General Information (Except Sti): Other Subaru Impreza GH

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 142

SI UNITS

Measurements in this Information are according to the SI units. Metric and yard/pound measurements are also included.

Example

Tightening torque: 45 N.m (4.6 kgf-m, 33.2 ft-lb)

EXPLANATION OF TERMINOLOGY

1. List

AAI : Air Assist Injection

AAR : Angular Adjusted Roller

A/B : Airbag

ABS : Anti-lock Brake System

A/C : Air Conditioner

AC : Angular Contact

ACC : Accessory

A/F : Air Fuel Ratio

ALT : Generator

ASSY : Assembly

AT : Automatic Transmission

ATF : Automatic Transmission Fluid

AVCS : Active Valve Control System

AWD : All Wheel Drive

BATT : Battery

BJ : Bell Joint

CAN : Controller Area Network

CD : Compact Disc

COMPL : Complete

CPU : Central Processing Unit

DOHC : Double Overhead Camshaft

DTC : Diagnosis Trouble Code

DOJ : Double Offset Joint

DVD : Digital Versatile Disc or Digital Video Disc

EBD : Electronic Brake Distribution

EBJ : High-efficiency Compact Ball Fixed Joint

EDJ : High-efficiency Compact Double Offset Joint

ECM : Engine Control Module

EGI : Electronic Gasoline Injection

E/G : Engine

EGR : Exhaust Gas Recirculation

EX : Exhaust

ETC : Electronic Throttle Control

F/B : Fuse&Joint Box

FWD : Front Wheel Drive

GPS : Global Positioning System

HID : High-Intensity Discharge

H/U : Hydraulic Unit

IG : Ignition

IN : Intake

INT : Intermittent

I/O : Input/Output

ISC : Idle Speed Control

LAN : Local Area Network

LCD : Liquid Crystal Display

LED : Light Emitting Diode

LH : LH (Left Hand)

LSD : Limited Slip Differential

M/B : Main Fuse&Relay Box

MFI : Multi Point Injection

MP-T : Multi-Plate Transfer

MT : Manual Transmission

NA : Natural Aspiration

OP : Option Parts

OBD : On-Board Diagnosis

P/S : Power Steering

P/W : Power Window

PCV : Positive Crankcase Ventilation

PID : Parameter Identification

RAM : Random Access Memory

RH : RH (Right Hand)

ROM : Read Only Memory

rpm : Revolution Per Minute

SOHC : Single Overhead Camshaft

SRS : Supplemental Restraint System

SSM : Subaru Select Monitor

ST : Special Tool

SW : Switch

TGV : Tumble Generator Valve

VDC : Vehicle Dynamics Control

V.I.N. : Vehicle Identification Number

VTD : Variable Torque Distribution

DIMENSION

DOOR SPECIFICATION

ENGINE

ENGINE SPECIFICATION

ELECTRICAL

ELECTRICAL SPECIFICATION

TRANSMISSION

TRANSMISSION SPECIFICATION

5MT: 5-forward speeds, 1-reverse

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

DSPD: Dry Single Plate Diaphragm

TCC: Torque Converter Clutch

STEERING

STEERING SPECIFICATION

SUSPENSION

SUSPENSION SPECIFICATION

BRAKE

BRAKE SPECIFICATION

TIRE

TIRE SPECIFICATION

WEIGHT

WEIGHT CHART

MODEL SPECIFICATION

MODEL SPECIFICATION

MODEL SPECIFICATION

MODEL SPECIFICATION

MODEL SPECIFICATION

CAUTION

Please clearly understand and adhere to the following general precautions for environmental protection and 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 parts which are not instructed in this information. Follow the directions in this information 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. Follow the directions in this information when performing maintenance on the VDCCM&H/U. When parts other than those specified are disassembled, it is possible that the VDC system will not operate 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 information when performing maintenance on or near the airbag components, around front of the vehicle (radiator panel, front wheel apron, front side frame, front bumper, front hood, front fender), around side of the vehicle (front door, rear door, center pillar, rear fender, side sill, rear wheel apron), around rear of the vehicle (rear seat cushion, rear floor, rear crossmember), and on or near the airbag wiring harnesses.

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

AIRBAG DISPOSAL

To prevent bodily injury from unexpected airbag deployment, do not dispose the airbag modules 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 falling, resulting in accidents and injury.

OIL

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

1. Prepare a container and cloth to prevent scattering of oil when performing work where oil can be spilled. If the 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 that the finished work is of a good quality.

FASTENERS NOTICE

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

Always 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.

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.

Note. When using a lift, follow its operation information before work. When using, insert the body flange to the attachment groove. When the side sill cover contacts the lift arm, use a lift attachment. Do not work or leave unattended while the vehicle is supported with jack, support it with rigid racks. Be sure to use the rigid racks with rubber attached to cradle to support the vehicle. When using a plate lift, use a rubber attachment. (Model with side sill cover)

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1. Do not use the plate lift whose attachment does not reach the supporting locations. The figure of vehicle indicates the supporting locations, supporting procedures, etc. for 5 door model, and they are same for 4 door model. Supporting locations Pantograph jack Lift Rigid rack Plate lift
2. Use the attachment by aligning its position as follows. Model without side sill spoiler For the models without side sill spoiler, align the center of attachment with the center of cutout portions. Front Rear
3. Model with side sill spoiler For the models with side sill spoiler, align the center of attachment with the center of vehicle cutout portion (the center of spoiler cutout portion). Front Rear

TIE-DOWNS

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

1. TIE-DOWN LOCATION

Scheme 154

1. TIE-DOWN HOOK&EYE BOLT

Scheme 155

1. TIE-DOWN DIRECTION

TIE-DOWN DIRECTION CHART Recommended NG Tie-down direction

Scheme 156

1. TIE-DOWN RANGE

For ground transportation

Scheme 157

For sea transportation

Scheme 158

1. VEHICLE SINKING VOLUME AT TIE-DOWN CONDITION

1. Measure the distance (A) between the center of wheel and highest arch point.
2. Compare the measured dimensions of before and after tie-down.
3. If the difference is less than 50 mm (1.97 in), it is judged as OK. If the difference is 50 mm (1.97 in) or more, it is judged as NG because the tension is too high.

Scheme 159

1. NOTES FOR THE USE OF TIE-DOWN HOOK

When the vehicle is tied down from the rear side, use the holes at the rear side, and when the vehicle is tied down from the front side, use the holes at the front side.

When the vehicle is tied down from vehicle inside, hook the hooks of tie-down chain from vehicle inside, and when the vehicle is tied down from vehicle outside, hook the hooks of tie-down chain from vehicle outside.

Scheme 160

TOWING

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

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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. FRONT
4. REAR

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1. Always perform works such as inspections and maintenance with both damper stays attached. CAUTION: At the inspection and general maintenance, do not detach the damper stays.
2. When wider hood opening is necessary, set the damper stay below as shown in the figure.

Tightening torque: Refer to FRONT HOOD , COMPONENT, General Description.

Scheme 167

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 GE636X9G500001 [

The starting and ending brackets (] [) are stop marks.

MODEL NUMBER LABEL CHART

MODEL NUMBER LABEL

The model number label 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.

GHCBY7J

MODEL NUMBER LABEL CHART

The engine and transmission type are as follows.

Engine

EJ253BS1FB

MODEL NUMBER LABEL CHART

Transmission (MT)

TY758VC2AA

MODEL NUMBER LABEL CHART

Transmission (AT)

TZ1B8LCEBA

MODEL NUMBER LABEL CHART

Rear differential

MODEL NUMBER LABEL CHART

Option code

U4FW

MODEL NUMBER LABEL CHART

1. 3-digit number 3-DIGIT NUMBER REFERENCE F I K N T U V Y Z Aluminum wheel - o o - o o o o o Cruise control o o o o o o o o o Leather package - o o - o o o o o Genuine leather seat - - - - - - - - o High grade audio - o o - o - - - o Navigation system - - - - - o o - - Satellite tuner - - - - o o o - - Rear disc brake package - o - o - - o - - Audio satellite switch - o o - o o o - o
2. 4-digit number

4-DIGIT NUMBER REFERENCE

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

Always use gasoline of the same or higher octane value than specified in the owner's information booklet. Ignoring the specifications below will result in damage or poor performance of engine and fuel injection system. Use the specified gasoline to correct performance.

Unleaded gasoline

In order to reduce air pollution, use unleaded gasoline for the vehicle equipped with catalytic converter. Using leaded gasoline may damage the catalytic converter.

LUBRICANTS

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

LUBRICANT CHART Lubricant Recommended materials API standard ILSAC standard Engine oil Choose oil suitable for the standard from the right. SM "Energy conserving" GF-4 Manual transmission oil GL-5 - AT front differential gear oil GL-5 - Rear differential gear oil GL-5

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COOLANT

Use the coolants specified in the table below to protect the 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 compressor oil except for DH-PR.

REFRIGERANT SPECIFICATION

GREASE

Use grease and supplementary lubricants shown in the table below.

LUBRICANT CHART

ADHESIVE

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

ADHESIVE CHART

SEAL MATERIAL

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

SEAL MATERIAL SPECIFICATION

CANADA

MAINTENANCE SCHEDULE

PROCEDURE (WITHOUT BELT TENSION GAUGE)

1. Replace the belts if cracks, fraying or wear are 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-357229-S27645314372010031100000) , 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 171

PROCEDURE (WITH BELT TENSION GAUGE)

1. Replace the belts if cracks, fraying or wear are found.
2. Remove the V-belt covers and radiator reservoir tank.
3. Check the belt tension, using the belt tension gauge. Adjust the tension, if necessary by changing the generator installing position or idler pulley installing position.

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 172

V-BELT COVER

Remove the V-belt covers.

Scheme 173

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

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

Scheme 174

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. Idle the engine for approx. 5 min. to normalize the V-belt. (With using tension gauge)
8. Stop the engine, and then check the belt tension and adjust it. (With using tension gauge)
9. Idle the engine for approx. 1 min. to normalize the V-belt. (With using tension gauge)
10. Stop the engine, and then check the belt tension is within specified value. (With using tension gauge)
11. Adjust the belt tension until the value within specification. (With using tension gauge)

REAR SIDE BELT (FOR A/C)

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-357236-S17667560432010031100000) , INSTALLATION, V-belt. Refer to «REAR SIDE BELT»(ref-357237-S18785472122010031100000) , INSTALLATION, V-belt.
4. Install the front side belt. Refer to «FRONT SIDE BELT»(ref-357236-S39328741062010031100000) , INSTALLATION, V-belt.

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Scheme 177

1. Remove the radiator fan and air conditioner fan. Refer to «REMOVAL»(ref-357238-S08418752692010031100000) , Radiator Main Fan and Fan Motor. Refer to «REMOVAL»(ref-357238-S23662050652010031100000) , 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-357236-S14836131932010031100000) , V-belt.
5. Remove the crank pulley. Refer to «REMOVAL»(ref-357236-S03660225752010031100000) , Crank Pulley.
6. Remove the timing belt cover. Refer to «REMOVAL»(ref-357236-S36954403142010031100000) , Timing Belt Cover.
7. Using ST, turn the crankshaft and align the alignment marks on crankshaft and left and right cam sprockets with alignment marks of belt cover and oil pump. ST 499987500 CRANKSHAFT SOCKET
8. Remove the belt idler (A).
9. Remove the belt idler No. 2 (B).
10. Remove the timing belt.
11. Remove the automatic belt tension adjuster assembly.
12. Install in the reverse order of removal. Refer to «INSTALLATION»(ref-357236-S17220510322010031100000) , Timing Belt.

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1. Remove the radiator fan and air conditioner fan. Refer to «REMOVAL»(ref-357239-S09180537772010031100000) , Radiator Main Fan and Fan Motor. Refer to «REMOVAL»(ref-357239-S30238734992010031100000) , Radiator Sub Fan and Fan Motor.
2. Protect the radiator with cardboard and blanket.
3. Remove the V-belts. Refer to «REMOVAL»(ref-357237-S00077187882010031100000) , V-belt.
4. Remove the crank pulley. Refer to «REMOVAL»(ref-357237-S09849468212010031100000) , Crank Pulley.
5. Remove the timing belt cover. Refer to «REMOVAL»(ref-357237-S37379900212010031100000) , Timing Belt Cover.
6. Remove the timing belt guide. (MT model)
7. Using ST, turn the crankshaft and align the alignment marks on crankshaft and left and right cam sprockets with alignment marks of belt cover and oil pump. ST 499987500 CRANKSHAFT SOCKET
8. Remove the belt idler.
9. Remove the timing belt.
10. Remove the automatic belt tension adjuster assembly.
11. Install in the reverse order of removal. Refer to «INSTALLATION»(ref-357237-S29727762582010031100000) , Timing Belt.

Scheme 186

Scheme 187

1. Remove the timing belt cover (LH).
2. Turn the crank pulley to set #1 cylinder piston to top dead center of compression stroke and check the followings. Check that the arrow (A) of camshaft pulley LH points to the upright. Remove the sealing rubber (B) of the timing belt cover RH. Check that the arrow (C) of camshaft pulley RH points to the upright.
3. When camshaft pulley or timing belt position is offset, check for any defect and repair or replace as required.

SOHC MODEL (CHECK FOR OTHERS)

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. When the side part of timing belt (arrow direction shown in the figure) is abnormally worn (fluff or jumping out of core) or damaged, check the idlers, tensioner, water pump pulley and cam sprocket to determine idler alignment (squareness). Replace the worn or damaged timing belt.
4. Install the timing belt cover (LH).

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Scheme 189

1. Remove the timing belt cover (LH) and (RH).
2. Turn the crank pulley and align single line mark (A) on the intake camshaft pulley (RH) with notch (B) on timing belt cover and check the following. Make sure double lines (C) on intake and exhaust camshaft pulley (RH side) are aligned. Make sure single line (D) on exhaust cam shaft pulley (RH side) is aligned to timing belt cover notch (E). Make sure single line (A) on intake cam shaft pulley (LH side) is aligned to timing belt cover notch (B). Make sure double lines (C) on intake and exhaust camshaft pulley (LH side) are aligned. Make sure single line (D) on exhaust cam shaft pulley (LH side) is aligned to timing belt cover notch (E).
3. When camshaft pulley position is offset, check for any defect and repair or replace as required.

Scheme 190

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 faulty timing belts with new parts as required.
3. When the side part of timing belt (arrow direction shown in the figure) is abnormally worn (fluff or jumping out of core) or damaged, check the idlers, tensioner, water pump pulley and cam sprocket to determine idler alignment (squareness). Replace the worn timing belt with new part.
4. Install the timing belt cover (LH).

FRONT DIFFERENTIAL (AT MODEL)

1. Park the vehicle on a level surface.
2. Remove the differential oil level gauge and wipe it clean.
3. Reinsert the level gauge all the way. Make sure the level gauge is inserted correctly and in the proper orientation.
4. Remove the oil level gauge again, and check the level of differential gear oil. If the differential gear oil level is below "L" line, add oil to bring the level up to "F" line.

Note. To prevent overfilling the differential gear oil, do not fill oil above the "F" line.

Scheme 191

REAR DIFFERENTIAL

1. Remove the filler plug, and then check the gear oil. Replace the gear oil if it is contaminated or deteriorated.
2. Check that the gear oil level is up to the bottom of the filler plug hole. If the level is low, refill up to the bottom of filler plug.

Scheme 192

FRONT DIFFERENTIAL (MT MODEL)

For MT model, differential oil is used as manual transmission oil for lubricating the differential. Refer to "Transmission Oil". Refer to TRANSMISSION GEAR OIL .

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1. Lift up the vehicle.
2. Drain the differential gear oil by removing drain plug using TORX® bit T70. CAUTION: If the differential gear oil is spilt over exhaust pipe, wipe it off with cloth to avoid emitting smoke or causing a fire. NOTE: Before starting work, cool off the differential gear oil well.
3. Replace the gasket with a new part and tighten the differential 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 silver) 70 N.m (7.1 kgf-m, 51.6 ft-lb) (Copper gasket brown) 70 N.m (7.1 kgf-m, 51.6 ft-lb) (Metal gasket black)
4. Lower the vehicle.
5. Fill differential gear oil through the oil level gauge hole. Recommended fluid: Refer to «LUBRICANTS»(ref-357229-S15315371372010031100000) , 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 195

1. Drain the oil by removing drain plug.
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 the 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.
5. Attach the filler plug to the rear differential case securely. NOTE: Apply liquid gasket to the filler plug threads. Liquid gasket: THREE BOND 1105 (Part No. 004403010) Tightening torque: 49 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 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 illuminate. 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 10N(1 kgf, 2 lbf) or less. Brake pedal play: 0.5 - 2.0 mm (0.02 - 0.08 in)
2. If the free play is out of specifications above, adjust the brake pedal as follows. Make sure the engine is off. (No vacuum is applied to brake booster.) There should be play between brake booster clevis and pin at brake pedal installing portion. [Depress brake pedal pad with a force of 10 N (1 kgf, 2 lbf) or less to a stroke of 0.5 to 2.0 mm (0.02 to 0.08 in).] Pull the brake pad by hand. If there is no play between clevis pin and clevis, turn the brake switch to the left to loosen. Loosen the operating rod lock nut to turn the operating rod, and then tighten the lock nut after adjusting the pedal to the specified height. Lock nut 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)] Push the brake switch until the thread end of the brake switch contacts the stopper while pulling the brake pedal. Turn the switch to the right to secure it while pushing the brake switch thread end against the stopper. Check that the clearance (C) between stopper and brake switch thread end is within the specification. Pull the pedal pad and check the play. Check that the stop light goes out when the pedal is not depressed.
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 pedal stroke is normal if the difference between two measured values is the specified value or less. If the measured value is specification or more, 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.

Scheme 202

1. With the engine off, depress the brake pedal several times applying the same pedal force. Make sure the travel distance should not change.
2. With the brake pedal depressed, start the engine. Make sure the pedal should move slightly toward the floor.
3. With the brake pedal depressed, stop the engine and keep the pedal depressed for 30 seconds. Make sure the pedal height should not change.
4. A check valve is built into the vacuum hose. Disconnect the vacuum hose to inspect function of check valve. Blow compressed air into vacuum hose from the end of brake booster side. Check that the air flows from the air hose on engine side. Next blow air into hose from engine side: Check that the air does not flow 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.
5. Check the vacuum hose for cracks or other damage. NOTE: When installing the vacuum hose on the engine and brake booster, do not use soapy water or lubricating oil on their connections.
6. Check the vacuum hose to make sure it is tightly secured.

PARKING BRAKE (REAR DISC BRAKE)

1. Measure the brake disc rotor inside diameter. If the disc is scored or worn, replace the brake disc rotor. Disc rotor inside diameter: Standard: 190 mm (7.48 in) Service limit: 191 mm (7.52 in)
2. Measure the lining thickness. If it exceeds the limit, replace the brake shoe.

Lining thickness

Standard: 2.8 mm (0.11 in)

Service limit: 1.5 mm (0.059 in)

Note. Replace the right and left brake shoe as a set.

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 203

1. Return the parking brake pedal fully.
2. Loosen the adjusting nut, and make the cable free.
3. Remove the adjusting hole cover from the disc rotor.
4. Using a flat tip screwdriver, turn the adjusting screw in the direction of the arrow (shoe extension direction) as shown in the figure until it is locked slightly (until the disc no longer rotates with both hands).
5. Loosen the adjusting screw by 5 notches to opposite direction of arrow. CAUTION: Check there is no brake drag. If the amount that the adjusting screw is turned back is little, securely loosen it by 5 notches to avoid dragging.
6. Install the adjusting hole cover to the disc rotor.
7. Adjust the parking brake lever stroke. Refer to «LEVER STROKE»(ref-357246-S04711123672010031100000) , ADJUSTMENT, Parking Brake Assembly (Rear Disc Brake).

Scheme 204

Scheme 205

1. Jack-up the vehicle until front wheels are off ground.
2. Grasp the bottom of tire and move it in and out in axial direction. If relative movement (B) is observed between the brake disc cover (A) and the end of front arm (D), ball joint (C) may be excessively worn.
3. Grasp the end of front arm and move it up and down. Relative movement (A) between the housing (D) and front arm (C) boss indicates ball joint (B) may be excessively worn.
4. If the relative movement is observed in the preceding two steps, remove and inspect the ball joint. If the free play exceeds the standard, replace the ball joint. Refer to «FRONT BALL JOINT»(ref-357247-S33907914232010031100000) .
5. Damage of dust boots

Visually inspect the ball joint dust boots. If it is damaged, remove the front arm. Refer to FRONT ARM . Measure the play of the ball point. Refer to FRONT BALL JOINT .

1. When looseness exceeds the standard, replace the ball joint.
2. If the dust boots are damaged, replace with a new ball joint.

Note. When the front arm ball joint has been removed or replaced, check the toe of front wheel. If the front wheel toe-in is not at specified value, adjust the toe-in. Refer to WHEEL ALIGNMENT .

Scheme 206

FRONT, REAR SUSPENSION BUSHING

Apply pressure with tire lever etc. to inspect the bushing for fatigue or cracks. If defective, replace the bushing.

Scheme 207

WHEEL ARCH HEIGHT

1. Unload the cargoes and set the vehicle in curb weight (empty) condition.
2. Check the wheel arch height of front and rear suspensions to ensure that they are within specified values. Refer to «WHEEL ALIGNMENT»(ref-357247-S38606193512010031100000) .
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 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. Refer to «WHEEL ALIGNMENT»(ref-357247-S38606193512010031100000) .

OIL LEAKAGE OF STRUT AND SHOCK ABSORBER

Visually inspect the front strut and rear shock absorber for oil leakage. Replace the front strut and rear shock absorber if oil leaks excessively.

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 formation, 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 required.

FRONT HUB UNIT

1. Jack-up the front side of 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: Straight-ahead position within 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 AAR of front drive shaft from transmission. Refer to «FRONT AXLE»(ref-357249-S20912022772010031100000) .
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, replace the front hub unit.

Scheme 208

REAR HUB UNIT

1. Jack-up the rear side of vehicle.
2. While holding the rear wheel by hand, swing it in and out to check bearing free play.
3. Loosen the wheel nuts, and remove 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: Straight-ahead position within 0.05 mm (0.0020 in)
5. Remove the DOJ of rear drive shaft from rear differential. Refer to «REAR DRIVE SHAFT»(ref-357249-S14385318992010031100000) .
6. While supporting rear drive shaft horizontally with one hand, turn the hub with the other to check for noise or binding.

If the hub is noisy or binds, replace the rear hub unit.

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

Scheme 209

Scheme 210

PROPELLER SHAFT

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

Scheme 211

Scheme 212

Scheme 213

Scheme 214

1. When the tread has worn down to less than 1.6 mm (0.063 in) or the wear indicator appears across the tire 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, make sure tires are worn evenly. When the direction of tire rotation is not specified With instruction for the direction of tire rotation

Scheme 215

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 at the outer periphery of wheel. Steering wheel free play: 0 - 17 mm (0 - 0.67 in) Move the steering wheel vertically toward the shaft to ascertain if there is play in the direction. Maximum permissible play: 0.5 mm (0.020 in)
3. Drive the vehicle and check the following items during operation. Steering force: The effort required for steering should be smooth and even at all points, and should not vary. Pulled to one side: Steering wheel should not be pulled to either side while driving on a level surface. Wheel runout: Steering wheel should not show any sign of runout. Return factor: Steering wheel should return to its original position after it has been turned 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 216

Scheme 217

1. With the vehicle placed on a level surface, turn the steering wheel 90° in both the left and right directions. While the wheel is being rotated, reach under the vehicle and check for looseness in gearbox. 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 placed 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.

Scheme 218

1. Tighten the adjusting screw to 25 N.m (2.5 kgf-m, 18 ft-lb) and then loosen.
2. Tighten the adjusting screw to 3.9 N.m (0.4 kgf-m, 2.9 ft-lb) and then loosen it within 20°.
3. Apply liquid gasket to at least 1/3 of entire perimeter of adjusting screw thread.
4. 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): 25 N.m (2.5 kgf-m, 18.4 ft-lb) Hold the adjusting screw with wrench to prevent it from turning while tightening the lock nut.

Scheme 219

1. Check the tie-rod and tie-rod ends for bends, scratches or other damage.
2. Check the connections of knuckle ball joints for play, inspect for damage on dust seals, and check free play of ball studs. If castle nut is loose, retighten it to the specified torque, then further tighten up to 60° until the cotter pin hole is aligned. Tightening torque: 27 N.m (2.75 kgf-m, 19.9 ft-lb)
3. Check the lock nut on the tie-rod end for tightness. If it is loose, retighten it to the specified torque. Tightening torque: 85 N.m (8.7 kgf-m, 62.7 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 part if necessary.

Note. Prevent hoses from turning and/or bending when installing hoses.

Scheme 220

POWER STEERING PIPES FOR DAMAGES

Check the power steering pipes for corrosion and damage.

Replace the pipes with new parts if necessary.

GEARBOX BOOTS

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

1. Positions (A) and (B) of the gearbox boot are fitted correspondingly in grooves (A) and (B) of the gearbox and rod (C).
2. Clips are fitted outside of positions (A) and (B) of boot.
3. Boot does not have crack or hole.

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 221

FITTING BOLTS AND NUTS

Inspect the fitting bolts and nuts of oil pump and bracket for looseness, and retighten them if necessary. Inspect and/or retighten them when engine is cold.

Scheme 222

Scheme 223

Scheme 224

1. Remove the glove box damper.
2. Disengage the stopper section and pull the glove box lid to remove it.
3. Pinch the claw to unlock and remove the A/C filter.
4. Install in the reverse order of removal.