SUBARU 1989 SERVICE MANUAL QUICK REFERENCE INDEX (1] GENERAL SECTION Bieselaouen sd D pels ea ea exc) PRE-DELIVERY INSPECTION ied PERIODIC MAINTENANCE SERVICES Ato) SPECIAL TOOLS ] (2) ENGINE SECTION EMISSION CONTROL SYSTEM AND VACUUM FITTING ON-CAR SERVICES B CARBURETOR eee B Saou Bane CLUTCH PONE mao Soe MOUNTING SYSTEM a1 TRANSMISSION AND DIFFERENTIAL SECTION MANUAL TRANSMISSION oye tas al AT mi Lo) 3-2 EPs a Riise Re kL eee eoLL=aal 4WD SYSTEM ofe 1 oABBREVIATION LIST Alc ‘Air Conditioner cywe Gross Vehicle Weight Rating Acc ‘Accessory HI High (Speea) AIC pulley Ar Conditioner compressor pulley He Horse Power ALT pulley Alternator pulley I6-COW Ignition Coil API American Petroleum Institute IG SWITCH Ignition Switch Approx Approximately INT Intermittent (Wiper) ASsY Assembly ue Idler Pulley as Air Suction Valve LH Left-hand aT ‘Automatic Transmission Lo Low (Speed) ATE ‘Automatic Transmission Fluid isd Limited Slip Differential BILEV Bi-evel MPFI Multi Point Fuel Injection BJ Joint MT Manual Transmission BP British Petroleum, Pov Positive Grankcase Ventilation Broo Before Top Dead Center PHY Pressure Holding Valve Cali. California PIN Parts Number Carb, Carburetor P/S pulley Power Steering oll pump pulley cP Complete RAD FAN Radiator Fan or Crankshaft Pulley DEF oar Defogger TR Center RH Right-hand cw Curb Weight SAE Society of Automotive Engineers Inc. DIFF Differential ‘SPFI ‘Single Point Fue! Injection Dos Double Offset Joint S/R Single-range DIR Dual-range To Torque Converter psPD Dry Single Plate Diaphragm TEMP GAUGE Temperature Gauge Eos. Electric Control System var Variable Gear Ratio FMVSS Federal Motor Vehicle Safety vn Vehicle Identification Number Standards W/height control with height contro! Fwo Front whee! drive (2WD) WIP pulley Water Pump pulleySPECIFICATIONS SUBARU | circ noon. 1989SPECIFICATIONS 4DOOR SEDAN MODEL wo out0 OL BL ot st | cu | Se set | seri | seri | serv | seri | MPF ae sur | gat | swt | sat | gat } sat aes yam | ame | 445 | 408 | aaa | aaa | 8A36 ennai tm | zee | ozs | ates | ares | zs | 740) Overs with ‘mins | 982 | 1880 | tes0 [eso | 1se0 | 1.660 isa | (ca | cs | tsa) | 54) | 165.4) vse | vase | 1ase | isa) tase | 1,004 vera height ro in ; aah a Toman men woe0 | t.080 | 1080 | 1060 [1.060 [1.060 eae gun | an | on | an | aun | ann Rear Min, om tnd | (298 = Ld La} eee csr {esa | 52 | a5 | 52 | 52 ‘compere Hara ase 954 954 354 ose | 64 ment | eas ere | ers | ire | ore | G26 | Gre rom aman | 228 228 78 228 928 928 ess | ess) | oso | ces | ces) | 65) ‘rovider room amin | 1360 | 160 | 1as0 | taco | 1250 | 1.360 cs | ess | oss | oss) | eos | 05) ana mean} 2470 | 2470 | 247 | 2470 | 2470 |” 2470 Aides Gor] tra _| ora | tera | ora | wa | wa Tom aman | 1425 | teas | taos | 1aze | teas [1628 eee won [| en | wen | gen | 6x | icon mu wwnmp | 125 | tae | tas [teas [1425 | 1425 won | wen | con | een | cen | i660 Wirimum road cearonce| vam fay | 1906.1) | 190152 | 190151) | 130168 | 12006.) | 130660) Tom gem FTO fot 62s [oa exe [ez 637-3 Gas [-3 707 3) aaa) | nae | ars | aos | t.c0s_| 1560) ror Spee mewn |? 408 ht 408 [2 ats Pa a0 [oa aaa [5 486 USA “ se [* ceo _| arsi_| 25) | e800 _| 11,0051 Four wpm PERO [11098 [21099 [rz 057 |-s aaa” [es 1.168 cue 3) | 'iaiae0) | t2200 | 12.200 | was | 248s | 12.565) weit Fon wpe 7,70, [7 625 [rr ont [m1 635 *3 703 gsa5 | 0380 | aso | cacao | (1.550) For = 405 [aoe [oa aig [oa 237 a 490 bie Canaan | Peer *9 | cas) | 1900) fF (901 = 1016 [11,098 731.182 Tow! tote) | gzaoy_| 2.280) a (2540) ea 346 302 ‘352 From K9(0) | fxa601_|_ 11.8601 s000_| 1.3000 crouverice TR ago | 72 72 72 712 730 730 weight | aso | csr | trs7o | aso | asta | 110, Ton wpe | 1856 | 1866” | vs86 [uses | 602) 1802 ow 400) | giao | aes | caso | aso | stor | sto Sir The weight of power eering # inched im GWE +2: The wnight of power steering, power window, and aute door lack system is included in CN, <3) The weight of sunroof, aie conditioner. power steering, power window, digits instrument pane! crulse control and auto door lock system f included in CW.SPECIFICATIONS 1 000k SEDAN ODE a Farina | Pane | Fane “no” | “ano” | “awe oe bi RX GLA0 GL10 runeo | rune | +0m09 oF wer | wri sur | Set | See |r] MRE vrew om om_|_ in oF cam | e438] anaes] aan] ase] aaa ones fo) | a7as) 174.6) 1974.6) 4174.6) (174.6) ae vomins) 1880 | 3880 | 160 sae0 | ss Creat: a (65.4) (65.4) (65.4) {65.41 Swan maa} 238] e380 ‘a0 | 1410 eee Vel | 6a) (54.3) (88.5) 165.5) ‘oe0 feo ‘om | 1980 fF oe eee eer eae (4.7) a7) (ant) sts00m Sel neon 08 | ae on . (38.2) (38.2) 438.2) (35.2) eamenr yor aman} at] ate esa] 84 mant Head t (37.6) (37.6) 37.6) 376) 137.6) room mam | 808] ame | ean] om oe 7 436.5) 136.5) (38.8) (36.5) (36.5) wonmuen mam | tase | tao] 180] 1860] 1860 ion | ao | tom | es | com Henn oun | ass [aes ass | 2455 irar_| foro) fro_|_6701 ce amen fs | 0 ‘aio | 10 ae isso) | ton aa |_ ioe wa wma | aes | as eas) as ise | ten iseni_| tan ii cad ewan at | apie | e016. | vee | v60 6) | Y09 63 cow bow |? 82 [2 oe Ps OR [Te [8 ey | “wen | “evseo | “ware | Seems ta Ta wun PE ate [2 ame PO wor | se ono visa [Fer #9 | “isoaoy | “c.04sr | 1.008) (0.190) oar naw PRAT 21.20.00 “5 258 cus case [ero | ees) cr vo 69 | we 7 ferrite beth atet 9,420) ee # (1.665) fos aa [a a 7 a at Canace | °F 9") | 11,035) (1,040) i 7 (1,130) Fie Pie ie - Tout koto) | zaasy | ‘aso | - = 2795) con won| a8) ae] ome a0 | 00. | g00 | 15250 | 1.625) Grom sete wm] ca 38 | me | e2 weight Rear #9) | 1660) (1,660) (1,725) 41,728) 11,728) caw moun | 2see | ssaa [sero [neo | rr0 ba fe (3,460) 13,460) (3,550) (3,550) (3,560) 7 The weight of power steering is inluded in GON. "2: The weign of power staring, power window and auto door lock system i included in CW, +3: The weight of ai concition Power steering, poner window, auto door lok system, L.S.0, and AX package it included in CW, 4; The weight of sunroof, ar conditioner, power stering, power window, digital Instrument panel, cruise contol, aute door lock system and LSD. is inluded In Ci, “5: The woight of sunroof, air coniioner, power staring, ower window, digital instrurmont pane, cr Ince in CW. contal and ate door lack system it1 SPECIFICATIONS 4.DOOR SEDAN MODEL FW Cer OL ou. ou ou cero | Suto, seri) seri | seet | sort | sori NPE 7 AT 3AT eal MT aAT swt | 3m 3 Seating pasny enon 3 Horizontally opposed, liquid cooled, cylinder, 4stroke gasoline engine ‘wih Malt Engine ype Point Feel Wi SinglePoit Fut rection cancel rstocks Vane arora Svea coma noe Bore xavoke ont 32 x67 (962x264) Daplcemenn =a lovin 1.794 10858) Comprenion reve ws [ss] es | 05 | 9 7 Firing order 1324 Innion timing diva peed eTOCIomey | aorr00 | zar/v00 | 20r00 | z0"r00 | 20°/700 | 20"/e00 iaing peed revel, Nor Pasion rpm | 700s100 | To0rr00 | 7oos100" | 7o0=100 | 700s100 | 800s100 NGK;—__GPRGES.11 (or PRBES-7, BPATESA Som ous | Type and manutectorer Nippondenso: W2OEPR-UI for WIBEPRAU1, WZZEPR-UNTD Ghompion:_ ANBYCA oximum outst Wirom 8418200 19615200, ‘Maximum toraue Nim tegen, Feb) 737 (74.0, 1019/2,800 TBS | Type a6a0R MF RSD2GRIF[50020R-MF BEOZIRMF [SGDZORME [5029 aocey — [Resrncanaciy mind | 7 | mms ~ [om | om |e Coldcrankingamarre amo.) | 308 | ao | aoe | #20 | «20 | «90 Hera 12v.60A Gite ype ee a Te ronson 58 2 73 2 3 3 3 1" zeae | a0 | sea | aaa | zai | 2021 2nd 1960 | 1569 | 1950 | 1850 | 169 | 1.589 cerane [2.0700 1364 | 1.000 | 1248 | 1.000 | +000 | 1.000 ae oan | - | osm | - = = Bh ‘ome | - | ov | = = = Revere ano | 22s? [asso | 2267 | aze7_| 2287 Foxifory | vigh ~ = = = = a grave” [tow = = = = = 7 Redocuon Pe [PEO = raver | re mur” | eeuction [Recvctinaaraie | =| ose | _- | oa | care batait Final ‘Type of gear Hypoid Hypoid Hypoid Hypoid Hypoid Hypoid one reduction | Reduction gear ratio | 3.900. 3.700. 3.900 3.700 3.700, 3.484 SPD: ry Sle Pe Dap 1" Withowt suum Te + Torq Converter 52, Stonmra needs with schromesh and {eve +3: Full aomatie, Mforward and reverseSPECIFICATIONS 1-1 4.000R SEDAN ~ Fulltime | Fulltime | Full time iad = ‘RX GL10 GLO ge | se |e | me [me ioe ‘Tyee J50020R.MF [6s023R-mF |50020R MF [50020R-MF |75023R-MF Se ‘sth oreo | — on oar 7 etter a aot ae ee ee eos [um ooze tot se Sn ‘eae reduction | Reduction gear ratio |= 0.974 7 = 1.000 (Front Final “Type of gear Hyooid | Hypoid | Hypoid | Hypois | Hypoic ariel | reduction [Reouetion gear vo | 3900 | 3.700_| 3.700 | 3.700 700, SPD: Dry Single Plate Diaphragm TC: Torque Converter +2: 3 5: 6: TWeihaur vacuum Fall automatic, forward and reverse S5x2forwerd spzeds with syrehvomesh and treverse (Dual ange) Sx2torword speece with synehromenh a ‘veeverts (Dua ng) ~ with centr efferent Stforward speeds with eynchramean and T~ravers (Single range! ~ with center iferential Full automat onward and VreverseSPECIFICATIONS 4-DOOR SEDAN ‘MODEL FWD eu10 DL. OL. ou ou Going evan seri | seri | seri | sper | srt Mri aut | oar swt | 3aT aaT 3AT rem varter [Tbe oF gear = = a = 7 - Reduction | Tans eee sear reduction [Reduction aearratio | _— = = = = = (pear Pinas | Tvpe of eae = = 7 7 a tive)” [resuction [Reauetion searratio | = = = = = Typ Rack and pinion steering | Turns, lock t tok 37, system inimom turning ia ‘tire e518) circle"! ia At bumper 10.8 (942) Front MacPherson strut type, Independent, Coll spring Suspension Fear Semisrailing arm type, Independent, Coil soring ‘Service brake system ‘Dual ercult hydraulic with vacuum suspended power unit Front Ventilated dive broke Brake esr Drom brat Disc brake Parking brake Size 1S55R13 175/708R13 A7570HRI Tyee ‘Steal bated radial, Tubes Fuel enk capacity 2 (US, imp abl) 60 (15.9, 182) Engine [ Unperievel @(USat Imo at 40 142,95) oil [Lower level _® (US at Imp atl 30 182,26) i 26 26 ze 7 e Teansmision gear ol! 2¢USatImoat) | 755] - | sea Raia 62:01 eisoa | 62101 | 62001 eles etusa,inpan | - | weeror, | - | t6e.0.1, | (eso, | eee01, 3 55:01) 35:01) | S5x0.11 | 5.40.1) ‘AT eiforential gor 12 1 12 12 Sau etusartmeal | fossa | 7 Losin | asin | os “20D vou differential failed 2UUSat Imad | — 7 ~ - - - ; o7 o7 O7 7 o7 7 Powerrewrina fis BAUS at impat! | (07,06) | (0.7.06) | 10.7.0) | 07,06) | (0.7.06) | 17,08 60 3,83) Engine coolant (US, imp ath 55(68,48) a (53,48) “T Cubwecub "2; For CANADASPECIFICATIONS 4-D00R SEDAN wWODEL ai i Ful tine] Full ame | Fa me ‘wo | “awe” | “ano be a RX GLO Gio rurao_| runso | vuneo w]e, | wT Pr : sur | SE | Se Sire | mee rem on om_| om momen | tater rorstoer a Reswcton | fection [Reduevon arto | 1000 | 09a [1000x000 | = {em Tri | Toner oe Vvoo'd | ryeai@ | Pyocia | Hyped | wrod a reduction | Reduction gear ratio | 3.800 3.900 3.700, 3.700. Type ack ea pio stieing [Tor eck oreck 2 system Minimum wrri9g ay ALO wwe STS) Sart ‘Avbumser” 108 (8) aa WesPoeon srt ve, independent, - oi er ‘Suspension oe erin meer = ising wm Brae, 7 fe Coil spring Sena bake natn leat hyalina wipeded power wie Fone Ventated ic bake Brake rum brake Z ids [Leading & trailing type) en Fang Boe uranic on on Bake . ee Tarosna resr0nhi8 Pe Type ‘Stee! belted radiet, Tubeless Fon tok epecly 21S, root c01r58, 182) nine | Uboeeet_¢(USat, Ir a 49162.38) ot | Lower val € (Sar, lp at 302,28) a3 as | 38 Tananisiongeerot 2080 mea | 235 | - | aca | wean canon Astomatie wae 35 > | Aone tusa.incad} - | teaor, | - etal z | nontns e010 tvoa. 8a) 8 | araiieonian er 12 a oil he meee ii (25,21) ss af 13.0.2.5) rr aa a a TT gear cil (USat.ImP a? | (9.8.0.7) | (08,0.71 | 10.8,0.71 | (0.8.0.7) | 10.8,0.7) a7 | 07 [07 07] a7 A bcssdtensatatd 81USat.Imeat | 7,061 | 10.7,061 | 10.7.0.) | 107,08) | 10.7,08) Eegine coolant 8 (US a, Ino g s8i60.48) Sy eu oa 52. since su ye, ndepeden, Prnumatc venom wih Reig cont 3: Sersi-riting am type, Independent, Preurnaticsusoersion with height contol For CANADA, 11 SPECIFICATIONS STATION WAGON MODEL, FWD suo bu. ou ou cu ciao | Sino seri | seri | seri} spet | seri | Mort asia SMT 3aT eur SAT SAT aT 7290 aa cm to) |,.0788) | 4490 4490 | 4490 | 4,490 beaaio | zee. | 0768) | ca) | 1768) | (768) 073.6) euiait nmin | 1260 | 1860 | 1600 | 4600 | ves0 [1.650 sa) | ssi | tos) | sa | ese) | 654) aeoeae many) 145 | 1045 | 1345 | saae | taas | aaae wo | sor | a0 | wo | 30) | 301 mame mmm | 1 | 1605 | 1805 | tees | 160s | 1645 ae was | asi | wa | waar | caar | t64ai pte [sep gag Seeataay: |e 205 205 805 205 005 ei | om | orm | arn | ein | in ara Kamau mim | 1860 | 1360 | 1360 | 1aeo | iae0 | 1,300 pelea |paeaatta| eet si | os5 | was) | was | oss) | 38) ene mim | 130 | 1360 | 1360 | 1360 | 1260 | 1360 wos) | 635 | a5 | ws | oss | 26) mae aera ee 395 25 295 95 395 = 52) | 52 | 52 | wz | woz) | 52 r 2aes | 2408 | 2.066 | 2468 | 2405 | 2468 eee mind | zo | ozo | ero | io | 701 | i970 yon amin} 1420 | 1420] 1420 | 1420 | 1420 | 1420 ea cso | so | so | ws | aso | so for mmimy | 125 | tees | teas | faze | taas | 128 : wen | sen | wan | wen | wer) | sar ‘Minimum road eiarance metal | 140165) | 140156) | 14058) | 140;85) | 140165) | 1401581 “7 608 1 wont egiby |, 19401 [*2 619 [+2 61s [ez ot |v 676 Ia 700 lI lee 695 | anaes) | cass» | «1.3901 | 490) | e550) 4,200) “467 For | car ui |, (1.0201 1474 rz aga dea ana [oo 506 9 58 usa, 4458 | inoasy | 0,085) | “c,0001 | aati) | 11.135) (1910) cub weignt | Our ee sy1o93 f2107 |o24a28 +3 x82 fra sai | ° weir | r2aa0r | “24801 | 20s) | (2.685 ere 1 619 [1 12 [1 628 *3 703 ponies cas) | caso | oes | 4.580) ror [, wore [1 207 aa Yt ase TY 50 (S58 Canada | Per 1930) | troasy | 4.075) | (1.0801 1138) Tow wow [11075 [1.000 [11,100 [ria | _ — [srai8 * @ar | sr | ars | anes 7585) 77 The weight of power seering i included n GW. +2: “The weignt af poner searing, power windows and auto door lok system i included In CW. +3: The weight of suneoof, ai conditioner, pone steering, dower window, digital instrument panel, euise control end auto door loek system it included in Ca “A For Puerto Alco model onlySPECIFICATIONS 11 STATION WAGON woDEL 0 Full ume | Full time cL awa | WD i a oo TURBO GLA0 GL10 Tumse | run wa] art wwe wo ee rem sm |_on am |_am ae amie | 4830 | 4400 | aa0 | 490 | aac | 4.490 Avectell i Fol) 76.80 076.8) (176.8) (076.8) 176.8) 4176.8) aaa au | 1880} ano] —va80 | i000] 800) v0 tesa | tsa | en | wom | tem | sal aaa cam | 1898 1488] sas [155 | —sa95 | 45 : (54.9) (54.9) (54.9) (84.9) (54.9) (66.1) cama amen} tae] tae] nas | aa} nace] 1808 ae tear | eo | wen | wen | wen | eer Bete eat eC 205 805 805 60s | 85 ann | orn {| arm | ain | ern | an corg0 m?usa mmm | 1880 | 1260 | 1360. | 1a60 | 1260 [1360 | an was | oo | won | eam | on | can Temew pun] 4380] 1200] 1380" "[ ae | —va60 | 1360 : 153.5) (53.5) (53.5) 153.5) (53.5) (53.51 a cau} a8] aa "886 | 95 —] 95] — 088 asa | cea | esa | esa | asa | ssa : mun} 2880] 2480] aes] —aaco | 200] 2A Pei fl | 96.0) (96.9) (96.9) (98.9) (96.9) 197.0) Fan mmna | ato | tate —| iano] sata] —sa10 [420 ee - (55.5) (55.5) 155.5) (55.5) (65.5) (55.9) me mw pats | ize | taas J as] nas | 425 wen | wen | wen | wom | en | con Tino ad aman rata’ [vastea) | ws 6a [as ear [Tastee | reser | 0 es) som agtwy [°2, 890. |*2. 646. | 2 es fea oar | +4 700 | +8 700 = 390) 41,425) (1.440) (1.518) 11,660) (0,658) for si sas jez sao Jez sco [oa sco |e si | 8 sos usa. | Re =v (0.158) 41.190) (1.190) (1,190) 11,245}, cue Weight | ght ort xguoy {72884 24198 [+2 1989 ]-9 1297 [4 1296 fos 1.306 pa _ (2,545) (2,615) (2,630) 12,705) (2,790) (2,900) Tea wu |e Pe ee] ee] * (1,390) (1,420) (1,435) (1,685) Pea ere Ce tes ‘Canada | 74" a 11,1851 (1,180), 43,180) (1,245) Ta ne PTH Pare Pa vies | ~ Pea base = (2,545) (2,600) {2.615} (2,900) 2 3: The weight of poner saering le includea Ia G3 The weight of power ring, power window and xo door lock system i Included in CW. “The weight of sir conctioner, power steering, ower window and auto door lock system it included in C3. “The weight of sunreot ir conditioner, powor stern, Bower window, LS. eystem i netuded tn Cw “The weight of sunroot ir conditioner. power stering, Bower window, included in CW rument pone, rue contrat, auto door lock and intrument panel euise control ond auto door lock system i1 SPECIFICATIONS STATION WAGON woDeL ro DL OL GL ot cue | er seri | seri | seri | sees | sper | art eee sur | ar | wr | gar | gat | gar Fon sees} | ere | oe | oes | Gar | oar (1.8001 | «1.8001 | ts60) | 1160) | e1.a60)_| 11.390) wean |e [Re HOT eo. | eraeor | meron | azton | ame) | aan Toa memes) ter | tsi is65 | 10s [100 | 102 asso | ess | aero | wero | azo | ero ‘Seating eapacty erent 5 ‘oppose, quid cooled, Aevinde, 4rakegortine engine With lt Paes ‘With Single Point Fue Injection rome roel | frurboshors| Vane srengpment ‘vahead eat vpe Bore xeoke rom in 92 x67 (962x254) Displacement ‘em? (cu int 1,781 (108.68) _ Compresion rato 2s 35 35 35 35 a Fisng oder er Tgniton tiningat Gingspeed aTOGIemei | 20700 | 20r7700 | 20°00 | zovr00 | xF/r00 | 20°00 idling peed aeural, Nor Ppoation om | To0s100 | 700+100 | TaDsi00 | roosT00 | 700-100 | 60:100 T NK. ‘BPRGES1 (or BPABES-11, SPR7EST1) Sear plug | Type and manufacturer Nipponcensa: W2DEPR-UST for WIGEPAATS, W22EPR.UI1E Champion: ANDYC4 Maximum outout ce 9075 200 11575200 ‘Weximum torque Wem (ism, feiblirpm | 139 (44.0, 101172,800 ye \~ Tee [50020R-MF[65023R-MF [50020F-MF|660230-MF[65D230-MF [75023R-MF eauery — [Reanecamaciy tind | _78 ™ 78 1" mm Coiderenkingampew tomer | 366 | a0 | 0s [| «20 | a0 | «80 Berraor vave0R nich woe ovo [76 | bso [te [tee ‘Transmission type i te 3 2 "3 3 a aah [aes [ae [aes [ami | ae | aa ed 1.980 1569 | 1.960 vss9 | 1-989) 1.559 fee tine ‘aed {Orive) ae 1,344 1.000 | 34a 1.000 | 1-000 4 097 = [esr : [se | 0783 7 0.783 = = of Reverse ae 3583 2.287 3.583 2.257 227 | 2787 | ‘Auniary High : = E = ae Z gareain | tow = = = = = (05°: Ory Sila Pate Dapnraym ———*1” Wihowt visa To: Torque Converter “2: Storard speeds wih synelvomesh and Weve 83: Full automatic, Monward ang TeeverseSPECIFICATIONS STATION WAGON wooee m7 Farine | Farce a | “ano” | “eno ~ ee ae TURBO GL10 GLA0 runso_| Tueo war wer | wer sor | we) | Str | Sime] MEET vem am_|_om om_| sin Tan notes) 80] 08] am] ore] are | ao cam | oor | sare | aoe | ose | ner sox | onwnce [soma] ate] tn | oso [77 | ar 0 Wet | sight = allo) yaos) (1,898) (1,898) (1,938) 1,935) 41,940) Fou agian] 062 [3400] 1982] 1886 | 1086 [790 dees, | esos | cae | aro | ae | ears) Taig ap ramen ¢ oni opoie eu cola vind, ake ain rine Enon oe en Mat oie Ful ver arora fn neton | thMaNH Pit Fat ake anno Orariad cae Soe xk ro) oa 07 062x266) Deseo ea fun 1.7% (1088) Camere ao eee ee Fring oe aaa Ignition timing at iling speed BTOCkpmrt | 20°7700 | 20"/700 | 20"/700 | ae/700 | 20/700 | 20°7@00 Taling speed et neutral, Nar Pposiion rom | 700=100 | 7002100 | 709100 | 7002100 | 700=100 | 600=100 NGK: ‘GPRGES-11 (or SPAGESA1, OPRTES11) rk lua | Type end manufacturer NNippondonco: W2OEPR.UTI for WISEPR-U11, W22EPR.UTI) CChamaion:— RNGYC- Maximum output Hire 3016,200 11575,200 Maximumrereue tm kgm, fuibV om 137 (140, 101172800 Tar 115, 1341/2600 Tee [500201 mF [50020R MF 65020R MF S0D20R-MF] S0D70R-MF|IS023F-F Battery Resewecapaciy mind | 78 7 m1 78 78 ut Cold erankingemoere lomo.) | 906 308 a0 | 306 | 306 | a0 ‘Aiternator T2V-508 ‘Clutch type ae DsPD 08D Te DaPD ‘DsPD Te “Transmission Pe "2 “4 "3 "2 6 5 1 eas | 260s [20a | 50 | 50s | 2705 2a veer | vey | _vsse | 2a | 2a | _ 1805 coorrove | alee v366 | 1368 | 1000 | 144 | 1488 | 1.000 a oer | 0972 > 1083 | 1088 | 0.604 Sth 0.780 0.780 = “0871 0871 = Reverse - ate | 3416 2257 3416 | 3416 2272 ‘Aonilory | High 7 1.000 = 7 = | gai. [tow oe = = = ‘O5PD" Ory Single Pinte Dipragm eer TO: Torque Converter 12: Sforward speeds with synchromesh and Ireverse +3 Full automatic, Horward ond averse Ha: Sx2ocward speeds with eynchromesh and T-reverse (Dus range) 5: ull automatic, forward ane revere "6: Sfornard speeds with syechromesh and I-veveese (Single range) ~ with canter diferentiel u11 SPECIFICATIONS STATION WAGON MODEL PND : 110 ou tL ou ot | ceo | Se, ser sort | sori | seri | sort | tet ee sur | gar | wr | sar | gar | gar, = Tae of ear = [fete | r aieal_| Wael resuetion | 7 “ len ger” [reduction [Reduction serra | — | 0976 = [esr [0976 | os7e trom Twp of ae tects | Hyped | Prpad | Hypoid | Hvpoia | typed wt) | reauenon | Resuction garrate | 3900 | 3700 | 3800 | 3700 | 700 | ssa eduction | Taner | TYPE of por 7 = 7 = = = Gear” | reduction Resuetion anor = = 7 = 7 = (Ger [nat (Tweet 7 = = = = = : redvetion [Radvetion gearratio | = = 7 = 7 7 Tyee, ack ord pinion sexing [Turn lack to osi 37 sys Winimom wring gay Be wom 98 IST ercle't Atbumpar.. 10.8 (943) Front ‘MacPherson sr ype, Independent, Col on suspension vee eo : Fe Semarang rm type, Independor, Col sriae Savies rake atm ‘a Scie hyereulio with vacuum surpended poner unit aan Front Ventilated diss broke Fear ‘eum brake (Leading & wailing pe) Diss brake Paring be Mechanieal on fron brake = Sie essRT9 17S /7OSRTS ETORANS, Tyee Sta belted ail, Tobe Fost tank cpacity _# (OS al, IMD wa) 60 1158, 132) Engine | Unper level @1US at np ath 40042,38) ott [ower ever £108 at. Imp ath 3062.26) 26 25 Transmission geeront 2tusarinpad | 2%) - fata ]| - - - eee eee ra) noi | 6x0; | 62001 = | Auomaticwanms suse, imoad | - | waror, | - | teeso, | teoe0., | 6620.1 a 55:0. ssiati | S520.) | 6520.1) § [Avaiteentaseer es usquimpan| - 12 ze 12 2 12 oil (usar. impand asia oat | asin | asin “AWD rear dierent s1usatimoad | — . 7 is a - ao (Sat. ima) 7 : “oF a7 7 oF ar oF s1usar.imeat| ior 06 | (07.08) | 07,081 | 07.08 | 02.08 | 02,0) 30 63,83) Enginecoolant US gt, Imp at $5158,48) ne (38,4. “1 Cub toeur +2: Fer CANADA, 2SPECIFICATIONS STATION WAGON fey ia eee [ams | telat rasa as Se |e | ee [ae [ae [we seer reduction [eduction grar ratio | 1000 | 4.000 | 0848 | 1.000} 1.000 = ena Final ‘Type of gear Hypoid Hypoid ‘Hyped ‘Hypoid Hypoid Hypold Reduction | Transfer [Type ot eer | Helical Helical Helical | Helical ‘Helical a ee Final “Type of gear ‘Hypoid ‘Hypoid Hypoid ‘Hypoid Hypoid Hypoid ‘See [eaciras | eee AS SS system Minimum twning gy Aetie 96 (SS) ia ‘Type ii ‘Steel belted radial, Tubeless: romanoratea etecioel | wila | otan | wnae Lona | wan [wpe : cet nee aoe peer ae H15 ued vo curd "2: MacPherson strut type, Independent, Pneumatic suspension with height con +3: Semisaling arm type, Independent, Preumatic uspension with height conto "4: For CANADASPECIFICATIONS. 30008 WOOL re om Fane “0 geet ore aeigcteal| tues ae gcc Hug uaaite em ruReo cert | srr ct | | oon | Mem oe sur | sar set | Mt | Sar | MT a | aa] ane cas | aass | amas] aos oneneee in) | (174.6) (174.6) 1746) (174.6) (974.6) 174.6) ae sammy | 1880] 1.880 ‘50 | sso | 1860 | 1880 een ol | esa (66.4) 165.4) (65.4) (65.4) (65.4) i ase | 1a rate | ager | ast a7 oa ee (51.8) (51.8) (51.8) (53.4) (53.4) (53.4) ror] 1078 1075] 197 | 10% | 107% nies Fon ented (42.2) (42.2) (42.2) (42.2) 142.2) (42.2) q aeaeceegerace or ee 328 38 328 78 a8 fee ? (32.6) 326) (32.6) (32.6) 132.6) (32.6) coms Tom wer) 388] 8 a fewest re_|_ ore aro | ere | ore | are com Dae | 900 coe | 200} so | oop asa) |_ ose) cea | Goer | ano | Goa aaa a 1360 taco] 1801380) 1380 eee eee (53.5) (53.5) (53.5) (53.5) (53.5) 5 2A70 zaro | 2405 | 208 | 2085 ee eee 97.2) (97.2) 197.0) (97.0) (97.0) can mma | tate | tas va2 | ato] 1410 | 110 oe ten | Gon gon | toe | ces | too Raaaneane se) raaae io] aaa vaas | avs | aos | 18 a fo) | sean [wa wer | en) | tsa) | e601 imum ond care Temi | 1306.07} 720.6.) | 90167) | 130069) | Ta01sA) | T9016 | To0t6A et CC ‘9 9.330) 1,365) (1,360) (1,395) (1,405), 1,420) 1,540) te Fa mm pea aes [a aaa ao [2 ooo fr oo [so USA. = (950) (955) (985) (990) (1,100), (9,108) 41,130) Trew | Hee P82 Ps 8e pa rae [2 a8 [21.145 9130 Curb z (2,260) (2,320) (2.348) (2.385) (2,505) (2,525) (2,670) seine ee CC CC Ce) a 1.330) 0,365) (1,385), (1,390) (1,400) 41,415) (1,540) te Pee a PEE fT a [car fa aao PT aos Poo LS 88 Canada | PPT - (950) (955) (985) (990) (4.190) 1,105) (1.130) Town key [72008 [a8 Pam | nom | e198 ra in ‘0 (2,280) (2,320) (2,340) 42,380) (2,500) (2,520) 42,670) Maem | ae fae paw [ae |e | a | ow - (1,800) (1,200) (1,800) 41,800), (1,800) (1,800) 44,8001 croswnise [eof mee] mae] a8 J a8 J t80 J m90 [700 weight = (1,620) 1,620) (1,620) (1,620) 1,720) 1,720) (1,720) Tar neon | res nase | nssn [ses | gor sso 17 iste = (3,420) 13.420) (3.420) (3,420! 43,520) (3,520) (3,520) *Tr_The weight of poner eerng is lncladed i GH +2: The weight of pomerstering, power window and 9uto door lek systam i included in C.W. "3: The welghe of ar conditioner, power steering, ower window, auto door lock system, L.S.D. and AX package is includ In CW. “4SPECIFICATIONS 1 3p00R woDEL 0 aH o fo | a | ala fa | et ruRe0 ee |e cor | Sar] er | osar | St | Sar | ow ring a = Horizontally oppose ‘quid cooled, &-eylinder, 4atroke gesting engine With Mute Point Fuet ‘With Single-Point Fuel Injection Injection and Turbo: ie ore Volve erongement ‘Qverheod eamahale yee Bore x stroke ‘om tinh 92 67 (3.62% 260) Displacement en? (eu in) 7,781 (708.68) ‘Compresion rata a5 28 35 25 95 os 7 Firing order ya28 Ignition timing at ting speed OTDCirom* | 208/700 | 20°/700 | 20°/700_ | 20°/700 | 20°/700 | 20°/700 | 20/700 Idling speed at neutral, Nor Position ram | 700:100 | 7002100 | 700:100 | 700:700 | 700100 | 700100 | 700#100 NGK: ‘BPRGES-1 (or BPAGES11, BPATES 11) Spark plug | Type nd manufacturer Nippondento: W20EPRLUIT for WIGEPR-UI1, W22EPR-UTT) Champion: ANOYC-4 Waximom output Pleo '90/5,200 ‘9015,200, 11875,200 1a Maximum torave Nem (kom, fb] “tom 137 (14.0, 1011/2,800 197 (149, ro1V72,800 | 18.5, 194), 123800 Tyee [s0020R. MF [os029R MF [50020R mF [55025 wFls0020R-MF @5D23R-MF |s0020R.MF Reserve cepocity mind [78 a 78 m7 7 m1 78 ‘Cold eranking ampere temp.) | 506 220 306) 420 308 20 7306 ‘inernatar T2V-60A Giutch tye SPD Tc 0880 Te. 50) Te sO “Transmission woe "2 3 2 "3 “4 “3 6 ist gene | 2021 | 3006 | 2021 | 3505 | 2e2 | 506 2a vo50 | 1.60 | 1.950 | usso | 1947 | vss | ut con od vee | 1000 | 1a tooo | 1366 | 1.000 | 1048 rte Tae 0971 7 0.971 = 0972 = 088 | eh 0783 = 0.783, = 780 = bar Reverse asea_| 2257 | 3500 | 2257 | 3416 ‘Auniiry | igh = = = = 1.000 = 1.900 gearratio [Low = = = 7 1502 = 1198 SPD: Ory Siaie Plata Olaphregm “without vacuum TC: Torque Converter "2: Slorward speeds with synchromesh and Vreverse +3: Full automatic, JHorward ond Traverse +2; x2 forward speed with eynchromarh and I-revete (Dualeange) 5: Sn2forward speds with synchromath and Trevere (Duateange] ~ with center giferentia 161 SPECIFICATIONS 3.0008 wODEL aio “nb Falane “wo Grate eee bese fet ate ee eee te Tard Eee URe0 sri | ser | coms | cos | A | coms | MOF i eye san | rete esate | eee oar ert savin | HP tvencta iB : 7 ction [Reduction sew aie |_| as [= | 09 | - | os | — (front rina [Tp ator yoo _| Hypoa | Hyped | rypoid | wvpois | Hvpoid | Hynoie fe reduction | Reduction gear ratio | 3.900 3.700 3.900 3.700. 3.900, 3.700 3.700 fReduetion | Transfer | Type of pear = = = = Helical | _Welcal | Hetial ‘ear reduction [Reduction gear ratio [__— 7 7 = x00 | 0948 | 1.000 {ow [Figs [Trantor : = = =| Wid | ‘Hve0e | tnaia ve) | raucwon [Reaverion sew ave | — = 7 = { ae00 [2900 [3.700 Tree eck aa pinion Turn ak ose 37 Winimam 898 gn Aiton 86 BB) caer ‘tounge 108 48) Front WesPheion srt toe, aspen, Co ‘Suspension, ves seee 8 eriiaing wr pe, Ingeponans, Co rin Seve broke oat Dia eeu hyve with voir panded power unit Front Verne gs ate brake Drum bake fear Drom brake (Leading wating we) | ag SUM BARE] arate Torkog ate Takai on on ake "esr a ex 1ssen9 v75r708n19 vsrosnss | gly Tree San oda Tee Foal ank anosiy# (US, pH 20 059,13) Engine | Upper lvel_@1US at, Imp at) 4.0 (4.2, 3.5) oil [overeat # US tir at 3002.26 ; z 2] 2 [33 35 aerated atc get tetera tatters | asta ave eee GL 6. 2 3.30) = | Automatic transmis. Lie oeee eeeet | Aatorat swusa.ino| - | aor} - | @eror,) - | iesior, | ~ i B80) 8:0.) 56:0.) 8 12 12 pee a Ee 13,140) — 40.3, 1.0b Be oy os | a8 2 (US qt. Imo qu) ae 7 as st: 10.8,0.7) | (0.8,0.7) | (0.80.7) Tusamean} a? | o7_| 07 a7 | 07 [07 | a7 eee 107.061 | (0.7,0.61 | (07,06) | (07,06) | (0.7,0.6) | (0.7,0.6) | 0.7.0.6) Tignecoom AUS ar nwa About. 66,48 7 Gab wa 16TOURING WAGON SPECIFICATIONS custo TuReo Fert aes wou | SAO “a80 aa00 490 Seeeene hal 176.8) (976.8) 176.8) (176.8) 1.560 1,600 280 "880 Serene een (65.4) (654) (65.4) (65.4) 1,388 1385 305 186 eee: pee (54.5) (94.8) (94.5) {84.51 oxzsots mii) | (888 te ra ee fae (oa on (638) 8) = 7 m8 205; 205 5 ae sets mom int Bun (31.7) (31.7) 81.7) cago 1380 1380 1360 1.380 me | gy LAE | sat 635) oo | 6s) 1.380 1360 1.360 1360 oe eee (53.5) (53.5) (53.5) (53.5) ca aacroe 235 5 | ots 35.8 68) esa | asa Rana mmo | 285 785 7A65 Za6 ‘en hea! 197.0) (97.0) (97.0) {97.0} Fon aim} 142 1420 1420 1420 fee (659) (65) 659) ‘i501 Reece ay iam 1425 725 1425 (san 531 son (so) inimom road lewance contin) | 140165) | 14065) | _veo!6s) | 14055) rom igen |? 818 [°2 650 [3 657 | 3. 600 . (1,365) 11,990) A701 (1,520) For vom |? [2 aes aoe [8 aD Usa x3 41,090) (3,095) 41,095) 1,100) cu Tm vo [2 1308 [2 sey fates | 3 188 Wotaht | psight eae (2,448) (2,485) (2.565) (2,620) a (1 a8 "3 580 reenter 1,350), 19,388) a |__ 1,820) For “1 4s0 [7492 7 550 Canada | FT ks bh 41,080) (1,085), - (1,100) =~ a0 [1 1.320 731308 eects (2,430) (2,470) iH (2,620) 7 2 new, ‘of power steering inetuced in GW ‘of power stering, power window and auto door lock system s included in CW. +3: The weight of sir eonctioner, ower steering, ower window, digital instrument panel crue eonwol and auto doar lock system "7 Ww ‘includes1-1 SPECIFICATIONS. Recess EEE TOURING WAGON ro a canner Fare [Fal ie a “wo” | "ano ae ot ‘TURBO GLO GLA0 ar wee | — wr Se [owe | Sar | Se fe ew om an on . 176.8) (176.8) 976.8) (176.8) (176.8) aes — two] 1880 | a8 | — 150] — 80 peer hid (65.4) (654) (65.4) (65.4) (65.4) ; ass] tase] at | aoe | ass einer adel (56.5) (56.5) (66.5) (56.8) (56.5) amma PE] tae | es | aie es | as | ee | es | ete atSsets mm (in) a see inl 205 _ on | ae | em | orm | an cue yen ame | nae] —¥a80 | — tao a60 1380 Soe a | as | ies | es | ies van Toe lca saan laa ae Pa s_ | ws | @s | a | as Ta am) 25 26 5 35 ca | osm | oo wos | eam an —,, | 2450 | 2400 | — ano | 200 | — 2a wo | sa | fe | ss | bo Se ato [an aro] na | ato oe is | as | do | | tse mamma pai [aes | as [eas] ae wo | tae | en |e | tn iit od Sw ent | e663) | sea | ost6a | vascea) | 160169) Fou ney [PE 68 |B om |S oS eS ee cay | naw [aro |" oso | a fer Fe [a a [O oea [wae YO ae peer er kg (tb) (1.195) (1,198) 1,198), 1,220) (9,228) ws 2 aaa [ra tes a tae [> 1307 Weight | eight ie wee 42,620) (2,835) no (2.750) 7 ft ee st rant kg to) | azo (1495) = a fos 7 sie [om canada | Peer 2 tb) (1,185) 43,188) a i poeta tey (2,608) (2,620) ai 4 "Tr The weight of power storing it included in CW. +2: The weight of power steering, poner window end auto door lock system i included in CW. *3: The weight of sir conditioner, power sesrng, power window anc auto door lock system is included in CW. +4; The weight of air conditioner, pone steering, power wind, digital instrument panel rue conto}, eure door lock and L.S.0. system i included in GW. 15: The weight of air conditioner, power steering, ewer window, digital instrament panel cruise control and auto door lock system i included in CW. 18SPECIFICATIONS 11 a TOURING WAGON ce cu GL10 ree Sete ee teen tow so | germ | arm | a0 aia epon ig pint ‘With Sngie-Point Fusl Injection ae ee eae Tainan iieenl wegen | we arr aa Seaete meas Maximum era Nm bm 137140, 0172580 nA Es | ee er Rae a cre oro eet ete tee = ao [ ise [aes aor faerie ftveor eames a = Soe etaes sacar ca ee Se eestor fe eee Pleats tetas +3: Full sutomatie,3foruard and reverse 19SPECIFICATIONS TOURING WAGON woDEL aw Fane | Fane a wo “wo ee be ‘TURBO eto sui0 tums | Tunwo wi won| wer Fi . er poet on ar wre re orn on om wee wr oe ia eo Front wae) | 1.770) 1.70) (1,808), (9,808) (8751 ne | Sessile Peay 060 80 or an 0 Weight | wight Few ou (1,898) (1,898) (1,938) (1,938) 1,940) ra aaa a cisaeg | nrnaea Tete poe same Ll aaa - (3,665) (3.665) (3,740) 13,7401 (3.818) Beating capacity persone 3 Horizontally opposed, liauid coated, ‘Aeylindar, stroke gacotine engine ae ae With Single-Point With Multi-Point Fuel Injection | as ea eect Yanan Shand ana oe ne ant carer e726) ae ea vin Te se) Conerain os ro i: a ] Firing order z 1324 Veneta igteed aToOremT | a0Theo | anes _[_avereo | —arnoo_| 10 Ticgepentnn to Pesan ran [760-100 | 7oon0 —| —700:100 | —Tooa10 | soosto0 soorsiuy | Te and mnvtacre Mao: REREERNT er roePmoNT MzEPRUT ben Raves Tana cope he 5200 Tem Mexinomorve Nev itgn athom | 157140, 01/2800 Tor as, 19800 Te coononur | Somnr | omRNE | eabaonar | TORRE ee of 73 7! 1 Gad eanngasee Tome) | 268 0 308 ee i coat ee ccc “# =a F s 5 i [ae [ae Ses saan |e wad Seeger al a 4th 0.972 - 1.088 1,088 oom | és a7e0 2 can} oa : ae uae} am | ae | eae aa tert” | tow 1502 = = Dano Do Srge aw Dagwayn TE Bonard wei cone od aaa Rittronete stomerene tae ee ee coneane eee +6: Sorward spends with synchromesh and 1-roverse (Single range) — with canter citferentia 20SPECIFICATIONS a iat TOURING WAGON ou ou co | kt se See ears eee eae (Front Final Type of gear Hypoid Hypoid Hypoid Hypoid ee reduction | Reduction gear 3.900 3.700 3.700 3.454 ‘e0r reduction |” Reduction gear ratio = = = = Lt Final ‘Type of gear = = = = bias reduction | Reduation gear rato = es 7 = Tae eras Seats Minimum 100g gy ‘Attire 96 (75) Sone Tee eee nee eaT th ero ails eae mia me Sarna tae e agree ie Typo, ‘Stoel belted radial, Tubeless ot” Loew a Haseciones Transmission gar ot 21USat,imatd | 25. - - - ‘mission fluid 8(US gt, Imp qu) oo (6.6:0.1, (6.60.1, 2 6,620.1) 5,540.1) BUD cr dient gsae,imoad | = 7 = - foversteningtnid ‘Auxillary purge vent To canter ® ® Non-TURBO: Purge vent © ae. ‘TURBO: ‘Mein purge vent From feul tank -»> 5 Vacuum vent Vacuum oni: 2 vane"A" tha fie 3 cae 4 Spring 5 Retainer as.192 pgas urge cont valve Activated carton 3) Purge line and canister er (1) Disconnect tho vacuum hose. Orally blow air through the hore to ensure that air doos not leak. {2} Disconnect the purge hose or first purge hose Lira] {TURBO vehicle). Orally blow alr through the hose to => Fig 26 ensure that air Flows. (3) Disconnect the evaporation hose from the fuel tank side. Orally blow air through the hose to ensure that air Be careful not to suck on the hose as this causes fuel evaporat- ing gas to enter your mouth. 16Fig. 27 a, Do notattempt to clean eee ea enn trai lost along with the viscous Under extremely dusty conditions, replace it more fre- PERIODIC MAINTENANCE SERVICES 1-5 Air Filter Elements ae eee needa) (Air cleaner) wae [78 | [ze] [ara] @ [me[ oo x 1,000km | 12 | 24 | 36 60 | 72 | a4 | 96 a ir cleaner element, ment is wetted with a special non-inflammable slow-evaporating viscous liquid. It is resistant to cold weather and has a long sorvice life, Dirt adhering to this filter paper forms porous laminations with |, which function as a filtration layer to ion into the filter paper. If this filter layer thus formed will bePERIODIC MAINTENANCE SERVICES Spark Plug MAINTENANCE INTERVAL [Number of months or km (elas, whichever occurs frst] Monts | 25] 18 [225] 90 [375] 45 [625] 60 xg00%m | 12 | 24 | 36 | 48 | 60 | 72 | o | 06 x 1,000mies [75 | 15 |225| 30 |a75| 45 | 525] 60 geass Recommended-spark plugs NGK: BPREES.11 (or BPRSES-11, BPR7ES-11) Nippondenso: W20EPR-U11 {or W1GEPR-11, W22EPR-UT1) Champion; RNGYC-4 ‘Spork plug gap 1.0 ~ 1.1 mm (0.039 — 0.043 in} 1.0 = 1.1 mm (0.099 ~ 0.043 in} Spark plug tread Dia, = 14 ene (0.55 in) Pitch = 1.25 mn (0.0482 in) 29.163 Fig. 28 18 When installing spark plugs on eylinder head, tighten to the specified torque, Tightening torque: 18 — 24 N.m (1.8 —24 kgm, 13 — 17 feb) Be sure to place the gesket between the cylinder head and spark plug.PERIODIC MAINTENANCE SERVICES. Transmission/ Differential (Front and rear) Lubricants (Gear oil) MANUAL TRANSMISSION Inspect the transmission gear oil level, If the oil level is at the lower point or balow, add rome oil through the oil level gauge hole up to the upper point of gauge, FWD Non TURBO) aN /FWO ‘TURBO. 1567 Fig. 29 FRONT DIFFERENTIAL (Automatic Transmission) il level should be maintained between two points on the level gauge. If the oil level is at lower point or below, add some oil ‘up to upper point, razah Upper Loner love Laas? MAINTENANCE INTERVAL [Number of months or km (niles, whichever occurs fet) Monts [75] 15 [225] 30 [ars] as [525] 60 xto00wm | 12 | 24 | 36 | aa | 60 | 72 | a | 06 x1000mies | 7.5 | 16 [225] 20 [37.5] 45 [52s] oo REAR DIFFERENTIAL (4WD Vehicle) Remove plug of filler hole and check the oil level, Cil level should be maintained fully to the filler hole If the ol level is below the mouth of filler hole, add some oll up to the mouth, Fig. 37 = Se a, Each oil manufacturer has its base oil and additives. Thus, do not mix two or more brands, bb. *For differential gear oil (AT) 191-5 PERIODIC MAINTENANCE SERVICES Automatic Transmission Fluid Z High mark AK 7, of Lom mek INSPECTION L164 WAINTENANGE INTERVAL {tuner of monty ork ile, whicherer ours iat woume [78 | 1 [228] 20 [78] a5 [625] 60 xraoowm | 12 | a | 36 | «8 | 60 | 72 | 0 | 06 ‘1000 mis | 78 | 18 [228] 20 [avs| as [520] eo FH vice o “0 ice a a poet Test condition sect ange: “P* fuga Engine ding (engine reveluton 700 — 790 com] . temperature) Sar a a 7 enter t - t . 2] Lower iit a teu igh 2 temperature) = ‘Upper limit Fluid | uae Temper 2) temperature) Esco 2 ieee 5 tra : peat 3] Lower eT iF a temperature) ° 30, 40 50 70° 80, 30 700°C en rc) ATE temperature User Fig. 32PERIODIC MAINTENANCE SERVICES, 1-5 Sere) MAINTENANCE INTERVAL {umber of months ot kr (il), whichever occu Hs] 11. Drive vehicle several km (miles) to bring automatic trans- [Monts | 78 | 16 [22] 20 [375] 45 [525] 60 mission fluid (ATF) up to normal operating temperature. | o000m | 12 | a | as |e | 60 | 72 |e | oe Normal operating temperature is 60 to 80°C (140 to 176°F). 2). Park vehicle on a level surface. x 1.000 mies | 75 | 18 |z25| 30 | 375] 45 [525] 60 3) After selecting all positions, place selector lever in “” pottion and run engine on a idling speed. o 4) Remove level gauge and wipe it clean, 5) Reinsert the level gauge all the way. 6) Remove it again and note reading. If the fluid level is below the center between high and low marks, add recom- mended ATF until the fluid level is within the specified renge {above the center between high and low marks). When trans mission is hot, the level should be above the center of upper and lower marks, and when it is cold, the level should be below the center of these two marks. ATF level gauge hole also serves as fluid filer NOTE: Do not fill the fluid above upper point of level gau Recommended automatic transmission fluid (ATF Dexron I} ees 1). Drain fluid by removing drain plug after allowing the engine to cool for 3 to 4 hours. 2 2) Reinstall drain plug after draining fiuid, and tighten it to the specified toraue. Tightening torque: 25 Nem (2.5 kam, 18 ft) a, Be sure to place a gasket between oil pan and drain plug. b. Replace the gasket with new one. 3) Fill ATF through the fluid level gauge hole. i capacity: FWO SAT: 6.2 2 (6.6 US qt, 5.5 Imp qt) 4w0 2aT: 6.56 £ 6.9 US at, 5.8 Imp qt) awo 4a: 95.2(10.0 US qt. 84 Imp at) When replacing ATF, the normal refilling capacity is about 25 to 3.02(26 to 3.2 US qt, 2.2 to 26 Imp qt) (except WD GAT), 6.5 to 7 2 (6.9 to 7.4 US gt, 5.7 to 6.2 Imp gt) (WD aan. 4)_ Run the vehicle until the ATF temperature rises to 60 to 80°C (140 to 176°F) and then check the ATF level1-5 PERIODIC MAINTENANCE SERVICES Brake Fluid Geet 1) Either jack up the front end of vehicle and place a safety stand under it, oF drive vehicle onto the pit and then jack up the front end. 2) Remove both left and right front wheels 3} Remove filler cap from brake fluid tank. Install one end of a vinyl tube onto the air bleedar of front brake and insert the other end of the tube into a container to collect the brake fluid To drain fluid into container, open the air bleeder and repeatedly depress and release the brake pedal until a small ‘amount of fluid remains in the reservoir tank. ‘Then tighten the bleeder screw. Fig. 35 4. The brake piping consists of @ dual system, cross design, ‘The piping on the primary side connects the right front brake and the rear left brake and the piping on the secondary side ‘connects the left front brake and rear right brake. 'b, For convenience and safety, itis advisable to have two men working. ©, Be careful not to spill brake fluid onto the painted surface, 4. Discard the drained brake fluid and do not reuse it. 4) Refill reservoir tank with recommended brake fluid Recommended brake fluid: FMVSS No. 116, fresh DOTS or DOTS brake fluid MAINTENANCE INTERVAL [Number of months or km (mite, whichover occurs fst] Months] 7.8] 15 [225] 90 [37s] 48 [525] 60 xig00Km | 12 | 24 | a6 | a0 | 60 | 72 | a | 96 x1,900mile | 7.6 | 18 | 226] 30 [375] 45 [525| 60 4. Avoid mixing different brands of brake fluid to prevent grading the quality of the fluid. '. Be careful not to allow dirt or dust to get into the reservoir ‘tank, «. Use fresh DOTS or DOTA brake refilling the fluid. . Always check to be sure a smalt amount of brake fluid is, in the tank while changing brake fluid. #. The amount of brake fluid required is approximately 270 me (9.1 US fl oz, 9.5 Imp fl cz) for total brake system, 4. Bleed air according to illustrated sequence. when replacing or Bleeding sequence = Q- O~ @ rie seni} t oO Frontieft Fear eight Coe ® Feerlett 17-150 Fig. 36 5). Instruct your co-worker to dapress the brake pedal slowly ‘wo or three times and then hold it depressed. 6) Loosen bleeder screw approximately 1/4 turn until a small amount of brake fluid drains into container, and then quickly tighten screw. 7) Repeat steps 5) and 6) above until there are no air bubbles in drained brake fluid and new fluid flows through vinyl tube. ‘Add brake fluid as necessary while performing the air bleed ‘operation, in order to prevent the tank from running short of brake fluid. 8) After completing the bleeding operation, hold brake pedal depressed and tighten screw and install bleeder cap. Tightening torque (Bleeder serew): 79 Nem (0.7 — 0.9 kgm, 5.1 ~ 65 fib) 22PERIODIC MAINTENANCE SERVICES 1-5 9) Bleed air from each wheel cylinder using the seme pro- cedures as described in steps 5) through 8) above, 10) Depress brake pedal with a force of approximately 294 N {80 kg, 66 Ib) and hold it there for approximately 20 seconds, At this time check pedal to see if it shows any unusual move- ment. Visually inspect bleeder screws and brake pipe joints to make sure that there is no fluid leakage, 11) Install wheels, and drive car for a short distance between 2.10.3 km (1 t0 2 miles) to make sure that brakes are operating properly. 231-5 PERIODIC MAINTENANCE SERVICES Disc Brake Pad and Disc/Front and Rear Axle Boots and Axle Shaft Joint Portions MAINTENANCE INTERVAL {Number of months or km (rites), whichever occurs frst) Montts | 75] 15 [225] 30 [375] a8 [525] 60 x1000Km | 12 | 24 | 36 | 48 | 60 | 72 | 04 | 96 x1.000mile | 7.5] 18 |225| 90 [375] «5 |s28| 60 INSPECTION IA] Disc Brake Pad and Disc (Front and Rear) 1). Jack up vehicle and support with rigid racks. Then remove whools. 2), Visually check pad thickness through inspection hole of dise brake assembly. Replace pad if necessary. FRONT Lining “Thickness of pod um Fig. 39 REAR 11.088 Fig. 40 Pod thickness including back metal mm (in) Front eer Standard 18 (0708) 76 (0.591) Wear iit 7.5 (0.285) 6.5 10.286) Wr iit 7 {exclude back metal) 155 10.059) (0.0891 24PERIODIC MAINTENANCE SERVICES a. When replacis loft and right wheels at if they are twisted of wor 1b, The clip incorporated with pad is also used as a warning device for worn pads. When wear occurs on the pad to such an extent that the clip comes into contact with the rotor, unusual noise (squeak) is produced, If such a noise is noticed, replace the pads. 3). Disc rotor Check for wear and damage, and correct or replace if ab- normal. always replace the pads for both the same time. Also replace pad clips 1-5 [B] Front and Rear Axle Boots Inspect front and rear axle boots for deformation, damage or failure. If faulty, replace ther with new ones. rake die thickness ram Gn) Front esr Standerd 18 (0,709) 30 (09981 Wor limit 16 (0.690) 8.5 0.936) “Thickness of ise Liar Fig. 41 Disc rotor runout: Limit: 0.10 mm (0.04 Measure the dise rotor runout in) from the outer periphery of 11-9501-5 PERIODIC MAINTENANCE SERVICES Brake Lining and Drum srumae or MAINTENANCE INTERVAL f months or kr (miles), whichever occurs frst] Monts | 75 | 18 | 226] 30 [37s] 45 [25 xi000km | 12 | 26 | 35 | 48 | 60 | 72 | 0 x1000mies [75 | 15 |z25| 20 [ars] 45 | 525 2). Check brake drum for wear, dents or other damage. Saal If the inside surface of brake drum is streaked, correct the surface with emery cloth (#200 or more). If it is unevenly, Inepect brake linings and drums of both sides of the rear brake worn, taperingly streaked, or the outside surface of brake giels/e at the same time by removing brake drums. drum fs damaged, correct or replace it. 1} Inspect brake shoes for damage or deformities and check, brake linings for wear. Brake drum inside diamete Standard: ‘Always replace both leading and trailing brake shoes for the 480 mm (7.089 in} left and right wheels at the same time. Weor limit: 162 mm (7.17 in} Brake lining thickness excluding beck metal: ‘Standard: 45 mm (0.177 in) Wear limit: 45 mm (0.059 in) ‘Thickness of brake ing (Exclude beck metal] ‘Measuring inside diameter Fig. 46 3) If the deformation or wear of back plate, shoe, etc. are notable, replace them. Fig. 48 4) When the shoe return spring tension is excessively ‘weakened, replace it, taking care to identify upper and lower springs. 5) If grease has leaked from brake drum, replace oil seal or drum. 66) If drum bearing is abnormal or loose, replace itPERIODIC MAINTENANCE SERVICES +5 Inspect Brake Line and tuner of monty eR nl wehee occur ist Check Operation of wont [78 | 16 [225] ao [ars] a [oes] 60 Parking and Service x2000%m | 32 | 24 | a6 | a8 | 60 | 72 | o | 06 Brake System x1,000mie | 75 | 18 [az 90 [a7a| «= [eas| co a) ja @ |e DNS eeu) BRAKE LINE 1) Check seratches, swelling and/or traces off brake hoses or pipe joints. [A] Service Brake 1) Check the free play of brake pedal with a force of less than 10.N (7 kg, 2 Ib) Brake pedal free play: (0.5 — 2.5 mm (0.020 — 0.098 in) If the free play is out of specifications above, adjust the brake pedal as follows: (1) Be sure engine is off. (No vacuum is applied to brake booster.) (2) There should be play between broke booster clevis ‘and pin at brake pedal installing portion (Depress brake pedal pad with a force of less than 10 NV (1 kg 2 Ib) to stroke of 0.6 to 2.6. mm (0.020 to 0.098 in} Fig. 47 Clevs pin Loc nut ‘rake booster. cparating roa Play a pin evs Pedal play 05 ~ 28mm {0.020 — 0.098 in) Fig. 48 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, seratches, ete. on master cylinder, whee! cylinder, pressure control valve and hill-holder. When the brake fluid level in the reservoir tank is lower than the specified limit, the brake fluid waraing light on the instru ‘ment panel will come on, Fig. 49 (3) Depress the surtace of brake pad by hand, (4) If there is no free play between clevis pin and clevis, loosen lock ut for operating rod and adjust operating ‘od by turning in the direction that shortens it. 271-5 4, Make sure that the stop lamp operates normally. b. After adjustment, make sure there is no brake drag 2} Adjust lining cle (FWD only] (1) Jack up vehicle to release tires and wheels slightly from the ground. (2) Tighten adjusting serew on back side of rear brake drum fully until tire and wheel ceases to rotate. (3) Turn back adjusting screw by 180" and lining clearance will be 0.1 to 0.15 mm (0.004 to 0.0059 inl. (4) Be sure to rotate tire and wheel lightly by hand, (5) Adjust lining clearance of another side rear brake with the same manner. mnces of rear drum brake as follows. 3) Measure the distance between brake pedal and floor when the pedal is dapressed with a force of approximately 294 N (30 ka, 66 1b) Brake pedal reserve distance: ‘More than 67 mm (2.64 in)/294 N (30 kg, 66 Ib) PERIODIC MAINTENANCE SERVICES 4) Check to see if air is in the hydraulic brake line by the feel of the pedal operation. If air appears to exist in the line, blood it from the system. 5) Check for even operation of all brakes, using a brake tester or by driving the vet straight road, [B] Parking Brake 1). After confirming the proper operation of brake ped, pull parking brake lever with a force of approximately 245 N (25 kg, 55 Ib} to make sure lever still has a short length of stroke to go. Parking brake lever stroke: (With engine on) Standard: ‘3 — 4 notches/245 N (25 kg, 55 tb} Torque (Adjuster lock nut: ‘4.4 — 7.4 Nem (0.45 — 0.75 kgm, 3.3 — 5.4 ft-lb) 2) If the parking beake lever pull is not within the above specifications, adjust it as follows: (1) Pull parking brake lever forcibly three to five times. (2) Loosen the lock nut and change the setting of adjuster until the play at point A is 0 to 0.5 mm (0 to 0.020 in), Stop lamp wit Free play 05-25 mm (0.020 ~0.098 in} Stroke Reserve distance ae “Toe boars Fig. 52 (3) Make sure that vehicle stops on uphill road properly bby operating parking lever. [C] Brake Servo System 1) With the engine off, depress the brake pedal several times applying the seme pedal force: Make sure the travel distance should not change. 2) With the brake pedal depressed, start the engine: Make sure the padal 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 chenge. 2Bhose to inspect function of check vale. PERIODIC MAINTENANCE SERVICES 1-5 4) Check valve is built into vacuum hose. Disconnect vacuum 5) Check vacuum hose for eracks or ather damage. Blow air into vacuum hose from its brake booster side end: When installing the vaeuum hose on the engine and broke Air must flow out of engine side end of hose. Next blow air into hose from engine side: Air should not flow out of hose. Replace both check valve and vacuum hose If check valve is faulty. Engine side of vacuum hose is indicated by marking "E" a8 shown, “* {ets Fig. 53 booster, do not use soapy water or lubricating oil on their connections. 6) Check vacuum hose to make sure it is tight and secure 29PERIODIC MAINTENANCE SERVICES Clutch and Hill-holder System eeecuen Ea eu nis 1. Inspect the clutch free play and check the fill holdor operation. Hit is out of the specified value, adjust it by turning adjusting rut on engine side end of clutch cable at release fork. 1) Cluteh free play (1) Remove the spare tire. (2) Position a serowari rotate the lever in the direction indicated by the errow. This is necessary to remove hill holder load from the release lever to determina accurate clutch free play. Mave sereneriver baci fires ais Fig. 9 (3) Lightly move the clutch lever with your hand to check free play, Standard of free play: ‘At clutch pedal: 10 — 20 mm (0.39 — 0.79 in) At center of cable on clutch release fork: FWD Non-TURBO: 2~ 3mm (0.08 — 0.12 in} 4WD/FWD TURBO: 3 — 4 mm (0.12 — 0.16 in) Pedal play 10-20: (0.2 1-060 Free play Full soke as shown, and move it back to 1 Lock aut 2 Adjusting not 3. Release fork 820951 Fig. 55 MAINTENANCE INTERVAL [umber of months or kr (miles, whichever occurs frst] ‘Monts [78] 18 [226] 30 575] 45 [525] 60 x1000Km | 12 | 24 | 36 | 4a | co | 72 | os x 1000mie | 75 | 18 [225] 90 a7s| 45 [528 © o Tightening torque (Adjusting nut on release fork) 5.4 — 9.3 Nem (0.55 — 0.95 kgm, 4.0 — 6.9 ftib) a, When replacing clutch cable with new one and/or making free play adjustment of clutch pedal, make adjustment of hil-holder system vi thout fail as follows. b, After replacing chrtch cable and/or pressure hold valve (PHV) cable with new ane, depress clutch pedat about thirty (30) times as a running-in operation prior to this adjustment. 2). Confirm stopping and starting performance by activating hillnoider on an uphill road of 3° or higher inclination 1) If vehicle does not stop: Tighten adjusting nut of PHV cable. 30PERIODIC MAINTENANCE SERVICES 1-5 (2) If vehicle does not start properly: © Case A — When hill-holder is released later than engage gr PHV cable with new ono, if they are defective and/or b, Replace pressure hold valve (PHV), return spring of PHY rent of clutch (engine tends to stall): Loosen adjusting nut gradually until smooth starting is enabled. Case B — When hill-holder is released earlier than engagement of clutch (vehicle slips down slightly): Tighten adjusting nut so that hill-holder is released later than engagement of clutch (status in Case Al. ‘Then make adjustment the same as in Case A. damaged. a. Whenever turning adjusting nut, prevent PHV cable from ‘evolving as following illustration, aPERIODIC MAINTENANCE SERVICES. Steering and MAINTENANCE INTERVAL {umber of months or km (riles), whichever occurs ist] Monts | 7.5 | 18 [228] 30 [375] a5 [525] 60 x1g00%m | 12 | 2 | 36 | ae | 60 | 72 | a | 05 x1000miles | 7.5 | 16 [225] a0 |a75| 45 [525| 60 Se =caen! STEERING WHEEL 1). Set steering whee! in 2 straightahead potition, and check wheel spokes to make sure they are correctly set in their specified positions, 2). Lightly turn steering whee! to the left and right to deter- ‘mine the point where front wheels start to move. (Meature the distance of the movement of steering wheel at the ‘outer periphery of wheel. Steoring wheel free play: (0 25 mm (0 - 0.98 in) Freeplay 0-25 mm (o~ 098 ind fe Fig. 58 3) Move steering wheel vertically toward the shaft to ascertain if there is play in that direction Maximum permissible play: 0.5 mm (0.020 in) 4) Drive vehicle and check the following items during ‘operation. (1) Steering F028 anne The effort required for steering should be smooth and ‘even at all points, and should not vary. (2) Pull 10 07€ Sid sono Steering wheel should not be pulled to either side while driving on a level surface. 22 (3) Wheel runout ‘Steering wheal should not show any sign of runout. (4) Return factor Steering wheel should return to its original position after it has been turned end then released. STEERING SHAFT JOINT 1) When steering wheel free play is excessive, disconnect ‘universal joint of steering shaft and check it for any play and. ‘yawing torque (at the point of the crossing direction). Also Ingpact for any damage to sealing or Worn serrations. If the joint is loose, retighten the mounting bolts to the specified torque, Tightening torque: 21 = 26 Nem (2.1 — 2.7 kom, 15 ~ 20 ftb) GEARBOX 1) With wheals placed on a level surface, turn steering wheel 20° in both the left and right directions. While wheel is being rotated, reach under vehicte and check for looseness in gearbox. Tightening torque: 47 — 71 Nem (88 ~ 7.2 kg-m, 35 — 52 fib)PERIODIC MAINTENANCE SERVICES 1-5 (3) From that position, turn back adiusting screw 15” and then tighten lock nut securely. ing torque: = 49 Nem (3, 5.0 kg-m, 22 — 36 feb) Hold the adjusting screw with a wrench to prevent it from ‘turning while tightening the lock mut. TIE-ROD 1) Check tierod and tieod ends for bends, scratches or other damage, 2). Check connections of knuckle ball joints for play, inspect for damage on dust seals, and check the free play of ball studs 3) Make sure that the cotter pin is installed correctly in the castle nut of the tlerod end, 2) With vei an level ure, quickly wun ning whe to the tft and right. While steering whet! sbng rotated, check the ges bls If any unuail noe i notes, aust te gear backlash as follows 11) Loosen gearbox mounting clas, and sgt tower gearbox 12) Looten lock nut by using SPANNER (976230000) ad tighten adusting sere uly. & es yy L509 SPANNER (926230000) can be also used for manual stering. > ig POWER STEERING FLUID LEVEL 1) Place vehicle with engine “off” on the flat and level surface, 31-5 PERIODIC MAINTENANCE SERVICES. Ores eat, [momen | tno Fig. 64 (2) Check at temperature 60°C (140°F} of fluid temper ature A3-206 Fig. 65 3) Fluid level should be maintained in the each specified range on the indicator of filler cap, If fluid level is at lower point or below, add fluid to keep the level in the specified range of indicator If fluid level is at upper point or above, drain fluid to keep the fel in the specified range of indicator by using a syringe or the like. are CASTROL Dexron 11 aT Fluid capacity: 0.7 2(1.5 US pt, 1.2 Imp pt) POWER STEERING FLUID FOR LEAKS Inspect the underside of oil pump and gearbox for power steering system, hoses, piping and thelr couplings for fluid leaks. If fluid feaks are found, correct them by retightening their ‘iting bolts (or nuts) and/or replacing thelr parts, 2. Wipe the leakage fluid off after correcting fluid leeks, or 3 ‘wrong diagnosis is taken later. b. Also pay attention to clearances between hoses (or pipings) ‘and other parts when inspecting fluid leaks. HOSES OF OIL PUMP FOR DAMAGES Check pressure hose and return hose of oil pump for crack, ‘swell or damage. Replace hose with naw one if necessary, Prevent hoses from revolving and/or tuning when installing hoses. 34PERIODIC MAINTENANCE SERVICES 1-5 POWER STEERING PIPES FOR DAMAGE Check power steering pipes for corrosion and damage. 1 cw Replace pipes with new ont 2 Strainer (a) 2 Ob nk oQ 4 Ovieg GEARBOX BOOTS 5 Pioe ae r 5 Ol pump if Inspect both sides of gesrbox boots sr follows, and correct | § Oi Pun m if 8 Pulley IS 9 (lar (with rubber 4 ip (Sma) 2 ip (Less) 3 Boot Liss Fig, 28 L501 Fig. 68 1). A and B position of gearbox boot are fitted correspond: ingly in A and B grooves of gearbox and the rod 2) Clips are fitted outside of A and 8 potitions of boot. 3) Boot does not have erack, hole. Tightening torque: ‘Nut A (one): Rotate B position of gearbox boot against twist of it produced 42 — 62 Nem (4.3 — 6.3 kg-m, 31 — 46 ft-tb) by adjustment of toe: Bolt B (two): 20 — 29 N-m (2.0 — 3.0 kg-m, 14 — 22 ft-lb) Bolt C (three): FITTING BOLTS AND NUTS 18 — 22 Nem (1.8 2.2 kgm, 13 — 16 feb) Bolt D (thre): Inspect fitting bolts and nuts of oll pump and bracket for looseness, and retighten them if necessary. - 19 Nom (3,0 — 5.0 kgm, 22 — 36 fb) Inspect and/or retighten them when engine is cold. SUSPENSION SYSTEM ‘Care should be taken not to apply paint, undercoating agent, anti-corrosive wax, etc, to the following parts of air-susp equipped models while refinishing the undercarriage, (1) Digphragm and rolling surfaces (2) Air suspension compressor and dryer assembly 315 PERIODIC MAINTENANCE SERVICES 1). Play of front ball joint ...... Inspect every 24,000 km (15,000 miles) or 15 months, whichever occurs first, (1) Jack up vehicle until front wheels are off ground 2s instructed in "Pre-Delivery Inspection.” (2) Next, grasp bottom of tire and move it in and out. If relative movement is observed between brake disc cover and end of transverse link, ball joint may be excessively Housing “Teaneveree lnk Pa al join Feative movement Lae Fig. 69 (3) Next, grasp end of transverse link and move it up and down, Relative movement between housing and transverse link boss indicates ball joint may be excessively worn, Housing Y Relative movement Transverse ink joint L235 Fig. 70 (4) If relative movement is observed in tests (2) and (3) above, remove and inspect ball Joint according to chapter 4-1. If looseness exceeds standard, replace ball joint. 2) Damage of dust seal ...... Inspect every 24,000 km (18,000 miles) or 16 months, whichever occurs first. Visually inspect ball joint dust seal. If itis damaged, remove ball joint a¢ instructed in chapter 4-1 and measure looseness of ball joint (1) When looseness exceeds standard value, replace ball Joint. (2) When tooseness is less than standard value, wipe off cold grease, apply the proper amount [about 3 q (0.11 o2)] of designated grease (SUNLIGHT 2, P/N 003602010), and install @ new dust seal When transverse link ball joint has been removed or replaced, check tocin (or side lip) of front wheel. Hf front wheel toe-in (or side slip) is not at specified value, adjust according to chapter 4-1 so that toe.in conforms to service standard. 3) Wheel alignment and ground clearance ...... Inspect ‘every 48,000 km (30,000 miles) or 30 months, whichever ‘occurs frst. (1) Unioad cargoes and set vehicle in curb weight (empty) condition. (2) Then, check ground clearance of front and rear suspensions to ensure that they are within specified values. (Adjusting procedure) When ground clearance is out of standard, visually inspect following components and replace deformed parts. © Suspensions components (Front: strut assembly, cross member, transverse link, etc. Rear: shock absorber, inner arm, outer arm, ete.) ‘© Body parts to which suspensions are installed. When no components are deformed, adjust ground clearance by replacing coll spring in the suspension whose ground clearance is out of standard. (3) Check alignment of front suspension to ensure that following items conform to standard values provided in chapters 4-1 and 4-3, © Toerin {or side slip) © Camber angle © Caster angle © Turning angle of tire (Adjusting procedure) — Front suspension alignment (a) Camber and caster angles are not adjustable. When camber or caster angle does not conform to standard value, visually inspect following components and:replace deformed parts ‘© Suspension components (Strut assembly, crossmember, transverse link, etc.] ‘© Body parts to which suspensions are installed. {b) When toe-in (or side slip) is out of standard value ‘adjust by the method described in chapter 4-1 so that it ‘conforms to service standard, fe} When right-and-left turning angles of tire are out of standard, adjust to standard value by method described in chapter 4-3. 36PERIODIC MAINTENANCE SERVICES 1-5 (4) Check alignment of rear suspension to ensure that following iterns are within standard values. © Toe-in (or side slip) © Camber angle (Adjusting procedure) — Rear suspension alignment When toe (or side slip) or camber angle does not con- form to standard value, visually inspect parts listed below. If deformation is observed, replace damaged perts. © Suspension components [Shock absorber, inner arm, ‘outer arm, crossmember, etc] © Body parts to which suspensions are installed. When no components are deformed, adjust alignment as Instructed below so that it conforms to service standard. Toe {a} Jack up rear of vehicle as shown in “Pre-Delivery Inspection,” and remove rear wheels, {b) Loosen outer arm mounting bolts. lnner arm ASSY- Outer ern ASSY Lier] (a) Adjust toe within service standard by repeating steps in 2) and 3) above for for both right and left wheels. Cambor angle (a) Jack up rear of vehicle as shown in “Pre-Delivery Inspection,” and remove wheel whose camber angle is out of standard. (b) Remove bolt linking lower end of shock absorber to {e] Then, loosen outer arm mounting bolts, Id) If camber angle is excessive in @ direction, use a piece of wood as a lever and change relative angle between inner arm and outer arm so that angle @ formed by inner farm and outer arm centerlines (See below.) increases. Then, tighten outer arm mounting bolts. Cente ine of innge stm L480] Fig. 70 (6) When toe-in (or side slip) is excessive, tighten outer farm mounting bolts shown above while pulling end of spindle towards ear of vehicle (in direction of arrow see below]. When toe-out (or side slip) is excessive, tighten ‘outer arm mounting bolts while pushing end of spindle ‘toward front of vehicle (in opposite direction of arrow see below). uy498 Fig. 72 Fig. 73 (c) If camber angle is excessive in © direction, use a piece of wood as a lever and change relative angle between inner and outer arms so that angle @ formed by inner arm and outer arm centerlines decreases, Then, tighten outer ‘arm mounting bolts, (f) Adjust camber angle to conform to service standard by repeating steps 4) and 6) above 1, Adjusting toe (or side stip) results in @ change in camber angle, while adjusting camber angle causes a change of toe (or side slip), Therefore, when either is adjusted, always check that the other remains within service standard. b, After both toe (or side slip) and camber angle have been adjusted within service standard, be sure to tighten bolts to torque specified in chapter 4-1. 4) Oil leakage of shock absorber... ... Inspect every 48,000 km (30,000 miles) or 30 months, whichever occurs first. Remove tire and visually inspect shock absorber for oil leakage a5 instructed in chapter 4-1. Replace shock absorber if oil leaks excessively. 5) Tightness of bolts and outs «+ Inspect every 48,000 km (20,000 mites) or 30 months, whichever oceurs first5 PERIODIC MAINTENANCE SERVICES Check bolts shown below for looseness, Retighten bolts to xd torque. Further, check that cotter pin in place 3 sp shown below. If not, install new cotter pin. FRONT 7 ee : Moe TEX IE, 7 h aN = J S as9 11240 Fig. 36 Tightening torque: Nem (kg-m, f-b) Ti: 38 ~ 50 (3.9 ~ §.1, 28 — 37) 72: 88 ~ 103 (9.0 ~ 10.5, 65 — 76) 3: 118 ~ 147 (12.0 — 15.0, 87 — 108) Ta: 74 — 88 (7.5 — 9.0, 54 — 65) 6 +t on and damage to rolling diaphragm of sir suspension ss s++ Inspect every 24,000 km (15,000 miles) of 16 months, Whichever occurs frst. (1) After loosening wheel nuts, jack up vehicle until all four wheels are off ground according to instructions in “Pre-Dolivery Inspection,” Remove tires, (2) Visually inspect rolling diaphragm. If dirty, remove dirt from diaphragm. Be careful not to damage dia- phragms, {3) Visually inspect rolling digphregm. Replace sir sus- pension ASSY if damaged. However, replacement Is not Fequired if only fine scratches on diaphragm surface caused by sand. These do not present a problem. (4) Visually inspect rolling diaphragm for rust. If rusty, remove rust and touch up. When touching up disphragm, be careful paint does not adhere to diaphragm. (Lower jeck efter touch-up paint hes dried completely.) 7) Damage to suspension parts ‘Check the following parts and the fastening portion of the ‘car body for deformity or excessive rusting which impairs ‘the suspension. Replace faulty parts. if minor rust forme: ‘tion, pitting, ete. are noted, romove rust and apply remedial anti-corrosion measures. (1) Front suspension + Transverse link + Crossmember + Strut (including air suspension} + Leading rod + Leading rod bracket (2) Rear suspension + Crossmember + Inner arm + Outer arm Bracket + Shock absorber {including air suspension) 38PERIODIC MAINTENANCE SERVICES Grease on Front and s VA Rear Wheel Bearings eee Inspect the condition and the amount of front and rear wheel bearing grease as follows: FRONT WHEEL BEARING 11 Apply parking brake. 2}. Raise front wheel with a jack, and remove wheel. Remove cotter pin from axle shaft and remover castie nut. 3} Remove bolts which secure disc rotor to front whee! hub, and remove hub, 4) Remove oil seal from housing, and check the condition of bearing grease. 4. If either the grease appeats to be white or if only a small amount of grease remains, remove the bearing from the hhousing, clean it, and pack it with grease. . Discard the old seal and install a new one. un Fig, 76 5} Installation is in the reverse order of removal Tightening torque (Castle nut): 196 N-m {20 kgm, 145 fttb) ‘After tightening the castle nut to the specified torque, tighten additionally in one sixth (1/6) turn until both holes of bolt and castle nut align each other. 39 MAINTENANCE INTERVAL umber of months or km (its), whichever occur first) Monts | 75] 15 [228] 30 [378] 45 [526] 50 xigookm | 12 | 24 [38 | aa | 60 | 72 | a | 06 x1000miles | 75 | 15 225] a0 |a7s| 5 |s2s| oo Tightening torque (Hub to disc rotor bolts): 44 — BB Nem (4.5 — 6.9 kgm, 33 — 43 flb) REAR WHEEL BEARING [FWD vehicle) 1) Apply parking brake, and loosen rear wheel nuts. 2). Jack up vehicle, support it with safety stands (rigid racks) and remove rear tres and wheels. 3) Pry brake drum cap by screwdriver off drum. 4) Flatten lock washer and loosen axle nut, then remove lock ‘washer, lock plate and brake drum so as not to drop inner race of outer taper roller bearing. Outer bearing, outer race of inner bearing and oil seal can be rernoved together with drum. 5) Check condition of bearing grease, a. If either the grease appears to be white or if only a small amount of grease remains, remove the bearing ftom the housing clean it, and pack it with grease. b, Discard the old sea! and install a new one, (outer bearing noer bearing it set Fig. 77 6) Apply approximately 4g (0.14 02) of grease to inner bearing and 3 g (0.11 02) to outer bearing, Fill the hub of drum with approximately 30.9 (1.06 2) of grease, 7) Install drum, inner race of outer bearing, lock plate, lock \washer and axle nut in this order onto the spindle. Be sure to use new lock plate and new lock washer without fail.1-5 PERIODIC MAINTENANCE SERVICES. REAR WHEEL BEARING [4WD vehicle} 1) Apply parking brake, 2) Remove rear wheel cap and cotter pin, and loosen castle nut and wheel nuts. 3). Detach shock absorber from inner tralling arm. 4) Loosen locking bolts of crossmember outer bushing, 5) Jack up vehicle, support it with safety stand (rigid racks) ‘and remove rear tires and wheels. 6) Remove castle nut and brake drum. 7) Drive out spring pins of inner and outer 0.0. by usinga steel rod of 6 mm diameter. 8) Remove outer D,O.J, from spindie of trailing arm with trailing arm lowered fully. 9) Remove rear exhaust pipe, muffler and exhaust cover in that order. 10) Disconnect brake pipe from brake hose. Fit air breather cap anto end of brat ‘fluid from pouring out, hhose to prevent brake 11) Remove brake assembly from trailing arm. 12) Remove bolt holding inner bushing of inner trating arm. 13) Remove three bolts, and take out inner arm. 14) Vise inner arm, and straighten staked portion of housing, ‘then remove ring nut by using HOUSING NUT WRENCH (925660000). 15) Exteact spindle inwardly by tapping it from outside with ‘plastic hammer. 16) Remove oil seal 17) Check condition of bearing grease, a. If either the grease appears to be white or if only a small amount of grease remains, remave the bearing from the hhousing, clean it, and pack it with grease. b, Discard the old seal and install a new one, | > 1 ieee ; win 2 L178 Fig. 78 18) Apply grease of 20 to 30g (0.71 to 1.06 oz) to bearing outer race in housing. 19) Insert spindle from inside, and press inner race of outer bearing from outside by using a pipe of 35mm (1.38 in) in inner diameter while tapping itwith a hammer. Apply grease sufficiently on the inner and outer bearing area. 20) Install ring nut to housing, Tightoning torque: 172 — 221 Nem (17.5 — 22.5 kom, 127 ~ 163 ft-lb) Fig. 79 21) Lock the ring nut by staking @ point on the housing surface facing the ring nut groove. Fig. 80 22) Install outer oil seal by using OIL SEAL INSTALLER (925530000). Be sure to renew the oil seat,PERIODIC MAINTENANCE SERVICES 5 23) Install Inner il seal by using OIL SEAL INSTALLER 27) Temporarily fit brake drum, center piece, washer spring (Special tool). and castle nut to spindle in this order, Be sure to renew the oil seal. 2, Play on spindle is not a fault when mounting brake drum, 'b, Don't confuse orientation of washer spring, 24) Mount inner arm to vehicle body. Tightening torque: Inner bush bolt: 74 — 93 Nim (7.5 — 9.5 kg-m, 64 — 69 ft-lb) Inner and outer arms connecting bolts: 118-147 Nm (12.0 — 15.0 kg-m, 87 ~ 108 ft4b) 25) Install rear brake assembly to inner arm, end connect brake pipes ete Paint mark Waser ning 18107 Fig. 83 28) Bleed brake system, jefore bleeding brake system, check pedal play and brake fluid level in reserve tank. b, Bleed air from four veheels without fai 28) Tighten castle nut, insert cotter pin and bend it firmly Tightening torque (Back plate): ‘with foot brake applied to lock the wheel and axle. 46 — 5B Nom (4.7 —5.9 kgm, 34 — 43 fttb) Tightening torque: 196 N-m (20 kgm, 145 fib) After tightening castle mut to the specified torque tighten further within 30° to align holes on nut and spindle, 26) Connect brake hose and brake pipe. 30) Install packing to rear spindle, and mount D.0.J. on rear ‘rive shaft onto spindle with trailing arm lowered all the way. When mounting, mate the spline teeth properly so that the 1.0.4. and spindle spring pin hole will align. a1-5 PERIODIC MAINTENANCE SERVICES Fig. 84 31) Drive spring pins into D.O.J. ‘a, Before driving in the spring pin, confirm alignment of the holes, ', Be sure to renew the spring pin to be driven in. 32) Install wheels, outer arms, etc 33) Lower vehicle on the ground, and install lower end of shock absorber. Fig. 85 42 Fig. 86 Tightening torque: ‘88 — 118 Nem (9 — 12 ko-m, 65 — 87 feb) 34} Check and adjust reer vehicle height and rear whee! align ment 36) Tighten outer arm lock bolts. For vehicle with dise brakes, inspect in the same manner 2s with drum brakes.SPECIAL TOOLS qje SUBARL 1989 ENGINE TOOLS . ‘iE MANUAL TRANSMISSION AND DIFFERENTIAL TOOLS AUTOMATIC TRANSMISSION AND DIFFERENTIAL TOOLS REAR WHEEL DRIVE SYSTEM (4WD MODELS) TOOLS... SUSPENSION TOOLS . WHEELS AND AXLES TOOLS . STEERING SYSTEM TOOLS . BRAKES TOOLS AIR CONDITIONING SYSTEM TOOLS . BODY TOOLS ..1-6 SPECIAL TOOLS Engine Tools 1398744300 396852100, 1399094310 399288300 PISTON GUIDE O1L SEAL INSTALLER PISTON PIN REMOVER ASSY | PISTON PIN GUIDE ‘Used 10 instal piston in evlinder. | For presiting of intake and | Used to remove piston pins by | Used to instal piston pin in piston exhaust value guide ol seal. Inserting this soe trough crank- | Sn ponneeting ros, cave pug holes =H} Sa, as.158 sT.054 asa 8.166 ‘399762103 399762704 “499027000 "498037000 VALVE GUIDE REMOVER —_| VALVE GUIDE REAMER CAMSHAFT HOLDER, INSTALLER, For removing of vave guide For reaming of valve guide {Used 0 hold camenatt when | Used eo install camshat ot sea Drove fitting crtlbutor gest 10 Eamahafe, —>s— asia? L093 498267100 498277000 496497000 499007000) CYLINDER HEAD TABLE FLYWHEEL STOPPER CP ORIVE PLATE STOPPER TENSIONER WRENCH For repiacing of valve guide ‘Used ta top rotation of tyhes!| Used to stap rotation of ceive | Used to holdup versiones No.2 \when loosening and tightening | plate when loosening ane ‘en reducing sing bait toaion Crankshaft pulley ott ete. fighteniog evnienaf pulley bolt, Manual transmission vehicle _| Automatic transmission whicle Li.086 Li-095 1.276SPECIAL TOOLS 1-6 499037000 1499207000 "499437000 1499867000 REMOVER & REPLACEA GAMSHAFT SPROCKET ELT TENSION WRENCH cP | INSTALLER. WRENCH Connecting rod bushing ‘Used 19 remove andi arnt sprocket ‘When installing timing belt, ua to toply the speci torave to camahal ouley 30.8 to get the Speciied belt ension Used 10 instal rankeese front ell A ) asses css es0 mean a areal aoa ne sea ony meee er amie mnie oon SOCKET WRENCH (17) sockET VALVE SPRING PRESS ASSY VALVE GUIDE AQUUSTER For rtightening eylinder esd, (Oxygen (0,) sensor. pring ‘Uzad to remove and install vee Ure to neal intake and oxtaust valve guides. Lra08 810-133 asa S| asaSPECIAL TOOLS 1-6 Manual Transmission and Differential Tools 300405200, 308701600 STAND oummy COLLAR AeMoveR I Fear drve sate Oil sal input at hole, | tap hat aap ig ug in Tart ie awo. 4970 Dus range 4¥10 Dus range 13208 aizt74 oes 3600 Remover INSTALLER Spring pin (Sapeedh “Transmison main cove everest ail am Exon aro awo 1 srano crrassasi20) 2 Soc Tiorenan 3 socrioresroroy ene an2a70 19496 Se07H0T10 sear INSTALLER olor bearing Diferentad, | ole Bering (Differant. | Prelod on ol berng ove bearing, (iferentia ISR STi! WO Non-TUREO 0 TURBO AWO FWD Non-TURBO ana a2a7sSPECIAL TOOLS 1-6 "498057000 498057100 "490057200 "498087000 OIL SEAL INSTALLER INSTALLER OILSEAL INSTALLER ‘TRANSFER RACE PRESS Trensler cos il sal ‘Transfer fron il sa “Transfer reer il sel “Transfer race awo 4010 uot range 410 Duatrange wo L105 L106 Lrt07 L108 498077000, 498147000 490247001 498247100 STH ORIVE Gear nemover | vEPTH GAUGE MAGNET BASE DIAL GAUGE ‘5th driven ger, FWO TUREO -4WD Main shoft axial end play ‘Backlash between sige gear and Hiypoid gear backlash ‘akin between sige gear and Hypold gear backlash, L908 1298427000, 498617000 st-146 498787000 sr.156| stas7 498787100 STOPPER REPLACER STOPPER MAIN SHAFT STOPPER Fer sacurng the drive pinion shat [ASSY and driven gear ASSY when femoving the erve pinion shat IASSY Took aut (18 x 135) Drive pinion thrust slate a naedle Bearing race FWD Non-TURBO od “Transmiesion main shat, WO Non-TURBO “Transmizsion main shat FWD TURBO - WO L308 sTast anaa7s Lato1-6 SPECIAL TOOLS 498957000 499287200 499277000 499277100 TRANSMISSION HOLOER STOPPER PIN, INSTALLER, BUSH 1-2 INSTALLER “Transmission main shaft lock nut. | Tronafe eve and fork highew — | Drive pinion. {st driven gear theust plate. fod, 1st Sand en gear bash WO TURO- 4wO ANID Dual range EWO Non-TURBO FWD TURBO - aw L277 12.296 Lin 490277200 1499747000 499747100 499757001 INSTALLER, GUIDE CLUTCH pise GUIDE SNAP RING GUIDE For pres fisting the 2nd ivan | hutch ase. Clutch ate ‘Snap ring (OUT 25) sear roller baarngr, @ 6h crven Star onto the driven snaft FWD Non-TURBO FWD TURBO - 4D AWD Dual ange L381 st70 wats 490757002 1499787000 1498797000 "499627000 SNAP RING PRESS. WRENCH ASSY O1L SEAL INSTALLER PRESS ‘Seep ving {OUT 25) Differential sige retainer. Differential side retainer oi sal, | Oi eal (Speedometer. pearing (25 82 x 17), 4v10 Dust range FWD TURBO. awo arr uate starSPECIAL TOOLS 1-6 Tene 790700 2 7e08i 7600 REMOVER ASSY racessinsrauien | Gauoe assy? DRIVE PINION GAUGE ASSY ‘To remove the driven gear ASSY Sth poor ‘Neeale bearing th and Sh aces ‘Transmsion mein hott rer ball bearing. FAD TURGO ao Drive pinion him, FWD Non-TURBO Drive pinion shim adjustment. FWD TURBO - «WO | 47 1 Pore 2 Seale 569 Lene an2a88 L20 499827000 499927100 499987008, 490987300 HANDLE ANOLE SOCKET WRENCH (38) SOCKET WRENCH (60) Transmission main shalt FWD Non-TURBO ‘Transmission mein shalt, FWD TURBO 2wD Drive pinion tek nut Main shaft tock nut AWD) “To remove the driven gear ASSY OD fm \\) \ W aren areas Lies weamnae00 seomreice o0sae700 ess0100 wouoeR EXPANDER Pucuenser InstaLen Trarnision mane smog Taterbeving Oiiearva | anaminion gin PB ciaion man tate eacepiion eae fhe Beh Fo Non TUR 40 usta [wo Hon-TUR8o avai araa7e on ma16 SPECIAL TOOLS mona waar wens oo RETAINER mess assy ess RETAINER Tecaiser paneer, | Tarsnason mpnagiy, | Ouahraunw barra rode [Tarennion mina BREDA Ae Shane, | ARTETA on exeon SSR 00 wo non-TuR0 Fo NosTURWO Guide é hee oo avast avasa asvaxs oo ceoamuioo eearaica aaeaico oa newoven INSTALLER HoLDer ewover Tresrinicnmainstat, | Teraisian main tan, | prwpinon, Raw avesat, | Sram pin ire Brian bargin Booty Fee E ese natin arasea ava vasa arzaer cd SOCKET WRENCH (27) “Trantmision main shatt (FWD) Fear drive share (aWO) arzi91SPECIAL TOOLS 1-6 Automatic Transmission and Differential Tools 1. Special Tools for Differential 398437700) 208643600) 308653600 398781600 RIFT Gauce SHAFT STOPPER Drive pinion front bearing cup. | Low & revere broke, otal Drive pinion and reduction cvive_| advection drive gear endpiay, cll pum, dive pinion | ger Ce) | alt= 16.006 aigan 913.192 Aiza7s 398833600 300813600 399520105 1399703600 auroe INSTALLER SEAT PULLER, ‘Needle bearing. Drive pinion ear bearing cup. | Rollr basring (Differential ‘Axle shaft bearing esp, arai9 13196 i247 anate6 309780711 (300790710 399913607 1369913608 wrencn INSTALLER, MasTER HOLOER Folier bearing (Oifferendat) | Orive pinion ‘Drive pinion ‘Axle shal il seal holder Axle shott ol sl ang90 aig99 aizi68 A2781-6 SPECIAL TOOLS 390973604 "496247001 492247700 "496677000 SPACER MAGNET BASE DIAL GAUGE HANDLE Drive pinion Backlash of gears. ‘Backlash of gears ‘Bearing eup, reese beara, “rive invon Iront bearing fetainer and imeller bushing anaie7 sT.186 sT157 st-159 498817000 498567000 490907000 "498647000 REPLACER PULLEY BEARING GUIDE o1L seat GUIDE Drive pinion front bearing core, | Preload check Needle bearing Oi seat holder Stasi aisst3 aias12 13515 "499247000 499247700 "390247200 296267100 INSTALLER, OILSEAL INSTALLER INSTALLER SPACER, Drive pinion ol seat ‘it sal Hower Fina eduction cae (i sea holder wo anssia asst aussi Ans 516 10SPECIAL TOOLS 1-6 “490427000, 499827000 499667000 1489097000 INSTALLER PRESS Remover PLIERS Drive pinion front bearing cup, | Speedometer shaft ol sea Needle bearing at reduction drive | Srap ring fxle sha bearing cup end th ea aisor sme anss19 499017400 499997000) 490987700 399524109 MASTER? DIFFERENTIAL STAND SOCKET WRENCH (35) PULLER SET Drive pinion Final reduction setion. Drive pinion Rolter bearing (Diferentia Pla cp Aisi a13509 aigsit apeaz 1899580100 1299904100 ‘399824100 INSTALLER REMOVER HANDLE Drive pinion Different case. eduction drive gear o——- Annas anzaar An2489 "1-6 SPECIAL TOOLS 2. 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