Subaru Forester 2003 Service Manual
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Subaru Forester 2003 Service Manual

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See also: Owner's Manual
2003 Model Year
PDF Service Manual
GENERAL INFORMATION SECTION (Pub.No.G8070GE1)
ENGINE 1 SECTION (Pub.No.G8070GE2)
ENGINE 2 SECTION (Pub.No.G8070GE3)
TRANSMISSION SECTION (Pub.No.G8070GE4)
CHASSIS SECTION (Pub.No.G8070GE5)
BODY SECTION (Pub.No.G8070GE6)
WIRING SYSTEM SECTION (Pub.No.G8070GE7)

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  • Page 1 2003 Model Year PDF Service Manual GENERAL INFORMATION SECTION (Pub.No.G8070GE1) ENGINE 1 SECTION (Pub.No.G8070GE2) ENGINE 2 SECTION (Pub.No.G8070GE3) TRANSMISSION SECTION (Pub.No.G8070GE4) CHASSIS SECTION (Pub.No.G8070GE5) BODY SECTION (Pub.No.G8070GE6) WIRING SYSTEM SECTION (Pub.No.G8070GE7)
  • Page 3 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 5 FOREWORD Page Foreword .....................2...
  • Page 6 FOREWORD 1. Foreword A: FOREWORD These manuals are used when performing mainte- nance, repair, or diagnosis of the Subaru FOREST- Applied model: SG***** from 2003MY The manuals contain the latest information at the time of publication. Changes in specifications, methods, etc. may be made without notice.

  • Page 7: How To Use This Manuals

    HOW TO USE THIS MANUALS Page How to Use This Manuals ................2...
  • Page 8 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 9 HOW TO USE THIS MANUALS HOW TO USE THIS MANUALS 3. COMPONENTS Illustrations are listed for each component. The information necessary for repair work (tightening torque, grease up points, etc.) is described on these illustrations. Information is described using symbol. To order the parts, refer to parts catalogue.
  • Page 10 HOW TO USE THIS MANUALS HOW TO USE THIS MANUALS 4. SPECIFICATIONS If necessary, specifications are also included. 5. INSPECTION Inspections are included to be carried out before and after maintenance. 6. MAINTENANCE • Maintenance instructions for serviceable parts describes work area and detailed steps with illustration. It also describes the use of special tool, tightening torque, cautions for each procedure.
  • Page 11 HOW TO USE THIS MANUALS HOW TO USE THIS MANUALS 7. DIAGNOSIS Tables showing a step-by-step process make it easy to conduct diagnosis. 8. SI UNITS Measurements in these manuals are according to the SI units. Metric and yard/pound measurements are also included.
  • Page 12 HOW TO USE THIS MANUALS HOW TO USE THIS MANUALS HU-6...

  • Page 13: Specifications

    SPECIFICATIONS Page Forester.......................2...
  • Page 14 FORESTER SPECIFICATIONS 1. Forester A: DIMENSIONS Model 2.0L Non-turbo 2.0L Turbo 2.5L Non-turbo Overall length mm (in) 4,450 (175.2) Overall width mm (in) 1,735 (68.3) Overall height (at C.W.) mm (in) 1,590 (62.6) 1,585 (62.4) 1,590 (62.6) Compartment Length mm (in) 1,795 (70.7) Width mm (in)
  • Page 15 FORESTER SPECIFICATIONS C: ELECTRICAL Model 2.0L Non-turbo 2.0L Turbo 2.5L Non-turbo Ignition timing at BTDC/rpm MT: 10°±10°/650 10°±10°/650 12°±10°/700 idling speed AT: 15°±10°/650 Spark plug Type and manufacturer CHAMPION: RC10YC4 CHAMPION: RC10YC4 Alternate Alternate NGK: PFR6G CHAMPION: RC8YC4 CHAMPION: RC8YC4 NGK: BKR6E-11 NGK: BKR6E-11 DENSO: K20PR-U11...
  • Page 16 FORESTER SPECIFICATIONS G: BRAKE Model 2.0L Non-turbo, 2.5L Non-turbo 2.0L Turbo, 2.5L Non-turbo# Service brake system Dual circuit hydraulic with vacuum suspended power unit Front Ventilated disc brake Rear Drum brake Disc brake Parking brake Mechanical on rear brakes #: RHD model H: TIRE 15 ×...
  • Page 17 FORESTER SPECIFICATIONS J: WEIGHT 1. LHD MODEL Option code# Model 2.0L 2.5L 2.0X 2.5X Curb weight (C.W.) Front kgf (lb) (1,675) (1,710) (1,710) (1,740) (1,720) (1,765) Rear kgf (lb) (1,325) (1,325) (1,310) (1,310) (1,365) (1,365) Total kgf (lb) 1,360 1,375 1,370 1,385 1,400...
  • Page 18 FORESTER SPECIFICATIONS Option code# Model 2.0L 2.0XT Curb weight (C.W.) Front kgf (lb) (1,740) (1,785) (1,795) (1,840) Rear kgf (lb) (1,365) (1,365) (1,390) (1,390) Total kgf (lb) 1,410 1,430 1,445 1,465 (3,105) (3,150) (3,185) (3,230) Maximum permissi- Front kgf (lb) 1,010 1,010 1,010...
  • Page 19 FORESTER SPECIFICATIONS 2. RHD MODEL Option code# Model 2.0L 2.5L 2.0L 2.0X 2.5X 2.0XT Curb weight (C.W.) Front kgf (lb) (1,705) (1,740) (1,685) (1,730) (1,795) (1,840) Rear kgf (lb) (1,325) (1,325) (1,380) (1,380) (1,400) (1,400) Total kgf (lb) 1,375 1,390 1,390 1,410 1,450...
  • Page 20 FORESTER SPECIFICATIONS 3. OPTION Option Front kgf (lb) Rear kgf (lb) Total kgf (lb) Sport package base 0.1 (0.2) 0.4 (0.9) 0.5 (1.1) −6.5 (−14.3) −6.5 (−14.3) −13.0 (−28.6) Aluminum wheel 15 IN −7.3 (−16.1) −7.3 (−16.1) −14.6 (−32.2) 16 IN −0.1 (−0.2) Front fog light 0.7 (1.5)
  • Page 21 PRECAUTION Page Precaution ....................2...
  • Page 22 PRECAUTION PRECAUTION 1. Precaution 7. AIRBAG MODULE Adhere to the following when handing and storing A: PRECAUTION the airbag module to prevent bodily injury from un- Please clearly understand and adhere to the follow- expected deployment: ing general precautions. They must be strictly fol- •...
  • Page 23 NOTE Page Note......................2...
  • Page 24 ECM from rush current. 4. SERVICE PARTS Use authentic service parts for maximum perfor- mance and maintenance, when conducting repairs. Subaru/FHI will not be responsible for poor perfor- mance resulting from the use of parts not specified by a genuine dealer. NT-2...
  • Page 25 NOTE NOTE 5. LIFTS AND JACKS When using a lift or jack-ridged rack to raise a vehicle, always follow instructions concerning jack-up points and weight limits to prevent the vehicle from falling, which could result in injury. Be especially careful to make sure the vehicle is balanced before raising it.
  • Page 26 NOTE NOTE • Lift NT-00003 • Safety stand NT-00004 NT-4...
  • Page 27 NOTE NOTE • Jack-up point NT-00005 Front Rear NT-5...
  • Page 28 NOTE NOTE 6. TIE-DOWNS Tie-downs are used when transporting vehicles and when using the chassis dynamo. Attach tie-downs only to the specified points on the vehicle. NT-00006 Front Hook for towing and tie-down Hook for tie-down Rear NT-6...
  • Page 29 NOTE NOTE NT-00007 : (A) NT-00008 (A) Tie-down range 7. TOWING Avoid towing vehicles except when the vehicle can- not be driven. Use a loader instead of towing. When towing other vehicles, to prevent excessive weight from damaging the hook or vehicle: •...
  • Page 30 For information about training, contact a dealer or Using general scan tools will greatly improve effi- agent. ciency of repairing engine electronic controls. The Subaru Select Monitor can be used to diagnose the engine and also the ABS, the air conditioner, and other parts. NT-8...
  • Page 31 IDENTIFICATION Page Identification ....................2...
  • Page 32 IDENTIFICATION IDENTIFICATION 1. Identification A: IDENTIFICATION 1. IDENTIFICATION NUMBER AND LABEL LOCATIONS The VIN (Vehicle Identification Numbers) is used to classify the vehicle. Positioning of the plate label for identification Vacuum hose piping label Emission control label Vehicle identification number Saudi Arabia plate (Saudi Arabia model) Built date plate...
  • Page 33 IDENTIFICATION IDENTIFICATION ID-00016 Model number plate FUJI HEAVY INDUSTRIES LTD. J F 1 S G 5 L K 4 3 G 0 0 2 0 0 S G 5 A L 1 K option code applied model E J 2 0 1 NWU A A trim code engine type 2 3 0...
  • Page 34 IDENTIFICATION IDENTIFICATION 2. MEANING OF V.I.N. The meaning of the VIN is as follows: • Europe, Australia and General (Except GCC) ]JF1SG5LK43G002001[ The starting and ending brackets ( ][ ) are stop marks. Digits Code Meaning Details 1 to 3 Manufacturer body area JF1: Passenger car, FHI made JF2: MPV, FHI made Car line...
  • Page 35 IDENTIFICATION IDENTIFICATION 3. MODEL NUMBER PLATE The model number plate indicates: the applied model, the option code, the trim code, the engine type, the transmission type, and the exterior color code. This information is helpful when placing orders for parts. SG5AL1K Digits Code...
  • Page 36 IDENTIFICATION IDENTIFICATION • Transmission TY755XF3AA Digits Code Meaning Details Transmission T: Transmission Transmission type Y: Full-time AWD MT center differential Z: Full-time AWD AT MPT 3 and 4 Classification 75: MT 1A: AT Series 3: AT 5: MT Transmission specifica- V: Full-time AWD 5-speed MT with viscous coupling center dif- tions ferential single range...
  • Page 37 RECOMMENDED MATERIALS Page Recommended Materials ................2...
  • Page 38 RECOMMENDED MATERIALS RECOMMENDED MATERIALS 1. Recommended Materials poor operation of the engine and fuel injection sys- tem. Use the specified gasoline to correct perfor- A: RECOMMENDED MATERIALS mance. • Unleaded gasoline 1. GENERAL Use unleaded gasoline and not leaded gasoline in- To insure the best performance, always use the stalled to reduce air pollution.
  • Page 39 RECOMMENDED MATERIALS RECOMMENDED MATERIALS SAE viscosity No. and applicable temperature SAE J300 Engine oil –20 –10 (˚C) –30 –22 –4 (˚F) 10W-30 or 10W-40 5W-30 Recommend RM-00003 Manual transmission oil and rear differential –30 –20 –10 (˚F) –22 –4 (˚C) 75W-90 RM-00004 RM-3...
  • Page 40 Distilled water — Tap water (Soft water) 6. REFRIGERANT Standard air conditioners on Subaru vehicles use HFC134a refrigerant. Do not mix it with other refrigerants. Also, do not use any air compressor oil except for ZXL200PG. Air conditioner Recommended Item number...
  • Page 41 RECOMMENDED MATERIALS RECOMMENDED MATERIALS Grease Application point Recommended Item number Alternative Grease MT main shaft FX 2200 clutch grease 000040901 — Clutch master cylinder Slicolube G-40M 004404003 — push rod • Gear shift lever SUNLIGHT2 003602010 — • Select lever •...
  • Page 42 RECOMMENDED MATERIALS RECOMMENDED MATERIALS RM-6...
  • Page 43 PRE-DELIVERY INSPECTION Page Pre-delivery Inspection................2...
  • Page 44 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 1. Pre-delivery Inspection A: GENERAL The purposes of the pre-delivery inspection (PDI) are as follows. • Remove the additional parts used for ensuring the vehicle quality during transportation and restore the vehicle to its normal state. •...
  • Page 45 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION B: PDI PROCEDURE Follow the procedures shown in the table below. Static Checks Just After Vehicle Receipt Step Check point 1. Appearance check (1) If the vehicle is covered with protective coating, visually check the vehicle body for damage and dents.
  • Page 46 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION Checks with the Engine Running Step Check point 26. Test mode connectors (1) Test mode connectors 27. Starting condition (2) Start the engine and check that the engine starts smoothly. 28. Exhaust system (3) Check that the exhaust noise is normal and no leaks are found. 29.
  • Page 47 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 1. APPEARANCE CHECK 4. CONNECTION OF AIR CONDITIONER HARNESS 1) If the vehicle is covered with protective coating, visually check the vehicle body for damage and A vehicle just delivered has its air conditioner har- dents. ness disconnected to protect the air conditioner 2) If there is no protective coating, check the body compressor.
  • Page 48 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 2) Close the driver's door completely, and place the 4) Verify that all the doors including rear gate are door lock knob (A) to the lock position. Then pull in- not unlocked when pressing power door lock switch side door handles (B) to ensure that doors will not to unlock side.
  • Page 49 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION (2) Using a screwdriver, check the rear gate is 11.OPERATION CHECK OF HOOD LOCK lock/unlock. RELEASE SYSTEM Operate the hood release knob and check that the hood is unlocked normally. PI-00007 9. OPERATION CHECK OF FUEL LID PI-00071 OPENER LOCK RELEASE LEVER Operate the lever (A) and check that the hood is...
  • Page 50 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 12.BATTERY 15.TRANSMISSION FLUID Check the battery terminals to make sure that no Check the transmission fluid amount. If the amount rust or corrosions due to fluid leaks are found. is insufficient, check that no leaks are found. Then, Check that the battery caps are securely tightened.
  • Page 51 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 18.CLUTCH FLUID • Press the “LOCK” button on the transmitter once and check if all the doors are locked, and the haz- Check the clutch fluid amount. If the amount is in- ard light flashes once. sufficient, check that no leaks are found.
  • Page 52 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 22.SEAT 30.RADIO Check that each seat provides full functionality in Check the radio for full functionality and normal sliding and reclining. Check all available functions noise level. Also check the CD unit operations. of the rear seat. 31.CIGARETTE LIGHTER 23.SEAT BELT Check the cigarette lighter operations.
  • Page 53 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 35.POWER WINDOW OPERATION CHECK 42.ATF LEVEL Manipulate the power window switches one by one Check that the ATF level is normal. If insufficient, to check that each of the power windows goes up check that no leaks are found. Then add the neces- and down with no abnormal noises.
  • Page 54 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION • Close all windows completely, and then close all doors tightly. Close the hood before starting the test. • Connect a hose to a tap, and spray water on the vehicle. The rate of water discharge must be ap- prox.

  • Page 55: Table Of Contents

    PERIODIC MAINTENANCE SERVICES Page General Description ..................2 Schedule .....................3 Engine Oil....................6 Engine Oil Filter...................8 Spark Plugs....................9 Drive Belt(s) ....................10 Camshaft Drive Belt ..................12 Fuel Line ....................15 Fuel Filter ....................16 Air Cleaner Element ..................17 Cooling System ..................18 Coolant......................19 Clutch System ...................21 Transmission Oil ..................22 Hill-holder System ..................23 ATF ......................24...

  • Page 56: General Description

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

  • Page 57: Table Of Contents

    SCHEDULE PERIODIC MAINTENANCE SERVICES 2. Schedule A: MAINTENANCE SCHEDULE 1 1. FOR EUROPE AREA For periodic maintenance of over 120,000 km (75,000 miles) or 96 months, carry out inspection by referring to the following table. For a maintenance period gone beyond these tables, apply them repeatedly as a set of 120,000 km (75,000 miles) or 96 months.
  • Page 58 SCHEDULE PERIODIC MAINTENANCE SERVICES 2. EXCEPT FOR EUROPE AREA For periodic maintenance of over 50,000 km (30,000 miles) or 48 months, carry out inspections by referring to the following tables. For a maintenance period gone beyond these tables, apply them repeatedly as a set of 50,000 km (30,000 miles) or 48 months.
  • Page 59 SCHEDULE PERIODIC MAINTENANCE SERVICES B: MAINTENANCE SCHEDULE 2 Item Every Repeat short Repeat Extremely Salt or other High humid- Repeat tow- distance drive rough/muddy cold weather corrosive ity or moun- ing trailer road drive area used or tain area coastal area Engine oil Replace Replace...

  • Page 60: Engine Oil

    ENGINE OIL PERIODIC MAINTENANCE SERVICES 3. Engine Oil 4) Drain the engine oil by loosening engine oil drain plug. A: REPLACEMENT 1) Open the engine oil filler cap for quick draining of the engine oil. LU-00007 (A) Oil drain plug PM-00074 5) Replace the drain plug gasket.
  • Page 61 API classification and SAE viscosity No. designated by SUBARU. • If vehicle is used in desert areas with very high temperatures or for other heavy duty applications,...

  • Page 62: Engine Oil Filter

    ENGINE OIL FILTER PERIODIC MAINTENANCE SERVICES 4. Engine Oil Filter NOTE: The filter element and filter case are permanently A: REPLACEMENT joined; therefore, interior cleaning is not necessary. 1) Remove six clips. 8) Check the engine oil level. <Ref. to PI-3, PDI PROCEDURE, Pre-delivery Inspection.>...

  • Page 63: Spark Plugs

    SPARK PLUGS PERIODIC MAINTENANCE SERVICES 5. Spark Plugs A: REPLACEMENT 1) Remove the intake duct and intake chamber. 2) Remove the washer tank and put it aside. 3) Disconnect the spark plug cord. 4) Remove the spark plug with a plug-wrench. PM-00001 5) Set the new spark plug.
  • Page 64 DRIVE BELT(S) PERIODIC MAINTENANCE SERVICES 6. Drive Belt(s) B: REPLACEMENT A: INSPECTION 1. V-BELT COVER 1) Replace the belts, if cracks, fraying or wear is 1) Remove the V-belt cover. found. NON-TURBO MODEL 2) Check the drive belt tension and adjust it if nec- essary by changing the generator installing position and/or idler pulley installing position.
  • Page 65 DRIVE BELT(S) PERIODIC MAINTENANCE SERVICES 6) Tighten the slider bolt (B). Tightening torque: Lock bolt 25 N·m (2.5 kgf-m, 18 ft-lb) Slider bolt: 8 N·m (0.8 kgf-m, 5.8 ft-lb) PM-00004 3. REAR SIDE BELT (DRIVING AIR CONDI- TIONER) NOTE: Wipe off any oil or water on the belt and pulley. 1) Remove the front side belt.
  • Page 66 CAMSHAFT DRIVE BELT PERIODIC MAINTENANCE SERVICES 7. Camshaft Drive Belt 7) Remove the crankshaft pulley. 8) Remove the left side belt cover. A: REPLACEMENT 9) Remove the front timing belt cover. 10) Remove the timing belt guide. (MT vehicle 1. NON-TURBO MODEL only) 1) Remove the radiator fan and air conditioner fan.
  • Page 67 CAMSHAFT DRIVE BELT PERIODIC MAINTENANCE SERVICES 13) Remove the belt idler (No. 2). 6) Remove the crankshaft pulley. 7) Remove the air conditioning compressor drive belt tensioner. 8) Remove the belt cover (LH). 9) Remove the belt cover (RH). 10) Remove the front belt cover. 11) Turn the crankshaft and align alignment marks on crankshaft, and right and left camshaft sprock- ets with notches of belt cover and cylinder block.
  • Page 68 CAMSHAFT DRIVE BELT PERIODIC MAINTENANCE SERVICES 14) Remove the automatic belt tension adjuster as- pump pulley and cam sprocket to determine idler sembly. alignment (squareness). Replace the worn timing belt. 4) Install the timing belt cover (LH). PM-00096 15) Install in the reverse order of removal. <Ref. to PM-00097 ME(TURBO)-48, Timing Belt Assembly.>...

  • Page 69: Fuel Line

    FUEL LINE PERIODIC MAINTENANCE SERVICES 8. Fuel Line A: INSPECTION The fuel line is located mostly internally, so check pipes, areas near pipes, and engine compartment piping for rust, hose damage, loose bands, etc. If faulty parts are found, repair or replace them. <Ref. to FU(SOHC)-65, Fuel Delivery, Return and Evap- oration Lines.>...

  • Page 70: Fuel Filter

    FUEL FILTER PERIODIC MAINTENANCE SERVICES 9. Fuel Filter A: REPLACEMENT For fuel filter replacement procedures, refer to “FU” section. <Ref. to FU(SOHC)-62, Fuel Filter.> B: INSPECTION 1) If it is clogged, or if replacement interval has been reached, replace it. 2) If water is found in it, shake and expel the water from inlet port.

  • Page 71: Air Cleaner Element

    AIR CLEANER ELEMENT PERIODIC MAINTENANCE SERVICES 10.Air Cleaner Element 2. TURBO MODEL 1) Remove the clip (B) above the air cleaner case. A: REPLACEMENT 1. NON-TURBO MODEL 1) Remove the air intake duct from air cleaner case. 2) Remove the bolt (A) which installs air cleaner case to stays.

  • Page 72: Cooling System

    • When performing this check, be sure to keep the ator Cap.> engine stationary and fill the radiator with coolant. 4) Check the electric fan operates using Subaru • Wipe off check points before applying pressure. Select Monitor, when the coolant temperature ex- ceeds 95°C (203°F).
  • Page 73 NOTE: The SUBARU Genuine Coolant containing anti- freeze and anti-rust agents is especially made for SUBARU engine, which has an aluminum crank- case. Always use SUBARU Genuine Coolant, since other coolant may cause corrosion. 12) Securely install the radiator cap.
  • Page 74 The concentration and safe operating temperature tion in the above diagram and replace the of the SUBARU coolant is shown in the diagram. necessary amount of coolant with an undiluted so- Measuring the temperature and specific gravity of lution of SUBARU genuine coolant (concentration the coolant will provide this information.

  • Page 75: Clutch System

    CLUTCH SYSTEM PERIODIC MAINTENANCE SERVICES 13.Clutch System CAUTION: Prevent the clutch fluid from being splashed A: INSPECTION AND ADJUSTMENT over vehicle body. If the clutch fluid is splashed 1) Push the release lever to retract the push rod of over vehicle body, flush it, and then wipe it up. the operating cylinder and check if the fluid level in NOTE: the clutch reservoir tank rises or not.

  • Page 76: Transmission Oil

    TRANSMISSION OIL PERIODIC MAINTENANCE SERVICES 14.Transmission Oil A: REPLACEMENT 1. MANUAL TRANSMISSION 1) Drain the gear oil by removing drain plug after al- lowing the engine to cool for 3 to 4 hours. NOTE: • Before starting work, cool off the engine well. •...

  • Page 77: Hill-Holder System

    HILL-HOLDER SYSTEM PERIODIC MAINTENANCE SERVICES 15.Hill-holder System A: INSPECTION AND ADJUSTMENT 1) Confirm the stopping and starting performance by activating the hill-holder on an uphill road of 3° or higher inclination. (1) When the vehicle does not stop; Tighten the adjusting nut of PHV cable. (2) When the vehicle does not start properly;...
  • Page 78 3 to 4 hours. gine to raise ATF temperature to 60 — 80 °C (140 NOTE: — 176 °F) on Subaru Select Monitor. <Ref. to AT- Before starting work, cool off the engine well. 18, READ CURRENT DATA, OPERATION, Suba- ru Select Monitor.>...
  • Page 79 PERIODIC MAINTENANCE SERVICES 4) Check the ATF level. <Ref. to PM-24, INSPEC- TION, ATF.> PM-00033 (A) Level gauge (B) Hot side (C) Upper level (D) Lower level (E) Cold side (F) Upper level (G) Lower level 2. ATF FILTER NOTE: ATF filter is a maintenance free part.
  • Page 80 FRONT & REAR DIFFERENTIAL OIL PERIODIC MAINTENANCE SERVICES 17.Front & Rear Differential Oil Differential gear oil capacity: 1.1 — 1.3 2 (1.2 — 1.4 US qt, 1.0 — 1.1 lmp qt) A: REPLACEMENT 1. FRONT DIFFERENTIAL (MANUAL TRANSMISSION) For MT vehicle, manual transmission oil works as differential oil to lubricate differential.
  • Page 81 FRONT & REAR DIFFERENTIAL OIL PERIODIC MAINTENANCE SERVICES 2.0L NON-TURBO MODEL PM-00102 (A) Filler plug (B) Drain plug Oil capacity: 0.8 2 (0.8 US qt, 0.7 lmp qt) NOTE: Each oil manufacturer has its base oil and addi- tives. Thus, do not mix two or more brands. 5) Install the filler plug onto rear differential gear case firmly.
  • Page 82 BRAKE LINE PERIODIC MAINTENANCE SERVICES 18.Brake Line B: CHECKING A: INSPECTION 1. SERVICE BRAKE 1) Check the free play of brake pedal with a force of 1. BRAKE LINE less than 10 N (1 kgf, 2 lb). 1) Check scratches, swelling, corrosion, traces of Brake pedal free play: fluid leakage on the brake hoses or pipe joints.
  • Page 83 BRAKE LINE PERIODIC MAINTENANCE SERVICES (4) If there is no free play between clevis pin 4) Check to see if air is in the hydraulic brake line and clevis, turn the brake switch adjusting nut by the feel of pedal operation. If air appears to exist until the clearance between stopper and screw in the line, bleed it from the system.

  • Page 84: Brake Fluid

    BRAKE FLUID PERIODIC MAINTENANCE SERVICES 19.Brake Fluid • During the bleeding operation, keep the brake reservoir tank filled with brake fluid to eliminate en- A: REPLACEMENT try of air. 1) Either jack-up the vehicle and place a safety • The brake pedal operating must be very slow. stand under it, or lift-up the vehicle.

  • Page 85: Disc Brake Pads And Discs

    DISC BRAKE PADS AND DISCS PERIODIC MAINTENANCE SERVICES 20.Disc Brake Pads and Discs 3) Check the disc rotor, and correct or replace if it is damaged or worn. A: INSPECTION Brake disc thickness mm (in) 1. DISC BRAKE PAD AND DISC Front Rear Standard...
  • Page 86 BRAKE LININGS AND DRUMS PERIODIC MAINTENANCE SERVICES 21.Brake Linings and Drums If deformation or wear of back plate, shoe, etc. is noticeable, replace the affected parts. A: INSPECTION 1. REAR DRUM BRAKE 1) Remove the brake drum, and check that there is no fluid leakage from wheel cylinder.
  • Page 87 BRAKE LININGS AND DRUMS PERIODIC MAINTENANCE SERVICES 2) Check the disk rotor for wear, dents or other B: ADJUSTMENT damage. If the inside surface of disk rotor is 1. REAR DRUM BRAKE streaked, correct the surface with emery cloth (#200 or more). If it is unevenly worn or tapered, The main brake is adjusted automatically, and so correct or replace it.
  • Page 88 SUSPENSION PERIODIC MAINTENANCE SERVICES 22.Suspension If the front wheel toe-in is not at specified value, ad- just the toe-in. <Ref. to FS-7, Wheel Alignment.> A: INSPECTION 1. SUSPENSION BALL JOINT 1) Jack-up the vehicle until front wheels are off ground. 2) Next, grasp the bottom of tire and move it in and out.
  • Page 89 SUSPENSION PERIODIC MAINTENANCE SERVICES 4. WHEEL ALIGNMENT OF FRONT SUS- 7. TIGHTNESS OF BOLTS AND NUTS PENSION Check the bolts and nuts shown in the figure for looseness. Retighten the bolts and nuts to speci- 1) Check the alignment of front suspension to en- fied torque.

  • Page 90: Wheel Bearing

    WHEEL BEARING PERIODIC MAINTENANCE SERVICES 23.Wheel Bearing Service limit: Straight-ahead position within 0.05 mm A: INSPECTION (0.0020 in) 5) Remove the DOJ of rear drive shaft from rear dif- 1. FRONT WHEEL BEARING ferential. <Ref. to DS-37, Rear Drive Shaft.> NOTE: 6) While supporting the rear drive shaft horizontally Inspect the condition of front wheel bearing grease.

  • Page 91: Axle Boots & Joints

    AXLE BOOTS & JOINTS PERIODIC MAINTENANCE SERVICES 24.Axle Boots & Joints A: INSPECTION 1. FRONT AND REAR AXLE BOOTS Inspect the front axle boots (A) and rear axle boots (B) for deformation, damage or failure. If faulty, re- place them with new ones. <Ref. to DS-31, Front Drive Shaft.>...

  • Page 92: Tire Rotation

    TIRE ROTATION PERIODIC MAINTENANCE SERVICES 25.Tire Rotation A: INSPECTION 1) Replace the tire if the tread depth is less than 1.6 mm (0.063 in) or if wear indicators appear across the tire tread. (It is recommended that both right and left tires are replace as a set.) 2) Adjust the wheel alignment if abnormally uneven tire wear is found.
  • Page 93 STEERING SYSTEM (POWER STEERING) PERIODIC MAINTENANCE SERVICES 26.Steering System (Power 2. STEERING SHAFT JOINT Steering) 1) When the steering wheel free play is excessive, disconnect the universal joint of steering shaft and A: INSPECTION check it for any play and yawing torque (at the point of the crossing direction).
  • Page 94 STEERING SYSTEM (POWER STEERING) PERIODIC MAINTENANCE SERVICES (2) Retighten the adjusting screw to 7.4 N·m 3) Check the lock nut on tie-rod end for tightness. If (0.75 kgf-m, 5.4 ft-lb) and back off 25°. it is loose, retighten it to the specified torque. (3) Apply liquid packing to at least 1/3 of entire Tightening torque: perimeter of adjusting screw thread.
  • Page 95 STEERING SYSTEM (POWER STEERING) PERIODIC MAINTENANCE SERVICES 7. HOSES OF OIL PUMP FOR DAMAGES Check the pressure hose and return hose of oil pump for crack, swell or damage. Replace the hose with a new one if necessary. NOTE: Prevent the hoses from revolving and/or turning when installing hoses.

  • Page 96: Supplemental Restraint System

    SUPPLEMENTAL RESTRAINT SYSTEM PERIODIC MAINTENANCE SERVICES 27.Supplemental Restraint System A: INSPECTION Check the airbag system in accordance with the result of the self-diagnosis. <Ref. to AB-2, Basic Diagnostic Procedure.> 1) Ensure that airbag connectors are connected. If not, properly connect. When the ignition switch is turned ON with the connector(s) disconnected, the airbag warning light blinks to identify the fault.

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