2004 SUBARU LIBERTY Service and Repair Manual

FW-2 Foreword FOREWORD 1. Foreword A: FOREWORD These manuals are used when performing maintenance, repair or diagnosis of Subaru LEGACY. Applicable model: 2008MY BL*****, BP***** The manuals contain the latest information at the time of publication. Changes in the specifications, methods, etc. may be made without notice.

HU-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 component. 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-3 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: HU-00017 (14) (9) (8) (7) (6) (10) (4) (10) (22) (11) (19) (17) (15) (13) (12) (18) (16) (1) (2) (3) (4) (5) (6) (7) (8) (11) (10) (9) (12) (13) (19) (18) (20) (17) (16) (24) (10) (25) (5) (4) (4) (4) (3) (3) (3) (2) (1) (21) (15) (23) T7 T2 T2 T2 T2 T2 T2 T4 T5 T5 T8 T6 T6 T6 T11 T10 T1 T1 T3 T3 T3 T1 T9 T4 T5 T5 T3 T4 T3 T2 T4 T2 T1 T3 (20) (21) (23) (22) (10) (24) (25) (26) (35) (34) (27) (14) (28) (29) (31) (32) (37) (30) (33) (36) T3 T2 T1 .... , : Selective part : Replacement part : Sealing point : Should be lubricated with oil. : Should be lubricated with grease. : Tightening torque

HU-4 How to Use This Manuals HOW TO USE THIS MANUALS 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. • If many serviceable parts are included in one service procedure, appropriate reference is provided for each parts. Example: (A) Component (D) Cautions (G) Tightening torque (B) Process (E) Tool number of special tool (H) Illustration (C) Reference (F) Name of special tool HU-00020 1) Remove the manual transmission assembly from vehicie. <Ref. to MT-33, REMOVAL, Manual Transmission Assembly.> 15.Main Shaft Assembly for Sin- gle-Range A: REMOVAL 11) Tighten the lock nuts to the specified torque using ST1 and ST2. NOTE: Secure the lock nuts in two places after tightening. ST1 498937000 TRANSMISSION HOLDER (A) (B) (C) (D) (G) (E) (F) (H) Tightening torque: 118 N m (12.0 kgf-m, 86.8 ft-lb) ST1 ST2 ST2 499987003 SOCKET WRENCH (35)

HU-5 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 SI units. Metric and yard/pound measurements are also included. Example: Tightening torque: 44 N·m (4.5 kgf-m, 33 ft-lb) The figure used in these manuals are described in the SI units and conventional units are described in ( ). Item SI units Conventional unit Remarks Force N (Newton) kgf 1 kgf = 9.80655 N Mass (Weight) kg, g kg, g Capacity 2, m2 or cm 3 2or cc 1 cc = 1 cm 3 = 1 m2 Torque N·m kgf-m, kgf-cm 1 kgf-m = 9.80655 N·m Rotating speed rpm rpm Pressure kPa (kilopascal) kgf/cm 2 1 kgf/cm 2 = 98.0655 kPa mmHg 1 mmHg = 0.133322 kPa Power W PS 1 PS = 0.735499 kW Calorie W·h cal 1 kcal = 1.16279 W·h Fuel consumption rate g/kw·h g/PS·h 1 g/PS·h = 1.3596 g/kW·h

HU-6 How to Use This Manuals HOW TO USE THIS MANUALS 9. EXPLANATION OF TERMINOLOGY List AAI : Air Assist Injection MD : Mini Disc A/B : Airbag MID : Multi-information Display ABS : Anti-lock Brake System MFI : Multi Point Injection A/C : Air Conditioner MP-T : Multi-Plate Transfer A/F : Air Fuel Ratio MT : Manual Transmission ALT : Generator NA : Natural Aspiration ASSY : Assembly NC : Normal Close (Relay) AT : Automatic Transmission NO : Normal Open (Relay) ATF : Automatic Transmission Fluid OP : Option Parts AWD : All Wheel Drive P/S : Power Steering BATT : Battery P/W : Power Window CD-R/RW : CD Recordable/Rewritable PCD : Pitch Circle Diameter CPU : Central Processing Unit PCV : Positive Crankcase Ventilation DOHC : Double Overhead Camshaft RH : RH (Right Hand) DVD : Digital Versatile Disc Rr : Rear ECM : Engine Control Module SI-DRIVE : SUBARU Intelligent Drive EGR : Exhaust Gas Recirculation SOHC : Single Overhead Camshaft ELR : Emergency Locking Retractor SRS : Supplemental Restraint System EX : Exhaust SSM : Subaru Select Monitor F/B : Fuse & Joint Box ST : Special Tool FL : Fusible Link SW : Switch Ft : Full-time (AWD) TCS : Traction Control System FWD : Front Wheel Drive TGV : Tumble Generator Valve GPS : Global Positioning System T/M : Transmission H/U : Hydraulic Unit TPMS : Tire Pressure Monitoring System IG : Ignition ViS-C : Viscous Coupling INT : Intermittent VSV : Vacuum Switching Valve ISC : Idle Speed Control VTD : Variable Torque Distribution LH : LH (Left Hand) W/H : Wiring Harness LSD : Limited Slip Differential Pr : Primary M/B : Main Fuse & Relay Box 2ndr : Secondary

SPC-2 LEGACY SPECIFICATIONS 1. LEGACY A: DIMENSION 1. SEDAN MODEL *1 : With sunroof *2 : 2.5 GT spec. B model 2. WAGON MODEL *1 : With sunroof B: ENGINE Model 2.5 L SOHC 2.5 L DOHC turbo 3.0 L DOHC Overall length mm (in) 4,700 (185.0) Overall width mm (in) 1,730 (68.1) Overall height (at C.W.) mm (in) 1,425 (56.1) 1,425 (56.1), 1,435 (56.5) *2 1,435 (56.5) Compartment Length mm (in) 1,900 (74.8) Width mm (in) 1,445 (56.9) Height mm (in) 1,165 (45.9), 1,100 (43.3) *1 Wheelbase mm (in) 2,670 (105.1) Tread Front mm (in) 1,495 (58.9) Rear mm (in) 1,485 (58.5) Minimum road clearance mm (in) 150 (5.9) 150 (5.9), 160 (6.3) *2 160 (6.3) Model 2.5 L SOHC 2.5 L DOHC turbo Overall length mm (in) 4,785 (188.4) Overall width mm (in) 1,730 (68.1) Overall height (at C.W.) mm (in) 1,475 (58.1) Compartment Length mm (in) 1,840 (72.4) Width mm (in) 1,445 (56.9) Height mm (in) 1,190 (46.9), 1,145 (45.1) *1 Wheelbase mm (in) 2,670 (105.1) Tread Front mm (in) 1,495 (58.9) Rear mm (in) 1,485 (58.5) Minimum road clearance mm (in) 150 (5.9) 155 (6.1) Model 2.5 L SOHC 2.5 L DOHC turbo 3.0 L DOHC Engine type Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine Horizontally opposed, liquid cooled, 6-cylinder, 4-stroke gasoline engine Valve arrangement Overhead camshaft Bore × stroke mm (in) 99.5 × 79.0 (3.917 × 3.110) 89.2 × 80.0 (3.512 × 3.150) Displacement cm 3 (cu in) 2,457 (149.9) 3,000 (183.06) Compression ratio 10.0 8.4 10.7 Ignition order 1 — 3 — 2 — 4 1 — 6 — 3 — 2 — 5 — 4 Idle speed at Park or Neutral position rpm 650 (MT) 700 (AT) 750 650 Maximum output kW (HP)/rpm 125 (170)/6,000 184 (243)/6,000 185 (245)/6,600 Maximum torque N·m (kgf-m, ft-lb)/rpm 230 (23.5, 170)/4,400 327 (33.3, 241)/3,600 291 (29.7, 215)/4,200

SPC-3 LEGACY SPECIFICATIONS C: ELECTRICAL D: TRANSMISSION 5MT: 5-forward speeds with synchromesh and 1-reverse 4AT: Electronically controlled fully-automatic, 4-forward speeds and 1-reverse 5AT: Electronically controlled fully-automatic, 5-forward speeds and 1-reverse DSPD: Dry Single Plate Diaphragm TCC: Torque Converter Clutch E: STEERING *1 : 2.5 GT spec. B model F: SUSPENSION Model 2.5 L SOHC 2.5 L DOHC turbo 3.0 L DOHC Ignition timing (at idling) BTDC 13° MT: 12° AT: 17° 15° Spark plug Type and manufacturer NGK: FR5AP-11 NGK: SILFR6A NGK: ILFR6B Generator 12V — 110A Battery Type and capacity (5HR) MT 12V — 48AH (55D23L) AT 12V — 52AH (75D23L) Model 2.5 L SOHC 2.5 L DOHC turbo 3.0 L DOHC Transmission type 5MT 4AT 5MT 5AT 6MT 5AT Clutch type DSPD TCC DSPD TCC DSPD TCC Gear ratio 1st 3.454 2.785 3.166 3.540 3.636 3.540 2nd 2.062 1.545 1.882 2.264 2.235 2.264 3rd 1.448 1.000 1.296 1.471 1.521 1.471 4th 1.088 0.694 0.972 1.000 1.137 1.000 5th 0.780 — 0.738 0.834 0.891 0.834 6th — — — — 0.707 — Rev. 3.333 2.272 3.333 2.370 3.545 2.370 Reduction gear (Front) 1st reduction Type of gear — Helical — Helical — Helical Gear ratio — 1.000 — 1.000 — 1.000 Final reduction Type of gear Hypoid Hypoid Hypoid Hypoid Hypoid Hypoid Gear ratio 3.900 4.111 3.900 3.083 3.900 3.272 Reduction gear (Rear) Transfer reduction Type of gear Helical — Helical — Helical — Gear ratio 1.000 — 1.000 — 1.100 — Final reduction Type of gear Hypoid Hypoid Hypoid Hypoid Hypoid Hypoid Gear ratio 3.900 4.111 3.900 3.083 3.545 3.272 Model 2.5 L SOHC 2.5 L DOHC turbo 3.0 L DOHC Type Rack & pinion Turns, lock to lock 3.2 2.8, 2.6 *1 2.6 Minimum turning diameter m (ft) Curb to curb 10.8 (35.4), 11.6 (38.0) *1 11.6 (38.0) Wall to wall 11.6 (38.1), 12.4 (40.7) *1 12.4 (40.7) Front Macpherson strut type suspension Rear Multi-link type suspension

SPC-4 LEGACY SPECIFICATIONS G: BRAKE H: TIRE *1 : 2.5 GT spec. B model *2 : Model for Canada I: CAPACITY Model 2.5 L SOHC 2.5 L DOHC turbo 3.0 L DOHC Service brake system Dual circuit hydraulic with vacuum suspended power unit Front Ventilated disc brake Rear Disc brake Ventilated disc brake Parking brake Mechanical on rear brakes Model 2.5 L SOHC 2.5 L DOHC turbo 3.0 L DOHC Wheel size 16 × 6 1 / 2 JJ *2 , 17 × 7JJ 17 × 7JJ, 18 × 7JJ *1 18 × 7JJ Tire size P205/55 R16 89H *2 , P205/50 R17 88V 215/45 R17 91W, 215/45 R18 89Y *1 P215/45 R18 89W Type Tubeless, Steel belted radial Model 2.5 L SOHC 2.5 L DOHC turbo 3.0 L DOHC 5MT 4AT 5MT 5AT 6MT 5AT Fuel tank 2 (US gal, Imp gal) 64 (16.9, 14.1) Engine oil Total capacity (Overhaul) 2 (US qt, Imp qt) 5.0 (5.3, 4.4) 7.0 (7.4, 6.2) Filling amount of engine oil 2 (US qt, Imp qt) When replacing engine oil and oil filter 4.2 (4.4, 3.7) 4.3 (4.5, 3.8) 5.7 (6.0, 5.0) When replacing engine oil only 4.0 (4.2, 3.5) 5.5 (5.8, 4.8) Transmission gear oil 2 (US qt, Imp qt) 3.5 (3.7, 3.1) — 3.5 (3.7, 3.1) — 4.1 (4.3, 3.6) — ATF 2 (US qt, Imp qt) — 9.3 (9.8, 8.2) — 9.8 (10.4, 8.6) — 9.8 (10.4, 8.6) Front differential gear oil 2 (US qt, Imp qt) — 1.2 (1.3, 1.1) — 1.4 (1.5, 1.2) — 1.4 (1.5, 1.2) Rear differential gear oil 2 (US qt, Imp qt) 0.8 (0.8, 0.7) 1.0 (1.1, 0.9) 0.8 (0.8, 0.7) Power steering fluid 2 (US qt, Imp qt) 0.7 (0.7, 0.6) Engine coolant 2 (US qt, Imp qt) 6.4 (6.8, 5.6) 6.3 (6.7, 5.5) 7.3 (7.7, 6.4) 7.2 (7.6, 6.3) 7.3 (7.7, 6.4) 7.2 (7.6, 6.3)

SPC-5 LEGACY SPECIFICATIONS J: WEIGHT 1. US MODEL Model Sedan 2.5 L SOHC 2.5 i 2.5 i Limited 5MT 4AT 4AT Curb weight (C.W.) Front kg (lb) 819 (1,805) 826 (1,820) 839 (1,850) 846 (1,865) 841 (1,855) 850 (1,875) 853 (1,880) Rear kg (lb) 665 (1,465) 674 (1,485) 669 (1,475) 678 (1,495) 669 (1,475) 676 (1,490) 676 (1,490) Total kg (lb) 1,483 (3,270) 1,499 (3,305) 1,508 (3,325) 1,524 (3,360) 1,510 (3,330) 1,526 (3,365) 1529 (3,370) Gross axle weight ratio (G.A.W.R.) Front kg (lb) 1,040 (2,295) 1,040 (2,295) 1,040 (2,295) 1,040 (2,295) 1,040 (2,295) 1,040 (2,295) 1,040 (2,295) Rear kg (lb) 1,060 (2,340) 1,060 (2,340) 1,060 (2,340) 1,060 (2,340) 1,060 (2,340) 1,060 (2,340) 1,060 (2,340) Gross vehicle weight (G.V.W.) kg (lb) 1,960 (4,325) 1,960 (4,325) 1,960 (4,325) 1,960 (4,325) 1,960 (4,325) 1,960 (4,325) 1,960 (4,325) Option Vehicle dynamics control — — — — — Power package — — — — — Side airbag Curtain airbag Sunroof — — — Navigation (DVD) — — — — — — —

2004 SUBARU LIBERTY Service and Repair Manual

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