Impreza 1993-1996 SUBARU' ee SUPPLEMENT SUBARU. IMPREZA © General Information Section eRepair Section * Diagnostics Section * Wiring Diagram Section Eo sA 1 @ a Ga Ua RHD MODELSS TABLE OF CONTENTS GENERAL INFORMATION SECTION 1-1 Specifications 122 ised 1-3 General Information 11-4 Pre-Delivery Inspection 1-5 Periodic Maintenance Services 16 Special Toots REPAIR SECTION Ba anak 22 On-Car Services }2-3b Engine (DOHC) }2-4 Engine Lubrication System eucrresrresccT’ ENGINE SECTION 246 ddd 2-7 Fuel injection System [MF/-TURBO} 28 Fuel System 29 Exhaust System 240 Clutch 211 Engine and Transmission Mounting System 37 Manual Transmission and Differential ‘TRANSMISSION AND DIFFERENTIAL |3-2 Automatic Transmission and Differential SECTION 83 ideo 3-4 __ AWD System 41 Suspension 4-2 Wheels and Axles MECHANICAL COMPONENTS Gal careenanee pein 44 Brakes |45 Pedal System and Control Cables eerrecererces 147__Air Conditioning System 51 Body and Exterior 52 deidendiokioe BODY SECTION eek n aoe 53 54 Instrument Pane! 55 Supplemental Restraint System BA OSA, 6-2 Body Electrical System ELECTRICAL SECTIONDIAGNOSTICS SECTION [2-76 Fuel Injection System [MFI-TURBO] Peeccrecucccoced Ak eid eacooioeaek 565 odode J6-2 Body Electrical System WIRING DIAGRAM SECTION [6-3 Wiring DiagramSPECIFICATIONS 1-1 Page @ S SPECIFICATIONS ae 2 1. 4-door Sedan 2 2. 5-door 74-1. S101) SPECIFICATIONS 41.4-door Sedan 1. 4-door Sedan 1. DIMENSIONS ide 1600 7600 2000 oy WO oy veraongin amie) 00 (749, 487A ~ [4380 0709) veal wih mm) 7,680,665), ‘Overat height (at GW) rmmin) | 1400/65) | 14180657) | 1405653) | 141857) | 1400651) 405,684) | 11565779 415 (85.7) | Coneanment [Length mm) 18200717) wat co) 1968 6885) Height mmr) 4.17046.) Wheebase 7 o read Fron rmmin)] 1475600 | 1460675) "i489 67.7, seo 575) ear amin] sassern® | asse7a | es5;79, | vassers | 1As5673) "438 657.3) 0187) | 1450 (67.1) | Timm ead dearance mmin| 15069 | veoes) | 1069 | veo(6a) | 15069) "176, Counties “2th $3 ncn woot ‘3! Alsvalan model 2._ENGINE We 1600 I 100 Engine ype 7 Horizontal opposed, iq soled, tyinr, 40080 Vale arangement ‘Ovetead camena ype Bore x Stroke rom in) | 679x658 (8461x2591) | 679x75(6461x295) | 92x75 (862x288) Deplacoment em®euin)| 1897 (9745) 7.800 (r18.06) | 1.888 121.67) Compression ato a4 [Fring orser 7 _ Ie speed a Parka postion ‘om Maximom ouput RW iPSiom| 66 00/5600 Maxima toraue Nim tm, Oyo 728 (18.0, 944,000 270 (27.6, 20094 800 3._ELECTRICAL ia | ws os Fo losing aig peed BO [ iw Spon] Tie andmaetc T i Be wana Wan FR ses | NGk Ste Seen nya | _ oto BeEsrcsa tet Se a ‘Battery | Type and For Europe ‘SMT: 12V— 44H ~ ect ae ae Ore Baya a eeSPECIFICATIONS (si0) 1-1 1. 4-door Sedan 4. TRANSMISSION nde! = Fanenason pe ae Chutch type | - _ ToC | (Gear rato | 7 ~_1:000, ose 227 ‘Ausaryanamission gear rato Reduction gear [ist (From ative) | reduction Roduction goar | 1st Hoical (Frontarve) | reduction te 7.000 Final___| Tye of gear Tipe Hypo Hiypoid Fiypaia reduction | Gear rato 3000 | Cae 3.900 ai educion gear | Transfer | Tyoe of gear = S = = (Fearaive) | reducton [Gear ratio = | = = = [Final |Ty50 of goar = [ = = = [teeuevon [ear ratio = t = = = ‘Mosel Transmission type Cute ype Gear ratio ‘Raxilary transmission gear Final reduction Reduction gear | Transfer (oar dive) | reduction Hypoid Hypoid Yipod | Aypaid 3.900 aim | 3900 - = [__ Fetcal 7.000 S [+000 | Hypoid Hypo Typos | ypaia ‘3.900 3.900 ain 3585, SMT" forward apeeds wih aynchromesh and [reverse 44A7": Electronically controled full automatic, (forward speeds and t-overso SMT-2:Sfonvara speeds wih synehmesh and reverse with conor aifecentil and viscous couping {2A7": Electronically contol full sutomate, 4orward speeds and I-verse - wih hydraulically controled transer clutch SPD: Diy Single Pate Diaphragm TCC: Torque Converter Ctch1-1 (8105) SPECIFICATIONS 1, 4-door Sedan 5. STEERING Model ‘Non TURBO TURBO HO 7} Type - _ Rack and Pinion Tums, isk to lock 32 28 30 ‘Miami cla mt) ‘Curb curb: 102 (295) Curb to carb: 10.4 (941) ‘Curb to curb: 10.8 5.4) 6._ SUSPENSION Front ‘Macpherson sul lype, Independent, Col spring ear Duan stp, Independet Col sping 7. BRAKE Tl Taro ABS TABS TURBO Senco bake sem Dual che yee wih vac suspended power ont Fron Verlaed des trako Fear Dunbake Dac bake Paina bake Macarical on ear bakes 8. TIRE ode! Non TURES TURES Rimaica 1ax5008 Taxeiau 5x8) The se 16518 T7si70Rv8 TOBA rie Goolbeted ada, Tabotes 9. CAPACITY Tol Non TORE TURES wo AW ear war oat [aa out Foalank 70S oak imp oa 9082.10) 59,93) engnset ‘Upperievel — € (US qt, Imp qt) - 4.0 (4.2, 3.5) - 45 (4.8, 4.0) Lowerlevel (US np a 302.26) 3567.39) Transmission gear ol CUSat mpg | 2627.23 [| — 4.0 (4.2, 3.5) = 40 (42,35) Aomatcransmissonts CUSeine@ | — | 7a@aro | — | 7ewaro | — AT eternal oar of cusamea | — | 20ary | — | anaen | — [AWD reardifferential gear oil ¢ (US qt, Imp qt) = 0.8 (0.8, 0.6) “| Power serng tid US inp a o707.08) Engr costar “(US a Imp a 1000: 6.4 (68,56), 1000162166, 55) 72 eySPECIFICATIONS {sto1o) 1-1 4. 4-door Sedan 10. WEIGHT Model 1600 esrop0, General ~ tao a oe I L | _ _ [sar aa aa wat | owt aa curb weight (Cw) [Font ‘a (| 605 (1.555) | 660,435) | 676,0.955) | 6601455) | 625(5,900) | B70 LAT) (Rear 19) | 00(680) | 410,005) | 410(005) | 415 (615) | 425 (005) | 490,050) Fear eg (io) | 1,005 2.218) | 1,060 2.836) | 1,025 2,260) | 1,078 (2.370) | 1,050 2.315) | 1,100 (2.425) [Maximum permissi- | Front ‘kg () | 790(1,750) | 830 (1,830) | 790(1,750) | 890(%,890) | 810 (1,785) | 850(1,875) arawy [eer ea) | TOUGATH) | 7HOCTAO) | THOURTE) | TOOCTTAO) | 77OUUTOO) | 600875) Maximum permis | Total ig te) | 1520 380 | 1590 805) | 7 520(9.350)| 1.590 8.505) | 1.805 6.485) 1.640 T=) biewoght LPL) | ! oer a 7800 7000 “europe, General — a =) T on (eye I _ ce [ [Corb weigh (Cw) | Font Pr a a) ] (naz) | (35) Rar rot) | 470 475 | wea | c.oes) Toa rote) vats | aa | eise0) | 2480) Maximum pemisst | Front rate] 10 | 90 bese woh | 785) | 830) PAW) Fear @)| 0] eo | 770 | a00 300 | 50 | crs) | 880) | (700) | 760) (1350) | 875) oman gems [Toa wwib)| 1620 | 3690 | 1560 | 690 20 | 1730 Dewar (PW) sro | Geis | cas | 615) 705) _|_('860) Mosel ECC. Countres — oar [ ont T cur weight CW) | wo] eas nae) «| ——s0NB) ab) 410 (005) [25 35) [435 660) ka(e)| _v0ss(2508 | 107s ara) | _——_130@400) [Gross vehicle weight w 610(1.785), [7 er0(4705) [210 (0.850) foun eas 9 (b) 770 9.700) 770,1.700) | 800,785) Total kay 15806485) | 150063405) | _1 640615)4-1. [s1010) SPECIFICATIONS 1.4-door Sedan Tiosel 71600 7800 — 72000 = Aestrain— [wo wo T oo x i ox x ov |_at_| ara ‘Uniaden mass (UM) ] Fron wei] 610 | 650 | Co 3s) | (485) | cass) |_ 00) Rear re] 0 | 425 | ao | as 25 | 35) a7) _| (107) Teal ro) | 1.090 | 1.075 300 | 1920 2m) | e570) 2425) | e470) ‘Gross vehicle mass. | Front gb) 1890 (1,830) 890 (1,690) "830 (1,890) (evi) L- _ jo Rear vow | 75008655) 7a0 0720) 190 (1.890) "Totat kg) | 1,580(8-485) 1.610350) 1,860 (8.660) NoTe: ‘When any of the folowing optional parts ar installed, adhe weight tothe curb weight oc unladen mas, If pomer tering not equipped subtract the weight rom he curd woigt Wogtot | Power] Power] ABS Rr] Suneot] Power] SRS Aeon] SAS Ar bag cptnaipars | window | oorlock condoning | | steorng | Owen | “towera | Passenger) [Front kg (by | 412) 010) 14) 19 (42) sin 8 (18) sa (18) 1840) Rear Woe] 2) Te) acy | eco | ec) | 10a 12 00 - 132) oe oe Toa ke t@)| 3) 2 19,42) 13.9) Tr) ry 51168) 15 tmcase that the ABS is installed on 13 in-wheel equipped vehicles, the wheels must be exchanged or 14n. ones To obtain the curb weight ofthe vehicie, therefore, the values shown in must be adeoSPECIFICATIONS [s203} 1-1 2. S-door 2. 5-door 1. DIMENSIONS Model 7600 1800 00 [_Fwo AWD FWO ‘AND. Sieralengh mm) 4350 (719) 4575 (0722) 4340 0709) Overall width - mm (in) 1,690 (66.5) [Overt niger OW rom) | 4405 653"% | 14201658) | 1410655) | 14200658 | 1A00/68.0, 8100655) nasi." 108 (60.574 Companmnent [Lanai om) 1.790703) with mm) 1.985 645) Height mm (in) 1,170 (46.1), _ Whesibace mm) 2520 (68.2) Tread Front mmm ny] taveean® | 1asorers) | 1asscer7, | 1ae0 7S | 1AeSer7) {s65 (61.7 400675) Rear ‘mm (in) | 4.460 (57.5) | 1.450(57.1) | 1,450(57.1) | 1.45057.) | 1.480(67.1) 80087.) iim road clearance min] 150;69 | veo1ea) | vs069) | 16069) | 1506) "TGC. Counts “22th $9 neh whoo! 3; Austraan meds wrth rt ra 2. ENGINE Weel 1600, 1600 2000 Engine We Horizontal opposed ig cooled, inde, oe gasoline engine [Valve arrangement _ Overhead camshaft type Bowe x Sok come) | 79x65 (4012501) | 979x75(@481x205) | _sox7e(a6ax005) Daplacoment em®tcum | __ 158770748) 194 (128.67) ‘Compression ratio 94 so Fring oer [iting speed at ParkiNeuiral position om, 700 ‘900 ‘Maximum ouput RWiPSirom | 65,9075 600 76 (105)5.600 155:01076 000 Maximum ore Nim (com nanyipm | 128(59.0, 946,000 | 147 150, 108y4.400 | 2702762004800 3. ELECTRICAL Mal 1600, 7200, 2000 Ignon ing ating speed BTOCipm 15700 187900 Spark [Type and manufacture NGK: BKAGE (without catalyst, - NGK: PFREG oe Gk: BRRBE-* (wth cate) CHAMPION: RCBYCA (th eae) Generator tav-— 75a Baty | Type ard Fer Europe ‘Bat Vaan air av — HAH capacty (SHA) aia 120 — Seah Ones MT: 12V —Z7AH ‘Bat av —Z7AR ‘int 12V— ean ory aaah1-1 [S204] SPECIFICATIONS 2. S-door 4. TRANSMISSION Model 1600 1200) FWD “Transmission ype eur a ur ar Clutch ype 2 Toc SPO Too ‘Gear rato 1s 2788 3.636 2785 ‘nd 2.105 Te 2.105 15s ‘re 1428 | 1000 1428 1.000 an 1.098 0.696 1.089 oc 3th 0.825 = 0.825 Reverse 3583, 22re 3583 ‘Ausllary vanemission gear | High = = = = rato = = = = = eduction gear | 1st Type of gear = Helical = Helical (Frontive) | reduction Gear ratio = 1.000 5 71000 Final | Type of gear Hypo Hypo Hypoid Hypoid reduction [Gear ratio ‘3.900 aus 3.900 att Reduction gear | Tansler | Type ol goar = = = = (Beardie) |redueton oo = = = — Fil Type of gear = = = = retin [oon = = = — ‘Model 1600 1600 "2000 aWO ‘Transmission type MTs su? aan? ‘sur? ‘SMT? Cun ‘D5PD ‘05PD ToC SPO DSPO (Gear rato tat 3586 3545 2785 3.588 3545 2nd 2a aan 1585 am "1987 ae 16 186 1.000 148 1366 ah 1.088 "1088 604 1.086 are sth 0.825 01825 = 0.825 0738 | [Rovewe | 3416 3416 2272 S416 ‘aat6 /Auxitary vanamision gear | High 7.000 1.000 = = = me Low 1592 1592 = = = Reduction gear [iat Type of gear = = Heal 5 = (Front dive) | reduction = = Gear ratio = = 71000 = = Final | Type of gear Hirpoid Hiypaid Hypoid Hypoid| Hypo reduction Gear ratio 3.900 3.900 aa 3.900 3.900 Reduction gear | Transter | Type of gear Helical “Helical = Helical Helical (Rearce) | reavetion [Gear ratio 7.000 +000 = 7.000 71100 Final Type of gear Hypo Hypoid Hypoid Hyped Hypoid eavton Teac ratio 3.900 "3.900 ant 3.900 3.545 SMT S forward speade wih synchvomesh and Teveree 4A7"™: Electronical controled Wl automate, forward speeds and ‘-reverse SMT. Sorward speeds with synchromesh and treverse — wih center diferent and viscous couping 447-2: Electronically controled fu automate, 4-orward speeds and {reverse — wit hydraulcaly contoted transler latch SMT: 5 x 2 forward speeds wih synchromesh and t-everse— with center siferental and viscous coupling SPO: Bry Singlo Piste aphagmn ‘TOO: Torque Convertor CunSPECIFICATIONS (209) 4-1 2.5:door 5. STEERING Tse TonTURBS TURES CC HD ‘LHD pe ack and Pron Ture bee ibak : I 32 2a 30 nr ing oe mio | Cotman: 1025) | Cabana GT | Cubwoue OSREA SUSPENSION Tit Tiperson Sl Wp ponte Cas Rear ‘Dual link strut type, Independent, Coil spring ~ BRAKE Bel aha BS TAS TURBO Serco bak gion ‘vaca yan wih veoum sponded paver nt Front Vertaed ee ‘Rear ‘Drum brake Disc brake | Parking brake _ Mechanical on ear brakes 8. TIRE se Ten TURBO Tae in se OT cs ae Tie ze wean TsroRte aE [oe Set otes ada Tubs 9. CAPACITY Te TonTURBO TURBO Ao "avo au = ou ar ar Foon (US pti oa wor82 a) wos9 132) Urge (US mo a 40(42.85) 4514840) ead Lower level € (US qt, Imp qt) 3.0 (3.2, 2.6) 35 (3.7, 3.1) | Transmission gear oi CUS at, imp qh | 26(27,23) = 40 (42,35) = 40 (42,35) Auonatctenenisientad —eUSamea| _— | 7e@ara | — | 7ewaro | — a afro goarot Cusauimay | =| 20a oat | [AWD ear renal guar 58 (US amp a | "0808.08 Powe seeing aa US a mo a a7 07.08) Engine coolant (US imo @) 1600; 64 (68,58), 1200.62 68,55) zoitees)1-1 [82010] SPECIFICATIONS 2 Boo! 10.WEIGHT ira fea pecan = ; at a x | a Sur “ar ot [aa oT | Sur [Curb weight (GW) | Front kg) | 610 (1.845) | 655 (1.445) | 620.(,366) | 665 (1.465) | 645(1.420) | 650.(1.435) Rear ‘kg () | 450(990) | 460(7,015) | 460 (1.015) | 465 (7,025) | 510 (1,125) | 510,125) [Tota ‘kg () | 1.060 (2.395) | 1.115 (2.460) | 1,080 (2.380) | 1,130 ( 1185 (2.545) | 1,160 (2.5¢0) san [pnt aa svt [son | watts | petty aoe | Ser ett, [Rar wows | omen [wore [omar [wna [ear [oo | Maximum permissi- | Total ‘kg (to) | 1,590 (8,508) | 1,640 (9,615) | 1,690 (2.595) | 1,680 (3,705) | 1,670 (9.680) | 1,690 (9,725) acne, ‘Model I 1800 T2000 os = — Ca —Odt~<“—tSCstS~‘“C~;CSCSYSC Rg MT “aaT out wat SMT Gab wane) [ Ft Taw) | eas n8e0) | ero naTe) | eats) | emo) | 78 a0 ps irene an me aoe mmc [nes RETA Total gto) | 1.080 (2,300) | 1.135 2.500) | 1.165(2.570) | 1,105(2.638) | 1.270 (2.800, tar | Set RTT [uSOT SOOT ATT eT AHIR RERI™ — [per won| ets | sors | onan | onsen | tomy |Maximom permissi- | Total kg (ib) | 1,690 (3,585) | 1,680(3.705) | 1,720 (3,795) | 1,720 (3,786) | 1,800 (3,970) Sree oor a = come co i e- 7 ee or ca | Curb weight (Cw) | Front kg (b) 640,(1.410), I 1690 (1,520) 665 (1,465) Rear =k (Bb) 465 (1,025) a7o(1o3s) «| SSS (135) = cer eae Tet re [Gross vehicle weight | Front ko) | __-800(1.765) _ 1890 (1,890) 1850 (1,875) fava) Rear kg (b) "830 (1,830), 60 (1,895) £870 (1,820) Total kg (io) 1,630 (3.595) P7690 (8.725), 41,720 (3,795) 10SPECIFICATIONS [s2010) 4-1 2. door Toca 700 Ea “eine — — a ox x winx aa war aur ar sur nian mass (UM) [rot aie] eros) | esocnaasy | 2501400] e70NA76) | 7aB 600) Rear go) 47040085) | ars cnoasy | ~seo(t.as) | 06.160) | 8650205) Tos ao) | 10802000) | 7.105.400) | 7.155°@.545) | 1.195 2605) | 7290 @.20) Grass vehile nase [Font 96) 70 (1.800) e70(1 820) 0 985) (evan) ‘Rear kg () 820 (1,810) 870 (1,920) 900 (1,985) Teil 56) 7.600 (725) 1.740 (8855) 1.90 (8.97) Nore ‘When nyo he folowing optional parts re instaled, add ne weight othe curb weight or unladen as. power tering not equppes, rst he wight fom Wouhtat] Pow] Power] ABS hz] Sonveol] Powor | SASAibag] SRS Arbo coptensipans | window | doorack centring sting | “owes” | Stover senger Font wey) 1) o@ | wen | wa) san] ea | san] oc stolen) Rear voy) 20 7@ | sn) | aca] ca) tea | te oy (een Tear kee) | 8a va | 194 | wen | wen | 70a | ea | ecm) Brean {incase thatthe ABS installed on 13in-nheel equipped vehicles, the wheels must be exchanged for 14. ones. To obtain the curb weight ofthe vehicle, theretore, the values shown in [ ‘must be added "GENERAL INFORMATION 1-3 Page 1, General Precautions 2. Precaution for Supplemental Restraint System (Airbag) 3. Vehicle Identification Numbers (V.I.N.) 2 4, Identification Number and Label Locations 6 5. Recommended Fuel, Lubricants, Sealants and Adhesives 8 6. Tightening Torque of Standard Bolts and Nuts 7. Lifting, Towing and Tie-down Points 1"1-3. [03A1] GENERAL INFORMATION 3. Vehicle Identification Numbers (V.LN) 3. Vehicle Identification Numbers (V.I.N) A. APPLICABLE V.I.N. IN THIS MANUAL 1. LEFT-HAND DRIVE VEHICLE out] J] F]1]6]C]5]6[t]0]e]6]0]0] 210] 0] 1 [andater eee Ce ewt_|vlF]1elcls[eltlolelelolol2|olo|1 |andater reooce |% _[aar___[u [Fs fofe]s}ejelole|Klolo|2|olo| 1 |andater enone | [owt [stelsfalclslslelolelslolole|olo|+|ansater aat___[slFla[ole|s|e|tlole|K}olo|2|olo|1 | andater ao awox [suru F[1[afcl«|e(elolela[olo|2|o lo] 1 |andater Sedan awoar [sur [i [F[s[alc]«|eltlolelalolol2|olo|1 |andater ewt__|J[F[+[Glc[s|8|tlole|s|olo|2|olo|1 | andater teo0ce | _faar [uff [soles [e]cfole|Klolo|2olo| 1 landater orang Joa ME [felt felcle [elt lolela}olo2o]o| 1 |andaner aat__ulF[vfolele [ele lole[H|olo|2|oo| 1 |andater Povoce | awo donc |AWO,, Jar ule |i jefcle|e|tjo|sja)olo}2}olo| 1 | andater engine wr _falFlvfolrls[alelolelelolol2|olo| 1 |andater [ar —Tatr[sfolr [set fole[Kolo|2[olo] landater reooce [g [ewt__[v lr [a [elelslelelolelslolol2lolo|s |ansater engine aat___[a[F[+[o[r]s [elt lolelx{olo]2|oo| 1 [endater ‘awowx [ewron |J[F[1/6/F]«|8[tlole|s|olo|2|olo|t |andater ‘awo Gt [swror [oF [+ [el[rl«{e[elole|s{olo]2|o|o| 1 [andater S-Door er _[s[F [solr [s {elt jole/elolo|2{ojo|1 landaner reooce [St __[aar Tule [s ole [s[e[elole|«lolo|2|olo|t |andater crane | og, iTon [STF[alelelelelelole|s[olol2|olo| + |andater aat__|a fF {solr [e[e[elole/Hn[olol2{olo] landaner zo0oce | awo cone’ [Meo jut fale ls iolele|s|tjojefs)ojo|z| ojo} 1 jantate DR: Dualrange 2. RIGHT-HAND DRIVE VEHICLE swt] ]F[+]@]e]s[8[R]o]e]®]0]o]2]0]0] 1 [anak far ToT rf Tefelstatalole|K}olo|2 oo] |andater reooe [a [eut_[slr[sfelclalelalolelelolol2 ool |andater engine aat__[s|F[rfalc]s[a[alole|K]olo]2|o[o]1 |andater a awoix [euT_|s[F[1/@/c]4|B[Rlole|G|o|o|2|0|0| 1 |andater Sedan ‘awoG.|smt [J |F[1]6]c]«|elrlole|s]o|o|2|o|o| 1 |andator we002 ano or [MT™__[4[F [+ ]e]clelelrlole|alolol2 [ol ols |andater engine aat__|s|F[1]@[cle|e[rlole|Hjo|o|2|oo| 1 |andater 2ococe | awo pone” |AWO, leur fule|s|olclelejmalo|s|clolo/2|olo|: |andater engineGENERAL INFORMATION fosa4] 1-3 3. Vehicle Identification Numbers (V..N) [x eT __]J]F]1|/G|F]3|8|R[0[€[8]0]0]2]0]0]1 |andalter | emt |slF[1telr[s{elrlole|s[olol2{o[o]1 [andater seooee {GL faar [s TF [1 [a] F]3 [8 [Role] Klo enone o[2 [00] 1 [endater mox [sro [y[F|1 ele] «lelalole|slololelololt [andater Door awo au fswron [se [tjelr|4[efAlole|s|olol2|olo|t [andater 72006 [awo ex [eMTOR |v [ela [ee fefs[alole|s[olol2 [ol o|s [ansane ‘engine 4AT JIF1/G/F/6/B/R/O/}E}H/O|0) 2/0) 0) 1 | andater Bone" fAWO. Bone out |ulelilalelefelalolelclofo|2|o|o| + |antater Re | TURBO Dik Duahrange 3, AUSTRALIA 780066 Jy MT [J ]F[1]6[¢]s]8]R]0][8]0]0]2]0]0] 1 | andater engine at [3 [F]1[Glc{s[elR[ole|K[o[0|2[0|0| 1 |andater ox et _[atelrfefetsfelalofelelolole lolol |andaner poor | 1800 ce aat__|3[F[1[G|cls[8|R[ol[e|K[0[0]2[0|0| 1 |andater ~ ore MT Fle and ater Sedat wo ox [ST Glelelelalole|c|olol2 [oot |andan at [sf [2lelcle|eirlole|H|olol2{olo|t |andater 3000 [ayo Bone sur fulelz|alcle|slalo|slalolol2|o|o| 1 | andaner Bowe | wx ox tale ly felelsletalotelelolol2[o lols [adater oe wt[alr[t[e[r[sfelalole|elolo[2|o[o|1 |andater ne MT o[0[2 [0 [0 [1 |andater soon |" tawoax |! vlFlelelrfelstrtole|elolo aat__[ JF l2[a|Fle[elrlole|Hlolo|2|olol1| 20000 |awo Bone or [ulel2|ale|elelalolslalolol2/o|o|s | andaker Bowe x 4. G.C.C. COUNTRIES x ‘SMT JIFI1[G]C]3]8[t [ole [8] 0[0[2]0[0] 4 [andater gBer |so0oce | Jew tr[rfalelelefefofels/ofole lolol |andarer wat [alr [rfeltelatelelolelejolole [oo] + |andater Toe |g fee atettelefstetetolelslolol2]olol [andere ergne andafer doo {22 ats [F [alr [a felelolelelofol2 [oo] t |andan tecnee [awo ot. [sir Jale[sfelrfelefu]ofelelofo]2folo| + |antater1-3. [0361] 3. Vehicle Identification Numbers (V. ,GENERAL INFORMATION B. THE MEANING OF V.I.N. 4. LEFT-HAND DRIVE VEHICLE JYFIGC5BLOEBOO2001[ 7 —_— + stop: mark (engine 3 rors marntactrer itettior Vehicle descriptor section Vehicle indicator section Stop-mark ‘Sequential number ‘Transmission 8B: SMT G: Fulltime AWD SMT, Singlerange Fulltime AWD 4A Fulltime AWD SMT, Dual-range 4A sz Engine fuel supply system E: Mult-point fuel injection B: TURBO Dummy Steering whee! position Lett ‘Annual minor modification code ‘Changes to A, 8... annually (94 MY: B) 1 type and series 1800 ce Engine 1600 oc Engine AWD 5: 1800 oo Engine 1800 ce Engine AWD £2000 ce Engine AWD Body type 1G: 4-door Sedan F: S-door Carine ‘G: SUBARU G line Type ofthe vehicle 1: Passenger vehicle : Full Hevy Industries Lid. and, SUBARU I: Asia, JapanGENERAL INFORMATION fo3B2] 1-3 3. Vehicle Identification Numbers (V.I.N) 2. RIGHT-HAND DRIVE VEHICLE lJ Ea Stop- mark FIGC5BROEBOO2001[ === World manufacturer identiior Vehicle descriptor section Vehicle indicator section & stop-mark Sequential number ‘Transmission B: SMT G: Ful time AWD SMT, Single-ange H: Fullime AWD 4AT 4: Fulltime AWD SMT, Dual-range kc 4aT Engine fuel supply system : Mult-point fuel injection B: TURBO Dummy ‘Steering whee! position Rr Right ‘Annual minor modification code Changes to A,B... annually (94MY: 8) Engine type and serios, ‘2: 1600 eo Engine 4: 1600 cc Engine AWD 5: 1800 co Engine 6: 1800 cc Engine AWD ‘8 2000 cc Engine AWD Body type G: 4-door Sedan F: 5-door Carine ‘G: SUBARU G line Type of the vehicle Except Ausiala 1: Passenger vehicle Australia 4: Passenger vehicle (FWD) 2: Passenger vehicle (AWD) F: Fuji Hevy Industries Lid. and ‘SUBARU J: Asia, Japan4-3 [0400] GENERAL INFORMATION 4, Identification Number and Label Locations 4.|dentification Number and Label Locations Engine, transmission and vehicle identification numbers are used for factory communica- tions such as Technical Information, Service Bulletins and other information. Venice dentiicaton Emission conto! abe omer Teo abel ID plate (Europe model) ihosse Tre\abelEmigsion contol abet 10 ‘Sentieation rombor Most ‘umber plate “Tie iriaton pressure labo ‘uit date plate (ef side) (Australia mosel) 10 pate Europe mode ‘ADR compliance pate (Australia mode!) cess,GENERAL INFORMATION [0400] 1-3 4, Identification Number and Label Locations Engine sei number gy1-3 (0501) 5. Recommended Fuel, Lubricants, Sealants and Adhesives GENERAL INFORMATION 5.Recommended Fuel, cants, Sealants and Adhe: 4. FUEL 1) With catalytic convertor # Non-turbo model The engine is designed to provide satistac- tory performance while producing low ex- aust emissions by using unleaded gaso- line with an octane rating 90 or above (the octane rating selected by the Research Me- thos) Lubri- 2) # Turbo model The engine is designed to provide satisfac- tory performance while producing low ex- haust emissions by using unleaded gaso- line with an octane rating 95 or above (the octane rating selected by the Research Me- thos) Without catalytic convertor The engine is designed to provide satisfac- tory performance while producing low ex- haust emissions by using gasoline with an octane rating 90 or above (the octane rating selected by the Research Methos) Lubrieants Specifications Remarks © ILSAC Certified ‘© Engine oi ‘© API Classification: SH or SG. ‘© COMC Specification: G4 or G5 For SAE viscosity number, refer to the following table, «© Ifitis impossible to get SH or SG ‘grade, you may use SF grade. “Tranemission and diferential gear oll ‘© AWD rear diferential gear oll, ‘© API Classification: GLS '® For SAE viscosity number, refer to the following table. © Automatic transmission fluid mmission fuid ‘© “DEXRON IF type auotmatic trans- ‘© Power steering fuid ‘© "DEXRON IF" or DEXRON IE" type automatic transmission fluid © Coolant '* Genuine SUBARU Coolant (Part No. (000016218) (Antifreeze, ant-corro- sive ethylene glycol base) ‘© For further coolant specifications, refer to the following table. © Brake tid ‘© DOTS or DOTS ‘© FMVSS NO. 116 © Avoid mixing brake fui of diferent ‘brands to prevent the fluid performance from degrading. ‘© When brake fluid is added, be careful not to allow any dust into the reservoir. © Clutch fuid © DOTS or DOTS ‘* FMVSS NO. 116 1 Avoid mixing clutch fuid of different ‘brands to prevent the fluid performance: trom degrading. ‘© When clutch Midis added, be caretul not to allow any dust into the reservoirGENERAL INFORMATION 5. Recommended Fuel, Lubricants, Sealants and Adhesives fo501] 1-3 Ta Tacormanded Tepaton Calon SUBARU ore + Sony tire [SUBARU CRC — Siasing al baing Bor snc ilortanclvaratason - Sar sinojton Tolan gave ez (PIN 003608001) Gere! _ Tigo Ax? in bot oss ake and TPA atasoc00 or 25t01040) | cian = ‘Molykote No. 7439 (PIN 725191460) ‘Contacting surfaces of drum brake shoes and shoe clear- ance adjuster ‘BJ and DO (or except Font (on 728225010) axle of AT vehicle) joints of _ aoe axle shafts wu-sar0e (PIN 2sz25GA050) | DOU ot Font axe of AT vex = wrezzie (PIN 280834020) UFJ joints of axe shafts — FX clutch grease ‘Splines of transmission main _ {IN 000040903), Ea Control cables and carburetor 20M linkages subject to col weath- (envoossosoee) wer pump impel, door - sich, striker, battery terminals, et vem Engine ot ‘Tranamigsion ear a “AWD rear ous - 5 = ‘aerial gear = on 0 Front tern = rdamate as = 5 ow. ‘ranomason | eow.e0| | | | T Succ)1-3 [0502] GENERAL INFORMATION 5, Recommended Fuel, Lubricants, Sealants and Adhesives CAUTION: ‘* Each oll manufacturer has its base oil and additives. Thus, do not mix two or more brands (Except engine oil). 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 classification and SAE viscosity No. desig- nated by SUBARU. © SAE 5W-30 is not recommended for sustained high speed driving. NOTE: If vehicle is used in desert areas with very high temperatures or for other heavy duty applications, the following viscosity oils may be used: 30, 40, 10W-50, 20W-40, 20W-50 Coolant Specifications Lowest antici | SUBARU ‘Specification gravity pated atmo- | coolant-to- Freezing Spherie tem- | ‘water ratio | at 10°C at 20°C at 30°C at 40°C. at 50°C pont perature | (Volume) % | (50°F) (68°F) (@6°F) (104°) (22°F) ‘Above -30°C rd eee | s0—50 1.084 1.080 1.074 1.088 1.062 an ‘Above 15°C 45°C wa 30—70 1.050 1.047 1.042 1.037 1.032 Ger) * is recommended that distiled water be used. CAUTION: * Avoid using any coolant or only water other than this designated type to prevent corro- sion. ¢ SUBARU’s engine is aluminum alloy, and so speci care Is necessary. 2. SEALANTS. = Recommended ‘ation Eaaivalent Thro Bond 08 ear darrian pg, bearha cap FN, oon Gomng's no (P/N 004403010) etc. er ens Thro Bord 15 Watching suas of al pup, rananison caso, ; (PIN 004409007) etc, Flywheel and drive plate tightening bolts, etc. | CW Coming’s No. 7238 Scaling BSA ean aaina water and dust ey trough ps Sean bmi (P/N 000018901) weatherstrips, grommets, etc. Cee ae one Tirge Bod 7276 acing surtaceof ol pa, ress ch - Three Bod 02 ‘Soong gear box agut sow — 3. ADHESIVES ‘Weatherstrips and other rubber parts, plastics and textiles excopt soft vinyl parts. ‘Soft vinyl parts, and other parts subject to gasoiine, Comedie 540 ‘grease oF ol, e.g. rim leather, gear shift boot, door Adhesive inner remote cover, etc = Bonding metals, glass, plastic and rubber pats. ee) Repairing slightly tom weatherstrips, etc. ‘Cemedine 54301 ‘M's EC-1770 EC-1968 ‘M's EC-776 EC-847 EC-1022 (Spray Typa) ‘Armstrong's Eastman 910 Essex Chemical OOPS | wings body panel Sunstar 560 10GENERAL INFORMATION fo701]_ 1-3 7. Lifting, Towing and Tie-down Points 7. Lifting, Towing and Tie-down Points WARNING: © Never get under the vehicle while it is supported by a jack. ¢ When jacking up the vehicle, place chocks to hold wheels. After jacking up the vehicle with garage jack, be sure to support the vehicle with stands for safety. © Be sure to lift vehicle at the same four positions as those for pantograph jack. CAUTION: Be sure to lift, tow and tie-down the vehicle at the designated positions. 1. GARAGE JACK1-3 GENERAL INFORMATION (0702 7. Lifting, Towing and Tie-down Points 2. PANTOGRAPH JACK, SAFETY STAND AND LIFT GtH0909GENERAL INFORMATION z WARNING: [0703] 1-3 * Never get under the vehicle while itis supported only by the jack. Always use safety stands to support body when you have to get under the car. * Block the wheels diagonally by wheel chocks. CAUTION: ‘* Make sure the jack is set at the correct position on the flange of side sill. * Be careful not to set the jack at the air flap portion. 3. TOWING AND TIE-DOWN HOOKS, Rear CAUTION: * Avoid towing another car with front towing hooks. * Do not tow a vehicle which is heavier than towing vehicle. * Do not apply excessive lateral load to tow- ing hook. ‘© Wrap the towing rope with cloth to prevent damaging bumper, etc. * Keep the vehicle level during towing. © Tie the front and rear tie-down hooks in the same direction. 13PRE-DELIVERY INSPECTION 1-4 Page 1. List of Pre-delivery Inspection 2 2. Pre-road Test Inspection 4 HOOD OPERATION 4 DOOR OPERATION, DOOR LOCK AND REGULATOR ‘TRUNK LID, REAR GATE AND FUEL LID OPERATION BRAKE FLUID LEVEL AND BRAKE PIPING INSTALLATION 4 BATTERY FLUID LEVEL AND BATTERY INSTALLATION COOLANT LEVEL AND COOLING FAN INSTALLATION ; ENGINE OIL LEVEL 5 TRANSMISSION AND DIFFERENTIAL GEAR OIL LEVEL... 6 AIR CLEANER JACK INSTALLATION WASHER AND WIPERS |: WHEEL NUTS FOR LOOSENESS AND TIRE INFLATION PRESSURE 8 ‘SEAT ADJUSTER AND SEAT BELTS FUSES LIGHTS AND SWITCHES PREPARATION FOR UNDERSIDE INSPECTION ... READ MEMORY AND TEST MODE CONNECTORS INSTALLATION OF STEERING COMPONENTS. EXHAUST PIPE AND MUFFLER FUEL SYSTEM FOR LEAKAGE PROTECTOR : CLUTCH FLUID LEVEL (TURBO MODEL) 3. Road Test Inspection ‘A: OPERATION OF INDICATOR LIGHTS AND GAUGES B: TACHOMETER, RADIO, ETC. C: STARTING CONDITION OF ENGINE D: DRIVING TEST 9 4, Post-road Test inspection 13 AUTOMATIC TRANSMISSION FLUID (ATF) LEVEL POWER STEERING FLUID LEVEL 13 WHEEL ALIGNMENT UNDERSIDE WATER LEAKAGE EXTERNAL APPEARANCE AND EQUIPMENT SSCHOR OVOZ ENASTONMOODE coo ™MOOD>1-4 [0100] 1. List of Pre-dolivery Inspection 1. List of Pre-delivery Inspection PRE-DELIVERY INSPECTION INSPECTION TEM CHECK POINTS 2. Pre-road Test inspection ‘A [HOOD OPERATION 1 Operation of hood release and lock 2. Condition of lock 3. Fitting of hood 'B | DOOR OPERATION, DOOR LOCK AND REGULATOR 1. Door “Open-closs" operation 2! Operation of door release and lock 8. Loose or damaged parts 4. Regulator handle operation 5. Postion of door window glass 6. Operation of power window switches 7. Power door locking operation REAR GATE AND FUEL LID OPERATION 1. Trunk lid, rear gate and fuel ld “open-ciose” operation 2! Operation of trunk lid and rear gate (release and lock) 8 Fiftng of trunk lie, rear gate and fuel id 4. Operation of trunk ld, rear gate and fuel id opener cancel lever | BRAKE FLUID LEVEL AND BRAKE PIPING INSTALLATION 1. Brake fluid levelin reserve tank 2. Wiring of fui leveller and its operation 83. Brake booster, raster cylinder and pressure contro valve for proper installation; brake pipe, brake hose and ‘connectors for proper fiting 4. Leakage in any ef the above | BATTERY FLUID LEVEL AND BATTERY INSTALLATION |1, External parts 2. Electrolyte level 3. Specific gravity F | COOLANT LEVEL AND COOLING FAN INSTALLATION |, Coolant level 2. Cooling fan moter and witing 3. Water leakage and hose damage G | ENGINE OWL LEVEL 4. Engine ol level 2. Engine oil leakage of contamination 1H | TRANSMISSION AND DIFFERENTIAL GEAR OIL LEVEL 1, Level of transmission gear ol for manual transmission 2. Level of rear iferential gear ol for AWD model 3. Level of diferental gear ol for automatic transmission 1 | DRIVE BELT TENSION 1. Belt tension 2. Damage to belt J [AIR CLEANER: 1, Contamination of air cleaner element 2. Related pans {JAOK INSTALLATION 1: Installed condition of jack L | WASHER AND WIPERS 7. Installation of washer tank 2. Checking of uid level 43. Direction and quantity of washer fluid sprayed 4 Operation of wiper and washer M | WHEEL NUTS FOR LOOSENESS AND TIRE INFLATION PRESSURE 1. Whee! nut tightening torque. 2. Tire inflation pressure and tie specification 3. Damage to tre and rim N | SEAT ADJUSTER AND SEAT BELTS 1. Front and rear seats, and thei facing materials 2. Front seat operation 3, Rear seat folding operation 4, Seat belts and thai ft © | FUSES 1. Fuse installation 2. Spare fuse.PRE-DELIVERY INSPECTION INSPECTION ITEM CHECK POINTS LIGHTS AND SWITCHES 1. Vieual inspection of lights (instalation, damage, dity lenses, water inside, etc) 2. Operation ofall lights and switches Horn operation |- Operation of head light washer and switch 2] PREPARATION FOR UNDERSIDE INSPECTION ‘Jacking up and iting point. Refer to 1-3, READ MEMORY AND TEST MODE CONNECTORS ‘Check engine light flashing Read memory and test mode connectors disconnection INSTALLATION OF STEERING COMPONENTS Installation of universal joints Steering gear box for looseness, play, or backlash, and boots for damage 3. Tie-od and tie-Fod end for proper installation, or damage EXHAUST PIPE AND MUFFLER, Installation of exhaust system Exnaust gas leakage from parts or joints © FUEL SYSTEM FOR LEAKAGE | Inetallation of fuel hose and pipe. And condition of ‘lamps Ful system for leakage PROTECTOR 1. Protector removal ‘CLUTCH FLUID LEVEL (TURBO MODEL) 1. Clutch fui level oad Test Inspection Vv w 3. a ‘OPERATION OF INDICATOR LIGHTS AND GAUGES: ‘Operation of indicator lights | 2: Operation of gauges 8 ‘TACHOMETER, RADIO, ETC. ‘Operation of tachometer, radio, cigarette ighter, ete. c ‘STARTING CONDITION OF ENGINE Staring condition of engine D DRIVING TEST ‘Operation of foot brake and parking brake lespect the clutch free play (Operation of speedometer (Turbo model for Europe and Australia) (Operation of clutch and gear shit (Operation of selector lever (Automatic transmission) (Operation of steering and postion of steering whee! (peration of tum signal cancel cam (Gperation of ventilation system and heater ‘Abnormal noises or vibration 10, Operation of drive select lever (AWD mode! only) 41. Operation of air conditioning 12. Operation of cruise contr Post-road Test Inspection ‘AUTOMATIC TRANSMISSION FLUID LEVEL 1. Level of automatic transmission fig POWER STEERING FLUID LEVEL 1 Level of power steering fig a A 5 c WHEEL ALIGNMENT 7. Toe of front and rear wheels 2. Camber of front wheels D UNDERSIDE 1. Leakage of engine ol, transmission gear oi, differential ‘gear ol, et. 2. Leakage of coolant 8. Leakage of brake fluid 4, Looee suspension mountings or steering mounting WATER LEAKAGE 1. Water leakage by pouring water EXTERNAL APPEARANCE AND EQUIPMENT 1. Paint 2. Seratches and damage to glass 43, Rust formation 4. Contamination of interior parts 5. Inetalation of equipment1-4 [ozA0) 2. Pre-road Test Inspection PRE-DELIVERY INSPECTION 2. Pre-road Test Inspection A: HOOD OPERATION CHECK POINTS 1. Operation of hood release and lock 2. Condition of lock 3. Fitting of hood © Check the opening, closing and locking of hood. 1) Pull the hood lock release knob in the pas- senger compartment. (The hood will it a step.) Check if the cable moves easily and lightly with- out dragging. 3) Remove the stay and lower the hood until it approaches about 10 om (3.9 in.) from the closed position and let it drop. After closing the hood, be sure the hood is securely locked. 4) Confirm by repeating the steps 1) to 3) above two or three times. © Check the installation of hood. ‘After having closed the hood, ensure the hood fits properly. NOTE: The clearance between the hood and front fender is uniform. @ The hood's front end is parallel with the front fender. © The slope of hood is the same as the parts of body surrounding it, «he hood and weatherstrip stick fast o each other. 2) _ Release the lock by pushing the lock lever while pushing the hood down with slight pres- sure. Hold the hood open with the stay. Check the way the safety lock mechanism is re- leased and that the hood opens and closes without any abnormal noise and does not con- tact the body. e1Hoaes D: BRAKE FLUID LEVEL AND BRAKE PIPING INSTALLATION CHECK POINTS 1. Fluid level in brake reserve tank 2.Wiring of fluid leveller and its operation 3. Brake booster, master cylinder and pressure control valve for proper installation; brake pipe, brake hose and connectors for proper fitting 4. Leakage in any of the above © Check fluid leveller operation while push- ing it down with a screwdriver. aPRE-DELIVERY INSPECTION (0201) 1-4 Pre-road Test Inspecion Recommended brake fluid FMVSS No. 116, fresh DOT3 or DOT4 brake fluid CAUTION: © The fluid level must be kept at “MAX” level. * Do not mix different brands of brake fluid. * When adding brake fluid, be careful not to, allow any dirt, water, or oil around the fluid tank to enter it. * Use special care notto spill any brake fluid on the vehicle's painted surfaces, because it will quickly erode them. In case of an acci- dent, wipe it off as quickly and as cleanly a: possible. NOTE «Never use engine ol, gear ol, or any mineral ol ¢ Use extreme care not to allow any water to get into the fluid; water in the brake fluid will lower the fluid’s boiling point and cause vapor-lock ¢ If too much brake fluid is missing, check the brake line for possible leakage. © After adding brake fluid, any excess must be stored in a tightly sealed container. © When checking the operation of leveller, use clean screwdriver or the like and be careful not to allow dirt or dust to get into the tank. 1) Check that the brake pipes, hoses and connectors are in good condition. (1). Brake fluid is not oozing or leaking from the brake fluid lines. (2) The connectors and clamps are not loose. (3). There is no possibilty of the pipes and hoses contacting the body or other mechan- ical parts due to vibration during running. G: ENGINE OIL LEVEL CHECK POINTS 1. Engine oil level 2. Engine oil leakage or contamination 1. Check the engine oil level The level should be within the specified range marked on the gauge. NOTE: © Check engine oil level before starting the en- gine, when engine oil is cold, to obtain correct level reading, After stopping a hot engine, wait about § minutes until oil returns to oll pan before checking oil level. Oil evel reading will be slight- ly higher than when engine is cold due to oil ex- pansion, tt is advisable to check oil level each time oil is replenished. ¢ Insert the oil level gauge into guide hole.‘ 1 41-4 (02H 2. Pre-road Test Inspection le|— Vover love ‘About 1.06 (rus a, |} | aime 2] Lowerievel GiH0307 Recommended oi! ‘API classification: SH or SG, CCMC specification G4 or G5, or ILSAC certification mark is displayed on the container (f it is impossible to get SH or SG grade, you may use SF grade.) ‘SAE Vscosiy No, and Applicable Temperature PRE-DELIVERY INSPECTION 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 classification and SAE viscosity No. designated by SUBARU. © SAE 5W-30 is not recommended for sus- tained high speed driving. H: TRANSMISSION AND DIFFEREN- TIAL GEAR OIL LEVEL CHECK POINTS 1.Level of transmission gear oil for manual transmission 2. Level of rear differential gear oil for AWD model 3. Level of differential gear oil for auto- matic transmission omt027 0 2 2 a 1. Check the level of transmission gear oil u oe for manual transmission NOTE: The level should be within the specified range marked on the gauge. 10990, 10W40 ona larHoaea —|— Lower tovet c1H0396PRE-DELIVERY INSPECTION © Recommended oil fo2H3] 1-4 2. Pre-road Test Inspection © Recommended oil Trew TEM “Transmision gear ol Fer ater gear [APT Casateaton APT Gasstcaton us cis SAE Vscooly No. and Appicable Tempera a a or en er Lt i a ow I 73050 I I a TET CAUTION: CAUTION: When inserting the level gauge into trans- mission gear, align the protrusion on the side of the top partof the level gauge with the notch in the gauge hole. 2. Check the level of rear differential gear oil for AWD model The ol level must be kept above the bottom of the filer bolt or plug. If below that level, add oil up to the bottom line, arHos99 Each manufacturer uses different base oils and additives. Thus, do not mix brands. 3. Check the level of front differential gear oil for automatic transmission NOTE: The level should be within the specified range marked on the gauge. © Recommended oil Drain pug arHo401 Tew ‘¢ Front diferent gear il “APT Cassieaion Gus ‘SAE Vssosiy No. and Appizable Temperature C0 _o 2 Oo co) m8 eB = ‘ow.90 [einai1-4 [o2mo 2. Pre-road Test Inspection PRE-DELIVERY INSPECTION CAUTION: When inserting the level gauge into differen- tial gear, align the protrusion on the side of the top part of the level gauge with the notch in the gauge hole. M:WHEEL NUTS FOR LOOSENESS AND TIRE INFLATION PRESSURE CHECK POINTS 1. Whee! nut tightening torque 2.Tire inflation pressure and tire specification 3, Damage to tire and rim Tightening torque: 88 + 10N.m (9+ 1 kg-m, 65 + 7 ft-lb) NOTE: © When checking the wheel nuts, be sure touse torque wrench, and tighten the nutsto the spe- cified torque. After inspecting and adjusting the tire pres- sure, be sure to put the valve cap back CAUTION: Check that all tires are adjusted to the speci- fied tire inflation pressure. V: PROTECTOR CHECK POINTS 1.Protector removal The following parts are covered to prevent splashing of wax. Remove protector. NOTE, Label of rear differential is covered by tape. Re- move it. 'Non-Turbo model @ “Te inflation pressure ory kPa (kglem?: psi), Front Rear 165/013 83H 220(2.2,31) | 200(20,29) PI7S/70R14 84H 220(2.2,31) | 200(20,29) PROS/SSAIS 87V 226 (2.3, 93) | 220 (22,81) T type tire 410 (42,58)—— PRE-DELIVERY INSPECTION W:CLUTCH FLUID LEVEL (TURBO MODEL) CHECK POINTS 1. Clutch fluid level Check the fluid level using the scale on the out- side of the clutch master cylinder tank. Ifthe lev- el is below “MIN", add clutch fluid to bring it up to "MAX" Recommended cluth fluid: FMVSS No. 116, fresh DOT 3 or DOT 4 brake fluid CAUTION: © Avoid mixing different brands of brake fluid to prevent degradation of the fluid. Be careful not to allow dirt or dust to get into the reservoir tank. © Use fresh DOT 3 or DOT 4 brake fluid when refilling fluid. [0301] 1-4 3. Road Test Inspection 3. Road Test Inspection D: DRIVING TEST CHECK POINTS 1. Operation of foot brake and parking brake 2.Inspect the clutch pedal free play 3.Operation of speedometer (Turbo model for Europe and Australia) 4, Operation of clutch and gear shift 5. Operation of select lever (Automatic transmission) 6. Operation of steering and position of steering wheel 7. Operation of turn signal cancel cam 8. Operation of ventilation system and heater 9, Abnormal noises or vibration 10. Operation of drive select lever (AWD model only) 11, Operation of air conditioner 12. Operation of cruise control 1. Check the foot and parking brakes’ op- eration 1) Driveonadry, level, paved road, and apply normal braking. Look for uneven or improper ‘operation, or pulling to one side. CAUTION: Be sure to perform this test in a safe area. 2) _ Press the brake pedal in two or three times, and keep it fully depressed. Make sure that the brake can be kept that way for at least five se- conds. Also check for air in the brake system, or brake fluid leakage. 3) Perform the adjustment of operating rod assembly as follows: (1) Be sure engine is off. (No vacuum is ap- lied to brake booster). (2) There should be play between brake booster clevis and pin at brake pedal instal- ling portion. [Depress brake pedal pad with a force of ess than 10 N (1 kg, 2 Ib) toa stroke of 1 to 3mm (0.04 to 0.12 in) }1-4 = [0302] 3. Road Test Inspection PRE-DELIVERY INSPECTION (3) Depress the surface of brake pad by hand. (4) If there is no free play between clevis pin and clevis, loosen lock nut for operating Tod and adjust operating rod by turning in the direction that itis shortened. (8) After adjustment, make sure there is no brake dragging 4) Pull the parking brake lever completely out, and check its operation. Also check the ratchet for normal functioning Check the parking brake lever stroke. If itis out of specification, adjust it by turning adjusting nut at parking brake lever. Parking brake lever stroke: ‘Standard: 7 —8 notches/196 N (20 kg, 44 Ib) 2. Inspect the clutch pedal free play 1) Mechanical application type (1). Lightly press the clutch pedal down with a finger to check the free play. Freeplay "0-20 (0390.79) G1H0407 ‘Unit: mm (in) 20 (3.15) (2) If itis out of specification, adjust it by turning adjusting nut on engine side end of clutch cable at release fork Ful sok: 255mm (tin) tt Lock mut ‘Adjusting nut ~~ Release eHo057 10PRE-DELIVERY INSPECTION {o3D5] 1-4 3. Road Test Inspection Tightening torque: 4.5—7.5 Nm (0.45 — 0.75 kg-m, 3.5 — 5.5 ft-lb) Hydraulic application type (1). Lightly press the clutch pedal down with a finger to check the free play. (2) Ifit is out of specification, loosen lock nut for push rod and adjust push rod by turn- ing in the direction that shortens or length- ens it. Uni: me in) lock nat £20 (2.15) end more Reserve ditance 445 (571) (RH) 150 (591) (LH) 1H04se Standard free play: 5 — 15mm (0.20 — 0.59 in.) Tightening torque (Adjusting lock nut): 9—11Nm (0.9 — 1.1 kg-m, 6.5 — 8.0 ft-lb) 3. Operation of s; (Turbo model for Europe and Australia) 1) Drive the car at various speeds, and make sure that the pointer of speedometer indicates the position of each speed correctly. lometer "1 4. Check the operation of clutch and gear shifting 1) With the engine idling and the shift lever in neu‘ral, gradually depress the clutch pedal, to see if it generates any abnormal noise. NOTE: Carefully compare a normal clutch’s operating ‘sounds to the clutch being tested. 2) _Pullthe parking brake lever completely out, and place wheel chocks under the tires. Then depress the clutch pedal completely, and place the shift lever in 5th speed. Raise engine rpm alittle, gradually engage the clutch, and see if the engine stalls. Ifthe engine stalls, it means that the clutch is not slipping, CAUTION: © Be sure to perform this test in a safe area. © Do not repeat this test. 3)_ Remove the wheel chocks, and return the shift lever to neutral, then check the gear shift- ing mechanism for excessive play. 4) Drive the car at various speeds. While de- pressing the clutch pedal completely, move the gear shift lever into each position, and check for any unusual play or unusual resistance. 5. Operation of selector lever (Automatic transmission models) 1) Place the selector lever in each position, and make sure that the pointer indicates the position of each range correctly. not t ‘Depress the broke pedal ‘and push the bufon when shin soect ove. Push the bution when ‘shifting select lever. Select over canbe sited wihout pushing ‘he buton Es g at D 3 2 a G1Ho0se1-4 [o3D6] 3. Road Test Inspection PRE-DELIVERY INSPECTION 6. Operation of steering and position of steering wheel 1) Check the steering wheel for free play. Steering wheel free play: ‘0 — 17 mm (0 — 0.67 in) - artost2 2) With the car moving straight ahead, check for hard steering, shimmy, or other abnormali- ties. 3) Make a turn, and check for hard or heavy steering wheel operation, or poor stability 7. Operation of turn signal cancel cam Make a right or left turn with the tur signal on, and make sure that the turn signal switch re- turns automatically to the OFF position when the steering wheel is returned to the straight ahead position, 8. Operation of ventilation system and heat- er 1) While driving, move the control lever and dial into each position, and check the ventilation system's operation. Also check for unusual vibration or noises. 2) Move the temperature control lever and fan switch, and make sure’ that warm air is dis- charged into the compartment. 9. Abnormal noises or vibration 1) Whenstarting the engine, and while driving the vehicle, check the engine, transmission, body, suspension, and steering system for any unusual noises or vibration. Do this when idling the engine, accelerating, decelerating, and running at low, middle and high speeds, 2) Depress the accelerator pedal, and make i s sure that the engine rpm increase smoothly and that the vehicle accelerates smoothly. 3) While driving, turn the steering wheel right and left to test the vehicle's stability and re- sponse. CAUTION: Be sure to perform this test in a safe area. 10.Operation of AWD drive selector lever (AWD dual-range models) While driving, check the operation of the AWD drive select. Also check that indicator light on instrument panel comes on CAUTION: Never shift the drive select while the wheels are spinning or slipping. 11. Operation of air conditioning ‘Turn the air conditioning switch "ON", and make sure that cool air is discharged into the compartment. 12. Operation of cruise control Check the operation of the cruise control ac- cording to “Owner's manual” CAUTION: Be sure to conduct driving tests using a chassis dynamometer with front wheels set in operation, or tests on an authorized race course or similar place.TT PRE-DELIVERY INSPECTION [o4Bo) 1-4 4. Post-road Test Inspection B: POWER STEERING FLUID LEVEL CHECK POINTS 1. Level of power steering fluid The power steering fluid shoud be maintained at a proper level. Check level as follows: 1)__ Drive the car several miles or kilometers to bring power steering system up to the normal operating temperature of about 60°C (140°F). 2) Park the car ona level surface and stop the engine. 3) Remove the level gauge and wipe it clean. 4) Reinstall the level gauge firmly. 5) Remove it again and read the level on the "HOT" side. If the fluid level is at the lower level or below it, add recommended power steering fluid up to the high level. When the fluid level is to be checked without warming up the power steer- ing system [at approximately 21°C (70°F)], read the fiuid level at the “COLD” position of the level gauge. CAUTION: The available power steering fluid is ATF DEXRON Il or Il E. Be sure to use the recommended fluid. When power steering fluid is added, be care- ful not to allow any dust into the tank. Post-road Test Inspection9 PERIODIC MAINTENANCE SERVICES 1 5 Page SCHEDULE OF INSPECTION AND MAINTENANCE SERVICES ......._ 2 1. Drive Belt(s) [Except Camshaft] (Inspect drive belt tension) 2. Camshaft Drive Belt (Timing Belt) 4 3. Engine Oil 6 4. Engine Oil Filter 5. Replace Engine Coolant and Inspect Cooling System, Hoses and Connections 9 6. Replace Fuel Filter and Inspect Fuel System, . Lines and Connections 7. Air Cleaner Element 8. Spark Plugs 13 9. Idle Mixture [Except for Catalyst Model] 10. Transmission/Differential (Front and rear) Lubricants (Gear oil) 15 11, Automatic Transmission Fiuid 12. Brake Fluid 13.Disc Brake Pads and Discs/Front and Rear Axle Boots and Axle Shaft Joint Portions 18 14.Brake Linings and Drums 15. Inspect Brake Lines and Check Operation of Parking and Service Brake System 16.Clutch Operation System 19 > 17.Steering and Suspension System at 18.Front and Rear Wheel Bearing Lubricant1-5 (0000) PERIODIC MAINTENANCE SERVICES SCHEDULE OF INSPECTION AND MAINTENANCE SERVICES Cann erode maintenance beyond 1090004 | | mag Symbols used {60,000 mies) or & mont by returng the tat lace Colum of the maintnance actecule and accing | | — Mepect and then acust, corrector replace necessary 00.0004 (60000 mies)r 48 monfhetotnecae | | P-Peverm tr oad (1): Recommended sence for ste vice operation - | WMAINTENANGE INTERVAL (suber of mons oF km (les) chever our fs) wanrenance rem [Monte L_| 2] = | 6 | «| — pewanks 7,000 am te | 25 | #0 | 7 | 100 x4,000miles | 1 15 | 30 | 45 | 60 [Dive belts) Exces camshat T 7 2 | Camshat ve be Timing bet f ‘Ghange every 18500 kn (7.500 mies) or 2 [Emine ot _| Sarpe.rgy aston © to lls) | seg nore 1) wer ‘ange ever 12,500 km (7,500 mies) o 4 [Ene ot te mere 1200 Kn (500m) = |e NOTE ) = | Replace engine coolant and inspec cooing sytem, > > Feses and Somecions 7 | | Replace fue iter and inspect fue ayte, ead . | « | exe ue ° ey|asrors 7 [Air cleaner elmer es Except Sweden ata tA] R «| Sparkpugs For Sweden | Change avery 30,000 kn (8.500 mie) | For Turbo R 5 [ee mitre Except for eatayst mode Dp 1 Transmssion/iferental (Fon & ea) beans ce 10 | Gearei) R | seonoTe 4) 77 [Automate wansmission fd a ®_|SeeNOTE®) 12 | Brake id R | See NOTES) Disc brake pads and dissent and ear 3 | pools and axle shatt joint portions ' ' Ee eee) 7a | Brake tings and crus (Parking Brake) 1 [See NOTE) Inspect bake Ines and check operation of parking [+= | epee ies and p |p |e | e |seonores) ‘jst pedal ree play 16 | cc operation system vf fou fa [attobtien |_| {00 mies |_| | Steerng and suspension system TP _ [see nore 3 | [re | Fron and ear whee bearing kbcant 0——————— PERIODIC MAINTENANCE SERVICES {0000} 1-5 NOTES: 1) When the vehicle is used under severe driving conditions mentioned below’, the engine oil and oil filter should be changed more frequently. 2) When the vehicle is used under severe driving conditions mentioned below’, the air cleaner element should be replaced more frequently. 3) When the vehicle is used under severe driving conditions mentioned below’, inspection should be performed at every 12,500 km (7,500 miles) or 6 months whichever occurs first. 4) When the automatic transmission vehicle is frequently operated under severe condi- tions, such as pulling trailer or driving on sand, replacement of automatic transmission fluid and front differential gear oil should be performed more frequently. 5) When the vehicle is used under following areas, change fluid every 25,000 km (15,000 miles) or 12 months whichever occurs first. (1) High humidity areas (2) Mountainous areas * Severe driving conditions: (1) Operating in extremely cold weather (Items 3, 4 and 17 only) Pulling trailer (Items 3, 4, 13 and 14 only) Repeated short trips (Items 3, 4, 13 and 14 only) Driving in dusty roads (Items 7, 13, 14 and 17 only) Driving in rough and/or muddy roads (Items 13, 14 and 17 only) Driving in areas using road salt or other corrosive materials (Items 6, 13, 14, 15 and 17 only) (7) Living in coastal areas (Items 6, 13, 14, 15 and 17 only) SESES.1-5 (022) PERIODIC MAINTENANCE SERVICES 2. Camshaft Drive Belt (Timing Belt) 2. Camshaft Drive Belt (Timing Belt) MAINTENANCE INTERVAL [Number of months of km (miles) whichever occurs first) Norns 2 [| «6 | «8 moore | as | so | 7 | 100 ool a | is | oo | | @ a ‘A: REPLACEMENT 2. DOHC MODEL 1) Referto 1) to 7) of camshatt drive belt. 2) Remove pulley bolt. To lock crankshaft use ST. ST 499977000 CRANKSHAFT PULLEY WRENCH 3) Remove crankshaft pulley. 4) Remove lett side belt cover. 5) Remove right side belt cover. 6) Remove front belt cover. 7) Ifalignment mark and/or arrow mark (which indicates rotation direction) on timing belt fade away, put new marks before removing timing belt as follows: (1) Turn crankshaft and align alignment marks on crankshaft, and left and right cam- shaft sprockets with notches of belt cover and oylinder block. ‘ST 499987500 CRANKSHAFT SOCKET (2) Using white paint, put alignment and/or arrow marks on timing belts in relation to the sprockets. 8) Loosen tensioner adjuster mounting bolts. 9) Remove belt idler. 10)Remove belt idler No.2. 11) Remove timing belt. Z;, 54.5 tooth length Zp, 51 tooth length , 28 tooth lengthPERIODIC MAINTENANCE SERVICES fo2c2] 1-5 2, Camshaft Drive Belt (Timing Bett) B: INSTALLATION 2. DOHC MODEL To install, reverse order of removal procedures. For installation of tensioner adjuster and cam- shaft drive belt, refer to"2-3b ENGINE” [W2C0] INSPECTION 2. DOHC MODEL 1) Remove left and right timing belt covers © and @. 2) While cranking engine at least four rotations, check timing belt back surface for cracks or damage. Replace faulty timing belt as needed. 3) Measure timing belt width W. Ifitis less than 30 mm (1.18 in), check idlers, tensioner, water pump pulley and cam sprocket to determine idler alignment (squareness). Replace worn timing belt. 4) Install left and right timing belt covers @ and @.1-5 [03A0) PERIODIC MAINTENANCE SERVICES 3. Engine Oil 3. Engine Oil MAINTENANCE INTERVAL [Number of months of km (miles) whichever occurs fist Months w | 2 | 9% | 1,000 [em | ts | 2 | 5 | 75 | 100 1,000 «1.000 | ws | @ | 4 | oo ‘Change every 12,500 km (7,500 miles) or ‘Gmonths. Whichever accurs frst. A: REPLACEMENT 1) Drain engine oll by loosening engine oil drain plug. 2) Open engine oil filler cap for quick draining Of the engine oil Replace drain plug gasket. 3) Tighten engine oil drain plug after draining engine oil Tightening torque: 44 N.m (4.5 kg-m, 33 ft-lb)PERIODIC MAINTENANCE SERVICES TT [oso] 1-5 3. Engine Oil SSAE Viscosity No. and Appicable Temperature oo OO oO. 10920, 10W-40 ‘5.00 lerhoaea ‘omio27 Suge ed), Engin of iter cap Je|—-veverieve! About 1.06 (tus || | eaimeat 3} cower love, rhoae7 4) Fill engine oil through filler pipe up to upper point on level gauge. Make sure that vehicle is placed level when checking oil level. Use en- gine oil of proper quality and viscosity, selected in accordance with the table in figure. Recommended oil API classification: SH or SG, CCMC specifiction G4 or G5, or ILSAC certification mark is displayed on the container (if it is impossible to get SH or SG grade, you may use SF grade.) The proper viscosity helps car get good cold and hot starting by reducing viscous friction and thus increasing cranking speed. 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 classification and SAE viscosity No. designated by SUBARU. © SAE 5W-30 is not recommended for sus- tained high speed driving. 5) Close engine oil filler cap. 6) Start engine and warm it up for a time. 7) Aiter engine stops, recheck the oil level. Ifnecessary, add engine oil up to upper level on level gauge.1-5 (0360) PERIODIC MAINTENANCE SERVICES 3. Engine Oil B: INSPECTION re 1) Park vehicle on a level surface. Sutovei gains oe —_— 2) Remove oil level gauge and wipe it clean "Engin of ar ca 3) Reinsert the level gauge all the way. Be sure j¢|—j Ueverieve! | that the level gauge is correctly inserted and in avoutoc| the proper orientation, {3.488 | 4) Remove it again and note the reading. If the a|_deawee | engine oil lovol is bolow the *L" line, add oil to bring the level up to the “F line. 5) After turning off the engine, wait a few min- utes for the cil fo drain backinto the oil pan be- fore checking the level 6) Just after driving or wile 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 the engine oil 7) To prevent overfilling the engine oil, do not add oll above the *F” line when the engine is cold. Engine oil capacity (Non-Turbo model): Upper level 4.0 € (4.2 US qt, 3.5 Imp qt) Lower level 3.0 € (3.2 US qt, 2.6 Imp qt) Engine oil capacity (Turbo model): Upper level 4.5 € (4.8 US qt, 4.0 Imp qt) Lower level 3.5¢ (3.7 US qt, 3.1 Imp qt)—$——————————— PERIODIC MAINTENANCE SERVICES f05A1] 1-5 5. Replace Engine Coolant and Inspect Cooling System, Hoses and Connections . _ MAINTENANCE INTERVAL 5. Replace Engine Coolant {Number of months of km (miles) whichever occurs fist and Inspect Cooling pastas pM | 3% | 4 System, Hoses and Mam | t8 | 2 | 50 | 75 | 100 Connections oo Ty | as | a | as | oo Pp P A: REPLACEMENT 1. REPLACEMENT OF COOLANT (NON-TURBO MODEL) WARNIN The radiator is of the pressurized type. Do not attempt to open the radiator cap immedi- ately after the engine has been stopped. \ 1) Place a container under drain tube, and loosen drain plug. 2) Loosen radiator cap to drain coolant eit0075 CAUTION: Be careful not to spill coolant on the floor. 3) Drain coolant from reserve tank. 4) Tighten radiator drain plug securely after draining coolant. (Drain tube may face down- ward.) 5) Install reserve tank to original position 6) Slowly pour prepared coolant from radiator d filler port to neck of filler, then pour into reserve tank up to "FULL" level Coolant capacity (fill up to “FULL” level) MT: ‘Approx. 6.3 ¢ (6.7 US qt, 5.5 Imp qt) AT: ‘Approx. 6.2 € (6.6 US qt, 5.5 Imp qt) CAUTION: The SUBARU Genuine Coolant containing anti-freeze and anti jents is especially made for SUBARU engine, which has an alu- minum crankcase. Always use SUBARU Genuine Coolant, since other coolant may cause corrosion.1-5 [05A2} PERIODIC MAINTENANCE SERVICES 5, Replace Engine Coolant and Inspect Cooling System, Hoses and Connections 7) Securely install radiator cap. 8) Run engine for more than five minutes at 2,000 to 3,000 rpm. (Run engine until radiator becomes hot in order to purge air trapped in cooling system.) 9) Stop engine and wait until coolant tempera- ture lowers. Then open radiator cap to check coolant level and add coolant up to radiator filler neck. Next, add coolant into reserve tank up to “FULL" level. 10)After adding coolant, securely install radia- tor and reserve tank caps. 2. REPLACEMENT OF COOLANT (TURBO MODEL) 1) Loosen radiator drain plug after following the same procedures 1) as described for the Non-TURBO model. 2) Loosen coolant flow tank cap to drain cool- ant. 3) Tighten radiator drain plug securely. 4) Slowly pour prepared coolant from coolant flow tank filer port up to the brim of port, and install cap, then pour coolant into reserve tank up to "FULL" level. 5) Run engine for about 15 minutes, not ex- ceeding 2,000 rpm. (Run engine until radiator becomes hot in order to purge air trapped in cooling system.) 6) Stop engine and wait until coolant tempera- ture lowers. [below 50°C (122°F) or 60°C (140°F)] Open coolant flow tank cap and add Coolant up to the brim of the port. 7) Wait until coolant temperature lowers further | [below 30°C (86°F)], then pour into reserve tank up to the “FULL" level. 8) Runthe vehicle untilthe coolant temperature rises to 80°C (176°F) and check the level in the coolant flow tank, add coolant up to the “FULL” level. Coolant capacity (fill up to “FULL” level): Approx. 7.2 € (7.6 US qt, 6.3 Imp qt) CAUTION: The SUBARU Genuine Coolant contai anti-freeze and anti-rust agents is especially made for SUBARU engine, which has an alu- minum crankcase. Always use SUBARU Genuine Coolant, since other coolant may cause corrosion. 10 _ 4—<$—$__————— PERIODIC MAINTENANCE SERVICES fosag) 1-5 '5. Replace Engine Coolant and Inspect Cooling System, Hoses and Connections, 3. RELATIONSHIP OF SUBARU COOLANT CONCENTRATION AND FREEZING TEM- concenuaton PERATURE pp oteooiae ‘The concentration and safe operating tempera- ic sy ture of the SUBARU coolant is shown in the dia- gram. Measuring the temperature and specific 1.080 ~ Gravity of the coolant will provide this informa- 1.080 tion. § tor Pa % 1060 $ 1.050 we $ 1040 i 30% & 1.090 1.020 20% 1010 1.000 i025 00702030055 (40}-22)-4) (14) (82) (60) 68) (6) (1044122) Coolant temperature °C °F) sHon6d ‘anya circ be rained TUS ea 4. PROCEDURE TO ADJUST THE CON- CENTRATION OF THE COOLANT To adjust the concentration of the coolant ac- cording to temperature, find the proper fluid concentration in the above dagram and re- place 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 dagram [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 verti Concatatn cot inf vet cong sys cal axis of the graph at height A. The quantity of coolant to be drained is 2.1 liters (2.2 US gt, 1.8 Connontinsanter enone ia vehiea Imp qt). Drain 2.1 liters (2.2 US qt, 1.8 Imp Qt) ‘and quan tobe orined of coolant from the cooling systam and add 2.1 liters (2.2 US gt, 1.8 Imp qt) of the undiluted solution of SUBARU coolant. a coolant concentration of 50% is needed, drain all the coolant and refill with the undiluted usnooss | Solution only. 4 2.29} esa] cn oa "1-5 [0580] 5, Replace Engine Coolant and Inspect Cooling System, PERIODIC MAINTENANCE SERVICES Hoses and Connections G1Hooe0 B: INSPECTION 1) Check radiator for leakage, filling it with coolant and attach radiator cap tester fo the fill- erneck. Then apply a pressure of 157 kPa (1.6 kg/cm?, 23 psi) and check the following points: ‘* Each portion of radiator for leakage '® Hose joints and other connections for leak- age ‘CAUTION: When attaching or detaching tester and when operating tester, use special care not to deform radiator filler neck. NOTE: ¢ When performing this check, be sure to keep the engine stationary and fill radiator with cool- ant © Wipe off check points before applying pres- sure. # Use care not to spill coolant when detaching tester from radiator. 2) Check the radiator cap valve open pressure using radiator cap tester. 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 @ pressure above the service limit value has been maintained for this period Radiator cap valve open pressure Standard value: 78—98 kPa (0.8 — 1.0 kg/cm?, 11 — 14 psi) Service limit: 69 kPa (0.7 kg/cm?, 10 psi) CAUTION: Rust or dirt on cap may prevent valve from functioning normally: be sure to clean cap before testing. 3) If the coolant temperature exceeds 76.0 to 80.0°C (169 to 176°F) while radiator is not so hot, check thermostat. If thermostat does not ‘open at 76.0 to 80.0°C (169 to 176°F), replace it with a new one. 4) Ifelectric fan does not operate when coolant temperature exceeds 90 to 94°C (194 to 201°F), check thermoswitch or fan motor. 12 a<$—_———————— PERIODIC MAINTENANCE SERVICES fosat] 1-5 8, Spark Plugs Sak Plugs 8. Spark Plugs Spark pug thread ‘Daa = 12 mm (0.47 in) Pic = 125mm GHo0e4 TANTENANGE RTERVAL INunbor ot mrs fh es) never occur ts rs 2 [| | «© | «@ 1,000 25 50 75 100 1,000 “s 00 [| «© | Excopi 1 Srecon| | @ | R | | olen | __ change ever 20,00 kn (18500 mes For } : - 1 i A: REPLACEMENT 1. REPLACEMENT OF SPARK PLUGS (NON-TURBO MODEL) 1) Disconnect spak plug cord, 2) Remove spark plug with a plug-wrench. 3) Set new spark plug 4) Tighten spark plug lightly with hand, and then secure with a plug-wrench to the specified torque. Tightening torque: 18—24N.m (1.8—2.4 kg-m, 13— 17 ft-lb) CAUTION: Be sure to place the gasket between the cyl- inder head and spark plug. NOTE If torque wrench is not available, tighten spark plug until gasket contacts cylinder head; then tighten further 1/4 to 1/2 turns. 1800 cc Recommended spark plug: NGK BKRG6E-11 CHAMPION RCBYC4 Spark plug gap 1.0 — 1.1 mm (0.039 — 0.043 in) 1600 cc Recommended spark plug: NGK BKR6E CHAMPION RC8YC4 Spark plug gap 0.8 mm (0.031 in) NOTE: 131-5 [08az) 8. Spark Plugs PERIODIC MAINTENANCE SERVICES Ignition cou (LH) // NL ortiieo Spark pug thread ‘Da = 42mm (047 in) Phci= 125mm Gio08s 2. REPLACEMENT OF SPARK PLUGS (TURBO MODEL) 1) Removal of ignition coil (RH). (1) Dismount accelerator cable from clamps. (2) Remove air intake boot and air cleaner case. (3) Disconnect ignition coil harness con- nector. (4) Remove ignition coi 2) Removal of ignition coil (LH). (1) Remove battery and window washer tank, (2) Disconnect ignition coil harness con- nector. (3) Remove ignition coil 3) Remove spark plug with a plug-wrench, 4) Set new spark plug. 5) Tighten spark plug lightly with hand, and then secure with a plug-wrench to the specified torque. Tightening torque: 18—24N.m (1.8—2.4 kg-m, 13—17 ft-lb) CAUTION: Be sure to place the gasket between the cyl- inder head and spark plug. NOTE: If torque wrench is not available, tighten spark plug until gasket contacts cylinder head; then tighten further 1/4 to 1/2 turns. Recommended spark plug: NGK PFR6G Spark plug gap: 0.7— 0.8 mm (0.028 — 0.031 in) 14PERIODIC MAINTENANCE SERVICES foway] 1-5 10. Transmission/Ditferential (Front and rear) Lubricants (Gear oil) 10. Transmission/Differential (Front and rear) Lubricants (Gear oil) MAINTENANCE INTERVAL [Number of manths of km (miles) whichever occurs firs) ents 2 [= [6 | « xia |e | as | so | 7 | 1 ao ly [as | a | as |e a a A: REPLACEMENT 1. MANUAL TRANSMISSION 1) Drain gear oil by removing drain plug atter allowing the engine to cool for 3 to 4 hours. CAUTION: Before starting work, cool off the engine well. 2) Reinstall drain plug after draining gear oil and tighten it to the specified torque. Tightening torq ‘41 —47N.m (4.2—4.8 kg-m, 30—35 ft-lb) CAUTION: © Be sure to place a gasket between the transmission case and drain plug. © Replace the gasket with a new one. NOTE: inspect the transmission gear oil level. If the oil level is at the lower point or below, add some oil through the oil level gauge hole up to the upper point of gauge Gear oil capacity: FWD model:2.6 ¢ (2.7 US qt, 2.3 Imp qt) AWD model:4.0 ¢ (4.2 US qt, 3.5 Imp qt) 151-5 10. [01043] PERIODIC MAINTENANCE SERVICES ransmission/Differential (Front and rear) Lubricants (Gear: TEN a “ranemission gear oll in Cassia | 'SAE_ Viscosity No and Applicable Tenperaire a a] 2 8 0 co) 34 Bo we ‘Non-Turbo model G1H0990 Recommended oil CAUTION: Each oil manufacturer has its base oil and additives. Thus, do not mix two or more brands. 3. REAR DIFFERENTIAL (AWD MODEL) 1) Drain oil by removing drain bolt or plug. 2) Remove filler bolt or plug for quick draining oil 3) Tighten drain bolt or plug after draining oil CAUTION: © Non-Turbo model Always use a new aluminum gasket. Tightening torque: 344 4N.m (3.5% 0.4 kg-m, 25.3 2.9 ft-lb) © Turbo model Apply fluid packing to drain plug threads be- fore installation. Fluid packing: Three Bond 1205 or equivalent Tightening torque: 49+ 9.8 N.m (5+ 1 kg-m, 36+ 7.2 ft-lb) 4) After installing drain bolt or plug onto rear differential gear case firmly, fill oil up fully to the mouth of filler bolt or plug. Oil capacity: 0.8 (0.8 US qt, 0.7 Imp qt) 5) Install filler bolt or plug onto rear differential gear case firmly. CAUTION: * Non-Turbo model Always use a new aluminum gasket. Tightening torque: 34+ 4/N.m (3.5% 0.4 kg-m, 25.3 2.9 ft-lb) ‘* Turbo mode! Apply fluid packing to filler plug threads be- fore installation. 16—————— PERIODIC MAINTENANCE SERVICES, foros] 1-5 10. Transmission/Ditferential (Front and rear) Lubricants (Gear oil) Fluid packing: Three Bond 1205 or equivalent Tightening torque: 49+ 9.8 N.m (5+ 1 kg-m, 36+ 7.2 ft-lb) Te Recommended oil Fear dierent gear ot CAUTION: Each oil manufacturer has its base oil and additives. Thus, do not mix two or more brands. 7 71-5 [013A1) PERIODIC MAINTENANCE SERVICES isc Brake Pads and Discs/Front and Rear Axle Boots and Axle Shaft Joint Portions MAINTENANCE INTERVAL 13.Disc Brake Pads and {Number of ment of rn tes) whienever occurs fst) Discs/Front and Rear Axle Cou ea 2a | 2s 2) Boots and Axle Shaft Joint | |*im°| 16 | 2 | %© | 7% | 100 portions) aol: [as | | «© | wo 1 1 1 1 A: INSPECTION 1. DISC BRAKE PAD AND DISC 1) Jack up vehicle and support with rigid ( racks. Then remove wheels. 2) Visually check pad thickness through in- spection hole of disc brake assembly. Replace Pad if necessary. Pad thickness including back metal mm Gn) Front Rear Catoor ody aiHo0es | [Standard 17 (087) 15 (0.59) Service tit 7510295 | 65 (0.256) Service tit Thcnoes Senice mt | 1510.05) | 1.5(0.059) otpad (exclude back metal) Ling, 3), Check the disc rotor, and correct or replace ax | ifitis damaged or worn. ra ‘Brake disc thickness mm (in) Front Rear wae = Standaré__| 24094) | 80071 | 100088) arnooes| [wearin | 22087 | 16(06%) | €5 (0.995) Measure the disc rotor runout at a point less than 5 mm (0.20in) from the outer periphery of the rotor. Disc rotor runout limit: Front: 0.075 mm (0.00295 in) Rear: 0.100 mm (0.00394 in) CAUTION: When replacing a pad, always replace the pads for both the left and right wheels at the same time. Also replace pad clips if they are crroos7 | twisted or worn.PERIODIC MAINTENANCE SERVICES ee [oat] 1-5 16. Clutch Operation System 1. Clutch Operation Systorn 16.Clutch Operation System Froe| 10S mm (09—070in) GtH0107 Ful stoke: [25mm 1 in) MAINTENANCE INTERVAL [Number of months of km (miles) whichever occurs first Months we] ~ | 9% | 4 4m [se [a | so | 7s | 100 els [we | w |e | tty i A: INSPECTION AND ADJUSTMENT 1. MECHANICAL APPLICATION TYPE 1) Inspect free play of clutch pedal by operat- ing pedal by hand Ifitis out of the specified value, adjust it by turn- ing wing nut on engine side of clutch cable at re- lease fork. Tightening torque (Adjusting nut on release fork): 6+ 1.5N.m (0.61 + 0.15kg-m, 4.4+ 1.1 ft-lb) Standard free play: At clutch pedal 10 — 20 mm (0.39 — 0.79 in) Fork lever free play allowance: 3—4 mm (0.12 — 0.16 in) NOTE: When replacing clutch cable with new one and/ or marking free play adjustment of clutch pedal, make adjustment of hill-hoider system without fail as follows. After replacing clutch cable [and/or pressure hold valve (PHV) cable] with a new one, de- press clutch pedal about thirty (30) times as a Tunning-in operation prior to this adjustment. 2) Pedal-to-floor plate gap in disengaged posi- tion (1) With the engine idling, pull parking brake lever completely. (2) Slowly depress clutch pedal while mov- ing shift lever into reverse. (3) Stop depressing clutch pedal when gearshifting is complete. With clutch pedal in this position, measure the distance be- tween the upper side of pedal pad and the 191-5 (016A3) 16, Clutch Operation System Unis me i) Lock ut HD: 145 (5.73) LD: 150 (6.31) GiHoese SS) PERIODIC MAINTENANCE SERVICES lower end of front panel (intersection of front panel with floor). Check that the measured value is within the specified standard. Standard: 80 mm (3.15 in) or more 3) Pedal height Check that the clutch pedal pad surface is level with or higher than brake pedal pad surface. 3. HYDRAULIC APPLICATION TYPE 41) Inspect free play of clutch pedal by operat- ing pedal by hand. If tis out of the specified value, loosen lock nut for push rod and adjust push rod by turning in the direction that shortens or lengthens it. Standard free play: 5 — 15 mm (0.2 — 0.59 in) Tightening torque (Adjusting lock nut): 10 1 Nam (1.0 + 0.1 kg-m, 7.25 * 0.75 ft-lb) 2) Check the fluid level using the scale on the outside of the clutch master cylinder tank. Ifthe level is below "MIN", add clutch fluid to bring it up to “MAX”, Recommended clutch fluid: FMVSS No. 116, fresh DOT3 or DOT4 brake fluid CAUTION © Avoid mixing different brakes of brake fluid to prevent degradation of the fluid. © Be careful not to allow dirt or dust to get into the reservoir tank. © Use fresh DOTS or DOTS brake fluid when refilling fluid. 20 —_PERIODIC MAINTENANCE SERVICES fo17A5) 1-5 17. Steering and Suspension System 17.Steering and Suspension System inort2 irons at MAINTENANGE WTERVAL {Number of men of hn (ie) Weve oxcurs frst Months we | 2 [6 | 4 x00 16 | as | 6 | 75 | 100 rr er a A: INSPECTION 5. POWER STEERING FLUID LEVEL 1) Place vehicle with engine “off” on the flat and level surface. 2), Check the fluid level by removing filler cap of oil pump. (1) Check at temperature 21°C (70°F) of fluid temperature, (2) Check at temperature 60°C (140°F) of fluid temperature. 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 tokeep the leveliin the specified range of indica- tor. Iffluid level is at upper point or above, drain fluid tokeep the level in the specified range of indica- tor by using a syringe or the like.1-5 (01747) PERIODIC MAINTENANCE SERVICES 17. Steering and Suspension System Recommended fui Manufacturer BP, CALTEX “Dexron Il orl" ype CASTROL automat transmission fid MOBI SHELL TEXACO Fluid capacity: 0.7¢ (0.7 US qt, 0.6 Imp qt) 7. HOSES OF OIL PUMP FOR DAMAGES Check pressure hose and return hose of cil pump or crack, swell or damage. Replace hose with new one if necessary. NOTE: Prevent hoses from revolving and/or turning when installing hoses. 10.FITTING BOLTS AND NUTS Inspect fiting bolts and nuts of oil pump and bracket for looseness, and retighten them if necessary. Inspect and/or retighten them when engine is cold. Tightening torque: Tt: 20.5 + 2.5N.m (2.05 + 0.25 kg-m, 15 2 ft-lb) Tz: 52+ 10N.m (6.3 + 1.0 kg-m, 38.5 + 7.5 ft-lb) T3: 22+ 2N.m (2.2 * 0.2 kg-m, 15.5 1.5 ft-lb) Ta: 8 2N.m (0.8 = 0.2 kg-m, 5.5 + 1.5 ft-lb) Ts: 18°§ Nm (1.8° 85 kg-m, 13.0° 3° ft-lb) 76: 7.4+2.0Nm (0.75 * 0.20 kg-m, 5.4 1.4 ft-lb) 22FS eenNomaene SPECIAL TOOLS 1-6 Page Engine Tools 2 Manual Transmission and Differential Tools Automatic Transmission and Differential Tools Rear Differential Tools (AWD Models) 4 Suspension Tools Wheels and Axles Tools 8 Steering System Tools Brake Tools Body Tools ‘Supplemental Restraint System Tools 10 Select Monitor and Cartridge 1"1-6 (0100) SPECIAL TOOLS 41. Engine Tools, 1. Engine Tools 498267600" 498457000, 498457100, 498497100 CYLINDER HEAD TABLE | ENGINE STAND ADAPTER | ENGINE STAND ADAPTER | CRANKSHAFT STOPPER * For replacing valve guides, | Used with ENGINE STAND | Used with ENGINE STAND | Used to stop rotation of. Used to remove andinstali_| (499817000). (499817000), fywhas when loesenng and valve springs. tightening crankshaft puley 1 For DOHC engine. bolt, et. itosr iHo128 arHotze tH0130 "498547000 398744300 "498857100 498017100 [OIL FILTER WRENCH PISTON GUIDE VALVE OIL SEAL GUIDE _| PISTON PIN GUIDE Used to remove and instal oil [© Used to install piston in cy | For press-fiting of intake and_ | Used to instal piston pin, iter Inder exhaust valve guide ol seals. | piston and connecting rod. 1 For DOHC engine. & cae | coer inorst civorse iver ervors TaR0TI00 TeUOHTEOO TaRRTI00 TeRETIOD CONNECTING ROD BUSH \BUSH- TmsTON PIN REMOVER [CamSHarT SPROCKET | CAMSHAFT OL SEAL ING REMOVER & IN aso WaERaH ce RSrALLER Used to remove andinstat [Used oremove pion pin Used ormovg andinsta |» Used io tal raha Soon ted bushing cachet Spek oi seat + Bosd nin CAMSHAFT OI SER Se ebasor000) mons ortoros citotsr ines “Nowy adopted Tol—$—$— <$<$<$—————— SPECIAL TOOLS [100] 4-6 1. Engine Tools ears eo0 eran om Saaenart Ot SEAL | repay on SEAL Spanner OL SEAL pase ong crane VALVE SPRING REMOVER + Gsdts naa cana] Unesa ma cara o | Uesio Waa Sanaa” [Undo ono an rsa aa Pe re Sees iN aesereesnremoerdl Gas teromerarrorl tates ornare eee eine eames eraae conta eesti ean pe CO ) 9 G1HO1S9 G1HO140 GiHoI4t (GaHiorar ae earn ied eesirDD TE GUIDE ROIUSTER [WANE Cube REMOVER [WANE Gus REANER [ENE aN Used al rs and | Forencvng ee pes Foreaning ave ues. | > ned edo SS eee Seana ergs, Sensis gs «Seema egE Sead a Se ores S ee | eee et ears on ened etre arom a QRANK PULLEY WRENCH | CranxsHaFT SOCKET Used to stop rotation of Used to rotate crankshaft crankshaft pulley when foosening and tightening [crankshaft pulley bots. Grhors7 GrHor4e “Newly adopted tool1-6 — {0400} SPECIAL TOOLS 4, Rear Differential Tools (AWD Models) 4. Rear Differential Tools (AWD Models) eer eer areas eral tani insbarea [bor natores———[Rewbaseam ———[beresar @ os a> be ea7eOT 498447120 498427200 7498447100 ae arr GE ween |r Este eee aren ons onsen [or oe emotes ernozes nmaze cerhnzc0 399520705 390467700 w99ne5%00___| __ 498808501 SEAT DRIFT DRIFT GAUGE Sie bearing cone | pie, Fis beara, | Sse besing or Pinion height austen ont bearing cone rtos0s iHo2e4 rhozes ed—$—<—<—<—<—_—_—_ SPECIAL TOOLS {0400} 1-6 4. Rear Differential Tools (AWD Models) eur Wea S2265AANOO WaTOAGE BEARING OUTER RACE | ouynay SHAFT DUMMY COLLAR seat For pressing the bearing | Pirin height and Prload ad- | Pinion height and Preload ad | Side bearing cu race (ron) of aiferertialcar- | justment. justment. ee. te. | rhoaer ewa2e8 orHo229 eroaoe ROTOR Bea7aOIOe 390580100, w0e7aI00 PULLEY ASSY WEIGHT INSTALLER INSTALLER (Oi sea, Side bearing cup. | Frontbearng cone, Pict | Front bearing cone, Plot | Companion fange bearing, Companion flange. _| beating, — ww an @ rtcea2 erHo294 ro235 erHo2a6 1399008100 498247001 498267100 398177700 ‘STRAIGHT PIN REMOVER | MAGNET BASE DIAL GAUGE INSTALLER Diferenta pinion shaft lock | Used to measure backlash |» Used to measure backlash | Rear bearing cone. pin between side gear and pin- |” between side gear and pin- ig and pol ger ional yea gar + Usod wit IAL GAUGE | Used wih MAGNET BASE (498247100). (498247001) | | ntces7 iHorso | rHore0 itoass 5—_—_—_——_—.- 1-6 [0400] SPECIAL TOOLS 4, Rear Differential Tools (AWD Models) 498517210" 98405800 98515500 308887700, REPLAGER, SIDE BEARING DRIFT | DRIVE PINION BEARING | ATTACHMENT REPLAGER Side bearing cone. For pressing the sie | For removing he ave prion | » Side bearing retainer ° Bearing cone of iferentia, | Bearing cone (ron, 2 For TURBO model tH0979 ttoss7 rH095e rHos86 396257700 398877700 308427705, 398497700, GAUGE DRIFT DRIFT2 DRIFT * Side bearing * Oi sea * For press-fting the bearing | » Oi sea. For TURBO model + For TURBO model face (ron) of ferental”™ | 8 For TURBO model «For TURBO model g inoa72 rhoa7a G1H0956 GiHos75 398507702 "398507705 388507704 "398517700 DUMMY SHAFT DUMMY COLLAR ‘BLOOK REPLAGER ‘ Pinion height and Preload |» Pinion height and Preload | Pinion height and Preload |» Rear bearing cone. adjustment. adjustment adjustment * For TURBO model ‘¢ For TURBO model «¢ For TURBO mode! «¢ For TURBO model P= | GiHo976 iHos77 GrHoare GiH0979 “Newly adopted too!SPECIAL TOOLS “Newly adopted too! {0400 1-6 4. Rear Differential Tools (AWD Models) (398487700 T 398507701 398527700 498517200 * DRIFT [Gauge PULLEVASSY REPLAGER ide bearing cone | Brion height ausment. Oi sea, Sige bearing cup. | » So bearng cone $ For TURBO model ¢ For TURBO model 3 For TURBO mode! + For TURBO model a at ovena| ea BO8287TOO WeIGnT + Sce bearing 3 For TURBO mode! cetmeaes1-6 [0600] 6. Wheels and Axles Tools SPECIAL TOOLS 6. Wheels and Axles Tools 1922431000 "925081000 1926470000 1927060000, [AXLE SHAFT INSTALLER BAND TIGHTENING TOOL ‘AXLE SHAFT PULLER HUB REMOVER * Used to install axle shaft into housing Used with ADAPTER (927380000), For tightening boot band. Used to remove front axle shat Used fo remove front hub. is EXTENSION AXLE SHAFT eee Romie ornoeey ornoats corneas rneaso Ea sarro0000 BET A008 TETaRO0 HUB STAND BEARING PULLER DQESHAPTPULLER — Tapapren sod o dsassarbo and as~ |» Usodto deaseorbe and | Same es pat ncudedin | Used as an adapter for AXLE Semblonbbat nroarhi” |" essombietortouseg” | ASCE SPAPTAULLER” "| SEAM ROTALLER & earn, Gerorto00) ezss1000, Pio «= Beed din Housina SANE taa00000) ineast crmcasa moots thoes TEra0000 waraTa000 Pa eareROON HOUSING STAND. OIL SEAL INSTALLER [HUB REMOVER HOUSING STAND + Used io deassonbie and | Used inal ol seal iio | Used to remove earhub GP. | « Used io deassonble and soonbietonttoung” | kon house ssomble ear fous feanrg feerng « Bein Bearine PuLL- « Besd in BEARING PULL- ERTGET"00000. erteereeo000) corneas ) crvase ineesr xmoass Lo SERVICE PROCEDURE. .........ocsnennnnnsnnnennnnsinnnnnnensninennld 1. General Precautions ...nnisnsennns esenennned 2. Timing Belt . 12 3. Camshaft 26 4, Cylinder Head ...ensnensennesns sotsnnnentnnsenneanseneee ST 5. Cylinder BIOCK. nn... a eee so) T DIAGNOSTICS. evnenn 74 1. Engine Trouble in General ....conneeen : sea 2. Engine Noise.. soeTT2-3b [sia] SPECIFICATIONS AND SERVICE DATA 4. Engine 1. Engine A: SPECIFICATIONS Horizontally opposed, liquid ype cooled, écylinder, roke ‘gasoline engine Belt driven, double overhead Vatve arangement camnsha svatveleyinger Bore x Stroke ‘mm (i)| 92x 75 (862 x 296) Piston displacement ent (oui) 1.984 (12867) Compression ratio 80 engine (Compression pressure (at 200 — 300 rem) ea igiem®. ws] 49 ta gaa azn) Nurber of piston rings Pressure ring: 2, Oil ring: 1 Opening e BT0C Intake valve timing (Closing '56" ABDC. (Opening ‘55° BBDG Exhaust valve timing [Closing a ATDS rom| ‘900: 100 (No load) Tana Ignition timing BTOCIpm 18° 107000SPECIFICATIONS AND SERVICE DATA [s180) 2-3b 4. Engine B: SERVICE DATA eee |Prottusion of acster rod 154 — 164 mm (0.606 — 0.648 in) Spacer 00. 16 mm (065) FTensionor bush LD. 16:16 mm (0.6962 inp (st 0117 — 0.180 mm (0.0066 — 0.0071 Belt tensioner | Clearance between spacer and bush eee aa Limit [0.230 mm (0.0084 in) S10 037 — 058 mm (0.0146 — 0.0815 np Side clearance of spacer ‘= Lint [08mm (0.081 in) Bend limit 0.20 mm (0.0079 in) _ a S10 0015 — 0070 mm (0,0008 — 010028 in) Limit 010 mm (0.089 in) a STO 41,78 — 41.88 mm (1.6449 — 1.6488 inp Cam tobe Limit 1.62 mm (1.685 in) camsnan frelon fT sto 21.78 — 4188 mm (1.6449 — 1.6488 inp shaust Limit 1.62 mm (1.6365 in) Front 31.946 — 91963 mm (12577 — 12564 in) Journal 0.0. | sto ~ [Genter rear |27.986— 27.963 mm (7.1002 — 11009 in) a STO 0087 — 007 mm (0.0015 — 0.0028 inp Lit (0:10 mm (0.0089 in) Surtace warpage lit 0.05 mm (0.0020 in) Cylinder head | Surface grinding limit (03 mm (0.072 in) Standard height 1275 mm (6.02 in) Refacing anale 20" st 1.0 mm (0.0889) Intake valve seat | contacting _ Lit 17 mm (0087 in) width stD 4.5 mm (0.059 in) Exhaust Limit [22 mm (0.067 in) ave gunae [ner dlameter 5.000 — 6018 mm (0.2982 — 0.2368 np su Protrusion above head 120 —12.4 mm (0.472 — 0.488 in) [ato 12 mm (0087) Intake Head edge Limit [08 mm (@.081 in) thickness sto 15 mm (0.059 in) Exhaust Limit [08 mm (0.054 In) : intake [5.950 — 5.965 mm (0.2343 — 0.2548 in) tom diameter Valve Exhaust [5.880 — 6.965 mm (0.2348 — 0.2848 in) Intake [0.035 — 0.062 mm (0.0014 — 0.0028 inp stem oi [STO panes Exhaust [0.080 — 0.067 mm (0.0016 — 0.0026 in) Limit 0.5 mm (0.089 in) intake [98.3 mm (673 19) vera length Exhaust [996 mm (2.585 in) STD: Standard 1D; Inner dameler 1D: Outer diameter 32-3b [5180] SPECIFICATIONS AND SERVICE DATA engine Tree brah a a Tear) Savarese Bs. 7 am (0.087) Vive Sa ee88 2618 W rin 3 87 by, 814 — 58.9 BySt mm (122) Ta e808 8815 Ward — Ba, 1041 — 106 By 232 nm (0019) Surtece warpage Unt (maha wit yndor bead) [0.05 mm ean) Surteegrning Hit ome (a0) x 200s ibm sam — 3) | Cylinder bore 8 o4.95— 62.005 mm 8 — 362221) 7 st [oore mm (0.008 ytnaer Ta - - 4 xin init [oso (0.020 i) S10 [0010 mm (6.008 iy ovtteoundna init [0.080 me (6.020) a sto [ao — ono mm (c.0008 — 02012) json lerance Lim J0080 mer (0002) Energia ocr) os mm (0.020) ae 91095 — 8105 mm ea —aezIe 3 6197591905 mm eat — e214) outer damater Paton 0.25 mm 0H6 ny O8 | 2728 — 82296 mm (eaEO — 2.609 i) 080 mm 00187) 08 2478 — 02486 mm (06607 —264tT in) Sandia ier lamer a piston pin ole 23.000 — 23.00 mn (0.088 — 00067 i) Outer diameter 22994 — 23.00 mm (0.9089 — 00065 i) Standard clearance Buiwen ison pn and 30% Lo 903 oats mm ~ sons reson pn | o.oo: — oars (0.0004 — 0.006) Piston pin ust be ied no poion wih hun a6 Deore of ten st [oa0—028 wm oor aaa 0p ing int [08 mm (0.020 1) = Goons an [S10 fos? — asm (0.0146 — 002 in Uo? "9 Time 4.0 mm (0.039 in) sto [a20— 070mm (0.078 —oaaT6 Piston eng on ang tints mm (0.089) Foamy [5 (e018 — ont) [Clearance between piston | 1°? "9 Limit {0.0059 in) ng aniston rng S10 (oor — aa > | Second ring ii (0.089) BenaiwietperToomm BOTA ‘ow m Connecting [ena ro sr (aos —aT.O side clearance im ‘core 08 OversizeSPECIFICATIONS AND SERVICE DATA [s180] 2-3b 1 Engh S10 [0.025 — 0086 mm (c.00%0 — 0.0022 inp Limit (0.0024 inp Connecting sto (0.0585 — 0.0589 in) | 104 beat" |rhiekness at center por- [0.08 mm (000%2 in) US (0.0589 — 0.0508 in) tion 0.05 mm (0.0020 in) US| 1.515 — 1.518 mm (020596 — 0.0588 in) 0.25 mm (00096 in) US| 1.615 — 1.616 mm (0.0636 — 0.0657 inp Connecting [Clearance between piston pin and [STO Jo — 0.022 mm (0 = 0.0008 in) ‘0 bushing | bushing Limit 0.090 mm (0.00%2 in) Bend limit [0.035 mm (0.00% in) [orankpin and erank jours [Outot roundness (0.030 mm (0.00%2 in) or less ral ringing limit (0.250 mm (0.0088 in) [sto 51.964 — 52.000 mm (2.0866 — 2.0472 inp (0.03 mm (00082 im) US_ [51.954 — 61.970 mm (2.0854 — 2.0461 in) Crankpin outer diameter , os er eou mus |stenr towne nas Spo 0.25 mm (0.0086 in) US _ [51.734 — 51.750 mm (2.0868 — 2.0878 in) [sr 59.964 — 60.000 mm (2.3616 — 2.3622 in) rankshatt_ crank journal outer diam. {2.09 mm (000%2 in) US _ [59.954 — 69.970 mm (2.3604 — 2.3610 in) eter [0.05 mm (0.0020 in) US _|58.894 — 69.950 mm (2.3596 — 2.3602 in) 0.25 mm (0.0086 in) US [59.734 — 69.780 mm (2.9517 — 2.3524 inp stb (0.030 — 0.15 mm (0.0012 — 0.0045 iny thrust clearance Limit 025 mm (0.086 i) [sto (0.010 — 0090 mm (0.0008 — 0.0072 inp #8, 45 Limit [0.080 mm (0.0086 in) Oil clearance ene 0.010 — 0030 mm (0.0008 — 0.0012 inp FEE TCimit [1095 mm (0.0078 inp st 1.998 — 2011 mm (0.0787 — 0.0782 np (0.03 mm » (0.0012 in) | 2.017 — 2.020 mm (0.0796 — 0.0705 in) us pugs [005mm (0.0020 in) | 2.027 — 2.090 mm (0.0798 — 0.0799 in) us 0.25 mm (0.0086 in) |2.t27 — 2.130 mm (0.0897 — 0.0839 in) Jcrankshatt_|crankshatt bearing thick- us bearing [ness S10 2.000 — 20% mm (0.0787 — 0.0785 inp 003 mm (0.0012 in) 2.019 — 2.022 mm (0.0795 — 0.0796 in) us 2,49, #4 [0.05 mm #21848 Goo20 in) |2.009— 2.092 mm (0.0799 — 0.0600 in) lus 0.25 mm (0.0098 in) ]2.129 —2.182 mm (0.0838 — 0.0899 in) us Ds senaare Ur tar aoe 52-3b [c100} COMPONENT PARTS 4. Timing Belt 1. Timing Belt @® Right-hand belt cover No. 2 @ Crankshatt sprocket @ Lottnand belt cover No. 2 @ Tensioner bracket © Tensioner adjuster @ Right-hand exhaust camshatt sprocket @ Right-hand intake camshaft sprocket @ Letthnand intake camshaft sprocket {@ Letthand exhaust camshatt sprocket ® Timing belt ® Bolt idler No. 2 @® Bottidier @ Lofterand belt cover ® Front belt cover ® Righthand belt cover @ Crankshaft pulley Tigh 5 Nm (gm, Rb) 940.5 (0.50.05, 3640.4) Tz: 1542 (25402, 181414) 73: $944 (400.8, 28912.) Ta: 1845 (80205, 57.9431 15:98:45 (100405, 72.34COMPONENT PARTS [c200) 2-3b 2. Cylinder Head and Camshatt 2. Cylinder Head and Camshaft ® Rocker cover (RH) Rocker cover gasket (RH) Oil separator cover Gasket Intake camshatt cap (Front RH) Intake camshatt cap (Center RH) Intake camshaft cap (Rear RH) intake camshatt (RH) Exhaust camshaft cap (Front RH) Exhaust camshaft cap (Center BH) Exhaust camshaft eap (Rear RH) Exhaust camshatt (RH) Intake valve guide 8889888383888 Exhaust valve guide Cylinder head bolt Oil seat Cylinder head (RH) Oyinder head gasket (RH) Cylinder head gasket (LH) Cylinder head (LH) Intake camshaft (LH) Exhaust camshatt (LH) Intake camshaft cap (Front LH) Intake camshaft cap (Genter LH) Intake camshatt cap (Rear LH) Exhaust camshat (Front LH) @ Exhaust camshaft cap (Center LH) Exhaust camshaft cap (Rear LH) Rocker cover gasket (LH) Rocker cover (LH) it filer cap Gasket Oil filer duct Gasket @ @ @ ® ® ® e Tightening torque: Nom (kgm, Rib) Ti: Refer to [WSET]. 12:5 (05, 38) 3:10 (1.0, 7)2-3b [300] COMPONENT PARTS 3. Oylinder Head and Valve Assembly 3. Cylinder Head and Valve Assembly 89869080COMPONENT PARTS [c400) 2-3b 4. Cylinder Block 4. Cylinder Block © O' pressure ewiteh ® Joint plug © Metal gasket @ Right-hand eylindor block ® Service hole plug @ Oil level gauge guide TH: 5 (05, 36) © Engine coolant pipe A 13: 10 (1.0, 7) © Fear oll seat P Ta: 2522 (25402, 181414) ® Oring @ Front oll seal 15: 4743 (48403, 347422) ® Oring ® Bale plate Te: 697 (7.0507, 506+5.1) ® Oring ® Oil strainer stay Service hole cover ® O-ring ® Lett-nand eylinder blooc 2 Oil strainer © Gasket @ Gasket ® Engine coolant pump @ Oil pan © Metal gasket @ Oil drain plug2-3b [cs00} COMPONENT PARTS '5. Crankshaft and Piston 5. Crankshaft and Piston @ Fiywheet ® Connecting rod cap @ Bell bearing © Crankahat @ Top ring ® Woodrut key @ Second ring ® Crankshatt bearing #1, #5 @ Oilring (© Crankshatt bearing #2, #4 Piston ® Crankshatt bearing #3 @ Piston pin See © Circtip ® Connecting rod bolt ® Connecting rod Connecting rod bearing—<$_ $< SERVICE PROCEDURE [W100] 2-3b 4. General Precautions 1. General Precautions 1) Before disassembling engine, place it on ST3. ST1 498457000 ENGINE STAND ADAPTER RH ST2 498457100 ENGINE STAND ADAPTER LH ST3 499817000 ENGINE STAND On turbocharged engine, remove exhaust manifolds, turbo joint pipe and turbocharger before placing it on ST3. 2) All parts should be thoroughly cleaned, paying special attention to the engine oil passages, pistons and bearings. 3) Rotating parts and sliding parts such as piston, bear- ing and gear should be coated with oil prior to assembly, 4) Be careful not to let oil, grease or coolant contact the timing belt, clutch disc and flywheel. 5) All removed parts, if to be reused, should be reinstalled in the original positions and directions. 6) Gaskets and lock washers must be replaced with new ones. Liquid gasket should be used where specified to prevent leakage. 7) Bolts, nuts and washers should be replaced with new ones as required, 8) Even if necessary inspections have been made in advance, proceed with assembly work while making rechecks. "2-3b [weary SERVICE PROCEDURE 2. Timing Belt 2. Timing Belt A: REMOVAL 1. CRANKSHAFT PULLEY AND BELT COVER cauors 1) Remove V-belt. 2) Remove pulley bolt. To lock crankshaft, use ST. 8) Remove crankshaft pulley. 4) Remove left-hand belt cover. 5) Remove right-hand belt cover 6) Remove front belt cover. ST 499977000 CRANKSHAFT PULLEY WRENCHSERVICE PROCEDURE 2. TIMING BELT ‘ett cover: en et cove ny Aigo na tong ‘ange tate cananat—/ tte cast spon tron Agent rk — ee ‘couse a) ‘eae ie) Noten 4A Noten bot cover et cover somst canst sprocket manne Alyn ac Algol mark tan e) teoge me) cht consat socket 4) if alignment mark and/or arrow mark (which indicates rotation direction) on timing belt fade away, put new marks before removing timing belt as follows: (1) Turn crankshaft using ST, and align alignment marks on crankshaft sprocket, left-hand intake cam- shaft sprocket, left-hand exhaust camshalt sprocket, right-hand intake camshaft sprocket and right hand exhaust camshaft sprocket with notches of belt cover and cylinder block ST 499987500 CRANKSHAFT SOCKET 82-3b [waz] SERVICE PROCEDURE 2. Timing Belt (2) Using white paint, put alignment and/or arrow marks on timing belts in relation to the sprockets, Z,! 54.5 tooth length Zz: 51 tooth length Zz; 28 tooth length 2) Loosen tensioner adjuster mounting bolts. 3) Remove belt idler. 4) Remove timing belt.SERVICE PROCEDURE twas] 2-3b 2. Timing Belt 3. BELT TENSIONER AND IDLER 1) Remove belt idler. 2) Remove belt idler No. 2 3) Remove belt tensioner and spacer. 4) Remove belt tension adjuster. CAUTION: After timing belt has been removed, never rotate intake and exhaust, camshaft sprock It camshaft sprocket is rotated, the intake and exhaust valve heads strike together and valve stems are bent. For this reason, when removing camshaft sprocket, lock the camshaft sprocket using ST so as to avoid turning camshaft. ST 499207100 CAMSHAFT SPROCKET WRENCH 15jb waa) SERVICE PROCEDURE 4. SPROCKET 1) Remove left-hand intake camshaft sprocket. 2) Remove left-hand exhaust camshaft sprocket. 3) Remove right-hand intake camshaft sprocket. 4) Remove right-hand exhaust camshaft sprocket ST 499207100 CAMSHAFT SPROCKET WRENCH 5) Remove crankshaft sprocket, 6) Remove tensioner bracket. 7) Remove left-hand belt cover No. 2. 8) Remove right-hand belt cover No. 2. B: INSPECTION 1, TIMING BELT 1) Check timing bet teeth for breaks, cracks, and wear. If any fault is found, replace belt 2) Check the condition of back side of belt; if any crack is found, replace 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 belt sharply. Bending radius: h 60 mm (2.36 in) or more 16SERVICE PROCEDURE tw2B4] 2-3b 2. ing Belt 4 | 2. BELT TENSION ADJUSTER 1) Visually check oil seals for leaks, and rod ends for abnormal wear or scratches. if necessary, replace faulty parts. CAUTION: Slight traces of oil at rod’s oil seal does not indicate a problem. 2) While holding tensioner with both hands, push the rod section against floor or wall with a force of 147 to 490 N (15 to 50 kg, 83 to 110 Ib) to ensure that the rod section does not move. If it moves, replace tension adjuster with a new one. 3) Measure the extension of rod beyond the body. If it is not within specifications, replace with a new one. Rod extension: H 15.4 — 16.4 mm (0.606 — 0.646 in) 3. BELT TENSIONER 1) Check mating surfaces of timing belt and contact point of tension adjuster rod for abnormal wear or scratches. Replace belt tensioner if faulty 2) Check spacer and tensioner bushing for wear. 4, BELT IDLER Check idler for smooth rotation. Replace if noise or exces sive play is noted 72-3b [weer] SERVICE PROCEDURE 2. Timing Belt C: INSTALLATION 4. SPROCKET | Tightening torque: Nem (kgm, Rib) ! 4905 (052005, 3.6+0.4) 2 (25202, 181.4) +5 (8005, 5843.6) 4) Install right-hand belt cover No. 2. 2) Install left-hand belt cover No. 2. 3) Install tensioner bracket 4) Install crankshaft sprocket 5) Install right-hand exhaust camshaft sprocket. To lock camshaft, use ST. 6) Install right-hand intake camshatt sprocket using ST. 7) Install lefl-and exhaust camshatt sprocket using ST. 8) Install left-hand intake camshaft sprocket using ST. ST 499207100 CAMSHAFT SPROCKET WRENCH bo a—<$—<—<$_—__ SERVICE PROCEDURE (w2cz] 2-3b 271 2, BELT TENSIONER AND IDLER m (kgm, fb) Ti: 252 (250.2, 1841.4) 12: 39:4 (400.4, 29429) 1) Installation of belt tensioner adjuster (1) Insert stopper pin 1.5 mm (0,059 in) dia. into place while pushing tension adjuster rod into body using a trove noes <7 Dress, se aiged CAUTION: ‘ Do not allow press pressure to exceed 9,807 N (1,000 kg, 2,205 Ib). ‘© Do not release press pressure until stopper pin is, completely i ‘© Push tension adjuster rod vertically.2-3b [wec3} SERVICE PROCEDURE 2, Timing Belt (2) Temporarily tighten bolts while tension adjuster is pushed all the way to the right 2) Install belt tensioner. 3) Install belt idler. 4) Install belt idler No. 2. 3, TIMING BELT camer] Tightening torque: Nem (kg-m, fib) T:2944 (4004, 29:2.) 20 _i 2. CAMSHAFT LH 1) Remove camshatt position sensor. 2) Remove ignition coils. 3) Remove cylinder head cover and gasket. 4) Loosen intake camshaft cap bolts equally, a little at a time in the numerical sequence shown in figure. 5) Remove camshaft caps and intake camshatt. 26SERVICE PROCEDURE twsp1) 2-3b ‘3, Camshat 6) Loosen exhaust camshaft cap bolts equally, a little at a time in the numerical sequence shown in figure, 7) Remove camshalt caps and exhaust camshaft CAUTION: Arrange camshaft caps in order so that they can be installed in their original positions. 8) Similarly, remove right-hand camshafts and related parts. B: INSPECTION 1. CAMSHAFT 1) Measure the bend, and repair or replace if necessary. Limit: 0.020 mm (0.0008 in) 2) Check journal for damage and wear. Replace if faulty 3) Measure outside diameter of camshatt journal. If the journal diameter is not as specified, check the oil clear- ance. [Camshaft journal Front (Center, rear ee [31.946 — 91.963 mm [27.986 — 27.969 mm meen (1.2577 — 1.2586 in) _|(1.1002 — 1.1009 in) 4) Measurement of the camshaft journal oil clearance (1) Clean the bearing caps and camshaft journals. (2) Place the camshafts on the oylinder head. (With- ut installing valve rocker.) (3) Place plastigauge across each of the camsha’t journals. (4) Install the bearing caps. CAUTION: Do not turn the camshaft. (5) Remove the bearing caps. (6) Measure the widest point of the plastigauge on each journal If the oil clearance exceeds the limit, replace the cam- shaft. If necessary, replace the camshaft caps and cylinder head as a set Standard oil clearance: 0.037 — 0.072 mm (0.0015 — 0.0028 in) Limit: 0.10 mm (0.0039 in) (7) Completely remove the plastigauge. a72-3b [wsct) 3. Camshatt SERVICE PROCEDURE _— 28 mm (1.30 9) 5) Check cam face condition; remove minor faults by grinding with oil stone. Measure the cam height H; replace if the limit has been exceeded 41.88 mm (1.6449 — 1.6488 in) Limit: 41.62 mm (1.6386 in) 6) Measure the thrust clearance of camshaft with dial gauge. If the clzarance exceeds the limit, replace caps and cylinder head as a set. if necessary replace camshaft Standard: .070 mm (0.0006 — 0.0028 in) 0.1 mm (0.004 in) C: INSTALLATION 1. CAMSHAFT Tighiening torque: Nm (kg-m, eb) $0.7 (1.0007, 72405) £2 (2.0202, 145414) 28—$—__—_—_— SERVICE PROCEDURE 1) Camshaft installation Apply engine oil to cylinder head at camshaft bearing location before installing camshaft. Install camshaft so that rocker arm is close to or in contact with “base circle” of cam lobe. CAUTION: ‘© When camshafts are positioned as shown in figure, camshafts need to be rotated at a minimum to align with timing belt during installation, @ Right-hand camshaft need not be rotated when set at position shown in figure. Left-hand intake camshaft: Rotate 80° clockwise. Left-hand exhaust camshaft: Rotate 45° counter-clock- wise. 2) Camshatt cap installation (1) Apply fluid packing sparingly to cap mating sur- face. CAUTION: Do not apply fluid packing excessively. Failure to do so may cause excess packing to come out and flow toward oil seal, resulting in oil leaks. Fluid packing: THREE BOND 1215 or equivalent (2) Apply engine oil to cap bearing surface and install cap on camshaft as shown by identification mark (8) Gradually tighten cap in at least two stages in the numerical order shown in figure, and then tighten to specified torque. (4) Similarly, tighten cap on exhaust side. After tightening cap, ensure camshaft rotates only slightly while holding it at "base" circle. 3) Camshaft oil seal installation Apply grease to new oil seal lips and press onto front end of camshaft by using ST1 and ST2, CAUTION: Use a new oil seal. ST1 499587100 OIL SEAL INSTALLER ST2 499597000 OIL SEAL GUIDE2-3b twsc2] SERVICE PROCEDURE 4) Rocker cover installation (1) Install gasket on rocker cover. Install peripheral gasket and ignition coil gasket (2) Apply fluid packing to four front open edges of peripheral gasket. Fluid packing: THREE BOND 1215 or equivalent (3) install rocker cover on cylinder head. Ensure gas- ket is properly positioned during installation. 5) Install ignition coil 6) Install cam angle sensor. 7) Similarly, install parts on right-hand side. 2. RELATED PARTS Install timing belt, camshaft sprockets and related parts $$<———_——_—_—_—_— SERVICE PROCEDURE 4. Cylinder Head A: REMOVAL 1. INTAKE MANIFOLD 1) Remove V-belt. 2) Remove alternator, air conditioner compressor and brackets. 3) Remove hoses and tubes from cylinder block. 4) Disconnect each connector and/or remove connector bracket 5) Remove coolant filler tank. 6) Remove intake manifold assembly and gasket. 7) Remove water pipe. 8) Remove crank angle sensor, cam angle sensor and knock sensor. 9) Remove timing belt, camshaft sprockets and related parts. 10) Remove rocker cover, camshafts and related parts. 2. CYLINDER HEAD 31SERVICE PROCEDURE 1) Remove oil level gauge guide attaching bolt (left-hand only). 2) Remove cylinder head bolts in numerical sequence shown in figure. CAUTION: Leave bolts @ and @ engaged by three or four threads vent cylinder head from falling. 3) While tapping cylinder head with a plastic hammer, separate it from cylinder block Remove bolts @ and @ to remove cylinder head. 4) Remove cylinder head gasket. 5) Similarly, remove right-hand cylinder head. B: DISASSEMBLY canara 32$$ SERVICE PROCEDURE (wact] 2-3b 4. Cylinder Head 1) Remove hydraulic lash adjusters. 2) Compress the valve spring and remove the valve spring retainer key. Remove each valve and valve spring, ST1 498267600 CYLINDER HEAD TABLE ‘ST2_ 499718000 VALVE SPRING REMOVER CAUTION: ‘® Mark each valve to prevent confusion. © Use extreme care not to damage the lips of the intake valve oil seals and exhaust valve oil se C: INSPECTION 1. CYLINDER HEAD 1) Make sure that no crack or other damage exists. In addition to visual inspection, inspect important areas by means of red check 2) Measure the warping of the cylinder head surface that mates with crankcase by using a straight edge and thick- ness gauge. If the warping exceeds 0.05 mm (0.0020 in), regrind the surface with a surface grinder. Warping limi 0.05 mm (0.0020 in) Grinding limit: 0.3 mm (0.012 in) Standard height of cylinder head: 127.5 mm (5.02 in) CAUTION: Uneven torque for the cylinder head nuts can cayse warping. When reassembling, pay special attention to the torque so as to tighten evenly.2-3b [wac2) SERVICE PROCEDURE 4. Oylinder Head 2. VALVE SEAT Inspect intake and exhaust valve seats, and correct the contact surfaces with valve seat cutter if they are defec- tive or when vaive guides are replaced. Valve seat width: W Intake ‘Standard 1.0 mm (0.039 in) Limit 1.7 mm (0.067 in) Exhaust Standard 1.5 mm (0.059 in) Limit 2.2 mm (0.087 in) | 3. VALVE GUIDE 41) Check the clearance between valve guide and stem The clearance can be checked by measuring the outside diameter of valve stem and the inside diameter of valve guide with outside and inside micrometers respectively Clearance between the valve guide and valve stem: Standard Intake 0.035 — 0.062 mm (0.0014 — 0.0024 in) Exhaust 0.040 — 0.067 mm (0.0016 — 0.0026 in) Limit 0.15 mm (0.0059 in) Valve guide inner diameter: 6.000 — 6.015 mm (0.2362 — 0.2368 in) Valve stem outer diamet Intake 5.950 — 5.965 mm (0.2343 — 0.2348 in) Exhaust 5.950 — 5.965 mm (0.2343 — 0.2348 in)$< $$ SERVICE PROCEDURE 2) If the clearance between valve guide and stem exceeds the specification, replace guide as follows: (1) Place cylinder head on ST1 with the combustion chamber upward so that valve guides enter the holes. in ST1 (2) Insert ST2 into valve guide and press it down to remove valve guide. ST1 498267300 CYLINDER HEAD TABLE S12 499767300 VALVE GUIDE REMOVER (3) Turn cylinder head upside down and place ST as shown in the figure. ST 499767100 VALVE GUIDE ADJUSTER (4) Before installing new valve guide, make sure that neither scratches nor damages exist on the inside sur- face of the valve guide holes in cylinder head, (6) Put new valve guide, coated with sufficient oil, in cylinder, and insert ST1 into valve guide. Press in until the valve guide upper end is flush with the upper sur- face of ST2 ST1 499767200 VALVE GUIDE REMOVER ST2 499767000 VALVE GUIDE ADJUSTER (6) Check the valve guide protrusion. Valve guide protrusion: L 13.3 — 13.7 mm (0.524 — 0.539 in) (7) Ream the inside of valve guide with ST. Gently rotate the reamer clockwise while pressing it lightly into valve guide, and return it also rotating clockwise. Alter reaming, clean valve guide to remove chips. ST _ 499767400 VALVE GUIDE REAMER CAUTION: © Apply engine oil to the reamer when reaming. @ Ifthe inner surface of the valve guide is torn, the edge of the reamer should be slightly ground with an oil stone. @ If the inner surface of the valve guide becomes lus- trous and the reamer does not chips, use a new reamer or remedy the reamer. (8) Recheck the contact condition between valve and valve seat after replacing valve guide. a5——<$<—_ 2-3b twice 4 Cylinder Head SERVICE PROCEDURE 4. INTAKE AND EXHAUST VALVE 1) Inspect the flange and stem of valve, and replace if damaged, worn, or deformed, or if "His less than the specified limit. H Intake Standard 1.2 mm (0.047 In) Limit 0.8 mm (0.031 in) Exhaust Standard 1.5 mm (0.059 in) Limit 0.8 mm (0.031 in) Valve overall length: Intake 93.3 mm (3.673 in) Exhaust 93.6 mm (3.685 in) 2) Put a small amount of grinding compound on the seat surface and lap the valve and seat surface. Install a new intake vaive oil seal after lapping. 5. VALVE SPRINGS 1) Check valve springs for damage, free length, and ten- sion, Replace valve spring if it is not to the specifications presented below. 2) To measure the squareness of the valve spring, stand the spring on a surface plate and measure its deflection al the top using a try square. Valve spring 39.8 mm (1.987 in) 2285 — 2618N (23:3 — 267 kg, 51.4 — 58.9 Iby31.0 mm (1-220 in) Fr nat Tension/spring height 462.9 — S315N (47.2 — 54.2 kg, 108.1 — 119.5 1823.2 mm (0.913 in) 25°, 1.7 mm (0.087 in)$< SERVICE PROCEDURE twac7] 2-3b 4. Cylinder Head 6. INTAKE AND EXHAUST VALVE OIL SEAL Replace oil seal with new one, if lip is damaged or spring out of place, or when the surfaces of intake valve and valve seat are reconditioned or intake valve guide is replaced 1) Place cylinder head on ST1 2) Press in oil seal to the specified dimension indicated in the figure by using ST2. ST1 498267200 CYLINDER HEAD TABLE ST2 498857100 VALVE OIL SEAL GUIDE CAUTION: © Apply engine oil to oil s Differentiate between exhaust valve oil seal by noting their difference in color. Color of rubber part: Intake [Black] Exhaust [Brown] Color of spring part: Intake [Black] Exhaust [Black] 7. VALVE LASH ADJUSTER 1) Check valve lash adjuster visually. 2) Measure outer diameter of valve lash adjuster. Outer diameter: 29.959 — 29.975 mm (1.1795 — 1.1801 in) 3) Measure inner diameter of bush on cylinder head. Inner diameter: 29,994 — 30.016 mm (1.1809 — 1.1817 in) CAUTION: Hf difference between outer diameter of valve lash adjuster and inner diameter of bush is over the limit, replace cylinder head. Standarc 0.019 — 0.057 mm (0.0007 — 0.0022 in) Limit: 0.100 mm (0.0039 in) 372-3b _{wano] SERVICE PROCEDURE 4, Oylinder Head D: ASSEMBLY camara a 1) Installation of valve spring and valve (1) Coat stem of each valve with engine oil and insert valve into valve guide. CAUTION: When inserting valve into valve guide, use special care not to damage the oil seal lip. (2) Set cylinder head on ST1 (3) Instail vaive spring and retainer using ST2 ST1 498267600 CYLINDER HEAD TABLE ST2 499718000 VALVE SPRING REMOVER CAUTION: Be sure to install the valve springs with their close- coiled end facing the seat on the cylinder head. | (4) Compress valve spring and fit valve spring retainer| key. | (6) After installing, tap valve spring retainers lightly! with wooden hammer for better seating. 2) Install hydraulic lash adjuster.SERVICE PROCEDURE wae) 2-3b % 4. E: INSTALLATION 1. CYLINDER HEAD camer 1) Install cylinder head and gaskets on cylinder block, CAUTION: Use new cylinder head gaskets. 2) Tighten cylinder head bolts, (1) Apply a coat of engine oil to washers and bolt threads. (2) First tighten all bolts to 29 Nem (3.0 kg-m, 22 ft-lb) in the order shown in the figure. After this, tighten them further to 69 Nm (7.0 kg-m, 51 ft-lb) in the same order. (3) Back off all bolts by 180°. After this, back therr off another 180°. (4) Tighten all bolts to 29 N-m (3.0 kg-m, 22 ft-Ib) in the order shown in the figure (8) Tighten all bolts by 80° to 90° in numerical sequence. CAUTION: Do not tighten bolts more than 90°. (6) Further tighten all bolts by 40° to 45° in numerical sequence (7) Further tighten bolts @ and ® by 40° to 45°. CAUTION Ensure not exceed 45°. ightening angle” [steps (6) and (7)] do 39vr 2-3b [wae2] SERVICE PROCEDURE 4, Gylinder Head © Ensure that the total “re-tightening angle” [steps (6) and (7)] do not exceed 90°. 8) install oil level gauge guide attaching bolt (left-hand only). 2. INTAKE MANIFOLD 1) Install camshafts, cylinder head cover and ‘elated parts. $e SERVICE PROCEDURE twaez] 243b 4. Cylinder Head 2) Install camshaft sprockets, timing belt and related parts. 3) Install water pipe CAUTION: Use new gaskets. a—_— 2-3b (wae) SERVICE PROCEDURE 4, Gylinder Head 4) Install intake manifold CAUTION: Use new gasket 5) Install coolant filler tank. 6) Install crankshaft position sensor, camshaft position sensor and knock sensor. Use dry compressed air to remove foreign particles before installing sensors 7) Connect each connector and/or install connector bracket, 8) Connect hoses and tubes to cylinder block 9) Install brackets, alternator and air conditioner com- pressor. 10) Install V-belt. : a$e SERVICE PROCEDURE twsaty 2-3b 5. Cylinder Block 5. Cylinder Block A: REMOVAL 1, RELATED PARTS 1) Remove timing belt, camshaft sprockets and related parts. 2-3b [wsa1} SERVICE PROCEDURE 5. Cylinder Block 2) Remove cylinder head covers, camshafts and related parts. (wsat) 2-3b 5. Cylinder Block SERVICE PROCEDURE 3) Remove cylinder heads, 3b [wsaz] SERVICE PROCEDURE 5. Gylinder Block 2. OIL PUMP AND ENGINE COOLANT PUMP—— SERVICE PROCEDURE [wsa2} 2-3b 5. Oylinder Block 1) Remove housing cover. 2) Remove flywheel. Using ST, lock crankshaft. ST — 498497100 CRANKSHAFT STOPPER, 3) Remove oil separator cover. 4) Remove engine coolant pipe. 5) Remove engine coolant pump. 6) Remove oil pump trom cylinder block. Use a flat-bladed screwdriver as shown in figure when removing oil pump. CAUTION: Be careful not to scratch the mating surface of cylinder block and olf pump. Parbiades 7) Removal of oil pan (1) Turn cylinder block with #2 and #4 piston sides facing upward. (2) Remove bolts which secure oil pan to cylinder block (3) Insert a oil pan cutter blade between cylinder block-to-oll pan clearance and remove oil pan, CAUTION: Do not use a screwdriver or similar tool in place of oil cas} pan cutter blade. 8) Remove oil strainer stay. 9) Remove oil strainer. 472-3b [wsa2) SERVICE PROCEDURE 5. Cylinder Block 10) Remove battle plate. 11) Remove oil filter. 12) Disconnect U-shaped hose from cylinder block, 13) Remove bolt which secure engine coolant pipe to cyl- inder block. 14) Remove connector pipe. 15) Remove oil cooler. 16) Remove engine coolant pipe from oil cooler.SERVICE PROCEDURE Iwse1] 2-3b 5. Cylinder Block B: DISASSEMBLY 1. PISTON PIN AND CYLINDER BLOCK CONNECTING BOLT 1) Remove service hole cover and service hole plugs using hexagon wrench (14 mm). 2) Rotate crankshaft to bring #1 and #2 pistons to BDC position, then remove piston circlip through service hole of #1 and #2 cylinders.2-3b [wsB1] SERVICE PROCEDURE 5. Gylinder Block 3) Draw out piston pin from #1 and #2 pistons by using ST. ST _ 499097500 PISTON PIN REMOVER CAUTION: Be careful not to confuse original combination of piston, piston pin and cylinder. 4) Similarly remove piston pins from #3 and #4 pistons by using ST. 5) Remove bolts which connect cylinder block on the side of #2 and #4 cylinders, 6) Back off bolts which connect cylinder block on the side of #1 and #3 cylinders two or three turns. 50 |SERVICE PROCEDURE (wse2} 2-3b 5. Cylinder Block 2. CYLINDER BLOCK 41) Set up cylinder block so that #1 and #3 cylinders are on the upper side, then remove cylinder block connecting bolts. 2) Separate left-hand and right-hand cylinder blocks. CAUTION: When separating cylinder block, do not allow the con- necting rod to fall and damage the cylinder block. 3) Remove rear oil seal 4) Remove crankshaft together with connecting rod 5) Remove crankshatt bearings from cylinder block using hammer handle. CAUTION: Do not confuse combination of crankshaft bearings. Press bearing at the end opposite to locking lip. 6) Draw out each piston from cylinder block using wooden bar or hammer handle. CAUTION: Do not confuse combination of piston and cylinder. 512-3b [wse3] SERVICE PROCEDURE 55. Gylinder Block 3. CRANKSHAFT AND PISTON 1) Remove connecting rod cap. 2) Remove connecting rod bearing, CAUTION: Arrange removed connecting rod, connecting rod cap and bearing in order to prevent confusion. 3) Remove piston rings using the piston ring expander. 4) Remove the oil ring by hand CAUTION: Arrange the removed piston rings in good order to pre- vent confusion. 5) Remove circlip. 52 jrr SERVICE PROCEDURE [wscz] 2-3b 5. Cylinder Block C: INSPECTION 4. CYLINDER BLOCK 1) Check for cracks and damage visually. Especially, inspect important parts by means of red check. 2) Check the oil passages for clogging, 3) Inspect crankcase surface that mates with cylinder head for warping by using a straight edge, and correct by arinding if necessary. Warping limit: 0.05 mm (0.0020 in) Grinding limit: 0.1 mm (0.004 in) 2. CYLINDER AND PISTON 1) The cylinder bore size is stamped on the cylinder block's front upper surface. NOTE: Standard sized pistons are classified into three grades, “A” and “B", These grades should be used as a guide line in selecting a standard piston. Standard diameter: ‘A: 92.005 — 92.015 mm (3.6222 — 3.6226 in) B: 91.995 — 92.005 mm (3.6218 — 3.6222 in) Main journal size mar. 77 peau ace Ru #2 cylinder bore size mare tt eytinder bore size mark | gS eyinder bore size marc 532-3b [wsc2} 5, Oylinder Block SERVICE PROCEDURE [AS Thvust direction BB Piston pin rection it mm fn) 10 (0.36) 451.77) 20 (3.15) 115 1653) 520 mm 2097 ny 2) How to measure the inner diameter of each cylinder Measure the inner diameter of each cylinder in both the thrust and pistcn pin directions at the heights shown in the figure, using a cylinder bore gauge. CAUTION: Measurement should be performed at a temperature 20°C (68°F). Taper: Standard 0.015 mm (0.0006 in) Limit 0.050 mm (0.0020 in) Out-of-roundness: Standard 0.010 mm (0.0004 in) Limit 0.050 mm (0.0020 in) 3) When piston is to be replaced due to general or cylin- der wear, determine a suitable sized piston by measuring the piston clearance. 4) How to measure the outer diameter of each piston Measure the ouler diameter of each piston at the height shown in the figure. (Thrust direction) CAUTION: Measurement should be performed at a temperature of 20°C (68°F). Piston outer diameter: Standard ‘A: 91.985 — 91.995 mm (3.6214 — 3.6218 in) B: 91.975 — 91.985 mm (3.6211 — 3.6214 in) 0.25 mm (0.0098 in) oversize 92.225 — 92.235 mm (3.6309 — 3.6313 in) 0.50 mm (0.0197 in) oversize 92.475 — 92.485 mm (3.6407 — 3.6411 in) 5) How to measure the clearance between cylinder and piston CAUTION: Measurement should be performed at a temperature of 20°C (68°F). Cylinder to piston clearance at 20°C (68°F): Standard 0.010 — 0.030 mm (0.0004 — 0.0012 in) Limit 0.060 mm (0.0024 in)SERVICE PROCEDURE 6) Boring and honing (1) Ifthe value of taper, out-of-roundness, or cylinder- to-piston clearance measured exceeds the specified limit or if there is any damage on the cylinder wall, rebore it to use an oversize piston. CAUTION: When any of the cylinders needs reboring, all other cyl- inders must be bored at the same time, and use over- size pistons. Do not perform boring on one cylinder only, nor use an oversize piston for one cylinder only. (2) Ifthe cylinder inner diameter exceeds the limit after boring and honing, replace the crankcase. CAUTION: Immediately after reboring, the cylinder diameter may differ from its real diameter due to temperature rise. Thus, pay attention to this when measuring the cylinder diameter. Limit of cylinder enlarging (boring): 0.5 mm (0.020 in) 55r__ 2-3b [wsc3} SERVICE PROCEDURE 5. Cylinder Block 3. PISTON AND PISTON PIN 1) Check pistons and piston pins for damage, cracks, and wear and the piston ring grooves for wear and damage, Replace if defective. 2) Measure the piston-to-cylinder clearance at each cy inder as instructed in 2. CYLINDER AND PISTON [WSC2]. If any of the clearances is not to specification, replace the piston or bore the cylinder to use an oversize piston 3) Make sure that piston pin can be inserted into the pis- ton pin hole with a thumb at 20°C (68°F). Replace if defec- tive. Standard clearance between piston pin and hole in piston: 0.001 — 0.013 mm (0.00004 — 0.00051 in) Standard clearance between piston pin and hole in connecting rod: 0 — 0.022 mm (0 — 0.0008 in)‘Second ing ORY or ak SERVICE PROCEDURE twscs] 2-3b 5. Oylinder Block 4. PISTON RING 1) If piston ring is broken, damaged, or worn, or if its ten sion is insufficient, or when the piston is replaced, replace piston ring with a new one of the same size as the piston, CAUTION: ‘© “R” or “N” is marked on the end of the top and sec- ‘ond rings. When installing the rings to the piston, face this mark upward. © The oil ring is a combined ring consisting of two rails and a spacer in between. When installing, be careful to semble correctly. 2) Squarely place piston ring and oil ring in cylinder, and measure the piston ring gap with a thickness gauge. rome | ait thm | e000 Peleesreene | wais tins | 080 ovement | Qa oy | 18005 3) Measure the clearance between piston ring and piston ring groove with a thickness gauge. CAUTION: Before measuring the clearanc groove and piston ring. clean the piston ring Unit: mm (in) ‘Standard Limit ‘0.04 — 008 Clearance | Tepring (o.oo1s— | 0.15 (0.0059) ‘between piston 8.0031) ing and piston 003 — 0.07 ring groove | second ring o.oor2— | 0.15 (o.00sa) .0028) 87r 2-3b [wscs) 5. Cylinder Block SERVICE PROCEDURE ‘S.Gylinder Bloc ccomors| 5. CONNECTING ROD 1) Replace connecting rod, if the large or small end thrust surtace is damaged, 2) Check for bend or twist using a connecting rod aligner. Replace connecting rod if the bend or twist exceeds the limit. Limit of bend or twist per 100 mm (3.94 in) in leng! 0.10 mm (0.0039 in) @ Thickness gauge @ Connecting rod 3) Install connecting rod fitted with bearing to crankshaft and measure the side clearance (thrust clearance). Replace connacting rod if the side clearance exceeds the specified limit Connecting rod side clearance: Standard 0.070 — 0.330 mm (0.0028 — 0.0130 in) Limit 0.4 mm (0.016 in) 4) Inspect connecting rod bearing for scar, peeling, seizure, melting, wear, etc.SERVICE PROCEDURE twscs) 2-3b 5. Cylinder Block 5) Measure the oil clearance on individual connecting rod bearings by means of plastigauge. If any oil clearance is not within specitication, replace the detective bearing with ‘@_new one of standard size or undersize as necessary. (Gee the table below.) Connecting rod oil clearance: Standard 0.0158 — 0.0438 mm (0.0006 — 0.0017 in) Limit 0.05 mm (0.0020 in) Unit: mm (i) arin Bearing size Outer diameter of batts) (Thickness at center) crank pin — 1.492 — 1.501 ‘1.984 — 52.000 (0.057 — 0.0581) _| (2.0486 — 2.0472) (0.03 (0.0012) 1510— 1513 ‘51.958 — 51.970 undersize (0.0594 — 0.0896) | @o4s4 — 2.0461) ‘0.05 (0.0020) 1520 — 1.823 ‘51.998 — 51.950 undersize {0.0588 — 0.0600) | (2.0446 — 2.0459) 0.25 (0.0088) 1.600 — 1.623 51.794 — 51.750 Uundersize (0.0638 — 0.0639) | (2.0368 — 2.0874) 6) Inspect bushing at connecting rod small end, and replace if worn or damaged. Also measure the piston pin clearance at the connecting rad small end Clearance between piston pin and bushing: Standard 0 — 0.022 mm (0 — 0.0009 in) Limit 0.030 mm (0.0012 in) 592-3b [wsce) SERVICE PROCEDURE 55, Gylinder Block 7) Replacement procedure is as follows: (1) Remove bushing from connecting rod with ST and press. (2) Press bushing with ST after applying oil on the periphery of bushing. ST 499037100 CONNECTING ROD BUSHING REMOVER AND INSTALLER (3) Make two 3 mm (0.12 in) holes in bushing. Ream the inside of bushing (4) After completion of reaming, clean bushing to remove chips. 6. CRANKSHAFT AND CRANKSHAFT BEARING 1) Clean crankshaft completely and check for cracks by means of red check etc., and replace if defective, 2) Measure the crankshaft bend, and correct or replace if it exceeds the limit CAUTION: Ifa suitable V-block Is not available, install #1 and #5 crankshaft bearing on cylinder block, position crank- shaft on these bearings and measure crankshaft bend using a dial gaug Crankshaft bend limit: 0.035 mm (0.0014 in)SERVICE PROCEDURE twscs] 2-3b 5. Cylinder Block 3) Inspect the crank journal and crank pin for wear. If not to specifications, replace bearing with an undersize one, and replace or recondition crankshaft as necessary. When grinding crank journal or crank pin, finish them to the specified dimensions according to the undersize bearing to be used Crank pin and crank journi Out-of-roundness 0.03 mm (0.0012 in) or less Taper limit 0.07 mm (0.0028 in) Grinding limit 0.25 mm (0.0098 in) (Thickness at cen- ter) (0.0837 — 0.0809) | (0.0888 — 0.0828) | (0.0838 — 0.0839) | (0.0638 — 0.0699) Unt mm (n) Crank journal s ‘Crank pin 0.0. Hs BH 6 aa ose — 60000 | sece«—eaan0 | eoaes—coooo | si0ea—sa000 ceaere— 2262 | (22st —2oeze) | (2oeie— zee | couse — 20472 hme Bearing size 1908-2011 | 2000-201 | 2000-2019 | s402—1510 neiromatcan | giier—aoreg | gor aacen | womr—eosy | wom — eos Journal 0.0. oo ae oan) - . 51.956 — 51.970 wr (2.3604 — 2.3610) (2.0454 — 2.0461) 0.09 20012 ner Beara ze por —auw | 201-202 | 20m—200 | ss0—1510 fenines atcem | orar—aores | oars oar) | ores ors) | (ent —oosen as sees — taco 7 Sree — si 880 ‘oural (2.3596 — 2.3602) - (2.0446 — 2.0453) 00s (0.0020 undersize Bearing size zozr—2000 | 200—20% | 20-202 | 1500-1509 rianessatcen | worse —ogme) | (oor —aoar) | Care —oanon | (ose —00e) op wares — ta760 7 7 Biya 81780 i (2.3517 — 2.3524) (2.0368 — 2.0374) 0. 0088 indersize arar—2190 | 210-210 | 210—a1se | 1920— 1000 OD. Outer diameter 612-3b [wsce) SERVICE PROCEDURE 5, Oylinder Block 4) Measure the thrust clearance of crankshaft at center bearing. If the clearance exceeds the limit, replace bear- ing, Crankshaft thrust clearance: Standard 0.030 — 0.115 mm (0.0012 — 0.0045 in) Limit 0.25 mm (0.0098 in) 5) Inspect individual crankshaft bearings for signs of flaking, seizure, melting, and wear. 6) Measure the oil clearance on each crankshaft bearing by means of plastigauge. If the measurement is not within the specification, replace defective bearing with an under- size one, and replace or recondition crankshaft as neces- sary. Unit: mm (in) Crankshatt ol clearance ‘0010 — 0030 eee {0.0004 — 0012) Standard 0.010 —0030 (0.0004 — 0.0012) Lime 0.040 (0.0016) 0.035 (0.0014)SERVICE PROCEDURE twso1] 2-3b 5. Cylinder Block D: ASSEMBLY 1. CRANKSHAFT AND PISTON Tightening torque: Nom (kg-m, Rb) Te 446415 (4550.15, 32941.1) 4) Install connecting rod bearings on connecting rods and connecting rod caps CAUTION: Apply oil to the surfaces of the connecting rod bearings. 2) Install connecting rod on crankshatt. CAUTION: Position each connecting rod with the side marked fac- ing forward. 3) Install connecting rod cap with connecting rod nut Ensure the arrow on connecting rod cap faces the front during installation. CAUTION: Each connecting rod has its own mating cap. Make that they are assembled correctly by checking their matching number. ‘© When tightening the connecting rod nuts, apply oil on the threads.2-3b [wsp1) SERVICE PROCEDURE 5. Oylinder Block 4) Installation of piston rings and oil ring (1) Install oil ring spacer, upper rail and lower rail in this order by hand. Then install second ring and top ring with a piston ring expander. (2) Position the gaps of the piston rings and oil ring as shown in the figure, @®: Oil ring lower rail ®: Oil ring upper rail ©: Top ring ©: Second ring 5) Install circtip. Install circlips in piston holes located opposite service holes in oylinder block, when positioning all pistons in the corresponding cylinders. wren ade a enueSERVICE PROCEDURE twsp2] 2-3b 5. Cylinder Block 2. CYLINDER BLOCK 1) Install ST to cylinder block, then install crankshaft bearings, ST 499817000 ENGINE STAND CAUTION Remove oil the mating surface of bearing and cylinder block before installation. Also apply a coat of engine oil to crankshaft pins. 2) Position crankshaft on the #2 and #4 cylinder block. Tightening torque: TH: 255 Nem (2.50.5 kg-m, 18.143.6 ft-lb) T2: 473 Nem (4.80.3 kg-m, 34.742.2 ft-lb) 652-3b [wsp2) SERVICE PROCEDURE 5, Oylinder Block Fs ack \ 3) Apply fluid packing to the mating surface of #1 and #3. cylinder block, and position it on #2 and #4 cylinder block Fluid packing: THREE BOND 1215 or equivalent CAUTION Do not allow fluid packing to jut into O-ring grooves, oll Passages, bearing grooves, etc. 4) Temporarily tighten 10 mm cylinder block connecting bolts in numerical order shown in figure 5) Tighten 10 mm cylinder block connecting bolts in numerical order. ightening torque: 473 Nem (4.80.3 kg-m, 34.7 42.2 ft-lb) 6) Tighten 8 mm and 6 mm cylinder block connecting bolts in numerical order shown in figure, Tightening torque: @ — ©: 2542 Nem (2,540.2 kg-m, 18.1 £1.4 ft-lb) @®: 6.4 N-m (0.65 kg-m, 4.7 ft-Ib) 7) Install rear oil seal by using ST1 and ST2. ST1 499597100 OIL. SEAL GUIDE ST2 499587200 OIL SEAL INSTALLERSERVICE PROCEDURE (wsp3] 2-3b 5. Oylinder’ 3. PISTON AND PISTON PIN (#1 AND #2) 1) Installing piston (1) Turn cylinder block so that #1 and #2 oylinders face upward (2) Using ST1, turn crankshaft so that #1 and #2 con- necting rods are set at bottom dead center. ST1 499987500 CRANKSHAFT SOCKET (3) Apply a coat of engine oil to pistons and cylinders. and insert pistons in their cylinders by using ST2. ST2 498747300 PISTON GUIDE 2) Installing piston pin (1) Insert $73 into service hole to align piston pin hole with connecting rod small end. CAUTION: Apply a coat of engine oil to STS before insertion. ST3 499017100 PISTON PIN GUIDE er2-3b [ws03] SERVICE PROCEDURE 5. Cylinder Block (2) Apply @ coat of engine oil to piston pin and insert piston pin nto piston and connecting rod through service hole. 8) Install circlip. CAUTION: Use a new circlip. 4) Install service hole plug and gasket CAUTION: Use a new gasket and apply a coat of fluid packing to it before installation. Fluid packing: THREE BOND 1215$< SERVICE PROCEDURE wsp4) 2-3b 5. Cylinder Block 4, PISTON AND PISTON PIN (#3 AND #4) Tightening torque: Nem (kg-m, fb) TH 6. 12: 697 (7.0507, 50825.) Turn cylinder block so that #3 and #4 cylinders face upward. Using the same procedures as used for #1 and #2 cylinders, install pistons and piston pins,2-3b [wse1) SERVICE PROCEDURE 5. Oylinder Block E: INSTALLATION 1. OIL PUMP AND ENGINE COOLANT PUMP 7 Tighiening torque: Nm (kg-m, fib) 115 (05,3 12: 6.4 (0.85, 4.7) 73:10 (1, 7) Ta 5445 (55405, 99.83. Ts: 7243 (7.30.3, 82 Te: First 1242 (1.20.2, 8741.4) Second 1222 (1.2402, 8721.4) 70SERVICE PROCEDURE (wse1]) 2-3b 5. Cylinder Block 1) Install baffle plate. 2) Install oil strainer and O-ring 3) Install oil strainer stay. 4) Apply fluid packing to matching surfaces and install oil pan. Fluid packing: THREE BOND 1215 or equivalent 5) Apply fluid packing to matching surfaces and install oil separator cover. Fluid packing: aa THREE BOND 1215 or equivalent 6) Install flywheel. Set ST, and tighten retaining bolts. ST 498497100 CRANKSHAFT STOPPER 7) Install housing cover. 8) Installation of oil pump (1) Discard front oil seal after removal. Replace with a new one by using ST. ST 499587100 OIL SEAL INSTALLER (2) Apply fluid packing to matching surface of oil pump. Fluid packing: THREE BOND 1215 or equivalent (3) Install oll pump on cylinder block. Be careful not to damage oil seal during installation. CAUTION: © Do not forget to install O-ring and seal when install- ing oi! pump. 12-3b [wse1} SERVICE PROCEDURE 5. Cylinder Block. © Align flat surface of oil pump's inner rotor with crank- shatt before installation. 9) Install engine coolant pump and gasket. CAUTION: © Be sure to use a new gasket. © When installing engine coolant pump, tighten bolts in two stages in numerical sequence as shown in figure. 10) Install engine coolant pipes to engine coolant pump. 414) Install oil cooler. 12) Install engine coolant pipe to oil cooler. 48) Install oil filter. 72 jer SERVICE PROCEDURE [sez] 2-3b 5. Cylinder Block 2. RELATED PARTS 1) Install oylinder head and intake manifold. 2) Install timing belt, camshaft sprocket and related parts 2-3b rio) DIAGNOSTICS 41. Engine Trouble in General 1. Engine Trouble in General to the possibilty of reason for the trou- Engine will not star. g ls ls Starter does not turn. Engine stalls after initial combustion Rough idle and engine stall Low output, hesitation and poor acc Dieseling (Run-on} ‘Aer burning in exhaust system. Excessive engine oil consumption Excessive fuel consumotion. z Knocking Surging. POSSIBLE CAUSE STARTER * Detective battery-to-starter harness, Defective tarter ewiteh Detective inhibitor switch 3 [Detective [BATTERY 1 /s Poor terminal connection, a [e Rur-down battery 2 [e Detective charging system teehee 1 [Mel SYSTEM IGNITION SYSTEM 2fel+i+f+{+[a[+]a 1 [e incorrect ignition timing, 3 3. [+ Disconnection of ignition col 2 1 [2 «Detective ignitor. {Detective ignition coll Detective cord or wiring 1 Detective spark plug. 3 2/2 Incorrect eam timing 74DIAGNOSTICS TROUBLE Engine will ot start € 3 € combustion eccurs. Starter does not turn. Engine stalls after i le and engine stal Rough Low output, hesitation and poor acceleration Surging. Engine does not return to ia ‘After burning in exhaust eystem. Excessive engine oil consumption. Knocking, Excessive fuel consumption INTAKE SYSTEM Improper idle adjustment. [* Loosened oF cracked Intake duct | Loosened oF cracked blow-by hose. fe Loosened or cracked vacuum hose. /e Detective air cleaner gasket fe Detective intake manifold gasket [e Detective throttle body gasket. [e Detective POV valve fe Loosened oil filer cap, [e Dirty alr cleaner element FUEL LINE, ‘Defective fuel pump. # Clogged fuel line. [Lack of oF insufficient fuel BELT 2 Detective, Detective timing. FRICTION Seizure of crankshaft and connecting rod bearng ‘Seized camshaft ¢ Seized or stuck piston and cylinder. [COMPRESSION fe Detective hydraulic ih adjuster, [e Loosened epark plugs oF defective gasket fe Loosened oylinder head nuts or detective gasket /e Improper valve seating [e Detective valve ster, fe Worn or broken valve spring. [e Worn or stuck piston rings, cylinder and piston =lele[e[elelel= fe Incorrest valve timing. wlelelslolelelole »|=[elelefelefels [e Improper engine oll (low viscosliy) 752-3b ri00) DIAGNOSTICS 4. Engine Trouble in General TROUBLE Engine witrotstat.] | & 2 5 § a j Blas e| |als | i glele £ t 8\e 2/elels|2 flels| [3] 3 Zlalel3 Bley €\3 4 2/2] 8] slslel sells 3 glele|elelslz}s]3l3 H e/2(2/e|e/2)2/8) 8] & é El é{ alae] s[2[e [a] a UBRIGATION SYSTEM z[2 3 2 |e incorrect oi pressure 7 | [a toosened ot pump ataching boli and delaive i 2 2 3 2 [|e Detective rocker cover gasket 2 | |e Loosened ot drain plug or detective gasket 2 | [e-Loosened ol pan iting bots or detective ol pan i COOLING SYSTEM afelel [2 i e Overheating 3 3 3 |e over cooing loTHens Thats 3 Je Malfunction of Evaporative Emission Contra System 1 e Stuck or damaged throte valve 2[2 2 [> Accelerator cable out of adustment, 76$e DIAGNOSTICS 11200) 2-3b 2. Engine Noise Hydraulic valve lash adjusters may make clicking noise once engine starts. It is normal if clicking noise ceases ater a few minutes, It clicking noise continues after a few minutes, check engine oil level and add oil if necessary. Warm-up engine {or five minutes, then operate it at approximately 3,000 rom for twenty minutes. If noise still exists, conduct diagnostics procedures in accordance with the following table, CAUTION: Do not disconnect ignition coil from spark plug while engine is running. ‘Type of sound Condition Possible cause Valve mechanism is defective Je Broken lash adjuster Sound increases as engine |e Worn valve rocker. speed increases. Je Worn camshaft /¢ Broken valve spring Je Worn valve liter hole. Regular clicking sound Je Worn crankshaft main bearing, Je Worn connecting rod bearing (big end). [+ Loose tlywhee! mounting bolts. Je Damaged engine mounting, Oil pressure is low. Heavy and dull metallic knock. Oil pressure is normal ignition timing advanced High pitched metallic knock |Sound is noticeable when} Accumulation of carbon inside combustion chamber. (Engine knocking) accelerating with an overload. | Wrong spark plug [+ improper gasoline Metalic Knock when engine| Sound is reduced when fuel speed is medium (1,000 to| injector connector of noisy! 2006 rpm cylinder is disconnected ‘© Worn crankshaft main bearing. ‘© Worn bearing at crankshaft end of connecting rod Knocking sound when engine | cylinder is disconnected. |e Worn piston pin and hole at piston end of connecting rod. disconnected in turn. ‘¢ Worn camsialt journal bore in crankcase, Squeaky sound. = * Insufficient alternator lubrication, ‘I Rubbing sound = [Detective alternator brush and rotor contac. Gear scream when starting _ Detective ignition starter switch. engine Je Worn gear and starter pinion. Sound like polishing al Je Loose timing belt ith a dry cloth. Je Detective engine coolant pump shat [+ Loss of compression. Hissing sound = Js Air leakage in air intake system, hoses, connections or manifolds. [+ Loose timing bet. Timing bett noi S HW Belt contacting case/adiacer 7ENGINE LUBRICATION SYSTEM 2-4 Page S SPECIFICATIONS AND SERVICE DATA 1. Specifications © COMPONENT PARTS 1. Lubrication System W SERVICE PROCEDURE ..........c.scsesestensen sesso 2 1. Oil Pump 2. Oil Pan and Oil Strainer 3. Oil Pressure Switch 4. Oil Cooler (Turbo model) .....:.sese T DIAGNOSTICS 1. Engine Lubrication System © The descriptions in this section apply to the turbo model.2-4 [wang] SERVICE PROCEDURE 4. Oi Cooler (Turbo model) 4. Oil Cooler (Turbo model) A: REMOVAL 1) Remove water pipe. 2) Remove oil filter 3) Remove connector and remove oil cooler. B: INSPECTION 1) Check that coolant passages are not clogged using air blow method. 2) Check mating surfaces of cylinder block, O-ring groove and oil filter for damage.SERVICE PROCEDURE [waco] 2-4 4.01 Cooler (Turbo model) C: INSTALLATION 1) Install oil cooler on cylinder block with connector pipe. 2) Install oil filter Tightening torque: T: 49 — 59 N-m (5.0 — 6.0 kg-m, 36 — 43 ft-Ib) CAUTION: Always use a new O-ring.FUEL INJECTION SYSTEM [MFI-TURBO] 2-7b (© COMPONENT PARTS 2 4. Collector Chamber and Intake Manifold. 2 2. Air Intake System 3 3. Air Cleaner. oo 4 4. Turbocharger Unit... : : 5 S SERVICE PROCEDURE. . 6 Air Cleaner and Air Intake Duct 6 7 7 8 1 2. Intercooler 3. Mass Air Flow Sensor 4. Throttle Body. . = 5. Collector Chamber and Intake Manifold. concen 6. Engine Coolant Temperature Sensor : 15 7. Crankshatt Position Sensor... nee . 16 8 Oxygen Sensor. . corner TB 9. Knock Sensor 17 10. Throttle Position Sensor. 18 11. Camshaft Position Sensor eoentatnmneanneneseseie 12. Idle Air Control Solenoid Valve . . 20 43. Purge Control Solenoid Valve. 24 14, Turbocharger Unit... 24 15. Fuel Injector . 24 16. Engine Contro! Module. 25 17. Main Relay and Fuel Pump Relay... 262-7 {C100} COMPONENT PARTS 4, Collector Chamber and Intake Manifold 1. Collector Chamber and Intake Manifold ‘manifold gasket LH ® Insulator manifold ® Fuel injector save @ OFA @ @ @ Plug ® ong JOT ewsine cooker fewer) ® Fue injector pipe © Engine coolant hose 8 etwas @ Air control valve 2 Me tld gask @ Air control valve spring 2) Remove intercooler.2-7b [wsao} ‘5. Collector Chamber and Intake Manifold SERVICE PROCEDURE 3) Disconnect accelerator cable ® 4) Disconnect connector from throttle position sensor. 5) Disconnect connectors from fuel injectors. 6) Disconnect engine coolant hose from idle air control solenoid valve 7) Disconnect air inlet hose. 8) Disconnect engine coolant hoses from throttle body.SERVICE PROCEDURE [sao] 2-7b 5. Collector Chamber and Intake Manifold 9) Disconnect brake booster hose. 10) Disconnect air by-pass hoses from intake manifold. 11) Disconnect emission hoses from intake manifold. 12) Remove coolant filler tank. 18) Disconnect canister hose from pipe. 14) Disconnect fuel hosas from pipes, WARNING: Catch fuel from hoses in a container. 15) Remove bolts which hold power steering pipe bracket onto intake manifold, 16) Remove bolts which hold intake manifold onto cylin- der heads.2-7b [wsBo) SERVICE PROCEDURE 5. Collector Chamber and Intake Manifold 17) Disconnect connector from purge control solenoid valve on inner side of collector chamber. 18) Remove collector chamber and intake manifold. B: DISASSEMBLY 1) Remove throttle body. 2) Remove idle air control solenoid valve. C: ASSEMBLY 1) Assemble idle air control solenoid valve. ( CAUTION: Replace gaskets with new ones. Tightening torque: 6 —7 Nem (0.6 — 0.7 kg-m, 4.3 — 5.1 ft-lb) 2) Assemble thrcttle body. CAUTION: Replace gasket with a new one. Tightening torque: 14 — 24 Nem (1.4 — 2.4 kg-m, 10 — 17 ft-lb) 2 aSERVICE PROCEDURE twsp0) 2-7b 8. Collector Chamber and Intake Manifold D: INSTALLATION 1) Connect connector to purge control solenoid valve on inner side of collector chamber. 2) Install intake manifold and collector chamber onto cy inder heads. CAUTION: Always use new gaskets. Tightening torque: 20 — 34 Nem (2.0 — 3.5 kg-m, 14 — 25 ft-lb) 3) Install power steering pipe bracket onto intake mani- fold 4) Connect fuel hoses. 5) Connect canister hoses.5. Collector Chamber and Intake Manifold 2-7b [wspo} SERVICE PROCEDURE 6) Connect brake booster vacuum hose. 7) Connect air by-pass hoses. 8) Connect emisson hoses. 9) Install engine coolant filler tank 10) Connect engire coolant hoses to throttle body. 11) Connect engine coolant hose to idle air contro! sole- noid valve, ( 12) Connect air inlet hose 13) Connect connectors to fuel injectors.SERVICE PROCEDURE 5 5. Colector Chamber andItake Maid - 6 Engine Coolant Temporary Seer, 14) Connect connector to throttle position sensor. 18) Connect accelerator cable ® 16) Install intercooler. 6. Engine Coolant Temperature Sensor A: REMOVAL AND INSTALLATION 1) Remove resonator chamber and air inlet duct A 2) Disconnect connector from engine coolant tempera- \ ture sensor. 3) Remove engine coolant temperature sensor.2-7b [w7ao} SERVICE PROCEDURE 6. Engine Coolant Temperature Sensor - 8. Oxygen Sensor 4) Installation is in the reverse order of removal. Tightening torque: 22 — 27 Nm (2.2 — 2.8 kg-m, 16 — 20 ft-lb) 7. Crankshaft Position Sensor A: REMOVAL AND INSTALLATION 1) Remove bolt which install crankshatt position sensor to cylinder block 2) Remove crankshaft position sensor, and disconnect connector from it. 8. Oxygen Sensor ‘A: REMOVAL 1) Disconnect conrector from oxygen sensor. 2) Apply SUBARU CRC or its equivalent to threaded por- tion of oxygen sensor, and leave it for one minute or more. SUBARU CRC (Part No. 004301003) 3) Remove oxygen sensor. CAUTION: When removing oxygen sensor, do not force oxygen sensor free, especially when exhaust pipe is cold. Otherwise, it will damage exhaust pipe.SERVICE PROCEDURE twsao] 2-7b 8_ Oxygen Sensor - 9. Knock Sensor B: INSTALLATION 1) Before installing oxygen sensor, apply anti-seize com- Pound only to threaded portion of oxygen sensor to make the next removal easier. Anti-seize compound: $8-30 by JET LUBE CAUTION: Never apply anti-seize compound to protector of oxygen sensor. 2) Install oxygen sensor. Tightening torque: 41 — 47 Nem (4.2 — 4.8 kg-m, 30 — 35 ft-lb) 3) Connect connector of oxygen sensor. 9. Knock Sensor A: REMOVAL AND INSTALLATION 1) Remove intercooler. 2) Disconnect connector from knock sensor. 3) Remove knock sensor on cylinder block. 4) Installation is in the reverse order of removal.SERVICE PROCEDURE 10. Throttle Position Sensor A: REMOVAL AND INSTALLATION 1) Disconnect connector from throttle position sensor. 2) Remove throttle position sensor holding screws, and remove it 3) Installation is in the reverse order of removal Tightening torque: 2.0 — 2.4 Nem (0.20 — 0.24 kg-m, 1.4 — 1.7 ft-lb) CAUTION: When installing throttle position sensor, adjust to the specified data. B: ADJUSTMENT 1. THROTTLE POSITION SENSOR 1) Turn ignition switch to OFF. 2) Loosen throttle position sensor holding screws, 3) When using voltage meter; (1) Take out ECM, (2) Turn ignition switch to ON. (3) Adjust throttle position sensor to specified voltage between ECM connector terminal. Connector & Terminal | Specified voltage LHD (B108) No. 2 — (B108) No. 1 | 4.5 —5.5 V RHD (B95) No. 2 — (B95) No.1 | 4.5—5.5 V [Fully closed.] (4) Tighten threttle position sensor holding screws, 4) When using the Select Monitor; (1) Attach Select Monitor. (2) Turn ignition switch to ON. (8) Select mode "F10” (4) Adjust throtle position sensor to specified data Condition 1 Specified dat Throttle fully closed. | 4.7 V (6) Tighten throttle position sensor holding screws 18SERVICE PROCEDURE twi1ao) 2-7b 40. Throt ion Sensor - 11. Camshatt Position Sensor 2, IDLE SWITCH 1) Turn ignition switch to OFF. 2) Loosen throttle position sensor holding screws. 3) When using voltage meter; (1) Take out ECM (2) Turn ignition switch to ON. (3) Adjust throttle position sensor to specified voltage between ECM connector terminal. Connector & Terminal / Specified voltage LHD (B109) No. 6 — Body | 0 V RHD (B96) No. 6 — Body 0 V [Fully closed.) (4) Tighten throttle position sensor holding screws. 4) When using the Select Monitor, (1) Attach Select Monitor, (2) Turn ignition switch to ON. (3) Select mode “FA1". (4) Make sure that No. 1 LED is turned ON when throttle valve is fully closed (6) Tighten throttle position sensor holding screws. 11. Camshaft Position Sensor : REMOVAL AND INSTALLATION 1) Disconnect connector from camshaft position sensor. 2) Remove camshaft position sensor from camshaft sup- port LH. 192-7b [wizao} SERVICE PROCEDURE 411, Camshatt Position Sensor - 12. Idle Air Control Solenoid Valve 3) Installation is in the reverse order of removal. Tightening torque: 49 N-m (5.0 kg-m, 36 ft-lb) 12. Idle Air Control Solenoid Valve A: REMOVAL AND INSTALLATION 1) Remove intercooler. 2) Disconnect connector from idle air control solenoid valve. 3) Disconnect engine coolant hose from idle air control solenoid valve. 4) Disconnect air inlet hose. 5) Remove bolts which install idle air contro! solenoid valve to collector chamber. 6) Installation is in the reverse order of removal proce- dure. CAUTION: Replace gasket with a new one. Tightening torque: 6 —7 Nem (0.6 — 0.7 kg-m, 4.3 — 5.1 ft-lb)SERVICE PROCEDURE twiaao) 2-7b 13. Pure Control Solenoid Valve - 14. Turbocharger Unit 13. Purge Control Solenoid Valve A: REMOVAL AND INSTALLATION 1) Remove bolt which installs bracket of purge control solenoid valve onto collector chamber. 2) Take out purge control solenoid valve with bracket through the bottom of the collector chamber. 3) Disconnect connector and hoses from purge control solenoid valve. 4) Installation is in the reverse order of removal 14. Turbocharger Unit A: REMOVAL 1) Remove intercooler. 2) Remove turbocharger cooling duct. 3) Remove turbocharge’ lower cover. 4) Disconnect connector from oxygen sensor. 212-7b [wi4ao) SERVICE PROCEDURE 414, Turbocharger Unit 5) Remove nuts and bolts which install center exhaust pipe to turbocharger. 6) Lift-up the vehcle. 7) Separate center exhaust pipe trom rear exhaust pipe. 8) Remove bolt which installs center exhaust pipe to bracket 9) Remove center exhaust pipe 10) Lower the vehicle. 11) Separate intercooler air duct from turbocharger. 22SERVICE PROCEDURE twi4a0] 2-7b 14. Turbocharger Unit 12) Disconnect hoses of pressure control line from turbo- charger unit, 13) Disconnect engine coolant hose and engine oil hose. 14) Remove bolt which installs oil pipe bracket onto tur- bocharger unit 15) Remove nuts which install turbocharger unit on turbo joint pipe, 16) Remove turbocharger unit.2-7b [wisao] SERVICE PROCEDURE 44, Turbocharger Unit - 15. Fuel Injector 17) Installation is in the reverse order of removal proce- dure. CAUTION: When installing turbocharger unit, connect engine coolant outlet hose to turbocharger unit. © Replace gasket with a new one. Tightening torque: 29:3 Nem (3.00.3 kg-m, 222.2 ft-lb) 15. Fuel Injector A: REMOVAL AND INSTALLATION 1) When removing the #1 fuel injector, remove coolant filler tank, 2) When removing the #3 fuel injector, remove resonator chamber and air inlet duct A 3) Release fuel pressure. 4) Disconnect connector from fuel injector. 5) Remove fuel injector from fuel pipe assembly. 24SERVICE PROCEDURE 15, Fuel Injector S@s—~~ y SISA 6) Installation is in the reverse order of removal. cauTior Replace O-rings and insulator. Tightening torqui : 21 — 2.9 Nem (0.21 — 0.30 kg-m, 1.5 — 2.2 ft-lb) ® Oring B @ O-ring A ® Fuel injector @ Insulator © Fuel injector cup 16. Engine Control Module A: REMOVAL AND INSTALLATION 1) Disconnect battery ground cable. 2) Detach floor mat of front passenger seat. 3) Remove protect cover. 4) Remove nuts which install ECM onto body. 5) Take out ECM and disconnect connector from it. 252-7b [wi7Ao] 46. Engine Control Module - 17. SERVICE PROCEDURE lay and Fuel Pump Relay. ‘) 6) Installation is in the reverse order of removal. 17. Main Relay and Fuel Pump Relay A: REMOVAL AND INSTALLATION 1) Disconnect battery ground cable. 2) Remove screw which installs bracket of main relay @ and fuel pump reley @ 3) Disconnect comectors from main relay and fuel pump relay. 4) Installation is in the reverse order of removal @ Main relay @ Fuel pump relay 26FUEL SYSTEM 2-8 Page S SPECIFICATIONS AND SERVICE DATA 1. Specifications © COMPONENT PARTS 1. Fuel Tank. 2, Fuel Line W_ SERVICE PROCEDURE... 1. Precautions 2. OnCar Services 3. Fuel Tank 4. Fuel Filler Pipe 5. Fuel Filter 6. 7. 8. 9. Fuel Pump. Fuel Meter Unit Fuel Delivery, Return and Evaporation Lines Canister 10. Fuel Sub Meter Unit (Turbo model only) 41. Fuel Cut Valve (AWD model only) .. T DIAGNosTics 1. Fuel System2-8 [c103] 4. Fuel Tank COMPONENT PARTS 1. Fuel Tank 3. TURBO MODEL 7 B2e809000080 Heat sealed cover Fuel tank band Protector LH. Protector RH Fuel tank Fuel pump gasket Fuel pump ASSY Fuel cut valve gasket Fuel cut valve Evaporation hose C Evaporation hose A Clip ® Clamp ® 4) Fuel pipe ASSY @ Jet pump hoe B @ ® Evaporation hose E @ Fuel sub meter gasket @ Jet pump titer @ Fuel sub meter unit Tightening torque: Nm (kg-m, fb) Th: 3—6(0.3—08,22— 4.3) 12 55 70) 72)SERVICE PROCEDURE twioao} 2-8 40. Fuel Sub Meter Unit (Turbo model only} 10. Fuel Sub Meter Unit (Turbo model only) A: REMOVAL AND INSTALLATION 1) Disconnect battery ground cable. 2) Remove rear seat, 3) Remove service hole cover, 4) Disconnect connector from fuel sub meter. 5) Disconnect fuel jet pump hose. 6) Remove fuel sub meter unit 7) Installation is in the reverse order of removal proce- dure Tightening torque: T: 3 — 6 Nem (0.3 —0.6 kg-m, 2.2 — 4.3 ft-lb)2-8 pwitag) SERVICE PROCEDURE 11, Fuel Cut Valve (AWD model only) 11. Fuel Cut Valve (AWD model only) A: REMOVAL AND INSTALLATION 1) Remove fuel tank, 2) Disconnect evaporation hose from fuel cut valve. 3) Remove fuel cut valve, 4) Installation is in the reverse order of removal proce- dure. Tightening torque: 3 — 6 Nem (0.3 — 0.6 kg-m, 2.2 — 4.3 ft-lb)EXHAUST SYSTEM 2-9 Page © COMPONENT PARTS......... ; 1. Exhaust System 2. Exhaust System (Turbo model)... - 2 W SERVICE PROCEDURE...........- sveneinn 4 1. Front Exhaust Pipe and Center Exhaust Pipe 2. Rear Exhaust Pipe 3. Muffler 4, Front Exhaust Pipe (Turbo model)... oe wa 5. Center Exhaust Pipe (Turbo model) 8 ‘© The descriptions in this section apply to the turbo model2-9 [c201) 2. Exhaust System (Turbo model) COMPONENT PARTS: 2. Exhaust System (Turbo model) 1, FRONT EXHAUST PIPE Gasket Upper exhaust manifold cover (RH) Exhaust manifold (RH) Lower exhaust manifold cover (RH) Bracket ® Upper clamp B Upper cover © Upper insulator 8 Upper insulator A Gasket Front joint pipe ® Lower insulator B ® Lower insulator A ® Lower cover C ® Lower clamp B Gasket Gasket Upper exheust manifold cover (LH) Exhauet manifold (LH) Lower exhaust manifold cover (LH) Gasket Turbocharger joint pipe Gasket eeeeeess z : z = i = 3 3: 30 — 9 (3. 0) Ta: 34— 44 (3.5 — 45, 25 — 33)COMPONENT PARTS 2.Ex [¢202] 2-9 ist System (Turbo mod 2, CENTER AND REAR EXHAUST PIPE, AND MUFFLER oe 3 t e D Gasket ® Bot 2 Oxygen sensor © Cushion 3. Upper center pipe cover ® Gasket 4 Center exhaust pipe ® Cushion 5) Lower center pipe cover ® Mutter 8 Bracket (MT) ® Mutier cuter ee Tiahening torque © Fear exhaust pipe ning torque: Nn ® Upper cover eae Lower cover Upper cover A ® Lower cover A ® Spring2-9 twaao} SERVICE PROCEDURE 4, Front Exhaust Pipe (Turbo model) 4, Front Exhaust Pipe (Turbo model) A: REMOVAL 1) Remove lower exhaust manifold cover (RH). 2) Remove lower and upper exhaust manifold covers (LH). 3) Remove bolts and nuts which hold front exhaust pipe assembly to turbocharger joint pipe. 4) While holding front exhaust pipe assembly with one hand, remove nuts which hold front exhaust pipe asser- bly to cylinder head exhaust port. 5) Remove front exhaust pipe assembly. 6) Remove covers from exhaust manifold and front exhaust pipe. 7) Separate front exhaust pipe from exhaust manifolds. 8) Remove turbocharger cooling duct. 9) Remove turbocharger joint pipe.SERVICE PROCEDURE (wapo] 2-9 4, Front Exhaust Pipe (Turbo model) B: INSTALLATION CAUTION: Replace gaskets with new ones. 4) Install turbocharger joirt pipe. Tightening torque: 25 — 35 N-m (2.6 — 3.6 kg-m, 19 — 26 ft-lb) 2) Install turbocharger cooling duct. Tightening torque: 5.4 — 9.3 Nem (0.55 — ).95 kg-m, 4.0 — 6.9 ft-lb) 3) Assemble front exhaust pipe and exhaust manifolds. Tightening torque: 25 — 35 N-m (2.6 — 3.6 kg-m, 19 — 26 ft-lb) 4) Install front exhaust pipe covers. Tightening torque: 30 — 40 N-m (3.1 — 4.1 kg-m, 22 — 30 ft-lb) 5) Install upper exhaust manifold cover (RH). Tightening torque: 17 — 20 N-m (1.7 — 20 kg-m, 12 — 14 ft-lb) 6) Install front exhaust pipe assembly. Tightening torque: 34 — 44 Nm (3.5 — 45 kg-m, 25 — 33 ft-lb) 7) Connect exhaust manifold (RH) to turbocharger joint pipe. Tightening torque: 25 — 35 Nem (2.6 — 3.6 kg-m, 19 — 26 ft-lb) 8) Install upper and lower exhaust manifold covers (LH) Tightening torque: 17 — 20 Nem (1.7 — 2.0 kg-m, 12 — 14 ft-lb) 9) Install lower exhaust manifold cover (RH), Tightening torque: 17 — 20 Nem (1.7 — 2.0 kg-m, 12 — 14 ft-lb)2-9 (wsao) SERVICE PROCEDURE 5. Center Exhaust Pipe (Turbo model) 5. Center Exhaust Pipe (Turbo model) A: REMOVAL 1) Remove turbocharger cooling duct. 2) Disconnect connector from oxygen sensor. 3) Remove turbocharger lower cover. 4) Separate center exhaust pipe from turbocharger. 5) Separate center exhaust pipe from rear exhaust pipe.SERVICE PROCEDURE [wse0] 2-9 5. Center Exhaust Pipe (Turbo model) 6) Remove intercooler bracket. 7) Remove bolt which holds center exhaust pipe to hanger bracket CAUTION: Be careful not to pull down center exhaust pipe. 8) Remove center exhaust pipe, B: INSTALLATION CAUTION: Replace gaskets with new ones. 1) Install center exhaust pipe and temporarily tighten bolt which holds center exhaust pipe to hanger bracket. 2) Install center exhaust pipe to rear exhaust pipe. Tightening torque: 13 — 23 Nm (1.3 — 2.3 kg-m, 9 — 17 ft-lb) 3) Install intercooler bracket and loosely tighten bolts. 4) Connect center exhaust pipe to turbocharger. Tightening torque: 25 — 35 Nem (2.6 — 3.6 kg-m, 19 — 26 ft-lb)2-9 [wseo) SERVICE PROCEDURE 5. Center Exhaust Pipe (Turbo model) 5) Tighten bolt which holds center exhaust pipe to hanger bracket, Tightening torqu 30 — 40 N-m (3.1 — 4.1 kg-m, 22 — 30 ft-Ib) 6) Tighten bolts which hold intercooler bracket. Tightening torque: 30 — 40 Nem (3.1 — 4.1 kg-m, 22 — 30 ft-lb) 7) Install turbocharger lower cover. Tightening torque: 5.4 — 9.3 Nem (0.55 — 0.95 kg-m, 4.0 — 6.9 ft-lb} 8) Connect connector to oxygen sensor. 9) Install turbocharger cooling duct. Tightening torque: 5.4 — 9.3 Nem (0.55 — 0.95 kg-m, 4.0 — 6.9 ft-lb)S SPECIFICATIONS AND SERVICE DATA W SERVICE PROCEDURE. 4. Clutch System nner © COMPONENT PARTS 1. Clutch System... : 2. Clutch System (Hydraulic application type) 3 Master Cylinder and Reservoir Tank wc. 1. General. On-Car Service Release Bearing and Lever .. Clutch Disc and Cover nner Operating Cylinder.. Master Cylinder and Reservoir Tank (LHD Mode). Master Cylinder and Reservoir Tank (RHD Model) Clutch Damper (LHD Model) ..... DIAGNOSTICS 1. Clutch System @Ne@maen-2-10 [s1A0) SPECIFICATIONS AND SERVICE DATA 4, Clutch System 1. Clutch System A: SPECIFICATIONS FWD AWD) 2000 ce 1600 ce 1800 ce weo0ee | teo0ee | 2002 e Push ype Pulltype cute cover 2 a 2 Diaphragm set load kg (b) 400 (082) 440 (970) | 450/092) | 700 (1.548) Facing mater 7 Woven (Non asbestos) 490 x 192 x 8.5]200 x 130 x 35]215 x 10x 35 a Jctuch disc 0.0. x1.0.x thickness mm (n)| (7.48. x 520 x|(787 x 512 x|(648 x 581 x] igae'sereoris8) 0.198) 0.198) 0.198) e * Spline 06, ‘im (in| 222 (0.874), (No. of teeth: 21) 25.2 (0.982), (No. of teeth: 24) ae lever ratio 30 17 Grease-packed sel-aligning : SERVICE DATA Ao ry woe | womce | voor | twee | me coo pda! [Fuerte rom seo — 150,651 —599) aa) svoxe mm) 24 — 25 0.94 — 1.02 os —osre oes eer Play at ralease lever center a — 4 (0.12016) 13—19 3319 Depth of rivet head | "248" ost —o.o7s)| 4 1.958) (0.051 — 0.075) mm (in) [Limit of clutch aise sinking 0.3 (0.012) 110 (0088) at A] .0 (0.036) at A 1.0 (0.039) at R t Limit for detection mm (in| ‘© (0050) 8 Bead 02 (uaz) | 12 (2.098) at R = 107 (4.29COMPONENT PARTS {c100) 2-10 4. Clutch System 1. Clutch System @ Clutch cable bracket © Cteh disc @ Clutch release lever sealing @ Return spring @ Retainer spring © Clutch return spring bracket @ Pivot © Clutch release lever Tightening torque: Wm (kgrm, fib) © Clip Te157245 (62015, 1.621.) ® Clutch release bearing ® Clutch cover2-10 [c201) COMPONENT PARTS 2. Clutch System (Hydraulic application type) 2. Clutch System (Hydraulic appli type) 1. LHD MODEL coma a — say enee © Clutch hose & Release j ‘ @ Clutch damper (@ Release bearing ‘T3: 397 £3 (3.80.3, 27.5+2.2)COMPONENT PARTS {c202] 10 2, Clutch System (Hydraulic application type) 2. RHD MODEL @ snap pin @ Operating cylinder ® Cluten disc @ Release lever dust cover © Flywheel Tightening torque: Wm (kg-m, 1b) TH: 1843 (1.8403, 130222) 12: 3743 (3.8402, 27522) T3: 4443 (45403, 925422) © Sealed cover © Clutch pipe ® Clutch hose2-10 [ca01) COMPONENT PARTS 3. Master Cylinder and Reservoir Tank 3. Master Cylinder and Reservoir Tank 4. LHD MODEL © Reservoir cap @ Master cylinder @ Reservoir tank © Piston © Reser band rofeated feta @ Piston stop ringCOMPONENT PARTS [e307] 2-10 3. Master Cylinder and Reservoir Tank 2, RHD MODEL, @ Reservoir cap @ Master cylinder @ Reservoir tank © Piston @ Reservoir band @ Push rod @ Seat © Piston stop ring 72-10 twiao} o Service SERVICE PROCEDURE 1. General A: PRECAUTION When servicing clutch system, pay attention to the follow- ing items. 2. HYDRAULIC APPLICATION TYPE 1) Check fluid level using scale on outside of reservoir tank. 2) Make sure that clutch fluid does not leak from master cylinder, operating cylinder and piping. 3) Apply grease sufficiently to the release lever pinion, 2. On-Car Service 2. HYDRAULIC APPLICATION TYPE Bleed air from oil line with the help of a co-worker. 1) Fit one end of a vinyl tube into the air bleeder of clutch damper and put the other end into a clutch fluid con- tainer. 2) Slowly depress the clutch pedal and keep it depressed. Then open the air bleeder to discharge air together with the fluid. Release the air bleader for 1 or 2 seconds. Next, with the bleeder closed, slowly release the clutch pedal. 3) Repeat these steps until there are no more air bubbles, in the vinyl tube CAUTION: Cover bleeder with waste cloth when loosening it, to prevent clutch fluid from being splashed over surround- ing parts.SERVICE PROCEDURE 2, On-Gar Servi 4) Tighten air bleeder. Tightening torque: T: 18£3 Nem (1.840.3 kg-m, 13.0 £2.2 ft-lb) 5) Repeat steps 1) through 3) using air bleeder on oper- ating cylinder. 6) Tighten air bleeder. Tightening torque: T: 183 Nem (1.80.3 kg-m, 13.0 2.2 ft-lb) 7) After depressing the clutch pedal, make sure that there are no leaks evident in the entire system. 8) For RHD models, repeat steps 5) through 7) of LHD models 3. Release Bearing and Lever A: REMOVAL 2. HYDRAULIC APPLICATION TYPE Remove release bearing and lever after separating engine and transmission. 1) Remove release lever from transmission. 2) Put release bearing in engine side. 3) Remove release bearing from clutch cover using flat- type screwdriver.2-10 twscoy 3. Release Bearing and Lev Ne “Wy 1 4 Ke | SERVICE PROCEDURE C: INSTALLATION Before or during assembling, lubricate the following points with a light coat of grease. @ Inner groove of release bearing © Contact surface of lever and pivot ¢ Contact surface of lever and bearing @ Transmission main shaft spline (Use grease containing molybdenum disulphide.) 2. HYDRAULIC APPLICATION TYPE 1) Position both release lever and bearing on transmis- sion. 2) Install release lever shatt CAUTION: Be sure to fit groove on release lever shaft into pin located at through-hole. 3) With release lever held in that position, connect engine and transmission, 4) Push release lever to fit bearing into clutch cover. 5) Install plug. Tightening torque: 4443 Nem (4540.3 kg-m, 32.542.2 ftolb) 10SERVICE PROCEDURE wast] 2-10 4, Clutch Disc and Cover 4. Clutch Disc and Cover B: INSPECTION 1. CLUTCH Disc 1) Facing wear Measure the depth of rive! head from the surface of fac- ing. Replace if facings are worn locally or worn down to less than the specified value. Depth of rivet head: Standard value 1800 cc FWD model: 1.4 mm (0.055 in) 1600 cc FWD model: 1.3 — 1.9 mm (0.051 — 0.075 in) AWD model: 1.3 — 1.9 mm (0.051 — 0.075 in) Limit of sinking 0.3 mm (0.012 in) CAUTION: Do not wash clutch disc with any cleaning flui 2) Hardened facing Correct by using emery peper or replace. 3) Oil soakage on facing Replace clutch disc and inspect transmission front oil seal, transmission case mating surface, engine rear oil seal and other points for oil leakage. 4) Deflection on facing If deflection exceeds the specified value at the outer cir- cumference of facing, repair or replace. Limit for deflection: 1800 cc FWD model: 1.0 mm (0.039 in) at R 1600 cc FWD model: 1.0 mm (0.039 in) at R 1600 cc AWD model: 4.0 mm (0.039 in) at R = 102 mm (4.02 in) 1800 ce AWD and 2000 cc TURBO model: 1.0 mm (0.039 in) at R = 107 mm (4.21 in) 95 mm (3.74 in) 90 mm (3.54 in) n2-10 [wsao] SERVICE PROCEDURE 4, Clutch Disc and Cover - 5. Operating Cylinder 5) Worn spline, loose rivets and torsion spring failure Replace defective parts, 5. Operating Cylinder A: REMOVAL AND INSTALLATION 1) Remove intercooler. 2) Remove clutch hase from operating cylinder. CAUTION: Cover hose joint to prevent clutch fluid from flowing out. 3) Remove operating cylinder from transmission. 4) Installation is in the reverse order of removal. Tightening torque: Tt: 18:43 Nem (1.80.3 kg-m, 13.0+2.2 ft-lb) T2: 3743 Nem (3.80.3 kg-m, 27.5 42.2 ft-lb)SERVICE PROCEDURE tweao] 2-10 6. Master Cylinder and Reser ir Tank (LHD Model) 6. Master Cylinder and Reservoir Tank (LHD Model) A: REMOVAL 1) Remove snap pin @, clevis pin @ and separate push rod @ of master cylinder from clutch pedal. 2) Remove intercooler. 3) Remove clutch hose from master cylinder. CAUTION: Plug up hose connection to prevent clutch fluid from spilling out. 4) Remove master cylinder with reservoir tank 3Reserva tank Ss So = Bracket SERVICE PROCEDURE der and Reservoir Tank (LHD Modé INSPECTION It any damage, deformation, wear, swelling, rust or other faults are found on the cylinder, piston, push rod, fluid reservoir, seat and gesket, replace the faulty part. C: INSTALLATION 4) Install master cylinder to body, CAUTION: Always use a new gasket. Tightening torqu 1843 N-m (1.840.3 kg-m, 13.0+2.2 ft-lb) 2) Install clutch hose to master cylinder. CAUTION: Check that hose is routed properly. Tightening torque: 18:43 Nem (1.80.3 kg-m, 13.0 2.2 ft-lb) 3) Connect push rod @ of master cylinder to clutch pedal, and install clevs pin @ and snap pin ® 14SERVICE PROCEDURE twrag) 2-10 6, Master Cylinder and Reservoir Tank (LHD Model) -7. Master Gylinder and Reservoir Tank (RHD Model) 4) Install intercooler. 7. Master Cylinder and Reservoir Tank (RHD Model) A: REMOVAL 1) Remove snap pin ®, ckvis pin @ and separate push rod @ of master cylinder from clutch pedal 2) Remove clutch pipe from master cylinder. CAUTION: Plug up hose connection to prevent clutch fluid from spilling out. 3) Remove master cylinder with reservoir tank.SERVICE PROCEDURE INSPECTION I any damage, deformation, wear, swelling, rust or other faults are found on the cylinder, piston, push rod, fluid reservoir, seat and gasket, replace the faulty part. C: INSTALLATION 1) Install master cylinder to body. CAUTION: Always use a new gasket. Tightening torque: 2183 Nem (1.80.3 kg-m, 13.0+2.2 ft-lb) 2) Install clutch hose to master cylinder. CAUTION: Check that hose is routed properly. Tightening torque: T: 18:43 Nem (1.840.3 kg-m, 13.0+2.2 ft-lb) 3) Connect push rod @ of master cylinder to clutch pedal, and install clevis pin @ and snap pin @ 16SERVICE PROCEDURE 10) 2-10 8, Clutch Damper (LHD Model 8. Clutch Damper (LHD Model) A: REMOVAL AND INSTALLATION 1) Remove clutch hoses from clutch damper, CAUTION: Cover hose joint to prevent clutch fluid from flowing out. 2) Remove clutch damper with bracket. 3) Installation is in the reverse order of removal Tightening torqi T1: 18-3 Nem (1.80.3 kg-m, 13.0 2.2 ft-lb) 72: 373 Nem (3.80.3 kg-m, 2752.2 ft-lb)ENGINE AND TRANSMISSION MOUNTING SYSTEM -l 1 © COMPONENT PARTS. 1. Engine Mounting. 2 2. Transmission Mounting a 3 W SERVICE PROCEDURE 7 4 1. General Precaution 4 2. Engine — 5 3. Transmission... eo : 29 © The descriptions in this section apply to the turbo model.2-11 [c100) COMPONENT PARTS 41. Engine Mounting 1. Engine Mounting como @ Heat shield cover Tightening torque: Nem (haem, Fb) @ Front cushion rubber en nee ae @ Front engine mounting bracket 12:91 51 (92 — 52,29 — 38) TS: 54 — 83 (55 — 85, 40 — 61)COMPONENT PARTS [203 2-11 2. Transmission Mounting 2 anission Mounting 2. Transmission Mounting 3. TURBO MODEL Pitching stopper Rear cushion rubber (AWD) }) Rear crossmember 3) Cushion 0 3) Center crossmember © Cushion ® Rear plate Front erossmember Spacer Front plate Tightening torque: Kim (kg-m, eb) Ti: 28 — 38 (28 — 3.9, 21 — 28)2-11. p10 SERVICE PROCEDURE 4. General Precaution ——_—_—_—WJ 1. General Precaution 1) Remove or install engine and transmission in an area where chain hoists, lifting devices, etc. are available for ready use. 2) Be sure not to damage coated surfaces of body pan- els with tools or stain seats and windows with coolant or oll. Place a cover over fenders, as required, for protection 3) Prior to starting work, prepare the following: Service tools, clean cloth, containers to catch coolant and oil, wire ropes, chain hoist, transmission jacks, etc. 4) Lift up or lower the vehicle when necessary. Make sure to support the correct positions. (Refer to Chapter 1-3 "General Information”.)SERVICE PROCEDURE tw2ao) 2-11 2. Engine 2. Engine REMOVAL 7 Set the vehicle on Hit arms, |2 Open front hood and support with a stay jease fuel pressure. SSCS {8 Remove battery from vehicle. 5 Remove window washer tank 6, Drain coolant [7 Remove cooling system. SS™~S~SC«SY: wit Ar 1 [f. Collect refrigerant, and remove pressure hose. —————e—eoeee [a Remove air inake system ¥ 16. Remove canister and bracket. + Fi, Disconnect connectors, cables and hoses. ¥ [12 Remove starter. | Td. Remove power sleering pump from bracket. + [4 Remove center exhaust pipe id t 15, Remove nuis which hold lower side of ransmission To engine. 16. Remove nuts which install front cushion rubber onto front cxosemember 7. Separate clutch 18. Remove pitching stopper. Penne reat | 18. Disconnect fuel delivery hose, return hose and evapora tion hose, [20. Remove fuel iter and bracket 21. Support engine with a liting device and wire ropes. | 22. Suppor transmission with a garage jack. 23. Remove baits which hol engine Lees 28. Remove engine Wom vehicle Transmission to ‘upperSERVICE PROCEDURE >A VV IPF comeo| 1) Set the vehicle on ift arms, 2) Open front hood fully and support with stay. 3) Release {uel pressure (1) Disconnect connector from fuel pump. (2) Start the engine, and run until it stalls (8) After the engine stalls, crank it for five seconds more. (4) Turn ignition switch to “OFF”. 4) Remove battery from vehicle. 5) Remove window washer tank. 6) Drain coolant Set container under the vehicle, and remove drain cock from radiator.SERVICE PROCEDURE tweag) 2-11 2. Engine 7) Remove cooling system. (1) Disconnect radiator fan motor connector. (2) Disconnect radiator outlet hose from thermostat cover. (3) Remove V-belt cover. (4) Disconnect radiator inlet hose from radiator. (5) Remove coolant filler tank,2-11 [wag] SERVICE PROCEDURE 2. Engine (6) Remove radiator upper bracket, and remove radi- ator assembly from vehicle. 8) Collect refrigerant, and remove pressure hoses. (With Alc) (1) Place and connect the attachment hose to the refrigerant recycle system. (2) Collect refrigerant from A/C system, (3) Disconnect A‘C pressure hoses from A/C com- pressor. 9) Remove air intake system (1) Remove resonator chamber. (2) Disconnect connector from mass air flow sensor. (3) Remove air ceaner upper cover and air cleaner element.SERVICE PROCEDURE (weno) au gine (4) Remove intercooler. 10) Remove canister and bracket 11) Disconnect connectors, cables and hoses. (1) Disconnect the following connectors, ® Engine harness connectors @ Engine ground terminal @ Battery ground harness @ Alternator connector and terminal ® AIC compressor connectors (With A/C)2-11 tw2ao} SERVICE PROCEDURE 2. Engine CAUTION: When disconnecting battery ground harness @, remove bracket.SERVICE PROCEDURE (2) Disconnect the following cables. ‘Accelerator cable @® Clutch release spring2-11 (w2ao) SERVICE PROCEDURE 2. Engine (8) Disconnect the following hoses. @® Brake booster vacuum hose @ Heater inlet and outlet hosesSERVICE PROCEDURE (weno) al gine 12) Remove starter. 13) Remove power steering pump from bracket. (1) Loosen lock bolt and slider bolt, and remove front side V-belt. (2) Remove pipe with bracket from intake manifold (3) Remove bolts which install power steering pump from bracket. (4) Place power steering pump on the right side whee! apron.2-11 [w2ao} SERVICE PROCEDURE 14) Remove center exhaust pipe. (1) Remove turbocharger cooling duct. (2) Remove turbocharger lower cover. (3) Disconnect connector from oxygen sensor. (4) Remove nuts and bolts which install center exhaust pipe to turbocharger. (6) Lift up the vericle. (6) Remove intercooler bracket.SERVICE PROCEDURE (wao} 2-11 2. Engine (7) Separate center exhaust pipe from rear exhaust pipe. (8) Remove bolt which installs center exhaust pipe on hunger bracket. CAUTION: Exhaust pipe will drop when all bolts are removed. So, hold it when removing the last bolt. (9) Remove center exhaust pipe. 15) Remove nuts which hold lower side of transmission to engine. 16) Remove nuts which install front cushion rubber onto front crossmember.2-11 [w2aoy SERVICE PROCEDURE 17) Separate clutch release fork from release bearing. (1) Remove clutch operating cylinder, from transmis- sion. (2) Remove plug using 10 mm hexagon wrench, (3) Screw 6 mm dia. bolt into release fork shaft, and remove it. (4) Raise release ‘ork and untasten release bearing tabs to free release fork CAUTION: Step (4) is required to prevent interference with engine when removing engine from transmission. 18) Remove pitching stopper. 19) Disconnect fuel delivery hose, return hose and evap- oration hose. CAUTION: Catch fuel irom hose into con! 16SERVICE PROCEDURE (weao) 2-11 2. Engine 20) Remove fuel filter and bracket. 21) Support engine with a lifting device and wire ropes. 22) Support transmission with a garage jack. CAUTION: Before moving engine away from transmission, check to be sure no work has been overlooked. Doing this is very important in order to facilitate re-installation and because transmission lowers under its own weight, 23) Remove bolt which holds right upper side of transmis- sion to engine.SERVICE PROCEDURE 24) Remove engine from vehicle. (1) Slightly raise engine. (2) Raise transmission with garage jack. (3) Move engine horizontally until mainshatt is with- drawn from clutch cover. (4) Slowly move engine away from engine compart- ment CAUTION: Be careful not to damage adjacent parts or body panels with crank pulley, oil pressure gauge, etc. 18SERVICE PROCEDURE (w2e0) 2-11 2. Engi : INSTALLATION iTinstal clutch release Tork and bearing onto transmission, install engine to wanemission__——=~S~*~*~«~d Tighten bolts which hold upper side of Wanemission fo engine =e Remove lifting device and wire rope, i. Remove garage Jack ‘instal pitchin _ ‘TTnstal starter OY] Tinstal el iter and bracket ———SSSS~S~S~SY ‘TTastall canister and bracket 0. Install power steering pump on bracket, ‘7 Tighten nuts which hold lower ede of tanemission to engine 2, Tighten nuts which install front cushion rubber onto crossmember. 3 Install center exhaust pipe. Connect hoses, connectors and cables 5 Install ar intake system: ae J 6. Install A/C pressure hoses, Tinatall cooing ayatom——SSCSCSC~S~S~S*id “install window washer Tank Install battery onto the vehicle, and connect cables. Fill coolant, Charge A/C system with refrigerant. Remove front hood stay, and close front hood. 192-11 [w2e0) 2.Engine SERVICE PROCEDURE 1) Install clutch release fork and bearing onto transmis- sion. (1) Remove release bearing from clutch cover with flat type screw driver. (2) Install release bearing on transmission. (3) Insert release fork into release bearing tab. (sunucH 2) (4) Apply grease to specified points: Spline FX2200 © Shaft SUNLIGHT 2 (5) Insert release fork shatt into release fork. CAUTION: Make sure the cutout portion of release fork shaft con- tacts spring pin. 20SERVICE PROCEDURE (6) Tighten plug. Tightening torque: 39 — 49 N-m (4.0 — 5.0 kg-m, 29 — 36 ft-lb) 2) Install engine onto transmission. (1) Position engine in engine compartment and align itwith transmission. CAUTION: Be careful not to damage adjacent parts or body panels with crank pulley, oil pressure gauge, etc. (2) Apply a small amount of grease to splines of main- shatt 3) Tighten bolt which hold right upper side of transmis- sion to engine Tightening torque: 46 — 54 Nem (4.7 — 5.5 kg-m, 34 — 40 ft-lb) 4) Remove lifting device and wire ropes. 5) Remove garage jack. 6) Install pitching stopper. Tightening torque: Ti: 44 — 4 Nem (4.5 — 5.5 kg-m, 33 — 40 ft-lb) Ta: 47 — 67 N-m (4.8 — 6.8 kg-m, 35 — 49 ft-lb) 242-11 wee0] SERVICE PROCEDURE 2. Engine, 7) Install starter. 8) Install fuel filter and bracket. 9) Install canister and bracket. CAUTION: Insert air vent hose of canister into the hole on body. 10) Install power steering pump on bracket (1) Install power steering pump on bracket, and tighten bolts. Tightening torque 29 — 49 N-m (3 — 5 kg-m, 22 — 36 ft-lb) (5 Bain exif ant (2) Install power steering pipe bracket on right side intake manifold, and install spark plug codes. 22SERVICE PROCEDURE (w2e0) 2-11 2. Engine (3) Install front side V-belt, and adjust it. 11) Tighten nuts which hold lower side of transmission to engine. Tightening torque: 46 — 54 N-m (4.7 — 5.5 kg-m, 34 — 40 ft-lb) 12) Tighten nuts which install front cushion rubber onto crossmember. Tightening torque: 54 — 83 N-m (5.5 — 8.5 kg-m, 40 — 61 ft-lb) CAUTION: Be sure to tighten front cushion rubber mounting bolts in the innermost elliptical hole in the front crossmem- ber. 18) Install center exhaust pipe. (1) Place center exhaust pipe on vehicle. (2) Install center exhaust pipe to rear exhaust pipe.2-11 [w2B0] SERVICE PROCEDURE (3) Install intercooler bracket. (4) Install bolt which installs center exhaust pipe to hanger bracket. (5) Lower the vehicle. (6) Install nuts and bolts which install center exhaust pipe to turbocharger. (7) Attach connector to oxygen sensor. (8) Install turbocharger lower cover. 24SERVICE PROCEDURE (weo) 2-11 2. Engine (9) Install turbocharger cooling duct. 14) Connect hoses, connectors and cables. (1) Connect the following hoses. © Fuel delivery hese, return hose and evaporation hose © Heater inlet and outlet hoses © Brake booster vacuum hose (2) Connect the following connectors and terminals. Engine ground terminal © Engine harness connectors # Alternator connector and terminal ‘© AC compressor connectors (With A/C) (3) Connect the following cables. © Accelerator cable @ Clutch release spring CAUTION: After connecting each cable, adjust them. 15) Install air intake system. (1) Install intercooler. (2) Install air cleane’ element and air cleaner upper cover.2-11 (w250) SERVICE PROCEDURE (3) Install resonator chamber. (4) Connect connector to mass air flow sensor. 16) Install A/C pressure hoses. (With A/C) CAUTION: Use new O-rings. Tightening torque 18 — 31 Nem (1.8 — 3.2 kg-m, 13 — 23 ft-lb) 17) Install cooling system. (1) Attach radiator mounting cushions to pins on lower side of radiator. (2) Fit cushions on lower side of radiator, into holes on body side ang install radiator.SERVICE PROCEDURE (wepo) 2-11 2. Engine (3) Install radiator brackets and tighten bolts, Tightening torque: 12.3 — 15.2 Nm (1.25 — 1.55 kg-m, 9.0 — 11.2 ft-lb) (4) install coolant filer tank. (6) Connect radiator inlet hose. (6) Connect radiator outlet hose. (7) Connect radiator fan motor connector. (8) Install V-belt cover.2-11 [w2e0) SERVICE PROCEDURE 2. Engine en 18) Install window washer tank. 49) Install battery ir the vehicle, and connect cables. 20) Fill coolant. 21) Charge A/C system with refrigerant, 22) Remove front hood stay, and close front hood, 23) Remove the veticle from lift arms. 28SERVICE PROCEDURE [wsao] 2-11 —_— — — iission 3. Transmission ‘A: REMOVAL 7 Open front hood fully, and support it with stay 2. Disconnect battery ground termin 4. Disconnect connectors and cables ee Remove starter + [&. Remove operating cylinder 7. Remove clutch damper. a fg. Remove plching stopper (9, Remove transmission connector bracket 41, Remove propeller shaft. + 12, Remove gear shift rod and stay from Wanemission, 18. Set special to [14 Remove bolt which hoids right upper side of transmis- sion to engine {cere —__-—_________] 16. Remove bolle which Intall slablizer clamp onto crass member 16, Remove front drive shalt from Wwanemission, ————————————— 17, Remove nuls which hold lower side of Wransmission to engine, 18. Place tansmission jack une - 19, Remove wanemission rear orossmember (20. Remove Wansmission,2-11 [wsao) SERVICE PROCEDURE 3. Transmission 1) Open front hocd fully, and support with stay. 2) Disconnect battery ground terminal, 3) Remove air inteke system. (1) Remove resonator chamber. (2) Remove intercooler. 4) Disconnect connectors and cables. (1) Disconnect the following connectors. © Vehicle speed sensor 2 @ Transmission harness connector @ Transmission ground terminalSERVICE PROCEDURE twaao} 2-11 3. Transmission (2) Disconnect the following cable. © Clutch release spring 5) Remove starter. (1) Disconnect connectors and terminal from starter. (2) Remove bolt which installs upper side of starter. (3) Remove nut which installs lower side of starter, and remove starter from transmission. 6) Remove operating cylinder. I Dervs Ae Xj OR \) N 7) Remove clutch damper. 8) Remove pitching stopper. 312-11 (w3aoy SERVICE PROCEDURE 3. Transmission 9) Remove transmission connector holder bracket. 10) Remove exhaust system (1) Remove turbocharger cooling duct. (2) Remove turbocharger lower cover. (3) Disconnect connector from oxygen sensor. (4) Remove nuts and bolts which install center exhaust pipe to turbocharger. 32SERVICE PROCEDURE (5) Lift up the vehicle. (6) Remove intercooler bracket. (7) Separate center exhaust pipe from rear exhaust pipe. (8) Remove bolt which installs center exhaust pipe on hunger bracket. CAUTION: Exhaust pipe will drop when all bolts are removed. So, hold it when removing the last bolt. (9) Remove center exhaust pipe. (10) Separate rear exhaust pipe from muffler.2-11 [wag] SERVICE PROCEDURE 3. Transmission (11) Remove rear exhaust pipe. 11) Remove propeller shatt (1) Remove heat shield cover. (2) Remove front cover of rear differential mount. (3) Separate propeller shaft from rear differential (4) Remove bots which hold center bearing onto body. CAUTION: Be careful not to drop propeller shaft. (5) Remove propeller shaft from transmission. CAUTION: © Be sure to use an empty container to catch oil flow- Ing out when removing propeller shaft. © Be sure not to damage oll seals and the frictional surface of sleeve yoke. © Be sure to plug the opening in transmission after removal of propeller shaft.SERVICE PROCEDURE 12) Remove gear shift rod and stay from transmission. (1) Remove spring (2) Disconnect stay from transmission. (3) Disconnect rod ‘tom transmission. 18) Lower the vehicle, and set special tool. ST 41099AA000 ENGINE SUPPORT NOTE: Also is available Part No. 927670000. 14) Remove bolt which holds right upper side of transmis- sion to engine. 1) Remove bolts which install stabilizer clamp onto crossmember. 16) Remove front drive shaft from transmission. (1) Remove transverse link from housing. (2) Lower transverse link.2-11 wsao} SERVICE PROCEDURE 3 Transmission (3) Remove spring pin and separate front drive shaft from each side of the transmission ‘CAUTION: Discard removing spring pin. Replace with a new one, 17) Remove nuts which hold lower side of transmission to engine, 18) Place transmission jack under transmission. CAUTION: Always support transmission case with a transmission Jack. 19) Remove transmission rear crossmember. 20) Remove transmission. CAUTION: Move transmission jack t withdrawn from clutch cov ard rear until mainshatt is 36SERVICE PROCEDURE [spo] 2-11. B: INSTALLATION [i Install clutch release fork and bearing onto transmission. | [2 install wanemission to engine, —SSSS~«@d: ee [S_ntal ranamission —— +d [& Take off wanemiasion jack [f: Tighten nuts which hold lower side of transmission to] engine. {spe [& Tighten balt which holds right upper side of transmission 7. Remove special tools. i + Tr stall gear shift rod and stay, + [i install propeliershaft——SCSCS~S~S~S«S 13, natal exhaust ayater 14, Wnstall clutch damper 15. Irstal operating eylind t 16, lasall wanemission connector holder bracket + 17. Connect connectors and cables 18. estall starter 18. instal i intake system + 20, Connect battery ground cable. 21. Take off the vet le from lift arm, 372-11 (wse0) SERVICE PROCEDURE (suNUGHT 2) 1) Install clutch release fork and bearing onto transmis- sion. (1) Remove relzase bearing from clutch cover with flat type screwdriver. (2) Install release bearing onto transmission. (3) Insert release fork into release bearing tab. (4) Apply grease to specified points: © Spline FX2200 @ Shaft SUNLIGHT 2 (6) Insert release fork shaft into release fork. CAUTION: Make sure the cutout portion of release fork shaft con- tacts spring pin. 38SERVICE PROCEDURE twse0) 2-11 3. Transmission (6) Install plug. Tightening torque: 41 — 47 Nm (4.2 — 4.8 kg-m, 30 — 35 ft-Ib) 2) Install transmission onto engine. (1) Gradually raise transmission with transmission jack. (2) Engage them at splines CAUTION: Be careful not to strike mainshatt against clutch cover. 8) Install transmission rear cross member. Tightening torque: 4 — 83 N-m (5.5 — 8.5 kg-m, 40 — 61 ft-lb) 18 — 157 Nem (12 — 16 kg-m, 87 — 116 ft-lb) 4) Take off transmission jack. 5) Tighten nuts which hold lower side of transmission to engine. Tightening torque: 46 — 54 N-m (4.7 — 5.5 kg-m, 34 — 40 ft-lb) 6) Tighten bolt which holds right upper side of transmis- sion to engine Tightening torque: 46 — 54 Nem (4.7 — 5.5 kg-m, 34 — 40 ft-lb)2-11 [wsB0) SERVICE PROCEDURE 3, Transmission 7) Remove special tcol. 8) Install pitching stopper. Tightening torque: Ti: 44 — 54 N-m (4.5 — 5.5 kg-m, 33 — 40 ft-lb) T2: 47 — 67 Nem (4.8 — 6.8 kg-m, 35 — 49 ft-lb) 9) Install front drive shaft into transmission. (1) Lift up the vehicle (2) Install front drive shatt into transmission. (3) Drive spring pin into chamfered hole of drive shaft CAUTION: Always use a new spring pin. (4) Install ball joint of lower arm into knuckle arm of housing, and tighten installing bolt Tightening torque: 25 — 29 Nem (2.5 — 3.0 kg-m, 18 — 22 ft-Ib) 10) Install stabilizer Tightening torque: 21 — 28 Nem (2.1 — 2.9 kg-m, 15 — 21 ft-lb) mp onto front cross member. 40SERVICE PROCEDURE Iwse0) 2-11 3. Transmission 11) Install gear shift rod and stay. (1) Install gear shitt rod onto transmission. (2) Install stay onto transmission. (3) Install spring 12) Install propeller shaft. (1) Install propeller shatt into transmission (2) Tighten bolts which install propeller shaft onto companion flange of rear differential Tightening torque: 24 — 39 Nem (2.4 — 4.0 kg-m, 17 — 29 ft-lb) (3) Install center bearing bracket on body. Tightening torque: 47 — 57 N-m (4.8 — 5.8 kg-m, 35 — 42 ft-lb) (4) Install heat shield cover. 43) Install exhaust system. (1) Install rear exhaust pipe to muffler Tightening torque: 43 — 53 Nm (4 4 — 5.4 kg-m, 32 — 39 ft-lb) 4 i2-11 [wsB0] SERVICE PROCEDURE 3. Transmiss (2) Place center exhaust pipe on vehicle. (3) Install center exhaust pipe to rear exhaust pipe. 1.3 — 2.3 kg-m, 9 — 17 ft-lb) (4) Tighten bolt which installs center exhaust pipe to hunger bracket. Tightening torque: 25 — 35 Nem (2.5 — 3.6 kg-m, 18 — 26 ft-lb) (5) Install intercooler bracket (6) Lower the vehicle. (7) Install nuts and bolts which install center exhaust pipe to turboctarger. 42SERVICE PROCEDURE {wso] 2-11 3.4 (8) Install turbocharger lower cover. (9) Attach connector to oxygen sensor. (10) Install turbocharger cooling duct. 14) Install clutch damper. (LHD model) Tightening torque: 10 — 31 N-m (1.8 — 3.2 kg-m, 13 — 29 ft-lb) 15) Install operating cylinder. Tightening torqué 34 — 40 Nem (3.5 — 4.1 kg-m, 25 — 30 ft-lb)SERVICE PROCEDURE cauen 16) Install transmission connector holder bracket. 17) Connect conneciors and cables. (1) Connect the ‘ollowing connectors. © Transmission harness connectors @ Transmission ground terminal © Vehicle spead sensor 2 (2) Connect the following cable. @ Clutch release spring 18) Install starter. (1) Install starter onto transmission case, and connect connectors and terminals, (2) Tighten bolt and nut which install starter onto transmission Tightening torque: | 46 — 54 Nem (4.7 — 5.5 kg-m, 34 — 40 ft-lb) 19) Install air intake system, (1) Install interccoler.SERVICE PROCEDURE (2) Install resonator chamber. 20) Connect battery ground cable. 21) Take off vehicle from lift arms. [wseo) 2-11 3. TransmissionMANUAL TRANSMISSION AND DIFFERENTIAL 3 S SPECIFICATIONS AND SERVICE DATA. 1. Manual Transmission and Differential... © COMPONENT PARTS... sensenason Transfer Case and Extension (AWD) Rear Case (FWD) Transmission Case. Shifter Fork and Shifter Rod Drive Pinion Assembly Main Shaft Assembly Center Differential Front Differential RVICE PROCEDURE ... General Transfer Case and Extension (AWD Model) Rear Case (FWD Model) Transmission Case (AWD Single-range Model). Transmission Case (AWD Dual-range Model) Transmission Case (FWD Model) Drive Pinion Assembly (AWD Model) Drive Pinion Assembly (FWD Model) Input Shaft Assembly (AWD Dual-range Model) 10. Main Shaft Assembly (AWD Dual-range Model) 11. Main Shaft Assembly (AWD Single-range Model) 12. Main Shaft Assembly (FWD Model) 13. Center Differential (AWD Model) 14. Front Differential T DIAGNOSTICS 1, Manual Transmission and Differential Bieta oats elena terre © The descriptions in this section apply to the turbo model 1 e 2 2 4 163-1 [s1a0] SPECIFICATIONS AND SERVICE DATA J. Manual Transmission and Differential 1. Manual Transmission and Differential A: SPECIFICATIONS Mode! tem FW AWD 2000 ce 1600 ce 1800 ce 1600 ce 1800 ce 2000 ee Sorward speeds with synchromesh and treverse Tyee 11 (8 x 24orward speeds with synchromesh and t-reverse) 1st 3.598 3.586 3.454 2nd 2.105 2a 1.987 ra 1428 148 1368 Transmission gear ratio oS 1.088 1.088 0.972 sth 0.825 0.825 0738 Reverse 3.588 3416 3416 7 High 1.000 ‘Auxiliary transmission gear = - ratio Low 11592 Front [Type of gear Hypoid reduction [Final [Gear ratio ‘3.900 ‘3.900 Type of gear = Helical Transfer yee ct Gear ratio = 1.000 500 - Type of gear = Hypoid (Gear ratio = ‘3.900 3546 fro | pinion: 2, Bevel gear: Fret inlay [TYP and number of gear Straight bevel gear (Bevel pinion: 2, Bevel gear: 2) fa ‘Siraight bevel gear Center ‘Type and number af gear - (Bevel pinion: 2, Bevel gear: 2 and viscous sitferentiat coupling) Rear Straight bevel gear ditferentiat_|T¥P@ and number of gear = (Bevel pinion: 2, Bevel gear: 2) ‘Transmission gear oil os ‘Transmission gear oil capacity 26 €(27 US at, 23 Imp at "2.40 € (42 US qt, 35 Imp a) Rear diferential gear oll capacity = 08 £ (0.8 US at. 07 Imp at “ Duabrange model only "2 Fulltime AWD onlySPECIFICATIONS AND SERVICE DATA [s1810) 3-1 ‘1. Manual Transmission and Differential B: SERVICE DATA 10. DRIVE PINION ASSEMBLY (Full-time wo) Proload adjustment of thrust bearing Starting torque 0.3 —08 Nim (8 —8 kg-cm, 26 — 69 in-b) ‘Adjusting washer No. 1 PartNo. Thickness ram (in) 200026054 3.025 (0.1545) | ‘00025052 3.950 (0.1555) 909025053 ‘3.975 (01565) 909025054 “4.000 (0.1875) 03025055 4.025 (0.1585) s025086 4.050 (0.1594) 03026057 4.075 (0.1604) ‘Adjusting washer No. 2 PartNo. Thiokness mm (in) ‘00026059 8.850 (0.1516) ‘00026054 4.000 (0.1678) ‘00025058 4.150 (0.1634) ‘Assemble a driven sha and tal driven gear that are selected forthe proper radial clearance adjustment. Daven shat ist aiven gear artno. | P'ameter® | panne, | spec 49960 — | scasiaazro aaazannso | S009 vscce — [ szasraasoo | Tube «ager — | szzsianceo | Nonturbo sezaonnizo | f0075_ eara | sezaraaseo | Turbo3-1 [C300] rec ‘ansmission Case COMPONENT PARTS 3. Transmission Case @ Transmission case ASSY @ Gasket @ Drain plug @ Snap ring (Outer) ® Speedometer driven gear © Washer @ Speedometer shat @ Snap ring (Outer) @ Oil seat @ Oil level gauge { Pitching stopper bracket ® clamp @ Clip ® Oil seal (AWD Dual-range) ® Oil level gauge (Turbo model) Tightening torque: Nm (ka-m, lb) T4483 (45403, 925222) she ‘All models Torque: 8mm bolt o-6 25L2Nm (2502 ko-m, 18.1214 tb) 10 mm bolt @-@ o-® 392m (402 kam, 2891.4 hb)COMPONENT PARTS [cso 3-1 6. Main Shaft Assembly 6. Main Shaft Assembly 1. AWD SINGLE-RANGE MODEL © Olt seat @® Needle bearing @ Transmission main shaft @ in needle bearing race ® Needle bearing ® Coupling sleeve ® Shitting insert @ 4th drive gear ® 4th goar thrust washer ® Sth drive gear @ Insert stopper plate @ Lock washer3-1 pw SERVICE PROCEDURE Satin Case (AWD Single range Model) 4. Transmission Case (AWD Single-range Model) A: DISASSEMBLY 3. SEPARATION OF TRANSMISSION CASE (TURBO. MODEL) 1) Remove clutch release lever @ and bearing @). (Refer to 2-10 clutch.) 2) Remove bearing mounting bolts.SERVICE PROCEDURE waasy 4. Transmission Case (AWD Single-range Model 3) Remove main shaft rear plate @ 4) Separating transmission case (1) Put vinyl tape around splines of right and left axle drive shafts to prevent damage to oil seals (2) Separate transmission case into right and et cases by loosening seventeen coupling bolts and nuts, 5) Remove drive pinion shaft assembly © trom lett side transmission case NOTE: Use a hammer handle, etc. to remove if too tight. 6) Remove main shaft assembly @ 7) Remove differential assembly ® CAUTION: © Be careful not to confuse right and left roller bearing outer races. © Be careful not to damage retainer oil seal.3-1 [wasa] ‘SERVICE PROCEDURE Transmission Case (AWD Single-range Model) B: ASSEMBLY 3. COMBINATION OF TRANSMISSION CASE (TUREO MODEL) Tightening rque: Nm (kg-m, Rb) @5, 18) £3 (3.00.3, 21.7422) 1) Alignment marks/figures on hypoid gear set ® The upper figure on driven pinion is the match number for combining it with hypoid driven gear. The lower figure is {for shim adjustment. If no lower figure is shown, the value is zero. The figure on hypoid driven gear indicates a rum- ber for combination with drive pinion.SERVICE PROCEDURE (wap3] 3-1 | 4, Transmission Case (AWD Single-range Model) 2) Adjustment of drive pinion shim @ ate (1) Place drive pinion shaft assembly on right hand transmission main case without shim and tighten bearing mounting bolts. (2) Inspection and adjustment of ST NOTE: wae © Loosen the two bolts and adjust so that the scale indi- cates 05 correctly when the plate end and the scale end Vea are on the same level cauosss] _@ Tighten the two bolls. ST 499917500 DRIVE PINION GAUGE ASSY ‘lust cearance to zor (3) Position the ST by inserting the knock pin of ST witout shim, into the knock hole in the transmission case. (4) Slide the drive pinion gauge scale with finger tip and read the value at the point where it matches with the end face of drive pinion. (6) The thickness of shim shall be determined by add- ing the value indicated on drive pinion to the value indicated on the ST. (Add if the figure on drive pinion is prefixed by + and subtract if the figure is prefixed by—) ST 499917500 DRIVE PINION GAUGE ASSY Select one to three shims from the next table for the value determined as described above and take a shim thickness which is closest to the said value. eve pio om Paria Thickness mm Uo) deaa8An0st 0.150 (0.086 8A 0.175 (0.080 SOSA 0.200 (0.078) OSA 0.225 (0.080) MSAAITH 0.280 (0.086 i ‘32295AA081 0.275 (0.0108) iW ‘22206AA081 0.300 (0.0118) i SREGAATO 0500 (00187) | © rocamara 10 SERVICE PROCEDURE 3) Install differential assembly ® on left hand transmis- sion case. CAUTION: Be careful not to {old the sealing lip of oll seal. NOTE: Wrap the left and right splined sections of axle shaft with vinyl tape to prevent scratches, 4) Install needle bearing and oil seal onto the front of transmission main shaft assembly @, and position in left side transmission case. CAUTION: © Wrap clutch splined section with vinyl tape to prevent lamage to oil seal. © Apply grease (Unilube #2 or equivalent) to the seal- ing lip of oil seal. NOTE: @ Align the end face of seal with surface A of left side transmission main case when installing oil seal. © Be careful not to drop oil seal when installing right side transmission main case. © Make sure straight pin is positioned in hole in needle bearing’s outer race. 5) Install drive pinion shaft assembly @ with shims selected before into transmission case. NOTE: Ensure that the knack pin of the case is fited into the hole in the bearing outer race.SERVICE PROCEDURE (waps) 3-1 ‘4, Transmission Case (AWD Single-range Model) 6) Selection of suitable tst-2nd, Srd-4th and Sth shifter fork Set transmission main shaft assembly and drive pinion shaft assembly in position (so there is no clearance between the two when moved all the way to the front). Select suitable 1st-2nd, 3rd-4th and 5th shifter fork so that coupling sleeve and reverse driven gear are positioned in tsteriven, ‘ear if the center of their synchronizing mechanisms, wil . | isn ster ay —T Ten 33 apogee Ropes ios gery (0388) —_/ 9.3 (0.966) enaeeny 1 [0.2 mm (0.008 in), ard drive gear | Pe ce one I | sesowaare | 8, [staana Town | ReroaoBa earby 0.2 mim (0.008 in) ‘rd-tthshitier fork PartNo. No. Remarks ‘coos ‘Approach to ah gear by eee 1 [012 mm (0.008 in) 93 mm No | standar or 32810AA070 ine, | Standard sth erve gear ‘Couping stove ‘Approach to Grd gear by = 28100A100 3 [oz mm (0.008 in) ‘th shitter fork No, Remarks ‘Approach to Sth gear by ce) 1 [012 mm (0.008 in) couas No | standar 3281248070 mo, | Standara aerBAA0 4 _[ Become distant trom Sth gear by 0.2 mm (0.008 in) 7) Inspection of rod end clearance Measure rod end clearances A and B. If any clearance is not within specifications, replace rod or fork as required. ‘Ac tet2nd to Grd (05 — 1.5 mm (0.020 — 0.059 in) 1 Gra-ath 10 6th (0.6 — 1.4 rom (0.024 — 0.055 in) "3-1 pwaBsy ‘SER' 44 Transmission Case (AWD (0 VICE PROCEDURE » 8) Combination of transmission case (1) Wipe off grease, oil and dust on the mating sur- faces of transmission cases with white gasoline, and apply liquid gasket, and then put case right side and left side together. Liquid gasket: THREE BOND 1215 or equivalent (2) Tighten 17 bolts with bracket, clip, etc. as shown in the figure. Tightening torque: 8 mm bolt 25:42 Nem (2.50.2 kg- 10 mm bolt 39-43 Nem (4.00.3 kg-m, 28.9 + 2.2 ft-lb) NOTE: @ Insert bolts from the bottom and tighten nuts at the top. © Put cases together so that drive pinion shim and input shaft holder shim are not caught up in between ‘© Confirm that counter gear and speedometer gear are meshed 1, 18.1 + 1.4 ft-lb) 9) Tighten ball bearing attachment bolts. Tightening torque: 29-3 N-m (3.00.3 kg-m, 21.7+2.2 ft-lb) 10) Backlash adjustment of hypoid gear and preload adjustment of roller bearing NOTE: Support drive pinion assembly with ST. ST 498427100 STOPPER 12 _4SERVICE PROCEDURE wap] 3-1 4. Transmission Case (AWD Single-r (ode!) (1) Place the transmission with case left side facing downward and put ST1 on bearing cup. f ; (2) Screw retainer assembly into left case from the Sie i bottom with ST2. Fit ST3 on the transmission main shatt. Shift gear into 4th or Sth and turn the shaft sev- f a eral times. Screw in the retainer while turning ST3 until = a slight resistance is felt on ST2. This is the contact point of hypoid gear and drive pinion shalt. Repeat the above sequence several times ame] _to ensure the contact point STI 399780104. WEIGHT $T2 499787000 WRENCH ASSY S73 499927100 HANDLE (3) Remove weight and screw in retainer without O-ring on the upper side and stop at the point where slight resistance is felt. NOTE: ‘At this point, the backlash between the hypoid gear and drive pinion shatt is zero. ST 499787000 WRENCH ASSY (4) Fit lock plate @ . Loosen the retainer on the lower side by 1-1/2 notches of lock plate and turn in the retainer on the upper side by the same amount in order to obtain the backlash. NOTE: The notch on the lock plate moves by 1/2 notch if the plate is turned upside down. (8) Turn in the retainer on the upper side additionally by 1 notch in order to apply preload on taper roller bearing, (6) Tighten temporarily both the upper and lower lock plates and mark both holder and lock plate for later readjustment. (7) Turn transmission main shaft several times while tapping around retainer lightly with plastic hammer. (8) Set ST1 and ST2, insert the needle through trans- mission oil drain plug hole so that the needle comes in contact with the tooth surface at a right angle and check the backlash. 3‘3-1 [wass] SERVICE PROCEDURE 4 ST1 498247001 MAGNET BASE ST2 498247100 DIAL GAUGE Backlas! 0.13 — 0.18 mm (0.0051 — 0.0071 in) NOTE: @ If backlash is cutside specified range, adjust it by turn- ing holder in right side case. ‘© Turning holder paw! 1/2 rotation changes backlash by approximately 0.04 mm (0.0016 in). (9) Check tooth contact of hypoid gear as follows: Apply a uniform thin coat of red lead on both tooth surfaces of 3 or 4 teeth of the hypoid gear. Move the hypoid gear back and forth by turning the transmis- sion main shaft until a definite contact pattern is developed on hypoid gear, and judge whether face contact is correct. @ Tooth contact is correct, Deve side Heel ~ oni ade NOTE couse] If itis incorrect, make the following correction © Backlash is excessive. Tee To reduce backlash, loosen holder on the upper side (case right side) and turn in the holder on the lower side (case lefl side) by the same amount. ¢ Backlash is insufficient. Toe. To increase backlash, loosen holder on the lower side (case left side) and turn in the holder on the upper side (case right side) by the same amount. © The drive pinion shim selected before is too thick 08 Reduce its thickness. Dive side —"— Hel const oie 4 aSERVICE PROCEDURE 4. Tranei ission Case (AWD Sin; Trve side Hest coast sie © The drive pinion shim selected before is too thin Increase its thickness, 11) After checking the tooth contact of hypoid gears, remove the lock plate . Then loosen retainer until the O-ring groove appears. Fit O-ring into the groove and tighten retainer into the position where retainer has been tightened in. Tighten lock plate Tightening torque: 25-43 Nem (2.50.3 kg-m, 18.1 2.2 ft-lb) NOTE: Carry out this job on both upper and lower retainers. 12) Selecting of main shaft rear plate Using ST, measure the amount A of ball bearing protru- sion trom transmission main case surface and select the proper plate in the following table: ST 498147000 DEPTH GAUGE Dimension i“ fm Part No. ‘Mark sian | mone eisai | mee : NOTE: Before measuring, tap the end of main shaft with a plas- tic hammer lightly in order to make the clearance zero between the main case surface and the moving flange of bearing 16SERVICE PROCEDURE 13) Install clutch release lever and bearing 7. Drive Pinion Assembly (AWD Model) B: ASSEMBLY 1. GEAR AND HUB ASSEMBLY NOTE Position open ends of springs 120° apart 2. DRIVEN GEAR ASSEMBLY Assemble a driven shaft and 1st driven gear that select for adjustment the proper radial clearance. Driven shaft ‘st arven gear PartNo | Diameter A mm tin) | — PartNo. Spee 149959 — 49.966 | S2201AA27O | Nonsurbo 3222084190 | 19969 — 1.9672) | ap9tAn60o | Turbo 49967 — 49.075 | 32231AK260_| Nomturbo ono) Lona | nase — 1907) [sezsiansoo | — Turbo =a 1) Install 1st driven gear, 1st-2nd baulk ring and gear and | \| hub assembly onto driven shaft \\ NOTE: | a Take care to install gear hub in proper direction it] | 2) Install 2nd driven gear bushing onto driven shaft using VAL ST1, ST2 and press, rt 45 ST1 499277200 INSTALLER a waste com | ST2 499587000 INSTALLER Ls! = CAUTION: is i cows] Attach a cloth to the end of driven shaft to prevent dam- 16