Legacy Chassis

2004 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX
CHASSIS SECTION
FRONT SUSPENSION FS
REAR SUSPENSION RS
WHEEL AND TIRE SYSTEM WT
DIFFERENTIALS DI
This service manual has been prepared
to provide SUBARU service personnel
TRANSFER CASE TC
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles. DRIVE SHAFT SYSTEM DS
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of ABS ABS
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual ABS (DIAGNOSTICS) ABS(diag)
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition. VEHICLE DYNAMICS CONTROL (VDC) VDC
When replacement of parts during
repair work is needed, be sure to use VEHICLE DYNAMICS CONTROL (VDC)
SUBARU genuine parts. VDC(diag)
(DIAGNOSTICS)
BRAKE BR
PARKING BRAKE PB
POWER ASSISTED SYSTEM PS

(POWER STEERING)
All information, illustration and specifi-

cations contained in this manual are
based on the latest product information
available at the time of publication
approval.
FUJI HEAVY INDUSTRIES LTD. G2320GE6

FRONT SUSPENSION
FS
Page
1. General Description ....................................................................................2
2. Wheel Alignment .........................................................................................8
3. Front Crossmember Support Plate ...........................................................15
4. Front Stabilizer ..........................................................................................16
5. Front Ball Joint ..........................................................................................17
6. Front Arm ..................................................................................................19
7. Front Strut .................................................................................................22
8. Front Crossmember ..................................................................................26
9. General Diagnostic Table..........................................................................27
General Description
FRONT SUSPENSION
1. General Description
A: SPECIFICATION
Sedan Wagon
OUTBACK
Model 2.5 i,
2.0 i 2.5 i 2.0 GT 3.0 R 2.0 i 2.5 i 2.0 GT 3.0 R
OUTBACK
3.0 R
Wheel arch height
[Tolerance: +12 !24 mm mm (in) 376 (14.8) 381 (15.0) 376 (14.8) 429 (16.9)
(+0.47 in !0.94 in)]
Camber (Tolerance: "0#45$%
Differences between RH and !0#20$ !0#15$ !0#20$ 0#30$
LH: 45$ or less)
Front Caster 6#00$ 5#45$ 5#05$
Inner
37.3# 37.8#
Steering angle (Toler- wheel
ance: "1.5#) Outer
33.0# 33.5#
wheel
Toe-in mm (in) 0"3 (0"0.12) Toe angle (sum of both wheels): 0#"0#15$
Kingpin angle 13#50$ 13#45$ 13#50$ 12#25$
Diameter of stabilizer mm (in) 20 (0.79) 21 (0.83) 20 (0.79) 21 (0.83)
Wheel arch height
[Tolerance: +12 !24 mm mm (in) 360 (14.2) 375 (14.8) 430 (16.9)
(+0.47 in !0.94 in)]
Rear Differences between RH and !0#45$ !0#30$ 0#00$
LH: 45$ or less)
Thrust angle (Tolerance: "0#30$) 0#
20
Diameter of stabilizer mm (in) 17.3 (0.68) 19.1 (0.75) 19.1 (0.75) 17.3 (0.68)
(0.78)
FS-2
General Description
FRONT SUSPENSION
NOTE:
• Front and rear toe-ins and front camber can be
adjusted. If the toe-in or camber tolerance exceeds
specifications, adjust them.
• Other items indicated in the specification table
cannot be adjusted. If those items exceed specifi-
cations, check suspension parts and connections
for deformities; replace with new ones as required.
(1)
FS-00001
(1) Front
A ! B = Positive: Toe-in, Negative: Toe-out
& = Each toe angle
FS-3
General Description
FRONT SUSPENSION
B: COMPONENT
T1
(16) (1) (2)

T5
T6
(25)
(17)
T9
(15) T8
(8)
(18) (25)
T7 (6)
T8
(5)
(19)
(3) T9
(25)
(20) (7) (4)
T7 (24) T10
T3
(21) T7
(13)
(26)
(12)
T4
(25) T4 (25)
(22)
(23)
(11) (9)
(10)
(14)
T2 T7
T7 (25)
(25)
T2
T11
FS-00131
(1) Front crossmember (14) Crossmember support plate Tightening torque: N'm (kgf-m, ft-lb)
(2) Housing (Small type) T1: 20 (2.0, 14.5)
(3) Ball joint (15) Jack-up plate T2: 25 (2.5, 18.1)
(4) Front arm (16) Dust seal T3: 39 (4.0, 28.8)
(5) Support plate (17) Strut mount T4: 45 (4.6, 33.2)
(6) Rear bushing (18) Upper spring seat T5: 50 (5.1, 36.9)
(7) Front bushing (19) Dust cover T6: 55 (5.6, 41)
(8) Stud bolt (20) Helper T7: 60 (6.1, 44.3)
(9) Stabilizer link (21) Coil spring T8: 95 (9.7, 70.1)
(10) Bracket (22) Damper strut T9: 110 (11.2, 81.1)
(11) Bushing (23) Adjusting bolt T10: 150 (15.3, 110.6)
(12) Stabilizer (24) Castle nut T11: 175 (17.8, 129)
(13) Crossmember support plate (25) Self-locking nut
(Large type) (26) Cotter pin
FS-4
General Description
FRONT SUSPENSION
C: CAUTION
• Wear work clothing, including a cap, protective
goggles, and protective shoes during operation.
• Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly and replacement.
• Use SUBARU genuine grease or the equivalent.
Do not mix grease, etc. with that of another grade
or from other manufacturers.
• Before securing a part on a vice, place cushion-
ing material such as wood blocks, aluminum plate,
or cloth between the part and the vice.
• Be sure to tighten fasteners including bolts and
nuts to the specified torque.
• Place shop jacks or rigid racks at the specified
points.
FS-5
General Description
FRONT SUSPENSION
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
927380002 ADAPTER Used as an adapter for camber & caster gauge
when measuring camber and caster.
(1) 28199AC000 PLATE
(2) 28199AC010 BOLT
(1)
(2)
ST-927380002
927680000 INSTALLER & Used for replacing the front arm front bushing.
REMOVER SET
ST-927680000
20299AG000 REMOVER Used for replacing the front arm rear bushing.
(Newly adopted tool) Used with BASE (20999AG010).
ST20299AG000
20299AG010 BASE Used for replacing the front arm rear bushing.
(Newly adopted tool) Used with REMOVER (20999AG000).
ST20299AG010
FS-6
General Description
FRONT SUSPENSION

20299AG020 STUD BOLT Used for removing and installing the stud bolt for
(Newly adopted tool) SOCKET front arm installing portion.
ST20299AG020
20399AG000 STRUT MOUNT Used for disassembling and assembling the strut
(Newly adopted tool) SOCKET mount.
ST20399AG000
2. GENERAL TOOL
TOOL NAME REMARKS
Alignment gauge Used for wheel alignment measurement.
Turning radius gauge Used for wheel alignment measurement.
Toe-in gauge Used for toe-in measurement.
Dial gauge Used for damper strut measurement.
Coil spring compressor Used for strut assembly/disassembly.
FS-7
Wheel Alignment
FRONT SUSPENSION
2. Wheel Alignment
A: INSPECTION
Check the following items before taking wheel alignment measurement.
Check items before taking wheel alignment measurement:
• Tire inflation pressure
• Unbalanced right and left tire wear, size difference
• Tire runout
• Excessive play and wear in ball joint
• Excessive play and wear in tie rod end
• Excessive play in wheel bearing
• Right and left wheel base imbalance
• Deformation and excessive play in steering link
• Deformation and excessive play in suspension parts
Check, adjust and measure the wheel alignment in accordance with the procedures indicated in the figure.
Wheel arch height (front and rear wheels)
<Ref. to FS-9, WHEEL ARCH HEIGHT, INSPECTION, Wheel Alignment.>
(
Camber (front and rear wheels)
<Ref. to FS-10, CAMBER, INSPECTION, Wheel Alignment.>
(
Caster (front wheel)
<Ref. to FS-11, CASTER, INSPECTION, Wheel Alignment.>
(
Steering angle
<Ref. to FS-11, STEERING ANGLE, INSPECTION, Wheel Alignment.>
(
Front wheel toe-in
<Ref. to FS-12, FRONT WHEEL TOE-IN, INSPECTION, Wheel Alignment.>
(
Rear wheel toe-in
<Ref. to FS-12, REAR WHEEL TOE-IN, INSPECTION, Wheel Alignment.>
(
Thrust angle
<Ref. to FS-14, THRUST ANGLE, INSPECTION, Wheel Alignment.>
FS-8
Wheel Alignment
FRONT SUSPENSION
1. WHEEL ARCH HEIGHT 3) Set the steering wheel in a straight-ahead posi-

tion, and stabilize the suspensions by moving the
1) Park the vehicle on a level surface.
vehicle straight more than 5 m (16 ft).
2) Set the vehicle under “curb weight” condition.
4) Suspend a thread from wheel arch (point “A” in
(Make the luggage compartment empty, install the
the figure below) to determine the point directly
spare tire, jack and service tools, and top up the
above the center of wheel.
fuel tank.)
5) Measure the distance between the point “A” and
the center of wheel.
(2) (3)
A
A
(1)
(1)
A
(6)
(7)
(4) (5) (1)
(8)
FS-00125
(1) Wheel arch height (4) Front wheel arch height (7) Point of measurement
(2) Front fender (5) Rear wheel arch height (8) Tip end of spindle
(3) Rear quarter (6) Flange bend line
Wheel arch height standard value mm (in) (Tolerance "12 mm)

Sedan Wagon
OUTBACK
Model 2.5 i,
2.0 i 2.5 i 2.0 GT 3.0 R 2.0 i, 2.5 i 2.0 GT, 3.0 R
OUTBACK
3.0 R
Front 376 (14.8) 381 (15.0) 376 (14.8) 429 (16.9)
Rear 360 (14.2) 375 (14.8) 430 (16.9)
FS-9
Wheel Alignment
FRONT SUSPENSION
2. CAMBER 3) Turn the camber adjusting bolt so that the cam-

ber is set at specification.
• INSPECTION
NOTE:
1) Place the front wheel on turning radius gauge.
Moving the adjusting bolt by one scale changes the
Make sure the ground contacting surfaces of front
camber by approx. 0#15$.
and rear wheels are set at the same height.
2) Set the ST into the center of wheel, and then set
(1)
the wheel alignment gauge.
ST 927380002 ADAPTER
(4) (5)
ST
(6) (7)
(1)
(2)
FS-00007
(1) Alignment gauge

(2) Turning radius gauge
3) Measure the camber angle in accordance with

the operation manual for wheel alignment gauge. (2)
Camber (Differences between (3)

Model
RH and LH: 45$ or less) FS-00008
Sedan !0#20$"0#45$
2.0 i, 2.5 i !0#15$"0#45$ (1) Strut
2.0 GT, 3.0 R !0#20$"0#45$ (2) Adjusting bolt
Wagon (3) Housing
OUTBACK 2.5 i,
0#30$"0#45$ (4) Outer
OUTBACK 3.0 R
(5) Inner
• FRONT CAMBER ADJUSTMENT (6) Camber is increased.
1) When adjusting the camber, adjust it to the fol- (7) Camber is decreased.
lowing value.
Camber (Differences between
Model
RH and LH: 45$ or less)
Sedan !0#20$"0#30$
2.0 i, 2.5 i !0#15$"0#30$
2.0 GT, 3.0 R !0#20$"0#30$
Wagon
OUTBACK 2.5 i,
0#30$"0#30$
OUTBACK 3.0 R
2) Loosen the two self-locking nuts located at the

lower front portion of strut.
NOTE:
When the adjusting bolt needs to be loosened or
tightened, hold its head with a wrench and turn the
self-locking nut.
FS-10
Wheel Alignment
FRONT SUSPENSION
To increase camber.
Rotate the left side counterclockwise. Rotate the right side clockwise.
FS-00009 FS-00010
To decrease camber.
Rotate the left side clockwise. Rotate the right side counterclockwise.
FS-00010 FS-00009
4) Tighten two new self-locking nuts. 3) Measure the caster angle in accordance with the
operation manual for wheel alignment gauge.
Tightening torque:
175 N'm (17.8 kgf-m, 129 ft-lb) Model Caster
Sedan 6#00$
3. CASTER
Wagon 5#45$
• INSPECTION OUTBACK 5#05$
1) Place the front wheel on turning radius gauge.
Make sure the ground contacting surfaces of front 4. STEERING ANGLE
and rear wheels are set at the same height. • INSPECTION
2) Set the ST into the center of wheel, and then set
the wheel alignment gauge. 1) Place the vehicle on turning radius gauge.
ST 927380002 ADAPTER 2) While depressing the brake pedal, turn the steer-
ing wheel fully to the left and right. With the steering
wheel held at each fully turned position, measure
ST
both the inner and outer wheel steering angle.
Model Inner wheel Outer wheel
(1) OUTBACK 37.8#"1.5# 33.5#"1.5#
Except for OUT-
37.3#"1.5# 33.0#"1.5#
BACK
(2)
FS-00007
(1) Alignment gauge

(2) Turning radius gauge
FS-11
Wheel Alignment
FRONT SUSPENSION
• ADJUSTMENT • ADJUSTMENT
1) Turn the tie-rod to adjust the steering angle of When adjusting the toe-in, adjust it to the following
both inner and outer wheels. value.
2) Check the toe-in.
Toe-in:
NOTE: 0"2 mm (0"0.08 in)
Correct the boot if it is twisted. 1) Check that the left and right wheel steering angle
is within specifications.
2) Loosen the left and right side steering tie-rod
lock nuts.
3) Turn the left and right tie rods equal amounts un-
til the toe-in is at the specification.
Both the left and right tie-rods are right-hand
(1) threaded. To increase toe-in, turn both tie-rods
clockwise by equal amount (viewing from the inside
of vehicle).
FS-00014
(1) Lock nuts
5. FRONT WHEEL TOE-IN

• INSPECTION
(1)
Toe-in:
0"3 mm (0"0.12 in)
1) Set the toe-in gauge in the position at wheel axis FS-00014
center height behind the right and left front tires.
2) Measure the distance “A” between the marks (1) Lock nuts
which are put on the centers of left and right tires.
3) Move the vehicle forward and rotate the tires 4) Tighten the tie-rod lock nut.
180#. Tightening torque:
NOTE: 85 N'm (8.7 kgf-m, 62.7 ft-lb)
Be sure to rotate the tires in the forward direction. NOTE:
4) Measure the distance “B” between the left and Check and correct the tie rod boot if twisted.
right marks. Detect toe-in by the following equation:
6. REAR WHEEL TOE-IN
A ! B = Toe-in
• INSPECTION
Toe-in:
0"3 mm (0"0.12 in)
B A
Refer to “FRONT WHEEL TOE-IN” for rear toe-in
inspection procedure.
<Ref. to FS-12, FRONT WHEEL TOE-IN, INSPEC-
TION, Wheel Alignment.>
• ADJUSTMENT
When adjusting, adjust it to the following value.
FS-00015 Toe-in:
0"2 mm (0"0.08 in)
FS-12
Wheel Alignment
FRONT SUSPENSION
1) Loosen the self-locking nut on the inner side of 2) Turn the adjusting bolt until toe-in is at the spec-
rear link. ification.
NOTE: NOTE:
When loosening or tightening the adjusting bolt, When the left and right wheels are adjusted for toe-
hold the bolt head and turn self-locking nut. in at the same time, the movement of one scale
graduation changes toe-in by approx. 0.6 mm (0.02
in).
(1)
(2)
FS-00103
(1) Adjusting bolt

(2) Rear link
To increase toe-in.
Rotate the left side clockwise. Rotate the right side counterclockwise.
FS-00018 FS-00019
To decrease toe-in.
Rotate the left side counterclockwise. Rotate the right side clockwise.
FS-00019 FS-00018
3) Tighten a new self-locking nut.

Tightening torque:
120 N'm (12.2 kgf-m, 88.5 ft-lb)
FS-13
Wheel Alignment
FRONT SUSPENSION
7. THRUST ANGLE 3) When the left and right adjusting bolts are turned
by one graduation, the thrust angle will change ap-
• INSPECTION
prox. 17$ [“L” is approx. 13 mm (0.51 in)].
1) Park the vehicle on a level surface.
NOTE:
2) Move the vehicle 3 to 4 meters (10 to 13 feet) di- Thrust angle refers to a mean value of left and right
rectly forward. rear wheel toe angles in relation to the vehicle body
3) Draw the center of loci of both the front and rear center line. Vehicle is driven straight in the thrust
axles. angle direction while slanting in the oblique direc-
4) Measure the distance “L” between center lines of tion depending on the degree of the mean thrust
the loci of axles. angle.
Thrust angle:
0#"30$
(1)
Less than 30$ when “L” is less than 23 mm (3)

(0.9 in).
(2)
(1)
FS-00024
(1) Front
(2) (2) Thrust angle
(3) Body center line
Thrust angle: r = (& ! ))/2

&: Rear RH wheel toe-in angle
): Rear LH wheel toe-in angle
Use only positive toe-in values from each wheel to
substitute for & and ) in the equation.
(1) (2)
L
FS-00022
(1) Center line of loci (front axle)

(2) Center line of loci (rear axle)
• ADJUSTMENT
FS-00976
When adjusting, adjust it to the following value.
Thrust angle: (1) Front
0#"20$ (2) Body center line
Less than 20$ when “L” is less than 15 mm
(0.6 in).
1) Make the thrust angle adjustments by turning the
toe-in adjusting bolts of rear suspension equally in
the same direction.
2) When one rear wheel is adjusted in a toe-in di-
rection, adjust the other rear wheel equally in toe-
out direction, in order to make the thrust angle ad-
justment.
FS-14
Front Crossmember Support Plate
FRONT SUSPENSION
3. Front Crossmember Support

Plate
A: REMOVAL
1) Lift-up the vehicle.
2) Remove the front under cover. <Ref. to EI-26,
REMOVAL, Front Under Cover.>
3) Remove the bolt and remove front crossmember
support plate.
• Large type
FS-00104
• Small type
(1)
(2)
(1) FS-00105
(1) Crossmember support plate

(2) Jack-up plate
B: INSTALLATION
Install in the reverse order of removal.
NOTE:
Tighten the small type crossmember support plate
together with stabilizer bracket.
After installing the stabilizer bracket to crossmem-
ber, tighten the crossmember support plate togeth-
er.
Tightening torque:
Crossmember support plate:
60 N'm (6.1 kgf-m, 44.3 ft-lb)
Crossmember support plate (Joint tightening
portion of stabilizer bracket):
25 N'm (2.5 kgf-m, 18.1 ft-lb)
Jack-up plate:
60 N'm (6.1 kgf-m, 44.3 ft-lb)
FS-15
Front Stabilizer
FRONT SUSPENSION
4. Front Stabilizer • Stabilizer bracket has an orientation, so install it

with the arrow mark faced to the front side of vehi-
A: REMOVAL cle.
1) Lift-up the vehicle, and then remove the front
(1)
wheels.
2) Remove the front under cover. <Ref. to EI-26,
REMOVAL, Front Under Cover.>
3) Remove the front crossmember support plate.
<Ref. to FS-15, REMOVAL, Front Crossmember
Support Plate.>
4) Remove the stabilizer link.
FS-00116
(1) Front side of vehicle
Tightening torque:
Stabilizer link
45 N'm (4.6 kgf-m, 33.2 ft-lb)
Stabilizer bracket
FS-00117 25 N'm (2.5 kgf-m, 18.1 ft-lb)
5) Remove the stabilizer bracket. C: INSPECTION
1) Check the bushing for crack, fatigue or damage.
2) Check the stabilizer link for damage.
FS-00114
B: INSTALLATION
NOTE:
• Use a new self-locking nut.
• Ensure that the stabilizer bushing and stabilizer
have the same identification colors.
• Install the stabilizer bushing (front crossmember
side) while aligning it with the paint mark on stabi-
lizer.
FS-16
Front Ball Joint
FRONT SUSPENSION
5. Front Ball Joint NOTE:

Stabilizer bracket has an orientation, so install it
A: REMOVAL with the arrow mark faced to the front side of vehi-
1) Lift-up the vehicle and remove the front wheels. cle.
2) Remove the both sides of stabilizer bracket.
(1)
FS-00116
FS-00114
3) Pull out the pin from ball stud, remove the castle (1) Front side of vehicle
nut, and extract the ball stud from front arm.
4) Remove the bolt installing ball joint to housing. Tightening torque:
25 N'm (2.5 kgf-m, 18.1 ft-lb)
5) Install the front wheels.
C: INSPECTION
1) Measure the play of ball joint by the following
procedures. Replace with a new one when the play
exceeds specified value.
(1) With 686 N (70 kgf, 154 lb) loaded in direc-
tion shown in the figure, measure the dimension
2 1.
FS-00115
5) Extract the ball joint from housing.

B: INSTALLATION
1) Insert the ball joint into housing.
Tightening torque (Bolt):
50 N'm (5.1 kgf-m, 36.9 ft-lb)
CAUTION:
Do not apply grease to the tapered portion of
FS-00035
ball stud.
2) Install the ball joint into front arm. (2) With 686 N (70 kgf, 154 lb) loaded in direc-
tion shown in the figure, measure the dimension
Tightening torque (Castle nut) 2 2.
Front arm:
39 N'm (4.0 kgf-m, 28.8 ft-lb)
3) Retighten the castle nut further within 60# until
the hole in ball stud is aligned with a slot in castle
nut. Then, insert a new cotter pin and bend it
around castle nut.
4) Install the stabilizer bracket.
FS-00036
(3) Determine the plays from the following for-

mula. S = 22 – 21
FS-17
Front Ball Joint
FRONT SUSPENSION
(4) Replace with a new one when the play ex-

ceeds specified value.
FRONT BALL JOINT
Specified play for replacement S:
Less than 0.3 mm (0.012 in)
2) When the play is within specified value, visually
check the dust cover.
3) Remove the ball joint and cover, check them for
wear, damage or cracks, and then replace them if
any defective part is found.
4) If the dust cover is damaged, replace with a new
ball joint.
FS-18
Front Arm
FRONT SUSPENSION
6. Front Arm CAUTION:

Do not remove the stud bolt without necessity.
A: REMOVAL Always replace the parts with new ones when
1) Lift-up the vehicle, and then remove the front removed.
wheels.
2) Remove the front crossmember support plate.
<Ref. to FS-15, REMOVAL, Front Crossmember
Support Plate.>
3) Remove the front stabilizer. <Ref. to FS-16, RE- (1)
MOVAL, Front Stabilizer.>
4) Remove the ball joint of front arm. (2)
ST
FS-00109
(1) Vehicle body

(2) Stud bolt
B: INSTALLATION
1) Using the ST, install the stud bolt.
FS-00106 ST 20299AG020 STUD BOLT SOCKET
5) Remove the nut securing the front arm to cross- Tightening torque:
member. (Do not remove the bolt.) 110 N'm (11.2 kgf-m, 81.1 ft-lb)
2) Using new bolts and self-locking nuts, temporari-
ly tighten the front arm to crossmember.
3) Secure the front arm to body, and then install the
support plate with new bolts and self-locking nuts.
Tightening torque:
Support plate-to-Front arm:
110 N'm (11.2 kgf-m, 81.1 ft-lb)
Support plate-to-Body:
150 N'm (15.3 kgf-m, 110.6 ft-lb)
FS-00107
4) Install the ball joint into housing.
6) Remove the front arm support plate.
Tightening torque:
50 N'm (5.1 kgf-m, 36.9 ft-lb)
5) Install the stabilizer. <Ref. to FS-16, INSTALLA-
TION, Front Stabilizer.>
6) Lower the vehicle from the lift, and tighten the
bolt which secures the front arm to crossmember at
the state that wheels are in full contact with the
ground and the vehicle is curb weight.
Tightening torque:
95 N'm (9.7 kgf-m, 70.1 ft-lb)
FS-00108
NOTE:
7) Remove the bolt securing the front arm to cross-
Inspect the wheel alignment and adjust if neces-
member and extract the front arm from crossmem-
sary.
ber.
8) To remove the stud bolt, use ST.
ST 20299AG020 STUD BOLT SOCKET
FS-19
Front Arm
FRONT SUSPENSION
C: DISASSEMBLY 2) Using the ST and a press, remove the rear bush-

ing.
1. FRONT BUSHING ST1 20299AG000 REMOVER
Using the ST and a press, remove the front bush- ST2 20299AG010 BASE
ing. (1)
ST 927680000 INSTALLER & REMOVER
SET ST1
(2)
ST2
ST
(3)
FS-00126
(1) Press
FS-00110
(2) Front arm
(3) Rear bushing
2. REAR BUSHING
1) Scribe an aligning mark on the front arm based D: ASSEMBLY
on the center of rear bushing recess portion. 1. FRONT BUSHING
CAUTION: Assemble in the reverse order of disassembly.
Always put an alignment mark for aligning the
position on bushing installation. CAUTION:
Install the front bushing in proper direction as
shown in the figure.
(1) (3)
(1)
(2)
(2)
(1)
FS-00136
(1) Put an alignment mark. FS-00102
(2) Recess portion

(1) Face the bushing toward the center of ball joint.
(2) Ball joint
(3) "3#
FS-20
Front Arm
FRONT SUSPENSION
2. REAR BUSHING 3) Using the ST and a press, install the rear bush-
ing.
1) Install the rear bushing with its longer inner cyl-
ST1 20299AG000 REMOVER
inder faced upward and its shorter one faced down-
ward and protruding part rearward as shown in the ST2 20299AG010 BASE
figure. (1)
ST1
(1)
(5)
(3) (2)
(3)
(4)
ST2
(2) FS-00127
FS-00113
(1) Press
(1) Front arm (2) Front arm
(2) Bushing inner cylinder (3) Rear bushing
(3) Longer
E: INSPECTION
(4) Shorter
1) Check the front arm for wear, damage or cracks,
(5) Protrusion portion
and correct or replace if defective.
2) Align the center of rear bushing recess portion 2) Check the bushing for crack, fatigue or damage.
with the aligning mark on the front arm.
(1)
(2)
(1)
FS-00136
(1) Alignment mark

(2) Recess portion
FS-21
Front Strut
FRONT SUSPENSION
7. Front Strut 6) Remove the three nuts securing strut mount to

body.
A: REMOVAL
wheels.
2) Scribe an alignment mark on the camber adjust-
ing bolt and strut.
3) Remove the bolt securing brake hose from strut.
FS-00037
4) Remove the bolt securing ABS wheel speed

sensor harness.
FS-00039
B: INSTALLATION
1) Install the strut mount at the upper side of strut to
body, and tighten it with new self-locking nuts.
Tightening torque:
20 N'm (2.0 kgf-m, 14.5 ft-lb)
2) Align alignment marks on the camber adjusting
FS-00038
bolt and strut.
5) Remove the two bolts securing housing to strut. Using new self-locking nuts, install the strut to
NOTE: housing.
While holding the head of adjusting bolt, loosen the NOTE:
self-locking nut. While holding the head of adjusting bolt, tighten the
self-locking nut.
Tightening torque:
175 N'm (17.8 kgf-m, 129 ft-lb)
3) Secure the ABS wheel speed sensor harness to
strut.
Tightening torque:
33 N'm (3.4 kgf-m, 24.3 ft-lb)
4) Install the bolts which secure the brake hose to
strut.
Tightening torque:
33 N'm (3.4 kgf-m, 24.3 ft-lb)
NOTE:
Inspect the wheel alignment and adjust if neces-
sary.
FS-22
Front Strut
FRONT SUSPENSION
C: DISASSEMBLY (5) Repeat 3 to 4 times from the step (1).

1) Using a coil spring compressor, compress the NOTE:
coil spring. After completely purging air from the strut, be sure
to place the strut with the piston rod facing up. If the
strut is laid down and set, check for the entry of air
in accordance with “Check for 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.
(1)
FS-00040
2) Using the ST, remove the self-locking nut. (2)

ST 20399AG000 STRUT MOUNT SOCKET
ST
(3) FS-00042
(1) Diameter is small (Upper part)

(2) Identification paint
(3) Diameter is large (Bottom part)
FS-00041
3) Remove the strut mount and upper spring seat 5) Set the coil spring correctly so that its end face
from strut. fits well into the spring seat as shown in the figure.
4) Gradually decrease the compression force of
compressor, and remove the coil spring.
5) Remove the dust cover and helper spring.
D: ASSEMBLY
1) Before installing the coil spring, strut mount, etc.
on strut, check for the presence of air in the damp-
ening force generating mechanism of the strut
since air prevents proper dampening force produc-
tion. (1)
2) Check for presence of air FS-00043

(1) Place the strut vertically with the piston rod
facing up. (1) Coil spring end face
(2) Move the piston rod to the center of its entire
6) Install the helper and dust cover to piston rod.
stroke.
(3) While holding the piston rod end with finger-
tips, move the rod up and down.
(4) If the piston rod moves at least 10 mm (0.39
in) in the former step, purge air from the strut.
3) Air purging procedure
(1) Place the strut vertically with the piston rod
facing up.
(2) Fully extend the piston rod.
(3) With the piston rod fully extended, place the
piston rod side down. The strut must stand ver-
tically.
(4) Fully contract the piston rod.
FS-23
Front Strut
FRONT SUSPENSION
7) Pull the piston rod fully upward, and install the E: INSPECTION
spring seat. Check the removed part for wear, damage or
NOTE: cracks, and then repair or replace it if defective.
Ensure the upper spring seat is positioned as
1. DAMPER STRUT
shown in the figure.
1) Check for oil leaks.
2) Move the piston rod up and down to check that it
operates smoothly without any hitch.
3) Piston rod play
• Measure the play as follows:
Fix the outer shell and fully extend the rod. Set a
dial gauge at the end of rod L [10 mm (0.39 in)], and
then read the dial gauge indication P1 while apply-
ing a force of W [20 N (2 kgf, 4 lb)] to threaded por-
(1)
tion. Apply a force of 20 N (2 kgf, 4 lb) in the
FS-00128 opposite direction of “W”, and then read the dial
gauge indication P2.
(1) Outside of body
8) Install the strut mount to piston rod, and tighten a

new self-locking nut temporarily.
9) Using a hexagon wrench to prevent strut rod W
from turning, tighten the new self-locking nut with
ST.
L
ST 20399AG000 STRUT MOUNT SOCKET
Tightening torque:
55 N'm (5.6 kgf-m, 41 ft-lb)
FS-00046
Play limit (P1 + P2):

ST 0.8 mm (0.031 in)
If the play exceeds limit, replace the strut.
2. STRUT MOUNT
Check the rubber part for deformation, cracks or
deterioration, and then replace it with a new one if
defective.
FS-00041 3. DUST COVER
10) Loosen the coil spring carefully. If any cracks or damage are found, replace it with a
new one.
4. COIL SPRING
If a permanent strain is found, replaced it with a
new one.
5. HELPER
Replace it with a new one if cracked or damaged.
FS-24
Front Strut
FRONT SUSPENSION
F: DISPOSAL
CAUTION:
• Before handling struts, be sure to wear gog-
gles to protect eyes from gas, oil and cutting
powder.
• Do not disassemble the strut damper or place
into a fire.
• Drill a hole into struts in case of discarding
struts filled with gas.
1) Place the strut on a level surface with the piston
rod fully expanded.
2) Using a 2 to 3 mm (0.08 to 0.12 in) dia. drill,
make holes in areas shown in the figure.
(1)
FS-00047
(1) 40 mm (1.57 in)
FS-25
Front Crossmember
FRONT SUSPENSION
8. Front Crossmember B: INSTALLATION

1) Install in the reverse order of removal.
A: REMOVAL
1) Lift-up the vehicle, and then remove the front NOTE:
wheels. • Use a new bolt and self-locking nut. For the parts
2) Remove the front exhaust pipe. which are not reusable, refer to “COMPONENT”.
3) Remove the front crossmember support plate. <Ref. to FS-4, COMPONENT, General Descrip-
<Ref. to FS-15, REMOVAL, Front Crossmember tion.>
Support Plate.> • Always tighten the bushing in the state that
4) Remove the front stabilizer. <Ref. to FS-16, RE- wheels are in full contact with the ground and the
MOVAL, Front Stabilizer.> vehicle is curb weight.
5) Disconnect the tie-rod end from housing. Tightening torque:
6) Remove the front arm. <Ref. to FS-19, REMOV- Crossmember to body:
AL, Front Arm.> 95 N'm (9.7 kgf-m, 70.1 ft-lb)
7) Remove the nuts attaching the engine mount Engine mounting to crossmember:
cushion rubber to crossmember. 85 N'm (8.7 kgf-m, 62.7 ft-lb)
Front arm-to-Crossmember:
95 N'm (9.7 kgf-m, 70.1 ft-lb)
Front arm-to-Support plate:
110 N'm (11.2 kgf-m, 81.1 ft-lb)
Support plate body:
150 N'm (15.3 kgf-m, 110.6 ft-lb)
Tie-rod end to housing:
27.0 N'm (2.75 kgf-m, 19.9 ft-lb)
Retighten the castle nut further within 60# until the
FS-00118
hole in ball stud is aligned with a slot in castle nut
after tightening in specified torque.
8) Remove the steering universal joint. Universal joint:
9) Disconnect the power steering hose from steer- 24 N'm (2.4 kgf-m, 17.4 ft-lb)
ing gearbox. Stabilizer bracket:
10) Lift the engine approx. 10 mm (0.39 in) using a 25 N'm (4.6 kgf-m, 33.2 ft-lb)
chain block. Stabilizer link:
11) Support the crossmember with a jack, remove 45 N'm (2.5 kgf-m, 18.4 ft-lb)
the bolts securing crossmember to body, and then
Power steering hose-to-Steering gearbox:
gradually lower the crossmember with steering
15 N'm (1.5 kgf-m, 11 ft-lb)
gearbox as a unit.
2) Purge air from the power steering system.
CAUTION: 3) Inspect the wheel alignment and adjust if neces-
When removing the crossmember downward, sary.
be careful that the tie-rod end does not interfere
with drive shaft boot. C: INSPECTION
Check the crossmember for wear, damage or
cracks, and then repair or replace if defective.
FS-00119
FS-26
General Diagnostic Table
FRONT SUSPENSION
9. General Diagnostic Table

A: INSPECTION
1. IMPROPER VEHICLE POSTURE OR IMPROPER WHEEL ARCH HEIGHT
Possible cause Corrective action
(1) Permanent distortion or breakage of coil spring Replace.
(2) Rough operation of damper strut or shock absorber Replace.
(3) Installation of wrong strut or shock absorber Replace with proper parts.
(4) Installation of wrong coil spring Replace with proper parts.
2. POOR RIDE COMFORT

1) Large rebound shock
2) Rocking of the vehicle continues too long after running over bump and hump.
3) Large shock in bumping
(1) Breakage of coil spring Replace.
(2) Overinflating pressure of tire Adjust.
(3) Improper wheel arch height Adjust or replace the coil springs with new ones.
(4) Fault in operation of damper strut or shock absorber Replace.
(5) Damage or deformation of strut mount or shock absorber mount Replace.
(6) Unsuitability of maximum or minimum length of damper strut or shock Replace with proper parts.
absorber
(7) Deformation or loss of bushing Replace.
(8) Deformation or damage of helper in strut assembly or shock absorber Replace.
(9) Oil leakage of damper strut or shock absorber Replace.
3. NOISE
(1) Wear or damage of damper strut or shock absorber component parts Replace.
(2) Loosening of suspension link installing bolt Tighten to specified torque.
absorber
(6) Wear or damage of ball joint Replace.
(7) Deformation of stabilizer clamp Replace.
FS-27
FRONT SUSPENSION
FS-28
CHASSIS SECTION
FRONT SUSPENSION FS
REAR SUSPENSION RS
DIFFERENTIALS DI
TRANSFER CASE TC
(DIAGNOSTICS)
BRAKE BR
PARKING BRAKE PB

(POWER STEERING)

approval.

REAR SUSPENSION
RS
Page
2. Wheel Alignment .........................................................................................8
3. Rear Stabilizer.............................................................................................9
4. Rear Arm...................................................................................................10
5. Upper Link.................................................................................................14
6. Rear Shock Absorber................................................................................16
7. Front Link ..................................................................................................18
8. Rear Link...................................................................................................19
9. Sub Frame Support Arm ...........................................................................21
10. Sub Frame Support Plate..........................................................................22
11. Rear Sub Frame........................................................................................23
12. Helper........................................................................................................24
General Description
REAR SUSPENSION
A: SPECIFICATION
Sedan Wagon
Model OUTBACK 2.5 i,
2.0 i, 2.5 i 2.0 GT, 3.0 R 2.0 i 2.5 i
OUTBACK 3.0 R
Wheel arch height
[Tolerance: +12 mm !24 mm (in) 360 (14.2) 375 (14.8) 430 (16.9)
+0.47 in
mm ( !0.94 in)]
Differences between RH and LH: !0#45$ !0#30$ 0#00$
45$ or less)
Thrust angle (tolerance: "0#30$& 0#
Diameter of stabilizer mm (in) 17.3 (0.68) 19.1 (0.75) 19.1 (0.75) 20 (0.78) 17.3 (0.68)
NOTE:
• Front and rear toe-ins and front camber can be
adjusted. If the toe-in or camber tolerance exceeds
specifications, adjust them.
• Other items indicated in the specification table
cannot be adjusted. If other items exceeds specifi-
cations, check suspension parts and connections
for deformation, and replace with new ones as re-
quired.
(1)
FS-00001
(1) Front
A ! B = Positive: Toe-in, Negative: Toe-out
' = Each toe angle
RS-2
General Description
REAR SUSPENSION
B: COMPONENT
1. REAR SUSPENSION
(2)
T1
(1)
(21)
(23)
(3)
T6
(2)
T12 (5)
(4)
(6) T3
T7 T12
(8)
T4
(9)
(10)
(2) (2) (2)
(7) T5
T5
(2)
(2)
T9
T5 (11)
(20) (2)
(18) T7
(17) T2 T7 (12)
(16)
(14) (2)
(2)
(19)
T10 (13)
(15)
(22)
T8
T11
T12
RS-00137
(1) Shock absorber (14) Rear arm bracket Tightening torque: N(m (kgf-m, ft-lb)
(2) Self-locking nut (15) Hub bearing unit T1: 30 (3.1, 22.4)
(3) Stabilizer (16) Helper T2: 32 (3.3, 24)
(4) Stabilizer bushing (17) Upper link T3: 40 (4.1, 30)
(5) Bracket (18) Upper link bushing (inner side) T4: 44 (4.5, 32.5)
(6) Stabilizer link (19) Upper link bushing (outer side) T5: 57 (5.8, 42)
(7) Rear link (20) Front link T6: 62 (6.3, 48)
(8) Adjusting bolt (21) Rear sub frame T7: 65 (6.6, 48)
(9) Rear link bushing (22) Sub frame support arm T8: 80 (8.2, 59)
(10) Adjusting washer (23) Sub frame support plate T9: 120 (12.2, 89)
(11) Rear arm T10: 125 (12.7, 92)
(12) Rear arm rear bushing T11: 150 (15.3, 111)
(13) Rear arm front bushing T12: 175 (17.8, 129)
RS-3
General Description
REAR SUSPENSION
2. SHOCK ABSORBER
T1
(6)
(4)
(6)
T2
(1)
(2)
(3)
(5)
T3
(6)
RS-00037
(1) Mount (4) Coil spring Tightening torque: N(m (kgf-m, ft-lb)
(2) Upper rubber sheet (5) Shock absorber T1: 30 (3.1, 22.4)
(3) Dust cover (6) Self-locking nut T2: 35 (3.6, 26)
T3: 62 (6.3, 48)
C: CAUTION
• Before discarding shock absorbers, be sure to
bleed gas completely. Also, do not throw away in
fire.
• Use SUBARU genuine grease etc. or the equiv-
alent. Do not mix grease, etc. with that of another
grade or from other manufacturers.
or cloth between the part and the vice.
nuts to specified torque.
points.
RS-4
General Description
REAR SUSPENSION
D: PREPARATION TOOL
1. SPECIAL TOOL

927380002 ADAPTER Used for an adapter of camber & caster gauge
when measuring the camber and caster.
(1) 28199AC000 PLATE
(2) 28199AC010 BOLT
(1)
(2)
ST-927380002
20099AE000 INSTALLER & Used for replacing the rear link bushing.
REMOVER
ST20099AE000
20099AE010 INSTALLER & Used for replacing the upper link bushing.
REMOVER
ST20099AE010
20099AE020 INSTALLER & Used for replacing the rear arm front bushing.
REMOVER SET
ST20099AE020
RS-5
General Description
REAR SUSPENSION

20099AE040 INSTALLER & Used for replacing the rear arm rear bushing.
REMOVER SET
ST20099AE040
20099AE030 HELPER SOCKET Used for replacing the helper.
WRENCH
ST20099AE030
20399AG000 STRUT MOUNT Used for removing and installing the shock
(New adopted tool) SOCKET mount.
ST20399AG000
28099PA090 OIL SEAL PROTEC- • Used for installing the rear drive shaft to rear
TOR differential.
• For oil seal protection
ST28099PA090
RS-6
General Description
REAR SUSPENSION

28099PA100 REMOVER Used for removal of DOJ.
ST28099PA100
2. GENERAL TOOL
TOOL NAME REMARKS
Alignment gauge Used for wheel alignment measurement.
Turning radius gauge Used for wheel alignment measurement.
Toe-in gauge Used for toe-in measurement.
Transmission jack Used for removing and installing suspension.
Bearing puller Used for removing bushings.
Coil spring compressor Used for disassembling and assembling shock absorber.
RS-7
Wheel Alignment
REAR SUSPENSION
2. Wheel Alignment
A: INSPECTION
NOTE:
Measure and adjust the front and rear wheel align-
ment at a time. Refer to “FS” section for measure-
ment and adjustment of wheel alignment. <Ref. to
FS-8, INSPECTION, Wheel Alignment.>
RS-8
Rear Stabilizer
REAR SUSPENSION
3. Rear Stabilizer 2) Always tighten the stabilizer bushing in the state

that wheels are in full contact with the ground and
A: REMOVAL the vehicle is curb weight.
1) Lift-up the vehicle, and then remove the rear
Tightening torque:
wheels.
Stabilizer link
44 N(m (4.5 kgf-m, 32.5 ft-lb)
Stabilizer bracket
40 N(m (4.1 kgf-m, 30 ft-lb)
C: INSPECTION
1) Check the bushing for crack, fatigue and dam-
age.
2) Check the stabilizer link for damage.
RS-00038
3) Remove the stabilizer bracket.
RS-00116
B: INSTALLATION
NOTE:
• Ensure the stabilizer bushing and stabilizer have
the same identification colors.
• To install the stabilizer bushing, align the paint
mark end of stabilizer to the end of stabilizer bush-
ing.
• Stabilizer bracket has an orientation, so install it
with the arrow mark faced to the upper side of ve-
hicle.
(1)
RS-00117
(1) Paint mark
RS-9
Rear Arm
REAR SUSPENSION
4. Rear Arm 7) Remove the bolts which secure the brake hose
bracket to rear arm. Remove the bolts which se-
A: REMOVAL cure the ABS wheel speed sensor to rear arm.
wheels.
2) Remove the sub frame support arm.
<Ref. to RS-21, REMOVAL, Sub Frame Support
Arm.>
3) Remove the bearing unit.
<Ref. to DS-19, REMOVAL, Rear Hub Unit Bear-
ing.>
4) Hang the back plate from sub frame.
RS-00124
8) Remove the stabilizer link from rear arm.
RS-00043
5) Remove the bolts which secure the parking

brake cable clamp to rear arm bracket.
RS-00044
9) Remove the shock absorber from rear arm.
RS-00040
6) Remove the bolt which hold the brake hose

bracket and ABS wheel speed sensor bracket to RS-00045
rear arm. 10) Support the rear arm horizontally using a trans-
mission jack.
RS-00041
RS-00046
RS-10
Rear Arm
REAR SUSPENSION
11) Remove the nuts which hold the rear arm to 14) Loosen the nut which hold the upper link to rear
bracket. Remove the rear arm bracket. arm.
RS-00050
15) Remove the bolt which secure the rear arm to

the link, and then remove the rear arm.
B: INSTALLATION
NOTE:
Use a new bolt and self-locking nut. For the parts
which are not reusable, refer to “COMPONENT”.
<Ref. to RS-3, REAR SUSPENSION, COMPO-
NENT, General Description.>
1) Support the rear arm using a transmission jack.
RS-00118 2) Install the rear arm and temporarily tighten the
12) Loosen the nut which hold the front link to rear bolts which hold the rear arm to the link.
arm. 3) Install the bearing unit.
<Ref. to DS-20, INSTALLATION, Rear Hub Unit
Bearing.>
4) Install the bolts which secure the ABS wheel
speed sensor to rear arm.
5) Install the bolts which secure the brake hose to
rear arm.
6) Install the bolts which secure the parking brake
cable clamp to rear arm bracket.
7) Set the jack which is originally equipped to the
vehicle under the upside down situation, and place
RS-00048 the jack between rear link and sub frame. Align the
13) Loosen the nut which hold the rear link to rear installing position of rear shock absorber and rear
arm. arm by adjusting the jack position, temporarily tight-
en the bolt and nut.
CAUTION:
Protect the rear link and sub frame from scratch
in the way of putting a cloth between the jack
and mating portion.
RS-00049
RS-00051
RS-11
Rear Arm
REAR SUSPENSION
8) Using the transmission jack, support the rear 3) Place the ST B on bushing, and push the bush-
arm horizontally. ing out.
9) Tighten the nuts and bolts which hold the rear ST A 20099AE020 INSTALLER & REMOVER
arm, front link, rear link, upper link and shock ab- SET
sorber. ST B 20099AE020 INSTALLER & REMOVER
NOTE: SET
Always tighten the bushing in the state that wheels
are in full contact with the ground and the vehicle is
curb weight. ST-B
(1)
ST-A
(1) RS-00119
(2)
(1) Bushing
RS-00052 2. REAR BUSHING

(1) Rear arm Using the ST C and bearing puller, press the rear
(2) Transmission jack bushing out of place.
ST C 20099AE040 INSTALLER & REMOVER
10) Install the sub frame support arm. SET
NOTE:
Inspect the wheel alignment and adjust it if neces- ST-C
sary.
Tightening torque:
Refer to “COMPONENT” of “General Descrip-
tion” for tightening torque. <Ref. to RS-3, (1)
REAR SUSPENSION, COMPONENT, General
Description.>
C: DISASSEMBLY
RS-00054
1. FRONT BUSHING
(1) Bearing puller
1) Set the ST A with the larger side of its inner di-
ameter turned upward. D: ASSEMBLY
2) Set the rear arm with the protruding side of bush-
ing turned upward. 1. FRONT BUSHING
1) Set the ST A with the larger side of its inner di-
ameter turned upward.
2) Set the rear arm with the vehicle inner side of
arm turned downward.
3) Place the bushing on rear arm as shown in the
figure.
RS-12
Rear Arm
REAR SUSPENSION
4) Place the ST B on bushing, and press-fit until E: INSPECTION

each edge surface of bushing and rear arm comes Check the rear arm for bend, corrosion or damage.
to be aligned.
ST A 20099AE020 INSTALLER & REMOVER
SET
ST B 20099AE020 INSTALLER & REMOVER
SET
(2)
(1)
ST-B
ST-A
RS-00120
(1) 0"5#
(2) Identification paint: Assemble with the
identification paint side faced to the arm
inner side.
2. REAR BUSHING
1) Press the bushing into the bore inside of ST D.
2) Set the ST C, ST D and bearing puller in the
specified position as shown in the figure, and then
press-fit the bush until the outer end of bush and
rear end of rear arm in flat.
ST C 20099AE040 INSTALLER & REMOVER
SET
ST D 20099AE040 INSTALLER & REMOVER
SET
ST-C ST-D
RS-00056
RS-13
Upper Link
REAR SUSPENSION
5. Upper Link 2) Using new self-locking nuts, install the upper

link.
A: REMOVAL
wheels.
2) Using the transmission jack, support the rear
arm horizontally.
(1)
(2)
RS-00052
(1) (1) Rear arm

(2) (2) Transmission jack
RS-00052 NOTE:
Inspect the wheel alignment and adjust it if neces-
(1) Rear arm sary.
(2) Transmission jack Tightening torque:
3) Remove the bolt which secure the upper link to Upper link to Sub frame
sub frame. 57 N(m (5.8 kgf-m, 42 ft-lb)
Upper link to Rear arm
65 N(m (6.6 kgf-m, 48 ft-lb)
C: DISASSEMBLY
Using the ST, press the bushing out of place.
ST 20099AE010 INSTALLER & REMOVER
RS-00058
ST
4) Remove the bolts which secure the upper link to
rear arm, and then remove the upper link.
RS-00061
D: ASSEMBLY
Using the ST, press the bushing into place.
ST 20099AE010 INSTALLER & REMOVER
RS-00059
B: INSTALLATION ST
arm horizontally.
RS-00090
RS-14
Upper Link
REAR SUSPENSION
CAUTION:
Outer side bushing has an orientation. Assem-
ble it with the longer protrusion faced to the
rear side of vehicle.
(2)
(3)
(1)
RS-00121
(1) Rear arm

(2) Rear sub frame
(3) Rear side of vehicle
E: INSPECTION
1) Visually check the upper link for damage and de-
formation.
2) Visually check the bush for crack, damage and
fatigue.
RS-15
Rear Shock Absorber
REAR SUSPENSION
6. Rear Shock Absorber CAUTION:

Protect the rear link and sub frame from scratch
A: REMOVAL in the way of putting a shop cloth between the
1) Remove the luggage floor mat. (Wagon model) jack and the mating portion.
2) Roll up the trunk side trim. (Sedan model)
wheels.
4) Remove the bolts which secure the shock ab-
sorber to rear arm.
RS-00051

arm horizontally.
5) Using new self-locking nuts, tighten the bolt and
RS-00065
nut which secure the shock absorber.
5) Support the shock absorber using a jack.
6) Remove the nuts which secure the shock ab-
sorber mount to vehicle.
(1)
(2)
RS-00052
(1) Rear arm

(2) Transmission jack
RS-00066
7) Remove the shock absorber. Tightening torque:

62 N(m (6.3 kgf-m, 48 ft-lb)
B: INSTALLATION 6) Install the floor mat. (Wagon model)
1) Support the shock absorber using a jack. 7) Set the trunk side trim. (Sedan model)
2) Using new self-locking nuts, secure the shock
absorber to vehicle. NOTE:
Check the wheel alignment and adjust it if neces-
Tightening torque: sary.
30 N(m (3.1 kgf-m, 22.4 ft-lb)
C: DISASSEMBLY
3) Set the jack which is originally equipped to the
Refer to Front Strut for disassembly procedures.
vehicle under the upside down situation, and place
<Ref. to FS-23, DISASSEMBLY, Front Strut.>
the jack between rear link and sub frame. Align the
installing position of rear shock absorber and rear D: ASSEMBLY
arm by adjusting the jack position. Using new self- Refer to Front Strut for installation procedures.
locking nuts, temporary tighten the bolt. <Ref. to FS-23, ASSEMBLY, Front Strut.>
E: INSPECTION
Refer to “Front Strut” for inspection procedures.
<Ref. to FS-24, INSPECTION, Front Strut.>
RS-16
Rear Shock Absorber
REAR SUSPENSION
F: DISPOSAL
CAUTION:
• Before handling shock absorbers, be sure to
wear goggles to protect eyes from gas, oil and
cutting powder.
• Do not disassemble the shock absorber or
place it into a fire.
• Drill a hole into shock absorbers in case of
discarding shock absorbers filled with gas.
1) Place the shock absorber on a level surface with
the piston rod fully expanded.
2) Make a hole into the specified position 30 mm
(1.18 in) deep using a drill with 2 to 3 mm (0.08 to
0.12 in) diameter.
(1)
RS-00135
(1) 40 mm (1.57 in)
RS-17
Front Link
REAR SUSPENSION
7. Front Link 2) Using new self-locking nuts, install the front link.
A: REMOVAL
wheels.
arm horizontally.
(1)
(2)
RS-00052
(1) Rear arm

(2)
CAUTION:
RS-00052 Install the front link with the protrusion side
faced to the front side of vehicle.
(1) Rear arm
3) Remove the bolt which secure the front link to

sub frame.
(1)
RS-00075
(1) Front
NOTE:
RS-00072 Inspect the wheel alignment and adjust it if neces-
sary.
4) Remove the bolt which secure the front link to
rear arm, and then remove the front link. Tightening torque:
57 N(m (5.8 kgf-m, 42 ft-lb)
C: INSPECTION
Visually check the front link for damage and defor-
mation.
RS-00073
B: INSTALLATION
arm horizontally.
RS-18
Rear Link
REAR SUSPENSION
8. Rear Link B: INSTALLATION

A: REMOVAL arm horizontally.
1) Lift-up the vehicle, and then remove the rear 2) Using new self-locking nuts, install the rear link.
wheels.
2) Remove the rear stabilizer. <Ref. to RS-9, RE-
MOVAL, Rear Stabilizer.>
arm horizontally.
(1)
(2)
RS-00052
(1)
(1) Rear arm
RS-00052 NOTE:
• Tighten the self-locking nut with the bolt head se-
(1) Rear arm cured when installing the adjusting bolt.
(2) Transmission jack • Inspect the wheel alignment and adjust it if nec-
essary.
4) Remove the bolts which secure the rear link to
rear arm. Tightening torque:
Rear link to Sub frame
120 N(m (12.2 kgf-m, 89 ft-lb)
Rear link to Rear arm
57 N(m (5.8 kgf-m, 42 ft-lb)
C: DISASSEMBLY
Using the ST A and ST B, press the bushing out of
place.
RS-00080
5) Put alignment marks on the rear link adjusting

bolt and sub frame. ST-A
6) Remove the bolt which secure the rear link to
sub frame, and then remove the rear link.
CAUTION:
Loosen the nut with the bolt head secured
when loosening the adjusting bolt.
ST-B
RS-00083
RS-00081
RS-19
Rear Link
REAR SUSPENSION
D: ASSEMBLY
Using the ST A and ST B, press-fit the bushing.
ST-A
ST-B
RS-00083
E: INSPECTION
Visually check the rear link for damage and defor-
mation.
RS-20
Sub Frame Support Arm
REAR SUSPENSION
9. Sub Frame Support Arm

A: REMOVAL
1) Lift-up the vehicle, and support the rear sub
frame with support stand.
RS-00088
B: INSTALLATION
Tightening torque:
Sub frame support arm to Rear arm bracket
80 N(m (8.2 kgf-m, 59 ft-lb)
Sub frame support arm to Rear sub frame
175 N(m (17.8 kgf-m, 129 ft-lb)
C: INSPECTION
Visually check the sub frame support arm for dam-
age and deformation.
RS-21
Sub Frame Support Plate
REAR SUSPENSION
10.Sub Frame Support Plate

A: REMOVAL
1) Lift-up the vehicle, and support the rear sub
frame with support stand.
2) Remove the sub frame support plate.
FU-01134
B: INSTALLATION
Tightening torque:
Support plate to Sub frame
175 N(m (17.8 kgf-m, 129 ft-lb)
Support plate to Body
65 N(m (6.6 kgf-m, 48 ft-lb)
C: INSPECTION
Visually check the support plate for damage.
RS-22
Rear Sub Frame
REAR SUSPENSION
11.Rear Sub Frame 3) Using the transmission jack, support the rear
arm horizontally. Then tighten the nuts and bolts
A: REMOVAL which hold the rear arm, front link, rear link, upper
1) Separate the front exhaust pipe from rear ex- link and shock absorber.
haust pipe.
2) Remove the rear exhaust pipe and muffler.
3) Remove the rear differential.
T-type
<Ref. to DI-29, REMOVAL, Rear Differential (T-
type).>
VA-type (1)
<Ref. to DI-46, REMOVAL, Rear Differential (VA-
(2)
type).>
4) Remove the rear stabilizer. <Ref. to RS-9, RE-
RS-00052
MOVAL, Rear Stabilizer.>
5) Remove the bolts which secure the rear shock (1) Rear arm
absorber to rear arm.
6) Support the sub frame using a transmission jack.
NOTE:
Check the wheel alignment and adjust it if neces-
sary.
C: INSPECTION
Check the removed parts for wear, damage and
crack, and repair or replace them if faulty.
RS-00085
7) Remove the front link from sub frame.

<Ref. to RS-18, REMOVAL, Front Link.>
8) Remove the rear link from sub frame.
<Ref. to RS-19, REMOVAL, Rear Link.>
9) Remove the upper link from sub frame.
<Ref. to RS-14, REMOVAL, Upper Link.>
11) After removing the bolt, remove the sub frame
and sub frame support plate from vehicle.
B: INSTALLATION
2) Follow the procedure below for the rear differen-
tial installation and tightening torque.
T-type
<Ref. to DI-30, INSTALLATION, Rear Differential
(T-type).>
VA-type
<Ref. to DI-47, INSTALLATION, Rear Differential
(VA-type).>
RS-23
Helper
REAR SUSPENSION
12.Helper
A: REMOVAL
wheels.
2) Remove the helper using ST.
ST 20099AE030 HELPER SOCKET WRENCH
ST
RS-00087
B: INSTALLATION
Tightening torque:
32 N(m (3.3 kgf-m, 24 ft-lb)
C: INSPECTION
Check the helper for crack, fatigue and damage.
RS-24
REAR SUSPENSION
13.General Diagnostic Table

A: INSPECTION
1. IMPROPER VEHICLE POSTURE OR IMPROPER WHEEL ARCH HEIGHT
(1) Permanent distortion or breakage of coil spring Replace.
(2) Rough operation of damper strut or shock absorber Replace.
(3) Installation of wrong strut or shock absorber Replace with proper parts.
(4) Installation of wrong coil spring Replace with proper parts.
2. POOR RIDE COMFORT

1) Large rebound shock
2) Rocking of the vehicle continues too long after running over bump and hump.
3) Large shock in bumping
(2) Overinflating pressure of tire Adjust.
(3) Improper wheel arch height Adjust or replace the coil springs with new ones.
(4) Fault in operation of damper strut or shock absorber Replace.
(5) Damage or deformation of strut mount or shock absorber mount Replace.
absorber
(8) Deformation or damage of helper in strut assembly or shock absorber Replace.
(9) Oil leakage of damper strut or shock absorber Replace.
3. NOISE
(1) Wear or damage of damper strut or shock absorber component parts Replace.
(2) Loosening of suspension link installing bolt Tighten to the specified torque.
absorber
(6) Wear or damage of ball joint Replace.
(7) Deformation of stabilizer clamp Replace.
RS-25
REAR SUSPENSION
RS-26
CHASSIS SECTION
FRONT SUSPENSION FS
REAR SUSPENSION RS
DIFFERENTIALS DI
TRANSFER CASE TC
(DIAGNOSTICS)
BRAKE BR
PARKING BRAKE PB

(POWER STEERING)

approval.

WHEEL AND TIRE SYSTEM
WT
Page
2. Tire ..............................................................................................................4
3. Steel Wheel.................................................................................................5
4. Aluminum Wheel .........................................................................................6
5. Wheel Balancing .........................................................................................7
6. “T-type” Tire ................................................................................................9
General Description
A: SPECIFICATION
1. WHEEL AND TIRE SIZE
WT-00001
(1) Offset
(2) P.C.D.
Tire inflation pressure

Offset P.C.D.
Specification Tire size Wheel size kPa (kgf/cm2, psi)
mm (in) mm (in)
Front wheel Rear wheel
2.0 i, 2.5 i 205/55R16 89V 16 ! 61/2JJ 220 (2.2, 32) 220 (2.2, 32)
2.5 i (OP) 215/45R17 87W 17 ! 7JJ 230 (2.3, 33) 220 (2.2, 32)
Sedan 2.5 i (KA model) 215/45R17 87W 17 ! 7JJ 230 (2.3, 33) 220 (2.2, 32)
3.0 R 215/45R17 87W 17 ! 7JJ 230 (2.3, 33) 220 (2.2, 32)
2.0 GT 215/45R17 87W 17 ! 7JJ 230 (2.3, 33) 220 (2.2, 32)
55 (2.17)
2.0 i, 2.5 i 205/55R16 89V 16 ! 61/2JJ 220 (2.2, 32) 220 (2.2, 32)
2.5 i (OP) 215/45R17 87W 17 ! 7JJ 230 (2.3, 33) 210 (2.1, 31)
100 (3.94)
2.5 i (KA model) 215/45R17 87W 17 ! 7JJ 230 (2.3, 33) 210 (2.1, 31)
Wagon 3.0 R 215/45R17 87W 17 ! 7JJ 230 (2.3, 33) 210 (2.1, 31)
2.0 GT 215/45R17 87W 17 ! 7JJ 230 (2.3, 33) 210 (2.1, 31)
OUTBACK 2.5 i 215/60R16 95V 16 ! 61/2JJ 210 (2.1, 31) 200 (2.0, 29)
48 (1.89)
OUTBACK 3.0 R 215/55R17 94V 17 ! 7JJ 210 (2.1, 31) 200 (2.0, 29)
“T-type” 2.0 GT, 3.0 R T135/70D17 102M 17 ! 4T 40 (1.57)
420 (4.2, 60)
Tire 2.0 i, 2.5 i T135/80D16 101M 16 ! 4T 50 (1.97)
NOTE:
• Except for KA, KS model, “T-type” tire for temporary use is supplied as a spare tire.
• For KA, KS model, a spare tire of standard tire size is supplied.
WT-2
General Description
2. SERVICE DATA Balance weight part number

(Adhesive type weight for alumi- Weight
Part Axial runout Radial runout num wheel)
Steel wheel 1.5 mm (0.059 in) 28101AG000 5 g (0.18 oz)
Aluminum wheel 1.0 mm (0.039 in) 28101AG010 7.5 g (0.26 oz)
28101AG020 10 g (0.35 oz)
3. ADJUSTING PARTS
28101AG030 12.5 g (0.44 oz)
Wheel balancing Standard Service limit 28101AG040 15 g (0.53 oz)
Dynamic unbalance 10 g (0.35 oz) or less 28101AG050 17.5 g (0.62 oz)
28101AG060 20 g (0.71 oz)
Balance weight part number 28101AG070 22.5 g (0.79 oz)
(Knock-on type weight for steel Weight 28101AG080 25 g (0.88 oz)
wheel) 28101AG090 27.5 g (0.97 oz)
28101TC000 5 g (0.18 oz) 28101AG100 30 g (1.06 oz)
28101SA060 10 g (0.35 oz) 28101AG110 32.5 g (1.15 oz)
28101SA070 15 g (0.53 oz) 28101AG120 35 g (1.23 oz)
28101SA080 20 g (0.71 oz) 28101AG130 37.5 g (1.32 oz)
28101SA090 25 g (0.88 oz) 28101AG140 40 g (1.41 oz)
723141340 30 g (1.06 oz) 28101AG150 42.5 g (1.50 oz)
723141350 35 g (1.23 oz) 28101AG160 45 g (1.59 oz)
723141360 40 g (1.41 oz) 28101AG170 47.5 g (1.68 oz)
723141370 45 g (1.59 oz) 28101AG180 50 g (1.76 oz)
723241380 50 g (1.76 oz) 28101AG190 52.5 g (1.85 oz)
723241580 55 g (1.94 oz) 28101AG200 55 g (1.94 oz)
723241590 60 g (2.12 oz) 28101AG210 57.5 g (2.03 oz)
28101AG220 60 g (2.12 oz)
(Knock-on type weight for alumi- Weight 28101AG240 65 g (2.29 oz)
num wheel)
28101AG250 67.5 g (2.38 oz)
28101SA000 5 g (0.18 oz)
28101AG260 70 g (2.47 oz)
28101SA010 10 g (0.35 oz)
28101AG270 72.5 g (2.56 oz)
28101SA020 15 g (0.53 oz)
28101AG280 75 g (2.65 oz)
28101SA030 20 g (0.71 oz)
28101AG290 77.5 g (2.73 oz)
28101SA040 25 g (0.88 oz)
28101AG300 80 g (2.82 oz)
23141GA512 30 g (1.06 oz)
28101AG310 82.5 g (2.91 oz)
23141GA522 35 g (1.23 oz)
28101AG320 85 g (3.00 oz)
23141GA532 40 g (1.41 oz)
28101AG330 87.5 g (3.09 oz)
23141GA542 45 g (1.59 oz)
28101AG340 90 g (3.17 oz)
23141GA552 50 g (1.76 oz)
28101AG350 92.5 g (3.26 oz)
— 55 g (1.94 oz)
28101AG360 95 g (3.35 oz)
23141GA572 60 g (2.12 oz)
28101AG370 97.5 g (3.44 oz)
28101AG380 100 g (3.53 oz)
B: PREPARATION TOOL
1. GENERAL TOOL
TOOL NAME REMARKS
Used for measuring tire inflation pres-
Air pressure gauge
sure.
Dial gauge with
Used for measuring wheel runout.
magnet stand
Wheel balancer Used for adjusting wheel balance.
WT-3
Tire
2. Tire
A: INSPECTION
1) Take stones, glass, nails etc. out of the tread
groove.
2) Replace the tire if as follows.
CAUTION:
When replacing a tire, make sure to use only
the same size, construction and load range as
originally installed.
(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.
WT-00002
(1) Tread wear indicator

(2) Tire tread
3) When a crack on tire valve is found, replace the

tire valve.
1. TIRE ROTATION
Rotate tires periodically (5,000 km/3,100 miles) as
shown in the figure, in order to prevent them from
uneven wear and to prolong their life.
WT-00003
WT-4
Steel Wheel
3. Steel Wheel 3) Slowly rotate the wheel to check rim “runout” us-
ing a dial gauge.
A: REMOVAL
1) Apply the parking brake, and position the select
lever to “P” or “LOW”.
2) Set the shop jacks or a lift to specified point, and
support the vehicle with its wheels slightly contact-
ing 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.
WT-00004
NOTE:
• When removing the wheels, prevent hub bolts Rim runout:
from damage.
Axial runout limit Radial runout limit
• Place the wheels with their outer sides facing up-
1.5 mm (0.059 in)
ward to prevent wheels from damage.
B: INSTALLATION 4) If the rim runout exceeds specifications, remove
1) Remove dirt from the mating surface of wheel the tire from wheel and check runout while attach-
and brake rotor. ing the dial gauge to positions shown in the figure.
2) Attach the wheel to the hub by aligning the wheel
bolt hole with the hub bolt.
3) Temporarily attach the wheel nuts to the hub
bolts. (In the case of aluminum wheel, use SUBA-
RU genuine wheel nut for aluminum wheel.) (1)
4) Manually tighten the nuts making sure the wheel (1)
hub hole is aligned correctly to the guide portion of (1)

hub.
5) Tighten the wheel nuts in a diagonal selection to
the specified torque. Use a wheel nut wrench.
WT-00005
Wheel nut tightening torque:
90 N"m (9.1 kgf-m, 65.7 ft-lb) (1) Approx. 7 mm (0.28 in)
CAUTION: 5) If the measured runout still exceeds specifica-

• Tighten the wheel nuts in two or three steps tions, replace the wheel.
by gradually increasing the torque and working
diagonally, until they reach the specified
torque.
• Do not depress the wrench with foot. Always
use both hands when tightening.
• Make sure the bolt, nut and the nut seating
surface of the wheel are free from oil.
6) If a wheel is removed for replacement or for re-
pair of a puncture, retighten the wheel nuts to the
specified torque after running 1,000 km (600
miles).
C: INSPECTION
1) Deformation or damage on the rim may cause
air leakage. Check the rim flange for deformation,
crack or damage, and repair or replace as neces-
sary.
2) Jack-up the vehicle until wheels clear the floor.
WT-5
Aluminum Wheel
4. Aluminum Wheel
A: REMOVAL
Refer to “Steel Wheel” for removal procedure of
aluminum wheels. <Ref. to WT-5, REMOVAL,
Steel Wheel.>
B: INSTALLATION
Refer to “Steel Wheel” for installation procedure of
aluminum wheels. <Ref. 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:
Axial runout limit Radial runout limit
1.0 mm (0.039 in)
D: CAUTION
Aluminum wheels are easily scratched. To main-
tain their appearance and safety, do the followings:
1) Do not damage the aluminum wheels during re-
moval, installation, wheel balancing, etc. After re-
moving the aluminum wheels, place them on a
rubber mat, etc.
2) While driving the vehicle, 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 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 au-
tomatic car washer.
WT-6
Wheel Balancing
5. Wheel Balancing Balance weight part number

(Adhesive type weight for alumi- Weight
A: ADJUSTMENT num wheel)
NOTE: 28101AG000 5 g (0.18 oz)
Change the setting of wheel balancer to adhesive 28101AG010 7.5 g (0.26 oz)
type weight as adhesive type weight is adopted for 28101AG020 10 g (0.35 oz)
outside balance weight of 17-inch wheel. 28101AG030 12.5 g (0.44 oz)
1) Remove the balance weights. 28101AG040 15 g (0.53 oz)
CAUTION: 28101AG050 17.5 g (0.62 oz)
• Be careful not to damage the wheel. 28101AG060 20 g (0.71 oz)
• Completely remove the two-sided tape of the 28101AG070 22.5 g (0.79 oz)
adhesive type weight from the wheel. 28101AG080 25 g (0.88 oz)
2) Using the wheel balancer, measure the wheel 28101AG090 27.5 g (0.97 oz)
balance. 28101AG100 30 g (1.06 oz)
3) Select a weight close to the value measured by 28101AG110 32.5 g (1.15 oz)
wheel balancer. 28101AG120 35 g (1.23 oz)
CAUTION: 28101AG130 37.5 g (1.32 oz)
Use SUBARU genuine balance weight. 28101AG140 40 g (1.41 oz)
28101AG150 42.5 g (1.50 oz)
Balance weight part number
28101AG160 45 g (1.59 oz)
(Knock-on type weight for steel Weight
wheel) 28101AG170 47.5 g (1.68 oz)
28101TC000 5 g (0.18 oz) 28101AG180 50 g (1.76 oz)
28101SA060 10 g (0.35 oz) 28101AG190 52.5 g (1.85 oz)
28101SA070 15 g (0.53 oz) 28101AG200 55 g (1.94 oz)
28101SA080 20 g (0.71 oz) 28101AG210 57.5 g (2.03 oz)
28101SA090 25 g (0.88 oz) 28101AG220 60 g (2.12 oz)
723141340 30 g (1.06 oz) 28101AG230 62.5 g (2.20 oz)
723141350 35 g (1.23 oz) 28101AG240 65 g (2.29 oz)
723141360 40 g (1.41 oz) 28101AG250 67.5 g (2.38 oz)
723141370 45 g (1.59 oz) 28101AG260 70 g (2.47 oz)
723241380 50 g (1.76 oz) 28101AG270 72.5 g (2.56 oz)
723241580 55 g (1.94 oz) 28101AG280 75 g (2.65 oz)
723241590 60 g (2.12 oz) 28101AG290 77.5 g (2.73 oz)
28101AG300 80 g (2.82 oz)
(Knock-on type weight for alumi- Weight 28101AG320 85 g (3.00 oz)
num wheel) 28101AG330 87.5 g (3.09 oz)
28101SA000 5 g (0.18 oz) 28101AG340 90 g (3.17 oz)
28101SA010 10 g (0.35 oz) 28101AG350 92.5 g (3.26 oz)
28101SA020 15 g (0.53 oz) 28101AG360 95 g (3.35 oz)
28101SA030 20 g (0.71 oz) 28101AG370 97.5 g (3.44 oz)
28101SA040 25 g (0.88 oz) 28101AG380 100 g (3.53 oz)
23141GA512 30 g (1.06 oz)
23141GA522 35 g (1.23 oz) 4) Install the selected weight to the point designat-
23141GA532 40 g (1.41 oz)
ed by wheel balancer.
23141GA542 45 g (1.59 oz) CAUTION:
23141GA552 50 g (1.76 oz) • Remove grease from adhesive type weight
— 55 g (1.94 oz) applying surface of wheel.
23141GA572 60 g (2.12 oz)
• Press the adhesive type weight by 25 N (2.5
kgf, 5.6 lb) or more per 5 g (0.18 oz) for 2 sec-
onds at least to attain close contact.
• Make all amounts of the applied adhesive
type weight to be 100 g (3.53 oz) or less.
WT-7
Wheel Balancing
5) Using the wheel balancer, measure the wheel

balance again. Check that wheel balance is cor-
rectly adjusted.
NOTE:
• 55 g (1.94 oz) knock-on type weight used with
aluminum wheel is not available.
• Balance weights of knock-on type weight for alu-
minum wheel are available for use with any of 15-
to 17-inch aluminum wheels.
A A
WT-00006
(1) Knock-on type weight for aluminum wheel

(2) Knock-on type weight for steel wheel
Service limit: A
Knock-on type weight for steel wheel:
5 — 25 g (0.18 — 0.88 oz) 2.0 mm (0.08 in)
30 g (1.06 oz) or more 1.8 mm (0.07 in)
Knock-on type weight for aluminum wheel:
5 — 25 g (0.18 — 0.88 oz) 5.0 mm (0.20 in)
30 g (1.06 oz) or more 4.5 mm (0.177 in)
WT-8
“T-type” Tire
6. “T-type” Tire
A: NOTE
“T-type” tire for temporary use is prepared as a
spare tire. (Except for KA, KS model)
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 100 km/h
(62 MPH).
• Drive as slowly as possible and avoid pass-
ing over bumps.
B: REPLACEMENT
Refer to “Steel Wheel” for installation procedure of
“T-type” tire. <Ref. to WT-5, REMOVAL, Steel
Wheel.>
CAUTION:
Replace with a conventional tire as soon as
possible since the “T-type” tire is only for tem-
porary use.
C: INSPECTION
1) Check the tire air pressure.
Specifications:
420 kPa (4.2 kg/cm2, 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 if defective.
WT-9

A: INSPECTION
Symptom Possible cause Corrective action
Wheel wobble. Improperly inflated tire. Adjust the tire pressure.
Uneven wear Check the tire referring to Abnormal
tire wear in this table, carry out the
procedure and replace the tire.
Front wheel alignment Check the front wheel alignments.
<Ref. to FS-8, INSPECTION, Wheel
Alignment.>
Rear wheel alignment Check the rear wheel alignments.
<Ref. to RS-8, INSPECTION, Wheel
Alignment.>
Front strut Check the front strut. <Ref. to FS-
24, INSPECTION, Front Strut.>
Rear shock absorber Check the rear shock absorber.
<Ref. to RS-16, INSPECTION, Rear
Shock Absorber.>
Front axle Check the front axle. <Ref. to DS-
15, INSPECTION, Front Axle.>
Front hub unit bearing Check the front hub unit bearing.
<Ref. to DS-18, INSPECTION, Front
Hub Unit Bearing.>
Rear hub unit bearing Check the rear hub unit bearing.
<Ref. to DS-21, INSPECTION, Rear
Hub Unit Bearing.>
Vehicle is abnormally out of Improperly inflated tire. Adjust the tire pressure.
balance. Uneven wear Check the tire referring to Abnormal
Front stabilizer Check the front stabilizer. <Ref. to
FS-16, INSPECTION, Front Stabi-
lizer.>
Alignment.>
Alignment.>
Abnormal wheel vibration Improperly inflated tire. Adjust the tire pressure.
Uneven wear Check the tire referring to Abnormal
Improper wheel balancing Check the wheel balance. <Ref. to
WT-7, ADJUSTMENT, Wheel Bal-
ancing.>
Front axle Check the front axle. <Ref. to DS-
15, INSPECTION, Front Axle.>
Front hub unit bearing Check the front hub unit bearing.
<Ref. to DS-18, INSPECTION, Front
Hub Unit Bearing.>
Rear hub unit bearing Check the rear hub unit bearing.
<Ref. to DS-21, INSPECTION, Rear
Hub Unit Bearing.>
WT-10

Abnormal tire wear Improperly inflated tire. Adjust the tire pressure.
Improper wheel balancing Check the wheel balance. <Ref. to
WT-7, ADJUSTMENT, Wheel Bal-
ancing.>
Alignment.>
Alignment.>
WT-11
WT-12
CHASSIS SECTION
FRONT SUSPENSION FS
REAR SUSPENSION RS
DIFFERENTIALS DI
TRANSFER CASE TC
(DIAGNOSTICS)
BRAKE BR
PARKING BRAKE PB

(POWER STEERING)

approval.

DIFFERENTIALS
DI
Page
2. Differential Gear Oil...................................................................................26
3. Front Differential Assembly .......................................................................28
4. Rear Differential (T-type)...........................................................................29
5. Rear Differential (VA-type) ........................................................................46
6. Rear Differential Front Oil Seal .................................................................72
7. Rear Differential Side Oil Seal ..................................................................74
8. Rear Differential Front Member.................................................................75
General Description
DIFFERENTIALS
A: SPECIFICATION
1. REAR DIFFERENTIAL
When replacing a rear differential assembly, select the correct one according to the following table.
NOTE:
• Using the different rear differential assembly causes the drive line and tires to “drag” or emit noise.
• For option code, refer to “ID” section. <Ref. to ID-2, IDENTIFICATION, Identification.>
Sedan, Wagon
2.0 L Non-turbo 2.5 L 3.0 L 2.0 L Turbo
Model MT
AT MT AT EC, EK, AT
KA, KS★1
K4★1
Rear differential type VA1-type T-type VA2-type
Classification XJ T2 VB XT XU
LSD type — Viscous coupling
Type of gear Hypoid gear
Gear ratio (Number of gear 3.700 3.083 3.272
4.111 (37/9)
teeth) (37/10) (37/12) (36/11)
Oil capacity 0.82 (0.8 US qt, 0.7 Imp qt)
Rear differential gear oil GL-5
OUTBACK
2.5 L 3.0 L
Model MT
AT EC, EK, AT
KS, KA★1
K4★1
Rear differential type T-type VA2-type
Classification CF EZ JE XU
LSD type Viscous coupling
Type of gear Hypoid gear
Gear ratio (Number of gear 4.444 3.900 4.111 3.272
teeth) (40/9) (39/10) (37/9) (36/11)
Oil capacity 0.82 (0.8 US qt, 0.7 Imp qt)
Rear differential gear oil GL-5
★1:
Option code
DI-2
General Description
DIFFERENTIALS
2. CLASSIFICATION • VA2-type
Identification label positions are shown in the fol-
lowing figures. For details concerning identification,
refer to “ID” section.
(1)
• T-type
(1)
DI-00397
(1) Identification
3. REAR DIFFERENTIAL GEAR OIL

ID-00056
Recommended gear oil:
(1) Identification GL-5 (75W-90)
• VA1-type NOTE:
Each oil manufacturer has its base oil and addi-
tives. Thus, do not mix two or more brands.
(1)
(1) (2)
(3)
GL-5
(4)
( C) -30 -26 -15 -5 0 15 25 30
( F) -22 -15 5 23 32 59 77 86
90
85W
80W
DI-00396
75W -90
(1) Identification MT-00001
(1) Item
(2) Rear differential gear oil
(3) API classification
(4) SAE viscosity No. and applicable temperature
4. SERVICE DATA
Drive pinion bearing preload T-type 18.1 — 38.8 (1.8 — 4.0, 4.1 — 8.7)
N (kgf, lb)
(at companion flange bolt hole) VA-type 12.7 — 32.4 (1.3 — 3.3, 2.9 — 7.3)
T-type 0.10 — 0.20 (0.0039 — 0.0079)
Side gear backlash mm (in)
VA1-type only 0.05 — 0.15 (0.0020 — 0.0059)
Side bearing standard width mm (in) 20.00 (0.7874)
Hypoid driven gear to drive pinion T-type 0.10 — 0.20 (0.0039 — 0.0079)
mm (in)
backlash VA-type 0.10 — 0.15 (0.0039 — 0.0059)
Hypoid driven gear runout on its
mm (in) T-type only 0.05 (0.0020)
back surface
DI-3
General Description
DIFFERENTIALS
5. ADJUSTING PART
• T-type
Drive pinion bearing preload (at companion

18.1 — 38.8 (1.8 — 4.0, 4.1 — 8.7)
flange bolt hole) N (kgf, lb)
Part No. Length mm (in)
383695201 56.2 (2.213)
383695202 56.4 (2.220)
Preload adjusting collar 383695203 56.6 (2.228)
383695204 56.8 (2.236)
383695205 57.0 (2.244)
383695206 57.2 (2.252)
383705200 2.59 (0.1020)
383715200 2.57 (0.1012)
383725200 2.55 (0.1004)
383735200 2.53 (0.0996)
383745200 2.51 (0.0988)
383755200 2.49 (0.0980)
383765200 2.47 (0.0972)
Preload adjusting washer
383775200 2.45 (0.0965)
383785200 2.43 (0.0957)
383795200 2.41 (0.0949)
383805200 2.39 (0.0941)
383815200 2.37 (0.0933)
383825200 2.35 (0.0925)
383835200 2.33 (0.0917)
383845200 2.31 (0.0909)
Part No. Thickness mm (in)
383495200 3.09 (0.1217)
383505200 3.12 (0.1228)
383515200 3.15 (0.1240)
383525200 3.18 (0.1252)
383535200 3.21 (0.1264)
383545200 3.24 (0.1276)
383555200 3.27 (0.1287)
383565200 3.30 (0.1299)
383575200 3.33 (0.1311)
Pinion height adjusting washer 383585200 3.36 (0.1323)
383595200 3.39 (0.1335)
383605200 3.42 (0.1346)
383615200 3.45 (0.1358)
383625200 3.48 (0.1370)
383635200 3.51 (0.1382)
383645200 3.54 (0.1394)
383655200 3.57 (0.1406)
383665200 3.60 (0.1417)
383675200 3.63 (0.1429)
383685200 3.66 (0.1441)
Side gear backlash mm (in) 0.1 — 0.2 (0.0039 — 0.0079)
DI-4
General Description
DIFFERENTIALS

Side gear thrust washer 383445201 0.75 — 0.80 (0.0295 — 0.0315)
(Model without LSD) 383445202 0.80 — 0.85 (0.0315 — 0.0335)
383445203 0.85 — 0.90 (0.0335 — 0.0354)
Side bearing standard width mm (in) — 20.00 (0.7874)
383475201 0.20 (0.0079)
383475202 0.25 (0.0098)
Side bearing retainer shim
383475203 0.30 (0.0118)
383475204 0.40 (0.0157)
383475205 0.50 (0.0197)
Hypoid driven gear to drive pinion backlash 0.10 — 0.20 (0.0039 — 0.0079)
Hypoid driven gear runout on its back sur- Limit mm (in)
0.05 (0.0020)
face
DI-5
General Description
DIFFERENTIALS
• VA1-type

12.7 — 32.4 (1.3 — 3.3, 2.9 — 7.3)
32288AA040 52.3 (2.059)
32288AA050 52.5 (2.067)
31454AA100 52.6 (2.071)
32288AA060 52.7 (2.075)
Preload adjusting collar
31454AA110 52.8 (2.079)
32288AA070 52.9 (2.083)
31454AA120 53.0 (2.087)
32288AA080 53.1 (2.091)
32288AA090 53.3 (2.098)
38336AA000 1.500 (0.0591)
38336AA120 1.513 (0.0596)
38336AA010 1.525 (0.0600)
38336AA130 1.538 (0.0606)
38336AA020 1.550 (0.0610)
38336AA140 1.563 (0.0615)
38336AA030 1.575 (0.0620)
38336AA150 1.588 (0.0625)
38336AA040 1.600 (0.0630)
38336AA160 1.613 (0.0635)
38336AA050 1.625 (0.0640)
38336AA170 1.638 (0.0645)
38336AA060 1.650 (0.0650)
38336AA180 1.663 (0.0655)
38336AA070 1.675 (0.0659)
38336AA190 1.688 (0.0665)
38336AA080 1.700 (0.0669)
38336AA200 1.713 (0.0674)
38336AA090 1.725 (0.0679)
38336AA210 1.738 (0.0684)
38336AA100 1.750 (0.0689)
38336AA220 1.763 (0.0694)
38336AA110 1.775 (0.0699)
32295AA200 0.150 (0.0059)
32295AA210 0.175 (0.0069)
Pinion height adjusting washer 32295AA220 0.200 (0.0079)
32295AA230 0.225 (0.0089)
32295AA240 0.250 (0.0098)
32295AA250 0.275 (0.0108)
Side gear backlash mm (in) 0.05 — 0.15 (0.0020 — 0.0059)
803135011 0.925 — 0.950 (0.0364 — 0.0374)
803135012 0.950 — 0.975 (0.0374 — 0.0384)
Side gear thrust washer 803135013 0.975 — 1.000 (0.0384 — 0.0394)
803135014 1.000 — 1.025 (0.0394 — 0.0404)
803135015 1.025 — 1.050 (0.0404 — 0.0413)
Hypoid driven gear to drive pinion backlash Limit mm (in) 0.10 — 0.15 (0.0039 — 0.0059)
DI-6
General Description
DIFFERENTIALS
• VA2-type

12.7 — 32.4 (1.3 — 3.9, 2.9 — 7.3)
31454AA250 51.05 (2.010)
31454AA260 51.25 (2.018)
31454AA270 51.35 (2.022)
31454AA280 51.45 (2.026)
Preload adjusting collar
31454AA290 51.55 (2.030)
31454AA300 51.65 (2.033)
31454AA310 51.75 (2.037)
31454AA320 51.85 (2.041)
31454AA330 52.05 (2.049)
38336AA430 1.500 (0.0591)
38336AA440 1.513 (0.0596)
38336AA450 1.525 (0.0600)
38336AA460 1.538 (0.0606)
38336AA470 1.550 (0.0610)
38336AA480 1.563 (0.0615)
38336AA490 1.575 (0.0620)
38336AA500 1.588 (0.0625)
38336AA510 1.600 (0.0630)
38336AA520 1.613 (0.0635)
38336AA530 1.625 (0.0640)
38336AA540 1.638 (0.0645)
38336AA550 1.650 (0.0650)
38336AA560 1.663 (0.0655)
38336AA570 1.675 (0.0659)
38336AA580 1.688 (0.0665)
38336AA590 1.700 (0.0669)
38336AA600 1.713 (0.0674)
38336AA610 1.725 (0.0679)
38336AA620 1.738 (0.0684)
38336AA630 1.750 (0.0689)
38336AA640 1.763 (0.0694)
38336AA650 1.775 (0.0699)
32295AA350 0.150 (0.0059)
32295AA360 0.175 (0.0069)
Pinion height adjusting washer 32295AA370 0.200 (0.0079)
32295AA380 0.225 (0.0089)
32295AA390 0.250 (0.0098)
32295AA400 0.275 (0.0108)
Hypoid driven gear to drive pinion backlash Limit mm (in) 0.10 — 0.15 (0.0039 — 0.0059)
DI-7
General Description
DIFFERENTIALS
B: COMPONENT
1. REAR DIFFERENTIAL WITHOUT LSD (T-TYPE)
(1) (18)
(19) (21)
(2) (20)
(3)
(4)
(5) (19)
(20) (18)
(23) ( 1 ) (21)
(22)
(25)
T4 (26)
(27) T3
T1
(16) (28)
T3
(15)
(14) (24)
(23) T2
(13) (30)
(17)
(31)
(29)
(6)
(7)
T1
(13)
(14)
(15)
(8) (16)
(9) (17)
(10)
(11)
(12) T5
DI-00260
(1) Hypoid driven gear and drive pin- (13) Side bearing (26) Stud bolt
ion set (14) O-ring (27) Oil filler plug
(2) Pinion height adjusting washer (15) Side bearing retainer shim (28) Oil drain plug
(3) Rear bearing (16) Side bearing retainer (29) Rear cover
(4) Bearing preload adjusting collar (17) Side oil seal (30) Differential case
(5) Bearing preload adjusting washer (18) Side gear thrust washer (31) Gasket
(6) Differential carrier (19) Side gear
(7) Front bearing (20) Pinion mate gear Tightening torque: N!m (kgf-m, ft-lb)
(8) Collar (21) Pinion mate gear washer T1: 10.3 (1.05, 7.6)
(9) Pilot bearing (22) Pinion shaft lock pin T2: 29 (3.0, 21.7)
(10) Front oil seal (23) Snap ring T3: 49 (5.0, 36.2)
(11) Companion flange (24) Pinion mate shaft T4: 105 (10.7, 77.4)
(12) Self-locking nut (25) Air breather cap T5: 181 (18.5, 134)
DI-8
General Description
DIFFERENTIALS
2. REAR DIFFERENTIAL WITH LSD (T-TYPE)
(1)
(2)
(3)
(4)
(5)
(1)
(21) (22)
(23) T3
T4
T1 (20)
(15)
(19) (24)
(13) T3
(17) (18) T2
(16) (6)
(14)
(14)
(15)
(7)
(13)
T1
(16)
(8) (17)
(9)
(10)
T5
(12) (11)
DI-00002
(1) Hypoid driven gear and drive pin- (11) Companion flange (22) Stud bolt
ion set (12) Self-locking nut (23) Oil filler plug
(2) Pinion height adjusting washer (13) Side bearing (24) Oil drain plug
(3) Rear bearing (14) O-ring
(4) Bearing preload adjusting collar (15) Side bearing retainer shim Tightening torque: N!m (kgf-m, ft-lb)
(5) Bearing preload adjusting washer (16) Side bearing retainer T1: 10.3 (1.05, 7.6)
(6) Differential carrier (17) Side oil seal T2: 29 (3.0, 21.7)
(7) Front bearing (18) Gasket T3: 49 (5.0, 36.2)
(8) Collar (19) Differential case ASSY T4: 105 (10.7, 77.4)
(9) Pilot bearing (20) Rear cover T5: 181 (18.5, 134)
(10) Front oil seal (21) Air breather cap
DI-9
General Description
DIFFERENTIALS
3. REAR DIFFERENTIAL (VA1-TYPE)
(18) (19)
(20)
(1)
(19)
(18)
(21)
(2)
(3)
(4)
(5) T3
(17)
(16)
(23) (22)
(15)
(14)
(30) (25)
T2
(24)
T1 (27)
(26)
(13)
(28)
(6)
(26)
(7)
(29) T1
(13)
(14)
T1
(15)
(8) (16)
(9) (17)
(10)
(11)
(12) T4
DI-00296
(1) Hypoid driven gear and drive pin- (13) Lock plate (26) Gasket
ion set (14) Side bearing (27) Oil filler plug
(2) Pinion height adjusting washer (15) O-ring (28) Oil drain plug
(3) Rear bearing (16) Axle shaft holder (29) Rear cover
(4) Bearing preload adjusting collar (17) Side oil seal (30) Gasket
(5) Bearing preload adjusting washer (18) Side gear thrust washer
(6) Differential carrier (19) Side gear Tightening torque: N!m (kgf-m, ft-lb)
(7) Front bearing (20) Pinion mate gear T1: 25 (2.5, 18.1)
(8) Collar (21) Pinion shaft lock pin T2: 34 (3.5, 25.3)
(9) Pilot bearing (22) Differential case T3: 62 (6.3, 45.6)
(10) Front oil seal (23) Pinion mate shaft T4: 191 (19.5, 141)
(11) Companion flange (24) Air breather cap
(12) Self-locking nut (25) Stud bolt
DI-10
General Description
DIFFERENTIALS
4. REAR DIFFERENTIAL (VA2-TYPE)
(1)
(2)
(3)
(4)
(5) T4
(17)
(16)
(15) (18)
(14)
(20)
(25)
T1 (19)
(23)
(13)
T2
(22)
(21)
(21)
T3
(7)
(6) (24)
(13)
(14)
T1
(15)
(8) (16)
(9) (17)
(10)
T5
(12) (11)
DI-00349
(1) Hypoid driven gear and drive pin- (11) Companion flange (22) Oil filler plug
ion set (12) Self-locking nut (23) Oil drain plug
(2) Pinion height adjusting washer (13) Lock plate (24) Rear cover
(3) Rear bearing (14) Side bearing (25) Gasket
(4) Bearing preload adjusting collar (15) O-ring
(5) Bearing preload adjusting washer (16) Axle shaft holder Tightening torque: N!m (kgf-m, ft-lb)
(6) Differential carrier (17) Side oil seal T1: 25 (2.5, 18.1)
(7) Front bearing (18) Differential case ASSY T2: 29 (3.0, 21.4)
(8) Collar (19) Air breather cap T3: 34 (3.5, 25.3)
(9) Pilot bearing (20) Stud bolt T4: 62 (6.3, 45.6)
(10) Front oil seal (21) Gasket T5: 191 (19.5, 141)
DI-11
General Description
DIFFERENTIALS
5. REAR DIFFERENTIAL MOUNTING SYSTEM
(4)
T2
(3) (5)
(2)
(5)
T3
(1)
(5)
T1
DI-00350
(1) Rear differential front member (4) Sub frame Tightening torque: N!m (kgf-m, ft-lb)
(2) Rear differential member plate (5) Self-locking nut T1: 52 (5.3, 38)
(3) Rear differential ASSY T2: 70 (7.1, 51)
T3: 110 (11.2, 81)
DI-12
General Description
DIFFERENTIALS
C: CAUTION • Be sure to tighten fasteners including bolts and

• Wear work clothing, including a cap, protective nuts to the specified torque.
goggles and protective shoes during operation. • Place shop jacks or rigid racks at the specified
• Remove contamination including dirt and corro- points.
sion before removal, installation or disassembly. • Apply gear oil onto sliding or revolution surfaces
• Keep the disassembled parts in order and pro- before installation.
tect them from dust and dirt. • Before installing O-rings or snap rings, apply suf-
• Before removal, installation or disassembly, be ficient amount of gear oil to avoid damage and de-
sure to clarify the failure. Avoid unnecessary re- formation.
moval, installation, disassembly and replacement. • Before securing a part on a vice, place cushion-
• Be careful not to burn yourself, because each ing material such as wood blocks, aluminum plate,
part on the vehicle is hot after running. or shop cloth between the part and the vice.
• Use SUBARU genuine gear oil, grease etc. or • Avoid damaging the mating surface of the case.
the equivalent. Do not mix gear oil, grease etc. with
that of another grade or from other manufacturers.
D: PREPARATION TOOL
1. SPECIAL TOOL
398477701 HANDLE Used for installing front and rear bearing cone.
ST-398477701
398477702 DRIFT • Used for press-fitting the bearing cone of dif-
ferential carrier (front).
• For T-type
ST-398477702
398217700 ATTACHMENT SET Stand for rear differential carrier disassembly
and assembly.
ST-398217700
DI-13
General Description
DIFFERENTIALS

498447120 INSTALLER Used for installing front oil seal.
ST-498447120
498427200 FLANGE WRENCH Used for stopping rotation of companion flange
when removing and tightening self-locking nut.
ST-498427200
398467700 DRIFT • Used for removing pinion, pilot bearing and
front bearing cone.
• For T-type and VA1-type
ST-398467700
399780104 WEIGHT Used for installing front bearing cone and pilot
bearing companion flange.
ST-399780104
DI-14
General Description
DIFFERENTIALS

899580100 INSTALLER Used for press-fitting front bearing cone and pilot
bearing.
ST-899580100
899904100 STRAIGHT PIN Used for driving out differential pinion shaft lock
REMOVER pin.
ST-899904100
498247001 MAGNET BASE • Used for measuring backlash between side
gear and pinion, and hypoid gear.
• Used with DIAL GAUGE (498247100).
ST-498247001
498247100 DIAL GAUGE • Used for measuring backlash between side
gear and pinion, and hypoid gear.
• Used with MAGNET BASE (498247001).
ST-498247100
DI-15
General Description
DIFFERENTIALS

398507704 BLOCK • Used for adjusting pinion height and preload.
ST-398507704
398177700 INSTALLER • Used for installing rear bearing cone.
ST-398177700
398457700 ATTACHMENT • Used for removal of side bearing retainer.
• For T-type
ST-398457700
398477703 DRIFT 2 • Used for press-fitting bearing race (rear) of dif-
ferential carrier.
ST-398477703
DI-16
General Description
DIFFERENTIALS

398437700 DRIFT • Used for installing side oil seal.
ST-398437700
398507702 DUMMY SHAFT • Used for adjusting pinion height and preload.
• For T-type
ST-398507702
398507703 DUMMY COLLAR • Used for adjusting pinion height and preload.
• For T-type
ST-398507703
398517700 REPLACER • Used for removing rear bearing cone.
ST-398517700
DI-17
General Description
DIFFERENTIALS

398487700 DRIFT • Used for press-fitting side bearing cone.
ST-398487700
398507701 DIFFERENTIAL • Used for adjusting pinion height.
CARRIER GAUGE • For T-type
ST-398507701
398527700 PULLER ASSY • Used for removing front oil seal.
• Used for removing side bearing cup. (T-type)
ST-398527700
398227700 DRIFT • Used for installing side bearing.
ST-398227700
DI-18
General Description
DIFFERENTIALS

28099PA090 OIL SEAL PROTEC- • Used for installing the rear drive shaft to rear
TOR differential.
• For oil seal protection
ST28099PA090
398237700 DRIFT • Used for installing side bearing.
• For T-type
ST-398237700
28099PA100 DRIVE SHAFT • Used for removing rear drive shaft from rear
REMOVER differential.
• For T-type
ST28099PA100
399703600 PULLER ASSY Used for removing companion flange.
ST-399703600
DI-19
General Description
DIFFERENTIALS

899874100 INSTALLER Used for installing companion flange.
ST-899874100
498077000 REMOVER • Used for removing side bearing cone from dif-
ferential.
• For VA2-type
ST-498077000
899864100 REMOVER Used for removing differential side bearing.
ST-899864100
499277200 INSTALLER • Used for installing front bearing cone.
• For VA2-type
ST-499277200
DI-20
General Description
DIFFERENTIALS

18758AA000 PULLER • Used for removing side bearing cup.
• For VA2-type
ST18758AA000
18759AA000 PULLER ASSY • Used for removing differential from side bear-
(Newly adopted tool) ing cone.
• For T-type
ST18759AA000
18678AA000 DUMMY SHAFT • Used for adjusting pinion height and preload.
(Newly adopted tool) • For VA2-type
ST18678AA000
18831AA010 DIFFERENTIAL • Used for adjusting pinion height.
(Newly adopted tool) CARRIER GAUGE • For VA2-type
ST18831AA010
DI-21
General Description
DIFFERENTIALS

18630AA010 WRENCH ASSY • Used for removing and installing side oil seal
(Newly adopted tool) holder.
• For VA2-type
NOTE:
Also available for VA1-type.
ST18630AA010
498175500 INSTALLER • Used for installing rear bearing cone.
• For VA1-type
ST-498175500
499785500 WRENCH ASSY • Used for removing and installing side oil seal
holder.
• For VA1-type
ST-499785500
498447100 INSTALLER • Used for installing oil seal.
• For VA1-type
ST-498447100
DI-22
General Description
DIFFERENTIALS

399520105 SEAT • Used for removing side bearing cone.
• Used with PULLER SET (899524100).
• For VA-type
ST-399520105
498485400 DRIFT • Used for installing side bearing cone.
• For VA1-type
ST-498485400
498505501 DIFFERENTIAL • Used for adjusting pinion height.
CARRIER GAUGE • For VA1-type
ST-498505501
498447110 DRIFT • Used for press-fitting the bearing race (front)
of differential carrier.
• For VA1-type
ST-498447110
DI-23
General Description
DIFFERENTIALS

498447150 DUMMY SHAFT • Used for adjusting pinion height and preload.
• For VA1-type
ST-498447150
498515500 REPLACER • Used for removing rear bearing cone.
• For VA1-type
ST-498515500
32285AA000 DUMMY COLLAR • Used for adjusting pinion height and preload.
• For VA1-type
ST32285AA000
499705404 SEAT • Used for removing side bearing race.
• Used with PULLER ASSY (499705401).
• For VA1-type
ST-499705404
DI-24
General Description
DIFFERENTIALS

499705401 PULLER ASSY • Used for removing side bearing race.
• Used with SEAT (499705404).
• For VA-type
ST-499705401
2. GENERAL PURPOSE TOOL

TOOL NAME REMARKS
Transmission jack Used for assembly/disassembly of rear differential.
Puller Used for removal of side bearing retainer.
Thickness gauge Used for measuring clearance.
Hexagon wrench Used for installing and removing filler and drain plug.
Tire lever Used for removal of rear drive shaft. (VA-type)
DI-25
Differential Gear Oil
DIFFERENTIALS
2. Differential Gear Oil • Except for VA2-type
A: INSPECTION
1) Remove the filler plug, and then check the gear (A)
oil. If it is contaminated or deteriorated, replace the (B)
gear oil. <Ref. to DI-26, REPLACEMENT, Differen-

tial Gear Oil.>
2) Check that the gear oil level is up to the bottom
of filler plug hole. If the level is low, refill up to the
bottom of filler plug hole.
• Except for VA2-type
DI-00356
(A)
(A) Filler plug
(B) Drain plug
• VA2-type
(A)
(B)
DI-00354
(A) Filler plug

(B) Drain plug
(B)
• VA2-type
DI-00357
(A) Filler plug

(B) Drain plug
3) Tighten the oil drain plug.

NOTE:
• Apply liquid gasket to the drain plug threads for
T-type.
(A)
(B)
Liquid gasket:
DI-00355
THREE BOND 1105 (Part No. 004403010) or
(A) Filler plug
equivalent
(B) Drain plug • Use a new aluminum gasket for VA1-type.
• Use a new metal gasket for VA2-type.
B: REPLACEMENT Tightening torque:
1) Jack-up the vehicle and support it with rigid T-type:
racks. 49 N!m (5.0 kgf-m, 36.2 ft-lb)
2) Remove the oil drain plug and filler plug, and VA1-type:
drain the gear oil. 34 N!m (3.5 kgf-m, 25.3 ft-lb)
CAUTION: VA2-type:
Be careful not to burn your hands, because 29 N!m (3.0 kgf-m, 21.4 ft-lb)
gear oil becomes extremely hot after running. 4) Fill the differential carrier with gear oil to the bot-
tom of filler plug.
NOTE:
• Carefully refill oil while watching the level. Exces-
sive or insufficient oil must be avoided.
DI-26
Differential Gear Oil
DIFFERENTIALS
Recommended gear oil:

<Ref. to DI-2, SPECIFICATION, General De-
scription.>
Oil capacity:
0.8 2 (0.8 US qt, 0.7 Imp qt)
• Except for VA2-type
(A)
(B)
DI-00391
(A) Filler plug

(B) Drain plug
• VA2-type
(A)
(B) DI-00355
(A) Filler plug

(B) Drain plug
5) Install the filler plug.

NOTE:
• Apply liquid gasket to the filler plug threads for T-
type.
Liquid gasket:
equivalent
• Use a new aluminum gasket for VA1-type.
• Use a new metal gasket for VA2-type.
Tightening torque:
T-type:
49 N!m (5.0 kgf-m, 36.2 ft-lb)
VA1-type:
34 N!m (3.5 kgf-m, 25.3 ft-lb)
VA2-type:
29 N!m (3.0 kgf-m, 21.4 ft-lb)
DI-27
Front Differential Assembly
DIFFERENTIALS
3. Front Differential Assembly

A: NOTE
1. AT MODEL
• 4AT
For front differential of 4AT model, refer to “4AT”
section. <Ref. to 4AT-113, Front Differential As-
sembly.>
• 5AT
For front differential of 5AT model, refer to “5AT”
section. <Ref. to 5AT-94, Front Differential.>
2. MT MODEL
For front differential of manual transmission, refer
to “5MT” section. <Ref. to 5MT-85, Front Differen-
tial Assembly.>
DI-28
Rear Differential (T-type)
DIFFERENTIALS
4. Rear Differential (T-type) ST 28099PA100 DRIVE SHAFT REMOVER
A: REMOVAL
1) Disconnect the ground cable from battery. ST
2) Move the select lever or gear shift lever to neu-
tral.
4) Release the parking brake.
5) Jack-up the vehicle and support it with rigid
racks.
6) Remove the rear wheels.
(A) DI-00270
• 2.0 L SOHC and DOHC non-turbo model
(A) Bolt
<Ref. to EX(H4SO 2.0)-11, Rear Exhaust Pipe.>
<Ref. to EX(H4SO 2.0)-13, Muffler.> 12) Remove the rear differential front member.
• 2.0 L DOHC turbo model
<Ref. to EX(H4DOTC)-11, Rear Exhaust Pipe.>
8) Remove the propeller shaft.
<Ref. to DS-10, REMOVAL, Propeller Shaft.>
9) Prepare the transmission jack and band.
DI-00358
13) Support the rear differential with transmission

jack.
DI-00268
10) Loosen the self-locking nuts which hold the

rear differential to rear crossmember.
DI-00273
14) Secure the rear differential using band.

15) Remove the self-locking nuts which hold the
rear differential to crossmember.
16) Remove the rear differential stud bolt from rear
DI-00269
crossmember bushing.
11) Remove the DOJ of rear drive shaft from rear
differential using ST.
DI-29
DIFFERENTIALS
NOTE: 20) Secure the rear drive shaft to lateral link using
When removing the stud bolt, carefully adjust the wire.
angle and location of transmission jack and jack
stand, if necessary.
DI-00277
21) Remove the rear differential member plate from

DI-00400 rear differential.
17) Lower the transmission jack stand after remov- (A)
ing the rear differential stud bolt from rear cross-
member. Rear drive shaft should not come into
contact with lateral link bolt.
DI-00359
(A) Rear differential member plate
B: INSTALLATION
DI-00392
1) Install the rear differential member plate to rear
18) Pull out the axle shaft from rear differential. differential.
NOTE: (A)
If it is difficult to remove the axle shaft from rear dif-
ferential, remove it using ST.
ST 28099PA100 DRIVE SHAFT REMOVER
DI-00359
2) Set the rear differential to transmission jack.

DI-00276
NOTE:
19) Lower the transmission jack. Secure the rear differential to transmission jack us-
ing band.
DI-30
DIFFERENTIALS
3) Install the ST to rear differential. 8) After inserting the rear differential stud bolt into
ST 28099PA090 OIL SEAL PROTECTOR rear crossmember bushing, lift up the transmission
jack and align the rear differential with its own posi-
tion.
ST
DI-00279
4) Insert the spline shaft until the spline portion

DI-00283
comes inside the side oil seal.
9) Tighten the rear crossmember self-locking nut
temporarily.
DI-00280
5) Remove ST from rear differential.

DI-00269
ST 28099PA090 OIL SEAL PROTECTOR
6) Push the rear differential to insert the axle shaft 10) Remove the band from rear differential. Lift up
into rear differential. the rear differential until the rear differential is sep-
arated from the transmission jack.
11) Install the rear differential front member.
Tightening torque:
T1: 52 N!m (5.3 kgf-m, 38 ft-lb)
T2: 110 N!m (11.2 kgf-m, 81 ft-lb)
T2
DI-00281
7) Adjust the transmission jack, if necessary, and

insert the rear differential stud bolt into rear cross-
member bushing properly.
T1
DI-00284
DI-00393
DI-31
DIFFERENTIALS
12) Tighten the self-locking nut. C: DISASSEMBLY

Tightening torque: To detect the real cause of trouble, inspect the fol-
70 N!m (7.1 kgf-m, 51 ft-lb) lowing items before disassembling.
• Tooth contact of hypoid driven gear and drive
pinion, and backlash
• Hypoid driven gear runout on its back surface
• Total preload of drive pinion
1) Set the ST on vise and install the differential as-
sembly to ST.
ST 398217700 ATTACHMENT
DI-00269
13) Lower the transmission jack.

14) Install the propeller shaft. <Ref. to DS-11, IN-
STALLATION, Propeller Shaft.>
15) Install the heat shield cover.
16) Install the rear exhaust pipe and muffler. ST
17) After installing the rear differential carrier to the DI-00061
vehicle, remove the filler plug, and refill the gear oil
to the bottom of plug hole. 2) Drain the gear oil by removing plug.
3) Remove the air breather cap.
Oil capacity:
NOTE:
0.8 2 (0.8 US qt, 0.7 Imp qt)
• Do not attempt to replace the air breather cap un-
less necessary.
(A)
• Replace the air breather cap with a new one
when removing it.
(A)
(B) DI-00285
(B)
(A) Filler plug

(B) Drain plug
DI-00062
18) Tighten the filler plug.
(A) Air breather cap
NOTE:
(B) Rear cover
Apply liquid gasket to the drain plug.
Liquid gasket:
equivalent
Tightening torque:
49.0 N!m (5.0 kgf-m, 36.2 ft-lb)
DI-32
DIFFERENTIALS
4) Remove the bolts, and then remove the rear 7) When replacing the side bearing, remove the
cover. bearing cup from side bearing retainer using ST.
NOTE: ST 398527700 PULLER ASSY
Remove it by tapping with plastic hammer.
(B)
ST
(A)
DI-00066
DI-00063 8) Extract the bearing cone with ST.

NOTE:
(A) Rear cover
• Do not attempt to disassemble the parts unless
(B) Differential carrier necessary.
5) Keep the side bearing retainers RH and LH sep- • Set the puller so that its claws catch the edge of
arately for easier reassembly. Remove the side the bearing cone.
bearing retainer attaching bolts, set the ST to differ- • Never mix up the bearing races RH and LH and
ential case, and extract the side bearing retainers cones.
RH and LH with a puller. ST 18759AA000 PULLER ASSY
NOTE:
Each shim, which is installed to adjusted the side
ST
bearing preload, should be kept together with its
mating retainer.
ST
DI-00316
9) Remove the hypoid driven gear by loosening hy-

poid driven gear bolts.
DI-00064
6) Pull out the differential case assembly from dif-

ferential carrier.
NOTE:
Be careful not to hit the teeth against the case.
DI-00068
10) Drive out the pinion shaft lock pin from hypoid
driven gear side (Model without LSD).
NOTE:
The lock pin is staked at the pin hole end on the dif-
ferential carrier. Do not drive it out forcibly before
removing the stake.
DI-00065
DI-33
DIFFERENTIALS
ST 899904100 STRAIGHT PIN REMOVER 13) Extract the companion flange with a puller.
ST
DI-00237 DI-00072
11) Draw out the pinion mate shaft and remove pin- 14) Press the end of drive pinion shaft and extract it
ion mate gears, side gears and thrust washers. together with rear bearing cone, pinion height ad-
(Model without LSD) just washer and washer.
NOTE: NOTE:
The gears should be marked or kept separated Hold the drive pinion so as not to drop it.
right and left, and front and rear as well as thrust ST 398467700 DRIFT
washers.
ST
DI-00073
DI-00238
15) Remove the rear bearing cone from drive pin-
(A) Side gear
ion by supporting the cone with ST.
(B) Pinion mate gear NOTE:
(C) Thrust washer Place the replacer so that its center-recessed side
(D) Differential case faces the pinion gear.
(E) Pinion mate shaft ST 398517700 REPLACER
12) Hold the companion flange with ST and remove

the self-locking nut.
ST 498427200 FLANGE WRENCH
ST
DI-00074
ST
DI-00071
DI-34
DIFFERENTIALS
16) Remove the front oil seal from differential carri- D: ASSEMBLY
er using ST.
ST 398527700 PULLER ASSY NOTE:
• Assemble in the reverse order of disassembly.
• Check and adjust each part during assembly.
(A)
• Keep the shims and washers in order, so that
they are not improperly installed.
• Thoroughly clean the surfaces on which the
shims, washers and bearings are to be installed.
• Apply gear oil to the bearings and thrust washers
when installing them.
• Be careful not to mix up the bearing races RH
(B) and LH.
DI-00145 • Use new O-rings and gasket.
• Replace the oil seals with new ones at every dis-
(A) Differential carrier assembly. Apply grease to the lips when installing
(B) Front oil seal the oil seals.
• Be careful not to mix up the differential oil seal
17) Remove the pilot bearing together with front RH and LH.
bearing cone and collar using ST.
ST 398467700 DRIFT
ST
(D) (B) DI-00078

(C) (A)
DI-00076 1) Adjusting preload for front and rear bearings:
Adjust the bearing preload with collar and washer
(A) Pilot bearing between front and rear bearings. Pinion height ad-
(B) Collar justing washer are not affected by this adjustment.
(C) Front bearing The adjustment must be carried out without oil seal
(D) Rear bearing cup inserted.
(1) Press the rear bearing race into differential
18) When replacing the bearings, hit out the front carrier with ST1 and ST2.
bearing cup and rear bearing cup in this order out of ST1 398477701 HANDLE
case using a brass bar. ST2 398477703 DRIFT 2
(A)
ST2
ST1
(B) DI-00077 DI-00079
(A) 2 cutouts along diagonal lines (2) Install the front bearing race to differential
(B) Hit out alternately with brass bar
carrier using ST1 and ST2.
ST1 398477701 HANDLE
ST2 398477702 DRIFT
DI-35
DIFFERENTIALS
(3) Measure and record the thickness of pinion • Measure the preload in direction of tangent to
height adjust washer. flange.
NOTE: ST1 398507702 DUMMY SHAFT
If tooth contact (drive pinion, hypoid driven gear) is ST2 398507704 BLOCK
normal in the inspection before disassembling, ver- Tightening torque:
ify that the washer is not deformed, and then re-use 181 N!m (18.5 kgf-m, 134 ft-lb)
the used washer.
(4) Insert the ST1 into carrier with pinion height
adjusting washer and rear bearing cone fitted
onto it.
NOTE:
Use new rear bearing cone. ST1
(5) Install the preload adjusting collar and
washer, front bearing cone, ST2, companion ST2
flange, and washer and drive pinion nut.
ST1 398507702 DUMMY SHAFT
DI-00081
ST2 398507703 DUMMY COLLAR
(A) Drive pinion bearing preload
(B)
(C) 18.1 — 38.8 N (1.8 — 4.0 kgf, 4.1 — 8.7 lb)
at companion flange bolt hole
ST2 ST1 DI-00080
(A) Pinion height adjusting washer

(B) Preload adjusting collar
(C) Preload adjusting washer DI-00117
(6) Turn the ST1 with hand to make it seated, Part No. Thickness mm (in)
and tighten the self-locking nut while measuring 383705200 2.59 (0.1020)
the preload with spring balance. Select the pre- 383715200 2.57 (0.1012)
load adjusting washer and collar so that the
383725200 2.55 (0.1004)
specified preload is obtained when nut is tight-
ened to the specified torque. 383735200 2.53 (0.0996)
383745200 2.51 (0.0988)
383755200 2.49 (0.0980)
Preload adjusting 383765200 2.47 (0.0972)
washer 383775200 2.45 (0.0965)
383785200 2.43 (0.0957)
383795200 2.41 (0.0949)
383805200 2.39 (0.0941)
383815200 2.37 (0.0933)
383825200 2.35 (0.0925)
383835200 2.33 (0.0917)
DI-00117
383845200 2.31 (0.0909)
NOTE:
• Be careful not to give excessive preload.
• When tightening the self-locking nut, lock ST1
with ST2 as shown in the figure.
DI-36
DIFFERENTIALS
Part No. Length mm (in) NOTE:

383695201 56.2 (2.213) Use copies of this page.
383695202 56.4 (2.220)
Preload adjusting T Thickness of pinion height adjusting
383695203 56.6 (2.228) washer mm (in)
collar
383695204 56.8 (2.236) To Thickness of washer temporally
383695205 57.0 (2.244) inserted mm (in)
383695206 57.2 (2.252) N Clearance of thickness gauge mm (in)
2) Adjusting drive pinion height: H Figure marked on drive pinion head
Adjust the drive pinion height with washer installed Memo:
between the rear bearing cone and the back of pin-
ion gear.
(1) Install the ST2.
ST1 398507702 DUMMY SHAFT (Example of calculation)
ST2 398507701 DIFFERENTIAL CARRIER To = 2.20 + 1.20 = 3.40 mm
GAUGE N = 0.23 mm H = + 1
ST3 398507703 DUMMY COLLAR T = 3.40 + 0.23 " 0.01 " 0.20 = 3.42
Result: Thickness = 3.42 mm
ST3 ST1 RH ST2 Therefore use the pinion height adjusting wash-
N
er of part number 383605200.
Pinion height adjusting washer
383495200 3.09 (0.1217)
383505200 3.12 (0.1228)
383515200 3.15 (0.1240)
(A)
LH 383525200 3.18 (0.1252)
DI-00083
383535200 3.21 (0.1264)
(A) Pinion height adjusting washer 383545200 3.24 (0.1276)
383555200 3.27 (0.1287)
(2) Measure the clearance N between the end 383565200 3.30 (0.1299)
of ST2 and the end surface of ST1 by using a 383575200 3.33 (0.1311)
thickness gauge.
383585200 3.36 (0.1323)
NOTE: 383595200 3.39 (0.1335)
Make sure there is no clearance between the case 383605200 3.42 (0.1346)
and ST2. 383615200 3.45 (0.1358)
ST1 398507702 DUMMY SHAFT 383625200 3.48 (0.1370)
ST2 398507701 DIFFERENTIAL CARRIER 383635200 3.51 (0.1382)
GAUGE 383645200 3.54 (0.1394)
383655200 3.57 (0.1406)
ST2 383665200 3.60 (0.1417)
383675200 3.63 (0.1429)
383685200 3.66 (0.1441)
ST1
DI-00084
(3) Obtain the thickness of pinion height adjust-

ing washer to be inserted from the following for-
mula, and replace the temporarily installed
washer with this one.
T = To + N " (H # 0.01) " 0.20 mm
DI-37
DIFFERENTIALS
3) Install the selected pinion height adjusting wash- 6) Insert the collar, then press-fit the pilot bearing
er on drive pinion, and press the rear bearing cone with ST1 and ST2.
into position with ST. ST1 399780104 WEIGHT
ST 398177700 INSTALLER ST2 899580100 INSTALLER
ST2
ST
ST1
DI-00085 DI-00088
4) Insert the drive pinion into differential carrier, in- 7) Fit a new oil seal with ST.
stall the selected bearing preload adjusting collar NOTE:
and washer. • Press-fit until end of oil seal is 1 mm (0.04 in) in-
(A)
ward from end of carrier.
• Apply grease to the oil seal lips.
(B) ST 498447120 INSTALLER
(C)
ST
(D)
DI-00086
(A) Drive pinion

(B) Bearing preload adjusting collar
DI-00089
(C) Bearing preload adjusting washer
(D) Differential carrier 8) Press-fit the companion flange with ST1 and
ST2.
5) Press-fit the front bearing cone into case with
ST1, ST2 and ST3. NOTE:
ST1 398507703 DUMMY COLLAR Be careful not to damage the bearing.
ST2 399780104 WEIGHT ST1 899874100 INSTALLER
ST3 899580100 INSTALLER ST2 399780104 WEIGHT
ST3 ST1
ST1
ST2 ST2
DI-00087 DI-00090
DI-38
DIFFERENTIALS
9) Install a new self-locking nut and secure the (1) Measure the side gear backlash.
companion flange using ST and tighten the nut.
Side gear backlash:
0.10 — 0.20 mm (0.0039 — 0.0079 in)
Tightening torque:
181 N!m (18.5 kgf-m, 134 ft-lb)
DI-00240
ST (2) Adjust the side gear backlash as specified
DI-00091
by selecting side gear thrust washer.
10) Assembling differential case
Side gear thrust washer
Install the side gears and pinion mate gears, with
their thrust washers and pinion mate shaft, into dif-
ferential case. (Model without LSD) 383445201 0.75 — 0.80 (0.0295 — 0.0315)
383445202 0.80 — 0.85 (0.0315 — 0.0335)
NOTE:
383445203 0.85 — 0.90 (0.0335 — 0.0354)
• Apply gear oil on both sides of the washer and on
the side gear shaft before installing. (3) Check the condition of rotation after apply-
• Insert the pinion mate shaft into the differential ing oil to the gear tooth surfaces and thrust sur-
case by aligning the lock pin holes. faces.
(4) After inserting the pinion shaft lock pin into
differential case, stake the both sides of the hole
to prevent pin from falling off.
11) Install the hypoid driven gear to differential
case.
NOTE:
• Before installing bolts, apply Lock Tite to bolt
threads.
Lock Tite:
THREE BOND 1324 (Part No. 004403042)
• Tighten diagonally while tapping the bolt heads.
Tightening torque:
105 N!m (10.7 kgf-m, 77.4 ft-lb)
DI-00239
DI-00068
DI-39
DIFFERENTIALS
12) Press the side bearing into differential case us- (4) Align the arrow mark on differential carrier
ing ST. with the mark on side retainer during installation.
ST 398227700 DRIFT NOTE:
Be careful that side bearing outer race is not dam-
aged by bearing roller.
ST
(A)
DI-00095
13) Press-fit the side bearing cone to the side bear-

ing retainer using ST. DI-00097
ST 398437700 DRIFT
14) Adjusting the side bearing retainer shims (A) Arrow mark
(1) The hypoid driven gear backlash and side
bearing preload can be adjusted by the side (5) Tighten the side bearing retainer bolts.
bearing retainer shim thickness. Tightening torque:
(2) Install the differential assembly into differen- 10.3 N!m (1.05 kgf-m, 7.6 ft-lb)
tial carrier in the reverse order of disassembly.
DI-00098
DI-00065
(6) Measure the hypoid driven gear to drive pin-
(3) Install the side bearing retainer shims to re- ion backlash. Set the magnet base on differen-
tainers RH and LH from which they were re- tial carrier. Align the contact point of dial gauge
moved. with tooth face of hypoid driven gear, and move
NOTE: hypoid driven gear while holding drive pinion
Replace the broken or corroded side retainer shim still. Read the value indicated on dial gauge.
with a new one of same thickness. If the backlash exceeds 0.2 mm (0.08 in), re-
duce the thickness of shim on the back face of
Side bearing retainer shim hypoid driven gear and increase the thickness of
Part No. Thickness mm (in) shim on the tooth face of hypoid driven gear. If
383475201 0.20 (0.0079) the backlash is less than 0.1 mm (0.004 in), in-
383475202 0.25 (0.0098) crease the thickness of shim on the back face of
383475203 0.30 (0.0118) hypoid driven gear and reduce the thickness of
383475204 0.40 (0.0157) shim on the tooth face of hypoid driven gear.
383475205 0.50 (0.0197)
DI-40
DIFFERENTIALS
Backlash: Hypoid driven gear runout on its back surface:

0.10 — 0.20 mm (0.0039 — 0.0079 in) 0.05 mm (0.0020 in)
DI-00099 DI-00101
(7) At the same time, measure the total preload 17) Checking and adjusting the tooth contact of hy-
of drive pinion. Compared with the resistance poid driven gear
when differential case is not installed, if the total (1) Apply an even coat of red lead on both sides
preload is not within specification, adjust the of three or four teeth on the hypoid driven gear.
thickness of side bearing retainer shims, in- Check the contact pattern after rotating the hy-
creasing/reducing by an even amount at a time. poid driven gear several revolutions back and
forth until a definite contact pattern appears on
Total preload:
the hypoid driven gear.
20.7 — 54.4 N (2.1 — 5.5 kgf, 4.7 — 12.2 lb)
(2) When the contact pattern is incorrect, read-
15) Recheck the hypoid driven gear to drive pinion just.
backlash.
NOTE:
Backlash: Be sure to wipe off red lead completely after adjust-
0.10 — 0.20 mm (0.0039 — 0.0079 in) ment is completed.
• Correct tooth contact
Checking item: Tooth contact pattern is slightly
shifted toward toe side under no-load rotation.
[When loaded, contact pattern moves toward
heel.]
(A)
DI-00099
16) Check the hypoid driven gear runout on its

back surface, and make sure that pinion and hy-
(B)
poid driven gear rotates smoothly.
If the hypoid driven gear runout on its back surface
exceed the specification, verify that there is any for- AT-00207
eign material between hypoid driven gear and dif-
ferential case, and they are not deformed. (A) Toe side
(B) Heel side
DI-41
DIFFERENTIALS
• Face contact • Toe contact (inside end contact)

Checking item: Backlash is too large. Checking item: Contact areas is small
Contact pattern Contact pattern
AT-00208 AT-00210
Corrective action: Increase thickness of drive pin- Corrective action: Reduce thickness of drive pinion
ion height adjusting washer in order to bring drive height adjusting washer in order to bring drive pin-
pinion close to hypoid driven gear. ion away from hypoid driven gear.
AT-00212 AT-00213
• Flank contact • Heel contact (outside end contact)

Checking item: Backlash is too small. Checking item: Contact areas is small
AT-00209 AT-00211
Corrective action: Reduce thickness of drive pinion Corrective action: Increase thickness of drive pin-
height adjusting washer in order to bring drive pinion height adjusting washer in order to bring drive
ion away from hypoid driven gear. pinion close to hypoid driven gear.
AT-00213 AT-00212
DI-42
DIFFERENTIALS
18) If proper tooth contact is not obtained, once 25) Install the breather cap.
again adjust the drive pinion height by changing RH 26) Install the drain plug and filler plug.
and LH side bearing retainer shims and the hypoid
Tightening torque:
gear backlash.
49 N!m (5.0 kgf-m, 36.2 ft-lb)
19) Remove the RH and LH side bearing retainer.
20) Install a new O-ring to side bearing retainer of E: INSPECTION
both side. Wash all the disassembled parts clean, and exam-
21) Using the ST, install the oil seal to the side ine them for wear, damage and other defects. Re-
bearing retainer of both side. pair or replace the defective parts as necessary.
ST 398437700 DRIFT 1) Hypoid driven gear and drive pinion
22) Align the arrow mark on differential carrier with • If abnormal tooth contact is evident, find out the
the mark on side retainer during installation. cause and adjust to give correct tooth contact. Re-
place the gear if excessively worn or incapable of
adjustment.
• If crack, score or seizure is evident, replace as a
(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 evi-
dent on tooth surface.
• Replace if thrust washer contacting surface is
worn or seized. Slight damage of the surface can
DI-00097 be corrected by oil stone or the like.
3) Bearings
(A) Arrow mark
Replace if seizure, peeling, wear, rust, dragging
23) Tighten the side bearing retainer bolts. during rotation, noise or other defect is evident.
4) Thrust washers of side gear and pinion mate
Tightening torque: gear:
10.3 N!m (1.05 kgf-m, 7.6 ft-lb) Replace if seizure, flaw, abnormal wear or other
defect is evident.
5) Oil seal
Replace if deformed or damaged, and at every dis-
assembling.
6) Differential carrier
Replace if the bearing bores are worn or damaged.
7) Differential case
Replace if its sliding surfaces are worn or cracked.
8) Companion flange
DI-00098
Replace if the oil seal lip contacting surfaces have
flaws.
24) Install the new gasket and rear cover to the dif-
ferential carrier, and tighten the bolts to specified 1. SIDE GEAR BACKLASH
torque. Using a dial gauge, check the backlash of the side
Tightening torque: gear. (Model without LSD)
29 N!m (3.0 kgf-m, 21.7 ft-lb) Side gear backlash:
0.1 — 0.2 mm (0.004 — 0.008 in)
DI-00113
DI-43
DIFFERENTIALS
If the side gear backlash is not within the specifica- 4. TOOTH CONTACT BETWEEN HYPOID
tion, adjust it as specified by selecting side gear DRIVEN GEAR AND DRIVE PINION
thrust washer.
Inspect the tooth contact between hypoid driven
gear and drive pinion. <Ref. to DI-35, ASSEMBLY,
Rear Differential (T-type).>
5. TOTAL PRELOAD
Using a spring balance, check the total preload.
Total preload:
20.7 — 54.4 N (2.1 — 5.5 kgf, 4.7 — 12.2 lb)
If the total preload is not within the specification,
adjust the side bearing retainer shims.
DI-00315
2. HYPOID DRIVEN GEAR BACKLASH

Using a dial gauge, check the backlash of hypoid
driven gear.
Hypoid driven gear backlash:
0.1 — 0.2 mm (0.004 — 0.008 in)
If the hypoid driven gear backlash is not within the
specification, adjust the side bearing preload or re-
pair if necessary.
DI-00117
6. COMPANION FLANGE
1) If rust or dirt is attached to the companion flange,
remove them.
2) Set a dial gauge at a companion flange surface
(mating surface of propeller shaft and companion
flange), and then measure the companion flange
runout.
Limit of runout:
DI-00099 0.08 mm (0.0031 in)
3. HYPOID DRIVEN GEAR RUNOUT ON ITS
BACK SURFACE
Using a dial gauge, check the hypoid driven gear
runout on its back surface.
Hypoid driven gear runout on its back surface:
0.05 mm (0.0020 in)
If the hypoid driven gear runout exceeds 0.05 mm
(0.0020 in), replace the hypoid driven gear.
DI-00360
DI-00101
DI-44
DIFFERENTIALS
3) Set the gauge inside of the companion flange,

and measure the runout.
Limit of runout:
0.08 mm (0.0031 in)
DI-00361
4) If either runout exceeds the limit, move the

phase of companion flange and drive pinion 90$
each, and find the point where the runout is within
the limit.
5) If the runout exceeds the limit after changing the
phase, replace the companion flange and recheck
the runout.
6) If the runout exceeds the limit after replacing the
companion flange, the drive pinion may be assem-
bled incorrectly or bearing is faulty.
F: ADJUSTMENT
1. SIDE GEAR BACKLASH
Adjust the side gear backlash.
<Ref. to DI-35, ASSEMBLY, Rear Differential (T-
type).>
Adjust hypoid driven gear backlash.
type).>
3. TOOTH CONTACT BETWEEN HYPOID
DRIVEN GEAR AND DRIVE PINION
Adjust the tooth contact between hypoid driven
gear and drive pinion gear.
type).>
4. TOTAL PRELOAD
Adjust the side bearing shim.
type).>
DI-45
Rear Differential (VA-type)
DIFFERENTIALS
5. Rear Differential (VA-type) 12) Remove the DOJ of rear drive shaft from rear
differential.
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Move the select lever or gear shift lever to neu-
tral.
4) Release the parking brake. (A)
5) Jack-up the vehicle and support it with rigid
racks.
6) Remove the rear wheels. (B)
DI-00287
8) Remove the heat shield cover.
(A) Tire lever
(B) Bolt
13) Remove the nuts which hold the rear differen-

tial front member.
AT-01331
9) Remove the propeller shaft.

<Ref. to DS-10, REMOVAL, Propeller Shaft.>
10) Prepare the transmission jack and band.
DI-00358
14) Support the rear differential with transmission

jack.
DI-00268
11) Loosen the self-locking nuts which hold the

DI-00273
15) Remove the rear differential front member.

16) Secure the rear differential using band.
17) Remove the self-locking nuts which hold the
DI-00269
DI-46
DIFFERENTIALS
18) Remove the rear differential stud bolt from rear 22) Secure the rear drive shaft to lateral link using
crossmember bushing. wire.
NOTE:
When removing the stud bolt, carefully adjust the
angle and location of transmission jack and jack
stand, if necessary.
DI-00277
23) Remove the rear differential member plate from

rear differential.
(A)
DI-00400
19) Lower the transmission jack stand after remov-

ing the rear differential stud bolt from rear cross-
member. Rear drive shaft should not come into
contact with lateral link bolt.
DI-00359
B: INSTALLATION
1) Insert the rear differential member plate into rear
differential.
DI-00392
(A)
20) Pull out the axle shaft from rear differential.
NOTE:
If it is difficult to remove the axle shaft from rear dif-
ferential, remove it using tire lever.
DI-00359
2) Set the rear differential to transmission jack.

NOTE:
DI-00276
Secure the rear differential to transmission jack us-
21) Lower the transmission jack. ing band.
DI-47
DIFFERENTIALS
3) Install the ST to rear differential. 8) After inserting the rear differential stud bolt into
ST 28099PA090 OIL SEAL PROTECTOR rear crossmember bushing, lift up the transmission
jack and align the rear differential to the height of
rear differential.
ST
DI-00300
4) Insert the spline shaft until the spline portion

DI-00283
comes inside the side oil seal.
ST 28099PA090 OIL SEAL PROTECTOR 9) Tighten a new self-locking nut temporarily to rear
crossmember.
ST
DI-00289
DI-00269
5) Remove ST from rear differential.
ST 28099PA090 OIL SEAL PROTECTOR 10) Remove the band from rear differential. Lift up
6) Push the rear differential to insert the axle shaft the rear differential until the rear differential is left
into rear differential. from the transmission jack.
11) Install the rear differential front member with a
new self-locking nut.
Tightening torque:
T1: 52 N!m (5.3 kgf-m, 38 ft-lb)
T2: 110 N!m (11.2 kgf-m, 81 ft-lb)
T2
DI-00281
7) Adjust the transmission jack, if necessary, and

insert the rear differential stud bolt into rear cross-
member bushing properly.
T1
DI-00284
DI-00393
DI-48
DIFFERENTIALS
12) Tighten the self-locking nut. 3) Remove the rear cover by loosening retaining
bolts.
Tightening torque:
70 N!m (7.1 kgf-m, 51 ft-lb)
DI-00130
DI-00269 4) Remove the air breather cap.

13) Lower the transmission jack. NOTE:
14) Install the propeller shaft. • Do not attempt to remove the air breather cap
<Ref. to DS-11, INSTALLATION, Propeller Shaft.> unless necessary.
15) Install the heat shield cover. • When removing the air breather cap, replace it
16) Install the rear exhaust pipe and muffler. with a new one.
C: DISASSEMBLY (A)
1. VA1-TYPE
(B)
To detect the real cause of trouble, inspect the fol-
lowing items before disassembling.
• Tooth contact and backlash between hypoid driv-
en gear and drive pinion
1) Set the ST on vise and install the differential as- DI-00131
sembly to ST.
ST 398217700 ATTACHMENT (A) Air breather cap
(B) Rear cover
5) Remove the lock plate RH and LH.
ST
DI-00129
2) Drain the gear oil by removing plug.

DI-00132
DI-49
DIFFERENTIALS
6) Remove the holder RH and LH with ST. NOTE:

ST 499785500 WRENCH ASSY Perform this operation only when changing oil seal.
ST
DI-00133 DI-00136
7) Pull out the differential case assembly from dif- 10) Extract the bearing cone with ST1 and ST2.
ferential carrier.
NOTE:
NOTE: • Do not attempt to disassemble the parts unless
Be careful not to hit the teeth against the case. necessary.
• Set the puller so that its claws catch the edge of
the bearing cone.
• Never mix up the bearing races RH and LH and
cones.
ST1 899524100 PULLER SET
ST2 399520105 SEAT
ST1
DI-00134
8) Remove the bearing race from holder RH and ST2

LH with ST1 and ST2.
ST1 499705401 PULLER ASSY
ST2 499705404 SEAT
DI-00137
11) Remove the hypoid driven gear by loosening

ST1
hypoid driven gear bolts.
(A)
ST2
(B)
DI-00135
(A) Bearing race

(B) Holder
9) Remove the oil seal from holder RH and LH us- DI-00068

ing screwdriver. 12) Drive out the pinion shaft lock pin from hypoid
driven gear side.
NOTE:
The lock pin is staked at the pin hole end on the dif-
ferential case. do not drive it out forcibly before
unstaking it.
DI-50
DIFFERENTIALS
ST 899904100 STRAIGHT PIN REMOVER 15) Extract the companion flange with a puller.
(A)
ST
DI-00237 (B) DI-00142
13) Draw out the pinion mate shaft and remove pin-
(A) Companion flange
ion mate gears, side gears and thrust washers.
(B) Puller
NOTE:
The gears should be marked or kept separated 16) Press the end of drive pinion shaft and extract it
right and left, and front and rear as well as thrust together with rear bearing cone, pinion height ad-
washers. just washer and washer.
NOTE:
Hold the drive pinion so as not to drop it.
ST 398467700 DRIFT
ST
DI-00238
(A) Side gear

(B) Pinion mate gear DI-00073
(C) Thrust washer
(D) Differential case
17) Remove the rear bearing cone from drive pin-
ion by supporting the cone with ST.
(E) Pinion mate shaft
NOTE:
14) Support the companion flange with ST and re- Place the replacer so that its center-recessed side
move self-locking nut. faces the pinion gear.
ST 498427200 FLANGE WRENCH ST 498515500 REPLACER
ST
ST
DI-00141
DI-00074
DI-51
DIFFERENTIALS
18) Remove the front oil seal from differential carri- 2. VA2-TYPE
er using ST.
To detect the real cause of trouble, inspect the fol-
ST 398527700 PULLER SET
lowing items before disassembling.
• Tooth contact and backlash between hypoid driv-
(A) en gear and drive pinion
1) Set the ST on vise and install the differential as-
sembly to ST.
(B)
DI-00145
(A) Differential carrier

(B) Front oil seal
19) Remove the pilot bearing together with front

bearing cone and collar using ST.
ST 398467700 DRIFT ST
DI-00363
ST 2) Drain the gear oil by removing plug.
3) Remove the rear cover by loosening retaining
bolts.
(D) (B)
(C) (A)
DI-00076
(A) Pilot bearing

(B) Collar
(C) Front bearing
DI-00388
(D) Rear bearing cup
4) Remove the lock plate RH and LH.
20) When replacing the bearings, hit out the front
bearing cup and rear bearing cup in this order out of
case by using a brass bar.
(A)
DI-00364
(B) DI-00077
(A) 2 cutouts along diagonal lines

(B) Hit out alternately with brass bar
DI-52
DIFFERENTIALS
5) Remove the holder RH and LH with ST. • Set the puller so that its claws catch the groove of
ST 18630AA010 WRENCH holder.
ST
ST
(A)
ST (B)
DI-00365 DI-00367
6) Pull out the differential case assembly from dif- (A) Groove
ferential carrier.
(B) Claw
NOTE:
Be careful not to hit the teeth against the case.
(A)
ST
DI-00368
DI-00366
(A) Holder
7) Remove the bearing race from holder RH and
LH with ST1 and press. 8) Remove the oil seal from holder RH and LH us-
ST 18758AA000 PULLER ing screwdriver.
NOTE: NOTE:
• Make sure the bolt of puller turn manually. Perform this operation only when changing oil seal.
DI-00369
9) Extract the bearing cone with ST1, ST2 and

ST3.
NOTE:
• Do not attempt to disassemble the parts unless
necessary.
• Never mix up the bearing races RH and LH and
cones.
DI-53
DIFFERENTIALS
ST1 498077000 REMOVER 13) Removes the drive pinion shaft.

ST2 399520105 SEAT 14) Remove the rear bearing cone from drive pin-
ST3 899864100 REMOVER ion by supporting cone with ST.
NOTE:
Place the replacer so that its center-recessed side
ST1 faces the pinion gear.
ST3
ST 398517700 REPLACER
ST2
DI-00370
10) Remove the hypoid driven gear by loosening ST
hypoid driven gear bolts.
DI-00373
15) Remove the front oil seal from differential carri-

er using screwdriver.
16) Remove the pilot bearing, front bearing cone
and collar.
DI-00371
11) Support the companion flange with ST and re-

move self-locking nut.
(D) (B)
(C) (A)
DI-00374
ST
(A) Pilot bearing

(B) Collar
(C) Front bearing
(D) Rear bearing cup
17) When replacing the bearings, hit out the front

DI-00372 bearing cup and rear bearing cup in this order out of
12) Extract the companion flange with a puller. case by using a brass bar.
(A)
(A)
(B) (B) DI-00077

DI-00394
(A) Companion flange (A) 2 cutouts along diagonal lines

(B) Puller (B) Hit out alternately with brass bar
DI-54
DIFFERENTIALS
D: ASSEMBLY ST1 398477701 HANDLE

ST2 498447110 DRIFT
1. VA1-TYPE (3) Insert the front bearing cone.
NOTE: NOTE:
• Assemble in the reverse order of disassembly. Use new front bearing cone.
• Check and adjust each part during assembly. (4) Measure and record the thickness of pinion
• Use a new gasket. height adjust washer.
NOTE:
they are not improperly installed.
If tooth contact (drive pinion, hypoid driven gear) is
• Thoroughly clean the surfaces on which the normal in the inspection before disassembling, ver-
shims, washers and bearings are to be installed. ify that the washer is not deformed, and then re-use
• Apply gear oil when installing the bearings and the used washer.
thrust washers.
• Be careful not to mix up the bearing races RH (5) Insert the ST1 into the case with pinion
and LH. height adjusting washer and rear bearing cone
fitted onto it.
• Replace the oil seal with a new one at every dis-
assembly. Apply grease to the lips when installing NOTE:
the oil seal. Use new rear bearing cone.
• Be careful not to mix up the differential oil seal (6) Install the preload adjusting collar and
RH and LH. washer, front bearing cone, ST2, companion
flange, and washer and self-locking nut.
ST2 32285AA000 DUMMY COLLAR
(A)
(B)
(C)
DI-00078
1) Adjusting preload for front and rear bearings:

Adjust the bearing preload with collar and washer ST2 ST1
DI-00150
between front and rear bearings. Pinion height ad-
justing washer are not affected by this adjustment. (A) Pinion height adjusting washer
The adjustment must be carried out without oil seal
inserted.
(C) Preload adjusting washer
(1) Install the rear bearing race into differential
carrier with ST1 and ST2. (7) Turn the ST1 with hand to make it seated,
ST1 398477701 HANDLE and tighten the self-locking nut while measuring
ST2 398477702 DRIFT the preload with spring balance. Select the pre-
ST1 specified preload is obtained when nut is tight-
ened to the specified torque.
ST2
DI-00149
(2) Install the front bearing race to differential

carrier using ST1 and ST2.
DI-00152
DI-55
DIFFERENTIALS
NOTE: Part No. Length mm (in)

• Use a new self-locking nut. 32288AA040 52.3 (2.059)
• Be careful not to give excessive preload. 32288AA050 52.5 (2.067)
• When tightening the self-locking nut, lock ST1 31454AA100 52.6 (2.071)
with ST2 as shown in the figure. Preload adjusting 32288AA060 52.7 (2.075)
• Measure the preload in direction of tangent to collar 31454AA110 52.8 (2.079)
flange. 32288AA070 52.9 (2.083)
ST1 498447150 DUMMY SHAFT 31454AA120 53.0 (2.087)
ST2 398507704 BLOCK 32288AA080 53.1 (2.091)
Tightening torque: 32288AA090 53.3 (2.098)
191 N!m (19.5 kgf-m, 141 ft-lb) 2) Adjusting drive pinion height:
Adjust the drive pinion height with washer installed
ion gear.
ST1 ST2 498505501 DIFFERENTIAL CARRIER
GAUGE
ST2 ST3 32285AA000 DUMMY COLLAR
ST3 ST1 RH ST2

DI-00081 N
Drive pinion bearing preload

For new bearing:
12.7 — 32.2 N (1.3 — 3.3 kgf, 2.9 — 7.3 lb)
Measure at companion flange bolt hole

38336AA000 1.500 (0.0591) LH
(A) DI-00083
38336AA120 1.513 (0.0596)
38336AA010 1.525 (0.0600) (A) Pinion height adjusting washer
38336AA130 1.538 (0.0606)
(2) Measure the clearance N between the end
38336AA020 1.550 (0.0610) of ST2 and the end surface of ST1 by using a
38336AA140 1.563 (0.0615) thickness gauge.
38336AA030 1.575 (0.0620)
NOTE:
38336AA150 1.588 (0.0625)
Make sure there is no clearance between the case
38336AA040 1.600 (0.0630) and ST2.
38336AA160 1.613 (0.0635)
Preload adjusting 38336AA050 1.625 (0.0640)
ST2 498505501 DIFFERENTIAL CARRIER
washer 38336AA170 1.638 (0.0645) GAUGE
38336AA060 1.650 (0.0650)
38336AA180 1.663 (0.0655)
38336AA070 1.675 (0.0659) ST2
38336AA190 1.688 (0.0665)
38336AA080 1.700 (0.0669)
38336AA200 1.713 (0.0674)
ST1
38336AA090 1.725 (0.0679)
38336AA210 1.738 (0.0684)
38336AA100 1.750 (0.0689)
38336AA220 1.763 (0.0694)
DI-00084
38336AA110 1.775 (0.0699)
DI-56
DIFFERENTIALS
(3) Obtain the thickness of pinion height adjust- 4) Insert the drive pinion into differential carrier, in-
ing washer to be inserted from the following for- stall the selected bearing preload adjusting collar
mula, and replace the temporarily installed and washer.
(A)
NOTE:
Adjust it using the 1 — 3 washers. (B)
T = To + N " 0.05 (mm) (C)
T Thickness of pinion height adjusting

washer mm (in)
To Thickness of washer temporally
inserted mm (in)
N Clearance of thickness gauge mm (in)
(D)
Memo: DI-00156
(A) Drive pinion

(Example of calculation)
(D) Differential carrier
To = 0.15 mm
N = 0.1 mm 5) Press-fit the front bearing cone into carrier with
T = 0.15 + 0.1 " 0.05 = 0.2 mm ST1, ST2 and ST3.
Result: Thickness = 0.2 mm ST1 32285AA000 DUMMY COLLAR
Therefore use the pinion height adjusting washer of ST2 399780104 WEIGHT
part number 32295AA220. ST3 899580100 INSTALLER
Part No. Thickness mm (in) ST3
32295AA200 0.150 (0.0059)
ST1
32295AA210 0.175 (0.0069)
32295AA220 0.200 (0.0079)
32295AA230 0.225 (0.0089)
32295AA240 0.250 (0.0098)
32295AA250 0.275 (0.0108) ST2
3) Install the selected pinion height adjusting wash- DI-00087

er on drive pinion, and press the rear bearing cone
6) Insert the collar, then press-fit the pilot bearing
into position with ST.
with ST1 and ST2.
ST 498175500 INSTALLER
ST1 399780104 WEIGHT
ST2 899580100 INSTALLER
ST2
ST
DI-00085 ST1
DI-00088
7) 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 to the oil seal lips.
DI-57
DIFFERENTIALS
ST 498447120 INSTALLER • Insert the pinion mate shaft into the differential
case by aligning the lock pin holes.
ST
DI-00089
8) Press-fit the companion flange with ST1 and

ST2.
NOTE:
Be careful not to damage the bearing.
ST1 899874100 INSTALLER
ST2 399780104 WEIGHT
ST1
DI-00239
(1) Measure the side gear backlash.

Side gear backlash:
ST2 0.05 — 0.15 mm (0.0020 — 0.0059 in)
DI-00090
9) Install a new self-locking nut, and secure the

companion flange using ST, and tighten the nut.
Tightening torque:
191 N!m (19.1 kgf-m, 141 ft-lb)
DI-00240
(2) Adjust the side gear backlash as specified

by selecting side gear thrust washer.
ST
Side gear thrust washer
803135011 0.925 — 0.950 (0.0364 — 0.0374)
DI-00161 803135012 0.950 — 0.975 (0.0374 — 0.0384)
10) Assembling differential case 803135013 0.975 — 1.000 (0.0384 — 0.0394)
Install the side gears and pinion mate gears, with 803135014 1.000 — 1.025 (0.0394 — 0.0404)
their thrust washers and pinion mate shaft, into dif- 803135015 1.025 — 1.050 (0.0404 — 0.0413)
ferential case.
(3) Check the condition of rotation after apply-
NOTE: ing oil to the gear tooth surfaces and thrust sur-
• Apply gear oil to both sides of the washer and the faces.
side gear shaft before installing. (4) After inserting the pinion shaft lock pin into
differential case, stake the both sides of the hole
to prevent pin from falling off.
DI-58
DIFFERENTIALS
11) Install the hypoid driven gear on differential (2) Install the bearing race into holder RH and
case. LH.
NOTE: ST 398477702 DRIFT
• Before installing bolts, apply Lock Tite to bolt CAUTION:
threads. Make sure that the oil seal, bearing outer race
Lock Tite: and cone are properly assembled.
THREE BOND 1324 (Part No. 004403042)
• Tighten diagonally while tapping the bolt heads.
Tightening torque:
62 N!m (6.3 kgf-m, 45.6 ft-lb) ST
DI-00167
(3) Install the differential assembly into differen-

DI-00068
12) Press the side bearing into differential case us-

ing ST.
ST 498485400 DRIFT
DI-00134
ST
(4) Temporally tighten the side holder RH and
LH in differential carrier to install.
14) Perform the backlash adjustment between the
hypoid driven gear and drive pinion, and preload
adjustment of differential side bearing.
DI-00095 (1) Turn the drive pinion with ST for better fitting
13) Assemble holders. of differential side bearing.
(1) Install the oil seal into holder RH and LH. ST 498427200 FLANGE WRENCH
ST
ST
DI-00169
DI-00166
DI-59
DIFFERENTIALS
(2) Screw in the side holder LH until light con- Backlash:

tact is made with ST. 0.10 — 0.15 mm (0.0039 — 0.0059 in)
ST 499785500 WRENCH
ST DI-00172
DI-00133
15) Draw a matching mark on both differential car-
(3) Back off the side (hypoid driven gear side) rier and holder. Remove the holder side at a time.
holder approx. 1 1/2 teeth of holder, and tighten Replace in the original position after inserting an O-
the other side holder by approx. 2 teeth (approx. ring and applying grease to threaded portion.
1 1/2 + 1/2 teeth). [Back off amount of side (hy-
poid driven gear side) holder + 1/2 tooth.]
This + 1/2 tooth gives preload. (A)
(4) Temporarily tighten the lock plate.
NOTE:
Turn over the lock plate to displace the holder 1/2
tooth.
(B)
DI-00173
(A) Alignment mark

(B) Holder
16) Tighten the bolt of lock plate to specified

torque.
DI-00132
Tightening torque:
25 N!m (2.5 kgf-m, 18.1 ft-lb)
(5) Measure the hypoid driven gear-to-drive
pinion backlash. Set the magnet base on differ-
ential carrier. Align the contact point of dial
gauge with tooth face of hypoid driven gear, and
move hypoid driven gear while holding drive pin-
ion still. Read the value indicated on dial gauge.
NOTE:
If measured backlash is not within specified range,
repeat the procedures for pinion driven gear set
backlash adjustment and differential side bearing
preload adjustment. DI-00132
DI-60
DIFFERENTIALS
17) Recheck the hypoid driven gear to pinion back- • Face contact
lash. Checking item: Backlash is too large.
Backlash: Contact pattern
0.10 — 0.15 mm (0.0039 — 0.0059 in)
AT-00208
DI-00172 Corrective action: Increase thickness of drive pin-

ion height adjusting washer in order to bring drive
18) Checking and adjusting the tooth contact of hy- pinion close to hypoid driven gear.
poid driven gear
(1) Apply an even coat of red lead on both sides
of three or four teeth on the hypoid driven gear.
Check the contact pattern after rotating the hy-
poid driven gear several revolutions back and
just.
NOTE:
Be sure to wipe off red lead completely after adjust- AT-00212
ment is completed. • Flank contact
• Correct tooth contact Checking item: Backlash is too small.
Checking item: Tooth contact pattern is slightly Contact pattern
shifted toward to toe side under no-load
rotation. [When loaded, contact pattern moves
toward heel.]
(A)
AT-00209
(B)
Corrective action: Reduce thickness of drive pinion
height adjusting washer in order to bring drive pin-
AT-00207
ion away from hypoid driven gear.
(A) Toe side
(B) Heel side
AT-00213
DI-61
DIFFERENTIALS
• Toe contact (inside end contact) 19) If proper tooth contact is not obtained, once
Checking item: Contact areas is small again adjust the drive pinion height and the differ-
Contact pattern ential side bearing preload (already mentioned)
and the hypoid gear backlash.
20) Install the new gasket and rear cover to differ-
ential carrier and tighten the bolts to specified
torque.
Tightening torque:
25 N!m (2.5 kgf-m, 18.1 ft-lb)
(A)
AT-00210
Corrective action: Reduce thickness of drive pinion

height adjusting washer in order to bring drive pin-
ion away from hypoid driven gear.
DI-00189
(A) Rear cover
2. VA2-TYPE
NOTE:
• Assemble in the reverse order of disassembly.
AT-00213 • Check and adjust each part during assembly.
• Use a new gasket.
• Heel contact (outside end contact)
Checking item: Contact areas is small they are not improperly installed.
Contact pattern • 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 bearing races RH
and LH.
• Replace the oil seal with a new one at every dis-
assembly. Apply grease to the lips when installing
the oil seal.
• Be careful not to mix up the differential oil seal
AT-00211
RH and LH.
Corrective action: Increase thickness of drive pin-
ion height adjusting washer in order to bring drive
pinion close to hypoid driven gear.
DI-00078
AT-00212
DI-62
DIFFERENTIALS
1) Adjusting preload for front and rear bearings: ST1 18678AA000 DUMMY SHAFT
Adjust the bearing preload with collar and washer
between front and rear bearings. Pinion height ad- (A) (B)
(C) (D)
justing washer are not affected by this adjustment.
The adjustment must be carried out without oil seal
inserted.
(1) Install the rear bearing race into differential
carrier with ST1 and ST2.
ST1 398477701 HANDLE
ST2 398477703 DRIFT 2
ST1
DI-00377
ST1
(C) Preload adjusting washer
(D) Collar
(7) Turn the ST1 with hand to make it seated,

ST2
and tighten the self-locking nut while measuring
DI-00375
the preload with spring balance. Select the pre-
(2) Using the ST, install the front bearing race to specified preload is obtained when nut is tight-
the differential carrier. ened to the specified torque.
ST
DI-00152
DI-00376
NOTE:
(3) Insert the front bearing cone. • Use a new self-locking nut.
NOTE: • Be careful not to give excessive preload.
Use new front bearing cone. • When tightening the self-locking nut, lock com-
(4) Measure and record the thickness of pinion panion flange with ST2 as shown in the figure.
adjust washer. • Measure the preload in direction of tangent to
NOTE: flange.
If tooth contact (drive pinion, hypoid driven gear) is ST1 18678AA000 DUMMY SHAFT
normal in the inspection before disassembling, ver- ST2 498427200 FLANGE WRENCH
ify that the washer is not deformed, and then re-use
the used washer.
(5) Insert the ST1 into carrier with pinion height
adjusting washer and rear bearing cone fitted
onto it.
NOTE:
Use new rear bearing cone.
(6) Install the preload adjusting collar and
washer, front bearing cone, collar, companion
flange, and washer and self-locking nut.
DI-63
DIFFERENTIALS
Tightening torque: 2) Adjusting drive pinion height:

191 N!m (19.5 kgf-m, 141 ft-lb) Adjust the drive pinion height with washer installed
ion gear.
ST2 ST1 18678AA000 DUMMY SHAFT
ST2 18831AA010 DIFFERENTIAL CARRIER
GAUGE
ST1 RH ST2
N
DI-00398
Drive pinion bearing preload

12.7 — 32.4 N (1.3 — 3.3 kgf, 2.9 — 7.3 lb)
(at companion flange bolt hole)
LH
Part No. Thickness mm (in) (A) DI-00379
38336AA430 1.500 (0.0591)
38336AA440 1.513 (0.0596)
38336AA450 1.525 (0.0600) (2) Install the side holder LH to the left side of
38336AA460 1.538 (0.0606) differential carrier in reverse direction.
38336AA470 1.550 (0.0610)
38336AA480 1.563 (0.0615)
38336AA490 1.575 (0.0620)
38336AA500 1.588 (0.0625)
38336AA510 1.600 (0.0630)
38336AA520 1.613 (0.0635)
washer 38336AA540 1.638 (0.0645)
38336AA550 1.650 (0.0650)
38336AA560 1.663 (0.0655) DI-00380
38336AA570 1.675 (0.0659)
(3) Measure the clearance N between the end
38336AA580 1.688 (0.0665)
of ST2 and the end surface of ST1 by using a
38336AA590 1.700 (0.0669) thickness gauge.
38336AA600 1.713 (0.0674)
NOTE:
38336AA610 1.725 (0.0679)
Make sure there is no clearance between the case
38336AA620 1.738 (0.0684)
and ST2.
38336AA630 1.750 (0.0689)
ST1 18678AA000 DUMMY SHAFT
38336AA640 1.763 (0.0694)
ST2 18831AA010 DIFFERENTIAL CARRIER
38336AA650 1.775 (0.0699)
GAUGE
31454AA250 51.05 (2.010)
ST2
31454AA260 51.25 (2.018)
31454AA270 51.35 (2.022)
ST1
collar 31454AA290 51.55 (2.030)
31454AA300 51.65 (2.033)
31454AA310 51.75 (2.037)
31454AA320 51.85 (2.041)
31454AA330 52.05 (2.049)
DI-00381
DI-64
DIFFERENTIALS
(4) Obtain the thickness of pinion height adjust- 4) Insert the drive pinion into differential carrier, in-
ing washer to be inserted from the following for- stall the previously selected bearing preload adjust-
mula, and replace the temporarily installed ing collar and washer.
(A)
NOTE:
Adjust it using the 1 — 3 washers.
(B)
T = To + N " 0.05 (mm) (C)
T Thickness of pinion height adjusting

washer mm (in)
To Thickness of washer temporally
inserted mm (in)
N Clearance of thickness gauge mm (in)
(D)
Memo: DI-00382
(A) Drive pinion

(Example of calculation)
(D) Differential carrier
To = 0.15 mm
N = 0.1 mm 5) Set ST and differential carrier to the press and
T = 0.15 + 0.1 " 0.05 = 0.2 mm install the front bearing cone.
Result: Thickness = 0.2 mm ST 399780104 WEIGHT
Therefore use the pinion height adjusting washer of
part number 32295AA370.
32295AA350 0.150 (0.0059)
32295AA360 0.175 (0.0069) ST
32295AA370 0.200 (0.0079)
32295AA380 0.225 (0.0089)
32295AA390 0.250 (0.0098)
32295AA400 0.275 (0.0108) DI-00383
3) Install the selected pinion height adjusting wash- NOTE:

er on drive pinion, and press the rear bearing cone Set the carrier to the press until the companion
into position with ST. flange is installed.
ST 398177700 INSTALLER 6) Insert the collar, then install the pilot bearing.
(A)
(B)
ST
DI-00085 DI-00389
(A) Pilot bearing

(B) Collar
DI-65
DIFFERENTIALS
7) Fit a new oil seal with ST. 10) Install the hypoid driven gear on differential
NOTE: case.
• Press-fit until end of oil seal is 1 mm (0.04 in) in- NOTE:
ward from end of carrier. • Tighten diagonally while tapping the bolt heads.
• Apply grease to the oil seal lips. • Set a cushioning such as wooden block, alumi-
ST 499277200 INSTALLER num plate or shop cloth between vise and differen-
tial case if the side gear comes into contact with
vise.
ST Tightening torque:
62 N!m (6.3 kgf-m, 45.6 ft-lb)
DI-00089
8) Press-fit the companion flange with ST.

NOTE:
Be careful not to damage the bearing.
DI-00371
11) Press the side bearing into differential case us-
ing ST.
ST 398227700 DRIFT
ST
ST
DI-00384
9) Install a new self-locking nut, and secure the

companion flange using ST, and tighten the nut.
DI-00095
12) Assemble holders.
Tightening torque: (1) Install the new oil seal into holder RH and
191 N!m (19.1 kgf-m, 141 ft-lb) LH.
ST
ST
DI-00372
DI-00166
DI-66
DIFFERENTIALS
(2) Install the bearing race into holder RH and (2) Screw in the side holder LH until light con-
LH. tact is made with ST.
ST 398487700 DRIFT ST 18630AA010 WRENCH
CAUTION:
Make sure that the oil seal, bearing outer race
and cone are properly assembled.
ST
ST
DI-00399
(3) Back off the side (hypoid driven gear side)

holder approx.1 1/2 teeth of holder, and tighten
DI-00167 the other side holder by approx. 2 teeth (approx.
1 1/2 + 1/2 teeth). [Back off amount of side (hy-
(3) Install the differential assembly into differen- poid driven gear side) holder + 1/2 tooth.]
This + 1/2 tooth gives preload.
(4) Temporarily tighten the lock plate.
NOTE:
Turn over the lock plate to displace the holder 1/2
tooth.
DI-00366
(4) Temporally tighten the side holder RH and

LH in differential carrier to install.
13) Perform the backlash adjustment between the
hypoid driven gear and drive pinion, and preload
DI-00364
adjustment of differential side bearing.
(1) Turn the drive pinion with ST for better fitting (5) Measure the hypoid driven gear-to-drive
of differential side bearing. pinion backlash. Set the magnet base on differ-
ST 498427200 FLANGE WRENCH ential carrier. Align the contact point of dial
gauge with tooth face of hypoid driven gear, and
move hypoid driven gear while holding drive pin-
ion still. Read the value indicated on dial gauge.
NOTE:
ST
If measured backlash is not within specified range,
repeat the procedures for pinion driven gear set
backlash adjustment and differential side bearing
preload adjustment.
DI-00385
DI-67
DIFFERENTIALS
Backlash: 16) Recheck the hypoid driven gear to pinion back-

0.10 — 0.15 mm (0.0039 — 0.0059 in) lash.
Backlash:
0.10 — 0.15 mm (0.0039 — 0.0059 in)
DI-00172
14) Draw a matching mark on both differential car-

rier and holder. Remove the holder side at a time. DI-00172
Replace in the original position after inserting an O-
17) Checking and adjusting the tooth contact of hy-
ring and applying grease to threaded portion.
poid driven gear
(A)
(1) Apply an even coat of red lead on both sides
of three or four teeth on the hypoid driven gear.
Check the contact pattern after rotating the hy-
(B) poid driven gear several revolutions back and
just.
NOTE:
DI-00386 Be sure to wipe off red lead completely after adjust-
ment is completed.
(A) Alignment mark • Correct tooth contact
(B) Holder Checking item: Tooth contact pattern is slightly
15) Tighten the bolt of lock plate to specified shifted toward toe side under no-load rotation.
torque. [When loaded, contact pattern moves toward
heel.]
Tightening torque:
25 N!m (2.5 kgf-m, 18.1 ft-lb)
(A)
(B)
AT-00207
DI-00364 (A) Toe side

(B) Heel side
DI-68
DIFFERENTIALS
• Face contact • Toe contact (inside end contact)

Checking item: Backlash is too large. Checking item: Contact areas is small
AT-00208 AT-00210
Corrective action: Increase thickness of drive pin- Corrective action: Reduce thickness of drive pinion
ion height adjusting washer in order to bring drive height adjusting washer in order to bring drive pin-
pinion close to hypoid driven gear. ion away from hypoid driven gear.
AT-00212 AT-00213
• Flank contact • Heel contact (outside end contact)

Checking item: Backlash is too small. Checking item: Contact areas is small
AT-00209 AT-00211
Corrective action: Reduce thickness of drive pinion Corrective action: Increase thickness of drive pin-
height adjusting washer in order to bring drive pinion height adjusting washer in order to bring drive
ion away from hypoid driven gear. pinion close to hypoid driven gear.
AT-00213 AT-00212
DI-69
DIFFERENTIALS
18) If proper tooth contact is not obtained, once 1. SIDE GEAR BACKLASH
again adjust the drive pinion height and the differ-
Using a dial gauge, check the backlash of the side
ential side bearing preload (already mentioned)
gear. (VA1-type only)
and the hypoid gear backlash.
19) Install the new gasket and rear cover to differ- Side gear backlash:
ential carrier and tighten the bolts to specified 0.05 — 0.15 mm (0.0020 — 0.0059 in)
torque. If the side gear backlash is not within the specifica-
Tightening torque: tion, adjust it as specified by selecting side gear
25 N!m (2.5 kgf-m, 18.1 ft-lb) thrust washer.
DI-00240
DI-00387
E: INSPECTION 2. HYPOID DRIVEN GEAR BACKLASH

Wash all the disassembled parts clean, and exam- Using a dial gauge, check the backlash of hypoid
ine them for wear, damage and other defects. Re- driven gear.
pair or replace the defective parts as necessary. Hypoid driven gear backlash:
1) Hypoid driven gear and drive pinion 0.10 — 0.15 mm (0.0039 — 0.0059 in)
• If abnormal tooth contact is evident, find out the
cause and adjust to give correct tooth contact. Re- If the hypoid driven gear backlash is not within the
place the gear if excessively worn or incapable of specification, adjust the side bearing preload or re-
adjustment. pair if necessary.
• 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 evi-
dent 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) Bearings DI-00099
Replace if seizure, peeling, wear, rust, dragging
during rotation, noise or other defect is evident. 3. TOOTH CONTACT BETWEEN HYPOID
4) Thrust washers of side gear and pinion mate DRIVEN GEAR AND DRIVE PINION
gear: Inspect the tooth contact between hypoid driven
Replace if seizure, flaw, abnormal wear or other gear and drive pinion. <Ref. to DI-55, ASSEMBLY,
defect is evident. Rear Differential (VA-type).>
5) Oil seal
Replace if deformed or damaged, and at every dis- 4. COMPANION FLANGE
assembling. 1) If rust or dirt is attached to the companion flange,
6) Differential carrier remove them.
Replace if the bearing bores are worn or damaged. 2) Set a dial gauge at a companion flange surface
7) Differential case (mating surface of propeller shaft and companion
Replace if its sliding surfaces are worn or cracked. flange), and then measure the companion flange
8) Companion flange runout.
Replace if the oil seal lip contacting surfaces have
flaws.
DI-70
DIFFERENTIALS
Limit of runout: 3. TOOTH CONTACT BETWEEN HYPOID

0.08 mm (0.003 in) DRIVEN GEAR AND DRIVE PINION
Adjust the tooth contact between hypoid driven
gear and drive pinion gear.
<Ref. to DI-55, ASSEMBLY, Rear Differential (VA-
type).>
DI-00360
3) Set the gauge inside of the companion flange,

and measure the runout.
Limit of runout:
0.08 mm (0.003 in)
DI-00361
4) If either runout exceeds the limit, move the

phase of companion flange and drive pinion 90$
each, and find the point that the runout is within the
limit.
5) If the runout exceeds the limit after changing the
phase, replace the companion flange and recheck
the runout.
6) If the runout exceeds the limit after replacing the
companion flange, the drive pinion may be assem-
bled incorrectly or bearing is faulty.
F: ADJUSTMENT
1. SIDE GEAR BACKLASH
Adjust the side gear backlash. (VA1-type)
type).>
Adjust hypoid driven gear backlash.
type).>
DI-71
Rear Differential Front Oil Seal
DIFFERENTIALS
6. Rear Differential Front Oil Tightening torque:

T-type:
Seal 49 N!m (5.0 kgf-m, 36.2 ft-lb)
A: INSPECTION VA1-type:
Make sure that there is no leakage from front oil 34 N!m (3.5 kgf-m, 25.3 ft-lb)
seal portion. If there is any leakage, replace the oil For VA2-type:
seal and inspect the propeller shaft. 29 N!m (3.0 kgf-m, 21.4 ft-lb)
6) Jack-up the rear wheel and support the body
B: REPLACEMENT with rigid racks.
1) Disconnect the ground cable from battery. 7) Remove the rear exhaust pipe and muffler.
2) Move the select lever or gear shift lever to neu- 8) Remove the propeller shaft. <Ref. to DS-10, RE-
tral. MOVAL, Propeller Shaft.>
3) Release the parking brake. 9) Remove the self-locking nut while holding the
4) Remove the oil drain plug, and drain gear oil. companion flange with ST.
• Except for VA2-type ST 498427200 FLANGE WRENCH
(A)
ST
(B)
DI-00356
DI-00194
(A) Filler plug 10) Extract the companion flange using ST.
(B) Drain plug ST 399703600 PULLER ASSY
• VA2-type ST
(A)
(B) DI-00196
11) Remove the oil seal using ST or screwdriver.

DI-00357
ST 398527700 PULLER ASSY
(A) Filler plug
(B) Drain plug
5) Install the oil drain plug.

NOTE:
• Apply liquid gasket to the oil drain plug for T-type.
• Use a new aluminum gasket for VA1-type.
• Use a new metal gasket for VA2-type. ST
Liquid gasket:
THREE BOND 1105 (Part No. 004403010) or DI-00197
equivalent
DI-72
Rear Differential Front Oil Seal
DIFFERENTIALS
12) Install a new oil seal with ST.

ST 498447120 OIL SEAL INSTALLER
ST
DI-00292
13) Install the companion flange.

NOTE:
Use a plastic hammer to install companion flange.
14) Tighten the self-locking nut within the specified
torque range so that the turning resistance of com-
panion flange becomes the same as that of before
oil seal replacement.
NOTE:
Use a new self-locking nut.
Tightening torque:
T-type:
181 N!m (18.5 kgf-m, 134 ft-lb)
VA-type:
191 N!m (19.5 kgf-m, 141 ft-lb)
ST
DI-00194
15) Hereafter, reassemble in the reverse order of

disassembly.
DI-73
Rear Differential Side Oil Seal
DIFFERENTIALS
7. Rear Differential Side Oil Seal

A: INSPECTION
Make sure that there is no leakage from side oil
seal. If there is any leakage, replace the oil seal.
B: REPLACEMENT
1) Remove the rear differential. <Ref. to DI-29, RE-
MOVAL, Rear Differential (T-type).> <Ref. to DI-46,
REMOVAL, Rear Differential (VA-type).>
2) Remove the rear differential side oil seal using a
screwdriver wrapped with vinyl tape to prevent the
side retainer from scratches.
3) Using the ST, install the oil seal to the side re-
tainer.
• T-type and VA2-type
ST 398437700 DRIFT
ST
DI-00209
• VA1-type
ST
DI-00221
4) Install the rear differential. <Ref. to DI-30, IN-

STALLATION, Rear Differential (T-type).> <Ref. to
DI-47, INSTALLATION, Rear Differential (VA-
type).>
DI-74
Rear Differential Front Member
DIFFERENTIALS
8. Rear Differential Front Mem-

ber
A: REMOVAL
3) Support the rear differential using transmission
jack, and then remove the rear differential front
member.
(A) DI-00293
(A) Rear differential front member
B: INSTALLATION
Install the rear differential front member with a new
self-locking nut.
Tightening torque:
T1: 52 N!m (5.3 kgf-m, 38 ft-lb)
T2: 110 N!m (11.2 kgf-m, 81 ft-lb)
T2
T1
DI-00294
C: INSPECTION
1) Check the rear differential front member for
damage, bend and corrosion.
If damage, bend or corrosion is excessive, replace
the rear differential front member.
2) Check the bushings of rear differential member
for cracking, hardening and damage.
If cracking, hardening or damage is excessive, re-
place rear differential front member.
DI-75
DIFFERENTIALS

A: INSPECTION
Symptom or trouble Possible cause Remedy
1. Oil leakage (1) Worn, scratched or incorrectly seated Correct or replace.
front or side oil seal. Scored, battered or
excessively worn sliding surface of com-
panion flange.
(2) Clogged or damaged air breather. Clean, repair or replace.
(3) Loose bolts on differential spindle or Tighten the bolts to specified torque.
side retainer, or incorrectly fitted O-ring. Replace the O-ring.
(4) Loose rear cover attaching bolts or Tighten the bolts to specified torque.
damaged gasket. Replace gasket and apply liquid gasket.
(5) Loose oil filler or drain plug. Retighten and apply liquid gasket.
(6) Wear, damage or incorrectly fitting for Correct or replace.
spindle, side retainer and oil seal.
2. Seizure (1) Insufficient backlash for hypoid gear. Readjust or replace.
NOTE: (2) Excessive preload for side, rear or Readjust or replace.
Seized or damaged parts should be re- front bearing.
placed, and also other parts should be
(3) Insufficient or improper oil used. Replace seized part and fill with specified
thoroughly checked for any defect and
oil to specified level.
should be repaired or replaced as re-
quired.
3. Damage (1) Improper backlash for hypoid gear. Replace.
NOTE: (2) Insufficient or excessive preload for Readjust or replace.
Damaged parts should be replaced, and side, rear or front bearing.
also other parts should be thoroughly
(3) Excessive backlash for differential Replace gear or thrust washer.
checked for any defect and should be re-
gear.
paired or replaced as required.
(4) Loose bolts and nuts such as hypoid Retightening.
driven gear bolt.
(5) Damage due to overloading. Replace.
4. Noises when starting or shifting (1) Excessive backlash for hypoid gear. Readjust.
gears (2) Excessive backlash for differential Replace gear or thrust washer.
NOTE: gear.
Noises may be caused by differential as-
(3) Insufficient preload for front or rear Readjust.
sembly, universal joint, wheel bearing,
bearing.
etc. Find out what is actually making noise
before disassembling. (4) Loose drive pinion nut. Tighten to specified torque.
(5) Loose bolts and nuts such as side Tighten to specified torque.
bearing retainer attaching bolt.
5. Noises when cornering (1) Damaged differential gear. Replace.
(2) Excessive wear or damage of thrust Replace.
washer.
(3) Broken pinion mate shaft. Replace.
(4) Seized or damaged side bearing. Replace.
DI-76
DIFFERENTIALS
Symptom or trouble Possible cause Remedy

6. Gear noise (1) Improper tooth contact of hypoid gear. Readjust or replace hypoid gear set.
NOTE: (2) Improper backlash for hypoid gear. Readjust.
Since noises from engine, muffler, trans-
(3) Scored or chipped teeth of hypoid Replace hypoid gear set.
mission, propeller shaft, wheel bearings,
gear.
tires, and body are sometimes mistaken
for noises from differential assembly, be (4) Seized hypoid gear. Replace hypoid gear set.
careful in checking them. Inspection (5) Improper preload for front or rear Readjust.
methods to locate noises include coast- bearings.
ing, accelerating, cruising, and jacking-up (6) Seized, scored or chipped front or Replace.
all four wheels. Perform these inspections rear bearing.
according to condition of trouble. When (7) Seized, scored or chipped side bear- Replace.
listening to noises, shift gears into four ing.
wheel drive and fourth speed position, try-
(8) Vibrating differential carrier. Replace.
ing to pick up only differential noise.
DI-77
DIFFERENTIALS
DI-78
CHASSIS SECTION
FRONT SUSPENSION FS
REAR SUSPENSION RS
DIFFERENTIALS DI
TRANSFER CASE TC
(DIAGNOSTICS)
BRAKE BR
PARKING BRAKE PB

(POWER STEERING)

approval.

TRANSFER CASE
TC
Page
2. Transfer Case and Extension Case Assembly............................................3
3. Transfer Clutch............................................................................................4
4. Extension Case ...........................................................................................5
5. Extension Case and Intermediate Case......................................................6
6. Oil Seal........................................................................................................7
7. Transfer Drive Gear ....................................................................................8
8. Transfer Driven Gear ..................................................................................9
9. Reduction Drive Gear................................................................................10
10. Center Differential Carrier .........................................................................11
11. Reduction Driven Gear..............................................................................12
12. Center Differential .....................................................................................13
13. Transfer Clutch Pressure Test ..................................................................14
General Description
TRANSFER CASE
A: NOTE
For general description, refer to “4AT”, “5AT” or
“5MT” section.
4AT model:
<Ref. to 4AT-2, General Description.>
5AT model:
<Ref. to 5AT-2, General Description.>
5MT model:
<Ref. to 5MT-2, General Description.>
TC-2
Transfer Case and Extension Case Assembly
TRANSFER CASE
2. Transfer Case and Extension

Case Assembly
A: NOTE
For removal, installation and inspection, refer to
“5MT” section. <Ref. to 5MT-44, Transfer Case and
Extension Case Assembly.>
TC-3
Transfer Clutch
TRANSFER CASE
3. Transfer Clutch
A: NOTE
“4AT” or “5AT” section.
4AT model:
<Ref. to 4AT-86, Transfer Clutch.>
5AT model:
<Ref. to 5AT-74, Transfer Clutch.>
TC-4
Extension Case
TRANSFER CASE
4. Extension Case
A: NOTE
“4AT” section. <Ref. to 4AT-82, Extension Case.>
TC-5
Extension Case and Intermediate Case
TRANSFER CASE
5. Extension Case and Interme-

diate Case
A: NOTE
“5AT” section. <Ref. to 5AT-72, Extension Case &
Intermediate Case.>
TC-6
Oil Seal
TRANSFER CASE
6. Oil Seal
A: NOTE
For replacement and inspection, refer to “4AT”,
“5AT” or “5MT” section.
4AT model:
<Ref. to 4AT-50, Extension Case Oil Seal.> <Ref.
to 4AT-51, Differential Side Retainer Oil Seal.>
5AT model:
<Ref. to 5AT-49, Extension Case Oil Seal.> <Ref.
to 5AT-50, Differential Side Retainer Oil Seal.>
5MT model:
<Ref. to 5MT-39, Oil Seal.> <Ref. to 5MT-40, Dif-
ferential Side Retainer Oil Seal.>
TC-7
Transfer Drive Gear
TRANSFER CASE
7. Transfer Drive Gear

A: NOTE
“5MT” section. <Ref. to 5MT-48, Transfer Drive
Gear.>
TC-8
Transfer Driven Gear
TRANSFER CASE
8. Transfer Driven Gear

A: NOTE
“5MT” section. <Ref. to 5MT-50, Transfer Driven
Gear.>
TC-9
Reduction Drive Gear
TRANSFER CASE
9. Reduction Drive Gear

A: NOTE
“4AT” section. <Ref. to 4AT-96, Reduction Drive
Gear.>
TC-10
Center Differential Carrier
TRANSFER CASE
10.Center Differential Carrier

A: NOTE
4AT model:
<Ref. to 4AT-98, Center Differential Carrier.>
5AT model:
<Ref. to 5AT-80, Center Differential Carrier.>
TC-11
Reduction Driven Gear
TRANSFER CASE
11.Reduction Driven Gear

A: NOTE
4AT model:
<Ref. to 4AT-94, Reduction Driven Gear.>
5AT model:
<Ref. to 5AT-78, Reduction Driven Gear.>
TC-12
Center Differential
TRANSFER CASE
12.Center Differential
A: NOTE
“5MT” section. <Ref. to 5MT-52, Center Differen-
tial.>
TC-13
Transfer Clutch Pressure Test
TRANSFER CASE
13.Transfer Clutch Pressure

Test
A: NOTE
For inspection, refer to “4AT” or “5AT” section.
4AT model:
<Ref. to 4AT-39, Transfer Clutch Pressure Test.>
5AT model:
<Ref. to 5AT-36, Transfer Clutch Pressure Test.>
TC-14
CHASSIS SECTION
FRONT SUSPENSION FS
REAR SUSPENSION RS
DIFFERENTIALS DI
TRANSFER CASE TC
(DIAGNOSTICS)
BRAKE BR
PARKING BRAKE PB

(POWER STEERING)

approval.

DRIVE SHAFT SYSTEM
DS
Page
2. Propeller Shaft ..........................................................................................10
3. Front Axle..................................................................................................13
4. Front Hub Unit Bearing .............................................................................17
5. Rear Hub Unit Bearing ..............................................................................19
6. Front Drive Shaft .......................................................................................22
7. Rear Drive Shaft........................................................................................26
General Description
DRIVE SHAFT SYSTEM
A: SPECIFICATION
1. PROPELLER SHAFT
Model 5MT 4AT 5AT
Propeller shaft type EDJ
Propeller shaft length: L mm (in) 1490 (58.66) 1430 (56.30) 1317 (51.85)
Front propeller shaft Joint-to-joint length: L1 mm (in) 735 (28.9) 675 (26.6) 562 (22.1)
Rear propeller shaft Joint-to-Joint length: L2 mm (in) 755 (29.7)
D1 63.5 (2.50)
Outer diameter of tube: mm (in)
D2 57.5 (2.26)
L1 L2
D1 D2
DS-00226
DS-2
General Description
DRIVE SHAFT SYSTEM
2. FRONT DRIVE SHAFT ASSEMBLY

Axle diameter ! D Axle length L
Model Type of drive shaft
mm (in) mm (in)
Turbo AT, 3.0 L EBJ87+PTJ82 32 (1.3) 349.6 (13.76)
Except turbo AT, 3.0 L EBJ87+PTJ82 26 (1.0) 349.6 (13.76)
(B)
(A)
DS-00227
(A) Axle diameter (B) Axle length
3. REAR DRIVE SHAFT ASSEMBLY

Axle diameter ! D Axle length L
Model Type of drive shaft
mm (in) mm (in)
2.0 L Non-turbo AT BJ75+DOJ75 22 (0.87) 366.5 (14.43)
Except 2.0 L Non-turbo AT EBJ82+DOJ79 22 (0.87) 375.1 (14.77)
(B)
(A)
DS-00228
(A) Axle diameter (B) Axle length
DS-3
General Description
DRIVE SHAFT SYSTEM
B: COMPONENT
1. PROPELLER SHAFT
(1)
(2)
(3)
(2)
T1
T2
(4)
T1
(5)
T1
DS-00229
(1) Propeller shaft (4) Rear differential (T-type) Tightening torque: N"m (kgf-m, ft-lb)
(2) Bushing (5) Rear differential (VA2-type) T1: 31 (3.2, 23.1)
(3) Rear differential (VA1-type) T2: 52 (5.3, 38.3)
DS-4
General Description
DRIVE SHAFT SYSTEM
2. FRONT AXLE
(1)
(2)
(3)
(4)
(5)
(6)
(8)
(10)
(9)
(7)
T2
(14)
(11)
T1
(12)
(13)
DS-00232
(1) Spring pin (7) Boot band (13) Front hub unit bearing
(2) Baffle plate (8) Boot (PTJ) (14) Axle nut
(3) Outer race (PTJ) (9) Boot (EBJ)
(4) Snap ring (10) EBJ shaft ASSY Tightening torque: N"m (kgf-m, ft-lb)
(5) Trunnion (11) Housing T1: 220 (22.4, 162)
(6) Circlip (12) Hub bolt T2: 65 (6.6, 47.9)
DS-5
General Description
DRIVE SHAFT SYSTEM
3. REAR AXLE
(1)
(2)
(3)
(5)
(6)
(7)
(8)
(8)
(10)
(4)
(9)
(8)
(11)
(12)
(13)
(14)
T2
T1
DS-00233
(1) Baffle plate (DOJ) (8) Boot band (12) Rear hub unit bearing
(2) Outer race (DOJ) (9) Boot (DOJ) (13) Hub bolt
(3) Snap ring (10) Boot (BJ) (14) Axle nut (olive color)
(4) Inner race (11) BJ shaft ASSY (2.0 L Non-turbo
(5) Ball AT model) Tightening torque: N"m (kgf-m, ft-lb)
(6) Cage EBJ shaft ASSY (Except 2.0 L T1: 65 (6.6, 47.9)
(7) Snap ring Non-turbo AT model) T2: 190 (19.4, 140)
DS-6
General Description
DRIVE SHAFT SYSTEM
C: CAUTION • Use SUBARU genuine grease etc. or the equiv-

• Wear work clothing, including a cap, protective alent. Do not mix grease, etc. with that of another
goggles, and protective shoes during operation. grade or from other manufacturers.
• Remove contamination including dirt and corro- • Be sure to tighten fasteners including bolts and
sion before removal, installation or disassembly. nuts to the specified torque.
• Keep the disassembled parts in order and pro- • Place shop jacks or rigid racks at the specified
tect them from dust and dirt. points.
• Before removal, installation or disassembly, be • Apply grease onto sliding or revolution surfaces
sure to clarify the failure. Avoid unnecessary re- before installation.
moval, installation, disassembly and replacement. • Before installing snap rings, apply sufficient
• Be careful not to burn yourself, because each amount of grease to avoid damage and deforma-
part on the vehicle is hot after running. tion.
• Before securing a part on a vise, place cushion-
or shop cloth between the part and the vise.
D: PREPARATION TOOL
1. SPECIAL TOOL
922431000 AXLE SHAFT • Used for installing axle shaft into housing.
INSTALLER • Used with ADAPTER (927390000).
ST-922431000
925091000 BAND TIGHTENING Used for tightening boot band.
TOOL (A) Jig for band
(A) (B) Ratchet wrench
(B)
ST-925091000
926470000 AXLE SHAFT Used for removing axle shaft.
PULLER
ST-926470000
DS-7
General Description
DRIVE SHAFT SYSTEM

18675AA000 DIFFERENTIAL Used for installing differential side retainer oil
SIDE OIL SEAL seal.
INSTALLER
ST18675AA000
927080000 HUB STAND Used for assembling hub bolt in hub.
ST-927080000
927140000 AXLE SHAFT Same as plate 2 included in AXLE SHAFT
PULLER PLATE PULLER (926470000).
ST-927140000
28099PA090 OIL SEAL PROTEC- • Used for installing rear drive shaft into rear dif-
TOR ferential.
• For protecting oil seal.
ST28099PA090
DS-8
General Description
DRIVE SHAFT SYSTEM

28399SA010 OIL SEAL PROTEC- • Used for installing front drive shaft into front
TOR differential.
• For protecting oil seal.
ST28399SA010
28399AG000 HUB STAND Used for extracting hub bolt.
(New adopted tool)
ST28399AG000
2. GENERAL TOOL
DESCRIPTION REMARKS
Puller Used for removing ball joint from knuckle arm.
Dial gauge Used for inspecting propeller shaft run-out.
Extension cap Used for preventing leak of gear oil or ATF.
Bar Used for extracting drive shaft.
DS-9
Propeller Shaft
DRIVE SHAFT SYSTEM
2. Propeller Shaft 8) Make matching marks on the flange yoke and

rear differential before removal.
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
(A)
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.
DS-00028
(A) Alignment mark
9) Remove the three bolts which hold propeller

shaft to rear differential.
10) Remove the remaining bolt.
11) Remove the two bolts which hold center bear-
ing to vehicle body.
DS-00239

2) Shift the select lever or gear shift lever to neutral.
5) Remove the center exhaust pipe.
7) Remove the heat shield cover. DS-00141
12) Remove the propeller shaft from transmission.

CAUTION:
• Be careful not to damage oil seals and fric-
tional surface of sleeve yoke.
• Cover the center exhaust pipe with a cloth to
(A) keep off any ATF or oil spilled from transmis-
sion when removing propeller shaft.
NOTE:
DS-00230
Use a container to catch ATF or oil flowing from
propeller shaft.
(A) Heat shield cover
DS-00030
13) Install the extension cap to transmission.
DS-10
Propeller Shaft
DRIVE SHAFT SYSTEM
NOTE: 7) Connect the battery ground cable to battery.

If extension cap is not available, place vinyl bag C: INSPECTION
over opening and fasten with string to prevent gear
oil or ATF from leaking. NOTE:
Do not disassemble propeller shaft. Check the fol-
lowing and replace if necessary.
(A)
• Tube surface for dents of cracks
• Splines for deformation or abnormal wear
• Joints for non-smooth operation or abnormal
noise
• Center bearing for free play, noise or non-
smooth operation.
• Oil seals for abnormal wear or damage
• Center bearing for breakage
DS-00031 Check the following points with propeller shaft in-
stalled in vehicle.
(A) Extension cap
1. JOINTS AND CONNECTIONS
B: INSTALLATION 1) Remove the center exhaust pipe.
1) Insert the sleeve yoke into the transmission and 2) Remove the heat shield cover.
attach center bearing to body. 3) Check for any looseness of the yoke flange
Tightening torque: mounting bolts which connect to rear differential
52 N"m (5.3 kgf-m, 38.3 ft-lb) and center bearing bracket mounting bolts.
2. SPLINES AND BEARING
1) Remove the center exhaust pipe.
4) Turn the propeller shaft by hand to see if abnor-
mal free play exists at splines. Also move yokes to
see if abnormal free play exists at spiders and
bearings.
DS-00141
2) Align the matching marks and connect the flange

yoke and rear differential.
Tightening torque:
31 N"m (3.2 kgf-m, 23.1 ft-lb)
DS-00035
3. RUNOUT OF PROPELLER SHAFT

(A) 1) Remove the center exhaust pipe.
4) Set the dial gauge with its indicator stem at cen-
DS-00028 ter of propeller shaft tube.
5) Turn the propeller shaft slowly by hands to check
(A) Alignment mark for “runout” of propeller shaft.
3) Install the heat shield cover.
4) Install the center exhaust pipe.
5) Install the rear exhaust pipe and muffler.
6) Lower the vehicle.
DS-11
Propeller Shaft
DRIVE SHAFT SYSTEM
Runout:
Service limit 0.6 mm (0.024 in)
(A)
(B)
DS-00036
(A) Propeller shaft

(B) Dial gauge
4. CENTER BEARING FREE PLAY

1) Remove the front and center exhaust pipe.
4) Move the propeller shaft near center bearing up
and down, and left and right with your hand to
check for any abnormal bearing free play.
DS-00037
DS-12
Front Axle
DRIVE SHAFT SYSTEM
3. Front Axle 8) Remove the cotter pin and castle nut which se-
cure tie-rod end to housing knuckle arm.
A: REMOVAL
(A)
2) Lift-up the vehicle and remove the front wheels.
3) Unlock the axle nut.
(B)
(C)
DS-00042
(A) Cotter pin

(B) Castle nut
DS-00038 (C) Tie-rod
4) Remove the axle nut using a socket wrench 9) Using a puller, remove the tie-rod ball joint from
while depressing the brake pedal. knuckle arm.
CAUTION:
Remove the wheel before loosening the axle
nut. Failure to follow this rule may damage the
wheel bearings.
DS-00043
10) Remove the ABS wheel speed sensor assem-

bly and harness.
DS-00143
6) Remove the disc brake caliper from housing,

and suspend it from strut using a wire.
7) Remove the disc rotor from hub.
NOTE:
If the disc rotor seizes up within hub, drive disc rotor
out by installing an 8-mm bolt in screw hole on ro-
tor. DS-00249
11) Remove the bolts which secure sensor harness

to strut.
DS-00041
DS-00144
DS-13
Front Axle
DRIVE SHAFT SYSTEM
12) Remove the front arm ball joint from housing. 3) Install the front arm ball joint to housing.
Tightening torque:
49 N"m (5.0 kgf-m, 36 ft-lb)
4) Install the ABS wheel speed sensor harness to
strut.
5) Install the ABS wheel speed sensor on housing.
Tightening torque:
32 N"m (3.3 kgf-m, 23.9 ft-lb)
6) Install the disc rotor on hub.
DS-00045
7) Install the disc brake caliper on housing.
13) Remove the PTJ from transmission. Tightening torque:
14) Remove the front drive shaft assembly from 78 N"m (8.0 kgf-m, 57.9 ft-lb)
hub. If it is hard to remove, use STs. 8) Install the stabilizer link.
ST1 926470000 AXLE SHAFT PULLER 9) Connect the tie-rod end ball joint to the knuckle
ST2 927140000 AXLE SHAFT PULLER arm with a castle nut.
PLATE Tightening torque:
27.0 N"m (2.75 kgf-m, 19.9 ft-lb)
CAUTION:
When connecting, do not hit the cap at bottom
of tie-rod end with hammer.
10) Tighten the castle nut to specified torque and
ST1
tighten further within 60# until the pin hole is aligned
with the slot in nut. Bend the cotter pin to lock.
ST2
(A)
DS-00145
15) After scribing an alignment mark on camber ad-

(B)
justing bolt head, remove the bolts which connect
housing and strut, and disconnect the housing from
strut.
(C)
DS-00042
(A) Cotter pin

(B) Castle nut
(C) Tie-rod
11) While depressing the brake pedal, tighten a

new axle nut (olive color) to specified torque and
DS-00046
lock it securely.
B: INSTALLATION Tightening torque:
1) While aligning the alignment mark on the cam- 220 N"m (22.4 kgf-m, 162 ft-lb)
ber adjusting bolt head, tighten the housing and
strut using a new self-locking nut. CAUTION:
• Install the wheel after installation of axle nut.
Tightening torque: Failure to follow this rule may damage the
177 N"m (18.0 kgf-m, 130 ft-lb) wheel bearing.
2) Install the front drive shaft. <Ref. to DS-22, IN- • Be sure to tighten the axle nut to specified
STALLATION, Front Drive Shaft.> torque. Do not overtighten it as this may dam-
age wheel bearing.
DS-14
Front Axle
DRIVE SHAFT SYSTEM
12) After tightening the axle nut, lock it securely. D: ASSEMBLY

1) Assemble the front hub unit bearing. <Ref. to
DS-18, ASSEMBLY, Front Hub Unit Bearing.>
2) Place the disc cover between housing and front
hub unit, and tighten the four bolts.
Tightening torque:
65 N"m (6.6 kgf-m, 47.9 ft-lb)
DS-00048
(A)
13) Install the wheel and tighten the wheel nuts to
specified torque.
Tightening torque:
90 N"m (9.2 kgf-m, 66 ft-lb)
C: DISASSEMBLY
DS-00231
1) Remove the four bolts from housing, and re-
move the front hub unit bearing and disc cover. (A) Housing
CAUTION:
• Do not get closer the tool which charged
(A) magnetism to magnetic encorder.
• Be careful not to damage the magnetic en-
coder.
(2)
(1)
DS-00231
(A) Housing
CAUTION:
magnetism to magnetic encorder.
DS-00250
coder. (1) Magnetic encoder
(2) Front hub unit bearing
(2)
(1) E: INSPECTION
1) Moving the front tire up and down by hand,
check there is no backlash in bearing, and check
the wheel rotates smoothly.
DS-00250
(1) Magnetic encoder

(2) Front hub unit bearing
2) Disassemble the front hub unit bearing. <Ref. to

DS-18, DISASSEMBLY, Front Hub Unit Bearing.>
DS-00061
DS-15
Front Axle
DRIVE SHAFT SYSTEM
2) Inspect the lean of axis direction using a dial

gauge. Replace the bearing if the load range ex-
ceeds the limitation.
Service limit:
Maximum: 0.05 mm (0.0020 in)
DS-00062
DS-16
Front Hub Unit Bearing
DRIVE SHAFT SYSTEM
4. Front Hub Unit Bearing CAUTION:

A: REMOVAL magnetism to magnetic encorder.
1) Disconnect the ground cable from battery. • Be careful not to damage the magnetic en-
2) Lift-up the vehicle and remove the front wheels. coder.
(2)
(1)
DS-00250
DS-00038
4) Remove the axle nut using a socket wrench (1) Magnetic encoder
while depressing the brake pedal. (2) Front hub unit bearing
CAUTION: 8) Remove the front hub unit bearing. If it is hard to

Remove the wheel before loosening the axle remove, use STs.
nut. Failure to follow this rule may damage the ST1 926470000 AXLE SHAFT PULLER
wheel bearings. ST2 927140000 AXLE SHAFT PULLER
5) Remove the disc brake caliper from housing, PLATE
and suspend it from strut using a wire.
NOTE:
If the disc rotor seizes up within hub, drive disc rotor
out by installing an 8-mm bolt in screw hole on ro-
tor. ST1
ST2
DS-00145
B: INSTALLATION
1) Place the disc cover between housing and front
hub unit, and tighten the four bolts.
Tightening torque:
65 N"m (6.6 kgf-m, 47.9 ft-lb)
DS-00041
7) Remove four bolts from housing.
(A)
(A)
DS-00231
DS-00231 (A) Housing
(A) Housing
DS-17
Front Hub Unit Bearing
DRIVE SHAFT SYSTEM
2) Install the front drive shaft. <Ref. to DS-22, IN- NOTE:

STALLATION, Front Drive Shaft.> Since the hub unit bearing can not be disassem-
3) Tighten the axle nut temporarily. bled, only hub bolts can be removed.
5) Install the disc brake caliper on the housing. (1)
Tightening torque:
78 N"m (8.0 kgf-m, 57.9 ft-lb)
6) While depressing the brake pedal, tighten a new
axle nut (olive color) to specified torque and lock it
securely. ST
Tightening torque:
220 N"m (22.4 kgf-m, 162 ft-lb)
DS-00252
CAUTION:
• Install the wheel after installation of the axle (1) Front hub unit bearing
wheel bearing. D: ASSEMBLY
• Be sure to tighten the axle nut to specified 1) Attach the hub to ST securely.
torque. Do not overtighten it as this may dam- ST 927080000 HUB STAND
age wheel bearing.
7) After tightening the axle nut, lock it securely. (1)
ST
DS-00253
DS-00048 (1) Front hub unit bearing

8) Install the wheel and tighten the wheel nuts to 2) Using a press, press new hub bolts until their
specified torque. seating surfaces contact the hub.
Tightening torque: NOTE:
90 N"m (9.2 kgf-m, 66 ft-lb) Use 12 mm (0.47 in) dia. holes in HUB STAND to
C: DISASSEMBLY prevent bolts from tilting.
Using the ST and a hydraulic press, drive hub bolts E: INSPECTION
out. Refer to “FRONT AXLE” for inspection procedures.
ST 28399AG000 HUB STAND <Ref. to DS-15, INSPECTION, Front Axle.>
CAUTION: CAUTION:
• Be careful not to hammer the hub bolts. This If there is any fault in the bearing, replace hub
may deform the hub. unit bearing.
• Do not reuse the hub bolt.
DS-18
Rear Hub Unit Bearing
DRIVE SHAFT SYSTEM
5. Rear Hub Unit Bearing • If the disc rotor seizes up within hub, drive the
disc rotor out by installing an 8-mm bolt in screw
A: REMOVAL hole on rotor.
1) Disconnect the ground cable from battery. 9) Remove the four bolts from rear arm.
wheels.
DS-00149
10) Remove the hub unit bearing.

DS-00038 CAUTION:
4) While applying the parking brake, remove the
coder.
axle nut using the socket wrench.
CAUTION: magnetism to magnetic encorder.
nut. Failure to follow this rule may damage the (2)
wheel bearings.
(1)
6) Remove the rear ABS wheel speed sensor.
DS-00251

(2) Rear hub unit bearing
DS-00147
7) Remove the disc brake caliper from back plate,

and suspend it from stabilizer using wire.
DS-00150
DS-00148

NOTE:
• Mark the mating surface of hub and disc rotor be-
fore removing the disc rotor to avoid confusing
when installing.
DS-19
DRIVE SHAFT SYSTEM
NOTE: 2) Tighten the four bolts to the back plate.

If it is hard to remove, use STs. Tightening torque:
ST1 926470000 AXLE SHAFT PULLER 65 N"m (6.6 kgf-m, 47.9 ft-lb)
ST2 927140000 AXLE SHAFT PULLER
PLATE
ST1
ST2
DS-00149
DS-00122
3) Remove the axle nut.
4) Draw the rear drive shaft into specified position.
B: INSTALLATION 5) Tighten the new axle nut temporarily.
1) Aligning the hub unit bearing to the mounting
CAUTION:
hole of the back plate, install the hub unit assembly
Use a new axle nut (olive color).
and back plate. Tighten the axle nut temporarily.
CAUTION: 7) Install the disc brake caliper on back plate.
coder. Tightening torque:
• Do not get closer the tool which charged 52 N"m (5.3 kgf-m, 38.3 ft-lb)
(2)
(1)
DS-00152
DS-00251
8) Install the rear ABS wheel speed sensor and
brake cable bracket.
DS-00147
9) Adjust the parking brake lever stroke by turning

DS-00151 adjuster. <Ref. to PB-5, ADJUSTMENT, Parking
Brake Lever.>
DS-20
DRIVE SHAFT SYSTEM
10) While applying the parking brake and depress- D: ASSEMBLY

ing the brake pedal, tighten a new axle nut (olive 1) Attach the hub to ST securely.
color) to the specified torque and lock it securely. ST 927080000 HUB STAND
Tightening torque:
190 N"m (19.4 kgf-m, 140 ft-lb)
(1)
CAUTION:
• Install the wheel after installation of the axle
wheel bearing.
• Be sure to tighten the axle nut to specified
torque. Do not overtighten it as this may dam- ST
age wheel bearing.
11) After tightening the axle nut, lock it securely. DS-00255
2) Using a press, press the new 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.
E: INSPECTION
DS-00048 1) Moving the rear tire up and down by hand, check
there is no backlash in bearing, and check the
12) Install the wheel and tighten the wheel nuts to wheel rotates smoothly.
specified torque.
Tightening torque:
90 N"m (9.2 kgf-m, 66 ft-lb)
C: DISASSEMBLY
Using the ST and a hydraulic press, drive hub bolts
out.
ST 28399AG000 HUB STAND
CAUTION:
• Be careful not to hammer the hub bolts. This
may deform the hub. DS-00183
• Do not reuse the hub bolt. 2) Inspect the lean of axis direction using a dial
NOTE: gauge. Replace the hub bearing if the lean range
Since the hub unit bearing can not be disassem- exceed the limitation.
bled, only hub bolts can be removed. Service limit:
Maximum: 0.05 mm (0.0020 in)
(1)
ST
DS-00254
DS-00062
DS-21
Front Drive Shaft
DRIVE SHAFT SYSTEM
6. Front Drive Shaft NOTE:

After pulling out the drive shaft, be sure to replace
A: REMOVAL with a new oil seal.
3) Unlock the axle nut. ST
MT-00103
2) Insert the EBJ into hub splines.

DS-00038
3) Draw the drive shaft into specified position.
4) Remove the axle nut using a socket wrench CAUTION:
while depressing the brake pedal. Do not hammer drive shaft when installing it.
4) Tighten the axle nut temporarily.
CAUTION:
5) Using the ST, install the front drive shaft to trans-
mission.
wheel bearings. ST 28399SA010 OIL SEAL PROTECTOR
5) Remove the stabilizer link from front arm.
6) Disconnect the front arm from housing.
7) Remove the front drive shaft assembly. If it is
hard to remove, use ST1 and ST2.
PLATE
ST
AT-00110
6) Connect the front arm to housing.

Tightening torque:
ST1
49 N"m (5.0 kgf-m, 36 ft-lb)
CAUTION:
ST2
Be sure to use a new self-locking nut.
DS-00145 7) Install the stabilizer bracket.
8) While depressing the brake pedal, tighten a new
8) Using a bar, remove the front drive shaft from axle nut (olive color) to the specified torque and
transmission. lock it securely.
CAUTION:
Tightening torque:
Be careful not to allow the bar to damage holder
220 N"m (22.4 kgf-m, 162 ft-lb)
area.
CAUTION:
B: INSTALLATION • Install the wheel after installation of the axle
1) Using the ST, replace the differential side retain- nut. Failure to follow this rule may damage the
er oil seal with a new one. wheel bearing.
ST 18675AA000 DIFFERENTIAL SIDE OIL • Be sure to tighten axle nut to specified
SEAL INSTALLER torque. Do not overtighten it as this may dam-
age wheel bearing.
9) After tightening axle nut, lock it securely.
DS-22
Front Drive Shaft
DRIVE SHAFT SYSTEM
C: DISASSEMBLY 6) Place alignment marks on the roller kit and trun-

1) Place alignment marks on the shaft and outer nion.
race.
DS-00106
2) Remove the PTJ boot band and boot.

CAUTION:
Be careful not to damage boot.
DS-00109
7) Remove the roller kit from trunnion.

CAUTION:
Be careful with the roller kit position.
DS-00107
8) Place alignment marks on the trunnion and
3) Remove the snap ring from PTJ outer race. shaft.
DS-00108 DS-00110
4) Remove the PTJ outer race from shaft assem- 9) Remove the snap ring and trunnion.
bly.
5) Wipe off grease.
CAUTION:
The grease is a special grease. Do not confuse
with other greases.
DS-00111
CAUTION:
Be sure to wrap shaft splines with vinyl tape to
prevent boot from scratches.
DS-23
Front Drive Shaft
DRIVE SHAFT SYSTEM
10) Remove the PTJ boot. 7) Align alignment marks on the shaft and outer
NOTE: race, and install outer race.
Further disassembly of axle is impossible because
the BJ cannot be disassembled.
D: ASSEMBLY
1) Place the PTJ boot at the center of shaft.
2) Align alignment marks and install the trunnion on
the shaft.
DS-00106
8) Install the snap ring in the groove on PTJ outer

race.
CAUTION:
Pull the shaft lightly and assure that the snap
ring is completely fitted in the groove.
DS-00110 9) Apply an even coat of the specified grease 30 to
40 g (1.06 to 1.41 oz.) to the entire inner surface of
3) Install the snap ring to shaft.
boot.
CAUTION: 10) Install the PTJ boot taking care not to twist it.
Confirm that the snap ring is completely fitted
in shaft groove. CAUTION:
• The large end of PTJ boot and the boot
4) Fill 100 to 110 g (3.53 to 3.88 oz.) of specified groove shall be cleaned completely so as to be
grease into the interior of PTJ outer race. free from grease and other substances.
5) Apply a thin coat of specified grease to the roller • When installing PTJ boot, position outer race
kit and trunnion. of PTJ at center of its travel.
6) Align alignment marks on roller kit and trunnion
11) Put a new band through the clip and wind twice
and install the roller kit.
in alignment with band groove of boot.
CAUTION: 12) Pinch the end of band with pliers. Hold the clip
Be careful with the roller kit position. and tighten securely.
NOTE:
When tightening boot, use care so that the air with-
in the boot is appropriate.
13) Tighten the band using ST.
ST 925091000 BAND TIGHTENING TOOL
NOTE:
Tighten the band until it cannot be moved by hand.
DS-00132
DS-00109
DS-24
Front Drive Shaft
DRIVE SHAFT SYSTEM
14) 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.
DS-00133
15) Cut off the band with an allowance of about 10

mm (0.39 in) left from the clip and bend this allow-
ance over the clip.
CAUTION:
Be careful so that the end of the band is in close
contact with clip.
16) Extend and retract the PTJ to provide equal
grease coating.
E: INSPECTION
Check the removed parts for damage, wear, corro-
sion etc. If faulty, repair or replace.
• PTJ (pillow tripod joint)
Check for seizure, corrosion, damage, wear and
excessive play.
• EBJ (high-efficiency compact ball fixed joint)
Check for seizure, corrosion, damage and exces-
sive play.
• Shaft
Check for excessive bending, twisting, damage
and wear.
• Boot
Check for wear, warping, breakage and scratches.
• Grease
Check for discoloration and fluidity.
DS-25
Rear Drive Shaft
DRIVE SHAFT SYSTEM
7. Rear Drive Shaft B: INSTALLATION

1) Insert the BJ or EBJ into rear hub splines.
A: REMOVAL
1) Disconnect the ground cable from battery. CAUTION:
2) Lift-up the vehicle, and then remove the rear • Be careful not to damage the magnetic en-
wheels. coder.
3) Unlock the axle nut. • Do not get closer the tool which charged
(2)
(1)
DS-00038
DS-00251
4) While applying the parking brake, remove the
axle nut using the socket wrench. (1) Magnetic encoder
CAUTION: (2) Rear hub unit bearing
nut. Failure to follow this rule may damage the 2) Draw the rear drive shaft into specified position.
wheel bearings. CAUTION:
5) Remove the rear differential assembly. Do not hammer drive shaft when installing it.
• T-type 3) Tighten the axle nut temporarily.
<Ref. to DI-29, REMOVAL, Rear Differential (T- 4) Install the rear differential assembly.
type).> • T-type
• VA-type <Ref. to DI-30, INSTALLATION, Rear Differential
<Ref. to DI-46, REMOVAL, Rear Differential (VA- (T-type).>
type).> • VA-type
6) Remove the axle nut and rear drive shaft. If it is <Ref. to DI-47, INSTALLATION, Rear Differential
hard to remove, use ST1 and ST2. (VA-type).>
ST1 926470000 AXLE SHAFT PULLER 5) While applying the parking brake and depress-
ST2 927140000 AXLE SHAFT PULLER ing the brake pedal, tighten a new axle nut (olive
PLATE color) to specified torque and lock it securely.
CAUTION: Tightening torque:
• Do not hammer drive shaft when removing. 190 N"m (19.4 kgf-m, 140 ft-lb)
• Do not damage the oil seal and magnetic en- CAUTION:
coder. • Install the wheel after installation of the axle
wheel bearing.
• Be sure to tighten the axle nut to specified
ST1
ST2 torque. Do not overtighten it as this may dam-
age wheel bearing.
DS-00122
DS-26
Rear Drive Shaft
DRIVE SHAFT SYSTEM
6) Lock the axle nut securely. 7) Wipe off the grease and take out balls.
CAUTION:
The grease is a special grease (grease for con-
stant velocity joint). Do not confuse with other
greases.
NOTE:
Disassemble exercising care not to lose balls (6
pcs).
DS-00048
(A)
7) Install the wheel. (B)
Tightening torque:
90 N"m (9.2 kgf-m, 66 ft-lb)
C: DISASSEMBLY
1) Straighten the bent claw of larger end of DOJ
boot. DS-00126
2) Loosen the band by means of screwdriver or pli-
ers. (A) Outer race
CAUTION: (B) Grease
Be careful not to damage boot.
8) To remove the cage from inner race, turn the
cage by a half pitch to the track groove of inner race
and shift the cage.
9) Remove the snap ring, which fixes inner race to
shaft, using pliers.
10) Take out the DOJ inner race.
11) Take off the DOJ cage from shaft and remove
DOJ boot.
CAUTION:
Be sure to wrap shaft splines with vinyl tape to
DS-00124 prevent boot from scratches.
3) Remove the boot band on the small end of DOJ 12) Remove the BJ boot or EBJ boot in the same
boot in the same manner. procedure as DOJ boot.
4) Remove the larger end of DOJ boot from DOJ NOTE:
outer race. Further disassembly of axle is impossible because
5) Pry and remove the round circlip located at the the BJ and EBJ cannot be disassembled.
neck of DOJ outer race with a screwdriver.
D: ASSEMBLY
NOTE:
Use specified grease.
BJ side:
NTG2218-M (Part No. 28395AG010)
EBJ side:
NTG2218-M (Part No. 28395AG000)
DOJ side:
DS-00125 NKG205 (Part No. 28495AG000)
6) Take out the DOJ outer race from shaft assem- 1) Install the BJ or EBJ boot in specified position,
bly. and fill it with 60 to 70 g (2.12 to 2.47 oz.) of speci-
fied grease.
DS-27
Rear Drive Shaft
DRIVE SHAFT SYSTEM
2) Place the DOJ boot at the center of shaft. 5) Install the cage to inner race fixed upon shaft.
CAUTION: NOTE:
Be sure to wrap shaft splines with vinyl tape to Fit the cage with the protruded part aligned with the
prevent boot from scratches. track on the inner race and then turn by a half pitch.
3) Insert the DOJ cage onto shaft.
NOTE: (B)
(A)
Insert the cage with the cut-out portion facing the
shaft end, since the cage has an orientation.
(A)
DS-00129
(A) Inner race

(B) Cage
(B)
DS-00127 6) Fill 80 to 90 g (2.82 to 3.17 oz.) of specified
grease into the interior of DOJ outer race.
(A) Cage 7) Apply a coat of specified grease to the cage
(B) Cutout pocket and six balls.
8) Insert six balls into the cage pocket.
4) Install the DOJ inner race on shaft and fit the
9) Align the outer race track and ball positions, and
snap ring with pliers.
place the shaft, inner race, cage and balls in the
NOTE: original positions and then fit outer race.
Confirm that the snap ring is completely fitted in the
shaft groove.
(A)
(B)
DS-00126
DS-00128 (A) Outer race

(B) Grease
10) Install the snap ring in the groove on DOJ outer

race.
NOTE:
• Assure that the balls, cage and inner race are
completely fitted in the outer race of DOJ.
• Use care not to place the matched position of
snap ring in the ball groove of outer race.
DS-28
Rear Drive Shaft
DRIVE SHAFT SYSTEM
• Pull the shaft lightly and assure that the circlip is 16) Tap on the clip with the punch provided at the
completely fitted in the groove. end of ST.
NOTE:
Tap to an extent that the boot underneath is not
damaged.
DS-00125
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. DS-00133
NOTE: 17) Cut off the band with an allowance of about 10

• The inside of the larger end of DOJ boot and the mm (0.39 in) left from the clip and bend this allow-
boot groove shall be cleaned so as to be free from ance over the clip.
grease and other substances. NOTE:
• When installing DOJ boot, position outer race of Be careful so that the end of the band is in close
DOJ at center of its travel. contact with clip.
13) Put a new band through the clip and wind twice 18) Install the BJ boot or EBJ boot in the same pro-
in alignment with band groove of boot. cedure as DOJ boot.
14) Pinch the end of band with pliers. Hold the clip 19) Extend and retract the DOJ to provide equal
and tighten securely. grease coating.
NOTE:
When tightening boot, exercise care so that the air
E: INSPECTION
within the boot is appropriate. Check the removed parts for damage, wear, corro-
sion etc. Repair or replace if defective.
15) Tighten the band by using ST. • DOJ (Double Offset Joint)
ST 925091000 BAND TIGHTENING TOOL Check for seizure, corrosion, damage, wear and
NOTE: excessive play.
Tighten the band until it cannot be moved by hand. • EBJ (high-efficiency compact ball fixed joint)
Check for seizure, corrosion, damage, wear and
excessive play.
• Shaft
Check for excessive bending, twisting, damage
and wear.
• BJ (Bell Joint)
Check for seizure, corrosion, damage and exces-
sive play.
• Boot
Check for wear, warping, breakage and scratches.
DS-00132 • Grease
Check for discoloration and fluidity.
DS-29
DRIVE SHAFT SYSTEM

A: INSPECTION
NOTE:
Vibration while cruising may be caused by an unbalanced tire, improper tire inflation pressure, improper
wheel alignment, etc.
Noise or vibration from propeller shaft Center bearing Check the center bearing. <Ref. to DS-12, CEN-
TER BEARING FREE PLAY, INSPECTION,
Propeller Shaft.>
Runout of propeller shaft Check the vibration of propeller shaft. <Ref. to
DS-11, RUNOUT OF PROPELLER SHAFT,
INSPECTION, Propeller Shaft.>
Loose or free play of connection Check joint and connector. <Ref. to DS-11,
JOINTS AND CONNECTIONS, INSPECTION,
Propeller Shaft.>
Check splines and bearing. <Ref. to DS-11,
SPLINES AND BEARING, INSPECTION, Pro-
peller Shaft.>
Abnormal wheel vibration Wheel is out of balance. Check the wheel balance. <Ref. to WT-7,
ADJUSTMENT, Wheel Balancing.>
Front wheel alignment Check the front wheel alignment. <Ref. to FS-8,
INSPECTION, Wheel Alignment.>
Rear wheel alignment Check the rear wheel alignment. <Ref. to RS-8,
Front strut Check the front strut. <Ref. to FS-24, INSPEC-
TION, Front Strut.>
Rear shock absorber Check the rear shock absorber. <Ref. to RS-16,
INSPECTION, Rear Shock Absorber.>
Front drive shaft Check the front drive shaft. <Ref. to DS-25,
INSPECTION, Front Drive Shaft.>
Rear drive shaft Check the rear drive shaft. <Ref. to DS-29,
INSPECTION, Rear Drive Shaft.>
Front hub unit bearing Check the front hub unit bearing. <Ref. to DS-18,
INSPECTION, Front Hub Unit Bearing.>
Rear hub unit bearing Check the rear hub unit bearing. <Ref. to DS-21,
INSPECTION, Rear Hub Unit Bearing.>
Noise from the underbody Wheel is out of balance. Check the wheel balance. <Ref. to WT-7,
ADJUSTMENT, Wheel Balancing.>
Front wheel alignment Check the front wheel alignment. <Ref. to FS-8,
Rear wheel alignment Check the rear wheel alignment. <Ref. to RS-8,
Front strut Check the front strut. <Ref. to FS-24, INSPEC-
TION, Front Strut.>
Rear shock absorber Check the rear shock absorber. <Ref. to RS-16,
INSPECTION, Rear Shock Absorber.>
DS-30
CHASSIS SECTION
FRONT SUSPENSION FS
REAR SUSPENSION RS
DIFFERENTIALS DI
TRANSFER CASE TC
(DIAGNOSTICS)
BRAKE BR
PARKING BRAKE PB

(POWER STEERING)

approval.

ABS
ABS
Page
2. ABS Control Module and Hydraulic Control Unit (ABSCM&H/U)....................................................... 6
3. ABS Sequence Control .............................................................................10
4. Front ABS Wheel Speed Sensor...............................................................13
5. Rear ABS Wheel Speed Sensor ...............................................................15
6. Front Magnetic Encoder............................................................................16
7. Rear Magnetic Encoder ............................................................................17
8. G Sensor ...................................................................................................18
General Description
ABS
A: SPECIFICATION
Item Standard value or identification
ABS wheel speed sensor gap (for refer- Front 0.77 — 1.43 mm (0.030 — 0.056 in)
ence) Rear 0.64 — 1.56 mm (0.025 — 0.061 in)
RH K1 (White)
ABS wheel speed sensor Front
LH K2 (Yellow)
Marks of harness (Marks, Color)
RH K5 (White)
Rear
LH K6 (Yellow)
G sensor G sensor voltage 2.3!0.2 V
AT (Except for OUTBACK) J1
ABSCM&H/U identifica- MT (Except for OUTBACK) J2
tion AT (OUTBACK) J3
MT (OUTBACK) J4
ABS-2
General Description
ABS
B: COMPONENT
1. ABS WHEEL SPEED SENSOR
T1
T1
(1) T2
(4)
T2
(6)
(5)
T1
(3)
(2)
T2
ABS00380
(1) G sensor (4) Rear ABS wheel speed sensor LH Tightening torque: N"m (kgf-m, ft-lb)
(2) Front ABS wheel speed sensor LH (5) Hub unit bearing T1: 7.5 (0.76, 5.5)
(3) Front housing (6) Magnetic encoder T2: 33 (3.3, 24)
ABS-3
General Description
ABS
2. ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U)

(5)
(4)
(3)
(2) (7)
(6)
(1)
T2
(9)
(8)
(10) T1
(11)
T2
T2
ABS00381
(1) ABS control module and hydraulic (6) Primary inlet (11) Bracket
control unit (ABSCM&H/U) (7) Secondary inlet
(2) Front outlet RH (8) Damper Tightening torque: N"m (kgf-m, ft-lb)
(3) Rear outlet LH (9) Spacer T1: 7.5 (0.76, 5.5)
(4) Rear outlet RH (10) Damper T2: 33 (3.3, 24)
(5) Front outlet LH
C: CAUTION
goggles and protective shoes during operation.
• Before disconnecting electrical connectors of
sensors or units, be sure to disconnect the ground
cable from battery.
• Be careful not to burn yourself, because each
part on the vehicle is hot after running.
points.
ABS-4
General Description
ABS
D: PREPARATION TOOL
1. SPECIAL TOOL
24082AA230 CARTRIDGE Troubleshooting for electrical system.
ST24082AA230
22771AA030 SUBARU SELECT Troubleshooting for electrical system.
MONITOR KIT • English: 22771AA030 (Without printer)
• German: 22771AA070 (Without printer)
• French: 22771AA080 (Without printer)
• Spanish: 22771AA090 (Without printer)
ST22771AA030
2. GENERAL TOOL
TOOL NAME REMARKS
Circuit tester Used for measuring resistance, voltage and ampere.
Pressure gauge Used for measuring oil pressure.
Oscilloscope Used for measuring sensor.
ABS-5
ABS Control Module and Hydraulic Control Unit (ABSCM&H/U)
ABS
2. ABS Control Module and Hy- 8) Remove the ABSCM&H/U bracket.

draulic Control Unit (AB- B: INSTALLATION
1) Install the ABSCM&H/U bracket.
SCM&H/U)
Tightening torque:
A: REMOVAL 33 N"m (3.3 kgf-m, 24 ft-lb)
2) Install the ABSCM&H/U aligning the groove of
2) Use compressed air to get rid of water around
damper on ABSCM&H/U side with the pawl of
the ABSCM&H/U.
bracket.
NOTE:
NOTE:
When dust and dirt are attached to the terminal,
Check the identification mark of ABSCM&H/U.
they may cause poor contact.
3) Disconnect the ABSCM&H/U connector pulling Tightening torque:
up the lock lever. 7.5 N"m (0.76 kgf-m, 5.5 ft-lb)
CAUTION:
Do not pull the harness when disconnecting
connector.
ABS00383
3) Connect the brake pipes to their correct AB-

SCM&H/U positions.
ABS00382 Tightening torque:
4) Remove the harness clip. 15 N"m (1.5 kgf-m, 10.8 ft-lb)
5) Disconnect the brake pipes from ABSCM&H/U. 4) Using a harness clip, secure the ABSCM&H/U
6) Wrap the brake pipe using a vinyl bag not to spill harness to bracket.
the brake fluid on the vehicle body. 5) Connect the connector to ABSCM&H/U.
CAUTION: NOTE:
When brake fluid is attached to the vehicle • Be sure to remove all foreign matters from inside
body, wash it off with water and wipe the water. the connector before connecting.
7) Remove the nuts and remove the ABSCM&H/U. • Ensure the ABSCM&H/U connector is securely
CAUTION: locked.
• Do not drop or bump the ABSCM&H/U. 6) Bleed air from the brake system.
• Do not turn ABSCM&H/U upside down or C: INSPECTION
place it sideways for storage. 1) Check the connected and fixed condition of con-
• Be careful that no foreign objects are mixed nector.
in ABSCM&H/U. 2) Check the mark used for ABSCM&H/U identifi-
• Be careful that no water enters inside the cation.
connectors.
ABS00383
ABS-6
ABS
Refer to “SPECIFICATION” for mark. <Ref. to 7) Read values indicated on the pressure gauge
ABS-2, SPECIFICATION, General Description.> and check if the fluctuation of the values between
decompression and compression meets the stan-
dard values. Depress the brake pedal and check
(1) that the kick-back is normal, and tightness is nor-
mal.
3,500 kPa 3,500 kPa
Initial value
(36 kgf/cm2, 511 psi) (36 kgf/cm2, 511 psi)
When 500 kPa 500 kPa
decom- (5 kgf/cm2, 73 psi) (5 kgf/cm2, 73 psi)
ABS00384 pressed or less or less
3,500 kPa 3,500 kPa
(1) Mark When com-
pressed (36 kgf/cm2, 511 psi) (36 kgf/cm2, 511 psi)
or more or more
1. CHECKING THE HYDRAULIC UNIT ABS
OPERATION BY PRESSURE GAUGE 8) Remove the pressure gauges from the FL and
FR caliper bodies.
1) Lift-up the vehicle, and then remove the wheels. 9) Connect the air bleeder screws of the FL and FR
2) Disconnect the air bleeder screws from the FL caliper bodies.
and FR caliper bodies. 10) Remove the air bleeder screws from the RL
3) Connect two pressure gauges to the FL and FR and RR caliper bodies.
caliper bodies. 11) Connect two pressure gauges to the RL and
CAUTION: RR caliper bodies.
• Pressure gauges used exclusively for brake 12) Bleed air from the brake system.
fluid must be used. 13) Bleed air from the pressure gauges and the RL
• Do not use the pressure gauge for the mea- and RR caliper bodies.
surement of transmission oil pressure since 14) Perform ABS sequence control.
the piston seal may be expanded and de- <Ref. to ABS-10, ABS Sequence Control.>
formed. 15) When the hydraulic unit begins to work, first the
NOTE: RR side performs decompression, holding and
Wrap a sealing tape around the pressure gauge. compression, and then the RL side performs de-
compression, holding and compression.
16) Read values indicated on the pressure gauge
and check if the fluctuation of the values between
dard values. Depress the brake pedal and check
that the kick-back is normal, and tightness is nor-
mal.
17) Remove the pressure gauge from the RL and
RR caliper bodies.
18) Connect the air bleeder screws of the RL and
ABS00134 RR caliper bodies.
19) Bleed air from the brake system.
4) Bleed air from the pressure gauges and the FL
and FR caliper bodies.
5) Perform ABS sequence control.
<Ref. to ABS-10, ABS Sequence Control.>
6) When the hydraulic unit begins to work, first the
FL side performs decompression, holding and
compression, and then the FR side performs de-
compression, holding and compression.
ABS-7
ABS
2. CHECKING THE HYDRAULIC UNIT ABS (1) The FL wheel performs decompression,
OPERATION WITH BRAKE TESTER holding and compression in sequence, and sub-
sequently the FR wheel repeats the cycle.
1) Install the spare fuse to the FWD connector lo-
(2) The RR wheel performs decompression,
cated in the main fuse box for the model without AT
holding and compression in sequence, and sub-
VTD.
sequently the RL wheel repeats the cycle.
8) Read values indicated on the brake tester and
(1) check if the fluctuation of the values between de-
compression and compression meets the standard
values.
1,000 N 1,000 N
Initial value
(2) (102 kgf, 225 lb) (102 kgf, 225 lb)
When 500 N 500 N
decom- (51 kgf, 112 lb) (51 kgf, 112 lb)
ABS00392 pressed or less or less
1,000 N 1,000 N
(1) Main fuse box When com-
(102 kgf, 225 lb) (102 kgf, 225 lb)
pressed
(2) FWD connector or more or more
2) Since the MT model and AT VTD model cannot 9) After the inspection, depress the brake pedal
cut off the AWD circuit forcibly, set the wheels other and check that it is not abnormally hard, and tight-
than measured one onto free rollers. ness is normal.
3) Prepare for the ABS sequence control.
D: REPLACEMENT
4) Set the front wheels or rear wheels on the brake CAUTION:
tester and set the select lever to “neutral”. • Because the seal of ABSCM cannot be re-
placed, do not pull or peel it with lifting up.
• Because the screw part of H/U deteriorates in
every replacement procedure, do not perform
the replacement more than five times on it.
When the malfunction is found though the re-
placement that performed is less than five
times, replace the H/U body.
• Use new screws for installation of ABSCM.
• When the sealing surface of ABSCM or H/U is
(1)
dirty or damaged and it cannot be removed or
ABS00136 repaired, replace it with new one.
1) Remove the ABSCM&H/U. <Ref. to ABS-6, RE-
MOVAL, ABS Control Module and Hydraulic Con-
trol Unit (ABSCM&H/U).>
2) To prevent entering foreign matter and brake flu-
id leakage, plug the oil pressure port of ABSCM&H/
U using screw plug and etc.
3) Set the pump motor part of removed ABSCM&H/
U faces down on a vise.
(1)
ABS00137
(1) Brake tester
5) Operate the brake tester.

6) Perform ABS sequence control.
7) When the hydraulic unit begins to work, check
the following working sequence.
ABS-8
ABS
NOTE: CAUTION:
Before securing a part on a vice, place cushioning Always use new screws.
material such as wood blocks, aluminum plate or
Tightening torque:
cloth between the part and vice.
1.5 N"m (0.15 kgf-m, 1.1 ft-lb)
(1) (3)
(1)
(2)
ABS00430 (4) (2)

ABS00432
(1) Aluminum plate or etc. 10) Check that there is no foreign matter in aligning
(2) Vise part between ABSCM and H/U.
11) Using TORX® bit T20, tighten the screws step-
4) Using TORX® bit T20, remove the four screws of wise in the order of (1) through (4) again.
ABSCM.
Tightening torque:
NOTE:
Always use new screws. 3 N"m (0.3 kgf-m, 2.2 ft-lb)
12) Check that there is no clearance in aligning part
between ABSCM and H/U.
13) Install the ABSCM&H/U to vehicle.
ABS00431
5) Slowly remove the ABSCM upward from H/U.

NOTE:
To prevent damaging of coil part, remove the AB-
SCM straightly from H/U.
6) Ensure there are no dirt or damage on sealing
surface of H/U.
CAUTION:
• Do not clean the ABSCM & H/U with applying
compressed air.
• Do not repair the damages of H/U sealing sur-
face using file or metal scraper. To remove the
sealing, use resin scraper. Do not use the
chemical materials (thinner and etc.).
7) Position the coil of new ABSCM to align H/U
valve.
8) To prevent deforming of ABSCM housing cover,
hold the corner of ABSCM and install it to the H/U
without tilting.
9) Using TORX® bit T20, tighten the screws step-
wise in the order of (1) through (4).
ABS-9
ABS Sequence Control
ABS
3. ABS Sequence Control 5) When the “Function check sequence” is select-

ed, the “ABS sequence control” will start.
A: OPERATION 6) Execute the following operations when the mes-
1) While the ABS sequence control is performed, sage “Press the brake pedal so that the brake ped-
the operation of the hydraulic unit can be checked al force is between 100 and 150 kgf” is displayed.
using the brake tester or pressure gauge after the (1) When the brake tester is used, press brake
hydraulic unit solenoid valve operation. pedal pad with a force of 1,000 N (102 kgf, 225
2) ABS sequence control can be started by diagno- lb).
sis connector or Subaru Select Monitor. (2) When using the pressure gauge, press the
brake pedal so as to make the pressure gauge
1. ABS SEQUENCE CONTROL WITH DIAG- indicate 3,500 kPa (36 kg/cm2, 511 psi).
NOSIS CONNECTOR 7) “Press the [YES] key” will be displayed. Press
NOTE: the [YES] key.
In the event of any trouble, the ABS sequence con- 8) The brake line being operated is displayed on
trol is not operated. the Subaru Select Monitor.
1) Turn the ignition switch to OFF at the vehicle sta-
tionary mode.
2) Take out the diagnosis connector from the inside
of instrument panel lower cover on the driver’s side,
and connect one of ground terminal to connector
terminal No. 8.
B82
1 2 3
4 5 6 7 8 ABS00466
3) Turn the ignition switch to ON without depress-

ing the brake pedal.
4) After the ABS warning light is turned off, perform
the brake pedal operation as follows; press it within
3 seconds, # release it, # press it again, # re-
lease it again, # and then press it.
NOTE:
Engine must not start.
5) After completion of ABS sequence control, turn
the ignition switch to OFF.
2. ABS SEQUENCE CONTROL WITH SUB-
ARU SELECT MONITOR
NOTE:
In the event of any trouble, the ABS sequence con-
trol is not operated.
1) Connect the Subaru Select Monitor to data link
connector under the driver’s side instrument panel
lower cover.
2) Turn the ignition switch to ON.
3) Set the Subaru Select Monitor switch to ON.
4) Set the Subaru Select Monitor to “Brake Control”
mode.
ABS-10
ABS
3. CONDITIONS FOR ABS SEQUENCE CONTROL
V max < 4 km/h (2.5 MPH)

(1) V max < 10 km/h (6 MPH)
(16) (17)
(2)
OFF ON
(3) (18) (21) (22) (23) (22) (23) (24)
(19) (20) (19) (20) (19) (20) (19)

(4)
OFF ON
(5)
OFF ON (25)
(6)
(22)
OFF ON
(7)
OFF ON
(8)
(25)
OFF (22)
(9) ON
(10) OFF ON
(11) OFF ON
OFF ON
(12)
OFF ON
(13)
(14) OFF ON
OFF ON
(15)
(26) (27)
(28)
(29)
(30)
(31)
(32)
ABS00385
ABS-11
ABS
(1) All wheel speed (13) RL decompression valve (21) Within 3 seconds
(2) DL terminal (14) RL compression valve (22) 1.0 second
(3) Ignition key (15) Pump motor (23) 1.4 seconds
(4) ABS warning light (16) Diagnosis connector and connec- (24) 0.6 second
(5) Stop light switch tion (25) 0.4 second
(6) Valve relay (17) When using the Subaru Select (26) Point A
(7) FL decompression valve Monitor, both connection and non- (27) Reset
(8) FL compression valve connection of diagnosis connector (28) Master cylinder pressure
are acceptable.
(9) FR decompression valve (29) FL wheel cylinder pressure
(10) FR compression valve (18) 1.5 seconds (30) FR wheel cylinder pressure
(11) RR decompression valve (19) Light OFF (31) RR wheel cylinder pressure
(12) RR compression valve (20) Light ON (32) RL wheel cylinder pressure
NOTE:
When using the Subaru Select Monitor, the control
operation starts from point A. The patterns from ig-
nition key ON to the point A show that operation is
started by diagnosis connector. (However, it is re-
quired to turn the stop light switch to ON before
point A.)
B: SPECIFICATION
1. 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 the diagnosis connector is disconnected.
(Without Subaru Select Monitor)
3) When the brake pedal is released during ABS
sequence control and the stop light switch goes
OFF.
4) When the brake pedal is depressed after the ig-
nition key is turned to ON, but before ABS warning
light goes out. (Without Subaru Select Monitor)
5) When the ignition key is turned to ON, but the
brake pedal is not depressed within 3 seconds after
ABS warning light goes OFF. (Without Subaru Se-
lect Monitor)
6) After completion of ABS sequence control.
7) When malfunction is detected.
ABS-12
Front ABS Wheel Speed Sensor
ABS
4. Front ABS Wheel Speed Sen- • Do not apply excessive force to the sensor
harness.
sor
A: REMOVAL
2) Disconnect the ABS wheel speed sensor con-
nector located next to the front strut mounting
house in engine compartment.
3) Separate the sensor connector and vehicle se-
curing clip. Apply force in the direction of (2) to un-
lock the pawl, and then slide the connector in the
direction of (3). Pull out the connector to the tire
ABS00387
side from grommet hole.
CAUTION: B: INSTALLATION
Clip would break when removing the clip with- Install in the reverse order of removal.
out separating sensor connector and clip. Tightening torque:
Sensor:
(3) 7.5 N"m (0.76 kgf-m, 5.5 ft-lb)
Bracket:
33 N"m (3.3 kgf-m, 24 ft-lb)
CAUTION:
Be careful not to damage the sensor portion.
NOTE:
• Check the identification (mark) on the harness to
(1) make sure that no warp exists. (RH: K1 (White),
(2)
ABS00434 LH: K2 (Yellow))
• Check if the harness is not pulled and does not
(1) Pawl come in contact with the suspension or body during
4) Remove the sensor harness bracket. steering wheel effort.
(1)
C: INSPECTION
1. INSPECTION WITH SUBARU SELECT
MONITOR
connector.
(2)
2) Select {Current Data Display & Save}. Check if
the speed indicated on the display change in re-
sponse to the speedometer reading during acceler-
ation/deceleration when the steering wheel is in the
ABS00386
straight-ahead position.
(1) To front ABS wheel speed sensor connector 3) If the speed indicated on the display does not
(2) Sensor harness bracket
change, check the ABS wheel speed sensor. <Ref.
to ABS-13, ABS WHEEL SPEED SENSOR, IN-
5) Remove the bolts which secure sensor harness SPECTION, Front ABS Wheel Speed Sensor.>
to front strut.
6) Remove the front ABS wheel speed sensor from
housing. 1) Check the pole piece of the ABS wheel speed
sensor for foreign particles or damage. If neces-
CAUTION:
sary, clean the pole piece or replace the ABS wheel
• Be careful not to damage the sensor portion.
speed sensor.
ABS-13
ABS
2) Charge a 12 V power supply to the No. 2 termi-

nal of sensor connector as shown in the figure, and
then install the resistance to No. 1 terminal. Rotate
the wheel about 2.75 km/h (2 MPH) or equivalent,
measure the voltage using oscilloscope.
Standard value of output voltage:
0.7 — 1.4 V
1.4 V
0.7 V
(1)
12 V
1 2
2
(2)
1
100
ABS00388
(1) Oscilloscope
(2) ABS wheel speed sensor
NOTE:
Check the ABS wheel speed sensor cable for dis-
continuity. If necessary, replace with a new one.
ABS-14
Rear ABS Wheel Speed Sensor
ABS
5. Rear ABS Wheel Speed Sen- CAUTION:

• Be careful not to damage the sensor portion.
sor • Do not apply excessive force to the sensor
A: REMOVAL harness.
2) Disconnect the connector from rear ABS wheel
speed sensor.
ABS00390
B: INSTALLATION
ABS00389
3) Remove the sensor harness bracket from rear CAUTION:

arm. Be careful not to damage the sensor portion.
Tightening torque:
Sensor:
7.5 N"m (0.76 kgf-m, 5.5 ft-lb)
Bracket:
33 N"m (3.3 kgf-m, 24 ft-lb)
NOTE:
Check the identification (mark) on the harness to
make sure that no warp exists. (RH:K5(White),
LH:K6(Yellow))
ABS00166 C: INSPECTION
<Ref. to ABS-13, ABS WHEEL SPEED SENSOR,
INSPECTION, Front ABS Wheel Speed Sensor.>
ABS00167
ABS00168
4) Remove the rear ABS wheel speed sensor from

rear arm.
ABS-15
Front Magnetic Encoder
ABS
6. Front Magnetic Encoder

A: REMOVAL
Refer to “Front Hub Bearing” for removal, because
the front magnetic encoder is integrated with front
hub bearing.
<Ref. to DS-17, REMOVAL, Front Hub Unit Bear-
ing.>
B: INSTALLATION
Refer to “Front Hub Bearing” for installation, be-
cause the front magnetic encoder is integrated with
front hub bearing.
<Ref. to DS-17, INSTALLATION, Front Hub Unit
Bearing.>
C: INSPECTION
Visually check the magnetic encoder for any dam-
age. If necessary, replace with a new hub unit bear-
ing.
NOTE:
Replace the hub unit bearing with a new one if
there is any defect found on the magnetic encoder,
since the magnetic encoder is integrated with hub
unit bearing assembly.
ABS-16
Rear Magnetic Encoder
ABS
7. Rear Magnetic Encoder

A: REMOVAL
Refer to “Rear Hub Unit Bearing” for removal, be-
cause the rear magnetic encoder is integrated with
rear hub unit bearing.
<Ref. to DS-19, REMOVAL, Rear Hub Unit Bear-
ing.>
B: INSTALLATION
Refer to “Rear Hub Unit Bearing” for installation,
because the rear magnetic encoder is integrated
with rear hub unit bearing.
<Ref. to DS-20, INSTALLATION, Rear Hub Unit
Bearing.>
C: INSPECTION
Visually check the magnetic encoder for any dam-
age. If necessary, replace with a new hub unit bear-
ing.
NOTE:
Replace the hub unit bearing with a new one if
there is any defect found on the magnetic encoder,
since the magnetic encoder is integrated with hub
unit bearing assembly.
ABS-17
G Sensor
ABS
8. G Sensor
A: REMOVAL
2) Remove the console box.
<Ref. to EI-53, REMOVAL, 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.
• Since G sensor is a unit with the bracket, do
not disassemble them.
ABS00463
B: INSTALLATION
CAUTION:
Do not drop or bump the G sensor.
Tightening torque:
7.5 N"m (0.76 kgf-m, 5.5 ft-lb)
ABS-18
G Sensor
ABS
C: INSPECTION
Step Check Yes No
1 CHECK G SENSOR. Is the value $1.2 — 1.2 m/s 2 Go to step 2. Repair the har-
1) Turn the ignition switch to OFF. when the vehicle is in horizon- ness connector
2) Connect the Subaru Select Monitor to data tal position? between G sensor
link connector. and ABSCM&H/U.
3) Set the Subaru Select Monitor to the {Brake Or replace G sen-
Control} mode. sor.
4) Set the display in the {Current Data Display
& Save} mode.
5) Read the G sensor output value.
2 CHECK G SENSOR. Is the value 8.1 — 11.2 m/s2 Go to step 3. Repair the har-
1) Remove the console box. when G sensor is inclined for- ness connector
2) Remove the G sensor from vehicle. (Do not ward to 90%? between G sensor
disconnect connector.) and ABSCM&H/U.
3) Read the Subaru Select Monitor display. Or replace G sen-
sor.
3 CHECK G SENSOR. Is the value $8.1 — $11.2 m/s2 G sensor is nor- Repair the har-
Read the Subaru Select Monitor display. when G sensor is inclined mal. ness connector
backward to 90%? between G sensor
and ABSCM&H/U.
Or replace G sen-
sor.
ABS-19
G Sensor
ABS
ABS-20
CHASSIS SECTION
FRONT SUSPENSION FS
REAR SUSPENSION RS
DIFFERENTIALS DI
TRANSFER CASE TC
(DIAGNOSTICS)
BRAKE BR
PARKING BRAKE PB

(POWER STEERING)

approval.

ABS (DIAGNOSTICS)
ABS(diag)
Page
1. Basic Diagnostic Procedure ........................................................................2
2. Check List for Interview...............................................................................4
4. Electrical Component Location .................................................................10
5. Control Module I/O Signal .........................................................................12
6. Subaru Select Monitor...............................................................................15
7. Read Diagnostic Trouble Code (DTC) ......................................................25
8. Inspection Mode........................................................................................26
9. Clear Memory Mode..................................................................................27
10. ABS Warning Light / Brake Warning Light Illumination Pattern ................28
11. List of Diagnostic Trouble Code (DTC) .....................................................39
12. Diagnostic Procedure with Diagnostic Trouble Code (DTC) .....................42
Basic Diagnostic Procedure
ABS (DIAGNOSTICS)
1. Basic Diagnostic Procedure

A: PROCEDURE
CAUTION:
Remove foreign matters (dust, water, oil, etc.) from the ABSCM&H/U connector during removal and
installation.
NOTE:
• To check harness for broken wires or short circuits, shake trouble spot or connector.
• Refer to “Check List for Interview”. <Ref. to ABS(diag)-4, Check List for Interview.>
Step Check Yes No

1 CHECK PRE-INSPECTION. Is the component that might Go to step 2. Repair or replace
1) Ask the customer when and how the trou- influence the ABS problem each unit.
ble occurred using interview checklist. <Ref. to normal?
ABS(diag)-4, Check List for Interview.>
2) Before performing diagnostics, check the
component which might affect ABS problems.
<Ref. to ABS(diag)-8, INSPECTION, General
Description.>
2 CHECK INDICATION OF DTC ON SCREEN. Is DTC displayed? Go to step 4. Go to step 3.
1) Turn the ignition switch to OFF.
2) Connect the Subaru Select Monitor to data
link connector.
3) Turn the ignition switch to ON and Subaru
Select Monitor to ON.
NOTE:
If the communication function of the Subaru Se-
lect Monitor cannot be executed normally,
check the communication circuit. <Ref. to
ABS(diag)-18, COMMUNICATION FOR INI-
TIALIZING IMPOSSIBLE, INSPECTION, Sub-
aru Select Monitor.>
4) Read the DTC. <Ref. to ABS(diag)-25,
OPERATION, Read Diagnostic Trouble Code
(DTC).>
5) Record all DTCs and Freeze Frame Data.
3 PERFORM THE GENERAL DIAGNOSTICS. Does the ABS warning light go Finish the diagno- Check in accor-
1) Inspect using “General Diagnostic Table”. off after turning the ignition sis. dance with “Diag-
<Ref. to ABS(diag)-82, General Diagnostic switch to ON? nostic Procedure
Table.> for ABS”. <Ref. to
2) Perform clear memory mode. <Ref. to ABS(diag)-21,
ABS(diag)-17, CLEAR MEMORY MODE, WITHOUT DTC,
OPERATION, Subaru Select Monitor.> INSPECTION,
3) Perform the inspection mode. <Ref. to Subaru Select
ABS(diag)-26, Inspection Mode.> Monitor.>
READ DIAGNOSTIC TROUBLE CODE (DTC),
OPERATION, Subaru Select Monitor.>
Check the DTC does not displayed.
ABS(diag)-2
ABS (DIAGNOSTICS)
Step Check Yes No

4 PERFORM THE DIAGNOSIS. Is DTC displayed? Repeat step 1 to 4 Finish the diagno-
1) Refer to the “List of Diagnostic Trouble until DTC is not sis.
Code (DTC)”. <Ref. to ABS(diag)-39, LIST, List shown.
of Diagnostic Trouble Code (DTC).>
2) Fix the wrong part.
3) Perform clear memory mode. <Ref. to
ABS(diag)-17, CLEAR MEMORY MODE,
4) Perform the inspection mode. <Ref. to
ABS(diag)-26, Inspection Mode.>
READ DIAGNOSTIC TROUBLE CODE (DTC),
ABS(diag)-3
Check List for Interview
ABS (DIAGNOSTICS)
2. Check List for Interview

A: CHECK
Check the following items about the vehicle’s state.
1. STATE OF ABS WARNING LIGHT
ABS warning light ❏ Always
comes on. ❏ Sometimes
❏ Only once
❏ Not come on
! When / how long does it come on?
Ignition key position ❏ LOCK
❏ ACC
❏ ON (before starting engine)
❏ START
❏ ON (after Engine starting, engine is running)
❏ ON (after Engine starting, engine is at a standstill)
Timing ❏ Immediately after turning the ignition to ON
❏ Immediately after turning the ignition to START
❏ When accelerating — km/h
— MPH
❏ When driving at a constant speed km/h MPH
❏ When decelerating — km/h
— MPH
❏ When turning to the right Steering angle: deg
Steering time: Sec.
❏ When turning to the left Steering angle: deg
Steering time: Sec.
❏ When operating other electrical parts
! Parts name:
! Operating condition:
2. STATE OF BRAKE WARNING LIGHT

Brake warning light ❏ Always
comes on. ❏ Sometimes
❏ Only once
❏ Not come on
❏ When pulling the parking brake lever up.
❏ When releasing the parking brake lever down.
! When / how long does it come on?
❏ ACC
❏ START
❏ ON (after Engine starting, engine is running)
❏ ON (after Engine starting, engine is at a standstill)
ABS(diag)-4
ABS (DIAGNOSTICS)
Timing ❏ Immediately after turning the ignition to ON

❏ Immediately after turning the ignition to START
— MPH
— MPH
Steering time: Sec.
Steering time: Sec.
! Parts name:
3. SYMPTOMS
ABS operating condi- ❏ Does not move.
tion ❏ Operates only when applying an abrupt brake. Vehicle speed: km/h
MPH
! How to step on brake pedal:
a) Operating time: Sec.
b) Operating noise: ❏ Occurs. / ❏ Does not occur.
! What kind of noise? ❏ Knocking
❏ Gong gong
❏ Bong
❏ Buzz
❏ Gong gong buzz
❏ Others:
c) Reaction force of brake pedal
❏ Stick
❏ Weak pedal resistance
❏ Strong pedal resistance
❏ Others:
ABS(diag)-5
ABS (DIAGNOSTICS)
Behavior of vehicle a) Directional stability cannot be obtained or the steering refuses to work when applying brakes:
❏ Yes / ❏ No
! When: ❏ When turning to the right
❏ When turning to the left
❏ When spinning
❏ Others:
a) Directional stability cannot be obtained or the steering refuses to work when accelerating:
❏ Yes / ❏ No
! When: ❏ When turning to the right
❏ When turning to the left
❏ When spinning
❏ Others:
c) Poor brake performance: ❏ Yes / ❏ No
! What kind: ❏ Long braking/stopping distance
❏ Brakes lock or drag
❏ Long pedal stroke
❏ Pedal sticks.
❏ Others:
d) Poor acceleration: ❏ Yes / ❏ No
! What kind: ❏ Not accelerate
❏ Engine stalls.
❏ Others:
e) Occurrence of vibration: ❏ Yes / ❏ No
! Where
! What kind:
f) Occurrence of noise: ❏ Yes / ❏ No
! Where
! What kind:
g) Other troubles occurred: ❏ Yes / ❏ No
! What kind:
4. CONDITIONS UNDER WHICH TROUBLE OCCURS

Environment a) Weather ❏ Fine
❏ Cloudy
❏ Rainy
❏ Snowy
❏ Others:
b) Ambient temperature "C ("F)
c) Road ❏ Inner city
❏ Suburbs
❏ Highway
❏ Local street
❏ Uphill
❏ Downhill
❏ Paved road
❏ Gravel road
❏ Muddy road
❏ Sandy place
❏ Others:
d) Road surface ❏ Dried
❏ Wet
❏ Covered with fresh snow
❏ Covered with hardened snow
❏ Frozen slope
❏ Others:
ABS(diag)-6
ABS (DIAGNOSTICS)
Condition a) Brakes Deceleration: G

❏ Intermittent / ❏ Temporary
b) Accelerator Acceleration: G
❏ Intermittent / ❏ Temporary
c) Vehicle speed km/h MPH
❏ Advancing
❏ When accelerating
❏ When decelerating
❏ At low speed
❏ When turning
❏ Others:
d) Tire inflation pressure Front RH tire: kPa
Front LH tire: kPa
Rear RH tire: kPa
Rear LH tire: kPa
e) Degree of wear Front RH tire:
Front LH tire:
Rear RH tire:
Rear LH tire:
f) Genuine parts are used.: ❏ Yes / ❏ No
g) Tire chain is attached.: ❏ Yes / ❏ No
h) T-type tire is used.: ❏ Yes / ❏ No
i) Condition of suspension alignment:
j) Loading state:
k) Repair parts are used.: ❏ Yes / ❏ No
! Contents:
l) Others:
ABS(diag)-7
General Description
ABS (DIAGNOSTICS)
3. General Description 6. TIRE

A: CAUTION Check the tire specifications, tire wear and air pres-
sure. <Ref. to WT-2, SPECIFICATION, General
1. SUPPLEMENTAL RESTRAINT SYSTEM Description.>
“AIRBAG”
Airbag system wiring harness is routed near the
ABS wheel speed sensor and ABSCM&H/U.
CAUTION:
• All airbag system wiring harness and con-
nectors are colored yellow. Do not use the elec-
trical test equipment on these circuits.
• Be careful not to damage the airbag system
wiring harness when servicing the ABS wheel
speed sensor and ABSCM&H/U.
B: INSPECTION
Before performing diagnosis, check the following
items which might affect ABS problems.
1. BATTERY
Measure battery voltage and check electrolyte.
Standard voltage: 12 V or more
Specific gravity: More than 1.260
2. BRAKE FLUID
1) Check the brake fluid level.
2) Check the brake fluid for leaks.
3. HYDRAULIC UNIT
Check the hydraulic unit.
• With brake tester <Ref. to ABS-8, 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-7, CHECK-
ING THE HYDRAULIC UNIT ABS OPERATION
BY PRESSURE GAUGE, INSPECTION, ABS
Control Module and Hydraulic Control Unit (AB-
SCM&H/U).>
4. BRAKE DRAG
Check for brake drag.
5. BRAKE PAD AND ROTOR
Check the brake pad and rotor.
• FRONT <Ref. to BR-18, INSPECTION, Front
Brake Pad.> <Ref. to BR-19, INSPECTION, Front
Disc Rotor.>
• REAR <Ref. to BR-25, INSPECTION, Rear
Brake Pad.> <Ref. to BR-26, INSPECTION, Rear
Disc Rotor.>
ABS(diag)-8
General Description
ABS (DIAGNOSTICS)
C: PREPARATION TOOL
1. SPECIAL TOOL
ST24082AA230

ST22771AA030
2. GENERAL TOOL
TOOL NAME REMARKS
ABS(diag)-9
Electrical Component Location
ABS (DIAGNOSTICS)
4. Electrical Component Location

A: LOCATION
(13)
(4)
(5)
(3)
(2)
(1)
(9)
(7)
(8)
(10)
(6)
(11)
(12)
(8) (7) (9)
ABS00458
(1) ABS control module and hydraulic (5) Data link connector (9) Caliper body
control unit (ABSCM&H/U) (For Subaru Select Monitor) (10) G sensor
(2) Two-way connector (6) Transmission control module (11) Stop light switch
(3) Diagnosis connector (Used for (TCM) (AT model) (12) Master cylinder
ABS sequence control.) (7) Magnetic encoder seal (13) Brake and EBD warning light
(4) ABS warning light (8) ABS wheel speed sensor
ABS(diag)-10
ABS (DIAGNOSTICS)
(1) (3)
ABS00405 ABS00106
(13)
(5)
(4)
ABS00438 ABS00464
(8) (8)
FRONT (7) REAR (7)
(7) (7)
ABS00408 ABS00407
(10)
ABS00406
ABS(diag)-11
Control Module I/O Signal
ABS (DIAGNOSTICS)
5. Control Module I/O Signal

A: ELECTRICAL SPECIFICATION
(1)
B301
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15
16 17 18 19 20 21 22 23 24 25 26
ABS00409
(1) ABS control module and hydraulic

control unit (ABSCM&H/U) con-
nector
NOTE:
• Terminal numbers in ABSCM&H/U connector are as shown in the figure.
• ABS warning light is illuminates when the connector is removed from ABSCM&H/U.
ABS(diag)-12
ABS (DIAGNOSTICS)
Terminal Input/Output signal

Description No.
(+) — (#) Measured value and measuring conditions
Power
16 — 15 4.5 — 16.5 V
Front LH wheel supply
Signal 1 5.9 — 16.8 mA: Rectangle waveform
Power
5 — 15 4.5 — 16.5 V
Front RH wheel supply
ABS wheel speed sen- Signal 6 5.9 — 16.8 mA: Rectangle waveform
sor
(Wheel speed sensor) Power
2 — 15 4.5 — 16.5 V
Rear LH wheel supply
Power
3 — 15 4.5 — 16.5 V
Rear RH wheel supply
CAN communication line (+) 26 2.5 — 1.5 V pulse signal
CAN communication line (#) 11 3.5 — 2.5 V pulse signal
Valve relay power supply *1 14 — 15 10 — 15 V
Motor relay power supply *1 13 — 15 10 — 15 V
Power supply 24 — 10 4.75 — 5.25 V
G sensor Ground 10 —
Output 21 — 10 2.1 — 2.5 V when the vehicle is on a level surface
Less than 1.5 V when the stop light is OFF; otherwise,
Stop light switch *1 20 — 15
10 — 15 V when the stop light is ON.
After turning the ignition switch to ON, 10 — 15 V during
ABS warning light 22 — 15 1.5 seconds and less than 1.5 V after 1.5 seconds
passed.
Brake warning light (EBD warning light) 8 — 15 1.5 seconds and less than 1.5 V after 1.5 seconds
passed.
Less than 1.5 V when no data is received.
Subaru Select Monitor 7 — 15
0 $% 12 V pulse (in communication)
ABS diagnosis connector 25 — 15 When the ignition switch is ON, 10 — 15 V.
Power supply *1 18 — 15 When the ignition switch is ON, 10 — 15 V.
Grounding line 15 —
Vehicle speed output signal 23 — 15 0 $% 5 V pulse
*1: Measure the I/O signal voltage after removing the connector from the ABSCM&H/U terminal.
ABS(diag)-13
ABS (DIAGNOSTICS)
B: WIRING DIAGRAM
(3)
(16)
(30) (5)
(1)
(31)
(17)
(18)
(2) (19)
(20) (6)
(28) (29)
(4)
(21)
M (7)
(22)
(8)
(9)
(23) (10)
(11)
(12)
(24)
(13)
(25)
(14)
(26)
(15)
(27)
ABS00470
(1) Battery (12) Rear inlet solenoid valve LH (24) Front ABS wheel speed sensor LH
(2) Ignition switch (13) Rear outlet solenoid valve LH (25) Front ABS wheel speed sensor
(3) ABS control module and hydraulic (14) Rear inlet solenoid valve RH RH
control unit (ABSCM&H/U) (15) Rear outlet solenoid valve RH (26) Rear ABS wheel speed sensor LH
(4) ABS control module (16) Body integrated unit (27) Rear ABS wheel speed sensor
(5) Valve relay (17) Diagnosis connector RH
(6) Motor relay (18) Data link connector (28) Parking brake switch
(7) Motor (19) ABS warning light (29) Brake fluid level switch
(8) Front inlet solenoid valve LH (20) Brake warning light (30) Engine control module (ECM)
(9) Front outlet solenoid valve LH (21) Stop light switch (31) Transmission control module
(10) Front inlet solenoid valve RH (22) Stop light (TCM)
(11) Front outlet solenoid valve RH (23) G sensor
ABS(diag)-14
Subaru Select Monitor
ABS (DIAGNOSTICS)
6. Subaru Select Monitor CAUTION:

Do not connect the scan tools except for Suba-
A: OPERATION ru Select Monitor.
1. READ DIAGNOSTIC TROUBLE CODE 5) Turn the ignition switch to ON (engine OFF) and
(DTC) turn the Subaru Select Monitor switch to ON.
1) Prepare the Subaru Select Monitor kit. <Ref. to
ABS(diag)-9, SPECIAL TOOL, PREPARATION (1)
TOOL, General Description.>
ABS00114
(1) Power switch
ABS00111 6) On the «Main Menu» display screen, select the

{Each System Check} and press the [YES] key.
2) Connect the diagnosis cable to Subaru Select
7) On the «System Selection Menu» display
Monitor.
screen, select the {Brake Control} and press the
3) Insert the cartridge to Subaru Select Monitor. [YES] key.
<Ref. to ABS(diag)-9, SPECIAL TOOL, PREPA-
8) Press the [YES] key after the {ABS} is displayed.
RATION TOOL, General Description.>
9) On the «ABS Diagnosis» display screen, select
the {DTC Display} and press the [YES] key.
NOTE:
• For details concerning operation procedure, re-
fer to the “SUBARU SELECT MONITOR OPERA-
TION MANUAL”.
• For details concerning DTCs, refer to the “List of
Diagnostic Trouble Code (DTC)”. <Ref. to ABS(di-
ag)-39, List of Diagnostic Trouble Code (DTC).>
• DTCs are displayed up to three in detected or-
ABS00112 der.
4) Connect the Subaru Select Monitor to data link • If a particular DTC is not properly stored in mem-
connector. ory (due to a drop in ABSCM&H/U power supply,
(1) Data link connector is located in the lower etc.) on the occurrence of a problem, the DTC
portion of the instrument panel (on the driver’s which is suffixed with a question mark “?” appears
side). on the Subaru Select Monitor display. This shows it
may be an unreliable reading.
10) If ABS and Subaru Select Monitor cannot com-
municate, check the communication circuit. <Ref.
to ABS(diag)-18, COMMUNICATION FOR INI-
(1)
TIALIZING IMPOSSIBLE, INSPECTION, Subaru
Select Monitor.>
ABS00465
(1) Data link connector
(2) Connect the diagnosis cable to data link

connector.
ABS(diag)-15
ABS (DIAGNOSTICS)
11) When DTC is not displayed, check the meter

circuit or CAN communication circuit. <Ref. to
ABS(diag)-21, WITHOUT DTC, INSPECTION,
Subaru Select Monitor.>
Display Contents to be monitored
Indicate the latest DTC on the Subaru
Current
Select Monitor display.
Indicate the latest DTC in previous trou-
Old
ble on the Subaru Select Monitor display.
Indicate the latest DTC in second previ-
Older ous trouble on the Subaru Select Monitor
display.
Indicate the latest DTC in third previous
Before 3 trouble on the Subaru Select Monitor dis-
play.
2. READ CURRENT DATA

1) On the «Main Menu» display screen, select the {Each System Check} and press the [YES] key.
2) On the «System Selection Menu» display screen, select the {Brake Control} and press the [YES] key.
4) On the «Brake Control Diagnosis» screen, select the {Current Data Display/Save}, and then press the
[YES] key.
5) On the «Data Display Menu» screen, select the data display style and press the [YES] key.
6) Using a scroll key, move the display screen up or down until necessary data is shown.
• A list of the support data is shown in the following table.
Display Contents to be monitored Unit of measure
Wheel speed detected by front ABS wheel speed sensor RH is dis-
FR Wheel Speed km/h or MPH
played.
Wheel speed detected by front ABS wheel speed sensor LH is dis-
FL Wheel Speed km/h or MPH
played.
Wheel speed detected by rear ABS wheel speed sensor RH is dis-
RR Wheel Speed km/h or MPH
played.
Wheel speed detected by rear ABS wheel speed sensor LH is dis-
RL Wheel Speed km/h or MPH
played.
BLS Signal Brake ON/OFF is displayed. ON or OFF
G Sensor Vehicle acceleration detected by analog G sensor is displayed. m/s (m/s2)
Valve Relay Signal Valve relay operation signal is displayed. ON or OFF
ABS Warning Light ON operation of the ABS warning light is displayed. ON or OFF
EBD Warning Light ON operation of the EBD warning light is displayed. ON or OFF
Motor Relay Monitor Motor relay monitor voltage is displayed. V
IG power supply voltage Voltage supplied to ABSCM&H/U is displayed. V
ABS Control Flag ABS control condition is displayed. ON or OFF
ABS OK B Signal ABS system normal/abnormal is displayed. OK or NG
NOTE:
For details concerning operation procedure, refer to the “SUBARU SELECT MONITOR OPERATION MAN-
UAL”.
ABS(diag)-16
ABS (DIAGNOSTICS)
3. CLEAR MEMORY MODE Display Contents to be monitored

1) On the «Main Menu» display screen, select the IG power supply Voltage supplied (V) to ABSCM&H/U is
{2. Each System Check} and press the [YES] key. voltage displayed.
2) On the «System Selection Menu» display Vehicle acceleration detected by analog
G Sensor
G sensor is displayed.
[YES] key. Motor relay mon-
Motor relay condition is displayed.
itor
4) On the «Brake Control Diagnosis» display BLS Signal Brake ON/OFF is displayed.
screen, select the {Clear Memory} and press the Vehicle speed calculated by ABS control
Vehicle speed
[YES] key. module is displayed.
ABS Control
Display Contents to be monitored ABS control condition is displayed.
Flag
Clear memory? Function of clearing DTC. Power Supply Whether abnormal voltage occurred or
Failure not is displayed during malfunction.
5) When “Done” and “Turn ignition switch OFF” are
shown on the display screen, turn the Subaru Se-
lect Monitor and ignition switch to OFF.
NOTE:
For details concerning operation procedure, refer
to the “SUBARU SELECT MONITOR OPERATION
MANUAL”.
4. ABS SEQUENCE CONTROL
Display Contents to be monitored Index No.
Operate the valve and <Ref. to ABS-
ABS
pump motor continuously 10, ABS
sequence
to perform the ABS Sequence Con-
control
sequence control. trol.>
5. 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 up to three.
• If a Freeze Frame Data is not properly stored in
memory (due to a drop in ABS control module pow-
er supply, etc.), the DTC which is suffixed with a
question mark “?” appears on the Subaru Select
Monitor display. This shows it may be an unreliable
reading.
Wheel speed detected by the Front ABS
FR Wheel wheel speed sensor RH is displayed in
km/h or MPH.
Wheel speed detected by the Front ABS
FL Wheel wheel speed sensor LH is displayed in
km/h or MPH.
Wheel speed detected by the Rear ABS
RR Wheel wheel speed sensor RH is displayed in
km/h or MPH.
Wheel speed detected by the Rear ABS
RL Wheel wheel speed sensor LH is displayed in
km/h or MPH.
ABS(diag)-17
ABS (DIAGNOSTICS)
B: INSPECTION
1. COMMUNICATION FOR INITIALIZING IMPOSSIBLE
DETECTING CONDITION:
Defective harness connector
TROUBLE SYMPTOM:
Communication is impossible between ABS and Subaru Select Monitor.
WIRING DIAGRAM:
BATTERY
SBF-1
E
SBF-7
No.13
IGNITION
SWITCH
DATA LINK
CONNECTOR
1
10
B40
No.33
E
15
18
B301 ABSCM & H/U
B40 B301
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15
16 17 18 19 20 21 22 23 24 25 26
9 10 11 12 13 14 15 16
ABS00411
ABS(diag)-18
ABS (DIAGNOSTICS)
Step Check Yes No

1 CHECK IGNITION SWITCH. Does the ignition switch turn to Go to step 2. Turn the ignition
ON? switch to ON, and
select ABS mode
using Subaru
Select Monitor.
2 CHECK BATTERY. Is the voltage more than 11 V? Go to step 3. Charge or replace
1) Turn the ignition switch to OFF. the battery.
2) Measure the battery voltage.
3 CHECK BATTERY TERMINAL. Is there poor contact at battery Repair or tighten Go to step 4.
terminal? the battery termi-
nal.
4 CHECK SUBARU SELECT MONITOR COM- Is the system name and model Go to step 8. Go to step 5.
MUNICATION. year displayed on Subaru
1) Turn the ignition switch to ON. Select Monitor?
2) Using Subaru Select Monitor, check
whether communication to other system can
be executed normally.
5 CHECK SUBARU SELECT MONITOR COM- Is the system name and model Replace Go to step 6.
MUNICATION. year displayed on Subaru ABSCM&H/U.
1) Turn the ignition switch to OFF. Select Monitor? <Ref. to ABS-6,
2) Disconnect the ABSCM&H/U connector. ABS Control Mod-
3) Turn the ignition switch to ON. ule and Hydraulic
4) Check whether communication to other Control Unit
systems can be executed normally. (ABSCM&H/U).>
6 CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 Go to step 7. Repair the har-
EACH CONTROL MODULE AND DATA LINK M&? ness and connec-
CONNECTOR. tor between each
1) Turn the ignition switch to OFF. control module
2) Disconnect ABSCM&H/U, ECM and TCM. and data link con-
3) Measure the resistance between data link nector.
connector and chassis ground.
Connector & terminal
(B40) No. 10 — Chassis ground:
7 CHECK OUTPUT SIGNAL FOR ABSCM&H/ Is the voltage less than 1 V? Go to step 8. Repair the har-
U. ness and connec-
1) Turn the ignition switch to ON. tor between each
2) Measure the voltage between ABSCM&H/ control module
U and chassis ground. and data link con-
Connector & terminal nector.
(B40) No. 10 (+) — Chassis ground (#):
8 CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 0.5 Go to step 9. Repair the har-
ABSCM&H/U AND DATA LINK CONNEC- &? ness and connec-
TOR. tor between
Measure the resistance between ABSCM&H/U ABSCM&H/U and
connector and data link connector. data link connec-
Connector & terminal tor.
(B301) No. 7 — (B40) No. 10:
9 CHECK INSTALLATION OF ABSCM&H/U Is the ABSCM&H/U connector Go to step 10. Insert ABSCM&H/
CONNECTOR. inserted into ABSCM&H/U until U connector into
Turn the ignition switch to OFF. it is locked by clamps? ABSCM&H/U.
10 CHECK POWER SUPPLY CIRCUIT. Is the voltage 10 — 15 V? Go to step 11. Repair the open
1) Turn the ignition switch to ON. (engine circuit in harness
OFF) between
2) Measure the ignition power supply voltage ABSCM&H/U and
between ABSCM&H/U connector and chassis battery.
ground.
ABS(diag)-19
ABS (DIAGNOSTICS)
Step Check Yes No

11 CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 0.5 Go to step 12. Repair the open
ABSCM&H/U AND CHASSIS GROUND. &? circuit in harness
1) Turn the ignition switch to OFF. between
2) Disconnect the connector from ABSCM&H/ ABSCM&H/U and
U. inhibitor side con-
3) Measure the resistance of harness nector, and poor
between ABSCM&H/U and chassis ground. contact in cou-
Connector & terminal pling connector.
12 CHECK POOR CONTACT IN CONNECTOR. Is there poor contact in control Repair the con- Replace the
module power supply, ground nector. ABSCM only.
circuit and data link connector? <Ref. to ABS-8,
REPLACEMENT,
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
ABS(diag)-20
ABS (DIAGNOSTICS)
2. WITHOUT DTC
• Defective combination meter
• Open in harness
TROUBLE SYMPTOM:
• ABS warning light does not go off.
• “NO TROUBLE CODE” will be displayed on the Subaru Select Monitor.
NOTE:
When the ABS warning light is OFF and “NO TROUBLE CODE” is displayed on Subaru Select Monitor, the
system is in normal condition.
ABS(diag)-21
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
• LHD model
BATTERY
SBF-1
SBF-7
E
IGNITION
SWITCH
No.5
No.33
3
4
COMBINATION
METER
GROUND
WARNING
WARNING
A: i10 TERMINAL
BRAKE
LIGHT
LIGHT
B82
ABS
B81
5
7
i3
20
B38
25
15
18
22
8
B301 ABSCM & H/U E E
A: i10 B301 B38 B82
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 1 2
12 13 14 15 10 11 12 13 14 15 16 17 18 19 20 3 4 5 6
11 12 13 14 15 16 17 18 19 20 21 22 16 17 18 19 20 21 22 23 24 25 26
ABS00459
ABS(diag)-22
ABS (DIAGNOSTICS)
• RHD model
BATTERY
SBF-1
SBF-7
E
IGNITION
SWITCH
No.5
No.33
3
4
COMBINATION
METER
GROUND
WARNING
WARNING
A: i10 TERMINAL
BRAKE
LIGHT
LIGHT
B82
ABS
B81
5
7
i1
3
4
B36
25
15
18
22
8
A: i10 B301 i1 B82
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 1 2
12 13 14 15 3 4 5 6
11 12 13 14 15 16 17 18 19 20 21 22 16 17 18 19 20 21 22 23 24 25 26 1 2 3 4
5 6 7 8 9 10
11 12 13 14 15 16
17 18 19 20 21 22
23 24 25 26 27 28
ABS00440
ABS(diag)-23
ABS (DIAGNOSTICS)
Step Check Yes No

1 DATA CHECK SUBARU SELECT MONITOR. Is “ON” indicated? Replace the Go to step 2.
1) Select {Current Data Display & Save} in ABSCM only.
Subaru Select Monitor. <Ref. to ABS-8,
2) Read the condition of “ABS warning light”. REPLACEMENT,
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
2 CHECK WIRING HARNESS. Is the resistance less than 0.5 Go to step 3. Repair the har-
Measure the resistance between ABSCM con- &? ness and connec-
nector and combination meter connector. tor between
Connector & terminal ABSCM&H/U and
(i10) No. 5 — (B301) No. 22: combination meter
connector.
3 CHECK POOR CONTACT IN CONNECTOR. Is there poor contact in Repair the con- Check the combi-
ABSCM connector and combi- nector. nation meter.
nation meter connector?
ABS(diag)-24
Read Diagnostic Trouble Code (DTC)
ABS (DIAGNOSTICS)
7. Read Diagnostic Trouble

Code (DTC)
A: OPERATION
For details about reading of DTCs, refer to “Subaru
Select Monitor”. <Ref. to ABS(diag)-15, Subaru Se-
lect Monitor.>
ABS(diag)-25
Inspection Mode
ABS (DIAGNOSTICS)
8. Inspection Mode
A: PROCEDURE
Reproduce the malfunction occurrence condition
as possible.
Drive the vehicle at a speed more than 40 km/h (25
MPH) for at least one minute.
ABS(diag)-26
Clear Memory Mode
ABS (DIAGNOSTICS)
9. Clear Memory Mode

A: OPERATION
For details concerning DTC clear operation, refer to
“Subaru Select Monitor”. <Ref. to ABS(diag)-15,
ABS(diag)-27
ABS Warning Light / Brake Warning Light Illumination Pattern
ABS (DIAGNOSTICS)
10.ABS Warning Light / Brake Warning Light Illumination Pattern

A: INSPECTION
(4)
(3) (3)
(2)
(1)
(7)
(6) (6)
(5)
(8)
(7)
(6) (6)
(9)
(10)
(11)
ABS00442
(1) Ignition switch (5) ABS warning light (9) Brake warning light (EBD warning
(2) OFF (6) Light OFF light)
(3) ON (7) Light ON (10) Parking brake
(4) Start (8) 1.5 seconds (11) Released
ABS(diag)-28
ABS (DIAGNOSTICS)
1) When the ABS warning light and brake warning light do not illuminate in accordance with this illumination
pattern, there must be an electrical malfunction.
2) When ABS warning light remains constantly OFF, check the combination meter circuit. <Ref. to ABS(di-
ag)-30, ABS WARNING LIGHT DOES NOT COME ON, ABS Warning Light / Brake Warning Light Illumina-
tion Pattern.>
3) When ABS warning light does not go off, check the combination meter circuit. <Ref. to ABS(diag)-33, ABS
WARNING LIGHT DOES NOT GO OFF, ABS Warning Light / Brake Warning Light Illumination Pattern.>
4) When brake warning light does not go off, check the brake warning light circuit, combination meter circuit.
<Ref. to ABS(diag)-36, BRAKE WARNING LIGHT DOES NOT GO OFF, ABS Warning Light / Brake Warning
Light Illumination Pattern.>
NOTE:
Even though the ABS warning light does not go off after 1.5 seconds from ABS warning light illumination, the
ABS function operates normally when the warning light goes off while driving at approximately 12km/h (7
MPH). However, the ABS function does not operate while the ABS warning light is illuminated.
ABS(diag)-29
ABS (DIAGNOSTICS)
B: ABS WARNING LIGHT DOES NOT COME ON

• Defective harness
TROUBLE SYMPTOM:
When the ignition switch is turned to ON (engine OFF), ABS warning light does not come on.
WIRING DIAGRAM:
• LHD model
BATTERY
SBF-1
SBF-7
E
IGNITION
SWITCH
No.5
No.33
3
4
COMBINATION
METER
GROUND
WARNING
WARNING
A: i10 TERMINAL
BRAKE
LIGHT
LIGHT
B82
ABS
B81
5
7
i3
20
B38
25
15
18
22
8
A: i10 B301 B38 B82
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 1 2
12 13 14 15 10 11 12 13 14 15 16 17 18 19 20 3 4 5 6
11 12 13 14 15 16 17 18 19 20 21 22 16 17 18 19 20 21 22 23 24 25 26
ABS00459
ABS(diag)-30
ABS (DIAGNOSTICS)
• RHD model
BATTERY
SBF-1
SBF-7
E
IGNITION
SWITCH
No.5
No.33
3
4
COMBINATION
METER
GROUND
WARNING
WARNING
A: i10 TERMINAL
BRAKE
LIGHT
LIGHT
B82
ABS
B81
5
7
i1
3
4
B36
25
15
18
22
8
A: i10 B301 i1 B82
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 1 2
12 13 14 15 3 4 5 6
11 12 13 14 15 16 17 18 19 20 21 22 16 17 18 19 20 21 22 23 24 25 26 1 2 3 4
5 6 7 8 9 10
11 12 13 14 15 16
17 18 19 20 21 22
23 24 25 26 27 28
ABS00440
ABS(diag)-31
ABS (DIAGNOSTICS)
Step Check Yes No

1 CHECK ILLUMINATION OF OTHER LIGHTS. Do other warning lights illumi- Go to step 2. Check the combi-
Turn the ignition switch to ON. (engine OFF) nate? nation meter.
2 READ DTC. Is DTC displayed? Perform the diag- Go to step 3.
Read the DTC. <Ref. to ABS(diag)-25, Read nosis according to
Diagnostic Trouble Code (DTC).> DTC.
3 CHECK GROUND SHORT OF HARNESS. Is the resistance more than 1 Go to step 4. Repair the har-
1) Turn the ignition switch to OFF. M&? ness and connec-
2) Disconnect the connector (B301) from tor between
ABSCM&H/U. ABSCM&H/U and
3) Disconnect the connector (i10) from the combination meter
combination meter. connector.
4) Measure the resistance between ABSCM
4 CHECK ABSCM. Is the resistance more than 1 Check the combi- Replace the
1) Connect the connector (B301) to the M&? nation meter. ABSCM only.
ABSCM&H/U. <Ref. to ABS-8,
2) Turn the ignition to ON. REPLACEMENT,
3) Immediately after turning ignition switch to ABS Control Mod-
ON (within 1.5 seconds), measure the resis- ule and Hydraulic
tance of harness between the combination Control Unit
meter connector and chassis ground. (ABSCM&H/U).>
(i10) No. 5 — Chassis ground:
ABS(diag)-32
ABS (DIAGNOSTICS)
C: ABS WARNING LIGHT DOES NOT GO OFF

• Open in harness
TROUBLE SYMPTOM:
When starting the engine, the ABS warning light is kept on.
WIRING DIAGRAM:
• LHD model
BATTERY
SBF-1
SBF-7
E
IGNITION
SWITCH
No.5
No.33
3
4
COMBINATION
METER
GROUND
WARNING
WARNING
A: i10 TERMINAL
BRAKE
LIGHT
LIGHT
B82
ABS
B81
5
7
i3
20
B38
25
15
18
22
8
A: i10 B301 B38 B82
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 1 2
12 13 14 15 10 11 12 13 14 15 16 17 18 19 20 3 4 5 6
11 12 13 14 15 16 17 18 19 20 21 22 16 17 18 19 20 21 22 23 24 25 26
ABS00459
ABS(diag)-33
ABS (DIAGNOSTICS)
• RHD model
BATTERY
SBF-1
SBF-7
E
IGNITION
SWITCH
No.5
No.33
3
4
COMBINATION
METER
GROUND
WARNING
WARNING
A: i10 TERMINAL
BRAKE
LIGHT
LIGHT
B82
ABS
B81
5
7
i1
3
4
B36
25
15
18
22
8
A: i10 B301 i1 B82
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 1 2
12 13 14 15 3 4 5 6
11 12 13 14 15 16 17 18 19 20 21 22 16 17 18 19 20 21 22 23 24 25 26 1 2 3 4
5 6 7 8 9 10
11 12 13 14 15 16
17 18 19 20 21 22
23 24 25 26 27 28
ABS00440
ABS(diag)-34
ABS (DIAGNOSTICS)
Step Check Yes No

1) Turn the ignition switch to OFF. &? ness and connec-
2) Disconnect the connector (B301) from tor between
4) Measure the resistance between ABSCM
connector and combination meter connector.
(B301) No. 22 — (i10) No. 5:
3 CHECK POOR CONTACT IN CONNECTOR. Is there poor contact? Repair the con- Go to step 4.
Check poor contact in all connectors. nector.
4 CHECK ABSCM. Is the resistance less than 0.5 Check the combi- Replace the
1) Connect the connector (B301) to the &? nation meter. ABSCM only.
ABSCM&H/U. <Ref. to ABS-8,
2) Turn the ignition switch to ON. REPLACEMENT,
3) Measure the resistance between combina- ABS Control Mod-
tion meter connector and chassis ground. ule and Hydraulic
Connector & terminal Control Unit
(i10) No. 5 — Chassis ground: (ABSCM&H/U).>
ABS(diag)-35
ABS (DIAGNOSTICS)
D: BRAKE WARNING LIGHT DOES NOT GO OFF

• Brake warning light circuit is shorted.
• Defective sensor/connector
TROUBLE SYMPTOM:
After starting the engine, the brake warning light is kept on though the parking lever is released.
WIRING DIAGRAM:
• LHD model
BATTERY
SBF-1
SBF-7
IGNITION
SWITCH
E
No.5
A4
A3
WARNING
BRAKE
LIGHT
A: i10
A8
A7
BRAKE FLUID
8
LEVEL SWITCH
i1 i3
16
20
B301 ABSCM & H/U

B36 B38
1
2
B16
B97
2
1
4
R1 B229
R4
PARKING
BRAKE
SWITCH
E
B16 i1 B301 A: i10
1 1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10 11
2 1 2 3 4 12 13 14 15
16 17 18 19 20 21 22 23 24 25 26 11 12 13 14 15 16 17 18 19 20 21 22
5 6 7 8 9 10
11 12 13 14 15 16
17 18 19 20 21 22
23 24 25 26 27 28
B229 B38 B97
1 2 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7
10 11 12 13 14 15 16 17 18 19 20 8 9 10 11 12 13 14 15 16
ABS00460
ABS(diag)-36
ABS (DIAGNOSTICS)
• RHD model
BATTERY
SBF-1
SBF-7
IGNITION
SWITCH
E
NO.5
A4
A3
WARNING
BRAKE
LIGHT
A: i10
A8
A7
BRAKE FLUID
8
LEVEL SWITCH
i1
16
B301 ABSCM & H/U

B36
1
2
B16
B97
2
1
5
R1 B229
R4
PARKING
BRAKE
SWITCH
E
B16 i1 B301 A: i10
1 1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10 11
2 1 2 3 4 12 13 14 15
16 17 18 19 20 21 22 23 24 25 26 11 12 13 14 15 16 17 18 19 20 21 22
5 6 7 8 9 10
11 12 13 14 15 16
17 18 19 20 21 22
23 24 25 26 27 28
B229 B97
1 2 1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
ABS00412
ABS(diag)-37
ABS (DIAGNOSTICS)
Step Check Yes No

1 CHECK INSTALLATION OF ABSCM&H/U Is the connector correctly Go to step 2. Insert the
CONNECTOR. inserted? ABSCM&H/U con-
1) Turn the ignition switch to OFF. nector until the
2) Check that the ABSCM&H/U connector is clamp locks onto
inserted to ABSCM&H/U until the clamp locks it.
onto it.
3 CHECK THE BRAKE FLUID AMOUNT. Is the amount of brake fluid Go to step 4. Replenish brake
Check the amount of brake fluid in the reser- between the lines of MAX and fluid to the speci-
voir tank of master cylinder. MIN? fied value.
4 CHECK BRAKE FLUID LEVEL SWITCH. Is the resistance more than 1 Go to step 5. Replace the mas-
1) Disconnect the level switch connector (B16) M&? ter cylinder.
from master cylinder.
2) Measure the resistance of master cylinder
terminals.
Terminals
No. 1 — No. 2:
5 CHECK PARKING BRAKE SWITCH. Is the resistance more than 1 Go to step 6. Replace the park-
1) Disconnect the connector (R4) from park- M&? ing brake switch.
ing brake switch.
3) Measure the resistance between parking
brake switch terminal and chassis ground.
1) Disconnect the connector (i10) from combi- M&? ness connector
nation meter. between combina-
2) Measure the resistance between combination meter and
tion meter connector and chassis ground. parking brake
Connector & terminal switch.
(i10) No. 8 — Chassis ground:
7 CHECK HARNESS. Is the resistance less than 0.5 Go to step 8. Repair harness
1) Disconnect the connector (B301) from &? between
3) Measure the resistance between
ABSCM&H/U connector and combination
meter connector.
(B301) No. 8 — (i10) No. 7:
9 CHECK ABSCM. Is the resistance less than 0.5 Check the combi- Replace the
1) Connect the connector to the ABSCM&H/U. &? nation meter. ABSCM only.
2) Turn the ignition switch to ON. <Ref. to ABS-8,
3) Measure the resistance between combina- REPLACEMENT,
tion meter connector and chassis ground. ABS Control Mod-
Connector & terminal ule and Hydraulic
(i10) No. 7 — Chassis ground: Control Unit
(ABSCM&H/U).>
ABS(diag)-38
List of Diagnostic Trouble Code (DTC)
ABS (DIAGNOSTICS)
11.List of Diagnostic Trouble Code (DTC)

A: LIST
DTC Content of diagnosis Display Reference target
<Ref. to ABS(diag)-42, DTC C0101 ABS
Rear Right ABS Sen- WHEEL SPEED SENSOR RR MALFUNC-
Rear ABS wheel
C0101 sor Circuit Open or TION (BROKEN WIRE, INPUT VOLTAGE
speed sensor RH
Shorted Battery TOO HIGH), Diagnostic Procedure with
Diagnostic Trouble Code (DTC).>
Rear Left ABS Sensor WHEEL SPEED SENSOR RL MALFUNC-
Rear ABS wheel
C0102 Circuit Open or TION (BROKEN WIRE, INPUT VOLTAGE
speed sensor LH
ABS wheel speed sen- Diagnostic Trouble Code (DTC).>
sor malfunction (Bro-
ken wire, short) <Ref. to ABS(diag)-42, DTC C0103 ABS
Front Right ABS Sen- WHEEL SPEED SENSOR FR MALFUNC-
Front ABS wheel
C0103 sor Circuit Open or TION (BROKEN WIRE, INPUT VOLTAGE
speed sensor RH
Front Left ABS Sensor WHEEL SPEED SENSOR FL MALFUNC-
Front ABS wheel
C0104 Circuit Open or TION (BROKEN WIRE, INPUT VOLTAGE
speed sensor LH
Abnormal signal of WHEEL SPEED SENSOR RR MALFUNC-
Rear Right ABS Sen-
C0105 rear ABS wheel speed TION (ABS WHEEL SPEED SENSOR
sor Signal
sensor RH ABNORMAL SIGNAL), Diagnostic Proce-
dure with Diagnostic Trouble Code (DTC).>
Abnormal signal of WHEEL SPEED SENSOR RL MALFUNC-
Rear Left ABS Sensor
C0106 rear ABS wheel speed TION (ABS WHEEL SPEED SENSOR
Signal
ABS wheel speed sen- sensor LH ABNORMAL SIGNAL), Diagnostic Proce-
sor malfunction (ABS dure with Diagnostic Trouble Code (DTC).>
wheel speed sensor <Ref. to ABS(diag)-46, DTC C0107 ABS
abnormal signal) Abnormal signal of WHEEL SPEED SENSOR FR MALFUNC-
Front Right ABS Sen-
C0107 front ABS wheel speed TION (ABS WHEEL SPEED SENSOR
sor Signal
sensor RH ABNORMAL SIGNAL), Diagnostic Proce-
Abnormal signal of WHEEL SPEED SENSOR FL MALFUNC-
Front Left ABS Sensor
C0108 front ABS wheel speed TION (ABS WHEEL SPEED SENSOR
Signal
sensor LH ABNORMAL SIGNAL), Diagnostic Proce-
<Ref. to ABS(diag)-65, DTC C0109 POWER
Power Supply Voltage VOLTAGE MALFUNCTION, Diagnostic Pro-
C0109 Power voltage malfunction
Failure cedure with Diagnostic Trouble Code
(DTC).>
CONTROL MODULE MALFUNCTION,
C0110 ABS control module malfunction ECM
Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>
<Ref. to ABS(diag)-71, DTC C0111
MOTOR/MOTOR RELAY MALFUNCTION,
C0111 Motor/motor relay on failure Motor and Motor Relay
ble Code (DTC).>
<Ref. to ABS(diag)-69, DTC C0114 VALVE
C0114 Valve relay on failure Valve Relay RELAY MALFUNCTION, Diagnostic Proce-
ABS(diag)-39
ABS (DIAGNOSTICS)

ABS wheel speed sen-
Abnormal ABS wheel WHEEL SPEED SENSOR SIGNAL MAL-
sor malfunction (ABS Any One of Four ABS
C0115 speed sensor on any FUNCTION IN ONE OF FOUR WHEELS,
wheel speed sensor Sensors Signal
one of four sensors Diagnostic Procedure with Diagnostic Trou-
abnormal signal)
ble Code (DTC).>
<Ref. to ABS(diag)-74, DTC C0116 FAULTY
C0116 Stop light switch signal circuit malfunction Brake Light Switch STOP LIGHT SWITCH, Diagnostic Proce-
<Ref. to ABS(diag)-76, DTC C0118 G SEN-
SOR OUTPUT VOLTAGE MALFUNCTION,
C0118 Faulty G sensor output voltage G Sensor Failure
ble Code (DTC).>
<Ref. to ABS(diag)-79, DTC C0119 G SEN-
SOR OUTPUT VOLTAGE MALFUNCTION,
C0119 Abnormal G sensor output voltage G Sensor Signal
ble Code (DTC).>
<Ref. to ABS(diag)-55, DTC C0120 FRONT
INLET SOLENOID VALVE LH MALFUNC-
Inlet valve malfunction FL Hold Valve mal- TION IN ABS CONTROL MODULE AND
C0120 Front inlet valve LH
in hydraulic unit function HYDRAULIC CONTROL UNIT (ABSCM&H/
U), Diagnostic Procedure with Diagnostic
Trouble Code (DTC).>
OUTLET SOLENOID VALVE LH MAL-
Outlet valve malfunc- FL Pressure Reducing FUNCTION IN ABS CONTROL MODULE
C0121 Front outlet valve LH
tion in hydraulic unit Valve malfunction AND HYDRAULIC CONTROL UNIT
(ABSCM&H/U), Diagnostic Procedure with
INLET SOLENOID VALVE RH MALFUNC-
Inlet valve malfunction FR Hold Valve mal- TION IN ABS CONTROL MODULE AND
C0122 Front inlet valve RH
OUTLET SOLENOID VALVE RH MAL-
Outlet valve malfunc- FR Pressure Reducing FUNCTION IN ABS CONTROL MODULE
C0123 Front outlet valve RH
tion in hydraulic unit Valve malfunction AND HYDRAULIC CONTROL UNIT
<Ref. to ABS(diag)-55, DTC C0124 REAR
INLET SOLENOID VALVE LH MALFUNC-
Inlet valve malfunction RL Hold Valve mal- TION IN ABS CONTROL MODULE AND
C0124 Rear inlet valve LH
OUTLET SOLENOID VALVE LH MAL-
Outlet valve malfunc- RL Pressure Reduc- FUNCTION IN ABS CONTROL MODULE
C0125 Rear outlet valve LH
tion in hydraulic unit ing Valve malfunction AND HYDRAULIC CONTROL UNIT
INLET SOLENOID VALVE RH MALFUNC-
Inlet valve malfunction RR Hold Valve mal- TION IN ABS CONTROL MODULE AND
C0126 Rear inlet valve RH
ABS(diag)-40
ABS (DIAGNOSTICS)

OUTLET SOLENOID VALVE RH MAL-
Outlet valve malfunc- RR Pressure Reduc- FUNCTION IN ABS CONTROL MODULE
C0127 Rear outlet valve RH
tion in hydraulic unit ing Valve malfunction AND HYDRAULIC CONTROL UNIT
<Ref. to ABS(diag)-68, DTC C0140 CAN
Improper CAN com- COMMUNICATION MALFUNCTION, Diag-
C0140 CAN communication malfunction
munication nostic Procedure with Diagnostic Trouble
Code (DTC).>
ABS(diag)-41
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
ABS (DIAGNOSTICS)
12.Diagnostic Procedure with Diagnostic Trouble Code (DTC)

A: DTC C0101 ABS WHEEL SPEED SENSOR RR MALFUNCTION (BROKEN
WIRE, INPUT VOLTAGE TOO HIGH)
NOTE:
For the diagnostic procedure, refer to DTC C0104. <Ref. to ABS(diag)-43, DTC C0104 ABS WHEEL SPEED
SENSOR FL MALFUNCTION (BROKEN WIRE, INPUT VOLTAGE TOO HIGH), Diagnostic Procedure with
B: DTC C0102 ABS WHEEL SPEED SENSOR RL MALFUNCTION (BROKEN
NOTE:
C: DTC C0103 ABS WHEEL SPEED SENSOR FR MALFUNCTION (BROKEN
NOTE:
ABS(diag)-42
ABS (DIAGNOSTICS)
D: DTC C0104 ABS WHEEL SPEED SENSOR FL MALFUNCTION (BROKEN

DTC DETECTING CONDITION:
• Defective ABS wheel speed sensor (broken wire, input voltage too high)
• Defective harness connector
TROUBLE SYMPTOM:
ABS does not operate.
WIRING DIAGRAM:
• LHD model
B301 ABSCM & H/U
15
16
17
5
6
3
4
2
1
B98
15
14
6
5
R2
TWISTED WIRE
TWISTED WIRE
TWISTED WIRE
TWISTED WIRE
B15 B6
R73 R72
1
2
1
2
1
2
1
2
FRONT ABS FRONT ABS

WHEEL SPEED WHEEL SPEED REAR ABS REAR ABS
SENSOR LH SENSOR RH WHEEL SPEED WHEEL SPEED
SENSOR LH SENSOR RH
B6 R72 B98 B301
B15 R73
1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 10 11
8 9 10 11 12 13 14 15 16 12 13 14 15
16 17 18 19 20 21 22 23 24 25 26
1 2
ABS00461
ABS(diag)-43
ABS (DIAGNOSTICS)
• RHD model
B301 ABSCM & H/U
15
16
17
5
6
3
4
2
1
B97
19
18
8
7
R1
TWISTED WIRE
TWISTED WIRE
TWISTED WIRE
TWISTED WIRE
B15 B6
R73 R72
1
2
1
2
1
2
1
2
FRONT ABS FRONT ABS

SENSOR LH SENSOR RH
B6 R72
B97 B301
B15 R73
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10 11
10 11 12 13 14 15 16 17 18 19 20 12 13 14 15
1 2 16 17 18 19 20 21 22 23 24 25 26
ABS00413
ABS(diag)-44
ABS (DIAGNOSTICS)
Step Check Yes No

Check the poor contact between ABSCM&H/U nector.
and ABS wheel speed sensor.
ABSCM&H/U AND ABS WHEEL SPEED &? ness connector
SENSOR. between
1) Disconnect the connector (B301) from ABSCM&H/U and
ABSCM&H/U. ABS wheel speed
2) Disconnect the connector from ABS wheel sensor.
speed sensor.
ABSCM&H/U connector and ABS wheel speed
sensor connector.
DTC C0101
(B301) No. 3 — (R72) No. 1:
(B301) No. 4 — (R72) No. 2:
DTC C0102
(B301) No. 2 — (R73) No. 1:
(B301) No. 17 — (R73) No. 2:
DTC C0103
(B301) No. 5 — (B6) No. 1:
(B301) No. 6 — (B6) No. 2:
DTC C0104
(B301) No. 16 — (B15) No. 1:
(B301) No. 1 — (B15) No. 2:
Measure the resistance between ABSCM&H/U M&? ness connector
connector and chassis ground. between
Connector & terminal ABSCM&H/U and
DTC C0101 ABS wheel speed
(B301) No. 4 — Chassis ground: sensor.
DTC C0102
DTC C0103
DTC C0104
4 CHECK ABS WHEEL SPEED SENSOR POW- Is the voltage 5 — 16 V? Go to step 6. Go to step 5.
ER SUPPLY CIRCUIT.
1) Connect the ABSCM&H/U connector.
3) Measure the voltage between ABS wheel
speed sensor connector and chassis ground.
DTC C0101
(R72) No. 1 — Chassis ground (#):
DTC C0102
(R73) No. 1 — Chassis ground (#):
DTC C0103
DTC C0104
ABS(diag)-45
ABS (DIAGNOSTICS)
Step Check Yes No

5 CHECK ABSCM&H/U POWER SUPPLY CIR- Is the voltage 10 — 15 V? Go to step 7. Check the genera-
CUIT. tor, battery,
1) Turn the ignition switch to OFF. ABSCM&H/U
2) Disconnect the ABSCM&H/U connector. power circuit.
4) Measure the voltage between ABSCM&H/
U connector and chassis ground.
(B301) No. 18 (+) — (B301) No. 15 (#):
6 CHECK ABS WHEEL SPEED SENSOR SIG- Is the pattern the same wave- Go to step 7. Replace the speed
NAL. form as shown in the figure? sensor.
1) Install the ABS wheel speed sensor.
2) Prepare an oscilloscope.
3) Check ABS wheel speed sensor. <Ref. to
ABS-13, ABS WHEEL SPEED SENSOR,
INSPECTION, Front ABS Wheel Speed Sen-
sor.>
7 CHECK ABSCM&H/U. Is the same DTC displayed? Replace the Go to step 8.
1) Connect all the connectors. ABSCM only.
2) Erase the memory. <Ref. to ABS-8,
3) Perform the inspection mode. <Ref. to REPLACEMENT,
ABS(diag)-17, CLEAR MEMORY MODE, ABS Control Mod-
OPERATION, Subaru Select Monitor.> ule and Hydraulic
4) Read the DTC. Control Unit
(ABSCM&H/U).>
8 CHECK ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Perform the diag- It results from a
nosis according to temporary noise
DTC. interference.
E: DTC C0105 ABS WHEEL SPEED SENSOR RR MALFUNCTION (ABS WHEEL

SPEED SENSOR ABNORMAL SIGNAL)
NOTE:
SENSOR FL MALFUNCTION (ABS WHEEL SPEED SENSOR ABNORMAL SIGNAL), Diagnostic Proce-
F: DTC C0106 ABS WHEEL SPEED SENSOR RL MALFUNCTION (ABS WHEEL
NOTE:
G: DTC C0107 ABS WHEEL SPEED SENSOR FR MALFUNCTION (ABS WHEEL
NOTE:
ABS(diag)-46
ABS (DIAGNOSTICS)
H: DTC C0108 ABS WHEEL SPEED SENSOR FL MALFUNCTION (ABS WHEEL

• Defective ABS wheel speed sensor signal (noise, abnormal signal, etc.)
TROUBLE SYMPTOM:
WIRING DIAGRAM:
• LHD model
B301 ABSCM & H/U
15
16
17
5
6
3
4
2
1
B98
15
14
6
5
R2
TWISTED WIRE
TWISTED WIRE
TWISTED WIRE
TWISTED WIRE
B15 B6
R73 R72
1
2
1
2
1
2
1
2
FRONT ABS FRONT ABS

SENSOR LH SENSOR RH
B6 R72 B98 B301
B15 R73
1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 10 11
8 9 10 11 12 13 14 15 16 12 13 14 15
16 17 18 19 20 21 22 23 24 25 26
1 2
ABS00461
ABS(diag)-47
ABS (DIAGNOSTICS)
• RHD model
B301 ABSCM & H/U
15
16
17
5
6
3
4
2
1
B97
19
18
8
7
R1
TWISTED WIRE
TWISTED WIRE
TWISTED WIRE
TWISTED WIRE
B15 B6
R73 R72
1
2
1
2
1
2
1
2
FRONT ABS FRONT ABS

SENSOR LH SENSOR RH
B6 R72
B97 B301
B15 R73
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10 11
10 11 12 13 14 15 16 17 18 19 20 12 13 14 15
1 2 16 17 18 19 20 21 22 23 24 25 26
ABS00413
ABS(diag)-48
ABS (DIAGNOSTICS)
Step Check Yes No

1 CHECK OUTPUT OF ABS WHEEL SPEED Does the speed indicated on Go to step 2. Go to step 7.
SENSOR USING SUBARU SELECT MONI- the display change in response
TOR. to the speedometer reading
1) Select {Current Data Display & Save} in during acceleration/decelera-
Subaru Select Monitor. tion when the steering wheel is
2) Read the ABS wheel speed sensor output in the straight-ahead position?
corresponding to the faulty wheel in Subaru
Select Monitor data display mode.
2 CHECK POOR CONTACT IN CONNECTOR. Is there poor contact in con- Repair the con- Go to step 3.
Turn the ignition switch to OFF. nectors between ABSCM&H/U nector.
and ABS wheel speed sensor?
3 CHECK SOURCES OF SIGNAL NOISE. Is the car phone, radio wave Go to step 4. Install the radio
Make sure the car phone, radio wave device device like radio and etc., elec- wave device and
like radio and etc., electric components are tric components installed cor- electric compo-
installed correctly. rectly? nents properly.
4 CHECK SOURCES OF SIGNAL NOISE. Is the noise sources installed? Install the noise Go to step 5.
Check that the noise sources are (such as an sources apart from
antenna) installed near the sensor harness. the sensor har-
ness.
(ABSCM&H/U).>
DTC. interference.
7 CHECK INSTALLATION OF ABS WHEEL Is the ABS wheel speed sen- Go to step 8. Tighten the ABS
SPEED SENSOR. sor installation bolt tightened wheel speed sen-
7.5 N'm (0.76 kgf-m, 5.5 ft-lb)? sor installation
bolts.
8 CHECK ABS WHEEL SPEED SENSOR SIG-Does the oscilloscope indicate Go to step 10. Go to step 9.
NAL. the waveform pattern like
1) Install the ABS wheel speed sensor.
shown in the figure when the
2) Prepare an oscilloscope. tire is slowly turned? Does the
3) Check ABS wheel speed sensor. <Ref. to
oscilloscope indication repeat
ABS-13, ABS WHEEL SPEED SENSOR, the waveform pattern like
INSPECTION, Front ABS Wheel Speed Sen-
shown in the figure when the
sor.> tire is slowly turned in equal
speed for more one rotation?
9 CHECK ABS WHEEL SPEED SENSOR AND Is there foreign particles, Remove dirt com- Go to step 10.
MAGNETIC ENCODER. breakage or damage in the pletely. Replace
pole piece of ABS wheel speed the ABS wheel
sensor or magnetic encoder? speed sensor or
magnetic encoder
as a unit with hub
unit bearing when
it is broken or
damaged.
Make sure the car phone, radio wave device device like radio and etc., elec- wave device and
like CB and etc., electric components are tric components installed cor- electric compo-
installed correctly. rectly? nents properly.
ABS(diag)-49
ABS (DIAGNOSTICS)
Step Check Yes No

11 CHECK SOURCES OF SIGNAL NOISE. Are noise sources installed? Go to step 12. Install the noise
Check if the noise sources are (such as an sources apart from
ness.
(ABSCM&H/U).>
DTC. interference.
NOTE:
Though ABS warn-
ing light remains to
illuminate at this
time, it is normal.
Drive the vehicle at
more than 12 km/h
(7 MPH) in order to
make ABS warning
light go off. Be sure
to drive the vehicle
and check the
warning light goes
off.
ABS(diag)-50
ABS (DIAGNOSTICS)
I: DTC C0115 ABS WHEEL SPEED SENSOR SIGNAL MALFUNCTION IN ONE

OF FOUR WHEELS
• Defective ABS wheel speed sensor signal (noise, abnormal signal, etc.)
• Defective magnetic encoder
• When a wheel is turned freely for a long time
TROUBLE SYMPTOM:
• ABS does not operate.
• EBD does not operate.
NOTE:
Brake warning light comes on as well as ABS warning light.
ABS(diag)-51
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
• LHD model
B301 ABSCM & H/U
15
16
17
5
6
3
4
2
1
B98
15
14
6
5
R2
TWISTED WIRE
TWISTED WIRE
TWISTED WIRE
TWISTED WIRE
B15 B6
R73 R72
1
2
1
2
1
2
1
2
FRONT ABS FRONT ABS

SENSOR LH SENSOR RH
B6 R72 B98 B301
B15 R73
1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 10 11
8 9 10 11 12 13 14 15 16 12 13 14 15
16 17 18 19 20 21 22 23 24 25 26
1 2
ABS00461
ABS(diag)-52
ABS (DIAGNOSTICS)
• RHD model
B301 ABSCM & H/U
15
16
17
5
6
3
4
2
1
B97
19
18
8
7
R1
TWISTED WIRE
TWISTED WIRE
TWISTED WIRE
TWISTED WIRE
B15 B6
R73 R72
1
2
1
2
1
2
1
2
FRONT ABS FRONT ABS

SENSOR LH SENSOR RH
B6 R72
B97 B301
B15 R73
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10 11
10 11 12 13 14 15 16 17 18 19 20 12 13 14 15
1 2 16 17 18 19 20 21 22 23 24 25 26
ABS00413
ABS(diag)-53
ABS (DIAGNOSTICS)
Step Check Yes No

1 WHETHER A WHEEL TURNED FREELY OR Did the wheels turn freely? ABS is normal. Go to step 2.
NOT. Erase the memory.
Check if the wheels have been turned freely for NOTE:
more than one minute, such as when the vehi- When the wheels
cle is jacked-up, under full-lock cornering or turn freely for a
when the wheels are not in contact with road long time, such as
surface. when the vehicle is
towed or jacked-
up, or when steer-
ing wheel is contin-
uously turned all
the way, this diag-
nostic trouble code
may sometimes
occur.
2 CHECK TIRE SPECIFICATIONS. Are the tire specifications cor- Go to step 3. Replace the tire.
Turn the ignition switch to OFF. rect?
3 CHECK WEAR OF TIRE. Is the tire worn excessively? Replace the tire. Go to step 4.
4 CHECK TIRE INFLATION PRESSURE. Is the tire pressure correct? Go to step 5. Adjust the tire
pressure.
(four of them) bolts.
6 CHECK ABS WHEEL SPEED SENSOR SIG- Does the oscilloscope indicate Go to step 8. Go to step 7.
NAL. the waveform pattern like
1) Install the ABS wheel speed sensor. shown in the figure when the
2) Prepare an oscilloscope. tire is slowly turned? Does the
3) Check ABS wheel speed sensor. <Ref. to oscilloscope indication repeat
ABS-13, ABS WHEEL SPEED SENSOR, the waveform pattern like
INSPECTION, Front ABS Wheel Speed Sen- shown in the figure when the
sor.> tire is slowly turned in equal
speed for more one rotation?
7 CHECK ABS WHEEL SPEED SENSOR AND Is there foreign particles, Remove dirt com- Go to step 8.
MAGNETIC ENCODER. breakage or damage in the pletely. Replace
pole piece of ABS wheel speed the ABS wheel
magnetic encoder
as a unit with hub
unit bearing when
it is broken or
damaged.
(ABSCM&H/U).>
ABS(diag)-54
ABS (DIAGNOSTICS)
Step Check Yes No

DTC. interference.
NOTE:
Though ABS warn-
ing light remains to
illuminate at this
time, it is normal.
more than 12 km/h
(7 MPH) in order to
make ABS warning
and check the
warning light goes
off.
J: DTC C0120 FRONT INLET SOLENOID VALVE LH MALFUNCTION IN ABS

CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U)
NOTE:
For the diagnostic procedure, refer to DTC C0126. <Ref. to ABS(diag)-56, DTC C0126 REAR INLET SOLE-
NOID VALVE RH MALFUNCTION IN ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (AB-
SCM&H/U), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
K: DTC C0122 FRONT INLET SOLENOID VALVE RH MALFUNCTION IN ABS
NOTE:
L: DTC C0124 REAR INLET SOLENOID VALVE LH MALFUNCTION IN ABS
NOTE:
ABS(diag)-55
ABS (DIAGNOSTICS)
M: DTC C0126 REAR INLET SOLENOID VALVE RH MALFUNCTION IN ABS

• Defective inlet solenoid valve in ABSCM&H/U
TROUBLE SYMPTOM:
NOTE:
ABS(diag)-56
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
BATTERY
SBF-1
GENERATOR
SBF-7
IGNITION
SWITCH
No.33
E
18
15
B301 ABSCM & H/U
B301
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15
16 17 18 19 20 21 22 23 24 25 26
ABS00414
ABS(diag)-57
ABS (DIAGNOSTICS)
Step Check Yes No

1 CHECK INPUT VOLTAGE OF ABSCM&H/U. Is the voltage 10 — 15 V? Go to step 2. Repair the
2) Disconnect the connector from ABSCM&H/ power circuit.
U.
3) Run the engine at idle.
2 CHECK GROUND CIRCUIT OF ABSCM&H/U. Is the resistance less than 0.5 Go to step 3. Repair the
1) Turn the ignition switch to OFF. &? ABSCM&H/U
2) Measure the resistance between ground harness.
ABSCM&H/U connector and chassis ground.
nector between generator, bat- nector.
tery and ABSCM&H/U?
4 CHECK ABSCM&H/U. Is the same DTC displayed? Replace Go to step 5.
1) Connect all the connectors. ABSCM&H/U.
3) Perform the inspection mode. ABS Control Mod-
4) Read the DTC. ule and Hydraulic
Control Unit
(ABSCM&H/U).>
5 CHECK ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Inspect the DTC Temporary poor
using “List of Diag- contact occurs.
nostic Trouble
Code (DTC)”.
<Ref. to
ABS(diag)-39, List
of Diagnostic Trou-
ble Code (DTC).>
ABS(diag)-58
ABS (DIAGNOSTICS)
N: DTC C0121 FRONT OUTLET SOLENOID VALVE LH MALFUNCTION IN ABS

NOTE:
For the diagnostic procedure, refer to DTC C0127. <Ref. to ABS(diag)-60, DTC C0127 REAR OUTLET SO-
LENOID VALVE RH MALFUNCTION IN ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT
(ABSCM&H/U), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
O: DTC C0123 FRONT OUTLET SOLENOID VALVE RH MALFUNCTION IN ABS
NOTE:
P: DTC C0125 REAR OUTLET SOLENOID VALVE LH MALFUNCTION IN ABS
NOTE:
ABS(diag)-59
ABS (DIAGNOSTICS)
Q: DTC C0127 REAR OUTLET SOLENOID VALVE RH MALFUNCTION IN ABS

• Defective outlet solenoid valve in ABSCM&H/U
TROUBLE SYMPTOM:
NOTE:
ABS(diag)-60
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
BATTERY
SBF-1
GENERATOR
SBF-7
IGNITION
SWITCH
No.33
E
18
15
B301 ABSCM & H/U
B301
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15
16 17 18 19 20 21 22 23 24 25 26
ABS00414
ABS(diag)-61
ABS (DIAGNOSTICS)
Step Check Yes No

2) Disconnect the connector from ABSCM&H/ power circuit.
U.
tery and ABSCM&H/U?
Control Unit
(ABSCM&H/U).>
nostic Trouble
Code (DTC)”.
<Ref. to
ABS(diag)-39, List
of Diagnostic Trou-
ble Code (DTC).>
ABS(diag)-62
ABS (DIAGNOSTICS)
R: DTC C0110 ABS CONTROL MODULE MALFUNCTION

Defective ABSCM&H/U
TROUBLE SYMPTOM:
NOTE:
WIRING DIAGRAM:
B301 ABSCM & H/U
15
B301
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15
16 17 18 19 20 21 22 23 24 25 26
ABS00415
ABS(diag)-63
ABS (DIAGNOSTICS)
Step Check Yes No

2) Disconnect the connector from ABSCM&H/ ground harness.
U.
ABSCM&H/U and chassis ground.
nectors between battery, igni- nector.
tion switch and ABSCM&H/U?
3 CHECK SOURCES OF SIGNAL NOISE. Is the car telephone or the Go to step 4. Properly install the
radio properly installed? car telephone or
the wireless trans-
mitter.
4 CHECK SOURCES OF SIGNAL NOISE. Are noise sources (such as an Install the noise Go to step 5.
antenna) installed near the sources apart from
sensor harness? the sensor har-
ness.
3) Perform the inspection mode. REPLACEMENT,
4) Read the DTC. ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
nostic Trouble
Code (DTC)”.
<Ref. to
ABS(diag)-39, List
of Diagnostic Trou-
ble Code (DTC).>
ABS(diag)-64
ABS (DIAGNOSTICS)
S: DTC C0109 POWER VOLTAGE MALFUNCTION

Power voltage of the ABSCM&H/U is too low or too high.
TROUBLE SYMPTOM:
• EBD may not operate.
NOTE:
If EBD does not operate, brake warning light comes on as well as ABS warning light. Both warning lights go
off if voltage returns.
ABS(diag)-65
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
BATTERY
SBF-1
GENERATOR
SBF-7
IGNITION
SWITCH
No.33
E
18
15
B301 ABSCM & H/U
B301
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15
16 17 18 19 20 21 22 23 24 25 26
ABS00414
ABS(diag)-66
ABS (DIAGNOSTICS)
Step Check Yes No

1 CHECK GENERATOR. Is the voltage 10 — 15 V? Go to step 2. Repair the genera-
1) Start the engine. tor.
2) Run the engine at idle after warming up.
3) Measure the voltage between generator B
terminal and chassis ground.
Terminals
Generator B terminal (+) — Chassis
ground (#):
2 CHECK BATTERY TERMINAL. Are the positive and negative Go to step 3. Tighten the termi-
Turn the ignition switch to OFF. battery terminals clamped nal.
tightly?
1) Disconnect the connector from ABSCM&H/ ABSCM&H/U
U. power circuit.
3) Operate the devices such as headlights, air
conditioner, defogger, etc. which produce
much electrical loading.
tery and ABSCM&H/U?
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
nostic Trouble
Code (DTC)”.
<Ref. to
ABS(diag)-39, List
of Diagnostic Trou-
ble Code (DTC).>
ABS(diag)-67
ABS (DIAGNOSTICS)
T: DTC C0140 CAN COMMUNICATION MALFUNCTION

Defective CAN communication
TROUBLE SYMPTOM:
Possibly the vehicle speed cannot output on CAN.
Step Check Yes No

1 CHECK LAN SYSTEM. Is there any fault in LAN sys- Repair it according Replace the
Perform the diagnosis for LAN system. <Ref. to tem? to DTC of LAN ABSCM only.
LAN(diag)-24, OPERATION, Read Diagnostic system. <Ref. to ABS-8,
Trouble Code (DTC).> REPLACEMENT,
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
ABS(diag)-68
ABS (DIAGNOSTICS)
U: DTC C0114 VALVE RELAY MALFUNCTION

Defective valve relay
TROUBLE SYMPTOM:
• EBD does not operate depending on the trouble contents.
NOTE:
Brake warning light comes on as well as ABS warning light when EBD does not operate.
WIRING DIAGRAM:
BATTERY
SBF-1
SBF-7
No.1
IGNITION
SWITCH E
No.33
B301
15
14
18
MOTOR RELAY
PUMP MOTOR
RR OUTLET
FR OUTLET
RL OUTLET
FL OUTLET
SOLENOID
RL INLET
FR INLET
RR INLET
FL INLET
VALVE
ABSCM & H/U

M
VALVE RELAY
B301
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15
16 17 18 19 20 21 22 23 24 25 26
ABS00416
ABS(diag)-69
ABS (DIAGNOSTICS)
Step Check Yes No

1 CHECK INPUT VOLTAGE OF ABSCM&H/U. Is the voltage 10 — 15 V? Go to step 2. Repair the har-
1) Turn the ignition switch to OFF. ness connector
2) Disconnect the connector from ABSCM&H/ between battery
U. and ABSCM&H/U.
3 CHECK VALVE RELAY IN ABSCM&H/U. Is the resistance more than 1 Go to step 4. Replace the
Measure the resistance between ABSCM&H/U M&? ABSCM only.
terminals. <Ref. to ABS-8,
Terminals REPLACEMENT,
No. 14 — No. 15: ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
tery and ABSCM&H/U?
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
nostic Trouble
Code (DTC)”.
<Ref. to
ABS(diag)-39, List
of Diagnostic Trou-
ble Code (DTC).>
ABS(diag)-70
ABS (DIAGNOSTICS)
V: DTC C0111 MOTOR/MOTOR RELAY MALFUNCTION

• Defective motor
• Defective motor relay
TROUBLE SYMPTOM:
WIRING DIAGRAM:
BATTERY
SBF-2 SBF-1
SBF-7
IGNITION
SWITCH E
No.33
B301
15
12
13
18
MOTOR RELAY
PUMP MOTOR
RR OUTLET
FR OUTLET
RL OUTLET
FL OUTLET
SOLENOID
RL INLET
FR INLET
RR INLET
FL INLET
ABSCM & H/U

VALVE
VALVE RELAY
E E
B301
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15
16 17 18 19 20 21 22 23 24 25 26
ABS00417
ABS(diag)-71
ABS (DIAGNOSTICS)
Step Check Yes No

2) Disconnect the connector from ABSCM&H/ between battery
U. and ABSCM&H/U.
2 CHECK GROUND CIRCUIT OF MOTOR. Is the resistance less than 0.5 Go to step 3. Repair the
1) Run the engine at idle. ness connector
2) Measure the voltage between ABSCM&H/ between battery,
U connector and chassis ground. ignition switch and
Connector & terminal ABSCM&H/U.
5 CHECK MOTOR OPERATION. Can the motor revolution noise Go to step 6. Replace
Operate the ABS sequence control. <Ref. to (buzz) be heard when carrying ABSCM&H/U.
ABS-10, ABS Sequence Control.> out the ABS sequence control? <Ref. to ABS-6,
NOTE: ABS Control Mod-
Use the diagnosis connector to operate the ule and Hydraulic
ABS sequence control. Control Unit
(ABSCM&H/U).>
Turn the ignition switch to OFF. nector between generator, bat- nector.
tery and ABSCM&H/U?
Control Unit
(ABSCM&H/U).>
ABS(diag)-72
ABS (DIAGNOSTICS)
Step Check Yes No

nostic Trouble NOTE:
Code (DTC)”. Though ABS warn-
<Ref. to ing light remains to
ABS(diag)-39, List illuminate at this
of Diagnostic Trou- time, it is normal.
ble Code (DTC).> Drive the vehicle at
more than 12 km/h
(7 MPH) in order to
make ABS warning
and check the
warning light goes
off.
ABS(diag)-73
ABS (DIAGNOSTICS)
W: DTC C0116 FAULTY STOP LIGHT SWITCH

Defective stop light switch
WIRING DIAGRAM:
BATTERY
SBF-1
E
SBF-3
No.8
STOP LIGHT SWITCH

OC WC
1 2
2 3
B64 : OC
B65 : WC
9
B159
5
WC : WITH CRUISE CONTROL
OC : WITHOUT CRUISE CONTROL

20
B301 ABSCM & H/U
B64 B65 B159 B301
1 2 1 2 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15
3 4 5 6 7 8 9 16 17 18 19 20 21 22 23 24 25 26
ABS00462
ABS(diag)-74
ABS (DIAGNOSTICS)
Step Check Yes No

1 CHECK OUTPUT OF STOP LIGHT SWITCH Is “OFF” displayed on the dis- Go to step 2. Go to step 3.
USING SUBARU SELECT MONITOR. play?
1) Select {Current Data Display & Save} in
Subaru Select Monitor.
2) Release the brake pedal.
3) Read the stop light switch signal in Subaru
Select Monitor.
2 CHECK OUTPUT OF STOP LIGHT SWITCH Is “ON” displayed on the dis- Go to step 5. Go to step 3.
USING SUBARU SELECT MONITOR. play?
1) Depress the brake pedal.
2) Read the stop light switch output in Subaru
Select Monitor.
3 CHECK IF STOP LIGHTS COME ON. Does the stop light illuminate? Go to step 4. Repair the stop
Depress the brake pedal. lights circuit.
4 CHECK OPEN CIRCUIT IN HARNESS. Is the voltage 10 — 15 V? Go to step 5. Repair harness
1) Turn the ignition switch to OFF. between stop light
2) Disconnect the connector from ABSCM&H/ switch and
U. ABSCM&H/U con-
3) Depress the brake pedal. nector.
5 CHECK POOR CONTACT IN CONNECTOR. Is there poor contact in con- Go to step 6. Repair the con-
nector between stop light nector.
switch and ABSCM&H/U?
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
nostic Trouble
Code (DTC)”.
<Ref. to
ABS(diag)-39, List
of Diagnostic Trou-
ble Code (DTC).>
ABS(diag)-75
ABS (DIAGNOSTICS)
X: DTC C0118 G SENSOR OUTPUT VOLTAGE MALFUNCTION

Defective G sensor
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B301 ABSCM & H/U
21
24
10
15
B292
1
2
3
ABS G SENSOR
B292 B301
1 2 3 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15
16 17 18 19 20 21 22 23 24 25 26
ABS00419
ABS(diag)-76
ABS (DIAGNOSTICS)
Step Check Yes No

1 CHECK OUTPUT OF G SENSOR USING Is the reading indicated on dis- Go to step 2. Go to step 5.
SUBARU SELECT MONITOR. play #1.2 — 1.2 m/s when G
1) Select {Current Data Display & Save} in sensor is horizontal?
2) Read the G sensor output on Subaru
Select Monitor.
nector between ABSCM&H/U nector.
and G sensor?
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
nostic Trouble
Code (DTC)”.
<Ref. to
ABS(diag)-39, List
of Diagnostic Trou-
ble Code (DTC).>
5 CHECK INPUT VOLTAGE OF G SENSOR. Is the voltage 4.75 — 5.25 V? Go to step 6. Repair the har-
2) Remove the console box. between G sensor
3) Remove the G sensor from vehicle. (Do not and ABSCM&H/U.
disconnect connector.)
5) Measure the voltage between G sensor
connector terminals.
(B292) No. 1 (+) — No. 3 (#):
6 CHECK OPEN CIRCUIT IN G SENSOR OUT- Is the resistance 1.8 — 2.4 Go to step 7. Repair the har-
PUT HARNESS AND GROUND HARNESS. k&? ness connector
1) Turn the ignition switch to OFF. between G sensor
2) Disconnect the connector from ABSCM&H/ and ABSCM&H/U.
U.
ABSCM&H/U connector terminals.
(B301) No. 21 — No. 10:
7 CHECK GROUND SHORT IN G SENSOR Is the resistance more than 1 Go to step 8. Repair the har-
OUTPUT HARNESS. M&? ness between G
1) Disconnect the connector from G sensor. sensor and
2) Measure the resistance between ABSCM&H/U.
8 CHECK G SENSOR. Is the voltage 2.1 — 2.5 V Go to step 9. Replace G sen-
1) Connect the connector to G sensor. when G sensor is on a level? sor. <Ref. to ABS-
2) Connect the connector to ABSCM&H/U. 18, G Sensor.>
(B292) No. 2 (+) — No. 3 (#):
ABS(diag)-77
ABS (DIAGNOSTICS)
Step Check Yes No

Measure the voltage between G sensor con- when G sensor is inclined for- sor. <Ref. to ABS-
nector terminals. wards to 90"? 18, G Sensor.>
(B292) No. 2 (+) — No. 3 (#):
Measure the voltage between G sensor con- when G sensor is inclined sor. <Ref. to ABS-
nector terminals. backward to 90"? 18, G Sensor.>
(B292) No. 2 (+) — No. 3 (#):
Turn the ignition switch to OFF. nector between ABSCM&H/U nector.
and G sensor?
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
nostic Trouble
Code (DTC)”.
<Ref. to
ABS(diag)-39, List
of Diagnostic Trou-
ble Code (DTC).>
ABS(diag)-78
ABS (DIAGNOSTICS)
Y: DTC C0119 G SENSOR OUTPUT VOLTAGE MALFUNCTION

Defective G sensor output signal
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B301 ABSCM & H/U
21
24
10
15
B292
1
2
3
ABS G SENSOR
B292 B301
1 2 3 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15
16 17 18 19 20 21 22 23 24 25 26
ABS00419
ABS(diag)-79
ABS (DIAGNOSTICS)
Step Check Yes No

1 WHETHER A WHEEL TURNED FREELY OR Have the wheels been turned ABS is normal. Go to step 2.
NOT. freely when the vehicle is lifted Erase the memory.
up or drove on a rolling road?
2 CHECK OUTPUT OF G SENSOR USING Is the reading indicated on dis- Go to step 3. Go to step 8.
SUBARU SELECT MONITOR. play #1.2 — 1.2 m/s when G
1) Select {Current Data Display & Save} in sensor is on a level?
2) Read the Subaru Select Monitor display.
3 CHECK OUTPUT OF G SENSOR USING Is the reading indicated on dis- Go to step 4. Replace G sen-
SUBARU SELECT MONITOR. play 8.1 — 11.2 m/s when G sor. <Ref. to ABS-
1) Turn the ignition switch to OFF. sensor is inclined forward to 18, G Sensor.>
2) Remove the console box. 90"?
3) Remove the G sensor from vehicle. (Do not
disconnect connector.)
6) Read the Subaru Select Monitor display.
4 CHECK OUTPUT OF G SENSOR USING Is the reading indicated on dis- Go to step 5. Replace G sen-
SUBARU SELECT MONITOR. play #8.1 — #11.2 m/s when G sor. <Ref. to ABS-
Read the Subaru Select Monitor display. sensor is inclined backward to 18, G Sensor.>
90"?
Turn the ignition switch to OFF. nector between ABSCM&H/U nector.
and G sensor?
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
nostic Trouble
Code (DTC)”.
<Ref. to
ABS(diag)-39, List
of Diagnostic Trou-
ble Code (DTC).>
8 CHECK OPEN CIRCUIT IN G SENSOR OUT- Is the resistance 1.8 — 2.4 Go to step 9. Repair the har-
PUT HARNESS AND GROUND HARNESS. k&? ness connector
1) Turn the ignition switch to OFF. between G sensor
2) Disconnect the connector from ABSCM&H/ and ABSCM&H/U.
U.
ABSCM&H/U connector terminals.
(B301) No. 21 — No. 10:
Measure the resistance between ABSCM&H/U M&? ness connector
connector and chassis ground. between G sensor
Connector & terminal and ABSCM&H/U.
ABS(diag)-80
ABS (DIAGNOSTICS)
Step Check Yes No

1) Remove the console box. when G sensor is on a level? sor. <Ref. to ABS-
2) Remove the G sensor from vehicle. 18, G Sensor.>
3) Connect the connector to G sensor.
4) Connect the connector to ABSCM&H/U.
(B292) No. 2 (+) — No. 3 (#):
Measure the voltage between G sensor con- when G sensor is inclined for- sor. <Ref. to ABS-
nector terminals. wards to 90"? 18, G Sensor.>
(B292) No. 2 (+) — No. 3 (#):
Measure the voltage between G sensor con- when G sensor is inclined sor. <Ref. to ABS-
nector terminals. backward to 90"? 18, G Sensor.>
(B292) No. 2 (+) — No. 3 (#):
1) Turn the ignition switch to OFF. ABSCM only.
2) Connect all the connectors. <Ref. to ABS-8,
3) Erase the memory. REPLACEMENT,
Control Unit
(ABSCM&H/U).>
nostic Trouble
Code (DTC)”.
<Ref. to
ABS(diag)-39, List
of Diagnostic Trou-
ble Code (DTC).>
ABS(diag)-81
ABS (DIAGNOSTICS)

A: INSPECTION
Symptom Problem parts
• ABSCM&H/U (solenoid valve)
• ABS wheel speed sensor
• Brake (caliper, piston and pads)
Vehicle is pulled to either right or
• Wheel Alignment
left side.
• Tire specifications, tire wear and air pressures
• Incorrect wiring or piping connections
Vehicle instability during braking • Road surface (uneven, camber)
Vehicle spins. • Brake (pads)
• Brake (pads)
Long braking/stopping distance • Air in brake line
• ABSCM&H/U (solenoid valve, motor)
Wheel locks. • ABS wheel speed sensor
• Master cylinder
Brake drag • Brake (caliper and piston)
• Parking Brake
Poor brake performance • Axle and wheels
• Brake pedal play
• Air in brake line
Long brake pedal stroke
• Suspension play or fatigue (reduced damping)
Vehicle vertical pitching • Incorrect wiring or piping connections
• Road surface (uneven)
• Brake (caliper, piston and pads)
Unstable or uneven braking
Excessive pedal vibration
• ABSCM&H/U (mount bushing)
Noise from ABSCM&H/U • ABS wheel speed sensor
• Brake line
• ABSCM&H/U (mount bushing)
Vibration and/or noise • Master cylinder
Noise from front of vehicle • Brake (caliper, piston, pads and rotor)
(while driving on slippery roads)
• Brake line
• Brake booster and check valve
• Suspension play or fatigue
• Brake (caliper, piston, pads and rotor)
Noise from rear of vehicle • Parking Brake
• Brake line
• Suspension play or fatigue
ABS(diag)-82
CHASSIS SECTION
FRONT SUSPENSION FS
REAR SUSPENSION RS
DIFFERENTIALS DI
TRANSFER CASE TC
(DIAGNOSTICS)
BRAKE BR
PARKING BRAKE PB

(POWER STEERING)

approval.

VEHICLE DYNAMICS CONTROL
(VDC)
VDC
Page
2. VDC Control Module & Hydraulic Control Unit (VDCCM&H/U)...................7
3. ABS Sequence Control .............................................................................10
4. VDC Sequence Control.............................................................................11
5. Yaw Rate & Lateral G Sensor ...................................................................14
6. Steering Angle Sensor ..............................................................................16
7. Front ABS Wheel Speed Sensor...............................................................18
8. Rear ABS Wheel Speed Sensor ...............................................................19
9. Front Magnetic Encoder............................................................................20
10. Rear Magnetic Encoder ............................................................................21
11. VDC OFF Switch.......................................................................................22
General Description
VEHICLE DYNAMICS CONTROL (VDC)
A: SPECIFICATION
Item Standard values or identification
ABS wheel speed sensor Front 0.77 — 1.43 mm (0.030 — 0.056 in)
gap (for reference) Rear 0.64 — 1.56 mm (0.025 — 0.061 in)
ABS wheel speed RH K1 (White)
Front
sensor Marks of harness LH K2 (Yellow)
(Marks, Color) RH K5 (White)
Rear
LH K6 (Yellow)
Yaw rate & lateral G
Lateral G sensor voltage 2.5!0.2 V
sensor
Wagon 2.5 i G3
Sedan 2.5 i G9
Marks of VDCCM&H/U Wagon 3.0 R G4
Sedan 3.0 R GA
OUTBACK 3.0 R G2
VDC-2
General Description
B: COMPONENT
T1
T2
(3)
T2
(5)
T1
(4)
(2)
(1)
T2
VDC00194
(1) Front ABS wheel speed sensor (4) Hub unit bearing Tightening torque: N"m (kgf-m, ft-lb)
(2) Front housing (5) Magnetic encoder T1: 7.5 (0.76, 5.5)
(3) Rear ABS wheel speed sensor T2: 33 (3.4, 24)
VDC-3
General Description
2. YAW RATE & LATERAL G SENSOR
(1)
(2)
VDC00195
(1) Yaw rate & lateral G sensor (2) Bracket Tightening torque: N"m (kgf-m, ft-lb)
T: 7.5 (0.76, 5.5)
3. STEERING ANGLE SENSOR
(1)
VDC00196
(1) Steering angle sensor
VDC-4
General Description
4. VDC CONTROL MODULE & HYDRAULIC CONTROL UNIT (VDCCM&H/U)
(6) (8) (7) (9)

(5)
(4)
(10)
T T
(3)
(1)
T (11)
(2)
T
VDC00197
(1) VDC control module and hydraulic (5) Rear LH outlet (10) Pressure sensor
control unit (VDCCM&H/U) (6) Secondary inlet (11) Damper
(2) Clip (7) Primary inlet
(3) Bracket (8) Front LH outlet Tightening torque: N"m (kgf-m, ft-lb)
(4) Rear RH outlet (9) Front RH outlet T: 33 (3.4, 24)
VDC-5
General Description
C: CAUTION • Before removal, installation or disassembly, be

• Wear work clothing, including a cap, protective sure to clarify the failure. Avoid unnecessary re-
goggles and protective shoes during operation. moval, installation, disassembly and replacement.
• Remove contamination including dirt and corro- • Be careful not to burn yourself, because each
sion before removal, installation or disassembly. part on the vehicle is hot after running.
• Keep the disassembled parts in order and pro- • Be sure to tighten fasteners including bolts and
tect them from dust and dirt. nuts to the specified torque.
• Before disconnecting electrical connectors of • Place shop jacks or rigid racks at the specified
sensors or units, be sure to disconnect the ground points.
cable from battery.
D: PREPARATION TOOL
1. SPECIAL TOOL
ST24082AA230

ST22771AA030
2. GENERAL TOOL
TOOL NAME REMARKS
Pressure gauge Used for measuring oil pressure.
VDC-6
VDC Control Module & Hydraulic Control Unit (VDCCM&H/U)
2. VDC Control Module & Hy- 7) Remove the clips, and then remove the VDC-
CM&H/U.
draulic Control Unit (VDC-
CM&H/U)
A: REMOVAL
2) Use compressed air to get rid of water and dust
around the VDCCM&H/U.
NOTE:
When dust and dirt are attached to the terminal,
they may cause poor contact.
VDC00201
3) Disconnect the pressure sensor connector.
CAUTION:
• VDCCM&H/U cannot be disassembled. Do
not attempt to loosen the bolts and nuts.
• Do not drop or bump the VDCCM&H/U.
• Do not turn VDCCM&H/U upside down or
place it sideways for storage.
• Be careful that no foreign objects are mixed
in VDCCM&H/U.
• Be careful that no water enters connectors.
VDC00198
4) Disconnect the VDCCM&H/U connector with

pulling up the lock lever.
CAUTION:
Do not pull the harness when disconnecting
connector.
VDC00200
8) Remove the VDCCM&H/U bracket.

B: INSTALLATION
1) Install the VDCCM&H/U bracket.
Tightening torque:
33 N"m (3.3 kgf-m, 24 ft-lb)
VDC00199 2) Install the VDCCM&H/U to bracket.
5) Disconnect the brake pipes from VDCCM&H/U. 3) Install the clip.
6) Wrap the brake pipe using a vinyl bag not to spill
the brake fluid on the vehicle body.
CAUTION:
When the brake fluid is attached to vehicle
body, wash it off with water and wipe the water.
VDC00201
NOTE:
Hook the clip on the pawl of bracket securely.
VDC-7
4) Connect the brake pipes to their specified VDC- CAUTION:

CM&H/U positions. • Pressure gauges used exclusively for brake
Tightening torque: fluid must be used.
15 N"m (1.5 kgf-m, 11.1 ft-lb) • Do not use the pressure gauge for the mea-
surement of transmission oil pressure since
5) Connect the connector to VDCCM&H/U.
the piston seal may be expanded and de-
NOTE: formed.
• Be sure to remove all foreign matters from inside
NOTE:
the connector before connecting.
Wrap a sealing tape around the pressure gauge.
• Ensure that the VDCCM&H/U connector is se-
curely locked.
6) Connect the pressure sensor connector.
C: INSPECTION
1) Check the connected and fixed condition of con-
nector.
2) Check the mark used for VDCCM&H/U identifi-
cation.
Refer to “SPECIFICATION” for mark. <Ref. to
ABS00134
VDC-2, SPECIFICATION, General Description.>
4) Bleed air from the pressure gauges.
5) Perform VDC sequence control.
(1) <Ref. to VDC-11, VDC Sequence Control.>
6) When the hydraulic unit begins to work, first the
FL side performs compression, holding, and de-
compression, and then the FR side performs com-
pression, holding, and decompression.
7) Read values indicated on the pressure gauge
and check if the fluctuation of the values between
VDC00202 dard values. Depress the brake pedal and check
that it is not abnormally hard, and tightness is nor-
(1) Mark mal.
1. CHECKING THE HYDRAULIC UNIT ABS Front wheel Rear wheel
OPERATION BY PRESSURE GAUGE 3,000 kPa 2,000 kPa
When com- (31 kgf/cm2, 441 (20 kgf/cm2, 284
<Ref. to ABS-7, CHECKING THE HYDRAULIC pressed psi) psi)
UNIT ABS OPERATION BY PRESSURE GAUGE, or more or more
INSPECTION, ABS Control Module and Hydraulic
500 kPa 500 kPa
Control Unit (ABSCM&H/U).> When decom-
pressed (5 kgf/cm2, 73 psi) (5 kgf/cm2, 73 psi)
2. CHECKING THE HYDRAULIC UNIT ABS or less or less
OPERATION WITH BRAKE TESTER
8) Disconnect the pressure gauges from FL and FR
<Ref. to ABS-8, CHECKING THE HYDRAULIC caliper bodies.
UNIT ABS OPERATION WITH BRAKE TESTER, 9) Install the air bleeder screws of FL and FR cali-
INSPECTION, ABS Control Module and Hydraulic per bodies.
Control Unit (ABSCM&H/U).> 10) Remove the air bleeder screws from the RL
3. CHECKING THE HYDRAULIC UNIT VDC and RR caliper bodies.
OPERATION BY PRESSURE GAUGE 11) Connect two pressure gauges to the RL and
RR caliper bodies.
1) Lift-up the vehicle, and then remove the wheels. 12) Bleed air from the pressure gauges and the RL
2) Remove the air bleeder screws from the FL and and RR caliper bodies.
FR caliper bodies. 13) Perform VDC sequence control.
3) Connect two pressure gauges to the FL and FR <Ref. to VDC-11, VDC Sequence Control.>
caliper bodies.
VDC-8
14) When the hydraulic unit begins to work, first the (2) The RR wheel performs compression, hold-
RR side performs compression, holding, and de- ing and decompression in sequence, and sub-
compression, and then the RL side performs com- sequently the RL wheel repeats the cycle.
pression, holding, and decompression. 7) Read values indicated on the brake tester and
15) Read the values indicated on the pressure check if the fluctuation of the values between de-
gauges and check it within specified. Depress the compression and compression meets the standard
brake pedal and check that it is not abnormally values.
hard, and tightness is normal.
16) Disconnect the pressure gauge from the RL
and RR caliper bodies. 2,000 N 1,000 N
When com-
(203 kgf, 447 lb) (102 kgf, 225 lb)
17) Install the air bleeder screws of RL and RR cal- pressed
or more or more
iper bodies.
500 N 500 N
18) Bleed air from the brake line. When decom-
(51 kgf, 112 lb) (51 kgf, 112 lb)
pressed
4. CHECK HYDRAULIC UNIT VDC OPERA- or less or less
TION WITH BRAKE TESTER 8) After the inspection, depress the brake pedal
1) Set the wheels other than the measured one on and check that it is not abnormally hard, and tight-
free rollers. ness is normal.
2) Prepare for operating the VDC sequence con- D: ADJUSTMENT
trol.
When the following replacement, removal and in-
<Ref. to VDC-11, VDC Sequence Control.> stallation is performed, be sure to perform the cen-
3) Set the front wheels or rear wheels on the brake tering setting of steering angle sensor and zero
tester and set the select lever position to “N” range. point setting of yaw rate & lateral G sensor.
• VDCCM&H/U
• Steering angle sensor
• Yaw rate & lateral G sensor
• Steering wheel parts (Including airbag)
• Suspension parts
• Wheel alignment adjustment
1) Park the vehicle straight on a level surface. (En-
gine operation on “P” or “N” range)
(1) 2) Check that steering wheels are positioned in
ABS00136 center. (When the center position is not correct, ad-
just the wheel alignment.)
3) Set the Subaru Select Monitor to vehicle, select
the {Set up mode for Neutral of Steering Angle
Sensor & Lateral G Sensor 0 point} on «Function
check sequence» display. (Follow the step on dis-
play.)
4) On the «Brake Control System» display screen,
select the {Current Data Display & Save}, and
check that the steering angle sensor is displayed “0
(1) deg”.
ABS00137
5) When the “0 deg” is not displayed, repeat the
above steps and check that the “0 deg” is dis-
(1) Brake tester played.
6) Drive the vehicle for 10 minutes, and check that
4) Operate the brake tester. the ABS and VDC warning light is not illuminated.
5) Perform VDC sequence control. 7) Check that the unnecessary operation of VDC,
<Ref. to VDC-11, VDC Sequence Control.> or losing control of steering is not occurred. And
6) When the hydraulic unit begins to work; check when the malfunction occurred, repeat the above
the following working sequence. steps.
(1) The FL wheel performs compression, hold-
ing and decompression in sequence, and sub-
sequently the FR wheel repeats the cycle.
VDC-9
3. ABS Sequence Control

A: OPERATION
<Ref. to ABS-10, OPERATION, ABS Sequence
Control.>
1. ABS SEQUENCE CONTROL WITH DIAG-
NOSIS CONNECTOR
<Ref. to ABS-10, ABS SEQUENCE CONTROL
WITH DIAGNOSIS CONNECTOR, OPERATION,
ABS Sequence Control.>
2. ABS SEQUENCE CONTROL WITH SUB-
ARU SELECT MONITOR
<Ref. to ABS-10, ABS SEQUENCE CONTROL
WITH SUBARU SELECT MONITOR, OPERA-
TION, ABS Sequence Control.>
3. CONDITIONS FOR ABS SEQUENCE
CONTROL
<Ref. to ABS-11, CONDITIONS FOR ABS SE-
QUENCE CONTROL, OPERATION, ABS Se-
quence Control.>
B: SPECIFICATION
ABS SEQUENCE CONTROL
<Ref. to ABS-12, CONDITIONS FOR COMPLE-
TION OF ABS SEQUENCE CONTROL, SPECIFI-
CATION, ABS Sequence Control.>
VDC-10
VDC Sequence Control
4. VDC Sequence Control 5) When the “VDC Inspection Mode” is selected

from the “Function check sequence” menu, the
A: OPERATION “VDC sequence control” will start.
1) While the VDC sequence control is performed, 6) Since “Press the [YES] key” is displayed, press
the operation of the hydraulic unit can be checked the YES key.
using the brake tester or pressure gauge after the 7) Operation points will be displayed on the Subaru
hydraulic unit solenoid valve is operated. Select Monitor.
2) VDC sequence control can be started by diagno-
sis connector or Subaru Select Monitor.
1. VDC SEQUENCE CONTROL WITH DIAG-
NOSIS CONNECTOR
NOTE:
In the event of any trouble, the VDC sequence con-
trol is not operated.
1) Turn the ignition switch to OFF at the vehicle sta-
tionary mode.
2) Take out the diagnosis connector from the inside
of instrument panel lower cover on the driver’s side
and connect one of the ground terminals to connec-
tor terminal No. 8.
B82
1 2 3
4 5 6 7 8 ABS00466
3) Turn the ignition switch to ON and start the en-

gine immediately without pressing the brake pedal.
4) After VDC warning light goes out and starting the
engine, perform the brake pedal operation as fol-
lows; depress it within 3 seconds, # release it, #
depress it again, # release it again.
5) After completion of VDC sequence control, turn
the ignition switch to OFF.
2. VDC SEQUENCE CONTROL WITH SUB-
ARU SELECT MONITOR
NOTE:
In the event of any trouble, the sequence control
may not be operative.
connector under the driver’s side instrument panel
lower cover.
3) Set the Subaru Select Monitor switch to ON.
4) Set the Subaru Select Monitor to the “Brake
Control” mode.
VDC-11
3. CONDITIONS FOR VDC SEQUENCE CONTROL
V max < 4 km/h (2.5 MPH)

(1) V max < 10 km/h (6 MPH)
(21) (35)
(2)
OFF ON (23)
(3) (22) (24) (27) (28) (27) (29)
(25) (26) (25) (26) (25) (26) (25)

(4)
(5) VDC
OFF ON
(6)
OFF ON
(7)
(8)
(9)
(32) (28) (33) (34)
OFF
(10)
(32) (28) (33) (34)
OFF
(11)
OFF
(12)
OFF
(13)
OFF
(14)
OFF
(15)
OFF
(16)
OFF
(17)
OFF
(18)
OFF
(19)
(20) ON
(30) (31)
(36)
(37)
(38)
(39)
(40)
VDC00203
VDC-12
(1) All wheel speed (16) RR decompression valve (30) Point A

(2) DL terminal (17) RR compression valve (31) Reset
(3) Ignition key (18) RL decompression valve (32) 0.8 sec.
(4) ABS warning light (19) RL compression valve (33) 1.2 sec.
(5) VDC warning light (20) Pump motor (34) 0.4 sec.
(6) Stop light switch (21) Diagnosis connector and connec- (35) When using the Subaru Select
(7) Valve relay tion Monitor, both connection and non-
(8) VDC switching valve 1 FL (22) 1.5 sec. connection of diagnosis connector
are acceptable.
(9) VDC switching valve 1 FR (23) Approx. 3 sec.
(10) VDC switching valve 2 FL (24) Within 3 sec. (36) Master cylinder pressure
(11) VDC switching valve 2 FR (25) Light OFF (37) FR wheel cylinder pressure
(12) FL decompression valve (26) Light ON (38) FL wheel cylinder pressure
(13) FL compression valve (27) 3.4 sec. (39) RL wheel cylinder pressure
(14) FR decompression valve (28) 1 sec. (40) RR wheel cylinder pressure
(15) FR compression valve (29) 1.6 sec.
NOTE:
When using the Subaru Select Monitor, the control
operation starts from point A. The patterns from ig-
nition key ON to the point A show that operation is
started by diagnosis connector.
B: SPECIFICATION
VDC SEQUENCE CONTROL
When the following conditions develop, the VDC
sequence control stops and VDC 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 the diagnosis connector is disconnected.
(Without Subaru Select Monitor)
3) When the brake pedal is pressed during se-
quence control and the stop light switch is set to
ON.
4) When the brake pedal is pressed after the igni-
tion key is turned to ON, and before VDC warning
light goes out. (Without Subaru Select Monitor)
5) Turn the ignition key to ON and when 3 seconds
or more have elapsed after the VDC warning light
goes OFF.
6) After completion of VDC sequence control.
7) When malfunction is detected.
VDC-13
Yaw Rate & Lateral G Sensor
5. Yaw Rate & Lateral G Sensor CAUTION:

After completion of installation, set the follow-
A: REMOVAL ing two positions.
1) Disconnect the ground cable from battery. • Positioning to the center of steering angle
2) Remove the console box. sensor
<Ref. to EI-53, Console Box.> • Positioning of the yaw rate & lateral G sensor
3) Disconnect the connector from the yaw rate & to zero
lateral G sensor. The above procedure is required VDCCM&H/U
4) Remove the yaw rate & lateral G sensor. to identify the vehicle position afterward. For
CAUTION: the setting procedure of step 2 above, refer to
Do not drop or bump the yaw rate & lateral G “VDC Control Module & Hydraulic Control
sensor. Unit”. <Ref. to VDC-9, ADJUSTMENT, VDC Con-
trol Module & Hydraulic Control Unit (VDC-
CM&H/U).>
VDC00204
B: INSTALLATION
NOTE:
Install the yaw rate & lateral G sensor to body with
directing the arrow mark on sensors to vehicle
front.
VDC00205
Tightening torque:
7.5 N"m (0.76 kgf-m, 5.5 ft-lb)
VDC-14
Yaw Rate & Lateral G Sensor
C: INSPECTION
1. YAW RATE & LATERAL G SENSOR SIGNAL
Step Check Yes No

1 CHECK YAW RATE & LATERAL G SENSOR. Are the indicated values when Go to step 2. Repair the har-
1) Turn the ignition switch to OFF. the vehicle is placed horizon- ness connector
2) Connect the Subaru Select Monitor con- tally between yaw rate
nector to data link connector. Lateral G sensor: $1.5 — 1.5 & lateral G sensor
3) Turn the ignition switch to ON. m/s and VDCCM&H/U.
4) Set the Subaru Select Monitor connector to Yaw rate sensor: $4 — 4 deg/ Or replace the yaw
the {Brake Control} mode. s? rate & lateral G
5) Select {Current Data Display & Save}. sensor.
6) Read the output voltage of yaw rate & lat-
eral G sensor.
2 CHECK LATERAL G SENSOR. Is the value 6.8 — 12.8 m/s Go to step 3. Repair the har-
1) Remove the console box. when the yaw rate & lateral G ness connector
2) Remove the yaw rate & lateral G sensor sensor are inclined rightward between yaw rate
from vehicle. (Do not disconnect the connec- to 90%? & lateral G sensor
tor.) and VDCCM&H/U.
3) Read the display of Subaru Select Monitor. Or replace the yaw
NOTE: rate & lateral G
When the yaw rate & lateral G sensor is moved sensor.
with its power supply on, DTC of yaw rate & lat-
eral G sensor may be recorded.
3 CHECK LATERAL G SENSOR. Is the value $6.8 — $12.8 m/s Yaw rate & lateral Repair the har-
Read the display of Subaru Select Monitor. when the yaw rate & lateral G G sensor is nor- ness connector
NOTE: sensor are inclined leftward to mal. between yaw rate
When the yaw rate & lateral G sensor is moved 90%? & lateral G sensor
with its power supply on, DTC of yaw rate & lat- and VDCCM&H/U.
eral G sensor may be recorded. Or replace the yaw
rate & lateral G
sensor.
VDC-15
Steering Angle Sensor
6. Steering Angle Sensor 9) Remove the steering angle sensor from roll con-
nector.
A: REPLACEMENT
CAUTION:
• Do not perform the removal except when the
replacement.
• When replacing more than three times, re-
place the combination switch as assembly to
protect screw part.
1) Set the steering wheel in a wheel-forward posi-
tion.
2) Disconnect the ground cable from battery. VDC00208
3) Remove the airbag module.
<Ref. to AB-14, REMOVAL, Driver’s Airbag Mod- 10) Turn the protrusion portion of new steering an-
ule.> gle sensor to match the alignment mark of inspec-
tion hole.
WARNING:
Always refer to “Airbag System” when perform-
ing the airbag module repair service.
<Ref. to AB-4, CAUTION, General Description.> (1)
4) Remove the steering wheel. (2)

<Ref. to PS-20, REMOVAL, Steering Wheel.> (3)
5) Remove the screws and detach the steering col-
umn lower cover.
6) Remove the two screws securing the steering
column upper cover.
VDC00209
7) Unlock the harness band and disconnect the
connector of steering angle sensor. (1) Protrusion portion
(2) Inspection hole
(3) Alignment mark
CAUTION:
Be careful not to allow foreign particles to enter
(1)
from inspection hole.
11) Align the center of roll connector.
<Ref. to AB-23, INSTALLATION, Roll Connector.>
(2)
VDC00093
(1) Harness band

(2) Connector
8) Remove the screws which secure the roll con-

nector to steering column.
VDC00207
VDC-16
Steering Angle Sensor
12) Apply thin coat of grease which is enclosed 17) Connect the battery ground cable to battery.
with new part to the protruding parts (four) of steer- CAUTION:
ing angle sensor. After completion of installation, adjust the fol-
lowing two positions.
• Positioning to the center of steering angle
sensor
• Positioning of the yaw rate & lateral G sensor
to zero
The above procedure is required for VDCCM to
identify the vehicle position afterward. For the
(1) setting procedure of step 2 above, refer to
“VDC Control Module & Hydraulic Control
Unit”. <Ref. to VDC-9, ADJUSTMENT, VDC Con-
ABS00435
trol Module & Hydraulic Control Unit (VDC-
(1) Apply grease. CM&H/U).>
13) Align the position of protrusion portion and in-

stall the roll connector to the steering angle sensor.
Tightening torque:
0.5 N"m (0.05 kgf-m, 0.36 ft-lb)
VDC00208
14) Install the roll connector to combination switch.
VDC00207
15) Install the steering wheel.

<Ref. to PS-20, INSTALLATION, Steering Wheel.>
Tightening torque:
44 N"m (4.5 kgf-m, 32.5 ft-lb)
16) Install the airbag module to steering wheel.
<Ref. to AB-14, INSTALLATION, Driver’s Airbag
Module.>
WARNING:
Always refer to “Airbag System” before per-
forming the service operation.
<Ref. to AB-4, CAUTION, General Description.>
VDC-17
7. Front ABS Wheel Speed Sen-

sor
A: NOTE
For the vehicle equipped with VDC, it has the same
ABS wheel speed sensor as installed to the vehicle
equipped with ABS. For removal, installation and
inspection procedure, refer to ABS section.
<Ref. to ABS-13, Front ABS Wheel Speed Sen-
sor.>
VDC-18
Rear ABS Wheel Speed Sensor
8. Rear ABS Wheel Speed Sen-

sor
A: NOTE
ABS wheel speed sensor as installed to the vehicle
<Ref. to ABS-15, Rear ABS Wheel Speed Sen-
sor.>
VDC-19
Front Magnetic Encoder
9. Front Magnetic Encoder

A: NOTE
magnetic encoder as installed to the vehicle
<Ref. to ABS-16, Front Magnetic Encoder.>
VDC-20
Rear Magnetic Encoder
10.Rear Magnetic Encoder

A: NOTE
magnetic encoder as installed to the vehicle
<Ref. to ABS-17, Rear Magnetic Encoder.>
VDC-21
VDC OFF Switch
11.VDC OFF Switch

A: REMOVAL
1) Remove the instrument panel lower cover.
2) Remove the screws, and then remove the VDC
OFF switch.
• RHD model
4 3 2 1
VDC00210
• LHD model
7 6 5 4 3 2 1
15 14 13 12 11 10 9 8
VDC00240
B: INSTALLATION
C: INSPECTION
Measure the resistance between VDC OFF switch
terminals.
• RHD model
Switch position Terminal No. Standard
OFF 2—3 More than 1 M&
ON 2—3 Less than 1 &
• LHD model
Switch position Terminal No. Standard
OFF 2 — 15 More than 1 M&
ON 2 — 15 Less than 1 &
If NG, replace the VDC OFF switch.
VDC-22
CHASSIS SECTION
FRONT SUSPENSION FS
REAR SUSPENSION RS
DIFFERENTIALS DI
TRANSFER CASE TC
(DIAGNOSTICS)
BRAKE BR
PARKING BRAKE PB

(POWER STEERING)

approval.

(DIAGNOSTICS)
VDC(diag)
Page
1. Basic Diagnostic Procedure ........................................................................2
2. Check List for Interview...............................................................................4
4. Electrical Component Location .................................................................10
5. Control Module I/O Signal .........................................................................12
6. Subaru Select Monitor...............................................................................16
7. Read Diagnostic Trouble Code (DTC) ......................................................22
8. Inspection Mode........................................................................................23
9. Clear Memory Mode..................................................................................24
10. Warning Light Illumination Pattern ............................................................25
11. List of Diagnostic Trouble Code (DTC) .....................................................37
12. Diagnostic Procedure with Diagnostic Trouble Code (DTC) .....................43
13. General Diagnostic Table........................................................................132
VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS)
1. Basic Diagnostic Procedure

A: PROCEDURE
CAUTION:
When the Subaru Select Monitor is communicating (except when displaying the data), the ABS warn-
ing light flashes and VDC warning light illuminates in the combination meter. Do not communicate
with the Subaru Select Monitor while driving, because the ABS and VDC functions are disabled. Care-
fully drive the vehicle, when you have to communicate with the Subaru Select Monitor. When the data
is displayed by the {Current Data Display & Save} menu, both the ABS and VDC warning lights are
turned off and ABS and VDC functions are enabled.
NOTE:
• To check the harness for broken wires or short circuits, shake problem spot or connector.
• Refer to “Check List for Interview”. <Ref. to VDC(diag)-4, Check List for Interview.>
Step Check Yes No

1 CHECK PRE-INSPECTION. Is the component that might Go to step 2. Repair or replace
1) Ask the customer when and how the trou- influence the VDC problem each component.
ble occurred using the interview checklist. normal?
<Ref. to VDC(diag)-4, Check List for Inter-
view.>
2) Before performing diagnostics, check the
component which might affect VDC problems.
<Ref. to VDC(diag)-8, INSPECTION, General
Description.>
2 CHECK INDICATION OF DTC. Is DTC displayed? Go to step 4. Go to step 3.
2) Connect the Subaru Select Monitor to data
link connector.
3) Turn the ignition switch to ON, and the Sub-
aru Select Monitor switch to ON.
4) Read the DTC. <Ref. to VDC(diag)-22,
(DTC).>
NOTE:
If the communication function of the Subaru Se-
lect Monitor cannot be executed normally,
check the communication circuit. <Ref. to
VDC(diag)-19, COMMUNICATION FOR INI-
TIALIZING IMPOSSIBLE, INSPECTION, Sub-
aru Select Monitor.>
5) Record all DTCs and freeze frame data.
3 PERFORM GENERAL DIAGNOSTICS. Do the VDC warning light and Finish the diagno- Check the combi-
1) Inspect using “General Diagnostic Table”. ABS warning light go off after sis. nation meter cir-
<Ref. to VDC(diag)-132, INSPECTION, Gen- starting the engine? cuit. <Ref. to
eral Diagnostic Table.> VDC(diag)-30,
2) Perform the clear memory mode. <Ref. to ABS WARNING
VDC(diag)-24, OPERATION, Clear Memory LIGHT DOES
Mode.> NOT GO OFF,
3) Perform the inspection mode. <Ref. to Warning Light Illu-
VDC(diag)-23, PROCEDURE, Inspection mination Pattern.>
Mode.> <Ref. to
4) Read the DTC. <Ref. to VDC(diag)-22, VDC(diag)-33,
OPERATION, Read Diagnostic Trouble Code VDC WARNING
(DTC).> LIGHT AND VDC
5) Check the DTC does not displayed. OFF INDICATOR
LIGHT DO NOT
GO OFF, Warning
Light Illumination
Pattern.>
VDC(diag)-2
Step Check Yes No

4 PERFORM DIAGNOSIS. Is DTC displayed? Repeat step 4 until Finish the diagno-
1) Refer to “List of Diagnostic Trouble Code DTC is not shown. sis.
(DTC)”.
NOTE:
For the DTC list, refer to “List of Diagnostic
Trouble Code (DTC)”. <Ref. to VDC(diag)-37,
LIST, List of Diagnostic Trouble Code (DTC).>
2) Fix the wrong part.
3) Perform the clear memory mode. <Ref. to
VDC(diag)-24, OPERATION, Clear Memory
Mode.>
4) Perform the inspection mode. <Ref. to
VDC(diag)-23, PROCEDURE, Inspection
Mode.>
5) Read the DTC. <Ref. to VDC(diag)-22,
(DTC).>
VDC(diag)-3
2. Check List for Interview

A: CHECK
Check the following items about the vehicle’s state.
1. STATE OF ABS WARNING LIGHT
ABS warning light ❏ Always
come on. ❏ Sometimes
❏ Only once
❏ Not come on
! When / How long does it come on?
❏ ACC
❏ START
❏ ON (after engine starting, engine is running)
❏ ON (after engine starting, engine is at a standstill)
Timing ❏ Immediately after turning the ignition switch to ON
❏ Immediately after turning the ignition switch to START
— MPH
— MPH
Steering time: Sec.
Steering time: Sec.
! Part name:
VDC(diag)-4
2. STATE OF VDC WARNING LIGHT AND VDC OFF INDICATOR LIGHT

VDC warning light ❏ Always
and VDC OFF indi- ❏ Sometimes
cator light come on. ❏ Only once
❏ Not come on
❏ ACC
❏ START
— MPH
— MPH
Steering time: Sec.
Steering time: Sec.
! Part name:
3. STATE OF VDC INDICATOR LIGHT

VDC operation indi- ❏ Always
cator light comes on. ❏ Sometimes
❏ Only once
❏ Not come on
❏ ACC
❏ START
— MPH
— MPH
Steering time: Sec.
Steering time: Sec.
! Part name:
VDC(diag)-5
4. CONDITIONS UNDER WHICH TROUBLE OCCURS

Environment a) Weather ❏ Fine
❏ Cloudy
❏ Rainy
❏ Snowy
❏ Others:
b) Ambient temperature "C ("F)
c) Road ❏ Inner city
❏ Suburbs
❏ Highway
❏ Local street
❏ Uphill
❏ Downhill
❏ Paved road
❏ Gravel road
❏ Muddy road
❏ Sandy place
❏ Straight road
❏ Sharp curve
❏ Gentle curve
❏ S-curve
❏ Road with a slope on both sides
❏ Others:
d) Road surface ❏ Dried
❏ Wet
❏ Covered with fresh snow
❏ Covered with hardened snow
❏ Frozen slope
❏ Others:
VDC(diag)-6
Condition a) Brakes Deceleration: G

❏ continuous / ❏ intermittent
b) Accelerator Acceleration: G
❏ continuous / ❏ intermittent
c) Vehicle speed km/h MPH
❏ Advancing
❏ When accelerating
❏ When decelerating
❏ At low speed
❏ When turning
❏ Others:
d) Tire inflation pressure Front RH tire: kPa
Front LH tire: kPa
Rear RH tire: kPa
Rear LH tire: kPa
e) Degree of wear Front RH tire:
Front LH tire:
Rear RH tire:
Rear LH tire:
f) Steering wheel ❏ Sharp turning
❏ Gentle turning
❏ Straight forward motion
❏ Gentle return
❏ Sharp return
g) Tire/Wheel size ❏ Specified size
❏ Except specification ( )
h) Tire variation ❏ Summer tire
❏ Studless tire (Brand: )
i) Tire chains are fitted: ❏ Yes / ❏ No
j) T-type tire is used: ❏ Yes / ❏ No
k) Condition of suspension alignment:
l) Loading state:
m) Repair parts are used: ❏ Yes / ❏ No
! Contents:
n) Others:
VDC(diag)-7
General Description
3. General Description 6. TIRE

A: CAUTION Check the tire specifications, tire wear and air pres-
sure. <Ref. to WT-2, SPECIFICATION, General
1. SUPPLEMENTAL RESTRAINT SYSTEM Description.>
“AIRBAG”
ABS wheel speed sensor and VDCCM&H/U.
CAUTION:
wiring harness when servicing the ABS wheel
speed sensor and VDCCM&H/U.
B: INSPECTION
Before performing diagnosis, check the following
items which might affect VDC problems.
1. BATTERY
Measure battery voltage and check electrolyte.
Standard voltage: 12 V or more
Specific gravity: More than 1.260
2. BRAKE FLUID
1) Check the brake fluid level.
2) Check the brake fluid for leaks.
3. HYDRAULIC UNIT
Check the hydraulic unit.
• With brake tester <Ref. to VDC-8, CHECKING
THE HYDRAULIC UNIT ABS OPERATION WITH
BRAKE TESTER, INSPECTION, VDC Control
Module & Hydraulic Control Unit (VDCCM&H/U).>
• Without brake tester <Ref. to VDC-8, CHECK-
ING THE HYDRAULIC UNIT ABS OPERATION
BY PRESSURE GAUGE, INSPECTION, VDC
Control Module & Hydraulic Control Unit (VDC-
CM&H/U).>
4. BRAKE DRAG
Check for brake drag.
5. BRAKE PAD AND ROTOR
Check the brake pad and rotor.
• FRONT <Ref. to BR-18, INSPECTION, Front
Brake Pad.> <Ref. to BR-19, INSPECTION, Front
Disc Rotor.>
• REAR <Ref. to BR-25, INSPECTION, Rear
Brake Pad.> <Ref. to BR-26, INSPECTION, Rear
Disc Rotor.>
VDC(diag)-8
General Description
C: PREPARATION TOOL
1. SPECIAL TOOL
ST24082AA230
ST22771AA030
2. GENERAL TOOL
TOOL NAME REMARKS
Circuit tester Used for measuring resistance, voltage and current.
VDC(diag)-9
4. Electrical Component Location

A: LOCATION
(8) (9)
(7)
(4) (5) (6)
(15)
(1) (2)
(12) (11) (10)

(13)
(14)
(3)
(16)
(11) (10)
VDC00241
(1) VDC control module and hydraulic (5) ABS warning light (11) ABS wheel speed sensor
control unit (VDCCM&H/U) (6) VDC indicator light (12) Yaw rate & lateral G sensor
(2) Pressure sensor (7) VDC warning light and VDC OFF (13) Data link connector
(3) Transmission control module indicator light (14) Diagnosis connector (Used for
(TCM) (8) Steering angle sensor ABS sequence control)
(4) Brake warning light (EBD warning (9) VDC OFF switch (15) Engine control module (ECM)
light) (10) Magnetic encoder (16) Stop light switch
VDC(diag)-10
(4)
(2) (1)
(5) (7) (6)

VDC00231 VDC00251
(8) (11)
(10)
(10)
VDC00235 VDC00234
(12)
(13)
VDC00250 VDC00242
(14)
VDC00230
VDC(diag)-11
5. Control Module I/O Signal

A: ELECTRICAL SPECIFICATION
B310
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
VDC00211
NOTE:
• Terminal numbers in VDCCM&H/U connector are as shown in the figure.
• When the connector is removed from VDCCM&H/U, the ABS warning light and VDC warning light illumi-
nate.
VDC(diag)-12
Terminal Input/Output signal

Content No.
(+) — (#) Measured value and measuring conditions
Power supply 14 — 6 When the ignition switch is ON, 10 — 15 V.
Power
41 — 6 4.5 — 16.5 V
Front LH wheel supply
Power
22 — 6 4.5 — 16.5 V
Front RH wheel supply
ABS wheel speed sen- Signal 21 5.9 — 16.8 mA: Rectangle waveform
sor Power
24 — 6 4.5 — 16.5 V
Rear LH wheel supply
Power
23 — 6 4.5 — 16.5 V
Rear RH wheel supply
Output (Lateral G sensor) 3 — 16 When the vehicle is on level, 2.35 — 2.65 V.
Power supply 30 — 16 When the ignition switch is ON, 8 — 16 V.
Waveform
Output (Yaw rate sensor) 28 — 16 <Ref. to VDC(diag)-15, WAVEFORM, MEASURE-
Yaw rate & lateral G MENT, Control Module I/O Signal.>
sensor Standard (Yaw rate sensor) 1 — 16 2.1 — 2.9 V
5 — 1 V cycle for 40 ms pulse signal.
Test 2 — 16 <Ref. to VDC(diag)-15, WAVEFORM, MEASURE-
MENT, Control Module I/O Signal.>
Ground 16 —
CAN communication line (+) 13 2.5 — 1.5 V pulse signal
CAN communication line (#) 29 3.5 — 2.5 V pulse signal
Valve relay power supply 5—6 When the ignition switch is ON, 10 — 15 V.
Motor relay power supply 9 — 10 When the ignition switch is ON, 10 — 15 V.
Power supply 27 — 12 When the ignition switch is ON, 4.75 — 5.25 V.
Pressure sensor Output voltage 11 — 12 0.48 — 0.72 V (when releasing the brake pedal)
Ground 12 —
ABS warning light 35 — 6 1.5 seconds and less than 1.5 V after 1.5 seconds
passed.
Brake warning light (EBD warning light) 20 — 6 1.5 seconds and less than 1.5 V after 1.5 seconds
passed.
Less than 1.5 V when the stop light is OFF; otherwise,
Stop light switch 37 — 6
10 — 15 V when the stop light is ON.
Diagnosis connector 17 When the ignition switch is ON, 10 — 15 V.
Subaru Select Monitor 26 — 6 0 $% 12 V pulse (in communication)
Vehicle speed output signal 36 0 $% 5 V pulse
Ground 6 —
VDC(diag)-13
B: WIRING DIAGRAM
(3)
(5)
(20)
(1)
(21)
(22)
(23)
(24)
(2) (25)
(26) (6)
(27)
(4)
(30)
(28) (29)
(31) (32)
(33)
M (7)
(34) (8)
(9)
(35)
(10)
(11)
(36) (12)
(13)
(37) (14)
(15)
(38)
(16)
(39) (17)
(40) (18)
(41) (19)
VDC00236
(1) Battery (16) Primary cut solenoid valve (30) Stop light switch
(2) Ignition switch (17) Primary suction solenoid valve (31) Stop light
(3) VDC control module and hydraulic (18) Secondary cut solenoid valve (32) Body integrated unit
control unit (VDCCM&H/U) (19) Secondary suction solenoid valve (33) Engine control module (ECM)
(4) VDC control module (20) Diagnosis connector (34) Transmission control module
(5) Valve relay (21) Data link connector (TCM)
(6) Motor relay (22) VDC OFF switch (35) Steering angle sensor
(7) Motor (23) Combination meter (36) Yaw rate & lateral G sensor
(8) Front inlet solenoid valve LH (24) VDC indicator light (37) Pressure sensor
(9) Front outlet solenoid valve LH (25) VDC warning light and VDC OFF (38) Front ABS wheel speed sensor LH
(10) Front inlet solenoid valve RH indicator light (39) Front ABS wheel speed sensor
(11) Front outlet solenoid valve RH (26) ABS warning light RH
(12) Rear inlet solenoid valve LH (27) Brake warning light (40) Rear ABS wheel speed sensor LH
(13) Rear outlet solenoid valve LH (28) Parking brake switch (41) Rear ABS wheel speed sensor
(14) Rear inlet solenoid valve RH (29) Brake fluid level switch RH
(15) Rear outlet solenoid valve RH
VDC(diag)-14
C: MEASUREMENT
Measure input and output signal voltage.
1. WAVEFORM
(1) (V)
(2) 28 – 16
2
10
2.1 – 2.9 V
5 (3)
1
5.0 V
(2) 2 – 16 0
20 ms
VDC00212
(1) Yaw rate sensor (2) Terminal No. (3) Vehicle is at a standstill.
VDC(diag)-15
6. Subaru Select Monitor (1) Data link connector is located in the lower
portion of instrument panel (on the driver’s side).
A: OPERATION
CAUTION:
When the Subaru Select Monitor is communi-
cating (except when displaying the data), the (1)
ABS warning light flashes and VDC warning
light illuminates in the combination meter. Do
not communicate with the Subaru Select Moni-
tor while driving, because the ABS and VDC
functions are disabled. Carefully drive the vehi-
cle, when you have to communicate with the
ABS00465
Subaru Select Monitor. When the data is dis-
played by the {Current Data Display & Save} (1) Data link connector
menu, both the ABS and VDC warning lights are
turned off and ABS and VDC functions are en- (2) Connect the diagnosis cable to data link
abled. connector.
1. READ DIAGNOSTIC TROUBLE CODE CAUTION:
(DTC) Do not connect the scan tools except for Suba-
ru Select Monitor.
1) Prepare the Subaru Select Monitor kit. <Ref. to
VDC(diag)-9, SPECIAL TOOL, PREPARATION 5) Turn the ignition switch to ON (engine OFF) and
TOOL, General Description.> turn the Subaru Select Monitor switch to ON.
(1)
ABS00114
ABS00111
2) Connect the diagnosis cable to Subaru Select (1) Power switch

Monitor.
3) Insert the cartridge to Subaru Select Monitor. 6) On the «Main Menu» display screen, select the
<Ref. to VDC(diag)-9, SPECIAL TOOL, PREPA- {Each System Check} and press the [YES] key.
RATION TOOL, General Description.> 7) On the «System Selection Menu» display
[YES] key.
8) Press the [YES] key after the {VDC AWD AT} is
displayed.
9) On the «VDC Diagnosis» display screen, select
the {Diagnostic Code(s) Display}, and then press
the [YES] key.
NOTE:
• For details concerning operation procedure, re-
fer to “SUBARU SELECT MONITOR OPERATION
ABS00112 MANUAL”.
4) Connect the Subaru Select Monitor to data link • For details concerning DTCs, refer to “List of Di-
connector. agnostic Trouble Code (DTC)”. <Ref. to VDC(di-
ag)-37, List of Diagnostic Trouble Code (DTC).>
• DTCs are displayed up to three in detected or-
der.
VDC(diag)-16
• If a particular DTC is not properly stored in mem-

ory (due to a drop in VDCCM&H/U power supply,
Indicate the latest DTC on the Subaru
etc.) on the occurrence of a problem, the DTC Current
Select Monitor display.
which is suffixed with a question mark “?” appears
Indicate the latest DTC in previous trou-
on the Subaru Select Monitor display. This shows it Old
ble on the Subaru Select Monitor display.
may be an unreliable reading.
Indicate the latest DTC in second previ-
10) If VDC and Subaru Select Monitor cannot com- Older ous trouble on the Subaru Select Monitor
municate, check the communication circuit. <Ref. display.
to VDC(diag)-19, COMMUNICATION FOR INI- Indicate the latest DTC in third previous
TIALIZING IMPOSSIBLE, INSPECTION, Subaru Before 3 trouble on the Subaru Select Monitor dis-
Select Monitor.> play.
2. READ CURRENT DATA

1) On the «Main Menu» display screen, select the {Each System Check} and press the [YES] key.
2) On the «System Selection Menu» display screen, select the {Brake Control} and press the [YES] key.
3) Press the [YES] key after {VDC 4WD AT} is displayed.
4) On the «Brake Control Diagnosis» display screen, select the {Current Data Display/Save}, and then press
the [YES] key.
5) On the «Data Display Menu» display screen, select the display method, and press the [YES] key.
6) Using a scroll key, scroll the display screen up or down until necessary data is shown.
• A list of the support data is shown in the following table.
Display Contents to be monitored Unit of measure
Wheel speed detected by front ABS wheel speed sensor RH is dis-
FR Wheel Speed km/h or MPH
played.
Wheel speed detected by front ABS wheel speed sensor LH is dis-
FL Wheel Speed km/h or MPH
played.
Wheel speed detected by rear ABS wheel speed sensor RH is dis-
RR Wheel Speed km/h or MPH
played.
Wheel speed detected by rear ABS wheel speed sensor LH is dis-
RL Wheel Speed km/h or MPH
played.
Steering Angle Sensor Steering angle detected by steering angle sensor is displayed. deg
Yaw Rate Sensor Vehicle angular speed detected by yaw rate sensor is displayed. deg/s
Pressure Sensor Brake fluid pressure detected by pressure sensor is displayed. bar
Vehicle lateral acceleration detected by lateral G sensor is dis-
Lateral G Sensor m/s (m/s^2)
played.
IG power supply voltage Voltage supplied to VDCCM&H/U is displayed. V
EMA signal Engine control command signal is displayed. 1 or 0
TCS Operation Light TCS operation condition is displayed. ON or OFF
VDC Operation Light VDC operation condition is displayed. ON or OFF
VDC OFF Light ON/OFF condition of VDC OFF indicator light is displayed. ON or OFF
EBD Warning Light ON operation of the EBD warning light is displayed. ON or OFF
ABS Warning Light ON operation of the ABS warning light is displayed. ON or OFF
VDC Warning Light ON operation of the VDC warning light is displayed. ON or OFF
Malfunction of VDC sensor (except for vehicle speed sensor) is
VDC OK-B signal 1 or 0
displayed.
Valve Relay Signal Valve relay operation signal is displayed. ON or OFF
Motor Relay Signal Motor relay operation signal is displayed. ON or OFF
Motor Relay Monitor Motor relay monitor signal is displayed. ON or OFF
PATA Signal Operation condition of VDC OFF switch is displayed. ON or OFF
BLS Signal Brake ON/OFF is displayed. ON or OFF
Gear position Present gear position is displayed. —
Engine Speed Current engine speed is displayed. rpm
PW Signal Acceleration opening is displayed. %
VDC(diag)-17
NOTE: Display Contents to be monitored

For details concerning operation procedure, refer Steering angle Steering angle detected by steering
to “SUBARU SELECT MONITOR OPERATION sensor angle sensor is displayed.
MANUAL”. Vehicle angular speed detected by yaw
Yaw rate sensor
rate sensor is displayed.
3. CLEAR MEMORY MODE Vehicle lateral acceleration detected by
Lateral G sensor
1) On the «Main Menu» display screen, select the lateral G sensor is displayed.
{Each System Check} and press the [YES] key. Brake fluid pressure detected by pres-
Pressure sensor
2) On the «System Selection Menu» display sure sensor is displayed.
screen, select the {Brake Control} and press the Vehicle speed calculated by VDC control
Vehicle Speed
[YES] key. module is displayed.
3) Press the [YES] key after {VDC 4WD AT} is dis- FR Wheel
Wheel speed detected by front ABS
played. Speed
wheel speed sensor RH is displayed in
4) On the «Brake Control Diagnosis» display km/h or MPH.
screen, select the {Memory Clear} and press the Wheel speed detected by front ABS
[YES] key. FL Wheel Speed wheel speed sensor LH is displayed in
km/h or MPH.
Display Contents to be monitored Wheel speed detected by rear ABS
RR Wheel
Clear memory? DTC deleting function wheel speed sensor RH is displayed in
Speed
km/h or MPH.
5) When “Done” and “Turn ignition switch OFF” are Wheel speed detected by rear ABS
shown on the display screen, turn the Subaru Se- RL Wheel
wheel speed sensor LH is displayed in
lect Monitor and ignition switch to OFF. Speed
km/h or MPH.
NOTE: Required torque Engine required torque is displayed.
For details concerning operation procedure, refer Current torque
Current engine torque on malfunction
to “SUBARU SELECT MONITOR OPERATION occurrence is displayed.
MANUAL”. Target torque Engine target torque is displayed.
PW signal Acceleration opening is displayed.
4. ABS SEQUENCE CONTROL
Engine speed on malfunction occur-
Engine Speed
rence is displayed.
Reference tar-
Display Contents to be monitored Gear position on malfunction occurrence
get Gear position
is displayed.
Operate the valve and <Ref. to ABS-
ABS IG power supply Voltage supplied to VDC control module
pump motor continuously 10, ABS
sequence voltage is displayed.
to perform the ABS Sequence Con-
control
sequence control. trol.> Absolute angle Whether the absolute angle was deter-
Operate the valve and <Ref. to VDC- recognition flag mined is displayed.
VDC confir-
pump motor continuously 11, VDC Decreasing Whether the torque decrease is required
mation
to perform the VDC Sequence Con- required torque to engine is displayed.
mode
sequence control. trol.> Engine control command signal is dis-
EMA signal
played.
5. FREEZE FRAME DATA VDC O control VDC oversteer control condition is dis-
flag played.
NOTE:
VDC U control VDC understeer control condition is dis-
• Data stored at the time of trouble occurrence is flag played.
shown on display.
BMR control flag Brake control condition is displayed.
• Each time trouble occurs, the latest information
AMR control flag Engine control condition is displayed.
is stored in the freeze frame data in memory.
• If a freeze frame data is not properly stored in ABS control flag ABS control condition is displayed.
memory (due to a drop in VDC control module pow- ON/OFF condition of VDC OFF indicator
VDC OFF light
er supply, etc.), the DTC which is suffixed with a light is displayed.
question mark “?” appears on the Subaru Select Valve Relay Sig-
Valve relay operation signal is displayed.
Monitor display. This shows it may be an unreliable nal
reading. Motor Relay
Motor relay monitor signal is displayed.
Monitor
BLS signal Brake ON/OFF is displayed.
VDC(diag)-18
B: INSPECTION
1. COMMUNICATION FOR INITIALIZING IMPOSSIBLE
Defective harness connector
TROUBLE SYMPTOM:
Communication is impossible between VDC and Subaru Select Monitor.
WIRING DIAGRAM:
BATTERY
SBF-1
E
SBF-7
DATA LINK
CONNECTOR
IGNITION
SWITCH 1
10
B40
No.33
E
14
26
B310 VDCCM & H/U
B40 B310
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
9 10 11 12 13 14 15 16
VDC00244
VDC(diag)-19
Step Check Yes No

1 CHECK IGNITION SWITCH. Is the ignition switch ON? Go to step 2. Turn the ignition
switch to ON, and
select VDC mode
using Subaru
Select Monitor.
2 CHECK BATTERY. Is the voltage more than 11 V? Go to step 3. Charge or replace
1) Turn the ignition switch to OFF. the battery.
2) Measure the battery voltage.
3 CHECK BATTERY TERMINAL. Is there poor contact at battery Repair or tighten Go to step 4.
terminal? the battery termi-
nal.
4 CHECK SUBARU SELECT MONITOR COM- Are the system name and Go to step 8. Go to step 5.
MUNICATION. model year displayed on Sub-
1) Turn the ignition switch to ON. aru Select Monitor?
2) Using the Subaru Select Monitor, check
whether communication to other system can
be executed normally.
5 CHECK SUBARU SELECT MONITOR COM- Are the system name and Replace the Go to step 6.
MUNICATION. model year displayed on Sub- VDCCM&H/U.
1) Turn the ignition switch to OFF. aru Select Monitor? <Ref. to VDC-7,
2) Disconnect the VDCCM&H/U connector. VDC Control Mod-
3) Turn the ignition switch to ON. ule & Hydraulic
4) Check whether communication to other Control Unit
systems can be executed normally. (VDCCM&H/U).>
6 CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 Go to step 7. Repair the har-
EACH CONTROL MODULE AND DATA LINK M&? ness and connec-
CONNECTOR. tor between each
1) Turn the ignition switch to OFF. control module
2) Disconnect the VDCCM&H/U, ECM and and data link con-
TCM. nector.
3) Measure the resistance between data link
7 CHECK OUTPUT SIGNAL FOR VDCCM&H/ Is the voltage less than 1 V? Go to step 8. Repair the har-
U. ness and connec-
1) Turn the ignition switch to ON. tor between each
2) Measure the voltage between VDCCM&H/ control module
U and chassis ground. and data link con-
Connector & terminal nector.
VDCCM&H/U AND DATA LINK CONNEC- &? ness and connec-
TOR. tor between
Measure the resistance between VDCCM&H/U VDCCM&H/U and
connector and data link connector. data link connec-
Connector & terminal tor.
(B310) No. 26 — (B40) No. 10:
9 CHECK INSTALLATION OF VDCCM&H/U Is the VDCCM&H/U connector Go to step 10. Insert the
CONNECTOR. inserted into VDCCM&H/U VDCCM&H/U con-
Turn the ignition switch to OFF. until the clamp locks onto it? nector into
VDCCM&H/U.
VDC(diag)-20
Step Check Yes No

10 CHECK POWER SUPPLY CIRCUIT. Is the voltage 10 — 15 V? Go to step 11. Repair the open
1) Turn the ignition switch to ON. (engine circuit in harness
OFF) between
2) Measure the ignition power supply voltage VDCCM&H/U and
between VDCCM&H/U connector and chassis battery.
ground.
11 CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 0.5 Go to step 12. Repair the open
VDCCM&H/U AND CHASSIS GROUND. &? circuit in harness
2) Disconnect the connector from VDCCM&H/ VDCCM&H/U and
U. inhibitor side con-
3) Measure the resistance of harness nector, and poor
between VDCCM&H/U and chassis ground. contact in cou-
Connector & terminal pling connector.
12 CHECK POOR CONTACT IN CONNECTOR. Is there poor contact in control Repair the con- Replace the
module power supply, ground nector. VDCCM&H/U.
circuit and data link connector? <Ref. to VDC-7,
VDC Control Mod-
ule & Hydraulic
Control Unit
(VDCCM&H/U).>
VDC(diag)-21
Read Diagnostic Trouble Code (DTC)
7. Read Diagnostic Trouble

Code (DTC)
A: OPERATION
For details concerning DTC reading procedure, re-
fer to “Subaru Select Monitor”. <Ref. to VDC(diag)-
16, Subaru Select Monitor.>
VDC(diag)-22
Inspection Mode
8. Inspection Mode
A: PROCEDURE
Reproduce the malfunction occurrence condition
as possible.
Drive the vehicle at least ten minutes.
NOTE:
Make sure the vehicle is not dragged to one side
under usual driving condition.
VDC(diag)-23
Clear Memory Mode
9. Clear Memory Mode

A: OPERATION
For details concerning DTC clear operation, refer to
“Subaru Select Monitor”. <Ref. to VDC(diag)-16,
VDC(diag)-24
Warning Light Illumination Pattern
10.Warning Light Illumination Pattern

A: INSPECTION
(4)
(3) (3)
(2)
(1)
(7)
(6) (8) (6)

(5)
(7)
(6) (6)
(9)
(7)
(6) (6)
(10)
(11)
(7)
(6)
(12)
(13) (14)
VDC00214
(1) Ignition switch (7) Light ON (11) Several seconds (depending on

(2) OFF (8) 1.5 sec. engine coolant temperature)
(3) ON (9) VDC indicator light (12) Brake warning light (EBD warning
(4) Engine start (10) VDC warning light and VDC OFF light)
(5) ABS warning light indicator light (13) Parking brake
(6) Light OFF (14) Released
1) When warning lights or indicator lights do not illuminate in accordance with this illumination pattern, there
must be an electrical malfunction.
2) When warning lights or indicator lights remain constantly OFF, check the combination meter circuit or CAN
communication circuit. <Ref. to VDC(diag)-26, VDC WARNING LIGHT, VDC OFF INDICATOR LIGHT AND
VDC INDICATOR LIGHT DO NOT COME ON, Warning Light Illumination Pattern.>
3) When ABS warning light does not go off, check the combination meter circuit. <Ref. to VDC(diag)-30, ABS
WARNING LIGHT DOES NOT GO OFF, Warning Light Illumination Pattern.>
4) When the VDC indicator light, VDC warning light and VDC OFF indicator light do not go off, check the com-
bination meter circuit or CAN communication circuit. <Ref. to VDC(diag)-32, VDC INDICATOR LIGHT DOES
NOT GO OFF, Warning Light Illumination Pattern.>
NOTE:
• Even though the ABS warning light does not go off after 1.5 seconds from ABS warning light illumination,
the ABS system operates normally when the warning light goes off while driving at approximately 12 km/h (7
MPH). However, the ABS system does not work while the ABS warning light is illuminated.
• It may take several minutes before VDC warning light and VDC OFF indicator light goes off if the vehicle
is parked under low temperature for a specified time. This is not defective because it is resulted from low en-
gine coolant temperature.
VDC(diag)-25
• With the vehicle jack-up/lift-up or set on free rollers, when the wheels lock or spin after starting the engine,
ABS warning light, VDC warning light and VDC OFF indicator light may illuminate because VDCCM&H/U de-
tects the abnormal conditions from ABS wheel speed sensors. In this case, this is not a malfunction. Perform
the clear memory mode.
B: VDC WARNING LIGHT, VDC OFF INDICATOR LIGHT AND VDC INDICATOR
LIGHT DO NOT COME ON
• Defective CAN communication
TROUBLE SYMPTOM:
When the ignition switch is turned to ON (engine OFF), VDC indicator light, VDC warning light and VDC OFF
indicator light do not come on.
NOTE:
When pressing VDC OFF switch for more than 10 seconds, VDC OFF indicator light goes off and cannot op-
erate any more. When turning the ignition switch from OFF to ON, the OFF operation enabled status is re-
stored.
Step Check Yes No

1 CHECK OTHER INDICATOR LIGHT. Does other indicator light illu- Go to step 2. Perform the self-
Turn the ignition switch to ON. minate soon after “ON”? diagnosis of com-
bination meter.
2 CHECK VDCCM. Is “VDC warning light” output Go to step 3. Replace the
When the engine does not start, display the set to “ON”? VDCCM.
current data of VDCCM using Subaru Select
Monitor.
3 CHECK LAN SYSTEM. Is there any fault in LAN sys- Perform the diag- Go to step 4.
Perform the diagnosis for LAN system. <Ref. to tem? nosis according to
LAN(diag)-24, OPERATION, Read Diagnostic DTC for LAN sys-
Trouble Code (DTC).> tem.
4 CHECK COMBINATION METER. Is combination meter OK? Replace the Repair the combi-
Check the combination meter. VDCCM&H/U. nation meter
assembly.
VDC(diag)-26
C: ABS WARNING LIGHT DOES NOT COME ON

• Defective harness
TROUBLE SYMPTOM:
When the ignition switch is turned to ON (engine OFF), ABS warning light does not come on.
WIRING DIAGRAM:
• LHD model
BATTERY
SBF-1
SBF-7
IGNITION
SWITCH
E
NO.5
A4
A3
A: i10
WARNING
WARNING
BRAKE
LIGHT
LIGHT
ABS
A8
A7
A5
20
35
BRAKE FLUID
LEVEL SWITCH
i1 i3
16
20
9
B36 B38 B310 VDCCM & H/U
1
2
B16
B97
2
1
4
R1 B229
R4
PARKING
BRAKE
SWITCH
E
B16 i1 B310 A: i10
1 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
2 1 2 3 4 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 11 12 13 14 15 16 17 18 19 20 21 22
5 6 7 8 9 10 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
11 12 13 14 15 16
17 18 19 20 21 22
23 24 25 26 27 28
B229 B38 B97
1 2 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7
10 11 12 13 14 15 16 17 18 19 20 8 9 10 11 12 13 14 15 16
VDC00245
VDC(diag)-27
• RHD model
BATTERY
SBF-1
SBF-7
IGNITION
SWITCH
E
NO.5
A4
A3
WARNING A: i10
WARNING
BRAKE
LIGHT
LIGHT
ABS
20
35
A8
A7
BRAKE FLUID A5
LEVEL SWITCH
i1
16
B36 B310 VDCCM & H/U
1
2
B16
B97
2
1
5
R1 B229
R4
PARKING
BRAKE
SWITCH
E
B16 i1 B310 A: i10
1 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
2 1 2 3 4 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 11 12 13 14 15 16 17 18 19 20 21 22
5 6 7 8 9 10 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
11 12 13 14 15 16
17 18 19 20 21 22
23 24 25 26 27 28
B229 B97
1 2 1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
VDC00238
VDC(diag)-28
Step Check Yes No

1 CHECK OTHER LIGHTS TURN ON. Do other warning lights illumi- Go to step 2. Check the combi-
Turn the ignition switch to ON. (engine OFF) nate? nation meter.
Read the DTC. <Ref. to VDC(diag)-22, Read nosis according to
3 CHECK GROUND SHORT CIRCUIT OF HAR- Is the resistance more than 1 Go to step 4. Repair the har-
NESS. M&? ness connector
2) Disconnect the connector (B310) from VDCCM&H/U and
VDCCM&H/U. combination
3) Disconnect the connector (i10) from combi- meter.
nation meter.
VDCCM&H/U connector and chassis ground.
4 CHECK VDCCM. Is the resistance more than 1 Check the combi- Replace
1) Connect the connector (B310) to M&? nation meter. VDCCM&H/U.
VDCCM&H/U.
3) Measure the resistance between the com-
bination meter connector and chassis ground
soon after the ignition switch is turned to ON
(within 1.5 seconds).
(i10) No. A5 — Chassis ground:
VDC(diag)-29
D: ABS WARNING LIGHT DOES NOT GO OFF

• Open in harness
TROUBLE SYMPTOM:
When starting the engine, the ABS warning light is kept ON.
WIRING DIAGRAM:
• LHD model
BATTERY
SBF-1
SBF-7
IGNITION
SWITCH
E
NO.5
A4
A3
A: i10
WARNING
WARNING
BRAKE
LIGHT
LIGHT
ABS
A8
A7
A5
20
35
BRAKE FLUID
LEVEL SWITCH
i1 i3
16
20
9
1
2
B16
B97
2
1
4
R1 B229
R4
PARKING
BRAKE
SWITCH
E
B16 i1 B310 A: i10
1 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
2 1 2 3 4 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 11 12 13 14 15 16 17 18 19 20 21 22
5 6 7 8 9 10 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
11 12 13 14 15 16
17 18 19 20 21 22
23 24 25 26 27 28
B229 B38 B97
1 2 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7
10 11 12 13 14 15 16 17 18 19 20 8 9 10 11 12 13 14 15 16
VDC00245
VDC(diag)-30
• RHD model
BATTERY
SBF-1
SBF-7
IGNITION
SWITCH
E
NO.5
A4
A3
WARNING A: i10
WARNING
BRAKE
LIGHT
LIGHT
ABS
20
35
A8
A7
BRAKE FLUID A5
LEVEL SWITCH
i1
16
1
2
B16
B97
2
1
5
R1 B229
R4
PARKING
BRAKE
SWITCH
E
B16 i1 B310 A: i10
1 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
2 1 2 3 4 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 11 12 13 14 15 16 17 18 19 20 21 22
5 6 7 8 9 10 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
11 12 13 14 15 16
17 18 19 20 21 22
23 24 25 26 27 28
B229 B97
1 2 1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
VDC00238
VDC(diag)-31
Step Check Yes No

1) Turn the ignition switch to OFF. &? ness connector
2) Disconnect the connector (B310) from between
VDCCM&H/U. VDCCM&H/U and
3) Disconnect the connector (i10) from combi- combination
nation meter. meter.
VDCCM&H/U connector and combination
meter connector.
(B310) No. 35 — (i10) No. A5:
4 CHECK VDCCM. Is the resistance less than 0.5 Check the combi- Replace the
1) Connect the connector to VDCCM&H/U &? nation meter. VDCCM&H/U.
(B310).
3) Measure the resistance between combina-
tion meter connector and chassis ground.
E: VDC INDICATOR LIGHT DOES NOT GO OFF

TROUBLE SYMPTOM:
When starting the engine, VDC indicator light is kept ON.
Step Check Yes No

Check the combination meter. VDCCM&H/U. nation meter.
VDC(diag)-32
F: VDC WARNING LIGHT AND VDC OFF INDICATOR LIGHT DO NOT GO OFF
• Defective engine
• VDC OFF switch is shorted.
TROUBLE SYMPTOM:
When starting the engine, VDC OFF indicator light is kept ON.
NOTE:
When pressing the VDC OFF switch for more than 10 seconds, the VDC OFF indicator light goes off and can-
not operate any more. When turning the ignition switch from OFF to ON, the OFF operation enabled status
is restored.
Step Check Yes No

2 CHECK ENGINE. Does the malfunction indicator Repair the engine. Go to step 3.
light illuminate?
3 CHECK ENGINE COOLANT. When the engine coolant tem- Normal Operation Go to step 4.
Warm up the engine and check if VDC warning perature is too low, VDC warn-
light and VDC OFF indicator light illumination ing light and VDC OFF
condition changes. indicator light illuminate. Does
the lights go off when the
engine is warmed-up?
4 CHECK VDC OFF SWITCH. Is VDC OFF switch normal? Go to step 5. Replace the VDC
Remove and check VDC OFF switch. OFF switch.
Check the combination meter. VDCCM&H/U. nation meter.
VDC(diag)-33
G: BRAKE WARNING LIGHT DOES NOT GO OFF

• Brake warning light circuit is shorted.
• Defective sensor/connector
TROUBLE SYMPTOM:
After starting the engine, the brake warning light is kept on though the parking lever is released.
WIRING DIAGRAM:
• LHD model
BATTERY
SBF-1
SBF-7
IGNITION
SWITCH
E
NO.5
A4
A3
A: i10
WARNING
WARNING
BRAKE
LIGHT
LIGHT
ABS
A8
A7
A5
20
35
BRAKE FLUID
LEVEL SWITCH
i1 i3
16
20
9
1
2
B16
B97
2
1
4
R1 B229
R4
PARKING
BRAKE
SWITCH
E
B16 i1 B310 A: i10
1 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
2 1 2 3 4 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 11 12 13 14 15 16 17 18 19 20 21 22
5 6 7 8 9 10 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
11 12 13 14 15 16
17 18 19 20 21 22
23 24 25 26 27 28
B229 B38 B97
1 2 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7
10 11 12 13 14 15 16 17 18 19 20 8 9 10 11 12 13 14 15 16
VDC00245
VDC(diag)-34
• RHD model
BATTERY
SBF-1
SBF-7
IGNITION
SWITCH
E
NO.5
A4
A3
WARNING A: i10
WARNING
BRAKE
LIGHT
LIGHT
ABS
20
35
A8
A7
BRAKE FLUID A5
LEVEL SWITCH
i1
16
1
2
B16
B97
2
1
5
R1 B229
R4
PARKING
BRAKE
SWITCH
E
B16 i1 B310 A: i10
1 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
2 1 2 3 4 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 11 12 13 14 15 16 17 18 19 20 21 22
5 6 7 8 9 10 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
11 12 13 14 15 16
17 18 19 20 21 22
23 24 25 26 27 28
B229 B97
1 2 1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
VDC00238
VDC(diag)-35
Step Check Yes No

1 CHECK INSTALLATION OF VDCCM&H/U Is the connector firmly Go to step 2. Insert the
CONNECTOR. inserted? VDCCM&H/U con-
1) Turn the ignition switch to OFF. nector until it is
2) Check that VDCCM&H/U connector is locked by clamp.
inserted until it is locked by clamp.
3 CHECK BRAKE FLUID AMOUNT. Is the amount of brake fluid Go to step 4. Replenish brake
Check the amount of brake fluid in the reser- between the lines of “MAX” fluid to the speci-
voir tank of master cylinder. and “MIN”? fied value.
4 CHECK BRAKE FLUID LEVEL SWITCH. Is the resistance more than 1 Go to step 5. Replace the mas-
1) Turn the ignition switch to OFF. M&? ter cylinder.
2) Disconnect the level switch connector (B16)
from master cylinder.
3) Measure the resistance of master cylinder
terminals.
Terminals
No. 1 — No. 2:
5 CHECK PARKING BRAKE SWITCH. Is the resistance more than 1 Go to step 6. Replace the park-
1) Disconnect the connector (R4) from park- M&? ing brake switch.
ing brake switch.
3) Measure the resistance between parking
brake switch terminal and chassis ground.
1) Disconnect the connector (i10) from combi- M&? ness connector
nation meter. between combina-
2) Measure the resistance between combination meter brake
tion meter connector and chassis ground. fluid level switch
Connector & terminal and parking brake
(i10) No. A7 — Chassis ground: switch.
7 CHECK HARNESS CONNECTOR. Is the resistance less than 0.5 Go to step 8. Repair the har-
1) Disconnect the connector (B310) from &? ness connector
VDCCM&H/U. between
2) Disconnect the connector (i10) from combi- VDCCM&H/U and
nation meter. combination
3) Measure the resistance between meter.
VDCCM&H/U connector and combination con-
nector.
(B310) No. 20 — (i10) No. A7:
9 CHECK VDCCM. Is the resistance less than 0.5 Check the combi- Replace the
1) Connect the connector (B310) to &? nation meter. VDCCM&H/U.
VDCCM&H/U.
2) Turn the ignition to ON.
3) Measure the resistance between combina-
tion meter connector and chassis ground.
VDC(diag)-36
11.List of Diagnostic Trouble Code (DTC)

A: LIST
Detailed
DTC Display Content of diagnosis Reference target
code
<Ref. to VDC(diag)-43, DTC C0021 FRONT ABS
Abnormal power sup-
FR sensor power supply WHEEL SPEED SENSOR RH POWER SUPPLY
698XH ply of front ABS wheel
failure MALFUNCTION, Diagnostic Procedure with Diag-
speed sensor RH
nostic Trouble Code (DTC).>
C0021
<Ref. to VDC(diag)-46, DTC C0021 OPEN/HIGH
Front Right ABS Sensor Open/high input of front
INPUT OF FRONT ABS WHEEL SPEED SEN-
6A0XH Circuit Open or Shorted ABS wheel speed sen-
SOR RH, Diagnostic Procedure with Diagnostic
Battery sor RH
68CXH
68EXH Front ABS wheel speed
Front Right ABS Sensor WHEEL SPEED SENSOR RH SIGNAL MAL-
C0022 690XH sensor RH signal mal-
Signal FUNCTION, Diagnostic Procedure with Diagnos-
694XH function
tic Trouble Code (DTC).>
696XH
Front ABS wheel speed
FL sensor power sup- WHEEL SPEED SENSOR LH POWER SUPPLY
618XH sensor LH power sup-
ply failure MALFUNCTION, Diagnostic Procedure with Diag-
ply malfunction
C0023
Front Left ABS Sensor Open/high input of front
INPUT OF FRONT ABS WHEEL SPEED SEN-
620XH Circuit Open or Shorted ABS wheel speed sen-
SOR LH, Diagnostic Procedure with Diagnostic
Battery sor LH
60CXH
60EXH Front ABS wheel speed
Front Left ABS Sensor WHEEL SPEED SENSOR LH SIGNAL MAL-
C0024 610XH sensor LH signal mal-
614XH function
616XH
<Ref. to VDC(diag)-43, DTC C0025 REAR ABS
Rear ABS wheel speed
RR sensor power sup- WHEEL SPEED SENSOR RH POWER SUPPLY
658XH sensor RH power sup-
ply failure MALFUNCTION, Diagnostic Procedure with Diag-
ply malfunction
C0025
Rear Right ABS Sensor Open/high input of rear
INPUT OF REAR ABS WHEEL SPEED SENSOR
660XH Circuit Open or Shorted ABS wheel speed sen-
RH, Diagnostic Procedure with Diagnostic Trouble
Battery sor RH
Code (DTC).>
64CXH
64EXH Rear ABS wheel speed
Rear Right ABS Sensor WHEEL SPEED SENSOR RH SIGNAL MAL-
C0026 650XH sensor RH signal mal-
654XH function
656XH
Rear ABS wheel speed
RL sensor power supply WHEEL SPEED SENSOR LH POWER SUPPLY
6D8XH sensor LH power sup-
failure MALFUNCTION, Diagnostic Procedure with Diag-
ply malfunction
C0027
Rear Left ABS Sensor Open/high input of rear
INPUT OF REAR ABS WHEEL SPEED SENSOR
6E0XH Circuit Open or Shorted ABS wheel speed sen-
LH, Diagnostic Procedure with Diagnostic Trouble
Battery sor LH
Code (DTC).>
6CCXH
6CEXH Rear ABS wheel speed
Rear Left ABS Sensor WHEEL SPEED SENSOR LH SIGNAL MAL-
C0028 6D0XH sensor LH signal mal-
6D4XH function
6D6XH
VDC(diag)-37
Detailed
code
608XH
648XH
688XH
6C8XH
704XH
606XH
646XH
<Ref. to VDC(diag)-57, DTC C0029 ABS WHEEL
686XH ABS wheel speed sen-
Any One of Four ABS SPEED SENSOR SIGNAL MALFUNCTION IN
C0029 6C6XH sor signal malfunction
Sensors Signal ONE OF FOUR WHEELS, Diagnostic Procedure
702XH in one of four wheels
with Diagnostic Trouble Code (DTC).>
604XH
644XH
684XH
6C4XH
70CXH
720XH
710XH
<Ref. to VDC(diag)-61, DTC C0031 FRONT
Front inlet solenoid
FR hold valve malfunc- INLET SOLENOID VALVE RH MALFUNCTION
C0031 320XH valve RH malfunction in
tion IN VDCCM&H/U, Diagnostic Procedure with Diag-
VDCCM&H/U
<Ref. to VDC(diag)-61, DTC C0032 FRONT OUT-
Front outlet solenoid
FR pressure reducing LET SOLENOID VALVE RH MALFUNCTION IN
C0032 360XH valve RH malfunction in
valve malfunction VDCCM&H/U, Diagnostic Procedure with Diag-
VDCCM&H/U
<Ref. to VDC(diag)-61, DTC C0033 FRONT
Front inlet solenoid
FL hold valve malfunc- INLET SOLENOID VALVE LH MALFUNCTION IN
C0033 220XH valve LH malfunction in
tion VDCCM&H/U, Diagnostic Procedure with Diag-
VDCCM&H/U
<Ref. to VDC(diag)-61, DTC C0034 FRONT OUT-
Front outlet solenoid
FL pressure reducing LET SOLENOID VALVE LH MALFUNCTION IN
C0034 260XH valve LH malfunction in
VDCCM&H/U
<Ref. to VDC(diag)-61, DTC C0035 REAR INLET
Rear inlet solenoid
RR hold valve malfunc- SOLENOID VALVE RH MALFUNCTION IN
C0035 2A0XH valve RH malfunction in
VDCCM&H/U
<Ref. to VDC(diag)-62, DTC C0036 REAR OUT-
Rear outlet solenoid
RR pressure reducing LET SOLENOID VALVE RH MALFUNCTION IN
C0036 2E0XH valve RH malfunction in
VDCCM&H/U
<Ref. to VDC(diag)-62, DTC C0037 REAR INLET
Rear inlet solenoid
RL hold valve malfunc- SOLENOID VALVE LH MALFUNCTION IN
C0037 3A0XH valve LH malfunction in
VDCCM&H/U
<Ref. to VDC(diag)-62, DTC C0038 REAR OUT-
Rear outlet solenoid
RL pressure reducing LET SOLENOID VALVE LH MALFUNCTION IN
C0038 3E0XH valve LH malfunction in
VDCCM&H/U
<Ref. to VDC(diag)-62, DTC C0061 SECOND-
Secondary cut valve
Normal opening valve 1 ARY CUT VALVE MALFUNCTION IN
C0061 4A0XH malfunction in
malfunction VDCCM&H/U, Diagnostic Procedure with Diag-
VDCCM&H/U
<Ref. to VDC(diag)-62, DTC C0062 PRIMARY
Primary cut valve mal-
Normal opening valve 2 CUT VALVE MALFUNCTION IN VDCCM&H/U,
C0062 4E0XH function in VDCCM&H/
malfunction Diagnostic Procedure with Diagnostic Trouble
U
Code (DTC).>
VDC(diag)-38
Detailed
code
<Ref. to VDC(diag)-62, DTC C0063 SECOND-
Secondary suction
Normal closing valve 1 ARY SUCTION VALVE MALFUNCTION IN
C0063 520XH valve malfunction in
VDCCM&H/U
<Ref. to VDC(diag)-63, DTC C0064 PRIMARY
Primary suction valve
Normal closing valve 2 SUCTION VALVE MALFUNCTION IN
C0064 560XH malfunction in
VDCCM&H/U
000XH
002XH
004XH
006XH
010XH
012XH
014XH
016XH
018XH
01AXH
01EXH
024XH <Ref. to VDC(diag)-65, DTC C0041 VDC CON-
VDC control module
C0041 026XH ECM TROL MODULE MALFUNCTION, Diagnostic Pro-
(VDCCM) malfunction
028XH cedure with Diagnostic Trouble Code (DTC).>
02AXH
02CXH
02EXH
030XH
03AXH
03CXH
03DXH
03EXH
034XH
036XH
038XH
<Ref. to VDC(diag)-67, DTC C0042 POWER
7CEXH Power supply voltage Power voltage malfunc-
VOLTAGE MALFUNCTION, Diagnostic Proce-
7D0XH failure tion
C0042 <Ref. to VDC(diag)-70, DTC C0042 ABS WHEEL
Speed sen. power sup- ABS wheel speed sen- SPEED SENSOR POWER MALFUNCTION,
7CCXH
ply failure sor power malfunction Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
CAN communication <Ref. to VDC(diag)-70, DTC C0044 AT COMMU-
TCM communication
C0044 9A0XH malfunction of transmis- NICATION, Diagnostic Procedure with Diagnos-
circuit
sion control module tic Trouble Code (DTC).>
<Ref. to VDC(diag)-71, DTC C0045 DIFFERENT
970XH Incorrect VDC Control Different VDC control VDC CONTROL MODULE SPECIFICATION,
822XH Module specifications module specification Diagnostic Procedure with Diagnostic Trouble
C0045 Code (DTC).>
<Ref. to VDC(diag)-72, DTC C0045 AT CON-
AT control module mal-
972XH TCM malfunction TROL MODULE MALFUNCTION, Diagnostic Pro-
function
cedure with Diagnostic Trouble Code (DTC).>
788XH
<Ref. to VDC(diag)-73, DTC C0047 IMPROPER
78CXH Improper CAN commu- Improper CAN commu-
C0047 CAN COMMUNICATION, Diagnostic Procedure
7A0XH nication nication
7A4XH
VDC(diag)-39
Detailed
code
<Ref. to VDC(diag)-75, DTC C0051 VALVE
Valve relay OFF mal-
048XH Valve relay OFF failure RELAY OFF MALFUNCTION, Diagnostic Proce-
function
04AXH
Valve relay Valve relay system RELAY MALFUNCTION, Diagnostic Procedure
04CXH
C0051
Valve relay test mal-
06AXH Valve relay test failure RELAY TEST MALFUNCTION, Diagnostic Proce-
function
Valve relay ON mal-
00DXH Valve relay ON failure RELAY ON MALFUNCTION, Diagnostic Proce-
function
<Ref. to VDC(diag)-83, DTC C0052 MOTOR/
Motor/motor relay sys-
58AXH Motor and motor relay MOTOR RELAY MALFUNCTION, Diagnostic
tem
Procedure with Diagnostic Trouble Code (DTC).>
Motor and motor relay Motor/motor relay OFF MOTOR RELAY OFF MALFUNCTION, Diagnos-
5A0XH
OFF failure malfunction tic Procedure with Diagnostic Trouble Code
C0052 (DTC).>
Motor and motor relay Motor/motor relay ON
58EXH MOTOR RELAY ON MALFUNCTION, Diagnostic
ON failure malfunction
<Ref. to VDC(diag)-88, DTC C0052 MOTOR,
58CXH Motor malfunction Motor Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
<Ref. to VDC(diag)-89, DTC C0054 BLS OPEN
0A0XH Brake Light Switch BLS open circuit CIRCUIT, Diagnostic Procedure with Diagnostic
C0054
<Ref. to VDC(diag)-91, DTC C0054 BLS ON
08CXH BLS ON malfunction BLS ON malfunction MALFUNCTION, Diagnostic Procedure with Diag-
CAN communication <Ref. to VDC(diag)-93, DTC C0057 EGI COM-
EGI communication cir-
C0057 820XH malfunction of engine MUNICATION, Diagnostic Procedure with Diag-
cuit
control module nostic Trouble Code (DTC).>
VDC(diag)-40
Detailed
code
<Ref. to VDC(diag)-94, DTC C0071 EXCESSIVE
Excessive steering
Steering angle sensor STEERING ANGLE SENSOR OUTPUT OFFSET,
148XH angle sensor output off-
offset is too big Diagnostic Procedure with Diagnostic Trouble
set
Code (DTC).>
<Ref. to VDC(diag)-96, DTC C0071 EXCESSIVE
Change range of steer- Excessive variation
VARIATION AMOUNT OF STEERING ANGLE
14AXH ing angle sensor is too amount of steering
SENSOR OUTPUT, Diagnostic Procedure with
big angle sensor output
142XH
144XH
146XH
14EXH
158XH
15AXH
15CXH <Ref. to VDC(diag)-98, DTC C0071 STEERING
C0071 Steering angle sensor Steering angle sensor
15EXH ANGLE SENSOR OUTPUT, Diagnostic Proce-
malfunction output
14CXH dure with Diagnostic Trouble Code (DTC).>
164XH
166XH
16AXH
16CXH
16EXH
170XH
<Ref. to VDC(diag)-100, DTC C0071 STEERING
No signal from steering Steering angle sensor
160XH ANGLE SENSOR COMMUNICATION, Diagnostic
angle sensor communication
<Ref. to VDC(diag)-103, DTC C0071 STEERING
Steering angle sensor
Steering angle sensor ANGLE SENSOR POWER SUPPLY MALFUNC-
764XH power supply malfunc-
malfunction TION, Diagnostic Procedure with Diagnostic Trou-
tion
ble Code (DTC).>
184XH <Ref. to VDC(diag)-106, DTC C0072 YAW RATE
Abnormal yaw rate sen-
188XH Yaw rate sensor output SENSOR OUTPUT, Diagnostic Procedure with
sor output
18EXH Diagnostic Trouble Code (DTC).>
180XH
182XH
186XH
<Ref. to VDC(diag)-106, DTC C0072 YAW RATE
190XH Abnormal yaw rate sen-
Yaw rate sensor output SENSOR OUTPUT, Diagnostic Procedure with
194XH sor output
196XH
198XH
19AXH
C0072 Abnormal yaw rate sen-
192XH Yaw rate sensor output SENSOR OUTPUT, Diagnostic Procedure with
sor output
Voltage inputted to yaw <Ref. to VDC(diag)-108, DTC C0072 YAW RATE
1A0XH Yaw rate sensor power
rate sensor exceeds SENSOR POWER/OUTPUT, Diagnostic Proce-
18BXH supply/output
specification dure with Diagnostic Trouble Code (DTC).>
Abnormal yaw rate sen- Yaw rate sensor refer-
19CXH SENSOR REFERENCE, Diagnostic Procedure
sor reference voltage ence
<Ref. to VDC(diag)-114, DTC C0072 EXCES-
Change range of yaw Excessive variation
SIVE VARIATION AMOUNT OF YAW RATE
18CXH rate sensor signal is too amount of yaw rate sen-
SENSOR OUTPUT, Diagnostic Procedure with
big sor output
VDC(diag)-41
Detailed
code
Excessive amount of
1C8XH Lateral G sensor offset SIVE AMOUNT OF LATERAL G SENSOR OUT-
lateral G sensor output
1CAXH is too big PUT OFFSET, Diagnostic Procedure with
offset
1C0XH <Ref. to VDC(diag)-117, DTC C0073 LATERAL G
Abnormal lateral G sen-
1C6XH Lateral G sensor output SENSOR OUTPUT, Diagnostic Procedure with
sor output
1D8XH Diagnostic Trouble Code (DTC).>
Excessive variation
C0073 Change range of lateral SIVE VARIATION AMOUNT OF LATERAL G
1CCXH amount of lateral G
G sensor is too big SENSOR OUTPUT, Diagnostic Procedure with
sensor output
Excessive lateral G sen- Excessive lateral G
1D2XH SIVE LATERAL G SENSOR OUTPUT, Diagnostic
sor signal sensor output
Voltage inputted to lat- <Ref. to VDC(diag)-120, DTC C0073 LATERAL G
Lateral G sensor power/
1E0XH eral G sensor exceeds SENSOR POWER/OUTPUT, Diagnostic Proce-
output
specification dure with Diagnostic Trouble Code (DTC).>
<Ref. to VDC(diag)-123, DTC C0074 PRESSURE
Pressure sensor test Pressure sensor test
118XH SENSOR TEST MALFUNCTION, Diagnostic Pro-
failure malfunction
cedure with Diagnostic Trouble Code (DTC).>
Pressure sensor offset Excessive pressure SIVE PRESSURE SENSOR OUTPUT OFFSET,
110XH
is too big sensor output offset Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
C0074 120XH Pressure sensor power/ Pressure sensor power/
SENSOR POWER/OUTPUT, Diagnostic Proce-
113XH output output
102XH
Pressure sensor output Pressure sensor output SENSOR OUTPUT, Diagnostic Procedure with
108XH
Pressure sensor power Pressure sensor power
124XH SENSOR POWER MALFUNCTION, Diagnostic
supply malfunction supply malfunction
<Ref. to VDC(diag)-131, DTC C0081 SYSTEM
C0081 746XH System failure System malfunction MALFUNCTION, Diagnostic Procedure with Diag-
VDC(diag)-42
12.Diagnostic Procedure with Diagnostic Trouble Code (DTC)

A: DTC C0021 FRONT ABS WHEEL SPEED SENSOR RH POWER SUPPLY
MALFUNCTION
NOTE:
For the diagnostic procedure, refer to DTC C0027 “REAR ABS WHEEL SPEED SENSOR LH POWER SUP-
PLY MALFUNCTION”. <Ref. to VDC(diag)-44, DTC C0027 REAR ABS WHEEL SPEED SENSOR LH POW-
ER SUPPLY MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
B: DTC C0023 FRONT ABS WHEEL SPEED SENSOR LH POWER SUPPLY
MALFUNCTION
NOTE:
C: DTC C0025 REAR ABS WHEEL SPEED SENSOR RH POWER SUPPLY MAL-
FUNCTION
NOTE:
VDC(diag)-43
D: DTC C0027 REAR ABS WHEEL SPEED SENSOR LH POWER SUPPLY MAL-
FUNCTION
Defective ABS wheel speed sensor
TROUBLE SYMPTOM:
• VDC does not operate.
WIRING DIAGRAM:
BATTERY
SBF-1
GENERATOR
SBF-7
IGNITION
SWITCH
No.33
E
14
B310 VDCCM & H/U
B310
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
VDC00216
VDC(diag)-44
Step Check Yes No

Check if there is poor contact in VDCCM&H/U nector.
power supply circuit.
2 CHECK VDCCM&H/U POWER SUPPLY CIR- Is the voltage 10 — 15 V? Go to step 3. Check the genera-
CUIT. tor, battery and
1) Turn the ignition switch to OFF. VDCCM&H/U
2) Disconnect the VDCCM&H/U connector. power supply cir-
3) Turn the ignition switch to ON. cuit.
4) Measure the voltage between VDCCM&H/
U connector terminals.
Terminals
(B310) No. 14 (+) — (B310) No. 6 (#):
3 CHECK VDCCM&H/U. Is the same DTC displayed? Replace the Go to step 4.
1) Connect all the connectors. VDCCM&H/U.
2) Erase the memory.
3) Perform the inspection mode.
4) Read the DTC.
4 CHECK OTHER DTC DETECTION. Is any other DTC displayed? Perform the diag- It results from a
DTC. interference.
VDC(diag)-45
E: DTC C0021 OPEN/HIGH INPUT OF FRONT ABS WHEEL SPEED SENSOR RH

NOTE:
For the diagnostic procedure, refer to DTC C0027 “OPEN/HIGH INPUT OF REAR ABS WHEEL SPEED
SENSOR LH”. <Ref. to VDC(diag)-47, DTC C0027 OPEN/HIGH INPUT OF REAR ABS WHEEL SPEED
SENSOR LH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
F: DTC C0023 OPEN/HIGH INPUT OF FRONT ABS WHEEL SPEED SENSOR LH
NOTE:
G: DTC C0025 OPEN/HIGH INPUT OF REAR ABS WHEEL SPEED SENSOR RH
NOTE:
VDC(diag)-46
H: DTC C0027 OPEN/HIGH INPUT OF REAR ABS WHEEL SPEED SENSOR LH

• Defective ABS wheel speed sensor (broken wire, input voltage too high)
TROUBLE SYMPTOM:
WIRING DIAGRAM:
• LHD model
B310 VDCCM & H/U
24
40
25
22
21
23
38
41
6
TWISTED WIRE
TWISTED WIRE
B98
15
14
5
R2
TWISTED WIRE
TWISTED WIRE
B15 B6
R73 R72
1
2
1
2
1
2
1
2
FRONT ABS FRONT ABS

SENSOR LH SENSOR RH
B6 R72
B98 B310
B15 R73
1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 10
8 9 10 11 12 13 14 15 16 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
1 2
27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
VDC00246
VDC(diag)-47
• RHD model
B310 VDCCM & H/U
24
40
25
22
21
23
38
41
6
TWISTED WIRE
TWISTED WIRE
B97
19
18
7
R1
TWISTED WIRE
TWISTED WIRE
B15 B6
R73 R72
1
2
1
2
1
2
1
2
FRONT ABS FRONT ABS

SENSOR LH SENSOR RH
B6 R72
B97 B310
B15 R73
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10
10 11 12 13 14 15 16 17 18 19 20 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
1 2
27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
VDC00215
VDC(diag)-48
Step Check Yes No

Check if there is poor contact between nector.
VDCCM&H/U and ABS wheel speed sensor.
VDCCM&H/U AND ABS WHEEL SPEED &? ness connector
SENSOR. between
1) Disconnect the connector (B310) from VDCCM&H/U and
VDCCM&H/U. ABS wheel speed
2) Disconnect the connector from ABS wheel sensor.
speed sensor.
VDCCM&H/U connector and ABS wheel
speed sensor connector.
DTC C0021
(B310) No. 22 — (B6) No. 1:
(B310) No. 21 — (B6) No. 2:
DTC C0023
(B310) No. 41 — (B15) No. 1:
(B310) No. 25 — (B15) No. 2:
DTC C0025
(B310) No. 23 — (R72) No. 1:
(B310) No. 38 — (R72) No. 2:
DTC C0027
(B310) No. 24 — (R73) No. 1:
(B310) No. 40 — (R73) No. 2:
Measure the resistance between VDCCM&H/U M&? ness connector
connector and chassis ground. between
Connector & terminal VDCCM&H/U and
DTC C0021 ABS wheel speed
(B310) No. 21 — Chassis ground: sensor.
DTC C0023
DTC C0025
DTC C0027
4 CHECK ABS WHEEL SPEED SENSOR POW- Is the voltage 5 — 16 V? Go to step 6. Go to step 5.
ER SUPPLY CIRCUIT.
1) Connect the VDCCM&H/U connector.
3) Measure the voltage between ABS wheel
speed sensor connector and chassis ground.
DTC C0021
DTC C0023
DTC C0025
(R72) No. 1 (+) — Chassis ground (#):
DTC C0027
(R73) No. 1 (+) — Chassis ground (#):
VDC(diag)-49
Step Check Yes No

5 CHECK VDCCM&H/U POWER SUPPLY CIR- Is the voltage 10 — 15 V? Go to step 7. Check the genera-
CUIT. tor, battery and
1) Turn the ignition switch to OFF. VDCCM&H/U
2) Disconnect the VDCCM&H/U connector. power supply cir-
3) Turn the ignition switch to ON. cuit.
(B310) No. 14 (+) — (B310) No. 6 (#):
6 CHECK ABS WHEEL SPEED SENSOR SIG- Is waveform pattern same as Go to step 7. Replace the ABS
NAL. shown in the figure. wheel speed sen-
1) Install the ABS wheel speed sensor. sor.
2) Prepare an oscilloscope.
3) Check the ABS wheel speed sensor. <Ref.
to ABS-15, ABS WHEEL SPEED SENSOR,
INSPECTION, Rear ABS Wheel Speed Sen-
sor.>
2) Erase the memory. <Ref. to VDC-7,
3) Perform the inspection mode. <Ref. to VDC Control Mod-
VDC(diag)-23, PROCEDURE, Inspection ule & Hydraulic
Mode.> Control Unit
4) Read the DTC. (VDCCM&H/U).>
DTC. interference.
VDC(diag)-50
I: DTC C0022 FRONT ABS WHEEL SPEED SENSOR RH SIGNAL MALFUNC-

TION
NOTE:
For the diagnostic procedure, refer to DTC C0028 “REAR ABS WHEEL SPEED SENSOR LH SIGNAL MAL-
FUNCTION”. <Ref. to VDC(diag)-52, DTC C0028 REAR ABS WHEEL SPEED SENSOR LH SIGNAL MAL-
FUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
J: DTC C0024 FRONT ABS WHEEL SPEED SENSOR LH SIGNAL MALFUNC-
TION
NOTE:
K: DTC C0026 REAR ABS WHEEL SPEED SENSOR RH SIGNAL MALFUNC-
TION
NOTE:
VDC(diag)-51
L: DTC C0028 REAR ABS WHEEL SPEED SENSOR LH SIGNAL MALFUNC-

TION
• Defective ABS wheel speed sensor signal (noise, irregular signal, etc.)
TROUBLE SYMPTOM:
VDC(diag)-52
WIRING DIAGRAM:
• LHD model
B310 VDCCM & H/U
24
40
25
22
21
23
38
41
6
TWISTED WIRE
TWISTED WIRE
B98
15
14
5
R2
TWISTED WIRE
TWISTED WIRE
B15 B6
R73 R72
1
2
1
2
1
2
1
2
FRONT ABS FRONT ABS

SENSOR LH SENSOR RH
B6 R72
B98 B310
B15 R73
1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 10
8 9 10 11 12 13 14 15 16 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
1 2
27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
VDC00246
VDC(diag)-53
• RHD model
B310 VDCCM & H/U
24
40
25
22
21
23
38
41
6
TWISTED WIRE
TWISTED WIRE
B97
19
18
7
R1
TWISTED WIRE
TWISTED WIRE
B15 B6
R73 R72
1
2
1
2
1
2
1
2
FRONT ABS FRONT ABS

SENSOR LH SENSOR RH
B6 R72
B97 B310
B15 R73
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10
10 11 12 13 14 15 16 17 18 19 20 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
1 2
27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
VDC00215
VDC(diag)-54
Step Check Yes No

1 CHECK OUTPUT OF ABS WHEEL SPEED Does the speed indicated on Go to step 2. Go to step 7.
SENSOR USING SUBARU SELECT MONI- the display change in response
TOR. to the speedometer reading
1) Select {Current Data Display & Save} in during acceleration/decelera-
Subaru Select Monitor. tion when the steering wheel is
2) Read the ABS wheel speed sensor output in the straight-ahead position?
corresponding to the faulty wheel in Subaru
Select Monitor data display mode.
Turn the ignition switch to OFF. nectors between VDCCM&H/U nector.
and ABS wheel speed sensor?
3 CHECK SOURCES OF SIGNAL NOISE. Are the car phone, radio wave Go to step 4. Install the radio
Make sure the car phone, radio wave device device like radio and etc., or wave device and
like radio and etc., or electric device are electric device installed cor- electric device
installed correctly. rectly? properly.
4 CHECK SOURCES OF SIGNAL NOISE. Are noise sources installed? Install the noise Go to step 5.
Check if the noise sources (such as an sources apart from
antenna) are installed near the sensor har- the sensor har-
ness. ness.
Mode.> Control Unit
DTC. interference.
bolts.
8 CHECK ABS WHEEL SPEED SENSOR SIG- Is the oscilloscope pattern the Go to step 9. Go to step 13.
NAL. same waveform as shown in
1) Install the ABS wheel speed sensor. the figure when the tire is
2) Prepare an oscilloscope. rotated? Is the pattern as
3) Check ABS wheel speed sensor. <Ref. to shown in the figure displayed
ABS-13, ABS WHEEL SPEED SENSOR, regularly in the oscilloscope
INSPECTION, Front ABS Wheel Speed Sen- when the tire is slowly rotated
sor.> more than one revolution with
even speed?
9 CHECK ABS WHEEL SPEED SENSOR OR Are there foreign materials, Remove dirt thor- Go to step 10.
MAGNETIC ENCODER. breakage or damage in the oughly. Replace
protrusion of ABS wheel speed the ABS wheel
magnetic encoder
as a unit with hub
unit bearing when
it is broken or
damaged.
Make sure the car phone, radio wave device device like radio and etc., or wave device and
like radio and etc., or electric device are electric device installed cor- electric device
installed correctly. rectly? properly.
11 CHECK SOURCES OF SIGNAL NOISE. Are noise sources installed? Go to step 12. Install the noise
Check if the noise sources are (such as an sources apart from
ness.
VDC(diag)-55
Step Check Yes No

Mode.> Control Unit
DTC. interference.
NOTE:
Though the ABS
warning light re-
mains on at this
time, it is normal.
more than 12 km/h
(7 MPH) in order to
turn ABS warning
light off. Be sure to
drive the vehicle
and check the
warning light goes
off.
VDC(diag)-56
M: DTC C0029 ABS WHEEL SPEED SENSOR SIGNAL MALFUNCTION IN ONE

OF FOUR WHEELS
• Defective ABS wheel speed sensor signal (noise, irregular signal, etc.)
• Defective magnetic encoder
• When a wheel is turned freely for a long time
TROUBLE SYMPTOM:
NOTE:
Brake warning light comes on as well as ABS warning light when EBD does not operate.
VDC(diag)-57
WIRING DIAGRAM:
• LHD model
B310 VDCCM & H/U
24
40
25
22
21
23
38
41
6
TWISTED WIRE
TWISTED WIRE
B98
15
14
5
R2
TWISTED WIRE
TWISTED WIRE
B15 B6
R73 R72
1
2
1
2
1
2
1
2
FRONT ABS FRONT ABS

SENSOR LH SENSOR RH
B6 R72
B98 B310
B15 R73
1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 10
8 9 10 11 12 13 14 15 16 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
1 2
27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
VDC00246
VDC(diag)-58
• RHD model
B310 VDCCM & H/U
24
40
25
22
21
23
38
41
6
TWISTED WIRE
TWISTED WIRE
B97
19
18
7
R1
TWISTED WIRE
TWISTED WIRE
B15 B6
R73 R72
1
2
1
2
1
2
1
2
FRONT ABS FRONT ABS

SENSOR LH SENSOR RH
B6 R72
B97 B310
B15 R73
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10
10 11 12 13 14 15 16 17 18 19 20 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
1 2
27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
VDC00215
VDC(diag)-59
Step Check Yes No

1 WHETHER A WHEEL TURNED FREELY OR Did the wheels turn freely? VDC is normal. Go to step 2.
NOT. Erase the memory.
Check if the wheels have been turned freely for NOTE:
more than one minute, such as when the vehi- When the wheels
cle is jacked-up, under full-lock cornering or turn freely for a
when the wheels are not in contact with road long time, such as
surface. when the vehicle is
towed or jacked-
up, or when steer-
ing wheel is contin-
uously turned all
the way, this diag-
nostic trouble code
may sometimes
occur.
2 CHECK TIRE SPECIFICATIONS. Are the tire specifications cor- Go to step 3. Replace the tire.
Turn the ignition switch to OFF. rect?
3 CHECK WEAR OF TIRE. Is the tire worn excessively? Replace the tire. Go to step 4.
4 CHECK TIRE INFLATION PRESSURE. Is the tire pressure correct? Go to step 5. Adjust the tire
pressure.
5 CHECK INSTALLATION OF ABS WHEEL Are the ABS wheel speed sen- Go to step 6. Tighten the ABS
SPEED SENSOR. sor installation bolts tightened wheel speed sen-
to 7.5 N'm (0.76 kgf-m, 5.5 ft- sor installation
lb)? (For four wheels) bolts.
6 CHECK ABS WHEEL SPEED SENSOR SIG- Is the oscilloscope pattern the Go to step 8. Go to step 7.
NAL. same waveform as shown in
1) Install the ABS wheel speed sensor. the figure when the tire is
2) Prepare an oscilloscope. rotated? Is the pattern as
3) Check the ABS wheel speed sensor. <Ref. shown in the figure displayed
to ABS-13, ABS WHEEL SPEED SENSOR, regularly in the oscilloscope
INSPECTION, Front ABS Wheel Speed Sen- when the tire is slowly rotated
sor.> more than one revolution with
even speed?
7 CHECK ABS WHEEL SPEED SENSOR OR Are there foreign materials, Remove dirt thor- Go to step 8.
MAGNETIC ENCODER. breakage or damage in the oughly. Replace
protrusion of ABS wheel speed the ABS wheel
magnetic encoder
as a unit with hub
unit bearing if
there is breakage
or damage.
Mode.> Control Unit
VDC(diag)-60
Step Check Yes No

DTC. interference.
NOTE:
Though the ABS
warning light re-
mains on at this
time, it is normal.
more than 12 km/h
(7 MPH) in order to
turn off the ABS
warning light. Be
sure to drive the
vehicle and check
the warning light
goes off.
N: DTC C0031 FRONT INLET SOLENOID VALVE RH MALFUNCTION IN VDC-

CM&H/U
NOTE:
For the diagnostic procedure, refer to DTC C0064 “PRIMARY SUCTION VALVE MALFUNCTION IN VDC-
CM&H/U”. <Ref. to VDC(diag)-63, DTC C0064 PRIMARY SUCTION VALVE MALFUNCTION IN VDC-
CM&H/U, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
O: DTC C0032 FRONT OUTLET SOLENOID VALVE RH MALFUNCTION IN VDC-
CM&H/U
NOTE:
P: DTC C0033 FRONT INLET SOLENOID VALVE LH MALFUNCTION IN VDC-
CM&H/U
NOTE:
Q: DTC C0034 FRONT OUTLET SOLENOID VALVE LH MALFUNCTION IN VDC-
CM&H/U
NOTE:
R: DTC C0035 REAR INLET SOLENOID VALVE RH MALFUNCTION IN VDC-
CM&H/U
NOTE:
VDC(diag)-61
S: DTC C0036 REAR OUTLET SOLENOID VALVE RH MALFUNCTION IN VDC-

CM&H/U
NOTE:
T: DTC C0037 REAR INLET SOLENOID VALVE LH MALFUNCTION IN VDC-
CM&H/U
NOTE:
U: DTC C0038 REAR OUTLET SOLENOID VALVE LH MALFUNCTION IN VDC-
CM&H/U
NOTE:
V: DTC C0061 SECONDARY CUT VALVE MALFUNCTION IN VDCCM&H/U
NOTE:
W: DTC C0062 PRIMARY CUT VALVE MALFUNCTION IN VDCCM&H/U
NOTE:
X: DTC C0063 SECONDARY SUCTION VALVE MALFUNCTION IN VDCCM&H/U
NOTE:
VDC(diag)-62
Y: DTC C0064 PRIMARY SUCTION VALVE MALFUNCTION IN VDCCM&H/U

• Defective VDCH/U solenoid valve
TROUBLE SYMPTOM:
WIRING DIAGRAM:
BATTERY
SBF-1
GENERATOR
SBF-7
IGNITION
SWITCH
No.33
E
14
B310 VDCCM & H/U
B310
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
VDC00216
VDC(diag)-63
Step Check Yes No

1 CHECK INPUT VOLTAGE FOR VDCCM&H/ Is the voltage 10 — 15 V? Go to step 2. Repair the power
U. supply circuit.
2) Disconnect the connector from VDCCM&H/
U.
2 CHECK GROUND CIRCUIT FOR VDCCM&H/ Is the resistance less than 0.5 Go to step 3. Repair the
U. &? VDCCM&H/U
1) Turn the ignition switch to OFF. ground harness.
3 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in con- Repair the con- Go to step 4.
tery and VDCCM&H/U?
3) Perform the inspection mode. VDC Control Mod-
4) Read the DTC. ule & Hydraulic
Control Unit
(VDCCM&H/U).>
5 CHECK OTHER DTC DETECTION. Is any other DTC displayed? Perform the diag- Temporary poor
nosis according to contact occurs.
DTC.
VDC(diag)-64
Z: DTC C0041 VDC CONTROL MODULE MALFUNCTION

Defective VDCCM&H/U
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B310
VDCCM & H/U
B310
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
VDC00217
VDC(diag)-65
Step Check Yes No

U. &? VDCCM&H/U
U.
VDCCM&H/U and chassis ground.
nectors between battery, igni- nector.
tion switch and VDCCM&H/U?
3 CHECK SOURCES OF SIGNAL NOISE. Is the car phone or radio prop- Go to step 4. Install the car
erly installed? phone or radio
properly.
4 CHECK SOURCES OF SIGNAL NOISE. Are noise sources (such as an Install the noise Go to step 5.
antenna) installed near the sources apart from
sensor harness? the sensor har-
ness.
Control Unit
(VDCCM&H/U).>
DTC. <Ref. to
VDC(diag)-37, List
of Diagnostic Trou-
ble Code (DTC).>
VDC(diag)-66
AA:DTC C0042 POWER VOLTAGE MALFUNCTION

Defective VDCCM&H/U power voltage
TROUBLE SYMPTOM:
NOTE:
Warning lights go off if voltage returns.
VDC(diag)-67
WIRING DIAGRAM:
BATTERY
SBF-1
GENERATOR
SBF-7
IGNITION
SWITCH
No.33
E
14
B310 VDCCM & H/U
B310
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
VDC00216
VDC(diag)-68
Step Check Yes No

1 CHECK GENERATOR. Is the voltage 10 — 15 V? Go to step 2. Repair the genera-
1) Start the engine. tor. <Ref. to
2) Run the engine at idle after warming up. SC(H4SO 2.0)-14,
3) Measure the voltage between generator B Generator.>
terminal and chassis ground.
Terminals
Generator B terminal (+) — Chassis
ground (#):
2 CHECK BATTERY TERMINAL. Are the positive and negative Go to step 3. Tighten the termi-
Turn the ignition switch to OFF. battery terminals clamped nal.
tightly?
U. supply circuit.
U.
3) Operate the devices such as headlights, air
conditioner, defogger, etc. which produce
much electrical loading.
U. &? VDCCM&H/U
tery and VDCCM&H/U?
Control Unit
(VDCCM&H/U).>
DTC. <Ref. to
VDC(diag)-37, List
of Diagnostic Trou-
ble Code (DTC).>
VDC(diag)-69
AB:DTC C0042 ABS WHEEL SPEED SENSOR POWER MALFUNCTION

NOTE:
For the diagnostic procedure, refer to DTC C0042 “POWER VOLTAGE MALFUNCTION”. <Ref. to VDC(di-
ag)-67, DTC C0042 POWER VOLTAGE MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
AC:DTC C0044 AT COMMUNICATION
No CAN signal from TCM.
TROUBLE SYMPTOM:
Step Check Yes No

2 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in TCM Repair the con- Go to step 3.
connector? nector.
3 CHECK TCM. Is the TCM normal? Go to step 4. Replace the TCM.
<Ref. to 4AT-65,
Transmission Con-
trol Module
(TCM).> <Ref. to
5AT-61, Transmis-
sion Control Mod-
ule (TCM).>
4) Read the DTC.
DTC. interference.
VDC(diag)-70
AD:DTC C0045 DIFFERENT VDC CONTROL MODULE SPECIFICATION

Different control module specification
TROUBLE SYMPTOM:
Step Check Yes No

1 CHECK VDCCM&H/U SPECIFICATION. Is the identification mark of Go to step 2. Replace the
Check the identification mark of VDCCM&H/U. VDCCM&H/U the same as VDCCM&H/U.
Identification mark of VDCCM&H/U vehicle specification? <Ref. to VDC-7,
OUTBACK 3.0 R: G2 VDC Control Mod-
Wagon model 2.5 i: G3 ule & Hydraulic
Wagon model 3.0 R: G4 Control Unit
Sedan model 2.5 i: G9 (VDCCM&H/U).>
Sedan model 3.0 R: GA
2 CHECK TCM SPECIFICATION. Is the specification of TCM Go to step 3. Replace the TCM.
Check the TCM specification. same as vehicle specification? <Ref. to 4AT-65,
Transmission Con-
trol Module
(TCM).> <Ref. to
5AT-61, Transmis-
sion Control Mod-
ule (TCM).>
3 CHECK AT SYSTEM. Is DTC of AT system dis- Repair the AT sys- Go to step 4.
1) Start the engine. played? tem.
2) Check the DTC in AT system.
4 CHECK ECM SPECIFICATION. Is the specification of ECM Go to step 5. Replace the ECM.
Check the ECM specification. same as vehicle specification? <Ref. to FU(H4SO
2.0)-34, Engine
Control Module
(ECM).> <Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>
<Ref. to
FU(H6DO)-34,
Engine Control
Module (ECM).>
4) Read the DTC.
DTC. interference.
VDC(diag)-71
AE:DTC C0045 AT CONTROL MODULE MALFUNCTION

Defective TCM
TROUBLE SYMPTOM:
Step Check Yes No

1 CHECK AT SYSTEM. Is DTC of AT system dis- Repair the AT sys- Go to step 2.
1) Start the engine. played? tem.
2) Check the DTC in AT system.
4) Read the DTC.
DTC. interference.
VDC(diag)-72
AF:DTC C0047 IMPROPER CAN COMMUNICATION

CAN communication line circuit is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B310 VDCCM & H/U
13
29
30
TWISTED WIRE
2
1
4
B231
STEERING
ANGLE SENSOR
3
B231 B310
1 2 3 4 1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
VDC00247
VDC(diag)-73
Step Check Yes No

2 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in Repair the con- Go to step 3.
VDCCM&H/U connector? nector.
3 CHECK VDCCM&H/U. Is the same DTC displayed? Replace the Temporary poor
1) Connect all the connectors. VDCCM&H/U. contact occurs.
Control Unit
(VDCCM&H/U).>
VDC(diag)-74
AG:DTC C0051 VALVE RELAY OFF MALFUNCTION

TROUBLE SYMPTOM:
WIRING DIAGRAM:
BATTERY
SBF-1
SBF-7
No.21
IGNITION
SWITCH E
No.33
B310
14
6
5
SECONDARY SUCTION
MOTOR RELAY
PRIMARY SUCTION
SECONDARY CUT
PRIMARY CUT
PUMP MOTOR
RR OUTLET
FR OUTLET
RL OUTLET
FL OUTLET
SOLENOID
RL INLET
FR INLET
RR INLET
FL INLET
VALVE
VDCCM & H/U

M
VALVE RELAY
B310
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
VDC00219
VDC(diag)-75
Step Check Yes No

1 CHECK INPUT VOLTAGE FOR VDCCM&H/ Is the voltage 10 — 15 V? Go to step 2. Repair the har-
U. ness connector
1) Turn the ignition switch to OFF. between battery
2) Disconnect the connector from VDCCM&H/ and VDCCM&H/U.
U.
U. &? VDCCM&H/U
tery and VDCCM&H/U?
Control Unit
(VDCCM&H/U).>
DTC.
VDC(diag)-76
AH:DTC C0051 VALVE RELAY MALFUNCTION

TROUBLE SYMPTOM:
WIRING DIAGRAM:
BATTERY
SBF-1
SBF-7
No.21
IGNITION
SWITCH E
No.33
B310
14
6
5
SECONDARY SUCTION
MOTOR RELAY
PRIMARY SUCTION
SECONDARY CUT
PRIMARY CUT
PUMP MOTOR
RR OUTLET
FR OUTLET
RL OUTLET
FL OUTLET
SOLENOID
RL INLET
FR INLET
RR INLET
FL INLET
VALVE
VDCCM & H/U

M
VALVE RELAY
B310
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
VDC00219
VDC(diag)-77
Step Check Yes No

U. supply circuit.
U.
(B310) No. 14 (+) —Chassis ground (#):
2 CHECK INPUT VOLTAGE FOR VDCCM&H/ Is the voltage difference Repair the power Go to step 3.
U. between A and B more than 2 supply circuit.
Calculate the voltage difference measured in V?
step 1.
A:(B310) No. 14 (+) — Chassis ground (#):
B:(B310) No. 5 (+) — Chassis ground (#):
U. &? VDCCM&H/U
4 CHECK VALVE RELAY FOR VDCCM&H/U. Is the resistance more than 1 Go to step 5. Replace the
Measure the resistance between VDCCM&H/U M&? VDCCM&H/U.
(B310) No. 5 — (B310) No. 6:
tery and VDCCM&H/U?
Control Unit
(VDCCM&H/U).>
DTC.
VDC(diag)-78
AI: DTC C0051 VALVE RELAY TEST MALFUNCTION

TROUBLE SYMPTOM:
WIRING DIAGRAM:
BATTERY
SBF-1
SBF-7
No.21
IGNITION
SWITCH E
No.33
B310
14
6
5
SECONDARY SUCTION
MOTOR RELAY
PRIMARY SUCTION
SECONDARY CUT
PRIMARY CUT
PUMP MOTOR
RR OUTLET
FR OUTLET
RL OUTLET
FL OUTLET
SOLENOID
RL INLET
FR INLET
RR INLET
FL INLET
VALVE
VDCCM & H/U

M
VALVE RELAY
B310
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
VDC00219
VDC(diag)-79
Step Check Yes No

U. supply circuit in
1) Turn the ignition switch to OFF. VDCCM&H/U.
U.
2 CHECK GROUND CIRCUIT FOR VDCCM&H/ Is the resistance less than 0.5 Go to step 3. Repair the ground
U. &? circuit in
3 CHECK VALVE RELAY FOR VDCCM&H/U. Is the resistance more than 1 Go to step 4. Replace the H/U.
Measure the resistance between VDCCM&H/U M&?
(B310) No. 5 — (B310) No. 6:
tery and VDCCM&H/U?
Control Unit
(VDCCM&H/U).>
DTC.
VDC(diag)-80
AJ:DTC C0051 VALVE RELAY ON MALFUNCTION

TROUBLE SYMPTOM:
WIRING DIAGRAM:
BATTERY
SBF-1
SBF-7
No.21
IGNITION
SWITCH E
No.33
B310
14
6
5
SECONDARY SUCTION
MOTOR RELAY
PRIMARY SUCTION
SECONDARY CUT
PRIMARY CUT
PUMP MOTOR
RR OUTLET
FR OUTLET
RL OUTLET
FL OUTLET
SOLENOID
RL INLET
FR INLET
RR INLET
FL INLET
VALVE
VDCCM & H/U

M
VALVE RELAY
B310
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
VDC00219
VDC(diag)-81
Step Check Yes No

1 CHECK VALVE RELAY FOR VDCCM&H/U. Is the resistance more than 1 Go to step 2. Replace the
1) Disconnect the connector from VDCCM&H/ M&? VDCCM&H/U.
U. <Ref. to VDC-7,
2) Measure the resistance between VDC Control Mod-
VDCCM&H/U connector terminals. ule & Hydraulic
Terminals Control Unit
No. 5 — No. 6: (VDCCM&H/U).>
tery and VDCCM&H/U?
Control Unit
(VDCCM&H/U).>
DTC. <Ref. to
VDC(diag)-37, List
of Diagnostic Trou-
ble Code (DTC).>
VDC(diag)-82
AK:DTC C0052 MOTOR/MOTOR RELAY MALFUNCTION

• Defective motor and motor relay
TROUBLE SYMPTOM:
WIRING DIAGRAM:
BATTERY
SBF-2 SBF-1
SBF-7
IGNITION
SWITCH E
No.33
B310
10
14
6
9
SECONDARY SUCTION
PRIMARY SUCTION
MOTOR RELAY
SECONDARY CUT
PRIMARY CUT
PUMP MOTOR
RR OUTLET
FR OUTLET
RL OUTLET
FL OUTLET
SOLENOID
RL INLET
FR INLET
RR INLET
FL INLET
VALVE
VDCCM & H/U

M
VALVE RELAY
E E
B310
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
VDC00220
VDC(diag)-83
Step Check Yes No

U. supply circuit in
U.
U. &? VDCCM&H/U
3 CHECK MOTOR RELAY FOR VDCCM&H/U. Is the resistance more than 1 Go to step 4. Replace the
Measure the resistance between VDCCM&H/U M&? VDCCM&H/U.
Terminals
No. 9 — No. 10:
4 CHECK MOTOR OPERATION. Is the motor revolution noise Go to step 5. Replace the
Operate the sequence control. (buzz) heard when carrying out VDCCM&H/U.
the sequence control? <Ref. to VDC-7,
VDC Control Mod-
ule & Hydraulic
Control Unit
(VDCCM&H/U).>
Turn the ignition switch to OFF. nector between generator, bat- nector.
tery and VDCCM&H/U?
Control Unit
(VDCCM&H/U).>
DTC. <Ref. to NOTE:
VDC(diag)-37, List Though the ABS
of Diagnostic Trou- warning light re-
ble Code (DTC).> mains on at this
time, it is normal.
more than 12 km/h
(7 MPH) in order to
turn ABS warning
drive the vehicle
and check the
warning light goes
off.
VDC(diag)-84
AL:DTC C0052 MOTOR/MOTOR RELAY OFF MALFUNCTION

TROUBLE SYMPTOM:
NOTE:
For the diagnostic procedure, refer to DTC C0052 “MOTOR/MOTOR RELAY MALFUNCTION” <Ref. to
VDC(diag)-83, DTC C0052 MOTOR/MOTOR RELAY MALFUNCTION, Diagnostic Procedure with Diagnos-
VDC(diag)-85
AM:DTC C0052 MOTOR/MOTOR RELAY ON MALFUNCTION

TROUBLE SYMPTOM:
WIRING DIAGRAM:
BATTERY
SBF-2 SBF-1
SBF-7
IGNITION
SWITCH E
No.33
B310
10
14
6
9
SECONDARY SUCTION
PRIMARY SUCTION
MOTOR RELAY
SECONDARY CUT
PRIMARY CUT
PUMP MOTOR
RR OUTLET
FR OUTLET
RL OUTLET
FL OUTLET
SOLENOID
RL INLET
FR INLET
RR INLET
FL INLET
VALVE
VDCCM & H/U

M
VALVE RELAY
E E
B310
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
VDC00220
VDC(diag)-86
Step Check Yes No

1 CHECK MOTOR RELAY FOR VDCCM&H/U. Is the resistance more than 1 Go to step 2. Replace the
1) Disconnect the connector from VDCCM&H/ M&? VDCCM&H/U.
U. <Ref. to VDC-7,
2) Measure the resistance between VDC Control Mod-
VDCCM&H/U connector terminals. ule & Hydraulic
Terminals Control Unit
No. 9 — No. 10: (VDCCM&H/U).>
Control Unit
(VDCCM&H/U).>
DTC. <Ref. to NOTE:
VDC(diag)-37, List Though the ABS
of Diagnostic Trou- warning light re-
ble Code (DTC).> mains on at this
time, it is normal.
more than 12 km/h
(7 MPH) in order to
turn ABS warning
drive the vehicle
and check the
warning light goes
off.
VDC(diag)-87
AN:DTC C0052 MOTOR

• Defective motor
TROUBLE SYMPTOM:
NOTE:
For the diagnostic procedure, refer to DTC C0052 “MOTOR/MOTOR RELAY MALFUNCTION” <Ref. to
VDC(diag)-83, DTC C0052 MOTOR/MOTOR RELAY MALFUNCTION, Diagnostic Procedure with Diagnos-
VDC(diag)-88
AO:DTC C0054 BLS OPEN CIRCUIT

TROUBLE SYMPTOM:
WIRING DIAGRAM:
BATTERY
SBF-1
E
SBF-3
No.8
STOP LIGHT SWITCH

OC WC WC : WITH CRUISE CONTROL
1 2
2 3 OC : WITHOUT CRUISE CONTROL
B64 : OC
B65 : WC
9
B159
5
37
B310 VDCCM & H/U
B64 B65 B159 B310
1 2 1 2 1 2 3 4 1 2 3 4 5 6 7 8 9 10
3 4 5 6 7 8 9 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
VDC00221
VDC(diag)-89
Step Check Yes No

1 CHECK OUTPUT OF STOP LIGHT SWITCH Is OFF displayed on the dis- Go to step 2. Go to step 3.
WITH SUBARU SELECT MONITOR. play?
2) Release the brake pedal.
Select Monitor.
2 CHECK OUTPUT OF STOP LIGHT SWITCH Is ON displayed on the dis- Go to step 5. Go to step 3.
WITH SUBARU SELECT MONITOR. play?
1) Depress the brake pedal.
Select Monitor.
3 CHECK IF STOP LIGHTS COME ON. Does the stop light illuminate? Go to step 4. Repair the stop
Depress the brake pedal. lights circuit.
4 CHECK OPEN CIRCUIT OF HARNESS. Is the voltage 10 — 15 V? Go to step 5. Repair the har-
1) Turn the ignition switch to OFF. ness between stop
2) Disconnect the connector from VDCCM&H/ light switch and
U. VDCCM&H/U con-
3) Depress the brake pedal. nector.
5 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in con- Go to step 6. Repair the con-
nector between stop light nector.
switch and VDCCM&H/U?
Control Unit
(VDCCM&H/U).>
DTC.
VDC(diag)-90
AP:DTC C0054 BLS ON MALFUNCTION

TROUBLE SYMPTOM:
WIRING DIAGRAM:
BATTERY
SBF-1
E
SBF-3
No.8
STOP LIGHT SWITCH

OC WC WC : WITH CRUISE CONTROL
1 2
2 3 OC : WITHOUT CRUISE CONTROL
B64 : OC
B65 : WC
9
B159
5
37
B310 VDCCM & H/U
B64 B65 B159 B310
1 2 1 2 1 2 3 4 1 2 3 4 5 6 7 8 9 10
3 4 5 6 7 8 9 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
VDC00221
VDC(diag)-91
Step Check Yes No

1 CHECK STOP LIGHT SWITCH. Is the resistance more than 1 Go to step 2. Replace the stop
1) Turn the ignition switch to OFF. M& when switch is OFF (when light switch.
2) Disconnect the stop light switch connector. pedal is not depressed)?
3) Measure the resistance of stop light switch
terminals.
2 INTERVIEWING CUSTOMERS. Were the acceleration pedal System is in good Go to step 3.
Make sure that the operation was performed in and brake pedal depressed order. (DTC may
which accelerator pedal and brake pedal were simultaneously during driving? be recorded while
depressed simultaneously (with depressing brake is applied
brake pedal with left foot). during driving.)
Control Unit
(VDCCM&H/U).>
DTC. <Ref. to
VDC(diag)-37, List
of Diagnostic Trou-
ble Code (DTC).>
VDC(diag)-92
AQ:DTC C0057 EGI COMMUNICATION

No CAN signal from ECM.
TROUBLE SYMPTOM:
Step Check Yes No

2 CHECK POOR CONTACT IN CONNECTORS. Is the poor contact in ECM Repair the con- Go to step 3.
connector? nector.
3 CHECK ECM. Is ECM normal? Go to step 4. Replace the ECM.
4 CHECK VDCCM&H/U. Is the same DTC displayed? Replace the It results from a
1) Connect all the connectors. VDCCM&H/U. temporary noise
2) Erase the memory. <Ref. to VDC-7, interference.
Control Unit
(VDCCM&H/U).>
DTC.
VDC(diag)-93
AR:DTC C0071 EXCESSIVE STEERING ANGLE SENSOR OUTPUT OFFSET

Defective steering angle sensor
TROUBLE SYMPTOM:
VDC does not operate.
WIRING DIAGRAM:
B310 VDCCM & H/U
13
29
30
TWISTED WIRE
2
1
4
B231
STEERING
ANGLE SENSOR
3
B231 B310
1 2 3 4 1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
VDC00247
VDC(diag)-94
Step Check Yes No

1 CHECK STEERING WHEEL. Is the deviation from the center Go to step 2. Perform the cen-
1) Drive the vehicle on a flat road. of steering wheel less than 5"? tering adjustment
2) Park the vehicle straight. of steering wheel.
3) Check the steering wheel for deviation from
center.
2) Connect all the connectors. <Ref. to VDC-7,
3) Erase the memory. VDC Control Mod-
4) Perform the inspection mode. ule & Hydraulic
(VDCCM&H/U).>
DTC. <Ref. to
VDC(diag)-37, List
of Diagnostic Trou-
ble Code (DTC).>
VDC(diag)-95
AS:DTC C0071 EXCESSIVE VARIATION AMOUNT OF STEERING ANGLE SEN-

SOR OUTPUT
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B310 VDCCM & H/U
13
29
30
TWISTED WIRE
2
1
4
B231
STEERING
ANGLE SENSOR
3
B231 B310
1 2 3 4 1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
VDC00247
VDC(diag)-96
Step Check Yes No

(VDCCM&H/U).>
DTC. <Ref. to
VDC(diag)-37, List
of Diagnostic Trou-
ble Code (DTC).>
VDC(diag)-97
AT:DTC C0071 STEERING ANGLE SENSOR OUTPUT

TROUBLE SYMPTOM:
WIRING DIAGRAM:
B310 VDCCM & H/U
13
29
30
TWISTED WIRE
2
1
4
B231
STEERING
ANGLE SENSOR
3
B231 B310
1 2 3 4 1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
VDC00247
VDC(diag)-98
Step Check Yes No

1 CHECK STEERING WHEEL. Is the deviation from the center Go to step 2. Perform the cen-
1) Drive the vehicle on a flat road. of steering wheel less than 5"? tering adjustment
2) Park the vehicle straight. of steering wheel.
3) Check the steering wheel for deviation from
center.
2 CHECK DRIVING PLACE. VDCCM&H/U may Go to step 3.
Did the vehicle run the road
Check if the vehicle ran the road with banks or with banks or sandy surfacerecord DTC when
sandy surface (which does not mean a dirt (which does not mean a dirtthe vehicle ran the
road). road)? road with banks or
sandy surface
(which does not
mean a dirt road).
3 CHECK OUTPUT OF STEERING ANGLE Does the steering angle sensor Go to step 4. Replace the steer-
SENSOR WITH SUBARU SELECT MONI- output value on the display ing angle sensor.
TOR. vary in accordance with steer-
1) Select {Current Data Display & Save} in ing operation when turning the
Subaru Select Monitor. steering wheel to the right or
2) Read the steering angle sensor output dis- left?
played on display.
(VDCCM&H/U).>
DTC.
VDC(diag)-99
AU:DTC C0071 STEERING ANGLE SENSOR COMMUNICATION

Signal does not come from the steering angle sensor.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B310 VDCCM & H/U
13
29
30
TWISTED WIRE
2
1
4
B231
STEERING
ANGLE SENSOR
3
B231 B310
1 2 3 4 1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
VDC00247
VDC(diag)-100
Step Check Yes No

1 CHECK POWER SUPPLY FOR STEERING Is the voltage 10 — 15 V? Go to step 4. Go to step 2.
ANGLE SENSOR.
2) Disconnect the connector from steering
angle sensor.
4) Measure the voltage between steering
angle sensor and chassis ground.
2 CHECK OUTPUT VOLTAGE OF VDCCM&H/ Is the voltage 10 — 15 V? Repair the har- Go to step 3.
U. ness between
Measure the voltage between VDCCM&H/U steering angle
and chassis ground. sensor and
Connector & terminal VDCCM&H/U.
3 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in con- Correct or replace Go to step 9.
nector? the connector.
4 CHECK GROUND CIRCUIT FOR STEERING Is the resistance 0.5 &? Go to step 5. Repair ground cir-
ANGLE SENSOR. cuit in the steering
Measure the resistance between steering angle sensor.
5 CHECK STEERING ANGLE SENSOR HAR- Is the resistance 0.5 &? Go to step 6. Repair the har-
NESS. ness between
1) Disconnect the connector from VDCCM&H/ steering angle
U. sensor and
2) Measure the resistance between VDCCM&H/U.
VDCCM&H/U and steering angle sensor.
(B231) No. 1 — (B310) No. 29:
(B231) No. 2 — (B310) No. 13:
6 CHECK GROUND SHORT CIRCUIT OF Is the resistance more than 1 Go to step 7. Repair the har-
STEERING ANGLE SENSOR HARNESS. M&? ness between
Measure the resistance between steering steering angle
angle sensor and chassis ground. sensor and
(B231 No. 2 — Chassis ground:
7 CHECK STEERING ANGLE SENSOR. Is the same DTC displayed? Go to step 8. Go to step 10.
2) Connect all the connectors.
5) Read the DTC.
2) Replace the steering angle sensor. <Ref. to VDC-7,
(VDCCM&H/U).>
VDC(diag)-101
Step Check Yes No

9 CHECK STEERING ANGLE SENSOR. Is the same DTC displayed? Replace the Go to step 10.
(VDCCM&H/U).>
DTC.
11 CHECK OTHER DTC DETECTION. Is any other DTC displayed? Perform the diag- Original steering
nosis according to angle sensor mal-
DTC. function
VDC(diag)-102
AV:DTC C0071 STEERING ANGLE SENSOR POWER SUPPLY MALFUNCTION

TROUBLE SYMPTOM:
NOTE:
• Warning light does not illuminate though problem is detected.
• The ABS and VDC operate normally if voltage returns.
VDC(diag)-103
WIRING DIAGRAM:
B310 VDCCM & H/U
13
29
30
TWISTED WIRE
2
1
4
B231
STEERING
ANGLE SENSOR
3
B231 B310
1 2 3 4 1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
VDC00247
VDC(diag)-104
Step Check Yes No

1 CHECK POWER SUPPLY FOR STEERING Is the voltage 10 — 15 V? Go to step 4. Go to step 2.
ANGLE SENSOR.
2) Disconnect the connector from steering
angle sensor.
4) Measure the voltage between steering
U. ness between
Measure the voltage between VDCCM&H/U steering angle
4 CHECK GROUND CIRCUIT FOR STEERING Is the resistance 0.5 &? Go to step 5. Repair ground cir-
ANGLE SENSOR. cuit in the steering
Measure the resistance between steering angle sensor.
5 CHECK STEERING ANGLE SENSOR. Is the same DTC displayed? Go to step 6. Go to step 8.
5) Read the DTC.
2) Replace the steering angle sensor. <Ref. to VDC-7,
(VDCCM&H/U).>
7 CHECK STEERING ANGLE SENSOR. Is the same DTC displayed? Replace the Go to step 8.
(VDCCM&H/U).>
DTC.
9 CHECK OTHER DTC DETECTION. Is any other DTC displayed? Perform the diag- Original steering
nosis according to angle sensor mal-
DTC. function
VDC(diag)-105
AW:DTC C0072 YAW RATE SENSOR OUTPUT

Defective yaw rate sensor
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B310 VDCCM & H/U
30
28
16
1
2
6
B312
1
B347
B230
3
1
2
4
5
6
YAW RATE &

LATERAL G SENSOR
E
B230 B310 B312
1 2 3 4 5 6 7 8 9 10
1 2 3 1 2
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
4 5 6 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
VDC00222
VDC(diag)-106
Step Check Yes No

1 CHECK DRIVING PLACE. Did the vehicle run the road VDCCM&H/U may Go to step 2.
Check if the vehicle ran the road with banks or with banks or sandy surface record DTC when
sandy surface (which does not mean a dirt (which does not mean a dirt the vehicle ran the
sandy surface
(which does not
mean a dirt road).
2 CHECK YAW RATE & LATERAL G SENSOR Is the yaw rate & lateral G sen- Go to step 3. Tighten the yaw
INSTALLATION. sor installation bolt tightened to rate & lateral G
7.5 N'm (0.76 kgf-m, 5.5 ft-lb)? sensor installation
bolt.
3 CHECK OUTPUT OF YAW RATE & LATER- Is the reading indicated on Go to step 4. Replace the yaw
AL G SENSOR WITH SUBARU SELECT monitor display #4 — 4 deg/s? rate & lateral G
MONITOR. sensor.
1) Drive the vehicle on a flat road.
2) Park the vehicle straight.
4) Read the yaw rate output displayed on dis-
play.
4 CHECK OUTPUT OF STEERING ANGLE Is the reading indicated on Go to step 5. Perform the cen-
SENSOR WITH SUBARU SELECT MONI- monitor display #5 — 5"? tering adjustment
TOR. of steering wheel.
1) Drive the vehicle on a flat road.
2) Park the vehicle straight.
4) Read the steering angle sensor output dis-
played on display.
5 CHECK YAW RATE & LATERAL G SENSOR. Is the same DTC displayed? Go to step 6. Go to step 7.
5) Read the DTC.
2) Replace the yaw rate & lateral G sensor. <Ref. to VDC-7,
(VDCCM&H/U).>
DTC.
8 CHECK OTHER DTC DETECTION. Is any other DTC displayed? Perform the diag- Malfunction is
nosis according to found in original
DTC. yaw rate & lateral
G sensor.
VDC(diag)-107
AX:DTC C0072 YAW RATE SENSOR POWER/OUTPUT

TROUBLE SYMPTOM:
WIRING DIAGRAM:
B310 VDCCM & H/U
30
28
16
1
2
6
B312
1
B347
B230
3
1
2
4
5
6
YAW RATE &

LATERAL G SENSOR
E
B230 B310 B312
1 2 3 4 5 6 7 8 9 10
1 2 3 1 2
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
4 5 6 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
VDC00222
VDC(diag)-108
Step Check Yes No

1 CHECK YAW RATE & LATERAL G SENSOR Is the voltage 10 — 15 V? Go to step 4. Go to step 2.
POWER SUPPLY.
2) Disconnect the connector from the yaw rate
& lateral G sensor.
4) Measure the voltage between yaw rate &
lateral G sensor and chassis ground.
U. ness between yaw
Measure the voltage between VDCCM&H/U rate & lateral G
4 CHECK GROUND CIRCUIT OF YAW RATE & Is the resistance less than 0.5 Go to step 7. Go to step 5.
LATERAL G SENSOR. &?
Measure the resistance between yaw rate &
5 CHECK GROUND CIRCUIT FOR VDCCM&H/ Is the resistance less than 0.5 Repair the har- Go to step 6.
U. &? ness between yaw
Measure the resistance between VDCCM&H/U rate & lateral G
7 CHECK YAW RATE & LATERAL G SENSOR Is the resistance less than 0.5 Go to step 8. Repair the har-
HARNESS. &? ness between yaw
1) Disconnect the connector from VDCCM&H/ rate & lateral G
U. sensor and
VDCCM&H/U and yaw rate & lateral G sensor.
(B310) No. 28 — (B230) No. 4:
Measure the resistance between VDCCM&H/U M&? ness between yaw
connector and chassis ground. rate & lateral G
Connector & terminal sensor and
(B310) No. 28 — Chassis ground: VDCCM&H/U.
9 CHECK YAW RATE & LATERAL G SENSOR. Is the oscilloscope pattern the Go to step 10. Replace the yaw
1) Connect all the connectors. same waveform as shown in rate & lateral G
2) Turn the ignition switch to ON. the figure? sensor.
3) Check the signal pattern of oscilloscope
between VDCCM&H/U connector terminals.
<Ref. to VDC(diag)-15, WAVEFORM, MEA-
SUREMENT, Control Module I/O Signal.>
(B310) No. 2 — No. 16:
(B310) No. 28 — No. 16:
VDC(diag)-109
Step Check Yes No

10 CHECK YAW RATE & LATERAL G SENSOR. Is the same DTC displayed? Replace the Go to step 11.
(VDCCM&H/U).>
DTC.
VDC(diag)-110
AY:DTC C0072 YAW RATE SENSOR REFERENCE

TROUBLE SYMPTOM:
WIRING DIAGRAM:
B310 VDCCM & H/U
30
28
16
1
2
6
B312
1
B347
B230
3
1
2
4
5
6
YAW RATE &

LATERAL G SENSOR
E
B230 B310 B312
1 2 3 4 5 6 7 8 9 10
1 2 3 1 2
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
4 5 6 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
VDC00222
VDC(diag)-111
Step Check Yes No

1 CHECK POWER SUPPLY FOR YAW RATE & Is the voltage 10 — 15 V? Go to step 3. Go to step 2.
LATERAL G SENSOR.
2) Disconnect the connector from yaw rate &
lateral G sensor.
U. ness between yaw
6 CHECK HARNESS OF YAW RATE & LATER- Is the resistance less than 0.5 Go to step 7. Repair the har-
AL G SENSOR. &? ness between yaw
1) Turn the ignition switch to OFF. rate & lateral G
2) Disconnect the connector from VDCCM&H/ sensor and
U. VDCCM&H/U.
(B310) No. 1 — (B230) No. 1:
NESS. M&? ness between yaw
8 CHECK THE YAW RATE & LATERAL G SEN- Is the voltage 2.1 — 2.9 V? Go to step 9. Replace the yaw
SOR. rate & lateral G
1) Turn the ignition switch to OFF. sensor. <Ref. to
2) Install the yaw rate & lateral G sensor to VDC-14, Yaw Rate
body. & Lateral G Sen-
3) Connect all the connectors. sor.>
(B310) No. 1 (+) — No. 16 (#):
VDC(diag)-112
Step Check Yes No

(VDCCM&H/U).>
DTC.
VDC(diag)-113
AZ:DTC C0072 EXCESSIVE VARIATION AMOUNT OF YAW RATE SENSOR

OUTPUT
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B310 VDCCM & H/U

30
28
16
1
2
6
B312
1
B347
B230
3
1
2
4
5
6
YAW RATE &

LATERAL G SENSOR
E
B230 B310 B312
1 2 3 4 5 6 7 8 9 10
1 2 3 1 2
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
4 5 6 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
VDC00222
VDC(diag)-114
Step Check Yes No

1 CHECK DRIVING PLACE. Did the vehicle run the road VDCCM&H/U may Go to step 2.
Check if the vehicle ran the road with banks or with banks or sandy surface record DTC when
sandy surface (which does not mean a dirt (which does not mean a dirt the vehicle ran the
sandy surface
(which does not
mean a dirt road).
bolt.
POWER SUPPLY.
lateral G sensor.
U. ness between yaw
8 CHECK HARNESS OF YAW RATE & LATER- Is the resistance less than 0.5 Go to step 9. Repair the har-
AL G SENSOR. &? ness between yaw
U. sensor and
(B310) No. 1 — (B230) No. 1:
(B310) No. 2 — (B230) No. 2:
(B310) No. 28 — (B230) No. 4:
NESS. M&? ness between yaw
connector and chassis ground. sensor and
VDC(diag)-115
Step Check Yes No

10 CHECK YAW RATE & LATERAL G SENSOR. Is the voltage 2.1 — 2.9 V? Go to step 11. Replace the yaw
1) Turn the ignition switch to OFF. rate & lateral G
2) Connect all the connectors. sensor.
(B310) No. 1 (+) — No. 16 (#):
11 CHECK YAW RATE & LATERAL G SENSOR. Is the oscilloscope pattern the Go to step 12. Replace the yaw
1) Turn the ignition switch to ON. same waveform as shown in rate & lateral G
2) Check the signal pattern of oscilloscope the figure? sensor.
between VDCCM&H/U connector terminals.
<Ref. to VDC(diag)-15, WAVEFORM, MEA-
SUREMENT, Control Module I/O Signal.>
(B310) No. 2 — No. 16:
(B310) No. 28 — No. 16:
12 CHECK YAW RATE & LATERAL G SENSOR. Is the same DTC displayed? Go to step 13. Go to step 15.
5) Read the DTC.
2) Replace the yaw rate & lateral G sensor. <Ref. to VDC-7,
(VDCCM&H/U).>
14 CHECK YAW RATE & LATERAL G SENSOR. Is the same DTC displayed? Replace the Go to step 15.
(VDCCM&H/U).>
DTC.
16 CHECK OTHER DTC DETECTION. Is any other DTC displayed? Perform the diag- Malfunction is
nosis according to found in original
DTC. yaw rate & lateral
G sensor.
VDC(diag)-116
BA:DTC C0073 EXCESSIVE AMOUNT OF LATERAL G SENSOR OUTPUT OFF-

SET
NOTE:
For the diagnostic procedure, refer to DTC C0073. <Ref. to VDC(diag)-118, DTC C0073 EXCESSIVE LAT-
ERAL G SENSOR OUTPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
BB:DTC C0073 LATERAL G SENSOR OUTPUT
NOTE:
BC:DTC C0073 EXCESSIVE VARIATION AMOUNT OF LATERAL G SENSOR
OUTPUT
NOTE:
VDC(diag)-117
BD:DTC C0073 EXCESSIVE LATERAL G SENSOR OUTPUT

Defective lateral G sensor
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B310 VDCCM & H/U
30
28
16
1
2
6
B312
1
B347
B230
3
1
2
4
5
6
YAW RATE &

LATERAL G SENSOR
E
B230 B310 B312
1 2 3 4 5 6 7 8 9 10
1 2 3 1 2
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
4 5 6 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
VDC00222
VDC(diag)-118
Step Check Yes No

bolt.
2 CHECK LATERAL G SENSOR OUTPUT. Is the indicated reading on the Go to step 3. Replace the yaw
1) Park the vehicle on a level surface. monitor display #1.5 — 1.5 rate & lateral G
2) Select {Current Data Display & Save} in m/s2? sensor.
3) Read the lateral G sensor output displayed
on display.
3 CHECK LATERAL G SENSOR OUTPUT. When the yaw rate & lateral G Go to step 4. Replace the yaw
1) Turn the ignition switch to OFF. sensor is inclined 90" to the rate & lateral G
2) Remove the yaw rate & lateral G sensor right, is the indicated value 6.8 sensor.
from vehicle. — 12.8 m/s2?
3) Turn the ignition switch to ON, and select
{Current Data Display & Save} in Subaru
Select Monitor.
on display.
4 CHECK LATERAL G SENSOR. When the yaw rate & lateral G Go to step 5. Replace the yaw
Read the lateral G sensor output displayed on
sensor is inclined 90" to the rate & lateral G
screen. left, is the indicated value #6.8 sensor.
— #12.8 m/s2?
Turn the ignition switch to OFF. nector between VDCCM&H/U nector.
and yaw rate & lateral G sen-
sor?
Control Unit
(VDCCM&H/U).>
DTC.
VDC(diag)-119
BE:DTC C0073 LATERAL G SENSOR POWER/OUTPUT

Defective lateral G sensor
WIRING DIAGRAM:
B310 VDCCM & H/U
30
28
16
1
2
6
B312
1
B347
B230
3
1
2
4
5
6
YAW RATE &

LATERAL G SENSOR
E
B230 B310 B312
1 2 3 4 5 6 7 8 9 10
1 2 3 1 2
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
4 5 6 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
VDC00222
VDC(diag)-120
Step Check Yes No

1 CHECK LATERAL G SENSOR OUTPUT. Is the indicated reading on the Go to step 2. Go to step 3.
1) Park the vehicle on a level surface. monitor display #1.5 — 1.5
2) Select {Current Data Display & Save} in m/s2?
on display.
Turn the ignition switch to OFF. nector between VDCCM&H/U nector.
sor?
POWER SUPPLY.
lateral G sensor.
U. ness between yaw
5 CHECK POOR CONTACT IN CONNECTORS Is there poor contact in con- Correct or replace Go to step 10.
6 CHECK OPEN CIRCUIT IN LATERAL G SEN- Is the resistance less than 0.5 Go to step 7. Repair the har-
SOR OUTPUT HARNESS. &? ness connector
1) Disconnect the connector from yaw rate & between yaw rate
lateral G sensor. & lateral G sensor
2) Disconnect the connector from VDCCM&H/ and VDCCM&H/U.
U.
(B310) No. 3 — (B230) No. 5:
7 CHECK GROUND SHORT CIRCUIT FOR Is the resistance more than 1 Go to step 8. Repair the har-
YAW RATE & LATERAL G SENSOR HAR- M&? ness connector
NESS. between yaw rate
Measure the resistance between VDCCM&H/U & lateral G sensor
connector and chassis ground. and VDCCM&H/U.
8 CHECK LATERAL G SENSOR. Is the voltage 2.35 — 2.65 V Go to step 9. Replace the yaw
1) Turn the ignition switch to OFF. when yaw rate & lateral G sen- rate & lateral G
2) Remove the yaw rate & lateral G sensor sor is on level? sensor.
from vehicle.
3) Connect the connector to the yaw rate &
lateral G sensor.
4) Connect the connector to VDCCM&H/U.
lateral G sensor connector terminals.
(B230) No. 5 (+) — No. 6 (#):
VDC(diag)-121
Step Check Yes No

nector between VDCCM&H/U nector.
sor?
Control Unit
(VDCCM&H/U).>
DTC.
VDC(diag)-122
BF:DTC C0074 PRESSURE SENSOR TEST MALFUNCTION

Defective pressure sensor
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B310
VDCCM & H/U
12
11
27
B348
1
2
3
PRESSURE SENSOR
B310 B348
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 1
3
27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 2
VDC00223
VDC(diag)-123
Step Check Yes No

1 CHECK PRESSURE SENSOR POWER SUP- Is the voltage 4.75 — 5.25 V? Go to step 4. Go to step 2.
PLY.
2) Disconnect the connector from pressure
sensor.
4) Measure the voltage between pressure
sensor connector and chassis ground.
2 CHECK OUTPUT VOLTAGE OF VDCCM&H/ Is the voltage 4.75 — 5.25 V? Repair the har- Go to step 3.
U. ness between
Measure the voltage between VDCCM&H/U pressure sensor
and chassis ground. and VDCCM&H/U.
4 CHECK GROUND CIRCUIT OF PRESSURE Is the resistance less than 0.5 Go to step 7. Go to step 5.
SENSOR. &?
Measure the resistance between pressure
sensor and chassis ground.
5 CHECK GROUND CIRCUIT OF VDCCM&H/U. Is the resistance less than 0.5 Repair the har- Go to step 6.
Measure the resistance between VDCCM&H/U &? ness between
and chassis ground. pressure sensor
Connector & terminal and VDCCM&H/U.
7 CHECK PRESSURE SENSOR HARNESS. Is the resistance less than 0.5 Go to step 8. Repair the har-
1) Turn the ignition switch to OFF. &? ness between yaw
U. sensor and
VDCCM&H/U and pressure sensor.
(B310) No. 11 — (B348) No. 2:
9 CHECK VDCCM&H/U. Is DTC displayed? Replace the Go to step 10.
Control Unit
(VDCCM&H/U).>
DTC.
VDC(diag)-124
BG:DTC C0074 EXCESSIVE PRESSURE SENSOR OUTPUT OFFSET

TROUBLE SYMPTOM:
WIRING DIAGRAM:
B310
VDCCM & H/U
12
11
27
B348
1
2
3
PRESSURE SENSOR
B310 B348
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 1
3
27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 2
VDC00223
VDC(diag)-125
Step Check Yes No

1 CHECK STOP LIGHT SWITCH CIRCUIT. Is the stop light switch circuit Go to step 2. Repair the stop
Check stop light switch open circuit. OK? light switch circuit.
Control Unit
(VDCCM&H/U).>
DTC. <Ref. to
VDC(diag)-37, List
of Diagnostic Trou-
ble Code (DTC).>
BH:DTC C0074 PRESSURE SENSOR POWER/OUTPUT

TROUBLE SYMPTOM:
NOTE:
For the diagnostic procedure, refer to DTC C0074 “PRESSURE SENSOR TEST MALFUNCTION”. <Ref. to
VDC(diag)-123, DTC C0074 PRESSURE SENSOR TEST MALFUNCTION, Diagnostic Procedure with Di-
agnostic Trouble Code (DTC).>
VDC(diag)-126
BI: DTC C0074 PRESSURE SENSOR OUTPUT

TROUBLE SYMPTOM:
WIRING DIAGRAM:
B310
VDCCM & H/U
12
11
27
B348
1
2
3
PRESSURE SENSOR
B310 B348
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 1
3
27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 2
VDC00223
VDC(diag)-127
Step Check Yes No

1 CHECK STOP LIGHT SWITCH CIRCUIT. Is the stop light switch circuit Go to step 2. If there is malfunc-
Check stop light switch open circuit. OK? tion in the stop
light switch circuit,
DTC may be
recorded in the
memory.
2 CHECK PRESSURE SENSOR POWER SUP- Is the voltage 4.75 — 5.25 V? Go to step 5. Go to step 3.
PLY.
2) Disconnect the connector from pressure
sensor.
4) Measure the voltage between pressure
sensor connector and chassis ground.
3 CHECK OUTPUT VOLTAGE OF VDCCM&H/ Is the voltage 4.75 — 5.25 V? Repair the har- Go to step 4.
U. ness between
Measure the voltage between VDCCM&H/U pressure sensor
and chassis ground. and VDCCM&H/U.
5 CHECK GROUND CIRCUIT OF PRESSURE Is the resistance less than 0.5 Go to step 8. Go to step 6.
SENSOR. &?
Measure the resistance between pressure
sensor and chassis ground.
6 CHECK GROUND CIRCUIT OF VDCCM&H/U. Is the resistance less than 0.5 Repair the har- Go to step 7.
Measure the resistance between VDCCM&H/U &? ness between
and chassis ground. pressure sensor
Connector & terminal and VDCCM&H/U.
8 CHECK PRESSURE SENSOR HARNESS. Is the resistance less than 0.5 Go to step 9. Repair the har-
1) Turn the ignition switch to OFF. &? ness between yaw
U. sensor and
VDCCM&H/U and pressure sensor.
(B310) No. 11 — (B348) No. 2:
10 CHECK VDCCM&H/U. Is DTC displayed? Replace the Go to step 11.
Control Unit
(VDCCM&H/U).>
VDC(diag)-128
Step Check Yes No

DTC.
VDC(diag)-129
BJ:DTC C0074 PRESSURE SENSOR POWER MALFUNCTION

TROUBLE SYMPTOM:
WIRING DIAGRAM:
BATTERY
SBF-1
GENERATOR
SBF-7
IGNITION
SWITCH
No.33
E
14
B310 VDCCM & H/U
B310
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
VDC00216
VDC(diag)-130
Step Check Yes No

1 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact? Repair the con- Go to step 2.
Check if there is poor contact in VDCCM&H/U nector.
power supply circuit.
2 CHECK VDCCM&H/U POWER SUPPLY CIR- Is the voltage 10 — 15 V? Go to step 3. Check the power
CUIT. supply circuit in
2) Disconnect the VDCCM&H/U connector.
(B310) No. 14 (+) — (B310) No. 6 (#):
Control Unit
(VDCCM&H/U).>
DTC. interference.
BK:DTC C0081 SYSTEM MALFUNCTION

VDC long time sequential control
TROUBLE SYMPTOM:
Step Check Yes No

1 CHECK POOR CONTACT IN CONNECTOR. Is there poor contact in the Repair the con- Go to step 2.
VDCCM&H/U and yaw rate & nector.
lateral G sensor connector?
2 CHECK VDCCM&H/U. Is the same DTC displayed? Replace the Malfunction is
1) Replace the yaw rate & lateral G sensor. VDCCM&H/U. found in original
2) Connect all the connectors. yaw rate & lateral
3) Erase the memory. G sensor.
5) Read the DTC.
VDC(diag)-131

A: INSPECTION
Symptom Main probable cause Other probable cause
Poor brake per- Long braking/ • VDCCM&H/U • Defective ABS wheel speed sensor or sensor
formance stopping dis- • Brake pad gap
tance • Aeration to brake line • Defective steering angle sensor or improper
• Tire specifications, tire wear and air neutral position
pressures • Defective yaw rate & lateral G sensor or
• Incorrect wiring or piping connections improper installation
• Master cylinder
• Brake caliper
• Disc rotor
• Brake pipe
• Brake booster
Wheel lock • VDCCM&H/U • Defective steering angle sensor or improper
• Defective ABS wheel speed sensor or neutral position
sensor gap • Defective yaw rate & lateral G sensor or
• Incorrect wiring or piping connections improper installation
• Brake caliper
• Brake pipe
Brake drag • VDCCM&H/U • Defective steering angle sensor or improper
• Defective ABS wheel speed sensor or neutral position
sensor gap • Defective yaw rate & lateral G sensor or
• Master cylinder improper installation
• Brake caliper • Brake pad
• Parking brake • Brake pipe
• Axle and wheels
Long brake • Aeration to brake line • VDCCM&H/U
pedal stroke • Brake pedal play • Master cylinder
• Brake caliper
• Brake pad
• Brake pipe
• Brake booster
Vehicle vertical • VDCCM&H/U • Defective ABS wheel speed sensor or sensor
pitching • Road surface (uneven) gap
• Suspension play or fatigue (reduced • Defective steering angle sensor or improper
damping) neutral position
• Incorrect wiring or piping connections • Defective yaw rate & lateral G sensor or
improper installation
Poor brake per- Unstable or • VDCCM&H/U • Defective ABS wheel speed sensor or sensor
formance uneven braking • Defective ABS wheel speed sensor or gap
sensor gap • Defective steering angle sensor or improper
• Brake caliper neutral position
• Brake pad • Defective yaw rate & lateral G sensor or
• Road surface (uneven) improper installation
• Tire specifications, tire wear and air • Master cylinder
pressures • Disc rotor
• Incorrect wiring or piping connections • Brake pipe
• Axle and wheels
• Road with crowns or banks
• Suspension play or fatigue (poor damping)
VDC(diag)-132

Vibration or Excessive • Road surface (uneven) • VDCCM&H/U
noise brake pedal • Incorrect wiring or piping connections • Brake booster
• When brak- vibration • Suspension play or fatigue (poor damping)
ing suddenly Strange noise • VDCCM&H/U (mount bushing) • VDCCM&H/U
• When accel- from VDCH/U • Defective ABS wheel speed sensor or • Defective steering angle sensor or improper
erating sud- sensor gap neutral position
denly • Brake pipe • Defective yaw rate & lateral G sensor or
• While driving improper installation
on a slippery Noise from the • VDCCM&H/U (mount bushing) • Axle and wheels
road front side of • Defective ABS wheel speed sensor or • Tire specifications, tire wear and air pressures
vehicle sensor gap
• Master cylinder
• Brake caliper
• Brake pad
• Disc rotor
• Brake pipe
• Brake booster
• Suspension play or fatigue (poor damp-
ing)
Noise inside • VDCCM&H/U
passenger seat • Defective steering angle sensor or improper
neutral position
• Defective yaw rate & lateral G sensor or
improper installation
Noise from the • Defective ABS wheel speed sensor or • Axle and wheels
rear side of sensor gap • Tire specifications, tire wear and air pressures
vehicle • Brake caliper
• Brake pad
• Disc rotor
• Parking brake
• Brake pipe
ing)
Engine does not accelerate or • VDCCM&H/U • Defective steering angle sensor or improper
goes into a stall when accelerat- • Defective ABS wheel speed sensor or neutral position
ing suddenly or driving on a slip- sensor gap • Defective yaw rate & lateral G sensor or
pery surface. • Master cylinder improper installation
• Brake caliper • Brake pad
• Parking brake • Brake pipe
• Incorrect wiring or piping
VDC(diag)-133

Poor change- Deviation to • VDCCM&H/U • Disc rotor
direction-opera- right or left • Defective ABS wheel speed sensor or • Brake pipe
tion stability of direction sensor gap • Axle and wheels
TCS • Defective steering angle sensor or • Suspension play or fatigue (poor damping)
improper neutral position
• Defective yaw rate & lateral G sensor
or improper installation
• Brake caliper
• Brake pad
• Wheel alignment
• Tire specifications, tire wear and air
pressures
Vehicle spin • VDCCM&H/U • Brake caliper
• Defective ABS wheel speed sensor or • Brake pipe
sensor gap
• Defective steering angle sensor or
• Brake pad
pressures
Steering wheel drag while driving • VDCCM&H/U • Brake caliper
• Defective ABS wheel speed sensor or • Brake pad
sensor gap • Disc rotor
• Defective steering angle sensor or • Wheel alignment
improper neutral position • Road surface (uneven)
• Defective yaw rate & lateral G sensor • Road with crowns or banks
or improper installation • Suspension play or fatigue (poor damping)
• Incorrect wiring or piping connections • Tire specifications, tire wear and air pressures
• Power steering system
VDC operates while driving nor- • VDCCM&H/U
mally. • Defective ABS wheel speed sensor or
sensor gap
• Defective steering angle sensor or
• Wheel alignment
ing)
pressures
• Power steering system
VDC(diag)-134

VDC OFF indicator light does not • Harness
come on when the VDC OFF • Indicator light bulb
switch is depressed. • VDC OFF switch
NOTE:
When pressing VDC OFF switch
for more than 10 seconds, VDC
OFF indicator light goes off and
cannot operate any more. When
turning the ignition switch from
OFF to ON, the previous status is
restored.
VDC(diag)-135
VDC(diag)-136
CHASSIS SECTION
FRONT SUSPENSION FS
REAR SUSPENSION RS
DIFFERENTIALS DI
TRANSFER CASE TC
(DIAGNOSTICS)
BRAKE BR
PARKING BRAKE PB

(POWER STEERING)

approval.

BRAKE
BR
Page
2. Front Brake Pad ........................................................................................16
3. Front Disc Rotor ........................................................................................19
4. Front Disc Brake Assembly.......................................................................20
5. Rear Brake Pad.........................................................................................25
6. Rear Disc Rotor.........................................................................................26
7. Rear Disc Brake Assembly .......................................................................28
8. Master Cylinder .........................................................................................30
9. Brake Booster ...........................................................................................32
10. Brake Fluid ................................................................................................36
11. Air Bleeding...............................................................................................38
12. Brake Hose ...............................................................................................40
13. Brake Pipe.................................................................................................42
14. Brake Pedal...............................................................................................43
15. Stop Light Switch ......................................................................................45
16. Diagnosis ..................................................................................................47
General Description
BRAKE
A: SPECIFICATION
OUTBACK 2.5 i,
Model 2.0 i, 2.5 i 2.0 GT, 3.0 R
OUTBACK 3.0 R
Size 15-inch type 16-inch type 17-inch type
Type Disc (Floating type, ventilated)
Effective disc diameter mm (in) 228 (8.98) 244 (4.61) 261 (10.28)
Disc thickness ! Outer
mm (in) 24 ! 277 (0.94 ! 10.91) 24 ! 294 (0.94 ! 11.57) 30 ! 316 (1.18 ! 12.44)
Front disc diameter
brake Effective cylinder diameter 42.8 (1.685) ! 2
Pad dimensions
130.0 ! 53.5 ! 11.0
(length ! width ! thick- mm (in) 117.8 ! 50.5 ! 11.0 (4.638 ! 1.988 ! 0.433)
(5.118 ! 2.106 ! 0.433)
ness)
Clearance adjustment Automatic adjustment
Size 15-inch type
Disc (Floating type, ven-
Type Disc (Floating type, solid)
tilated)
Effective disc diameter mm (in) 238 (9.37) 254 (10.0)
Disc thickness ! Outer
mm (in) 10 ! 274 (0.39 ! 10.79) 18 ! 290 (0.71 ! 11.42)
Rear disc diameter
brake Effective cylinder
mm (in) 38.1 (1.500)
diameter
Pad dimensions
82.4 ! 33.7 ! 9.0
(length ! width ! thick- mm (in) 92.0 ! 33.0 ! 9.0 (3.622 ! 1.299 ! 0.354)
(3.244 ! 1.327 ! 0.354)
ness)
Clearance adjustment Automatic adjustment
Type Tandem
Effective diameter mm (in) 23.8 (15/16)
Master
Reservoir type Sealed type
cylinder
Brake fluid reservoir cm3 205 (12.51)
capacity (cu in)
Brake Type Vacuum suspended
booster Effective diameter mm (in) 208 + 229 (8.19 + 9.02)
Brake line Dual circuit system
Brake fluid
CAUTION:
• Avoid mixing brake fluid of different
brands to prevent fluid performance from
degrading.
FMVSS No. 116, DOT3
• When brake fluid is supplemented, be
careful not to allow any dust into the reser-
voir.
• Use fresh SUBARU genuine brake fluid
when replacing or refilling the fluid.
NOTE:
Refer to “PB” section for parking brake specifications. <Ref. to PB-2, SPECIFICATION, General Descrip-
tion.>
BR-2
General Description
BRAKE
Item Standard value Limit

Except 17-inch
Pad thickness 11 (0.43) 1.5 (0.059)
type
mm (in)
17-inch type 11 (0.43) 1.5 (0.059)
Front brake Except 17-inch
Disc thickness 24 (0.94) 22 (0.87)
type
mm (in)
17-inch type 30 (1.18) 28 (1.10)
Disc runout mm (in) — 0.05 (0.0020)
Pad thickness Solid disc 9.0 (0.354) 1.5 (0.059)
mm (in) Ventilated disc 9.0 (0.354) 1.5 (0.059)
Rear brake (Disc
Disc thickness Solid disc 10 (0.39) 8.5 (0.335)
type)
mm (in) Ventilated disc 18 (0.71) 16 (0.63)
Disc runout mm (in) — 0.05 (0.0020)
Inside diameter mm (in) 170 (6.69) 171 (6.73)
Parking brake Lining thickness mm (in) 3.2 (0.126) 1.5 (0.059)
Lever stroke 5 — 6 notches/200 N (20 kgf, 45 lb)
Brake pedal force Fluid pressure kPa (kg/cm2, psi)

N (kgf, lb) 15-inch type 16-inch type 17-inch type
Brake fluid pressure without 147 (15, 33) 545 (6, 79)
engine running 294 (30, 66) 1,564 (16, 227)
Brake Brake fluid pressure with 147 (15, 33) 6,003 (61, 871) 5,381 (55, 780) 4,963 (51, 720)
Booster engine running and vacuum
at 66.7 kPa (500 mmHg, 294 (30, 66) 11,273 (115, 1,635) 10,982 (112, 1,593) 10,055 (103, 1,458)
19.69 inHg)
Free play 0.5 — 2 (0.02 — 0.08)

Brake pedal
mm (in) [When pulling the brake pedal upward with a force of less than 10 N (1 kgf, 2 lb).]
BR-3
General Description
BRAKE
B: COMPONENT
1. FRONT DISK BRAKE
• Except for EC, EK, OUTBACK model
T2 T1
(2)
(3)
(4)
T3 (1)
(5)
(6)
(7)
(A)
(9)
(8)
(10) (17)
(11) (4)
(12)
(B)
(14)
(13)
(12)
(11)
(11)
(16)
(12)
(14)
(15)
(13)
(12)
(11)
BR-00332
(A) 15, 16-inch type (7) Piston boot (16) Disc cover
(B) 17-inch type (8) Lock pin (Yellow) (17) Bushing
(9) Support
(1) Caliper body (10) Pad clip Tightening torque: N"m (kgf-m, ft-lb)
(2) Air bleeder screw (11) Outer shim T1: 8 (0.8, 5.8)
(3) Guide pin (Green) (12) Inner shim T2: 27 (2.8, 19.9)
(4) Pin boot (13) Pad (Outside) T3: 80 (8.2, 59)
(5) Piston seal (14) Pad (Inside)
(6) Piston (15) Disc rotor
BR-4
General Description
BRAKE
• EC, EK, OUTBACK model
T2 T1
(2)
(3)
(4)
T3 (1)
(5)
(6)
(7)
(9)
(8)
(10) (17)
(11) (4)
(12)
(14)
(13)
(11)
(16)
(15)
BR-00373
(1) Caliper body (9) Support (17) Bushing

(2) Air bleeder screw (10) Pad clip
(3) Guide pin (Green) (11) Outer shim Tightening torque: N"m (kgf-m, ft-lb)
(4) Pin boot (12) Inner shim T1: 8 (0.8, 5.8)
(5) Piston seal (13) Pad (Outside) T2: 27 (2.8, 19.9)
(6) Piston (14) Pad (Inside) T3: 80 (8.2, 59)
(7) Piston boot (15) Disc rotor
(8) Lock pin (Yellow) (16) Disc cover
BR-5
General Description
BRAKE
2. REAR DISC BRAKE
(34) T1
(2)
T2
(3)
T3 (4)
(35) (1) (5)

(6)
(7)
(8)
(14)
(14)
(12) (9)
(10)
(4)
(11)
(14)
T4
(17)
(16)
(11)
(13)
(18)
(19)
(20)
(21) (23)
(24)
(25)
(26)
(27)
(22)
(33) (29)
(28)
(32)
(31) (30)
(15) BR-00374
(1) Caliper body (15) Shoe hold-down pin (29) Adjuster

(2) Air bleeder screw (16) Cover (30) Shoe hold-down cup
(3) Guide pin (Green) (17) Back plate (31) Shoe hold-down spring
(4) Pin boot (18) Retainer (32) Disc rotor (Solid type)
(5) Piston seal (19) Spring washer (33) Disc rotor (Ventilated type)
(6) Piston (20) Parking brake lever (34) Bolt (For solid disc brake)
(7) Piston boot (21) Parking brake shoe (Secondary) (35) Bolt (For ventilated disc brake)
(8) Support (22) Parking brake shoe (Primary)
(9) Lock pin (Yellow) (23) Strut Tightening torque: N"m (kgf-m, ft-lb)
(10) Bushing (24) Strut shoe spring T1: 8 (0.8, 5.8)
(11) Pad clip (25) Shoe guide plate T2: 27 (2.8, 19.9)
(12) Inner pad (26) Secondary shoe return spring T3: 37 (3.8, 27.5)
(13) Outer pad (27) Primary shoe return spring T4: 53 (5.4, 39.1)
(14) Shim (28) Adjusting spring
BR-6
General Description
BRAKE
3. MASTER CYLINDER
• LHD model
(1)
(2)
(10) (3)
(9) T
(8)
(11)
(4)
(5)
(6)
(7)
BR-00371
(1) Cap (6) Secondary piston (11) O-ring

(2) Filter (7) Cylinder body
(3) Reservoir tank (8) Cylinder pin Tightening torque: N"m (kgf-m, ft-lb)
(4) C-ring (9) Seal T: 13 (1.3, 9.6)
(5) Primary piston (10) Pin
BR-7
General Description
BRAKE
• RHD model
(1)
(2)
(10) (3)
(9) T
(8)
(11)
(4)
(5)
(6)
(7)
BR-00334
(1) Cap (6) Secondary piston (11) O-ring

(2) Filter (7) Cylinder body
(3) Reservoir tank (8) Cylinder pin Tightening torque: N"m (kgf-m, ft-lb)
(4) C-ring (9) Seal T: 13 (1.3, 9.6)
(5) Primary piston (10) Pin
BR-8
General Description
BRAKE
4. FRONT BRAKE PIPES AND HOSE

• LHD model
(8) (2)
(B)
T2
T3
T1
(1)
T3 T2
(5)
(A) T4
T3 (9)
(8) T3 (5)
(2) (10)
T2 (3)
(6) (4)
T1 T1
T1
(1) T2
T4
T2
T1 T2
(6)
(7)
T1
(5)
(9)
T4 T1 (5)
(3)
(4)
(6) T1
T2 T4
T2
(6)
BR-00372
(A) Model with ABS (5) Clamp Tightening torque: N"m (kgf-m, ft-lb)
(B) Model with Vehicle dynamics con- (6) Gasket T1: 15 (1.5, 10.8)
trol (VDC) (7) ABS control module and hydraulic T2: 18 (1.8, 13.0)
control unit (ABSCM&H/U) T3: 19 (1.9, 14.0)
(1) Front brake pipe ASSY (8) Bracket T4: 33 (3.4, 24.3)
(2) Two-way connector (9) Master cylinder
(3) Front brake hose RH (10) VDC control module & hydraulic
(4) Front brake hose LH control unit (VDCCM&H/U)
BR-9
General Description
BRAKE
• RHD model
(8) (2)
(B)
T2
T3
(1)
T1
T3 T2
(5)
T3 (9)
(A) T4
T3 (5)
(8) (2) (10)

T2 (3)
T1 (6) (4)
T1
T1 (1)
T2
T4
T2
T1 T2
(6)
(7)
T1
(5)
T1 (9)
(5)
T4
(3)
(4)
T1
(6)
T2 T4
T2
(6)
BR-00336
(A) Model with ABS (6) Gasket Tightening torque: N"m (kgf-m, ft-lb)
(B) Model with VDC (7) ABS control module and hydraulic T1: 15 (1.5, 10.8)
control unit (ABSCM&H/U) T2: 18 (1.8, 13.0)
(1) Front brake pipe ASSY (8) Bracket T3: 19 (1.9, 14.0)
(2) Two-way connector (9) Master cylinder T4: 33 (3.4, 24.3)
(3) Front brake hose RH (10) VDC control module & hydraulic
(4) Front brake hose LH control unit (VDCCM&H/U)
(5) Clamp
BR-10
General Description
BRAKE
5. CENTER AND REAR BRAKE PIPES AND HOSE
T3
(11) (8)
(6) (11)
(10)
(10)
T1 T2
(12)
T2 (10)
T3
(3) (4)
T2
T1 T3
(11)
T1 (10) (9)
(2) (11)
(10)
T2 (7)
T3
T1 T1
T1
(10)
T1 (5)
(1)
BR-00337
(1) Center brake pipe ASSY (7) Rear brake pipe LH Tightening torque: N"m (kgf-m, ft-lb)
(2) Two-way connector (8) Rear brake hose rear RH T1: 15 (1.5, 10.8)
(3) Rear brake pipe ASSY (9) Rear brake hose rear LH T2: 18 (1.8, 13.0)
(4) Rear brake hose RH (10) Clamp T3: 33 (3.4, 24.3)
(5) Rear brake hose LH (11) Gasket
(6) Rear brake pipe RH (12) Bracket
BR-11
General Description
BRAKE
6. BRAKE BOOSTER
(1)
BR-00335
(1) Brake booster
BR-12
General Description
BRAKE
7. BRAKE PEDAL
• LHD MT model
T2
T2
T2
(1)
T2 (2)
T1
(6)
T1
(3)
(4)
(5)
BR-00375
(1) Brake pedal ASSY (4) Clutch pedal Tightening torque: N"m (kgf-m, ft-lb)
(2) Stop light switch (5) Clutch pedal pad T1: 8 (0.8, 5.8)
(3) Brake pedal pad (6) Clutch switch T2: 18 (1.8, 13.0)
BR-13
General Description
BRAKE
• LHD AT model, RHD model
T2
(1)
(2)
T1
T2 T1
(3)
BR-00338
(1) Brake pedal ASSY (3) Brake pedal pad Tightening torque: N"m (kgf-m, ft-lb)
(2) Stop light switch T1: 8 (0.8, 5.8)
T2: 18 (1.8, 13.0)
BR-14
General Description
BRAKE
C: CAUTION
• Use SUBARU genuine grease etc. or equivalent.
Do not mix grease, etc. with that of another grade
or from other manufacturers.
or shop cloth between the part and the vice.
points.
D: PREPARATION TOOL
1. GENERAL TOOL
TOOL NAME REMARKS
Snap ring pliers Used for removing and installing snap ring.
BR-15
Front Brake Pad
BRAKE
2. Front Brake Pad (4) Attach a rod of less than 12 mm (0.47 in) di-
ameter to the shaded area of the brake pad, and
A: REMOVAL strike the rod with a hammer to drive brake pad
out of place.
1. 15-INCH TYPE
2) Remove the caliper bolt.
BR-00014
2. 16-INCH TYPE
BR-00339 Refer to 15-inch type. <Ref. to BR-16, 15-INCH
3) Raise the caliper body and support it. TYPE, REMOVAL, Front Brake Pad.>
NOTE: 3. 17-INCH TYPE
Do not disconnect the brake hose from caliper Refer to 15-inch type. <Ref. to BR-16, 15-INCH
body. TYPE, REMOVAL, Front Brake Pad.>
4) Remove the pad.
B: INSTALLATION
1. 15-INCH TYPE
1) Apply a thin coat of Molykote M7439 to the pad
clip.
BR-00012
NOTE:
If the brake pad is difficult to remove, proceed as
follows:
(1) Remove the caliper body from support. BR-00340
(2) Remove the support. 2) Apply a thin coat of Molykote AS880N (Part No.
(3) Place the support in a vise between wooden K0779YA010) to the frictional portion between pad
blocks. and pad inner shim.
(1)
(2) BR-00013 BR-00238
(1) Support
(2) Wooden block
BR-16
Front Brake Pad
BRAKE
3) Apply a thin coat of Molykote AS880N (Part No. 3) Apply a thin coat of Molykote AS880N (Part No.
K0779YA010) to the three frictional portions be- K0779YA010) to the three frictional portions be-
tween inner shim and outer shim of outer pads. tween inner shim and outer shim of outer pads.
BR-00341 BR-00341
4) Install the pad on support. 4) Install the pad on support.

5) Install the caliper body on support. NOTE:
Tightening torque: Install the pad indicator in proper direction.
27 N"m (2.8 kgf-m, 19.9 ft-lb)
2. 16-INCH TYPE (1)
(6)
Refer to 15-inch type. <Ref. to BR-16, 15-INCH
TYPE, INSTALLATION, Front Brake Pad.>
3. 17-INCH TYPE (5)
(2)
clip.
(6)
(3)
(6)
(5)
(4)
BR-00340
2) Apply a thin coat of Molykote AS880N (Part No. (6)

K0779YA010) to the frictional portion between pad BR-00342
and pad inner shim.
(1) LH # IN
(2) LH # OUT
(3) RH # IN
(4) RH # OUT
(5) Pad indicator
(6) Pad return spring
CAUTION:
• Correctly install the pad return spring to sup-
porting surface of pad clip as shown in the fig-
BR-00238
ure.
BR-17
Front Brake Pad
BRAKE
• When the pad return spring is deformed or 3. 17-INCH TYPE

damaged, replace the brake pad with new one.
Check the pad thickness A.
(1) A
(2)
BR-00343
BR-00360

Standard
(2) Supporting surface of pad clip Pad thickness 11 (0.43)
value
mm (in)
5) Install the caliper body on support. Wear limit 1.5 (0.059)

27 N"m (2.8 kgf-m, 19.9 ft-lb) • Always replace the pads for both right and left
wheels at the same time.
C: INSPECTION • Replace the pad if there is oil or grease on it.
1. 15-INCH AND 16-INCH TYPE
BR-00360
Pad thickness Standard value 11 (0.43)

mm (in) Wear limit 1.5 (0.059)
NOTE:
• Always replace the pads for both right and left
• Also replace the pad clips if they are twisted or
worn.
• Replace the pad if there is oil or grease on it.
2. 16-INCH TYPE
AND 16-INCH TYPE, INSPECTION, Front Brake
Pad.>
BR-18
Front Disc Rotor
BRAKE
3. Front Disc Rotor C: INSPECTION

1) Check front wheel bearing play and axial hub
A: REMOVAL runout before disc rotor runout limit inspection.
1. 15-INCH TYPE <Ref. to DS-15, INSPECTION, Front Axle.>
2) Secure the disc rotor by tightening five wheel
1) Lift-up the vehicle, and remove the front wheels. nuts.
2) Remove the caliper body and the support from 3) Set a dial gauge 10 mm (0.39 in) inward of rotor
housing, and suspend it from strut using a wire. outer perimeter. Turn the disc rotor to check runout.
If the disc rotor runout exceeds specified value, re-
place with a new disc rotor.
BR-00017
3) Remove the disc rotor.

BR-00019
NOTE:
If the disc rotor seizes up within hub, drive the disc Disc rotor runout limit:
rotor out by pushing with an 8 mm bolt in holes B on 0.05 mm (0.0020 in)
the rotor. 4) Set a micrometer 10 mm (0.39 in) inward of the
rotor outer perimeter, and then measure the disc
rotor thickness. If the thickness of disc rotor is out-
side the service limit, replace with a new disc rotor.
B
A
BR-00018 B
4) Clean mud and foreign particles from the caliper A
body assembly and the support.
BR-00018
2. 16-INCH TYPE
Disc rotor
Refer to 15-inch type. <Ref. to BR-19, 15-INCH Standard
Limit outer diam-
TYPE, REMOVAL, Front Disc Rotor.> value
eter
3. 17-INCH TYPE 15$ 24 (0.94) 22 (0.87)
277
(10.91)
Refer to 15-inch type. <Ref. to BR-19, 15-INCH Disc rotor
294
TYPE, REMOVAL, Front Disc Rotor.> thickness A 16$ 24 (0.94) 22 (0.87)
(11.57)
mm (in)
B: INSTALLATION 17$ 30 (1.18) 28 (1.10)
316
1) Install the disc rotor. (12.44)
2) Install the caliper body and the support to hous-
ing.
Tightening torque:
80 N"m (8.2 kgf-m, 59 ft-lb)
BR-19
Front Disc Brake Assembly
BRAKE
4. Front Disc Brake Assembly 6) Clean mud and foreign particles from the caliper
body assembly and the support.
A: REMOVAL
2. 16-INCH TYPE
1. 15-INCH TYPE Refer to 15-inch type. <Ref. to BR-20, 15-INCH
CAUTION: TYPE, REMOVAL, Front Disc Brake Assembly.>
Do not allow brake fluid to come in contact with 3. 17-INCH TYPE
vehicle body; wash away with water and wipe
off completely if spilled. Refer to 15-inch type. <Ref. to BR-20, 15-INCH
1) Lift-up the vehicle, and remove the front wheels. TYPE, REMOVAL, Front Disc Brake Assembly.>
2) Remove the union bolt, and disconnect the B: INSTALLATION
brake hose from caliper body assembly.
1. 15-INCH TYPE
1) Install the support on housing.
Tightening torque:
80 N"m (8.2 kgf-m, 59 ft-lb)
clip.
BR-00021
3) Remove the bolt securing lock pin to caliper

body.
BR-00340
3) Apply a thin coat of Molykote AS880N (Part No.

K0777YA010) to the frictional portion between pad
and inner shim.
BR-00022
4) Raise the caliper body, and then move it toward

vehicle center to separate it from support.
5) Remove the support from housing.
NOTE:
Remove the support only when replacing itself or
rotor. It need not be removed when servicing the
caliper body assembly. BR-00238
BR-00023
BR-20
BRAKE
4) Apply a thin coat of Molykote AS880N (Part No. 3) Apply a thin coat of Molykote AS880N (Part No.
K0777YA010) to the three frictional portions be- K0777YA010) to the frictional portion between pad
tween inner shim and outer shim of outer pads. and inner shim.
BR-00341 BR-00238
5) Install the pad on support. 4) Apply a thin coat of Molykote AS880N (Part No.
6) Install the caliper body on support. K0779YA010) to the three frictional portions be-
tween inner shim and outer shim of outer pads.
Tightening torque:
27 N"m (2.8 kgf-m, 19.9 ft-lb)
7) Using new brake hose gaskets, connect the
brake hose.
Tightening torque:
18 N"m (1.8 kgf-m, 13.0 ft-lb)
8) Bleed air from brake system.
2. 16-INCH TYPE
Refer to 15-inch type. <Ref. to BR-20, 15-INCH BR-00341
TYPE, INSTALLATION, Front Disc Brake Assem-
bly.>
3. 17-INCH TYPE
Tightening torque:
80 N"m (8.2 kgf-m, 59 ft-lb)
clip.
BR-00340
BR-21
BRAKE
5) Install the pad on support. 7) Using new brake hose gaskets, connect the
NOTE: brake hose.
Install the pad indicator in proper direction. Tightening torque:
18 N"m (1.8 kgf-m, 13.0 ft-lb)
(1)
(6)
C: DISASSEMBLY
1. 15-INCH TYPE
(5) 1) Clean mud and foreign particles from the caliper
(2) body assembly and the support.
CAUTION:
(6) inlet (at brake hose connector).
(3) 2) Place a wooden block in caliper body as shown
(6) in the figure to prevent piston from jumping out and
avoid being damaged.
3) Gradually supply compressed air via installation
hole of brake hose to force the piston out.
(5)
(4)
(6)
BR-00342
(1) LH # IN
(2) LH # OUT
(3) RH # IN (1)
(4) RH # OUT BR-00026
(5) Pad indicator

(1) Place a 30 mm (1.18 in) wide wood block here.
4) Remove the piston boot.
CAUTION:
• Correctly install the pad return spring to sup-
porting surface of pad clip as shown in the fig-
ure.
• When the pad return spring is deformed or
damaged, replace the brake pad with new one.
BR-00240
5) Remove the piston seal from caliper body cylin-

der.
(1)
(2)
BR-00343

(2) Supporting surface of pad clip
6) Install the caliper body on support.
BR-22
BRAKE
CAUTION: CAUTION:
Do not damage the cylinder and piston seal Do not force the piston into cylinder.
groove.
(2)
(1)
(1)
BR-00242
BR-00027
(1) Piston
(1) Piston seal (2) Piston boot
6) Remove the guide pin and boot from caliper 6) Position the boot in the grooves on cylinder and
body. piston.
2. 16-INCH TYPE (3)
Refer to 15-inch type. <Ref. to BR-22, 15-INCH (4)

(2)
TYPE, DISASSEMBLY, Front Disc Brake Assem-
bly.>
(1)
3. 17-INCH TYPE
TYPE, DISASSEMBLY, Front Disc Brake Assem-
bly.>
BR-00243
D: ASSEMBLY
1. 15-INCH TYPE (1) Piston
(2) Piston boot
1) Clean the caliper body interior using brake fluid. (3) Caliper body
2) Apply a coat of brake fluid to the piston seal and (4) Piston seal
fit piston seal in groove on caliper body.
3) Apply a coat of brake fluid to the entire inner sur- 7) Apply a coat of specified grease to the lock pin
face of cylinder and outer surface of piston. and guide pin outer surface, cylinder inner surface,
4) Apply a coat of specified grease to the boot and and boot grooves.
fit in to the groove on ends of cylinder.
Grease:
Grease: NIGLUBE RX-2 (Part No. K0779GA102)
NIGLUBE RX-2 (Part No. K0779GA102) 8) Install the lock pin and guide pin boot on support.
5) Insert the piston into cylinder.
: (3)
(1)
(2)
BR-00362
(1) Pin boot

(2) Lock pin or guide pin
(3) Apply grease.
BR-23
BRAKE
2. 16-INCH TYPE
TYPE, ASSEMBLY, Front Disc Brake Assembly.>
3. 17-INCH TYPE
TYPE, ASSEMBLY, Front Disc Brake Assembly.>
E: INSPECTION
1) Repair or replace the faulty parts.
2) Check the caliper body and piston for uneven
wear, damage or rust.
3) Check the rubber parts for damage and deterio-
ration.
BR-24
Rear Brake Pad
BRAKE
5. Rear Brake Pad 4) Install the caliper body on support.
A: REMOVAL Tightening torque:

Solid disc brake model
27 N"m (2.8 kgf-m, 19.9 ft-lb)
wheels.
2) Remove the caliper bolt. Ventilated disc brake model
37 N"m (3.7 kgf-m, 27.2 ft-lb)
C: INSPECTION
BR-00344
3) Raise the caliper body and support it.

A
NOTE: BR-00016
Do not disconnect the brake hose from caliper
body. Type of disc rotor Solid Ventilated
4) Remove the pad. Standard
Pad thickness 9.0 (0.35) 9.0 (0.35)
NOTE: value
mm (in)
If the brake pad is difficult to remove, use the same Wear limit 1.5 (0.059) 1.5 (0.059)
procedure as for front disc brake pad.
<Ref. to BR-16, REMOVAL, Front Brake Pad.> NOTE:
• Always replace the pads for both right and left
• Also replace 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 wear indicator contacts 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.
BR-00032
B: INSTALLATION
clip.
BR-00345

and shim.
3) Install the pad on support.
BR-25
Rear Disc Rotor
BRAKE
6. Rear Disc Rotor (2) If the disc rotor seizes up within hub, drive
the disc rotor out by pushing with an 8 mm bolt in
A: REMOVAL holes B on the rotor.
wheels.
3) Remove the two mounting bolts, and remove the
disc brake assembly.
B
A
BR-00036
B: INSTALLATION
2) Adjust the parking brake. <Ref. to PB-9, AD-
BR-00346
JUSTMENT, Parking Brake Assembly (Rear Disc
Brake).>
4) Suspend the disc brake assembly so that the
hose is not stretched. C: INSPECTION
5) Remove the disc rotor. 1) Check rear wheel bearing play and axial hub
runout before disc rotor runout limit inspection.
NOTE: <Ref. to DS-21, INSPECTION, Rear Hub Unit
If the disc rotor is difficult to remove, try following Bearing.>
two methods in order.
2) Secure the disc rotor by tightening five wheel
(1) Turn the adjusting screw using a flat tip nuts.
screwdriver until the brake shoe gets away 3) Set a dial gauge 10 mm (0.39 in) inward of rotor
enough from the disc rotor. outer perimeter. Turn the disc rotor to check runout.
If the disc rotor runout exceeds specified value, re-
(2) place with a new disc rotor.
(3)
(1)
(4)
BR-00155
(1) Adjusting screw

BR-00037
(2) Cover
(3) Flat tip screwdriver Disc rotor runout limit:
(4) Back plate 0.05 mm (0.0020 in)
BR-26
Rear Disc Rotor
BRAKE
4) Set a micrometer 10 mm (0.39 in) inward of the

rotor outer perimeter, and then measure the disc
rotor thickness. If the thickness of disc rotor is out-
side the service limit, replace with a new disc rotor.
B
A
BR-00036
Standard value Limit Disc outer dia.

Disc rotor thickness A Solid disc 10 (0.39) 8.5 (0.335) 274 (10.79)
mm (in) Ventilated disc 18 (0.71) 16 (0.63) 290 (11.42)
BR-27
Rear Disc Brake Assembly
BRAKE
7. Rear Disc Brake Assembly B: INSTALLATION

A: REMOVAL
Tightening torque:
CAUTION: 53 N"m (5.4 kgf-m, 39.1 ft-lb)
Do not allow brake fluid to come in contact with
vehicle body; wash away with water and wipe 2) Apply a thin coat of Molykote M7439 to the pad
off completely if spilled. clip.
wheels.
2) Disconnect the brake hose from caliper body as-
sembly.
3) Remove the caliper lower bolts.
BR-00345

and shim.
4) Install the pad on support.
BR-00347 5) Install the caliper body on support.
4) Raise the caliper body, and then move it toward Tightening torque:
vehicle center to separate it from the support. Solid disc brake model
5) Remove the support from housing. 27 N"m (2.8 kgf-m, 19.9 ft-lb)
NOTE: Ventilated disc brake model
Remove the support only when replacing itself or 37 N"m (3.7 kgf-m, 27.2 ft-lb)
rotor. It need not be removed when servicing the 6) Replace the brake hose gaskets with new ones,
caliper body assembly. and then connect the brake hose.
6) Clean mud and foreign particles from the caliper Tightening torque:
body assembly and the support. 18 N"m (1.8 kgf-m, 13.0 ft-lb)
CAUTION: 7) Bleed air from brake system.
inlet (at brake hose connector).
C: DISASSEMBLY
1) Remove the piston boot.
BR-00041
2) Place a wooden block in caliper body as shown

in the figure to prevent the piston from jumping out
and avoid being damaged.
BR-28
Rear Disc Brake Assembly
BRAKE
3) Gradually supply compressed air via installation 6) Position the boot in grooves on cylinder and pis-
hole of brake hose to force the piston out. ton.
(3)
(4)
(2)
(1)
(1)
BR-00042 BR-00243
(1) Place a 30 mm (1.18 in) wide wooden block (1) Piston

here. (2) Piston boot
(3) Caliper body
4) Remove the piston seal from caliper body cylin-
der. (4) Piston seal
CAUTION: 7) Apply a coat of specified grease to the guide pin,

Do not damage the cylinder and piston seal outer surface, sleeve outer surface, cylinder inner
groove. surface, and boot grooves.
Grease:
NIGLUBE RX-2 (Part No. K0779GA102)
: (3)
(1)
(2)
BR-00043
5) Remove the lock pin sleeve and boot from cali-

per body. BR-00362
6) Remove the guide pin boot.
(1) Pin boot
D: ASSEMBLY (2) Lock pin or guide pin
1) Clean the caliper body interior using brake fluid.
(3) Apply grease.
2) Apply a coat of brake fluid to the piston seal and
fit piston seal in groove on caliper body. 8) Install the guide pin boot on support.
3) Apply a coat of brake fluid to the entire inner sur- 9) Install the lock pin boot on support, and then in-
face of cylinder and outer surface of piston. sert the lock pin sleeve into specified point.
4) Apply a coat of specified grease to the boot and
fit in to the groove on ends of cylinder. E: INSPECTION
1) Repair or replace the faulty parts.
Grease: 2) Check the caliper body and piston for uneven
NIGLUBE RX-2 (Part No. K0779GA102) wear, damage or rust.
5) Insert the piston into cylinder. 3) Check the rubber parts for damage or deteriora-
CAUTION: tion.
Do not force the piston into cylinder.
BR-29
Master Cylinder
BRAKE
8. Master Cylinder NOTE:

To avoid damaging master cylinder, use aluminum
A: REMOVAL plate while holding with vise.
CAUTION: 3) Remove the pin which secures the reservoir tank
Do not allow brake fluid to come in contact with to master cylinder, and then remove the reservoir
vehicle body; wash away with water and wipe tank and seal.
off completely if spilled.
1) Thoroughly drain the brake fluid from reservoir
tank.
2) Disconnect the fluid level gauge harness con-
nector.
3) Remove the brake pipes from master cylinder.
4) Remove the master cylinder mounting nuts, and
take out the master cylinder from brake booster.
B: INSTALLATION
1) Replace the O-ring for the master cylinder with a BR-00364
new one. 4) With pushing-in the primary piston, remove the
CAUTION: C-ring using pliers.
Do not install the O-ring in wrong place.
(3)
(2)
(1)
BR-00169
BR-00363 5) With pushing-in the primary piston, remove the
straight pin from the port on installation part of res-
(1) Primary piston ervoir tank using magnet pick-up tool.
(2) O-ring
(3) Do not install the O-ring on this groove. (1)

Tightening torque:
Master cylinder mounting nut
13 N"m (1.3 kgf-m, 9.6 ft-lb)
Piping flare nut
Model with ABS
15 N"m (1.5 kgf-m, 10.8 ft-lb)
BR-00069
Model with VDC
19 N"m (1.9 kgf-m, 14.0 ft-lb)
(1) Straight pin
CAUTION:
Be sure to use recommended brake fluid. 6) Extract the primary piston assembly and sec-
3) Bleed air from brake system. <Ref. to BR-38, ondary piston assembly straight out, while taking
PROCEDURE, Air Bleeding.> care not to scratch the inner surface of cylinder.
7) Clean the inside of master cylinder with brake
C: REPLACEMENT fluid. Check the inside of cylinder for damage, de-
1) Remove mud and dirt from the surface of brake form and wear. Replace the master cylinder as as-
master cylinder. sembly if faulty.
2) Secure the master cylinder on a vise. 8) Apply recommended brake fluid to the inner wall
of master cylinder, and outer surface of piston as-
sembly.
BR-30
Master Cylinder
BRAKE
9) Ensure that the inner wall of master cylinder, and D: INSPECTION

piston assembly are free of dirt when assembling. Inspect for oil leakage from the master cylinder.
Install the primary piston assembly and secondary
piston assembly, while taking care not to damage NOTE:
the master cylinder inner wall. After replacing piston kit; when the oil leakage is
10) With pushing-in the primary piston, install the found without damaging or scratching the inside of
cylinder pin. cylinder, wear of master cylinder inner wall may be
11) With pushing-in the primary piston, install the the cause. In this case, replace the master cylinder
C-ring to groove using pliers. as assembly.
BR-00169
CAUTION:
Ensure the secure installation.
12) Install the seal to reservoir tank.
(1) BR-00072
(1) Seal
13) Install the reservoir tank to master cylinder, and

secure with pin.
14) Replace the O-ring for the master cylinder with
a new one.
(3)
(2)
(1)
BR-00363
(1) Primary piston

(2) O-ring
(3) Do not install the O-ring on this groove.
BR-31
Brake Booster
BRAKE
9. Brake Booster • Use care when placing the brake booster on the
floor.
A: REMOVAL • Do not change the push rod length.
1) Remove or disconnect the following parts at en- CAUTION:
gine compartment. • Do not disassemble the brake booster.
(1) Disconnect the connector for brake fluid lev- • If external force is applied from above when
el gauge. brake booster is placed in this position, the res-
(2) Remove the brake pipes from master cylin- in portion as indicated by “P”, may be dam-
der. aged.
(3) Remove the master cylinder installing nuts.
(4) Disconnect the vacuum hose from brake (1)
booster.
2) Remove the following parts from pedal bracket.
(1) Snap pin and clevis pin
(2) Four brake booster installing nuts P
(1) BR-00075
(1) Force
B: INSTALLATION
1) Check and adjust the operating rod of brake
booster.
Standard L:
LHD: 136.3 mm (5.38 in)
(2) RHD: 155.2 mm (6.11 in)
(3)
If it is not within the specified value, adjust it by ad-
justing the brake booster operating rod.
L
(4)
BR-00073
(1) Nut
(2) Clevis pin
(3) Snap pin
(4) Operating rod BR-00076
3) Remove the brake booster while shunning brake 2) Mount the brake booster in position.
pipes.
NOTE:
• Do not apply strong impact to booster shell and
vacuum pipe.
• Be careful not to drop the brake booster. The
brake booster should be replaced 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 %3&, it may result in damage to the power piston
cylinder.
BR-32
Brake Booster
BRAKE
3) Connect the operating rod to brake pedal with 8) Measure the clearance between the threaded
clevis pin and snap pin. end of stop light switch and stopper.
If it is not within specified value, adjust it by adjust-
ing the position of stop light switch. <Ref. to BR-45,
ADJUSTMENT, Stop Light Switch.>
CAUTION:
(1)
Be careful not to rotate the stop light switch.
Stop light switch clearance A:
0.3 mm (0.012 in)
(2)
(3)
BR-00079
9) Apply grease to operating rod connecting pin to

(4) prevent it from wearing.
BR-00073 10) Bleed air from brake system.
(1) Nut
Tightening torque (Air bleeder screw):
(2) Clevis pin
8 N"m (0.8 kgf-m, 5.8 ft-lb)
(3) Snap pin 11) Conduct road tests to ensure brakes do not
(4) Operating rod
drag.
C: INSPECTION
NOTE:
Apply a thin coat of grease [SUNLIGHT 2 (Part No. 1. OPERATION CHECK (WITHOUT GAUG-
003602010) or equivalent] to clevis pin. ES)
4) Connect the vacuum hose to brake booster. CAUTION:
5) After replacing the O-ring with a new one, install When checking operation, be sure to securely
the master cylinder to brake booster. apply the parking brake.
(3) • CHECKING WITHOUT GAUGES
(2) This method cannot determine the exact portion
(1) which has failed. But it can provide a rough under-
standing of the nature of failure if checking is con-
ducted in accordance with the following
procedures.
BR-00363
(1) Primary piston

(2) O-ring
(3) Do not install the O-ring on this groove.
6) Connect the brake pipes to master cylinder.

7) Connect the connector for brake fluid level
gauge.
BR-33
Brake Booster
BRAKE
• AIR TIGHTNESS CHECK 3) As engine starts, the brake pedal should move
Start the engine, and idle it for 1 to 2 minutes, then slowly toward the floor. If no change occurs in the
turn it OFF. Depress the brake pedal several times pedal height, the brake booster is faulty.
applying the same pedal force as that used in ordi- NOTE:
nary braking operations. The pedal stroke should If faulty, check precisely with gauges.
be greatest on the 1st depression, and it should be- • LOADED AIR TIGHTNESS CHECK
come smaller with each successive depression. If
no change occurs in the pedal height while in a de- Depress the brake pedal while engine is running,
pressed state, the brake booster is faulty. and turn OFF the engine while the pedal is still de-
pressed. Keep the pedal depressed for 30 sec-
onds; if no change occurs in the pedal height, the
(1) (2) brake booster is functioning normally; if the pedal
height increases, it is faulty.
NOTE:
If faulty, check precisely with gauges.
(5)
2. OPERATION CHECK (WITH GAUGES)
(4) CAUTION:
(3)
When checking operation, be sure to securely
BR-00080 apply the parking brake.
(1) Normal Operation
• CHECKING WITH GAUGES
(2) Not OK Connect gauges as shown in the figure. After
(3) 1st bleeding air from pressure gauges, proceed to
(4) 2nd each check.
(5) 3rd (1) (2)
NOTE: (3) (4) (5)

• In the event of defective operation, also 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.
• OPERATION CHECK BR-00082
1) With the engine OFF, depress the brake pedal
several times applying the same pedal force and (1) Pressure gauge
make sure that the pedal height does not vary with (2) Vacuum gauge
each depression of the pedal. (3) Adapter hose
(4) Vacuum hose
(1) (2) (5) Pedal force gauge
BR-00081
(1) When engine is stopped

(2) When engine is started
2) With the brake pedal depressed, start the en-

gine.
BR-34
Brake Booster
BRAKE
• AIR TIGHTNESS CHECK 2) Stop the engine and watch vacuum gauge.
1) Start the engine and keep it running until a vac- If the vacuum drop range is less than 3.3 kPa (25
uum of 66.7 kPa (500 mmHg, 19.69 inHg) = point A mmHg, 0.98 inHg) within 15 seconds after stopping
is indicated on vacuum gauge. Do not depress the the engine, brake booster is functioning properly.
brake pedal at this moment. If defective, refer to “AIR TIGHTNESS CHECK”.
<Ref. to BR-33, INSPECTION, Brake Booster.>
(1) (2) A 3) If any fault is found on brake booster, replace the
brake booster with a new one.
• 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.
147 294
Brake pedal force N (kgf, lb)
BR-00083 (15, 33) (30, 66)
Fluid pressure 545 1,564
(1) Pressure gauge kPa (kg/cm2, psi) (6, 79) (16, 227)
(2) Vacuum gauge
• BOOSTING ACTION CHECK
2) Stop the engine and watch the gauge. If the vac- Set the vacuum gauge reading at 66.7 kPa (500
uum drop range is less than 3.3 kPa (25 mmHg, mmHg, 19.69 inHg) by running engine. Then,
0.98 inHg) within 15 seconds after stopping the en- check the fluid pressure when brake pedal is de-
gine, brake booster is functioning properly. pressed. The pressure must be greater than the
If defective, the cause may be one of those listed standard value listed.
below.
• Check valve malfunction Brake pedal force N (kgf, lb)
147 294
• Leak from vacuum hose (15, 33) (30, 66)
• Leak from shell jointed portion or stud bolt weld- 15$ 6,003 11,273
ed portion 16$ OUTBACK (61, 871) (115, 1,635)
Fluid pres-
• Damaged diaphragm sure 16$
5,381 10,982
• Leak from valve body seal and bearing portion (Except for
kPa (kg/cm2, OUTBACK) (55, 780) (112, 1,593)
• Leak from plate and seal assembly portion psi)
4,963 10,055
• Leak from poppet valve assembly portion 17$
(51, 720) (103, 1,458)
• LOADED AIR TIGHTNESS CHECK
1) Start the engine and depress the brake pedal
with pedal force of 196 N (20 kgf, 44 lb). Keep the
engine running until a vacuum of 66.7 kPa (500
mmHg, 19.69 inHg) = point B is indicated on vacu-
um gauge while the pedal is still depressed.
(1) (2) B
(3)
(4)
BR-00084
(1) Pressure gauge

(2) Vacuum gauge
(3) Pedal force gauge
(4) Depressed
BR-35
Brake Fluid
BRAKE
10.Brake Fluid 5) Install one end of a vinyl tube onto air bleeder
and insert the other end of the tube into a container
A: INSPECTION to collect brake fluid.
1) Check that the brake fluid level remains between
“MIN” and “MAX”. If out of the specified range, refill
or drain fluid. If the fluid level becomes close to
“MIN”, refill fluid.
2) Check the fluid for discoloration. If the fluid color
has excessively changed, drain the fluid and refill
with new fluid.
B: REPLACEMENT
CAUTION:
• To always maintain the brake fluid character- BR-00087
istics, replace the brake fluid according to
CAUTION:
maintenance schedule or earlier than that when
Brake fluid replacement sequence; (A) Front
used in severe condition.
RH ' (B) Rear LH ' (C) Front LH ' (D) Rear RH
• Fresh Subaru genuine fluid must be used.
• Cover the bleeder with cloth, when loosening
it, to prevent brake fluid from being splashed (A) (1) (D)
over surrounding parts.
• Do not allow brake fluid to come in contact
(2)
with vehicle body; wash away with water and
wipe off completely if spilled.
• Avoid mixing different brands of brake fluid
to prevent degrading the quality of fluid.
(C) (3) (B)
• Be careful not to allow dirt or dust to get into
the reservoir tank. BR-00089
NOTE:
• During the bleeding operation, keep the brake (1) Master cylinder
reservoir tank filled with brake fluid to eliminate en- (2) Hydraulic unit
try of air. (3) Proportioning valve
• The brake pedal operating must be very slow.
• For convenience and safety, two people should 6) Instruct your co-worker to depress the brake
do the work. pedal slowly two or three times and then hold it de-
pressed.
• The amount of brake fluid required is approxi-
mately 500 m2 (16.9 US fl oz, 17.6 Imp fl oz) for to- 7) Loosen the bleeder screws to drain brake fluid.
tal brake system. And then quickly tighten the screw.
8) Release the brake pedal slowly. Repeat steps 6)
1) Either lift-up the vehicle to place a rigid rack un- through 8) until there are no more air bubbles in the
der it, or lift-up the vehicle. drained brake fluid.
2) Remove both the front and rear wheels.
3) Draw out the brake fluid from master cylinder. NOTE:
4) Refill the reservoir tank with recommended Add brake fluid as necessary while performing air
brake fluid. bleed operation, in order to prevent the tank from
running short of brake fluid.
Recommended brake fluid: 9) After completing the bleeding operation, hold the
Refer to the specification. <Ref. to BR-2, brake pedal depressed and tighten the screw and
SPECIFICATION, General Description.> install bleeder cap.
Tightening torque (Bleeder screw):
8 N"m (0.8 kgf-m, 5.8 ft-lb)
10) Bleed air from each wheel cylinder using the
same procedures as described in steps 6) through
8) above.
BR-36
Brake Fluid
BRAKE
11) Depress the brake pedal with a force of approx-

imately 294 N (30 kgf, 66 lb) and hold it there for ap-
proximately 20 seconds to check for no entry of air
and if pedal height remain same.
Visually inspect the bleeder screws and brake pipe
joints to make sure that there is no fluid leakage.
12) Install the wheels, and drive vehicle for a short
distance between 2 to 3 km (1 to 2 miles) to make
sure that brakes are operating properly.
BR-37
Air Bleeding
BRAKE
11.Air Bleeding 6) Repeat the step4) and 5) until brake fluid is com-
pletely drained from outlet plug.
A: PROCEDURE 7) Remove the plastic bag.
CAUTION: 8) Install the brake pipes to master cylinder.
• Fresh Subaru genuine fluid must be used. Tightening torque:
• Cover the bleeder with cloth, when loosening 15 N"m (1.5 kgf-m, 10.8 ft-lb)
it, to prevent brake fluid from being splashed 9) Bleed air from the brake line. <Ref. to BR-38,
over surrounding parts. BRAKE LINE, PROCEDURE, Air Bleeding.>
• Do not allow brake fluid to come in contact
with vehicle body; wash away with water and 2. BRAKE LINE
wipe off completely if spilled.
NOTE:
• Avoid mixing different brands of brake fluid
• During the bleeding operation, keep the reservoir
to prevent degrading the quality of fluid.
tank filled with brake fluid to eliminate entry of air.
• Be careful not to allow dirt or dust to get into
the reservoir tank.
• For convenience and safety, two people should
1. MASTER CYLINDER do the work.
NOTE: 1) Make sure that there is no leak from joints and
• If the master cylinder is disassembled or reser- connections of the brake system.
voir tank is empty, bleed the master cylinder. 2) Fit one end of vinyl tube into the air bleeder and
• During the bleeding operation, keep the brake put the other end into a brake fluid container.
reservoir tank filled with brake fluid to eliminate en-
try of air.
• For convenience and safety, two people should
do the work.
1) Loosen the wheel nuts, jack-up the vehicle, sup-
port it with rigid racks, and remove the wheels.
2) Disconnect the brake line at primary and sec-
ondary sides.
3) Put a plastic bag cover on master cylinder. BR-00087
4) Carefully depress and hold the brake pedal.
CAUTION:
Brake fluid replacement sequence; (A) Front
RH ' (B) Rear LH ' (C) Front LH ' (D) Rear RH
(A) (1) (D)
(2)
BR-00090
(3)
5) Close the outlet plug with your finger, and then (C) (B)
release the brake pedal. BR-00089
(1) Master cylinder

(2) Hydraulic unit
(3) Proportioning valve
BR-00091
BR-38
Air Bleeding
BRAKE
3) Slowly depress the brake pedal and keep it de- 7) If the distance is more than specified, there is a
pressed. Then, open the air bleeder to discharge possibility that air is in the brake line. Bleed the
air together with the fluid. brake line until pedal stroke meets the specifica-
Release the air bleeder for 1 to 2 seconds. tion.
Next, with the bleeder closed, slowly release the 8) Operate the hydraulic control unit in the se-
brake pedal. quence control mode. <Ref. to ABS-10, ABS Se-
Repeat these steps until there are no more air bub- quence Control.>
bles in the vinyl tube. 9) Recheck the pedal stroke.
Allow 3 to 4 seconds between two brake pedal op- 10) If the distance is more than specified, there is a
erations. possibility that air is in the inside of the hydraulic
CAUTION: unit. Repeat above steps 2) to 9) until pedal stroke
Cover the bleeder with cloth, when loosening it, meets the specification.
to prevent brake fluid from being splashed over 11) Add brake fluid to the required level (“MAX” lev-
surrounding parts. el) of reservoir tank.
12) As a final step, test run the vehicle at low speed
NOTE: and ensure that brakes provide normal braking ac-
The brake pedal operating must be very slow. tion.
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
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 approx-
imately 20 seconds to make sure that there is no
leak evident in the entire system.
6) Check the pedal stroke.
While the engine is idling after warming up, de-
press the brake pedal with a 500 N (51 kgf, 112 lb)
load and measure the distance between brake ped-
al and steering wheel. With the brake pedal re-
leased, measure the distance between pedal and
steering wheel again. The difference between the
two measurements must not be more than speci-
fied value.
(1)
2
1 2
(2)
BR-00094
(1) Steering wheel

(2) Toe board
Specified pedal stroke:

95 mm (3.74 in) or less
When depressing brake pedal with a 500 N
(51 kgf, 112 lb) load.
BR-39
Brake Hose
BRAKE
12.Brake Hose 3) Remove the clamp and remove the brake hose.
A: REMOVAL
1. FRONT BRAKE HOSE
(2)
1) Separate the brake pipe from brake hose using a (1)
flare nut wrench.
2) Remove the clamp, bolt at strut mount, and
union bolt.
(1)
BR-00349
(1) Brake pipe

(2) (2) Brake hose clamp
(1)
BR-00095
(1) Brake hose

(2) Brake pipe
2. REAR BRAKE HOSE (2)

(3)
1) Remove the union bolt from rear brake caliper. BR-00350
(1) Brake pipe

(1) (2) Brake hose
(3) Brake hose clamp
B: INSTALLATION
1. FRONT BRAKE HOSE
1) Secure the brake hose to strut mount.
BR-00348
Tightening torque:
33 N"m (3.4 kgf-m, 24.3 ft-lb)
(1) Brake hose 2) Install the brake hose to caliper using a new gas-
ket.
2) Separate the brake pipe from brake hose using a
flare nut wrench. Tightening torque (Union bolt):
18 N"m (1.8 kgf-m, 13.0 ft-lb)
BR-00021
3) Position the disc in straight-forward direction and

route the brake hose through the hole in bracket on
wheel apron side.
BR-40
Brake Hose
BRAKE
CAUTION: 3) Install the brake hose to rear brake caliper using

Be sure the brake hose is not twisted. a new gasket.
4) Temporarily tighten the flare nut to connect the Tightening torque (Union bolt):
brake pipe and hose. 18 N"m (1.8 kgf-m, 13.0 ft-lb)
5) Fix the brake hose with clamp at wheel apron
bracket.
6) Tighten the flare nut to specified torque.
(1)
Tightening torque (Brake pipe flare nut):
15 N"m (1.5 kgf-m, 10.8 ft-lb)
2. REAR BRAKE HOSE
1) Pass the brake hose through the hole of bracket,
and lightly tighten the flare nut to connect brake BR-00348
pipe.
2) Insert the clamp upward to fix brake hose. (1) Brake hose
4) Tighten the flare nut to specified torque.

Tightening torque (Brake pipe flare nut):
(1)
15 N"m (1.5 kgf-m, 10.8 ft-lb)
C: INSPECTION
Ensure there are no cracks, breakage or damage
(2) on hoses. Check joints for fluid leakage. If any
(3)
cracks, breakage, damage or fluid leakage is
BR-00350 found, repair or replace the hose.
(1) Brake pipe
(2) Brake hose
(2)
(1)
BR-00349
(1) Brake pipe

BR-41
Brake Pipe
BRAKE
13.Brake Pipe
A: REMOVAL
NOTE:
center brake pipe.
CAUTION:
wiring harness when servicing the center brake
pipe.
• When removing the brake pipe, make sure
that it is not bent.
B: INSTALLATION
NOTE:
center brake pipe.
CAUTION:
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 air.
• After installing the brake hose, make sure
that it does not touch the tire or suspension as-
sembly, etc.
Brake pipe tightening torque:
15 N"m (1.5 kgf-m, 10.8 ft-lb)
C: INSPECTION
Ensure there are no cracks, breakage or damage
on pipes. Check joints for fluid leakage. If any
cracks, breakage, damage or fluid leakage is
found, repair or replace the pipes.
NOTE:
Use a mirror when inspecting the low-visible part or
backside.
BR-42
Brake Pedal
BRAKE
14.Brake Pedal 4) Remove the bolts and nuts which secure pedal
bracket.
A: REMOVAL
1. LHD MT MODEL
1) Remove the steering shaft.
2) Disconnect the connectors (stop light switch)
from pedal bracket.
3) Remove the clevis pin which secures lever to
push rod.
4) Remove the nuts which secure clutch master
cylinder.
5) Remove the bolts and nuts which secure pedal
bracket.
(1)
(2)
(3)
BR-00351
BR-00128
(1) Clevis pin
2. LHD AT MODEL
(2) Snap pin
1) Remove the steering shaft. (3) Operating rod
2) Disconnect the connectors (stop light switch)
from pedal bracket. 3. RHD MODEL
3) Remove the clevis pin which secures lever to
push rod. Refer to LHD AT model. <Ref. to BR-43, LHD AT
MODEL, REMOVAL, Brake Pedal.>
B: INSTALLATION
CAUTION:
Always use new clevis pins.
2) Inspect the brake pedal after installation. <Ref.
to BR-43, INSPECTION, Brake Pedal.>
C: INSPECTION
1) Move the brake pedal pads in the lateral direc-
tion with a force of approx. 10 N (1 kgf, 2 lb) to en-
sure pedal deflection is in specified range.
BR-43
Brake Pedal
BRAKE
CAUTION:
If excessive deflection is noted, replace the
bushing with a new one.
Deflection of brake pedal:
Limit
5.0 mm (0.197 in) or less
(1)
BR-00105
(1) Brake pedal
2) Check the position of pedal pad.

Pedal height L:
LHD: 150 — 160 mm (5.91 — 6.30 in)
RHD: 162 — 172 mm (6.38 — 6.77 in)
Brake pedal free play A:
0.5 — 2 mm (0.02 — 0.08 in) [When the brake
pedal is pulled upward with force of less than
10 N (1 kgf, 2 lb).]
(1)
(3) (4)
A
(2)
L
BR-00106
(1) Stop light switch

(2) Mat
(3) Toe board
(4) Brake booster operating rod
3) If it is not within the specified value, adjust it by

adjusting the brake booster operating rod length.
BR-44
Stop Light Switch
BRAKE
15.Stop Light Switch Specified position L:

2 mm (0.079 in)
A: REMOVAL
2) Disconnect the stop light switch connector.
3) Loosen the nuts, and unscrew the stop light L
switch to remove.
(1)
BR-00109
2) Measure the clearance between the threaded

end of stop light switch and stopper.
CAUTION:
BR-00107 Be careful not to rotate the stop light switch.
Stop light switch clearance A:
0.3 mm (0.012 in)
B: INSTALLATION
1) Screw the stop light switch onto a bracket and
(1)
secure it temporarily with a nut.
2) Adjust the stop light switch position, and then
A
tighten the nut.
<Ref. to BR-45, ADJUSTMENT, Stop Light
Switch.>
(2)
Tightening torque:
8 N"m (0.8 kgf-m, 5.8 ft-lb) (3)
BR-00110

(2) Stopper
(3) Brake pedal
3) If it is not within the specified value, adjust it by

T
adjusting the position of stop light switch.
CAUTION:
Be careful not to rotate the stop light switch.
BR-00108
D: ADJUSTMENT
C: INSPECTION Loosen the lock nut, and adjust the stop light switch
1) If the stop light switch does not operate properly position until the clearance between the threaded
(or if it does not fix at the specified position), re- end of the stop light switch and stopper (A) be-
place with a new one. comes 0.3 mm (0.012 in). Then, tighten the lock
nut.
BR-45
Stop Light Switch
BRAKE
Tightening torque:
8 N"m (0.8 kgf-m, 5.8 ft-lb)
(1)
(2)
(3)
A
(4)
(5)
BR-00111

(2) Lock nut A
(3) Lock nut B
(4) Stopper
(5) Brake pedal
NOTE:
Tighten the lock nut B until the clearance between
the threaded end of stop light switch and stopper
becomes 0 mm (0 inch). Hold the stop light switch
to prevent turning, and then loosen the lock nut B
approx. 60&. The clearance (A) becomes 0.3 mm
(0.012 in).
BR-46
Diagnosis
BRAKE
16.Diagnosis
A: INSPECTION
Trouble and possible cause Corrective action
1. Insufficient braking (1) Fluid leakage from the hydraulic mechanism Correct or replace. (cup, piston seal, piston
boot, master cylinder piston kit, pipe or
hose)
(2) Entry of air into the hydraulic mechanism Bleed air.
(3) Wear, deteriorated surface material, adhering water or Replace, grind or clean.
fluid on the lining
(4) Improper operation of master cylinder, disc caliper, Correct or replace.
brake booster or check valve
2. Unstable or uneven (1) Fluid on the lining or rotor Eliminate cause of fluid leakage, and clean
braking or replace.
(2) Rotor eccentricity Correct or replace the rotor.
(3) Improper lining contact, deteriorated surface material, Correct by grinding, or replace.
improper inferior material, or wear
(4) Deformed back plate Rectify or replace.
(5) Improper tire inflation Adjust to correct pressure.
(6) Disordered wheel alignment Adjust alignment.
(7) Loosened back plate or the support installing bolts Retighten to specified torque.
(8) Faulty wheel bearing Replace.
(9) Trouble in hydraulic system Replace the cylinder, brake pipe or hose.
(10) Uneven effect of the parking brake Check, adjust, or replace the rear brake
and cable system.
3. Excessive pedal (1) Entry of air into the hydraulic mechanism Bleed air.
stroke (2) Excessive play in the master cylinder push rod Adjust.
(3) Fluid leakage from the hydraulic mechanism Correct or replace. (cup, piston seal, piston
boot, master cylinder piston kit, pipe or
hose)
(4) Improper lining contact or worn lining Correct or replace.
4. Brake dragging or (1) Insufficient pedal play Adjust play.
improper brake (2) Improper master cylinder return Clean or replace the cylinder.
return (3) Clogged hydraulic system Replace.
(4) Improper return or adjustment of parking brake Correct or adjust.
(5) Weakened spring tension or breakage of shoe return Replace the spring.
spring
(6) Improper disc caliper operation Correct or replace.
(7) Faulty wheel bearing Replace.
5. Brake noise (1) (1) Hardened or deteriorated brake pad Replace the pad.
(creak sound) (2) Worn brake pad Replace the pad.
(3) Loosened back plate or the support installing bolts Retighten to specified torque.
(4) Loose wheel bearing Retighten to specified torque.
(5) Dirty rotor Clean the rotor, or clean and replace brake
assembly.
6. Brake noise (2) (1) Worn brake pad Replace the pad.
(hissing sound) (2) Improper installed pad Correct or replace the pad.
(3) Loose or bent rotor Retighten or replace.
7. Brake noise (3) Excessively worn pad or the support Replace the pad or the support.
(click sound)
BR-47
Diagnosis
BRAKE
BR-48
CHASSIS SECTION
FRONT SUSPENSION FS
REAR SUSPENSION RS
DIFFERENTIALS DI
TRANSFER CASE TC
(DIAGNOSTICS)
BRAKE BR
PARKING BRAKE PB

(POWER STEERING)

approval.

PARKING BRAKE
PB
Page
2. Parking Brake Lever....................................................................................5
3. Parking Brake Cable ...................................................................................6
4. Parking Brake Assembly (Rear Disc Brake) ...............................................7
General Description
PARKING BRAKE
A: SPECIFICATION
Type Mechanical on rear brakes, drum in disc
Effective drum
mm (in) 170 (6.69)
diameter
Lining dimensions
163.1 ! 30.0 ! 3.2
(length ! width ! mm (in)
(6.421 ! 1.181 ! 0.126)
thickness)
Clearance adjustment Manual adjustment
Lever stroke notches/N (kgf, lb) 5 to 6/200 (20.4, 45)
PB-2
General Description
PARKING BRAKE
B: COMPONENT
1. PARKING BRAKE (REAR DISC BRAKE)
(1)
(17)
(2)
(3)
(4)
(8)
(6)
(7)
(9)
(11)
(13)
(5) (10)
(12)
(15)
(14)
(16)
PB-00048
(1) Back plate (7) Strut spring (13) Adjuster

(2) Retainer (8) Strut (14) Shoe hold-down cup
(3) Spring washer (9) Shoe guide plate (15) Shoe hold-down spring
(4) Lever (10) Primary return spring (16) Shoe hold-down pin
(5) Parking brake shoe (Primary) (11) Secondary return spring (17) Adjusting hole cover
(6) Parking brake shoe (Secondary) (12) Adjusting spring
PB-3
General Description
PARKING BRAKE
2. PARKING BRAKE CABLE
(8)
(7) T2
(8)
T2
T1 T1
(6)
(3)
(1)
(5)
T1 T1 (9)
T1 (4) T1
(2)
T1
PB-00056
(1) Parking brake lever (6) Clamp Tightening torque: N"m (kgf-m, ft-lb)
(2) Parking brake switch (7) Parking brake cable RH T1: 18 (1.8, 13.0)
(3) Adjusting nut (Self-locking nut) (8) Clamp T2: 33 (3.4, 24.3)
(4) Equalizer (9) Parking brake cable LH
(5) Bracket
C: CAUTION
• Be careful not to burn your hands, because each
• Use SUBARU genuine grease etc. or the equiv-
alent. Do not mix grease etc. with that of another
grade or from other manufacturers.
points.
or shop cloth between the part and the vice.
• Keep grease etc. away from parking brake
shoes.
PB-4
Parking Brake Lever
PARKING BRAKE
2. Parking Brake Lever

A: REMOVAL
1) Set the wheel stoppers to tires.
2) Remove the console box.
3) Disconnect the parking brake switch connector.
4) Remove the parking cable adjusting nut (self-
locking nut).
5) Remove the parking brake lever.
PB-00053
B: INSTALLATION
Tightening torque:
Parking brake lever
18 N"m (1.8 kgf-m, 13.0 ft-lb)
2) Install a new adjusting nut (self-locking nut).
3) Adjust the lever stroke. <Ref. to PB-5, ADJUST-
MENT, Parking Brake Lever.>
C: INSPECTION
1) Operate the parking brake lever 3 to 4 times and
return the lever fully.
2) While pulling the parking brake lever upward,
count the notches.
Lever stroke:
5 to 6 notches when pulled with a force of 200
N (20.4 kgf, 45 lb)
If it is not within the specified value, adjust the park-
ing brake. <Ref. to PB-9, ADJUSTMENT, Parking
Brake Assembly (Rear Disc Brake).>
D: ADJUSTMENT
Adjust the parking lever stroke. <Ref. to PB-9, LE-
VER STROKE, ADJUSTMENT, Parking Brake As-
sembly (Rear Disc Brake).>
PB-5
Parking Brake Cable
PARKING BRAKE
3. Parking Brake Cable 12) Remove the cable assembly.
A: REMOVAL B: INSTALLATION
1) Remove the rear seat cushion. 1) Install in the reverse order of removal.
2) Remove the console box. NOTE:
3) Remove the parking cable adjusting nut (self- Be sure to pass the cable through the cable guide
locking nut). inside tunnel.
4) Remove the parking brake lever. <Ref. to PB-5, 2) Adjust the lever stroke. <Ref. to PB-5, ADJUST-
REMOVAL, Parking Brake Lever.> MENT, Parking Brake Lever.>
5) Roll up the floor mat and remove the clamps.
C: INSPECTION
Check and replace the removed cable if damaged,
rusty or faulty.
1) Check the cable for smooth operation.
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 corro-
sion.
PB-00043
6) Remove the inner cable end from equalizer.
PB-00008
(1) Equalizer
(2) Inner cable end

wheels.
8) Remove the parking brake cable from rear
brake. <Ref. to PB-7, REMOVAL, Parking Brake
Assembly (Rear Disc Brake).>
9) Remove the clamp from rear brake.
10) Remove the cable clamp from rear arm brack-
et.
11) Remove the cable clamp from rear floor.
PB-00026
PB-6
Parking Brake Assembly (Rear Disc Brake)
PARKING BRAKE
4. Parking Brake Assembly (2) If the disc rotor seizes up within hub, drive
out the disc rotor by pushing two 8 mm bolts in
(Rear Disc Brake) holes B on rotor.
A: REMOVAL
2) Remove the two mounting bolts and remove the
brake caliper assembly.
B
A
BR-00036
5) Remove the shoe return spring from parking

brake assembly.
6) Remove the front shoe hold down spring and
BR-00346 pin.
3) Suspend the brake caliper assembly so that the
hose is not stretched.
4) Remove the disc rotor.
NOTE:
If the disc rotor is difficult to remove, try the follow-
ing two methods in order.
(1) Turn the adjusting screw using a flat tip
screwdriver until the brake shoe gets away
enough from the disc rotor.
PB-00028
(2)
7) Remove the strut and strut spring.
8) Remove the adjuster assembly from parking
(3) brake assembly.
9) Remove the brake shoe.
10) Remove the rear shoe hold down spring and
pin with pliers.
(1)
11) Remove the parking brake cable from lever.
(4)
BR-00155
(1) Adjuster
(2) Adjusting hole cover (rubber)
(3) Flat tip screwdriver
(4) Back plate
PB-00014
(1) Parking brake cable

(2) Lever
12) Using a flat tip screwdriver, raise the retainer.

Remove the parking lever and washer from brake
shoe.
PB-7
PARKING BRAKE
B: INSTALLATION • Install the adjuster assembly with screw on left

side.
CAUTION:
Be sure the lining surface is free from oil and
grease contamination.
1) Apply brake grease to the following places.
Brake grease:
Brake Grease (Part No. 003602002)
• Six contact surfaces of shoe rim and back plate
packing
• Contact surface of shoe wave and anchor pin
• Contact surface of lever and strut PB-00016
• Contact surface of shoe wave and adjuster as-
sembly (1) LH
• Contact surface of shoe wave and strut
• Contact surface of lever and shoe wave 7) Install the secondary return spring and adjusting
2) Insert the primary side brake shoe into anchor spring.
pin groove.
(1)
3) Secure the brake shoe with the shoe hold-down (2)
pin and cup.
4) Install the plate to anchor pin, and then assem- (4)
ble the primary return spring to anchor pin. (3)
(2)
(1) (5)
(7)
(3) (6)
(8)
PB-00017
(1) Lever
(4) (2) Secondary brake shoe
(3) Strut spring
(5)
PB-00039 (4) Strut
(5) Return spring
(1) Primary return spring (6) Adjuster
(2) Anchor pin (7) Shoe hold-down cup
(3) Plate (8) Adjusting spring
(4) Primary shoe
(5) Shoe hold-down pin and shoe hold-down cup 8) Adjust the parking brake. <Ref. to PB-9, AD-
JUSTMENT, Parking Brake Assembly (Rear Disc
5) Install the parking brake cable to parking brake Brake).>
lever. 9) Drive the vehicle for parking brake lining “break-
6) Assemble the strut and adjuster, and then se- in”.
cure the secondary side brake shoe with shoe hold- (1) Drive the vehicle at about 35 km/h (22
down pin and cup. MPH).
NOTE: (2) With the parking brake release button
• Install the strut spring of both right and left wheel pushed in, pull the parking brake lever gently.
facing vehicle front. (3) Drive the vehicle for about 200 m (0.12 mile)
in this condition.
(4) Wait 5 to 10 minutes for the parking brake to
cool down.
Repeat once more from step (1).
(5) After breaking-in, re-adjust the parking
brakes.
PB-8
PARKING BRAKE
C: INSPECTION 2. LEVER STROKE

1) Measure the brake disc rotor inside diameter. If 1) Adjust the shoe clearance before lever stroke
the disc is scored or worn, replace the brake disc adjustment. <Ref. to PB-9, SHOE CLEARANCE,
rotor. ADJUSTMENT, Parking Brake Assembly (Rear
Disc rotor inside diameter: Disc Brake).>
Standard: 2) Remove the parking lever cover.
170 mm (6.69 in) 3) Operate the parking brake lever 3 to 4 times.
Service limit: 4) Turn the adjusting nut until lever stroke is at the
171 mm (6.73 in) specification.
2) Measure the lining thickness. If it exceeds the Lever stroke:
limit, replace shoe assembly. 5 to 6 notches when pulled with a force of 200
N (20.4 kgf, 45 lb)
Lining thickness:
Standard:
3.2 mm (0.126 in)
Service limit:
1.5 mm (0.059 in)
NOTE:
Replace the right and left brake shoe as a set.
D: ADJUSTMENT
1. SHOE CLEARANCE (1)
PB-00054
1) Return the parking brake lever fully.
2) Remove the adjusting hole cover from back (1) Adjusting nut (Self-locking nut)
plate.
3) Turn the adjusting screw using a flat tip screw- 5) Check there is no brake drag.
driver until the brake shoe is in close contact with 6) Install the parking lever cover.
disc rotor.
(2)
(3)
(1)
(4)
PB-00032
(1) Adjusting screw

(2) Adjusting hole cover (rubber)
(3) Flat tip screwdriver
(4) Back plate
4) Turn back (downward) the adjusting screw 3 to 4

notches.
CAUTION:
Check there is no brake drag.
5) Install the adjusting hole cover to back plate.
6) Adjust the parking lever stroke. <Ref. to PB-9,
LEVER STROKE, ADJUSTMENT, Parking Brake
Assembly (Rear Disc Brake).>
PB-9
PARKING BRAKE

A: INSPECTION
Symptom Possible cause Remedy
Parking brake lever is maladjusted. Adjustment.
Parking brake cable does not move. Repair or replace.
Brake drag
Parking brake shoe clearance is maladjusted. Adjustment.
Return spring is faulty. Replace.
Return spring is faulty. Replace.
Noise from brake
Shoe hold-down spring is faulty. Replace.
PB-10
CHASSIS SECTION
FRONT SUSPENSION FS
REAR SUSPENSION RS
DIFFERENTIALS DI
TRANSFER CASE TC
(DIAGNOSTICS)
BRAKE BR
PARKING BRAKE PB

(POWER STEERING)

approval.

POWER ASSISTED SYSTEM
(POWER STEERING)
PS
Page
2. Steering Wheel..........................................................................................20
3. Universal Joint...........................................................................................21
4. Tilt Steering Column..................................................................................23
5. Steering Gearbox [LHD Model] .................................................................25
6. Steering Gearbox [RHD Model] ................................................................46
7. Pipe Assembly [LHD Model] .....................................................................65
8. Pipe Assembly [RHD Model].....................................................................71
9. Oil Pump ...................................................................................................77
10. Reservoir Tank..........................................................................................83
11. Power Steering Fluid.................................................................................84
General Description
POWER ASSISTED SYSTEM (POWER STEERING)
A: SPECIFICATION
Non-turbo
Model Turbo 3.0 R
(Except for 3.0 R)
Minimum turning radius m (ft) 5.4 (17.8)
2.0 i, 2.5 i: 37.3! — 33.0!, 2.0 GT, 3.0 R: 37.2! — 32.9!,
Steering angle (Inside — outside)
Whole OUTBACK: 37.8! — 33.5!
system Steering wheel diameter mm (in) 375 (14.76)
Overall gear ratio (Turns, lock to lock
3.2 2.8
Gearbox)
Type Rack and Pinion, Integral
Gearbox Backlash 0 (Automatically adjustable)
Valve (Power steering system) Rotary valve
Type Vane pump
Oil tank Installed on body
Specific output cm3 (cu in)/rev. 7.2 (0.439) 8.5 (0.519) 9.6 (0.586)
6,767 — 7,453 7,350 — 8,036 8,300 — 9,000
Pump
(Power
Relief pressure kPa (kg/cm2, psi) (69 — 76, (75 — 82, (85 — 92,
981 — 1,081) 1,067 — 1,165) 1,204 — 1,305)
steering
system) Hydraulic fluid control Dropping in response to increased engine revolutions
1,000 rpm: 6.5 (6.9, 5.7) 1,000 rpm: 6.15 (6.5, 5.4) 1,000 rpm: 6.5 (6.9, 5.7)
Hydraulic fluid 2 (US qt, Imp qt)
3,000 rpm: 5 (5.3, 4.4) 3,000 rpm: 5.5 (5.8, 4.8) 3,000 rpm: 5.5 (5.8, 4.8)
Range of revolution rpm 680 — 9,800 680 — 9,600
Revolving direction Clockwise
Working Fluid ATF DEXRON III or equivalent
fluid Oil tank 0.2 (0.2, 0.2)
(Power Capacity
steering 2 (US qt, Imp qt) Whole sys- 0.7 (0.7, 0.6)
system) tem
PS-2
General Description
Steering
Free play mm (in) 17 (0.67)
wheel
2.0 i, 2.5 i: 37.3!"1.5!, 2.0 GT, 3.0 R: 37.2!"1.5!,
Inner wheel
Steering OUTBACK: 37.8!"1.5!
angle 2.0 i, 2.5 i: 33.0!"1.5!, 2.0 GT, 3.0 R: 32.9!"1.5!,
Outer wheel
OUTBACK: 33.5!"1.5!
Steering Clearance between steering wheel and
mm (in) 3.0 (0.12)
shaft column cover
314 (32, 71) or less
Sliding resistance N (kgf, lb) Difference between right and left sliding resistance:
Less than 20%
LHD 0.3 (0.16) or less
Right-turn
mm (in) Horizontal movement: 0.6 (0.024) or less
Steering Rack shaft play steering RHD
Vertical movement: 0.4 (0.016) or less
gearbox in radial direc-
tion Horizontal movement: 0.6 (0.024) or less
(Power Left-turn LHD
mm (in) Vertical movement: 0.4 (0.016) or less
steering steering
system) RHD 0.3 (0.16) or less
In radial direction mm (in) 0.18 (0.0071) or less
Input shaft play
In axial direction mm (in) 0.27 (0.0106) or less
Maximum allowable value: 13 (1.3, 2.9) or less
Resistance to rotation N (kgf, lb) Difference between right and left sliding resistance:
Less than 20%
Radial play mm (in) 0.4 (0.016) or less
Oil pump Pulley shaft
Axial play mm (in) 0.9 (0.035) or less
(Power
Ditch deflection mm (in) 1.0 (0.039) or less
steering Pulley
system) Resistance to rotation N (kgf, lb) 9.22 (0.94, 2.07) or less
Regular pressure (Unloaded)kPa (kg/cm2, psi) 981 (10, 142) or less
Steering At standstill with engine idling on a con-
N (kgf, lb) 29.4 (3.0, 6.6) or less
wheel crete road
effort
(Power At standstill with engine stalled on a con-
steering N (kgf, lb) 294.2 (30, 66.2) or less
crete road
system)
Recommended power steering fluid Manufacturer

B.P.
CALTEX
CASTROL
ATF DEXRON III or equivalent
MOBIL
SHELL
TAXACO
PS-3
General Description
B: COMPONENT
1. STEERING WHEEL AND COLUMN
(1)
(8) (2)
(3)
T2
(4)
(7) T3
(5)
T1
(6)
PS-00501
(1) Bushing (5) Steering wheel Tightening torque: N#m (kgf-m, ft-lb)
(2) Steering shaft (6) Airbag module T1: 1.2 (0.12, 0.9)
(3) Steering roll connector (7) Steering wheel lower cover T2: 25 (2.5, 18.1)
(4) Column cover (8) Insulator T3: 45 (4.6, 33.2)
PS-4
General Description
2. POWER ASSISTED SYSTEM

• Hose and tank
(16)
(19)
(19)
T3 (17)
(15)
T3
(19) (18)
(7) (19)
T2
(2)
T1
(8) (20)
(12)
(4) (5)
T5
(4) T3 (1)
(5)
(13)
(11)
(6)
(3)
(4)
(14) (10)
(4) (9) T4
PS-00479
(1) Eye bolt (10) Oil pump (19) Clip

(2) Hose (11) Suction hose (Non-turbo model) (20) Clip
(3) Eye bolt gasket (12) Suction hose (Turbo model)
(4) Clip (13) Suction hose (Turbo model) Tightening torque: N#m (kgf-m, ft-lb)
(5) Clamp E (14) Suction hose (Turbo model) T1: 7.4 (0.75, 5.4)
(6) O-ring (15) Return hose T2: 17.6 (1.79, 13.0)
(7) Cap (16) Oil cooler T3: 12.7 (1.30, 9.4)
(8) Reservoir tank (17) Return hose T4: 15 (1.5, 10.8)
(9) Pulley (18) Hose bracket T5: 39.2 (4.0, 28.9)
PS-5
General Description
• Gearbox (LHD model)
(39) (3) T6
T1
(20) T10 T2
T7
(21) T7
(16) (17) (18) (19)
T6
T9 T5 (4)
(2) (5)
(22)
(34) (6)
T8 (41) (3)
(23) (33) (7)
(14) T5
(24)
(8)
(25) (12) (1) (9)
T4
(13) (10)
(26) (39) (15)
(31) (42) (11)
T11
T3
(32) T4 (22)
(27) (23)
(27)
(28) (40) (30)
(29) T8
T9 (24)
(30) (29)
(28) (25)
T11
(38)
(37) (26)
T3
(36)
(35)
PS-00560
(1) Pipe C (20) Adapter (39) O-ring

(2) Pipe D (21) Clamp (40) Bracket
(3) Clamp plate (22) Cotter pin (41) Bushing
(4) Universal joint (23) Castle nut (42) Lock washer
(5) Dust seal (24) Dust cover
(6) Valve housing (25) Clip Tightening torque: N#m (kgf-m, ft-lb)
(7) Gasket (26) Tie-rod end T1: 6 (0.6, 4.3)
(8) Oil seal (27) Clip T2: 7.4 (0.75, 5.4)
(9) Bushing (28) Boot T3: 85 (8.6, 62.2)
(10) Seal ring (29) Band T4: 13 (1.3, 9.4)
(11) Pinion & valve ASSY (30) Tie-rod T5: 15 (1.5, 10.8)
(12) Oil seal (31) Pipe B T6: 24 (2.4, 17.4)
(13) Back-up washer (32) Pipe A T7: 25 (2.5, 18.1)
(14) Ball bearing (33) Steering body T8: 27 (2.75, 19.9)
(15) Snap ring (34) Oil seal T9: 60 (6.1, 44.1)
(16) Lock nut (35) Piston ring T10: 39 (4.0, 28.9)
(17) Adjusting screw (36) Rack T11: 78 (8.0, 57.9)
(18) Spring (37) Rack bushing
(19) Sleeve (38) Holder
PS-6
General Description
• Gearbox (RHD model)
(1)
(35)
(19)
T6
T4
(34) (9)
(33)
(28)
(32) (2)
(31) (3) T5
(27)
T3 (26)
(4)
(5)
T8 (30)
(25)
T4 T3
(6)
(29)
T4
(24)
(23)
(22)
(36) (21)
(20) (7)
T1
(8)
T6
T7 T2 (12)
(37) T5
(19) (11)
(10)
(18) (13)
(14)
T7 (17)
(16)
(15)
PS-00505
(1) Universal joint (17) Boot (33) Spring

(2) Dust cover (18) Band (34) Sleeve
(3) Plug (19) Tie-rod (35) Bushing
(4) O-ring (20) Holder (Turbo, 3.0 R model) (36) Bracket
(5) Oil seal (21) Bushing (37) Holder (Except for turbo, 3.0 R
(6) Control valve (22) Oil seal model)
(7) Seal ring (23) Oil seal
(8) Oil seal (24) O-ring Tightening torque: N#m (kgf-m, ft-lb)
(9) Adapter (25) Rack T1: 27 (2.75, 19.9)
(10) Clamp (26) Oil seal T2: 85 (8.6, 62.2)
(11) Castle nut (27) Back-up washer T3: 20 (2.0, 14.5)
(12) Cotter pin (28) Steering body T4: 24 (2.4, 17.4)
(13) Dust seal (29) Pipe A T5: 64 (6.5, 47.0)
(14) Clip (30) Pipe B T6: 90 (9.0, 65.1)
(15) Tie-rod end (31) Lock nut T7: 60 (6.1, 44.1)
(16) Clip (32) Adjusting screw T8: 39 (4.0, 28.9)
PS-7
General Description
3. OIL PUMP
T1
T5
T3 (1)
(2)
T2
(3)
T3
T3 (4)
T4
PS-00480
(1) Oil pump Tightening torque: N#m (kgf-m, ft-lb)

(2) Pulley T1: 8 (0.8, 5.8)
(3) Bracket T2: 15.7 (1.6, 11.6)
(4) Belt tension nut T3: 22 (2.2, 15.9)
T4: 25 (2.5, 18.1)
T5: 37.3 (3.8, 27.5)
PS-8
General Description
C: CAUTION
goggles and protective shoes during operation.
• Be careful not to burn yourself, because each
• Use SUBARU genuine power steering fluid,
grease etc. or the equivalent. Do not mix fluid,
grease etc. with that of another grade or from other
manufacturers.
points.
• Before securing a part on a vise, place cushion-
ing material such as wooden blocks, aluminum
plate or cloth between the part and the vise.
PS-9
General Description
D: PREPARATION TOOL
1. SPECIAL TOOL
925711000 PRESSURE Used for measuring oil pump pressure.
GAUGE
ST-925711000
926200000 STAND • Used when inspecting characteristic of gear-
box assembly and disassembling it.
• Used with BOSS D (34199AG000).
ST-926200000
34099AC010 ADAPTER HOSE A Used with PRESSURE GAUGE (925711000).
ST34099AC010
34099AC020 ADAPTER HOSE B Used with PRESSURE GAUGE (925711000).
ST34099AC020
PS-10
General Description

926230000 SPANNER For the lock nut when adjusting backlash of gear-
box.
ST-926230000
34099PA100 SPANNER Used when measuring the rotating resistance of
gearbox assembly.
ST34099PA100
926420000 PLUG When fluid leaks from pinion side of gearbox

assembly, remove pipe B from valve housing,
attach this tool and check fluid leaking points.
ST-926420000
926250000 GUIDE • Used for installing holder assembly into rack
housing.
• Except for turbo and 3.0 R model.
ST-926250000
PS-11
General Description

34099FA060 PUNCH HOLDER Used for caulking.
ST34099FA060
34099FA080 PUNCH • Used for removing caulking.
• For RHD model.
ST34099FA080
34199AE090 PLUG WRENCH • Used for removing plug.
• For RHD model.
ST34199AE090
34199AE100 OIL SEAL PLUG • Used for removing oil seal plug.
REMOVER • For RHD model.
ST34199AE100
PS-12
General Description

34199AE110 OIL SEAL PLUG • Used for installing oil seal plug.
INSTALLER • For RHD model.
ST34199AE110
34199AE120 GEARBOX OIL • Used for removing gearbox oil seal.
SEAL REMOVER • For RHD model.
ST34199AE120
34199AE130 GEARBOX OIL • Used for installing gearbox oil seal.
SEAL INSTALLER • For RHD model.
ST34199AE130
34199FE040 INSTALLER A, B, C • Used for installing oil seal to rack assembly.

• For turbo and 3.0 R model.
ST34199FE040
PS-13
General Description

927490000 INSTALLER A, B, C • Used for installing oil seal to rack assembly.
ST-927490000
34199FE010 REMOVER • Used for removing backup ring and oil seal.
ST34199FE010
927580000 REMOVER • Used for removing backup ring and oil seal.
ST-927580000
34199FE050 GUIDE • Used for installing rack and seal into housing
assembly.
ST34199FE050
PS-14
General Description

34199AE000 GUIDE • Used for installing rack and seal into housing
assembly.
ST34199AE000
34199FE000 INSTALLER & • Used for removing and installing rack oil seal
REMOVER (outer & inner).
ST34199FE000
34199FA030 INSTALLER & • Used for removing and installing rack oil seal
REMOVER (outer & inner).
ST34199FA030
34199FE060 INSTALLER • Used for installing rack oil seal (outer).

• For RHD model.
ST34199FE060
PS-15
General Description

34199AE010 INSTALLER • Used for installing rack oil seal (outer).
• For RHD model.
ST34199AE010
34199FE020 BASE • Used for support housing assembly.
• For RHD model.
ST34199FE020
34099FA070 BASE • Used for support housing assembly.
• For RHD model.
ST34099FA070
34199AG000 BOSS D • Used for inspecting characteristic of gearbox
assembly and disassembling it.
• Used with STAND (926200000).
ST34199AG000
PS-16
General Description

34199AG040 GUIDE • Used for installing sealing of rack.
• For 3.0 R model.
• For LHD model.
ST34199AG040
34199AG030 GUIDE • Used for installing seal ring of rack.

• Except for 3.0 R model.
• For LHD model.
ST34199AG030
34199AG070 FORMER • Used for forming seal ring of pinion.

• For LHD model.
ST34199AG070
34199AG020 GUIDE • Used for installing seal ring of pinion.

• For LHD model.
ST34199AG020
PS-17
General Description

34199AG060 GUIDE G (26) • Used for forming seal ring of rack.
• For 3.0 R model.
• For LHD model.
• Used with FORMER PISTON (34199AG080).
ST34199AG060
34199AG050 GUIDE G (24) • Used for forming seal ring of rack.

• Except for 3.0 R model.
• For LHD model.
• Used with FORMER PISTON (34199AG080).
ST34199AG050
34199AE050 OIL SEAL • Used for removing oil seal.

REMOVER • Except for 3.0 R model.
• For LHD model.
ST34199AE050
34099PA010 OIL SEAL • Used for removing oil seal.

REMOVER • For 3.0 R model.
• For LHD model.
ST34099PA010
PS-18
General Description

34199AG090 INSTALLER & • Used for installing oil seal of valve housing.
REMOVER • Used with SEAL INSTALLER (34099FA130).
• Used for installing ball bearing of valve hous-
ing.
• Used for removing oil seal and ball bearing
from valve housing.
• For LHD model.
ST34199AG090
34199AG080 FORMER PISTON • Used for forming seal of rack.

• For LHD model.
• Used with GUIDE G (26) (34199AG060) or
GUIDE G (24) (34199AG050).
ST34199AG080
34199AG010 INSTALLER • Used for press-fit oil seal of gearbox cylinder.

• For LHD model.
ST34199AG010
PS-19
Steering Wheel
2. Steering Wheel 2) Check the splines on the steering wheel for dam-
age. If the damage is excessive, replace the steer-
A: REMOVAL ing wheel.
2) Set the tire to the straight-ahead position.
3) Remove the airbag module. <Ref. to AB-14, RE-
MOVAL, Driver’s Airbag Module.>
WARNING:
forming airbag module service. <Ref. to AB-4,
CAUTION, General Description.>
4) Place alignment marks on the steering wheel
and steering shaft.
(1)
PS-00552
(1) Alignment mark
5) Remove the steering wheel nut, and then draw

out the steering wheel from shaft using steering
puller.
B: INSTALLATION
WARNING:
forming airbag module service. <Ref. to AB-4,
CAUTION, General Description.>
1) Align the center of roll connector. <Ref. to AB-
23, ADJUSTMENT, Roll Connector.>
NOTE:
Align the alignment marks on the steering wheel
and steering shaft.
Tightening torque:
45 N#m (4.6 kgf-m, 33.2 ft-lb)
Column cover-to-steering wheel clearance:
2 — 4 mm (0.08 — 0.16 in)
CAUTION:
Insert roll connector guide pin into guide hole
on lower end of surface of steering wheel to
prevent damage.
C: INSPECTION
1) Check the steering wheel for deformation. If the
deformation is excessive, replace the steering
wheel.
PS-20
Universal Joint
3. Universal Joint Tightening torque:

24 N#m (2.4 kgf-m, 17.4 ft-lb)
A: REMOVAL CAUTION:
1) Remove the steering wheel. <Ref. to PS-20, RE- Excessively large tightening torque of univer-
MOVAL, Steering Wheel.> sal joint bolts may lead to heavy steering wheel
2) Place alignment marks on universal joint. operation.
3) Remove the universal joint bolts and then re-
move the universal joint. Clearance between coupling of universal joint
to turbo cover:
15 mm (0.59 in) or more
5) Install the steering wheel. <Ref. to PS-20, IN-
STALLATION, Steering Wheel.>
C: INSPECTION
Check for wear, damage or any other faults. If nec-
essary, replace it.
PS-00443 Service limit:
B: INSTALLATION Universal joint play: 0 mm (0 in)
1) Align the cutout at serrated section of the column Maximum swing torque: 0.3 N (0.03 kgf, 0.07
shaft and yoke, then install the universal joint into lb)
column shaft.
(1)
(2)
PS-00033
(1) Swinging torque

(2) Play
Measure the folding torque of universal joint.

Service limit:
Maximum load: 3.8 N (0.39 kgf, 0.86 lb) or less
PS-00032
(1) Cutout
(2) Yoke
(3) Column shaft
(4) Column shaft side PS-00034
(5) Gearbox side
(1) Yoke (Gearbox side)
2) Install the universal joint to the serrations of
gearbox assembly by matching alignment marks.
3) Tighten the bolt.
PS-21
Universal Joint
Service limit:
PS-00035
(1) Yoke (Gearbox side)
Service limit:
PS-00036
(1) Yoke (Steering column side)
Service limit:
PS-00037
(1) Yoke (Steering column side)
PS-22
Tilt Steering Column
4. Tilt Steering Column

A: REMOVAL
(1)
(2)
PS-00466
(1) Tilt steering column (2) Universal joint

1) Remove the steering wheel. <Ref. to PS-20, RE- CAUTION:
MOVAL, Steering Wheel.> • Be sure to remove the universal joint before
2) Remove the universal joint. <Ref. to PS-21, RE- removing steering shaft assembly installing
MOVAL, Universal Joint.> bolts when removing steering shaft assembly
3) Remove the instrument panel lower cover under. or when lowering it for servicing of other parts.
4) Remove the instrument panel lower cover upper. • Do not loosen the tilt lever when the steering
5) Remove all connectors from the steering col- column is not secured to the vehicle.
umn.
6) Remove the two bolts under instrument panel
securing steering column.
PS-00444
7) Pull out the steering shaft assembly from the

hole on toe board.
PS-23
Tilt Steering Column
B: INSTALLATION D: ASSEMBLY
1) Install the grommet to toe board. 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.
Tightening torque:
1.2 N#m (0.12 kgf-m, 0.9 ft-lb)
CAUTION:
Do not overtorque the screw.
PS-00041
E: INSPECTION
2) Insert the end of steering shaft into toe board 1. BASIC INSPECTION
grommet. Measure the overall length of steering column. If
3) With the tilt lever secured, tighten the steering not as specified, replace it.
shaft mounting bolts under instrument panel.
Overall length L:
Tightening torque:
25 N#m (2.5 kgf-m, 18.1 ft-lb) Standard value
Except for OUTBACK model
4) Connect all the connectors under instrument
833.6"1.5mm (32.82"0.059 in)
panel.
OUTBACK model
5) Connect the airbag system connector at the har-
ness spool. 825.4"1.5mm (32.50"0.059 in)
NOTE:
Make sure to apply double lock.
6) Install the instrument panel lower cover with tilt
lever held in the lowered position.
7) Install the universal joint. <Ref. to PS-21, IN-
STALLATION, Universal Joint.>
L
STALLATION, Steering Wheel.> PS-00491
CAUTION: 2. AIRBAG MODEL INSPECTION

Insert roll connector guide pin into guide hole
on lower end of steering wheel surface to pre- WARNING:
vent damage. For airbag inspection procedures, refer to “Air-
bag System”. <Ref. to AB-4, CAUTION, General
C: DISASSEMBLY Description.>
Remove the two screws securing upper steering
column covers, and the two screws securing com-
bination switch, and then remove the related parts.
PS-24
Steering Gearbox [LHD Model]
5. Steering Gearbox [LHD Mod- 9) Remove the one pipe joint at the center of gear-
box, and connect the vinyl hose to the pipe and the
el] joint. Discharge the fluid by turning steering wheel
A: REMOVAL fully clockwise and counterclockwise. Discharge
the fluid similarly from other pipes.
1) Set the vehicle on a lift.
3) Loosen the front wheel nuts.
5) Remove the under cover. <Ref. to EI-26, RE-
MOVAL, Front Under Cover.> (1)
6) Remove the front exhaust pipe assembly. (Non-
turbo model) <Ref. to EX(H4SO 2.0)-7, REMOVAL,
Front Exhaust Pipe.>
WARNING: (2)
Be careful, not to burn your hand because the PS-00553
exhaust pipe is hot.
(1) Pipe A
7) Using a puller, remove the tie-rod end from the
(2) Pipe B
knuckle arm after pulling off cotter pin and remov-
ing castle nut. 10) Remove the universal joint. <Ref. to PS-21,
REMOVAL, Universal Joint.>
11) Disconnect the pipe C from pressure hose first,
and pipe D from return hose second.
PS-00043
(4)
(1) Castle nut
(3)
(2) Tie-rod end
(3) Knuckle arm (2)
8) Remove the front crossmember support plate,

jack-up plate and front stabilizer. <Ref. to FS-16,
REMOVAL, Front Stabilizer.> (1)
PS-00538
(1) Pipe C
(1)
(2) (2) Pipe D
(1) FS-00105 (3) Pressure hose
(4) Return hose
(1) Crossmember support plate
(2) Jack-up plate
PS-25
12) Remove the clamp bolts securing gearbox to 3) Tighten the gearbox to the crossmember bracket
crossmember, and remove the clamp. via clamp with bolt temporarily.
(1) (1)
PS-00554 PS-00554
(1) Clamp (1) Clamp
13) Remove the bolts which secure gearbox brack- 4) Tighten the bolts which temporary tightening the
et, and remove the bracket and gearbox. clamp and bracket of gearbox to specified torque.
Tightening torque:
60 N#m (6.1 kgf-m, 44.1 ft-lb)
(1) 5) Connect the pipe D to return hose first, and the
pipe C to pressure hose second.
Tightening torque:
15 N#m (1.5 kgf-m, 10.8 ft-lb)
PS-00555
(1) Bracket
B: INSTALLATION
1) Insert the gearbox into crossmember, being
careful not to damage gearbox boot. (4)
2) Install the gearbox and bracket. Tighten the bolt (3)

temporarily.
(2)
(1)
(1)
PS-00555 PS-00538
(1) Bracket (1) Pipe C

(2) Pipe D
(3) Pressure hose
(4) Return hose

7) Connect the tie-rod end and knuckle arm, and
tighten with castle nut.
PS-26
Castle nut tightening torque: NOTE:

27 N#m (2.75 kgf-m, 19.9 ft-lb) When adjusting toe-in, hold the boot as shown to
CAUTION: prevent it from being rotated or twisted. If twisted,
When connecting, do not hit cap at the bottom straighten it.
of tie-rod end with hammer.
8) After tightening the castle nut to specified tight-
ening torque, tighten it further within 60! until cotter
pin hole is aligned with slot in the nut. Fit the cotter
pin into nut, and then bend the pin to lock.
(A)
(B)
PS-00051
C: DISASSEMBLY
(C)
1. RACK HOUSING ASSEMBLY
1) Disconnect the four pipes from gearbox.
DS-00042
NOTE:
(A) Cotter pin Remove the pipes C and D, which are fixed to
(B) Castle nut clamp plate, as a single unit.
(C) Tie-rod end 2) Secure the gearbox removed from vehicle in
vice using ST.
9) Install the front stabilizer. <Ref. to FS-16, IN- ST1 926200000 STAND
STALLATION, Front Stabilizer.> ST2 34199AG000 BOSS D
10) Install the front crossmember support plate and
jack-up plate. CAUTION:
11) Install the front exhaust pipe assembly. (Non- Secure the gearbox in a vise using ST as
turbo model) <Ref. to EX(H4SO 2.0)-8, INSTALLA- shown. Do not attempt to secure it without this
TION, Front Exhaust Pipe.> ST.
12) Install the under cover. <Ref. to EI-26, INSTAL- (1)
LATION, Front Under Cover.>
14) Tighten the wheel nuts to specified torque.
Tightening torque:
90 N#m (9.1 kgf-m, 65.8 ft-lb)
16) Remove the steering wheel. <Ref. to PS-20, ST1
REMOVAL, Steering Wheel.> ST2
PS-00492
(1) Clamp
STALLATION, Steering Wheel.> 3) Remove the tie-rod end and lock nut from gear-
19) Connect the battery ground cable to battery. box.
20) Pour fluid into the oil tank, and bleed air. <Ref.
to PS-84, Power Steering Fluid.>
21) Check for fluid leaks.
22) Check the fluid level in oil tank.
23) After adjusting toe-in and steering angle, tight-
en the lock nut on tie-rod end.
Tightening torque:
85 N#m (8.7 kgf-m, 62.7 ft-lb)
PS-27
4) Remove the small clip from the boot using pliers, 7) Tighten the adjusting screw until it no longer
and then move the boot to tie-rod end side. tightens.
(1) (1)
PS-00508 PS-00495
(1) Clip (1) Adjusting screw
5) Using a flat-tip screwdriver, remove the band 8) Hold the rack with a wrench [22 mm width across
from boot. flats], and then remove the tie-rod using a wrench
NOTE: [32 mm width across flats] or adjustable wrench.
Replace the boot it there is damage, cracks or de-
terioration.
(1)
PS-00511
9) Loosen the adjusting screw, and then remove

PS-00509 the spring and sleeve.
10) Remove the two bolts securing valve assem-
(1) Band bly.
6) Using the ST, loosen the lock nut.
ST 926230000 SPANNER
ST
PS-00116
(1)
PS-00494
(1) Lock nut
PS-28
11) Carefully draw out the input shaft, and then re- 16) Insert the ST from pinion housing side, and
move the valve assembly. then remove the oil seal using a press.
ST 34099PA010 OIL SEAL REMOVER (3.0 R
model)
ST 34199AE050 OIL SEAL REMOVER (Except
for 3.0 R model)
(1)
PS-00117
ST
12) Using a drill, release the caulking of holder.
CAUTION:
Make a hole approx. 2 mm (0.08 in) depth using
a drill bit of 3 mm (0.12 in) diameter.
(2)
PS-00516 PS-00138
13) Using a spanner [36 mm width across flats] or (1) Press

adjustable wrench, remove the holder. (2) Oil seal
17) Using a press, remove the bushing at gearbox

installation portion.
(1)
PS-00512
(1) Holder
PS-00517
14) Remove the rack bushing and rack stopper
from rack assembly. 2. CONTROL VALVE
15) Remove the oil seal from rack.
1) Disconnect the pipes A and B from gearbox.
2) Secure the gearbox removed from the vehicle in
vise using ST.
ST1 926200000 STAND
ST2 34199AG000 BOSS D
PS-29
CAUTION: 6) Remove the two bolts securing valve assembly.

Secure the gearbox in a vise using ST as
shown. Do not attempt to secure it without this
ST.
(1)
PS-00116
ST1 7) Carefully draw out the input shaft, and then re-
ST2 move the valve assembly.
PS-00492
(1) Clamp
3) Using the ST, loosen the lock nut.

ST
PS-00143
8) Wrap the tape to spline part, and slide the dust

cover out.
(1)
(1)
PS-00494
(1) Lock nut
4) Tighten the adjusting screw until it no longer

tightens.
(1)
PS-00144
(1) Dust cover
PS-00495
(1) Adjusting screw
5) Loosen the adjusting screw, and then remove

the spring and sleeve.
PS-30
9) Using a press remove the pinion & valve assem- CAUTION:

bly from valve housing. Be careful not to scratch the pinion & valve as-
sembly.
(1) (4)
(2) (3)
(2)
(3)
(1)
PS-00149
PS-00518
(1) Pinion & valve ASSY
(2) Valve housing (1) Snap ring
(3) Cloth (2) Valve
10) Using the ST and press, remove the bushing (3) Oil seal
and oil seal from valve housing. (4) Backup ring
ST 34199AG090 INSTALLER & REMOVER
D: ASSEMBLY
CAUTION:
• Do not apply force to the end surface of valve 1. RACK HOUSING ASSEMBLY
housing. 1) Using a press, install the bushing to the gearbox
• Do not reuse the oil seal after removal. installation portion.
ST
(1)
(2)
PS-00150 PS-00519
(1) Oil seal

2) Insert the ST into rack.
(2) Bushing
ST 34199AG040 GUIDE (3.0 R model)
ST 34199AG030 GUIDE (Except for 3.0 R mod-
11) Using a snap ring pliers, remove the snap ring, el)
valve, oil seal and backup washer.
(1)
(2)
ST
PS-00520
(1) Seal ring

(2) Rack
PS-31
3) Install the seal ring to piston portion of rack. (3) Insert the ST-A with oil seal assembled from
(1) Using the ST, form the seal ring properly the gear side of rack. Remove the oil seal from
ST1 34199AG080 FORMER PISTON ST-A near piston, and then remove the ST-A
ST2 34199AG060 GUIDE G (26) (3.0 R model) from rack.
ST2 34199AG050 GUIDE G (24) (Except for 3.0
R model) (C)
(1) (2)
(B)
ST A
(A)
PS-00076
ST2 ST1 (A) Oil seal

PS-00559
(B) Rack
(1) Seal ring (C) Piston
(2) Rack
4) Install the backup washer from gear side of rack.
(2) Using ST-B and ST-C, install the oil seal to
ST-A.
ST 34199FE040 INSTALLER A, B, C (3.0 R
model)
ST 927490000 INSTALLER A, B, C (Except
for 3.0 R model)
NOTE:
Face the oil seal in the direction as shown in the fig-
ure.
PS-00077
ST B ST A
ST C (1) Oil seal
(2) Backup washer
(3) Rack
5) Install the ST on rack, and equally apply a thin

coat of grease to the rack and ST, then install the oil
(A) seal.
ST 926250000 GUIDE
PS-00075
CAUTION:
(A) Oil seal
Be careful not to scratch the oil seal lips with
the inner ring section of piston.
PS-32
NOTE: 11) Using a press, press-fit until the groove of ST

Do not use this ST for turbo model. reaches the end of holder.
ST
(1)
(2)
PS-00078 PS-00522
(1) Rack piston inner ring (1) Groove

(2) Outer side oil seal (2) Holder
(3) Rack 12) Secure the gearbox in a vice using ST.
6) Apply a coat of grease to the grooves in rack, ST1 926200000 STAND
sliding surface of sleeve and sealing surface of pis- ST2 34199AG000 BOSS D
ton. Then insert the rack into steering body from
(1)
cylinder side.
7) Check the thread part of holder and end of gear-
box cylinder for burrs and scratches. Correct if nec-
essary.
8) Insert the ST into gearbox cylinder, and then
press-fit the oil seal.
ST 34199AG010 INSTALLER
ST1
ST2
ST PS-00492
(1) Clamp
13) Tighten the holder.

Tightening torque:
3.0 R model
90 N#m (9.18 kgf-m, 66.4 ft-lb)
PS-00521
Except for 3.0 R model
64 N#m (6.5 kgf-m, 47.0 ft-lb)
9) Temporarily install the holder to gearbox cylin-
der.
10) Set the ST to the end of rack.
ST 34199FE000 INSTALLER & REMOVER
(3.0 R model)
ST 34099FA030 INSTALLER & REMOVER
(Except for 3.0 R model)
(1)
PS-00512
(1) Holder
14) Using ST, caulk the gearbox cylinder at 2 mm

(0.08 in) from end to make punch hole 2 to 2.5 mm
(0.08 to 0.10 in) in diameter.
PS-33
ST 34099FA060 PUNCH HOLDER 17) Install a new gasket on valve assembly. Insert
the valve assembly into place while facing the rack
(1) teeth toward pinion.
(2)
(4)
(3)
PS-00523
(1) 2 mm (0.08 in) PS-00117

(2) Diameter: 2 — 2.5 mm (0.08 — 0.10 in)
18) Tighten the bolts alternately to secure valve as-
(3) End of cylinder sembly.
(4) Holder
Tightening torque:
15) Apply vinyl tape to spline portion, and apply 25 N#m (2.5 kgf-m, 18.1 ft-lb)
genuine grease to dust cover, and then install the
CAUTION:
dust cover to valve assembly.
Be sure to alternately tighten the bolts.
CAUTION: 19) Temporarily install the rack, and then operate it
Be sure to install the dust cover to groove on from lock to lock two or three times to make it fit in.
shaft properly. Remove the grease blocking air vent hole.
(1) CAUTION:
If operating the rack from lock to lock without
installing tie-rod, it may damage the oil seal. Al-
ways install the tie-rods LH and RH.
20) Apply a coat of grease to the sliding surface of
sleeve and seating surface of spring, and then in-
(2)
sert sleeve into steering body.
Charge the adjusting screw with grease, and then
insert the spring into adjusting screw and install on
PS-00534 steering body.
(1) Dust cover

(2) Groove
16) Apply genuine grease to the pinion gear and

bearing of valve assembly.
(3)
(2)
(1)
PS-00167
(1) Sleeve
(2) Spring
(3) Adjusting screw
PS-00165 21) Tighten the adjusting screw to specified torque.

Tightening torque:
7.4 N#m (0.75 kgf-m, 5.4 ft-lb)
22) After tightening the adjusting screw with the
specified tightening torque, loosen it by 25!.
23) Remove the tie-rod.
PS-34
24) Verify that play is within specified value. <Ref. Tightening torque:
to PS-43, SERVICE LIMIT, INSPECTION, Steer- 78 N#m (8.0 kgf-m, 57.9 ft-lb)
ing Gearbox [LHD Model].>
25) Loosen the adjusting screw, and then apply liq-
(2)
uid gasket to at least 1/3 of the entire perimeter of
adjusting screw thread.
Liquid gasket:
THREE BOND 1141
(1)
PS-00439
(1) Lock washer

(2) Approx. 40 mm (1.57 in)
31) Bend the lock washer.

CAUTION:
PS-00092
Be careful not to scratch the rack when bending
(1) Apply liquid gasket to at least 1/3 of entire lock washer.
perimeter.
26) Tighten the adjusting screw to specified torque.

Tightening torque:
7.4 N#m (0.75 kgf-m, 5.4 ft-lb)
specified tightening torque, loosen it by 25!.
28) Install the lock nut. While holding the adjusting
screw with a wrench, tighten lock nut using ST.
Tightening torque (Lock nut):
39 N#m (4.0 kgf-m, 28.9 ft-lb)
NOTE:
Hold the adjusting screw with a wrench to prevent it
from turning while tightening lock nut.
29) Extend the rack approx. 40 mm (1.57 in) be-
yond side of steering body.
30) Install the tie-rod and a new lock washer into
rack.
PS-00093
(1) Lock washer
32) Apply a coat of grease to the tie-rod groove,

and then install the boot to housing.
PS-35
CAUTION: 33) Install a new boot band. Using band clamp pli-
Right side boot has groove for identification. ers, caulk the boot band until caulking part clear-
Be sure to install the boots after identifying left ance is 2 mm (0.079 in) or less.
and right boots.
(1)
(B)
(2)
(A)
PS-00524
(1) Right side boot

(2) Groove for identification
NOTE:
Make sure that the boot is installed without unusual
inflation or deflation.
PS-00499
(A) Boot band

(B) 2 mm (0.079 in) or less
34) Fix the boot end with clip (small).
PS-00194
PS-00053
(1) Clip
35) After installing, check the boot end is posi-

tioned into groove on tie-rod.
36) If the tie-rod end has been removed, screw in
the lock nut and tie-rod end to screwed portion of
tie-rod, and then tighten the lock nut temporarily in
a position as shown in the figure.
PS-36
Installed tie-rod length L: (2) Connect the pipe C and D to gearbox.

31 mm (1.22 in)
Tightening torque:
Pipe C: 15 N#m (1.5 kgf-m, 10.8 ft-lb)
Pipe D: 25 N#m (2.5 kgf-m, 18.1 ft-lb)
(2)
PS-00097
37) Inspect the gearbox as follows:

(1)
“A” Holding the tie-rod end, repeat lock to lock two PS-00525
or three times as quickly as possible.
“B” Holding the tie-rod end, turn it slowly at a radius (1) Pipe C
one or two times as large as possible. (2) Pipe D
After all, make sure that the boot is installed in
specified position without deflation. 2. CONTROL VALVE ASSEMBLY
Specified steering grease:
VALIANT GREASE M2 (Part No. 003608001)
A B
1) Clean all parts and tools before reassembling.
2) Apply a coat of specified power steering fluid to
the inner wall of valve housing.
PS-00098
38) Remove the gearbox from ST.

ST1 926200000 STAND
39) Install the four pipes on gearbox.
(1) Connect the pipe A and B to four pipe joints (1)
PS-00169
of gearbox.
(1) Apply fluid.
Tightening torque:
13 N#m (1.3 kgf-m, 9.4 ft-lb) 3) To avoid scratching the oil seal, apply a coat of
grease to the contact surface of installer and oil
seal.
4) Verify the oil seal direction.
Attach the oil seal to installer and position in valve
housing before pressing into place.
PS-37
5) Press the oil seal into place using a press. 8) Install the backup ring and oil seal to pinion, and
ST 34199AG090 INSTALLER & REMOVER then remove the vinyl tape.
(3)
(2)
(1)
PS-00528
(1) Oil seal

(2) Vinyl tape
(3) Backup ring
ST
9) Set the ST to pinion, and install the seal ring.
ST 34199AG020 GUIDE
ST
PS-00526
6) Attach the bearing to ST, and then position in

value housing. Using the ST and press, install the
special bearing in valve housing.
(1)
ST 34199AG090 INSTALLER & REMOVER
PS-00529
ST
(1) Seal ring
10) Remove the ST GUIDE, and form the seal ring

properly using ST FORMER.
(1) ST 34199AG070 FORMER
(2)
PS-00527
(1) Special bearing ST

(2) Oil seal
7) Apply vinyl tape to the groove portion of pinion. (1)
PS-00530
(1) Seal ring
11) Put vinyl tape around the pinion shaft splines to

protect oil seal from damage.
PS-38
12) Install the valve to pinion, and install the snap 16) Install the dust cover on valve assembly.
ring. CAUTION:
Be sure to install the dust cover to groove on
shaft properly.
(1)
(2)
(1) (2)
PS-00531
(1) Snap ring

PS-00534
(2) Valve
13) Fit the pinion & valve assembly into valve hous- (1) Dust cover
ing. (2) Groove
17) Apply genuine grease to the pinion gear and

bearing of valve assembly.
(2)
(1)
PS-00532
(1) Valve housing

PS-00165
18) Install a new O-ring on valve assembly.
14) Using a press, press-fit the pinion & valve as-
sembly into housing by pressing the bearing outer
race.
(1)
(1)
(2)
PS-00535
(3)
(1) O-ring
PS-00533

(2) Bearing
(3) Housing
15) Apply the specified grease to dust cover.
PS-39
19) Insert the valve assembly into place while fac- Liquid gasket:
ing rack teeth toward pinion. THREE BOND 1141
PS-00143 PS-00092
20) Tighten the bolts alternately to secure valve as-
sembly. (1) Apply liquid gasket to at least 1/3 of entire
perimeter.
Tightening torque:
25 N#m (2.5 kgf-m, 18.1 ft-lb) 26) Tighten the adjusting screw to specified torque.
CAUTION: Tightening torque:
Be sure to alternately tighten the bolts. 7.4 N#m (0.75 kgf-m, 5.4 ft-lb)
21) Apply a coat of grease to the sliding surface of 27) After tightening to the specified tightening
sleeve and seating surface of spring, and then in- torque, loosen it by 25!.
sert the sleeve into steering body. 28) Install the lock nut. While holding the adjusting
Charge the adjusting screw with grease, and then screw with a wrench, tighten the lock nut using ST.
insert the spring into adjusting screw and install on ST 926230000 SPANNER
steering body.
39 N#m (4.0 kgf-m, 28.9 ft-lb)
NOTE:
29) Remove the gearbox from ST.
ST1 926200000 STAND
(3) ST2 34199AG000 BOSS D
(2)
30) Install the four pipes on gearbox.
(1)
(1) Connect the pipe A and B to the gearbox.
PS-00167
Tightening torque:
(1) Sleeve 13 N#m (1.3 kgf-m, 9.4 ft-lb)
(2) Spring
(3) Adjusting screw
22) Tighten the adjusting screw with specified

torque.
Tightening torque:
7.4 N#m (0.75 kgf-m, 5.4 ft-lb)
23) After tightening to the specified tightening
torque, loosen it by 25!.
24) Verify that play is within specified value. <Ref.
to PS-43, SERVICE LIMIT, INSPECTION, Steer-
ing Gearbox [LHD Model].>
PS-40
(2) Connect the pipe C and D to gearbox.

Tightening torque:
Pipe C: 15 N#m (1.5 kgf-m, 10.8 ft-lb)
Pipe D: 25 N#m (2.5 kgf-m, 18.1 ft-lb)
(2)
(1)
PS-00525
(1) Pipe C
(2) Pipe D
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 the inside of gearbox for water. If any water is found, carefully check the boot
for damage, input shaft dust seal, adjusting screw and boot clips for poor sealing. If faulty, replace with new
parts.
No. Parts Inspection Corrective action
(1) Bend of input shaft If the bend or damage is excessive, replace the entire
1 Input shaft
(2) Damage on serration gearbox.
(1) Crack or damage If the outer wall slips, the lip is worn out or damage is
2 Dust seal
(2) Wear found, replace it with a new one.
(1) Adjust the backlash properly.
By measuring the turning torque of gearbox and sliding
resistance of rack, check if rack & pinion engage uni-
formly and smoothly with each other. (Refer to “Service
3 Rack & pinion Poor mating of rack with pinion limit”.)
(2) Keeping the 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 gearbox.
(1) Bend of rack shaft
(2) Bend of cylinder portion
Replace the gearbox with a new one.
(3) Crack or damage on cast iron
portion
(4) Wear or damage on rack bush If the free play of rack shaft in radial direction is out of the
4 Gearbox unit
specified range, replace the gearbox with a new one.
(Refer to “Service limit”.)
(5) Wear on input shaft bearing If the free plays of input shaft in radial and axial directions
are out of the specified ranges, replace the gearbox with
a new one. (Refer to “Service limit”.)
5 Boot Crack, damage or deterioration Replace.
(1) Looseness of ball joint
6 Tie-rod Replace.
(2) Bend of tie-rod
Damage or deterioration on dust
7 Tie-rod end Replace.
seal
Adjusting screw
8 Deterioration Replace.
spring
9 Boot clip Deterioration Replace.
10 Sleeve Damage Replace.
(1) Damage to flared surface
11 Pipes (2) Damage to flare nut Replace.
(3) Damage to pipe
PS-42
2. SERVICE LIMIT On condition

L: 5 mm (0.20 in)
Make a measurement as follows. If it exceeds the
specified service limit, adjust or replace. P: 122.6 N (12.5 kgf, 27.6 lb)
NOTE: L
When making a measurement, vise the gearbox
using ST. Never vise the gearbox by inserting alu-
minum plates, etc. between vise and gearbox.
ST1 926200000 STAND
Sliding resistance of rack shaft: P
Service limit
400 N (41 kgf, 90 lb) or less PS-00101
Left-turn steering:
Service limit
Direction
Direction
0.15 mm (0.0059 in) or less
5 mm(0.20 in)
PS-00099
98N
(10 kgf, 22 lb)
PS-00102
4. INPUT SHAFT PLAY

In radial direction:
PS-00100
Service limit
3. RACK SHAFT PLAY IN RADIAL DIREC- 0.18 mm (0.0071 in) or less
TION On condition
Right-turn steering: P: 98 N (10 kgf, 22 lb)
Service limit
P
0.19 mm (0.0075 in) or less
PS-00103
In axial direction:
Service limit
PS-43
On condition 5. TURNING RESISTANCE OF GEARBOX

P: 20 — 49 N (2 — 5 kgf, 4 — 11 lb)
Using the ST, measure the gearbox turning resis-
tance.
ST 34099PA100 SPANNER
Service limit:
Maximum allowable resistance:
10.5 N (1.1 kgf, 2.4 lb) or less
P
Difference between right and left turning re-
sistance:
20% or less
PS-00104
PS-00105
6. OIL LEAKING
a
(5)
(1) d
(4) (3) (2)

c
(6)
d
f
e
d g
d d
g
PS-00272
(1) Power cylinder (3) Rack piston (5) Input shaft

(2) Cylinder (4) Rack axle (6) Valve housing
PS-44
1) Lift up the vehicle. F: ADJUSTMENT

2) Even if the location of leak can be easily found 1) Adjust the front toe. <Ref. to FS-12, FRONT
by observing the leaking condition, it is necessary WHEEL TOE-IN, INSPECTION, Wheel Align-
to thoroughly remove the fluid from the suspected ment.>
portion and turn the steering wheel from lock to lock
about thirty to forty times with engine running, then Standard of front toe:
make comparison of the suspected portion be- IN 3 — OUT 3 mm (IN 0.12 — OUT 0.12 in)
tween immediately after and several hours after
this operation.
3) Cause and measure for oil leakage from “a”
The oil seal is damaged. Replace the valve assem-
bly with a new one.
4) Cause and measure for oil leakage from “b”
The torsion bar O-ring is damaged. Replace the
valve assembly with a new one.
5) Cause and measure for oil leakage from “c”
PS-00107
bly or oil seal with a new one.
6) Cause and measure for oil leakage from “d”
(1) Lock nut
The pipe is damaged. Replace the faulty pipe or O-
ring. 2) Adjust the steering angle of wheels.
7) Cause and measure for oil leakage from “g”
The hose is damaged. Replace the hose with a Standard of steering angle:
new one. Model 2.0 i, 2.5 i 3.0 R OUTBACK
8) If leak is other than a, b, c, d, or g, and if oil is Inner
leaking from the gearbox, move the right and left 37.3!"1.5! 37.2!"1.5! 37.8!"1.5!
wheel
boots toward tie-rod end side, respectively, with the Outer
gearbox mounted to the vehicle, and remove fluid 33.0!"1.5! 32.9!"1.5! 33.5!"1.5!
wheel
from the surrounding portions. Then, turn the steer-
ing wheel from lock to lock thirty to forty times with 3) If the steering wheel spokes are not horizontal
the engine running, and make comparison of the when wheels are set in the straight ahead position,
leaked portion immediately after and several hours and error is more than 5! on the periphery of steer-
after this operation. ing wheel, correctly re-install the steering wheel.
(1) Leakage from “e”
The cylinder seal is damaged. Replace the rack (1)
bush with a new one.
(2) Leakage from “f”
There are two possible causes. Take the follow-
ing step first. Remove the pipe assembly B from
the valve housing, and close the circuit with ST.
ST 926420000 PLUG
Turn the steering wheel from lock to lock thirty to
forty times with the engine running, then make
PS-00513
comparison of the leaked portion between im-
mediately after and several hours after this op- (1) Within 5!
eration.
• If leakage from “f” is noted again: 4) If the steering wheel spokes are not horizontal
The oil seal of pinion & valve assembly is dam- with vehicle set in the straight ahead position after
aged. Replace the pinion & valve assembly with a this adjustment, correct it by turning the right and
new one. Or replace the oil seal and parts that are left tie-rods in opposite direction by same angle.
damaged during disassembly with new ones.
• If oil stops leaking from “f”:
The oil seal of rack housing is damaged. Replace
the oil seal and the parts that are damaged during
disassembly with new ones.
PS-45
Steering Gearbox [RHD Model]
6. Steering Gearbox [RHD Mod- • Small type

el]
A: REMOVAL
1) Set the vehicle on a lift.
3) Loosen the front wheel nuts.
5) Remove the under cover. <Ref. to EI-26, RE-
MOVAL, Front Under Cover.> (2)
(1)
6) Remove the front exhaust pipe assembly. (Non- (1) FS-00105
turbo model) <Ref. to EX(H4SO 2.0)-7, REMOVAL,
Front Exhaust Pipe.> (1) Front crossmember support plate
WARNING: (2) Jack-up plate
Be careful, not to burn your hand because the
9) Remove the one pipe joint at the center of gear-
exhaust pipe is hot.
box, and connect the vinyl hose to the pipe and the
7) Using a puller, remove the tie-rod end from the joint. Discharge the fluid by turning steering wheel
knuckle arm after pulling off cotter pin and remov- fully clockwise and counterclockwise. Discharge
ing castle nut. the fluid similarly from other pipes.
(1)
(2)
PS-00043 PS-00446
(1) Castle nut (1) Pipe A

(2) Tie-rod end (2) Pipe B
(3) Knuckle arm
10) Remove the universal joint. <Ref. to PS-21,
8) Remove the front crossmember support plate, REMOVAL, Universal Joint.>
jack-up plate and front stabilizer. <Ref. to FS-16,
REMOVAL, Front Stabilizer.>
• Large type
(1)
PS-00445
(1) Front crossmember support plate
PS-46
11) Disconnect the return hose and pressure hose 13) Remove the bolts which secure the gearbox
from gearbox. bracket, and remove the bracket and gearbox.
(1)
(2)
PS-00449
(1) Bracket
B: INSTALLATION
1) Insert the gearbox into the crossmember, being
(1)
careful not to damage gearbox boot.
2) Install the gearbox and bracket. Tighten the bolt
temporarily.
PS-00536 (1)
(1) Return hose

(2) Pressure hose
12) Remove the clamp bolts securing gearbox to

crossmember, and remove the clamp.
PS-00449
(1) Bracket
3) Tighten the gearbox to the crossmember bracket

via clamp with bolt temporarily.
(1)
PS-00448
(1) Clamp
(1)
PS-00448
(1) Clamp
4) Tighten the bolts which temporary tightening the

clamp and bracket of gearbox to specified torque.
Tightening torque:
60 N#m (6.1 kgf-m, 44.1 ft-lb)
PS-47
5) Connect the return hose and pressure hose to 8) After tightening the castle nut to specified tight-
gearbox. ening torque, tighten it further within 60! until cotter
pin hole is aligned with slot in the nut. Fit the cotter
Tightening torque:
pin into nut, and then bend the pin to lock.
15 N#m (1.5 kgf-m, 10.8 ft-lb)
(A)
(B)
(C)
(2)
DS-00042
(A) Cotter pin

(B) Castle nut
(C) Tie-rod end
(1)
9) Install the front stabilizer. <Ref. to FS-16, IN-
STALLATION, Front Stabilizer.>
jack-up plate.
11) Install the front exhaust pipe assembly. (Non-
turbo model) <Ref. to EX(H4SO 2.0)-8, INSTALLA-
TION, Front Exhaust Pipe.>
PS-00536
12) Install the under cover. <Ref. to EI-26, INSTAL-
(1) Return hose LATION, Front Under Cover.>
(2) Pressure hose 13) Install the front wheels.
14) Tighten the wheel nuts to specified torque.
Tightening torque:
90 N#m (9.1 kgf-m, 65.8 ft-lb)
7) Connect the tie-rod end and knuckle arm, and
tighten with castle nut. 15) Lower the vehicle.
16) Remove the steering wheel. <Ref. to PS-20,
Castle nut tightening torque: REMOVAL, Steering Wheel.>
27 N#m (2.75 kgf-m, 19.9 ft-lb) 17) Align the center of roll connector. <Ref. to AB-
CAUTION: 23, ADJUSTMENT, Roll Connector.>
When connecting, do not hit cap at the bottom 18) Install the steering wheel. <Ref. to PS-20, IN-
of tie-rod end with hammer. STALLATION, Steering Wheel.>
19) Connect the battery ground cable to battery.
20) Pour fluid into the oil tank, and bleed air. <Ref.
21) Check for fluid leaks.
22) Check the fluid level in oil tank.
23) After adjusting toe-in and steering angle, tight-
en the lock nut on tie-rod end.
Tightening torque:
85 N#m (8.7 kgf-m, 62.7 ft-lb)
PS-48
NOTE: 3) Remove the tie-rod end and lock nut from gear-
When adjusting toe-in, hold the boot as shown to box.
prevent it from being rotated or twisted. If twisted, 4) Remove the clip from outside boot using pliers,
straighten it. and then move the boot to tie-rod end side.
PS-00051 PS-00053
C: DISASSEMBLY (1) Clip

1) Disconnect the pipes A and B from steering body
and control valve housing. 5) Using a flat tip screwdriver, remove the band
from boot.
NOTE:
Replace the boot if there is damage, cracks or de-
terioration.
(1)
(2)
(1)
PS-00496
(1) Pipe A
(2) Pipe B
PS-00493
2) Secure the gearbox removed from vehicle in a
vice using ST. (1) Band
ST1 926200000 STAND
ST2 34199AG000 BOSS D 6) Using the ST, loosen the lock nut.
CAUTION: ST 926230000 SPANNER
Secure the gearbox assembly in a vice using
the ST as shown. Do not secure the gearbox ST
without this ST.
(1)
(1)
PS-00494
ST1 (1) Lock nuts

ST2
PS-00492
(1) Clamp
PS-49
7) Tighten the adjusting screw until it no longer ST 34199AE090 PLUG WRENCH

tightens.
(1)
PS-00495
(1) Adjusting screw
8) Using a 32 mm spanner or adjustable wrench

with cinching boot, remove the tie-rod.
PS-00061
(1) Plug
12) Remove the valve assembly paying attention

PS-00058
not to scratch seal ring or valve housing inner sur-
face.
(1) Tie-rod
9) Loosen the adjusting screw and remove the

spring and sleeve.
10) Clean the dirt adherent to the input shaft. Re-
move the dust cover paying attention not to scratch
the housing or input shaft and not to allow foreign
matter to enter the gear box interior.
CAUTION:
Wrap the tape to the spline part of input shaft to
avoid damaging dust cover.
(1)
PS-00497 PS-00062
(1) Dust cover (1) Valve ASSY

(2) Seal ring
11) Align the ST pin with the plug hole to install. Ro-
tate the ST counterclockwise to remove the plug.
PS-50
13) Remove the holder using a 36 mm spanner or 15) Insert the ST from the valve side and press the
adjustable wrench. back-up ring and oil seal out.
ST 34199FE010 REMOVER (Turbo and 3.0 R
model)
ST 927580000 REMOVER (Except for turbo
and 3.0 R model)
PS-00498
14) Install the ST on valve side of rack and press

outer side oil seal out taking care not to contact
rack with steering body inner surface.
ST 34199FE010 INSTALLER & REMOVER
(Turbo and 3.0 R model)
ST 34199FA030 INSTALLER & REMOVER
(Except for turbo and 3.0 R
model)
NOTE:
Block the pipe connection of steering body to pre-
vent fluid from flowing out.
PS-00065
PS-00064
(1) Rack piston

(2) Outer side oil seal
PS-51
16) Using ST1 and ST2, repair the caulking portion NOTE:
of cylinder. Do not apply force on the plug edge surface.
ST1 34099FA080 PUNCH
ST2 34199FE020 BASE (Turbo and 3.0 R mod-
el)
ST2 34099FA070 BASE (Except for turbo and
3.0 R model)
PS-00068
(1) Oil seal

(2) O-ring
19) Set the ST in the dimension as shown in the fig-

ure.
ST 34199AE120 GEARBOX OIL SEAL RE-
MOVER
PS-00066
(1) Cylinder
PS-00069
17) If the cylinder edge is deformed in a convex

(1) 70 mm (2.76 in)
shape, repair using an oil stone.
PS-00067
18) Remove the oil seal using ST and press from

plug.
ST 34199AE100 OIL SEAL PLUG REMOVER
PS-52
20) Set the stopper to gearbox, and then insert the 22) While fixing the 2-surface width, pull out the oil
tip of ST to gearbox. seal by rotating nut.
CAUTION:
Take care not to scratch the gearbox inner sur-
face.
PS-00070
(1) Stopper
(2) Oil seal
PS-00072
21) By fixing the 2-surface width, press-in by rotat-
ing the rod and attach to oil seal. (1) 2-surface width
(2) Nut
D: ASSEMBLY
1) Apply a coat of grease to the inside and outside
of new oil seal.
Steering grease:
VALIANT GREASE M2 (Part No. 003608001)
2) Verify the oil seal direction and installation posi-
tion. Using the ST and press, press-fit the oil seal to
gearbox.
ST 34199AE130 GEARBOX OIL SEAL IN-
STALLER
PS-00071
PS-00073
(1) Rod
(2) 2-surface width (1) Oil seal
PS-53
3) Attach the steering body to ST as shown in the 5) Insert the ST-A with oil seal assembled from the
figure. Apply a coat of grease to needle bearing. gear side of rack. Remove the oil seal from ST-A
ST1 926200000 STAND near piston, and then remove the ST-A from rack.
CAUTION: (C)
Ensure the needle bearing is free from defects.
If it is faulty, replace the steering body with a
new one.
(1)
(B)
ST A
(A)
PS-00076
(A) Oil seal

(B) Rack
ST1 (C) Piston
ST2
PS-00492 6) Install the back-up washer from gear side of
rack.
(1) Clamp
4) Using ST-B and ST-C, install the oil seal to ST-

A.
ST 34199FE040 INSTALLER A, B, C (Turbo
and 3.0 R model)
ST 927490000 INSTALLER A, B, C (Except
for turbo and 3.0 R model)
NOTE:
Face the oil seal in the direction as shown in the fig-
ure. PS-00077
ST A (1) Oil seal

ST B
ST C (2) Back-up washer
(3) Rack
7) Install the ST on rack, and equally apply a thin

coat of grease to the rack and ST, then install the oil
seal.
(A) ST 926250000 GUIDE
CAUTION:
PS-00075 Be careful not to scratch the oil seal lips with
the inner ring section of piston.
(A) Oil seal
PS-54
NOTE: ST2 34199FE060 INSTALLER (Turbo and 3.0 R

Do not use this ST for turbo model. model)
34199AE010 INSTALLER (Except for turbo
and 3.0 R model)
ST2
(1)
ST1
(2)
PS-00078 (3)
(1) Rack piston inner ring PS-00431

(3) Rack
(2) Rack piston
8) Apply a coat of grease to the grooves in rack, (3) Inner side oil seal
sliding surface of sleeve and sealing surface of pis-
ton. Install ST on the end of steering body cylinder. 10) Install a new holder to the cylinder side of steer-
Then insert the rack into steering body from cylin- ing body.
der side. Tightening torque:
ST 34199FE050 GUIDE (Turbo and 3.0 R mod- Turbo and 3.0 R model
el) 90 N#m (9.18 kgf-m, 66.4 ft-lb)
ST 34199AE000 GUIDE (Except for turbo and Except for turbo and 3.0 R model
3.0 R model) 64 N#m (6.5 kgf-m, 47.0 ft-lb)
CAUTION:
Do not allow grease to block the air vent hole on
rack.
PS-00498
11) Using the ST, caulk the steering body at one

point less than 3mm (0.12 in) from holder.
PS-00079
CAUTION:
(1) Cylinder side of steering body Be careful not to deform the holder.
(2) Air vent hole
(3) Oil seal
(4) Rack
9) Make the ST2 pass through rack, and then

press-in the rack and ST2 using press.
Press-in the rack until ST1 comes in contact with
ST2 and the edge surface of rack is aligned with
that of ST2.
ST1 34199FE050 GUIDE (Turbo and 3.0 R mod-
el)
34199AE000 GUIDE (Except for turbo and
3.0 R model)
PS-55
ST 34099FA060 PUNCH HOLDER 13) Apply a coat of grease on the gear teeth of
valve assembly, and then attach the valve assem-
ST bly taking care not to scratch oil seal and seal ring.
(A)
(B)
ST
PS-00084
(A) Holder PS-00086

(B) 3 mm (0.12 in)
(1) Seal ring
12) Roll the vinyl tape on serration part of valve as- (2) Oil seal
sembly, and then apply grease on the tape surface.
14) Apply grease on the oil seal circumference, and
then press it into the plug using ST and press. Re-
place the O-rings of plug circumference with new
ones.
ST 34199AE110 OIL SEAL PLUG INSTALLER
CAUTION:
Install the oil seal paying attention to its direc-
tion.
PS-00085
(1) Vinyl tape
PS-00087
(1) Plug
(2) O-ring
(3) Oil seal
PS-56
15) Using the ST, install plug. Charge the adjusting screw with grease, and then
ST 34199AE090 PLUG WRENCH insert the spring into adjusting screw and install on
steering body.
Tightening torque:
64 N#m (6.5 kgf-m, 47.0 ft-lb)
(3)
(2)
(1)
PS-00167
(1) Sleeve
(2) Spring
(3) Adjusting screw
19) Tighten the adjusting screw to specified torque.

Tightening torque:
9.8 N#m (1.0 kgf-m, 7.2 ft-lb)
specified tightening torque, loosen it.
Tightening torque:
PS-00088
4.9 N#m (0.50 kgf-m, 3.6 ft-lb)
(1) Plug specified tightening torque, loosen 37! it.
16) Install the dust cover. Remove the vinyl tape. Tightening torque:
4.9 N#m (0.50 kgf-m, 3.6 ft-lb)
22) Remove the tie-rod.
23) Verify that play is within specified value. <Ref.
(1) to PS-61, LIMIT, INSPECTION, Steering Gearbox
[RHD Model].>
Liquid gasket:
PS-00497 THREE BOND 1141 (Part No. 004403006)
(1) Dust cover
17) Temporarily install the tie-rod to the rack, and

then operate it from lock to lock two or three times
to make it fit in. Remove the grease blocking air
vent hole.
CAUTION:
If operating the rack from lock to lock without
installing tie-rod, it may damage the oil seal. Al-
ways install the tie-rods LH and RH. PS-00092
18) Apply a coat of grease to the sliding surface of

(1) Apply liquid gasket to at least 1/3 of entire
sleeve and seating surface of spring, and then in-
perimeter.
sert the sleeve into spring body.
PS-57
25) Install the lock nut. While holding adjusting NOTE:

screw with a wrench, tighten the lock nut using ST. Use a new boot band.
39 N#m (4.0 kgf-m, 28.9 ft-lb)
NOTE:
26) Install the tie-rod into rack.
Tightening torque: (B)
90 N#m (9.0 kgf-m, 65.1 ft-lb)
NOTE: (A)
Check the mating face of rack and tie-rod for for-
eign material, dirt and etc.
27) Apply a coat of grease to the tie-rod groove,
and then install the boot to housing.
NOTE:
Make sure that the boot is installed without unusual
inflation or deflation.
PS-00499
(A) Boot band

(B) 2 mm (0.08 in) or less
29) Fix the boot end with clip (small).
PS-00094
28) Caulk the boot so the space inside boot band

caulking portion becomes 2 mm (0.08 in) or less.
PS-00053
(1) Clip
30) After installing, check that the boot end is posi-

tioned into groove on tie-rod.
31) If the tie-rod end has been removed, screw in
lock nut and tie-rod end to the screwed portion of
tie-rod, and tighten the lock nut temporarily in a po-
sition as shown in figure.
PS-58
Installed tie-rod length L:

31 mm (1.22 in)
PS-00097
32) Inspect the gearbox as follows:

“A” Holding tie-rod end, repeat lock to lock two or
three times as quickly as possible.
“B” Holding tie-rod end, turn it slowly at a radius one
or two times as large as possible.
After all, make sure that the boot is installed in the
specified position without deflation.
A B
PS-00098
33) Take off the gearbox from ST.

ST1 926200000 STAND
34) Install the pipe A and B to steering body and
control valve housing.
Tightening torque:
T1: 20 N#m (2.0 kgf-m, 14.5 ft-lb)
T2: 24 N#m (2.4 kgf-m, 17.4 ft-lb)
T1 T1
T2
(2)
T2
(1) PS-00500
(1) Pipe A
(2) Pipe B
PS-59
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. Parts INSPECTION Corrective action
(1) Bend of input shaft If the bend or damage is excessive, replace the entire
1 Input shaft
(2) Damage on serration gearbox.
(1) Crack or damage If the outer wall slips, the lip is worn out or damage is
2 Dust seal
(2) Wear found, replace it with a new one.
(1) Adjust the backlash properly.
By measuring turning torque of gearbox and sliding resis-
tance of rack, check if rack & pinion engage uniformly and
smoothly with each other. (Refer to “Service limit”.)
3 Rack & Pinion Poor mating of rack with pinion
(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 gearbox.
(1) Bend of rack shaft
(2) Bend of cylinder portion
Replace the gearbox with a new one.
(3) Crack or damage on cast iron
portion
If the free play of rack shaft in radial direction is out of the
4 Gearbox unit
(4) Wear or damage on rack bush specified range, replace the gearbox with new one. (Refer
to “Service limit”.)
If the free play of rack shaft in radial and axial direction is
(5) Wear on input shaft bearing out of the specified range, replace the gearbox with a new
one. (Refer to “Service limit”.)
5 Boot Crack, damage or deterioration Replace.
(1) Looseness of ball joint
6 Tie-rod Replace.
(2) Bend of tie-rod
Damage or deterioration on dust
7 Tie-rod end Replace.
seal
Adjusting screw
8 Deterioration Replace.
spring
9 Boot clip Deterioration Replace.
10 Sleeve Damage Replace.
(1) Damage to flared surface
11 Pipes (2) Damage to flare nut Replace.
(3) Damage to pipe
PS-60
2. LIMIT On condition
L: 5 mm (0.20 in)
specified service limit, adjust or replace. P: 98 N (10 kgf, 22 lb)
NOTE:
When making a measurement, vise the gearbox
using ST. Never vise the gearbox by inserting alu-
minum plates, etc. between vise and gearbox.
ST1 926200000 STAND
P (1)
Sliding resistance of rack shaft: (4)
(2)
Limit
(3) L L
314 N (32 kgf, 71 lb) or less PS-00326
Difference between right and left sliding resis- (1) Under the step
tance:
(2) Right-turn steering
20% or less
(3) Measure point
(4) Right
Left-turn steering:
(1)
Limit
Direction
PS-00324
(1) Right-turn steering

P
(1)
(2)
(1)
(3) L (4) L
PS-00327
(1) Under the step

(2) Left-turn steering
(3) Measure point
(4) Left
PS-00325
4. INPUT SHAFT PLAY
(1) Left-turn steering In radial direction:
3. RACK SHAFT PLAY IN RADIAL DIREC- Limit
TION 0.18 mm (0.0071 in) or less
Right-turn steering:
Limit
Direction
Direction
PS-61
On condition
P: 98 N (10 kgf, 22 lb)
PS-00328
In axial direction:
Service limit
0.27 mm (0.0106 in) or less
On condition
P: 20 — 49 N (2 — 5 kgf, 4 — 11 lb)
PS-00329
5. TURNING RESISTANCE OF GEARBOX

Using the ST, measure the gearbox turning resis-
tance.
ST 34099PA100 SPANNER
Service limit:
Maximum allowable resistance:
13 N (1.3 kgf, 9.6 lb) or less
Difference between right and left turning re-
sistance:
20% or less
ST
PS-00330
PS-62
6. OIL LEAKING
(5)
a
b
(1)
d (6) c (4) (3) (2) c
d d
PS-00331
(1) Power cylinder (3) Rack piston (5) Input shaft

(2) Cylinder (4) Rack axle (6) Valve housing
1) Lift-up the vehicle. F: ADJUSTMENT
2) Even if the location of leak can be easily found 1) Adjust the front toe.
by observing leaking condition, it is necessary to <Ref. to FS-12, FRONT WHEEL TOE-IN, INSPEC-
thoroughly remove the oil from suspected portion TION, Wheel Alignment.>
and turn steering wheel from lock to lock about 30
to 40 times with engine running, then reinspect the Standard of front toe:
suspected portion immediately after and several IN 3 — OUT 3 mm (IN 0.12 — OUT 0.12 in)
hours after this operation.
3) Cause and measure for oil leakage from “a”
bly with a new one.
4) Cause and measure for oil leakage from “b”
The torsion bar O-ring is damaged. Replace the
valve assembly with a new one.
5) Cause and measure for oil leakage from “c”
The oil seal is damaged. Replace the oil seal with a
new one.
PS-00107
6) Cause and measure for oil leakage from “d”
The pipe is damaged. Replace the faulty pipe or O-
(1) Lock nut
ring.
2) Adjust the steering angle of wheels.
Standard of steering angle:
Model 2.0 i, 2.5 i 2.0 GT, 3.0 R OUTBACK
Inner
37.3!"1.5! 37.2!"1.5! 37.8!"1.5!
wheel
Outer
33.0!"1.5! 32.9!"1.5! 33.5!"1.5!
wheel
PS-63
3) If the steering wheel spokes are not horizontal

when wheels are set in the straight ahead position,
or error is more than 5! on the periphery of steering
wheel, correctly re-install the steering wheel.
(1)
PS-00513
(1) Within 5!
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 opposite direction each other by
the same angle.
PS-64
Pipe Assembly [LHD Model]
7. Pipe Assembly [LHD Model] 5) Disconnect the return hose and pipe D, pressure
hose and pipe C.
A: REMOVAL
crossmember support plate and jack-up plate.
(4)
(3)
(2)
(1)
(2)
(1) FS-00105
(1)

(2) Jack-up plate
3) Remove one pipe joint at the center of gearbox,

and connect the vinyl hose to the pipe and the joint.
Discharge the fluid by turning steering wheel fully
clockwise and counterclockwise. Discharge the flu- PS-00538
id similarly from other pipes.
(1) Pipe C
(2) Pipe D
(3) Pressure hose
(4) Return hose
(1) 6) Remove the air intake duct. <Ref. to

IN(H4DOTC)-9, REMOVAL, Air Intake Duct.>
<Ref. to IN(H4SO 2.0)-9, REMOVAL, Air Intake
Duct.>
(2) 7) Disconnect the suction hose and pressure hose
PS-00553 from oil pump.
(1) Pipe A
(2) Pipe B (1)
4) Remove the clamp E from return hose and pres-

sure hose.
(2)
(3) PS-00460
(2)
(1) (1) Suction hose

(2) Pressure hose
PS-00537
(1) Return hose

(2) Pressure hose
(3) Clamp E
PS-65
8) Disconnect the suction hose and return hose CAUTION:

from reservoir tank. Remove the oil cooler from oil Align the installation position of the resin clip
cooler bracket. with the protector edge of suction hose.
(4)
(2)
(3)
(5)
(1)
(1) (3)
(4)
(2)
PS-00482
PS-00455
(1) Reservoir tank (1) Resin clip

(2) Suction hose (2) Protector
(3) Return hose (3) Suction hose
(4) Oil cooler (4) Pressure hose
(5) Oil cooler bracket
3) Connect the suction hose and return hose to res-
9) Remove the hose bracket and take out the hose ervoir tank. Install the oil cooler to oil cooler brack-
assembly from vehicle. et.
CAUTION:
Firmly insert the resin clip of return hose to the
bracket.
(2) (4)
(3)
(1)
(5)
PS-00451
(1)
(1) Hose ASSY
(2)
(2) Hose bracket
PS-00482
B: INSTALLATION
1) Temporarily tighten the bolt of hose bracket. (1) Reservoir tank
(2) Suction hose
(3) Return hose
(4) Oil cooler
(2)
4) Connect the suction hose and pressure hose to
the oil pump. Tighten the eye bolt of pressure hose.
(1)
PS-00451
(1) Hose ASSY

(2) Hose bracket
2) Install the resin clip to the pressure hose and

suction hose.
PS-66

39 N#m (4.0 kgf-m, 28.9 ft-lb) Ensure that the letter “8” on each clamp are diago-
nally opposite each other as shown in the figure.
(1)
(1)
(2) (3)
(2)
PS-00460
PS-00540
(1) Suction hose
(2) Pressure hose (1) Clamp E
(2) Pressure hose
5) Temporarily connect the pressure hose and pipe (3) Return hose
C, the return hose and D. Place the clamp E in the
position shown in the figure, and tighten the bolt 6) Tighten the clamp E.
temporarily.
Tightening torque:
7.4 N#m (0.75 kgf-m, 5.4 ft-lb)
7) Tighten the pressure hose and pipe C, the return
hose and pipe D.
Tightening torque:
15 N#m (1.5 kgf-m, 10.8 ft-lb)
8) Connect the pipe A and B to the four pipe joints
(3)
(1)
of gearbox.
(2) Tightening torque:
13 N#m (1.3 kgf-m, 9.4 ft-lb)
(6)
(4)
(5)
(1)
(2)
PS-00539 PS-00553
(1) Return hose (1) Pipe A

(2) Pressure hose (2) Pipe B
(3) Approx. 18 mm (0.71 in)
(4) Clamp E jack-up plate.
(5) Pipe C 10) Lower the vehicle.
(6) Pipe D 11) Tighten the bolts which hold the hose bracket.
PS-67
Tightening torque:
13 N#m (1.3 kgf-m, 9.4 ft-lb)
(2)
(1)
PS-00451
(1) Hose ASSY

(2) Hose bracket
12) Install the air intake duct.

<Ref. to IN(H4DOTC)-9, INSTALLATION, Air In-
take Duct.> <Ref. to IN(H4SO 2.0)-9, INSTALLA-
TION, Air Intake Duct.>
14) Feed the specified fluid.
CAUTION:
Never start the engine before feeding the fluid;
otherwise vane pump might be seized up.
15) Finally, check clearance between pipes or hos-
es as shown in the figure indicated in “General Di-
agnostic Table”. <Ref. to PS-89, INSPECTION OF
CLEARANCE, INSPECTION, General Diagnostic
Table.>
PS-68
C: INSPECTION
Check all disassembled parts for wear, damage or other abnormalities. Repair or replace defective parts as
necessary.
Parts Maintenance Parts Corrective action
• O-ring fitting surface for damage
Pipe • Nut for damage Replace with a new one.
• Pipe for damage
Clamp • Clamps for weak clamping force Replace with a new one.
• Flare surface for damage
• Flare nut for damage
• Outer surface for cracks
Hose Replace with a new one.
• Outer surface for wear
• Clip for damage
• End coupling or adapter for deformation
CAUTION:
Although surface layer materials of rubber hoses have excellent weathering resistance, heat resis-
tance and resistance for low temperature brittleness, they are likely to be damaged chemically by
brake fluid, battery electrolyte, engine oil and automatic transmission fluid and their service lives are
to be very shortened. Wipe out immediately when the hoses are adhered with the fluids.
Since resistances for heat or low temperature brittleness are gradually declining according to time
accumulation of hot or cold conditions for the hoses and their service lives are shortening accord-
ingly, it is necessary to perform careful inspection frequently when the vehicle is used in hot weather
areas, cold weather areas and a driving condition in which many steering operations are required in
short time.
Particularly continuous work of relief valve over 5 seconds causes to reduce service lives of the hos-
es, the oil pump, the fluid, etc. due to over heat.
Trouble Possible cause Corrective action
Excessive holding time of relief status Instruct customers.
Pressure hose burst Malfunction of relief valve Replace oil pump.
Poor cold characteristic of fluid Replace fluid.
Poor connection Repair.
Forced out return hose Poor holding of clip Retighten.
Wrong layout, tensioned Replace hose.
Fluid bleeding out of hose Excessive play of engine due to deterioration of
Replace the parts if defective.
slightly engine mounting rubber
Improper stop position of pitching stopper Replace the parts if defective.
Replace.
Excessive holding time of relief status
Instruct customers.
Excessive tightening torque of return hose clip Replace.
Crack on hose Power steering fluid, engine oil, electrolyte adhere Replace.
on the hose surface Pay attention on service work.
Replace.
Too many times use in extremely cold weather
Instruct customers.
PS-69
NOTE:
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 main-
tenance.
(A) (B)
(7)
(11)
(22)
(15) (14) (16)
(18)
(8)
(19) (2) (3) (17)

(12)
(21) (4)
(1) (5) (6)
(20) (9)
(10)
(13)
PS-00541
(A) 3.0 L model (B) Except for 3.0 L model
Fluid leaking area Possible cause Corrective action

Insufficient tightening of flare nut, adhesion of Loosen and retighten. Replace if ineffec-
dirt, damage to flare or flare nut or eye bolt tive.
Leakage from connecting portions of
Poor insertion of hose or clamping Retighten or replace the clamp.
pipes and hoses, numbered with (1)
through (8) in figure Replace O-ring or gasket pipe or hose
Damaged O-ring or gasket with new one, if ineffective, replace the
gearbox also.
Leakage from hose (9) through (13) in Crack or damage in hose Replace with a new one.
figure Crack or damage in hose hardware Replace with a new one.
Leakage from surrounding of cast iron Damaged O-ring Replace the oil pump.
portion of oil pump (14) and (15) in
figure Damaged gasket Replace the oil pump.
Leakage from oil tank (16) and (17) in
Crack in oil tank Replace the oil tank.
figure
Damaged cap packing Replace the cap.
Leakage from filler neck (18) Crack in root of filler neck Replace the oil tank.
High fluid level Adjust the fluid level.
Leakage from surrounding of power
Damaged oil seal Replace the oil seal.
cylinder of gearbox (19) in figure
Leakage from control valve of gear- Damaged packing or oil seal Replace the problem parts.
box (20) and (21) in figure Damage in control valve Replace the control valve.
(22) Leakage from connecting por-
Insufficient tightening of connecting portion. Loosen and retighten.
tion of cooler pipe and hose.
PS-70
Pipe Assembly [RHD Model]
8. Pipe Assembly [RHD Model] 4) Remove the clamp E from the return hose and
pressure hose.
A: REMOVAL
crossmember support plate and jack-up plate.
• Large type (2)
(1)
(3)
(1)
PS-00445
• Small type
PS-00542
(1) Return hose

(2) Pressure hose
(3) Clamp E
5) Disconnect the return hose and pressure hose

(2)
(1) from gearbox.
(1) FS-00105

(2) Jack-up plate
3) Remove one pipe joint at the center of gearbox,

and connect the vinyl hose to the pipe and the joint.
Discharge the fluid by turning steering wheel fully
(2)
clockwise and counterclockwise. Discharge the flu-
id similarly from other pipes.
(1)
(1)
(2)
PS-00446
(1) Pipe A PS-00543
(2) Pipe B
(1) Return hose
(2) Pressure hose
PS-71
6) Remove the air intake duct. <Ref. to 9) Remove the hose bracket and take out the hose
IN(H4DOTC)-9, REMOVAL, Air Intake Duct.> assembly from vehicle.
Duct.>
7) Disconnect the suction hose and pressure hose
from the oil pump.
• Non-turbo model (2)
(1)
(1)
PS-00451
(1) Hose ASSY

(2) (2) Hose bracket
PS-00460 B: INSTALLATION
1) Temporarily tighten the bolt of hose bracket.
• Turbo model
(2)
(1)
(1)
PS-00451
(2) PS-00452
(1) Hose ASSY

(1) Suction hose
(2) Hose bracket
(2) Pressure hose
2) Install the resin clip to the pressure hose and
8) Disconnect the suction hose and return hose
suction hose.
from reservoir tank. Remove the oil cooler from oil
cooler bracket. CAUTION:
Align the installation position of the resin clip
(4)
with the protector edge of suction hose.
(3)
• Non-turbo model
(5) (2)
(1) (1)
(2)
PS-00482 (3)
(4)
(1) Reservoir tank
(2) Suction hose PS-00455
(3) Return hose
(4) Oil cooler (1) Resin clip
(5) Oil cooler bracket (2) Protector
(3) Suction hose
(4) Pressure hose
PS-72
• Turbo model • Non-turbo model
(2) (1)
(1)
(4)
(2)
(3)
PS-00456 PS-00460
(1) Resin clip (1) Suction hose

(2) Protector (2) Pressure hose
(3) Suction hose
• Turbo model
(4) Pressure hose
3) Connect the suction hose and return hose to res-

ervoir tank. Install the oil cooler to oil cooler brack-
et.
CAUTION: (1)
Firmly insert the resin clip of return hose to the
bracket.
(4)
(3)
(2) PS-00452
(5)
(1) Suction hose
(2) Pressure hose
(1)
(2)
PS-00482
(1) Reservoir tank

(2) Suction hose
(3) Return hose
(4) Oil cooler
4) Connect the suction hose and pressure hose to

the oil pump. Tighten the eye bolt of pressure hose.
Tightening torque:
39 N#m (4.0 kgf-m, 28.9 ft-lb)
PS-73
5) Temporarily connect the return hose and pres- 7) Tighten the joint nut.
sure hose to gearbox. Place the clamp E in the po-
Tightening torque:
sition shown in the figure, and tighten the bolt
15 N#m (1.5 kgf-m, 10.8 ft-lb)
temporarily.
8) Connect the pipe A and B to the four pipe joints
of gearbox.
Tightening torque:
13 N#m (1.3 kgf-m, 9.4 ft-lb)
(4)
(2) (1)
(2)
PS-00446
(3) (1)
(1) Pipe A
(2) Pipe B

jack-up plate.
PS-00467
11) Tighten the bolts which hold the hose bracket.
(1) Return hose Tightening torque:
(2) Pressure hose 13 N#m (1.3 kgf-m, 9.4 ft-lb)
(3) Approx. 27 mm (1.06 in)
(4) Clamp E
NOTE:
Ensure that the letter “8” on each clamp are diago-
(2)
nally opposite each other as shown in the figure.
(1) (1)
PS-00451
(2) (3)
(1) Hose ASSY
(2) Hose bracket

PS-00540 <Ref. to IN(H4DOTC)-9, INSTALLATION, Air In-
(1) Clamp E TION, Air Intake Duct.>
(2) Pipe C 13) Connect the battery ground cable to battery.
(3) Return hose 14) Feed the specified fluid.
6) Tighten the clamp E. CAUTION:
Tightening torque: otherwise vane pump might be seized up.
7.4 N#m (0.75 kgf-m, 5.4 ft-lb)
PS-74
15) Finally, check clearance between pipes or hos-

es as shown in the figure indicated in “General Di-
agnostic Table”. <Ref. to PS-89, INSPECTION OF
CLEARANCE, INSPECTION, General Diagnostic
Table.>
C: INSPECTION
Check all disassembled parts for wear, damage or other abnormalities. Repair or replace defective parts as
necessary.
Parts Maintenance Parts Corrective action
• O-ring fitting surface for damage
Pipe • Nut for damage Replace with a new one.
• Pipe for damage
Clamp • Clamps for weak clamping force Replace with a new one.
• Flare surface for damage
• Flare nut for damage
• Outer surface for cracks
Hose Replace with a new one.
• Outer surface for wear
• Clip for damage
• End coupling or adapter for deformation
CAUTION:
Although surface layer materials of rubber hoses have excellent weathering resistance, heat resis-
tance and resistance for low temperature brittleness, they are likely to be damaged chemically by
brake fluid, battery electrolyte, engine oil and automatic transmission fluid and their service lives are
to be very shortened. Wipe out immediately when the hoses are adhered with the fluids.
Since resistances for heat or low temperature brittleness are gradually declining according to time
accumulation of hot or cold conditions for the hoses and their service lives are shortening accord-
ingly, it is necessary to perform careful inspection frequently when the vehicle is used in hot weather
areas, cold weather areas and a driving condition in which many steering operations are required in
short time.
Particularly continuous work of relief valve over 5 seconds causes to reduce service lives of the hos-
es, the oil pump, the fluid, etc. due to over heat.
Excessive holding time of relief status Instruct customers.
Pressure hose burst Malfunction of relief valve Replace oil pump.
Poor connection Repair.
Forced out return hose Poor holding of clip Retighten.
Wrong layout, tensioned Replace hose.
Fluid bleeding out of hose Excessive play of engine due to deterioration of
Replace the parts if defective.
slightly engine mounting rubber
Improper stop position of pitching stopper Replace the parts if defective.
Replace.
Excessive holding time of relief status
Instruct customers.
Excessive tightening torque of return hose clip Replace.
Crack on hose Power steering fluid, engine oil, electrolyte adhere Replace.
on the hose surface Pay attention on service work.
Replace.
Too many times use in extremely cold weather
Instruct customers.
PS-75
NOTE:
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 main-
tenance.
(A) (B)
(10)
(11)
(22) (15) (16)

(14) (18)
(9)
(3) (17)
(6) (19)
(5)
(12)
(20)
(4) (1)
(2) (7)
(21) (8)
(13)
PS-00562
(A) 3.0 L model (B) Except for 3.0 L model
Fluid leaking area Possible cause Corrective action

Insufficient tightening of flare nut, adhesion of Loosen and retighten. Replace if ineffec-
dirt, damage to flare or flare nut or eye bolt tive.
Leakage from connecting portions of
Poor insertion of hose or clamping Retighten or replace the clamp.
pipes and hoses, numbered with (1)
through (10) in figure Replace O-ring or gasket pipe or hose
Damaged O-ring or gasket with new one, if ineffective, replace the
gearbox also.
Leakage from hose (11), (12) and Crack or damage in hose Replace with a new one.
(13) in figure Crack or damage in hose hardware Replace with a new one.
Leakage from surrounding of cast iron Damaged O-ring Replace the oil pump.
portion of oil pump (14) and (15) in
figure Damaged gasket Replace the oil pump.
Leakage from oil tank (16) and (17) in
Crack in oil tank Replace the oil tank.
figure
Damaged cap packing Replace the cap.
Leakage from filler neck (18) Crack in root of filler neck Replace the oil tank.
High fluid level Adjust the fluid level.
Leakage from surrounding of power
Damaged oil seal Replace the oil seal.
cylinder of gearbox (19) in figure
Leakage from control valve of gear- Damaged packing or oil seal Replace the problem parts.
box (20) and (21) in figure Damage in control valve Replace the control valve.
(22) Leakage from connecting por-
Insufficient tightening of connecting portion. Loosen and retighten.
tion of cooler pipe and hose.
PS-76
Oil Pump
9. Oil Pump • Turbo model
A: REMOVAL
2) Remove the air intake duct. <Ref. to
IN(H4DOTC)-9, REMOVAL, Air Intake Duct.> (1)
Duct.>
3) Remove the pulley belt cover.
4) Loosen the belt tension securing bolt and gener-
ator securing bolt, and then remove the power (2)
steering pump V-belt. PS-00459
(1) Suction hose

(2) Pressure hose
7) Remove the bolts which hold the power steering

pump bracket.
PS-00461
5) Disconnect the connector from power steering

pump switch.
6) Disconnect the pressure hose and suction hose
from oil pump.
PS-00188
CAUTION:
• Do not allow fluid to come into contact with 8) Place the oil pump bracket in a vise, and remove
pulley belt. the two bolts from the front side of oil pump.
• To prevent foreign matter from entering the CAUTION:
hose and pipe, cover the open ends with a When securing the oil pump bracket in a vice,
clean cloth. hold the oil pump bracket with the least possi-
• Non-turbo model ble force between two wood pieces.
(1)
(2)
PS-00460 PS-00128
(1) Suction hose 9) Remove the bolt from the rear side of oil pump.
(2) Pressure hose
PS-77
Oil Pump
10) Disassemble the oil pump and bracket by in- Tightening torque:
serting a flat tip screwdriver as shown in the figure. 37.3 N#m (3.8 kgf-m, 27.5 ft-lb)
PS-00129 PS-00137
B: INSTALLATION 2) Tighten the bolts which hold the power steering

1) Install the oil pump to bracket. pump 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 contact with oil pump
mounting surface.
CAUTION:
When securing the oil pump bracket on a vice,
hold the oil pump bracket with the least possi-
ble force between two wood pieces.
PS-00188
3) Interconnect the pressure hose and suction

hose.
Tightening torque:
Eye bolt
39 N#m (4.0 kgf-m, 28.9 ft-lb)
CAUTION:
PS-00135
If a hose is twisted at this step, take care the
hose may come into contact with some other
(1) Bushing parts.
(2) Nut • Non-turbo model
(3) 21 mm
(4) 14 mm
(5) Bolt (1)
(2) Tighten the bolt which holds the oil pump to

bracket.
Tightening torque:
15.7 N#m (1.6 kgf-m, 11.6 ft-lb) (2)
PS-00460
(1) Suction hose

(2) Pressure hose
PS-00128
PS-78
Oil Pump
• Turbo model
(1)
(2)
PS-00459
(1) Suction hose

(2) Pressure hose
4) Connect the connector to power steering pump

switch.
5) Install the V-belts to oil pump.
6) Check the tension of V-belt.
<Ref. to ME(H4SO 2.0)-39, INSPECTION, V-belt.>
7) Tighten the belt tension bolt.
Tightening torque:
25 N#m (2.5 kgf-m, 18.1 ft-lb)
8) Install the pulley belt cover.
<Ref. to IN(H4DOTC)-9, INSTALLATION, Air In-
TION, Air Intake Duct.>
11) Feed the specified power steering fluid. <Ref.
CAUTION:
otherwise vane pump might be seized up.
PS-79
Oil Pump
C: INSPECTION
1. BASIC INSPECTION
Perform the following inspection procedures and replace defective parts.
No. Parts INSPECTION Corrective action
(1) Crack, damage or oil leakage Replace the oil pump with a new one.
1 Oil pump (Exterior) Measure the radial play and axial play.
(2) Play of pulley shaft If any of these exceeds the service limit, replace the
oil pump with a new one.
(1) Damage Replace with a new one.
2 Pulley Measure the V ditch deflection.
(2) Bend If it exceeds the service limit, replace the pulley with a
new one.
Check the resistance to the rotation of pulley.
(1) Defect or burning of vane pump If it exceeds the service limit, replace the oil pump with
a new one.
3 Oil pump (Interior) Oil pump emits a noise that is markedly different in
(2) Bend in the shaft or damage to tone and loudness from a sound of a new oil pump
bearing when turning its pulley which is put around with a
string, replace the oil pump with a new one.
4 O-ring Crack or deterioration Replace with a new one.
5 Bracket Crack Replace with a new one.
2. SERVICE LIMIT Service limit:

Radial play (Direction )
service limit, replace with a new one. 0.4 mm (0.016 in) or less
CAUTION: (1)
• When securing the oil pump on a vice, hold
the oil pump with the least possible force be-
tween two wood pieces.
• Do not set outside of flow control valve or
pulley on a vice; otherwise outside or pulley
might be deformed. Select properly sized wood
pieces.
1) Play of the pulley shaft
P PS-00145
Condition:
P: When applying the force of 9.8 N (1.0 kgf, (1) Dial gauge
2.2 lb)
Axial play (Direction )
(1)
P
PS-00146
(1) Dial gauge
PS-80
Oil Pump
2) Ditch deflection of pulley • Put cloth at a place where fluid drops before
pressure gauge is installed. Wipe off spilt fluid thor-
Service limit:
oughly after the measurement.
1) Regular pressure measurement
NOTE: (1) Connect ST1, ST2 and ST3.
Read the value for one surface of V ditch, and then ST1 925711000 PRESSURE GAUGE
the value for another off the dial. ST2 34099AC020 ADAPTER HOSE B
ST3 34099AC010 ADAPTER HOSE A
(2) Remove the air intake duct.
(3) Disconnect the pipe C from pump.
(4) Using the gasket (Part No. 34621AC021)
and bolt (Part No. 34620AC010), install the ST2
to pump instead of pressure hose.
• Non-turbo model
PS-00147 (1)
(1) Dial gauge
3) Resistance to rotation of pulley

Service limit: (2)
Maximum load: 9.22 N (0.94 kgf, 2.07 lb) or
less
PS-00460
NOTE:
• A rather higher value may be indicated when pul- (1) Suction hose
ley starts turning. (2) Pressure hose
• Measure the load during rotation to make a judg-
ment. • Turbo model
(1)
(2)
PS-00459
PS-00148
(1) Suction hose

(1) Spring balance
(2) Pressure hose
3. HYDRAULIC PRESSURE (5) Install the ST3 to the end of pressure hose
NOTE: which is removed from pump.
• Be sure to complete all items aforementioned in (6) Replenish the power steering fluid up to
“INSPECTION”, prior to measuring hydraulic pres- specified level.
sure. Otherwise, pressure cannot be measured (7) Open the valve, and start the engine.
correctly. <Ref. to PS-85, 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 dam-
aged due to long keep of these conditions.
PS-81
Oil Pump
(8) Measure the regular pressure. 3) Measure working pressure.

ST1 925711000 PRESSURE GAUGE (1) Using the STs, measure the working pres-
ST2 34099AC020 ADAPTER HOSE B sure.
ST3 34099AC010 ADAPTER HOSE A (2) Open the valve.
(3) Measure the working pressure of control
valve by turning steering wheel from stop to
stop.
ST1 925711000 PRESSURE GAUGE
ST2 34099AC020 ADAPTER HOSE B
ST3 34099AC010 ADAPTER HOSE A
PS-00152
(1) Valve
Service limit:
981 kPa (10 kg/cm2, 142 psi) or less
(9) If it is not within the specified value, replace PS-00152
the troubled part caused by following symptoms.
(Pipe or hose clogged, leaks from fluid line, and (1) Valve
mixture of foreign matters in fluid line)
2) Measure the relief pressure. Service limit:
(1) Using the STs, measure the relief pressure. 7,650 — 8,330 kPa (78 — 85 kg/cm2, 1,110 —
(2) Close the valve. 1,208 psi)
(3) Measure the relief pressure. (4) If it is not within the specified value, mea-
ST1 925711000 PRESSURE GAUGE sure the steering effort. <Ref. to PS-88, MEA-
ST2 34099AC020 ADAPTER HOSE B SUREMENT OF STEERING EFFORT,
ST3 34099AC010 ADAPTER HOSE A INSPECTION, General Diagnostic Table.> If it is
not within specified value, replace the control
valve itself or control valve and pinion as a sin-
gle unit with new ones.
PS-00153
(1) Valve
Service limit:
Non-turbo model (Except for 3.0 R model):
6,767 — 7,453 kPa
(69 — 76 kg/cm2, 981 — 1,081 psi)
Turbo model:
7,350 — 8,036 kPa
(75 — 82 kg/cm2, 1,067 — 1,165 psi)
3.0 R model:
8,300 — 9,000 kPa
(85 — 92 kg/cm2, 1,204 — 1,305 psi)
(4) If it is not within the specified value, replace
the oil pump.
PS-82
Reservoir Tank
10.Reservoir Tank C: INSPECTION

Check the reservoir tank for cracks, breakage and
A: REMOVAL damage. If a failure is found, replace the reservoir
1) Drain fluid from the reservoir tank. tank.
2) Disconnect the hose from reservoir tank.
CAUTION:
To prevent foreign matter from entering the
hose and pipe, cover the open ends of them
with a clean cloth.
(4)
(3)
(5)
(1)
(2)
PS-00482
(1) Reservoir tank

(2) Suction hose
(3) Return hose
(4) Oil cooler
3) Remove the reservoir tank from body.

B: INSTALLATION
1) Install the reservoir tank to body.
Tightening torque:
13 N#m (1.3 kgf-m, 9.4 ft-lb)
2) Connect the hose to reservoir tank.
(4)
(3)
(5)
(1)
(2)
PS-00482
(1) Reservoir tank

(2) Suction hose
(3) Return hose
(4) Oil cooler
3) Feed the power steering fluid to specified level.

<Ref. to PS-84, Power Steering Fluid.>
PS-83
Power Steering Fluid
11.Power Steering Fluid 6) If turning the steering wheel in low fluid level
condition, air will be sucked in pipe. In this case,
A: SPECIFICATION leave it about half an hour and then do the step 5)
again.
Recommended power steering fluid Manufacturer
7) Start the engine and let it idle.
B.P.
8) Continue to turn the steering wheel slowly from
CALTEX lock to lock again until the bubbles stop appearing
CASTROL on oil surface while keeping the fluid at the level in
ATF DEXRON III or equivalent
MOBIL Step 4).
SHELL Normally bubbles stop appearing after three times
TAXACO turning of steering wheel from lock to lock.
9) In case bubbles do not stop appearing in the
B: INSPECTION tank, leave it about half an hour and then do the
1) Check the power steering fluid for deterioration step 4) all over again.
and contamination. If the fluid is highly deteriorated 10) Lower the vehicle, and then idle the engine.
or contaminated, drain it and refill with new fluid. 11) Continue to turn the steering wheel from lock to
2) Check the joints and units for oil leakage. If any lock until the bubbles stop appearing and change of
oil leaks are found, repair or replace the applicable the fluid level is within 3 mm (0.12 in).
part. 12) In case the following happens, leave it about
3) Inspect the fluid level on flat and level surface half an hour and then do step 8) to 11) again.
with engine “OFF” by indicator of reservoir tank. (1) The fluid level changes over 3 mm (0.12 in).
If the level is at “MIN.” point or below, add fluid to (2) Bubbles remain on the upper surface of the
keep the level in the specified range of the indica- fluid.
tor. If at “MAX.” point or above, drain fluid by using (3) Grinding noise is generated from oil pump.
a syringe or the like. 13) Check the fluid leakage after turning steering
(1) Check at power steering fluid temperature wheel from lock to lock with engine running.
20!C (68!F); read the fluid level on the “COLD”
side.
(2) Check at power steering fluid temperature
80!C (176!F); read the fluid level on the “HOT”
side.
HOT MAX
COLD MAX
HOT MIN
COLD MIN
PS-00463
C: REPLACEMENT
2) Remove the crossmember support.
3) Remove the pipe joint in the center of gearbox,
and connect the vinyl hose to the pipe and joint.
Wipe fluid off while turning the steering wheel.
4) Add the specified fluid to reservoir tank at MAX
level.
5) Continue to turn the steering wheel slowly from
lock to lock until the bubbles stop appearing on oil
surface while keeping the fluid at the level in the
Step 4).
PS-84

A: INSPECTION
• Heavy steering effort in all 1. Pulley belt
ranges • Unequal length of pulley belts
• Heavy steering effort at • Adhesion of oil and grease
stand still • Loose or damage of pulley belt
Adjust or replace.
• Steering wheel surges when • Poor uniformity of pulley belt cross section
turning. • Pulley belt touches to pulley bottom
• Poor revolution of pulleys except oil pump pulley
• Poor revolution of oil pump pulley
2. Tire and wheel
• Improper tires out of specification*1
Replace or reinflate.
• Improper wheel out of specification*1
• Tires not properly inflated
3. Fluid
• Low fluid level
• Aeration Refill, bleed air, replace or
• Dust mix instruct customer.
• Deterioration of fluid
• Poor warming-up of fluid *2
4. Idle speed
• Lower idle speed
Adjust or instruct customer.
• Excessive drop of idle speed at start or at turning steering
wheel *3
5. Measure hydraulic pressure. <Ref. to PS-80, INSPECTION,
Replace the problem parts.
Oil Pump.>
6. Measure steering effort. <Ref. to PS-88, MEASUREMENT
OF STEERING EFFORT, INSPECTION, General Diagnostic Adjust or replace.
Table.>
• Vehicle leads to one side or 1. Fluid line
the other • Folded hose Correct or replace.
• Poor return of steering wheel • Flattened pipe
to center 2. Tire and wheel
• Steering wheel surges when • Flat tire
turning. • Mix use of different tires
• Mix use of different wheels Adjust, fix or replace.
• Abnormal wear of tire
• Unbalance of remained grooves
• Unbalance of tire pressure
3. Front alignment
• Improper or unbalance caster
Adjust or retighten.
• Improper or unbalance toe-in
• Loose connection of suspension
4. Others
• Damaged joint assembly Replace, adjust or instruct cus-
• Unbalanced height tomer.
• Unbalanced weight
5. Measure steering effort. <Ref. to PS-88, MEASUREMENT
OF STEERING EFFORT, INSPECTION, General Diagnostic Adjust or replace.
Table.>
*1 If the tires or wheels are wider than specifications, the load to power steering system is increased. 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.
PS-85
*3 In cold weather or with insufficient warm-up of engine, steering effort may be heavy due to excessive drop of idling when turn-
ing steering wheel. In this case, it is recommended to start the vehicle with increasing engine speed than usual. Then if steering
effort reduces normally, there is no abnormal thing.
1. NOISE AND VIBRATION

CAUTION:
Do not keep the relief valve operated over five 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 char-
acteristic 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 turning the steering wheel with service brake and/or parking brake applied, the noise is generated
by creaking between disc and pads. However this does not indicate abnormal function in 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 be-
cause of combined conditions, i.e., road surface and tire surface, engine speed and turning speed of steering
wheel, fluid temperature and braking condition.
These phenomena do not indicate there are some abnormal functions in the system.
Confirm the vibration by turning the steering wheel repeatedly at various speeds from slow to rapid step by
step with parking brake applied on concrete road and in “D” range for AT model.
Relief valve emits operating sound when steering wheel is
completely turned in either direction. (Do not keep this Normal Operation
Hiss noise (continuous) condition over five seconds.)
While engine is running.
Relief valve emits operating sound when steering wheel is
Replace the oil pump.
not turned. This means that the relief valve is defective.
Check the clearance.
Correct if necessary.
Interference with adjacent parts
<Ref. to PS-69, INSPECTION,
Pipe Assembly [LHD Model].>
Loosened installation of oil pump, oil tank, pump bracket,
Rattling noise (intermittent) Retighten.
gearbox or crossmember
While engine is running.
Loosened installation of oil pump pulley or other pulley(s) Retighten.
Loosened linkage or play of steering or suspension Loos-
Retighten or replace.
ened tightening of joint or steering column
Replace the faulty parts of the
Sound generates from the inside of gearbox or oil pump.
gearbox or oil pump.
Knocking Excessive backlash
Adjust and retighten.
When turning steering wheel in Loosened lock nut for adjusting backlash
both directions with small angle
repeatedly at engine ON or OFF. Loosened tightening or play of tie-rod, tie-rod end Retighten or replace.
Inspect and retighten the fluid
Vane pump aeration line connection.
Grinding noise (continuous) Refill the fluid and vent air.
While engine is running. Vane pump seizing Replace the oil pump.
Pulley bearing seizing of oil pump Replace the oil pump.
Folded hose, flattened pipe Replace.
PS-86

Maladjustment of pulley belt
Adjust or replace.
Squeal, squeak (intermittent or Damaged or charged pulley belt
(Replace two belts as a set.)
continuous) Unequal length of pulley belts
While engine is running. Runout or defacement of V-groove surface of oil pump pul-
Clean or replace.
ley
Fix the wrong part causing aera-
Fluid aeration tion.
Replace the fluid and vent air.
Sizzling noise (continuous) Damaged pipe of gearbox Replace the pipe.
While engine is running. Abnormal inside of hose or pipe
Rectify or replace.
Flattened hose or pipe
Abnormal inside of oil tank Replace.
Removed oil tank cap Install cap.
Whistle (continuous) Replace the faulty parts of the
Abnormal pipe of gearbox or abnormal inside of hose
While engine is running. gearbox or hose.
Loosened installation of oil pump, oil pump bracket Retighten.
Whine or growl (intermittent or Replace the oil pump or hose, if
continuous) Abnormal inside of oil pump, hose the noise can be heard when
While engine is running with/ running as well as stand still.
without steering turned. Remove the power steering pul-
Torque converter growl, air conditioner compression growl
ley belt and confirm.
Replace the faulty parts of gear-
Abnormal inside of gearbox
Grinding noise (continuous) box.
While engine is running with the Abnormal bearing for steering shaft Apply grease or replace.
steering turned. Generates when turning steering wheel with brake (ser- If the noise goes off when brake
vice or parking) applied. is released, it is normal.
Too low engine speed Adjust and instruct customers.
Fix the wrong part.
Vibration Vane pump aeration
Vent air.
While engine is running with/
without steering turned. Replace the oil pump, faulty parts
Damaged valve in oil pump, gearbox
of gearbox.
Looseness of play of steering, suspension parts Retighten.
PS-87
2. MEASUREMENT OF STEERING EFFORT
Step Check Yes No

1 CHECK STEERING EFFORT. Is the steering effort less than Go to step 2. Adjust the back-
1) Stop the vehicle on a concrete road. 29.4 N (3.0 kgf, 6.6 lb)? lash.
2) Start the engine.
4) Install a spring scale on the steering wheel.
5) Pull the spring scale at a right angle to the
steering wheel, and measure both right and left
steering wheel efforts.
NOTE:
When turning the steering more quickly than
necessary from a direction to the other direction
at an engine speed over 2,000 rpm, steering ef-
fort may be heavy. This is caused by flow char-
acteristic of oil pump and is not defective.
2 CHECK STEERING EFFORT. Is the steering effort less than Go to step 3. Perform adjust-
1) Stop the engine. 294.2 N (30 kgf, 66.2 lb)? ment.
2) Pull the spring scale at a right angle to the
steering wheel, and measure both right and left
steering wheel efforts.
3 CHECK STEERING WHEEL EFFORT. Is steering effort less than 2.26 Go to step 4. Check, adjust and
1) Remove the universal joint. N (0.23 kgf, 0.51 lb)? replace if neces-
2) Measure steering wheel effort. sary.
4 CHECK STEERING WHEEL EFFORT. Is the difference of steering Go to step 5. Check, adjust and
Measure steering wheel effort. effort between clockwise and replace if neces-
counterclockwise less than sary.
20%?
5 CHECK UNIVERSAL JOINT. Is the folding torque less than Go to step 6. Replace with a
Measure the folding torque of the joint (yoke of 7.3 N (0.74 kgf, 1.64 lb)? new one.
steering column side). <Ref. to PS-21,
INSPECTION, Universal Joint.>
6 CHECK UNIVERSAL JOINT. Is the folding torque less than Go to step 7. Replace with a
Measure the folding torque of the joint (yoke of 3.8 N (0.39 kgf, 0.86 lb)? new one.
gearbox side). <Ref. to PS-21, INSPECTION,
Universal Joint.>
7 CHECK FRONT WHEEL. If the front wheels have Inspect, readjust Go to step 8.
Check the front wheel. unsteady revolution or rattling and replace if nec-
and brake for dragging? essary.
8 CHECK TIE-ROD ENDS. If the tie-rod ends of suspen- Inspect and Go to step 9.
Remove the tie-rod ends. sion have unsteady revolution replace if neces-
or rattling? sary.
9 CHECK BALL JOINT. If the ball joints of suspension Inspect and Go to step 10.
Remove the ball joint. have unsteady revolution or replace if neces-
rattling? sary.
10 CHECK GEARBOX. Is the rotating resistance of Go to step 11. Readjust the back-
Measure the rotating of gearbox. steering gearbox less than lash, and if ineffec-
<Ref. to PS-44, TURNING RESISTANCE OF 10.5 N (1.1 kgf, 2.4 lb)? Is the tive, replace the
GEARBOX, INSPECTION, Steering Gearbox difference between clockwise faulty parts.
[LHD Model].> and counterclockwise less than
20%?
11 CHECK GEARBOX. Is the sliding resistance of Steering effort is Readjust the back-
Measure the sliding of gearbox. steering gearbox less than 314 normal. lash, and if ineffec-
<Ref. to PS-43, SERVICE LIMIT, INSPEC- N (32 kgf, 71 lb)? Is the differ- tive, replace the
TION, Steering Gearbox [LHD Model].> ence between right and left faulty parts.
sliding resistances less than
20%?
PS-88
3. INSPECTION OF CLEARANCE
This table lists various clearances that must be correctly adjusted to ensure the normal vehicle driving with-
out interfering noise, or any other faults.
LOCATION Minimum allowance mm (in)
(1) Crossmember-to-Hose ASSY 3 (0.12)
(2) Front exhaust pipe-to-Hose ASSY (Turbo model) 15 (0.59)
(3) Front frame side-to-Hose ASSY 10 (0.39)
(4) Turbo cover-to-Hose ASSY (Turbo model) 10 (0.39)
(5) Master cylinder-to-Return hose (Turbo model) 10 (0.39)
(6) Master cylinder-to-Hose clip (Model with vehicle dynamics control (VDC)) 10 (0.39)
(7) VDC H/U-to-Hose ASSY (Model with vehicle dynamics control (VDC)) 5 (0.20)
(8) Air cleaner-to-Hose ASSY (Turbo model) 5 (0.20)
(9) Air boot-to-Hose ASSY 10 (0.39)
(10) Protector-to-Hose ASSY (Turbo model, DOHC non-turbo model) 10 (0.39)
(11) Blow-by-to-Hose ASSY (Turbo model) 8 (0.31)
(12) Over flow hose-to-Hose ASSY (Turbo model) 8 (0.31)
(13) Brake pipe-to-Return hose (Model with ABS) 10 (0.39)
(14) Front suspension bracket-to-Return hose 5 (0.20)
(15) Front wheel apron-to-Return hose 5 (0.20)
(16) VDC H/U bracket-to-Suction hose (Model with vehicle dynamics control (VDC)) 5 (0.20)
(17) Air cleaner case-to-Suction hose 5 (0.20)
(18) Air intake duct-to-Suction hose (Turbo model) 10 (0.39)
(19) Air duct-to-Suction hose (Turbo model) 10 (0.39)
(20) Front wheel apron-to-Reservoir tank 5 (0.20)
(21) VDC H/U-to-Reservoir tank (Model with vehicle dynamics control (VDC)) 5 (0.20)
(22) Valve housing-to-DOJ (MT model) 12 (0.47)
(23) Valve housing-to-Crossmember (Hole) 1 (0.04)
(24) Bracket-to-Crossmember 1 (0.04)
(25) Cylinder-to-Crossmember 5 (0.20)
(26) Elbow-to-Crossmember 1 (0.04)
(27) Cylinder-to-Exhaust pipe 18 (0.71)
(28) Universal joint coupling-to-Turbo cover (Turbo model) 15 (0.59)
(29) Universal joint column side yoke-to-Master cylinder (Closest approach point when uni-
5 (0.20)
versal joint turns by 360!) (OUTBACK model)
(30) Cruise control-to-Hose ASSY (Model with cruise control) 10 (0.39)
(31) Universal joint coupling-to-ATF level gauge (LHD model) 10 (0.39)
(32) Boot-to-Exhaust pipe (LHD model) 18 (0.71)
(33) Return hose-to-Pressure hose No contact between hoses
PS-89
• LHD model
(19)
(12) (18)
(17)
(8),(9)
(10),(11),(16)
(27)
(24) (26) (1) (7) (21) (20)
(32) (2)
(3) (13),(14)
(22) (6) (15)

(23) (25)
(5)
(28),(31) (4) (33)
(30)
(29)
PS-00515
• RHD model
(12) (19) (18)
(17)
(8),(9)
(10),(11),(16)
(26) (24) (27) (1) (2)
(7) (21) (20)
(3)
(13),(14)
(15)
(6)
(25)
(23) (5)
(22)
(4)
(28) (33)
(29)
PS-00514
PS-90

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2004 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX

WHEEL AND TIRE SYSTEM WT

POWER ASSISTED SYSTEM PS

All information, illustration and specifi-

FUJI HEAVY INDUSTRIES LTD. G2320GE6

(16) (1) (2)

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

1. WHEEL ARCH HEIGHT 3) Set the steering wheel in a straight-ahead posi-

(4) (5) (1)

Wheel arch height standard value mm (in) (Tolerance "12 mm)

2. CAMBER 3) Turn the camber adjusting bolt so that the cam-

(1) Alignment gauge

3) Measure the camber angle in accordance with

Camber (Differences between (3)

2) Loosen the two self-locking nuts located at the

(1) Alignment gauge

(1) Lock nuts

5. FRONT WHEEL TOE-IN

(1) Adjusting bolt

3) Tighten a new self-locking nut.

Less than 30$ when “L” is less than 23 mm (3)

Thrust angle: r = (& ! ))/2

(1) Center line of loci (front axle)

3. Front Crossmember Support

(1) Crossmember support plate

4. Front Stabilizer • Stabilizer bracket has an orientation, so install it

(1) Front side of vehicle

5. Front Ball Joint NOTE:

5) Extract the ball joint from housing.

(3) Determine the plays from the following for-

(4) Replace with a new one when the play ex-

6. Front Arm CAUTION:

(1) Vehicle body

C: DISASSEMBLY 2) Using the ST and a press, remove the rear bush-

(1) Put an alignment mark. FS-00102

(2) Recess portion

(1) Alignment mark

7. Front Strut 6) Remove the three nuts securing strut mount to

4) Remove the bolt securing ABS wheel speed

C: DISASSEMBLY (5) Repeat 3 to 4 times from the step (1).

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

(1) Diameter is small (Upper part)

2) Check for presence of air FS-00043

8) Install the strut mount to piston rod, and tighten a

Play limit (P1 + P2):

(1) 40 mm (1.57 in)

8. Front Crossmember B: INSTALLATION

9. General Diagnostic Table

2. POOR RIDE COMFORT

WHEEL AND TIRE SYSTEM WT

POWER ASSISTED SYSTEM PS

All information, illustration and specifi-

FUJI HEAVY INDUSTRIES LTD. G2320GE6

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

3. Rear Stabilizer 2) Always tighten the stabilizer bushing in the state

3) Remove the stabilizer bracket.

(1) Paint mark

8) Remove the stabilizer link from rear arm.