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Subaru Legacy / Outback / B4 / Wagon / Lancaster 1998-2003 года выпуска: Устройство, техническое обслуживание и ремонт

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5. 2003 Legacy
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• Page 1
  2003 Model Year PDF Service Manual GENERAL INFORMATION SECTION (Pub.No.G2300GE1) ENGINE SECTION 1 (Pub.No.G2300GE2) ENGINE SECTION 2 (Pub.No.G2300GE3) ENGINE SECTION 3 (Pub.No.G2300GE4) TRANSMISSION SECTION (Pub.No.G2300GE5) CHASSIS SECTION (Pub.No.G2300GE6) BODY SECTION (Pub.No.G2300GE7) WIRING SYSTEM SECTION (Pub.No.G2300GE8)
• Page 2
  2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX GENERAL INFORMATION SECTION FOREWORD HOW TO USE THIS MANUALS SPECIFICATIONS PRECAUTION This service manual has been prepared to provide SUBARU service personnel NOTE with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
• Page 3
  FOREWORD Page Foreword …………………2…
• Page 4
  1. Foreword A: FOREWORD These manuals are used when performing mainte- nance, repair, or diagnosis of the Subaru Legacy. Applied model: BE***** and BH***** from 2003MY. The manuals contain the latest information at the time of publication. Changes in specifications, methods, etc.

• Page 5: How To Use This Manuals

  HOW TO USE THIS MANUALS Page How to Use This Manuals …………….2…

• Page 6
  HOW TO USE THIS MANUALS HOW TO USE THIS MANUALS 1. How to Use This Manuals A: HOW TO USE THIS MANUALS 1. STRUCTURE Each section consists of SCT that are broken down into SC that are divided into sections for each com- ponent.
• Page 7
  HOW TO USE THIS MANUALS HOW TO USE THIS MANUALS 3. COMPONENTS Illustrations are listed for each component. The information necessary for repair work (tightening torque, grease up points, etc.) is described on these illustrations. Information is described using symbol. To order the parts, refer to parts catalogue.
• Page 8
  HOW TO USE THIS MANUALS HOW TO USE THIS MANUALS 4. SPECIFICATIONS If necessary, specifications are also included. 5. INSPECTION Inspections are included to be carried out before and after maintenance. 6. MAINTENANCE • Maintenance instructions for serviceable parts describes work area and detailed steps with illustration. It also describes the use of special tool, tightening torque, cautions for each procedure.
• Page 9
  HOW TO USE THIS MANUALS HOW TO USE THIS MANUALS 7. DIAGNOSIS Tables showing a step-by-step process make it easy to conduct diagnosis. 8. SI UNITS Measurements in these manuals are according to the SI units. Metric and yard/pound measurements are also included.
• Page 10
  HOW TO USE THIS MANUALS HOW TO USE THIS MANUALS MEMO: HU-6…

• Page 11: Specifications

  SPECIFICATIONS Page Legacy………………….2 OUTBACK………………..10…

• Page 12
  LEGACY SPECIFICATIONS 1. Legacy A: DIMENSIONS Model Sedan Wagon 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)
• Page 13
  LEGACY SPECIFICATIONS C: ELECTRICAL Model Sedan/Wagon 2.0 L Non-TURBO 2.5 L Non-TURBO Ignition timing at idling speed BTDC/rpm 10°±10° Spark plug Type and manufacturer Without OBD NGK: BKR6E (without catalyst) CHAMPION: RC10YC4 (with catalyst) Alternate NGK: BKR5E-11 (with catalyst) With OBD CHAMPION: RC10YC4 Alternate NGK: BKR6E-11…
• Page 14
  LEGACY SPECIFICATIONS Model Sedan 2.0 L TURBO Transmission type 4AT-SS Clutch type DSPD Gear ratio 3.166 2.785 1.882 1.545 1.296 1.000 0.972 0.694 0.738 — Reverse 3.333 2.272 Reduction gear 1st reduction Type of gear — Helical (Front drive) Gear ratio —…
• Page 15
  LEGACY SPECIFICATIONS I: CAPACITY Model Sedan/Wagon 2.0 L 2.5 L 2 (US gal, Imp gal) Fuel tank 64 (16.9, 14.1) 2 (US qt, Imp qt) Engine oil (When replacing) Approx. 4.0 (4.2, 3.5), 4.5 (4.8, 4.0)* 2 (US qt, Imp qt) Transmission gear oil 3.5 (3.7, 3.1) —…
• Page 16
  LEGACY SPECIFICATIONS Option code *1 Model 2.5 L Curb weight (C.W.) Front kg (lb) (1,775) (1,830) (1,750) (1,810) (1,730) (1,785) Rear kg (lb) (1,335) (1,345) (1,345) (1,355) (1,345) (1,355) Total kg (lb) 1,410 1,440 1,405 1,435 1,395 1,425 (3,110) (3,175) (3,095) (3,165) (3,075)
• Page 17
  LEGACY SPECIFICATIONS Option code *1 Model 2.0 L 2.5 L GL (GX) GX (RX) Unladen mass (U.M.) Front kg (lb) 780 (1,720) 775 (1,710) 775 (1,710) 785 (1,730) 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)
• Page 18
  LEGACY SPECIFICATIONS 2. WAGON • LHD Vehicle Option code *1 KO, KS Model 2.0 L Curb weight (C.W.) Front kg (lb) (1,720) (1,765) (1,710) (1,740) (1,740) (1,775) Rear kg (lb) (1,435) (1,435) (1,445) (1,445) (1,445) (1,445) Total kg (lb) 1,430 1,450 1,430 1,445…
• Page 19
  LEGACY SPECIFICATIONS • RHD Vehicle Option code *1 Model 2.0 L 2.5 L Curb weight (C.W.) Front kg (lb) (1,710) (1,740) (1,750) (1,785) (1,740) (1,775) Rear kg (lb) (1,445) (1,445) (1,435) (1,435) (1,445) (1,445) Total kg (lb) 1,430 1,445 1,445 1,460 1,445 1,460…
• Page 20
  OUTBACK SPECIFICATIONS 2. OUTBACK A: DIMENSIONS Model OUTBACK 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…
• Page 21
  OUTBACK SPECIFICATIONS C: ELECTRICAL Model OUTBACK 2.5 L 3.0 L Ignition timing at idling BTDC/rpm 10°±10° 10°±8° speed Spark plug Type and manufacturer CHAMPION: RC10YC4 NGK: PLFR6A-11 Alternate NGK: BKR6E-11 NGK: BKR5E-11 Generator 12V — 90A 12V — 100A Battery Type and capacity (5HR) For Europe and MT: 12V —…
• Page 22
  OUTBACK SPECIFICATIONS E: STEERING Model OUTBACK Type Rack and Pinion Turns, lock to lock Minimum turning circle Curb to curb 11.2±1.0 (36.7±3.3) m (ft) Wall to wall 12.0±1.0 (39.4±3.3) F: SUSPENSION Model OUTBACK Front Macpherson strut type, Independent, Coil spring Rear Multi-link type, Independent, Coil spring G: BRAKE…
• Page 23
  OUTBACK SPECIFICATIONS J: WEIGHT 1. OUTBACK • LHD vehicle Option code *1 Model 2.5 L Curb weight (C.W.) Front kg (lb) 810 (1,785) 825 (1,820) 815 (1,795) 830 (1,830) Rear kg (lb) 670 (1,475) 670 (1,475) 670 (1,475) 670 (1,475) Total kg (lb) 1,480 (3,265)
• Page 24
  OUTBACK SPECIFICATIONS • RHD vehicle Option code *1 Model 2.5 L 3.0 L 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 Front…
• Page 25
  PRECAUTION Page Precaution ………………..2…
• Page 26
  PRECAUTION PRECAUTION 1. Precaution 7. AIRBAG MODULE Adhere to the following when handing and storing A: PRECAUTION the airbag module to prevent bodily injury from un- Please clearly understand and adhere to the follow- expected deployment: ing general precautions. They must be strictly fol- •…
• Page 27
  NOTE Page Note………………….2…
• Page 28
  ECM from rush current. 4. SERVICE PARTS 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.
• Page 29
  NOTE NOTE • Pantograph jack With side sill cover NT-00049 Without side sill cover NT-00050 • Lift NT-00046 NT-3…
• Page 30
  NOTE NOTE • Safety stand NT-00047 Front Front crossmember Rear differential gear Rear NT-00036 NT-4…
• Page 31
  NOTE NOTE 6. TIE DOWNS Tie-downs are used when transporting vehicles and when using the chassis dynamo. • Tie-down points Attach tie-downs only to the specified points on the vehicle. Hook for towing (Except OUTBACK) Hook for towing (OUTBACK) Hook for tie-down Hook for towing Hook for tie-down and tie-down…
• Page 32
  NOTE NOTE • Chain direction at tie-down condition 7. TOWING Avoid towing vehicles except when the vehicle can- not be driven. For vehicles with AWD, AT or VTD, use a loader instead of towing. When towing other vehicles, to prevent excessive weight from damag- ing the hook or vehicle: •…
• Page 33
  For information about training, contact a dealer or Using general scan tools will greatly improve effi- agent. ciency 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 34
  NOTE NOTE MEMO: NT-8…
• Page 35
  IDENTIFICATION Page Identification ………………..2…
• Page 36
  IDENTIFICATION IDENTIFICATION 1. Identification A: IDENTIFICATION 1. IDENTIFICATION NUMBER AND LABEL LOCATIONS The VIN (Vehicle Identification Numbers) is used to classify the vehicle. Positioning of the plate label for identification Emission control label Vehicle identification number • ID plate (Europe model) •…
• Page 37
  IDENTIFICATION IDENTIFICATION Model number plate J F 1 B E 5 L J 3 3 G 0 E 9 E L 7 J E J 2 5 1 N J E A A T Y 7 5 4 V F B A A ID-00049 2.
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  IDENTIFICATION IDENTIFICATION • GCC countries (Saudi Arabia, etc.) ]JF1BE54MX3G002001[ The starting and ending brackets ( ][ ) are stop marks. Digits Code Meaning Details 1 to 3 Manufacturer body area JF1: Passenger car, FHI made Car line Legacy/OUTBACK series Body type E: Sedan H: Station Wagon/OUTBACK Displacement…
• Page 39
  IDENTIFICATION IDENTIFICATION The engine and transmission type are as follows: • Engine EJ251NJEAA Digits Code Meaning Details 1 and 2 Engine type EJ: 4 cylinders EZ: 6 cylinders 3 and 4 Displacement 20: 2.0 L 25: 2.5 L 30: 3.0 L Fuel feed system 1: D-MPI SOHC-A 6: MPI TWIN TURBO…
• Page 40
  IDENTIFICATION IDENTIFICATION • Rear differential 2 • Option code ECPS Code Reduction Digits Code Meaning Details gear ratio 1 to 2 Destination EC: EC 3.900 KO: KO K4: K4 4.111 KS: KS 4.444 EK: EK 4.444 No (Strengthened type) KA: KA 3.700 K1: K1 4.444…
• Page 41
  RECOMMENDED MATERIALS Page Recommended Materials …………….2…

• Page 42: Gasoline Engines

  RECOMMENDED MATERIALS RECOMMENDED MATERIALS 1. Recommended Materials • Unleaded gasoline Use unleaded gasoline and not leaded gasoline on A: RECOMMENDED MATERIALS vehicles with catalytic converter installed to reduce air pollution. Using leaded gasoline will damage the 1. GENERAL catalytic converter. To insure the best performance, always use the specified oil, gasoline, adhesive, sealant, etc.

• Page 43
  RECOMMENDED MATERIALS RECOMMENDED MATERIALS SAE viscosity No. and applicable temperature Engine oil (˚C) –30 –20 –10 –4 (˚F) –22 10W-30 or 10W-40 5W-30 Recommend RM-00003 Manual transmission oil and rear differential gear oil –30 –20 –10 (˚C) –22 –4 (˚F) 75W-90 RM-00004 RM-3…
• Page 44
  Water for dilution Distilled water — Tap water 6. REFRIGERANT 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. Air conditioner Recommended Item number…
• Page 45
  7. GREASE Use the grease and supplementary lubricants shown in the table below. Grease Application point Recommended Item number Alternative Supplementary lubricants • O2 sensor SUBARU CRC 004301003 — • Bolts, etc. Grease MT main shaft FX clutch grease 000040901 —…
• Page 46
  RECOMMENDED MATERIALS RECOMMENDED MATERIALS MEMO: RM-6…
• Page 47
  PRE-DELIVERY INSPECTION Page Pre-delivery Inspection…………….2…
• Page 48
  PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 1. Pre-delivery Inspection A: GENERAL The purposes of the pre-delivery inspection (PDI) are as follows. • Remove the additional parts used for ensuring the vehicle quality during transportation and restore the vehicle to its normal state. •…
• Page 49
  PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION B: PDI PROCEDURE 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 film, visually check the vehicle body for damage and dents.
• Page 50
  PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION Checks with the Engine Running Step Check point 1. Test mode connector (1) Disconnect the test mode connector. 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.
• Page 51
  PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 1. APPEARANCE CHECK 3.0 L model 1) When vehicle is covered with protective film, in- spect visually for damage or dents to vehicle body surface. 2) When protective film is removed, check the body paints for small areas of damage or stains and re- pair as necessary.
• Page 52
  PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION • Vehicles with power door locks: • Using the key, open the trunk lid several times to check for normal operation. Sit in the driver seat, close the driver’s door com- • Open and close the trunk lid several times for pletely, and place the lock lever to the lock position.
• Page 53
  PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 9. OPERATION CHECK OF FUEL LID 11. OPERATION CHECK OF HOOD LOCK OPENER LOCK RELEASE LEVER RELEASE SYSTEM Operate the fuel lid opener and verify that the fuel By operating front hood release knob, confirm front lid opens normally.
• Page 54
  PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 13. BRAKE FLUID 16. AT FRONT DIFFERENTIAL OIL Check the brake fluid amount. If the amount is in- Check the AT front differential oil amount. If the sufficient, carry out a brake line test to identify amount is insufficient, check that no leaks are brake fluid leaks and check the brake operation.
• Page 55
  PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 20. FRONT HOOD LATCH CHECK 24. WHEEL ALIGNMENT Retract the front hood stay and close the hood. Check the wheel alignments. <Ref. to FS-6, Wheel Check that the front hood is securely latched. Alignment.> and <Ref. to RS-8, Wheel Align- ment.>…
• Page 56
  PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 26. STARTING CONDITION Front Injection position: Start the engine and check that the engine starts A: 350 mm (13.78 in) smoothly. If any battery voltage problems are B: 150 mm (5.91 in) found, recharge or replace the battery. If any ab- C: 300 mm (11.81 in) normal noises are observed, immediately stop the D: 600 mm (23.62 in)
• Page 57
  PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 38. AT SHIFT CONTROL 42. ATF LEVEL Set the AT select lever to each gear position while Check that the ATF level is normal. If insufficient, checking that the demanded gear position is cor- check that no leaks are found. Then add the neces- rectly attained.
• Page 58
  PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 45. WATER LEAK TEST • It is desirable not to make corrections to the body paint unless absolutely needed. However, if any Spray the vehicle with water and check that no wa- corrections are required to remove scratches or ter enters the passenger compartment.

• Page 59: Table Of Contents

  PERIODIC MAINTENANCE SERVICES Page General Description ………………2 Schedule …………………3 Engine Oil………………..7 Engine Oil Filter……………….9 Spark Plugs………………..10 Drive Belt(s) ………………..12 Camshaft Drive Belt ………………15 Fuel Line ………………..18 Fuel Filter ………………..19 Air Cleaner Element ………………20 Cooling System ………………21 Coolant………………….22 Clutch System ……………….24 Hill-holder System ………………25 Idle Mixture………………..26 Transmission Oil ………………27…

• Page 60: General Description

  GENERAL DESCRIPTION PERIODIC MAINTENANCE SERVICES 1. General Description A: GENERAL Be sure to perform periodic maintenance in order to maintain vehicle performance and find problems before they become serious. PM-2…

• Page 61
  SCHEDULE PERIODIC MAINTENANCE SERVICES 2. Schedule A: MAINTENANCE SCHEDULE 1 1. EUROPE For periodic maintenance of over 120,000 km (75,000 miles) or 96 months, carry out inspection by referring to the following table. For a maintenance period gone beyond these tables, apply them repeatedly as a set of 120,000 km (75,000 miles) or 96 months.
• Page 62
  SCHEDULE PERIODIC MAINTENANCE SERVICES 2. EXCEPT EUROPE 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.
• Page 63
  SCHEDULE PERIODIC MAINTENANCE SERVICES B: MAINTENANCE SCHEDULE 2 1. EUROPE Item Every Repeat short Repeat Extremely Salt or other High humid- Repeat tow- distance drive rough/muddy cold weather corrosive ity or moun- ing trailer road drive area used or tain area coastal area Engine oil Replace…
• Page 64
  SCHEDULE PERIODIC MAINTENANCE SERVICES 2. EXCEPT EUROPE Item Every Repeat short Repeat Extremely Salt or other High humid- Repeat tow- distance drive rough/muddy cold weather corrosive ity or moun- ing trailer road drive area used or tain area coastal area Engine oil Replace Replace…

• Page 65: Engine Oil

  ENGINE OIL PERIODIC MAINTENANCE SERVICES 3. Engine Oil 3.0 L model A: REPLACEMENT ( B ) ( A ) NOTE: ( C ) Replace engine oil and engine oil filter at the same ( E ) time. ( D ) 1) Drain engine oil by loosening engine oil drain plug.

• Page 66
  ( D ) gine; however, use oil having the API classification, and SAE viscosity No. designated by SUBARU. • If vehicle is used in desert areas with very high temperatures or for other heavy duty applications,…

• Page 67: Engine Oil Filter

  ENGINE OIL FILTER PERIODIC MAINTENANCE SERVICES 4. Engine Oil Filter 2) Remove under cover. 3) Remove oil filter with ST. A: REPLACEMENT ST 498547000 OIL FILTER WRENCH 1. EXCEPT 3.0 L MODEL 1) Remove oil filter with ST. ST 498547000 OIL FILTER WRENCH ( B ) PM-00109…

• Page 68: Spark Plugs

  SPARK PLUGS PERIODIC MAINTENANCE SERVICES 5. Spark Plugs 2. 2.0 L TURBO AND 3.0 L MODEL 1) Disconnect battery cables and then remove bat- A: REPLACEMENT tery and battery carrier. 1. 2.0 L NON-TURBO AND 2.5 L MODEL 2) Remove washer tank and put it aside. 3) Remove air cleaner lower case.

• Page 69
  SPARK PLUGS PERIODIC MAINTENANCE SERVICES 9) Tighten ignition coil. Tightening torque: 16 N·m (1.6 kgf-m, 11.7 ft-lb) NOTE: • Be sure to place the gasket between the cylinder head and spark plug. • If torque wrench is not available, tighten spark plug until gasket contacts cylinder head: then tight- en further 1/4 to 1/2 turn.
• Page 70
  DRIVE BELT(S) PERIODIC MAINTENANCE SERVICES 6. Drive Belt(s) 2. 3.0 L MODEL 1) Replace belts, if cracks, fraying or wear is found. A: INSPECTION 2) Check that the V-belt automatic tensioner indica- 1. EXCEPT 3.0 L MODEL tor is within the range (D). 1) Replace belts, if cracks, fraying or wear is found.
• Page 71
  DRIVE BELT(S) PERIODIC MAINTENANCE SERVICES B: REPLACEMENT 11) Install a new belt, and tighten the slider bolt so as to obtain the specified belt tension. 1. EXCEPT 3.0 L MODEL 12) Tighten the lock bolt (A). 13) Tighten the slider bolt (B). 1) Remove V-belt cover.
• Page 72
  DRIVE BELT(S) PERIODIC MAINTENANCE SERVICES 3) Install in the reverse order of removal. ( F ) ( A ) ( D ) ( E ) ( B ) ( C ) PM-00119 (A) Power steering oil pump (B) Belt tension adjuster (C) Crankshaft pulley (D) A/C compressor (E) Belt idler…
• Page 73
  CAMSHAFT DRIVE BELT PERIODIC MAINTENANCE SERVICES 7. Camshaft Drive Belt 9) Remove timing belt guide. (MT vehicle only) A: REPLACEMENT 1. NON-TURBO MODEL 1) Remove radiator fan. <Ref. to CO(H4SO)-28, Radiator Main Fan and Fan Motor.> and <Ref. to CO(H4SO)-30, Radiator Sub Fan and Fan Motor.>…
• Page 74
  CAMSHAFT DRIVE BELT PERIODIC MAINTENANCE SERVICES 13) Remove timing belt. 10) Remove timing belt guide. (MT vehicle only) 14) Remove automatic belt tension adjuster as- sembly. PM-00008 11) Turn the crankshaft and align the alignment PM-00123 marks on crankshaft, and left and right camshaft sprockets with notches of belt cover and cylinder 15) Install in the reverse order of removal.
• Page 75
  CAMSHAFT DRIVE BELT PERIODIC MAINTENANCE SERVICES 13) Remove the timing belt. 2. TURBO MODEL 14) Remove the automatic belt tension adjuster as- 1) Remove the left and right timing belt covers. sembly. 2) While cranking the engine at least four rotations, check the timing belt back surface for cracks or damage.

• Page 76: Fuel Line

  FUEL LINE PERIODIC MAINTENANCE SERVICES 8. Fuel Line A: INSPECTION 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. •…

• Page 77: Fuel Filter

  FUEL FILTER PERIODIC MAINTENANCE SERVICES 9. Fuel Filter A: REPLACEMENT Refer to Fuel section for replacing fuel filter. • 2.0 L non-TURBO and 2.5 L with OBD models <Ref. to FU(H4SO)-67, Fuel Filter.> • 2.0 L non-TURBO and 2.5 L without OBD models <Ref.

• Page 78: Air Cleaner Element

  AIR CLEANER ELEMENT PERIODIC MAINTENANCE SERVICES 10.Air Cleaner Element 2. 2.0 L TURBO AND 3.0 L MODEL 1) Loosen clamp (A), and separate air cleaner up- A: REPLACEMENT per cover and air intake boot. (3.0 L model) 1. 2.0 L NON-TURBO AND 2.5 L MODEL 2) Remove the clip (B) above the air cleaner upper cover.

• Page 79: Cooling System

  COOLING SYSTEM PERIODIC MAINTENANCE SERVICES 11.Cooling System 2) Check the radiator cap valve open pressure us- ing radiator cap tester. A: INSPECTION NOTE: 1) Check radiator for leakage, filling it with coolant Rust or dirt on cap may prevent valve from func- and attach radiator cap tester (A) to the filler neck.

• Page 80
  Approx. 7.9 2 (8.4 US qt, 7.0 Imp qt) NOTE: The SUBARU Genuine Coolant containing anti- freeze and anti-rust agents is especially made for SUBARU engine, which has an aluminum crank- case. Always use SUBARU Genuine Coolant, since other coolant may cause corrosion. 9) Securely install radiator cap.
• Page 81
  The concentration and safe operating temperature tion in the above diagram and replace the of the SUBARU coolant is shown in the diagram. necessary amount of coolant with an undiluted so- Measuring the temperature and specific gravity of lution of SUBARU genuine coolant (concentration the coolant will provide this information.

• Page 82: Clutch System

  CLUTCH SYSTEM PERIODIC MAINTENANCE SERVICES 13.Clutch System 5) Check the fluid level using the scale on the out- side of the clutch master cylinder tank (A). If the lev- A: INSPECTION AND ADJUSTMENT el is below “MIN” (B), add clutch fluid to bring it up to “MAX”…

• Page 83: Hill-Holder System

  HILL-HOLDER SYSTEM PERIODIC MAINTENANCE SERVICES 14.Hill-holder System A: INSPECTION AND ADJUSTMENT 1) Confirm stopping and starting performance by activating hill-holder on an uphill road of 3° or high- er inclination. (1) When vehicle does not stop; Tighten adjusting nut of PHV cable. (2) When vehicle does not start properly;…

• Page 84: Idle Mixture

  IDLE MIXTURE PERIODIC MAINTENANCE SERVICES 15.Idle Mixture A: INSPECTION AND ADJUSTMENT 1. IDLE MIXTURE Before measuring the idle mixture, make sure that the ignition timing and the engine idle speed are within specifications. 1) Set the gear position at “Neutral” for MT, or “N” or “P”…

• Page 85: Transmission Oil

  TRANSMISSION OIL PERIODIC MAINTENANCE SERVICES 16.Transmission Oil A: REPLACEMENT 1. MANUAL TRANSMISSION 1) Drain gear oil by removing drain plug after allow- ing the engine to cool for 3 to 4 hours. NOTE: • Before starting work, cool off the engine well. •…

• Page 86
  PERIODIC MAINTENANCE SERVICES 17.ATF 4) Fluid temperature rising speed • By idling the engine A: INSPECTION Time for temperature rise to 70°C (158°F) with at- 1) Raise ATF temperature to 70 to 80°C (158 to mospheric temperature of 0°C (32°F): More than 176°F) by driving for approx.
• Page 87
  PERIODIC MAINTENANCE SERVICES B: REPLACEMENT 1. AUTOMATIC TRANSMISSION FLUID 1) Drain ATF (Automatic Transmission Fluid) by re- moving drain plug after allowing the engine to cool for 3 to 4 hours. NOTE: Before starting work, cool off the engine well. PM-00032 (A) Front differential drain plug (B) ATF drain plug…
• Page 88
  FRONT & REAR DIFFERENTIAL OIL PERIODIC MAINTENANCE SERVICES 18.Front & Rear Differential Oil 2) Reinstall drain plug after draining differential gear oil and tighten it to the specified torque. A: REPLACEMENT Tightening torque: 1. FRONT DIFFERENTIAL (MANUAL 44 N·m (4.5 kgf-m, 32.5 ft-lb) TRANSMISSION) NOTE: •…
• Page 89
  FRONT & REAR DIFFERENTIAL OIL PERIODIC MAINTENANCE SERVICES 3. REAR DIFFERENTIAL 4) After installing drain plug onto rear differential gear case firmly, fill oil up fully to the mouth of filler • VA type plug. 1) Drain oil by removing drain plug. 2) Remove filler plug for quicker draining.
• Page 90
  BRAKE LINE PERIODIC MAINTENANCE SERVICES 19.Brake Line B: CHECKING A: INSPECTION 1. SERVICE BRAKE 1) Check the free play of brake pedal with a force of 1. BRAKE LINE less than 10 N (1 kgf, 2 lb). 1) Check scratches, swelling, corrosion and/or Brake pedal free play: traces of fluid leakage on brake hoses or pipe 1 —…
• Page 91
  BRAKE LINE PERIODIC MAINTENANCE SERVICES (4) If there is no free play between clevis pin 4) Check to see if air is in the hydraulic brake line and clevis, turn brake switch adjusting nut until by the feel of pedal operation. If air appears to exist the clearance between stopper and screw of in the line, bleed it from the system.

• Page 92: Brake Fluid

  BRAKE FLUID PERIODIC MAINTENANCE SERVICES 20.Brake Fluid NOTE: • Cover bleeder with waste cloth, when loosening A: REPLACEMENT it, to prevent brake fluid from being splashed over 1) Either jack up vehicle and place a safety stand surrounding parts. under it, or lift up vehicle. •…

• Page 93: Disc Brake Pads And Discs

  DISC BRAKE PADS AND DISCS PERIODIC MAINTENANCE SERVICES 21.Disc Brake Pads and Discs • Turbo model Brake disc thickness mm (in) A: INSPECTION Front Rear 1. DISC BRAKE PAD AND DISC Standard 24 (0.94) 18 (0.71) Wear limit 22 (0.87) 16 (0.63) 1) Jack up vehicle and support with rigid racks.

• Page 94: Parking Brake

  PARKING BRAKE PERIODIC MAINTENANCE SERVICES 22. Parking Brake 3) If the deformation or wear of back plate, shoe, etc. is noticeable, replace them. A: INSPECTION 4) When the shoe return spring tension is exces- Inspect brake linings and drums of both sides of the sively weakened, replace it, taking care to identify rear brake at the same time by removing brake upper and lower springs.

• Page 95
  PARKING BRAKE PERIODIC MAINTENANCE SERVICES B: ADJUSTMENT 1. SHOE CLEARANCE 1) Remove adjusting hole cover from back plate. 2) Turn adjusting screw using a slot-type screw- driver until brake shoe is in close contact with disc rotor. PM-00056 (A) Adjusting screw (B) Cover (rubber) (C) Back plate 3) Turn back (downward) adjusting screw 3 or 4…
• Page 96
  SUSPENSION PERIODIC MAINTENANCE SERVICES 23.Suspension 5) Damage of dust seal Visually inspect ball joint dust seal. If it is damaged, A: INSPECTION remove transverse link. <Ref. to FS-14, Front Transverse Link.> And measure free play of ball 1. SUSPENSION BALL JOINT joint.
• Page 97
  SUSPENSION PERIODIC MAINTENANCE SERVICES 3. WHEEL ARCH HEIGHT 6. OIL LEAKAGE OF STRUT AND SHOCK ABSORBER 1) Unload cargoes and set vehicle in curb weight (empty) condition. Visually inspect front strut and rear shock absorber 2) Then, check wheel arch height of front and rear for oil leakage as instructed.

• Page 98: Wheel Bearing

  WHEEL BEARING PERIODIC MAINTENANCE SERVICES 24.Wheel Bearing 2. REAR WHEEL BEARING 1) Jack up the rear of vehicle. A: INSPECTION 2) While holding rear wheel by hand, swing it in and 1. FRONT WHEEL BEARING out to check bearing free play. 3) Loosen wheel nuts and remove rear wheel.

• Page 99: Axle Boots & Joints

  AXLE BOOTS & JOINTS PERIODIC MAINTENANCE SERVICES 25.Axle Boots & Joints A: INSPECTION 1. FRONT AND REAR AXLE BOOTS 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-28, Front Drive Shaft.>…

• Page 100: Tire Rotation

  TIRE ROTATION PERIODIC MAINTENANCE SERVICES 26.Tire Rotation A: INSPECTION 1) Replace the tire if the tread depth is less than 1.6 mm (0.063 in) or if wear indicators appear across the tire tread. (It is recommended that both right and left tires are replaced as a set.) 2) Adjust the wheel alignment if abnormally uneven tire wear is found.

• Page 101
  STEERING SYSTEM (POWER STEERING) PERIODIC MAINTENANCE SERVICES 27.Steering System (Power 2. STEERING SHAFT JOINT Steering) 1) When steering wheel free play is excessive, dis- connect universal joint of steering shaft and check A: INSPECTION it for any play and yawing torque (at the point of the crossing direction).
• Page 102
  STEERING SYSTEM (POWER STEERING) PERIODIC MAINTENANCE SERVICES (3) Apply liquid packing to at least 1/3 of entire 5. POWER STEERING FLUID LEVEL perimeter of adjusting screw thread. 1) Place vehicle with engine “off” on the flat and level surface. 2) Inspect fluid level by indicator of reservoir tank. If the level is at lower point or below, add fluid to keep the level in the specified range of the indica- tor.
• Page 103
  STEERING SYSTEM (POWER STEERING) PERIODIC MAINTENANCE SERVICES 7. HOSES OF OIL PUMP FOR DAMAGES Check pressure hose and return hose of oil pump for crack, swell or damage. Replace hose with a new one if necessary. NOTE: Prevent hoses from revolving and/or turning when installing hoses.
• Page 104
  STEERING SYSTEM (POWER STEERING) PERIODIC MAINTENANCE SERVICES MEMO: PM-46…