SONY 00035071 Service Manual

http://listado.mercadolibre.com.mx/_CustId_67027869

rodcasti@gmail.com

I

3

2002

IMPREZA SERVICE MANUAL

GENERAL INFOMATION SECTION

This service manual has been prepared

to

provide SUBARU service personnel with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. This manual includes the procedures

c-

.

for maintenance, disassembling, reassembling, inspection and adjustment of components and diagnostics for guidance of experienced mechanics.

Please peruse and utilize this manual

fully

to

ensure complete repair work for satisfying our customers by keeping their vehicle in optimum condition. When replacement

repair work is needed, be sure SUBARU genuine parts.

of

parts during

to

QUICK REFERENCE INDEX

use

All information, illustration and specifications contained in this manual are based on the latest product information available at the time of publication approval.

FUJI

HEAVY

INDUSTRIES LTD.

G1830BE1

I

FOREWORD

1

.

Foreword

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..

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...

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...

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FWa

Page

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.2

FOREWORD

~

1.

Foreword

A:

FOREWORD

These manuals are used when performing mainte-

nance, repair or diagnosis of the Subaru IMPREZA.

2001

Applied model: GG***** and GD***** from The additional manuals below are also available:

AUTOMATIC TRANSMISSION SERVICE MANUAL (Pub. No. G0853ZE)

The manuals contain the latest information at the time

of

publication. Changes in the specifications,

methods, etc. may be made without notice.

MY.

FW-2

HOW

TO

USE

How

1.

THIS MANUALS

to

Use

This

Manuals

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

HU

Paae

--

2

I

HOW TO USE THIS MANUALS

HOW

TO

USE

THIS

MANUALS

1.

How

A:

HOW

1.

STRUCTURE

Each section consists of SCT that are broken down into

SC

ponent. The specification, maintenance and other

information for the components are included, and the diagnosis information has also been added where necessary.

2.

INDEX

The first page has an index with tabs. And at the end of each section is an alphabetical index.

3.

COMPONENTS

For each component, a composition drawing is included.

4.

SPECIFICATIONS

to

Use

TO

that are divided into sections for each com-

This

Manuals

USE THIS MANUALS

ff

necessary, specifications are also included

5.

INSPECTION

Inspections are included to be carried out before and after maintenance.

6.

MAINTENANCE

Maintenance instructions are provided for each

component. When multiple components comprise one process, refer to the instructions for that process for each component.

7.

DIAGNOSIS

Tables showing a step-by-step process make it easy to conduct diagnosis.

8.

SI

UNITS

Measurements in these manuals are according to

the

SI

units. Metric and yard/pound measurements

are also included.

H

U-2

SPECIFICATIONS

SPC

1

.

lmpreza

...

.

. .

. . . . . .

. . .

,

. . .

. .

.

. .

.

. . . . , . . . .

. . .

,

. . .

. . . . . . . . .

. .

,

.

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. . , .

. . . . . . . ..

. . . .

. .

.

. . ..

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...

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Page

.2

a

SPECIFICATIONS

1.

lmpreza

A:

DIMENSIONS

IMPREZA

Model Overall lennth mm (in) Overall width mm (in) Overall height (at CW)

Compartment Length mm (in)

Width mm (in)

I

Height

Tread

Minimum road clearance mm (in)

B:

ENGINE

Model

I

valve arranqement Bore x Stroke mm (in)

Displacement cm3 (cu in) ComDression ratio

I

Firinq order Idle speed at Park/Neutral

I

position (NC OFF) Maximum output Maximum torque

I

Front mm (in) Rear mm (in)

N.m (kgf-m, ft-lb)/rpm 294

mm (in)

mm

rpm

kW (HP)/rpm 169 (227)/6,000

(in)

\I

Sedan Waaon OUTBACK

I

1,730 (68.1) 1,695 (66.7) 1,710 (67.3) 1,440 (56.7) 1,890 (74.4) 1,845 (72.6)

I

1

,I

80 (46.5)

I

1.485 (58.5)

,\,

1,475 (58.1

1,480 (58.3)*1

150 (5.9), 150 (5.9),

155 (6.1)*1 155 (6.1)*1

),

Turbo 2.0

L

I

92

x

75

(3.62

x

2.95)

1,994 (121.67)

8.0

I

(30.0,

750

217)/4,000

I

4,405 (173.4)

1,465 (57.7), 1,475 (58.1),

1,485 (58.5)*2 1,495 (58.9)*2

1,380 (54.3)

1,200 (47.2), 1,200 (47.2),

I

1,150 (45.3)*3

1.465 (57.7) 1.460 (57.5)

.\,

1,455 (57.3) 1,455 (57.3)

Overhead camshaft tvDe

1-3-2-4

I

2.5

99.5

(3.91 7

2,457

10.0

650 (MT)

700 (AT)

123 (165)/5,600

226 (23.0, 166)/4,000

1,150 (45.3)*3

I\,

160 (6.3)

L

x

79.0

x

3.1

IO)

(1

49.9)

-1

1

SPC-2

C:

ELECTRICAL

IMPREZA

I

SPECIFICATIONS

Model Turbo 2.0 L Ignition timing at idling speed BTDC/rpm

Spark plug

Generator Battery Type

Reserve capacity min

Cold cranking amp amperes

rMm

Transmission type Clutch type

-'

Gear ratio

I

'

Reduction gear

,

(Front drive) Gear ratio

I

Reduction gear (Rear drive)

~

1

st

reduction Type

Final reduction Type

I I

Transfer reduction Type

Final reduction Type

I

1st 3.454 2.785

L

1

3rd

L

14th

5th 0.738 Reverse

of

Gear ratio

of

Gear ratio 1.100

of

Gear ratio 3.545 4.111

I

12"+10"/750

NGK: PFR6G NGK: BKR5E-11

-

12V

MT: 12V

AT: 12V

-

48AH (55D23L)

-

52AH (65D23L)

MT: 99 MT: 99

AT:

MT: 356 MT: 356

AT: 420 AT: 520

I

5MTSrl 4ATlr2

DSPD TCC

I

gear

gear Hypoid Hypoid

I

gear Helical

gear Hypoid Hypoid

1.366

0.972

3.333 2.272

-

3.900

75A

111

I

CHAMPION: RCI OYC4(Standard)

MT: 12V

AT: 12V

Turbo

2.0

L

I

I I

2.5

MT: 1 O"k1 0°/650

AT: 1 O"k1 0"/700

NGK: BKR6E-11

12V

-

48AH (55D23L)

-

52AH (75D23L)

AT: 118

1

.ooo

0.694

-

Helical

1.000

I

4.1

11

-

L

90A

I

4

I

SPC-3

IM

PREZA

SPECIFICATIONS

Model

Transmission type Clutch type

I

1st

2nd 3rd 4th 5th

I

Reverse Dual range

1

st

reduction Reduction gear

(Front drive)

Final reduction

r

Reduction gear (Rear drive)

r

I

5MTM : 5 forward speeds with synchromesh and I -reverse 4AT+2: Electronically controlled fully-automatic, 4-forward speeds and DSPD: Dry Single Plate Diaphragm TCC: Torque Converter Clutch

Transfer reduction

Final reduction

Type of gear Gear ratio

Type of gear Gear ratio Type

of

gear Gear ratio Type of gear Gear ratio

5MT*1 4ATlr2 5MTlrl 4AT*2

DSPD TCC DSPD TCC

I

3.454

2.062 1.619 2.062 1.545

1.448

1.088 0.694 1.088 1.694

0.780

I

3.333

- - - -

-

Hypoid Hypoid Hypoid

11

4.1

I

ical

He

1

.ooo

Hypoid Hypoid

11

4.1

RS

I

2.5

L

3.027

1

.ooo

-

2.272

Helical

1

.ooo

4.444 3.900

I

-

4.444 3.900

1

-reverse

Others

3.454

1.448

0.780

3.333

-

He I ical

1.000

Hypoid Hypoid

I

2.785

~~~

1

.ooo

-

2.272

Helical

1

.ooo

...

Hypoid

11

4.1

-

11

4.1

I

1

E: STEERING

Type Turns, lock

Minimum turning circle m

Front Rear

Model Service brake system

Front Rear Parking brake

H:

to

TIRE

lock

(ft)

Curb

Wall

to

curb wall

Rack and Pinion

3.2 3

10.2 (33.5)

11

.I

(36.3) 11.7 (38.3)

Macpherson strut type, Independent, Coil spring

Dual-link strut type, Independent, Coil spring

SEDAN WAGON

Dual circuit hydraulic with vacuum suspended power unit

Ventilated disc brake

Disc brake Drum brake, Disc brakelrl

Mechanical on rear brakes

I

10.8

(35.4)

Rim size Tire size

Type

15 x 6JJ

PI 95/60R15 87H P205/55R16 89V

Steel belted radial, Tubeless

16

x

6’/2JJ

SPC-4

I:

CAPACITY

IMPREZA

SPECIFICATIONS

Fuel tank Engine oil Upper level

Lower level

Transmission gear oil

Automatic transmission fluid AT differential gear oil AWD rear differential gear oil

Power steering fluid Engine coolant

Model

Q

t-

Curb weight

I

Gross vehicle weight

.V.

W.)

(G

(C.W.)

Front kg (Ib) Rear

I

Total ka (Ib) I 1,395 (3,075)

Front Rear

Total

(US gal, Imp gal)

Q

(US qt, Imp qt)

Q

(US qt, Imp qt)

Q

(US qt, Imp qt)

Q

(US qt, Imp qt)

Q

(US qt, Imp qt)

Q

(US qt, Imp qt)

Q

(US qt, Imp qt)

Q

(US qt, Imp qt)

I

826 (1,820) 851 (1,875)

ka

(Ibl

w.

kg (Ib) kg (Ib) kg (Ib)

569 (1.255) 569 (1.255)

I1

998 (2,200) 998 (2,200) 857 (1,890) 857 (1,890)

1,837 (4,050) 1,795 (4,050)

I

5MTlrl 4ATJrl

5MT

3.5

(3.7, 3.1) (3.7, 3.1)

-

7.7 (8.1, 6.8)

Turbo 2.0

WRX

..

I

60 (1 5.9, 13.2)

4.5 (4.8, 4.0)

3.5 (3.7, 3.1)

4AT

-

9.3 (9.8, 8.2)

1.2 (1.3, 1 .I)

I

7.6 (8.0, 6.7)

L

I I

I

I. I I.

1,420 (3,130)

I

0.8 (0.8, 0.6)

0.7 (0.7, 0.6)

I

AWD

1

1,345 (2,965)

1,778 (3,920) 1,837 (4,050)

5MT

3.5

-

7.0 (7.4, 6.2)

5MT 4AT 778 (1,715) 803 (1,770) 567 (1.250) 567 (1,250)

939 (2,070) 939 (2,070) 857 (1,890) 857 (1,890)

I

60 (1 5.9, 13.2)

4.0 (4.2, 3.5)

3.0 (3.2, 2.6)

9.5 (10.0, 8.4)

1.2 (1.3, 1.1)

1

6.9 (7.3, 6.1)

2.5 L RS

.

I

1,370 (3,020)

4AT

-

I

SPC-5

SPECIFICATIONS

IM

PREZA

I

Model

Curb weight (C.W.) Front kg (Ib)

Rear ka (Ib)

~~

~

Gross vehicle weight

.

V.

W.

)

(G

Curb weight (C.W.) Front kg (Ib)

Gross vehicle weight Front kg (Ib)

-(

G

.

v.

w.

)

tl:

Excludes weight

t2: Excludes weight

htai ka ob)

Front kg (Ib) Rear kg (Ib) 925 (2,040)

Total kg (Ib) 1,901 (4,190)

Rear kg (Ib)

Total

Rear kg (Ib) Total kg (Ib) [ 1,833 (4,040)

of

ABS,

of

side air bag.

kg

(Ib)

-

cruise control.

AWD

Xirbo 2.0

5MTt2 4ATt2

825 (1,820) 851 (1,875)

606

(1.335) 605 (1,335)

1

-

5MTtl 4ATt 773 (1,705) 603 (1,330)

1,376 (3,035) 1,402 (3,090) 1,384 (3,050)

939 (2,070) 939 (2,070) 925 (2,040)

1,431 (3,155)

998 (2,200)

TS

796 (1,755) 783 (1,725) 606 (1,335) 601 (1,325)

925 (2,040) 925 (2,040)

I

1,833 (4,040)

1

WRX

I

2.5

I

L

939 (2,070)

1,833 (4,040)

1,458 (3,210)

998 (2,200) 925 (2,040)

1,901 (4,190)

OUTBACK

5MT 4AT

805 (1,775) 603 (1,330)

1,408 (3,l 05)

939 (2,070) 925 (2,040)

I

1,833 (4,040)

SPC-6

2.

CANADA SPEC. VEHICLE

Sedan

Model

Curb weight

Gross vehicle weight

.V.

W.

(G

(C.W.)

)

Front

Rear Total Front

Rear Total

Wagon

.-

IMPREZA

5MT

kg (Ib) kg (Ib) 573 (1,265) kg (Ib) kg (Ib) kg (Ib) kg Ob)

826 (1,820)

1,399 (3,085)

998 (2,200) 998 (2,200) 857 (1,890) 857 (1,890)

1,837 (4,050) 1,837 (4,050)

Turbo 2.0

WRX

SPECIFICATIONS

2.5

L

4AT 5MT 851 (1,875) 778 (1,715) 803 (1,770) 573 (1,265) 567 (1,250)

1,424 (3,140) 1,345 (2,965) 1,370 (3,020)

939 (2,070) 939 (2,070) 857 (1,890)

1,778 (3,920) 1,778 (3,920)

L

RS

4AT

567 (1,250)

857 (1,890)

I

*1: Excludes weight

of

air conditioner

SPC-7

SPECIFICATIONS

IMPREZA

c-

.

SPC-8

PRECAUTION

Precaution

1

.

...........

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

PC

Page

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

I

2

PRECAUTION

1.

Precaution

A:

PRECAUTION

Please clearly understand and adhere to the following general precautions. They must be strictly followed to avoid minor or serious injury to the person

doing the work or people in the area.

1. ABS

Handle the ABS as a total system. Do not disas-

semble or attempt to repair individual parts. Doing

so

could prevent the ABS system from operating when needed or cause it to operate incorrectly and result in injury.

2.

BRAKE FLUID

If

brake fluid gets in your eyes or on your skin, do

the following:

Wash out your eyes and seek immediate medical

attention.

Wash your skin with soap and then rinse thor-

oughly with water.

3.

ELECTRIC FAN

The electric fan may rotate without warning, even when the engine is not on. Do not place your hand, cloth, tools or other items near the fan at any time.

7.

AIRBAG MODULE

Adhere to the following when handing and storing the airbag module to prevent bodily injury from unexpected deployment:

Do

not hold the harnesses or connectors to carry

the module.

Do not face the bag in the direction that it opens

towards yourself or other people.

Do not face the bag in the direction that it opens

towards the floor or walls.

8.

AIRBAG SPECIAL TOOLS

To

prevent unexpected deployment, only use spe-

cial tools.

9.

WINDOW

Always wear safety glasses when working around any glass to prevent glass fragments from damaging your eyes.

1O.WINDOW ADHESIVE

Atways use the specified urethane adhesive when attaching glass to prevent it from coming loose and falling, resulting in accidents and injury.

4.

ROADTESTS

Always conduct road tests in accordance with traffic rules and regulations to avoid bodily injury and interrupting traffic.

5.

AIRBAG

To prevent bodily injury from unexpected deployment of airbags and unnecessary maintenance, follow the instructions in this manual when performing maintenance on the airbag components or nearby, and the airbag wiring harnesses or nearby. To

prevent unexpected deployment, perform one of the steps below and then wait at least to discharge electricity before beginning work.

Step

1

:

Turn the ignition switch OFF.

Step

2:

Remove the negative battery terminal.

6.

AIRBAG DISPOSAL

To prevent bodily injury from unexpected airbag deployment, do not dispose the airbag modules in the same way as other refuse. Follow instructions of SOA (distributor) service for disposal of airbag module. Follow all government regulations concerning the disposal of refuse.

20

seconds

PC-2

NOTE

1

.

NT

Note

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

I

Page

2

NOTE

1.

Note

A:

NOTE

This is the information that can improve the effi-

ciency of maintenance and assure the sound work.

1.

FASTENER NOTICE

Fasteners are used to prevent the parts from damage and dislocation due to looseness. Fasteners must be tightened to the specified torque. Do not apply paint, lubricant, rust retardant or other

substances to the surface around bolts, fasteners,

etc. Doing rect torque and result in looseness and other problems.

2.

STATIC ELECTRICITY DAMAGE

Do

not touch the and other such parts when there is a risk of static electricity. Always use a static electricity prevention cord or touch grounded metal before conducting work.

so

will make it difficult to obtain the cor-

ECM,

connectors, logic boards

NOTE

3.

IGNITION

When removing the battery cables, always be sure to turn the ignition off to prevent electrical damage to the

4.

mance and maintenance, when conducting repairs. Subaru/FHI will not be responsible for poor performance resulting from the use of parts not specified by a genuine dealer.

ECM

SERVICE PARTS

Use authentic service parts for maximum perfor-

OFF

BATTERY

from rush current.

NT-2

NOTE

5.

LIFTS

When using a lift or jack-ridged rack to raise a vehicle, always follow the instructions concerning jack-up points and weight limits to prevent the vehicle from falling, which could result in injury. Be especially careful

to make sure the vehicle is balanced before raising it.

AND

JACKS

Support locations

Pantograph jack

A

Without side sill cover

I

With-ver

fi.w

I

Lift

Safety stand

GI0166

NT-3

NOTE

I

Front

Rear

nt

cross member

Rear differential

GI0121

NT-4

NOTE

6.

TIE

DOWNS

Tie downs are used when transporting vehicles and when using the chassis dynamo. Attach tie downs only

to the specified points on the vehicle.

Hook

for

tie-down

3

Hook

for

1-

towing

Hook

for

tie-down

Hook

for

towing

and tie-down

GI0122

NT-5

I

NOTE

I

20 20’

20 20”

20 20” 20

7.

TOWING

Avoid towing vehicles except when the vehicle cannot be driven. For vehicles with AWD, AT or VTD, use a loader instead of towing. When towing other vehicles, to prevent excessive weight from damaging the hook or vehicle:

Do not tow other vehicles with a front towing

hook.

Make sure the vehicle towing is heavier than the

vehicle being towed.

8.

TRAINING

For an information about training, contact a dealer or agent.

20”

9. GENERAL SCAN TOOL

Using general scan tools will greatly improve the ef-

ficiency of repairing engine electronic controls. The

Subaru Select Monitor can be used to diagnose the engine and also the ABS, the air conditioner and other parts.

NT-6

IDENTIFICATION

Identification

1

.

....

. ... .

....

.. . .

...

. .

... . ...

....

.

...

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

...

.

....

. .. . .. .

. .. . . .

...

ID

. ..

...

... .

.. . ..

Page

.....

.

.2

IDENTIFICATION

I

DE

NTI

F I CAT1 0 N

1.

Identification

A:

IDENTIFICATION

1.

IDENTIFICATION NUMBER AND LABEL LOCATIONS

The VIN (Vehicle Identification Numbers) is used to classify the vehicle.

Positioning of the plate label for identification

Vacuum hose piping label

/

..

I

number plate

pressure label

Vehicle

Engine sdrial number G l0007A

'

Model number plate

I

Transmission serial number

o.

G10008A

GI0161

I

D-2

I

DENTI FlCATlON

I

IDENTIFICATION

Model number

plate

U

/

b

'I

L3

F

trim code engine

9+#L2-F

2

3

0

r'z"'!it

sv53>w

type

E

J

2

0

ENMABA~

GlOOllA

I

D-3

IDENTIFICATION

2.

MEANING

The meaning

North

America

of

OF

the

V.I.N.

VIN

is

as

follows:

]JF1 GD255X2G500001[

The starting and ending brackets

(

I[

IDENTIFICATION

)

are

stop

marks.

Digits Code

1

to3

4 G

5

JFI

ID

6

7

8

9

10

11

12

to

17

2 Displacement

5

X Check digit 2 Model year

G

500001

Meaning Manufacturer body area Car line

Grade

Restraint

Transmission type

Manufacture number

Details

JFI: Passenger car, FHI made

G: IMPREZA D: 4 Door Sedan

G: Waaon

2: 2.0 L AWD Turbo

6:

2.5 LAWD

5:

TS

7:

RS

8:

OUTBACK

9:

WRX

5:

Manual belts, dual airbag.

6:

Manual belts, dual airbag, side airbag.

0-9

&

x

2: 2002MY 3:

2003MY

G:

Full-time AWD 5-speed MT

H:

Full-time AWD 4-speed AT

From

500001

800001 : Waaon

From

:

4 Door Sedan

I

D-4

IDENTIFICATION

3.

MODEL NUMBER

The model number plate indicates: the applied model, the option code, the trim code, the engine type, the transmission type, and the exterior color code. This information is helpful when placing orders for parts.

GDEAY4R

PLATE

2

5

7

Digits

3

and 4

5

6

7

8

9to10

Digits

Code

Series Body style

ID

Engine displacement Drive system

Sumension svstem

Minor chanae

IY

IR

Code Meaning Details

25 Displacement 20: 2.0

1

A Exhaust reuulations US Federal

Destination

Grade

Transmission, fuel feed system

Fuel feed system

Transmission

Iw

3

AB

Minor change 3: 3 is applied for this vehicle. Detailed specifications

Meaning

G: IMPREZA D:

4

Door Sedan

G: Wagon A: 2.0

L

E: 2.5

L

A: Initial

Y:

Left-hand drive for United States and Canada

4:

TS

6: RS

7:

OUTBACK

8:

WRX

R:

SOHC MPI 4-speed AT P: DOHC J: SOHC MPI 5-speed MT AWD D: DOHC B MPI 5-s~eed MT AWD

L

25: 2.5

5: MPI Turbo

L

1:

D-MPI SOHC-A

I

Used when ordering parts. See the parts catalog for details.

AWD Turbo AWD

B

MPI 4-speed AT

&

California

Details

I

D-5

I

IDENTIFICATION

Transmission

TV1 A421 AA

I

DENTI FlCATlON

Z

AA

Code

I

No

Viscous

Digits

I

3

and 4

5

14

6

7

8

to

10

Rear differential

EH

Code Reduction LSD

I

EG

I1

I

aear ratio

13.900

4.1

11

4.1

11

Meaning Transmission Transmission type

Classification

Series IMT 14:5MT

Transmission specifications

Minor change Detailed specifications I Used when ordering parts. See the parts catalog for details.

T: Transmission

Y:

Full-time AWD MT center differential

V: Full-time AWD AT center differential

Z:

Full-time AWD AT MPT

75:

MT

1A: AT

AT 14: New AT V: Full-time AWD 5-speed MT with viscous coupling center dif-

ferential single range

Z:

Full-time AWD 4-speed AT with MPT

Y:

Full-time AWD 4-speed AT with VTD

I

I:

Initial

Details

I

D-6

RECOMMENDED MATERIALS

Recommended

1

.

Materials

,...

...

..

. . .. . . .. . . . .. . . . . . , .

. . . . . . . .. .

RIM

..

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

Page

.

. .. .

.

I

.2

I

RECOMMENDED MATERIALS

~

1.

Recommended

A:

RECOMMENDED MATERIALS

1.

GENERAL

To

insure the best performance, always use the

specified oil, gasoline, adhesive, sealant, etc. or

that of equivalent quality.

2.

FUEL

Always use a gasoline of the same or higher octane value than specified in the owner's manual. Ignoring the specifications below will result in damage poor operation of the engine and fuel injection system. Use the specified gasoline to correct performance.

Unleaded gasoline

Materials

or

Use unleaded gasoline and vehicles with a catalytic converter installed to reduce air pollution. Using leaded gasoline will dam-

age ihe catalytic converter.

not

leaded gasoline on

RM-2

RECOMMENDED MATERIALS

3.

LUBRICANTS

Use either the lubricants in the table below or equivalent lubricants. See the table below to choose the correct

SAE

viscosity.

Lubricant

API

Spec. ACEA Spec.

Engine oil

Manual transmission oil GL-5

Front differential GL-5 Rear differential GL-5

SJ

Grade “Energy conserving” API:

Recommended Alternative

A1

,

A2

or

A3

GlOOOl

GI0002

-

SH

or SG

-

SAE viscosity Engine oil

SAE viscosity

<

No.

and applicable temperature SAE

J300

5W-30 Recommend

I

G10003A

RM-3

RECOMMEND ED MATER I ALS

RECOMMENDED

MATERIALS

SAE viscosity Manual transmission oil

3ear differential

'ront differential

SAE viscosity No. and applicable temperature SAE J300

("C)

(OF)

7

('C)

(OF)

-30

-22

I I I

ll

-30

-22

-20

-4 14

I I

I

-20

-4 14

-1

0 0

I

32

I

85W

80W

I I I

75W-90

0

32

10

50

I I I I

10

50

20 30

68 86

90

I

20 30

68 86

I

40

104

40

104

>

/

2

G10004A

4.

FLUID

Use the fluids specified in the table below. Do not mix two different kinds or makes

Fluid Recommended

Automatic transmission fluid DEXRON

Power steerina fluid DEXRON Brake fluid Clutch fluid FMVSS No.

5.

COOLANT

FMVSS No. 1 16 DOT3 FMVSS No. 116 DOT4

Ill

1

16 DOT3

Alternative Remarks

-

FMVSS No. 116 DOT4

of

fluid.

Use the genuine coolant to protect the engine. The table below shows the ratio of coolant

Coolant Coolant Water for dilution

Air conditioner Refrigerant Compressor oil

Pre-delivery Inspection

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

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

PI

Page

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

I

2

I

PRE-DELIVERY INSPECTION

1.

Pre-delivery Inspection

A: GENERAL

The purposes of the pre-delivery inspection (PDI) are as follows.

Remove the additional parts used for ensuring

the vehicle quality during transportation and restore

to

the vehicle

Check if the vehicle before delivery is in a normal

state.

Check for any damage or missing parts that may

have taken place during transportation or storage.

Make sure

customer.

Because must always carry

vehicle.

In addition, all franchised shops and PDI centers must check the status of every vehicle received identify who is responsible for any possible defects.

its normal state.

to

provide a complete vehicle to the

of

the above reasons, all dealerships

out

the PDls before delivering a

to

PI-2

PRE-DELIVERY INSPECTION

B:

PDI PROCEDURE

Follow the procedures shown in the table below.

Static Checks Just After Vehicle Receipt

PRE-DELIVERY INSPECTION

Step

I.

Appearance check

2.

Tire check

3.

Fuse installation

Eheck the doors for locklunlock and openlclose iperations.

5.

Power window oDeration check

ii+ Check the trunk lid openlclose operations.

7.

Check the rear gate for locklunlock and open1

:lose operations.

3.

Operation check of trunk lid release handle

3.

Operation check of fuel lid opener lock release

ever

10.

Accessory check

11. Operation check of hood lock release system

12. Connection of air conditioner harness

13. Battery

14. Brake fluid

15. Engine oil

16. Transmission fluid

17.

AT front differential oil

18. Coolant

19. Clutch fluid

20. Window washer fluid

21. Hood latch check

Check point

(1) If the vehicle is covered with protective coating, visually check the vehicle body for damage and dents. visually check the body paints for small areas of damage or stains. (2) Visually check the glass and light lenses for any damage and cracks or excessive gaps to the body sheet metal. (3) Visually check the plated parts for any damage.

(4)

Check the tires for damage, abnormal conditions, and dents on the wheels. f5) Check the tire air Dressure.

~

(6)

If the vehicle is about to be delivered to the customer, attach a room lamp

fllRF!

(7) Using the key, check (8) Open and close all doors (9) Operate the power door locking switch and unlocked normally.

(1

0)

Check the power window for correct operations.

(1 1) Operate the trunk lock release lever to check that the trunk opens normally. (12) Using the key, check if the trunk lid can be unlocked normally. (1 3) Open and close the trunk lid to see that there are no abnormal condi-

tions.

(14) Using the key, check (15) Open and close the rear gate to see that there are no abnormal conditions. (16) Operate the power door locking switch to check that the rear gate is locked and unlocked normally.

(17) Operate the trunk lid release lever to check the trunk is unlocked normally.

(18) Operate the fuel lid opener to check that the fuel lid is unlocked normally.

Check the following accessories are provided:

Owner's manual Warranty booklet

Service booklet

Spare key Jack Tool set

Spare tire

(1) Operate the hood lock release lever to check that the hood opens normallv.

~

(2)

If

the vehicle is about to be delivered to the customer, connect the air con-

ditioner harness. (3) Check the battery for any abnormal conditions such as rust and trace of

battery fluid leaks. (4) Check the fluid amount. (5) Check the oil amount. (6) Check the fluid amount.

(7)

For AT, check the front differential oil.

(8) Check the AT front differential oil amount.

f9) Check the coolant amount. (10)

Check the clutch fluid amount. (1 1) Check the window washer fluid amount. (12) Check that the hood is closed and latched securely.

If

the protective coating has been removed,

if

the door can be locked and unlocked normally.

to

see that there are no abnormal conditions.

to

check that all doors is locked

if

the rear gate can be lock and unlocked normally.

PI-3

PRE-DELIVERY

INSPECTION

PRE-DELIVERY INSPECTION

I

Step

22. Keyless entry system

23. Securitv svstem

124.

Seat

125. Seat belt

126. Wheel alignment

Checks with the Engine Running

I

27. Read memory and test mode connectors

28. Starting condition

29. Exhaust system

30. Indicator liaht

I

31. Clock

132. Radio

33. Cigarette lighter

34. Lighting system

35. Window washer

36. WiDer

I

Step

Pynamic Test with the Vehicle Running

Step

37. Brake test

38. Parkina brake

MAT

I

shift control

40. Heater & ventilation

41. Air conditioner

42. Cruise control

Check point (1 3) Check that the keyless entry system operates normally. (14) Check that the securitv svstem operates normallv. (15) Check the seat surfaces for smears or dirt.

(1 6) Check the seat installation conditions and functionality.

I

(17) Check the seat belt installation conditions and functionality.

I

(18) Check that the wheel alignments are properly adjusted.

I

(1) Read memory and test mode connectors (2) Start the engine and check that the engine starts smoothly. (3) Check that the exhaust noise is normal and no leaks are found. (4) Check that all indicator liahts operate normally.

I

(5)

Check that the clock operates normally.

I

(6) Check that the radio system operates normally. (7) Check that the cigarette lighter operates normally. (8) Check that the lighting systems operate normally.

(9)

Check that the window washer system operates normally.

(10) Check that the wiper svstem oDerates normally.

~.

(1) Check that the foot brake operates normally. (2) Check that the parkina brake operates normally.

I

(3) Check that the AT shift patterns are correct.

I

(4)

Check that the heater & ventilation system operates normally.

(5)

Check that the air conditioner operates normally.

(6) Check that the cruise control system operates normally.

.-

Check point

I

I I

I

43. ATF level

44. Power steerina fluid level

I

45. Fluid leak check

146. Water leak check

47. Appearance check 2

Step

.8

I

(1) Check that the ATF level is normal.

I

12)

Check that the Dower steerina fluid level is normal.

,\I

I

13) Check for fluid/oil leaks.

\,

I

(4) Sprav the vehicle with water and check for water leaks.

(5)

Remove the protective coating (if any).

(6)

Check the body paints for damage and smears.

(7) Check the plated parts for damage and rust.

Check point

I

1

PI-4

PRE-DELIVERY INSPECTION

1.

APPEARANCE CHECK

If

the vehicle is covered with protective coating,

visually check the vehicle body for damage and dents.

If

there is no protective coating, check the body paints for small areas of damage or stains and repair as necessary.

Check the window glass, door glass, and lights

for any cracks or damage and repair or replace the

parts as necessary.

Check the plated parts, such as the grilles and door knobs, for damage or or replace the parts as necessary.

2.

TIRECHECK

Check the tire outer faces for any damage.

Check the tire air pressure by referring to the following table.

Tire size Tire inflation pressure

PI 95/60R1587H P205/55R1689V

220 (2.2, 32) 200 (2.0, 25) 220 (2.2. 32) 200 (2.0, 25)

loss

kPa (kg/cm2,

Front

of gloss and repair

psi)

PRE-DELIVERY

4.

CHECK THE DOOR OPERATIONS,

INSPECTION

LOCWUNLOCK AND OPENELOSE, AS FOLLOWS.

Using the key, lock and unlock the door several times to check for normal operation. Open and close the door several times for smooth movement.

GI0148

Operate the power door locking switch on the front

door arm rest, and check that all doors lock and un-

lock normally.

1

3.

FUSE INSTALLATION

A

vehicle just- delivered has no fuses for the room

lamp circuit to prevent battery discharge. Attach a

15

A fuse as shown in the figure.

(A)

G10084A

5. POWER WINDOW OPERATION CHECK

Manipulate the power window switches one by one to check that each of the power windows goes up and down with no abnormal noises.

PI-5

I

PRE-DELIVERY INSPECTION

6.

CHECK THE TRUNK LID OPERATIONS,

OPEN/CLOSE, AS FOLLOWS.

Operate the trunk lock release lever and verify

that the trunk lid opens.

Using the key, open the trunk lid several times to

check for normal operation.

Open and close the trunk lid several times for

smooth movement.

7.

CHECK THE REAR GATE OPERATIONS,

kOCWUNLOCK AND OPEN/CLOSE, AS

FOLLOWS.

Using the key, lock and unlock the rear gate sev-

eral times to check for normal opeartion.

Open and close the rear gate several times for

smooth movement.

8.

OPERATION CHECK

OF

TRUNK LID RE-

LEASE HANDLE

1)

Use a screwdriver with a thin blade. Slide the

screwdriver blade from the slit aperture of the lock

to

assembly fully places the latch in the locked position.

Locked

I

the end until you hear a click. This

GI0157

mni

w

171

Operate the power door locking switch to check

that the rear gate is locked and unlocked normally.

2)

Move the release handle from outside the vehi-

to

cle, in the direction of the arrow is released.

check if the latch

PI-6

I

GI0160

I

PRE-DELIVERY INSPECTION

PRE-DELIVERY

I

INSPECTION

9.

OPERATION CHECK OF FUEL LID

OPENER LOCK RELEASE LEVER

Operate the fuel lid opener and verify that the fuel

lid opens normally. Check that the filler cap is se-

curely closed.

1O.ACCESSORY CHECK

Check that the following accessories are provided

in the luggage compartment or cargo area.

Owner's manual Warranty booklet

Service booklet

Spare key Jack Tool

set

Spare tire

11 .OPERATION CHECK OF HOOD LOCK RELEASE SYSTEM

Unlatch and open the hood while checking that

abnormal conditions are found. Then, support the

hood with the hood stay.

no

P

GI0151

1-7

I

PRE-DELIVERY INSPECTION

I

12.CONNECTION OF AIR CONDITIONER HARNESS

A vehicle just delivered has its air conditioner harness disconnected to protect the air conditioner compressor. Connect the harness as shown in the figure.

13.BATTERY

Check the battery terminals to make sure that no rust or corrosions due to fluid leaks are found. check that the battery caps are securely tightened.

16.TRANSMISSION FLUID

Check the transmission fluid amount. is insufficient, check that no leaks are found. Then, add the necessary amount of the specified fluid.

Oil

level gauge

I

_-

If

the amount

Upper level Lower level

G10088A

I

17.AT FRONT DIFFERENTIAL OIL

Check the AT front differential oil amount. amount is insufficient, check that no leaks are found. Then, add the necessary amount of the specified AT front differential oil.

If

the

14.BRAKE FLUID

Check the brake fluid amount. sufficient, carry out a brake line test to identify

brake fluid leaks and check the brake operation. After that, refill the brake fluid tank with the specified type of fluid.

If

the amount is in-

15.ENGINE OIL

Check the engine oil amount. ficient, check that no leaks are found. Then, add the necessary amount of the specified engine oil.

If

the amount is insuf-

P Upper level

About

1

.O

us

Imp

e

qt,

qt)

(1.1

0.9

Lower level

-

Upper level

_I

-Lower level

1

GlOO89Al

18.COOLANT

Check the coolant amount on the reservoir. amount is insufficient, check that no leaks are found. Then, add the necessary amount of coolant with the specified concentration.

If

the

19.CLUTCH FLUID

Check the clutch fluid amount. sufficient, check that no leaks are found. Then, add the necessary amount of the specified fluid.

I

If

the amount is in-

I

G10087A

I

PI-8

PRE-DELIVERY INSPECTION

PRE-DELIVERY

I

INSPECTION

20.WlNDOW WASHER FLUID

Check the window washer fluid amount. amount is insufficient, check that no leaks are found. Then, add the necessary amount of washer fluid commercially available.

If

the

21.HOOD LATCH CHECK

Retract the hood stay and close the hood. Check

that the hood is securely latched.

22.KEYLESS ENTRY SYSTEM

Check the keyless entry system operations as follows:

Fully open all the door windows. Remove the key from the ignition switch and

close all the doors including rear gate (wagon).

Press the “LOCWARM” button on the transmitter

if

momentarily once and check locked and the horn chirps once.

I

all the doors are

Press the “LOCWARM” button on the transmitter

momentarily once with one of the doors including

the rear gate (wagon) open and check

if

the horn chirps three times to warn of a door ajar. Then, bring all the doors including the rear gate

(wagon) in closed condition and check

if

all the

doors are locked and the horn chirps once.

Press the “LOCK side of the power door locking

switch with any one of the doors including the rear gate (wagon) open. Then, bring all the doors including the rear gate (wagon) in the closed condition and check if all the doors are locked and the

horn chirps once.

LOCK

GI0091

Press the “UNLOCWDISARM” button on the transmitter momentarily once and check if the driver’s door is unlocked, the horn chirps twice and the dome light illuminates.

I

GI0092

Press the “UNLOCWDISARM” button on the transmitter momentarily once again within five seconds and check if all the doors including the rear gate on wagon are unlocked.

Press the “LOCWARM” button on the transmitter a little bit of time (approx.

sec.) and check

if

a

1.5

panicking condition occurs; the horn sounds continuously. Also, check

if

that condition lasts for

30

sec-

onds or until any button of the transmitter is

pressed.

Check selecting audible signal operation.

Using the horn, the system will give you an audi-

ble signal when the doors lock and unlock.

If

desired, you may turn the audible signal off.

To turn the audible signal off, carry out the unlock-

ing procedure of keyless entry system, then simul-

taneously depress LOCWARM and UNLOCW

DISARM buttons for more than two seconds. The horn will sound two times to inform you that the audible signal has been turned off. To turn the audible signal on, carry out the unlock-

ing procedure of keyless entry system, then simultaneously depress LOCWARM and UNLOCW

DISARM buttons for more than two seconds. The forn will sound one time

to

inform you that the

audible signal has been turned on.

I

PRE-DELIVERY INSPECTION

PRE-DELIVERY

INSPECTION

23.SECURITY SYSTEM

Check the security system operations as follows:

Fully open all the door windows. Remove the key from the ignition switch and

close all the doors including rear gate (wagon).

Press the “LOCWARM” button on the transmitter

momentarily once and check if all the doors are locked, the horn chirps once, the parking lights

flash once and the security indicator light flashes

to

slowly brought into the arming state.

c-

Press the “UNLOCWDISARM” button on the transmitter momentarily once and check er’s door is unlocked, the horn chirps twice, the parking light flash twice, the dome light illuminates and the security indicator light goes off to ensure that the system has been brougt into the disarming state.

Press the “UNLOCWDISARM” button on the

transmitter momentarily once again within five seconds and check if all the doors including the rear gate on wagon are unlocked.

Press the “LOCWARM” button on the transmitter

a little bit of time (approx.

panicking condition occurs; the horn sounds continuously, the parking lights flash and the security in-

dicator light flashes rapidly. Also, check if that condition lasts for the transmitter is pressed.

Press the “LOCWARM” button on the transmitter momentarily once with one of the doors including

the rear gate (wagon) open and check if the horn chirps three times to warn of a door ajar.

ensure that the security system has been

I

1.5 sec.) and check if a

30

seconds or until any button of

GI0091

if

the driv-

GI0092

I

Then, bring all the doors including the rear gate (wagon) in closed condition and check if the arming condition is brought about; all the doors are locked, the horn chirps once and the parking lights flash once.

Press the “LOCK’ side of the power door locking switch with any one of the doors including the rear gate (wagon) open. Then, bring all the doors in-

cluding the rear gate (wagon) in the closed condition and check if all the doors are locked, the horn

to

chirps once and the parking lights flash once

ensure that the security system has been brought into the arming state.

LOCK

Unlock a door using the inner lock knob or the

key and open the door while the security system is in the arming state. Check to ensure that the alarming condition occurs, i.e. the horn sounds continu-

ously, the parking lights flash and security indicator

30

light flashes rapidly, and that it lasts for

seconds

or until the “UNLOCWDISARM” button on the

to

transmitter is pressed. Also, check

to

turning the ignition key

the “START position in

ensure that

the arming state does not cause the starter motor

to

turn, thus the engine being prevented from start-

ing.

Apply a shock

to

the vehicle body with the security system in arming state, and check to ensure that the alarming condition occurs.

Troubleshoot the security system if any one of

the above-mentioned checks does not meet the re-

qui remen

ts.

24.SEAT

Check that each seat provides full functionality in

sliding and reclining. Check all available functions of the rear seat such as a trunk-through center arm

rest.

25.SEAT BELT

Pull out the seat belt and then release it. Check

that the belt webbing retracts smoothly.

Check the seatbelt warning light and chime oper-

ations.

PI-I

0

PRE-DELIVERY INSPECTION

1

PRE-DELIVERY INSPECTION

26.WHEEL ALIGNMENT

Check the wheel alignments. <Ref. to Alignment.> and <Ref. to

.>

RS-9,

FS-8,

Wheel

Wheel Alignment,

27.READ MEMORY AND TEST MODE CONNECTORS

Turn the ignition switch

check-engine light starts blinking. return the ignition key to LOCK and disconnect the test mode connector. Then, turn the ignition key to

ON

again.

If

the check-engine light blinks at that time in spite of the disconnected test mode connector, carry out an engine diagnosis.

to

ON

and check that the

If

the light blinks,

35. LIGHTING SYSTEM

Check the headlight operations.

Check the brake light operations.

Check the other lights for normal operations. Check the daytime running light system opera-

tions.

Check the illumination brightness control system

operations.

36.WINDOW WASHER

Check that the washer fluid to the specified area of the windshield shown in the figure.

Front Injection position:

A:

257”

B:

512”

window washer system injects

(IO.

12

in)

(20.16

in)

___

28.KEY WARNING SYSTEM

Check that the chime sounds when the driver’s door opens and the key is in the “LOCK’ or “ACC” position.

29. STA RTI N G CON DIT1 0 N

Start the engine and check that the engine starts smoothly.

found, recharge or replace the battery.

If

any battery voltage problems are

If

any abnormal noises are observed, immediately stop the engine and check and repair the necessary components.

30.EXHAUST SYSTEM

Listen to the exhaust noise to see if no abnormal noises are observed.

31 .INDICATOR LIGHT

Check that all the indicator lights are off.

32.CLOCK

Check the clock for normal operations and enough accuracy.

Rear Injection position:

A:

39

mm

(2.36

in)

B:

72”

I\

1?K

(/

I\

Nozzle

33.RADIO

Check the radio for full functionality and normal

noise level. Also check the CD unit operations.

34.CIGARETTE LIGHTER

Check the cigarette lighter operations.

PI-I

1

I

PRE-DELIVERY

INSPECTION

PRE-DELIVERY

INSPECTION

40.AT SHIFT CONTROL

Set the AT selector lever to each gear position while checking that the demanded gear position is correctly attained.

Selector lever gate pattern

Selector Gear

Position

Yes Yes Yes Yes Yes Yes

2

I

Yes

I

1

I

Yes

Check the shift lock system operations. Check the key interlock system operations.

I

Yes

Position

I

41 .HEATER & VENTILATION

Operate the heater and ventilation system to check for normal airflow and heating capacity.

42.AIR CONDITIONER

Operate the air conditioner. Check that the A/C compressor operates normally and enough cooling is provided.

43.CRUISE CONTROL

Operate the cruise control system. Check that the system is activated and deactivated correctly.

44.ATF LEVEL

Check that the ATF level is normal. check that no leaks are found. Then add the necessary amount of the specified ATF.

Lower level

If

insufficient,

<-upper

1-

Lower level

level

G10098A

45.POWER STEERING FLUID LEVEL

Check that the power steering fluid level is normal.

If

insufficient, check that no leaks are found. Then add the necessary amount of the specified power steering fluid.

46.FLUID LEAK CHECK

Check the entire areas of the vehicle for any trace of coolant/oil/fluid leaks.

47.WATER LEAK TEST

Spray the vehicle with water and check that no wa-

ter enters the passenger compartment.

Before performing the water leakage test, re-

move anything that may obstruct the operation or

which must be kept dry.

Close all of the windows completely, and then

close all of the doors tightly. Close the hood and

trunk lid before starting the test.

Connect a hose to a tap, and spray water on the

vehicle. The rate of water discharge must be ap-

6.6

prox. 20 to 25 liters (5.3 to Imp gal) per minute.

When spraying water on areas adjacent to the floor and wheel house, increase the pressure. When di-

recting water on areas other than the floor portion

and wheel house, decrease the pressure. But the force of water must be made strong occasionally by

pressing the end of the hose. NOTE:

Be sure to keep the hose at least

from the vehicle.

Check the following areas:

Front window and body framework mating

portion

Door mating portions Glass mating portions

Rear quarter window mating portions Rear window and body framework mating

portion

Around roof drips

US gal, 4.4 to

10 cm

(3.9

5.5

in)

PI-I

2

I

PRE-DELIVERY INSPECTION

If

any dampness in the compartments is discov-

ered after the water has been applied, carefully check all areas that may have possibly contributed to

the leak.

48.APPEARANCE CHECK 2

Check the vehicle body paints, plated faces, glass,

for

and lenses

any dirt or damage.

I

PRE-DELIVERY INSPECTION

PI-I

3

PRE-DELIVERY INSPECTION

I

PI-I

4

PERIODIC MAINTENANCE SERVICES

General Description

1

.

Schedule

2

.

Engine Oil

3 .

Engine Oil Filter

4 .

Spark Plugs

5 .

Drive Belt(s)

6 .

Camshaft Drive Belt

7 .

Fuel Line

8

.

Fuel Filter

9

.

Air Cleaner Element

..

10 .

Cooling System

11

.

Coolant

12 .

Idle Mixture

13 .

Clutch System

14 .

Transmission Oil

15 .

ATF 23

16

.

Front

17 .

Brake Line

18 .

Brake Fluid

19 . 20 . 21 22 23 . 24 . 25 . 26 .

Disc Brake Pads and Discs Brake Linings and Drums

.

Suspension 31

.

Wheel Bearing Axle Boots

Steering System (Power Steering) Supplemental Restraint System

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

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

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

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

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

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

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

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

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

&

Rear Differential Oil

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

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

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

&

Joints

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

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

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

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

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

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

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

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

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

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

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

............................................................ 35

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

PM

Page

2

3 5

7

8

9

11 14

15 16 17 18 20

21 22

24 25 27

28 29

33 34

38

GENERAL DESCRIPTION

PERIODIC MAINTENANCE SERVICES

1.

General Description

A:

GENERAL

Be sure to perform periodic maintenance in order to maintain vehicle performance and find problems before they become serious.

I

P

M-2

SCHEDULE

I

PERIODIC MAINTENANCE SERVICES

--I1

--Clutch system

12

Transmission oil

13

ATF

14

Front

8,

rear

differential oil

15

Brake line

16

Brake fluid

17

Disc brake pads discs

18

Brake linings and

drums

19

Parking brake

20

Suspension

21

Wheel bearing

22

Axle boots &joints

23

Tire rotation

24

Steering system (Power steering)

25

Supplement restraint system

Symbols used:

R:

Replace

I:

Inspection

(R)

or

(I):

Recommended service for safe vehicle operation.

NOTE:

(1)

This inspection is not required

EPA’s in-use compliance program.

(2)

When the vehicle is used in extremely dusty conditions, the air cleaner element should be replaced more often.

(3)

ATF filter is maintenance free part. ATF filter needs replacement, when it has physically damaged or (4) A tire should be replaced when the tread wear indicator appears as a solid band across the tread. The indicators appear when the remaining tread has been worn to

&

I

I I

I

I I I

I

to

maintain emission warranty eligibility and it dose not affect the manufacturer’s obligations under

1.6

I I I I I I I

I

R R R

I I

I

I I

I

I I

mm

(0.063

I

I I

I

I I

I

Inspect every

in) or less.

I

I I

I

10

years

I

I I

I

I I

I

I I I

I

I I

I

I I

I

I I I

I

ATF

leaked.

I

I I

Note

I

R

I

(1)

I

INote(4)

I

(3)

PM-3

I

PERIODIC MAINTENANCE SERVICES

B:

MAINTENANCE SCHEDULE

SCHEDULE

2

Item

Engine oil

Engine oil filter

Fuel filter

Fuel line

Transmission oil

-.

AT

F

Front & rear differential oil

Brake line

Brake fluid

3.75 months

6,000

km

3,750 miles

15 months

24,000 km

15,000 miles 15 months

24,000 km

15,000 miles 15 months

15,000 miles

15 months 24,000 km 15,000 miles

15 months

24,000 km

15,000 miles 15 months

R

High humid- Repeat towity or moun- ing trailer

road drive

used or coastal area

tain area

R

I

Disc brake pads

&

discs

Brake linings and drums

Parking brake

Suspension

Axle boots joints

Steering system (Power steering)

&

15,000 miles

15 months

24,000 km

15,000 15 months

ziGlK-7

15,000 miles

7.5 months

7,500 miles

-izzzGl

7,500 miles

7.5

months 12,000 km 7,500 miles

miles

I

I I

I

1

I

I-

I

T

PM-4

ENGINE

3.

Engine Oil

A:

REPLACEMENT

1)

Drain the engine oil by loosening engine oil drain

Plug.

2) Open the engine oil filler cap for quick draining of

the engine oil.

Upper level

1.0

us

Imp

L

qt, qt)

About

(1.1

0.9 Lower level

OIL

PERIODIC MAINTENANCE SERVICES

5)

Fill the engine oil through filler pipe up to the upper point on level gauge. Make sure that the vehicle is placed level when checking oil level. Use engine oil of proper quality and viscosity, selected in accordance with the table in figure.

Engine oil capacity (Non-TURBO model):

Upper level

4.0

0

(4.2

US

qt, 3.5 Imp qt)

Lower level

0

(3.2

US

3.0

Engine oil capacity (TURBO model):

Upper level

0

4.5

(4.8

Lower level

0

3.5

(3.7

SAE Viscosity

("C)

-30 -20-15

(OF)

-22

I

qt, 2.6 Imp qt)

US

qt, 4.0 Imp qt)

US

qt, 3.1 Imp qt)

No.

and

4

5

II

32

Applicable Temperature

0

I I

15

59

30

40

86 104

II

G10015A

I

3)

Replace the drain plug gasket.

U

G10013A

4) Tighten the engine oil drain plug after draining engine oil.

Tightening torque:

44 N-m (4.5 kgf-m, 33 fi-lb)

Thc

proper viscosity helps vehicle get good cold

and hot starting by reducing viscous friction and

thus increasing cranking speed.

NOTE:

When replenishing oil, it does not matter

to

be added is a different brand from that in the en-

if

the oil

gine; however, use oil having the API classification and SAE viscosity

If

vehicle is used in desert areas with very high

No.

designated by SUBARU.

temperatures or for other heavy duty applications, the following viscosity oils may be used:

SJ

or

API classification:

SAE Viscosity

No.:

SH

30,

40, 1OW-50, 2OW-40, 20W-

50

6)

Close the engine oil filler cap.

7)

Start the engine and warm it up for a time.

PM-5

I

ENGINE

PERIODIC MAINTENANCE SERVICES

8)

After the engine stops, recheck the oil level.

If

necessary, add the engine oil up to the upper lev-

el on level gauge.

Oil

level

gauge

I-&

Notch mark

Upper level

About

1.OL

(1.1

us

0.9

qt,

Imp

qt)

Lower level

G10016A

OIL

B:

INSPECTION

1)

Park vehicle on a level surface.

2)

Remove the oil level gauge and wipe it clean.

3)

Reinsert the level gauge all the way. Be sure that the level gauge is correctly inserted and in the proper orientation.

4)

Remove it again and note the reading. gine oil level is below the the level up to the

5)

After turning off the engine, wait a few minutes

“F

line.

“L”

line, add oil to bring

for the oil to drain back into the oil pan before checking the level.

6) Just after driving or while the engine is warm, the engine oil level may show in the range between the

‘IF”

line and the notch mark. This is caused by ther-

mal expansion of the engine oil.

7)

To prevent overfilling the engine oil, do not add the oil above the

‘IF’

line when the engine is cold.

If

the en-

PM-6

I

ENGINE OIL FILTER

4.

Engine Oil Filter

A:

REPLACEMENT

1)

Remove the oil filter with ST.

ST 498547000 OIL FILTER WRENCH

2)

Get a new oil filter and apply a thin coat of engine

oil to the seal rubber.

3) Install the oil filter by turning it by hand, being careful not to damage seal rubber.

4)-Tighten more (approximately ter the seal rubber contacts the oil pump case. not tighten excessively, or oil may leak.

5)

After installing oil filter, run the engine and make

sure that no oil is leaking around seal rubber. NOTE:

The filter element and filter case are permanently joined; therefore, interior cleaning is not necessary.

6)

Check the engine oil level. <Ref. to PI-3, PDI

PROCEDURE, P re-delivery Inspection

2/3

to 3/4 turn) af-

.>

Do

PERIODIC MAINTENANCE

1

SERVICES

PM-7

I

SPARK PLUGS

PERIODIC MAINTENANCE SERVICES

5.

Spark

A:

REPLACEMENT

1)

Remove the intake duct and intake chamber.

2)

Remove the washer tank and put it aside.

3)

Disconnect the spark plug cord.

4) Remove the spark plug with a plug-wrench.

5) Set the new spark plug.

c-

Recommended - spark plug

Non-Turbo model

CHAMPION RClOYC4 (Standard) NGK BKRSE-11 NGK BKRGE-11 Spark plug gap

1.0

-

Turbo model

NGK PFRGG Spark plug gap

0.7- 0.8

6)

Tighten the spark plug lightly with hand, and then

secure with a plug-wrench

Plugs

:

1.1

mm (0.039 - 0.043 in)

mm

(0.028

-

0.03 1 in)

to

the specified torque.

Tightening torque:

20.6

N.m

(2.10

kgf-m, 15.19 ft-lb)

NOTE:

Be sure to place the gasket between the cylinder

head and spark plug.

If

the torque wrench is not available, tighten

spark plug until gasket contacts cylinder head; then

1/4

to

1/2

tighten further

turns.

PM-8

DRIVE BELT(S)

1

PERIODIC MAINTENANCE SERVICES

6.

Drive

A:

INSPECTION

1)

Replace the belts,

found.

2)

Check the drive belt tension and adjust it if necessary by changing generator installing position and/or idler pulley installing position.

Belt tension

Belt(s)

if

cracks, fraying or wear is

(4

replaced: reused: 9.0

(9)

*

replaced: 7.5 reused: 9.0

*:

There is no belt

ditioner.

7

-

9 mm (0.276 - 0.354 in)

-

10.0 mm (0.354 - 0.394 in)

-

8.5 mm (0.295 - 0.335 in)

-

10.0 mm (0.354 - 0.394 in)

(B)

on models without an air con-

98

N

(10

ka.

22

Ib)

B: REPLACEMENT

1.

V-BELT COVER

1)

Remove the V-belt cover.

2.

FRONT SIDE BELT (DRIVING POWER

STEERING

NOTE:

Wipe off any oil or water on the belt and pulley.

1)

Loosen the lock bolt

2)

Loosen the slider bolt

3)

Remove the front side belt

4)

Install a new belt, and tighten the slider bolt so as

to

obtain the specified belt tension.

5) Tighten the slider bolt

6)

Tighten the lock bolt

OIL

PUMP AND GENERATOR)

(A).

(B).

(C).

(B).

(A).

C/P

GEN Generator P/S A/C I/P

Crankshaft pulley

Power steering oil pump pulley

Air

conditioning compressor pulley

Idler pulley

Tightening torque:

Lock bolt, through bolt:

25 N-m (2.5 kgf-m, 18 ft-lb)

Slider bolt:

8 N.m (0.8 kgf-m, 5.8 ft-lb)

G10021A

PM-9

I

DRIVE

PERIODIC MAINTENANCE SERVICES

3.

REAR

TIONER)

NOTE:

Wipe

Before removing the rear side belt, remove the

front side belt.

1)

Loosen the lock nut

2)

Loosen the slider bolt (9).

3)

Remove the rear side belt.

4)

Install a new belt, and tighten the slider bolt

to obtain the specified belt tension.

5)

Tighten the slider bolt (9).

6)

Tighten the lock nut

Tightening torque:

22.6

SIDE

off

any oil or water on the belt and pulley.

N*m

BELT (DRIVING AIR CONDI-

(A).

(2.3 kgf-m, 16.6

ff-lb)

so

BELT(S)

as

PM-10

CAMSHAFT DRIVE BELT

7.

Camshaft

A:

REPLACEMENT

1.

SOHC

1) Remove the radiator fan <Ref. to CO-9, Radia-

tor Main Fan System.> and air conditioner fan.

<Ref. to CO-17, Radiator Sub Fan System.>

2) Remove the V-belt cover.

MODEL

Drive

Belt

PERIODIC MAINTENANCE SERVICES

10)

Turn the crankshaft and align alignment marks on crankshaft, and left and right camshaft sprockets with notches of belt cover and cylinder block: ST 499987500 CRANKSHAFT SOCKET

Notch

ent

mark

Notch

1

3)Remove the V-belts. <Ref. to ME(S0HC)-43, Vbelt.>

4) Remove the air conditioning compressor drive belt tensioner.

5)

Remove the pulley bolt. To lock crankshaft use ST. ST 499977t00 CRANKSHAFT PULLEY

WRENCH

6)

Remove the crankshaft pulley.

7) Remove the left side belt cover.

8) Remove the front belt cover.

9) Remove the timing belt guide. (MT vehicle only)

G10025A

11) Remove the belt idler.

12) Remove the belt idler (No. 2).

GI0026

13) Remove the timing belt.

14) Remove the automatic belt tension adjuster as-

sembly.

PM-11

I

PERIODIC MAINTENANCE

SERVICES

CAMSHAFT

DRIVE

BELT

3

2.

DOHCMODEL

1) Remove the radiator fan and air conditioner fan.

to

2) Remove the V-belts. <Ref.

ME(D0HC TUR-

BO)-44, V-belt.>

3) Remove the air conditioning compressor drive belt tensioner.

4) Remove the pulley bolt. To lock crankshaft use ST. ST 499977300 CRANKSHAFT PULLEY

c-

.

WRENCH

10) Turn the crankshaft and align alignment marks on crankshaft, and left and right camshaft sprockets with notches of belt cover and cylinder block.

To turn crankshaft, use ST: ST 499987500CRANKSHAFT SOCKET

Notch Notch

Alignment mark

Notch

-

Alignment mark

,Alignment

5)

Remove the crankshaft pulley.

6)

Remove the air conditioning compressor drive

belt tensioner.

7) Remove the left side belt cover.

8) Remove the right side belt cover.

9)

Remove the front belt cover.

BOO1

39

11) Remove the belt idler.

12) Remove the timing belt.

13) Remove the automatic belt tension adjuster assembly.

PM-12

CAMSHAFT

DRIVE

BELT

I

PERIODIC MAINTENANCE SERVICES

B:

INSTALLATION

1.

SOHC MODEL

To

install, reverse order of removal procedures.

to

<Ref.

2.

To install, reverse order of removal procedures. <Ref. to ME(D0HC TURBO)-48, Timing Belt Assem bly.>

CAUTION: When installing the timing belt, be sure to align all alignment marks on the belt with corresponding marks on the sprockets.

installed, interference between pistons and

valves may occur.

ME(S0HC)-47, Timing Belt Assembly.>

DOHCMODEL

If

incorrectly

--

C: INSPECTION

1.

SOHC MODEL

1)

Remove the left and right timing belt covers.

2) While cranking engine at least four rotations, check the timing belt back surface for cracks or damage. Replace the faulty timing belt as needed.

3)

Measure the timing belt width W. If it is less than

(1.06

27 mm pump pulley and cam sprocket to determine idler alignment (squareness). Replace the worn timing

belt.

I

4) Install the left and right timing belt covers.

in), check the idlers, tensioner, water

2.

DOHCMODEL

1)

Remove the left and right timing belt covers.

2)

While cranking engine at least four rotations, check the timing belt back surface for cracks or damage. Replace the faulty timing belt as needed.

3)

Measure the timing belt width W.

30

mm

(1.1

8

in), check the idlers, tensioner, water pump pulley and cam sprocket to determine idler alignment (squareness). Replace the worn timing belt.

4) Install the left and right timing belt covers.

If

it is less than

GI0143

PM-13

I

FUEL LINE

PERIODIC MAINTENANCE SERVICES

8.

Fuel

A:

INSPECTION

The fuel line is located mostly internally, the pipes, areas near pipes, and engine compart-

ment piping for rust, hose damage, loose bands, etc. If the faulty parts are found, repair or replace them. <Ref. to FU(S0HC)-68, Fuel Delivery, Return and Evaporation Lines.> or <Ref. to FU(D0HC TURBO)-68, Fuel Delivery, Return and Evaporation Lines.>

Line

so

check

c-

.

PM-14

FUEL FILTER

9.

Fuel

A:

REPLACEMENT

For fuel filter replacement procedures, refer to “FU” section. <Ref. FU(D0HC TURBO)-65, Fuel Filter.>

to

Filter

FU(S0HC)-65, Fuel Filter.> or <Ref. to

PERIODIC MAINTENANCE SERVICES

PM-15

I

AIR CLEANER ELEMENT

PERIODIC MAINTENANCE SERVICES

1

O.Air

A:

NOTE:

Do The filter paper of the element is wetted with a special non-inflammable slow-evaporating viscous liq-

uid. service life. Dirt adhering

porous laminations with the viscous liquid, which function as a filtration layer tion into the filter paper.

cleaned, the filtration layer thus formed will be lost

along with the viscous liquid.

1.

NON-TURBO MODEL

Cleaner Element

REPLACEMENT

not attempt

It

is resistant

to

clean the air cleaner element.

to

cold weather and has a long

to

this filter paper forms

to

reduce dust penetra-

If this filter paper is

2.

TURBO MODEL

01

1)

Remove the clip (B) above the air cleaner case.

2E

1)

Remove the bolt

case

to

stays.

2)

Remove the clip

3)

Remove the air cleaner.

4)

Install in the reverse order of removal.

CAUTION:

Fasten with a clip after inserting the lower tab

of the case.

(A)

which install air cleaner

(B)

above the air cleaner case.

2)

Remove the air cleaner.

3)

Install in the reverse order of removal.

CAUTION:

Before installing air cleaner upper cover, align holes with protruding portion of air cleaner low-

er case, then secure upper cover to lower case.

PM-16

COOLING

SYSTEM

3

PERIODIC MAINTENANCE SERVICES

11

.Cooling

A:

INSPECTION

1) Check the radiator for leakage, filling it with cool-

ant and attach radiator cap tester

Then apply a pressure of 157 kPa (1.6 kg/cm2

psi) and check the following points:

Each portion of radiator for leakage Hose joints and other connections for leakage

NOTE:

When attaching or detaching tester and when

operating tester, use special care not

diator filler neck.

System

to the filler neck.

,

23

to

deform ra-

Radiator cap valve open pressure

Standard value:

-

123 kPa (0.95 - 1.25 kg/cd, 14 - 18

93

Psi)

Service limit:

83

kPa (0.85 kg/cd

,

12

psi)

TURBO model

When performing this check, be sure to keep the

engine stationary and fill radiator with coolant.

Wipe

off

check points before applying pressure.

Use care not to spill coolant when detaching

tester from radiator.

2) Check the radiator cap valve open pressure using radiator cap tester.

NOTE:

Rust or dirt on cap may prevent valve from func-

to

tioning normally: be sure ing.

Raise the pressure until the needle of gauge stops and see if the pressure can be retained for five to six seconds. The radiator cap is normal if a pressure above the service limit value has been maintained for this period.

clean cap before test-

/

Crack, deformation

3)

If

the coolant temperature exceeds 76.0 to

to

80.0"C (1 69 check thermostat.

to

76.0 one.

4)

temperature exceeds 90 to 94°C (194

check thermoswitch or fan motor.

80.0"C (1 69 to 176"F), replace it with a new

If electric fan does not operate when coolant

176°F) while radiator is not

If

thermostat does not open at

damage, rust

tion,

G10035P

to

so

hot,

201"F),

PM-17

I

COOLANT

PERIODIC MAINTENANCE SERVICES

12.Coolant

A:

REPLACEMENT

1.

REPLACEMENT

WARNING: The radiator is

attempt to open the radiator cap immediately

after the engine has been stopped.

1)

Lift up the vehicle.

2)

Remove the under cover.

3)

Place a container under drain pipe.

4) Loosen and remove the drain plug to drain en-

gine coolant into the container.

of the pressurized type.

OF

COOLANT

Do

not

11)

Stop the engine and wait until coolant temperature lowers. Then open the radiator cap to check coolant level and add coolant up to radiator filler neck. Next, add coolant into reservoir tank up to “FULL” level.

12)

After adding coolant, securely the install radiator and reservoir tank caps.

5)

For quick draining, open the radiator cap.

CAUTION:

Be careful not to spill coolant on the floor.

6)

Drain the coolant from reservoir tank.

7)

Tighten the radiator drain screw securely after

draining coolant.

8)

Slowly pour the prepared coolant from radiator filler port to neck of filler, then pour into the reservoir tank up to “FULL” level.

Coolant capacity (fill up to

Non-turbo AT model:

Approx. 6.9

Non-turbo MT model:

Approx. 7.0

Turbo AT model:

Approx. 7.6

Turbo MT

Approx. 7.7 Q (8.1

NOTE: The SUBARU Genuine Coolant containing anti-

freeze and anti-rust agents is especially made for

SUBARU engine, which has an aluminum crankcase. Always use SUBARU Genuine Coolant, since other coolant may cause corrosion.

9)

Securely install the radiator cap.

10)

Run engine for more than five minutes at

to

3,000

hot in order to purge air trapped in cooling system.)

rpm. (Run engine until radiator becomes

Q Q Q

model:

(7.3 (7.4 (8.0

“FULL”

US

qt, 6.1 Imp qt)

US

qf,

6.2

US

qt, 6.7 Imp qt)

US

qt, 6.8 Imp qt)

level)

Imp qt)

2,000

PM-18

COOLANT

2.

RELATIONSHIP OF SUBARU COOLANT CONCENTRATION AND FREEZING TEMPERATURE

The concentration and safe operating temperature of the SUBARU coolant is shown in the diagram.

Measuring the temperature and specific gravity of

the coolant will provide this information.

[Example]

If

the coolant temperature is

specific gravity is

1.054,

(point A), the safe operating temperature is (7°F) (point B), and the freezing temperature is

20°C

(-4°F) (point

C).

Safe operating temperature

/

25°C

(77°F) and its

the concentration is

-1 4°C

,Concentration

of coolant

35%

-

PERIODIC MAINTENANCE SERVICES

3.

PROCEDURE TO ADJUST THE CON-

CENTRATION OF THE COOLANT

To adjust the concentration of the coolant according to temperature, find the proper fluid concentration in the above diagram and replace the necessary amount of coolant with an undiluted lution of SUBARU genuine coolant (concentration

50).

The amount of coolant that should be replaced can

be determined using the diagram.

[Example] Assume that the coolant concentration must be increased from

25%

line of coolant concentration intersects with

the

40%

25%

to

40%.

Find point A, where the

curve of the necessary coolant concentration, and read the scale on the vertical axis of the graph at height drained is

2.1

liters

(2.2

cooling system and add

2.1

A.

liters

US qt,

The quantity of coolant to be

(2.2

US qt,

1.8

Imp qt) of coolant from the

2.1

1.8

liters

Imp qt). Drain

(2.2

US qt,

Imp qt) of the undiluted solution of SUBARU cool-

ant.

If

a coolant concentration of

50%

is needed, drain all the coolant and refill with the undiluted solution only.

so-

1.8

I

Coolant temperature "C

("F)

G10037A

-

I

U

-

2

I

U

c

0

%

c

-

c

(t(

3

r

10

Concentration cooling system

Concentration and quantity

Necessary concentration

of

coolant

20

to

30

of

coolant in the vehicle

of

coolant in vehicle

be drained

40

G10038A

I

5C

PM-19

PERIODIC MAINTENANCE SERVICES

IDLE MIXTURE

13.Idle

A:

INSPECTION AND ADJUSTMENT

1.

IDLE MIXTURE

Before measuring the idle mixture, make sure that the ignition timing and the engine idle speed are within specifications.

1)

Set the gear position at “Neutral” for MT, or “N” or

“P”

for AT.

2)

Warm up the engine sufficiently until cooling fan

starts to operate.

3)

Measure the idle mixture with the

Mixture

Engine idle speed

700+100

rpm

CO

meter.

co

1.0+0.5%

I

NOTE:

If

driving the vehicle on out of specified data, the

“trouble code

49”

is indicated in many case.

GI01

14A

1

PM-20

CLUTCH SYSTEM

14.Clutch

A:

INSPECTION AND ADJUSTMENT

1)

Push the release lever to retract the push rod of the operating cylinder and check the clutch reservoir tank rises or not.

System

if

the fluid level in

PERIODIC MAINTENANCE SERVICES

5)

Check the fluid level using the scale on the outside of the clutch master cylinder tank (A). el is below to “MAX

Recommended clutch fluid:

FMVSS fluid

NOTE:

Avoid mixing different brakes of brake fluid to

prevent degradation of the fluid.

Be careful not to allow dirt or dust to get into the

reservoir tank.

“MIN”

(C).

No.

(B), add clutch fluid to bring it up

116,

fresh

DOT3

or

DOT4

If

the lev-

brake

1

TURBO model,

2)

If

the fluid level rises, pedal free play is correct.

3)

If

the fluid level does not rise, or the push rod cannot be retracted, adjust the clutch pedal. <Ref. to

CL-26,

4)

Inspect the underside of master cylinder, clutch damper and operating cylinder for clutch system, hoses, piping and their couplings for fluid leaks.

If

the fluid leaks are found, correct them by retight-

ening their fitting bolt and/or replacing their parts.

Clutch Pedal.>

\

PM-21

I

TRANSMISSION OIL

PERIODIC MAINTENANCE SERVJCES

15.Transmission Oil

A:

REPLACEMENT

1.

MANUAL TRANSMISSION

1)

Drain the gear oil by removing drain plug after al-

3

lowing the engine to cool for NOTE:

Before starting work, cool off the engine well.

to 4 hours.

~ ~~

2)

Reinstall the drain plug after draining gear oil

and tighten it to the specified torque.

Tightening torque:

44 N.m (4.5 kgf-m, 32.5

NOTE:

Be sure to place a gasket between the transmis-

sion case and drain plug.

Replace the gasket with a new one. Each oil manufacturer has its base oil and addi-

do

tives. Thus,

3)

Fill the transmission gear oil through the oil level

gauge hole up

Gear

oil

capacity:

3.5

8

(3.7

not mix two or more brands.

to

the upper point of level gauge.

US

qt, 3.1 Imp qt)

ft-lb)

--Lower \-upper level level

I

G10042P

PM-22

ATF

1

PERIODIC MAINTENANCE SERVICES

16.ATF

A:

REPLACEMENT

1.

AUTOMATIC TRANSMISSION FLUID

1) Drain ATF (Automatic Transmission Fluid) by removing drain plug after allowing the engine to cool for

3

to 4 hours.

NOTE: Before starting work, cool off the engine well.

2)

Reinstall the drain plug after draining ATF, and

tighten it to the specified torque.

2.

ATF FILTER

NOTE: ATF filter is maintenance free part. ATF filter needs replacement, when it has physically damaged or ATF leaked.

For the replacement procedures <Ref. to AT-44, ATF Filter.>

Of

the ATF filter:

Tigh fening torque:

24.5

N.m

(2.5

kgf-m,

3)

Fill ATF

level gauge by using the gauge hole.

Recommended fluid:

Dexron

Fluid capacity:

Fill the same amount drained from ATF drain

plug hole.

4) Run the vehicle until the ATF temperature rises

to

60

level.

up

to

the middle of the “COLD” side on

111

type automatic transmission fluid

to

80°C (140 to 176°F) and check the ATF

I

78.7

ff-16)

“Hot”

Lower level

G10044P

PM-23

I

FRONT & REAR DIFFERENTIAL OIL

PERIODIC MAINTENANCE SERVICES

17.Front & Rear Differential

A:

REPLACEMENT

1.

FRONT DIFFERENTIAL (MANUAL

TRANSMISSION)

For

M/T

vehicle, manual transmission oil works as differential oil to lubricate differential. Refer to “Transmission Oil”. <Ref. to Oil.>

2. FRONT DIFFERENTIAL (AUTOMATIC TRANSMISSION)

1)

Drain the differential gear oil by removing drain plug after allowing the engine to cool for hours.

NOTE: Before starting work, cool

PM-22,

off

the engine well.

Transmission

Oil

3

to

4

3.

REAR DIFFERENTIAL

1)

Drain the oil by removing drain plug.

2)

Remove the filler plug for quick draining oil.

3)

Reinstall the drain plug after draining oil.

NOTE:

Apply the fluid packing to drain plug threads be-

fore installation in Except Non-TURBO AT model.

Fluid packing:

Three Bond 1105

Tightening torque:

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

4)

After installing drain plug onto rear differential

gear case firmly, Plug.

fill

oil up fully to the mouth of filler

I

2)

Reinstall drain plug after draining differential

gear oil and tighten it to the specified torque.

Tightening torque:

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

NOTE:

Be sure to place a gasket between the transmis-

sion case and drain plug.

Replace the gasket with a new one. Each oil manufacturer has its base oil and addi-

tives. Thus, do not mix two or more brands.

3)

Fill differential gear oil through the oil level gauge

hole up to the upper point of level gauge.

Differential gear oil capacity:

8

1.1-1.3

(1.2-11.4US9t, l.0-11.11mp9t)

L

Drain

plug

GI0165

Oil capacity:

0.8 8 (0.8

NOTE: Each oil manufacturer has its base oil and addi-

tives. Thus, do not mix two or more brands.

5)

Install the filler plug onto rear differential gear

case firmly.

NOTE: Apply the fluid packing to filler plug before installation.

Fluid packing:

Three Bond 1105

Tightening torque:

49.0 Nom (5.0 kgf-m, 36.2 ff-lb)

US

9t,

0.7

Imp 9t)

-Upper

-Lower level

level

G10046A

PM-24

BRAKE LINE

I

PERIODIC MAINTENANCE SERVICES

18.Brake

A:

INSPECTION

1.

BRAKE LINE

1

)

Check the scratches, swelling, corrosion and/or

Line

traces of fluid leakage on brake hoses or pipe

joints.

2)

Check the possibility of adjacent parts interfering with brake pipedhoses during driving, and loose connections/clamps.

3)

Check any trace of fluid leakage, scratches, etc. on master cylinder, wheel cylinder and pressure control valve.

NOTE:

When the brake fluid level in the reservoir tank is

lower than the specified limit, the brake fluid warning light on the combination meter will come on.

Visually check brake hose (using a mirror where

it is difficult to see) for any damage.

C.

-

48A

B: CHECKING

1.

SERVICE BRAKE

1)

Check the free play of brake pedal with a force of

less than

Brake

1

just the brake pedal as follows:

(1)

plied to brake booster.)

(2)

er clevis and pin at brake pedal installing portion. [Depress brake pedal pad with a force than

(0.04 (3)

(4)

and clevis, turn brake switch adjusting nut until the clearance between stopper and screw of brake switch becomes

10

N

(1

kgf, 2 Ib).

pedal

-

3

Brake booster

operating rod

mm

free

(0.04

play:

-

0.12

in)

Pedal play

1-3"

(0.04

-

0.12

in)

G10050A

he free play is out of specifications above, ad-

Be sure the engine is off. (No vacuum is ap-

There should be play between brake boost-

of

10

N

(1

kgf, 2 Ib) to a stroke of 1 to 3 mm

to

0.12

in).]

Depress the surface of brake pad by hand.

If

there is no free play between clevis pin

0.3

mm

(0.01 2 in).

less

56

PM-25

Lock nut

Brake booster

operating rod

Play at pin

\

Brake

/

0.3

(0.04.-

switch

mm

(0.012

0.12

in)

G10051A

I

PERIODIC MAINTENANCE SERVICES

BRAKE

LINE

I

3)

Check the pedal stroke.

While the engine is idling, depress the brake pedal

with a 490

N

(50

kgf,

110

Ib) load and measure the

distance between the brake pedal and steering

wheel. With the brake pedal released, measure the

distance between the pedal and steering wheel again. The difference between the two measurements must be less than 95 mm (3.74 in).

If

the dis-

tance is more than specified, there is a possibility

air is in the inside of the hydraulic unit.

Brake pedal reserve distance:

more than 95 mm (3.74 in)/490 N (50 kgf,

lb)

ti

-

12

=

A

I

c-

.

4) Check to see the feel of pedal operation.

if

air is in the hydraulic brake line by

A

steer i ng

If

air appears to exist in

4\

1

10

the line, bleed it from the system.

5)

Check for even operation of all brakes, using a brake tester or by driving the vehicle for a short distance on a straight road.

4) Check the valve is built into vacuum hose. Dis-

connect the vacuum hose to inspect function of

check valve.

Blow air into vacuum hose from its brake booster side end: Air must flow out of engine side end of hose. Next blow air into hose from engine side: Air should not flow out of hose. Replace the both check valve and vacuum hose

if

the check valve is faulty. Engine side of vacuum

hose

is

indicated by marking “ENGINE as shown.

Engine side

5)

Check the vacuum hose for cracks or other dam-

Brake

booster side

G10053A

age. NOTE:

When installing the vacuum hose on the engine and brake booster, do not use soapy water or lubricating oil on their connections.

6)

Check the vacuum hose to make sure it is tight

and secure.

2.

BRAKE

1)

With the engine off, depress the brake pedal

SERVO

SYSTEM

several times applying the same pedal force: Make sure the travel distance should not change.

2)

With the brake pedal depressed, start the engine: Make sure the pedal should move slightly toward the floor.

3)

With the brake pedal depressed, stop the engine

and keep the pedal depressed for 30 seconds:

Make sure the pedal height should not change.

PM-26

BRAKE FLUID

I

PERIODIC MAINTENANCE SERVICES

19.Brake

A:

REPLACEMENT

1) Either jack up the vehicle and place a safety stand under it, or lift up the vehicle.

2) Remove the both front and rear wheels.

3)

Draw out the brake fluid from master cylinder

with syringe.

4)

Refill the reservoir tank with recommended

brake fluid.

Recommended brake fluid:

FMVSS

NOTE:

Avoid mixing different brands of brake fluid to

prevent degrading the quality of the fluid.

Be careful not to allow dirt or dust

reservoir tank. Bleeding sequence (1)

I

No.

Fluid

116,

fresh DOT3 or 4 brake fluid

to

-+

(2)

-+

(3)

-+

get into the

(4)

I

NOTE:

Cover the bleeder with waste cloth, when loosen-

ing it, to prevent brake fluid from being splashed

over surrounding parts.

During bleeding operation, keep the brake reserve tank filled with brake fluid to eliminate entry of air.

Brake pedal operation must be very slow.

For convenience and safety, have two men working.

The amount of brake fluid required is approxi-

mately

tal brake system.

6) Instruct your co-worker to depress the brake pedal slowly two or three times and then hold it depressed.

7)

until a small amount of brake fluid drains into con-

tainer, and then quickly tighten screw.

8) air bubbles in drained brake fluid and new fluid

flows through vinyl tube.

NOTE:

Add the brake fluid as necessary while performing the air bleed operation, in order from running short of brake fluid.

9)

brake pedal depressed and tighten the screw and install the bleeder cap.

500

m 0 (1 6.9

Loosen the bleeder screw approximately 1/4 turn

Repeat steps 6) and

After completing the bleeding operation, hold

US

fl

oz,

7)

above until there are no

it

is advisable to

17.6 Imp

to

fl

02)

prevent the tank

for to-

(1)

Front right

(2)

Rear left

(3)

Front left

(4)

Rear right

(5)

Secondary

(6)

Primary

5)

Install one end of a vinyl tube onto the air bleeder and insert the other end of the tube into a container to collect the brake fluid.

I

GI0055

Tightening torque:

8

Nom

(0.8

kgf-m,

10) Bleed the air from each wheel cylinder by following the previous

11) Depress the brake pedal with a force of approximately 294 N proximately 20 seconds. At this time check pedal see

if

it

makes any unusual movement. Visually inspect bleeder screws and brake pipe joints to make sure that there is no fluid leakage.

12) Install the wheels, and drive the vehicle for a short distance between 2 to make sure that brakes are operating properly.

(30

5.8

ft-lb)

5

steps.

kgf, 66 Ib) and hold it there for ap-

to

3

km (1 to 2 miles) to

PM-27

DISC BRAKE PADS AND DISCS

PERIODIC MAINTENANCE SERVICES

20.Disc Brake Pads and Discs

A:

INSPECTION

1.

DISC BRAKE PAD AND DISC

1)

Jack up the vehicle and support with rigid racks.

Then remove wheels.

2)

Visually check pad thickness through inspection hole of disc brake assembly. Replace the pad if necessary.

4)

Measure the disc rotor runout at a point less than

5

mm

(0.20

in) from the outer periphery of the rotor.

Disc rotor runout limit:

Front:

Rear:

0.075

0.070

mm

(0.0030

(0.0028

in)

NOTE: When replacing a pad, always replace the pads for both the left and right wheels at the same time.

Also

replace pad clips if they are twisted or worn.

G10056A

Pad thickness including back metal mm (in)

Front

Standard

I

Service limit

3)

Check the disc rotor, and correct or replace if it is

17 (0.67)

I

7.5 (0.295)

~I

Thickness

pad

of

14

1

I

6.5 (0.256)

Rear

(0.55)

..

damaged or worn.

Brake disc thickness mm (in)

Rear

10

(0.39)

8.5 (0.335)

Standard Wear limit

Front 24 (0.94) 22 (0.87)

GI0147

I

1

PM-28

BRAKE LININGS AND DRUMS

21.Brake Linings and Drums

A:

INSPECTION

1.

REAR

1)

Remove the brake drum, and check that there is

no fluid leakage from wheel cylinder.

If

there is fluid leakage from wheel cylinder, replace

it.

2)

Inspect the brake shoes for damage or deformi-

ties and check the brake linings for wear. NOTE:

Always replace both leading and trailing brake

shoes for the left and right wheels at the same time.

When either the left or the right brake assembly is replaced, always replace the leading shoe and trailing shoe of the other.

The cotter pin, once removed, cannot be reused.

DRUM

BRAKE

PERIODIC MAINTENANCE

3)

Check the brake drum for wear, dents or other

SERVICES

damage.

If

the inside surface of brake drum is streaked, cor-

rect the surface with emery cloth

(#200

or more).

If

it is unevenly worn, tapered, or the outside surface

of brake drum is damaged, correct or replace it.

Brake drum inner diameter

Standard value: 228.6 mm (9.000 in) Service limit: 230.6 mm (9.079 in)

If

deformation or wear of back plate, shoe, etc. is

noticeable, replace the affected parts.

1

Thickness

of

lining (except back metal)

Standard value: 4.1 mm (0.161 in)

--

-

Service limit: 1.5 mm (0.059 in)

(1)

Rotational direction

(2)

Wheel cylinder

(3)

Upper shoe return spring

(4)

Adjusting lever

(5)

Trailing shoe

(6)

Lower shoe return spring

(7)

Leading shoe

To

replace the trailing shoe, remove the cotter pin.

of

drum (Forward)

Clevis pin should also be replaced if worn.

I I

2.

PARKING BRAKE (REAR

Y

Measuring inside diameter

DISC

G10060A

BRAKE)

Inspect brake linings and drums of both sides of the rear brake at the same time by removing brake

drums.

1)

Inspect the brake shoes for damage or deforma-

tion and check the brake linings for wear.

NOTE: Always replace both primary and secondary brake shoes for the left and right wheels at the same time.

Brake lining thickness excluding back metal

Standard value: 3.2 mm (0.126 in)

Wear limit: 1.5 mm (0.059 in)

PM-29

Brake

shoe’-

(Primary) (Secondary)

Brake

shoe

G10061A

I

BRAKE LININGS AND DRUMS

PERIODIC MAINTENANCE

2)

Check the brake drum for wear, dents or other damage. streaked, correct the surface with emery cloth

(#200

the outside surface rect or replace it.

Brake drum inside diameter

Standard value: 170 mm (6.69 in)

Wear limit: 171 mm (6.73 in)

If

the inside surface of brake drum is

or more).

If

it is unevenly worn, tapered, or

of

-U

Measuring inside diameter

SERVICES

brake drum is damaged, cor-

G10062A

B: ADJUSTMENT

1.

REAR

The main brake is adjusted automatically, and so there is no need to adjust it.

2.

PARKING BRAKE (REAR

For rear disc brake, adjust parking brake after

bleeding the air.

1)

Remove rear cover (rubber) installed at back

plate.

2)

Turn adjuster toward arrow mark (upward) until it is locked slightly, by using slot-type screwdriver as shown in illustration.

Adjuster

\

DRUM

BRAKE

DISC

BRAKE)

1

3).

If

the deformation or wear of back plate, shoe,

etc. is noticeable, replace them.

4)

When the shoe return spring tension is exces-

sively weakened, replace it, taking care to identify

upper and lower springs.

G10063A

3)

Turn back (downward) the adjuster 3 to 4 notch-

es.

4)

Install the cover (rubber) at original position cor-

rectly.

PM-30

SUSPENSION

22.Suspension

A:

INSPECTION

1.

SUSPENSION BALL JOINT

1) Jack up the vehicle until front wheels are

ground.

2)

Next, grasp the bottom of tire and move it in and

out.

If

relative movement is observed between

brake disc cover and end of transverse link, ball

joint may be excessively worn.

3)

Next, grasp the end of transverse link and move it up and down. Relative movement between housing and transverse link boss indicates ball joint may be excessively worn.

4)

If

the relative movement is observed in the im-

mediately preceding two steps, remove and inspect

the ball joint.

If

the free play exceeds standard, re-

place the ball joint. <Ref. to FS-19, Front Ball

Joint.>

off

PERIODIC MAINTENANCE SERVICES

5)

Damage of dust seal

Visually inspect ball joint dust seal.

If

it is damaged, remove the transverse link. <Ref. to FS-17, Front Transverse Link.> And measure free play

of

ball

joint. <Ref. to FS-19, Front Ball Joint.>

(1)

When looseness exceeds standard value,

replace ball joint.

(2)

If

the dust seal is damaged, replace with the

new ball joint.

NOTE: When transverse link ball joint has been removed or replaced, check toe-in of front wheel.

If

front wheel toe-in is not at specified value, adjust toe-in. <Ref. to FS-8, Wheel Alignment.>

I

Transv

Ball

Transverse

Ball join;

join{

link

-Disc cover

wive movement

Relative movement

G10064A

G10065A

G10066b

2.

TRANSVERSE LINK'S REAR BUSHING

Check oil leaks at around liquid-filled bushing.

leaks, replace bushing.

If

oil

PM-31

I

SUSPENSION

PERIODIC MAINTENANCE SERVICES

3.

WHEEL ARCH HEIGHT

1)

Unload the cargoes and set the vehicle in curb

weight (empty) condition.

2)

Then, check the wheel arch height of front and

rear suspensions to ensure that they are within

specified values.

3)

When the wheel arch height is out of standard,

visually inspect following components and replace

deformed parts.

Suspension components [Front strut assembly

and rear strut assembly]

Body parts to which suspensions are installed.

4)

When no components are deformed, adjust wheel arch height by replacing coil spring in the suspension whose wheel arch height is out of stan-

dard. <Ref. to FS-8, Wheel Alignment.> <Ref. to

RS-9,

4.

PEN

Sure that following items conform to standard val-

ues.

<Ref. to FS-8, Wheel Alignment.>

2) When the caster angle does not conform to standard value, visually inspect following components and replace deformed parts.

member, transverse link, etc.]

3)

value, adjust them tive service standard.

4)

out of standard, adjust to standard value.

5.

PEN

Wheel Alignment.>

WHEEL ALIGNMENT OF FRONT SUS-

S

I

0

N

1) Check the alignment of front suspension to en-

Toe-in

Camber angle Caster angle Steering angle

Suspension components [Strut assembly, crossBody parts to which suspensions are installed.

When the toe-in and camber are out of standard

so

that they conform to respec-

When the right-and-left turning angles of tire are

WHEEL ALIGNMENT OF REAR SUS-

S

I

0

N

3)

When the toe-in and thrust angle are out of standard value, adjust them spective service standard.

6.

OIL LEAKAGE OF STRUT AND SHOCK

so

that they conform to re-

ABSORBER

Visually inspect front strut and rear strut for oil leakage as instructed. Replace front strut and rear strut if oil leaks excessively.

7.

TIGHTNESS OF BOLTS AND NUTS

Check the bolts and nuts shown in the figure for looseness. Retighten the bolts and nuts to speci-

fied torque.

replace them with new ones. Front suspension: <Ref. to FS-2, General Descrip-

tion.>

Rear suspension: <Ref. to RS-2, General Description.>

8.

DAMAGE

1)

Check the following parts and the fastening por-

tion of the vehicle body for deformation or exces-

sive rusting which impairs the suspension. necessary, replace damaged parts with new ones.

If

minor rust formation, pitting, etc. are noted, remove rust and apply remedial anti-corrosion measures.

Front suspension

Transverse link

Crossmember Strut

Rear suspension

Crossmember

Lateral links

Trailing link

Strut

In the district where salt is sprayed to melt snow

on a road in winter, check suspension parts for damage caused by rust every 12 months after lapse of as required.

If

self-lock nuts and bolts are removed,

TO

SUSPENSION PARTS

60

months. Take rust prevention measure

If

I

1) Check the alignment of rear suspension to ensure that following items are within standard values.

Toe-in Camber angle Thrust angle

<Ref. to

2) When the camber angle does not conform to standard value, visually inspect parts listed below.

If

the deformation is observed, replace damaged

parts.

Suspension components [Strut assembly, cross-

member, trailing link, lateral links, etc.]

Body parts to which suspensions are installed.

RS-9,

Wheel Alignment.>

PM-32

WHEEL BEARING

23.Wheel

A:

INSPECTION

1.

FRONT WHEEL BEARING

NOTE: Inspect the condition of front wheel bearing grease.

1) Jack up the front of vehicle.

2)

While holding front wheel by hand, swing it in

and out to check bearing free play.

3)

Loosen the wheel nuts and remove the front

wheel.

4)

If

the bearing free play exists in step

tach a dial gauge to hub and measure axial dis-

placement in axial direction.

Service limit:

Straight-ahead position within

(0.0020

5)

Remove the bolts and self-locking nuts, and ex-

tract transverse link from the front crossmember.

--

6)

While lightly hammering spring pin which se-

cures S.F.J. to transmission spindle, remove it.

7) Extract S.F.J. from the transmission spindle. <Ref. to DS-17, Front Axle.>

8)

While supporting front drive shaft horizontally with one hand, turn the hub with the other to check for noise or binding.

If

the hub is noisy or binds, disassemble the front

axle and check condition of oil seals, bearing, etc.

Bearing

in)

2)

0.05

above, at-

mm

PERIODIC MAINTENANCE SERVICES

6)

While supporting rear drive shaft horizontally with one hand, turn the hub COMPL with the other to check for noise or binding.

If

the hub COMPL is noisy or binds, disassemble the rear axle and check condition of oil seals, bearings, etc.

1

Outer

oil

seal

I

2.

REAR WHEEL BEARING

1)

Jack up the rear of vehicle.

2)

While holding rear wheel by hand, swing it in and

out to check bearing free play.

3)

Loosen the wheel nuts and remove the rear

wheel.

4)

If

the bearing free play exists in step

tach a dial gauge to hub COMPL and measure ax-

ial displacement in axial direction.

Service limit:

Straight-ahead position within

(0.0020

5)

Remove the DOJ of rear drive shaft from rear dif-

ferential. <Ref. to

in)

DS-39,

Hub’

Rear Drive Shaft.>

2)

0.05

GI0133

above, at-

mm

PM-33

I

PERIODIC MAINTENANCE SERVICES

AXLE

BOOTS & JOINTS

I

24.Axle

A:

INSPECTION

1.

FRONT AND REAR AXLE

Inspect the front axle boots

(B)

for deformation, damage or failure. place them with new ones. <Ref. to Drive Shaft.> <Ref. to

c-

.

Boots

&

Joints

(A)

DS-39,

BOOTS

and rear axle boots

Rear Drive Shaft.>

If

faulty, re-

DS-32,

Front

2.

PROPELLER SHAFT

Inspect the propeller shaft for damage or failure. faulty, replace with new one. <Ref. to peller Shaft

.>

DS-14,

Pro-

If

PM-34

STEERING SYSTEM (POWER STEERING)

25.Steering System (Power Steering)

A:

INSPECTION

1.

STEERING WHEEL

1)

Set the steering wheel in a straight-ahead position, and check the wheel spokes to make sure they are correctly set in their specified positions.

2)

Lightly turn the steering wheel to the left and right to determine the point where front wheels start to move. Measure the distance of the movement of steering wheel at the outer periphery of wheel.

Steering wheel free play:

0

-

17 mm

(0

-

0.67

in)

PERIODIC MAINTENANCE SERVICES

2.

STEERING SHAFT JOINT

1)

When the steering wheel free play is excessive, disconnect the universal joint of steering shaft and check it for any play and yawing torque (at the point

Also

of the crossing direction). age to sealing or worn serrations. If the joint is loose, retighten the mounting bolts to the specified

torque.

Tightening torque:

24 N.m (2.4 kgf-m, 17.4 ff-lb)

inspect for any dam-

I

Move the steering wheel vertically toward the shaft

to ascertain

Maximum permissible play:

0.5

3)

Drive the vehicle and check the following items

during operation.

(1)

The effort required for steering should be smooth and even at all points, and should not vary. (2) Steering wheel should not be pulled to either side while driving on a level surface.

(3)

Steering wheel should not show any sign of runout. (4) Return factor: Steering wheel should return to its original position after it has been turned and then released.

Maximum permissible play:

0.5

if

mm

(0.020

Steering force:

Pull

to one side:

Wheel runout:

mm (0.020 in)

-Free

there is play in the direction.

in)

play

G10074A

3.

GEARBOX

1)

With wheels placed on a level surface, turn the

90"

steering wheel tions. While the wheel is being rotated, reach under vehicle and check for looseness in gearbox.

Tigh tening torque:

59

N-m

(6.0

2)

Check the boot for damage, cracks or deteriora-

tion.

3)

With vehicle on a level surface, quickly turn steering wheel to the left and right. While steering wheel is being rotated, check the gear backlash.

just the gear backlash in the following manner.

(1)

Tighten adjusting screw to 7.4 N.m (0.75 kgf-m, 5.4 ft-lb) and then loosen. Repeat this operation twice. (2)

Retighten adjusting screw to 7.4 N.m (0.75

kgf-m, 5.4 ft-lb) and back off 25".

in both the left and right direc-

kgf-m, 43.4 ff-lb)

If

any unusual noise is noticed, ad-

PM-35

I

STEERING

PERIODIC MAINTENANCE SERVICES

SYSTEM

(POWER STEERING)

(3) Apply the liquid packing to at least

tire perimeter of adjusting screw thread.

Apply liquid packing

to

at least 1/3

perimeter

w

(4) Install the lock nut. While holding adjusting

screw with a wrench, tighten lock nut using ST.

ST 926230000 SPANNER

Tightening torque (Lock nut):

39 N.m

Hold the adjusting screw with a wrench to pre-

c-

vent it from turning while tightening the lock nut.

4.

TIE-ROD

1)

Check the tie-rod and tie-rod ends for bends,

scratches or other damage.

(4.0

kgf-m, 29

ft-lb)

113

of

entire

G10077A

of en-

5.

POWER STEERING FLUID LEVEL

NOTE: The fluid level must be checked when the temperature of the reservoir tank surface is approximately 20°C (68°F).

1)

Place the vehicle with engine “off” on the flat and

level surface.

2) Check the fluid level using the scale on the outside of the reservoir tank (A). “MIN”

NOTE: keep the level in the specified range of indicator by

using a syringe or the like.

(B),

add fluid to bring it up to “MAX’ (C).

If

fluid level is at MAX level or above, drain fluid to

If

the level is below

\

G10105A

2)

Check the connections of knuckle ball joints for

play, inspect for damage on dust seals, and check free play of ball studs. en it to the specified torque, then tighten further up to 60” until cotter pin hole is aligned.

Tightening torque:

27 N.m (2.75 kgf-m, 79.9

3) Check the lock nut on the tie-rod end for tight-

ness. torque

Tightening torque:

If

it is loose, retighten it to the specified

.

83 N-m (8.5 kgf-m,

If

castle nut is loose, retight-

ft-lb)

67.5

ft-lb)

Recommended fluid:

Dexron

Fluid capacity:

0.7

6.

POWER STEERING FLUID FOR LEAKS

Inspect the underside of oil pump and gearbox for power steering system, hoses, piping and their couplings for fluid leaks.

If

the fluid leaks are found, correct them by retightening their fitting bolts (or nuts) and/or replacing their parts.

NOTE:

Wipe the leakage fluid

leaks, or a wrong diagnosis is taken later.

Also pay attention to clearances between hoses (or pipings) and other parts when inspecting fluid leaks.

Q

IIE or

(0.7

US

Ill

qt,

0.6

Imp qt)

off

after correcting fluid

PM-36

STEERING SYSTEM (POWER STEERING)

~

7.

HOSES OF OIL PUMP FOR DAMAGES

Check the pressure hose and return hose of oil pump for crack, swell or damage. Replace the hose

if

with new one

NOTE:

Prevent hoses from revolving and/or turning when installing hoses.

8.

POWER STEERING PIPES FOR DAM-

A-G

E

Check the power steering pipes for corrosion and damage.

Replace the pipes with new one if necessary.

necessary.

PERIODIC MAINTENANCE SERVICES

9.

GEARBOX BOOTS

Inspect both sides of gearbox boots as follows, and

correct the defects if necessary.

1)

(A)

and (B) positions of gearbox boot are fitted

(A)

correspondingly in

and (B) grooves of gearbox

and the rod.

2)

Clips are fitted outside of

(A)

and (B) positions of

boot.

3)

Boot does not have crack and hole.

NOTE:

Rotate (B) position of gearbox boot against twist of it produced by adjustment of toe-in, etc.

Apply

clrease

G10023A

10.FITTING BOLTS AND NUTS

if

neces-

and

Inspect the fitting bolts and nuts of oil pump bracket for looseness, and retighten them sary. Inspect and/or retighten them when engine is cold.

PM-37

I

SUPPLEMENTAL RESTRAINT SYSTEM

PERIODIC MAINTENANCE SERVICES

26.Supplemental Restraint System

A:

INSPECTION

Check the airbag system in accordance with the result of the self-diagnosis. <Ref.

Procedure.

1)

Ensure that airbag connectors are connected.

ON

with the connector(s) disconnected, the airbag warning light blinks to identify the fault.

>

If

not, properly connect. When the ignition switch is turned

to

AB-2, Basic Diagnostic

U

2) Turn the ignition switch below lower cover) to the ground terminal.

3)

The warning light blinks

order (no trouble codes are stored in the memory), the warning light blinks on and off at

(as long as the diagnosis terminal is connected to the ground terminal).

4)

When the warning light indicates a trouble code, check the airbag system in accordance with the trouble-

shooting procedure. <Ref.

ON,

and connect the airbag diagnosis terminal of the service connector (located

to

indicate a trouble code (a fault is identified). When the airbag system is in good

0.6

second intervals

to

AB-2, Basic Diagnostic Procedure.>

PM-38

SONY 00035071 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

FOREWORD

SPECIFICATIONS

PRECAUTION

NOTE

IDENTIFICATION

RECOMMENDED MATERIALS

Pre-delivery Inspection

PERIODIC MAINTENANCE SERVICES

GENERAL DESCRIPTION

SCHEDULE

Engine Oil

ENGINE OIL FILTER

SPARK PLUGS

DRIVE BELT(S)

CAMSHAFT DRIVE BELT

FUEL LINE

FUEL FILTER

AIR CLEANER ELEMENT

COOLANT

IDLE MIXTURE

CLUTCH SYSTEM

TRANSMISSION OIL

FRONT & REAR DIFFERENTIAL OIL

BRAKE LINE

BRAKE FLUID

DISC BRAKE PADS AND DISCS

BRAKE LININGS AND DRUMS

SUSPENSION

WHEEL BEARING

STEERING SYSTEM (POWER STEERING)

SUPPLEMENTAL RESTRAINT SYSTEM