Subaru 2001 LEGACY Service Manual

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Page 1 SUPPLEMENT FOR 6 CYLINDER ENGINE MODEL This service manual has been prepared to provide SUBARU service personnel with the necessary infor- mation and data for the correct maintenance and repair of SUBARU vehicles. This manual includes the procedures for maintenance,...
Page 2 2001 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX SUPPLEMENT FOR 6 CYLINDER ENGINE MODEL G2281GE...
Page 3 FOREWORD Page Foreword .....................2...
Page 4 FOREWORD Foreword 1. Foreword SA01674 A: FOREWORD SA01674G21 These manuals are used when performing maintenance, repair, or diagnosis of the Subaru Legacy. Applied model: BE***** and BH***** from 2001MY. The additional manuals below are also available: AUTOMATIC TRANSMISSION SERVICE MANUAL (Pub. No. G0853ZE) The manuals contain the latest information at the time of publication.
Page 5 FOREWORD Foreword MEMO: FW-3...
Page 6 FOREWORD Foreword FW-4...
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 SA02675 A: HOW TO USE THIS MANUALS SA02675F69 1. STRUCTURE SA02675F6901 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 MEMO: HU-3...
Page 10 HOW TO USE THIS MANUALS How to Use This Manuals HU-4...
Page 11: Specifications
SPECIFICATIONS Page Legacy ......................2 OUTBACK ....................9...
Page 12 LEGACY Specifications 1. Legacy SA08704 A: DIMENSIONS SA08704G28 Model Sedan Wagon Overall length mm (in) 4,605 (181.3) 4,680 (184.3) Overall width mm (in) 1,695 (66.7) 1,695 (66.7) Overall height (at CW) mm (in) 1,415 (55.7) 1,515 (59.6) Compartment Length mm (in) 1,965 (77.4) 1,925 (75.8) Width...
Page 13 LEGACY Specifications C: ELECTRICAL SA08704G30 Model Sedan/Wagon 2.0 L 2.5 L Ignition timing at idling speed BTDC/rpm 10°±10°/700 Spark plug Type and manufacturer Without OBD NGK: BKR6E (without catalyst) CHAMPION: RC10YC4 (with catalyst) NGK: BKR5E-11 (with catalyst) With OBD RC10YC4 ..CHAMPION Alternate RC8YC4 ..
Page 14 LEGACY Specifications F: SUSPENSION SA08704G33 Model Conventional suspension Pneumatic suspension Front Macpherson strut type, Independent, Coil spring Macpherson strut type, Independent, Pneumatic suspension with height control Rear Multi-link type, Independent, Coil spring Multi-link type, Independent, Pneumatic suspension with height control G: BRAKE SA08704G34 Model...
Page 15 LEGACY Specifications J: WEIGHT SA08704G37 1. EUROPE SPEC. VEHICLE SA08704G3703 Model Sedan 2.0 L 5MT*2 4AT*2 5MT*3 4AT*4 Curb weight (C.W.) Front kgf (lb) 770 (1,698) 785 (1,731) 810 (1,786) 785 (1,731) 810 (1,786) Rear kgf (lb) 585 (1,290) 605 (1,334) 605 (1,334) 605 (1,334) 605 (1,334)
Page 16 LEGACY Specifications Model Wagon 2.0 L 5MT*2 4AT*2 5MT*3 4AT*3 Curb weight (C.W.) Front kgf (lb) 770 (1,698) 785 (1,731) 800 (1,764) 785 (1,731) 800 (1,764) Rear kgf (lb) 630 (1,389) 650 (1,433) 650 (1,433) 650 (1,433) 650 (1,433) Total kgf (lb) 1,400 (3,087) 1,435 (3,164)
Page 17 LEGACY Specifications 2. AUSTRALIA SPEC. VEHICLE SA08704G3704 Model Sedan 2.0 L 2.5 L 5MT*1 4AT*2 5MT*2 4AT*2 Unladen mass (U.M.) Front kgf (lb) 780 (1,720) 775 (1,709) 775 (1,709) 785 (1,731) Rear kgf (lb) 585 (1,290) 585 (1,290) 595 (1,312) 595 (1,312) Total kgf (lb)
Page 18 LEGACY Specifications 3. OTHERS SA08704G3705 Model Sedan 2.0 L 2.5 L 4AT*1 5MT*1 4AT*1 Curb weight (C.W.) Front kgf (lb) (1,687) (1,709) (1,764) (1,764) (1,731) (1,786) Rear kgf (lb) (1,301) (1,345) (1,345) (1,334) (1,345) (1,356) Total kgf (lb) 1,355 1,385 1,410 1,405 1,395...
Page 19 OUTBACK Specifications 2. OUTBACK SA08705 A: DIMENSIONS SA08705G28 Model OUTBACK Overall length mm (in) 4,720 (185.8) Overall width mm (in) 1,745 (68.7) Overall height (at CW) mm (in) 1,580 (62.2), 1,590 (62.6)*3 Compartment Length mm (in) 1,925 (75.8) Width mm (in) 1,440 (56.7), 1,420 (55.9)*1 Height mm (in)
Page 20 OUTBACK Specifications C: ELECTRICAL SA08705G30 Model OUTBACK 2.5 L 3.0 L Ignition timing at idling BTDC/rpm 10°±10°/700 10°±8°/600 speed Spark plug Type and manufacturer RC10YC4 ..CHAMPION PLFR6A ..NGK Alternate RC8YC4 ..CHAMPION BKR6E-11 ..NGK K20PR-U11 ..NIPPONDENSO Generator 12V —...
Page 21 OUTBACK Specifications E: STEERING SA08705G32 Model OUTBACK Type Rack and Pinion Turns, lock to lock LHD 3.4/RHD 3.0 Minimum turning circle m (ft) Curb to curb: 11.2±1.0 (36.7±3.3) Wall to wall: 12.0±1.0 (39.4±3.3) F: SUSPENSION SA08705G33 Model OUTBACK Front Macpherson strut type, Independent, Coil spring Rear Multi-link type, Independent, Coil spring G: BRAKE...
Page 22 OUTBACK Specifications J: WEIGHT SA08705G37 1. EUROPE SPEC. VEHICLE SA08705G3703 Model OUTBACK 4 cylinders 6 cylinders 5MT*1 4AT*1 5MT*2 4AT*2 Curb weight (C.W.) Front kgf (lb) (1,797) (1,830) (1,764) (1,797) (2,018) Rear kgf (lb) (1,488) (1,488) (1,477) (1,477) (1,532) Total kgf (lb) 1,490 1,505...
Page 23 OUTBACK Specifications 2. AUSTRALIA SPEC. VEHICLE SA08705G3704 Model OUTBACK 4 cylinders 6 cylinders 5MT* 4AT* Unladen mass (U.M.) Front kgf (lb) 790 (1,742) 800 (1,764) 900 (1,985) Rear kgf (lb) 650 (1,433) 650 (1,433) 690 (1,521) Total kgf (lb) 1,440 (3,175) 1,450 (3,197) 1,590 (3,506) Gross vehicle mass...
Page 24 OUTBACK Specifications MEMO: SPC-14...
Page 25 PRECAUTION Page Precaution ....................2...
Page 26 PRECAUTION Precaution 1. Precaution 7. AIRBAG MODULE SA04677F5907 SA04677 Adhere to the following when handing and storing A: PRECAUTION SA04677F59 the airbag module to prevent bodily injury from Please clearly understand and adhere to the fol- unexpected deployment: ¼ Do not hold harnesses or connectors to carry lowing general precautions.
Page 27 PRECAUTION Precaution MEMO: PC-3...
Page 28 PRECAUTION Precaution PC-4...
Page 29 NOTE Page Note ......................2...
Page 30 ECM from rush current. 4. SERVICE PARTS SA03676A1504 Use authentic service parts for maximum perfor- mance maintenance, when conducting repairs. Subaru/FHI will not be responsible for poor performance resulting from the use of parts not specified by a genuine dealer. NT-2...
Page 31 NOTE Note 5. LIFTS AND JACKS SA03676A1505 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 32 NOTE Note GI0101B NT-4...
Page 33 NOTE Note 6. TIE DOWNS SA03676A1506 Tie downs are used when transporting vehicles and when using the chassis dynamo. Attach tie downs only to the specified points on the vehicle. GI0116A NT-5...
Page 34 For information about training, contact a dealer or agent. 9. GENERAL SCAN TOOL SA03676A1509 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, and other parts. NT-6...
Page 35 NOTE Note MEMO: NT-7...
Page 36 NOTE Note NT-8...
Page 37 IDENTIFICATION Page Identification ....................2...
Page 38 IDENTIFICATION Identification 1. Identification SA06679 A: IDENTIFICATION SA06679F70 1. IDENTIFICATION NUMBER AND LABEL LOCATIONS SA06679F7001 The VIN (Vehicle Identification Numbers) is used to classify the vehicle. Positioning of the plate label for identification GI0112A GI0007A GI0008A GI0009A ID-2...
Page 39 IDENTIFICATION Identification GI0010A GI0011A ID-3...
Page 40 IDENTIFICATION Identification 2. MEANING OF V.I.N. SA06679F7002 The meaning of the VIN is as follows: ¼ Europe, Australia and General (Except GCC) ]JF1BE5LJ31G002001[ 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 41 IDENTIFICATION Identification 3. MODEL NUMBER PLATE SA06679F7003 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. BE9CL7R Digits Code...
Page 42 IDENTIFICATION Identification ¼ Transmission TV1A4YCAAA Digits Code Meaning Details Transmission T: Transmission Transmission type Y: Full-time AWD MT center differential V: Full-time AWD AT VTD Z: Full-time AWD AT MPT 3 and 4 Classification 75: MT 1A: New AT Series 4: 3rd Generation Legacy Transmission specifica- V: Full-time AWD 5-speed MT with viscous coupling center...
Page 43 RECOMMENDED MATERIALS Page Recommended Materials ................2...
Page 44 RECOMMENDED MATERIALS Recommended Materials 1. Recommended Materials SA05678 A: RECOMMENDED MATERIALS SA05678G22 1. GENERAL SA05678G2201 To insure the best performance, always use the specified oil, gasoline, adhesive, sealant, etc. or that of equivalent quality. 2. FUEL SA05678G2202 Always use a gasoline of the same or higher octane value than specified in the owner’s manual.
Page 45 RECOMMENDED MATERIALS Recommended Materials 3. LUBRICANTS SA05678G2203 Use either the lubricants in the table below or equivalent lubricants. See the table below to choose the cor- rect SAE viscosity. Lubricant Recommended Alternative API Spec. CCMC Spec. ACEA Spec. Engine oil SJ Grade “Energy conserving”...
Page 46 5. COOLANT SA05678G2205 Use genuine coolant to protect the engine. The table below shows the ratio of coolant to distilled water. Coolant Recommended Item number Alternative Coolant SUBARU coolant 000016218 None Water for dilution Distilled water — Tap water RM-4...
Page 47 Recommended Materials 6. REFRIGERANT SA05678G2206 Standard air conditioners on Subaru vehicles use HFC134a refrigerant. Do not mix it with other refriger- ants. Also, do not use any air compressor oil except for ZXL200PG and DENSO OIL 9. Air conditioner Recommended...
Page 48 RECOMMENDED MATERIALS Recommended Materials 9. SEAL MATERIAL SA05678G2209 Use seal material shown in the table below, or equivalent. Seal material Application point Recommended Item number Alternative Engine case Three Bond 1215 004403007 Dow Corning’s No. 7038 Transmission Three Bond 1217B K0877YA020 —...
Page 49 PRE-DELIVERY INSPECTION Page Pre-delivery Inspection................2...
Page 50 PRE-DELIVERY INSPECTION Pre-delivery Inspection 1. Pre-delivery Inspection SA09719 A: GENERAL SA09719G23 The purposes of the pre-delivery inspection (PDI) are as follows. ¼ Remove the additional parts used for ensuring the vehicle quality during transportation and restore the vehicle to its normal state. ¼...
Page 51 PRE-DELIVERY INSPECTION Pre-delivery Inspection B: PDI PROCEDURE SA09719G50 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 52 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 (1) Start the engine and check that the engine starts smoothly. 3.
Page 53 PRE-DELIVERY INSPECTION Pre-delivery Inspection 1. APPEARANCE CHECK 4. CONNECTION OF AIR CONDITIONER SA09719G5001 CUT CONNECTOR ¼ If the vehicle is covered with protective coating, SA09719G5051 visually check the vehicle body for damage and A vehicle just delivered has its air conditioner cut dents.
Page 54 PRE-DELIVERY INSPECTION Pre-delivery Inspection ¼ Vehicles with power door locks: 10. ACCESSORY CHECK SA09719G5008 Sit in the driver seat, close the driver’s door Check that the following accessories are provided completely, and place the door lock knob (A) to the in the luggage compartment or cargo area.
Page 55 PRE-DELIVERY INSPECTION Pre-delivery Inspection 11. OPERATION CHECK OF HOOD LOCK 14. ENGINE OIL SA09719G5014 RELEASE SYSTEM SA09719G5009 Check the engine oil amount. If the amount is insufficient, check that no leaks are found. Then, Unlatch and open the hood while checking that no add the necessary amount of the specified engine abnormal conditions are found.
Page 56 PRE-DELIVERY INSPECTION Pre-delivery Inspection 17. COOLANT 21. KEYLESS ENTRY SYSTEM SA09719G5017 SA09719G5021 Check the coolant amount on the reservoir. If the Check the keyless entry system operations as fol- amount is insufficient, check that no leaks are lows. ¼ Remove the key from the ignition switch and found.
Page 57 PRE-DELIVERY INSPECTION Pre-delivery Inspection 25. READ MEMORY AND TEST MODE 30. RADIO SA09719G5033 CONNECTORS Check the radio for full functionality and normal SA09719G5050 noise level. Also check the CD unit operations. Turn the ignition switch to ON and check that the check-engine light starts blinking.
Page 58 PRE-DELIVERY INSPECTION Pre-delivery Inspection 37. AT SHIFT CONTROL 42. POWER STEERING FLUID LEVEL SA09719G5041 SA09719G5046 Set the AT select lever to each gear position while checking that the demanded gear position is cor- Check that the power steering fluid level is normal. rectly attained.
Page 59 PRE-DELIVERY INSPECTION Pre-delivery Inspection 44. WATER LEAK TEST SA09719G5048 Spray the vehicle with water and check that no water enters the passenger compartment. ¼ Before performing the water leakage test, remove anything that may obstruct the operation or which must be kept dry. ¼...
Page 60 PRE-DELIVERY INSPECTION Pre-delivery Inspection MEMO: PI-12...
Page 61: Table Of Contents
PERIODIC MAINTENANCE SERVICES Page General Description..................2 Schedule......................3 Engine Oil....................6 Engine Oil Filter...................9 Spark Plugs ....................10 Drive Belt(s)....................11 Camshaft Drive Belt ..................14 Valve Clearance ..................16 Fuel Line....................17 Fuel Filter ....................18 Air Cleaner Element ..................19 Cooling System ..................20 Coolant ......................21 Idle Mixture....................23 Clutch System ...................24 Hill-holder System ..................25 Transmission Oil..................26...
Page 62: General Description
GENERAL DESCRIPTION Periodic Maintenance Services 1. General Description SA07001 A: GENERAL SA07001G23 Be sure to perform periodic maintenance in order to maintain vehicle performance and find problems before they become serious. PM-2...
Page 63 SCHEDULE Periodic Maintenance Services 2. Schedule SA07682 A: MAINTENANCE SCHEDULE 1 SA07682G24 1. MAINTENANCE SCHEDULE 1 – (1) SA07682G2401 For periodic maintenance of over 50,000 km (30,000 miles) or 48 months, carry out inspections by refer- ring 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 64 SCHEDULE Periodic Maintenance Services Maintenance Interval [Number of months or km (miles), whichever occurs first] Months Remarks × 1,000 km × 1,000 miles Disc brake pads & discs Brake linings and drums Parking brake Suspension Wheel bearing Axle boots & joints Steering system (Power steering) Symbols used:...
Page 65 SCHEDULE Periodic Maintenance Services B: MAINTENANCE SCHEDULE 2 SA07682G25 Item Every Repeat short Repeat Extremely Salt or other High humidity Repeat tow- distance drive rough/muddy cold weather corrosive or mountain ing trailer road drive area used or area coastal area Engine oil Replace more Replace more...
Page 66: Engine Oil
ENGINE OIL Periodic Maintenance Services 3. Engine Oil 3.0 L model SA07077 A: REPLACEMENT SA07077A20 1) Drain engine oil by loosening engine oil drain plug. 2.5 L model B2M4534A 3) Replace drain plug gasket. 4) Tighten engine oil drain plug after draining engine oil.
Page 67 API classifica- tion and SAE viscosity No. designated by SUBARU. ¼ If vehicle is used in desert areas with very high temperatures or for other heavy duty applications,...
Page 68 ENGINE OIL Periodic Maintenance Services B: INSPECTION SA07077A10 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 69: Engine Oil Filter
ENGINE OIL FILTER Periodic Maintenance Services 4. Engine Oil Filter SA07585 A: REPLACEMENT SA07585A20 1. 2.5 L MODEL SA07585A2001 1) Remove oil filter with ST. ST 498547000 OIL FILTER WRENCH B2M3887 3) 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.
Page 70: Spark Plugs
SPARK PLUGS Periodic Maintenance Services 5. Spark Plugs 2. 3.0 L MODEL SA07683A2002 SA07683 1) Disconnect battery cables and then remove A: REPLACEMENT SA07683A20 battery and battery carrier. 1. 2.5 L MODEL 2) Remove washer tank and put it aside. SA07683A2001 3) Remove air cleaner lower case.
Page 71 DRIVE BELT(S) Periodic Maintenance Services 6. Drive Belt(s) 2. 3.0 L MODEL SA07684A1002 SA07684 1) Replace belts, if cracks, fraying or wear is A: INSPECTION SA07684A10 found. 1. 2.5 L MODEL 2) Check that the V-belt automatic tensioner indi- SA07684A1001 cator is within the range (D).
Page 72 DRIVE BELT(S) Periodic Maintenance Services Tightening torque: B: REPLACEMENT SA07684A20 Lock bolt, through bolt: 1. 2.5 L MODEL 25 N·m (2.5 kgf-m, 18 ft-lb) SA07684A2004 Slider bolt: 1) Remove V-belt cover. 8 N·m (0.8 kgf-m, 5.8 ft-lb) GI0020 GI0021A NOTE: 11) Install a new belt, and tighten the slider bolt so Wipe off any oil or water on the belt and pulley.
Page 73 DRIVE BELT(S) Periodic Maintenance Services 3) Install in the reverse order of removal. B2M4013A Power steering oil pump Belt tension adjuster Crankshaft pulley A/C compressor Belt idler Generator PM-13...
Page 74 CAMSHAFT DRIVE BELT Periodic Maintenance Services 7. Camshaft Drive Belt 10) Turn crankshaft and align alignment marks on SA07685 crankshaft, and left and right camshaft sprockets A: REPLACEMENT with notches of belt cover and cylinder block: SA07685A20 ST 499987500 CRANKSHAFT SOCKET 1) Remove radiator fan <Ref.
Page 75 CAMSHAFT DRIVE BELT Periodic Maintenance Services B: INSTALLATION C: INSPECTION SA07685A11 SA07685A10 To install, reverse order of removal procedures. 1) Remove left and right timing belt covers. <Ref. to ME(H4)-52 INSTALLATION, Timing Belt 2) While cranking engine at least four rotations, Assembly.>...
Page 76: Valve Clearance
VALVE CLEARANCE Periodic Maintenance Services 8. Valve Clearance SA07083 A: INSPECTION SA07083A10 For the inspection procedures of the valve clear- ance: <Ref. to ME(H4)-59 Valve Rocker Assem- bly.> or <Ref. to ME(H6)-26, Valve Clearance.> PM-16...
Page 77: Fuel Line
FUEL LINE Periodic Maintenance Services 9. Fuel Line SA07686 A: INSPECTION SA07686A10 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(H4withOBD)-78 Fuel Delivery, Return and Evaporation Lines.>...
Page 78: Fuel Filter
FUEL FILTER Periodic Maintenance Services 10. Fuel Filter SA07027 A: REPLACEMENT SA07027A20 For fuel filter replacement procedures, refer to “FU” section. <Ref. to FU(H4withOBD)-75 Fuel Filter.> or <Ref. to FU(H4w/oOBD)-70 Fuel Filter.> or <Ref. to FU(H6)-69, Fuel Filter.> PM-18...
Page 79: Air Cleaner Element
AIR CLEANER ELEMENT Periodic Maintenance Services 11. Air Cleaner Element 2. 3.0 L MODEL SA07687A2006 SA07687 1) Remove the clip (A) above the air cleaner upper A: REPLACEMENT SA07687A20 cover. NOTE: Do not attempt to clean the air cleaner element. The filter paper of the element is wetted with a special non-flammable slow-evaporating viscous liquid.
Page 80: Cooling System
COOLING SYSTEM Periodic Maintenance Services 12. Cooling System SA07688 A: INSPECTION SA07688A10 1) Check radiator for leakage, filling it with coolant and attach radiator cap tester (A) to the filler neck. Then apply a pressure of 157 kPa (1.6 kg/cm , 23 psi) and check the following points: ¼...
Page 81 2. RELATIONSHIP OF SUBARU COOLANT CONCENTRATION AND FREEZING TEMPERATURE SA07689A2002 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. GI0036A [Example] If the coolant temperature is 25°C (77°F) and its...
Page 82 SUBARU genuine coolant (concentration 50). The amount of coolant that should be replaced can be determined using the diagram.
Page 83: Idle Mixture
IDLE MIXTURE Periodic Maintenance Services 14. Idle Mixture SA07734 A: INSPECTION AND ADJUSTMENT SA07734G26 1. IDLE MIXTURE SA07734G2601 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 84: Clutch System
CLUTCH SYSTEM Periodic Maintenance Services 15. Clutch System SA07690 A: INSPECTION AND ADJUSTMENT SA07690G26 1) Push the release lever to retract the push rod of the operating cylinder and check if the fluid level in the clutch reservoir tank rises or not. GI0039A 2) If the fluid level rises, pedal free play is correct.
Page 85: Hill-Holder System
HILL-HOLDER SYSTEM Periodic Maintenance Services 16. Hill-holder System SA07735 A: INSPECTION AND ADJUSTMENT SA07735G26 1) Confirm stopping and starting performance by activating hill-holder on an uphill road of 3° or higher inclination. (1) When vehicle does not stop; Tighten adjusting nut of PHV cable. (2) When vehicle does not start properly;...
Page 86: Transmission Oil
TRANSMISSION OIL Periodic Maintenance Services 17. Transmission Oil SA07691 A: REPLACEMENT SA07691A20 1. MANUAL TRANSMISSION SA07691A2001 1) Drain gear oil by removing drain plug after allowing 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 87 Periodic Maintenance Services 18. ATF 2. ATF FILTER SA07692A2002 SA07692 NOTE: A: REPLACEMENT SA07692A20 ATF filter is maintenance free part. ATF filter needs 1. AUTOMATIC TRANSMISSION FLUID replacement, when it has physically damaged or ATF leaked. SA07692A2001 For the replacement procedures of the ATF filter: 1) Drain ATF (Automatic Transmission Fluid) by <Ref.
Page 88 FRONT & REAR DIFFERENTIAL OIL Periodic Maintenance Services 19. Front & Rear Differential Oil SA07693 A: REPLACEMENT SA07693A20 1. FRONT DIFFERENTIAL (MANUAL TRANSMISSION) SA07693A2001 For M/T vehicle, manual transmission oil works as differential oil to lubricate differential. Refer to “Transmission Oil”. <Ref. to PM-26 MANUAL GI0046A TRANSMISSION, REPLACEMENT, Transmission Oil.>...
Page 89 FRONT & REAR DIFFERENTIAL OIL Periodic Maintenance Services 5) Install filler plug onto rear differential gear case firmly. NOTE: ¼ Apply fluid packing to filler plug before installa- tion in T-type. ¼ VA-type uses a new aluminum gasket. Fluid packing: Three Bond 1105 Tightening torque: T-type:...
Page 90 BRAKE LINE Periodic Maintenance Services 20. Brake Line B: CHECKING SA07694G27 SA07694 1. SERVICE BRAKE A: INSPECTION SA07694G2701 SA07694A10 1) Check the free play of brake pedal with a force 1. BRAKE LINE SA07694A1001 of less than 10 N (1 kgf, 2 lb). 1) Check scratches, swelling, corrosion and/or Brake pedal free play: traces of fluid leakage on brake hoses or pipe...
Page 91 BRAKE LINE Periodic Maintenance Services 3) Check the pedal stroke. While the engine is idling, depress the brake pedal with a 490 N (50 kgf, 110 lb) load and measure the distance between the brake pedal and steering wheel. With the brake pedal released, measure the distance between the pedal and steering wheel again.
Page 92: Brake Fluid
BRAKE FLUID Periodic Maintenance Services 21. Brake Fluid NOTE: SA07162 ¼ Cover bleeder with waste cloth, when loosening A: REPLACEMENT it, to prevent brake fluid from being splashed over SA07162A20 surrounding parts. 1) Either jack up vehicle and place a safety stand ¼...
Page 93: Disc Brake Pads And Discs
DISC BRAKE PADS AND DISCS Periodic Maintenance Services 22. Disc Brake Pads and Discs NOTE: When replacing a pad, always replace the pads for SA07695 both the left and right wheels at the same time. A: INSPECTION Also replace pad clips if they are twisted or worn. SA07695A10 1.
Page 94 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. SA07696 A: INSPECTION SA07696A10 1. REAR DRUM BRAKE SA07696A1001 1) Remove brake drum, and check that there is no fluid leakage from wheel cylinder.
Page 95 BRAKE LININGS AND DRUMS Periodic Maintenance Services 2) Check brake drum for wear, dents or other B: ADJUSTMENT SA07696A01 damage. If the inside surface of brake drum is 1. REAR DRUM BRAKE streaked, correct the surface with emery cloth SA07696A0101 (#200 or more).
Page 96 SUSPENSION Periodic Maintenance Services 24. Suspension SA07697 A: INSPECTION SA07697A10 1. SUSPENSION BALL JOINT SA07697A1001 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 GI0066A joint may be excessively worn.
Page 97 SUSPENSION Periodic Maintenance Services 4. WHEEL ALIGNMENT OF FRONT 8. DAMAGE TO SUSPENSION PARTS SUSPENSION SA07697A1008 SA07697A1004 1) Check the following parts and the fastening por- 1) Check alignment of front suspension to ensure tion of the vehicle body for deformation or exces- that following items conform to standard values.
Page 98: Wheel Bearing
WHEEL BEARING Periodic Maintenance Services 25. Wheel Bearing 6) While supporting rear drive shaft horizontally SA07698 with one hand, turn hub assembly with the other to A: INSPECTION check for noise or binding. SA07698A10 If hub assembly is noisy or binds, disassemble rear 1.
Page 99: Axle Boots & Joints
AXLE BOOTS & JOINTS Periodic Maintenance Services 26. Axle Boots & Joints SA07699 A: INSPECTION SA07699A10 1. FRONT AND REAR AXLE BOOTS SA07699A1001 Inspect front axle boots (A) and rear axle boots (B) for deformation, damage or failure. If faulty, replace them with new ones.
Page 100 STEERING SYSTEM (POWER STEERING) Periodic Maintenance Services 27. Steering System (Power 2. STEERING SHAFT JOINT SA07701A1002 Steering) 1) When steering wheel free play is excessive, SA07701 disconnect universal joint of steering shaft and A: INSPECTION check it for any play and yawing torque (at the SA07701A10 point of the crossing direction).
Page 101 STEERING SYSTEM (POWER STEERING) Periodic Maintenance Services 3) With vehicle on a level surface, quickly turn Tightening torque: 83 N·m (8.5 kgf-m, 61.5 ft-lb) steering wheel to the left and right. While steering wheel is being rotated, check the 5. POWER STEERING FLUID LEVEL gear backlash.
Page 102 STEERING SYSTEM (POWER STEERING) Periodic Maintenance Services 7. HOSES OF OIL PUMP FOR DAMAGES 10. FITTING BOLTS AND NUTS SA07701A1010 SA07701A1007 Inspect fitting bolts and nuts of oil pump and Check pressure hose and return hose of oil pump bracket for looseness, and retighten them if neces- for crack, swell or damage.
Page 103: Supplemental Restraint System
SUPPLEMENTAL RESTRAINT SYSTEM Periodic Maintenance Services 28. Supplemental Restraint System SA07702 A: INSPECTION SA07702A10 Check the airbag system in accordance with the result of the self-diagnosis. <Ref. to AB-2 Basic Diagnos- tic 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 104 SUPPLEMENTAL RESTRAINT SYSTEM Periodic Maintenance Services MEMO: PM-44...

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