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2004 Model Year PDF Service Manual GENERAL INFORMATION SECTION (Pub.No.G2320GE1) ENGINE SECTION 1 (Pub.No.G2320GE2) ENGINE SECTION 2 (Pub.No.G2320GE3) ENGINE SECTION 3 (Pub.No.G2320GE4) TRANSMISSION SECTION (Pub.No.G2320GE5) CHASSIS SECTION (Pub.No.G2320GE6) BODY SECTION (Pub.No.G2320GE7) WIRING SYSTEM SECTION (Pub.No.G2320GE8)
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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...
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Foreword FOREWORD 1. Foreword A: FOREWORD These manuals are used when performing mainte- nance, repair, or diagnosis of Subaru LEGACY. Applied model: BL*****, BP***** from 2004MY The manuals contain the latest information at the time of publication. Changes in specifications, methods, etc.
HOW TO USE THIS MANUALS Page How to Use This Manuals ................2...
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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.
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How to Use This Manuals HOW TO USE THIS MANUALS 3. COMPONENT Illustrations are provided for each component. The information necessary for repair work (tightening torque, grease up points, etc.) is described on these illustrations. Information is described using symbol. To order parts, refer to parts catalogue.
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How to Use This Manuals HOW TO USE THIS MANUALS 4. SPECIFICATION If necessary, specifications are also included. 5. INSPECTION Inspections to be carried out before and after maintenance are included. 6. 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.
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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.
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: Exhaust Gas Recirculation SOHC : Single Overhead Camshaft : Emergency Locking Retractor : Supplemental Restraint System : Exhaust : Subaru Select Monitor : Fuse & Joint Box : Special Tool : Fusible Link : Switch : Full-time AWD : Traction Control System...
LEGACY SPECIFICATIONS 1. LEGACY A: DIMENSION 1. SEDAN MODEL Model 2.0 L SOHC 2.0 L DOHC turbo 2.5 L SOHC 3.0 L DOHC Overall length mm (in) 4,665 (183.7) Overall width mm (in) 1,730 (68.1) Overall height (at C.W.) mm (in) 1,425 (56.1) Length mm (in)
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LEGACY SPECIFICATIONS B: ENGINE Model 2.0 L SOHC 2.0 L DOHC turbo 2.5 L SOHC 3.0 L DOHC Horizontally opposed, liquid Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gas- Engine type cooled, 6-cylin- oline engine der, 4-stroke gas- oline engine Valve arrangement Overhead camshaft 99.5 ×...
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LEGACY SPECIFICATIONS D: TRANSMISSION SEDAN, WAGON 2.0 L Model 3.0 L 2.0 L SOHC DOHC 2.5 L SOHC DOHC turbo Transmission type Clutch type DSPD DSPD 2.785 3.454 3.540 2.785 3.454 3.540 1.545 1.947 2.264 1.545 2.062 2.264 1.000 1.366 1.471 1.000 1.448...
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LEGACY SPECIFICATIONS 5AT: Electronically controlled fully-automatic, 5-forward speeds and 1-reverse DSPD: Dry Single Plate Diaphragm TCC: Torque Converter Clutch ★1 : KA, K4 model ★2 : Dual range model only E: STEERING SEDAN, WAGON Model 2.0 L SOHC 2.0 L DOHC turbo 2.5 L SOHC 3.0 L DOHC Type...
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Precaution PRECAUTION 1. Precaution 7. AIRBAG DISPOSAL To prevent bodily injury from unexpected airbag A: CAUTION deployment, do not dispose airbag modules in the Please clearly understand and adhere to the follow- same way as other refuse. Follow the special in- ing general precautions.
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4. SERVICE PARTS not reach the supporting locations. Use genuine parts for maximum performance and maintenance when conducting repairs. Subaru/FHI will not be responsible for poor performance result- ing from the use of parts except for genuine parts. 5. PROTECTING VEHICLE UNDER MAIN-...
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Note NOTE NT-00086 Supporting locations Swing arm lift Plate lift Pantograph jack Rigid rack Attachment NT-3...
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Note NOTE NT-00072 Front Rear Front crossmember Rear differential NT-4...
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Note NOTE 8. TIE DOWNS Tie downs are used when transporting vehicles and when using the chassis dynamo. Attach tie-down only to the specified locations on the vehicle. • TIE-DOWN LOCATION NT-00073 Hook for tie-down NT-5...
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Note NOTE • CHAIN DIRECTION AT TIE-DOWN CONDI- • VEHICLE SINKING VOLUME AT TIE-DOWN TION CONDITION Measure the distance between the highest tire point and highest arch point before and after tie- down. Difference of measurement value (sinking volume) shall be within 50 mm (1.97 in) and make sure to fix the vehicle securely.
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Note NOTE 9. TOWING Avoid towing vehicles except when the vehicle cannot be driven. For models with AWD, AT or VTD, use a loader instead of towing. When towing other vehicles, pay attention to the following to prevent hook or vehicle damage resulting from excessive weight.
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Note NOTE • NOTES Towing Notes ❍ ❍ Lifting up four wheels (On a trailer) Towing the vehicle after lifting up all four wheels is a basic rule for AWD model. NT-00023 ❍ ▲ Rope • Check if both front and rear wheels are rotated nor- mally.
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Note NOTE CAUTION: • Check ATF, gear oil and rear differential oil before driving. • Place the shift lever in “N” position during towing. • Do not lift up the rear wheels to avoid unsteady rotation. • Turn the ignition key to “ACC”, then check the steering wheel moves freely. •...
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Fix the vehicle using a pulling metal (chain or Subaru Select Monitor can be used to diagnose the wire) to the front and rear towing hooks or tie- engine, ABS, air conditioner and other parts.
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Note NOTE 14.BRAKE TEST Specifications: 1) Full-time AWD MT model Braking force (1) Perform this test after driving the vehicle 2 to Rear wheel total More than 10% of load on front or rear 3 km (1.24 to 1.86 miles) on road in order to sta- wheels bilize the viscous torque of viscous coupling.
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Identification IDENTIFICATION 1. Identification A: IDENTIFICATION 1. IDENTIFICATION NUMBER AND LABEL LOCATIONS The V.I.N. (Vehicle Identification Numbers) is used to classify the vehicle. • POSITIONING OF THE PLATE LABEL FOR IDENTIFICATION ID-00072 ID plate (EC and EK model) Tire inflation pressure label (Driver Saudi Arabia plate (Saudi Arabia ADR compliance plate (KA model) side) (KA model)
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Identification IDENTIFICATION • MANUAL TRANSMISSION VA1-TYPE ID-00068 DI-00396 (1) Transmission serial No. (1) Type (label) (2) MT type label VA2-TYPE • REAR DIFFERENTIAL T-TYPE DI-00397 (1) Type (label) ID-00056 (1) Type (white paint) • MODEL NUMBER PLATE ID-00073 ID-3...
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Identification IDENTIFICATION 2. MEANING OF V.I.N. The meaning of the V.I.N. is as follows: • EC, EK, KA AND K4 MODEL ]JF1BL5LJ34G002001[ The starting and ending brackets ( ] [ ) are stop marks. Digits Code Meaning Details 1 — 3 Manufacturer body area JF1: Passenger car, FHI made (Except for KA OUTBACK model) JF2: Passenger car, FHI made (KA OUTBACK model)
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Identification IDENTIFICATION 3. MODEL NUMBER PLATE The model number plate indicates the type, V.I.N. <Ref. to ID-4, MEANING OF V.I.N., IDENTIFICATION, Identification.>, applied model, option code, trim code, engine type, transmission type and the exterior color code. This information is helpful when placing orders for parts. •...
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Identification IDENTIFICATION • TRANSMISSION TY757VRAAB Digits Code Meaning Details Transmission T: Transmission Transmission type Y: Full-time AWD MT center differential V, G: Full-time AWD AT center differential Z: Full-time AWD AT MPT 3 and 4 Classification 75: 5MT 1B: 4AT 5C: 5AT Series LEGACY...
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Identification IDENTIFICATION • OPTION ECXV Digits Code Meaning Details 1 — 2 Destination EC: For Europe (LHD model) EK: For Europe (RHD model) KS: For GCC counties K4: For Middle and South America KA: For Australia Nothing: For Hong Kong Option equipment A: Vehicle dynamics control, Cruise control, Power pack, 17 inch tire...
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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.
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Recommended Materials RECOMMENDED MATERIALS 3. LUBRICANTS Use either the lubricants in the table below or equivalent. See the table below to choose the correct SAE vis- cosity. Lubricant Recommended Alternative API Spec. CCMC Spec. ACEA Spec. API Spec. Engine oil SL, SJ Grade “Energy conserving”, or SH G4 or G5 A1, A2 or A3...
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Recommended Materials RECOMMENDED MATERIALS SAE viscosity No. and applicable temperature Engine oil SOHC model (˚C) –30 –20 –10 (˚F) –22 –4 10W-30 or 10W-40 5W-30 0W-20 Recommend RM-00007 3.0 L and DOHC turbo model –20 –10 (˚C) –30 –22 –4 (˚F) 10W-30 or 10W-40 5W-30 Recommend...
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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 compressor oil other than DENSO OIL 8. Air conditioner Recommended...
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Recommended Materials RECOMMENDED MATERIALS 7. GREASE Use the grease and supplementary lubricants shown in the table below. Grease Application point Recommended Item number Alternative Supplementary • Oxygen sensor Spray type lubricant — — lubricants • Bolts, etc. Grease MT main shaft CLUTCH GREASE K0879Y0501 —...
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Recommended Materials RECOMMENDED MATERIALS 9. SEAL MATERIAL Use the seal material shown in the table below, or equivalent. Seal material Application point Recommended Item number Alternative Seal material • MT transmission case • Cylinder block • Converter case THREE BOND 1215 004403007 DOW CORNING’s No.
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• Check if the vehicle after repair is in a normal state. • Make sure to provide a complete vehicle to the customer. For the above reasons, all SUBARU dealers (dealerships) carry out the PDIs before delivering a vehicle. Refer to this manual unless otherwise specified.
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Pre-delivery Inspection PRE-DELIVERY INSPECTION PROCEDURE Check point 15. Engine oil Check that the oil level is normal. 16. Transmission gear oil Check that the transmission gear oil level is normal. 17. AT front differential oil Check that the AT front differential oil level is normal. 18.
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Pre-delivery Inspection PRE-DELIVERY INSPECTION PROCEDURE Check point 53. Fluid leak check Check for fluid/oil leaks. 54. Water leak test Spray the vehicle with water and check for water leaks. 55. Appearance check 2 (1) Remove the protective coating (if any). (2) Check the body paints for damage and stain.
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Pre-delivery Inspection PRE-DELIVERY INSPECTION For other doors, place the door lock knob (A) to lock 6. CHECK DOUBLE LOCK OPERATION position and then pull the inner remote (B) to en- 1) Fully open all the windows. sure that doors will not open. 2) Remove the key.
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Pre-delivery Inspection PRE-DELIVERY INSPECTION 3) Put the lever (A) in the cancel lever of trunk lid to 11.ACCESSORY CHECK cancel position, and close the trunk lid. Check that Check that the following accessories are provided. the trunk lid will not open even when the trunk lock •...
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Pre-delivery Inspection PRE-DELIVERY INSPECTION Operate the lever (B) and check that the front hood 14.BRAKE FLUID is opened normally. Support the front hood with Check that the brake fluid level is normal. If the hood stay. amount is insufficient, carry out a brake line test to identify brake fluid leaks and check the brake oper- ation.
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Pre-delivery Inspection PRE-DELIVERY INSPECTION • 3.0 L model 17.AT FRONT DIFFERENTIAL OIL Check that the AT front differential oil level is nor- mal. If the amount of oil is insufficient, check that no leaks are found. Then, add the necessary amount of the specified AT front differential oil.
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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. <Ref. to LAN(diag)-26, OPERATION, Read Current Data.> 1) Fully open all the door windows.
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Pre-delivery Inspection PRE-DELIVERY INSPECTION 7) Press the “UNLOCK” button momentarily on the 26.TEST MODE CONNECTOR keyless transmitter. Check that the driver’s door is Turn the ignition switch to ON and check that the unlocked and hazard light blinks twice and room malfunction indicator light starts blinking.
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Pre-delivery Inspection PRE-DELIVERY INSPECTION 28.STARTING CONDITION 39.WINDOW WASHER Start the engine and check that the engine starts Check that the window washer system injects smoothly. If the battery voltage is low, recharge or washer fluid to the specified area of the windshield replace the battery.
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Pre-delivery Inspection PRE-DELIVERY INSPECTION 45.BRAKE TEST 50.CRUISE CONTROL Check the foot brake for normal operations. Operate the cruise control system. Check that the system is activated and deactivated correctly. 46.PARKING BRAKE 51.ATF LEVEL Check the parking brake for normal operations. When applying the parking brake with force of 200 While engine is idling, check that the ATF level is N (20.4 kgf, 45.0 lb), check that the lever stroke of...
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Pre-delivery Inspection PRE-DELIVERY INSPECTION 52.POWER STEERING FLUID LEVEL 55.APPEARANCE CHECK 2 Check that the power steering fluid level is normal. 1) When vehicle body is covered with protective If the amount is insufficient, check that no leaks are film, peel it off. found.
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Pre-delivery Inspection PRE-DELIVERY INSPECTION 6) Peel the protective tape, vinyl wrapping and identification seal attached to the following places. • Seat • Door trim • Floor carpet • Side sill • Front hood lock release lever • Edge rear • Rear wiper •...
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...
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Schedule PERIODIC MAINTENANCE SERVICES 2. Schedule A: MAINTENANCE SCHEDULE 1 1. 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.
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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.
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Schedule PERIODIC MAINTENANCE SERVICES B: MAINTENANCE SCHEDULE 2 1. EUROPE AREA Salt or other Repeat Extremely High humid- Repeat short corrosive Repeat tow- Item Every rough/muddy cold weather ity or moun- distance drive used or ing trailer road drive area tain area coastal area Engine oil...
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Schedule PERIODIC MAINTENANCE SERVICES 2. EXCEPT FOR EUROPE AREA Salt or other Repeat Extremely High humid- Repeat short corrosive Repeat tow- Item Every rough/muddy cold weather ity or moun- distance drive used or ing trailer road drive area tain area coastal area Engine oil Replace...
Engine Oil PERIODIC MAINTENANCE SERVICES 3. Engine Oil • 2.0 L non-turbo and 2.5 L model A: REPLACEMENT 1) Open the engine oil filter cap for quick draining of engine oil. • Except for 3.0 L model LU-00218 • 3.0 L model PM-00161 (A) Oil level gauge (B) Oil filler cap...
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(A) Oil level gauge the engine; however, use oil having the API classification and SAE viscosity No. designat- (B) Oil filler cap ed by SUBARU. (C) Upper level (D) Lower level NOTE: If the vehicle is used in areas with very high temper-...
Engine Oil Filter PERIODIC MAINTENANCE SERVICES 4. Engine Oil Filter 6) After installing the oil filter, run the engine and make sure that no oil is leaking around seal rubber. A: REPLACEMENT NOTE: 1) Remove the under cover. The filter element and filter case are permanently 2) Remove the oil filter using ST.
Spark Plug PERIODIC MAINTENANCE SERVICES 5. Spark Plug • 3.0 L model A: REPLACEMENT 1. SOHC MODEL 1) Remove the intake duct and intake chamber. 2) Remove the battery. 3) Disconnect the spark plug cord. 4) Remove the spark plug with a spark plug socket. IG-02004 (A) Bracket (B) Connector...
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V-belt PERIODIC MAINTENANCE SERVICES 6. V-belt Belt tension (with belt tension gauge): A: INSPECTION When installing new one: 640 — 785 N (65.3 — 80.0 kgf, 144 — 176 lb) 1. EXCEPT FOR 3.0 L MODEL At inspection: 490 — 640 N (50 — 65 kgf, 1) Replace the belts if crack, fraying or wear is 110 —...
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V-belt PERIODIC MAINTENANCE SERVICES 2. 3.0 L MODEL • Turbo model 1) Replace the belts if crack, fraying or wear is found. 2) Check that the V-belt automatic tensioner indica- tor (A) is within the range (D). ME-00807 3) Loosen the lock bolt (A). 4) Loosen the slider bolt (B).
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V-belt PERIODIC MAINTENANCE SERVICES Tightening torque: ⋅ 23 N m (2.3 kgf-m, 17.0 ft-lb) PM-00005 7) Install the front side belt. • Non-turbo model <Ref. to ME(H4SO 2.0)-38, FRONT SIDE BELT, INSTALLATION, V-belt.> • Turbo model <Ref. to ME(H4DOTC)-39, FRONT SIDE BELT, INSTALLATION, V-belt.>...
Timing Belt PERIODIC MAINTENANCE SERVICES 7. Timing Belt ST 499987500 CRANKSHAFT SOCKET A: REPLACEMENT 1. SOHC MODEL 1) Protect the radiator with cardboard and blanket. 2) Remove the V-belt covers. PM-00003 3) Remove the V-belts. <Ref. to ME(H4SO 2.0)-38, V-belt.> 4) Remove the A/C compressor V-belt tensioner.
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Timing Belt PERIODIC MAINTENANCE SERVICES 2. DOHC MODEL 9) Remove the timing belt guide. (Except for non- turbo AT model) 1) Protect the radiator with cardboard and blanket. 2) Remove the V-belts. <Ref. to ME(H4DOTC)-39, V-belt.> 3) Remove the A/C compressor V-belt tensioner. 4) Remove the pulley bolt.
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Timing Belt PERIODIC MAINTENANCE SERVICES ST 499987500 CRANKSHAFT SOCKET CAUTION: When installing the timing belt, be sure to align all alignment marks on the belt with corre- sponding marks on the sprockets. If incorrectly installed, interference between pistons and valves may occur. B: INSPECTION 1.
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 band, etc. If faulty parts are found, repair or replace them. •...
Air Cleaner Element PERIODIC MAINTENANCE SERVICES 9. Air Cleaner Element • Non-turbo model A: REPLACEMENT 1) Disconnect the ground cable from battery. PM-00182 • Turbo model IN-00203 2) Disconnect the connector from mass air flow sensor. (2.0 L turbo, 3.0 L and 2.5 L EC, EK, K4 model) •...
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Air Cleaner Element PERIODIC MAINTENANCE SERVICES • Refer to “COMPONENT” for tightening torque. 2.0 L non-turbo and 2.5 L model <Ref. to IN(H4SO 2.0)-2, COMPONENT, Gen- eral Description.> Turbo model <Ref. to IN(H4DOTC)-2, COMPONENT, Gener- al Description.> 3.0 L model <Ref.
Cooling System PERIODIC MAINTENANCE SERVICES 10.Cooling System NOTE: Rust or dirt on the cap may prevent valve from func- A: INSPECTION tioning normally: be sure to clean the cap before 1) To check the radiator for leakage, fill it with en- testing.
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CO(H6DO)-12, Thermostat.> <Ref. to CO(H6DO)- 13, Radiator.> <Ref. to CO(H6DO)-16, Radiator Cap.> 4) Check the radiator fan operates using Subaru Select Monitor, when the coolant temperature ex- ceeds 95°C (203°F). If it does not operate, check the radiator fan system.
9) Pour the coolant from radiator filler port to neck freeze and anti-rust agents is especially made for of filler. Then, pour the coolant into reservoir tank SUBARU engine, which has an aluminum crank- up to “FULL” level. case. Always use SUBARU Genuine Coolant, since other coolant may cause corrosion.
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CONCENTRATION AND FREEZING TEM- only. PERTAURE Concentration and safe operating temperature of SUBARU coolant is shown in the diagram. Measur- ing the temperature and specific gravity of the cool- ant will provide this information. [Example] If the coolant temperature is 25°C (77°F), its specif- Necessary Concentration ic gravity is 1.054 and the concentration is 45%...
Clutch System PERIODIC MAINTENANCE SERVICES 12.Clutch System • Be careful not to allow dirt or dust to get into the reservoir tank. A: INSPECTION AND ADJUSTMENT 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.
Transmission Gear Oil PERIODIC MAINTENANCE SERVICES 13.Transmission Gear Oil A: REPLACEMENT 1. MANUAL TRANSMISSION 1) Drain the gear oil by removing drain plug. NOTE: • Before starting work, cool off the transmission gear oil well. • If transmission gear oil adheres to the exhaust pipe, wipe it off completely.
5 to 10 km (3 to 6 miles). Otherwise, idle the en- gine to raise ATF temperature to 70 — 80°C (158 PI-00190 — 176°F) on Subaru Select Monitor. <Ref. to (A) Level gauge 4AT(diag)-17, READ CURRENT DATA, OPERA- TION, Subaru Select Monitor.>...
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Automatic Transmission Fluid PERIODIC MAINTENANCE SERVICES B: REPLACEMENT • 4AT model 1. AUTOMATIC TRANSMISSION FLUID 1) Drain the ATF by removing drain plug. NOTE: Before starting work, cool off the ATF well. • 4AT model PI-00189 (A) Level gauge (B) ATF level range at “HOT” [70 — 80°C (158 — 176°F)] (C) Upper level (D) Lower level...
Front and Rear Differential Gear Oil PERIODIC MAINTENANCE SERVICES 15.Front and Rear Differential NOTE: Each oil manufacturer has its base oil and addi- Gear Oil tives. Thus, do not mix two or more brands. A: REPLACEMENT Differential gear oil capacity: 4AT model 1.
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Front and Rear Differential Gear Oil PERIODIC MAINTENANCE SERVICES Tightening torque: Liquid gasket: T-type THREE BOND 1105 (Part No. 004403010) ⋅ 49.0 N m (5.0 kgf-m, 36.2 ft-lb) Tightening torque: VA1-type T-type ⋅ 34 N m (3.5 kgf-m, 25.3 ft-lb) ⋅...
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Brake Line PERIODIC MAINTENANCE SERVICES 16.Brake Line Brake pedal free play (Pulling up direction of pedal) A: INSPECTION 0.5 — 2.0 mm (0.02 — 0.08 in) 1. BRAKE LINE 1) Check for scratches, swelling, corrosion, traces of fluid leakage on the brake hoses or pipe joints. 2) Check the possibility of adjacent parts interfering with brake pipes/hoses during driving, and loose connections/clamps.
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Brake Line PERIODIC MAINTENANCE SERVICES 3) Check the pedal stroke. Replace the both check valve and vacuum hose if the check valve is faulty. Engine side of vacuum While the engine is idling, depress the brake pedal hose is indicated by marking “ENG” as shown. with a 490 N (50 kgf, 110 lb) load and measure the distance between the brake pedal and steering wheel.
Brake Fluid PERIODIC MAINTENANCE SERVICES 17.Brake Fluid NOTE: • Cover the bleeder with cloth, when loosening it, A: REPLACEMENT to prevent brake fluid from being splashed over sur- 1) Either jack-up the vehicle and place a rigid rack rounding parts. under it, or lift-up the vehicle.
Disc Brake Pad and Disc PERIODIC MAINTENANCE SERVICES 18.Disc Brake Pad and Disc A: INSPECTION 1) Jack-up the vehicle and support with rigid racks. Then remove the wheels. 2) Visually check the pad thickness through inspec- tion hole of disc brake assembly. Replace the pad if necessary.
Parking Brake PERIODIC MAINTENANCE SERVICES 19.Parking Brake 4) When the shoe return spring tension is exces- sively weakened, replace it. A: INSPECTION B: ADJUSTMENT Inspect the brake linings and disc rotor of both For rear disc brake, adjust the parking brake after sides of the rear brake at the same time by remov- bleeding air.
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Suspension PERIODIC MAINTENANCE SERVICES 20.Suspension NOTE: When the front arm ball joint has been removed or A: INSPECTION replaced, check the toe-in of front wheel. If the front wheel toe-in is not at specified value, adjust the 1. SUSPENSION BALL JOINT toe-in.
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Suspension PERIODIC MAINTENANCE SERVICES 4. WHEEL ALIGNMENT OF FRONT SUS- • Rear suspension PENSION <Ref. to RS-2, General Description.> 1) Check the alignment of front suspension to en- 8. DAMAGE TO SUSPENSION PARTS sure that following items conform to standard val- Check the following parts and the fastening portion ues.
Wheel Bearing PERIODIC MAINTENANCE SERVICES 21.Wheel Bearing If the hub is noisy or binds, replace the rear axle. 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.
Axle Boots and Joints PERIODIC MAINTENANCE SERVICES 22.Axle Boots and 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-22, Front Drive Shaft.>...
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Steering System (Power Steering) PERIODIC MAINTENANCE SERVICES 23.Steering System (Power 2. STEERING SHAFT JOINT Steering) 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).
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Steering System (Power Steering) PERIODIC MAINTENANCE SERVICES 3) With the vehicle placed on a level surface, quick- 4. TIE-ROD ly turn the steering wheel to the left and right. 1) Check the tie-rod and tie-rod ends for bends, While steering wheel is being rotated, check the scratches or other damage.
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Steering System (Power Steering) PERIODIC MAINTENANCE SERVICES 2) Clips are fitted outside of positions (A) and (B) of NOTE: boot. If fluid level is at MAX level or above, drain fluid to 3) Boot does not have crack and hole. keep the level in the specified range of indicator by using a syringe or the like.
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Steering System (Power Steering) PERIODIC MAINTENANCE SERVICES PM-42...
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