!!! Leg3 - Gen - Splošno - Vzdrževalni Načrt

2003 Model Year
PDF Service Manual

GENERAL INFORMATION SECTION (Pub.No.G2300GE1)
ENGINE SECTION 1 (Pub.No.G2300GE2)
TRANSMISSION SECTION (Pub.No.G2300GE5)
CHASSIS SECTION (Pub.No.G2300GE6)
BODY SECTION (Pub.No.G2300GE7)
WIRING SYSTEM SECTION (Pub.No.G2300GE8)

2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX
GENERAL INFORMATION
SECTION
FOREWORD FW
HOW TO USE THIS MANUALS 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. G2300GE1

FOREWORD
FW
Page
1. Foreword .....................................................................................................2
FOREWORD
FOREWORD
1. Foreword
A: FOREWORD
These manuals are used when performing mainte-
nance, repair, or diagnosis of the Subaru Legacy.
Applied model: BE***** and BH***** from 2003MY.
The manuals contain the latest information at the

time of publication. Changes in specifications,
methods, etc. may be made without notice.
FW-2
HOW TO USE THIS MANUALS
HU
Page
1. How to Use This Manuals ...........................................................................2
1. How to Use This Manuals

A: HOW TO USE THIS MANUALS
1. STRUCTURE
Each section consists of SCT that are broken down
into SC that are divided into sections for each com-
ponent. 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.
HU-2
3. COMPONENTS
Illustrations are listed for each component. The information necessary for repair work (tightening torque,
grease up points, etc.) is described on these illustrations. Information is described using symbol. To order the
parts, refer to parts catalogue.
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-00001
HU-3
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
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)
HU-5
MEMO:
HU-6
SPECIFICATIONS
SPC
Page
1. Legacy.........................................................................................................2
2. OUTBACK.................................................................................................10
LEGACY
SPECIFICATIONS
1. Legacy
A: DIMENSIONS
Model Sedan Wagon
AWD
Overall length mm (in) 4,605 (181.3) 4,680 (184.3)
Overall width mm (in) 1,695 (66.7) 1,695 (66.7)
Overall height (at CW) mm (in) 1,415 (55.7) 1,515 (59.6)
Compartment Length mm (in) 1,965 (77.4) 1,925 (75.8)
Width mm (in) 1,440 (56.7), 1,420 (55.9)*1 1,440 (56.7), 1,420 (55.9)*1
Height mm (in) 1,155 (45.5) 1,190 (46.9), 1,175 (46.3)*2
Wheelbase mm (in) 2,650 (104.3) 2,650 (104.3)
Tread Front mm (in) 1,460 (57.5) 1,460 (57.5)
Rear mm (in) 1,460 (57.5) 1,455 (57.3)
Minimum road clearance mm (in) 155 (6.1) 155 (6.1)
*1: With leather seat

*2: With sunroof
B: ENGINE
Model Sedan/Wagon
AWD
2.0 L Non-TURBO 2.5 L Non-TURBO
Engine type Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine
Valve arrangement Overhead camshaft type
Bore × Stroke mm (in) 92 × 75 (3.62 × 2.95) 99.5 × 79.0 (3.917 × 3.110)
Displacement cm3 (cu in) 1,994 (121.67) 2,457 (149.9)
Compression ratio 10.0
Firing order 1—3—2—4
Idle speed at Park/ Without OBD 700±100
Neutral position rpm With OBD 650±100
Maximum output kW (PS)/rpm 92 (125)/5,600 115 (156)/5,600
Maximum torque N·m (kgf-m, ft-lb)/rpm 184 (18.8, 136.0)/3,600 223 (22.7, 164.2)/3,600
Model Sedan
AWD
2.0 L TURBO
5MT 4AT-SS
Engine type Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine
Valve arrangement Double overhead camshaft type
Bore × Stroke mm (in) 92 × 75 (3.62 × 2.95)
Displacement 3
cm (cu in) 1,994 (121.67)
Compression ratio 9.0±0.2
Firing order 1—3—2—4
Idle speed at Park/ rpm 700±100 650±100
Neutral position
Maximum torque N·m (kgf-m, ft-lb)/rpm 320 (32.6, 235.8)/4,800 309 (31.5, 227.8)/4,800
SPC-2
LEGACY
SPECIFICATIONS
C: ELECTRICAL
Model Sedan/Wagon
AWD
Ignition timing at idling speed BTDC/rpm 10°±10°
Spark plug Type and manufacturer Without OBD NGK: BKR6E (without catalyst)
CHAMPION: RC10YC4 (with catalyst)
Alternate NGK: BKR5E-11 (with catalyst)
With OBD CHAMPION: RC10YC4
Alternate NGK: BKR6E-11
NGK: BKR5E-11
Generator 12V — 90A
Battery Type and capacity For Europe and MT: 12V — 48AH (55D23L) MT: 12V — 48AH (55D23L)
(5HR) South America AT: 12V — 52AH (65D23L) AT: 12V — 52AH (75D23L)
Others 12V — 27AH (34B19L)
Model Sedan
AWD
2.0 L TURBO
Ignition timing at idling speed BTDC/rpm 14°±10°
Spark plug NGK: PFR6G
Generator 12V — 90A
Battery Type and capacity (5HR) 12V— 48AH (55D23L)
D: TRANSMISSION
Model Sedan/Wagon
AWD
Transmission type 5MT 4AT 5MT 4AT
Clutch type DSPD TCC DSPD TCC
Gear ratio 1st 3.454 2.785 3.454 2.785
2nd 2.062 1.545 2.062 1.545
3rd 1.448 1.000 1.448 1.000
4th 1.088 0.694 1.088 0.694
5th 0.825 — 0.825*1, 0.780*2 —
Reverse 3.333 2.272 3.333 2.272
Auxiliary transmission gear ratio High 1.000 — 1.000 —
Low 1.447 — 1.196 —
Reduction gear 1st reduction Type of gear — Helical — Helical
(Front drive) Gear ratio — 1.000 — 1.000
Final reduction Type of gear Hypoid Hypoid Hypoid Hypoid
Gear ratio 3.900 4.111 3.700*1, 4.111*2 4.111
Reduction gear Transfer reduc- Type of gear Helical — Helical —
(Rear drive) tion Gear ratio 1.000 — 1.000 —
Final reduction Type of gear Hypoid Hypoid Hypoid Hypoid
Gear ratio 3.900 4.111 3.700*1, 4.111*2 4.111
SPC-3
LEGACY
SPECIFICATIONS
Model Sedan
AWD
2.0 L TURBO
Transmission type 5MT 4AT-SS
Clutch type DSPD TCC
Gear ratio 1st 3.166 2.785
2nd 1.882 1.545
3rd 1.296 1.000
4th 0.972 0.694
5th 0.738 —
Reverse 3.333 2.272
Reduction gear 1st reduction Type of gear — Helical
(Front drive) Gear ratio — 1.000
Final reduction Type of gear Hypoid Hypoid
Gear ratio 4.111 4.111
Reduction gear Transfer reduc- Type of gear Helical —
(Rear drive) tion Gear ratio 1.000 —
Gear ratio 4.111 4.111
5MT: 5 forward speeds with synchromesh and 1-reverse

4AT: Electronically controlled fully-automatic, 4-forward speeds and 1-reverse
DSPD: Dry Single Plate Diaphragm
TCC: Torque Converter Clutch
*1: Except Australia spec. vehicles
*2: Australia spec. vehicles
E: STEERING
Model 2.0 L, 2.5 L Non-TURBO 2.0 L TURBO
Type Rack and Pinion
Turns, lock to lock 3.1 3.0
Minimum turning circle Curb to curb 10.8±1.0 (35.4±3.3) 11.2±1.0 (36.7±3.3)
m (ft) Wall to wall 11.5±1.0 (37.7±3.3) 12.0±1.0 (39.4±3.3)
F: SUSPENSION
Model Conventional suspension
Front Macpherson strut type, Independent, Coil spring
Rear Multi-link type, Independent, Coil spring
G: BRAKE
Model 2.0 L, 2.5 L Non-TURBO 2.0 L TURBO
Service brake system Dual circuit hydraulic with vacuum suspended power unit
Front Ventilated disc brake
Rear Disc brake Ventilated disc brake
Parking brake Mechanical on rear brakes
H: TIRE
Rim size 15 × 6JJ 16 × 61/2JJ 17 × 7JJ
Tire size 195/60R15 205/50R16 215/45ZR17
Type Steel belted radial, Tubeless
SPC-4
LEGACY
SPECIFICATIONS
I: CAPACITY
Model Sedan/Wagon
AWD
2.0 L 2.5 L
5MT 4AT 5MT 4AT
Fuel tank 2 (US gal, Imp gal) 64 (16.9, 14.1)
Engine oil (When replacing) 2 (US qt, Imp qt) Approx. 4.0 (4.2, 3.5), 4.5 (4.8, 4.0)*
Transmission gear oil 2 (US qt, Imp qt) 3.5 (3.7, 3.1) — 3.5 (3.7, 3.1) —
Automatic transmission fluid 2 (US qt, Imp qt) — 9.3 – 9.6 — 9.3 – 9.6
(9.8 – 10.1, (9.8 – 10.1,
8.2 – 8.4) 8.2 – 8.4)
AT differential gear oil 2 (US qt, Imp qt) — 1.1 – 1.3 — 1.1 – 1.3
(1.2 – 1.4, (1.2 – 1.4,
1.0 – 1.1) 1.0 – 1.1)
AWD rear differential gear oil 2 (US qt, Imp qt) 0.8 (0.8, 0.6)
Power steering fluid 2 (US qt, Imp qt) 0.7 (0.7, 0.6)
Engine coolant 2 (US qt, Imp qt) 7.0 (7.4, 6.2) 6.9 (7.3, 6.1) 6.8 (7.2, 6.0) 6.7 (7.1, 5.9)
7.7 (8.1, 6.8)* 7.6 (8.0, 6.7)*
*: TURBO model
J: WEIGHT
1. SEDAN
• LHD Vehicle
Option code *1 EC K4 KO, KS

Model 2.0 L
AWD
GL
5MT 4AT 5MT 4AT 5MT 4AT
Curb weight (C.W.) Front kg (lb) 785 810 775 800 790 815
(1,730) (1,785) (1,710) (1,765) (1,740) (1,795)
Rear kg (lb) 605 605 610 610 610 610
(1,335) (1,335) (1,345) (1,345) (1,345) (1,345)
Total kg (lb) 1,390 1,415 1,385 1,410 1,400 1,425
(3,065) (3,120) (3,055) (3,110) (3,085) (3,140)
Maximum permissible Front kg (lb) 970 970 970 970 970 970
axle weight (M.P.A.W.) (2,140) (2,140) (2,140) (2,140) (2,140) (2,140)
Rear kg (lb) 975 975 975 975 975 975
(2,150) (2,150) (2,150) (2,150) (2,150) (2,150)
Maximum permissible Total kg (lb) 1,870 1,870 1,870 1,870 1,870 1,870
weight (M.P.W.) (4,125) (4,125) (4,125) (4,125) (4,125) (4,125)
Option Side airbag ❍ ❍ — — — —
Air conditioner — — — — ❍ ❍
Audio — — — — ❍ ❍
Cruise control — — — — — —
Cold weather pack — — — — — —
SPC-5
LEGACY
SPECIFICATIONS
Option code *1 EC K4 KS
Model 2.5 L
AWD
GX
(1,775) (1,830) (1,750) (1,810) (1,730) (1,785)
Rear kg (lb) 605 610 610 615 610 615
(1,335) (1,345) (1,345) (1,355) (1,345) (1,355)
Total kg (lb) 1,410 1,440 1,405 1,435 1,395 1,425
(3,110) (3,175) (3,095) (3,165) (3,075) (3,140)
axle weight (M.P.A.W.) (2,170) (2,170) (2,170) (2,170) (2,170) (2,170)
Rear kg (lb) 1,000 1,000 1,000 1,000 1,000 1,000
(2,205) (2,205) (2,205) (2,205) (2,205) (2,205)
weight (M.P.W.) (4,210) (4,210) (4,210) (4,210) (4,210) (4,210)
Air conditioner ❍ ❍ ❍ ❍ — —
Audio — — — — ❍ ❍
Cruise control — — ❍ ❍ — —
*1: For option code, refer to ID section. <Ref. to ID-4, MODEL NUMBER PLATE, IDENTIFICATION, Identification.>
• RHD Vehicle
Option code *1 K1 EK
Model 2.0 L 2.5 L
AWD
GL GX
4AT 5MT 4AT 5MT 4AT
Curb weight (C.W.) Front kg (lb) 800 (1,765) 795 (1,750) 820 (1,810) 795 (1,750) 820 (1,810)
Rear kg (lb) 605 (1,335) 605 (1,335) 605 (1,335) 605 (1,335) 610 (1,345)
Total kg (lb) 1,405 (3,100) 1,400 (3,085) 1,425 (3,145) 1,400 (3,085) 1,430 (3,155)
Maximum permissible Front kg (lb) 970 (2,140) 970 (2,140) 970 (2,140) 985 (2,170) 985 (2,170)
axle weight (M.P.A.W.) Rear kg (lb) 975 (2,150) 975 (2,150) 975 (2,150) 1,000 (2,205) 1,000 (2,205)
Maximum permissible Total kg (lb) 1,870 (4,125) 1,870 (4,125) 1,870 (4,125) 1,910 (4,210) 1,910 (4,210)
weight (M.P.W.)
Option Side airbag — ❍ ❍ ❍ ❍
Air conditioner — ❍ ❍ — —
Audio ❍ ❍ ❍ ❍ ❍
Cruise control — — — — —
Cold weather pack — — — — —
SPC-6
LEGACY
SPECIFICATIONS
Option code *1 KA
Model 2.0 L 2.5 L
AWD
GL (GX) GX (RX)
5MT 4AT 5MT 4AT
Unladen mass (U.M.) Front kg (lb) 780 (1,720) 775 (1,710) 775 (1,710) 785 (1,730)
Rear kg (lb) 585 (1,290) 585 (1,290) 595 (1,310) 595 (1,310)
Total kg (lb) 1,365 (3,010) 1,360 (3,000) 1,370 (3,020) 1,380 (3,040)
Gross vehicle mass Front kg (lb) 930 (2,050) 930 (2,050) 940 (2,075) 940 (2,075)
(G.V.M.) Rear kg (lb) 970 (2,140) 970 (2,140) 980 (2,160) 980 (2,160)
Total kg (lb) 1,900 (4,190) 1,900 (4,190) 1,920 (4,235) 1,920 (4,235)
Option Side airbag — — — —
Air conditioner ❍ — — —
Audio ❍ ❍ ❍ ❍
Cruise control ❍ — — —
Cold weather pack — — — —
Option code *1 KA
Model 2.0 L
AWD
B4
5MT 4AT-SS
Unladen mass (U.M.) Front kg (lb) 875 (1,930) 900 (1,985)
Rear kg (lb) 620 (1,365) 620 (1,365)
Total kg (lb) 1,495 (3,295) 1,520 (3,350)
Gross vehicle mass Front kg (lb) 1,005 (2,215) 1,005 (2,215)
(G.V.M.) Rear kg (lb) 980 (2,160) 980 (2,160)
Total kg (lb) 1,985 (4,375) 1,985 (4,375)
Option Side airbag — —
Air conditioner ❍ ❍
Audio ❍ ❍
Cruise control — —
Cold weather pack — —
Leather trim ❍ ❍
Rear spoiler ❍ ❍
SPC-7
LEGACY
SPECIFICATIONS
2. WAGON
• LHD Vehicle
Option code *1 EC K4 KO, KS

Model 2.0 L
AWD
GL
(1,720) (1,765) (1,710) (1,740) (1,740) (1,775)
Rear kg (lb) 650 650 655 655 655 655
(1,435) (1,435) (1,445) (1,445) (1,445) (1,445)
Total kg (lb) 1,430 1,450 1,430 1,445 1,445 1,460
(3,155) (3,200) (3,155) (3,185) (3,185) (3,220)
axle weight (M.P.A.W.) (2,115) (2,115) (2,115) (2,115) (2,115) (2,115)
Rear kg (lb) 1,030 1,030 1,030 1,030 1,030 1,030
(2,270) (2,270) (2,270) (2,270) (2,270) (2,270)
weight (M.P.W.) (4,235) (4,235) (4,235) (4,235) (4,235) (4,235)
Option Side airbag — ❍ — — — —
Air conditioner — — — — ❍ ❍
Audio — — — — ❍ ❍
Option code *1 EC K4 KS
Model 2.5 L
AWD
GX
(1,740) (1,810) (1,740) (1,775) (1,720) (1,785)
Rear kg (lb) 655 655 655 655 655 655
(1,445) (1,445) (1,445) (1,445) (1,445) (1,445)
Total kg (lb) 1,445 1,475 1,445 1,460 1,435 1,465
(3,185) (3,255) (3,185) (3,220) (3,165) (3,230)
axle weight (M.P.A.W.) (2,195) (2,195) (2,195) (2,195) (2,195) (2,195)
Rear kg (lb) 1,050 1,050 1,050 1,050 1,050 1,050
(2,315) (2,315) (2,315) (2,315) (2,315) (2,315)
weight (M.P.W.) (4,365) (4,365) (4,365) (4,365) (4,365) (4,365)
Air conditioner — ❍ ❍ ❍ — ❍
Audio — — — — ❍ ❍
Cruise control — ❍ ❍ ❍ — ❍
Cold weather pack — ❍ — — — —
SPC-8
LEGACY
SPECIFICATIONS
• RHD Vehicle
Option code *1 K1 EK
Model 2.0 L 2.5 L
AWD
GL GX
(1,710) (1,740) (1,750) (1,785) (1,740) (1,775)
Rear kg (lb) 655 655 650 650 655 655
(1,445) (1,445) (1,435) (1,435) (1,445) (1,445)
Total kg (lb) 1,430 1,445 1,445 1,460 1,445 1,460
(3,155) (3,185) (3,185) (3,220) (3,185) (3,220)
axle weight (M.P.A.W.) (2,115) (2,115) (2,115) (2,115) (2,195) (2,195)
Rear kg (lb) 1,030 1,030 1,030 1,030 1,050 1,050
(2,270) (2,270) (2,270) (2,270) (2,315) (2,315)
weight (M.P.W.) (4,235) (4,235) (4,235) (4,235) (4,365) (4,365)
Option Side airbag — — ❍ ❍ ❍ ❍
Air conditioner — — ❍ ❍ — —
Audio ❍ ❍ ❍ ❍ ❍ ❍
Option code *1 KA
Model 2.0 L 2.5 L
AWD
GL (GX) GX (RX)
5MT 4AT 5MT 4AT
Unladen mass (U.M.) Front kg (lb) 775 775 765 780
(1,710) (1,710) (1,685) (1,720)
Rear kg (lb) 635 635 645 645
(1,400) (1,400) (1,420) (1,420)
Total kg (lb) 1,410 1,410 1,410 1,425
(3,110) (3,110) (3,105) (3,140)
Gross vehicle mass Front kg (lb) 930 930 950 950
(G.V.M.) (2,050) (2,050) (2,095) (2,095)
Rear kg (lb) 1,010 1,010 1,040 1,040
(2,225) (2,225) (2,295) (2,295)
Total kg (lb) 1,940 1,940 1,990 1,990
(4,275) (4,275) (4,390) (4,390)
Air conditioner ❍ — — —
Audio ❍ ❍ ❍ ❍
Cruise control ❍ — — —
SPC-9
OUTBACK
SPECIFICATIONS
2. OUTBACK
A: DIMENSIONS
Model OUTBACK
AWD
Overall length mm (in) 4,720 (185.8)
Overall width mm (in) 1,745 (68.7)
Overall height (at CW) mm (in) 1,580 (62.2), 1,590 (62.6)*3
Compartment Length mm (in) 1,925 (75.8)
Width mm (in) 1,440 (56.7), 1,420 (55.9)*1
Height mm (in) 1,190 (46.9), 1,175 (46.3)*2
Wheelbase mm (in) 2,650 (104.3)
Tread Front mm (in) 1,470 (57.9)
Rear mm (in) 1,460 (57.5)*3 , 1,465 (57.7)
Minimum road 2.5 L mm (in) 190 (7.5)
clearance 3.0 L mm (in) 200 (7.9)
*1: With leather seat

*2: With sunroof
B: ENGINE
Model OUTBACK
AWD
2.5 L 3.0 L
Engine type Horizontally opposed, liquid cooled, 4- Horizontally opposed, liquid cooled, 6-
cylinder, 4-stroke gasoline engine cylinder, 4-stroke gasoline engine
Valve arrangement Overhead camshaft type Double overhead camshaft type
Bore × Stroke mm (in) 99.5 × 79.0 (3.917 × 3.110) 89.2 × 80.0 (3.512 × 3.150)
Displacement 3
cm (cu in) 2,457 (149.9) 3,000 (183.06)
Compression ratio 10.0 10.7
Firing order 1—3—2—4 1—6—3—2—5—4
Idle speed at Park/ rpm Without OBD 700±100 600±100
Neutral position With OBD 650±100
Maximum torque N·m (kgf-m, ft-lb)/rpm 223 (22.7, 164.2)/3,600 282 (28.8, 208)/4,400
SPC-10
OUTBACK
SPECIFICATIONS
C: ELECTRICAL
Model OUTBACK
AWD
2.5 L 3.0 L
Ignition timing at idling BTDC/rpm 10°±10° 10°±8°
speed
Spark plug Type and manufacturer CHAMPION: RC10YC4 NGK: PLFR6A-11
Alternate NGK: BKR6E-11
NGK: BKR5E-11
Generator 12V — 90A 12V — 100A
Battery Type and capacity (5HR) For Europe and MT: 12V — 48AH (55D23L) 12V — 52AH (75D23L)
South America AT: 12V — 52AH (75D23L)
Others 12V — 27AH (34B19L) 12V — 48H (55D23L)
D: TRANSMISSION
Model OUTBACK
AWD
2.5 L 3.0 L
Transmission type 5MT 4AT 4AT
Clutch type DSPD TCC TCC
Gear ratio 1st 3.454 2.785
2nd 2.062 1.545
3rd 1.448 1.000
4th 1.088 0.694
5th 0.825 —
Reverse 3.333 2.272
Auxiliary transmission gear ratio High 1.000 —
Low 1.196 —
Reduction gear 1st Reduction Type of gear — Helical
(Front drive) Gear ratio — 1.000
Gear ratio 3.900*1, 4.111*2 4.444 4.111
Reduction gear Transfer reduction Type of gear Helical —
(Rear drive) Gear ratio 1.000 —
Gear ratio 3.900*1, 4.111*2 4.444 4.111
5MT: 5 × 2 forward speeds with synchromesh and 1-reverse

4AT: Electronically controlled fully-automatic, 4-forward speeds and 1-reverse
DSPD: Dry Single Plate Diaphragm
TCC: Torque Converter Clutch
*1: Except Australia spec. vehicles
SPC-11
OUTBACK
SPECIFICATIONS
E: STEERING
Model OUTBACK
Type Rack and Pinion
Turns, lock to lock 3.0
Minimum turning circle Curb to curb 11.2±1.0 (36.7±3.3)
m (ft) Wall to wall 12.0±1.0 (39.4±3.3)
F: SUSPENSION
Model OUTBACK
Front Macpherson strut type, Independent, Coil spring
Rear Multi-link type, Independent, Coil spring
G: BRAKE
Model OUTBACK
Service brake system Dual circuit hydraulic with vacuum suspended power unit
Front Ventilated disc brake
Rear Disc brake
Parking brake Mechanical on rear brakes
H: TIRE
Model OUTBACK
Rim size 16 × 61/2JJ
Tire size 215/60R16
Type Steel belted radial, Tubeless
I: CAPACITY
Model OUTBACK
AWD
2.5 L 3.0 L
5MT 4AT
Fuel tank 2 (US gal, Imp gal) 64 (16.9, 14.1)
Engine oil (When replacing) 2 (US qt, Imp qt) Approx. 4.0 (4.2, 3.5) Approx. 5.6 (5.9, 4.9)
Transmission gear oil 2 (US qt, Imp qt) 4.0 (4.2, 3.5) —
Automatic transmission fluid 2 (US qt, Imp qt) — 9.3 – 9.6 (9.8 – 10.1, 8.2 – 8.4)
AT differential gear oil 2 (US qt, Imp qt) — 1.1 – 1.3 (1.2 – 1.4, 1.0 – 1.1)
AWD rear differential gear oil 2 (US qt, Imp qt) 0.8 (0.8, 0.7)
Power steering fluid 2 (US qt, Imp qt) 0.7 (0.7, 0.6)
Engine coolant 2 (US qt, Imp qt) 6.8 (7.2, 6.0) 6.7 (7.1, 5.9) 7.9 (8.4, 7.0)
SPC-12
OUTBACK
SPECIFICATIONS
J: WEIGHT
1. OUTBACK
• LHD vehicle
Option code *1 K4 KS
Model 2.5 L
AWD
5MT 4AT 5MT 4AT
Curb weight (C.W.) Front kg (lb) 810 (1,785) 825 (1,820) 815 (1,795) 830 (1,830)
Rear kg (lb) 670 (1,475) 670 (1,475) 670 (1,475) 670 (1,475)
Total kg (lb) 1,480 (3,265) 1,495 (3,295) 1,485 (3,275) 1,500 (3,310)
Maximum permissible Front kg (lb) 995 (2,195) 995 (2,195) 995 (2,195) 995 (2,195)
axle weight (M.P.A.W.) Rear kg (lb) 1,050 (2,315) 1,050 (2,315) 1,050 (2,315) 1,050 (2,315)
Maximum permissible Total kg (lb) 2,000 (4,410) 2,000 (4,410) 2,000 (4,410) 2,000 (4,410)
weight (M.P.W.)
Air conditioner ❍ ❍ ❍ ❍
Audio — — ❍ ❍
Cruise control ❍ ❍ ❍ ❍
Leather trim — — — —
Sunroof — — — —
Option code *1 EC
Model 2.5 L 3.0 L
AWD
5MT 4AT
Curb weight (C.W.) Front kg (lb) 805 (1,775) 830 (1,830) 915 (2,020)
Rear kg (lb) 680 (1,500) 675 (1,490) 695 (1,530)
Total kg (lb) 1,485 (3,275) 1,505 (3,320) 1,610 (3,550)
Maximum permissible Front kg (lb) 1,010 (2,225) 1,010 (2,225) 1,040 (2,295)
axle weight (M.P.A.W.) Rear kg (lb) 1,060 (2,335) 1,060 (2,335) 1,060 (2,335)
Maximum permissible Total kg (lb) 2,015 (4,445) 2,015 (4,445) 2,085 (4,595)
weight (M.P.W.)
Option Side airbag ❍ ❍ ❍
Air conditioner — ❍ ❍
Audio ❍ — —
Cruise control ❍ — ❍
Cold weather pack ❍ — —
Leather trim — — ❍
Sunroof — — ❍
Self-levelizer ❍ — ❍
SPC-13
OUTBACK
SPECIFICATIONS
• RHD vehicle
Option code *1 EK
Model 2.5 L 3.0 L
AWD
5MT 4AT
Curb weight (C.W.) Front kg (lb) 800 (1,765) 815 (1,795) 915 (2,020)
Rear kg (lb) 670 (1,475) 670 (1,475) 695 (1,530)
Total kg (lb) 1,470 (3,240) 1,485 (3,275) 1,610 (3,550)
Maximum permissible Front kg (lb) 1,010 (2,225) 1,010 (2,225) 1,040 (2,295)
axle weight (M.P.A.W.) Rear kg (lb) 1,060 (2,335) 1,060 (2,335) 1,060 (2,335)
Maximum permissible Total kg (lb) 2,015 (4,445) 2,015 (4,445) 2,085 (4,595)
weight (M.P.W.)
Option Side airbag — — ❍
Air conditioner — — ❍
Audio ❍ ❍ ❍
Cruise control — — ❍
Cold weather pack — — ❍
Sunroof — — ❍
Self-levelizer — — ❍
Option code *1 KA
Model 2.5 L 3.0 L
AWD
5MT 4AT
Unladen mass (U.M.) Front kg (lb) 790 (1,740) 800 (1,765) 900 (1,985)
Rear kg (lb) 650 (1,435) 650 (1,435) 690 (1,520)
Total kg (lb) 1,440 (3,175) 1,450 (3,200) 1,590 (3,505)
Gross vehicle mass Front kg (lb) 970 (2,140) 970 (2,140) 1,035 (2,280)
(G.V.M.) Rear kg (lb) 1,050 (2,315) 1,050 (2,315) 1,050 (2,315)
Total kg (lb) 2,020 (4,455) 2,020 (4,455) 2,085 (4,595)
Option Side airbag — — ❍
Air conditioner — — ❍
Audio ❍ ❍ ❍
Cruise control — — ❍
Cold weather pack — — —
Sunroof — — ❍
Self-levelizer — — ❍
SPC-14
PRECAUTION
PC
Page
1. Precaution ...................................................................................................2
PRECAUTION
PRECAUTION
1. Precaution 7. AIRBAG MODULE

A: PRECAUTION Adhere to the following when handing 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 harnesses or connectors to carry the
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 individual parts. Doing towards the floor or walls.
so could prevent the ABS system from operating 8. AIRBAG SPECIAL TOOLS
when needed or cause it to operate incorrectly and
result in injury. To prevent unexpected deployment, only use spe-
cial tools.
2. BRAKE FLUID
9. WINDOW
If brake fluid gets in your eyes or on your skin, do
the following: Always wear safety glasses when working around
• Wash out your eyes and seek immediate medical any glass to prevent glass fragments from damag-
attention. ing your eyes.
• Wash your skin with soap and then rinse thor- 10.WINDOW ADHESIVE
oughly with water.
Always use the specified urethane adhesive when
3. ELECTRIC FAN attaching glass to prevent it from coming loose and
falling, resulting in accidents and injury.
The electric 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 airbag components or nearby, and
airbag wiring harnesses or nearby.
To prevent unexpected deployment, perform one of
the steps below and then wait at least 20 seconds
to discharge electricity before beginning work.
• Step 1: Turn the ignition switch OFF.
• Step 2: Remove the negative battery terminal.
6. AIRBAG DISPOSAL
To prevent bodily injury from unexpected airbag
deployment, do not dispose airbag modules in the
same way as other refuse. Follow all government
regulations concerning disposal of refuse.
PC-2
NOTE
NT
Page
1. Note.............................................................................................................2
NOTE
NOTE
1. Note
A: NOTE
This is information that can improve efficiency of maintenance and assure sound work.
1. FASTENER NOTICE
Fasteners are used to prevent parts from damage and dislocation due to looseness. Fasteners must be tight-
ened to the specified torque.
Do not apply paint, lubricant, rust retardant, or other substances to the surface around bolts, fasteners, etc.
Doing so will make it difficult to obtain the correct torque and result in looseness and other problems.
2. STATIC ELECTRICITY DAMAGE
Do not touch the ECM, connectors, logic boards, and other such parts when there is a risk of static electricity.
Always use a static electricity prevention cord or touch grounded metal before conducting work.
3. IGNITION OFF BATTERY
When removing the battery cables, always be sure to turn the ignition off to prevent electrical damage to the
ECM from rush current.
4. SERVICE PARTS
Use authentic service parts for maximum performance and maintenance, when conducting repairs. Subaru/
FHI will not be responsible for poor performance resulting from the use of parts not specified by a genuine
dealer.
5. LIFTS AND JACKS
When using a lift or jack-ridged rack to raise a vehicle, always follow instructions concerning jack-up points
and weight limits to prevent the vehicle from falling, which could result in injury. Be especially careful to make
sure the vehicle is balanced before raising it.
• Support locations
Without side sill cover
With side sill cover

NT-00048
NT-2
NOTE
NOTE
• Pantograph jack
With side sill cover
NT-00049
Without side sill cover
NT-00050
• Lift
NT-00046
NT-3
NOTE
NOTE
• Safety stand
NT-00047
Front
Front crossmember
Rear differential gear

Rear
NT-00036
NT-4
NOTE
NOTE
6. TIE DOWNS
Tie-downs are used when transporting vehicles and when using the chassis dynamo.
• Tie-down points
Attach tie-downs only to the specified points on the vehicle.
Hook for towing

(Except OUTBACK) Hook for towing
(OUTBACK)
Hook for tie-down Hook for towing

Hook for tie-down
and tie-down
NT-00059
NT-5
NOTE
NOTE
• Chain direction at tie-down condition 7. TOWING

Avoid towing vehicles except when the vehicle can-
not be driven. For vehicles with AWD, AT or VTD,
use a loader instead of towing. When towing other
vehicles, to prevent excessive weight from damag-
ing the hook or vehicle:
• Do not tow other vehicles with a front towing
hook.
• Make sure the vehicle towing is heavier that the
vehicle being towed.
NT-00038
• Chain pulling range at tie-down condition
20˚ 20˚
20˚ 20˚
20˚ 20˚
20˚ 20˚
45˚ 45˚ 45˚ 45˚

: Tie-down range NT-00039
• Vehicle sinking volume at tie-down condition

Measure 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 a vehicle securely.
L L
NT-00040
NT-6
NOTE
NOTE
8. FRONT HOOD STAY INSTALLATION

• At the check and general maintenance
NT-00041
• When wider hood opening is necessary

Set stay into the hole of hood inner as shown in the figure below.
NOTE:
Before setting the hood in this position, remove the windshield washer hose attaching clip from the hood.
NT-00042
9. TRAINING 10.GENERAL SCAN TOOL

For information about training, contact a dealer or Using general scan tools will greatly improve effi-
agent. 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-7
NOTE
NOTE
MEMO:
NT-8
IDENTIFICATION
ID
Page
1. Identification ................................................................................................2
IDENTIFICATION
IDENTIFICATION
1. Identification
A: IDENTIFICATION
1. IDENTIFICATION NUMBER AND LABEL LOCATIONS
The VIN (Vehicle Identification Numbers) is used to classify the vehicle.
Positioning of the plate label for identification
Emission control label
Vehicle identification number
• ID plate (Europe model)

• ADR compliance plate
(Australia model)
• Saudi Arabia plate (Saudi Arabia model)

• Built date plate (Australia model)
• Tire inflation pressure label
(Driver side) (Australia model)
• Tire pressure label
(Driver side) (Except Australia model)
Model number plate ID-00048
ENGINE 5MT Transmission serial number
Engine serial number ID-00011 ID-00013
4AT Transmission serial number
Stamp location
ID-00012 ID-00014
ID-2
IDENTIFICATION
IDENTIFICATION
Model number plate
J F 1 BE 5 L J 3 3G0 0 2 0 0 1
BE 9 EL 7 J
EJ 2 5 1 NJ E A A
TY 7 5 4VFBAA
ID-00049
2. MEANING OF V.I.N.
The meaning of the VIN is as follows:
• Europe, Australia and General (Except GCC)
]JF1BE5LJ33G002001[
The starting and ending brackets ( ][ ) are stop marks.
Digits Code Meaning Details
1 to 3 JF1 Manufacturer body area JF1: Passenger car, FHI made
JF2: MPV, FHI made
4 B Car line Legacy/OUTBACK series
5 E Body type E: Sedan
H: Station Wagon/OUTBACK
6 5 Displacement 5: 2.0 L AWD
9: 2.5 L AWD
E: 3.0 L AWD
7 L Steering position K: RHD (Right-hand drive)
L: LHD (Left-hand drive)
8 J Engine & transmission E: DOHC MPI 4AT
J: SOHC MPI 5F
R: SOHC MPI 4AT
D: DOHC MPI TURBO 5F
T: DOHC MPI TURBO 4AT-SS
9 3 Drive type 3: Full-time AWD 5-speed MT single range
4: Full-time AWD 5-speed MT dual range
5: Full-time AWD 4-speed AT
A: Full-time AWD 4-speed AT OUTBACK
B: Full-time AWD 5-speed MT dual range OUTBACK
10 3 Model year 3: 2003MY
4: 2004MY
5: 2005MY
11 G Factory location G: FHI (Gunma)
12 to 17 002001 Serial number —
ID-3
IDENTIFICATION
IDENTIFICATION
• GCC countries (Saudi Arabia, etc.)

]JF1BE54MX3G002001[
The starting and ending brackets ( ][ ) are stop marks.
1 to 3 JF1 Manufacturer body area JF1: Passenger car, FHI made
4 B Car line Legacy/OUTBACK series
5 E Body type E: Sedan
6 5 Displacement 5: 2.0 L AWD
9: 2.5 L AWD
7 4 Grade 4: GL
6: GX
8: OUTBACK
8 M Restraint M: Manual belts, dual airbag
9 X Check digit 0—9&X
10 3 Model year 3: 2003MY
4: 2004MY
5: 2005MY
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 —
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.
BE9EL7J
1 B Series B: Legacy/OUTBACK
2 E Body style E: Sedan
3 9 Engine displacement 5: 2.0 L AWD
Drive system 9: 2.5 L AWD
Suspension system E: 3.0 L AWD
4 E Minor change 2003MY
5 L Destination K: RHD (Right-hand drive)
L: LHD (Left-hand drive)
6 7 Grade 4: GL
7: GX
9: B4
B: OUTBACK
C: OUTBACK — 6 cylinders
7 J Transmission, fuel feed E: DOHC MPI 4-speed AT
system J: SOHC MPI center differential
R: SOHC MPI 4-speed AT
D: DOHC MPI TURBO center differential
T: DOHC MPI TURBO 4-speed AT-SS
ID-4
IDENTIFICATION
IDENTIFICATION
The engine and transmission type are as follows:

• Engine
EJ251NJEAA
1 and 2 EJ Engine type EJ: 4 cylinders
EZ: 6 cylinders
3 and 4 25 Displacement 20: 2.0 L
25: 2.5 L
30: 3.0 L
5 1 Fuel feed system 1: D-MPI SOHC-A
6: MPI TWIN TURBO
8: MPI HI-POWER TWIN TURBO
D: D-MPI DOHC 6 cylinders
6 N Detailed specifications —
7 J Transmission W: AWD MT (Flexible)
J: AWD MT (Dual mass)
X: AWD AT
8 to 10 EAA Detailed specifications Used when ordering parts. See the parts catalog for details.
• Transmission
TY754VFBAA
1 T Transmission T: Transmission
2 Y Transmission type Y: Full-time AWD MT center differential
V: Full-time AWD AT VTD
Z: Full-time AWD AT MPT
3 and 4 75 Classification 75: MT
1A, 1B: AT
5 4 Series 4: 5th Generation Legacy
6 V Transmission specifica- V: Full-time AWD 5-speed MT with viscous coupling center dif-
tions 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 F Engine type S, R: 920SO
F: 925SO
B, N: 920DO TURBO
M: 930DO
8 to 10 BAA Detailed specifications Used when ordering parts. See the parts catalog for details.
• Rear differential 1
VA1REG
1 V For AWD V: AWD
2 A Type A: A type
3 1 Hypoid gear diameter 1: 152 dia.
4 R Installation position R: Rear
5 E Reduction gear ratio E: 4.111
6 G Specification differ- G: Case B
ences H: Case B with cooling fin
ID-5
IDENTIFICATION
IDENTIFICATION
• Rear differential 2 • Option code

T1 ECPS
Code Reduction LSD Digits Code Meaning Details
gear ratio 1 to 2 EC Destination EC: EC
T1 3.900 No KO: KO
T2 4.111 No K4: K4
TP 4.444 No KS: KS
EK: EK
BL 4.444 No (Strengthened type)
KA: KA
VB 3.700 No K1: K1
CF 4.444 Viscous 3 to 4 PS Main options –
JP 4.111 Viscous on vehicle
ID-6
RECOMMENDED MATERIALS
RM
Page
1. Recommended Materials ............................................................................2
1. Recommended Materials • Unleaded gasoline

Use unleaded gasoline and not leaded gasoline on
A: RECOMMENDED MATERIALS vehicles with catalytic converter installed to reduce
1. GENERAL air pollution. Using leaded gasoline will damage the
catalytic converter.
To insure the best performance, always use the
specified oil, gasoline, adhesive, sealant, etc. or a Model Petrol RON
substitute of equivalent quality. More than 95 RON
2.0 L, 2.5 L Unleaded
More than 90 RON*
2. FUEL
TURBO Unleaded More than 98 RON
Always use a gasoline of the same or higher octane 3.0 L Unleaded More than 95 RON
value than specified in the owner's manual. Ignor-
ing the specifications below will result in damage or *: Australia specification
poor operation of the engine and fuel injection sys- • Leaded gasoline
tem. Use the specified gasoline to correct perfor- On vehicles without catalytic converter, use leaded
mance. gasoline with an octane value of 90 RON or higher.
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 or SJ Grade “Energy conserving” G4 or G5 A1, A2 or A3 SG,SF
SERVICE S
PI
A
SAE
5W-30
EN
NG
R
E
VI
GY R
CONS E
RM-00001
T R OL E U M
PE
N
IN
FOR
AM E RIC A
ST
IT UT E
GASOLINE
ENGINES
C D
ER
T I F IE
RM-00002
Manual transmission oil GL-5 — — —
AT front differential gear oil GL-5 — — —
Rear differential gear oil GL-5 — — —
RM-2
SAE viscosity No. and applicable temperature

Engine oil
(˚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
Manual transmission oil and rear differential gear oil
(˚C) –30 –20 –10 0 10 20 30 40
(˚F) –22 –4 14 32 50 68 86 104
90
85W
80W
75W-90
RM-00004
RM-3
SAE viscosity No. and applicable temperature

AT front differential gear oil
(˚C) –30 –20 –10 0 10 20 30 40
(˚F) –22 –4 14 32 50 68 86 104
90
85W
80W
80W-90
RM-00005
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 FMVSS No. 116 DOT4
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
6. REFRIGERANT
Standard air conditioners on Subaru vehicles use HFC134a refrigerant. Do not mix it with other refrigerants.
Also, do not use any air compressor oil except for ZXL200PG.
Air conditioner Recommended Item number Alternative
Refrigerant HFC134a — None
Compressor oil ZXL200PG — None
RM-4
7. GREASE
Use the grease and supplementary lubricants shown in the table below.
Grease Application point Recommended Item number Alternative
Supplementary lubricants • O2 sensor SUBARU CRC 004301003 —
• Bolts, etc.
Grease MT main shaft FX clutch grease 000040901 —
Clutch master cylinder push rod Slicolube G-40M 004404003 —
• Gear shift lever SUNLIGHT2 003602010 —
• Select lever
• Clutch operating cylinder
• Accelerator pedal
• Clutch pedal
• Brake pedal
• Clutch bearing
• Clutch release lever
• Steering shaft bearing
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 SFJ SSG-6003 28093TA000 —
Front axle BJ NTG2218 28093AA000 —
Rear axle BJ Molylex No. 2 003601001 —
Rear axle DOJ VU-3A702 23223GA050 —
• Throttle cable end Slicolube G-30M 004404002 —
• Door latch
• Door striker
8. ADHESIVES
Use the adhesives shown in the table below, or equivalent.
Adhesive Application point Recommended Item number Alternative
Adhesive Windshield and body Essex Chemical Crop's Urethane E — Sunstar 580
Soft vinyl Cemedine 540 — 3M's EC-776 EC-847 or EC-1022 (Spray
type)
Momentary sealant Cemedine 3000 — Armstrong's Eastman 910
9. SEAL MATERIAL
Use seal material shown in the table below, or equivalent.
Seal material Application point Recommended Item number Alternative
• Cylinder block Three Bond 1215 004403007 Dow Corning's No. 7038
• Torque converter clutch case
Transmission oil pan Three Bond 1217B K0877YA020 —
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 —
• H6 oil pan, chain cover
• Front sealing cover 3 M Butyl Rubber — —
• Rear sealing cover 8626
RM-5
MEMO:
RM-6
PRE-DELIVERY INSPECTION
PI
Page
1. Pre-delivery Inspection................................................................................2
1. Pre-delivery Inspection
A: GENERAL
The purposes of the pre-delivery inspection (PDI)
are as follows.
• Remove the additional parts used for ensuring
the vehicle quality during transportation and restore
the vehicle to its normal state.
• Check if the vehicle before delivery is in a normal
state.
• Check for any damage or missing parts that may
have taken place during transportation or storage.
• Make sure to provide a complete vehicle to the
customer.
Because of the above reasons, all dealerships
must always carry out the PDIs before delivering a
vehicle.
In addition, all franchised shops and PDI centers
must check the status of every vehicle received to
identify who is responsible for any possible defects.
PI-2
B: PDI PROCEDURE
Follow the procedures shown in the table below.
Static Checks Just After Vehicle Receipt
Step Check point
1. Appearance check (1) If the vehicle is covered with protective film, visually check the vehicle
body for damage and dents.
(2) If the protective film has been removed, visually check the body paints for
small areas of damage or stains.
(3) Visually check the glass and light lenses for any damage and cracks or
excessive gaps to the body sheet metal.
(4) 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 (1) If the vehicle is about to be delivered to the customer, attach a fuse.
4. Connection of air conditioner cut connector (1) If the vehicle is about to be delivered to the customer, connect air condi-
tioner cut connector or air conditioner harness.
5. Check the doors for lock/unlock and open/close (1) Using the key, check if the door can be locked and unlocked normally.
operations. (2) Open and close the all doors to see that there are no abnormal condi-
tions.
6. Operation check of child lock system (1) Inspect whether child lock system operates properly.
7. Check the trunk lid open/close operations. (1) Operate the trunk lock release lever to check that the trunk opens nor-
mally.
(2) Using the key, check if the trunk lid can be unlocked normally.
(3) Open and close the trunk lid to see that there are no abnormal conditions.
8. Check the rear gate for lock/unlock and open/ (1) Using the key, check if the rear gate can be lock and unlocked normally.
close operations. (2) Open and close the rear gate to see that there are no abnormal condi-
tions.
(3) Operate the power door locking switch to check that the rear gate is
locked and unlocked normally.
9. Operation check of fuel lid opener lock release (1) Operate the fuel lid opener to check that the fuel lid is unlocked normally.
lever
10. Accessory check Check the following accessories are provided:
• Owner's manual
• Warranty booklet
• Service booklet
• Spare key
• Jack
• Tool set
• Spare tire
11. Operation check of hood lock release system (1) Operate the hood lock release lever to check that the hood opens nor-
mally.
12. Battery (1) Check the battery for any abnormal conditions such as rust and trace of
battery fluid leaks.
13. Brake fluid (1) Check the fluid amount.
14. Engine oil (1) Check the oil amount.
15. Transmission fluid (1) Check the fluid amount.
16. AT front differential oil (1) Check the AT front differential oil amount.
17. Coolant (1) Check the coolant amount.
18. Clutch fluid (1) Check the clutch fluid amount.
19. Window washer fluid (1) Check the window washer fluid amount.
20. Hood latch check (1) Check that the front hood is closed and latched securely.
21. Keyless entry system (1) Check that the keyless entry system operates normally.
22. Seat (1) Check the seat surfaces for smears or dirt.
(2) Check the seat installation conditions and functionality.
23. Seat belt (1) Check the seat belt installation conditions and functionality.
24. Wheel alignment (1) Check that the wheel alignments are properly adjusted.
PI-3
Checks with the Engine Running

Step Check point
1. Test mode connector (1) Disconnect the test mode connector.
2. Starting condition (1) Start the engine and check that the engine starts smoothly.
3. Exhaust system (1) Check that the exhaust noise is normal and no leaks are found.
4. Indicator light (1) Check that all the indicator lights operate normally.
5. Clock (1) Check that the clock operate normally.
6. Radio (1) Check that the radio system operates normally.
7. Cigarette lighter (1) Check that the cigarette lighter operates normally.
8. Lighting system (1) Check that the lighting systems operate normally.
9. Window washer (1) Check that the window washer system operates normally.
10. Wiper (1) Check that the wiper system operates normally.
11. Power window operation check (1) Check the power window for correct operations.
Dynamic Test with the Vehicle Running

Step Check point
1. Brake test (1) Check that the foot brake operates normally.
2. Parking brake (1) Check that the parking brake operates normally.
3. AT shift control (1) Check the AT shift patterns are correct.
4. Heater & ventilation (1) Check that the heater & ventilation system operates normally.
5. Air conditioner (1) Check that the air conditioner operates normally.
6. Cruise control (1) Check that the cruise control system operates normally.
Checks after Dynamic Test

Step Check point
1. ATF level (1) Check that the ATF level is normal.
2. Power steering fluid level (1) Check that the power steering fluid level is normal.
3. Fluid leak check (1) Check for fluid/oil leaks.
4. Water leak check (1) Spray the vehicle with water and check for water leaks.
5. Appearance check 2 (1) Remove the protective film (if any).
(2) Check the body paints for damage and smears.
(3) Check that no crack and no damage are found on glass or light lens.
(4) Check the plated parts for damage and rust.
PI-4
1. APPEARANCE CHECK 3.0 L model

1) When vehicle is covered with protective film, in-
spect visually for damage or dents to vehicle body
surface.
2) When protective film is removed, check the body
paints for small areas of damage or stains and re-
pair as necessary.
3) Check the window glass, door glass, and lights
for any cracks or damage and repair or replace the
parts as necessary.
4) Check the plated parts, such as the grilles and PI-00115
door knobs, for damage or loss of gloss and repair
or replace the parts as necessary. Except 3.0 L model
2. TIRE CHECK
• Check the tire outer faces for any damage.
• Check the tire air pressure by referring to the fol-
lowing table.
Tire size Tire inflation pressure
kPa (kg/cm2, psi)
Front Rear
195/60R15 220 (2.2, 32) 210 (2.1, 30)
205/50R16 230 (2.3, 33) 220 (2.2, 32) PI-00002
215/60R16 200 (2.0, 29) 190 (1.9, 28)
215/45ZR17 230 (2.3, 33) 220 (2.2, 32) 5. CHECK THE DOOR OPERATIONS,
LOCK/UNLOCK AND OPEN/CLOSE, AS
3. FUSE INSTALLATION FOLLOWS.
A vehicle just delivered has no fuses for the room Using the key, lock and unlock the door several
lamp circuit to prevent battery discharge. Attach a times to check for normal operation. Open and
15 A fuse as shown in the figure. close the door several times for smooth movement.
(A)
(B)
(A) PI-00087
PI-00085
4. CONNECTION OF AIR CONDITIONER (A) Unlock

CUT CONNECTOR (B) Lock
A vehicle just delivered has its air conditioner cut • Vehicles with manual door locks:
connector or air conditioner haness disconnected
to protect the air conditioner compressor. Connect Sit in all the seats, close the door completely, and
as shown in the figure. move the lock lever to the lock position. Then, pull
the inside door handle to ensure the door will not
open.
PI-5
• Vehicles with power door locks: • Using the key, open the trunk lid several times to
Sit in the driver seat, close the driver's door com- check for normal operation.
pletely, and place the lock lever to the lock position. • Open and close the trunk lid several times for
Then pull the all inside door handles to ensure that smooth movement.
the all doors will not open.
For other doors, place the lock levers to the lock po-
sitions and then pull the inside door handles to en-
sure that the doors will not open.
(A)
(A)
PI-00089
(A) Open
(B) • Set the trunk lid release lever to the cancel posi-
PI-00088
tion, and check that the trunk lid can only be
opened with the key.
(A) Lock lever
(B) Inside door handle
6. CHECK THE OPERATION OF CHILD

SAFETY LOCKS
1) Set the child safety lock on both rear doors to the
lock positions.
2) Close the rear doors completely.
3) Check that the lock levers of the rear doors are in
the unlock positions. Then, pull the inside door han-
PI-00090
dles of the rear doors to ensure that the doors will
open. 8. CHECK THE REAR GATE OPERATIONS,
4) Next, pull the outside door handles of the rear
LOCK/UNLOCK AND OPEN/CLOSE, AS
doors to ensure that the doors will open.
FOLLOWS.
• Using the key, lock and unlock the rear gate sev-
eral times to check for normal operation.
(C) • Open and close the rear gate several times for
(A) smooth movement.
(B)
PI-00084
(A) Unlock
(A)
(B) Lock (B)
(C) Child safety lock
PI-00091
7. CHECK THE TRUNK LID OPERATIONS,
OPEN/CLOSE, AS FOLLOWS. (A) Lock
(B) Unlock
• Operate the trunk lock release lever and verify
that the trunk lid opens. • Operate the lock lever to check that the rear gate
is locked and unlocked normally.
PI-6
9. OPERATION CHECK OF FUEL LID 11. OPERATION CHECK OF HOOD LOCK

OPENER LOCK RELEASE LEVER RELEASE SYSTEM
Operate the fuel lid opener and verify that the fuel By operating front hood release knob, confirm front
lid opens normally. Check that the filler cap is se- hood will unlock properly.
curely closed.
10. ACCESSORY CHECK
Check that the following accessories are provided
in the luggage compartment or cargo area.
• Owner's manual
• Warranty booklet
• Service booklet
• Spare key
• Jack
• Tool set PI-00096
• Spare tire By operating lever, confirm front hood will open

Sedan properly. Next, support the front hood with front
hood stay.
(A)
(B)
PI-00094
PI-00097
(A) Jack
(B) Jack handle 12. BATTERY
Wagon Check the battery terminals to make sure that no
rust or corrosions due to fluid leaks are found.
Check that the battery cap is securely tightened.
(A)
(A)
(B)
(B)
PI-00095
(C)
PI-00012
(A) Jack
(B) Jack handle
(A) Cap
(B) Upper level
(C) Lower level
PI-7
13. BRAKE FLUID 16. AT FRONT DIFFERENTIAL OIL

Check the brake fluid amount. If the amount is in- Check the AT front differential oil amount. If the
sufficient, carry out a brake line test to identify amount is insufficient, check that no leaks are
brake fluid leaks and check the brake operation. Af- found. Then, add the necessary amount of the
ter that, refill the brake fluid tank with the specified specified AT front differential oil.
type of fluid.
14. ENGINE OIL
Check the engine oil amount. If the amount is insuf- (B) (A)
ficient, check that no leaks are found. Then, add (C)
the necessary amount of the specified engine oil.
(F)
(A)
(B)
(C) PM-00035
F
(E)
(A) Oil level gauge
L
(D)
(B) Upper level
(C) Lower level
PI-00116 17. COOLANT

Check the coolant amount on the reservoir. If the
(A) Oil level gauge
amount is insufficient, check that no leaks are
(B) Engine oil filler cap
found. Then, add the necessary amount of coolant
(C) Upper level with the specified concentration.
(D) Lower level
(E) Approx. 1.02 (1.1 US qt, 0.9 Imp qt) 18. CLUTCH FLUID
Check the clutch fluid amount. If the amount is in-
15. TRANSMISSION FLUID sufficient, check that no leaks are found. Then, add
Check the transmission fluid amount. If the amount the necessary amount of the specified fluid.
is insufficient, check that no leaks are found. Then,
add the necessary amount of the specified fluid. (A)
(C)
(A)
(B) (B)
(C)
PI-00099
PM-00030 (A) Reservoir tank

(B) MIN level
(A) Oil level gauge (C) MAX level
(B) Upper level
(C) Lower level 19. WINDOW WASHER FLUID
Check the window washer fluid amount. If the
amount is insufficient, check that no leaks are
found. Then, add the necessary amount of washer
fluid commercially available.
PI-8
20. FRONT HOOD LATCH CHECK 24. WHEEL ALIGNMENT

Retract the front hood stay and close the hood. Check the wheel alignments. <Ref. to FS-6, Wheel
Check that the front hood is securely latched. Alignment.> and <Ref. to RS-8, Wheel Align-
ment.>
21. KEYLESS ENTRY SYSTEM
Check the keyless entry system operations as fol- 25. TEST MODE CONNECTOR
lows. Turn the ignition switch to ON and check that the
• Remove the key from the ignition switch and check-engine light starts blinking. If the light blinks,
close all the doors including rear gate (wagon). return the ignition key to LOCK and disconnect the
• Press the “LOCK” button on the transmitter mo- test mode connector. Then, turn the ignition key to
mentarily once and check if all the doors are locked ON again. If the check-engine light blinks at that
and the hazard light flashes ones. time in spite of the disconnected test mode connec-
tor, carry out an engine diagnosis.
With OBD model
(A)
PI-00117
PI-00119
(A) Test mode connector (Green)
Without OBD model
(B)
PI-00118
• Press the “OPEN” button on the transmitter mo-

mentarily once and check if the driver's door is un- (A)
locked, the hazard light flashes twice and the dome
light illuminates.
PI-00120
• Close all doors and rear gate, press the “LOCK”
button of the transmitter. Press the “OPEN” button
(A) Test mode connector (Green)
of the transmitter and wait for 30 seconds. Check
that all doors and the rear gate are automatically (B) Lead memory connector (Black)
locked again.
22. SEAT
Check that each seat provides full functionality in
sliding and reclining. Check all available functions
of the rear seat such as a trunk-through center arm
rest.
23. SEAT BELT
Pull out the seat belt and then release it. Check that
the belt webbing retracts smoothly.
PI-9
26. STARTING CONDITION Front

Injection position:
Start the engine and check that the engine starts
smoothly. If any battery voltage problems are A: 350 mm (13.78 in)
found, recharge or replace the battery. If any ab- B: 150 mm (5.91 in)
normal noises are observed, immediately stop the C: 300 mm (11.81 in)
engine and check and repair the necessary compo- D: 600 mm (23.62 in)
nents.
27. EXHAUST SYSTEM A A
B B
Listen to the exhaust noise to see if no abnormal
noises are observed.
28. INDICATOR LIGHT
Check that all the indicator lights are off.
29. CLOCK C D
PI-00121
Check the clock for normal operations and enough
accuracy.
Rear
30. RADIO Injection position:
Check the radio for full functionality and normal A: 60 mm (2.36 in)
noise level. Also check the CD unit operations. B: 42°
31. CIGARETTE LIGHTER

Check that the cigarette lighter operations.
A
32. LIGHTING SYSTEM
• Check the headlight operations.
• Check the brake light operations.
B
• Check the other lights for normal operations.
33. WINDOW WASHER
PI-00104
• Before inspection of the window washer system,
connect the washer connector to the washer motor. 34. WIPER
Check the front and rear wipers for normal opera-
tions.
35. POWER WINDOW OPERATION CHECK
Manipulate the power window switches one by one
to check that each of the power windows goes up
and down with no abnormal noises.
36. BRAKE TEST
PI-00102 Check the foot brake for normal operations.
• Check that the window washer system injects 37. PARKING BRAKE
washer fluid to the specified area of the windshield Check the parking brake for normal operations.
shown in the figure.
NOTE:
If the washer fluid does not cover the specified ar-
ea, clean the nozzle.
PI-10
38. AT SHIFT CONTROL 42. ATF LEVEL

Set the AT select lever to each gear position while Check that the ATF level is normal. If insufficient,
checking that the demanded gear position is cor- check that no leaks are found. Then add the neces-
rectly attained. sary amount of the specified ATF.
• Except SPORT shift
(A)
F
(C)
HOT
(B)
L
R (D)
N
D
F
3 (C)
COLD
(E)
L
2 (D)
1
PI-00105
AT-00413
(A) Level gauge
• SPORT shift
(B) “HOT” side
(C) Upper level
(D) Lower level
(E) “COLD” side
P
R 43. POWER STEERING FLUID LEVEL

N
D Check that the power steering fluid level is normal.
3
2 If insufficient, check that no leaks are found. Then
1
add the necessary amount of the specified power
steering fluid.
AT-00761
(A)
Selector Position Gear Position
1st 2nd 3rd 4th
D Yes Yes Yes Yes
(C)
3 Yes Yes Yes
2 Yes
1 Yes
(B)
SPORT shift Yes Yes Yes Yes
PI-00070
39. HEATER & VENTILATION
Operate the heater and ventilation system to check (A) Reservoir tank
for normal airflow and heating capacity. (B) MIN level
40. AIR CONDITIONER (C) MAX level
Operate the air conditioner. Check that the A/C 44. FLUID LEAK CHECK
compressor operates normally and enough cooling
is provided. Check the entire areas of the vehicle for any trace
of coolant/oil/fluid leaks.
41. CRUISE CONTROL
Operate the cruise control system. Check that the
system is activated and deactivated correctly.
PI-11
45. WATER LEAK TEST • It is desirable not to make corrections to the body
paint unless absolutely needed. However, if any
Spray the vehicle with water and check that no wa-
corrections are required to remove scratches or
ter enters the passenger compartment.
rust, the area to be corrected must be limited as
• Before performing the water leakage test, re-
much as possible. Re-painting and spray painting
move anything that may obstruct the operation or
must be avoided whenever possible.
which must be kept dry.
• Close all of the windows completely, and then 3) Carefully check each window glass for scratch-
close all of the doors tightly. Close the hood and es. Slight damage may be removed by polishing
trunk lid before starting the test. with cerium oxide. (Half-fill a cup with cerium oxide,
• Connect a hose to a tap, and spray water on the and add warm water to it. Then agitate the content
vehicle. The rate of water discharge must be ap- until it turns to wax. Apply this wax to a soft cloth,
prox. 20 to 25 liters (5.3 to 6.6 US gal, 4.4 to 5.5 and polish the glass.)
Imp gal) per minute. 4) Check each portion of the vehicle body and un-
When spraying water on areas adjacent to the floor derside components for the formation of rust. If rust
and wheel house, increase the pressure. When di- is discovered, remove it with #80 — #180 emery
recting water on areas other than the floor portion paper, and treat the surface with rust preventive.
and wheel house, decrease the pressure. But the After this treatment is completed, flush the portion
force of water must be made strong occasionally by thoroughly, and prepare the surface for repair
pressing the end of the hose. painting.
5) Check each portion of the body and all of the
NOTE: chrome parts for deformation or distortion. Also
Be sure to keep the hose at least 10 cm (3.9 in) check each lamp lens for cracks.
from the vehicle.
• Check the following areas:
• Front window and body framework mating
portion
• Door mating portions
• Glass mating portions
• Rear quarter window mating portions
• Rear window and body framework mating
portion
• Around roof drips
• If any dampness in the compartments is discov-
ered after the water has been applied, carefully
check all areas that may have possibly contributed
to the leak.
46. APPEARANCE CHECK 2
1) Check the paint after removing the paint protec-
tive coating and washing the vehicle.
NOTE:
Before removing the protective coating, be sure to
wash the vehicle, because the painted surface may
be scratched if the surface is rubbed with sand or
other hard particles which may be attached to the
protective coating.
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.
PI-12
PERIODIC MAINTENANCE SERVICES
PM
Page
1. General Description ....................................................................................2
2. Schedule .....................................................................................................3
3. Engine Oil....................................................................................................7
4. Engine Oil Filter...........................................................................................9
5. Spark Plugs...............................................................................................10
6. Drive Belt(s) ..............................................................................................12
7. Camshaft Drive Belt ..................................................................................15
8. Fuel Line ...................................................................................................18
9. Fuel Filter ..................................................................................................19
10. Air Cleaner Element ..................................................................................20
11. Cooling System .........................................................................................21
12. Coolant......................................................................................................22
13. Clutch System ...........................................................................................24
14. Hill-holder System .....................................................................................25
15. Idle Mixture................................................................................................26
16. Transmission Oil .......................................................................................27
17. ATF ...........................................................................................................28
18. Front & Rear Differential Oil ......................................................................30
19. Brake Line .................................................................................................32
20. Brake Fluid ................................................................................................34
21. Disc Brake Pads and Discs.......................................................................35
22. Parking Brake............................................................................................36
23. Suspension ...............................................................................................38
24. Wheel Bearing...........................................................................................40
25. Axle Boots & Joints ...................................................................................41
26. Tire Rotation..............................................................................................42
27. Steering System (Power Steering)............................................................43
GENERAL DESCRIPTION
1. General Description
A: GENERAL
Be sure to perform periodic maintenance in order to
maintain vehicle performance and find problems
before they become serious.
PM-2
SCHEDULE
2. Schedule
A: MAINTENANCE SCHEDULE 1
1. EUROPE
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]
Months 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 For 3.0 L R R R R R R R R R
Others R R R R R R R R
2 Engine oil filter For 3.0 L R R R R R R R R R
Others R R R R R R R R
3 Spark plug For 3.0 L R
Others R R R R
4 Drive belt(s) I I I I I I I I For 3.0 L model,
replace every
160,000 km
(100,000 miles).
5 Camshaft drive belt R
6 Fuel line I I I I
7 Fuel filter 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 I I I I
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 Disc brake pads & discs I I I I I I I I
19 Parking brake I I I I
20 Suspension I I I I
21 Wheel bearing (I)
22 Axle boots & joint I I I I I I I I
23 Steering system I I I I
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 maintenance free part. ATF filter needs replacement, when it is physically damaged or ATF leaked.
(3) Periodic inspection and replacement of the camshaft drive chains on the 3.0 L models is not required.
PM-3
SCHEDULE
2. EXCEPT EUROPE
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
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 For 3.0 L R R R R R
Others R R R R
2 Engine oil filter For 3.0 L R R R R R
Others 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
Months 12 24 36 48 Remarks
× 1,000 km 1.6 25 50 75 10
0
× 1,000 miles 1 15 30 45 60
3 Spark plugs For Turbo and 3.0 L R
Others R R R R
4 Drive belt(s) I I I I For 3.0 L model, replace every 160,000 km (100,000
miles).
5 Camshaft drive belt R
6 Fuel line I I
7 Fuel filter R
8 Air cleaner element I R I R
9 Cooling system I I
10 Coolant R R
11 Idle mixture I I I I In case of model without catalytic converter
12 Clutch system I I I I
13 Hill-holder system I I I I
14 Transmission oil R R
15 ATF R R
16 Front & rear differential oil I I
17 Brake line R R
18 Brake fluid R R
19 Disc brake pads & discs I I I I
20 Parking brake I I
21 Suspension I I I I
22 Wheel bearing (I)
23 Axle boots & joint I I I I
24 Steering system (Power steering) I I I I
Symbols used: NOTE:
R: Replace (1) When the vehicle is used in extremely dusty conditions,
I: Inspection the air cleaner element should be replaced more often.
(I): Recommended service for safe vehicle operation. (2) ATF filter is maintenance free part. ATF filter needs
replacement, when it is physically damaged or ATF leaked.
(3) Periodic inspection and replacement of the camshaft drive
chains on the 3.0 L models is not required.
PM-4
SCHEDULE
B: MAINTENANCE SCHEDULE 2
1. EUROPE
Item Every Repeat short Repeat Extremely Salt or other High humid- Repeat tow-
distance drive rough/muddy cold weather corrosive ity or moun- ing trailer
road drive area used or tain area
coastal area
Engine oil Replace Replace Replace
more fre- more fre- more fre-
quently quently quently
Engine oil filter Replace Replace Replace
Fuel line 12 months I
15,000 km
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 I I I
15,000 km
9,000 miles
Brake fluid 12 months R
15,000 km
9,000 miles
Brake pads 12 months I I I I
15,000 km
9,000 miles
Parking brake 12 months I I I I
15,000 km
9,000 miles
Suspension 12 months I I I
15,000 km
9,000 miles
Axle boots & 12 months I I I I
joints 15,000 km
9,000 miles
Steering system 12 months I I I
(Power steering) 15,000 km
9,000 miles
PM-5
SCHEDULE
2. EXCEPT EUROPE
Item Every Repeat short Repeat Extremely Salt or other High humid- Repeat tow-
distance drive rough/muddy cold weather corrosive ity or moun- ing trailer
road drive area used or tain area
coastal area
Engine oil Replace Replace Replace
Engine oil filter Replace Replace Replace
Fuel line 6 months I
12,500 km
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 I I I
12,500 km
7,500 miles
Brake fluid 12 months R
25,000 km
15,000 miles
Brake pads 6 months I I I I
12,500 km
7,500 miles
Parking brake 6 months I I I I
12,500 km
7,500 miles
Suspension 6 months I I I
12,500 km
7,500 miles
Axle boots & 6 months I I I I
joints 12,500 km
7,500 miles
Steering system 6 months I I I
(Power steering) 12,500 km
7,500 miles
PM-6
ENGINE OIL
3. Engine Oil 3.0 L model
A: REPLACEMENT (B)
(A)
NOTE: (C)
F
Replace engine oil and engine oil filter at the same (E)
time.
L
(D)
1) Drain engine oil by loosening engine oil drain
plug.
Except 3.0 L model
PM-00106
(A) Oil level gauge

(B) (B) Engine oil filler cap
(C) Upper level
(D) Lower level
(E) About 1.0 2 (1.1 US qt, 0.9 imp qt)
(F) Notch
(A) PM-00104
3) Replace drain plug gasket.
(A) Drain plug
4) Tighten engine oil drain plug after draining en-
gine oil.
(B) Oil filter
Tightening torque:
3.0 L model 44 N·m (4.5 kgf-m, 33 ft-lb)
5) Fill engine oil through filler pipe up to upper point
on level gauge. Make sure that vehicle is placed
level when checking oil level. Use engine oil of
proper quality and viscosity, selected in accor-
dance with the table in figure.
Engine oil amount for preparation:
(A) 2.0 L non-turbo and 2.5 L models
Approx. 4.0 2 (4.2 US qt, 3.5 Imp qt)
2.0 L turbo model
PM-00105 Approx. 4.5 2 (4.8 US qt, 4.0 Imp qt)
3.0 L model
(A) Drain plug Approx. 5.6 2 (5.9 US qt, 4.9 Imp qt)
2) Open engine oil filler cap for quick draining of the
engine oil.
Except 3.0 L model SAE Viscosity No. and Applicable Temperature
(˚C) –30 –20 –15 0 15 30 40
(F) (˚F) –22 –4 5 32 59 86 104
(B)
(A) 10W-30, 10W-40
(C) 5W-30 PREFERRED

F
(E)
PM-00107
L
(D)
PM-00144
PM-7
ENGINE OIL
The proper viscosity helps vehicle get good cold 3.0 L model
and hot starting by reducing viscous friction and
(B)
thus increasing cranking speed.
(A)
NOTE: (C)
F
• When replenishing oil, it does not matter if the oil (E)
to be added is a different brand from that in the en-
L
(D)
gine; however, use oil having the API classification,
and SAE viscosity No. designated by SUBARU.
• If vehicle is used in desert areas with very high
temperatures or for other heavy duty applications,
the following viscosity oils may be used:
PM-00106
API classification: SL
SAE Viscosity No.: 30, 40, 10W-50, 20W-40, 20W-
(A) Oil level gauge
50
6) Close engine oil filler cap.
(C) Upper level
7) Start engine and warm it up for a time.
(D) Lower level
8) After engine stops, recheck the oil level.
(E) About 1.0 2 (1.1 US qt, 0.9 imp qt)
If necessary, add engine oil up to upper level on
level gauge. B: INSPECTION
Except 3.0 L model
1) Park vehicle on a level surface.
(F) 2) Remove oil level gauge and wipe it clean.
(B)
3) Reinsert the level gauge all the way. Be sure that
(A) the level gauge is correctly inserted and in the
(C) proper orientation.
F
4) Remove it again and note the reading. If the en-

(E)
gine oil level is below the “L” line, add oil to bring
the level up to the “F” line.
L
(D)
5) After turning off the engine, wait a few minutes
for the oil to drain back into the oil pan before
PM-00144 checking the level.
6) Just after driving or while the engine is warm, en-
(A) Oil level gauge gine oil level may show in the range between the
“F” line and the notch mark. This is caused by ther-
mal expansion of the engine oil.
(C) Upper level
7) To prevent overfilling the engine oil, do not add
(D) Lower level
oil above the “F” line when the engine is cold.
(E) Approx. 1 2 (1.1 US qt, 0.9 Imp qt)
(F) Notch mark
PM-8
ENGINE OIL FILTER
4. Engine Oil Filter 2) Remove under cover.

3) Remove oil filter with ST.
A: REPLACEMENT ST 498547000 OIL FILTER WRENCH
1. EXCEPT 3.0 L MODEL
1) Remove oil filter with ST.
ST 498547000 OIL FILTER WRENCH
(B)
PM-00109
4) Get a new oil filter and apply a thin coat of engine

oil to the rubber seal.
(A) PM-00104 5) Install oil filter by turning it by hand, being careful
not to damage rubber seal.
(A) Drain plug 6) Tighten more (approximately 2/3 to 3/4 turn) af-
(B) Oil filter
ter the rubber seal contacts the oil cooler. Do not
tighten excessively, or oil may leak.
2) Get a new oil filter and apply a thin coat of engine 7) After installing oil filter, run engine and make
oil to the seal rubber. sure that no oil is leaking around rubber seal.
3) Install oil filter by turning it by hand, being careful NOTE:
not to damage seal rubber. The filter element and filter case are permanently
4) Tighten more (approximately 2/3 to 3/4 turn) af- jointed; therefore, interior cleaning is not neces-
ter the seal rubber contacts the cylinder block. Do sary.
not tighten excessively, or oil may leak. 8) Fill the engine oil. <Ref. to PM-7, Engine Oil.>
5) After installing oil filter, run 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.
6) Check the engine oil level. <Ref. to PM-7, En-
gine Oil.>
2. 3.0 L MODEL
1) Drain engine oil by loosening engine oil drain
plug.
(A)
PM-00105
(A) Drain plug
PM-9
SPARK PLUGS
5. Spark Plugs 2. 2.0 L TURBO AND 3.0 L MODEL

A: REPLACEMENT 1) Disconnect battery cables and then remove bat-
tery and battery carrier.
1. 2.0 L NON-TURBO AND 2.5 L MODEL 2) Remove washer tank and put it aside.
1) Disconnect battery ground cable. 3) Remove air cleaner lower case.
2) Remove intake duct and intake chamber. 4) Disconnect connector from ignition coil.
3) Remove washer tank and put it aside. 5) Remove ignition coil.
4) Disconnect spark plug cord. • 3.0 L model
5) Remove spark plug with a plug-wrench.
PM-00111
PM-00110 • Turbo model

6) Set new spark plug.
Recommended spark plug :
With OBD
CHAMPION RC10YC4
CHAMPION RC8YC4
NGK BKR6E-11
NIPPONDENSO K20PR-U11
Spark plug gap
1.0 — 1.1 mm (0.039 — 0.043 in)
PM-00145
Without OBD
NGK BKR6E (Without catalytic converter) 6) Remove spark plug with a spark plug socket.
CHAMPION RC10YC4 (With catalytic con-
verter)
NGK BKR5E-11 (With catalytic converter)
Spark plug gap
0.7 — 0.8 mm (0.028 — 0.031 in) (Without
catalytic converter)
1.0 — 1.1 mm (0.039 — 0.043 in) (With cat-
alytic converter)
7) Tighten spark plug lightly with hand, and then
secure with a plug-wrench to the specified torque.
PM-00112
Tightening torque:
21 N·m (2.1 kgf-m, 15 ft-lb) 7) Set new spark plug.
NOTE: Recommended spark plug:
• Be sure to place the gasket between the cylinder • 3.0 L model
head and spark plug. NGK PLFR 6A-11
• If torque wrench is not available, tighten spark • Turbo model
plug until gasket contacts cylinder head; then tight- NGK PFR 6G
en further 1/4 to 1/2 turns. 8) Tighten spark plug lightly with hand, and then
secure with a plug-wrench to the specified torque.
Tightening torque:
21 N·m (2.1 kgf-m, 15 ft-lb)
PM-10
SPARK PLUGS
9) Tighten ignition coil.

Tightening torque:
16 N·m (1.6 kgf-m, 11.7 ft-lb)
NOTE:
• Be sure to place the gasket between the cylinder
head and spark plug.
• If torque wrench is not available, tighten spark
plug until gasket contacts cylinder head: then tight-
en further 1/4 to 1/2 turn.
PM-11
DRIVE BELT(S)
6. Drive Belt(s) 2. 3.0 L MODEL

A: INSPECTION 1) Replace belts, if cracks, fraying or wear is found.
2) Check that the V-belt automatic tensioner indica-
1. EXCEPT 3.0 L MODEL tor is within the range (D).
1) Replace belts, if cracks, fraying or wear is found.
2) Check drive belt tension and adjust it if neces- (A)
sary by changing generator installing position and/
or idler pulley installing position.
Belt tension (D)
(A)
replaced: 7.0 — 9.0 mm (0.276 — 0.354 in)
reused: 9.0 — 11.0 mm (0.354 — 0.433 in)
(B)* (C)
(B)
replaced: 7.5 — 8.5 mm (0.295 — 0.335 in)
reused: 9.0 — 10.0 mm (0.354 — 0.394 in)
*: There is no belt (B) on models without an air con-
ditioner.
98 N (10 kg, 22 lb)
GEN A/C
P/S (A) (B)
PM-00114
I/P
C/P
(A) Indicator
PM-00113 (B) Generator
(C) Power steering oil pump
C/P Crankshaft pulley
(D) Service limit
GEN Generator
P/S Power steering oil pump pulley
A/C Air conditioning compressor pulley
I/P Idler pulley
PM-12
DRIVE BELT(S)
B: REPLACEMENT 11) Install a new belt, and tighten the slider bolt so
as to obtain the specified belt tension.
1. EXCEPT 3.0 L MODEL 12) Tighten the lock bolt (A).
1) Remove V-belt cover. 13) Tighten the slider bolt (B).
NOTE: Tightening torque:
Wipe off any oil or water on the belt and pulley. Lock bolt:
2) Loosen the lock bolt (A). 25 N·m (2.5 kgf-m, 18 ft-lb)
3) Loosen the slider bolt (B). Slider-bolt:
4) Remove the front side belt (C). 8 N·m (0.8 kgf-m, 5.8 ft-lb)
(B) (B)
(C) (C)
(A) (A)
PM-00116 PM-00116
5) Loosen the lock nut (A). 14) Install V-belt cover.

6) Loosen the through-bolt (B).
2. 3.0 L MODEL
7) Remove the rear side belt (C).
1) Fit the tool to the belt tensioner mounting bolt.
(B) 2) Turn the tool clockwise, and loosen the V-belt to
remove.
(A)
(C)
PM-00117
8) Install a new belt, and tighten the through-bolt so

as to obtain the specified belt tension. PM-00118
9) Tighten the lock nut (A).
Tightening torque:
22.6 N·m (2.3 kgf-m, 16.6 ft-lb)
(B)
(A)
(C)
PM-00117
10) Tighten the through-bolt (B).

Tightening torque:
8 N·m (0.8 kgf-m, 5.8 ft-lb)
PM-13
DRIVE BELT(S)
3) Install in the reverse order of removal.
(F)
(A)
(D)
(B) (E)
(C) PM-00119
(A) Power steering oil pump

(B) Belt tension adjuster
(C) Crankshaft pulley
(D) A/C compressor
(E) Belt idler
(F) Generator
PM-14
CAMSHAFT DRIVE BELT
7. Camshaft Drive Belt 9) Remove timing belt guide. (MT vehicle only)
A: REPLACEMENT
1. NON-TURBO MODEL
1) Remove radiator fan.
<Ref. to CO(H4SO)-28, Radiator Main Fan and
Fan Motor.> and <Ref. to CO(H4SO)-30, Radiator
Sub Fan and Fan Motor.>
2) Remove V-belt cover.
PM-00008
10) Turn crankshaft and align alignment marks on

crankshaft, and left and right camshaft sprockets
with notches of belt cover and cylinder block:
ST 499987500 CRANKSHAFT SOCKET
(A)
(B)
PM-00115
3) Remove V-belts.
<Ref. to ME(H4SO)-41, V-belt.>
4) Remove air conditioning compressor drive belt
tensioner. (B)
5) Remove pulley bolt. To lock crankshaft use ST.
2.0 L model:
ST 499977400 CRANKSHAFT PULLEY
WRENCH
2.5 L model:
ST 499977100 CRANKSHAFT PULLEY (A)
WRENCH (B)
ST
PM-00121
(A) Notch
(B) Alignment mark
PM-00120 11) Remove belt idler.

6) Remove crankshaft pulley. 12) Remove belt idler (No. 2).
7) Remove left side belt cover.
8) Remove front belt cover.
PM-00122
PM-15
CAMSHAFT DRIVE BELT
13) Remove timing belt. 10) Remove timing belt guide. (MT vehicle only)
14) Remove automatic belt tension adjuster as-
sembly.
PM-00008
PM-00123
11) Turn the crankshaft and align the alignment
marks on crankshaft, and left and right camshaft
15) Install in the reverse order of removal. sprockets with notches of belt cover and cylinder
<Ref. to ME(H4SO)-46, Timing Belt Assembly.> block. To turn the crankshaft, use ST:
ST 499987500 CRANKSHAFT SOCKET
2. TURBO MODEL
1) Remove the radiator fan and air conditioner fan.
<Ref. to CO(H4DOSTC)-28, Radiator Main Fan (A) (A)
and Fan Motor.>
<Ref. to CO(H4DOSTC)-30, Radiator Sub Fan (B) (B)
and Fan Motor.>
2) Remove the V-belts. <Ref. to ME(H4DOSTC)-
42, V-belt.> (B) (B)
3) Remove the air conditioning compressor drive (A) (A)
belt tensioner. (B) (B)
4) Remove the pulley bolt. To lock the crankshaft
use ST.
MT model:
(B)
WRENCH
AT model:
WRENCH
PM-00094
(A) Notch
(B) Alignment mark
12) Remove the belt idler.

ST
PM-00093
5) Remove the crankshaft pulley.

6) Remove the air conditioning compressor drive
belt tensioner.
7) Remove the left side belt cover.
8) Remove the right side belt cover.
9) Remove the front belt cover.
PM-00095
PM-16
CAMSHAFT DRIVE BELT
13) Remove the timing belt. 2. TURBO MODEL

14) Remove the automatic belt tension adjuster as-
1) Remove the left and right timing belt covers.
sembly.
2) While cranking the engine at least four rotations,
check the timing belt back surface for cracks or
damage. Replace the faulty timing belt as needed.
3) Measure the timing belt width W. If it is less than
30 mm (1.18 in), check the idlers, tensioner, water
pump pulley and cam sprocket to determine idler
alignment (squareness). Replace the worn timing
belt.
PM-00096 W

<Ref. to ME(H4DOSTC)-47, Timing Belt Assem-
bly.>
B: INSPECTION
1. NON-TURBO MODEL
PM-00097
1) Remove front timing belt cover and timing belt
cover (LH). 4) Install the left and right timing belt covers.
2) While cranking engine at least four rotations,
check timing belt back surface for cracks or dam-
age. Replace faulty timing belt as needed.
3) Measure 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 align-
ment (squareness). Replace worn timing belt.
PM-00124
4) Install front timing belt cover and timing belt cov-

er (LH).
PM-17
FUEL LINE
8. Fuel Line
A: INSPECTION
The fuel line is located mostly internally, so check
pipes, areas near pipes, and engine compartment
piping for rust, hose damage, loose bands, etc. If
faulty parts are found, repair or replace them.
• 2.0 L non-turbo and 2.5 L with OBD models
<Ref. to FU(H4SO)-70, Fuel Delivery, Return and
Evaporation Lines.>
• 2.0 L non-turbo and 2.5 L without OBD models
<Ref. to FU(H4SOw/oOBD)-67, Fuel Delivery, Re-
turn and Evaporation Lines.>
• 3.0 L model
<Ref. to FU(H6DO)-73, Fuel Delivery, Return and
Evaporation Lines.>
• TURBO model
<Ref. to FU(H4DOSTC)-67, Fuel Delivery, Return
and Evaporation Lines.>
PM-18
FUEL FILTER
9. Fuel Filter
A: REPLACEMENT
Refer to Fuel section for replacing fuel filter.
• 2.0 L non-TURBO and 2.5 L with OBD models
<Ref. to FU(H4SO)-67, Fuel Filter.>
• 2.0 L non-TURBO and 2.5 L without OBD models
<Ref. to FU(H4SOw/oOBD)-64, Fuel Filter.>
• 2.0 L TURBO model
<Ref. to FU(H4DOSTC)-64, Fuel Filter.>
• 3.0 L model
<Ref. to FU(H6DO)-70, Fuel Filter.>
B: INSPECTION
1) If clogged or exceeds the service limit for re-
placement, replace the fuel filter.
2) If water remains, shake the fuel filter to drain.
PM-19
AIR CLEANER ELEMENT
10.Air Cleaner Element 2. 2.0 L TURBO AND 3.0 L MODEL

A: REPLACEMENT 1) Loosen clamp (A), and separate air cleaner up-
per cover and air intake boot. (3.0 L model)
1. 2.0 L NON-TURBO AND 2.5 L MODEL 2) Remove the clip (B) above the air cleaner upper
cover.
1) Remove the air intake duct from air cleaner
case. • 3.0 L model
2) Remove the bolt (A) which installs air cleaner (A)
(B)
case to stays.
3) Remove the clip (B) above the air cleaner case.
(A) (B)
(B)
(B)
(B) PM-00126
• 2.0 L turbo model
IN-00039 (B)
4) Remove the air cleaner element.
PM-00099
3) Remove air cleaner element.

PM-00087
NOTE:
5) Install in the reverse order of removal. Before installing air cleaner upper cover, align
NOTE: holes with protruding portions of air cleaner lower
case, then secure upper cover to lower case.
Fasten with a clip after inserting the lower tab of the
case.
PM-00127
PM-20
COOLING SYSTEM
11.Cooling System 2) Check the radiator cap valve open pressure us-
ing radiator cap tester.
A: INSPECTION NOTE:
1) Check radiator for leakage, filling it with coolant Rust or dirt on cap may prevent valve from func-
and attach radiator cap tester (A) to the filler neck. tioning normally: be sure to clean cap before test-
Then apply a pressure of 157 kPa (1.6 kg/cm2, 23 ing.
psi) and check the following points:
Raise the pressure until the needle of gauge stops
• Each portion of radiator for leakage
and see if the pressure can be retained for five to
• Hose joints and other connections for leakage
six seconds. The radiator cap is normal if a pres-
NOTE: sure above the service limit value has been main-
• When attaching or detaching tester and when tained for this period.
operating tester, use special care not to deform ra-
diator filler neck. Radiator cap valve open pressure
• Non-turbo model Standard value:
93 — 123 kPa (0.95 — 1.25 kg/cm2, 14 — 18
psi)
Service limit:
83 kPa (0.85 kg/cm2 , 12 psi)
(A) PM-00128
• Turbo model
(A) PM-00023
(A)
CO-00043
• When performing this check, be sure to keep the (B)

(A)
engine stationary and fill radiator with coolant. PM-00089
• Wipe off check points before applying pressure.
• Use care not to spill coolant when detaching (A) Check position for deformation
tester from radiator. (B) Check position for deformation, damage and
rust.
3) If the coolant temperature exceeds 76.0 to

80.0°C (169 to 176°F) while radiator is not so hot,
check thermostat. If thermostat does not open at
76.0 to 80.0°C (169 to 176°F), replace it with a new
one.
4) If electric fan does not operate when coolant
temperature exceeds 95°C (203°F), check the
electric fan system.
PM-21
COOLANT
12.Coolant 8) Slowly pour prepared coolant from radiator filler

port to neck of filler, then pour into reservoir tank up
A: REPLACEMENT to “FULL” level.
1. REPLACEMENT OF COOLANT Coolant amount for preparation
WARNING: 2.0 L non-turbo and 2.5 L models
The radiator is of the pressurized type. Do not MT model:
attempt to open the radiator cap immediately Approx. 6.8 2 (7.2 US qt, 6.0 Imp qt)
after the engine has been stopped. AT model:
1) Lift up the vehicle.
2) Remove under cover. 2.0 L turbo model
3) Place a container under drain pipe. MT model:
4) Loosen and remove drain screw to drain engine Approx. 7.7 2 (8.1 US qt, 6.8 Imp qt)
coolant into container. AT model:
Except 3.0 L model Approx. 7.6 2 (8.0 US qt, 6.7 Imp qt)
3.0 L model
NOTE:
The SUBARU Genuine Coolant containing anti-
freeze and anti-rust agents is especially made for
SUBARU engine, which has an aluminum crank-
case. Always use SUBARU Genuine Coolant,
since other coolant may cause corrosion.
9) Securely install radiator cap.
PM-00129 10) Run engine for more than five minutes at 2,000
3.0 L model to 3,000 rpm. (Run engine until radiator becomes
hot in order to purge air trapped in cooling system.)
11) Stop engine and wait until coolant temperature
lowers. Then open radiator cap to check coolant
level and add coolant up to radiator filler neck.
Next, add coolant into reservoir tank up to “FULL”
level.
12) After adding coolant, securely install radiator
and reservoir tank caps.
PM-00130
5) For quick draining, open radiator cap.

CAUTION:
Be careful not to spill coolant on the floor.
6) Drain coolant from reservoir tank.
7) Tighten radiator drain screw securely after drain-
ing coolant.
PM-22
COOLANT
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
Safe operating temperature
the 40% curve of the necessary coolant concentra-
tion, and read the scale on the vertical axis of the
Concentration graph at height A. The quantity of coolant to be
of coolant drained is 2.1 liters (2.2 US qt, 1.8 Imp qt). Drain
1.100 2.1 liters (2.2 US qt, 1.8 Imp qt) of coolant from the
cooling system and add 2.1 liters (2.2 US qt, 1.8
1.090
Imp qt) of the undiluted solution of SUBARU cool-
1.080 ant.
Specific gravity of coolant
60%
1.070 B If a coolant concentration of 50% is needed, drain
C 50% all the coolant and refill with the undiluted solution
1.060
(1.054)
A only.
1.050 40%
1.040
1.030 Freezing 30%

temperature
(US qt, lmp qt)
1.020
20%
(77˚F)
1.010
25˚C
10% Necessary concentration

1.000 _ 40 _ 30 _ 20 _ 10 0 10 20 30 40 50 of coolant
( _ 40)( _ 22)( _ 4)(14) (32) (50) (68)(86)(104)(122) 3
Coolant temperature ˚C (˚F) (3.2, 2.6)
Quantity of coolant to be drained
45%
A
PM-00131 2 40%
35%
(2.1, 1.8) 30%
1 25%
20%
(1.1, 0.9) 15%
10%
0
10 20 30 40 50
Concentration of coolant in the vehicle
cooling system %
Concentration of coolant in vehicle

and quantity to be drained
PM-00132
PM-23
CLUTCH SYSTEM
13.Clutch System 5) Check the fluid level using the scale on the out-
side of the clutch master cylinder tank (A). If the lev-
A: INSPECTION AND ADJUSTMENT el is below “MIN” (B), add clutch fluid to bring it up
1) Push the release lever to retract the push rod of to “MAX” (C).
the operating cylinder and check if the fluid level in
Recommended clutch fluid:
the clutch reservoir tank rises or not.
FMVSS No. 116, fresh DOT3 or DOT4 brake
• Non-turbo model
fluid
(A) NOTE:
• Avoid mixing different brakes of brake fluid to
(B) prevent degradation of the fluid.
• Be careful not to allow dirt or dust to get into the
reservoir tank.
(A)
(C)
(C) PM-00075
(A) Release lever

(B) Push rod
(B)
(C) Operating cylinder
• Turbo model PI-00099
(C) (A) Reservoir tank

(A)
(B) MIN. level
(C) MAX. level
(B)
PM-00101
(A) Release lever

(B) Push rod
(C) Operating cylinder
2) If the fluid level rises, pedal free play is correct.

3) If the fluid level does not rise, or the push rod
cannot be retracted, adjust the clutch pedal. <Ref.
to CL-33, Clutch Pedal.>
4) Inspect the underside of master cylinder, clutch
damper and operating cylinder for clutch system,
hoses, piping and their couplings for fluid leaks.
If fluid leaks are found, correct them by retightening
their fitting bolt and/or replacing their parts.
PM-24
HILL-HOLDER SYSTEM
14.Hill-holder System
A: INSPECTION AND ADJUSTMENT
1) Confirm stopping and starting performance by
activating hill-holder on an uphill road of 3° or high-
er inclination.
(1) When vehicle does not stop;
Tighten adjusting nut of PHV cable.
(2) When vehicle does not start properly;
A; When hill-holder is released later than en-
gagement of clutch (engine tends to stall): Loos-
en adjusting nut gradually until smooth starting
is enabled.
B; When hill-holder is released earlier than en-
gagement to clutch (vehicle slips down slightly):
Tighten adjusting nut so that hill-holder is re-
leased later than engagement of clutch (status
in A). Then make adjustment the same as in A.
NOTE:
• Whenever turning adjusting nut, hold inner cable
with pliers to prevent it from turning.
• Replace pressure hold valve (PHV), return
spring of PHV or PHV cable with 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-25
IDLE MIXTURE
15.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 engine sufficiently until cooling fan
starts to operate.
3) Measure the idle mixture with the 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
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 CO ad-
justing screw (A).
Specified data:
0.28 — 4.22 V
(A)
PM-00146
NOTE:
If driving the vehicle on out of specified data, the
“trouble code 49” is indicated in many case.
PM-26
TRANSMISSION OIL
16.Transmission Oil
A: REPLACEMENT
1. MANUAL TRANSMISSION
1) Drain gear oil by removing drain plug after allow-
ing the engine to cool for 3 to 4 hours.
NOTE:
• Before starting work, cool off the engine well.
• If transmission gear oil splashes on exhaust
pipe, wipe it clean.
PM-00029
2) Reinstall drain plug after draining gear oil and

tighten it to the specified torque.
Tightening torque:
44 N·m (4.5 kgf-m, 32.5 ft-lb)
NOTE:
• Replace the gasket with a new one.
• Each oil manufacturer has its base oil and addi-
tives. Thus, do not mix two or more brands.
3) Fill transmission gear oil through the oil level
gauge hole up to the upper point of level gauge.
Gear oil capacity:
Single range transmission
3.5 2 (3.7 US qt, 3.1 Imp qt)
Dual range transmission
4.0 2 (4.2 US qt, 3.5 Imp qt)
(A)
(B)
(C)
PM-00030
(A) Oil level gauge

(B) Upper level
(C) Lower level
PM-27
ATF
17.ATF 4) Fluid temperature rising speed

• By idling the engine
A: INSPECTION Time for temperature rise to 70°C (158°F) with at-
1) Raise ATF temperature to 70 to 80°C (158 to mospheric temperature of 0°C (32°F): More than
176°F) by driving for approx. 10 min. 25 minutes
NOTE: <Reference>
The level of ATF varies with fluid temperature. Pay Time for temperature rise to 30°C (86°F) with atmo-
attention to the fluid temperature when checking oil spheric temperature of 0°C (32°F): Approx. 8 min-
level. utes
• By running the vehicle
(A) Time for temperature rise to 70°C (158°F) with at-
mospheric temperature of 0°C (32°F): More than
10 minutes
5) Method for checking fluid level upon delivery or
at periodic inspection
F
(C)
HOT
(B)
Check fluid level after a warm-up run of approx. 10
L
(D)
minutes. During the warm-up period, the automatic
transmission functions can also be checked.
F
(C)
COLD
(E)
L
(D)
PI-00105
(A) Level gauge

(B) Check line, HOT condition
(C) Upper level
(D) Lower level
(E) Check line, COLD condition
2) Make sure the vehicle is level. After selecting all

positions (P, R, N, D, 3, 2, 1), set the select leveler
in “P” range. Measure fluid level with the engine
idling.
NOTE:
After running, idle the engine for one or two min-
utes before measurement.
3) If the fluid level is below the center between up-
per and lower marks, add the recommended ATF
until the fluid level is found within the specified
range (above the center between upper and lower
marks). When the transmission is hot, the level
should be above the center of upper and lower
marks, and when it is cold, the level should be
found below the center of these two marks.
CAUTION:
• Use care not to exceed the upper limit level.
• ATF level varies with temperature. Remem-
ber that the addition of fluid to the upper limit
mark when the transmission is cold will result
in the overfilling of fluid.
PM-28
ATF
B: REPLACEMENT
1. AUTOMATIC TRANSMISSION FLUID
1) Drain ATF (Automatic Transmission Fluid) by re-
moving drain plug after allowing the engine to cool
for 3 to 4 hours.
NOTE:
Before starting work, cool off the engine well.
(B)
(A)
PM-00032
(A) Front differential drain plug

(B) ATF drain plug
2) Reinstall drain plug after draining ATF, and tight-

en it to the specified torque.
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
3) Pour ATF into the oil charge pipe.
Recommended fluid:
Dexron III type automatic transmission flu-
id
ATF amount:
Refill with the same amount of ATF that
was drained.
4) Check the level of the ATF. Refer to “INSPEC-
TION”.
2. ATF FILTER
NOTE:
ATF filter is maintenance free part. ATF filter needs
replacement, when it has physically damaged or
ATF leaked.
For the replacement procedures of the ATF filter:
<Ref. to AT-73, ATF Filter.>
PM-29
FRONT & REAR DIFFERENTIAL OIL
18.Front & Rear Differential Oil 2) Reinstall drain plug after draining differential
gear oil and tighten it to the specified torque.
A: REPLACEMENT
Tightening torque:
1. FRONT DIFFERENTIAL (MANUAL 44 N·m (4.5 kgf-m, 32.5 ft-lb)
TRANSMISSION) NOTE:
For M/T vehicle, manual transmission oil works as • Be sure to place a gasket between the transmis-
differential oil to lubricate differential. Refer to sion case and drain plug.
“Transmission Oil”. <Ref. to PM-27, MANUAL • Replace the gasket with a new one.
TRANSMISSION, REPLACEMENT, Transmission • Each oil manufacturer has its base oil and addi-
Oil.> tives. Thus, do not mix two or more brands.
2. FRONT DIFFERENTIAL (AUTOMATIC 3) Fill differential gear oil through the oil level
gauge hole up to the upper point of level gauge.
TRANSMISSION)
1) Drain differential gear oil by removing drain plug Differential gear oil capacity:
after allowing the engine to cool for 3 to 4 hours. 1.1 — 1.3 2 (1.2 — 1.4 US qt, 1.0 — 1.1 Imp
qt)
NOTE:
• Before starting work, cool off the engine well.
• If transmission gear oil splashes on exhaust
pipe, wipe it clean.
(B) (A)
(C)
PM-00035
(A) Oil level gauge

(B) Upper level
PM-00034
(C) Lower level
PM-30
FRONT & REAR DIFFERENTIAL OIL
3. REAR DIFFERENTIAL 4) After installing drain plug onto rear differential

gear case firmly, fill oil up fully to the mouth of filler
• VA type
plug.
1) Drain oil by removing drain plug.
2) Remove filler plug for quicker draining. (A)
3) Replace drain plug gasket with a new one.
4) Tighten drain plug to the specified torque.
Tightening torque:
34 N·m (3.5 kgf-m, 25.3 ft-lb)
5) After installing drain plug, fill oil fully up to the
mouth of filler plug.
(B)
(A)
PM-00037
(A) Filler plug

(B) Drain plug
Oil capacity:
0.8 2 (0.8 US qt, 0.7 Imp qt)
(B) NOTE:
PM-00147 Each oil manufacturer has its base oil and addi-
tives. Thus, do not mix two or more brands.
(A) Filler plug 5) Install filler plug onto rear differential gear case
(B) Drain plug firmly.
NOTE:
Oil capacity: Apply fluid packing to filler plug before installation.
0.8 2 (0.8 US qt, 0.7 Imp qt)
Fluid packing:
6) Replace filler plug gasket with a new one.
Three Bond 1105 (Part No. 004403010)
7) Install filler plug onto rear differential gear case.
Tightening torque:
Tightening torque:
49.0 N·m (5.0 kgf-m, 36.2 ft-lb)
34 N·m (3.5 kgf-m, 25.3 ft-lb)
• T type
1) Drain oil by removing drain plug.
2) Remove filler plug for quicker draining.
3) Tighten drain plug after draining oil.
NOTE:
Apply fluid packing to drain plug threads before in-
stallation.
Fluid packing:
Three Bond 1105 (Part No. 004403010)
Tightening torque:
49.0 N·m (5.0 kgf-m, 36.2 ft-lb)
PM-31
BRAKE LINE
19.Brake Line B: CHECKING

A: INSPECTION 1. SERVICE BRAKE
1. BRAKE LINE 1) Check the free play of brake pedal with a force of
less than 10 N (1 kgf, 2 lb).
1) Check scratches, swelling, corrosion and/or
traces of fluid leakage on brake hoses or pipe Brake pedal free play:
joints. 1 — 3 mm (0.04 — 0.12 in)
2) Check the possibility of adjacent parts interfering
with brake pipes/hoses during driving, and loose
connections/clamps.
3) Check any trace of fluid leakage, scratches, etc.
on master cylinder, wheel cylinder and pressure
control valve.
NOTE:
(A)
• When the brake fluid level in the reservoir tank is
lower than the specified limit, the brake fluid warn-
ing light on the combination meter will come on.
PM-00078
• Visually check brake hose (using a mirror where
it is difficult to see) for any damage.
(A) Pedal play
2) If the free play is out of specifications above, ad-

(A)
just the brake pedal as follows:
(1) Be sure engine is off. (No vacuum is applied
to brake booster.)
(2) There should be play between brake boost-
er clevis and pin at brake pedal installing por-
tion.
(3) Depress the surface of brake pad by hand.
(B)
[Depress brake pedal pad with a force of less
PM-00134 than 10 N (1 kgf, 2 lb) to a stroke of 1 to 3 mm
(0.04 to 0.12 in).]
(A) Front brake pipe
(B) Front brake hose
(A)
PM-00135
(A) Rear brake hose
PM-32
BRAKE LINE
(4) If there is no free play between clevis pin 4) Check to see if air is in the hydraulic brake line
and clevis, turn brake switch adjusting nut until by the feel of pedal operation. If air appears to exist
the clearance between stopper and screw of in the line, bleed it from the system.
brake switch becomes 0.3 mm (0.012 in). 5) Check for even operation of all brakes, using a
brake tester or by driving the vehicle for a short dis-
(A)
tance on a straight road.
(H) (B)
(C) 2. BRAKE SERVO SYSTEM

(D) 1) With the engine off, depress the brake pedal
(I) (E) several times applying the same pedal force: Make
(F)
(J)
sure the travel distance should not change.
(G) 2) With the brake pedal depressed, start the en-
gine: Make sure the pedal should move slightly to-
ward the floor.
PM-00041 3) With the brake pedal depressed, stop the engine
and keep the pedal depressed for 30 seconds:
(A) Brake switch Make sure the pedal height should not change.
(B) Adjusting nut 4) Check valve is built into vacuum hose. Discon-
(C) 0.3 mm (0.012 in) nect vacuum hose to inspect function of check
(D) Stopper valve.
(E) Clevis pin Blow air into vacuum hose from its brake booster
(F) Clevis side end: Air must flow out of engine side end of
(G) Pedal play
hose. Next blow air into hose from engine side: Air
1 - 3 mm (0.04 - 0.12 in) should not flow out of hose.
(H) Lock nut
Replace both check valve and vacuum hose if
check valve is faulty. Engine side of vacuum hose
(I) Brake booster operating nut
is indicated by marking “ENG” as shown.
(J) Play at pin
3) Check the pedal stroke.

While the engine is idling, depress the brake pedal
with a 490 N (50 kgf, 110 lb) load and measure the
distance between the brake pedal and steering (A) (B)
wheel. With the brake pedal released, measure the (C)
distance between the pedal and steering wheel
again. The difference between the two measure-
ments must be less than 95 mm (3.74 in). If the dis-
tance is more than specified, there is a possibility
air is in the inside of the hydraulic unit. PM-00046
Brake pedal reserve distance: A (A) Engine side

more than 95 mm (3.74 in)/ 490 N (50 kgf, (B) Brake booster side
110 lb) (C) ENG
1 2 =A 5) Check vacuum hose for cracks or other damage.

NOTE:
(A)
When installing the vacuum hose on the engine
and brake booster, do not use soapy water or lubri-
1 cating oil on their connections.
2
6) Check vacuum hose to make sure it is tight and
secure.
(B)
PM-00045
(A) Steering wheel

(B) Toe board
PM-33
BRAKE FLUID
20.Brake Fluid NOTE:

• Cover bleeder with waste cloth, when loosening
A: REPLACEMENT it, to prevent brake fluid from being splashed over
1) Either jack up vehicle and place a safety stand surrounding parts.
under it, or lift up vehicle. • During bleeding operation, keep the brake re-
2) Remove both front and rear wheels. serve tank filled with brake fluid to eliminate entry of
3) Draw out the brake fluid from master cylinder air.
with syringe. • Brake pedal operation must be very slow.
4) Refill reservoir tank with recommended brake • For convenience and safety, it is advisable to
fluid. have two men working.
Recommended brake fluid: • The amount of brake fluid required is approxi-
FMVSS No. 116, fresh DOT3 or 4 brake fluid mately 500 m2 (16.9 US fl oz, 17.6 Imp fl oz) for to-
tal brake system.
NOTE:
6) Instruct your co-worker to depress the brake
• Avoid mixing different brands of brake fluid to
pedal slowly two or three times and then hold it de-
prevent degrading the quality of the fluid.
pressed.
• Be careful not to allow dirt or dust to get into the
7) Loosen bleeder screw approximately 1/4 turn
reservoir tank.
until a small amount of brake fluid drains into con-
Bleeding sequence (1) → (2) → (3) → (4) tainer, and then quickly tighten screw.
(1) (4)
8) Repeat steps 6) and 7) above until there are no
air bubbles in drained brake fluid and new fluid
flows through vinyl tube.
NOTE:
(5) (6) Add brake fluid as necessary while performing the
air bleed operation, in order to prevent the tank
from running short of brake fluid.
9) After completing the bleeding operation, hold
brake pedal depressed and tighten screw and in-
(3) (2) stall bleeder cap.
PM-00047
Tightening torque:
(1) Front right 8 N·m (0.8 kgf-m, 5.8 ft-lb)
(2) Rear left
10) Bleed air from each wheel cylinder by following
(3) Front left
the previous 5 steps.
(4) Rear right 11) Depress brake pedal with a force of approxi-
(5) Secondary mately 294 N (30 kgf, 66 lb) and hold it there for ap-
(6) Primary proximately 20 seconds. At this time check pedal to
see if it makes any unusual movement. Visually in-
5) Install one end of a vinyl tube onto the air bleeder
spect bleeder screws and brake pipe joints to make
and insert the other end of the tube into a container
sure that there is no fluid leakage.
to collect the brake fluid.
12) Install wheels, and drive vehicle for a short dis-
tance between 2 to 3 km (1 to 2 miles) to make sure
that brakes are operating properly.
PM-00048
PM-34
DISC BRAKE PADS AND DISCS
21.Disc Brake Pads and Discs • Turbo model
A: INSPECTION Brake disc thickness mm (in)

Front Rear
1. DISC BRAKE PAD AND DISC Standard 24 (0.94) 18 (0.71)
1) Jack up vehicle and support with rigid racks. Wear limit 22 (0.87) 16 (0.63)
Then remove wheels.
4) Measure the disc rotor runout at a point less than
2) Visually check pad thickness through inspection
10 mm (0.39 in) from the outer periphery of the ro-
hole of disc brake assembly. Replace pad if neces-
tor.
sary.
Disc rotor runout limit:
Front: 0.075 mm (0.0030 in)
Rear: 0.070 mm (0.0028 in)
NOTE:
When replacing a pad, always replace the pads for
both the left and right wheels at the same time. Also
replace pad clips if they are twisted or worn.
(A)
PM-00049
(A) Inspection hole
Pad thickness mm (in)

Front Rear
Standard 11 (0.43) 9 (0.35)
Service limit 1.5 (0.059) 1.5 (0.059) PM-00051
(A)
(C)
(B)
PM-00140
(A) Thickness of pad

(B) Back metal
(C) Lining
3) Check the disc rotor, and correct or replace if it is

damaged or worn.
• Non-turbo model
Brake disc thickness mm (in)
Front Rear
Standard 24 (0.94) 10 (0.39)
Wear limit 22 (0.87) 8.5 (0.335)
PM-35
PARKING BRAKE
22. Parking Brake 3) If the deformation or wear of back plate, shoe,

etc. is noticeable, replace them.
A: INSPECTION 4) When the shoe return spring tension is exces-
Inspect brake linings and drums of both sides of the sively weakened, replace it, taking care to identify
rear brake at the same time by removing brake upper and lower springs.
drums.
1) Inspect brake shoes for damage or deformation
and check brake linings for wear.
NOTE:
Always replace both primary and secondary brake
shoes for the left and right wheels at the same time.
Brake lining thickness excluding back metal
Standard value: 3.2 mm (0.126 in)
Wear limit: 1.5 mm (0.059 in)
(A)
(B)
(C)
PM-00054
(A) Front
(B) Brake shoe (Primary)
(C) Brake shoe (Secondary)
2) Check brake drum for wear, dents or other dam-

age. If the inside surface of brake drum is streaked,
correct the surface with emery cloth (#200 or
more). If it is unevenly worn, tapered, or the outside
surface of brake drum is damaged, correct or re-
place it.
Brake drum inside diameter
Standard value: 170 mm (6.69 in)
Wear limit: 171 mm (6.73 in)
(B)
(A)
PM-00055
(A) Measuring inside diameter

(B) Disc
PM-36
PARKING BRAKE
B: ADJUSTMENT
1. SHOE CLEARANCE
1) Remove adjusting hole cover from back plate.
2) Turn adjusting screw using a slot-type screw-
driver until brake shoe is in close contact with disc
rotor.
(A)
(B)
(C)
PM-00056
(A) Adjusting screw

(B) Cover (rubber)
(C) Back plate
3) Turn back (downward) adjusting screw 3 or 4

notches.
4) Install adjusting hole cover to back plate.
2. LEVER STROKE
1) Remove console box lid.
2) Forcibly pull parking brake lever 3 to 5 times.
3) Adjust parking brake lever by turning adjuster
until parking brake lever stroke is set at 6 notches
with operating force of 196 N (20 kgf, 44 lb).
(A)
(B)
(C)
PM-00136
(A) Parking brake lever

(B) Lock nut
(C) Adjusting nut
4) Tighten lock nut.

5) Install console box lid.
Lever stroke:
7 to 8 notches when pulled with a force of
196 N (20 kgf, 44 lb)
Tightening torque (Adjuster lock nut):
5.9 N·m (0.60 kgf-m, 4.3 ft-lb)
PM-37
SUSPENSION
23.Suspension 5) Damage of dust seal

Visually inspect ball joint dust seal. If it is damaged,
A: INSPECTION remove transverse link. <Ref. to FS-14, Front
Transverse Link.> And measure free play of ball
1. SUSPENSION BALL JOINT joint. <Ref. to FS-16, Front Ball Joint.>
1) Jack up vehicle until front wheels are off ground. (1) When looseness exceeds standard value,
2) Next, grasp bottom of tire and move it in and out. replace ball joint.
If relative movement is observed between brake (2) If the dust seal is damaged, replace with the
disc cover and end of transverse link, ball joint may new ball joint.
be excessively worn.
NOTE:
3) Next, grasp end of transverse link and move it up When transverse link ball joint has been removed
and down. Relative movement between housing or replaced, check toe-in of front wheel. If front
and transverse link boss indicates ball joint may be wheel toe-in is not at specified value, adjust toe-in.
excessively worn. <Ref. to FS-6, Wheel Alignment.>
4) If relative movement is observed in the immedi-
ately preceding two steps, remove and inspect ball
joint. If free play exceeds standard, replace ball
joint. <Ref. to FS-16, Front Ball Joint.>
(A)
(E)
PM-00059
(A)
(D)
(A) Dust seal
(C) (B)
PM-00057
2. TRANSVERSE LINK'S REAR BUSHING
(A) Disc cover Check oil leaks at around liquid-filled bushing. If oil
(B) Relative movement leaks, replace bushing.
(C) Ball joint
(D) Transverse link
(A)
(E) Housing
(D)
(B)
PM-00060
(A)
(C)
(A) Rear bushing
(B) Transverse link
(B)
PM-00058
(A) Relative movement

(B) Ball joint
(C) Transverse link
(D) Housing
PM-38
SUSPENSION
3. WHEEL ARCH HEIGHT 6. OIL LEAKAGE OF STRUT AND SHOCK

1) Unload cargoes and set vehicle in curb weight ABSORBER
(empty) condition. Visually inspect front strut and rear shock absorber
2) Then, check wheel arch height of front and rear for oil leakage as instructed. Replace front strut and
suspensions to ensure that they are within speci- rear shock absorber if oil leaks excessively.
fied values.
3) When wheel arch height is out of standard, visu- 7. TIGHTNESS OF BOLTS AND NUTS
ally inspect following components and replace de- Check bolts and nuts shown in the figure for loose-
formed parts. ness. Retighten bolts and nuts to specified torque.
• Suspension components [Front strut assembly If self-lock nuts and bolts are removed, replace
and rear shock absorber assembly] them with new ones.
• Body parts to which suspensions are installed. Front suspension: <Ref. to FS-3, COMPONENT,
4) When no components are deformed, adjust General Description.>
wheel arch height by replacing coil spring in the Rear suspension: <Ref. to RS-3, COMPONENT,
suspension whose wheel arch height is out of stan- General Description.>
dard. <Ref. to FS-6, Wheel Alignment.> <Ref. to
RS-8, Wheel Alignment.>
8. DAMAGE TO SUSPENSION PARTS
1) Check the following parts and the fastening por-
4. WHEEL ALIGNMENT OF FRONT SUS- tion of the vehicle body for deformation or exces-
PENSION sive rusting which impairs the suspension. If
1) Check alignment of front suspension to ensure necessary, replace damaged parts with new ones.
that following items conform to standard values. If minor rust formation, pitting, etc. are noted, re-
• Toe-in move rust and apply remedial anti-corrosion mea-
• Camber angle sures.
• Caster angle • Front suspension
• Steering angle • Transverse link
<Ref. to FS-6, Wheel Alignment.> • Crossmember
2) When caster angle does not conform to standard • Strut
value, visually inspect following components and • Rear suspension
replace deformed parts. • Sub frame
• Suspension components [Strut assembly, cross- • Link F
member, transverse link, etc.] • Link R
• Body parts to which suspensions are installed. • Link UPR
3) When toe-in and camber are out of standard val- • Arm R
ue, adjust them so that they conform to respective • Shock absorber
service standard. • In the district where salt is sprayed to melt snow
4) When right-and-left turning angles of tire are out on a road in winter and coastal area, check suspen-
of standard, adjust to standard value. sion parts for damage caused by rust every months
5. WHEEL ALIGNMENT OF REAR SUS- or km (miles) specified in "MAINTENANCE
SCHEDULE 2".
PENSION
1) Check alignment of rear suspension to ensure
that following items are within standard values.
• Toe-in
• Camber angle
• Thrust angle
<Ref. to RS-8, Wheel Alignment.>
2) When camber angle does not conform to stan-
dard value, visually inspect parts listed below. If de-
formation is observed, replace 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 toe-in and thrust angle are out of standard
value, adjust them so that they conform to respec-
tive service standard.
PM-39
WHEEL BEARING
24.Wheel Bearing 2. REAR WHEEL BEARING

A: INSPECTION 1) Jack up the rear of vehicle.
2) While holding rear wheel by hand, swing it in and
1. FRONT WHEEL BEARING out to check bearing free play.
3) Loosen wheel nuts and remove rear wheel.
NOTE:
4) If bearing free play exists in step 2) above, at-
Inspect the condition of front wheel bearing grease. tach a dial gauge to hub assembly and measure
1) Jack up the front of vehicle. axial displacement in axial direction.
2) While holding front wheel by hand, swing it in
and out to check bearing free play. Service limit:
3) Loosen wheel nuts and remove front wheel. Straight-ahead position within 0.05 mm
4) If bearing free play exists in step 2) above, at- (0.0020 in)
tach a dial gauge to hub and measure axial dis- 5) Remove the DOJ of rear drive shaft from rear dif-
placement in axial direction. ferential. <Ref. to DS-34, Rear Drive Shaft.>
6) While supporting rear drive shaft horizontally
Service limit: with one hand, turn hub assembly with the other to
Straight-ahead position within 0.05 mm check for noise or binding.
(0.0020 in) If hub assembly is noisy or binds, disassemble rear
5) Remove bolts and self-locking nuts, and extract axle and check condition of oil seals, bearings, etc.
transverse link from front crossmember.
6) While lightly hammering spring pin which se- (A)
(B)
cures SFJ to transmission spindle, remove it.
7) Extract SFJ from transmission spindle. <Ref. to
DS-17, Front Axle.>
8) While supporting front drive shaft horizontally
with one hand, turn hub with the other to check for
noise or binding.
If hub is noisy or binds, disassemble front axle and
check condition of oil seals, bearing, etc. (C)
PM-00137
(A) (F)
(A) Hub unit
(B) Hub bolt
(G) (C) Hub
(B)
(C)
(D)
(E)
PM-00061
(A) Inner oil seal

(B) Snap ring
(C) Bearing
(D) Housing
(E) Outer oil seal
(F) Hub bolt
(G) Hub
PM-40
AXLE BOOTS & JOINTS
25.Axle Boots & Joints

A: INSPECTION
1. FRONT AND REAR AXLE BOOTS
Inspect front axle boots (A) and rear axle boots (B)
for deformation, damage or failure. If faulty, replace
them with new ones. <Ref. to DS-28, Front Drive
Shaft.> <Ref. to DS-34, Rear Drive Shaft.>
(A)
PM-00063
(B)
PM-00138
2. PROPELLER SHAFT
Inspect propeller shaft for damage or failure. If
faulty, replace with a new one. <Ref. to DS-14, Pro-
peller Shaft.>
PM-41
TIRE ROTATION
26.Tire Rotation
A: INSPECTION
1) Replace the tire if the tread depth is less than 1.6
mm (0.063 in) or if wear indicators appear across
the tire tread. (It is recommended that both right
and left tires are replaced as a set.)
2) Adjust the wheel alignment if abnormally uneven
tire wear is found.
3) Also, rotate the tires between the front and rear
tires as illustrated, in order to ensure uniform tire
wear.
PM-00079
(A) (B)
(C)
PM-00080
(A) New tread

(B) Worn tread
(C) Tread wear indicator
PM-42
STEERING SYSTEM (POWER STEERING)
27.Steering System (Power 2. STEERING SHAFT JOINT

Steering) 1) When steering wheel free play is excessive, dis-
connect universal joint of steering shaft and check
A: INSPECTION it for any play and yawing torque (at the point of the
crossing direction). Also inspect for any damage to
1. STEERING WHEEL
sealing or worn serrations. If the joint is loose, re-
1) Set steering wheel in a straight-ahead position, tighten the mounting bolts to the specified torque.
and check wheel spokes to make sure they are cor-
rectly set in their specified positions. Tightening torque:
2) Lightly turn steering wheel to the left and right to 24 N·m (2.4 kgf-m, 17.4 ft-lb)
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
3. GEARBOX
SUBARU
SRS AIRBAG
1) With wheels placed on a level surface, turn
steering wheel 90° in both the left and right direc-
tions.
While wheel is being rotated, reach under vehicle
PM-00065 and check for looseness in gearbox.
(A) Free play Tightening torque:
59 N·m (6.0 kgf-m, 43.4 ft-lb)
Move steering wheel vertically toward the shaft to
ascertain if there is play in the direction. (A)
Maximum permissible play:
0.5 mm (0.020 in)
3) Drive vehicle and check the following items dur-
ing operation.
(1) Steering force ..............
The effort required for steering should be
smooth and even at all points, and should not (B)
vary. PM-00067
(2) Pull to one side ............
Steering wheel should not be pulled to either (A) Boot
side while driving on a level surface.
(B) Gearbox mounting bolts
(3) Wheel runout ................
Steering wheel should not show any sign of 2) Check boot for damage, cracks or deterioration.
runout. 3) With vehicle on a level surface, quickly turn
(4) Return factor ............... steering wheel to the left and right.
Steering wheel should return to its original posi- While steering wheel is being rotated, check the
tion after it has been turned and then released. gear backlash. If any unusual noise is noticed, ad-
just the gear backlash in the following manner.
(1) Tighten adjusting screw to 7.4 N·m (0.75
kgf-m, 5.4 ft-lb) and then loosen. Repeat this op-
eration twice.
(2) Retighten adjusting screw to 7.4 N·m (0.75
kgf-m, 5.4 ft-lb) and back off 25°.
PM-43
(3) Apply liquid packing to at least 1/3 of entire 5. POWER STEERING FLUID LEVEL
perimeter of adjusting screw thread.
1) Place vehicle with engine “off” on the flat and
level surface.
2) Inspect fluid level by indicator of reservoir tank.
If the level is at lower point or below, add fluid to
(A) keep the level in the specified range of the indica-
tor. If at upper point or above, drain fluid by using a
syringe or the like.
(1) Check at temperature 20°C (68°F) on reser-
voir surface of oil pump; read the fluid level on
the “COLD” side.
PM-00068
(2) Check at temperature 80°C (176°F) on res-
ervoir surface of oil pump; read the fluid level on
(A) Apply liquid packing to at least 1/3 of entire
the “HOT” side.
perimeter.
HOT MAX.COLD MAX.
(4) Install lock nut. While holding adjusting HOT MIN.
screw with a wrench, tighten lock nut using ST.
ST 926230000 SPANNER COLD MIN.
Tightening torque (Lock nut):

39 N·m (4.0 kgf-m, 29 ft-lb)
Hold the adjusting screw with a wrench to pre-
vent it from turning while tightening the lock nut.
PS-00159
4. TIE-ROD
1) Check tie-rod and tie-rod ends for bends, 3) Bleed air when the following cases occur with
scratches or other damage. engine running or stopped:
(1) When fluid level varies 3 mm (0.12 in) or
more.
(2) When foam is produced on the fluid surface.
(3) When oil pump produces squeaky noise.
6. POWER STEERING FLUID FOR LEAKS
Inspect the underside of oil pump and gearbox for
power steering system, hoses, piping and their
(A) couplings for fluid leaks.
If fluid leaks are found, correct them by retightening
(B)
PM-00069 their fitting bolts (or nuts) and/or replacing their
parts.
(A) Tie-rod end NOTE:
(B) Knuckle arm • Wipe the leakage fluid off after correcting fluid
leaks, or a wrong diagnosis is taken later.
2) Check connections of knuckle ball joints for play,
inspect for damage on dust seals, and check free • Also pay attention to clearances between hoses
play of ball studs. If castle nut is loose, retighten it (or pipings) and other parts when inspecting fluid
to the specified torque, then tighten further up to leaks.
60° until cotter pin hole is aligned.
Tightening torque:
27 N·m (2.75 kgf-m, 19.9 ft-lb)
3) Check lock nut on the tie-rod end for tightness. If
it is loose, retighten it to the specified torque.
Tightening torque:
83 N·m (8.5 kgf-m, 61.5 ft-lb)
PM-44
7. HOSES OF OIL PUMP FOR DAMAGES

Check pressure hose and return hose of oil pump
for crack, swell or damage. Replace hose with a
new one if necessary.
NOTE:
Prevent hoses from revolving and/or turning when
installing hoses.
MAX
M IN
PI-00071
8. POWER STEERING PIPES FOR DAM-

AGE
Check power steering pipes for corrosion and dam-
age.
Replace pipes with new ones 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.
2) Clips are fitted outside of (A) and (B) positions of
boot.
3) Boot does not have crack and hole.
NOTE:
Rotate (B) position of gearbox boot against twist of
it produced by adjustment of toe-in, etc. Apply
grease to the groove (C).
(C)
(B)
(A)
PM-00090
10.FITTING BOLTS AND NUTS

Inspect fitting bolts and nuts of oil pump and brack-
et for looseness, and retighten them if necessary.
Inspect and/or retighten them when engine is cold.
PM-45
MEMO:
PM-46

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2003 Model Year

PDF Service Manual

ENGINE SECTION 1 (Pub.No.G2300GE2)

ENGINE SECTION 2 (Pub.No.G2300GE3)

ENGINE SECTION 3 (Pub.No.G2300GE4)

TRANSMISSION SECTION (Pub.No.G2300GE5)

CHASSIS SECTION (Pub.No.G2300GE6)

BODY SECTION (Pub.No.G2300GE7)

WIRING SYSTEM SECTION (Pub.No.G2300GE8)

HOW TO USE THIS MANUALS HU

All information, illustration and specifi-

FUJI HEAVY INDUSTRIES LTD. G2300GE1

Applied model: BE***** and BH***** from 2003MY.

The manuals contain the latest information at the

1. How to Use This Manuals

:Should be lubricated with oil.

(20) :Should be lubricated with grease.

15.Main Shaft Assembly for Sin- (A)

11) Tighten the lock nuts to the specified torque us-

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

*1: With leather seat

5MT: 5 forward speeds with synchromesh and 1-reverse

Option code *1 EC K4 KO, KS

Option code *1 EC K4 KO, KS

*1: With leather seat

5MT: 5 × 2 forward speeds with synchromesh and 1-reverse

1. Precaution 7. AIRBAG MODULE

Without side sill cover

With side sill cover

With side sill cover

Without side sill cover

Rear differential gear

Hook for towing

Hook for tie-down Hook for towing

• Chain direction at tie-down condition 7. TOWING

• Chain pulling range at tie-down condition

45˚ 45˚ 45˚ 45˚

• Vehicle sinking volume at tie-down condition

8. FRONT HOOD STAY INSTALLATION

• When wider hood opening is necessary

9. TRAINING 10.GENERAL SCAN TOOL

Vehicle identification number

• ID plate (Europe model)

• Saudi Arabia plate (Saudi Arabia model)

ENGINE 5MT Transmission serial number

Engine serial number ID-00011 ID-00013

4AT Transmission serial number

Model number plate

• GCC countries (Saudi Arabia, etc.)

3. MODEL NUMBER PLATE

The engine and transmission type are as follows:

• Rear differential 2 • Option code

1. Recommended Materials • Unleaded gasoline

SAE viscosity No. and applicable temperature

(˚C) –30 –20 –10 0 10 20 30 40

(˚F) –22 –4 14 32 50 68 86 104

Manual transmission oil and rear differential gear oil

(˚C) –30 –20 –10 0 10 20 30 40

(˚F) –22 –4 14 32 50 68 86 104

Applied model: BE* and BH* from 2003MY.