Subaru EA 82 Service Manual Part 1

QUICK REFERENCE
INDEX
[IJ GENERAL SECTION
SUBARU 1989
SIE~V~C~ MA [N {LJJ A IL
SPECIFICATIONS
1-1
************
GENERAL INFORMATION PRE-DELIVERY INSPECIfION PERIODICMAINTENANCE SERVICES SPECIAL TOOLS
1-2
1-3 1-4 1- 5 1-6
[g] ENGINE SECTION

EMISSION CONTROL SYSTEM AND VACUUM FITTING ON-CAR SERVICES EN~NE ENGINE LUBRICATIONSYSTEM ENGINE COOLINGSYSTEM CARBURETOR FUEL INJECTION SYSTEM FUEL SYSTEM EXHAUST SYSTEM CLUTCH ENGINE AND TRANSMISSION MOUNTINGSYSTEM 2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-8 2-9 2-1 2-1
@] TRANSMISSION
DIFFERENTIAL
AND SECTION
3-1 3-2 3-3 3-4
MANUAL TRANSMISSION AND DIFFERENTIAL AUTOMATICTRANSMISSION AND DIFFERENTIAL TRANSMISSION CONTROL SYSTEM 4WD SYSTEM
ABBREVIATION
AIC ACC AIC pulley ALT pulley API Approx ASSY ASV AT ATF BILEV BJ BP BTDC Calif. Carbo CP CIP CTR CW DIFF DOJ D/R DSPD ECS FMVSS FWD Air Conditioner Accessory Air Conditioner compressor pulley Alternator pulley American Petroleum Institute Approximately Assembly Air Suction Valve Automatic Transmission Automatic Transmission Fluid Bi-Ievel Joint British Petroleum Before Top Dead Center California Carburetor Complete Crankshaft Pulley Center Curb Weight Differential Double Offset Joint Dual-range Dry Single Plate Diaphragm Electric Control System Federal Motor Vehicle Safety Standards Front wheel drive (2WD) GVWR HI HP IG-COIL IG SWITCH INT liP LH LO LSD MPFI MT PCV PHV
LIST
Gross Vehicle Weight Rating High (Speed) Horse Power Ignition Coil Ignition Switch Intermittent (Wiper) Idler Pulley Left-hand Low (Speed) Limited Slip Differential Multi Point Fuel Injection Manual Transmission Positive Crankcase Ventilation Pressure Holding Valve Parts Number PIN Power Steering oil pump pulley PIS pulley Radiator Fan RAD FAN Rear Defogger R-DEF Right-hand RH Society of Automotive Engineers Inc. SAE Single Point Fuel Injection SPFI Single-range SIR Torque Converter TC Temperature Gauge TEMP GAUGE Variable Gear Ratio VGR VIN Vehicle Identification Number W/height control With height control W/P pulley Water Pump pulley
SPECIFICATIONS
I
SUBARU
1989
4-DOOR SEDAN STATION 3-DOOR WAGON
_ .• __ •
....
_. _ .........••.. _ •.
. __ .
- . - - - - - - - - ..
page. 2
8
- ......•.•••..•...•.
.........•.....•.•.....•....••..•.
. _..
14
1-1
4-DOOR SEDAN
MODEL
SPECIFICATIONS
FWD GL-l0 TURBO
DL
Dl
Gl
Gl
Gl·l0
ITEM Overall length Overall width Overall height mm [in) mm [in) mm [in) Front Max. mm (in) Leg room Rear Min. Cornpartment Front Rear mm (in) mm [in) mm (in) mm (in) mm [in) Front Tread Rear Minimum road clearance Front For U.S.A. Rear Total Front For Canada Rear Total Front Gross vehicle weight Rear Total ·1; ·2; '3; mm [in) mm (in) kg (tb) kg [Ibl kg (lb) kg Ub) kg Ob) kg (lb) kg Ilb) kg Ob) kg (lb) mm [in)
SPFI 5MT 4,435 (174.6) 1,660 (65.4) 1,334 [52.5) 1,060 (41.7) 895 (35.2) 954 [37.6) 928 (36.5) 1,360 [53.5) 2,470 [97.2) 1,425 (56.1 ) 1,425 [56.1 } 130 [5.1) ·1 '1 610 (1,345) 406 (895)
SPFI 3AT 4,435 [174.6) 1,660 (65.4) 1,334 (52.5) 1,060 (41.7) 895 (35.2) 954 [37.6) 928 (36.5) 1,360 (53.5) 2,470 [97.2) 1,425 (56.1 ) 1,425 [56.1 ) 130(5.1) '1 '1 626 [1,380) 408 (900)
SPFI 5MT 4,435 (174.6) 1,660 (65.4) 1,334 (52.5) 1,060 [41.7) 895 (35.2) 954 [37.6} 928 (36.5) 1,360 [53.5) 2,470 [97.2) 1,425 (56.1 ) 1,425 (56.1 ) 130 (5.1) ·2 '2 624 (1,375) 415 (915)
SPFI 3AT 4,435 (174.6) 1,660 (65.4) 1,334 (52.5) 1,060 (41.7) 895 (35.2) 954 [37.6) 928 [36.5) 1,360 (53.5) 2,470 (97.2) 1.425 [56.1 ) 1,425 [56.1 ) 130 (5.1) 637 '2 (1,405) ·2 420 [925)
SPFI 3AT 4,435 (174.6) 1,660 (65.4) 1,334 (52.5) 1,060 [41.7) 895 (35.2) 954 (37.6) 928 [36.5) 1,360 (53.5) 2,470 [97.2) 1,425 [56.1 ) 1,425 (56.1 ) 130 (5.1) ·3 *3 683 (1,505) 444 (980)
MPFI 3AT 4,435 [174.6) 1,660 (65.4) 1,334 (52.5) 1,060 (41.7) 895 [35.2) 954 (37.6) 928 [36.5) 1,360 (53.5) 2,470 (97.2) 1,425 [56.11 1,425 (56.1 ) 130(5.1) ·3 '3 707 [1.560} 456 (1.005)
Head room
Shoulder room Wheelbase
Curb weight
'1 1,016 [2.240) '1 ·1 610 (1.345) 406 (8S5)
·1 1,034 (2,280) ·1 '1 626 (1.380) 408 (900)
*2 1,039 (2,290) '1 ·1 621 (1,370) 413 (910)
'2 1,057 (2.330)
.,
'1
·31,127 (2,485) -
·31.163 (2,565) ·3 ·3 703 [1.550) 449 (990)
635 (1,400) 417 (920)
Weight
·1 1,016 [2,240) 844

(t ,8601
'1 1,034 (2.280) 844 (1,860) 712 (1.570) 1,556 (3,430)
·1 1,034 (2.280) 844 (1,8601 712 11,570) 1.556 (3,430)
'1 1.052 (2,320) 844 [1,860) 712 (1,570) 1,556 (3,430)
862 (1,9001 730 [1.610) 1.592 [3,510)
·3 1,152 (2,540) 862 (1,900) 730 [1,610) 1,592 (3,510)
712 (1,570) 1,556 (3.430)
The.weight of power steering is included in C.W. The weight of power steering. power window. and auto door lock system is included in C.W. The weight of sunroof. air conditioner, power steering, power window. digital instrument panel, cruise control and auto door lock system is included in C.W.
SPECI FICATIONS
4-DOOR SEDAN
MODEL 4WD Full time 4WD RX TURBO MPFI 5MT Full time 4WD Full time 4WD
1-1
GL
GL
cr-io
ct.io
TURBO MPFI 5MT
TURBO MPFI 4AT 4,435 (174.6) 1,660 (65.4) 1,410 (55.5) 1,060 [41.7) 895 [35.2} 954 [37.6) 928 [36.5) 1,360 [53.5) 2,465 (97.0) 1,420 (55.9) 1,425 [56.11 160 (6.3) +5 755 (1,665) "5 513 (1,130)
SPFI 5MT ITEM Overall length Overall width Overall height mm (in) mm (in) mm (in) Front Max. mm [in) Leg room Rear Min. Compartment Front Rear mm [in) mm (ln) mm linJ rnrn (in) mm [in) Front Tread Rear Minimum road clearance Front For U.S.A. Rear Total Front For Canada Rear Total Front Gross vehicle weight Rear Total '1: '2: +3: +4: mm (in) mm lin) kg (lb) kg Ob) kg Obi kg Obi kg (tb l kg (lb) kg (lbJ kg lIbJ kg Ob) mm On)
D/R
4,435 (174.6) 1,660 (65.4) 1,380 (54.3) 1,060 (41.7) 895 (35.2) 954 (37.6J 928 (36.5) 1,360 (53.5) 2,465 [97.0) 1,410 155.5J 1,425 (56.1 ) 130 [5.11 '2 642 [1,415)
SPFI 3AT 4,435 (174.6) 1,660 (65.4) 1,380 (54.3) 1,060 (41.7) 895 (35.2) 954 {37.6J 928 (36.5J 1,360 (53.5) 2,465 [97.0) 1.410 155.5J 1,425 156.1J 13015.1) '2 646 (1,425) +2 474 [1.045J +21,120 (2,470) '1 644 (1,42oJ
D/R
4,435 (174.6) 1,660 (65.4) 1,380 (54.3) 1,060 (41.7) 895 (35.2) 954 [37.6} 928 (36.5) 1,360 [53.5) 2,465 (97.0) 1,410 155.51 1,425 (56.1 ) 130 (5.1) '3 703 (1,550J
SIR
4,435 (174.6) 1,660 (65.4) 1,410 (55.5) 1,060 [41.71 895 (35.2) 954 [37.6) 928 [36.5) 1,360 153.5) 2,465 (97.0) 1,420 (55.9) 1,425 156.11 160 (6.3) ·4 "4 712 [1.570) 515 (1,135)
Head room
+2 472 (1,040) +21.114 [2,455) 'I 640 (1,41OJ
+3 497 (1,0951 '3 1.200 (2,645) -
Curb weight
+4 1,227 [2,705) 828 11,825) 782 [1,725) 1,610 [3,550)
"5 1,268 (2,795) '5 755 (1,665)
Weight
+1 469 (1,035) +1 1,109 (2,445) 816 [1,8ooJ
+1 472 (1,040) +11.116 [2,46oJ 816 (1,800) 753 [1,6601 1,569 (3,460)
828 11.825J 782 (1,725) 1,610 (3,55O)
+5 513 (1,130J • 5 1,268 (2,795J 828 (l,825J 782 (1,725) 1,610 13,550)
n.sso:
1,569 [3,460)
753
The weight of power steering is included in C.W. The weight of power steering, power window and auto door lock system is included in C.W. The weight of air conditioner, power steering, power window, auto door lock system, L.S.D. and RX package is included in C.W. The weight of sunroof, air conditioner. power steering, power window, digital instrument panel, cruise control, auto door lock system and L.S.D. is included in C.W. 'S: The weight of sunroof, air conditioner, power steering, power window, digital instrument panel, cruise control and auto door lock system is included in C.W.
1-1
4-DOOR SEDAN
MODEL
SPECIFICATIONS
FWD GL-l0 TUR.BO
DL
DL
GL
GL
GL·l0
ITEM Seating capacity persons
SPFI SMT
SPFI 3AT
SPFI SMT S
SPFI 3AT
SPFI 3AT
MPFI 3AT
Horizontally opposed, liquid cooled, 4-cylinder, 4·stroke gasoline engine Engine type With Single·Point Fuel Injection Overhead camshaft type mm (in) crn' [cu in) 9.S 9.5 92 x 67 (3.62 x 2.64) 1.781 (108.68) 9.5 1·3-2-4 BTDC/rpm*1 rpm 20° 1100 700±100 20° /700 700±100 20° /700 700±100 20°/700 700±100 20° 1100 700±100 20° 1800 800±100 9.S 9.S 7.7 With MultiPoint Fuel Injection and Turbocharger
Valve arrangement Bore x stroke Displacement Compression ratio Firing order Ignition timing at idling speed
Idling speed at neutral. N or P position Spark plug Maximum output Maximum torque Type Battery Reservecapacity Cold cranking ampere Alternator Clutch type Transmission type 1st 2nd Gear ratio 3rd (Drivel 4th 5th Reverse Auxiliary transmission gear ratio Reduction gear [Front drivel
151
Type and manufacturer HP/rpm N·m (kg·m, ft·lbl/rpm
NGK: Nippondenso: Champion:
BPR6ES·l1 (or BPR5ES·l1, BPR7ES·l1) W20EPR·Ul1 (or W16EPR-Ull. W22EPR·Ul11 RN9YC-4 84/5,200 137 [14.0.1011/2.800 115/5,200 11~lH~·& 65D23R-MF 111 420 75D23R-MF '11 490
SOD20R-MF 65D23R·MF (rnin.]

(arnp.]
50D20R·MF 78 306
65D23R-MF 111 420
78 306
111 420
12V·60A DSPD *2 3.636 1.950 1.344 0.911 0.783 3.S83 Type of gear Reduction gear ratio Type of gear Reduction gear ratio '1; *2; '3: TC ·3 2.821 1.559 1.000 DSPD '2 3.636 1.9S0 1.344 0.971 0.783 3.583 TC *3 2.B21 1.559 1.000 TC "3 2.821 1.559 1.000 TC *3 2.821 1.559 1.000
2.257
2.257 -
2.2S7
2.257
High Low
Helical 0.976 Hypoid 3.700
Helical 0.976 Hvpoid 3.454
Hypoid 3.900
reduction Final reduction
Hypoid 3.900
DSPD; Dry Single Plate Diaphragm TC Torque Converter
Without vacuum S·forward speeds with synchromesh and t-reverse Full automatic, 3-forward and 1-reverse
SPECIFICATIONS
4-DOOR SEDAN
MODEL 4WD Full time 4WO RX TURBO MPFI 5MT D/R 5 Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine Engine type With Single-Point Fuel Injection With Multi·Point Fuel Injection and Turbocharger Overhead camshaft type mm (in]
ern? (cu in]
1-1
GL
GL
Full time 4WO GL-l0 TURBO MPFI 5MT SIR
Full time 4WO GL-l0 TURBO MPFI 4AT
SPFI 5MT D/R
SPFI 3AT
Valve arrangement Bore x stro ke Displacement Compression ratio Firing order Ignition timing at idling speed BTDC/rpm·l rpm 20°/700 700±100
92 x 67 (3.62 x 2.64) 1,781 (108.681 9.5 9.5 7.7 1-3-2-4 20° /700 700±100 20°/700 700±100 20°/700 700±100 20° /800 800±100 7.7 7.7
Idling speed at neutral, Nor P position Spark plug Maximum output Maximum torque Type Battery Reservecapacity Cold cranking ampere Alternator Clutch type Transmission type 1st 2nd Gear ratio 3rd [Drive) 4th 5th Reverse Auxiliary transmission gear ratio Reduction gear [Front drive) High Low 1st reduction Final reduction Type of gear Type and manufacturer
BPR6ES-ll (or BPR5ES-l1,BPR7ES·l1f NGI<: Nippondenso: W20EPR-Ul1 (or W16EPR·Ull, W22EPR·Ul1) Champion: RN9YC·4 HP/rpm 90/5,200 137 (14.0, 101)/2,800 115/5,200 181 (18.5,134)/2,800 50D20R·MF 75D23R-MF 78 306
N·m (kg·m, ft·lbl/rpm
50D20R-MF 65D23R·MF 50D20R-MF

(rnin.] (arnp.)
78 306
11' 420
78 306 12V-60A
'11
490
DSPD '3 3.545 1.947 1.366 0.972 0.780 3.416 1.000 1.592 -
TC '2 2.821 1.559 1.000 2.257 Helical 0.974 Hypoid 3.700
DSPD ·4 3.545 2.11 , 1.448 '.088 0.871 3.416 1.000 1.196 Hypoid 3.700
DSPD '5 3.545 2.11 , 1.448 1.088 0.871 3.416 Hypoid 3.700
TC '6 2.785 1.545 1.000 0.694
2.272
Reduction gear ratio Type of gear Reduction gear ratio '1: '2: '3: '4: '5: '6:
Hvpoid 3.900
DSPD: Dry Single Plate Diaphragm TC Torque Converter
Without vacuum Full automatic. 3-forward and t-reverse 5x2-forward speedswith synchromesh and I-reverse (Dual range) 5x2-forward speedswith synchromesh and l-reverse (Dual range) - with center differential 5-forward speedswi th synchromesh and 1-reverse (Single rangel - with center differential Fu II automatic, 4-forward and t-reverse
1-1
4·DOOR SEDAN
MODEL
SPECIFICATIONS
FWD GL-l0 TURBO
DL
DL
GL
GL
GL·l0
ITEM Reduction gear (Rear drive) Transfer reduction Final reduction Type Steering system Turns, lock to lock Minimum turning circle" 1 Front Suspension Rear Service brake system Front Brake Rear Parking brake Tire Size Type Fuel tank capacity Engine oil
Q (US gaL, Imp gaL) Q (US qt, Imp qt)
SPFI 5MT Type of gear Reduction gear ratio Type of gear Reduction gear ratio -
SPFI 3AT -
SPFI 5MT
SPFI 3AT -
SPFI 3AT -
MPFI 3AT -
3.7
Rack and pinion
m (ft)
At tire ........... 9.6 (31.5) At bumper ..... 10.6 (34.8) MacPherson strut type, Independent, Coil spring Semi-trailing arm type, Independent, Coil spring Dual circuit hydraulic with vacuum suspended power unit Ventilated disc brake Drum brake (Leading & trailing type) Mechanical on front brake 155SR13 175/70SR13 Steel belted radial, Tubeless 60 (15.9, 13.2) 4.0 (4.2, 3.5) 3.0 (3.2, 2.B) 2.B (2.7,2.3) 175nOHR13 Disc brake
Upper level
Lower level Q (US qt, Imp qt)

Q (US qt, Imp qt)
Transmission gear oil Automatic transrnission fluid AT differentia I gear oil 4WD rear differential gear oil Power steering fluid
B.2±0.1 (6.6±0.l, 5.5±0.1) 1.2 (1.3, 1.1) 0.7 (0.7.0.B)
2.B (2.7,2.3) -
B.2±0.1 (6.6±0.l, 5.5:1:0.1) 1.2 (1.3.1.1) 0.7 (0.7.0.B)
6.2±0.1 (B.BfO.l, 5.5±0.1) 1.2 (1.3, 1.1)
6.2±0.1
'r:; '" c.
?:
Q (US qt, Imp qt]
(6.6tO.l,
5.5±0.1I 1.2 (1.3, 1.1)
Q (US
ct.
Imp qt)
0.7 (0.7,0.6)
Q (US qt. Imp qt)
0.7 (0.7.0.6)
0.7 (0.7.0.B)
0.7 (0.7,0.6) 6.0 (B.3,5.3) +2 5.5 (5.B,4.8)
(US qt, Imp qt)
Engine coolant
.2 (US qt, Imp qt)
5.5 (5.8,4.8)
·1: '2:
Curb to curb For CANADA
SPECIFICATIONS
4-DOOR SEDAN
MODEL 4WD Full time 4WD RX TURBO MPFI 5MT Full time 4WD GL-l0 TURBO MPFI 5MT SIR Helical 1.000 Hypoid 3.700 Full time 4WD GL-l0 TURBO MPFI 4AT -
1-1
GL
GL
SPFI 5MT ITEM Reduction gear [Rear drivel Transfer reduction Final reduction Type Steering system Turns, lock to lock Minimum turning circle" 1 Front Suspension Rear Service brake system Front Brake Rear Parking brake Tire Size Type Fuel tank capacity Engine oil
Q
D/R
Type of gear Reduction gear ratio Type of gear Reduction gear ratio Helical 1.000 Hypoid 3.900
SPFI 3AT Helical 0.948 Hypoid 3.900
D/R
Helical 1.000 Hypoid 3.700 Rack and pinion 3.7
Hypoid 3.700
m (ftJ
At tire ......... 9.6 (31.51 At bumper ... 10.6 (34.8J MacPhersonstrut type, Independent, Coil spring Serni-trallinq arm type, Independent, COil spring ·2 ·3
Dual circuit hydrau lie with vacuum suspended power unit Ventilated disc brake Drum brake (Leading & trailing typeJ Disc brake
Mechanical on front brake
175/70SR13
(US gaL, Imp gaLf
Q (US qt, Imp qt)
Q
185170HR13 Steel belted radial, Tubeless 60 (15.9, 13.2) 4.0 (4.2, 3.5) 3.0 (3.2, 2.6)
Upper level Lower level
(US et, Imp ct) (US qt, Imp qt) 3.3 (3.5,2.9) 6.5S±0.1 16.9±0.1, 5.8±O.1) , .2 (2.5,2.1) 0.8 (0.8, 0.7) 0.7 (0.7, 0.6)
Transmission gear oil Automatic transmissian fluid AT differential gear oil 4WD rear differential gear oil Power steering fluid
3.5 [3.7,3.11 -
3.5 (3.7,3.11 -
9.5 [10.0,8.4) 1.4 (3.0,2.5) 0.8 (0.8, 0.7) 0.7 (0.7, 0.6) 6.0 [6.3,5.3) '4 5.5 (5.8,4.8)
.t: o
>-
II [US qt, Imp qt)
(3
'"
c.
(US pt, Imp pt] (US qt, Imp qt] (US qt , Imp qt]
0.8 (0.8, 0.7) 0.7 (0.7, 0.6l
0.8 (0.8, 0.7) 0.7 [0.7, 0.6)
0.8 (0.8,0.7) 0.7 (0.7, 0.6J
Engine coolant
(US qt , Imp qt)
5.5 (5.8,4.8)
, 1: '2: '3; '4:
Curb to curb MacPhersonstrut type, Independent. Pneumatic suspension with height control Semi-trailing arm type, Independent, Pneumatic suspension with height control For CANADA
1-1
STATION WAGON
MODEL
SPECIFICATIONS
FWD GL-l0 TURBO
DL
DL
GL
GL
GL·l0
ITEM
SPFI 5MT 4,490 [176.8) '44,410 [173.6) 1,660 [65.4) 1,345 (53.0) 1,645 (64.8) 805 [31.7) 1,360 [53.5) 1,360 (53.5) 895 (35.2) 2,465 [97.0) 1,420 [55.91 1,425 [56.11 140 (5.5) '1 Front kg [Ib) ·4 608 [1,340) 585 (1,290) '1
SPFI 3AT
SPFI 5MT
SPFI 3AT
SPFI 3AT
MPFI 3AT
Overall length
mm (in)
4,490 (176.8) 1,660 (65.4) 1,345 (53.0) 1,645 (64.8) B05 [31.7) 1,360 (53.5) 1,360 (53.5) 895 [35.2) 2,465 (97.0) 1,420 [55.9) 1,425 [56.11 140 [5.5) '2 619 (1,365)
4,490 [176.8) 1,660 [65.4) 1,345 (53.0) 1,645 (64.8) 805 [31.7) 1,360 [53.5) 1,360 (53.5) 895 (35.2) 2,465 [97.0) 1,420 [55.9) 1,425 [56.11 140 (5.5) *2 615 [1,355)
4,490 [176.8) 1,660 (65.4) 1,345 (53.0) 1,645 (64.8) 805 [31.71 1,360 [53.5) 1,360 [53.5) 895 (35.2) 2,465 (97.0) 1,420 (55,9) 1,425 (56.11 140 (5.5) "2 631 [1,390)
4,490 [176.8) 1,660 (65.4) 1,345 (53.0) 1,645 (64.8) 805 [31.7J 1,360 (53.51 1,360 [53.5) 895 (35.2) 2,465 [97.0) 1,420 [55.91 1,425 (56.1) 140 (5.5) '3 676 [1,490)
4,490 (176.8) 1,660 (65.4) 1,345 (53.0) 1,645 (64.8) 805 (31.7) 1,360 [53.5) 1,360 (53.5) 895 [35.21 2,465 [97.01 1,420 (55.9) 1,425 (56.1 ) 140 [5.51 '3 703 (1,550)
Overall width Overall height at 2 seats Length at 5 seats Cargo space at 2 seats Width at 5 seats Height Wheelbase Front Tread Rear Minimum road clearance
mm (in) mm (in) mm (in) mm (in) mm [in) mm [in) mm (inJ mm [ln] mm [in) mm (inl mm (in)
'1 For U.S.A. Rear kg [Ib)
467 (1,030) *4 458 [1,010)
474 [1,045)
'2
492 (1,0851
'2
494 (1.090)
'3
506 (1,115)
*3
515 (1,135)
Weight
Curb weight
Total
kg lib)
·1 1,075 [2,370) "4 1,043 (2,300) '1 *1 608 (1,340) 467 [1,030)
"
1,093 (2,410) 619 (1,365) 474 [1,045)
'2 1,107 (2,440) '1 *1 612 (1,350) 488 [1,075)
*2 1,125 (2,480) *1 '1 628 [1,385) 490 [1,080)
·3 1,182 [2,605)
'31,218 [2,685) '3 '3 703 [1,550) 515 [1,135)
Front For Canada Rear Total '1: ·2: *3: '4: The weight The weight The weight included in
..
kg lib) kg lib) kg lib)
*1 '1
'1 1,075 [2,370)
'1 1,093 (2.410)
'1 1,100 (2.425J
'11,118 (2,465)
'31,218 [2,685)
of power steering ISIncluded In C.W. of power steering, power window and auto door lock system is included in C.W. of sunroof, air conditioner, power steering, power window, digital instrument panel, cruise control and auto door lock system is C.W.
For Puerto Rico model only
SPECIFICATIONS
STATION WAGON
MODEL 4WD GL TURBO MPFI 5MT SIR 4,490
(t 76.8)
1-1
DL
GL
GL
Full time 4WD GL·l0 TURBO MPFI 5MT SIR 4,490 1176.B) 1,660 (65.4) 1,395 (54.9) 1,645 (64.81 805 131.71 1,360 (53.5) 1,360 (53.5) 895 (35.2) 2,460 (96.9) 1,410 (55.51 1,425 (56.11 135 (5.3) '4 703 [1.5501
Full time 4WD GL·l0 TURBO MPFI 4AT
ITEM
SPFI 5MT SIR 4,490 [176.8) 1,660 (65.4) 1,395 (54.9) 1,645 (64.BI B05 131.7) 1,360 (53.5) 1,360 (53.5) 895 (35.2) 2,460 (96.9) 1,410 [55.5) 1,425 [56.11 135 (5.3) 'I 630 (1.3901
SPFI 5MT D/R 4,490 [176.81 1,660 165.41 1,395 154.9) 1,645 164.B) 805 (31.7) 1,360 (53.5) 1,360 (53.51 895 135.2) 2,460 (96.9) 1,410 155.5) 1,425 [56.1 ) 135 (5.3) '2 646 (1,425)
SPFI 3AT
Overall length
mm [in)
o 76.BI
1,660 (65.4) 1,395 154.9) 1,645 (64.B) 805 (31.71 1,360 (53.5) 1,360 (53.5) 895 (35.21 2,460 (96.9) 1,410 (55.5) 1,425 156.11 135 [5.3) '2 653 [1,440)
4,490
4,490 (176.8) 1,660 (65.4) 1,425 156.1) 1,645 164.8) 805 (31.7) 1,360 (53.5) 1,360 (53.5) 895 (35.2) 2,465 (97.0) 1,420 (55.9) 1,425 [56.1 ) 160 [6.3) '5 750 [1,655)
Overall width Overall height at 2 seats Length at 5 seats Cargo space at 2 seats Width at 5 seats Height Wheelbase Front Tread Rear Minimum road clearance
mm (in) mm (in) mm (inl mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)
1,660 (65.41 1.395 (54.9) 1,645 164.8) 805 (31.7) 1.360 (53.5) 1,360 (53.51 895 (35.21 2,460 196.9) 1,410 [55.5) 1,425 (56.1 ) 135 (5.3) +3 687 (1.515)
Front
kg lib)
For U.S.A.
Rear
kg Obi
'I
524 [1,155)
'2
540 [1.190)
'2
540 11,1901
'3
540 (1,190)
'4
563 (1.240)
+5 565 0.245)
Weight
Curb weight
Total
kg lib)
'1 1.154 [2.5451 '1

'I
'2 1.186 (2,615) 644 (1,4201 535 (1.180) 1,179 [2,6001
'21,193 (2,630) 651 (1,435) 535 (1,180)
'3 1,227 [2,705)
'4 1.266 12,790)
'51,315 (2,900) '5 '5 750 (1,655) 565 11,2451
Front For Canada Rear Total '1; '2: '3: '4: '5:
kg [Ib) kg lIbl kg Obi
630 (1.390) 524 11,155) 1,154 (2,545)
'I
'I
'1 'I
'I
'I
'1 1,186 [2,615)
'51,315 (2,9001
The weight of power steering is included in C.W. The weight of power steering, power window and auto door lock system is included in C.W. The weight of air conditioner, power sleering, power window and auto door lock system is inctuded in C.W. The weight of sunroof, air conditioner. power steering. power window, digital instrument panel, cruise control. auto door lock and L.S.D. system is included in C.W. The weight of sunroof, air conditioner, power steering, power window. digital insrrurnant panel, cruise control and auto door lock system is included in C.W.
1-1
STATION WAGON
MODEL
SPECIFICATIONS
FWD
DL
DL
GL
GL
GL-l0
GL-l0 TURBO
SPFI ITEM Front Gross vehicle weight kg lib) 5MT 816 (1,800) 794 (1,750) 1,610 [3,550)
SPFI 3AT 816 (1,800J 794 [1,750) 1,610 (3,550J
SPFI 5MT 844 (1,B601 821 [1,810) 1,665 [3,670) 5
SPFI 3AT 844 [1,B601 821 [1,810J 1,665 (3,670)
SPFI 3AT 857 (1,890) 835 (1,840) 1,692 (3,730)
MPFI 3AT 857 11,8901 835 (1,840) 1,692 [3,730)
Weight
Rear
kg (tb)
Total Seating capacity
kg (lb) persons
Horizontally Engine type
opposed,
liquid
cooled,
4-cylinder,
4-stroke
gasoline
engine With MultiPoint Fuel Injection and Turbocharger
With
Single-Point
Fuel Injection
Valve arrangement
Overhead mm [in] em' [cu in] 9.S 9.5
camshaft
type
Bore x st ro ke
Displacement Compression Firing Ignition Idling order timing at idling speed ratio
92 x 67 [3.62 1,781 9.5
x 2_64J
[108.68) 9.5 1-3-2-4 9.5 7.7
BTDC/rpm·l rpm
20° /700 700.100
20°/700 700.100
20°/700 700.100
20°/700 700.100
20°/700 7001100
20° /800 800±100
speed at neutral,
N or P Position
Spark
plug
Type
and manufacturer
SPR6ES-l1 [or BPR5ES-ll, BPR7ES-ll) NGK: [or W16EPR-Ul1, W22 EPR-Ul1) N ippo nd enso : W20EPR-Ul1 Champion: RN9YC-4 90/5,200 137 [14.0, SOD20R-MF Imin.1 lamp.1 78 306 65D23R-MF 111 420 101]/2,800 65D23R-MF 1 I1 420 12V-60A DSPD TC '3 2.821 1.559 .. 1.000 DSPD '2 TC '3 TC '3 TC '3 2.821 1.559 1.000 65D23R-MF 111 420
Maximum Maximum
output torque Type
HP/rpm N·m [kq-rn, ft-Ib)/rpm
l' 5/5,200
11~)/~~·66 75D23R-MF 1I 1 490
50D20R-MF 78 306
Battery
Reserve capacity Cold cranking ampere
Alternator Clutch type type 1st 2nd Gear ratio 3rd (Drivel 4th 5th Reverse Auxiliary transmission gear ratio DSPD: TC Low • 1: '2· • 3: Without 5·forward High ._-
Transmission
'2 3.636 1.950 1.344 0.971 0.783 3.583
.-
3.636 1.950
2.821 2.821 _. ----- t----.-
-~
1.559
~-
1.559 1.000
-.
_ _
1.344 0.971 . _. 0.783 3.583
_ ---------_
1.000
----
---~-
2.257
2.257
------~ 2.257
_ _
vacuum speeds with
synchromesh
2.257
_ _
Dry Single Plate Diaphragm Torque Converter
and 1-reverse
Full au tornat ic, 3-forward
and I -reverse
10
SPECIFICATIONS
STATION WAGON
MODEL 4WD GL TURBO MPFI 5MT SIR B19 (1.B05) 877 (1,935) 1,696 (3,740) 5 Horizontally opposed, liquid cooled, 4·cylinder, 4·stroke gasoline engine Engine'type With Single·Point Fuel Injection Valve arrangement Bore x stroke Displacement Compression ratio Firing order Ignition timing at idling speed BTDC/rpmol rpm 20°/700 700±100 20· 1700 700±100 mm (in) em' [cu in) 9.5 9.5 With Multi·Point Fuel Injection and Turbocharger Full time 4WD GL·l0 TURBO MPFI 5MT SIR 819 (1,805) 877 (1,935) 1,696 (3.740) Full time 4WD GL·l0 TURBO MPFI 4AT 850 (1,B75) 880 (1,940) 1.730 (3,815)
1-1
DL
GL
GL
ITEM Front Weight Gross vehicle weight Rear Total Seating capacity kg (lb) kg (Ib) kg (Ib) persons
SPFI 5MT SIR 803 (1,770) 859 (1.895) 1,662 (3,665)
SPFI 5MT DIR B03 (1,770J 859 (1,8951 1,662 (3,665)
MPFI 3AT B03 (1,770) 859 (1,B95) 1,662 [3.665)
Overhead camshaft type 92 x 67 [3.62 x 2.64) 1,781 (108.58) 9.5 1·3-2-4 20' 1700 700il00 20° /700 700±100 20· /700 700±100 20· IBOO 800±100 7.7 7.7 7.7
Idling speedat neutral, N or P position Spark plug Maximum output Maximum torque Type Battery Reservecapacity Cold cranking ampere Alternator Clutch type Transmission tvpe 1st 2nd Gear ratio 3rd (Drive) 4th 5th Reverse Auxiliary transmission gear ratio High Low Type and manufacturer
NGK: BPR6ES-l1 (or BPR5ES-l1, BPR7ES-ll) Nippondenso: W20EPR·Ull (or W16EPR·U II, W22EPR-Ul1) Champion: RN9YC-4 HP/rpm 90/5,200 137 {14.0,1011/2.800 115/5,200 181 (18.5,134)/2,800
N·m (kg·m, f!-Ibl/rpm
50D20R·MF 50D20R-MF 65D20R-MF 50D20R-MF 50D20R-MF 75D23R-MF
Irnm.l
(arnp.]
78 306
78 306
111 420 12V-50A
78 306
78 306
111 490
DSPD '2 3.545 1.947 1.366 0.972 0.780 3.416 '1: '2: '3: '4: '5: '6:
DSPD '4 3.545 1.947 1.366 0.972 0.780 3.416 1.000 1.592
TC '3 2.821 1.559 1.000 -
DSPD '2 3.545 2.111 1.448 1.088 0.871 3.416
DSPD '6 3.545 2.111 1.448 1.088 0_871 3.416 -
TC
°S
2.785 1.545 1.000 0.694 2.272 -
2.257 -
Without vacuum 5-forward speedswith synchromesh and t-raverse Full automatic, 3-forward and I-reverse 5x2-forward speedswith synchromesh and t-raverse (Dual rangel Full automatic, 4-forward and I-reverse 5·forward speedswith synchromesh and l-reverse (Single range) - with center differential
11
1-1
STATION WAGON
MODEL
SPECIFICATIONS
FWD GL-l0 TURBO
DL
DL
GL
GL
GL-l0
ITEM Reduction gear (Front drive) 1st reduction Final reduction Transfer reduction Final reduction Type Steering system Turns. lock to lock Minimum turning circle"l Front Rear Service brake system Brake Front Rear Parking brake Tire Size Type Fuel tank capacity Engine oil
Q (US gaL. Imp gal.)
Q
SPFI 5MT Type of gear Reduction gear ratio Type of gear Reduction gear ratio Type of gear Reduction gear ratio Type of gear Reduction gear ratio Hvpoid 3.900
SPFI 3AT Helical 0.976 Hypoid 3.700 -
SPFI 5MT Hypoid 3.900 -
SPFI 3AT Helical 0.976 Hypoid 3.700 -
MPFI 3AT Helical 0.976 Hypoid 3.454 -
Reduction gear (Rear drive)
3.7
Rack and pinion
m (tt)
At tire ..._ ..... 9.6 (31.5) At bumper, ... 10.6 [34.8) MacPherson strut type, Independent, Coil spring Semi-trailing arm type, Independent, Coil spring Dual circuit hydraul ic with vacuum suspended power unit Ventilated disc brake Drum brake (Leading & trailing type) Mechanical on front brake 155SR13 175170SR13 Steel belted radial, Tubeless 60 (15.9, 13.21 4.0 (4.2,3.5) 3.0 (3.2,2.6) 2.6 (2.7,2.31 6.2±0.1 (6.6±0.1, 5.5±0.1 ) 1.2 (1.3, 1.11 0.7 (0.7,0.6) 2.6 (2.7,2.3) 6.2±0.1 (6.6±0.1, 5.5±0.11 1.2 (1.3,1.1) 0.7 (0.7,0.6) 175nOHR13 Disc brake
Suspension
(US qt, Imp qt)
Q (US qt. Imp qt l Q (US qt, Imp qt]
Transmission gear oil Automatic transrnission fluid AT differential gear oil 4WD rear differential gear oil Power steering fluid
6.2±0.1 (6.6±0.1, 5.5±0.1 ) 1.2 (1.3. 1.1) 0.7 (0.7,0.6)
6.2±0.1 (6.6±0.1. 5.5±0.1 } 1.2 (1.3,1.1 ) 0.7 (0.7, 0.61 6.0 (6.3,5.3) "2 5.5 (5.8,4.8)
~
:0-
(US qt, Imp qt]
'" o
Q.
'"
Q (US qt. Imp qt)
0.7 (0.7,0.6)
2 (US qt, Imp qt)

Q (US qt, Imp qt)
0.7 iD.7,0.6}
Engine coolant
(US qt, Imp qt)
5.5 (5.8,4.8)
*1: Curb to curb *2: For CANADA
12
SPECIFICATIONS
STATION WAGON
MODEL 4WD GL TURBO MPFI 5MT SIR Helical 1.000 Hypoid 3.700 Helical 1.000 Hypoid 3.700 Full time 4WD GL·l0 TURBO MPFI 5MT Full time 4WD GL·l0 TURBO MPFI 4AT
1-1
DL
GL
GL
ITEM Reduction gear {Rear drivel Transfer reduction Final reduction Transfer reduction Final reduction Type Steeri.ng system Turns, lock to lock Minimum turning circle" Front Rear Service brake system Brake Front Rear Parking brake Tire Size Tvpe Fuel tank capacity Engine oil
Q
SPFI 5MT SIR Type of gear Reduction gear ratio Type of gear Reduction gear ratio Tvpe of gear Reduction gear ratio Tvpe of gear Reduction gear ratio Helical 1.000 Hypoid 3.900 Helical 1.000 Hypoid 3.900
SPFI 5MT D/R Helical 1.000 Hypoid 3.900 Helical 1.000 Hypoid 3.900
SPFI 3AT Helical 0.948 Hypoid 3.900 Helical 0.948 Hypoid 3.900
SIR
Helical 1.000 Hvpoid 3.700 Helical 1.000 Hypoid 3.700
Hvpoid 3.700
Reduction gear (Rear drivel
Hypoid 3.700
Rack and pinion 3.7 m [h) At tire ......... 9.6 (31.5) At bumper ... , 0.6 (34.8) MacPherson strut type, Independent, Coil spring Semi-trailing arm type, Independent, Coil spring Dual circuit hydraulic with vacuum suspended power unit Ventilated disc brake Drum brake (Leading & trailing typel Mechanical on front brake ,65SR13 185170SR13 185/70HR13 Disc brake '2 '3
Suspension
Steel belted radial, Tubeless (US gal., Imp gal.)

Q Q
60 [15.9, 13.2) 4.0 (4.2, 3.5) 3.0 (3.2,2.6) 3.3 (3.5,2.9) 3.3 (3.5,2.91 6.55±0.1 (6.9±0.1, 5.S±0.11 1.2 [2.5,2.11 0.8 [O.S, 0.71 0.7 [0.7,0.6] 3.3 (3.5,2.91 3.5 (3.7,3.11
(US qt, Imp qr) (US qt, Imp qt)
Transmission gear oil Automatic transrnissian fluid A T differential gear oil 4WD rear differential gear oil Power steering fluid
Q (US qt, Imp qrl
9.5 (10.0,8.41 1.4 (3.0,2.5) 0.8 (O.S,0.71 0.7 (0.7, 0.6] 6.0 [6.3,5.31 5.5 '2 [5.8,4.S]
?: 'u
o '"
II (US qt, Imp qt)
O.S (0.8, 0.71 0.7 (0.7,0.61
'" a.
12 (US pt, Imp pt} 12 [US qt, Imp qt] 11 [US qt, Imp qt]
0.8 (O.S,0.71 0.7 (0.7,0.61
0.8 (0.8,0.71 0.7 10.7, 0.61
O.S [O.S,0.71 0.7 [0.7,0.61
Engine coolant
11 (US qt, Imp qt)
5.5 (5.8, 4.SI
',: Curb to curb '2: MacPhersonstrut type, Independent, Pneumatic suspension with height control ·3: Semi·trailing arm type, Independent, Pneumatic suspension with height control ·4: For CANADA
13
1-1
3·DOOR
MODEL
SPECIFICATIONS
FWD
4WD Fu II time 4WD RX TURBO MPFI 5MT D/R 4,435 (174.6) 1,660 (65.4) 1,357 (53.4) 1,073 (42.2) 828 [32.6) 955 (37.6) 909 (35.8) 1,360 [53.5) 2,465 (97.0) 1,410 (55.5) 1,425 [56.11 130 [5.11 "3 698 [1,540]
DL
DL
GL
GL
GL
GL
ITEM Overall length Overall width Overall height mm [inl mm (in) mm (in) Front Max. mm (in) Leg room Rear Min. Compart· ment Front Rear mm [inJ mm (in] mm [in) mm (in) mm (In) Front Tread Rear Minimum road clearance Front For U.S.A. Rear Total Front For Canada Rear Total Front Grossvehicle weight Rear Total '1; "2; "3; mm [in) mm (in) kg lib] kg lib) kg lib) kg lib] kg lib) kg lib) kg lib) kg lib) kg lib] mm (in)
SPFI 5MT 4,435 [174.61 1,660 [65.4) 1,316 (51.8) 1,073 (42.2) 828 [32.6J 955 (37.6) 909 [35.8) 1,360 (53.51 2,470 [97.2] 1,425 (56.1 ) 1,425 [56.1 ) 130 [5.11 "1 '1 603 (1,3301 431 (950)
SPFI 3AT 4,435 [174.61 1,660 (65.4) 1,316 (51.8J 1,073 [42.2) 828 [32.6) 955 (37.6) 909 [35.8) 1,360 [53.5) 2,470 (97.21 1,425 [56.1] 1,425 [56.1 ) 130 [5.1 J +1 619 (1,365) '1 433 (955)
SPFI 5MT 4,435 [174.6) 1,660 (65.4) 1,316 [51.8) 1,073 [42.2) 828 (32.6) 955 [37.61 909 [35.8) 1,360 [53.5) 2,470 [97.2) 1,425 [56.1 ) 1,425 [56.1 I 130 [5.1) +2 617 [1,360) '2 447 (985)
SPFI 3AT 4,435 [174.6) 1,660 (65.4) 1,316 [51.8) 1,073 [42.2) 828 (32.61 955 [37.6) 909 (35.81 1,360 (53.5) 2,470 [97.2) 1,425 [56.11 1,425 (56.1) 130 [5.1) '2 633 [1,395) '2 449 (990)
SPFI 5MT D/R 4,435 [174.61 1,660 (65.4) 1,357 (53.41 1,073 [42.2) 828 [32.6) 955 [37.6) 909 [35.8) 1,360 (53.5) 2,465 (97.01 1,410 (55.5) 1,425 (56.1] 130(5.11 "2 '2 637 (1,405) 499 (1,100)
SPFI 3AT 4,435 [174.6) 1,660 (65.4) 1,357 (53.41 1,073 (42.21 828 [32.6) 955 [37.61 909 [35.8) 1,360 [53.5) 2,465 [97.0) 1,410 [55.5) 1,425 [56.1 I 130 (5.11 +2 644 [1,420) +2 501 [1,105)
Head room
..
+3 513 (1,130) +31,211 [2,670) '3 698 [1,540)
Curb weight
·1 1,034 [2,2801 "1 "1 603 (1,330) 431 (950]
'1 1,052 (2,320) '1 619 0,365)
+21,064 (2,3451
+2 1,082 (2,385)
'21.136 (2.505] '1 "1 " 635 [1,400] 499 (1,100) 1,134 [2,500] 817 (1,800) 780 (1,720] 1,597 (3,520)
'21,145 [2,525J ·1 ·1 642 (1,415) 501

(1, 105]
Weight
'1 433 (955) ·1 1,052 (2,320) 816 (l,800J 735 (1,6201 1,551 (3.420)
.,
"1
614 (1,355) 447 (985)
"I
631 (1,390)
·1 449 (9901 '1 1.080 [2,380) 816 (l,800J 735 (1,620) 1,551 (3,420)
+3 513 (1,130) '3 1,211 (2,6701 817 (1,800) 780 (1.720] 1,597 (3,520)
'1 1,034 [2,280) 816 (1,800) 735 (1,620) 1.551 [3,420]
'1 ,,061 [2,340] 816 (1,800) 735 (1,620) 1,551 (3,4201
'1 1,143 (2,520) 817 (1,8001 780 (1,720) 1,597 (3,520)
The weight of power steering is included in C.W. The weight of power steering, power window and auto door lock system is included in C.W. The weight of air conditioner, power steering, power window, auto door lock system, L.S.D. and RX package is included in C.W.
14
SPECIFICATIONS
3-000R
MODEL FWD 4WD
1-1
DL
DL
GL
GL
GL
GL
Full time 4WD RX TURBO MPFI SMT D/R
SPFI SMT
SPFI 3AT
SPFI SMT
SPFI 3AT S
SPFI SMT D/R
SPFI 3AT
Horizontally opposed, liquid cooled, 4'cylinder, 4·stroke gasoline engine With Multi· Point Fuel Injection and Turbocharger
Engine type With Single·Point Fuel Injection
Valve arrangement Bore x stroke Displacement Compression ratio Firing order Ignition timing at idling speed BTDC/rpm'l rpm 20° /700 700±100 20° /700 700±100 mm (in) ern? (cu in) 9.5 9.S 9.S
Overhead camshaft type 92 x 67 (3.62 x 2.64) 1,781 [10B.68) 9.S 1-3-2-4 20° /700 700±100 20° /700 700±100 20° /700 700:tl00 20° /700 700±100 20° /700 700±100 9.S 9.5 7.7
Idling speed at neutral, Nor P position Spark plug Maximum output Maximum torque Type Battery Reservecapacity Cold cranking ampere Alternator Clutch type Transmission type 1st 2nd Gear ratio 3rd 4th 5th Reverse Auxiliary transmission gear ratio High Low Type and manufacturer
NGK: BPR6ES-11 (or BPRSES·ll, BPR7ES-l1) Nippondenso: W20EPR-Ul1 (or W16EPR·U11, W22EPR-U11I Champion: RN9YC-4 HP/rpm 90/S,200 137 114.0, 101) (2,800 SOD20R·MF 6SD23R·MF SOD20R-MF 65D23R-MF (rnln.)
(arnp.)
90/S,200 137 [14.0, 101 )/2,BOO
115/5,200 181 118.S,134) /2,800
N'm (kg·m, ft-Ib l/rprn
50D20R-MF 6SD23R·MF SOD20R·MF 78 306 111 420 78 306
78 306
111 420
78 306
111 420 12V·60A
DSPD '2 3.636 1.950 1.344 0.971 0.7B3 3.583 '1: '2: '3: '4: 'S:
TC ·3 2.821 1.S59 1.000
DSPD "2 3.636 1.950 1.344 0.971 0.783 3.583 -
TC "3 2.821 1.559 1.000
DSPD '4 3.545 1.947 1.366 0.972 0.7BO 3.416 1.000 1.592
TC "3 2.821 1.SS9 1.000 -
DSPD "S 3.54S 2.111 1.448 1.0B8 0.871 3.416 1.000 1.196
2.257
2.257 -
2.257 -
Without vacuum 5·forward speedswith synchromesh and 1-reverse Full automatic. 3·forward and 1-reverse Sx2·forward speedswith synchromesh and t-raverse {Dual-ranqe) Sx2·forward speedswith synchromesh and 1-reverse (Duat-ranqe) - with center differential
15
1-1
3·DOOR
MODEL
SPECIFICATIONS
FWD
4WD Full time
DL
DL
GL
GL
GL
GL
4WD
RX
TURBO MPFI 5MT D/R
SPFI ITEM Reduction gear (Front drive) 1st reduction Final reduction Transfer reduction Final reduction Type Steering system Turns, lock to lock turning m (h) Type of gear Reduction gear ratio 5MT
SPFI 5MT
SPFI 5MT D/R
Hypoid 3.900
Hypoid 3.900
Hypoid 3.900 Helical 1.000 Hypoid 3.900
Type of gear Reduction Type gear ratio
of gear gear ratio
Reduction
Type of gear Reduction gear ratio
Rack and pinion 3.7 At tire .......... At bumper
Minimum circle" Front 1
9.6 (31.5)
... 10.6 (34.8) Independent, Independent, vacuum Coil spring Coil spring power unit
MacPherson Semi-trailing Dual circuit
strut
type,
Suspension Rear Service brake system Front Brake Rear Parking Size Tire Type Fuel tank Engine oil capacity Upper Lower level level
Q
arm type, with
hydraulic
suspended
Ventilated Drum bra ke 155SR13 brake (Leading
disc brake Drum (Leading on front brake 175/70SRI3 radial, Tubeless 185/ 70HR13 brake type) Disc brake
& trailing
type)
& trailing
Mechanical 175/70SR13 Steel belted
(US gaL, Imp gal.)

Q Q
60 (15.9,
13.2)
(US qt, Imp qt) (US qt, Imp qtl Imp qt] 2.6 (2.7.2.3)
4.0 (4.2, 3.5) 3.0 (3.2,2.6)
Transmission
gear oil
2 (US qt.
6.2~0.1 (6.6iO.l, 5.5±0.1)
2.6 12.7,2.31
6.2±0.1 (6.6±0.1, 5.5~0.1 ) 1.2 (1.3, 1.1 )
3.3 (3.5,2.9)
6.55±0.1 16.9±0.1, 5.8±0.1 )
3.5 (3.7.3.1 )
.~
u
Q,
..
Automatic sion fluid
transrnts-
2 (US qt, Imp qrl
0.7 (0.7,0.61 About
AT differential oil
gear
2 (US qt, Imp qtl
0.7 (0.7.0.61
1.2 (1.3, 1 .1 I
0.8 (0_8,0.71 0.7 (0.7,0.61
1.2 (1.3, 1.11 0.8 (0.8.0.71 0.7 (0.7,0.6)
0.8 (0.8,0.7) 0.7 (0.7,0.6)
4WD rear differential gear oil Power steering Engine coolant ·1: Curb to curb fluid
1I (US qt. Imp qr]
0.7 (0.7.0.6)
0.7 (0.7.0.6) 5.5 (5.8,4.81
(US qt. Imp qtl
2 (US qt, Imp qt l
16
SPECIFICATIONS
TOURING WAGON
MODEL FWD GL-l0 TURBO
1-1
GL
GL
GL-l0
ITEM Overell length Overall width Overall height at 2 SBtS Length at 5 sets Cargo space at 2 sets Width at 5 sets Haight Wheelbase Front Tread Rear Minimum road clearance Front For U.S.A. Weight Curb weight Rear Totel Front For Canada Rear Total mm (in) mm (in) kg lib) kg lib) kg (lb] kg (lb] kg lib) kg lib) ·2 ·2 ·2 +1 ·1 rnrn (in) mm (in) rnm On) mm (in) mm (in) rnrn (in) mm (in) mm (in)
SPFI 5MT 4,490 (176.8) 1,660 (65.4) 1,385 (54.5) 1,645 (64.8) B05 (31.7) 1,360 (53_5) 1,360 (53.5) 935 (36.8) 2,465 (97.0) 1,420 (55.9) 1,425 (56.1 ) 140 (5.5) 615 (1,355) 494 (1,090) 1.109 (2,445) 612 (1,350) 490 (1,080) 1,102 (2,430J +2 ·2 +2 +1
$PFI 3AT 4,490 (176.8) 1,660 (65.4) 1,385 (54.5) 1,645 (64.B) B05 (31.7) 1,360 (53.5) 1,360 (53.5) 935 (36.S) 2,465 (97.0) 1,420 (55.9) 1,425 (56.1) 140 (5.5) 630 (1,390) 497 (1,095) 1,'27 (2,485) 628 (1,385) 492 (1,085) , ,120 (2,470) ·3 ·3 +3
SPFI 3AT 4,490 (176.8) 1,660 (65.4) 1,385 (54.5) 1,645 (64.8) 805 (31.7) T ,360 (53.5) 1,360 (53.5) 935 (36.8) 2,465 (97.0) 1,420 (55.9) 1,425 (56.1) 140 (5.5) 667
FPFI 3AT 4,490 (176.8) 1,660 (65.4) 1,385 (54.5) 1,645 (64.B) 805 (31.7) 1,360 (53.5) 1,360 (53.5) 935 (36.8) 2,465 (97.0) 1,420 (55.9) 1,425 (56.1 ) 140 (5.5) +3 ·3 ·3 ·3 ·3 689 (1,520) 499 (1,100) 1,188 (2,620) 689 (1,520) 499 (1.100) (2,620)
rnrn (in)
mm (in)
l1 ,470)
496 (1,095) 1,163 (2,565)
"'
.,
+3 , .188
·1: The weight of power steering is included in C.W. ·2: The weight of power steering, power window and auto door lock system is included in C.W. +3: The weight of air conditioner, power steering, power window, digital instrument panel, cruise control and auto door lock system is included in C.W.
17
1-1
TOURING WAGON
MODEL
SPECIFICATIONS
4WD GL TURBO MPFI 5MT SIR 4,490 (176.8) 1,660 (65.4] 1,435 (56.5) 1,645 (64.8) 805 (31.7) 1,360 (53.5) 1,360 (53.5) 935 (36.8) 2,460 {96.9} 1,410 (55.5) 1,425 (56.1) 135 (5.3) '3 '3 ·3 687 (1,515) 542 (1,195) 1,229 (2,710) '4 ·4 "4 Full time 4WD GL-l0 TURBO MPFI 5MT SIR 4,490 (176.8) 1,660 (65.4) 1,435 (56.5] 1,645 (64.8) 805 (31.7) 1,360 {53.5} 1,360 {53.5} 935 (36.8) 2,460 (96.9) 1,410 {55.5} 1,425 (56.1 ) 135 (5.3) 694 (1,530) 553 [1,220) 1,247 (2,750) "5 ·5 *5 ·5 "5 "5 Full time 4WD GL-l0 TURBO MPFI 4AT 4,490 (176.8) 1,660 (65.4) 1,465 (56.5) 1,645 (64.8) 805 (31.7) 1,360 (53.5) 1,360 {53.5} 935 (36.8) 2,465 {97.0} 1,420 (55.9) 1,425 {56.1 } 160 (6.3) 744 (1,640) 556 (1,225) 1,300 (2,865) 744 (1,640) 556 (1,225) 1,300 (2.865)
GL
GL
ITEM Overall length Overall width Overall height at 2 sets Length at 5 sets Cargo space at 2 sets Width at 5 sets Height Wheelbase Front Tread Rear Minimum road clearance Front For U.S.A. Weight Curb weight Rear Total Front For Canada Rear Total • 1: ·2: *3: '4: mm !in} mm (in) kg (tb) kg Ob) kg (Ib] kg (tb) kg Ob) kg (tb) *2 ·2 '2 ·1 '1 '1 mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) rnrn (in)
SPFI 5MT D/R 4,490 (176.8) 1,660 (65.4) 1,435 {56.5] 1,645 (64.8) 805 (31.7) 1,360 (53.5) 1,360 (53.5) 935 (36.8) 2,460 {96.9} 1,410 (55.5) 1,425 {56.1} 135 (5.3) 646 (1,425) 542 (1,195) 1,188 (2,620) 644 (1,420) 538 (1.185) 1,182 {2,605} *2 ·2 "2 ·1 ·1 ·1
SPFI 3AT 4,490 (176.8) 1,660 (65.4) 1,435 (56.5) 1,645 (64.8) 805 (31.7) 1,360 (53.5) 1,360 {53.5} 935 (36.8) 2,460 {96.9} 1,410 (55.5) 1,425 {56.1 } 135 (5.3) 653 (1,440) 542 (1,195) 1,195 [2,635) 651 (1,435) 537 0,185) 1,188 (2,620)
The weight of power steering is included in C.W. The weight of power steering, power window and auto door lock system is included in C.W. The weight of air conditioner, power steering, power window and auto door lock system is included in C.W. The weight of air conditioner, power steering, power window, digital instrument panel, cruise control, auto door lock and L.S.D. system is included in C.W. "5: The weight of air conditioner, power steering, power window, digital instrument panel, cruise control and auto door lock system is included in CW.
18
SPECIFICATIONS
TOURING WAGON
MODEL FWD GL-l0 TURBO
1-1
GL
GL
GL-10
ITEM Front Weight Gross vehicle weight Rear Total Seating capacity kg (lbl kg (tbl kg (JbJ persons
SPFI 5MT 844 (1,8601 821 (l,810J 1,665 {3,670J
SPFI 3AT 844 (1,8601 821 (1,810) 1,665 (3,670) 5
SPFI 3AT 857 (l,890) 835 (1,840) 1,692 (3,730J
MPFI 3AT 857 (l,B90] 835 (1,840) 1,692 (3,730)
Horizontally opposed, liquid cooled, 4-cylinder, 4-5troke gaoline engine Engine type With Sngle-Point Fuel Injection With MultiPoint Fuel Injection and Tu rboch arger
Valve arrangement Bore x stroke Displacement Compression ratio Firing order Ignition timing at idling speed BTDC/rpm*l rpm 20°/700 700:tl00 mm (in) ern" (cu in) 9.5
Overhead camshaft type 92 x 67 (3.62 x 2.64) 1,781 [108.68J 9.5 1-3-2-4 20°/700 700:tl00 20°/700 700:tl00 20° /800 800:t100 9.5 7.7
Idling speed at neutral, N or P position Spark plug Maximum output Maximum torque Type Battery Reservecapacity Cold cranking ampere Alternator Clutch tvpe Transmission type 1st 2nd Gear ratio 3rd (DriveJ 4th 5th Reverse Auxiliary transmission gear ratio High Low Type and manufacturer
BPR6ES-ll [or BPR5ES-11, BPR7ES-l1 J NGK: Nippondenso: W20EPR-Ul1 (or W16EPR-U11, W22EPR-Ul1) Champion: RN9YC-4 HP/rpm 90/5,200 137 (14.0, 101 J/2,800 50D20R-MF (min.J
(arnp.]
115/5,200 181 (18.5, 134J/2,800 65D23R-MF 111 420 75D23R-MF 111 490
N·m (kg-m, ft,lb)/rpm
65D23R-MF 111 420
78 306
12V-60A DSPD *2 3.636 1.950 1.344 0.971 0.783 3.583 TC +3 2.821 1.559 1.000 TC *3 2.821 1.559 1.000 TC *3 2.821 1.559 1.000 2.257
2.257
2.257 -
+1: Without vacuum '2: 5-forward speeds with synchromesh and t-reverse +3: Full automatic, 3-forward and t-reverse
19
1-1
TOURING WAGON
MODEL
SPECIFICATIONS
4WD GL TURBO MPFI 5MT SIR 819 [1,805) 877 (1,935) 1,696 (3,740) 5 Horizontallv opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine Full time 4WD GL-l0 TURBO MPFI 5MT SIR 819 (1,805) 877 (1,935) 1,696 (3,740) Full time 4WD GL-l0 TURBO MPFI 4AT 850 (1,875) 880 (1,940) 1,730 (3,815)
GL
GL
ITEM Front Weight Gross vehicl e weight Rear Total Seating capacity kg (Ib) kg (lb) kg (lb) persons
SPFI 5MT D/R 803 (1,770) 859 (1,895) 1,662 (3,665)
MPFI 3AT 803 (1,770) 859 !l,895} 1,662 (3,665)
Engine type
With Single·Point Fuel Injection
With Multi·Point Fuel Injection and Turbocharger Overhead camshaft type
Valve arrangement Bore x stroke Displacement Compression ratio Firing order Ignition timing at idling speed BTDC/rpm+' rpm 20° /700 700±100 20° /700 700±100 mm (in) ern? (cu in) 9.5 9,5
92 x 67 (3.62 x 2.64) 1,7B1 (108.68) 7.7 1·3·24 20°C/700 700±100 20° /700 700±100 20° /800 800:1:100 7.7 7.7
Filing speed at neutral, N or P position Spark plug Maximum output Maximum torque Type Battery Reserve capaci ty Cold cranking ampere Alternator Clutch type Transmission type 1st 2nd Gear ratio 3rd (Drivel 4th 5th Reverse Auxiliary transmission gear ratio High Low Type and manufacturer
NGK; Nippondenso: Champion: HP/rpm 90/5,200
BPR6ES-l1 (or BPR5ES-' 1, BPR7ES·' 1) W20EPR·Ull [or W16EPR·Ull, W22EPR-U11) RN9YC4 115/5,200 181 [18.5, 134}/2,800 50D20R-MF 78 30S 12V-SOA 50D20R-MF 78 306 75D23R·MF 1" 490
N·m (kg-m, ft·lb)/rpm
137 (14.0, 101 )/2,800 50D20R·MF 65D20R-MF 111 420
(min.)
(arnp.)
78 306
DSPO +4 3.545 1.947 1.366 0.972 0.780 3.416 1.000 1.592 +2; ·3; +4; "5; "S;
TC +3 2.821 1.559 1.000 2.257 -
OSPD +2 3.545 2.111 1.448 1.088 0.871 3.416
OSPD +6 3.545 2.111 1.448 1.088 0.871 3.416
TC ·5 2.785 1.545 1.000 0.694 2.272
DSPO; Dry Single Plate Diaphragm TC Torque Converter +1: Without vacuum
5-forward speeds with synchromesh and t-roverse Full automatic, 3-forward and 1-reverse 5x2-forward speedswith synchromesh and t-raverse (Dual range) Full automatic, 4-forward and l-reverse 5-torward speeds with synchromesh and t-reverse (Single range) - with center differential
20
SPECIFICATIONS
TOURING WAGON
MODEL FWD GL-10 TURBO
1-1
GL
GL
GL-10
ITEM Reduction gear ( Front driveJ 1st reduction Final reduction Transfer reduction Final reduction Type Steering system Turns, lock to lock Minimum turning circle·1 Front Rear Service brake system Brake Front Rear Parking brake Tire Size Type Fuel ta nk capacity Engine oil
.It (US gal., Imp gal.J
SPFI 5MT Type of gear Reduction gear ratio Type of gear Reduction gear ratio Type of gear Reduction gear ratio Type of gear Reduction gear ratio
MPFI 3AT Helical 0.976 Hypoid 3.454
Hypoid 3.900 -
Reduction gear (Rear driveJ
Rack and pinion 3.7
m (ftl
At tire .......... 9.6 (31.5J At bumper .... 10.6 (34.8J MacPherson strut type, Independent, Coil spring Semi-trailing arm type, Independent, Coil spring Dual circuit hydraulic with vacuum suspended power unit Ventilated disc brake Drum brake (Leading & trailing typeJ Mechanical on front brake 175/70SR13 175/70HR13 Disc brake
Suspension
Steel belted radial, Tubeless 6005.9,13.2] 4.0 (4.2, 3.5J 3.0 (3.2, 2.6J 2.6 (2.7,2.3J
Upper level .It (US qt, Imp qt] Lower level

Q
(US qt, Imp qt)
Transmission gear oil Automatic transmission fluid A T differential oil gear
l! (US qt, Imp qt)
6.2±0.1 {6.6±0.1, 5.5±0.lJ 1.2 (1.3, 1.1 J
6.2±0.1 [6.6±0.1, 5.5±0.1 J 1.2 (1.3, 1.1 J
6.2±0.1 (6.6±0.1, 5.5±0.1 J 1.2 {1.3, 1.1 J 0.7 [0.7,0.6J 6.0 (6.3,5.3] +2 5.5 (5.8,4.8]
·u
> ...
Co
(US
ct.
Imp qtJ
0.7 {O.7,0.6J
..
(3
(US qt, Imp qt) (US qt, Imp qt]
4WD rear differential gear oil Power steering fluid
0.7 (0.7,O.6J
0.7 {D.7,O.6J
l! (US qt, Imp qt)
Engine coolant
l! (US qt, Imp qt]
5.5 [5.8,4.8]
·1: Curb to curb +2: For CANADA
21
1-1
TOURING WAGON
MODEL
SPECIFICATIONS
4WD GL TURBO MPFI 5MT SIR Full time 4WD GL-l0 TURBO MPFI SMT SIR Full time 4WD GL-10 TURBO MPFI 4AT Helical 1.000 Hypoid 3.700 -
GL
GL
SPFI SMT ITEM Reduction gear (Front drive) 1st reduction , Final reduction Transfer reduction Final reduction Type Steering system Turns, lock to lock Minimum turning circle*l Front Rear Service brake system Front Brake Rear Parking brake Tire Size Type Fuel tank capacity Engine oil 2 (US gaL, Imp gal.) m (h) Type of gear Reduction gear ratio Type of gear Reduction gear ratio Type of gear Reduction gea~ratio Type of gear Reduction gear ratio
DIR
Hypoid 3.700 Helical 1.000 Hypoid 3.700 Rack and pinion 3.7 At tire .......... 9.6 (31.S) At bumper .... 10.6 (34.8)
Hypoid 3.700
Suspension
MacPherson strut type, Independent, Coil spring Semi-trailing arm type, Independent, Coil spring Dual circuit hydraulic with vacuum suspended power unit Ventilated disc brake Drum brake (Leading & trailing typeJ Disc brake Mechanical on front brake 185170SR13 18S/70HR13 Steel belted radial, Tubeless 60 (15.9,13.2) 4.0 (4.2,3.5) 3.0 (3.2,2.6) 3.3 (3.5,2.9J 6.55±0.1 (6.9tO.l, 5.8±0.11 1.2 l1.3,l.11 0.8 (0.8,0.71 0.7 iD.7,O.6) 3.3 (3.5,2.9) 3.5 (3.7,3.1) -
+2 *3
Upper level Jl (US qt, Imp qt) Lower level 2 (US qt, Imp qt] 2 (US qt, Imp qt)
Transmission gear oil Automatic transmission fluid AT differential gear oil 4WD rear differential gear oil Power steering fluid
9.5 (10.0,8.4) 1.4 (1.5, 1.21 0.8 (0.8,0.7) 0.7 (0.7,0.61 6.0 (6.3,5.3) '4 5.5 (5.8,4.8)
2 (US qt, Imp qt]
'0
>... a. '"
'"
2 (US qt, Inp qt] 2 (US qt, Imp qt] 2 (US qt, Imp qt]
0.8 (0.8,0.7] 0.7 iD.7,O.6)
0.8 (0.8, 0.7) 0.7 (D.7, 0.6)
O.B
lO.8,O.71 0.7 (0.7,0.6)
Engine coolant
2 (US qt, Imp qt)
5.5 (5.8,4.8)
+1; Curb to curb +2: MacPherson strut type, Independent, Pneumatic suspension with heigt. t control *3: Semi-trailing arm type, Independent. Pneumatic suspension with height control +4: For CANADA
22
GENERAL INFORMATION
BUBARU
1989
Page GENERAL PRECAUTIONS ....•.........•................•. VEHICLE IDENTIFICATION IDENTIFICATION NUMBERS (V.I.N.) ..•.••.....•..... NUMBER AND LABEL LOCATIONS 2 9 12_ 14 18 19
RECOMMENDED FUEL, LUBRICANTS, SEALANTS AND ADHESIVES ......•••......•...••...•••.........•...... TIGHTENING TORQUE OF STANDARD BOLTS AND NUTS ...•.... LIFTING, TOWING AND TlE·DOWN POINTS .......•....•......
1-3
GENERAL INFORMATION
General Precautions
Precautions to take before starting service
1) Be sure to perform the jobs Iistad in the Periodic Mainte· nance Schedule. 2) When a vehicle is brought in for maintenance, carefully listen to the owner's explanations of the symptoms exhibited by the vehicle. List the problems i~ your notebook, and refer to them when trying to diagnose the trouble. 3) All jewelry should be removed. Suitable work clothes should be worn. 4) Be sure to wear goggles. 5) Use fender, floor and seat covers to prevent the vehicle from being scratched or damaged. 6) Never smoke while working. 7) 4WD models (Except full time 4WD) When front wheels are jacked up, or placed on test rollers (= chassis dynamometer) for operation, be sure to set "4WD switch" to "OF F" for both AT and MT Single range and select lever to "FWD" for MT Dual range. On MT Single range, in addition, disconnect harness connector for 4WD solenoid valve inside engine compartment. On AT, in addition, disconnect harness connector for transfer solenoid inside engine compartment. Fig. 3
Fig. 4
L1·594
Fig. 1
Fig. 5 8) Pneumatic suspension models w/height control These models are provided with height control mechanisms. Be sure to return the height control to "Normal" position (low) and support the vehicle with a jack before getting under it for servicing, etc. To check any system, other than electrical, under the vehicle, disconnect cables from battery in advance. 9) Before installing underfloor bolts (include the rear differential filler plug) coated with bituminous wax, remove old Wax and re-coat with new wax.
~ ..~- -... ~ 1 J.
;-",
v-
OM·1547
Fig. 2
GENERAL INFORMATION
Precautions in handling a full time 4WD vehicle
1-3
• Speedometer test Generally, when testing the speedometer of a full-time 4WD vehicle, even if the engine is running at a relatively slow speed, releasing the clutch abruptly jump off of the test machine. this. 1) Testinq'Methods (1) Jack-up Method Fig. 6 The usual speedometer tester is used and the rear wheels are tested with the front wheels raised off the ground and the center differential locked. may still cause the vehicle to Be especially careful to avoid
Precautions while working

1) When jacking up the vehicle, be sure to use safety stands. 2) When jacking up the front or rear end of the car body, be sure to chock the tires remaining in contact with the ground. 3) Keep the parking brake applied when working on the vehicle. Set the shift lever to REVERSE, when the parking brake cannot be applied, such as when the brakes are being worked on. 4) Keep the ignition key turned "OF F" if at all possible. 5) Be cautious while working when the ignition key is "ON"; if the temperature in the engine compartment increases, the cooling fan can start to operate. 6) While the engine is in operation, properly ventilate the workshop. 7) While the engine is in operation, be aware of any moving parts, such as the cool ing fan and the drive belt. 8) Keep your hands off any metal parts such as the radiator, exhaust manifold, exhaust pipe, and muffler, to prevent burning yourself. 9) When servicing the electrical system or the fuel system, disconnect the ground cable from the battery. 10) When disassembl ing. arrange the parts in the order that they were disassembled. 11) When removing a wiring connector, do not pull the wire unit but remove the connector unit by holding it. 12) When removing a hose or tube, remove the cl ip first. Then, pull the hose or tube while holding its end fitting. 13) Replace the gasket, a·ring, snap ring, lock washer, etc. with new ones. 14) When tightening torque. 15) When performing a bolt or nut, tighten work requiring special it to the specified tools, be sure to Fig. 8
L1·358
Safety stand
L1·357
Fig. 7 (2) Adapter Method An adapter is installed and cable, and testing tester with the center speedometer will then Therefore, an adapter
between the vehicle's speedometer is done using the usual speedometer differential operating. The vehicle's indicate 1/2 actual wheel speed. wh ich doubles the speed is neces-
sarv,
Wheel block
use the designated ones. 16) After completing the work, make certain that the hoses, tubes and wiring harnesses are securely connected. 17) After completing the work, be sure to wash the vehicle.
Use the adapter method only when the jack-up method cannot be employed at the service garage.
3
1-3
2)
GENERAL INFORMATION
If the differential lock switch is in the "ON" position, but the differential lock indicator light is not on, rock the vehicle slightly forward or backward to lock the differential. Operate the differential lock switch before setting the speedometer tester. Never operate the differ· ential lock switch while the vehicle is on the free rollers. (There is a chance that the vehicle may jump off the rollers.)
Testing Procedures (1) Jack-up Method CD Equipment • Speedometer tester 1 • Garage jack 1 • Safety stand 2 ® Precautions • Test the speedometer using the rear wheels. (Vehicle stability is better than with the front wheels.)
.~ ..;:':j:~~ .
.........
.... I' I'
-......
+
'- /'
II
_+-
.....
'\ I
II
\.
",' '.... _"",'
Tester roll ers L1·359 ~----------------------------------------~ Fig. 9
L1·361
Fig. 11
Place the garage jack and safety stands in their proper positions. Also, in order to prevent the vehicle from slipping due to vibration, do not place any wooden blocks or similar items between the safety stands and the vehicle.
1
Front (]
rAPprox.
80 mm (3.15 inl "OFF" "ON" U-362
Fig. 12
L1·360
Fig. 10
For safety, start in second gear. Never make any abrupt speed changes or maneuvers during the test. (2) Adapter Method CD Equipment • Speedometer tester 1 • Wheel blocks 2 • ADAPTER (499827100) "1
Since the front wheels will also be rotating, do not place anything near them. Also, make sure that nobody goes in front of the vehicle. • With the center differential locked, confirm that the differential lock indicator light is lit. 4
Since the speedometer detector is on the engine side of the center differential, if the front wheels are locked, the vehicle's speedometer will only indicate 1/2 the speed of the rear wheels. Thus an adapter which doubles the speed is necessary.
GENERAL INFORMATION
•
ADAPTER (499827100)
1-3
rear wheels on the speed-
Do the test with the ometer tester rollers.
L1·363
Tester rollers L'-366
Fig. 13
®
•
Precautions Do the testing
Fig. 16 with the differential lock cancelled.
Confirmation that the differential lock is cancelled can be done with the differential lock indicator light, but for this test, confirm with actual driving, that there is no braking phenomenon sharp corners at low speed. when turning • In order to prevent the vehicle from jumping off the tester, be certain to apply the parking brake and place wheel blocks in front of the front wheels. Also, make sure that nobody goes in front of the vehicle.
III.'
o
II"
"OFF"
"ON" L1·364
Wheel block Tester rollers
Fig. 14 • Since the vehicle speedometer indicates 1/2 the actual speed of the rotating wheels, be certain to install an ADAPTER (499827100).
LT ·367 Fig. 17
• •
For safety, start in second gear. Never make any abrupt speed changes or maneuvers during the test. The center differential will be rotating faster than normal. Check the transmission oil which also serves as the center differential oil and add if oil level is low. Keep maximum speed below 50 km/h (31 MPH) and for less than 1 minute. Adapter Installation Procedures a. Remove the trim panel (D) below the driver's side instrument panel.
®
Fig. 15
1-3
GENERAL INFORMATION
• Brake Test When using the brake tester, do so with the differential lock cancelled. Turn the differential lock switch off and make sure that the differential lock indicator light ("DIFF LOCK") has gone off. • Chassis Dynamometer Test The propeller shaft must be removed and the vehicle made into front wheel drive. To undo the propeller shaft, do not disconnect the front propeller shaft ASSY. Only disconnect the rear propeller shaft ASSY and lock the center differential.
Fig. 18
When reconnecting the front and rear propeller shaft ASSY's, align the matching marks very carefully.
• Tire Balance Test (On-car-rnachlne) For safety when doing the tire balance testing, disconnect the propeller shaft and keep the center differential locked. Also, do not drive the tires with the engine, but use the on-carmachine to rotate the tires and do the balance testing.
b. Disconnect the speedometer cable from the speedometer. c. Connect the speedometer cable to the ADAPTER gear box.
a. In doing the testing, be sure to jack up both the left and right sides and put wheel blocks behind the tires contacting the ground. b. Make sure that the transmission is in neutral gear position.
• Towing If the following conditions cannot be met, raise and support all four wheels to move the vehicle.
Fig. 79
d. Connect the speedometer to the ADAPTE R speedometer cable.
a. Before towing, check transmission oil and differential oil levels and top up to the specified level if necessary. b, The ignition switch should be in the "ACC" position while the vehicle is being tov..ed. c. Never use the tie down tabs for towing. d. Remember that brake booster and pov..er steering will not work when the engine is "OFF", You will have to use greater effort for the brake pedal and steering wheel.
Place the cable so that it does not get in the way when pressing down the Accelerator pedal.
o
L 1·365
Fig. 20
GENERAL INFORMATION
1} Rope Towing Turn the differential lock switch to the "OFF" position and make sure that the differential lock indicator light ("DIFF LOCK") has gone off. (Confirmation of differential lock cancellation.)
1-3
CD
• Differential Lock Cancelling Method 1) Under normal circumstances, start the engine, turn the differential lock switch off and, with the tires pointed straight, move the vehicle either forward or backward. 2} If the engi ne cannot be started, such as with a dead battery or when the vacuum actuator is not working, raise the front (or rear) wheels and move the differential lock lever, on the right vehicle. side of the transmission, towards the rear of the
When the vehicle has a large air spoiler skirt on it, wrap the tow rope with a rag to prevent the rope from scratching the air spoiler. Tow the vehicle with the engine off.
"Front
c
Rag
L1·370
L1·372
Fig. 21
Fig. 23
2}
Towing with Front Wheels Raised Turn the differential lock switch to the "OFF" position and make sure that the differential lock indicator light ("D IFF LOCK") has gone off. (Confirmation of differential lock cancellation.)
CD
®
The
center
differential
will
be rotating
faster
than
normal. Check the transmission oil which also serves as the center differential oil and add if oil level is low. Tow at less than 30 km/h (19 MPH).
• Before checking or servicing the car with the front wheels raised or on rollers (brake tester, chassis dynamometer, etc.), always set the car in the FWD mode. To set the car in the FWD mode, disconnect the 4WD circuit by inserting a fuse in the FWD connector inside the engine compartment. Also chock the rear wheels firmly. If the car is left in the 4WD mode, it will surge abruptly turn, possibly damaging the transfer clutch. when the wheels
Do not tow for more than 50 km (31 miles).

Transmission oil level check
Towing distance within 50 km [31 milesJ.
Towing speed under 30 km/h (19 MPHf. L1·371
Fig. 22
Fig. 24
1-3
•
GENERAL INFORMATION
• Towing If the following conditions cannot be met, raise and support all four wheels to move the vehicle.
Also ensure that the FWD pilot light is on.
Analogue
meter
I
-p -R -N -D -3 -2
Digital meter
~ rm
IiiO
lEI {®l
r"'~K
'"~.
.::; rn
'l:Qf,iTMI
IJD~
rn~
TURBO
a. Before towing, check transmission oil and differential oil levels and top up to the specified level if necessary. b. The ignition switch should be in the "ACC" position while the vehicle is being towed. c. Never use the tie down tabs for towing. d. Remember that brake booster and power steering will not work when the engine is "OFF". You will have to use greater effort for the brake pedal and steering wheel.
L1-593
1HOLD "::1 ::::EIG=H""Y =co~N:"'YIilll='' ' 1 H
Fig.
25
Rope towing CD Place the selector lever is "N" position and put a spare fuse inside the FWD connector. ® Tow at less than 30 km/h (19 MPH). @ Do not tow for more than 10 km (6 miles).
GENERAL INFORMATION
1-3
Vehicle Identification Numbers (V.I.N.)

1. Applicable V.1.N. in This Manual
• 1800 cc Engine DL DL GL GL GL GL-10 GL-l0 GL-10 TURBO 4-DOOR SEDAN "GUO TURBO GL-10 TURBO 4WD GL 4WDGL (SPFI,5MT) (SPFI,3AT) (SPF1,5MT) (SPF1,3AT) (SPFI, 3ATwith (SPFI,3AT) (SPFI, 3AT with passive belt) (MPFI,5MT) (MPFI,3AT) (MPF I, 3AT with passive belt) (SPFI, 5MT Dual-range) (SPFI,3AT) passive belt) J J J J F1AC4 F1AC4 F1AC4 2 2 3 BXJ BXJ BXJ
8 C
B C
F1AC4 3BXJ F1AC432XJ F1AC44 BXJ
J J J J J J J J J
J
C C
B
F 1AC44 2 XJ C
F1AC45 F1AC45 F1AC4 BXJ BXJ
52XJ BXJ BXJ
C C
E F G
200001 and after
F2AC53 F2AC53
FULL TIME 4WD RX TURBO (MPFI, 5MT Dual-range) FULL TIME 4WD GL-1Q TURBO (MPFI, 5MT Single-range) FULL TIME 4WD GL-l0 TURBO (MPFI,4AT) DL DL GL GL GL GL-lO GL-lO GL-l0 STATION WAGON "GL-l0 TURBO TURBO (SPFI,5MT) (SPFI,3AT) (SPFI,5MT) (SPFI,3AT) (SPF I, 3AT with passive belt) (SPFI,3AT) (SPF I, 3AT with passive belt) (MPFI,5MT) (MPFI,3AT) (MPFI, 3AT with passive belt) (SPFI, 5MT Single-range) (SPFI, 5MT Dual-range) (SPFI,3AT) (MPFI, 5MT Single-range)
F2AC56BXJ BXJ
F2AC75
J J J J J J J J J J
J J J J J J
F2AC75BXJ
F 1 A N4 F 1A N4
2B
2
XJ 8 8XJ C
B
F1AN4 3 F1AN4 3
8XJ C
F1AN4 3 2
XJ C
C
8 C C D E F D G 400001 and after
F1 AN4 4 BXJ F1 AN4 4 2 F 1 A N4 F1AN4 5B 5B
XJ C XJ XJ XJ X
J
GL-lO TURBO 4WD DL 4WD GL 4WD GL 4WD GL TURBO
F1AN4 5 2 F2 AN52 B
F2AN53B F2 F2 AN53B AN57 B
XJ XJ X X
J J
FULL TIME 4WD GL-10 TURBO (MPFI, 5MT Single-range) FULL TIME 4WD GL-l0 TURBO (MPFI,4AT) " Canada model
F2 AN55 8 2 AN75 B
JIF
XJ
1-3
GL GL GL-10 GL-10TURBO TOURING WAGON 4WDGL 4WD GL 4WD GL TURBO
GENERAL INFORMATION
(SPFI,5MT) (SPFI,3AT) (SPFI,3AT) (MPFI,3AT) (SPFI, 5MT, Dual-range) (SPFI,3AT) (MPFI, 5MT, Single-range)
J J J J J J J J J J J J J J J J
F1AK43 F1AK4 3 F1AK44
BXKB BXKC BXKC
F 1A K4 5 BX KC F2AK53BXKE F2AK53 BXKF 002001 and after
F2AK57BXKD F2AK55 BXKG
FULL TIME 4WD GL-10 TURBO (MPFI, 5MT Single-range) FULL TIME 4WD GL-10 TURBO (MPFI,4AT) DL DL GL 3-DOOR GL 4WD-GL 4WD-GL (SPFI,5MT) (SPFI,3AT) (SPFI,5MT) (SPFI,3AT) (SPF I, 5MT Dual-range) (SPFI,3AT)
F2AK75
BXKH
F 1 AG4 2
BXJ
F1AG4 2 BXJ C
F 1 AG4 3 F1 AG4 3 F2 AG53 F2AG53 B
8
B
XJ B XJ C
E F G
BXJ
800001 and after
XJ XJ
FULL TIME 4WD RX TURBO (MPFI, 5MT Dual-range)
F2 AG5 6 B
10
GENERAL INFORMATION
2. The Meaning of V.1. N.
...----------------------.------------------...-----------Vehicle Maker identifier Vehicle attribute identification
1-3
J F 1 A C 4 2 B X K B 2 000
- .'-,...-r--'
II
1 Sequential number 200001 and after: 400001 and after: 002001 and after: 800001 and after:
1'---------
4-Door Sedan Station Wagon Touring Wagon 3-Door and transmission type 5MT AT 4WD 5MT 4WD, Dual-range 4WD AT Full time 4WD MT Full time 4WD AT
L...-
Plant of manufacture Gunma Gunma Gunma Gunma Gunma Gunma H Gunma Model year K: 1989 B C D E F G
manufacture manufacture manufacture manufacture manufacture manufacture manufacture
1--
L...-
Check digit
o thru
'---------------
9 and X, varies
Weight class and restraint type B 3,001 to 4,000 Ib GVWR without passive restraint 2 : 3,001 to 4,000 Ib GVWR with passive restraint GVWR: Model 2 3 4 5 DL model GL model GL-10 model GL-10 TURBO model RX TU RBO model GL TURBO model 1800cc engine 1800cc engine 4WD (except model equipped with air suspension) 1800 cc engine 4WD (model equipped with air suspension) 4-Door Sedan Station Wagon Fuji SUBARU : : L line Gross Vehicle Weight Rating
6 7
L...-
Series and engine type 4 5 7
L...-------------------Bodytype C
L...-
G
K
3-Door Touring Wagon
N Line A
L...-
Type of vehicle 1 2 Passenger car Multipurpose passenger vehicle and make
L...-
Manufacturer
Fuji Heavy Industries Ltd. SUBARU
11
1-3
GENERAL INFORMATION
Identification Number and Label Locations

1. Vehicle Identification Number
The vehicle identification number panel of the engine compartment. is stamped on the bulkhead
3. Transmission Serial Number

The transmission number label is stuck on the upper surface of main case (MT) or converter housing (AT).
1 MT: 4WD/FWD
TURBO
I"
Fig. 26
Fig. 28
2. Engine Serial Number

The engine serial number crankcase at the front. is stamped on the right side of the
Fig. 29
Fig. 27
Fig. 30
12
GENERAL INFORMATION
Transmission serial number
1-3
5. Vehicle Emission Control Information Labels

Vehicle emission control information labels are stuck under the engine hood.
Vacuum hose piping label
Ll421
Fig. 31
TURBO only
Engine, transmission and vehicle identification numbers are used for factory communications such as Technical informa· tion, Service bulletins and other information.
L1·585
Fig. 33
6. Vehicle Identification Number Plate
4. Safety Certification Plate

Safety certification striker. plate is stuck near the driver's side door
Fig. 34
7. Color Code Label
Ll·373
Fig. 32
Fig. 35
13
1-3
GENERAL INFORMATION
Recommended Fuel, Lubricants, Sealants and Adhesives

1. Fuel
The SUBARU engine is designed to use only unleaded gasoline with an octane rating of 87 AKI or higher. [This octane rating is the average of the Research Octane and Motor Octane numbers and is commonly referred to as the Anti-Knock Index (AKI).] Use of fuels containing proper detergents is recornmended for good performance and emission control. The neck of the fuel filler pipe is designed to accept only an unleaded gasoline filler nozzle. Under no circumstances should leaded gasoline be used since it will damage the emission control system and may impair driveability and fuel economy. • • Never use fuel containing grain alcohol). more than 10% ethanol (ethyl or Methanol (methyl or wood alcohol) is sometimes mixed with unleaded gasoline. Methanol can be used in your vehicle ONL V if it does not exceed 5% of the fuel mixture AND it is accompanied by sufficient quantities of the proper cosolvents and corrosion inhibitors required to prevent fuel system damage. Otherwise, fuel containing methanol • should not be used. Un leaded fuel blends which contain no more than 15% MTBE (methyl tertiary butyl ether) or other oxygenates and which are approved by the Environmental Protection Agency may be used. Vou should avoid using fuels mixed with alcohol or other oxygenates on an exclusive basis. If driving problems such as engine stalling or hard starting result when such fuels are used, immediately discontinue their use and switch back to unleaded gasoline that does not contain alcohol or other oxygenates.
2. Fuels Containing Alcohol

Some gasoline blends sold at service stations contain alcohol or other oxygenates even though that fact may not be fully disclosed. If you are not sure whether there is alcohol present in the fuel, ask your service station operator. Do not use such fuels unless the gasoline/alcohol blend is suitable for your vehicle as explained • The fuel should below: be unleaded and have an octane
above.
Take care not to spill fuel during refueling. Fuels containing alcohol may cause paint damage.
rating no
lower than that recommended
14
GENERAL INFORMATION
Lubricants Recommended FX clutch grease (PIN 000040901) Molylex No.2 Application Splines of transmission main shaft. Equivalent
1-3
--
(PIN 723223010) PBC (PIN 003607000) Silicone KS64 (PIN 003606010)
BJ and DOJ joints of axle shafts. Stopper plugs of the front disc brake caliper. Brake cal iper body (Piston, spindle adjuster O-ring). battery terminals, distributor, hood latch, etc. linkages
---
-----
Control cables and carburetor Silicolube G-30M
subject to cold weather, water-pump impeller, door latch, striker, battery terminals, etc.
Grease
(PIN 004404002)
Dow Corning Molykote (PIN 725191460) Niglube RX-2 (PIN 003606000) Val iant grease M-2 (PIN 003608001 ) SUNLIGHT 2 (PIN 00360201 0)
No. 7439
Contacting surfaces of drum brake shoes and shoe clearance adjuster. Disc brake caliper (lever, connecting link and spindle head). Steering gearbox (Both manual and power steering) Steering shaft bearing, bushing for gear shift system, etc. TU RBO unit and O2 sensor.
--
---
------
Spray lubricants
SUBARU CRC (PIN 004301003)
15
1-3
GENERAL INFORMATION
ITEM
API Glnssif ica-
SAE viscosity
No. and Applicable 0 30 0 60
Temperature 90 32
tion
(oFI
-30 -34
( c:
SE • Engine oil or SF
<:
-18
16 10W·30, 10W-40
5W-30
I I
SOW 75W-90, 'SOW·90 90 S5W
• Transmission and differential gear oil .4WD rear differential gear oil
GL·5
<
<
>
L1-513
Fig. 36
a. Each oil manufacturer has its base oil and additives. Thus, do not mix two or more brands. (Except engine oil) b. 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. c. SAE 5W·]O is not recommended for sustained high speed driving. d. If vehicle is used in desert areas or 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
e. * For differential gear oil (AT)
Coolant Specifications Lowest atmospheric anticipated temperature Above -30°C (-22°F) SUBARU coolant-to"water ratio (Volume) % 50 - 50 Specific gravity at 10°C (50°F) 1.078 at 20°C (68°F) 1.074 at 30°C (86°F) 1.069 at 40°C (104°F) 1.063 at 50°C (122°F) 1.057 Freezing point
-36°C (-33°F)
"" It is recommended that distilled water be used.
a. Avoid using any coolant or only water other than this designated type to prevent corrosion. b. SUBARU's engine is aluminum alloy, and so special care is necessary.
16
GENERAL INFORMATION
3. Sealants and Adhesives
Recommended Three Bond 1105 (PIN 004403010) Sealant Three Bond 1215 (PIN 004403007) Starcalking B-33A (PIN 000018901) Mating surfaces etc. Periphery Flywheel housing, Application of transmission cases, plugs, seal. Equivalent Dow Corning's No. 7038 Dow Corning's No. 7038 Butyl Rubber Sealant 3M's EC-1770 EC-1368 3M's EC-776 EC-847 EC-1022
1-3
of water pump mechanical bolts, mating
surface of flywheel
crank case and cam case.
Seal ing against water and dust entry through weatherstrips, grommets, etc. Weatherstrips and other rubber parts,
Cemedine
5430L
plastics and textiles parts.
except
soft vinyl
Cemedine Adhesive
540
Soft vinyl parts, and other parts subject to gasoline, grease or oil, e.q. trim leather, gear shift boot, door inner remote cover, etc.
(Spray Type)
Cemedine
3000
Bonding metals, glass, plastic and rubber parts, Repairing slightly torn weatherstrips, etc.
Armstrong's Eastman 910
Essex Chem ical Corp's Urethane E
Windshield
to body panel.
--
17
1-3
GENERAL INFORMATION
Tightening Torque of Standard Bolts and Nuts

(1) ENGINE & TRANSMISSION
5T 1.0 -1.5 (0.105 - 0.155, 0.8 - 1.1) 2.5 - 3.0 (0.255 - 0.305, 1.B - 2.2) 4.4 - 5.4 (0.45 - 0.55, 3.3 - 4.0) 12 - 14 (1.2 -1.4, 9 -10) 25 - 28 (2.5 - 2.9, 18 - 21) 41 - 49 (4.2 - 5.0, 30 - 36) 71 - 84 (7.2 - 8.6, 52 - 62) 7T 1.5-2.0 (0.155 - 0.205,1.1 9T 2.5 - 3.0 (0.255 - 0.305, 1.8 - 2.2) 4.9 -5.9 (0.50 - 0.60, 3.6 - 4.31 9.4 - 10.8 (0.955 - 1.105, 6.9 - 8.0) 23 - 26 (2.3 - 2.7,17 - 20) 46 - 54 (4.7 - 5.5, 34 - 40) 84 -98 (8.6 - to.O, 62 - 72) 139-165 [14.2 -16.8, 103 - 122) Unit: N·m {kq-rn, tt-Ib] lOT 3.0 - 3.5 (0.305 - 0.355, 2.2 - 2.6) 5.4 - 6.4 (0.55 - 0.65,4.0 - 4.7) 10 -12 (1.0 - 1.2,7 - 9] 25 - 28 (2.5 - 2.9,18 - 21) 49.5 - 58.4 (5.05 - 5.95, 36.5 - 43,0) 88 -106 (9.0 -10.8, 65 - 78) 147 - 175 (15,O -17.8,108 -129) Dia. x Pitch (mm1 4 x 0.75
- 1.51
5 xO.9
2.9 - 3.9 (0.30 - 0.40, 2.2 - 2.9) 5.9 -6.9 (0.60 - 0.70,4.3
6 x 1.0
- 5.1)
8 x 1.25
14.2 - 17.2 (1.45 - 1.75, 10.5 - 12.7) 30 - 36 (3.1 - 3.7, 22 - 27) 53 - 63 (5.4 - 6.4, 39 - 46) 88 - 106 (9.0 - 10.8,65 - 78)
10 x 1.25
12 x 1.5
14 x 1.6
(2)
BODY
Dia. (mrn] 4 4T 1.7 - 2.6 (0.17 - 0.27,1.2 - 2.0J 2.9 - 5.9 (0.30 - 0.60, 2.2 - 4.31 5.4 - 9.3 (0.55 - 0.95, 4.0 - 6.9) 12.7 - 22.6 (1.30 - 2.30,9.4 - 16.6) 27.5 - 47.1 (2.80 - 4.80, 20.3 - 34.7) 52.0 - 85.3 (5.30 - 8.70, 38.3 - 62.9) 1.2-2.2 (0.12 -0.22, 0.9 -1.6) 2.5 - 4.4 (O.25 - 0.45, 1.8 - 3.3) 4.4-7.4 (0.45 - 0.75. 3.3 - 5.4) 9.8 - 17.7 (1.00 - 1.80,7.2 - 13.0) 22.6 - 36.3 (2.30 - 3.70,16.6 - 26.8J 39.2 - 64.7 (4.00 - 6.60,28.9 - 47.7) 17.7-31.4 (1.80 - 3.20, 13.0 - 23.1) 37.3 - 66.7 (3.80 - 6.80, 27.5 - 49.2) 68.6 - 117.7 (7.00 - 12.00,50.6 - 86.8) 22.6 - 42.2 (2.30 - 4.30,16.6 - 31.1) 51.0 - 86.3 (5.20 - 8.80, 37.6 - 63.7) 88.3 - 156.9 (9.00 -16.00,65.1 -115.7) 7T
Unit:
N·m (kg-m, tr-lb) 9T
~ ~
31.4 - 51.0 (3.20 - 5.20, 23.1 - 37.6) 62.8 -107.9 {6.40 - 11.00,46.3 - 79.61 117.7-196.1 (12.00 - 20.00, 86.8 - 144.7)
~
10 TC·002
Fig. 31
12
~ ~ ~
TC-003
23.5 - 39.2 (2.40 - 4.00, 17.4 - 28.9) 48.1 - 83.4 (4.90 - 8.50, 35.4 - 61.5) 88.3 - 147.1 {9.00 - 15.00,65.1 - 108.51
Fig. 38
Including bott or nut with washer or spring washer only
10
12
The mark is embossed on the bolt head as follows: 4T-'-4 9T-9
5T -5 7T--7
lOT --
10
18
GENERAL INFORMATION
1-3
Lifting, Towing and Tie-down Points

Be sure to lift, tow and tie-down the vehicle at the designated positions.
1. Garage Jack
Crossmember
[F)
Fig. 39
REAR
4WD
Rear differential
L1·012
Fig. 40
a. When jacking up the vehicle, place chocks to hold wheels. b. After jacking up the vehicle with garage jack, be sure to support the vehicle with safety stands for safety.
19
1-3
2. Pantograph Jack
GENERAL INFORMATION
L1-013
Fig. 41
a. Never get under the vehicle while it is supported only by the jack. Always use safety stands to support body when you have to get under the car. b. Block the wheels diagonally by wheel chocks. c. Make sure the jack is set at the correct position on the flange of side sill. d. Be careful not to set the jack at the air flap portion.
3. Safety Stand
Be sure to lift vehicle at the same four positions as those of pantograph jack.
L1-014
Fig. 42
20
GENERAL INFORMATION 4. Lift
1-3
L1-015
Fig. 43
a. Be sure to lift vehicle at the same four positions as those of pantograph jack. b. Be careful not to set the lift at the air flap portion.
5. Towing and Tie-down Hooks

Avoid towing another car with front towing hooks.
I Front I
\~J l
__________ o
L1·017
Fig. 44
Fig. 45
21
PERIODIC MAINTENANCE SERVICES
1JC~
Page SERVICES. . . . .• 2 3 5 8 10_ 11 14 17 18 19 20 22 24 26 27 30 32 39
SUBARU
1989
SCHEDULE OF INSPECTION AND MAINTENANCE
1. DRIVE BELT(S) [EXCEPT CAMSHAFT] (INSPECT DRIVE BELT TENSION) . . • • . . . . • . . . . . . . . • . . . . .• 2. CAMSHAFT DRIVE BELT ....•.....•......•..•..•....•• 3. ENGINE OIL .•. . . • • . . . • . • . . . . . . . . . . . . . . . . . • . . . . . . . .. 4. ENGINE OIL FILTER ...•..•.••...••..........•.•...... 5. REPLACE ENGINE COOLANT AND INSPECT COOLING SYSTEM, HOSES AND CONNECTIONS ........•..•......... 6. REPLACE FUEL FILTER AND INSPECT FUEL SYSTEM HOSES AND CONNECTIONS ................•...• 7. AIR FILTER ELEMENTS (AIR CLEANER) ...•..•.••.....•.. 8. SPARK PLUG •••.•..•........................•..••.•• 9. TRANSMISSION/DIFFERENTIAL (FRONT AND REAR) LUBRICANTS (GEAR OIL).. . . . . . . . . . . . . . . . . . . • . . . • . . . •. 10. AUTOMATIC TRANSMISSION FLUID ...•.........•..•••••. 11. BRAKE FLUID .................•....•..........•..•.. 12. DISC BRAKE PAD AND DISC/FRONT AND REAR AXLE BOOTS ..•...•.•.......•.......•......•.. 13. BRAKE LINING AND DRUM •.•..••..•...•.....•......•. 14. INSPECT BRAKE LINE AND CHECK OPERATION OF PARKING AND SERVICE BRAKE SYSTEM .....•....•..•••. 15. CLUTCH AND HILL·HOLDER SYSTEM ..•...••..•.••..•.••. 16. STEERING AND SUSPENSION ....•.......•...•....••.••• 17. GREASE ON FRONT AND REAR WHEEL BEARINGS
1-5
SCHEDULE OF INSPECTION MAINTENANCE SERVICES

Continue periodic maintenance beyond 96,000 km (60,000 miles) or 60 months by retu rning to the fi rst column of the maintenance schedule and adding 96,000 km (60,000 miles) or 60 months to the column headings. Symbols used:
AND
R: I: P; (I) or (P)": Replace Inspect, and then adjust, correct or replace if necessary. Perform Recommended service for safe vehicle operation
[Number MAINTENANCE ITEM Months
MAINTENANCE INTERVAL of months or km (miles), whichever 7.5 12 7.5 15 24 15 22.5 36 22.5 30 48 30 I
occurs first] 45 72 45 52.5 60 96 60 R R REMARKS
37.5 60 37.5
x 1,000 krn
x 1,000 miles 1 2 3 4 Drive belt'[s] Camshaft Engine oil Engine oil filter Replace engine coolant and connections and inspect Non·TURBO TURBO vehicle [Except camshaft] (Inspect drive belt tension)
84
52.5
drive belt R R· R R R R R R R R R
See NOTE 1
R
R R R
R
R P P R R See NOTE 3 See NOTE 4 See NOTE 2 &6
vehicle
R (P)
(P)
5 6 7
cooling system, hoses line
Replace fuel filter and inspect fuel system, and connections Air filter elements Spark plug Transmission/Differential Lubricants (Gear oil) Automatic Brake fluid Disc brake pad and disc/Front axle shaft joint portions. Brake lining and drum Inspect brake line and check operation and service brake system Clutch and hill-holder Steering and suspension system transmission (Front fluid & Read (Air cleaner!
R
R I I
R
8 9
10 11 12 13 14 15 16 17 .:
R
I I I P I I P
I
See NOTE 5 See NOTE 6 See NOTE 6 See NOTE 6
and rear axle boots and
I I
of parking
P I I
P I I
I
(I)
See NOTE 6
Grease on front and rear wheel bearings whichever occurs first.
Only lit first 12,000 km (7,500 miles) Dr 7.5 months
NOTES: 1) When the vehicle is used under severe driving conditions such es thosa mentioned below·, the engine oil should be changed more often. 2) When the vehicle is used in extromoly cold or hot weether areas, contaminetion of the filter mlly occur end filter replacement should be per· formed 85 necessary. 31 When the vehicle is frequently operllted under severe conditions, replacement should be performed every 48,000 km (30,000 mites). 41 When the vehicle is frequentlv operated under SIIvere conditions, replacement shOUld be performed every 24,000 km (15,000 miles). 51 When the vehicle is used in high humidity IIr8BS or in mountainous areas, change the brake fluid every 24.000 km (15,000 milesl or 15 months, whichever occurs first. S) Whan the vehicle is uSIId under SIIVllre driving conditions such BS those montioned below·, inspoction should be performed evory 12,000 km (7,500 milesl or 7.5 months, whichever occurs first. • Examples of sevare driving conditions: (1) Repeatod short distence driving (Item 3, 12 and 13 onlv) (2) Driving on rough lind/or muddy roads (Item 12, 13 lind 16 only) (3) Driving in dusty conditions (4) Driving in extremely cold weather (Item 3 and 16 onlyl (5) Driving in areas where roads salts or other corrosive materials are used. (ltom 6, 12, 13, 14 and 16 only) (6) Living in coastal araas litem 6, 12, 13,14 and 16 only)
1-5
Drive Belt(s) (Except Camshaft) ( Inspect drive belt tension)
MAINTENANCE INTERVAL [Number of months or km (milas), which.var occurs firstl Months )( 1,000 km )( 1,000 miles 7.5 12 7,5 15 24 22.5 36 22.5 30 48 30 37.5 60 37.5 45 72 45 52.5 84 52.5 60 96
15
0
INSPECTION
1) Replace belts, if cracks, fraying or wear is found. mm ([n)/98 New belt 2) Check drive belt tension changing alternator installing installing position.
60
and adjust it if necessary by position and/or idler pulley
Type
Pulley arrangement
Tension N (10 kg, 22 Ib) Existing belt
Power steeri ng equipped model
7 - 9.1 (0.28 - 0.35)
9 -11 (0.35 - 0.43)
Power steering and air conditioner equipped model

Rear PANASONIC
7.5 - 8.5 *2 (0.295 - 0.335)
Lt·595 Figures in parentheses refer to the number of grooves in pulleys. C/P : Crankshaft pulley W/P : Water pump pulley Al T; Alternator pulley
PIS:
Ale:
lIP:
Power steering oil pump pulley Air conditioner compressor pulley Idler pulley
Fig. 1
"1 Raplaca two baits simultaneously if the above fault is found on one of the two baits. "2 When replacing belt with a new one, adjust its tansion to the specification and then readjust it to the same specificetion after running engina for 5 minutes in consideration of its initial
expansion.
1-5

2) Install new belt(s) and tighten alternator installing bolts as to obtain the specified belt tension shown in the above table. 3) Wipe off any oil or water on belts and pulleys.
REPLACEMENT
[A] Alternator drive belt(s)
On vehicles equipped with HITACHI air conditioner, remove pulser before replacing belt After installing new belt, be sure to install the pulser to the original position.
1) Loosen alternator mounting bolts and remove belt(s).
[8]
Rear side belt (not driving alternator)
On vehicles equipped with HITACKI air conditioner, remove pulser before replacing belt, and install the pulser after completion of replacement.
1) Loosen bolt and special nut, securing idler pulley then remove belt.
Fig. 2 Fig. 3
2) Attach new belt and apply proper tension to belt as shown above.
EJ
1-5
Camshaft Drive Belt
[Number Months x 1,000 km x 1,000 miles
MAINTENANCE INTERVAL of months or km (milesl. whichever 7.5 12 7.5 15 24 15 22.5 36 22.5 30 48 30 37.5 60 37.5
occurs first) 45 72 45 52.5 60 96 60
84
52.5
m
REPLACEMENT a. Before replacing timing belts, remove radiator fan. b. Timing belts should be replaced when engine is cold. c. Be extremely careful not to allow nuts, washers, and other foreign matters to enter belt cover.
REMOVAL
1) Loosen water pump pulley nut until it can be turned with fingers. 2) 3) Loosen two alternator mounting bolts. Detach V-belts. 10) Remove front belt cover by loosening eight 6 mm bolts. 11) Remove timing belts: (1) Loosen bolts securing tensioner on the side of #1 and #3 cylinders, and move tensioner upward completely. Then temporarily tighten bolts. Use special tool "TENS10NER WRENCH" (499007000) to move up #2 and #4 side tensioner. (2) Detach timing belt on the side of #1 and ders. (3) Remove crankshaft sprocket CPo (4) Detach timing belt on the side of #2 and ders.
#3
cvlin-
#4
cvlin-
4) Disconnect harness for oil pressure switch or oil pressure gauge. 5) Remove crankshaft pulley: Loosen crank pulley bolt, and remove pulley.
Put arrow mark to indicate the direction in which belts move before detaching belts.
INSTALLATION
Loosen the upper bolts

1) Install timing belts:
® and © by
1/2 turn in advance.
AT: STOPPER (4984970001 MT: STOPPER (4982770001

...ft\"1 '111_ \
1\
(1) AI ign center line of three lines scribed on flywheel with timing mark on flywheel housing by moving fly· wheel. (2) Align timing mark scribed on left-hand camshaft sprocket with notch on belt cover.
Fig. 4
Timing mark
6)
Remove water pump pulley and pulley cover by loosening
four 6 mm nuts. 7) Remove level gauge guide together with level gauge by loosening one 8 mm bolt. 8) Remove belt cover plate CP by loosening three 6 mm bolts. (For TURBO equipped models only) 9) Remove right-hand and left-hand belt covers by loosening eight 6 mm bolts.
Ll-25B
Fig.
1-5
(3) Attach No.2 pump sprocket,

timing belt to crankshaft idler CP, and camshaft not to slacken belt. of belt by loosening sprocket, sprocket tensioner oil in bolt (8) Be sure the three lines on flywheel and timing mark on camshaft sprocket are respectively positioned as specified in steps (1) and (2) above. (9) Rotate crankshaft clockwise one turn and align center line of scribed three lines on flywheel with timing mark on flywheel housing. (10) Install crankshaft sprocket CPo (11) Align timing mark of rlqht-hand with notch on belt cover. (12) Attach timing belt to crankshaft
sequence. Be careful (4) Adjust tension
by 1/2 turn.
camshaft sprocket
sprocket and cam-
shaft sprocket. Be careful not to slacken belt. (13) Loosen tensioner bolt @ 1/2 turn, and apply tension to timing belt. (14) Push timing belt with finger to ensure smooth move-
ment of tensioner. (15) Using special tool "BE LT TENSION WR ENCH CP" (499437000)' apply the specified torque counterclockwise to camshaft tighten tensioner Fig. 6 bolt sprocket. Under this state, temporarily bolt @ and then temporarily tighten
@.
(5) Push timing moves smoothly.
belt
with
finger
and
ensure
tensioner
(6) Using special tool "BELT TENSION WRENCH CP" (499437000), apply the specified torque counterclockwise to camshaft tighten tensioner bOlt@. sprocket. Under this state, temporarily bolt @ and then temporarily tighten
Specified timing belt tension and torque to be applied to camshaft sprocket
Fig. 7
Belt tension:
147 - 245 N (15 - 25 kg, 33 - 551b)

Torque to be applied to camshaft sprocket:
(16) Sequentially torque. Tightening torque:
tighten
bolts
@ and @ to the specified
24 - 25 N·m (2.4 - 2.6 kg-m, 17 - 19 ft·lb)
17.2 - 20.1 N·m (1.75 - 2.05 kg-m, 12.7 - 14.8 ft-lb)
When specified belt tension is applied to timing belt, notch of special tool "BEL T TENSION WRENCH CP" will be aligned with belt cover notch. Timing under tensioned state can be ascertained by this method.
2) (7) Sequentially tighten bolts
(17) Be sure the three lines on flywheel and timing mark on camshaft sprocket are respectively positioned as specified insteps (11) and (12) above. Install front belt cover: belt cover
and @ to the specified
torque. Tightening torque:
Attach front and rear belt cover sealings, and timing plug to front belt cover. Install it to cylinder block.
17.2 - 20.1 N·m (1.75 - 2.05 kg-m, 12.7 - 14.8 ft-Ibl
Be sure that no foreign matter such as nut, washer, etc. is left inside the belt cover.

3) Install crank pulley: Lock crank pulley using special tool "FLYWHEEL STOPPER CP" (for AT) or "DRIVE PLATE STOPPER" (for MT) and tighten crank pulley bolt. Tightening torque:
1-5
89 - 107 N·m (9.1 - 10.9 kq-m, 66 -79 ft-Ib)

4) Install water pump pulley: Assemble water pump pulley and pulley ily tighten bolts.
cover, and temporar-
5) Install oil level No.2 guide ASSY and oil level gauge CPo Coat O·ring with engine oil when installing. 6) Install right-hand and left-hand belt covers. Then install belt cover plate CP (TURBO equipped models only). 7) Install V-belts. 8) Tighten water pump pulley bolt to the specified Tightening torque:
torque.
9.1 - 10.5 N·m (0.93 - 1.07 kg-m, 6.7 -7.7 ft-lb)

Crankshaft pulley
L._ ___:._...:._
L1-259
_____l
9) Connect harness to oil pressure switch gauge and clamp harness to level gauge guide.
or oil pressure
Fig. 8
1-5
II

MAINTENANCE INTERVAL [Number of months or km (miles), whichllVer occurs first) Months x 1,000 km x 1,000 miles
Engine Oil
7.5 12 7.5
15 24 15
22.5 36 22.5
30 48 30
37.5 60 37.5
45
72
52.5
84
60 96
mm
iii iii
mm
45
52.5
iii
60
REPLACEMENT
1) Drain engine oil by loosening engine oil drain plug.
2) oil.
Open engine oil filler cap for quick draining of the engine
Fig. 70 Fig. 9 3) Tighten engine oil drain plug after draining engine oil. Tightening torque:
25 N·m (2.5 kg·m, 18 ft-Ib)

4) Fill engine oil through filler oil level. pipe up to upper point on of proper quality and
level gauge. Make sure that checking
vehicle is placed level when
Use engine oil
viscosity, selected in accordance with the table below.
ITEM
API Classlflcation
SAE viscosity No. and Applicable Temperatura (0 F)

(DC)
_30
QO
_18°
30 0
60° 16°
90 32
_34°
Engine oil
SE or SF
10W·30, 10W·40
I
Ll-445
<
SW-30
Fig. 71

The proper viscosity helps car get good cold and hot starting by reducing viscous friction and thus increasing cranking speed. Engine oil capacity: Upper level 4.0 Q (4.2 US qt, 3.5 Imp qt] lower level
1-5
a. 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 SU BARU. b. SAE 5W-JO is not recommended for sustained high speed driving. c. If vehicle is used in desert areas or areas with very high temperatures or for other heavy duty applications, the following viscosity oils may be used:
30,40, 1OW-50, 20W-40, 20W-50
3.0 Q (3.2 US qt, 2.6 Imp qt)

5) 6) Close engine oil filler cap. Start engi ne and warm it up for a time.
7) After stopping the engine, recheck the oil levei. If necessary, add oil up to the upper point on level gauge.
:I
• Lower level L1·028
Upper level
Fig. 12
1-5
II

MAINTENANCE INTERVAL [Number of months or km (miles), whichever occurs first) Months
l(
Engine Oil Filter
7.5 12 7.5
15 24
22.5 36 22.5
30
37.5 60 37.5
45
52.5 84 52.5
60 96
1.000 km
48
30
72
45
x 1,000 miles Non·TURBO vehicle TURBO vehicle
15
iii
mm
m
iii
mm
m
iii
60
REPLACEMENT
1) 2) Remove oil filter with an oil filter wrench. Get a new oil filter and apply a thin coat of engine oil to
the seal rubber. 3) Install oil filter by turning it with hand, being careful not to damage seal rubber. 4) Tighten more approximately two thi rds turn after the seal rubber contacts the oil pump case. Do not tighten excessively, or oil may leak. 5) After installing oil filter, run engine and make sure that no oil is leaking around seal rubber.
The filter element and filter case are permanently joined; therefore, interior cleaning is not necessary.
Fig. 13
10
1-5
R Replace g Coolant
Engine and Inspect Cooling System, Hoses and Connections
MAINTENANCE INTERVAL [Number of months or km [mites), whichever occurs first] Months x 1,000 km x 1,000 mires 7.5 12 7.5 15 24 15 22.5 36 22.5 30 48 30 37.5 60 37.5 45 72 45 52.5 B4 52.5 60 96 60
[[j]
REPLACEMENT
1) Pull out the end of drain tube to the underside of body from between undercover and skirt. 5)
Remove two drain plugs on engine side, and drain coolant.
Fig. 76
6f
Fig. 14
Securely tighten engine side drain plugs. 7) Tighten radiator drain plug securely. (Drain tube may face downward.) 8) Install reserve tank to original position. 9) Carefully pour prepared coolant from radiator filler port to neck of filler, level. then pour into reserve tank up to "FU LL"
2) Place a container under drain tube, and loosen drain plug. 3) Loosen radiator cap to drain coolant. 4) Drain coolant from reserve tank. Be sure to remove fusible link case from reserve tank in advance when removing reserve tank from body.
Coolant capacity (Pour up to "FULL" level): Except TURBO AT: Approx. 5.5 Q (5.8 US qt, 4.8 Imp qt) TURBO AT: Approx. 6.0 Q (6.3 US qt, 5.3 Imp qt)
The SUBARU Genuine Coolant containing anti-freeze and anti-rust agents is especially made for SU BARU engine, which has an aluminum crankcase. Always use SU BARU Genuine Coolant, since other coolant may cause corrosion.
10) Securely install radiator cap. 11) 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 svstern.] 12) Stop engine and wait until coolant temperature lowers.
Reserv~a\~~ ~ rc::f A _____
Fig. 15
Then open radiator cap to check coolant level and add coolant up to radiator fi lIer neck. Next, add coolant into reserve tank up to "FULL" level.
11
1-5

PROCEDURE TO ADJUST THE CONCENTRATION OF THE COOLANT
To adjust the concentration of the coolant according to temperature, find the proper fluid concentration in the above diagram and replace the necessary amount of coolant with an undiluted solution of SUBARU genuine coolant (concerrtration 50%). The amount of coolant that should be replaced can be determined using the following diagram. '0'0-
The radiator is of the pressurized type. Do not attempt to open the radiator cap immediately after the engine has been stopped.
13) After adding coolant, securely install radiator and reserve tank caps.
RELATIONSHIP OF SUBARU COOLANT CONCENTRATION AND FREEZING TEMPERATURE

The concentration and safe operating ternerature of the SUBARU coolant is shown in the following diagram. Measuring the temperature and specific gravity of the coolant will provide this information.
c. E (5.3,4.4)
tf.)
2
~
..c
[4.2,3.5)
.: 3 ~ (3.2,2.6J
III
S 1.100 1.090 1.080 Safe operati ng temperatu re
.::
'" '0 o
1:: (2.1,1.8)
1
.~
o (1.1,0.9)
"8
o
~ 1.070
'" 8
Fig, 78
1::
10
20
30
40
50
~1.060
Concentration of coolant in the vehicle cooling system % Concentration of coolant in vehicle and quantity to be drained L2.049
~ (1.0491 ':;1.050 -------E

Cl
~ 1.040
.~
[Example)
Freezing temperature
~1.030 1.020 1.010 1.000
k~
D
iii
20% 10%
u~ ~I
-40 -30 -20 -10 (-40) (-22) (-4) (14)
10 20 30 40 50 (321 (50) (681 (86) (1041 (122)

L1479
Coolant temperature DC (OF) Fig. 77
Assume that the coolant concentration must be increased from 30% to 40%. Find point A, where the 30% line of coolant concentration intersects with the 40% curve of the necessary coolant concentration, and read the scale on the vertical axis of the graph at height A. The quantity of coolant to be drained is 2.5 liters (2.6 US qt, 2,2 Imp qt), Drain 2.5 liters (2.6 US qt, 2.2 Imp qtl of coolant from the cooling system and add 2.5 liters (2.6 US qt. 2,2 Imp qt) of the undiluted solution of SUBARU coolant. If a coolant concentration of 50% is needed, drain all the coolant and refill with the und iluted solution only.
[Example] If the coolant temperature is 25°C (77°F) and its specific gravity is 1.049, the concentration is 35% {point A). the safe operating temperature is -14°C (7°F) (point B), and the freezing temperature is -20°C (-4°F) (point C).
INSPECTION
1) Check the radiator reserve tank and hoses for damage or clogging. 2) Check the hose connections for leakage. 3) Check the valve, spring and packing in the cap for damage. 4) Check rubber seal on cap for tears, cracks or deterioration after cleaning it. Install the cap on a tester and if cap does not hold or does not release the specified pressu re, replace cap.
12

Cap relief pressure: 88 kPa (0.9 kg/cm2, 13 psi)
1-5
Fig. 20
A7-D25
Fig. 19
5) Check the radiator for leakage. Inspect radiator for leakage using a cap tester and applying a pressure of 157 kPa (1.6 kg/cm2, 23 psi). If a leakage is detected, repair or replace the radiator.
6) If the coolant temperature exceeds 86.5 to 89.5°C (188 to 193°F) while radiator is not so hot, check thermostat. 7) If thermostat does not open at 86.5 to 89.5°C (188 to 193°F), replace it with a new one. 8) If electric fan does not operate with coolant temperature above 93 to 97°C (199 to 207°F), check thermoswitch or fan motor.
13
1-5

MAINTENANCE INTERVAL [Number of months or km (miles!. whichever occurs first]
Months
_ Replace Fuel Filter and ..-Inspect Fuel System, Line and Connections
7.5 12 7.5
15 24 15
22.5 36 22.5
30 48 30
37.5 60 37.5
45
52.5 84 52.5
60 96 60
x 1,000 km x 1,000 miles
72
45
[Ii)
REPLACEMENT a. • • b.
1) (3) Remove the filter from the holder.
Before starting the job, be sure to carry out the following. Place liNa fire" signs near the working area. Disconnect ground cable from battery. Be careful not to spill fuel on the floor.
Removal (1) Before
removing
the hose, filter,
pump,
etc., be sure
to release the fuel pressure, as follows: • Disconnect the wiring connector •
of the fuel pump.
Crank the engine for more than five seconds. If the engine starts, let the engine run until it stops. • After turning IG switch OFF, connect the wiring connector of the fuel pump. (2) Loosen the screw of the hose clamp and pu II off the hose from the filter.
Fig. 1 2) Installation (1) Install the filter to the holder. (2) Connect the hose as illustrated
below:
Unit: mm (in I
25 -30
r=:
(0.98 -1.18)
---.1.-1--+01--4 - 7 (0.16 - 0.28)

When fitting length
is specified
When fitting length is not specified A21·232
Fig. 2 (3) Tighten the hose clamp screw to the specified torque. so that it will not interfere with the filter body or washer
tank, before tightening
the screw of the hose clamp.
Tightening torque:
1.0 - 1.5 N·m (0.1 - 0.15 kg-m, 0.7 - 1,1 ft-lb] (4) If the hose is damaged at replace the hose with a new one. (5) If the new one. hose clamp the clamping replace portion, with a
is too deformed,
(61 Fit the hose to the filter, then install the filter to the holder. Correct the hose position by removing any twist 14

INSPECTION
FUEL PIPING AND CONNECTIONS
for leakage, scratches, Check fuel tank, piping and connections swelling and corrosion.
1-5
[ SPFII
---Vacuum line
I I
Pressure
regulator
Fuel injector
I Fuel damper
Fuel delivery Tank
line 2-way
t
Canister
l
return line
Filter pipe
L2-1243
Fig. 23
I MPFI
(TURBO)
Filler pipe
L2-605
Fig. 24 15
1-5
21

Two-way valve (1) Check for air passage with slight resistance due to the valve by blowing air into the nipple on the side marked with letters "To engine". (2) Repeat the same step on the other nipple. (3) Check for the valve case with no crack. If cracked, replace it with new one. (4) Disconnect the second purge hose from the air intake boots. Orally blow air through the hose to ensure that there is an air flow with a slight resistance (TURBO vehicle).
Be careful not to suck on the hose as this causes fuel evaporating gas to enter your mouth.
(5) Check the exterior of the canister to ensure that it is not cracked or scratched.
TURBO vehicle: Au)(iliary purge vent To canister
Non-TURBO: TURBO:
Purge vent Main purge vent
1 Valve "8" 2 Valve "A" 3 Case 4 Spring 5 Retainer
A3-192 Purge control valve
Fig. 25
Activated carbon
3)
Purge line and canister (1) Disconnect the vacuum hose. Orally blow air through the hose to ensure that air does not leak. (2) Disconnect the purge hose or first purge hose (TURBO vehicle). Orally blow air through the hose to ensure that air flows. (3) Disconnect the evaporation hose from the fuel tank side. Orally blow air through the hose to ensure that air
flows.
Filter
L 1·310
Fig.
26
Be careful not to suck on the hose as this causes fuel evaporating gas to enter your mouth.
16
1-5
II
Air Filter Elements (Air cleaner)
MAINTENANCE INTERVAL [Number of months or km [miles], whichever occurs first! Months x 1,000 km x 1,000 miles 7.5 12 7.5 15 24 15 22.5 36 22.5 30 48 30 37.5 60 37.5 45
52.5 84
52.5
60 96 60
72
45
OJ
REPLACEMENT
Ii]
Fig.
27
a. Do not attempt to clean the air cleaner element. The filter paper of the element is wetted with a special nun-intlammable slow·evaporating viscous liquid. It is resistant to cold weather and has a long service life. Dirt adhering to this filter paper forms porous laminations with the viscous liquid, which function as a filtration layer to reduce dust penetration into the filter paper. If this filter paper is cleaned, the filtration layer thus formed will be lost along with the viscous liquid. b. Under extremely dusty conditions, replace it more fraquently.
17
1-5
Dspark
Plug
MAINTENANCE INTERVAL [Number of months or km (miles}. whichwer occurs first] Months x 1,000 km 7.5 12 7.5 15 24 15 22.5 36 22.5 30 48 30 37.5 60 37.5 45 52.5 84 52.5 60 96 60
72
45
x 1,000 miles
OJ
REPLACEMENT
Recommended·spark plugs NGK: BPR6ES-11 (or BPR5ES-ll, BPR7ES-11) Nippondenso: W20EPR-Ull (orW16EPR-ll, W22EPR-Ul1) Champion: RN9YC-4
OJ
When installing spark plugs on cylinder head, tighten to the specified torque. Tightening torque: 18 - 24 N·m (1.8 - 2.4 kg-m, 13 - 17 ft-lb]
Be sure to place the gasket between the cylinder head and spark plug.
Spark plug gap 1.0 - 1.1 mm (0.039 - 0.043 in)
1.0 - 1.1 mm [0.039 - 0.043 in! Spark plug thread Dia. = 14 mm (0.55 in! Pitch = 1.25 mm (0.0492 in! A9·163
Fig. 28
18
1-5
II!II Transmission/
...
Differential (Front and rear) lubricants (Gear oil)
MAINTENANCE INTERVAL [Number of months or km (milasl, whichever occurs first! Months x 1,000 km x 1.000 miles 7.5 12 7.5 15 24 15 22.5 36 22.5 30 48 30 37.5 60 37.5 45 72 45 52.5 60
84
52.5
96 60
D
INSPECTION
MANUAL TRANSMISSION REAR DIFFERENTIAL (4WD Vehicle)
Remove plug of filler hole and check the oil level. Oil level should be maintained fully to the filler hole. If the oil level is below the mouth of filler hole, add some oil up to the mouth.
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. FWD Non-TURBO
4WD/FWD TURBO
u,
Upper
LL
-leIJel
_,
L 1-547
Fig. 31
Fig_ 29
FRONT DIFFERENTIAL (Automatic Transmission)

Oil level should be maintained between two points on the level gauge_ If the oil level is at lower point or below, add some oil up to upper point.
Recommended oil
ITEM API Classification SAE Vi:tCO:S.if'fNo, Bnd Applicable (OF)
(OC)
Ternpersrure
-30 -34
30 0
60
16
90
90
-18
32
Transmission and differenl.iat gea..-oil 4WD rear dirterenrial gear oil
GL·5
< <
I ,.w
BOW 15WOO.
3
>
4SOW·go
a. Each oil manufacturer has its base oil and additives. Thus, do not mix two or more brands. b. *For differential gear oil (AT)
Upper
lellel
Lower level
Ll·157
Fig. 30
19
1-5
~Automatic ~ Transmission Fluid

High mark
Low mark
INSPECTION
Fig. 33
MAINTENANCE INTERVAL [Number of months or km (miles). whichever eceurs first] Months 7.5 12 7.5 15 24 15 22.5 36 22.5 30 48 30 37.5 60 37.5 45 52.5 60 96 60
LH64
x 1,000 km
x 1,000 miles FWD vehicle 4WD vehicle
72
45
84
52.5
D
iii
m
Test condition select range: "P." Engine: Idling (Engine revolution 700 - 750 rpm)
0 LL
Upper limit (Fluid high temperature)
·""t,:,=,:,,:,,:::::::::,,::::;:;::,:
:..
:, .....
C
in
2
E
OJ
r--
E
Lower limit (Fluid high temperature) Upper limit (Fluid high temperatu reI
.s
l!l
S
E
OJ _j
r-
~--+-----+----+-----+:,"'".:
Lower limit (Fluid low temperature) 30 (86) 40
(104)
.. :, ·· I --f,:i.:i:f.:::+------t------l
Fluid :: temperature :::: range for fluid level check 'I{::··
.t
50 (122)
60 (140)
·~:ib:;;~::;:l,l~
70 (158) 80 (176)
.;tt:..
""~~~;;;~~g
,:>: ... :..
90
(194)
ATF temperature
L1·587
Fig. 32
20
1-5
INSPECTION .
1) Drive vehicle several km (miles) to bring automatic transmission fluid (ATF) up to normal operating temperature. Normal operating temperature is 60 to SO°C (140 to 176°F). 2) 3) Park vehicle on a level surface. After selecting ali positions, place selector lever in "ph
MAINTENANce INTERVAL [Number of months or km (miles), whichevsr occurs first] Months x 1,000 km x 1,000 miles 7.5 12 7.5 15 24 15 22.5 36 22.5 30 48 30 37.5 60 37.5 45 72 45 52.5 84 52.5 60 96 60
position and run engine on at idling speed. 4) Remove level gauge and wipe it clean. 5) Reinsert the level gauge all the way. 6) Remove it again and note reading. If the fluid level is below the center between high and low marks, add recornmended ATF unti I the fluid level is within the specified' range (above the center between high and low marks). When transmission is hot, the level should be above the center of upper and lower marks, and when it is cold, the level should be below the center of these two marks. ATF level gauge hole also serves as fluid filler.
NOTE: Do not fill the fluid above upper point of level gauge.
Recommended automatic transmission fluid (ATF Dexron II) Fig, 4 4AT
REPLACEMENT
1) Drain fluid by removing drain engine to cool for 3 to 4 hours. plug after allowing the 2) Reinstall drain plug after draining fluid, the specified torque. Tightening torque: and tighten it to
25 N·m (2.5 kg·m, 18 ft·lbl
a. Be sure to place a gasket between oil pan and drain plug. b. Replace the gasket with new one.
3) Fill ATF through the fluid level gauge hole.
Oil capacity:
FWD 3AT:
6.21! (6.6 US qt, 5.5 Imp qt)

4WD3AT: Fig. 3 3AT
6.55 Q (6.9 US qt, 5.8 Imp qtl

4WD4AT:
9.51! (10.0 US qt, 8.4 Imp qt)
When replacing ATF, the normal refilling capacity is about 2.5 to 3.0 £ (2.6 to 3.2 US qt, 2.2 to 2.6 Imp qt) (except 4WO 4AT), 6.5 to 7 Q (6.9 to 7.4 US qt, 5.7 to 6.2 Imp qt) (4WO 4AT).
4) Run the vehicle until the ATF temperature rises to 60 to SOoC (140 to 17SoF) and then check the ATF level.
21
1-5

MAINTENANCE INTERVAL [Number of months or km (milasl, whichever occurs first] Months x 1,000 km x 1,000 miles 7.5 12 7.5 15 24 15 22.5 36 22.5 30 48 30 37.5 60 37.5 45 72 45 52.5 60
Brake Fluid
84
52.5
96
60
III
REPLACEMENT
1) Either jack up the front end of vehicle and place a safety stand under it, or drive vehicle onto the pit and then jack up the front end. 2) Remove both left and right front wheels. 3) Remove filler cap from brake fluid tank. Install one end of a vinyl tube onto the air bleeder of front brake and insert the other end of the tube into a container to collect the brake fluid. To drain fluid into container, open the air bleeder and repeatedly depress and release the brake pedal until a small amount of fluid remains in the reservoir tank. Then tighten the bleeder screw.
a, Avoid mlxmg different brands of brake fluid to prevent degrading the quality of the fluid. b. Be careful not to allow dirt or dust to get into the reservoir tank. c. Use fresh DOT3 or 00T4 brake fluid when replacing or refillin g the flu id. d. Always check to be sure a small amount of brake fluid is in the tank while changing brake fluid. e. The amount of brake fluid required is approximately 270 m2 (9.1 US fl oz, 9.5 Imp fl oz) for total brake system. f. Bleed air according to illustrated sequence.
Bleeding sequence
<D ® ®
-+ -+
-+
@
Rear right
Front right
Primary
Front left
Rear left A 17-150
Fig. 36
Fig. 35
a. The brake piping consists of a dual system, cross design. The piping on the primary side connects the right front brake and the rear left brake and the piping on the secondary side connects the left front brake and rear right brake. b. For convenience and safety, it is advisable to have two men working. c. Be careful not to spill brake fluid onto the painted surface. d. Discard the drained brake fluid and do not reuse it.
4) Refill reservoir tank with recommended brake fluid. Recommended brake fluid: FMVSS No. 116, fresh DOT3 or DOT4 brake fluid
5) Instruct your co-worker to depress the brake pedal slowly two or three times and then hold it depressed. 6) Loosen bleeder screw approximately 1/4 turn until a small amount of brake fluid drains into container, and then quickly tighten screw. 7) Repeat steps 5) and 6) above until there are no air bubbles in drained brake fluid and new fluid flows through vinyl tube,
Add brake fluid as necessary while performing the air bleed operation, in order to prevent the tank from running short of brake fluid.
8)
After completing the bleeding operation, hold brake pedal depressed and tighten screw and install bleeder cap.
Tightening torque [Bleeder screw): 7 - 9 N·m (0.7 - 0.9 kg·m, 5.1 - 6.5 ft-Ib)
22

9) Bleed air from each wheel cylinder using the same procedures as described in steps 5} through 8) above.
1-5
10} Depress brake pedal with a force of approximately 294 N (30 kg, 66 Ib) and hold it there for approximately 20 seconds. At this time check pedal to see if it shows any unusual movement. Visually inspect bleeder screws and brake pipe joints to make sure that there is no fluid leakage. 11) Install wheels, and drive car for a short distance between 2 to 3 km (1 to 2 miles) to make sure that brakes are operating properly.
Fig. 37
23
1-5
I!II Disc Brake

~
Pad and Disc/Front and Rear Axle Boots and Axle Shaft Joint Portions
MAINTENANCE INTERVAL [Number of months or km (miles), whichever occurs firstl Months xl ,000 km x 1.000 miles
7.5 12 7.5
15 24 15
22.5 36 22.5
30 48 30
37.5 60 37.5
45
72
52.5 84 52.5
60 96 60
45
D
INSPECTION
[A] Disc Brake Pad and Disc (Front and Rear)
I REAR I
1) Jack up vehicle and support with rigid racks. Then remove wheels. 2) Visually check pad thickness through inspection hole of disc brake assembly. Replace pad if necessary.
I FRONT I
Fig. 40
Pad thickness including back metal Front Standard Inspection hole Wear limit
mm (in) Rear
18
(0.709)
15
(0.5911
7.5 (0.2951 1.5 [0.059)
6.5 [0.2561 1.5 (0.059)
L1-048
Fig. 38
Back metal Lining
Wear limit (exclude back metal)
Thickness of pad
L ,.171
Fig. 39
24

a. 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 twisted or worn. b. The clip incorporated with pad is also used as a warning device for worn pads. When wear occurs on the pad to such an extent that the clip comes into contact with the rotor, unusual noise (squeak) is produced. If such a noise is noticed, replace the pads.
3) Disc rotor Check for wear and damage, and correct or replace if abnormal.
Brake disc thickness Front Standard Wear limit 18 (0.709) 16 (0.630) 10 rnrn (in) Rear (0.394)
1-5
[B]
Front and RearAxle Boots

damage or
Inspect front and rear axle boots for deformation, failure. If faulty, replace them with new ones.
8.5 (0.335)
Ll-588
Thickness of disc
--
Fig. 43
t-.-
~
~'-.
Ll-172
Fig. 41 Fig. 44
Disc rotor runout: Limit: 0.10 mm (0.0039 in)
Measure the disc rotor runout at a point less than 5 mm (0.20 in) from the outer periphery of the rotor.
Ll-050
Fig. 42
25
1-5
IE!
Brake Lining and Drum
MAINTENANCE INTERVAL [Number of months or km (miles). whichever occurs first] Months x 1,000 km x 1,000 miles 7.5 12 7.5 15 24 15 22.5 36 22.5 30 48 30 37.5 60 37.5 45 52.5
60
96
72
45
84
52.5
60
D
INSPECTION
Inspect brake linings and drums of both sides of the rear brake at the same time by removing brake drums. 1) Inspect brake shoes for damage or deformities and check Brake drum inside diameter: Standard: brake linings for wear.
2) Check brake drum for wear, dents or other damage. If the inside surface of brake drum is streaked, correct the surface with emery cloth (#200 or more). If it is unevenly worn, taperingly drum is damaged, streaked, or the outside correct or replace it. surface of brake
Always replace both leading and trailing brake shoes for the left and right wheels at the same time.
Brake lining thickness excluding Standard: 4.5 mm (0.177 in) Wear limit: 1.5 mm (0.059 in) back metal:
180 mm (7.09 in)

Wear limit: 182 mm (7.17 in)
Th lcknsss of brake lining (Exclude back metal] Measuring inside diameter L 1-054
Fig. 46
Ll-053
Fig. 45
3) If the deformation or wear of back plate, shoe, etc. are notable, replace them. 4) When the shoe return spring tension is excessively weakened, replace it, taking care to identify upper and lower springs. 5) If grease has leaked from brake drum, replace oil seal or drum. 6) If drum bearing is abnormal or loose, replace it.
26
1-5
",Inspect Brake Line and Check Operation of Parking and Service Brake System
Iii.I
MAINTENANCE INTERVAL [Number of months or km (mltesl, whichever occurs first! Months x 1,000 krn x 1,000 miles 7.5 12 7.5 15 24 15 22.5 36 22.5 30 48 30 37.5 60 37.5 45 72 45 52.5 60 96
84
52.5
60
m
INSPECTION
BRAKE LINE
traces of fluid leakage on
Ii
Ii
CHECKING
[A] Service Brake
pedal with
1) Check scratches, swelling and/or brake hoses or pipe joints.
1) Check the free play of brake than 10 N (1 kg, 2 Ib). Brake pedal free play:
a force of less
0.5 - 2.5 mm (0.020 - 0.098 in)

If the free play is out of specifications pedal as follows: above, adjust the brake brake clevis 10 N 0.098
(1) Be sure engine is off. (No vacuum is applied to booster. I (2) There should be play between brake booster and pin at brake pedal installing portion. (Depress brake pedal pad with a force of less than [1 kg 2 lb] to a stroke of 0.5 to 2.5 mm (0.020 to in]. Fig. 47
Clevis pin
Clevis
l"-
L1·056
Fig. 48 2) Check the possibil ity of adjacent parts interfering with brake pipes/hoses during driving, and loose connections/ clamps. 3) Check any trace of fluid leakage, scratches, etc. on master cylinder, wheel cylinder, pressure control valve and hill-holder. Fig. 49
L4·928
(3)
Depress the surface of brake pad by hand.
When the brake fluid level in the reservoir tank is lower than the specified limit, the brake fluid warning light on the instrument panel will come on. 27
(4) If there is no free play between clevis pin and clevis, loosen lock nut for operati ng rod and adjust operating rod by turning in the direction that shortens it.
1-5

4) Check to see if air is in the hydraulic brake line by the feel of the pedal operation. If air appears to exist in the line, bleed it from the system. 5) Check for even operation of all brakes, using a brake tester or by driving the vehicle for a short distance on a straight road.
a. Make sure that the stop lamp operates normally. b. After adjustment, make sure there is no brake dragging.
2) Adjust lining clearances of rear drum brake as follows. [FWD only] (1) Jack up vehicle to release tires and wheels slightly from the ground. (2) Tighten adjusting screw on back side of rear brake drum fully until tire and wheel ceases to rotate. 0 (3) Turn back adjusting screw by 180 and lining clearance will be 0.1 to 0.15 mm (0.004 to 0.0059 in). (4) 8e sure to rotate tire and wheel lightly by hand. (5) Adjust lining clearance of another side rear brake with the same manner.
[B) Parking Brake

1) After confirming the proper operation of brake pedal, pull parking brake lever with a force of approximately 245 N (25 kg, 55 Ib) to make sure lever still has a short length of stroke to go. Parking brake lever stroke: (With engine on) Standard: 3 - 4 notches/245 N (25 kg, 55 Ib) Torque (Adjuster lock nut]: 4.4 - 7.4 N·m (0.45 - 0.75 kg-m, 3.3 - 5.4 ft-Ib)
2) If the parking brake lever pull is not within the above specifications, adjust it as follows: (1) Pull parking brake lever forcibly three to five times. (2) Loosen the lock nut and change the setting of adjuster until the play at point A is 0 to 0.5 mm (0 to 0.020 in).
Fig. 50
3) Measure the distance between brake pedal and floor when the pedal is depressed with a force of approximately 294 N (30 kg, 66 Ib). Brake pedal reserve distance: More than 67 mm (2.64 in)/294 N (30 kg, 661b)
Fig. 52
1 2
® ®
3 4 5 6
StOP lamp switch Free play 0.5 - 2.5 mm (0.020 - 0.098 in) Stroke Reserve distance Mat Toe board
(3) Make sure that vehicle stops on uphill road properly by operating parking lever.
[Cl
Brake servo System
L4-905
Fig. 51
1) With the engine off, depress the brake pedal several times applying the same pedal force: Make sure the travel distance should not change. 2) With the brake pedal depressed, start the engine: Make sure the pedal should move slightly toward the floor. 3) With the brake pedal depressed, stop the engine and keep the pedal depressed for 30 seconds: Make sure the pedal height should not change. 28

4) Check valve is built into vacuum hose. Disconnect vacuum hose to inspect function of check valve. Blow air into vacuum hose from its brake booster side end: Air must flow out of engine side end of hose. Next blow air into hose from engine side: Air should not flow out of hose. Replace both check valve and vacuum hose if check valve is faulty. Engine side of vacuum hose is indicated by marking "E" as shown. 5) Check vacuum hose for cracks or other damage.
1-5
When installing the vacuum hose on the engine and brake booster, do not use soapy water or lubricating oil on their connections.
6) Check vacuum hose to make sure it is tight and secure.
Brake
Ll-059
Fig_ 53
29
1-5
'" Clutch and Hill-holder IiiISystem
INSPECTION AND ADJUSTMENT

1. Inspect the clutch free play and check the hi II holder operation. If it is out of the specified
1)
Pedal play:
10·20
mm [0.39·0.79
ill)
L'·060
Fig. 54
Free play
value, adjust
it by turni ng adjusting
nut on engine side end of clutch
cable at release fork.
Clutch free play (1) Remove the spare tire. (2) Position a screwdriver as shown, and move it back to rotate the lever in the di rection indicated by the arrow. This is necessary to remove hill holder load from release lever to determine accurate clutch free play. the
-,
Full stroke
, 2 3
Lock nut Adiusting nut Release fork
A20-051
Fig. 55
MAINTENANCE INTERVAL (Number of months or km (miles), whichever occurs firstl Months x 1,000 km x 1,000 miles 7.5 12 7.5 15 24 15 22.5 36 22.5 30 48 30 37.5 60 37.5 45 72 45 52.5 84 52.5 60 96 60
Fig. 9
0
Lightly move the clutch lever with your hand to
. (3)
check free play. Tightening torque (Adjusting nut on release fork): 5.4 - 9.3 N'm (0.55 - 0.95 kg-m, 4.0 - 6.9 ft-lbl Standard of free play: At clutch pedal: 10 - 20 mm (0.39 - 0.79 in) At center of cable on clutch release fork: FWD Non-TURBO: 2 - 3 mm (0.08 - 0.12 in) 4WD/FWD TURBO: 3 - 4 mm (0.12 - 0.16 in)
a. When replacing clutch cable with new one and/or making free play adjustment of clutch pedal, make adjustment of hill-holder system without fail as follows. b. After replacing clutch cable and/or pressure hold valve (PHV) cable with new one, depress clutch pedal about thirty (30) times as a running-in operation prior to this adjustment.
2) Confi rm stopping and starting performance by activating hill-holder on an uphill road of 3° or higher inclination. (1) If vehicle does not stop; Tighten adjusting nut of PHV cable.
30
1-5
Fig. 56 (2) If vehicle does not start properly; • Case A - When hill-holder is released ment of clutch (engine tends to stall); Loosen adjusting nut gradually until •
Fig. 57
later than enqaqesmooth starting
b. Replace pressure hold valve (PHV), return spring of PHV or PHV cable with new one, if they are defective and/nr damaged.
is enabled . Case B - When hill-holder is released earlier than engagement of clutch (vehicle slips down sl ightly); Tighten adjusting nut later than engagement Then make adjustment so that hill-holder is released of clutch (status in Case A). the same as in Case A.
a. Whenever turning adiusting nut, prevent PHV cable from revolving as following illustration.
31
1-5
Steering and Suspension
[Number Months x 1.000 km x 1.000 miles
MAINTENANCE INTERVAL of months or km (miles), whichever occurs first) 7.5 12 7.5 15 24 15 22.5 36 22.5 30 48 30 37.5 60 37.5 45 52.5 84 52.5 60 96 60
72
45
D
INSPECTION
STEERING WHEEL
(3) Wheel runout .
Steering wheel should not show any sign of runout. (4) Return factor . Steering wheel should return to its original position it has been turned and then released.
after
1) Set steering wheel in a straight-ahead position, and check wheel spokes to make sure they are correctly set in their specified positions. 2) Lightly turn steering wheel to the left and right to deterwheel at the
STEERING
SHAFT JOINT
mine the point where front wheels start to move. Measure the distance of the movement of steering outer periphery Steering of wheel.
1) When steering wheel free play is excessive, disconnect universal joint of steering shaft and check it for any play and yawing torque (at the point of the crossing direction)' inspect for any damage to sealing or Worn serrations. Also
o-
wheel free play:
25 mm (0 - 0.98 in)
Fig. 59
L1-548
Fig. 58
If the joint is loose, specified torque. toward the shaft to ascertain Tightening torque:
retighten
the
mounting
bolts
to the
3) Move steering wheel vertically if there is play in that direction. Maximum permissible play:
21 - 26 N·m (2.1 - 2.7 kg-m, 15 - 20 ft-lb) 0.5 mm (0.020 in)
GEARBOX
4) Drive vehicle and check the following items during operation. (1) Steering force The effort required even at all points, (2) Pull to one side Steering wheel should d riving on a level surface. . for steering . not be pulled to either side while should be smooth and 1)
0
With wheels
placed
on a level surface,
turn steering
wheel
90 in both the left and right di rections. Wh ile wheel is being rotated, reach under vehicle and check for looseness in gearbox. torque:
and should
not vary.
Tightening
47 - 71 N'm (4.8 - 7.2 kg-m, 35 - 52 ft-lb)
32
1-5
Fig. 60
~. nrnr ~~/nn
Check boot for damage, cracks or deterioration.
c~dlbl~~~~
Fig. 62
2)
(3) From that position, turn back adjusting screw 15° and then tighten lock nut securely. Tightening torque:
29 - 49 N·m (3.0 - 5.0 kg-m, 22 - 36 ft-Ib)
Hold the adjusting screw with a wrench to prevent it from turning while tightening the lock nut.
TIE-ROD
1) Check tie-rod and tie-rod ends for bends, scratches or other damage. 2) Check connections of knuckle ball joints for play, inspect for damage on dust seals, and check the free play of ball studs. 3) Make sure that the cotter pin is installed correctly in the castle nut of the tie-rod end.
Fig. 61
3) With vehicle on a level su rface, quickly turn steering wheel to the left and right. While steering wheel is being rotated, check the gear backlash. If any unusual noise is noticed, adjust the gear backlash as follows: (1) Loosen gearbox mounting clamps, and slightly lower gear box. (2) Loosen lock nut by using SPANNER (926230000) and tighten adjusting screw fully.
SPANNER (926230000) can be also used for manual steering.
Fig. 63
POWER STEERING
FLUID
LEVEL
on the flat and level
1) Place vehicle with engine "off" surface. 33
1-5
2)

Recommended fluid Manufacturer B.P. CAlTEX ATF Dexron II CASTROl MOBil SHEll TEXACO
Check the fluid level by removing filler cap of oil pump. (1) Check at temperature 21°C (70°F) of fluid temperature.
Fluid capacity: 0.7 Q (1.5 US pt, 1.2 Imp pt) A3·285 Fig. 64
POWER STEERING
(2) Check at temperature 60°C (140°F) of fluid temperature.
FLUID
FOR LEAKS
Inspect the underside of oil pump and gearbox for power steering system, hoses, piping and their couplings for fluid leaks. If fluid leaks are found, correct them by retightening their fitting bolts (or nuts) and/or replacing their parts.
a. Wipe the leakage fluid off after correcting fluid leaks, or a wrong diagnosis is taken later. b. Also pay attention to clearances between hoses (or pipings) and other parts when inspecting fluid leaks.
HOSES OF OIL PUMP FOR DAMAGES
A3·286 Fig. 65
Hoses===-..,.
SUBARU
~W&1'jj'rw~mJ@
3)
Fluid
level should be maintained
in the each specified
range on the indicator of filler cap. If fluid level is at lower point or below, add fluid to keep the level in the specified range of indicator. If fluid level is at upper point or above, drain fluid to keep the level in the specified range of indicator by using a syringe or the like. Check pressure hose and return hose of oil pump for crack, swell or damage. Replace hose with new one if necessary.
Fig. 66
Prevent hoses from revolving and/or turning when installing hoses.

34

POWER STEERING PIPES FOR DAMAGE
Cap Strainer 3 Oil tank 4 a-ring 5 Pipe 6 Oil pump 7 1 2
1-5
Check power steering pipes for corrosion and damage. Replace pipes with new ones if necessary.
GEARBOX
BOOTS
boots as follows, and correct
CD~
~~
Inspect both sides of gearbox the defects if necessary.
®__'_'l ~~~r--;=
I I
"..... '
'
CD
Fig. 28
®
1 Clip [Small)
®
2 Clip [Large) 3 Boot
L 1-618
L1-591
Fig_ 68
1) A and B position of gearbox boot are fitted correspondingly in A and B grooves of gearbox and the rod. 2) Clips are fitted outside of A and B positions of boot. 3) Boot does not have crack, hole.
Tightening torque: Nut A (one): 42 - 62 N·m (4.3 - 6.3 kg-m, 31 - 46 ft-lb) Bolt B (two): 20 - 29 N·m (2.0 - 3.0 kg·m, 14 - 22 ft-lb) Bolt C (three): 18 - 22 N·m (1_8 - 2.2 kq-rn, 13 -16ft-lb) Bolt D (three): 29 - 49 N'm (3.0 - 5.0 kg-m, 22 - 36 ft-lbl
Rotate B position of gearbox boot against twist of it produced by adjustment of toe-in, etc.
FITTING
BOLTS AND NUTS

and bracket for
Inspect fitting bolts and nuts of oil pump looseness, and retighten them if necessary.
Inspect and/or retighten them when engine is cold. SUSPENSION SYSTEM Care should be taken not to apply paint, undercoating agent, anti-corrosive wax, etc. to the following parts of air-suspension equipped models while refinishing the undercarriage. (1) Diaphragm and rolling surfaces (2) Air suspension compressor and dryer assembly
35
1-5
1) Play of front ball joint (15,000 miles) or 15 months, (1) Jack up vehicle

Inspect every 24,000 whichever occurs first. front wheels km (2) When looseness grease is less than standard amount [about (SUN LIGHT value, wi pe off 3 g (0.11 ozl] old grease, apply the proper of designated and install a new dust seal.
until
are off ground
2, PIN 003602010)'
as instructed in "Pre-Delivery Inspection." (2) Next, grasp bottom of tire and move it in and out. If relative movement is observed between brake disc cover and end of transverse link, ball joint may be excessively worn.
When transverse link ball joint has been removed or replaced, check toe-in (or side slip) of front wheel. If front wheel toe-in (or side slip) is not at specified value, adjust according to chapter 4-1 so that toe-in conforms to service standard.
3) Wheel alignment and ground clearance every 48,000 km (30,000 miles) or 30 months, Inspect whichever
occurs first. (1) Unload cargoes and set vehicle in curb weight (empty I condition. (2) Then, check ground clearance of front suspensions to ensure that they are within values. Relative movement
Ll-234
and rear specified
(Adjusting
procedure)
Fig. 69
(3) Next, grasp end of transverse link and move it up and down. Relative movement between housing and transverse link boss indicates ball joint may be excessively worn.
When ground clearance is out of standard, visually inspect following components and replace deformed parts. • Suspensions components [Front: strut assembly, crossmember, transverse link, etc. Rear: shock absorber, inner arm, outer arm, etc.l
• Body parts to which suspensions are installed. When no components are deformed, adjust ground clearance by replacing coil spring in the suspension whose ground clearance is out of standard. (3) Check alignment of front suspension to ensu re that following items conform to standard values provided in chapters 4·1 and 4-3.
. Transverse link Ball joint L
~~:t:=:~± ___ ...,..,..,d
• Relative movement • • •
Toe-in (or side slip) Camber angle Caster angle Turning angle of tire
Fig. 70
-=-=~
L 1-235
(Adjusting procedure) - Front suspension alignment (a) Camber and caster angles are not adjustable. camber or caster angle does not conform value, visually inspect followi ng components deformed parts. • Suspension components transverse link, etc.l [Strut assembly,
When
to standard and ·replace crossmember,
(4) If relative movement is observed in tests (2) and (3) above, remove and inspect ball joint according to chapter 4-1. If looseness exceeds standard, replace ball joint. 2) Damage of dust seal (15,000 mi les] or 15 months, Inspect every 24,000 whichever occurs first. km
• Body parts to which suspensions are installed. (b) When toe-in (or side slip) is out of standard adjust by the method descri bed in chapter angles conforms to service standard. (c) When riqht-and-left turning standard, adjust chapter 4·3. to standard
value, it
4-1 so that
Visually inspect ball joint dust seal. If it is damaged, remove ball joint as instructed in chapter 4-' and measure looseness of ball joint. (1 I When joint. looseness exceeds standard value, replace ball
of tire are out of described in
value by method
36

(4) • • Check alignment of rear suspension values. to ensure that following Camber items are within standard angle
1-5
(d) Adjust toe with in service standard by repeating steps in 2) and 3) above for for both right and left wheels. Camber angle (a) Jack up rear of vehicle as shown in "Pre-Delivery Inspection," and remove wheel whose camber angle is out of standard. (b) Remove inner arm. (c) Then, bolt linking loosen outer lower end of shock absorber arm mounting bolts. to
Toe-in (or side slip)
(Adjusting procedure) - Rear suspension alignment When toe (or side slip) or camber angle does not conform to standard value, visually inspect parts listed below. If deformation is observed, replace damaged parts. • Suspension components [Shock absorber, inner arm, outer arm, crossmember, etc.I • Body parts to which suspensions are installed. When no components are deformed, adjust alignment as instructed Toe (a) Jack below so that it conforms to service standard.
(d) If camber angle is excessive in EEl direction, use a piece of wood as a lever and change relative angle between inner arm and outer arm so that angle (J formed by inner arm and outer arm centerlines Then, tighten outer arm mounting (See below.) bolts. increases.
up rear
of vehicle
as shown
in "Pre-Deliverv
Inspection," and remove rear wheels. (b) Loosen outer arm mounting bolts.
Crossmember
·-Center line of outer arm

L1489
Fig. 73
L1487
Fig. 71 (c) When toe-in (or side slip) is excessive, tighten outer arm mounting bolts shown above while pulling end of spindle towards rear of vehicle (in direction of arrow see below). When toe-out (or side slip) is excessive, tighten outer arm mounting bolts while pushing end of spindle toward below). front of vehicle (in opposite direction of arrow see
(e)
If camber
angle
is excessive
in
8 direction,
use a
piece of wood as a lever and change
relative angle between
inner and outer arms so that angle () formed by inner arm and outer arm centerlines decreases. Then, tighten outer arm mounting bolts. (f) Adjust camber angle to conform to service standard by repeating steps 4) and 5) above.
Inner arm ASSY
a. Adjusting toe (or side slip) results in a change in camber angle, while adjusting camber angle causes a change of toe (or side slip). Therefore, when either is adjusted, always check that the other remains within service standard. b. After both toe (or side slip) and camber angle have been adjusted within servica standard, be sure to tighten bolts to torque specified in chapter 4·1..
4) Oil leakage of shock absorber Inspect every 48,000 km (30,000 miles) or 30 months, whichever occurs first. Remove tire and visually inspect shock absorber for oil leakage as instructed excessively.
L1488
in chapter
4-1. Replace shock absorber
if oil leaks
Fig. 72
5) Tightness of bolts and nuts km (30,000 miles) or 30 months,
whichever
Inspect every 48,000 occurs first.
37
1-5

6) Dirt on and damage to rolling diaphragm of air suspension ...... Inspect every 24,000 km (15,000 miles) or 15 months, whichever occurs first. (1) After loosening wheel nuts, jack up vehicle until all four wheels are off ground according to instructions in "Pre-Delivery Inspection." Remove tires. (2) Visually inspect rolling diaphragm. If dirty, remove dirt from diaphragm. Be careful not to damage diaphragms. (3) Visually inspect rolling diaphragm. Replace air suspension ASS¥ if damaged. However, replacement is not required if only fine scratches on diaphragm surface caused by sand. These do not present a problem. (4) Visually inspect rolling diaphragm for rust. It rusty, remove rust and touch up.
Check bolts shown below for looseness. Retighten bolts to specified torque. Further, check that cotter pin in place as shown below. If not, install new cotter pin. IFRONTI
.__
Cotter pin
---=-L1:....:.2:.:3~9
When touching up diaphragm, be careful paint does not adhere to diaphragm. (Lower jack aftar teueh-up paint has dried completelv.)
7) Damage to suspension parts Check the following parts and the fastening portion of the car body for deformity or excessive rusting which impairs the suspension. Replace faulty parts. If minor rust formation, pitting, etc. are noted, remove rust and apply remedial anti-corrosion measures. (1) Front suspension Transverse link • Cross member Strut (including air suspension) Leading rod Leading rod bracket (2) Rear suspension • Crossmember Inner arm Outer arm Bracket • Shock absorber (including air suspension)
Fig. 35
L1·240
Fig. 36
Tightening torque N·m (kg·m, ft-lb] T1: 38 - 50 (3.9 - 5.1, 28 T2: 88 - 103 (9.0 - 10.5,65 - 76) T3: 118 - 147 (12.0 - 15.0,87 - 108) T4: 74 - 88 (7.5 - 9.0, 54 - 65)
3n
38
1-5
Grease on Front and Rear Wheel Bearings
[Number Months
MAINTENANCE INTERVAL of months or km [miles], whichever
occurs firstl
7.5 12 7.5
15 24 15
22.5 36 22.5
30 48 30
37.5 60 37.5
45
72
52.5 84 52.5
60 96 60
x 1,000 km x 1,000 miles
45
[II)
INSPECTION
Inspect the condition and the amount beari ng grease as follows; of front and rear wheel Tightening torque (Hub to disc rotor bolts): 44 - 58 N·m (4.5 - 5.9 kg-rn, 33 - 43 ft-Ib)
FRONT
1,
WHEEL
BEARING
REAR WHEEL [FWD vehicle]
BEARING
Apply parking brake.
2) Raise front wheel with a jack, and remove wheel. Remove cotter pin from axle shaft and remover castle nut. 3) Remove bolts which secure disc rotor to front wheel hub, and remove hub. 4) Remove oil seal from housing, and check the condition of bearing grease.
1) Apply parking brake, and loosen rear wheel nuts. 2) Jack up vehicle, support it with safety stands (rigid racks) and remove rear tires and wheels, 31 4) Pry brake drum cap by screwdriver off drum. Flatten lock washer and loosen axle nut, then remove lock
washer, lock plate and brake drum so as not to drop inner race of outer taper roller bearing. Outer bearing, outer race of inner bearing and oil seal can be removed together with drum. 5) Check condition of bearing grease.
a. If either the grease appears to be white or if only a small amount of grease remains, remove the bearing from the housing, clean it, and pack it with grease. b. Discard the old seal and install a new one.
Inner bearing
L1-177 Fig. 76 Fig. 77 6) Apply approximately 4 g (0.14 oz) of grease to inner bearing and 3 g (0.11 oz) to outer bearing. Fill the hub of drum with approximately 30 g (1.06 oz) of grease. 7) Install drum, inner race of outer bearing, lock plate, lock washer and axle nut in this order onto the spindle.
Oil seal
L1-592
5)
I nstallation
is in the reverse order of removal.
Tightening torque (Castle nut): 196 N·m (20 kg-m, 145 ft-lb]
After tightening the castle nut to the specified torque, tighten additionally in one sixth (1/6) turn until both holes of bolt and castle nut align each other.
39
Be sure to use new lock plate and new lock washer without fail.
1-5
REAR WHEEL [4WD vehicle]
1) 2)

BEARING
18) Apply grease of 20 to 30 g (0.71 to 1.06 oz) to bearing outer race in housing. 19) I nsert spindle from inside, and press inner race of outer bearing from outside by using a pipe of 35 mm (1.38 in) in inner diameter while tapping it with a hammer.
Apply parking brake. Remove rear wheel cap and cotter pin, and loosen castle
nut and wheel nuts. 3) Detach shock absorber from inner trailing arm. 4) Loosen locking bolts of crossrnernber outer bushing. 5) Jack up vehicle, support it with safety stand (rigid racks) and remove rear tires and wheels. 6) 7) Remove castle nut and brake drum. Drive out spring pins of inner and outer D.O.J. by using a arm with
Apply grease sufficiently on the inner and outer bearing area.

20) Install ring nut to housing.
steel rod of 6 mm diameter. 8) Remove outer D.O.J. from spindle of trailing trailing arm lowered fully.
Tightening torque: 172 - 221 N·m (17.5 - 22.5 kq-rn, 127 - 163 ft-lb]
9) Remove rear exhaust pipe, muffler and exhaust cover in that order. 10) Disconnect brake pipe from brake hose.
Fit air breather cap onto end of brake hose to prevent brake fluid from pouring out.
11) Remove brake assembly from trailing arm. 12) Remove bolt holdi ng inner bushing of inner trai ling arm. 13) Remove three bolts. and take out inner arm. 14) Vise inner arm, and straighten staked portion of housing, then remove ring nut by using HOUSING NUT WRENCH (925550000). 15) Extract spindle inwardly by tapping it from outside with a plastic hammer. 16) Remove oil seal. 17) Check condition of bearing grease. Fig. 79
21) Lock
the ring nut by staking a point
on the housing
surface facing the ring nut groove.
I nner oil seal
Fig. 80
L1·178
Fig. 78
22) Install outer oil seal by using OIL SEAL (925530000) .
INSTALLER
Be sure to renew the oil seal.
40

23) Install inner oil seal by using OIL SEAL INSTALLER (Special tool). 27) Temporarily fit brake drum, center and castle nut to spindle in this order. piece,
1-5
washer spring
Be sure to renew the oil seal.

24) Mount inner arm to vehicle body.
a. Play on spindle is not a fault when mounting brake drum. b. Don't confuse orientation of washer spring.
Tightening torque: Inner bush bolt: 74 - 93 N·m (7.5 - 9.5 kq-m, 54 - 69 ft-lb] Inner and outer arms connecting bolts: 118 -147 N·m (12.0 - 15.0 kq-m, 87 - 108 ft-lbl
25)
Install
rear
brake
assembly
to
inner
arm,
and connect
brake pipes etc.
Nut side"
Washer spring
l
•
mark ~aint 1
2 3 4
Cotter pin
Castle nut Washer spring Cen ter piece
Center piece side
A16·197
Fig. 83
28) Bleed brake system.
Fig. 81
a. Before bleeding brake system, check pedal play and brake fluid level in reserve tank. b. Bleed air from four wheels without fail.
torque (Back plate): 46 - 58 N·m (4.7 - 5.9 kg-m, 34 - 43 ft-lb] 29) Tighten castle nut, insert cotter pin and bend with foot brake applied to lock the wheel and axle. Tightening torque: it firmly
Tightening
196 N'm (20 kg-m, 145 ft-lb)

26) Connect brake hose and brake piPe.
After tightening castle nut to the specified torque tighten further within 30 to align holes on nut and spindle.
0
30) Install packing to rear spindle, and mount D.O.J. on rear drive shaft onto spindle with trailing arm lowered all the way.
When mounting, mate the spline teeth properly so that the D.O.J. and spindle spring pin hole will align.
Fig. 82
41
1-5

32) Install wheels, outer arms, etc. 33) Lower vehicle on the ground, shock absorber. and install lower end of
Fig. 84
\
Fig. 86
31) Drive spring pins into D.O.J.
a. Before driving in the spring pin, confirm alignment holes. b. Be sure to renew the spring pin to be driven in.
of the
Tightening torque: 88 - 118 N·m (9 - 12 kg-m, 65 - 87 ft-Ib) 34) Check ment. 35) Tighten and adjust rear vehicle height and rear wheel align-
outer arm lock bolts.
For vehicle with disc brakes, inspect in the same manner as with drum brakes.
Fig. 85
42
SPECIAL TOOLS
Page
SUBARU
ENGlr~E TOOLS...... MANUAL AUTOMATIC
. . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . .. TOOLS ...•••.•.. TOOLS •.....• TOOLS. . . • . . . . . .. AND DIFFERENTIAL
TRANSMISSION AND DIFFERENTIAL TRANSMISSION
4
9 15 17 18 19 21 22 23
1989
REAR WHEEL DRIVE SYSTEM (4WD MODelS) SUSPENSION TOOLS •....................•.......•....... WHEelS AND AXLES TOOLS ......•...........•...•....... STEERING SYSTEM TOOLS ...•....•....................... BRAKES TOOLS ........•..•.•......•................... AIR CONDITIONING SYSTEM TOOLS BODY TOOLS .......••.......•...•.•...................
1-6
SPECIAL TOOLS
Engine Tools
398744300 PISTON GUIDE
Used to install piston in cylinder.
398852100 OIL SEAL INSTALLER

For press-fitting of intake and exhaust valve guide oil seals.
399094310 PISTON PIN REMOVER ASSY

Used to remove piston pins by inserting this tool through crankcase plug holes.
399284300 PISTON PIN GUIDE

Used to install piston and connecting rod. pin in piston
B
A5-155 399762103 VALVE GUIDE REMOVER
of valve guide.
ST-054 399762104 VALVE GUIDE REAMER 498027000 CAMSHAFT HOLDER
A5-143 498037000 INSTALLER

when gear to Used to install camshaft
A5-156
For removing
For reaming of valve guide.
Used to hold camshaft press-fitting distributor camshaft.
oil seal.
A5-147 498267100 CYLINDER

For replacing
A5-150 498277000 FLYWHEEL STOPPER CP

Used to stop rotation of flywheel when loosening and tightening crankshaft pulley bolt, etc. Manual transmission vehicle
Ll-093 498497000 DRIVE PLATE STOPPER

Used to stop rotation of drive plate when loosening and tightening crankshaft pulley bolt, etc. Automatic transmission vehicle
499007000 TENSIONER WRENCH

Used to hold up tensioner No.2 when reducing timing belt tension.
HEAD TABLE
of valve guide.
Ll·094
Ll-095
L 1-096
LI-276
SPECIAL TOOLS
499037000
REMOVER Connecting & REPLACER rod bushing CAMSHAFT WRENCH
1-6
499567000
CP INSTALLER Used to install crankcase seal. front oil
499207000
SPROCKET
499437000
BELT TENSION WRENCH
Used to remove and install camshaft sprocket.
When installing timing belt. used to apply the specified torque to camshaft pulley so as to get the specified belt tension.
A5·389 499587000
INSTALLER Used to install crankcase rear oil. REMOVER
L1-188 499717100
SET INSTALLER Used to install intake and exhaust valve oil seal.
499717900
Engine stand
499817000
Used to remove and install valve spring.
Stand used for engine disassembly and ASSY. Two pieces are needed.
Ll-378 499987200
SOCKET WRENCH
Ll·l02 899724100
VALVE SPRING PRESS ASSY VALVE
499990110
SOCKET head. Oxygen
[0.) sensor.
899768603
GUIDE ADJUSTER and exhaust
(17)
For retightening
cylinder
Used to remove and install valve spring.
Used to install intake va Ive gu ides.
L 1-103
A5-149
A5-149
1-6
SPECIAL TOOLS
Manual Transmission and Differential Tools

398405200 STAND Rear drive shaft. 398507703 DUMMY COLLAR Oil seal of input shaft holder. PLIERS Input shaft snap ri ng. 398663600 398791600 REMOVER II Straight pin (Transfer shifter fork).
4WD
4WD Dual-range
4WD Dual-range
--::iT-144
0
A14-082 399295120
.oo;z:::J
A13-205 399411700 INSTALLER Reverseshifter rail arm.
i
399513600 INSTALLER Extension rear oil seal, 4WD
A12-174
398791700 REMOVER II Spring pin (5·speed)
STAND SET Transmission main case.
i
399520105 SEAT FWD Non-TURBO
\...
"
CD
~
WEIGHT
A12-174
1 2 3 4
STAN0 CP 1399935120) BOLT(016510600) ...10x60mm SOLT(016510700) ...10x70mm SOLT(016510400)...10,,40mm ST·169 399527700
~
A12-170 399780104
~
A13-196 399790110 INSTALLER Roller bearing, [Differential) Axle shaft oil seal. FWD Non-TURBO
PULLER SET Roller bearing (Differential],
Roller bearing [Differentlal).
Preload on roller bearing,
FWD TURBO· 4WD
Q
A12·171
6
~
A14·075 A12-T72
~
, 2 3 4 5 6
(j)
BOLTI89952,412) PULLeR 13995277021 HOLDER (3995277031 ADAPTE A 13984977D1) BOLTI999520,07) NUTI02'OOBOOO)
(GJ -
Al 2-175
SPECIAL TOOLS
498057000 OIL SEAL INSTALLER Transfer case oil seal. 498057100 INSTALLER Transfer front oil seal. 498057200 OIL SEAL INSTALLER Transfer rear oil seal. 498067000 TRANSFER RACE PRESS
1-6
Transfer race.
4WD
4WD Dual-range
4WD Dual·range
4WD
Ll-105 498077000 5TH DRIVE GEAR REMOVER 5th driven gear. 498147000 DEPTH GAUGE Main shaft axial end play adjustment
LH06 498247001 MAGNET BASE
Ll-l07 498247100 DIAL GAUGE
Ll-108
Backlash between side gear and pinion, Hypoid gear backlash.
Backlash between side gear and pinion, Hypoid gear backlash.
FWD TURBO - 4WO
~~
,
ST-146 498517000 498787000 STOPPER Transmission main shaft. ST·156 FWD Non·TURBO
~
ST·157 498787100 MAIN SHAFT STOPPER Transmission main shah.
Ll-109 499427000 STOPPER For securing the drive pinion shaft ASSY and driven gear ASSY when removing the drive pinion shah ASSY lock nut [18 x 13.5l.
REPLACER Drive pinion thrust plate and needle bearing race. FWD Non·TURBO
FWD TURBO· 4WD
L'-388
ST·151
A12-173
Ll-l10
1-6
498937000 TRANSMISSION HOLDER Transmission main shaft lock nut.
SPECIAL TOOLS
499267200 STOPPER PIN Transfer caseand fork high-low rod. 4WD Dual-range 499277000 INSTALLER Drive pinion. 499277100 BUSH 1-2 INSTALLER 1st driven gear thrust plate. 1st-2nd driven gear bush. FWD TURBO· 4WD
FWD TURBO· 4WD
FWD Non-TURBO
L 1-277 499277200 INSTALLER For press fitting the 2nd driven gear, roller bearings, & 5th driven gear onto the driven shaft. GUIDE Clutch disc. 499747000 499747100 CLUTCH DISC GUIDE Clutch disc.
A12-296 499757001 SNAP RING GUIDE Snap ring (OUT 25)
L'_'13
FWD Non-TURBO
FWD TURBO· 4WD
4WD Dual-range
L1-391 499757002 SNAP RING PRESS Snap ring (OUT 25J Ball bearing (25 x 62 x 17J 4WD Dual-range 499787000 WRENCH ASSY Differential side retainer.
ST·170 499797000 OIL SEAL INSTALLER
L1-114 499827000 PRESS Oil seal (SpeedometerJ.
L1·115
Differential side retainer oil seal.
FWD TURBO· 4WD
L 1·117
L1·1l8
ST·147
SPECIAL TOOLS
499857000
REMOVER ASSY To remove the driven gear ASSY 5th gear. RACE 4-5
1-6
499917500
DRIVE PINION GAUGE ASSY Drive pinion shim adjustment.
499877000
INSTALLER
499917100
GAUGE ASSY 2 Drive pinion shim.
Needle bearing 4th and 5th races. Transmission main shaft rear ball bearing. FWD TURBO· 4WD
FWD Non-TURBO
FWD TURBO· 4WD
...__'_._'~i--<fl
L,.,19 499927000
HANDLE Transmission main shaft. HANDLE Transmission main shaft.
Plate 2 Scale
A12-188 499987003
SOCKET WRENCH [35) Drive pinion lock nut Main shaft lock nut [4WD)
499927100
499987300
SOCKET WRENCH [50) To remove the driven gear ASSY lock nut.
FWD Non-TURBO
FWD TUR80·
4WD
A12-189 898938600
HOLDER Transmission main shaft.
A12-191 899474100
EXPANDER Snap ring [Transmission main shaft) 4WD Dual·range
899524100
PULLER SET Roller bearing (Differential) INSTALLER
899580100
Transmission main shaft. Drive pinion, Ball bearing (Rear drive shaft)
FWD Non-TURBO
FWD Non-TURBO
A12-176
A12·178
A5·142
A 12-179
1-6
899714110 RETAINER Transmission main shaft, Drive pinion, Rear drive shaft.
SPECIAL TOOLS
899754110 PRESS ASSY Transmission main shaft, Needle bearing (transfer case), Rear drive shaft 4WD PRESS Clutch release bearing holder. 899754112 899858600 RETAINER II Transmission main shaft, Drive pinion. FWD Non-TURBO
FWD Non·TURBO
Guide
o i-899874100
Press
i-Press
~
A12·181 899864100 REMOVER Transmission main shaft, Drive pinion. A12-182 899884100 HOLDER Drive pinion, Rear drive shaft, Extension ASSY Al1-{125
~
A12-183 899904100 REMOVER Straight pin (Differential).
INSTALLER Transmission main shaft, Drive pinion, Transfer drive gear bushing.
~
A12·184 899988608 SOCKET WRENCH (27) Transmission main shah [FWD) Rear drive shaft (4WD)
q
A12·185
I
A12·186
A12·187
~
A12·191
SPECIAL TOOLS
1-6
Automatic
Transmission and Differential Tools
1. Special Tools for Differential

398437700 DRIFT Drive pinion front bearing cup. GAUGE Low & reverse brake, total endplav, oil pump, drive pinion height. 398643600 SHAFT Drive pinion and reduction drive gear. 398653600 398781600 STOPPER Reduction drive gear.
(
~
A14·046 398833600 GUIDE Needle bearing.
\
A13·211
IIIlI=A13·192 399520105 SEAT Roller bearing (Differential) PULLER
f
A12-T73 399703600 Axle shaft bearing cup.
399513600 INSTALLER Drive pinion rear bearing cup.
~
A13·194 399780111 WRENCH Axle shaft oil seal holder.
~
A13·196 399790110 INSTALLER Roller bearing [Differential) Axle shaft oil seal. MASTER
Q
A12·171 399913601 Drive pinion.
A13-186 399913603 HOLDER Drive pinion.
~
A12·168
lO) A12-175
(2
A13·190
~
A 13·189
1-6
399913604 SPACER Drive pinion.
SPECIAL TOOLS
498247001 MAGNET BASE Backlash of gears. 498247100 DIAL GAUGE Backlash of gears. HANDLE Bearing cup, needle bearing, drive pinion front bearing retainer and impeller bushing. 498477000
({fa,
A13-187 498517000 REPLACER Drive pinion front bearing core. PULLEY
!
ST-156 498567000 Preload check.
~
ST-157 498807000 BEARING GUIDE Needle bearing.
~
ST-150 498847000 OILSEAL GUIDE
Oil seal holder
~
ST-151 499247000 INSTALLER Drive pi nion oi I seaI 499247100 01 L SEAL INSTALLER Oil seal holder.
~~l
A 13-513
GJ
--
C!th
A13-S15 499267100 SPACER Oil seal holder.
A13-512
499247200 INSTALLER Final reduction case.
4WD
,
A13-51B
Q A13-514
~2)
A13-517
0
A13-S16
10
SPECIAL TOOLS
499427000 INSTALLER Drive pinion front bearing CUP. axle shaft bearing cup and thrust bearing retainer. PRESS Speedometer shaft oil seal. 499827000 REMOVER Needle bearing at reduction drive gear. 499867000 Pli ERS Snap ring. 499897000
1-6
A14·079 499917400 MASTER 2 Drive pinion. 499937000 DIFFERENTIAL STAND
ST-147 499987100 SOCKET WRENCH (35) Drive pinion. 899524100 PULLER SET
A13-519
Final reduction section.
Roller bearing (Differential)
Cap
Q
A5-142
A13·510 899580100 INSTALLER Drive pinion. REMOVER Differential case. 899904100
A13-509 899924100 HANDLE Reduction drive gear.
A13-511
A 12·179
A12-187
A12-189
11
1-6
SPECIAL TOOLS
2. Special Tools for Transmission and Extension

398308700 PULLER Transmission case oil seal 398534800 ADAPTER 2 Line pressure SOCKET Brake band 398603610 PLIER Governor v alve 398663600
~ ~
A13-215 398673600 COMPRESSOR Reverse clutch, forward clutch and low & reverse brake 398863600 INSTALLER 2 A13-203
@
A13-209 399248700 INSTALLER 2 Transmission case oil seal
...:Q ~ ~
A13-205 399543600 INSTALLER Needle bearing and bushing on oil pump housing
Needle bearing on oil pump carrier
~
A13-208 399793600 INSTALLER Final reduction case PLiER
9
A13-213 399893600 REMOVER 2 Reverse clutch, forward clutch and low & reverse brake
®
A13-216 A13-212 ~ 498057300 INSTALLER Extension oil seal 4AT
399903600
Needle bearing and bushing on oil pump carrier
)
~
A13-214 *NewlY adopted tool
A13-207
A13-217
L 1-603
12

Subaru EA 82 Service Manual Part 1

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QUICK REFERENCE

[IJ GENERAL SECTION

[g] ENGINE SECTION

4-DOOR SEDAN STATION 3-DOOR WAGON

FWD GL-l0 TURBO

Shoulder room Wheelbase

'1 1,016 [2.240) '1 ·1 610 (1.345) 406 (8S5)

·1 1,034 (2,280) ·1 '1 626 (1.380) 408 (900)

*2 1,039 (2,290) '1 ·1 621 (1,370) 413 (910)

'2 1,057 (2.330)

·31.163 (2,565) ·3 ·3 703 [1.550) 449 (990)

635 (1,400) 417 (920)

·1 1,016 [2,240) 844

'1 1,034 (2.280) 844 (1,860) 712 (1.570) 1,556 (3,430)

·1 1,034 (2.280) 844 (1,8601 712 11,570) 1.556 (3,430)

'1 1.052 (2,320) 844 [1,860) 712 (1,570) 1,556 (3,430)

862 (1,9001 730 [1.610) 1.592 [3,510)

·3 1,152 (2,540) 862 (1,900) 730 [1,610) 1,592 (3,510)

712 (1,570) 1,556 (3.430)

TURBO MPFI 5MT

Shoulder room Wheelbase

+2 472 (1,040) +21.114 [2,455) 'I 640 (1,41OJ

+3 497 (1,0951 '3 1.200 (2,645) -

+4 1,227 [2,705) 828 11,825) 782 [1,725) 1,610 [3,550)

"5 1,268 (2,795) '5 755 (1,665)

+1 469 (1,035) +1 1,109 (2,445) 816 [1,8ooJ

828 11.825J 782 (1,725) 1,610 (3,55O)

FWD GL-l0 TUR.BO

ITEM Seating capacity persons

Type and manufacturer HP/rpm N·m (kg·m, ft·lbl/rpm

NGK: Nippondenso: Champion:

SOD20R-MF 65D23R·MF (rnin.]

65D23R-MF 111 420

Helical 0.976 Hypoid 3.700

Helical 0.976 Hypoid 3.700

Helical 0.976 Hvpoid 3.454

Helical 0.976 Hypoid 3.700

reduction Final reduction

DSPD; Dry Single Plate Diaphragm TC Torque Converter

Full time 4WO GL-l0 TURBO MPFI 5MT SIR

Full time 4WO GL-l0 TURBO MPFI 4AT

ITEM Seating capacity persons

SPFI 5MT D/R

N·m (kg·m, ft·lbl/rpm

50D20R-MF 65D23R·MF 50D20R-MF

TC '2 2.821 1.559 1.000 2.257 Helical 0.974 Hypoid 3.700

TC '6 2.785 1.545 1.000 0.694

Helical 1.000 Hypoid 3.700

DSPD: Dry Single Plate Diaphragm TC Torque Converter

FWD GL-l0 TURBO

Rack and pinion

Lower level Q (US qt, Imp qt)

B.2±0.1 (6.6±0.l, 5.5±0.1) 1.2 (1.3, 1.1) 0.7 (0.7.0.B)

B.2±0.1 (6.6±0.l, 5.5:1:0.1) 1.2 (1.3.1.1) 0.7 (0.7.0.B)

6.2±0.1 (B.BfO.l, 5.5±0.1) 1.2 (1.3, 1.1)

Q (US qt, Imp qt]

Q (US qt. Imp qt)

0.7 (0.7,0.6) 6.0 (B.3,5.3) +2 5.5 (5.B,4.8)

(US qt, Imp qt)

.2 (US qt, Imp qt)

Curb to curb For CANADA

SPFI 3AT Helical 0.948 Hypoid 3.900

2 1,125 (2,480) 1 '1 628 [1,385) 490 [1,080)