PM-6
Engine Oil
PERIODIC MAINTENANCE SERVICES
3. Engine Oil
A: REPLACEMENT
1) Open the engine oil filter cap for quick draining of
the engine oil.
2) Drain the engine oil by removing the engine oil
drain plug.
3) Tighten the engine oil drain plug after draining
the engine oil.
NOTE:
Use a new drain plug gasket.
Tightening torque:
44 N·m (4.5 kgf-m, 33 ft-lb)
4) Fill engine oil through the level gauge up to the
center between the upper level and the lower level.
Place the vehicle on a level surface when checking
oil level. Use engine oil of the proper quality and
viscosity, selected in accordance with the following.
Recommended oil:
Refer to “RM” section.
ommended Materials.>
Engine oil capacity
When replacing engine oil and oil filter
Upper level
Approx. 5.7 2 (6.0 US qt, 5.0 Imp qt)
Lower level:
Approx. 4.7 2 (5.0 US qt, 4.10 Imp qt)
When replacing engine oil only
Upper level:
Approx. 5.5 2 (5.8 US qt, 4.8 Imp qt)
Lower level:
Approx. 4.5 2 (4.8 US qt, 4.0 Imp qt)
The proper viscosity oil helps the engine maintain
its ideal temperature, and cranking speed in-
creased by reducing viscosity friction in hot condi-
tion.
CAUTION:
When replenishing oil, it does not matter if the
oil to be added is a different brand from that in
the engine; however, use oil having the API
standard and SAE viscosity No. designated by
SUBARU.
NOTE:
If the vehicle is used in areas with very high temper-
atures or for other heavy duty applications, the fol-
lowing viscosity oils must be used:API Standard:
SM SAE Viscosity No.: 30, 40, 10W-50, 20W-40,
20W-50
5) Close the engine oil filler cap.
6) Start the engine and warm it up for a time.
7) Stop the engine to inspect the oil level again.
(A) Oil level gauge
(B) Oil filler cap
(C) Upper level
(D) Lower level
PM-00279
(A)
(B)
(C)
(D)
PM-00280
PM-00280
PM-18
Front & Rear Differential Oil
PERIODIC MAINTENANCE SERVICES
12.Front & Rear Differential Oil
A: REPLACEMENT
1. FRONT DIFFERENTIAL
1) Drain the differential gear oil by removing drain
plug using TORX® BIT T70.
NOTE:
•Before starting work, cool off the differential gear
oil well.
•If front differential gear oil adheres to the exhaust
pipe, wipe it off completely.
2) Replace the gasket with new one, and then tight-
en the drain plug to specified torque.
Tightening torque:
70 N·m (7.1 kgf-m, 51.6 ft-lb)
3) Fill differential gear oil through the oil level
gauge hole up to the upper point of level gauge.
Recommended gear oil:
Refer to “RM” section.
ommended Materials.>
NOTE:
Each oil manufacturer has its base oil and addi-
tives. Thus, do not mix two or more brands.
Gear oil capacity:
1.3 — 1.5 2 (1 . 4 — 1 .6 U S q t , 1 . 1 — 1 .3 lmp q t)
2. REAR DIFFERENTIAL
1) Drain the oil by removing drain plug.
2) Remove the filler plug for quick draining oil.
3) Tighten the drain plug after draining oil and re-
placing with a new gasket.
Tightening torque:
29 N·m (3.1 kgf-m, 21.4 ft-lb)
4) Pour oil to the bottom end of filler plug hole.
Recommended gear oil:
Refer to “RM” section.
ommended Materials.>
Oil capacity:
0.8 2 (0.8 US qt, 0.7 lmp qt)
NOTE:
Each oil manufacturer has its base oil and addi-
tives. Thus, do not mix two or more brands.
5) Replace the gasket with a new one and tighten
the filler plug.
Tightening torque:
29 N·m (3.1 kgf-m, 21.4 ft-lb)
(A) Oil level gauge
(B) Upper level
(C) Lower level
PM-00170
PI-00184
(A)
(C)
(B)
(A)
F
L
(A) Filler plug
(B) Drain plug
(B)DI-00355
(A)
PM-19
Brake Line
PERIODIC MAINTENANCE SERVICES
13.Brake Line
A: INSPECTION
1. BRAKE LINE
1) Check for scratches, swelling, corrosion, traces
of fluid leakage on the brake hoses or pipe joints.
2) Check the possibility of adjacent parts interfering
with brake pipes/hoses during driving, and loose
connections/clamps.
3) Check any trace of fluid leakage, scratches, etc.
on master cylinder, wheel cylinder and pressure
control valve.
NOTE:
•When the brake fluid level in the reservoir tank is
lower than specified limit, the brake warning light
on the combination meter will come on.
•Visually check the brake hose for damage. (Use
a mirror where it is difficult to see)
2. SERVICE BRAKE
1) Check the free play of brake pedal with pulling
up the force of less than 10 N (1 kgf, 2 lb).
Brake pedal free play (Pulling up direction of
pedal)
0.5 — 2.0 mm (0.02 — 0.08 in)
2) If the free play is out of specifications above, ad-
just the brake pedal as follows.
(1) Make sure the engine is off. (No vacuum is
applied to brake booster.)
(2) There should be play between brake boost-
er clevis and pin at brake pedal installing por-
tion. [Pulling up the brake pedal pad with a force
of less than 10 N (1 kgf, 2 lb) to a stroke of 0.5
to 2.0 mm (0.02 to 0.08 in).]
(3) If there is no free play between clevis pin
and clevis, turn brake switch adjusting nut until
the clearance between stopper and screw of
brake switch becomes 0.8 mm (0.031 in).
(1) Front brake hose
(2) Front brake pipe
(1) Rear brake pipe
(2) Rear brake hose
PM-00288
(2)
(1)
PM-00289(1)
(2)
(A) Pedal free play
(A) Brake switch
(B) Adjusting nut
(C) 0.8 mm (0.031 in)
(D) Stopper
(E) Clevis pin
(F) Clevis
(G) Pedal free play
(H) Lock nut
(I) Brake booster operating rod
(J) Play at pin
PM-00313
(A)
PM-00314
(G)
(A)(D)(E)
(B)
(C)
(F)
(J)(I)
(H)
PM-20
Brake Line
PERIODIC MAINTENANCE SERVICES
3) Check the pedal stroke.
While the engine is idling, depress the brake pedal
with a 500 N (51 kgf, 112 lb) load and measure the
distance between the brake pedal and steering
wheel. With the brake pedal released, measure the
distance between pedal and steering wheel again.
The difference between the two measured values
must be less than specified value. If the measured
value is more than specification, there is possibility
of entering air in hydraulic unit.
Brake pedal stroke A:
115 mm (4.5 in)/ 500 N (51 kgf, 112 kg) or less
4) Check to see if air is in the hydraulic brake line
by the feel of pedal operation. If air appears to exist
in the line, bleed it from the system.
5) Check for even operation of all brakes, using a
brake tester or by driving the vehicle for a short dis-
tance on a straight road.
3. BRAKE SERVO SYSTEM
1) With the engine off, depress the brake pedal
several times applying the same pedal force. Make
sure the travel distance should not change.
2) With the brake pedal depressed, start the en-
gine. Make sure the pedal should move slightly to-
ward the floor.
3) With the brake pedal depressed, stop the engine
and keep the pedal depressed for 30 seconds.
Make sure the pedal height should not change.
4) A check valve is incorporated into the vacuum
hose part. Disconnect the vacuum hose to inspect
function of check valve.
Make sure air flows from the booster end to engine
end but does not flow in the opposite direction in
the check valve.
5) Check the vacuum hose for cracks or other dam-
age.
NOTE:
When installing the vacuum hose on the engine
and brake booster, do not use soapy water or lubri-
cating oil on their connections.
6) Check the vacuum hose to make sure it is tightly
secured.
(A) Steering wheel
(B) Toe board
PM-00045(B)
(A)
= A
1
12
2
(A) Vacuum hose
(B) Check valve
(C) Engine side
(D) Brake booster side
PM-21
Brake Fluid
PERIODIC MAINTENANCE SERVICES
14.Brake Fluid
A: REPLACEMENT
1) Either jack-up the vehicle and place a rigid rack
under it, or lift-up the vehicle.
2) Remove all the wheels.
3) Drain the brake fluid from master cylinder.
4) Refill the reservoir tank with recommended
brake fluid.
Recommended brake fluid:
Refer to “RM” section.
ed Materials.>
NOTE:
•Avoid mixing different brands of brake fluid to
prevent degrading the quality of fluid.
•Be careful not to allow dirt or dust to get into the
reservoir tank.
Bleeding sequence (1) → (2) → (3) →(4)
5) Install one end of a vinyl tube onto the air bleeder
and insert the other end of the tube into a container
to collect the brake fluid.
NOTE:
•Cover the bleeder with cloth, when loosening it,
to prevent brake fluid from being splashed over sur-
rounding parts.
•During air bleeding, keep the reservoir tank filled
with brake fluid to eliminate entry of air.
•Operate the brake pedal slowly.
•For convenience and safety, two people should
work together.
•The amount of brake fluid required is approx. 600
m2 (20.3 US fl oz, 21.1 Imp fl oz) for total brake
system.
6) Instruct your co-worker to depress the brake
pedal slowly two or three times and then hold it de-
pressed.
7) Loosen the bleeder screw approximately 1/4
turn until a small amount of brake fluid drains into
the container, and then quickly tighten the screw.
8) Repeat steps 6) and 7) until there are no air bub-
bles in drained brake fluid and new fluid flows
through vinyl tube.
NOTE:
Add brake fluid as necessary while bleeding air, so
that the brake fluid in the tank is always between
MAX and MIN.
9) After completing the bleeding operation, hold the
brake pedal depressed and tighten the screw and
install bleeder cap.
Tightening torque:
8 N·m (0.8 kgf-m, 5.8 ft-lb)
10) Bleed air from each wheel cylinder by following
steps from 5) to 9).
11) Depress the brake pedal with a force of approx.
294 N (30 kgf, 66 lb) and hold it there for approx. 20
seconds. At this time check the pedal to see if it
makes any unusual movement. Visually inspect the
bleeder screws and brake pipe joints to confirm
there is no fluid leakage.
12) Install the wheels, and drive the vehicle for a
short distance between 2 to 3 km (1 to 2 mile) to
confirm brakes are operating properly.
(1) Front RH
(2) Rear LH
(3) Front LH
(4) Rear RH
(5) Secondary
(6) Primary
(1) (4)
(2)(3)
(5) (6)
PM-00047
PM-00048
5AT-3
General Description
AUTOMATIC TRANSMISSION
8. COOLING AND HARNESS
9. TRANSFER
10.FINAL REDUCTION GEAR
11.RECOMMENDED GEAR OIL
Cooling systemLiquid-cooler incorporated in
radiator
Tr a n s m i s s i o n h a r n e s s 2 0 + 8 p o l e s
Tr a n s f e r t y p eVa r i a b l e t o r q u e d i s t r i b u t i o n
(VTD)
Number of transfer clutch
drives & driven plates4
Reduction gear ratio 1.000 (41/41)
Fr o nt f in a l r e du ct i o n g ea r
ratio3.583
Lubrication oil
(1) Item (3) API standard
(2) Front differential gear oil (4) SAE viscosity No. and applicable
temperature
Fr o nt d if fer e nt i a l g ea r oi l c a pa ci t y
2(US qt, Imp qt)1.3 — 1.5 (1.4 — 1.6, 1.1 — 1.3)
MT-00001
(1)
(4)GL-5(3)
(2)
( C)( F)-30 -26 -15 15
9085W80W75W -90
25 30 -5 0-22-1523328659775
5AT-4
General Description
AUTOMATIC TRANSMISSION
B: COMPONENT
1. TORQUE CONVERTER CLUTCH & TRANSMISSION ASSEMBLY
(1) Torque converter ASSY (15) Oil charge pipe (29) Nipple
(2) Circlip (16) O-ring (30) O-ring
(3) Oil pump shaft (17) Gasket (31) Oil seal
(4) Differential oil level gauge (18) Union screw (32) Dust cover
(5) Pitching stopper bracket (19) Ball (33) Floating bracket
(6) Differential oil drain plug (20) Spring (34) Turbine speed sensor 1
(7) Gasket (21) Union screw
(8) Oil seal (22) ATF outlet pipeTightening torque: N·m (kgf-m, ft-lb)
(9) Lock plate (23) ATF inlet pipeT1: 5 (0.5, 3.7)
(10) Side retainer (24) MagnetT2: 20 (2.0, 14.8)
(11) O-ring (25) Oil panT3: 25 (2.5, 18)
(12) Oil Seal (26) GasketT4: 40 (4.1, 29.5)
(13) ATF level gauge (27) ATF drain plugT5: 45 (4.6, 33.2)
(14) O-ring (28) Breather hoseT6: 70 (7.1, 51.6)
T6
T4
T3
T5
T1
T2
T4
T3
(12)
(11)
(7)(6)
(10)
(21)
(20)
(23)
(26)
(25)(24)(27)
(30)
(19)(22)
(18)
(17)
(34)
(32)
(16)
(15)
(14)
(13)
(28)
(4)
(5)
(1)
(2)(3)
(8)
(29)
(33)
(31)
(9)
(17)
AT-03368
5AT-10
General Description
AUTOMATIC TRANSMISSION
7. DIFFERENTIAL GEAR
(1) Retainer plate RH (6) Hypoid driven gear (11) Differential case LH
(2) Differential side retainer RH (7) Drive pinion shaft (12) Differential bevel gear
(3) O-ring (8) Pinion shaft (13) Washer
(4) Oil seal (9) Straight pin (14) Differential bevel pinion
(5) Taper roller bearing (10) Differential case RH (15) Differential side retainer LH
AT-03008
(1)
(7)
(8)
(13)(12)
(12)
(14)
(13)
(1)
(2)
(3)
(5)
(10)
(6)
(9)
(11)
(5)
(3)
(15)
(4)
(4)
(14)