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1. 9 o Sideairbag _ Ownategg _ Sunroof O Navigation system 9 y Selfleveizer LP Gradeup 1 For option code refer to ID section Ref to ID 5 MODEL NUMBER PLATE IDENTIFICATION Identification Vehicle Dynamics Cruise conor o o audio MEER M RI MEE Option SPC 36 SPECIFICATIONS Option code AWD Model 55 A m mas 2203 U Rear kgf Ib 1 060 bos 1 060 Bol 1 060 uem 1 060 1 060 2 336 Gros vehicle Tota kgf Ib 1 945 4 288 1 945 4 288 1 945 4 288 1 945 4 288 1 945 4 288 mass G V M Leatherinterior_ O _ Winterpack _ poo ichtie _ E 1 I s Jj Sideairbag O _ Curtain airbag O _ Sunroof O _ Navigation system Selflevelzer aep O _ 1 For option code refer to ID section Ref ID 5 MODEL NUMBER PLATE IDENTIFICATION Identification Vehicle Dynamics Cruise o Mcintosh audio MEME MEUM RA e
2. 5 1 1 7 SENI Wwe x x s XS gt gt O Sideaibag _ Curtain airbag _ E un dd ME 2 gt gt Navigation system _ gt Seflelizer l gt 1 For option code refer to ID section lt Ref to ID 5 MODEL NUMBER PLATE IDENTIFICATION Identification gt SPC 17 SPECIFICATIONS 2 0 L SOHC 2 5 L SOHC Model 251 LE nm Maximum permissible axle weight Rear kgf Ib 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 M P A W Maximum permissible Total kgf Ib 1 900 4 189 1 900 4 189 1 930 4 255 1 930 4 255 1 930 4 255 1 930 4 255 weight M P W Mcintosh audio MC M MAN Leatherinterior_ O Winterpak __ PE PU AE A O PEC gt _ p gt a o o __ Sideairbag___ _ Curtain airbag _ Swot ___ 9 o o AO Navigation system Seflveizr _ 1 For option code refer to ID section Ref to ID 5 MODEL NUMBER PLATE IDENTIFICATION Identification
3. donde 2 1 e _ WO 9 Sieabg O _ Curtain airbag _ Sa 4 c xn or uw gc Navigation system Seflelizr gt _ 1 For option code refer to ID section Ref to ID 5 MODEL NUMBER PLATE IDENTIFICATION Identification Vehicle Dynamics Control Cruise contol O Option SPC 33 SPECIFICATIONS Option AWD Model 201 NENNEN lr m radon mas 1040 2293 U Rear kgf Ib 1 060 5526 1 060 1 060 i ass 1 060 45 1 060 1 060 2 336 oe 2 Total kgf Ib 1 925 4 244 1 925 4 244 1 925 4 244 1 925 4 244 1 925 4 244 1 925 4 244 Leatherinterior po Winterpack o o _ __ v oc _ o p I 0 i Sideairbag po Curtain airbag _ Sunroof pos Navigation 1 Seflveizr LP Gradeup 1 For option code refer to ID section Ref to ID 5 MODEL NUMBER PLATE IDENTIFICATION Identification Vehicle Dynamics ea Cruise contol o Mcintosh audio ee NN Option SPC 3
4. _ 1 For option code refer to ID section Ref 5 MODEL NUMBER PLATE IDENTIFICATION Identification Vehicle Dynamics o Mcintosh audio RE EE RI UM RM Option SPC 24 LEGACY SPECIFICATIONS 2 WAGON MODEL LHD model EC 2 0 L SOHC Model 2 01 5 Dual range 770 1 698 Rear Total b Maximum Front kgf Ib 1 040 2 293 1 040 2 293 2 293 1 040 2 293 2 298 1 040 2 293 2 293 1 040 2 293 2 293 1 040 2 293 2 293 1 040 2 293 2 293 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 1 925 4 244 1 925 4 244 1 925 4 244 1 925 4 244 permissible axle weight Rear kgf Ib 1 060 2 336 M P A W Maximum permissible Total kgf Ib 1 925 4 244 1 925 4 244 weight M P W Vehicle Dynamics Control Cruise control McIntosh audio Leather interior Winter pack _ _ se gt y 91 Sideabg Curtain airbag ETT Navigation system EC A A ee eee 1 For option code refer to ID section Ref to ID 5 MODEL NUMBER PLATE IDENTIFICATION Identification gt u SPC 25 SPECIFICATIONS 2 0 L SOHC AWD 2 01 Maximum permissible axle weight Rear kgf Ib 1 060 2 336 1 060 2
5. _ Winterpags 9 9 dd A em A BET gt o EN 405 NM Sideaibag Curtain airbag _ Swot _ 9 9 ll o gt Navigation system o Selfleveizer _ 1 For option code refer to ID section Ref to ID 5 MODEL NUMBER PLATE IDENTIFICATION Identification gt Vehicle Dynamics Canro Cruise contol Option SPC 10 SPECIFICATIONS 2 5 L SOHC AWD 2 5i Maximum permissible axle weight Rear kgf Ib 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 M P A W Maximum permissible Total kgf Ib 1 930 4 255 1 930 4 255 1 930 4 255 1 930 4 255 1 930 4 255 1 930 4 255 weight M P W Model D AR O IR E Leatherinterior_ _ _ Winterpack O m AECI o ae A ee Sideaibag Oo Curtain airbag O _ Qc gt Navigation system _ _ Sefleveizr _ 1 For option code refer to ID se
6. t t ly 0 0 21 Steering system 1 3 Symbols used Replace Inspection 1 Recommended service for safe vehicle operation NOTE 1 When the vehicle is used in extremely dusty conditions the air cleaner element should be replaced more often 2 ATF filter is maintenance free part ATF filter needs replacement when it is physically damaged or ATF leaked 3 Periodic inspection and replacement of the camshaft drive chains on the 3 0 L models is not required PM 3 Schedule PERIODIC MAINTENANCE SERVICES 2 EXCEPT FOR EUROPE AREA For periodic maintenance of over 50 000 km 30 000 miles or 48 months carry out inspections by referring to the following tables For a maintenance period gone beyond these tables apply them repeatedly as a set of 50 000 km 30 000 miles or 48 months Number of months or km miles whichever occurs first OS Remarks Engine oil 30L Others Engine oil filter For periodic maintenance of over 100 000 km 60 000 miles or 48 months carry out inspections by referring to the following tables For a maintenance period gone beyond these tables apply them repeatedly as a set of 100 000 km 60 000 miles or 48 months Maintenance interval Number of months or km miles whichever occurs first Moms 12 24 s as Remarks 1 000 miles 1 15 3 45 80 E 2 5 L 2 0 L non fuse
7. Ale For 3 0 L model replace every 160 000 km 100 000 miles o o O a 77 Ardenedemm PR Pe Coot R R Ho Ouhssem LN SSC EC EL 13 Front amp reardiferenialol 14 __ 2 15 ER PR 16 brake pads amp dises J iz Parkingbrake TE AO 18 Suspension gt 19 Wheel bearing gt 20 boots amp joint EE EE Steering system Power steering Symbols used Replace I Inspection 1 Recommended service for safe vehicle operation NOTE 1 When the vehicle is used in extremely dusty conditions the air cleaner element should be replaced more often 2 ATF filter is maintenance free part ATF filter needs replacement when it is physically damaged or ATF leaked 3 Periodic inspection and replacement of the camshaft drive chains on the 3 0 L models is not required PM 4 Schedule PERIODIC MAINTENANCE SERVICES B MAINTENANCE SCHEDULE 2 1 EUROPE AREA Engine oil Engine oil filter Fuel line Transmission oil Front amp rear dif ferential oil Brake fluid Brake pads Brake linings and drums Parking brake Axle boots amp joints Steering system Power steering Every 12 months 15 000 km 9 000 miles 12 months 15 000 km 9 000 miles 15 000 km 9 000 miles 12 months
8. DOW CORNING No 7088 CORNING DOW CORNING No 7088 No 7038 PCV valve Steering adjusting screw THREE 1141 004403006 NW ELI 2 SOHC camshaft cap Cam 3 01 model e Semicircular plug 3 0 L model Rocker cover 3 0 model Oil pan Pan upper Block Pan upper Back cover Front cover block head pan upper Front sealing cover 3M Butyl Rubber 8626 Rear sealing cover THREE BOND 1280B K0877YA018 THREE BOND 1217G RM 7 Recommended Materials RECOMMENDED MATERIALS RM 8 PRE DELIVERY INSPECTION 1 Inspection bli 2 Pre delivery Inspection PRE DELIVERY INSPECTION 1 Pre delivery Inspection A GENERAL DESCRIPTION The purposes of the pre delivery inspection are as follows Remove the additional parts used for ensuring the vehicle quality during transportation and restore the ve hicle to its normal state e Check if the vehicle before delivery is in a normal state Check for any damage to the vehicle or parts that may have taken place during transportation or storage Check if the vehicle after repair is in a normal state Make sure to provide a complete vehicle to the customer For the above reasons all SUBARU dealers dealerships carry out the PDIs before delivering a vehicle Refer to this manual unless otherwise specified B PRE DELIVERY INSPECTION PDI PROCEDURE STATIC CHECKS JUST
9. Option SPC 37 LEGACY SPECIFICATIONS 3 OUTBACK LHD model E 2 5 L SOHC Model zu OBK 2 5 i 5MT Dual range 4AT 805 1 774 cw gt Bear kgf b Total kgf bb Maximum Front kgf Ib 1 040 2 293 1 040 2 293 2 293 1 040 2 293 2 293 1 040 2 293 2 293 1 040 2 293 2 293 permissible M P A W permissible Total kgf Ib 1 960 4 321 1 960 4 321 1 960 4 321 1 970 4 343 1 970 4 343 1 970 4 343 weight M P W _ Cruise control 9 _ 9 _ _ __ Leather interior o winterpack 9 H5mh e E O ac 9 9 9 9 9 S abg 9 9 o 0 9 oOo Selfleveizer 9 o 1 For option code refer to ID section Ref to ID 5 MODEL NUMBER PLATE IDENTIFICATION Identification gt SPC 38 SPECIFICATIONS 3 0 L DOHC 2 5 L SOHC AWD OBK 3 0 R OBK 3 0 R A 2 51 zd 217 Maximum permissible axle weight Rear kgf Ib 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 M P A W Maxi
10. Option SPC 31 SPECIFICATIONS Option code K4 2 5 L SOHC AWD 2 5 1 a ai Maximum permissible axle weight Rear kgf Ib 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 M P A W Maximum permissible Total kgf Ib 1 935 4 266 1 935 4 266 1 935 4 266 1 935 4 266 1 945 4 288 1 945 4 288 weight M P W Model A A Leatherinterior_ Winterpack RS O E A _ 8 y PET dame gt m _ ____ __ a o O 9 Curtain airbag _ _ Sunroof o Navigation system Seflveizr _ 1 For option code refer to ID section Ref to ID 5 MODEL NUMBER PLATE IDENTIFICATION Identification Vehicle Dynamics OO Cruise contol Option SPC 32 SPECIFICATIONS Option K4 2 5 L SOHC 3 0 L DOHC AWD 3 0R AMT Ron Em Toia kgf b Maximum permissible M P A W Maximum permissible Total kgf Ib 1 945 4 288 1 945 4 288 1 945 4 288 1 945 4 288 2 050 4 519 weight M P W Mcintosh audio _ Leatherinterior_ _
11. Upper level Lower level ATF level range at COLD 20 30 C 68 86 E moo e BAT model A Level gauge ATF level range at HOT 70 80 158 176 Upper level D Lower level E ATF level range at COLD 20 30 C 68 86 2 FILTER Basically filter is maintenance free but when it has physically damaged or leaked the fil ter needs replacement For the replacement procedure of ATF filter refer to ATF FILTER model lt Ref to 4AT 64 Filter gt model lt Ref to 60 Filter gt PM 27 Front and Rear Differential Gear Oil PERIODIC MAINTENANCE SERVICES 15 Front and Rear Differential Gear Oil A REPLACEMENT 1 FRONT DIFFERENTIAL MT MODEL Front differential gear oil for MT model lubricates the transmission and differential together Refer to Transmission Oil for replacement procedure lt Ref to PM 25 Transmission Gear gt 2 FRONT DIFFERENTIAL AT MODEL 1 Drain the differential gear oil by removing drain plug using TORX 70 Before starting work cool off the differential gear oil well e f front differential gear oil adheres to the exhaust pipe wipe it off completely e model 2 Replace the gasket with new one and then tight en the drain plug to specified torque Tightening torq
12. 3 0 model lt Ref to FU H6DO 54 Fuel Delivery Return and Evaporation Lines gt PM 17 PERIODIC MAINTENANCE SERVICES Air Cleaner Element PERIODIC MAINTENANCE SERVICES 9 Air Cleaner Element Non turbo model A REPLACEMENT 1 Disconnect the ground cable from battery 2 Disconnect the connector from mass air flow sensor 2 0 L turbo 3 0 L and 2 5 L EC EK K4 model 3 01 and 2 5 L EC EK model d 5 Remove air cleaner case rear Y 6 Remove the air cleaner element Arba Turbo model c Ton EIN DI Le FF 2 1 13 00206 7 Install in the reverse order of removal NOTE Fasten with a clip after inserting the lower tab of the case 3 Loosen the clamps A which connect the air cleaner case to intake duct Turbo model 4 Remove the clips B on air cleaner case PM 18 Air Cleaner Element PERIODIC MAINTENANCE SERVICES Refer to COMPONENT for tightening torque 2 0 L non turbo and 2 5 L model Ref to IN H4SO 2 0 2 COMPONENT Gen eral Description Turbo model Ref to IN HADOTO 2 COMPONENT Gener al Description 3 0 L model Ref to IN H6DO 2 COMPONENT General Description PM 19 Cooling System PERIODIC MAINTENANCE SERVICES 10 Cooling System A INSPECTION 1 To check the radiator for leakage fill it with en gine coolant and attach the radiator cap tester to the filler neck and apply
13. 9 Sunroof o Navigation system Seflveizr _ 1 For option code refer to ID section Ref to ID 5 MODEL NUMBER PLATE IDENTIFICATION Identification Vehicle Dynamics CONIO Cruise contol Option SPC 40 LEGACY SPECIFICATIONS 2 5 L SOHC 3 01 DOHC AWD Model 2 5 i OBK 3 0 R OBK 3 0 R A nv Maximum permissible M P A W Maximum permissible Total kgf Ib 1 970 4 343 1 970 4 343 1 970 4 343 2 060 4 542 2 060 4 542 weight M P W Mcintosh audio _ Leatherinterior _ _ _ PETT _ LA _ 2 gt Qe o A O E O O Side airbag____ __ __ _ gt ___ __ Curtain airbag _ Swot _ 9 Navigation system o o o Sefleeizr _ 1 For option code refer to ID section Ref to ID 5 MODEL NUMBER PLATE IDENTIFICATION Identification gt Vehicle Dynamics Control Cruise control Option SPC 41 LEGACY SPECIFICATIONS RHD model Option 2 5 L 3 0 L DOHC AWD A OBK 3 0 R Su aras QW Rear Maximum Fon kgf b permissible M P A W Maxi
14. Use care not to exceed the upper limit level e Addition of ATF to the upper limit mark on side when the ATF temperature is below 70 158 F will overfilling of ATF causing a transmission failure 6 Check ATF level after raising ATF temperature to 70 80 C 158 176 F by running the vehicle or by idling the engine again 7 Check the ATF for leaks Check for leaks in the transmission there are leaks it is necessary to repair or replace gasket oil seals plugs or other parts PM 26 Automatic Transmission Fluid B REPLACEMENT 1 AUTOMATIC TRANSMISSION FLUID 1 Drain the ATF by removing drain plug NOTE Before starting work cool off the ATF well model Front differential gear oil drain plug B drain plug e BAT model A ATF drain plug 2 Replace the gasket with new one and then tight en the drain plug to specified torque Tightening torque 4AT model 25 2 55 kgf m 18 4 ft Ib 5AT model 20 N m 2 0 kgf m 4 5 ft Ib 3 Pour ATF from the ATF charge pipe Recommended ATF Refer to RM section Ref to RM 5 FLUID RECOMMENDED MATERIALS Hecommend ed Materials Capacity Fill the same amount of ATF drained 4 Check the ATF level Ref to PM 26 INSPEC TION Automatic Transmission Fluid PERIODIC MAINTENANCE SERVICES model gt Level gauge ATF level range at HOT 70 80 C 158 176
15. A 15 Due AAA A ee QA 40 49 O EM EH _ Curtain airbag Sunroof _ Navigation system Seflveizr 1 For option code refer to ID section Ref to ID 5 MODEL NUMBER PLATE IDENTIFICATION Identification Vehicle Dynamics ORO Cruise control Option SPC 13 SPECIFICATIONS 2 0 L SOHC 2 5 L SOHC Model AWD a_i 7 EM nv Maximum permissible axle weight Rear kgf Ib 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 M P A W Maximum permissible Total kgf Ib 1 900 4 189 1 900 4 189 1 900 4 189 1 900 4 189 1 900 4 189 1 930 4 255 weight M P W A Leatherinterior_ _ Lu PE _ 1 88 y PETT A _ Side airbag___ _ O Curtain airbag _ Sunroof _ Navigation system Seflveizr gt 1 For option code refer to ID section Ref to ID 5 MODEL NUMBER PLATE IDENTIFICATION Identification Vehicle Dynami
16. Vehicle Dynamics Cruise contol o audio ME EM ERE E NE UK RE UN RR UN RN Option SPC 21 SPECIFICATIONS Option sd 2 0 L SOHC 2 0 L DOHC turbo 2 5 L SOHC 2 ant ST Single radon mas 1040 2293 U Rear kgf Ib 1 060 21 1 060 1 060 EON 1 060 bus 1 060 1 060 2 336 enc total kgf Ib 1 900 4 189 1 900 4 189 2 000 4 409 2 000 4 409 1 930 4 255 1 930 4 255 mass G V M Leatherinterior _ Winterpak _ pS 121 9 3 AC _____ O x uw wm d Sideairbag _ Curtain airbag _ ET 71 l 2 e o o y Sar xe A MAS 3 _ _ 1 For option code refer to ID section Ref ID 5 MODEL NUMBER PLATE IDENTIFICATION Identification Vehicle Dynamics Cruise o Mcintosh audio eo Option SPC 22 SPECIFICATIONS Option code AWD Model 25i NNNM 11 o m radon mas 225 U Rear kgf Ib 1 060 um 1 060 um 1 060 EON 1 060 1 060 1 060 2 336 Gros vehicle Total kgf Ib 1 930 4 255 1 930 4 255 1 930 4 255 1 930 4 255 1 93
17. _ Winterpack _ ISimhtie on 9 v peo lo o 4 408 406 O O Curtain _ Sunroof _ Navigation system _ Selfleveizer _ _ 1 For option code refer to ID section Ref to ID 5 MODEL NUMBER PLATE IDENTIFICATION Identification gt Vehicle Dynamics Control Cruise control Option SPC 20 SPECIFICATIONS Option code AWD Model 201 NNENUEEERL 0 7 radon mas 1040225 U Rear kgf Ib 1 060 bum 1 060 1 060 1 060 un 1 060 1 060 2 336 Gros vehicle Tota kgf Ib 1 900 4 189 1 900 4 189 1 900 4 189 1 900 4 189 1 900 4 189 1 900 4 189 mass G V M Leatherinterior _ y 5imh e _ cul uw 2 p o n uw Sideairbag Curtain airbag ran d e p Jg ro pe nos o rene cp xe cq d 3 gt _ 1 For option code refer to ID section Ref ID 5 MODEL NUMBER PLATE IDENTIFICATION Identification
18. 15 000 km 9 000 miles Repeat short distance drive Replace more fre quently Replace more fre quently cold weather Salt or other High humid corrosive ity or moun used or tain area coastal area Replace Replace more fre more fre quently quently Replace Replace more fre more fre quently quently Extremely Repeat tow ing trailer Replace more fre quently Replace more fre quently Replace more fre quently Schedule PERIODIC MAINTENANCE SERVICES 2 EXCEPT FOR EUROPE AREA Salt or other High humid corrosive Repeat Extremely Repeat tow ing trailer Repeat short distance drive rough muddy cold weather ity or moun used road drive area tain area coastal area Engine oil Replace Replace Replace more fre more fre more fre quently quently quently Engine oil filter Item Replace Replace Replace more fre more fre more fre quently Fuel line Replace more fre quently ATF Replace more fre quently Front amp rear dif Replace Transmission oil ferential oil more fre quently Brake line REC polt Brake fluid Brake pads Brake linings and drums 6 months 12 500 km Parking brake Suspension Axle boots amp joints 12 500 km 7 500 miles Steering system Power steering Eel ttt PM 6 Engine Oil PERIODIC MAINTENANCE SERVICES 3 Engine Oil 2 0 L non turbo and 2 5 model A RE
19. Vehicle Dynamics OU Cruise control Option SPC 18 SPECIFICATIONS Option code EK 2 5 L SOHC AWD 2 5i E E i Maximum permissible axle weight Rear kgf Ib 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 M P A W Maximum permissible Total kgf Ib 1 930 4 255 1 930 4 255 1 930 4 255 1 930 4 255 1 930 4 255 1 930 4 255 weight M P W Model 7 NU M ON Leatherinterior_ O _ Winterpak 9 29 1 o o lo o _ O Sihtie 1 0 1 v p gt ae o Sideairbag___ _ Curtain airbag _ Swot _ 9 gt Navigation system _ Seflveizr _ 1 For option code refer to ID section Ref to ID 5 MODEL NUMBER PLATE IDENTIFICATION Identification Vehicle Dynamics CONIO Cruise control Option SPC 19 SPECIFICATIONS EK 2 51 SOHC AWD e Maximum permissible M P A W Maximum permissible Total kgf Ib 1 930 4 255 1 930 4 255 1 930 4 255 2 030 4 475 2 030 4 475 weight M P W Mcintosh audio Leather interior O
20. 2 L Body type L Sedan MES DN 3 5 Engine displacement 5 2 0 L AWD Drive system 9 2 5 L AWD Suspension system E 3 0 L AWD 5 L Destination K Right hand drive model market L Left hand drive model market H Grade B 2 0 GT 2 0 2 5 3 0 R M 3 0 R A 3 0 3 0 OUTBACK 2 5 V OUTBACK 3 0 W 3 0 R A 7 Transmission fuel feed J SOHC MPI 5MT system K SOHC MPI Dual range 5MT SOHC MPI 4AT V DOHC MPI Turbo 5AT TIP U DOHC MPI 5AT TIP The engine and transmission type are as follows ENGINE EJ202NTAHB Digi 1 2 Engine type EJ 4 cylinders EZ 6 cylinders Fuel feed system 2 D MPI NA SOHC B 3 MPI NA SOHC D MPI NA DOHC H6 X Twin scroll single turbo 6 Detailed specifications Used when ordering parts See the parts catalog for details 7 Transmission L 5AT without ATF cooler with warmer function P 4AT without ATF cooler with warmer function S 5MT Flexible type flywheel T 5MT Dual mass type flywheel V 4AT with ATF cooler with warmer function H4 5AT H6 Detailed specifications Used when ordering parts See the parts catalog for details ID 5 Identification IDENTIFICATION TRANSMISSION TY757VRAAB p T Full time AWD center differential V Full time AWD AT center differential Z Full time AWD AT MPT LEGACY
21. 3 0 kgf m 21 4 ft Ib Refer to RM section lt Ref to RM 3 LUBRI CANTS RECOMMENDED MATERIALS Rec ommended Materials Except for VA2 type A B VA2 type Filler plug Drain plug A B Oil capacity 0 8 0 0 8 US qt 0 7 Imp qt NOTE Filler plug Drain plug Each oil manufacturer has its base oil and addi tives Thus do not mix two or more brands 5 Install the filler plug NOTE Apply liquid gasket to the filer plug threads for T Use a new aluminum gasket for VA type PM 29 Brake Line PERIODIC MAINTENANCE SERVICES 16 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 noses 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 15 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 qa y F J T o oe at gt PM 00171 1 Front brake hose 2 Front brake pipe 00172 1 Rear brake pipe 2 Rear brake hose 2 SERVICE BRAKE 1 Check the free play of brake pedal
22. 105 1 1 495 58 9 1 485 58 5 200 7 9 1 With sunroof SPC 2 LEGACY SPECIFICATIONS B ENGINE 201 SOHC 201 DOHC turbo 251 SOHC 3 0 L DOHC Horizontally Horizontally cooled 4 cylinder 4 stroke gas Oppose ae Engine type cooled 6 cylin oline engine der 4 stroke gas oline engine Valve arrangement Overhead camshaft 99 5 79 0 89 2 80 0 Bore x Stroke mm in 92 x 75 3 62 x 2 95 3 917 x 3 110 3 512 3 150 Displacement cm cu in 1 994 121 67 2 457 149 9 3 000 183 06 10 0 1 6 3 2 rr 19 24 position Maximum output kW PS rom 101 137 5 600 180 245 6 400 121 165 5 600 180 245 6 600 187 19 1 137 9 310 31 6 228 6 226 23 0 166 7 297 30 3 219 1 Maximum torque N m kgf m ft Ib rpm 4 400 2 400 4 400 4 200 C ELECTRICAL Model 2 0 L SOHC 2 0 L DOHC turbo 2 5 L SOHC 3 0 L DOHC ignition timing at iding BTDC CHAMPION RC10YC4 Spark plug Type and manufacturer NGK ILFR6B NGK ILFR6B 5 11 12 110A Battery capacity 5HR 12V 52AH 12V 52AH 12V 52AH 65D23L 75D23L 75D23L 12V 48AH 12V 48AH 12V 48AH KA 55D23L 12V 27AH 12V 48AH m 12V 27AH 34 191 550231 34B19L 1 EC EK model SPC 3 LEGACY SPECIFICATIONS D TRANSMISSION SEDAN WAGON 2 0 3 01 2015 DOHC OHC DOHC turb
23. 4 Tire inflation pressure label Driver 5 Saudi Arabia plate Saudi Arabia ADR compliance plate KA model side KA model model 2 Vehicle identification number Tire inflation pressure label Driver Built date plate KA model VIN side Except for KA model 6 Vehicle identification number 3 Model number plate VIN EK and KA model ENGINE e AUTOMATIC TRANSMISSION 1 Engine serial number Punch mark 1 AT type label 2 Engine type Crankcase upper side 2 Transmission serial number label ID 2 Identification IDENTIFICATION MANUAL TRANSMISSION VA1 TYPE 1 Transmission serial No 1 Type label 2 MT type label VAS e REAR DIFFERENTIAL T TYPE 1 Type label 1 Type white paint MODEL NUMBER PLATE FUJI HEAVY INDUSTRIES LTD di JF1BL5LJ34G002001 Ot BLSALHJ 433 ECXV YA E 220 177 EJ202NTAHB Engine type a 22 320 TY757VRAAB Transmission type ELE TSE ID 3 Identification IDENTIFICATION 2 MEANING OF V I N The meaning of the 1 is as follows EC EK KA AND K4 MODEL JF1BL5LJ34G002001 The starting and ending brackets are stop marks Manufacturer body area JF1 Passenger car made Except for KA OUTBACK model JF2 Passenger car FHI made KA OUTBACK model B line LEGACY fe type Displacement 5 2 0 L AWD 9 2 5 L AWD
24. Lower level 16 TRANSMISSION GEAR OIL A Oil level gauge Check that the transmission gear oil level is normal B Upper level If the amount of fluid is insufficient check that no C Lower level leaks are found Then add the necessary amount of the specified transmission gear oil SAT model A Oil level gauge B Upper level C Lower level A Oil level gauge B Upper level C Lower level 18 ENGINE COOLANT Check that the engine coolant level on the reservoir tank is normal If the amount of engine coolant is in sufficient check that no leaks are found Then add the necessary amount of coolant with the specified concentration 8 Pre delivery Inspection 19 CLUTCH FLUID Check that the clutch fluid level is normal If the amount of fluid is insufficient check that no leaks are found Then add the necessary amount of specified fluid Heservoir tank MIN level MAX level 20 WINDOW WASHER FLUID Check that the window washer fluid level is normal If the amount is insufficient check that no leaks are found Then add the necessary amount of washer fluid 21 FRONT HOOD LATCH CHECK Retract the hood stay and close the front hood Check that the front hood is securely latched 22 KEYLESS ENTRY SYSTEM NOTE The following inspections show the initial settings When the settings are different from the initial set tings use Subaru Select Monitor to check the de tails of each setti
25. Window washer fluid Check that the window washer fluid level is normal 21 Front hood latch check Check that the hood 15 closed and latched securely 22 Keyless entry system Check that the keyless entry system operates normally 23 Seat 1 Check the seat surfaces for stain or dirt 2 Check the seat installation conditions and functionality 24 Seat belt Check the seat belt installation conditions and functionality 25 Wheel alignment Check that the wheel alignments are properly adjusted CHECKS WITH ENGINE RUNNING PROCEDURE Check point 26 Test mode connector Test mode connectors 27 Immobilizer system 1 Check that the engine starts with all keys that are equipped on vehicle 2 60 seconds after turning ignition switch from ON to or OFF or imme diately after removing key check that the security indicator light blinking 29 Exhaust system 30 Indicator and warning lights 31 Clock 32 Audio 33 Navigation system 1 Check all display functions for normal operation 2 Check the map disc DVD are provided on vehicle 3 Check that the navigation system operates normally 35 Lighting system Check that the lighting system operates normally 36 Wiper deicer Check that the wiper deicer operates normally 37 Rear fog light Check that the rear fog light operates normally 38 Illumination control Check that the illumination control operates normally 39 Window washer Check that the window washer system operate
26. mal expansion of engine oil 7 To prevent overfilling the engine oil do not add oil above the F line when the engine is cold PM 8 Engine Oil Filter PERIODIC MAINTENANCE SERVICES 4 Engine Oil Filter 6 After installing the oil filter run the engine and make sure that no oil is leaking around seal rubber A REPLACEMENT NOTE 1 Remove the under cover The filter element and filter case are permanently 2 Remove the oll filter using ST jointed therefore interior cleaning is not neces ST 18332AA000 OIL FILTER WRENCH Outer Ene 7 Check the engine oil level Ref to PM 8 IN SI 18332AA010 OIL FILTER WRENCH Outer diameter 65 mm 2 56 in e 20L non turbo and 2 5 L model ST 498547000 OIL FILTER WRENCH 3 01 model E IRL LU 00131 3 Obtain a new oil filter and apply a thin coat of en gine oil to the seal rubber 4 Install the oil filter by turning it by hand being careful not to damage seal rubber 5 Tighten more approx 1 turn for oil filter 68 mm 2 68 in in outer diameter approx 3 4 turn for oil filter 65 mm 2 56 in in outer diameter after the seal rubber contacts the cylinder block Do not tighten excessively or oil may leak 9 Spark Plug PERIODIC MAINTENANCE SERVICES 5 Spark Plug A REPLACEMENT 1 SOHC MODEL Remove the intake duct and intake chamber 2 Remove the battery 3 Disconnect the spark plug cord 4 R
27. tached to cradle to support the vehicle When using a plate lift use a rubber attachment A 80 mm 3 1 in or more B 100 150 mm 3 94 5 91 in C 120 190 mm 4 72 7 48 in Align the cushion rubber end of plate lift with the end of rubber attachment portion b Also align the protrusion portion of the supporting locations with the end of attachment portion a Do not use the plate lift whose attachment does not reach the supporting locations NT 2 1 2 3 4 5 E 9 3 NT 00086 1 Supporting locations 3 Swing arm lift 5 Plate lift 2 Pantograph jack 4 Rigid rack 6 Attachment NT 3 Note NOTE 5 Oe q A Front B Rear 1 Front crossmember 2 Rear differential NT 4 Note NOTE 8 TIE DOWNS downs are used when transporting vehicles and when using the chassis dynamo Attach tie down only to the specified locations on the vehicle TIE DOWN LOCATION 1 Hook for tie down NT 5 CHAIN DIRECTION AT TIE DOWN CONDI TION e CHAIN PULLING RANGE AT TIE DOWN CON DITION Chain pulling range at tie down condition 20 45 NT 6 VEHICLE SINKING VOLUME AT TIE DOWN CONDITION Measure the distance between the highest tire point and highest arch point before and after tie down Difference of measurement value sinking volume shall be within 50 mm 1 97 in
28. 3 0 L AWD Steering position L LHD Left hand drive model K RHD Right hand drive model Engine amp transmission J SOHC MPI 5MT Single range K SOHC MPI 5MT Dual range L SOHC MPI 4AT SS U DOHC MPI 5AT SS V DOHC Turbo 5AT SS Drive type 3 Full time AWD Single range 4 Full time AWD Dual range 5 AWD AT A AND AT OUTBACK B Full time AWD Dual range OUTBACK 4 Model year 4 2004MY 18 Factory location FHI Gunma 12 17 002001 From 002001 KS MODEL 1 18154 4 0002001 The starting and ending brackets are stop marks Ds ossis Manufacturer body area JF1 Passenger car FHI made B Carline line LEGACY Bo fame type L 2 Displacement 5 2 0 9 2 5 L AWD Grade 4 2 0i 6 2 5i 8 OUTBACK 2 5 i Restraint 7 M Manual belts dual airbag XxX Check digit 0 9 amp X 4 2004MY 11 Transmission type G Full time AWD 5MT Single range H Full time AWD 4AT J Full time AWD 5MT Dual range 12 17 002001 From 002001 ID 4 Identification IDENTIFICATION 3 MODEL NUMBER PLATE The model number plate indicates the type V I N Ref to ID 4 MEANING OF V I N IDENTIFICATION Identification gt applied model option code trim code engine type transmission type and the exterior color code This information is helpful when placing orders for parts BL5ALHJ B Sees o
29. 4 SPECIFICATION If necessary specifications are also included 5 INSPECTION Inspections to be carried out before and after maintenance are included 6 MAINTENANCE Maintenance instructions for serviceable parts describe work area and detailed step with illustration It also describes the use of special tool tightening torque caution for each procedure e If many serviceable parts are included one service procedure appropriate reference is provided for each parts Example 15 Main Shaft Assembly for Sin gle Range REMOVAL 1 Remove the manual transmission assembly from vehicie Ref to MT 33 REMOVAL Manual Transmission Assembly 11 Tighten the lock nuts to the specified torque us ing ST1 and ST2 NOTE _ _ _ __ _______ 0 Secure the lock nuts in two Places affer tightening ST2 499987003 SOCKET WRENCH ST1 498937000 TRANSMISSION HOLDER E Tightening torque 118 12 0 kgf m 86 8 ft Ib HU 00020 A Component D Cautions Tightening torque B Process Tool number of special tool H Illustration C Reference F Name of special tool HU 4 How to Use This Manuals HOW TO USE THIS MANUALS 7 DIAGNOSIS Tables showing a step by step process make it easy to conduct diagnosis 8 SI UNITS Measurements in these manuals are according to the Sl units Metric and yard pound measurements are al
30. 6 3 Imp qt 3 0 L model with ATF cooler with warmer Approx 7 7 0 8 1 US qt 6 8 Imp qt LHD MT model 2 0 L non turbo and 2 5 L model Approx 6 4 0 6 8 US qt 5 6 Imp qt RHD AT model 2 0 L non turbo and 2 5 L model without ATF cooler with warmer Approx 6 4 0 6 8 US qt 5 6 Imp qt 2 0 L non turbo and 2 5 L model with ATF cooler with warmer Approx 6 8 0 7 2 US qt 6 0 Imp qt Turbo model Approx 7 3 0 7 7 US qt 6 4 Imp qt 3 0 L model without ATF cooler with warm Approx 7 2 0 7 6 US qt 6 3 Imp qt 3 0 L model with ATF cooler with warmer Approx 7 8 0 8 2 US qt 6 9 Imp qt RHD MT model 2 0 L non turbo and 2 5 L model Approx 6 5 0 6 9 US qt 5 7 Imp qt NOTE The SUBARU Genuine Coolant containing anti freeze and anti rust agents is especially made for SUBARU engine which has an aluminum crank case Always use SUBARU Genuine Coolant since other coolant may cause corrosion 10 Securely install the radiator cap 11 Run the engine for more than five minutes at 2 000 to 3 000 rpm Run engine until radiator be comes hot in order to purge air trapped in cooling system 12 Stop the engine and wait until coolant temper ature lowers Then open the radiator cap to check coolant level and add coolant up to radiator filler neck Next add coolant into reservoir tank up to FULL level 13 After adding coolant securely install the radia tor and reservoir tank caps PM 22 Engine
31. AFTER VEHICLE RECEIPT PROCEDURE Check point 1 Appearance check 1 Ifthe vehicle is covered with protective coating visually check the vehicle body for damage and dents If the protective coating has been removed visually check the body paints for damage or stains in detail 2 Visually check the glass and light lenses for any damage cracks or excessive gaps to the body sheet metal 3 Visually check the plated parts for any damage 2 Tire check 1 Check the tires for damage abnormal conditions and dents on the wheels 2 Check the tire air pressure 3 Fuse installation If the vehicle is about to be delivered to the customer attach a back up fuse 4 Air conditioner harness connection If the vehicle is about to be delivered to the customer connect air conditioner TUS 5 Check the doors for lock unlock and open close 1 Using the key check if the trunk lid can be locked or unlocked normally operations Open and close all doors to see that there are no abnormal conditions 3 Operate the power door lock switch to check that the door rear gate is locked and unlocked normally 6 Double lock operation check Check the double lock for normal operations 7 Check the operation of child safety lock system Check that the child safety lock system operates normally 8 Check the trunk lid for open close operations 1 Operate the trunk lock release lever to check that the trunk opens nor mally 2 Operate the opene
32. C Full time AWD VTD type 5AT L Full time AWD MPT type 4AT M Full time AWD VTD type 4AT V Full time AWD 5MT Single range with viscous coupling cen ter differential X Full time AWD 5MT Dual range with viscous coupling center differential RAAB Detailed specifications Used when ordering parts See the parts catalog for details REAR DIFFERENTIAL 05000 4H 2 e VB 180 ez h Xu o hre Vsms CN Vsus ID 6 Identification IDENTIFICATION OPTION ECXV 1 2 Destination EC For Europe LHD model EK For Europe RHD model KS For GCC counties K4 For Middle and South America KA For Australia Nothing For Hong Kong 3 Option equipment A Vehicle dynamics control Cruise control Power pack 17 inch tire B Cruise control Winter pack 17 inch tire E Vehicle dynamics control Cruise control Power pack F Cruise control Winter pack G Cruise control 15 inch tire Cruise control Winter pack Power pack 17 inch tire K Cruise control 17 inch tire 5 Cruise control Winter pack Power pack U Cruise control V 17 inch tire X Nothing Y Vehicle dynamics control Cruise control Power pack Winter pack 17 inch tire Z Vehicle dynamics control Cruise control Power pack Winter pack 2 Cruise control Power pack 17 inch tire 3 Cruise control Power pack 4 Cruise control McIntosh audio Power pack 5 Cruis
33. Coolant 2 RERATIONSHIP OF SUBARU COOLANT CONCENTRATION AND FREEZING TEM PERTAURE Concentration and safe operating temperature of SUBARU coolant is shown in the diagram Measur ing the temperature and specific gravity of the cool ant will provide this information Example If the coolant temperature is 25 C 77 F its specif ic gravity is 1 054 and the concentration is 4596 point A the safe operating temperature is 14 C 7 F point B and the freezing temperature 15 20 C 4 point C Safe operating temperature Concentration of coolant Specific gravity 3 of coolant gt h Freezing temperature 40 30 20 10 0 10 20 30 40 40 22 4 14 32 50 68 86 104 122 Coolant temperature F CO 00237 3 PROCEDURE TO ADJUST THE CON CENTRATION OF THE COOLANT To adjust the concentration of coolant according to temperature find the proper fluid concentration in the above diagram and replace the necessary amount of coolant with an undiluted solution of SUBARU genuine coolant concentration 50 The amount of coolant that should be replaced can be determined using the diagram Example Assume that the coolant concentration must be in creased from 25 to 40 Find point A where the 2596 line of coolant concentration intersects with the 4096 curve of the necessary coolant concentra tion and read the scale on the vertical axis of the graph at height A The quantit
34. Engine Coolant PERIODIC MAINTENANCE SERVICES 11 Engine Coolant A REPLACEMENT 1 REPLACEMENT OF COOLANT WARNING The radiator is of the pressurized type Do not attempt to open the radiator cap immediately after the engine has been stopped 1 Lift up the vehicle 2 Remove the under cover 3 Place a container under drain pipe 4 Remove the drain cock to drain engine coolant into container 5 For quick draining open the radiator cap NOTE Forturbo model be sure to open the radiator on the filler tank side Be careful not to spill coolant on the floor 6 Drain the coolant from reservoir tank 7 Tighten the radiator drain cock securely after draining coolant 8 Slowly pour the coolant into radiator Pour the coolant up to air bleeder hole and then install the cap Turbo model 9 Pour the coolant from radiator filler port to neck of filler Then pour the coolant into reservoir tank up to FULL level Recommended engine coolant Refer to RM section lt Ref to RM 5 COOL ANT RECOMMENDED MATERIALS Recom mended Materials gt Coolant capacity fill up to FULL level LHD AT model 2 0 L non turbo and 2 5 L model without A TF cooler with warmer Approx 6 3 0 6 7 US qt 5 5 Imp qt 2 0 L non turbo and 2 5 L model with ATF cooler with warmer Approx 6 7 0 7 1 US qt 5 9 Imp qt 3 0 L model without ATF cooler with warm Approx 7 2 0 7 6 US qt
35. Ib 2 Check the boot for damage cracks or deteriora tion PM 39 Steering System Power Steering PERIODIC MAINTENANCE SERVICES 3 With the vehicle placed on a level surface quick ly turn the steering wheel to the left and right While steering wheel is being rotated check the gear backlash If any noise is noticed adjust the gear backlash 4 Adjustment for LHD model 1 Apply liquid gasket to at least 1 3 of entire perimeter of adjusting screw thread 2 Tighten adjusting screw to 25 N m 2 5 kgf m 18 0 ft Ib and then loosen 3 Tighten adjusting screw to 3 9 0 40 kgf m 2 9 ft lb and then loosen 20 5 Adjustment for RHD model 1 Apply liquid gasket to at least 1 3 of entire perimeter of adjusting screw thread 2 Tighten adjusting screw to 9 8 N m 1 0 kgf 7 2 ft lb and then loosen 3 Tighten adjusting screw to 4 9 N m 0 50 kgf m 3 6 ft lb and then loosen 4 Tighten adjusting screw to 4 9 N m 0 50 kgf m 3 6 ft lb and then loosen 37 A Apply liquid gasket to at least 1 3 of entire perimeter 6 Install the lock nut While holding adjusting screw with a wrench tighten the lock nut using ST ST 926230000 SPANNER Tightening torque lock nut LHD model 25 2 5 kgf m 18 0 ft lb RHD model 39 4 0 kgf m 28 9 ft lb Hold the adjusting screw with a wrench to prevent it from turning while tightening the lock nut 4 TIE ROD 1 Check the tie rod and tie rod e
36. PERIODIC MAINTENANCE SERVICES 1 2 3 4 5 6 7 8 9 YNNN N HSH HS 0 General TEE RE a 2 nn 3 ENGINE _________ 7 jore DR MUNIRI 9 10 A 11 e 14 PIE 17 tino v bein EROR pics 18 El T a Lu 20 Engine CODA lector ion ii 22 24 Transmission Gear Ollas iii 25 Automatic Transmission Fluid 26 Front and Rear Differential Gear 28 A dete uem eR iU n LUN 30 Sisi c O 32 Disc Brake Pad ana DISC usus andara ae Cue 39 PAKINO mi cis eO tds 34 JA O PU EET 35 37 Axe Boos ANG OMS ri 38 Steering System Power 39 General Description PERIODIC MAINTENANCE SERVICES 1 General Description A GENERAL DESCRIPTION Be sure to perform periodic maintenance in order to maintain vehicle performance and find problems before they occur PM 2 Schedule PERIODIC MAINTENANCE SERVICES 2 Schedule A MAINTENANCE SCHEDULE 1 1 EUROPE AREA For periodic maintenance of over 120
37. Strut Hear suspension Sub frame e Front link Rear link Upper link e Rear arm Shock absorber e In the area where salt is sprayed to melt snow a road in winter check suspension parts for dam age caused by rust every 12 months after lapse of 60 months Take rust prevention measure as re quired PM 36 Wheel Bearing 21 Wheel Bearing A INSPECTION 1 FRONT WHEEL BEARING NOTE Inspect the condition of front wheel bearing grease 1 Jack up the front side of vehicle 2 While holding the front wheel by hand swing it in and out to check bearing free play 3 Loosen the wheel nuts and remove the front wheel 4 If the bearing free play exists in step 2 above attach a dial gauge to the hub and measure axial play in axial direction Service limit Straight ahead position within 0 05 mm 0 0020 in 5 Remove the bolts and self locking nuts and ex tract the front arm from front crossmember 6 Remove the of front drive shaft from trans mission Ref to 05 13 Front Axle 7 While supporting the front drive shaft horizontal ly with one hand turn the hub with the other hand to check for noise or binding If the hub is noisy or binds replace the front axle 2 REAR WHEEL BEARING 1 Jack up the rear side of vehicle 2 While holding the rear wheel by hand swing it in and out to check bearing free play 3 Loosen the wheel nuts and remove the rear wheel 4 If the bear
38. and make sure to fix the vehicle securely Note NOTE 9 TOWING Avoid towing vehicles except when the vehicle cannot be driven For models with AWD or VID use a loader instead of towing When towing other vehicles pay attention to the following to prevent hook or vehicle damage resulting from excessive weight Do not tow other vehicles with a front tie down hook Make sure the towing vehicle is heavier than the towed vehicle FRONT Remove the fog light cover except for OUTBACK model and hook cover and then install the hook NT 00087 A Fog light cover except for OUT B Hook cover C Hook BACK model e REAR NT 7 5 Lifting up four wheels a trailer Towing the vehicle after lifting up all four wheels is a basic rule for AWD model NT 00023 Check if both front and rear wheels are rotated mally AT model driving conditions Allow driving speed less than 30 km h 19 MPH Allow driving distance less than 30 km 19 miles NT 00024 Raising the front wheels Prohibited for full time AWD model lt 6 0 NT 00025 Lifting up the front wheels Prohibited due to damage on bumper front grille etc Do not raise the vehicle with bumper NT 00026 Marked O OK Marked X Prohibited Marked Conditionally OK NT 8 Note NOTE CAUTION Check ATF gear oil and rear differential oil before dr
39. following items are within standard val ues Toe in Camber Thrust angle Ref to RS 8 Wheel Alignment 2 When the camber angle does not conform to standard value visually inspect the following com ponents If the deformation is observed replace the damaged parts Suspension components Shock absorber front link rear link upper link rear arm sub frame etc Parts connecting suspension and body 3 When the toe in and thrust angle are out of stan dard value adjust them so that they conform to standard value 6 OIL LEAKAGE OF STRUT AND SHOCK ABSORBER Visually inspect the front strut and rear shock ab sorber for oil leakage Replace the front strut and rear shock absorber if oil leaks excessively 7 TIGHTNESS OF BOLTS AND NUTS Check the bolts and nuts for looseness Retighten the bolts and nuts to specified torque If the self locking nuts and bolts are removed replace them with new ones Front suspension Ret to FS 2 General Description Hear suspension Ref to RS 2 General Description 8 DAMAGE TO SUSPENSION PARTS Check the following parts and the fastening portion of the vehicle body for deformation or excessive rusting which impairs the suspension If necessary replace the damaged parts with new ones If minor rust formation pitting etc are noted remove the rust and take rust prevention measure Front suspension Front arm Crossmember e
40. outer periphery of wheel Steering wheel free play 0 17 mm 0 0 67 in 1 Steering wheel free play Move the steering wheel vertically toward the shaft to ascertain if there is play in the direction Maximum permissible play 0 5 mm 0 020 in 3 Drive the vehicle and check the following items during operation 1 Steering force The effort required for steering should be smooth and even at all points and should not vary 2 Pulled to one side Steering wheel should not be pulled to either side while driving on a level surface 3 Wheel runout oteering wheel should not show any sign of runout 4 Return factor oteering wheel should return to its original posi tion after it has been turned and then released PERIODIC MAINTENANCE SERVICES 2 STEERING SHAFT JOINT When the steering wheel free play is excessive disconnect the universal joint of steering shaft and check it for any play and yawing torque at the point of the crossing direction Also inspect for any dam age to sealing or worn serrations If the joint is loose retighten the mounting bolts to the specified torque Tightening torque 24 2 4 kgf m 17 4 ft Ib 3 GEARBOX 1 With the vehicle placed on a level surface turn the steering wheel 90 in both the left and right di rections While the wheel is being rotated reach under the vehicle and check for looseness in gearbox Tightening torque 59 6 0 kgf m 43 4 ft
41. reserve distance A 95 mm 3 7 in 490 N 50 kgf 110 Ib or less A Steering wheel B Toe board 4 Check to see if air is in the hydraulic brake line by the feel of pedal operation If air appears to exist in the line bleed it from the system 5 Check for even operation of all brakes using a brake tester or by driving the vehicle for a short 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 built into the vacuum hose Dis connect the vacuum hose to inspect function of check valve Blow compressed air into vacuum hose from its brake booster side end Make sure air must flow out of engine side end of hose Next blow com pressed air into hose from engine side Make sure air should not flow out of hose PERIODIC MAINTENANCE SERVICES Replace the both check valve and vacuum hose if the check valve is faulty Engine side of vacuum hose is indicated by marking ENG as shown A Engine side B Brake booster side C ENG 5 Check the vacuum hose for cracks or other dam age NOTE When insta
42. thickness through inspec tion hole of disc brake assembly Replace the pad if necessary NOTE When replacing a pad always replace the pads for both the left and right wheels the same time Also replace the pad clips if they are twisted or worn A Inspection hole Front Pad thickness n n n 1 5 0 059 mm in 0 43 0 43 0 43 Pad thickness mm in Solid disc type 9 0 35 Ventilated disc type 9 0 35 Standard Solid disc type 1 5 0 059 Wear limit Ventilated disc type 1 5 0 059 PERIODIC MAINTENANCE SERVICES A Pad thickness B Back metal C Lining 3 Check the disc rotor and correct or replace if it is damaged or worn e Front Disc rotor thickness mm in mm in 10 0 39 18 0 71 8 5 0 34 16 0 63 Disc rotor thickness 4 Remove the caliper body lt Ref to BR 20 Front Disc Brake Assembly gt lt Ref to BR 28 Rear Disc Brake Assembly gt 5 Tighten the wheel nuts to secure disk rotor 6 Set a dial gauge at a point less than 10 mm 0 39 in from outer periphery of the rotor and then mea sure the disk rotor runout Disc rotor runout limit Front 0 05 mm 0 002 in Rear 0 05 mm 0 002 in PM 33 Parking Brake PERIODIC MAINTENANCE SERVICES 19 Parking Brake A INSPECTION Inspect the brake linings and disc rotor of both sides of the rear brake the same time by remov ing disc rotor 1 Inspect the brake shoes for da
43. wear is found 2 Check that the V belt automatic tensioner indica tor A is within the range D 3 Loosen the lock bolt A 4 Loosen the slider bolt B 5 Remove the front side belt C 6 Install a new V belt and tighten the slider bolt so as to obtain the specified belt tension 7 Tighten the lock bolt A 8 Tighten the slider bolt B Tightening torque Lock bolt 25 2 5 kgf m 18 ft lb Slider bolt 8 N m 0 8 kgf m 5 8 ft Ib Indicator Generator Power steering oil pump D Service limit B REPLACEMENT 1 FRONT SIDE BELT FOR POWER STEERING OIL PUMP AND GENERATOR 2 REAR SIDE BELT FOR A C s NOTE Wipe off any oil and water on the belt and pulley Wipe off any oil and water on the belt and pulley 1 Remove the collector cover If equipped 1 Remove the front side belt 2 Remove the V belt covers 2 Loosen the lock nut A Non turbo model 3 Loosen the slider bolt B 4 Remove the rear side belt 5 Install a new V belt and tighten the slider bolt so as to obtain the specified belt tension 6 Tighten the lock nut A PM 12 V belt Tightening torque 23 2 3 kgf m 17 0 ft Ib 7 Install the front side belt e Non turbo model lt Ref to ME H4SO 2 0 38 FRONT SIDE BELT INSTALLATION V belt gt Turbo model Ref to ME HADOTO 39 FRONT SIDE BELT INSTALLATION V belt gt 3 3 0 L MODEL 1 Fit t
44. 0 4 255 1 930 4 255 mass G V M Leatherinterior Winterpack _ J 9 sd ox gm c m e qm e mod mo Sideairbag _ _ Sunroof _ Nimes Tp _ JD vw 7 Selfleveizer J _ 1 For option code refer to ID section Ref to ID 5 MODEL NUMBER PLATE IDENTIFICATION Identification Vehicle Dynamics ea Cruise contol o Mcintosh audio Option SPC 23 SPECIFICATIONS Option code AWD Model 25i radon mas 1040 225 U Rear kgf Ib 1 060 53 1 060 1 060 1 060 bum 1 060 os 1 060 2 336 Gros vehicle Total kgf Ib 1 930 4 255 1 930 4 255 1 930 4 255 1 930 4 255 1 930 4 255 1 930 4 255 mass G V M fleatherinterion O _ _ _ _ pon d q se qm m e m gt nm mo e Sideairbag O _ _ _ 9 UM Navigation system SS 1 qp o EA A OR aep
45. 000 km 75 000 miles or 96 months carry out inspection by referring to the following table For a maintenance period gone beyond these tables apply them repeatedly as a set of 120 000 km 75 000 miles or 96 months Maintenance interval Number of months or km miles whichever occurs first Mots 12 24 36 48 60 72 84 960 1 001 G 166 15 30 45 60 75 90 105 120 Remarks 1 000 mies 7 7 1 3 9 19 28 38 47 56 66 75 Engine 30L Others Engine filter 30L Others plug E IO A ese soL R R 5 n 3 0 L model replace every 160 000 km 100 000 miles 5 Camsaftdivebet J SEM RO RSS IS 7 Aircleanerelement _ RRP 8 Coolingsystem pep _ _ ____ Coolant 18 8 2 10 tg 11 Transmission oil Jo j 18 RP ____ 0 qr jJ 13 Front amp rear differentia J 1 8 1f R 14 Brake lines Y _ ___ _ _____ 15 1 8 R 8 16 Disc brake pads amp dises J EET ET EP ET 17 Parking brake 2 1 18 Suspension 0 _ _ _ ____ 19 Wheel bearing Jo J 0 20 Adebots amp jon
46. 30 4 475 weight M P W Mcintosh audio _ Leatherinterior _ _ _ PETT _ LA _ 2 gt Qe o A O E O O Side airbag____ __ __ _ gt ___ __ Curtain airbag _ Swot 9 Navigation system _ gt _ 1 For option code refer to ID section lt Ref to ID 5 MODEL NUMBER PLATE IDENTIFICATION Identification gt Vehicle Dynamics Control Cruise control Option SPC 16 SPECIFICATIONS RHD model 2 01 AWD 2 01 5MT Single range 755 1 664 760 1 676 770 1 698 775 1 709 775 1 709 780 1 720 590 1 301 590 1 301 605 1 334 610 1 345 590 1 301 590 1 301 Total kgf lb 1 345 2 965 1 350 2 976 1 375 3 031 1 385 3 053 1 365 3 009 1 370 3 020 Maximum Front kgf lo permissible axle weight Rear kgf Ib 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 M P A W Maximum weight M P W Coma poo Cruise control Melntosh audio Leather interior Winterpak _
47. 336 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 M P A W Maximum permissible Total kgf Ib 1 925 4 244 1 925 4 244 1 925 4 244 1 925 4 244 1 925 4 244 1 925 4 244 weight M P W Model I IC IC RC Leatherinterior_ Winterpak A NE PEC _ dam 1 1 p m p 1 _ e o O Sideairbag___ 2 Curtain airbag _ _ _ Sat Navigation system o Seflveizr _ 1 For option code refer to ID section Ref to ID 5 MODEL NUMBER PLATE IDENTIFICATION Identification Vehicle Dynamics Cruise control o Option SPC 26 SPECIFICATIONS 2 5 L SOHC AWD 2 5i zd T TO Maximum permissible axle weight Rear kgf Ib 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 M P A W Maximum permissible Total kgf Ib 1 935 4 266 1 935 4 266 1 935 4 266 1 935 4 266 1 935 4 266 1 935 4 266 weight M P W Model Leatherinterior_ O _ A O O Sihtie vw j AC o gt O
48. 4 SPECIFICATIONS Option code 2 01 DOHC turbo 2 5 SOHC Model AWD ode 2 0 GT RA radon mas 1040 2293 U Rear kgf Ib 1 060 5526 1 060 ee 1 060 ee 1 060 25 1 060 E 1 060 2 336 vehicle Total kgf Ib 2 010 4 431 2 010 4 431 2 010 4 431 1 935 4 266 1 935 4 266 1 935 4 266 mass G V M Leatherinterior_ Winterpack __ Sich e on _ p pov _ Ac I xe Sideairbag po Curtain airbag po Sunroof _ Navigation gt e LP _ 1 For option code refer to ID section Ref to ID 5 MODEL NUMBER PLATE IDENTIFICATION Identification Vehicle Dynamics Cruise conor o o audio MINE XM NE IND Option SPC 35 SPECIFICATIONS Option AWD Model 25i EL radon mas 1040 2253 U Rear kgf Ib 1 060 6336 1 060 1 060 i ass 1 060 25 1 060 1 060 2 336 Gros vehicle Total kgf Ib 1 935 4 266 1 935 4 266 1 945 4 288 1 945 4 288 1 945 4 288 1 945 4 288 mass G V M Leatherinterior pon Winterpack _
49. AKS Inspect the underside of oil pump and gearbox of power steering system hoses pipes and their cou plings for fluid leaks If the fluid leaks are found retighten their fitting bolts or nuts and or replace their parts NOTE Wipe the leaked fluid off after correcting fluid leaks e Also pay attention to clearances between hoses or pipes and other parts when inspecting fluid leaks 7 HOSES OF OIL PUMP FOR DAMAGES Check the pressure hose and return hose of oil pump for crack swell or damage Replace the hose with a new one if necessary NOTE Prevent hoses from turning and or bending when installing hoses 8 POWER STEERING PIPES FOR DAMAG ES Check the power steering pipes for corrosion and damage Replace the pipes with new ones if necessary 9 GEARBOX BOOTS Inspect both sides of the gearbox boot as follows and correct the defects if necessary 1 Positions A and B of the gearbox boot are fit ted correspondingly in grooves A and B of the gearbox and rod C PERIODIC MAINTENANCE SERVICES 2 Clips are fitted outside of positions A and B of boot 3 Boot does not have crack and hole NOTE Rotate the position B of gearbox boot against the twist of it produced by adjustment of toe in etc Ap ply grease to the groove C 10 FITTING BOLTS AND NUTS Inspect the fitting bolts and nuts of oil pump and bracket for looseness and retighten them if neces sary Inspect and or
50. Do not operate the clutch quickly and do not ac celerate or decelerate suddenly during work NT 10 14 1 Full time AWD model 1 Perform this test after driving the vehicle 2 to km 1 24 to 1 86 miles on road in order to sta bilize the viscous torque of viscous coupling 2 Keep the front or rear wheels on the ground for this test NOTE Effect of the viscous torque on braking force will be added approx 25 kg compared with FWD model A Brake tester B Position for measuring front wheel C Position for measuring rear wheel 3 When the brake dragging force is large Check the dragging of brake pad or brake shoe Since it may be affected by the viscosity of viscous couping jack up either of the front or rear two wheels to check the each wheel rota tion condition with the viscous coupling affection removed 2 Full time AWD AT model 1 Keep the front or rear wheels on the ground during measurement A Brake tester B Position for measuring front wheel C Position for measuring rear wheel 2 When the brake dragging force is large Check the dragging of brake pad or brake shoe Note NOTE Specifications Baking force Hear wheel total More than 10 of load on front or rear wheels Difference between Less than 8 of load on front or rear right and left wheels wheels Grand total More than 5096 of vehicle weight at the time of test When measure
51. N CENE CSS Curtain airbag O _ Sunroof 9 Navigation system Seflveizr __ _ 1 For option code refer to ID section Ref to ID 5 MODEL NUMBER PLATE IDENTIFICATION Identification gt Vehicle Dynamics OM Cruise control o Option SPC 7 SPECIFICATIONS 2 0 L SOHC AWD 2 01 Maximum permissible axle weight Rear kgf Ib 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 M P A W Maximum permissible Total kgf Ib 1 900 4 189 1 900 4 189 1 900 4 189 1 900 4 189 1 900 4 189 1 900 4 189 weight M P W Model A TR E Leatherinterior_ _ Winterpak _ _ 9 PETT Armar vm E j AA E LA ee LA Sideairbag___ _ 9 Curtain airbag _ _ Sunroof 1 O _ Navigation system o Sefleveizr _ 1 For option code refer to ID section Ref to 5 MODEL NUMBER PLATE IDENTIFICATION Identification Vehicle Dynamics OUO Cruise control Option SPC 8 SPECIFICATI
52. O Mcintosh audio Leather interior Option SPC 43 SPECIFICATIONS Option AWD 2 51 xu radon mas 104012293 0 kgf Ib 1 060 5526 1 060 1 060 1 060 45 1 060 E 1 060 2 336 Gros vehicle Total kgf Ib 1 960 4 321 1 960 4 321 1 960 4 321 1 960 4 321 1 970 4 343 1 970 4 343 mass G V M Leatherinterior_ _ Winterpack _ _ __ _ gt ow 2 o Sideairbag _ Curtain airbag _ Sunroof 1 po Navigation system 9 Selfleveizer _ gaew _ 1 For option code refer to ID section Ref to ID 5 MODEL NUMBER PLATE IDENTIFICATION Identification Vehicle Dynamics Owsecowd o audio MEER MR RN RR Option SPC 44 SPECIFICATIONS Option code 2 5 L SOHC 3 0L DOHC Model AWD dk OBK 2 5i OBK 3 0 R OBK 3 0 R A A 12202252 U Rear kgf Ib 1 060 2526 1 060 1 060 25 1 060 45 1 060 2 336 vehicle Total kgf Ib 1 970 4 343 1 970 4 343 2 060 4 542 2 060 4 542 2 060 4 542 m
53. ONS 2 5 L SOHC AWD 2 5i E T nm Maximum permissible axle weight Rear kgf Ib 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 M P A W Maximum permissible Total kgf Ib 1 930 4 255 1 930 4 255 1 930 4 255 1 930 4 255 1 930 4 255 1 930 4 255 weight M P W Model 7 1 M E Leatherinterior_ _ _ Winterpak Al A O 40 5ihtie j Dee gt O0 1 vw j 9 _ eo O A _ Sideaibag Curtain airbag Sunroof Navigation system O _ Seflveizr _ 1 For option code refer to ID section Ref to ID 5 MODEL NUMBER PLATE IDENTIFICATION Identification gt Vehicle Dynamics Canro Cruise contol Option SPC 9 SPECIFICATIONS 2 5 L SOHC AWD 2 5 a Maximum permissible axle weight Rear kgf Ib 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 M P A W Maximum permissible Total kgf Ib 1 930 4 255 1 930 4 255 1 930 4 255 1 930 4 255 1 930 4 255 1 930 4 255 weight M P W Model A 5 Leatherinterior_
54. PLACEMENT 1 Open the engine oil filter cap for quick draining of engine oll e Except for 3 0 model A Oil level gauge B Oil filler cap 3 01 model 3 Tighten the engine oil drain plug after draining engine oil NOTE Use a new drain plug gasket Tightening torque 44 4 5 kgf m 33 ft Ib DOHC turbo model Oil level gauge Oil filler cap Upper level Lower level 2 Drain the engine oil by removing engine oil drain plug DOHC turbo model 7 Engine Oil PERIODIC MAINTENANCE SERVICES 3 01 model 4 Fill engine oil through level gauge up to the cen ter between upper level and lower level Place the vehicle on a level surface when checking oil level Use engine oil of proper quality and viscosity se lected in accordance with following Recommended oil Refer to RM section lt Ref to RM 3 LUBRI CANTS RECOMMENDED MATERIALS Rec ommended Materials gt Engine oil capacity Except for 3 0 L model Upper level Approx 4 0 0 4 2 US qt 3 5 Imp qt Lower level Approx 3 0 0 3 2 US qt 2 6 Imp qt 3 0 L model Upper level Approx 5 5 0 5 8 US qt 4 8 Imp qt Lower level Approx 4 5 0 4 8 US qt 4 0 Imp qt The proper viscosity oil make the engine ideal tem perature and cranking speed increased by reduc ing viscaus friction in hot condition CAUTION When replenishing oil it does not matter if the oil to be added is a different b
55. S 2 5 L SOHC AWD 2 5i Maximum permissible axle weight Rear kgf Ib 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 M P A W Maximum permissible Total kgf Ib 1 945 4 288 1 945 4 288 1 945 4 288 1 945 4 288 1 945 4 288 1 945 4 288 weight M P W Model RR E Leatherinterior_ _ _ Winterpack O m PEC ue A Ju ee Sideaibag Oo Curtain airbag O _ FOIE uL Qc gt __ Navigation system O _ Seflveizr 9 _ 1 For option code refer to ID section Ref to 5 MODEL NUMBER PLATE IDENTIFICATION Identification Vehicle Dynamics OO Cruise control Option SPC 29 SPECIFICATIONS 3 0 L DOHC 2 0 L SOHC Model NNNM Maximum permissible axle weight Rear kgf Ib 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 M P A W Maximum permissible Total kgf Ib 2 050 4 519 2 050 4 519 2 050 4 519 1 925 4 244 1 925 4 244 1 925 4 244 weight M P W a Leatherinteri
56. SUBARU LEGACY 2004 Model Year PDF Service Manual GENERAL INFORMATION SECTION Pub No G2320GE1 ENGINE SECTION 1 Pub No G2320GE2 ENGINE SECTION 2 Pub No G2320GE3 ENGINE SECTION 3 Pub No G2320GE4 TRANSMISSION SECTION Pub No G2320GE5 CHASSIS SECTION Pub No G2320GE6 BODY SECTION Pub No G2320GE7 WIRING SYSTEM SECTION Pub No G2320GE8 2004 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX GENERAL INFORMATION SECTION FOREWORD HOW TO USE THIS MANUALS SPECIFICATIONS PRECAUTION This service manual has been prepared to provide SUBARU service personnel with the necessary information and data for the correct maintenance and repair IDENTIFICATION ID This manual includes the procedures for maintenance disassembling reas sembling inspection and adjustment of RECOMMENDED MATERIALS RM components and diagnostics for guid ance of experienced mechanics Please peruse and utilize this manual PRE DELIVERY INSPECTION Pl fully to ensure complete repair work for satisfying our customers by keeping their vehicle in optimum condition When replacement of parts during repair work is needed be sure to use SUBARU genuine parts PERIODIC MAINTENANCE SERVICES All information illustration and specifi cations contained in this manual are based on the latest product information available at the time of publication approval FUJI HEAVY INDUSTRIES LTD G2320GE1 FOREWORD Forewo
57. Sideaibag Curtain airbag Sunroof Navigation system O _ Seflveizr _ 1 For option code refer to ID section Ref to ID 5 MODEL NUMBER PLATE IDENTIFICATION Identification gt Vehicle Dynamics ORO Cruise contol Option SPC 27 SPECIFICATIONS 2 5 L SOHC AWD 2 5 EN ___ DUE Maximum permissible axle weight Rear kgf Ib 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 M P A W Maximum permissible Total kgf Ib 1 935 4 266 1 935 4 266 1 935 4 266 1 945 4 288 1 945 4 288 1 945 4 288 weight M P W Model ME NEN NA Leatherinterior_ _ 9 A mm A BET o c j ee AC O 405 NM Sideaibag Curtain airbag _ Swot _ 9 9 ll o gt Navigation system o Selfleveizer _ 1 For option code refer to ID section Ref to ID 5 MODEL NUMBER PLATE IDENTIFICATION Identification gt Vehicle Dynamics Cruise contol Option SPC 28 SPECIFICATION
58. T Check that the rear fog light operates normally 38 ILLUMINATION CONTROL Check that the illumination control operates nor mally PI 11 PRE DELIVERY INSPECTION 39 WINDOW WASHER Check that the window washer system injects washer fluid to the specified area of the windshield shown in the figure Front injection position A 250 mm 9 84 in B 435 mm 17 1 in A A gt FA 2 ZS 1 Nozzle Rear injection position Wagon model A 70 mm 2 8 in 70 40 WIPER Check the front and rear wipers for normal opera tions 41 POWER WINDOW OPERATION CHECK Operate the power window switches one by one to check that each of the power windows goes up and down without noises 42 CARGO FAN Check the cargo fan for normal operations 43 SUNROOF Check the sunroof for normal operations 44 DOOR MIRROR Check the remote control mirror for normal opera tions Pre delivery Inspection PRE DELIVERY INSPECTION 45 BRAKE TEST Check the foot brake for normal operations 46 PARKING BRAKE Check the parking brake for normal operations When applying the parking brake with force of 200 20 4 kgf 45 0 Ib check that the lever stroke of parking brake lever is 5 to 6 notches 47 AT SHIFT CONTROL 1 Turn the ignition switch to ON 2 While brake pedal is not depressed check if the select lever does not move from P range 3 While brake pedal is depressed check if the se lect l
59. age the catalytic converter Unleaded More than 95 RON More than 90 RON TURBO Unleaded more than 98 RON gasoline Unleaded More than 95 RON gasoline and KS model RM 2 Recommended Materials RECOMMENDED MATERIALS 3 LUBRICANTS Use either the lubricants in the table below or equivalent See the table below to choose the correct SAE vis cosity Lubricant Recommended API Spec CCMC Spec ACEA Spec API Spec Engine oil SL SJ Grade Energy conserving or SH G4 or G5 1 A2 or SG SF Manual transmission front differential gear GL 5 oil GL 5 Se RM 3 Recommended Materials RECOMMENDED MATERIALS SAE viscosity No and applicable temperature Engine oil SOHC model 10W 30 or 10W 40 0W 20 Recommend RM 00007 3 0 L and DOHC turbo model 10 20 30 40 4 14 32 50 68 86 104 10W 30 or 10W 40 5W 30 Recommend RM 00003 RM 4 Recommended Materials RECOMMENDED MATERIALS SAE viscosity No and applicable temperature Manual transmission oil rear differential gear oil and AT front differential gear oil 75W 90 RM 00004 4 FLUID Use the fluids specified in the table below Do not mix two different kinds or makes of fluid CAUTION Be sure to use the recommended or equivalent ATF for 5AT Using the ATF other than recommended or equivalent would be a trouble cause Atermativ Automatic tr
60. ansmission If it is impossible to fluid IDEMITSU APOL get recommended or SUBARU ATF K0410Y0700 LOIL ATF HP alternative ATF Castrol Transmax J DEXRON can be used SUBARU ATR ATF K0410Y0700 IDEMITSU ATF HP po Transmax J Power steering fluid Brake fluid FMVSS No 116 DOT3 Clutch fluid FMVSS No 116 DOT3 5 COOLANT Use genuine coolant to protect the engine Maa SUBARU coclan 000016218 Water for dilution Distilled water AN Tap water Soft water 6 REFRIGERANT Standard air conditioners on Subaru vehicles use HFC134a refrigerant Do not mix it with other refrigerants Also do not use any compressor oil other than DENSO OIL 8 Refigeran 4 one Compressor oil DENSO OIL 8 777727227 RM 5 Recommended Materials RECOMMENDED MATERIALS 7 GREASE Use the grease and supplementary lubricants shown in the table below Grease Application point Item number Alternative Supplementary Oxygen sensor 4 lubricants Bolts etc Spray type lubricant Grease MT main shaft CLUTCH GREASE 0879 0501 Clutch master cylinder push SILICONE GREASE G 40M 004404003 Gear shift lever Select lever Clutch operating cylinder Clutch pedal SUNLIGHT2 003602010 Brake pedal Clutch bearing Clutch release lever Door latch SILICONE GREASE G 30M 004404002 Door striker Steering gearbox VALIANT GREASE M2 003608001 Disc brake Lock pin guide pin pist
61. ass G V M Leatherinterior_ V IWmerpck _ 5ih e po gt Sideairbag Curtain airbag Sunroof O _ Navigation system 9 Selflevelzer _ 1 For option code refer to ID section Ref to ID 5 MODEL NUMBER PLATE IDENTIFICATION Identification Vehicle Dynamics OU Cruise o Mcintosh audio ME MEME RE EE ER MN D Option SPC 45 LEGACY SPECIFICATIONS SPC 46 PRECAUTION Precaution PRECAUTION 1 Precaution A CAUTION Please clearly understand and adhere to the follow ing general precautions They must be strictly fol lowed to avoid minor or serious injury to the person doing the work or people in the area 1 ABS Handle the ABS as a total system Do not disas semble or attempt to repair parts which are not in structed in this manual Follow the instructions in this manual during performing the maintenance of ABSCM amp H U To disassemble parts without in structions could prevent the ABS system from op erating when needed or cause it to operate incorrectly and result in injury 2 VEHICLE DYNAMICS CONTROL VDC Handle the VDC as a total system Do not disas semble or attempt to r
62. automatic belt tension adjuster as sembly 15 Install in the reverse order of removal Ret to 45 2 0 44 INSTALLATION Timing Belt PM 14 Timing PERIODIC MAINTENANCE SERVICES 2 DOHC MODEL 9 Remove the timing belt guide Except for non 1 Protect the radiator with cardboard and blanket AT mode 2 Remove the V belts Ref to ME H4DOTC 39 V belt gt 3 Remove the A C compressor V belt tensioner 4 Remove the pulley bolt Use the ST to lock crankshaft Except for turbo MT model ST 499977400 CRANK PULLEY WRENCH Turbo MT model ST 499977100 CRANK PULLEY WRENCH emove the crank pulley emove the belt cover LH emove the belt cover RH 5 6 7 8 Remove the front belt cover JJ 2 ZU ZU 10 the crankshaft and align the alignment marks on crankshaft and left and right cam sprock ets with notches of belt cover and cylinder block Use the ST to turn crankshaft PM 15 Timing PERIODIC MAINTENANCE SERVICES ST 499987500 CRANKSHAFT SOCKET 12 Remove the timing belt 13 Remove the automatic belt tension adjuster as sembly 00096 14 Install in the reverse order of removal Ref to ME HADOTO 43 Timing Belt CAUTION When installing the timing belt be sure to align all alignment marks on the belt with corre sponding marks on the sprockets If incorrectly installed interference between pis
63. condition 2 Check the wheel arch height of front and rear suspensions to ensure that they are within speci fied values Ref to FS 8 Wheel Alignment 3 When the wheel arch height is out of standard visually inspect following components and replace deformed parts Suspension components Front strut assembly and rear damper assembly Parts connecting suspension and body 4 no components are deformed adjust the wheel arch height by replacing the suspension which wheel arch height is out of standard Ref to FS 8 Wheel Alignment Ref to RS 8 Wheel Alignment PM 35 Suspension PERIODIC MAINTENANCE SERVICES 4 WHEEL ALIGNMENT OF FRONT SUS PENSION 1 Check the alignment of front suspension to en sure that following items conform to standard val ues Toe in Camber Caster Steering angle Ref to FS 8 Wheel Alignment 2 When the caster angle does not conform to ref erence obviously visually inspect the following components and replace deformed parts Suspension components Strut assembly cross member front arm etc Parts connecting suspension and body 3 When the toe in and camber are out of standard value adjust them so that they conform to standard value 4 When the right and left turning angles of tire are out of standard adjust to standard value 5 WHEEL ALIGNMENT OF REAR SUS PENSION 1 Check the alignment of rear suspension to en sure that
64. cs Cruise control Option SPC 14 SPECIFICATIONS Ka 25 L SOHC AWD Model 25i a E 2199 x Maximum permissible axle weight Rear kgf Ib 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 M P A W Maximum permissible Total kgf Ib 1 930 4 255 1 930 4 255 1 900 4 189 1 900 4 189 1 900 4 189 1 900 4 189 weight M P W Mcintosh audio a EE EB Leatherinterior_ _ _ Winterpak A Al Ae _ A PET A m ee _ o Sideaibag _ Curtain airbag O _ Sunroof o Navigation system _ Seflveizr _ 1 For option code refer to ID section Ref to ID 5 MODEL NUMBER PLATE IDENTIFICATION Identification Vehicle Dynamics EO Cruise control Option SPC 15 SPECIFICATIONS AWD mw Total kof Ib 1 375 3 031 1 395 3 075 1 400 3 086 1 525 3 362 1 515 3 340 Maximum Front kgf Ib 1 040 2 293 1 040 2 293 1 040 2 293 1 040 2 293 1 040 2 293 permissible M P A W Maximum permissible Total kgf Ib 1 930 4 255 1 930 4 255 1 930 4 255 2 030 4 475 2 0
65. ction Ref to 5 MODEL NUMBER PLATE IDENTIFICATION Identification Vehicle Dynamics OUO Cruise contol Option SPC 11 LEGACY SPECIFICATIONS 3 0 L DOHC AWD 3 0 R 3 0 R A Maximum permissible M P A W Maximum permissible Total kgf Ib 2 030 4 475 2 030 4 475 2 030 4 475 2 030 4 475 weight M P W Model Mcintosh audio Leatherinterior_ _ Winterpack _ ASinchtire _ po m gt el Qe o LO LO 4 M Sideairbag___ _ _ Curtain airbag _ Sunroof O _ Navigation system _ Seflevlizer o 1 For option code refer to ID section Ref to 5 MODEL NUMBER PLATE IDENTIFICATION Identification Vehicle Dynamics Control 9 Option SPC 12 SPECIFICATIONS Option code 2 0 L SOHC AWD 2 0i ze E Maximum permissible axle weight Rear kgf Ib 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 M P A W Maximum permissible Total kgf Ib 1 900 4 189 1 900 4 189 1 900 4 189 1 900 4 189 1 900 4 189 1 900 4 189 weight M P W Model 7 1 M Leatherinterior_ _ Lu AAA Al A
66. d is approx 500 16 9 US fl oz 17 6 Imp fl oz for total brake system 6 Instruct your co worker to depress the brake pedal slowly two or three times and then hold it 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 performing the air bleed operation in order to prevent the tank from running short of brake fluid 9 After completing the bleeding operation hold the brake pedal depressed and tighten the screw and install bleeder cap Tightening torque 8 N m 0 8 kgf m 5 8 ft Ib 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 30 kgf 66 Ib 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 miles to confirm brakes are operating properly PM 32 Disc Brake Pad and Disc 18 Disc Brake Pad and Disc A INSPECTION 1 Jack up the vehicle and support with rigid racks Then remove the wheels 2 Visually check the pad
67. e control McIntosh audio Power pack 17 inch tire 4 V Option equipment A A C B A C Side airbag Self levelizer F A C Grade up pack J A C Sunroof K A C Side airbag Curtain airbag Navigation system N A C Side airbag Curtain airbag Navigation system Self levelizer Sunroof O A C Side airbag Navigation system Q A C Side airbag Curtain airbag Sunroof Grade up pack S A C Self levelizer U A C Sunroof Self levelizer V Side airbag W A C Side airbag Curtain airbag Sunroof X nothing Y A C Side airbag Curtain airbag Sunroof Self levelizer Z A C Side airbag ID 7 Identification IDENTIFICATION ID 8 RECOMMENDED MATERIALS 1 Recommended 8 8 2 Recommended Materials RECOMMENDED MATERIALS 1 Recommended Materials A RECOMMENDED MATERIALS 1 GENERAL To insure the best performance always use the specified oil gasoline adhesive sealant etc or a substitute of equivalent quality 2 FUEL Always use gasoline of the same or higher octane value than specified in the owner s manual Ignor ing the specifications below will result in damage or poor operation of the engine and fuel injection sys tem Use the specified gasoline to correct perfor mance Unleaded gasoline Use unleaded gasoline and not leaded gasoline for the vehicle with catalytic converter installed to re duce air pollution Using leaded gasoline will dam
68. e left side of engine room to select the FWD Since electronically controlled MT P hy draulic multi plate clutch is adapted for center dif ferential select FWD When maintenance is performed with jack up or on the free roller check the illumination of AWD warning light in the combi nation meter NT 00081 A FWD fuse holder B AWD warning light 13 SPEEDOMETER TEST 1 Rear wheel free roller system 1 Set the free roller on the floor of rear wheel side securely according to the wheel base and rear tread of the vehicle 2 Let the vehicle ride on the tester and free roller gently CAUTION Fix the vehicle using a pulling metal chain or wire to the front and rear towing hooks or tie down hook to prevent the lateral runout of front wheels and springing out of vehicle s T A NT 00033 A Free roller 3 Set the speedometer tester 4 Conduct the speedometer test work CAUTION Do not operate the clutch quickly and do not ac celerate or decelerate suddenly during work 2 Rear wheel jack up system 1 Set the vehicle on speedometer tester CAUTION Fix the vehicle using a pulling metal chain or wire to the front and rear towing hooks or tie down hook to prevent the lateral runout of front wheels and springing out of vehicle 2 Jack up the rear wheels and set the rigid racks to the specified locations of side sill A Rigid rack 3 Conduct the speedometer test work CAUTION
69. eaks If fluid leaks are found repair or replace If fluid leaks are not found add clutch fluid to bring it up to MAX C of clutch reservoir tank Recommended clutch fluid Refer to RM section lt Ref to RM 5 FLUID RECOMMENDED MATERIALS Recommend ed Materials CAUTION Prevent the clutch fluid from being splashed over vehicle body If the clutch fluid is splashed over vehicle body flush it and then wipe it up NOTE Avoid mixing different brands of brake fluid to prevent degradation of the fluid PM 24 A Reservoir tank B MIN level C MAX level Transmission Gear Oil 13 Transmission Gear Oil A REPLACEMENT 1 MANUAL TRANSMISSION 1 Drain the gear oil by removing drain plug NOTE Before starting work cool off the transmission gear oil well f transmission 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 69 7 0 kgf m 50 6 ft Ib 3 Fill the transmission gear oil through the oil level gauge hole up to the upper point of level gauge Recommended gear oil Refer to RM section lt Ref to RM 3 LUBRI CANTS RECOMMENDED MATERIALS Rec ommended Materials NOTE Each oil manufacturer has its base oil and addi tives Thus do not mix two or more brands Gear oil capacity 3 5 0 3 7 US qt 3 1 Imp qt A Oil level gauge B Upper
70. ehicle until front wheels are off ground 2 Grasp the bottom of tire and move it in and out If relative movement is observed between the brake disc cover A and end of front arm D ball joint may be excessively worn 3 Grasp the end of front arm and move it up and down Relative movement A between the housing D and front arm C boss indicates ball joint B may be excessively worn 4 If relative movement is observed in the step 2 3 remove and inspect the ball joint If the free play exceeds standard value replace the ball joint lt Ref to FS 17 Front Ball Joint 5 Damage of dust seal Visually inspect the ball joint dust seal If it is dam aged remove the front arm Ref to FS 19 Front Arm And measure free play of ball joint Ref to FS 17 Front Ball Joint 1 When looseness exceeds standard value replace the ball joint 2 If the dust seal is damaged replace with a new ball joint PERIODIC MAINTENANCE SERVICES NOTE When the front arm ball joint has been removed or replaced check the toe in of front wheel If the front wheel toe in is not at specified value adjust the toe in Ref to FS 8 Wheel Alignment A Dust seal 2 FRONT REAR SUSPENSION BUSHING Apply pressure with tire lever etc and inspect the bushing for wear or crack Replace the bushings if there is wear or crack 3 WHEEL ARCH HEIGHT 1 Unload the cargoes and set the vehicle in curb weight empty
71. emove the spark plug with a spark plug socket CY NE e NS 7 PM 00001 5 Tighten the new spark plug lightly with hand and then secure with a spark plug socket to the speci fied torque Recommended spark plug 2 5 L EC EK model NGK PFR5B 11 Except for 2 5 L EC EK model CHAMPION RC10YC4 Tightening torque 21 2 1 kgf m 15 2 ft lb NOTE Be sure to place the gasket between the cylinder head and spark plug lfthe torque wrench is not available tighten the spark plug until gasket contacts cylinder head then tighten further 1 4 to 1 2 turns 2 DOHC MODEL 1 Remove the battery and battery carrier Remove the air cleaner case Detach the connector from ignition coil Remove the ignition coil Except for 3 0 L model 2 3 4 7 S ar 3 0 L model eee RAT wo Lo PA 9 gt LEE ES O AJO QN b C LGA WS B A Bracket B Connector 5 Remove the spark plug with a spark plug socket 6 Tighten the new spark plug lightly with hand and then secure with a spark plug socket to the speci fied torque Recommended spark plug NGK ILFR6B Tightening torque 21 N m 2 1 kgf m 15 2 ft lb 7 Tighten the ignition coll Tightening torque 16 1 6 kgf m 11 7 ft lb NOTE Be sure to place the gasket between the cylinder head and spark plug f the torque wrench is not available tighten the spark
72. epair individual parts Doing so could prevent the VDC system from operating when needed or cause it to operate incorrectly and result in injury 3 BRAKE FLUID If brake fluid gets in your eyes or on your skin do the following Wash out your eyes and seek immediate medical attention Wash your skin with soap and then rinse thor oughly with water 4 RADIATOR FAN The radiator fan may rotate without warning even when the engine is not ON Do not place your hand cloth tools or other items near the fan at any time 5 ROAD TEST Always conduct road tests in accordance with traf fic rules and regulations to avoid bodily injury and interrupting traffic 6 AIRBAG To prevent bodily injury from unexpected deploy ment of airbags and unnecessary maintenance fol low the instructions in this manual when performing maintenance on the airbag components or nearby and the airbag wiring harnesses or nearby To prevent unexpected deployment turn the igni tion switch to OFF and disconnect the ground cable from battery then wait at least 20 seconds to dis charge electricity before beginning work 7 AIRBAG DISPOSAL To prevent bodily injury from unexpected airbag deployment do not dispose airbag modules in the same way as other refuse Follow the special in structions for disposal in this manual Follow all government regulations concerning disposal of refuse 8 AIRBAG MODULE Adhere to the following when handi
73. et metal and repair as necessary Visually check the plated parts such as the grilles and door knobs for damage or loss of gloss and replace the parts as necessary 2 TIRE CHECK Check the tires for damage abnormal condi tions and dents on the wheels Check the tire size spare tire and tire air pres sure described on the tire air pressure label driv er s side 3 FUSE INSTALLATION Fuses for the back up circuit have been removed to prevent battery discharge If the vehicle is about to be delivered to the customer attach a 20 A fuse A as shown in the figure 4 4 CONNECTION AIR CONDITIONER HARNESS A vehicle just delivered has its air conditioner har ness disconnected to protect the air conditioner compressor Connect the harness as shown in the figure Except for 3 0 L model 5 CHECK DOORS FOR LOCK UNLOCK AND OPEN CLOSE OPERATIONS 1 Using the key lock and unlock the door several times to check for normal operation Open and close the door several times for smooth movement 00191 Unlock Lock 2 Completely close the driver s door and then check the smooth movement with operating door lock knob from lock to unlock several times Set the door lock knob A to lock position Then pull the inner remote B to ensure that doors will not open Pre delivery Inspection For other doors place the door lock knob A to lock position and then pull the inner remote B t
74. ever moves from P range 4 Set the select lever to other than P range 5 When the ignition switch is turned OFF check if the ignition key switch cannot be removed 6 Set the AT select lever to each gear position and check the shifting while driving the vehicle Selector Posi IE E EE SPORT shift OK OK Selector Post tion o 48 HEATER VENTILATION Operate the heater and ventilation system to check for normal airflow outlet control air inlet control air flow capacity and heating performance 49 AIR CONDITIONER Operate the air conditioner Check that the A C compressor operates normally and enough cooling Is provided 50 CRUISE CONTROL Operate the cruise control system Check that the system is activated and deactivated correctly 51 ATF LEVEL While engine is idling check that the ATF level is normal If the amount is insufficient check that no leaks are found Then add the necessary amount of the specified ATF gt Level gauge ATF level range 70 80 158 176 F at HOT Upper level Lower level ATF level range 20 30 C 68 86 F at COLD E moo SAT A Level gauge ATF level range 70 80 C 158 176 F at HOT Upper level Lower level ATF level range 20 30 C 68 86 F at COLD E moo 12 Pre del
75. g cm 12 psi Radiator side Standard 122 152 kPa 1 24 1 55 kg cm 18 22 psi Service limit 112 kPa 1 14 16 psi A Check points for deformation B Check points for deformation damage rust PM 20 Cooling System 3 Start the engine and then check it does not overheat or it is cooled excessively it overheats or it is cooled excessively check the cooling sys tem 2 0 L non turbo and 2 5 L model Ref to 450 2 0 15 Water Pump lt Ref to 45 2 0 18 Thermostat Hef to CO H4SO 2 0 20 Radiator lt Ref to CO HASO 2 0 24 Radiator Cap Turbo model Ref to CO HADOTO 15 Water Pump Ret to CO H4DOTC 17 Thermostat lt Ref to CO HADOTO 19 Radiator Het to CO HADOTO 23 Radiator Cap 3 0 L model Ref to CO H6DO 11 Water Pump lt Ref to CO H6DO 12 Thermostat Ref to CO H6DO 13 Radiator Ref to CO H6DO 16 Radiator Cap 4 Check the radiator fan operates using Subaru oelect Monitor when the coolant temperature ex ceeds 95 203 F If it does not operate check the radiator fan system 2 0 L non turbo and 2 5 L model Ref to 45 2 0 8 INSPECTION Radiator Fan System Turbo model lt Ref to CO HADOTO 9 INSPECTION Radiator Fan System 3 0 L model Ref to CO H6DO 7 INSPECTION Radiator Fan System gt PM 21 PERIODIC MAINTENANCE SERVICES
76. handles to ensure that doors will open 8 CHECK TRUNK LID FOR OPEN CLOSE OPERATIONS 1 Operate the trunk lock release lever to check that the trunk opens normally 2 Open and close the trunk lid several times for smooth movement Pre delivery Inspection PRE DELIVERY INSPECTION 3 Put the lever A in the cancel lever of trunk lid to cancel position and close the trunk lid Check that the trunk lid will not open even when the trunk lock release lever 15 operated Also check that the trunk lid will open with keyless transmitter then put the lever back 9 CHECK REAR GATE FOR LOCK UN LOCK AND OPEN CLOSE OPERATIONS 1 Open and close the rear gate several times for smooth movement 2 Operate the rear gate lever to check that the rear gate 15 locked and unlocked normally 1 Remove the cover inside the rear gate 2 Operate the lever to check that the rear gate is locked and unlocked normally 10 OPERATION CHECK OF FUEL LID OPENER LOCK RELEASE LEVER Operate the fuel lid opener and verify that the fuel lid is unlocked normally Check that the filler cap is securely closed 11 ACCESSORY CHECK Check that the following accessories are provided Owner s manual e Warranty booklet Maintenance note opare key Jack Tool set Spare tire A Jack B Jack handle 12 OPERATION CHECK OF FRONT HOOD LOCK RELEASE SYSTEM Operate the front hood lock release lever A to check that the fr
77. he tool to the belt tensioner mounting bolt 2 Turn the tool clockwise and loosen the V belt to remove LEIN ot LDS 3 Remove the V belt cover 4 Install in the reverse order of removal NZ AN Y CRG EN 054 Qu 2 P S 4 Y Y s TN OR y V 6 gt 00474 1 Power steering oil pump 2 Belt tension adjuster 3 Crankshaft pulley 4 A C compressor 5 Belt idler 6 Generator PM 13 PERIODIC MAINTENANCE SERVICES Timing PERIODIC MAINTENANCE SERVICES 7 Timing Belt A REPLACEMENT 1 SOHC MODEL 1 Protect the radiator with cardboard and blanket 2 Remove the V belt covers PM 00003 3 Remove the V belts Ref to 45 2 0 38 V belt gt 4 Remove the A C compressor V belt tensioner 5 Use the ST to lock the crankshaft and remove the pulley bolt ST 499977100 CRANK PULLEY WRENCH 24 i EX UNES y SY 6 Remove the crank pulley 7 Remove the belt cover LH 8 Remove the front timing belt cover 9 Remove the timing belt guide MT model 10 Turn the crankshaft and align the alignment marks on crankshaft and left and right cam sprock ets with notches of belt cover and cylinder block CRANKSHAFT SOCKET ST 499987500 A Notch B Alignment mark 11 Remove the belt idler 12 Remove the belt idler No 2 13 Remove the timing belt 14 Remove the
78. ically controlled fully automatic 5 forward speeds and 1 reverse DSPD Dry Single Plate Diaphragm TCC Torque Converter Clutch 1 model 2 Dual range model only E STEERING SEDAN WAGON 20LSOHC 1201 turbo 251 5 3 01 DOHC Rack Pinion Turns lock to lock Center of tire Minimum turning width to center of 10 8 35 4 diameter m ft tire width Wall to wall 11 6 38 1 Type Turns lock To lock Center of tire Minimum turning width to center of 10 8 35 4 diameter m ft tire width Wall to wall 11 6 38 1 F SUSPENSION Macpherson strut Qype suspension Multilink type suspension G BRAKE Model Except for 2 0 L DOHC turbo 2 0 L DOHC turbo Service brake system Dual circuit hydraulic with vacuum suspended power unit Front Ventilated disc brake Ventilated disc brake Parking Brake Mechanical on rear brakes H TIRE SEDAN WAGON OUTBACK 2 0 L SOHC 2 0 2 5 L SOHC 3 0 L DOHC 251 SOHC 3 0 L DOHC 1 X 205 55 R16 89V 215 60 R16 95V 215 55 R17 94V Tire size 205 55 R16 89V 215 45 R17 87W 215 45 R17 87W 215 60 R16 215 55 R17 215 45 R17 87W n 95H 93H Type Steel belted radial Tubeless 1 KA model SPC 5 LEGACY SPECIFICATIONS I CAPACITY 2 0 L SOHC 2 0 L DOHC turbo Model T LHD RHD LHD RHD Fuel tank US gal Imp gal 64 16 9 14 1 Capacity at overhaul 95 95 40 5 4 8 4 0 0 5 3 4 4 Filling am
79. ing free play exists in step 2 above attach a dial gauge to the hub and measure axial play in axial direction Service limit Straight ahead position within 0 05 mm 0 0020 in 5 Remove the DOJ of rear drive shaft from rear dif ferential Ref to DS 26 Rear Drive Shaft 6 While supporting rear drive shaft horizontally with one hand turn the hub with the other hand to check for noise or binding PERIODIC MAINTENANCE SERVICES If the hub is noisy or binds replace the rear axle PM 37 Axle Boots and Joints PERIODIC MAINTENANCE SERVICES 22 Axle Boots and Joints A INSPECTION 1 FRONT AND REAR AXLE BOOTS Inspect the front axle boots A and rear axle boots B for deformation damage or failure If faulty re place them with new ones lt Ref to DS 22 Front Drive Shaft Ref to 05 26 Rear Drive Shaft Front 2 PROPELLER SHAFT Inspect the propeller shaft for damage or failure If faulty replace them with new ones Ref to DS 10 Propeller Shaft PM 38 Steering System Power Steering 23 Steering System Power Steering A INSPECTION 1 STEERING WHEEL 1 Set the steering wheel in a straight ahead posi tion and check the wheel spokes to make sure they are correctly set in their specified positions 2 Lightly turn the steering wheel to the left and right to determine the point where front wheels start to move Measure the distance of the movement of steering wheel at the
80. ion Natural Aspiration Normal Close Relay Normal Open Relay Option Parts Power Steering Power Window Pitch Circle Diameter Positive Crankcase Ventilation RH Right Hand Rear Single Overhead Camshaft Supplemental Restraint System Subaru Select Monitor Special Tool Switch Traction Control System Tumble Generated Valve Transmission Viscous Coupling Vacuum Switching Valve Variable Torque Distribution Wiring Harness Primary Secondary SPECIFICATIONS age gt MUECA cH SPECIFICATIONS 1 LEGACY A DIMENSION 1 SEDAN MODEL 2 0 L SOHC 2 0 L DOHC turbo 2 5 L SOHC 3 0 L DOHC Overall length mm in 4 665 183 7 1 730 68 1 1 900 74 8 1 445 56 9 1 165 45 9 1 100 43 3 2 670 105 1 1 495 58 9 1 490 58 7 Minimum road clearance 150 5 9 1 With sunroof 2 WAGON MODEL 2 0 L SOHC 2 0 L DOHC turbo 2 5 L SOHC 3 0 L DOHC Overall length mm in 4 720 185 8 Overall width mm in 1 730 68 1 1 840 72 4 Compartment 1 445 56 9 1 190 46 9 1 145 45 1 Wheelbase 2 670 105 1 1 495 58 9 Tread i 1 485 58 5 Minimum road clearance mm in 155 6 1 1 With sunroof 3 OUTBACK MODEL 4 730 186 2 Overall width mm in 1 770 69 7 Overall height at C W 1 545 60 8 1 840 72 4 Compartment 1 445 56 9 1 190 46 9 1 145 45 1 Wheelbase 2 670
81. ivery Inspection 52 POWER STEERING FLUID LEVEL Check that the power steering fluid level is normal If the amount is insufficient check that no leaks found Then add the necessary amount of the specified power steering fluid HOT MAX COLD MIN COLD MIN 53 FLUID LEAK CHECK Check entire areas of the vehicle for any trace of coolant oil fluid leaks 54 LEAK TEST Spray the vehicle with water using hose and check that no water enters the passenger compart ment Before performing the water leakage test re move anything that may obstruct the operation or which must be kept dry Close all the windows and doors securely Close the hood and trunk lid before starting the test Spray the vehicle with water using a hose The rate of water spray must 20to 25 0 5 3 to 6 6 US gal 4 4 to 5 5 Imp gal per minute When spraying water on areas adjacent to the floor and wheel house increase the pressure When spraying water on areas other than the floor and wheel house decrease the pressure But the force of water must be made strong occasionally by pressing the end of the hose NOTE Be sure to keep the hose at least 10 cm 3 9 from vehicle Check the following areas Front window and body framework mating por tion Door mating portions Glass mating portions e Rear quarter window mating portions Hear window and bod
82. iving Place the shift lever in N position during towing Do not lift up the rear wheels to avoid unsteady rotation Turn the ignition key to ACC then check the steering wheel moves freely Release the parking brake to avoid tire dragging Since the power steering does not work be careful for the heavy steering effort When engine is stopped Since the servo brake does not work be careful that the brake 15 not applied effectively When en gine is stopped case of the malfunction of internal transmission or drive system lift up four wheels on a trailer for towing 10 FRONT HOOD STAY INSTALLATION AT THE CHECK AND GENERAL MAINTENANCE WHEN WIDER HOOD OPENING IS NECESSARY oet the stay into the hole of lower hood as shown in the figure below 11 GENERAL SCAN TOOL Using general scan tools will greatly improve the ef ficiency of repairing engine electronic controls Subaru Select Monitor can be used to diagnose the engine ABS air conditioner and other parts 12 AWD CIRCUIT MEASURES 1 Full time AWD MT model Since viscous coupling limited slip differential 15 used in the center differential cut off of AWD circuit cannot be carried out 2 Full time AWD 5AT model Since VTD type 15 used in the center differential cut off of AWD circuit cannot be carried out 3 Full time AWD 4AT model Insert a spare fuse into FWD fuse holder in the fuse box located in th
83. level C Lower level PM 25 PERIODIC MAINTENANCE SERVICES Automatic Transmission Fluid PERIODIC MAINTENANCE SERVICES 14 Automatic Transmission Flu Id A INSPECTION CAUTION The level of ATF varies with fluid temperature Pay attention to the fluid temperature when checking ATF level 1 Raise the ATF temperature by driving a distance of 5 to 10 km 3 to 6 miles Otherwise idle the en gine to raise ATF temperature to 70 80 C 158 176 F on Subaru Select Monitor Ref to 4AT diag 17 READ CURRENT DATA OPERA TION Subaru Select Monitor 2 Make sure the vehicle is level 3 After selecting all positions P D shift the select lever in P range Measure the ATF level with engine idling for one or two minutes 4AT model gt Level gauge ATF level range at HOT 70 80 C 158 176 Upper level Lower level E SO ATF level range at COLD 20 30 C 68 86 F e BAT model A Level gauge ATF level range at HOT 70 80 158 176 Upper level D Lower level E ATF level range at COLD 20 30 C 68 86 4 Make sure that level is above the center of upper and lower marks at HOT side 5 If the ATF level is below the center between up per and lower marks add the recommended ATF until the fluid level is found above the center be tween upper and lower marks CAUTION
84. lling 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 PM 31 Brake Fluid PERIODIC MAINTENANCE SERVICES 17 Brake Fluid A REPLACEMENT 1 Elther 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 HM section lt Ref to RM 5 FLUID RECOMMENDED MATERIALS Recommend ed Materials NOTE e Avoid mixing different brands of brake fluid to prevent degrading the quality of fluid Be careful not to allow dirt or dust to get into the reservoir tank Air bleeding sequence 1 2 gt 3 4 1 Front RH 2 Rear LH 3 Front LH 4 Rear RH b Secondary 6 Primary 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 the bleeding operation keep the brake reservoir tank filled with brake fluid to eliminate en try of air he brake pedal operation must be very slow For convenience and safety two people should do the work he amount of brake fluid require
85. mage or deforma tion and check the brake linings for wear NOTE Always replace both primary and secondary brake shoes for the left and right wheels at the same time Thickness of brake lining except for back met al Standard value 3 2 mm 0 126 in Wear limit 1 5 mm 0 059 in A Forward B Brake shoe Primary side C Brake shoe Secondary side 2 Check the inside of disk rotor for wear dents or other damage If the inside surface of dick rotor is streaked correct the surface with emery cloth 200 or more If it is unevenly worn or tapered correct or replace it Brake drum inside diameter Standard value 170 mm 6 69 in Wear limit 171 mm 6 73 in A Inside diameter B Disc 3 If the deformation or wear of back plate shoe etc is noticeable replace them 4 When the shoe return spring tension is exces sively weakened replace it B ADJUSTMENT For rear disc brake adjust the parking brake after bleeding air 1 Remove the rear cover rubber installed at back plate 2 the adjuster toward arrow mark upward until it is locked slightly by using flat tip screwdriver as shown in the illustration A Adjuster B Cover rubber C Back plate 3 back downward the adjuster 3 to 4 notch es 4 Install the cover rubber in original position cor rectly PM 34 Suspension 20 Suspension A INSPECTION 1 SUSPENSION BALL JOINT 1 Jack up the v
86. ment is difficult to carry out be cause both of front wheels are locked check if break force measurement in this condition con forms to grand total 15 0N THE CAR WHEEL BALANCING CAUTION e Carry out this procedures after measuring the balance of each single tire Set the vehicle so that the front and rear wheels are same height Release the parking brake during measure ment Rotate each wheel by hands and make sure it rotates without dragging Do not operate the clutch quickly and do not accelerate or decelerate suddenly during work When an error is indicated during engine drive do not use the motor drive together 1 Set the rigid rack to the specified locations of side sill jack up the front or rear two wheels of non measuring side and set the pickup stands to two wheels of measuring side A Balancer body B Pickup stand 2 For drive wheel drive the tires with engine for measurement 3 For non drive wheel drive the tires from the on the car wheel balancer for measurement NT 11 Note NOTE NT 12 IDENTIFICATION a Identification IDENTIFICATION 1 Identification A IDENTIFICATION 1 IDENTIFICATION NUMBER AND LABEL LOCATIONS The V I N Vehicle Identification Numbers is used to classify the vehicle POSITIONING OF THE PLATE LABEL FOR IDENTIFICATION ID 00072 1 ID plate EC and EK model
87. mum permissible Total kgf Ib 1 960 4 321 1 960 4 321 1 970 4 343 1 970 4 343 1 970 4 343 2 060 4 542 weight M P W a A loathor _ Winterpak _ _ Saa ew d ELI ae dal e seam o Curtain airbag _ ELO ____ A REE NEQNE O E ES NAM Navigation system _ Selflevelzer _ 1 For option code refer to ID section Ref to 5 MODEL NUMBER PLATE IDENTIFICATION Identification gt Vehicle Dynamics ODIO Owsecow o Option SPC 42 LEGACY SPECIFICATIONS Option sd code D TEE AWD age 3 0 R 8 0 RA cw _ Maximum permissible axle weight Rear kgf Ib 2 336 000 2298 2 336 M PA W Maximum permissible Total kgf Ib 2 060 4 542 2 060 4 542 weight M P W Winter pack o J o mhire Nc 9 o o wnamag Sm 0o Navigation system o Saiflevelizer OO 1 For option code refer to ID section Ref to 5 MODEL NUMBER PLATE IDENTIFICATION Identification mu Control Cruise control
88. mum permissible Total kgf Ib 2 060 4 542 2 060 4 542 2 060 4 542 2 060 4 542 1 960 4 321 1 960 4 321 weight M P W Model EN Leatherinterior_ _ Winterpack _ 9 PETT J a a lo O Sideaibag Oo Curtain airbag o Swot c 27 5 __ Navigation system Setleveizer _ 1 For option code refer to ID section Ref to ID 5 MODEL NUMBER PLATE IDENTIFICATION Identification gt Vehicle Dynamics Cruise contol Option SPC 39 SPECIFICATIONS 2 5 2 51 A ME NENNEN AUN mw i Maximum permissible axle weight Rear kgf Ib 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 1 060 2 336 M P A W Maximum permissible Total kgf Ib 1 960 4 321 1 960 4 321 1 960 4 321 1 970 4 343 1 970 4 343 1 970 4 343 weight M P W Model 7 1 M NN GA Lemherieront O _ Lu A __ o Al _ _ A A ____ ____ 1 gt O Sideaibag O Curtain airbag
89. nds for bends scratches or other damage Tie rod end B Knuckle arm 2 Check the connections of knuckle ball joints for play inspect for damage on dust seals and check free play of ball studs If castle nut is loose retight en it to the specified torque then tighten further up to 60 until cotter pin hole is aligned Tightening torque 27 2 75 kgf m 19 9 ft Ib 3 Check the lock nut on the tie rod for tightness If it is loose retighten it to the specified torque Tightening torque 83 8 5 kgf m 61 5 ft Ib 5 POWER STEERING FLUID LEVEL NOTE At power steering fluid temperature 20 C 68 F read the fluid level on the COLD side At power steering fluid temperature 80 176 F read the fluid level on the side 1 Place the vehicle with engine OFF on a level surface 2 Remove the cover 3 0 L and turbo model 3 Check the fluid level using the scale on the out side of the reservoir tank A If the level is below MIN B add fluid to bring it up to MAX C PM 40 Steering System Power Steering NOTE If fluid level is at MAX level or above drain fluid to keep the level in the specified range of indicator by using a syringe or the like Recommended fluid Refer to RM section lt Ref to RM 5 FLUID RECOMMENDED MATERIALS Recommend ed Materials gt Fluid capacity 0 8 0 0 8 US qt 0 7 Imp qt 6 POWER STEERING FLUID FOR LE
90. ng and storing the airbag module to prevent bodily injury from un expected deployment Do not hold the harnesses or connectors to carry the module Do not face the bag in the direction that it opens towards yourself or other people Do not face the bag in the direction that it opens towards the floor or walls 9 AIRBAG SPECIAL TOOL To prevent unexpected deployment only use spe cial tools 10 WINDOW Always wear safety glasses when working around any glass to prevent glass fragments from damag ing your eyes 11 WINDOW ADHESIVE Always use the recommended or equivalent adhe sive when attaching glass to prevent it from coming loose and falling resulting in accidents and injury PC 2 1 Note This is the information that can improve the effi ciency of maintenance and assure the sound work 1 FASTENERS NOTICE Fasteners are used to prevent the parts from dam age dislocation and play due to looseness Fasten ers must be tightened to the specified torque Do not apply paint lubricant rust retardant or other substance to the surface around bolts nuts etc Doing so will make it difficult to obtain the correct torque and result in looseness and other problem 2 STATIC ELECTRICITY DAMAGE Do not touch the control modules connectors logic boards and other such parts when there 15 a possi bility of static electricity Always use a static elec tricity preve
91. ng for inspections Ref to LAN diag 26 OPERATION Read Current Data 1 Fully open all the door windows 2 Remove the key from the ignition switch and close all the doors including rear gate 3 Press the LOCK or UNLOCK button on the keyless transmitter 1 sec or more and check if the door window of driver seat is opened closed 9 PRE DELIVERY INSPECTION 4 Press the trunk open button except for EK mod el or UNLOCK button EK model for more than one second Check if the trunk is unlocked and the hazard light flashes twice 5 Press the LOCK button on the keyless trans mitter with the trunk lock opened Check if the all doors are locked hazard light blinks five times and warning shows trunk open 6 Press the LOCK button momentarily on the keyless transmitter Check that all the doors are locked and room light goes off Pre delivery Inspection PRE DELIVERY INSPECTION 7 Press the UNLOCK button momentarily on the keyless transmitter Check that the driver s door 15 unlocked and hazard light blinks twice and room light is lit for 15 seconds And press the UNLOCK button momentarily again in 5 seconds except for EK model Check that all the doors including rear gate are unlocked 8 Close all the doors including rear gate and press the LOCK button on the keyless transmitter Press the OPEN button on the keyless transmitter and wait for 25 seconds Check if all the d
92. ntion cord or touch grounded metal for the elimination of static electricity before conduct ing work 3 BATTERY When removing the battery terminal always be sure to turn the ignition switch to OFF to prevent electrical damage of the control module from over current Be sure to remove the battery ground ca ble first 4 SERVICE PARTS Use genuine parts for maximum performance and maintenance when conducting repairs Subaru FHI will not be responsible for poor performance result ing from the use of parts except for genuine parts 5 PROTECTING VEHICLE UNDER MAIN TENACE Make sure to attach the fender cover seat covers etc before work 6 ENSURING SECURITY DURING WORK When working in a group of two or more perform the work with calling each other to ensure mutual safety 7 LIFTS AND JACKS When using a lift or shop jack to raise a vehicle or using rigid rack to support a vehicle always follow instructions concerning jack up points and weight limits to prevent the vehicle from falling which could result in injury Be especially careful that the vehicle is balanced before raising it Be sure to set the wheel stoppers when jacking up only the front or rear side of the vehicle Note NOTE When using lift follow its operation manual be fore work Do not work or leave unattended while the vehi cle is supported with jack support it with rigid racks Be sure to use the rigid racks with rubber at
93. o Transmission type 4A OHC 25LS Transmission aM 5A w Gear ratio ath t 0 780 Auxiliary transmission gear High ___ 4000 ratio 12 1 ee OW istreduc Type ofgear ion 100 100 190 1000 e Final 370 reduction 4 111 4 111 3 272 4 111 Ne 3 083 Transfer Typeofgear_ Reducti reduction Gear ratio 1000 100 2 of gear Hypoid Hypoid Hypoid Hypoid Final 3 700 reduction Gear ratio 4 111 4 111 3 272 4 111 4 11191 OUTBACK Model 3 0L 2 5 L SOHC DOHC Transmission type Clutch type TCC DSPD 2785 100 sh 088 956 Auxiliary transmission gear 100 Gearratio 100 1 000 Reduction gear Front Final 3 900 reduction Gear ratio 4 444 499 3 272 Transfer Type ofgear reduction gear easton 100 Rear Type of gear Hypoid Hypoid Hypoid Final 3 900 reduction 4 444 4144 3 272 5 forward speeds with synchromesh and 1 reverse 4AT Electronically controlled fully automatic 4 forward speeds and 1 reverse SPC 4 LEGACY SPECIFICATIONS 5AT Electron
94. o determine an inspection pattern in order to avoid missing an area since the total in spection area Is wide Do not repair the body paint unless absolutely necessary Also if the vehicle is in need of repair to remove scratches or corroded paint the repair area must be limited to the minimum Re painting and spray painting must be avoided as possible 3 Check each window glass for scratches careful ly Slight damage may be removed by polishing with cerium oxide Fill a cup half with cerium oxide and add warm water to it Then agitate the content until it turns to wax Apply this wax to a soft cloth and polish the glass with it 4 Check each portion of the vehicle body and un derside components for the formation of rust If rust is discovered remove it with sandpaper of 80 to 180 and treat the surface with rust preventive Af ter this treatment is completed flush the portion thoroughly and prepare the surface for repair painting 5 Check each portion of body and all of the plated parts for deformation or distortion Also check each lamp lens for cracks 13 Pre delivery Inspection PRE DELIVERY INSPECTION 6 Peel the protective tape vinyl wrapping and identification seal attached to the following places Seat e Door trim Floor carpet Side sill Front hood lock release lever Edge rear Rear wiper Sedan rear combination light Trunk lid opening portion Roof rail Door mirror 14
95. o en sure that doors will not open Door lock knob B Inner remote 3 Close all the doors and then press the lock on power door lock switch at driver s side Check that all doors including rear gate are locked 4 Press the driver s side power door lock switch to unlock side Check that all doors including rear gate are unlocked 5 Insert the key to ignition switch and open the driver s side door Press lock on power door lock Check that the door is not locked PRE DELIVERY INSPECTION 6 CHECK DOUBLE LOCK OPERATION 1 Fully open all the windows 2 Remove the key 3 Lock all the doors using the door key cylinder or keyless transmitter 4 Verify that all the doors including rear gate are not unlocked when pressing power door lock switch to unlock side 5 Verify that the door is not opened when operat ing door lock knob to unlock position and pulling in ner remote Perform the same check for other doors 6 Check that all the doors are unlocked when door is unlocked using door key cylinder or keyless transmitter or ignition switch is turned to ON 7 CHECK OPERATION OF CHILD SAFETY LOCK SYSTEM 1 Set the child safety lock on both rear doors to the lock position 2 Close the rear doors completely 3 Check that the lock levers of the rear doors are in the unlock position Then pull inner remote of rear doors to ensure that doors will not open A Lock B Unlock 4 Pull the outer
96. on boot NIGLUBE RX 2 K0779GA102 Between brake pad and shim Molykote AS 880N 0777 010 Brake pad clip Molykote M7439 Front axle PTJ NSG301 Front axle Rear axle BJ NTG2218 M Rear axle Rear axle DOL NKGmp 8 ADHESIVE Use the adhesives shown in the table below or equivalent Applicaton Aternaiiv Adhesive Windshield rear window Dow Automotive s glass rear quarter Adhesive Gurit ESSEX glass rear gate and Betaseal 1502 or equivalent body Glass primer Betawipe VP 04604 Betawipe 5001 Paint surface primer Betap rime 5402 REPAIRKTTINMR 669950 Soft vinyl o 3M s EC 776 EC 847 or EC 1022 Spray type ARMSTRONG s Eastman 910 Momentary sealant CEMEDINE 3000 RM 6 Recommended Materials RECOMMENDED MATERIALS 9 SEAL MATERIAL Use the seal material shown in the table below or equivalent Seal material Application point Alternative Seal material MT transmission case Cylinder block Converter case THREE BOND 1215 004403007 DOW CORNING s No 7038 DOHC camshaft cap Turbo model Transmission oil pan AT THREE BOND 12178 K0877YA020 model Engine oil pan Except BOND 1207C 004403012 for 3 0 L model Rear differential Engine oil pressure switch Cylinder head Nip THREE BOND 1324 004403042 ple Camshaft bowl shape plug rana THREE THREE BOND 1105 1105
97. ont hood is unlocked normally Pre delivery Inspection Operate the lever B and check that the front hood is opened normally Support the front hood with hood stay 13 BATTERY Check the battery terminals to make sure that there are no rust or corrosions due to fluid leaks Check that the battery caps are securely tightened A Cap B Upper level C Lower level PRE DELIVERY INSPECTION 14 BRAKE FLUID Check that the brake fluid level is normal If the amount is insufficient carry out a brake line test to identify brake fluid leaks and check the brake oper ation After that refill the brake fluid tank with the specified type of fluid A MAX level B MIN level 15 ENGINE OIL Check the engine oil amount If the amount of oil is insufficient check that no leaks are found Then add the necessary amount of the specified engine oil Except for 3 0 L model Oil level gauge A B Engine oil filler cap C Upper level D Lower level E Approx 1 0 0 1 1 US qt 0 9 Imp qt 7 Pre delivery Inspection PRE DELIVERY INSPECTION 3 0 model 17 AT FRONT DIFFERENTIAL OIL Check that the AT front differential oil level is nor mal If the amount of oil is insufficient check that no leaks are found Then add the necessary amount of the specified AT front differential oil model LU 00111 gt Oil level gauge Engine oil filler cap C Upper level
98. oors in cluding rear gate are locked Except for EK model 23 SEAT 1 Check the seat surfaces for stains or dirt 2 Check that each seat provides full functionality in sliding and reclining Check all available functions of the rear seat such as a trunk through center arm rest 24 SEAT BELT 1 Check installation condition of seat belt 2 Pull out the seat belt and then release it Check that the belt retracts smoothly 25 WHEEL ALIGNMENT Check the wheel alignment Ref to FS 8 Wheel Alignment Ref to RS 8 Wheel Alignment 26 TEST MODE CONNECTOR Turn the ignition switch to ON and check that the malfunction indicator light starts blinking If the light blinks return the ignition key to LOCK Pull out the test mode connector from the back of glove box lower cover and disconnect the test mode connec tor Then turn the ignition key to ON again If the malfunction indicator light blinks at that time in spite of the disconnected test mode connector carry out an engine diagnosis A Test mode connector green NOTE If it is difficult to pull out the test mode connector remove the glove box lower cover and disconnect the test mode connector A Test mode connector green B Glove box lower cover 27 IMMOBILIZER SYSTEM 1 Check that the engine starts with all keys that are equipped on vehicle 2 60 seconds after turning the ignition switch from ON to ACC or OFF or immediately after remo
99. or_ Winterpack _ _ 1 _ _ em ALA NNNM OA LL 55 OA Sideairbag___ _ Curtain airbag _ _ Swot 2 9 9 Navigation system Seflveizr gt _ 1 For option code refer to ID section Ref to ID 5 MODEL NUMBER PLATE IDENTIFICATION Identification gt Vehicle Dynamics 09070 Cruise contol Option SPC 30 SPECIFICATIONS 2 0 LSOHC AWD 2 01 5 zT uud Front ow Total koil Maximum permissible M P A W Maximum permissible Total kgf Ib 1 925 4 244 1 925 4 244 1 925 4 244 1 925 4 244 1 925 4 244 weight M P W Leatherinterior_ _ _ 4 1 _ _ _ se Sideairbag _ Curtain airbag 4005 5 Navigation system _ _ Sefleelizer gt _ 1 For option code refer to ID section Ref to ID 5 MODEL NUMBER PLATE IDENTIFICATION Identification Vehicle Dynamics Eon Cruise control Mcintosh audio o o
100. ount of engine oil at replace Transmission gear oil US at Imp qt 3 5 3 7 3 1 4 0 4 2 is LA Font renal gear ol 8 1261810 0 Engine coolant 0 US at Imp at Engine oil 0 US qt Imp at 2 5 L SOHC 3 0 L DOHC Model SAT Fuel tank US gal Imp gal 64 16 9 14 1 Capacity at overhaul 0 US qt Imp qt 5 4 8 4 0 2 7 6 6 3 engine cil 8 95 95 Imp ab Approx 5 5 5 8 4 8 at replace 9 5 9 7 94 Transmission gear oil 0 US qt Imp at 4 0 4 2 3 5 US qt Imp at 8 2 9 8 10 4 8 6 Eon differential gear oil US at Imp at 1 3 1 1 1 4 1 5 1 2 gt gt Rear differential gear oil i Us qt Imp 8 0 8 0 7 Power steering fluid 0 US at Imp at 8 0 8 0 7 7 2 7 6 6 3 0 US at Imp at 1 With ATF cooler with warmer function 2 Dual range model only SPC 6 LEGACY SPECIFICATIONS WEIGHT 1 SEDAN MODEL LHD model 2 0 L SOHC AWD 2 0i a Hem eo Total kgr Maximum permissible M P A W Maximum permissible Total kgf Ib 1 900 4 189 1 900 4 189 1 900 4 189 1 900 4 189 1 900 4 189 1 900 4 189 weight M P W Model 31 31 SE Leatherinterior Winterpack doce 9 BASLE a LLL A a ee NE LONE ME N
101. plug until gasket contacts cylinder head then tighten further 1 4 to 1 2 turns PM 10 V belt PERIODIC MAINTENANCE SERVICES 6 V belt Belt tension with belt tension gauge A A INSPECTION When installing new one 640 785 65 3 80 0 kgf 144 176 Ib 1 EXCEPT FOR 3 0 L MODEL At inspection 490 640 50 65 kgf 1 Replace the belts if crack fraying or wear is 110 144 Ib found B 2 Check the V belt tension and adjust it if neces When installing new one 620 760 N 63 sary by changing the generator installing position 77 kgf 140 170 Ib or idler pulley installing position Ref to PM 12 At inspection 350 450 N 36 46 kgf 79 REPLACEMENT V belt gt 101 Ib Belt tension without belt tension gauge A When installing new one 7 9 mm 0 276 0 354 in At inspection 9 11 mm 0 354 0 433 in B When installing new one 7 5 8 5 mm 0 295 0 335 in At inspection 9 0 10 0 mm 0 354 0 394 in A Front side belt B Rear side belt C P Crank pulley GEN Generator P S Power steering oil pump pulley compressor pulley UP Idler pulley 98 N 10kg A Front side belt B Rear side belt C P Crank pulley GEN Generator P S Power steering oil pump pulley A C compressor pulley UP Idler pulley PM 11 V belt PERIODIC MAINTENANCE SERVICES 2 3 0 L MODEL Turbo model 1 Replace the belts if crack fraying or
102. pressure Check the fol lowing points Non turbo model 157 kPa 1 6 23 psi Turbo model 122 kPa 1 2 kg cm 18 psi Each portion of radiator for leakage Hose joints and other connections for leakage NOTE Forturbo model be sure to install the tester to fill er tank side When attaching or detaching tester or when op erating tester use special care not to deform radi ator filler neck Non turbo model When performing this check be sure to keep the engine stationary and fill radiator with coolant Wipe off check points before applying pressure Use care not to spill coolant when detaching tester from radiator e Do not remove the radiator side cap Turbo model 2 Check the radiator cap valve open pressure us ing radiator cap tester NOTE Rust or dirt on the cap may prevent valve from func tioning normally be sure to clean the cap before testing Raise the pressure until the needle of gauge stops and see if the pressure can be retained for five to six seconds The radiator cap is normal if a pres sure above the service limit value has been main tained for this period Radiator cap valve open pressure Non turbo model Standard 93 123 kPa 0 95 1 25 kg cm 14 18 psi Service limit 83 kPa 0 85 kg cm 12 psi Turbo model Filler tank side Standard 93 123 kPa 0 95 1 25 kg cm 14 18 psi Service limit 83 kPa 0 85 k
103. r cancel lever of trunk lock to check that it operates normally 3 Open and close the trunk lid to see that there are no abnormal conditions 9 Check the rear gate for lock unlock and open 1 Check if the rear gate can be unlocked normally through the emergency close operations hole 2 Open and close the rear gate to see that there are no abnormal condi tions 10 Operation check of fuel lid opener lock release Operate the fuel lid opener to check that the fuel lid is unlocked normally lever 11 Accessory check Check that the following accessories are provided Owner s manual Warranty booklet Maintenance note Spare key Jack e Tool set Spare tire 12 Operation check of front hood lock release Operate the front hood lock release lever to check that the front hood 15 system unlocked normally 13 Battery Check the battery terminals for any abnormal conditions such as rust and trace of battery fluid leaks 14 Brake fluid Check that the fluid level is normal 2 Pre delivery Inspection PRE DELIVERY INSPECTION PROCEDURE Check point 15 Engine oil Check that the oil level is normal 16 Transmission gear oil Check that the transmission gear oil level is normal 17 AT front differential oil Check that the AT front differential oil level is normal 18 Engine coolant Check that the engine coolant level is normal 19 Clutch fluid Check that the clutch fluid level is normal 20
104. rand from that in the engine however use oil having the API classification and SAE viscosity No designat ed 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 classification SL SJ or SH SAE Viscosity No 30 40 10W 50 20W 40 20W 50 5 Close the engine oil filler 6 Start the engine and warm it up for a time 7 After the engine stops recheck the oil level lt Ref to PM 8 INSPECTION Engine Oil B INSPECTION 1 Park the vehicle on a level surface 2 Remove the oil level gauge and wipe it clean 3 Reinsert the level gauge all the way Be sure that the level gauge is correctly inserted and in the proper orientation 4 Remove it again and note the reading If the en gine oil level is below the L line add oil to bring the level up to the F line Except for 3 0 L model gt Oil level gauge Oil filler cap Upper level Lower level Approx 1 0 1 1 US at 0 9 Imp at 3 01 model a gt LU 00111 A Oil level gauge B Oil filler cap C Upper level D Lower level 5 After turning off the engine wait a few minutes for the oil to drain back into the oil pan before checking the level 6 Just after driving or while the engine is warm en gine oil level may show in the range between the F line and the notch mark This is caused by ther
105. rd FOREWORD 1 Foreword A FOREWORD These manuals are used when performing mainte nance repair or diagnosis of Subaru LEGACY Applied model BL BP from 2004MY The manuals contain the latest information at the time of publication Changes in specifications methods etc may be made without notice FW 2 HOW USE THIS MANUALS 1 How to Use This 2 How to Use This Manuals HOW TO USE THIS MANUALS 1 How to Use This Manuals A HOW TO USE THIS MANUALS 1 STRUCTURE Each section consists of SCT that are broken down into SC that are divided into sections for each com ponent The specification maintenance and other information for the components are included and the diagnostic information has also been added where necessary 2 CONTENTS The first page has an index with tabs HU 2 How to Use This Manuals HOW TO USE THIS MANUALS 3 COMPONENT Illustrations are provided for each component The information necessary for repair work tightening torque grease up points etc is described on these illustrations Information is described using symbol To order parts refer to parts catalogue Example Selective part Replacement part Sealing point Should be lubricated with oil Should be lubricated with grease tTightening torque HU 00017 HU 3 How to Use This Manuals HOW TO USE THIS MANUALS
106. retighten them when engine is cold PM 41 Steering System Power Steering PERIODIC MAINTENANCE SERVICES PM 42
107. s normally 40 Wiper Check that the wiper system operates normally 41 Power window operation check Check the power window for normal operations 42 Cargo fan Check that the cargo fan operates normally 43 Sunroof Check that the sunroof operates normally 44 Door mirror Check that the remote control mirror operates normally DYNAMIC TEST WITH VEHICLE RUNNING 45 Brake tos 46 Parking brako 47 AT shit conira 48 Heater amp ventilation 49 Air conditioner 50 Cruise contro CHECKS AFTER DYNAMIC TEST PROCEDURE Check point 51 ATF level Check that the ATF level is correct 52 Power steering fluid level Check that the power steering fluid level is normal 3 Pre delivery Inspection PRE DELIVERY INSPECTION PROCEDURE Check point 53 Fluid leak check Check for fluid oil leaks 54 Water leak test Spray the vehicle with water and check for water leaks 55 Appearance check 2 1 Remove the protective coating if any 2 Check the body paints for damage and stain 3 Check the plated parts for damage and rust 1 APPEARANCE CHECK e f the vehicle is covered with protective coating visually check the vehicle body for damage and dents e When the protective coating is removed visually check the body paints for damage or stains in detail and repair as necessary Visually check the windshield glass door glass es and light lenses for any damage cracks or ex cessive gaps to the body she
108. so included Example Tightening torque 44 N m 4 5 kgf m 33 ft lb Mass Weigh Rotating speed hm Sim tg immHgz0183982kPa _ Caloris Fuel consumption rate The figure used in these manuals are described in the SI units and conventional units are described in HU 5 How to Use This Manuals HOW USE THIS MANUALS 9 EXPLANATION OF TERMINOLOGY List AAI A B ABS A C A F ALT ASSY AT ATF BATT CD R RW CPU DOHC DVD ECM EGR ELR EX F B FL Ft FWD GPS H U INT ISC LH LSD Air Assist Injection Airbag Antilock Brake System Air Conditioner Air Fuel Ratio Generator Assembly Automatic Transmission Automatic Transmission Fluid Battery CD Recordable Rewritable Central Processing Unit Double Overhead Camshaft Digital Versatile Disc Engine Control Module ECM Exhaust Gas Recirculation Emergency Locking Retractor Exhaust Fuse amp Joint Box Fusible Link Full time AWD Front Wheel Drive Global Positioning System Hydraulic Unit Ignition Intermittent Idle Speed Control LH Left Hand Limited Slip Differential M B MD Non turbo P S P W PCD PCV RH Rr SOHC SHS SSM ST SW TCS TGV T M ViS C VSV VTD W H Pr 2 6 Main Fuse 4 Relay Box Mini Disc Multi Point Injection Multi Plate Transfer Manual Transmiss
109. tons and valves may occur B INSPECTION 1 SOHC MODEL 1 Remove the front timing belt cover and timing belt cover LH 2 While cranking engine at least four rotations check the timing belt back surface for cracks or damage Replace the faulty timing belt as needed 3 Measure the timing belt width W If it is less than 2 mm 1 06 in check idlers tensioner water pump pulley and cam sprocket to determine idler alignment squareness Replace the worn timing belt 4 Install the front timing belt cover and timing belt cover LH 2 DOHC MODEL 1 Remove the timing belt cover LH 2 While cranking engine at least four rotations check the timing belt back surface for cracks or damage Replace the faulty timing belt as needed 3 Measure the timing belt width W If it is less than 30 mm 1 18 in check idlers tensioner water pump pulley and cam sprocket to determine idler alignment squareness Replace the worn timing belt 4 Install the timing belt cover LH PM 16 Fuel Line 8 Fuel Line A INSPECTION The fuel line is located mostly internally so check pipes areas near pipes and engine compartment piping for rust hose damage loose band etc faulty parts are found repair or replace them e 2 0 non turbo and 2 5 model Ref to FU H4SO 2 0 53 Fuel Delivery Return and Evaporation Lines gt Turbo model Ref to FU H4DOTC 56 Fuel Delivery Return and Evaporation Lines gt
110. ue 70 7 1 kgf m 16 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 lt Ref to RM 3 LUBRI CANTS RECOMMENDED MATERIALS Rec ommended Materials gt NOTE Each oil manufacturer has its base oil and addi tives Thus do not mix two or more brands Differential gear oil capacity 4AT model 1 1 1 3 0 1 2 1 4 US qt 1 0 1 1 Imp qt A Oil level gauge B Upper level C Lower level 5AT model 1 3 1 5 0 1 4 1 6 US qt 1 1 1 3 Imp qt A Oil level gauge B Upper level C Lower level 3 REAR DIFFERENTIAL 1 Drain the oil by removing drain plug 2 Remove the filler plug for quick draining oil 3 Install the drain plug after draining oil NOTE Apply liquid gasket to the drain plug threads for T type Use a new gasket for VA type Liquid gasket THREE BOND 1105 Part No 004403010 PM 28 Front and Rear Tightening torque T type 49 0 5 0 kgf m 36 2 ft Ib VA1 type 34 3 5 kgf m 25 3 ft Ib VA2 type 29 N m 3 0 kgf m 21 4 ft Ib 4 Pour oil to the bottom end of filler plug hole Recommended gear oil Differential Gear Oil PERIODIC MAINTENANCE SERVICES Liquid gasket THREE BOND 1105 Part No 004403010 Tightening torque T type 49 0 5 0 kgf m 36 2 ft Ib VA1 type 34 N m 3 5 kgf m 25 3 ft lb VA2 type 29
111. ving the key check that the security indicator light blink ing NOTE If malfunctions occur refer to IMMOBILIZER DI AGNOSIS 10 Pre delivery Inspection 28 STARTING CONDITION Start the engine and check that the engine starts smoothly If the battery voltage is low recharge or replace the battery If any noises are observed im mediately stop the engine and check and repair the abnormal components 29 EXHAUST SYSTEM Listen to the exhaust sound to see if no noises are observed Check the exhaust leaks 30 INDICATOR AND WARNING LIGHTS Check that all the indicator and warning lights are off 31 CLOCK Check the clock for normal operations and enough accuracy 32 AUDIO Check the radio for full functionality and normal noise level Also check the CD MD unit operations 33 NAVIGATION SYSTEM 1 Check all display function for normal operation For operating procedure refer to operating manu als 2 Check the map disc DVD are provided on vehi cle 3 Check that the navigation systems operate nor mally 34 FRONT ACCESSORY POWER SUPPLY SOCKET 1 Check operation for the front accessory power Socket 2 Check operation of the accessory power socket in console box 35 LIGHTING SYSTEM 1 Check the headlight operations 2 Check the stop light operation 3 Check other lights for normal operations 36 WIPER DEICER Check that the wiper deicer operates normally 37 REAR FOG LIGH
112. with pulling up the force of less than 10 1 2 Ib Brake pedal free play Pulling up direction of pedal 0 5 2 0 mm 0 02 0 08 in A Pedal free play 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 1 kgf 2 Ib to a stroke of 0 5 to 2 0 mm 0 02 to 0 08 in 3 If there is no free play between clevis pin and clevis turn brake switch adjusting nut until the clearance between stopper and screw of brake switch becomes 0 3 mm 0 012 in A Brake switch Adjusting nut 0 3 mm 0 012 in Stopper Clevis pin Clevis Pedal free play Lock nut Brake booster operating rod Play at pin 30 Brake Line 3 Check the pedal stroke While the engine is idling depress the brake pedal with a 490 50 kgf 110 Ib load and measure the distance between the brake pedal and steering wheel With the brake pedal released measure the distance between pedal and steering wheel again The difference between the two measurements must be less than specified value If the distance is more than specified value there is possibility of air inside the hydraulic unit Brake pedal
113. y framework mating portion Around roof drips If any dampness in the compartments is discovered after the water has been applied carefully check all the areas that may have possibly contributed to the leak PRE DELIVERY INSPECTION 55 APPEARANCE CHECK 2 1 When vehicle body is covered with protective film peel it off NOTE Use of steam facilitates peeling off the warp guard For the vehicle left for a long time or at low tem perature sprinkle some water heated 50 60 122 14092 over the vehicle to raise its surface temperature before peeling off the wrap guard Do not use the water heated to over 60 140 F the adhesive remains exists the coated sur face soak a flannel rag etc with a small amount of coating wax or solvent such as oil benzene and IPA put the soaked cloth on the remains lightly and then wipe them off with a flannel rag etc Keep solvent from touching the resin or rubber parts Do not use coating wax or solvent while the component surface temperature is high due to hot weather etc e f the coated surface is swollen out due to seams or moisture expose the vehicle to the sunlight for a few hours or heat the seam and swollen portions using a dryer etc Dispose of the peeled wrap guard as burnable in dustrial garbage 2 Check the whole vehicle body for flaking paint damage by transportation corrosion dirt cracks or blisters NOTE is better t
114. y of coolant to be drained is 2 1 0 2 2 US qt 1 8 Imp qt Drain 2 1 0 2 2 US qt 1 8 Imp qt of coolant from the cool ing system and add 2 1 0 2 2 US qt 1 8 Imp at of the undiluted solution of SUBARU coolant PERIODIC MAINTENANCE SERVICES If a coolant concentration of 5096 is needed drain all the coolant and refill with the undiluted solution only Necessary Concentration of coolant Quantity of coolant to be 3 2 w drained f US qt Imp at TO om ar 30 Concentration of coolant in the vehicie cooling system Concentration of coolant in vehicie and quantity to be drained 00012 23 Clutch System PERIODIC MAINTENANCE SERVICES 12 Clutch System Be careful not to allow dirt or dust to get into the reservoir tank A INSPECTION AND ADJUSTMENT 1 Push the release lever to retract the push rod of the operating cylinder and check if the fluid level in the clutch reservoir tank rises or not A Release lever B Push rod C Operating cylinder 2 If the fluid level rises pedal free play is correct 3 If the fluid level does not rise or the push rod cannot be retracted adjust the clutch pedal Ref to CL 26 Clutch Pedal 4 Check the fluid level using the scale on the out side of the clutch reservoir tank A If the level is below MIN B inspect the clutch master cylinder operating cylinder and hydraulic line for fluid l

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