Subaru April BRZ Service Manual
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Subaru April BRZ Service Manual

Subaru April BRZ Service Manual

2012
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2012 APRIL BRZ SERVICE MANUAL

GENERAL INFORMATION

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
NOTE
FW
HU
SPC
PC
NT
ID
RM
PI
PM
G4400BE

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  • Page 1 2012 APRIL BRZ SERVICE MANUAL QUICK REFERENCE INDEX GENERAL INFORMATION 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 FOREWORD 1. Foreword A: FOREWORD These manuals are used when performing mainte- nance, repair or diagnosis of Subaru BRZ. Applicable model: 2013 MY ZC***** The manuals contain the latest information at the time of publication. Changes in the specifications, methods, etc.
  • Page 5 HOW TO USE THIS MANUALS Page How to Use This Manuals ................2...

  • Page 6: How To Use This Manuals

    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 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.
  • Page 8 How to Use This Manuals HOW TO USE THIS MANUALS 4. DEFINITIONS OF “NOTE”, “CAUTION”, AND “WARNING” • NOTE: The supplementary explanation to facilitate the work is described. • CAUTION: The matter that must not be performed because failure to follow the description causes damage to the vehi- cle or parts, and the one to which attention should be particularly paid during the work are described.
  • Page 9 How to Use This Manuals HOW TO USE THIS MANUALS 7. MAINTENANCE • Maintenance instructions for serviceable parts describe work area and detailed step with illustration. It also describes the use of special tool, tightening torque, caution for each procedure. •...
  • Page 10 How to Use This Manuals HOW TO USE THIS MANUALS 9. SI UNITS Measurements in these manuals are according to the SI units. Metric and yard/pound measurements are also included. Example: Tightening torque: 45 N·m (4.6 kgf-m, 33.2 ft-lb) List of SI unit Item SI units Conventional unit...
  • Page 11 Right Hand Drive Exhaust Gas Recirculation Read Only Memory Emergency Locking Retractor Revolution Per Minute Electronic Throttle Control Rear Exhaust Subaru Diagnostic Interface Fuse & Joint Box Subaru Intelligent Fusible Link SOHC Single Overhead Camshaft Front Supplemental Restraint System Front Wheel Drive...
  • Page 12 How to Use This Manuals HOW TO USE THIS MANUALS Turbocharger Traction Control System Transmission Control Module Tumble Generator Valve Transmission TPMS Tire Pressure Monitoring System Universal Joint Ultraviolet Vehicle Dynamics Control V.I.N. Vehicle Identification Number ViS-C Viscous Coupling Vacuum Switching Valve Variable Torque Distribution Wiring Harness HU-8...
  • Page 13 SPECIFICATIONS Page BRZ ......................2...
  • Page 14 SPECIFICATIONS 1. BRZ A: DIMENSION Model 2.0 L non-turbo Overall length mm (in) 4,235 (166.7) Overall width mm (in) 1,775 (69.9) 1,430 (56.3) Overall height mm (in) 1,425 (56.1) Length mm (in) 1,615 (63.6) Compartment Width mm (in) 1,490 (58.7) Height mm (in) 1,060 (41.7)
  • Page 15 SPECIFICATIONS D: TRANSMISSION 1. MT Model 2.0 L non-turbo Transmission Clutch type DSPD 3.626 2.188 1.541 Gear ratio 1.213 1.000 0.767 Rev. 3.437 Type of gear Hypoid Reduction gear (Rear) Final reduction Gear ratio 4.100 6MT: 6-forward speeds and 1-reverse with synchromesh DSPD: Dry Single Plate Diaphragm 2.
  • Page 16 SPECIFICATIONS G: BRAKE Service brake system Dual circuit hydraulic with vacuum suspended power unit Front Ventilated disc brake Rear Solid disc brake Ventilated disc brake Parking brake Mechanical on rear brakes H: TIRE Rim size 16 × 6.5J, 16 × 6.5JJ 17 ×...
  • Page 17 SPECIFICATIONS J: WEIGHT 2 door Model Transmission OP code 1,253 1,255 1,253 1,255 1,274 1,276 1,274 1,276 Total (lb) (2,762) (2,767) (2,762) (2,767) (2,809) (2,813) (2,809) (2,813) Curb weight Front (C.W.) (lb) (1,523) (1,523) (1,523) (1,523) (1,565) (1,565) (1,565) (1,565) Rear (lb) (1,239)
  • Page 18 SPECIFICATIONS 2 door Model Transmission OP code 1,259 1,259 1,280 1,280 Total (lb) (2,776) (2,776) (2,822) (2,822) Curb weight Front (C.W.) (lb) (1,528) (1,528) (1,570) (1,570) Rear (lb) (1,248) (1,248) (1,252) (1,252) 1,670 1,670 1,700 1,700 Gross vehicle weight (G.V.W.) (lb) (3,682) (3,682)
  • Page 19 PRECAUTION Page Precaution ....................2...
  • Page 20 Precaution PRECAUTION 1. Precaution 6. AIRBAG MODULE AND SEAT BELT PRETENSIONER DISPOSAL A: CAUTION To prevent bodily injury from unexpected airbag Please clearly understand and adhere to the follow- deployment, do not dispose the airbag modules or ing general precautions for environmental protec- seat belt pretensioner in the same way as other tion and to avoid minor or serious injury to the waste.
  • Page 21 Precaution PRECAUTION 12.FUEL 15.REMOVAL AND INSTALLATION OPERA- TION OF HOSES, ETC. When handling and storing fuel, adhere to the fol- lowing to prevent from unexpected accident. 1. Before the removal and installation operation • Be careful with fire. of hoses, etc. •...
  • Page 22 Precaution PRECAUTION • If you keep using the hose, perform the in- • Follow the instructions below during installa- spection below and replace the hose with a new tion. part if faulty. • Check carefully for assembling position. • Replace the hose with a new part if it rides •...
  • Page 23 Precaution PRECAUTION • For hose clips and hose clamps, perform the inspection below and replace them with a new part if faulty. • Check for deformation, rust, damage or for- eign matters. • For hose clip, check if it works and has clamp- ing force.
  • Page 24 Precaution PRECAUTION 16.HANDLING PRECAUTIONS FOR SILICON-CONTAINING SPRAY When a silicone contained in the lubricant, rust inhibitor or glazing agent adheres to the electrical contact of the relay or switch, nonconducting silica dioxide (SiO ) film will be formed, which may lead to poor continuity. Therefore, the following precautions must be observed when using the silicon-containing spray.
  • Page 25 NOTE Page Note ......................2...
  • Page 26 Note NOTE 1. Note A: BASIC REPAIR HINT This section describes basic points that the service operator must understand before performing the service operation. 1. APPEARANCE • Always wear clean work clothing. • Wear a cap and protective shoes. 2. PROTECTION OF VEHICLE UNDER MAINTENANCE AND PREPARATION OF TOOLS/ EQUIPMENT •...
  • Page 27 Note NOTE 5. REMOVED PART • A removed part must be organized to avoid mixing up with similar parts. When same parts are used in mul- tiple locations, such as pistons in engine, manage the parts by using labels with cylinder No. so that the parts are not installed to the wrong location.
  • Page 28 (indicator of the push button ignition switch goes Use genuine parts for maximum performance and off) before disconnecting the battery ground termi- maintenance when conducting repairs. Subaru/FHI nal. will not be responsible for poor performance result- ing from the use of parts except for genuine parts.
  • Page 29 Note NOTE 10.LIFT AND JACK When using a lift or shop jack to raise a vehicle or using rigid rack to support a vehicle, always follow instructions concerning jack-up points and weight limits to prevent the vehicle from falling, which could result in injury.
  • Page 30 Note NOTE • Support locations NT-00467 Jack-up point • Pantograph jack CAUTION: When storing the jack holder after use, store with the jack handle mount of the jack facing the inside of the trunk. NT-00459 Jack-up point NT-6...
  • Page 31 Note NOTE • Lift NT-00271 CAUTION: For models with side under skirt, use a spacer or an attachment to lift up the vehicle securely at jack up point, without contact of side under skirt and lift. • Rigid rack NT-00242 Attachment NT-7...
  • Page 32 Note NOTE • Plate lift NT-00452 Jack-up point Attachment • Jack-up point (When using a garage jack) NT-00447 Front Rear Frame Rear differential CAUTION: If jacking up the front side of the vehicle, make sure that the jack is attached at the center of the jack- up plate not at the sides.
  • Page 33 Note NOTE 11.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-00453 Hook for tie-down Tie-down hole • Chain direction at tie-down condition CAUTION: •...
  • Page 34 Note NOTE • Tie-down range For ground transportation CAUTION: To tie down the vehicle from the vehicle interior, hook the hooks of the tie-down chain on the rear tie- down holes from the vehicle interior. When the vehicle is tied down from vehicle outside, hook the hooks of tie-down chain on the rear tie-down hooks from vehicle outside.
  • Page 35 Note NOTE For sea transportation CAUTION: The eye bolts are exclusively used for towing and sea transportation tie-down, and do not use them for ground and freight transportation. 70˚ :(C) NT-00463 Front tie-down hook Chain pulling range at tie-down 1,500 mm (59.1 in) condition Eye bolt 400 mm (15.7 in)
  • Page 36 Note NOTE • Vehicle sinking volume at tie-down condition CAUTION: The vehicle sinking volume at tie-down condition should be less than 50 mm (1.97 in) and make sure to fix the vehicle securely. Check to see if the tensions of chains or belts at tie-down condition are appropriate in the following procedures.
  • Page 37 Note NOTE 12.TOWING Avoid towing vehicles except when the vehicle cannot be driven. For AT models, use a loader instead of tow- ing. When towing other vehicles, pay attention to the following to prevent hook or vehicle damage resulting from excessive weight. •...
  • Page 38 Note NOTE • Precautions Towing Precautions Lifting up four wheels (On a trailer) Use car carrier truck when the chassis or drivetrain of a vehi- cle has been damaged in an accident. NT-00023 Rope • Check if both front and rear wheels are rotated normally. •...
  • Page 39 Note NOTE CAUTION: • Place the shift lever in “N” position during towing. • Do not lift up the rear wheels to avoid unsteady rotation. • Turn the ignition key to “ACC”, then check the steering wheel moves freely. (Models without the keyless access with push button start system) •...
  • Page 40 Installation position at full open 15.GENERAL SCAN TOOL Using general scan tools will greatly improve the efficiency of repairing engine electronic controls. Subaru Select Monitor can be used to diagnose the engine, vehicle dynamic control (VDC), air conditioner and other electrically controlled parts.
  • Page 41 Note NOTE 16.SPEEDOMETER TEST 2) When the brake dragging force is large. • Check the dragging of brake pad or brake shoe. 1) Set the vehicle on speedometer tester. Specifications: CAUTION: Fix the vehicle using a pulling metal (chain or Braking force wire) to the front and rear towing hooks or tie- Rear wheel total...
  • Page 42 Note NOTE NT-18...
  • Page 43 IDENTIFICATION Page Identification ....................2...
  • Page 44 Identification IDENTIFICATION 1. Identification A: IDENTIFICATION 1. IDENTIFICATION NUMBER & LABEL LOCATIONS The V.I.N. (Vehicle Identification Numbers) is used to classify the vehicle. • POSITIONING OF THE LABEL FOR IDENTIFICATION ID-00399 Vehicle identification number Tire inflation pressure label Vehicle identification number (V.I.N.) (below the driver’s floor (V.I.N.
  • Page 45 Identification IDENTIFICATION • ENGINE • REAR DIFFERENTIAL ID-00384 ID-00398 (1) Engine serial number (1) Identification label (2) Engine type (casting) cylinder block upper side • FMVSS LABEL, CMVSS LABEL Example (FMVSS label) • AUTOMATIC TRANSMISSION ID-00321 • MODEL NUMBER LABEL ID-00402 (1) Transmission serial No.
  • Page 46 Identification IDENTIFICATION 2. MEANING OF V.I.N. The meaning of the V.I.N. is as follows: ]JF1ZCAB1XD160001[ The starting and ending brackets ( ] [ ) are stop marks. Digits Code Meaning Details 1 — 3 Manufacturer body area JF1: Passenger car, FHI made Car line Z: BRZ Body type...
  • Page 47 Identification IDENTIFICATION • Transmission 1. MT 81 (MT ID label) Digits Code Meaning Details 1 — 2 MT model classification 81: TL701VD90A TL701VD90A Digits Code Meaning Details Transmission T: Transmission Transmission system L: FR (MT) 3 and 4 Distance between gear 70: Between main shaft and drive pinion center Classification...
  • Page 48 Identification IDENTIFICATION ID-6...
  • Page 49 RECOMMENDED MATERIALS Page Recommended Materials ................2...
  • Page 50 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 • Use unleaded gasoline to reduce air pollution, because using leaded gasoline will damage the catalytic converter.
  • Page 51 Recommended Materials RECOMMENDED MATERIALS SAE viscosity No. and applicable temperature Engine oil –20 –10 (˚C) –30 –22 –4 (˚F) RM-00075 (1) 0W-20 (synthetic oil) Recommended Manual transmission gear oil and rear differential gear oil –20 –10 (˚C) –30 –22 –4 (˚F) RM-00075 (1) 75W-85, 75W-90...

  • Page 52: Engine Coolant

    Cooling system conditioner SOA345001 — agent 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 ND-OIL8. Air Conditioner Recommended materials Item number...
  • Page 53 Recommended Materials RECOMMENDED MATERIALS 8. ADHESIVE Use the adhesives shown in the table below, or equivalent. Adhesive Application point Recommended materials Item number Alternative Dow Automotive’s Windshield glass, rear Adhesive: ESSEX U-400HV or equivalent Adhesive quarter glass, rear win- — —...
  • Page 54 Recommended Materials RECOMMENDED MATERIALS RM-6...
  • Page 55 PRE-DELIVERY INSPECTION Page Pre-delivery Inspection ................2...
  • Page 56 Pre-delivery Inspection PRE-DELIVERY INSPECTION 1. Pre-delivery Inspection A: GENERAL DESCRIPTION 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 ve- hicle to its normal condition. •...
  • Page 57 Pre-delivery Inspection PRE-DELIVERY INSPECTION Step Check point 13. Engine oil Check the engine oil amount. 14. Transmission gear oil Check for leakage of the transmission gear oil. 15. Rear differential gear oil Check for leakage of gear oil from the rear differential. 16.
  • Page 58 Pre-delivery Inspection PRE-DELIVERY INSPECTION Dynamic Test with the Vehicle Running Step Check point 50. Brake test Check the foot brake for normal operations. 51. Parking brake Check the parking brake for normal operations. 52. Shift control Check that the shift patterns are correct. 53.
  • Page 59 Pre-delivery Inspection PRE-DELIVERY INSPECTION 4. LOCK/UNLOCK AND OPEN/CLOSE OP- 4) Press the driver’s side power door lock switch to ERATION CHECKS OF DOORS unlock side. Check that all doors unlock. 1) Using the key, lock and unlock the door several times to check for normal operation.
  • Page 60 Pre-delivery Inspection PRE-DELIVERY INSPECTION 6. OPERATION CHECK OF TRUNK LID RE- 8. TOWING HOOK (EYEBOLT) LEASE HANDLE NOTE: At factory shipment, the towing hook (eyebolt) is in- CAUTION: stalled to the rear bumper for securing the vehicle Do not check the trunk lid release handle when during transportation.
  • Page 61 Pre-delivery Inspection PRE-DELIVERY INSPECTION 9. ACCESSORY 10.FRONT HOOD LOCK RELEASE Check that the following accessories are provided. Operate the front hood release lever to check that the front hood is unlocked normally. • Owner’s manual • Warranty booklet • Maintenance note •...
  • Page 62 Pre-delivery Inspection PRE-DELIVERY INSPECTION 12.BRAKE FLUID 6) After turning off the engine, wait five minutes or more for the oil to return to the oil pan before check- Check the brake fluid amount. If the amount is in- ing the oil level. sufficient, carry out a brake line test to identify brake fluid leaks and check the brake operation.
  • Page 63 Pre-delivery Inspection PRE-DELIVERY INSPECTION 16.ENGINE COOLANT 20.KEYLESS ENTRY SYSTEM Check the coolant amount on the reservoir. If the Check the keyless entry system operations as fol- amount of engine coolant is insufficient, check that lows: no leaks are found. Then, add the necessary •...
  • Page 64 The following inspections show the initial settings. When the settings are different from the initial set- tings, use Subaru Select Monitor to check the de- tails of each setting for inspections. • While carrying the access key, check that the...
  • Page 65 Pre-delivery Inspection PRE-DELIVERY INSPECTION NOTE: • With the access key in the vehicle, check that • The hazard lights flash twice and the buzzer warning buzzer sounds and locking does not occur when you touch the door touch sensor. sounds twice when unlocking. •...
  • Page 66 Pre-delivery Inspection PRE-DELIVERY INSPECTION 7) Press the access key “UNLOCK” button once. 16) Momentarily press the “LOCK” button of the power door lock switch with any one door open. • Driver’s side PI-00814 8) The driver’s door unlocks and the alarm system is in the non-monitoring condition.
  • Page 67 Pre-delivery Inspection PRE-DELIVERY INSPECTION 23.SEAT 25.TPMS (U.S. MODEL) 1) Check that each seat provides full functionality in 1) Turn the ignition switch to ON, and check that sliding and reclining. Check all available functions the TPMS warning light is in a normal operation of the rear seat such as the backrest tilt knob.
  • Page 68 Pre-delivery Inspection PRE-DELIVERY INSPECTION 30.DELIVERY MODE CONNECTOR NOTE: To prevent the insufficient lubrication of the air con- Connect the delivery mode connector of the driv- ditioner, operate the air conditioner for five minutes er's side A pillar lower area. After connection, at idling.
  • Page 69 Pre-delivery Inspection PRE-DELIVERY INSPECTION 43.ILLUMINATION CONTROL Check that the illumination control operates normally. 44.WINDOW WASHER Check that the window washer system injects washer fluid to the specified area of the windshield shown in the figure. Front spray position: PI-00794 Washer nozzle 660 mm (25.98 in) 684 mm (26.93 in) 247 mm (9.72 in)
  • Page 70 NOTE: For detailed operation procedures, refer to “PC ap- 53.CRUISE CONTROL plication help for Subaru Select Monitor”. Operate the cruise control system. Check that the 2) Clear Memory Mode system is activated and deactivated correctly.
  • Page 71 Pre-delivery Inspection PRE-DELIVERY INSPECTION 55.WATER LEAK TEST • Keep solvent from touching the resin or rubber parts. Do not use coating wax or solvents while the Spray the vehicle with water using a hose and component surface temperature is hot due to hot check that no water enters the passenger compart- weather etc.
  • Page 72 Pre-delivery Inspection PRE-DELIVERY INSPECTION PI-18...
  • Page 73 PERIODIC MAINTENANCE SERVICES Page General Description ...................2 Schedule ....................3 Engine Oil ....................5 Engine Oil Filter ..................8 Spark Plug ....................9 V-belt ......................25 Fuel Line ....................30 Fuel Filter ....................31 Air Cleaner Element .................55 Cooling System ..................57 Engine Coolant ..................58 Clutch System ..................61 Transmission Gear Oil ................66 Automatic Transmission Fluid ..............68 Differential Gear Oil ..................76...

  • Page 74: General Description

    General Description PERIODIC MAINTENANCE SERVICES 1. General Description A: GENERAL DESCRIPTION Be sure to perform periodic maintenance in order to maintain vehicle performance and find problems before they occur. PM-2...
  • Page 75 Schedule PERIODIC MAINTENANCE SERVICES 2. Schedule A: MAINTENANCE SCHEDULE 1 1. U.S. MODELS Replacement interval [Number of months or km (miles), whichever occurs first] Months 3 7.5 15 22.5 30 37.5 45 52.5 60 67.5 75 82.5 90 97.5 105 112.5 120 132 ×...
  • Page 76 Schedule PERIODIC MAINTENANCE SERVICES B: MAINTENANCE SCHEDULE 2 Item Maintenance Repeat short Repeat driving Driving in Area where salt High humidity or interval distance driving on bumpy extremely cold or other corro- mountain area muddy road weather sive substance used, or coastal area Engine oil Every 3.75...

  • Page 77: Engine Oil

    Engine Oil PERIODIC MAINTENANCE SERVICES 3. Engine Oil A: INSPECTION CAUTION: If the engine oil is spilt over exhaust pipe or the under cover, wipe it off with cloth to avoid emitting smoke or causing a fire. 1) Park the vehicle on a level surface. 2) Remove the oil level gauge and wipe away the oil.
  • Page 78 Engine Oil PERIODIC MAINTENANCE SERVICES B: REPLACEMENT CAUTION: If the engine oil is spilt over exhaust pipe or the under cover, wipe it off with cloth to avoid emitting smoke or causing a fire. 1) Open the oil filler cap for quick draining of engine oil. 2) Lift up the vehicle.
  • Page 79 Engine Oil PERIODIC MAINTENANCE SERVICES 5) Lower the vehicle. 6) Select engine oil of adequate quality and viscosity and fill it through the oil filler duct to the “F” mark on the oil level gauge. Make sure that the vehicle is parked on a level surface when checking oil level. Recommended oil: Refer to “RM”...

  • Page 80: Engine Oil Filter

    Engine Oil Filter PERIODIC MAINTENANCE SERVICES 4. Engine Oil Filter A: REPLACEMENT CAUTION: If the engine oil is spilt over exhaust pipe or the under cover, wipe it off with cloth to avoid emitting smoke or causing a fire. 1) Remove the oil filter using an oil filter wrench. NOTE: •...

  • Page 81: Spark Plug

    Spark Plug PERIODIC MAINTENANCE SERVICES 5. Spark Plug A: REPLACEMENT 1. REMOVAL 1) Disconnect the ground cable from battery. CAUTION: Disconnect the ground cable from the battery with the driver’s and the passenger’s doors open (with the glass lowered to a position where the door can be opened/closed with no problems). This is to prevent molding damage that occurs when opening/closing a door with the glass fully closed and the ground cable disconnected due to the power window index function that slightly opens/closes the glass in conjunction with opening/closing doors.
  • Page 82 Spark Plug PERIODIC MAINTENANCE SERVICES 5) Disconnect the front oxygen (A/F) sensor connector (A) and rear oxygen sensor connector (B). PM-00636 6) Remove the two bolts securing the harness of the front oxygen (A/F) sensor, and remove the two clips from the stay.
  • Page 83 Spark Plug PERIODIC MAINTENANCE SERVICES 9) Remove the 12 bolts and seven clips to remove engine under cover No. 1. PM-00638 10) Remove the seven bolts to remove engine under cover No. 2. PM-00639 PM-11...
  • Page 84 Spark Plug PERIODIC MAINTENANCE SERVICES 11) Remove the three clips to remove the front mat guard under RH. PM-00640 12) Remove the two nuts and disconnect the joint pipe. PM-00641 PM-12...
  • Page 85 Spark Plug PERIODIC MAINTENANCE SERVICES 13) Remove the two nuts, two bolts and two compression springs to disconnect the exhaust center pipe as- sembly. PM-00642 14) Remove the bolt to remove the exhaust pipe assembly FR. PM-00643 PM-13...
  • Page 86 Spark Plug PERIODIC MAINTENANCE SERVICES 15) Remove the two nuts and disconnect the joint pipe. AT-00000 16) Remove the six nuts to remove the exhaust manifold sub-assembly. PM-00645 PM-14...
  • Page 87 Spark Plug PERIODIC MAINTENANCE SERVICES 17) Tie the joint pipe to the front crossmember using string. CAUTION: This procedure is necessary to prevent the joint pipe from falling off. PM-00646 18) Remove the nuts which secure the engine mounting to the front crossmember. PM-00647 19) Lower the vehicle.
  • Page 88 Spark Plug PERIODIC MAINTENANCE SERVICES 20) Remove clip (A) securing the engine harness to the engine hanger, clip (B) securing the battery cable and clip (C) securing the generator cable to the intake manifold protector RH, and clip (D) securing the gen- erator cable to the fuse box.
  • Page 89 Spark Plug PERIODIC MAINTENANCE SERVICES 22) Install the ST1 and ST2 to the engine assembly. Tightening torque: 43 N·m (4.4 kgf-m, 31.7 ft-lb) ST1 12281-38150 ENGINE HANGER NO. 1 ST2 90119-14120 BOLT PM-00652 PM-17...
  • Page 90 Spark Plug PERIODIC MAINTENANCE SERVICES 23) Remove the clip securing the bulkhead harness to the vehicle. • Left Hand PM-00653 • Right Hand PM-00654 PM-18...
  • Page 91 Spark Plug PERIODIC MAINTENANCE SERVICES 24) Set the ST1 and ST2 to vehicle in order to support the engine. ST1 99099AJ000 ENGINE HANGER ST2 18679AA020 ADJUSTER CAUTION: • Set the ST on the vehicle being careful not to pinch the harness. •...
  • Page 92 Spark Plug PERIODIC MAINTENANCE SERVICES 27) Install the ST between the engine mount and crossmember. ST 18632AA020 STAND ASSY PM-00656 28) Lower the vehicle. 29) Rotate the handle on the top of the ST counterclockwise to slowly lower the engine. 30) Remove the ST (ENGINE HANGER) from the vehicle.
  • Page 93 Spark Plug PERIODIC MAINTENANCE SERVICES (3) Remove the three bolts and the fuel injector CM. PM-00658 (4) Disconnect the ignition coil connector and remove the ignition coil. PM-00659 (5) Remove the spark plug with a spark plug socket. PM-21...
  • Page 94 Spark Plug PERIODIC MAINTENANCE SERVICES 32) Remove the LH spark plugs. (1) Remove the bracket securing the fuel hose. PM-00660 (2) Remove the two bolts and collision protector LH. PM-00661 PM-22...
  • Page 95 Spark Plug PERIODIC MAINTENANCE SERVICES (3) Disconnect the ignition coil connector and remove the ignition coil. PM-00662 (4) Remove the spark plug with a spark plug socket. PM-23...
  • Page 96 Spark Plug PERIODIC MAINTENANCE SERVICES 2. INSTALLATION Install in the reverse order of removal. CAUTION: • Before installation, degrease the ignition coil installation parts and mounting bolts. • After all installation, check adjustment of the AT shift lever because all engine mounting bolts are removed in 18).
  • Page 97 V-belt PERIODIC MAINTENANCE SERVICES 6. V-belt A: INSPECTION 1) Check the V-belt for cracks, tear or wear. 2) Check the V-belt tensioner assembly and idler pulley for deformation, cracks or other damages. 3) Check that the V-belt ribs are securely placed on the rib grooves for each pulleys. PM-00587 B: REPLACEMENT NOTE:...
  • Page 98 V-belt PERIODIC MAINTENANCE SERVICES 2) Removing belt cover No. 1 (1) Remove the two bolts and the belt cover No. 1. PM-00590 3) Removing belt cover No. 2 (1) Release the clip and disconnect the wire harness. (2) Remove the two bolts, belt cover No. 2, clip securing the A/C compressor connector from the V-belt cover LH (models with A/C only), then remove the V-belt cover LH.
  • Page 99 V-belt PERIODIC MAINTENANCE SERVICES 4) Removing the fan & generator V-belt (1) Set the tool on the pulley set bolt of the belt tensioner, rotate the belt tensioner counterclockwise to loosen the tension and remove the fan & generator V-belt. CAUTION: As the pulley set bolt uses a left-threaded screw, rotating clockwise loosens the pulley set bolt.
  • Page 100 V-belt PERIODIC MAINTENANCE SERVICES 5) Install in the reverse order of removal. CAUTION: • Do not use the V-belt if there is any oil, grease or coolant on the belt. • Be careful not to rub the V-belt end surface with bare hands; exposed core may cause injury. •...
  • Page 101 V-belt PERIODIC MAINTENANCE SERVICES Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) PM-00591 PM-00590 PM-29...

  • Page 102: Fuel Line

    Fuel Line PERIODIC MAINTENANCE SERVICES 7. Fuel Line A: INSPECTION The fuel line is located mostly internally, so check pipes, areas near pipes, and engine compartment piping for rust, hose damage, loose bands and fuel leakage. If faulty parts are found, repair or replace them. PM-30...

  • Page 103: Fuel Filter

    Fuel Filter PERIODIC MAINTENANCE SERVICES 8. Fuel Filter A: REPLACEMENT WARNING: Place “NO OPEN FLAMES” signs near the working area. CAUTION: • Perform the work with the engine coolant at a temperature of 60°C (140°F) or less. • Before removing fuel system parts, be sure to take measures to prevent fuel from flowing out. •...
  • Page 104 Fuel Filter PERIODIC MAINTENANCE SERVICES 2) Remove the fuel pump fuse from the engine room relay block. PM-00680 (A) Fuel pump fuse 3) Start the engine. 4) After the engine stops naturally, turn the key to IG OFF. 5) Crank the engine again and check that the engine does not start. NOTE: Check/Delete diagnostic codes after performing procedures as some diagnostic code might have been de- tected.
  • Page 105 (2) Connect the ST to the fuel hose. ST 18471AA000 (3) Connect the gasoline-proof hose to the ST and put the end of the hose in the container. (4) Drive the fuel pump and drain the fuel using Subaru Select Monitor. PM-33...
  • Page 106 Fuel Filter PERIODIC MAINTENANCE SERVICES 11) If the fuel gauge indicates that two thirds or more of the fuel is remaining, drain fuel according to the fol- lowing procedures. (Method for draining from fuel tank to filler pipe hose) WARNING: Vehicle components are extremely hot after driving.
  • Page 107 Fuel Filter PERIODIC MAINTENANCE SERVICES (4) Remove the four cushion rubbers and the exhaust tail pipe assembly. PM-00718 (5) Loosen the hose clamp, and disconnect the fuel tank to filler pipe hose. CAUTION: • Before performing the procedures, remove any foreign material such as mud adhering to the con- necting parts of the fuel tank to filler pipe hose.
  • Page 108 Fuel Filter PERIODIC MAINTENANCE SERVICES 14) Press in the grommet and remove the grommet from rear floor service hole cover No. 2. PM-00683 15) Peel off the butyl tape and remove rear floor service hole cover No. 2. 16) Disconnect the fuel pump connector. PM-00684 PM-36...
  • Page 109 Fuel Filter PERIODIC MAINTENANCE SERVICES 17) Disconnect the fuel pump tube connector. CAUTION: Be careful not to spill fuel. PM-00685 18) Remove the fuel pump tube from the fuel tank. PM-00686 PM-37...
  • Page 110 Fuel Filter PERIODIC MAINTENANCE SERVICES 19) Loosen the fuel pump gauge retainer using the ST. ST 42099CA000 ST FUEL PUMP CAUTION: • Do not use any tool other than the ST. • Be careful not to damage the tube with the ST. •...
  • Page 111 Fuel Filter PERIODIC MAINTENANCE SERVICES 21) Disconnect the fuel tube connector, and remove the fuel suction tube assembly from the fuel tank. CAUTION: • Do not pull with excessive force on the tube when disconnecting the fuel tube connector. • Make sure not to bend the arm of the fuel sender gauge. •...
  • Page 112 Fuel Filter PERIODIC MAINTENANCE SERVICES 24) Remove the harness from the clamp, press and lift up the tab, and remove the fuel sender gauge assem- bly. CAUTION: Make sure not to bend the arm of the fuel sender gauge assembly. PM-00690 25) Disconnect the fuel pump connector.
  • Page 113 Fuel Filter PERIODIC MAINTENANCE SERVICES 26) Press the fuel suction plate in the direction indicated in the figure, and remove the E ring using needle nose pliers. PM-00601 27) Release the tab using a flat tip screwdriver wrapped by protective tape and disconnect the jet pump noz- zle.
  • Page 114 Fuel Filter PERIODIC MAINTENANCE SERVICES 28) Release the three tabs using a flat tip screwdriver wrapped by protective tape and pull out the fuel suction plate. CAUTION: Do not damage the fuel sub tank or fuel filter. PM-00603 29) Release the tab using a flat tip screwdriver wrapped by protective tape and disconnect the jet pump. PM-00604 PM-42...
  • Page 115 Fuel Filter PERIODIC MAINTENANCE SERVICES 30) Remove the O-ring from the fuel sub tank. PM-00605 31) Release the two tabs using a flat tip screwdriver wrapped by protective tape. PM-00606 PM-43...
  • Page 116 Fuel Filter PERIODIC MAINTENANCE SERVICES 32) Release the three tabs using a flat tip screwdriver wrapped by protective tape and pull out the fuel pump keeping it completely straight. PM-00607 33) Remove the O-ring (A), spacer (B) and connector cable (C) from the fuel pump. PM-00608 PM-44...
  • Page 117 Fuel Filter PERIODIC MAINTENANCE SERVICES 34) Remove the pressure regulator from the fuel filter assembly. PM-00609 35) Remove the O-rings (A) and (B) and back-up ring (C) from the pressure regulator. PM-00610 PM-45...
  • Page 118 Fuel Filter PERIODIC MAINTENANCE SERVICES 36) Install new O-rings (A) and (B), and new back-up ring (C) to the pressure regulator. PM-00610 37) Install the pressure regulator to the fuel filter assembly. CAUTION: Make sure that the O-ring is not cut or pinched when installing. NOTE: Apply gasoline to the pressure regulator.
  • Page 119 Fuel Filter PERIODIC MAINTENANCE SERVICES 38) Install a new O-ring (A), spacer (B) and new connector cable (C) to the fuel pump. NOTE: Apply gasoline to the O-ring and spacer. PM-00608 39) Install the fuel pump to the fuel filter assembly. PM-00611 PM-47...
  • Page 120 Fuel Filter PERIODIC MAINTENANCE SERVICES 40) Install a new O-ring to the fuel filter assembly. CAUTION: Make sure that the O-ring is not cut or pinched when installing. NOTE: Apply gasoline to the O-ring. PM-00612 41) Install the jet pump to the fuel sub tank. 42) Engage the three tabs, and install the fuel filter to the fuel sub tank.
  • Page 121 Fuel Filter PERIODIC MAINTENANCE SERVICES 43) Engage the tab, and install the jet pump nozzle to sub tank No. 1. PM-00613 44) Install the E-ring. PM-00614 PM-49...
  • Page 122 Fuel Filter PERIODIC MAINTENANCE SERVICES 45) Connect the fuel pump harness connector and secure with the clip. PM-00600 46) Engage the tab, and install the fuel sender gauge assembly No. 2 to the fuel delivery tube. 47) Connect the fuel sender gauge assembly No. 2 connector, and install the harness to the clamp. 48) Inspect the fuel level sensor.
  • Page 123 Fuel Filter PERIODIC MAINTENANCE SERVICES 49) Install a new gasket to the fuel suction tube assembly (with pump & gauge). PM-00710 (A) Gasket PM-51...
  • Page 124 Fuel Filter PERIODIC MAINTENANCE SERVICES 50) Connect the fuel tube connector. CAUTION: • Do not pull with excessive force on the tube when connecting the fuel tube connector. • Make sure not to bend the arm of the fuel sender gauge. 51) Insert the fuel suction tube assembly (with pump &...
  • Page 125 Fuel Filter PERIODIC MAINTENANCE SERVICES 52) Apply gasoline to the gasket. CAUTION: • When applying gasoline to the gasket, apply it to the area as shown in the figure. • Be careful not to spill gasoline on the screw section of the fuel tank. •...
  • Page 126 59) Connect the ground cable to battery. 60) Apply fuel pressure and check that there are no leaks in the fuel system using the Subaru Select Monitor. 61) Install rear floor service hole cover No. 2 using new butyl tape.

  • Page 127: Air Cleaner Element

    Air Cleaner Element PERIODIC MAINTENANCE SERVICES 9. Air Cleaner Element A: INSPECTION 1) Check that the air cleaner element has no deformation, cracks or other damages. 2) Check the air cleaner element for excessive dirt. B: REPLACEMENT CAUTION: Do not place an excessive load on the air cleaner case with grasping with your hands in order to pre- vent damaging the plastic bracket.
  • Page 128 Air Cleaner Element PERIODIC MAINTENANCE SERVICES 3) Raise the air cleaner case (rear) at an angle as shown in the figure, and remove the air cleaner filter ele- ment. PM-00597 4) Raise the air cleaner case (rear) at an angle, and install the air cleaner filter element. 5) Connect the two tabs of the air cleaner case (rear) to the air cleaner case (front).

  • Page 129: Cooling System

    Cooling System PERIODIC MAINTENANCE SERVICES 10.Cooling System A: INSPECTION 1. RADIATOR 1) Check that the radiator does not have deformation, cracks or damage. 2) Check that the hose has no cracks, damage or loose part. 3) Check that there is no engine coolant leakage from the hose connection parts. 4) Remove the radiator cap, fill the radiator with engine coolant, and then install the radiator cap tester to the filler neck of radiator.
  • Page 130 Engine Coolant PERIODIC MAINTENANCE SERVICES 11.Engine Coolant A: INSPECTION 1) Park the vehicle on a level surface. 2) Check that the reservoir tank fluid level is between the FULL and LOW lines when the engine is cool. CAUTION: • Do not substitute water for the coolant fluid. •...
  • Page 131 Refer to the “SPC” section. <Ref. to SPC-4, CAPACITY, BRZ.> CAUTION: The SUBARU Super Coolant contains anti-freeze and anti-rust agents, and is especially made for Subaru engines with an aluminum cylinder block. Be sure to use SUBARU Super Coolant, since other coolant may cause corrosion. PM-59...
  • Page 132 Engine Coolant PERIODIC MAINTENANCE SERVICES 9) Open the air bleeding plug on the heater hose side. PM-00663 10) If the engine coolant level drops, add engine coolant into radiator up to the filler neck position. 11) Close the air bleeder valve when engine coolant comes out of the air bleeder plug on the heater hose side.

  • Page 133: Clutch System

    Clutch System PERIODIC MAINTENANCE SERVICES 12.Clutch System A: INSPECTION AND ADJUSTMENT 1. INSPECTION Move the clutch pedal in the lateral direction with a force of approximately 10 N (1 kgf, 2 lbf) to check that the clutch pedal deflection is within the service limit. CAUTION: If it exceeds the service limit, replace the clutch pedal assembly with a new part.
  • Page 134 Clutch System PERIODIC MAINTENANCE SERVICES 2. ADJUSTMENT 1) If the full stroke of the clutch pedal is not within the specified value, loosen the lock nuts of the clutch switch and adjust the full stroke of the clutch pedal with the clutch switch. CAUTION: When adjusting the full stroke of clutch pedal, do not turn the clutch switch.
  • Page 135 Clutch System PERIODIC MAINTENANCE SERVICES 3) Rotate the push rod to adjust. PM-00722 (A) In the longer direction (B) In the shorter direction 4) Make sure that the clutch pedal contacts the clutch pedal bracket stopper when the clutch pedal is at the maximum stroke position.
  • Page 136 Clutch System PERIODIC MAINTENANCE SERVICES 8) Turn further in the direction that will shorten the push rod by 270°. PM-00722 (A) In the longer direction (B) In the shorter direction 9) Check that the clevis pin moves smoothly by moving it in the left and right directions. 10) Tighten the push rod lock nut of the master cylinder.
  • Page 137 Clutch System PERIODIC MAINTENANCE SERVICES 13) Push the release lever until the operating cylinder push rod retracts. Make sure that the clutch fluid level in the reservoir tank increases. If the clutch fluid level increases, the hydraulic clutch is properly adjusted. If the clutch fluid level does not increase or the push rod does not retract, replace the master cylinder with a new part.

  • Page 138: Transmission Gear Oil

    Transmission Gear Oil PERIODIC MAINTENANCE SERVICES 13.Transmission Gear Oil A: INSPECTION Check for leakage of gear oil from the transmission. B: REPLACEMENT CAUTION: • Immediately after running the vehicle or after idling for a long time, the transmission gear oil will be hot.
  • Page 139 Transmission Gear Oil PERIODIC MAINTENANCE SERVICES 10) Install engine under cover No. 2. 11) Install engine under cover No. 1. PM-67...

  • Page 140: Automatic Transmission Fluid

    Automatic Transmission Fluid PERIODIC MAINTENANCE SERVICES 14.Automatic Transmission Fluid A: INSPECTION Check for leakage of ATF from transmission. B: REPLACEMENT 1) Lift up the vehicle and maintain in a horizontal position.[*1] 2) Remove engine under cover No. 1. 3) Remove engine under cover No. 2. 4) Remove the drain plug and gasket, and drain the fluid.[*2] 5) Temporarily tighten the drain plug using a new gasket.[*3] NOTE:...
  • Page 141 Automatic Transmission Fluid PERIODIC MAINTENANCE SERVICES 8) Add fluid through the refill hole until the fluid flows out of the overflow tube.[*6] CAUTION: • Use auto-fluid WS. • Slowly add the fluid. Adding the fluid rapidly can cause the fluid to hit internal parts and splash around resulting in fluid flowing out of the refill hole.
  • Page 142 Automatic Transmission Fluid PERIODIC MAINTENANCE SERVICES C: ADJUSTMENT Fluid refill and adjustment image: Initial refill Specified amount refill Refill the oil pan with fluid to a Refill with the specified amount certain amount. according to the operation. Specified amount Refills to the extent that the Overflow plug Overflow tube...
  • Page 143 Automatic Transmission Fluid PERIODIC MAINTENANCE SERVICES 1. AUTOMATIC TRANSMISSION FLUID FILLING CAUTION: • Perform procedures when the automatic transmission fluid is sufficiently cool. • Always be sure to switch to oil amount adjustment mode when filling automatic transmission fluid. • Slowly add the fluid. Adding the fluid rapidly can cause the fluid to hit internal parts and splash around resulting in fluid flowing out of the refill hole.
  • Page 144 If the temperature is 42°C (107.6°F) or more, leave the vehicle in a cool location and restart procedures after the ATF temperature has decreased. (5) Increase the oil temperature by idling the engine while checking the ATF temperature from the Subaru Select Monitor screen.
  • Page 145 Automatic Transmission Fluid PERIODIC MAINTENANCE SERVICES (6) Adjust the oil amount as soon as reaching the starting temperature for oil adjustment procedures (42°C (109.4°F)). CAUTION: Always be sure to adjust the ATF (overflow plug tightening) when at the proper temperature. Lower than proper temperature Proper temperature Higher than proper temperature...
  • Page 146 Automatic Transmission Fluid PERIODIC MAINTENANCE SERVICES (6) After changing to oil pressure adjustment mode, switch to the “P” range. (7) Remove the short of data link connectors No. 13 and No. 4. (8) Check the status of the upshift/downshift permitted indicator lamps [ ]/[ ]. CAUTION: If only the [ ] indicator lamp is illuminated or both [ ] and [ ] are illuminated simultaneously, stop performing procedures and leave the vehicle in a cool location.
  • Page 147 Automatic Transmission Fluid PERIODIC MAINTENANCE SERVICES 7) Install engine under cover No. 1. Tightening torque: M10: 7.5 N·m (0.8 kgf-m, 5.5 ft-lb) M12: 30 N·m (3.1 kgf-m, 22.1 ft-lb) 8) Lower the vehicle. 9) Turn the ignition to OFF. PM-75...

  • Page 148: Differential Gear Oil

    Differential Gear Oil PERIODIC MAINTENANCE SERVICES 15.Differential Gear Oil A: INSPECTION 1. REAR DIFFERENTIAL Check for leakage of gear oil from the rear differential. B: REPLACEMENT 1. REAR DIFFERENTIAL CAUTION: • Gear oil is extremely hot just after driving. Be wary of receiving burns. •...
  • Page 149 Differential Gear Oil PERIODIC MAINTENANCE SERVICES 6) Install the filler plug. NOTE: Use a new gasket. Tightening torque: 49 N·m (5.0 kgf-m, 36.1 ft-lb) PM-77...
  • Page 150 Brake Line PERIODIC MAINTENANCE SERVICES 16.Brake Line A: INSPECTION 1. BRAKE LINE 1) Check for scratches, swelling, corrosion, traces of fluid leakage on the brake hoses or pipe joints. 2) Make sure that brake pipes/hoses do not interfere with adjacent parts and there is no loose connector/ clamp during driving.
  • Page 151 Brake Line PERIODIC MAINTENANCE SERVICES PM-00583 (A) Brake pipe (B) Rear brake hose (C) Clamp 2. SERVICE BRAKE 1) Move the brake pedal pads in a horizontal direction with a force of approx. 10 N (1 kgf, 2 lbf), and check that the pedal deflection is in the range of specifications.
  • Page 152 Brake Line PERIODIC MAINTENANCE SERVICES 2) Check the position of the pedal pad. Pedal height L: AT: 150 mm (5.90 in) MT: 145 mm (5.71 in) Brake pedal free play A: 0.5 — 2 mm (0.020 — 0.079 in) [When pulling the brake pedal upward with a force of less than 10 N (1 kgf, 2 lbf).] BR-00960 Switch - stop light...
  • Page 153 Brake Line PERIODIC MAINTENANCE SERVICES 3. BRAKE SERVO SYSTEM 1) With the engine off, depress the brake pedal several times applying the same pedal force. Check that the travel distance should not change. 2) With the brake pedal depressed, start the engine. Check that the pedal moves slightly toward the floor. 3) With the brake pedal depressed, stop the engine and keep the pedal depressed for 30 seconds.

  • Page 154: Brake Fluid

    3) Drain brake fluid from the reservoir tank. 4) Refill the reservoir tank with recommended brake fluid. Recommended brake fluid: SUBARU genuine brake fluid Perform the same procedure as for bleeding the brake line, until new brake fluid comes out from vinyl tube. PM-82...

  • Page 155: Disc Brake Pad And Disc

    Disc Brake Pad and Disc PERIODIC MAINTENANCE SERVICES 18.Disc Brake Pad and Disc A: INSPECTION 1) Lift up the vehicle, and remove the wheels. 2) Visually check the pad thickness through inspection hole of disc brake assembly. Replace the pad if nec- essary.
  • Page 156 Disc Brake Pad and Disc PERIODIC MAINTENANCE SERVICES • Front Pad thickness mm (in) Standard 11 (0.43) Wear limit 1.5 (0.059) • Rear Pad thickness mm (in) Ventilated 11 (0.43) Standard Solid 9 (0.35) Ventilated 1.5 (0.059) Wear limit Solid 1.5 (0.059) 3) Check the disc rotor, and correct or replace if it is damaged or worn.

  • Page 157: Parking Brake

    Parking Brake PERIODIC MAINTENANCE SERVICES 19.Parking Brake A: INSPECTION 1) Measure the inner diameter of the rear disc rotor. If scoring or worn is found on the disc, replace the rear disc rotor. Disc rotor inner diameter: Specification: 190 mm (7.48 in) Service limit: 191 mm (7.52 in) 2) Measure the lining thickness.
  • Page 158 Parking Brake PERIODIC MAINTENANCE SERVICES 2. LEVER STROKE 1) Adjust the parking shoe clearance before adjusting lever stroke. 2) Release the claws, and then remove the boot - parking brake. PM-00666 3) Pull the lever assembly - hand brake hard 3 to 5 times. 4) Turn the adjusting nut until the lever stroke is at the specified value.
  • Page 159 Suspension PERIODIC MAINTENANCE SERVICES 20.Suspension A: INSPECTION 1. FRONT SUSPENSION BALL JOINT 1) Lift up the vehicle until front wheels are off ground. 2) Grasp the bottom of tire and move it in and out in axial direction. If movement (B) is observed between the brake disc cover (A) and end of front arm (D), ball joint (C) may be excessively worn.
  • Page 160 Suspension PERIODIC MAINTENANCE SERVICES 5) Damage of dust boots Visually inspect the ball joint dust boots. Replace if the front arm assembly is damaged. NOTE: When the front arm assembly is removed or replaced, check the toe-in of the front wheel. If it is not within the specified value, adjust the toe-in.
  • Page 161 Suspension PERIODIC MAINTENANCE SERVICES 6) Damage of dust boots Visually inspect the ball joint dust boots. Replace if front lateral link is damaged. 7) Check the upper arm ball joint and the pillow ball bushing of housing in the same manner. PM-00705 (A) Upper arm ball joint 3.
  • Page 162 Suspension PERIODIC MAINTENANCE SERVICES • Rear suspension bushing PM-00737 4. WHEEL ARCH HEIGHT Check the wheel arch height. 5. WHEEL ALIGNMENT Measure and adjust the front and rear wheel alignment at a time. 6. OIL LEAKAGE OF STRUT AND SHOCK ABSORBER Visually inspect the front strut and rear shock absorber for oil leakage.

  • Page 163: Wheel Bearing

    Wheel Bearing PERIODIC MAINTENANCE SERVICES 21.Wheel Bearing A: INSPECTION 1. FRONT WHEEL BEARING NOTE: Inspect the condition of front wheel bearing grease. 1) Jack-up the front side of vehicle. 2) While holding the front wheel by hand, swing it in and out to check bearing free play. 3) Loosen the wheel nuts, and remove the front wheel.
  • Page 164 Wheel Bearing PERIODIC MAINTENANCE SERVICES 6) While supporting rear drive shaft horizontally with one hand, turn the hub with the other hand to check for noise or binding. If the hub is noisy or binds, replace the rear axle. PM-00701 PM-92...
  • Page 165 Axle Boots & Joints PERIODIC MAINTENANCE SERVICES 22.Axle Boots & Joints A: INSPECTION 1. REAR AXLE BOOTS Inspect the rear axle boots (A) for deformation, damage or failure. If faulty, replace with new part. PM-00593 2. PROPELLER SHAFT Inspect the propeller shaft for damage or failure. If faulty, replace with new part. PM-93...
  • Page 166 Tire Check and Rotation PERIODIC MAINTENANCE SERVICES 23.Tire Check and Rotation A: INSPECTION 1) When the tread has worn to less than 1.6 mm (0.063 in) or the tread wear indicator appears across the tread, replace the tire. (Replace the right and left tire as a set.) PM-00080 (A) New tread (B) Damaged tread...
  • Page 167 Steering System (Power Steering) PERIODIC MAINTENANCE SERVICES 24.Steering System (Power Steering) A: INSPECTION 1. STEERING WHEEL 1) Set the steering wheel in a straight-ahead position, and check the wheel spokes to make sure they are cor- rectly set in their specified positions. 2) Lightly turn the steering wheel to the left and right to determine the point where front wheels start to move.
  • Page 168 Steering System (Power Steering) PERIODIC MAINTENANCE SERVICES 3. GEARBOX 1) Set the steering wheel in the straight position, then rotate it 90° in both the left and right directions. While steering wheel is being rotated, check the looseness of the gearbox. Tightening torque: 60 N·m (6.1 kgf-m, 44.3 ft-lb) PM-00668...
  • Page 169 Steering System (Power Steering) PERIODIC MAINTENANCE SERVICES 2) Confirm that the connections of knuckle ball joints for play, and then check for damage on dust boots and free play of ball studs. If castle nut is loose, retighten it to the specified torque, then tighten further up to a maximum of 60°...
  • Page 170 A/C Filter PERIODIC MAINTENANCE SERVICES 25.A/C Filter A: REPLACEMENT 1) Open the glove box and remove the damper stay pin. PM-00669 2) Press the glove box sidewall inwards and remove the upper grommet. PM-00670 3) Remove the tab of the lower part of the glove box. CAUTION: •...
  • Page 171 A/C Filter PERIODIC MAINTENANCE SERVICES 5) Remove the filter and install a new filter. NOTE: Install with “UP” mark facing upwards. PM-00673 6) Install in the reverse order of removal. PM-99...
  • Page 172 A/C Filter PERIODIC MAINTENANCE SERVICES PM-100...

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