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A/t & M/t Control Systems: Other Subaru Outback BP рестайлинг

Automatic Trans 107 illustrations ~3123 words

CAUTION

  1. Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work.
  2. Remove contamination including dirt and corrosion before removal, installation or disassembly.
  3. Keep the disassembled parts in order and protect them from dust and dirt.
  4. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement.
  5. Use SUBARU genuine fluid, grease etc. or equivalent. Do not mix fluid, grease, etc. of different grades or manufacturers.
  6. Be sure to tighten fasteners including bolts and nuts to the specified torque.
  7. Place shop jacks or rigid racks at the specified points.
  8. Apply grease onto sliding or revolving surfaces before installation.
  9. Before installing O-rings or snap rings, apply sufficient amount of fluid to avoid damage and deformation.
  10. Before securing a part in a vise, place cushioning material such as wood blocks, aluminum plate or cloth between the part and the vise.
  11. Before disconnecting electrical connectors, be sure to disconnect the negative terminal from battery.

Scheme 775

Scheme 775: LOCATION
Scheme 775: LOCATION

Scheme 776

Scheme 776
Scheme 776

Scheme 777

Scheme 777: ELECTRICAL SPECIFICATION
Scheme 777: ELECTRICAL SPECIFICATION
ItemConnector No.Terminal No.Input/Output signal
Measured value and measuring conditions
Backup power supplyB28119 - 16 V
2
Ignition power supplyI84110 - 15 V when ignition switch is at ON or START.
I842410 - 15 V when ignition switch is at ACC.
TCM ("P" range)B28020Pulse signal
B28030
Stop light switchB281239 - 16 V when stop light switch is ON. 0 V when stop light switch is OFF.
"P" range switchB281130 V when select lever is in "P" range. 9 - 16V when select lever is in other positions than "P" range.
Shift lock solenoid signalB28068.5 - 16 V when shift lock is released. 0 V when shift lock is operating.
Key warning switch signalB28179 - 16 V when key is inserted. 0 V when key is removed.
Key lock solenoid signalB28057.5 - 16 V when ignition switch is turned ON, with select lever in "P" range and brake switch ON. 0 V at other conditions than above.
GroundB28022
I8421
B2818
9

INPUT/OUTPUT VOLTAGE SIGNAL CHART

Scheme 778

Scheme 778: WIRING DIAGRAM
Scheme 778: WIRING DIAGRAM

SHIFT LOCK OF SELECT LEVER CANNOT BE RELEASED

StepCheckYesNo
1 CHECK IGNITION POWER.Is the voltage 9 V or more?Go to step 2.Check the ignition switch harness.
2 CHECK DTC OF BODY INTEGRATED UNIT. Turn the ignition switch to ON. Read the DTC of body integrated unit using Subaru Select Monitor.Is B1106 current malfunction?Repair or replace it according to the DTC.Go to step 3.
3 CHECK DTC OF BODY INTEGRATED UNIT.Are U1213 and U1223 current malfunction?Check the CAN communication system.Go to step 4.
4 CHECK DTC OF BODY INTEGRATED UNIT.Are U1212 and U1222 current malfunction?Check the CAN communication system.Go to step 5.
5 CHECK INPUT SIGNAL OF BODY INTEGRATED UNIT USING SUBARU SELECT MONITOR. Read the input signal of front wheel speed from Subaru Select Monitor.Is the front wheel speed 10 km/h or more?Check the VDC/ABS CM.Go to step 6.
6 CHECK INPUT SIGNAL OF BODY INTEGRATED UNIT USING SUBARU SELECT MONITOR. Read the input signal of shift position from Subaru Select Monitor. < Ref. to OPERATION , Subaru Select Monitor . >Is "7" displayed in the "P" range and displayed other than "7" except in the "P" range?Inspect the inhibitor switch and TCM.Go to step 7.
7 CHECK INPUT SIGNAL OF BODY INTEGRATED UNIT USING SUBARU SELECT MONITOR. Read the input signal of "P" range switch from the Subaru Select Monitor. < Ref. to OPERATION , Subaru Select Monitor . >Is "ON" displayed in the "P" range and displayed "OFF' except in the "P" range?Go to step 3.Go to step 8.
8 CHECK HARNESS BETWEEN BODY INTEGRATED UNIT AND "P" RANGE SWITCH. Disconnect the connector of the "P" range switch. Measure the resistance of harness between the body integrated unit and the "P" range switch. Connector & terminal (B116) No. 1 (+) - (B281) No. 13 (-)Is the resistance 1 Mohms or more?Repair the open circuit of harness between the body integrated unit and the "P" range switch.Go to step 9.
9 CHECK HARNESS BETWEEN "P" RANGE SWITCH AND CHASSIS GROUND. Measure the resistance of harness between "P" range switch and chassis ground. Connector & terminal (B116) No. 2 - Chassis groundIs the resistance 1 Mohms or more?Repair the open circuit of harness between "P" range switch and chassis ground.Go to step 10.
10 CHECK "P" RANGE SWITCH. Shift the select lever to the "P" range. Measure the resistance between "P" range switch connector terminals. Terminals No.2 - No.1Is the resistance less than 1 ohms?Go to step 11.Replace the "P" range switch.
11 CHECK "P" RANGE SWITCH. Shift the select lever to other than "P" range. Measure the resistance between "P" range switch connector terminals. Terminals No.2 - No.1Is the resistance 1 Mohms or more?Replace the body integrated unit.Replace the "P" range switch.
12 CHECK INPUT SIGNAL OF BODY INTEGRATED UNIT USING SUBARU SELECT MONITOR. Read the input signal of stop light switch from Subaru Select Monitor. < Ref. to OPERATION , Subaru Select Monitor . >Is "ON" displayed when the brake pedal is depressed and displayed "OFF when not depressed?Go to step 14.Go to step 13.
13 CHECK STOP LIGHT SWITCH INPUT SIGNAL. Turn the ignition switch to OFF. Disconnect the connector from body integrated unit. Measure the voltage between the body integrated unit connector terminal and chassis ground. Connector & terminal (B281) No. 23 (+) - Chassis ground (-)Is the voltage 9 V or more when the brake pedal is depressed, and approx. 0 V when not depressed?Replace the body integrated unit.Check the stop light system.
14 CHECK SHIFT LOCK SOLENOID. Disconnect the connector from the shift lock solenoid. Measure the resistance of shift lock solenoid terminals. Terminals No. 3 - No. 4Is the resistance between 19.5 - 25.5 ohms?Go to step 15.Replace the shift lock solenoid.
15 CHECK SHIFT LOCK SOLENOID. Connect the battery to the shift lock solenoid connector terminal, and then operate the solenoid. Terminals No.3 (+) - No.4 (-)Does the shift lock solenoid operate normally?Go to step 16.Replace the shift lock solenoid unit.
16 CHECK INPUT SIGNAL OF BODY INTEGRATED UNIT USING SUBARU SELECT MONITOR. Turn the ignition switch to ON. Shift the select lever to the "P" range. Depress the brake pedal. Read the output signal of shift lock solenoid from the Subaru Select Monitor. < Ref. to OPERATION , Subaru Select Monitor . >Is "ON" displayed?Go to step 17.Replace the body integrated unit.
17 CHECK HARNESS BETWEEN BATTERY AND BODY INTEGRATED UNIT. Disconnect the connector of body integrated unit. Measure the voltage between body integrated unit and chassis ground. Connector & terminal (B281) No. 1 (+) - Chassis ground (-)Is the voltage 9 V or more?Replace the body integrated unit.Check the harness for open between the body integrated unit and battery or the fuse (No. 14).

SHIFT LOCK OF SELECT LEVER OPERATION CHART

Scheme 779

Scheme 779: KEY INTERLOCK CANNOT BE LOCKED OR RELEASED
Scheme 779: KEY INTERLOCK CANNOT BE LOCKED OR RELEASED
StepCheckYesNo
1 CHECK INPUT SIGNAL OF BODY INTEGRATED UNIT USING SUBARU SELECT MONITOR. Turn the ignition switch to OFF. Connect the Subaru Select Monitor to the data link connector. Run the Subaru Select Monitor. Read the input signal of the key warning switch from the Subaru Select Monitor. < Ref. to OPERATION , Subaru Select Monitor . >Is "ON" displayed when the key is inserted and displayed "OFF when removed?Go to step 7.Go to step 2.
2 CHECK HARNESS BETWEEN BATTERY AND KEY WARNING SWITCH. Disconnect the connector of key warning switch. Measure the voltage of harness between key warning switch and chassis ground. Connector & terminal (B350) No. 3 (+) - Chassis ground (-)Is the voltage 9 - 16 V?Go to step 3.Repair the open or short circuit of harness between battery and key warning switch.
3 CHECK HARNESS BETWEEN KEY WARNING SWITCH AND BODY INTEGRATED UNIT. Measure the resistance between key warning switch and body integrated unit. Connector & terminal (B281) No. 7 - (B350) No. 4Is the resistance less than 1 ohms?Go to step 4.Repair the open circuit of harness between key warning switch connector and body integrated unit.
4 CHECK HARNESS BETWEEN KEY WARNING SWITCH AND BODY INTEGRATED UNIT. Measure the resistance of harness between key warning switch and chassis ground. Connector & terminal (B281) No. 7 - Chassis groundIs the resistance 1 Mohms or more?Go to step 5.Repair the short circuit of harness between key warning switch and chassis ground.
5 CHECK KEY WARNING SWITCH. Measure the resistance between connector terminals of key warning switch. Terminals No. 3 - No. 4Is the resistance 1 Mohms or more?Replace the key warning switch.Go to step 6.
6 CHECK KEY WARNING SWITCH. Remove the key. Measure the resistance between connector terminals of key warning switch. Terminals No. 3 - No. 4Is the resistance 1 Mohms or more?Replace the body integrated unit.Replace the key warning switch.
7 CHECK IGNITION POWER.Is the voltage 9 V or more?Go to step 8.Check the ignition switch harness.
8 CHECK DTC OF BODY INTEGRATED UNIT. Shift the select lever to "N" range. Check DTC indicated by body integrated unit using Subaru Select Monitor.Is B1105 current malfunction?Repair or replace it according to the DTC.Go to step 9.
9 CHECK INPUT SIGNAL OF BODY INTEGRATED UNIT USING SUBARU SELECT MONITOR. Read the input signal of "P" range switch from the Subaru Select Monitor. < Ref. to OPERATION , Subaru Select Monitor . >Is "ON" displayed in the "P" range and displayed "OFF except in the "P" range?Go to step 14.Go to step 10.
10 CHECK HARNESS BETWEEN BODY INTEGRATED UNIT AND "P" RANGE SWITCH. Disconnect the connector of the "P" range switch. Measure the resistance of harness between the body integrated unit and the "P" range switch. Connector & terminal (B116) No. 1 - (B281) No. 13Is the resistance 1 Mohms or more?Repair the open circuit of harness between the body integrated unit and the "P" range switch.Go to step 11.
11 CHECK HARNESS BETWEEN "P" RANGE SWITCH AND CHASSIS GROUND. Measure the resistance of harness between "P" range switch and chassis ground. Connector & terminal (B116) No. 2 - Chassis groundIs the resistance 1 Mohms or more?Repair the open circuit of harness between "P" range switch and chassis ground.Go to step 12.
12 CHECK "P" RANGE SWITCH. Shift the select lever to the "P" range. Measure the resistance between "P" range switch connector terminals. Terminals No.2 - No.1Is the resistance less than 1 ohms?Go to step 13.Replace the "P" range switch.
13 CHECK "P" RANGE SWITCH. Shift the select lever to other than "P" range. Measure the resistance between "F' range switch connector terminals. Terminals No.2 - No.1Is the resistance 1 Mohms or more?Replace the body integrated unit.Replace the "P" range switch.
14 CHECK TEST MODE CONNECTOR. Check that the test mode connector is disconnected. Measure the resistance between the body integrated unit and chassis ground. Connector & terminal (i84) No. 3 - Chassis groundIs the resistance 1 Mohms or more?Go to step 15.Repair the short circuit of the harness between the body integrated unit and test mode connector.
15 CHECK HARNESS BETWEEN KEY LOCK SOLENOID AND BODY INTEGRATED UNIT. Measure the resistance between key lock solenoid and body integrated unit. Terminals (B280) No. 5 - (B350) No. 2Is the resistance less than 1 ohms?Go to step 16.Repair the open circuit of harness between key lock solenoid connector and body integrated unit.
16 CHECK HARNESS BETWEEN KEY LOCK SOLENOID AND CHASSIS GROUND. Measure the resistance of harness between key lock solenoid and chassis ground. Terminals (B280) No. 5 - Chassis groundIs the resistance 1 Mohms or more?Go to step 17.Repair short circuit of harness between key lock solenoid and chassis ground.
17 CHECK KEY LOCK SOLENOID. Disconnect the connector from the key lock solenoid. Measure the resistance of key lock solenoid connector terminals. Terminals No.2 - No.1Is the resistance between 12.5 - 14.5 ohms?Go to step 18.Replace the key lock solenoid.
18 CHECK KEY LOCK SOLENOID. Connect all connectors. Operate the key lock solenoid.Does the key lock solenoid operate normally?Go to step 19.Replace the key lock solenoid.
19 CHECK INPUT SIGNAL OF BODY INTEGRATED UNIT USING SUBARU SELECT MONITOR. Turn the ignition switch to OFF. Read the output signal of key interlock from the Subaru Select Monitor. < Ref. to OPERATION , Subaru Select Monitor . >Is "OFF displayed in the "P" range and displayed "ON" except in the "P" range?Go to step 20.Replace the body integrated unit.
20 CHECK HARNESS BETWEEN BATTERY AND BODY INTEGRATED UNIT. Disconnect the connector of body integrated unit. Measure the voltage between body integrated unit and chassis ground. Connector & terminal (B281) No. 1 (+) - Chassis ground (-)Is the voltage 9 V or more?Replace the body integrated unit.Check the harness for open between the body integrated unit and battery or the fuse (No. 14).

KEY INTERLOCK OPERATION CHART

Scheme 780

Scheme 780: REMOVAL
Scheme 780: REMOVAL

Scheme 781

Scheme 781
Scheme 781

Scheme 782

Scheme 782
Scheme 782

Scheme 783

Scheme 783
Scheme 783

Scheme 784

Scheme 784
Scheme 784
  1. Set the vehicle on a lift.
  2. Disconnect the ground cable from the battery.
  3. Shift the select lever to "N" range.
  4. Lift up the vehicle.
  5. Remove the rear exhaust pipe and muffler. SOHC model < Refer to «REMOVAL»(ref-303062-S03550092122008102300000) , Rear Exhaust Pipe. > , < Refer to «REMOVAL»(ref-303062-S33146222992008102300000) , Muffler. > DOHC turbo model < Refer to «REMOVAL»(ref-303072-S10709691202008102300000) , Rear Exhaust Pipe. > < Refer to «REMOVAL»(ref-303072-S24288710222008102300000) , Muffler. > DOHC 3.0 L model < Ref. to «REMOVAL»(ref-306933-S27072536742008122600000) , Rear Exhaust Pipe . > < Ref. to «REMOVAL»(ref-306933-S17571294492008122600000) , Muffler . >
  6. Remove the heat shield cover.
  7. Remove the cable from arm assembly.
  8. Raise the claw of clamp to remove the cable.
  9. Lower the vehicle.
  10. Remove the console box. < Ref. to «REMOVAL»(ref-306930-S31661521552008122600000) , Console Box . >
  11. Remove the center console. < Ref. to «REMOVAL»(ref-306930-S06963119072008122600000) , Center Console . >
  12. Remove the harness clips from the bracket.
  13. Disconnect the connectors, and then remove the four bolts to take out the select lever assembly from vehicle body.

Scheme 785

Scheme 785: INSTALLATION
Scheme 785: INSTALLATION
  1. Set the select lever to vehicle body.
  2. Tighten the four bolts to install the select lever to vehicle body, and then connect the connector. Temporarily tighten the bolt A. Tighten the bolt B. Tighten the bolt A. Tighten the bolts C and D. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb)
  3. Install the harness clips to the bracket.
  4. Install the center console. < Ref. to «INSTALLATION»(ref-306930-S42087330282008122600000) , Center Console . >
  5. Install the console box. < Ref. to «INSTALLATION»(ref-306930-S24160774402008122600000) , Console Box . >
  6. Shift the select lever to "N" range.
  7. Lift up the vehicle.
  8. Shift the range select lever to the "N" range.
  9. Secure the cable to the bracket. < Ref. to «INSTALLATION»(ref-306940-S18339415202008122600000) , Select Cable . >
  10. Adjust the select cable position. < Ref. to «ADJUSTMENT»(ref-306940-S29860562182008122600000) , Select Cable . >
  11. After the completion of adjustment, confirm that the select lever operates properly at all range positions.
  12. Install the heat shield cover.
  13. Install the rear exhaust pipe and muffler. SOHC model < Refer to «REMOVAL»(ref-303062-S03550092122008102300000) , Rear Exhaust Pipe. > < Refer to «REMOVAL»(ref-303062-S33146222992008102300000) , Muffler. > DOHC turbo model < Refer to «REMOVAL»(ref-303072-S10709691202008102300000) , Rear Exhaust Pipe. > < Refer to «REMOVAL»(ref-303072-S24288710222008102300000) , Muffler. > DOHC 3.0 L model < Ref. to «INSTALLATION»(ref-306933-S27723276652008122600000) , Rear Exhaust Pipe . > < Ref. to «INSTALLATION»(ref-306933-S10632792442008122600000) , Muffler . >
  14. Inspect the following items. When a malfunction is found in the inspection, adjust the select cable and inhibitor switch. NOTE: Inhibitor switch for 5AT model is not adjustable. < Ref. to «ADJUSTMENT»(ref-306940-S29860562182008122600000) , Select Cable . > < Ref. to «ADJUSTMENT»(ref-306923-S17623238882008122600000) , Inhibitor Switch . > Engine starts when the select lever is in "P" and "N" range, but not in other ranges. Back-up light illuminates when the select lever is in the "R" range, but not in other ranges. Select lever and indicator positions are matched.

Scheme 786

Scheme 786: DISASSEMBLY
Scheme 786: DISASSEMBLY

Scheme 787

Scheme 787
Scheme 787

Scheme 788

Scheme 788
Scheme 788

Scheme 789

Scheme 789
Scheme 789

Scheme 790

Scheme 790
Scheme 790

Scheme 791

Scheme 791
Scheme 791

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Scheme 793
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Scheme 795

Scheme 795
Scheme 795

Scheme 796

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Scheme 796

Scheme 797

Scheme 797
Scheme 797

Scheme 798

Scheme 798
Scheme 798

Scheme 799

Scheme 799
Scheme 799

Scheme 800

Scheme 800
Scheme 800
  1. Shift the select lever to "N" range.
  2. Remove the indicator light.
  3. Remove the grip.
  4. Remove the indicator assembly.
  5. Remove the blind.
  6. Shift the select lever to the N range, and then remove the detent spring.
  7. Remove the bolt, and separate the guide plate upper from plate lower.
  8. Remove the connector from the guide plate upper.
  9. Remove the sheet, and remove the shift lock solenoid assembly.
  10. Remove the switch assembly.
  11. Remove the check plate.
  12. Raise the claw of connector.
  13. Disconnect the terminals of the SPORT mode switch and shift lock solenoid assembly from the connector, using a flat-tip screwdriver with a thin tip.
  14. Remove the cable bracket.
  15. Remove the cover.
  16. Remove the select lever assembly.
  17. Remove the clamp, and remove the arm assembly and bushing plate.

Scheme 801

Scheme 801: ASSEMBLY
Scheme 801: ASSEMBLY
  1. Clean all the parts before assembly.
  2. Apply NIGTIGHT LYW No. 2 grease or equivalent to each part. < Ref. to «AT SELECT LEVER»(ref-306940-S15200775722008122600000) , COMPONENT, General Description . >
  3. Assemble in the reverse order of disassembly. NOTE: Refer to "COMPONENT" for each tightening torque. < Ref. to «AT SELECT LEVER»(ref-306940-S15200775722008122600000) , COMPONENT, General Description . > Connect the switch terminal to the connector.
  4. After completing installation, shift the select lever from "P" range to "D" range, then check whether the indicator and select lever matches, whether the pointer and position mark matches and what the operating force is.

NOTE

Refer to "Body Integrated Unit" for removal and installation procedure. < Ref. to BODY INTEGRATED UNIT . >

Scheme 802

Scheme 802: 5MT MODEL
Scheme 802: 5MT MODEL

Scheme 803

Scheme 803
Scheme 803

Scheme 804

Scheme 804
Scheme 804

Scheme 805

Scheme 805
Scheme 805

Scheme 806

Scheme 806
Scheme 806

Scheme 807

Scheme 807
Scheme 807

Scheme 808

Scheme 808
Scheme 808

Scheme 809

Scheme 809
Scheme 809

Scheme 810

Scheme 810
Scheme 810
  1. Set the vehicle on a lift.
  2. Disconnect the ground cable from the battery.
  3. Remove the gear shift knob.
  4. Remove the console box. < Ref. to «REMOVAL»(ref-306930-S31661521552008122600000) , Console Box . >
  5. Remove the front cover assembly.
  6. Remove the clamp.
  7. Remove the bushing and insulator assembly.
  8. Remove the harness clamp from the plate assembly.
  9. Remove the plate assembly from the vehicle body.
  10. Lift up the vehicle.
  11. Remove the rear exhaust pipe and muffler. SOHC MODEL < Refer to «REMOVAL»(ref-303062-S03550092122008102300000) , Rear Exhaust Pipe.> < Refer to «REMOVAL»(ref-303062-S33146222992008102300000) , Muffler. > DOHC turbo model < Refer to «REMOVAL»(ref-303072-S10709691202008102300000) , Rear Exhaust Pipe. > < Refer to «REMOVAL»(ref-303072-S24288710222008102300000) , Muffler. >
  12. Remove the heat shield cover.
  13. Remove the stay from transmission bracket.
  14. Remove the rod from joint.
  15. Remove the cushion rubber from the vehicle body.
  16. Extract the spring pin and remove the joint.
  17. Lower the vehicle.
  18. Remove the gear shift lever.

Scheme 811

Scheme 811
Scheme 811

Scheme 812

Scheme 812
Scheme 812

Scheme 813

Scheme 813
Scheme 813

Scheme 814

Scheme 814
Scheme 814

Scheme 815

Scheme 815
Scheme 815
  1. Set the vehicle on a lift.
  2. Disconnect the ground cable from the battery.
  3. Remove the gear shift knob.
  4. Remove the console box front. < Ref. to «REMOVAL»(ref-306930-S31661521552008122600000) , Console Box . >
  5. Remove the front cover assembly.
  6. Remove the clamp.
  7. Remove the bushing and insulator assembly.
  8. Remove the harness clamp from the plate assembly.
  9. Remove the plate assembly from the vehicle body.
  10. Lift up the vehicle.
  11. Remove the under cover.
  12. Remove the rear exhaust pipe and muffler. < Refer to (H4DOTC) «REMOVAL»(ref-303072-S10709691202008102300000) , Rear Exhaust Pipe. > < Refer to (H4DOTC) «REMOVAL»(ref-303072-S24288710222008102300000) , Muffler. >
  13. Remove the heat shield cover.
  14. Remove the crossmember. < Ref. to «REMOVAL»(ref-306941-S02406830142008122600000) , Transmission Mounting System . >
  15. Remove the snap pin and washer, and remove the reverse check cable from the reverse check lever.
  16. Move the transmission to the right side, and remove the joint COMPL, stay bolts and reverse check cable. NOTE: If the transmission is not moved aside, the joint COMPL and stay bolts may contact the body and cause damage.
  17. Remove the cushion rubber from the vehicle body.
  18. Lower the vehicle.
  19. Remove the gear shift lever.

Scheme 816

Scheme 816
Scheme 816

Scheme 817

Scheme 817
Scheme 817

Scheme 818

Scheme 818
Scheme 818

Scheme 819

Scheme 819
Scheme 819
  1. Install the joint to the transmission and secure with a spring pin.
  2. Insert the gear shift lever from the room side. NOTE: Insert the rod and the stay, and then temporarily set them onto the transmission mount.
  3. Lift up the vehicle.
  4. Mount the cushion rubber on the vehicle body. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb)
  5. Using new self-locking nuts, connect the rod to the joint. Tightening torque: 18 N.m (1.8 kgf-m. 13.3 ft-lb)
  6. Using new self-locking nuts, connect the stay to the transmission bracket. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb)
  7. Install the heat shield cover.
  8. Install the rear exhaust pipe and muffler. SOHC MODEL < Refer to «REMOVAL»(ref-303062-S03550092122008102300000) , Rear Exhaust Pipe. > < Refer to «REMOVAL»(ref-303062-S33146222992008102300000) , Muffler. > DOHC turbo model < Refer to «REMOVAL»(ref-303072-S10709691202008102300000) , Rear Exhaust Pipe. > < Refer to «REMOVAL»(ref-303072-S24288710222008102300000) , Muffler. >
  9. Install the plate assembly to the vehicle body. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb) Set the plate assembly to the vehicle. Temporarily tighten the bolt (A). Tighten the bolt (B). Tighten the bolt (A). Tighten the bolts (C) and (D).
  10. Install the harness clamp to the plate.
  11. Install the boot and insulator assembly, and secure with a clamp.
  12. Install the front cover assembly.
  13. Install the console box. < Ref. to «INSTALLATION»(ref-306930-S24160774402008122600000) , Console Box . >

Scheme 820

Scheme 820
Scheme 820

Scheme 821

Scheme 821
Scheme 821

Scheme 822

Scheme 822
Scheme 822
  1. Insert the gear shift lever from the room side. NOTE: After inserting the rod and stay, temporarily put them onto transmission mount.
  2. Mount the cushion rubber on the vehicle body. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb)
  3. Move the transmission to the right side of the vehicle, and attach the joint COMPL and stay. Tightening torque: T1: 12 N.m (1.2 kgf-m, 8.9 ft-lb) T2: 32 N.m (3.3 kgf-m, 23.6 ft-lb)
  4. Install the cross member. < Ref. to «INSTALLATION»(ref-306941-S41272869672008122600000) , Transmission Mounting System . >
  5. Install the reverse cable end, washer and snap pin to the reverse check lever. NOTE: Take care to install the snap pin in proper direction. Before installing, adjust the reverse check cable. < Ref. to «ADJUSTMENT»(ref-306940-S01071571592008122600000) , Reverse Check Cable . >
  6. Install the heat shield cover.
  7. Install the rear exhaust pipe and muffler. < Refer to (H4DOTC) «REMOVAL»(ref-303072-S10709691202008102300000) , Rear Exhaust Pipe. > < Refer to (H4DOTC) «REMOVAL»(ref-303072-S24288710222008102300000) , Muffler. >
  8. Install the under cover.
  9. install the plate assembly to the vehicle body. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb) Set the plate assembly to the vehicle. Temporarily tighten the bolt (A). Tighten the bolt (B). Tighten the bolt (A). Tighten the bolts (C) and (D).
  10. Install the harness clamp to the plate assembly.
  11. Install the boot and insulator assembly, and secure with a clamp.
  12. Install the front cover assembly.
  13. Install the console box. < Ref. to «INSTALLATION»(ref-306930-S24160774402008122600000) , Console Box . >
  14. Check that the gear shift can be shifted to each gear properly.

Scheme 823

Scheme 823: 5MT MODEL
Scheme 823: 5MT MODEL

Scheme 824

Scheme 824
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Scheme 828

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Scheme 829

Scheme 829
Scheme 829

Scheme 830

Scheme 830
Scheme 830

Scheme 831

Scheme 831
Scheme 831
  1. Remove the lock wires.
  2. Remove the rod from lever.
  3. Separate the rod and inner boot.
  4. Remove the snap ring from the stay.
  5. Separate the gear shift lever and the stay.
  6. Remove the boot, bushing and snap ring from gear shift lever.
  7. Remove the spring pin, and then remove the bushing and snap ring.
  8. Remove the boss from the joint.
  9. Remove the bushing and spacer from the boss.
  10. Remove the bushing and cushion rubber from the stay.

Scheme 832

Scheme 832: 6MT MODEL
Scheme 832: 6MT MODEL

Scheme 833

Scheme 833
Scheme 833

Scheme 834

Scheme 834
Scheme 834

Scheme 835

Scheme 835
Scheme 835

Scheme 836

Scheme 836
Scheme 836

Scheme 837

Scheme 837
Scheme 837

Scheme 838

Scheme 838
Scheme 838

Scheme 839

Scheme 839
Scheme 839

Scheme 840

Scheme 840
Scheme 840

Scheme 841

Scheme 841
Scheme 841

Scheme 842

Scheme 842
Scheme 842

Scheme 843

Scheme 843
Scheme 843

Scheme 844

Scheme 844
Scheme 844

Scheme 845

Scheme 845
Scheme 845
  1. Remove the spring pin from the slider.
  2. Remove the slider and spring.
  3. Cut the band clip.
  4. Remove the reverse check cable from the cable plate.
  5. Remove the reverse check cable from the gear shift assembly.
  6. Remove the holder and spring.
  7. Disassemble the lock wires. NOTE: Do not reuse the lock wire.
  8. Remove the boss from the rod.
  9. Remove the rod from lever.
  10. Separate the rod and inner boot.
  11. Remove the snap ring from the stay.
  12. Separate the gear shift lever and the stay.
  13. Remove the boot and bushing from gear shift lever.
  14. Remove the spring pin, and then remove the bushing and snap ring.
  15. Remove the bushing and spacer from the boss.
  16. Remove the bushing and cushion rubber from the stay.

5MT MODEL

Note. Clean all the parts before assembly. Apply NIGTIGHT LYW No. 2 grease or equivalent to each part.

Scheme 846

Scheme 846: 5MT MODEL
Scheme 846: 5MT MODEL

Scheme 847

Scheme 847
Scheme 847

Scheme 848

Scheme 848
Scheme 848

Scheme 849

Scheme 849
Scheme 849

Scheme 850

Scheme 850
Scheme 850

Scheme 851

Scheme 851
Scheme 851

Scheme 852

Scheme 852
Scheme 852

Scheme 853

Scheme 853
Scheme 853
  1. Mount the bushing and cushion rubber to the stay.
  2. Install the bushing and spacer to boss.
  3. Using new self-locking nuts, install the boss to the joint. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb)
  4. Install the snap ring to gear shift lever and install the bushing. NOTE: Apply grease to the bushing.
  5. Apply grease to the bushing and O-ring, and then install to gear shift lever.
  6. Apply sufficient grease into boss, and then install the gear shift lever to the stay.
  7. Install the washer and snap ring.
  8. Insert the gear shift lever and rod into boot hole.
  9. Install the rod. Tightening torque: 12 N.m (1.2 kgf-m, 8.9 ft-lb)
  10. Install a new lock wire. NOTE: Install the lock wire to the stay groove. Bend the extra wire to the same direction of lock wire winding.

6MT MODEL

Note. Clean all the parts before assembly. Apply NIGTIGHT LYW No. 2 grease or equivalent to each part.

Scheme 854

Scheme 854: 6MT MODEL
Scheme 854: 6MT MODEL

Scheme 855

Scheme 855
Scheme 855

Scheme 856

Scheme 856
Scheme 856

Scheme 857

Scheme 857
Scheme 857

Scheme 858

Scheme 858
Scheme 858

Scheme 859

Scheme 859
Scheme 859

Scheme 860

Scheme 860
Scheme 860

Scheme 861

Scheme 861
Scheme 861

Scheme 862

Scheme 862
Scheme 862

Scheme 863

Scheme 863
Scheme 863

Scheme 864

Scheme 864
Scheme 864

Scheme 865

Scheme 865
Scheme 865

Scheme 866

Scheme 866
Scheme 866

Scheme 867

Scheme 867
Scheme 867
  1. Mount the bushing and cushion rubber to the stay.
  2. Install the bushing and spacer to boss.
  3. Install the snap ring to gear shift lever and install the bushing. NOTE: Apply grease to the bushing.
  4. Apply grease to the bushing and O-ring, and then install to gear shift lever.
  5. Apply sufficient grease into boss, and then install the gear shift lever to the stay.
  6. Install the washer and snap ring.
  7. Insert the gear shift lever and rod into boot hole.
  8. Install the rod. Tightening torque: 12 N.m (1.2 kgf-m, 8.9 ft-lb)
  9. Install the boss to the rod. Tightening torque: 12 N.m (1.2 kgf-m, 8.9 ft-lb)
  10. Install a new lock wire. NOTE: Install the lock wire to the stay groove. Bend the extra wire to the same direction of lock wire winding.
  11. Install the holder. Tightening torque: 1.3 N.m (0.13 kgf-m, 0.96 ft-lb)
  12. Insert the reverse check cable into the boot hole.
  13. Insert the reverse check cable to the gear shift assembly, and affix with a band clip. NOTE: Cut the excess band clip. Make sure that the reverse check cable is inserted into the gear shift lever assembly without inter-space.
  14. Attach the seat cushion and spring.
  15. Using the spring pin, fix the end of reverse check cable and slider. NOTE: Apply grease to the moving part of slider.
  16. With the cable pulled (the slider is lowered), adjust the distance between the edge of cable plate and the reverse check cable to 84 mm (3.31 in), and tighten the lock nut. Tightening torque: 6 N.m (0.6 kgf-m, 4.4 ft-lb)
  17. Fix the reverse check cable to the stay clip. NOTE: Install the reverse check cable on top of the stay.

Scheme 868

Scheme 868: 5MT MODEL
Scheme 868: 5MT MODEL

Scheme 869

Scheme 869
Scheme 869
  1. Check the parts (bushing, cushion rubber, spacer, boot, stay and rod, etc.) for deformation, damage and wear. If necessary, correct or replace faulty parts. Compare the removed parts with new parts to judge if there are damages or not.
  2. Check the swing torque of rod linked with the gear shift lever. If the torque exceeds the specifications, replace the bushing or retighten nuts. Swing torque: 3.7 N (0.38 kgf, 0.83 lbf) or less

Check the parts (bushing, cushion rubber, spacer, boot, stay and rod, etc.) for deformation, damage and wear. If necessary, correct or replace faulty parts. Compare the removed parts with new parts to judge if there are damages or not.

Scheme 870

Scheme 870: 6MT MODEL
Scheme 870: 6MT MODEL

Scheme 871

Scheme 871: REMOVAL
Scheme 871: REMOVAL

Scheme 872

Scheme 872
Scheme 872

Scheme 873

Scheme 873
Scheme 873

Scheme 874

Scheme 874
Scheme 874

Scheme 875

Scheme 875
Scheme 875

Scheme 876

Scheme 876
Scheme 876
  1. Set the vehicle on a lift.
  2. Remove the gear shift knob.
  3. Remove the console box front. < Ref. to «REMOVAL»(ref-306930-S31661521552008122600000) , Console Box . >
  4. Remove the front cover assembly.
  5. Remove the spring pin from the slider.
  6. Remove the slider and spring.
  7. Cut the band clip, and separate the reverse check cable from the gear shift lever.
  8. Lift up the vehicle.
  9. Remove the under cover.
  10. Remove the rear exhaust pipe and muffler. < Refer to (H4DOTC) «REMOVAL»(ref-303072-S10709691202008102300000) , Rear Exhaust Pipe. > < Refer to (H4DOTC) «REMOVAL»(ref-303072-S24288710222008102300000) , Muffler. >
  11. Remove the crossmember. < Ref. to «REMOVAL»(ref-306941-S02406830142008122600000) , Transmission Mounting System . >
  12. Remove the snap pin and washer, and separate the reverse check cable from the reverse check lever.
  13. Move the transmission to the right side, and remove the stay bolts and reverse check cable. NOTE: If the transmission is not moved aside, the stay bolts may contact the body and cause damage.
  14. Lift the stay clip, and separate the stay and reverse check cable.
  15. Pull out the reverse check cable from underside of the vehicle to remove it. NOTE: Be careful not to damage the inner boot.
  16. Loosen the lock nut, and remove the reverse check cable from the cable plate.

Scheme 877

Scheme 877: INSTALLATION
Scheme 877: INSTALLATION

Scheme 878

Scheme 878
Scheme 878

Scheme 879

Scheme 879
Scheme 879

Scheme 880

Scheme 880
Scheme 880

Scheme 881

Scheme 881
Scheme 881
  1. Insert the reverse check cable into the inner boot hole from underside of the vehicle.
  2. Insert the reverse check cable to the gear shift lever assembly, and affix with a band clip. NOTE: Cut the excess band clip. Make sure that the reverse check cable is inserted into the gear shift lever assembly without inter-space.
  3. Using the spring pin, fix the end of reverse check cable and slider. NOTE: Apply grease to the moving part of slider.
  4. Lift up the vehicle.
  5. With the cable pulled (the slider is lowered), adjust the distance between the edge of cable plate and the reverse check cable to 84 mm (3.31 in), and tighten the lock nut. Tightening torque: 6 N.m (0.6 kgf-m, 4.4 ft-lb)
  6. Move the transmission to the right side, and attach the stay. Tightening torque: T: 32 N.m (3.3 kgf-m, 23.6 ft-lb)
  7. Attach the reverse check cable, washer and snap pin to the reverse check lever. NOTE: Take care to install the snap pin in proper direction.
  8. Fix the reverse check cable to the stay clip. NOTE: Install the reverse check cable on top of the stay.
  9. Install the rear exhaust pipe and muffler. < Refer to (H4DOTC) «REMOVAL»(ref-303072-S10709691202008102300000) , Rear Exhaust Pipe. > , < Refer to (H4DOTC) «REMOVAL»(ref-303072-S24288710222008102300000) , Muffler. >
  10. Lower the vehicle.
  11. Install the front cover assembly.
  12. Install the console box. < Ref. to «INSTALLATION»(ref-306930-S24160774402008122600000) , Console Box . >

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