Subaru Legacy 2002, Legacy 2002 Workshop Manual

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Page 1

2002 Model Year

PDF Service Manual

GENERAL INFORMA TION SECTION (Pub.No.G2290GE1)

ENGINE 1 SECTION (Pub.No.G2290GE2)

ENGINE 2 SECTION (Pub.No.G2290GE3)

TRANSMISSION SECTION (Pub.No.G2290GE4)

CHASSIS SECTION (Pub.No.G2290GE5)

BOD Y SECTION (Pub.No.G2290GE6)

WIRING SYSTEM SECTION (Pub.No.G2290GE7)

Page 2

2002 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX GENERAL INFORMATION

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 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 of parts during repair work is needed, be sure to use SUBARU genuine parts.

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

FUJI HEAVY INDUSTRIES LTD.

G2290GE1

Page 3

2002 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE 1 SECTION

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.

G2290GE2

Page 4

2002 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE 2 SECTION

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.

G2290GE3

Page 5

2002 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX TRANSMISSION SECTION

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.

G2290GE4

Page 6

2002 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX CHASSIS SECTION

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.

G2290GE5

Page 7

2002 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX BODY SECTION

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.

G2290GE6

Page 8

2002 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX BODY SECTION

G2290GE6

Page 9

2002 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX WIRING SYSTEM SECTION

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.

G2290GE7

Page 10

FOREWORD

1. Foreword .....................................................................................................2

Page

Page 11

Foreword

1. Foreword SA01674

A: FOREWORD SA01674G21

These manuals are used when performing maintenance, repair, or diagnosis of the Subaru Legacy.

Applied model: BE***** and BH***** from 2002MY.

The additional manuals below are also available: AUTOMATIC TRANSMISSION SERVICE MANUAL (Pub. No. G0864ZE)

The manuals contain the latest information at the time of publication. Changes in specifications, methods, etc. may be made without notice.

FOREWORD

FW-2

Page 12

HOW TO USE THIS MANUAL

1. How to Use This Manual.............................................................................2

Page

Page 13

How to Use This Manual

1. How to Use This Manual SA02675

A: HOW TO USE THIS MANUAL

SA02675F69

1. STRUCTURE SA02675F6901

Each section consists of SCT that are broken down into SC that are divided into sections for each component. The specifications, maintenance procedures and other information for the components are included, and diagnostic information has also been added where necessary.

2. INDEX SA02675F6902

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

3. COMPONENTS SA02675F6903

For each component, a composition drawing is included.

4. SPECIFICATIONS SA02675F6904

HOW TO USE THIS MANUAL

If necessary, specifications are also included.

5. INSPECTION SA02675F6905

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

6. MAINTENANCE SA02675F6906

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 SA02675F6907

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

8. SI UNITS SA02675F6909

Measurements in these manuals are according to the SI units. Metric and yard/pound measurements are also included.

HU-2

Page 14

SPECIFICATIONS

1. Legacy.........................................................................................................2

2. OUTBACK .................................................................................................10

SPC

Page

Page 15

Specifications

1. Legacy SA08704

A: DIMENSIONS SA08704G28

Model Sedan Wagon

AWD Overall length mm (in) 4,605 (181.3) 4,680 (184.3) Overall width mm (in) 1,695 (66.7) 1,695 (66.7) Overall height (at CW) mm (in) 1,415 (55.7) 1,515 (59.6) Compartment Length mm (in) 1,965 (77.4) 1,925 (75.8)

Width mm (in) 1,440 (56.7), 1,420 (55.9)*1 1,440 (56.7), 1,420 (55.9)*1

Height mm (in) 1,155 (45.5) 1,190 (46.9), 1,175 (46.3)*2 Wheelbase mm (in) 2,650 (104.3) 2,650 (104.3) Tread Front mm (in) 1,460 (57.5) 1,460 (57.5)

Rear mm (in) 1,460 (57.5) 1,455 (57.3)

LEGACY

Minimum road clearance

*1: With leather seat *2: With sunroof

Without catalytic

converter

With catalytic

converter

Australia mm (in) 155 (6.1) 155 (6.1)

mm (in) 160 (6.3) 165 (6.5)

mm (in) 155 (6.1) 155 (6.1)

B: ENGINE SA08704G29

Model Sedan/Wagon

AWD

2.0 L 2.5 L Engine type Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine Valve arrangement Overhead camshaft type Bore × Stroke mm (in) 92 × 75 (3.62 × 2.95) 99.5 × 79.0 (3.917 × 3.110) Displacement cm Compression ratio 10.0 Firing order 1 — 3 — 2 — 4 Idle speed at Park/Neutral

position Maximum output kW (HP)/rpm 92 (123)/5,600 115 (154)/5,600 Maximum torque N·m (kgf-m, ft-lb)/rpm 184 (18.8, 136.0)/3,600 223 (22.7, 164.2)/3,600

(cu in) 1,994 (121.67) 2,457 (149.9)

rpm 700±100

SPC-2

Page 16

LEGACY

Specifications

C: ELECTRICAL SA08704G30

Model Sedan/Wagon

AWD

2.0 L 2.5 L

Ignition timing at idling speed BTDC/rpm 10°±10°/700 Spark plug Type and manufacturer Without OBD NGK: BKR6E (without catalyst)

CHAMPION: RC10YC4 (with catalyst)

NGK: BKR5E-11 (with catalyst)

With OBD RC10YC4 .......... CHAMPION

Alternate RC8YC4 .......... CHAMPION

BKR6E-11 .......... NGK

K20PR-U11 .......... NIPPONDENSO

Generator 12V — 90A Battery Type and capacity

(5HR)

For Europe and South America

Others 12V — 27AH (34B19L)

MT: 12V — 48AH (55D23L)

AT: 12V — 52AH (65D23L)

MT: 12V — 48AH (55D23L)

AT: 12V — 52AH (75D23L)

D: TRANSMISSION SA08704G31

Model Sedan/Wagon

AWD

2.0 L 2.5 L Transmission type 5MT 4AT 5MT 4AT Clutch type DSPD TCC DSPD TCC Gear ratio 1st 3.454 2.785 3.454 2.785

2nd 2.062 1.545 2.062 1.545 3rd 1.448 1.000 1.448 1.000 4th 1.088 0.694 1.088 0.694 5th 0.825 — 0.825*1, 0.780*2 — Reverse 3.333 2.272 3.333 2.272

Auxiliary transmission gear ratio High 1.000 – 1.000 –

Low 1.447 – 1.196 –

Reduction gear (Front drive)

Reduction gear (Rear drive)

5MT: 5 forward speeds with synchromesh and 1-reverse 4AT: Electronically controlled fully-automatic, 4-forward speeds and 1-reverse DSPD: Dry Single Plate Diaphragm TCC: Torque Converter Clutch *1: Except Australia spec. vehicles *2: Australia spec. vehicles

1st reduction Type of gear — Helical — Helical

Gear ratio — 1.000 — 1.000

Final reduction Type of gear Hypoid Hypoid Hypoid Hypoid

Gear ratio 3.900 4.111 3.700*1, 4.111*2 4.111

Transfer reduction

Final reduction Type of gear Hypoid Hypoid Hypoid Hypoid

Type of gear Helical — Helical — Gear ratio 1.000 — 1.000 —

Gear ratio 3.900 4.111 3.700*1, 4.111*2 4.111

SPC-3

Page 17

Specifications

E: STEERING SA08704G32

LEGACY

Model Models with

185/70R14 tires Type Rack and Pinion Turns, lock to lock 3.1 Minimum turning circle m (ft) Curb to curb: 10.8±1.0 (35.4±3.3)

Wall to wall: 11.5±1.0 (37.7±3.3)

Models with

195/60R15 tires

Models with

205/50R16 tires

F: SUSPENSION SA08704G33

Model Conventional suspension Front Macpherson strut type, Independent, Coil spring Rear Multi-link type, Independent, Coil spring

G: BRAKE SA08704G34

Service brake system Dual circuit hydraulic with vacuum suspended power unit Front Ventilated disc brake Rear Disc brake Parking brake Mechanical on rear brakes

H: TIRE SA08704G35

Rim size 14 × 51/2JJ 15 × 6JJ 16 × 61/2JJ Tire size 185/70R14 195/60R15 205/50R16 Type Steel belted radial, Tubeless

I: CAPACITY SA08704G36

Model Sedan/Wagon

AWD

2.0 L 2.5 L

5MT 4AT 5MT 4AT Fuel tank  (US gal, Imp gal) 64 (16.9, 14.1) Engine oil Total capacity  (US qt, Imp qt) 4.0 (4.2, 3.5)

Engine oil amount for

refill Transmission gear oil  (US qt, Imp qt) 3.5 (3.7, 3.1) — 3.5 (3.7, 3.1) — Automatic transmission fluid  (US qt, Imp qt) — 8.4 – 8.7

AT differential gear oil  (US qt, Imp qt) — 1.1 – 1.3

AWD rear differential gear oil  (US qt, Imp qt) 0.8 (0.8, 0.6) Power steering fluid  (US qt, Imp qt) 0.7 (0.7, 0.6) Engine coolant  (US qt, Imp qt) 7.0 (7.4, 6.2) 6.9 (7.3, 6.1) 6.8 (7.2, 6.0) 6.7 (7.1, 5.9)

 (US qt, Imp qt) Approx. 4.0 (4.2, 3.5)

— 9.3 – 9.6

(8.9 – 9.2,

7.4 – 7.7) — 1.1 – 1.3

(1.2 – 1.4,

1.0 – 1.1)

(9.8 – 10.1,

8.2 – 8.4)

(1.2 – 1.4,

1.0 – 1.1)

SPC-4

Page 18

LEGACY

Specifications

J: WEIGHT SA08704G37

1. SEDAN SA08704G3708

쐌 LHD Vehicle

Option code *1 EC K4 KO, KS Model 2.0 L

4WD

5MT 4AT 5MT 4AT 5MT 4AT

Curb weight (C.W.) Front kg (lb) 785

(1,730)

Rear kg (lb) 605

(1,335)

Total kg (lb) 1,390

(3,065)

Maximum permissible axle weight (M.P.A.W.)

Maximum permissible weight (M.P.W.)

Option Side airbag 쎻쎻 ––––

Front kg (lb) 970

(2,140)

Rear kg (lb) 975

(2,150)

Total kg (lb) 1,870

(4,125)

Air conditioner ––––쎻쎻 Audio ––––쎻쎻 Cruise control –––––– Cold weather pack ––––––

810

(1,785)

605

(1,335)

1,415

(3,120)

970

(2,140)

975

(2,150)

1,870

(4,125)

775

(1,710)

610

(1,345)

1,385

(3,055)

970

(2,140)

975

(2,150)

1,870

(4,125)

800

(1,765)

610

(1,345)

1,410

(3,110)

970

(2,140)

975

(2,150)

1,870

(4,125)

790

(1,740)

610

(1,345)

1,400

(3,085)

970

(2,140)

975

(2,150)

1,870

(4,125)

815

(1,795)

610

(1,345)

1,425

(3,140)

970

(2,140)

975

(2,150)

1,870

(4,125)

Option code *1 EC K4 KO, KS Model 2.5 L

4WD

5MT 4AT 5MT 4AT 5MT 4AT

Curb weight (C.W.) Front kg (lb) 805

(1,775)

Rear kg (lb) 605

(1,335)

Total kg (lb) 1,410

(3,110)

Maximum permissible axle weight (M.P.A.W.)

Maximum permissible weight (M.P.W.)

Option Side airbag 쎻쎻 ––––

*1: For option code, refer to ID section. <Ref. to ID-5, MODEL NUMBER PLATE, IDENTIFICATION, Identification.>

Front kg (lb) 985

(2,170)

Rear kg (lb) 1,000

(2,205)

Total kg (lb) 1,910

(4,210)

Air conditioner 쎻쎻쎻쎻 –– Audio ––––쎻쎻 Cruise control ––쎻쎻 –– Cold weather pack ––––––

830

(1,830)

610

(1,345)

1,440

(3,175)

985

(2,170)

1,000

(2,205)

1,910

(4,210)

795

(1,755)

610

(1,345)

1,405

(3,100)

985

(2,170)

1,000

(2,205)

1,910

(4,210)

820

(1,810)

615

(1,355)

1,435

(3,165)

985

(2,170)

1,000

(2,205)

1,910

(4,210)

785

(1,730)

610

(1,345)

1,395

(3,075)

985

(2,170)

1,000

(2,205)

1,910

(4,210)

810

(1,785)

615

(1,355)

1,425

(3,140)

985

(2,170)

1,000

(2,205)

1,910

(4,210)

SPC-5

Page 19

Specifications

LEGACY

쐌 RHD Vehicle

Option code *1 K1 EK Model 2.0 L 2.5 L

4WD

GL GX

4AT 5MT 4AT 5MT 4AT

Curb weight (C.W.) Front kg (lb) 800 (1,765) 785 (1,730) 810 (1,785) 795 (1,755) 820 (1,810)

Rear kg (lb) 605 (1,335) 605 (1,335) 605 (1,335) 605 (1,335) 610 (1,345) Total kg (lb) 1,405 (3,100) 1,390 (3,065) 1,415 (3,120) 1,400 (3,085) 1,430 (3,155)

Maximum permissible axle weight (M.P.A.W.)

Maximum permissible weight (M.P.W.)

Option Side airbag – 쎻쎻쎻쎻

Option code *1 KA Model 2.0 L 2.5 L

Unladen mass (U.M.) Front kg (lb) 780 (1,720) 775 (1,710) 775 (1,710) 785 (1,730)

Gross vehicle mass (G.V.M.)

Option Side airbag ––––

*1: For option code, refer to ID section. <Ref. to ID-5, MODEL NUMBER PLATE, IDENTIFICATION, Identification.>

Front kg (lb) 970 (2,140) 970 (2,140) 970 (2,140) 985 (2,170) 985 (2,170) Rear kg (lb) 975 (2,150) 975 (2,150) 975 (2,150) 1,000 (2,205) 1,000 (2,205) Total kg (lb) 1,870 (4,125) 1,870 (4,125) 1,870 (4,125) 1,910 (4,210) 1,910 (4,210)

Air conditioner ––––– Audio 쎻쎻쎻쎻쎻 Cruise control ––––– Cold weather pack –––––

4WD

GL (GX) GX (RX)

5MT 4AT 5MT 4AT

Rear kg (lb) 585 (1,290) 585 (1,290) 595 (1,310) 595 (1,310) Total kg (lb) 1,365 (3,010) 1,360 (3,000) 1,370 (3,020) 1,380 (3,045) Front kg (lb) 930 (2,050) 930 (2,050) 940 (2,075) 940 (2,075) Rear kg (lb) 970 (2,140) 970 (2,140) 980 (2,160) 980 (2,160) Total kg (lb) 1,900 (4,190) 1,900 (4,190) 1,920 (4,235) 1,920 (4,235)

Air conditioner 쎻 ––– Audio 쎻쎻쎻쎻 Cruise control 쎻 ––– Cold weather pack ––––

SPC-6

Page 20

LEGACY

Specifications

2. WAGON SA08704G3709

쐌 LHD Vehicle

Option code *1 EC K4 KO, KS Model 2.0 L

4WD

5MT 4AT 5MT 4AT 5MT 4AT

Curb weight (C.W.) Front kg (lb) 780

(1,720)

Rear kg (lb) 650

(1,435)

Total kg (lb) 1,430

(3,155)

Maximum permissible axle weight (M.P.A.W.)

Maximum permissible weight (M.P.W.)

Option Side airbag – 쎻 ––––

Front kg (lb) 960

(2,115)

Rear kg (lb) 1,030

(2,270)

Total kg (lb) 1,920

(4,235)

Air conditioner ––––쎻쎻 Audio ––––쎻쎻 Cruise control –––––– Cold weather pack ––––––

800

(1,765)

650

(1,435)

1,450

(3,195)

960

(2,115)

1,030

(2,270)

1,920

(4,235)

775

(1,710)

655

(1,445)

1,430

(3,155)

960

(2,115)

1,030

(2,270)

1,920

(4,235)

790

(1,740)

655

(1,445)

1,445

(3,185)

960

(2,115)

1,030

(2,270)

1,920

(4,235)

790

(1,740)

655

(1,445)

1,445

(3,185)

960

(2,115)

1,030

(2,270)

1,920

(4,235)

805

(1,775)

655

(1,445)

1,460

(3,220)

960

(2,115)

1,030

(2,270)

1,920

(4,235)

Option code *1 EC K4 KO, KS Model 2.5 L

4WD

5MT 4AT 5MT 4AT 5MT 4AT

Curb weight (C.W.) Front kg (lb) 790

(1,740)

Rear kg (lb) 655

(1,445)

Total kg (lb) 1,445

(3,185)

Maximum permissible axle weight (M.P.A.W.)

Maximum permissible weight (M.P.W.)

Option Side airbag 쎻쎻 ––––

*1: For option code, refer to ID section. <Ref. to ID-5, MODEL NUMBER PLATE, IDENTIFICATION, Identification.>

Front kg (lb) 995

(2,195)

Rear kg (lb) 1,050

(2,315)

Total kg (lb) 1,980

(4,365)

Air conditioner – 쎻 ––쎻쎻 Audio ––––쎻쎻 Cruise control – 쎻 –––– Cold weather pack – 쎻 ––––

820

(1,810)

655

(1,445)

1,475

(3,250)

995

(2,195)

1,050

(2,315)

1,980

(4,365)

775

(1,710)

655

(1,445)

1,430

(3,155)

960

(2,115)

1,030

(2,270)

1,920

(4,235)

790

(1,740)

655

(1,445)

1,445

(3,185)

960

(2,115)

1,030

(2,270)

1,920

(4,235)

790

(1,740)

655

(1,445)

1,445

(3,185)

960

(2,115)

1,030

(2,270)

1,920

(4,235)

805

(1,775)

655

(1,445)

1,460

(3,220)

960

(2,115)

1,030

(2,270)

1,920

(4,235)

SPC-7

Page 21

Specifications

LEGACY

쐌 RHD Vehicle

Option code *1 K1 EK Model 2.0 L 2.5 L

4WD

GL GX

5MT 4AT 5MT 4AT 5MT 4AT

Curb weight (C.W.) Front kg (lb) 775

(1,710)

Rear kg (lb) 655

(1,445)

Total kg (lb) 1,430

(3,155)

Maximum permissible axle weight (M.P.A.W.)

Maximum permissible weight (M.P.W.)

Option Side airbag ––쎻쎻쎻쎻

Front kg (lb) 960

(2,115)

Rear kg (lb) 1,030

(2,270)

Total kg (lb) 1,920

(4,235)

Air conditioner –––––– Audio 쎻쎻쎻쎻쎻쎻 Cruise control –––––– Cold weather pack ––––––

790

(1,740)

655

(1,445)

1,445

(3,185)

960

(2,115)

1,030

(2,270)

1,920

(4,235)

785

(1,731)

650

(1,435)

1,435

(3,165)

960

(2,115)

1,030

(2,270)

1,920

(4,235)

800

(1,765)

650

(1,435)

1,450

(3,195)

960

(2,115)

1,030

(2,270)

1,920

(4,235)

790

(1,740)

655

(1,445)

1,445

(3,185)

995

(2,195)

1,050

(2,315)

1,980

(4,365)

805

(1,775)

655

(1,445)

1,460

(3,220)

995

(2,195)

1,050

(2,315)

1,980

(4,365)

Option code *1 KA Model 2.0 L 2.5 L

4WD

GL (GX) GX (RX)

5MT 4AT 5MT 4AT

Unladen mass (U.M.) Front kg (lb) 775

(1,710)

Rear kg (lb) 635

(1,400)

Total kg (lb) 1,410

(3,110)

Gross vehicle mass (G.V.M.)

Option Side airbag ––––

*1: For option code, refer to ID section. <Ref. to ID-5, MODEL NUMBER PLATE, IDENTIFICATION, Identification.>

Front kg (lb) 930

(2,050)

Rear kg (lb) 1,010

(2,225)

Total kg (lb) 1,940

(4,280)

Air conditioner 쎻 ––– Audio 쎻쎻쎻쎻 Cruise control 쎻 ––– Cold weather pack ––––

775

(1,710)

635

(1,400)

1,410

(3,110)

930

(2,050)

1,010

(2,225)

1,940

(4,280)

765

(1,685)

645

(1,420)

1,410

(3,110)

950

(2,095)

1,040

(2,295)

1,990

(4,390)

780

(1,720)

645

(1,420)

1,425

(3,140)

950

(2,095)

1,040

(2,295)

1,990

(4,390)

SPC-8

Page 22

LEGACY

NOTE: When any of the following optional parts are installed, add the weight to the curb weight.

Specifications

Weight of optional parts

Front kg (lb) 6.5 (14.33) 2.1 (4.6) 13.9 (30.6) 10.9 (24.0) 1.8 (4.0) 2.9 (6.4) Rear kg (lb) 0.1 (0.22) 0.3 (0.7) −0.1 (−0.2) 16.4 (36.2) 3.1 (6.8) 3.0 (6.6) Total kg (lb) 6.6 (14.55) 2.4 (5.3) 13.8 (30.4) 27.3 (60.2) 4.9 (10.8) 5.9 (13.0)

Weight of optional parts

Front kg (lb) 0.2 (0.44) 1.8 (4.0) −0.7 (−1.54) −1.4 (−3.09) 0.2 (0.4) Rear kg (lb) 0.2 (0.44) 0.7 (1.5) 3.2 (7.06) −3.8 (−8.38) 4.2 (9.3) Total kg (lb) 0.4 (0.88) 2.5 (5.5) 2.5 (5.51) − 5.2 (−11.47) 4.4 (9.7)

VDC Cruise control Air conditioner Sunroof Leather interior SRS Airbag

(Side)

Cold weather

pack

Audio Rear spoiler Sports package Self-leveling rear sus-

pension

SPC-9

Page 23

Specifications

2. OUTBACK SA08705

A: DIMENSIONS SA08705G28

Model OUTBACK

AWD Overall length mm (in) 4,720 (185.8) Overall width mm (in) 1,745 (68.7) Overall height (at CW) mm (in) 1,580 (62.2), 1,590 (62.6)*3 Compartment Length mm (in) 1,925 (75.8)

Width mm (in) 1,440 (56.7), 1,420 (55.9)*1

Height mm (in) 1,190 (46.9), 1,175 (46.3)*2 Wheelbase mm (in) 2,650 (104.3) Tread Front mm (in) 1,470 (57.9)

Rear mm (in) 1,460 (57.5)*3 , 1,465 (57.7)

OUTBACK

Minimum road clearance

*1: With leather seat *2: With sunroof *3: Australia spec. vehicles

Without catalytic

converter

With catalytic

converter

Australia mm (in) 200 (7.9)

mm (in) 195 (7.7)

mm (in) 190 (7.5)

B: ENGINE SA08705G29

Model OUTBACK

AWD

2.5 L 3.0 L

Engine type Horizontally opposed, liquid cooled,

4-cylinder, 4-stroke gasoline engine

Valve arrangement Overhead camshaft type Double overhead camshaft type Bore × Stroke mm (in) 99.5 × 79.0 (3.917 × 3.110) 89.2 × 80.0 (3.512 × 3.150) Displacement cm Compression ratio 10.0 10.7 Firing order 1 — 3 — 2 — 41— 6 — 3 — 2 — 5 — 4 Idle speed at Park/Neutral

position Maximum output kW (HP)/rpm 115 (154)/5,600 154 (206)/6,000 Maximum torque N·m (kgf-m, ft-lb)/rpm 223 (22.7, 164.2)/3,600 282 (28.8, 208)/4,400

(cu in) 2,457 (149.9) 3,000 (183.06)

rpm 700±100 600±100

Horizontally opposed, liquid cooled, 6-cylinder, 4-stroke gasoline engine

SPC-10

Page 24

OUTBACK

Specifications

C: ELECTRICAL SA08705G30

Model OUTBACK

AWD

2.5 L 3.0 L

Ignition timing at idling speed

Spark plug Type and manufacturer RC10YC4 .......... CHAMPION PLFR6A .......... NGK

Generator 12V — 90A 12V — 100A Battery Type and capacity (5HR) For Europe and

BTDC/rpm 10°±10°/700 10°±8°/600

Alternate RC8YC4 .......... CHAMPION

BKR6E-11 .......... NGK

K20PR-U11 .......... NIPPONDENSO

MT: 12V — 48AH (55D23L)

South America Others 12V — 27AH (34B19L) 12V — 48H (55D23L)

AT: 12V — 52AH (75D23L)

12V — 52AH (75D23L)

D: TRANSMISSION SA08705G31

Model OUTBACK

AWD

2.5 L 3.0 L Transmission type 5MT 4AT 4AT Clutch type DSPD TCC TCC Gear ratio 1st 3.454 2.785

2nd 2.062 1.545 3rd 1.448 1.000 4th 1.088 0.694 5th 0.825 — Reverse 3.333 2.272

Auxiliary transmission gear ratio High 1.000 —

Low 1.196 —

Reduction gear (Front drive)

Reduction gear (Rear drive)

5MT: 5 × 2 forward speeds with synchromesh and 1-reverse 4AT: Electronically controlled fully-automatic, 4-forward speeds and 1-reverse DSPD: Dry Single Plate Diaphragm TCC: Torque Converter Clutch *1: Except Australia spec. vehicles *2: Australia spec. vehicles

1st Reduction Type of gear — Helical

Gear ratio — 1.000

Final reduction Type of gear Hypoid Hypoid

Gear ratio 3.900*1, 4.111*2 4.444 4.111

Transfer reduction Type of gear Helical —

Gear ratio 1.000 —

Final reduction Type of gear Hypoid Hypoid

Gear ratio 3.900*1, 4.111*2 4.444 4.111

SPC-11

Page 25

Specifications

E: STEERING SA08705G32

OUTBACK

Model OUTBACK Type Rack and Pinion Turns, lock to lock 3.0 Minimum turning circle m (ft) Curb to curb: 11.2±1.0 (36.7±3.3)

Wall to wall: 12.0±1.0 (39.4±3.3)

F: SUSPENSION SA08705G33

Model OUTBACK Front Macpherson strut type, Independent, Coil spring Rear Multi-link type, Independent, Coil spring

G: BRAKE SA08705G34

Model OUTBACK Service brake system Dual circuit hydraulic with vacuum suspended power unit Front Ventilated disc brake Rear Disc brake Parking brake Mechanical on rear brakes

H: TIRE SA08705G35

Model OUTBACK Rim size 16 × 6 Tire size 215/60R16 Type Steel belted radial, Tubeless

/2JJ

I: CAPACITY SA08705G36

Model OUTBACK

AWD

2.5 L 3.0 L

5MT 4AT Fuel tank  (US gal, Imp gal) 64 (16.9, 14.1) Engine oil Total capacity  (US qt, Imp qt) 4.0 (4.2, 3.5) 6.8 (7.2, 6.0)

Engine oil amount for

refill Transmission gear oil  (US qt, Imp qt) 4.0 (4.2, 3.5) — Automatic transmission fluid  (US qt, Imp qt) — 9.3 – 9.6 (9.8 – 10.1, 8.2 – 8.4) AT differential gear oil  (US qt, Imp qt) — 1.1 – 1.3 (1.2 – 1.4, 1.0 – 1.1) AWD rear differential gear oil  (US qt, Imp qt) 0.8 (0.8, 0.7) Power steering fluid  (US qt, Imp qt) 0.7 (0.7, 0.6) Engine coolant  (US qt, Imp qt) 6.8 (7.2, 6.0) 6.7 (7.1, 5.9) 7.7 (8.1, 6.8)

 (US qt, Imp qt) Approx. 4.0 (4.2, 3.5) Approx. 5.8 (6.1, 5.1)

SPC-12

Page 26

OUTBACK

Specifications

J: WEIGHT SA08705G37

1. OUTBACK SA08705G3707

쐌 LHD vehicle

Option code *1 K4 KS KO Model 2.5 L

4WD

5MT 4AT 5MT 4AT

Curb weight (C.W.) Front kg (lb) 810 (1,785) 825 (1,820) 815 (1,795) 830 (1,830) 785 (1,730)

Rear kg (lb) 670 (1,475) 670 (1,475) 670 (1,475) 670 (1,475) 650 (1,435) Total kg (lb) 1,480 (3,265) 1,495 (3,295) 1,485 (3,275) 1,500 (3,310) 1,435 (3,165)

Maximum permissible axle weight (M.P.A.W.)

Maximum permissible weight (M.P.W.)

Option Side airbag –––––

Front kg (lb) 995 (2,195) 995 (2,195) 995 (2,195) 995 (2,195) 960 (2,115) Rear kg (lb) 1,050 (2,315) 1,050 (2,315) 1,050 (2,315) 1,050 (2,315) 1,030 (2,270) Total kg (lb) 2,000 (4,410) 2,000 (4,410) 2,000 (4,410) 2,000 (4,410) 1,920 (4,235)

Air conditioner 쎻쎻쎻쎻쎻 Audio ––쎻쎻쎻 Cruise control 쎻쎻쎻쎻쎻 Cold weather pack ––––– Leather interior ––––쎻 Sunroof ––––쎻

Option code *1 EC Model 2.5 L 3.0 L

4WD

5MT 4AT

Curb weight (C.W.) Front kg (lb) 815 (1,795) 830 (1,830) 915 (2,020)

Rear kg (lb) 675 (1,490) 675 (1,490) 695 (1,530) Total kg (lb) 1,490 (3,285) 1,505 (3,320) 1,610 (3,550)

Maximum permissible axle weight (M.P.A.W.)

Maximum permissible weight (M.P.W.)

Option Side airbag 쎻쎻쎻

*1: For option code, refer to ID section. <Ref. to ID-5, MODEL NUMBER PLATE, IDENTIFICATION, Identification.>

Front kg (lb) 1,010 (2,225) 1,010 (2,225) 1,040 (2,295) Rear kg (lb) 1,060 (2,335) 1,060 (2,335) 1,060 (2,335) Total kg (lb) 2,015 (4,445) 2,015 (4,445) 2,085 (4,595)

Air conditioner 쎻쎻쎻 Audio ––쎻 Cruise control ––쎻 Cold weather pack ––쎻 Leather interior ––쎻 Sunroof ––쎻

SPC-13

Page 27

Specifications

OUTBACK

쐌 RHD vehicle

Option code *1 EK Model 2.5 L 3.0 L

4WD

5MT 4AT

Curb weight (C.W.) Front kg (lb) 800 (1,765) 815 (1,795) 915 (2,020)

Rear kg (lb) 670 (1,475) 670 (1,475) 695 (1,530) Total kg (lb) 1,470 (3,240) 1,485 (3,275) 1,610 (3,550)

Maximum permissible axle weight (M.P.A.W.)

Maximum permissible weight (M.P.W.)

Option Side airbag ––쎻

Front kg (lb) 1,010 (2,225) 1,010 (2,225) 1,040 (2,295) Rear kg (lb) 1,060 (2,335) 1,060 (2,335) 1,060 (2,335) Total kg (lb) 2,015 (4,445) 2,015 (4,445) 2,085 (4,595)

Air conditioner ––쎻 Audio 쎻쎻쎻 Cruise control ––쎻 Cold weather pack ––쎻 Leather interior ––쎻 Sunroof ––쎻

Option code *1 KA Model 2.5 L 3.0 L

4WD

5MT 4AT

Unladen mass (U.M.) Front kg (lb) 790 (1,740) 800 (1,765) 900 (1,985)

Rear kg (lb) 650 (1,435) 650 (1,435) 690 (1,520) Total kg (lb) 1,440 (3,175) 1,410 (3,110) 1,590 (3,505)

Gross vehicle mass (G.V.M.)

Option Side airbag ––쎻

*1: For option code, refer to ID section. <Ref. to ID-5, MODEL NUMBER PLATE, IDENTIFICATION, Identification.>

Front kg (lb) 970 (2,140) 970 (2,140) 1,035 (2,280) Rear kg (lb) 1,050 (2,315) 1,050 (2,315) 1,050 (2,315) Total kg (lb) 2,020 (4,455) 2,020 (4,455) 2,085 (4,595)

Air conditioner ––쎻 Audio 쎻쎻쎻 Cruise control ––쎻 Cold weather pack ––쎻

NOTE: When any of the following optional parts are installed, add the weight to the curb weight.

Weight of

optional

parts

Front kg

(lb)

Rear kg

(lb)

Total kg

(lb)

Cruise control

2.1

(4.6)

0.3

(0.7)

2.4

(5.3)

Self

levelizer

0.2

(0.4)

4.2

(9.3)

4.4

(9.7)

Air condi-

tioner

13.9

(30.6)

−0.1

(−0.2)

13.8

(30.4)

Sunroof Leather

interior

10.9

(24.0)

16.4

(36.2)

27.3

(60.2)

1.8

(4.0)

3.1

(6.8)

4.9

(10.8)

SRS

Airbag

(Side)

2.9

(6.4)

3.0

(6.6)

5.9

(13.0)

Cold

weather

pack

0.2

(0.44)

0.2

(0.44)

0.4

(0.88)

Audio Rear

spoiler

1.8

(4.0)

0.7

(1.5)

2.5

(5.5)

−0.7

(−1.54)

3.2

(7.06)

2.5

(5.51)

Sports

package

−1.4

(−3.09)

−3.8

(−8.38)

−5.2

(−11.47)

SPC-14

Page 28

PRECAUTION

1. Precaution ...................................................................................................2

Page

Page 29

Precaution

PRECAUTION

1. Precaution SA04677

A: PRECAUTION SA04677F59

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 SA04677F5901

Handle the ABS as a total system. Do not disassemble 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 SA04677F5902

If brake fluid gets in your eyes or on your skin, do the following: 쐌 Wash out your eyes and seek immediate medical attention. 쐌 Wash your skin with soap and then rinse thoroughly with water.

3. ELECTRIC FAN SA04677F5903

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 SA04677F5907

Adhere to the following when handing and storing the airbag module to prevent bodily injury from unexpected deployment: 쐌 Do not hold harnesses or connectors to carry the module. 쐌 Do not face the bag in the direction that it opens towards yourself or other people. 쐌 Do not face the bag in the direction that it opens towards the floor or walls.

8. AIRBAG SPECIAL TOOLS SA04677F5908

To prevent unexpected deployment, only use special tools.

9. WINDOW SA04677F5909

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

10. WINDOW ADHESIVE SA04677F5910

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

4. ROAD TESTS SA04677F5904

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

5. AIRBAG SA04677F5905

To prevent bodily injury from unexpected deployment of airbags and unnecessary maintenance, follow the instructions in this manual when performing maintenance on airbag components or nearby, and airbag wiring harnesses or nearby. To prevent unexpected deployment, perform one of the steps below and then wait at least 20 seconds to discharge electricity before beginning work.

쐌 Step 1: Turn the ignition switch OFF. 쐌 Step 2: Remove the negative battery terminal.

6. AIRBAG DISPOSAL SA04677F5906

To prevent bodily injury from unexpected airbag deployment, do not dispose airbag modules in the same way as other refuse. Follow the special instructions for disposal in this manual. Follow all government regulations concerning disposal of refuse.

PC-2

Page 30

NOTE

Page

1. Note.............................................................................................................2

Page 31

Note

1. Note SA03676

A: NOTE SA03676A15

This is information that can improve efficiency of maintenance and assure sound work.

1. FASTENER NOTICE SA03676A1501

Fasteners are used to prevent 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 so will make it difficult to obtain the correct torque and result in looseness and other problems.

2. STATIC ELECTRICITY DAMAGE SA03676A1502

Do not touch the ECM, connectors, logic boards, 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.

NOTE

3. IGNITION OFF BATTERY SA03676A1503

When removing the battery cables, always be sure to turn the ignition off to prevent electrical damage to the ECM from rush current.

4. SERVICE PARTS SA03676A1504

Use authentic service parts for maximum performance 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.

NT-2

Page 32

NOTE

Note

5. LIFTS AND JACKS SA03676A1505

When using a lift or jack-ridged rack to raise a vehicle, always follow 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.

NT-3

GI0100A

Page 33

Note

NOTE

GI0101B

NT-4

Page 34

NOTE

Note

6. TIE DOWNS SA03676A1506

Tie downs are used when transporting vehicles and when using the chassis dynamo. Attach tie downs only to the specified points on the vehicle.

NT-5

B1M0489A

Page 35

Note

NOTE

7. TOWING SA03676A1507

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: 쐌 Do not tow other vehicles with a front towing hook. 쐌 Make sure the vehicle towing is heavier that the vehicle being towed.

GI0103

GI0104A

NT-6

Page 36

NOTE

8. FRONT HOOD STAY INSTALLATION SA03676A1510

쐌 At the check and general maintenance

Note

B1M0496

쐌 When wider hood opening is necessary

Set stay into the hole of hood inner as shown in the figure below. NOTE:

Before setting the hood in this position, remove the windshield washer hose attaching clip from the hood.

B1M0493

9. TRAINING SA03676A1508

For information about training, contact a dealer or agent.

10. GENERAL SCAN TOOL SA03676A1509

Using general scan tools will greatly improve efficiency 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-7

Page 37

Note

MEMO:

NOTE

NT-8

Page 38

IDENTIFICATION

1. Identification ................................................................................................2

Page

Page 39

Identification

1. Identification SA06679

A: IDENTIFICATION SA06679F70

1. IDENTIFICATION NUMBER AND LABEL LOCATIONS SA06679F7001

The VIN (Vehicle Identification Numbers) is used to classify the vehicle. Positioning of the plate label for identification

IDENTIFICATION

GI0007A

GI0112A

GI0008A

GI0009A

ID-2

Page 40

IDENTIFICATION

GI0010A

Identification

ID-3

GI0011A

Page 41

Identification

IDENTIFICATION

2. MEANING OF V.I.N. SA06679F7002

The meaning of the VIN is as follows:

쐌 Europe, Australia and General (Except GCC)

]JF1BE5LJ32G002001[

The starting and ending brackets ( ][ ) are stop marks.

Digits Code Meaning Details

1 to 3 JF1 Manufacturer body area JF1: Passenger car, FHI made

JF2: MPV, FHI made 4 B Car line Legacy/OUTBACK series 5 E Body type E: Sedan

H: Station Wagon/OUTBACK 6 5 Displacement 5: 2.0 L AWD

9: 2.5 L AWD

E: 3.0 L AWD 7 L Steering position K: RHD (Right-hand drive)

L: LHD (Left-hand drive) 8 J Engine & transmission E: DOHC MPI 4AT

J: SOHC MPI 5F

R: SOHC MPI 4AT 9 3 Drive type 3: Full-time AWD 5-speed MT single range

4: Full-time AWD 5-speed MT dual range

5: Full-time AWD 4-speed AT

A: Full-time AWD 4-speed AT OUTBACK

B: Full-time AWD 5-speed MT dual range OUTBACK 10 2 Model year 2: 2002MY

3: 2003MY 11 G Factory location G: FHI (Gunma) 12 to 17 002001 Serial number

쐌 GCC countries (Saudi Arabia, etc.)

]JF1BE54MX2G002001[

The starting and ending brackets ( ][ ) are stop marks.

Digits Code Meaning Details 1 to 3 JF1 Manufacturer body area JF1: Passenger car, FHI made 4 B Car line Legacy/OUTBACK series 5 E Body type E: Sedan

H: Station Wagon/OUTBACK

6 5 Displacement 5: 2.0 L AWD

9: 2.5 L AWD

7 4 Grade 4: GL

6: GX

8: OUTBACK 8 M Restraint M: Manual belts, dual airbag 9 X Check digit 10 2 Model year 2: 2002MY

3: 2003MY 11 G Transmission type G: Full-time AWD 5-speed MT single range

H: Full-time AWD 4-speed AT

J: Full-time AWD 5-speed MT dual range 12 to 17 002001 Serial number

ID-4

Page 42

IDENTIFICATION

Identification

3. MODEL NUMBER PLATE SA06679F7003

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.

BE9CL7R

Digits Code Meaning Details 1 B Series B: Legacy/OUTBACK 2 E Body style E: Sedan

H: Station Wagon/OUTBACK

3 9 Engine displacement

Drive system

Suspension system 4 C Minor change 2002MY 5 L Destination K: Right-hand drive for general market

6 7 Grade 4: GL

7 R Transmission, fuel feed

system

5: 2.0 L AWD 9: 2.5 L AWD E: 3.0 L AWD

L: Left-hand drive for general market Y: Left-hand drive for United States, Canada, and Taiwan

7: GX B: OUTBACK C: OUTBACK — 6 cylinders

E: DOHC MPI 4-speed AT J: SOHC MPI center differential AWD R: SOHC MPI 4-speed AT

The engine and transmission type are as follows:

쐌 Engine

EZ30DAXBBB

Digits Code Meaning Details

1 and 2 EZ Engine type EJ: 4 cylinders

EZ: 6 cylinders

3 and 4 30 Displacement 20: 2.0 L

25: 2.5 L 30: 3.0 L

5 D Fuel feed system 1: D-MPI SOHC-A

D: D-MPI DOHC 6 cylinders 6 A Detailed specifications Used when ordering parts. See the parts catalog for details. 7 X Transmission W: AWD MT

X: AWD AT 8 to 10 BBB Detailed specifications Used when ordering parts. See the parts catalog for details.

ID-5

Page 43

Identification

IDENTIFICATION

쐌 Transmission

TV1A4YCAAA

Digits Code Meaning Details 1 T Transmission T: Transmission 2 V Transmission type Y: Full-time AWD MT center differential

V: Full-time AWD AT VTD Z: Full-time AWD AT MPT

3 and 4 1A Classification 75: MT

1A, 1B: AT 5 4 Series 4: 4th Generation Legacy 6 Y Transmission specifica-

tions

7 R Engine type R: 920SO

8 to 10 AAA Detailed specifications Used when ordering parts. See the parts catalog for details.

V: Full-time AWD 5-speed MT with viscous coupling center

differential single range

X: Full-time AWD 5-speed MT with viscous coupling center

differential dual range

Z: Full-time AWD 4-speed AT with MPT

Y: Full-time AWD 4-speed AT with VTD

F: 925SO

V: 930DO

쐌 Rear differential 1

VA1REF

Digits Code Meaning Details 1 V For AWD V: AWD 2 A Type A: A type 3 1 Hypoid gear diameter 1: 152 dia.

2: 160 dia. 4 R Installation position R: Rear 5 E Reduction gear ratio E: 4.111

F: 4.444 6 F Specification differences F: Case A

G: Case B

H: Case B with cooling fin

쐌 Rear differential 2

Code Reduction

gear ratio T1 3.900 No T2 4.111 No TP 4.444 No BL 4.444 No (Strengthened type) VB 3.700 No CF 4.444 Viscous JP 4.111 Viscous

LSD

쐌 Option code

ECPS

Digits Code Meaning Details

1 to 2 EC Destination EC: EC

3 to 4 PS Main options

KO: KO K4: K4 KS: KS EK: EK KA: KA K1: K1

–

on vehicle

ID-6

Page 44

RECOMMENDED MATERIALS

1. Recommended Materials ............................................................................2

Page

Page 45

Recommended Materials

1. Recommended Materials SA05678

A: RECOMMENDED MATERIALS

SA05678G22

1. GENERAL SA05678G2201

To insure the best performance, always use the specified oil, gasoline, adhesive, sealant, etc. or that of equivalent quality.

2. FUEL SA05678G2202

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 or poor operation of the engine and fuel injection system. Use the specified gasoline to correct performance.

쐌 Unleaded gasoline

Use unleaded gasoline and not leaded gasoline on vehicles with catalytic converter installed to reduce air pollution. Using leaded gasoline will damage the catalytic converter.

RECOMMENDED MATERIALS

쐌 Leaded gasoline

On vehicles without catalytic converter, use gasoline with an octane value of 90 RON or higher.

RM-2

Page 46

RECOMMENDED MATERIALS

Recommended Materials

3. LUBRICANTS SA05678G2203

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

Lubricant Recommended Alternative

API Spec. CCMC Spec. ACEA Spec.

Engine oil SL or SJ Grade “Energy conserving”

B1M0495

G4 or G5 A1, A2 or A3 API: SH

GI0002

Manual transmission oil GL-5 ———

Front differential GL-5 ———

Rear differential GL-5 ———

RM-3

Page 47

Recommended Materials

RECOMMENDED MATERIALS

SAE viscosity SAE viscosity No. and applicable temperature SAE J300 Engine oil

Manual transmission oil

GI0003A

Rear differential

Front differential

GI0004A

GI0005A

RM-4

Page 48

RECOMMENDED MATERIALS

Recommended Materials

4. FLUID SA05678G2204

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

Fluid Recommended Alternative Remarks Automatic transmission fluid DEXRON III — Power steering fluid DEXRON III — Brake fluid FMVSS No. 116 DOT3 FMVSS No. 116 DOT4 Clutch fluid FMVSS No. 116 DOT3 FMVSS No. 116 DOT4

5. COOLANT SA05678G2205

Use genuine coolant to protect the engine.

Coolant Recommended Item number Alternative Coolant SUBARU coolant 000016218 None Water for dilution Distilled water — Tap water

6. REFRIGERANT SA05678G2206

Standard air conditioners on Subaru vehicles use HFC134a refrigerant. Do not mix it with other refrigerants. Also, do not use any air compressor oil except for ZXL200PG and DENSO OIL 9.

Air conditioner Recommended Item number Alternative Refrigerant HFC134a — None Compressor oil LHD: ZXL200PG

RHD: DENSO OIL 9

— None

7. GREASE SA05678G2207

Use the grease and supplementary lubricants shown in the table below.

Grease Application point Recommended Item number Alternative

Supplementary lubricants 쐌 O2 sensor

쐌 Bolts, etc.

Grease MT main shaft FX clutch grease 000040901 —

Clutch master cylinder push rod

쐌 Steering shaft bushing (Toe board) 쐌 Gear shift bushing

Steering gear box Valiant grease M-2 003608001 — Disc brake Niglube RX-2 725191040 — Drum brake Molykote No. 7439 725191460 —

쐌 Brake pad 쐌 Brake shoe

Front axle SFJ SSG-6003 28093TA000 — Front BJ NTG 2218 28093AA000 — Rear axle BJ Molylex No. 2 723223010 — Rear axle DOJ VU-3A702 23223GA050 —

쐌 Control cable 쐌 Throttle linkage 쐌 Water pump 쐌 Door latch 쐌 Door striker

SUBARU CRC 004301003 —

Slicolube G-40M 004404003 —

SUNLIGHT2 003602010 —

Molykote AS-880N K0777YA010 —

Slicolube G-30M 004404002 —

RM-5

Page 49

Recommended Materials

RECOMMENDED MATERIALS

8. ADHESIVES SA05678G2210

Use the adhesives shown in the table below, or equivalent.

Adhesive Application point Recommended Item number Alternative

Adhesive Windshield and body Essex Chemical Crop’s

Urethane E

Soft vinyl Cemedine 540 — 3M’s EC-776 EC-847 or

Momentary sealant Cemedine 3000 — Armstrong’s Eastman 910

9. SEAL MATERIAL SA05678G2209

Use seal material shown in the table below, or equivalent.

Seal material Application point Recommended Item number Alternative

쐌 Engine case (Except

3.0 L)

쐌 Cylinder block (3.0 L) 쐌 Torque converter clutch

case Transmission oil pan Three Bond 1217B K0877YA020 — Rear differential Three Bond 1324 004403042 — Rear differential Three Bond 1105 004403010 Dow Corning’s No. 7038 Weatherstrip Starcalking B-33A 000018901 Butyl Rubber sealant Steering adjusting screw Three Bond 1141 004403006 —

쐌 Camshaft cap (SOHC) 쐌 Oil pan, chain cover

(3.0 L)

Three Bond 1215 004403007 Dow Corning’s No. 7038

Three Bond 1280B K0877YA018 —

— Sunstar 580

EC-1022 (Spray type)

RM-6

Page 50

PRE-DELIVERY INSPECTION

1. Pre-delivery Inspection ................................................................................2

Page

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Pre-delivery Inspection

1. Pre-delivery Inspection SA09719

A: GENERAL SA09719G23

The purposes of the pre-delivery inspection (PDI) are as follows. 쐌 Remove the additional parts used for ensuring the vehicle quality during transportation and restore the vehicle to its normal state. 쐌 Check if the vehicle before delivery is in a normal state. 쐌 Check for any damage or missing parts that may have taken place during transportation or storage. 쐌 Make sure to provide a complete vehicle to the customer. Because of the above reasons, all dealerships must always carry out the PDIs before delivering a vehicle. In addition, all franchised shops and PDI centers must check the status of every vehicle received to identify who is responsible for any possible defects.

PRE-DELIVERY INSPECTION

PI-2

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PRE-DELIVERY INSPECTION

Pre-delivery Inspection

B: PDI PROCEDURE SA09719G50

Follow the procedures shown in the table below.

Static Checks Just After Vehicle Receipt

Step Check point

1. Appearance check (1) If the vehicle is covered with protective coating, visually check the

vehicle body for damage and dents. If the protective coating has been removed, 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.

2. Tire check (1) Check the tires for damage, abnormal conditions, and dents on the

wheels. (2) Check the tire air pressure.

3. Fuse installation (1) If the vehicle is about to be delivered to the customer, attach a room

lamp fuse.

4. Connection of air conditioner harness (1) If the vehicle is about to be delivered to the customer, connect the air

conditioner harness.

5. Check the doors for lock/unlock and open/ close operations.

6. Check the trunk lid open/close operations. (1) Operate the trunk lock release lever to check that the trunk opens nor-

7. Check the rear gate for lock/unlock and open/ close operations.

8. Operation check of fuel lid opener lock release lever

9. Accessory check Check the following accessories are provided:

10. Operation check of hood lock release system (1) Operate the hood lock release lever to check that the hood opens nor-

11. Battery (1) Check the battery for any abnormal conditions such as rust and trace

12. Brake fluid (1) Check the fluid amount.

13. Engine oil (1) Check the oil amount.

14. Transmission fluid (1) Check the fluid amount.

15. AT front differential oil (1) Check the AT front differential oil amount.

16. Coolant (1) Check the coolant amount.

17. Clutch fluid (1) Check the clutch fluid amount.

18. Window washer fluid (1) Check the window washer fluid amount.

19. Hood latch check (1) Check that the hood is closed and latched securely.

20. Keyless entry system (1) Check that the keyless entry system operates normally.

(1) Using the key, check if the door can be locked and unlocked normally. (2) Open and close the all doors to see that there are no abnormal conditions.

mally. (2) Using the key, check if the trunk lid can be unlocked normally. (3) Open and close the trunk lid to see that there are no abnormal conditions.

(1) Using the key, check if the rear gate can be lock and unlocked normally. (2) Open and close the rear gate to see that there are no abnormal conditions. (3) Operate the power door locking switch to check that the rear gate is locked and unlocked normally.

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

쐌 Owner’s manual 쐌 Warranty booklet 쐌 Service booklet 쐌 Spare key 쐌 Jack 쐌 Tool set 쐌 Spare tire

mally.

of battery fluid leaks.

(2) For AT, check the front differential oil.

PI-3

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Pre-delivery Inspection

PRE-DELIVERY INSPECTION

Step Check point

21. Seat (1) Check the seat surfaces for smears or dirt.

(2) Check the seat installation conditions and functionality.

22. Seat belt (1) Check the seat belt installation conditions and functionality.

23. Wheel alignment (1) Check that the wheel alignments are properly adjusted.

Checks with the Engine Running

Step Check point

1. Read memory and test mode connectors (1) Read memory and test mode connectors

2. Starting condition (1) Start the engine and check that the engine starts smoothly.

3. Exhaust system (1) Check that the exhaust noise is normal and no leaks are found.

4. Indicator light (1) Check that all the indicator lights operate normally.

5. Clock (1) Check that the clock operate normally.

6. Radio (1) Check that the radio system operates normally.

7. Cigarette lighter (1) Check that the cigarette lighter operates normally.

8. Lighting system (1) Check that the lighting systems operate normally.

9. Window washer (1) Check that the window washer system operates normally.

10. Wiper (1) Check that the wiper system operates normally.

11. Power window operation check (1) Check the power window for correct operations.

Dynamic Test with the Vehicle Running

Step Check point

1. Brake test (1) Check that the foot brake operates normally.

2. Parking brake (1) Check that the parking brake operates normally.

3. AT shift control (1) Check the AT shift patterns are correct.

4. Heater & ventilation (1) Check that the heater & ventilation system operates normally.

5. Air conditioner (1) Check that the air conditioner operates normally.

6. Cruise control (1) Check that the cruise control system operates normally.

Checks after Dynamic Test

Step Check point

1. ATF level (1) Check that the ATF level is normal.

2. Power steering fluid level (1) Check that the power steering fluid level is normal.

3. Fluid leak check (1) Check for fluid/oil leaks.

4. Water leak check (1) Spray the vehicle with water and check for water leaks.

5. Appearance check 2 (1) Remove the protective coating (if any).

(2) Check the body paints for damage and smears. (3) Check the plated parts for damage and rust.

PI-4

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PRE-DELIVERY INSPECTION

Pre-delivery Inspection

1. APPEARANCE CHECK SA09719G5001

쐌 If the vehicle is covered with protective coating, visually check the vehicle body for damage and dents. 쐌 If there is no protective coating, check the body paints for small areas of damage or stains and repair as necessary. 쐌 Check the window glass, door glass, and lights for any cracks or damage and repair or replace the parts as necessary. 쐌 Check the plated parts, such as the grilles and door knobs, for damage or loss of gloss and repair or replace the parts as necessary.

2. TIRE CHECK SA09719G5002

쐌 Check the tire outer faces for any damage. 쐌 Check the tire air pressure by referring to the

following table.

Tire size Tire inflation pressure

kPa (kg/cm

Front Rear 185/70R14 220 (2.2, 32) 210 (2.1, 30) 195/70R15 220 (2.2, 32) 210 (2.1, 30) 205/50R16 230 (2.3, 33) 220 (2.2, 32) 215/60R16 200 (2.0, 29) 200 (2.0, 29)

, psi)

4. CONNECTION OF AIR CONDITIONER CUT CONNECTOR

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

SA09719G5051

B1M0484

5. CHECK THE DOOR OPERATIONS, LOCK/UNLOCK AND OPEN/CLOSE, 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.

SA09719G5003

3. FUSE INSTALLATION SA09719G5010

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.

GI0084A

GI0078A

쐌 Vehicles with manual door locks:

Sit in all seats, close the door completely, and move the lock lever to the lock position. Then, pull the inside door handle to ensure the door will not open.

PI-5

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Pre-delivery Inspection

PRE-DELIVERY INSPECTION

쐌 Vehicles with power door locks:

Sit in the driver seat, close the driver’s door completely, and place the power door locking switch (A) to the lock position. Then pull the all inside door handles (B) to ensure that the all doors will not open. For other doors, place the lock levers to the lock positions and then pull the inside door handles to ensure that the doors will not open.

GI0079A

6. CHECK THE TRUNK LID OPERATIONS, OPEN/CLOSE, AS FOLLOWS.

쐌 Operate the trunk lock release lever and verify that the trunk lid opens. 쐌 Using the key, open the trunk lid several times to check for normal operation. 쐌 Open and close the trunk lid several times for smooth movement.

SA09719G5055

7. CHECK THE REAR GATE OPERATIONS, LOCK/UNLOCK AND OPEN/CLOSE, AS FOLLOWS.

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

쐌 Operate the power door locking switch to check that the rear gate is locked and unlocked normally.

SA09719G5053

B1M0487A

8. 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 securely closed.

SA09719G5007

B1M0485A

쐌 Set the trunk lid release lever to the cancel position, and check that the trunk lid can only be opened with the key.

B1M0486

PI-6

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PRE-DELIVERY INSPECTION

Pre-delivery Inspection

9. ACCESSORY CHECK SA09719G5008

Check that the following accessories are provided in the luggage compartment or cargo area.

쐌 Owner’s manual 쐌 Warranty booklet 쐌 Service booklet 쐌 Spare key 쐌 Jack 쐌 Tool set 쐌 Spare tire

GI0080A

10. OPERATION CHECK OF HOOD LOCK RELEASE SYSTEM

Unlatch and open the hood while checking that no abnormal conditions are found. Then, support the hood with the hood stay.

SA09719G5009

GI0082A

GI0081A

GI0083A

11. BATTERY SA09719G5012

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

GI0086A

12. BRAKE FLUID SA09719G5013

Check the brake fluid amount. If the amount is insufficient, 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.

PI-7

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Pre-delivery Inspection

PRE-DELIVERY INSPECTION

13. ENGINE OIL SA09719G5014

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

GI0087A

14. TRANSMISSION FLUID SA09719G5015

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

16. COOLANT SA09719G5017

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

17. CLUTCH FLUID SA09719G5018

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

GI0090A

18. WINDOW WASHER FLUID SA09719G5019

GI0088A

15. AT FRONT DIFFERENTIAL OIL SA09719G5016

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

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

19. HOOD LATCH CHECK SA09719G5020

Retract the hood stay and close the hood. Check that the hood is securely latched.

GI0089A

PI-8

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PRE-DELIVERY INSPECTION

Pre-delivery Inspection

20. KEYLESS ENTRY SYSTEM SA09719G5021

Check the keyless entry system operations as follows. 쐌 Remove the key from the ignition switch and close all the doors including rear gate (wagon). 쐌 Press the “LOCK” button on the transmitter momentarily once and check if all the doors are locked and the hazard light flashes ones.

B5M1182

쐌 Press the “OPEN” button on the transmitter momentarily once and check if the driver’s door is unlocked, the hazard light flashes twice and the dome light illuminates. 쐌 Close all doors and rear gate, press the “LOCK” button of the transmitter. Press the “OPEN” button of the transmitter and wait for 30 seconds. Check that all doors and the rear gate are automatically locked again.

24. READ MEMORY AND TEST MODE CONNECTORS

Turn the ignition switch to ON and check that the check-engine light starts blinking. If the light blinks, 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.

With OBD model

Without OBD model

SA09719G5050

GI0095A

21. SEAT SA09719G5023

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.

22. SEAT BELT SA09719G5024

Pull out the seat belt and then release it. Check that the belt webbing retracts smoothly.

23. WHEEL ALIGNMENT SA09719G5026

Check the wheel alignments. <Ref. to FS-6, Wheel Alignment.> and <Ref. to RS-8, Wheel Alignment.>

GI0119A

25. STARTING CONDITION SA09719G5029

Start the engine and check that the engine starts smoothly. If any battery voltage problems are found, recharge or replace the battery. If any abnormal noises are observed, immediately stop the engine and check and repair the necessary components.

26. EXHAUST SYSTEM SA09719G5030

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

27. INDICATOR LIGHT SA09719G5031

Check that all the indicator lights are off.

28. CLOCK SA09719G5032

Check the clock for normal operations and enough accuracy.

PI-9

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Pre-delivery Inspection

PRE-DELIVERY INSPECTION

29. RADIO SA09719G5033

Check the radio for full functionality and normal noise level. Also check the CD unit operations.

30. CIGARETTE LIGHTER SA09719G5034

Check that the cigarette lighter operations.

31. LIGHTING SYSTEM SA09719G5035

쐌 Check the headlight operations. 쐌 Check the brake light operations. 쐌 Check the other lights for normal operations.

32. WINDOW WASHER SA09719G5036

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

37. AT SHIFT CONTROL SA09719G5041

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

GI0113A

Selector Position

D Yes Yes Yes Yes

3 Yes Yes Yes 2 Yes Yes 1Yes

1st 2nd 3rd 4th

Gear Position

GI0118A

33. WIPER SA09719G5037

Check the front and rear wipers for normal operations.

34. 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.

SA09719G5004

38. HEATER & VENTILATION SA09719G5042

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

39. AIR CONDITIONER SA09719G5043

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

40. CRUISE CONTROL SA09719G5044

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

41. ATF LEVEL SA09719G5045

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

35. BRAKE TEST SA09719G5038

Check the foot brake for normal operations.

36. PARKING BRAKE SA09719G5039

Check the parking brake for normal operations.

GI0098A

PI-10

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PRE-DELIVERY INSPECTION

Pre-delivery Inspection

42. POWER STEERING FLUID LEVEL

SA09719G5046

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.

GI0099A

43. FLUID LEAK CHECK SA09719G5047

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

44. WATER LEAK TEST SA09719G5048

check all areas that may have possibly contributed to the leak.

45. APPEARANCE CHECK 2 SA09719G5049

Check the vehicle body paints, plated faces, glass, and lenses for any dirt or damage.

Spray the vehicle with water and check that no water enters the passenger compartment. 쐌 Before performing the water leakage test, remove anything that may obstruct the operation or which must be kept dry. 쐌 Close all of the windows completely, and then close all of the doors tightly. Close the hood and trunk lid before starting the test. 쐌 Connect a hose to a tap, and spray water on the vehicle. The rate of water discharge must be approx. 20 to 25 liters (5.3 to 6.6 US gal, 4.4 to 5.5 Imp gal) per minute. When spraying water on areas adjacent to the floor and wheel house, increase the pressure. When directing 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 10 cm (3.9 in) from the vehicle.

쐌 Check the following areas:

쐌 Front window and body framework mating

portion

쐌 Door mating portions 쐌 Glass mating portions 쐌 Rear quarter window mating portions 쐌 Rear window and body framework mating

portion

쐌 Around roof drips

쐌 If any dampness in the compartments is discov-

ered after the water has been applied, carefully

PI-11

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Pre-delivery Inspection

MEMO:

PRE-DELIVERY INSPECTION

PI-12

Page 62

PERIODIC MAINTENANCE SERVICES

1. General Description.....................................................................................2

2. Schedule......................................................................................................3

3. Engine Oil....................................................................................................6

4. Engine Oil Filter...........................................................................................8

5. Spark Plugs .................................................................................................9

6. Drive Belt(s)...............................................................................................10

7. Camshaft Drive Belt ..................................................................................13

8. Fuel Line....................................................................................................15

9. Fuel Filter ..................................................................................................16

10. Air Cleaner Element ..................................................................................17

11. Cooling System .........................................................................................18

12. Coolant ......................................................................................................19

13. Idle Mixture ................................................................................................21

14. Clutch System ...........................................................................................22

15. Hill-holder System .....................................................................................23

16. Transmission Oil........................................................................................24

17. ATF ............................................................................................................25

18. Front & Rear Differential Oil......................................................................27

19. Brake Line .................................................................................................29

20. Brake Fluid ................................................................................................31

21. Disc Brake Pads and Discs ......................................................................32

22. Parking Brake ............................................................................................33

23. Suspension................................................................................................34

24. Wheel Bearing ...........................................................................................36

25. Axle Boots & Joints...................................................................................37

26. Steering System (Power Steering)............................................................38

27. Supplemental Restraint System................................................................41

Page

Page 63

Periodic Maintenance Services

1. General Description SA07001

A: GENERAL SA07001G23

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

GENERAL DESCRIPTION

PM-2

Page 64

SCHEDULE

Periodic Maintenance Services

2. Schedule SA07682

A: MAINTENANCE SCHEDULE 1 SA07682G24

1. MAINTENANCE SCHEDULE1–(1) SA07682G2401

For periodic maintenance of over 50,000 km (30,000 miles) or 48 months, carry out inspections by referring to the following tables. For a maintenance period gone beyond these tables, apply them repeatedly as a set of 50,000 km (30,000 miles) or 48 months.

Maintenance Interval [Number of months or km (miles), whichever occurs first]

Months 12 24 36 48 Remarks

× 1,000 km 5 12.5 25 37.5 50 × 1,000 miles 3 7.5 15 22.5 30

1 Engine oil For 3.0 L RRRRRForchain drive

Others RRRR

2 Engine oil filter For 3.0 L RRRRRForchain drive

Others RRRR

2. MAINTENANCE SCHEDULE1–(2) SA07682G2402

For periodic maintenance of over 100,000 km (60,000 miles) or 48 months, carry out inspections by referring to the following tables. For a maintenance period gone beyond these tables, apply them repeatedly as a set of 100,000 km (60,000 miles) or 48 months.

Maintenance Interval [Number of months or km (miles), whichever occurs first]

Months 12 24 36 48 Remarks

× 1,000 km 1.6 25 50 75 100 × 1,000 miles 1 15 30 45 60

3 Spark plugs For 3.0 L R

Others R R

4 Drive belt(s) For 3.0 L IIIIReplace every 160,000 km

(100,000 miles)

Others IIII 5 Camshaft drive belt Except 3.0 L R 6 Fuel line I I 7 Fuel filter R 8 Air cleaner element I R I R 9 Cooling system I I

10 Coolant R R 11 Idle mixture IIIIIFormodels without catalyst con-

verter 12 Clutch system IIII 13 Hill-holder system IIIII 14 Transmission oil R R 15 ATF R R 16 Front & rear differ-

ential oil 17 Brake line I I 18 Brake fluid R R 19 Disc brake pads &

discs 20 Parking brake IIII 21 Suspension IIII 22 Wheel bearing (I)

IIII

PM-3

Page 65

Periodic Maintenance Services

SCHEDULE

Maintenance Interval [Number of months or km (miles), whichever occurs first]

Months 12 24 36 48 Remarks

× 1,000 km 1.6 25 50 75 100

× 1,000 miles 1 15 30 45 60

23 Axle boots & joints IIII 24 Steering system

(Power steering)

Symbols used: R: Replace I: Inspection (R) or (I): Recommended service for safe vehicle operation. NOTE: (1) Periodic inspection and replacement of the camshaft drive chains on the 3.0 liter models are not required. (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 ATF leaked.

IIII

PM-4

Page 66

SCHEDULE

B: MAINTENANCE SCHEDULE 2 SA07682G25

Periodic Maintenance Services

Item Every Repeat short

distance drive

Engine oil Replace more

frequently

Engine oil filter Replace more

frequently

Fuel line 6 months I

12,500 km 7,500 miles

Transmission oil Replace more

ATF Replace more

Front & rear differential oil

Brake line 6 months I I I I

12,500 km 7,500 miles

Brake fluid 12 months R

25,000 km 15,000 miles

Brake pads 6 months I I I I

12,500 km 7,500 miles

Parking brake 6 months I I I I

12,500 km 7,500 miles

Suspension 6 months I I I I

12,500 km 7,500 miles

Axle boots & joints

Steering system (Power steering)

6 months IIII I 12,500 km 7,500 miles 6 months IIII I 12,500 km 7,500 miles

Repeat rough/muddy road drive

Extremely cold weather area

Replace more frequently

Salt or other corrosive used or coastal area

High humidity or mountain area

Repeat towing trailer

Replace more frequently

frequently

frequently Replace more

frequently

PM-5

Page 67

Periodic Maintenance Services

ENGINE OIL

3. Engine Oil SA07077

A: REPLACEMENT SA07077A20

1) Drain engine oil by loosening engine oil drain plug.

Except 3.0 L model

GI0012A

3.0 L model

B2M4534A

3) Replace drain plug gasket.

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

Tightening torque:

44 N·m (4.5 kgf-m, 33 ft-lb)

B2M3884

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

Except 3.0 L model

GI0013A

GI0012A

5) Fill engine oil through filler pipe up to upper point on level gauge. Make sure that 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 amount for preparation:

2.5 L model Approx. 4.0  (4.2 US qt, 3.5 Imp qt)

3.0 L model Approx. 5.5  (5.8 US qt, 4.8 Imp qt)

GI0015A

PM-6

The proper viscosity helps vehicle get good cold and hot starting by reducing viscous friction and thus increasing cranking speed.

Page 68

ENGINE OIL

Periodic Maintenance Services

NOTE: 쐌 When replenishing oil, it does not matter if the oil to be added is a different brand from that in the engine; however, use oil having the API classification and SAE viscosity No. designated by SUBARU. 쐌 If vehicle is used in desert areas with very high temperatures or for other heavy duty applications, the following viscosity oils may be used: API classification: SJ or SH SAE Viscosity No.: 30, 40, 10W-50, 20W-40, 20W-50

6) Close engine oil filler cap.

7) Start engine and warm it up for a time.

8) After engine stops, recheck the oil level. If necessary, add engine oil up to upper level on level gauge.

Except 3.0 L model

B: INSPECTION SA07077A10

1) Park vehicle on a level surface.

2) Remove 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. If the engine oil level is below the “L” line, add oil to bring the level up to the “F” line.

5) After turning off the engine, wait a few minutes for the oil to drain back into the oil pan before checking the level.

6) Just after driving or while the engine is warm, engine oil level may show in the range between the “F” line and the notch mark. This is caused by thermal expansion of the engine oil.

7) To prevent overfilling the engine oil, do not add oil above the “F” line when the engine is cold.

3.0 L model

GI0016A

B2M4534A

PM-7

Page 69

Periodic Maintenance Services

ENGINE OIL FILTER

4. Engine Oil Filter SA07585

A: REPLACEMENT SA07585A20

1. EXCEPT 3.0 L MODEL SA07585A2003

1) Remove oil filter with ST. ST 498547000 OIL FILTER WRENCH

GI0012A

2) Get a new oil filter and apply a thin coat of engine oil to the rubber seal.

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

4) Tighten more (approximately 2/3 to 3/4 turn) after the rubber seal contacts the oil pump case. Do not tighten excessively, or oil may leak.

5) After installing oil filter, run engine and make sure that no oil is leaking around rubber seal.

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-8, ENGINE OIL, PDI PROCEDURE, Pre-delivery Inspection.>

2. 3.0 L MODEL SA07585A2002

1) Drain engine oil by loosening engine oil drain plug.

B2M3887

3) Remove oil filter with ST. ST 498547000 OIL FILTER WRENCH

B2M4548

4) Get a new oil filter and apply a thin coat of engine oil to the rubber seal.

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

6) Tighten more (approximately 3/4 turn) after the rubber seal contacts the oil pump case or oil cooler. Do not tighten excessively, or oil may leak.

7) After installing oil filter, run engine and make sure that no oil is leaking around rubber seal.

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

8) Check the engine oil level. <Ref. to LU(H6)-10, INSPECTION, Engine Oil.>

2) Remove access lid.

B2M3884

PM-8

Page 70

SPARK PLUGS

Periodic Maintenance Services

5. Spark Plugs SA07683

A: REPLACEMENT SA07683A20

1. 2.5 L MODEL SA07683A2001

1) Disconnect battery ground cable.

2) Remove intake duct and intake chamber.

3) Remove washer tank and put it aside.

4) Disconnect spark plug cord.

5) Remove spark plug with a plug-wrench.

GI0018

6) Set new spark plug.

Recommended spark plug :

With OBD

CHAMPION RC10YC4 CHAMPION RC8YC4 NGK BKR6E-11 NIPPONDENSO K20PR-U11 Spark plug gap

1.0 — 1.1 mm (0.039 — 0.043 in)

Without OBD

NGK BKR6E (Without catalytic converter) CHAMPION RC10YC4 (With catalytic converter) NGK BKR5E-11 (With catalytic converter) Spark plug gap

0.7— 0.8 mm (0.028 — 0.031 in) (Without catalytic converter)

1.0 — 1.1 mm (0.039 — 0.043 in) (With catalytic converter)

7) Tighten spark plug lightly with hand, and then secure with a plug-wrench to the specified torque.

Tightening torque:

20.6 N·m (2.10 kgf-m, 15.19 ft-lb)

NOTE: 쐌 Be sure to place the gasket between the cylinder head and spark plug. 쐌 If torque wrench is not available, tighten spark plug until gasket contacts cylinder head; then tighten further 1/4 to 1/2 turns.

2. 3.0 L MODEL SA07683A2002

1) Disconnect battery cables and then remove battery and battery carrier.

2) Remove washer tank and put it aside.

3) Remove air cleaner lower case.

4) Disconnect connector from ignition coil.

5) Remove ignition coil.

B2M4336

6) Remove spark plug with the spark plug socket.

B2M4333

7) Set new spark plug.

Recommended spark plug:

NGK PLFR 6A-11

8) Tighten spark plug lightly with hand, and then secure with a plug-wrench to the specified torque.

Tightening torque:

21 N·m (2.1 kgf-m, 15 ft-lb)

9) Tighten ignition coil.

Tightening torque:

16 N·m (1.6 kgf-m, 12 ft-lb)

NOTE: 쐌 Be sure to place the gasket between the cylinder head and spark plug. 쐌 If torque wrench is not available, tighten spark plug until gasket contacts cylinder head: then tighten further 1/4 to 1/2 turn.

PM-9

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Periodic Maintenance Services

DRIVE BELT(S)

6. Drive Belt(s) SA07684

A: INSPECTION SA07684A10

1. EXCEPT 3.0 L MODEL SA07684A1003

1) Replace belts, if cracks, fraying or wear is found.

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

Belt tension

(A)

replaced: 7 — 9 mm (0.276 — 0.354 in) reused: 9.0 — 10.0 mm (0.354 — 0.394 in)

(B)*

replaced: 7.5 — 8.5 mm (0.295 — 0.335 in) reused: 9.0 — 10.0 mm (0.354 — 0.394 in)

*: There is no belt (B) on models without an air conditioner.

2. 3.0 L MODEL SA07684A1002

1) Replace belts, if cracks, fraying or wear is found.

2) Check that the V-belt automatic tensioner indicator is within the range (D).

C/P Crankshaft pulley GEN Generator P/S Power steering oil pump pulley A/C Air conditioning compressor pulley I/P Idler pulley

GI0019B

B2M4014A

(A) Indicator (B) Generator (C) Power steering oil pump (D) Service limit

PM-10

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DRIVE BELT(S)

Periodic Maintenance Services

B: REPLACEMENT SA07684A20

1. EXCEPT 3.0 L MODEL SA07684A2006

1) Remove V-belt cover.

GI0020

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

2) Loosen the lock bolt (A).

3) Loosen the slider bolt (B).

4) Remove the front side belt (C).

8) Install a new belt, and tighten the slider bolt so as to obtain the specified belt tension.

9) Tighten the slider bolt (B).

10) Tighten the lock nut (A).

Tightening torque:

22.6 N·m (2.3 kgf-m, 16.6 ft-lb)

GI0022A

11) Install a new belt, and tighten the slider bolt so as to obtain the specified belt tension.

12) Tighten the slider bolt (B).

13) Tighten the lock bolt (A).

Tightening torque:

Lock bolt, through bolt:

25 N·m (2.5 kgf-m, 18 ft-lb)

Slider bolt:

8N·m (0.8 kgf-m, 5.8 ft-lb)

5) Loosen the lock nut (A).

6) Loosen the slider bolt (B).

7) Remove the rear side belt.

GI0021A

2. 3.0 L MODEL SA07684A2005

1) Fit the tool to the belt tensioner mounting bolt.

2) Turn the tool clockwise, and loosen the V-belt to remove.

GI0022A

B2M4012

PM-11

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Periodic Maintenance Services

3) Install in the reverse order of removal.

B2M4013A

(1) Power steering oil pump (2) Belt tension adjuster (3) Crankshaft pulley (4) A/C compressor (5) Belt idler (6) Generator

DRIVE BELT(S)

PM-12

Page 74

CAMSHAFT DRIVE BELT

Periodic Maintenance Services

7. Camshaft Drive Belt SA07685

A: REPLACEMENT SA07685A20

1. SOHC MODEL SA07685A2001

1) Remove radiator fan <Ref. to CO-26, Radiator Main Fan and Fan Motor.> and air conditioner fan <Ref. to CO-29, Radiator Sub Fan and Fan Motor.>.

2) Remove V-belt cover.

GI0020

3) Remove V-belts. <Ref. to ME-45, REMOVAL, V-belt.>

4) Remove air conditioning compressor drive belt tensioner.

5) Remove pulley bolt. To lock crankshaft use ST. ST 499977100 CRANKSHAFT PULLEY

WRENCH

10) Turn 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

GI0025A

11) Remove belt idler.

12) Remove belt idler (No. 2).

GI0024A

6) Remove crankshaft pulley.

7) Remove left side belt cover.

8) Remove front belt cover.

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

S2M0294

GI0026

13) Remove timing belt.

14) Remove automatic belt tension adjuster assembly.

GI0027

PM-13

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Periodic Maintenance Services

CAMSHAFT DRIVE BELT

B: INSTALLATION SA07685A11

1. SOHC MODEL SA07685A1101

To install, reverse order of removal procedures. <Ref. to ME-51, INSTALLATION, Timing Belt Assembly.>

NOTE: When installing the timing belt, be sure to align all alignment marks on the belt with corresponding marks on the sprockets. If incorrectly installed, interference between pistons and valves may occur.

C: INSPECTION SA07685A10

1. SOHC MODEL SA07685A1001

1) Remove left and right timing belt covers.

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

3) Measure timing belt width W. If it is less than 27 mm (1.06 in), check idlers, tensioner, water pump pulley and cam sprocket to determine idler alignment (squareness). Replace worn timing belt.

GI0028A

4) Install left and right timing belt covers.

PM-14

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FUEL LINE

8. Fuel Line SA07686

A: INSPECTION SA07686A10

The fuel line is located mostly internally, so check pipes, areas near pipes, and engine compartment piping for rust, hose damage, loose bands, etc. If faulty parts are found, repair or replace them. <Ref. to FU-78, Fuel Delivery, Return and Evaporation Lines.> or <Ref. to FU(w/oOBD)-72, Fuel Delivery, Return and Evaporation Lines.> or <Ref. to FU(H6)-73, Fuel Delivery, Return and Evaporation.>

Periodic Maintenance Services

PM-15

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Periodic Maintenance Services

9. Fuel Filter SA07027

A: REPLACEMENT SA07027A20

For fuel filter replacement procedures, refer to “FU” section. <Ref. to FU-75, Fuel Filter.> or <Ref. to FU(w/oOBD)-69, Fuel Filter.> or <Ref. to FU(H6)70, Fuel Filter.>

FUEL FILTER

PM-16

Page 78

AIR CLEANER ELEMENT

Periodic Maintenance Services

10. Air Cleaner Element SA07687

A: REPLACEMENT SA07687A20

NOTE: Do not attempt to clean the air cleaner element. The filter paper of the element is wetted with a special non-flammable slow-evaporating viscous liquid. It is resistant to cold weather and has a long service life. Dirt adhering to this filter paper forms porous laminations with the viscous liquid, which function as a filtration layer to reduce dust penetration into the filter paper. If this filter paper is cleaned, the filtration layer thus formed will be lost along with the viscous liquid.

1. 2.5 L MODEL SA07687A2005

2. 3.0 L MODEL SA07687A2006

1) Remove the clip (A) above the air cleaner upper cover.

B2M4401B

2) Remove air cleaner.

3) Install in the reverse order of removal.

NOTE: Before installing air cleaner upper cover, align holes with protruding portions of air cleaner lower case, then secure upper cover to lower case.

GI0032

1) Remove bolt (A) which install air cleaner case to stays.

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

H2M2947A

3) Remove air cleaner.

4) Install in the reverse order of removal.

Tightening torque:

32.3 N·m (3.3 kgf-m, 23.9 ft-lb)

CAUTION: Fasten with a clip after inserting the lower tab of the case.

B2M4403

PM-17

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Periodic Maintenance Services

11. Cooling System SA07688

A: INSPECTION SA07688A10

1) Check radiator for leakage, filling it with coolant

COOLING SYSTEM

and attach radiator cap tester (A) to the filler neck. Then apply a pressure of 157 kPa (1.6 kg/cm psi) and check the following points:

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

NOTE: 쐌 When attaching or detaching tester and when operating tester, use special care not to deform radiator filler neck.

,23

GI0034

GI0033A

쐌 When performing this check, be sure to keep the engine stationary and fill radiator with coolant.

쐌 Wipe off check points before applying pressure. 쐌 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 functioning normally: be sure to clean cap before testing.

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.

Radiator cap valve open pressure

Standard value:

93 — 123 kPa (0.95 — 1.25 kg/cm

,14—

18 psi)

Service limit:

83 kPa (0.85 kg/cm

, 12 psi)

GI0035A

3) If the coolant temperature exceeds 76.0 to

80.0°C (169 to 176°F) while radiator is not so hot, check thermostat. If thermostat does not open at

76.0 to 80.0°C (169 to 176°F), replace it with a new one.

4) If electric fan does not operate when coolant temperature exceeds 90 to 94°C (194 to 201°F), check thermoswitch or fan motor.

PM-18

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COOLANT

Periodic Maintenance Services

12. Coolant SA07689

A: REPLACEMENT SA07689A20

1. REPLACEMENT OF COOLANT SA07689A2001

WARNING: The radiator is of the pressurized type. Do not attempt to open the radiator cap immediately after the engine has been stopped.

1) Lift up the vehicle.

2) Remove under cover.

3) Place a container under drain pipe.

4) Loosen and remove drain screw (A) to drain engine coolant into container.

2.5 L model

GI0036A

3.0 L model

NOTE: The SUBARU Genuine Coolant containing antifreeze 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 radiator cap.

10) Run engine for more than five minutes at 2,000 to 3,000 rpm. (Run engine until radiator becomes hot in order to purge air trapped in cooling system.)

11) Stop engine and wait until coolant temperature lowers. Then open 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 install radiator and reservoir tank caps.

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 25°C (77°F) and its specific gravity is 1.054, the concentration is 35% (point A), the safe operating temperature is –14°C (7°F) (point B), and the freezing temperature is –20°C(–4°F) (point C).

SA07689A2002

B2M4428

5) For quick draining, open radiator cap.

CAUTION: Be careful not to spill coolant on the floor.

6) Drain coolant from reservoir tank.

7) Tighten radiator drain screw securely after draining coolant.

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

Coolant capacity (fill up to “FULL” level)

2.5 L MT model: Approx. 6.8  (7.2 US qt, 6.0 Imp qt)

2.5 L AT model: Approx. 6.7  (7.1 US qt, 5.9 Imp qt)

3.0 L model Approx. 7.7  (8.1 US qt, 6.8 Imp qt)

GI0037A

PM-19

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Periodic Maintenance Services

COOLANT

3. PROCEDURE TO ADJUST THE CONCENTRATION OF THE COOLANT

SA07689A2003

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 solution 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% to 40%. Find point A, where the 25% line of coolant concentration intersects with the 40% curve of the necessary coolant concentration, and read the scale on the vertical axis of the graph at height A. The quantity of coolant to be drained is 2.1 liters (2.2 US qt, 1.8 Imp qt). Drain 2.1 liters (2.2 US qt, 1.8 Imp qt) of coolant from the cooling system and add 2.1 liters (2.2 US qt, 1.8 Imp qt) of the undiluted solution of SUBARU coolant. If a coolant concentration of 50% is needed, drain all the coolant and refill with the undiluted solution only.

GI0038B

PM-20

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IDLE MIXTURE

13. Idle Mixture SA07734

A: INSPECTION AND ADJUSTMENT

SA07734G26

1. IDLE MIXTURE SA07734G2601

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 engine sufficiently until cooling fan starts to operate.

3) Measure the idle mixture with the CO meter.

Engine idle speed CO

700±100 rpm 1.0±0.5%

4) If out of specification, adjust the idle mixture using CO adjusting screw of mass air flow sensor.

5) After adjusting the CO value, check and adjust increment coefficient of CO resistor by using Select Monitor.

(1) Select “Current data display & Save” on the select monitor. (2) If out of specified data, adjust the increment coefficient of CO resistor while rotating CO adjusting screw.

Specified data:

0.28 — 4.22 V

Periodic Maintenance Services

GI0114A

NOTE: If driving the vehicle on out of specified data, the “trouble code 49” is indicated in many case.

PM-21

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Periodic Maintenance Services

14. Clutch System SA07690

A: INSPECTION AND ADJUSTMENT

SA07690G26

1) Push the release lever to retract the push rod of the operating cylinder and check if the fluid level in the clutch reservoir tank rises or not.

GI0039A

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-27, Clutch Pedal.>

4) Inspect the underside of master cylinder, clutch damper and operating cylinder for clutch system, hoses, piping and their couplings for fluid leaks. If fluid leaks are found, correct them by retightening their fitting bolt and/or replacing their parts.

5) Check the fluid level using the scale on the outside of the clutch master cylinder tank (A). If the level is below “MIN” (B), add clutch fluid to bring it up to “MAX” (C).

Recommended clutch fluid:

FMVSS No. 116, fresh DOT3 or DOT4 brake fluid

NOTE: 쐌 Avoid mixing different brakes of brake fluid to prevent degradation of the fluid. 쐌 Be careful not to allow dirt or dust to get into the reservoir tank.

CLUTCH SYSTEM

GI0040A

PM-22

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HILL-HOLDER SYSTEM

15. Hill-holder System SA07735

A: INSPECTION AND ADJUSTMENT

SA07735G26

1) Confirm stopping and starting performance by activating hill-holder on an uphill road of 3° or higher inclination.

(1) When vehicle does not stop; Tighten adjusting nut of PHV cable. (2) When vehicle does not start properly; A; When hill-holder is released later than engagement of clutch (engine tends to stall): Loosen adjusting nut gradually until smooth starting is enabled. B; When hill-holder is released earlier than engagement to clutch (vehicle slips down slightly): Tighten adjusting nut so that hill-holder is released later than engagement of clutch (status in A). Then make adjustment the same as in A.

NOTE: 쐌 Whenever turning adjusting nut, hold inner cable with pliers to prevent it from turning. 쐌 Replace pressure hold valve (PHV), return spring of PHV or PHV cable with new one, if they are defective and/or damaged.

Periodic Maintenance Services

GI0115A

PM-23

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Periodic Maintenance Services

16. Transmission Oil SA07691

A: REPLACEMENT SA07691A20

1. MANUAL TRANSMISSION SA07691A2001

1) Drain gear oil by removing drain plug after allowing the engine to cool for 3 to 4 hours.

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

GI0041

2) Reinstall drain plug after draining gear oil and tighten it to the specified torque.

Tightening torque:

44 N·m (4.5 kgf-m, 32.5 ft-lb)

NOTE: 쐌 Be sure to place a gasket between the transmission case and drain plug.

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

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

3) Fill transmission gear oil through the oil level gauge hole up to the upper point of level gauge.

Gear oil capacity:

Single range model

3.5  (3.7 US qt, 3.1 Imp qt)

Dual range model

4.0  (4.2 US qt, 3.5 Imp qt)

TRANSMISSION OIL

GI0042A

PM-24

Page 86

ATF

Periodic Maintenance Services

17. ATF SA07692

A: INSPECTION SA07692A10

1) Raise ATF temperature to 60 to 80°C (140 to 176°F) from 40 to 60°C (104 to 140°F) (when cold) by driving a distance of 5 to 10 km (3 to 6 miles).

NOTE: The level of ATF varies with fluid temperature. Pay attention to the fluid temperature when checking oil level.

B3M1020B

(A) ATF level gauge (B) Upper level (C) Lower level

4) Fluid temperature rising speed 쐌 By idling the engine Time for temperature rise to 60°C (140°F) with atmospheric temperature of 0°C (32°F): More than 25 minutes <Reference> Time for temperature rise to 30°C (86°F) with atmospheric temperature of 0°C (32°F): Approx. 8 minutes 쐌 By running the vehicle Time for temperature rise to 60°C (140°F) with atmospheric temperature of 0°C (32°F): More than 10 minutes

5) Method for checking fluid level upon delivery or at periodic inspection Check fluid level after a warm-up run of approx. 10 minutes. During the warm-up period, the automatic transmission functions can also be checked.

2) Make sure the vehicle is level. After selecting all positions (P, R, N, D, 3, 2, 1), set the select leveler in “P” range. Measure fluid level with the engine idling.

NOTE: After running, idle the engine for one or two minutes before measurement.

3) If the fluid level is below the center between upper and lower marks, add the recommended ATF until the fluid level is found within the specified range (above the center between upper and lower marks). When the transmission is hot, the level should be above the center of upper and lower marks, and when it is cold, the level should be found below the center of these two marks.

CAUTION:

쐌 Use care not to exceed the upper limit level. 쐌 ATF level varies with temperature. Remem-

ber that the addition of fluid to the upper limit mark when the transmission is cold will result in the overfilling of fluid.

PM-25

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Periodic Maintenance Services

B: REPLACEMENT SA07692A20

1. AUTOMATIC TRANSMISSION FLUID

SA07692A2001

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.

GI0043A

ATF

2) Reinstall drain plug after draining ATF, and tighten it to the specified torque.

Tightening torque:

24.5 N·m (2.5 kgf-m, 18.1 ft-lb)

3) Fill ATF up to the middle of the “COLD” side on level gauge by using the gauge hole.

Recommended fluid:

Dexron III type automatic transmission fluid

Fluid capacity:

Fill the same amount drained from ATF drain plug hole.

4) Check the level of the ATF. Refer to “INSPECTION”.

2. ATF FILTER SA07692A2002

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

For the replacement procedures of the ATF filter: <Ref. to AT-47, ATF Filter.>

PM-26

Page 88

FRONT & REAR DIFFERENTIAL OIL

18. Front & Rear Differential Oil

SA07693

A: REPLACEMENT SA07693A20

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 PM-24, MANUAL TRANSMISSION, REPLACEMENT, Transmission Oil.>

2. FRONT DIFFERENTIAL (AUTOMATIC TRANSMISSION)

1) Drain differential gear oil by removing drain plug after allowing the engine to cool for 3 to 4 hours.

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

SA07693A2001

SA07693A2002

Periodic Maintenance Services

GI0046A

3. REAR DIFFERENTIAL SA07693A2003

1) Drain oil by removing drain plug.

2) Remove filler plug for quick draining oil.

3) Reinstall drain plug after draining oil.

NOTE: 쐌 Apply fluid packing to drain plug threads before installation in T-type. 쐌 VA-type uses a new aluminum gasket.

GI0045

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 ft-lb)

NOTE: 쐌 Be sure to place a gasket between the transmission case and drain plug.

쐌 Replace the gasket with a new one. 쐌 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:

1.1 — 1.3  (1.2 — 1.4 US qt, 1.0 — 1.1 lmp qt)

Fluid packing:

Three Bond 1105

Tightening torque:

T-type:

49.0 N·m (5.0 kgf-m, 36.2 ft-lb)

VA-type:

34 N·m (3.5 kgf-m, 25.3 ft-lb)

4) After installing drain plug onto rear differential gear case firmly, fill oil up fully to the mouth of filler plug.

GI0047A

Oil capacity:

0.8  (0.8 US qt, 0.7 lmp qt)

NOTE: Each oil manufacturer has its base oil and additives. Thus, do not mix two or more brands.

PM-27

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Periodic Maintenance Services

FRONT & REAR DIFFERENTIAL OIL

5) Install filler plug onto rear differential gear case firmly.

NOTE: 쐌 Apply fluid packing to filler plug before installation in T-type. 쐌 VA-type uses a new aluminum gasket.

Fluid packing:

Three Bond 1105

Tightening torque:

T-type:

49.0 N·m (5.0 kgf-m, 36.2 ft-lb)

VA-type:

34 N·m (3.5 kgf-m, 25.3 ft-lb)

PM-28

Page 90

BRAKE LINE

Periodic Maintenance Services

19. Brake Line SA07694

A: INSPECTION SA07694A10

1. BRAKE LINE SA07694A1001

1) Check scratches, swelling, corrosion and/or traces of fluid leakage on brake hoses or pipe joints.

2) Check the possibility of adjacent parts interfering with brake pipes/hoses 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: 쐌 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. 쐌 Visually check brake hose (using a mirror where it is difficult to see) for any damage.

GI0048A

B: CHECKING SA07694G27

1. SERVICE BRAKE SA07694G2701

1) Check the free play of brake pedal with a force of less than 10 N (1 kgf, 2 lb).

Brake pedal free play:

1 — 3 mm (0.04 — 0.12 in)

GI0050A

2) If the free play is out of specifications above, adjust the brake pedal as follows:

(1) Be sure engine is off. (No vacuum is applied to brake booster.) (2) There should be play between brake booster clevis and pin at brake pedal installing portion. [Depress brake pedal pad with a force of less than 10 N (1 kgf, 2 lb) to a stroke of 1 to 3 mm (0.04 to 0.12 in).] (3) Depress the surface of brake pad by hand. (4) If there is no free play between clevis pin and clevis, turn brake switch adjusting nut until the clearance between stopper and screw of brake switch becomes 0.3 mm (0.012 in).

GI0049A

GI0051A

PM-29

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Periodic Maintenance Services

BRAKE LINE

3) Check the pedal stroke. While the engine is idling, depress the brake pedal with a 490 N (50 kgf, 110 lb) 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 distance is more than specified, there is a possibility air is in the inside of the hydraulic unit.

Brake pedal reserve distance: A

more than 95 mm (3.74 in)/ 490 N (50 kgf, 110 lb)

GI0053A

5) Check vacuum hose for cracks or other damage.

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 vacuum hose to make sure it is tight and secure.

GI0052A

4) Check to see if air is in the hydraulic brake line by the feel of pedal operation. If air appears to exist in 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.

2. BRAKE SERVO SYSTEM SA07694G2702

1) With the engine off, depress the brake pedal 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.

4) Check valve is built into vacuum hose. Disconnect 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 both check valve and vacuum hose if check valve is faulty. Engine side of vacuum hose is indicated by marking “ENGINE” as shown.

PM-30

Page 92

BRAKE FLUID

Periodic Maintenance Services

20. Brake Fluid SA07162

A: REPLACEMENT SA07162A20

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

2) Remove both front and rear wheels.

3) Draw out the brake fluid from master cylinder with syringe.

4) Refill reservoir tank with recommended brake fluid.

Recommended brake fluid:

FMVSS No. 116, fresh DOT3 or 4 brake fluid

NOTE: 쐌 Avoid mixing different brands of brake fluid to prevent degrading the quality of the fluid. 쐌 Be careful not to allow dirt or dust to get into the reservoir tank.

Bleeding sequence (1) → (2) → (3) → (4)

GI0054A

(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.

NOTE: 쐌 Cover bleeder with waste cloth, when loosening it, to prevent brake fluid from being splashed over surrounding parts. 쐌 During bleeding operation, keep the brake reserve tank filled with brake fluid to eliminate entry of air.

쐌 Brake pedal operation must be very slow. 쐌 For convenience and safety, it is advisable to

have two people working. 쐌 The amount of brake fluid required is approximately 500 m (16.9 US fl oz, 17.6 Imp fl oz) for total brake system.

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

7) Loosen bleeder screw approximately 1/4 turn until a small amount of brake fluid drains into container, and then quickly tighten screw.

8) Repeat steps 6) and 7) above until there are no air bubbles in drained brake fluid and new fluid flows through vinyl tube.

NOTE: Add brake fluid as necessary while performing the air bleed operation, in order to prevent the tank from running short of brake fluid.

9) After completing the bleeding operation, hold brake pedal depressed and tighten screw and install bleeder cap.

Tightening torque:

8N·m (0.8 kgf-m, 5.8 ft-lb)

10) Bleed air from each wheel cylinder by following the previous 5 steps.

11) Depress brake pedal with a force of approximately 294 N (30 kgf, 66 lb) and hold it there for approximately 20 seconds. At this time check pedal to 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 wheels, and drive vehicle for a short distance between 2 to 3 km (1 to 2 miles) to make sure that brakes are operating properly.

GI0055

PM-31

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Periodic Maintenance Services

DISC BRAKE PADS AND DISCS

21. Disc Brake Pads and Discs

SA07695

A: INSPECTION SA07695A10

1. DISC BRAKE PAD AND DISC SA07695A1001

1) Jack up vehicle and support with rigid racks. Then remove wheels.

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

GI0056A

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.

GI0058

Pad thickness including back metal mm (in)

Front Rear Standard 17 (0.67) 14 (0.55) Service limit 7.5 (0.295) 6.5 (0.256) Service limit

(exclusive back metal)

1.5 (0.059) 1.5 (0.059)

GI0057A

3) Check the disc rotor, and correct or replace if it is damaged or worn.

Brake disc thickness mm (in)

Front Rear Standard 24 (0.94) 10 (0.39) Wear limit 22 (0.87) 8.5 (0.335)

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: 0.075 mm (0.0030 in) Rear: 0.075 mm (0.0030 in)

PM-32

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PARKING BRAKE

Periodic Maintenance Services

22. Parking Brake SA07813

A: INSPECTION SA07813A10

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

1) Inspect brake shoes for damage or deformation and check 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)

B: ADJUSTMENT SA07813A01

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.

GI0063A

3) Turn back (downward) adjuster 3 to 4 notches.

4) Install cover (rubber) at original position correctly.

GI0061A

2) Check brake drum for wear, dents or other damage. If the inside surface of brake drum is streaked, correct 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 inside diameter

Standard value: 170 mm (6.69 in) Wear limit: 171 mm (6.73 in)

GI0062A

3) If the deformation or wear of back plate, shoe, etc. is noticeable, replace them.

4) When the shoe return spring tension is excessively weakened, replace it, taking care to identify upper and lower springs.

PM-33

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Periodic Maintenance Services

SUSPENSION

23. Suspension SA07697

A: INSPECTION SA07697A10

1. SUSPENSION BALL JOINT SA07697A1001

1) Jack up vehicle until front wheels are off ground.

2) Next, grasp 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 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 relative movement is observed in the immediately preceding two steps, remove and inspect ball joint. If free play exceeds standard, replace ball joint. <Ref. to FS-16, Front Ball Joint.>

GI0066A

2. TRANSVERSE LINK’S REAR BUSHING

SA07697A1002

Check oil leaks at around liquid-filled bushing. If oil leaks, replace bushing.

GI0064A

GI0065A

5) Damage of dust seal Visually inspect ball joint dust seal. If it is damaged, remove transverse link. <Ref. to FS-14, Front Transverse Link.> And measure free play of ball joint. <Ref. to FS-16, 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-6, Wheel Alignment.>

GI0067A

3. WHEEL ARCH HEIGHT SA07697A1003

1) Unload cargoes and set vehicle in curb weight (empty) condition.

2) Then, check wheel arch height of front and rear suspensions to ensure that they are within specified values.

3) When wheel arch height is out of standard, visually inspect following components and replace deformed parts. 쐌 Suspension components [Front strut assembly and rear shock absorber assembly] 쐌 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 standard. <Ref. to FS-6, Wheel Alignment.> <Ref. to RS-8, Wheel Alignment.>

PM-34

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SUSPENSION

Periodic Maintenance Services

4. WHEEL ALIGNMENT OF FRONT SUSPENSION

1) Check alignment of front suspension to ensure that following items conform to standard values.

쐌 Toe-in 쐌 Camber angle 쐌 Caster angle 쐌 Steering angle

<Ref. to FS-6, Wheel Alignment.>

2) When caster angle does not conform to standard value, visually inspect following components and replace deformed parts. 쐌 Suspension components [Strut assembly, crossmember, transverse link, etc.] 쐌 Body parts to which suspensions are installed.

3) When toe-in and camber are out of standard value, adjust them so that they conform to respective service standard.

4) When right-and-left turning angles of tire are out of standard, adjust to standard value.

SA07697A1004

5. WHEEL ALIGNMENT OF REAR SUSPENSION

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

쐌 Toe-in 쐌 Camber angle 쐌 Thrust angle

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

2) When camber angle does not conform to standard value, visually inspect parts listed below. If deformation is observed, replace damaged parts. 쐌 Suspension components [Shock absorber, link F, link R, link UPR, arm R, sub frame, etc.] 쐌 Body parts to which suspensions are installed.

3) When toe-in and thrust angle are out of standard value, adjust them so that they conform to respective service standard.

SA07697A1005

8. DAMAGE TO SUSPENSION PARTS

SA07697A1008

1) Check the following parts and the fastening portion of the vehicle body for deformation or excessive rusting which impairs the suspension. If necessary, replace damaged parts with new ones. If minor rust formation, pitting, etc. are noted, remove rust and apply remedial anti-corrosion measures.

쐌 Front suspension

쐌 Transverse link 쐌 Crossmember 쐌 Strut

쐌 Rear suspension

쐌 Sub frame 쐌 Link F 쐌 Link R 쐌 Link UPR 쐌 Arm R 쐌 Shock absorber

쐌 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 60 months. Take rust prevention measure as required.

6. OIL LEAKAGE OF STRUT AND SHOCK ABSORBER

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

SA07697A1006

7. TIGHTNESS OF BOLTS AND NUTS

SA07697A1007

Check bolts and nuts shown in the figure for looseness. Retighten bolts and nuts to specified torque. If self-lock nuts and bolts are removed, replace them with new ones. Front suspension: <Ref. to FS-2, General Description.> Rear suspension: <Ref. to RS-2, General Description.>

PM-35

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Periodic Maintenance Services

WHEEL BEARING

24. Wheel Bearing SA07698

A: INSPECTION SA07698A10

1. FRONT WHEEL BEARING SA07698A1001

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 wheel nuts and remove front wheel.

4) If bearing free play exists in step 2) above, attach a dial gauge to hub assembly and measure axial displacement in axial direction.

Service limit:

Straight-ahead position within 0.05 mm (0.0020 in)

5) Remove bolts and self-locking nuts, and extract transverse link from front crossmember.

6) While lightly hammering spring pin which secures S.F.J. to transmission spindle, remove it.

7) Extract S.F.J. from transmission spindle. <Ref. to DS-16, Front Axle.>

8) While supporting front drive shaft horizontally with one hand, turn hub with the other to check for noise or binding. If hub is noisy or binds, disassemble front axle and check condition of oil seals, bearing, etc.

6) While supporting rear drive shaft horizontally with one hand, turn hub assembly with the other to check for noise or binding. If hub assembly is noisy or binds, disassemble rear axle and check condition of oil seals, bearings, etc.

GI0069A

B1M0494A

2. REAR WHEEL BEARING SA07698A1002

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 wheel nuts and remove rear wheel.

4) If bearing free play exists in step 2) above, attach a dial gauge to hub assembly and measure axial displacement in axial direction.

Service limit:

Straight-ahead position within 0.05 mm (0.0020 in)

5) Remove the DOJ of rear drive shaft from rear differential. <Ref. to DS-31, Rear Drive Shaft.>

PM-36

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AXLE BOOTS & JOINTS

25. Axle Boots & Joints SA07699

A: INSPECTION SA07699A10

1. FRONT AND REAR AXLE BOOTS SA07699A1001

Inspect front axle boots (A) and rear axle boots (B) for deformation, damage or failure. If faulty, replace them with new ones. <Ref. to DS-26, Front Drive Shaft.> <Ref. to DS-31, Rear Drive Shaft.>

GI0070A

Periodic Maintenance Services

GI0071A

2. PROPELLER SHAFT SA07699A1002

Inspect propeller shaft for damage or failure. If faulty, replace with new one. <Ref. to DS-13, Propeller Shaft.>

PM-37

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Periodic Maintenance Services

STEERING SYSTEM (POWER STEERING)

26. Steering System (Power Steering) SA07701

A: INSPECTION SA07701A10

1. STEERING WHEEL SA07701A1001

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

2) Lightly turn 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)

2. STEERING SHAFT JOINT SA07701A1002

1) When steering wheel free play is excessive, disconnect universal joint of steering shaft and check it for any play and yawing torque (at the point of the crossing direction). Also inspect for any damage 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 ft-lb)

GI0075A

3. GEARBOX SA07701A1003

GI0074A

Move steering wheel vertically toward the shaft to ascertain if there is play in the direction.

Maximum permissible play:

0.5 mm (0.020 in)

3) Drive vehicle and check the following items during operation.

(1) Steering force ..............

The effort required for steering should be smooth and even at all points, and should not vary.

(2) Pull to one side ............

Steering wheel should not be pulled to either side while driving on a level surface.

(3) Wheel runout ................

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 mm (0.020 in)

1) With wheels placed on a level surface, turn steering wheel 90° in both the left and right directions. While wheel is being rotated, reach under vehicle and check for looseness in gearbox.

Tightening torque:

59 N·m (6.0 kgf-m, 43.4 ft-lb)

GI0076A

2) Check boot for damage, cracks or deterioration.

PM-38

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STEERING SYSTEM (POWER STEERING)

Periodic Maintenance Services

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. If any unusual noise is noticed, adjust 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°. (3) Apply liquid packing to at least 1/3 of entire perimeter of adjusting screw thread.

GI0077A

Tightening torque:

83 N·m (8.5 kgf-m, 61.5 ft-lb)

5. POWER STEERING FLUID LEVEL

SA07701A1005

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

1) Place 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). If the level is below “MIN” (B), add fluid to bring it up to “MAX” (C).

(4) Install lock nut. While holding adjusting screw with a wrench, tighten lock nut using ST.

ST 926230000 SPANNER

Tightening torque (Lock nut):

39 N·m (4.0 kgf-m, 29 ft-lb)

Hold the adjusting screw with a wrench to prevent it from turning while tightening the lock nut.

4. TIE-ROD SA07701A1004

1) Check tie-rod and tie-rod ends for bends, scratches or other damage.

GI0105A

2) Check connections of knuckle ball joints for play, inspect for damage on dust seals, and check free play of ball studs. If castle nut is loose, retighten 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, 19.9 ft-lb)

3) Check lock nut on the tie-rod end for tightness. If it is loose, retighten it to the specified torque.

GI0014A

NOTE: If fluid level is at MAX level or above, drain fluid to keep the level in the specified range of indicator by using a syringe or the like.

Recommended fluid:

Dexron IIE or III

Fluid capacity:

0.7  (0.7 US qt, 0.6 Imp qt)

6. POWER STEERING FLUID FOR LEAKS

SA07701A1006

Inspect the underside of oil pump and gearbox for power steering system, hoses, piping and their couplings for fluid leaks. If fluid leaks are found, correct them by retightening their fitting bolts (or nuts) and/or replacing their parts.

NOTE: 쐌 Wipe the leakage fluid off after correcting fluid leaks, or a wrong diagnosis is taken later. 쐌 Also pay attention to clearances between hoses (or pipings) and other parts when inspecting fluid leaks.

PM-39