Mechanical Components.pdf - Ken Gilbert

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2. Wheel Alignment Front Rear 2200 cc 2500 cc Sedan, Coupe Wagon OUTBACK Coupe Sedan Camber (tolerance: ±0°30′) 0° 0° 0° −0°25′ −0°25′ Caster (common difference: ±1°) 3° 3° 3° 0±3 mm(0±0.12 in) 3°05′ 3°05′ Toe-in Each toe-in angle: −0°09′ [when toe-in is −3 mm (−0.12 in)] Each toe-out angle: 0°09′ [when toe-out is 3 mm (0.12 in)] Kingpin angle 14° 14° 14° 14° 14° Wheel arch height [tolerance: +12 / −24 mm ( +0.47 / − 0.94 in)] Camber (tolerance: ±0°45′) 391 mm (15.39 in) 391 mm (15.39 in) 394 mm (15.51 in) 371 mm (14.61 in) 371 mm (14.61 in) −0°55′ −0°55′ −0°55′ −1°10′ −1°10′ Toe-in 0±3 mm(0±0.12 in) Each toe-in angle: 0°±18′ Wheel arch height [tolerance: +12 / −24 mm ( +0.47 / − 0.94 in)] Thrust angle (tolerance: 0°±20′) 379 mm (14.92 in) NOTE: Front and rear toe-ins and front camber can be adjusted. If toe-in or camber tolerance exceeds specifications, adjust toe-in and camber to the specification. The other items indicated in the specification table cannot be adjusted. If the other items exceeds specifications, check suspension parts and connections for deformities; and replace with new ones as required. SPECIFICATION AND SERVICE DATA B4M2250A 379 mm (14.92 in) 386 mm (15.20 in) 363 mm (14.29 in) 363 mm (14.29 in) 0° 0° 0° 0° 0° 3 [S200] 4-1 2. Wheel Alignment
4-1 [C100] COMPONENT PARTS 1. Front Suspension 1. Front Suspension (1) Crossmember (2) Bolt ASSY (3) Housing (4) Washer (5) Stop rubber (Rear) (6) Rear bushing (7) Stop rubber (Front) (8) Ball joint (9) Transverse link (10) Cotter pin (11) Front bushing (12) Stabilizer link (13) Clamp (14) Bushing (15) Stabilizer (16) Jack-up plate (Except 2500 cc MT model) (17) Dust seal (18) Strut mount (19) Spacer (20) Upper spring seat (21) Rubber seat (22) Dust cover (23) Helper (24) Coil spring (25) Damper strut (26) Adjusting bolt (27) Castle nut (28) Self-locking nut (29) Dynamic damper (2500 cc MT model) 4 (30) Jack-up plate (2500 cc MT model) H4M1287A
Page 1: 4-1 [S100] SPECIFICATION AND SERVIC
Page 5 and 6: 4-1 [C200] COMPONENT PARTS 2. Rear
Page 7 and 8: 4-1 [W1B1] SERVICE PROCEDURE 1. On-
Page 13 and 14: 4-1 [W2A0] SERVICE PROCEDURE 2. Fro
Page 15 and 16: 4-1 [W2E0] SERVICE PROCEDURE 2. Fro
Page 19 and 20: 4-1 [W4C2] SERVICE PROCEDURE 4. Fro
Page 23 and 24: 4-1 [W6B0] SERVICE PROCEDURE 6. Fro
Page 25 and 26: 4-1 [W7B1] SERVICE PROCEDURE 7. Rea
Page 27 and 28: 4-1 [W7E0] SERVICE PROCEDURE 7. Rea
Page 29 and 30: 4-1 [W8B0] SERVICE PROCEDURE 8. Lat
Page 31 and 32: 4-1 [W8E0] SERVICE PROCEDURE 8. Lat
Page 33 and 34: 4-1 [W9B0] SERVICE PROCEDURE 9. Rea
Page 35 and 36: 4-1 [W10B0] SERVICE PROCEDURE 10. R
Page 37 and 38: 4-1 [W11C0] SERVICE PROCEDURE 11. R
Page 39 and 40: 4-1 DIAGNOSTICS MEMO: 40
Page 41 and 42: 3. Front Drive Shaft Assembly Model
Page 43 and 44: 1. Front Axle (1) Baffle plate (SFJ
Page 45 and 46: 1. Front Axle A: REMOVAL 1) Disconn
Page 47 and 48: 3) Remove disc cover from housing.
Page 49 and 50: 11) Attach hub to ST1 securely. 12)
Page 51 and 52: 8) Disconnect parking brake cable e
Page 53 and 54:
12) Remove bolts which secure later
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3) Clean housing interior completel
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10) Bleed air from brake system. 1
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2. REAR DRIVE SHAFT 1) Disconnect g
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8) Place alignment mark on trunnion
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3) Apply a coat of specified grease
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3) Insert DOJ cage onto shaft. NOTE
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CAUTION: Use a new axle nut. Alwa
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5. Steel Wheel and Tire A: INSPECTI
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8. Tire Rotation If tires are maint
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4-3 [S1A0] SPECIFICATIONS AND SERVI
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4-3 [S1C0] SPECIFICATIONS AND SERVI
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4-3 [C200] COMPONENT PARTS 2. Power
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4-3 [C300] COMPONENT PARTS 3. Power
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4-3 [W2B0] SERVICE PROCEDURE 2. Til
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4-3 [W2D0] SERVICE PROCEDURE 2. Til
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4-3 [W3A0] SERVICE PROCEDURE 3. Ste
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4-3 [W3C0] SERVICE PROCEDURE 3. Ste
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4-3 [W3C3] SERVICE PROCEDURE 3. Ste
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4-3 [W3D0] SERVICE PROCEDURE 3. Ste
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4-3 [W3F0] SERVICE PROCEDURE 3. Ste
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4-3 [W4B0] SERVICE PROCEDURE 4. Con
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4-3 [W4C2] SERVICE PROCEDURE 4. Con
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4-3 [W4D1] SERVICE PROCEDURE 4. Con
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4-3 [W5A0] SERVICE PROCEDURE 5. Pip
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4-3 [W5C0] SERVICE PROCEDURE 5. Pip
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4-3 [W6A0] SERVICE PROCEDURE 6. Oil
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4-3 [W6B1] SERVICE PROCEDURE 6. Oil
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4-3 [W6D0] SERVICE PROCEDURE 6. Oil
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4-3 [W6E0] SERVICE PROCEDURE 6. Oil
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4-3 [W7A0] SERVICE PROCEDURE 7. Pow
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4-3 [K1B0] DIAGNOSTICS 1. Power Ste
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4-3 [K1C0] DIAGNOSTICS 1. Power Ste
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4-3 [K1C0] DIAGNOSTICS 1. Power Ste
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4-3 [K1E0] DIAGNOSTICS 1. Power Ste
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4-3 [K1F0] DIAGNOSTICS 1. Power Ste
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4-3 DIAGNOSTICS MEMO: 54
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2. 2500 cc MODEL SPECIFICATIONS AND
Page 129 and 130:
1. Front Disc Brake A: EXCEPT 2500
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2. Rear Disc Brake (1) Caliper body
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4. Master Cylinder A: WITH ABS VEHI
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5. Brake Booster A: MODELS WITH ABS
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B: ABS CONTROL MODULE AND HYDRAULIC
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1. Front Disc Brake A: ON-CAR SERVI
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5) Remove disc rotor from hub. NOTE
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1) Clean mud and foreign particles
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1) Clean mud and foreign particles
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F: INSTALLATION 1) Install disc rot
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B: REMOVAL (1) Caliper body (2) Air
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E: ASSEMBLY 1) Clean caliper body i
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NOTE: If it is difficult to remove
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D: ASSEMBLY 1. WHEEL CYLINDER 1) Cl
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4. Parking Brake (Rear Disc Brake)
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D: ADJUSTMENT 1. SHOE CLEARANCE 1)
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6. Brake Booster A: REMOVAL 1) Remo
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3. OPERATION CHECK 1) With engine o
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7) While holding hexagonal part of
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11) Remove bolt and clamp from rear
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11. Brake Fluid A: REPLACEMENT CAUT
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CAUTION: Do not disassemble or adju
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3. OUTPUT VOLTAGE Output voltage ca
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14. ABS Control Module and Hydrauli
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9) Remove air bleeder screws from t
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SERVICE PROCEDURE 4. CONDITIONS FOR
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15B2 : CHECK G SENSOR. Measure volt
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1. Entire Brake System DIAGNOSTICS
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4-5 [S100] SPECIFICATIONS AND SERVI
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4-5 [C1A2] COMPONENT PARTS 1. Pedal
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4-5 [W1A1] SERVICE PROCEDURE 1. Ped
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4-5 [W1A4] SERVICE PROCEDURE 1. Ped
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4-5 [W1C1] SERVICE PROCEDURE 1. Ped
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4-5 [W1F1] SERVICE PROCEDURE 1. Ped
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4-5 [W3A0] SERVICE PROCEDURE 3. Acc
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4-5 [K100] DIAGNOSTICS 1. Pedal Sys
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1. Heater Unit (1) Vent door (2) DE
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3. Control Unit (1) Temperature con
Page 205 and 206:
3. Blower Motor Assembly A: REMOVAL
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4-7 [S100] SPECIFICATIONS 1. Specif
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4-7 [C200] COMPONENT PARTS 2. Intak
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4-7 [W1A0] SERVICE PROCEDURE 1. Saf
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4-7 [W300] SERVICE PROCEDURE 3. Too
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4-7 [W300] SERVICE PROCEDURE 3. Too
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4-7 [W4D0] SERVICE PROCEDURE 4. O-r
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4-7 [W600] SERVICE PROCEDURE 6. Dis
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4-7 [W7C0] SERVICE PROCEDURE 7. Eva
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4-7 [W8A0] SERVICE PROCEDURE 8. Lea
Page 225 and 226:
4-7 [W8A7] SERVICE PROCEDURE 9. Lub
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4-7 [W11B0] SERVICE PROCEDURE 11. C
Page 229 and 230:
4-7 [W11C0] SERVICE PROCEDURE 11. C
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4-7 [W13A0] SERVICE PROCEDURE 13. R
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4-7 [W15A0] SERVICE PROCEDURE 15. C
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4-7 [W17B0] SERVICE PROCEDURE 18. P
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4-7 [K200] DIAGNOSTICS 2. Performan
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4-7 [K200] DIAGNOSTICS 2. Performan
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4-7 [K400] DIAGNOSTICS 4. Compresso
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4-7 [K600] DIAGNOSTICS 6. Radiator
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4-7 [K800] DIAGNOSTICS 8. Condenser
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B: ELECTRICAL INSPECTION DIAGNOSTIC
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B4M1226B H4M1304A S4M0055A B4M2201C
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MEMO: DIAGNOSTICS 7 [T400] 4-4 4. S
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ABS sensor*2 (Wheel speed sensor) C
Page 255 and 256:
6. Diagnostics Chart for On-board D
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Behavior of vehicle a) Directional
Page 259 and 260:
1. CALLING UP A TROUBLE CODE 1) Tak
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MEMO: [T6D2] 4-4 DIAGNOSTICS 6. Dia
Page 263 and 264:
7A1 : CHECK IF OTHER WARNING LIGHTS
Page 265 and 266:
7A10 : CHECK POOR CONTACT IN CON- N
Page 267 and 268:
7B1 : CHECK INSTALLATION OF ABSCM&H
Page 269 and 270:
7B10 : CHECK WIRING HARNESS. Measur
Page 271 and 272:
7C1 : CHECK DIAGNOSIS TERMINAL. Mea
Page 273 and 274:
8. Diagnostics Chart with Trouble C
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8E1 : CHECK FRONT ABS SENSOR. 1) Tu
Page 277 and 278:
DIAGNOSTICS 8E8 : CHECK BATTERY SHO
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DIAGNOSTICS 8E16 : CHECK GROUND SHO
Page 281 and 282:
8I1 : CHECK INSTALLATION OF ABS SEN
Page 283 and 284:
8I10 : CHECK RESISTANCE OF FRONT AB
Page 285 and 286:
8I16 : CHECK GROUND SHORT OF HAR- N
Page 287 and 288:
MEMO: DIAGNOSTICS [T8I23] 4-4 8. Di
Page 289 and 290:
8J1 : CHECK IF THE WHEELS HAVE TURN
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MEMO: DIAGNOSTICS [T8J14] 4-4 8. Di
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8N1 : CHECK INPUT VOLTAGE OF ABSCM&
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8R1 : CHECK INPUT VOLTAGE OF ABSCM&
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8S1 : CHECK GROUND CIRCUIT OF ABSCM
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8T1 : CHECK GENERATOR. 1) Start eng
Page 301 and 302:
MEMO: DIAGNOSTICS [T8T7] 4-4 8. Dia
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8U1 : CHECK SPECIFICATIONS OF THE A
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8U10 : CHECK ANY OTHER TROUBLE CODE
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8V1 : CHECK INPUT VOLTAGE OF ABSCM&
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MEMO: DIAGNOSTICS [T8V6] 4-4 8. Dia
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8W1 : CHECK INPUT VOLTAGE OF ABSCM&
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MEMO: DIAGNOSTICS [T8W8] 4-4 8. Dia
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8X1 : CHECK STOP LIGHTS COME ON. De
Page 317 and 318:
8Y1 : CHECK ALL FOUR WHEELS FOR FRE
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DIAGNOSTICS 8Y8 : CHECK GROUND SHOR
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MEMO: DIAGNOSTICS [T8Y14] 4-4 8. Di
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6. FREEZE FRAME DATA NOTE: Data st
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B: LIST OF DIAGNOSTIC TROUBLE CODE
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10C1 : CHECK IGNITION SWITCH. : Is
Page 329 and 330:
MEMO: DIAGNOSTICS 85 [T10C9] 4-4 10
Page 331 and 332:
10D1 : CHECK WIRING HARNESS. 1) Tur
Page 333 and 334:
MEMO: DIAGNOSTICS 89 [T10D6] 4-4 10
Page 335 and 336:
WIRING DIAGRAM: DIAGNOSTICS 91 [T10
Page 337 and 338:
10H7 : CHECK POOR CONTACT IN CON- N
Page 339 and 340:
DIAGNOSTICS 10H16 : CHECK HARNESS/C
Page 341 and 342:
10H23 : CHECK HUB RUNOUT. Measure h
Page 343 and 344:
MEMO: DIAGNOSTICS 99 [T10H28] 4-4 1
Page 345 and 346:
10L1 : CHECK OUTPUT OF ABS SENSOR U
Page 347 and 348:
10L13 : CHECK ABS SENSOR SIGNAL. DI
Page 349 and 350:
DIAGNOSTICS 10L21 : CHECK HARNESS/C
Page 351 and 352:
10L28 : CHECK SHIELD CIRCUIT. DIAGN
Page 353 and 354:
10M1 : CHECK IF THE WHEELS HAVE TUR
Page 355 and 356:
MEMO: DIAGNOSTICS 111 [T10M14] 4-4
Page 357 and 358:
10Q1 : CHECK INPUT VOLTAGE OF ABSCM
Page 359 and 360:
10U1 : CHECK INPUT VOLTAGE OF ABSCM
Page 361 and 362:
10V1 : CHECK GROUND CIRCUIT OF ABSC
Page 363 and 364:
10W1 : CHECK GENERATOR. 1) Start en
Page 365 and 366:
MEMO: DIAGNOSTICS 121 [T10W7] 4-4 1
Page 367 and 368:
10X1 : CHECK GENERATOR. 1) Start en
Page 369 and 370:
MEMO: DIAGNOSTICS 125 [T10X7] 4-4 1
Page 371 and 372:
10Y1 : CHECK SPECIFICATIONS OF THE
Page 373 and 374:
MEMO: DIAGNOSTICS 129 [T10Y8] 4-4 1
Page 375 and 376:
DIAGNOSTICS 10Z1 : CHECK BATTERY SH
Page 377 and 378:
MEMO: DIAGNOSTICS 133 [T10Z6] 4-4 1
Page 379 and 380:
10AA1 : CHECK INPUT VOLTAGE OF ABSC
Page 381 and 382:
10AB1 : CHECK VALVE RELAY IN ABSCM&
Page 383 and 384:
10AC1 : CHECK INPUT VOLTAGE OF ABSC
Page 385 and 386:
10AD1 : CHECK MOTOR RELAY IN ABSCM&
Page 387 and 388:
10AE1 : CHECK INPUT VOLTAGE OF ABSC
Page 389 and 390:
MEMO: DIAGNOSTICS 145 [T10AE8] 4-4
Page 391 and 392:
10AF1 : CHECK OUTPUT OF STOP LIGHT
Page 393 and 394:
MEMO: DIAGNOSTICS 149 [T10AF7] 4-4
Page 395 and 396:
10AG1 : CHECK OUTPUT OF G SENSOR US
Page 397 and 398:
10AG9 : CHECK G SENSOR. Measure vol
Page 399 and 400:
10AH1 : CHECK OUTPUT OF G SENSOR US
Page 401 and 402:
10AH15 : CHECK OPEN CIRCUIT IN G SE
Page 403 and 404:
10AH21 : CHECK POOR CONTACT IN CONN
Page 405 and 406:
10AI1 : CHECK OUTPUT OF G SENSOR US
Page 407 and 408:
10AI10 : CHECK ABSCM&H/U. 1) Turn i
Page 409 and 410:
10AJ1 : CHECK ALL FOUR WHEELS FOR F
Page 411 and 412:
10AJ10 : CHECK G SENSOR. Measure vo
Page 413 and 414:
B: CHECKING THE HYDRAULIC UNIT OPER
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