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Subaru 2001 IMPREZA Service Manual

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2001 IMPREZA SERVICE MANUAL
GENERAL INFOMATION
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
G1830GE1

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  • Page 1 2001 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX GENERAL INFOMATION SECTION FOREWORD HOW TO USE THIS MANUALS SPECIFICATIONS PRECAUTION This service manual has been prepared to provide SUBARU service personnel NOTE with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
  • Page 3 FOREWORD Page Foreword .....................2...
  • Page 4 FOREWORD 1. Foreword A: FOREWORD These manuals are used when performing mainte- nance, repair, or diagnosis of the Subaru IMPRE- Applied model: GG***** and GD***** from 2001MY. The additional manuals below are also available: AUTOMATIC TRANSMISSION SERVICE MANU- AL (Pub. No. G0853ZE) The manuals contain the latest information at the time of publication.

  • Page 5: How To Use This Manuals

    HOW TO USE THIS MANUALS Page How to Use This Manuals ................2...
  • Page 6 HOW TO USE THIS MANUALS HOW TO USE THIS MANUALS 1. How to Use This Manuals A: HOW TO USE THIS MANUALS 1. STRUCTURE Each section consists of SCT that are broken down into SC that are divided into sections for each com- ponent.

  • Page 7: Specifications

    SPECIFICATIONS Page Impreza .......................2...
  • Page 8 IMPREZA SPECIFICATIONS 1. Impreza A: DIMENSIONS Model Sedan Wagon OUTBACK Overall length mm (in) 4,405 (173.4) Overall width mm (in) 1,730 (68.1) 1,695 (66.7) 1,710 (67.3) Overall height (at CW) mm (in) 1,465 (57.7), 1,475 (58.1), 1,440 (56.7) 1,485 (58.5) 4 1,495 (58.9) 4 Compartment Length...
  • Page 9 IMPREZA SPECIFICATIONS C: ELECTRICAL Model 1.6 L Non Turbo 2.0 L Turbo 2.0 L Ignition timing at idling speed BTDC/rpm 5°±10°/700 10°±10°/700 12°±10°/750 Spark plug Type and manu- Without OBD NGK: BKR6E (without catalyst) facturer CHAMPION: RC10YC4 (with catalyst) — NGK: BKR5E-11 (with catalyst) With OBD RC10YC4 ..
  • Page 10 IMPREZA SPECIFICATIONS Model 1.6 L Non Turbo 2.0 L Turbo 2.0 L Transmission type 5MT 1 5MT 1 4AT 2 5MT 1 Clutch type DSPD DSPD DSPD Gear ratio 3.454 3.454 2.785 3.454 2.062 2.062 1.545 1.947 1.448 1.448 1.000 1.336 1.088 1.088...
  • Page 11 IMPREZA SPECIFICATIONS I: CAPACITY Model 1.6 L 2 (US gal, Imp gal) Fuel tank 50 (13.2, 11.0) 2 (US qt, Imp qt) Engine oil Upper level 4.0 (4.2, 3.5) 2 (US qt, Imp qt) Lower level 3.0 (3.2, 2.6) 2 (US qt, Imp qt) Transmission gear oil 3.3 (3.5, 2.9) —...
  • Page 12 IMPREZA SPECIFICATIONS J: WEIGHT 1. EUROPE SPEC. VEHICLE Sedan Model 1.6 L BASE 5MT 1 4AT 1 5MT 1 4AT 1 Curb weight (C.W.) Front kgf (lb) 715 (1,576) 760 (1,676) 715 (1,576) 760 (1,676) Rear kgf (lb) 470 (1,036) 470 (1,036) 470 (1,036) 470 (1,036)
  • Page 13 IMPREZA SPECIFICATIONS Wagon Model 1.6 L BASE 5MT 1 4AT 4 5MT 1 4AT 1 Curb weight (C.W.) Front kgf (lb) 710 (1,565) 765 (1,687) 710 (1,565) 760 (1,676) Rear kgf (lb) 490 (1,080) 495 (1,091) 490 (1,080) 490 (1,080) Total kgf (lb) 1,200 (2,646)
  • Page 14 IMPREZA SPECIFICATIONS Model 2.0 L 5MT 3 5MT 4 Curb weight (C.W.) Front kgf (lb) 805 (1,775) 765 (1,687) Rear kgf (lb) 585 (1,290) 570 (1,257) Total kgf (lb) 1,390 (3,064) 1,335 (2,943) Maximum permissible Front kgf (lb) 970 (2,138) 970 (2,138) axle weight (M.P .A.W.) Rear...
  • Page 15 IMPREZA SPECIFICATIONS 2. AUSTRALIA SPEC. VEHICLE Sedan Model 2.0 L 5MT 2 Curb weight (C.W.) Front kgf (lb) 750 (1,653) 775 (1,709) 830 (1,830) Rear kgf (lb) 535 (1,179) 530 (1,168) 560 (1,235) Total kgf (lb) 1,285 (2,833) 1,305 (2,877) 1,390 (3,064) Maximum permissible Front...
  • Page 16 IMPREZA SPECIFICATIONS 3. OTHERS Sedan Model 1.6 L 2.0 L BASE 4AT 1 Curb weight (C.W.) Front kgf (lb) 705 (1,554) 750 (1,653) 740 (1,631) 750 (1,653) 780 (1,720) Rear kgf (lb) 485 (1,069) 485 (1,069) 535 (1,179) 545 (1,202) 540 (1,191) Total kgf (lb)
  • Page 17 PRECAUTION Page Precaution ....................2...
  • Page 18 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 19 NOTE Page Note......................2...
  • Page 20 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 21 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 22 NOTE NOTE Front Front cross member Rear Rear differential GI0121 NT-4...
  • Page 23 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. Hook for tie-down Hook for towing Hook for tie-down Hook for towing and tie-down GI0122 NT-5...
  • Page 24 9. GENERAL SCAN TOOL Using general scan tools will greatly improve effi- 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-6...
  • Page 25 IDENTIFICATION Page Identification ....................2...
  • Page 26 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 Emisson control label ID plate (Europe model) ADR compliance plate (Australia model) Tire inflation pressure label...
  • Page 27 IDENTIFICATION IDENTIFICATION GI0010A GI0011A ID-3...
  • Page 28 IDENTIFICATION IDENTIFICATION 2. MEANING OF V.I.N. The meaning of the VIN is as follows: • Europe, Australia and General (Except GCC) ]JF1GD5LJ31G002001[ The starting and ending brackets ( ][ ) are stop marks. Digits Code Meaning Details 1 to 3 Manufacturer body area JF1: Passenger car, FHI made Car line IMPREZA...
  • Page 29 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. GD9AL7R Digits Code...
  • Page 30 IDENTIFICATION IDENTIFICATION • Transmission TV1B4A1AA Digits Code Meaning Details Transmission T: Transmission Transmission type A: FWD AT M: FWD MT Y: Full-time AWD MT center differential V: Full-time AWD AT center differential Z: Full-time AWD AT MPT 3 and 4 Classification 75: MT 1B: AT...
  • Page 31 RECOMMENDED MATERIALS Page Recommended Materials ................2...
  • Page 32 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 that of equivalent quality. 2. FUEL Always use a gasoline of the same or higher octane value than specified in the owner's manual.
  • Page 33 RECOMMENDED MATERIALS RECOMMENDED MATERIALS 3. LUBRICANTS Use either the lubricants in the table below or equivalent lubricants. See the table below to choose the correct SAE viscosity. Lubricant Recommended Alternative API Spec. CCMC Spec. ACEA Spec. Engine oil SJ Grade “Energy conserving” G4 or G5 A1, A2 or A3 API: SH or SG...
  • Page 34 Distilled water — Tap water 6. REFRIGERANT Standard air conditioners on Subaru vehicles use HFC134a refrigerant. Do not mix it with other refrigerants. Also, do not use any air compressor oil except for ZXL200PG and DENSO OIL 9. Air conditioner Recommended...
  • Page 35 7. GREASE Use the grease and supplementary lubricants shown in the table below. Grease Application point Recommended Item number Alternative Supplementary lubricants • O2 sensor SUBARU CRC 004301003 — • Bolts, etc. Grease MT main shaft FX clutch grease 000040901 —...
  • Page 36 RECOMMENDED MATERIALS RECOMMENDED MATERIALS RM-6...
  • Page 37 PRE-DELIVERY INSPECTION Page Pre-delivery Inspection................2...
  • Page 38 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 39 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 40 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION Checks with the Engine Running Step Check point 1. Read memory and test mode connectors (1) Read memory and test mode connectors 2. Starting condition (2) Start the engine and check that the engine starts smoothly. 3.
  • Page 41 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 1. APPEARANCE CHECK 4. CHECK THE DOOR OPERATIONS, LOCK/UNLOCK AND OPEN/CLOSE, AS • If the vehicle is covered with protective coating, FOLLOWS. visually check the vehicle body for damage and dents. Using the key, lock and unlock the door several •...
  • Page 42 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 7. OPERATION CHECK OF REAR GATE 10.OPERATION CHECK OF HOOD LOCK LOCK RELEASE LEVER RELEASE SYSTEM Operate the rear gate lock release lever and verify Unlatch and open the hood while checking that no that the rear gate is unlocked and opened smooth- abnormal conditions are found.
  • Page 43 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 12.BATTERY 16.AT FRONT DIFFERENTIAL OIL Check the battery terminals to make sure that no Check the AT front differential oil amount. If the rust or corrosions due to fluid leaks are found. amount is insufficient, check that no leaks are Check that the battery tent is securely tightened.
  • Page 44 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 21.KEYLESS ENTRY SYSTEM With OBD model Check the keyless entry system operations as fol- lows. • Remove the key from the ignition switch and close all the doors including rear gate (wagon). • Press the “LOCK” button on the transmitter mo- mentarily once and check if all the doors are locked and the hazard light flashes once.
  • Page 45 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 33.WINDOW WASHER 37.AT SHIFT CONTROL Check that the window washer system injects Set the AT select lever to each gear position while washer fluid to the specified area of the windshield checking that the demanded gear position is cor- shown in the figure.
  • Page 46 PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION 42.POWER STEERING FLUID LEVEL 45.APPEARANCE CHECK 2 Check that the power steering fluid level is normal. Check the vehicle body paints, plated faces, glass, If insufficient, check that no leaks are found. Then and lenses for any dirt or damage. add the necessary amount of the specified power steering fluid.

  • Page 47: 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 Valve Clearance..................15 Fuel Line ....................16 Fuel Filter ....................17 Air Cleaner Element ..................18 Cooling System ..................19 Coolant......................20 Idle Mixture....................22 Clutch System ...................23 Hill-holder System ..................25 Transmission Oil ..................26...

  • Page 48: 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 49 SCHEDULE PERIODIC MAINTENANCE SERVICES 2. Schedule A: MAINTENANCE SCHEDULE 1 1. MAINTENANCE SCHEDULE 1 – (1) 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 50 SCHEDULE PERIODIC MAINTENANCE SERVICES Maintenance Interval [Number of months or km (miles), whichever occurs first] Months Remarks × 1,000 km × 1,000 miles Suspension Wheel bearing Axle boots & joints Steering system (Power steering) Symbols used: R: Replace I: Inspection (R) or (I): Recommended service for safe vehicle operation.
  • Page 51 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 52: Engine Oil

    44 N·m (4.5 kgf-m, 33 ft-lb) gine; however, use oil having the API classification and SAE viscosity No. designated by SUBARU. • If vehicle is used in desert areas with very high temperatures or for other heavy duty applications,...
  • Page 53 ENGINE OIL PERIODIC MAINTENANCE SERVICES B: INSPECTION 1) Park vehicle on a level surface. 2) Remove oil level gauge and wipe it clean. 3) Reinsert the level gauge all the way. Be sure that the level gauge is correctly inserted and in the proper orientation.

  • Page 54: Engine Oil Filter

    ENGINE OIL FILTER PERIODIC MAINTENANCE SERVICES 4. Engine Oil Filter A: REPLACEMENT 1) Remove oil filter with ST. ST 498547000 OIL FILTER WRENCH GI0012A 2) Get a new oil filter and apply a thin coat of engine oil to the seal rubber. 3) Install oil filter by turning it by hand, being careful not to damage seal rubber.

  • Page 55: Spark Plugs

    SPARK PLUGS PERIODIC MAINTENANCE SERVICES 5. Spark Plugs A: REPLACEMENT 1) Remove intake duct and intake chamber. 2) Remove washer tank and put it aside. 3) Disconnect spark plug cord. 4) Remove spark plug with a plug-wrench. GI0018A 5) Set new spark plug. Recommended spark plug : SOHC CHAMPION RC10YC4...
  • Page 56 DRIVE BELT(S) PERIODIC MAINTENANCE SERVICES 6. Drive Belt(s) B: REPLACEMENT 1. V-BELT COVER A: INSPECTION 1) Replace belts, if cracks, fraying or wear is found. 1) Remove V-belt cover. 2) Check drive belt tension and adjust it if neces- sary by changing generator installing position and/ or idler pulley installing position.
  • Page 57 DRIVE BELT(S) PERIODIC MAINTENANCE SERVICES 3. REAR SIDE BELT (DRIVING AIR CONDI- TIONER) NOTE: • Wipe off any oil or water on the belt and pulley. • Before removing the rear side belt, remove the front side belt. 1) Loosen the lock nut (A). 2) Loosen the slider bolt (B).
  • Page 58 CAMSHAFT DRIVE BELT PERIODIC MAINTENANCE SERVICES 7. Camshaft Drive Belt 10) Turn crankshaft and align alignment marks on crankshaft, and left and right camshaft sprockets A: REPLACEMENT with notches of belt cover and cylinder block: ST 499987500 CRANKSHAFT SOCKET 1. SOHC MODEL 1) Remove radiator fan <Ref.
  • Page 59 CAMSHAFT DRIVE BELT PERIODIC MAINTENANCE SERVICES 2. DOHC MODEL 10) Turn crankshaft and align alignment marks on crankshaft, and left and right camshaft sprockets 1) Remove radiator fan and air conditioner fan. with notches of belt cover and cylinder block. To turn crankshaft, use ST: ST 499987500 CRANKSHAFT SOCKET...
  • Page 60 CAMSHAFT DRIVE BELT PERIODIC MAINTENANCE SERVICES B: INSTALLATION C: INSPECTION 1. SOHC MODEL 1. SOHC MODEL To install, reverse order of removal procedures. 1) Remove left and right timing belt covers. <Ref. to ME(SOHC)-46, Timing Belt Assembly.> 2) While cranking engine at least four rotations, check timing belt back surface for cracks or dam- 2.

  • Page 61: Valve Clearance

    VALVE CLEARANCE PERIODIC MAINTENANCE SERVICES 8. Valve Clearance A: INSPECTION For the inspection procedures of the valve clear- ance: <Ref. to ME(SOHC)-29, Valve Clearance.> or <Ref. to ME(DOHC TURBO)-28, Valve Clear- ance.> PM-15...

  • Page 62: Fuel Line

    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, etc. If faulty parts are found, repair or replace them. <Ref. to FU(SOHC)-64, Fuel Delivery, Return and Evap- oration Lines.>...

  • Page 63: Fuel Filter

    FUEL FILTER PERIODIC MAINTENANCE SERVICES 10.Fuel Filter A: REPLACEMENT For fuel filter replacement procedures, refer to “FU” section. <Ref. to FU(SOHC)-61, Fuel Filter.> or <Ref. to FU(SOHCw/oOBD)-57, Fuel Filter.> or <Ref. to FU(DOHC TURBO)-61, Fuel Filter.> PM-17...

  • Page 64: Air Cleaner Element

    AIR CLEANER ELEMENT PERIODIC MAINTENANCE SERVICES 11.Air Cleaner Element 2. TURBO MODEL A: REPLACEMENT NOTE: Do not attempt to clean the air cleaner element. The filter paper of the element is wetted with a spe- cial non-inflammable slow-evaporating viscous liq- uid.

  • Page 65: Cooling System

    COOLING SYSTEM PERIODIC MAINTENANCE SERVICES 12.Cooling System Radiator cap valve open pressure Standard value: A: INSPECTION 93 — 123 kPa (0.95 — 1.25 kg/cm , 14 — 18 psi) 1) Check radiator for leakage, filling it with coolant Service limit: and attach radiator cap tester to the filler neck.
  • Page 66 4) Loosen and remove drain screw (A) to drain en- gine coolant into container. The concentration and safe operating temperature of the SUBARU coolant is shown in the diagram. Measuring the temperature and specific gravity of the coolant will provide this information.
  • Page 67 2.1 liters (2.2 US qt, 1.8 Imp qt) of coolant from the cooling system and add 2.1 liters (2.2 US qt, 1.8 Imp qt) of the undiluted solution of SUBARU cool- ant. If a coolant concentration of 50% is needed, drain all the coolant and refill with the undiluted solution only.

  • Page 68: Idle Mixture

    IDLE MIXTURE PERIODIC MAINTENANCE SERVICES 14.Idle Mixture A: INSPECTION AND ADJUSTMENT 1. IDLE MIXTURE Before measuring the idle mixture, make sure that the ignition timing and the engine idle speed are within specifications. 1) Set the gear position at “Neutral” for MT, or “N” or “P”...

  • Page 69: Clutch System

    CLUTCH SYSTEM PERIODIC MAINTENANCE SERVICES 15.Clutch System 3) Pedal height Check that the clutch pedal pad surface is level A: INSPECTION AND ADJUSTMENT with or higher than brake pedal pad surface. 2. HYDRAULIC CLUTCH TYPE 1. MECHANICAL CLUTCH TYPE 1) Push the release lever to retract the push rod of 1) Inspect free play of clutch pedal by operating the operating cylinder and check if the fluid level in pedal by hand.
  • Page 70 CLUTCH SYSTEM PERIODIC MAINTENANCE SERVICES • Be careful not to allow dirt or dust to get into the reservoir tank. GI0040A PM-24...

  • Page 71: Hill-Holder System

    HILL-HOLDER SYSTEM PERIODIC MAINTENANCE SERVICES 16.Hill-holder System A: INSPECTION AND ADJUSTMENT 1) Confirm stopping and starting performance by activating hill-holder on an uphill road of 3° or high- er inclination. (1) When vehicle does not stop; Tighten adjusting nut of PHV cable. (2) When vehicle does not start properly;...

  • Page 72: Transmission Oil

    TRANSMISSION OIL PERIODIC MAINTENANCE SERVICES 17.Transmission Oil A: REPLACEMENT 1. MANUAL TRANSMISSION 1) Drain gear oil by removing drain plug after allow- ing the engine to cool for 3 to 4 hours. NOTE: Before starting work, cool off the engine well. GI0041 2) Reinstall drain plug after draining gear oil and tighten it to the specified torque.
  • Page 73 PERIODIC MAINTENANCE SERVICES 18.ATF A: REPLACEMENT 1. AUTOMATIC TRANSMISSION FLUID 1) Drain ATF (Automatic Transmission Fluid) by re- moving drain plug after allowing the engine to cool for 3 to 4 hours. NOTE: Before starting work, cool off the engine well. GI0043A 2) Reinstall drain plug after draining ATF, and tight- en it to the specified torque.
  • Page 74 FRONT & REAR DIFFERENTIAL OIL PERIODIC MAINTENANCE SERVICES 19.Front & Rear Differential Oil 3. REAR DIFFERENTIAL 1) Drain oil by removing drain plug. A: REPLACEMENT 2) Remove filler plug for quick draining oil. 3) Reinstall drain plug after draining oil. 1.
  • Page 75 FRONT & REAR DIFFERENTIAL OIL PERIODIC MAINTENANCE SERVICES 5) Install filler plug onto rear differential gear case firmly. NOTE: • Apply fluid packing to filler plug before installa- tion in Except Non-TURBO AT model. • Non-TURBO AT model uses a new aluminum gasket.
  • Page 76 BRAKE LINE PERIODIC MAINTENANCE SERVICES 20.Brake Line B: CHECKING 1. SERVICE BRAKE A: INSPECTION 1) Check the free play of brake pedal with a force of 1. BRAKE LINE less than 10 N (1 kgf, 2 lb). 1) Check scratches, swelling, corrosion and/or trac- Brake pedal free play: es of fluid leakage on brake hoses or pipe joints.
  • Page 77 BRAKE LINE PERIODIC MAINTENANCE SERVICES 3) Check the pedal stroke. 4) Check valve is built into vacuum hose. Discon- While the engine is idling, depress the brake pedal nect vacuum hose to inspect function of check valve. with a 490 N (50 kgf, 110 lb) load and measure the distance between the brake pedal and steering Blow air into vacuum hose from its brake booster wheel.

  • Page 78: Brake Fluid

    BRAKE FLUID PERIODIC MAINTENANCE SERVICES 21.Brake Fluid NOTE: • Cover bleeder with waste cloth, when loosening A: REPLACEMENT it, to prevent brake fluid from being splashed over 1) Either jack up vehicle and place a safety stand surrounding parts. under it, or lift up vehicle. •...

  • Page 79: Disc Brake Pads And Discs

    DISC BRAKE PADS AND DISCS PERIODIC MAINTENANCE SERVICES 22.Disc Brake Pads and Discs 3) Check the disc rotor, and correct or replace if it is damaged or worn. A: INSPECTION Non Turbo Model 1. DISC BRAKE PAD AND DISC Brake disc thickness mm (in) Front Rear 1) Jack up vehicle and support with rigid racks.
  • Page 80 BRAKE LININGS AND DRUMS PERIODIC MAINTENANCE SERVICES 23.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 brake drum, and check that there is no fluid leakage from wheel cylinder.
  • Page 81 BRAKE LININGS AND DRUMS PERIODIC MAINTENANCE SERVICES 2) Check brake drum for wear, dents or other dam- B: ADJUSTMENT age. If the inside surface of brake drum is streaked, 1. REAR DRUM BRAKE correct the surface with emery cloth (#200 or more).
  • Page 82 SUSPENSION PERIODIC MAINTENANCE SERVICES 24.Suspension A: INSPECTION 1. SUSPENSION BALL JOINT 1) Jack up vehicle until front wheels are off ground. 2) Next, grasp bottom of tire and move it in and out. If relative movement is observed between brake disc cover and end of transverse link, ball joint may be excessively worn.
  • Page 83 SUSPENSION PERIODIC MAINTENANCE SERVICES 4. WHEEL ALIGNMENT OF FRONT SUS- 8. DAMAGE TO SUSPENSION PARTS PENSION 1) Check the following parts and the fastening por- tion of the vehicle body for deformation or exces- 1) Check alignment of front suspension to ensure sive rusting which impairs the suspension.

  • Page 84: Wheel Bearing

    WHEEL BEARING PERIODIC MAINTENANCE SERVICES 25.Wheel Bearing 6) While supporting rear drive shaft horizontally with one hand, turn hub COMPL with the other to A: INSPECTION check for noise or binding. If hub COMPL is noisy or binds, disassemble rear 1.

  • Page 85: Axle Boots & Joints

    AXLE BOOTS & JOINTS PERIODIC MAINTENANCE SERVICES 26.Axle Boots & Joints A: INSPECTION 1. FRONT AND REAR AXLE BOOTS Inspect front axle boots (A) and rear axle boots (B) for deformation, damage or failure. If faulty, replace them with new ones. <Ref. to DS-32, Front Drive Shaft.>...
  • Page 86 STEERING SYSTEM (POWER STEERING) PERIODIC MAINTENANCE SERVICES 27.Steering System (Power 2. STEERING SHAFT JOINT Steering) 1) When steering wheel free play is excessive, dis- connect universal joint of steering shaft and check A: INSPECTION it for any play and yawing torque (at the point of the crossing direction).
  • Page 87 STEERING SYSTEM (POWER STEERING) PERIODIC MAINTENANCE SERVICES (3) Apply liquid packing to at least 1/3 of entire 5. POWER STEERING FLUID LEVEL perimeter of adjusting screw thread. NOTE: The fluid level must be checked when the temper- ature of the reservoir tank surface is approximately 20°C (68°F).
  • Page 88 STEERING SYSTEM (POWER STEERING) PERIODIC MAINTENANCE SERVICES 7. HOSES OF OIL PUMP FOR DAMAGES Check pressure hose and return hose of oil pump for crack, swell or damage. Replace hose with new one if necessary. NOTE: Prevent hoses from revolving and/or turning when installing hoses.

  • Page 89: Supplemental Restraint System

    SUPPLEMENTAL RESTRAINT SYSTEM PERIODIC MAINTENANCE SERVICES 28.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 (also double lock the connector). When the ignition switch is turned ON with the connector(s) disconnected, the airbag warning light blinks to identify the fault.
  • Page 90 SUPPLEMENTAL RESTRAINT SYSTEM PERIODIC MAINTENANCE SERVICES PM-44...

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