General Information: Other Subaru Forester SG рестайлинг

DIMENSION

FORESTER DIMENSION SPECIFICATION

ENGINE

FORESTER ENGINE SPECIFICATION

ELECTRICAL

FORESTER ELECTRICAL SPECIFICATION

TRANSMISSION

FORESTER TRANSMISSION SPECIFICATION

STEERING

FORESTER STEERING SPECIFICATION

SUSPENSION

FORESTER SUSPENSION SPECIFICATION

BRAKE

FORESTER BRAKE SPECIFICATION

TIRE

FORESTER TIRE SPECIFICATION

FOR U.S. MODEL

FORESTER WEIGHT SPECIFICATION - FOR U.S. MODEL

FORESTER WEIGHT SPECIFICATION - FOR U.S. MODEL

FOR CANADA MODEL

FORESTER WEIGHT SPECIFICATION - FOR CANADA MODEL

FORESTER WEIGHT SPECIFICATION - FOR CANADA MODEL

FORESTER WEIGHT SPECIFICATION - FOR CANADA MODEL

OPTIONAL PARTS

FORESTER WEIGHT SPECIFICATION - OPTIONAL PARTS

CAUTION

Please clearly understand and adhere to the following. They must be strictly followed to avoid minor or serious injury to the person doing the work or people in the area.

ABS

Handle the ABS as a total system. Do not disassemble or attempt to repair individual parts. Follow the directions in this manual when performing maintenance on the ABSCM&H/U When parts other than those specified are disassembled, it is possible that the ABS system will not operate when needed or cause it to operate incorrectly and result in injury.

VEHICLE DYNAMICS CONTROL (VDC)

Handle the VDC as a total system. Do not disassemble or attempt to repair individual parts. Doing so could prevent the VDC system from operating when needed or cause it to operate incorrectly and result in injury.

RADIATOR FAN

The radiator fan may rotate without warning, even when the engine is not ON. Do not place your hand, cloth, tools or other items near the fan at any time.

AIRBAG

To prevent bodily injury from unexpected deployment of airbags and unnecessary maintenance, follow the instructions in this manual when performing maintenance on the airbag components or nearby, around front of the vehicle (radiator panel, front wheel apron, front side frame, front bumper, front hood panel, front fender panel), around side of the vehicle (front door panel, center pillar, side sill), and the airbag wiring harnesses or nearby.

To prevent unexpected deployment, turn the ignition switch to OFF and disconnect the ground cable from battery, then wait at least 20 seconds to discharge electricity before starting work.

AIRBAG MODULE AND SEAT BELT PRETENSIONER DISPOSAL

To prevent bodily injury from unexpected airbag deployment, do not dispose the airbag modules and seat belt pretensioner in the same way as other waste. Follow all government regulations concerning disposal of refuse.

AIRBAG MODULE

Adhere to the following when handing and storing the airbag module to prevent bodily injury from unexpected deployment

1. Do not hold the harnesses or connectors to carry the module.
2. Do not face the bag in the direction that it opens towards yourself or other people.
3. Do not face the bag in the direction that it opens towards the floor or walls.

WINDOW

Always wear safety glasses when working around any glass to prevent glass fragments from damaging your eyes.

WINDOW ADHESIVE

Always use the recommended or equivalent adhesive when attaching glass to prevent it from coming loose and falling, resulting in accidents and injury.

OIL

When handling oil, adhere to the following to prevent from unexpected accident.

1. Prepare a container and cloth when performing work which oil possibly spills. If oil spills, wipe it off immediately to prevent from penetrating into floor or flowing out for environmental protection.
2. Follow all government and local regulations concerning disposal of refuse when disposing.

FUEL

When handling and storing fuel, adhere to the following to prevent from unexpected accident.

1. Be careful with fire.
2. Prepare a container and cloth to prevent scattering of fuels when performing work where fuels can be spilled. If the fuel spills, wipe it off immediately to prevent from penetrating into floor or flowing out for environmental protection.
3. Follow all government and local regulations concerning disposal of refuse when disposing.

ENGINE COOLANT

When handling engine coolant, adhere to the following to prevent from unexpected accident.

1. Never remove the radiator cap since engine coolant may blow out when it is hot.
2. Prepare a container and cloth to prevent scattering of engine coolant when performing work where engine coolant can be spilled. If the fuel spills, wipe it off immediately to prevent from penetrating into floor or flowing out for environmental protection.
3. Follow all government and local regulations concerning disposal of refuse when disposing.

AIR CONDITIONER REFRIGERANT

In order to prevent from global warming, avoid releasing air conditioner refrigerant into the atmosphere. Using a refrigerant recovery system, discharge and reuse it.

NOTE

This is the information that can improve the efficiency of maintenance and assure the sound work.

FASTENER NOTICE

Fasteners are used to prevent the parts from damage, dislocation and play due to looseness. Fasteners must be tightened to the specified torque.

Do not apply paint, lubricant, rust retardant or other substance to the surface around bolts, nuts, etc. Doing so will make it difficult to obtain the correct torque and result in looseness and other problem.

STATIC ELECTRICITY DAMAGE

Do not touch the control modules, 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 for the elimination of static electricity before conducting work.

BATTERY

When removing the battery cables, always be sure to turn the ignition switch to OFF to prevent electrical damage to the control module from overcurrent.

SERVICE PARTS

Use genuine parts for maximum performance and maintenance when conducting repairs. Subaru/FHI will not be responsible for poor performance resulting from the use of parts except for genuine parts.

ENSURING SAFETY DURING WORK

When working in a group of two or more, perform the work with calling each other to ensure mutual safety.

LIFTS AND JACKS

When using a lift or shop jack raise a vehicle or using rigid rack to support a vehicle, always follow instructions concerning jack-up points and weight limits to prevent the vehicle from falling, which could result in injury. Be especially careful that the vehicle is balanced before raising it. Be sure to set the wheel stoppers when jacking-up only the front or rear side of the vehicle.

SUPPORT LOCATIONS

Identifying Vehicle Support Locations. Scheme 37

PANTOGRAPH JACK

Identifying Pantograph Jack. Scheme 38

LIFT

Identifying Lift. Scheme 39

RIGID RACK

Identifying Rigid Rack. Scheme 40

JACK-UP POINT

Identifying Jack-Up Point. Scheme 41

TIE-DOWNS

Tie downs are used when transporting vehicles and when using the chassis dynamo. Attach tie-down only to the specified place on the vehicle.

Identifying Tie-Downs. Scheme 42

CHAIN DIRECTION AT TIE-DOWN CONDITION

Identifying Chain Direction At Tie-Down Condition. Scheme 43

CHAIN PULLING RANGE AT TIE-DOWN CONDITION

Identifying Chain Pulling Range At Tie-Down Condition. Scheme 44

VEHICLE SINKING VOLUME AT TIE-DOWN CONDITION

Measure the distance between the highest tire point and highest arch point before and after tie-down. Difference of measured values (sinking volume) should be within 50 mm (1.97 in) and make sure to fix the vehicle securely.

Identifying Distance Between Highest Tire Point And Highest Arch Point. Scheme 45

TOWING

Avoid towing vehicles except when the vehicle cannot be driven. For models with AWD or AT, use a loader instead of towing. When towing other vehicles, pay attention to the following to prevent hook or vehicle damage resulting from excessive weight.

1. Do not tow other vehicles with a front tie-down hook.
2. Make sure the vehicle towing is heavier than the vehicle being towed.

TRAINING

For an information about training, contact a dealer or agent.

MEANING OF V.I.N

The meaning of the V.I.N. is as follows

]JF1 SG636X6G700001 [

The large parentheses (][) located in front and back are stop marks.

VIN MEANING SPECIFICATION

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.

SG9DY4J

MODEL NUMBER PLATE SPECIFICATION

The engine and transmission type are as follows.

Engine

EJ253BSRHB

ENGINE TYPE SPECIFICATION

Transmission

TY755VC7AA

TRANSMISSION TYPE SPECIFICATION

Rear differential

T2

REAR DIFFERENTIAL SPECIFICATION

Option code

U4QW

OPTION CODE SPECIFICATION

To insure the best performance, always use the specified oil, gasoline, adhesive, sealant, etc. or a substitute of equivalent quality.

1. Use unleaded gasoline to reduce air pollution, because using leaded gasoline will damage the catalytic converter.
2. Do not use the low quality gasoline, or improper fuel such as diesel fuel, fuel alcohol, or gasoline additive because they will adversely affect on engine components.
3. Always use gasoline that is equivalent to that prescribed in the instruction manual or that of high octane value. There is the possibility of damaging or improper operation of the engine and fuel injection system if the specifications are not observed. Use the prescribed gasoline type to maintain proper vehicle performance.

LUBRICANTS

Use the lubricants shown in the table below, or equivalent. See the table below to choose the correct SAE viscosity.

LUBRICANT SPECIFICATION Lubricants Recommended materials API spec. ILSAC spec. Engine oil Manual transmission oil GL-5 - Front differential oil GL-5 - Rear differential oil GL-5

Scheme 46

Scheme 47

Engine Oil SAE Viscosity Chart (3 Of 3). Scheme 48

Scheme 49

Use genuine engine coolant to protect the engine.

ENGINE COOLANT SPECIFICATION

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 other than ZXL200PG.

REFRIGERANT SPECIFICATION

GREASE

Use the grease and supplementary lubricants shown in the table below.

GREASE SPECIFICATION

ADHESIVES

Use the adhesives shown in the table below, or equivalent.

ADHESIVES SPECIFICATION

SEAL MATERIAL

Use the seal material shown in the table below, or equivalent.

SEAL MATERIAL SPECIFICATION SPECIFICATION

MAINTENANCE SCHEDULE CHART - FOR U.S. MODEL

MAINTENANCE SCHEDULE CHART - FOR CANADA MODEL

V-BELT COVER

Remove the V-belt covers.

Scheme 50

1. Non-turbo model see scheme 31: Locating V-Belt Cover Bolts (Non-Turbo Model)
2. Turbo model

Locating V-Belt Cover Bolts (Turbo Model). Scheme 51

FRONT SIDE BELT (FOR POWER STEERING OIL PUMP AND GENERATOR)

Note. Wipe off any oil or water on the belt and pulley.

1. Loosen the lock bolt (A).
2. Loosen the slider bolt (B).
3. Remove the front side bolt (C).
4. Install a new belt, and tighten the slider bolt so as to obtain the specified belt tension.
5. Tighten the lock bolt (A).
6. Tighten the slider bolt (B).

Tightening torque

Lock bolt

25 N.m (2.5 kgf-m, 18 ft-lb)

Slider bolt

8 N.m (0.8 kgf-m, 5.8 ft-lb)

Scheme 52

REAR SIDE BELT (FOR AIR CONDITIONER)

Note. Wipe off any oil or water on the belt and pulley.

1. Remove the front side belts.
2. Loosen the lock nut (A).
3. Loosen the slider bolt (B).
4. Remove the rear side belt.
5. Install a new belt, and tighten the slider bolt so as to obtain the specified belt tension.
6. Tighten the lock nut (A).
7. Install the front side belt. FRONT SIDE BELT , INSTALLATION, V-belt. >

Tightening torque

23 N.m (2.3 kgf-m, 17.0 ft-lb)

Identifying Lock Nut And Slider Bolt. Scheme 53

Scheme 54

Scheme 55

Scheme 56

Scheme 57

Scheme 58

1. Remove the radiator fan and air conditioner fan. TURBO MODEL, REMOVAL, Radiator Main Fan and Fan Motor. > RADIATOR SUB FAN AND FAN MOTOR. >
2. Protect the radiator with cardboard and blanket.
3. Remove the V-belt covers. (Scheme 52): Locating V-Belt Cover Bolts (Non-Turbo Model)
4. Remove the V-belts. V-BELT. >
5. Remove the A/C compressor V-belt tensioner.
6. Using the ST, lock the crankshaft and remove pulley bolt. ST 499977100 CRANK PULLEY WRENCH see scheme 36: Removing Pulley Bolt Using Crank Pulley Wrench ST499977100
7. Remove the crank pulley.
8. Remove the belt cover LH.
9. Remove the front timing belt cover.
10. Remove the timing belt guide. (MT model) see scheme 37: Locating Timing Belt Guide Bolts
11. Turn the crankshaft and align the alignment marks on crankshaft, and left and right cam sprockets with notches of belt cover and cylinder block. ST 499987500 CRANKSHAFT SOCKET (Scheme 54): Identifying Alignment Marks On Crankshaft And Cam Sprockets
12. Remove the belt idler.
13. Remove the belt idler (No. 2). (Scheme 55): Removing Belt Idler
14. Remove the timing belt.
15. Remove the automatic belt tension adjuster assembly. (Scheme 56): Removing Automatic Belt Tension Adjuster Assembly
16. Install in the reverse order of removal. INSTALLATION, Timing Belt. >

Scheme 59

Scheme 60

Scheme 61

Scheme 62

Scheme 63

Scheme 64

Scheme 65

Scheme 66

1. Remove the radiator fan and air conditioner fan. RADIATOR MAIN FAN AND FAN MOTOR. > RADIATOR SUB FAN AND FAN MOTOR. >
2. Protect the radiator with cardboard and blanket.
3. Remove the V-belts. V-BELT. >
4. Remove the A/C compressor V-belt tensioner.
5. Using the ST, lock the crankshaft and remove pulley bolt. ST 499977100 CRANK PULLEY WRENCH (Scheme 57): Removing Pulley Bolt Using Crank Pulley Wrench ST499977100
6. Remove the crank pulley.
7. Remove the belt cover (LH).
8. Remove the belt cover (RH).
9. Remove the front belt cover.
10. Remove the timing belt guide. (MT model) (Scheme 58): Locating Timing Belt Guide Bolts (1 Of 4) (Scheme 59): Locating Timing Belt Guide Bolt (2 Of 4) see scheme 44: Locating Timing Belt Guide Bolt (3 Of 4) (Scheme 60): Locating Timing Belt Guide Bolt (4 Of 4)
11. Turn the crankshaft and align the alignment marks on crankshaft, and left and right cam sprockets with notches of belt cover and cylinder block. Use the ST to turn crankshaft. ST 499987500 CRANKSHAFT SOCKET (Scheme 61): Identifying Alignment Marks On Crankshaft And Cam Sprockets (Scheme 62): Aligning Alignment Marks On Crankshaft And Cam Sprockets
12. Remove the belt idler. (Scheme 63): Removing Belt Idler
13. Remove the timing belt.
14. Remove the automatic belt tension adjuster assembly. (Scheme 64): Identifying Automatic Belt Tension Adjuster Assembly
15. Install in the reverse order of removal. INSTALLATION, Timing Belt. >

Scheme 67

1. Remove the front timing belt cover and timing belt cover (LH).
2. While cranking engine at least four rotations, check the timing belt back surface for cracks or damage. Replace the faulty timing belt as needed.
3. Measure the timing belt width W. If it is less than 27 mm (1.06 in), check the idlers, tensioner, water pump pulley and cam sprocket to determine idler alignment (squareness). Replace the worn timing belt. (Scheme 65): Identifying Timing Belt Width - SOHC Model
4. Install the front timing belt cover and timing belt cover (LH).

Scheme 68

1. Remove the timing belt cover (LH).
2. While cranking 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 29 mm (1.14 in), check the idlers, tensioner, water pump pulley and cam sprocket to determine idler alignment (squareness). Replace the worn timing belt. (Scheme 66): Identifying Timing Belt Width - DOHC Model
4. Install the timing belt cover (LH).

NON-TURBO MODEL

Install in the reverse order of removal.

Scheme 69

TURBO MODEL

Install in the reverse order of removal.

Locating Air Cleaner Upper Cover. Scheme 70

Scheme 71

Scheme 72

Scheme 73

Scheme 74

1. To check the radiator for leakage, fill it with engine coolant, and attach the radiator cap tester (A) to the filler neck, and apply pressure. Pressure: Non-turbo model 157 kPa (1.6 kg/cm 2, 23 psi) Turbo model 122 kPa (1.2 kg/cm 2,18 psi) Check the following points: Leak from radiator Hose joints and other connections for leakage CAUTION: For Turbo model, inspection must be carried out at the side of coolant filler tank, not at the side of radiator. Be particularly careful not to deform the filler neck of radiator when installing and removing the tester and after testing. When performing this check, be sure to keep the engine stationary and fill radiator with coolant. Wipe off check points before applying pressure. Use care not to spill coolant when detaching tester from radiator. Non-turbo model (Scheme 69): Identifying Radiator Cap Tester - Non-Turbo Model Turbo model see scheme 59: Identifying Radiator Cap Tester - Turbo Model
2. Check the radiator cap valve open pressure using radiator cap tester. Raise the pressure until the needle of gauge stops and see if the pressure can be retained for five to 6 seconds. The radiator cap is normal if a pressure above the service limit value has been maintained for this period. CAUTION: Rust or dirt on the cap may prevent valve from functioning normally: be sure to clean the cap before testing. Radiator side for Non-turbo model and coolant filler tank side for Turbo model Specification: 93 - 123 kPa (0.95 - 7.25 kg/cm 2, 14 - 18 psi) Service limit pressure: 83 kPa (0.85 kg/cm 2, 12 psi) Radiator side of Turbo model Specification: 122 - 152 kPa (1.24 - 1.55 kg/cm 2, 18 - 22 psi) Service limit pressure: 112 kPa (1.14 kg/cm 2, 16 psi) (Scheme 71): Checking Radiator Cap Valve Open Pressure (Scheme 72): Identifying Radiator Cap Valve Check Points For Deformation
3. Start the engine, and then inspect that it does not overheat or it is cooled excessively. If it overheats or it is cooled excessively, check the cooling system. INSPECTION, Water Pump. > INSPECTION, Thermostat. > RADIATOR. > RADIATOR CAP. >
4. Check the radiator fan operates using Subaru Select Monitor, when the coolant temperature exceeds 95°C (203°F). If it does not operate, check the radiator fan system. RADIATOR FAN SYSTEM. >

RELATIONSHIP OF SUBARU COOLANT CONCENTRATION AND FREEZING TEMPERATURE

The concentration and safe operating temperature of the SUBARU coolant is shown in the diagram. Measuring the temperature and specific gravity of the coolant will provide this information.

[Example]

If the coolant temperature is 25°C (77°F) and its specific gravity is 1.054, the concentration is 35% (point A), the safe operating temperature is -14°C (7°F) (point B), and the freezing temperature is -20°C (-4°F) (point C).

Scheme 75

ATF FILTER

Note. ATF filter needs replacement when it is physically damaged or ATF leaked.

For the replacement procedure of ATF filter, refer to " ATF FILTER ". ATF FILTER. >

FRONT DIFFERENTIAL (MT MODEL)

For MT model, differential gear oil works as manual transmission gear oil to lubricate differential. TRANSMISSION GEAR OIL. >

Scheme 76

1. Drain the differential gear oil by removing drain plug using TORX® T70. CAUTION: Before starting work, cool off the differential gear oil well. see scheme 73: Identifying Drain Plug
2. Replace the gasket with new one, and then tighten the drain plug to specified torque. Tightening torque: Aluminum gasket 44 N.m (4.5 kgf-m, 32.5 ft-lb) Copper gasket 70 N.m (7.1 kgf-m, 51.6 ft-lb)
3. Fill differential gear oil through the oil level gauge hole up to the upper point of level gauge.

Gear oil capacity

1.1 - 1.3 l (1.2 - 1.4 US qt, 1.0 - 1.1 Imp qt)

Identifying Differential Gear Oil Level. Scheme 77

Scheme 78

1. Remove the drain plug, and drain the differential gear oil.
2. Remove the filler plug for quick draining oil.
3. Install the drain plug after draining oil. NOTE: Apply liquid gasket to the drain plug threads. Liquid gasket: Three bond 1105 (Part No.004403010) Tightening torque: 49.0 N.m (5.0 kgf-m, 36.2 ft-lb)
4. After installing drain plug onto rear differential gear case firmly, fill oil up fully to the mouth of filler plug. (Scheme 76): Identifying Filler Plug And Drain Plug Oil capacity: 0.8 l (0.8 US qt, 0.7 Imp qt) CAUTION: Each oil manufacturer has its base oil and additives. Thus, do not mix two or more brands.
5. Install the filler plug onto rear differential gear case firmly.

Note. Apply liquid gasket to the threads of the filler plug screws.

Liquid gasket

Three bond 1105 (Part No.004403010)

Tightening torque

49.0 N.m (5.0 kgf-m, 36.2 ft-lb)

Brake Line

1. Check for scratches, swelling, corrosion, traces of fluid leakage on the brake hoses or pipe joints.
2. Check the possibility of adjacent parts interfering with brake pipes/hoses during driving, and loose connections/clamps.
3. Check any trace of fluid leakage, scratches, etc. on master cylinder, wheel cylinder and pressure control valve.

Note. When the brake fluid level in the reservoir tank is lower than specified limit, the brake warning light on the combination meter will come on. Visually check the brake hose for damage. (Use a mirror where it is difficult to see)

Locating Front Brake Hose And Brake Pipe. Scheme 79

Scheme 80

Scheme 81

Scheme 82

Scheme 83

1. Check the free play of brake pedal with a force of less than 10 N (1 kgf, 2 lb). Brake pedal free play: 0.5 - 2.0 mm (0.02 - 0.08 in) see scheme 78: Identifying Brake Pedal Free Play
2. If the free play is out of the specifications values, adjust the brake pedal as follows. Make sure the engine is off. (No vacuum is applied to brake booster.) Inspect that there is play between brake booster clevis and pin at brake pedal installing portion. [Depress brake pedal pad with a force of less than 10 N (1 kgf, 2 lb) to a stroke of 0.5 to 2.0 mm (0.02 to 0.08 in).] Depress the surface of brake pad by hand. If there is no free play between clevis pin and clevis, turn brake switch adjusting nut until the clearance between stopper and screw of brake switch becomes 0.3 mm (0.012 in). (Scheme 80): Identifying Brake Pedal Free Play
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 wheel. With the brake pedal released, measure the distance between pedal and steering wheel again. The difference between the two measured values must be less than specified value. If the measured value is more than specification, there is possibility of entering air in hydraulic unit. Brake pedal stroke A 105 mm (4.13 in) or less/490 N (50 kgf, 110 lb) (Scheme 81): Identifying Distance Between Pedal And Steering Wheel
4. Check to see if air is in the hydraulic brake line by the feel of pedal operation. If air appears to exist in the line, bleed it from the system.
5. Check for even operation of all brakes, using a brake tester or by driving the vehicle for a short distance on a straight road.

Scheme 84

1. With the engine off, depress the brake pedal several times applying the same pedal force. Make sure the travel distance should not change.
2. With the brake pedal depressed, start the engine. Check that the pedal moves slightly toward the floor.
3. With the brake pedal depressed, stop the engine and keep the pedal depressed for 30 seconds. Check that the pedal height does not change.
4. A check valve is built into the vacuum hose. Remove the vacuum hose to inspect function of the check valve. Blow air into vacuum hose from its brake booster side. Check that the air flows out to the engine side of the air hose. Next blow air into hose from engine side: Check that the air does not flow out to the brake booster side. Replace the both check valve and vacuum hose if the check valve is faulty. Engine side of vacuum hose is indicated by marking "ENG" as shown. (Scheme 82): [Identifying Vacuum Hose Marking ENG]
5. Check the vacuum hose for cracks or other damage. CAUTION: When installing the vacuum hose on the engine and brake booster, do not use soapy water or lubricating oil on their connections.
6. Check that the vacuum hose is securely mounted.

Scheme 85

Scheme 86

1. Lift-up the vehicle.
2. Remove all of the tires.
3. Drain the brake fluid from master cylinder.
4. Refill the reservoir tank with recommended brake fluid. Recommended brake fluid: FMVSS No. 116, New part DOT3 or DOT4 brake fluid CAUTION: Avoid mixing brake fluid of different brands to prevent fluid performance from degrading. Be careful not to allow dirt or dust to enter into reservoir tank. Bleeding sequence (1) --> (2) --> (3) --> (4) (Scheme 83): Identifying Brake Fluid Bleeding Sequence
5. Install one end of a vinyl tube onto the air bleeder and insert the other end of the tube into a container to collect the brake fluid. (Scheme 84): Collecting Brake Fluid CAUTION: Cover the bleeder with cloth, when loosening it, to prevent brake fluid from being splashed over surrounding parts. During air bleeding, keep the reservoir tank filled with brake fluid to eliminate entry of air. The brake pedal operation must be very slow. For convenience and safety, two people should do the work. NOTE: The amount of brake fluid required is approx. 500 l C (16.9 US fl oz, 17.6 Imp fl oz) for total brake system.
6. Instruct your co-worker to depress the brake pedal slowly two or three times and then hold it depressed.
7. Loosen the bleeder screw approximately 1/4 turn until a small amount of brake fluid drains into the container, and then quickly tighten the screw.
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: 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 the brake pedal depressed and tighten the bleeder and install bleeder cap. Tightening torque: 8 N.m (0.8 kgf-m, 5.8 ft-lb)
10. Bleed air from each wheel cylinder by following steps from 5) to 9).
11. Depress the brake pedal with a force of approx. 294 N (30 kgf, 66 lb) and hold it there for approx. 20 seconds. At this time check the pedal to see if it makes any unusual movement. Visually inspect the bleeder screws and brake pipe joints to confirm there is no fluid leakage.
12. Install the wheels, and drive the vehicle for a short distance between 2 to 3 km (1 to 2 miles) to confirm brakes are operating properly.

Scheme 87

Scheme 88

1. Lift-up the vehicle and remove wheel.
2. Visually check the pad thickness through inspection hole of disc brake assembly. Replace the pad if necessary. CAUTION: When replacing a pad, always replace the pads for both the left and right wheels at the same time. Also replace the pad clips if they are twisted or worn. (Scheme 85): Identifying Inspection Hole Of Disc Brake Assembly PAD THICKNESS SPECIFICATION Pad thickness mm (in) Front Rear Standard 11 (0.43) 9 (0.35) Wear limit 1.5(0.059) 1.5 (0.059) (Scheme 86): Identifying Pad Thickness
3. Check the disc rotor, and correct or replace if it is damaged or worn. BRAKE DISC THICKNESS SPECIFICATION Brake disc thickness mm (in) Front Rear Standard 24 (0.94) 10 (0.39) Wear limit 22 (0.87) 8.5 (0.335)
4. Remove the caliper body. FRONT DISC BRAKE ASSEMBLY. > REAR DISC BRAKE ASSEMBLY. >
5. Tighten the wheel nuts to secure disk rotor.
6. Set a dial gauge at a point less than 10 mm (0.39 in) from outer periphery of the rotor, and then measure the disk rotor runout.

Disc rotor runout limit

Front

0.075 mm (0.0030 in)

Rear

0.070 mm (0.0028 in)

Identifying Brake Drum Inside Diameter. Scheme 89

Scheme 90

1. Remove the brake drum and check for fluid leaks from the wheel cylinder. If fluid leaks are found in the wheel cylinder, check the wheel cylinder and repair or replace it.
2. Inspect the brake shoes for damage or deformation and check the brake linings for wear beyond limit values. CAUTION: Always replace the wheel leading and trailing brake shoes for the left and right wheels at the same time. When replacing either the left or the right brake assembly, always replace the leading shoe and the trailing shoe of one side. Thickness of lining (except for back metal) Standard: 4.1 mm (0.161 in) Service limit: 1.5 mm (0.059 in) (Scheme 88): Identifying Drum Rotating Direction (Forward)
3. Check the brake drum for wear, dents or other damage.

If the inside surface of brake drum is streaked, correct the surface with emery cloth (#200 or more). If it is unevenly worn or tapered, or the outer surface of the brake drum is damaged, repair or replace it.

Brake drum inside diameter

Standard

228.6 mm (9.000 in)

Service limit

230.6 mm (9.079 in)

If the deformation or wear of back plate, shoe, etc. is noticeable, replace problem parts.

PARKING BRAKE (REAR DISC BRAKE)

Inspect the brake linings and disc rotor of both sides of the rear brake at the same time by removing disc rotor.

Scheme 91

Scheme 92

1. Inspect the brake shoes for damage or deformation and check the brake linings for wear beyond limit values. CAUTION: Always replace both primary and secondary brake shoes for the left and right wheels at the same time. Thickness of brake lining (except for back metal): Standard: 3.2 mm (0.126 in) Service limit: 1.5 mm (0.059 in) (Scheme 90): Identifying Brake Shoe
2. Check the inside of disk rotor for wear, dents or other damage. If the inside surface of dick rotor is streaked, correct the surface with emery cloth (#200 or more). If it is unevenly worn or tapered, correct or replace it. Brake drum inside diameter: Standard: 170 mm (6.69 in) Service limit: 171 mm (6.73 in) see scheme 90: Identifying Brake Drum Inside Diameter
3. If the deformation or wear of back plate, shoe, etc. is noticeable, replace problem parts.
4. When the shoe return spring tension is excessively weakened, replace it.

REAR DRUM BRAKE

The main brake automatically adjusts itself, so no adjustments are needed.

For rear disc brake, adjust the parking brake after bleeding air.

Scheme 93

1. Remove the rear cover (rubber) installed at back plate.
2. Turn the adjuster toward arrow mark (upward) until it is locked slightly, by using flat-tip screwdriver as shown in the figure. (Scheme 91): Locking Adjuster
3. Turn back (downward) the adjuster 3 to 4 notches.
4. Install the rear cover (rubber) in original position correctly.

Scheme 94

Scheme 95

Scheme 96

1. Lift up the vehicle until front wheels are off ground.
2. Grasp the bottom of tire and move it in and out. If relative movement (B) is observed between the brake disc cover (A) and end of transverse link (D), ball joint (C) may be excessively worn. (Scheme 92): Identifying Brake Disc Cover And Ball Joint
3. Next, grasp the end of transverse link (C) and move it up and down. Relative movement (A) between the housing (D) and transverse link (C) boss indicates ball joint (B) may be excessively worn. (Scheme 93): Identifying Ball Joint And Brake Disc Cover
4. If the relative movement is observed in the preceding two steps, remove and inspect the ball joint. If the free play exceeds standard value, replace the ball joint. FRONT BALL JOINT. >
5. Damage of dust seal Visually inspect the ball joint dust seal. When there is damage, remove the transverse link to measure the play of ball joint. FRONT TRANSVERSE LINK. > FRONT BALL JOINT. > When looseness exceeds standard value, replace the ball joint. If the dust seal is damaged, replace it with a new ball joint. NOTE: When the transverse link ball joint has been removed or replaced, check the toe-in of front wheel. If it is not within the specified value, adjust the toe-in. WHEEL ALIGNMENT. > (Scheme 94): Identifying Dust Seal

TRANSVERSE LINK REAR BUSHING

Check around the rear bushing for oil leaks. If oil leaks, replace bushing.

Identifying Inner Oil Seal, Snap Ring, Bearing, Tone Wheel And Hub Bolt. Scheme 97

WHEEL ARCH HEIGHT

1. Unload the cargoes and set the vehicle in curb weight (empty) condition.
2. Then, check the wheel arch height of front and rear suspensions to ensure that they are within specified values. WHEEL ALIGNMENT . >
3. When the wheel arch height is out of standard, visually inspect the following components and replace deformed parts. Suspension components [Front strut assembly and rear strut assembly] Parts connecting suspension and body
4. When no components are deformed, adjust wheel arch height by replacing coil spring in the suspension whose wheel arch height is out of standard. WHEEL ALIGNMENT . > WHEEL ALIGNMENT . >

OIL LEAKAGE OF STRUT

Visually inspect the front strut and rear strut for oil leakage. If there is a bad oil leak, replace the front strut and rear strut.

TIGHTNESS OF BOLTS AND NUTS

Check the bolts and nuts for looseness. Retighten the bolts and nuts to specified torque. If the self-locking nuts and bolts are removed, replace them with new ones.

Front suspension: GENERAL DESCRIPTION . >

Rear suspension: GENERAL DESCRIPTION . >

DAMAGE TO SUSPENSION PARTS

Check the following parts and the fastening portion of the vehicle body for deformation or excessive rusting which impairs the suspension. If necessary, replace the damaged parts with new ones. If minor rust, pitting, etc. are noted, remove the rust and take rust prevention measure.

1. FRONT SUSPENSION Transverse link Crossmember Strut
2. Rear suspension Crossmember Lateral link Trailing link Strut
3. In the area where salt is sprayed to melt snow on a road in winter, check suspension parts for damage caused by rust every 12 months after lapse of 60 months. Also, take rust prevention measure as required.

FRONT WHEEL BEARING

Note. Inspect the condition of front wheel bearing grease.

1. Lift-up the vehicle.
2. While holding the front wheel by hand, swing it in and out to check that there is no bearing free play.
3. Loosen the wheel nuts, and remove the front wheel.
4. If the bearing free play exists in step 2) above, attach a dial gauge to hub and measure the looseness in the axial direction. Service limit: 0.05 mm (0.0020 in) Max.
5. Remove the bolts and self-locking nuts, and extract transverse link from the front crossmember.
6. Remove the AARi of front drive shaft from transmission. FRONT AXLE . >
7. While supporting the front drive shaft horizontally with one hand, turn the hub with the other hand to check for noise or binding.

If the hub is noisy or binds, disassemble the front axle and replace the oil seals or bearing.

Identifying Front Axle Boot. Scheme 98

REAR WHEEL BEARING

1. Lift-up the vehicle.
2. While holding the rear wheel by hand, swing it in and out to check that there is no bearing free play.
3. Loosen the wheel nuts, and remove the rear wheel.
4. If the bearing free play exists in step 2) above, attach a dial gauge to hub COMPL and measure the looseness in the axial direction. Service limit: 0.05 mm (0.0020 in) Max.
5. Remove the DOJ of rear drive shaft from rear differential. REAR DRIVE SHAFT . >
6. While supporting rear drive shaft horizontally with one hand, turn the hub COMPL with the other to check for noise or binding.

If the hub COMPL is noisy or binds, disassemble the rear axle and replace the oil seals or bearing.

FRONT AND REAR AXLE BOOTS

Inspect the front axle boots (A) and rear axle boots (B) for deformation, damage or failure. If faulty, replace with new one. FRONT DRIVE SHAFT . > REAR DRIVE SHAFT . >

Identifying Rear Axle Boot. Scheme 99

PROPELLER SHAFT

Inspect the propeller shaft for damage or failure. If faulty, replace with new one. PROPELLER SHAFT . >

STEERING SHAFT JOINT

When the steering wheel free play is excessive, disconnect the universal joint of steering shaft and check it for any play and yawing torque (at the point of the crossing direction). Also inspect for any damage to sealing or worn serrations. If the joint is loose, retighten the mounting bolts to the specified torque.

Tightening torque

24 N.m (2.4 kgf-m, 17.4 ft-lb)

Locating Steering Shaft Joint Mounting Bolts. Scheme 100

Scheme 101

Scheme 102

1. Set the steering wheel in the straight position, then rotate it 90° in both the left and right directions. While steering wheel is being rotated, check the looseness of the gear box. Tightening torque: 59 N.m (6.0 kgf-m, 43.4 ft-lb) see scheme 104: Identifying Boot And Gearbox Mounting Bolts
2. Check the boot for damage, cracks or deterioration.
3. With the vehicle stopped on a level surface, quickly turn the steering wheel to the left and right. While steering wheel is being rotated, check the gear backlash. If any noise is noticed, adjust the gear backlash in the following manner. Tighten the adjusting screw to 9.8 N.m (0.99 kgf-m, 7.2 ft-lb) and then loosen. Tighten the adjusting screw to 4.9 N.m (0.49 kgf-m, 3.6 ft-lb) and then loosen. Tighten the adjusting screw to 4.9 N.m (0.49 kgf-m, 3.6 ft-lb) and then loosen 26°. Apply liquid gasket to at least 1/3 of entire perimeter of adjusting screw thread. see scheme 105: Identifying Liquid Gasket Applying Area Install the lock nut. While holding the adjusting screw with wrench, tighten the lock nut using ST. ST 926230000 SPANNER Tightening torque (lock nut): 39 N.m (4.0 kgf-m, 29 ft-lb) Hold the adjusting screw with a wrench to prevent it from turning while tightening the lock nut.

Scheme 103

1. Check the tie-rod and tie-rod ends for bends, scratches or other damage. (Scheme 101): Identifying Tie-Rod End And Knuckle Arm
2. Check the connections of the knuckle ball joints for play, inspect for damage on dust seals, and check that there is no free play in the ball studs. If castle nut is loose, retighten it to the specified torque, then tighten further up to a maximum of 60° until the cotter pin hole is aligned. Tightening torque: 27 N.m (2.75 kgf-m, 19.9 ft-lb)
3. Check the lock nut on the tie-rod end for tightness. If it is loose, retighten it to the specified value.

Tightening torque

83 N.m (8.5 kgf-m, 61.5 ft-lb)

HOSES OF OIL PUMP FOR DAMAGES

Check the pressure hose and return hose of oil pump for crack, swell or damage. Replace the hose with a new one if necessary.

Scheme 104

POWER STEERING PIPES FOR DAMAGE

Check the power steering pipes for corrosion and damage.

Replace the pipes with new ones if necessary.

GEARBOX BOOTS

Inspect both sides of the gearbox boot as follows, and correct the defects if necessary.

1. The (A) and (B) positions of the gearbox boot are fitted in (A) and (C) grooves of gearbox and the rod.
2. Clips are fitted outside of positions (A) and (B) of boot.
3. Check that there is no cracks or holes in the boot.

Note. Rotate (B) position of gearbox boot against the torsion produced by the adjustment of toe-in etc. Apply grease to the groove (C).

Identifying Gearbox Boots Position. Scheme 105

FITTING BOLTS AND NUTS

Inspect the installation bolts and nuts of the oil pump and bracket for looseness, and retighten them if necessary.

Note. Inspect and/or retighten the bolts and nuts when the engine is cold.