General Information: Other Subaru Outback BP рестайлинг

SEDAN MODEL

DIMENSION SPECIFICATION (SEDAN MODEL)

WAGON MODEL

DIMENSION SPECIFICATION (WAGON MODEL)

ENGINE

DIMENSION SPECIFICATION (ENGINE)

ELECTRICAL

DIMENSION SPECIFICATION (ELECTRICAL)

TRANSMISSION

DIMENSION SPECIFICATION (TRANSMISSION)

STEERING

DIMENSION SPECIFICATION (STEERING)

SUSPENSION

DIMENSION SPECIFICATION (SUSPENSION)

BRAKE

DIMENSION SPECIFICATION (BRAKE)

TIRE

DIMENSION SPECIFICATION (TIRE)

US MODEL

WEIGHT SPECIFICATION (US MODEL)

WEIGHT SPECIFICATION (US MODEL)

CANADA MODEL

WEIGHT SPECIFICATION (CANADA MODEL)

WEIGHT SPECIFICATION (CANADA MODEL)

WEIGHT SPECIFICATION (CANADA MODEL)

OPTION

WEIGHT SPECIFICATION (OPTION)

DIMENSION SPECIFICATION (WAGON MODEL)

ENGINE SPECIFICATION

ELECTRICAL SPECIFICATION

TRANSMISSION SPECIFICATION

STEERING SPECIFICATION

SUSPENSION SPECIFICATION

BRAKE SPECIFICATION

TIRE SPECIFICATION

WEIGHT SPECIFICATION (US MODEL)

WEIGHT SPECIFICATION (US MODEL)

WEIGHT SPECIFICATION (US MODEL)

WEIGHT SPECIFICATION (US MODEL)

WEIGHT SPECIFICATION (CANADA MODEL)

WEIGHT SPECIFICATION (CANADA MODEL)

WEIGHT SPECIFICATION (CANADA MODEL)

WEIGHT SPECIFICATION (OPTION)

CAUTION

Please clearly understand and adhere to the following general precautions. 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 parts which are not instructed in this article. Follow the directions in this article 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 article 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 article 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 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 falling, resulting in accidents and injury.

OIL

When handling oil, carefully observe the following to prevent unexpected accidents.

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

FUEL

When handling and storing fuel, carefully observe the following to prevent unexpected accidents.

1. Be careful of fires.
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 it from penetrating the floor or flowing out, to protect the environment.
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 because of the danger of engine coolant blowing out when the engine coolant is hot.
2. Prepare a container and cloth to prevent spraying of engine coolant when performing work in which 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.

FASTENERS 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 possibility 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 terminal, always be sure to turn the ignition switch to OFF to prevent electrical damage of the control module from over-current. Be sure to remove the battery ground cable first.

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 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 manual before work. 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. Align the cushion rubber end of plate lift with the end of rubber attachment. (Portion b) Also, align the protrusion portion of the supporting locations with the end of attachment. (Portion a) Do not use the plate lift whose attachment does not reach the supporting locations.

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.

1. TIE-DOWN LOCATION

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1. CHAIN DIRECTION AT TIE-DOWN CONDITION

Note. Pull the chains LH and RH in the same direction, but front and rear side in the counter direction. Pull all the chains in a same moment.

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1. CHAIN PULLING RANGE AT TIE-DOWN CONDITION
2. 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.

TOWING

Avoid towing vehicles except when the vehicle cannot be driven. For models with AWD, AT or VTD, use a loader instead of towing. When towing other vehicles, 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. Front

Remove the fog light cover (except for OUTBACK model) and hook cover, and then install the hook.

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1. Rear
2. Notes

TOWING PRECAUTIONS CHART Towing Precautions MT AT Lifting up four wheels (On a trailer) Towing the vehicle after lifting up all four wheels is a basic rule for AWD model. o o Rope Check if both front and rear wheels are rotated normally. AT model driving conditions: Driving speed 50 km/h (31 MPH) or less Allow driving distance 30 km (19 miles) or less o Raising the front wheels Prohibited for full-time AWD model. X X Lifting up the front wheels Prohibited, due to damage on bumper, front grille, etc. Do not raise the vehicle with bumper. X X Marked o: OK, Marked X: Prohibited, Marked : Conditionally OK

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1. At the check and general maintenance
2. When wider hood opening is necessary

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

Scheme 81

ON THE CAR WHEEL BALANCING

Scheme 82

1. Set the rigid rack to the specified locations of side sill, jack up the front or rear two wheels of non-measuring side and set the pickup stands to two wheels of measuring side.
2. For drive wheel, drive the tires with engine for measurement.
3. For non-drive wheel, drive the tires from the on the car wheel balancer for measurement.

MEANING OF V.I.N

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

]4S3BL616X86200001[

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

MEANING OF V.I.N

MODEL NUMBER PLATE

The model number plate indicates the type, V.I.N. < Ref. to MEANING OF V.I.N. , IDENTIFICATION, Identification . >, applied model, option code, trim code, engine type, transmission type and the exterior color code. This information is helpful when placing orders for parts.

1. BL9DYHJ MODEL NUMBER PLATE DESCRIPTION Digits Code Meaning Details 1 B Series LEGACY 2 L Body type L: Sedan P: Wagon 3 9 Engine displacement Drive system Suspension system 9:2.5 L AWD E: 3.0 L AWD 4 D Model year D: 2008MY 5 Y Destination Y: U.S., Canada 6 H Grade C: 2.5 GT Limited D: OUTBACK 2.5 XT Limited F: 2.5 GT spec. B H: 2.5 i K: 2.5 i Limited P: OUTBACK 2.5 BASE S: OUTBACK 2.5 i T: OUTBACK 2.5 i Limited U: OUTBACK 3.0 R V: OUTBACK 3.0 R Limited X: OUTBACK 3.0 R L.L.Bean 7 J Transmission, fuel feed system D: DOHC MFI Turbo 5MT J: SOHC MFI 5MT H: DOHC MFI Turbo 6MT L: SOHC MFI 4AT TIP U: DOHC MFI 5AT TIP V: DOHC MFI Turbo 5AT TIP The engine and transmission type are as follows.
2. ENGINE EJ253BSEFB ENGINE DESCRIPTION Digits Code Meaning Details 1 and 2 EJ Engine type EJ: 4 cylinder EZ: 6 cylinders 3 and 4 25 Displacement 25: 2.5 L 30: 3.0 L 5 3 Fuel feed system 3: MFI non-turbo (SOHC) 5: MFI turbo D: MFI non-turbo (DOHC, H6) 6 B Emission control B: For USA 7 S Mounted transmission C: D-5AT E: 5MT (Flexible type flywheel, Wide angle damper type disc wheel) G: 6MT P: 4AT S: 5MT (Flexible type flywheel) 8 - 10 EFB Detailed specifications
3. TRANSMISSION TY758VCEAA TRANSMISSION DESCRIPTION Digits Code Meaning Details 1 T Transmission T: Transmission 2 Y Transmission type G: Full-time AWD 5AT center differential V: Full-time AWD AT center differential Y: Full-time AWD MT center differential Z: Full-time AWD AT MPT 3 and 4 75 Identification 1B: 4AT 5D: 5AT 75: 5MT 85: 6MT 5 8 Series 6: 6MT 7: 5AT 8: 5MT or 4AT 6 V Transmission specifications C: Full-time AWD VTD 5AT L: Full-time AWD MPT 4AT M: Full-time AWD center differential 4AT V: Full-time AWD 5MT single range with viscous coupling center differential W: Full-time AWD 6MT single range with viscous coupling center differential 7 C Mounted vehicle C: 2.5 L SOHC F: 2.5 L SOHC V: 3.0 L DOHC W: 2.5 L DOHC Turbo 8 - 10 EAA Detailed specifications
4. REAR DIFFERENTIAL XJ REAR DIFFERENTIAL DESCRIPTION Code Reduction gear ratio LSD CD 4.444 Viscous CF 4.444 Viscous EW 3.900 Viscous HY 3.545 Torsen JE 4.111 Viscous T1 3.900 None T2 4.111 None TP 4.444 None XJ 4.111 None XU 3.272 Viscous XZ 3.083 Viscous
5. OPTION U5UC OPTION DESCRIPTION Digits Code Meaning Details 1 - 2 U5 Destination C0: Canada U4: U.S. For USA U5: U.S. For states using California emission standards U6: U.S. For states not using California emission standards 3 U Option equipment 3: Cruise control, Power pack D: Vehicle dynamics control (VDC), Cruise control E: Vehicle dynamics control (VDC), Cruise control, Power pack U: Cruise control 4 C Option equipment C: A/C, Side airbag, Curtain airbag K: A/C, Side airbag, Curtain airbag, Sunroof, Navigation system W: A/C, Side airbag, Curtain airbag, Sunroof

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 manual. 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 either lubricants in the table below or equivalent. See the table below to choose the correct SAE viscosity.

LUBRICANTS AND RECOMMENDED MATERIALS REFERENCE Lubricants 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 genuine coolant 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 other than DENSO OIL 8.

REFRIGERANT SPECIFICATION

GREASE

Use grease and supplementary lubricants shown in the table below.

GREASE SPECIFICATION

ADHESIVE

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

ADHESIVE SPECIFICATION

SEAL MATERIAL

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

SEAL MATERIAL SPECIFICATION

U.S

1. Other than U5 model

MAINTENANCE SCHEDULE CHART (OTHER THAN U5 MODEL)

1. U5 model

MAINTENANCE SCHEDULE CHART (U5 MODEL)

MAINTENANCE SCHEDULE CHART

CANADA

MAINTENANCE SCHEDULE CHART (CANADA)

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

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

Scheme 86

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Scheme 88

1. Remove the collector cover. (If equipped)
2. Remove the V-belt covers. 2.5 L non-turbo model 2.5 L turbo model
3. Loosen the lock bolt (A).
4. Loosen the slider bolt (B).
5. Remove the front side belt (C).
6. Install a new V-belt, and tighten the slider bolt so as to obtain the specified belt tension.
7. Tighten the lock bolt (A).
8. Tighten the slider bolt (B). Tightening torque: Lock bolt 25 N.m (2.5 kgf-m, 18.1 ft-lb) Slider bolt 8 N.m (0.8 kgf-m, 5.8 ft-lb)

REAR SIDE BELT (FOR A/C)

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

Scheme 89

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 V-belt, and tighten the slider bolt so as to obtain the specified belt tension.
6. Tighten the lock nut (A). Tightening torque: 23 N.m (2.3 kgf-m, 17.0 It-lb)
7. Install the front side belt. 2.5 L non-turbo model < Ref. to «FRONT SIDE BELT»(ref-287680-S06518172592008061600000) , INSTALLATION, V-belt. > 2.5 L turbo model < Ref. to «FRONT SIDE BELT»(ref-287681-S12695488942008061600000) , INSTALLATION, V-belt. >

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Scheme 91

1. Fit the tool to the belt tensioner mounting bolt.
2. Turn the tool clockwise, and loosen the V-belt to remove.
3. Remove the V-belt cover.
4. Install in the reverse order of removal.

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1. Protect the radiator with cardboard and blanket.
2. Remove the V-belt covers.
3. Remove the V-belts. < Ref. to «V-BELT»(ref-287680-S39675615292008061600000) . >
4. Remove the A/C compressor V-belt tensioner.
5. Use the ST to lock the crankshaft, and remove the pulley bolt. ST 499977100 CRANK PULLEY WRENCH
6. Remove the crank pulley.
7. Remove the belt cover (LH).
8. Remove the front timing belt cover.
9. Remove the timing belt guide. (MT model)
10. If the alignment mark (a) or arrow mark (which indicates rotation direction) on the timing belt has faded away, put new marks on the belt before removing as shown in procedures below. Use the ST to turn crankshaft. Align the mark (a) of sprocket to the cylinder block notch (b), and then ensure the right side cam sprocket mark (c), cam cap and cylinder head matching surface (d) or left side cam sprocket mark (e), timing belt cover notch (f) are properly adjusted. ST 499987500 CRANKSHAFT SOCKET
11. Remove the belt idler.
12. Remove the belt idler (No. 2).
13. Remove the timing belt.
14. Remove the automatic belt tension adjuster assembly.
15. Install in the reverse order of removal. < Ref. to «INSTALLATION»(ref-287680-S41510240272008061600000) , Timing Belt. >

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1. Protect the radiator with cardboard and blanket.
2. Remove the V-belts. < Ref. to «V-BELT»(ref-287681-S41163989682008061600000) , V-belt. >
3. Remove the A/C compressor V-belt tensioner.
4. Remove the pulley bolt. Using the ST, lock the crankshaft. ST 499977100 CRANK PULLEY WRENCH
5. Remove the crank pulley.
6. Remove the belt cover (LH).
7. Remove the belt cover (RH).
8. Remove the front belt cover.
9. Remove the timing belt guide. (MT model)
10. 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
11. Remove the belt idler.
12. Remove the timing belt.
13. Remove the automatic belt tension adjuster assembly.
14. Install in the reverse order of removal. < Ref. to «TIMING BELT»(ref-287681-S29503612742008061600000) , 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 107

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 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.
4. Install the timing belt cover (LH).

Scheme 108

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 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.
4. Install the timing belt cover (LH).

RELATIONSHIP OF SUBARU COOLANT CONCENTRATION AND FREEZING TEMPERATURE

The concentration and safe operating temperature of 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 109

ATF FILTER

Note. Basically, the ATF filter is maintenance free, but when it is rusted or physically damaged or leaking, the ATF filter needs to be replaced.

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

1. 4AT model

< Ref. to ATF FILTER . >

1. 5AT model

< Ref. to ATF FILTER . >

FRONT DIFFERENTIAL (MT MODEL)

Front differential gear oil for MT model lubricates the transmission and differential together. Refer to "Transmission Oil" for replacement procedure. < Ref. to TRANSMISSION GEAR OIL . >

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1. Drain the differential gear oil by removing drain plug using TORX® BIT T70. CAUTION: If the front 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. 4AT model 5AT model
2. Replace the gasket with new part, and then tighten the drain plug to specified torque. Tightening torque: 4AT model Copper gasket 70 N.m (7.1 kgf-m, 51.6 ft-lb) Aluminum gasket 44 N.m (4.5 kgf-m, 32.5 ft-lb) 5AT model 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. Recommended gear oil: Refer to "RM" section. < Ref. to «LUBRICANTS»(ref-306916-S13819006042008122600000) , 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: 4AT model 1.1 - 1.3 l (12 - 1.4 US qt, 1.0 - 1.1 lmp qt) 5AT model 1.3 - 1.5 l (1.4 - 1.6 US qt, 1.1 - 1.3 lmp qt)

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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 for T-type (except for turbo 6MT model). Use a new gasket for VA-type and T-type (turbo 6MT model). Liquid gasket: THREE BOND 1105 (Part No. 004403010) Tightening torque: T-type (except for turbo 6MT model) 49.0 N.m (5.0 kgf-m, 36.2 ft-lb) T-type (turbo 6MT model) 60 N.m (6.1 kgf-m, 44.3 ft-lb) VA1-type 34 N.m (3.5 kgf-m, 25.3 ft-lb) VA2-type 29 N.m (3.0 kgf-m, 21.4 ft-lb)
4. Pour oil to the bottom end of filler plug hole. Recommended gear oil: Refer to "RM" section. < Ref. to «LUBRICANTS»(ref-306916-S13819006042008122600000) , RECOMMENDED MATERIALS, Recommended Materials . > Except for VA2-type VA2-type Oil capacity: Except for turbo 6MT model 0.8 l (0.8 US qt, 0.7 lmp qt) Turbo 6MT model 1.0 l (1.1 US qt, 0.9 lmp qt) NOTE: Each oil manufacturer has its base oil and additives. Thus, do not mix two or more brands.
5. Install the filler plug. NOTE: Apply liquid gasket to the drain plug threads for T-type (except for turbo 6MT model). Use a new gasket for VA-type and T-type (turbo 6MT model). Liquid gasket: THREE BOND 1105 (Part No. 004403010) Tightening torque: T-type (except for turbo 6MT model) 49.0 N.m (5.0 kgf-m, 36.2 ft-lb) T-type (turbo 6MT model) 60 N.m (6.1 kgf-m, 44.3 ft-lb) VA1-type 34 N.m (3.5 kgf-m, 25.3 ft-lb) VA2-type 29 N.m (3.0 kgf-m, 21.4 ft-lb)

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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 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 by pulling up the pedal with a force of 10 N (1 kgf, 2 lb) or less. Brake pedal free play (Pulling up direction of pedal) 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. [Pulling up the brake pedal pad with a force of 10 N (1 kgf, 2 lb) or less to a stroke of 0.5 to 2.0 mm (0.02 to 0.08 in).] 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).
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 pedal stroke is normal if the difference between two measured values is the specified value or less. If the measured value is the specification or more, there is possibility of entering air in hydraulic unit. Brake pedal stroke A: 95 mm (3.7 in)/ 490 N (50 kgf, 110 lb) 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 121

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 incorporated into the brake booster nipple part. Disconnect the vacuum hose to inspect function of check valve. Make sure air flows from the booster end to engine end but does not flow in the opposite direction in the check valve.
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.

Scheme 122

1. Either jack-up the vehicle and place a rigid rack under it, or lift up the vehicle.
2. Remove all the wheels.
3. Drain the brake fluid from master cylinder.
4. Refill the reservoir tank with recommended brake fluid. Recommended brake fluid: Refer to "RM" section. < Ref. to «FLUID»(ref-306916-S00450311242008122600000) , RECOMMENDED MATERIALS, Recommended Materials . > NOTE: Avoid mixing different brands of brake fluid to prevent degrading the quality of fluid. Be careful not to allow dirt or dust to get into the reservoir tank. Perform the operation in the order from farthest wheel cylinder to the master cylinder.
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. NOTE: Cover the bleeder with cloth, when loosening it, to prevent brake fluid from being splashed over surrounding parts. While bleeding air, keep the reservoir tank filled with brake fluid to prevent entry of air. Operate the brake pedal slowly. For convenience and safety, two people should do the work. The amount of brake fluid required is approx. 500 m 0 (16.9 US fl oz, 17.6 lmp fl 02) 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 ) 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 screw 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 distance of 2 to 3 km (1 to 2 miles) to confirm that brakes are operating properly.

Scheme 123

Scheme 124

Scheme 125

1. Jack-up the vehicle and support with rigid racks. Then remove the wheels.
2. Visually check the pad thickness through inspection hole of disc brake assembly. Replace the pad if necessary. NOTE: 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. Front PAD THICKNESS SPECIFICATION - FRONT Pad thickness mm (in) Standard 16-inch 11 (0.43) 17-inch 11 (0.43) Wear limit 16-inch 1.5 (0.059) 17-inch 1.5 (0.059) Rear PAD THICKNESS SPECIFICATION - REAR Pad thickness mm (in) Standard Solid disc type 9 (0.35) Ventilated disc type 9 (0.35) Wear limit Solid disc type 1.5 (0.059) Ventilated disc type 1.5 (0.059)
3. Check the disc rotor, and correct or replace if it is damaged or worn. Front DISC ROTOR THICKNESS SPECIFICATION - FRONT Disc rotor thickness mm (in) Standard 16-inch 24 (0.94) 17-inch 30 (1.18) Wear limit 16-inch 22 (0.87) 17-inch 28 (1.10) Rear DISC ROTOR THICKNESS SPECIFICATION - REAR Disc rotor thickness mm (in) Standard Solid disc type 10 (0.39) Ventilated disc type 18 (0.71) Wear limit Solid disc type 8.5 (0.34) Ventilated disc type 16 (0.63)
4. Remove the caliper body. < Ref. to «FRONT DISC BRAKE ASSEMBLY»(ref-288625-S01295902872008062500000) . > < Ref. to «REAR DISC BRAKE ASSEMBLY»(ref-288625-S40610296882008062500000) . >
5. Tighten the wheel nuts to secure disc 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 disc rotor runout. Disc rotor runout limit: Front: 0.05 mm (0.002 in) Rear: 0.05 mm (0.002 in)

FRONT, REAR SUSPENSION BUSHING

Apply pressure with tire lever etc. to inspect the bushing for abnormal fatigue or damage. Replace the bushings if there is abnormal fatigue or damage.

Scheme 126

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. < Ref. to «WHEEL ALIGNMENT»(ref-287691-S21648381852008061600000) . >
3. When the wheel arch height is out of standard, visually inspect following components and replace deformed parts. Suspension components [Front strut assembly and rear damper 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. < Ref. to «WHEEL ALIGNMENT»(ref-287691-S21648381852008061600000) . > < Ref. to «WHEEL ALIGNMENT»(ref-287692-S15560494022008061600000) . >

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.

1. Front suspension < Ref. to «COMPONENT»(ref-287691-S29329211132008061600000) . >
2. Rear suspension

< Ref. to COMPONENT . >

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 link Rear link Upper link Rear arm 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 WHEEL BEARING

Note. Inspect the condition of front wheel bearing grease.

Scheme 127

1. Jack-up the front side of vehicle.
2. While holding the front wheel by hand, swing it in and out to check 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 the hub and measure axial play in axial direction. Service limit: Straight-ahead position within 0.05 mm (0.0020 in)
5. Remove the bolts and self-locking nuts, and extract the front arm from front crossmember.
6. Remove the PTJ of front drive shaft from transmission. < Ref. to «FRONT AXLE»(ref-287693-S04033490302008061600000) . >
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 axle.

REAR WHEEL BEARING

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 the hub and measure axial play in 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. < Ref. to «REAR DRIVE SHAFT»(ref-287693-S06804221852008061600000) . >
6. While supporting rear 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 rear axle.

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. < Ref. to FRONT DRIVE SHAFT . > < Ref. to REAR DRIVE SHAFT . >

Scheme 128

Scheme 129

1. Front
2. Rear

PROPELLER SHAFT

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

Scheme 130

Scheme 131

Scheme 132

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, make sure tires are worn evenly. When the direction of tire rotation is not specified With instruction for the direction of tire rotation
4. Re-register the transmitter ID when rotation was performed. (3.0 L U4 model) < Ref. to «REGISTER TRANSMITTER ID»(ref-306925-S11772456092008122600000) . >

Scheme 133

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, 17.7 ft-lb)

Scheme 134

Scheme 135

Scheme 136

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, 44.1 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.
4. Apply liquid gasket to at least 1/3 of entire perimeter of adjusting screw thread.
5. Tighten the adjusting screw to 25 N.m (2.5 kgf-m, 18.1 ft-lb) and then loosen.
6. Tighten the adjusting screw to 3.9 N.m (0.40 kgf-m, 2.9 ft-lb) and then loosen 20°.
7. Install the lock nut. While holding the adjusting screw with wrench, tighten the lock nut using ST. ST 926230000 SPANNER Tightening torque (lock nut): 25 N.m (2.5 kgf-m, 18.1 ft-lb) Hold the adjusting screw with wrench to prevent it from turning while tightening the lock nut.

Scheme 137

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 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 for tightness. If it is loose, retighten it to the specified torque. Tightening torque: 85 N.m (8.7 kgf-m, 63 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 138

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.

Scheme 139

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).

FITTING BOLTS A

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.