Subaru 2004 user manual
552010 2004 Model Year
PDF Service Manual
GENERAL INFORMATION SECTION (Pub.No.G1870GE1) ENGINE SECTION 1 (Pub.No.G1870GE2) ENGINE SECTION 2 (Pub.No.G1870GE3)
TRANSMISSION SECTION (Pub.No.G1870GE4) CHASSIS SECTION (Pub.No.G1870GE5) BODY SECTION (Pub.No.G1870GE6)
WIRING SYSTEM SECTION (Pub.No.G1870GE7)
2004 IMPREZA SERVICE MANUAL
GENERAL INFORMATION SECTION
FOREWORD
QUICK REFERENCE INDEX
FW
HOW TO USE THIS MANUAL
HU
SPECIFICATIONS
SPC
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, reassembling, inspection and adjustment of components and diagnostics for guidance 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.
PRECAUTION
PC
NOTE
NT
IDENTIFICATION
ID
RECOMMENDED MATERIALS
RM
PRE-DELIVERY INSPECTION
PI
PERIODIC MAINTENANCE SERVICES PM
All information, illustration and specifications contained in this manual are based on the latest product information available at the time of publication approval.
FUJI HEAVY INDUSTRIES LTD.
G1870GE1
FOREWORD
FW
Page 1. Foreword .....................................................................................................2
FOREWORD
Foreword
1. Foreword
A: FOREWORD
These manuals are used when performing maintenance, repair, or diagnosis of the Subaru IMPREZA.
Applied model: GD*****, GG***** from 2004MY
The manuals contain the latest information at the time of publication. Changes in specifications, methods, etc. may be made without notice.
FW-2
HOW TO USE THIS MANUAL
HU
Page 1. How to Use This Manual .............................................................................2
HOW TO USE THIS MANUAL
How to Use This Manual
1. How to Use This Manual
A: HOW TO USE THIS MANUAL
1. STRUCTURE
Each section consists of SCT that are broken down into SC that are divided into sections for each component. The specification, maintenance and other information for the components are included, and diagnosis information has also been added where necessary.
2. INDEX
The first page has an index with tabs.
3. COMPONENTS
Illustrations are listed for each component. The information necessary for repair work (tightening torque, grease up points, etc.) is described on these illustrations. Information is described using symbol. To order the parts, refer to parts catalogue.
HU-2
Example:
How to Use This Manual
HOW TO USE THIS MANUAL
T8
T10
T6
(5) T2
T5
(1)
(2)
(4)
T6
(3)
(7)
(15)
(4) (3) (9)
(4) (10) (4)
T3
(2) T1 (1) T2
(3) (6)
T2
(5) (7)
T3
(4)
(8)
(20) (21) T3
T3
(6) T4
(11) (10)
(12) (22)
(23) T3
(9)
(14) (16)
(10) (11) (13)
(18) T1
T2
(15) (17)
(19)
T4
T2 (8)
T2
T11
T6 (22)
(10) (14)
(23) T7
T5
(3)
(12)
T2 (24)
T4 (27)
(26)
(25)
(24)
T5 (34)
(10) (16)
T3 T1
T2 (17) (18)
T1
(13) (21)
(25)
(29) (28)
(31) (30)
(37) (33) (32)
T4
:Selective part :Replacement part :Sealing point
(35) T3
(36) T5
:Should be lubricated with oil.
(20) T9 (19)
:Should be lubricated with grease.
T1 , T2 .... :Tightening torque
HU-00017
HU-3
HOW TO USE THIS MANUAL
How to Use This Manual
4. SPECIFICATIONS
If necessary, specifications are also included.
5. INSPECTION
Inspections are included to be carried out before and after maintenance.
6. MAINTENANCE
· Maintenance instructions for serviceable parts describes work area and detailed steps with illustration. It also describes the use of special tool, tightening torque, cautions for each procedure. · If many serviceable parts are included in one service procedure, appropriate reference are provided for each part. Example:
15.Main Shaft Assembly for Sin-
(A)
gle-Range
A: REMOVAL
(B)
1) Remove the manual transmission assembly
from vehicie. <Ref. to MT-33, REMOVAL, Manual
Transmission Assembly.>
(C)
11) Tighten the lock nuts to the specified torque using ST1 and ST2.
NOTE:
(D)
Secure the lock nuts in two Places affer tightening.
ST2 499987003 SOCKET WRENCH
ST1 498937000 TRANSMISSION HOLDER
(E)
(F)
Tightening torque:
118 N m (12.0 kgf-m, 86.8 ft-lb)
(G)
(H)
ST2
ST1
(A) Component (B) Process (C) Reference
(D) Caution (E) Tool number of special tool (F) Name of special tool
(G) Tightening torque (H) Illustration
HU-00002
HU-4
How to Use This Manual
HOW TO USE THIS MANUAL
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. Example:
Tightening torque: 44 N·m (4.5 kgf-m, 33 ft-lb)
Item Force Mass (Weight) Capacity Torque Rotating speed Pressure
Power Calorie Fuel consumption rate
SI Units N (Newton) kg, g 2, m2 or cm3 N·m rpm kPa (kilopascal)
W Wh g/kwh
Conventional unit kgf kg, g 2 or cc
kgf-m, kgf-cm rpm kgf/cm2 mmHg PS cal g/PSh
Remarks 1 kgf = 9.80655 N
1 cc = 1 cm3 = 1 m2 1 kgf-m = 9.80655 N·m
1 kgf/cm2 = 98.0655 kPa 1 mmHg = 0.133322 kPa 1 PS = 0.735499 kW 1 kcal = 1.16279 Wh 1 g/PSh = 1.3596 g/kWh
The figure used in this manuals are described in the SI units and conventional units are described in ( ).
HU-5
HOW TO USE THIS MANUAL
How to Use This Manual
9. EXPLANATION OF TERMINOLOGY
· List
AAI A/B ABS A/C A/F ALT ASSY AT ATF AVCS AWD BATT CD-R/RW COMPL CPU DOHC ECM EGI E/G EGR ELR F/B FL FWD HID H/U IG IN INT ISC
: Air Assist Injection : Airbag : Antilock Brake System : Air conditioner : Air Fuel Ratio : Generator : Assembly : Automatic transmission : Automatic transmission fluid : Active Valve Control System : All Wheel Drive : Battery : CD Recordable/ReWritable : Complete : Central Processing Unit : Double Overhead Camshaft : Engine Control Module (ECM) : Electronic Gasoline Injection : Engine : Exhaust Gas Recirculation : Emergency Locking Retractor : Fuse & Joint Box : Fusible Link : Front Wheel Drive : High-Intensity Discharge : Hydraulic Unit : Ignition : Intake : Intermittent : Idle Speed Control
LH LSD M/B MD MPi MP-T MT Nonturbo
NC NO OP P/S P/W PCD PCV RH SOHC SRC SSM ST SW TGV T/M ViS-C VSV VTD W/H Pr 2ndr
: LH (Left Hand) : Limited Slip Differential : Main Fuse & Relay Box : Mini Disc : Multi Point injection : Multi-Plate Transfer : Manual transmission : Natural Aspiration
: Normal Close (Relay) : Normal Open (Relay) : Option Parts : Power Steering : Power Window : Pitch Circle Diameter : Positive Crankcase Ventilation : RH (Right Hand) : Single Overhead Camshaft : Supplemental Restraint System : Subaru Select Monitor : Special Tool : Switch : Tumble generated valve : Transmission : Viscous Coupling : Vacuum Switching Valve : Variable Torque Distribution : Wiring harness : Primary : Secondary
HU-6
SPECIFICATIONS
SPC
Page 1. Impreza .......................................................................................................2
SPECIFICATIONS
1. Impreza
A: DIMENSIONS
Model Overall length Overall width Overall height (at C.W.)
Compartment
Length Width Height
Wheelbase Tread
Front
Rear
Minimum road clearance
Without catalytic converter
With catalytic converter
#1: 1.6 L #2: 2.0 L
#3: 2.0 L Turbo
#4: With roof rail #5: With sun roof
mm (in) mm (in) mm (in)
mm (in) mm (in) mm (in)
mm (in) mm (in)
mm (in)
mm (in)
mm (in)
Impreza
Sedan
1,740 (68.4) 1,440 (56.7) 1,890 (74.4)
1,180 (46.5), 1,125 (44.3)#5
1,485 (58.5) 1,475 (58.1), 1,480 (58.3)#3
150 (5.9), 155 (6.1)#2 150 (5.9), 155 (6.1)#3
Wagon
OUTBACK
4,415 (173.8)
1,695 (66.7)
1,710 (67.3)
1,465 (57.7), 1,485 (58.5)#4
1,475 (58.1), 1,495 (58.9)#4
1,845 (72.6)
1,380 (54.3)
1,200 (47.2), 1,150 (45.3)#5
1,200 (47.2), 1,150 (45.3)#5
2,525 (99.4)
1,460 (57.5)#1, 1,465 (57.7)
1,460 (57.5)
1,450 (57.1)#1, 1,455 (57.3)
1,455 (57.3)
150 (5.9), 155 (6.1)#2
160 (6.3)
150 (5.9), 155 (6.1)#3
160 (6.3)
STi 1,740 (68.1) 1,440 (56.7) 1,890 (74.4)
1,180 (46.5)
1,490 (58.7) 1,480 (58.3)
-- 155 (6.1)
SPC-2
Impreza
SPECIFICATIONS
B: ENGINE
Model Engine type Valve arrangement Bore × Stroke
Displacement Compression ratio Firing order Idle speed at Park/Neutral position Maximum output
Maximum torque
mm (in) cm3 (cu in)
rpm kW (HP)/rpm
N·m (kgf-m, ft-lb) /rpm
1.6 L
Non-turbo 2.0 L Turbo 2.0 L
2.5 L
STi
Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine
Overhead camshaft type
87.9 × 65.8 (3.461 × 2.591)
92 × 75 (3.62 × 2.95)
99.5 × 79 (3.92 × 3.11)
92 × 75 (3.62 × 2.95)
1,597 (97.45)
1,994 (121.67)
2,457 (149.9) 1,994 (121.67)
10.0±0.2
8.0±0.2
10.0±0.2
8.0±0.2
1 -- 3 -- 2 -- 4
650±100#2 700±100#1
650±100#2 700±100#1
700±100#4 750±100
650±100
700±100
70 (94)/5,200
92 (123)/5,600
160 (215)/5,600
168 (225)/6,000#3
165 (221)/5,600#4
112 (150)/5,600
195 (261)/6,000
143 (14.6, 105.5)
/3,600
184 (18.8, 136.0)
/3,600
292 (29.8, 215.4)
/3,600 300
(30.6, 221.3) /3,600#3, 4,000#4
223 (22.7, 164.5)
/3,600
343 (35.0, 253.0)
/4,000
#1: Without OBD
#2: With OBD #3: Australia model
#4: Europe model
C: ELECTRICAL
Model Ignition timing at idling Spark Type and plug manufacturer
Generator Battery Type and
capacity (5HR)
BTDC Without OBD
With OBD
For Europe and South America For Australia Others
1.6 L
5°±10°
NGK: BKR6E (without catalyst)
CHAMPION: RC8YC4
(with catalyst) NGK: BKR6E-11
(with catalyst) CHAMPION:
RC8YC4 Alternate NGK: BKR6E-11
12V -- 48AH (55D23L)
--
Non-turbo 2.0 L Turbo 2.0 L
10°±10°
12°±10°
NGK: BKR6E (without catalyst)
CHAMPION: RC10YC4
(with catalyst) NGK: BKR5E-11
(with catalyst)
CHAMPION: RC10YC4
Alternate NGK: BKR5E-11
--
NGK: PFR6G 12V -- 75A
MT: 12V -- 48AH (55D23L) AT: 12V -- 52AH (65D23L)
12V -- 27AH (34B19L)
12V -- 40AH (50D20L)
12V -- 27AH (34B19L)
2.5 L MT: 10°±10° AT: 15°±10°
CHAMPION: RC10YC4
NGK: BKR5E-11
--
-- 12V -- 27AH
(34B19L)
STi 12°±10°
--
NGK: PFR6G
12V -- 48AH (55D23L)
12V -- 40AH (50D20L) --
SPC-3
SPECIFICATIONS
Impreza
D: TRANSMISSION
Model
Transmission type
Clutch type
Gear ratio
1st
2nd
3rd
4th 5th
6th
Reduction 1st gear (Front reduction drive)
Final reduction
Reduction gear (Rear drive) (AWD model)
Transfer reduction
Final reduction
Reverse Dual range Type of gear Gear ratio Type of gear Gear ratio
Type of gear Gear ratio
Type of gear Gear ratio
1.6 L
5MT
4AT
DSPD TCC
3.454 2.785
2.062 1.545
1.448 1.088 0.825
1.000 0.694
--
-- 3.333 1.447
-- 2.272
--
Non-turbo 2.0 L
5MT
4AT
DSPD TCC
3.454 2.785
2.062 1.545
1.448 1.088 0.825
1.000 0.694
--
-- 3.333 1.447
-- 2.272
--
Turbo 2.0 L
5MT
4AT
DSPD TCC
3.454, 3.166#1 2.785
1.947, 1.882#1 1.545
1.366, 1.296#1 1.000
0.972 0.694
0.738
--
-- 3.333
--
-- 2.272
--
2.5 L
5MT
4AT
DSPD TCC
3.454 2.785
2.062 1.545
1.448 1.000
1.088
0.871, 0.780#1
0.694 --
--
--
3.333 2.272
--
--
STi 6MT DSPD
3.636
2.375
1.761
1.346 0.971, 1.062#1 0.756, 0.842#1 3.545
--
--
Helical
--
Helical
--
Helical
--
Helical
--
--
1.000
--
1.000
--
1.000
--
1.000
--
Hypoid 4.111 Helical 1.000 Hypoid 4.111
Hypoid 4.444
-- -- Hypoid 4.444
Hypoid 3.900 Helical 1.000 Hypoid 3.900
Hypoid Hypoid Hypoid
3.900, 4.111 4.444#1 4.444
--
Helical
--
1.100,
--
1.000#1
--
Hypoid Hypoid Hypoid
3.545, 4.111 4.444#1 4.444
Hypoid 4.111 Helical 1.000 Hypoid 4.111
Hypoid Hypoid
4.111 3.900
--
Helical
1.100,
--
1.000#1
Hypoid Hypoid
3.545, 4.111 3.900#1
5MT: 5-forward speeds with synchromesh and 1-reverse 4AT: Electronically controlled fully-automatic, 4-forward speeds and 1-reverse 6MT: 6-forward speeds with synchromesh and 1-reverse DSPD: Dry Single Plate Diaphragm TCC: Torque Converter Clutch #1: Australia spec vehicle
E: STEERING
Model Type Turns, lock to lock
Minimum turning circle m (ft)
F: SUSPENSION
Turbo 2.0 L, 2.5 L
Curb to curb Wall to wall
RHD: 2.69 LHD: 3.02 11 (36.1) 12.0 (39.4)
OUTBACK
2.0 L NA, 1.6 L
Rack and Pinion
3.02
3.22
11 (36.1) 11.6 (38.1)
10.4 (34.1) 11.2 (36.7)
STi
2.69 11 (36.1) 12.0 (39.4)
Front Rear
Macpherson strut type, Independent, Coil spring Dual-link type, Independent, Coil spring
SPC-4
Impreza
SPECIFICATIONS
G: BRAKE
Model Service brake system Front Rear Parking brake
H: TIRE
1.6 L
Non-turbo 2.0 L, 2.5 L
Turbo 2.0 L, STi
Dual circuit hydraulic with vacuum suspended power unit
Ventilated disc brake
Drum brake
Disc brake
Ventilated disc brake
Mechanical on rear brakes
Model
BASE, TS
Rim size Tire size
14 × 51/2JJ 185/70R14 88H
Type
I: CAPACITY
GX, TS 15 × 6JJ 195/60R15 88H
RS, WRX
OUTBACK
16 × 61/2JJ
16 × 61/2JJ
205/50R16 87V P205/55R16 89V
Steel belted radial, Tubeless
WRX 17 × 7JJ 215/45R17 87W
STi 17 × 71/2JJ 225/45R17 90W
Model
Fuel tank
2 (US gal, Imp gal)
Engine Total 2 (US qt,
oil
capacity Imp qt)
1.6 L FWD 5MT 4AT
1.6 L AWD Non-turbo 2.0 L Turbo 2.0 L 5MT 4AT 5MT 4AT 5MT 4AT
2.5 L 5MT 4AT
50 (13.2, 11.0)
60 (15.9, 13.2)
4.0 (4.2, 3.5)
4.5 (4.8, 4.0) 4.0 (4.2, 3.5)
Engine oil amount for refill Transmission gear oil
ATF
Front differential gear oil
Rear differential gear oil
2 (US qt, Imp qt)
2 (US qt, Imp qt)
2 (US qt, Imp qt)
2 (US qt, Imp qt)
2 (US qt, Imp qt)
3.3 (3.5, -- 2.9)
8.0 -- (8.5,
7.0) 1.2 -- (1.3, 1.1)
--
3.5 (3.7, 3.1), 4.0 (4.2, 3.5)#1
--
--
Approx. 4.0 (4.2, 3.5)
3.5
(3.7,
3.1),
--
4.0
--
(4.2, 3.5)
#1
8.4
8.4
(8.9, -- (8.9,
7.4)
7.4)
1.2
1.2
(1.3, -- (1.3,
1.1)
1.1)
3.5 (3.7, 3.1)
--
--
0.8 (0.8, 0.7)
--
9.3 (9.8, 8.2) 1.2 (1.3, 1.1)
3.5 (3.7, 3.1)
--
--
--
9.3 (9.8, 8.2) 1.2 (1.3, 1.1)
Power steering fluid
Engine coolant
2 (US qt, Imp qt)
2 (US qt, Imp qt)
#1: Dual range
7.4 (7.8, 6.5)
7.3 (7.7, 6.4)
7.4 (7.8, 6.5)
7.3 (7.7, 6.4)
0.7 (0.7, 0.6)
7.0 (7.4, 6.2)
6.9 (7.3, 6.1)
7.7 (8.1, 6.8)
7.6 (8.0, 6.7)
7.0 (7.4, 6.2)
6.9 (7.3, 6.1)
STi 6MT
4.5 (4.8, 4.0)
4.1 (4.3, 3.6)
--
-- 1.0 (1.1, 0.9)
7.7 (8.1, 6.8)
SPC-5
SPECIFICATIONS
Impreza
J: WEIGHT
1. LHD MODEL
Sedan
Option code#1
E2
Model
FWD
Base
5MT
4AT
Curb weight (C.W.)
Front
kgf (lb) 720
765
770
(1,587) (1,687) (1,698)
Rear
kgf (lb) 470
470
470
(1,036) (1,036) (1,036)
Total
kgf (lb) 1,190 1,235 1,240 (2,624) (2,723) (2,734)
Maximum permissible Front axle weight (M.P.A.W.)
kgf (lb) 890
890
890
(1,962) (1,962) (1,962)
Rear
kgf (lb) 890
890
890
(1,962) (1,962) (1,962)
Maximum permissible Total weight (M.P.W.)
kgf (lb) 1,660 1,660 1,660 (3,660) (3,660) (3,660)
Option
Air conditioner
ABS
--
--
Side airbag
--
--
--
Sunroof
--
--
--
Aluminium wheel --
--
--
Audio
--
--
--
Seat in pure hide --
--
--
Rear spoiler
--
--
--
Front LSD
--
--
--
Driver's control center differential
--
--
--
#1: For option code, refer to ID section. <Ref. to ID-7, Option code.>
EC 1.6 L
735 (1,620)
520 (1,146) 1,255 (2,756)
890 (1,962)
890 (1,962) 1,700 (3,748)
-- -- -- -- -- -- -- --
--
755 (1,664)
520 (1,146) 1,275 (2,810)
890 (1,962)
890 (1,962) 1,700 (3,748)
-- -- -- -- -- -- --
--
K0
AWD TS 5MT 750
(1,654) 520
(1,146) 1,270 (2,800) 890 (1,962) 890 (1,962) 1,700 (3,748)
-- -- -- -- -- -- -- --
--
K4
750 (1,654)
520 (1,146) 1,270 (2,800)
890 (1,962)
890 (1,962) 1,700 (3,748)
-- -- -- -- -- -- -- --
--
KS
740 (1,631)
535 (1,179) 1,275 (2,810)
890 (1,962)
890 (1,962) 1,700 (3,748)
-- -- -- -- -- -- -- --
--
SPC-6
Impreza
SPECIFICATIONS
Option code#1 Model
EC
K0
1.6 L
TS
4AT
Curb weight (C.W.)
Front
kgf (lb) 755
775
770
(1,644) (1,709) (1,698)
Rear
kgf (lb) 520
520
520
(1,146) (1,146) (1,146)
Total
kgf (lb) 1,275 1,295 1,290 (2,810) (2,855) (2,844)
Maximum permissible Front axle weight (M.P.A.W.)
kgf (lb) 890
890
890
(1,962) (1,962) (1,962)
Rear
kgf (lb) 890
890
890
(1,962) (1,962) (1,962)
Maximum permissible Total weight (M.P.W.)
kgf (lb) 1,700 1,700 1,700 (3,748) (3,748) (3,748)
Option
Air conditioner
--
ABS
--
Side airbag
--
--
--
Sunroof
--
--
--
Aluminium wheel --
--
--
Audio
--
--
--
Seat in pure hide --
--
--
Rear spoiler
--
--
--
Front LSD
--
--
--
Driver's control center differential
--
--
--
#1: For option code, refer to ID section. <Ref. to ID-7, Option code.>
K4
KS
AWD
770 (1,698)
520 (1,146) 1,290 (2,844)
890 (1,962)
890 (1,962) 1,700 (3,748)
-- -- -- -- -- -- -- --
--
760 (1,676)
530 (1,168) 1,295 (2,855)
890 (1,962)
890 (1,962) 1,700 (3,748)
-- -- -- -- -- -- -- --
--
750 (1,654)
535 (1,179) 1,285 (2,833)
950 (2,094)
910 (2,006) 1,760 (3,880)
-- -- -- -- -- -- -- --
--
EC 2.0 L
GX 5MT 770 (1,698) 535 (1,179) 1,305 (2,877) 950 (2,094) 910 (2,066) 1,760 (3,880)
-- -- -- -- -- -- --
--
765 (1,687)
535 (1,179) 1,300 (2,866)
950 (2,094)
910 (2,066) 1,760 (3,880)
-- -- -- -- --
--
SPC-7
SPECIFICATIONS
Impreza
Option code#1
E2
K4
K0
Model
2.0 L
AWD
GX
5MT
Curb weight (C.W.)
Front
kgf (lb) 770
765
770
765
760
(1,698) (1,687) (1,698) (1,687) (1,676)
Rear
kgf (lb) 535
535
535
530
525
(1,179) (1,179) (1,179) (1,168) (1,157)
Total
kgf (lb) 1,305 1,300 1,305 1,295 1,285 (2,877) (2,866) (2,877) (2,855) (2,833)
Maximum permissible Front axle weight (M.P.A.W.)
kgf (lb) 950
950
950
950
950
(2,094) (2,094) (2,094) (2,094) (2,094)
Rear
kgf (lb) 910
910
910
910
910
(2,066) (2,066) (2,066) (2,066) (2,066)
Maximum permissible Total weight (M.P.W.)
kgf (lb) 1,760 1,760 1,760 1,760 1,760 (3,880) (3,880) (3,880) (3,880) (3,880)
Option
Air conditioner
ABS
Side airbag
--
--
--
--
Sunroof
--
--
--
--
--
Aluminium wheel --
--
--
Audio
--
--
--
--
--
Seat in pure hide --
--
--
--
--
Rear spoiler
--
--
--
--
--
Front LSD
--
--
--
--
--
Driver's control center differential
--
--
--
--
--
#1: For option code, refer to ID section. <Ref. to ID-7, Option code.>
KS
765 (1,687)
560 (1,235) 1,325 (2,921)
950 (2,094)
910 (2,066) 1,760 (3,880)
-- -- -- -- --
--
EC
4AT
775
795
(1,709) (1,753)
530
530
(1,168) (1,168)
1,305 1,325 (2,877) (2,921)
950
950
(2,094) (2,094)
910
910
(2,006) (2,006)
1,760 1,760 (3,880) (3,880)
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
SPC-8
Impreza
SPECIFICATIONS
Option code#1 Model
EC
E2
Curb weight (C.W.)
Front
kgf (lb) 790
795
790
(1,742) (1,742) (1,742)
Rear
kgf (lb) 530
530
530
(1,168) (1,168) (1,168)
Total
kgf (lb) 1,320 1,325 1,320 (2,910) (2,921) (2,910)
Maximum permissible Front axle weight (M.P.A.W.)
kgf (lb) 950
950
950
(2,094) (2,094) (2,094)
Rear
kgf (lb) 910
910
910
(2,006) (2,006) (2,006)
Maximum permissible Total weight (M.P.W.)
kgf (lb) 1,760 1,760 1,760 (3,880) (3,880) (3,880)
Option
Air conditioner
ABS
Side airbag
--
Sunroof
--
--
--
Aluminium wheel
--
Audio
--
--
--
Seat in pure hide --
--
--
Rear spoiler
--
--
--
Front LSD
--
--
--
Driver's control center differential
--
--
--
#1: For option code, refer to ID section. <Ref. to ID-7, Option code.>
K4
2.0 L
AWD
GX
4AT
795
790
(1,753) (1,742)
530
525
(1,168) (1,157)
1,325 1,315 (2,921) (2,899)
950
950
(2,094) (2,094)
910
910
(2,006) (2,006)
1,760 1,760 (3,880) (3,880)
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
K0
795 (1,753)
530 (1,168) 1,325 (2,921)
950 (2,094)
910 (2,006) 1,760 (3,880)
-- -- -- -- -- -- --
--
KS
790 (1,753)
555 (1,224) 1,325 (2,921)
950 (2,094)
910 (2,006) 1,760 (3,880)
-- -- -- --
--
EC 2.0 L Turbo
WRX 5MT 835 (1,841) 560 (1,235) 1,395 (3,075) 990 (2,185) 920 (2,028) 1,850 (4,079)
-- -- -- -- --
--
SPC-9
SPECIFICATIONS
Impreza
Option code#1 Model
Curb weight (C.W.)
Front
kgf (lb) 820
835
835
(1,808) (1,841) (1,841)
Rear
kgf (lb) 550
555
560
(1,213) (1,224) (1,235)
Total
kgf (lb) 1,370 1,390 1,395 (3,020) (3,065) (3,075)
Maximum permissible Front axle weight (M.P.A.W.)
kgf (lb) 990
990
990
(2,185) (2,185) (2,185)
Rear
kgf (lb) 920
920
920
(2,028) (2,028) (2,028)
Maximum permissible Total weight (M.P.W.)
kgf (lb) 1,850 1,850 1,850 (4,079) (4,079) (4,079)
Option
Air conditioner
--
ABS
Side airbag
--
--
Sunroof
--
--
--
Aluminium wheel --
--
--
Audio
--
--
--
Seat in pure hide --
--
--
Rear spoiler
--
--
--
Front LSD
--
--
--
Driver's control center differential
--
--
--
#1: For option code, refer to ID section. <Ref. to ID-7, Option code.>
EC
2.0 L Turbo
AWD
WRX
5MT
840
835
(1,852) (1,840)
570
565
(1,257) (1,246)
1,410 1,400 (3,109) (3,087)
990
990
(2,185) (2,185)
920
920
(2,028) (2,028)
1,850 (4,079)
1,850 (4,079)
--
--
--
--
--
--
--
--
--
--
--
840 (1,852)
570 (1,257) 1,410 (3,109)
990 (2,185)
920 (2,028) 1,850 (4,079)
-- -- -- -- --
--
840 (1,852)
570 (1,257) 1,410 (3,109)
990 (2,183)
920 (2,028) 1,850 (4,079)
-- -- -- --
--
840 (1,852)
575 (1,268) 1,415 (3,120)
990 (2,183)
920 (2,028) 1,850 (4,079)
-- --
--
SPC-10
Impreza
SPECIFICATIONS
Option code#1
K4
Model
WRX
Curb weight (C.W.)
Front
kgf (lb) 835
840
840
(1,840) (1,852) (1,852)
Rear
kgf (lb) 560
575
575
(1,235) (1,268) (1,268)
Total
kgf (lb) 1,395 1,415 1,415 (3,075) (3,120) (3,120)
Maximum permissible Front axle weight (M.P.A.W.)
kgf (lb) 990
990
990
(2,183) (2,183) (2,183)
Rear
kgf (lb) 920
920
920
(2,028) (2,028) (2,028)
Maximum permissible Total weight (M.P.W.)
kgf (lb) 1,850 1,850 1,850 (4,079) (4,079) (4,079)
Option
Air conditioner
ABS
Side airbag
--
Sunroof
--
Aluminium wheel --
--
--
Audio
--
--
--
Seat in pure hide --
--
Rear spoiler
Front LSD
--
--
--
Driver's control center differential
--
--
--
#1: For option code, refer to ID section. <Ref. to ID-7, Option code.>
2.0 L Turbo AWD
5MT
885
865
(1,951) (1,907)
585
585
(1,290) (1,290)
1,470 1,450 (3,241) (3,197)
1,030 1,030 (2,271) (2,271)
920
920
(2,028) (2,028)
1,880 1,880 (4,145) (4,145)
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
EC
STi
885 (1,951)
585 (1,290) 1,470 (3,241) 1,030 (2,271)
920 (2,028) 1,880 (4,145)
-- -- -- -- --
--
885 (1,951)
585 (1,290) 1,470 (3,241) 1,030 (2,271)
920 (2,028) 1,880 (4,145)
-- -- -- -- -- --
865 (1,907)
585 (1,290) 1,450 (3,197) 1,030 (2,271)
920 (2,028) 1,880 (4,145)
-- -- -- -- -- -- --
SPC-11
SPECIFICATIONS
Impreza
Wagon
Option code#1
EC
K0
K4
Model
1.6 L
AWD
TS
5MT D/R
Curb weight (C.W.)
Front
kgf (lb) 740
740
760
755
755
(1,631) (1,631) (1,676) (1,664) (1,664)
Rear
kgf (lb) 545
550
545
545
545
(1,202) (1,213) (1,202) (1,202) (1,202)
Total
kgf (lb) 1,285 1,290 1,305 1,300 1,300 (2,833) (2,844) (2,877) (2,866) (2,866)
Maximum permissible Front axle weight (M.P.A.W.)
kgf (lb) 900
900
900
900
900
(1,984) (1,984) (1,984) (1,984) (1,984)
Rear
kgf (lb) 910
910
910
910
910
(2,006) (2,006) (2,006) (2,006) (2,006)
Maximum permissible Total weight (M.P.W.)
kgf (lb) 1,730 1,730 1,730 1,730 1,730 (1,609) (1,609) (1,609) (1,609) (1,609)
Option
Air conditioner
--
--
ABS
--
--
Side airbag
--
--
--
--
Sunroof
--
--
--
--
--
Aluminium wheel --
--
--
--
--
Audio
--
--
--
--
Seat in pure hide --
--
--
--
--
Spoiler pack
--
--
--
--
--
#1: For option code, refer to ID section. <Ref. to ID-7, Option code.> D/R: Dual range
KS
745 (1,643)
560 (1,235) 1,305 (2,877)
900 (1,984)
910 (2,006) 1,730 (1,609)
-- -- -- -- -- -- --
EC
4AT
755
755
(1,664) (1,664)
545
550
(1,202) (1,213)
1,300 1,305 (2,866) (2,877)
900
900
(1,984) (1,984)
910
910
(2,006) (2,006)
1,730 1,730 (1,609) (1,609)
--
--
--
--
--
--
--
--
--
--
--
--
SPC-12
Impreza
SPECIFICATIONS
Option code#1 Model
EC
K0
K4
1.6 L
TS
4AT
Curb weight (C.W.)
Front
kgf (lb) 775
770
770
(1,709) (1,698) (1,698)
Rear
kgf (lb) 545
545
545
(1,202) (1,202) (1,202)
Total
kgf (lb) 1,320 1,315 1,315 (2,910) (2,899) (2,899)
Maximum permissible Front axle weight (M.P.A.W.)
kgf (lb) 900
900
900
(1,984) (1,984) (1,984)
Rear
kgf (lb) 910
910
910
(2,006) (2,006) (2,006)
Maximum permissible Total weight (M.P.W.)
kgf (lb) 1,730 1,730 1,730 (1,609) (1,609) (1,609)
Option
Air conditioner
ABS
--
--
Side airbag
--
--
--
Sunroof
--
--
--
Aluminium wheel --
--
--
Audio
--
--
--
Seat in pure hide --
--
--
Spoiler pack
--
--
--
#1: For option code, refer to ID section. <Ref. to ID-7, Option code.>
D/R: Dual range
KS AWD
760 (1,676)
560 (1,235) 1,320 (2,910)
900 (1,984)
910 (2,006) 1,730 (1,609)
-- -- -- -- -- -- --
760 (1,676)
570 (1,257) 1,330 (2,932)
950 (2,094)
960 (2,0116)
1,800 (3,969)
-- -- -- -- -- -- --
EC 2.0 L
GX
5MT D/R
785
780
(1,731) (1,720)
585
570
(1,290) (1,257)
1,370 1,350 (3,020) (2,977)
950
950
(2,094) (2,094)
960
960
(2,116) (2,116)
1,800 1,800 (3,969) (3,969)
--
--
--
--
--
--
--
--
--
775 (1,709)
570 (1,257) 1,345 (2,965)
950 (2,094)
960 (2,116) 1,800 (3,969)
-- -- -- --
SPC-13
SPECIFICATIONS
Impreza
Option code#1 Model
K0
K4
5MT D/R
Curb weight (C.W.)
Front
kgf (lb) 780
780
775
(1,720) (1,720) (1,709)
Rear
kgf (lb) 570
570
565
(1,257) (1,257) (1,246)
Total
kgf (lb) 1,350 1,350 1,340 (2,977) (2,977) (2,955)
Maximum permissible Front axle weight (M.P.A.W.)
kgf (lb) 950
950
950
(2,094) (2,094) (2,094)
Rear
kgf (lb) 960
960
960
(2,116) (2,116) (2,116)
Maximum permissible Total weight (M.P.W.)
kgf (lb) 1,800 1,800 1,800 (3,969) (3,969) (3,969)
Option
Air conditioner
ABS
Side airbag
--
--
--
Sunroof
--
--
--
Aluminium wheel --
--
Audio
--
--
--
Seat in pure hide --
--
--
Spoiler pack
--
--
--
#1: For option code, refer to ID section. <Ref. to ID-7, Option code.>
D/R: Dual range
KS 2.0 L AWD GX
770 (1,698)
590 (1,300) 1,360 (2,999)
950 (2,094)
960 (2,116) 1,800 (3,969)
-- -- -- --
775 (1,709
565 (1,246) 1,340 (2,955)
950 (2,094)
960 (2,116) 1,800 (3,969)
-- -- -- -- -- -- --
EC
4AT
800
795
(1,764) (1,753)
580
565
(1,279) (1,246)
1,380 1,360 (3,042) (2,999)
950
950
(2,094) (2,094)
960
960
(2,116) (2,116)
1,800 1,800 (3,969) (3,969)
--
--
--
--
--
--
--
--
--
790 (1,742)
565 (1,246) 1,355 (2,987)
950 (2,094)
960 (2,116) 1,800 (3,969)
-- -- -- --
SPC-14
Impreza
SPECIFICATIONS
Option code#1 Model
K0
K4
2.0 L
GX
4AT
Curb weight (C.W.)
Front
kgf (lb) 795
795
790
(1,753) (1,753) (1,742)
Rear
kgf (lb) 565
565
560
(1,246) (1,246) (1,235)
Total
kgf (lb) 1,360 1,360 1,350 (2,999) (2,999) (2,977)
Maximum permissible Front axle weight (M.P.A.W.)
kgf (lb) 950
950
950
(2,094) (2,094) (2,094)
Rear
kgf (lb) 960
960
960
(2,116) (2,116) (2,116)
Maximum permissible Total weight (M.P.W.)
kgf (lb) 1,800 1,800 1,800 (3,969) (3,969) (3,969)
Option
Air conditioner
ABS
Side airbag
--
--
--
Sunroof
--
--
--
Aluminium wheel --
--
Audio
--
--
--
Seat in pure hide --
--
--
Spoiler pack
--
--
--
#1: For option code, refer to ID section. <Ref. to ID-7, Option code.>
D/R: Dual range
KS AWD
790 (1,742)
580 (1,279) 1,370 (3,020)
950 (2,094)
960 (2,116) 1,800 (3,969)
-- -- -- --
805 (1,775)
585 (1,290) 1,390 (3,065)
990 (2,183)
950 (2,094) 1,860 (4,101)
-- -- -- -- -- -- --
EC 2.0 L Turbo
WRX
5MT
825
830
(1,819) (1,830)
585
600
(1,290) (1,322)
1,410 1,430 (3,109) (3,153)
990
990
(2,183) (2,183)
950
950
(2,094) (2,094)
1,860 1,860 (4,101) (4,101)
--
--
--
--
--
--
--
--
--
830 (1,830)
600 (1,322) 1,430 (3,153)
990 (2,183)
950 (2,094) 1,860 (4,101)
-- -- --
SPC-15
SPECIFICATIONS
Impreza
Option code#1
EC
K4
Model
2.0 L Turbo
AWD
WRX
5MT
Curb weight (C.W.)
Front
kgf (lb) 830
830
(1,830) (1,830)
Rear
kgf (lb) 600
595
(1,322) (1,311)
Total
kgf (lb) 1,430 1,425 (3,153) (3,142)
Maximum permissible Front axle weight (M.P.A.W.)
kgf (lb) 990
990
(2,183) (2,183)
Rear
kgf (lb) 950
950
(2,094) (2,094)
Maximum permissible Total weight (M.P.W.)
kgf (lb) 1,860 1,860 (4,101) (4,101)
Option
Air conditioner
ABS
Side airbag
Sunroof
Aluminium wheel --
--
Audio
--
Seat in pure hide
--
Spoiler pack
--
--
#1: For option code, refer to ID section. <Ref. to ID-7, Option code.>
D/R: Dual range
SPC-16
Impreza
SPECIFICATIONS
2. RHD MODEL
Sedan
Option code#1 Model
EK 1.6 L
TS
5MT
4AT
Curb weight (C.W.)
Front
kgf (lb) 740
760
760
(1,631) (1,676) (1,676)
Rear
kgf (lb) 520
520
520
(1,146) (1,146) (1,146)
Total
kgf (lb) 1,260 1,280 1,280 (2,778) (2,822) (2,822)
Maximum permissible Front axle weight (M.P.A.W.)
kgf (lb) 890
890
890
(1,962) (1,962) (1,962)
Rear
kgf (lb) 890
890
890
(1,962) (1,962) (1,962)
Maximum permissible Total weight (M.P.W.)
kgf (lb) 1,700 1,700 1,700 (3,748) (3,748) (3,748)
Option
Air conditioner
--
--
ABS
Side airbag
--
--
--
Sunroof
--
--
--
Aluminium wheel --
--
--
Audio
--
--
--
Seat in pure hide --
--
--
Rear spoiler
--
--
--
Spoiler pack
--
--
--
Front LSD
--
--
--
Cruise control
--
--
--
#1: For option code, refer to ID section. <Ref. to ID-7, Option code.>
K1
AWD
5MT 750 (1,654) 520 (1,146) 1,270 (2,800) 890 (1,962) 890 (1,962) 1,700 (3,748) -- -- -- -- -- -- -- -- -- --
4AT 770 (1,698) 520 (1,146) 1,290 (2,844) 890 (1,962) 890 (1,962) 1,700 (3,748) -- -- -- -- -- -- -- -- -- --
EK 2.0 L
5MT 770 (1,698) 535 (1,179) 1,305 (2,877) 950 (2,094) 910 (2,006) 1,760 (3,880) -- -- -- -- -- --
GX 4AT 795 (1,753) 530 (1,168) 1,325 (2,921) 950 (2,094) 910 (2,006) 1,760 (3,880) -- -- -- -- -- --
K1
5MT 770 (1,698) 535 (1,179) 1,305 (2,877) 950 (2,094) 910 (2,006) 1,760 (3,880) -- -- -- -- -- -- -- -- --
SPC-17
SPECIFICATIONS
Impreza
Option code#1
K1
EK
Model
2.0 L
2.0 L Turbo
AWD
GX
WRX
4AT
5MT
Curb weight (C.W.)
Front
kgf (lb) 795
835
835
840
840
(1,753) (1,841) (1,841) (1,852) (1,852)
Rear
kgf (lb) 530
565
560
570
575
(1,168) (1,246) (1,246) (1,257) (1,268)
Total
kgf (lb) 1,325 1,400 1,395 1,410 1,415 (2,921) (3,086) (3,075) (3,109) (3,120)
Maximum permissible Front axle weight (M.P.A.W.)
kgf (lb) 950
990
990
990
990
(2,094) (2,183) (2,183) (2,183) (2,183)
Rear
kgf (lb) 910
920
920
920
920
(2,006) (2,028) (2,028) (2,028) (2,028)
Maximum permissible Total weight (M.P.W.)
kgf (lb) 1,760 1,850 1,850 1,850 1,850 (3,880) (4,079) (4,079) (4,079) (4,079)
Option
Air conditioner
ABS
Side airbag
--
--
Sunroof
--
--
--
Aluminium wheel --
--
--
--
--
Audio
--
--
--
--
--
Seat in pure hide --
--
--
--
Rear spoiler
--
Spoiler pack
--
--
--
--
--
Front LSD
--
--
--
--
--
Cruise control
--
--
--
--
--
#1: For option code, refer to ID section. <Ref. to ID-7, Option code.>
STi
6MT
885
885
(1,952) (1,952)
585
585
(1,290) (1,290)
1,470 1,470 (3,241) (3,241)
1,030 1,030 (2,271) (2,271)
920
920
(2,028) (2,028)
1,880 1,880 (4,145) (4,145)
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
SPC-18
Impreza
SPECIFICATIONS
Option code#1 Model
Unladen weight (U.W.)
Gross vehicle mass (G.V.M.)
Option
Front kg (lb)
Rear
kg (lb)
Total
kg (lb)
Front kg (lb)
Rear
kg (lb)
Total
kg (lb)
Air conditioner ABS Side airbag Sunroof Aluminium wheel Audio Seat in pure hide Rear spoiler Spoiler pack Front LSD Cruise control Driver's control center differential
KA
2.0 L
2.5 L
AWD
GX
RS
5MT
4AT
5MT
4AT
750
765
775
790
780
805
(1,654) (1,687) (1,709) (1,742) (1,720) (1,775)
535
535
530
530
540
535
(1,179) (1,179) (1,168) (1,168) (1,191) (1,179)
1,285 1,300 1,305 1,320 1,320 1,340 (2,833) (2,866) (2,877) (2,910) (2,910) (2,955)
950
950
950
950
950
950
(2,094) (2,094) (2,094) (2,094) (2,094) (2,094)
910
910
910
910
910
910
(2,006) (2,006) (2,006) (2,006) (2,006) (2,006)
1,760 (3,880)
--
1,760 (3,880)
1,760 (3,880)
--
1,760 (3,880)
1,780 (3,924)
1,780 (3,924)
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
#1: For option code, refer to ID section. <Ref. to ID-7, Option code.>
2.0 L Turbo
WRX
5MT
840
835
(1,852) (1,841)
575
560
(1,268) (1,235)
1,415 1,395 (3,120) (3,075)
990
990
(2,183) (2,183)
920
920
(2,028) (2,028)
1,850 1,850 (4,079) (4,079)
--
--
--
--
--
--
--
--
--
--
--
--
--
SPC-19
SPECIFICATIONS
Impreza
Option code#1 Model
Unladen weight (U.W.)
Gross vehicle mass (G.V.M.)
Option
Front kg (lb)
Rear
kg (lb)
Total
kg (lb)
Front kg (lb)
Rear
kg (lb)
Total
kg (lb)
Air conditioner ABS Side airbag Sunroof Aluminium wheel Audio Seat in pure hide Rear spoiler Spoiler pack Front LSD Cruise control Driver's control center differential
5MT 840 (1,852) 570 (1,257) 1,410 (3,109) 990 (2,183) 920 (2,028) 1,850 (4,079) -- -- -- -- -- --
--
KA
2.0 L Turbo
AWD
WRX
4AT
860
865
865
(1,896) (1,907) (1,907)
555
565
570
(1,234) (1,246) (1,257)
1,415 1,430 1,435 (3,120) (3,153) (3,164)
990
990
990
(2,183) (2,183) (2,183)
920
920
920
(2,028) (2,028) (2,028)
1,850 (4,079)
--
1,850 (4,079)
--
1,850 (4,079)
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
#1: For option code, refer to ID section. <Ref. to ID-7, Option code.>
STi
6MT
885
885
(1,952) (1,952)
585
585
(1,290) (1,290)
1,470 1,470 (3,241) (3,241)
1,030 1,030 (2,271) (2,271)
920
920
(2,028) (2,028)
1,880 1,880 (4,145) (4,145)
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
SPC-20
Impreza
SPECIFICATIONS
Wagon
Option code#1 Model
EK 1.6 L
TS
5MT D/R
4AT
Curb weight (C.W.)
Front
kgf (lb) 745
765
760
(1,642) (1,687) (1,676)
Rear
kgf (lb) 545
545
545
(1,202) (1,202) (1,202)
Total
kgf (lb) 1,290 1,310 1,305 (2,844) (2,888) (2,877)
Maximum permissible Front axle weight (M.P.A.W.)
kgf (lb) 900
900
900
(1,984) (1,984) (1,984)
Rear
kgf (lb) 910
910
910
(2,006) (2,006) (2,006)
Maximum permissible Total weight (M.P.W.)
kgf (lb) 1,730 1,730 1,730 (1,609) (1,609) (1,609)
Option
Air conditioner
--
--
ABS
Side airbag
--
--
--
Sunroof
--
--
--
Aluminium wheel --
--
--
Audio
--
--
--
Seat in pure hide --
--
--
Spoiler pack
--
--
--
Cruise control
--
--
--
#1: For option code, refer to ID section. <Ref. to ID-7, Option code.>
D/R: Dual range
K1
AWD
5MT D/R 755
(1,664) 545
(1,202) 1,300 (2,866) 900 (1,984) 910 (2,006) 1,730 (1,609)
-- -- -- -- -- -- -- --
4AT 770 (1,698) 545 (1,202) 1,315 (2,899) 900 (1,984) 910 (2,006) 1,730 (1,609) -- -- -- -- -- -- -- --
EK 2.0 L
5MT D/R 780
(1,720) 570
(1,257) 1,350 (2,977) 950 (2,094) 960 (2,116) 1,800 (3,969)
-- -- -- -- --
GX 4AT 795 (1,753) 565 (1,246) 1,360 (2,999) 950 (2,094) 960 (2,116) 1,800 (3,969) -- -- -- -- --
K1
5MT D/R 780
(1,720) 570
(1,257) 1,350 (2,977) 950 (2,094) 960 (2,116) 1,800 (3,969)
-- -- -- -- -- -- --
SPC-21
SPECIFICATIONS
Impreza
Option code#1
K1
EK
Model
2.0 L
2.0 L Turbo
AWD
GX
WRX
4AT
5MT
Curb weight (C.W.)
Front
kgf (lb) 795
825
825
830
(1,753) (1,819) (1,819) (1,830)
Rear
kgf (lb) 565
585
590
600
(1,246) (1,830) (1,301) (1,323)
Total
kgf (lb) 1,360 1,410 1,415 1,430 (2,999) (3,109) (3,120) (3,153)
Maximum permissible Front axle weight (M.P.A.W.)
kgf (lb) 950
990
990
990
(2,094) (2,183) (2,183) (2,183)
Rear
kgf (lb) 960
950
950
950
(2,116) (2,094) (2,094) (2,094)
Maximum permissible Total weight (M.P.W.)
kgf (lb) 1,800 1,860 1,860 1,860 (3,969) (4,101) (4,101) (4,101)
Option
Air conditioner
ABS
Side airbag
--
--
Sunroof
--
--
--
Aluminium wheel --
--
--
--
Audio
--
--
--
--
Seat in pure hide --
--
--
--
Spoiler pack
--
--
--
--
Cruise control
--
--
--
--
#1: For option code, refer to ID section. <Ref. to ID-7, Option code.>
D/R: Dual range
830 (1,830)
600 (1,323) 1,430 (3,153)
990 (2,183)
950 (2,094) 1,860 (4,101)
-- -- -- --
SPC-22
Impreza
SPECIFICATIONS
Option code#1
KA
Model
2.0 L
AWD
GX
OUTBACK
5MT D/R
4AT
5MT D/ R
4AT
Unladen weight (U.W.) Front
kg (lb) 760
775
775
790
770
785
(1,676) (1,709) (1,709) (1,742) (1,698) (1,731)
Rear
kg (lb) 570
570
565
565
570
570
(1,257) (1,257) (1,246) (1,246) (1,257) (1,257)
Total
kg (lb) 1,330 1,345 1,340 1,355 1,340 1,355 (2,932) (2,965) (2,955) (2,987) (2,955) (2,987)
Gross vehicle mass (G.V.M.)
Front
kg (lb) 950
950
950
950
950
950
(2,094) (2,094) (2,094) (2,094) (2,094) (2,094)
Rear
kg (lb) 960
960
960
960
960
960
(2,116) (2,116) (2,116) (2,116) (2,116) (2,116)
Total
kg (lb) 1,800 1,800 1,800 1,800 1,800 1,800 (3,969) (3,969) (3,969) (3,969) (3,969) (3,969)
Option
Air conditioner
--
--
ABS
Side airbag
--
--
--
--
--
--
Sunroof
--
--
--
--
--
--
Aluminium wheel --
--
--
--
Audio
--
--
--
--
--
--
Seat in pure hide --
--
--
--
--
--
Spoiler pack
--
--
--
--
Cruise control
#1: For option code, refer to ID section. <Ref. to ID-7, Option code.>
D/R: Dual range
2.0 L Turbo
WRX
5MT
4AT
825 (1,819)
585 (1,830) 1,410 (3,109)
990 (2,183)
950 (2,094) 1,860 (4,101)
-- -- -- -- -- --
850 (1,874)
585 (1,830) 1,435 (3,164)
990 (2,183)
950 (2,094) 1,860 (4,101)
-- -- -- -- -- --
SPC-23
SPECIFICATIONS
Impreza
SPC-24
PRECAUTION
PC
Page 1. Precaution ...................................................................................................2
PRECAUTION
Precaution
1. Precaution
A: PRECAUTION
Please clearly understand and adhere to the following general precautions. They must be strictly followed to avoid minor or serious injury to the person doing the work or people in the area.
1. ABS
Handle the ABS as a total system. Do not disassemble or attempt to repair parts which are not instructed in this manual. Follow the instructions in this manual during performing the maintenance of ABSCM&H/U. To disassemble parts without instructions could prevent the ABS system from operating when needed or cause it to operate incorrectly and result in injury.
2. BRAKE FLUID
If brake fluid gets in your eyes or on your skin, do the following: · Wash out your eyes and seek immediate medical attention. · Wash your skin with soap and then rinse thoroughly with water.
3. RADIATOR FAN
The radiator fan may rotate without warning, even when the engine is not on. Do not place your hand, cloth, tools, or other items near the fan at any time.
4. ROAD TESTS
Always conduct road tests in accordance with traffic rules and regulations to avoid bodily injury and interrupting traffic.
5. AIRBAG
To prevent bodily injury from unexpected deployment of airbags and unnecessary maintenance, follow the instructions in this manual when performing maintenance on the airbag components or nearby, and the airbag wiring harnesses or nearby. To prevent unexpected deployment, turn the ignition switch to OFF and disconnect the ground cable from battery, then wait at lease 20 seconds to discharge electricity before beginning work.
6. AIRBAG DISPOSAL
To prevent bodily injury from unexpected airbag deployment, do not dispose airbag modules in the same way as other refuse. Follow the special instructions for disposal in this manual. Follow all government regulations concerning disposal of refuse.
7. AIRBAG MODULE
Adhere to the following when handling and storing the airbag module to prevent bodily injury from unexpected deployment: · Do not hold the harnesses or connectors to carry module. · Do not face the bag in the direction that it opens towards yourself or other people. · Do not face the bag in the direction that it opens towards the floor or walls.
8. AIRBAG SPECIAL TOOLS
To prevent unexpected deployment, only use special tools.
9. WINDOW
Always wear safety glasses when working around any glass to prevent glass fragments from damaging your eyes.
10.WINDOW ADHESIVE
Always use the recommended or alternative adhesive when attaching glass to prevent it from coming loose and falling, resulting in accidents and injury.
PC-2
NOTE
NT
Page 1. Note.............................................................................................................2
NOTE
Note
1. Note
A: NOTE
This is information that can improve efficiency of maintenance and assure sound work.
1. FASTENER NOTICE
Fasteners are used to prevent parts from damage and dislocation due to looseness. Fasteners must be tightened to the specified torque. Do not apply paint, lubricant, rust retardant, or other substances to the surface around bolts, fasteners, etc. Doing so will make it difficult to obtain the correct torque and result in looseness and other problems.
2. STATIC ELECTRICITY DAMAGE
Do not touch the control unit, connectors, logic boards, and other such parts when there is a risk of static electricity. Always use a static electricity prevention cord or touch grounded metal before conducting work.
3. BATTERY
When removing the battery cables, always be sure to turn the ignition off to prevent electrical damage to the control unit from rush current.
4. SERVICE PARTS
Use authentic service parts for maximum performance and 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.
5. PROTECTING VEHICLE UNDER MAINTENANCE
Make sure to attach the fender cover, seat covers, etc. before work.
6. ENSURING SAFETY DURING WORK
When working in a group of two or more, perform the work with calling each other to ensure mutual safety.
NT-2
Note
NOTE
7. LIFTS AND JACKS
When using a lift or jack 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. Be sure to set the wheel stoppers when jacking-up only the front or rear of the vehicle.
(1)
(5) (6) (2)
(3)
(4)
(1) Support locations (2) Pantograph jack
(3) Lift (4) Rigid rack
NT-3
NT-00060
(5) Without side sill cover (6) With side sill cover
NOTE
(A)
(B)
Note
(1) (2)
NT-00062
(A) Front
(B) Rear
(1) Front crossmember
(2) Rear differential
8. TIE-DOWNS
Tie downs are used when transporting vehicles and when using the chassis dynamo. Attach tie downs only to the specified points on the vehicle. · Tie-down point
(1) (1)
(1) Hook for tie-down
(2) Hook for towing and tie-down
NT-4
(2) NT-00063
· Chain direction at tie-down condition
Note
NOTE
NT-00038
· Chain pulling range at tie-down condition
20°
20°
20°
20°
20°
20°
20°
20°
45° 45°
45° 45°
: (1)
NT-00064
(1) Chain pulling range at tie-down condition
· Vehicle sinking volume at tie-down condition
Measure the distance L between tire highest point to arch highest point before tie-down and after tiedown. Difference of measurement value (drop height) shall be within 50.8 mm (1.97 in). Make sure to fix the vehicle securely.
L
L
NT-00065
NT-5
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, to prevent excessive weight from damaging the hook or vehicle: · Do not tow other vehicles with a front hook for tie down. · Make sure the vehicle towing is heavier that the vehicle being towed. · Front
· Rear
NT-00067
NT-6
NT-00066
· NOTES
Towing Lifting up four wheels (On a trailer)
Note
NOTE
Notes
Towing the vehicle after lifting up all four wheels is a basic rule for AWD model.
MT AT
Rope
NT-00023
· Check if both front and rear wheels are rotated nor-
L
mally.
· AT model driving conditions: Allow driving speed less
than 30 km/h (19 MPH).
Allow driving distance less than 30 km (19 miles).
Raising the front wheels
NT-00024
Prohibited for full-time AWD model.
Lifting up the front wheels
NT-00025
· Prohibited, due to damage on bumper, front grille, etc.
· Do not raise the vehicle with bumper.
NT-00026
Marked : OK, Marked : Prohibited, Marked : Conditionally OK.
NT-7
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. · Release the parking brake to avoid tire dragging. · Since the power steering does not work, be careful for the heavy steering effort (When engine is stopped) · Since the servo brake does not work, be careful that the brake is not applied effectively. (When engine is stopped) · In case of the malfunction of internal transmission or drive system, lift up four wheels (on a trailer) for towing.
10.FRONT HOOD STAY INSTALLATION
· At the check and general maintenance
· When wider hood opening is necessary Set stay into the hole of hood inner as shown in the figure below.
NT-00068
NT-8
NT-00069
Note
11.TRAINING
For information about training, contact a dealer or agent.
12.GENERAL SCAN TOOL
Using general scan tools will greatly improve efficiency of repairing engine electronic controls. The Subaru Select Monitor can be used to diagnose the engine and also the ABS, the air conditioner, and other parts.
NOTE
NT-9
NOTE
Note
NT-10
IDENTIFICATION
ID
Page 1. Identification ................................................................................................2
IDENTIFICATION
Identification
1. Identification
A: IDENTIFICATION
1. IDENTIFICATION NUMBER AND LABEL LOCATIONS
The VIN (Vehicle Identification Numbers) is used to classify the vehicle. · POSITIONING OF THE PLATE LABEL FOR IDENTIFICATION
(3)
(2) (1)
(4)
(5) (7) (6)
ID-00052
(1) ID plate (Europe model) ADR compliance plate (Australia model)
(2) Vehicle identification number (VIN)
(3) Emission control label
· ENGINE
(4) Tire inflation pressure label (Driver (6) Model number plate
side) (Australia model)
(7) Vehicle identification number
Tire inflation pressure label (Driver
(VIN) (Europe RHD model and
side) (Except Australia model)
Australia turbo model)
(5) Saudi Arabia plate (Saudi Arabia model) Built date plate (Australia model)
· AUTOMATIC TRANSMISSION
(1)
(1)
(1) Engine serial number
ID-00053
(1) Transmission serial number
ID-00054
ID-2
· MANUAL TRANSMISSION
(1)
Identification
· REAR DIFFERENTIAL · T-type
IDENTIFICATION
(1)
(1) Transmission serial number
ID-00055
(1) Type (white paint)
· VA-type
(1)
ID-00056
· MODEL NUMBER PLATE
(1) Type (label)
DI-00396
ID-3
ID-00075
IDENTIFICATION
Identification
2. MEANING OF V.I.N.
The meaning of the VIN is as follows: · Europe, Australia and General (Except GCC)
]JF1GD4LG94G002001[ The starting and ending brackets ( ][ ) are stop marks.
Digits 1 to 3 4 5
6
Code JF1 G D
4
7
L
8
G
9
10 11 12 to 17
9
4 G 002001
Meaning Manufacturer body area Car line Body type Displacement
Steering position Engine & transmission
Drive type
Model year Factory location Serial number
Details
JF1: Passenger car, FHI made
IMPREZA
D: 4 Door Sedan G: Wagon
4: 1.6 L FWD 5: 1.6 L AWD 9: 2.0 L AWD A: 2.0 L AWD Turbo B: 2.0 L AWD High power turbo E: 2.5 L AWD
K: RHD (Right-hand drive model) L: LHD (Left-hand drive model)
G: SOHC MPI 5-speed MT R: SOHC MPI 4-speed AT J: SOHC MPI Full-time AWD 5-speed MT K: SOHC MPI Full-time AWD 5-speed MT Dual range D: DOHC Turbo Full-time AWD 5-speed MT H: DOHC Turbo Full-time AWD 6-speed MT T: DOHC Turbo 4-speed AT Sport Shift
3: Full-time AWD Single range 4: Full-time AWD Dual range 5: AWD AT 9: FWD
4: 2004MY
G: FHI (Gunma)
--
· GCC countries (Saudi Arabia, etc.)
]JF1GD45MX4G002001[ The starting and ending brackets ( ][ ) are stop marks.
Digits 1 to 3 4 5
6
7
8 9 10 11
12 to 17
Code JF1 G D
4
5
M X 4 G
002001
Meaning
Details
Manufacturer body area JF1: Passenger car, FHI made
Car line
IMPREZA
Body type
D: 4 Door Sedan G: Wagon
Displacement
4: 1.6 L AWD 8: 2.0 L AWD
Grade
5: TS 7: GX
Restraint
M: Manual belts, dual airbag
Check digit
0 to 9 & X
Model year
4: 2004MY
Transmission type
G: Full-time AWD 5-speed MT single range H: Full-time AWD 4-speed AT J: Full-time AWD 5-speed MT dual range
Serial number
--
ID-4
Identification
IDENTIFICATION
3. MODEL NUMBER PLATE
The model number plate indicates: the applied model, the option code, the trim code, the engine type, the transmission type, and the exterior color code. This information is helpful when placing orders for parts. GD9DL5R
Digits 1 2
3
Code G D
9
4
D
5
L
6
5
7
R
Meaning Series Body style Engine displacement Drive system Suspension system
Model year Destination Grade
Transmission, fuel feed system
Details
IMPREZA
D: 4 Door Sedan G: Wagon
4: 1.6 L FWD 5: 1.6 L AWD 9: 2.0 L AWD A: 2.0 L AWD Turbo B: 2.0 L AWD High power turbo E: 2.5 L AWD
D: 2004MY
K: Right-hand drive model market L: Left-hand drive model market
3: BASE 4: TS 5: GX 6: RS 7: OUTBACK 8: WRX E: STi
K: SOHC MPI Dual range 5-speed MT G: SOHC MPI 5-speed MT R: SOHC MPI 4-speed AT T: DOHC B MPI 4-speed AT Sport Shift J: SOHC MPI 5-speed MT AWD D: DOHC B MPI 5-speed MT AWD H: DOHC B MPI 6-speed MT AWD
The engine and transmission type are as follows: · Engine
EJ161RW6AA
Digits 1 and 2 3 and 4
5
6 7 8 to 10
Code EJ 16
1
R W 6AA
Meaning Engine type Displacement
Fuel feed system
Detailed specifications Transmission Detailed specifications
Details EJ: 4 cylinders
16: 1.6 L 20: 2.0 L 25: 2.5 L 1: D-MPI SOHC-A 5: MPI Turbo 7: MPI High power turbo
Used when ordering parts. See the parts catalog for details. W: MT X: AT
Used when ordering parts. See the parts catalog for details.
ID-5
IDENTIFICATION
Identification
· Transmission TM754RY5AA
Digits 1 2
Code T M
3 and 4
75
5
4
6
R
7 to 10
Y5AA
· Rear differential 1 VA-type
Meaning Transmission Transmission type
Classification Series Transmission specifications
Detailed specifications
Details
T: Transmission
Y: Full-time AWD MT center differential V: Full-time AWD AT center differential Z: Full-time AWD AT MPT M: FWD MT A: FWD AT
75: 5MT 85: 6MT 1A: AT 1B: AT
MT 4: 5MT 6: 6MT
AT 4: AT
A: FWD 4-speed AT R: FWD Single Range 5-speed MT V: Full-time AWD 5-speed MT with viscous coupling center differential single range W: Full-time AWD 6-speed MT with viscous coupling center differential single range X: Full-time AWD 5-speed MT with viscous coupling center differential dual range Z: Full-time AWD 4-speed AT with MPT Y: Full-time AWD 4-speed AT with VTD
Used when ordering parts. See the parts catalog for details.
Code
Reduction gear ratio
LSD
XN
4.111
No
XP
4.444
No
· Rear differential 2 T-type
Code
Reduction gear ratio
LSD
EG
3.900
No
EM
4.444
SURETRAC
EJ
4.111
Viscous
EF
3.545
Viscous
HJ
3.545
SURETRAC
HG
3.900
SURETRAC
HN
3.545
Mechanical
HK
3.900
Mechanical
ID-6
· Option code E2BL
Digits
1 -- 2
E2
Code
3
B
Identification
IDENTIFICATION
Meaning Destination
Option equipment
Details
EC: Europe model (LHD model) EK: Europe model (RHD model) EH: China model KS: Middle East model K4: Central and South America model KA: Australia model E2: Israel model K0: General model (LHD model) K1: General model (RHD model) Blank: Hong Kong model
A: Power window, Power door lock, ABS, Aluminum wheel B: Power window, Power door lock C: Power window, Power door lock, Cruise control, ABS, Aluminum wheel D: Power window, Power door lock, Cruise control, ABS, Front LSD, Driver's control center differential E: Power window, Power door lock, ABS F: Power window, Power door lock, Cruise control, ABS L: Power window, Power door lock, ABS, Roof rail, Aluminum wheel M: Power window, Power door lock, ABS, Roof rail N: Power window, Power door lock, Cruise control, ABS, Roof rail O: Power window, Power door lock, Cruise control, ABS, Roof rail, Aluminum wheel P: Power window, Power door lock, Aluminum wheel Q: Power window, Power door lock, Aluminum wheel R: Power window, Power door lock, Roof rail, Aluminum wheel T: Power window, Power door lock, Cruise control, ABS, Front LSD V: Power window, Power door lock, ABS, Front LSD Y: Power window, Power door lock, ABS, Front LSD, Driver's control center differential 6: Special edition model
ID-7
IDENTIFICATION
Digits
4
L
Code
Identification
Meaning Option equipment
Details
B: A/C, Airbag, Spoiler package C: A/C, Airbag, Rear spoiler F: A/C, Airbag, Sunroof G: A/C, Airbag, Side airbag I: A/C, Airbag, Audio, Rear spoiler J: A/C, Airbag, Spoiler package, Rear spoiler K: Airbag, Side airbag, Audio L: A/C, Airbag M: Airbag O: A/C, Sunroof, Airbag, Side airbag, Leather seat & door trim decorative woodturning, Audio, Rear spoiler P: A/C, Sunroof, Airbag, Side airbag, Rear spoiler Q: A/C, Sunroof, Airbag, Audio, Rear spoiler R: A/C, Airbag, Rear spoiler S: A/C, Airbag, Audio T: A/C, Sunroof, Airbag, Side airbag, Leather seat & door trim decorative woodturning, Audio U: A/C, Sunroof, Airbag, Side airbag V: A/C, Sunroof, Airbag, Side airbag, Leather seat & door trim decorative woodturning W: A/C, Sunroof, Airbag, Rear spoiler Y: A/C, Sunroof, Airbag, Side airbag, Audio Z: A/C, Sunroof, Airbag, Side airbag, Leather seat & door trim decorative woodturning, Rear spoiler 1: Special edition model 2: Special edition model 3: Special edition model
ID-8
RECOMMENDED MATERIALS
RM
Page 1. Recommended Materials ............................................................................2
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 a gasoline of the same or higher octane value than specified in the owner's manual. Ignoring the specifications below will result in damage or poor operation of the engine and fuel injection system. Use the specified gasoline to correct performance. · Unleaded gasoline
Use unleaded gasoline and not leaded gasoline on vehicles with catalytic converter installed to reduce air pollution. Using leaded gasoline will damage the catalytic converter.
Model SOHC DOHC turbo
Petrol Unleaded Unleaded
RON More than 95 RON More than 90 RON* More than 98 RON
*: KA, KS model
· Leaded gasoline
On vehicles without catalytic converter, use leaded gasoline with an octane value of 90 RON or higher.
RM-2
Recommended Materials
RECOMMENDED MATERIALS
3. LUBRICANTS
Use either the lubricants in the table below or equivalent lubricants. See the table below to choose the correct SAE viscosity.
Lubricant Engine oil
Recommended
API Spec.
CCMC Spec.
SL, SJ Grade "Energy conserving", or SH
G4 or G5
ACEA Spec. A1, A2 or A3
Alternative API Spec.
SG, SF
A VING
L ENE
PI SERVICE S
SAE 0W-20
RGY CONSER
RM-00006
A VING
L ENE
PI SERVICE S
SAE 5W-30
RGY CONSER
RM-00001
PETROLEUM
AMERICAN
INSTITUTE
FOR
GASOLINE
ENGINES
CE RTIFIED
RM-00002
Manual transmission oil
GL-5
--
--
--
AT front differential gear oil
GL-5
--
--
--
Rear differential gear oil
GL-5#1
--
--
--
#1: Use LSD oil for model with driver's control center differential.
RM-3
RECOMMENDED MATERIALS
Recommended Materials
SAE viscosity No. and applicable temperature Engine oil
SOHC model
(°C) 30
20
(°F) 22
4
10
0
14
32
10
20
50
68
10W-30 or 10W-40
30
40
86
104
5W-30
(°C)
30
20
(°F)
22
4
0W-20 Recommend
DOHC turbo model
10
0
14
32
10
20
50
68
RM-00007
30
40
86
104
10W-30 or 10W-40
5W-30 Recommend
RM-00003
RM-4
Recommended Materials
RECOMMENDED MATERIALS
SAE viscosity No. and applicable temperature Manual transmission oil, AT front differential gear oil and rear differential gear oil
(°F)
30
20
10
0
(°C)
22
4
14
32
10
20
50
68
30
40
86
104
90
85W
80W
75W-90
RM-00004
4. FLUID
Use the fluids specified in the table below. Do not mix two different kinds or makes of fluid.
Fluid Automatic transmission fluid Power steering fluid Brake fluid Clutch fluid
Recommended DEXRON III DEXRON III
FMVSS No. 116 DOT3 FMVSS No. 116 DOT3
Alternative -- -- --
FMVSS No. 116 DOT4
Remarks -- -- -- --
5. COOLANT
Use genuine coolant to protect the engine.
Coolant Coolant Water for dilution
Recommended SUBARU coolant
Distilled water
Item number 000016218
--
Alternative None
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 except for DH-PR.
Air conditioner Refrigerant Compressor oil
Recommended HFC134a DH-PR
Item number -- --
Alternative None None
RM-5
RECOMMENDED MATERIALS
Recommended Materials
7. GREASE
Use the grease and supplementary lubricants shown in the table below.
Grease Supplementary lubricants
Grease
Application point
· O2 sensor · Bolts, etc.
MT main shaft
Clutch master cylinder push rod
· Gear shift lever · Select lever · Clutch operating cylinder · Accelerator pedal · Clutch pedal · Brake pedal · Clutch bearing · Clutch release lever · Steering shaft bearing
Steering gear box
· Disc brake · Drum brake wheel cylinder
· Drum brake · Brake shoe
Brake pad
Front axle PTJ
· Front axle EBJ · Front axle BJ · Rear axle EBJ · Rear axle BJ
· Front axle DOJ · Rear axle DOJ
Throttle cable end
Recommended Spray type lubricant
Clutch grease Silicolube G-40M
SUNLIGHT2
Valiant grease M-2 Niglube RX-2
Molykote No. 7439 Molykote AS-880N
NSG301 NTG2218-M
NKG205 Silicolube G-30M
Item number --
K0879Y0501 004404003 003602010
003608001 K0779GA102
003602001 K0777YA010 28395AG020 28395FE010
28395FE020 004404002
Alternative -- -- -- --
-- -- -- -- -- --
-- --
8. ADHESIVES
Use the adhesives shown in the table below, or equivalent.
Adhesive Adhesive
Application point Windshield, rear window glass, rear quarter glass and body
Inner rearview mirror base Soft vinyl
Recommended Dow Automotive's Adhesive: Gurit-ESSEX Betaseal 1502 or equivalent Glass primer: Betawipe VP 04604, Betaprime 5001 Paint surface primer: Betaprime 5402
REPAIR KIT IN MR
Cemedine 540
Item number --
65029FC000 --
Momentary sealant
Cemedine 3000
--
Alternative --
-- 3M's EC-776, EC-847 or EC-1022
(Spray type) Armstrong's Eastman 910
RM-6
Recommended Materials
RECOMMENDED MATERIALS
9. SEAL MATERIAL
Use seal material shown in the table below, or equivalent.
Seal material Seal material
Application point
· Cylinder block · Torque converter clutch case · Transmission oil pan (6MT model) Transmission oil pan (AT model) Rear differential Rear differential
Steering adjusting screw Camshaft cap · Front sealing cover · Rear sealing cover
Recommended Three Bond 1215B
Three Bond 1217B Three Bond 1324 Three Bond 1105 Three Bond 1141 Three Bond 1280B 3M Butyl tape 8626
Item number 004403007
K0877YA020 004403042 004403010 004403006 K0877YA018
--
Alternative Dow Corning's No. 7038
-- -- Dow Corning's No. 7038 -- -- --
RM-7
RECOMMENDED MATERIALS
Recommended Materials
RM-8
PRE-DELIVERY INSPECTION
PI
Page 1. Pre-delivery Inspection................................................................................2
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 vehicle to its normal state. · Check if the vehicle before delivery is in a normal state. · Check for any damage to the vehicle or parts that may have taken place during transportation or storage. · 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.
B: PRE-DELIVERY INSPECTION (PDI) PROCEDURE
STATIC CHECKS JUST AFTER VEHICLE RECEIPT
PROCEDURE 1. Appearance check
2. Tire check
3. Fuse installation 4. Air conditioner harness connection 5. Check the doors for lock/unlock and open/close operations.
6. Double lock operation check 7. Check the operation of child safety lock system 8. Check the trunk lid for open/close operations.
9. Check the rear gate for lock/unlock and open/ close operations.
10. Operation check of fuel lid opener lock release lever 11. Accessory check
12. Operation check of front hood lock release system 13. Battery 14. Brake fluid 15. Engine oil 16. Transmission gear oil
Check point
(1) If the vehicle is covered with protective coating, visually check the vehicle body for damage and dents. If the protective coating has been removed, visually check the body paints for damage or stains in detail. (2) Visually check the glass and light lenses for any damage, cracks or excessive gaps to the body sheet metal. (3) Visually check the plated parts for any damage.
(1) Check the tires for damage, abnormal conditions, and dents on the wheels. (2) Check the tire air pressure.
If the vehicle is about to be delivered to the customer, attach a back-up fuse.
If the vehicle is about to be delivered to the customer, connect air conditioner harness.
(1) Using the key, check if the trunk lid can be locked or unlocked normally. (2) Open and close all doors to see that there are no abnormal conditions. (3) Operate the power door lock switch to check that the door (rear gate) is locked and unlocked normally.
Check the double lock for normal operations.
Check that the child safety lock system operates normally.
(1) Operate the trunk lock release lever to check that the trunk opens normally. (2) Open and close the trunk lid to see that there are no abnormal conditions.
(1) Check if the rear gate can be unlocked normally through the emergency hole. (2) Open and close the rear gate to see that there are no abnormal conditions.
Operate the fuel lid opener to check that the fuel lid is unlocked normally.
Check that the following accessories are provided. · Owner's manual · Warranty booklet · Maintenance note · Spare key · Jack · Tool set · Spare tire
Operate the front hood lock release lever to check that the front hood is unlocked normally.
Check the battery terminals for any abnormal conditions such as rust and trace of battery fluid leaks.
Check that the fluid level is normal.
Check that the oil level is normal.
Check that the transmission gear oil level is normal.
PI-2
Pre-delivery Inspection
PRE-DELIVERY INSPECTION
PROCEDURE 17. AT front differential oil 18. Engine coolant 19. Clutch fluid 20. Window washer fluid 21. Front hood latch check 22. Keyless entry system 23. Seat
24. Seat belt 25. Wheel alignment
Check point Check that the AT front differential oil level is normal. Check that the engine coolant level is normal. Check that the clutch fluid level is normal. Check that the window washer fluid level is normal. Check that the hood is closed and latched securely. Check that the keyless entry system operates normally. (1) Check the seat surfaces for stain or dirt. (2) Check the seat installation conditions and functionality. Check the seat belt installation conditions and functionality. Check that the wheel alignments are properly adjusted.
CHECKS WITH ENGINE RUNNING
PROCEDURE 26. Test mode connector 27. Immobilizer system
28. Starting condition 29. Exhaust system 30. Indicator and warning lights 31. Clock 32. Audio 33. Front accessory power supply socket 34. Lighting system 35. Window washer 36. Wiper 37. Power window operation check 38. Sunroof 39. Door mirror
Check point Test mode connectors (1) Check that the engine starts with all keys that are equipped on vehicle. (2) 60 seconds after turning ignition switch from ON to ACC or OFF, or immediately after removing key, check that the security indicator light blinking. Start the engine and check that the engine starts smoothly. Check that the exhaust noise is normal and no leaks are found. Check that all the indicator and warning lights are gone out. Check that the clock operates normally. Check the radio, CD and MD player for normal operation. Check that the front accessory power socket operates normally. Check that the lighting system operates normally. Check that the window washer system operates normally. Check that the wiper system operates normally. Check the power window for normal operations. Check that the sunroof operates normally. Check that the remote control mirror operates normally.
DYNAMIC TEST WITH VEHICLE RUNNING
PROCEDURE 40. Brake test 41. Parking brake 42. AT shift control 43. Heater & ventilation 44. Air conditioner 45. Cruise control
Check point Check the foot brake for normal operations. Check the parking brake for normal operations. Check that the AT shift patterns are correct. Check that the heater & ventilation system operates normally. Check that the air conditioner operates normally. Check that the cruise control system operates normally.
CHECKS AFTER DYNAMIC TEST
PROCEDURE 46. ATF level 47. Power steering fluid level 48. Fluid leak check 49. Water leak test 50. Appearance check 2
Check point Check that the ATF level is correct. Check that the power steering fluid level is normal. Check for fluid/oil leaks. Spray the vehicle with water and check for water leaks. (1) Remove the protective coating (if any). (2) Check the body paints for damage and stain. (3) Check the plated parts for damage and rust.
PI-3
PRE-DELIVERY INSPECTION
Pre-delivery Inspection
1. APPEARANCE CHECK
· If the vehicle is covered with protective coating, visually check the vehicle body for damage and dents. · If there is no protective coating, check the body paints for small areas of damage or stains and repair as necessary. · Check the window glass, door glass, and lights for any cracks or damage and repair or replace the parts as necessary. · Check the plated parts, such as the grilles and door knobs, for damage or loss of gloss and repair or replace the parts as necessary.
2. TIRE CHECK
· Check the tires for damage, abnormal conditions, and dents on the wheels. · Check the tire size, spare tire and tire air pressure described on the tire air pressure label (driver's side).
3. FUSE INSTALLATION
A vehicle just delivered has no fuse for the back-up circuit to prevent battery discharge. Attach a 15 A fuse (A) as shown in the figure.
5. CHECK THE DOORS FOR LOCK/UNLOCK AND OPEN/CLOSE OPERATIONS
1) Using the key, lock and unlock the door several times to check for normal operation. Open and close the door several times for smooth movement.
(A) (B)
PI-00140
(A) Unlock (B) Lock
2) Close the driver's door completely, and place the door lock knob (A) to the lock position. Then pull inner remotes (B) to ensure that doors will not open. For other doors, place the door lock knob (A) to the lock positions and then pull the inner remote to ensure that the doors will not open.
(A)
PI-00001
4. CONNECTION OF AIR CONDITIONER HARNESS
A vehicle just delivered has its air conditioner harness disconnected to protect the air conditioner compressor. Connect the harness as shown in the figure.
(B) PI-00004
(A) Door lock knob (B) Inner remote
3) Press the driver's side power door lock switch to lock side. Check that all doors including rear gate are locked.
PI-00139
PI-4
PI-00142
Pre-delivery Inspection
PRE-DELIVERY INSPECTION
4) Press the driver's side power door lock switch to unlock side. Check that all doors including rear gate are unlocked.
4) Next, pull the outside door handles of the rear doors to ensure that the doors will open.
(C) (A)
PI-00143
6. CHECK DOUBLE LOCK OPERATION
1) Fully open all the windows. 2) Remove the key. 3) Lock all the doors using the door key cylinder or transmitter. 4) Verify that all the doors including rear gate are not unlocked when pressing power door lock switch to unlock side. 5) Verify that the door is not opened when operating door lock knob to unlock position and pulling inner remote. Perform the same check for other doors. 6) Check that all the doors are unlocked when door is unlocked using door key cylinder or transmitter, or ignition switch is turned to ON.
7. CHECK THE OPERATION OF CHILD SAFETY LOCKS
1) Set the child safety lock on both rear doors to the lock positions. 2) Close the rear doors completely. 3) Check that the lock levers of the rear doors are in the unlock positions. Then, pull the inner remotes of the rear doors to ensure that the doors will not open.
(B)
PI-00084
(A) Unlock (B) Lock (C) Child safety lock
8. CHECK THE TRUNK LID FOR OPEN/ CLOSE OPERATIONS
1) Operate the trunk lock release lever and verify that the trunk lid opens. 2) Using the key, open the trunk lid several times to check for normal operation. 3) Open and close the trunk lid several times for smooth movement.
PI-00144
4) Set the trunk lid release lever to the cancel position, and check that the trunk lid can only be opened with the key.
PI-5
PI-00149
PRE-DELIVERY INSPECTION
Pre-delivery Inspection
9. CHECK THE REAR GATE FOR LOCK/ UNLOCK AND OPEN/CLOSE OPERATIONS
1) Open and close the rear gate several times for smooth movement. 2) Operate the rear gate lever to check that the rear gate is locked and unlocked normally.
(1) Remove the blind cover inside the rear gate.
11.ACCESSORY CHECK
Check that the following accessories are provided in the luggage compartment or cargo area. · Owner's manual · Warranty booklet · Service booklet · Spare key · Jack · Tool set · Spare tire · Immobilizer cover (EK model) · Immobilizer relay (EK model)
PI-00147
(2) Check that the rear gate is locked correctly when lever is operated using a finger.
(A)
(B) (A)
PI-00145
PI-00148
10.OPERATION CHECK OF FUEL LID OPENER LOCK RELEASE LEVER
Operate the fuel lid opener and verify that the fuel lid opens normally. Check that the filler cap is securely closed.
(B)
PI-00146
(A) Jack (B) Jack handle
12.OPERATION CHECK OF HOOD LOCK RELEASE SYSTEM
Operate the hood release knob (A) and check that the hood is unlocked normally.
PI-6
PI-00071
Pre-delivery Inspection
PRE-DELIVERY INSPECTION
Operate the lever (A) and check that the hood is opened normally. Then support the hood with hood stay.
15.ENGINE OIL
Check the engine oil amount. If the amount is insufficient, check that no leaks are found. Then, add the necessary amount of the specified engine oil.
(A)
(B)
(C) (E)
(D)
(A) PI-00151
13.BATTERY
Check the battery terminals to make sure that no rust or corrosions due to fluid leaks are found. Check that the battery caps are securely tightened.
(A)
LU-00138
(A) Oil level gauge (B) Engine oil filler cap (C) Upper level (D) Lower level (E) Approx. 1.0 2 (1.1 US qt, 0.9 Imp qt)
16.TRANSMISSION FLUID
Check the transmission fluid amount. If the amount is insufficient, check that no leaks are found. Then, add the necessary amount of the specified fluid.
(A)
(B) (C)
(B)
(C) PI-00012
(A) Cap (B) Upper level (C) Lower level
14.BRAKE FLUID
Check the brake fluid amount. If the amount is insufficient, carry out a brake line test to identify brake fluid leaks and check the brake operation. After that, refill the brake fluid tank with the specified type of fluid.
(A) Oil level gauge (B) Upper level (C) Lower level
PM-00030
PI-7
PRE-DELIVERY INSPECTION
Pre-delivery Inspection
17.AT FRONT DIFFERENTIAL OIL
Check the AT front differential oil amount. If the amount is insufficient, check that no leaks are found. Then, add the necessary amount of the specified AT front differential oil.
(A)
(B)
(A)
(C)
21.HOOD LATCH CHECK
Retract the hood stay and close the hood. Check that the hood is securely latched.
22.KEYLESS ENTRY SYSTEM
Check the keyless entry system operations as follows. · Remove the key from the ignition switch and close all the doors including rear gate (wagon model). · Press the "LOCK" button on the transmitter momentarily once and check that all the doors are locked and the hazard light flashes once.
PI-00183
(A) Oil level gauge (B) Upper level (C) Lower level
18.COOLANT
Check the coolant amount on the reservoir. If the amount is insufficient, check that no leaks are found. Then, add the necessary amount of coolant with the specified concentration.
19.CLUTCH FLUID
Check the clutch fluid amount. If the amount is insufficient, check that no leaks are found. Then, add the necessary amount of the specified fluid.
PI-00108
(A)
(C) (B)
PM-00076
(A) Reservoir tank (B) MIN level (C) MAX level
20.WINDOW WASHER FLUID
Check the window washer fluid amount. If the amount is insufficient, check that no leaks are found. Then, add the necessary amount of washer fluid commercially available.
PI-00109
· Press the "OPEN" button on the transmitter momentarily once and check that all doors are unlocked, the hazard light flashes twice and the interior light illuminates. · Close all doors and rear gate, press the "LOCK" button of the transmitter. Press the "OPEN" button of the transmitter and wait for 30 seconds. Check that all doors and the rear gate are automatically locked again.
23.SEAT
Check that each seat provides full functionality in sliding and reclining. Check all available functions of the rear seat such as a trunk-through center arm rest.
24.SEAT BELT
Pull out the seat belt and then release it. Check that the belt webbing retracts smoothly.
PI-8
Pre-delivery Inspection
PRE-DELIVERY INSPECTION
25.WHEEL ALIGNMENT
Check the wheel alignments. <Ref. to FS-6, Wheel Alignment.> and <Ref. to RS-10, Wheel Alignment.>
26.TEST MODE CONNECTOR
Turn the ignition switch to ON and check that the malfunction indicator light starts blinking. If the light blinks, return the ignition key to LOCK and disconnect the test mode connector. Then, turn the ignition key to ON again. If the malfunction indicator light blinks at that time in spite of the disconnected test mode connector, carry out an engine diagnosis. · With OBD MODEL
( A )
PI-00119 (A) Test mode connector (Green)
· Without OBD MODEL
( B )
( A )
PI-00120 (A) Read memory connector (Black) (B) Test mode connector (Green)
28.STARTING CONDITION
Start the engine and check that the engine starts smoothly. If any battery voltage problems are found, recharge or replace the battery. If any abnormal noises are observed, immediately stop the engine and check and repair the necessary components.
29.EXHAUST SYSTEM
Listen to the exhaust noise to see if no abnormal noises are observed.
30.INDICATOR LIGHT
Check that all the indicator lights are off.
31.CLOCK
Check the clock for normal operations and enough accuracy.
32.AUDIO
Check if the radio for functions fully, speaker emitts sound normally and noise level is normal. Also check the CD, MD unit operations.
33.FRONT ACCESSORY POWER SUPPLY SOCKET
Check the front accessory power supply socket operations.
34.LIGHTING SYSTEM
· Check the headlight operations. · Check the stop light operations. · Check the other lights for normal operations.
35.WINDOW WASHER
Check that the window washer system injects washer fluid to the specified area of windshield shown in the figure.
Front injection position: A: 350 mm (13.78 in) B: 162 mm (5.91 in) C: 300 mm (11.81 in) D: 500 mm (23.62 in)
27.IMMOBILIZER SYSTEM
1) Check that the engine starts with all keys that are equipped on vehicle. 2) 60 seconds after turning the ignition switch from ON to ACC or OFF, or immediately after removing the key, check that the security indicator light blinking.
NOTE: If malfunctions occur, refer to "IMMOBILIZER (DIAGNOSIS)".
A
A
BB
CD
PI-00121
PI-9
PRE-DELIVERY INSPECTION
Rear injection position: A: 39 mm (2.36 in) B: 72°
Pre-delivery Inspection
42.AT SHIFT CONTROL
Set the AT select lever to each gear position and check the shifting while driving the vehicle.
A
B
PI-00104
36.WIPER
Check the front and rear wipers for normal operations.
37.POWER WINDOW OPERATION CHECK
Manipulate the power window switches one by one to check that each of the power windows goes up and down with no abnormal noises.
38.SUNROOF
Check that the sunroof operates normally.
39.DOOR MIRROR
Check that the remote control mirror operates normally.
40.BRAKE TEST
Check the foot brake for normal operations.
41.PARKING BRAKE
Check the parking brake for normal operations. When applying the parking brake with force of 196 N (20 kgf, 44 lb), check that the lever stroke of parking brake lever is 7 to 8 notches.
P
R N D 3 2 1
(1)
(1) RHD model (2) LHD model
(2) PI-00112
P
R N D 3 2 1
AT-00761
Selector
Gear Position
Position
1st
2nd
3rd
4th
D
Yes
Yes
Yes
Yes
3
Yes
Yes
Yes
--
2
Yes
Yes
--
--
1
Yes
--
--
--
Sports shift
Yes
Yes
Yes
Yes
43.HEATER & VENTILATION
Operate the heater and ventilation system to check for normal outlet selection, air inlet selection, airflow and heating capacity.
44.AIR CONDITIONER
Operate the air conditioner. Check that the A/C compressor operates normally and enough cooling is provided.
45.CRUISE CONTROL
Operate the cruise control system. Check that the system is activated and deactivated correctly.
PI-10
Pre-delivery Inspection
PRE-DELIVERY INSPECTION
46.ATF LEVEL
Check that the ATF level is normal when the engine at idle. If insufficient, check that no leaks are found. Then add the necessary amount of the specified ATF.
(A)
F
(C)
HOT
(B)
L
(D)
F
(C)
COLD
(E)
L
(D)
PM-00191
(A) Level gauge (B) ATF level range when "HOT" [70 -- 80°C (158
-- 176°F)] (C) Upper level (D) Lower level (E) ATF level range when "COLD" [20 -- 30°C (68
-- 86°F)]
47.POWER STEERING FLUID LEVEL
Check that the power steering fluid level is normal. If insufficient, check that no leaks are found. Then add the necessary amount of the specified power steering fluid.
PM-00070
(A) Reservoir tank (B) MIN level (C) MAX level
48.FLUID LEAK CHECK
Check the entire areas of the vehicle for any trace of coolant/oil/fluid leaks.
49.WATER LEAK TEST
Spray the vehicle with water and check that no water enters the passenger compartment. · Before performing the water leakage test, remove anything that may obstruct the operation or which must be kept dry. · Close all windows completely, and then close all doors tightly. Close the hood and trunk lid before starting the test. · Connect a hose to a tap, and spray water on the vehicle. The rate of water discharge must be approx. 20 -- 25 2 (5.3 -- 6.6 US gal, 4.4 -- 5.5 Imp gal) per minute. When spraying water on areas adjacent to the floor and wheel house, increase the pressure. When directing water on areas other than the floor portion and wheel house, decrease the pressure. But the force of water must be made strong occasionally by pressing the end of the hose.
NOTE: Be sure to keep the hose at least 10 cm (3.9 in) from the vehicle.
Check the following areas: · Front window and body framework mating portion · Door mating portions · Glass mating portions · Rear quarter window mating portions · Rear window and body framework mating portion · Around roof drips If any dampness in the compartment is discovered after the water has been applied, carefully check all areas that may have possibly contributed to the leak.
50.APPEARANCE CHECK 2
1) Check the paint after removing the paint protective coating and washing the vehicle.
NOTE: · Use of steam eases peeling off the warp guard. · When performing on the vehicles left for a long time, or during low temperature period, sprinkle some water heated to 50 -- 60°C (122 -- 140°F) over the vehicle to raise its surface temperature before peeling off the wrap guard. Do not use the water heated to over 60°C (140°F). · If the adhesive remains on the coated surface, rub the portion with a flannel rag, etc. soaked with a coat of coating wax or a solvent, such as oil benzene and IPA, and then wipe it off. · Avoid adhesion of the solvent to resin or rubber components. Do not use coating wax or a solvent while the component surface temperature is high due to hot weather, etc.
PI-11
PRE-DELIVERY INSPECTION
Pre-delivery Inspection
· If the coated surface is swollen out due to seams or moisture, expose the vehicle to the sun light for a few hours. Otherwise, heat the portion with seams or moisture using a dryer, etc. · Dispose of the peeled wrap guard as burnable industrial garbage.
2) Check the whole vehicle body for stains, flaking, damage caused by transportation, rust, dirt, cracks, or blistering.
NOTE: · It is better to determine an inspection pattern in order to avoid missing an area, since the total inspection area is wide. · It is desirable not to make corrections to the body paint unless absolutely needed. However, if any corrections are required to remove scratches or rust, the area to be corrected must be limited as much as possible. Re-painting and spray painting must be avoided whenever possible.
3) Carefully check each window glass for scratches. Slight damage may be removed by polishing with cerium oxide. (Half-fill a cup with cerium oxide, and add warm water to it. Then agitate the content until it turn to wax. Apply this wax to a soft cloth, and polish the glass.) 4) Check each portion of the vehicle body and underside components for the formation of rust. If rust is discovered, remove it with #80 -- #180 emery paper, and treat the surface with rust preventive. After this treatment is completed, flush the portion thoroughly, and prepare the surface for repair painting. 5) Check each portion of the body and all of the chrome parts for deformation or distortion. Also check each lamp lens for cracks. 6) Peel the protective tape, vinyl wrapping and identification seal attached to the following places. · Seat · Door trim · Floor carpet · Side sill · Back of rear view mirror
PI-12
PERIODIC MAINTENANCE SERVICES
PM
Page 1. General Description ....................................................................................2 2. Schedule .....................................................................................................3 3. Engine Oil....................................................................................................7 4. Engine Oil Filter...........................................................................................9 5. Spark Plugs...............................................................................................10 6. V-belt.........................................................................................................11 7. Timing Belt ................................................................................................13 8. Fuel Line ...................................................................................................16 9. Fuel Filter ..................................................................................................17 10. Air Cleaner Element ..................................................................................18 11. Cooling System .........................................................................................19 12. Coolant......................................................................................................21 13. Idle Mixture................................................................................................23 14. Clutch System ...........................................................................................24 15. Transmission Gear Oil ..............................................................................26 16. Hill-holder System .....................................................................................27 17. ATF ...........................................................................................................28 18. Front & Rear Differential Gear Oil .............................................................30 19. Brake Line .................................................................................................32 20. Brake Fluid ................................................................................................34 21. Disc Brake Pads and Discs.......................................................................35 22. Brake Linings and Drums..........................................................................36 23. Suspension ...............................................................................................38 24. Wheel Bearing...........................................................................................40 25. Axle Boots & Joints ...................................................................................42 26. Steering System (Power Steering)............................................................43
General Description
PERIODIC MAINTENANCE SERVICES
1. General Description
A: GENERAL
Be sure to perform periodic maintenance in order to maintain vehicle performance and find problems before they become serious.
PM-2
Schedule
PERIODIC MAINTENANCE SERVICES
2. Schedule
A: MAINTENANCE SCHEDULE 1
1. FOR EUROPE AREA
For periodic maintenance of over 120,000 km (75,000 miles) or 96 months, carry out inspection by referring to the following table. For a maintenance period gone beyond these tables, apply them repeatedly as a set of 120,000 km (75,000 miles) or 96 months.
Month × 1,000 km × 1,000 miles 1 Engine oil 2 Engine oil filter 3 Spark plug
4 Drive belt(s) 5 Camshaft drive belt 6 Fuel line 7 Fuel filter 8 Air cleaner element 9 Cooling system 10 Coolant 11 Clutch system
For Turbo Others
12 Hill-holder system 13 Transmission oil 14 ATF 15 Front & rear differential 16 Brake line 17 Brake fluid 18 Disk brake pads & discs 19 Brake linings & drums 20 Parking brake 21 Suspension 22 Wheel bearing 23 Axle boot & joint 24 Steering system 25 Clutch cable
Maintenance interval [Number of months or km (miles), whichever occurs first]
12 24 36 48 60 72 84 96
Remarks
1.6 5 15 30 45 60 75 90 105 120
1 3 9 19 28 38 47 56 66 75
RRRRRRRR
RRRRRRRR
R
R
R
R
R
IIIIIIII
R
I
I
I
I
R
R
IRIRIRIR
I
I
I
I
R
R
R
R
Adjust the clutch
I
I
I
I
pedal free play every 1,600 km
(1,000 miles)
I
I
I
I
I
R
I
R
I
R
I
R
I
R
I
R
I
I
I
I
R
R
R
R
IIIIIIII
I
I
I
I
I
I
I
I
I
I
I
I
(I)
IIIIIIII
I
I
I
I
R
Symbols used: R: Replace I: Inspection (I): Recommended service for safe vehicle operation.
NOTE: (1) When the vehicle is used in extremely dusty conditions, the air cleaner element should be replaced more often. (2) ATF filter is a maintenance free part. ATF filter needs replacement, when it is physically damaged or ATF leaked.
PM-3
PERIODIC MAINTENANCE SERVICES
Schedule
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.
Months × 1,000 km × 1,000 miles 1 Engine oil 2 Engine oil filter
Maintenance Interval [Number of months or km (miles), whichever occurs first]
12 24 36 48
Remarks
5 12.5 25 37.5 50
3 7.5 15 22.5 30
R
R
R
R
R
R
R
R
For periodic maintenance of over 100,000 km (60,000 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 100,000 km (60,000 miles) or 48 months.
Months × 1,000 km × 1,000 miles 3 Spark plugs
4 Drive belt(s) 5 Camshaft drive belt 6 Fuel line 7 Fuel filter 8 Air cleaner element 9 Cooling system 10 Coolant 11 Idle mixture
For Turbo Others
12 Clutch system
13 Hill-holder system 14 Transmission oil 15 ATF 16 Front & rear differential oil 17 Brake line 18 Brake fluid 19 Disc brake pads & discs 20 Brake linings and drums 21 Parking brake 22 Suspension 23 Wheel bearing 24 Axle boots & joints 25 Steering system (Power steering) 26 Clutch cable
Maintenance Interval [Number of months or km (miles), whichever occurs first]
12 24 36 48
Remarks
1.6 25 50 75 100
1
15 30 45 60
R
R
R
R
R
I
I
I
I
R
I
I
R
R
I
R
I
R
I
I
R
R
I
I
I
I
I
For models without catalyst converter
I
I
I
I
Adjust the clutch pedal free play every 1,600 km (1,000 miles)
I
I
I
I
R
R
R
R
R
R
I
I
R
R
I
I
I
I
I
I
I
I
I
I
I
I
I
I
(I)
I
I
I
I
I
I
I
I
R
Symbols used: R: Replace I: Inspection (R) or (I): Recommended service for safe vehicle operation.
PM-4
Schedule
PERIODIC MAINTENANCE SERVICES
NOTE: (1) When the vehicle is used in extremely dusty conditions, the air cleaner element should be replaced more often. (2) ATF filter is a maintenance free part. ATF filter needs replacement, when it is physically damaged or ATF leaked.
B: MAINTENANCE SCHEDULE 2
1. EUROPE AREA
Item Engine oil
Every
Engine oil filter
Fuel line Transmission oil
12 months 15,000 km 9,000 miles
ATF
Front & rear differential oil
Brake line
Brake fluid
Brake pads
Brake linings and drums Parking brake
Suspension
Axle boots & joints Steering system (Power steering)
12 months 15,000 km 9,000 miles 12 months 15,000 km 9,000 miles 12 months 15,000 km 9,000 miles 12 months 15,000 km 9,000 miles 12 months 15,000 km 9,000 miles 12 months 15,000 km 9,000 miles 12 months 15,000 km 9,000 miles 12 months 15,000 km 9,000 miles
Repeat short distance drive
Repeat rough/muddy
road drive
Extremely cold weather
area
Replace more frequently
Replace more frequently
Replace more frequently
Replace more frequently
Salt or other corrosive used or
coastal area
High humidity or moun-
tain area
Repeat towing trailer
Replace more frequently Replace more frequently
I
Replace more frequently
Replace more frequently
Replace more frequently
I
R
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
PM-5
PERIODIC MAINTENANCE SERVICES
2. EXCEPT FOR EUROPE AREA
Schedule
Item Engine oil
Every
Engine oil filter
Fuel line Transmission oil
6 months 12,500 km 7,500 miles
Repeat short distance drive
Repeat rough/muddy
road drive
Extremely cold weather
area
Replace more frequently
Replace more frequently
Replace more frequently
Replace more frequently
ATF
Front & rear differential oil
Brake line
6 months
12,500 km
7,500 miles
Brake fluid
12 months
25,000 km
15,000 miles
Brake pads
6 months
12,500 km
I
I
7,500 miles
Brake linings
6 months
and drums
12,500 km
I
I
7,500 miles
Parking brake 6 months
12,500 km
I
I
7,500 miles
Suspension
6 months
12,500 km
I
I
7,500 miles
Axle boots &
6 months
joints
12,500 km
I
I
7,500 miles
Steering system 6 months (Power steering) 12,500 km
I
I
7,500 miles
Salt or other corrosive used or
coastal area
I
I
I I I I I I
High humidity or moun-
tain area
R
Repeat towing trailer Replace more frequently Replace more frequently
Replace more frequently Replace more frequently Replace more frequently
I
I
I
I
PM-6
Engine Oil
PERIODIC MAINTENANCE SERVICES
3. Engine Oil
A: REPLACEMENT
1) Open the engine oil filler cap for quick draining of the engine oil.
· SOHC MODEL
(A)
(B)
PM-00155
(A) Oil level gauge (B) Oil filler cap
2) Remove the dip of service hole cover. (Turbo model)
LU-00193
4) Replace the drain plug gasket. 5) Tighten the engine oil drain plug after draining engine oil.
Tightening torque: 44 N·m (4.5 kgf-m, 33 ft-lb)
· DOHC TURBO MODEL
LU-00185
3) Drain the engine oil by loosening engine oil drain plug. · DOHC TURBO MODEL
· SOHC MODEL
LU-00186
LU-00186 LU-00193
PM-7
PERIODIC MAINTENANCE SERVICES
Engine Oil
6) Fill engine oil through the filler pipe up to center between upper level and lower level. Make sure that the vehicle is placed level when checking oil level. Use engine oil of proper quality and viscosity, selected in accordance with the table in figure.
Recommended oil API classification SL or SJ with the words "Energy Conserving or Energy conserving II", CCMC specification G4 or G5, ACEA specification A1, A2 or A3, or New API mark displayed on the container (If it is impossible to get SL or SJ grade, you may use SG or SH grade.)
Engine oil capacity Upper level: Approx. 4.0 2 (4.2 US qt, 3.5 Imp qt) Lower level: Approx. 3.0 2 (3.2 US qt, 2.6 Imp qt)
· SOHC MODEL
SAE (1)
( C) -30 -20 -15
0
( F) -22 -4 5
32
15
30 40
59
86 104
NOTE: · When replenishing oil, it does not matter if the oil to be added is a different brand from that in the engine; however, use oil having the API classification and SAE viscosity No. designated by SUBARU. · If vehicle is used in desert areas with very high temperatures or for other heavy duty applications, the following viscosity oils may be used: API classification: SL or SJ. SAE Viscosity No.: 30, 40, 10W-50, 20W-40, 20W50
7) Close the engine oil filler cap. 8) Start the engine and warm it up for a time. 9) After the engine stops, recheck the oil level. <Ref. to PM-8, INSPECTION, Engine Oil.>
B: INSPECTION
1) Park the vehicle on a level surface. 2) Remove the 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. 4) Remove it again and note the reading. If the engine oil level is below the "L" line, add oil to bring the level up to the "F" line.
10W-30,10W-40 5W-30,0W-20 (2)
(A)
(B)
LU-00071
(1) Viscosity No. and applicable temperature (2) Preferred
· EXCEPT FOR SOHC MODEL
SAE (1)
( C) -30 -20 -15
0
15
( F) -22 -4 5
32
59
10W-30,10W-40 5W-30 (2)
30 40 86 104
LU-00076
(1) Viscosity No. and applicable temperature (2) Preferred
The proper viscosity helps vehicle get good cold and hot starting by reducing viscous friction and thus increasing cranking speed.
(C)
(E)
(D)
LU-00138
(A) Oil level gauge (B) Oil filler cap (C) Upper level (D) Lower level (E) Approx. 1 2 (1.1 Us qt, 0.9 lmp qt)
5) After turning off the engine, wait a few minutes for the oil to drain back into oil pan before checking the level. 6) Just after driving or while the engine is warm, engine oil level may show in the range between the "F" line and the notch mark. This is caused by thermal expansion of the engine oil. 7) To prevent overfilling the engine oil, do not add oil above the "F" line when the engine is cold.
PM-8
Engine Oil Filter
4. Engine Oil Filter
A: REPLACEMENT
1) Remove the under cover. 2) Remove the oil filter with ST. ST 498547000 OIL FILTER WRENCH (Outer
diameter 80 mm (3.15 in)) ST 18332AA000 OIL FILTER WRENCH (Outer
diameter 68 mm (2.68 in)) ST 18332AA010 OIL FILTER WRENCH (Outer
diameter 65 mm (2.56 in)) · SOHC MODEL
PERIODIC MAINTENANCE SERVICES
· DOHC TURBO MODEL
LU-00194
LU-00190
3) Get a new oil filter and apply a thin coat of engine oil to the seal rubber. 4) Install the oil filter by turning it by hand, being careful not to damage the seal rubber. 5) Tighten more (approx. 1 turn for outer diameter 68 mm (2.68 in) oil filter, and 2/3 to 3/4 turn except for outer diameter 68 mm (2.68 in) oil filter) after the seal rubber contacts the cylinder block. Do not tighten excessively, or oil may leak. 6) After installing the oil filter, run the engine and make sure that no oil is leaking around seal rubber. NOTE: The filter element and filter case are permanently joined; therefore, interior cleaning is not necessary. 7) Check the engine oil level. <Ref. to PM-8, INSPECTION, Engine Oil.>
PM-9
PERIODIC MAINTENANCE SERVICES
Spark Plugs
5. Spark Plugs
A: REPLACEMENT
5) Remove the ignition coil.
1. SOHC MODEL
1) Remove the intake duct and intake chamber. 2) Remove the washer tank and put it aside. 3) Disconnect the spark plug cord. 4) Remove the spark plug with a plug-wrench.
PM-00145
6) Remove the spark plug with a spark plug socket.
PM-00001
5) Set the new spark plugs.
Recommended spark plug: 1.6 L SOHC model (with catalytic converter) CHAMPION: RC8YC4 NGK: BKR6E-11 (Alternate) 1.6 L SOHC model (without catalytic converter) NGK: BKR6E 2.0 and 2.5 L SOHC model (with catalytic converter) CHAMPION: RC10YC4 NGK: BKR5E-11 (Alternate) 2.0 SOHC model (without catalytic converter) NGK: BKR6E
6) Tighten the spark plug lightly with hand, and then secure with a plug-wrench to the specified torque.
Tightening torque: 21 N·m (2.1 kgf-m, 15.2 ft-lb)
NOTE: · Be sure to place the gasket between the cylinder head and spark plug. · If a torque wrench is not available, tighten the spark plug until gasket contacts cylinder head; then tighten further 1/4 to 1/2 turns.
2. DOHC MODEL
1) Disconnect the battery cables, and then remove the battery and battery carrier. 2) Remove the washer tank and put it aside. 3) Remove the air cleaner lower case. 4) Disconnect the connector from ignition coil.
PM-00112
7) Set new spark plugs.
Recommended spark plug: 2.0 L DOHC Turbo model NGK: PFR6G
8) Tighten the spark plug lightly with hand, and then secure with a plug-wrench to the specified torque.
Tightening torque: 21 N·m (2.1 kgf-m, 15.2 ft-lb)
9) Tighten the ignition coil.
Tightening torque: 16 N·m (1.6 kgf-m, 11.7 ft-lb)
NOTE: · Be sure to place the gasket between the cylinder head and spark plug. · If a torque wrench is not available, tighten the spark plug until gasket contacts cylinder head: then tighten further 1/4 to 1/2 turns.
PM-10
V-belt
PERIODIC MAINTENANCE SERVICES
6. V-belt
A: INSPECTION
1) Replace the belts, if cracks, fraying or wear is found. 2) Check the V-belt tension and adjust it if necessary by changing the generator installing position and/or idler pulley installing position. <Ref. to PM11, REPLACEMENT, V-belt.>
Belt tension (without belt tension gauge) (A) When installing new one: 7 -- 9 mm (0.276 -- 0.354 in) At inspection: 9 -- 11 mm (0.354 -- 0.433 in) (B) When installing new one: 7.5 -- 8.5 mm (0.295 -- 0.335 in) At inspection: 9.0 -- 10.0 mm (0.354 -- 0.394 in)
98 N (10kg)
Belt tension (with belt tension gauge) (A) When installing new one: 640 -- 785 N (65.3 -- 80.0 kgf, 144 -- 176 lb) At inspection: 490 -- 640 N (50 -- 65 kgf, 110 -- 144 lb) (B) When installing new one: 620 -- 760 N (63 -- 77 kgf, 140 -- 170 lb) At inspection: 350 -- 450 N (36 -- 46 kgf, 79 -- 101 lb)
(A)
P/S
GEN
A/C (B)
I/P C/P
PM-00154
P/S
GEN (A) (B)
A/C
I/P C/P
PM-00002
(A) Front side belt (B) Rear side belt C/P Crankshaft pulley GEN Generator P/S Power steering oil pump pulley A/C Air conditioning compressor pulley I/P Idler pulley
(A) Front side belt (B) Rear side belt C/P Crank pulley GEN Generator P/S Power steering oil pump pulley A/C A/C compressor pulley I/P Idler pulley
B: REPLACEMENT
1. FRONT SIDE BELT (DRIVING POWER STEERING OIL PUMP AND GENERATOR)
NOTE: Wipe off any oil or water on the belt and pulley. 1) Remove the V-belt cover. NON-TURBO MODEL
PM-11
PM-00003
PERIODIC MAINTENANCE SERVICES TURBO MODEL
V-belt
Tightening torque: 23 N·m (2.3 kgf-m, 17.0 ft-lb)
(B)
SC-00096
2) Loosen the lock bolt (A). 3) Loosen the slider bolt (B). 4) Remove the front side belt (C). 5) Install a new belt, and tighten the slider bolt so as to obtain the specified belt tension. 6) Tighten the lock bolt (A). 7) Tighten the slider bolt (B).
Tightening torque: Lock bolt: 25 N·m (2.5 kgf-m, 18 ft-lb) Slider bolt: 8 N·m (0.8 kgf-m, 5.8 ft-lb)
(A) PM-00005
(B) (C)
(A)
PM-00004
2. REAR SIDE BELT (DRIVING AIR CONDITIONER)
NOTE: Wipe off any oil or water on the belt and pulley.
1) Remove the front side belt. 2) Loosen the lock nut (A). 3) Loosen the slider bolt (B). 4) Remove the rear side belt. 5) Install a new belt, and tighten the slider bolt so as to obtain the specified belt tension. 6) Tighten the lock nut (A). 7) Install the front side belt. SOHC model <Ref. to ME(H4SO)-43, FRONT SIDE BELT, INSTALLATION, V-belt.> DOHC Turbo model <Ref. to ME(H4DOTC)-54, FRONT SIDE BELT, INSTALLATION, V-belt.>
PM-12
Timing Belt
PERIODIC MAINTENANCE SERVICES
7. Timing Belt
A: REPLACEMENT
1. NON-TURBO MODEL
1) Remove the radiator fan and air conditioner fan. <Ref. to CO(H4SO)-23, Radiator Main Fan and Fan Motor.>, <Ref. to CO(H4SO)-24, Radiator Sub Fan and Fan Motor.> 2) Shield the radiator from any damage using cardboard and blanket. 3) Remove the V-belt cover.
10) Remove the timing belt guide. (MT model)
PM-00008
11) Turn the crankshaft and align alignment marks on crankshaft, and right and left camshaft sprockets with notches of belt cover and cylinder block. ST 499987500 CRANKSHAFT SOCKET
(B)
PM-00003
4) Remove the V-belts. <Ref. to ME(H4SO)-43, Vbelt.> 5) Remove the air conditioning compressor drive belt tensioner. 6) To lock the crankshaft, use ST. Remove the pulley bolt. 2.5 L model: ST 499977100 CRANKSHAFT PULLEY
WRENCH Except for 2.5 L model: ST 499977400 CRANKSHAFT PULLEY
WRENCH
ST
PM-00007
7) Remove the crankshaft pulley. 8) Remove the left side belt cover. 9) Remove the front timing belt cover.
(B)
(A) (B)
(A) Notch (B) Alignment mark
12) Remove the belt idler. 13) Remove the belt idler (No. 2).
PM-00009
14) Remove the timing belt.
PM-13
PM-00010
PERIODIC MAINTENANCE SERVICES
Timing Belt
15) Remove the automatic belt tension adjuster assembly.
11) Remove the timing belt guide. (MT model)
PM-00011
16) Install in the reverse order of removal. <Ref. to ME(H4SO)-49, INSTALLATION, Timing Belt Assembly.>
2. DOHC MODEL
1) Remove the radiator fan and air conditioner fan. <Ref. to CO(H4DOTC)-28, Radiator Main Fan and Fan Motor.>, <Ref. to CO(H4DOTC)-30, Radiator Sub Fan and Fan Motor.> 2) Protect the radiator with cardboard and blanket. 3) Remove the V-belts. <Ref. to ME(H4DOTC)-54, V-belt.> 4) Remove the air conditioning compressor drive belt tensioner. 5) Remove the pulley bolt. To lock the crankshaft use ST. Except for STi model: ST 499977300 CRANKSHAFT PULLEY
WRENCH STi model: ST 499977300 CRANKSHAFT PULLEY
WRENCH
PM-00008 ME-00727 ME-00728
ST PM-00093
6) Remove the crankshaft pulley. 7) Remove the air conditioning compressor drive belt tensioner. 8) Remove the belt cover (LH). 9) Remove the belt cover (RH). 10) Remove the front belt cover.
ME-00729
12) Turn the crankshaft and align alignment marks on crankshaft, and right and left camshaft sprockets with notches of belt cover and cylinder block. To turn the crankshaft, use ST.
PM-14
ST 499987500
(B) (B) (A) (B)
Timing Belt
PERIODIC MAINTENANCE SERVICES
CRANKSHAFT SOCKET
(A)
(B) (B)
(A) (B)
(B)
CAUTION: When installing the timing belt, be sure to align all alignment marks on the belt with corresponding marks on the sprockets. If incorrectly installed, interference between pistons and valves may occur.
B: INSPECTION
1. SOHC MODEL
1) Remove the front timing belt cover and timing belt cover (LH). 2) While cranking the engine at least four rotations, check the timing belt back surface for cracks or damage. Replace the faulty timing belt as needed. 3) Measure the timing belt width W. If it is less than 27 mm (1.06 in), check idlers, tensioner, water pump pulley and cam sprocket to determine idler alignment (squareness). Replace the worn timing belt.
(A) Notch (B) Alignment mark
13) Remove the belt idler.
PM-00156
PM-00095
14) Remove the timing belt. 15) Remove the automatic belt tension adjuster assembly.
W
PM-00016
4) Install the front timing belt cover and timing belt cover (LH).
2. DOHC MODEL
1) Remove the timing belt cover (LH). 2) While cranking the engine at least four rotations, check the timing belt back surface for cracks or damage. Replace the faulty timing belt as needed. 3) Measure the timing belt width W. If it is less than 30 mm (1.18 in), check idlers, tensioner, water pump pulley and cam sprocket to determine idler alignment (squareness). Replace the worn timing belt. 4) Install the timing belt cover (LH).
W
PM-00096
16) Install in the reverse order of removal. <Ref. to ME(H4DOTC)-58, Timing Belt Assembly.>
PM-15
PM-00097
PERIODIC MAINTENANCE SERVICES
Fuel Line
8. Fuel Line
A: INSPECTION
The fuel line is located mostly internally, so check pipes, areas near pipes, and engine compartment piping for rust, hose damage, loose bands, etc. If faulty parts are found, repair or replace them. SOHC model <Ref. to FU(H4SO)-63, Fuel Delivery, Return and Evaporation Lines.> DOHC Turbo model <Ref. to FU(H4DOTC)-69, Fuel Delivery, Return and Evaporation Lines.>
PM-16
Fuel Filter
9. Fuel Filter
A: REPLACEMENT
For fuel filter replacement procedures, refer to "FU" section. SOHC model <Ref. to FU(H4SO)-60, Fuel Filter.> DOHC Turbo model <Ref. to FU(H4DOTC)-66, Fuel Filter.>
B: INSPECTION
1) If it is clogged, or if replacement interval has been reached, replace it. 2) If water is found in it, shake and expel the water from inlet port.
PERIODIC MAINTENANCE SERVICES
PM-17
Air Cleaner Element
PERIODIC MAINTENANCE SERVICES
10.Air Cleaner Element
A: REPLACEMENT
2) Remove the air cleaner.
1. NON-TURBO MODEL
1) Remove the air intake duct from air cleaner case. 2) Remove the bolt (A) which installs air cleaner case to stays. 3) Remove the clip (B) above the air cleaner case.
(B)
(A) (B)
PM-00098
(B)
3) Install in the reverse order of removal.
NOTE: Align the protruding portion of air cleaner upper cover with holes of air cleaner lower case, then secure upper cover to case.
4) Remove the air cleaner.
IN-00039
PM-00142
5) Install in the reverse order of removal. NOTE: Fasten with a clip after inserting the lower tab of the case.
2. TURBO MODEL
1) Remove the clip (B) above the air cleaner case.
(B)
PM-00100
PM-00099
PM-18
Cooling System
PERIODIC MAINTENANCE SERVICES
11.Cooling System
A: INSPECTION
1) Check the radiator for leakage, filling it with coolant and attach the radiator cap tester (A) to filler neck. Then apply a pressure. Check the following points:
Non-turbo model 157 kPa (1.6 kg/cm2, 23 psi)
Turbo model 122 kPa (1.2 kg/cm2, 18 psi)
· Each portion of radiator for leakage · Hose joints and other connections for leakage
NOTE: · For turbo model, be sure to install the tester to filler tank side. · When attaching or detaching tester and when operating tester, use special care not to deform radiator filler neck. NON-TURBO MODEL
(A)
PM-00128
TURBO MODEL
NOTE: Rust or dirt on the cap may prevent the valve from functioning normally: be sure to clean the cap before testing.
Raise the pressure until the needle of gauge stops and see if the pressure can be retained for 5 to 6 seconds. The radiator cap is normal if a pressure above the service limit value has been maintained for this period.
Radiator cap valve open pressure
Non-turbo model Standard value: 93 -- 123 kPa (0.95 -- 1.25 kg/cm2, 14 -- 18 psi) Service limit: 83 kPa (0.85 kg/cm2, 12 psi)
Turbo model Filler tank side: Standard value: 93 -- 123 kPa (0.95 -- 1.25 kg/cm2, 14 -- 18 psi) Service limit: 83 kPa (0.85 kg/cm2, 12 psi) Radiator side: Standard value: 122 -- 152 kPa (1.24 -- 1.55 kg/cm2, 18 -- 22 psi) Service limit: 112 kPa (1.14 kg/cm2, 16 psi)
(A)
PM-00023
PM-00150
· When performing this check, be sure to keep the engine stationary and fill the radiator with coolant. · Wipe off check points before applying pressure. · Use care not to spill coolant when detaching the tester from radiator. · Do not remove the radiator side cap. (Turbo model) 2) Check the radiator cap valve open pressure using radiator cap tester.
PM-19
(A)
(B) (A)
PM-00089
(A) Deformation (B) Deformation, damage, rust
PERIODIC MAINTENANCE SERVICES
Cooling System
3) Start the engine, and then check it does not overheat or it is cooled excessively. If it overheats or it is cooled excessively, check the cooling system. SOHC model <Ref. to CO(H4SO)-15, Water Pump.> <Ref. to CO(H4SO)-18, Thermostat.> <Ref. to CO(H4SO)-19, Radiator.> <Ref. to CO(H4SO)-22, Radiator Cap.> DOHC Turbo model <Ref. to CO(H4DOTC)-20, Water Pump.> <Ref. to CO(H4DOTC)-22, Thermostat.> <Ref. to CO(H4DOTC)-23, Radiator.> <Ref. to CO(H4DOTC)-27, Radiator Cap.> 4) Check the electric fan operates using Subaru Select Monitor, when the coolant temperature exceeds 95°C (203°F). If not operate, check the electric fan system. SOHC model <Ref. to CO(H4SO)-6, Radiator Main Fan System.> <Ref. to CO(H4SO)-9, Radiator Sub Fan System.> DOHC Turbo model <Ref. to CO(H4DOTC)-8, Radiator Main Fan System.> <Ref. to CO(H4DOTC)-13, Radiator Sub Fan System.>
PM-20
Coolant
PERIODIC MAINTENANCE SERVICES
12.Coolant
A: REPLACEMENT
1. REPLACEMENT OF COOLANT
WARNING: The radiator is of the pressurized type. Do not attempt to open the radiator cap immediately after the engine has been stopped.
1) Lift-up the vehicle. 2) Remove the under cover. 3) Place a container under drain pipe. 4) Loosen and remove the drain cock to drain engine coolant into container.
NOTE: The SUBARU Genuine Coolant containing antifreeze and anti-rust agents is especially made for SUBARU engine, which has an aluminum crankcase. Always use SUBARU Genuine Coolant, since other coolant may cause corrosion.
10) Securely install the radiator cap. 11) Run the engine for more than 5 minutes at 2,000 to 3,000 rpm. (Run the engine until radiator becomes hot in order to purge the air trapped in cooling system.) 12) Stop the engine and wait until coolant temperature lowers. Then open the radiator cap to check coolant level and add coolant up to radiator filler neck or filler tank filler neck. Next, add coolant into reservoir tank up to "FULL" level. 13) After adding coolant, securely install the radiator and reservoir tank caps.
CO-00009
5) For quick draining, open the radiator cap.
NOTE: Be careful not to spill coolant on the floor.
6) Drain the coolant from reservoir tank. 7) Tighten the radiator drain cock securely after draining coolant. 8) Pour the coolant to the filler neck of filler tank, and then pour into reservoir tank up to "FULL" level. (Turbo model) 9) Pour the coolant from radiator filler port to neck of filler, then pour into reservoir tank up to "FULL" level. (Non-turbo model)
Coolant capacity (fill up to "FULL" level) 1.6 L AT model: Approx. 7.3 2 (7.7 US qt, 6.4 Imp qt) 1.6 L MT model: Approx. 7.4 2 (7.8 US qt, 6.5 Imp qt) 2.0 L Non-turbo AT model: Approx. 6.9 2 (7.3 US qt, 6.1 Imp qt) 2.0 L Non-turbo MT model: Approx. 7.0 2 (7.1 US qt, 6.2 Imp qt) 2.0 L Turbo AT model: Approx. 7.6 2 (8.0 US qt, 6.7 Imp qt) 2.0 L Turbo MT model: Approx. 7.7 2 (8.1 US qt, 6.8 Imp qt) 2.5 L AT model: Approx. 6.9 2 (7.3 US qt, 6.1 Imp qt) 2.5 L MT model: Approx. 7.0 2 (7.4 US qt, 6.2 Imp qt)
PM-21
PERIODIC MAINTENANCE SERVICES
Coolant
2. RELATIONSHIP OF SUBARU COOLANT CONCENTRATION AND FREEZING TEMPERATURE
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. [Example] If the coolant temperature is 25°C (77°F) and its specific gravity is 1.054, the concentration is 35% (point A), the safe operating temperature is -14°C (7°F) (point B), and the freezing temperature is -20°C (-4°F) (point C).
(2) (3)
1.100
1.090
1.080
1.070
B C
1.060 (1)
(1.054)
1.050
1.040
1.030
(4)
60%
50% A
40%
30%
1.020 1.010 1.000
-40 -30 (-40) (-22)
-20 -10 (-4) (14)
25 C (77 F)
20%
10% 0 10 20 30 40 50 (32) (50) (68) (86) (104) (122)
(5) C ( F) PM-00025
(1) Coolant gravity (2) Safe operating temperature (3) Concentration of coolant (4) Freezing temperature (5) Coolant temperature
3. PROCEDURE TO ADJUST THE CONCENTRATION OF THE COOLANT
To adjust the concentration of the coolant according to temperature, find the proper fluid concentration in the above diagram and replace the necessary amount of coolant with an undiluted solution of SUBARU genuine coolant (concentration 50%). The amount of coolant that should be replaced can be determined using the diagram. [Example] Assume that the coolant concentration must be increased from 25% to 40%. Find point A, where the 25% line of coolant concentration intersects with the 40% curve of the necessary coolant concentration, and read the scale on the vertical axis of the graph at height A. The quantity of coolant to be drained is 2.12 (2.2 US qt, 1.8 Imp qt). Drain 2.1 2 (2.2 US qt, 1.8 Imp qt) of coolant from the cooling system and add 2.12 (2.2 US qt, 1.8 Imp qt) of the undiluted solution of SUBARU coolant. If a coolant concentration of 50% is needed, drain all the coolant and refill with the undiluted solution only.
(US qt, Imp qt)
(2)
3 (3.2,2.6)
2 (1) (2.1,1.8)
1 (1.1,0.9)
0
45% A
40% 35%
30% 25% 20% 15% 10%
10
20
30
40
50
(3)
%
PM-00026
(1) Quantity of coolant to be drained (2) Necessary concentration of coolant (3) Concentration of coolant in vehicle cooling sys-
tem
PM-22
Idle Mixture
13.Idle Mixture
A: INSPECTION AND ADJUSTMENT
1. IDLE MIXTURE
Before measuring the idle mixture, make sure that the ignition timing and the engine idle speed are within specifications. 1) Set the gear position at "Neutral" for MT, or "N" or "P" for AT. 2) Warm up the engine sufficiently until cooling fan starts to operate. 3) Measure the idle mixture using CO meter.
Engine idle speed 700±100 rpm
CO 1.0±0.5%
4) If out of specification, adjust the idle mixture using CO adjusting screw of mass air flow sensor. 5) After adjusting the CO value, check and adjust the increment coefficient of CO resistor by using Select Monitor.
(1) Select "Current data display & Save" on the select monitor.
(2) If out of specified data, adjust the increment coefficient of CO resistor while rotating the CO adjusting screw (A).
Specified data: 0.28 -- 4.22 V
PERIODIC MAINTENANCE SERVICES
(A)
PM-00146
NOTE: If driving the vehicle on out of specified data, the "DTC 49" is indicated in many case.
PM-23
PERIODIC MAINTENANCE SERVICES
Clutch System
14.Clutch System
A: INSPECTION AND ADJUSTMENT
1. MECHANICAL CLUTCH TYPE
1) Inspect the free play of clutch pedal by operating pedal by hand. If it is out of the specified value, adjust it by turning wing nut on engine side of clutch cable at release fork.
Tightening torque (Adjusting nut on release fork):
4.4 -- 7.4 N·m (0.45 -- 0.75 kgf-m, 3.3 -- 5.4 ft-lb)
Standard free play A: 10 -- 20 mm (0.39 -- 0.79 in)
Standard: 80 mm (3.15 in) or more
3) Pedal height Check that the clutch pedal pad surface is level with or higher than brake pedal pad surface.
2. HYDRAULIC CLUTCH TYPE
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. NON-TURBO MODEL
(A)
(B)
A
Fork lever free play allowance A: 2 -- 4 mm (0.08 -- 0.16 in)
(1) A
PM-00151
(C)
(A) Release lever (B) Push rod (C) Operating cylinder
TURBO MODEL
(A)
(C)
PM-00075
PM-00152
(1) Full stroke: 25.5 mm (1 in)
2) Pedal-to-floor plate gap in disengaged position. (1) With the engine idling, pull the parking brake lever completely. (2) Slowly depress the clutch pedal while moving shift lever into reverse. (3) Stop depressing the clutch pedal when gearshifting is complete. With the clutch pedal in this position, measure the distance between the upper side of pedal pad and the lower end of front panel (intersection of front panel with floor). Check that the measured value is within the specification.
(B)
PM-00101
(A) Release lever (B) Push rod (C) Operating cylinder
2) If the fluid level rises, pedal free play is correct. 3) If the fluid level does not rise, or the push rod cannot be retracted, adjust the clutch pedal. <Ref. to CL-40, Clutch Pedal.> 4) Check the fluid level using the scale on the outside of the clutch master cylinder tank (A). If the level is below "MIN" (B), inspect the clutch master cylinder, operating cylinder and hydraulic line for fluid leaks. If fluid leaks are found, repair or replace. If fluid leaks are not found, add clutch fluid to bring it up to "MAX" (C) of clutch reservoir tank.
PM-24
Clutch System
Recommended clutch fluid: FMVSS No. 116, fresh DOT3 brake fluid
CAUTION: Prevent the clutch fluid from being splashed over vehicle body. If the clutch fluid is splashed over vehicle body, flush it, and then wipe it up.
NOTE: · Avoid mixing different brakes of brake fluid to prevent degradation of the fluid. · Be careful not to allow dirt or dust to get into the reservoir tank.
PERIODIC MAINTENANCE SERVICES
(A) Reservoir tank (B) MIN level (C) MAX level
(A) (C) (B)
PM-00076
PM-25
Transmission Gear Oil
PERIODIC MAINTENANCE SERVICES
15.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. 5MT
Gear oil capacity: FWD model 3.3 L (3.5 US qt, 2.5 Imp qt) AWD model (5MT single range model): 3.5 L (3.7 US qt, 3.1 Imp qt) AWD model (5MT dual range model): 4.0 L (4.2 US qt, 3.5 Imp qt) 6MT: 4.1 L (4.3 US qt, 3.6 Imp qt)
(A)
(B) (C)
6MT
PM-00029
(A) Oil level gauge (B) Upper level (C) Lower level
PM-00030
(A)
(B)
MT-00450
(A) Drain plug (Oil pan side) (B) Drain plug (Clutch housing side)
2) Replace the gasket with new one, and then tighten it to the specified torque. Tightening torque:
5MT 70 N·m (7.1 kgf-m, 51.6 ft-lb)
6MT (Oil pan side): 44 N·m (4.5 kgf-m, 32.5ft-lb)
6MT (Clutch housing side): 70 N·m (7.1 kgf-m, 51.6 ft-lb)
3) Fill transmission gear oil through the oil level gauge hole up to the upper point of level gauge. NOTE: Each oil manufacturer has its base oil and additives. Thus, do not mix two or more brands.
PM-26
Hill-holder System
16.Hill-holder System
A: INSPECTION AND ADJUSTMENT
1) Confirm the stopping and starting performance by activating the hill-holder on an uphill road of 3° or higher inclination.
(1) When the vehicle does not stop; Tighten the adjusting nut of PHV cable. (2) When the vehicle does not start properly; A; When the hill-holder is released later than engagement of clutch (engine tends to stall): Loosen the adjusting nut gradually until smooth starting is enabled. B; When the hill-holder is released earlier than engagement to clutch (vehicle slips down slightly): Tighten the adjusting nut so that hill-holder is released later than engagement of clutch (status in A). Then make adjustment the same as in A.
NOTE: · Whenever turning the adjusting nut, hold the inner cable with pliers to prevent it from turning. · Replace the pressure hold valve (PHV) or PHV cable with a new one, if they are defective and/or damaged.
(B)
(A)
PERIODIC MAINTENANCE SERVICES
(C)
PM-00077
(A) Lock nut (B) Adjusting nut (C) Pressure hold valve
PM-27
PERIODIC MAINTENANCE SERVICES
ATF
17.ATF
A: INSPECTION
CAUTION: The level of ATF varies with fluid temperature. Pay attention to the fluid temperature when checking ATF level.
1) Raise the ATF temperature by driving a distance of 5 to 10 km (3 to 6 miles). Otherwise, idle the engine to raise ATF temperature to 70 -- 80°C (158 -- 176°F) on Subaru Select Monitor. <Ref. to 4AT(diag)-21, READ CURRENT DATA, OPERATION, Subaru Select Monitor.> 2) Make sure the vehicle is level. 3) After selecting all positions (P, R, N, D, 3, 2, 1), set the select lever in "P" range. Measure the ATF level with the engine idling for one or two minutes.
B: REPLACEMENT
1. AUTOMATIC TRANSMISSION FLUID
1) Drain the ATF (Automatic Transmission Fluid) by removing drain plug.
NOTE: · Before starting work, cool off the ATF well. · Check the condition of ATF drained. <Ref. to 4AT-32, CONDITION CHECK, Automatic Transmission Fluid.>
(B)
(A)
(A)
(C)
HOT
(B)
L
(D)
F
(C)
COLD
(E)
L
(D)
PM-00191
(A) Level gauge
(B) ATF level range at "HOT" [70 -- 80°C (158 -- 176°F)]
(C) Upper level
(D) Lower level
(E) ATF level range at "COLD" [20 -- 30°C (68 -- 86°F)]
4) Make sure that ATF level is the center of upper and lower level at "HOT" side. If the ATF level is below lower level, check the transmission for leaks. If there are leaks, it is necessary to repair or replace gasket, oil seals, plugs or other parts. 5) If the ATF level is below the center between upper and lower level, add the recommended ATF until the ATF level is found above the center between upper and lower level.
CAUTION: · Use care not to exceed the upper level. · Addition of ATF to the upper level when the transmission is cold will result in overfilling of ATF, causing a transmission failure.
6) Check ATF level after raising ATF temperature to 70 -- 80°C (158 --176°F) by running the vehicle or by idling the engine again.
F
AT-02389
(A) Oil pan (B) ATF drain plug
2) Replace the gasket with a new one, and then tighten the specified torque.
Tightening torque: 25 N·m (2.55 kgf-m, 18.4 ft-lb)
3) Fill ATF up to the middle of the "COLD" side on level gauge by using the gauge hole.
Recommended fluid: Dexron III type automatic transmission fluid
Fluid capacity: Fill the same amount drained from ATF drain plug hole.
PM-28
ATF
4) Check the ATF level. <Ref. to PM-28, INSPECTION, ATF.>
(A)
F
(C)
HOT
(B)
L
(D)
F
(C)
COLD
(E)
L
(D)
PM-00191
(A) Level gauge (B) ATF level range at "HOT" [70 -- 80°C (158 --
176°F)] (C) Upper level (D) Lower level (E) ATF level range at "COLD" [20 -- 30°C (68 --
86°F)]
2. ATF FILTER
NOTE: ATF filter is a maintenance free part. ATF filter needs replacement, when it has physically damaged or ATF leaked. For the replacement procedures of the ATF filter: <Ref. to 4AT-73, ATF Filter.>
PERIODIC MAINTENANCE SERVICES
PM-29
Front & Rear Differential Gear Oil
PERIODIC MAINTENANCE SERVICES
18.Front & Rear Differential Gear Oil
A: REPLACEMENT
1. FRONT DIFFERENTIAL (MT MODEL)
Differential oil works as manual transmission oil to lubricate differential. Refer to "Transmission Oil". <Ref. to PM-26, Transmission Gear Oil.>
2. FRONT DIFFERENTIAL (AT MODEL)
1) Drain the differential gear oil by removing drain plug using TORX®. NOTE: · Before starting work, cool off the differential gear oil well. · If front differential gear oil adheres to the exhaust pipe, wipe it off completely.
PM-00157
2) Replace the gasket with a new one, and then tighten the drain plug to specified torque. Tightening torque:
70 N·m (7.1 kgf-m, 51.6 ft-lb) 3) Fill differential gear oil through the oil level gauge hole up to the upper point of level gauge. NOTE: Each oil manufacturer has its base oil and additives. Thus, do not mix two or more brands. Recommended gear oil:
GL-5 (75W-90) or equivalent
Differential gear oil capacity: 1.1 -- 1.3 2 (1.2 -- 1.4 US qt, 1.0 -- 1.1 lmp qt)
(A)
(B)
(A)
(C)
PI-00183
(A) Oil level gauge (B) Upper level (C) Lower level
3. REAR DIFFERENTIAL
1) Drain the oil by removing drain plug. 2) Remove the filler plug or oil temperature switch for quick draining oil. 3) Install the drain plug after draining oil. NOTE: · Apply fluid packing to the drain plug threads for T type.
Fluid packing: Three Bond 1105 (Part No. 004403010)
· Use a new aluminum gasket for VA type.
Tightening torque: T type: 49.0 N·m (5.0 kgf-m, 36.2 ft-lb) VA type: 34 N·m (3.5 kgf-m, 25.3 ft-lb)
4) After installing the drain plug onto rear differential gear case firmly, fill oil up fully to the mouth of filler plug. T TYPE
(A)
(B)
(A) Filler plug (B) Drain plug
PM-30
PM-00037
VA TYPE
(A)
Front & Rear Differential Gear Oil
PERIODIC MAINTENANCE SERVICES
(B)
PM-00102
(A) Filler plug (B) Drain plug
Recommended gear oil: Except for STi model with driver's control center differential GL-5 (75W-90) or equivalent STi model with driver's control center differential GL-5 [LSD oil (90)] or equivalent
Oil capacity: Except for STi model: 0.8 2 (0.8 US qt, 0.7 lmp qt) STi model: 0.9 -- 1.12 (1.0 -- 1.2 US qt, 0.8 -- 1.0 lmp qt)
NOTE: · Each oil manufacturer has its base oil and additives. Thus, do not mix two or more brands. · For STi model with driver's control center differential, use mechanical LSD model. 5) Install the filler plug or oil temperature switch onto rear differential gear case firmly.
NOTE: · Apply fluid packing to the filler plug or oil temperature switch threads for T type.
Fluid packing: Three Bond 1105 (Part No. 004403010)
· Use a new aluminum gasket for VA type.
Tightening torque: T type: 49.0 N·m (5.0 kgf-m, 36.2 ft-lb) VA type: 34 N·m (3.5 kgf-m, 25.3 ft-lb)
PM-31
PERIODIC MAINTENANCE SERVICES
Brake Line
19.Brake Line
A: INSPECTION
1. BRAKE LINE
1) Check 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. 3) Check any trace of fluid leakage, scratches, etc. on the master cylinder, wheel cylinder and pressure control valve. NOTE: · When the brake fluid level in the reservoir tank is lower than the specified limit, the brake fluid warning light on the combination meter will come on. · Visually check the brake hose (using a mirror where it is difficult to see) for any damage.
(1)
(2)
BR-00095
Brake pedal free play: 0.5 -- 2.0 mm (0.02 -- 0.08 in)
(A)
PM-00078
(A) Brake pedal free play
2) If the free play is out of specifications above, adjust the brake pedal as follows:
(1) Be sure the engine is off. (No vacuum is applied to brake booster.) (2) There should be play between brake booster clevis and pin at brake pedal installing portion. [Depress brake pedal pad with a force of less than 10 N (1 kgf, 2 lb) to a stroke of 0.5 to 2.0 mm (0.02 to 0.08 in).] (3) Depress the surface of brake pad by hand. (4) If there is no free play between clevis pin and clevis, turn the brake switch adjusting nut until the clearance between stopper and screw of brake switch becomes 0.3 mm (0.012 in).
(1) Front brake hose (2) Front brake pipe
(2)
(3)
(1)
(3)
(H)
(I) (J)
(A) (B)
(C)
(D) (E) (F)
(G)
PM-00041
BR-00096
(1) Rear brake pipe (2) Brake hose (3) Clamp
B: CHECKING
1. SERVICE BRAKE
1) Check the free play of brake pedal with a force of less than 10 N (1 kgf, 2 lb).
(A) Brake switch (B) Adjusting nut (C) 0.3 mm (0.012 in) (D) Stopper (E) Clevis pin (F) Clevis (G) Brake pedal free play (H) Lock nut (I) Brake booster operating rod (J) Play at pin
PM-32
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 brake pedal and steering wheel. With the brake pedal released, measure the distance between pedal and steering wheel again. The difference between the two measurements must be less than specified value. If the distance is more than specified, there is possibility of air inside the hydraulic unit.
Brake pedal reserve distance: A 90 mm (3.54 in)/ 490 N (50 kgf, 110 lb) or less
1 2=A
(A)
1 2
(B) PM-00045
(A) Steering wheel (B) Toe board
4) Check to see if air is in the hydraulic brake line by the feel of pedal operation. If air appears to exist in the line, bleed it from the system. 5) Check for even operation of all brakes, using a brake tester or by driving the vehicle for a short distance on a straight road.
2. BRAKE SERVO SYSTEM
1) With the engine off, depress the brake pedal several times applying the same pedal force: Make sure the travel distance should not change. 2) With the brake pedal depressed, start the engine: Make sure the pedal should move slightly toward the floor. 3) With the brake pedal depressed, stop the engine and keep the pedal depressed for 30 seconds: Make sure the pedal height should not change. 4) Check valve is built into the vacuum hose. Disconnect the vacuum hose to inspect function of check valve. Blow air into the vacuum hose from its brake booster side end: Air must flow out of engine side end of hose. Next blow air into the hose from engine side: Air should not flow out of hose.
Replace both check valve and vacuum hose if the check valve is faulty. Engine side of vacuum hose is indicated by marking "ENG" as shown.
(A)
(B)
(C)
PM-00046
(A) Engine side (B) Brake booster side (C) ENG
5) Check the vacuum hose for cracks or other damage. NOTE: When installing the vacuum hose on the engine and brake booster, do not use soapy water or lubricating oil on their connections. 6) Check vacuum hose to make sure it is tight and secure.
PM-33
PERIODIC MAINTENANCE SERVICES
Brake Fluid
20.Brake Fluid
A: REPLACEMENT
1) Either jack-up the vehicle and place a safety stand under it, or lift-up the vehicle. 2) Remove both front and rear wheels. 3) Draw out the brake fluid from master cylinder with syringe. 4) Refill the reservoir tank with recommended brake fluid.
Recommended brake fluid: FMVSS No. 116, fresh DOT3 brake fluid
NOTE: · Avoid mixing different brands of brake fluid to prevent degrading the quality of the fluid. · Be careful not to allow dirt or dust to get into the reservoir tank.
Bleeding sequence (1) (2) (3) (4)
(1)
(4)
(5)
(6)
(3)
(2) PM-00047
(1) Front right (2) Rear left (3) Front left (4) Rear right (5) Secondary (6) Primary
5) Install one end of a vinyl tube onto the air bleeder and insert the other end of the tube into a container to collect the brake fluid.
· During the bleeding operation, keep the brake reservoir tank filled with brake fluid to eliminate entry of air. · The brake pedal operating must be very slow. · For convenience and safety, two people should do the work. · The amount of brake fluid required is approx. 500 m2 (16.9 US fl oz, 17.6 Imp fl oz) for total brake system.
6) Instruct your co-worker to depress the brake pedal slowly two or three times and then hold it depressed. 7) Loosen the bleeder screw approx. 1/4 turn until a small amount of brake fluid drains into container, and then quickly tighten the screw. 8) Repeat steps 6) and 7) above until there are no air bubbles in the drained brake fluid and new fluid flows through vinyl tube.
NOTE: Add brake fluid as necessary while performing the air bleed operation, in order to prevent the tank from running short of brake fluid.
9) After completing the bleeding operation, hold brake pedal depressed and tighten the screw and install bleeder cap.
Tightening torque: 8 N·m (0.8 kgf-m, 5.8 ft-lb)
10) Bleed air from each wheel cylinder by following the previous 5 steps. 11) Depress the brake pedal with a force of approx. 294 N (30 kgf, 66 lb) and hold it there for approx. 20 seconds. At this time check the pedal to see if it makes any unusual movement. Visually inspect the bleeder screws and brake pipe joints to make sure that there is no fluid leakage. 12) Install the wheels, and drive the vehicle for a short distance between 2 to 3 km (1 to 2 miles) to make sure that brakes are operating properly.
PM-00048
NOTE: · Cover the bleeder with waste cloth, when loosening it, to prevent brake fluid from being splashed over surrounding parts.
PM-34
Disc Brake Pads and Discs
PERIODIC MAINTENANCE SERVICES
21.Disc Brake Pads and Discs
A: INSPECTION
1. DISC BRAKE PAD AND DISC
1) Jack-up the vehicle and support with rigid racks. Then remove the wheels. 2) Visually check the pad thickness through inspection hole of disc brake assembly. Replace the pad if necessary.
NOTE: When replacing a pad, always replace the pads for both the right and left wheels at the same time. Also replace the pad clips if they are twisted or worn.
(A)
(C) (B)
(A) Thickness of pad (B) Back metal (C) Lining
PM-00140
3) Check the disc rotor, and correct or replace if it is damaged or worn. · Front
(A)
(A) Inspection hole
· Front
Pad thicknessmm (in) Standard
Service limit
14, 15 inch 16 inch 17 inch
14, 15 inch 16 inch 17 inch
· Rear
Pad thicknessmm (in) Standard
Service limit
14 inch 15 inch 17 inch 14 inch 15 inch 17 inch
PM-00049
11 (0.43) 10 (0.39) 9.2 (0.36) 1.5 (0.059) 1.5 (0.059) 1.2 (0.047)
9 (0.35) 11.5 (0.45)
9 (0.35) 1.5 (0.059) 1.5 (0.059) 1.2 (0.047)
Disc rotor thicknessmm (in)
Standard
14, 15, 16 inch 17 inch
Service limit
14, 15, 16 inch 17 inch
24 (0.94) 30 (1.18) 22 (0.87) 28 (1.10)
· Rear
Disc rotor thicknessmm (in)
14 inch
Standard
15 inch
17 inch
14 inch
Service limit
15 inch
17 inch
10 (0.39) 18 (0.71) 20 (0.79) 8.5 (0.34) 16 (0.63) 18 (0.71)
4) Remove the caliper body. <Ref. to BR-31, Front Disc Brake Assembly.>, <Ref. to BR-42, Rear Disc Brake Assembly.> 5) Tighten the wheel nuts to secure disk rotor. 6) Set a dial gauge at a point less than 10 mm (0.39 in) from outer periphery of rotor, and then measure the disk rotor runout.
Disc rotor runout limit: Front: 0.075 mm (0.0030 in) Rear: 0.070 mm (0.0028 in)
PM-35
PM-00051
Brake Linings and Drums
PERIODIC MAINTENANCE SERVICES
22.Brake Linings and Drums
A: INSPECTION
1. REAR DRUM BRAKE
1) Remove the brake drum, and check that there is no fluid leakage from wheel cylinder. If there is fluid leakage from wheel cylinder, inspect the wheel cylinder, and then repair or replace it. 2) Inspect the brake shoes for damage or deformities and check brake linings for wear.
NOTE: · Always replace both leading and trailing brake shoes for the right and left wheels at the same time. · When either the right and left brake assembly is replaced, always replace the leading shoe and trailing shoe of the other.
Thickness of lining (except back metal) Standard value: 4.1 mm (0.161 in) Service limit: 1.5 mm (0.059 in)
(B) (C)
(A)
(D)
(E)
(G)
(F)
PM-00052
If deformation or wear of back plate, shoe, etc. is noticeable, replace the affected parts.
(A) PM-00053
(A) Inside diameter
2. PARKING BRAKE (REAR DISC BRAKE)
Inspect the brake linings and drums of both sides of the rear brake at the same time by removing brake drums. 1) Inspect the brake shoes for damage or deformation and check brake linings for wear. NOTE: Always replace both primary and secondary brake shoes for the right and left wheels at the same time. Brake lining thickness (except back metal)
Standard value: 3.2 mm (0.126 in) Wear limit: 1.5 mm (0.059 in)
(A) Rotational direction of drum (Forward) (B) Wheel cylinder (C) Upper shoe return spring (D) Adjusting lever (E) Trailing shoe (F) Lower shoe return spring (G) Leading shoe
3) Check the brake drum for wear, dents or other damage. If the inside surface of brake drum is streaked, correct the surface with emery cloth (#200 or more). If it is unevenly worn, tapered, or the outside surface of brake drum is damaged, correct or replace it.
Brake drum inner diameter Standard value: 228.6 mm (9.000 in) Service limit: 230.6 mm (9.079 in)
(A)
(B)
(C)
PM-00054
(A) Forward (B) Brake shoe (Primary side) (C) Brake shoe (Secondary side)
2) Check the disk rotor for wear, dents or other damage. If the inside surface of disk rotor is streaked, correct the surface with emery cloth (#200 or more). If it is unevenly worn or tapered, correct or replace it.
PM-36
Brake Linings and Drums
PERIODIC MAINTENANCE SERVICES
Brake drum inside diameter Except for STi model Standard value: 170 mm (6.69 in) Wear limit: 171 mm (6.73 in) STi model Standard value: 190 mm (7.48 in) Wear limit: 191 mm (7.52 in)
3) Turn back (downward) the adjuster 3 to 4 notches. 4) Install the cover (rubber) at original position correctly.
(B)
(A)
PM-00055
(A) Inside diameter (B) Disk
3) If the deformation or wear of back plate, shoe, etc. is noticeable, replace them. 4) When the shoe return spring tension is excessively weakened, replace it.
B: ADJUSTMENT
1. REAR DRUM BRAKE
The main brake is adjusted automatically, and so there is no need to adjust it.
2. PARKING BRAKE (REAR DISC BRAKE)
For rear disc brake, adjust the parking brake after bleeding air. 1) Remove the rear cover (rubber) installed at back plate. 2) Turn the adjuster toward arrow mark (upward) until it is locked slightly, by using a flat tip screwdriver as shown in illustration.
(A)
(B)
(C)
(A) Adjuster (B) Cover (rubber) (C) Back plate
PM-00056
PM-37
PERIODIC MAINTENANCE SERVICES
Suspension
23.Suspension
A: INSPECTION
1. SUSPENSION BALL JOINT
1) Jack-up the vehicle until front wheels are off ground. 2) Next, grasp the bottom of tire and move it in and out. If relative movement (B) is observed between the brake disc cover (A) and end of transverse link (D), ball joint (C) may be excessively worn.
NOTE: When the transverse link ball joint has been removed or replaced, check the toe-in of front wheel. If the front wheel toe-in is not at specified value, adjust the toe-in. <Ref. to FS-6, Wheel Alignment.>
(A)
(D) (C)
(A)
(B) PM-00057
3) Next, grasp the end of transverse link and move it up and down. Relative movement (A) between the housing (D) and transverse link (C) boss indicates ball joint (B) may be excessively worn.
PM-00059
(A) Dust seal
2. TRANSVERSE LINK'S REAR BUSHING
Check oil leaks at around liquid-filled bushing. If oil leaks, replace the bushing.
(A)
(D)
(A)
(C) (B) PM-00058
4) If relative movement is observed in the immediately preceding two steps, remove and inspect the ball joint. If free play exceeds standard, replace the ball joint. <Ref. to FS-18, Front Ball Joint.> 5) Damage of dust seal Visually inspect the ball joint dust seal. If it is damaged, remove the transverse link. <Ref. to FS-15, Front Transverse Link.> And measure free play of ball joint. <Ref. to FS-18, Front Ball Joint.>
(1) When looseness exceeds standard value, replace the ball joint. (2) If the dust seal is damaged, replace with the new ball joint.
(B)
PM-00060
(A) Rear bushing (B) Transverse link
3. WHEEL ARCH HEIGHT
1) Unload cargoes and set the vehicle in curb weight (empty) condition. 2) Then, check the wheel arch height of front and rear suspensions to ensure that they are within specified values. <Ref. to FS-6, Wheel Alignment.> 3) When the wheel arch height is out of standard, visually inspect the following components and replace deformed parts. · Suspension components [Front strut assembly and rear shock absorber assembly] · Parts connecting between suspension and body. 4) When no components are deformed, adjust the wheel arch height by replacing coil spring in the suspension which wheel arch height is out of standard. <Ref. to FS-6, Wheel Alignment.> <Ref. to RS-10, Wheel Alignment.>
PM-38
Suspension
PERIODIC MAINTENANCE SERVICES
4. WHEEL ALIGNMENT OF FRONT SUSPENSION
1) Check the alignment of front suspension to ensure that following items conform to standard values. · Toe-in · Camber angle · Caster angle · Steering angle <Ref. to FS-6, Wheel Alignment.> 2) When the caster angle does not conform to reference, visually inspect the following components and replace deformed parts. · Suspension components [Strut assembly, crossmember, transverse link, etc.] · Body parts to which suspensions are installed. 3) When the toe-in and camber are out of standard value, adjust them so that they conform to respective service standard. 4) When the right-and-left turning angles of tire are out of standard, adjust to standard value.
5. WHEEL ALIGNMENT OF REAR SUSPENSION
1) Check the alignment of rear suspension to ensure that following items are within standard values. · Toe-in · Camber angle · Thrust angle <Ref. to RS-10, Wheel Alignment.> 2) When the camber angle does not conform to reference, visually inspect parts listed below. If deformation is observed, replace the damaged parts. · Suspension components [Shock absorber, link F, link R, link UPR, arm R, sub frame, etc.] · Body parts to which suspensions are installed. 3) When the toe-in and thrust angle are out of standard value, adjust them so that they conform to respective service standard.
6. OIL LEAKAGE OF STRUT
Visually inspect the front strut and rear strut for oil leakage as instructed. Replace front strut and rear strut if oil leaks excessively.
7. TIGHTNESS OF BOLTS AND NUTS
Check the bolts and nuts shown in the figure for looseness. Retighten the bolts and nuts to specified torque. If the self-lock nuts and bolts are removed, replace them with new ones. Front suspension: <Ref. to FS-2, General Description.> Rear suspension: <Ref. to RS-2, General Description.>
8. DAMAGE TO SUSPENSION PARTS
1) Check the following parts and the fastening portion of the vehicle body for deformation or excessive rusting which impairs the suspension. If necessary, replace the damaged parts with new ones. If minor rust formation, pitting, etc. are noted, remove the rust and apply remedial anti-corrosion measures. · Front suspension
· Transverse link · Crossmember · Strut · Rear suspension · Crossmember · Lateral links · Trailing link · Strut · In the district where salt is sprayed to melt snow on a road in winter, check suspension parts for damage caused by rust every 12 months after lapse of 60 months. Take rust prevention measure as required.
PM-39
PERIODIC MAINTENANCE SERVICES
Wheel Bearing
24.Wheel Bearing
A: INSPECTION
1. FRONT WHEEL BEARING
NOTE: Inspect the condition of front wheel bearing grease.
1) Jack-up the front 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 front wheel. 4) If bearing free play exists in step 2) above, attach a dial gauge to the hub and measure axial displacement in axial direction.
Service limit: Straight-ahead position within 0.05 mm (0.0020 in)
5) Remove the bolts and self-locking nuts, and extract transverse link from front crossmember. 6) Remove the SFJ of front drive shaft from transmission. <Ref. to DS-19, Front Axle.> 7) While supporting the front drive shaft horizontally with one hand, turn the hub with the other to check for noise or binding. If the hub is noisy or binds, disassemble the front axle and check condition of oil seals, bearing, etc.
(A)
(F)
(G) (B)
(C)
(D)
(E)
PM-00061
(A) Inner oil seal (B) Snap ring (C) Bearing (D) Housing (E) Outer oil seal (F) Hub bolt (G) Hub
2. REAR WHEEL BEARING
· AWD
1) Jack-up the rear of vehicle. 2) While holding the rear wheel by hand, swing it in and out to check bearing free play. 3) Loosen the wheel nuts and remove rear wheel.
4) If the bearing free play exists in step 2) above, attach a dial gauge to the hub COMPL and measure axial displacement in axial direction.
Service limit: Straight-ahead position within 0.05 mm (0.0020 in)
5) Remove the DOJ of rear drive shaft from rear differential. <Ref. to DS-44, Rear Drive Shaft.> 6) While supporting the rear drive shaft horizontally with one hand, turn the hub COMPL with the other to check for noise or binding. If the hub COMPL is noisy or binds, disassemble the rear axle and check condition of oil seals, bearings, etc.
(A)
(F) (G)
(H)
( I )
(B)
(C)
(D)
(E)
PM-00062
(A) Inner oil seal (B) Rear housing (C) Bearing (D) Snap ring (E) Outer oil seal (F) Tone wheel (G) Hub bolt (H) Hub (I) Socket bolt
· FWD
1) Jack-up the rear of vehicle. 2) While holding the rear wheel by hand, swing it in and out to check bearing free play. 3) Loosen the wheel nuts and remove rear wheel. 4) If the bearing free play exists in step 2) above, attach a dial gauge to the hub COMPL and measure axial displacement in axial direction.
Service limit: Straight-ahead position within 0.05 mm (0.0020 in)
PM-40
Wheel Bearing
5) Turn the hub unit COMPL with hand to check for noise or binding. If the hub unit COMPL is noisy or binds, replace the hub unit COMPL.
(A) (B) (C)
(D)
(F) (G) (H) (I)
(E) PM-00153
(A) Rear housing (B) Tone wheel (C) Hub bolt (D) Hub unit COMPL (E) Socket bolt (F) Washer (G) Hub nut (H) O-ring (I) Hub cap
PERIODIC MAINTENANCE SERVICES
PM-41
Axle Boots & Joints
PERIODIC MAINTENANCE SERVICES
25.Axle Boots & Joints
A: INSPECTION
1. FRONT AND REAR AXLE BOOTS
Inspect the front axle boots (A) and rear axle boots (B) for deformation, damage or failure. If faulty, replace them with new ones. <Ref. to DS-36, Front Drive Shaft.> <Ref. to DS-44, Rear Drive Shaft.>
(A) PM-00063
(B) PM-00064
2. PROPELLER SHAFT
Inspect the propeller shaft for damage or failure. If faulty, replace with a new one. <Ref. to DS-16, Propeller Shaft.>
PM-42
Steering System (Power Steering)
PERIODIC MAINTENANCE SERVICES
26.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 correctly set in their specified positions. 2) Lightly turn the steering wheel to the right and left to determine the point where front wheels start to move. Measure the distance of the movement of steering wheel at the outer periphery of wheel.
Steering wheel free play: 0 -- 17 mm (0 -- 0.67 in)
2. STEERING SHAFT JOINT
When the steering wheel free play is excessive, disconnect the universal joint of steering shaft and check it for any play and yawing torque (at the point of the crossing direction). Also inspect for any damage to sealing or worn serrations. If the joint is loose, retighten the mounting bolts to the specified torque.
Tightening torque: 24 N·m (2.4 kgf-m, 17.4 ft-lb)
(A)
SUBARU
SRS AIRBAG
PM-00065
(A) Steering wheel free play
Move the steering wheel vertically toward the shaft to ascertain if there is play in the direction.
Maximum permissible play: 0.5 mm (0.020 in)
3) Drive the vehicle and check the following items during operation.
(1) Steering force: The effort required for steering should be smooth and even at all points, and should not vary. (2) Pull to one side: Steering wheel should not be pulled to either side while driving on a level surface. (3) Wheel runout: Steering wheel should not show any sign of runout. (4) Return factor: Steering wheel should return to its original position after it has been turned and then released.
PM-00066
3. GEARBOX
1) With wheels placed on a level surface, turn the steering wheel 90° in both the right and left directions. While the wheel is being rotated, reach under the vehicle and check for looseness in gearbox. Tightening torque:
59 N·m (6.0 kgf-m, 43.4 ft-lb)
(A)
(B)
PM-00067
(A) Boot (B) Gear box mounting bolt
2) Check the boot for damage, cracks or deterioration. 3) With the vehicle on a level surface, quickly turn the steering wheel to the right and left. While the steering wheel is being rotated, check the gear backlash. If any unusual noise is noticed, adjust the gear backlash in the following manner.
(1) Tighten the adjusting screw to 7.4 N·m (0.75 kgf-m, 5.4 ft-lb) and then loosen. Repeat this operation twice.
PM-43
Steering System (Power Steering)
PERIODIC MAINTENANCE SERVICES
(2) Retighten the adjusting screw to 7.4 N·m (0.75 kgf-m, 5.4 ft-lb) and back off 25°. (3) Loosen the adjusting screw and apply liquid packing to at least 1/3 of entire perimeter of its thread.
(A)
PM-00068
(A) Apply liquid packing to at least 1/3 of entire perimeter
(4) Tighten the adjusting screw to 7.4 N·m (0.75 kgf-m, 5.4 ft-lb) and back off 25°. (5) Install the lock nut. While holding the adjusting screw with a wrench, tighten the lock nut using ST. ST 926230000 SPANNER Tightening torque (Lock nut): 39 N·m (4.0 kgf-m, 29 ft-lb) Hold the adjusting screw with a wrench to prevent it from turning, while tightening the lock nut.
4. TIE-ROD
1) Check the tie-rod and tie-rod ends for bends, scratches or other damage.
(A) (B)
PM-00069
(A) Tie-rod end (B) Knuckle arm
2) Check the connections of knuckle ball joints for play, inspect for damage on dust seals, and check free play of ball studs. If the castle nut is loose, retighten it to the specified torque, then tighten further up to 60° until the cotter pin hole is aligned.
Tightening torque: 27 N·m (2.75 kgf-m, 19.9 ft-lb)
3) Check the lock nut on tie-rod end for tightness. If it is loose, retighten it to the specified torque. Tightening torque:
83 N·m (8.5 kgf-m, 61.5 ft-lb)
5. POWER STEERING FLUID LEVEL
NOTE: · Check at power steering fluid temperature 20°C (68°F); read the fluid level on the "COLD" side. · Check at power steering fluid temperature 80°C (176°F); read the fluid level on the "HOT" side. 1) Place the vehicle with engine "OFF" on a flat and level surface. 2) Check the fluid level using the scale on the outside of reservoir tank (A). If the level is below "MIN" (B), add fluid to bring it up to "MAX" (C).
PM-00070
NOTE: If the fluid level is at MAX level or above, drain fluid to keep the level in specified range of indicator by using a syringe or the like. Recommended fluid:
Dexron III Fluid capacity:
0.7 2 (0.7 US qt, 0.6 Imp qt)
6. POWER STEERING FLUID FOR LEAKS
Inspect the underside of oil pump and gearbox for power steering system, hoses, piping and their couplings for fluid leaks. If fluid leaks are found, correct them by retightening their fitting bolts (or nuts) and/or replacing their parts. NOTE: · Wipe the leakage fluid off after repairing fluid leaks, or a wrong diagnosis is taken later. · Also pay attention to clearances between hoses (or pipings) and other parts when inspecting fluid leaks.
7. HOSES OF OIL PUMP FOR DAMAGES
Check the pressure hose and return hose of oil pump for crack, swell or damage. Replace the hose with a new one if necessary.
PM-44
Steering System (Power Steering)
PERIODIC MAINTENANCE SERVICES NOTE: Prevent the hoses from revolving and/or turning when installing hoses.
PM-00071
8. POWER STEERING PIPES FOR DAMAGE
Check the power steering pipes for corrosion and damage. Replace the pipes with a new one if necessary.
9. GEARBOX BOOTS
Inspect both sides of gearbox boots as follows, and correct the defects if necessary. 1) (A) and (B) positions of gearbox boot are fitted correspondingly in (A) and (B) grooves of gearbox and the rod (C). 2) Clips are fitted outside of (A) and (B) positions of boot. 3) Boot does not have crack and hole. NOTE: Rotate (B) the position of gearbox boot against twist of it produced by adjustment of toe-in, etc.
(C)
(B) (A)
PM-00090
10.FITTING BOLTS AND NUTS
Inspect the fitting bolts and nuts of oil pump and bracket for looseness, and retighten them if necessary. Inspect and/or retighten them when engine is cold.
PM-45
Steering System (Power Steering)
PERIODIC MAINTENANCE SERVICES
PM-46
Acrobat Distiller 4.05 for Windows