Page 1 SECTION FOREWORD HOW TO USE THIS MANUAL 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 The manuals contain the latest information at the time of publication. Changes in the specifications, methods, etc. may be made without notice. NOTE: “SUBARU” means Fuji Heavy Industry Ltd. and its affiliates and subsidiaries. “SUBARU dealer” means an authorized SUBARU dealer and/or repairer.
Page 5: How To Use This Manual
HOW TO USE THIS MANUAL Page How to Use This Manual ................2...
Page 6: A: How To Use This Manual
How to Use This Manual HOW TO USE THIS MANUAL 1. How to Use This Manual A: HOW TO USE THIS MANUAL 1. STRUCTURE Each section consists of SCT that are broken down into SC that are divided into sections for each compo- nent.
Page 7 How to Use This Manual HOW TO USE THIS MANUAL 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 Manual HOW TO USE THIS MANUAL 4. DEFINITIONS OF “NOTE”, “CAUTION”, AND “WARNING” • NOTE: Describes additional information to make works easier. • CAUTION: Describes prohibited matters to prevent vehicle or parts damage, or matters that requires special attention during work.
Page 9: Maintenance
How to Use This Manual HOW TO USE THIS MANUAL 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 Manual HOW TO USE THIS MANUAL 9. SI UNITS Measurements in these manuals are according to the SI units. Metric and yard/pound measurements are also included. Example: Tightening torque: 44 N·m (4.5 kgf-m, 33 ft-lb) List of SI unit Item SI units Conventional unit...
Page 11: Explanation Of Terminology
How to Use This Manual HOW TO USE THIS MANUAL 10.EXPLANATION OF TERMINOLOGY List Engine 2ndr Secondary Electronic Gasoline Injection Air Assist Injection Exhaust Gas Recirculation Angular Adjusted Roller Emergency Locking Retractor Airbag Electronic Parking Brake Anti-lock Brake System Electronic Throttle Control Air Conditioner Exhaust Angular Contact...
Page 12 Read Only Memory Rear Subaru Diagnostic Interface Subaru Intelligent SOHC Single Overhead Camshaft Steering Responsive Headlight Supplemental Restraint System SRVD Subaru Rear Vehicle Detection Subaru Select Monitor Special Tool Standard Side View Monitor Switch Turbocharger Traction Control System Transmission Control Module...
Page 13: Specifications
SPECIFICATIONS Page BRZ ......................2...
Page 14 SPECIFICATIONS 1. BRZ A: DIMENSION Model 2.0 L DOHC non-turbo Overall length mm (in) 4,240 (166.9) Overall width mm (in) 1,775 (69.9) Overall height mm (in) 1,320 (52.0) Length mm (in) 1,615 (63.6) Compartment Width mm (in) 1,490 (58.7) Height mm (in) 1,060 (41.7) Wheelbase...
Page 15 SPECIFICATIONS D: TRANSMISSION 1. MT Model 2.0 L DOHC 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 4.300 6MT: 6-forward speeds and 1-reverse with synchromesh DSPD: Dry Single Plate Diaphragm : MT model for KA 2.
Page 16 SPECIFICATIONS G: BRAKE Model 2.0 L DOHC non-turbo 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 Model 2.0 L DOHC non-turbo 17 ×...
Page 17 SPECIFICATIONS J: WEIGHT LHD model 2 door Model BRZ Limited Transmission OP code 1,261 1,263 1,259 1,261 1,261 1,263 1,258 1,260 1,261 1,263 Total kg (lb) (2,781) (2,785) (2,776) (2,781) (2,781) (2,785) (2,774) (2,778) (2,781) (2,785) Curb weight Front kg (lb) (C.W.) (1,521) (1,524)
Page 18 SPECIFICATIONS 2 door Model BRZ Limited Transmission OP code 1,249 1,247 1,253 1,251 1,258 1,260 1,258 1,260 1,258 1,260 1,262 1,264 Total kg (lb) (2,754) (2,750) (2,763) (2,758) (2,774) (2,778) (2,774) (2,778) (2,774) (2,778) (2,783) (2,787) Curb weight Front kg (lb) (C.W.) (1,506) (1,504)
Page 19 SPECIFICATIONS 2 door Model BRZ Limited Transmission OP code 1,241 1,243 1,243 1,245 1,241 1,243 1,243 1,245 Total kg (lb) (2,736) (2,741) (2,741) (2,745) (2,736) (2,741) (2,741) (2,745) Curb weight Front kg (lb) (C.W.) (1,517) (1,519) (1,521) (1,524 (1,517) (1,519) (1,521) (1,524) Rear...
Page 20 SPECIFICATIONS 2 door Model BRZ Limited Transmission OP code 1,258 1,260 1,262 1,264 1,258 1,260 1,249 1,247 1,253 1,251 Total kg (lb) (2,774) (2,778) (2,783) (2,787) (2,774) (2,778) (2,754) (2,750) (2,763) (2,758) Curb weight Front kg (lb) (C.W.) (1,521) (1,524) (1,519) (1,521) (1,521)
Page 21 SPECIFICATIONS 2 door Model BRZ Limited Transmission OP code 1,284 1,286 1,282 1,284 1,284 1,286 1,280 1,282 1,283 1,285 1,280 1,282 Total kg (lb) (2,831) (2,836) (2,827) (2,831) (2,831) (2,836) (2,822) (2,827) (2,829) (2,833) (2,822) (2,827) Curb weight Front kg (lb) (C.W.) (1,568) (1,570)
Page 22 SPECIFICATIONS 2 door Model BRZ Limited Transmission OP code 1,264 1,266 1,266 1,268 1,264 1,266 1,266 1,268 1,280 1,282 Total kg (lb) (2,787) (2,792) (2,792) (2,796) (2,787) (2,792) (2,792) (2,796) (2,822) (2,827) Curb weight Front kg (lb) (C.W.) (1,561) (1,563) (1,566) (1,568) (1,561)
Page 23 SPECIFICATIONS 2 door Model BRZ Limited Transmission OP code 1,280 1,282 1,284 1,286 1,280 1,282 1,284 1,286 1,280 1,282 Total kg (lb) (2,822) (2,827) (2,831) (2,836) (2,822) (2,827) (2,831) (2,836) (2,822) (2,827) Curb weight Front kg (lb) (C.W.) (1,570) (1,572) (1,568) (1,570) (1,570)
Page 24 SPECIFICATIONS 2 door Model BRZ Limited Transmission OP code 1,272 1,270 1,276 1,274 1,272 1,270 1,276 1,274 Total kg (lb) (2,805) (2,800) (2,814) (2,809) (2,805) (2,800) (2,814) (2,809) Curb weight Front kg (lb) (C.W.) (1,552) (1,550) (1,550) (1,548) (1,552) (1,550) (1,550) (1,548) Rear...
Page 25 SPECIFICATIONS RHD model 2 door Model BRZ Limited Transmission OP code 1,242 1,244 1,244 1,246 1,258 1,260 1,242 1,244 1,244 1,246 1,258 1,260 Total kg (lb) (2,739) (2,743) (2,743) (2,747) (2,774) (2,778) (2,739) (2,743) (2,743) (2,747) (2,774) (2,778) Curb weight Front kg (lb) (C.W.)
Page 26 SPECIFICATIONS 2 door Model BRZ Limited Transmission OP code 1,258 1,260 1,258 1,260 1,256 1,258 1,240 1,242 1,256 Total kg (lb) (2,774) (2,778) (2,774) (2,778) (2,769) (2,774) (2,734) (2,739) (2,769) Curb weight Front kg (lb) (C.W.) (1,521) (1,524) (1,521) (1,524) (1,519) (1,521) (1,524)
Page 27 SPECIFICATIONS 2 door Model BRZ Limited Transmission OP code 1,258 1,260 1,242 1,244 1,258 1,260 1,262 1,264 Total kg (lb) (2,774) (2,778) (2,739) (2,743) (2,774) (2,778) (2,783) (2,787) Curb weight Front kg (lb) (C.W.) (1,524) (1,526) (1,528) (1,530) (1,524) (1,526) (1,521) (1,524) Rear...
Page 28 SPECIFICATIONS 2 door Model BRZ Limited Transmission OP code 1,265 1,267 1,267 1,269 1,280 1,282 1,265 1,267 1,267 1,269 Total kg (lb) (2,789) (2,794) (2,794) (2,798) (2,822) (2,827) (2,789) (2,794) (2,794) (2,798) Curb weight Front kg (lb) (C.W.) (1,561) (1,563) (1,566) (1,568) (1,566)
Page 29 SPECIFICATIONS 2 door Model BRZ Limited Transmission OP code 1,280 1,282 1,280 1,282 1,280 1,282 1,278 1,280 1,262 1,264 Total kg (lb) (2,822) (2,827) (2,822) (2,827) (2,822) (2,827) (2,818) (2,822) (2,783) (2,787) Curb weight Front kg (lb) (C.W.) (1,566) (1,568) (1,566) (1,568) (1,566)
Page 30 SPECIFICATIONS 2 door Model BRZ Limited Transmission OP code 1,280 1,282 1,264 1,266 1,278 1,280 1,282 1,284 1,286 Total kg (lb) (2,822) (2,827) (2,787) (2,792) (2,818) (2,822) (2,827) (2,831) (2,836) Curb weight Front kg (lb) (C.W.) (1,566) (1,568) (1,570) (1,572) (1,577) (1,566) (1,568)
Page 31 PRECAUTION Page Precaution ....................2...
Page 32 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 33: 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 34 Precaution PRECAUTION • If you keep using the hose, perform the in- spection below and replace the hose with a new part if faulty. • 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...
Page 35: 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 36 Precaution PRECAUTION PC-6...
Page 37 NOTE Page Note ......................2...
Page 38: 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 39: 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 40 Note NOTE B: NOTE This is the information that can improve the efficiency of maintenance and assure the sound work. 1. CAR WASH • Perform procedures in a clean location and take measures to protect from dust. • Before disassembly, clean all parts except for assembly parts with steam etc. When steam cleaning, use vinyl tape or similar material to plug up parts such as the air breather, oil level gauge and connectors so as to prevent steam from getting inside such parts.
Page 41 Note NOTE 6) When checking continuity between connector terminals, or measuring voltage across the terminal and ground, always touch tester probe(s) to terminals from the harness side. If the probe is too thick to gain access to the terminal, do not push it in forcibly but use a mini test lead. 7) When measuring the voltage or resistance of individual sensor or all electrical control modules, use a ta- pered pin with a diameter of 0.6 mm (0.024 in) or less and touch it to the tip of terminal.
Page 42: Immobilizer Related Part
9. SERVICE PARTS Use genuine parts for maximum performance and maintenance when conducting repairs. Subaru/FHI will not be responsible for poor performance resulting from the use of parts except for genuine parts. 10.PROTECTING VEHICLE UNDER MAINTENANCE Make sure to attach the fender cover, seat covers, etc.
Page 43: Support Locations
Note NOTE • Support locations NT-00526 Jack-up point • Pantograph jack NT-00459 Jack-up point NT-7...
Page 44 Note NOTE CAUTION: When storing the jack holder after use, store with the jack handle mount of the jack facing the inside of the trunk. NT-00522 (A) Jack • Lift CAUTION: • Depending on the type of the two-post lift, the spoiler assembly side may contact the arm. In such a case, use the attachment of the regular option for the two-post lift.
Page 45 Note NOTE • Rigid rack NT-00242 Attachment • Plate lift NT-00527 Jack-up point Attachment NT-9...
Page 46 Note NOTE • Jack-up point (When using a garage jack) 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-10035 Front Rear Frame...
Page 47: Tie-Down Location
Note NOTE • Tie-down location NT-00528 Hook for tie-down Tie-down hole • 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.
Page 48 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 49 Note NOTE For sea transportation CAUTION: The eyebolts 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 Eyebolt 400 mm (15.7 in)
Page 50 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 51 Note NOTE 14.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 52 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 nor- mally.
Page 53: 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 switch to “ACC” or “ON” position, and check that the steering wheel moves freely.
Page 54: Front Hood Stay
Installation position at full open 17.GENERAL SCAN TOOL Using general scan tools will greatly improve the efficiency of repairing engine electronic controls. Subaru Select Monitor can be used to diagnose the engine, vehicle dynamic control (VDC), air conditioner and other electrically controlled parts.
Page 55: Speedometer Test
Note NOTE 18.SPEEDOMETER TEST 1) Set the vehicle on speedometer tester. CAUTION: Fix the vehicle using a pulling metal (chain or wire) to the front and rear towing hooks or tie-down hook to prevent the lateral runout of the rear wheels and sudden jumping out of the vehicle. NT-00458 2) Conduct the speedometer test work.
Page 56 Note NOTE 20.ON THE CAR WHEEL BALANCING CAUTION: • Carry out the procedures after measuring the balance of each single tire. • Set the vehicle so that the front and rear wheels are the same height. • Make sure that the VDC is deactivated. •...
Page 57 IDENTIFICATION Page Identification ....................2...
Page 58 Identification IDENTIFICATION 1. Identification A: IDENTIFICATION 1. IDENTIFICATION NUMBER & LABEL LOCATIONS The V.I.N. (Vehicle Identification Number) is used to classify the vehicle. • Positioning of the label for identification ID-10018 Plate compliance (for KA) ID label, Model No. label Plate V.I.N.
Page 59 Identification IDENTIFICATION • Engine • Rear differential ID-00384 ID-00398 (1) Engine serial number (punch mark) (1) Identification (2) Engine type (casting) crankcase upper side • Label ID, label model No. Europe (EC, E2, EK, ER, EP) • Automatic transmission ID-00416 ID-10001 (1) Label ID (1) Transmission serial No.
Page 60 Identification IDENTIFICATION • Label Saudi, label model No. • Plate compliance GCC countries (KS, KR) Australia (KA) ID-00344 ID-00231 • Plate V.I.N. (1) Label Saudi All models (2) Label model No. • Label model No. General (K4, E3, E1, K8, K2, KF, EN, E9, KY) ID-00365 •...
Page 61 Identification IDENTIFICATION 2. MEANING OF V.I.N. The meaning of the V.I.N. is as follows: • Europe/General (except for KS, KR, EH, ET models) ]JF1ZC6L71HG002001[ The starting and ending brackets ( ] [ ) are stop marks. Digits Code Meaning Details 1 —...
Page 62: Model Number Label
Identification IDENTIFICATION 3. MODEL NUMBER LABEL The model number label 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. •...
Page 63 Identification IDENTIFICATION • China national stage 4 emission standard (EH) (2) ZC6F81H Digits Code Meaning Details Series Z: BRZ Body type C: COUPE Total engine displace- 6: 2.0 L FR ment / drive system Grade F: BRZ Limited Fuel feed system / 7: DOHC MFI+DI 6AT transmission 8: DOHC MFI+DI 6MT...
Page 64 Identification IDENTIFICATION • Transmission 1. MT 82 (MT ID label) Digits Code Meaning Details 1 — 2 MT model classification 82: TL701VD50A TL701VD50A 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 65 Identification IDENTIFICATION • Option code 1-digit number 17-inch summer tire — 17-inch 7.5J summer tire — — — — — Brand brake — — — — — High µ pad brake — — — — — Large diameter brake 16-V —...
Page 66 Identification IDENTIFICATION ID-10...
Page 67: Recommended Materials
RECOMMENDED MATERIALS Page Recommended Materials ................2...
Page 68: 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 Always use gasoline of the same or higher octane value than specified in the owner’s manual. Ignoring the specifications will result in damage or poor performance of engine and fuel injection system.
Page 69 Recommended Materials RECOMMENDED MATERIALS 3. LUBRICANTS Use the lubricants shown in the table below, or equivalent. See the table below to choose the correct SAE viscosity. Recommended materials Lubricant Engine oil standard Engine oil Choose oil suitable for the standard from the right.
Page 70: Engine Coolant
Use genuine engine coolant to protect the engine. Engine coolant Recommended materials Item number Alternative Coolant SUBARU SUPER COOLANT K0670Y0001 Non-amine type* * When using alternative engine coolant, follow the instructions of the engine coolant for its diluting water, maintenance cycle, freezing concentration, etc. 6. REFRIGERANT Standard air conditioners on this vehicle use two kinds of refrigerant depending on the specification of the air conditioner.
Page 71 Recommended Materials RECOMMENDED MATERIALS 7. GREASE Use grease and supplementary lubricants shown in the table below. Application Recommended materials Grease Application point Alternative point (Item number) Supplemen- Spray type lubricant tary lubri- Exhaust Oxygen sensor — (004301003) cants MT main shaft (spline parts) Clutch release fork sub-assembly Clutch release bearing (inner circumference) NICHIMOLY N-130...
Page 72: Seal Material
Recommended Materials RECOMMENDED MATERIALS 8. ADHESIVE Use the adhesives shown in the table below, or an alternative. Adhesive Application point Application point Recommended materials Alternative • Dow Automotive’s adhesive: Windshield glass, rear window Gurit-ESSEX Betaseal 1502 or equivalent glass, rear quarter glass and —...
Page 73: Pre-Delivery Inspection
PRE-DELIVERY INSPECTION Page Pre-delivery Inspection ................2...
Page 74: A: General Description
• Make sure to provide a complete vehicle to customer. For above reasons, all SUBARU dealer must carry out the PDIs before delivery of vehicle. Besides, all SUBARU dealer and PDI center check the condition of all vehicles to make sure to take respon- sibility.
Page 75: Checks With The Engine Running
Pre-delivery Inspection PRE-DELIVERY INSPECTION Item Check point 21. Keyless entry system Check that the keyless entry system operates normally. 22. Keyless access system Check that the keyless access system operates normally. 23. Seat 1. Check the seat surfaces for stains or dirt. 2.
Page 76: Fuse Installation
Pre-delivery Inspection PRE-DELIVERY INSPECTION Checks after Dynamic Test Item Check point 55. Cruise control Check that the cruise control system operates normally. 56. Power steering system Check the steering warning light operation. 57. Fluid leakage Check for fluid/oil leaks. 58. Water leakage Spray the vehicle with water and check for water leaks.
Page 77: Double Lock
Pre-delivery Inspection PRE-DELIVERY INSPECTION 2) Completely close the driver’s door, and then 5. DOUBLE LOCK check the smooth movement with operating door 1) Fully open all windows. lock knob from lock to unlock several times. Set the 2) Lock the doors using the mechanical key or ac- door lock knob (A) to lock position.
Page 78 Pre-delivery Inspection PRE-DELIVERY INSPECTION 2) Store the towing hook (eyebolt) to the holder in the trunk. (Clean any dirt that is present.) PI-00756 (A) Jack handle PI-00942 Models with spare tire (A) Towing hook (eyebolt) (B) Jack 3) Install the supplied rear hook cover to rear bumper.
Page 79 Pre-delivery Inspection PRE-DELIVERY INSPECTION 10.FRONT HOOD LOCK RELEASE SYSTEM 12.BRAKE FLUID Operate the front hood lock release lever to check CAUTION: that the front hood is unlocked normally. If the brake fluid is spilt over exhaust pipe, wipe it off with cloth to avoid emitting smoke or causing a fire.
Page 80 Pre-delivery Inspection PRE-DELIVERY INSPECTION 6) After turning off the engine, wait five minutes or 16.REAR DIFFERENTIAL GEAR OIL more for the oil to return to the oil pan before check- CAUTION: ing the oil level. If the rear differential gear oil is spilt over ex- NOTE: haust pipe, wipe it off with cloth to avoid emit- To prevent overfilling of engine oil, do not add oil...
Page 81: Window Washer Fluid
NOTE: 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. 1) Fully open all the door windows. 2) Close all doors.
Page 82 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 83: Grommet Installation
Pre-delivery Inspection PRE-DELIVERY INSPECTION 24.SEAT BELT 26.GROMMET INSTALLATION 1) Check installation condition of seat belt. Install the grommet contained in the glove box to the tie-down hole. 2) Pull out the seat belt and then release it. Check that the belt retracts smoothly. CAUTION: 3) Check seat belt warning function Securely install the grommet to ensure that the...
Page 84 Pre-delivery Inspection PRE-DELIVERY INSPECTION 5) Make sure that the malfunction indicator light is 5) With the vehicle stopped, the engine running off. If the malfunction indicator light blinks, carry out and shift lever in N range, check that the engine an engine diagnosis.
Page 85 Pre-delivery Inspection PRE-DELIVERY INSPECTION 37.AIR CONDITIONER Operate the air conditioner. Check that the A/C compressor operates normally and enough cooling is provided. NOTE: To prevent the insufficient lubrication of the air con- ditioner, operate the air conditioner for five minutes at idling.
Page 86: Window Washer System
Pre-delivery Inspection PRE-DELIVERY INSPECTION 44.WINDOW WASHER SYSTEM Check that the window washer system injects washer fluid to the specified area of the windshield shown in the figure. Front injection position: • LHD model PI-00794 Washer nozzle 660 mm (25.98 in) 684 mm (26.93 in) 247 mm (9.72 in) 232 mm (9.13 in)
Page 87 Pre-delivery Inspection PRE-DELIVERY INSPECTION • RHD model PI-00793 Washer nozzle 684 mm (26.93 in) 660 mm (25.98 in) 232 mm (9.13 in) 247 mm (9.72 in) 250 mm (9.84 in) 268 mm (10.55 in) 299 mm (11.77 in) 253 mm (9.96 in) 250 mm (9.84 in) 300 mm (11.81 in) PI-15...
Page 88 Pre-delivery Inspection PRE-DELIVERY INSPECTION 45.HEADLIGHT WASHER 52.DIAGNOSTIC TROUBLE CODE (DTC) CHECK For models with headlight washer, turn the ignition switch and headlight switch to ON, and confirm that Read the diagnostic trouble code and check that the headlight washer operates with front wiper the diagnostic trouble code is not detected.
Page 89: Cruise Control
Pre-delivery Inspection PRE-DELIVERY INSPECTION • MT If any dampness in the compartments is discovered after the water has been applied, carefully check all 1) Check for smooth operation to each position. the areas that may have possibly contributed to the 2) Check that the lever cannot be moved to the re- leak.
Page 90 Pre-delivery Inspection PRE-DELIVERY INSPECTION 4) Check each portion of the vehicle body and un- derside components for the formation of rust. If rust is discovered, remove it with sandpaper of #80 to #180 and treat the surface with rust preventive. Af- ter this treatment is completed, flush the portion thoroughly, and prepare the surface for repair painting.
Page 91 PERIODIC MAINTENANCE SERVICES Page General Description ...................2 Schedule ....................3 Engine Oil ....................6 Engine Oil Filter ..................9 Spark Plug ....................10 V-belt ......................27 Fuel Line ....................31 Fuel Filter ....................32 Air Cleaner Element .................56 Cooling System ..................58 Engine Coolant ..................59 Clutch System ..................62 Transmission Gear Oil ................67 Automatic Transmission Fluid ..............68 Differential Gear Oil ..................75...
Page 92 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 93 Schedule PERIODIC MAINTENANCE SERVICES 2. Schedule A: MAINTENANCE SCHEDULE 1 For periodic maintenance of below 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 94 Schedule PERIODIC MAINTENANCE SERVICES Symbols used: R: Replace I: Inspection P: Perform (I): Recommended service for safe vehicle operation NOTE: 1. When the vehicle is used under severe condition, the oil and the oil filter should be replaced more often. 2.
Page 95 Schedule PERIODIC MAINTENANCE SERVICES B: MAINTENANCE SCHEDULE 2 Salt or other Maintenance Repeat short Repeat rough/ Extremely cold High humidity or Item corrosive used interval distance drive muddy road drive weather area mountain area or coastal area Engine oil Replace more Replace more frequently.
Page 96: 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 97 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 98 Engine Oil PERIODIC MAINTENANCE SERVICES 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 99: 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 100: 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 101 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 102 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-12...
Page 103 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-13...
Page 104 Spark Plug PERIODIC MAINTENANCE SERVICES 13) Remove the two nuts, two bolts and two compression springs to disconnect the exhaust pipe assembly CTR. PM-00642 14) Remove the bolt to remove the exhaust pipe assembly FR. PM-00643 PM-14...
Page 105 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-15...
Page 106 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 107 Spark Plug PERIODIC MAINTENANCE SERVICES 20) Remove clip (A) holding the battery cable to the intake manifold protector RH, clip (B) holding the gen- erator cable to the intake manifold protector RH, and clip (C) holding the generator cable to the fuse box. PM-00648 21) Release the clips, and disconnect the engine wiring.
Page 108 Spark Plug PERIODIC MAINTENANCE SERVICES 22) Remove the bolt securing the harness stay from the intake manifold protector LH, and the two clips se- curing the battery cable from the intake manifold. (LHD AT model and RHD model) PM-00675 23) Remove the hose bracket clamp from clutch pipe. (RHD, MT model) PM-00650 PM-18...
Page 109 Spark Plug PERIODIC MAINTENANCE SERVICES 24) Remove the bolt securing the clutch hose bracket (B) to the clutch hose bracket (A), and move the clutch hose bracket (B) to the left side of the vehicle. (RHD, MT model) PM-00651 25) 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.
Page 110 Spark Plug PERIODIC MAINTENANCE SERVICES 26) Remove the clip securing the bulkhead harness to the vehicle. • Left Hand PM-00653 • Right Hand PM-00654 PM-20...
Page 111 Spark Plug PERIODIC MAINTENANCE SERVICES 27) 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 112 Spark Plug PERIODIC MAINTENANCE SERVICES 30) Install the ST between the engine mount and crossmember. ST 18632AA020 STAND ASSY PM-10010 31) Lower the vehicle. 32) Rotate the handle on the top of the ST counterclockwise to slowly lower the engine. 33) Remove the ST (ENGINE HANGER) from the vehicle.
Page 113 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-23...
Page 114 Spark Plug PERIODIC MAINTENANCE SERVICES 35) 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-24...
Page 115 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-25...
Page 116: 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 117 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 118 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, then remove the V-belt cover LH.
Page 119 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 120 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 121 Fuel Line PERIODIC MAINTENANCE SERVICES 7. 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. PM-31...
Page 122: Fuel Filter
Fuel Filter PERIODIC MAINTENANCE SERVICES 8. 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 123 Fuel Filter PERIODIC MAINTENANCE SERVICES 2) Remove the fuel pump fuse from the engine room relay block. PM-00680 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 124 • Be careful not to spill fuel. • Catch the fuel from fuel hoses using a container. PM-00681 (2) Insert the end of the hose into the container. (3) Drive the fuel pump and drain the fuel using Subaru Select Monitor. PM-34...
Page 125 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 126 Fuel Filter PERIODIC MAINTENANCE SERVICES (4) Remove the four cushion rubbers and the exhaust tail pipe assembly. PM-10009 (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 127 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 128 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 19) Using the ST, loosen the fuel pump gauge retainer. ST 42099CA000 ST FUEL PUMP PM-38...
Page 129 Fuel Filter PERIODIC MAINTENANCE SERVICES CAUTION: • Do not use any tool other than the ST. • Be careful not to damage the tube with the ST. • Before setting the ST, move the tube to a position outside the ST. NOTE: Securely set the ST notch onto the rib part of the fuel pump gauge retainer.
Page 130 Fuel Filter PERIODIC MAINTENANCE SERVICES 23) Disconnect the fuel sender gauge connector and remove the harness from the clamp. PM-00689 PM-00740 PM-40...
Page 131 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 132 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 133 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-43...
Page 134 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-44...
Page 135 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-45...
Page 136 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-46...
Page 137 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 138 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-48...
Page 139 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 140 Fuel Filter PERIODIC MAINTENANCE SERVICES 43) Engage the tab, and install the jet pump nozzle to the fuel sub tank. PM-00613 44) Install a new E-ring. PM-00614 PM-50...
Page 141 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 142 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 143 Fuel Filter PERIODIC MAINTENANCE SERVICES 51) Insert the fuel suction tube assembly (with pump & gauge) into the fuel tank, and install the fuel suction tube assembly to which a new gasket was installed to the fuel tank. CAUTION: Check the entire circumference of the gasket and make sure that it is not curled or displaced when installing the gasket to the fuel tank.
Page 144 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 145 61) Connect the ground cable to battery. 62) Apply fuel pressure and check that there are no leaks in the fuel system using the Subaru Select Monitor. 63) Install rear floor service hole cover No. 2 using new butyl tape.
Page 146: Air Cleaner Element
Air Cleaner Element PERIODIC MAINTENANCE SERVICES 9. 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 147 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 148: Cooling System
Cooling System PERIODIC MAINTENANCE SERVICES 10.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 149: Engine Coolant
Engine Coolant PERIODIC MAINTENANCE SERVICES 11.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 150 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 151 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 152: Clutch System
Clutch System PERIODIC MAINTENANCE SERVICES 12.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 153 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 154 Clutch System PERIODIC MAINTENANCE SERVICES 3) Rotate the push rod to adjust. PM-00722 In the longer direction 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 155 Clutch System PERIODIC MAINTENANCE SERVICES 8) Turn further in the direction that will shorten the push rod by 270°. PM-00722 In the longer direction 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 156 Clutch System PERIODIC MAINTENANCE SERVICES 13) Push the release lever until the release 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 157: Transmission Gear Oil
Transmission Gear Oil PERIODIC MAINTENANCE SERVICES 13.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 158: Automatic Transmission Fluid
Automatic Transmission Fluid PERIODIC MAINTENANCE SERVICES 14.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 159 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 160 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 161 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 162 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 163 Automatic Transmission Fluid PERIODIC MAINTENANCE SERVICES 2) When shorting TC terminal circuit (1) Short the data link connectors No. 13 and No. 4. PM-00630 (2) Start the engine. (3) Turn off all parts effecting an electrical load such as air conditioner, audio and lights. (4) Operate the select lever in P →...
Page 164 Automatic Transmission Fluid PERIODIC MAINTENANCE SERVICES (9) Adjust the oil as soon as the proper temperature for oil amount adjustment is reached. CAUTION: Always be sure to adjust the ATF when at the proper temperature. Lower than proper temperature Proper temperature Higher than proper temperature ] and [ ] indicator lamps are illumi-...
Page 165: Differential Gear Oil
Differential Gear Oil PERIODIC MAINTENANCE SERVICES 15.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 166: Brake Line
Brake Line PERIODIC MAINTENANCE SERVICES 16.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 167: Service Brake
Brake Line PERIODIC MAINTENANCE SERVICES 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. CAUTION: If excessive deflection is noted, replace with a new bushing.
Page 168 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: 0.5 — 2.7 mm (0.020 — 0.106 in) [When pushing the brake pedal with a force of less than 10 N (1 kgf, 2 lbf)] BR-00960 Switch - stop light...
Page 169: 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 170: Brake Fluid
Brake Fluid PERIODIC MAINTENANCE SERVICES 17.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 171: Disc Brake Pad And Disc
Disc Brake Pad and Disc PERIODIC MAINTENANCE SERVICES 18.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 172 Disc Brake Pad and Disc PERIODIC MAINTENANCE SERVICES • Front Pad thickness mm (in) Normal type 11 (0.43) Standard Brembo type 8.9 (0.35) Normal type 1.5 (0.059) Wear limit Brembo type 1.2 (0.047) • Rear Pad thickness mm (in) Ventilated (except for brembo-type) 11 (0.43) Standard Ventilated (brembo-type)
Page 173 Disc Brake Pad and Disc PERIODIC MAINTENANCE SERVICES 6) Set a dial gauge at a point of 10 mm (0.39 in) or less from outer periphery of the rotor, and then measure the disc rotor runout. Disc rotor runout limit: Front: Normal type: 0.050 mm (0.0020 in) Brembo type: 0.075 mm (0.0030 in)
Page 174: Parking Brake
Parking Brake PERIODIC MAINTENANCE SERVICES 19.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 175: 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 176: Front Suspension Ball Joint
Suspension PERIODIC MAINTENANCE SERVICES 20.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 177: 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 178: 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 Upper arm ball joint 3.
Page 179 Suspension PERIODIC MAINTENANCE SERVICES • Rear suspension bushing PM-10006 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 180: Front Wheel Bearing
Wheel Bearing PERIODIC MAINTENANCE SERVICES 21.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 181: Rear Wheel Bearing
Wheel Bearing PERIODIC MAINTENANCE SERVICES 2. REAR WHEEL BEARING 1) Jack-up the rear side of vehicle. 2) While holding the rear wheel by hand, swing it in and out to check bearing free play. 3) Loosen the wheel nuts, and remove the rear wheel. 4) If the bearing free play exists in step 2) above, attach a dial gauge to the hub and measure axial play in axial direction.
Page 182: Axle Boots & Joints
Axle Boots & Joints PERIODIC MAINTENANCE SERVICES 22.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-92...
Page 183: Tire Inspection And Rotation
Tire Inspection and Rotation PERIODIC MAINTENANCE SERVICES 23.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 184: Steering System (Power Steering)
Steering System (Power Steering) PERIODIC MAINTENANCE SERVICES 24.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 185 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 186: 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 187 A/C Filter PERIODIC MAINTENANCE SERVICES 25.A/C Filter A: REPLACEMENT 1) Open the glove box and remove the damper stay pin. PM-00669 2) Press the glove box sidewall inwards and remove the upper grommet. PM-00670 PM-97...
Page 188 A/C Filter PERIODIC MAINTENANCE SERVICES 3) Open the glove box to the position where the claw of the hinge can be removed easily and then remove it by pulling toward. CAUTION: • Do not remove it forcibly except when the rotation axis and the claw of the hinge can be properly separated.
Page 189 A/C Filter PERIODIC MAINTENANCE SERVICES 5) Remove the filter and install a new filter. NOTE: Install with “UP” mark facing upwards. PM-00673 6) Install in the reverse order of removal. PM-99...
Page 190 A/C Filter PERIODIC MAINTENANCE SERVICES PM-100...

Subaru BRZ 2016 Service Manual

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