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)

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine
2004 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX

GENERAL INFORMATION
SECTION
FOREWORD FW

HOW TO USE THIS MANUAL HU

SPECIFICATIONS SPC

PRECAUTION PC
This service manual has been prepared
to provide SUBARU service personnel
NOTE NT
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles. IDENTIFICATION ID
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of RECOMMENDED MATERIALS RM
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual PRE-DELIVERY INSPECTION PI
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition. PERIODIC MAINTENANCE SERVICES PM
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.

All information, illustration and specifi-

cations contained in this manual are
based on the latest product information
available at the time of publication
approval.

FUJI HEAVY INDUSTRIES LTD. G1870GE1

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine
FOREWORD

FW
Page
1. Foreword .....................................................................................................2

Downloaded from www.Manualslib.com manuals search engine

Foreword
FOREWORD

1. Foreword
A: FOREWORD
These manuals are used when performing mainte-
nance, repair, or diagnosis of the Subaru IMPRE-
ZA.

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
Downloaded from www.Manualslib.com manuals search engine
HOW TO USE THIS MANUAL

HU
Page
1. How to Use This Manual .............................................................................2

Downloaded from www.Manualslib.com manuals search engine

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 com-
ponent. 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 in-
formation 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
Downloaded from www.Manualslib.com manuals search engine
How to Use This Manual
HOW TO USE THIS MANUAL

Example:

T2
(3) (6)
T3
(7)
(5) T3
(4)
(2)
(8)
T8 T1 (1) (20)
T2 (21) T3
T6 (5)
T10 T2
T5 (1) T3
(2)
(12) (22) (23) T3
(6) (9) (14) (16)
T4 (18)
(10)
(3) (11) T1
(4) (4) (11)
(13)
(10) (15)
(9) T2
(17)
(19)
T6
(4) (10) T4
(3)
(4)
(7) (15)

T2
T11 T6 (22) T5
(3) (12) (35)

T4 (34)
T5
(8) (27) T3
(10) T2
(26)
(23) (24)
T2 (14) (25)
T7
(24)
(36)
(25)
(13) (31)
(30)
T2 T5
(10) (29) (37) (33)
(17) (28) (32)
(16)
(18)
T4
T3 T1
:Selective part
T1 :Replacement part
(21)
:Sealing point

:Should be lubricated with oil.

(20) :Should be lubricated with grease.

T9 (19)
T1 , T2 .... :Tightening torque
HU-00017

HU-3
Downloaded from www.Manualslib.com manuals search engine
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 us-

ing 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

HU-00002

(A) Component (D) Caution (G) Tightening torque

(B) Process (E) Tool number of special tool (H) Illustration
(C) Reference (F) Name of special tool

HU-4
Downloaded from www.Manualslib.com manuals search engine
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 SI Units Conventional unit Remarks
Force N (Newton) kgf 1 kgf = 9.80655 N
Mass (Weight) kg, g kg, g
Capacity 2, m2 or cm3 2 or cc 1 cc = 1 cm3 = 1 m2
Torque N·m kgf-m, kgf-cm 1 kgf-m = 9.80655 N·m
Rotating speed rpm rpm
Pressure kPa (kilopascal) kgf/cm2 1 kgf/cm2 = 98.0655 kPa
mmHg 1 mmHg = 0.133322 kPa
Power W PS 1 PS = 0.735499 kW
Calorie W⋅h cal 1 kcal = 1.16279 W⋅h
Fuel consumption rate g/kw⋅h g/PS⋅h 1 g/PS⋅h = 1.3596 g/kW⋅h

The figure used in this manuals are described in the SI units and conventional units are described in ( ).

HU-5
Downloaded from www.Manualslib.com manuals search engine
How to Use This Manual
HOW TO USE THIS MANUAL

9. EXPLANATION OF TERMINOLOGY
• List
AAI : Air Assist Injection LH : LH (Left Hand)
A/B : Airbag LSD : Limited Slip Differential
ABS : Antilock Brake System M/B : Main Fuse & Relay Box
A/C : Air conditioner MD : Mini Disc
A/F : Air Fuel Ratio MPi : Multi Point injection
ALT : Generator MP-T : Multi-Plate Transfer
ASSY : Assembly MT : Manual transmission
AT : Automatic transmission Non- : Natural Aspiration
ATF : Automatic transmission fluid turbo
AVCS : Active Valve Control System NC : Normal Close (Relay)
AWD : All Wheel Drive NO : Normal Open (Relay)
BATT : Battery OP : Option Parts
CD-R/RW : CD Recordable/ReWritable P/S : Power Steering
COMPL : Complete P/W : Power Window
CPU : Central Processing Unit PCD : Pitch Circle Diameter
DOHC : Double Overhead Camshaft PCV : Positive Crankcase Ventilation
ECM : Engine Control Module (ECM) RH : RH (Right Hand)
EGI : Electronic Gasoline Injection SOHC : Single Overhead Camshaft
E/G : Engine SRC : Supplemental Restraint System
EGR : Exhaust Gas Recirculation SSM : Subaru Select Monitor
ELR : Emergency Locking Retractor ST : Special Tool
F/B : Fuse & Joint Box SW : Switch
FL : Fusible Link TGV : Tumble generated valve
FWD : Front Wheel Drive T/M : Transmission
HID : High-Intensity Discharge ViS-C : Viscous Coupling
H/U : Hydraulic Unit VSV : Vacuum Switching Valve
IG : Ignition VTD : Variable Torque Distribution
IN : Intake W/H : Wiring harness
INT : Intermittent Pr : Primary
ISC : Idle Speed Control 2ndr : Secondary

HU-6
Downloaded from www.Manualslib.com manuals search engine
SPECIFICATIONS

SPC
Page
1. Impreza .......................................................................................................2

Downloaded from www.Manualslib.com manuals search engine

Impreza
SPECIFICATIONS

1. Impreza
A: DIMENSIONS
Model Sedan Wagon OUTBACK STi
Overall length mm (in) 4,415 (173.8)
Overall width mm (in) 1,740 (68.4) 1,695 (66.7) 1,710 (67.3) 1,740 (68.1)
Overall height (at C.W.) mm (in) 1,465 (57.7), 1,475 (58.1),
1,440 (56.7) 1,440 (56.7)
1,485 (58.5)★4 1,495 (58.9)★4
Compartment Length mm (in) 1,890 (74.4) 1,845 (72.6) 1,890 (74.4)
Width mm (in) 1,380 (54.3)
Height mm (in) 1,180 (46.5), 1,200 (47.2), 1,200 (47.2),
1,180 (46.5)
1,125 (44.3)★5 1,150 (45.3)★5 1,150 (45.3)★5
Wheelbase mm (in) 2,525 (99.4)
Tread Front mm (in)
1,485 (58.5) 1,460 (57.5)★1, 1,460 (57.5) 1,490 (58.7)
1,465 (57.7)
Rear mm (in) 1,475 (58.1), 1,450 (57.1)★1, 1,455 (57.3) 1,480 (58.3)
1,480 (58.3)★3 1,455 (57.3)
Minimum road Without catalytic mm (in) 150 (5.9), 150 (5.9),
160 (6.3) —
clearance converter 155 (6.1)★2 155 (6.1)★2
With catalytic mm (in) 150 (5.9), 150 (5.9),
160 (6.3) 155 (6.1)
converter 155 (6.1)★3 155 (6.1)★3
★1: 1.6 L
★2: 2.0 L
★3: 2.0 L Turbo
★4: With roof rail
★5: With sun roof

SPC-2
Downloaded from www.Manualslib.com manuals search engine
Impreza
SPECIFICATIONS

B: ENGINE
Model 1.6 L Non-turbo 2.0 L Turbo 2.0 L 2.5 L STi
Engine type Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine
Valve arrangement Overhead camshaft type
Bore × Stroke mm (in) 87.9 × 65.8 92 × 75 99.5 × 79 92 × 75
(3.461 × 2.591) (3.62 × 2.95) (3.92 × 3.11) (3.62 × 2.95)
Displacement cm3 (cu in) 1,597 (97.45) 1,994 (121.67) 2,457 (149.9) 1,994 (121.67)
Compression ratio 10.0±0.2 8.0±0.2 10.0±0.2 8.0±0.2
Firing order 1—3—2—4
Idle speed at rpm 650±100★2 650±100★2 700±100★4
Park/Neutral position 650±100 700±100
700±100★1 700±100★1 750±100
Maximum output kW (HP)/rpm 160
(215)/5,600
70 92 168 112 195
(94)/5,200 (123)/5,600 (225)/6,000★3 (150)/5,600 (261)/6,000
165
(221)/5,600★4
Maximum torque N·m (kgf-m, ft-lb) 292
/rpm (29.8, 215.4)
143 184 /3,600 223 343
(14.6, 105.5) (18.8, 136.0) 300 (22.7, 164.5) (35.0, 253.0)
/3,600 /3,600 (30.6, 221.3) /3,600 /4,000
/3,600★3,
4,000★4
★1: Without OBD
★2: With OBD
★3: Australia model
★4: Europe model

C: ELECTRICAL
Model 1.6 L Non-turbo 2.0 L Turbo 2.0 L 2.5 L STi
Ignition timing at BTDC MT: 10°±10°
5°±10° 10°±10° 12°±10° 12°±10°
idling AT: 15°±10°
Spark Type and Without NGK: BKR6E NGK: BKR6E
plug manufacturer OBD (without catalyst) (without catalyst)
CHAMPION: CHAMPION: CHAMPION:
RC8YC4 RC10YC4 — RC10YC4 —
(with catalyst) (with catalyst) NGK: BKR5E-11
NGK: BKR6E-11 NGK: BKR5E-11
(with catalyst) (with catalyst)
With OBD CHAMPION: CHAMPION:
RC8YC4 RC10YC4
NGK: PFR6G — NGK: PFR6G
Alternate Alternate
NGK: BKR6E-11 NGK: BKR5E-11
Generator 12V — 75A
Battery Type and For
capacity Europe 12V — 48AH MT: 12V — 48AH (55D23L) 12V — 48AH
—
(5HR) and South (55D23L) AT: 12V — 52AH (65D23L) (55D23L)
America
For 12V — 27AH 12V — 40AH 12V — 27AH 12V — 40AH
—
Australia (34B19L) (50D20L) (34B19L) (50D20L)
Others 12V — 27AH (34B19L) —

SPC-3
Downloaded from www.Manualslib.com manuals search engine
Impreza
SPECIFICATIONS

D: TRANSMISSION
Model 1.6 L Non-turbo 2.0 L Turbo 2.0 L 2.5 L STi
Transmission type 5MT 4AT 5MT 4AT 5MT 4AT 5MT 4AT 6MT
Clutch type DSPD TCC DSPD TCC DSPD TCC DSPD TCC DSPD
Gear ratio 1st 3.454,
3.454 2.785 3.454 2.785 2.785 3.454 2.785 3.636
3.166★1
2nd 1.947,
2.062 1.545 2.062 1.545 1.545 2.062 1.545 2.375
1.882★1
3rd 1.366,
1.448 1.000 1.448 1.000 1.000 1.448 1.000 1.761
1.296★1
4th 1.088 0.694 1.088 0.694 0.972 0.694 1.088 0.694 1.346
5th 0.871, 0.971,
0.825 — 0.825 — 0.738 — —
0.780★1 1.062★1
6th 0.756,
— — — — — — — —
0.842★1
Reverse 3.333 2.272 3.333 2.272 3.333 2.272 3.333 2.272 3.545
Dual
1.447 — 1.447 — — — — — —
range
Reduction 1st Type of
— Helical — Helical — Helical — Helical —
gear (Front reduction gear
drive) Gear
— 1.000 — 1.000 — 1.000 — 1.000 —
ratio
Final Type of
Hypoid Hypoid Hypoid Hypoid Hypoid Hypoid Hypoid Hypoid Hypoid
reduction gear
Gear 3.900,
4.111 4.444 3.900 4.111 4.444 4.111 4.111 3.900
ratio 4.444★1
Reduction Transfer Type of
Helical — Helical — Helical — Helical — Helical
gear (Rear reduction gear
drive) Gear 1.100, 1.100,
(AWD 1.000 — 1.000 — — 1.000 —
ratio 1.000★1 1.000★1
model)
Final Type of
Hypoid Hypoid Hypoid Hypoid Hypoid Hypoid Hypoid Hypoid Hypoid
reduction gear
Gear 3.545, 3.545,
4.111 4.444 3.900 4.111 4.444 4.111 4.111
ratio 4.444★1 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 Turbo 2.0 L, 2.5 L OUTBACK 2.0 L NA, 1.6 L STi
Type Rack and Pinion
Turns, lock to lock RHD: 2.69
3.02 3.22 2.69
LHD: 3.02
Minimum turning circle m (ft) Curb to curb 11 (36.1) 11 (36.1) 10.4 (34.1) 11 (36.1)
Wall to wall 12.0 (39.4) 11.6 (38.1) 11.2 (36.7) 12.0 (39.4)

F: SUSPENSION
Front Macpherson strut type, Independent, Coil spring
Rear Dual-link type, Independent, Coil spring

SPC-4
Downloaded from www.Manualslib.com manuals search engine
Impreza
SPECIFICATIONS

G: BRAKE
Model 1.6 L Non-turbo 2.0 L, 2.5 L Turbo 2.0 L, STi
Service brake system Dual circuit hydraulic with vacuum suspended power unit
Front Ventilated disc brake
Rear Drum brake Disc brake Ventilated disc brake
Parking brake Mechanical on rear brakes

H: TIRE
Model BASE, TS GX, TS RS, WRX OUTBACK WRX STi
Rim size 14 × 51/ 2JJ 15 × 6JJ 16 × 61/ 2JJ 16 × 61/ 2JJ 17 × 7JJ 17 × 71/2JJ
Tire size 185/70R14 88H 195/60R15 88H 205/50R16 87V P205/55R16 89V 215/45R17 87W 225/45R17 90W
Type Steel belted radial, Tubeless

I: CAPACITY
Model 1.6 L FWD 1.6 L AWD Non-turbo 2.0 L Turbo 2.0 L 2.5 L STi
5MT 4AT 5MT 4AT 5MT 4AT 5MT 4AT 5MT 4AT 6MT
Fuel tank 2 (US gal,
50 (13.2, 11.0) 60 (15.9, 13.2)
Imp gal)
Engine Total 2 (US qt, 4.5
oil capacity Imp qt) 4.0 (4.2, 3.5) 4.5 (4.8, 4.0) 4.0 (4.2, 3.5) (4.8,
4.0)
Engine 2 (US qt,
oil Imp qt)
Approx. 4.0 (4.2, 3.5)
amount
for refill
Transmission 2 (US qt, 3.5 3.5
gear oil Imp qt) (3.7, (3.7,
3.3 3.1), 3.1), 3.5 3.5 4.1
(3.5, — 4.0 — 4.0 — (3.7, — (3.7, — (4.3,
2.9) (4.2, (4.2, 3.5) 3.1) 3.1) 3.6)
3.5)★1 ★1

ATF 2 (US qt, 8.0 8.4 8.4 9.3 9.3

Imp qt) — (8.5, — (8.9, — (8.9, — (9.8, — (9.8, —
7.0) 7.4) 7.4) 8.2) 8.2)
Front differential 2 (US qt, 1.2 1.2 1.2 1.2 1.2
gear oil Imp qt) — (1.3, — (1.3, — (1.3, — (1.3, — (1.3, —
1.1) 1.1) 1.1) 1.1) 1.1)
Rear differential 2 (US qt, 1.0
gear oil Imp qt) — 0.8 (0.8, 0.7) (1.1,
0.9)
Power steering 2 (US qt,
0.7 (0.7, 0.6)
fluid Imp qt)
Engine coolant 2 (US qt, 7.4 7.3 7.4 7.3 7.0 6.9 7.7 7.6 7.0 6.9 7.7
Imp qt) (7.8, (7.7, (7.8, (7.7, (7.4, (7.3, (8.1, (8.0, (7.4, (7.3, (8.1,
6.5) 6.4) 6.5) 6.4) 6.2) 6.1) 6.8) 6.7) 6.2) 6.1) 6.8)
★1: Dual range

SPC-5
Downloaded from www.Manualslib.com manuals search engine
Impreza
SPECIFICATIONS

J: WEIGHT
1. LHD MODEL
Sedan
Option code★1 E2 EC K0 K4 KS
Model 1.6 L
FWD AWD
Base TS
5MT 4AT 5MT
Curb weight (C.W.) Front kgf (lb) 720 765 770 735 755 750 750 740
(1,587) (1,687) (1,698) (1,620) (1,664) (1,654) (1,654) (1,631)
Rear kgf (lb) 470 470 470 520 520 520 520 535
(1,036) (1,036) (1,036) (1,146) (1,146) (1,146) (1,146) (1,179)
Total kgf (lb) 1,190 1,235 1,240 1,255 1,275 1,270 1,270 1,275
(2,624) (2,723) (2,734) (2,756) (2,810) (2,800) (2,800) (2,810)
Maximum permissible Front kgf (lb) 890 890 890 890 890 890 890 890
axle weight (M.P.A.W.) (1,962) (1,962) (1,962) (1,962) (1,962) (1,962) (1,962) (1,962)
Rear kgf (lb) 890 890 890 890 890 890 890 890
(1,962) (1,962) (1,962) (1,962) (1,962) (1,962) (1,962) (1,962)
Maximum permissible Total kgf (lb) 1,660 1,660 1,660 1,700 1,700 1,700 1,700 1,700
weight (M.P.W.) (3,660) (3,660) (3,660) (3,748) (3,748) (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.>

SPC-6
Downloaded from www.Manualslib.com manuals search engine
Impreza
SPECIFICATIONS

Option code★1 EC K0 K4 KS EC
Model 1.6 L 2.0 L
AWD
TS GX
4AT 5MT
Curb weight (C.W.) Front kgf (lb) 755 775 770 770 760 750 770 765
(1,644) (1,709) (1,698) (1,698) (1,676) (1,654) (1,698) (1,687)
Rear kgf (lb) 520 520 520 520 530 535 535 535
(1,146) (1,146) (1,146) (1,146) (1,168) (1,179) (1,179) (1,179)
Total kgf (lb) 1,275 1,295 1,290 1,290 1,295 1,285 1,305 1,300
(2,810) (2,855) (2,844) (2,844) (2,855) (2,833) (2,877) (2,866)
Maximum permissible Front kgf (lb) 890 890 890 890 890 950 950 950
axle weight (M.P.A.W.) (1,962) (1,962) (1,962) (1,962) (1,962) (2,094) (2,094) (2,094)
Rear kgf (lb) 890 890 890 890 890 910 910 910
(1,962) (1,962) (1,962) (1,962) (1,962) (2,006) (2,066) (2,066)
Maximum permissible Total kgf (lb) 1,700 1,700 1,700 1,700 1,700 1,760 1,760 1,760
weight (M.P.W.) (3,748) (3,748) (3,748) (3,748) (3,748) (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.>

SPC-7
Downloaded from www.Manualslib.com manuals search engine
Impreza
SPECIFICATIONS

Option code★1 E2 K4 K0 KS EC
Model 2.0 L
AWD
GX
5MT 4AT
Curb weight (C.W.) Front kgf (lb) 770 765 770 765 760 765 775 795
(1,698) (1,687) (1,698) (1,687) (1,676) (1,687) (1,709) (1,753)
Rear kgf (lb) 535 535 535 530 525 560 530 530
(1,179) (1,179) (1,179) (1,168) (1,157) (1,235) (1,168) (1,168)
Total kgf (lb) 1,305 1,300 1,305 1,295 1,285 1,325 1,305 1,325
(2,877) (2,866) (2,877) (2,855) (2,833) (2,921) (2,877) (2,921)
Maximum permissible Front kgf (lb) 950 950 950 950 950 950 950 950
axle weight (M.P.A.W.) (2,094) (2,094) (2,094) (2,094) (2,094) (2,094) (2,094) (2,094)
Rear kgf (lb) 910 910 910 910 910 910 910 910
(2,066) (2,066) (2,066) (2,066) (2,066) (2,066) (2,006) (2,006)
Maximum permissible Total kgf (lb) 1,760 1,760 1,760 1,760 1,760 1,760 1,760 1,760
weight (M.P.W.) (3,880) (3,880) (3,880) (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.>

SPC-8
Downloaded from www.Manualslib.com manuals search engine
Impreza
SPECIFICATIONS

Option code★1 EC E2 K4 K0 KS EC
Model 2.0 L
2.0 L
Turbo
AWD
GX WRX
4AT 5MT
Curb weight (C.W.) Front kgf (lb) 790 795 790 795 790 795 790 835
(1,742) (1,742) (1,742) (1,753) (1,742) (1,753) (1,753) (1,841)
Rear kgf (lb) 530 530 530 530 525 530 555 560
(1,168) (1,168) (1,168) (1,168) (1,157) (1,168) (1,224) (1,235)
Total kgf (lb) 1,320 1,325 1,320 1,325 1,315 1,325 1,325 1,395
(2,910) (2,921) (2,910) (2,921) (2,899) (2,921) (2,921) (3,075)
Maximum permissible Front kgf (lb) 950 950 950 950 950 950 950 990
axle weight (M.P.A.W.) (2,094) (2,094) (2,094) (2,094) (2,094) (2,094) (2,094) (2,185)
Rear kgf (lb) 910 910 910 910 910 910 910 920
(2,006) (2,006) (2,006) (2,006) (2,006) (2,006) (2,006) (2,028)
Maximum permissible Total kgf (lb) 1,760 1,760 1,760 1,760 1,760 1,760 1,760 1,850
weight (M.P.W.) (3,880) (3,880) (3,880) (3,880) (3,880) (3,880) (3,880) (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.>

SPC-9
Downloaded from www.Manualslib.com manuals search engine
Impreza
SPECIFICATIONS

Option code★1 EC
Model 2.0 L Turbo
AWD
WRX
5MT
Curb weight (C.W.) Front kgf (lb) 820 835 835 840 835 840 840 840
(1,808) (1,841) (1,841) (1,852) (1,840) (1,852) (1,852) (1,852)
Rear kgf (lb) 550 555 560 570 565 570 570 575
(1,213) (1,224) (1,235) (1,257) (1,246) (1,257) (1,257) (1,268)
Total kgf (lb) 1,370 1,390 1,395 1,410 1,400 1,410 1,410 1,415
(3,020) (3,065) (3,075) (3,109) (3,087) (3,109) (3,109) (3,120)
Maximum permissible Front kgf (lb) 990 990 990 990 990 990 990 990
axle weight (M.P.A.W.) (2,185) (2,185) (2,185) (2,185) (2,185) (2,185) (2,183) (2,183)
Rear kgf (lb) 920 920 920 920 920 920 920 920
(2,028) (2,028) (2,028) (2,028) (2,028) (2,028) (2,028) (2,028)
Maximum permissible Total kgf (lb) 1,850 1,850 1,850 1,850 1,850 1,850 1,850 1,850
weight (M.P.W.) (4,079) (4,079) (4,079) (4,079) (4,079) (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.>

SPC-10
Downloaded from www.Manualslib.com manuals search engine
Impreza
SPECIFICATIONS

Option code★1 K4 EC
Model 2.0 L Turbo
AWD
WRX STi
5MT
Curb weight (C.W.) Front kgf (lb) 835 840 840 885 865 885 885 865
(1,840) (1,852) (1,852) (1,951) (1,907) (1,951) (1,951) (1,907)
Rear kgf (lb) 560 575 575 585 585 585 585 585
(1,235) (1,268) (1,268) (1,290) (1,290) (1,290) (1,290) (1,290)
Total kgf (lb) 1,395 1,415 1,415 1,470 1,450 1,470 1,470 1,450
(3,075) (3,120) (3,120) (3,241) (3,197) (3,241) (3,241) (3,197)
Maximum permissible Front kgf (lb) 990 990 990 1,030 1,030 1,030 1,030 1,030
axle weight (M.P.A.W.) (2,183) (2,183) (2,183) (2,271) (2,271) (2,271) (2,271) (2,271)
Rear kgf (lb) 920 920 920 920 920 920 920 920
(2,028) (2,028) (2,028) (2,028) (2,028) (2,028) (2,028) (2,028)
Maximum permissible Total kgf (lb) 1,850 1,850 1,850 1,880 1,880 1,880 1,880 1,880
weight (M.P.W.) (4,079) (4,079) (4,079) (4,145) (4,145) (4,145) (4,145) (4,145)
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.>

SPC-11
Downloaded from www.Manualslib.com manuals search engine
Impreza
SPECIFICATIONS

Wagon
Option code★1 EC K0 K4 KS EC
Model 1.6 L
AWD
TS
5MT D/R 4AT
Curb weight (C.W.) Front kgf (lb) 740 740 760 755 755 745 755 755
(1,631) (1,631) (1,676) (1,664) (1,664) (1,643) (1,664) (1,664)
Rear kgf (lb) 545 550 545 545 545 560 545 550
(1,202) (1,213) (1,202) (1,202) (1,202) (1,235) (1,202) (1,213)
Total kgf (lb) 1,285 1,290 1,305 1,300 1,300 1,305 1,300 1,305
(2,833) (2,844) (2,877) (2,866) (2,866) (2,877) (2,866) (2,877)
Maximum permissible Front kgf (lb) 900 900 900 900 900 900 900 900
axle weight (M.P.A.W.) (1,984) (1,984) (1,984) (1,984) (1,984) (1,984) (1,984) (1,984)
Rear kgf (lb) 910 910 910 910 910 910 910 910
(2,006) (2,006) (2,006) (2,006) (2,006) (2,006) (2,006) (2,006)
Maximum permissible Total kgf (lb) 1,730 1,730 1,730 1,730 1,730 1,730 1,730 1,730
weight (M.P.W.) (1,609) (1,609) (1,609) (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

SPC-12
Downloaded from www.Manualslib.com manuals search engine
Impreza
SPECIFICATIONS

Option code★1 EC K0 K4 KS EC
Model 1.6 L 2.0 L
AWD
TS GX
4AT 5MT D/R
Curb weight (C.W.) Front kgf (lb) 775 770 770 760 760 785 780 775
(1,709) (1,698) (1,698) (1,676) (1,676) (1,731) (1,720) (1,709)
Rear kgf (lb) 545 545 545 560 570 585 570 570
(1,202) (1,202) (1,202) (1,235) (1,257) (1,290) (1,257) (1,257)
Total kgf (lb) 1,320 1,315 1,315 1,320 1,330 1,370 1,350 1,345
(2,910) (2,899) (2,899) (2,910) (2,932) (3,020) (2,977) (2,965)
Maximum permissible Front kgf (lb) 900 900 900 900 950 950 950 950
axle weight (M.P.A.W.) (1,984) (1,984) (1,984) (1,984) (2,094) (2,094) (2,094) (2,094)
Rear kgf (lb) 910 910 910 910 960 960 960 960
(2,006) (2,006) (2,006) (2,006) (2,0116) (2,116) (2,116) (2,116)
Maximum permissible Total kgf (lb) 1,730 1,730 1,730 1,730 1,800 1,800 1,800 1,800
weight (M.P.W.) (1,609) (1,609) (1,609) (1,609) (3,969) (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

SPC-13
Downloaded from www.Manualslib.com manuals search engine
Impreza
SPECIFICATIONS

Option code★1 K0 K4 KS EC
Model 2.0 L
AWD
GX
5MT D/R 4AT
Curb weight (C.W.) Front kgf (lb) 780 780 775 770 775 800 795 790
(1,720) (1,720) (1,709) (1,698) (1,709 (1,764) (1,753) (1,742)
Rear kgf (lb) 570 570 565 590 565 580 565 565
(1,257) (1,257) (1,246) (1,300) (1,246) (1,279) (1,246) (1,246)
Total kgf (lb) 1,350 1,350 1,340 1,360 1,340 1,380 1,360 1,355
(2,977) (2,977) (2,955) (2,999) (2,955) (3,042) (2,999) (2,987)
Maximum permissible Front kgf (lb) 950 950 950 950 950 950 950 950
axle weight (M.P.A.W.) (2,094) (2,094) (2,094) (2,094) (2,094) (2,094) (2,094) (2,094)
Rear kgf (lb) 960 960 960 960 960 960 960 960
(2,116) (2,116) (2,116) (2,116) (2,116) (2,116) (2,116) (2,116)
Maximum permissible Total kgf (lb) 1,800 1,800 1,800 1,800 1,800 1,800 1,800 1,800
weight (M.P.W.) (3,969) (3,969) (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 — — — — — — — —
★1:For option code, refer to ID section. <Ref. to ID-7, Option code.>
D/R: Dual range

SPC-14
Downloaded from www.Manualslib.com manuals search engine
Impreza
SPECIFICATIONS

Option code★1 K0 K4 KS EC
Model 2.0 L 2.0 L Turbo
AWD
GX WRX
4AT 5MT
Curb weight (C.W.) Front kgf (lb) 795 795 790 790 805 825 830 830
(1,753) (1,753) (1,742) (1,742) (1,775) (1,819) (1,830) (1,830)
Rear kgf (lb) 565 565 560 580 585 585 600 600
(1,246) (1,246) (1,235) (1,279) (1,290) (1,290) (1,322) (1,322)
Total kgf (lb) 1,360 1,360 1,350 1,370 1,390 1,410 1,430 1,430
(2,999) (2,999) (2,977) (3,020) (3,065) (3,109) (3,153) (3,153)
Maximum permissible Front kgf (lb) 950 950 950 950 990 990 990 990
axle weight (M.P.A.W.) (2,094) (2,094) (2,094) (2,094) (2,183) (2,183) (2,183) (2,183)
Rear kgf (lb) 960 960 960 960 950 950 950 950
(2,116) (2,116) (2,116) (2,116) (2,094) (2,094) (2,094) (2,094)
Maximum permissible Total kgf (lb) 1,800 1,800 1,800 1,800 1,860 1,860 1,860 1,860
weight (M.P.W.) (3,969) (3,969) (3,969) (3,969) (4,101) (4,101) (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-15
Downloaded from www.Manualslib.com manuals search engine
Impreza
SPECIFICATIONS

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 kgf (lb) 990 990
axle weight (M.P.A.W.) (2,183) (2,183)
Rear kgf (lb) 950 950
(2,094) (2,094)
Maximum permissible Total kgf (lb) 1,860 1,860
weight (M.P.W.) (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
Downloaded from www.Manualslib.com manuals search engine
Impreza
SPECIFICATIONS

2. RHD MODEL
Sedan
Option code★1 EK K1 EK K1
Model 1.6 L 2.0 L
AWD
TS GX
5MT 4AT 5MT 4AT 5MT 4AT 5MT
Curb weight (C.W.) Front kgf (lb) 740 760 760 750 770 770 795 770
(1,631) (1,676) (1,676) (1,654) (1,698) (1,698) (1,753) (1,698)
Rear kgf (lb) 520 520 520 520 520 535 530 535
(1,146) (1,146) (1,146) (1,146) (1,146) (1,179) (1,168) (1,179)
Total kgf (lb) 1,260 1,280 1,280 1,270 1,290 1,305 1,325 1,305
(2,778) (2,822) (2,822) (2,800) (2,844) (2,877) (2,921) (2,877)
Maximum permissible Front kgf (lb) 890 890 890 890 890 950 950 950
axle weight (M.P.A.W.) (1,962) (1,962) (1,962) (1,962) (1,962) (2,094) (2,094) (2,094)
Rear kgf (lb) 890 890 890 890 890 910 910 910
(1,962) (1,962) (1,962) (1,962) (1,962) (2,006) (2,006) (2,006)
Maximum permissible Total kgf (lb) 1,700 1,700 1,700 1,700 1,700 1,760 1,760 1,760
weight (M.P.W.) (3,748) (3,748) (3,748) (3,748) (3,748) (3,880) (3,880) (3,880)
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.>

SPC-17
Downloaded from www.Manualslib.com manuals search engine
Impreza
SPECIFICATIONS

Option code★1 K1 EK
Model 2.0 L 2.0 L Turbo
AWD
GX WRX STi
4AT 5MT 6MT
Curb weight (C.W.) Front kgf (lb) 795 835 835 840 840 885 885
(1,753) (1,841) (1,841) (1,852) (1,852) (1,952) (1,952)
Rear kgf (lb) 530 565 560 570 575 585 585
(1,168) (1,246) (1,246) (1,257) (1,268) (1,290) (1,290)
Total kgf (lb) 1,325 1,400 1,395 1,410 1,415 1,470 1,470
(2,921) (3,086) (3,075) (3,109) (3,120) (3,241) (3,241)
Maximum permissible Front kgf (lb) 950 990 990 990 990 1,030 1,030
axle weight (M.P.A.W.) (2,094) (2,183) (2,183) (2,183) (2,183) (2,271) (2,271)
Rear kgf (lb) 910 920 920 920 920 920 920
(2,006) (2,028) (2,028) (2,028) (2,028) (2,028) (2,028)
Maximum permissible Total kgf (lb) 1,760 1,850 1,850 1,850 1,850 1,880 1,880
weight (M.P.W.) (3,880) (4,079) (4,079) (4,079) (4,079) (4,145) (4,145)
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.>

SPC-18
Downloaded from www.Manualslib.com manuals search engine
Impreza
SPECIFICATIONS

Option code★1 KA
Model 2.0 L 2.5 L 2.0 L Turbo
AWD
GX RS WRX
5MT 4AT 5MT 4AT 5MT
Unladen weight (U.W.) Front kg (lb) 750 765 775 790 780 805 840 835
(1,654) (1,687) (1,709) (1,742) (1,720) (1,775) (1,852) (1,841)
Rear kg (lb) 535 535 530 530 540 535 575 560
(1,179) (1,179) (1,168) (1,168) (1,191) (1,179) (1,268) (1,235)
Total kg (lb) 1,285 1,300 1,305 1,320 1,320 1,340 1,415 1,395
(2,833) (2,866) (2,877) (2,910) (2,910) (2,955) (3,120) (3,075)
Gross vehicle mass Front kg (lb) 950 950 950 950 950 950 990 990
(G.V.M.) (2,094) (2,094) (2,094) (2,094) (2,094) (2,094) (2,183) (2,183)
Rear kg (lb) 910 910 910 910 910 910 920 920
(2,006) (2,006) (2,006) (2,006) (2,006) (2,006) (2,028) (2,028)
Total kg (lb) 1,760 1,760 1,760 1,760 1,780 1,780 1,850 1,850
(3,880) (3,880) (3,880) (3,880) (3,924) (3,924) (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 ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
Driver’s control
— — — — — — — —
center differential
★1: For option code, refer to ID section. <Ref. to ID-7, Option code.>

SPC-19
Downloaded from www.Manualslib.com manuals search engine
Impreza
SPECIFICATIONS

Option code★1 KA
Model 2.0 L Turbo
AWD
WRX STi
5MT 4AT 6MT
Unladen weight (U.W.) Front kg (lb) 840 860 865 865 885 885
(1,852) (1,896) (1,907) (1,907) (1,952) (1,952)
Rear kg (lb) 570 555 565 570 585 585
(1,257) (1,234) (1,246) (1,257) (1,290) (1,290)
Total kg (lb) 1,410 1,415 1,430 1,435 1,470 1,470
(3,109) (3,120) (3,153) (3,164) (3,241) (3,241)
Gross vehicle mass Front kg (lb) 990 990 990 990 1,030 1,030
(G.V.M.) (2,183) (2,183) (2,183) (2,183) (2,271) (2,271)
Rear kg (lb) 920 920 920 920 920 920
(2,028) (2,028) (2,028) (2,028) (2,028) (2,028)
Total kg (lb) 1,850 1,850 1,850 1,850 1,880 1,880
(4,079) (4,079) (4,079) (4,079) (4,145) (4,145)
Option 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
★1: For option code, refer to ID section. <Ref. to ID-7, Option code.>

SPC-20
Downloaded from www.Manualslib.com manuals search engine
Impreza
SPECIFICATIONS

Wagon
Option code★1 EK K1 EK K1
Model 1.6 L 2.0 L
AWD
TS GX
5MT D/R 4AT 5MT D/R 4AT 5MT D/R 4AT 5MT D/R
Curb weight (C.W.) Front kgf (lb) 745 765 760 755 770 780 795 780
(1,642) (1,687) (1,676) (1,664) (1,698) (1,720) (1,753) (1,720)
Rear kgf (lb) 545 545 545 545 545 570 565 570
(1,202) (1,202) (1,202) (1,202) (1,202) (1,257) (1,246) (1,257)
Total kgf (lb) 1,290 1,310 1,305 1,300 1,315 1,350 1,360 1,350
(2,844) (2,888) (2,877) (2,866) (2,899) (2,977) (2,999) (2,977)
Maximum permissible Front kgf (lb) 900 900 900 900 900 950 950 950
axle weight (M.P.A.W.) (1,984) (1,984) (1,984) (1,984) (1,984) (2,094) (2,094) (2,094)
Rear kgf (lb) 910 910 910 910 910 960 960 960
(2,006) (2,006) (2,006) (2,006) (2,006) (2,116) (2,116) (2,116)
Maximum permissible Total kgf (lb) 1,730 1,730 1,730 1,730 1,730 1,800 1,800 1,800
weight (M.P.W.) (1,609) (1,609) (1,609) (1,609) (1,609) (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

SPC-21
Downloaded from www.Manualslib.com manuals search engine
Impreza
SPECIFICATIONS

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) 795 825 825 830 830
(1,753) (1,819) (1,819) (1,830) (1,830)
Rear kgf (lb) 565 585 590 600 600
(1,246) (1,830) (1,301) (1,323) (1,323)
Total kgf (lb) 1,360 1,410 1,415 1,430 1,430
(2,999) (3,109) (3,120) (3,153) (3,153)
Maximum permissible Front kgf (lb) 950 990 990 990 990
axle weight (M.P.A.W.) (2,094) (2,183) (2,183) (2,183) (2,183)
Rear kgf (lb) 960 950 950 950 950
(2,116) (2,094) (2,094) (2,094) (2,094)
Maximum permissible Total kgf (lb) 1,800 1,860 1,860 1,860 1,860
weight (M.P.W.) (3,969) (4,101) (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

SPC-22
Downloaded from www.Manualslib.com manuals search engine
Impreza
SPECIFICATIONS

Option code★1 KA
Model 2.0 L 2.0 L Turbo
AWD
GX OUTBACK WRX
5MT D/
5MT D/R 4AT 4AT 5MT 4AT
R
Unladen weight (U.W.) Front kg (lb) 760 775 775 790 770 785 825 850
(1,676) (1,709) (1,709) (1,742) (1,698) (1,731) (1,819) (1,874)
Rear kg (lb) 570 570 565 565 570 570 585 585
(1,257) (1,257) (1,246) (1,246) (1,257) (1,257) (1,830) (1,830)
Total kg (lb) 1,330 1,345 1,340 1,355 1,340 1,355 1,410 1,435
(2,932) (2,965) (2,955) (2,987) (2,955) (2,987) (3,109) (3,164)
Gross vehicle mass Front kg (lb) 950 950 950 950 950 950 990 990
(G.V.M.) (2,094) (2,094) (2,094) (2,094) (2,094) (2,094) (2,183) (2,183)
Rear kg (lb) 960 960 960 960 960 960 950 950
(2,116) (2,116) (2,116) (2,116) (2,116) (2,116) (2,094) (2,094)
Total kg (lb) 1,800 1,800 1,800 1,800 1,800 1,800 1,860 1,860
(3,969) (3,969) (3,969) (3,969) (3,969) (3,969) (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

SPC-23
Downloaded from www.Manualslib.com manuals search engine
Impreza
SPECIFICATIONS

SPC-24
Downloaded from www.Manualslib.com manuals search engine
PRECAUTION

PC
Page
1. Precaution ...................................................................................................2

Downloaded from www.Manualslib.com manuals search engine

Precaution
PRECAUTION

1. Precaution 7. AIRBAG MODULE

A: PRECAUTION Adhere to the following when handling and storing
the airbag module to prevent bodily injury from un-
Please clearly understand and adhere to the follow-
expected deployment:
ing general precautions. They must be strictly fol-
• Do not hold the harnesses or connectors to carry
lowed to avoid minor or serious injury to the person
module.
doing the work or people in the area.
• Do not face the bag in the direction that it opens
1. ABS towards yourself or other people.
Handle the ABS as a total system. Do not disas- • Do not face the bag in the direction that it opens
semble or attempt to repair parts which are not in- towards the floor or walls.
structed in this manual. Follow the instructions in 8. AIRBAG SPECIAL TOOLS
this manual during performing the maintenance of
ABSCM&H/U. To disassemble parts without in- To prevent unexpected deployment, only use spe-
structions could prevent the ABS system from op- cial tools.
erating when needed or cause it to operate 9. WINDOW
incorrectly and result in injury.
Always wear safety glasses when working around
2. BRAKE FLUID any glass to prevent glass fragments from damag-
If brake fluid gets in your eyes or on your skin, do ing your eyes.
the following: 10.WINDOW ADHESIVE
• Wash out your eyes and seek immediate medical
attention. Always use the recommended or alternative adhe-
sive when attaching glass to prevent it from coming
• Wash your skin with soap and then rinse thor-
loose and falling, resulting in accidents and injury.
oughly 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 traf-
fic rules and regulations to avoid bodily injury and
interrupting traffic.
5. AIRBAG
To prevent bodily injury from unexpected deploy-
ment of airbags and unnecessary maintenance, fol-
low 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 igni-
tion switch to OFF and disconnect the ground cable
from battery, then wait at lease 20 seconds to dis-
charge 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 in-
structions for disposal in this manual. Follow all
government regulations concerning disposal of
refuse.

PC-2
Downloaded from www.Manualslib.com manuals search engine
NOTE

NT
Page
1. Note.............................................................................................................2

Downloaded from www.Manualslib.com manuals search engine

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 oth-
er substances to the surface around bolts, fasten-
ers, 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 pre-
vention cord or touch grounded metal before con-
ducting 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 perfor-
mance and maintenance, when conducting repairs.
Subaru/FHI will not be responsible for poor perfor-
mance resulting from the use of parts not specified
by a genuine dealer.
5. PROTECTING VEHICLE UNDER MAIN-
TENANCE
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
Downloaded from www.Manualslib.com manuals search engine
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)

NT-00060

(1) Support locations (3) Lift (5) Without side sill cover
(2) Pantograph jack (4) Rigid rack (6) With side sill cover

NT-3
Downloaded from www.Manualslib.com manuals search engine
Note
NOTE

(A) (1)

(2)
(B)

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) (2)
(1)

NT-00063

(1) Hook for tie-down (2) Hook for towing and tie-down

NT-4
Downloaded from www.Manualslib.com manuals search engine
Note
NOTE

• Chain direction at tie-down condition

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 tie-
down. 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
Downloaded from www.Manualslib.com manuals search engine
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

NT-00066

• Rear

NT-00067

NT-6
Downloaded from www.Manualslib.com manuals search engine
Note
NOTE

• NOTES

Towing Notes MT AT
Lifting up four wheels (On a trailer) Towing the vehicle after lifting up all four wheels is a ❍ ❍
basic rule for AWD model.

NT-00023
Rope • Check if both front and rear wheels are rotated nor- ❍ ▲
mally.
• AT model driving conditions: Allow driving speed less
than 30 km/h (19 MPH).
Allow driving distance less than 30 km (19 miles).

NT-00024
Raising the front wheels Prohibited for full-time AWD model. ✕ ✕

NT-00025
Lifting up the front wheels • 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
Downloaded from www.Manualslib.com manuals search engine
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 en-
gine 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

NT-00068

• When wider hood opening is necessary

Set stay into the hole of hood inner as shown in the figure below.

NT-00069

NT-8
Downloaded from www.Manualslib.com manuals search engine
Note
NOTE

11.TRAINING
For information about training, contact a dealer or
agent.
12.GENERAL SCAN TOOL
Using general scan tools will greatly improve effi-
ciency of repairing engine electronic controls. The
Subaru Select Monitor can be used to diagnose the
engine and also the ABS, the air conditioner, and
other parts.

NT-9
Downloaded from www.Manualslib.com manuals search engine
Note
NOTE

NT-10
Downloaded from www.Manualslib.com manuals search engine
IDENTIFICATION

ID
Page
1. Identification ................................................................................................2

Downloaded from www.Manualslib.com manuals search engine

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) (4) Tire inflation pressure label (Driver (6) Model number plate
ADR compliance plate (Australia side) (Australia model) (7) Vehicle identification number
model) Tire inflation pressure label (Driver (VIN) (Europe RHD model and
(2) Vehicle identification number side) (Except Australia model) Australia turbo model)
(VIN) (5) Saudi Arabia plate (Saudi Arabia
(3) Emission control label model)
Built date plate (Australia model)

• ENGINE • AUTOMATIC TRANSMISSION

(1)

(1)
ID-00053 ID-00054

(1) Engine serial number (1) Transmission serial number

ID-2
Downloaded from www.Manualslib.com manuals search engine
Identification
IDENTIFICATION

• MANUAL TRANSMISSION • REAR DIFFERENTIAL

• T-type
(1)

(1)

ID-00055
ID-00056
(1) Transmission serial number
(1) Type (white paint)

• VA-type

(1)

DI-00396

(1) Type (label)

• MODEL NUMBER PLATE

ID-00075

ID-3
Downloaded from www.Manualslib.com manuals search engine
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 Code Meaning Details
1 to 3 JF1 Manufacturer body area JF1: Passenger car, FHI made
4 G Car line IMPREZA
5 D Body type D: 4 Door Sedan
G: Wagon
6 4 Displacement 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
7 L Steering position K: RHD (Right-hand drive model)
L: LHD (Left-hand drive model)
8 G Engine & transmission 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
9 9 Drive type 3: Full-time AWD Single range
4: Full-time AWD Dual range
5: AWD AT
9: FWD
10 4 Model year 4: 2004MY
11 G Factory location G: FHI (Gunma)
12 to 17 002001 Serial number —

• GCC countries (Saudi Arabia, etc.)

]JF1GD45MX4G002001[
The starting and ending brackets ( ][ ) are stop marks.
Digits Code Meaning Details
1 to 3 JF1 Manufacturer body area JF1: Passenger car, FHI made
4 G Car line IMPREZA
5 D Body type D: 4 Door Sedan
G: Wagon
6 4 Displacement 4: 1.6 L AWD
8: 2.0 L AWD
7 5 Grade 5: TS
7: GX
8 M Restraint M: Manual belts, dual airbag
9 X Check digit 0 to 9 & X
10 4 Model year 4: 2004MY
11 G 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
12 to 17 002001 Serial number —

ID-4
Downloaded from www.Manualslib.com manuals search engine
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 Code Meaning Details
1 G Series IMPREZA
2 D Body style D: 4 Door Sedan
G: Wagon
3 9 Engine displacement 4: 1.6 L FWD
Drive system 5: 1.6 L AWD
Suspension system 9: 2.0 L AWD
A: 2.0 L AWD Turbo
B: 2.0 L AWD High power turbo
E: 2.5 L AWD
4 D Model year D: 2004MY
5 L Destination K: Right-hand drive model market
L: Left-hand drive model market
6 5 Grade 3: BASE
4: TS
5: GX
6: RS
7: OUTBACK
8: WRX
E: STi
7 R Transmission, fuel feed K: SOHC MPI Dual range 5-speed MT
system 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 Code Meaning Details
1 and 2 EJ Engine type EJ: 4 cylinders
3 and 4 16 Displacement 16: 1.6 L
20: 2.0 L
25: 2.5 L
5 1 Fuel feed system 1: D-MPI SOHC-A
5: MPI Turbo
7: MPI High power turbo
6 R Detailed specifications Used when ordering parts. See the parts catalog for details.
7 W Transmission W: MT
X: AT
8 to 10 6AA Detailed specifications Used when ordering parts. See the parts catalog for details.

ID-5
Downloaded from www.Manualslib.com manuals search engine
Identification
IDENTIFICATION

• Transmission
TM754RY5AA
Digits Code Meaning Details
1 T Transmission T: Transmission
2 M Transmission type 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
3 and 4 75 Classification 75: 5MT
85: 6MT
1A: AT
1B: AT
5 4 Series MT 4: 5MT
6: 6MT
AT 4: AT
6 R Transmission specifica- A: FWD 4-speed AT
tions R: FWD Single Range 5-speed MT
V: Full-time AWD 5-speed MT with viscous coupling center dif-
ferential single range
W: Full-time AWD 6-speed MT with viscous coupling center dif-
ferential single range
X: Full-time AWD 5-speed MT with viscous coupling center dif-
ferential dual range
Z: Full-time AWD 4-speed AT with MPT
Y: Full-time AWD 4-speed AT with VTD
7 to 10 Y5AA Detailed specifications Used when ordering parts. See the parts catalog for details.

• Rear differential 1
VA-type
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
Downloaded from www.Manualslib.com manuals search engine
Identification
IDENTIFICATION

• Option code
E2BL
Digits Code Meaning Details
1—2 E2 Destination 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
3 B Option equipment A: Power window, Power door lock, ABS, Aluminum wheel
B: Power window, Power door lock
C: Power window, Power door lock, Cruise control, ABS, Alumi-
num 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
Downloaded from www.Manualslib.com manuals search engine
Identification
IDENTIFICATION

Digits Code Meaning Details

4 L Option equipment 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
Downloaded from www.Manualslib.com manuals search engine
RECOMMENDED MATERIALS

RM
Page
1. Recommended Materials ............................................................................2

Downloaded from www.Manualslib.com manuals search engine

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. Ignor-
ing the specifications below will result in damage or
poor operation of the engine and fuel injection sys-
tem. Use the specified gasoline to correct perfor-
mance.
• 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 Petrol RON
More than 95 RON
SOHC Unleaded
More than 90 RON*
DOHC turbo Unleaded 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
Downloaded from www.Manualslib.com manuals search engine
Recommended Materials
RECOMMENDED MATERIALS

3. LUBRICANTS
Use either the lubricants in the table below or equivalent lubricants. See the table below to choose the correct
SAE viscosity.
Lubricant Recommended Alternative
API Spec. CCMC Spec. ACEA Spec. API Spec.
Engine oil SL, SJ Grade “Energy conserving”, or SH G4 or G5 A1, A2 or A3 SG, SF

SERVICE S
PI

L
SAE
0W-20
EN

NG
R
E

VI
GY R
CONS E
RM-00006

SERVICE S
PI
A

SAE
5W-30
EN

NG

R
E

VI

GY R
CONS E
RM-00001

TR OLEUM
PE
N

IN

FOR
AM ER I CA

ST I

GASOLINE
TUTE

ENGINES
C
ER D
T I F IE
RM-00002
Manual transmission oil GL-5 — — —
AT front differential gear GL-5 — — —
oil
Rear differential gear oil GL-5★1 — — —
★1: Use LSD oil for model with driver’s control center differential.

RM-3
Downloaded from www.Manualslib.com manuals search engine
Recommended Materials
RECOMMENDED MATERIALS

SAE viscosity No. and applicable temperature

Engine oil
SOHC model

(˚C) –30 –20 –10 0 10 20 30 40

(˚F) –22 –4 14 32 50 68 86 104

10W-30 or 10W-40

5W-30

0W-20 Recommend

RM-00007
DOHC turbo model

(˚C) –30 –20 –10 0 10 20 30 40

(˚F) –22 –4 14 32 50 68 86 104

10W-30 or 10W-40

5W-30 Recommend

RM-00003

RM-4
Downloaded from www.Manualslib.com manuals search engine
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 10 20 30 40

(˚C) –22 –4 14 32 50 68 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 Recommended Alternative Remarks
Automatic transmission fluid DEXRON III — —
Power steering fluid DEXRON III — —
Brake fluid FMVSS No. 116 DOT3 — —
Clutch fluid FMVSS No. 116 DOT3 FMVSS No. 116 DOT4 —

5. COOLANT
Use genuine coolant to protect the engine.
Coolant Recommended Item number Alternative
Coolant SUBARU coolant 000016218 None
Water for dilution Distilled water — Tap water (Soft water)

6. REFRIGERANT
Standard air conditioners on Subaru vehicles use HFC134a refrigerant. Do not mix it with other refrigerants.
Also, do not use any compressor oil except for DH-PR.
Air conditioner Recommended Item number Alternative
Refrigerant HFC134a — None
Compressor oil DH-PR — None

RM-5
Downloaded from www.Manualslib.com manuals search engine
Recommended Materials
RECOMMENDED MATERIALS

7. GREASE
Use the grease and supplementary lubricants shown in the table below.
Grease Application point Recommended Item number Alternative
Supplementary lubricants • O2 sensor Spray type lubricant — —
• Bolts, etc.
Grease MT main shaft Clutch grease K0879Y0501 —
Clutch master cylinder Silicolube G-40M 004404003 —
push rod
• Gear shift lever SUNLIGHT2 003602010 —
• Select lever
• Clutch operating cyl-
inder
• Accelerator pedal
• Clutch pedal
• Brake pedal
• Clutch bearing
• Clutch release lever
• Steering shaft bear-
ing
Steering gear box Valiant grease M-2 003608001 —
• Disc brake Niglube RX-2 K0779GA102 —
• Drum brake wheel
cylinder
• Drum brake Molykote No. 7439 003602001 —
• Brake shoe
Brake pad Molykote AS-880N K0777YA010 —
Front axle PTJ NSG301 28395AG020 —
• Front axle EBJ NTG2218-M 28395FE010 —
• Front axle BJ
• Rear axle EBJ
• Rear axle BJ
• Front axle DOJ NKG205 28395FE020 —
• Rear axle DOJ
Throttle cable end Silicolube G-30M 004404002 —

8. ADHESIVES
Use the adhesives shown in the table below, or equivalent.
Adhesive Application point Recommended Item number Alternative
Adhesive Windshield, rear window Dow Automotive’s — —
glass, rear quarter glass Adhesive: Gurit-ESSEX
and body Betaseal 1502 or equivalent
Glass primer: Betawipe VP
04604, Betaprime 5001
Paint surface primer: Betap-
rime 5402
Inner rearview mirror REPAIR KIT IN MR 65029FC000 —
base
Soft vinyl Cemedine 540 — 3M’s EC-776, EC-847 or EC-1022
(Spray type)
Momentary sealant Cemedine 3000 — Armstrong’s Eastman 910

RM-6
Downloaded from www.Manualslib.com manuals search engine
Recommended Materials
RECOMMENDED MATERIALS

9. SEAL MATERIAL
Use seal material shown in the table below, or equivalent.
Seal material Application point Recommended Item number Alternative
Seal material • Cylinder block Three Bond 1215B 004403007 Dow Corning’s No. 7038
• Torque converter
clutch case
• Transmission oil pan
(6MT model)
Transmission oil pan (AT Three Bond 1217B K0877YA020 —
model)
Rear differential Three Bond 1324 004403042 —
Rear differential Three Bond 1105 004403010 Dow Corning’s No. 7038
Steering adjusting screw Three Bond 1141 004403006 —
Camshaft cap Three Bond 1280B K0877YA018 —
• Front sealing cover 3M Butyl tape 8626 — —
• Rear sealing cover

RM-7
Downloaded from www.Manualslib.com manuals search engine
Recommended Materials
RECOMMENDED MATERIALS

RM-8
Downloaded from www.Manualslib.com manuals search engine
PRE-DELIVERY INSPECTION

PI
Page
1. Pre-delivery Inspection................................................................................2

Downloaded from www.Manualslib.com manuals search engine

Pre-delivery Inspection
PRE-DELIVERY INSPECTION

1. Pre-delivery Inspection
A: GENERAL DESCRIPTION
The purposes of the pre-delivery inspection (PDI) are as follows.
• Remove the additional parts used for ensuring the vehicle quality during transportation and restore the ve-
hicle to its normal 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 Check point
1. Appearance check (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.
2. Tire check (1) Check the tires for damage, abnormal conditions, and dents on the
wheels.
(2) Check the tire air pressure.
3. Fuse installation 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
4. Air conditioner harness connection harness.
5. Check the doors for lock/unlock and open/close (1) Using the key, check if the trunk lid can be locked or unlocked normally.
operations. (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.
6. Double lock operation check Check the double lock for normal operations.
7. Check the operation of child safety lock system Check that the child safety lock system operates normally.
8. Check the trunk lid for open/close operations. (1) Operate the trunk lock release lever to check that the trunk opens nor-
mally.
(2) Open and close the trunk lid to see that there are no abnormal conditions.
9. Check the rear gate for lock/unlock and open/ (1) Check if the rear gate can be unlocked normally through the emergency
close operations. hole.
(2) Open and close the rear gate to see that there are no abnormal condi-
tions.
10. Operation check of fuel lid opener lock release Operate the fuel lid opener to check that the fuel lid is unlocked normally.
lever
11. Accessory check Check that the following accessories are provided.
• Owner’s manual
• Warranty booklet
• Maintenance note
• Spare key
• Jack
• Tool set
• Spare tire
12. Operation check of front hood lock release Operate the front hood lock release lever to check that the front hood is
system unlocked normally.
13. Battery Check the battery terminals for any abnormal conditions such as rust and
trace of battery fluid leaks.
14. Brake fluid Check that the fluid level is normal.
15. Engine oil Check that the oil level is normal.
16. Transmission gear oil Check that the transmission gear oil level is normal.

PI-2
Downloaded from www.Manualslib.com manuals search engine
Pre-delivery Inspection
PRE-DELIVERY INSPECTION

PROCEDURE Check point

17. AT front differential oil Check that the AT front differential oil level is normal.
18. Engine coolant Check that the engine coolant level is normal.
19. Clutch fluid Check that the clutch fluid level is normal.
20. Window washer fluid Check that the window washer fluid level is normal.
21. Front hood latch check Check that the hood is closed and latched securely.
22. Keyless entry system Check that the keyless entry system operates normally.
23. Seat (1) Check the seat surfaces for stain or dirt.
(2) Check the seat installation conditions and functionality.
24. Seat belt Check the seat belt installation conditions and functionality.
25. Wheel alignment Check that the wheel alignments are properly adjusted.

CHECKS WITH ENGINE RUNNING

PROCEDURE Check point
26. Test mode connector Test mode connectors
27. Immobilizer system (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 imme-
diately after removing key, check that the security indicator light blinking.
28. Starting condition Start the engine and check that the engine starts smoothly.
29. Exhaust system Check that the exhaust noise is normal and no leaks are found.
30. Indicator and warning lights Check that all the indicator and warning lights are gone out.
31. Clock Check that the clock operates normally.
32. Audio Check the radio, CD and MD player for normal operation.
33. Front accessory power supply socket Check that the front accessory power socket operates normally.
34. Lighting system Check that the lighting system operates normally.
35. Window washer Check that the window washer system operates normally.
36. Wiper Check that the wiper system operates normally.
37. Power window operation check Check the power window for normal operations.
38. Sunroof Check that the sunroof operates normally.
39. Door mirror Check that the remote control mirror operates normally.

DYNAMIC TEST WITH VEHICLE RUNNING

PROCEDURE Check point
40. Brake test Check the foot brake for normal operations.
41. Parking brake Check the parking brake for normal operations.
42. AT shift control Check that the AT shift patterns are correct.
43. Heater & ventilation Check that the heater & ventilation system operates normally.
44. Air conditioner Check that the air conditioner operates normally.
45. Cruise control Check that the cruise control system operates normally.

CHECKS AFTER DYNAMIC TEST

PROCEDURE Check point
46. ATF level Check that the ATF level is correct.
47. Power steering fluid level Check that the power steering fluid level is normal.
48. Fluid leak check Check for fluid/oil leaks.
49. Water leak test Spray the vehicle with water and check for water leaks.
50. Appearance check 2 (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
Downloaded from www.Manualslib.com manuals search engine
Pre-delivery Inspection
PRE-DELIVERY INSPECTION

1. APPEARANCE CHECK 5. CHECK THE DOORS FOR LOCK/UN-

• If the vehicle is covered with protective coating, LOCK AND OPEN/CLOSE OPERATIONS
visually check the vehicle body for damage and 1) Using the key, lock and unlock the door several
dents. times to check for normal operation. Open and
• If there is no protective coating, check the body close the door several times for smooth movement.
paints for small areas of damage or stains and re-
pair 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
(A)
door knobs, for damage or loss of gloss and repair
or replace the parts as necessary. (B)

2. TIRE CHECK
• Check the tires for damage, abnormal condi- PI-00140
tions, and dents on the wheels.
• Check the tire size, spare tire and tire air pres- (A) Unlock
sure described on the tire air pressure label (driv- (B) Lock
er’s side).
2) Close the driver’s door completely, and place the
3. FUSE INSTALLATION door lock knob (A) to the lock position. Then pull in-
A vehicle just delivered has no fuse for the back-up ner remotes (B) to ensure that doors will not open.
circuit to prevent battery discharge. Attach a 15 A For other doors, place the door lock knob (A) to the
fuse (A) as shown in the figure. lock positions and then pull the inner remote to en-
sure that the doors will not open.

(A)

(B)
PI-00001
PI-00004
4. CONNECTION OF AIR CONDITIONER
HARNESS (A) Door lock knob
(B) Inner remote
A vehicle just delivered has its air conditioner har-
ness disconnected to protect the air conditioner 3) Press the driver’s side power door lock switch to
compressor. Connect the harness as shown in the lock side. Check that all doors including rear gate
figure. are locked.

PI-00139 PI-00142

PI-4
Downloaded from www.Manualslib.com manuals search engine
Pre-delivery Inspection
PRE-DELIVERY INSPECTION

4) Press the driver’s side power door lock switch to 4) Next, pull the outside door handles of the rear
unlock side. Check that all doors including rear doors to ensure that the doors will open.
gate are unlocked.

(C)
(A)

(B)

PI-00084
PI-00143
(A) Unlock
6. CHECK DOUBLE LOCK OPERATION (B) Lock
1) Fully open all the windows. (C) Child safety lock
2) Remove the key.
3) Lock all the doors using the door key cylinder or 8. CHECK THE TRUNK LID FOR OPEN/
transmitter. CLOSE OPERATIONS
4) Verify that all the doors including rear gate are 1) Operate the trunk lock release lever and verify
not unlocked when pressing power door lock switch that the trunk lid opens.
to unlock side. 2) Using the key, open the trunk lid several times to
5) Verify that the door is not opened when operat- check for normal operation.
ing door lock knob to unlock position and pulling in- 3) Open and close the trunk lid several times for
ner remote. Perform the same check for other smooth movement.
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 PI-00144

the unlock positions. Then, pull the inner remotes

of the rear doors to ensure that the doors will not 4) Set the trunk lid release lever to the cancel posi-
open. tion, and check that the trunk lid can only be
opened with the key.

PI-00149

PI-5
Downloaded from www.Manualslib.com manuals search engine
Pre-delivery Inspection
PRE-DELIVERY INSPECTION

9. CHECK THE REAR GATE FOR LOCK/ 11.ACCESSORY CHECK

UNLOCK AND OPEN/CLOSE OPERATIONS Check that the following accessories are provided
1) Open and close the rear gate several times for in the luggage compartment or cargo area.
smooth movement. • Owner’s manual
2) Operate the rear gate lever to check that the rear • Warranty booklet
gate is locked and unlocked normally. • Service booklet
(1) Remove the blind cover inside the rear gate. • Spare key
• Jack
• Tool set
• Spare tire
• Immobilizer cover (EK model)
• Immobilizer relay (EK model)

(A)

PI-00147

(2) Check that the rear gate is locked correctly

when lever is operated using a finger.

(B) PI-00145

(A)

PI-00148

10.OPERATION CHECK OF FUEL LID

OPENER LOCK RELEASE LEVER (B) PI-00146

Operate the fuel lid opener and verify that the fuel
lid opens normally. Check that the filler cap is se- (A) Jack
curely closed. (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-00071

PI-6
Downloaded from www.Manualslib.com manuals search engine
Pre-delivery Inspection
PRE-DELIVERY INSPECTION

Operate the lever (A) and check that the hood is 15.ENGINE OIL
opened normally. Then support the hood with hood
Check the engine oil amount. If the amount is insuf-
stay.
ficient, check that no leaks are found. Then, add
the necessary amount of the specified engine oil.

(A) (B)

(C)

(E)

(D)

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
(A)
PI-00151 Check the transmission fluid amount. If the amount
is insufficient, check that no leaks are found. Then,
13.BATTERY add the necessary amount of the specified fluid.
Check the battery terminals to make sure that no
rust or corrosions due to fluid leaks are found. (A)
Check that the battery caps are securely tightened.

(A)
(B)
(C)

(B) PM-00030

(A) Oil level gauge

(C)
PI-00012
(B) Upper level
(C) Lower level
(A) Cap
(B) Upper level
(C) Lower level

14.BRAKE FLUID
Check the brake fluid amount. If the amount is in-
sufficient, carry out a brake line test to identify
brake fluid leaks and check the brake operation. Af-
ter that, refill the brake fluid tank with the specified
type of fluid.

PI-7
Downloaded from www.Manualslib.com manuals search engine
Pre-delivery Inspection
PRE-DELIVERY INSPECTION

17.AT FRONT DIFFERENTIAL OIL 21.HOOD LATCH CHECK

Check the AT front differential oil amount. If the Retract the hood stay and close the hood. Check
amount is insufficient, check that no leaks are that the hood is securely latched.
found. Then, add the necessary amount of the
specified AT front differential oil. 22.KEYLESS ENTRY SYSTEM
Check the keyless entry system operations as fol-
(A) lows.
• Remove the key from the ignition switch and
(B) (A) close all the doors including rear gate (wagon mod-
(C) el).
• Press the “LOCK” button on the transmitter mo-
mentarily 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
PI-00108
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 in-
sufficient, check that no leaks are found. Then, add
the necessary amount of the specified fluid.

(A ) PI-00109

(C)
• Press the “OPEN” button on the transmitter mo-
mentarily once and check that all doors are un-
(B ) locked, the hazard light flashes twice and the
interior light illuminates.
• Close all doors and rear gate, press the “LOCK”
PM-00076
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
(A) Reservoir tank
locked again.
(B) MIN level
(C) MAX level 23.SEAT
Check that each seat provides full functionality in
20.WINDOW WASHER FLUID sliding and reclining. Check all available functions
Check the window washer fluid amount. If the of the rear seat such as a trunk-through center arm
amount is insufficient, check that no leaks are rest.
found. Then, add the necessary amount of washer
fluid commercially available. 24.SEAT BELT
Pull out the seat belt and then release it. Check that
the belt webbing retracts smoothly.

PI-8
Downloaded from www.Manualslib.com manuals search engine
Pre-delivery Inspection
PRE-DELIVERY INSPECTION

25.WHEEL ALIGNMENT 28.STARTING CONDITION

Check the wheel alignments. <Ref. to FS-6, Wheel Start the engine and check that the engine starts
Alignment.> and <Ref. to RS-10, Wheel Align- smoothly. If any battery voltage problems are
ment.> found, recharge or replace the battery. If any ab-
normal noises are observed, immediately stop the
26.TEST MODE CONNECTOR engine and check and repair the necessary compo-
Turn the ignition switch to ON and check that the nents.
malfunction indicator light starts blinking. If the light
blinks, return the ignition key to LOCK and discon- 29.EXHAUST SYSTEM
nect the test mode connector. Then, turn the igni- Listen to the exhaust noise to see if no abnormal
tion key to ON again. If the malfunction indicator noises are observed.
light blinks at that time in spite of the disconnected
test mode connector, carry out an engine diagno- 30.INDICATOR LIGHT
sis. Check that all the indicator lights are off.
• With OBD MODEL
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
(A) check the CD, MD unit operations.
33.FRONT ACCESSORY POWER SUPPLY
PI-00119 SOCKET
Check the front accessory power supply socket op-
(A) Test mode connector (Green) erations.
• Without OBD MODEL 34.LIGHTING SYSTEM
• Check the headlight operations.
• Check the stop light operations.
• Check the other lights for normal operations.
(B) 35.WINDOW WASHER
Check that the window washer system injects
washer fluid to the specified area of windshield
(A) shown in the figure.
Front injection position:
PI-00120 A: 350 mm (13.78 in)
B: 162 mm (5.91 in)
(A) Read memory connector (Black) C: 300 mm (11.81 in)
(B) Test mode connector (Green) D: 500 mm (23.62 in)

27.IMMOBILIZER SYSTEM
A A
1) Check that the engine starts with all keys that B B
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 blink-
ing.
NOTE: C D
If malfunctions occur, refer to “IMMOBILIZER (DI- PI-00121
AGNOSIS)”.

PI-9
Downloaded from www.Manualslib.com manuals search engine
Pre-delivery Inspection
PRE-DELIVERY INSPECTION

Rear injection position: 42.AT SHIFT CONTROL

A: 39 mm (2.36 in)
Set the AT select lever to each gear position and
B: 72° check the shifting while driving the vehicle.

P
A
R
N
D
B 3
2
1
PI-00104 (1) (2) PI-00112

36.WIPER (1) RHD model

Check the front and rear wipers for normal opera- (2) LHD model
tions.
37.POWER WINDOW OPERATION CHECK
Manipulate the power window switches one by one
to check that each of the power windows goes up P
and down with no abnormal noises.
R
N
38.SUNROOF D
3
Check that the sunroof operates normally. 2
1
39.DOOR MIRROR
AT-00761
Check that the remote control mirror operates nor-
mally.
Selector Gear Position
40.BRAKE TEST Position 1st 2nd 3rd 4th
Check the foot brake for normal operations. D Yes Yes Yes Yes
3 Yes Yes Yes —
41.PARKING BRAKE 2 Yes Yes — —
Check the parking brake for normal operations. 1 Yes — — —
When applying the parking brake with force of 196 Sports
Yes Yes Yes Yes
N (20 kgf, 44 lb), check that the lever stroke of park- shift
ing brake lever is 7 to 8 notches.
43.HEATER & VENTILATION
Operate the heater and ventilation system to check
for normal outlet selection, air inlet selection, air-
flow 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
Downloaded from www.Manualslib.com manuals search engine
Pre-delivery Inspection
PRE-DELIVERY INSPECTION

46.ATF LEVEL 49.WATER LEAK TEST

Check that the ATF level is normal when the engine Spray the vehicle with water and check that no wa-
at idle. If insufficient, check that no leaks are found. ter enters the passenger compartment.
Then add the necessary amount of the specified • Before performing the water leakage test, re-
ATF. move anything that may obstruct the operation or
which must be kept dry.
(A) • 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

F
(C) vehicle. The rate of water discharge must be ap-

HOT
(B)

L
(D) prox. 20 — 25 2 (5.3 — 6.6 US gal, 4.4 — 5.5 Imp
gal) per minute.
F
(C)
(E) COLD
When spraying water on areas adjacent to the floor
L (D)
and wheel house, increase the pressure. When di-
PM-00191 recting water on areas other than the floor portion
and wheel house, decrease the pressure. But the
(A) Level gauge force of water must be made strong occasionally by
(B) ATF level range when “HOT” [70 — 80°C (158 pressing the end of the hose.
— 176°F)]
NOTE:
(C) Upper level
Be sure to keep the hose at least 10 cm (3.9 in)
(D) Lower level from the vehicle.
(E) ATF level range when “COLD” [20 — 30°C (68
Check the following areas:
— 86°F)]
• Front window and body framework mating por-
47.POWER STEERING FLUID LEVEL tion
• Door mating portions
Check that the power steering fluid level is normal. • Glass mating portions
If insufficient, check that no leaks are found. Then • Rear quarter window mating portions
add the necessary amount of the specified power • Rear window and body framework mating portion
steering fluid. • 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 protec-
tive coating and washing the vehicle.
NOTE:
PM-00070 • Use of steam eases peeling off the warp guard.
• When performing on the vehicles left for a long
(A) Reservoir tank time, or during low temperature period, sprinkle
(B) MIN level some water heated to 50 — 60°C (122 — 140°F)
(C) MAX level
over the vehicle to raise its surface temperature be-
fore peeling off the wrap guard.
48.FLUID LEAK CHECK Do not use the water heated to over 60°C (140°F).
• If the adhesive remains on the coated surface,
Check the entire areas of the vehicle for any trace rub the portion with a flannel rag, etc. soaked with a
of coolant/oil/fluid leaks. coat of coating wax or a solvent, such as oil ben-
zene 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
Downloaded from www.Manualslib.com manuals search engine
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 in-
dustrial 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 in-
spection 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 scratch-
es. 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 un-
derside 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
Downloaded from www.Manualslib.com manuals search engine
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

Downloaded from www.Manualslib.com manuals search engine

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
Downloaded from www.Manualslib.com manuals search engine
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.
Maintenance interval
[Number of months or km (miles), whichever occurs first]
Month 12 24 36 48 60 72 84 96 Remarks
× 1,000 km 1.6 5 15 30 45 60 75 90 105 120
× 1,000 miles 1 3 9 19 28 38 47 56 66 75
1 Engine oil R R R R R R R R
2 Engine oil filter R R R R R R R R
3 Spark plug For Turbo R
Others R R R R
4 Drive belt(s) I I I I I I I I
5 Camshaft drive belt R
6 Fuel line I I I I
7 Fuel filter R R
8 Air cleaner element I R I R I R I R
9 Cooling system I I I I
10 Coolant R R R R
11 Clutch system Adjust the clutch
pedal free play
I I I I
every 1,600 km
(1,000 miles)
12 Hill-holder system I I I I
13 Transmission oil I R I R
14 ATF I R I R
15 Front & rear differential I R I R
16 Brake line I I I I
17 Brake fluid R R R R
18 Disk brake pads & discs I I I I I I I I
19 Brake linings & drums I I I I
20 Parking brake I I I I
21 Suspension I I I I
22 Wheel bearing (I)
23 Axle boot & joint I I I I I I I I
24 Steering system I I I I
25 Clutch cable 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
Downloaded from www.Manualslib.com manuals search engine
Schedule
PERIODIC MAINTENANCE SERVICES

2. EXCEPT FOR EUROPE AREA

For periodic maintenance of over 50,000 km (30,000 miles) or 48 months, carry out inspections by referring
to the following tables. For a maintenance period gone beyond these tables, apply them repeatedly as a set
of 50,000 km (30,000 miles) or 48 months.
Maintenance Interval
[Number of months or km (miles), whichever occurs first]
Months 12 24 36 48 Remarks
× 1,000 km 5 12.5 25 37.5 50
× 1,000 miles 3 7.5 15 22.5 30
1 Engine oil R R R R
2 Engine oil filter 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.
Maintenance Interval
[Number of months or km (miles), whichever occurs first]
Months 12 24 36 48 Remarks
× 1,000 km 1.6 25 50 75 100
× 1,000 miles 1 15 30 45 60
3 Spark plugs For Turbo R
Others R R R R
4 Drive belt(s) I I I I
5 Camshaft drive belt R
6 Fuel line I I
7 Fuel filter R R
8 Air cleaner element I R I R
9 Cooling system I I
10 Coolant R R
11 Idle mixture For models without catalyst con-
I I I I I
verter
12 Clutch system Adjust the clutch pedal free play
I I I I
every 1,600 km (1,000 miles)
13 Hill-holder system I I I I
14 Transmission oil R R
15 ATF R R
16 Front & rear differential oil R R
17 Brake line I I
18 Brake fluid R R
19 Disc brake pads & discs I I I I
20 Brake linings and drums I I
21 Parking brake I I I I
22 Suspension I I I I
23 Wheel bearing (I)
24 Axle boots & joints I I I I
25 Steering system (Power steering) I I I I
26 Clutch cable R

Symbols used:
R: Replace
I: Inspection
(R) or (I): Recommended service for safe vehicle operation.

PM-4
Downloaded from www.Manualslib.com manuals search engine
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
Salt or other
Repeat Extremely High humid-
Repeat short corrosive Repeat tow-
Item Every rough/muddy cold weather ity or moun-
distance drive used or ing trailer
road drive area tain area
coastal area
Engine oil Replace Replace Replace
more fre- more fre- more fre-
quently quently quently
Engine oil filter Replace Replace Replace
more fre- more fre- more fre-
quently quently quently
Fuel line 12 months
15,000 km I
9,000 miles
Transmission oil Replace
more fre-
quently
ATF Replace
more fre-
quently
Front & rear dif- Replace
ferential oil more fre-
quently
Brake line 12 months
15,000 km I
9,000 miles
Brake fluid 12 months
15,000 km R
9,000 miles
Brake pads 12 months
15,000 km I I I I
9,000 miles
Brake linings 12 months
and drums 15,000 km I I I I
9,000 miles
Parking brake 12 months
15,000 km I I I I
9,000 miles
Suspension 12 months
15,000 km I I I
9,000 miles
Axle boots & 12 months
joints 15,000 km I I I I
9,000 miles
Steering system 12 months
(Power steering) 15,000 km I I I
9,000 miles

PM-5
Downloaded from www.Manualslib.com manuals search engine
Schedule
PERIODIC MAINTENANCE SERVICES

2. EXCEPT FOR EUROPE AREA

Salt or other
Repeat Extremely High humid-
Repeat short corrosive Repeat tow-
Item Every rough/muddy cold weather ity or moun-
distance drive used or ing trailer
road drive area tain area
coastal area
Engine oil Replace Replace Replace
more fre- more fre- more fre-
quently quently quently
Engine oil filter Replace Replace Replace
more fre- more fre- more fre-
quently quently quently
Fuel line 6 months
12,500 km I
7,500 miles
Transmission oil Replace
more fre-
quently
ATF Replace
more fre-
quently
Front & rear dif- Replace
ferential oil more fre-
quently
Brake line 6 months
12,500 km I
7,500 miles
Brake fluid 12 months
25,000 km R
15,000 miles
Brake pads 6 months
12,500 km I I I I
7,500 miles
Brake linings 6 months
and drums 12,500 km I I I I
7,500 miles
Parking brake 6 months
12,500 km I I I I
7,500 miles
Suspension 6 months
12,500 km I I I
7,500 miles
Axle boots & 6 months
joints 12,500 km I I I I
7,500 miles
Steering system 6 months
(Power steering) 12,500 km I I I
7,500 miles

PM-6
Downloaded from www.Manualslib.com manuals search engine
Engine Oil
PERIODIC MAINTENANCE SERVICES

3. Engine Oil • SOHC MODEL

A: REPLACEMENT
1) Open the engine oil filler cap for quick draining of
the engine oil.

(A) (B)

LU-00193

4) Replace the drain plug gasket.

5) Tighten the engine oil drain plug after draining
PM-00155
engine oil.
Tightening torque:
(A) Oil level gauge 44 N·m (4.5 kgf-m, 33 ft-lb)
(B) Oil filler cap • DOHC TURBO MODEL
2) Remove the dip of service hole cover. (Turbo
model)

LU-00186

• SOHC MODEL
LU-00185

3) Drain the engine oil by loosening engine oil drain

plug.
• DOHC TURBO MODEL

LU-00193

LU-00186

PM-7
Downloaded from www.Manualslib.com manuals search engine
Engine Oil
PERIODIC MAINTENANCE SERVICES

6) Fill engine oil through the filler pipe up to center NOTE:

between upper level and lower level. Make sure • When replenishing oil, it does not matter if the oil
that the vehicle is placed level when checking oil to be added is a different brand from that in the en-
level. Use engine oil of proper quality and viscosity, gine; however, use oil having the API classification
selected in accordance with the table in figure. and SAE viscosity No. designated by SUBARU.
Recommended oil • If vehicle is used in desert areas with very high
API classification temperatures or for other heavy duty applications,
SL or SJ with the words “Energy Conserv- the following viscosity oils may be used:
ing or Energy conserving II”, CCMC speci- API classification: SL or SJ.
fication G4 or G5, ACEA specification A1, SAE Viscosity No.: 30, 40, 10W-50, 20W-40, 20W-
A2 or A3, or New API mark displayed on 50
the container (If it is impossible to get SL 7) Close the engine oil filler cap.
or SJ grade, you may use SG or SH grade.) 8) Start the engine and warm it up for a time.
9) After the engine stops, recheck the oil level.
Engine oil capacity
<Ref. to PM-8, INSPECTION, Engine Oil.>
Upper level:
Approx. 4.0 2 (4.2 US qt, 3.5 Imp qt) B: INSPECTION
Lower level: 1) Park the vehicle on a level surface.
Approx. 3.0 2 (3.2 US qt, 2.6 Imp qt) 2) Remove the oil level gauge and wipe it clean.
• SOHC MODEL 3) Reinsert the level gauge all the way. Be sure that
the level gauge is correctly inserted and in the
proper orientation.
SAE (1)
4) Remove it again and note the reading. If the en-
( C) -30 -20 -15 0 15 30 40
gine oil level is below the “L” line, add oil to bring
( F) -22 -4 5 32 59 86 104 the level up to the “F” line.

10W-30,10W-40 (A) (B)

5W-30,0W-20 (2)

(C)
LU-00071
(E)

(1) Viscosity No. and applicable temperature (D)

(2) Preferred

• EXCEPT FOR SOHC MODEL LU-00138

(A) Oil level gauge

SAE (1) (B) Oil filler cap
( C) -30 -20 -15 0 15 30 40 (C) Upper level
( F) -22 -4 5 32 59 86 104 (D) Lower level
10W-30,10W-40 (E) Approx. 1 2 (1.1 Us qt, 0.9 lmp qt)
5W-30 (2) 5) After turning off the engine, wait a few minutes
for the oil to drain back into oil pan before checking
the level.
LU-00076 6) Just after driving or while the engine is warm, en-
gine oil level may show in the range between the
(1) Viscosity No. and applicable temperature “F” line and the notch mark. This is caused by ther-
(2) Preferred mal expansion of the engine oil.
7) To prevent overfilling the engine oil, do not add
The proper viscosity helps vehicle get good cold oil above the “F” line when the engine is cold.
and hot starting by reducing viscous friction and
thus increasing cranking speed.

PM-8
Downloaded from www.Manualslib.com manuals search engine
Engine Oil Filter
PERIODIC MAINTENANCE SERVICES

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

LU-00194

• DOHC TURBO MODEL

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, IN-
SPECTION, Engine Oil.>

PM-9
Downloaded from www.Manualslib.com manuals search engine
Spark Plugs
PERIODIC MAINTENANCE SERVICES

5. Spark Plugs 5) Remove the ignition coil.

A: REPLACEMENT
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) PM-00112
CHAMPION: RC8YC4
NGK: BKR6E-11 (Alternate) 7) Set new spark plugs.
1.6 L SOHC model (without catalytic convert- Recommended spark plug:
er) 2.0 L DOHC Turbo model
NGK: BKR6E NGK: PFR6G
2.0 and 2.5 L SOHC model (with catalytic con-
8) Tighten the spark plug lightly with hand, and
verter)
then secure with a plug-wrench to the specified
CHAMPION: RC10YC4 torque.
NGK: BKR5E-11 (Alternate)
2.0 SOHC model (without catalytic converter) Tightening torque:
NGK: BKR6E 21 N·m (2.1 kgf-m, 15.2 ft-lb)
6) Tighten the spark plug lightly with hand, and 9) Tighten the ignition coil.
then secure with a plug-wrench to the specified Tightening torque:
torque. 16 N·m (1.6 kgf-m, 11.7 ft-lb)
Tightening torque: NOTE:
21 N·m (2.1 kgf-m, 15.2 ft-lb) • Be sure to place the gasket between the cylinder
NOTE: head and spark plug.
• Be sure to place the gasket between the cylinder • If a torque wrench is not available, tighten the
head and spark plug. spark plug until gasket contacts cylinder head: then
• If a torque wrench is not available, tighten the tighten further 1/4 to 1/2 turns.
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-10
Downloaded from www.Manualslib.com manuals search engine
V-belt
PERIODIC MAINTENANCE SERVICES

6. V-belt Belt tension (with belt tension gauge)

(A)
A: INSPECTION When installing new one: 640 — 785 N
1) Replace the belts, if cracks, fraying or wear is (65.3 — 80.0 kgf, 144 — 176 lb)
found. At inspection: 490 — 640 N (50 — 65 kgf,
2) Check the V-belt tension and adjust it if neces- 110 — 144 lb)
sary by changing the generator installing position (B)
and/or idler pulley installing position. <Ref. to PM- When installing new one: 620 — 760 N (63
11, REPLACEMENT, V-belt.> — 77 kgf, 140 — 170 lb)
Belt tension (without belt tension gauge) At inspection: 350 — 450 N (36 — 46 kgf, 79
(A) — 101 lb)
When installing new one: 7 — 9 mm (0.276 (A)
— 0.354 in)
At inspection: 9 — 11 mm (0.354 — 0.433 P/S GEN A/C
in) (B)
(B)
When installing new one: 7.5 — 8.5 mm
(0.295 — 0.335 in)
At inspection: 9.0 — 10.0 mm (0.354 — I/P
0.394 in) C/P
PM-00154
98 N (10kg)

P/S GEN A/C (A) Front side belt

(A) (B)
(B) Rear side belt
C/P Crank pulley
GEN Generator
P/S Power steering oil pump pulley
I/P
A/C A/C compressor pulley
C/P
I/P Idler pulley
PM-00002
B: REPLACEMENT
(A) Front side belt
1. FRONT SIDE BELT (DRIVING POWER
(B) Rear side belt
STEERING OIL PUMP AND GENERATOR)
C/P Crankshaft pulley
GEN Generator NOTE:
P/S Power steering oil pump pulley Wipe off any oil or water on the belt and pulley.
A/C Air conditioning compressor pulley 1) Remove the V-belt cover.
I/P Idler pulley NON-TURBO MODEL

PM-00003

PM-11
Downloaded from www.Manualslib.com manuals search engine
V-belt
PERIODIC MAINTENANCE SERVICES

TURBO MODEL Tightening torque:

23 N·m (2.3 kgf-m, 17.0 ft-lb)

(B)

(A)

SC-00096
PM-00005
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)

(B)
(C)

(A) PM-00004

2. REAR SIDE BELT (DRIVING AIR CONDI-

TIONER)
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, IN-
STALLATION, V-belt.>
DOHC Turbo model
<Ref. to ME(H4DOTC)-54, FRONT SIDE BELT,
INSTALLATION, V-belt.>

PM-12
Downloaded from www.Manualslib.com manuals search engine
Timing Belt
PERIODIC MAINTENANCE SERVICES

7. Timing Belt 10) Remove the timing belt guide. (MT model)

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 card-
board and blanket.
3) Remove the V-belt cover. PM-00008

11) Turn the crankshaft and align alignment marks

on crankshaft, and right and left camshaft sprock-
ets 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, V- (B)

belt.>
5) Remove the air conditioning compressor drive
belt tensioner.
6) To lock the crankshaft, use ST. Remove the pul-
ley bolt.
2.5 L model:
ST 499977100 CRANKSHAFT PULLEY (A)
WRENCH (B)
Except for 2.5 L model:
ST 499977400 CRANKSHAFT PULLEY
WRENCH

ST
PM-00009

(A) Notch
(B) Alignment mark

12) Remove the belt idler.

13) Remove the belt idler (No. 2).

PM-00007

7) Remove the crankshaft pulley.

8) Remove the left side belt cover.
9) Remove the front timing belt cover.

PM-00010

14) Remove the timing belt.

PM-13
Downloaded from www.Manualslib.com manuals search engine
Timing Belt
PERIODIC MAINTENANCE SERVICES

15) Remove the automatic belt tension adjuster as- 11) Remove the timing belt guide. (MT model)
sembly.

PM-00008
PM-00011

16) Install in the reverse order of removal. <Ref. to

ME(H4SO)-49, INSTALLATION, Timing Belt As-
sembly.>
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. ME-00727
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 ME-00728
WRENCH

ST ME-00729
PM-00093

6) Remove the crankshaft pulley. 12) Turn the crankshaft and align alignment marks
7) Remove the air conditioning compressor drive on crankshaft, and right and left camshaft sprock-
belt tensioner. ets with notches of belt cover and cylinder block. To
8) Remove the belt cover (LH). turn the crankshaft, use ST.
9) Remove the belt cover (RH).
10) Remove the front belt cover.

PM-14
Downloaded from www.Manualslib.com manuals search engine
Timing Belt
PERIODIC MAINTENANCE SERVICES

ST 499987500 CRANKSHAFT SOCKET CAUTION:

When installing the timing belt, be sure to align
(A)
all alignment marks on the belt with corre-
sponding marks on the sprockets. If incorrectly
(B)
installed, interference between pistons and
(B)
valves may occur.
B: INSPECTION
(B) (B)

(A) (A) 1. SOHC MODEL

(B) (B) 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
(B) 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.

PM-00156
W
(A) Notch
(B) Alignment mark

13) Remove the belt idler.

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
PM-00095 damage. Replace the faulty timing belt as needed.
14) Remove the timing belt. 3) Measure the timing belt width W. If it is less than
30 mm (1.18 in), check idlers, tensioner, water
15) Remove the automatic belt tension adjuster as-
pump pulley and cam sprocket to determine idler
sembly.
alignment (squareness). Replace the worn timing
belt.
4) Install the timing belt cover (LH).

PM-00096

16) Install in the reverse order of removal. <Ref. to

ME(H4DOTC)-58, Timing Belt Assembly.> PM-00097

PM-15
Downloaded from www.Manualslib.com manuals search engine
Fuel Line
PERIODIC MAINTENANCE SERVICES

8. Fuel Line
A: INSPECTION
The fuel line is located mostly internally, so check
pipes, areas near pipes, and engine compartment
piping for rust, hose damage, loose 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
Downloaded from www.Manualslib.com manuals search engine
Fuel Filter
PERIODIC MAINTENANCE SERVICES

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.

PM-17
Downloaded from www.Manualslib.com manuals search engine
Air Cleaner Element
PERIODIC MAINTENANCE SERVICES

10.Air Cleaner Element 2) Remove the air cleaner.

A: REPLACEMENT
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.

(A) (B) PM-00098

(B)
(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 se-
cure upper cover to case.

IN-00039

4) Remove the air cleaner.

PM-00100

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-00099

PM-18
Downloaded from www.Manualslib.com manuals search engine
Cooling System
PERIODIC MAINTENANCE SERVICES

11.Cooling System NOTE:

Rust or dirt on the cap may prevent the valve from
A: INSPECTION functioning normally: be sure to clean the cap be-
1) Check the radiator for leakage, filling it with cool- fore testing.
ant and attach the radiator cap tester (A) to filler Raise the pressure until the needle of gauge stops
neck. Then apply a pressure. and see if the pressure can be retained for 5 to 6
Check the following points: seconds. The radiator cap is normal if a pressure
Non-turbo model above the service limit value has been maintained
157 kPa (1.6 kg/cm2, 23 psi) for this period.
Turbo model Radiator cap valve open pressure
122 kPa (1.2 kg/cm2, 18 psi) Non-turbo model
• Each portion of radiator for leakage Standard value:
• Hose joints and other connections for leakage 93 — 123 kPa (0.95 — 1.25 kg/cm2, 14 — 18
NOTE: psi)
• For turbo model, be sure to install the tester to fill- Service limit:
er tank side. 83 kPa (0.85 kg/cm2, 12 psi)
• When attaching or detaching tester and when Turbo model
operating tester, use special care not to deform ra- Filler tank side:
diator filler neck. Standard value:
NON-TURBO MODEL 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-00128

TURBO MODEL

(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.
(A)
• Use care not to spill coolant when detaching the
tester from radiator.
• Do not remove the radiator side cap. (Turbo
model) (A)
(B)
PM-00089
2) Check the radiator cap valve open pressure us-
ing radiator cap tester.
(A) Deformation
(B) Deformation, damage, rust

PM-19
Downloaded from www.Manualslib.com manuals search engine
Cooling System
PERIODIC MAINTENANCE SERVICES

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 sys-
tem.
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 ex-
ceeds 95°C (203°F). If not operate, check the elec-
tric fan system.
SOHC model
<Ref. to CO(H4SO)-6, Radiator Main Fan Sys-
tem.>
<Ref. to CO(H4SO)-9, Radiator Sub Fan System.>
DOHC Turbo model
<Ref. to CO(H4DOTC)-8, Radiator Main Fan Sys-
tem.>
<Ref. to CO(H4DOTC)-13, Radiator Sub Fan Sys-
tem.>

PM-20
Downloaded from www.Manualslib.com manuals search engine
Coolant
PERIODIC MAINTENANCE SERVICES

12.Coolant NOTE:
The SUBARU Genuine Coolant containing anti-
A: REPLACEMENT freeze and anti-rust agents is especially made for
1. REPLACEMENT OF COOLANT SUBARU engine, which has an aluminum crank-
case. Always use SUBARU Genuine Coolant,
WARNING: since other coolant may cause corrosion.
The radiator is of the pressurized type. Do not 10) Securely install the radiator cap.
attempt to open the radiator cap immediately 11) Run the engine for more than 5 minutes at
after the engine has been stopped. 2,000 to 3,000 rpm. (Run the engine until radiator
1) Lift-up the vehicle. becomes hot in order to purge the air trapped in
2) Remove the under cover. cooling system.)
3) Place a container under drain pipe. 12) Stop the engine and wait until coolant temper-
4) Loosen and remove the drain cock to drain en- ature lowers. Then open the radiator cap to check
gine coolant into container. 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 radia-
tor 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
Downloaded from www.Manualslib.com manuals search engine
Coolant
PERIODIC MAINTENANCE SERVICES

2. RELATIONSHIP OF SUBARU COOLANT 3. PROCEDURE TO ADJUST THE CON-

CONCENTRATION AND FREEZING TEM- CENTRATION OF THE COOLANT
PERATURE To adjust the concentration of the coolant accord-
The concentration and safe operating temperature ing to temperature, find the proper fluid concentra-
of the SUBARU coolant is shown in the diagram. tion in the above diagram and replace the
Measuring the temperature and specific gravity of necessary amount of coolant with an undiluted so-
the coolant will provide this information. lution of SUBARU genuine coolant (concentration
[Example] 50%).
If the coolant temperature is 25°C (77°F) and its The amount of coolant that should be replaced can
specific gravity is 1.054, the concentration is 35% be determined using the diagram.
(point A), the safe operating temperature is −14°C [Example]
(7°F) (point B), and the freezing temperature is Assume that the coolant concentration must be in-
−20°C (−4°F) (point C). creased from 25% to 40%. Find point A, where the
25% line of coolant concentration intersects with
(2)
the 40% curve of the necessary coolant concentra-
tion, and read the scale on the vertical axis of the
(3) 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
1.100
(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
1.090 undiluted solution of SUBARU coolant.
1.080 If a coolant concentration of 50% is needed, drain
60% all the coolant and refill with the undiluted solution
1.070 B
C only.
1.060 50%
(1.054)
(1) A
1.050
40%
1.040
(4)
1.030 30%

1.020
20%
(77 F)

1.010
25 C

(US qt, Imp qt) (2)

10%
1.000 3
-40 -30 -20 -10 0 10 20 30 40 50
(3.2,2.6)
(-40) (-22) (-4) (14) (32) (50) (68) (86) (104) (122) 45%
(5) C ( F) PM-00025 A
2 40%
35%
(1) (2.1,1.8)
30%
(1) Coolant gravity 25%
1
20%
(2) Safe operating temperature (1.1,0.9)
15%
(3) Concentration of coolant 10%
0
(4) Freezing temperature 10 20 30 40 50
(3)
(5) Coolant temperature %

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
Downloaded from www.Manualslib.com manuals search engine
Idle Mixture
PERIODIC MAINTENANCE SERVICES

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 CO
700±100 rpm 1.0±0.5%

4) If out of specification, adjust the idle mixture us-

ing 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

(A)

PM-00146

NOTE:
If driving the vehicle on out of specified data, the
“DTC 49” is indicated in many case.

PM-23
Downloaded from www.Manualslib.com manuals search engine
Clutch System
PERIODIC MAINTENANCE SERVICES

14.Clutch System Standard:

80 mm (3.15 in) or more
A: INSPECTION AND ADJUSTMENT 3) Pedal height
1. MECHANICAL CLUTCH TYPE Check that the clutch pedal pad surface is level
with or higher than brake pedal pad surface.
1) Inspect the free play of clutch pedal by operating
pedal by hand. 2. HYDRAULIC CLUTCH TYPE
If it is out of the specified value, adjust it by turning 1) Push the release lever to retract the push rod of
wing nut on engine side of clutch cable at release the operating cylinder and check if the fluid level in
fork. the clutch reservoir tank rises or not.
Tightening torque NON-TURBO MODEL
(Adjusting nut on release fork):
(A)
4.4 — 7.4 N·m
(0.45 — 0.75 kgf-m, 3.3 — 5.4 ft-lb) (B)

Standard free play A:

10 — 20 mm (0.39 — 0.79 in)

(C)
PM-00075

(A) Release lever

(B) Push rod
(C) Operating cylinder
A
PM-00151 TURBO MODEL
Fork lever free play allowance A:
(A) (C)
2 — 4 mm (0.08 — 0.16 in)
(1)
A

(B)
PM-00101

(A) Release lever

PM-00152
(B) Push rod
(C) Operating cylinder
(1) Full stroke: 25.5 mm (1 in)
2) If the fluid level rises, pedal free play is correct.
2) Pedal-to-floor plate gap in disengaged position.
3) If the fluid level does not rise, or the push rod
(1) With the engine idling, pull the parking brake
cannot be retracted, adjust the clutch pedal. <Ref.
lever completely.
to CL-40, Clutch Pedal.>
(2) Slowly depress the clutch pedal while mov- 4) Check the fluid level using the scale on the out-
ing shift lever into reverse. side of the clutch master cylinder tank (A). If the lev-
(3) Stop depressing the clutch pedal when el is below “MIN” (B), inspect the clutch master
gearshifting is complete. With the clutch pedal in cylinder, operating cylinder and hydraulic line for
this position, measure the distance between the fluid leaks. If fluid leaks are found, repair or replace.
upper side of pedal pad and the lower end of If fluid leaks are not found, add clutch fluid to bring
front panel (intersection of front panel with floor). it up to “MAX” (C) of clutch reservoir tank.
Check that the measured value is within the
specification.

PM-24
Downloaded from www.Manualslib.com manuals search engine
Clutch System
PERIODIC MAINTENANCE SERVICES

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.

(A )

(C)

(B )

PM-00076

(A) Reservoir tank

(B) MIN level
(C) MAX level

PM-25
Downloaded from www.Manualslib.com manuals search engine
Transmission Gear Oil
PERIODIC MAINTENANCE SERVICES

15.Transmission Gear Oil Gear oil capacity:

FWD model
A: REPLACEMENT 3.3 L (3.5 US qt, 2.5 Imp qt)
AWD model (5MT single range model):
1. MANUAL TRANSMISSION
3.5 L (3.7 US qt, 3.1 Imp qt)
1) Drain the gear oil by removing drain plug. AWD model (5MT dual range model):
NOTE: 4.0 L (4.2 US qt, 3.5 Imp qt)
• Before starting work, cool off the transmission 6MT:
gear oil well. 4.1 L (4.3 US qt, 3.6 Imp qt)
• If transmission gear oil adheres to the exhaust
pipe, wipe it off completely.
(A)
5MT

(B)
(C)

PM-00030

(A) Oil level gauge

PM-00029 (B) Upper level
(C) Lower level
6MT

(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 tight-

en 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 addi-
tives. Thus, do not mix two or more brands.

PM-26
Downloaded from www.Manualslib.com manuals search engine
Hill-holder System
PERIODIC MAINTENANCE SERVICES

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 en-
gagement of clutch (engine tends to stall): Loos-
en the adjusting nut gradually until smooth
starting is enabled.
B; When the hill-holder is released earlier than
engagement to clutch (vehicle slips down slight-
ly): 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 in-
ner 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)

(C) PM-00077

(A) Lock nut

(B) Adjusting nut
(C) Pressure hold valve

PM-27
Downloaded from www.Manualslib.com manuals search engine
ATF
PERIODIC MAINTENANCE SERVICES

17.ATF B: REPLACEMENT
A: INSPECTION 1. AUTOMATIC TRANSMISSION FLUID
CAUTION: 1) Drain the ATF (Automatic Transmission Fluid)
The level of ATF varies with fluid temperature. by removing drain plug.
Pay attention to the fluid temperature when NOTE:
checking ATF level. • Before starting work, cool off the ATF well.
1) Raise the ATF temperature by driving a distance • Check the condition of ATF drained. <Ref. to
of 5 to 10 km (3 to 6 miles). Otherwise, idle the en- 4AT-32, CONDITION CHECK, Automatic Trans-
gine to raise ATF temperature to 70 — 80°C (158 mission Fluid.>
— 176°F) on Subaru Select Monitor. <Ref. to
4AT(diag)-21, READ CURRENT DATA, OPERA-
TION, Subaru Select Monitor.> (B) (A)
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.

(A)

AT-02389
F

(C)
HOT

(B) (A) Oil pan

L

(D)
(B) ATF drain plug
F

(C) 2) Replace the gasket with a new one, and then

COLD

(E)
L

(D) tighten the specified torque.

PM-00191
Tightening torque:
25 N·m (2.55 kgf-m, 18.4 ft-lb)
(A) Level gauge
(B) ATF level range at “HOT” [70 — 80°C (158 — 3) Fill ATF up to the middle of the “COLD” side on
176°F)] level gauge by using the gauge hole.
(C) Upper level Recommended fluid:
(D) Lower level Dexron III type automatic transmission fluid
(E) ATF level range at “COLD” [20 — 30°C (68 —
86°F)]
Fluid capacity:
Fill the same amount drained from ATF drain
4) Make sure that ATF level is the center of upper plug hole.
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 nec-
essary to repair or replace gasket, oil seals, plugs
or other parts.
5) If the ATF level is below the center between up-
per and lower level, add the recommended ATF un-
til 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.

PM-28
Downloaded from www.Manualslib.com manuals search engine
ATF
PERIODIC MAINTENANCE SERVICES

4) Check the ATF level. <Ref. to PM-28, INSPEC-

TION, 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 dam-
aged or ATF leaked.
For the replacement procedures of the ATF filter:
<Ref. to 4AT-73, ATF Filter.>

PM-29
Downloaded from www.Manualslib.com manuals search engine
Front & Rear Differential Gear Oil
PERIODIC MAINTENANCE SERVICES

18.Front & Rear Differential Gear Differential gear oil capacity:

1.1 — 1.3 2 (1.2 — 1.4 US qt, 1.0 — 1.1 lmp qt)
Oil
A: REPLACEMENT (A)

1. FRONT DIFFERENTIAL (MT MODEL)

(B) (A)
Differential oil works as manual transmission oil to (C)
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®. PI-00183

NOTE: (A) Oil level gauge

• Before starting work, cool off the differential gear
(B) Upper level
oil well.
(C) Lower level
• If front differential gear oil adheres to the exhaust
pipe, wipe it off completely.
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:
PM-00157 Three Bond 1105 (Part No. 004403010)
• Use a new aluminum gasket for VA type.
2) Replace the gasket with a new one, and then
tighten the drain plug to specified torque. Tightening torque:
T type:
Tightening torque:
49.0 N·m (5.0 kgf-m, 36.2 ft-lb)
70 N·m (7.1 kgf-m, 51.6 ft-lb)
VA type:
3) Fill differential gear oil through the oil level 34 N·m (3.5 kgf-m, 25.3 ft-lb)
gauge hole up to the upper point of level gauge. 4) After installing the drain plug onto rear differen-
NOTE: tial gear case firmly, fill oil up fully to the mouth of
Each oil manufacturer has its base oil and addi- filler plug.
tives. Thus, do not mix two or more brands. T TYPE
Recommended gear oil:
GL-5 (75W-90) or equivalent (A)

(B)
PM-00037

(A) Filler plug

(B) Drain plug

PM-30
Downloaded from www.Manualslib.com manuals search engine
Front & Rear Differential Gear Oil
PERIODIC MAINTENANCE SERVICES

VA TYPE

(A)

(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 differ-
ential
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 addi-
tives. Thus, do not mix two or more brands.
• For STi model with driver’s control center differ-
ential, 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 temper-
ature 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
Downloaded from www.Manualslib.com manuals search engine
Brake Line
PERIODIC MAINTENANCE SERVICES

19.Brake Line Brake pedal free play:

0.5 — 2.0 mm (0.02 — 0.08 in)
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. (A)
3) Check any trace of fluid leakage, scratches, etc.
on the master cylinder, wheel cylinder and pres-
sure control valve. PM-00078

NOTE:
• When the brake fluid level in the reservoir tank is (A) Brake pedal free play
lower than the specified limit, the brake fluid warn- 2) If the free play is out of specifications above, ad-
ing light on the combination meter will come on. just the brake pedal as follows:
• Visually check the brake hose (using a mirror (1) Be sure the engine is off. (No vacuum is ap-
where it is difficult to see) for any damage. plied to brake booster.)
(1) (2) There should be play between brake boost-
er clevis and pin at brake pedal installing por-
tion.
[Depress brake pedal pad with a force of less
(2) 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
BR-00095
of brake switch becomes 0.3 mm (0.012 in).
(1) Front brake hose (A)
(2) Front brake pipe (H) (B)

(C)

(2) (D)
(I) (E)
(F)
(J)
(3) (G)
(1) (3)

PM-00041

(A) Brake switch

BR-00096 (B) Adjusting nut
(C) 0.3 mm (0.012 in)
(1) Rear brake pipe (D) Stopper
(2) Brake hose (E) Clevis pin
(3) Clamp (F) Clevis
(G) Brake pedal free play
B: CHECKING (H) Lock nut
1. SERVICE BRAKE (I) Brake booster operating rod
(J) Play at pin
1) Check the free play of brake pedal with a force of
less than 10 N (1 kgf, 2 lb).

PM-32
Downloaded from www.Manualslib.com manuals search engine
Brake Line
PERIODIC MAINTENANCE SERVICES

3) Check the pedal stroke. Replace both check valve and vacuum hose if the
While the engine is idling, depress the brake pedal check valve is faulty. Engine side of vacuum hose
with a 490 N (50 kgf, 110 lb) load and measure the is indicated by marking “ENG” as shown.
distance between brake pedal and steering wheel.
With the brake pedal released, measure the dis-
tance between pedal and steering wheel again.
The difference between the two measurements
must be less than specified value. If the distance is (A) (B)
more than specified, there is possibility of air inside (C)
the hydraulic unit.
Brake pedal reserve distance: A
90 mm (3.54 in)/ 490 N (50 kgf, 110 lb) or less
PM-00046
1 2 =A
(A) Engine side
(A)
(B) Brake booster side
(C) ENG
1
2 5) Check the vacuum hose for cracks or other dam-
age.
NOTE:
(B) When installing the vacuum hose on the engine
PM-00045
and brake booster, do not use soapy water or lubri-
cating oil on their connections.
(A) Steering wheel
(B) Toe board 6) Check vacuum hose to make sure it is tight and
secure.
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 dis-
tance 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 en-
gine: Make sure the pedal should move slightly to-
ward 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. Dis-
connect the vacuum hose to inspect function of
check valve.
Blow air into the vacuum hose from its brake boost-
er 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.

PM-33
Downloaded from www.Manualslib.com manuals search engine
Brake Fluid
PERIODIC MAINTENANCE SERVICES

20.Brake Fluid • During the bleeding operation, keep the brake

reservoir tank filled with brake fluid to eliminate en-
A: REPLACEMENT try of air.
1) Either jack-up the vehicle and place a safety • The brake pedal operating must be very slow.
stand under it, or lift-up the vehicle. • For convenience and safety, two people should
2) Remove both front and rear wheels. do the work.
3) Draw out the brake fluid from master cylinder • The amount of brake fluid required is approx. 500
with syringe. m2 (16.9 US fl oz, 17.6 Imp fl oz) for total brake
4) Refill the reservoir tank with recommended system.
brake fluid. 6) Instruct your co-worker to depress the brake
Recommended brake fluid: pedal slowly two or three times and then hold it de-
FMVSS No. 116, fresh DOT3 brake fluid pressed.
7) Loosen the bleeder screw approx. 1/4 turn until a
NOTE: small amount of brake fluid drains into container,
• Avoid mixing different brands of brake fluid to and then quickly tighten the screw.
prevent degrading the quality of the fluid. 8) Repeat steps 6) and 7) above until there are no
• Be careful not to allow dirt or dust to get into the air bubbles in the drained brake fluid and new fluid
reservoir tank. flows through vinyl tube.
Bleeding sequence (1) → (2) → (3) → (4) NOTE:
(1) (4) 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
(5) (6)
brake pedal depressed and tighten the screw and
install bleeder cap.
Tightening torque:
8 N·m (0.8 kgf-m, 5.8 ft-lb)
(3) (2) 10) Bleed air from each wheel cylinder by following
PM-00047
the previous 5 steps.
11) Depress the brake pedal with a force of approx.
(1) Front right
294 N (30 kgf, 66 lb) and hold it there for approx. 20
(2) Rear left seconds. At this time check the pedal to see if it
(3) Front left makes any unusual movement. Visually inspect the
(4) Rear right bleeder screws and brake pipe joints to make sure
(5) Secondary that there is no fluid leakage.
(6) Primary 12) Install the wheels, and drive the vehicle for a
short distance between 2 to 3 km (1 to 2 miles) to
5) Install one end of a vinyl tube onto the air bleeder make sure that brakes are operating properly.
and insert the other end of the tube into a container
to collect the brake fluid.

PM-00048

NOTE:
• Cover the bleeder with waste cloth, when loosen-
ing it, to prevent brake fluid from being splashed
over surrounding parts.

PM-34
Downloaded from www.Manualslib.com manuals search engine
Disc Brake Pads and Discs
PERIODIC MAINTENANCE SERVICES

21.Disc Brake Pads and Discs

(A)
A: INSPECTION (C)
(B)
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 inspec-
tion hole of disc brake assembly. Replace the pad if
necessary.
PM-00140
NOTE:
When replacing a pad, always replace the pads for
(A) Thickness of pad
both the right and left wheels at the same time. Also
replace the pad clips if they are twisted or worn. (B) Back metal
(C) Lining

3) Check the disc rotor, and correct or replace if it is

damaged or worn.
• Front
Disc rotor thicknessmm (in)
14, 15, 16 inch 24 (0.94)
Standard
17 inch 30 (1.18)
(A) 14, 15, 16 inch 22 (0.87)
Service limit
17 inch 28 (1.10)
PM-00049
• Rear
(A) Inspection hole
Disc rotor thicknessmm (in)
• Front 14 inch 10 (0.39)
Standard 15 inch 18 (0.71)
Pad thicknessmm (in)
17 inch 20 (0.79)
14, 15 inch 11 (0.43)
14 inch 8.5 (0.34)
Standard 16 inch 10 (0.39)
Service limit 15 inch 16 (0.63)
17 inch 9.2 (0.36)
17 inch 18 (0.71)
14, 15 inch 1.5 (0.059)
Service limit 16 inch 1.5 (0.059) 4) Remove the caliper body. <Ref. to BR-31, Front
17 inch 1.2 (0.047) Disc Brake Assembly.>, <Ref. to BR-42, Rear Disc
Brake Assembly.>
• Rear 5) Tighten the wheel nuts to secure disk rotor.
Pad thicknessmm (in) 6) Set a dial gauge at a point less than 10 mm (0.39
14 inch 9 (0.35)
in) from outer periphery of rotor, and then measure
the disk rotor runout.
Standard 15 inch 11.5 (0.45)
17 inch 9 (0.35) Disc rotor runout limit:
14 inch 1.5 (0.059) Front: 0.075 mm (0.0030 in)
Service limit 15 inch 1.5 (0.059) Rear: 0.070 mm (0.0028 in)
17 inch 1.2 (0.047)

PM-00051

PM-35
Downloaded from www.Manualslib.com manuals search engine
Brake Linings and Drums
PERIODIC MAINTENANCE SERVICES

22.Brake Linings and Drums If deformation or wear of back plate, shoe, etc. is
noticeable, replace the affected parts.
A: INSPECTION
1. REAR DRUM BRAKE
1) Remove 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 deformi-
ties and check brake linings for wear.
NOTE: (A)
PM-00053
• Always replace both leading and trailing brake
shoes for the right and left wheels at the same time.
(A) Inside diameter
• When either the right and left brake assembly is
replaced, always replace the leading shoe and trail-
2. PARKING BRAKE (REAR DISC BRAKE)
ing shoe of the other.
Inspect the brake linings and drums of both sides of
Thickness of lining (except back metal) the rear brake at the same time by removing brake
Standard value: 4.1 mm (0.161 in) drums.
Service limit: 1.5 mm (0.059 in) 1) Inspect the brake shoes for damage or deforma-
tion and check brake linings for wear.
(B)
(C)
(A)
NOTE:
Always replace both primary and secondary brake
(D) 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)
(E)

(G) (F)
PM-00052

(A) Rotational direction of drum (Forward)

(B) Wheel cylinder (A)
(C) Upper shoe return spring
(D) Adjusting lever
(E) Trailing shoe
(B)
(C)
(F) Lower shoe return spring
PM-00054
(G) Leading shoe

3) Check the brake drum for wear, dents or other (A) Forward
damage. (B) Brake shoe (Primary side)
If the inside surface of brake drum is streaked, cor- (C) Brake shoe (Secondary side)
rect the surface with emery cloth (#200 or more). If
it is unevenly worn, tapered, or the outside surface 2) Check the disk rotor for wear, dents or other
of brake drum is damaged, correct or replace it. damage. If the inside surface of disk rotor is
streaked, correct the surface with emery cloth
Brake drum inner diameter (#200 or more). If it is unevenly worn or tapered,
Standard value: 228.6 mm (9.000 in) correct or replace it.
Service limit: 230.6 mm (9.079 in)

PM-36
Downloaded from www.Manualslib.com manuals search engine
Brake Linings and Drums
PERIODIC MAINTENANCE SERVICES

Brake drum inside diameter 3) Turn back (downward) the adjuster 3 to 4 notch-
Except for STi model es.
Standard value: 170 mm (6.69 in) 4) Install the cover (rubber) at original position cor-
Wear limit: 171 mm (6.73 in) rectly.
STi model
Standard value: 190 mm (7.48 in)
Wear limit: 191 mm (7.52 in)

(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 exces-
sively 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 screwdriv-
er as shown in illustration.

(A)

(B)

(C)

PM-00056

(A) Adjuster
(B) Cover (rubber)
(C) Back plate

PM-37
Downloaded from www.Manualslib.com manuals search engine
Suspension
PERIODIC MAINTENANCE SERVICES

23.Suspension NOTE:
When the transverse link ball joint has been re-
A: INSPECTION moved or replaced, check the toe-in of front wheel.
1. SUSPENSION BALL JOINT If the front wheel toe-in is not at specified value, ad-
just the toe-in. <Ref. to FS-6, Wheel Alignment.>
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 (A)
the brake disc cover (A) and end of transverse link
(D), ball joint (C) may be excessively worn.

PM-00059

(A) Dust seal

(A)
(D) 2. TRANSVERSE LINK’S REAR BUSHING
(C) (B)
PM-00057 Check oil leaks at around liquid-filled bushing. If oil
leaks, replace the bushing.
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 indi- (A)
cates ball joint (B) may be excessively worn.

(D)

(B)

PM-00060
(A)

(C) (A) Rear bushing

(B) (B) Transverse link
PM-00058

4) If relative movement is observed in the immedi- 3. WHEEL ARCH HEIGHT

ately preceding two steps, remove and inspect the 1) Unload cargoes and set the vehicle in curb
ball joint. If free play exceeds standard, replace the weight (empty) condition.
ball joint. <Ref. to FS-18, Front Ball Joint.> 2) Then, check the wheel arch height of front and
5) Damage of dust seal rear suspensions to ensure that they are within
Visually inspect the ball joint dust seal. If it is dam- specified values. <Ref. to FS-6, Wheel Alignment.>
aged, remove the transverse link. <Ref. to FS-15, 3) When the wheel arch height is out of standard,
Front Transverse Link.> And measure free play of visually inspect the following components and re-
ball joint. <Ref. to FS-18, Front Ball Joint.> place deformed parts.
(1) When looseness exceeds standard value, • Suspension components [Front strut assembly
replace the ball joint. and rear shock absorber assembly]
(2) If the dust seal is damaged, replace with the • Parts connecting between suspension and body.
new ball joint. 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 stan-
dard. <Ref. to FS-6, Wheel Alignment.> <Ref. to
RS-10, Wheel Alignment.>

PM-38
Downloaded from www.Manualslib.com manuals search engine
Suspension
PERIODIC MAINTENANCE SERVICES

4. WHEEL ALIGNMENT OF FRONT SUS- 8. DAMAGE TO SUSPENSION PARTS

PENSION 1) Check the following parts and the fastening por-
1) Check the alignment of front suspension to en- tion of the vehicle body for deformation or exces-
sure that following items conform to standard val- sive rusting which impairs the suspension. If
ues. necessary, replace the damaged parts with new
• Toe-in ones. If minor rust formation, pitting, etc. are noted,
• Camber angle remove the rust and apply remedial anti-corrosion
• Caster angle measures.
• Steering angle • Front suspension
<Ref. to FS-6, Wheel Alignment.> • Transverse link
2) When the caster angle does not conform to ref- • Crossmember
erence, visually inspect the following components • Strut
and replace deformed parts. • Rear suspension
• Suspension components [Strut assembly, cross- • Crossmember
member, transverse link, etc.] • Lateral links
• Body parts to which suspensions are installed. • Trailing link
3) When the toe-in and camber are out of standard • Strut
value, adjust them so that they conform to respec- • In the district where salt is sprayed to melt snow
tive service standard. on a road in winter, check suspension parts for
4) When the right-and-left turning angles of tire are damage caused by rust every 12 months after
out of standard, adjust to standard value. lapse of 60 months. Take rust prevention measure
as required.
5. WHEEL ALIGNMENT OF REAR SUS-
PENSION
1) Check the alignment of rear suspension to en-
sure that following items are within standard val-
ues.
• Toe-in
• Camber angle
• Thrust angle
<Ref. to RS-10, Wheel Alignment.>
2) When the camber angle does not conform to ref-
erence, visually inspect parts listed below. If defor-
mation 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 stan-
dard value, adjust them so that they conform to re-
spective 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 speci-
fied torque. If the self-lock nuts and bolts are re-
moved, replace them with new ones.
Front suspension: <Ref. to FS-2, General Descrip-
tion.>
Rear suspension: <Ref. to RS-2, General Descrip-
tion.>

PM-39
Downloaded from www.Manualslib.com manuals search engine
Wheel Bearing
PERIODIC MAINTENANCE SERVICES

24.Wheel Bearing 4) If the bearing free play exists in step 2) above,

attach a dial gauge to the hub COMPL and mea-
A: INSPECTION sure axial displacement in axial direction.
1. FRONT WHEEL BEARING Service limit:
Straight-ahead position within 0.05 mm
NOTE: (0.0020 in)
Inspect the condition of front wheel bearing grease.
5) Remove the DOJ of rear drive shaft from rear dif-
1) Jack-up the front of vehicle. ferential. <Ref. to DS-44, Rear Drive Shaft.>
2) While holding the front wheel by hand, swing it in 6) While supporting the rear drive shaft horizontally
and out to check bearing free play. with one hand, turn the hub COMPL with the other
3) Loosen the wheel nuts and remove front wheel. to check for noise or binding.
4) If bearing free play exists in step 2) above, at- If the hub COMPL is noisy or binds, disassemble
tach a dial gauge to the hub and measure axial dis- the rear axle and check condition of oil seals, bear-
placement in axial direction. ings, etc.
Service limit: (A)
Straight-ahead position within 0.05 mm
(0.0020 in) (F)
5) Remove the bolts and self-locking nuts, and ex- (G)
tract transverse link from front crossmember. (H)
6) Remove the SFJ of front drive shaft from trans-
mission. <Ref. to DS-19, Front Axle.> (I)
(B) (C)
7) While supporting the front drive shaft horizontal- (D)
ly with one hand, turn the hub with the other to (E)
check for noise or binding. PM-00062
If the hub is noisy or binds, disassemble the front
axle and check condition of oil seals, bearing, etc.
(A) Inner oil seal
(B) Rear housing
(A) (F) (C) Bearing
(D) Snap ring
(G) (E) Outer oil seal
(B)
(F) Tone wheel
(G) Hub bolt
(C)
(H) Hub
(I) Socket bolt
(D)
(E)
PM-00061 • FWD
1) Jack-up the rear of vehicle.
(A) Inner oil seal 2) While holding the rear wheel by hand, swing it in
(B) Snap ring and out to check bearing free play.
(C) Bearing 3) Loosen the wheel nuts and remove rear wheel.
(D) Housing 4) If the bearing free play exists in step 2) above,
(E) Outer oil seal attach a dial gauge to the hub COMPL and mea-
(F) Hub bolt sure axial displacement in axial direction.
(G) Hub Service limit:
Straight-ahead position within 0.05 mm
2. REAR WHEEL BEARING (0.0020 in)
• 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.

PM-40
Downloaded from www.Manualslib.com manuals search engine
Wheel Bearing
PERIODIC MAINTENANCE SERVICES

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

PM-41
Downloaded from www.Manualslib.com manuals search engine
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, re-
place 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, Pro-
peller Shaft.>

PM-42
Downloaded from www.Manualslib.com manuals search engine
Steering System (Power Steering)
PERIODIC MAINTENANCE SERVICES

26.Steering System (Power 2. STEERING SHAFT JOINT

Steering) When the steering wheel free play is excessive,
disconnect the universal joint of steering shaft and
A: INSPECTION check it for any play and yawing torque (at the point
of the crossing direction). Also inspect for any dam-
1. STEERING WHEEL age to sealing or worn serrations. If the joint is
1) Set the steering wheel in a straight-ahead posi- loose, retighten the mounting bolts to the specified
tion, and check the wheel spokes to make sure torque.
they are correctly set in their specified positions.
Tightening torque:
2) Lightly turn the steering wheel to the right and
24 N·m (2.4 kgf-m, 17.4 ft-lb)
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)

(A)

PM-00066

SUBARU
SRS AIRBAG
3. GEARBOX
1) With wheels placed on a level surface, turn the
steering wheel 90° in both the right and left direc-
tions.
PM-00065 While the wheel is being rotated, reach under the
vehicle and check for looseness in gearbox.
(A) Steering wheel free play
Tightening torque:
Move the steering wheel vertically toward the shaft 59 N·m (6.0 kgf-m, 43.4 ft-lb)
to ascertain if there is play in the direction.
Maximum permissible play: (A)

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. (B)

(2) Pull to one side: PM-00067

Steering wheel should not be pulled to either
side while driving on a level surface. (A) Boot
(3) Wheel runout: (B) Gear box mounting bolt
Steering wheel should not show any sign of
runout. 2) Check the boot for damage, cracks or deteriora-
(4) Return factor: tion.
Steering wheel should return to its original posi- 3) With the vehicle on a level surface, quickly turn
tion after it has been turned and then released. 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, ad-
just 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 op-
eration twice.

PM-43
Downloaded from www.Manualslib.com manuals search engine
Steering System (Power Steering)
PERIODIC MAINTENANCE SERVICES

(2) Retighten the adjusting screw to 7.4 N·m 3) Check the lock nut on tie-rod end for tightness. If
(0.75 kgf-m, 5.4 ft-lb) and back off 25°. it is loose, retighten it to the specified torque.
(3) Loosen the adjusting screw and apply liquid Tightening torque:
packing to at least 1/3 of entire perimeter of its
83 N·m (8.5 kgf-m, 61.5 ft-lb)
thread.
5. POWER STEERING FLUID LEVEL
NOTE:
• Check at power steering fluid temperature 20°C
(A) (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 out-
PM-00068 side of reservoir tank (A). If the level is below “MIN”
(B), add fluid to bring it up to “MAX” (C).
(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 adjust-
ing screw with a wrench, tighten the lock nut us-
ing ST.
ST 926230000 SPANNER
Tightening torque (Lock nut):
PM-00070
39 N·m (4.0 kgf-m, 29 ft-lb)
Hold the adjusting screw with a wrench to pre- NOTE:
vent it from turning, while tightening the lock nut. If the fluid level is at MAX level or above, drain fluid
4. TIE-ROD to keep the level in specified range of indicator by
using a syringe or the like.
1) Check the tie-rod and tie-rod ends for bends,
scratches or other damage. 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.
(A)
If fluid leaks are found, correct them by retightening
(B) their fitting bolts (or nuts) and/or replacing their
PM-00069
parts.
(A) Tie-rod end NOTE:
(B) Knuckle arm
• Wipe the leakage fluid off after repairing fluid
leaks, or a wrong diagnosis is taken later.
2) Check the connections of knuckle ball joints for • Also pay attention to clearances between hoses
play, inspect for damage on dust seals, and check (or pipings) and other parts when inspecting fluid
free play of ball studs. If the castle nut is loose, re- leaks.
tighten it to the specified torque, then tighten further
7. HOSES OF OIL PUMP FOR DAMAGES
up to 60° until the cotter pin hole is aligned.
Check the pressure hose and return hose of oil
Tightening torque: pump for crack, swell or damage. Replace the hose
27 N·m (2.75 kgf-m, 19.9 ft-lb) with a new one if necessary.

PM-44
Downloaded from www.Manualslib.com manuals search engine
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 DAM-

AGE
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 neces-
sary.
Inspect and/or retighten them when engine is cold.

PM-45
Downloaded from www.Manualslib.com manuals search engine
Steering System (Power Steering)
PERIODIC MAINTENANCE SERVICES

PM-46
Downloaded from www.Manualslib.com manuals search engine