:



2)Measure the resistance between connector


Connector

&

terminal

(F74) No. 19

-


CONNECTOR.

R?



I

Go

to

step

5.



Replace the

ABSCM&H/U.

<Ref. to

ABS-7,


Control Unit

(ABSCM&H/U).>

m

ABS-1 03



C: DTC21

OPEN OR SHORT CIRCUIT IN FRONT RIGHT ABS SENSOR CIRCUIT

NOTE:

For the diagnostic procedure, refer to DTC 27. <Ref. to ABS-I 05, DTC 27 OPEN OR SHORT CIRCUIT IN

REAR LEFT ABS SENSOR CIRCUIT, Diagnostics Chart with Subaru Select Monitor.>

D: DTC23

OPEN OR SHORT CIRCUIT IN FRONT LEFT ABS SENSOR CIRCUIT

NOTE:

For the diagnostic procedure, refer to DTC 27. <Ref. to ABS-I 05, DTC 27 OPEN

OR

SHORT CIRCUIT IN

REAR LEFT ABS SENSOR CIRCUIT, Diagnostics Chart with Subaru Select Monitor.>

E: DTC25

OPEN OR SHORT CIRCUIT IN REAR RIGHT ABS SENSOR CIRCUIT

NOTE:

For the diagnostic procedure, refer to DTC 27. <Ref. to ABS-105, DTC 27 OPEN OR SHORT CIRCUIT IN

REAR

LEFT ABS SENSOR CIRCUIT, Diagnostics Chart with Subaru Select Monitor.>

ABS-I 04


ABS (DIAGNOSTICS)

F:

DTC27

OPEN OR SHORT CIRCUIT IN REAR LEFT ABS SENSOR CIRCUIT

DIAGNOSIS:

Faulty ABS sensor (Broken wire, input voltage too high)




ABS-I 05


ABS

(DIAGNOSTICS)

WIRING DIAGRAM:


I

I

1.

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

5

7

I r'

@

FRONT

ABS

SENSOR LH

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

FRONT

ABS

SENSOR RH

1.

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I r'

@

1.

I

I

I

I

5

I

I

1.

I

I

I

I

I

I

',

I

1.

I

I

I

I

5

e

I

I

I

I

1.

.b

I

I

I

I

I

I

I

I

I

I

I

@

I

I

I

I

I

SHIELD JOINT

CONNECTOR

1

I

F

I

I

I

I

I

I

I I

-i

I

I

I

I

I

.

5

I

I

I

I

I

I

I

I

I

.

1

I

REAR

ABS

SENSOR LH

REAR

ABS

SENSOR RH

I

BROOM

ABS-I 06

I


ABS (DIAGNOSTICS)

Step

CHECK OUTPUT OF ABS SENSOR USING

SELECT MONITOR.

1)Select “Current data display & Save” on the select monitor.

2)Read the ABS sensor output corresponding to the faulty system in the select monitor data display mode.

CHECK INSTALLATION

OF

ABS SENSOR.


32 N.m (3.3 kgf-m, 24 ft-lb)


Measure the tone wheel to

ABS sensor piece gap over entire perimeter of the wheel.

front wheel

0.3

-

Rear wheel

0.7

-

-

in)

.CHECK TONE WHEEL RUNOUT.


CHECK ABS SENSOR.



3)Measure the resistance of ABS sensor connector terminals.

Terminal front

RH

No. 1 -No. 2: front LH No. 1 -No. 2:

Rear RH

No.

1

-

Rear LH No. 1

-

~

Check

Ioes the speed indicated on he display change in response

3

the speedometer reading luring acceleration/decelera- ion when the steering wheel is

I

the straight-ahead position?

Yes

30

to step 2. ire the ABS sensor installation

,olts tightened securely?

30

to step

3. s

the gap within the specifica- ions? s the runout less than 0.05 nm (0.0020 in)?

30

to step 4.

30

to step

5.

No

Go to step 8.


Adjust the gap.

NOTE:

Adjust the gap us ing spacers (Pal

No. 26755AA000:

If spacers cannc correct the gap, re place the wori sensor or wori tone wheel.


<Ref. to ABS-21,

Front Tone

Wheel.> Rear:

<Ref. to ABS-22,

Rear Tone

Wheel.>

Go

to step 6.



CHECK ABSCM&HN.


2)Erase the memory.



s

there poor contact in con- lectors between ABSCM&H/U ind ABS sensor? s the same diagnostic trouble





ire other diagnostic trouble

:odes being output? s the resistance between 1 ind 1.5 kR?

3epair the con- lector.

3eplace the

SBSCM&H/U.

:Ref. to ABS-7,

4BS Control Mod-

Ae and Hydraulic

2ontrol Unit

ABSCM&H/U).>

Go to step 7.

’roceed with the jiagnosis corresponding to the liagnostic trouble

:ode.


NOTE:

Check harnes and connector between AE

SCM&H/U an

ABS sensor.

30

to step 9. Replace the ABS sensor. Front:

<Ref. to ABS-14,


ABS Sensor.>

ABS-I 07

3



9

IO

I1

12

13

14

Step


SOR.


H/U.


Terminal


(+)


(+)

-

-

Rear RH

No. 1 (+)

Rear LH No. 1

(+)

CHECK BAlTERY SHORT OF ABS SEN-

SOR.



Terminal

Front RH No.

1

(+)

Front LH No. 1 (+)

Rear RH No. 1 (+)

-

-

Rear LH No.

1

(+)

CHECK HARNESSKONNECTOR BETWEEN

'nBSCM&HlU AND ABS SENSOR.






DTC 21 / (F49) NO. 11

DTC 23 / (F49) NO. 9

-

-

DTC 25 / (F49) NO. 14

NO. 12:

NO. 10:

-

DTC 2 7 / (F49) NO. 7

-

NO. 15:

NO. 8:



Connector

&

terminal

DTC 21 /(F49) No. 11

(+)

ground (-):

DTC 23 / (F49) No. 9

(+)

ground (-):

DTC 25

/ (F49) No. 14 (+)

ground (-):

DTC 27

/ (F49) No. 7 (+)

ground (-):





DTC 21 /(F49) No. 11

(+)

ground (-):

DTC 23 / (F49) No. 9 (+)

ground (-):

DTC 25 / (F49) No. 14 (+)

ground

I ) (

DTC 2 7 / (F49) No. 7 (+)

ground (-):



32 N.m (3.3 kgf-m, 24 ft-lb)

Check

s the voltage less than 1 V? s the voltage less than 1 V? s the resistance between 1 ind 1.5

kR?

s the voltage less than 1 V? s the voltage less than 1 V?

Ire the ABS sensor installation iolts tightened securely?

Yes

i o to step 10.

;o to step 11.

;o to step 12. i o to step

13.

i o to step 14. i o to step 15.

ABS-I 08

No


<Ref. to ABS-14,

Front ABS Sen- sor.> Rear: <Ref. to ABS-I

8,

Rear

ABS Sensor.>


<Ref. to ABS-14,

Front ABS Sen- sor.> Rear: <Ref. to ABS-I 8, Rear

ABS Sensor.>

Repair harness/ sonnector

Detween

4BSCM&H/U and

4BS sensor.

Repair harness

3etween

4BSCM&H/U and

4BS sensor.

3epair harness ietween

4BSCM&H/U and

4BS sensor. righten the ABS sensor installation iolts securely.


ABS

(DIAGNOSTICS)

~

Step



front wheel

0.3

-

mm (0.012

Rear wheel

0.7

-

mm (0.028

-



CHECK GROUND SHORT OF ABS SENSOR


2)Measure the resistance between ABS sensor and chassis ground.

Terminal



Rear RH No.

1

-

-

-

Rear LH No.

1


-

Check

;the gap within the specifica- ons?

Yes

i o to step 16.

3

the runout less than 0.05 nm (0.0020 in)?

s the resistance more than 1

An?

20

to step 17.

20

to step 18.





ABSCM&H/U connector terminal and chassis ground.

Connector

&

terminal

DTC 21 /(F49)

No.

11

DTC 23

/

(F49)

No.

9

-

-

Chassis ground

DTC 25

/

(F49) No. 14

DTC 27/(F49) No. 7


-

-

Chassis ground



s the resistance more than 1 nn?



2)Erase the memory.






:odes being output?

30

to step 19. s there poor contact in con- lectors between ABSCM&H/U md ABS sensor?

3epair the con- lector. s the same diagnostic trouble

;ode as in the current diagno-


3eplace the

4BSCM&H/U.

Go to step 21.

Droceed with the diagnosis corresponding to the jiagnostic trouble

:ode.


NOTE:

Check harnes! and connector! between AB

SCM&H/U anc

ABS sensor.

No

Adjust the gap.

NOTE:

Adjust the gap us. ing spacers (Pad

No. 26755AAOOO).

If spacers cannol correct the gap, replace the worr sensor or wow tone wheel.


<Ref. to ABS-21,

Front Tone

Wheel.> Rear:

<Ref. to ABS-22,

Rear Tone

Wheel.>

Replace the ABS sensor and

ABSCM&H/U.

Front: <Ref. to

ABS-14, Front

ABS Sensor.>

Rear: <Ref. to

ABS-18, Rear

ABS Sensor.> and <Ref. to

ABS-7, ABS Con- trol Module and

Hydraulic Control

Unit (ABSCM&H/

U).>


ABSCM&H/U and

ABS sensor.

And replace the

ABSCM&H/U.

<Ref. to ABS-7,


Control Unit

(ABSCM&H/U).>

Go to step 20.

ABS-I 09



G: DTC22

FRONT RIGHT ABNORMAL ABS SENSOR SIGNAL

NOTE:

For the diagnostic procedure, refer to DTC 28. <Ref. to ABS-1 11, DTC 28 REAR LEFT ABNORMAL ABS

SENSOR SIGNAL, Diagnostics Chart with Subaru Select Monitor.>

H: DTC24

FRONT LEFT ABNORMAL ABS SENSOR SIGNAL

NOTE:



I: DTC26

REAR RIGHT ABNORMAL ABS SENSOR SIGNAL

NOTE:



ABS-I 10

I

1

1 i

t



_ _ _ _ _ ~

J: DTC28

REAR LEFT ABNORMAL ABS SENSOR SIGNAL

DIAGNOSIS:

Faulty

ABS

sensor signal (noise, irregular signal, etc.)


TROUBLE

SYMPTOM:

ABS

does not operate.

m

ABS-1 11



WIRING DIAGRAM:

@


I

I

I

I

I

I

-

I

I

I

I

I

I

I

I-

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

1

1

FRONT

ABS

SENSOR LH

1

I

I-

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

1

I

I

I

I

I

I

I

I

I

I

I

I

I

I

e '

I

1

I

FRONT

ABS

SENSOR RH

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

c

I f

I

I

I I

I-

I

I I

I

I I

I

I

I I

I

I

I I

I

I

I I

I

I

I I

I

f

5

I

I

I

I

I

I

5

I.

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

.

I

I

5 .

I

I

I

I

I

I

I

I

I

I

I

I

I

i

I""

CONNECTOR

~

U

REAR

ABS

SENSOR LH

U

REAR

ABS

SENSOR

RH

BR0084

ABS-I 12


ABS (DIAGNOSTICS)

1

I

i r

I

3

~

IO

Step

Check

CHECK OUTPUT OF ABS SENSOR USING

SELECT MONITOR.

1)Select "Current data display & Save" on the select monitor.

2)Read the ABS sensor output corresponding to the faulty system in the select monitor data display mode.




Ioes the speed indicated on he display change in response o the speedometer reading luring acceleration/decelera- ion when the steering wheel is

n

the straight-ahead position? s there poor contact in con- lectors between ABSCM&H/U ind ABS sensor? s the car telephone or the vireless transmitter properly nstalled?

~~

Yes

io to step 2. iepair the con- lector. i o to step 4.

.


4re noise sources (such as an mtenna) installed near the iensor harness? istall the noise

Is the gap within the specifica-

!ions? l e sensor har- less.

So to step

6.




3)Measure the resistance between shield connector and chassis ground.


DTC 26 / (B200) No. 11

-

ground:

DTC 28 / (8200) No. 3

- s the resistance less than 0.5

3?

NOTE:


Go to step

6.

CHECK ABSCM&HIU.


2)Erase the memory.





s the same diagnostic trouble

:ode as in the current diagnosis still being output?


:odes being output?

3eplace the

4BSCM&H/U.

:Ref. to ABS-7,

4BS Control Mod- rle and Hydraulic

2ontrol Unit

ABSCM&H/U).>

'roceed with the iiagnosis corre-

;ponding to the iiagnostic trouble

:ode.

4re the ABS sensor installation iolts tightened securely?

;o to step 9.



32 N.m (3.3 kgf-m, 24 ft-lb)



Front wheel

0.3

-

mm (0.012

-

Rearwheel

0.7- 1.2" (0.028-0.047in)

;o to step 10.

No

i o to step

8.

So to step

3.

'roperly install the

:ar telephone or he wireless trans- nitter.

;o to step 5.

3epair the shield iarness.

30

to step 7.

1

temporary noise nterference. righten the ABS sensor installation iolts securely.

4djust the gap.

VOTE:

4djust the gap us. ng spacer (Par

10.

26755AA000) f spacers canno

:orrect the gap, re- ilace the worn sensor or worn

:one wheel.



30

to step 11.

ABS-I 13



1

2

3

4

5

6

Step


1)Raise all four wheels of ground.




5)Rotate the wheels and measure voltage at specified frequency. <Ref. to ABS-I

FORM, Control Module

110

Signal.>

NOTE:



Connector

&

terminal

DTC 22 /(F95) NO. 1

(+)

DTC 24

/

NO. 1

(+)

DTC 26/(899) NO. 9

(+)

DTC 28

/

NO. 4

(+)

-

2

(-):

-

-

70 (-):

5 (-):

CHECK CONTAMINATION

OF

OR TONE WHEEL.

Remove the disc rotor or drum from hub in accordance with diagnostic trouble code.


TONE WHEEL.

Check s

the oscilloscope pattern mooth, as shown in the fig-

Ire?

s

the ABS sensor piece or the

one

wheel contaminated by lirt or other foreign matter?

Ire there broken or damaged n the ABS sensor piece or the one wheel?



CHECK RESISTANCE OF ABS SENSOR.



3)Measure the resistance between ABS sensor connector terminals.

Terminal

Front RH No.

1

Front LH

No. 1 -No.

2:

Rear RH No. 1

Rear LH No. 1

-

-

2:

2:

CHECK GROUND SHORT OF ABS SENSOR

Measure the resistance between ABS sensor and chassis ground.

Terminal

Front RH


Rear RH

Rem LH

No. 1

-

No.

1

No.

1



-


-

-

s

the runout less than

0.05

nm (0.0020 in)?

s

the resistance between 1

n d 1.5 kR?

s

the resistance more than 1

VIR?

Yes

-horoughly emove dirt or

Ither foreign mat- e r. leplace the ABS iensor or tone vheel. Front: <Ref.

3

ABS-1 4, Front

iBS Sensor.> lear: <Ref. to iBS-18, Rear

\BS Sensor.> ind Front: <Ref.

3

ABS-21, Front one Wheel.> lear: <Ref. to rBS-22, Rear one Wheel.>

;o to step 15.

i o to step 16.

30

to step 13.

leplace the tone vheel. Front:

:Ref. to ABS-21,

:rant

Tone

Yheel.> Rear:

:Ref. to ABS-22, lear Tone

Yheel.> leplace the ABS lensor. Front:

:Ref. to ABS-14,

:rant ABS Sen-

;or.> Rear: <Ref.

Q

ABS-1 8, Rear

iBS Sensor.>

i o to step

17.

No

So to step 12.

leplace the ABS

;ensor. Front:

:Ref. to ABS-I 4,

:rant ABS Sen-

,or.> Rear: <Ref.

3

ABS-I 8, Rear

iBS Sensor.>

ABS-I 14

0

1

7

8

9

2

13

!4

15


ABS

/DIAGNOSTICS)

Step

Check

CHECK HARNESS/CONNECTOR BETWEEN

ABSCM&H/U AND ABS SENSOR.



H/U.

3)Measure the resistance at ABSCM&H/U connector terminals.

Connector

&

terminal

DTC 22/(F49) NO. 11

-

-

NO. 12:

DTC 24

/

(F49) No. 9

DTC 26

/

No. 10:

-

15:

DTC 28

/

(F49) NO. 7

s the resistance between 1

3nd 1.5

kR?




DTC 22

/

(F49) No. 11

DTC 24

/

DTC 26

/

DTC 28

/

-

-

-



s the resistance more than 1

WR?


Measure the resistance between ABSCM&H/U


D?

And chassis ground.


(F49) NO. 23

-


Is there poor contact in connectors between ABSCM&H/U and ABS sensor?


Is the car telephone or the vvireless transmitter properly installed?

Yes

io to step 18. io to step 19. i o to step 20. iepair the con- lector.



No

iepair harness/ onnector letween rBSCM&H/U and rBS sensor. iepair harness/ onnector letween rBSCM&H/U and iBS sensor. iepair the

\BSCM&H/U iround harness. io to step 21. i o to step 22. istall the noise ources apart from l e sensor har- less. i o to step 24.

'roperly install the

:ar telephone or he wireless trans- nitter. to step 23.

3epair the shield tarness.



2)Measure the resistance between shield connector and chassis ground.

Connector

&

terminal

DTC 26

/

11

-

ground:

DTC 28

/


NOTE:


Go to step 24.

CHECK ABSCM&HN.


2)Erase the memory.






Are other diagnostic trouble codes being output? ieplace the

\BSCM&H/U.

:Ref. to ABS-7,

IBS Control Mod- ile and Hydraulic

:ontrol Unit

ABSCM&H/U) .>

'roceed with the liagnosis corre-

,pending to the liagnostic trouble

:ode.

20

to step 25.

4

temporary noise nterference.

ABS-I 15



ABS-I 16


ABS (DIAGNOSTICS)

K: DTC29

ABNORMAL ABS SENSOR SIGNAL ON ANY ONE OF FOUR SENSOR

DIAGNOSIS:

Faulty ABS sensor signal (noise, irregular signal, etc.)

Faulty tone wheel

Wheels turning freely for a long time


ABS

does not operate.

3

ABS-I 17



WIRING DIAGRAM:

FRONT

ABS

SENSOR LH


1

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

5

\

E

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

!

@

I

SENSOR RH

1

1

I

@

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

--

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I r .

1

I

I,

,

.

I

I

I

I

I

.

I

I

:-

I

@

I

I

E f

I

I

5 -

k

I,'

,

I

I

I I

I-

I I

I

I I

I

I I

I

I I

I

I I

I

I

SHIELD JOINT

I

I

_ .

- .

I

CONNECTOR

1

I

F

I

I

I

I

5 -

'L

I

J-r

I

I

I

I

I

1

REAR

ABS

SENSOR LH

REAR

ABS

SENSOR RH

0R0084

ABS-I 18


ABS

(DIAGNOSTICS)

?

I

I

I

I i

Step

CHECK IF THE WHEELS HAVE TURNED

FREELY FOR A LONG TIME.

CHECK TIRE SPECIFICATIONS.


CHECK WEAR OF TIRE.

CHECK TIRE PRESSURE.

CHECK INSTALLATION

OF

ABS SENSOR.


32 N.m (3.3 kgf-m,

24 fl-lb)



Front wheel

0.3

-

mm

(0.012

-

Rear wheel

0.7

-

mm

(0.028

-

in)


Check

Yes

No

Check if the wheels have been turned freely for more than one

The ABS is normal. Erase the minute, such as when the vehicle is jacked-up, under full-lock diagnostic trouble code. cornering or when tire is not in contact with road surface.

NOTE:

When the wheels tum freely for a long time, such as when the vehicle is towed or jacked- up, or when steering wheel is contin- uously turned all the way, this diagnostic trouble code may sometimes occur.

30

to step 2.

Go to step

3.

Replace the tire.

Are the tire specifications correct?

Is

the tire worn excessively?

Is the tire pressure correct?

Replace the tire.

Go to step 5.

Go to step

4.

Adjust the tire pressure.

Are the ABS sensor installation bolts tightened securely?

Go to step 6.

Is the gap within the specifications?

Go to step 7.


Adjust the gap.


Go to step 8.

NOTE:

Adjust the gap us ing spacer (Par

No. 26755AAOOO)

If spacers canno correct the gap, re place the

won

sensor or wori tone wheel.

Go to step 9.

ABS-1 19


ABS (DIAGNOSTICS)

~~

I

I

0

1

2

3

~~ ~ ~~~~ ~~~

Step


1)Raise all four wheels of ground.


3)Connect the oscilloscope to the connector

(B99), (F95) or (F94) in accordance with trouble code.


5)Rotate the wheels and measure voltage at specified frequency. <Ref. to ABS-17, WAVE-


NOTE:




Front RH

(F95) NO. 1 (+)

-

(-):

Front LH

(F94) NO. 1 (+)

-

2

) (

Rear RH

(699) NO. 9 (+)

-

10

I (

Rear LH

(699) NO. 4 (+)

-

5

(-):

OF ABS SENSOR

OR TONE WHEEL.

Remove the disc rotor from hub.

3s

shown in the figure?


TONE WHEEL.

No

;o to step 9. s the ABS sensor piece or the one wheel contaminated by lirt or other foreign matter?

Thoroughly remove dirt or other foreign matter.

4re there broken or damaged eeth in the ABS sensor piece i r the tone wheel?

Replace the ABS sensor or tone wheel. Front: <Ref. to ABS-14, Front

ABS Sensor.>

Rear: <Ref. to

ABS-18, Rear

ABS Sensor.> and Front: <Ref. to ABS-21, Front

Tone Wheel.>

Rear: <Ref. to

ABS-22, Rear

I

Tone Wheel.>

30

to step 10. so to step 11.



~




3)Erase the memory.




BLE

CODES APPEARANCE.

nm (0.0020 in)? wheel. Front:

<Ref. to ABS-21,

Front Tone

Wheel.> Rear:

<Ref. to ABS-22,

Rear Tone

Wheel.> s the same diagnostic trouble Replace the

:ode as in the current diagno- ABSCM&H/U.

;is still being output? <Ref. to ABS-7,


Control Unit

(ABSCM&H/U).>

Go to step 13. ire other diagnostic trouble Proceed with the

:odes being output? diagnosis corresponding to the diagnostic trouble code.



ABS (DIAGNOSTICS)

L: DTC31

FRONT RIGHT INLET VALVE MALFUNCTION

NOTE:

For the diagnostic procedure, refer to DTC 37. <Ref. to ABS-121, DTC 37 REAR LEFT INLET VALVE MAL-


M: DTC33

FRONT LEFT INLET VALVE MALFUNCTION

NOTE:



N: DTC35

REAR RIGHT INLET VALVE MALFUNCTION

NOTE:



0: DTC37

REAR LEFT INLET VALVE MALFUNCTION

DIAGNOSIS:


Faulty inlet solenoid valve



I

ABS-I 21


ABS (DIAGNOSTICS)

WIRING DIAGRAM:

BATTERY

ABS-I 22

2

3

I

1

5

6

7

B

9 l o



~

Step

CHECK INPUT VOLTAGE OF RELAY HOLD

ER.


OFF.

2)Remove the fuse.



(8225)

No. 5 (+)

-



1)lnstall the fuse.





(8264) No. 2

(+)

-



Connector

&

terminal

(8264)

No. 1 (+)

CHECK GROUND CIRCUIT OF ABS RELAY




(8264) No. 3

(+)

-



No. 1 and 3.


CHECK INPUT VOLTAGE OF ABSCM&WU.



H/U.




(F49)

No. 1 (+)

-





Connector

&

terminal

(F49) No. 23

-


CHECK ABSCM&WU.


2)Erase the memory.



Check


Yes

30

to step

2.



3eplace the fuse.

30

to step

4.


30

step

5.


a?


Q?

Is the voltage between 10 and

15

V?


Q?

Isthere poorcontact in connectors between generator, battery and ABSCM&H/U?


30

step

6.

30

step

7.

Go to step 8.

Go to step 9.


No

Repair open circuit in harness setween battery snd relay holder sonnector.

Go to step

3.

Repair open circuit in harness between battery and relay holder sonnector.


ABS relay.




ABSCM&H/U.

Repair the


Go to step 10.

Replace the

ABSCM&H/U.

<Ref. to ABS-7,


Control Unit

(ABSCM&H/U).>

Go to step 11.

ABS-I 23

m



11

Step



Check Yes No

Are other diagnostic trouble

Proceed with the A temporary poor codes being output? diagnosis corre- contact. sponding to the diagnostic trouble code.

ABS-1 24



P: DTC32

FRONT RIGHT OUTLET VALVE MALFUNCTION

NOTE:

For the diagnostic procedure, refer to DTC 38. <Ref. to ABS-125, DTC 38 REAR LEFT OUTLET VALVE

MALFUNCTION, Diagnostics Chart with Subaru Select Monitor.>

Q:

DTC34

FRONT LEFT OUTLET VALVE MALFUNCTION

NOTE:



R: DTC36

REAR RIGHT OUTLET VALVE MALFUNCTION

NOTE:



S: DTC38

REAR LEFT OUTLET VALVE MALFUNCTION

DIAGNOSIS:


Faulty outlet solenoid valve



m

ABS-I 25


ABS IDIAGNOSTICS)

WIRING DIAGRAM:

BATTERY

I

n

RELAY

HOLDER

ABS

RELAY

B

I

@

ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT

I

I

11213141

n

101111121131 14

I

I

15

116117118119120

m

BR0085

ABS-1 26

I



~

Step

CHECK INPUT VOLTAGE OF RELAY HOLD

ER.


2)Remove the fuse.



(6225) No. 5

(+)

-


Check


Yes

Go to step 2.

Is the fuse blown out? Replace the fuse.


V? Go to step 4.


1)lnstall the fuse.





(6264) No. 2

(+)

-



Connector

&

terminal

.

(6264) No. 1

(+)

-


OF

ABS RELAY



Connector

&

terminal

(6264) No. 3

(+)


V?

Go to step

5.

Is the resistance less than 5 n?

Go to step 6.

Is

the resistance less than 10 n?

Go to step 7.



No. 1 and 3.


CHECK INPUT VOLTAGE OF ABSCM&WU.



H/U.



Connector

&

terminal

(F49)

No. 1 (+)


OF

ABSCM&H/U




Connector & terminel

(F49) No. 23

-


CHECK ABSCM&W.


2)Erase the memory.




15

V?

Is

the resistance less than

0.5 n?


Is

the same diagnostic trouble code as in the current diagnosis still being output?

Go to step 0.


No


Go to step

3.



ABS relay.

Repair open circuii between ABS relay and chassis ground.



ABSCM&H/U.


Go to step 10.

Replace the

ABSCM&H/U.

<Ref. to ABS-7,


Control Unit

(ABSCM&H/U).>

Go to step

11.

ABS-I 27




Check

codes being output? diagnosis corresponding to the diagnostic trouble code. contact.

ABS-1 28


ABS

(DIAGNOSTICS)

ABS-I 29


ABS

(DIAGNOSTICS)

T: DTC41

ABS CONTROL MODULE MALFUNCTION

DIAGNOSIS:

Faulty ABSCM&H/U


ABS does

not operate.

WIRING DIAGRAM:

ABS

CONTROL MODULE AND


I

ABS-I 30

B4M1457

2

3

I

1

5

6


ABS

(

D I AG NOSTl C S)

~

Step Check




H/U.



Connector 81 terminal

(F49) No. 23

-

ground:


R?


Is there poor contact in connectors between battery, ignition switch and ABSCM&H/U?


Is the car telephone or the wireless transmitter properly installed?


CHECK ABSCM&WU.



3)Erase the memory.





Yes

to step 2.


No

Repair the


Go to step

3.


~



;o

to step 4. Properly install the car telephone or the wireless transmitter.

Go to step 5. nstall the noise

;ources apart from he sensor har- less. qeplace the iBSCM&H/U.

:Ref. to ABS-7,


;ontrol Unit

ABSCM&H/U).>

Voceed with the liagnosis corre- iponding to the liagnostic trouble

:ode.

Go to step 6.

A


3

ABS-1 31


ABS

(DIAGNOSTICS)

U: DTC42

POWER SUPPLY VOLTAGE TOO LOW

DIAGNOSIS:

Power source voltage of the ABSCM&H/U is low.

TROUBLE

SYMPTOM:


WIRING DIAGRAM:

BATTERY

R E LAY

HOLDER

ABS

RELAY

ABS-I 32

BR0085

I

b i

!

I

?

I



Step


1)Start the engine.



Terminal

Generator B terminal

-



Check


I5 V?



H/U.




(F49) No. 1 (+)

-





\re the positive and negative iattery terminals tightly

Aamped? s the voltage between 10 and

I5 V? s the resistance less than 0.5

n?

Yes

;o

to step

2.

30

to step

3.

;o to step 4. i o to step

5.

No


13, Generator.>

Tighten the clamp of terminal.

Repair harness connector between battery, ignition switch anc

ABSCM&H/U.

Repair the


(F49) No. 23

-




2)Erase the memory.


4)Read out the diagnostic trouble code. s there poor contact in con- lectors between generator, iattery and ABSCM&H/U? s the same diagnostic trouble





\re other diagnostic trouble

:odes being output?


Go to step 6.

3eplace the

4BSCM&H/U.

:Ref. to ABS-7,


;ontrol Unit

ABSCM&H/U).>

Go to step

7.

'roceed with the jiagnosis corre- iponding to the iiagnostic trouble

:ode.


ABS-I 33


ABS

(DIAGNOSTICS)

V: DTC42

POWER SUPPLY VOLTAGE TOO HIGH

DIAGNOSIS:

Power source voltage of the ABSCM&H/U is high.


ABS does not operate.

WIRING DIAGRAM:

RELAY

HOLDER

ABS

RELAY

I

ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT

I

i l 2 1 3 1 4 l

n

101111121131 14

I

15 116117]18]19]20

ABS-1 34

0R0005

I

I

I

3 i

I lo



~

Step

Check


1)Start the engine.



Terminal

Generator 6 terminal

-


Turn the ignition switch to

OFF. s the voltage between 10 and

7

V?

ire the positive and negative

Iattery terminals tightly

:lamped?

Yes

30

to step 2.

30

to step

3.


ER.


2)Remove the fuse.



(6225) No. 5

(+)

-


s the voltage more than 10

V?

s the fuse blown out?


1)lnstall the fuse.



ON.


Connector

&

terminal

(8264) No. 2

(+) s the voltage more than 10 V?


Measure the voltage between ABS relay connector and chassis ground. s the voltage more than 10

V?


(8264) No.

1

(+)

-


OF

ABS RELAY.


2)Measure the resistance between ABS relay s the resistance less than

5

R?

connector and chassis ground.

Connector

&

terminal

(6264)

No.

3

(+)

-



No. 1 and 3.

2)Measure the resistance between ABS relay terminals. s the resistance less than 10

R?


17 V?



HIU.



Connector

&

terminal

(F49)

No. 1 (+)


R?





Connector

&

terminal

No.

23

30

to step

4.

3eplace the fuse.

So to step 6.

So to step 7.

Go to step 8.

Go to step 9.

Go to step 10.

Go to step 11.

No


13, Generator.>

Tighten the clamp of terminal.

Repair open circuit in harness between battery and Relay holder connector.

Go to step

5.

Repair open circuil in harness between battery and Relay holder connector.


ABS relay.

Repair open circui' between ABS relay and chassis ground.


Repair harness connector between battery, ignition switch anc

ABSCM&H/U.

Repair the


ABS-1 35



11

12

13

Step


1

)Connect all connectors.

2) E rase the memory.



Check







Yes


Replace the

ABSCM&H/U.

<Ref. to ABS-7,

ABS

Control Mod- ule and Hydraulic

Control Unit

(ABSCM&H/U).>


Go

No

to step

12.

Go to step 13.


ABS-I 36


ABS (DIAGNOSTICS)

ABS-I 37



W: DTC44

ABS-AT CONTROL (NON CONTROLLED)

DIAGNOSIS:

Combination of

AT

control faults


ABS

does not operate.

WIRING DIAGRAM:

c

A: 854

8 :

8

655 TCM

ABS-I 38

BR008f

~

1

2

3

4

5

6

7

8


ABS (DIAGNOSTICS)

Step

CHECK SPECIFICATIONS OF THE AB-

SCM&H/U

.


ABSCM&H/U.

CC: AT

CD: MT

Check

s an ABSCM&H/U for AT model installed on a MT nodel?

Yes

Replace the

ABSCM&H/U.

<Ref. to ABS-7,


Control Unit

(ABSCM&H/U).>

Go to step

3.

No

Go to step 2.





H/U.



Connector

&

terminal

(F49) 3

-

ground:

CHECK TCM.



3)Measure the voltage between TCM connec-

,tor terminal and chassis ground.

Connector

&

terminal

NON-TURBO MODEL:

(854) No. 19

(+)

-

TURBO MODEL:

(B55)

No. 21 (+)

-

CHECK AT.


MQ?


15 V?

Go to step 5.


ABSCM&H/U.

Go to step 4.

CHECK OPEN CIRCUIT OF HARNESS.



(F49) 3

(+)

31

(+)

-

-

Is the AT functioning normally? Replace the TCM.

Is the voltage more than

IO

V?


Is there poor contact in connectors between TCM and

ABSCM&H/U?

Go to step

6.


Repair the AT.

Repair harness/ connector between TCM and

ABSCM&H/U.

Go to step

7.

CHECK ABSCM&HN.

2)Erase the memory.







Replace the

ABSCM&H/U.

<Ref. to ABS-7,


Control Unit

(ABSCM&H/U).>

Go to step 8.



ABS-I

39


ABS (DIAGNOSTICSI

X: DTC44

ABS-AT CONTROL (CONTROLLED)

DIAGNOSIS:

Combination of AT control faults


ABS does

not operate.

WIRING DIAGRAM:

: TURBO ENGINE MODEL

a

z

m

+

m

7

a

T

(u

m

BR0086

ABS-I 40

t

2

3

6

Q

5



Step





HIU.



(F49) No.

3

(+)

-





(F49) No. 3

(+)

-

Check


Is the voltage less than 1

V?

CHECK OPEN CIRCUIT OF HARNESS.




4)Measure the voltage between ABSCM&H/U


13 V? connector and chassis ground.


(F49) No. 3

(+)

(F49)

No.

31

(+)

-

-



Turn the ignition switch to OFF. nectors between TCM and

ABSCM&H/U?



2)Erase the memory.







Yes

Go to step 2.

Go to step

3.

Go to step 4.

Repair the con- qector.

No


ABSCM&H/U.


ABSCM&H/U.

Re pair harness/ connector between TCM and

ABSCM&H/U.

Go to step

5.

Replace the

ABSCM&H/U.

<Ref. to ABS-7,


Control Unit

(ABSCM&H/U).>

Go to step

6.

Proceed with the diagnosis corresponding to the diagnositc trouble code.


ABS-1 41



ABS-1 42

i



Y: DTC51

VALVE RELAY MALFUNCTION

DIAGNOSIS:

Faulty valve relay


ABS does not operate.

3

ABS-1 43


ABS

(DIAGNOSTICS)

WIRING DIAGRAM:

SBF-1

BATTERY

( 3 c m

0 z

RELAY

t

U.

m r

IGNITION

P

I

SWITCH

r

1 r!l

I

-

I '

t I I I I I I I I I

I

I

I

rl



BR0087

ABS-1 44

2

3

5

6

7

B

I

1

9

10


ABS

(DIAGNOSTICS)

~~ ~

Step

Check



ER.


2)Remode the fuse.



No.

5

(+)

-





OF

ABS RELAY.

1)lnstall the fuse.





No.

(+)


V?



.


(6264) 1

(+)

-



Is

the resistance less than 5

a?



No.

3

(+)

-



No. 1 and 3.



Q?


15 V?




HIU.




No.

1

(+)

-

No.

(+)

-





Connector

&

terminal


Q?

Yes

30

to step 2.

3eplace the fuse.

30

step 4.

30

5.

So to step

6.

So to step 7.

Go to step 8.

Go to step 9.

No

3epair open circuit n harness ietween battery

3nd Relay holder

:onnector.

So to step

3.

Repair open circuit in harness between battery snd Relay holder sonnector.


ABS relay.



Repair harness connector between battery and ABSCM&H/U.

Repair the


CHECK POOR CONTACT IN CONNECTORS




2)Erase the memory.





Go to step 10.

Replace the

ABSCM&H/U.

<Ref. to ABS-7,

ABS Control Mod-

Go to step 11. ule and Hydraulic

Control Unit

(ABSCM&H/U).>

ABS-I 45

3



11

Step



codes being output? diagnosis corresponding to the diagnostic trouble

code.

contact.

ABS-1 46



Z: DTC

51

VALVE RELAY ON FAILURE

DIAGNOSIS:

Faulty valve relay


ABS

does not operate.

I

ABS-I 47


ABS (DIAGNOSTICS)

WIRING DIAGRAM:

RELAY

HOLDER

SBF-3 SBF-1

T

- i

IGNITION

R A T T F R Y

SWITCH



I

ABS-1 48

I

M

BR0087

I

2

3

I


ABS

IDIAGNOSTICS)

~

Step

Check

CHECK VALVE RELAY IN ABSCM&HIU.


Terminals

NO.

23

-

24

(-):

,s the resistance more than 1 wn?

~~

Yes

Go to step 2.

No

3eplace the

4BSCM&H/U.

:Ref. to ABS-7,

9BS Control Mod-

Jle and Hydraulic

Zontrol Unit

:ABSCM&H/U).>





2)Erase the memory.








30

step

3.

Replace the

ABSCM&H/U.

<Ref. to ABS-7,


Control Unit

(ABSCM&H/U).>


30

step 4.

A


-

ABS-I 49

I


ABS

(DIAGNOSTICSI

ABS-I 50



AA:DTC 52

OPEN CIRCUIT IN MOTOR RELAY CIRCUIT

DIAGNOSIS:

Faulty motor

Faulty motor relay



ABS does

not operate.

=

ABS-I 51


ABS

(DIAGNOSTICS)

WIRING DIAGRAM:

BATTERY

S B F - l

, m

1)

a

T

=

ABS RELAY 8225

1



1

ABS-I 52

4

5

1

2

3

6


ABS

(DIAGNOSTICS)

Step




H/U.



Connector

&

terminal

(F49)

No.

25

(+)

-






(F49) No. 26

-




NOTE:

Use the diagnosis connector to operate the se, quence control.

Check


13 V?


Q?

~~

Yes

30

step 2.

Go to step

3.

Can the motor revolution noise

(buzz) be heard when carrying out the check sequence?

Go to step 4.

~

No


SBFG.

Repair the


Replace the

ABSCM&H/U.

<Ref. to ABS-7,


Control Unit

(ABSCM&H/U).>

Go to step 5.

%HECK POOR CONTACT IN CONNECTORS




2)Erase the memory.



Is there poor contact in connector between hydraulic unit, relay box and ABSCM&H/U?






Replace the

ABSCM&H/U.

<Ref. to ABS-7,


Control Unit

(ABSCM&H/U).>


Go to step

6.


I

ABS-I 53



ABS-I 54

E

1

f

I



AB:DTC 52

MOTOR RELAY ON FAILURE

DIAGNOSIS:

Faulty motor

Faulty motor relay



ABS

does not operate.

I

ABS-1 55



WIRING DIAGRAM:

-

a

SBF-1

3 c

-



r

n

L

MOTOR RELAY

VALVE RELAY

ABS-I

56

!k

3 a

I I I

'd

1

2

5

I

3

1


ABS (DIAGNOSTICS)

Step

CHECK MOTOR RELAY IN ABSCM&H/U.


Terminals

NO.

25

-

26:




NOTE:

Use the diagnosis connector to operate the se quence control.

Check


No

?eplace the

4BSCM&H/U.

:Ref. to ABS-7,

4BS Control Mod-

Jle and Hydraulic

Zontrol Unit

:ABSCM&H/U).>

Replace the

4BSCM&H/U.

<Ref. to ABS-7,

4BS Control Mod- de and Hydraulic

Zontrol Unit

(ABSCM&H/U).>



Is there poor contact in connector between hydraulic unit, relay box and ABSCM&H/U?

CHECK ABSCM&HN.


2)Erase the memory.








Go to step 4.

Replace the

ABSCM&H/U.

<Ref. to ABS-7,


Control Unit

(ABSCM&H/U).>

Go to step 5.


A


m

ABS-I 57

1



ABS-I 58

r

t

I i



AC:DTC 52

MOTOR MALFUNCTION

DIAGNOSIS:

Faulty motor

Faulty motor relay



ABS does

not operate.

I

ABS-1 59


ABS (DIAGNOSTICS)

WIRING DIAGRAM:

SBF-1

9

!

I

T r

I

m

I

I I I I I

I d



--

VALVE RELAY MOTOR RELAY

I

11213141

n

10]11]121131 14

I

15

ABS-I 60

3 a

T

'Q

I

I

1



Step




Check


13 V?




(F49)

No.

(+)

-






(F49) No.

-


R?





(F49)

No,

(+)

-





15 V?

.CHECK GROUND CIRCUIT OF ABSCM&H/U.



R?




(F49) No.

-

Can the motor revolution noise


NOTE:

Use the diagnosis connector to operate the se. quence control.

~~

Yes

to step

2.

to step

3.

to step 4. to step 5. to step 6.

~~

NO


SBFG.

Repair the



ABSCM&H/U.

Repair the


Replace the

ABSCM&H/U.

<Ref. to ABS-7,


Control Unit

CHECK POOR CONTACT IN CONNECTORS,


Turn the ignition switch to OFF. nector between generator, battery and ABSCM&H/U?



2)Erase the memory.







Dair the con-

:tor.

Go to step 7.

Aace the

SCM&H/U. ef. to ABS-7,

S Control Mod- and Hydraulic itrol Unit

ECM&H/U).> ceed with the gnosis corre- mding to the gnostic trouble le.

Go to step 8.


ABS-I 61


ABS

(DIAGNOSTICS)

AD:DTC 54

STOP LIGHT SWITCH SIGNAL CIRCUIT MALFUNCTION

DIAGNOSIS:

Faulty stop light switch


ABS

does not operate.

WIRING DIAGRAM:

BATTERY m

STOP LIGHT

SWITCH


HYDRAULIC CONTROL UNIT i l 2 1 3 I T l n

101111121131 14

I

15 ]16117118]19120

BR0089

ABS-1 62


ABS

(

D I AG NOSTl CS)

I

2

r

5

5

3

I

Step

Check

CHECK OUTPUT OF STOP LIGHT SWITCH

USING SELECT MONITOR.


2)Release the brake pedal.

3)Read the stop light switch output in the select monitor data display.

CHECK OUTPUT OF STOP LIGHT SWITCH

USING SELECT MONITOR.


2)Read the stop light switch output in the select monitor data display.

CHECK IF STOP LIGHTS COME ON.

Depress the brake pedal.

Is the reading indicated on monitor display less than 1.5

V?

Is the reading indicated on monitor display between 10 and 15 V?

Do stop lights turn on?

CHECK OPEN CIRCUIT IN HARNESS.



H/U.


4)Measure the voltage between ABSCM&H/U

.connector and chassis ground.

Connector

&

terminal

(F49) No. 2

-



15 V?

CHECK ABSCM&HRI.


2)Erase the memory.



Is there poor contact in connector between stop light switch and ABSCM&H/U?





Yes

Go to step 2.

Go to step

5.

Go to step 4.

Go to step 5.


Replace the

ABSCM&H/U.

<Ref. to ABS-7,


Control Unit

(ABSCM&H/U).>


No

30

to step

3.

30

step

3.

3epair the stop ights circuit.

3epair harness

Detween stop light switch and

4BSCM&H/U con- lector.

30

step 6.

30

step 7.

4 temporary poor

:ontact.

ABS-1 63


ABS (DIAGNOSTICS)

ABS-I 64


ABS

(DIAGNOSTICS)

AE:DTC

56

OPEN OR SHORT CIRCUIT IN G SENSOR CIRCUIT

DIAGNOSIS:




ABS-I 65


ABS

(DIAGNOSTICSI

WIRING DIAGRAM:


\

@


I

I

I

2

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

~

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I t

SHIELD JOINT

CONNECTOR

I

I

I

I

1

7 -

ABS

G

SENSOR

BR0090

ABS-1 66


ABS

(DIAGNOSTICS)

T j

!

I

I

i i

Step

Check

CHECK OUTPUT OF G SENSOR USING SE-

LECT MONITOR.


2)Read the G sensor output in select monitor data display.

Is the G sensor output on the monitor display between 2.1 and 2.5

V

when the G sensor is in horizontal position?


Is there poor contact in con- nectar between ABSCM&H/U and G sensor?



2)Erase the memory.







Yes

to step

2.

Iepair the con- lector.


OF

G SENSOR.



3)Disconnect the G sensor from body. (Do not disconnect connector.)


ON.


Is

the voltage between 4.75 and 5.25

V?


(8292) NO.

1 (+)

-

CHECK OPEN CIRCUIT IN G SENSOR OUT-


Is

the resistance between 4.3 and 4.9 kR?



H/U.



Connector

&

terminal

(F49)

NO. 6

-

IS

the resistance more than 1

MR?

CHECK GROUND SHORT IN G SENSOR

OUTPUT HARNESS.




Connector

&

terminal

(F49)

No. 6

CHECK G SENSOR.


Is

the voltage between 2.1 and

2.5

V

when G sensor is hori-



.

4)Measure the voltage between G sensor con- zontal? nector terminals.

Connector

&

terminal

(8292) NO. 2

(+)

-

3

30

to step 7.

30

to step 8.

30

to step 9.

No

Go to step

5.

Go to step

3.

3eplace the

4BSCM&H/U.

:Ref. to ABS-7,


:ontrol Unit

ABSCM&H/U).>

Go to step

4.

’roceed with the fiagnosis corre- iponding to the iiagnostic trouble

:ode.

A


30

to step

6.

Repair harness/ connector between G sensoi and ABSCM&H/U


Repair harness between G sensoi and ABSCM&H/U



ABS-I 67



9

10

11

12

13

Step

CHECK G SENSOR.



(6292) NO. 2

(+)

-

Check


4.1 V when G sensor is inclined forwards to go"?

CHECK G SENSOR.



(6292) NO. 2

(+)

-

3


0.9 V when G sensor is inclined backwards to go"?



Turn the ignition switch to OFF. nector between ABSCM&H/U and G sensor?



2)Erase the memory.





.


I


Yes

Go to step 10.

Go to step 11.


No


ABS-23, G Sen- so r.

>



>

Go to step 12.

Replace the

ABSCM&H/U.

<Ref. to ABS-7,


Control Unit

(ABSCM&H/U).>

Go to step 13.



ABS-1 68

DIAGNOSTICS CHART

WITH SUBARU SELECT MONITOR


~

AF:DTC

56

BATTERY SHORT IN

G

SENSOR CIRCUIT

DIAGNOSIS:




ABS-I 69



WIRING DIAGRAM:

ABS CONTROL MODULE AND


SHIELD JOINT

CONNECTOR

+g

8200

L

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I t

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

3

0

U

BS

NSOR

P

11213141 n

101111121131 14

17 18 19

I

15 116117[18119120

BR0090

ABS-I 70

!

I

I

i i

T

5

B

IO

I1



~

~~

Step

~

Check

CHECK OUTPUT OF G SENSOR USING

SE-

5

the G sensor output on the

LECT MONITOR.

ionitor display between 2.1

1)Select “Current data display & Save” on the n d 2.5 V when the

G sensor select monitor.

j

in horizontal position?

2)Read the G sensor output in select monitor data display.


5

there poor contact in con- lector between ABSCM&H/U ind G sensor?


3

the same diagnostic trouble


2)Erase the memory.





ire other diagnostic trouble

:odes being output?

Yes

;o

to step

2.


No

Go to step 5.

Go to step

3.

3eplace the

4BSCM&H/U.

:Ref. to ABS-7,

4BS

Control Mod- ile and Hydraulic

2ontrol Unit

ABSCM&H/U) .>

Go to step

4.

A


’roceed with the iiagnosis corre- iponding to the liagnostic trouble

:ode.

50

to step 6.

Go to step 16.

CHECK FREEZE FRAME DATA.

1)Select “Freeze frame data” on the select monitor.

2)Read the front right wheel speed on the select monitor display.


Read the front left wheel speed on the select monitor display.


Read the rear right wheel speed on the select monitor display.


Read the rear left wheel speed on the select monitor display.


Read the G sensor output on the select monitor display.

CHECK OPEN CIRCUIT IN G SENSOR OUT.



2)Disconnect the connector from ABSCM8

H/U.




-

28:



OFF.

2)Remove the console

box.



H/U.

5)Measure the voltage between ABSCM&

H/U connector and chassis ground.

Connector

&

terminal

(F49)

No.

6

(+)

-

ground

(-):

s

the front right wheel speed

In monitor display 0 km? s the front left wheel speed on nonitor display 0 km? s the rear right wheel speed

)n monitor display 0 km? s the rear left wheel speed on nonitor display 0 km? s the G sensor output on mon- tor display more than 3.65

V?

20

to step 10. s the resistance between 4.3 ind 4.9 w1? s the voltage less than 1

V?

50

to step

7.

30

to step 8.

30

to step 9.

20

to step 11.

30

to step 12.

Go to step 16.

Go to step 16.

Go to step 16.

Go to step 16.


Repair harness between G senso and ABSCM&H/U

ABS-1 71


ABS

(DIAGNOSTICS)

12

13

14

15

16

17

18

19

!O

Step



ON.



No.

6

(+)

~~ ~

Check



Is there poor contact in connector between ABSCM&H/U and G sensor?

Yes

Go to step 13.


No


Go to step 14.



2)Erase the memory.







Replace the

ABSCM&H/U.

<Ref. to ABS-7,


Control Unit

(ABSCM&H/U).>

Go to step 15.


Go to step

17.

A temporary poor con tact.

Repair harness/ connector between G sensor and ABSCM&H/U.

CHECK INPUT VOLTAGE OF G SENSOR.



3)Disconnect the G sensor from body. (Do not disconnect connector.)




NO.

1

(+)

-





H/U.




NO.

-

Is the voltage between 4.75 and 5.25 V?

Is the resistance between 4.3 and 4.9 kn?

CHECK G SENSOR.






-


2.5 V when G sensor is horizontal?

CHECK G SENSOR.



-

3


3.7

4.1 V when G sensor is nclined forwards to 90°?

CHECK G SENSOR.



-

Go to step 18.

Go to step 19.

Go to step 20. s the voltage between 0.5 and

1.9 V when G sensor is nclined backwards to go"?

Go to step 21.






>



ABS-I 72

21

22

23



Step

I

Check






2)Erase the memory.







Yes


No

Go to step 22.

Replace the

ABSCM&H/U.

<Ref. to ABS-7,


Control Unit

(ABSCM&H/U).>

Go to step 23.



ABS-I73



ABS-1

74

Y

I


ABS (DIAGNOSTICS)

AG:DTC 56

ABNORMAL G

SENSOR HIGH

p

OUTPUT

DIAGNOSIS:



ABS does

not operate.



WIRING DIAGRAM:

@

ABS CONTROL MODULEAND


I

I

I

I

SHIELD JOINT

CONNECTOR

I

*

c

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I t

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

2

ABS

G

SENSOR

BR0090

ABS-I 76


ABS (DIAGNOSTICS)

,

I

~

Step


LECT MONITOR.


2)Read the G sensor output on the select monitor display.

Check

‘or display 2.3k0.2 V when the

: ion?





2)Erase the memory.





s there poor contact in con- lector between ABSCM&HlU ind G sensor? s the same diagnostic trouble



\re other diagnostic trouble

:odes being output? s the resistance between 4.3 ind 4.9 kR?


Replace the

ABSCM&H/U.

<Ref. to ABS-7,


Control Unit

(ABSCM&H/U).>


Go to step

6.




OFF.


HIU.




(F49)

NO.

6

-


Measure the resistance between ABSCM&HlU connector and chassis ground.

Connector

&

terminal

(F49)

No.

- s the resistance more than 1 m?

30 to step 7.

30

to step 8.

No

30

to step

6.

30

to step

3.

30

to step

4.

4 temporary poor

:ontact.

3epair harness1

:onnector

3etween G sensor m d ABSCM&H/U.

Repair harness

Detween G sensor m d ABSCM&H/U. aeplace

4BSCM&H/U.

<Ref. to ABS-7,

4BS Control Mod- ule and Hydraulic

Sontrol Unit

(ABSCM&H/U).

=.



CHECK G SENSOR.






6)Measure the voltage between

G sensor connector terminals.


(6292)

NO.

(+)

-

3

CHECK G SENSOR.


Connector

&

terminal

(8292)

NO.

(+)

-

3

s the voltage between 2.1 and

!.5 V when G sensor is hori- rontal? s the voltage between 3.7 and

&.I V when G sensor is nclined forwards to go”?


ABS-23, G Sen- so r. >

m

ABS-1 77

I



9

10

11

Step

CHECK G SENSOR.


Connector 8i terminal

(8292)

NO.

(+)

-

3

CHECK ABSCM&W.



3)Erase the memory.





Check

Yes


0.9 V when G sensor is inclined backwards to 90°?

Go to step 10.

No



Is the same diagnostic trouble Replace the code as in the current diagno- ABSCM&H/U. sis still being output? <Ref. to ABS-7,


Control Unit

(ABSCM&H/U).>

Are other diagnostic trouble Proceed with the codes being output? diagnosis corresponding to the diagnostic trouble code.

Go to step 11.


ABS-1 70



AH:DTC 56

DETECTION OF G SENSOR STICK

DIAGNOSIS:



ABS does

not operate.

ABS-I 79



WIRING DIAGRAM:

@



SHIELD JOINT

CONNECTOR

f

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

t

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

7

I

J

ABS

G SENSOR

BR0090

ABS-I 80


ABS (DIAGNOSTICS)

-

I

!

5

1

5

6

7

B

9

~

Step

CHECK ALL FOUR WHEELS FOR FREE

TURNING.

Check

lave the wheels been turned ireely such as when the vehicle s lifted up, or operated on a rolling road?


LECT MONITOR.

1)Select ”Current data display

8

select monitor.


Is the G sensor output on the monitor display between 2.1

2nd 2.5

V

when the vehicle is in horizontal position?


LECT MONITOR.



3)Remove the G sensor from vehicle. (Do not disconnect connector.)




Is the G sensor output on the monitor display between 3.7 and 4.1

V

when G sensor is inclined forwards to go”?


LECT MONITOR.

Read the select monitor display.

Is the

G sensor output on the monitor display between 0.5 and 0.9

V

when G sensor is inclined backwards to go“?

Yes

The ABS is nor- nal. Erase the jiagnostic trouble

:ode.

30

to step

3.

30 to step

4.

No

30

to step 2.

30

to step 8.

3eplace the G sensor. <Ref. to

465-23, G Sen- sor.>

20

to step

5.



Go to step 6.




Repair the con- lector.



2)Erase the memory.





code as in the current diagnosis still being output?


Replace the

4BSCM&H/U.

<Ref. to ABS-7,


Control Unit

(ABSCM&H/U).>

Go to step 7 .


Go to step 9.

A temporary contact. poor






H/U.



Is the resistance between 4.3 and 4.9

kR?


(F49)

NO. 6

-

28:

CHECK G SENSOR.






ON.

6)Measure the voltage between G sensor con-


2.5

V

when G sensor is horizontal? nector terminals.


(8292) NO. 2

(+)

-

Go to step 10. Replace the G sensor. <Ref. to


ABS-I 81

11

12

13


ABS

(DIAGNOSTICS)

10

Step

CHECK G SENSOR.



(8292) NO. 2

(+)

-

3

CHECK G SENSOR.

Measure the voltage between

G

sensor connector terminals.

Connector

&

terminal

(8292) NO. 2

(+)

-

3

CHECK ABSCM&W.



3)Erase the memory.





Check Yes

Is the voltage between 3.7 and Go to step 11.

4.1

V

when G sensor is inclined forwards to 90°?

Is the voltage between 0.5 and Go to step

12.

0.9

V

when G sensor is inclined backwards to 90°? sensor. <Ref. to

ABS-23, G Sen- sor.> sensor. <Ref. to


Is the same diagnostic trouble Replace the code as in the current diagno- ABSCM&H/U. sis still being output? <Ref. to ABS-7,


Control Unit

(ABSCM&H/U).>

Are other diagnostic trouble Proceed with the codes being output? diagnosis corresponding to the diagnostic trouble code.

Go to step 13.

A


I

ABS-I 82



14.General Diagnostics Table

A: INSPECTION

-~ dehicle instability during braking

Poor braking

Symptom

Vehicle pulls to either side.

Vehicle spins.

Long brakinglstopping distance

Wheel locks.

Brake dragging

Long brake pedal stroke

Vehicle pitching

Unstable or uneven braking

~~

Probable faulty units/parts

9

ABSCM&H/U (solenoid valve)

ABS sensor

Brake (caliper & piston, pads)

Wheel alignment

Tire specifications, tire wear and air pressures

Incorrect wiring or piping connections

Road surface (uneven, camber)


ABS sensor

Brake (pads)


Incorrect wiring or Piping connections


Brake (pads)

Air in brake line



ABSCM&H/U (solenoid valve, motor)

ABS sensor


9

9


ABS sensor

Master cylinder

Brake (caliper & piston)

Parking brake

Axle

& wheels

Brake pedal play

9

Air in brake line

Brake Pedal Play

*-Suspension play or fatigue (reduced damping)


* Road surface (uneven)

9

9

9

9


ABS sensor

Brake (caliper & piston, pads)



Road surface (uneven)

ABS-I83

ABS

(DIAGNOSTICS)

Vibration and/or noise

(while driving on slippery roads)


Symptom

Excessive pedal vibration

Noise from ABSCM&H/U

Noise from front of vehicle

Noise from rear of vehicle

Probable faulty unitslparts


Road surface (uneven)

ABSCM&H/U (mount bushing)

ABS sensor

Brake piping

ABSCM&H/U (mount bushing)

ABS sensor

Master cylinder

Brake (caliper & piston, pads, rotor)

Brake piping

Brake booster & check valve

Suspension play or fatigue

ABS sensor

Brake (caliper & piston, pads, rotor)

Parking brake

Brake piping

Suspension play or fatigue

ABS-I 84

BRAKE

BR

7

.

8

.

9

.

10

.

11

.

12

.

13

.

14 .

15

.

16

.

17

.

18

.

19 .

20

.

1

.

2

.

3

.

4

.

5

.

6

.

General Description

Front Brake Pad

Page

....................................................................................

2

........................................................................................

16

Front Disc Rotor

........................................................................................

18

Front Disc Brake Assembly

.......................................................................

19

Rear Brake Pad

.........................................................................................

24

Rear Disc Rotor

.........................................................................................

25

Rear Disc Brake Assembly

.......................................................................

27

Rear Drum Brake Shoe

.............................................................................

30

Rear Drum Brake Drum

............................................................................

32

Rear Drum Brake Assembly

......................................................................

33

Master Cylinder

Brake Booster

.........................................................................................

...........................................................................................

Proportioning Valve

36

38

...................................................................................

43

Brake Fluid

................................................................................................

44

Air Bleeding

...............................................................................................

46

Brake Hose

...............................................................................................

Brake Pipe

.................................................................................................

48

50

Brake Pedal

...............................................................................................

51

Stop Light Switch

......................................................................................

General Diagnostics

55

..................................................................................

57

.

BRAKE

1.


A:

SPECIFICATIONS


I

Non-turbo

I

Sedan and Turbo

Other

Front disc brake

Rear disc brake

Rear drum brake

Master cylinder

Effective drum diameter

Effective cylinder diameter

Lining dimensions

(length x width x thickness)

Clearance adiustment

Type

Effective diameter

Reservoir type

Brake fluid reservoir capacity

TvDe

< .

Brake booster

Effective diameter

Proportioning valve

Brake line

Brake fluid

Size

Type

Effective disc diameter

Disc thickness x Outer diameter


Pad dimensions

(lenath x width x thickness)

Clearance adjustment

Type

Effective disc diameter

Disc thickness x Outer diameter


Pad dimensions

(length x width x thickness)


Type

Split point

I

1

15 inch 16 inch

Disc (Floating type, ventilated)

247 mm (9.72 in)

228 mm (8.98 in)

24 x 277 mm

(0.94 x 10.91 in)

I

1

24 x 294 mm

10.94 x 11.57 in)

42.8 mm (1.685 in) x 2

1 0 5 . 0 ~ 5 0 . 5 x l 1 . 0 m m

(4.1 34 x 1.989 x 0.433 in)

Automatic adjustment

112.3 x 50.0 x 11.0 mm

(4.421 x 1.969 x 0.433 in)

-

-

Disc (Floating type)

230 mm (9.06 in)

-

-

10 x 266 mm

(0.39 x 10.47 in)

38.1 mm (1.500 in)

-

82.4 x 33.7 x 9.0 mm

(3.244 x 1.327 x 0.354 in)


-

Drum

(Leading-Trailing type)

-

228.6 mm (9 in)

19.0 mm (0.689 in)

-

-

21 9.3 x 35.0 x 4.1 mm

(8.63 x 1.378 x 0.161 in)

-


-

Tandem

26.99 mm (1-1/16 in)

Sealed type

205 cm3 (1 2.51 cu in)

Vacuum suspended

205

+

230 mm

(8.07

+

9.06 in)

1,961 kPa

(20 kg/cm2, 285 psi)

0.3

Dual circuit system

FMVSS No. 116, DOT3 or DOT4

NOTE:

Refer to “PB section” for parking brake SPECIFICATIONS. <Ref. to PB-2, SPECIFICATIONS, General De- scription .>

B R-2


BRAKE

Front brake

R~~~ b r a p

t .

[viab ksn-\ i y p c )

Rear brake (Drum type)

Parking brake

RII vy,

Disc thickness

Disc runout

I

Pad thickness

(including back metal)

I '

I

Disc thickness

I

I

Disc runout

Inside diameter

Linina thickness

Inside diameter

Lining thickness

Lever stroke

24 mm (0.94 in)

-

I 1 . 3 111111 ( U . L i l 3 I l l ]

22 mm (0.87 in)

0.075 mm (0.0030 in)

10 mm

(0.39 in)

-

I

I

8.5 mm (0.335 in)

0.07 mm (0.0028 in)

228.6 mm (9 in) 230.6 mm (9.08 in)

4.1 mm (0.161 in) 1.5 mm (0.059 in)

170 mm (6.69 in)

3.2 mm (0.126 in)

171

1.5 mm (6.73 in) mm (0.059 in)

7 to 8 notchesil96 N (20 kgf, 44

J

I

Brake booster

Brake pedal

Brake fluid pressure without engine running

Brake fluid pressure with engine running and vacuum at 66.7 kPa

(500 mmHg, 19.69 inHg)

Free play

147 N

294 N

(30 kgf, 66 Ib)

147 N

294 N

(30 kaf. 66 Ib)

Non-turbo

I

588 kPa

(6 kg/cm2, 85 psi)

1,471 kPa

Turbo

(1 5 kg/cm2, 21 3 psi)

5,296 kPa 5,688 kPa

(54 kg/cm2, 768 psi) (58 kg/cm2, 825 psi)

9,120 kPa

(93 ka/cm2. 1.323 Dsi)

1

-

-

[Depress brake pedal pad with a force of less than 10 N (1 kgf, 2 Ib).]

B R-3

BRAKE

B: COMPONENT

1.

FRONT DISK BRAKE

NON-TURBO MODEL


Caliper body

Air bleeder screw

Guide pin (Green)

Pin boot

Piston seal

Piston

Piston boot

Lock pin (Yellow)

Support

Pad clip

Outer shim

Inner shim

Pad (Outside)

Pad (Inside)

Disc rotor

Disc cover

B R-4

BR0097

(1

7) Lock pin sleeve


T1: 8 (0.8, 5.8)

T2: lS(1.8, 13.0)

T3: 26.5 (2.70, 19.5)

T4: 80 (8.2. 59)

TURBO MODEL


BRAKE

(1) Caliper body

(2) Air bleeder screw

(3) Guide pin (Green)

(4)

Pin boot

(5)

Piston seal

(6)

Piston

(7) Piston boot

(8)

Boot ring

(9) Lock pin (Yellow)

(10) Support

(11) Pad clip

(12) Outer shim

(13) Inner shim

(1 4) Pad (Outside)

(15) Pad (Inside)

(1 6) Disc rotor

(1 7) Disc cover

(18) Bush

Tightening torque: N.m (kgf-m, ff-lb)

T I : 8 (0.8, 5.8)

T2: 18(1.8, 13.0)

T3: 37 (3.8,27.5)

T4: 80 (8.2, 59)

B R-5

BRAKE

2. REAR

DISC

BRAKE


Caliper body

Air bleeder screw

Guide pin (Green)

Pin boot

Piston seal

Piston

Piston boot

Boot ring

(9) Lock pin (Yellow)

(IO)

Support

(11) Pad clip

(12) Inner pad

Shim

Shoe hold-down pin

Cover

Back plate

Retainer

Spring washer

Parking brake lever

Parking brake shoe (Secondary)

(22) Parking brake shoe (Primary)

(23) Strut

(24) Strut shoe spring

(25) Shoe guide plate

(26) Secondary shoe return spring

(27) Primary shoe return spring

(28) Adjusting spring

(29) Adjuster

(30) Shoe hold-down cup

(31) Shoe hold-down spring

(32) Disc rotor

(33) Bush


T1: 8 (0.8, 5.8)

T2: 37 (3.8,27.5)

T3: 53 (5.4, 39.1)

B

R-6

3. REAR

DRUM

BRAKE


BRAKE

(1)

Air bleeder cap

(2) Air bleeder screw

(3) Boot

(4) Piston

(5)

CUP

(6)

Spring

(7) Wheel cylinder body

(8) Pin

(9)

Plug

(1 0) Back plate

(1 1) Upper shoe return spring

(1

2) Retainer

(13) Washer


(15) Brake shoe (Trailing)

(16) Brake shoe (Leading)

(18) CUP

(1

9)

Adjusting lever

(20) Adjuster

B4M1120,

(21) Lower shoe return spring


(23) Drum


N.m


T7: 8 (0.8,

5.8)

72:

10 (1.0, 7.2)

T3: 53 (5.4, 39.7)

BR-7

k

BRAKE

4. MASTER CYLINDER


(1) Cap

( 2 )

Filter

( 3 )

Reservoir tank

(4)

Piston retainer

(5)

Primary piston

(6)

Secondary piston

(7) Cylinder body

( 8 )

Cylinder pin (with ABS)

(9) Seal

(10)

Pin

84M03250


T1: 14(1.4, 10.1)

B

R-8


5. FRONT BRAKE PIPES AND HOSE

BRAKE

(1)

Front brake pipe assembly

( 2 )

Proportioning valve

(3) Front brake hose RH

(4)

Front brake hose LH

( 5 )

Clamp

(6)

Gasket


(7) ABS control module and hydraulic

T1: 15 (1.5, 10.8)

control unit

T2: l B ( 1 . 8 , 13.0)

(8) Bracket

(9) Master Cylinder

T3: 32 (3.3, 23.6)


BRAKE

6.

CENTER AND REAR BRAKE PIPES AND HOSE

( 1

)

' / -

I/-

BR0078

(1) Clamp

(2) Center brake pipe assembly

(3) Two-way connector

(6)

Rear brake hose RH (Drum brake

(9)

Gasket model)

(7) Rear brake hose LH (Disc brake


(4) Rear brake pipe assembly model)

T1: 15 (1.5, 10.8)

( 5 )

Rear brake hose RH (Disc brake (8) Rear brake hose LH (Drum brake

T2; 18 (1.8, 13.0)

model) model)

BR-IO

7. BRAKE BOOSTER


BRAKE

(1) Push rod

(2) Return spring

(3) Reaction disc

(4)

Key

(5) Filter

(6) Silencer

(7) Operating rod

(8)

Poppet valve

(9) Valve body

(1

0) Plunger valve

(1 1 Diaphragm plate

(12)

Valve return spring

BR-I 1

BRAKE

8. BRAKE PEDAL

MT Model


(1)

Stopper

(2) Bushing

(3) Spring pin

(4) Snap pin

(5)

Brake pedal pad

(6) Brake pedal

(7) Clevis pin

(8) Brake pedal spring

(9) Clutch pedal pad

(10) Clutch pedal

(11) Bushing C

(12) Clutch clevis pin

(1 3) Assist rod A

(14) Clip

(1 5) Assist spring

(16) Assist bushing

(1 7) Assist rod B

(18) Spring S

(19) Rod S

(20) Bushing S

(21) O-ring

(22) Clip

BR-12

B4M2345A

(23) Clutch switch (Starter interlock)

(24)

Clutch switch (With cruise control)

(25) Stop light switch

(26) Pedal bracket

(27) Clutch master cylinder bracket

(28) Lever

Tightening torque: N-m (kgf-m, ff-lb)

T1: 8 (0.8, 5.8)

T2: lS(1.8, 13.0)

AT Model


BRAKE

(1) Stopper

(2) Bushing

(3) Pedal bracket

(4)

Stop light switch

( 5 )

Snap pin

(6)

Brake pedal pad

(7)

Brake pedal

( 8 )

Clevis pin

(9) Brake pedal spring

BR000;


T1: 8 (0.8, 5.8)

T2: lS(1.8, 13.0)

T3: 29 (3.0,21.7)

BR-13


BRAKE

C: CAUTION





Be careful not to burn your hands, because each part in the vehicle is hot after running.







Do not put fluid on body. If the body is tainted, wash away with water.

BR-14


BRAKE



ILLUSTRATION

I

TOOLNUMBER

926460000

DESCRIPTION

NHEEL CYLINDER

3/4”ADAPTER

REMARKS

Jsed

for

installing cup onto wheel cylinder piston

:Size 11/16 in).

B4M2 6

-

2.


SNAP RING PLIERS

TOOL NAME

REMARKS

Used

for

removing and installing snap ring.

BR-15

FRONT BRAKE PAD

BRAKE

2.

Front Brake Pad

A: REMOVAL

1)



3) Jack-up the vehicle, and remove the front wheel.

4)

Remove the lock pin.

5) Raise the caliper body.

6) Remove the pad.

(4)

Attach a rod of less than 12 mm (0.47 in) dia. to the shaded area of the brake pad, and strike the rod with a hammer to drive brake pad out of place. u

B4M2231

B: INSTALLATION

1)

Apply a thin coat of Molykote AS880N (Part No.

26298AC000) to the frictional portion between pad and pad clip.

2) Apply a thin coat of Molykote AS880N (Part No.

26298AC000) to the frictional portion between pad and pad inner shim.

NOTE:

.

If the brake pad is difficult to remove, proceed as follows:

(1) Remove the caliper body and fasten it provi- sionally to coil spring.

(2) Remove the support.

(3)

Place the support in a vise between wooden blocks.

(1) Support

(2)

Wooden blocks

( 5 )

B4M2230E

3) Install the pads on support.

4)

Install the caliper body on support.


Non-turbo model:

26.5 N.m (2.70 kgf-m, 19.5 ft-lb)

Turbo model:

37

N.m

(3.8 kgf-m, 27.5 ft-lb)

NOTE:

If it is difficult to push the piston during pad replacement, loosen the air bleeder to facilitate work.

5)

Install the front wheel.

BR-I 6

C: INSPECTION

Check the pad thickness A.

I

FRONT BRAKE PAD

I

BROI

0

I

Pad thickness

I

Standard value

I

17 mm (0.67 in)

I

Wear limit 7.5 mm (0.295 in) metal)

CAUTION:

Always replace the pads for both the left and right wheels at the same time. Also replace the pad clips if they are twisted or worn.

A wear indicator is provided on the inner disc brake pad. If the pad wears down to such an extent that the end of the wear indicator contacts the disc rotor, a squeaking sound is produced as the wheel rotates. If this sound is heard, replace the pad.

Replace the pad if there is oil or grease on it.

BRAKE

m

BR-17

FRONT DISC ROTOR

BRAKE

3. Front Disc Rotor

A:

REMOVAL

1)




4)

Remove the caliper body from housing, and suspend it from strut using a wire.

C: INSPECTION

1) Install the disc rotor

by

tightening the five wheel nuts.

2) Set a dial gauge on the disc rotor. Turn the disc rotor to check runout.

I

dl

RR007Fi

5)

Remove the disc rotor.

NOTE:

.

If

the disc rotor seizes up within the hub, drive the disc rotor out by installing an 8-mm bolt in holes B on the rotor.

NOTE:

Make sure the dial gauge is set 5 mm

(0.20

ward of rotor outer perimeter.

If the runout of disc rotor exceeds the limit, check for abnormal free play at hub bearing and runout in the thrust direction. <Ref. to DS-22, INSPECTION,

Front Axle.>

If the hub bearing is okay, replace the disc rotor.

Disc rotor runout limit:

0.075 mm

(0.0030 in)

3 )

Measure the disc rotor thickness.

If the thickness of disc rotor is below runout limit, replace the disc rotor.

G4M0365

I

6)

Clean mud and foreign particles from the caliper body assembly and support.

B: INSTALLATION

1)

Install the disc rotor.

2) Install the caliper body on housing.


80 N-m (8.2 kgf-m,

59 ft-lb)

3 )

Install the wheel.

G4M0365

I

NOTE:

Make sure the micrometer is set 5 mm (0.20 in) in- ward of rotor outer perimeter.

Disc rotor thickness A

1 I

Standard value

24.0mm

(0.945 in)

24.0mm

(0.945 in)

~

Service Disc outer limit

22.0mm

I

diameter

277mm

(10.91 in)

22.0mm 294mm

(0.866

(1

1.57

BR-18

4.

Front Disc

FRONT DISC BRAKE ASSEMBLY

Brake Assembly

A: REMOVAL




4) Remove the union bolt and disconnect the brake hose from caliper body assembly.

BRAKE

B:

INSTALLATION

1)

Install the support on housing.


80 (8.2 kgf-m, 59 ft-lb)

CAUTION:



When replacing the pads, replace the pads of the right and left wheels at the same time.




26298AC000) to the frictional portion between pad and inner shim. w

5) Remove the bolt securing lock pin to caliper body.

.

L

6) Raise the caliper body and move it toward the vehicle center to separate it from support.

7) Remove the support from housing.

NOTE:

Remove the support only when replacing it or the rotor. It need not be removed when servicing the caliper body assembly.

4)

Install the pads on support.

5) Install the caliper body on support.


Non-turbo model:

26.5 N.m (2.70 kgf-m, 19.5 ft-lb)

Turbo model:

37 N*m (3.8 kgf-m, 27.5 ft-lb)

6) Connect the brake hose.


18

N-m (1.8 kgf-m, 13.0 ft-lb)

CAUTION:

Replace the brake hose gaskets with new ones.


Air Bleeding.>

8) Clean mud and foreign particles from the caliper body assembly and support.

BR-19

FRONT DISC BRAKE ASSEMBLY

BRAKE

C: DISASSEMBLY

1. NON-TURBO MODEL


CAUTION:

Be careful not to allow foreign particles to enter inlet (at brake hose connector).

2) Gradually supply compressed air via caliper body brake hose to force piston out.

CAUTION:

Place a wooden block as shown in the figure to prevent damage to piston.

Do not apply excessively high-pressure.

5) Remove the guide pin and boot from caliper body.

2. TURBO MODEL

1)

Clean mud and foreign particles from the caliper body assembly and support.

CAUTION:


2)

Using a standard screwdriver, remove the boot ring from piston.

( 1 )-

( I ) Place a 30 mm

(1

.I8

here.

3) Remove the piston boot.

B4M1165C block

B4M1164C

(1)

Boot ring

3) Remove the boot from piston end.

4)

Gradually supply compressed air via caliper body brake hose to force piston out.

CAUTION:

Place a wooden block as shown in the figure to prevent damage to piston.

BROlOt

4)

Remove the piston seal from caliper body sylin- der.

( 1 ) - L 1 ,

B4M1165C

(1)

Place a 30 mm

(1

.I8

here.

BR-20

FRONT DISC BRAKE ASSEMBLY

5) Remove the piston seal from caliper body cylinder.

(1

1

Piston pin

6) Remove the lock pin boot and guide pin boot.

BRAKE

D: ASSEMBLY

1. NON-TURBO MODEL

1) Clean the caliper body interior using brake fluid.

2) Apply a coat of brake fluid to the piston seal and fit piston seal in groove on caliper body.

3) Apply a coat of brake fluid to the entire inner surface of cylinder and outer surface of piston.

4)

Apply a coat of specified grease to the boot and fit in the groove on ends of cylinder and piston boot onto cylinder.

Grease:

NIGLUBE RX-2 (Part No. 003606000)

5) Insert the piston into cylinder.

CAUTION:

Do not force the piston into cylinder.

I

( 1 )

Piston

(2)

Piston boot

6) Position the boot in grooves on cylinder and piston.

, - .

( 3 )

7

RRnin:

(1)

Piston

(2)

Piston boot

(3) Caliper

body

(4)

Piston seal

7) Apply a coat of specified grease to the lock pin and guide pin outer surface, cylinder inner surface, and boot grooves.

Grease:


BR-21


8) Install the lock and guide pin boot on support.

5)

Apply a coat of specified grease to the boot and fit in the groove on ends of cylinder and piston.

Grease:


To facilitate installation, fit the boot starting with piston end.

BRQlQ

(1)

Pin boot

(2)

Lock pin or guide pin

(3)

Apply grease.

2. TURBO MODEL


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 surface of cylinder and outer surface of piston.

4)

Insert the piston into cylinder.

CAUTION:


U

( 2 )

( 3 ) ( 4 )

S4MQ448A

(1) Piston boot

(2)

Boot ring

(3) Piston seal

(4) Caliper body

6 )

Position the boot in grooves on cylinder and piston.

7) Install the boot ring. Be careful not to scratch the boot.

8) Apply a coat of specified grease to lock pin and guide pin, outer surface, cylinder inner surface, and boot grooves.

Grease:


B4M1176E

(1) Pin boot

(2)

Lock

pin or guide pin

(3) Apply grease.

9) Install the lock pin boot and guide pin boot on support.

BR-22


E: INSPECTION

NOTE:

Repair or replace the faulty parts.

1) Check the caliper body and piston for uneven wear, damage or rust.

2) Check the rubber parts for damage or deterioration.

BRAKE

BR-23

REAR BRAKE PAD

BRAKE

5.

Rear

Brake Pad

A: REMOVAL



3) Jack-up the vehicle, and remove the rear wheel.

4) Remove the lock pin.

C: INSPECTION

Check the pad thickness A.

5) Raise the caliper body.

6) Remove the pad from support.

NOTE:

.

If

the brake pad is difficult to remove, use the same procedure as for front disc brake pad.

<Ref. to BR-16, REMOVAL, Front Brake Pad.>

I

Pad thickness

I

Standard value

I

14.0 mm

(0.551 in)

I

(including back

Wear limit 6.5 mm (0.256 in)

CAUTION:



Replace the pad if there is oil or grease on it.

B: INSTALLATION



2) Install the pad on support.

3) Install the caliper body on support.


37 N-m (3.8 kgf-m, 27.5 fi-lb)

NOTE:

If it is difficult to push the piston during pad replacement, loosen the air bleeder to facilitate work.

BR-24

6.

Rear Disc Rotor

REAR DISC ROTOR

BRAKE

(2) If the disc rotor seizes up within hub, drive the disc rotor out by installing an 8-mm bolt in holes B on the rotor.

A: REMOVAL

1) Lift-up the vehicle and remove the wheels.

2) Remove the two mounting bolts and remove the disc brake assembly.

I

I I

3) Suspend the disc brake assembly hose is not stretched. so that the

4)

Pull down and release the parking brake.

5) Remqve the disc rotor.

NOTE:

If the disc rotor is difficult to remove, try the following two methods in order.

(1) Turn the adjusting screw using a slot-type screwdriver until the brake shoe gets away enough from the disc rotor.

G4MQ38:

B: INSTALLATION


2) Adjust the parking brake. <Ref. to PB-12, AD-

JUSTMENT, Parking Brake Assembly (Rear Disc

Brake).>

(1) Adjusting screw

(2) Cover

(3) Slot-type screwdriver

(4)

Back plate

S4MQ569A

BR-25

REAR DISC ROTOR

BRAKE

C: INSPECTION

1)

Set a dial gauge on the disc rotor. Turn the disc rotor to check runout.

CAUTION:

Securely adjust the disc rotor to hub.

NOTE:

Make sure the dial gauge is set

5

mm (0.20 in) in- ward of rotor outer perimeter.

If the runout of disc rotor exceeds the limit, check for abnormal free play at hub bearing and runout in the thrust direction. <Ref. to

DS-31,

INSPECTION,

Rear Axle.>

If the hub bearing

is

okay, replace the disc rotor.

Disc rotor runout limit:

0.07 mm (0.0028 in)

2 )

Measure the disc rotor thickness.

If the thickness of disk rotor is below runout limit, replace the disk rotor.

NOTE:

Make sure the micrometer is set 5 mm (0.20 in) in- ward of rotor outer perimeter.

Standard value

10 mm (0.39 in)

Service limit

8.5 mm (0.335 in)

BR-26

7.

Rear

REAR DISC BRAKE ASSEMBLY

Disc Brake Assembly

A: REMOVAL

CAUTION:

Do

not allow brake fluid to come in contact with the vehicle body; wipe off completely if spilled.



3)

Lift-up the vehicle and remove the wheels.

4)

Disconnect the brake hose from caliper body assembly.

5 )

Remove the lock pin.

6) Raise the caliper body and move it toward the vehicle center to separate it from support.

7) Remove the support from back plate.

NOTE:

Remove the support only when replacing it or the rotor. It need not be removed when servicing the caliper body assembly.


CAUTION:


BRAKE

B: INSTALLATION

1)

Install the disc rotor on hub.

2) Install the support on back plate.


53 N-m (5.4 kgf-m, 39.1 ft-lb)

CAUTION:


A wear indicator is provided on the inner disc brake pad.

If

the pad wears down to such an extent that the end of the wear indicator contacts the disc rotor, a squeaking sound is produced as the wheel rotates. If this sound is heard, replace the pad.

Replace the pads if there is oil or grease on them.



4)

Install the pads on support.

5 )

Install the caliper body on support.


37 N-m (3.8 kgf-m, 27.5 ft-lb)

6) Connect the brake hose.

Tigh fening torque:

18 Nom kgf-m, 13.0 ft-lb)

CAUTION:

The brake hose must be connected without any twist.

Replace the brake hose gaskets with new ones.


Air Bleeding.>

-

BR-27

BRAKE

C: DISASSEMBLY

1)

Remove the boot ring.

.

.

REAR DISC BRAKE ASSEMBLY

4)

Remove the piston seal from caliper body cylinder.

S4M0120B

-

S4M0122

5) Remove the lock pin sleeve and boot from caliper body.

6)

Remove the guide pin boot.

(1)

Boot ring

2) Remove the piston boot.

I

1

S4M0121

3) Gradually supply compressed air via inlet of caliper body to force piston out.

CAUTION:

Place a wooden block as shown in the figure to prevent damage to piston.

Do not apply excessively high-pressure.

( 1

)-l-l--

B4M1174C

(1)

Place a 30 mm

(1.18 in) wide wooden block here.

BR-28

m

~~

D: ASSEMBLY

REAR

DISC BRAKE ASSEMBLY


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 surface of cylinder and outer surface of piston.

4)

Insert the piston into cylinder.

CAUTION:


5) Apply a coat of specified grease to the boot and fit in the groove on ends of cylinder and piston.

Grease:


6 )

Install the piston boot to the caliper body, and attach boot ring.

I

BRAKE

9)

Install the lock pin boot on caliper body and insert lock pin sleeve into place.

E: INSPECTION

NOTE:

Repair or replace the faulty parts.

1)

Check the caliper body and piston for uneven wear, damage or rust.

2)

Check the rubber parts for damage or deterioration.

\--

I

" J

~ 4 ~ 0 4 4 8 ~

(1) Piston boot

(2) Boot ring

(3) Piston seal

(4)

Caliper body

7)

Apply a coat of specified grease to guide pin, outer surface, sleeve outer surface, cylinder inner surface, and boot grooves.

Grease:


~ _ _ _

~

(1) Pin boot

(2) Lock pin or guide pin

(3) Apply grease.

8) Install the guide pin boot on caliper body.

BR-29

REAR DRUM BRAKE SHOE

BRAKE

8.

Rear Drum Brake Shoe

A: REMOVAL

1

Loosen the wheel nuts, jack-up the vehicle, support it with rigid racks, and remove the wheel.


3) Remove the brake drum from brake assembly.

NOTE:

If it is difficult to remove the brake drum, remove the adjusting hole cover from back plate, and then turn the adjuster assembly pawls using a slot-type screwdriver until the brake shoe separates from the drum.

I I

Wheel cylinder

5 )

Disconnect the hold-down cup from hold-down pin by rotating hold-down cup.

6)

Disconnect the lower shoe return spring from shoes.

Adjuster ASSY pawls

Adjusting lever

'

+

Push

G4MQ242

If the brake drum is difficult to remove, drive it out by installing an 8-mm bolt into bolt hole in brake drum. with adjuster.

CAUTION:

Be careful not to bend the parking brake cable excessively when removing the brake shoes.

I

Wheel cvlinder /Adjuster

I

I

Lower shoe retur; spring Pa;king lever

G4M0397

8) Disconnect the parking brake cable from parking lever.

4)

Hold the hold-down pin by securing rear of back plate with your hand.

I

1-

(2)

Hold-down pin

B R-30

B: INSTALLATION

REAR DRUM BRAKE SHOE

1)

Clean the back plate and wheel cylinder.

2) Apply grease to the portions indicated

by

arrows in the figure.

Brake grease:

Dow Corning Molykote No. 7439 (Part No.

725191460)

BRAKE

9) Set the outside diameter of brake shoes less than 0.5 to 0.8 mm (0.020 to 0.031 in) in comparison with the inside diameter of brake drum.

10) Install the drum. <Ref. to BR-32, INSTALLA-

TION,

Rear Drum Brake Drum.>

C: INSPECTION

1)

Measure the lining thickness.

Lining thickness:

Standard 4.1 mm (0.16 1 in)

Service limit 1.5 mm (0.059 in)

2)

If the deformation or wear etc. are notable, replace them. of back plate, shoe,

3)

When the shoe return spring tension is excessively weakened, replace it, taking care to identify upper and lower springs.

3) Apply grease to the adjusting screw and both ends of adjuster.

Brake grease:


7251 9 1460)

=

4)

Connect the upper shoe return spring to shoes.

5) Connect the parking brake cable to parking lever.

6)

While positioning the shoes (one at a time) in groove on wheel cylinder, secure shoes.

I

Wheel cylinder

\

Shoe

(Trailing)

G4M040E

7) Fix the shoes by connecting hold-down cup to hold-down pin.

8 )

Connect the lower shoe return spring.

BR-31

REAR DRUM BRAKE DRUM

BRAKE

9.

Rear Drum Brake Drum

A: REMOVAL

1)


2)

Release the parking brake.


NOTE:

If it is difficult to remove the brake drum, remove the adjusting hole cover from back plate, and then turn adjuster assembly pawls using a slot-type screwdriver until the brake shoe separates from the drum.

B: INSTALLATION

1) Set the outside diameter of brake shoes less than 0.5 to 0.8 mm (0.020 to 0.031 in) in comparison with the inside diameter of brake drum.

2) Install the drum.

3)

Install the rear wheel.

C: INSPECTION

1)

If the inside surface of brake drum is streaked, correct the surface. And, if it is unevenly worn, ta- peringly streaked, or the outside surface of brake drum is damaged, correct or replace it.

2) Measure the drum inner diameter.

Drum inner diameter: "L"

Standard 228 mm (9 in)

Service limit 230.6 mm (9.08 in)

Wheel cylinder

'

Adjuster ASSY pawls

Adjusting lever

*

Push

G4M0242

If the brake drum is difficult to remove, drive it out by installing an 8-mm bolt into bolt hole in brake drum.

I

I

L

G4M0403

BR-32

REAR DRUM BRAKE ASSEMBLY

10.Rear Drum Brake Assembly

A:

REMOVAL

1)




<Ref. to BR-32, REMOVAL, Rear Drum Brake

Drum.>

4)

Remove the brake shoe. <Ref. to BR-30,

MOVAL, Rear Drum Brake Shoe.>

RE-

5) Unscrew the brake hose flare nut and disconnect the brake hose.

BRAKE

B: INSTALLATION

1)

Clean the back plate and wheel cylinder.

2) Install the wheel cylinder on back plate, and tighten bolts.


10 N-m

(1.0 kgf-m, 7.2 ft-16)

m

6)

Remove the hub.

<Ref. to DS-23, REMOVAL, Rear Axle.>

7) Disconnect the ABS sensor from back plate.

(only vehicle equipped ABS)

8)

Remove the brake assembly.

3) Apply grease to the portions indicated by arrows in Figure.

Brake grease:


7251 9 1460)

G4M0400

9) Remove the bolts installing the wheel cylinder on back plate, and remove it.

4)

install the brale assembly on hopusing, tighten bolts to install the back plate. and


53 N m (5.4 kgf-m, 39.1 ft-l6)

5 )

Install the hub. <Ref. to DS-26, INSTALLATION,

Rear Axle.>

B R-33


BRAKE

6) Connect the brake hose, and tighten the brake hose flange nut.


15 N-m (1.5 kgf-m, 10.8 ft-lb)

7) Connect the ABS sensor to back plate. (only vehicle equipped with ABS)


32 N.m (3.3 kgf-m, 24 ft-lb)

8 )

Apply grease to the adjusting screw and both ends of adjuster.

Brake grease:


725191460)

C: DISASSEMBLY

1)

Remove the right and left dust boots from wheel cy1 inder.

B4M1126B

(1

) Bleeder cap

(2) Bleeder screw

(3) Spring

(4)

Cylinder

(5) CUP

(6) Piston

(7)

Boot

2) Remove the piston, cup, spring and air bleeder screw and cap.

k

S4M04570

I

9) Install the brake shoe. <Ref. to BR-31, INSTAL-

LATION, Rear Drum Brake Shoe.>

10) Install brake drum. <Ref. to BR-32, INSTALLA-

TION, Rear Drum Brake Drum.>

11) After installing brake assembly, bleed air from brake line. <Ref. to BR-46, Air Bleeding.>

BR-34


BRAKE

3) Apply rubber grease to the boot inside as shown in figure.

CAUTION:

Never use brake grease.

Grease:


I

Applicable size

19.0 mm (3/4 in)

Part No.

926460000

Ih;l

S4M04568

E: INSPECTION

1) Inspect the wheel cylinder for leakage.

2) If the deformation or wear of back plate, shoe, etc. are notable, replace them.

BR-35

MASTER CYLINDER

BRAKE

11 .Master Cylinder

A: REMOVAL

1) Thoroughly drain the brake fluid from reservoir tank.

2) Disconnect the fluid level indicator harness connector.

3) Remove the brake pipes from master cylinder.

3) Pry up the pawl and remove the piston retainer.

NOTE:

Piston may jump out from master cylinder. take out master cylinder from brake booster.

CAUTION:

Be extremely careful not to spill the brake fluid.

Brake fluid spilt on the vehicle body will harm the painted surface; wipe it off quickly if spilt.

B: INSTALLATION

1)

To install the master cylinder to the body, reverse the sequence of removal procedure.


Master cylinder mounting nut

14 N-m (1.4 kgf-m, 10.1 t?-16)

Piping flare nut

15 N.m (1.5 kgf-m, 10.8 ff-16)

CAUTION:

Be sure to use recommended brake fluid.


PROCEDURE, Air Bleeding.>

C: DISASSEMBLY

1. PRECAUTIONS FOR DISASSEMBLING

1) Remove mud and dirt from the surface of brake master cylinder.

2) Prepare the tools necessary for disassembly operation, and arrange them neatly on work bench.

3) Clean the work bench.

2.

DISASSEMBLING PROCEDURE

1)

Remove the pin with drift pin which secures the reserve tank to master cylinder.

2) Remove the cylinder pin with magnetic pick-up tool while pushing in primary piston. (with ABS)

I

S4M0121

I

4)

Extract the primary piston assembly and secondary piston assembly.

CAUTION:

Do not disassemble the piston assembly; otherwise, the spring set value may be changed.

Use brake fluid

or

methanol to wash inside wall of cylinder, careful pistons and piston cups. Be not to damage parts when washing. If methanol is used for washing, do not dip rubber parts, such as piston cups, in it for more than

30

seconds; otherwise, they may become swelled.

(-2

,

B

(1)

Cylinder pin

BR-36

D: ASSEMBLY

1. PRECAUTIONS

FOR

ASSEMBLING

1)

When assembling, be sure to use recommended brake fluid.

2) Ensure that the inside wall of cylinder, pistons, and piston cups are free from dirt when assembling.

3) Be extremely careful not to damage, scratch, or dent cylinder inside wall, pistons, and piston cups.

4)

Do not drop the parts. Never attempt to use any part that has been dropped accidentally.

2.

ASSEMBLING PROCEDURE

1) Assembling piston assembly:

Apply recommended brake fluid to inside wall of cylinder, and to outer surface of piston assembly, and install the piston assemblies carefully into cylinder.

2)

Assembling cylinder pin:

3) Press the pawl and install the piston retainer into the master cylinder.

MASTER CYLINDER

BRAKE

E: INSPECTION

If any damage, deformation, wear, swelling, rust, and other faults are found on the primary piston assembly, secondary piston assembly, supply valve stopper, or gasket, replace the faulty part.

CAUTION:

The primary and secondary pistons must be replaced as complete assemblies.

The service limit of the clearance between each piston and the master cylinder inner dia. is

0.11 mm (0.0043 in).

When handling parts, be extremely careful not to damage or scratch the parts, or let any foreign matter get on them.

I

4) Install the seal to reservoir tank.

(1)

Seal

5)

Install the pin with drift pins which secures the reservoir tank to master cylinder.

BR-37

BRAKE BOOSTER

BRAKE

12.Brake Booster

A: REMOVAL

1)

Remove or disconnect the following parts at engine compartment.

(1)

Disconnect the connector for brake fluid level indicator.

(2) Remove the brake pipes from master cylinder.

(3) Remove the master cylinder installing nuts.

(4)

Disconnect the vacuum hose from brake booster.

2) Remove the following parts from the pedal bracket.

(1)

Snap pin and clevis pin

(2) Four brake booster installing nuts

3) Remove the brake booster while shunning brake pipes.

NOTE:

Be careful not to drop the brake booster. Brake booster should be discarded if it has been dropped.

Use special care when handling the operating rod.

If excessive force is applied to operating rod, sufficient to cause a change in the angle in excess of

f3”,

may result in damage to the power piston cylinder.

Use care when placing the brake booster on the floor.

Do not change the push rod length.

If it has been changed, reset the projected length

“L” to the standard length.

Standard:

L

=

10.4 mm

(0.41 in)

CAUTION:

If external force is applied from above when brake booster is placed in this position, the res- in portion as indicated by “P”, may be damaged.

(1)

Force

S4M0464A

L

G4M0424

BR-38

B: INSTALLATION

BRAKE BOOSTER

1)

Mount the brake booster in position.

2) Connect the operating rod to brake pedal with clevis pin and snap pin.

BRAKE

7) Adjust the operating rod of brake booster.

Standard: L

LHD model:

144.6 mm (5.69 in)

RHD model:

7 73.2

mm (6.82 in)

If it is not in specified value, adjust it by adjusting the brake booster operating rod.

k

L

I

B4M0117C

(1) Nuts

(2) Clevis pin

(3)

Snap pin

(4)

Operating rod

3)

Connect the vacuum hose to brake booster.

MM0616P

8) Measure the clearance between threaded end of stop light switch and stopper.

If it is not in specified value, adjust it by adjusting the position of stop light switch.

CAUTION:

Be careful not to rotate the stop light switch.

Stop ljght switch clearance: A

0.3 mm (0.012 in)

A

4) Mount the master cylinder onto brake booster.

6) Connect the electric connector for brake fluid level indicator. u-

B4M0617H

9) Apply grease to operating rod connecting pin to prevent it from wearing.

10) Bleed air from the brake system.

Tightening torque (Air bleeder screw):

8 N.m (0.8 kgf-m, 5.8 ft-16)

11) Conduct road tests to ensure brakes do not drag.

BR-39

BRAKE BOOSTER

BRAKE

C: INSPECTION

1. OPERATION CHECK (WITHOUT GAUG-

ES)

CAUTION:

When checking operation, be sure to securely apply the hand brake.

Checking without gauges

This method cannot determine the exact portion which has failed, but it can provide a rough under- standing of the nature of the failure if checking is conducted in accordance with the following procedures.

Air tightness check

Start the engine, and run it for 1 to 2 minutes, then turn it off. Depress the brake pedal several times applying the same pedal force as that used in ordi- nary braking operations. The pedal stroke should be greatest on the 1 st depression, and it should become smaller with each successive depression. If no change occurs in the pedal height while in a depressed state, the brake booster is faulty.

Operation check

1)

With the engine off, depress the brake pedal several times applying the same pedal force and make sure that the pedal height does not vary with each depression of the pedal.

S4M0466A

(1)

OK

(2) NOTOK

(3) 1st

(4)

2nd

(5) 3rd

S4M0465A

(1)

When engine is stopped

(2) When engine is started

2) With the brake pedal depressed, start the engine.

3)

As engine starts, the brake pedal should move slightly toward the floor. If no change occurs in the pedal height, the brake booster is faulty.

NOTE:

If faulty, check precisely with gauges.

Loaded air tightness check

Depress the brake pedal while engine is running, and turn off the engine while the pedal is still depressed. Keep the pedal depressed for 30 seconds; if no change occurs in the pedal height, the brake booster is functioning normally; if the pedal height increases, it is faulty.

NOTE:

If faulty, check precisely with gauges.

NOTE:

In the event of defective operation, inspect the condition of the check valve and vacuum hose.

Replace them if faulty and conduct the test again.

If no improvement is observed, check precisely with gauges.

BR-40

BRAKE BOOSTER

2. OPERATION

CHECK (WITH

GAUGES)

CAUTION:

When checking operation, be sure to securely apply the hand brake.

Checking with gauges

Connect gauges as shown in the figure. After bleeding air from pressure gauges, proceed to each check.

BRAKE

Leak from the shell jointed portion or stud bolt welded portion

Damaged diaphragm

Leak from valve body seal and bearing portion

Leak from plate and seal assembly portion

Leak from poppet valve assembly portion

Loaded air tightness check

1) Start the engine and depress the brake pedal with pedal force of 196 N (20 kgf, 44 Ib). Keep the engine running until a vacuum of 66.7 kPa (500 mmHg, 19.69 inHg)

= point B is indicated on vacuum gauge while the pedal is still depressed.

,B

(1 )- Pressure gauge

(2)

Vacuum gauge

(3) Adapter hose

(4) Vacuum hose

(5) Pedal force gauge

Air tightness check

1) Start the engine and keep it running until a vacuum of 66.7 kPa (500 mmHg, 19.69 inHg)

= point A is indicated on vacuum gauge. Do not depress the brake pedal.

(1) Pressure gauge

(2) Vacuum gauge

2) Stop the engine and watch the gauge. If the vacuum drop range is less than 3.3 kPa (25 mmHg,

0.98 inHg) within 15 seconds after stopping the engine, the brake booster is functioning properly.

If defective, the cause may be one of those listed below.

Check valve malfunction

Leak from vacuum hose

S4M0469A

I

(1) Pressure gauge

(2) Vacuum gauge

(3) Pedal force gauge

(4)

Depress

2)

Stop the engine and watch vacuum gauge.

If the vacuum drop range is less than 3.3 kPa (25 mmHg, 0.98 inHg) within 15 seconds after stopping the engine, brake booster is functioning properly.

If defective, refer to “AIR TIGHTNESS CHECK’.

<Ref. to BR-40, INSPECTION, Brake Booster.>

Lack of boosting action check

Turn off the engine, and set the vacuum gauge reading at “0”. Then, check the fluid pressure when brake pedal is depressed. The pressure must be greater than the standard value listed.

Brake pedal force

Fluid pressure

147 N

(1 5 kgf, 33 Ib)

588 kPa

(6

kcdcm’, 85 psi)

294 N

(30 kgf, 66

Ib)

1,471 kPa

(15 kg/cm2, 213 psi)

BR-41

BRAKE BOOSTER

BRAKE

Boosting action check

Set the vacuum gauge reading at 66.7 kPa (500 mmHg, 19.69 inHg) by running engine. Then, check the fluid pressure when brake pedal is depressed. The pressure must be greater than the standard value listed. force

Fluid pressure

Turbo

5,688 kPa

BR-42

13.Proportioning Valve

A: REMOVAL

PROPORTIONING VALVE

BRAKE

C: INSPECTION

1)

Install the oil.pressure gauges to measure the master cylinder fluid pressure (front wheel brake fluid pressure) and rear wheel cylinder fluid pressure.

2) Bleed air from the oil pressure gauges.

3) Check the master cylinder fluid pressure and rear wheel cylinder fluid pressure.

The standard values are shown in the figure.

m

“%

BR0066

1)

Remove the brake pipe from proportioning valve at four places.

2) Remove the proportioning valve from its bracket.

CAUTION:

Do not disassemble or adjust the proportioning valve. (The proportioning valve must be replaced as an assembly.)

B: INSTALLATION

1)

Install the proportioning valve to bracket.

2) Connect the brake pipes correctly to proportioning valve.

3)

Bleed air, then check each joint of brake pipe for oil leaks.


Proportioning valve to brake pipe flare nut:

15 N-m (1.5 kgf-m, 10.8 ft-lb)

Proportioning valve to bracket

18

N-m

(1.8 kgf-m, 13.0 ff-lb)

are normal

Master cylinder fluid pressure:

Pz

BR0067

4) For the oil pressure in case of split point, refer to

.

<Ref. to BR-2, SPECIFICATIONS, General De- scription.>

BR-43

BRAKE FLUID

BRAKE

14.Brake Fluid

A: INSPECTION

1)

Check that the brake fluid level remains between

“MIN” and “MAX’. If out of the specified range, refill or drain fluid. If fluid level becomes close to “MIN”, refill fluid.

2) Check the fluid for discoloration. If fluid color has excessively changed, drain the fluid and refill with new fluid.

B: REPLACEMENT

CAUTION:

To always maintain the brake fluid character- istics, replace the brake fluid according to maintenance schedule or earlier than that when used in severe condition.

The FMVSS No. 116, fresh DOT3 or 4 brake fluid must be used.

Cover the bleeder with waste cloth, when loosening it, to prevent brake fluid from being splashed over surrounding parts.

Avoid mixing different brands of brake fluid to prevent degrading the quality of the fluid.

Be careful not to allow dirt or dust to get into the reservoir tank.

NOTE:

During bleeding operation, keep the brake reservoir tank filled with brake fluid to eliminate entry of air.

Brake pedal operating must be very slow.

For convenience and safety, two people should do the work.

The amount of brake fluid required is approximately 500 m 0 (1 6.9 US fl oz, 17.6 Imp fl oz) for total brake system.

1) Either jack-up the vehicle and place a safety stand under it, or lift up the vehicle.

2) Remove both front and rear wheels.

3) Draw out the brake fluid from master cylinder with syringe.

4)

Refill the reservoir tank with recommended brake fluid.

Recommended brake fluid:

FMVSS

No. 116, fresh DOT3 or 4 brake fluid

5) Install one end of a vinyl tube onto the air bleeder and insert the other end of the tube into a container to collect the brake fluid.

A m

Air bleeder screw

CAUTION:

Brake fluid replacement sequence; (A) Front right

-+

(8) Rear left

+

(C) Front left

+

(D) Rear right

I

-

r

S4M0475A

(1 )

Master cylinder

(2)

Hydraulic unit


6)

Instruct your co-worker to depress the brake pedal slowly two or three times and then hold it depressed.

7)

Loosen the bleeder screw approximately 1/4 turn until a small amount of brake fluid drains into the container, and then quickly tighten the screw.

BR-44

BRAKE FLUID

8)

Repeat steps 6) and 7) above until there are no air bubbles in drained brake fluid and new fluid flows through vinyl tube.

NOTE:

Add brake fluid as necessary while performing the air bleed operation, in order to prevent the tank from running short of brake fluid.

9 )

After completing the bleeding operation, hold the brake pedal depressed and tighten the screw and install bleeder cap.

Tightening torque (Bleeder screw):

8 N-m (0.8 kgf-m, 5.8 fi-lb)

10)

Bleed air from each wheel cylinder using the same procedures as described in steps 6) through

7) above.

11) Depress the brake pedal with a force of approximately 294 N (30 kgf, 66 Ib) and hold it there for approximately 20 seconds. At this time check the pedal to see if it shows any unusual movement.

Visually inspect the bleeder screws and brake pipe joints to make sure that there is no fluid leakage.

12) Install the wheels, and drive vehicle for a short distance between 2 to 3 km (1 to 2 miles) to make sure that brakes are operating properly.

BRAKE

Pls

BR-45

AIR BLEEDING

BRAKE

15.Air Bleeding

A:

PROCEDURE

CAUTION:

The FMVSS No. 116, fresh DOT3 or

4 brake fluid must be used.

Cover the bleeder with waste cloth when loosening it to prevent brake fluid from being splashed over surrounding parts.

Avoid mixing different brands of brake fluid to prevent degrading the quality of the fluid.

Be careful not to allow dirt or dust to get into the reservoir tank.

NOTE:

Start with the brakes (wheels) connected to the secondary chamber of the master cylinder.

The time interval between two brake pedal operations (from the time when the pedal is released to the time when it is depressed another time) shall be approximately 3 seconds.

The air bleeder on each brake shall be released for 1 to 2 seconds.

1.

MASTER CYLINDER

NOTE:

If the master cylinder is disassembled or reservoir tank is empty, bleed the master cylinder.

During the bleeding operation, keep the brake reservoir tank filled with brake fluid to eliminate entry of air.



1) Disconnect the brake line at primary and secondary sides.

2) Cover the master cylinder with vinyl bag.

3) Carefully depress and hold the brake pedal.

4) Close the outlet plug with your finger, and release the brake pedal.

I

S4M0541

5) Repeat the above step3) and 4) until brake fluid is completey bled from outlet plug.

6) Remove the vinyl bag, then connect the brake pipe to master cylinder.


8 N-m (0.8 kgf-m, 5.8 ff-lb)

7)

Using water, wash off the spilt brake fluid at the master cylinder surrounding, then wipe up the water.

8) Bleed air from the brake line. <Ref. to BR-46,

BRAKE LINE, PROCEDURE, Air Bleeding.>

2.

BRAKE LINE

NOTE:

During the bleeding operation, keep the brake reservoir tank filled with brake fluid to eliminate entry of air.



1) Make sure that there is no leak from joints and connections of the brake system.

2)

Fit one end of vinyl tube into the air bleeder and put the other end into a brake fluid container.

S4M0.540

W

S4M0246

BR-46

CAUTION:

AIR BLEEDING

Brake fluid replacement sequence; (A) Front right right

(6) Rear left

+

(C) Front left

+

(D) Rear

BRAKE

6)

Check the pedal stroke.

While the engine is idling, depress the brake pedal with a 490 N (50 kgf, 110 Ib) load and measure the distance between the brake pedal and steering wheel. With the brake pedal released, measure the distance between the pedal and steering wheel again. The difference between the two measure- ments must be more than specified.

is

I

S4M0475A

(1)

Master cylinder

(2) Hydraulic unit


3) Slowly depress the brake pedal and keep it depressed. Then, open the air bleeder to discharge air together with the fluid.

Release the air bleeder for 1 to 2 seconds.

Next, with the bleeder closed, slowly release the brake pedal.

Repeat these steps until there is no more air bubbles in the vinyl tube.

Allow 3 to 4 seconds between two brake pedal operations.

CAUTION:

Cover the bleeder with waste cloth, when loosening it, to prevent brake fluid from being splashed over surrounding parts.

NOTE:


4)

Tighten the air bleeder securely when no air bubbles are visible.

Air bleeder tightening torque:

8 N.m (0.8 kgf-m, 5.8 ft-lb)

5 )

Perform these steps for the brakes connecting to the secondary chamber of master cylinder, first, and then for the ones connecting to primary chamber. With all procedures completed, fully depress the brake pedal and keep it in that position for approximately 20 seconds to make sure that there is

no

leak evident in the entire system.

\

S4M0476A

(1)

Steering wheel

(2) Toe board

Specified pedal stroke:

Without ABS

90 mm (3.54 in)

With ABS

95 mm (3.74 in)

When depressing brake pedal with a 490 N

(50 kg, 110 lb) load.

7)

If the distance is more than specified, there is a possibility that air is in the brake line. Bleed the brake line until pedal stroke meets the specification.

8)

Operate the hydraulic control unit in the sequence control mode. (With ABS)


9) Recheck the brake stroke.

10)

If the distance is more than specified, there is a possibility air is in the inside of the hydraulic unit.

Repeat above steps 2) to 9) until pedal stroke meets the specification.

11) Add brake fluid to the required level (MAX. level) of reservoir tank.

12) As a final step, test run the vehicle at low speed and apply brakes relatively hard 2 to 3 times to ensure that brakes provide normal braking action on all four wheels without dragging and uneven braking.

BR-47

BRAKE HOSE

BRAKE

16.Brake Hose

A: REMOVAL

1.

FRONT

BRAKE HOSE

1) Separate the brake pipe from brake hose.

(Always use flare nut wrench and be careful not to deform flare nut.)

B: INSTALLATION

1. FRONT

BRAKE HOSE

1) Route the end of brake hose (on caliper side) through hole in brake hose bracket at strut location.

2) Tighten the end of brake hose at caliper using a union bolt.

Tightening torque (Union bolt):

18 N.m (1.8 kgf-m, 13.0 ff-lb)

(1) Brake hose

(2) Brake pipe

2)

Pull out the clamp to remove the brake hose.

3) Remove the bolt at strut and union bolt.

2. REAR BRAKE HOSE

1)

Separate the brake pipe from brake hose.

NOTE:

Always use flare nut wrench and be careful not to deform flare nut.

I1 844

3) Secure the middle fitting of brake hose to bracket at strut location using a clamp.

4) Position the disc in straight-forward direction and route the brake hose through hole in bracket on wheel apron side.

CAUTION:

Be sure the brake hose is not twisted.

5) Temporarily tighten the flare nut to connect brake pipe and hose.

6) Fix the brake hose with clamp at wheel apron bracket.

7) While holding the hexagonal part of brake hose fitting with a wrench, tighten the flare nut to the specified torque.

Tightening torque (Brake pipe flare nut):

15 N-m (1.5 kgf-m, 10.8 ff-lb)

8 )

Bleed air from the brake system. <Ref. to BR-46,

Air Bleeding.>

(1)

Brake hose clip

(2)

Brake hose

(3)

Brake pipe

2) Unscrew the brake hose flare nut, and disconnect the brake hose.

3) Pull out the clamp to remove the brake hose.

BR-48

BRAKE

HOSE

2.

REAR BRAKE HOSE

1) Pass the brake hose through the hole of bracket, and lightly tighten the flare nut to connect brake hose.

2)

Insert the clamp upward to fix brake hose.

3) While holding the hexagonal part of brake hose fitting with a wrench, tighten the flare nut to the specified torque.

Tightening torque (Brake pipe flare nut):

75

N*m (7.5 kgf-m, 70.8 ft-lb)

BRAKE

C: INSPECTION

Ensure there are no cracks, breakage, or damage on hoses. Check the Joints for fluid leakage. If any cracks, breakage, damage or leakage is found, repair or replace the hose.

ia

(1) Brake hose

clip

(2)

Brake hose

(3) Brake pipe


Air Bleeding.>

BR-49

BRAKE PIPE

BRAKE

17.Brake

Pipe

A:

REMOVAL

NOTE:

Airbag system wiring harness is routed near the center brake pipe.

CAUTION:

All Airbag system wiring harness and connectors are colored yellow. Do not use electrical test equipment on these circuits.

Be careful not to damage the Airbag system wiring harness when servicing the center brake pipe.

When removing the brake pipe, make sure that it is not bent.

B: INSTALLATION

NOTE:

Airbag system wiring harness is routed near the center brake pipe.

CAUTION:

All Airbag system wiring harness and connectors are colored yellow. Do not use electrical test equipment on these circuits.

Be careful not to damage the Airbag system wiring harness when servicing the center brake pipe.

When installing the brake pipe, make sure that it is not bent.

After installing the brake pipe and hose, bleed the air.

After installing the brake hose, make sure that it does not touch the tire or suspension assembly, etc.

Brake pipe tightening torque:

15

N*m

(1.5 kgf-m, 10.8 ft-lb)

C: INSPECTION

Ensure there are no cracks, breakage, or damage on pipes. Check the joints for fluid leakage. If any cracks, breakage, damage or leakage is found, repair or replace the pipe.

NOTE:

Use a mirror when inspecting the low-visible part or back side.

BR-50

18.Brake Pedal

A: REMOVAL

1.

MT MODEL

1) Remove the steering bolts.

2) Raise the vehicle on hoist and remove the two bolts which secure steering unit to underside of body.

3) Lower the vehicle to floor.

4) Remove the instrument panel lower cover from instrument panel.

5)

Disconnect the following parts from pedal bra&- et.

Operating rod of brake booster

Electrical connectors (for stop light switch, etc.)

6)

Remove the clevis pin which secures lever to push rod.

7) Remove the nut which secures clutch master cylinder.

8) Remove the steering assembly.

9) Remove the accelerator pedal.

10) Remove the bolts and nuts which secure pedal bracket.

BRAKE PEDAL

BRAKE

B: INSTALLATION

1 )


CAUTION:

If the cable clamp is damaged, replace it with a new one.

.

Never fail to cover the outer cable end with boot.

Be careful not to kink the accelerator cable.

Always use new clevis pins.

2)

Adjust the clutch pedal <Ref. to CL-27, ADJUST-

MENT, Clutch Pedal.>

3)

Inspect after pedal installation <Ref. to BR-53,

INSPECTION, Brake Pedal.>

1

2. ATMODEL

1 )


2)

Remove the instrument panel lower cover from instrument panel.

3)

Remove the clevis pin which secures brake pedal to brake booster operating rod. Also disconnect the stop light switch connector.

4) Remove the two bolts and four nuts which secure brake pedal to pedal.

BR-51

BRAKE PEDAL

BRAKE

C: DISASSEMBLY

1.

MT MODEL

1)

Remove the brake switch.

<Ref. to BR-55, REMOVAL, Stop Light Switch.>

2) Remove the clutch pedal.

<Ref. to CL-26, DISASSEMBLY, Clutch Pedal.>

3) Remove the clutch master cylinder bracket.

2.

ATMODEL

1) Remove the brake switch.

2)

Unbolt, and then remove the brake pedal.

3) Remove the bush, spacer and spring.

4)

Remove the bush, spring and stopper.

\)

B4M2350A

(1)

Stopper

(2) Bushing

(3)

Brake pedal

(4)

Brake pedal spring

5) Remove the brake pedal pad.

(1)

Plug

(2) Stopper

(3) Brake pedal

(4)

Brake pedal spring

4)

Remove the brake pedal pad.

BR-52

D: ASSEMBLY

1) Attach the stop light switch, etc. to pedal bracket temporarily.

2) Clean the inside of bores of clutch pedal and brake pedal, apply grease, and set bushings into bores.

3) Align bores of pedal bracket, clutch pedal and brake pedal, attach brake pedal return spring and clutch pedal effort reducing spring (vehicle with hill holder), and then install the pedal bolt.

NOTE:

Clean up inside of bushings and apply grease before installing the spacer.


T: 29 Nom kgf-m, 21.7 ft-lb)

BRAKE PEDAL

BRAKE

E: INSPECTION

1)

Move the brake and clutch pedal pads in the lateral direction with a force of approximately 10 N

(1 kgf, 2 Ib) to ensure pedal deflection is in specified range.

CAUTION:

If excessive deflection is noted, replace the bushings with new ones.

Deflection of brake and clutch pedal:

Service limit

5.0 mm (0.197 in) or less

1

4) Set the brake pedal position by adjusting the position of stop light switch.

Pedal position: L

125.9 mm (4.96 in)


T: 8 N.m (0.8 kgf-m, 5.8 ft-lb)

(1)

Clutch pedal

(2) Brake pedal

-

G4M0326

BR-53

BRAKE PEDAL

BRAKE

2) Check the position of pedal pad.

Pedal height:

L

148 mm (5.83 in)

Brake pedal free play: A

1

-

mm

(0.04

-

pedal pad with a force of less than 10 N (1 kgf,

2 lb).]

B4M03668

(1)

Stop light switch

(2)

Mat

(3) Toe board

(4)

Brake booster operating rod

3) If it is not in specified value, adjust it by adjusting the brake booster operating rod length.

BR-54

19.Stop

Light Switch

A:

REMOVAL

1)


2) Disconnect the stop light switch connector.

3) Loosen the nuts, and unscrew stop light switch to remove.

Is

STOP LIGHT SWITCH

BRAKE

C: INSPECTION

1)

If the stop light switch does not operate properly

(or if it does not stop at the specified position), replace with a new one.

Specified position:

L

2 mm (0.079 in)

7

A+-


B: INSTALLATION

1)

Screw the stop light switch onto a bracket and secure it temporarily with a nut.

2) Adjust the stop light switch position, and then tighten the nut.

<Ref. to BR-56, ADJUSTMENT, Stop Light

Switch.>


8 N.m (0.8 kgf-m, 5.8 ft-lb)

I

G4M0327

2) Measure the clearance between threaded end of stop light switch and stopper.

CAUTION:


Stop light switch clearance: A

0.3 mm (0.012 in)

( , , - - p 3 )

B4M0617E


(2) Stopper

(3) Brake pedal

3) If it is not in specified value, adjust it by adjusting the position of stop light switch.

CAUTION:


BR-55

STOP LIGHT SWITCH

BRAKE

D: ADJUSTMENT

Loosen the lock nut, and adjust the stop light switch position until the clearance between threaded end of the stop light switch and the stopper becomes

0.3 mm (0.012 in). Then, tighten the lock nut.

Ir'

B4M0617E

BR-56

GENERAL DIAGNOSTICS

BRAKE

20.General Diagnostics

A:

INSPECTION

1. Insufficient braking

2.

Unstable or uneven braking

3. Excessive pedal stroke

Trouble and possible cause

(1) Fluid leakage from the hydraulic mechanism

( 2 )

Entry of air into the hydraulic mechanism

(3) Excessively wide shoe clearance

Corrective action

Repair or replace (cup, piston seal, piston boot, master cylinder piston kit, pipe or hose).

1

Bleed the air.

]

Adjust the clearance.

(4)

Wear, deteriorated surface material, adhering water or fluid on the lining

Replace, grind or clean.

(5)

Improper operation of master cylinder, disc cal- iDer, brake booster or check valve

Correct or replace.

(1) Fluid on the lining, drum or rotor

(2)

Drum or rotor eccentricity

(3)

Worn brake drum, or damage to the drum caused by sand

(4)

Improper lining contact, deteriorated surface material, improper inferior material, or wear

Eliminate cause of fluid leakage, clean, or replace.

Correct or replace the drum or rotor.

Correct by grinding, or replace.

Correct by grinding, or replace.

(5) Deformed back plate

(6)

Improper tire inflation

(7) Disordered wheel alignment

Correct or replace.

Inflate to correct pressure.

Adjust alignment.

(8) Loosened back plate or the support installing bolts

Retighten.

(9)

Loosened wheel bearing

(10) Trouble in the hydraulic system

(1 1)

Uneven effect of the parking brake

(1) Entrv of air into the hvdraulic mechanism

(2)

Excessive play in the master cylinder push rod

I

Retighten to normal tightening torque or replace.

1

Replace the cylinder, brake pipe or hose.

1

Check, adjust, or replace the rear brake and cable

I system.

1

Bleed the air.

1

Adjust.

(3) Fluid leakage from the hydraulic mechanism

Repair or replace (cup, piston seal, piston boot, master cylinder piston kit, pipe or hose).

(4)

Improperly adjusted shoe clearance

(5)

ImDroDer linina contact or worn linina

Adjust.

Correct or replace.

4. Brake dragging or improper brake return

5.

Brake noise (1)

(creak sound)

6. Brake noise (2)

(hissing sound)

(2)

Improper master cylinder return

(3) Clogged hydraulic system

(4)

Improper return or adjustment of parking brake

1

Clean or replace the cylinder.

Replace.

Correct or adjust.

(5) Weakened spring tension or breakage of shoe return sDrina

~~~~~ ~ ~

(6)

Excessively narrow shoe clearance

( 7 )

lmprouer disc caliper operation

(8)

Improper adjusted wheel bearing

Replace the spring.

I

Adiust the clearance.

1

Correct or replace.

Adjust or replace.

(1)

Hardened or deteriorated lining

Replace the shoe assembly or pad.

Replace the shoe assembly

or

pad.

(2) Worn lining

(3)

Loosened back plate or the support installing bolts

Retighten.

(4)

Loose wheel bearing

( 5 )

Dirty drum or rotor

(1) Worn lining

(2)

ImDroDer installed shoe or Dad

(3)

Loose or bent drum or rotor

I

Retighten to normal tightening torque.

Clean the drum or rotor, or clean and replace the brake assembly.

Replace the shoe assembly or pad.

Correct or replace the shoe assembly or pad.

I

Retighten or replace.

BR-57

GENERAL DIAGNOSTICS

BRAKE

I

7.

Brake noise

(3)

(click sound)

Trouble and possible cause

In the case of the disc brake:

(1) Excessively worn pad or the support

In the case

of

the drum brake:

(1) Excessively worn shoe ridge

(2) Lack of oil on the shoe ridge surface and anchor

Corrective action

I

Replace the pad or the support.

Replace the back plate.

Add more grease.

BR-58

PARKING BRAKE

PB

1

.

3

.

4

.

5

.

~~ ~

Page

General Description

....................................................................................

2

Parking Brake Lever

....................................................................................

6

Parking Brake Cable

...................................................................................

8

Parking Brake Assembly (Rear Disc Brake)

.............................................

10


..........................................................................

13

PARKING BRAKE

1 General Description



Model

Type

Effective drum diameter

Lining dimensions

(length

x

width x thickness)


Lever stroke mm (in) mm (in) notches/N (kgf, Ib)

Rear drum brake Rear disc brake

Mechanical on rear brakes, drum in disc

228.6 (9)

x

35.0 4.1

0.161)


7 to

8/196

170 (6.69)

163.1

x

30.0 3.2

x

0.126)

Manual adjustment

1

PB-2


B: COMPONENT

1. PARKING BRAKE (REAR

DISC

BRAKE)

PARKING BRAKE

(1) Back plate

(2) Retainer

(10) Primary return spring

(1 1) Secondary return spring

(3) Spring washer

(4)

Lever


(1 3) Adjuster

(5) Parking brake shoe (Primary)

(14)

Shoe hold-down cup

(6) Parking brake shoe (Secondary) (1 5) Shoe hold down spring

(7) Strut spring (16) Shoe hold down pin

(8) Strut (17) Adjusting hole cover

(9)

Shoe guide plate


T:

53 (5.4, 39)

P B-3

PARKING BRAKE

2.

PARKING BRAKE CABLE


( 1 i


(2)

Parking brake switch

(3) Lock nut

(4)

Adjusting nut

(5) Equalizer

(6) Bracket

(7) Clamp

(8)

Parking brake cable RH

(9) Cable guide

(IO)

Clamp (Rear disc brake model only)

(1 1)

Parking brake cable LH

B4M0705B


T1: 6 (0.6, 4.4)

T2: lS(1.8, 13.0)

T3: 33 (3.4,24)

PB-4


C: CAUTION






Use SUBARU genuine grease etc. or the equivalent.

Do

not mix grease etc. with that of another grade or from other manufacturers.






Keep grease etc. away from parking brake shoes.

PARKING BRAKE is

PB-5

PARKING BRAKE LEVER

PARKING BRAKE

2. Parking Brake Lever

A: REMOVAL

1) Move the select lever to “P” position or gear shift lever to 1st gear, then block the wheels.

2)

Disconnect the battery ground terminal from battery.

3) Remove the console box. <Ref. to El-41, RE-

MOVAL, Console Box.>

4)

Disconnect the connector of parking brake switch.

5 )

Loosen the parking cable adjusting nut and console bracket.

6) Remove the parking brake lever.

8) Unbend the parking brake lever pawls and remove cable.

7) Remove the inner cable end from equalizer.

(1)

Parking brake lever

(2) Cable

B: INSTALLATION



Parking brake lever;

18

N.m (1.8 kgf-m, 13.0 ft-lb)

Adjusting nut;

6 N-m (0.6 kgf-m, 4.4 ft-lb)

NOTE:

Be sure to pass the cable through the guide inside tunnel.

Be sure to adjust the lever stroke. <Ref. to PB-7,

ADJUSTMENT, Parking Brake Lever.>

(1) Equalizer

-

S4M0473A

(2)

Inner cable end

PB-6

PARKING BRAKE LEVER

~~~ ~

C: INSPECTION

While pulling the parking brake lever upward, count the notches.

Lever stroke:

7t0 8notches when

N (20 kgf, 44 lb) with a force

Of

If incorrect, adjust the parking brake.

<Ref. to PB-12, ADJUSTMENT, Parking Brake AS- sembly (Rear Disc Brake).>

D: ADJUSTMENT



2) Forcibly pull the parking brake lever 3 to 5 times.

3) Adjust the parking brake lever by turning adjuster until the parking brake lever stroke is set at 7 to

8 notches with an operating force of 196 N (20 kgf,

44 Ib).

4)

Tighten the lock nut.

Lever stroke:

7 to 8 notches when pulled with a force of 796

N (20 kgc 44 lb)

Tightening torque (Lock nut):

5.9 N-m (0.6 kgf-m, 4.3 ft-lb)

1


(2) Locknut

(3) Adjusting nut

5 )

Install the console box. <Ref. to El-41, INSTAL-

LATION, Console Box.>

PB-7

I


PARKING BRAKE

3. Parking Brake Cable

A: REMOVAL


2) Remove the rear tires and wheels.

3) Remove the rear cushion.



5) Loosen the parking cable adjusting nut and console bracket.

6) Remove the parking brake lever.

10) Pull out the parking brake cable from rear brake.

Disc brake

<Ref. to PB-10, REMOVAL, Parking Brake As- sembly (Rear Disc Brake).>

Drum brake

<Ref. to BR-33, Rear Drum Brake Assembly.>

11) Pull out the clamp from rear brake.

12) Remove the bolt and bracket from trailing link bracket

.

13) Remove the bolt and clamp from rear floor.

7) Roll up the floor mat and remove clamps.

S4M0474A

(1) Grommet

(2)

Parking brake cable

14) Detach the grommet from rear floor.

15) Remove the cable assembly from cabin by forcibly pulling it backward.

16) Detach the parking brake cable from cable guide at rear trailing link.

0R0030

8) Remove the equalizer cover.

9) Remove the inner cable end from equalizer.

(1)

Equalizer

(2) Inner cable end

2)

S4M0473A

PB-8

B: INSTALLATION


Install the (new) parking brake assembly in the reverse order of removal.

NOTE:

Be sure to pass the cable through the cable guide inside tunnel.

Be sure to adjust the lever stroke. <Ref. to PB-7,

ADJUSTMENT, Parking Brake Lever.>

PARKING BRAKE

C: INSPECTION

Check the removed cable and replace if damaged, rusty or malfunctioning.

1) Check for smooth operation of the cable.

2) Check the inner cable for damage and rust.

3)

Check the outer cable for damage, bends, and cracks.

4)

Check the boot for damage, cracks, and deterioration.

a

P B-9

PARKING BRAKE

PARKING BRAKE ASSEMBLY (REAR DISC BRAKE)

4.

Parking Brake Assembly

(Rear Disc Brake)

A: REMOVAL

(2)

the disc rotor seizes up within the hub, drive the disc rotor out by installing an 8-mm bolt in holes B on the rotor.


4) Jack-up the vehicle, and remove wheel. disc brake assembly.

G4M0383

9)

Remove the primary and secondary return spring from parking brake assembly.

IO)

Remove the front shoe hold down spring and pin with pliers.

(1) Disc brake ASSY so that the hose is not stretched.

7)

Pull down and release the parking brake.

8) Remove the disc rotor.

NOTE:

If the disc rotor is difficult to remove try the following two methods in order.

(1)

Turn the adjusting screw using a slot-type screwdriver until the brake shoe gets away enough from the disc rotor.

12)

Remove the rear shoe hold-down spring and pin with pliers.

13)

Remove the adjuster assembly and adjusting spring from parking brake assembly.

14)

Remove the parking cable from parking lever.

(1)

Adjusting screw

(2) Cover (rubber)


(4)

Back plate

S4M0569A

(1) Parking brake cable

(2) Parking brake lever er. Remove the parking lever and washer from brake shoe.

PB-10

CAUTION: tamination.


B: INSTALLATION

Be sure the lining surface is free from oil con-

Dow

Corning Molykote

No.

7439 (Part No.

1) Apply brake grease to the following places.

NOTE: shown in Figure.

I

PARKING BRAKE

-

Brake grease:

7257 9 1460)

Six contact surfaces of shoe rim and back plate packing

Contact surface of shoe wave and anchor pin

Contact surface of lever and strut

S4M0462A Contact surface of shoe wave and adjuster assembly

Contact surface of shoe wave and strut

Contact surface of lever and shoe wave


(1)

Back plate

(2)

Shoe guide plate

(3) Retainer

Spring washer

CAUTION:

Use new retainers and clinch them when installing the brake shoes to levers.

Ensure that the parking lever moves smooth-

(4)

(5)

Lever

(6) Primary shoe return spring (Blue)

(7) Secondary shoe return spring (Yellow)

(8)

Parking brake shoe (Primary) ly- e

Do not confuse the left parking lever with right one.

Do

not confuse the left strut with right one.

(9) Parking brake shoe (Secondary)

3)

Adjust the parking brakes. <Ref. to PB-12, AD-

JUSTMENT, Parking Brake Assembly (Rear Disc

Brake) .>

NOTE:

Ensure that the adjuster assembly is securely installed with the screw in the left side, facing vehicle front.

CAUTION:

After replacing the parking brake lining, be sure to drive the vehicle for “break-in” purposes.

(1)

Drive the vehicle at about

35

km/h (22 MPH).

(2) With the parking brake release button pushed in, pull the parking brake lever gently. mile) in this condition.

(4) Wait 5 t o 10 minutes for the parking brake to

cool

down. Repeat this procedure once more.

(5) After breaking-in, re-adjust the parking brakes.

S4M0461A

(1) LEFT

PB-11

PARKING BRAKE


C: INSPECTION

1) Measure the brake disc inside diameter. If the disc is scored or worn, replace the brake disc.

Disc inside diameter:

Standard

170 mm (6.69 in)

Service limit

171 mm (6.73 in)

2) Measure the lining thickness. If it exceeds the limit, replace shoe assembly.

Lining thickness:

Standard

3.2 mm (0.126 in)

Service limit

1.5 mm (0.059 in)

CAUTION:

Replace the brake shoes on the right and left brake assembly at the same time.

D: ADJUSTMENT

1. SHOE CLEARANCE

1) Remove the adjusting hole cover from back plate.

2) Turn the adjusting screw using a slot-type screwdriver until the brake shoe is in close contact with disc rotor.

2.

LEVER

STROKE

1)

Remove the console box lid.

2)

Forcibly pull the parking brake lever 3 to 5 times.

3) Adjust the parking brake lever by turning adjuster until the parking brake lever stroke is set at 6 notches with operating force of 196 N (20 kgf, 44

Ib).

BR0054


(2) Locknut

(3)

Adjusting nut

4) Tighten the lock nut.

5)

Install the console box lid.

Lever stroke:

7 to 8 notches when pulled with a force of 196

N (20 kgf, 44 16)

Tightening torque (Adjuster lock nut):

6 N-m (0.6 kgf-m, 4.4 ft-16)

S4M0463A

I

(1) Adjusting screw

(2) Cover (rubber)


(4)

Back plate

3) Turn back (downward) the adjusting screw 3 or 4 notches.

4) Install the adjusting hole cover to back plate.

PB-I 2


5.


A: INSPECTION

Brake drag

Noise from brake

Possible cause

Parking brake lever is maladjusted.

Parkina brake cable does not move.

Parkina brake shoe clearance is maladiusted.

Return spring is faulty.

Return spring is faulty.

Shoe hold

down

spring is faulty.

PARKING BRAKE

Remedy

Adjustment.

Repair or replace.

1

Adjustment.

I

Replace.

Replace.

Replace.

I

I

PB-13

PARKING BRAKE


PB-14

POWER ASSISTED SYSTEM

(POWER STEERING)

1

.

2

.

3 .

4

.

5

.

9

.

10

.

Page

General Description

....................................................................................

2

Steering Wheel

..........................................................................................

19

Universal Joint

...........................................................................................

20

Tilt Steering Column

..................................................................................

23

Steering Gearbox

......................................................................................

26

Pipe Assembly

..........................................................................................

47

Oil Pump

...................................................................................................

55

Reservoir Tank

..........................................................................................

70

Power Steering Fluid

.................................................................................

72


..........................................................................

74


POWER ASSISTED SYSTEM (POWER STEERING)

1.

General

Description


Model

Whole svstem

Gearbox

Others

Non-TURBO

Sedan and

OUTBACK

5.1 (16.7)

Minimum turning radius m (ft)

Steering angle (Inside-Outside)

Steering wheel diameter mm (in)

Overall gear ratio (Turns, lock to lock

Gear box)

I

Type

Backlash

36'55'

3.22

I

Rack and pinion, Integral

0 (Automatically adjustable)

TURBO

34'05'

-

385 (15.16)

3.02

Valve (Power steerina svsteml

1

TvDe

Oil tank output cm3 (cu in)/rev.

I

Rotary valve

Vane pump

Installed on body

Pump

(Power steering system)

Working fluid

(Power steering system)

Relief pressure

1

Hvdraulic fluid control

Hydraulic fluid

Q kPa (kg/cm2, psi)

1,067- 1,165)

Dropping in response to increased engine revolutions

I

(US qt, Imp qt) rPm

1

3,000

rpm:

7

rpm:

5

I

I

700

-

7

I

(7.4,

.

6.2)'*

I

Range of revolution

Revolvina direction

Name

Oil tank

Capacity

Q

(US qt, Imp qt) Total

Clockwise

ATF DEXRON Ill

PS-2


POWER ASSISTED SYSTEM (POWER STEERING)

Steering wheel

Turning angle

Steering shaft

Free play

Inner tire & wheel mm (in)

TURBO, OUTBACK, Non-TURBO sedan other

Outer tire & wheel

TURBO, OUTBACK, Non-TURBO sedan

I other

Clearance between steering wheel and column

cover

mm (in)

I

I

Sliding resistance N (kgf, Ib)

Steering gearbox

(Power steering system)

Oil pump


~

Rack shaft play in radial direction

Left-turn steering mm (in)

I

Input shaft

Play

In radial direction

In axial direction

Turning resistance

Pulley shaft

Radial play

I

Axial play

I

I

Non-TURBO

TURBO

I I

I

Ditch deflection

Pulley

Regular pressure mm (in) mm (in)

N (kgf, Ib) mm (in)

I mm (in)

I

I ,

I mm (in)

\

I ,

I mm (in)

I

N (kqf, Ib)

I kPa (kg/cm2, psi)

Steering wheel effort


Relief pres- "+TURBO sure TURBO

At standstill with engine idling on a concrete road

At standstill with engine stalled on a concrete road kPa (kg/cm2, psi) kPa (kg/cm2, psi)

N (kgf, Ib)

N (kgf, Ib)

Recommended power steering fluid

ATF DEXRON Ill

L a

MOBIL

TEXACO

17 (0.67)

34"05'+1.5"

36"55'+1.5"

29"35'+1.5"

31 "35'+1.5"

3.0 (0.1 18)

340 (35, 76) or less

Horizontal movement:

0.1 5 (0.0059) or less

Vertical movement:

0.3 (0.01 2) or less

0.18 (0.0071) or less

0.5 (0.020) or less

Maximum allowable value: 12 (1.2, 2.7)

0.4 (0.01 6) or less

0.4 (0.016) or less

0.8 (0.031) or less

1 .O (0.039) or less

9.22 (0.94, 2.07) or less

981

(IO,

7,355 (75, 1,067)

7,845 (80, 1,138)

31.4 (3.2, 7.1) or less

294.2 (30, 66.2) or less

I

I

I

I

I

PS-3



CAUTION:

This table lists various clearances that must be correctly adjusted to ensure normal vehicle driving without interfering noise, or any other faults.

(1) Crossmember

-

(2) DOJ

-

(3) DOJ

-

(4) Pipe

-

(5) Stabilizer

-

(6)

Exhaust pipe

-

(7) Exhaust pipe

-

(8) Side frame

-

B

(9) Cruise control Dump

-

(IO)

-

(1 1) AT cooling hose -

Location

Minimum allowance

5 mm (0.20 in)

14 mm (0.55 in)

11 mm (0.43 in)

2 mm (0.08 in)

5 mm (0.20 in)

11 mm (0.43 in)

15 mm (0.59 in)

10 mm (0.39 in)

15 mm (0.59 in)

1.5 mm (0.059 in)

20 mm (0.79 in)

PS-4

ST0081



B: COMPONENT

1.

STEERING WHEEL AND COLUMN

(1)

Bushing

( 2 )

Knee protector

( 3 )

Steering shaft

(4)

Steering roll connector

( 5 )

Column cover

(6) Steering wheel

(7) Airbag module

(8) Lower steering wheel cover

STO10'


T1: 1.2 (0.72, 0.9)

T2: 3.4 (0.35, 2.5)

T3: 25 (2.5, 18.1)

T4: 44 (4.5, 32.5)

PS-5



2. POWER ASSISTED SYSTEM

I

I

TURBOMODEL

I

PS-6

STOlO2

(1) Eye bolt

(2) Pipe C

(3) Gasket

(4) Clip

(5)

Pipe D

(6) Clamp

E

(7) O-ring

(8) Cap

(9) Reservoir tank

Reservoir tank bracket

Pulley

Oil pump

Bracket

Belt tension nut

Bush

Belt cover

Pipe

E

Pipe F

Clamp plate

Universal joint

Dust seal

Valve housing

Gasket

Oil seal

Ball bearing

Seal ring



(27) Pinion and valve ASSY

(28) Oil seal

(29) Back-up washer

(30) Ball bearing

(31) Snap ring

(32) Locknut

(33) Adjusting screw

(34) Spring

(35) Sleeve

Adapter

Clamp

Cotter pin

Castle nut

Dust cover

Clip

Tie-rod end

Clip

Boot

Band

Tie-rod

Lock washer

Pipe B

Pipe A

Steering body

Oil seal

Piston ring

(53) Rack

(54) Rack bushing

(55)

Rack stopper

(56) Circlip

(57) Suction hose

(58) Tie-rod end plate

(59) Clamp plate

Tightening torque: N-m (kgf-m, ff-lb)

T1: 6 (0.6, 4.3)

T2: 7.4 (0.75, 5.4)

T3: 8 (0.8, 5.8)

T4: 13 (1.3, 9.4)

T5: 15(1.5, 10.8)

T6: 15(1.5, 10.8)

T7:

15.7(1.6, 11.6)

T8: 22 (2.2, 15.9)

T9: 24 (2.4, 17.4)

T10: 25 (2.5, 18.1)

T11: 25 (2.5, 18.1)

T12: 27(2.75, 19.9)

T13: 37.3 (3.8,27.5)

T14: 39 (4.0,28.9)

T15: 59 (6.0, 43)

T16: 78 (8.0, 58)

T17: 83 (8.5, 61.5)

T18: 25 (2.5, 18.1)

PS-7



3. OILPUMP

NON-TURBO MODEL

(1) Pulley

(2) Oil seal

(3) Shaft

(4) Connector

(5) O-ring

(6) Spool valve

(7) Spring

(8)

O-ring

(9)

Front casing

(1

0) Pressure switch

(11) O-ring

(12) O-ring

(1 3) Pressure plate

(14) Straight pin

(15) Vane

(16) Rotor

(17) Cam ring

(1 8) Retaining ring

(19) O-ring

(20) Rear cover

(21) Suction connector


T1: 21 (2.14, 15.5)

T2: 49 (5.0, 36.2)

T3: 52 (5.3, 38)

PS-8

TURBO MODEL



Lead wire

Pump switch

Rear cover

O-ring

Cam

Pressure plate

O-ring

Front casing

Front casing

Flow control spring

Flow control valve

Pulley

Oil seal

Suction connector

O-ring

Retaining ring

STOOOl

(17)

O-ring

Tightening torque: N.m


T1: 9.8 (1.0, 7.2)

T2: 27 (2.75, 19.9)

T3: 27.4 (2.8,20.3)

T4: 59 (6.0, 43)

T5: 11.8 (1.2, 8.7)

PS-9

I



C: CAUTION




Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement.


Use SUBARU genuine steering fluid, grease etc. or the equivalent. Do not mix steering fluid, grease etc. with that of another grade or from other manu- fact u rers.



Apply steering fluid onto sliding or revolution surfaces before installation.

Before installing O-rings or snap rings, apply sufficient amount of steering fluid to avoid damage and deformation.


PS-10




1.

SPECIAL TOOLS

ILLUSTRATION

TOOL NUMBER

I25700000

DESCRIPTION

VRENCH

REMARKS

Used for removing and installing tie-rod.

Apply this tool to rack.

1

B4M2411

32571 1000

'RESSURE

3AUGE

Used for measuring oil pump pressure.

84M241:

926200000

~

STAND

Used when inspecting characteristic of gearbox assembly and disassembling it.

B4M241

34099AC010

ADAPTER HOSE A 1

Used with PRESSURE GAUGE (92571 1000).

PS-11



I


34099FA100

DESCRIPTION

STAND BASE

REMARKS

Used for assembling power steering gearbox.

For LHD model.

ADAPTER HOSE B Used with PRESSURE GAUGE (92571 1000).

For the lock nut when adjusting backlash of gearbox.

04M2416

34099PA100 SPANNER Measurement of rotating resistance of gear-

~ box assembly.

I

ST0047

PS-12

ILLUSTRATION



I

TOOLNUMBER

134199AE020

For TURBO model.

B4M247 7

141 99AE030

NSTALLER

Jsed for installing oil seal into oil pump.

341 99AE040

31L CHARGE

SUIDE

K e d for charging power steering oil.

B4M241$

927640000

INSTALLER B

Used for installing ball bearing into housing.

B4M242

PS-13




926370000

DESCRIPTION

INSTALLER A

REMARKS

Used for installing valve assembly into valve housing assembly.

Used with STAND BASE (927630000).

84M2421

926390001 COVER &

REMOVER ASSY

~~~ ~

Used for assembling rack assembly.

84M2422

926420000 PLUG When oil leaks from pinion side of gearbox assembly, remove pipe B from valve housing, attach this tool and check oil leaking points.

04M2423

926400000 GUIDE

Right side of rack when installing rack bush.

Used with GUIDE (927660000).

84M2424

PS-14

ILLUSTRATION



927660000

DESCRIPTION

GUIDE

REMARKS

Right side of rack when installing rack bush.

Used with GUIDE (926400000).

B4M242!

927620000

~

INSTALLER B

b b

Used for installing oil seal of valve housing.

Used with INSTALLER A (926360000).

B4M242E

326360000 INSTALLER

A

'

1

Used as a guide to install oil seal.

Used with INSTALLER B (927620000).

04M2420

INSTALLER Jsed for installing oil seal.

B4M2429

PS-15




34099FA120

DESCRIPTION

INSTALLER AND

REMOVER SEAL

REMARKS

Used for installing and removing valve housing oil seal.

SI

H0030

34099FA130

INSTALLER SEAL

Used for installing valve housing oil seal.

Used with INSTALLER AND REMOVER SEAL

(34099FA120).

ST0007

341 99AE050 REMOVER OIL

SEAL

Used for removing back-up ring and oil seal.

84M2432

34099AC030

INSTALLER A Used for installing retaining ring.

Used with INSTALLER B (34099AC040).

For non-turbo model.

H4M1408

PS-1 6

ILLUSTRATION



TOOL NUMBER

34099AC040

DESCRIPTION

INSTALLER B

REMARKS

Used for installing retaining ring.

Used with INSTALLER A (34099AC030).

For non-turbo model.

H4M140E

PS-17


POWER ASSISTED SYSTEM (POWER STEERING)

2.

GENERAL PURPOSE

TOOLS

Spring scale

Snap ring pliers

Dial gauge

~

-

Used for measuring tightening torque.

Used for removina and installina snaD rina.

I

.

.

.

I

I

I

Used for measuring steering gearbox.

I

PS-18

2. Steering Wheel

A: REMOVAL


2) Set the tires to straight-ahead position.

3) Remove the airbag module. <Ref. to AB-12, RE-

MOVAL, Driver’s Airbag Module.>

WARNING:

Always refer t o “Air Bag System” before performing airbag module service. <Ref. t o AB-12,

CAUTION, Driver’s Airbag Module.>

4)

Remove the steering wheel nut, and then draw out the steering wheel from the shaft using steering puller.

NOTE:

Make the matching marks on the steering wheel and steering column in advance.

(1) Matching mark

STEERING WHEEL


B: INSTALLATION

1) Align the center of roll connector. <Ref. to AB-1 7,

ADJUSTMENT, Roll Connector.>


NOTE:

Align the matching marks on the steering wheel and steering column.


44 N.m (4.5 kgf-m, 32.5 ft-lb)

Column cover-to-steering wheel clearance:

2

-

mm

(0.08

-

in)

WARNING:

Always refer t o “Air Bag System” before performing airbag module service. <Ref. t o AB-1 2,


CAUTION:

Insert the roll connector guide pin into the guide hole on lower end of surface of steering wheel to prevent damage. Draw out the airbag system connector, horn connector and cruise control connectors from the guide hole of steering wheel lower end.

C: INSPECTION

1)

Check the steering wheel for deformation. If the deformation is excessive, replace the steering wheel.

2) Check the splines on the steering wheel for damage. If the damage is excessive, replace the steering wheel.

I

PS-19

UNIVERSAL JOINT


3.

Universal Joint

A: REMOVAL

1) Remove the steering wheel. <Ref. to PS-19, RE-

MOVAL, Steering Wheel.>

2) Remove the universal joint bolts and then remove the universal joint.

CAUTION

:

Scribe alignment marks on universal joint so that it can be reassembled at the original serration.

B: INSTALLATION

1) Install the universal joint.

(1) Align the cutout at serrated section of the column shaft and yoke, then insert the universal

(1)

cutout

(2) Yoke

(3) Column shaft

(4)

Column shaft side

(5) Gearbox side

(2) Align the bolt hole on the gearbox side of universal joint with the cutout at the serrated section of gearbox assembly. Lower the universal joint completely.

(3) Temporarily tighten the bolt on the gearbox side. Raise the universal joint to make sure the bolt is properly passing through the cutout at the serrated section.

(4) Tighten the bolt.


24 N-m (2.4 kgf-m, 17.4 ff-lb)

CAUTION:

Make sure that universal joint bolt is tightened through notch in shaft serration.

Excessively large tightening torque of universal joint bolts may lead to heavy steering wheel operation.

Standard clearance between gearbox to

DOJ:

Over 14 mm (0.55 in)

PS-20

UNIVERSAL JOINT


2)

Align the center of roll connector. <Ref. to AB-1 7,


CAUTION:

Ensure that front wheel are set straight forward direction.

3)

Install the steering wheel and airbag module.

<Ref. to PS-19, INSTALLATION, Steering Wheel.>

WARNING:

Always refer to “Air Bag System” before performing airbag module service. <Ref. to AB-1 2,

CAUTION, Driver’s Airbag Module.> and <Ref. to

AB-1

2,

INSTALLATION, Driver‘s Airbag Mod- ule.>

I

PS-21

UNIVERSAL JOINT


C: INSPECTION

Clean the disassembled parts with a cloth, and check for wear, damage, or any other faults. If necessary, repair or replace faulty parts.

Inspection

Corrective action

Free play

Swinging torque

Yawing torque

Looseness

1

Yawing torque

Replace if faulty.

Looseness

G4M0089

Standard value of universal joint free play: 0 mm (0 in)

Max. value of universal joint swinging torque: 0.3 N.m (0.03 kgf-m, 0.2 ft-lb)

Measurement of folding torque of universal joint is as shown in the figures.

Service limit:

Maximum load; 7.3 N (0.74 kgf, 1.64 lb) or less


Maximum load; 7.3 N (0.74 kgc 1.64 lb) or less

S4M0443A

(1)

Yoke (gearbox side)



S4M0445A

(1) Yoke (Steering column side)



(1)

Yoke (gearbox side)

.

, ,

.

S4M0444A

PS-22

(1) Yoke (Steering column side)

S4M0446A

TILT STEERING COLUMN


4. Tilt

Steering Column

A:

REMOVAL

I

n

ST0022

(1) Tilt steering column

(2)

Universal joint


2) Disconnect the battery ground terminal.

3) Remove the airbag module. <Ref. to AB-12,

RE-

MOVAL, Driver’s Airbag Module.>

WARNING:

Always refer to “Air Bag System” before performing airbag module service. <Ref. to AB-12,

CAUTION, Driver’s Airbag Module.>

4)

Remove the steering wheel. <Ref. to PS-19, RE-

MOVAL, Steering Wheel.>

PS-23


N.m (kgf-m, ft-lb)

T1: 24 (2.4, 17.4)

12: 25 (2.5, 18.1)

5 )

Remove the universal joint. .=Ref. to PS-20, RE-

MOVAL, Universal Joint.>

6)

Remove the trim panel under instrument panel.

I



7) Remove the screw securing lower steering column cover.

B: INSTALLATION

1) Set the grommet to the toe board.

8) Remove the knee bolster w

//

B4M1656

2)

Insert the end of steering shaft into the toe board grommet.

3)

Tighten the steering shaft mounting bolts under instrument panel.


25

N-m

(2.5 kgf-m, 78.7 fWb)

4)

Install the knee bolster.

9) Remove all connectors from the steering column.

10) Remove the two bolts under instrument panel securing steering column.

11) Pull out the steering shaft assembly from the hole on toe board.

CAUTION:

Be sure to remove the universal joint before removing steering shaft assembly installing bolts when removing steering shaft assembly or when lowering it for servicing of other parts.

5)

Connect all connectors under instrument panel.

6) Connect the airbag system connector at the harness spool.

NOTE:

Make sure to apply double lock.

7) Install the lower column cover with tilt lever held in the lowered position.

8) Install the universal joint. <Ref. to PS-20, IN-

STALLATION, Universal Joint .>

9)

Align the center of roll connector. <Ref. to AB-17,


CAUTION:

Ensure that front wheels are set in straight forward direction.

PS-24



10) Install the steering wheel. <Ref. to PS-19, IN-

STALLATION, Steering Wheel.>

Set the steering wheel to neutral and install it onto steering shaft.

CAUTION:

Insert roll connector guide pin into guide hole on lower end of surface of steering wheel t o prevent damage. Draw out airbag system connector, horn connector and cruise control connectors from guide hole of steering wheel lower end.

11) Install the airbag module to the steering wheel.

WARNING:

Always refer to “Air Bag System” before performing the service operation. <Ref. to AB-12,


C: DISASSEMBLY

Remove the two screws securing upper steering column covers, and the two screws securing combination switch, then remove the related parts.

D: ASSEMBLY

1)

Insert the combination switch to the upper column shaft, and install the upper column cover.

Then route the ignition key harness and combination switch harness between column cover mounting bosses.


1.2 N.m (0.12 kgf-m, 0.9 ft-lb)

CAUTION:

Don’t overtorque the screw.

E: INSPECTION

1.

BASIC INSPECTION

Clean the disassembled parts with a cloth, and check d r wear, damage, or any other faults. pair or replace faulty parts. necessary, re-

Corrective action

Overall length of steering column

Measure overall length of steering column.

Standard overall length of steering column:

Inspection

Replace steering column assembly.

825.7f1.5” (32.51+0.059in)

ST0024

2. AIRBAG MODEL INSPECTION

WARNING:

For airbag model inspection procedures, refer to “Air Bag System”. <Ref. to AB-12, CAUTION,

Driver’s Airbag Module.> and <Ref. t o AB-12,

INSPECTION, Driver’s Airbag Module.>

I

PS-25

STEERING GEARBOX

POWER ASSISTED SYSTEM (POWER STEERING)

5. Steering Gearbox

A: REMOVAL


2) Disconnect the battery ground terminal.

3) Loosen the front wheel nuts.

4) Lift the vehicle and remove the front wheels.


6) Remove the sub frame. <Ref. to FS-16, RE-

MOVAL, Sub Frame.>

7) Remove the front exhaust pipe assembly. (Non-

TURBO model)

<Ref. to EX(S0HC)-5, REMOVAL, Front Exhaust

Pipe.>

WARNING:

Be careful, exhaust pipe is hot.

8)

Using a puller, remove the tie-rod end from the knuckle arm after pulling off cotter pin and removing castle nut.

10) Remove the one pipe joint at the center of gearbox, and connect the vinyl hose to the pipe and joint. Discharge the fluid by turning steering wheel fully clockwise and counterclockwise. Discharge the fluid similarly from the other pipe.

(1) PipeA

(2) Pipe B

11) Remove the universal joint. <Ref. to PS-20,

REMOVAL, Universal Joint.>

12) Disconnect the pipes C and D from the pipe of gearbox.

CAUTION:

Be careful not to damage these pipes.

NOTE:

Disconnect the upper pipe D first, and lower pipe

C second.

(1) Castle nut

(2) Tie-rod end

(3) Knuckle arm

9)

Remove the jack-up plate and front stabilizer.

(1)

Pipe C

(2) Pipe

D

(1

) Jack-up plate

PS-26



13)

Remove the clamp bolts securing gearbox to the crossmember, and remove the gearbox.

(2)

Connect the pipes C and D to the gearbox.

Connect the upper pipe D first, and lower pipe C second.


15 N.m (1.5 kgf-m, 10.8 ft-16)

9

(1) Clamp

B: INSTALLATION

1)

Insert the gearbox into the crossmember, being careful not to damage gearbox boot.

2)

Tighten the gearbox to the crossmember bracket via clamp with bolt to the specified torque.


59 N-m (6.0 kgf-m, 43 ff-16)

(1)

Pipe C

(2) Pipe D

4)

Install the universal joint. <Ref. to PS-20, IN-

STALLATION, Universal Joint.>

5 )

Connect the tie-rod end and knuckle arm, and tighten with castle nut. Fit the cotter pin into the nut and bend the pin to lock.

Castle nut tightening torque:

Tighten to 27.0 N.m (2.75 kgf-m, 19.9 ft-lb), and tighten further within 60" until cotter pin hole is aligned with a slot in the nut.

CAUTION:

When connecting, do not hit cap at the bottom of tie-rod end with hammer.

(1) Clamp

3) Install the four pipes on the gearbox.

(1) Connect the pipes A and B to the four pipe joints of gearbox. Connect the upper pipe B first, and lower pipe A.


13 N.m (1.3 kgf-m, 9.4 ft-16)

/,

S4M0379A

(1)

Castle nut

(2) Tie-rod end

(3) Knuckle arm

6) Install the front stabilizer to vehicle.

7) Install the front exhaust pipe assembly.

8)

Install the sub frame. <Ref. to FS-16, INSTALLA-

TION, Sub Frame.>

PS-27



9) Align the center of roll connector. <Ref. to AB-1 7,


CAUTION:

Ensure that front wheels are set in straight forward direction.

10) Install the steering wheel. <Ref. to PS-19, IN-

STALLATION, Steering Wheel

.>

11) Install the tires.

12) Tighten the wheel nuts to the specified torque.


90 N-m (9.7 kgf-m, 66 ff-lb)

13) Connect the ground terminal to battery.

14) Pour the fluid into the oil tank, and bleed air.

<Ref. to PS-72, Power Steering Fluid.>

15) Check for fluid leaks.

16) Install the jack-up plate.

17) Lower the vehicle.

18)

Check the fluid level in oil tank.

19) After adjusting toe-in and steering angle, tighten the lock nut on tie-rod end.


83 N-m (8.5 kgf-m, 61.5 ff-lb)

CAUTION:

When adjusting toe-in, hold the boot as shown to prevent it from being rotated or twisted. If twisted, straighten it.

1.

RACK HOUSING ASSEMBLY

1) Disconnect the four pipes from the gearbox.

NOTE:

Remove the pipes E and F as a single unit being fixed at the clamp plate.

2) Secure the gearbox removed from the vehicle in vice using ST.

ST 926200000 STAND

CAUTION:

Secure the gearbox in a vice using the

ST as shown. Do not attempt to secure it without this

ST.

3) Remove the tie-rod end plate.

S4M0143A

G4M0132

C: DISASSEMBLY

NOTE:

Parts requiring replacement are described in the smallest unit of spare parts including damaged parts and spare parts damaged. In actual disassembly work, accidental damage as well as inevita- ble damage to some related parts must be taken into account, and spare parts for them must also be prepared. However, it is essential to pinpoint the cause of trouble, and limit the number of replacement parts as much as possible.

I

ST0084

4)

Remove the tie-rod end and lock nut from the gearbox.

5 )

Remove the small clip from the boot using pliers, and move the boot to the tie-rod end side.

I

S4M01448

(1)

Clip

PS-28


POWER

ASSISTED SYSTEM (POWER STEERING)

6)

Using standard screwdriver, remove the band from the boot.

9)

Tighten the adjusting screw until it no longer tightens.

1

S4M0145C

(1)

Band

7)

Extend the rack approximately 40 mm

(1.57

out. Unlock the lock wire at lock washer on each side of tie-rod end using a standard screwdriver.

CAUTION:

Be careful not to scratch rack surface as oil leaks may result.

S4M0140

Using a wrench

[32 (1.26

flats] or adjustable wrench, remove the tie-rod.

CAUTION:

Check ball joint for free play, and tie-rod for bends. Replace if necessary.

Check dust seals used with tie-rod end ball joint for damage or deterioration. Replace if necessary.

(1)

Lock washer

8)

Usina ST. loosen the lock nut.

ST

9F6230OOO

SPANNER

S4M0146C

11)

Loosen the adjusting screw and remove the spring and sleeve.

CAUTION:

Replace spring and/or sleeve if damaged.

S4M0147C

S4M0154

PS-29

I


POWER ASSISTED SYSTEM (POWER STEERING)

13) Carefully draw out the input shaft and remove the valve assembly.

16) Remove the rack bushing and rack stopper from the rack assembly.

CAUTION:

Do not reuse removed rack bushing and circlip.

17) Remove the oil seal from rack.

18) Insert ST from the pinion housing side and remove the oil seal using a press.

ST 34099FA110 INSTALLER

a

14) Using a sharp pointed pliers, rotate the rack stopper in the direction of the arrow until the end of the circlip comes out of the stopper. Rotate the circlip in the opposite direction and pull it out.

(1

Rack stopper

15) Pull the rack assembly from the cylinder side, and draw out the rack bushing and rack stopper together with the rack assembly.

CAUTION:

Be careful not to contact rack to inner wall of cylinder when drawing out. Any scratch on cylinder inner wall will cause oil leakage.

L A

(1)

Press

(2) Oil seal

NOTE:

Discard the removed the oil seal.

S4M01638

( 3 )

(1) Rack bushing

(2) RackASSY

(3) Rack stopper

S4M0402A

PS-30


POWER

ASSISTED SYSTEM (POWER STEERING)

2. CONTROL VALVE

1) Disconnect the four pipes from the gearbox.

NOTE:

Remove the pipes E and F as a single unit being fixed at the clamp plate.

2) Secure the gearbox removed from the vehicle in vice using ST.

ST 926200000 STAND

CAUTION:

Secure the gearbox in a vice using the ST as shown. Do not attempt to secure it without this

ST.

5)

Loosen the adjusting screw and remove the spring and sleeve.

CAUTION:

Replace the spring and/or sleeve if damaged.

6) Remove the two bolts securing valve assembly.

I

7) Carefully draw out the input shaft and remove the valve assembly.

1

3)

Usina ST, loosen the lock nut.

ST 926230000 SPANNER

S4M0143P

8) Slide the dust cover out.

T008!

4) Tighten the adjusting screw until it no longer tightens.

S4M01568

(1)

Dust cover

PS-31

I



9) Using a press remove pinion and valve assembly from the valve housing.

11) Remove the snap ring using snap ring pliers.

CAUTION:

Do not reuse removed snap ring.

Be careful not to scratch pinion and valve assembly.

(3)-

S4M01578

(1

) Valve ASSY

(2)

Valve housing

(3) Cloth

10) Using ST and press, remove the dust seal, oil seal and special bearing from the valve housing.

ST 34099FA120 INSTALLER & REMOVER

SEAL

CAUTION:

Do not apply a force to end surface of valve housing.

Do not reuse oil seal after removal.

12)

Press out the bearing together with the back up washer using pipe of I.D. 38.5 to 39.5 mm (1.516 to

1.555 in) and press.

CAUTION:

Do not reuse removed bearing.

(1) Oil seal

(2) Special bearing

S4M0159B

(1) Bearing

(2) Backing washer

(3) Oil seal

(4)

Pipe

13) Remove the oil seal.

CAUTION:

Do not reuse removed oil seal.

S4M0403A

PS-32

D: ASSEMBLY

1.

RACK HOUSING ASSEMBLY

CAUTION:

Use only SUBARU genuine grease for gearbox.

Specified grease for gearbox:

VALIANT GREASE M2 (Part No. 003608001)

1) Clean all parts and tools before reassembling.

2) Force-fit oil seal using ST.

ST 34099FA110 INSTALLER

CAUTION:

Be careful not to damage or scratch cylinder inner wall.

NOTE:

Apply specified power steering fluid to oil seal.

Pay special attention not to install oil seal in wrong direction.

Push oil seal until the stepped portion of A contacts end face of B.



Do not apply grease to threaded portion at end of rack shaft.

Move rack shaft to stroke end two (2) or three

(3)

times to squeeze grease which accumulates on both ends. Remove grease to prevent it from choking air passage hole.

4) Apply grease to the sleeve insertion hole.

5) Apply grease to the dust seal insertion hole.

CAUTION:

Apply clean grease with clean hands. If material having a sharp edge is used for applying grease, oil seal at the inside might be damaged.

6)

Fixing rack housing

Fix the rack housing in vice using ST.

ST

926200000 STAND

CAUTION:

When fixing rack housing in vice, be sure to use this special tool. Do not fix rack housing in vice using pad such as aluminum plates, etc.

When using old rack housing, be sure to clean and remove rust before assembling.

Check pinion housing bushing carefully.

7)

Install the oil seal to rack.

8)

Fit ST over toothed portion of rack assembly, and check for binding or unsmooth insertion. If any deformation is noted on flats at the end of rack, shape bv using file, and wash with cleaning fluid.

ST

'

926390061 COVER & REMOVER

m

S4M01648

(1) Press

(2) Oil seal

3) Apply grease to the teeth of rack so that the grease applied is about as high as teeth, and also apply a thin film of grease to the sliding portion of rack shaft.

CAUTION:

When moving rack to stroke end without tie- rod attached, prevent shocks from being applied at the end.

( 1 )

S4M0406A

(1) Rack ASSY

9) Apply genuine grease to the teeth of thoroughly washed rack assembly, and fit ST over the toothed portion.

CAUTION:

Be careful not to block air passage with grease. Remove excessive grease.

After fitting cover, check air passage hole for clogging. If clogged, open by removing grease from the hole.

Check rack shaft for damage.

Apply specified power steering fluid to this

ST and surface of piston ring to prevent seal from being damaged.

PS-33



10) Insert the rack assembly into the rack housing from cylinder side, and remove ST after it has passed completely through oil seal.

NOTE:

Before inserting rack assembly, apply a coat of specified power steering fluid to surfaces of ST and rack piston.

ST 926390001 COVER & REMOVER

11) Fit ST1 and ST2 over the end of rack, and install rack bushing.

STl 926400000 GUIDE

ST2 927660000 GUIDE

CAUTION:

If burrs, or nicks are found on this guide and rack shaft portion, remove by filing.

Dip rack bushing in specified power steering fluid before installing, and pay attention not to damage O-ring and oil seal.

13) Insert the rack stopper into the rack housing, and wrap the circlip using a sharp pointed pliers to secure the rack stopper in position.

CAUTION:

Be careful not to scratch rack while winding circlip.

NOTE:

Rotate the wrench another 90 to 180" after the end of circlip has been wrapped in.

S4M0167

14) Fit the mounting rubber onto the rack housing.

15) Apply the specified grease to the dust cover.

(1)

Rack

bushing

ASSY

12) Insert the rack stopper into the cylinder tube until internal groove (on cylinder side) is aligned with external groove (on rack stopper). Turn the rack stopper with ST so that the rack stopper hole is seen through cylinder slits.

I

S4M0166A

I

16) Install the dust cover on the valve assembly.

17) Apply genuine grease to the pinion gear and bearing of valve assembly.

G4M0158

PS-34



18) Install the gasket on the valve assembly. Insert the valve assembly into the place while facing rack teeth toward pinion.

CAUTION:

Be sure to use a new gasket.

NOTE:

Do not allow packing to be caught when installing valve assembly.

21) Install the lock washers and tighten the left and right tie-rods into the rack ends.

On condition

L: Approximately 40 mm (1.57 in)


78 N-m (8.0 kgf-m, 58 ft-16)

9

. S4M0155

19) Tighten the bolts alternately to secure the valve assembly.


25 N.m (2.5 kgf-m, 18.1 ft-16)

CAUTION:

Be sure to alternately tighten bolts.

20) Apply grease to the sliding surface of sleeve and spring seat, then insert the sleeve into the pinion housing. Fit the spring into the sleeve screw, pack grease inside of screw, then install the screw.

S4M01.508

(1)

Tie-rod

22) Bend the lock washer using a chisel.

CAUTION:

Be careful not to scratch rack when bending lock washer.

r

'

S4M0384A

(1)

Lock washer

B4M1129B

(1) Adjusting screw

(2)

Spring

(3)

Sleeve

PS-35



23) Rack and pinion backlash adjustment

(1) Loosen the adjusting screw.

(2) Rotate the input shaft so that the rack is in the straight ahead direction.

(3) Apply grease to the sleeve.

I

I

P-

B4M1130B

I

(1) Adjusting screw

(2) Lock nut

(3) Spring

(4)

Sleeve

(4) Tighten the adjusting screw by two threads.

I

I

(7) Install the lock nut. While holding adjusting screw with a wrench, tighten the lock nut using

ST.



39 N-m (4.0 kgf-m, 29 f?-lb)

NOTE:

Hold the adjusting screw with a wrench to prevent it from turning while tightening lock nut.

Make adjustment so that the steering wheel can be rotated fully from lock to lock without binding.

24) Check for service limit as per article of “Service limit”.cRef. to PS-42, INSPECTION, Steering

Gearbox.> Make replacement and adjustment if necessary

.

25) Install the boot to the housing.

NOTE:

Before installing boot, be sure to apply grease to the groove of tie-rod.

Install fitting portions of boots to the following portions in both sides of assembled steering gearbox.

The groove on gearbox

The groove on the rod

Make sure that the boot is installed without unusual inflation or deflation.

G4M0121

( 5 )

Apply liquid packing to at least 1/3 of entire perimeter of adjusting screw thread.

Liquid packing:

THREE BOND 1141

S4M0151A

I

S4M0385A

(1)

Apply liquid packing to at least

1/3 of entire perimeter.

(6) Tighten the adjusting screw to 7.4 N.m (0.75 kgf-m, 5.4 ft-lb) and back off 25”.

PS-36



26) Using a screwdriver, tighten the screw until the ends

“ A each other.

CAUTION:

Use a new band.

NOTE:

Always tighten the band from the underside of the gear box.

28) If the tie-rod end was removed, screw in lock nut and tie-rod end to the screwed portion of tie- rod, and tighten the lock nut temporarily in a position as shown in figure.

Installed tie-rod length: L

15 mm (0.59 in)

NOTE:

Pay attention to difference between right and left tie-rod ends.

il

A

L

r-

S4M0152A

27) Fix the boot end with clip (small).

CAUTION:

After installing, check boot end is positioned into groove on tie-rod.

G4M0126

29) Install the tie-rod end plate.


13 N.m (1.3 kgf-m, 9.4 ft-lb)

30) Inspect the gearbox as follows: three times as quickly as possible.

“ B Holding tie-rod end, turn it slowly at a radius one or two times as large as possible.

After all, make sure that the boot is installed in the specified position without deflation.

S4M0144B

(1)

Clip

G4M0127

31) Remove gearbox from

ST.

ST 926200000 STAND

32) Install the four pipes on gearbox.

(1) Connect the pipe A and B to the four pipe joints of gearbox.


13 N-m (1.3 kgf-m, 9.4 ft-lb)

(2) Connect the pipe E and F to the gearbox.


Pipe E: 15 N.m (1.5 kgf-m, 10.8 ft-lb)

Pipe F: 25 N.m (2.5 kgf-m, 18.1 ft-lb)

PS-37

I



2. CONTROL VALVE ASSEMBLY

Specified steering grease:

VALIANT GREASE M2 (Part No. 003608001)

1) Clean all parts and tools before reassembling.

2) Apply a coat of specified power steering fluid to the inner wall of valve housing.

4) Using ST and press, install the special bearing in valve housing.

ST 34099FA120 INSTALLER & REMOVER

SEAL

NOTE:

To facilitate installation, attach the ball bearing to the remover and position in valve housing before pressing it into place.

I

Fluid

I

S4M0162A

3) Attach ST2 to STI , and press the oil seal into the place using a press.

STI 34099FA120 INSTALLER & REMOVER

SEAL

ST2 34099FA130 INSTALLER SEAL

(1)

Face oil seal in the direction shown in figure when installing.

(2) To avoid scratching oil seal, apply a coat of grease to the contact surface of installer and oil seal.

(3) To facilitate installation, attach oil seal to the installer and position in valve housing before pressing into place.

S4M0161B

(1)

Special bearing

(2) Oil seal

5 )

Put vinyl tape around pinion shaft splines to protect oil seal from damage.

6) Fit pinion and valve assembly into valve housing.

7) Secure valve assembly to ST1 and ST2.

I

S4M0160A

PS-38



8 )

Put ST3 over pinion, and insert oil seal, then force-fit oil seal into housing using ST4.

ST1 926370000 INSTALLER A

ST2 34099FA100 STAND BASE


ST4 927620000 INSTALLER B

I

10) Force-fit ball bearing using ST3.


ST2 34099FA100 STAND BASE

ST3 927640000 INSTALLER B

.

II

S4M04051

(1) Ball bearing

(2)

Backing washer

NOTE:

Be careful not to tilt ball bearing during installation.

11) Install the snap ring using snap ring pliers.

NOTE:

Rotate the snap ring to check for proper installation.

12) Apply the specified grease to the dust cover.

S4M0404A

(1)

Oil seal

NOTE:

Apply the specified power steering fluid to the oil seal and ST3, being careful not to damage oil seal lip.

Push the oil seal until ST3 contacts housing end face.

9) Remove ST3, and fit backing washer.

I

S4M01566

(1)

Dust cover

13) Install the dust cover on the valve assembly.

14) Apply genuine grease to the pinion gear and bearing of valve assembly.

G4M0150

PS-39



15) Install the gasket on the valve assembly. Insert the valve assembly into the place while facing rack teeth toward pinion.

CAUTION:

Be sure to use a new gasket.

NOTE:

Do not allow packing to be caught when installing valve assembly.

20) Rack and pinion backlash adjustment

(1) Loosen the adjusting screw.

(2) Rotate the input shaft so that the rack is in the straight ahead direction.

(3) Apply grease to the sleeve.

_I r

I

(1) Adjusting screw

(2) Locknut

(3) Spring

(4) Sleeve 16)

Tighten the bolts alternately to secure the valve assembly.

(4) Tighten the adjusting screw by two threads. m


25 N-m (2.5 kgf-m, 18.1 ff-lb)

CAUTION:

Be sure to alternately tighten bolts.

17) Apply grease to the sleeve insertion hole.

18) Apply grease to the dust seal insertion hole.

CAUTION:

Apply clean grease with clean hands. If material having a sharp edge is used for applying grease, oil seal at the inside might be damaged.

19)

Apply grease to the sliding surface of sleeve and spring seat, then insert the sleeve into the pinion housing. Fit the spring into the sleeve the screw, pack grease inside of screw, then install the screw.

B4M1129B

1

(1) Apply liquid packing to at least 1/3 of entire perimeter.

' ( 1 )

S4M03851

(1) Adjusting screw

(2)

Spring

(5) Apply liquid packing to at least 1/3 of entire perimeter of adjusting screw thread.

Liquid packing:

THREE BOND 1141

(3) Sleeve

(6) Tighten the adjusting screw to 7.4 N-m (0.75 kgf-m, 5.4 ft-lb) and back off 25".

G4M0121

I

B4M1130E

PS-40


POWER ASSISTED SYSTEM [POWER STEERING)

(7)

Install the lock nut. While holding adjusting screw with a wrench, tighten the lock nut using

ST.



39 N-m (4.0 kgf-m, 29 ff-lb)

NOTE:

Hold the adjusting screw with a wrench to prevent it from turning while tightening lock nut.

Make adjustment so that the steering wheel can be rotated fully from lock to lock without binding.

21) Check for service limit as per article of “Service limit”.<Ref. to PS-42, INSPECTION, Steering

Gearbox.> Make replacement and adjustment if necessary.

22) Take off the gearbox from ST.

23) Install the four pipes on the gearbox.

(1)

Connect the pipe A and 6 to the gearbox.


13 N-m (1.3 kgf-m, 9.4 ft-lb)

(2)

Connect the pipe E and F to the gearbox.


Pipe E: 15 Nom

Pipe F: 25 N.m (2.5 kgf-m, 18.1 ft-lb)

1

PS-41



E: INSPECTION

1. BASIC INSPECTION

1)

Clean all disassembled parts, and check for wear, damage, or any other faults, then repair or replace as necessary.

2) When disassembling, check inside of gearbox for water. If any water is found, carefully check boot for damage, input shaft dust seal, adjusting screw and boot clips for poor sealing. If faulty, replace with new parts.

No.

1

2

3

4

5

6

7

8

9

10

11

Parts

Input shaft

Dust seal

Rack and pinion

Gearbox unit

Boot

Tie-rod

Tie-rod end

Adjusting screw swing

Boot clip

Sleeve

Pipes

Inspection

(1)

Bend of input shaft

(2)

Damage on serration

(1) Crack or damage

(2) Wear

Poor mating of rack with pinion

Corrective action

If the bend or damage is excessive, replace the entire gearbox.

If the outer wall slips, the lip is worn out or damage is

~~ found. redace it with new one.

(1) Adjust the backlash properly.

By measuring turning torque of gearbox and sliding resistance of rack, check if rack and pinion engage uniformly and smoothly with each other. (Refer to “Service limit”.)

(2)

Keeping rack pulled out all the way so that all teeth emerge, check teeth for damage.

Even if abnormality is found in either (1) or (2), replace the entire aearbox.

(1) Bend of rack shaft

(2)

Bend of cylinder portion

(3) Crack or damage on cast iron portion

Replace the gearbox with new one.

(4)

Wear or damage on rack bush

( 5 )

Wear on input shaft bearing

If the free play of rack shaft in radial direction is out of the specified range, replace the gearbox with new one. (Refer to “Service limit”.)

If the free plays of input shaft in radial and axial directions are out of the specified ranges, replace the gearbox with new one. (Refer to “Service limit”.)

Replace. Crack, damaae or deterioration

(1)

Looseness of ball joint

(2)

Bend of tie-rod

Damage or deterioration on dust seal

Replace.

Replace.

Deterioration

Deterioration

Damage

(1) Damage to flared surface

(2)

Damage to flare nut

(3)

Damage to pipe

Replace.

Replace.

Replace.

Replace.

PS-42



2.

SERVICE LIMIT

Make a measurement as follows. If it exceeds the specified service limit, adjust or replace.

NOTE:

When making a measurement, vise gearbox by using ST. Never vise gearbox by inserting aluminum plates, etc. between vise and gearbox.

ST 926200000 STAND

Sliding resistance of rack shaft:

Service limit

340

N

(35

kgf,

76

lb) or less

3.

RACK SHAFT PLAY IN RADIAL DIREC-

TION

Right-turn steering:

Service limit

0.19

mm

(0.0075

in) or less

On condition

L:

5

mm

(0.20

in)

P:

122.6

N

(12.5

kgf,

27.6

lb)

a

Left-turn steering:

Service limit

Direction

0.3

mm

(0.012

in) or less

Direction

+I)

0.15

mm

(0.0059

in) or less

G4M0110

G4M0112

PS-43



4.

INPUT SHAFT PLAY

In radial direction:

Service limit

0.18 mm (0.0071 in) or less

On condition

P: 98 N (10 kg< 22 lb)

5.

TURNING RESISTANCE

OF

GEARBOX

Using ST, measure gearbox turning resistance.

ST 34099PA100 SPANNER

Service limit

Maximum allowable resistance

Less than 12 N (1.2 kgf, 2.7 lb)

In axial direction:

Service limit

0.5 mm (0.020 in) or less

On condition

P:20-49N(2-5kgf,4- 11 lb)

PS-44

6.

OIL

LEAKING



1

S4M0153A

(1)

Power cylinder

(2)

Cylinder

(3) Rack piston

(4)

Rackaxle

NOTE:

If the gearbox is dismounted without confirming where the leak is, it must be mounted again to locate the leak point.

1)

Even if the location of the leak can be easily found by observing the leaking condition, it is necessary to thoroughly remove the oil from the suspected portion and turn the steering wheel from lock to lock about 30 to 40 times with engine running, then make comparison of the suspected portion between immediately after and several hours after this operation.

(5) Input shaft

(6)

Valve housing

2) Inspect leakage from “a”

The oil seal is damaged. Replace the valve assembly with a new one.

3) Inspect leakage from “ b

The torsion bar O-ring is damaged. Replace the valve assembly with a new one.

4)

Inspect leakage from “c”

The oil seal is damaged. Replace the valve assem-

bly or oil seal with a new one.

5 )

Inspect leakage from “d”

The pipe is damaged. Replace the faulty pipe or

0-

ring.

PS-45

I



6) If leak is other than a, b, c, or d, and if oil is leaking from the gearbox, move the right and left boots toward tie-rod end side, respectively, with the gearbox mounted to the vehicle, and remove oil from the surrounding portions. Then, turn the steering wheel from lock to lock 30 to 40 times with the engine running, then make comparison of the leaked portion immediately after and several hours after this operation.

(1 ) Leakage from "e"

The cylinder seal is damaged. Replace the rack bush with a new one.

(2) Leakage from "f"

There are two possible causes. Take the following step first. Remove the pipe assembly B from the valve housing, and close the circuit with ST.

ST 926420000 PLUG

Turn the steering wheel from lock to lock 30 to

40 times with the engine running, then make comparison of the leaked portion between immediately after and several hours after this operation.

CAUTION:

If leakage from "f" is noted again:

The oil seal of pinion and valve assembly is damaged. Replace pinion and valve assembly with a new one. Or replace the oil seal and the parts that are damaged during disassembly with new ones.

If oil stops leaking from "f":

The oil seal of rack housing is damaged. Re- place the oil seal and the parts that are damaged during disassembly with new ones.

F:

ADJUSTMENT

1)

Adjust the front toe.

Standard of front toe:

IN 3

-

-

2) Adjust the steering angle of wheels.

Standard of steering angle:

Model

Inner wheel

Outer wheel

TURBO, Sedan,

I

OUTBACK

34'05'

f

I

29'35'

f

Others

I

36'55'

k

1.5"

I

31 "35'

f

3) If the steering wheel spokes are not horizontal when wheels are set in the straight ahead position, and error is more than

5"

ing wheel, correctly re-install the steering wheel.

I

-0

-

17 mm in)

I

S A h l n i

R 8 A

4)

If the steering wheel spokes are not horizontal with vehicle set in the straight ahead position after this adjustment, correct it by turning the right and left tie-rods in the same direction by the same turns.

G4M0135

(1) Locknut

PS-46

PIPE ASSEMBLY


6.

Pipe Assembly

A: REMOVAL

1)

Disconnect the battery ground terminal.

2) Lift the vehicle and remove the jack-up plate.

I

4)

Remove the clamp E from pipes C and D.

1

(1) Jack-up plate

3)

Remove one pipe joint at the center of gearbox, and connect a vinyl hose to the pipe and joint. Dis- charge the fluid by turning steering wheel fully clockwise and counterclockwise. Discharge the fluid similarly from the other pipe.

CAUTION:

Improper removal and installation of parts often causes fluid leak trouble. To prevent this, clean the surrounding portions before disassembly and reassembly, and pay special attention to keep dirt and other foreign matter from mating surfaces.

S4M0437F

(1)

Return hose

(2) Pressure hose

(3) Clamp E

(4)

Pipe C

(5)

Pipe D

5) Disconnect the pipe C.D from the pipe (on the gearbox side).

CAUTION:

When disconnecting pipe C-D, use two wrenches to prevent deformities.

Be careful to keep pipe connections free from foreign matter.

(1)

Pipe

A

(2) Pipe B

(1)

Pipe C

(2) Pipe D

PS-47

PIPE ASSEMBLY


6 )

Non-TURBO model:

(1)

Remove the air intake duct. <Ref. to IN(S0-

HC)-7, REMOVAL, Air Intake Duct.>

(2)

Remove the bolt A.

(3) Disconnect the pipe C from the oil pump.

(4)

Disconnect the pipe D from the return hose.

CAUTION:

Do not allow fluid from the hose end to come into contact with pulley belt.

To prevent foreign matter from entering the hose and pipe, cover the open ends of them with a clean cloth.

(3)

Remove the coolant filler tank.

(1)

Bolt A

(2) Pipe

C

(3) Pipe

D

7) TURBO model:

(1)

Remove the air intake duct, air cleaner upper cover and air intake boot.

<Ref. to IN(D0HC TURBO)-8, REMOVAL, Air

Intake Duct.> and <Ref. to IN(D0HC TURBO)-

7, REMOVAL, Air Cleaner.>

(2) Remove the two bolts fixing pipe C and D.

(4)

Disconnect the pipe C from oil pump.

(5) Disconnect the pipe D from the return hose.

CAUTION:



(1)

Pipe C

(2)

Pipe D

PS-48

B: INSTALLATION

PIPE ASSEMBLY


1)

Temporarily tighten the bolts fixing pipe C and D.

CAUTION:

Visually check that hose between tank and pipe

D is free from bending or twisting.

Non-TURBO model

2) Install the coolant filler tank. (Turbo model)


T7: 79 N.m (7.9 kgf-m, 73.7 ff-lb)

T2: 27 N.m (2.7 kgf-m, 75.2 ff-lb)

3

(1) Bolt

A

(2) Pipe C

(3) Pipe D

TURBOmodel

(1) Pipe

C

(2)

Pipe D

(1) Connect the pipe D to oil tank.

(2) Install the pipe C to oil pump.

CAUTION:

Use a new gasket.


39 N.m (4.0 kgf-m, 28.9 ff-lb)

( 3 )

Tighten bolts fixing pipe C and D.


73 N.m (7.3 kgf-m, 9.4 ff-lb)

PS-49

PIPE ASSEMBLY


3)

Temporarily connect the pipes C and D to the pipes (on the gearbox side).

5) Tighten the clamp E firmly.


7.4 N-m (0.75 kgf-m, 5.4 ft-lb)

6) Tighten the joint nut.


15 N.m (1.5 kgf-m, 10.8 ft-lb)

7) Connect the pipes A and B to the four pipe joints of gearbox. Connect the upper pipe B first, and lower pipe A second.


13 N-m (1.3 kgf-m, 9.4 ft-lb)

I

S4M0430A

(1) Return hose

(2) Pressure hose

(3) Approx. 30 mm (1.18 in)

(4)

Clamp E

( 5 )

Pipe C

(6) Pipe

D

(7)

Pipe (on gearbox side)

4)

Temporarily install the clamp E on the pipes C and D.

CAUTION:

Ensure that the letter

“8”

on each clamp are diagonally opposite each other as shown in figure.

(1)

Pipe A

(2)

Pipe B

8) Install the jack-up plate.

9) Install the air intake duct. (Non-TURBO model).

<Ref. to IN(S0HC)-7, INSTALLATION, Air Intake

Duct.>

10)

Install the air intake duct, air intake boot and air cleaner upper cover. (TURBO model)

<Ref. to IN(D0HC TURBO)-7, INSTALLATION, Air

Cleaner.> and <Ref. to IN(D0HC TURBO)-8, IN-

STALLATION, Air Intake Duct.>

11) Connect the battery ground terminal.

I

(1)

Clamp E

(2) Pipe C

I

PS-50

PIPE ASSEMBLY


12) Feed the specified fluid.

NOTE:

Never start the engine before feeding the fluid; otherwise vane pump might be seized up.

1

(1) High-pressure hose

(2)

No

interference is allowed between hoses.

(3) Clearance between crossmember and pipe: 3 in)

13) Finally check clearance between pipes and/or hoses, as shown above.

If the clearance between cruise control pump and power steering hose

is

less than 10 mm (0.39 in), proceed as follows:

(1)

Move the clamped section

(A)

(refer to figure above.) down to a point where the pipe is close to crossmember.

Pipe-to-crossmember clearance:

10 mm (0.39 in), min.

( 2 )

Check that clearance between cruise control pump and power steering hose is at least 10 mm (0.39 in). If it is not, bend section (B) down until a clearance of at least 10 mm (0.39 in) is obtained.

- mm (0.1

2

PS-51

S4M02728

I

PIPE ASSEMBLY


C: INSPECTION

Check all disassembled parts for wear, damage or other abnormalities. Repair or replace faulty parts as re- qui red.

I

Part name

I

Pipe

Inspection

O-ring fitting surface for damage

Nut for damage

Pipe for damaae

I

Remedv

Replace with new one.


Flare nut for damage

Outer surface for cracks

Outer surface for wear

Clip for damage

End coupling or adapter for

I

CAUTION: degradation


Pressure hose burst

Forced out return hose

Fluid bleeding out of hose slightly

Crack on hose

Excessive holding time of relief status

Malfunction of relief valve

Poor cold characteristic of fluid

Poor connection

Poor holding of clip

Poor cold characteristic of fluid

1

Wronu lavout, tensioned

Excessive play of engine due to deterioration of engine mounting rubber

Instruct customers.

Replace oil pump.

Replace fluid.

Correct.

Retighten.

Replace fluid.

1

Replace hose.

Replace defective parts.

Replace defective parts. Improper stop position of pitching stopper

I

Excessive holding time of relief status

1

Excessive tightening torque for return hose clip

I

Replace.

Power steering fluid, brake fluid, engine oil, electro- Replace. lyte adhere on the hose surface Pay attention on service work.

I

Too many times use in extremely cold weather

Replace.

Instruct customers.

I

I

PS-52

PIPE ASSEMBLY


CAUTION:

It is likely that although one judges fluid leakage, there is actually no leakage. This is because the fluid spilt during the last maintenance was not completely wiped off. Be sure to wipe off spilt fluid thoroughly after maintenance.

I

PS-53

STOOl

PIPE ASSEMBLY


Fluid leaking area

Leakage from connecting portions of pipes and hoses, numbered with (1) through (10) in figure

Leakage from hose (1 l ) ,

(13) in figure

Leakage from surrounding of cast iron portion of oil pump (1 4) and (1 5) in fiaure

Leakage from oil tank (16) and (17) in figure

I

Possible cause

Insufficient tightening of flare nut, catching dirt or the like, damage to flare or flare nut or eye bolt

I

Corrective action

Loosen and retighten, if ineffective, replace.

Poor insertion of hose, poor clamping

Damaged O-ring or gasket

Crack or damage in hose

Crack or damage in hose hardware

Damaged O-ring

Retighten or replace the clamp.

Replace O-ring or gasket pipe or hose with new one, if ineffective, replace the gearbox also.

I

Replace with a new one.

I


Replace the oil pump.

Damaged gasket

Crack in oil tank


I

Replace the oil tank.

Leakage from filler neck (18)

Leakage from surrounding of power cylinder of gearbox (1 9) in figure

Damaged cap packing

Crack in root of filler neck

Hiah fluid level

I

Damaged oil seal

Replace the cap.

Replace the oil tank.

Adiust the fluid level.

1

Replace the oil seal.

Leakage from control valve of gearbox (20) and (21) in figure

Damaged packing or oil seal

Damage in control valve

Replace the problem parts.

Replace the control valve.

PS-54

7.

Oil Pump

A: REMOVAL

1.

NON-TURBO MODEL

1)

Remove the ground terminal from battery.

2)

Remove the pulley belt cover.

3) Loosen the oil pump pulley nut, then remove the bolts which secure alternator.

OIL PUMP


6) Disconnect the pipe C and suction hose from the oil pump.

CAUTION:

Do

not allow fluid from the hose end to come into contact with pulley belt.

To

prevent foreign matter from entering the hose, cover the open ends of them with a clean cloth.

II

4)

Loosen the lock bolt and slider bolt and remove the power steering pump drive V-belt.

(1) Suction hose

(2)

Pipe

C

7)

Remove the bolts, which install power steering pump bracket.

5) Disconnect the connector from the power steering pump switch.

8) Place the oil pump bracket in a vise, remove the two bolts from the front side of oil pump.

CAUTION:

Do

not place oil pump bracket directly in the vise; use soft pads and hold oil pump lightly to protect the pump.

I

STOOl6

I

9)

Remove the bolt from the rear side of oil pump.

PS-55

OIL PUMP


10) Disassemble the oil pump and bracket by inserting a screwdriver as shown in the figure.

6)

Remove the bolts which install power steering pump bracket

.

2.

TURBO MODEL

1) Remove the ground terminal from battery.

2)

Remove the pulley belt cover.

3) Loosen the lock bolt and slider bolt and remove the power steering pump drive V-belt.

7) Place the oil pump bracket in a vise, remove the two bolts from the front side of oil pump.

CAUTION:

Do not place oil pump bracket directly in the vise; use soft pads and hold oil pump lightly to protect the pump.

4)

Disconnect the connector from the power steering pressure switch.

5)

Disconnect the pipe C and suction hose from the oil pump.

CAUTION:


To prevent foreign matter from entering the hose and pipe, cover the open ends of them with a clean cloth. w

STOOl8

8)

Remove the bolt from the rear side of oil pump.

9)

Disassemble the oil pump and bracket by inserting a screwdriver as shown in the figure.

(1) Suction hose

(2)

Pipe C

PS-56

B: INSTALLATION

OIL PUMP



37.3 N.m (3.8 kgf-m, 27.5 ft-lb)


1)

Install the oil pump to the bracket.

(1) Place the oil pump bracket in a vise. Tighten the bushing using a 12.7 mm (1/2”) type 14 and

21-mm box wrench until it is in contact with oil pump mounting surface.

CAUTION:

Do not place oil pump bracket directly in the vise; use soft pads and hold oil pump lightly to protect the pump.

ST001 9

L

2) Tighten the bolt which installs power steering pump bracket.


22 N.m (2.2 kgf-m, 75.9 ft-lb)

s

B4M1670B

I

(1)

Bush

(2) Nut

(3) 21 mm

(4) 14

mm

(5)

Bolt

(2) Tighten the bolt which installs oil pump to the bracket.


75.7 N.m (7.6 kgf-m, 7 1.6 ft-lb)

3) Interconnect the pipe C and suction hose.


Joint nut

39.2 N.m (4 kgf-m, 28.9 ft-lb)

CAUTION:

If a hose is twisted at this step, the hose may come into contact with some other parts.

(1) Suction hose

(2) Pipe

C

4)

Connect the connector to the power steering pump switch.

5)

Install the pulley belt to the oil pump.

PS-57

OIL PUMP


6)

Tighten the oil pump pulley nut to the specified torque.


52 N.m (5.3 kgf-m, 38 ft-lb)

7) Check the pulley belt tension.

<Ref. to ME(S0HC)-44, INSPECTION, V-belt.>

8) Tighten the bolt belt tension.


8 N.m (0.8 kgf-m, 5.8 ft-lb)

(2) Tighten the bolt which installs oil pump to the bracket.


37.3 N-m (3.8 kgf-m, 27.5 ft-lb)

10) Connect the ground terminal of battery.

11) Feed the specified power steering fluid. <Ref. to PS-72, Power Steering Fluid.>

CAUTION:

Never start the engine before feeding the fluid; otherwise vane pump might be seized up.

2. TURBO MODEL

1) Install the oil pump to the bracket.

(1) Place the oil pump bracket in a vise. Tighten the bushing using a 12.7 mm (1/2”) type 14- and

21-mm box wrench until it is in contact with oil pump mounting surface.

CAUTION:

Do not place oil pump bracket directly in the vise; use soft pads and hold oil pump lightly to protect the pump.


mnni

FI

2) Tighten the bolt which install power steering pump bracket

.


22

N-m (2.2 kgf-m, 15.9 ft-lb)

(1)

Bush

(2) Nut

(3) 21 mm

(4)

14 mm

( 5 )

Bolt

PS-58

3)

Interconnect the pipes C and suction hose.


Joint nut

39.2 N-m (4 kgf-m, 28.9 fi-lb)

CAUTION:

If a hose is twisted at this step, the hose may come into contact with some other parts.

OIL PUMP


C: DISASSEMBLY

1.

NON-TURBO MODEL

1)

Remove the nut and detach oil pump pulley.

2) Remove the stay from the oil pump.

3) Remove the four bolts which secure rear cover.

I

(1) Suction hose

(2) Pipe C

4) Connect the connector to the power steering oil pressure switch.

5) Install the pulley belt to the oil pump.

6) Check the pulley belt tension. <Ref. to

ME(D0HC TURBO)-45, INSPECTION, V-belt.>

7) Tighten the bolt belt tension.


8

N m (0.8 kgf-m, 5.8 fi-lb)

8 )

Install the pulley belt cover.

9) Connect the ground terminal of battery.

10)

Feed the specified power steering fluid <Ref. to

PS-72, Power Steering Fluid.>

CAUTION:

Never start the engine before feeding the fluid; otherwise vane pump might be seized up.

v

STOOBZ

(1) Rear cover

4) Using a screwdriver, pry the retaining ring off.

(1) Retaining ring

(2) Screwdriver

5) Extract the shaft from the front casing.

PS-59

I

OIL PUMP

POWER ASSISTED SYSTEM (POWER STEERING)

6) Remove the following parts from the front casing.

CAUTION:

Discard old seal washer; replace with a new one.

9) Slightly loosen the outlet connector, and remove the connector.

(1)

O-ring

(2) Straight pin (2 ea.)

(3) Cam ring

(4)

Rotor

( 5 )

Vane (10 ea.)

(6) Pressure plate

(7)

O-ring (2 ea.)

7) Pry the oil seal off using a screwdriver.

CAUTION:

Be careful not to scratch inner surface of casing.

ST0092

(1) Flow control spring

(2) Spool valve assembly

(3)

O-ring

(4)

Connector

2.

TURBO MODEL

1)

Using ST, place the oil pump in a vise and remove the four bolts which secure rear cover.

ST 341 99AE020 MOUNT

2) Using a screwdriver, pry the retaining ring off.

CAUTION:

Do not remove cam ring, rotor, etc.

~~ ~

(1) Oil seal

(2) Screwdriver

8) Remove the pressure switch.

ST0091

3) Extract the oil pump pulley from the front casing.

PS-60

OIL PUMP


4)

Remove the following parts from the front casing.

(1)

O-ring

(2)

Straight pin (2 ea.)

(3) Cam ring

(4)

Rotor

( 5 )

Vane (10 ea.)

(6) Pressure plate

(7) O-ring (2 ea.)

5 )

Place the oil pump in a vise.

CAUTION:

Do not place oil pump directly in the vise, use soft pads and hold oil pump lightly to protect the pump.

6)

Pry the oil seal off using a screwdriver.

CAUTION:

Be careful not to scratch inner surface of casing.

D: ASSEMBLY

1.

NON-TURBO MODEL

1)

Reassembly precautions

(1)

Whenever the O-rings, oil seals, and snap rings are removed, they must be replaced with new ones.

(2) Thoroughly wash the parts and allow to dry.

They must be kept free from cleaning oil and dust.

(3)

Reassembly procedure must be performed in clean place. Ensure that the parts are kept away from the waste threads or other dust particles.

(4)

Cleaning oil tends to stay inside the front casing. Remove it completely by blowing compressed air.

(5)

Ensure that the parts are free from rust.

(Use specified hydraulic oil for rust prevention after cleaning and drying.)

(6) Reverse the sequence of disassembly procedures.

2) Apply the grease to the oil seal and inner surface of front casing (at bearing location).

CAUTION:

Make sure that the front body internal surfaces are free from damage.

3) Attach ST to the front body. Using a press, install the oil seal.

ST 341 99AE030

a

B4M1667A

4)

Press-fit the shaft assembly into the front body.

5 )

Apply the specified hydraulic oil to the O-rings and fit them into the front casing.

PS-61

OIL PUMP


6)

Install the side plate to the front casing.

CAUTION:

Use care not to let side plate gall.

10) Install the cam ring to the front casing, securing with knock pins.

CAUTION:

Do not use hammer to fit knock pins in position.

11) Mount the O-ring on the front casing.

I

ST0094

(1)

Front casing

( 2 )

O-ring

(3)

Side plate

7) Install the cam ring to the front casing with alignment mark facing forward.

(1) Rotor

(2) Vane

(3)

Radius facing

(4) Cam

ring

(5) O-ring r3

(1) Front

(2)

Alignment mark

8) Install the rotor to the front casing with groove facing rearward.

(1) Rear

( 2 )

Groove

9) Install the 10 vanes into the rotor with their nose radius facing toward cam ring.

PS-62

OIL PUMP


12) Using STs, press the retaining ring into the shaft groove.

CAUTION:

Discard retaining ring and replace with a new one.

NOTE:

Use ST2, bending its top edge slightly toward the inside.

ST1 34099AC030 INSTALLER RETAINING

RING CAP

ST2 34099AC040 INSTALLER RETAINING

RING PIPE

CAUTION:

Make sure the retaining ring is fit in the second groove of the shaft.

I

ST009C

Press

0

(1)

First groove

(2) Second groove

(3)

Shaft

(4)

Retaining ring

(5)

Rotor

13) Mount on pressure switch on front casing.

14) With knock pin positions aligned, install the rear cover.

CAUTION:

Loosely the tighten bolts in the sequence (A),

(B), (C), and (D) shown in figure. Then, tighten in the same sequence.


21 N.m (2.14 kgf-m, 15.5 fi-lb)

1

(1)

Shaft

(2)

Front casing

(3) 48 mm

(1.89

in)

(4)

Retaining ring

( 5 )

Block

I

ST009t

STOl OC

(1)

Rear cover

15) Install the spring into the front casing. Then, with spool valve dipped in specified hydraulic oil, install it into the front casing.

16) Using a 5-mm dia. round bar, ensure that the valve moves smoothly.

PS-63

OIL PUMP


17) Set the O-ring, with grease applied to it, onto the connector and secure connector to the front casing.

CAUTION:

Use care to prevent damage to O-ring at installation.

When tightening the connector, ensure that the O-ring does not protrude or get caught.


49 N-m (5.0 kgf-m, 36.2 ft-lb)

ST0092

(1) Flow control spring

(2) Spool valve assembly

(3) O-ring

(4)

Connector

18) Fix the oil pump pulley temporarily.

19) When the reassembly procedures have been completed, turn the shaft by hand to ensure it turns smoothly. If it binds or other unusual conditions are evident, disassemble again and check for foreign matter trapped on sliding surfaces and improper installation. Eliminate the cause of trouble.

20)

Check followings by referring to “CHECK article.

Excessive play in pulley shaft

Ditch deflection of pulley

Resistance to rotation of pulley

Measurement of generated oil pressure

2. TURBO MODEL

1) Reassembly precautions

(1) Whenever the O-rings, oil seals, and snap rings are removed, they must be replaced with new ones.

(2) Thoroughly wash the parts and allow to dry.

They must be kept free from cleaning oil and dust.

(3) Reassembly procedure must be performed in clean place. Ensure that the parts are kept away from the waste threads or other dust particles.

(4) Cleaning oil tends to stay inside the front casing. Remove it completely by blowing compressed air.

(5) Ensure that the parts are free from rust.

(Use specified hydraulic oil for rust prevention after cleaning and drying.)

(6)

Reverse the sequence of disassembly procedures.

2) Apply grease to the oil seal and inner surface of front casing (at bearing location).

CAUTION:

Make sure that the front body internal surfaces are free from damage.

3) Attach ST to front body. Using a press, install the oil seal.

ST 341 99AE030 INSTALLER

4) Install the pump pulley to front body.

5) Using ST, place the oil pump in a vise.

ST 34199AE020 MOUNT

6) Remove the rear cover.

PS-64

7) Install the following parts to casing.

OIL PUMP


9) Install the O-ring to the rear cover.

10) Install the rear cover.


27.5

N.m

(2.8 kgf-m, 20.3 ff-lb)

CAUTION:

Loosely tighten the bolts in the sequence (A),

(B), (C), and (D) shown in figure. Then, tighten in the same sequence.

ST007E

(1)

O-ring

(2) Pressure plate

(3) Rotor

(4)

Vane

(5)

Cam ring

(6) Straight pin

(7)

O-ring

NOTE:

Install the rotor with the mark facing the rear case side.

I

\ I

ST0046

1 1) When the reassembly procedures have been completed, turn the shaft by hand to ensure it turns smoothly. If it binds or other unusual conditions are evident, disassemble again and check for foreign matter trapped on sliding surfaces and improper installation. Eliminate the cause of trouble.

12) Check followings by referring to “CHECK article.

Excessive play in pulley shaft

Ditch deflection of pulley

Resistance to rotation of pulley

Measurement of generated oil pressure

(1)

Mark

(2) Rear

8) Using 8-mm box wrench, tap the retaining ring into the shaft groove.

ST004L

PS-65

OIL PUMP


E: INSPECTION

1.

BASIC INSPECTION

Perform the following inspection procedures and repair or replace defective parts.

Part name

Description Remedy

1.

Front casing

2. Rear cover

3. Shaft

4.

Pressure plate

5. Cam ring

6. Vane

7.

Rotor

8.

Connector

9. Spring

10. Bolts and nuts

2) Excessive wear on hole, into which spool valve is inserted.

3) Wear and damage on cartridge assembly mounting surface

4)

Wear and damage on surfaces in contact with shaft and oil seal

1) Damage on body surfaces

2) Wear and damage on sliding surfaces

1) Shaft bend

2) Wear and damage on surfaces in contact with bushing and oil seal

3) Wear and damage on rotor mounting surfaces

4)

Bearing damage

Wear and damage on sliding surfaces

Ridge wear on sliding surfaces

I

Excessive wear on nose radius and side surfaces

1) Wear and damage on sliding surfaces

2) Ridge wear on vane sliding grooves (If light

If the damage is serious, replace with a new cartridge assembly. leaks with vane in slit aaainst liaht source)

I

3) Damage resulting from snap ring removal

Correct with oil stone. If the damage is serious, replace with a new cartridge assembly.

I

Damage on threads Replace with a new one.


Damage

Damage on threads

Replace with a new one together with spool valve as selective fit is made.




Relslace with a new one.

In accordance with the following table, check all removed parts for wear and damage, and make repair or replacement if necessary.

No.

1

2

3

4

5

Parts Inspection

(1) Crack. damaae or oil leakaae

Oil pump (Exterior)

(2)

Play of pulley shaft

Pulley

Oil pump (Interior)

0-rina

Bracket

(1

) Damage

(2) Bend

(1)

Defect or burning of vane pump

(2) Bend in the shaft or damage to bearing

Crack or deterioration

Crack

Corrective action

Replace the oil pump with a new one.

Measure the radial play and axial play.

If any of these exceeds the service limit, replace the oil pump with a new one.

Replace it with a new one.

Measure the V ditch deflection.

If it exceeds the service limit, replace the pulley with a new one.

Check the resistance to the rotation of pulley.

If it is past the service limit, replace the oil pump with a new one.

Oil pump emits a noise that is markedly different in tone and loudness from a sound of a new oil pump when turning with a string put around its pulley, replace the oil pump with a new one.



PS-66

OIL PUMP


2.

SERVICE LIMIT

Make a measurement as follows. If it exceeds the specified service limit, replace the parts with new ones.

CAUTION:

Fix oil pump on a vise to make a measurement. At this time, hold oil pump with the least possible force between two wood pieces.

Do not set outside of flow control valve or pulley on a vise; otherwise outside or pulley might be deformed. Select properly sized wood pieces.

1) Play of pulley shaft

On condition:

P:

9.8 N (1.0 kgc

2.2

16)


Radial play (Direction c)

0.4 mm (0.016 in) or less

2) Ditch deflection of pulley


1.0 mm (0.039 in) or less

NOTE:

Read the value for one surface of the value for another off the dial.

V

ditch, and then

S4M0441

(1) Dial indicator

3) Resistance to rotation of pulley


Maximum load; 9.22 N (0.94 kgf, 2.07 16) or less

NOTE:

A

rather higher value may be indicated when pulley starts turning.

Measure the load during rotation and make a judgment.

5

S4M0439A

(1) Dial indicator

Axial play (Direction

a

Non-TURBO model

0.4 mm (0.016 in) or less

TURBO model

0.8 mm (0.031 in) or less

G ' ,

I

S4M0442A

(1) Spring balance

1

(1)

Dial indicator

PS-67

I

OIL PUMP


3.

HYDRAULIC PRESSURE

CAUTION:

Be sure to complete all items aforementioned in “INSPECTION”, prior to measuring hydraulic pressure. Otherwise, pressure can not be measured correctly. <Ref. to PS-74, INSPECTION,

General Diagnostic Table.>

Do not leave the valve of pressure gauge closed or hold the steering wheel at stop end for 5 seconds or more in any case, as the oil pump may be damaged due to long keep of these conditions.

Put cotton cloth waste at a place where fluid drops before pressure gauge is installed. Wipe off spilt fluid thoroughly after the measurement.

NOTE:

Keep engine idling during the measurement.

1) MEASURE REGULAR PRESSURE.

(1) Remove the two bolts securing power steering pipes to the engine.

(2) Install ST1,2 and 3 between power steering pump and pipes using gasket (Part No.

34621AC021) and bolt (Part No. 34620AC010).

(3) Replenish the power steering fluid up to specified level.

(4) Open the valve, and start the engine.

(5) Measure the regular pressure.

STI 92571 1000 PRESSURE GAUGE

ST2 34099AC020 ADAPTER HOSE B

ST3 34099AC010 ADAPTER HOSE A

2) Measure relief pressure.

(1) Using STs, measure the relief pressure.

(2) Close the valve.

(3) Measure the relief pressure.

ST1 92571 1000 PRESSURE GAUGE



I1

676A


TURBO model

-

(75

-


-

-

(4) If it is not within the specified value, replace the oil pump.

3) Measure working pressure.

(1)

Using STs, measure the working pressure.

(2) Open the valve.

(3) Measure the working pressure of control valve by turning wheel from stop to stop.

ST1 92571 1000 PRESSURE GAUGE



-

~ l675A


981 kPa

(IO

kg/cd, 142 psi) or less

(6) If it is not within the specified value, replace the troubled part caused by the following symptoms; pipe or hose clogged, leaks from fluid line, and mix of foreign objects in fluid line.


TURBO model

-

-

k g k d ,

-


1

675A

PS-68

OIL PUMP


(4)

If it is within the specified value, measure the steering effort. <Ref. to PS-78, MEASURE-

MENT OF STEERING EFFORT, INSPECTION,

General Diagnostic Table.> If it is not within specified value, replace the control valve itself or control valve and pinion as a single unit with new ones.

PS-69

RESERVOIR TANK


8.

Reservoir

A: REMOVAL

Tank


1)

Remove the air intake duct. <Ref. to IN(S0HC)-

7,

REMOVAL, Air Intake Duct.>

2) Drain the fluid from the reservoir tank.

3)

Disconnect the pipe D from the return hose and suction hose from the oil pump.

CAUTION:

Do not allow fluid from the hose end t o come into contact with pulley belt.


3) Disconnect the return hose and suction hose from the reservoir tank.

CAUTION:

Do not allow fluid from the hose end t o come into contact with pulley belt.

To prevent foreign matter from entering the hose, cover the open ends of them with a clean cloth.

(1) Suction hose

(2) Pipe D

(3)

Return hose

4)

Remove the reservoir tank from the bracket by pulling it upwards.

2.

TURBO MODEL

1)

Remove the air intake duct. <Ref. to IN(D0HC

TURBO)-9, REMOVAL, Intake Duct.>

2) Drain the fluid from the reservoir tank.

(1)

Suction hose

(2) Pipe D

(3) Return hose

4)

Remove the reservoir tank from the bracket by pulling it upwards.

B: INSTALLATION


1)

Install the reservoir tank to the bracket.

2)

Connect the pipes D to the return hose and suction hose to the oil pump.

(1) Suction hose

(2) Pipe

D

(3)

Return hose

3) Feed the specified power steering fluid. <Ref. to


PS-70

RESERVOIR TANK


2.

TURBO MODEL

1) Install the reservoir tank to the bracket.

2) Connect the pressure hose and suction hose to the oil pump.

m

(1) Suction hose

(2) Pipe D

(3) Return hose

3)

Feed the specified power steering fluid. <Ref. to


C: INSPECTION

Check the reservoir tank for cracks, breakage, or damage. If any cracks, breakage, or damage is found, replace the reservoir tank.

PS-71

POWER STEERING FLUID


C: INSTALLATION

9. Power Steering Fluid

A: SPECIFICATION

I

Recommended power steering fluid

[

Manufacturer

I

TEXACO

1) Set ST on the top of reservoir tank and fill it about half way with the specified fluid.

ST 341 99AE040

CALTEX

CASTROL

MOBIL

SHELL n

DEXRON Ill

B: INSPECTION

OIL

CHARGE

1) Check the power steering fluid for deterioration or contamination. If the fluid is highly deteriorated or contaminated, drain it and refill with new fluid.

2) Continue to turn the steering wheel slowly from lock to lock until the bubbles stop appearing in the tank while keeping the fluid at that level.

2) Check the joints and units for oil leakage. If any oil leaks are found, repair or replace the applicable part.

3) Inspect the fluid level on flat and level surface with engine “OFF by indicator of reservoir tank.

3) In case air is absorbed to deliver bubbles into piping because the fluid level is lower, leave it about half an hour and then do the step 2) all over again.

If the level is at lower point or below, add fluid to keep the level in the specified range of the indicator. If at upper point or above, drain the fluid by using a syringe or the like.

4) Start, and idle the engine.

5)

Continue to turn the steering wheel slowly from lock to lock again until the bubbles stop appearing

(1) Check at temperature 20°C (68°F) on reservoir surface of oil pump; read the fluid level on the “COLD” side. in the tank while keeping the fluid at that level.

It is normal that bubbles stop appearing after three times turning of steering wheel.

6) In case bubbles do not stop appearing in the tank, leave it about half an hour and then do the

(2) Check at temperature 80°C (176°F) on reservoir surface of oil pump: read the fluid level on the “HOT” side. step 5 ) all over again.

7) Stop the engine, and take out safety stands after jacking up vehicle again.

Then lower the vehicle, and idle the engine.

8) Continue to turn the steering wheel from lock to lock until the bubbles stop appearing and change of the fluid level is within 3 mm (0.12 in).

9) In case the following happens, leave it about half an hour and then do step 8) again.

(1) The fluid level changes over 3 mm (0.12 in).

(2) Bubbles remain on the upper surface of the fluid.

(3) Grinding noise is generated from oil pump.

PS-72

POWER STEERING FLUID


~~ ~~ ~

IO)

Check the fluid leakage at flare nuts after turning steering wheel from lock to lock with engine running.

CAUTION:

Before checking, wipe off any fluid on flare nuts and piping.

In case the fluid leaks from flare nut, it is caused by dust (or the like) and/or damage between flare and tapered seat in piping.

So remove the flare nut, tighten again it to the specified torque after cleaning flare and tapered seat. If flare or tapered seat is damaged, replace it with a new one.

I

PS-73



1O.General Diagnostic Table

A:

INSPECTION

Trouble ieavy steering effort in all ges ieavy steering effort at nd still steering wheel surges when ling.

Possible cause

1. Pulley belt

Unequal length of pulley belts

Adhesion of oil and grease

Loose or damage of pulley belt

Poor uniformity of pulley belt cross section

Pulley belt touches to pulley bottom

Poor revolution of pulleys except oil pump pulley

Poor revolution of oil pump pulley

2.

Tire and rim

Improper tires out of specification

Improper rims out of specification

Tires not properly inflated*l

3.

Fluid

Low fluid level

Aeration

Dust mix

Deterioration of fluid

Poor warming-up of fluid *2

Corrective action

Adjust or replace.

Replace or reinflate.

Refill, bleed air, replace or instruct customer.

/chicle leads to one side or other.

'oar return of steering wheel

:enter

Steering wheel surges when ning.

4. Idling speed

Lower idling speed

Excessive drop of idling speed at start or at turning steering wheel

*3

5.

Measure hydraulic pressure.<Ref. to PS-66, INSPECTION,

Oil Pump.>

6. Measure steering effort.<Ref. to PS-74, INSPECTION, Gen- eral Diagnostic Table.>

Adjust or instruct customer.

Replace problem parts.

Adjust or replace.

1. Fluid line

Folded hose

Flattened pipe

2.

Tire and rim

Flat tire

Mix use of different tires

Mix use of different rims

Abnormal wear of tire

Unbalance of remained grooves

Unbalance of tire pressure

Reform or replace.

Fix or replace.

3. Front alignment

Improper or unbalance caster

Improper or unbalance toe-in

Loose connection of suspension

Adjust or retighten.

4. Others

Damaged joint assembly

Unbalanced height

One-sided weight

Replace, adjust or instruct cus. tomer.

~~

5.

Measure steering effort.<Ref. to PS-74, INSPECTION, Gen- eral Diaanostic Table.>

Adjust or replace.

*1 If the tires and/or rims are wider, the load to power steering system is the more. Accordingly, in a condition, for example before fluid warms-up, relief valve may work before maximum turning angle. In this case, steering effort may be heavy. When the measured hydraulic pressure is normal, there is no abnormal thing.

*2 In cold weather, steering effort may be heavy due to increased flow resistance of cold fluid. After warming-up engine, turn the steering wheel from stop to stop several times to warm-up fluid. Then if steering effort reduces normally, there is no abnormal thing.

*3

In cold weather or with insufficient warm-up of engine, steering effort may be heavy due to excessive drop of idling when turning steering wheel. In this case, it is recommended to start the vehicle with increasing engine speed than usual. Then if steering effort reduces normally, there is no abnormal thing.

PS-74



1.

NOISE AND VIBRATION

CAUTION:

Don’t keep the relief valve operated over 5 seconds at any time or inner parts of the oil pump may be damaged due to rapid increase of fluid temperature.

NOTE:

Grinding noise may be heard immediately after the engine start in extremely cold condition. In this case, if the noise goes off during warm-up there is no abnormal function in the system. This is due to the fluid characteristic in extremely cold condition.

Oil pump makes whine or growl noise slightly due to its mechanism. Even if the noise can be heard when steering wheel is turned at stand still there is no abnormal function in the system provided that the noise eliminates when the vehicle is running.

When stopping with service brake and/or parking brake applied, power steering can be operated easily due to its light steering effort. If doing so, the disk rotates slightly and makes creaking noise. The noise is generated by creaking between the disk and pads. If the noise goes off when the brake is released, there is no abnormal function in the system.

There may be a little vibration around the steering devices when turning steering wheel at standstill, even though the component parts are properly adjusted and have no defects.

Hydraulic systems are likely to generate this kind of vibration as well as working noise and fluid noise because of combined conditions, Le., road surface and tire surface, engine speed and turning speed of steering wheel, fluid temperature and braking condition.

This phenomena does not indicate there is some abnormal function in the system.

The vibration can be known when steering wheel is turned repeatedly at various speeds from slow to rapid step by step with parking brake applied on concrete road and in “D” range for automatic transmission vehicle.

PS-75



Trouble

Hiss noise (continuous)

While engine is running.

Rattling noise (intermittent)


Knocking

When turning steering wheel in both direction with small angle repeatedly at engine ON or OFF.

Possible cause

Relief valve emits operating sound when steering wheel is completely turned in either direction. (Don't keep this condition over 5 seconds.)

Relief valve emits operating sound when steering wheel is not turned. This means that the relief valve is faulty.

Interference with adjacent parts

Normal

Corrective action

Defective


Check the clearance.

Correct if necessary.

<Ref. to PS-52, INSPECTION,

Pipe Assembly.>

Loosened installation of oil pump, oil tank, pump bracket, gearbox or crossmember

~~~

Loosened installation of oil D u m Dullev or other DulleW

Loosened linkage or play of steering or suspension Loos- ened tightening of joint or steering column

Retighten.

Retighten.

Retighten or replace.

Sound generates from the inside of gearbox or oil pump.

Replace the bad parts of the aearbox or oil wmu.

Excessive backlash

Loosened lock nut for adjusting backlash

Adjust and retighten.

Loosened tightening or play of tie-rod, tie-rod end Retighten or replace.

Vane pump aeration

Inspect and retighten the fluid line connection.

Grinding noise (continuous)


Squeal, squeak (intermittent or continuous)


Vane pump seizing

Pulley bearing seizing of oil pump

Folded hose. flat DiDe

Maladjustment of pulley belt

Damaged or charged pulley belt

Unequal length of pulley belts

Run out or soilage of V-groove surface of oil pump pulley

Replace.

Adjust or replace.

(Replace two belts as a set.)

Fluid aeration

Clean or redace.

Fix the wrong part causing aeration.

I

I

I

Sizzling noise (continuous)


Whistle (continuous)


Whine or growl (continuous or intermittent)

While engine is running with/ without steering turned.

Creaking noise (intermittent)

While engine is running with steering turned.

Damaged pipe of gearbox

Abnormal inside of hose or pipe

Flat hose or DiDe

Abnormal inside of oil tank

Removed oil tank cap

Abnormal pipe of gearbox or abnormal inside of hose

Loosened installation of oil Duma oil Dump bracket

~

Redace the DiDe.

Rectify or replace.

Replace.

I or hose.

RetiQhten.

Replace the oil pump, hose, if the noise can be heard when running

I

Abnormal inside of oil pump, hose

Torque converter growl, air conditioner compression growl

Remove the power steering pulley belt and confirm.

Replace the bad parts of gear-

Abnormal inside of gearbox

Abnormal bearing for steering shaft

Generates when turning steering wheel with brake (service or Darkina) amlied. is released, it is normal.

PS-76

Trouble

Vibration

While engine is running with/ without steering turned.



Possible cause

Too low engine speed at start

I

Vane pump aeration

Damaged valve in oil pump, gearbox

Looseness of play of steering, suspension parts

Corrective action

Adjust and instruct customers.

Fix the wrong part.

-

. . .

Replace the oil pump, bad parts of aearbox.

I

I

Retighten.

PS-77



2.

MEASUREMENT OF STEERING EFFORT

~~

!

I

I

i

I

5

3

I O

I1

Step

Check

CHECK STEERING EFFORT.

1)Stop the vehicle on a concrete road.

2)Start the engine.

3)ldle the engine.

4)lnstall the spring scale on the steering wheel.

5)Pull the spring scale at an right angle to the steering wheel, and measure both right and left steering wheel effort.

Is the steering effort 31.4 N

(3.2 kgf, 7.1 Ib) or less?

Yes

Go to step

2.

~~

No

4djustment back- ash.

NOTE:

When turning steering more quickly than necessary from a direction to the other direction at an engine speed over 2,000 rpm, steering effort may be heavy. This is caused by flow characteristic of oil pump and is not a problem.

CHECK STEERING EFFORT.

1)Stop the engine.

2)Pull the spring scale at an right angle to the steering wheel, and measure both right and left steering wheel effort.

Is the steering effort 294.2 N

(30 kgf, 66.2 Ib) or less?

CHECK STEERING WHEEL EFFORT.

1)Remove the universal joint.

2)Measure the steering wheel effort.

Is the maximum force steering wheel effort 2.26 N (0.23 kgf,

0.51 Ib) or less?

Go to step

3.

Go to step 4.

CHECK STEERING WHEEL EFFORT.

Measure the steering wheel effort.

Is the fluctuation width 1.08 N

(0.1

1 kgf, 0.24 Ib) or less?

Go to step 5. tdjustment.

Check, adjust and replace if necessary.

Check, adjust and replace if necessary.


CHECK UNIVERSAL JOINT.

Measure the folding torque of the joint (yoke of steering column side). <Ref. to PS-22,

INSPECTION, Universal Joint.>

Is the folding torque 7.3 N

(0.74 kgf, 1.64 Ib) or less?

Go to step 6.

CHECK UNIVERSAL JOINT.

Measure the folding torque of the joint (yoke of gearbox side). <Ref. to PS-22, INSPECTION,

Universal Joint.>

Is the folding torque 7.3 N

(0.74 kgf, 1.64 Ib) or less?

CHECK FRONT WHEEL.

CHECK TIE-ROD ENDS.

Remove the tie-rod ends.

CHECK BALL JOINT.

CHECK GEARBOX.

Measure the rotating of gearbox.

<Ref. to PS-44, TURNING RESISTANCE OF

GEARBOX, INSPECTION, Steering Gear- box.>

CHECK GEARBOX.

Measure sliding of gearbox.

<Ref. to PS-43, SERVICE LIMIT, INSPEC-

TION, Steering Gearbox.>

Go to step 7. Replace with new one.

Are the front wheels for unsteady revolution or rattling and brake for dragging?

Are the tie-rod ends of suspen sion for unsteady revolution or ratting?

Are the ball joints of suspension for unsteady revolution or ratting?

Inspect, readjust and replace if nec. essary.

Inspect and replace if necessary.

Inspect and replace if necessary.

Is rotating resistance 12.7 N

(1.3 kgf, 2.9 Ib) or less in all positions within 20% difference between clockwise and counterclockwise?

Go to step 11.

Is sliding resistance 340 N (35 kgf, 76 Ib) or less with 20% dif. ference between left and right direction?

Steering effort is normal.

Go to step 8.

Go to step 9.

Go to step 10.

Readjust backlash, and if ineffec tive, replace bad parts.

Readjust backlash, and if ineffec tive, replace bad

Darts.

PS-78