General Information: Other Subaru Forester SH

COMPONENT

Illustrations are provided for each component. The information necessary for repair work (tightening torque, grease up points, etc.) is described on these illustrations. Information is described using symbol. To order parts, refer to parts catalogue.

Example

Scheme 42

SI UNITS

Measurements in these Articles 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)

List

EXPLANATION OF TERMINOLOGY CHART

DIMENSION

FORESTER SPECIFICATIONS

ENGINE

ENGINE SPECIFICATIONS

ELECTRICAL

ELECTRICAL SPECIFICATIONS

MT

TRANSMISSION SPECIFICATIONS

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

DSPD: Dry Single Plate Diaphragm

TRANSMISSION SPECIFICATIONS

4AT: Electronically controlled fully-automatic, 4-forward speeds and 1-reverse

TCC: Torque Converter Clutch

STEERING

STEERING SPECIFICATIONS

SUSPENSION

SUSPENSION SPECIFICATIONS

BRAKE

BRAKE SPECIFICATIONS

TIRE

TIRE SPECIFICATIONS

NON-TURBO MODEL

WEIGHT SPECIFICATIONS

For option codes, refer to the ID article. Refer to MODEL NUMBER PLATE , IDENTIFICATION, Identification.

TURBO MODEL

WEIGHT SPECIFICATIONS

For option codes, refer to the ID article. Refer to MODEL NUMBER PLATE , IDENTIFICATION, Identification.

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.

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 the system may 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 information 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), rear door panel, C pillar, rear seat 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.

WIN DOW 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 recycle it.

NOTE

This information will improve the efficiency of maintenance and assure the sound work.

FASTENERS NOTICE

Replace the nonreusable parts with new parts. Check the tightening torque and tighten 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 SECURITY DURING WORK

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

LIFT AND JACK

When using a lift or shop jack to raise a vehicle or using rigid rack to support a vehicle, always follow instructions concerning jack-up points and weight limits to prevent the vehicle from falling, which could result in injury. 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.

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TIE-DOWNS

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

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Scheme 51

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.

Scheme 52

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.
3. When towing the vehicle, install the towing hook (eye bolt).

Scheme 53

WHEN WIDER HOOD OPENING IS NECESSARY

Set the damper stay below as shown in the illustration.

Scheme 54

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

] JF2SH636X9G700001 [

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

CODE CHART

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.

SH9AY4J

MODEL NUMBER PLATE CODE

The engine and transmission type are as follows.

EJ253ASZFB

ENGINE SPECIFICATIONS

TRANSMISSION

1. MT TY758VCZAA TRANSMISSION SPECIFICATIONS Digits Code Meaning Details 1 T Transmission T: Transmission 2 Y Transmission system Y: Full-time AWD MT center differential 3 and 4 75 Classification 75: 5MT 5 8 Series 8:5MT 6 V Transmission basic specifications V: Full-time AWD 5 speed MT single range with viscous coupling center differential 7 C Mounted engine C: 2.5 L SOHC 8 Z Model change Z: Start --> Y, X... 9-10 AA Detailed specifications Used for ordering parts. See the parts catalog for details.
2. AT TZ1B8LCZAA TRANSMISSION SPECIFICATIONS Digits Code Meaning Details 1 T Transmission T: Transmission 2 Z Transmission system Z: Full-time AWD AT MPT 3 and 4 1B Classification 1B: 4AT 5 8 Series 8: 4AT 6 L Transmission basic specifications L: MP-T full-time AWD direct 4 speed AT 7 C Mounted engine B: 2.5 L DOHC turbo C: 2.5 L SOHC 8 Z Model change Z: Start --> Y, X... 9-10 AA Detailed specifications Used for ordering parts. See the parts catalog for details.

REAR DIFFERENTIAL

T2

REAR DIFFERENTIAL SPECIFICATIONS

OPTION CODE

U5LK

OPTION CODE CHART

1. 3rd digit OP CODE CHART OP code E I L M N P Q T U Y 3 Aluminum wheel (16-inch) - - - - o - - - - - - Aluminum wheel (17-inch) o o - o - o o - o o o Leather seats and leather door trim center decoration o o - o - - o - o - o High grade audio o - - - o o o - o - o Navigation system - o - o - - - - - - - Front fog light o o - o o o o - o - o Cruise control o o o o o o o o o o o HID headlight - - - - - - o - o - - Dark colored glass o o - o o o o o o o o Roof spoiler o - - o - o o - - - - Leather package base (1) o o - o - - o - o - o (1) Leather-wrapped MT shift knob or leather-wrapped AT selector grip, leather-wrapped steering wheel
2. 4th digit OP CODE CHART OP code A B C D K L M Sunroof - o o - - o o VDC o o o o o o o Power seat - - - - - - o Seat heater o o - - - - o Fully automatic air conditioner - - - - - - o Manual air conditioner o o o o o o - Front wiper deicer - o o - - - o Heated mirror o o o o - - o Side airbag o o o o o o o Curtain airbag o o o o o o o

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.

LUBRICANTS SPECIFICATIONS Lubricants Recommended materials API spec. ILSAC spec. Engine oil Choose oil suitable for the standard from the right. Manual transmission oil GL-5 - Front differential oil GL-5 - Rear differential oil GL-5

Scheme 55

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Scheme 58

Use genuine engine coolant to protect the engine.

ENGINE COOLANT RECOMMENDED NUMBER

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 DH-PR.

AIR CONDITIONER ITEM NUMBER

GREASE

Use grease and supplementary lubricants shown in the table below.

ITEM NUMBER SPECIFICATION

ADHESIVE

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

ADHESIVE SPECIFICATION CHART

SEAL MATERIAL

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

SEAL MATERIAL SPECIFICATIONS CHART

FOR U.S. MODEL

MAINTENANCE CHART FOR U.S. MODEL

FOR CANADA MODEL

MAINTENANCE CHART FOR CANADA MODEL

DOHC MODEL

Recommended spark plug

Refer to ELECTRICAL , Forester.

Scheme 59

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Scheme 62

1. RH side Remove the collector cover. Disconnect the ground cable from the battery. Remove the air cleaner case. Refer to «REMOVAL»(ref-325300-S05802953992009071800000) , Air Cleaner Case. Disconnect the connector from ignition coil. Remove the ignition coil. NOTE: Turn #3 ignition coil by 180 degrees to remove it. Remove the spark plug with a spark plug socket. Install in the reverse order of removal. Tightening torque (Sparkplug): 21 N.m (2.1 kgf-m, 15.5 ft-lb) Tightening torque (Ignition coil): 16 N.m (1.6 kgf-m, 11.8 ft-lb)
2. LH side Remove the collector cover. Remove the battery and battery carrier. Disconnect the air duct from the secondary air pump. Remove the bolts that attach the air pump duct to the rocker cover (LH), and raise the air pump duct. Disconnect the connector from ignition coil. Remove the ignition coil. NOTE: Turn #4 ignition coil by 180 degrees to remove it. Remove the spark plug with a spark plug socket. Install in the reverse order of removal. Tightening torque (Spark plug): 21 N.m (2.1 kgf-m, 15.5 ft-lb) Tightening torque (Ignition coil): 16 N.m (1.6 kgf-m, 11.8 ft-lb) Tightening torque (Air pump duct): 9 N.m (0.9 kgf-m, 6.6 ft-lb)

PROCEDURE NOT USING BELT A TENSION GAUGE

1. Replace the belts, if crack, fraying or wear is found.
2. Check the V-belt tension and adjust it if necessary by changing the generator installing position or idler pulley installing position. Refer to «REPLACEMENT»(ref-325297-S06906628822009071800000) , V-belt.

Belt tension

(A)

When replacing: 7 - 9 mm (0.276 - 0.354 in)

When reusing: 9 - 11 mm (0.354 - 0.433 in)

(B)

When replacing: 7.5 - 8.5 mm (0.295 - 0.335 in)

When reusing: 9.0 - 10.0 mm (0.354 - 0.394 in)

Scheme 63

PROCEDURE WITH BELT TENSION GAUGE

1. Replace the belts, if crack, fraying or wear is found.
2. Remove the V-belt cover and radiator reservoir tank.
3. Check the tension of the V-belt using the belt tension gauge. Adjust the tension if necessary by adjusting the installation position of the generator or idler pulley.

Belt tension (Non-turbo model)

When installing new parts

640 - 780 N (65 - 80 kgf, 144 - 175 lbf)

At inspection

490 - 640 N (50 - 65 kgf, 110 - 144 lbf)

Belt tension (Turbo model)

When installing new parts

640 - 780 N (65 - 80 kgf, 144 - 175 lbf)

At inspection

490 - 640 N (50 - 65 kgf, 110 - 144 lbf)

Scheme 64

V-BELT COVER

Remove the V-belt covers. (Non-turbo model)

Scheme 65

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

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

Scheme 66

1. Loosen the lock bolt (A).
2. Loosen the slider bolt (B).
3. Remove the front side belt (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, 18.4 ft-lb) Slider bolt 8 N.m (0.8 kgf-m, 5.9 ft-lb)
7. Start and run the engine for approximately five minutes to allow the V-belt to become fitted. (When using the gauge)
8. Stop the engine, check the belt tension and adjust as necessary. (When using the gauge)
9. Start and run the engine for approximately one minute to allow the V-belt to become fitted. (When using the gauge)
10. Stop the engine and check that the belt tension is within the specification. (When using the gauge)
11. Adjust until the specified belt tension is obtained. (When using the gauge)

REAR SIDE BELT (FOR AIR CONDITIONER)

1. Remove the front side belts.
2. Cut the rear side belt.
3. Install a new belt using an installation jig. Refer to «REAR SIDE BELT»(ref-325301-S28281214402009071800000) , INSTALLATION, V-belt. Refer to «REAR SIDE BELT»(ref-325302-S07260117232009071800000) , INSTALLATION, V-belt.
4. Install the front side belt.

Refer to FRONT SIDE BELT , INSTALLATION, V-belt.

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1. Remove the radiator fan and air conditioner fan. Refer to «REMOVAL»(ref-325303-S22986777642009071800000) , Radiator Main Fan and Fan Motor. Refer to «REMOVAL»(ref-325303-S29286816082009071800000) , Radiator Sub Fan and Fan Motor.
2. Protect the radiator with cardboard and blanket.
3. Remove the V-belt covers.
4. Remove the V-belts. Refer to «REMOVAL»(ref-325301-S15291069492009071800000) , V-belt.
5. Remove the A/C compressor V-belt tensioner.
6. Using the ST, lock the crankshaft and remove pulley bolt. MT model ST 499977100 CRANK PULLEY WRENCH AT model ST 499977400 CRANK PULLEY WRENCH
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)
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
12. Remove the belt idler.
13. Remove the belt idler (No. 2).
14. Remove the timing belt.
15. Remove the automatic belt tension adjuster assembly.
16. Install in the reverse order of removal. Refer to «INSTALLATION»(ref-325301-S23320513242009071800000) , Timing Belt.

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1. Remove the radiator fan and air conditioner fan. Refer to «REMOVAL»(ref-325304-S15436844672009071800000) , Radiator Main Fan and Fan Motor. Refer to «REMOVAL»(ref-325304-S24801725262009071800000) , Radiator Sub Fan and Fan Motor.
2. Protect the radiator with cardboard and blanket.
3. Remove the V-belts. Refer to «REMOVAL»(ref-325302-S05347390512009071800000) , V-belt.
4. Remove the A/C compressor V-belt tensioner.
5. Remove the pulley bolt. Using the ST, lock the crankshaft. ST 499977400 CRANK PULLEY WRENCH
6. Remove the crank pulley.
7. Remove the A/C compressor V-belt tensioner.
8. Remove the belt cover (LH).
9. Remove the belt cover (RH).
10. Remove the front belt cover.
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
12. Remove the belt idler.
13. Remove the timing belt.
14. Remove the automatic belt tension adjuster assembly.
15. Install in the reverse order of removal. Refer to «INSTALLATION»(ref-325302-S01610024312009071800000) , Timing Belt. CAUTION: When installing the timing belt, be sure to align all alignment marks on the belt with corresponding marks on the sprockets. If incorrectly installed, interference between pistons and valves may occur.

Scheme 77

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. If the surface of timing belt (surface indicated by the arrow in the figure) is worn abnormally (scuffing and coming out of core) or damaged, inspect the idlers, tensioner, water pump pulley and cam sprocket and check the idler alignment for squareness. Replace the worn or damaged timing belt.
4. Install the timing belt cover (LH).

Scheme 78

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. If the surface of timing belt (surface indicated by the arrow in the figure) is worn abnormally (scuffing and coming out of core) or damaged, inspect the idlers, tensioner, water pump pulley and cam sprocket and check the idler alignment for squareness. Replace the worn or damaged timing belt.
4. Install the timing belt cover (LH).

FRONT DIFFERENTIAL (MT MODEL)

For MT model, differential oil works as manual transmission oil to lubricate differential. Refer to "Transmission Oil". Refer to TRANSMISSION GEAR OIL .

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1. Lift up the vehicle.
2. Remove the drain plug using TORX® bit T70, and then drain differential gear oil. CAUTION: If any differential gear oil is spilt on the exhaust pipe, wipe it off with a cloth to avoid emitting smoke or causing a fire. NOTE: Before starting work, allow the differential gear oil to cool completely.
3. Replace the gasket with a new part and tighten the differential gear oil drain plug to the specified torque using the TORX® bit T70. Tightening torque: 44 N.m (4.5 kgf-m, 32.5 ft-lb) (Aluminum gasket) 70 N.m (7.1 kgf-m, 51.6 ft-lb) (Copper gasket)
4. Lower the vehicle.
5. Fill differential gear oil from the oil. level gauge hole. Recommended fluid: Refer to «LUBRICANTS»(ref-325297-S01666082482009071800000) , RECOMMENDED MATERIALS, Recommended Materials. NOTE: Each oil manufacturer has its base oil and additives. Thus, do not mix two or more brands. Gear oil capacity: 1.1 - 1.3 l (1.2- 1.4 US qt, 1.0- 1.1 lmp qt)
6. Check the level of differential gear oil.

Refer to INSPECTION , Differential Gear Oil.

Scheme 81

1. Remove the oil drain plug and drain the 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 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. Recommended gear oil: GL-5 (75W-90) or equivalent Oil capacity: 0.8 l (0.8 US qt, 0.7 lmp qt) NOTE: Each oil manufacturer has its base oil and additives. Thus, do not mix two or more brands. CAUTION: If any gear oil is spilt on the exhaust pipe, wipe it off with a clean cloth to avoid emitting smoke or causing a fire.
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 N.m (5.0 kgf-m, 36.2 ft-lb)

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Scheme 83

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 and wheel cylinder. 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)

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1. Check the free play of brake pedal with a force of less than 10 N (1 kgf, 2 lbf). Brake pedal play 0.5 - 2.0 mm (0.02 - 0.08 in)
2. If the free play is out of the specifications values indicated above, 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 lbf) to a stroke of 0.5 to 2.0 mm (0.02 to 0.08 in).] Pull the brake pedal by hand. If there is no play between the clevis pin and the clevis, rotate the brake switch to the left. Loosen the operating rod locknut, rotate the operating rod, adjust the pedal to the specified height and tighten the locknut. Locknut tightening torque: 22 N.m (2.2 kgf-m, 16 ft-lb) Pedal height L: 150 - 160 mm (5.91 - 6.30 in) Brake pedal free play A: 0.5 - 2 mm (0.020 - 0.079 in) [When pulling the brake pedal upward with a force of less than 10 N (1 kgf, 2 lbf).] While pulling up the brake pedal, insert the brake switch until the end of the brake switch screw contacts the stopper. With the end of the brake switch screw pushed against the stopper, turn the switch to the right and secure the switch. Check that gap C between the stopper and the end of the brake switch screw is within the specification. Pull up the pedal pad and check the play. Check that the stop light goes out when the pedal is not pressed.
3. Check the pedal stroke. While the engine is idling, depress the brake pedal with a 490 N (50 kgf, 110 lbf) 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: 95 mm (3.74 in)/490 N (50 kgf, 110 lbf) or less
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.

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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. Disconnect the vacuum hose to inspect function of the check valve. Blow air into vacuum hose from the end of the brake booster side. Check that the air flows out from the engine side end of the air hose. Next blow air into hose from engine side: Check that the air does not flow out from the hose. 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 in illustration.
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.

FRONT/REAR SUSPENSION BUSHING

Apply pressure using the tire lever, and check the bushing for abnormal fatigue or damage. Replace the bushing if there is any damage.

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. Refer to «WHEEL ALIGNMENT»(ref-325311-S17163309962009071800000) .
3. When the wheel arch height is out of the tolerance value, visually inspect the following components and replace deformed parts. Suspension components [Front strut assembly and rear shock absorber 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. Refer to «WHEEL ALIGNMENT»(ref-325311-S17163309962009071800000) .

OIL LEAKAGE OF STRUT AND SHOCK ABSORBER

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

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 parts.

Front suspension: Refer to GENERAL DESCRIPTION .

Rear suspension: Refer to 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 parts. If minor rust, pitting, etc. are noted, remove the rust and take rust prevention measure.

1. Front suspension Front arm Crossmember Strut
2. Rear suspension Sub frame Front lateral link Rear lateral link Upper arm Trailing link Shock absorber
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. Take rust prevention measures as necessary.

FRONT HUB UNIT

1. Jack-up the front of the vehicle.
2. While holding the front wheel by hand, swing it in and out to check if there is any 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: From the straight-ahead position: Max. of 0.05 mm (0.0020 in)
5. Remove the bolts and self-locking nuts, and extract transverse link from the front crossmember.
6. Remove the PTJ of the front drive shaft from the transmission. Refer to «FRONT AXLE»(ref-325313-S23295924262009071800000) .
7. While supporting the front drive shaft horizontally with one hand, turn the hub with the other hand to check for noise or binding.

Replace the front hub unit if there is any abnormal noise from the hub or if it drags.

Scheme 90

REAR HUB UNIT

1. Jack-up the rear of the vehicle.
2. While holding the rear wheel by hand, swing it in and out to check if there is any 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 and measure the looseness in the axial direction. Service limit: From the straight-ahead position: Max. of 0.05 mm (0.0020 in)
5. Remove the DOJ of the rear drive shaft from the rear differential. Refer to «REAR DRIVE SHAFT»(ref-325313-S33172620752009071800000) .
6. While supporting the rear drive shaft horizontally with one hand, turn the hub with the other hand to check for noise or dragging/catching.

Replace the front hub unit if there is any abnormal noise from the hub or dragging/catching.

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 part. Refer to FRONT DRIVE SHAFT . Refer to REAR DRIVE SHAFT .

Scheme 91

Scheme 92

PROPELLER SHAFT

Inspect the propeller shaft for damage or failure. If faulty, replace with new part. Refer to PROPELLER SHAFT .

Scheme 93

Scheme 94

Scheme 95

1. When the tread has worn down to less than 1.6 mm (0.063 in) or the wear indicator appears across the tread, replace the tire. (Replace the right and left tire as a set).
2. If the tire appears to be worn unevenly, adjust the wheel alignment.
3. Next, make a tire rotation between front and rear as shown in the figure, to make sure that tires are worn evenly. When the direction of tire rotation is not specified When the direction of tire rotation is specified

Scheme 96

1. Set the steering wheel in a straight-ahead position, and check the wheel spokes to make sure they are correctly set in their specified positions.
2. Lightly turn the steering wheel to the left and right to determine the point where front wheels start to move. Measure the distance of the movement of steering wheel (outer periphery). Steering wheel free play: 0 - 17 mm (0 - 0.67 in) Move the steering wheel vertically toward the shaft to check if there is play in the direction. Limit of play: 0.5 mm (0.020 in)
3. Drive the vehicle and check the following items.

1. Steering force: The effort required for steering should be smooth and even at all points, and should not vary.
2. Pulled to one side: Steering wheel should not be pulled to either side while driving on a level surface.
3. Wheel runout: Steering wheel should not show any sign of runout.
4. Return shape

The steering wheel should return to its original position after it has been turned by hand and then released.

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)

Scheme 97

Scheme 98

Scheme 99

Scheme 100

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: 60 N.m (6.1 kgf-m, 44.3 ft-lb)
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 37°. Apply liquid gasket to at least 1/3 of entire perimeter of adjusting screw thread. Install the lock nut. While holding the adjusting screw with a wrench, tighten the lock nut using ST. ST 926230000 SPANNER Tightening torque (lock nut): 39 N.m (4.0 kgf-m, 29 ft-lb) Hold the adjusting screw with a wrench to prevent it from turning while tightening the lock nut.

Scheme 101

1. Check the tie-rod and tie-rod ends for bends, scratches or other damage.
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

85 N.m (8.7 kgf-m, 62.7 ft-lb)

HOSES OF OIL PUMP FOR DAMAGES

For the hydraulic power steering model, check the pressure hose and return hose of oil pump for crack, swell or damage. Replace the hose with a new part if necessary.

POWER STEERING PIPES FOR DAMAGES

Check the power steering pipes for corrosion and damage.

Replace the pipes with new parts if necessary.

GEARBOX BOOTS

For the hydraulic power steering model, 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).

Scheme 102

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.