Subaru 2005 Legacy
2015-10-24
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G2360GE.book 1 ページ ２００７年１１月２９日 木曜日 午後１時２８分 2005 Model Year PDF Service Manual GENERAL INFORMATION SECTION (Pub.No. G2360GE1) ENGINE SECTION 1 (Pub.No. G2360GE2) ENGINE SECTION 2 (Pub.No. G2360GE3) ENGINE SECTION 3 (Pub.No. G2360GE4) TRANSMISSION SECTION (Pub.No. G2360GE5) CHASSIS SECTION (Pub.No. G2360GE6) BODY SECTION (Pub.No. G2360GE7) WIRING SYSTEM SECTION (Pub.No. G2360GE8) G2360GE.book 2 ページ ２００７年１１月２９日 木曜日 午後１時２８分 G2360GE.book 3 ページ ２００７年１１月２９日 木曜日 午後１時２８分 2005 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX GENERAL INFORMATION SECTION This service manual has been prepared to provide SUBARU service personnel with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. This manual includes the procedures for maintenance, disassembling, reassembling, inspection and adjustment of components and diagnostics for guidance of experienced mechanics. Please peruse and utilize this manual fully to ensure complete repair work for satisfying our customers by keeping their vehicle in optimum condition. When replacement of parts during repair work is needed, be sure to use SUBARU genuine parts. FOREWORD FW HOW TO USE THIS MANUALS HU SPECIFICATIONS SPC PRECAUTION PC NOTE NT IIDENTIFICATION ID RECOMMENDED MATERIALS RM PRE-DELIVERY INSPECTION PI PERIODIC MAINTENANCE SERVICES PM All information, illustration and specifications contained in this manual are based on the latest product information available at the time of publication approval. FUJI HEAVY INDUSTRIES LTD. G2360GE1 G2360GE.book 4 ページ ２００７年１１月２９日 木曜日 午後１時２８分 G2360GE.book 1 ページ ２００７年１１月２９日 木曜日 午後１時２８分 FOREWORD FW 1. Page Foreword .....................................................................................................2 G2360GE.book 2 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Foreword FOREWORD 1. Foreword A: FOREWORD These manuals are used when performing maintenance, repair, or diagnosis of Subaru LEGACY. Applied model: BL*****, BP***** from 2005MY The manuals contain the latest information at the time of publication. Changes in specifications, methods, etc. may be made without notice. FW-2 G2360GE.book 1 ページ ２００７年１１月２９日 木曜日 午後１時２８分 HOW TO USE THIS MANUALS HU 1. Page How to Use This Manuals ...........................................................................2 G2360GE.book 2 ページ ２００７年１１月２９日 木曜日 午後１時２８分 How to Use This Manuals HOW TO USE THIS MANUALS 1. How to Use This Manuals A: HOW TO USE THIS MANUALS 1. STRUCTURE Each section consists of SCT that are broken down into SC that are divided into sections for each component. The specification, maintenance and other information for the components are included, and the diagnostic information has also been added where necessary. 2. CONTENTS The first page has an index with tabs. HU-2 Vehicle-id: SIE-id:Sa02675f69:A:HOW TO USE THIS MANUALS ∼ G2360GE.book 3 ページ ２００７年１１月２９日 木曜日 午後１時２８分 How to Use This Manuals HOW TO USE THIS MANUALS 3. 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: (7) (5) (21) T2 (5) T6 (8) (20) (1) T1 T3 (4) (2) T8 T2 (3) (6) T3 T2 T10 (1) T5 T3 T3 (2) T4 (4) (4) (3) (12) (22) (23) (16) (14) (9) (6) (10) (11) (11) (10) (9) T3 (18) T1 (13) (15) T2 (17) (19) T6 (4) (3) (7) T4 (10) (4) (15) T2 T11 T5 (22) T6 (3) (12) (35) T4 (8) (10) T3 (26) (23) (14) T2 T5 (27) T2 (34) (24) (25) T7 (24) (36) (25) (13) (31) (30) T2 T5 (29) (10) (17) (16) (37) (32) (28) (18) T3 (33) T4 T1 :Selective part T1 :Replacement part (21) :Sealing point :Should be lubricated with oil. (20) T9 :Should be lubricated with grease. (19) T1 , T2 .... :Tightening torque HU-00017 HU-3 G2360GE.book 4 ページ ２００７年１１月２９日 木曜日 午後１時２８分 How to Use This Manuals HOW TO USE THIS MANUALS 4. SPECIFICATION If necessary, specifications are also included. 5. INSPECTION Inspections to be carried out before and after maintenance are included. 6. MAINTENANCE • Maintenance instructions for serviceable parts describe work area and detailed step with illustration. It also describes the use of special tool, tightening torque, caution for each procedure. • If many serviceable parts are included in one service procedure, appropriate reference is provided for each parts. Example: 15.Main Shaft Assembly for Single-Range A: REMOVAL (A) (B) 1) Remove the manual transmission assembly from vehicie.(C) 11) Tighten the lock nuts to the specified torque using ST1 and ST2. NOTE: Secure the lock nuts in two Places affer tightening. ST2 499987003 SOCKET WRENCH ST1 498937000 TRANSMISSION HOLDER (E) (D) (F) Tightening torque: 118 N m (12.0 kgf-m, 86.8 ft-lb) (G) (H) ST2 ST1 HU-00020 (A) (B) (C) Component Process Reference (D) (E) (F) Cautions Tool number of special tool Name of special tool HU-4 Vehicle-id: SIE-id:Sa02675f69:A:HOW TO USE THIS MANUALS ∼ (G) (H) Tightening torque Illustration G2360GE.book 5 ページ ２００７年１１月２９日 木曜日 午後１時２８分 How to Use This Manuals HOW TO USE THIS MANUALS 7. DIAGNOSIS Tables showing a step-by-step process make it easy to conduct diagnosis. 8. SI UNITS Measurements in these manuals are according to the SI units. Metric and yard/pound measurements are also included. Example: Tightening torque: 44 N⋅m (4.5 kgf-m, 33 ft-lb) Item Force Mass (Weight) Capacity SI units N (Newton) kg, g Torque Rotating speed Pressure 2, m2 or cm3 N⋅m rpm kPa (kilopascal) Power Calorie Fuel consumption rate W W⋅h g/kw⋅h Conventional unit kgf kg, g 2 or cc kgf-m, kgf-cm rpm kgf/cm2 mmHg PS cal g/PS⋅h Remarks 1 kgf = 9.80655 N 1 cc = 1 cm3 = 1 m2 1 kgf-m = 9.80655 N⋅m 1 kgf/cm2 = 98.0655 kPa 1 mmHg = 0.133322 kPa 1 PS = 0.735499 kW 1 kcal = 1.16279 W⋅h 1 g/PS⋅h=1.3596 g/kW⋅h The figure used in these manuals are described in the SI units and conventional units are described in ( HU-5 ). G2360GE.book 6 ページ ２００７年１１月２９日 木曜日 午後１時２８分 How to Use This Manuals HOW TO USE THIS MANUALS 9. EXPLANATION OF TERMINOLOGY • List AAI A/B ABS A/C A/F ALT ASSY AT ATF BATT CD-R/RW CPU DOHC DVD ECM EGR ELR EX F/B FL Ft FWD GPS H/U IG INT ISC LH LSD : : : : : : : : : : : : : : : : : : : : : : : : : : : : : Air Assist Injection Airbag Antilock Brake System Air Conditioner Air Fuel Ratio Generator Assembly Automatic Transmission Automatic Transmission Fluid Battery CD Recordable/Rewritable Central Processing Unit Double Overhead Camshaft Digital Versatile Disc Engine Control Module (ECM) Exhaust Gas Recirculation Emergency Locking Retractor Exhaust Fuse & Joint Box Fusible Link Full-time AWD Front Wheel Drive Global Positioning System Hydraulic Unit Ignition Intermittent Idle Speed Control LH (Left Hand) Limited Slip Differential M/B MD MPI MP-T MT Non-turbo NC NO OP P/S P/W PCD PCV RH Rr SOHC SRS SSM ST SW TCS TGV T/M ViS-C VSV VTD W/H Pr 2ndr HU-6 Vehicle-id: SIE-id:Sa02675f69:A:HOW TO USE THIS MANUALS ∼ : : : : : : : : : : : : : : : : : : : : : : : : : : : : : Main Fuse & Relay Box Mini Disc Multi Point Injection Multi-Plate Transfer Manual Transmission Natural Aspiration Normal Close (Relay) Normal Open (Relay) Option Parts Power Steering Power Window Pitch Circle Diameter Positive Crankcase Ventilation RH (Right Hand) Rear Single Overhead Camshaft Supplemental Restraint System Subaru Select Monitor Special Tool Switch Traction Control System Tumble Generated Valve Transmission Viscous Coupling Vacuum Switching Valve Variable Torque Distribution Wiring Harness Primary Secondary G2360GE.book 1 ページ ２００７年１１月２９日 木曜日 午後１時２８分 SPECIFICATIONS SPC 1. Page LEGACY......................................................................................................2 G2360GE.book 2 ページ ２００７年１１月２９日 木曜日 午後１時２８分 LEGACY SPECIFICATIONS 1. LEGACY A: DIMENSION 1. SEDAN MODEL Model 2.0 L SOHC Overall length Overall width Overall height (at C.W.) Length Width Compartment mm (in) mm (in) mm (in) mm (in) mm (in) Height mm (in) Front Tread Rear Minimum road clearance mm (in) mm (in) mm (in) mm (in) Wheelbase ★1: 2.0 L DOHC turbo 2.5 L SOHC 3.0 L DOHC 5AT 4,665 (183.7) 1,730 (68.1) 1,425 (56.1) 1,900 (74.8) 1,445 (56.9) 3.0 L DOHC 6MT 1,435 (56.5) 1,165 (45.9), 1,100 (43.3)★1 2,670 (105.1) 1,495 (58.9) 1,490 (58.7) 150 (5.9) 155 (6.1) With sunroof 2. WAGON MODEL Model 2.0 L SOHC 2.0 L DOHC turbo 2.5 L SOHC 3.0 L DOHC 5AT Overall length Overall width Overall height (at C.W.) Length Width Compartment mm (in) mm (in) mm (in) mm (in) mm (in) 4,720 (185.8) 1,730 (68.1) 1,470 (57.9) 1,840 (72.4) 1,445 (56.9) Height mm (in) Front Tread Rear Minimum road clearance mm (in) mm (in) mm (in) mm (in) 1,190 (46.9), 1,145 (45.1)★1 2,670 (105.1) 1,495 (58.9) 1,485 (58.5) 155 (6.1) 150 (5.9) Wheelbase ★1: 150 (5.9) 1,475 (58.1) 155 (6.1) With sunroof 3. OUTBACK Model Overall length Overall width Overall height (at C.W.) Length Width Compartment mm (in) mm (in) mm (in) mm (in) mm (in) 4,730 (186.2) 1,770 (69.7) 1,545 (60.8) 1,840 (72.4) 1,445 (56.9) Height mm (in) Front Rear Minimum road clearance mm (in) mm (in) mm (in) mm (in) 1,190 (46.9), 1,145 (45.1)★1 2,670 (105.1) 1,495 (58.9) 1,485 (58.5) 200 (7.9) Wheelbase Tread ★1: 2.5 L SOHC With sunroof SPC-2 3.0 L DOHC 6MT 3.0 L DOHC G2360GE.book 3 ページ ２００７年１１月２９日 木曜日 午後１時２８分 LEGACY SPECIFICATIONS B: ENGINE Model 2.0 L SOHC 2.0 L DOHC turbo Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine Engine type Valve arrangement Bore × Stroke mm (in) Displacement cm3 (cu in) MT AT Compression ratio 92 × 75 (3.62 × 2.95) 9.0 9.5 10.0 MT AT MT kW (HP)/rpm AT rpm N⋅m (kgf-m, ft-lb)/ rpm MT AT 650 101 (137)/5,600 187 (19.1, 137.9)/ 4,400 700 650 190 (258)/6,400 180 (245)/6,400 330 (33.7, 243.4)/ 2,400 310 (31.6, 228.6)/ 2,400 3.0 L DOHC Horizontally opposed, liquid cooled, 6-cylinder, 4-stroke gasoline engine 89.2 × 80.0 (3.512 × 3.150) 2,457 (149.9) 3,000 (183.06) 10.0 10.7 1—3—2—4 Idle speed at Park or Neutral position Maximum torque Overhead camshaft 99.5 × 79.0 (3.917 × 3.110) 1,994 (121.67) Ignition order Maximum output 2.5 L SOHC 650 1—6—3—2— 5—4 750 650 121 (165)/5,600 180 (245)/6,600 226 (23.0, 166.7)/ 4,400 297 (30.3, 219.1)/ 4,200 C: ELECTRICAL Model 2.0 L SOHC Ignition timing (at idling) Spark plug BTDC 13° CHAMPION: RC10YC4 Type and manufacturer Generator Battery Type and capacity (5HR) EC, EK, K4, EH, ER 2.0 L DOHC turbo 14° 13° CHAMPION: RC10YC4 NGK: ILFR6B NGK: PFR5B11★1 12V — 110A 12V — 48AH — (55D23L) MT 12V — 48AH (55D23L) AT 12V — 52AH (65D23L) — KA — 12V — 48AH (55D23L) KS 12V — 27AH (34B19L) — ★1 : EC, EK, K4, EH, ER model SPC-3 2.5 L SOHC 3.0 L DOHC 15° NGK: ILFR6B 12V — 48AH (55D23L) 12V — 52AH (75D23L) 12V — 52AH (75D23L) 12V — 27AH (34B19L) 12V — 48AH (55D23L) G2360GE.book 4 ページ ２００７年１１月２９日 木曜日 午後１時２８分 LEGACY SPECIFICATIONS D: TRANSMISSION Model Transmission type Clutch type 1st 2nd 3rd 4th Gear ratio 5th Auxiliary transmission gear ratio★2 1st reduction Reduction gear (Front) Final reduction Transfer reduction Reduction gear (Rear) Final reduction 6th Rev. High Low Type of gear Gear ratio Type of gear Gear ratio Type of gear Gear ratio Type of gear Gear ratio 2.0 L SOHC 4AT 5MT TCC DSPD 2.785 3.454 1.545 1.947 1.000 1.366 0.694 0.972 Sedan, Wagon 2.0 L DOHC turbo 5AT 5MT TCC DSPD 3.540 3.166 2.264 1.882 1.471 1.296 1.000 0.972 — 0.738 0.834 0.738 — 2.272 — — Helical 1.000 Hypoid — 3.333 1.000 1.447 — — Hypoid — 2.370 — — Helical 1.000 Hypoid — 3.333 — — — — Hypoid 4.111 4.111 3.272 4.111 — — Hypoid Helical 1.000 Hypoid — — Hypoid Helical 1.000 Hypoid 4.111 4.111 3.272 4.111 Sedan, Wagon Model 3.0 L DOHC Transmission type Clutch type Gear ratio Auxiliary transmission gear ratio★2 1st reduction Reduction gear (Front) Final reduction Transfer reduction Reduction gear (Rear) Final reduction 1st 2nd 3rd 4th 5th 6th Rev. High Low Type of gear Gear ratio Type of gear Gear ratio Type of gear Gear ratio Type of gear Gear ratio OUTBACK 2.5 L SOHC 5AT TCC 3.540 2.264 1.471 1.000 0.834 — 2.370 — — Helical 1.000 Hypoid 6MT DSPD 3.636 2.375 1.761 1.346 0.971 0.756 3.545 — — — — Hypoid 4AT TCC 2.785 1.545 1.000 0.694 — — 2.272 — — Helical 1.000 Hypoid 3.083 3.900 4.444 — — Hypoid Helical 1.100 Hypoid — — Hypoid 3.083 3.545 4.444 SPC-4 2.5 L SOHC 4AT 5MT TCC DSPD 2.785 3.454 1.545 2.062 1.000 1.448 0.694 1.088 0.825, — 0.780★1 — — 2.272 3.333 — 1.000 — 1.196 Helical — 1.000 — Hypoid Hypoid 3.700, 4.111 4.111★1 — Helical — 1.000 Hypoid Hypoid 3.700, 4.111 4.111★1 5MT DSPD 3.454 2.062 1.448 1.088 0.825 — 3.333 1.000 1.196 — — Hypoid 3.900, 4.111★1 Helical 1.000 Hypoid 3.900, 4.111★1 3.0 L DOHC 5AT TCC 3.540 2.264 1.471 1.000 0.834 — 2.370 — — Helical 1.000 Hypoid 3.272 — — Hypoid 3.272 G2360GE.book 5 ページ ２００７年１１月２９日 木曜日 午後１時２８分 LEGACY SPECIFICATIONS 5MT: 5-forward speeds with synchromesh and 1-reverse 6MT: 6-forward speeds with synchromesh and 1-reverse 4AT: Electronically controlled fully-automatic, 4-forward speeds and 1-reverse 5AT: Electronically controlled fully-automatic, 5-forward speeds and 1-reverse DSPD: Dry Single Plate Diaphragm TCC: Torque Converter Clutch ★1 : KA, KS model ★2: Dual range model only E: STEERING Model 2.0 L SOHC Type Turns, lock to lock Minimum turning radius 3.2 m (ft) Curb to curb Wall to wall Model Type Turns, lock to lock Minimum turning radius m (ft) Curb to curb Wall to wall Sedan, Wagon 2.0 L DOHC turbo 2.5 L SOHC Rack and Pinion 2.8 3.2 10.8 (35.4) 11.6 (38.1) 3.0 L DOHC 2.8 OUTBACK 2.5 L SOHC 3.0 L DOHC Rack and Pinion 3.2 10.8 (35.4) 11.6 (38.1) F: SUSPENSION Front Rear Macpherson strut type suspension Multi-link type suspension G: BRAKE Model Service brake system Front Rear Parking brake Non-turbo 2.0 L, 3.0 L (EH) Turbo 2.0 L, 3.0 L (Except for EH) Dual circuit hydraulic with vacuum suspended power unit Ventilated disc brake Disc brake Ventilated disc brake Mechanical on rear brakes H: TIRE Model 2.0 L SOHC Wheel size Tire size Type ★1: Sedan, Wagon 2.0 L DOHC 2.5 L SOHC turbo 16 × 61/2JJ 17 × 7JJ 205/55 R16 89V 215/45 R17 87W 16 × 61/2JJ 17 × 7JJ OUTBACK 3.0 L DOHC 2.5 L SOHC 3.0 L DOHC 17 × 7JJ 18 × 7JJ 16 × 61/2JJ 17 × 7JJ 215/60 R16 95V 215/60 R16 95H★1 215/55 R17 94V 215/55 R17 93H★1 205/55 R16 89V 215/45 R17 87W 215/45 R17 87W 215/45 R18 89W Tubeless, Steel belted radial KA model SPC-5 G2360GE.book 6 ページ ２００７年１１月２９日 木曜日 午後１時２８分 LEGACY SPECIFICATIONS I: CAPACITY 2.0 L SOHC Model 4AT 5MT LHD 2 (US gal, Imp gal) Fuel tank Capacity (at overhaul) Engine oil RHD 4.5 (4.8, 4.0) When replacing Filling amount of engine oil and oil engine oil filter 2 (US qt, Imp qt) When replacing engine oil only 2 (US qt, Imp qt) ATF Front differential gear oil Rear differential gear oil Power steering fluid 2 (US qt, Imp qt) 2 (US qt, Imp qt) 2 (US qt, Imp qt) 2 (US qt, Imp qt) Engine coolant 2 (US qt, Imp qt) 4.2 (4.4, 3.7) 4.0 (4.2, 3.5) 3.5 (3.7, 3.1) 4.0 (4.2, 3.5)★2 — — — 8.4 — 8.7 (8.9 — 9.2, 7.4 — 7.7) 1.2 (1.3, 1.1) 0.8 (0.8, 0.7) 0.7 (0.7, 0.8) 6.3 (6.7, 5.5) 6.4 (6.8, 5.6) 6.4 (6.8, 5.6) 6.7 (7.1, 5.9)★1 6.8 (7.2, 6.0)★1 2.0 L DOHC turbo 5AT 5MT Model 2 (US gal, Imp gal) Fuel tank Capacity (at overhaul) 2 (US qt, Imp qt) When replacing Filling amount of engine oil and oil engine oil filter 2 (US qt, Imp qt) When replacing engine oil only Transmission gear oil 2 (US qt, Imp qt) Engine oil ATF 2 (US qt, Imp qt) Front differential gear oil Rear differential gear oil Power steering fluid Engine coolant 2 (US qt, Imp qt) 2 (US qt, Imp qt) 2 (US qt, Imp qt) 2 (US qt, Imp qt) RHD 64 (16.9, 14.1) 2 (US qt, Imp qt) Transmission gear oil LHD 64 (16.9, 14.1) 5.0 (5.3, 4.4) 4.2 (4.4, 3.7) 4.3 (4.5, 3.8) 4.0 (4.2, 3.5) — 3.5 (3.7, 3.1) 9.6 — 10.0 (10.1 — 10.6, 8.4 — — 8.8) 1.4 (1.5 1.2) — 0.8 (0.8, 0.7) 0.7 (0.7, 0.8) 7.3 (7.7, 6.4) 7.4 (7.8, 6.5) SPC-6 6.5 (6.9, 5.7) G2360GE.book 7 ページ ２００７年１１月２９日 木曜日 午後１時２８分 LEGACY SPECIFICATIONS 2.5 L SOHC Model 4AT LHD 2 (US gal, Imp gal) Fuel tank Capacity (at overhaul) Engine oil 5MT RHD 4.5 (4.8, 4.0) When replacing Filling amount of engine oil and oil engine oil filter 2 (US qt, Imp qt) When replacing engine oil only 2 (US qt, Imp qt) ATF Front differential gear oil Rear differential gear oil Power steering fluid 2 (US qt, Imp qt) 2 (US qt, Imp qt) 2 (US qt, Imp qt) 2 (US qt, Imp qt) Engine coolant 2 (US qt, Imp qt) RHD 64 (16.9, 14.1) 2 (US qt, Imp qt) Transmission gear oil LHD 4.2 (4.4, 3.7) 4.0 (4.2, 3.5) 3.5 (3.7, 3.1) 4.0 (4.2, 3.5)★2 — — — 9.3 — 10.1 (9.8 — 10.1, 8.2 — 8.4) 1.2 (1.3, 1.1) 0.8 (0.8, 0.7) 0.7 (0.7, 0.6) 6.3 (6.7, 5.5) 6.4 (6.8, 5.6) 6.4 (6.8, 5.6) 6.7 (7.1, 5.9)★1 6.8 (7.2, 6.0)★1 6.5 (6.9, 5.7) 3.0 L DOHC Model 5AT LHD 2 (US gal, Imp gal) Fuel tank Capacity (at overhaul) 2 (US qt, Imp qt) RHD 7.2 (7.6, 6.3) Engine oil Engine coolant LHD 64 (16.9, 14.1) 2 (US qt, Imp qt) When replacing Filling amount of engine oil and oil engine oil filter 2 (US qt, Imp qt) When replacing engine oil only Transmission gear oil 2 (US qt, Imp qt) ATF 2 (US qt, Imp qt) Front differential gear oil 2 (US qt, Imp qt) Rear differential gear oil 2 (US qt, Imp qt) Power steering fluid 2 (US qt, Imp qt) 6MT RHD 5.7 (6.0, 5.0) 5.5 (5.8, 4.8) — 9.6 — 10.0 (10.1 — 10.6, 8.4 — 8.8) 1.4 (1.5 1.2) 0.8 (0.8, 0.7) 0.7 (0.7, 0.6) 7.2 (7.6, 6.3) 7.7 (8.1, 6.7)★1 ★1 : Model with ATF cooler (with warmer function) : Dual range model only ★2 SPC-7 7.8 (8.2, 6.9)★1 4.1(4.3, 3.6) — — 7.3 (7.7, 6.4) G2360GE.book 8 ページ ２００７年１１月２９日 木曜日 午後１時２８分 LEGACY SPECIFICATIONS J: WEIGHT 1. SEDAN MODEL • LHD model Option code★1 EC Model Curb weight (C.W.) Maximum permissible axle weight (M.P.A.W.) Maximum permissible weight (M.P.W.) Option ★1: 2.0 L SOHC AWD 2.0 i 5MT (Single range model) 740 (1,631) 755 (1,664) 760 (1,676) 765 (1,686) 755 (1,664) 590 (1,301) 590 (1,301) 590 (1,301) 610 (1,345) 595 (1,312) 1,330 (2,932) 1,345 (2,965) 1,350 (2,976) 1,375 (3,032) 1,350 (2,977) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) Front Rear Total Front kg (lb) kg (lb) kg (lb) kg (lb) Rear kg (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) Total kg (lb) 1,900 (4,189) 1,900 (4,189) 1,900 (4,189) 1,900 (4,189) 1,900 (4,189) Vehicle Dynamics Control Cruise control McIntosh audio Leather interior Winter pack 15-inch tire 17-inch tire A/C Side airbag Curtain airbag Sunroof Navigation system Self levelizer — — — — — — — — — — — — ❍ — — — — — — — — — — ❍ ❍ — — — — ❍ — — ❍ — — ❍ ❍ — — — — ❍ — ❍ ❍ — — ❍ ❍ ❍ ❍ — — ❍ — — ❍ — — ❍ ❍ ❍ — — — For option code, refer to ID section. SPC-8 G2360GE.book 9 ページ ２００７年１１月２９日 木曜日 午後１時２８分 LEGACY SPECIFICATIONS Option code★1 EC Model Curb weight (C.W.) Maximum permissible axle weight (M.P.A.W.) Maximum permissible weight (M.P.W.) Option ★1: 2.0 L SOHC AWD 2.0 i 4AT 760 (1,676) 775 (1,709) 780 (1,720) 785 (1,731) 780 (1,720) 590 (1,301) 590 (1,301) 590 (1,301) 610 (1,345) 595 (1,312) 1,350 (2,976) 1,365 (3,009) 1,370 (3,020) 1,395 (3,076) 1,375 (3,032) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) Front Rear Total Front kg (lb) kg (lb) kg (lb) kg (lb) Rear kg (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) Total kg (lb) 1,900 (4,189) 1,900 (4,189) 1,900 (4,189) 1,900 (4,189) 1,900 (4,189) Vehicle Dynamics Control Cruise control McIntosh audio Leather interior Winter pack 15-inch tire 17-inch tire A/C Side airbag Curtain airbag Sunroof Navigation system Self levelizer — — — — — — — — — — — — ❍ — — — — — — — — — — ❍ ❍ — — — — ❍ — — ❍ — — ❍ ❍ — — — — ❍ — ❍ ❍ — — ❍ ❍ ❍ ❍ — — ❍ — — ❍ — — ❍ ❍ ❍ — — — For option code, refer to ID section. SPC-9 G2360GE.book 10 ページ ２００７年１１月２９日 木曜日 午後１時２８分 LEGACY SPECIFICATIONS Option code★1 EC Model Curb weight (C.W.) Maximum permissible axle weight (M.P.A.W.) Maximum permissible weight (M.P.W.) Option ★1: 2.5 L SOHC AWD 2.5 i 5MT (Single range model) 760 (1,676) 770 (1,698) 765 (1,686) 765 (1,686) 775 (1,709) 605 (1,334) 605 (1,334) 605 (1,334) 610 (1,345) 615 (1,356) 1,365 (3,010) 1,375 (3,031) 1,370 (3,021) 1,375 (3,031) 1,390 (3,064) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) Front Rear Total Front kg (lb) kg (lb) kg (lb) kg (lb) Rear kg (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) Total kg (lb) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255) Vehicle Dynamics Control Cruise control McIntosh audio Leather interior Winter pack 15-inch tire 17-inch tire A/C Side airbag Curtain airbag Sunroof Navigation system Self levelizer — — — — — ❍ — — — — — ❍ ❍ ❍ — — — ❍ — — — — ❍ ❍ ❍ — — — — ❍ — ❍ ❍ — — ❍ ❍ ❍ — ❍ — ❍ — ❍ ❍ — — ❍ ❍ ❍ — ❍ — ❍ — ❍ ❍ — — ❍ ❍ ❍ ❍ — — For option code, refer to ID section. SPC-10 G2360GE.book 11 ページ ２００７年１１月２９日 木曜日 午後１時２８分 LEGACY SPECIFICATIONS Option code★1 EC 2.5 L SOHC AWD 2.5 i Model Curb weight (C.W.) Maximum permissible axle weight (M.P.A.W.) Maximum permissible weight (M.P.W.) Option ★1: 5MT (Single range model) 4AT 780 (1,720) 785 (1,731) 780 (1,720) 790 (1,742) 785 (1,731) 785 (1,731) 625 (1,378) 625 (1,378) 605 (1,334) 605 (1,334) 610 (1,345) 610 (1,345) 1,405 (3,097) 1,410 (3,109) 1,385 (3,053) 1,395 (3,075) 1,395 (3,075) 1,395 (3,075) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) Front Rear Total Front kg (lb) kg (lb) kg (lb) kg (lb) Rear kg (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) Total kg (lb) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255) Vehicle Dynamics Control Cruise control McIntosh audio Leather interior Winter pack 15-inch tire 17-inch tire A/C Side airbag Curtain airbag Sunroof Navigation system Self levelizer — — — — — — ❍ — ❍ ❍ — ❍ ❍ ❍ ❍ ❍ — — ❍ — ❍ ❍ — ❍ ❍ ❍ ❍ ❍ ❍ — ❍ — — — — — ❍ ❍ ❍ — — — ❍ — — — — ❍ ❍ ❍ — — — — ❍ — ❍ ❍ — — ❍ ❍ ❍ — ❍ — ❍ — ❍ ❍ — — ❍ ❍ ❍ — — — For option code, refer to ID section. SPC-11 G2360GE.book 12 ページ ２００７年１１月２９日 木曜日 午後１時２８分 LEGACY SPECIFICATIONS Option code★1 EC 2.5 L SOHC Model Curb weight (C.W.) Maximum permissible axle weight (M.P.A.W.) Maximum permissible weight (M.P.W.) Option ★1: 3.0 L DOHC AWD 2.5 i 3.0 R 4AT 5AT 790 (1,742) 800 (1,764) 805 (1,774) 880 (1,940) 890 (1,962) 890 (1,962) 610 (1,345) 615 (1,356) 625 (1,378) 625 (1,378) 635 (1,400) 635 (1,400) 1,400 (3,087) 1,415 (3,120) 1,430 (3,153) 1,505 (3,319) 1,525 (3,362) 1,525 (3,362) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) Front Rear Total Front kg (lb) kg (lb) kg (lb) kg (lb) Rear kg (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) Total kg (lb) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255) 2,030 (4,475) 2,030 (4,475) 2,030 (4,475) Vehicle Dynamics Control Cruise control McIntosh audio Leather interior Winter pack 15-inch tire 17-inch tire A/C Side airbag Curtain airbag Sunroof Navigation system Self levelizer ❍ ❍ ❍ ❍ ❍ ❍ ❍ — ❍ ❍ — — ❍ ❍ ❍ — — — ❍ — ❍ ❍ — — ❍ ❍ ❍ ❍ — — ❍ — ❍ ❍ — ❍ ❍ ❍ ❍ ❍ — — ❍ — ❍ ❍ — — ❍ ❍ ❍ — — — ❍ — ❍ ❍ — — ❍ ❍ ❍ ❍ — — ❍ — ❍ ❍ — — ❍ ❍ ❍ ❍ ❍ — For option code, refer to ID section. SPC-12 G2360GE.book 13 ページ ２００７年１１月２９日 木曜日 午後１時２８分 LEGACY SPECIFICATIONS Option code★1 EC Model Curb weight (C.W.) Maximum permissible axle weight (M.P.A.W.) Maximum permissible weight (M.P.W.) Option ★1: 3.0 L DOHC AWD 3.0 R spec. B 6MT 885 (1,951) 895 (1,973) 895 (1,973) 895 (1,973) 635 (1,400) 645 (1,422) 645 (1,422) 645 (1,422) 1,520 (3,352) 1,540 (3,396) 1,540 (3,396) 1,540 (3,396) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) Front Rear Total Front kg (lb) kg (lb) kg (lb) kg (lb) Rear kg (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) Total kg (lb) 2,030 (4,475) 2,030 (4,475) 2,030 (4,475) 2,030 (4,475) Vehicle Dynamics Control Cruise control McIntosh audio Leather interior Winter pack 15-inch tire 17-inch tire A/C Side airbag Curtain airbag Sunroof Navigation system Self levelizer — — — ❍ ❍ — ❍ ❍ — — ❍ ❍ ❍ — — — ❍ — ❍ ❍ — — ❍ ❍ ❍ ❍ — — ❍ — ❍ ❍ — — ❍ ❍ ❍ ❍ ❍ — ❍ — ❍ ❍ — — ❍ ❍ ❍ ❍ — — For option code, refer to ID section. SPC-13 G2360GE.book 14 ページ ２００７年１１月２９日 木曜日 午後１時２８分 LEGACY SPECIFICATIONS Option code★1 K4 Model Curb weight (C.W.) Maximum permissible axle weight (M.P.A.W.) Maximum permissible weight (M.P.W.) Option ★1: KS K4 2.0 L SOHC AWD 2.0 i 5MT (Single range model) 4AT 750 (1,653) 750 (1,653) 760 (1,676) 770 (1,698) 770 (1,698) 590 (1,301) 590 (1,301) 600 (1,323) 590 (1,301) 590 (1,301) 1,340 (2,954) 1,340 (2,954) 1,360 (2,998) 1,360 (2,998) 1,360 (2,998) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) Front Rear Total Front kg (lb) kg (lb) kg (lb) kg (lb) Rear kg (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) Total kg (lb) 1,900 (4,189) 1,900 (4,189) 1,900 (4,189) 1,900 (4,189) 1,900 (4,189) Vehicle Dynamics Control Cruise control McIntosh audio Leather interior Winter pack 15-inch tire 17-inch tire A/C Side airbag Curtain airbag Sunroof Navigation system Self levelizer — — — — — — — — — — — ❍ — — — — — — — — — — — ❍ — — — — — — — — — — — ❍ — — ❍ — — — — — — — — ❍ — — — — — ❍ — — — — — ❍ — — — — — For option code, refer to ID section. SPC-14 G2360GE.book 15 ページ ２００７年１１月２９日 木曜日 午後１時２８分 LEGACY SPECIFICATIONS Option code★1 K4 KS KS 2.0 L SOHC Model Curb weight (C.W.) Maximum permissible axle weight (M.P.A.W.) Maximum permissible weight (M.P.W.) Option ★1: 2.5 L SOHC AWD 2.0 i 2.5 i 4AT 5MT (Single range model) 775 (1,709) 770 (1,698) 780 (1,720) 760 (1,676) 770 (1,698) 770 (1,698) 590 (1,301) 590 (1,301) 595 (1,312) 595 (1,312) 605 (1,334) 610 (1,345) 1,365 (3,009) 1,360 (2,998) 1,375 (3,031) 1,355 (2,987) 1,375 (3,031) 1,380 (3,042) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) Front Rear Total Front kg (lb) kg (lb) kg (lb) kg (lb) Rear kg (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) Total kg (lb) 1,900 (4,189) 1,900 (4,189) 1,900 (4,189) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255) Vehicle Dynamics Control Cruise control McIntosh audio Leather interior Winter pack 15-inch tire 17-inch tire A/C Side airbag Curtain airbag Sunroof Navigation system Self levelizer — — — — — — ❍ — — — — — ❍ ❍ — — — — — — — — — — ❍ — — — — — — — — — — — ❍ — — ❍ — — ❍ — — — — — ❍ — — — — — ❍ — — — — — ❍ — — ❍ — — ❍ — ❍ — — — ❍ — — ❍ — — For option code, refer to ID section. SPC-15 G2360GE.book 16 ページ ２００７年１１月２９日 木曜日 午後１時２８分 LEGACY SPECIFICATIONS Option code★1 K4 Model Curb weight (C.W.) Maximum permissible axle weight (M.P.A.W.) Maximum permissible weight (M.P.W.) Option ★1: KS EH 2.5 L SOHC AWD 2.5 i 4AT 790 (1,742) 795 (1,753) 780 (1,720) 790 (1,742) 790 (1,742) 800 (1,764) 605 (1,334) 610 (1,345) 595 (1,312) 605 (1,334) 610 (1,345) 615 (1,356) 1,395 (3,031) 1,405 (3,098) 1,375 (3,031) 1,395 (3,075) 1,400 (3,086) 1,415 (3,120) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) Front Rear Total Front kg (lb) kg (lb) kg (lb) kg (lb) Rear kg (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,236) Total kg (lb) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255) Vehicle Dynamics Control Cruise control McIntosh audio Leather interior Winter pack 15-inch tire 17-inch tire A/C Side airbag Curtain airbag Sunroof Navigation system Self levelizer — — — — — ❍ ❍ — — — — — ❍ ❍ — ❍ — — ❍ — ❍ — — — ❍ ❍ — ❍ — — ❍ — — — — — ❍ — — — — — ❍ — — — — — ❍ — — ❍ — — ❍ — ❍ — — — ❍ — — ❍ — — ❍ — ❍ ❍ — — ❍ ❍ ❍ ❍ — — For option code, refer to ID section. SPC-16 G2360GE.book 17 ページ ２００７年１１月２９日 木曜日 午後１時２８分 LEGACY SPECIFICATIONS Option code★1 K4 EH K4 3.0 L DOHC AWD Model Curb weight (C.W.) Maximum permissible axle weight (M.P.A.W.) Maximum permissible weight (M.P.W.) Option ★1: KS 3.0 R 3.0 R spec. B 5AT 6MT 890 (1,962) 880 (1,940) 890 (1,962) 880 (1,940) 895(1,973) 890 (1,962) 635 (1,400) 635 (1,400) 635 (1,400) 625 (1,378) 645 (1,422) 645 (1,422) 1,525 (3,362) 1,515 (3,340) 1,525 (3,362) 1,505 (3,319) 1,540 (3,396) 1,535 (3,385) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) Front Rear Total Front kg (lb) kg (lb) kg (lb) kg (lb) Rear kg (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) Total kg (lb) 2,030 (4,475) 2,030 (4,475) 2,030 (4,475) 2,030 (4,475) 2,030 (4,475) 2,030 (4,475) Vehicle Dynamics Control Cruise control McIntosh audio Leather interior Winter pack 15-inch tire 17-inch tire A/C Side airbag Curtain airbag Sunroof Navigation system Self levelizer ❍ — ❍ ❍ ❍ — ❍ — ❍ — — — ❍ ❍ ❍ ❍ — — ❍ — ❍ — — — ❍ ❍ ❍ ❍ — — ❍ — ❍ — — — ❍ ❍ ❍ ❍ — — ❍ — ❍ ❍ — — ❍ ❍ ❍ ❍ — — ❍ — ❍ — — — ❍ ❍ ❍ ❍ — — ❍ — ❍ — — — ❍ ❍ ❍ ❍ — — For option code, refer to ID section. SPC-17 G2360GE.book 18 ページ ２００７年１１月２９日 木曜日 午後１時２８分 LEGACY SPECIFICATIONS • RHD model Option code★1 EK 2.0 L SOHC AWD 2.0 i Model Curb weight (C.W.) Maximum permissible axle weight (M.P.A.W.) Maximum permissible weight (M.P.W.) Option ★1: Front Rear Total Front 5MT (Single range model) 4AT kg (lb) 760 (1,676) 760 (1,676) 770 (1,698) 780 (1,720) 780 (1,720) 790 (1,742) kg (lb) 590 (1,301) 595 (1,312) 605 (1,334) 590 (1,301) 595 (1,312) 605 (1,334) kg (lb) 1,350 (2,976) 1,355 (2,988) 1,375 (3,031) 1,370 (3,020) 1,375 (3,031) 1,395 (3,075) kg (lb) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) Rear kg (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) Total kg (lb) 1,900 (4,189) 1,900 (4,189) 1,900 (4,189) 1,900 (4,189) 1,900 (4,189) 1,900 (4,189) Vehicle Dynamics Control Cruise control McIntosh audio Leather interior Winter pack 15-inch tire 17-inch tire A/C Side airbag Curtain airbag Sunroof Navigation system Self levelizer — — — — — — — — — — — — ❍ ❍ — — — — — — — — — — ❍ ❍ ❍ — — — — — — — — — ❍ ❍ ❍ ❍ — — — — — — — — ❍ ❍ — — — — — — — — — — ❍ ❍ ❍ — — — — — — — — — ❍ ❍ ❍ ❍ — — For option code, refer to ID section. SPC-18 G2360GE.book 19 ページ ２００７年１１月２９日 木曜日 午後１時２８分 LEGACY SPECIFICATIONS Option code★1 EK Model Curb weight (C.W.) Maximum permissible axle weight (M.P.A.W.) Maximum permissible weight (M.P.W.) Option ★1: 2.5 L SOHC AWD 2.5 i 5MT (Single range model) 4AT 770 (1,698) 770 (1,698) 780 (1,720) 785 (1,731) 790 (1,742) 790 (1,742) 605 (1,334) 610 (1,345) 620 (1,367) 625 (1,378) 610 (1,345) 615 (1,356) 1,375 (3,031) 1,380 (3,043) 1,400 (1,323) 1,410 (3,109) 1,400 (3,086) 1,405 (3,098) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) Front Rear Total Front kg (lb) kg (lb) kg (lb) kg (lb) Rear kg (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) Total kg (lb) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255) Vehicle Dynamics Control Cruise control McIntosh audio Leather interior Winter pack 15-inch tire 17-inch tire A/C Side airbag Curtain airbag Sunroof Navigation system Self levelizer — — — — — — — — — — — ❍ ❍ ❍ — — — — — — ❍ ❍ — ❍ ❍ ❍ ❍ — — — — — — — — ❍ ❍ ❍ ❍ ❍ — — ❍ — ❍ ❍ — ❍ ❍ ❍ ❍ ❍ — — — — — — — ❍ ❍ ❍ — — — — — — ❍ ❍ — ❍ ❍ ❍ ❍ — — — For option code, refer to ID section. SPC-19 G2360GE.book 20 ページ ２００７年１１月２９日 木曜日 午後１時２８分 LEGACY SPECIFICATIONS Option code★1 EK 2.5 L SOHC Model Curb weight (C.W.) Maximum permissible axle weight (M.P.A.W.) Maximum permissible weight (M.P.W.) Option ★1: 3.0 L DOHC AWD 2.5 i 3.0 R 4AT 5AT 810 (1,785) 810 (1,785) 880 (1,940) 890 (1,962) 890 (1,962) 620 (1,367) 620 (1,367) 625 (1,378) 635 (1,400) 635 (1,400) 1,430 (3,153) 1,430 (3,153) 1,505 (3,319) 1,525 (3,362) 1,525 (3,362) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) Front Rear Total Front kg (lb) kg (lb) kg (lb) kg (lb) Rear kg (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) Total kg (lb) 1,930 (4,255) 1,930 (4,255) 2,030 (4,475) 2,030 (4,475) 2,030 (4,475) Vehicle Dynamics Control Cruise control McIntosh audio Leather interior Winter pack 15-inch tire 17-inch tire A/C Side airbag Curtain airbag Sunroof Navigation system Self levelizer ❍ ❍ ❍ ❍ ❍ ❍ — ❍ ❍ — ❍ ❍ ❍ ❍ ❍ — — ❍ — ❍ ❍ — ❍ ❍ ❍ ❍ ❍ ❍ — ❍ — ❍ ❍ — — ❍ ❍ ❍ — — — ❍ — ❍ ❍ — — ❍ ❍ ❍ ❍ — — ❍ — ❍ ❍ — — ❍ ❍ ❍ ❍ ❍ — For option code, refer to ID section. SPC-20 G2360GE.book 21 ページ ２００７年１１月２９日 木曜日 午後１時２８分 LEGACY SPECIFICATIONS Option code★1 EK Model Curb weight (C.W.) Maximum permissible axle weight (M.P.A.W.) Maximum permissible weight (M.P.W.) Option ★1: 3.0 L DOHC AWD 3.0 R spec. B 6MT 885 (1,951) 895 (1,973) 895 (1,973) 895 (1,973) 635 (1,400) 645 (1,422) 645 (1,422) 645 (1,422) 1,520 (3,352) 1,540 (3,396) 1,540 (3,396) 1,540 (3,396) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) Front Rear Total Front kg (lb) kg (lb) kg (lb) kg (lb) Rear kg (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) Total kg (lb) 2,030 (4,475) 2,030 (4,475) 2,030 (4,475) 2,030 (4,475) Vehicle Dynamics Control Cruise control McIntosh audio Leather interior Winter pack 15-inch tire 17-inch tire A/C Side airbag Curtain airbag Sunroof Navigation system Self levelizer — — — ❍ ❍ — ❍ ❍ — — ❍ ❍ ❍ — — — ❍ — ❍ ❍ — — ❍ ❍ ❍ ❍ — — ❍ — ❍ ❍ — — ❍ ❍ ❍ ❍ ❍ — ❍ — ❍ ❍ — — ❍ ❍ ❍ ❍ — — For option code, refer to ID section. SPC-21 G2360GE.book 22 ページ ２００７年１１月２９日 木曜日 午後１時２８分 LEGACY SPECIFICATIONS Option code★1 KA 2.0 L SOHC 2.0 L DOHC turbo AWD Model 2.0 i 2.0 GT 5MT (Single 4AT 5MT range model) 760 (1,676) 780 (1,720) 820 (1,808) 835 (1,841) 590 (1,301) 590 (1,301) 615 (1,356) 635 (1,400) 1,350 (2,976) 1,370 (3,020) 1,435 (3,164) 1,470 (3,241) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) Front Rear Total Front Rear kg (lb) kg (lb) kg (lb) kg (lb) kg (lb) Gross vehicle Mass (G.V.M.) Total kg (lb) 1,900 (4,189) 1,900 (4,189) 2,000 (4,409) 2,000 (4,409) Option Vehicle Dynamics Control Cruise control McIntosh audio Leather interior Winter pack 15-inch tire 17-inch tire A/C Side airbag Curtain airbag Sunroof Navigation system Self levelizer Grade up Curb weight (C.W.) Unladen Mass (U.M.) ★1: — — — — ❍ — — — — — ❍ — — — — — — ❍ — — — — — ❍ — — — — — — ❍ — — — — — ❍ ❍ — — — — — ❍ ❍ ❍ — — — ❍ ❍ ❍ ❍ — — — For option code, refer to ID section. SPC-22 G2360GE.book 23 ページ ２００７年１１月２９日 木曜日 午後１時２８分 LEGACY SPECIFICATIONS Option code★1 KA 2.0 L DOHC turbo 2.5 L SOHC AWD Model 2.0 GT 2.5 i 5AT 5MT (Single range model) 845 (1,863) 860 (1,896) 770 (1,698) 780 (1,720) 615 (1,356) 635 (1,400) 610 (1,345) 620 (1,367) 1,460 (3,219) 1,495 (3,296) 1,380 (3,042) 1,400 (3,086) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) Front Rear Total Front Rear kg (lb) kg (lb) kg (lb) kg (lb) kg (lb) Gross vehicle Mass (G.V.M.) Total kg (lb) 2,000 (4,409) 2,000 (4,409) 1,930 (4,255) 1,930 (4,255) Option Vehicle Dynamics Control Cruise control McIntosh audio Leather interior Winter pack 15-inch tire 17-inch tire A/C Side airbag Curtain airbag Sunroof Navigation system Self levelizer Grade up Curb weight (C.W.) Unladen Mass (U.M.) — — — — ❍ — — — — — ❍ ❍ — — — — — ❍ ❍ ❍ — — — ❍ ❍ ❍ ❍ — — — ❍ — — — — ❍ ❍ ❍ — — — — — ❍ — — — — ❍ ❍ ❍ ❍ ❍ — — — ★1 : For option code, refer to ID section. SPC-23 G2360GE.book 24 ページ ２００７年１１月２９日 木曜日 午後１時２８分 LEGACY SPECIFICATIONS Option code★1 KA 2.5 L SOHC 3.0 L DOHC AWD Model Front Rear Total Front Rear 2.5 i 3.0 R 4AT 5AT kg (lb) 790 (1,742) 800 (1,764) 805 (1,774) 890 (1,962) kg (lb) 610 (1,345) 625 (1,378) 625 (1,378) 635 (1,400) kg (lb) 1,400 (3,087) 1,425 (3,142) 1,430 (3,153) 1,525 (3,362) kg (lb) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) kg (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) Gross vehicle Mass (G.V.M.) Total kg (lb) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255) 2,030 (4,475) 2,030 (4,475) Option Vehicle Dynamics Control Cruise control McIntosh audio Leather interior Winter pack 15-inch tire 17-inch tire A/C Side airbag Curtain airbag Sunroof Navigation system Self levelizer Grade up Curb weight (C.W.) Unladen Mass (U.M.) 3.0 R spec. B 6MT 890 (1,962) 635 (1,400) 1,525 (3,362) 1,040 (2,293) 1,060 (2,336) — — — ❍ — ❍ — — — — ❍ ❍ ❍ — — — — — ❍ — — — — ❍ ❍ ❍ ❍ ❍ — — — ❍ — ❍ — — ❍ ❍ ❍ ❍ ❍ — — ❍ ❍ ❍ ❍ ❍ — — ❍ ❍ ❍ ❍ — — — ❍ ❍ ❍ — — — ❍ ❍ ❍ ❍ — — — ★1 : For option code, refer to ID section. SPC-24 G2360GE.book 25 ページ ２００７年１１月２９日 木曜日 午後１時２８分 LEGACY SPECIFICATIONS 2. WAGON MODEL • LHD model Option code★1 EC Model Curb weight (C.W.) Maximum permissible axle weight (M.P.A.W.) Maximum permissible weight (M.P.W.) Option ★1: 2.0 L SOHC AWD 2.0 i 5MT (Dual range model) 750 (1,653) 765 (1,686) 770 (1,698) 770 (1,698) 780 (1,720) 610 (1,345) 610 (1,345) 610 (1,345) 615 (1,356) 640 (1,411) 1,360 (2,998) 1,375 (3,031) 1,380 (3,042) 1,385 (3,054) 1,420 (3,131) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) Front Rear Total Front kg (lb) kg (lb) kg (lb) kg (lb) Rear kg (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) Total kg (lb) 1,925 (4,244) 1,925 (4,244) 1,925 (4,244) 1,925 (4,244) 1,925 (4,244) Vehicle Dynamics Control Cruise control McIntosh audio Leather interior Winter pack 15-inch tire 17-inch tire A/C Side airbag Curtain airbag Sunroof Navigation system Self levelizer — — — — — — — — — — — — ❍ — — — — — — — — — — ❍ ❍ — — — — ❍ — — ❍ — — ❍ ❍ — — — — ❍ — — ❍ — — ❍ ❍ ❍ — — — ❍ — ❍ ❍ — — ❍ ❍ ❍ ❍ — — For option code, refer to ID section. SPC-25 G2360GE.book 26 ページ ２００７年１１月２９日 木曜日 午後１時２８分 LEGACY SPECIFICATIONS Option code★1 EC Model Curb weight (C.W.) Maximum permissible axle weight (M.P.A.W.) Maximum permissible weight (M.P.W.) Option ★1: 2.0 L SOHC AWD 2.0 i 4AT 760 (1,676) 775 (1,709) 780 (1,720) 780 (1,720) 790 (1,742) 610 (1,345) 610 (1,345) 610 (1,345) 615 (1,356) 635 (1,400) 1,370 (3,020) 1,385 (3,053) 1,390 (3,064) 1,395 (3,076) 1,425 (3,142) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) Front Rear Total Front kg (lb) kg (lb) kg (lb) kg (lb) Rear kg (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) Total kg (lb) 1,925 (4,244) 1,925 (4,244) 1,925 (4,244) 1,925 (4,244) 1,925 (4,244) Vehicle Dynamics Control Cruise control McIntosh audio Leather interior Winter pack 15-inch tire 17-inch tire A/C Side airbag Curtain airbag Sunroof Navigation system Self levelizer — — — — — — — — — — — — ❍ — — — — — — — — — — ❍ ❍ — — — — ❍ — — ❍ — — ❍ ❍ — — — — ❍ — — ❍ — — ❍ ❍ ❍ — — — ❍ — ❍ ❍ — — ❍ ❍ ❍ ❍ — — For option code, refer to ID section. SPC-26 G2360GE.book 27 ページ ２００７年１１月２９日 木曜日 午後１時２８分 LEGACY SPECIFICATIONS Option code★1 EC Model Curb weight (C.W.) Maximum permissible axle weight (M.P.A.W.) Maximum permissible weight (M.P.W.) Option ★1: 2.5 L SOHC AWD 2.5 i 5MT (Dual range model) 770 (1,698) 780 (1,720) 780 (1,720) 775 (1,709) 785 (1,731) 785 (1,731) 625(1,378) 625 (1,378) 625 (1,378) 630 (1,389) 640 (1,411) 645 (1,422) 1,395 (3,075) 1,405 (3,097) 1,405 (3,097) 1,405 (3,097) 1,425 (3,142) 1,430 (3,153) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) Front Rear Total Front kg (lb) kg (lb) kg (lb) kg (lb) Rear kg (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) Total kg (lb) 1,935 (4,266) 1,935 (4,266) 1,935 (4,266) 1,935 (4,266) 1,935 (4,266) 1,935 (4,266) Vehicle Dynamics Control Cruise control McIntosh audio Leather interior Winter pack 15-inch tire 17-inch tire A/C Side airbag Curtain airbag Sunroof Navigation system Self levelizer — — — — — — ❍ — — — — — ❍ ❍ ❍ — — — ❍ — — — — ❍ ❍ ❍ — — — — ❍ — ❍ ❍ — — ❍ ❍ ❍ — ❍ — ❍ — ❍ ❍ — — ❍ ❍ ❍ — — — ❍ — — ❍ — — ❍ ❍ ❍ ❍ — — ❍ — ❍ ❍ — — ❍ ❍ ❍ ❍ — — For option code, refer to ID section. SPC-27 G2360GE.book 28 ページ ２００７年１１月２９日 木曜日 午後１時２８分 LEGACY SPECIFICATIONS Option code★1 EC 2.5 L SOHC AWD 2.5 i Model Curb weight (C.W.) Maximum permissible axle weight (M.P.A.W.) Maximum permissible weight (M.P.W.) Option ★1: 5MT (Dual 4AT range model) 790 (1,742) 780 (1,720) 790 (1,742) 785 (1,731) 785 (1,731) 795 (1,753) 655 (1,444) 625 (1,378) 625 (1,378) 630 (1,389) 630 (1,389) 640 (1,411) 1,445 (3,186) 1,405 (3,098) 1,415 (3,120) 1,415 (3,120) 1,415 (3,120) 1,435 (3,164) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) Front Rear Total Front kg (lb) kg (lb) kg (lb) kg (lb) Rear kg (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) Total kg (lb) 1,935 (4,266) 1,945 (4,288) 1,945 (4,288) 1,945 (4,288) 1,945 (4,288) 1,945 (4,288) Vehicle Dynamics Control Cruise control McIntosh audio Leather interior Winter pack 15-inch tire 17-inch tire A/C Side airbag Curtain airbag Sunroof Navigation system Self levelizer — — — — — — ❍ — ❍ ❍ — ❍ ❍ ❍ ❍ ❍ — — ❍ — — — — — ❍ ❍ ❍ — — — ❍ — — — — ❍ ❍ ❍ — — — — ❍ — ❍ ❍ — — ❍ ❍ ❍ — ❍ — ❍ — ❍ ❍ — — ❍ ❍ ❍ — — — ❍ — — ❍ — — ❍ ❍ ❍ ❍ — — For option code, refer to ID section. SPC-28 G2360GE.book 29 ページ ２００７年１１月２９日 木曜日 午後１時２８分 LEGACY SPECIFICATIONS Option code★1 EC 2.5 L SOHC Model Curb weight (C.W.) Maximum permissible axle weight (M.P.A.W.) Maximum permissible weight (M.P.W.) Option ★1: 3.0 L DOHC AWD 2.5 i 3.0 R 4AT 5AT 790 (1,742) 800 (1,764) 805 (1,775) 880 (1,940) 890 (1,962) 890 (1,962) 630 (1,389) 645 (1,422) 655 (1,444) 645 (1,422) 665 (1,466) 665 (1,466) 1,420 (3,087) 1,445 (3,186) 1,460 (3,219) 1,525 (3,363) 1,555 (3,428) 1,555 (3,428) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) Front Rear Total Front kg (lb) kg (lb) kg (lb) kg (lb) Rear kg (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) Total kg (lb) 1,945 (4,288) 1,945 (4,288) 1,945 (4,288) 2,050 (4,519) 2,050 (4,519) 2,050 (4,519) Vehicle Dynamics Control Cruise control McIntosh audio Leather interior Winter pack 15-inch tire 17-inch tire A/C Side airbag Curtain airbag Sunroof Navigation system Self levelizer ❍ ❍ ❍ ❍ ❍ ❍ ❍ — ❍ ❍ — — ❍ ❍ ❍ — — — ❍ — ❍ ❍ — — ❍ ❍ ❍ ❍ — — ❍ — ❍ ❍ — ❍ ❍ ❍ ❍ ❍ — — ❍ — ❍ ❍ — — ❍ ❍ ❍ — — — ❍ — ❍ ❍ — — ❍ ❍ ❍ ❍ — — ❍ — ❍ ❍ — — ❍ ❍ ❍ ❍ ❍ — For option code, refer to ID section. SPC-29 G2360GE.book 30 ページ ２００７年１１月２９日 木曜日 午後１時２８分 LEGACY SPECIFICATIONS Option code★1 EC K4 3.0 L DOHC 2.0 L SOHC AWD Model Curb weight (C.W.) Maximum permissible axle weight (M.P.A.W.) Maximum permissible weight (M.P.W.) Option ★1: KS 3.0 R spec. B 2.0 i 6MT 5MT (Dual range model) 885 (1,951) 895 (1,973) 895 (1,973) 760 (1,676) 760 (1,676) 655 (1,444) 675 (1,488) 675 (1,488) 610 (1,345) 610 (1,345) 1,540 (3,396) 1,570 (3,462) 1,570 (3,462) 1,370 (3,020) 1,370 (3,020) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) Front Rear Total Front kg (lb) kg (lb) kg (lb) kg (lb) Rear kg (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) Total kg (lb) 2,050 (4,519) 2,050 (4,519) 2,050 (4,519) 1,925 (4,244) 1,925 (4,244) Vehicle Dynamics Control Cruise control McIntosh audio Leather interior Winter pack 15-inch tire 17-inch tire A/C Side airbag Curtain airbag Sunroof Navigation system Self levelizer — — — — — ❍ — ❍ ❍ — — ❍ ❍ ❍ — — — ❍ — ❍ ❍ — — ❍ ❍ ❍ ❍ — — ❍ — ❍ ❍ — — ❍ ❍ ❍ ❍ ❍ — — — — — — — ❍ — — — — — — — — — — — ❍ — — — — — For option code, refer to ID section. SPC-30 G2360GE.book 31 ページ ２００７年１１月２９日 木曜日 午後１時２８分 LEGACY SPECIFICATIONS Option code★1 K4 KS K4 2.0 L SOHC Model Curb weight (C.W.) Maximum permissible axle weight (M.P.A.W.) Maximum permissible weight (M.P.W.) Option ★1: 2.5 L SOHC AWD 2.0 i 2.5 i 4AT 5MT (Dual range model) 770 (1,698) 770 (1,698) 775 (1,698) 770 (1,698) 780 (1,720) 790 (1,742) 610 (1,345) 610 (1,345) 610 (1,345) 610 (1,345) 645 (1,422) 650 (1,433) 1,380 (3,042) 1,380 (3,042) 1,385 (3,053) 1,380 (3,042) 1,425 (3,142) 1,440 (3,175) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) Front Rear Total Front kg (lb) kg (lb) kg (lb) kg (lb) Rear kg (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) Total kg (lb) 1,925 (4,244) 1,925 (4,244) 1,925 (4,244) 1,925 (4,244) 1,935 (4,266) 1,935 (4,266) Vehicle Dynamics Control Cruise control McIntosh audio Leather interior Winter pack 15-inch tire 17-inch tire A/C Side airbag Curtain airbag Sunroof Navigation system Self levelizer — — — — — — — — — — — — ❍ — — — — — ❍ — — — — — ❍ — — — — — ❍ — — — — — ❍ ❍ — — — — — — — — — — ❍ — — — — — ❍ — — — — — ❍ ❍ ❍ ❍ — — ❍ — — — — ❍ ❍ ❍ ❍ ❍ — — For option code, refer to ID section. SPC-31 G2360GE.book 32 ページ ２００７年１１月２９日 木曜日 午後１時２８分 LEGACY SPECIFICATIONS Option code★1 K4 Model Curb weight (C.W.) Maximum permissible axle weight (M.P.A.W.) Maximum permissible weight (M.P.W.) Option ★1: 2.5 L SOHC AWD 2.5 i 4AT 790 (1,742) 800 (1,764) 795 (1,753) 800 (1,764) 645 (1,422) 650 (1,433) 645 (1,422) 650 (1,433) 1,435 (3,164) 1,450 (3,196) 1,440 (3,175) 1,450 (3,196) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) Front Rear Total Front kg (lb) kg (lb) kg (lb) kg (lb) Rear kg (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) Total kg (lb) 1,945 (4,288) 1,945 (4,288) 1,945 (4,288) 1,945 (4,288) Vehicle Dynamics Control Cruise control McIntosh audio Leather interior Winter pack 15-inch tire 17-inch tire A/C Side airbag Curtain airbag Sunroof Navigation system Self levelizer — — — — ❍ — — — — — ❍ ❍ ❍ ❍ — — ❍ — — — — ❍ ❍ ❍ ❍ ❍ — — ❍ — ❍ — — — ❍ ❍ ❍ ❍ — — ❍ — ❍ — — ❍ ❍ ❍ ❍ ❍ — — For option code, refer to ID section. SPC-32 G2360GE.book 33 ページ ２００７年１１月２９日 木曜日 午後１時２８分 LEGACY SPECIFICATIONS Option code★1 K4 K4 3.0 L DOHC AWD Model Curb weight (C.W.) Maximum permissible axle weight (M.P.A.W.) Maximum permissible weight (M.P.W.) Option ★1: KS 3.0 R 3.0 R spec. B 5AT 6MT 890 (1,962) 890 (1,962) 880 (1,940) 890 (1,962) 895 (1,973) 665 (1,466) 665 (1,466) 665 (1,466) 675 (1,488) 675 (1,488) 1,555 (3,428) 1,555 (3,428) 1,545 (3,401) 1,565 (3,451) 1,570 (3,462) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) Front Rear Total Front kg (lb) kg (lb) kg (lb) kg (lb) Rear kg (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) Total kg (lb) 2,050 (4,519) 2,050 (4,519) 2,050 (4,519) 2,050 (4,519) 2,050 (4,519) Vehicle Dynamics Control Cruise control McIntosh audio Leather interior Winter pack 15-inch tire 17-inch tire A/C Side airbag Curtain airbag Sunroof Navigation system Self levelizer ❍ ❍ — — ❍ ❍ — ❍ — — — ❍ ❍ ❍ ❍ — — ❍ — ❍ — — — ❍ ❍ ❍ ❍ — — ❍ — ❍ — — — ❍ ❍ ❍ ❍ — — ❍ — ❍ — — — ❍ ❍ ❍ ❍ — — ❍ — ❍ — — — ❍ ❍ ❍ ❍ — — For option code, refer to ID section. SPC-33 G2360GE.book 34 ページ ２００７年１１月２９日 木曜日 午後１時２８分 LEGACY SPECIFICATIONS Option code★1 KA 2.0 L SOHC 2.0 L DOHC turbo AWD Model 2.0 i 2.0 GT 5MT (Dual 4AT 5MT range model) 770 (1,698) 780 (1,720) 820 (1,808) 835 (1,841) 610 (1,345) 610 (1,345) 635 (1,400) 665 (1,466) 1,380 (3,042) 1,390 (3,064) 1,455 (3,208) 1,500 (3,308) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) Front Rear Total Front Rear kg (lb) kg (lb) kg (lb) kg (lb) kg (lb) Maximum permissible weight (M.P.W.) Total kg (lb) 1,925 (4,244) 1,925 (4,244) 2,010 (4,431) 2,010 (4,431) Option Vehicle Dynamics Control Cruise control McIntosh audio Leather interior Winter pack 15-inch tire 17-inch tire A/C Side airbag Curtain airbag Sunroof Navigation system Self levelizer Grade up Curb weight (C.W.) Unladen Mass (U.M.) — — — — ❍ — — — — — ❍ — — — — — — ❍ — — — — — ❍ — — — — — — ❍ — — — — — ❍ ❍ — — — — — ❍ ❍ ❍ — — — ❍ ❍ ❍ ❍ — — — ★1 : For option code, refer to ID section. SPC-34 G2360GE.book 35 ページ ２００７年１１月２９日 木曜日 午後１時２８分 LEGACY SPECIFICATIONS Option code★1 KA 2.0 L DOHC turbo 2.5 L SOHC AWD Model 2.0 GT 2.5 i 5AT 5MT (Dual range model) 845 (1,863) 860 (1,896) 780 (1,720) 795 (1,753) 635 (1,400) 665 (1,466) 630 (1,389) 650 (1,433) 1,480 (3,263) 1,525 (3,362) 1,410 (3,109) 1,445 (3,186) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) Front Rear Total Front Rear kg (lb) kg (lb) kg (lb) kg (lb) kg (lb) Maximum permissible weight (M.P.W.) Total kg (lb) 2,010 (4,431) 2,010 (4,431) 1,935 (4,266) 1,935 (4,266) Option Vehicle Dynamics Control Cruise control McIntosh audio Leather interior Winter pack 15-inch tire 17-inch tire A/C Side airbag Curtain airbag Sunroof Navigation system Self levelizer Grade up Curb weight (C.W.) Unladen Mass (U.M.) ★1: — — — — ❍ — — — — — ❍ ❍ — — — — — ❍ ❍ ❍ — — — ❍ ❍ ❍ ❍ — — — ❍ — — — — ❍ ❍ ❍ — — — — — ❍ — — — — ❍ ❍ ❍ ❍ ❍ — — — For option code, refer to ID section. SPC-35 G2360GE.book 36 ページ ２００７年１１月２９日 木曜日 午後１時２８分 LEGACY SPECIFICATIONS Option code★1 KA 2.5 L SOHC 3.0 L DOHC AWD Model Front Rear Total Front Rear 2.5 i 3.0 R 4AT 5AT kg (lb) 790 (1,742) 800 (1,764) 805 (1,775) 885 (1,951) kg (lb) 630 (1,389) 650 (1,433) 650 (1,433) 665 (1,466) kg (lb) 1,420 (3,131) 1,450 (3,197) 1,455 (3,208) 1,550 (3,418) kg (lb) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) kg (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) Maximum permissible weight (M.P.W.) Total kg (lb) 1,945 (4,288) 1,945 (4,288) 1,945 (4,288) 2,050 (4,520) 2,050 (4,520) Option Vehicle Dynamics Control Cruise control McIntosh audio Leather interior Winter pack 15-inch tire 17-inch tire A/C Side airbag Curtain airbag Sunroof Navigation system Self levelizer Grade up Curb weight (C.W.) Unladen Mass (U.M.) ★1: 3.0 R spec. B 6MT 890 (1,962) 635 (1,400) 1,525 (3,362) 1,040 (2,293) 1,060 (2,336) — — — ❍ — ❍ — — — — ❍ ❍ ❍ — — — — — ❍ — — — — ❍ ❍ ❍ ❍ ❍ — — — ❍ — ❍ — — ❍ ❍ ❍ ❍ ❍ — — ❍ ❍ ❍ ❍ — — — ❍ ❍ ❍ ❍ — — — ❍ ❍ ❍ — — — ❍ ❍ ❍ ❍ — — — For option code, refer to ID section. SPC-36 G2360GE.book 37 ページ ２００７年１１月２９日 木曜日 午後１時２８分 LEGACY SPECIFICATIONS 3. OUTBACK • LHD model Option code★1 EC Model Curb weight (C.W.) Maximum permissible axle weight (M.P.A.W.) Maximum permissible weight (M.P.W.) Option ★1: 2.5 L SOHC AWD OUTBACK 2.5 i 5MT (Dual range model) 4AT 785 (1,731) 785 (1,731) 795 (1,753) 785 (1,731) 800 (1,764) 795 (1,753) 650 (1,433) 655 (1,444) 670 (1,477) 655 (1,444) 675 (1,488) 650 (1,433) 1,435 (3,164) 1,440 (3,175) 1,465 (3,175) 1,440 (3,175) 1,475 (3,252) 1,445 (3,186) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) Front Rear Total Front kg (lb) kg (lb) kg (lb) kg (lb) Rear kg (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) Total kg (lb) 1,960 (4,321) 1,960 (4,321) 1,960 (4,321) 1,960 (4,321) 1,960 (4,321) 1,970 (4,343) Vehicle Dynamics Control Cruise control McIntosh audio Leather interior Winter pack 15-inch tire 17-inch tire A/C Side airbag Curtain airbag Sunroof Navigation system Self levelizer — — — — — — — — — — — — ❍ ❍ ❍ — — ❍ ❍ — — ❍ — — ❍ ❍ ❍ — — ❍ ❍ — — ❍ — — ❍ ❍ ❍ ❍ — ❍ ❍ — ❍ ❍ — — ❍ ❍ ❍ — — ❍ ❍ — ❍ ❍ — — ❍ ❍ ❍ ❍ ❍ ❍ — — — — — — ❍ ❍ ❍ — — ❍ For option code, refer to ID section. SPC-37 G2360GE.book 38 ページ ２００７年１１月２９日 木曜日 午後１時２８分 LEGACY SPECIFICATIONS Option code★1 EC Model Curb weight (C.W.) Maximum permissible axle weight (M.P.A.W.) Maximum permissible weight (M.P.W.) Option ★1: 2.5 L SOHC AWD OUTBACK 2.5 i 4AT 795 (1,753) 805 (1,775) 800 (1,764) 810 (1,785) 815 (1,797) 815 (1,797) 655 (1,444) 670 (1,470) 655 (1,444) 675 (1,488) 670 (1,477) 675 (1,488) 1,450 (3,197) 1,475 (3,252) 1,455 (3,208) 1,485 (3,274) 1,485 (3,274) 1,490 (3,285) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) Front Rear Total Front kg (lb) kg (lb) kg (lb) kg (lb) Rear kg (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) Total kg (lb) 1,970 (4,343) 1,970 (4,343) 1,970 (4,343) 1,970 (4,343) 1,970 (4,343) 1,970 (4,343) Vehicle Dynamics Control Cruise control McIntosh audio Leather interior Winter pack 15-inch tire 17-inch tire A/C Side airbag Curtain airbag Sunroof Navigation system Self levelizer — — — — ❍ ❍ ❍ — — ❍ — — ❍ ❍ ❍ — — ❍ ❍ — — ❍ — — ❍ ❍ ❍ ❍ — ❍ ❍ — ❍ ❍ — — ❍ ❍ ❍ — — ❍ ❍ — ❍ ❍ — — ❍ ❍ ❍ ❍ ❍ ❍ ❍ — — ❍ — — ❍ ❍ ❍ ❍ — ❍ ❍ — ❍ ❍ — — ❍ ❍ ❍ ❍ ❍ ❍ For option code, refer to ID section. SPC-38 G2360GE.book 39 ページ ２００７年１１月２９日 木曜日 午後１時２８分 LEGACY SPECIFICATIONS Option code★1 EC K4 3.0 L DOHC 2.5 L SOHC AWD Model Curb weight (C.W.) Maximum permissible axle weight (M.P.A.W.) Maximum permissible weight (M.P.W.) Option ★1: KS OUTBACK 3.0 R OUTBACK 2.5 i 5AT 5MT (Dual range model) 890 (1,962) 900 (1,984) 900 (1,984) 785 (1,731) 795 (1,753) 785 (1,731) 670 (1,477) 685 (1,510) 685 (1,510) 645 (1,422) 670 (1,477) 640 (1,410) 1,560 (3,440) 1,585 (3,494) 1,585 (3,494) 1,430 (3,153) 1,465 (3,230) 1,425 (3,142) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) Front Rear Total Front kg (lb) kg (lb) kg (lb) kg (lb) Rear kg (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) Total kg (lb) 2,060 (4,542) 2,060 (4,542) 2,060 (4,542) 1,960 (4,321) 1,960 (4,321) 1,960 (4,321) Vehicle Dynamics Control Cruise control McIntosh audio Leather interior Winter pack 15-inch tire 17-inch tire A/C Side airbag Curtain airbag Sunroof Navigation system Self levelizer ❍ ❍ ❍ — — — ❍ — ❍ ❍ — — ❍ ❍ ❍ — — ❍ ❍ — ❍ ❍ — — ❍ ❍ ❍ ❍ — ❍ ❍ — ❍ ❍ — — ❍ ❍ ❍ ❍ ❍ ❍ ❍ — — — — — ❍ ❍ — — — — ❍ — — — — — ❍ ❍ ❍ ❍ — — ❍ — — — — — ❍ — — — — — For option code, refer to ID section. SPC-39 G2360GE.book 40 ページ ２００７年１１月２９日 木曜日 午後１時２８分 LEGACY SPECIFICATIONS Option code★1 KS K4 2.5 L SOHC AWD OUTBACK 2.5 i Model Curb weight (C.W.) Maximum permissible axle weight (M.P.A.W.) Maximum permissible weight (M.P.W.) Option ★1: KS 5MT (Dual range model) 4AT 795 (1,753) 795 (1,753) 795 (1,753) 805 (1,774) 810 (1,785) 795 (1,753) 655 (1,444) 660 (1,455) 645 (1,422) 670 (1,477) 670 (1,477) 640 (1,410) 1,450 (3,196) 1,455 (3,208) 1,440 (3,175) 1,475 (3,252) 1,480 (3,263) 1,435 (3,164) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) Front Rear Total Front kg (lb) kg (lb) kg (lb) kg (lb) Rear kg (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) Total kg (lb) 1,960 (4,321) 1,960 (4,321) 1,970 (4,343) 1,970 (4,343) 1,970 (4,343) 1,970 (4,343) Vehicle Dynamics Control Cruise control McIntosh audio Leather interior Winter pack 15-inch tire 17-inch tire A/C Side airbag Curtain airbag Sunroof Navigation system Self levelizer — — — — — — ❍ — — — — — ❍ — — ❍ — — ❍ — ❍ — — — ❍ — — ❍ — — ❍ — — — — — ❍ ❍ — — — — ❍ — — — — — ❍ ❍ ❍ ❍ — — ❍ — ❍ — — — ❍ ❍ ❍ ❍ — — ❍ — — — — — ❍ — — — — — For option code, refer to ID section. SPC-40 G2360GE.book 41 ページ ２００７年１１月２９日 木曜日 午後１時２８分 LEGACY SPECIFICATIONS Option code★1 KS K4 KS 2.5 L SOHC 3.0 L DOHC AWD Model Curb weight (C.W.) Maximum permissible axle weight (M.P.A.W.) Maximum permissible weight (M.P.W.) Option ★1: EH OUTBACK 2.5 i OUTBACK 3.0 R 4AT 5AT 805 (1,774) 805 (1,774) 900 (1,984) 890 (1,962) 900 (1,984) 900 (1,984) 655 (1,444) 660 (1,455) 685 (1,510) 685 (1,510) 685 (1,510) 685 (1,510) 1,460 (3,219) 1,465 (3,230) 1,585 (3,494) 1,575 (3,472) 1,585 (3,494) 1,585 (3,494) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) Front Rear Total Front kg (lb) kg (lb) kg (lb) kg (lb) Rear kg (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) Total kg (lb) 1,970 (4,343) 1,970 (4,343) 2,060 (4,542) 2,060 (4,542) 2,060 (4,542) 2,060 (4,542) Vehicle Dynamics Control Cruise control McIntosh audio Leather interior Winter pack 15-inch tire 17-inch tire A/C Side airbag Curtain airbag Sunroof Navigation system Self levelizer — — ❍ — ❍ ❍ ❍ — — — — — ❍ — — ❍ — — ❍ — ❍ — — — ❍ — — ❍ — — ❍ — ❍ — — — ❍ ❍ ❍ ❍ — ❍ ❍ — ❍ — — — ❍ ❍ ❍ ❍ — ❍ ❍ — ❍ — — — ❍ ❍ ❍ ❍ — ❍ ❍ — ❍ ❍ — — ❍ ❍ ❍ ❍ — ❍ For option code, refer to ID section. SPC-41 G2360GE.book 42 ページ ２００７年１１月２９日 木曜日 午後１時２８分 LEGACY SPECIFICATIONS • RHD model Option code★1 EK 2.5 L SOHC AWD OUTBACK 2.5 i Model Curb weight (C.W.) Maximum permissible axle weight (M.P.A.W.) Maximum permissible weight (M.P.W.) Option ★1: Front Rear Total Front 5MT (Dual range model) 4AT kg (lb) 800 (1,764) 790 (1,742) 790 (1,742) 810 (1,785) 800 (1,764) 820 (1,801) kg (lb) 675 (1,488) 645 (1,422) 655 (1,444) 670 (1,477) 645 (1,422) 670 (1,477) kg (lb) 1,475 (3,252) 1,435 (3,164) 1,445 (3,186) 1,480 (3,263) 1,445 (3,186) 1,490 (3,285) kg (lb) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) Rear kg (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) Total kg (lb) 1,960 (4,321) 1,960 (4,321) 1,960 (4,321) 1,970 (4,343) 1,970 (4,343) 1,970 (4,343) Vehicle Dynamics Control Cruise control McIntosh audio Leather interior Winter pack 15-inch tire 17-inch tire A/C Side airbag Curtain airbag Sunroof Navigation system Self levelizer — — — — — ❍ ❍ — ❍ ❍ — — ❍ ❍ ❍ ❍ — ❍ ❍ — — — — — ❍ ❍ — — — ❍ ❍ — ❍ ❍ — — ❍ ❍ ❍ — — ❍ ❍ — ❍ ❍ — — ❍ ❍ ❍ ❍ — ❍ ❍ — — — — — ❍ ❍ — — — ❍ ❍ — ❍ ❍ — — ❍ ❍ ❍ ❍ ❍ ❍ For option code, refer to ID section. SPC-42 G2360GE.book 43 ページ ２００７年１１月２９日 木曜日 午後１時２８分 LEGACY SPECIFICATIONS Option code★1 EK 2.5 L SOHC Model Curb weight (C.W.) Maximum permissible axle weight (M.P.A.W.) Maximum permissible weight (M.P.W.) Option ★1: 3.0 L DOHC AWD OUTBACK OUTBACK 3.0 R 2.5 i 4AT 5AT 800 (1,764) 895 (1,973) 905 (1,995) 905 (1,995) 655 (1,444) 670 (1,477) 685 (1,510) 685 (1,510) 1,455 (3,186) 1,565 (3,451) 1,590 (1,301) 1,590 (1,301) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) Front Rear Total Front kg (lb) kg (lb) kg (lb) kg (lb) Rear kg (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) Total kg (lb) 1,970 (4,343) 2,060 (4,542) 2,060 (4,542) 2,060 (4,542) Vehicle Dynamics Control Cruise control McIntosh audio Leather interior Winter pack 15-inch tire 17-inch tire A/C Side airbag Curtain airbag Sunroof Navigation system Self levelizer — ❍ ❍ ❍ ❍ — ❍ ❍ — — ❍ ❍ ❍ — — ❍ ❍ — ❍ ❍ — — ❍ ❍ ❍ — — ❍ ❍ — ❍ ❍ — — ❍ ❍ ❍ ❍ — ❍ ❍ — ❍ ❍ — — ❍ ❍ ❍ ❍ ❍ ❍ For option code, refer to ID section. SPC-43 G2360GE.book 44 ページ ２００７年１１月２９日 木曜日 午後１時２８分 LEGACY SPECIFICATIONS Option code★1 KA Model 2.5 L SOHC AWD OUTBACK 2.5 i 5MT (Dual range model) 790 (1,742) 800 (1,764) 800 (1,764) 645 (1,422) 665 (1,466) 670 (1,477) 1,435 (3,164) 1,465 (3,230) 1,470(3,241) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 4AT Front Rear Total Front Rear kg (lb) kg (lb) kg (lb) kg (lb) kg (lb) Gross vehicle Mass (G.V.M.) Total kg (lb) 1,960 (4,321) 1,960 (4,321) 1,960 (4,321) 1,970 (4,343) 1,970 (4,343) Option Vehicle Dynamics Control Cruise control McIntosh audio Leather interior Winter pack 15-inch tire 17-inch tire A/C Side airbag Curtain airbag Sunroof Navigation system Self levelizer Grade up Curb weight (C.W.) Unladen Mass (U.M.) 800 (1,764) 810 (1,785) 645 (1,422) 665 (1,466) 1,445 (3,186) 1,475 (3,252) 1,040 (2,293) 1,040 (2,293) 1,060 (2,336) 1,060 (2,336) — — — — — ❍ — — — — — ❍ ❍ — — — — — ❍ — — — — — ❍ ❍ ❍ ❍ — ❍ — ❍ — ❍ — — — ❍ ❍ ❍ ❍ — ❍ ❍ ❍ — — — — — ❍ ❍ — — — — — ❍ — — — — — ❍ ❍ ❍ ❍ — ❍ — ★1 : For option code, refer to ID section. SPC-44 G2360GE.book 45 ページ ２００７年１１月２９日 木曜日 午後１時２８分 LEGACY SPECIFICATIONS Option code★1 KA 2.5 L SOHC Model 3.0 L DOHC AWD OUTBACK OUTBACK 3.0 R 2.5 i 4AT 5AT 810 (1,785) 885 (1,951) 900 (1,984) 670 (1,477) 660 (1,455) 685 (1,510) 1,480 (3,263) 1,545 (3,407) 1,585 (3,494) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) Front Rear Total Front Rear kg (lb) kg (lb) kg (lb) kg (lb) kg (lb) Gross vehicle Mass (G.V.M.) Total kg (lb) 1,970 (4,343) 2,060 (4,542) 2,060 (4,542) Option Vehicle Dynamics Control Cruise control McIntosh audio Leather interior Winter pack 15-inch tire 17-inch tire A/C Side airbag Curtain airbag Sunroof Navigation system Self levelizer Grade up Curb weight (C.W.) Unladen Mass (U.M.) ★1: — — ❍ ❍ — ❍ — — — ❍ ❍ ❍ ❍ — ❍ ❍ ❍ — — — — — ❍ ❍ — — — ❍ — ❍ — ❍ — — — ❍ ❍ ❍ ❍ — ❍ — For option code, refer to ID section. SPC-45 G2360GE.book 46 ページ ２００７年１１月２９日 木曜日 午後１時２８分 LEGACY SPECIFICATIONS SPC-46 G2360GE.book 1 ページ ２００７年１１月２９日 木曜日 午後１時２８分 PRECAUTION PC 1. Page Precaution ...................................................................................................2 G2360GE.book 2 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Precaution PRECAUTION 1. Precaution 6. AIRBAG A: CAUTION To prevent bodily injury from unexpected deployment of airbags and unnecessary maintenance, follow the instructions in this manual when performing maintenance on the airbag components or nearby, around front of the vehicle (radiator panel, front wheel apron, front side frame, front bumper, front hood panel, front fender panel), around side of the vehicle (front door panel, rear door panel, center pillar, rear fender panel, side sill, rear wheel apron), 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. The following precautions must be understood and strictly adhered to avoid minor or serious injury to the person doing the work or people in the area, and to make an effort for environmental protection. 1. ABS Handle the ABS as a total system. Do not disassemble or attempt to repair parts which are not instructed in this manual. Follow the instructions in this manual during performing the maintenance of ABSCM&H/U. To disassemble parts without instructions could prevent the ABS system from operating when needed or cause it to operate incorrectly and result in injury. 2. 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 ABS system from operating when needed or cause it to operate incorrectly and result in injury. 3. BRAKE FLUID 7. AIRBAG MODULE AND SEAT BELT PRETENSIONER DISPOSAL To prevent bodily injury from unexpected airbag deployment, do not dispose airbag modules in the same way as other refuse. Follow the special instructions for disposal in this manual. Follow all government regulations concerning disposal of refuse. 8. AIRBAG MODULE If brake fluid gets in your eyes or on your skin, do the following: • Wash out your eyes and receive medical treatment from an eye doctor. • Wash your skin with soap and then rinse thoroughly with water. 4. 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. 5. ROAD TEST Always conduct road tests in accordance with traffic rules and regulations to avoid bodily injury and interrupting traffic. Adhere to the following when handling and storing the airbag module to prevent bodily injury from unexpected deployment: • Do not hold the harnesses or connectors to carry the module. • Do not face the airbag in the direction that it opens towards yourself or other people. • Do not face the airbag in the direction that it opens towards floor or walls. 9. AIRBAG SPECIAL TOOL To prevent unexpected deployment, only use special tools. 10.WINDOW Always wear safety glasses when working around any glass to prevent glass fragments from damaging your eyes. 11.WINDOW ADHESIVE Always use the recommended or equivalent adhesive when attaching glass to prevent it from coming off and being removed, resulting in accidents and injury. PC-2 G2360GE.book 3 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Precaution PRECAUTION 12.OIL When handing oil, adhere to the following to prevent from unexpected accident. • 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. • Follow all government and local regulations concerning disposal of refuse when disposing. 13.FUEL When handling and storing fuel, adhere to the following to prevent from unexpected accident. • Be careful with fire. • Prepare a container and cloth when performing work which fuel possibly spills to prevent from scatter. If fuel spills, wipe it off immediately to prevent from penetrating into floor or flowing out for environmental protection. • Follow all government and local regulations concerning disposal of refuse when disposing. 14.ENGINE COOLANT When handling engine coolant, adhere to the following to prevent from unexpected accident. • Never remove the radiator cap since engine coolant may blow out when it is hot. • Prepare a container and cloth when performing work which engine coolant possibly spills to prevent from scatter. If engine coolant spills, wipe it off immediately to prevent from penetrating into floor or flowing out for environmental protection. • Follow all government and local regulations concerning disposal of refuse when disposing. 15.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. PC-3 G2360GE.book 4 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Precaution PRECAUTION PC-4 G2360GE.book 1 ページ ２００７年１１月２９日 木曜日 午後１時２８分 NOTE NT 1. Page Note.............................................................................................................2 G2360GE.book 2 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Note NOTE 1. Note A: NOTE This is the information that can improve the efficiency of maintenance and assure the sound work. 1. 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. 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. 2. STATIC ELECTRICITY DAMAGE (A) 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. (C) (B) NT-00070 (A) 80 mm (3.1 in) or more (B) 100 — 150 mm (3.94 — 5.91 in) (C) 120 — 190 mm (4.72 — 7.48 in) 3. 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 overcurrent. Be sure to remove the battery ground cable first. 4. SERVICE PARTS • 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. 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. 5. PROTECTING VEHICLE UNDER MAINTENACE Make sure to attach the fender cover, seat covers, etc. before work. 6. ENSURING SECURITY DURING WORK When working in a group of two or more, perform the work with calling each other to ensure mutual safety. 7. LIFTS AND JACKS 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. NT-2 Vehicle-id: SIE-id:Sa03676a15:A:NOTE ∼ G2360GE.book 3 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Note NOTE (1) (2) (3) (6) (4) (6) (5) a b (6) (6) a NT-00086 (1) (2) Supporting locations Pantograph jack (3) (4) Swing arm lift Rigid rack NT-3 (5) (6) Plate lift Attachment G2360GE.book 4 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Note NOTE (1) (A) (2) (B) NT-00072 (A) Front (B) Rear (1) Front crossmember (2) Rear differential 8. 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. • TIE-DOWN LOCATION (1) (1) (1) NT-00073 (1) Hook for tie-down NT-4 Vehicle-id: SIE-id:Sa03676a15:A:NOTE ∼ G2360GE.book 5 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Note NOTE • 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. • VEHICLE SINKING VOLUME AT TIE-DOWN CONDITION Measure the distance between the highest tire point and highest arch point before and after tiedown. Difference of measurement value (sinking volume) shall be within 50 mm (1.97 in) and make sure to fix the vehicle securely. L L NT-00076 NT-00117 • CHAIN PULLING RANGE AT TIE-DOWN CONDITION (2) (2) (2) (2) (2) (2) (3) (3) (3) (3) : (1) NT-00122 (1) Chain pulling range at tie-down condition (2) 20° (3) 45° NT-5 G2360GE.book 6 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Note NOTE 9. 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. • Do not tow other vehicles with a front tie-down hook. • Make sure the towing vehicle is heavier than the towed vehicle. • FRONT Remove the fog light cover (except for OUTBACK model) and hook cover, and then install the hook. (A) (B) (A) (B) (C) (C) (C) NT-00087 (A) Fog light cover (except for OUTBACK model) (B) Hook cover • REAR NT-00078 NT-6 Vehicle-id: SIE-id:Sa03676a15:A:NOTE ∼ (C) Hook G2360GE.book 7 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Note NOTE • NOTES Towing Lifting up four wheels (On a trailer) Notes Towing the vehicle after lifting up all four wheels is a basic rule for AWD model. MT ❍ AT ❍ • Check if both front and rear wheels are rotated normally. • AT model driving conditions: Allow driving speed less than 30 km/h (19 MPH). Allow driving distance less than 30 km (19 miles). ❍ ▲ Prohibited for full-time AWD model. ✕ ✕ • Prohibited, due to damage on bumper, front grille, etc. • Do not raise the vehicle with bumper. ✕ ✕ NT-00023 Rope NT-00024 Raising the front wheels NT-00025 Lifting up the front wheels NT-00026 Marked ❍: OK, Marked ✕: Prohibited, Marked ▲: Conditionally OK. NT-7 G2360GE.book 8 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Note NOTE CAUTION: • Check ATF, gear oil and rear differential oil before driving. • Place the shift lever in “N” position during towing. • Do not lift up the rear wheels to avoid unsteady rotation. • Turn the ignition key to “ACC”, then check the steering wheel moves freely. • Release the parking brake to avoid tire dragging. • Since the power steering does not work, be careful for the heavy steering effort (When engine is stopped) • Since the servo brake does not work, be careful that the brake is not applied effectively. (When engine is stopped) • In case of the malfunction of internal transmission or drive system, lift up four wheels (on a trailer) for towing. 10.FRONT HOOD STAY INSTALLATION • AT THE CHECK AND GENERAL MAINTENANCE NT-00079 • WHEN WIDER HOOD OPENING IS NECESSARY Set the stay into the hole of lower hood as shown in the figure below. NT-00080 NT-8 Vehicle-id: SIE-id:Sa03676a15:A:NOTE ∼ G2360GE.book 9 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Note NOTE 11.GENERAL SCAN TOOL Using general scan tools will greatly improve the efficiency of repairing engine electronic controls. Subaru Select Monitor can be used to diagnose the engine, ABS, AT and other parts. 12.AWD CIRCUIT MEASURES 1) Full-time AWD MT model Since viscous coupling (limited slip differential) is used in the center differential, cut-off of AWD circuit cannot be carried out. 2) Full-time AWD 5AT model Since VTD type is used in the center differential, cut-off of AWD circuit cannot be carried out. 3) Full-time AWD 4AT model Insert a spare fuse into FWD fuse holder in the fuse box located in the left side of engine room to select the FWD. Since electronically controlled MT-P hydraulic multi-plate clutch is adapted for center differential, select FWD. When maintenance is performed with jack-up or on the free roller, check the illumination of AWD warning light in the combination meter. CAUTION: Fix the vehicle using a pulling metal (chain or wire) to the front and rear towing hooks or tiedown hook to prevent the lateral runout of front wheels and springing out of vehicle. (A) NT-00033 (A) Free roller (3) Set the speedometer tester. (4) Conduct the speedometer test work. CAUTION: Do not operate the clutch quickly and do not accelerate or decelerate suddenly during work. 2) Rear wheel jack-up system (1) Set the vehicle on speedometer tester. CAUTION: Fix the vehicle using a pulling metal (chain or wire) to the front and rear towing hooks or tiedown hook to prevent the lateral runout of front wheels and springing out of vehicle. (2) Jack up the rear wheels and set the rigid racks to the specified locations of side sill. (A) (B) (2) Let the vehicle ride on the tester and free roller gently. NT-00081 (A) NT-00034 (A) FWD fuse holder (B) AWD warning light (A) Rigid rack (3) Conduct the speedometer test work. 13.SPEEDOMETER TEST 1) Rear wheel free roller system (1) Set the free roller on the floor of rear wheel side securely according to the wheel base and rear tread of the vehicle. CAUTION: Do not operate the clutch quickly and do not accelerate or decelerate suddenly during work. NT-9 G2360GE.book 10 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Note NOTE 14.BRAKE TEST 1) Full-time AWD MT model (1) Perform this test after driving the vehicle 2 to 3 km (1.24 to 1.86 miles) on road in order to stabilize the viscous torque of viscous coupling. (2) Keep the front or rear wheels on the ground for this test. NOTE: Effect of the viscous torque on braking force will be added approx. 25 kg compared with FWD model. (2) When the brake dragging force is large. • Check the dragging of brake pad or brake shoe. Specifications: Rear wheel total Difference between right and left wheels Grand total Braking force More than 10% of load on front or rear wheels Less than 8% of load on front or rear wheels More than 50% of vehicle weight at the time of test • When measurement is difficult to carry out because both of front wheels are locked, check if break force measurement in this condition conforms to grand total. 15.ON THE CAR WHEEL BALANCING (C) (A) (B) NT-00029 (A) Brake tester (B) Position for measuring front wheel (C) Position for measuring rear wheel (3) When the brake dragging force is large. • Check the dragging of brake pad or brake shoe. • Since it may be affected by the viscosity of viscous couping, jack up either of the front or rear two wheels to check the each wheel rotation condition with the viscous coupling affection removed. 2) Full-time AWD AT model (1) Keep the front or rear wheels on the ground during measurement. CAUTION: • Carry out this procedures after measuring the balance of each single tire. • Set the vehicle so that the front and rear wheels are same height. • Release the parking brake during measurement. • Rotate each wheel by hands, and make sure it rotates without dragging. • Do not operate the clutch quickly and do not accelerate or decelerate suddenly during work. • When an error is indicated during engine drive, do not use the motor drive together. 1) Set the rigid rack to the specified locations of side sill, jack up the front or rear two wheels of nonmeasuring side and set the pickup stands to two wheels of measuring side. (A) (C) (A) (B) (B) NT-00031 NT-00029 (A) Brake tester (B) Position for measuring front wheel (C) Position for measuring rear wheel (A) Balancer body (B) Pickup stand 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. NT-10 Vehicle-id: SIE-id:Sa03676a15:A:NOTE ∼ G2360GE.book 1 ページ ２００７年１１月２９日 木曜日 午後１時２８分 IDENTIFICATION ID 1. Page Identification ................................................................................................2 G2360GE.book 2 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Identification IDENTIFICATION 1. Identification A: IDENTIFICATION 1. IDENTIFICATION NUMBER AND LABEL LOCATIONS The V.I.N. (Vehicle Identification Numbers) is used to classify the vehicle. • Positioning of the plate label for identification (2) (1) (4) (5) (6) (3) ID-00072 (1) (2) (3) ID plate (EC, EK, EH and ER model) ADR compliance plate (KA model) Vehicle identification number (VIN) Model number plate (4) Tire inflation pressure label (Driver’s side) (KA model) Tire inflation pressure label (Driver’s side) (Except for KA model) ID-2 (5) (6) Saudi Arabia plate (Saudi Arabia model) Built date plate (KA model) Vehicle identification number (VIN) (EK and KA model) G2360GE.book 3 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Identification IDENTIFICATION • Rear differential T-type • Engine (1) (1) (2) ID-00059 ID-00056 (1) Engine serial number (Punch mark) (2) Engine type (Crankcase upper side) (1) Type (white paint) VA1-type • Automatic transmission (1) (2) (1) DI-00396 ID-00067 (1) Type (label) (1) AT type label (2) Transmission serial number label VA2-type • Manual transmission (1) (1) (2) DI-00397 ID-00068 (1) Type (label) (1) Transmission serial number (2) MT type label ID-3 G2360GE.book 4 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Identification IDENTIFICATION • Model number plate ID-00111 2. MEANING OF V.I.N. The meaning of the V.I.N. is as follows: • EC, EK, KA AND K4 model ]JF1BL5LJ35G002001[ The starting and ending brackets ( ] [ ) are stop marks. Digits 1—3 Code JF1 4 5 B L 6 5 7 L 8 J 9 3 10 11 12 — 17 5 G 002001 Meaning Details Manufacturer body area JF1: Passenger car, FHI made (Except for KA OUTBACK model) JF2: Passenger car, FHI made (KA OUTBACK) Car line LEGACY Body type L: Sedan P: Wagon Displacement 5: 2.0 L AWD 9: 2.5 L AWD E: 3.0 L AWD Steering position L: LHD (Left-hand drive model) K: RHD (Right-hand drive model) Engine & transmission D: DOHC MPI Turbo 5MT Single range J: SOHC MPI 5MT Single range K: SOHC MPI 5MT Dual range L: SOHC MPI 4AT-SS N: DOHC MPI 6MT Single range U: DOHC MPI 5AT-SS V: DOHC MPI Turbo 5AT-SS Drive type 3: Full-time AWD Single range 4: Full-time AWD Dual range 5: AWD AT A: AWD AT OUTBACK B: Full-time AWD Dual range OUTBAKCK Model year 5: 2005MY Factory location G: FHI (Gunma) Serial number — ID-4 G2360GE.book 5 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Identification IDENTIFICATION • KS model ]JF1BL54MX5G002001[ The starting and ending brackets ( ] [ ) are stop marks. Digits 1—3 4 5 Code JF1 B L 6 5 7 4 8 M 9 10 11 X 5 G 12 — 17 002001 Meaning Details Manufacturer body area JF1: Passenger car, FHI made Car line LEGACY Body type L: Sedan P: Wagon Displacement 5: 2.0 L AWD 9: 2.5 L AWD 0: 3.0 L AWD Grade 4: 2.0 i 6: 2.5 i 8: OUTBACK 2.5 i 9: 3.0 R 0: OUTBACK 3.0 R Restraint M: Manual belts, Dual airbag N: Manual belts, Dual airbag, Side airbag Check digit 0—9&X Model year 5: 2005MY Transmission type G: Full-time AWD 5MT Single range H: Full-time AWD 4AT J: Full-time AWD 5MT Dual range M: Full-time AWD 5AT Serial number — 3. MODEL NUMBER PLATE The model number plate indicates the type, V.I.N. , applied model, option code, trim code, engine type, transmission type and the exterior color code. This information is helpful when placing orders for parts. • BL5BL4J Digits Code Meaning Details 1 2 B L Series Body type 3 5 4 5 B L Engine displacement Drive system Suspension system Model year Destination 6 4 Grade 7 J Transmission, fuel feed system LEGACY L: Sedan P: Wagon 5: 2.0 L AWD 9: 2.5 L AWD E: 3.0 L AWD B: 2005MY K: Right-hand drive model market L: Left-hand drive model market 4: 2.0 i B: 2.0 GT H: 2.5 i L: 3.0 R (Ivory interior) M: 3.0 R spec. B N: 3.0 R (Black interior) S: OUTBACK 2.5 i U: OUTBACK 3.0 R D: DOHC MPI Turbo 5MT J: SOHC MPI 5MT K: SOHC MPI Dual range 5MT L: SOHC MPI 4AT TIP N: DOHC MPI 6MT V: DOHC MPI Turbo 5AT TIP U: DOHC MPI 5AT TIP ID-5 G2360GE.book 6 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Identification IDENTIFICATION The engine and transmission type are as follows: • Engine EJ202NTBHA Digits 1 and 2 Code EJ Meaning Engine type Details 3 and 4 20 Displacement 5 2 Fuel feed system 6 N Detailed specifications 7 T Transmission 8 — 10 BHA Detailed specifications EJ: 4 cylinders EZ: 6 cylinders 20: 2.0 L 25: 2.5 L 30: 3.0 L 2: D-MPI-NA (SOHC) 3: MPI-NA (SOHC) D: MPI-NA (DOHC, H6) X: MPI Twin scroll single turbo Y: MPI High power twin scroll turbo Used when ordering parts. For details, refer to the parts catalog. G: 6MT K: 5AT with ATF cooler (with warmer function) L: 5AT without ATF cooler (with warmer function) P: 4AT without ATF cooler (with warmer function) S: 5MT (Flexible type flywheel) T: 5MT (Dual mass type flywheel) V: 4AT with ATF cooler (with warmer function) Used when ordering parts. For details, refer to the parts catalog. • Transmission TY757VRBAB 1 2 Digits T Y Code Meaning Transmission Transmission type 3 and 4 75 Classification 5 6 7 V Series Transmission specifications 7 — 10 RBAB Detailed specifications Details T: Transmission Y: Full-time AWD MT center differential V, G: Full-time AWD AT center differential Z: Full-time AWD AT MP-T 75: 5MT 85: 6MT 1B: 4AT 5C: 5AT LEGACY C: Full-time AWD VTD type 5AT L: Full-time AWD MP-T type 4AT M: Full-time AWD VTD type 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 X: Full-time AWD 5MT Dual range with viscous coupling center differential Used when ordering parts. For details, refer to the parts catalog. ID-6 G2360GE.book 7 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Identification IDENTIFICATION • Rear differential XJ Code XJ T2 VB EZ XU CF XT JE FM Reduction gear ratio 4.111 4.111 3.700 3.900 3.272 4.444 3.083 4.111 3.545 LSD None None None Viscous Viscous Viscous Viscous Viscous Viscous • Option ECXV Digits 1—2 EC Code Meaning Destination 3 X Option equipment Details EC: for Europe (LHD model) EK: for Europe (RHD model) KS: For GCC countries K4: For Middle and South America KA: For Australia ER: For Hong Kong EH: For China A: Vehicle dynamics control, Cruise control, Winter pack E: Vehicle dynamics control, Cruise control, Power pack F: Cruise control, Winter pack I: Cruise control, Winter pack, Power pack, 17 inch tire K: Cruise control, 17 inch tire S: Cruise control, Winter pack, Power pack U: Cruise control V: 17 inch tire X: Nothing Y: Vehicle dynamics control, Cruise control, Power pack, Winter pack, 17 inch tire Z: Vehicle dynamics control, Cruise control, Power pack, Winter pack 2: Cruise control, Power pack, 17 inch tire 3: Cruise control, Power pack 4: Cruise control, McIntosh audio, Power pack 5: Vehicle dynamics control, Cruise control, McIntosh audio, Power pack ID-7 G2360GE.book 8 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Identification IDENTIFICATION Digits 4 Code V Meaning Option equipment Details A: A/C B: A/C, Side airbag, Self levelizer C: A/C, Side airbag, Curtain airbag F: A/C, Side airbag, Sunroof J: A/C, Sunroof K: A/C, Side airbag, Curtain airbag, Sunroof, Navigation system L: A/C, Side airbag, Curtain airbag, Self levelizer N: A/C, Side airbag, Curtain airbag, Navigation system, Self levelizer, Sunroof O: A/C, Side airbag, Navigation system, Curtain airbag Q: A/C, Side airbag, Curtain airbag, Sunroof, Grade up pack U: A/C, Side airbag, Curtain airbag, Sunroof, Self levelizer, Grade up pack V: Side airbag W: A/C, Side airbag, Curtain airbag, Sunroof X: Nothing Y: A/C, Side airbag, Curtain airbag, Sunroof, Self levelizer Z: A/C, Side airbag ID-8 G2360GE.book 1 ページ ２００７年１１月２９日 木曜日 午後１時２８分 RECOMMENDED MATERIALS RM 1. Page Recommended Materials ............................................................................2 G2360GE.book 2 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Recommended Materials RECOMMENDED MATERIALS 1. Recommended Materials A: RECOMMENDED MATERIALS 1. GENERAL To insure the best performance, always use the specified oil, gasoline, adhesive, sealant, etc. or a substitute of equivalent quality. 2. FUEL 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 operation of the engine and fuel injection system. Use the specified gasoline to correct performance. • Unleaded gasoline Use unleaded gasoline and not leaded gasoline for the vehicle with catalytic converter installed to reduce air pollution. Using leaded gasoline will damage the catalytic converter. Model 2.0 L, 2.5 L TURBO 3.0 L Use kind Unleaded gasoline Unleaded gasoline Unleaded gasoline RON More than 95 RON More than 90 RON* More than 98 RON More than 95 RON *: KA and KS model RM-2 Vehicle-id: SIE-id:Sa05678g22:A:RECOMMENDED MATERIALS ∼ G2360GE.book 3 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Recommended Materials RECOMMENDED MATERIALS 3. LUBRICANTS Use either the lubricants in the table below or equivalent lubricants. See the table below to choose the correct SAE viscosity. GL-5 — — GL-5 — — GL-5 — — SERVICE S PI SAE 0W-20 E R GY NG EN ACEA standard A1, A2 or A3 Alternative API standard SH L A Engine oil Recommended API Standard or ILSAC Standard SL, SJ Grade “Energy conserving” VI Lubricant CONS E R SERVICE S PI L A RM-00006 E GY NG R VI EN SAE 5W-30 CONS E R RM-00001 GF-3 (the one that the following mark fas adhered) TR OLEUM C ER T I F IE TUTE FOR GASOLINE ENGINES ST I AM ER I CA IN N PE D RM-00002 Manual transmission oil AT front differential gear oil Rear differential gear oil RM-3 G2360GE.book 4 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Recommended Materials RECOMMENDED MATERIALS SAE viscosity No. and applicable temperature Engine oil SOHC model (˚C) –30 –20 –10 0 10 20 30 40 (˚F) –22 –4 14 32 50 68 86 104 10W-30 or 10W-40 5W-30 0W-20 Recommend RM-00007 3.0 L and DOHC turbo model (˚C) –30 –20 –10 0 10 20 30 40 (˚F) –22 –4 14 32 50 68 86 104 10W-30 or 10W-40 5W-30 Recommend RM-00003 RM-4 Vehicle-id: SIE-id:Sa05678g22:A:RECOMMENDED MATERIALS ∼ G2360GE.book 5 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Recommended Materials RECOMMENDED MATERIALS SAE viscosity No. and applicable temperature Manual transmission oil, rear differential gear oil and AT front differential gear oil (˚C) –30 –20 –10 0 10 20 30 40 (˚F) –22 –4 14 32 50 68 86 104 90 85W 80W 75W-90 RM-00045 4. FLUID Use the fluids specified in the table below. Do not mix two different kinds or makes of fluid. CAUTION: Be sure to use the recommended or equivalent ATF for 5AT. Using the ATF other than recommended or equivalent would be a trouble cause. Fluid Automatic transmission fluid Power steering fluid Brake fluid Clutch fluid Recommended Item number Alternative 4AT SUBARU ATF K0410Y0700 IDEMITSU: APOLLOIL ATF HP Castrol: Transmax J 5AT SUBARU ATF K0410Y0700 DEXRON III FMVSS No. 116 DOT3 FMVSS No. 116 DOT3 Remarks If it is impossible to get recommended or alternative ATF, DEXRON III can be used. — IDEMITSU: ATF HP Castrol: Transmax J — — — — — — — — — 5. COOLANT Use genuine coolant to protect the engine. Coolant Coolant Water for dilution Recommended SUBARU coolant Distilled water Item number 000016218 — Alternative None Tap water (Soft water) 6. 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. Air conditioner Refrigerant Compressor oil Recommended HFC134a DENSO OIL 8 Item number — — RM-5 Alternative None None G2360GE.book 6 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Recommended Materials RECOMMENDED MATERIALS 7. GREASE Use the grease and supplementary lubricants shown in the table below. Grease Supplementary lubricants Grease Application point • Oxygen sensor • Bolts, etc. MT main shaft Clutch master cylinder push rod • Gear shift lever • Select lever • Clutch operating cylinder • Clutch pedal • Brake pedal • Clutch bearing • Clutch release lever • Door latch • Door striker Steering gearbox Disc brake (Lock pin, guide pin, piston boot) Between brake pad and shim Brake pad clip Front axle PTJ • Rear axle BJ • Rear axle EBJ Rear axle DOJ Recommended Item number Alternative Spray type lubricant — — NICHIMOLY N-130 SILICONE GREASE G-40M — 004404003 — — KOPR-KOTE 003603001 — SILICONE GREASE G-30M 004404002 — VALIANT GREASE M2 003608001 One-Luber SG NIGLUBE RX-2 K0779GA102 — Molykote AS-880N Molykote M7439 NSG301 K0777YA010 003602001 28395AG020 — — — NTG2218-M 28395AG010 — NKG205 28495AG000 — 8. ADHESIVE Use the adhesives shown in the table below, or equivalent. Adhesive Adhesive Application point Windshield, rear window glass, rear quarter glass, rear gate and body Rearview mirror base Soft vinyl Momentary sealant Recommended Dow Automotive’s Adhesive: Gurit-ESSEX Betaseal 1502 or equivalent Glass primer: Betawipe VP 04604, Betaprime 5001 Paint surface primer: Betaprime 5402 REPAIR KIT IN MR 65029FC000 CEMEDINE 540 — CEMEDINE 3000 — RM-6 Vehicle-id: SIE-id:Sa05678g22:A:RECOMMENDED MATERIALS ∼ Item number Alternative — — — 3M’s EC-776, EC-847 or EC-1022 (Spray type) ARMSTRONG’s Eastman 910 G2360GE.book 7 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Recommended Materials RECOMMENDED MATERIALS 9. SEAL MATERIAL Use the seal material shown in the table below, or equivalent. Seal material Seal material Application point • MT transmission case • Cylinder block • Converter case • DOHC camshaft cap (Turbo model) Transmission oil pan (AT model) Engine oil pan (Except for 3.0 L model) • Rear differential • Engine oil pressure switch • Cylinder head (Nipple) (3.0 L model) • Camshaft bowl-shape plug (3.0 L model) • Rear differential • PCV valve Steering adjusting screw • SOHC camshaft cap • Cam cap (3.0 L model) • Cylinder head plug (3.0 L model) • Rocker cover (3.0 L model) • Oil pan (Pan upper) (3.0 L model) • Block (Pan upper) (3.0 L model) • Back chain cover (Front chain cover, block head, pan upper) (3.0 L model) • Front sealing cover • Rear sealing cover Recommended Item number Alternative THREE BOND 1215 004403007 DOW CORNING’s No. 7038 THREE BOND 1217B K0877YA020 — THREE BOND 1207C 004403012 — THREE BOND 1324 004403042 — THREE BOND 1105 004403010 DOW CORNING’s No. 7038 THREE BOND 1141 004403006 — THREE BOND 1280B K0877YA018 THREE BOND 1217G 3M Butyl Rubber 8626 — — RM-7 G2360GE.book 8 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Recommended Materials RECOMMENDED MATERIALS RM-8 Vehicle-id: SIE-id:Sa05678g22:A:RECOMMENDED MATERIALS ∼ G2360GE.book 1 ページ ２００７年１１月２９日 木曜日 午後１時２８分 PRE-DELIVERY INSPECTION PI 1. Page Pre-delivery Inspection................................................................................2 G2360GE.book 2 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Pre-delivery Inspection PRE-DELIVERY INSPECTION 1. Pre-delivery Inspection A: GENERAL DESCRIPTION The purposes of the pre-delivery inspection (PDI) are as follows. • Remove the additional parts used for ensuring the vehicle quality during transportation and restore the vehicle to its normal state. • Check if the vehicle before delivery is in a normal state. • Check for any damage to the vehicle or parts that may have taken place during transportation or storage. • Check if the vehicle after repair is in a normal state. • Make sure to provide a complete vehicle to the customer. For the above reasons, all SUBARU dealers (dealerships) carry out the PDIs before delivering a vehicle. Refer to this manual unless otherwise specified. B: PRE-DELIVERY INSPECTION (PDI) PROCEDURE STATIC CHECKS JUST AFTER VEHICLE RECEIPT PROCEDURE 1. Appearance check 2. Tire check 3. Fuse installation 4. Air conditioner harness connection 5. Check the doors for lock/unlock and open/close operations. 6. Double lock operation check 7. Check the operation of child safety lock system 8. Check the trunk lid for open/close operations. 9. Check the rear gate for lock/unlock and open/ close operations. 10. Operation check of fuel lid opener lock release lever 11. Accessory check 12. Operation check of front hood lock release system 13. Battery 14. Brake fluid Check point (1) If the vehicle is covered with protective coating, visually check the vehicle body for damage and dents. If the protective coating has been removed, visually check the body paints for damage or stains in detail. (2) Visually check the glass and light lenses for any damage, cracks or excessive gaps to the body sheet metal. (3) Visually check the plated parts for any damage. (1) Check the tires for damage, abnormal conditions, and dents on the wheels. (2) Check the tire air pressure. If the vehicle is about to be delivered to the customer, attach a back-up fuse. If the vehicle is about to be delivered to the customer, connect air conditioner harness. (1) Using the key, check if the trunk lid can be locked or unlocked normally. (2) Open and close all doors to see that there are no abnormal conditions. (3) Operate the power door lock switch to check that the door (rear gate) is locked and unlocked normally. Check the double lock for normal operations. Check that the child safety lock system operates normally. (1) Operate the trunk lock release lever to check that the trunk opens normally. (2) Operate the opener cancel lever of trunk lock to check that it operates normally. (3) Open and close the trunk lid to see that there are no abnormal conditions. (1) Check if the rear gate can be unlocked normally through the emergency hole. (2) Open and close the rear gate to see that there are no abnormal conditions. Operate the fuel lid opener to check that the fuel filler flap lid is unlocked normally. Check that the following accessories are provided. • Owner’s manual • Warranty booklet • Maintenance note • Spare key • Jack • Tool set • Spare tire Operate the front hood lock release lever to check that the front hood is unlocked normally. Check the battery terminals for any abnormal conditions such as rust and trace of battery fluid leaks. Check that the fluid level is normal. PI-2 G2360GE.book 3 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Pre-delivery Inspection PRE-DELIVERY INSPECTION PROCEDURE 15. Engine oil 16. Transmission gear oil 17. AT front differential oil 18. Engine coolant 19. Clutch fluid 20. Window washer fluid 21. Front hood latch check 22. Keyless entry system 23. Seat 24. Seat belt 25. Wheel alignment Check point Check that the oil level is normal. Check that the transmission gear oil level is normal. Check that the AT front differential oil level is normal. Check that the engine coolant level is normal. Check that the clutch fluid level is normal. Check that the window washer fluid level is normal. Check that the hood is closed and latched securely. Check that the keyless entry system operates normally. (1) Check the seat surfaces for stain or dirt. (2) Check the seat installation conditions and functionality. Check the seat belt installation conditions and functionality. Check that the wheel alignments are properly adjusted. CHECKS WITH ENGINE RUNNING PROCEDURE 26. Test mode connector 27. Immobilizer system 28. Starting condition 29. Exhaust system 30. Indicator and warning lights 31. Clock 32. Audio 33. Navigation system 34. Front accessory power supply socket 35. Lighting system 36. Wiper deicer 37. Rear fog light 38. Illumination control 39. Window washer 40. Wiper 41. Power window operation check 42. Sunroof 43. Door mirror Check point Test mode connectors (1) Check that the engine starts with all keys that are equipped on vehicle. (2) 60 seconds after turning ignition switch from ON to ACC or OFF, or immediately after removing key, check that the immobilizer indicator light blinking. Start the engine and check that the engine starts smoothly. Check that the exhaust noise is normal and no leaks are found. Check that all the indicator and warning lights are gone out. Check that the clock operates normally. Check the radio, CD and MD player for normal operation. (1) Check all display functions for normal operation. (2) Check the map disc (DVD) are provided on vehicle. (3) Check that the navigation system operates normally. Check that the front accessory power socket operates normally. Check that the lighting system operates normally. Check that the wiper deicer operates normally. Check that the rear fog light operates normally. Check that the illumination control operates normally. Check that the window washer system operates normally. Check that the wiper system operates normally. Check the power window for normal operations. Check that the sunroof operates normally. Check that the remote control mirror operates normally. DYNAMIC TEST WITH VEHICLE RUNNING PROCEDURE 44. Brake test 45. Parking brake 46. AT shift control 47. Heater & ventilation 48. Air conditioner 49. Cruise control Check point Check the foot brake for normal operations. Check the parking brake for normal operations. Check that the AT shift patterns are correct. Check that the heater & ventilation system operates normally. Check that the air conditioner operates normally. Check that the cruise control system operates normally. PI-3 G2360GE.book 4 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Pre-delivery Inspection PRE-DELIVERY INSPECTION CHECKS AFTER DYNAMIC TEST PROCEDURE 50. ATF level 51. Power steering fluid level 52. Fluid leak check 53. Water leak test 54. Appearance check 2 Check point Check that the ATF level is correct. Check that the power steering fluid level is normal. Check for fluid/oil leaks. Spray the vehicle with water and check for water leaks. (1) Remove the protective coating (if any). (2) Check the body paints for damage and stain. (3) Check the plated parts for damage and rust. 1. APPEARANCE CHECK 4. CONNECTION OF AIR CONDITIONER HARNESS • If the vehicle is covered with protective coating, visually check the vehicle body for damage and dents. • When the protective coating is removed, visually check the body paints for damage or stains in detail and repair as necessary. • Visually check the windshield glass, door glasses and light lenses for any damage, cracks or excessive gaps to the body sheet metal and repair as necessary. • Visually check the plated parts, such as the grilles and door knobs, for damage or loss of gloss and replace the parts as necessary. A vehicle just delivered has its air conditioner harness disconnected to protect the air conditioner compressor. Connect the harness as shown in the figure. 2. TIRE CHECK • Check the tires for damage, abnormal conditions, and dents on the wheels. • Check the tire size, spare tire and tire air pressure described on the tire air pressure label (driver’s side). PI-00159 5. CHECK DOORS FOR LOCK/UNLOCK AND OPEN/CLOSE OPERATIONS 1) Using the key, lock and unlock the door several times to check for normal operation. Open and close the door several times for smooth movement. 3. FUSE INSTALLATION Fuses for the back-up circuit have been removed to prevent battery discharge. If the vehicle is about to be delivered to the customer, attach a 20 A fuse (A) as shown in the figure. (A) (B) PI-00191 (A) (A) Unlock (B) Lock PI-00158 PI-4 G2360GE.book 5 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Pre-delivery Inspection PRE-DELIVERY INSPECTION 6. CHECK DOUBLE LOCK OPERATION 2) Completely close the driver’s door, and then check the smooth movement with operating door lock knob from lock to unlock several times. Set the door lock knob (A) to lock position. Then pull the inner remote (B) to ensure that doors will not open. For other doors, place the door lock knob (A) to lock position and then pull the inner remote (B) to ensure that doors will not open. 1) Fully open all the windows. 2) Remove the key. 3) Lock all the doors using the door key cylinder or keyless transmitter. 4) Verify that all the doors including rear gate are not unlocked when pressing power door lock switch to unlock side. 5) Verify that the door is not opened when operating door lock knob to unlock position and pulling inner remote. Perform the same check for other doors. 6) Check that all the doors are unlocked when door is unlocked using door key cylinder or keyless transmitter, or ignition switch is turned to ON. (A) (B) 7. CHECK OPERATION OF CHILD SAFETY LOCK SYSTEM PI-00192 1) Set the child safety lock on both rear doors to the lock position. 2) Close the rear doors completely. 3) Check that the lock levers of the rear doors are in the unlock position. Then, pull inner remote of rear doors to ensure that doors will not open. (A) Door lock knob (B) Inner remote 3) Close all the doors, and then press the lock on power door lock switch at driver’s side. Check that all doors including rear gate are locked. (A) (B) PI-00164 PI-00193 (A) Lock (B) Unlock 4) Press the driver’s side power door lock switch to unlock side. Check that all doors including rear gate are unlocked. 4) Pull the outer handles to ensure that doors will open. PI-00194 5) Insert the key to ignition switch, and open the driver’s side door. Press lock on power door lock. Check that the door is not locked. PI-5 G2360GE.book 6 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Pre-delivery Inspection PRE-DELIVERY INSPECTION 8. CHECK TRUNK LID FOR OPEN/CLOSE OPERATIONS 10.OPERATION CHECK OF FUEL LID OPENER LOCK RELEASE LEVER 1) Operate the trunk lock release lever to check that the trunk opens normally. 2) Open and close the trunk lid several times for smooth movement. 3) Put the lever (A) in the cancel lever of trunk lid to cancel position, and close the trunk lid. Check that the trunk lid will not open even when the trunk lock release lever is operated. Also, check that the trunk lid will open with keyless transmitter, then put the lever back. (EK model) Operate the fuel lid opener and verify that the fuel filler flap lid is unlocked normally. Check that the filler cap is securely closed. 11.ACCESSORY CHECK Check that the following accessories are provided. • Owner’s manual • Warranty booklet • Maintenance note • Spare key • Jack • Tool set • Spare tire (A) (B) (A) PI-00200 9. CHECK REAR GATE FOR LOCK/UNLOCK AND OPEN/CLOSE OPERATIONS PI-00168 1) Open and close the rear gate several times for smooth movement. 2) Operate the rear gate lever to check that the rear gate is locked and unlocked normally. (1) Remove the cover inside the rear gate. (B) (A) PI-00169 (A) Jack (B) Jack handle PI-00165 (2) Operate the lever to check that the rear gate is locked and unlocked normally. PI-00166 PI-6 G2360GE.book 7 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Pre-delivery Inspection PRE-DELIVERY INSPECTION 12.OPERATION CHECK OF FRONT HOOD LOCK RELEASE SYSTEM 13.BATTERY Check the battery terminals to make sure that there are no rust or corrosions due to fluid leaks. Check that the battery caps are securely tightened. Operate the front hood lock release lever (A) to check that the front hood is unlocked normally. (A) (B) (A) (C) PI-00012 PI-00195 Operate the lever (B) and check that the front hood is opened normally. Support the front hood with hood stay. (A) Cap (B) Upper level (C) Lower level 14.BRAKE FLUID Check that the brake fluid level is normal. If the amount is insufficient, carry out a brake line test to identify brake fluid leaks and check the brake operation. After that, refill the brake fluid tank with the specified type of fluid. (A) (B) PI-00172 (B) (A) MAX. level (B) MIN. level PI-00202 PI-7 G2360GE.book 8 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Pre-delivery Inspection PRE-DELIVERY INSPECTION 15.ENGINE OIL 16.TRANSMISSION GEAR OIL Check the engine oil amount. If the amount of oil is insufficient, check that no leaks are found. Then, add the necessary amount of the specified engine oil. • Except for 3.0 L model Check that the transmission gear oil level is normal. If the amount of fluid is insufficient, check that no leaks are found. Then, add the necessary amount of the specified transmission gear oil. • 5M model (B) (A) (A) (C) (E) (B) (C) (D) LU-00213 (A) (B) (C) (D) (E) PM-00030 Oil level gauge Engine oil filler cap Upper level Lower level Approx. 1.0 2 (1.1 US qt, 0.9 Imp qt) (A) Oil level gauge (B) Upper level (C) Lower level • 6MT model • 3.0 L model (A) (B) (A) F (A) (C) L (B) (D) (C) MT-00449 (A) Oil level gauge (B) Upper level (C) Lower level LU-00111 (A) (B) (C) (D) Oil level gauge Engine oil filler cap Upper level Lower level PI-8 G2360GE.book 9 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Pre-delivery Inspection PRE-DELIVERY INSPECTION 17.AT FRONT DIFFERENTIAL OIL 19.CLUTCH FLUID Check that the AT front differential oil level is normal. If the amount of oil is insufficient, check that no leaks are found. Then, add the necessary amount of the specified AT front differential oil. • 4AT model Check that the clutch fluid level is normal. If the amount of fluid is insufficient, check that no leaks are found. Then, add the necessary amount of specified fluid. (A) (B) (A) (A) (C) (C) (B) PI-00173 PI-00183 (A) Reservoir tank (B) MIN. level (C) MAX. level (A) Oil level gauge (B) Upper level (C) Lower level 20.WINDOW WASHER FLUID • 5AT model (A) Check that the window washer fluid level is normal. If the amount is insufficient, check that no leaks are found. Then, add the necessary amount of washer fluid. L F (A) 21.FRONT HOOD LATCH CHECK (B) (C) Retract the hood stay and close the front hood. Check that the front hood is securely latched. 22.KEYLESS ENTRY SYSTEM NOTE: The following inspections show the initial settings. When the settings are different from the initial settings, use Subaru Select Monitor to check the details of each setting for inspections. 1) Fully open all the door windows. 2) Remove the key from the ignition switch and close all the doors including rear gate. PI-00184 (A) Oil level gauge (B) Upper level (C) Lower level 18.ENGINE COOLANT Check that the engine coolant level on the reservoir tank is normal. If the amount of engine coolant is insufficient, check that no leaks are found. Then, add the necessary amount of coolant with the specified concentration. PI-9 G2360GE.book 10 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Pre-delivery Inspection PRE-DELIVERY INSPECTION 3) Press the trunk open button (except for EK model) or “UNLOCK” button (EK model) for more than one second. Check if the trunk is unlocked and the hazard light flashes twice. 6) Press the “UNLOCK” button momentarily on the keyless transmitter. Check that all the doors are unlocked, hazard light blinks twice and room light illuminates for 15 seconds. Also, when pressing the “UNLOCK” button of keyless transmitter momentarily driver’s door is unlocked (except for EK model with setting of select unlock). Then, check that all the doors including rear gate are unlocked when pressing the “UNLOCK” button momentarily again within 5 seconds. PI-00174 PI-00176 PI-00196 4) Press the “LOCK” button on the keyless transmitter with the trunk lock opened. Check if the all doors are locked, hazard light blinks five times and warning shows trunk open. 5) Press the “LOCK” button momentarily on the keyless transmitter. Check that all the doors are locked and room light goes off. PI-00196 7) Close all the doors including rear gate and press the “LOCK” button on the keyless transmitter. Press the “OPEN” button on the keyless transmitter and wait for 25 seconds. Check if all the doors including rear gate are locked. (Except for EK model) 23.SEAT PI-00175 1) Check the seat surfaces for stains or dirt. 2) Check that each seat provides full functionality in sliding and reclining. Check all available functions of the rear seat such as a trunk-through center armrest. 24.SEAT BELT 1) Check installation condition of seat belt. 2) Pull out the seat belt and then release it. Check that the belt retracts smoothly. 25.WHEEL ALIGNMENT Check the wheel alignment. PI-00108 PI-10 G2360GE.book 11 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Pre-delivery Inspection PRE-DELIVERY INSPECTION 26.TEST MODE CONNECTOR 28.STARTING CONDITION Turn the ignition switch to ON and check that the malfunction indicator light starts blinking. If the light blinks, return the ignition key to LOCK. Pull out the test mode connector from the back of glove box lower cover, and disconnect the test mode connector. Then, turn the ignition key to ON again. If the malfunction indicator light blinks at that time in spite of the disconnected test mode connector, carry out an engine diagnosis. Start the engine and check that the engine starts smoothly. If the battery voltage is low, recharge or replace the battery. If any noises are observed, immediately stop the engine and check and repair the abnormal components. 29.EXHAUST SYSTEM Listen to the exhaust sound to see if no noises are observed. Check the exhaust leaks. 30.INDICATOR AND WARNING LIGHTS Check that all the indicator and warning lights are off. 31.CLOCK (A) Check the clock for normal operations and enough accuracy. 32.AUDIO Check the radio for full functionality and normal noise level. Also check the CD, MD unit operations. PI-00201 (A) Test mode connector (green) 33.NAVIGATION SYSTEM NOTE: If it is difficult to pull out the test mode connector, remove the glove box lower cover, and disconnect the test mode connector. 1) Check all display function for normal operation. (For operating procedure, refer to operating manuals.) 2) Check the map disc (DVD) are provided on vehicle. 3) Check that the navigation systems operate normally. 34.FRONT ACCESSORY POWER SUPPLY SOCKET 1) Check operation for the front accessory power socket. 2) Check operation of the accessory power socket in console box. (B) (A) PI-00197 35.LIGHTING SYSTEM (A) Test mode connector (green) (B) Glove box lower cover 1) Check the headlight operations. 2) Check the stop light operation. 3) Check other lights for normal operations. 27.IMMOBILIZER SYSTEM 1) Check that the engine starts with all keys that are equipped on vehicle. 2) 60 seconds after turning the ignition switch from ON to ACC or OFF, or immediately after removing the key, check that the immobilizer indicator light blinking. 36.WIPER DEICER NOTE: If malfunctions occur, refer to “IMMOBILIZER (DIAGNOSIS)”. 38.ILLUMINATION CONTROL Check that the wiper deicer operates normally. 37.REAR FOG LIGHT Check that the rear fog light operates normally. Check that the illumination control operates normally. PI-11 G2360GE.book 12 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Pre-delivery Inspection PRE-DELIVERY INSPECTION 39.WINDOW WASHER 45.PARKING BRAKE Check that the window washer system injects washer fluid to the specified area of the windshield shown in the figure. Check the parking brake for normal operations. When applying the parking brake with force of 200 N (20.4 kgf, 45.0 lbf), check that the lever stroke of parking brake lever is 5 to 6 notches. Front injection position: A: 250 mm (9.84 in) B: 435 mm (17.1 in) A 46.AT SHIFT CONTROL 1) Turn the ignition switch to ON. 2) While brake pedal is not depressed, check if the select lever does not move from “P” range. 3) While brake pedal is depressed, check if the select lever moves from “P” range. 4) Set the select lever to other than “P” range. 5) When the ignition switch is turned OFF, check if the ignition key switch cannot be removed. 6) Set the AT select lever to each gear position and check the shifting while driving the vehicle. A B (1) PI-00185 (1) Nozzle P Rear injection position: Wagon model A: 70 mm (2.8 in) B: 70° R N D PI-00199 • 4AT model A Selector Position D SPORT shift B Selector Position 40.WIPER Check the front and rear wipers for normal operations. 41.POWER WINDOW OPERATION CHECK D SPORT shift 1st OK OK 2nd OK OK Gear Position 3rd 4th OK OK OK OK 5th OK OK 47.HEATER & VENTILATION Operate the power window switches one by one to check that each of the power windows goes up and down without noises. 42.SUNROOF Operate the heater and ventilation system to check for normal airflow outlet control, air inlet control, airflow capacity and heating performance. 48.AIR CONDITIONER Check the sunroof for normal operations. 43.DOOR MIRROR Check the remote control mirror for normal operations. Check the foot brake for normal operations. 4th OK OK • 5AT model PI-00104 44.BRAKE TEST Gear Position 2nd 3rd OK OK OK OK 1st OK OK Operate the air conditioner. Check that the A/C compressor operates normally and enough cooling is provided. 49.CRUISE CONTROL Operate the cruise control system. Check that the system is activated and deactivated correctly. PI-12 G2360GE.book 13 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Pre-delivery Inspection PRE-DELIVERY INSPECTION 50.ATF LEVEL 51.POWER STEERING FLUID LEVEL Set the selector lever “P” range after selecting all positions (P, R, N, D). Measure the ATF level after the engine idles for 1 to 2 minutes. If the amount is insufficient, check that no leaks are found. Then add the necessary amount of the specified ATF. • 4AT model Check that the power steering fluid level is normal. If the amount is insufficient, check that no leaks are found. Then add the necessary amount of the specified power steering fluid. (C) (E) COLD L F (D) L F HOT (A) (C) (D) PI-00189 (A) Level gauge (B) ATF level range [70 — 80°C (158 — 176°F)] at “HOT” (C) Upper level (D) Lower level (E) ATF level range [20 — 30°C (68 — 86°F)] at “COLD” • 5AT model (A) (C) L F HOT (A) (B) COLD L F (D) (E) HOT MAX COLD MAX HOT MIN COLD MIN (B) (C) (D) PI-00190 (A) Level gauge (B) ATF level range [70 — 80°C (158 — 176°F)] at “HOT” (C) Upper level (D) Lower level (E) ATF level range [20 — 30°C (68 — 86°F)] at “COLD” PS-00463 52.FLUID LEAK CHECK Check entire areas of the vehicle for any trace of coolant/oil/fluid leaks. 53.WATER LEAK TEST Spray the vehicle with water using a hose and check that no water enters the passenger compartment. • Before performing the water leakage test, remove anything that may obstruct the operation or which must be kept dry. • Close all the windows and doors securely. Close the hood and trunk lid before starting the test. • Spray the vehicle with water using a hose. The rate of water spray must be approx. 20 to 25 2 (5.3 to 6.6 US gal, 4.4 to 5.5 Imp gal) per minute. When spraying water on areas adjacent to the floor and wheel house, increase the pressure. When spraying water on areas other than the floor and wheel house, decrease the pressure. But the force of water must be made strong occasionally by pressing the end of the hose. NOTE: Be sure to keep the hose at least 10 cm (3.9 in) from vehicle. Check the following areas. • Front window and body framework mating portion • Door mating portions • Glass mating portions • Rear quarter window mating portions • Rear window and body framework mating portion • Around roof drips If any dampness in the compartments is discovered after the water has been applied, carefully check all the areas that may have possibly contributed to the leak. PI-13 G2360GE.book 14 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Pre-delivery Inspection PRE-DELIVERY INSPECTION 54.APPEARANCE CHECK 2 1) When vehicle body is covered with protective film, peel it off. NOTE: • Use of steam facilitates peeling off the warp guard. • For the vehicle left for a long time or at low temperature, sprinkle some water heated 50 — 60°C (122 — 140°F) over the vehicle to raise its surface temperature before peeling off the wrap guard. Do not use the water heated to over 60°C (140°F). • If the adhesive remains exists on the coated surface, soak a flannel rag, etc. with a small amount of coating wax or solvent such as oil benzene and IPA, put the soaked cloth on the remains lightly, and then wipe them off with a flannel rag, etc. • Keep solvent from touching the resin or rubber parts. Do not use coating wax or solvent while the component surface temperature is high due to hot weather, etc. • If the coated surface is swollen out due to seams or moisture, expose the vehicle to the sunlight for a few hours or heat the seam and swollen portions using a dryer, etc. • Dispose of the peeled wrap guard as burnable industrial garbage. 2) Check the whole vehicle body for flaking paint, damage by transportation, corrosion, dirt, cracks or blisters. 6) Peel the protective tape, vinyl wrapping and identification seal attached to the following places. • Seat • Door trim • Floor carpet • Side sill • Front hood lock release lever • Edge rear • Rear wiper • Sedan rear combination light (Trunk lid opening portion) • Roof rail • Door mirror • High-mounted stop light (Sedan model) NOTE: • It is better to determine an inspection pattern in order to avoid missing an area, since the total inspection area is wide. • Do not repair the body paint unless absolutely necessary. Also, if the vehicle is in need of repair to remove scratches or corroded paint, the repair area must be limited to the minimum. Re-painting and spray painting must be avoided as possible. 3) Check each window glass for scratches carefully. Slight damage may be removed by polishing with cerium oxide. (Fill a cup half with cerium oxide, and add warm water to it. Then agitate the content until it turns to wax. Apply this wax to a soft cloth, and polish the glass with it.) 4) Check each portion of the vehicle body and underside components for the formation of rust. If rust is discovered, remove it with sandpaper of #80 to #180 and treat the surface with rust preventive. After this treatment is completed, flush the portion thoroughly, and prepare the surface for repair painting. 5) Check each portion of body and all of the plated parts for deformation or distortion. Also, check each lamp lens for cracks. PI-14 G2360GE.book 1 ページ ２００７年１１月２９日 木曜日 午後１時２８分 PERIODIC MAINTENANCE SERVICES PM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. Page General Description ....................................................................................2 Schedule .....................................................................................................3 Engine Oil....................................................................................................7 Engine Oil Filter...........................................................................................9 Spark Plug.................................................................................................10 V-belt.........................................................................................................11 Timing Belt ................................................................................................14 Fuel Line ...................................................................................................17 Air Cleaner Element ..................................................................................18 Cooling System .........................................................................................20 Engine Coolant..........................................................................................22 Clutch System ...........................................................................................25 Transmission Gear Oil ..............................................................................26 Automatic Transmission Fluid ...................................................................27 Front & Rear Differential Gear Oil .............................................................29 Brake Line .................................................................................................31 Brake Fluid ................................................................................................33 Disc Brake Pad and Disc ..........................................................................35 Parking Brake............................................................................................36 Suspension ...............................................................................................37 Wheel Bearing...........................................................................................39 Axle Boots & Joints ...................................................................................40 Steering System (Power Steering)............................................................41 A/C Filter ...................................................................................................44 G2360GE.book 2 ページ ２００７年１１月２９日 木曜日 午後１時２８分 General Description PERIODIC MAINTENANCE SERVICES 1. General Description A: GENERAL DESCRIPTION Be sure to perform periodic maintenance in order to maintain vehicle performance and find problems before they occur. PM-2 G2360GE.book 3 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Schedule PERIODIC MAINTENANCE SERVICES 2. Schedule A: MAINTENANCE SCHEDULE 1 1. EUROPE AREA For periodic maintenance of less than 120,000 km (75,000 miles) or 96 months, carry out inspection by referring to the following table. For a maintenance period gone beyond these tables, apply them repeatedly as a set of 120,000 km (75,000 miles) or 96 months. Months × 1,000 km × 1,000 miles Engine oil Engine oil filter Spark plugs V-belt Timing belt Fuel line Air cleaner element Cooling system Coolant Clutch system Transmission oil ATF Front & rear differential oil Brake line Brake fluid Disc brake pads & discs Parking brake Suspension Wheel bearing Axle boots & joint Steering system A/C filter 3.0 L Others 3.0 L Others 2.0 L Others MAINTENANCE INTERVAL [Number of months or km (miles), whichever occurs first] 12 24 36 48 60 72 84 96 1.6 5 15 30 45 60 75 90 105 120 Remarks 1 3 9 19 28 38 47 56 66 75 R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R For 3.0 L model, I I I I I I I I replace every 160,000 km (100,000 miles). R Note (1) I I I I I R I R I R I R Note (2) I I I I R R R R I I I I I R I R Note (3) I R I R I R I R I I I I R R R R I I I I I I I I I I I I I I I I (I) I I I I I I I I I I I I Replace every 12 months 12,000 km (7,500 miles) Note (4) Symbols used: R: Replace I: Inspection (I): Recommended service for safe vehicle operation. NOTE: (1) Periodic inspection and replacement of the timing chains on the 3.0 L models is not required. (2) When the vehicle is used in extremely dusty conditions, the air cleaner element should be replaced more often. (3) ATF filter is maintenance free part. ATF filter needs replacement when it is physically damaged or ATF leaked. (4) When the A/C filter is installed. PM-3 G2360GE.book 4 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Schedule PERIODIC MAINTENANCE SERVICES 2. EXCEPT FOR EUROPE AREA For periodic maintenance of less than 50,000 km (30,000 miles) or 48 months, carry out inspections by referring to the following tables. For a maintenance period gone beyond these tables, apply them repeatedly as a set of 50,000 km (30,000 miles) or 48 months. Months × 1,000 km × 1,000 miles Engine oil Engine oil filter MAINTENANCE INTERVAL [Number of months or km (miles), whichever occurs first] 12 24 36 48 5 12.5 25 37.5 50 Remarks 3 7.5 15 22.5 30 R R R R R R R R R R R R R R R R R R Replace every 12 months 12,000 km Note (4) (7,500 miles) 3.0 L Others 3.0 L Others A/C filter For periodic maintenance of less than 100,000 km (60,000 miles) or 48 months, carry out inspections by referring to the following tables. For a maintenance period gone beyond these tables, apply them repeatedly as a set of 100,000 km (60,000 miles) or 48 months. Months × 1,000 km × 1,000 miles Spark plugs Turbo and 3.0 L 2.5 L, 2.0 L nonturbo V-belt Timing belt Fuel line Air cleaner element Cooling system Coolant Clutch system Transmission oil ATF Front & rear differential oil Brake line Brake fluid Disc brake pads & discs Parking brake Suspension Wheel bearing Axle boots & joint Steering system (Power steering) 1.6 1 12 25 15 MAINTENANCE INTERVAL [Number of months or km (miles), whichever occurs first] 24 36 48 50 75 100 Remarks 30 45 60 R R R R R I I I I I I I I I I I I R I R I R R R I R I I I I I I I I I I I I R I R I R I R R R I R I I I (I) I I Symbols used: R: Replace I: Inspection (I): Recommended service for safe vehicle operation. PM-4 For 3.0 L model, replace every 160,000 km (100,000 miles). Note (1) Note (2) Note (3) G2360GE.book 5 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Schedule PERIODIC MAINTENANCE SERVICES NOTE: (1) Periodic inspection and replacement of the timing chains on the 3.0 L models is not required. (2) When the vehicle is used in extremely dusty conditions, the air cleaner element should be replaced more often. (3) ATF filter is maintenance free part. ATF filter needs replacement when it is physically damaged or ATF leaked. (4) When the A/C filter is installed. B: MAINTENANCE SCHEDULE 2 1. EUROPE AREA Item Every Engine oil Repeat rough/muddy road drive Extremely cold weather area Replace more frequently Replace more frequently Engine oil filter Fuel line Repeat short distance drive Salt or other corrosive used or coastal area High humidity or mountain area Replace more frequently Replace more frequently 12 months 15,000 km 9,000 miles Replace more frequently Replace more frequently I Transmission oil Replace more frequently Replace more frequently Replace more frequently ATF Front & rear differential oil Brake line Brake fluid Brake pads Brake linings and drums Parking brake Suspension Axle boots & joints Steering system (Power steering) Repeat towing trailer 12 months 15,000 km 9,000 miles 12 months 15,000 km 9,000 miles 12 months 15,000 km 9,000 miles 12 months 15,000 km 9,000 miles 12 months 15,000 km 9,000 miles 12 months 15,000 km 9,000 miles 12 months 15,000 km 9,000 miles 12 months 15,000 km 9,000 miles I I I I R I I I I I I I I I I I I I I I I I I I I PM-5 I I G2360GE.book 6 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Schedule PERIODIC MAINTENANCE SERVICES 2. EXCEPT FOR EUROPE AREA Item Every Engine oil Repeat rough/muddy road drive Extremely cold weather area Replace more frequently Replace more frequently Engine oil filter Fuel line Repeat short distance drive Salt or other corrosive used or coastal area High humidity or mountain area Replace more frequently Replace more frequently 6 months 12,500 km 7,500 miles Replace more frequently Replace more frequently I Transmission oil Replace more frequently Replace more frequently Replace more frequently ATF Front & rear differential oil Brake line Brake fluid Brake pads Brake linings and drums Parking brake Suspension Axle boots & joints Steering system (Power steering) Repeat towing trailer 6 months 12,500 km 7,500 miles 12 months 25,000 km 15,000 miles 6 months 12,500 km 7,500 miles 6 months 12,500 km 7,500 miles 6 months 12,500 km 7,500 miles 6 months 12,500 km 7,500 miles 6 months 12,500 km 7,500 miles 6 months 12,500 km 7,500 miles I I I I R I I I I I I I I I I I I I I I I I I I I PM-6 I I G2360GE.book 7 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Engine Oil PERIODIC MAINTENANCE SERVICES 3. Engine Oil • 2.0 L non-turbo and 2.5 L model A: REPLACEMENT CAUTION: If the engine oil gets on the under cover, wipe it off with cloth. 1) Open the engine oil filter cap for quick draining of engine oil. • Except for 3.0 L model (A) (B) LU-00218 • 3.0 L model PM-00161 (A) Oil level gauge (B) Oil filler cap LU-02011 • 3.0 L model 3) Tighten the engine oil drain plug after draining engine oil. (B) L F (A) NOTE: Use a new drain plug gasket. (C) Tightening torque: 44 N⋅m (4.5 kgf-m, 32.5 ft-lb) • DOHC turbo model (D) LU-00111 (A) (B) (C) (D) Oil level gauge Oil filler cap Upper level Lower level 2) Drain the engine oil by removing engine oil drain plug. • DOHC turbo model LU-00219 • 2.0 L non-turbo and 2.5 L model LU-00219 LU-00218 PM-7 G2360GE.book 8 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Engine Oil PERIODIC MAINTENANCE SERVICES B: INSPECTION • 3.0 L model 1) Park the vehicle on a level surface. 2) Remove the oil level gauge and wipe it clean. 3) Reinsert the level gauge all the way. Be sure that the level gauge is correctly inserted and in the proper orientation. 4) Remove it again and checking. If the engine oil level is below the “L” line, add oil to bring the level up to the “F” line. • Except for 3.0 L model LU-02011 (B) (A) 4) Fill engine oil through level gauge up to the center between upper level and lower level. Place the vehicle on a level surface when checking oil level. Use engine oil of proper quality and viscosity, selected in accordance with following. (C) (E) (D) Recommended oil: Refer to “RM” section. LU-00213 Engine oil capacity: (A) (B) (C) (D) (E) Except for 3.0 L model Upper level Approx. 4.0 2 (4.2 US qt, 3.5 Imp qt) Lower level Approx. 3.0 2 (3.2 US qt, 2.6 Imp qt) Oil level gauge Oil filler cap Upper level Lower level Approx. 1 2 (1.1 US qt, 0.9 Imp qt) • 3.0 L model 3.0 L model Upper level Approx. 5.5 2 (5.8 US qt, 4.8 Imp qt) Lower level Approx. 4.5 2 (4.8 US qt, 4.0 Imp qt) The proper viscosity oil make the engine ideal temperature, and cranking speed increased by reducing viscaus friction in hot condition. (B) L F (A) CAUTION: When replenishing oil, it does not matter if the oil to be added is a different brand from that in the engine; however, use oil having the API standard and SAE viscosity No. designated by SUBARU. (C) (D) LU-00111 NOTE: If the vehicle is used in areas with very high temperatures or for other heavy duty applications, the following viscosity oils must be used: API standard: SL or SJ SAE Viscosity No.: 30, 40, 10W-50, 20W-40, 20W50. 5) Close the engine oil filler cap. 6) Start the engine and warm it up for a time. 7) After the engine stops, recheck the oil level. (A) (B) (C) (D) Oil level gauge Oil filler cap Upper level Lower level 5) After turning off the engine, wait a few minutes for the oil to drain back into the oil pan before checking the level. 6) Just after driving or while the engine is warm, engine oil level may show in the range between the “F” line and the notch mark. This is caused by thermal expansion of engine oil. 7) To prevent overfilling the engine oil, do not add oil above the “F” line when the engine is cold. PM-8 G2360GE.book 9 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Engine Oil Filter PERIODIC MAINTENANCE SERVICES 4. Engine Oil Filter A: REPLACEMENT CAUTION: If the engine oil gets on the exhaust pipe, wipe it off with cloth. 1) Remove the under cover. 2) Remove the oil filter using ST. ST 18332AA000 OIL FILTER WRENCH (Outer diameter: 68 mm (2.68 in)) ST 18332AA010 OIL FILTER WRENCH (Outer diameter: 65 mm (2.56 in)) • 2.0 L non-turbo and 2.5 L model 5) Tighten more (approx. 1 turn for oil filter 68 mm (2.68 in) in outer diameter, approx. 2/3 — 3/4 turn for oil filter 65 mm (2.56 in) in outer diameter, approx. 3/4 turn for oil filter 80 mm (3.15 in) in outer diameter) after the seal rubber contacts the cylinder block. Do not tighten excessively, or oil may leak. 6) After installing the oil filter, run the engine and make sure that no oil is leaking around seal rubber. NOTE: The filter element and filter case are permanently jointed; therefore, interior cleaning is not necessary. 7) Check the engine oil level. PM-00163 • Turbo model LU-00227 ST 498547000 OIL FILTER WRENCH (Outer diameter: 80 mm (3.15 in)) • 3.0 L model LU-00131 3) Obtain a new oil filter and apply a thin coat of engine oil to the seal rubber. 4) Install the oil filter by turning it by hand, being careful not to damage seal rubber. PM-9 G2360GE.book 10 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Spark Plug PERIODIC MAINTENANCE SERVICES 5. Spark Plug • 3.0 L model A: REPLACEMENT 1. SOHC MODEL (A) 1) Remove the intake duct and intake chamber. 2) Remove the battery. 3) Disconnect the spark plug cord. 4) Remove the spark plug with a spark plug socket. (B) IG-02004 (A) Bracket (B) Connector 5) Remove the spark plug with a spark plug socket. PM-00001 5) Tighten the new spark plug lightly with hand, and then secure with a spark plug socket to the specified torque. Recommended spark plug: 2.5 L EC, EK, K4, EH, ER model NGK: PFR5B-11 Except for 2.5 L EC, EK, K4, EH, ER model CHAMPION: RC10YC4 PM-00112 6) Tighten the new spark plug lightly with hand, and then secure with a spark plug socket to the specified torque. Tightening torque: 21 N⋅m (2.1 kgf-m, 15.2 ft-lb) NOTE: • Be sure to place the gasket between the cylinder head and spark plug. • If the torque wrench is not available, tighten the spark plug until gasket contacts cylinder head; then tighten further 1/4 to 1/2 turns. Recommended spark plug: NGK: ILFR6B Tightening torque: 21 N⋅m (2.1 kgf-m, 15.2 ft-lb) 7) Tighten the ignition coil. 2. DOHC MODEL Tightening torque: 16 N⋅m (1.6 kgf-m, 11.7 ft-lb) 1) Remove the battery and battery carrier. 2) Remove the air cleaner case. 3) Detach the connector from ignition coil. 4) Remove the ignition coil. • Except for 3.0 L model NOTE: • Be sure to place the gasket between the cylinder head and spark plug. • If the torque wrench is not available, tighten the spark plug until gasket contacts cylinder head; then tighten further 1/4 to 1/2 turns. PM-00145 PM-10 G2360GE.book 11 ページ ２００７年１１月２９日 木曜日 午後１時２８分 V-belt PERIODIC MAINTENANCE SERVICES 6. V-belt Belt tension (with belt tension gauge): A: INSPECTION (A) When installing new one: 640 — 785 N (65.3 — 80.0 kgf, 144 — 176 lbf) At inspection: 490 — 640 N (50 — 65 kgf, 110 — 144 lbf) 1. EXCEPT FOR 3.0 L MODEL 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. Belt tension (without belt tension gauge): (B) When installing new one: 620 — 760 N (63 — 77 kgf, 140 — 170 lbf) At inspection: 350 — 450 N (36 — 46 kgf, 79 — 101 lbf) (A) When installing new one: 7 — 9 mm (0.276 — 0.354 in) At inspection: 9 — 11 mm (0.354 — 0.433 in) (A) P/S (B) (B) When installing new one: 7.5 — 8.5 mm (0.295 — 0.335 in) At inspection: 9.0 — 10.0 mm (0.354 — 0.394 in) (C) P/S GEN (A) (B) I/P C/P PM-00272 (A) (B) (C) C/P GEN P/S A/C I/P I/P C/P PM-00154 (A) (B) C/P GEN P/S A/C I/P A/C Front side belt Rear side belt 98 N (10 kgf, 22 lbf) Crank pulley Generator Power steering oil pump pulley A/C compressor pulley Idler pulley PM-11 A/C GEN Front side belt Rear side belt Crank pulley Generator Power steering oil pump pulley A/C compressor pulley Idler pulley G2360GE.book 12 ページ ２００７年１１月２９日 木曜日 午後１時２８分 V-belt PERIODIC MAINTENANCE SERVICES 2. 3.0 L MODEL • Turbo model 1) Replace the belts if crack, fraying or wear is found. 2) Check that the V-belt automatic tensioner indicator (A) is within the range (D). (A) (D) ME-00807 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). (C) (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, 5.8 ft-lb) ME-00475 (A) (B) (C) (D) Indicator Generator Power steering oil pump Service limit (C) (B) B: REPLACEMENT 1. FRONT SIDE BELT (FOR POWER STEERING OIL PUMP AND GENERATOR) NOTE: Wipe off any oil and water on the belt and pulley. 1) Remove the collector cover. (If equipped) 2) Remove the V-belt covers. • Non-turbo model (A) PM-00004 2. REAR SIDE BELT (FOR A/C) NOTE: Wipe off any oil and water on the belt and pulley. 1) Remove the front side belt. 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). PM-00003 PM-12 G2360GE.book 13 ページ ２００７年１１月２９日 木曜日 午後１時２８分 V-belt PERIODIC MAINTENANCE SERVICES Tightening torque: 23 N⋅m (2.3 kgf-m, 17.0 ft-lb) (B) (A) PM-00005 7) Install the front side belt. • Non-turbo model • Turbo model 3. 3.0 L MODEL 1) Fit the tool to the belt tensioner mounting bolt. 2) Turn the tool clockwise, and loosen the V-belt to remove. ME-00473 3) Remove the V-belt cover. 4) Install in the reverse order of removal. (6) (1) (4) (5) (2) (3) (1) (2) (3) (4) (5) (6) ME-00474 Power steering oil pump Belt tension adjuster Crankshaft pulley A/C compressor Belt idler Generator PM-13 G2360GE.book 14 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Timing Belt PERIODIC MAINTENANCE SERVICES 7. Timing Belt ST 499987500 CRANKSHAFT SOCKET A: REPLACEMENT (B) 1. SOHC MODEL 1) Protect the radiator with cardboard and blanket. 2) Remove the V-belt covers. (B) (A) (B) PM-00003 3) Remove the V-belts. 4) Remove the A/C compressor V-belt tensioner. 5) Use the ST to lock the crankshaft, and remove the pulley bolt. ST 499977400 CRANK PULLEY WRENCH (2.0 L MODEL) ST 499977100 CRANK PULLEY WRENCH (2.5 L MODEL) PM-00009 (A) Notch (B) Alignment mark 11) Remove the belt idler. 12) Remove the belt idler (No. 2). ST PM-00007 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) Turn the crankshaft and align the alignment marks on crankshaft, and left and right cam sprockets with notches of belt cover and cylinder block. PM-00010 13) Remove the timing belt. 14) Remove the automatic belt tension adjuster assembly. PM-00011 15) Install in the reverse order of removal. PM-14 G2360GE.book 15 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Timing Belt PERIODIC MAINTENANCE SERVICES 2. DOHC MODEL 1) Protect the radiator with cardboard and blanket. 2) Remove the V-belts. 3) Remove the A/C compressor V-belt tensioner. 4) Remove the pulley bolt. Use the ST to lock crankshaft. • Except for turbo MT model: ST 499977400 CRANK PULLEY WRENCH • Turbo MT model: ST 499977100 CRANK PULLEY WRENCH 9) Remove the timing belt guide. (With timing belt guide model) PM-00008 ST PM-00093 5) Remove the crank pulley. 6) Remove the belt cover (LH). 7) Remove the belt cover (RH). 8) Remove the front belt cover. ME-00727 ME-00728 ME-00729 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. PM-15 G2360GE.book 16 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Timing Belt PERIODIC MAINTENANCE SERVICES ST 499987500 CRANKSHAFT SOCKET 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. B: INSPECTION 1. SOHC MODEL 1) Remove the front timing belt cover and timing belt cover (LH). 2) While cranking engine at least four rotations, check the timing belt back surface for cracks or damage. Replace the faulty timing belt as needed. 3) Measure the timing belt width W. If it is less than 27 mm (1.06 in), check idlers, tensioner, water pump pulley and cam sprocket to determine idler alignment (squareness). Replace the worn timing belt. ME-00070 ME-00071 11) Remove the belt idler. W PM-00016 4) Install the front timing belt cover and timing belt cover (LH). 2. DOHC MODEL PM-00095 12) Remove the timing belt. 13) Remove the automatic belt tension adjuster assembly. 1) Remove the timing belt cover (LH). 2) While cranking engine at least four rotations, check the timing belt back surface for cracks or damage. Replace the faulty timing belt as needed. 3) Measure the timing belt width W. If it is less than 30 mm (1.18 in), check idlers, tensioner, water pump pulley and cam sprocket to determine idler alignment (squareness). Replace the worn timing belt. W PM-00096 14) Install in the reverse order of removal. PM-00097 4) Install the timing belt cover (LH). PM-16 G2360GE.book 17 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Fuel Line PERIODIC MAINTENANCE SERVICES 8. Fuel Line A: INSPECTION The fuel line is located mostly internally, so check pipes, areas near pipes, and engine compartment piping for rust, hose damage, loose band, etc. If faulty parts are found, repair or replace them. • 2.0 L non-turbo and 2.5 L model • Turbo model • 3.0 L model PM-17 G2360GE.book 18 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Air Cleaner Element PERIODIC MAINTENANCE SERVICES 9. Air Cleaner Element • Non-turbo model A: REPLACEMENT 1) Disconnect the ground cable from battery. (B) PM-00182 • Turbo model IN-00203 2) Disconnect the connector from mass air flow sensor. (2.0 L turbo, 3.0 L and 2.5 L EC, EK, K4, EH, ER model) • 3.0 L and 2.5 L EC, EK, K4, EH, ER model (B) (B) (A) (A) PM-00183 5) Remove the air cleaner case (rear). 6) Remove the air cleaner element. IN-00204 • Turbo model IN-00206 7) Install in the reverse order of removal. NOTE: • Fasten with a clip after inserting the lower tab of the case. PM-00181 3) Loosen the clamps (A) which connect the air cleaner case to intake duct. (Turbo model) 4) Remove the clips (B) on air cleaner case. IN-00207 PM-18 G2360GE.book 19 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Air Cleaner Element PERIODIC MAINTENANCE SERVICES • Refer to “COMPONENT” for tightening torque. 2.0 L non-turbo and 2.5 L model Turbo model 3.0 L model PM-19 G2360GE.book 20 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Cooling System PERIODIC MAINTENANCE SERVICES 10.Cooling System A: INSPECTION 1) To check the radiator for leakage, fill it with engine coolant, and attach the radiator cap tester (A) to the filler neck, and apply pressure. Check the following points: Non-turbo model: 157 kPa (1.6 kgf/cm2, 23 psi) Turbo model: 122 kPa (1.2 kgf/cm2, 18 psi) • Each portion of radiator for leakage • Hose joints and other connections for leakage NOTE: • For turbo model, be sure to install the tester to filler tank side. • When attaching or detaching tester or when operating tester, use special care not to deform radiator filler neck. • Non-turbo model (A) NOTE: Rust or dirt on the cap may prevent valve from functioning normally: be sure to clean the cap before testing. Raise the pressure until the needle of gauge stops and see if the pressure can be retained for five to six seconds. The radiator cap is normal if a pressure above the service limit value has been maintained for this period. Radiator cap valve open pressure Non-turbo model Standard 93 — 123 kPa (0.95 — 1.25 kgf/cm2, 14 — 18 psi) Service limit 83 kPa (0.85 kgf/cm2, 12 psi) Turbo model Filler tank side Standard 93 — 123 kPa (0.95 — 1.25 kgf/cm2, 14 — 18 psi) Service limit 83 kPa (0.85 kgf/cm2, 12 psi) PM-00128 • Turbo model (A) PM-00184 • When performing this check, be sure to keep the engine stationary and fill radiator with coolant. • Wipe off check points before applying pressure. • Use care not to spill coolant when detaching tester from radiator. • Do not remove the radiator side cap. (Turbo model) 2) Check the radiator cap valve open pressure using radiator cap tester. PM-20 G2360GE.book 21 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Cooling System PERIODIC MAINTENANCE SERVICES Radiator side Standard 122 — 152 kPa (1.24 — 1.55 kgf/cm2, 18 — 22 psi) Service limit 112 kPa (1.14 kgf/cm2, 16 psi) • 2.0 L non-turbo and 2.5 L model • Turbo model • 3.0 L model PM-00023 (A) (A) (B) PM-00089 (A) Check points for deformation (B) Check points for deformation, damage, rust 3) Start the engine, and then check it does not overheat or it is cooled excessively. If it overheats or it is cooled excessively, check the cooling system. • 2.0 L non-turbo and 2.5 L model • Turbo model • 3.0 L model 4) Check the radiator fan operates using Subaru Select Monitor, when the coolant temperature exceeds 95°C (203°F). If it does not operate, check the radiator fan system. PM-21 G2360GE.book 22 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Engine Coolant PERIODIC MAINTENANCE SERVICES 11.Engine Coolant Coolant capacity (fill up to “FULL” level): A: REPLACEMENT LHD AT model 2.0 L non-turbo and 2.5 L model (without ATF cooler (with warmer)) 6.3 2 (6.7 US qt, 5.5 Imp qt) 2.0 L non-turbo and 2.5 L model (with ATF cooler (with warmer)) 6.7 2 (7.1 US qt, 5.9 Imp qt) 3.0 L model (without ATF cooler (with warmer)) 7.2 2 (7.6 US qt, 6.3 Imp qt) 3.0 L model (with ATF cooler (with warmer)) 7.7 2 (8.1 US qt, 6.8 Imp qt) 1. REPLACEMENT OF COOLANT WARNING: The radiator is of the pressurized type. Do not attempt to open the radiator cap immediately after the engine has been stopped. 1) Lift-up the vehicle. 2) Remove the under cover. 3) Place a container under drain pipe. 4) Remove the drain cock to drain engine coolant into container. CO-00248 5) For quick draining, open the radiator cap. NOTE: • For turbo model, be sure to open the radiator cap on the filler tank side. • Be careful not to spill coolant on the floor. 6) Drain the coolant from reservoir tank. 7) Tighten the radiator drain cock securely after draining coolant. 8) Pour the engine coolant into the radiator (for turbo model, coolant filler tank) up to the filler neck position. 9) Fill engine coolant into the reservoir tank up to “FULL” level. Recommended engine coolant: Refer to “RM” section. LHD MT model 2.0 L non-turbo and 2.5 L model 6.4 2 (6.8 US qt, 5.6 Imp qt) 3.0 L model 7.3 2 (7.7 US qt, 6.4 Imp qt) RHD AT model 2.0 L non-turbo and 2.5 L model (without ATF cooler (with warmer)) 6.4 2 (6.8 US qt, 5.6 Imp qt) 2.0 L non-turbo and 2.5 L model (with ATF cooler (with warmer)) 6.8 2 (7.2 US qt, 6.0 Imp qt) Turbo model 7.3 2 (7.7 US qt, 6.4 Imp qt) 3.0 L model (without ATF cooler (with warmer)) 7.2 2 (7.6 US qt, 6.3 Imp qt) 3.0 L model (with ATF cooler (with warmer)) 7.8 2 (8.2 US qt, 6.9 Imp qt) RHD MT model 2.0 L non-turbo and 2.5 L model 6.5 2 (6.9 US qt, 5.7 Imp qt) Turbo model 7.4 2 (7.8 US qt, 6.5 Imp qt) 3.0 L model 7.3 2 (7.7 US qt, 6.4 Imp qt) NOTE: The SUBARU Genuine Coolant containing antifreeze and anti-rust agents is especially made for SUBARU engine, which has an aluminum crankcase. Always use SUBARU Genuine Coolant, since other coolant may cause corrosion. 10) Close the radiator (for turbo model, coolant filler tank) cap to start the engine and race 5 to 6 times at less than 3,000 rpm, then stop the engine. (Complete this operation within 40 seconds.) PM-22 G2360GE.book 23 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Engine Coolant PERIODIC MAINTENANCE SERVICES 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), its specific gravity is 1.054 and 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). Concentration of coolant 1.100 1.090 60% 1.080 1.070 C 1.060 B 50% (1.054) A 1.050 1.040 1.030 40% 30% Freezing temperature 20% 1.020 1.010 1.000 PM-23 Safe operating temperature 25 C (77 F) NOTE: • Be careful with the engine coolant temperature gauge to prevent overheating. • If the radiator hose becomes to harden by the pressure of engine coolant, air bleeding operation seems to be almost completed. 16) Stop the engine and wait until engine coolant temperature lowers to 30°C (86°F) or less. 17) Open the radiator (for turbo model, coolant filler tank) cap. If the engine coolant level drops, add engine coolant to the filler neck position of radiator and the “FULL” level of reservoir tank. 18) Attach the radiator (for the turbo model, coolant filler tank) cap and reservoir tank cap properly. 19) Operate the heater at maximum hot position and the blower speed setting to “LO” and start the engine. Race at less than 3,000 rpm. If the flowing sound is heard, perform the procedures from 15) again. 2. RERATIONSHIP OF SUBARU COOLANT CONCENTRATION AND FREEZING TEMPERTAURE Specific gravity of coolant 11) Wait for one minute after the engine stops, open the radiator (for turbo model, coolant filler tank) cap. If the engine coolant level drops, add engine coolant to the filler neck position of radiator (for turbo model, coolant filler tank). 12) Perform the procedures 9) and 10) again. 13) Attach the radiator (for turbo model, coolant filler tank) cap and reservoir tank cap properly. 14) Start the engine and operate the heater at maximum hot position and the blower speed setting to “LO”. 15) Run the engine at 2,000 rpm or less until radiator fan starts and stops. 10% 0 10 20 30 40 -40 -30 -20 -10 (-40) (-22) (-4) (14) (32) (50) (68) (86) (104) Coolant temperature C ( F) CO-02172 G2360GE.book 24 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Engine Coolant PERIODIC MAINTENANCE SERVICES 3. PROCEDURE TO ADJUST THE CONCENTRATION OF THE COOLANT Quantity of coolant to be drained (US qt, Imp qt) To adjust the concentration of coolant according to temperature, find the proper fluid concentration in the above diagram and replace the necessary amount of coolant with an undiluted solution of SUBARU genuine coolant (concentration 50%). The amount of coolant that should be replaced can be determined using the diagram. [Example] Assume that the coolant concentration must be increased from 25% to 40%. Find point A, where the 25% line of coolant concentration intersects with the 40% curve of the necessary coolant concentration, and read the scale on the vertical axis of the graph at height A. The quantity of coolant to be drained is 2.1 2 (2.2 US qt, 1.8 Imp qt). Drain 2.1 2 (2.2 US qt, 1.8 Imp qt) of coolant from the cooling system and add 2.1 2 (2.2 US qt, 1.8 Imp qt) of the undiluted solution of SUBARU coolant. If a coolant concentration of 50% is needed, drain all the coolant and refill with the undiluted solution only. Necessary Concentration of coolant 3 (3.2, 2.6) 2 (2.1, 1.8) 1 (1.1, 0.9) 0 45% A 35% 40% 30% 25% 20% 10% 15% 10 20 30 40 50 Concentration of coolant in the vehicie cooling system % Concentration of coolant in vehicie and quantity to be drained CO-00012 PM-24 G2360GE.book 25 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Clutch System PERIODIC MAINTENANCE SERVICES 12.Clutch System A: INSPECTION AND ADJUSTMENT • Be careful not to allow dirt or dust to get into the reservoir tank. 1) Push the release lever to retract the push rod of the operating cylinder and check if the fluid level in the clutch reservoir tank rises or not. (A) (C) (B) (C) (B) (A) PM-00165 (A) Reservoir tank (B) MIN. level (C) MAX. level PM-00164 (A) Release lever (B) Push rod (C) Operating cylinder 2) If the fluid level rises, pedal free play is correct. 3) If the fluid level does not rise, or the push rod cannot be retracted, adjust the clutch pedal. 4) Check the fluid level using the scale on the outside of the clutch reservoir tank (A). If the level is below “MIN” (B), inspect the clutch master cylinder, operating cylinder and hydraulic line for fluid leaks. If fluid leaks are found, repair or replace. If fluid leaks are not found, add clutch fluid to bring it up to “MAX” (C) of clutch reservoir tank. Recommended clutch fluid: Refer to “RM” section. CAUTION: Prevent the clutch fluid from being splashed over vehicle body and exhaust pipe. If the clutch fluid is splashed over vehicle body and exhaust pipe, flush it quickly, and then wipe it up. NOTE: • Avoid mixing different brands of brake fluid to prevent degradation of the fluid. PM-25 G2360GE.book 26 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Transmission Gear Oil PERIODIC MAINTENANCE SERVICES 13.Transmission Gear Oil NOTE: Each oil manufacturer has its base oil and additives. Thus, do not mix two or more brands. A: REPLACEMENT 1. MANUAL TRANSMISSION 1) Drain the gear oil by removing drain plug. NOTE: • Before starting work, cool off the transmission gear oil well. • If transmission gear oil adheres to the exhaust pipe, wipe it off completely. • 5MT Gear oil capacity: 5MT 3.5 2 (3.7 US qt, 3.1 Imp qt) (A) (B) (C) PM-00030 (A) Oil level gauge (B) Upper level (C) Lower level 6MT 4.1 2 (4.3 US qt, 3.6 Imp qt) PM-00166 • 6MT (A) (A) (A) (B) (B) (C) MT-00449 MT-00450 (A) Drain plug (Oil pan side) (B) Drain plug (Clutch housing side) 2) Replace the gasket with new one, and then tighten the drain plug to specified torque. Tightening torque: 5MT 70 N⋅m (7.1 kgf-m, 51.6 ft-lb) 6MT (Oil pan side) 44 N⋅m (4.5 kgf-m, 32.5 ft-lb) 6MT (Clutch housing side) 70 N⋅m (7.1 kgf-m, 51.6 ft-lb) 3) Fill the transmission gear oil through the oil level gauge hole up to the upper point of level gauge. Recommended gear oil: Refer to “RM” section. PM-26 (A) Oil level gauge (B) Upper level (C) Lower level G2360GE.book 27 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Automatic Transmission Fluid PERIODIC MAINTENANCE SERVICES 14.Automatic Transmission Fluid • 5AT model (A) (C) CAUTION: The level of ATF varies with fluid temperature. Pay attention to the fluid temperature when checking ATF level. 1) Raise the ATF temperature by driving a distance of 5 to 10 km (3 to 6 miles). Otherwise, idle the engine to raise ATF temperature to 70 — 80°C (158 — 176°F) on Subaru Select Monitor. 2) Make sure the vehicle is level. 3) After selecting all positions (P, R, N, D), shift the select lever in “P” range. Measure the ATF level with engine idling for one or two minutes. • 4AT model (C) (E) COLD L F (D) L F HOT (A) (B) (C) (D) PI-00189 (A) Level gauge (B) ATF level range at “HOT” [70 — 80°C (158 — 176°F)] (C) Upper level (D) Lower level (E) ATF level range at “COLD” [20 — 30°C (68 — 86°F)] L F HOT (A) A: INSPECTION (B) (E) COLD L F (D) (C) (D) PI-00190 (A) Level gauge (B) ATF level range at “HOT” [70 — 80°C (158 — 176°F)] (C) Upper level (D) Lower level (E) ATF level range at “COLD” [20 — 30°C (68 — 86°F)] 4) Make sure that ATF level is above the center of upper and lower marks at “HOT” side. 5) If the ATF level is below the center between upper and lower marks, add the recommended ATF until the fluid level is found above the center between upper and lower marks. CAUTION: • Use care not to exceed the upper limit level. • Addition of ATF to the upper limit mark on “HOT” side when the ATF temperature is below 70°C (158°F) will overfilling of ATF, causing a transmission failure. 6) Check ATF level after raising ATF temperature to 70 — 80°C (158 — 176°F) by running the vehicle or by idling the engine again. 7) Check the ATF for leaks. Check for leaks in the transmission. If there are leaks, it is necessary to repair or replace gasket, oil seals, plugs or other parts. PM-27 G2360GE.book 28 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Automatic Transmission Fluid PERIODIC MAINTENANCE SERVICES B: REPLACEMENT 4) Check the ATF level. • 4AT model 1. AUTOMATIC TRANSMISSION FLUID 1) Drain the ATF by removing drain plug. (C) (E) COLD L F (D) L F HOT (A) NOTE: • Before starting work, cool off the ATF well. • If the ATF gets on the exhaust pipe, wipe it off. • 4AT model (B) (C) (D) PI-00189 (A) Level gauge (B) ATF level range at “HOT” [70 — 80°C (158 — 176°F)] (C) Upper level (D) Lower level (E) ATF level range at “COLD” [20 — 30°C (68 — 86°F)] (B) (A) PM-00167 (A) Front differential gear oil drain plug (B) ATF drain plug • 5AT model • 5AT model (A) (C) L F HOT (A) (B) (D) (E) COLD L F (A) (C) (D) PI-00190 PM-00168 (A) Level gauge (B) ATF level range at “HOT” [70 — 80°C (158 — 176°F)] (C) Upper level (D) Lower level (E) ATF level range at “COLD” [20 — 30°C (68 — 86°F)] (A) ATF drain plug 2) Replace the gasket with new one, and then tighten the drain plug to specified torque. Tightening torque: 4AT model 25 N⋅m (2.5 kgf-m, 18.4 ft-lb) 5AT model 20 N⋅m (2.0 kgf-m, 14.8 ft-lb) 3) Pour ATF from the ATF charge pipe. 2. ATF FILTER Recommended ATF: Refer to “RM” section. Capacity: Fill the same amount of ATF drained. NOTE: Basically ATF filter is maintenance free, but when it has physically damaged or ATF leaked, the ATF filter needs replacement. For the replacement procedure of ATF filter, refer to “ATF FILTER”. • 4AT model • 5AT model PM-28 G2360GE.book 29 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Front & Rear Differential Gear Oil PERIODIC MAINTENANCE SERVICES 15.Front & Rear Differential Gear Oil A: REPLACEMENT 1. FRONT DIFFERENTIAL (MT MODEL) Front differential gear oil for MT model lubricates the transmission and differential together. Refer to “Transmission Oil” for replacement procedure. 2. FRONT DIFFERENTIAL (AT MODEL) Recommended gear oil: Refer to “RM” section. NOTE: Each oil manufacturer has its base oil and additives. Thus, do not mix two or more brands. Differential gear oil capacity: 4AT model 1.1 — 1.3 2 (1.2 — 1.4 US qt, 1.0 — 1.1 Imp qt) 1) Drain the differential gear oil by removing drain plug using TORX® BIT T70. (A) NOTE: • Before starting work, cool off the differential gear oil well. • If front differential gear oil adheres to the exhaust pipe, wipe it off completely. • 4AT model (B) (A) (C) PI-00183 (A) Oil level gauge (B) Upper level (C) Lower level 5AT model 1.3 — 1.5 2 (1.4 — 1.6 US qt, 1.1 — 1.3 Imp qt) PM-00169 • 5AT model (A) L F (A) (B) (C) PI-00184 (A) Oil level gauge (B) Upper level (C) Lower level PM-00170 2) Replace the gasket with new one, and then tighten the drain plug to specified torque. Tightening torque: 44 N⋅m (4.5 kgf-m, 32.5 ft-lb) (Copper gasket) 70 N⋅m (7.1 kgf-m, 51.6 ft-lb) (Alminum gasket) 3) Fill differential gear oil through the oil level gauge hole up to the upper point of level gauge. 3. REAR DIFFERENTIAL 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. • Use a new gasket for VA-type. PM-29 G2360GE.book 30 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Front & Rear Differential Gear Oil PERIODIC MAINTENANCE SERVICES • Use a new aluminum gasket for VA-type. Liquid gasket: THREE BOND 1105 (Part No. 004403010) Liquid gasket: THREE BOND 1105 (Part No. 004403010) Tightening torque: T-type 49 N⋅m (5.0 kgf-m, 36.2 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. Tightening torque: T-type 49 N⋅m (5.0 kgf-m, 36.2 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) Recommended gear oil: Refer to “RM” section. • Except for VA2-type (A) (B) PM-00037 (A) Filler plug (B) Drain plug • VA2-type (A) (B) DI-00355 (A) Filler plug (B) Drain plug Oil capacity: 0.8 2 (0.8 US qt, 0.7 Imp 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 filer plug threads for Ttype. PM-30 G2360GE.book 31 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Brake Line PERIODIC MAINTENANCE SERVICES 16.Brake Line 2. SERVICE BRAKE A: INSPECTION 1) Check the free play of brake pedal with pulling up the force of less than 10 N (1 kgf, 2 lbf). 1. BRAKE LINE 1) Check for scratches, swelling, corrosion, traces of fluid leakage on the brake hoses or pipe joints. 2) Check the possibility of adjacent parts interfering with brake pipes/hoses during driving, and loose connections/clamps. 3) Check any trace of fluid leakage, scratches, etc. on master cylinder, wheel cylinder and pressure control valve. Brake pedal free play (Pulling up direction of pedal) 0.5 — 2.0 mm (0.02 — 0.08 in) 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) (2) (1) PM-00171 (1) Front brake hose (2) Front brake pipe (A) PM-00185 (A) Pedal free play 2) If the free play is out of specifications above, adjust the brake pedal as follows: (1) Make sure the engine is off. (No vacuum is applied to brake booster.) (2) 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 less than 10 N (1 kgf, 2 lbf) to a stroke of 0.5 to 2.0 mm (0.02 to 0.08 in).] (3) 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). (A) (B) (H) (2) (C) (1) (D) (E) (F) (I) (J) (G) PM-00186 PM-00172 (A) (B) (C) (D) (E) (F) (G) (H) (I) (J) (1) Rear brake pipe (2) Rear brake hose PM-31 Brake switch Adjusting nut 0.3 mm (0.012 in) Stopper Clevis pin Clevis Pedal free play Lock nut Brake booster operating rod Play at pin G2360GE.book 32 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Brake Line PERIODIC MAINTENANCE SERVICES 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 measurements must be less than specification. If the distance is more than specification, there is possibility of air inside the hydraulic unit. 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. (A) (B) (C) Brake pedal stroke A: 95 mm (3.7 in)/ 490 N (50 kgf, 110 lbf) or less PM-00046 1 2 =A (A) Engine side (B) Brake booster side (C) ENG (A) 1 5) Check the vacuum hose for cracks or other damage. 2 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. (B) PM-00045 (A) Steering wheel (B) Toe board 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. 3. BRAKE SERVO SYSTEM 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 its brake booster side end. Make sure air must flow out of engine side end of hose. Next, blow compressed air into hose from engine side. Make sure air should not flow out of hose. PM-32 G2360GE.book 33 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Brake Fluid PERIODIC MAINTENANCE SERVICES 17.Brake Fluid 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. A: REPLACEMENT CAUTION: Be careful not to let the brake fluid get on the vehicle body. If the brake fluid gets on the vehicle body, flush it quickly, and then wipe it off. 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. 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. Air bleeding sequence (1) → (2) → (3) → (4) (1) (5) (6) (3) (1) (2) (3) (4) (5) (6) (4) Front RH Rear LH Front LH Rear RH Secondary Primary (2) PM-00047 PM-00048 NOTE: • Cover the bleeder with cloth, when loosening it, to prevent brake fluid from being splashed over surrounding parts. • During the bleeding operation, keep the brake reservoir tank filled with brake fluid to eliminate entry of air. • The brake pedal operation must be very slow. • For convenience and safety, two people should do the work. • The amount of brake fluid required is approx. 500 m2 (16.9 US fl oz, 17.6 Imp fl oz) for total brake system. 6) Instruct your co-worker to depress the brake pedal slowly two or three times and then hold it depressed. 7) Loosen the bleeder screw approximately 1/4 turn until a small amount of brake fluid drains into the container, and then quickly tighten the screw. 8) Repeat steps 6) and 7) 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, 5.9 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 lbf) 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. PM-33 G2360GE.book 34 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Brake Fluid PERIODIC MAINTENANCE SERVICES 12) Install the wheels, and drive the vehicle for a short distance between 2 to 3 km (1 to 2 miles) to confirm brakes are operating properly. PM-34 G2360GE.book 35 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Disc Brake Pad and Disc PERIODIC MAINTENANCE SERVICES 18.Disc Brake Pad and Disc (A) A: INSPECTION (C) 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. (B) 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. PM-00140 (A) Pad thickness (B) Back metal (C) Lining 3) Check the disc rotor, and correct or replace if it is damaged or worn. • Front Disc rotor thickness 15, 16-inch Standard 17-inch 15, 16-inch Wear limit 17-inch (A) PM-00049 mm (in) 24 (0.94) 30 (1.18) 22 (0.87) 28 (1.10) (A) Inspection hole • Rear • Front Pad thickness Standard Wear limit 15-inch 16-inch 17-inch 15-inch 16-inch 17-inch mm (in) 11 (0.43) 11 (0.43) 11 (0.43) 1.5 (0.059) 1.5 (0.059) 1.5 (0.059) • Rear Standard Wear limit Pad thickness Solid disc type Ventilated disc type Solid disc type Ventilated disc type mm (in) 9 (0.35) 9 (0.35) 1.5 (0.059) 1.5 (0.059) Disc rotor thickness Solid disc type Standard Ventilated disc type Solid disc type Wear limit Ventilated disc type mm (in) 10 (0.39) 18 (0.71) 8.5 (0.34) 16 (0.63) 4) Remove the caliper body. 5) Tighten the wheel nuts to secure disk rotor. 6) Set a dial gauge at a point less than 10 mm (0.39 in) from outer periphery of the rotor, and then measure the disk rotor runout. Disc rotor runout limit: Front: 0.05 mm (0.002 in) Rear: 0.05 mm (0.002 in) PM-00051 PM-35 G2360GE.book 36 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Parking Brake PERIODIC MAINTENANCE SERVICES 19.Parking Brake 4) When the shoe return spring tension is excessively weakened, replace it. A: INSPECTION Inspect the brake linings and disc rotor of both sides of the rear brake at the same time by removing disc rotor. 1) Inspect the brake shoes for damage or deformation and check the brake linings for wear. NOTE: Always replace both primary and secondary brake shoes for the left and right wheels at the same time. B: ADJUSTMENT For rear disc brake, adjust the parking brake after bleeding air. 1) Remove the rear cover (rubber) installed at back plate. 2) Turn the adjuster toward arrow mark (upward) until it is locked slightly, by using flat-tip screwdriver as shown in the illustration. Thickness of brake lining (except for back metal): Standard: 3.2 mm (0.126 in) Wear limit: 1.5 mm (0.059 in) (A) (B) (C) PM-00056 (A) (B) (A) Adjuster (B) Cover (rubber) (C) Back plate (C) PM-00054 3) Turn back (downward) the adjuster 3 to 4 notches. 4) Install the cover (rubber) in original position correctly. (A) Forward (B) Brake shoe (Primary side) (C) Brake shoe (Secondary side) 2) Check the inside of disk rotor for wear, dents or other damage. If the inside surface of dick rotor is streaked, correct the surface with emery cloth (#200 or more). If it is unevenly worn or tapered, correct or replace it. Brake drum inside diameter: Standard: 170 mm (6.69 in) Wear limit: 171 mm (6.73 in) (B) (A) PM-00055 (A) Inside diameter (B) Disc 3) If the deformation or wear of back plate, shoe, etc. is noticeable, replace them. PM-36 G2360GE.book 37 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Suspension PERIODIC MAINTENANCE SERVICES 20.Suspension NOTE: When the front arm ball joint has been removed or replaced, check the toe-in of front wheel. If the front wheel toe-in is not at specification, adjust the toein. A: INSPECTION 1. SUSPENSION BALL JOINT 1) Jack-up the vehicle until front wheels are off ground. 2) Grasp the bottom of tire and move it in and out. If relative movement is observed between the brake disc cover (A) and end of front arm (D), ball joint (C) may be excessively worn. (A) PM-00059 (A) Dust seal (A) 2. FRONT, REAR SUSPENSION BUSHING (D) (C) (B) PM-00057 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. Apply pressure with tire lever etc, and inspect the bushing for wear or crack. Replace the bushings if there is wear or crack. (D) (A) PM-00180 (C) (B) 3. WHEEL ARCH HEIGHT PM-00058 4) If relative movement is observed in the step 2), 3), remove and inspect the ball joint. If the free play exceeds specification, replace the ball joint. 5) Damage of dust seal Visually inspect the ball joint dust seal. If it is damaged, remove the front arm. And measure free play of ball joint. (1) When looseness exceeds specification, replace the ball joint. (2) If the dust seal is damaged, replace with a new ball joint. 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 specification. 3) When the wheel arch height is out of specification, visually inspect following components and replace deformed parts. • Suspension components [Front strut assembly and rear damper assembly] • Parts connecting suspension and body 4) If no components are deformed, adjust the wheel arch height by replacing the suspension which wheel arch height is out of standard. PM-37 G2360GE.book 38 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Suspension PERIODIC MAINTENANCE SERVICES 4. WHEEL ALIGNMENT OF FRONT SUSPENSION 8. DAMAGE TO SUSPENSION PARTS 1) Check the alignment of front suspension to ensure that following items conform to specification. • Toe-in • Camber • Caster • Steering angle 2) When the caster angle does not conform to reference obviously, visually inspect the following components and replace deformed parts. • Suspension components [Strut assembly, crossmember, front arm, etc.] • Parts connecting suspension and body 3) When the toe-in and camber are out of specification, adjust them so that they conform to specification. 4) When the right-and-left turning angles of tire are out of standard, adjust to specification. 5. WHEEL ALIGNMENT OF REAR SUSPENSION Check the following parts and the fastening portion of the vehicle body for deformation or excessive rusting which impairs the suspension. If necessary, replace the damaged parts with new ones. If minor rust formation, pitting, etc. are noted, remove the rust and take rust prevention measure. • Front suspension • Front arm • Crossmember • Strut • Rear suspension • Sub frame • Front link • Rear link • Upper link • Rear arm • Shock absorber • 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 measure as required. 1) Check the alignment of rear suspension to ensure that following items are within specification. • Toe-in • Camber • Thrust angle 2) When the camber angle does not conform to specification, visually inspect the following components. If the deformation is observed, replace the damaged parts. • Suspension components [Shock absorber, front link, rear link, upper link, rear arm, sub frame, etc] • Parts connecting suspension and body 3) When the toe-in and thrust angle are out of specification, adjust them so that they conform to specification. 6. 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. 7. TIGHTNESS OF BOLTS AND NUTS Check the bolts and nuts for looseness. Retighten the bolts and nuts to specified torque. If the selflocking nuts and bolts are removed, replace them with new ones. • Front suspension • Rear suspension PM-38 G2360GE.book 39 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Wheel Bearing PERIODIC MAINTENANCE SERVICES 21.Wheel Bearing 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. A: INSPECTION 1. FRONT WHEEL BEARING NOTE: Inspect the condition of front wheel bearing grease. 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. 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. PM-00173 2. 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. PM-39 PM-00173 G2360GE.book 40 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Axle Boots & Joints PERIODIC MAINTENANCE SERVICES 22.Axle Boots & Joints A: INSPECTION 1. FRONT AND REAR AXLE BOOTS Inspect the front axle boots (A) and rear axle boots (B) for deformation, damage or failure. If faulty, replace them with new ones. • Front (A) PM-00174 • Rear (B) PM-00175 2. PROPELLER SHAFT Inspect the propeller shaft for damage or failure. If faulty, replace them with new ones. PM-40 G2360GE.book 41 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Steering System (Power Steering) PERIODIC MAINTENANCE SERVICES 23.Steering System (Power Steering) 2. STEERING SHAFT JOINT A: INSPECTION 1. STEERING WHEEL 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. 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) Steering wheel free play: 0 — 17 mm (0 — 0.67 in) (1) PS-00450 (1) Steering wheel free play 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. (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 factor: Steering wheel should return to its original position after it has been turned and then released. PM-00176 3. GEARBOX 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) PM-00177 2) Check the boot for damage, cracks or deterioration. PM-41 G2360GE.book 42 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Steering System (Power Steering) PERIODIC MAINTENANCE SERVICES 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) Adjustment for LHD model (1) Apply liquid gasket around the center of adjusting screw thread. (2) Tighten adjusting screw to 25 N⋅m (2.5 kgfm, 18.4 ft-lb) and then loosen. (3) Tighten adjusting screw to 3.9 N⋅m (0.40 kgf-m, 2.9 ft-lb) and then loosen 20°. 5) Adjustment for RHD model (1) Apply liquid gasket around the center of adjusting screw thread. (2) Tighten adjusting screw to 9.8 N⋅m (1.0 kgfm, 7.2 ft-lb) and then loosen. (3) Tighten adjusting screw to 4.9 N⋅m (0.50 kgf-m, 3.6 ft-lb) and then loosen approx 30°. 6) Install the lock nut. While holding adjusting screw with a wrench, tighten the lock nut using ST. ST 926230000 SPANNER Tightening torque (lock nut): LHD model 25 N⋅m (2.5 kgf-m, 18.4 ft-lb) RHD model 39 N⋅m (4.0 kgf-m, 28.9 ft-lb) Hold the adjusting screw with a wrench to prevent it from turning while tightening the lock nut. 4. TIE-ROD 1) Check the tie-rod and tie-rod ends for bends, scratches or other damage. 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, 62.7 ft-lb) 5. POWER STEERING FLUID LEVEL NOTE: • At power steering fluid temperature 20°C (68°F); read the fluid level on the “COLD” side. • At power steering fluid temperature 80°C (176°F); read the fluid level on the “HOT” side. 1) Place the vehicle with engine “OFF” on a level surface. 2) Remove the cover. (3.0 L and turbo model) 3) Check the fluid level using the scale on the outside of the reservoir tank (A). If the level is below “MIN” (B), add fluid to bring it up to “MAX” (C). (C) (A) (B) PM-00178 NOTE: If fluid level is at MAX level or above, drain fluid to keep the level in the specified range of indicator by using a syringe or the like. Recommended fluid: Refer to “RM” section. Fluid capacity: 0.8 2 (0.8 US qt, 0.7 Imp qt) 6. POWER STEERING FLUID FOR LEAKS (A) (B) Inspect the underside of oil pump and gearbox of power steering system, hoses, pipes and their couplings for fluid leaks. If the fluid leaks are found, retighten their fitting bolts (or nuts) and/or replace their parts. PM-00069 (A) Tie-rod end (B) Knuckle arm 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 60° until cotter pin hole is aligned. NOTE: • Wipe the leaked fluid off after correcting fluid leaks. • Also pay attention to clearances between hoses (or pipes) and other parts when inspecting fluid leaks. Tightening torque: 27 N⋅m (2.75 kgf-m, 19.9 ft-lb) PM-42 G2360GE.book 43 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Steering System (Power Steering) PERIODIC MAINTENANCE SERVICES 7. HOSES OF OIL PUMP FOR DAMAGES Check the pressure hose and return hose of oil pump for crack, swell or damage. Replace the hose with a new one if necessary. NOTE: Prevent hoses from turning and/or bending when installing hoses. PM-00179 8. POWER STEERING PIPES FOR DAMAGES Check the power steering pipes for corrosion and damage. Replace the pipes with new ones if necessary. 9. 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 and hole. NOTE: Rotate the position (B) of gearbox boot against the twist of it produced by adjustment of toe-in, etc. Apply grease to the groove (C). (C) (B) (A) PM-00090 10.FITTING BOLTS AND NUTS Inspect 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. PM-43 G2360GE.book 44 ページ ２００７年１１月２９日 木曜日 午後１時２８分 A/C Filter PERIODIC MAINTENANCE SERVICES 24.A/C Filter A: REPLACEMENT 1) Remove the instrument panel side cover. PM-00273 2) Remove the clips and damper. (1) (2) (1) PM-00274 (1) Clip (2) Damper 3) Remove the tray. PM-00275 4) Remove the A/C filter. PM-00276 5) Install in the reverse order of removal. PM-44 G2360GE.book 45 ページ ２００７年１１月２９日 木曜日 午後１時２８分 2005 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 This service manual has been prepared to provide SUBARU service personnel with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. This manual includes the procedures for maintenance, disassembling, reassembling, inspection and adjustment of components and diagnostics for guidance of experienced mechanics. Please peruse and utilize this manual fully to ensure complete repair work for satisfying our customers by keeping their vehicle in optimum condition. When replacement of parts during repair work is needed, be sure to use SUBARU genuine parts. All information, illustration and specifications contained in this manual are based on the latest product information available at the time of publication approval. FUJI HEAVY INDUSTRIES LTD. FUEL INJECTION (FUEL SYSTEMS) FU(H4SO 2.0) EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) EC(H4SO 2.0) INTAKE (INDUCTION) IN(H4SO 2.0) MECHANICAL ME(H4SO 2.0) EXHAUST EX(H4SO 2.0) COOLING CO(H4SO 2.0) LUBRICATION LU(H4SO 2.0) SPEED CONTROL SYSTEMS SP(H4SO 2.0) IGNITION IG(H4SO 2.0) STARTING/CHARGING SYSTEMS SC(H4SO 2.0) ENGINE (DIAGNOSTICS) EN(H4SO 2.0) (diag) FUEL INJECTION (FUEL SYSTEMS) FU(H4SO 2.5) EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) EC(H4SO 2.5) INTAKE (INDUCTION) IN(H4SO 2.5) MECHANICAL ME(H4SO 2.5) EXHAUST EX(H4SO 2.5) COOLING CO(H4SO 2.5) G2360GE2 G2360GE.book 216 ページ ２００７年１１月２９日 木曜日 午後１時２８分 G2360GE.book 46 ページ ２００７年１１月２９日 木曜日 午後１時２８分 2005 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SO 2.5) SPEED CONTROL SYSTEMS SP(H4SO 2.5) IGNITION IG(H4SO 2.5) STARTING/CHARGING SYSTEMS SC(H4SO 2.5) ENGINE (DIAGNOSTICS) EN(H4SO 2.5) (diag) G2360GE2 G2360GE.book 216 ページ ２００７年１１月２９日 木曜日 午後１時２８分 G2360GE.book 1 ページ ２００７年１１月２９日 木曜日 午後１時２８分 FUEL INJECTION (FUEL SYSTEM) FU(H4SO 2.0) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. Page General Description ....................................................................................2 Throttle Body.............................................................................................10 Intake Manifold..........................................................................................11 Engine Coolant Temperature Sensor........................................................20 Crankshaft Position Sensor.......................................................................21 Camshaft Position Sensor.........................................................................22 Knock Sensor............................................................................................23 Throttle Position Sensor............................................................................25 Manifold Absolute Pressure Sensor..........................................................26 Intake Air Temperature Sensor .................................................................27 EGR Valve ................................................................................................28 Fuel Injector ..............................................................................................29 Front Oxygen (A/F) Sensor .......................................................................32 Rear Oxygen Sensor.................................................................................33 Engine Control Module (ECM) ..................................................................34 Main Relay ................................................................................................35 Fuel Pump Relay.......................................................................................36 Electronic Throttle Control Relay ..............................................................37 Fuel ...........................................................................................................38 Fuel Tank ..................................................................................................39 Fuel Filler Pipe ..........................................................................................45 Fuel Pump.................................................................................................47 Fuel Level Sensor .....................................................................................49 Fuel Sub Level Sensor..............................................................................50 Fuel Filter ..................................................................................................51 Fuel Damper Valve ...................................................................................52 Fuel Delivery, Return and Evaporation Lines............................................53 Fuel System Trouble in General ...............................................................56 G2360GE.book 2 ページ ２００７年１１月２９日 木曜日 午後１時２８分 General Description FUEL INJECTION (FUEL SYSTEM) 1. General Description A: SPECIFICATION Fuel tank Fuel pump Capacity Location Type Shutoff discharge pressure Discharge rate Fuel filter 64 2 (16.9 US gal, 14.1 Imp gal) Under rear seat Impeller 441 — 686 kPa (4.50 — 7.00 kgf/cm2, 64.0 — 99.5 psi) 75 2 (19.8 US gal, 16.5 Imp gal)/h or more [12 V at 300 kPa (3.06 kgf/cm2, 43.5 psi)] In-tank type FU(H4SO 2.0)-2 G2360GE.book 3 ページ ２００７年１１月２９日 木曜日 午後１時２８分 General Description FUEL INJECTION (FUEL SYSTEM) B: COMPONENT 1. INTAKE MANIFOLD T4 T2 (7) (17) T2 (9) T4 (8) T6 T4 (19) (10) (11) (7) T5 T3 T2 T4 T4 (17) (14) (12) (4) T4 T2 (12) T5 (9) (8) T5 (10) T5 (13) (5) (2) (3) T3 (1) T5 T4 T4 (12) T1 T1 T1 (16) T2 (16) (18) (3) (2) (6) T1 (18) (15) T1 (16) T1 T4 T2 (18) FU-02056 FU(H4SO 2.0)-3 G2360GE.book 4 ページ ２００７年１１月２９日 木曜日 午後１時２８分 General Description FUEL INJECTION (FUEL SYSTEM) (1) (2) (3) (4) Intake manifold Gasket Guide pin EGR valve (EC, EK, K4, ER model) (5) (6) (7) (8) (9) Fuel pipe protector RH Fuel pipe protector LH Fuel injector pipe Fuel injector O-ring (10) (11) (12) (13) (14) (15) (16) (17) (18) (19) Tightening torque: N⋅m (kgf-m, ft-lb) T1: 1.25 (0.13, 0.94) T2: 6.4 (0.65, 4.7) T3: 17 (1.7, 12.5) T4: 19 (1.9, 14) T5: 25 (2.5, 18) T6: 23 (2.3, 17) O-ring Purge control solenoid valve Plug cord holder Nipple (LHD model) Nipple (RHD model) Fuel pipe ASSY Fuel hose Clip Clamp PCV valve 2. AIR INTAKE SYSTEM T1 (3) T2 (4) (2) (1) FU-02622 (1) (2) (3) Gasket Throttle body Manifold absolute pressure sensor (4) O-ring FU(H4SO 2.0)-4 Tightening torque: N⋅m (kgf-m, ft-lb) T1: 2 (0.2, 1.5) T2: 8 (0.8, 5.9) G2360GE.book 5 ページ ２００７年１１月２９日 木曜日 午後１時２８分 General Description FUEL INJECTION (FUEL SYSTEM) 3. CRANKSHAFT POSITION, CAMSHAFT POSITION AND KNOCK SENSORS T1 T2 (1) (2) T1 (4) (3) T1 FU-00414 (1) (2) Crankshaft position sensor Knock sensor (3) (4) Camshaft position sensor Camshaft position sensor support FU(H4SO 2.0)-5 Tightening torque: N⋅m (kgf-m, ft-lb) T1: 6.4 (0.65, 4.7) T2: 24 (2.4, 17.7) G2360GE.book 6 ページ ２００７年１１月２９日 木曜日 午後１時２８分 General Description FUEL INJECTION (FUEL SYSTEM) 4. FUEL TANK T1 (19) (17) (18) (15) (16) (8) T1 (17) (14) (7) (15) (10) (12) (9) (11) (1) (13) (22) T4 (6) (22) (5) (20) (3) (2) T4 (21) T4 (4) T3 T3 T3 T3 (23) (24) (25) T3 T2 T2 T3 FU-01080 FU(H4SO 2.0)-6 G2360GE.book 7 ページ ２００７年１１月２９日 木曜日 午後１時２８分 General Description FUEL INJECTION (FUEL SYSTEM) (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) Fuel tank Fuel tank band RH Fuel tank band LH Delivery tube Return tube Jet pump tube Fuel pump ASSY Fuel pump upper plate Fuel pump gasket Fuel level sensor Fuel sub level sensor (12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22) Fuel sub level sensor upper plate Fuel sub level sensor gasket Fuel filler hose Clamp Vent hose Clip Fuel tank protector RH (Rear) Fuel tank protector LH (Rear) Stopper RH Stopper LH Retainer FU(H4SO 2.0)-7 (23) (24) (25) Heat shield cover Fuel tank protector RH (Front) Fuel tank protector LH (Front) Tightening torque: N⋅m (kgf-m, ft-lb) T1: 4.4 (0.45, 3.2) T2: 9 (0.9, 6.6) T3: 17.5 (1.78, 12.9) T4: 33 (3.4, 24.3) G2360GE.book 8 ページ ２００７年１１月２９日 木曜日 午後１時２８分 General Description FUEL INJECTION (FUEL SYSTEM) 5. FUEL LINE T2 (1) (28) (18) (26) (23) (25) (27) (15) (17) (19) (1) (20) (22) (14) (13) (24) (21) T3 (1) A (16) (1) (1) (22) (34) (11) (29) (10) T3 (12) B T4 T3 T1 T1 (35) (1) (4) (5) (35) A T3 (1) (35) T1 (3) (35) (2) B T1 (33) (35) (6) T1 (35) (9) T1 (7) (32) (30) (31) (8) FU-02591 FU(H4SO 2.0)-8 G2360GE.book 9 ページ ２００７年１１月２９日 木曜日 午後１時２８分 General Description FUEL INJECTION (FUEL SYSTEM) (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) Clip Fuel return hose Evaporation hose A Fuel delivery hose A Fuel delivery hose B Fuel damper Fuel damper holder Fuel damper bracket Fuel pipe ASSY Clamp Canister Canister protector (Sedan model) Canister drain hose A Two-way valve hose A (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) Purge hose A Purge hose B Two-way valve hose B Canister drain hose B Two-way valve drain hose Two-way valve Two-way valve hose C Connector Evaporation hose holder Fuel filler pipe ASSY Filler pipe packing Filler ring Filler cap Tether C: CAUTION • Wear work clothing, including a cap, protective goggles, and protective shoes during operation. • Remove contamination including dirt and corrosion before removal, installation or disassembly. • Keep the disassembled parts in order and protect them from dust and dirt. • Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. (29) (30) (31) (32) (33) (34) (35) Clip Fuel hose Purge hose C Connector Purge pipe Two-way valve bracket Clamp Tightening torque: N⋅m (kgf-m, ft-lb) T1: 1.25 (0.13, 0.94) T2: 4.4 (0.45, 3.2) T3: 7.5 (0.76, 5.5) T4: 8.3 (0.85, 6.1) • Be careful not to burn yourself, because each part on the vehicle is hot after running. • Be sure to tighten fasteners including bolts and nuts to the specified torque. • Place shop jacks or rigid racks at the specified points. • Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from battery. • Place “NO FIRE” signs near the working area. • Be careful not to spill fuel on the floor. D: PREPARATION TOOL ILLUSTRATION TOOL NUMBER DESCRIPTION 18482AA000 CARTRIDGE (Newly adopted tool) REMARKS Troubleshooting for electrical system. ST18482AA000 22771AA030 SUBARU SELECT MONITOR KIT ST22771AA030 FU(H4SO 2.0)-9 Troubleshooting for electrical system. • English: 22771AA030 (Without printer) • German: 22771AA070 (Without printer) • French: 22771AA080 (Without printer) • Spanish: 22771AA090 (Without printer) G2360GE.book 10 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Throttle Body FUEL INJECTION (FUEL SYSTEM) 2. Throttle Body A: REMOVAL 1) Disconnect the ground cable from battery. IN-00203 2) Remove the air intake chamber. 3) Disconnect the connectors from the throttle position sensor and manifold absolute pressure sensor. (B) (A) FU-02058 (A) Throttle position sensor (B) Manifold absolute pressure sensor 4) Disconnect the engine coolant hoses from throttle body. 5) Remove the bolts which install throttle body to the intake manifold. FU-02059 B: INSTALLATION Install in the reverse order of removal. NOTE: Use a new gasket. Tightening torque: 8 N⋅m (0.8 kgf-m, 5.9 ft-lb) FU(H4SO 2.0)-10 G2360GE.book 11 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Intake Manifold FUEL INJECTION (FUEL SYSTEM) 3. Intake Manifold 9) Disconnect the engine harness connectors from bulkhead harness connectors. A: REMOVAL 1) Release the fuel pressure. 2) Open fuel filler flap lid, and remove fuel filler cap. 3) Disconnect the ground cable from battery. FU-02061 10) Disconnect the connectors from engine coolant temperature sensor. IN-00203 4) Remove the air cleaner case and air intake chamber. 5) Disconnect the spark plug cords from spark plugs. 6) Disconnect the engine coolant hoses from throttle body. FU-00055 11) Disconnect the knock sensor connector. FU-02060 7) Disconnect the PCV hoses from intake manifold. 8) Disconnect the brake booster hose. FU-01334 12) Disconnect the connector from crankshaft position sensor. FU-02089 FU-00056 13) Disconnect the connector from power steering pump switch (A). FU(H4SO 2.0)-11 G2360GE.book 12 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Intake Manifold FUEL INJECTION (FUEL SYSTEM) 14) Disconnect the connector from oil pressure switch (B). • Catch the fuel from hoses using a container or cloth. (A) (A) (B) (C) FU-01087 15) Disconnect the connector from camshaft position sensor. (B) FU-02062 (A) Fuel delivery hose (B) Return hose (C) Evaporation hose 18) Remove the bolts which secure intake manifold to cylinder head. FU-01335 16) Remove the EGR pipe from intake manifold. (EC, EK, K4, ER model) FU-00260 19) Remove the intake manifold. B: INSTALLATION 1) Install the intake manifold onto cylinder heads. NOTE: Use a new gasket. FU-00148 Tightening torque: 25 N⋅m (2.5 kgf-m, 18 ft-lb) 17) Disconnect the fuel hose from fuel pipe. WARNING: • Be careful not to spill fuel. FU-00260 2) Connect the fuel hoses. NOTE: If fuel hoses or clamps are damaged, replace them with new ones. FU(H4SO 2.0)-12 G2360GE.book 13 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Intake Manifold FUEL INJECTION (FUEL SYSTEM) Tightening torque: 1.25 N⋅m (0.13 kgf-m, 0.94 ft-lb) 6) Connect the connector to oil pressure switch (B). (A) (A) (B) (C) FU-01087 (B) FU-02062 (A) Fuel delivery hose (B) Return hose (C) Evaporation hose 7) Connect the connector to crankshaft position sensor. 3) Install the EGR pipe to intake manifold. (EC, EK, K4, ER model) Tightening torque: 34 N⋅m (3.4 kgf-m, 24.6 ft-lb) FU-00056 8) Connect the knock sensor connector. FU-00148 4) Connect the connector to camshaft position sensor. FU-01334 9) Connect the connectors to engine coolant temperature sensor. FU-01335 5) Connect the connector to power steering pump switch (A). FU-00055 10) Connect the PCV hose to intake manifold. FU(H4SO 2.0)-13 G2360GE.book 14 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Intake Manifold FUEL INJECTION (FUEL SYSTEM) C: DISASSEMBLY 11) Connect the brake booster hose. 1) Disconnect the engine ground terminal from intake manifold. FU-02089 12) Connect the engine harness connectors to bulkhead harness connectors. FU-02061 FU-02063 2) Remove the ignition coil and ignitor assembly. 3) Remove the throttle body. 4) Remove the EGR valve. (EC, EK, K4, ER model) 5) Disconnect the pressure regulator vacuum hose from intake manifold. 13) Connect the engine coolant hoses to throttle body. FU-02064 6) Remove the fuel pipe protector LH. FU-02060 14) Connect the spark plug cords to spark plugs. 15) Install the air cleaner case and air intake chamber. 16) Install the fuse of fuel pump to main fuse box. 17) Connect the ground cable to battery. FU-02065 IN-00203 FU(H4SO 2.0)-14 G2360GE.book 15 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Intake Manifold FUEL INJECTION (FUEL SYSTEM) 7) Remove the fuel pipe protector RH. 12) Remove the bolts which install injector pipe on the intake manifold as shown in the figure. • RH Side FU-02066 8) Disconnect the connector from fuel injector. FU-02070 FU-02067 9) Remove the purge control solenoid valve. 10) Remove the harness band (A) and bolts (B), (C) which secure engine harness to intake manifold. (B) FU-02071 • LH Side (A) FU-02072 (A) (A) FU-02068 (C) FU-02073 FU-02069 11) Remove the engine harness from intake manifold. FU(H4SO 2.0)-15 G2360GE.book 16 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Intake Manifold FUEL INJECTION (FUEL SYSTEM) 13) Remove the fuel injectors. (1) Remove the clip which secures fuel injector from injector pipe. 17) Remove the bolt which installs fuel pipes on intake manifold. FU-02077 FU-02074 (2) Remove the fuel injector while lifting up the fuel injector pipe. 14) Loosen the clamp which holds fuel injector pipe LH to fuel hose, and then disconnect the pipe from fuel hose. 18) Remove the fuel pipe assembly and pressure regulator from intake manifold. D: ASSEMBLY NOTE: When assembling the nipple, apply liquid gasket. Liquid gasket: THREE BOND 1105 (Part No. 004403010) Tightening torque: 17 N⋅m (1.7 kgf-m, 12.5 ft-lb) 1) Install the fuel pipe assembly and pressure regulator to intake manifold. 2) Tighten the bolt which installs fuel pipes on intake manifold. FU-02075 15) Loosen the clamp which holds fuel injector pipe RH to fuel hose, and then disconnect the pipe from fuel hose. Tightening torque: 6.4 N⋅m (0.65 kgf-m, 4.7 ft-lb) FU-02077 FU-02076 16) Remove the fuel injector pipe. FU(H4SO 2.0)-16 G2360GE.book 17 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Intake Manifold FUEL INJECTION (FUEL SYSTEM) 3) Connect the fuel injector pipe RH to fuel hose, and tighten the clamp. Tightening torque: 1.25 N⋅m (0.13 kgf-m, 0.94 ft-lb) 7) Tighten the bolts which install injector pipe on intake manifold. • RH Side Tightening torque: 19 N⋅m (1.9 kgf-m, 14 ft-lb) FU-02076 4) Connect the fuel injector pipe LH to fuel hose, and tighten the clamp. Tightening torque: 1.25 N⋅m (0.13 kgf-m, 0.94 ft-lb) FU-02070 Tightening torque: 6.4 N⋅m (0.65 kgf-m, 4.7 ft-lb) FU-02071 FU-02075 5) Install the fuel injectors. 6) Install the clip which secures fuel injector. • LH Side Tightening torque: 19 N⋅m (1.9 kgf-m, 14 ft-lb) FU-02074 FU(H4SO 2.0)-17 FU-02072 G2360GE.book 18 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Intake Manifold FUEL INJECTION (FUEL SYSTEM) 11) Connect the connectors to fuel injector. Tightening torque: 6.4 N⋅m (0.65 kgf-m, 4.7 ft-lb) FU-02067 FU-02073 8) Install the engine harness to intake manifold. 9) Hold the engine harness by harness band (A) and bolts (B), (C). 12) Install the fuel pipe protector RH. Tightening torque: 19 N⋅m (1.9 kgf-m, 14 ft-lb) Tightening torque: (B): 16 N⋅m (0.6 kgf-m, 11.8 ft-lb) (C): 6.4 N⋅m (0.65 kgf-m, 4.7 ft-lb) (B) (A) FU-02066 13) Install the fuel pipe protector LH. (A) (A) FU-02068 Tightening torque: 19 N⋅m (1.9 kgf-m, 14 ft-lb) (C) FU-02065 FU-02069 10) Install the purge control solenoid valve. 14) Connect the pressure regulator vacuum hose to intake manifold. FU-02064 FU(H4SO 2.0)-18 G2360GE.book 19 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Intake Manifold FUEL INJECTION (FUEL SYSTEM) 15) Install the EGR valve. (EC, EK, K4, ER model) 16) Install the throttle body to intake manifold. 17) Install the ignition coil and ignitor assembly. 18) Install the engine ground terminal to intake manifold. Tightening torque: 19 N⋅m (1.9 kgf-m, 14 ft-lb) FU-02063 E: INSPECTION Make sure the fuel pipe and fuel hoses are not damaged and the connections are tightened firmly. FU(H4SO 2.0)-19 G2360GE.book 20 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Engine Coolant Temperature Sensor FUEL INJECTION (FUEL SYSTEM) 4. Engine Coolant Temperature Sensor A: REMOVAL 1) Disconnect the ground cable from battery. IN-00203 2) Remove the generator. 3) Disconnect the connectors from engine coolant temperature sensor. FU-00055 4) Remove the engine coolant temperature sensor. B: INSTALLATION Install in the reverse order of removal. Tightening torque: 18 N⋅m (1.8 kgf-m, 13 ft-lb) FU(H4SO 2.0)-20 G2360GE.book 21 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Crankshaft Position Sensor FUEL INJECTION (FUEL SYSTEM) 5. Crankshaft Position Sensor B: INSTALLATION A: REMOVAL Install in the reverse order of removal. 1) Disconnect the ground cable from battery. Tightening torque: T: 6.4 N⋅m (0.65 kgf-m, 4.7 ft-lb) T IN-00203 2) Remove the bolt which installs crankshaft position sensor to cylinder block. FU-00056 3) Remove the crankshaft position sensor, and disconnect the connector from it. FU-00057 FU(H4SO 2.0)-21 FU-00058 G2360GE.book 22 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Camshaft Position Sensor FUEL INJECTION (FUEL SYSTEM) 6. Camshaft Position Sensor 6) Remove the camshaft position sensor itself. A: REMOVAL 1) Disconnect the ground cable from battery. FU-00179 B: INSTALLATION IN-00203 2) Disconnect the connector from camshaft position sensor. Install in the reverse order of removal. Tightening torque: Camshaft position sensor support 6.4 N⋅m (0.65 kgf-m, 4.7 ft-lb) Camshaft position sensor 6.4 N⋅m (0.65 kgf-m, 4.7 ft-lb) FU-01335 3) Remove the bolt which installs camshaft position sensor to the support. FU-00177 4) Remove the bolt which installs camshaft position sensor support to camshaft cap LH. FU-00178 5) Remove the camshaft position sensor and the support as a unit. FU(H4SO 2.0)-22 G2360GE.book 23 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Knock Sensor FUEL INJECTION (FUEL SYSTEM) 7. Knock Sensor B: INSTALLATION A: REMOVAL 1) Install the knock sensor to cylinder block. 1) Disconnect the ground cable from battery. NOTE: Extraction area of knock sensor cord must be positioned at a 60° angle relative to the engine rear. Tightening torque: 24 N⋅m (2.4 kgf-m, 17.7 ft-lb) (A) IN-00203 2) Remove the air cleaner case. 3) Remove the harness bracket from intake manifold. 60 FU-00413 (A) Front side 2) Connect the knock sensor connector. FU-02078 4) Disconnect the knock sensor connector. FU-01334 3) Install the harness bracket to intake manifold. Tightening torque: 6.4 N⋅m (0.65 kgf-m, 4.7 ft-lb) FU-01334 5) Remove the knock sensor from cylinder block. FU-02078 4) Install the air cleaner case. FU-00519 FU(H4SO 2.0)-23 G2360GE.book 24 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Knock Sensor FUEL INJECTION (FUEL SYSTEM) 5) Connect the ground cable to battery. IN-00203 FU(H4SO 2.0)-24 G2360GE.book 25 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Throttle Position Sensor FUEL INJECTION (FUEL SYSTEM) 8. Throttle Position Sensor A: SPECIFICATION Throttle body is a non-disassembled part, so do not remove the throttle position sensor from throttle body. Refer to “Throttle Body” for removal and installation procedure. FU(H4SO 2.0)-25 G2360GE.book 26 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Manifold Absolute Pressure Sensor FUEL INJECTION (FUEL SYSTEM) 9. Manifold Absolute Pressure Sensor A: REMOVAL 1) Disconnect the ground cable from battery. IN-00203 2) Disconnect the connector from manifold absolute pressure sensor. FU-02079 3) Remove the manifold absolute pressure sensor from throttle body. B: INSTALLATION Install in the reverse order of removal. NOTE: Use a new O-ring. Tightening torque: 2 N⋅m (0.2 kgf-m, 1.5 ft-lb) FU(H4SO 2.0)-26 G2360GE.book 27 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Intake Air Temperature Sensor FUEL INJECTION (FUEL SYSTEM) 10.Intake Air Temperature Sensor A: REMOVAL 1) Disconnect the ground cable from battery. IN-00203 2) Disconnect the connector from intake air temperature sensor. 3) Remove the intake air temperature sensor. FU-02080 B: INSTALLATION Install in the reverse order of removal. FU(H4SO 2.0)-27 G2360GE.book 28 ページ ２００７年１１月２９日 木曜日 午後１時２８分 EGR Valve FUEL INJECTION (FUEL SYSTEM) 11.EGR Valve A: REMOVAL NOTE: EGR valve is equipped to EC, EK, K4 and ER model. 1) Disconnect the ground cable from battery. IN-00203 2) Disconnect the connector from EGR valve. 3) Remove the EGR valve from intake manifold. FU-02082 B: INSTALLATION Install in the reverse order of removal. NOTE: Use a new gasket. Tightening torque: 19 N⋅m (1.9 kgf-m, 14 ft-lb) FU(H4SO 2.0)-28 G2360GE.book 29 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Fuel Injector FUEL INJECTION (FUEL SYSTEM) 12.Fuel Injector 8) Remove the clip which secure fuel injector. A: REMOVAL 1. RH SIDE 1) Release the fuel pressure. 2) Open fuel filler flap lid, and remove fuel filler cap. 3) Disconnect the ground cable from battery. FU-02074 9) Remove the bolts which hold fuel injector pipe to intake manifold. IN-00203 4) Remove the air cleaner case. 5) Remove the spark plug cords from spark plugs (#1 and #3 cylinders). 6) Remove the fuel pipe protector RH. FU-02070 FU-02071 FU-02066 7) Disconnect the connector from fuel injector. 10) Remove the fuel injector while lifting up the fuel injector pipe. 2. LH SIDE 1) Release the fuel pressure. 2) Open fuel filler flap lid, and remove fuel filler cap. 3) Remove the battery. 4) Remove the spark plug cords from spark plugs (#2 and #4 cylinders). FU-02067 FU(H4SO 2.0)-29 G2360GE.book 30 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Fuel Injector FUEL INJECTION (FUEL SYSTEM) 8) Remove the bolts which hold fuel injector pipe to intake manifold. 5) Remove the fuel pipe protector LH. FU-02065 6) Disconnect the connector from fuel injector. FU-02072 FU-02067 FU-02073 7) Remove the clip which secure fuel injector. 9) Remove the fuel injector while lifting up the fuel injector pipe. B: INSTALLATION 1. RH SIDE Install in the reverse order of removal. NOTE: Use a new O-ring. FU-02074 Tightening torque: 19 N⋅m (1.9 kgf-m, 14 ft-lb) FU-02070 FU(H4SO 2.0)-30 G2360GE.book 31 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Fuel Injector FUEL INJECTION (FUEL SYSTEM) Tightening torque: 6.4 N⋅m (0.65 kgf-m, 4.7 ft-lb) Tightening torque: 19 N⋅m (1.9 kgf-m, 14 ft-lb) FU-02071 Tightening torque: 19 N⋅m (1.9 kgf-m, 14 ft-lb) FU-02072 Tightening torque: 19 N⋅m (1.9 kgf-m, 14 ft-lb) FU-02066 2. LH SIDE Install in the reverse order of removal. NOTE: Use a new O-ring. Tightening torque: 6.4 N⋅m (0.65 kgf-m, 4.7 ft-lb) FU-02073 FU(H4SO 2.0)-31 FU-02065 G2360GE.book 32 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Front Oxygen (A/F) Sensor FUEL INJECTION (FUEL SYSTEM) 13.Front Oxygen (A/F) Sensor B: INSTALLATION A: REMOVAL 1) Before installing front oxygen (A/F) sensor, apply anti-seize compound only to the threaded portion of front oxygen (A/F) sensor to make the next removal easier. 1) Disconnect the ground cable from battery. Anti-seize compound: SS-30 JET LUBE CAUTION: Never apply anti-seize compound to the protector of front oxygen (A/F) sensor. 2) Install the front oxygen (A/F) sensor. IN-00203 Tightening torque: 21 N⋅m (2.1 kgf-m, 15.2 ft-lb) 2) Remove the air intake duct. 3) Remove the connector of front oxygen (A/F) sensor. FU-01114 ME-00859 4) Remove the clip which holds harness. 5) Lift-up the vehicle. 6) Remove the under cover. 7) Apply spray-type lubricant to the threaded portion of front oxygen (A/F) sensor, and leave it for one minute or more. 8) Remove the front oxygen (A/F) sensor. 3) Install the under cover. 4) Lower the vehicle. 5) Hold the harness with clip. 6) Connect the connector of front oxygen (A/F) sensor. CAUTION: When removing the front oxygen (A/F) sensor, wait until exhaust pipe cools, otherwise it will damage the exhaust pipe. ME-00859 7) Install the air intake duct. 8) Connect the ground cable to battery. FU-01114 IN-00203 FU(H4SO 2.0)-32 G2360GE.book 33 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Rear Oxygen Sensor FUEL INJECTION (FUEL SYSTEM) 14.Rear Oxygen Sensor B: INSTALLATION A: REMOVAL 1) Before installing the rear oxygen sensor, apply anti-seize compound only to the threaded portion of the rear oxygen sensor to make the next removal easier. 1) Disconnect the ground cable from battery. Anti-seize compound: SS-30 JET LUBE CAUTION: Never apply anti-seize compound to the protector of rear oxygen sensor. 2) Install the rear oxygen sensor. IN-00203 Tightening torque: 21 N⋅m (2.1 kgf-m, 15.2 ft-lb) 2) Lift-up the vehicle. 3) Disconnect the connector from rear oxygen sensor. FU-01117 3) Hold the harness with clip. 4) Connect the connector to rear oxygen sensor. FU-01116 4) Remove the clip which holds harness. 5) Apply spray-type lubricant to the threaded portion of rear oxygen sensor, and leave it for one minute or more. 6) Remove the rear oxygen sensor. CAUTION: When removing the rear oxygen sensor, wait until exhaust pipe cools, otherwise it will damage the exhaust pipe. FU-01116 5) Lower the vehicle. 6) Connect the ground cable to battery. FU-01117 IN-00203 FU(H4SO 2.0)-33 G2360GE.book 34 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Engine Control Module (ECM) FUEL INJECTION (FUEL SYSTEM) 15.Engine Control Module (ECM) B: INSTALLATION A: REMOVAL Install in the reverse order of removal. 1) Disconnect the ground cable from battery. CAUTION: • When replacing the ECM, be careful not to use the wrong spec. ECM to avoid any damage to fuel injection system. • When replacing the ECM, be careful not to damage the harnesses and connectors. Tightening torque: 5 N⋅m (0.5 kgf-m, 3.7 ft-lb) IN-00203 2) Remove the lower inner trim of passenger’s side. 3) Detach the floor mat of passenger’s seat. 4) Remove the protect cover. FU-02090 5) Remove the bolt and nut which hold the ECM to bracket. 6) Remove the clip (A) from bracket. (A) FU-02488 7) Disconnect the ECM connectors and take out the ECM. FU(H4SO 2.0)-34 G2360GE.book 35 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Main Relay FUEL INJECTION (FUEL SYSTEM) 16.Main Relay A: REMOVAL 1) Disconnect the ground cable from battery. IN-00203 2) Remove the glove box. 3) Remove the harness cover (A). (A) FU-02092 4) Disconnect the connector from main relay. FU-02093 B: INSTALLATION Install in the reverse order of removal. FU(H4SO 2.0)-35 G2360GE.book 36 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Fuel Pump Relay FUEL INJECTION (FUEL SYSTEM) 17.Fuel Pump Relay A: REMOVAL 1) Disconnect the ground cable from battery. IN-00203 2) Remove the glove box. 3) Remove the harness cover (A). (A) FU-02092 4) Disconnect the connector from fuel pump relay. FU-02094 B: INSTALLATION Install in the reverse order of removal. FU(H4SO 2.0)-36 G2360GE.book 37 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Electronic Throttle Control Relay FUEL INJECTION (FUEL SYSTEM) 18.Electronic Throttle Control Relay A: REMOVAL 1) Disconnect the ground cable from battery. IN-00203 2) Remove the glove box. 3) Remove the harness cover (A). (A) FU-02092 4) Disconnect the connector from electronic throttle control relay. FU-02095 B: INSTALLATION Install in the reverse order of removal. FU(H4SO 2.0)-37 G2360GE.book 38 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Fuel FUEL INJECTION (FUEL SYSTEM) 19.Fuel 6) Set a container under the vehicle and remove the drain plug from fuel tank to drain fuel from the fuel tank. A: PROCEDURE 1. RELEASING OF FUEL PRESSURE WARNING: • Place “NO FIRE” signs near the working area. • Be careful not to spill fuel on the floor. 1) Remove the fuse of fuel pump from main fuse box. FU-01123 7) Tighten the fuel drain plug. NOTE: Use a new gasket. FU-01122 2) Start the engine and run until it stalls. 3) After the engine stalls, crank it for five more seconds. 4) Turn the ignition switch to OFF. 2. DRAINING FUEL WARNING: • Place “NO FIRE” signs near the working area. • Be careful not to spill fuel on the floor. 1) Lift-up the vehicle. 2) Disconnect the ground cable from battery. Tightening torque: 26 N⋅m (2.65 kgf-m, 19.2 ft-lb) 8) Install the fuel tank protector. NOTE: Use a new nut. Tightening torque: Nut 9 N⋅m (0.9 kgf-m, 6.6 ft-lb) Bolt 17.5 N⋅m (1.78 kgf-m, 12.9 ft-lb) IN-00203 3) Open fuel filler flap lid, and remove fuel filler cap. 4) Lift-up the vehicle. 5) Remove the fuel tank protector. FU(H4SO 2.0)-38 G2360GE.book 39 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Fuel Tank FUEL INJECTION (FUEL SYSTEM) 20.Fuel Tank A: REMOVAL WARNING: • Place “NO FIRE” signs near the working area. • Be careful not to spill fuel on the floor. 1) Lift-up the vehicle. 2) Release the fuel pressure. 3) Drain fuel from fuel tank. 4) Remove the rear seat. 5) Remove the service hole cover of fuel pump. (1) Remove the bolts (A). (2) Push the grommet (B) down and remove service hole cover. (A) 7) Remove the service hole cover of fuel sub level sensor. (1) Remove the bolts (A). (2) Push the grommet (B) down and remove service hole cover. (A) (A) (B) FU-01126 8) Disconnect the connector (A) from fuel sub level sensor. 9) Disconnect the quick connector of the fuel delivery (B) and return hose (C). (A) (A) (C) (B) FU-01124 6) Disconnect the connector from fuel pump. (B) FU-01127 10) Lift-up the vehicle. 11) Remove the rear wheels. 12) Remove the bolts which secure the rear brake hose installation bracket. FU-01125 FU-01128 FU(H4SO 2.0)-39 G2360GE.book 40 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Fuel Tank FUEL INJECTION (FUEL SYSTEM) 13) Remove the rear brake caliper and tie it to the vehicle body side. 19) Remove the bolts which install the parking brake cable clamp. FU-00462 FU-01130 14) Remove the parking brake cable from parking brake assembly. 15) Remove the rear exhaust pipe. 16) Remove the propeller shaft. 17) Remove the heat shield cover. 18) Disconnect the connector from rear ABS wheel speed sensor. FU-01131 20) Remove the rear suspension assembly. CAUTION: A helper is required to perform this work. (1) Support the rear differential with transmission jack. (2) Remove the bolt which installs the rear shock absorber to rear suspension arm. FU-01129 FU-01132 FU(H4SO 2.0)-40 G2360GE.book 41 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Fuel Tank FUEL INJECTION (FUEL SYSTEM) (3) Remove the bolts which secure the rear suspension assembly to body. CAUTION: A helper is required to perform this work. FU-01133 FU-01137 B: INSTALLATION 1) Support the fuel tank with transmission jack, set the fuel tank, and then temporarily tighten the bolts of fuel tank band. CAUTION: A helper is required to perform this work. FU-01134 (4) Remove the rear suspension assembly. 21) Disconnect the two-way valve hose (A) from two-way valve, and then remove the two-way valve from bracket. FU-01137 (A) FU-01135 22) Loosen the clamp and disconnect the fuel filler hose (A) and vent hose (B) from fuel filler pipe. (A) (B) FU-01136 23) Support the fuel tank with transmission jack, remove the bolts from fuel tank bands, and dismount the fuel tank from vehicle. FU(H4SO 2.0)-41 G2360GE.book 42 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Fuel Tank FUEL INJECTION (FUEL SYSTEM) 2) Correctly insert the fuel filler hose (A) and vent hose (B) to specified position, and then tighten the clamp. Tightening torque: T1: 125 N⋅m (12.7 kgf-m, 92.2 ft-lb) T2: 65 N⋅m (6.6 kgf-m, 48 ft-lb) T3: 175 N⋅m (17.8 kgf-m, 129 ft-lb) (A) T1 T1 (B) T1 T1 FU-01136 FU-01150 (2) (1) (3) L/2 T3 L T2 T2 T3 FU-00104 FU-01138 (1) Hose (2) Clip or clamp (3) Pipe (3) Tighten the bolts which install the rear shock absorber to rear suspension arm. 3) Install the two-way valve to bracket, and connect the two-way valve hose (A) to two-way valve. Tightening torque: 62 N⋅m (6.3 kgf-m, 46 ft-lb) (A) FU-01135 FU-01132 4) Tighten the bolts of fuel tank band. Tightening torque: 33 N⋅m (3.4 kgf-m, 24.3 ft-lb) 5) Install the rear suspension assembly. CAUTION: A helper is required to perform this work. (1) Support the rear differential with transmission jack. (2) Support the rear suspension assembly, and then tighten the bolts which secure the rear suspension assembly to body. FU(H4SO 2.0)-42 G2360GE.book 43 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Fuel Tank FUEL INJECTION (FUEL SYSTEM) 6) Tighten the bolts which install the parking brake cable clamp. Tightening torque: 33 N⋅m (3.4 kgf-m, 24.3 ft-lb) Tightening torque: 18 N⋅m (1.8 kgf-m, 13 ft-lb) FU-01128 FU-01130 Tightening torque: 32 N⋅m (3.3 kgf-m, 23.9 ft-lb) 15) Install the rear wheels. 16) Lower the vehicle. 17) Connect the connector (A) to fuel sub level sensor. 18) Connect the quick connector to the fuel delivery (B) and return hose (C). NOTE: Be careful not to misconnect the delivery side and return side. FU-01131 (A) 7) Connect the connector to rear ABS wheel speed sensor. (C) (B) FU-01127 19) Install the service hole cover of fuel sub level sensor. (A) FU-01129 8) Install the heat shield cover. 9) Install the propeller shaft. 10) Install the rear exhaust pipe. 11) Lower the vehicle. 12) Connect the parking brake cable to parking brake assembly. 13) Install the rear brake caliper. 14) Tighten the bolt which secures rear brake hose installation bracket. (A) (B) (A) Bolt (B) Grommet FU(H4SO 2.0)-43 FU-01126 G2360GE.book 44 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Fuel Tank FUEL INJECTION (FUEL SYSTEM) 20) Connect the connector to fuel pump. FU-01125 21) Install the service hole cover of fuel pump. (A) (A) (B) FU-01124 (A) Bolt (B) Grommet 22) Install the rear seat. 23) Install the fuse of fuel pump to main fuse box. C: INSPECTION 1) Check that the fuel tank is not holed, cracked or otherwise damaged. 2) Make sure that the fuel pipe and fuel hose are not cracked and those connections are tight. FU(H4SO 2.0)-44 G2360GE.book 45 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Fuel Filler Pipe FUEL INJECTION (FUEL SYSTEM) 21.Fuel Filler Pipe 6) Set a container under the vehicle and remove the drain plug from fuel tank to drain fuel from the fuel tank. A: REMOVAL WARNING: • Place “NO FIRE” signs near the working area. • Be careful not to spill fuel on the floor. 1) Disconnect the ground cable from battery. FU-01123 7) Tighten the fuel drain plug. NOTE: Use a new gasket. IN-00203 2) Open the fuel filler flap lid, and remove the filler cap. 3) Remove the screws which secure the packing. Tightening torque: 26 N⋅m (2.65 kgf-m, 19.2 ft-lb) 8) Remove the mud guard. 9) Remove the rear sub frame. 10) Remove the bolts which hold the fuel filler pipe bracket on the body. FU-00095 4) Lift-up the vehicle. 5) Remove the rear wheel RH. FU-01139 11) Loosen the clamp and disconnect the fuel filler hose (A) and vent hose (B) from fuel filler pipe. (A) (B) FU-00096 FU-01136 12) Remove the fuel filler pipe to under side of the vehicle. FU(H4SO 2.0)-45 G2360GE.book 46 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Fuel Filler Pipe FUEL INJECTION (FUEL SYSTEM) B: INSTALLATION 1) Open the fuel filler flap lid. 2) Set the fuel saucer (A) with rubber packing (C) and insert the fuel filler pipe into hole from the inner side of apron. 3) Align the holes in fuel filler pipe neck and set the cup (B), and tighten the screws. 5) Tighten the bolts which hold the fuel filler pipe bracket on the body. Tightening torque: 7.5 N⋅m (0.76 kgf-m, 5.5 ft-lb) NOTE: If the edges of rubber packing are folded toward inside, straighten it with a flat tip screwdriver. (A) FU-01139 6) Install the rear sub frame. 7) Install the mud guard. 8) Install the rear wheel RH. (B) (C) FU-00103 4) Correctly insert the fuel filler hose (A) and vent hose (B) to specified position, and then tighten the clamp. (A) (B) FU-00096 9) Lower the vehicle. 10) Connect the ground cable to battery. FU-01136 (2) (1) (3) L/2 IN-00203 L FU-00104 (1) Hose (2) Clip or clamp (3) Pipe FU(H4SO 2.0)-46 G2360GE.book 47 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Fuel Pump FUEL INJECTION (FUEL SYSTEM) 22.Fuel Pump 7) Remove the nuts which install the fuel pump assembly to fuel tank. A: REMOVAL WARNING: • Place “NO FIRE” signs near the working area. • Be careful not to spill fuel on the floor. • Reduce the fuel in the fuel tank to less than 3/ 4 beforehand. Be careful that fuel may spill when the fuel is more than 3/4. NOTE: Fuel pump assembly consists of fuel pump and fuel level sensor. 1) Release the fuel pressure. 2) Drain fuel. 3) Remove the rear seat. 4) Remove the service hole cover. (1) Remove the bolts (A). (2) Push the grommet (B) down and remove service hole cover. (A) (B) (C) (A) FU-01140 (A) Delivery hose (B) Return hose (C) Jet pump hose 8) Remove the fuel pump assembly from fuel tank. B: INSTALLATION Install in the reverse order of removal. NOTE: Use a new gasket. (1) Ensure the sealing portion is free from fuel or foreign particles before installation. (2) Tighten the nuts to specified torque in the order as shown in the figure. Tightening torque: 4.4 N⋅m (0.45 kgf-m, 3.2 ft-lb) (A) 1 (B) 4 FU-01124 8 5) Disconnect the connector from fuel pump. 5 6 3 7 2 FU-01141 FU-01125 6) Disconnect the quick connector and then disconnect the fuel delivery hose, return hose and jet pump hose. FU(H4SO 2.0)-47 G2360GE.book 48 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Fuel Pump FUEL INJECTION (FUEL SYSTEM) C: INSPECTION Connect the lead harness to the connector terminal of fuel pump and apply the battery power supply to check whether the pump operates. WARNING: • Wipe off the fuel completely. • Keep battery as far apart from fuel pump as possible. • Be sure to turn the battery supply ON and OFF on battery side. • Do not run fuel pump for a long time under non-load condition. 2 1 4 3 6 5 FU-01330 FU(H4SO 2.0)-48 G2360GE.book 49 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Fuel Level Sensor FUEL INJECTION (FUEL SYSTEM) 23.Fuel Level Sensor A: REMOVAL WARNING: • Place “NO FIRE” signs near the working area. • Be careful not to spill fuel on the floor. • Reduce the fuel in the fuel tank to less than 3/ 4 beforehand. Be careful that fuel may spill when the fuel is more than 3/4. NOTE: Fuel level sensor is built in fuel pump assembly. 1) Remove the fuel pump assembly. 2) Disconnect the connector from fuel pump bracket. FU-01142 3) Remove the fuel level sensor. B: INSTALLATION Install in the reverse order of removal. FU(H4SO 2.0)-49 G2360GE.book 50 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Fuel Sub Level Sensor FUEL INJECTION (FUEL SYSTEM) 24.Fuel Sub Level Sensor 6) Remove the nuts and bolts which install the fuel sub level sensor on fuel tank. A: REMOVAL WARNING: • Place “NO FIRE” signs near the working area. • Be careful not to spill fuel on the floor. • Reduce the fuel in the fuel tank to less than 3/ 4 beforehand. Be careful that fuel may spill when the fuel is more than 3/4. 1) Drain fuel. 2) Remove the rear seat. 3) Remove the service hole cover. (1) Remove the bolts (A). (2) Push the grommet (B) down and remove the service hole cover. (C) (A) (B) FU-01144 (A) Jet pump hose (B) Delivery hose (C) Return hose 7) Remove the fuel sub level sensor. B: INSTALLATION (A) Install in the reverse order of removal. (A) (B) FU-01126 4) Disconnect the connector from fuel sub level sensor. NOTE: Use a new gasket. (1) Ensure the sealing portion is free from fuel or foreign particles before installation. (2) Tighten the nuts and bolts to specified torque in the order as shown in the figure. Tightening torque: 4.4 N⋅m (0.45 kgf-m, 3.2 ft-lb) 3 1 5 6 2 4 FU-01143 FU-01145 5) Disconnect the quick connector and then disconnect the fuel delivery hose, return hose and jet pump hose. FU-01146 FU(H4SO 2.0)-50 G2360GE.book 51 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Fuel Filter FUEL INJECTION (FUEL SYSTEM) 25.Fuel Filter A: SPECIFICATION Fuel filter forms a single unit with fuel pump. Refer to Fuel Pump for removal and installation procedures. FU(H4SO 2.0)-51 G2360GE.book 52 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Fuel Damper Valve FUEL INJECTION (FUEL SYSTEM) 26.Fuel Damper Valve A: REMOVAL 1. DELIVERY SIDE 1) Release the fuel pressure. 2) Remove the fuel damper valve from fuel delivery line. FU-01147 2. RETURN SIDE Fuel damper valve forms a unit with fuel injector pipe RH. Refer to “Intake Manifold” for removal. B: INSTALLATION 1. DELIVERY SIDE Install in the reverse order of removal. Tightening torque: 1.25 N⋅m (0.13 kgf-m, 0.94 ft-lb) 2. RETURN SIDE Fuel damper valve forms a unit with fuel injector pipe RH. Refer to “Intake Manifold” for installation. FU(H4SO 2.0)-52 G2360GE.book 53 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Fuel Delivery, Return and Evaporation Lines FUEL INJECTION (FUEL SYSTEM) 27.Fuel Delivery, Return and Evaporation Lines A: REMOVAL 1) Lift-up the vehicle. 2) Release the fuel pressure. 3) Open fuel filler flap lid, and remove fuel filler cap. 4) Remove the floor mat. 5) Disconnect the fuel delivery pipes and hoses, and then disconnect the fuel return pipes and hoses, evaporation pipes and hoses. FU-01148 6) In the engine compartment, disconnect the fuel delivery hoses, return hoses, and evaporation hose. (A) 8) Remove the fuel tank. 9) Separate the quick connector on fuel line. (1) Clean the pipe and connector, if they are covered with dust. (2) To prevent from damaging or entering foreign matter, wrap the pipes and connectors with plastic bag, etc. (C) (B) FU-02062 (A) Fuel delivery hose (B) Return hose (C) Evaporation hose FU-01333 7) Lift-up the vehicle. FU(H4SO 2.0)-53 G2360GE.book 54 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Fuel Delivery, Return and Evaporation Lines FUEL INJECTION (FUEL SYSTEM) (3) Hold the connector (A) and push retainer (B) down. (4) Pull out the connector (A) from retainer (B). (1) Set the new retainer (B) to connector (A). (2) Push the pipe into the connector completely. (A) CAUTION: Replace new retainer. (B) (C) (B) (C) (A) FU-00124 (A) Connector (B) Retainer (C) Pipe B: INSTALLATION 1) Connect the quick connector of fuel line. CAUTION: • Replace new retainer. • Make sure that the connected portion is not damaged or has dust. If necessary, clean the seal surface of pipe. FU-00126 (A) Connector (B) Retainer (C) Pipe CAUTION: • Pull the connector to ensure it is connected securely. • Ensure the two retainer pawls are engaged in their mating positions in the connector. • Be sure to inspect the hoses and their connections for fuel leakage. (A) (A) (B) (B) FU-00125 (A) Seal surface (B) Pipe (C) FU-00127 (A) Connector (B) Retainer (C) Pipe 2) Connect the fuel delivery hose and fuel return hose to the pipe with an overlap of 20 to 25 mm (0.79 to 0.98 in). Type A: When the amount to be inserted is specified. Type B: When the amount to be inserted is not specified. 2: 2.5±1.5 mm (0.098±0.059 in) L: 22.5±2.5 mm (0.886±0.098 in) FU(H4SO 2.0)-54 G2360GE.book 55 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Fuel Delivery, Return and Evaporation Lines FUEL INJECTION (FUEL SYSTEM) CAUTION: Be sure to inspect the hoses and their connections for fuel leakage. (3) (4) (5) (1) L (2) FU-00128 (1) (2) (3) (4) (5) Type A Type B Pipe Clamp Hose 3) Connect the evaporation hose to the pipe with an overlap of 15 to 20 mm (0.59 to 0.79 in). L = 17.5±2.5 mm (0.689±0.098 in) (2) (1) (3) L/2 L FU-00129 (1) Hose (2) Clip (3) Pipe C: INSPECTION 1) Make sure that there are no cracks on the fuel pipes and fuel hoses. 2) Make sure the fuel pipe and fuel hose connections are tightened firmly. FU(H4SO 2.0)-55 G2360GE.book 56 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Fuel System Trouble in General FUEL INJECTION (FUEL SYSTEM) 28.Fuel System Trouble in General A: INSPECTION Trouble and possible cause 1. Insufficient fuel supply to injector 1) Fuel pump does not operate. ❍ Corrective action Defective terminal contact ❍ Trouble in electromagnetic or electronic circuit parts 2) Decline of fuel pump function 3) Clogged dust or water in the fuel filter 4) Clogged or bent fuel pipe or hose 5) Air mixed in the fuel system 6) Clogged or bent air breather tube or pipe 7) Damaged diaphragm of pressure regulator 2. Leakage or blow out fuel 1) Loosened joints of the fuel pipe 2) Cracked fuel pipe, hose, and fuel tank 3) Defective welding part on the fuel tank 4) Defective drain packing of the fuel tank 5) Clogged or bent air breather tube or air vent tube 3. Gasoline smell inside of compartment Loose joints at air breather tube, air vent tube, and fuel filler 1) pipe 2) Defective packing air tightness on the fuel saucer 3) Defective fuel pump modulator or circuit 4. Defective fuel meter indicator 1) Defective operation of fuel level sensor 2) Defective operation of fuel meter 5. Noise 1) Large operation noise or vibration of fuel pump Inspect contact, especially ground, and tighten it securely. Replace the faulty parts. Replace the fuel pump. Replace fuel filter, clean or replace fuel tank. Clean, correct or replace the fuel pipe or hose. Inspect or retighten each connection part. Clean, correct or replace air breather tube or pipe. Replace. Retighten. Replace. Replace. Replace. Clean, correct or replace air breather tube or air vent tube. Retighten. Correct or replace the packing. Replace. Replace. Replace. Replace. NOTE: • When the vehicle is left unused for an extended period of time, water may accumulate in the fuel tank. Fill fuel fully to prevent those problem. And also drain the water condensation from fuel filter. • In snow-covered areas, mountainous areas, skiing areas, etc. where ambient temperatures drop below 0°C (32°F) throughout the winter season, use water removing agent in the fuel system to prevent freezing fuel system and accumulating water. Fill the water removing agent each time the fuel is reduced to half to maintain the advantage. • When water condensation is noticed in the fuel filter, drain the water from both the fuel filter and fuel tank or use water removing agent in the fuel tank. • Before using water removing agent, follow the cautions noted on the bottle. FU(H4SO 2.0)-56 G2360GE.book 1 ページ ２００７年１１月２９日 木曜日 午後１時２８分 EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) EC(H4SO 2.0) 1. 2. 3. 4. 5. 6. 7. 8. Page General Description ....................................................................................2 Front Catalytic Converter ............................................................................3 Rear Catalytic Converter.............................................................................4 EGR Valve ..................................................................................................5 Canister.......................................................................................................6 Purge Control Solenoid Valve .....................................................................7 Two-way Valve............................................................................................9 PCV Valve.................................................................................................10 G2360GE.book 2 ページ ２００７年１１月２９日 木曜日 午後１時２８分 General Description EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 1. General Description A: CAUTION • Wear work clothing, including a cap, protective goggles, and protective shoes during operation. • Remove contamination including dirt and corrosion before removal, installation or disassembly. • Keep the disassembled parts in order and protect them from dust and dirt. • Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. • Be careful not to burn yourself, because each part on the vehicle is hot after running. • Be sure to tighten fasteners including bolts and nuts to specified torque. • Place shop jacks or rigid racks at the specified points. • Before disconnecting electrical connectors of sensors or units, be sure to disconnect the ground cable from battery. EC(H4SO 2.0)-2 G2360GE.book 3 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Front Catalytic Converter EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 2. Front Catalytic Converter A: REMOVAL The front and rear catalytic converters are integrated into center exhaust pipe as one unit; therefore, refer to “Center Exhaust Pipe” for removal procedure. B: INSTALLATION The front and rear catalytic converters are integrated into center exhaust pipe as one unit; therefore, refer to “Center Exhaust Pipe” for installation procedure. C: INSPECTION 1) Check the connections and welds for exhaust leaks. 2) Make sure there are no holes or rusting. EC(H4SO 2.0)-3 G2360GE.book 4 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Rear Catalytic Converter EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 3. Rear Catalytic Converter A: REMOVAL The front and rear catalytic converters are integrated into center exhaust pipe as one unit; therefore, refer to “Center Exhaust Pipe” for removal procedure. B: INSTALLATION The front and rear catalytic converters are integrated into center exhaust pipe as one unit; therefore, refer to “Center Exhaust Pipe” for installation procedure. C: INSPECTION 1) Check the connections and welds for exhaust leaks. 2) Make sure there are no holes or rusting. EC(H4SO 2.0)-4 G2360GE.book 5 ページ ２００７年１１月２９日 木曜日 午後１時２８分 EGR Valve EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 4. EGR Valve A: SPECIFICATION Refer to “EGR valve” for removal and installation procedure. or EC(H4SO 2.0)-5 G2360GE.book 6 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Canister EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 5. Canister Tightening torque: 8.3 N⋅m (0.85 kgf-m, 6.1 ft-lb) A: REMOVAL 1) Lift-up the vehicle. 2) Remove the rear wheel LH. 3) Remove the rear mud guard LH. 4) Remove the protector. (Sedan model) 5) Disconnect the quick connector (A). 6) Remove the canister (B) from body. (B) (B) (A) (A) (B) (B) EC-02027 C: INSPECTION Make sure the canister and canister hoses are not cracked or loose. EC-02027 B: INSTALLATION Install in the reverse order of removal. NOTE: Make sure there are no damage or dust on the connection of quick connector. If necessary, clean the seal surface of pipe. EC(H4SO 2.0)-6 G2360GE.book 7 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Purge Control Solenoid Valve EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 6. Purge Control Solenoid Valve B: INSTALLATION A: REMOVAL Install in the reverse order of removal. 1) Disconnect the ground cable from battery. Tightening torque: 19 N⋅m (1.9 kgf-m, 14 ft-lb) • 2.0 L model IN-00203 2) Disconnect the connector and hoses of purge control solenoid valve, and then remove the purge control solenoid valve. • 2.0 L model EC-02015 • 2.5 L model EC-00223 EC-02015 • 2.5 L model NOTE: Connect the evaporation hose as shown in the following figure. • 2.0 L model (B) EC-00223 (A) EC-02016 (A) To fuel pipe (Evaporation line) (B) To intake manifold EC(H4SO 2.0)-7 G2360GE.book 8 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Purge Control Solenoid Valve EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) • 2.5 L model (B) (A) EC-00224 (A) To fuel pipe (Evaporation line) (B) To intake manifold C: INSPECTION Make sure that the hoses are not cracked or loose. EC(H4SO 2.0)-8 G2360GE.book 9 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Two-way Valve EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 7. Two-way Valve A: REMOVAL 1) Lift-up the vehicle. 2) Disconnect the evaporation hoses from two-way valve. 3) Remove the two-way valve as a unit with bracket from body. EC-00221 4) Remove the two-way valve from bracket. B: INSTALLATION Install in the reverse order of removal. Tightening torque: 7.5 N⋅m (0.76 kgf-m, 5.5 ft-lb) C: INSPECTION Make sure that the hoses are not cracked or loose. EC(H4SO 2.0)-9 G2360GE.book 10 ページ ２００７年１１月２９日 木曜日 午後１時２８分 PCV Valve EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 8. PCV Valve A: REMOVAL Disconnect the PCV hose and remove the PCV valve. • 2.0 L model EC-02029 • 2.5 L EC, EK, EH, ER, K4 model EC-00225 • 2.5 L KA, KS model EC-00228 B: INSTALLATION Install in the reverse order of removal. NOTE: Apply liquid gasket to the bolt threads of PCV valve. (2.0 L model and 2.5 L KA, KS model) Liquid gasket: THREE BOND 1105 (Part No. 004403010) Tightening torque: 23 N⋅m (2.3 kgf-m, 17 ft-lb) EC(H4SO 2.0)-10 G2360GE.book 1 ページ ２００７年１１月２９日 木曜日 午後１時２８分 INTAKE (INDUCTION) IN(H4SO 2.0) 1. 2. 3. 4. 5. 6. Page General Description ....................................................................................2 Air Cleaner Element ....................................................................................4 Air Cleaner Case.........................................................................................5 Air Intake Chamber .....................................................................................7 Air Intake Duct.............................................................................................8 Resonator Chamber....................................................................................9 G2360GE.book 2 ページ ２００７年１１月２９日 木曜日 午後１時２８分 General Description INTAKE (INDUCTION) 1. General Description A: COMPONENT T2 (15) (14) (14) (13) (11) T2 (13) (12) (10) T4 (22) T4 (16) (23) (19) T3 (18) T3 T4 T3 (17) T6 (9) (9) (21) (8) (7) T5 (4) (20) (3) T1 (2) (6) (6) (1) (5) (5) IN-02004 IN(H4SO 2.0)-2 G2360GE.book 3 ページ ２００７年１１月２９日 木曜日 午後１時２８分 General Description INTAKE (INDUCTION) (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) Air intake duct Clip Resonator chamber Air cleaner case (front) Spacer Cushion Air cleaner element Air cleaner case (rear) Clip Clamp Intake duct Clamp Cushion (14) (15) (16) (17) (18) (19) (20) (21) Spacer Air intake chamber Stay LH (MT model) Stay LH (AT model) Clamp Stay RH Cushion Mass air flow and intake air temperature sensor (2.5 L EC, EK, K4, EH, ER model) (22) Bushing (2.0 L model and 2.5 L KA, KS model) B: CAUTION • Wear work clothing, including a cap, protective goggles, and protective shoes during operation. • Remove contamination including dirt and corrosion before removal, installation or disassembly. • Keep the disassembled parts in order and protect them from dust and dirt. • Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. • Be careful not to burn yourself, because each part on the vehicle is hot after running. • Be sure to tighten fasteners including bolts and nuts to the specified torque. • Place shop jacks or rigid racks at the specified points. • Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from battery. IN(H4SO 2.0)-3 (23) Intake air temperature sensor (2.0 L model and 2.5 L KA, KS model) Tightening torque: N⋅m (kgf-m, ft-lb) T1: 6 (0.6, 4.4) T2: 6.5 (0.66, 4.8) T3: 16 (1.6, 11.8) T4: 3 (0.3, 2.2) T5: 7.5 (0.76, 5.5) T6: 1 (0.1, 0.7) G2360GE.book 4 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Air Cleaner Element INTAKE (INDUCTION) 2. Air Cleaner Element B: INSTALLATION A: REMOVAL Install in the reverse order of removal. 1) Disconnect the ground cable from battery. NOTE: Fasten with a clip after inserting the lower tab of the case. IN-00203 2) Disconnect the connector from mass air flow and intake air temperature sensor. (2.5 L EC, EK, K4, EH, ER model) IN-00207 C: INSPECTION Replace if excessively damaged or dirty. IN-00204 3) Remove the clip (A) securing upper side of air cleaner case. (A) IN-00254 4) Pull the air cleaner case (rear) backward of the vehicle, and remove the air cleaner element. NOTE: Be careful that the power steering hose is secured to the under side of air cleaner case (rear). IN(H4SO 2.0)-4 G2360GE.book 5 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Air Cleaner Case INTAKE (INDUCTION) 3. Air Cleaner Case 6) Remove the air cleaner case (rear) and air cleaner element. A: REMOVAL 1) Disconnect the ground cable from battery. IN-00206 IN-00203 7) Remove the bolts (A) and nut (B) which secure air cleaner case to body. 2) Remove the air intake duct. 3) Disconnect the connector from mass air flow and intake air temperature sensor. (2.5 L EC, EK, K4, EH, ER model) (B) (A) IN-00208 8) Remove the air cleaner case (front). B: INSTALLATION Install in the reverse order of removal. IN-00204 4) Loosen the clamps (A) which connect air cleaner case to intake duct. 5) Remove the clip (B) securing upper side of air cleaner case. Tightening torque: Bolt (A) 6 N⋅m (0.6 kgf-m, 4.4 ft-lb) Nut (B) 7.5 N⋅m (0.76 kgf-m, 5.5 ft-lb) (B) (B) (A) (A) IN-00205 IN(H4SO 2.0)-5 IN-00208 G2360GE.book 6 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Air Cleaner Case INTAKE (INDUCTION) NOTE: Fasten with a clip after inserting the lower tab of the case. IN-00207 C: INSPECTION Check for cracks or loose connections. IN(H4SO 2.0)-6 G2360GE.book 7 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Air Intake Chamber INTAKE (INDUCTION) 4. Air Intake Chamber B: INSTALLATION A: REMOVAL Install in the reverse order of removal. 1) Disconnect the ground cable from battery. (2.0 L model and 2.5 L KA, KS model) Tightening torque: Clamp (A), (B) 3 N⋅m (0.3 kgf-m, 2.2 ft-lb) Bolt (C) 6.5 N⋅m (0.66 kgf-m, 4.8 ft-lb) (C) (B) (C) (A) IN-00203 2) Disconnect the connector from intake air temperature sensor. (2.0 L model and 2.5 L KA, KS model) IN-02005 C: INSPECTION 1) Check for cracks or loose connections. 2) Check that no foreign objects are mixed in air intake chamber. FU-02080 3) Loosen the clamp (A) which connects air intake chamber to throttle body. 4) Loosen the clamp (B) which connects intake duct to air intake chamber. 5) Remove the bolt (C) which secures air intake chamber to the stay. (C) (B) (C) (A) IN-02005 6) Disconnect the blow-by hose at three points, and remove the air intake chamber. IN(H4SO 2.0)-7 G2360GE.book 8 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Air Intake Duct INTAKE (INDUCTION) 5. Air Intake Duct A: REMOVAL 1) Remove the clip securing air intake duct to body front area. 2) Remove the air intake duct. IN-00210 B: INSTALLATION Install in the reverse order of removal. C: INSPECTION 1) Check for cracks or loose connections. 2) Check that no foreign objects are mixed in air intake duct. IN(H4SO 2.0)-8 G2360GE.book 9 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Resonator Chamber INTAKE (INDUCTION) 6. Resonator Chamber A: REMOVAL The resonator chamber and air cleaner case are integrated into one unit; therefore, refer to “Air Cleaner Case” for removal procedure. B: INSTALLATION The resonator chamber and air cleaner case are integrated into one unit; therefore, refer to “Air Cleaner Case” for installation procedure. C: INSPECTION Check for cracks or loose connections. IN(H4SO 2.0)-9 G2360GE.book 10 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Resonator Chamber INTAKE (INDUCTION) IN(H4SO 2.0)-10 G2360GE.book 1 ページ ２００７年１１月２９日 木曜日 午後１時２８分 MECHANICAL ME(H4SO 2.0) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. Page General Description ....................................................................................2 Compression .............................................................................................22 Idle Speed .................................................................................................23 Ignition Timing...........................................................................................24 Intake Manifold Vacuum............................................................................25 Engine Oil Pressure ..................................................................................26 Fuel Pressure............................................................................................27 Valve Clearance........................................................................................28 Engine Assembly ......................................................................................30 Engine Mounting .......................................................................................35 Preparation for Overhaul...........................................................................36 V-belt.........................................................................................................37 Crank Pulley..............................................................................................40 Timing Belt Cover......................................................................................42 Timing Belt ................................................................................................43 Cam Sprocket ...........................................................................................48 Crank Sprocket .........................................................................................50 Valve Rocker Assembly ............................................................................51 Camshaft...................................................................................................53 Cylinder Head ...........................................................................................57 Cylinder Block ...........................................................................................64 Intake and Exhaust Valve .........................................................................85 Piston ........................................................................................................86 Connecting Rod ........................................................................................87 Crankshaft.................................................................................................88 Engine Trouble in General ........................................................................89 Engine Noise.............................................................................................95 G2360GE.book 2 ページ ２００７年１１月２９日 木曜日 午後１時２８分 General Description MECHANICAL 1. General Description A: SPECIFICATION Model 2.0 L 2.5 L Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine Belt driven, single over-head camshaft, 4 valve/cylinder 99.5 × 79.0 mm (in) 92 × 75 (3.62 × 2.95) (3.917 × 3.110) Cylinder arrangement Valve system mechanism Bore × Stroke cm3 (cu in) Displacement Engine Compression ratio Compression pressure (at 350 rpm) Number of piston rings 1,994 (121.67) 2,457 (150) 10.0 2, kPa (kgf/cm psi) Open Intake valve timing Close Open Exhaust valve timing Close Intake Valve clearance mm (in) Exhaust Idling speed [at neutral position on MT, or “P” or rpm “N” range on AT] Ignition order Ignition timing BTDC/rpm 1,020 — 1,275 (10.4 — 13.0, 148 — 185) Pressure ring: 2, Oil ring: 1 BTDC 2° BTDC 2° ABDC 54° ABDC 56° BBDC 39° BBDC 50° ATDC 5° ATDC 8° 0.20±0.04 (0.0079±0.0016) 0.25±0.04 (0.0098±0.0016) 650±100 (No load) 800±100 (A/C ON) 1→3→2→4 13°±10°/650 NOTE: US: undersize OS: oversize Belt tension adjuster Protrusion of adjuster rod mm (in) 5.2 — 6.2 (0.205 — 0.244) Belt tensioner Spacer O.D. Tensioner bushing I.D. Clearance between spacer and bushing Side clearance of spacer mm (in) mm (in) 17.955 — 17.975 (0.7069 — 0.7077) 18.00 — 18.08 (0.7087 — 0.7118) Valve rocker arm Clearance between shaft and arm Bend limit Thrust clearance 2.0 L Camshaft Cylinder head Cam lobe height mm (in) 2.5 L Camshaft journal O.D. Camshaft journal hole I.D. Oil clearance Surface warpage limit (mating with cylinder block) Grinding limit Standard height mm (in) Standard 0.025 — 0.125 (0.0010 — 0.0049) mm (in) Standard 0.20 — 0.55 (0.0079 — 0.0217) mm (in) Standard 0.020 — 0.054 (0.0008 — 0.0021) mm (in) mm (in) Standard Intake Standard Exhaust Standard Intake Standard Exhaust Standard mm (in) mm (in) mm (in) Standard 0.020 (0.00079) 0.030 — 0.090 (0.0012 — 0.0035) 39.646 — 39.746 (1.5609 — 1.5648) 39.351 — 39.451 (1.5493 — 1.5532) 39.485 — 39.585 (1.5545 — 1.5585) 39.904 — 40.004 (1.5710 — 1.5750) 31.928 — 31.945 (1.2570 — 1.2577) 32.000 — 32.018 (1.2598 — 1.2605) 0.055 — 0.090 (0.0022 — 0.0035) mm (in) 0.03 (0.001) mm (in) mm (in) 0.1 (0.004) 97.5 (3.84) ME(H4SO 2.0)-2 G2360GE.book 3 ページ ２００７年１１月２９日 木曜日 午後１時２８分 General Description MECHANICAL Refacing angle Valve seat Contacting width Inside diameter Valve guide Protrusion above head Head edge thickness Stem outer diameter Valve Valve stem gap Overall length Free length Squareness Intake mm (in) Exhaust Standard Standard mm (in) Intake mm (in) Exhaust Intake Standard mm (in) Exhaust Standard Intake mm (in) Exhaust Intake mm (in) Standard Exhaust Intake mm (in) Exhaust mm (in) Valve spring Set Tension/spring height N (kgf, lbf)/mm (in) Surface warpage limit (mating with cylinder head) Grinding limit Standard height Cylinder block Piston Piston pin Lift mm (in) mm (in) mm (in) A B Cylinder inner mm (in) diameter A 2.5 L Standard B Cylindricality mm (in) Standard Out-of-roundness mm (in) Standard Piston clearance mm (in) Standard A Standard B 2.0 L 0.25 (0.0098) OS 0.50 (0.0197) OS Outer diameter mm (in) A Standard B 2.5 L 0.25 (0.0098) OS 0.50 (0.0197) OS Piston pin specified diameter mm (in) Outer diameter mm (in) Standard clearance between piston and piston pin mm (in) 2.0 L Standard Degree of fit Top ring Piston ring Connecting rod Standard 2.0 L Standard Second Ring closed gap mm (in) ring 2.5 L Standard Oil ring Standard Top ring Standard Ring groove gap mm (in) Second ring Standard Bend or twist per 100 mm (3.94 in) in mm (in) Limit length Thrust clearance mm (in) Standard ME(H4SO 2.0)-3 90° 0.8 — 1.4 (0.03 — 0.055) 1.2 — 1.8 (0.047 — 0.071) 6.000 — 6.012 (0.2362 — 0.2367) 20.0 — 21.0 (0.787 — 0.827) 16.5 — 17.5 (0.650 — 0.689) 0.8 — 1.2 (0.03 — 0.047) 1.0 — 1.4 (0.039 — 0.055) 5.950 — 5.965 (0.2343 — 0.2348) 5.945 — 5.960 (0.2341 — 0.2346) 0.035 — 0.062 (0.0014 — 0.0024) 0.040 — 0.067 (0.0016 — 0.0026) 120.6 (4.75) 121.7 (4.79) 54.30 (2.1378) 2.5°, 2.4 mm (0.094 in) 214 — 246 (22 — 25, 48 — 55)/45.0 (1.772) 526 — 582 (54 — 59, 119 — 130)/34.7 (1.366) 0.025 (0.00098) 0.1 (0.004) 201.0 (7.91) 92.005 — 92.015 (3.6222 — 3.6226) 91.995 — 92.005 (3.6218 — 3.6222) 99.505 — 99.515 (3.9175 — 3.9179) 99.495 — 99.505 (3.9171 — 3.9175) 0.015 (0.0006) 0.010 (0.0004) −0.010 — 0.010 (−0.00039 — 0.00039) 92.005 — 92.015 (3.6222 — 3.6226) 91.995 — 92.005 (3.6219 — 3.6222) 92.245 — 92.265 (3.6317 — 3.6325) 92.495 — 92.515 (3.6415 — 3.6423) 99.505 — 99.515 (3.9175 — 3.9179) 99.495 — 99.505 (3.9171 — 3.9175) 99.745 — 99.765 (3.9270 — 3.9278) 99.995 — 100.015 (3.9368 — 3.9376) 23.000 — 23.006 (0.9055 — 0.9057) 22.994 — 23.000 (0.9053 — 0.9055) 0.004 — 0.008 (0.0002 — 0.0003) Piston pin must be fitted into position with thumb at 20°C (68°F). 0.20 — 0.35 (0.0079 — 0.0138) 0.40 — 0.50 (0.0157 — 0.0197) 0.37 — 0.52 (0.0146 — 0.0205) 0.20 — 0.50 (0.0079 — 0.0197) 0.040 — 0.080 (0.0016 — 0.0031) 0.030 — 0.070 (0.0012 — 0.0028) 0.10 (0.0039) 0.070 — 0.330 (0.0028 — 0.0130) G2360GE.book 4 ページ ２００７年１１月２９日 木曜日 午後１時２８分 General Description MECHANICAL Oil clearance Bearing of large end Bushing of small end Crankshaft Main bearing mm (in) Standard Standard Bearing size 0.03 (0.0012) US (Thickness at cenmm (in) 0.05 (0.0020) US ter) 0.25 (0.0098) US Clearance between piston pin and mm (in) Standard bushing Bend limit mm (in) Out-of-round2.0 L ness mm (in) 2.5 L Crank pin Cylindricality 2.0 L mm (in) 2.5 L Grinding limit (dia.) mm (in) Out-of-roundness mm (in) Crank journal Cylindricality mm (in) Grinding limit (dia.) mm (in) Standard 0.03 (0.0012) US Crank pin outer mm (in) diameter 0.05 (0.0020) US 0.25 (0.0098) US Standard 0.03 (0.0012) US Crank journal outer mm (in) diameter 0.05 (0.0020) US 0.25 (0.0098) US Thrust clearance mm (in) Standard Oil clearance mm (in) Standard Standard 0.03 (0.0012) US #1, #3 0.05 (0.0020) US 0.25 (0.0098) US Main bearing mm (in) Standard 0.03 (0.0012) US #2, #4, #5 0.05 (0.0020) US 0.25 (0.0098) US ME(H4SO 2.0)-4 0.016 — 0.044 (0.00063 — 0.0017) 1.492 — 1.501 (0.0587 — 0.0591) 1.510 — 1.513 (0.0594 — 0.0596) 1.520 — 1.523 (0.0598 — 0.0600) 1.620 — 1.623 (0.0638 — 0.0639) 0 — 0.022 (0 — 0.0009) 0.035 (0.0014) 0.005 (0.0002) 0.003 (0.0001) 0.006 (0.0002) 0.004 (0.0002) To 51.750 (2.0374) 0.005 (0.0002) 0.006 (0.0002) To 59.750 (2.3524) 51.984 — 52.000 (2.0466 — 2.0472) 51.954 — 51.970 (2.0454 — 2.0461) 51.934 — 51.950 (2.0446 — 2.0453) 51.734 — 51.750 (2.0368 — 2.0374) 59.992 — 60.008 (2.3619 — 2.3625) 59.962 — 59.978 (2.3607 — 2.3613) 59.942 — 59.958 (2.3599 — 2.3605) 59.742 — 59.758 (2.3520 — 2.3527) 0.030 — 0.115 (0.0012 — 0.0045) 0.010 — 0.030 (0.0004 — 0.0012) 1.998 — 2.011 (0.0787 — 0.0792) 2.017 — 2.020 (0.0794 — 0.0795) 2.027 — 2.030 (0.0798 — 0.0799) 2.127 — 2.130 (0.0837 — 0.0839) 2.000 — 2.013 (0.0787 — 0.0793) 2.019 — 2.022 (0.0795 — 0.0796) 2.029 — 2.032 (0.0799 — 0.0800) 2.129 — 2.132 (0.0838 — 0.0839) G2360GE.book 5 ページ ２００７年１１月２９日 木曜日 午後１時２８分 General Description MECHANICAL B: COMPONENT 1. TIMING BELT (5) T1 (1) (2) T2 T5 (3) (6) (4) T4 (7) (8) (12) T3 T1 (9) T4 T1 T4 (10) (13) (11) (15) T5 (14) T6 (16) T1 T7 ME-02593 (1) (2) (3) (4) (5) (6) (7) (8) (9) Timing belt cover No. 2 (RH) Timing belt guide (MT model) Crank sprocket Timing belt cover No. 2 (LH) Cam sprocket No. 1 Belt idler (No. 1) Tensioner bracket Belt idler (No. 2) Automatic belt tension adjuster ASSY (10) (11) (12) (13) (14) (15) (16) Belt idler No. 2 Cam sprocket No. 2 Timing belt Front timing belt cover Timing belt cover (LH) Crank pulley (2.0 L model) Crank pulley (2.5 L model) Tightening torque: N⋅m (kgf-m, ft-lb) T1: 5 (0.5, 3.7) T2: 10 (1.0, 7.4) T3: 24.5 (2.5, 18.1) T4: 39 (4.0, 28.9) T5: 78 (8.0, 57.9) T6: T7: ME(H4SO 2.0)-5 G2360GE.book 6 ページ ２００７年１１月２９日 木曜日 午後１時２８分 General Description MECHANICAL 2. CYLINDER HEAD AND CAMSHAFT (1) (20) (2) T3 T2 (4) T4 (6) (7) (8) T5 (3) (9) T3 (10) (8) (5) T1 (19) (8) (14) (15) T1 (16) (7) T6 (13) T4 (2) (10) (11) (17) (18) (21) (19) (12) T3 (5) T5 T3 T4 T2 (3) T5 (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) Rocker cover (RH) Intake valve rocker ASSY Exhaust valve rocker ASSY Camshaft cap (RH) Oil seal Camshaft (RH) Plug Spark plug pipe gasket Cylinder head (RH) Cylinder head gasket Cylinder head (LH) (12) (13) (14) (15) (16) (17) (18) (19) (20) (21) Camshaft (LH) Camshaft cap (LH) Oil filler cap Gasket Oil filler duct O-ring Rocker cover (LH) Stud bolt Rocker cover gasket (RH) Rocker cover gasket (LH) ME(H4SO 2.0)-6 ME-02594 Tightening torque: N⋅m (kgf-m, ft-lb) T1: T2: T3: T4: T5: T6: 5 (0.5, 3.7) 9.75 (1.0, 7.2) 18 (1.8, 13.3) 25 (2.5, 18.4) 6.4 (0.65, 4.7) G2360GE.book 7 ページ ２００７年１１月２９日 木曜日 午後１時２８分 General Description MECHANICAL 3. VALVE ROCKER ASSEMBLY (2) (1) (4) (3) (5) (4) (2) T2 (1) T1 (6) (1) (3) (2) (4) T3 (5) (4) (2) (3) (8) (1) (2) T1 (3) (2) T2 (7) T2 T2 (3) (3) T3 ME-00187 (1) (2) (3) (4) Intake valve rocker arm Valve rocker nut Valve rocker adjuster screw Spring (5) (6) (7) (8) Rocker shaft support Intake rocker shaft Exhaust rocker shaft Exhaust valve rocker arm ME(H4SO 2.0)-7 Tightening torque: N⋅m (kgf-m, ft-lb) T1: 5 (0.5, 3.7) T2: 9.75 (1.0, 7.2) T3: 25 (2.5, 18.4) G2360GE.book 8 ページ ２００７年１１月２９日 木曜日 午後１時２８分 General Description MECHANICAL 4. CYLINDER HEAD AND VALVE ASSEMBLY (1) (1) (3) (4) (5) (6) (7) (8) (2) (2) (3) (4) (9) (6) (7) (8) ME-02595 (1) (2) (3) Exhaust valve Intake valve Valve guide (4) (5) (6) Valve spring seat Intake valve oil seal Valve spring ME(H4SO 2.0)-8 (7) (8) (9) Retainer Retainer key Exhaust valve oil seal G2360GE.book 9 ページ ２００７年１１月２９日 木曜日 午後１時２８分 General Description MECHANICAL 5. CYLINDER BLOCK T2 T2 T6 T7 (7) (1) (5) T5 (2) (6) (3) (4) T2 T7 T10 T2 (10) (8) (11) (9) T2 (10) (4) T2 (3) T7 (14) (15) T10 (10) T9 (10) (26) (4) T10 (17) (16) (23) (3) (12) (22) T2 (18) T3 T5 T2 T7 (24) (21) T4 (13) (20) (25) T1 T8 (19) ME-02526 (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) Oil pressure switch Cylinder block (RH) Service hole plug Gasket Oil separator cover Water by-pass pipe Oil pump Front oil seal Rear oil seal O-ring Service hole cover Cylinder block (LH) Water pump (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) Baffle plate Oil filter connector Oil strainer Gasket Oil pan Drain plug Metal gasket Oil level gauge guide Water pump sealing Oil filter Gasket Water pump hose Seal ME(H4SO 2.0)-9 Tightening torque: N⋅m (kgf-m, ft-lb) T1: 5 (0.5, 3.7) T2: 6.4 (0.65, 4.7) T3: 10 (1.0, 7.4) T4: First 12 (1.2, 8.7) Second 12 (1.2, 8.7) T5: T6: T7: T8: T9: T10: 16 (1.6, 11.8) 25 (2.5, 18.4) 44 (4.5, 33) 45 (4.6, 33.3) 70 (7.1, 51.6) G2360GE.book 10 ページ ２００７年１１月２９日 木曜日 午後１時２８分 General Description MECHANICAL 6. CRANKSHAFT AND PISTON (1) T2 (4) (5) (6) (9) (8) (10) (11) (3) T2 (12) (9) (7) (14) T1 (12) (2) (13) T1 (9) (12) (7) (11) (15) (18) (10) (8) (9) (6) (4) (5) (17) (16) (16) (17) ME-02403 (1) (2) (3) (4) (5) (6) (7) Flywheel (MT model) Reinforcement (AT model) Drive plate (AT model) Top ring Second ring Oil ring Piston (8) (9) (10) (11) (12) (13) (14) Piston pin Snap ring Connecting rod bolt Connecting rod Connecting rod bearing Connecting rod cap Crankshaft ME(H4SO 2.0)-10 (15) Woodruff key (16) Crankshaft bearing #1, #3 (17) Crankshaft bearing #2, #4 (18) Crankshaft bearing #5 Tightening torque: N⋅m (kgf-m, ft-lb) T1: 45 (4.6, 33.3) T2: 72 (7.3, 52.8) G2360GE.book 11 ページ ２００７年１１月２９日 木曜日 午後１時２８分 General Description MECHANICAL 7. ENGINE MOUNTING • 2.0 L model T2 T2 (2) (2) T1 (1) (1) T1 T3 T3 ME-00413 (1) Front cushion rubber (2) Front engine mounting bracket ME(H4SO 2.0)-11 Tightening torque: N⋅m (kgf-m, ft-lb) T1: 35 (3.6, 25.8) T2: 42 (4.3, 31) T3: 85 (8.7, 62.7) G2360GE.book 12 ページ ２００７年１１月２９日 木曜日 午後１時２８分 General Description MECHANICAL • 2.5 L model (1) T1 T2 T1 T2 ME-02090 (1) Tightening torque: N⋅m (kgf-m, ft-lb) T1: 35 (3.6, 25.8) T2: 85 (8.7, 62.7) Front cushion rubber C: CAUTION • Wear work clothing, including a cap, protective goggles and protective shoes during operation. • Remove contamination including dirt and corrosion before removal, installation or disassembly. • Keep the disassembled parts in order and protect them from dust and dirt. • Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. • Be careful not to burn yourself, because each part on the vehicle is hot after running. • Be sure to tighten fasteners including bolts and nuts to the specified torque. • Place shop jacks or rigid racks at the specified points. • Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from battery. • All parts should be thoroughly cleaned, paying special attention to engine oil passages, pistons and bearings. • Rotating parts and sliding parts such as piston, bearing and gear should be coated with oil prior to assembly. • Be careful not to let oil, grease or coolant contact the timing belt, clutch disc and flywheel. • All removed parts, if to be reused, should be reinstalled in the original positions and directions. • Bolts, nuts and washers should be replaced with new ones as required. • Even if necessary inspections have been made in advance, proceed with assembly work while making rechecks. • Remove or install the engine in an area where chain hoists, lifting devices, etc. are available for ready use. • Be sure not to damage coated surfaces of body panels with tools, or not to stain seats and windows with coolant or oil. Place a cover over fender, as required, for protection. • Prior to starting work, prepare the following: Service tools, clean cloth, containers to catch coolant and oil, wire ropes, chain hoist, transmission jacks, etc. • Lift-up or lower the vehicle when necessary. Make sure to support the correct positions. ME(H4SO 2.0)-12 G2360GE.book 13 ページ ２００７年１１月２９日 木曜日 午後１時２８分 General Description MECHANICAL D: PREPARATION TOOL 1. SPECIAL TOOL ILLUSTRATION TOOL NUMBER 18231AA010 DESCRIPTION CAM SPROCKET WRENCH REMARKS • Used for removing and installing cam sprocket. (LH side) • CAM SPROCKET WRENCH (499207100) can also be used. ST18231AA010 18482AA000 CARTRIDGE (Newly adopted tool) Troubleshooting for electrical system. ST18482AA000 22771AA030 SUBARU SELECT MONITOR KIT Troubleshooting for electrical system. • English: 22771AA030 (Without printer) • German: 22771AA070 (Without printer) • French: 22771AA080 (Without printer) • Spanish: 22771AA090 (Without printer) 498267800 CYLINDER HEAD TABLE • Used for replacing valve guides. • Used for removing and installing valve spring. ST22771AA030 ST-498267800 ME(H4SO 2.0)-13 G2360GE.book 14 ページ ２００７年１１月２９日 木曜日 午後１時２８分 General Description MECHANICAL ILLUSTRATION TOOL NUMBER 498277200 DESCRIPTION STOPPER SET REMARKS Used for installing automatic transmission assembly to engine. 498457000 ENGINE STAND ADAPTER RH Used with ENGINE STAND (499817100). 498457100 ENGINE STAND ADAPTER LH Used with ENGINE STAND (499817100). 498497100 CRANKSHAFT STOPPER Used for stopping rotation of flywheel when loosening/tightening crank pulley bolt. ST-498277200 ST-498457000 ST-498457100 ST-498497100 ME(H4SO 2.0)-14 G2360GE.book 15 ページ ２００７年１１月２９日 木曜日 午後１時２８分 General Description MECHANICAL ILLUSTRATION TOOL NUMBER 398744300 DESCRIPTION PISTON GUIDE REMARKS Used for installing piston in cylinder. (2.0 L model) 498747300 PISTON GUIDE Used for installing piston in cylinder. (2.5 L model) 498857100 VALVE OIL SEAL GUIDE Used for press-fitting of intake and exhaust valve guide oil seals. 499017100 PISTON PIN GUIDE Used for installing piston pin, piston and connecting rod. ST-398744300 ST-498747300 ST-498857100 ST-499017100 ME(H4SO 2.0)-15 G2360GE.book 16 ページ ２００７年１１月２９日 木曜日 午後１時２８分 General Description MECHANICAL ILLUSTRATION TOOL NUMBER 499037100 DESCRIPTION CONNECTING ROD BUSHING REMOVER AND INSTALLER REMARKS Used for removing and installing connecting rod bushing. 499587200 CRANKSHAFT OIL SEAL INSTALLER • Used for installing crankshaft oil seal. • Used with CRANKSHAFT OIL SEAL GUIDE (499597100). 499587500 OIL SEAL INSTALLER • Used for installing camshaft oil seal. • Used with OIL SEAL GUIDE (499597000). 499587700 CAMSHAFT OIL SEAL INSTALLER Used for installing cylinder head plug. ST-499037100 ST-499587200 ST-499587500 ST-499587700 ME(H4SO 2.0)-16 G2360GE.book 17 ページ ２００７年１１月２９日 木曜日 午後１時２８分 General Description MECHANICAL ILLUSTRATION TOOL NUMBER 499097700 DESCRIPTION PISTON PIN REMOVER ASSY REMARKS Used for removing piston pin. 499207400 CAM SPROCKET WRENCH Used for removing and installing cam sprocket. (RH side) 499497000 TORX PLUS® Used for removing and installing camshaft cap. 499587100 OIL SEAL INSTALLER Used for installing oil pump oil seal. ST-499097700 ST-499207400 ST-499497000 ST-499587100 ME(H4SO 2.0)-17 G2360GE.book 18 ページ ２００７年１１月２９日 木曜日 午後１時２８分 General Description MECHANICAL ILLUSTRATION TOOL NUMBER 499597000 DESCRIPTION OIL SEAL GUIDE REMARKS • Used for installing camshaft oil seal. • Used with CAMSHAFT OIL SEAL INSTALLER (499587500). 499597100 CRANKSHAFT OIL SEAL GUIDE • Used for installing crankshaft oil seal. • Used with CRANKSHAFT OIL SEAL INSTALLER (499587200). 499718000 VALVE SPRING REMOVER Used for removing and installing valve spring. 499767200 VALVE GUIDE REMOVER Used for removing valve guides. ST-499597000 ST-499597100 ST-499718000 ST-499767200 ME(H4SO 2.0)-18 G2360GE.book 19 ページ ２００７年１１月２９日 木曜日 午後１時２８分 General Description MECHANICAL ILLUSTRATION TOOL NUMBER 499767400 DESCRIPTION VALVE GUIDE REAMER REMARKS Used for reaming valve guides. 499767700 VALVE GUIDE ADJUSTER Used for installing valve guides. (Intake side) 499767800 VALVE GUIDE ADJUSTER Used for installing valve guides. (Exhaust side) 499817100 ENGINE STAND • Used for disassembling and assembling engine. • Used with ENGINE STAND ADAPTER RH (498457000) & LH (498457100). ST-499767400 ST-499767700 ST-499767800 ST-499817100 ME(H4SO 2.0)-19 G2360GE.book 20 ページ ２００７年１１月２９日 木曜日 午後１時２８分 General Description MECHANICAL ILLUSTRATION TOOL NUMBER 499977400 DESCRIPTION CRANK PULLEY WRENCH REMARKS Used for stopping rotation of crank pulley when removing and tightening crank pulley bolt. (2.0 L model) 499977100 CRANK PULLEY WRENCH Used for stopping rotation of crank pulley when removing and tightening crank pulley bolt. (2.5 L model) 18332AA000 OIL FILTER WRENCH Used for removing and installing oil filter. (Outer diameter: 68 mm (2.68 in)) 18332AA010 OIL FILTER WRENCH Used for removing and installing oil filter. (Outer diameter: 65 mm (2.56 in)) ST-499977400 ST-499977100 ST18332AA000 ST18332AA010 ME(H4SO 2.0)-20 G2360GE.book 21 ページ ２００７年１１月２９日 木曜日 午後１時２８分 General Description MECHANICAL ILLUSTRATION TOOL NUMBER 499987500 DESCRIPTION CRANKSHAFT SOCKET REMARKS Used for rotating crankshaft. ST-499987500 2. GENERAL TOOL TOOL NAME Compression gauge Tachometer (Secondary pick-up type) Timing light REMARKS Used for measuring compression. Used for measuring idle speed. Used for measuring ignition timing. E: PROCEDURE It is possible to conduct the following service procedures with engine on the vehicle, however, the procedures described in this section are based on the condition that the engine is removed from the vehicle. • V-belt • Timing belt • Valve rocker assembly • Camshaft • Cylinder head ME(H4SO 2.0)-21 G2360GE.book 22 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Compression MECHANICAL 2. Compression A: INSPECTION CAUTION: After warming-up, engine becomes very hot. Be careful not to burn yourself during measurement. 1) After warming-up the engine, turn the ignition switch to OFF. 2) Make sure that the battery is fully charged. 3) Release the fuel pressure. 4) Remove all the spark plugs. 5) Fully open the throttle valve. 6) Check the starter motor for satisfactory performance and operation. 7) Hold the compression gauge tightly against the spark plug hole. NOTE: When using a screw-in type compression gauge, the screw (put into cylinder head spark plug hole) should be less than 18 mm (0.71 in) long. 8) Crank the engine by means of the starter motor, and read the maximum value on the gauge when the gauge needle is steady. ME-00192 9) Perform at least two measurements per cylinder, and make sure that the values are correct. Compression (350 rpm and fully opened throttle): Standard 1,020 — 1,275 kPa (10.4 — 13.0 kgf/cm2, 148 — 185 psi) Difference between cylinders 49 kPa (0.5 kgf/cm2, 7 psi) or less ME(H4SO 2.0)-22 G2360GE.book 23 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Idle Speed MECHANICAL 3. Idle Speed (2) Start the engine, and read the engine idle speed. A: INSPECTION 1) Before checking the idle speed, check the following: (1) Ensure the air cleaner element is free from clogging, ignition timing is correct, spark plugs are in good condition, and hoses are connected properly. (2) Ensure the malfunction indicator light does not illuminate. 2) Idle the engine. 3) Stop the engine, and turn the ignition switch to OFF. 4) When using Subaru Select Monitor, refer to the following. (1) Insert the cartridge to Subaru Select Monitor. (2) Connect the Subaru Select Monitor to data link connector. (1) ME-00811 NOTE: This ignition system provides simultaneous ignition for #1 and #2 plugs. It must be noted that some tachometers may register twice that of actual engine speed. 6) Check the idle speed when no-loaded. (Headlight, heater fan, rear defroster, radiator fan, A/C, etc. are OFF.) Idle speed [No load and gears in “N” or “P” range]: 650±100 rpm 7) Check the idle speed when loaded. (Turn the A/ C switch to “ON” and operate the compressor for at least one minute before measurement.) Idle speed [A/C “ON” and gears in “N” or “P” range]: 800±100 rpm AT-01712 (1) Data link connector (3) Turn the ignition switch to ON and the Subaru Select Monitor power switch to ON. (4) Select {Each System Check} in Main Menu. (5) Select {Engine} in Selection Menu. (6) Select {Current Data Display & Save} in Engine Control System Diagnosis. (7) Select {Data Display} in Data Display Menu. (8) Start the engine, and read the engine idle speed. 5) When using the tachometer (Secondary pick-up type): (1) Attach the pick-up clip to No. 1 cylinder spark plug cord. NOTE: Idle speed cannot be adjusted manually, because idle speed is automatically adjusted. If the idle speed is out of specifications, refer to General Diagnostic Table under “Engine Control System”. ME(H4SO 2.0)-23 G2360GE.book 24 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Ignition Timing MECHANICAL 4. Ignition Timing A: INSPECTION CAUTION: After warming-up, engine becomes very hot. Be careful not to burn yourself at measurement. 1) Idle the engine. 2) To check the ignition timing, connect a timing light to #1 cylinder spark plug cord, and illuminate the timing mark with the timing light. 3) Start the engine and check the ignition timing at the following idle speed. Ignition timing [BTDC/rpm]: 13°±10°/650 20 10 ME-00812 If the timing is not correct, check the ignition control system. ME(H4SO 2.0)-24 G2360GE.book 25 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Intake Manifold Vacuum MECHANICAL 5. Intake Manifold Vacuum A: INSPECTION 1) Idle the engine. 2) Disconnect the brake vacuum hose from the intake manifold, and then install the vacuum gauge. 3) Keep the engine at idle speed and read the vacuum gauge indication. By observing the gauge needle movement, the internal condition of the engine can be diagnosed with the following procedures. ME-00813 Vacuum pressure (at idling, A/C “OFF”): Less than −60.0 kPa (−450 mmHg, −17.72 inHg) Diagnosis of engine condition by measurement of intake manifold vacuum Vacuum gauge indication Possible engine condition 1. Needle is steady but lower than normal position. This tenAir leakage around intake manifold gasket, disconnection or dency becomes more evident as engine temperature rises. damage of vacuum hose 2. Needle intermittently drops to position lower than normal Leakage around cylinder position. 3. Needle drops suddenly and intermittently from normal posiValve anchoring tion. 4. When engine speed is gradually increased, needle begins to Weak or broken valve spring vibrate rapidly at certain speed, and then vibration increases as engine speed increases. 5. Needle vibrates above and below normal position in narrow Defective ignition system range. ME(H4SO 2.0)-25 G2360GE.book 26 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Engine Oil Pressure MECHANICAL 6. Engine Oil Pressure A: INSPECTION 1) Disconnect the ground cable from battery. IN-00203 2) Remove the generator from bracket. 3) Disconnect the connector from pressure switch. 4) Remove the pressure switch from cylinder block. 5) Connect the oil pressure gauge hose to cylinder block. 6) Connect the ground cable to battery. CAUTION: • If the oil pressure is out of standard, check oil pump, oil filter and lubrication line. • If the oil pressure warning light comes on though the oil pressure is within standard, replace the oil pressure switch. NOTE: The standard is based on an engine oil temperature of 80°C (176°F). 8) After measuring the oil pressure, install the oil pressure switch. Tightening torque: 25 N⋅m (2.5 kgf-m, 18.4 ft-lb) IN-00203 7) Start the engine, and measure the oil pressure. ME-00196 Oil pressure: Standard (at 600 rpm) 98 kPa (1.0 kgf/cm2, 14 psi) or more Standard (at 5,000 rpm) 294 kPa (3.0 kgf/cm2, 43 psi) or more ME(H4SO 2.0)-26 G2360GE.book 27 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Fuel Pressure MECHANICAL 7. Fuel Pressure A: INSPECTION WARNING: Before removing the fuel pressure gauge, release the fuel pressure. NOTE: When the fuel pressure is out of standard, check or replace the pressure regulator and pressure regulator vacuum hose. 1) Release the fuel pressure. 2) Open the fuel filler flap lid, and remove the fuel filler cap. 3) Disconnect the fuel delivery hose from fuel damper, and connect a fuel pressure gauge. ME-00814 4) Install the fuse of fuel pump to main fuse box. 5) Start the engine. 6) Measure the fuel pressure while disconnecting pressure regulator vacuum hose from intake manifold. Fuel pressure: Standard: 284 — 314 kPa (2.9 — 3.2 kgf/cm2, 41 — 46 psi) 7) After connecting the pressure regulator vacuum hose, measure the fuel pressure. Fuel pressure: Standard: 206 — 235 kPa (2.1 — 2.4 kgf/cm2, 30 — 34 psi) NOTE: The fuel pressure gauge registers 10 to 20 kPa (0.1 to 0.2 kgf/cm2, 1 to 3 psi) higher than standard during high-altitude operations. ME(H4SO 2.0)-27 G2360GE.book 28 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Valve Clearance MECHANICAL 8. Valve Clearance 9) Set #1 cylinder piston to top dead center of compression stroke by rotating the crank pulley clockwise using socket wrench. A: INSPECTION Inspection and adjustment of valve clearance should be performed while engine is cold. 1) Set the vehicle on a lift. 2) Lift-up the vehicle. 3) Remove the under cover. 4) Lower the vehicle. 5) Disconnect the ground cable from battery. NOTE: When the arrow mark (A) on cam sprocket (LH) comes exactly to the top, #1 cylinder piston is brought to the top dead center of compression stroke. (A) ME-00200 IN-00203 6) Remove the timing belt cover (LH). 10) Measure #1 cylinder valve clearance using thickness gauge. CAUTION: • Insert the thickness gauge (A) in as horizontally as possible with respect to the valve stem end face. • Measure the exhaust valve clearances while lifting-up the vehicle. ME-00199 7) When inspecting #1 and #3 cylinders: (1) Disconnect the spark plug cords from spark plugs RH side. (2) Disconnect the PCV hose from rocker cover (RH). (3) Remove the bolts, then remove the rocker cover (RH). 8) When inspecting #2 and #4 cylinders: (1) Disconnect the spark plug cords from spark plugs (LH side). (2) Disconnect the PCV hose from rocker cover (LH). (3) Remove the bolts, then remove the rocker cover (LH). Valve clearance (Standard): Intake 0.20±0.04 mm (0.0079±0.0016 in) Exhaust 0.25±0.04 mm (0.0098±0.0016 in) (A) ME-00201 11) If necessary, adjust the valve clearance. ME(H4SO 2.0)-28 G2360GE.book 29 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Valve Clearance MECHANICAL 12) Measure the valve clearance in #3, #2 and #4 cylinder in this order in the same measurement procedure as #1 cylinder. NOTE: • Be sure to set the cylinder pistons to their respective top dead centers on compression stroke before measuring valve clearances. • By rotating the crank pulley clockwise every 180° from the state that #1 cylinder piston is on the top dead center of compression stroke, #3, #2 and #4 cylinder pistons come to the top dead center of compression stroke in this order. 13) After inspection, install the related parts in the reverse order of removal. Valve clearance: Intake 0.20±0.04 mm (0.0079±0.0016 in) Exhaust 0.25±0.04 mm (0.0098±0.0016 in) B: ADJUSTMENT ME-00203 CAUTION: Adjustment of valve clearance should be performed while engine is cold. 1) Set #1 cylinder piston to top dead center of compression stroke by rotating the crank pulley clockwise using the socket wrench. NOTE: When the arrow mark (A) on cam sprocket (LH) comes exactly to the top, #1 cylinder piston is brought to the top dead center of compression stroke. (A) 3) Adjust the valve clearance in #3, #2 and #4 cylinder in this order in the same adjustment procedure as #1 cylinder. NOTE: • Be sure to set the cylinder pistons to their respective top dead centers on compression stroke before adjusting valve clearances. • By rotating the crank pulley clockwise every 180° from the state that #1 cylinder piston is on the top dead center of compression stroke, #3, #2 and #4 cylinder pistons come to the top dead center of compression stroke in this order. 4) Ensure the valve clearances of each cylinder are within specifications. If necessary, readjust the valve clearances. ME-00200 2) Adjust the #1 cylinder valve clearance. (1) Loosen the valve rocker nut and screw. (2) Place a suitable thickness gauge. (3) While noting the valve clearance, tighten the valve rocker adjusting screw. (4) When the specified valve clearance is obtained, tighten the valve rocker nut. Tightening torque: 9.75 N⋅m (1.0 kgf-m, 7.2 ft-lb) CAUTION: • Insert the thickness gauge in as horizontally as possible with respect to the valve stem end face. • Adjust the exhaust valve clearances while lifting-up the vehicle. ME(H4SO 2.0)-29 G2360GE.book 30 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Engine Assembly MECHANICAL 9. Engine Assembly 12) Disconnect the following connectors and cables. (1) Front oxygen (A/F) sensor connector A: REMOVAL 1) Set the vehicle on a lift. 2) Open the front hood fully and support it with front food stay. 3) Collect the refrigerant from A/C system. 4) Release the fuel pressure. or 5) Remove the fuel filler cap. 6) Disconnect the ground cable from battery. ME-00859 (2) Rear oxygen sensor connector FU-01116 IN-00203 7) Remove the air intake duct, air cleaner case and air intake chamber. 8) Remove the under cover. 9) Remove the radiator from vehicle. 10) Disconnect the A/C pressure hoses from A/C compressor. 11) Remove the air intake chamber stay. (3) Engine ground cable ME-00206 (4) Engine harness connectors ME-00816 ME(H4SO 2.0)-30 ME-00817 G2360GE.book 31 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Engine Assembly MECHANICAL (5) Generator connector and terminal 14) Remove the power steering pump. (1) Loosen the lock bolt and slider bolt, and remove the front side belt. (2) Remove the power steering pump. (A) (B) ME-00818 (A) Terminal (B) Generator connector (6) A/C compressor connector FU-00139 (3) Place the power steering pump onto right side wheel apron. 15) Remove the front and center exhaust pipe. 16) Remove the bolts and nuts which hold lower side of transmission to engine. ME-00819 (7) Power steering switch connector ME-00210 17) Remove the nuts which install front cushion rubber onto front crossmember. FU-00878 13) Disconnect the following hoses: (1) Brake booster vacuum hose LU-00223 ME-00820 (2) Heater inlet and outlet hoses 18) Separate the torque converter clutch from drive plate. (AT model) (1) Lower the vehicle. (2) Remove the service hole plug. (3) Remove the bolts which hold torque converter clutch to drive plate. ME(H4SO 2.0)-31 G2360GE.book 32 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Engine Assembly MECHANICAL (4) Remove other bolts while rotating the crankshaft using socket wrench. 22) Support the transmission with a garage jack. CAUTION: Doing this is very important because the transmission lowers for its own weight. This work is also of great importance for facilitating reinstallation. (A) (B) ME-00212 19) Remove the pitching stopper. ME-00215 (A) Transmission (B) Garage jack ME-00213 20) Disconnect the fuel delivery hose (A), return hose (B) and evaporation hose (C). CAUTION: • Collect fuel from the hose into container. • Disconnect the hose with its end wrapped with cloth to prevent fuel from splashing. CAUTION: Before removing the engine away from transmission, check to be sure no work has been overlooked. 23) Separation of engine and transmission (1) Remove the starter. (2) Remove the bolts which hold upper side of transmission to engine. (A) (C) (B) ME-00216 FU-01088 21) Support the engine with a lifting device and wire ropes. 24) Install the ST to converter case. (AT model) ST 498277200 STOPPER SET ST ME-00217 LU-00222 ME(H4SO 2.0)-32 G2360GE.book 33 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Engine Assembly MECHANICAL 25) Remove the engine from vehicle. (1) Slightly raise the engine. (2) Raise the transmission with garage jack. (3) Move the engine horizontally until main shaft is withdrawn from clutch cover. (4) Slowly move the engine away from engine compartment. 7) Install the pitching stopper. Tightening torque: T1: 50 N⋅m (5.1 kgf-m, 36.9 ft-lb) T2: 58 N⋅m (5.9 kgf-m, 42.8 ft-lb) NOTE: Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc. 26) Remove the front cushion rubbers. B: INSTALLATION 1) Install the front cushion rubbers. Tightening torque: 35 N⋅m (3.6 kgf-m, 25.8 ft-lb) 2) Position the engine in engine compartment and align it with transmission. NOTE: Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc. LU-00222 3) Apply a small amount of grease to the spline of main shaft. (MT model) 4) Tighten the bolts which hold upper side of transmission to engine. T2 T1 ME-00218 8) Remove the ST from converter case. (AT model) NOTE: Be careful not to drop the ST into the converter case when removing the ST. ST 498277200 STOPPER SET 9) Install the starter. 10) Install the torque converter clutch to drive plate. (AT model) (1) Tighten the bolts which hold torque converter clutch to drive plate. (2) Tighten other bolts while rotating the crankshaft using socket wrench. CAUTION: Be careful not to drop bolts into the torque converter clutch housing. Tightening torque: 25 N⋅m (2.5 kgf-m, 18.4 ft-lb) Tightening torque: 50 N⋅m (5.1 kgf-m, 36.9 ft-lb) ME-00212 ME-00216 5) Remove the lifting device and wire ropes. 6) Remove the garage jack. (3) Install the service hole plug to prevent foreign matters from being mixed. 11) Install the power steering pump. 12) Lift-up the vehicle. ME(H4SO 2.0)-33 G2360GE.book 34 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Engine Assembly MECHANICAL 13) Tighten the bolts and nuts which hold lower side of the transmission to engine. Tightening torque: 50 N⋅m (5.1 kgf-m, 36.9 ft-lb) ME-00219 14) Tighten the nuts which install the front cushion rubber onto crossmember. Tightening torque: 85 N⋅m (8.7 kgf-m, 62.7 ft-lb) NOTE: Make sure the front cushion rubber mounting bolts are securely installed. 19) Install the air intake chamber stay. Tightening torque: 16 N⋅m (1.6 kgf-m, 11.8 ft-lb) 20) Install the A/C pressure hoses. 21) Install the radiator to vehicle. 22) Install the air intake duct, air cleaner case and air intake chamber. 23) Install the under cover. 24) Install the battery in the vehicle and connect cables. 25) Fill engine coolant. 26) Check the ATF level and replenish it if necessary. 27) Charge the A/C system with refrigerant. 28) Remove the front hood stay, and close the front hood. 29) Take off the vehicle from a lift. C: INSPECTION LU-00223 1) Check the pipes and hoses are installed firmly. 2) Check the engine coolant and ATF are at specified levels. 15) Install the front and center exhaust pipe. 16) Lower the vehicle. 17) Connect the following hoses. (1) Fuel delivery hose, return hose and evaporation hose (2) Heater inlet and outlet hoses (3) Brake booster vacuum hose 18) Connect the following connectors: (1) Front oxygen (A/F) sensor connector (2) Rear oxygen sensor connector (3) Engine ground cable Tightening torque: 14 N⋅m (1.4 kgf-m, 10.1 ft-lb) (4) Engine harness connectors (5) Generator connector and terminal (6) A/C compressor connector ME(H4SO 2.0)-34 G2360GE.book 35 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Engine Mounting MECHANICAL 10.Engine Mounting A: REMOVAL 1) Remove the engine assembly. 2) Remove the engine mounting from engine assembly. B: INSTALLATION Install in the reverse order of removal. Tightening torque: Engine mounting 35 N⋅m (3.6 kgf-m, 25.8 ft-lb) C: INSPECTION Make sure that no crack or other damages do not exist. ME(H4SO 2.0)-35 G2360GE.book 36 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Preparation for Overhaul MECHANICAL 11.Preparation for Overhaul A: PROCEDURE 1) After removing the engine from body, secure it in the ST shown below. ST1 498457000 ENGINE STAND ADAPTER RH ST2 498457100 ENGINE STAND ADAPTER LH ST3 499817100 ENGINE STAND ST3 ST2 ST1 ME-00221 2) In this section the procedures described under each index are all connected and stated in order. The procedure for overhauling of the engine will be completed when you go through all steps in the process. Therefore, in this section, to conduct the particular procedure within the flow of a section, you need to go back and conduct the procedure described previously in order to do that particular procedure. ME(H4SO 2.0)-36 G2360GE.book 37 ページ ２００７年１１月２９日 木曜日 午後１時２８分 V-belt MECHANICAL 12.V-belt 4) Remove the belt tensioner. A: REMOVAL NOTE: Perform the following procedures with the engine installed to the body. 1. FRONT SIDE BELT 1) Remove the V-belt covers. ME-00225 B: INSTALLATION NOTE: Wipe off any oil or water on the belt and pulley. 1. FRONT SIDE BELT ME-00222 2) Loosen the lock bolt (A). 3) Loosen the slider bolt (B). 4) Remove the front side belt (C). (C) 1) Install the V-belt (C), and tighten the slider bolt so as to obtain the specified belt tension. 2) Tighten the lock bolt (A). 3) Tighten the slider bolt (B). Tightening torque: Lock bolt (A) 25 N⋅m (2.5 kgf-m, 18.4 ft-lb) Slider bolt (B) 8 N⋅m (0.8 kgf-m, 5.8 ft-lb) (B) (A) ME-00223 (C) (B) 2. REAR SIDE BELT 1) Loosen the lock nut (A). 2) Loosen the slider bolt (B). (A) (B) (A) ME-00224 3) Remove the rear side belt. ME(H4SO 2.0)-37 ME-00223 G2360GE.book 38 ページ ２００７年１１月２９日 木曜日 午後１時２８分 V-belt MECHANICAL 2. REAR SIDE BELT Belt tension (with belt tension gauge): 1) Install the belt tensioner. 2) Install the V-belt, and tighten the slider bolt (B) so as to obtain the specified belt tension. 3) Tighten the lock nut (A). Front side belt When installing new parts 618 — 755 N (63 — 77 kgf, 139 — 170 lbf) At inspection 490 — 640 N (50.0 — 65.3 kgf, 110.2 — 143.9 lbf) Tightening torque: Lock nut (A) 23 N⋅m (2.3 kgf-m, 17.0 ft-lb) Rear side belt When installing new parts: 740 — 880 N (75.5 — 89.7 kgf, 166 — 198 lbf) At inspection 350 — 450 N (35.7 — 45.9 kgf, 78.7 — 101.2 lbf) (B) (A) (A) P/S A/C GEN (B) ME-00224 C: INSPECTION 1) Replace the belts, if crack, fraying or wear is found. 2) Remove the V-belt cover and reservoir tank. (with belt tension gauge) 3) Check the V-belt tension and adjust it if necessary by changing the generator installing position or idler pulley installing position. I/P C/P PM-00154 (A) (B) C/P GEN P/S A/C I/P ME(H4SO 2.0)-38 Front side belt Rear side belt Crank pulley Generator Power steering oil pump pulley Air conditioning compressor pulley Idler pulley G2360GE.book 39 ページ ２００７年１１月２９日 木曜日 午後１時２８分 V-belt MECHANICAL Belt tension (without belt tension gauge): Front side belt When installing new parts 7 — 9 mm (0.276 — 0.354 in) At inspection 9 — 11 mm (0.354 — 0.433 in) Rear side belt When installing new parts 7.5 — 8.5 mm (0.295 — 0.335 in) At inspection 9.0 — 10.0 mm (0.354 — 0.394 in) (C) P/S GEN (A) (B) A/C I/P C/P ME-00226 (A) (B) (C) C/P GEN P/S A/C I/P Front side belt Rear side belt 98 N (10 kgf, 22 lbf) Crank pulley Generator Power steering oil pump pulley Air conditioning compressor pulley Idler pulley ME(H4SO 2.0)-39 G2360GE.book 40 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Crank Pulley MECHANICAL 13.Crank Pulley 3) Confirm that the tightening angle of the crank pulley bolt is 45° or more. Perform the following procedures when less than 45°. A: REMOVAL 1) Remove the V-belts. 2) Remove the crank pulley bolt. To lock the crankshaft, use the ST. ST 499977400 CRANK PULLEY WRENCH (2.0 L model) ST 499977100 CRANK PULLEY WRENCH (2.5 L model) ST ME-00227 3) Remove the crank pulley. B: INSTALLATION 1. 2.0 L MODEL 1) Install the crank pulley. 2) Install the pulley bolt. To lock the crankshaft, use the ST. ST 499977400 CRANK PULLEY WRENCH (1) Clean the crankshaft thread using compressed air. (2) Apply engine oil to the crank pulley bolt seat and thread. (3) Tighten the bolts temporarily with tightening torque of 44 N⋅m (4.5 kgf-m, 33 ft-lb). (4) Tighten the crank pulley bolts. Tightening torque: 130 N⋅m (13.3 kgf-m, 95.9 ft-lb) CAUTION: If the tightening angle of crank pulley bolt is less than 45°, the bolt should be damaged. In this case, the bolt must be replaced. (1) Replace the crank pulley bolts and clean them. Crank pulley bolt: Part No. 12369AA011 (2) Clean the crankshaft thread using compressed air. (3) Apply engine oil to the crank pulley bolt seat and thread. (4) Tighten the bolts temporarily with tightening torque of 44 N⋅m (4.5 kgf-m, 33 ft-lb). (5) Tighten the crank pulley bolts keeping them in an angle between 45 — 60°. NOTE: Conduct the tightening procedures by confirming the turning angle of crank pulley bolt referring to the gauge indicated on timing belt cover. 4) Install the belt tensioner. ME-00225 5) Install the V-belts. 2. 2.5 L MODEL ST ME-00227 1) Install the crank pulley. 2) Install the pulley bolt. To lock the crankshaft, use the ST. ST 499977100 CRANK PULLEY WRENCH (1) Clean the crankshaft thread using compressed air. (2) Apply engine oil to the crank pulley bolt seat and thread. (3) Tighten the bolts temporarily with tightening torque of 44 N⋅m (4.5 kgf-m, 33 ft-lb). ME(H4SO 2.0)-40 G2360GE.book 41 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Crank Pulley MECHANICAL (4) Tighten the crank pulley bolts. Tightening torque: 180 N⋅m (18.4 kgf-m, 132.8 ft-lb) ST ME-00227 3) Confirm that the tightening angle of the crank pulley bolt is 65° or more. Perform the following procedures when less than 65°. (1) Replace the crank pulley bolts and clean them. Crank pulley bolt: Part No. 12369AA011 (2) Clean the crankshaft thread using compressed air. (3) Apply engine oil to the crank pulley bolt seat and thread. (4) Tighten the bolts temporarily with tightening torque of 44 N⋅m (4.5 kgf-m, 33 ft-lb). (5) Tighten the crank pulley bolts keeping them in an angle between 65 — 75°. NOTE: Conduct the tightening procedures by confirming the turning angle of crank pulley bolt referring to the gauge indicated on timing belt cover. 4) Install the belt tensioner. ME-00225 5) Install the V-belts. C: INSPECTION 1) Make sure the V-belt is not worn or otherwise damaged. 2) Check the tension of the belt. ME(H4SO 2.0)-41 G2360GE.book 42 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Timing Belt Cover MECHANICAL 14.Timing Belt Cover A: REMOVAL 1) Remove the V-belts. 2) Remove the crank pulley. 3) Remove the timing belt cover (LH). 4) Remove the front timing belt cover. (B) (A) ME-00821 (A) Timing belt cover (LH) (B) Front timing belt cover B: INSTALLATION 1) Install the front timing belt cover. Tightening torque: 5 N⋅m (0.5 kgf-m, 3.7 ft-lb) 2) Install the timing belt cover (LH). Tightening torque: 5 N⋅m (0.5 kgf-m, 3.7 ft-lb) (B) (A) ME-00821 (A) Timing belt cover (LH) (B) Front timing belt cover 3) Install the crank pulley. 4) Install the V-belts. C: INSPECTION Check the cover for damage. ME(H4SO 2.0)-42 G2360GE.book 43 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Timing Belt MECHANICAL 15.Timing Belt A: REMOVAL (d) 1. TIMING BELT (c) 1) Remove the V-belts. 2) Remove the crank pulley. 3) Remove the timing belt cover. 4) Remove the timing belt guide. (MT model) (a) (b) (f) (e) ME-02533 ME-00065 5) If the alignment mark (a) or arrow mark (which indicates rotation direction) on timing belt fade away, put new marks before removing the timing belt as shown in procedures below. (1) Use the ST to turn crankshaft. Align the mark (a) of sprocket to the cylinder block notch (b), and then ensure the adjustments between right side cam sprocket mark (c) and cam cap and cylinder head matching surface (d), and between left side cam sprocket mark (e) and timing belt cover notch (f) are properly adjusted. ST 499987500 CRANKSHAFT SOCKET (2) Using white paint, put an alignment mark or an arrow mark on the timing belts in relation to the crank sprocket and cam sprocket. ME-00233 Specified data: Z1: 46.8 tooth length Z2: 43.7 tooth length Z1 Z2 ST ME-00231 ME-00234 6) Remove the belt idler (No. 2). ME(H4SO 2.0)-43 G2360GE.book 44 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Timing Belt MECHANICAL B: INSTALLATION 7) Remove the belt idler No. 2. 1. AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER 1) Preparation for installation of automatic belt tension adjuster assembly ME-00235 8) Remove the timing belt. ME-00236 2. BELT IDLER AND AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY 1) Remove the belt idler (No. 1). CAUTION: • Always use a vertical type pressing tool to move the adjuster rod down. • Do not use a lateral type vise. • Push the adjuster rod vertically. • Press-in the push adjuster rod gradually taking more than three minutes. • Do not allow press pressure to exceed 9,807 N (1,000 kgf, 2,205 lbf). • Press the adjuster rod as far as the end surface of the cylinder. Do not press the adjuster rod into cylinder. Doing so may damage the cylinder. • Do not release the press pressure before stopper pin is completely inserted. (1) Attach the automatic belt tension adjuster assembly to the vertical pressing tool. (2) Slowly move the adjuster rod down with a pressure of 294 N (30 kgf, 66 lbf) or more until the adjuster rod is aligned with the stopper pin hole in the cylinder. ME-00239 ME-02404 2) Remove the automatic belt tension adjuster assembly. (3) With a 2 mm (0.08 in) dia. stopper pin or a 2 mm (nominal) dia. hex wrench inserted into the stopper pin hole in cylinder, secure the adjuster rod. ME-00238 ME-00350 ME(H4SO 2.0)-44 G2360GE.book 45 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Timing Belt MECHANICAL 2) Install the automatic belt tension adjuster assembly. ST2 499207400 CAM SPROCKET WRENCH (A) Tightening torque: 39 N⋅m (4.0 kgf-m, 28.9 ft-lb) ME-00243 ME-00241 (2) While aligning alignment marks (B) on the timing belt with marks (A) on sprockets, position the timing belt properly. 3) Install the belt idler (No. 1). Tightening torque: 39 N⋅m (4.0 kgf-m, 28.9 ft-lb) ME-00244 3) Install the belt idler No. 2. ME-02404 2. TIMING BELT 1) Prepare for installation of automatic belt tension adjuster assembly. 2) Install the timing belt. (1) Turn the cam sprocket No. 2 using ST1, and turn the cam sprocket No. 1 using ST2 so that their alignment marks (A) come to top positions. ST1 18231AA010 CAM SPROCKET WRENCH Tightening torque: 39 N⋅m (4.0 kgf-m, 28.9 ft-lb) 4) Install the belt idler (No. 2). Tightening torque: 39 N⋅m (4.0 kgf-m, 28.9 ft-lb) NOTE: CAM SPROCKET WRENCH (499207100) can also be used. ME(H4SO 2.0)-45 ME-00235 G2360GE.book 46 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Timing Belt MECHANICAL 5) After ensuring the marks on timing belt and cam sprockets are aligned, remove the stopper pin from belt tension adjuster. (3) Tighten the timing belt guide mounting bolts. Tightening torque: 10 N⋅m (1.0 kgf-m, 7.4 ft-lb) ME-00245 6) Install the timing belt guide. (MT model) (1) Temporarily tighten the timing belt guide mounting bolts. ME-00247 7) Install the timing belt cover. 8) Install the crank pulley. 9) Install the V-belts. C: INSPECTION 1. TIMING BELT ME-00230 (2) Check and adjust the clearance between timing belt and timing belt guide by using thickness gauge. Clearance: 1.0±0.5 mm (0.039±0.020 in) 1) Check the timing belt teeth for breaks, cracks or wear. If any fault is found, replace the belt. 2) Check the condition of the backside of belt. If cracks are found, replace the belt. CAUTION: • Be careful not to let oil, grease or coolant contact the belt. Remove quickly and thoroughly if this happens. • Do not bend the timing belt sharply. In radial diameter h: 60 mm (2.36 in) or more h ME-00246 ME-00248 ME(H4SO 2.0)-46 G2360GE.book 47 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Timing Belt MECHANICAL 2. AUTOMATIC BELT TENSION ADJUSTER 1) Visually check the oil seals for leaks, and rod ends for abnormal wear and scratches. If necessary, replace the automatic belt tension adjuster assembly. NOTE: Slight traces of oil at rod’s oil seal does not indicate a problem. 2) Check that the adjuster rod does not move when a pressure of 294 N (30 kgf, 66 lbf) is applied to it. This is to check adjuster rod stiffness. 3) If the adjuster rod is not stiff and moves freely when applying 294 N (30 kgf, 66 lbf), check it using the following procedures: (1) Slowly press the adjuster rod down to the end surface of the cylinder. Repeat this operation two to three times. (2) With the adjuster rod moved all the way up, apply a pressure of 294 N (30 kgf, 66 lbf) to it. Check the adjuster rod stiffness. (3) If the adjuster rod is not stiff and moves down, replace the automatic belt tension adjuster assembly with a new one. 3. BELT TENSION PULLEY 1) Check the mating surfaces of timing belt and contact point of adjuster rod for abnormal wear or scratches. Replace the automatic belt tension adjuster assembly if faulty. 2) Check the belt tension pulley for smooth rotation. Replace if noise or excessive play occurs. 3) Check the belt tension pulley for grease leakage. 4. BELT IDLER 1) Check the belt idler for smooth rotation. Replace if noise or excessive play occurs. 2) Check the outer contacting surfaces of idler pulley for abnormal wear and scratches. 3) Check the belt idler for grease leakage. CAUTION: • Always use a vertical type pressing tool to move the adjuster rod down. • Do not use a lateral type vise. • Push the adjuster rod vertically. • Press the adjuster rod gradually taking more than three minutes. • Do not allow press pressure to exceed 9,807 N (1,000 kgf, 2,205 lbf). • Press the adjuster rod as far as the end surface of cylinder. Do not press the adjuster rod into cylinder. Doing so may damage the cylinder. 4) Measure the amount of rod protrusion beyond the body. If it is not within specifications, replace with a new one. Amount of rod protrusion H: 5.7±0.5 mm (0.224±0.020 in) H ME-00249 ME(H4SO 2.0)-47 G2360GE.book 48 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Cam Sprocket MECHANICAL 16.Cam Sprocket B: INSTALLATION A: REMOVAL 1) Install the cam sprocket No. 1. To lock the crankshaft, use the ST. ST 499207400 CAM SPROCKET WRENCH 1) Remove the V-belts. 2) Remove the crank pulley. 3) Remove the timing belt cover. 4) Remove the timing belt. 5) Remove the camshaft position sensor. 6) Remove the cam sprocket No. 2. To lock the camshaft, use the ST. ST 18231AA010 CAM SPROCKET WRENCH Tightening torque: 78 N⋅m (8.0 kgf-m, 57.9 ft-lb) NOTE: Do not confuse the cam sprocket LH with RH during installation. Cam sprocket No. 2 can be identified by a protrusion used to monitor the camshaft position sensor. ST NOTE: CAM SPROCKET WRENCH (499207100) can also be used. ME-00251 2) Install the cam sprocket No. 2. To lock the camshaft, use the ST. ST 18231AA010 CAM SPROCKET WRENCH NOTE: CAM SPROCKET WRENCH (499207100) can also be used. ST ME-00250 Tightening torque: 78 N⋅m (8.0 kgf-m, 57.9 ft-lb) 7) Remove the cam sprocket No. 1. To lock the camshaft, use the ST. ST 499207400 CAM SPROCKET WRENCH ST ST ME-00250 ME-00251 3) Install the camshaft position sensor. 4) Install the timing belt. 5) Install the timing belt cover. 6) Install the crank pulley. 7) Install the V-belts. ME(H4SO 2.0)-48 G2360GE.book 49 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Cam Sprocket MECHANICAL C: INSPECTION 1) Check the cam sprocket teeth for abnormal wear and scratches. 2) Make sure there is no free play between cam sprocket and key. 3) Check the cam sprocket protrusion used for sensor for damage and contamination of foreign matter. ME(H4SO 2.0)-49 G2360GE.book 50 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Crank Sprocket MECHANICAL 17.Crank Sprocket C: INSPECTION A: REMOVAL 1) Check the crank sprocket teeth for abnormal wear and scratches. 2) Make sure there is no free play between crank sprocket and key. 3) Check the crank sprocket protrusion used for sensor for damage and contamination of foreign matter. 1) Remove the V-belts. 2) Remove the crank pulley. 3) Remove the timing belt cover. 4) Remove the timing belt. 5) Remove the cam sprocket. 6) Remove the crank sprocket. ME-00103 B: INSTALLATION 1) Install the crank sprocket. ME-00103 2) Install the cam sprocket. 3) Install the timing belt. 4) Install the timing belt cover. 5) Install the crank pulley. 6) Install the V-belts. ME(H4SO 2.0)-50 G2360GE.book 51 ページ ２００７年１１月２９日 木曜日 午後１時２８分 Valve Rocker Assembly MECHANICAL 18.Valve Rocker Assembly (3) Tighten the bolts (a) through (d) to specified torque. A: REMOVAL 1) Remove the V-belts. 2) Remove the crank pulley.