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Subaru JULY BRZ 2013 Service Manual

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2013 JULY BRZ SERVICE MANUAL
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, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance 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 specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.
FUJI HEAVY INDUSTRIES LTD.
QUICK REFERENCE INDEX
FOREWORD
HOW TO USE THIS MANUALS
SPECIFICATIONS
PRECAUTION
NOTE
IDENTIFICATION
RECOMMENDED MATERIALS
PRE-DELIVERY INSPECTION
PERIODIC MAINTENANCE SERVICES
FW
HU
SPC
PC
NT
ID
RM
PI
PM
G4410BE

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  • Page 1 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. IDENTIFICATION This manual includes the procedures...
  • Page 3 FOREWORD Page Foreword ....................2...
  • Page 4 Foreword FOREWORD 1. Foreword A: FOREWORD These manuals are used when performing mainte- nance, repair or diagnosis of Subaru BRZ. Applicable model: 2014 MY ZC***** The manuals contain the latest information at the time of publication. Changes in the specifications, methods, etc.

  • Page 5: How To Use This Manuals

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

  • Page 6: A: How To Use This Manuals

    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. COMPONENT Illustrations are provided 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 parts, refer to parts catalogue.
  • Page 8 How to Use This Manuals HOW TO USE THIS MANUALS 4. DEFINITIONS OF “NOTE”, “CAUTION”, AND “WARNING” • NOTE: The supplementary explanation to facilitate the work is described. • CAUTION: The matter that must not be performed because failure to follow the description causes damage to the vehi- cle or parts, and the one to which attention should be particularly paid during the work are described.

  • Page 9: Maintenance

    How to Use This Manuals HOW TO USE THIS MANUALS 7. MAINTENANCE • Maintenance instructions for serviceable parts describe work area and detailed step with illustration. It also describes the use of special tool, tightening torque, caution for each procedure. •...
  • Page 10 How to Use This Manuals HOW TO USE THIS MANUALS 9. SI UNITS Measurements in these manuals are according to the SI units. Metric and yard/pound measurements are also included. Example: Tightening torque: 45 N·m (4.6 kgf-m, 33.2 ft-lb) List of SI unit Item SI units Conventional unit...

  • Page 11: Explanation Of Terminology

    Right Hand Drive Exhaust Gas Recirculation Read Only Memory Emergency Locking Retractor Revolution Per Minute Electronic Throttle Control Rear Exhaust Subaru Diagnostic Interface Fuse & Joint Box Subaru Intelligent Fusible Link SOHC Single Overhead Camshaft Front Supplemental Restraint System Front Wheel Drive...
  • Page 12 How to Use This Manuals HOW TO USE THIS MANUALS Standard Switch Turbocharger Traction Control System Transmission Control Module Tumble Generator Valve Transmission TPMS Tire Pressure Monitoring System Universal Joint Ultraviolet Vehicle Dynamics Control V.I.N. Vehicle Identification Number ViS-C Viscous Coupling Vacuum Switching Valve Variable Torque Distribution Wiring Harness...

  • Page 13: Specifications

    SPECIFICATIONS Page BRZ ......................2...
  • Page 14 SPECIFICATIONS 1. BRZ A: DIMENSION Model 2.0 L non-turbo Overall length mm (in) 4,235 (166.7) Overall width mm (in) 1,775 (69.9) 1,430 (56.3) Overall height mm (in) 1,425 (56.1) Length mm (in) 1,615 (63.6) Compartment Width mm (in) 1,490 (58.7) Height mm (in) 1,060 (41.7)
  • Page 15 SPECIFICATIONS D: TRANSMISSION 1. MT Model 2.0 L non-turbo Transmission Clutch type DSPD 3.626 2.188 1.541 Gear ratio 1.213 1.000 0.767 Rev. 3.437 Type of gear Hypoid Reduction gear (Rear) Final reduction Gear ratio 4.100 6MT: 6-forward speeds and 1-reverse with synchromesh DSPD: Dry Single Plate Diaphragm 2.
  • Page 16 SPECIFICATIONS G: BRAKE Service brake system Dual circuit hydraulic with vacuum suspended power unit Front Ventilated disc brake Rear Solid disc brake Ventilated disc brake Parking brake Mechanical on rear brakes H: TIRE Rim size 16 × 6.5J, 16 × 6.5JJ 17 ×...
  • Page 17 SPECIFICATIONS J: WEIGHT 2 door Model Premium Transmission OP code 1,253 1,255 1,253 1,255 1,274 1,276 1,274 1,276 Total (lb) (2,762) (2,766) (2,762) (2,766) (2,809) (2,813) (2,808) (2,813) Curb weight Front (C.W.) (lb) (1,523) (1,523) (1,523) (1,523) (1,565) (1,565) (1,565) (1,565) Rear (lb)
  • Page 18 SPECIFICATIONS 2 door Model Limited Transmission OP code 1,259 1,259 1,280 1,280 Total (lb) (2,776) (2,776) (2,822) (2,822) Curb weight Front (C.W.) (lb) (1,528) (1,528) (1,570) (1,570) Rear (lb) (1,248) (1,248) (1,252) (1,252) 1,670 1,670 1,700 1,700 Gross vehicle weight (G.V.W.) (lb) (3,682) (3,682)
  • Page 19 PRECAUTION Page Precaution ....................2...
  • Page 20 Precaution PRECAUTION 1. Precaution 6. AIRBAG MODULE AND SEAT BELT PRETENSIONER DISPOSAL A: CAUTION To prevent bodily injury from unexpected airbag Please clearly understand and adhere to the follow- deployment, do not dispose the airbag modules or ing general precautions for environmental protec- seat belt pretensioner in the same way as other tion and to avoid minor or serious injury to the waste.

  • Page 21: Engine Coolant

    Precaution PRECAUTION 13.ENGINE COOLANT When handling engine coolant, adhere to the following to prevent from unexpected accident. • Never remove the radiator cap since engine coolant may blow out when it is hot. • Prepare a container and cloth to prevent scattering of engine coolant when performing work where engine coolant can be spilled.
  • Page 22 Precaution PRECAUTION • Replace the hose with a new part if it rides over the stay or the top of spool. PC-00070 PC-00071 (1) Hose rides over the stay PC-00077 (1) Hose rides over the top of spool • Check if the surface and the inner surface of the hose are damaged, cracked, bend, hard- ened, softened, swelled, peeled or deformed due to the adherence or the entry of the foreign...

  • Page 23: Handling Precautions For Silicon-Containing Spray

    Precaution PRECAUTION • For hose clips and hose clamps, perform the inspection below and replace them with a new part if faulty. • Check for deformation, rust, damage or foreign matters. • For hose clip, check if it works and has clamping force. •...
  • Page 24 Precaution PRECAUTION PC-6...
  • Page 25 NOTE Page Note ......................2...

  • Page 26: A: Basic Repair Hint

    Note NOTE 1. Note A: BASIC REPAIR HINT This section describes basic points that the service operator must understand before performing the service operation. 1. APPEARANCE • Always wear clean work clothing. • Wear a cap and protective shoes. 2. PROTECTION OF VEHICLE UNDER MAINTENANCE AND PREPARATION OF TOOLS/ EQUIPMENT •...

  • Page 27: Removed Part

    Note NOTE 5. REMOVED PART • A removed part must be organized to avoid mixing up with similar parts. When same parts are used in mul- tiple locations, such as pistons in engine, manage the parts by using labels with cylinder No. so that the parts are not installed to the wrong location.
  • Page 28 7. SERVICE PARTS Use genuine parts for maximum performance and maintenance when conducting repairs. Subaru/FHI will not be responsible for poor performance result- ing from the use of parts except for genuine parts. 8. PROTECTING VEHICLE UNDER MAIN-...

  • Page 29: Lift And Jack

    Note NOTE 10.LIFT AND JACK When using a lift or shop jack to raise a vehicle or using rigid rack to support a vehicle, always follow instruc- tions concerning jack-up points and weight limits to prevent the vehicle from falling, which could result in in- jury.
  • Page 30 Note NOTE • Pantograph jack NT-00459 Jack-up point CAUTION: When storing the jack holder after use, store with the jack handle mount of the jack facing the inside of the trunk. NT-00491 Jack NT-6...
  • Page 31 Note NOTE • Lift NT-00271 CAUTION: For models with side under skirt, use a spacer or an attachment to lift up the vehicle securely at jack up point, without contact of side under skirt and lift. • Rigid rack NT-00242 Attachment NT-7...
  • Page 32 Note NOTE • Plate lift NT-00452 Jack-up point Attachment NT-8...
  • Page 33 Note NOTE • Jack-up point (When using a garage jack) NT-00492 Front Rear Frame Rear differential CAUTION: If jacking up the front side of the vehicle, make sure that the jack is attached at the center of the jack- up plate not at the sides. NT-9...
  • Page 34 Note NOTE 11.TIE-DOWNS Tie-downs are used when transporting vehicles and when using the chassis dynamo. Remove the grommet from the tie-down hole, and attach the tie-down only to the specified locations on the vehicle. NT-00486 Grommet • Tie-down location NT-00453 Hook for tie-down Tie-down hole NT-10...
  • Page 35 Note NOTE • Chain direction at tie-down condition CAUTION: • Pull the front and rear of the vehicle in the opposite direction, and pull the left and right of the ve- hicle in the same direction. • Patterns except for the followings (recommended) are not allowed. Recommended Tie-down direction NT-00214...
  • Page 36 Note NOTE • Tie-down range For ground transportation CAUTION: To tie down the vehicle from the vehicle interior, hook the hooks of the tie-down chain on the rear tie- down holes from the vehicle interior. When the vehicle is tied down from vehicle outside, hook the hooks of tie-down chain on the rear tie-down hooks from vehicle outside.
  • Page 37 Note NOTE For sea transportation CAUTION: The eye bolts are exclusively used for towing and sea transportation tie-down, and do not use them for ground and freight transportation. 70˚ :(C) NT-00463 Front tie-down hook Chain pulling range at tie-down 1,500 mm (59.1 in) condition Eye bolt 400 mm (15.7 in)
  • Page 38 Note NOTE • Vehicle sinking volume at tie-down condition CAUTION: The vehicle sinking volume at tie-down condition should be less than 50 mm (1.97 in) and make sure to fix the vehicle securely. Check to see if the tensions of chains or belts at tie-down condition are appropriate in the following procedures.
  • Page 39 Note NOTE 12.TOWING Avoid towing vehicles except when the vehicle cannot be driven. For AT models, use a loader instead of tow- ing. When towing other vehicles, pay attention to the following to prevent hook or vehicle damage resulting from excessive weight. •...
  • Page 40 Note NOTE • Precautions Towing Precautions Lifting up four wheels (On a trailer) Use car carrier truck when the chassis or drivetrain of a vehicle has been damaged in an accident. NT-00023 Rope • Check if both front and rear wheels are rotated normally. •...

  • Page 41: Carrier Car

    Note NOTE CAUTION: • Place the shift lever in “N” position during towing. • Do not lift up the rear wheels to avoid unsteady rotation. • Turn the ignition key to “ACC”, then check the steering wheel moves freely. (Models without the keyless access with push button start system) •...

  • Page 42: Front Hood Stay

    Note NOTE 14.FRONT HOOD STAY 1) Always attach the stay to the normal position when performing works such as inspections and general maintenance. CAUTION: • At the inspection and general maintenance, do not detach the stay. • Pay special attention to the stay since it may be blown off by a strong wind. NT-00450 Normal attached position 2) When a wider front hood opening is needed, set the stay to the fully open positions on both the hood and...

  • Page 43: General Scan Tool

    • Check the dragging of brake pad or brake shoe. Using general scan tools will greatly improve the ef- ficiency of repairing engine electronic controls. Specifications: Subaru Select Monitor can be used to diagnose the Braking force engine, vehicle dynamic control (VDC), air condi- Rear wheel total 10% or more of load on front or rear tioner and other electrically controlled parts.
  • Page 44 Note NOTE NT-20...
  • Page 45 IDENTIFICATION Page Identification ....................2...
  • Page 46 Identification IDENTIFICATION 1. Identification A: IDENTIFICATION 1. IDENTIFICATION NUMBER & LABEL LOCATIONS The V.I.N. (Vehicle Identification Numbers) is used to classify the vehicle. • Positioning of the label for identification ID-00399 Vehicle identification number Tire inflation pressure label Vehicle identification number (V.I.N.) (below right front floor car- (V.I.N.) plate pet)
  • Page 47 Identification IDENTIFICATION • Engine • Rear differential ID-00384 ID-00398 (1) Engine serial number (1) Identification (2) Engine type (casting) cylinder block upper side • FMVSS LABEL, CMVSS LABEL Example (FMVSS label) • Automatic transmission ID-00321 ID-00402 • Model number label (1) Transmission serial No.

  • Page 48: Model Number Label

    Identification IDENTIFICATION 2. MEANING OF V.I.N. The meaning of the V.I.N. is as follows: ]JF1ZCAB1XE960001[ The starting and ending brackets ( ] [ ) are stop marks. Digits Code Meaning Details 1 — 3 Manufacturer body area JF1: Passenger car, FHI made Car line Z: BRZ Body type...
  • Page 49 Identification IDENTIFICATION • Transmission 1. MT 81 (MT ID label) Digits Code Meaning Details 1 — 2 MT model classification 81: TL701VD90A TL701VD90A Digits Code Meaning Details Transmission T: Transmission Transmission system L: FR (MT) 3 and 4 Distance between gear 70: Between main shaft and drive pinion center Classification...
  • Page 50 Identification IDENTIFICATION • Option code 1-digit number A package Leather package Medium size spoiler Smart entry 2-digit number Spare tire HID light Leather seat 17-inch summer tire Manual A/C Auto A/C ID-6...

  • Page 51: Recommended Materials

    RECOMMENDED MATERIALS Page Recommended Materials ................2...

  • Page 52: A: Recommended Materials

    Recommended Materials RECOMMENDED MATERIALS 1. Recommended Materials A: RECOMMENDED MATERIALS 1. GENERAL To insure the best performance, always use the specified oil, gasoline, adhesive, sealant, etc. or a substitute of equivalent quality. 2. FUEL • Use unleaded gasoline to reduce air pollution, because using leaded gasoline will damage the catalytic converter.

  • Page 53: Engine Coolant

    — DOT4 5. ENGINE COOLANT Use genuine engine coolant to protect the engine. Engine coolant Recommended materials Item number Alternative Coolant SUBARU SUPER COOLANT — (Concentrated type) — SUBARU SUPER COOLANT K0670Y0001 (Diluted type) Water for dilution Distilled water —...
  • Page 54 Recommended Materials RECOMMENDED MATERIALS 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 ND-OIL8. Air Conditioner Recommended materials Item number Alternative...

  • Page 55: Seal Material

    Recommended Materials RECOMMENDED MATERIALS 8. ADHESIVE Use the adhesives shown in the table below, or equivalent. Adhesive Application point Recommended materials Item number Alternative Adhesive Windshield glass, rear quarter Dow Automotive’s glass, rear window glass and Adhesive: ESSEX U-400HV or equivalent —...
  • Page 56 Recommended Materials RECOMMENDED MATERIALS RM-6...

  • Page 57: Pre-Delivery Inspection

    PRE-DELIVERY INSPECTION Page Pre-delivery Inspection ................2...

  • Page 58: A: General Description

    Pre-delivery Inspection PRE-DELIVERY INSPECTION 1. Pre-delivery Inspection A: GENERAL DESCRIPTION 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 ve- hicle to its normal condition. •...
  • Page 59 Pre-delivery Inspection PRE-DELIVERY INSPECTION Step Check point 13. Engine oil Check the engine oil amount. 14. Transmission gear oil Check for leakage of the transmission gear oil. 15. Rear differential gear oil Check for leakage of gear oil from the rear differential. 16.
  • Page 60 Pre-delivery Inspection PRE-DELIVERY INSPECTION Dynamic Test with the Vehicle Running Step Check point 52. Brake test Check the foot brake for normal operations. 53. Shift control Check that the shift patterns are correct. 54. Cruise control Check that the cruise control system operates normally. Checks after Dynamic Test Step Check point...

  • Page 61: Fuse Installation

    Pre-delivery Inspection PRE-DELIVERY INSPECTION 3. FUSE INSTALLATION 2) Completely close the driver’s door, and then check the smooth movement with operating door The DCC (back-up) 30A fuse is moved from posi- lock knob from lock to unlock several times. Set the tion (A) to (B) as shown in the figure below to pre- door lock knob (A) to lock position.

  • Page 62: Trunk Lid Open/Close Operations

    Pre-delivery Inspection PRE-DELIVERY INSPECTION 5) Check that the passenger’s power door lock 6. OPERATION CHECK OF TRUNK LID RE- switch locks and unlocks normally in the same LEASE HANDLE manner. CAUTION: Do not check the trunk lid release handle when in the trunk.

  • Page 63: Towing Hook (Eyebolt)

    Pre-delivery Inspection PRE-DELIVERY INSPECTION 8. TOWING HOOK (EYEBOLT) 9. ACCESSORY Check that the following accessories are provided. NOTE: • Owner’s manual At factory shipment, the towing hook (eyebolt) is in- • Warranty booklet stalled to the rear bumper for securing the vehicle •...

  • Page 64: Front Hood Lock Release

    Pre-delivery Inspection PRE-DELIVERY INSPECTION 10.FRONT HOOD LOCK RELEASE 12.BRAKE FLUID Operate the front hood release lever to check that Check the brake fluid amount. If the amount is in- the front hood is unlocked normally. sufficient, carry out a brake line test to identify brake fluid leaks and check the brake operation.

  • Page 65: Window Washer Fluid

    Pre-delivery Inspection PRE-DELIVERY INSPECTION 6) After turning off the engine, wait five minutes or 16.ENGINE COOLANT more for the oil to return to the oil pan before check- Check the coolant amount on the reservoir. If the ing the oil level. amount of engine coolant is insufficient, check that no leaks are found.

  • Page 66: Keyless Entry System

    Pre-delivery Inspection PRE-DELIVERY INSPECTION 20.KEYLESS ENTRY SYSTEM • Press the “PANIC” button of the keyless trans- mitter. Check that the panic mode (the horn keeps Check the keyless entry system operations as fol- sounding) is initiated. Also, check that this condi- lows: tion continues for 30 seconds or until when any of •...
  • Page 67 The following inspections show the initial settings. When the settings are different from the initial set- tings, use Subaru Select Monitor to check the de- tails of each setting for inspections. • While carrying the access key, check that the...

  • Page 68: Security System

    Pre-delivery Inspection PRE-DELIVERY INSPECTION • With the access key in the vehicle, check that 7) Press the access key “UNLOCK” button once. warning buzzer sounds and locking does not occur when you touch the door touch sensor. CAUTION: Remove the mechanical key from the access key and hold the mechanical key.
  • Page 69 Pre-delivery Inspection PRE-DELIVERY INSPECTION 16) Momentarily press the “LOCK” button of the 23.SEAT power door lock switch with any one door open. 1) Check that each seat provides full functionality in • Driver’s side sliding and reclining. Check all available functions of the rear seat such as the backrest tilt knob.
  • Page 70 Pre-delivery Inspection PRE-DELIVERY INSPECTION 25.TPMS (U.S. MODEL) 30.DELIVERY MODE CONNECTOR 1) Turn the ignition switch to ON, and check that Connect the delivery mode connector of the driv- the TPMS warning light is in a normal operation er's side A pillar lower area. After connection, condition.
  • Page 71 Pre-delivery Inspection PRE-DELIVERY INSPECTION 36.AIR CONDITIONER 42.LIGHTING Operate the air conditioner. Check that the A/C 1) Check the headlight operations. When pulling compressor operates normally and enough cooling out the key, check if the headlight illuminates by is provided. turning the headlight switch from OFF to ON. 2) Check the stop light operation.

  • Page 72: Window Washer

    Pre-delivery Inspection PRE-DELIVERY INSPECTION 45.WINDOW WASHER Check that the window washer system injects washer fluid to the specified area of the windshield shown in the figure. Front spray position: PI-00794 Washer nozzle 660 mm (25.98 in) 684 mm (26.93 in) 247 mm (9.72 in) 232 mm (9.13 in) 268 mm (10.55 in)
  • Page 73 • MT For detailed operation procedures, refer to “PC ap- 1) Check for smooth operation to each position. plication help for Subaru Select Monitor”. 2) Check that the lever cannot be moved to the re- 2) Clear Memory Mode verse position unless the pull-ring is pulled up.

  • Page 74: Fluid Leakage

    Pre-delivery Inspection PRE-DELIVERY INSPECTION 56.FLUID LEAKAGE 58.APPEARANCE 2 Check entire areas of the vehicle for any trace of 1) If protective coating (wrap guard) is applied, re- coolant/oil (such as engine and gear oil)/fluid (such move it. as transmission and brake) leaks. NOTE: •...
  • Page 75 Pre-delivery Inspection PRE-DELIVERY INSPECTION 5) Check each portion of body and all of the exteri- or parts for deformation or distortion. Also, check each light lens for cracks. 6) Peel the protective tape, vinyl wrapping and identification seal attached to the following places. CAUTION: Be sure to always peel off the protective film of the SUS plate.
  • Page 76 Pre-delivery Inspection PRE-DELIVERY INSPECTION PI-20...
  • Page 77 PERIODIC MAINTENANCE SERVICES Page General Description ...................2 Schedule ....................3 Engine Oil ....................5 Engine Oil Filter ..................8 Spark Plug ....................9 V-belt ......................25 Hoses Related to Emission ..............29 PCV Valve ....................30 Fuel Line ....................31 Fuel Filter ....................32 Air Cleaner Element .................57 Cooling System ..................59 Engine Coolant ..................60 Clutch System ..................63 Transmission Gear Oil ................68...
  • Page 78 General Description PERIODIC MAINTENANCE SERVICES 1. General Description A: GENERAL DESCRIPTION Be sure to perform periodic maintenance in order to maintain vehicle performance and find problems before they occur. PM-2...
  • Page 79 Schedule PERIODIC MAINTENANCE SERVICES 2. Schedule A: MAINTENANCE SCHEDULE 1 1. U.S. MODELS Replacement interval [Number of months or km (miles), whichever occurs first] Months 7.5 15 22.5 30 37.5 45 52.5 60 67.5 75 82.5 90 97.5 105 112.5 120 132 ×...
  • Page 80 Schedule PERIODIC MAINTENANCE SERVICES B: MAINTENANCE SCHEDULE 2 Item Maintenance interval Repeat short Repeat driving Driving in Area where High humidity distance driving on bumpy extremely cold salt or other or mountain muddy road weather corrosive area substance used, or coastal area Engine oil Every 3.75 months...

  • Page 81: Engine Oil

    Engine Oil PERIODIC MAINTENANCE SERVICES 3. Engine Oil A: INSPECTION CAUTION: If the engine oil is spilt over exhaust pipe or the under cover, wipe it off with cloth to avoid emitting smoke or causing a fire. 1) Park the vehicle on a level surface. 2) Remove the oil level gauge and wipe away the oil.
  • Page 82 Engine Oil PERIODIC MAINTENANCE SERVICES B: REPLACEMENT CAUTION: If the engine oil is spilt over exhaust pipe or the under cover, wipe it off with cloth to avoid emitting smoke or causing a fire. 1) Open the oil filler cap for quick draining of engine oil. 2) Lift up the vehicle.
  • Page 83 Engine Oil PERIODIC MAINTENANCE SERVICES 5) Lower the vehicle. 6) Select engine oil of adequate quality and viscosity and fill it through the oil filler duct to the “F” mark on the oil level gauge. Make sure that the vehicle is parked on a level surface when checking oil level. Recommended oil: Refer to “RM”...

  • Page 84: Engine Oil Filter

    Engine Oil Filter PERIODIC MAINTENANCE SERVICES 4. Engine Oil Filter A: REPLACEMENT CAUTION: If the engine oil is spilt over exhaust pipe or the under cover, wipe it off with cloth to avoid emitting smoke or causing a fire. 1) Remove the oil filter using an oil filter wrench. NOTE: •...

  • Page 85: Spark Plug

    Spark Plug PERIODIC MAINTENANCE SERVICES 5. Spark Plug A: REPLACEMENT 1. REMOVAL 1) Disconnect the ground cable from battery. CAUTION: Disconnect the ground cable from the battery with the driver’s and the passenger’s doors open (with the glass lowered to a position where the door can be opened/closed with no problems). This is to prevent molding damage that occurs when opening/closing a door with the glass fully closed and the ground cable disconnected due to the power window index function that slightly opens/closes the glass in conjunction with opening/closing doors.
  • Page 86 Spark Plug PERIODIC MAINTENANCE SERVICES 5) Disconnect the front oxygen (A/F) sensor connector (A) and rear oxygen sensor connector (B). PM-00636 6) Remove the two bolts securing the harness of the front oxygen (A/F) sensor, and remove the two clips from the stay.
  • Page 87 Spark Plug PERIODIC MAINTENANCE SERVICES 9) Remove the 12 bolts and seven clips to remove engine under cover No. 1. PM-00638 10) Remove the seven bolts to remove engine under cover No. 2. PM-00639 PM-11...
  • Page 88 Spark Plug PERIODIC MAINTENANCE SERVICES 11) Remove the three clips to remove the front mat guard under RH. PM-00640 12) Remove the two nuts and disconnect the joint pipe. PM-00641 PM-12...
  • Page 89 Spark Plug PERIODIC MAINTENANCE SERVICES 13) Remove the two nuts, two bolts and two compression springs to disconnect the exhaust center pipe as- sembly. PM-00642 14) Remove the bolt to remove the exhaust pipe assembly FR. PM-00643 PM-13...
  • Page 90 Spark Plug PERIODIC MAINTENANCE SERVICES 15) Remove the two nuts and disconnect the joint pipe. AT-00000 16) Remove the six nuts to remove the exhaust manifold sub-assembly. PM-00645 PM-14...
  • Page 91 Spark Plug PERIODIC MAINTENANCE SERVICES 17) Tie the joint pipe to the front crossmember using string. CAUTION: This procedure is necessary to prevent the joint pipe from falling off. PM-00646 18) Remove the nuts which secure the engine mounting to the front crossmember. PM-00647 19) Lower the vehicle.
  • Page 92 Spark Plug PERIODIC MAINTENANCE SERVICES 20) Remove clip (A) securing the engine harness to the engine hanger, clip (B) securing the battery cable and clip (C) securing the generator cable to the intake manifold protector RH, and clip (D) securing the gen- erator cable to the fuse box.
  • Page 93 Spark Plug PERIODIC MAINTENANCE SERVICES 22) Install the ST1 and ST2 to the engine assembly. Tightening torque: 43 N·m (4.4 kgf-m, 31.7 ft-lb) ST1 12281-38150 ENGINE HANGER NO. 1 ST2 90119-14120 BOLT PM-00652 23) Remove the clip securing the bulkhead harness to the vehicle. •...
  • Page 94 Spark Plug PERIODIC MAINTENANCE SERVICES • Right Hand PM-00654 24) Set the ST1 and ST2 to vehicle in order to support the engine. ST1 99099AJ000 ENGINE HANGER ST2 18679AA020 ADJUSTER CAUTION: • Set the ST on the vehicle being careful not to pinch the harness. •...
  • Page 95 Spark Plug PERIODIC MAINTENANCE SERVICES PM-00742 25) Turn the handle on the top of the ST clockwise, and slowly lift the engine from the crossmember engine mount hole until it reaches the position where the engine mount stud bolts can be removed. CAUTION: •...
  • Page 96 Spark Plug PERIODIC MAINTENANCE SERVICES 27) Install the ST between the engine mount and crossmember. ST 18632AA020 STAND ASSY PM-00656 28) Lower the vehicle. 29) Rotate the handle on the top of the ST counterclockwise to slowly lower the engine. 30) Remove the ST (ENGINE HANGER) from the vehicle.
  • Page 97 Spark Plug PERIODIC MAINTENANCE SERVICES (3) Remove the three bolts and the fuel injector CM. PM-00658 (4) Disconnect the ignition coil connector and remove the ignition coil. PM-00659 (5) Remove the spark plug with a spark plug socket. PM-21...
  • Page 98 Spark Plug PERIODIC MAINTENANCE SERVICES 32) Remove the LH spark plugs. (1) Remove the bracket securing the fuel hose. PM-00758 (2) Remove the two bolts and collision protector LH. PM-00661 PM-22...
  • Page 99 Spark Plug PERIODIC MAINTENANCE SERVICES (3) Disconnect the ignition coil connector and remove the ignition coil. PM-00662 (4) Remove the spark plug with a spark plug socket. PM-23...

  • Page 100: Installation

    Spark Plug PERIODIC MAINTENANCE SERVICES 2. INSTALLATION Install in the reverse order of removal. CAUTION: • Before installation, degrease the ignition coil installation parts and mounting bolts. • After all installation, check adjustment of the AT shift lever because all engine mounting bolts are removed in 18).
  • Page 101 V-belt PERIODIC MAINTENANCE SERVICES 6. V-belt A: INSPECTION 1) Check the V-belt for cracks, tear or wear. 2) Check the V-belt tensioner assembly and idler pulley for deformation, cracks or other damages. 3) Check that the V-belt ribs are securely placed on the rib grooves for each pulleys. PM-00587 B: REPLACEMENT NOTE:...
  • Page 102 V-belt PERIODIC MAINTENANCE SERVICES 2) Removing belt cover No. 1 (1) Remove the two bolts and the belt cover No. 1. PM-00590 3) Removing belt cover No. 2 (1) Release the clip and disconnect the wire harness. (2) Remove the two bolts, belt cover No. 2, clip securing the A/C compressor connector from the V-belt cover LH (models with A/C only), then remove the V-belt cover LH.
  • Page 103 V-belt PERIODIC MAINTENANCE SERVICES 4) Removing the fan & generator V-belt (1) Set the tool on the pulley set bolt of the belt tensioner, rotate the belt tensioner counterclockwise to loosen the tension and remove the fan & generator V-belt. CAUTION: As the pulley set bolt uses a left-threaded screw, rotating clockwise loosens the pulley set bolt.
  • Page 104 V-belt PERIODIC MAINTENANCE SERVICES 5) Install in the reverse order of removal. CAUTION: • Do not use the V-belt if there is any oil, grease or coolant on the belt. • Be careful not to rub the V-belt end surface with bare hands; exposed core may cause injury. •...
  • Page 105 Hoses Related to Emission PERIODIC MAINTENANCE SERVICES 7. Hoses Related to Emission A: INSPECTION Check that the hose has no cracks, damage or loose part. PM-29...

  • Page 106: Pcv Valve

    PCV Valve PERIODIC MAINTENANCE SERVICES 8. PCV Valve A: INSPECTION 1) Install the hose to the PCV valve. 2) Check that air is easily discharged when air is blown from the cylinder head side. PM-00754 (A) Hose (B) Air 3) Check that air is not easily discharged when air is blown from the intake manifold side.
  • Page 107 Fuel Line PERIODIC MAINTENANCE SERVICES 9. 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 and fuel leakage. If faulty parts are found, repair or replace them.

  • Page 108: Fuel Filter

    Fuel Filter PERIODIC MAINTENANCE SERVICES 10.Fuel Filter A: REPLACEMENT WARNING: Place “NO OPEN FLAMES” signs near the working area. CAUTION: • Perform the work with the engine coolant at a temperature of 60°C (140°F) or less. • Before removing fuel system parts, be sure to take measures to prevent fuel from flowing out. •...
  • Page 109 Fuel Filter PERIODIC MAINTENANCE SERVICES 2) Remove the fuel pump fuse from the engine room relay block. PM-00680 (A) Fuel pump fuse 3) Start the engine. 4) After the engine stops naturally, turn the key to IG OFF. 5) Crank the engine again and check that the engine does not start. NOTE: Check/Delete diagnostic codes after performing procedures as some diagnostic code might have been de- tected.
  • Page 110 (2) Connect the ST to the fuel hose. ST 18471AA000 (3) Connect the gasoline-proof hose to the ST and put the end of the hose in the container. (4) Drive the fuel pump and drain the fuel using Subaru Select Monitor. PM-34...
  • Page 111 Fuel Filter PERIODIC MAINTENANCE SERVICES 11) If the fuel gauge indicates that two thirds or more of the fuel is remaining, drain fuel according to the fol- lowing procedures. (Method for draining from fuel tank to filler pipe hose) WARNING: Vehicle components are extremely hot after driving.
  • Page 112 Fuel Filter PERIODIC MAINTENANCE SERVICES (4) Remove the four cushion rubbers and the exhaust tail pipe assembly. PM-00718 (5) Loosen the hose clamp, and disconnect the fuel tank to filler pipe hose. CAUTION: • Before performing the procedures, remove any foreign material such as mud adhering to the con- necting parts of the fuel tank to filler pipe hose.
  • Page 113 Fuel Filter PERIODIC MAINTENANCE SERVICES 14) Press in the grommet and remove the grommet from rear floor service hole cover No. 2. PM-00683 15) Peel off the butyl tape and remove rear floor service hole cover No. 2. 16) Disconnect the fuel pump connector. PM-00684 PM-37...
  • Page 114 Fuel Filter PERIODIC MAINTENANCE SERVICES 17) Disconnect the fuel pump tube connector. CAUTION: Be careful not to spill fuel. PM-00685 18) Remove the fuel pump tube from the fuel tank. PM-00686 PM-38...
  • Page 115 Fuel Filter PERIODIC MAINTENANCE SERVICES 19) Loosen the fuel pump gauge retainer using the ST. ST 42099CA000 ST FUEL PUMP CAUTION: • Do not use any tool other than the ST. • Be careful not to damage the tube with the ST. •...
  • Page 116 Fuel Filter PERIODIC MAINTENANCE SERVICES 21) Disconnect the fuel tube connector, and remove the fuel suction tube assembly from the fuel tank. CAUTION: • Do not pull with excessive force on the tube when disconnecting the fuel tube connector. • Make sure not to bend the arm of the fuel sender gauge. •...
  • Page 117 Fuel Filter PERIODIC MAINTENANCE SERVICES 23) Disconnect the fuel sender gauge connector and remove the harness from the clamp. PM-00689 PM-00740 PM-41...
  • Page 118 Fuel Filter PERIODIC MAINTENANCE SERVICES 24) Remove the harness from the clamp, press and lift up the tab, and remove the fuel sender gauge assem- bly. CAUTION: Make sure not to bend the arm of the fuel sender gauge assembly. PM-00690 25) Disconnect the fuel pump connector.
  • Page 119 Fuel Filter PERIODIC MAINTENANCE SERVICES 26) Press the fuel suction plate in the direction indicated in the figure, and remove the E ring using needle nose pliers. PM-00601 27) Release the tab using a flat tip screwdriver wrapped by protective tape and disconnect the jet pump noz- zle.
  • Page 120 Fuel Filter PERIODIC MAINTENANCE SERVICES 28) Release the three tabs using a flat tip screwdriver wrapped by protective tape and pull out the fuel suction plate. CAUTION: Do not damage the fuel sub tank or fuel filter. PM-00603 29) Release the tab using a flat tip screwdriver wrapped by protective tape and disconnect the jet pump. PM-00604 PM-44...
  • Page 121 Fuel Filter PERIODIC MAINTENANCE SERVICES 30) Remove the O-ring from the fuel sub tank. PM-00605 31) Release the two tabs using a flat tip screwdriver wrapped by protective tape. PM-00606 PM-45...
  • Page 122 Fuel Filter PERIODIC MAINTENANCE SERVICES 32) Release the three tabs using a flat tip screwdriver wrapped by protective tape and pull out the fuel pump keeping it completely straight. PM-00607 33) Remove the O-ring (A), spacer (B) and connector cable (C) from the fuel pump. PM-00608 PM-46...
  • Page 123 Fuel Filter PERIODIC MAINTENANCE SERVICES 34) Remove the pressure regulator from the fuel filter assembly. PM-00609 35) Remove the O-rings (A) and (B) and back-up ring (C) from the pressure regulator. PM-00610 PM-47...
  • Page 124 Fuel Filter PERIODIC MAINTENANCE SERVICES 36) Install new O-rings (A) and (B), and new back-up ring (C) to the pressure regulator. PM-00610 37) Install the pressure regulator to the fuel filter assembly. CAUTION: Make sure that the O-ring is not cut or pinched when installing. NOTE: Apply gasoline to the pressure regulator.
  • Page 125 Fuel Filter PERIODIC MAINTENANCE SERVICES 38) Install a new O-ring (A), spacer (B) and new connector cable (C) to the fuel pump. NOTE: Apply gasoline to the O-ring and spacer. PM-00608 39) Install the fuel pump to the fuel filter assembly. PM-00611 PM-49...
  • Page 126 Fuel Filter PERIODIC MAINTENANCE SERVICES 40) Install a new O-ring to the fuel filter assembly. CAUTION: Make sure that the O-ring is not cut or pinched when installing. NOTE: Apply gasoline to the O-ring. PM-00612 41) Install the jet pump to the fuel sub tank. 42) Engage the three tabs, and install the fuel filter to the fuel sub tank.
  • Page 127 Fuel Filter PERIODIC MAINTENANCE SERVICES 43) Engage the tab, and install the jet pump nozzle to sub tank No. 1. PM-00613 44) Install a new E-ring. PM-00614 PM-51...
  • Page 128 Fuel Filter PERIODIC MAINTENANCE SERVICES 45) Connect the fuel pump harness connector, and install the harness to the four clamps. PM-00689 PM-00740 46) Engage the tab, and install the fuel sender gauge assembly No. 2 to the fuel delivery tube. 47) Connect the fuel sender gauge assembly No.
  • Page 129 Fuel Filter PERIODIC MAINTENANCE SERVICES 48) Inspect the fuel sender gauge assembly. (1) Check that the fuel sender gauge assembly is free of damage. (2) Check the dimensions from the float positions of floats F (upper limit) and E (lower limit) to the fuel tank seating surface.
  • Page 130 Fuel Filter PERIODIC MAINTENANCE SERVICES 50) Connect the fuel tube connector. CAUTION: • Do not pull with excessive force on the tube when connecting the fuel tube connector. • Make sure not to bend the arm of the fuel sender gauge. 51) Insert the fuel suction tube assembly (with pump &...
  • Page 131 Fuel Filter PERIODIC MAINTENANCE SERVICES 52) Apply gasoline to the gasket. CAUTION: • When applying gasoline to the gasket, apply it to the area as shown in the figure. • Be careful not to spill gasoline on the screw section of the fuel tank. •...
  • Page 132 59) Connect the ground cable to battery. 60) Apply fuel pressure and check that there are no leaks in the fuel system using the Subaru Select Monitor. 61) Install rear floor service hole cover No. 2 using new butyl tape.

  • Page 133: Air Cleaner Element

    Air Cleaner Element PERIODIC MAINTENANCE SERVICES 11.Air Cleaner Element A: INSPECTION 1) Check that the air cleaner element has no deformation, cracks or other damages. 2) Check the air cleaner element for excessive dirt. B: REPLACEMENT CAUTION: Do not place an excessive load on the air cleaner case with grasping with your hands in order to pre- vent damaging the plastic bracket.
  • Page 134 Air Cleaner Element PERIODIC MAINTENANCE SERVICES 3) Raise the air cleaner case (rear) at an angle as shown in the figure, and remove the air cleaner filter ele- ment. PM-00597 4) Raise the air cleaner case (rear) at an angle, and install the air cleaner filter element. 5) Connect the two tabs of the air cleaner case (rear) to the air cleaner case (front).

  • Page 135: Cooling System

    Cooling System PERIODIC MAINTENANCE SERVICES 12.Cooling System A: INSPECTION 1. RADIATOR 1) Check that the radiator does not have deformation, cracks or damage. 2) Check that the hose has no cracks, damage or loose part. 3) Check that there is no engine coolant leakage from the hose connection parts. 4) Remove the radiator cap, fill the radiator with engine coolant, and then install the radiator cap tester to the filler neck of radiator.

  • Page 136: Engine Coolant

    Engine Coolant PERIODIC MAINTENANCE SERVICES 13.Engine Coolant A: INSPECTION 1) Park the vehicle on a level surface. 2) Check that the reservoir tank fluid level is between the FULL and LOW lines when the engine is cool. CAUTION: • Do not substitute water for the coolant fluid. •...
  • Page 137 Engine Coolant PERIODIC MAINTENANCE SERVICES B: REPLACEMENT CAUTION: Do not remove the radiator cap sub-assembly while the engine and radiator are hot in order to pre- vent possible burns. There is a possibility of fluid or steam surging out due to pressurization. 1) Lift up the vehicle.
  • Page 138 CAUTION: The SUBARU Super Coolant contains anti-freeze and anti-rust agents, and is especially made for Subaru engines with an aluminum cylinder block. Be sure to use SUBARU Super Coolant, since other coolant may cause corrosion. 9) Open the air bleeding plug on the heater hose side.

  • Page 139: Clutch System

    Clutch System PERIODIC MAINTENANCE SERVICES 14.Clutch System A: INSPECTION AND ADJUSTMENT 1. INSPECTION Move the clutch pedal in the lateral direction with a force of approximately 10 N (1 kgf, 2 lbf) to check that the clutch pedal deflection is within the service limit. CAUTION: If it exceeds the service limit, replace the clutch pedal assembly with a new part.
  • Page 140 Clutch System PERIODIC MAINTENANCE SERVICES 2. ADJUSTMENT 1) If the full stroke of the clutch pedal is not within the specified value, loosen the lock nuts of the clutch switch and adjust the full stroke of the clutch pedal with the clutch switch. CAUTION: When adjusting the full stroke of clutch pedal, do not turn the clutch switch.
  • Page 141 Clutch System PERIODIC MAINTENANCE SERVICES 3) Rotate the push rod to adjust. PM-00722 (A) In the longer direction (B) In the shorter direction 4) Make sure that the clutch pedal contacts the clutch pedal bracket stopper when the clutch pedal is at the maximum stroke position.
  • Page 142 Clutch System PERIODIC MAINTENANCE SERVICES 8) Turn further in the direction that will shorten the push rod by 270°. PM-00722 (A) In the longer direction (B) In the shorter direction 9) Check that the clevis pin moves smoothly by moving it in the left and right directions. 10) Tighten the push rod lock nut of the master cylinder.
  • Page 143 Clutch System PERIODIC MAINTENANCE SERVICES 13) Push the release lever until the operating cylinder push rod retracts. Make sure that the clutch fluid level in the reservoir tank increases. If the clutch fluid level increases, the hydraulic clutch is properly adjusted. If the clutch fluid level does not increase or the push rod does not retract, replace the master cylinder with a new part.

  • Page 144: Transmission Gear Oil

    Transmission Gear Oil PERIODIC MAINTENANCE SERVICES 15.Transmission Gear Oil A: INSPECTION Check for leakage of gear oil from the transmission. B: REPLACEMENT CAUTION: • Immediately after running the vehicle or after idling for a long time, the transmission gear oil will be hot.

  • Page 145: Automatic Transmission Fluid

    Automatic Transmission Fluid PERIODIC MAINTENANCE SERVICES 16.Automatic Transmission Fluid A: INSPECTION Check for leakage of ATF from transmission. B: REPLACEMENT 1) Lift up the vehicle and maintain in a horizontal position. [*1] 2) Remove engine under cover No. 1. 3) Remove engine under cover No. 2. 4) Remove the drain plug and gasket, and drain the fluid.
  • Page 146 Automatic Transmission Fluid PERIODIC MAINTENANCE SERVICES 8) Add fluid through the refill hole until the fluid flows out of the overflow tube. [*6] CAUTION: • Use auto-fluid WS. • Slowly add the fluid. Adding the fluid rapidly can cause the fluid to hit internal parts and splash around resulting in fluid flowing out of the refill hole.
  • Page 147 Automatic Transmission Fluid PERIODIC MAINTENANCE SERVICES C: ADJUSTMENT Fluid refill and adjustment image: Initial refill Specified amount refill Refill the oil pan with fluid to a Refill with the specified amount certain amount. according to the operation. Specified amount Refills to the extent that the Overflow plug Overflow tube...
  • Page 148 Automatic Transmission Fluid PERIODIC MAINTENANCE SERVICES 1. AUTOMATIC TRANSMISSION FLUID FILLING CAUTION: • Perform procedures when the automatic transmission fluid is sufficiently cool. • Always be sure to switch to oil amount adjustment mode when filling automatic transmission fluid. • Slowly add the fluid. Adding the fluid rapidly can cause the fluid to hit internal parts and splash around resulting in fluid flowing out of the refill hole.
  • Page 149 Automatic Transmission Fluid PERIODIC MAINTENANCE SERVICES 6) Add fluid through the refill hole until the fluid flows out of the overflow tube. CAUTION: Slowly add the fluid. Adding the fluid rapidly can cause the fluid to hit internal parts and splash around resulting in fluid flowing out of the refill hole.
  • Page 150 If the temperature is 42°C (107.6°F) or more, leave the vehicle in a cool location and restart procedures after the ATF temperature has decreased. (5) Increase the oil temperature by idling the engine while checking the ATF temperature from the Subaru Select Monitor screen.
  • Page 151 Automatic Transmission Fluid PERIODIC MAINTENANCE SERVICES (5) Operate between N ← → D within 1.5 sec. for a continuous 6 sec. or more to switch to the oil amount adjustment mode. When the vehicle enters into oil amount adjustment mode, the upshift/downshift per- mitted indicator lights [ ]/[ ] in the combination meter light up simultaneously for 2 sec.
  • Page 152 Automatic Transmission Fluid PERIODIC MAINTENANCE SERVICES 3) Remove the overflow plug and check the oil amount when at the proper temperature for oil amount inspec- tion. • The oil amount is proper when fluid flows out of the overflow tube and then the flow of the fluid is thin. •...

  • Page 153: Differential Gear Oil

    Differential Gear Oil PERIODIC MAINTENANCE SERVICES 17.Differential Gear Oil A: INSPECTION 1. REAR DIFFERENTIAL Check for leakage of gear oil from the rear differential. B: REPLACEMENT 1. REAR DIFFERENTIAL CAUTION: • Gear oil is extremely hot just after driving. Be wary of receiving burns. •...
  • Page 154 Differential Gear Oil PERIODIC MAINTENANCE SERVICES 6) Install the filler plug. NOTE: Use a new gasket. Tightening torque: 49 N·m (5.0 kgf-m, 36.1 ft-lb) PM-78...

  • Page 155: Brake Line

    Brake Line PERIODIC MAINTENANCE SERVICES 18.Brake Line A: INSPECTION 1. BRAKE LINE 1) Check for scratches, swelling, corrosion, traces of fluid leakage on the brake hoses or pipe joints. 2) Make sure that brake pipes/hoses do not interfere with adjacent parts and there is no loose connector/ clamp during driving.

  • Page 156: Service Brake

    Brake Line PERIODIC MAINTENANCE SERVICES PM-00583 (A) Brake pipe (B) Rear brake hose (C) Clamp 2. SERVICE BRAKE 1) Move the brake pedal pads in a horizontal direction with a force of approx. 10 N (1 kgf, 2 lbf), and check that the pedal deflection is in the range of specifications.
  • Page 157 Brake Line PERIODIC MAINTENANCE SERVICES 2) Check the position of the pedal pad. Pedal height L: AT: 150 mm (5.90 in) MT: 145 mm (5.71 in) Brake pedal free play A: 0.2 — 2 mm (0.008 — 0.079 in) [When pushing the brake pedal with a force of less than 10 N (1 kgf, 2 lbf)] BR-00960 Switch - stop light...

  • Page 158: Brake Servo System

    Brake Line PERIODIC MAINTENANCE SERVICES 3. BRAKE SERVO SYSTEM 1) With the engine off, depress the brake pedal several times applying the same pedal force. Check that the travel distance should not change. 2) With the brake pedal depressed, start the engine. Check that the pedal moves slightly toward the floor. 3) With the brake pedal depressed, stop the engine and keep the pedal depressed for 30 seconds.
  • Page 159 Brake Fluid PERIODIC MAINTENANCE SERVICES 19.Brake Fluid A: INSPECTION 1) Check that the amount of brake fluid is between the lines of “MIN” and “MAX” from a straight view or within 90° to the right and left forward. If out of the specified range, refill with brake fluid or drain the fluid. If the brake fluid level is close to “MIN”, check the brake pad for wear and refill with brake fluid.

  • Page 160: Disc Brake Pad And Disc

    Disc Brake Pad and Disc PERIODIC MAINTENANCE SERVICES 20.Disc Brake Pad and Disc A: INSPECTION 1) Lift up the vehicle, and remove the wheels. 2) Visually check the pad thickness through inspection hole of disc brake assembly. Replace the pad if nec- essary.
  • Page 161 Disc Brake Pad and Disc PERIODIC MAINTENANCE SERVICES • Front Pad thickness mm (in) Standard 11 (0.43) Wear limit 1.5 (0.059) • Rear Pad thickness mm (in) Ventilated 11 (0.43) Standard Solid 9 (0.35) Ventilated 1.5 (0.059) Wear limit Solid 1.5 (0.059) 3) Check the disc rotor, and correct or replace if it is damaged or worn.

  • Page 162: Parking Brake

    Parking Brake PERIODIC MAINTENANCE SERVICES 21.Parking Brake A: INSPECTION 1) Measure the inner diameter of the rear disc rotor. If scoring or worn is found on the disc, replace the rear disc rotor. Disc rotor inner diameter: Specification: 190 mm (7.48 in) Service limit: 191 mm (7.52 in) 2) Measure the lining thickness.

  • Page 163: Lever Stroke

    Parking Brake PERIODIC MAINTENANCE SERVICES 2. LEVER STROKE 1) Adjust the parking shoe clearance before adjusting lever stroke. 2) Release the claws, and then remove the boot - parking brake. PM-00666 3) Pull the lever assembly - hand brake hard 3 to 5 times. 4) Turn the adjusting nut until the lever stroke is at the specified value.

  • Page 164: Front Suspension Ball Joint

    Suspension PERIODIC MAINTENANCE SERVICES 22.Suspension A: INSPECTION 1. FRONT SUSPENSION BALL JOINT 1) Lift up the vehicle until front wheels are off ground. 2) Grasp the bottom of tire and move it in and out in axial direction. If movement (B) is observed between the brake disc cover (A) and end of front arm (D), ball joint (C) may be excessively worn.

  • Page 165: Rear Suspension Ball Joint

    Suspension PERIODIC MAINTENANCE SERVICES 5) Damage of dust boots Visually inspect the ball joint dust boots. Replace if the front arm assembly is damaged. NOTE: When the front arm assembly is removed or replaced, check the toe-in of the front wheel. If it is not within the specified value, adjust the toe-in.

  • Page 166: Front, Rear Suspension Bushing

    Suspension PERIODIC MAINTENANCE SERVICES 6) Damage of dust boots Visually inspect the ball joint dust boots. Replace if front lateral link is damaged. 7) Check the upper arm ball joint and the pillow ball bushing of housing in the same manner. PM-00705 (A) Upper arm ball joint 3.
  • Page 167 Suspension PERIODIC MAINTENANCE SERVICES • Rear suspension bushing PM-00737 4. WHEEL ARCH HEIGHT Check the wheel arch height. 5. WHEEL ALIGNMENT Measure and adjust the front and rear wheel alignment at a time. 6. OIL LEAKAGE OF STRUT AND SHOCK ABSORBER Visually inspect the front strut and rear shock absorber for oil leakage.

  • Page 168: Front Wheel Bearing

    Wheel Bearing PERIODIC MAINTENANCE SERVICES 23.Wheel Bearing A: INSPECTION 1. FRONT WHEEL BEARING NOTE: Inspect the condition of front wheel bearing grease. 1) Jack-up the front side of vehicle. 2) While holding the front wheel by hand, swing it in and out to check bearing free play. 3) Loosen the wheel nuts, and remove the front wheel.
  • Page 169 Wheel Bearing PERIODIC MAINTENANCE SERVICES 6) While supporting rear drive shaft horizontally with one hand, turn the hub with the other hand to check for noise or binding. If the hub is noisy or binds, replace the rear axle. PM-00701 PM-93...

  • Page 170: Axle Boots & Joints

    Axle Boots & Joints PERIODIC MAINTENANCE SERVICES 24.Axle Boots & Joints A: INSPECTION 1. REAR AXLE BOOTS Inspect the rear axle boots (A) for deformation, damage or failure. If faulty, replace with new part. PM-00593 2. PROPELLER SHAFT Inspect the propeller shaft for damage or failure. If faulty, replace with new part. PM-94...

  • Page 171: Tire Inspection And Rotation

    Tire Inspection and Rotation PERIODIC MAINTENANCE SERVICES 25.Tire Inspection and Rotation A: INSPECTION 1) When the tread has worn to less than 1.6 mm (0.063 in) or the tread wear indicator appears across the tread, replace the tire. (Replace the right and left tire as a set.) PM-00080 (A) New tread (B) Damaged tread...

  • Page 172: Steering System (Power Steering)

    Steering System (Power Steering) PERIODIC MAINTENANCE SERVICES 26.Steering System (Power Steering) A: INSPECTION 1. STEERING WHEEL 1) Set the steering wheel in a straight-ahead position, and check the wheel spokes to make sure they are cor- rectly set in their specified positions. 2) Lightly turn the steering wheel to the left and right to determine the point where front wheels start to move.
  • Page 173 Steering System (Power Steering) PERIODIC MAINTENANCE SERVICES 3. GEARBOX 1) Set the steering wheel in the straight position, then rotate it 90° in both the left and right directions. While steering wheel is being rotated, check the looseness of the gearbox. Tightening torque: 120 N·m (12.2 kgf-m, 88.5 ft-lb) PM-00668...

  • Page 174: Gearbox Boots

    Steering System (Power Steering) PERIODIC MAINTENANCE SERVICES 2) Confirm that the connections of knuckle ball joints for play, and then check for damage on dust boots and free play of ball studs. If castle nut is loose, retighten it to the specified torque, then tighten further up to a maximum of 60°...
  • Page 175 A/C Filter PERIODIC MAINTENANCE SERVICES 27.A/C Filter 4) Remove the filter cover. A: REPLACEMENT 1) Open the glove box and remove the damper stay pin. PM-00672 5) Remove the filter and install a new filter. NOTE: Install with “UP” mark facing upwards. PM-00669 2) Press the glove box sidewall inwards and re- move the upper grommet.
  • Page 176 A/C Filter PERIODIC MAINTENANCE SERVICES PM-100...

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