Subaru Leone 1979 - To Remove and Install Kickdown Solenoid; To Remove and Install Vacuum Modulator; To Remove and Install Four Wheel Drive Transfer Solenoid

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Contents2
Introduction4
Tools and Equipment5
Basic Tool Kit5
Tool Selection and Care6
Miscellaneous Equipment and Stores6
Safety Tools7
Lubrication and Maintenance8
Specifications8
How to Grease and Oil Change8
Service Schedule11
Lubrication Chart16
Maintenance Chart17
Wheels and Tyres18
How to Change a Road Wheel18
Tyre Wear Trouble Shooting20
Care and Maintenance21
Engine Tune-Up22
Tune-Up Specifications22
Tune-Up Operations22
To Adjust Drive Belts22
To Service Air Cleaner23
To Check and Renew Fuel Filter23
To Service Contact Breaker Points24
To Service High Tension Leads25
To Service Spark Plugs25
To Adjust Valve Clearances27
To Test Compression28
To Adjust Dwell Angle and Ignition Timing28
To Adjust Idle Speed and Mixture29
Roadside Troubleshooting30
To Check Ignition and Electrical Systems30
To Check Fuel System32
To Check Mechanical System33
Cooling System Specifications35
Coolant Leakage - External35
Coolant Leakage - Internal35
Engine Overheating35
Coolant Circulation Faulty36
Cooling System Description36
Radiator37
To Check Coolant Level37
To Drain and Refill37
To Remove Radiator38
To Flush and Clean Radiator38
To Install Radiator39
To Test Fan Motor on Vehicle39
To Remove and Install Fan Motor39
To Remove and Install Thermoswitch39
To Remove and Install Water Pump41
To Renew Water Pump Drive Belt42
Heater Unit Assembly42
To Remove and Install 1985-1987 Sedan and Station Wagon Models42
To Remove and Install 1979-1984 and Utility Models43
To Remove and Install Heater Blower Motor44
Heater Controls44
Fuel System Specifications46
Fuel System Troubleshooting46
Engine will Not Start46
Engine Stalls at Idle Speed47
Flat Spot on Acceleration47
Engine Misfires or Cuts out at High Speed47
Excessive Fuel Consumption48
To Remove and Install Air Cleaner48
Carburetor49
To Remove and Install Carburetor50
To Service Carburetor51
To Dismantle Carburetor51
To Service Carburetor Top Cover52
To Service Carburetor Main Body53
To Service Throttle Body55
To Assemble Throttle Body55
To Adjust Float Level56
To Adjust Throttle Interlock56
To Adjust Fast Idle Speed57
To Adjust Choke Unloader Clearance, Automatic Choke Models57
To Check Automatic Choke Operation57
To Renew Automatic Choke Cover57
Electromagnetic Plunger Fuel Pump58
To Test Pump58
To Remove and Install Test Pump59
Electromagnetic Diaphragm Fuel Pump59
Electromagnetic Diaphragm Fuel Pump to Remove and Install60
Fuel Filter61
To Remove and Install Fuel Tank61
To Remove and Install Throttle Cable62
To Adjust Throttle Cable62
Clutch Specifications63
Clutch Shudder63
Clutch Slipping63
Clutch Grab63
Insufficient Clutch Release64
Clutch Noise64
To Remove Clutch Unit65
To Check and Inspect Clutch Unit65
To Install Clutch Unit65
Clutch Release Mechanism66
To Remove Clutch Release Mechanism66
To Install Clutch Release Mechanism67
To Remove and Install Clutch Pedal67
To Remove and Install Clutch Cable67
Clutch Adjustments68
To Check and Adjust Clutch Pedal Free Play68
To Check and Adjust Hill Holder Cable68
Manual Transaxle Specifications69
Transaxle Gear Clash on Changing down71
Transaxle Slipping out of Gear71
Transaxle Noise in Neutral71
Transaxle Noise (Forward Gears Engaged, Vehicle Moving)72
Difficult High to Low, or Low to High Range Change72
Difficult to Engage Four Wheel Drive72
Gear Selected but no Front Wheel Drive72
Front Wheel Noise(Apparent)73
Propeller Shaft Vibration73
Excessive Propeller Shaft Backlash73
Illustrated View of Four Wheel Drive Dual Ratio Mainshaft and Components74
Manual Transaxle Description74
Illustrated View of Four Wheel Drive Single Ratio Mainshaft and Components74
Illustrated View of Two Wheel Drive, Drive Pinion Shaft and Components75
Illustrated View of Four Wheel Drive, Drive Pinion Shaft and Components75
Illustrated View of Four Wheel Drive Rear Drive Pinion Shaft and Components76
Transaxle Assembly77
To Remove Transaxle77
To Install Transaxle80
To Renew Rear Case Oil Seal - Two Wheel Drive82
To Renew Rear Extension Oil Seal - Four Wheel Drive82
To Remove and Install Transaxle Controls83
To Adjust Four Wheel Drive Dual Ratio High/Low Linkage89
To Adjust Four Wheel Drive Single Ratio Cable90
To Remove and Dismantle Axle Shafts90
To Check and Inspect Axle Shafts91
To Assemble and Install Axle Shafts91
To Remove and Install Propeller Shaft92
To Renew Universal Joints92
To Remove and Install Centre Bearing Assembly93
Automatic Transaxle Specifications94
Automatic Transaxle Troubleshooting94
Transmission Fluid95
To Check and Top up Transmission Fluid95
To Drain and Refill Transmission Fluid96
To Adjust Brake Band96
To Remove and Install Kickdown Solenoid97
To Remove and Install Vacuum Modulator97
To Remove and Install Four Wheel Drive Transfer Solenoid97
To Remove and Install Automatic Four Wheel Drive Switch98
Neutral Safety Switch98
To Remove and Dismantle Selector Lever and Linkage99
To Assemble and Install Selector Lever and Linkage100
Rear Axle Specifications104
Rear Axle Troubleshooting104
Rear Axle Description106
To Remove Axle Shafts107
To Dismantle and Assemble Axle Shafts107
To Install Axle Shafts107
Differential Assembly107
To Renew Differential Drive Shaft Oil Seal109
To Renew Differential Drive Pinion Oil Seal109
To Renew and Install Differential Rear Cover109
To Renew Rear Crossmember Bushes110
To Renew Differential Mounting Bracket Bush110
Steering Troubleshooting112
Faults, Causes and Remedies112
Conventional Steering114
Conventional Steering Specifications114
Steering Gear Assembly114
To Remove Steering Gear114
To Dismantle Steering Gear115
To Clean and Inspect Steering Gear115
To Assemble Steering Gear115
To Install Steering Gear116
To Remove and Install Non-Adjustable Steering Column116
To Dismantle and Assemble Non-Adjustable Steering Column117
Tilt Adjustable Steering Column118
To Remove and Install Steering Column118
To Dismantle and Assemble Steering Column118
To Remove and Install Intermediate Shaft120
Power Steering121
Power Steering Specifications121
Preliminary Inspection Ans Testing of Power Steering121
Pump Drive Belt121
To Check Fluid Level/Fluid Leaks122
To Check Turning Effort122
Pump Drive Belt Tension122
To Purge the Power Steering System of Air122
To Flush the Power Steering System123
To Remove and Install Power Steering Pump123
To Dismantle Power Steering Pump123
Tp Inspect Power Steering Pump124
To Assemble Power Steering Pump124
To Remove and Install Power Steering Gear125
Steering Column126
Intermediate Shaft126
Front Suspension127
Front Suspension Specifications127
Front Suspension Troubleshooting127
Torque Wrench Settings127
To Remove and Dismantle Front Hub129
To Clean and Inspect Front Hub129
To Assemble and Install Front Hub130
To Remove Suspension Unit130
To Dismantle and Assemble Front Hub131
To Install Front Hub131
To Remove and Install Ball Joint132
To Remove and Install Suspension Control Arm132
To Remove and Install Radius Rod132
To Remove and Install Stabiliser Bar133
Steering Angles and Ground Clearance133
Wheel Alignment133
To Check and Adjust Ground Clearance134
To Check and Adjust Toe In/Out135
Rear Suspension Troubleshooting136
Torsion Bar Rear Suspension137
To Remove and Install Torsion Bar and Trailing Link137
Torsion Bar Rear Suspension Specifications137
To Remove Shock Absorber138
To Test and Bleed Shock Absorber138
To Install Shock Absorber139
To Remove and Install Trailing Arm139
Rear Hub139
Gas Pressured Shock Absorbers139
Coil Spring Rear Suspension Specifications140
To Remove and Install Trailing Link140
To Remove Coil Spring Rear Suspension Unit141
To Dismantle, Inspect and Assemble Coil Spring Rear Suspension Unit141
To Install Coil Spring Rear Suspension Unit142
To Remove and Install Rear Hub142
To Check and Inspect Rear Hub143
To Assemble and Install Rear Hub143
Brakes Specifications145
Brakes Troubleshooting145
To Remove and Install Master Cylinder148
To Dismantle Master Cylinder149
To Assemble Master Cylinder149
To Clean and Inspect Master Cylinder149
Front Disc Brake Assembly150
To Remove and Install Brake Pads150
To Overhaul Caliper151
To Remove and Install Brake Disc153
To Adjust Rear Brakes154
Rear Drum Brake Assembly154
To Remove and Dismantle Rear Drum Brake154
To Assemble and Install Rear Drum Brake155
To Check Operation of Brake Servo Unit156
To Test One Way Check Valve156
To Remove and Install Servo Unit157
To Adjust Handbrake157
To Remove and Install Handbrake Cables157
To Remove and Install Proportioning Valve159
To Adjust Hill Holder Valve(HHV)159
To Remove and Install Hill Holder Valve159
To Bleed Hydraulic System160
Electrical System Specifications161
Battery and Charging System Troubleshooting161
Battery and Starting System Troubleshooting163
Lighting System Troubleshooting163
Turn Signal Lamp Troubleshooting164
Ignition System Troubleshooting164
Test Equipment and some Applications165
Battery Maintenance166
To Remove and Install Battery167
To Clean Battery Case167
Alternator167
To Test Battery167
To Test Alternator on Vehicle168
To Remove and Install Alternator168
To Dismantle Alternator168
To Clean Alternator Parts169
To Check and Test Alternator Component Parts169
To Assemble Alternator170
External Voltage Regulator170
Starter Motor171
Starter Motor Test on Vehicle171
To Remove and Install Starter Motor172
To Dismantle Starter Motor172
To Check and Inspect Starter Motor173
To Assemble Starter Motor174
Breaker Point Distributor174
To Remove and Install Breaker Point Distributor175
To Dismantle Breaker Point Distributor175
To Clean and Inspect Distributor176
To Assemble Distributor176
Electronic Distributor Description177
To Remove and Install Electronic Distributor177
To Dismantle Electronic Distributor Description178
To Check and Inspect Electronic Distributor Description179
To Assemble Electronic Distributor Description180
Switches and Controls181
Ignition Switch181
Combination Switch181
Headlamp Switch181
Wiper/Washer Switch182
Heater Fan Switch182
Rear Demister Switch182
Rear Wiper/Washer Switch182
Stop Lamp Switch183
Reverse Lamp Switch - Manual Transaxle Models183
Handbrake Warning Lamp Switch183
Courtesy Lamp Door Switch183
Courtesy Lamp Tailgate Switch184
To Remove and Install Steering Wheel and Horn Control184
To Remove and Install 1979-1984 Instrument Cluster and All Utility Models184
To Remove and Install 1985-1987 Sedan Instrument Cluster and Station Wagon Models185
To Remove and Install Speedometer Cable186
To Remove and Install 1979-1984 Heater Blower Motor186
To Remove and Install 1985-1987 Sedan Heater Blower Motor and Station Wagon Models186
Lamp Units187
Park Lamp - Twin Headlamp Models187
Combination Lamp - Single Headlamp Models187
Front Turn Signal Lamp - Bumper Mounted190
Rear Combination Lamp190
Front Turn Signal Repeater Lamp - Fender Mounted190
Number Plate Lamp191
Courtesy Lamp192
Windscreen Wipers193
To Renew Wiper Blades193
To Remove and Install Wiper Arms193
To Remove and Install Wiper Motor193
To Renew Wiper Blade194
To Remove and Install Wiper Arm194
To Check and Renew Fuse195
To Check and Renew Fusible Link195
How to Wire up a Trailer196
Wiring Diagram for 1979-1981 Models198
Wiring Diagram for 1982 Models200
Wiring Diagram for 1983-1984 and Late Utility Models202
Wiring Diagram for 1985-1986 Sedan and Station Wagon Models204
Wiring Diagram for 1987 Models206
Wiring Diagram for Auto 4WD System 1983-1986 Models208
Wiring Diagram for Power Windows 1983-1984 Models209
Wiring Diagram for Power Windows and Door Locks 1985-1986 Models210
Fuse Box Wiring Diagram for 1979-1981 Models211
Fuse Box Wiring Diagram for 1982 Models211
Fuse Box Wiring Diagram for 1983 Models212
Fuse Box Wiring Diagram for 1984 Models212
Fuse Box Wiring Diagram for 1985 Models212
Fuse Box Wiring Diagram for 1986 Models213
Fuse Box Wiring Diagram for 1987 Models213
Emission Control214
Positive Crankcase Ventilation (PCV) System214
To Service the PCV System214
To Check Operation of PCV System214
Evaporative Control System215
To Test Two Way Evaporative Control System Valve215
To Test Charcoal Canister215
To Test Two Port Thermal Vacuum Valve216
To Test Three Port Thermal Vacuum Valve216
To Test Fuel Bowl Ventilation System216
Air Preheat System219
To Check Air Preheat System Operation219
Exhaust Gas Recirculation (EGR) System220
To Test EGR Valve221
To Test Speed Switch Solenoid Valve222
Coasting By-Pass System222
To Check Coasting By-Pass System Operation222
Air Injection System223
Reed Valve223
Catalytic Converter System224
Body Components225
Windscreen and Rear Glass225
Front Doors225
Interior Handles and Trim Panels225
Door Glass226
Window Regulator226
To Adjust Door Glass227
Remote Control and Door Lock227
Exterior Door Handle and Lock Cylinder227
Lock Striker228
Exterior Mirror228
To Remove and Install Engine Bonnet231
To Remove and Install Luggage Compartment Lid - Sedan and Coupe232
To Remove and Install Lid Lock and Lock Cylinder233
To Remove and Install Tailgate - Station Wagon233
To Remove and Install Lock, Lock Cylinder and Outer Handle234
To Remove and Install Tailgate - Utility235
To Remove and Install Tailgate Locks235
To Remove and Install Radiator Grille236
To Remove and Install Centre Console236
Vehicle Cleaning236
Cleaning the Exterior236
General Cleaning of Vinyl Upholstery and Trim237
To Remove Stubborn Stains on Vinyl Upholstery and Trim237
Cleaning Cloth Trim238
Body Repairs Introduction239
Body Repairs Safety239
Body Repairs Tools239
Body Repairs Equipment241
Body Repairs Materials242
Rust Repairs244
How to Repair Rust Damage Using Plastic Body Fillers244
To Repair Rust Damage244
How to Repair Rust Holes Using a Fill-In-One Type Product245
How to Repair Rust Holes Using Soldered Metal Patch246
Panel Damage247
Working Metal247
How to Use Slide Hammer247
Hand Bumping248
Planishing248
Hot Shrinking249
Panel Replacement250
How to Use Plastic Body Fillers251
Fundamentals of Spray Painting252
Selecting an Air Compressor252
Pressure Regulator/Filter252
Air Hoses252
Spray Guns253
How to Use a Spray Gun253
Painting with Aerosols254
Brush Touching255
Types of Paint255
Removing Exterior Trim256
Washing the Vehicle256
Paint Stripping256
Spray Painting258
Masking258
To Prepare the Surface for the Primer/Surfacer258
To Apply the Primer/Surfacer258
To Apply the Color Coats259
Fluid Leaking from Needle Gland Packing260
Fluid Leaking from Front of Gun260
Air Leaking from Front of Gun260
Intermittent Spray260
Paint Difficulties - Causes and Cures261
Blushing262
Chalking of Lacquers262
Compounding too Early262
Crazing, Cracking or Checking262
Orange Peel263
Overspray - Dry Spray263
Pinholing263
Shrinking and Splitting of Primer/Surfacer265
Wrinkling265
Finishing off Painting265
Hand Compounding265
Machine Compounding266
Conversion Tables267
Engine: Contents269
Specifications and Service Data270
Entire Engine Specifications270
Lubrication System Specifications271
Engine Oil Flow Diagram272
Engine Oil Cooling System272
Engine Cooling System Specifications274
Coolant275
Coolant Flow Diagram275
Automatic Transmission Fluid Cooling System276
Engine Service Data277
Crankcase Component Parts282
Cylinder Heads Parts283
Flywheel Housing and Fittings Parts284
Crankshaft and Related Parts285
Valve System Parts286
Valve Rocker Parts287
Emission Control Equipment Parts288
Intake Manifold Parts293
Oil Pan, Oil Filler Duct and Fittings297
Oil Pump Parts298
Engine Cooling System Parts299
Water Pump and Relative Fittings Parts300
Exhaust System Parts302
Turbocharger Parts304
On-Car Services305
Ignition Timing305
Engine Compression305
Intake Manifold Vacuum306
Hot Air Control System307
Engine Idle Speed and Idle Mixture308
Engine Idle Speed and Idle Mixture Troubleshooting309
Hydraulic Valve Lifter311
Engine Radiator311
Engine Exhaust System312
Oxygen(O2) Sensor313
Removal and Installation of Crank Pulley314
Turbocharger System Inspection314
Dismounting and Remounting315
Engine Inspection and Test321
Non-TURBO Vehicle Engine Removal322
TURBO Vehicle Engine Removal323
Engine Disassembly325
Intake Manifold Assembly325
Valve Rocker Assembly325
Cylinder Head/Crankshaft325
Engine Inspection and Adjustment326
Engine Assembly342
Engine Installation349

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Subaru Leone 1979 - To Remove and Install Kickdown Solenoid; To Remove and Install Vacuum Modulator; To Remove and Install Four Wheel Drive Transfer Solenoid

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