Resonator Diagram Muffler Ford Escape 2012

Page 987 3) Tighten two new self-locking nuts. Tightening torque: 175 Nm (17.8 kgf-m, 129 ft. lbs.) Page 509 Crankshaft Position, Camshaft Position And Knock Sensors Page 4932 R72-R145 R148 Page 2993 B136-B141 Page 4897 Starter Motor: Testing and Inspection Testing STARTER MOTOR CIRCUIT CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode and Inspection Mode. Wiring Diagram Service and Repair Control Module: Service and Repair Transmission Control Module (TCM) REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the lower cover and then disconnect the connector. 3) Remove the knee bolster. 4) Disconnect the connectors from TCM. 5) Remove the TCM. INSTALLATION 1) Install the TCM. 2) Connect the connectors to TCM. 3) Install in the reverse order of removal. 4) If replacing the TCM, execute the advance operation of learning control promotion. Page 6284 B17-B20 Page 801 F21-F61 Page 6668 Electrical Component Location Page 2827 Engine Control Module: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 5069 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 4516 F21-F61 Page 5745 Antitheft Relay: Service and Repair INTERRUPT RELAY REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the audio instrument. 3. Remove the interrupt relay. INSTALLATION Install in the reverse order of removal. Page 1260 Tire Monitoring System: Technical Service Bulletins Tire Monitor System - Valve Stem Cap Information 05 tire valve stem caps This is to remind you of the importance of the tire valve stem cap. These caps need to be installed on every tire, regardless if the vehicle is equipped with TPMS or not. Without these caps, dirt and moisture can interfere with the proper sealing of the tire valve stem. This can result in a gradual loss of tire pressure or interfere with adding air to the tire. In turn this may result in a TPMS lamp coming on and an inconvenienced customer. The cap is gray in color, part # S0A342LT09. The accessory SPT valve stem cap may also be used and will not affect the TPMS operation. Page 985 CAMBER ^ Inspection 1) Place the front wheel on turning radius gauge. Make sure ground contacting surfaces of front and rear wheels are set at the same height. 2) Set the adapter into the center of wheel, and then install the wheel alignment gauge. Page 2325 B134-B136 Page 6530 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 4818 CAUTION: When holding the rotor with a vise, place aluminum plates or wooden pieces on the vise jaws to prevent rotor from damage. 5. Remove the ball bearing as follows. 1. Remove the bolt, and then remove the bearing retainer. 2. Firmly install an appropriate tool (such as a fit socket wrench) to bearing inner race. 3. Push the ball bearing off the front cover using a press. 6. Remove the bearing from rotor using a bearing puller. Page 5067 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 6697 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 3280 Fuel Injector: Service and Repair Intake Manifold (Part 1) Intake Manifold (Part 2) Page 2812 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Vehicle - Recommended Fluids/Chemicals Drum Brake System: Technical Service Bulletins Vehicle - Recommended Fluids/Chemicals NUMBER: 01-067-08 DATE: 09/09/08 APPLICABILITY: All Subaru Vehicles SUBJECT: Recommended Materials Introduction Page 231 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 1493 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Locations Electrical Component Location Page 569 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 2964 The list above is of O2 Sensor related DTCs. (This list is for example only. Refer to the applicable service manual for a complete list of DTCs.) Note: When the DTCs for O2 sensor are stored in memory, do not replace the A/F sensor. Page 2349 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Capacity Specifications Differential Fluid - A/T: Capacity Specifications Automatic Transmission Differential Gear Oil Fluid Capacity ...................................................................................................................................... ......................... 1.2 liter (1.3 US qt, 1.1 Imp qt) Fluid Type API GL-5 (See figure above for applicable viscosity) Page 4570 7. Expand the pads and push piston back. 8. Remove the pad and shim. 3. 17 INCH TYPE 1. Set the vehicle on a lift. 2. Loosen the wheel nuts. 3. Lift-up the vehicle, and then remove the rear wheel. 4. Remove the clip. 5. Remove the pad pins and cross spring. Testing and Inspection Evaporative Check Valve: Testing and Inspection INSPECTION Make sure the hoses are not cracked or loose. Page 601 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 6350 B128-B134 Specifications Wheel Bearing: Specifications Subaru does not specify a wheel bearing grease. Testing and Inspection Wiper Blade Heater Switch: Testing and Inspection WIPER DEICER SWITCH INSPECTION Move wiper deicer switch to each position and check continuity between terminals. If NG, replace the switch. Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 4339 VTD model INSTALLATION Install in the reverse order of removal. NOTE: Replace with a new O-ring. Tightening torque: 7 Nm (0. 7 kgf-m, 5. 1 ft. lbs.) Page 4300 3) Separate the rod and inner boot. 4) Remove the snap ring from the stay. 5) Separate the gear shift lever and the stay. 6) Remove the boot, bushing and snap ring from gear shift lever. 7) Remove the spring pin, and then remove the bushing and snap ring. Page 4529 Disclaimer Page 1496 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 7180 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Engine Controls - DTC P0607 Diagnostic Information Engine Control Module: All Technical Service Bulletins Engine Controls - DTC P0607 Diagnostic Information NUMBER: 11-91-08 DATE: 12/05/08 APPLICABILITY: 2004-2008MY Impreza 2004-2008MY Forester 2005-2008MY Legacy/Outback 2006-2007MY Tribeca SUBJECT: DTC P0607 Control Module Performance Introduction The purpose of the bulletin is for information purposes when diagnosing DTC P0607. The following checks and information is in addition to what is listed in the Subaru Service Manual. This information is to be used in conjunction with the service manual. Repair Procedure/Information Additional items to check: ^ Rapid drop of voltage from a dead battery ^ Loose battery terminals ^ Loose ECM ground terminal ^ A short or open to the power or ground circuit If the malfunction criteria are met, the CEL will illuminate, the vehicle will go into fail safe and the throttle valve opening will be fixed at 6°. Fail safe will recover to normal mode if the ECM judges the criteria "OK" at the time of the next engine start. The CEL will not turn off until the "OK" driving cycle is completed 3 times in a row. The judgment is decided by the ECM to keep the CEL On or Off at the time the ignition switch is turned from ON to OFF. The ECM keeps DTC P0607 in memory even after the indicator light goes out. Therefore, it is important to erase memory after the repair is completed. Detail list of applicable model and engine type. Locations Air Bag Control Module: Locations Electrical Component Location Page 3045 5) Disconnect the inhibitor switch connector. 6) Remove the inhibitor switch connector from stay. 7) Lift-up the vehicle. 8) Remove the front and center exhaust pipes. 9) Remove the snap pin and washer from range select lever. 10) Remove the plate assembly from transmission case. 11) Remove the bolts. Page 2694 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Diagram Information and Instructions Seat Belt Reminder Lamp: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 6405 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 2229 Page 456 R58-R69 Page 7082 F61-R47 Page 3332 3. Connect the evaporation hose to the evaporation pipe. 4. Install the evaporation pipe to the fuel filler pipe. Page 3588 B17-B20 Page 3110 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 4028 Shifter A/T: Service Precautions CAUTION ^ Wear work clothing, including a cap, protective goggles, and protective shoes during operation. ^ Remove contamination including dirt and corrosion before removal, installation or disassembly. ^ Keep the disassembled parts in order and protect them from dust and dirt. ^ Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly, and replacement. ^ Use SUBARU genuine grease etc. or the equivalent. Do not mix grease etc. with that of another grade or from other manufacturers. ^ Be sure to tighten fasteners including bolts and nuts to the specified torque. ^ Place shop jacks or rigid racks at the specified points. ^ Apply grease onto sliding or revolution surfaces before installation. ^ Before installing O-rings or snap rings, apply sufficient amount of grease to avoid damage and deformation. ^ Before securing a part on a vise, place cushioning material such as wood blocks, aluminum plate, or shop cloth between the part and the vise. ^ Before disconnecting electrical connectors, be sure to disconnect the ground cable from battery. Page 2933 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 2290 F61-R47 Page 3614 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 989 FRONT WHEEL TOE-IN ^ Inspection Toe-in: 0±3 mm (0±0. 12 inch) (tolerance) 1) Set the toe-in gauge to rear sides of right and left front tires at height corresponding to center of spindle. 2) Mark each right and left tires at height corresponding to center of spindle and measure the distance "A" between marks. 3) Move the vehicle forward to rotate wheels 1800. NOTE: Whenever rotating the wheels, drive the vehicle forward. 4) Measure the distance "B" between right and left marks. Toe-in can then be obtained by the following equation: ^ Adjustment 1) Make sure that the right and left steering angles are within specified value. 2) Loosen the right and left side steering tie-rods lock nuts. 3) Turn the right and left tie rods equal amounts until the toe-in is at the specification. Toe-in: 0±2 mm (0±0.08 inch) (adjustment standard) Both the right and left tie-rods are right-hand threaded. To increase toe-in, turn both tie-rods clockwise equal amounts (as viewed from inside of the vehicle). 4) Tighten the tie-rod lock nut. Tightening torque: Non- turbo model: 83 Nm (8.5 kgf-m, 61.5 ft. lbs.) Locations System Relay: Locations Main Fuse Box (M/B) Testing and Inspection Fog/Driving Lamp Bulb: Testing and Inspection Front Fog Light Bulb INSPECTION 1. Visually check the bulb for blow out. 2. Check the bulb specification. 3. If NG, replace the bulb with a new one. Page 6343 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 5195 19) Install the dust cover. Remove the vinyl tape. 20) Temporarily install the rack, and then operate it from lock to lock two or three times to make it fit in. Remove the grease blocking air vent hole. CAUTION: If operating the rack from lock to lock without installing tie-rod, it may damage the oil seal. Always install the tie-rods LH and RH. 21) Apply a coat of grease to the sliding surface of seat pad, sleeve and seating surface of spring, and then insert sleeve into steering body. Charge the adjusting screw with grease, and then insert the spring into adjusting screw and install on steering body. Page 5995 5. Install the hood duct with clip (A) and seven bolts. Tightening torque: 1.0 N.m (0.1 kgf-m, 0.74 ft-lb) 6. Install the intercooler water spray hose. (STI model) Page 2584 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the bolt which installs the crankshaft position sensor to cylinder block. 3. Remove the crankshaft position sensor, and disconnect the connector from it. INSTALLATION Install in the reverse order of removal. Page 6373 - Do not allow water or oil to come in contact with the connector terminals. Do not touch the connector terminals. - Either of the airbag modules for driver, passenger or side, or pretensioner must not be disassembled. - The removed front seat with the airbag module must be kept at least 200 mm (8 in) away from walls and other objects. - Do not use the airbag or pretensioner parts from other vehicles. Always replace defective parts with new parts. - Never reuse a deployed airbag or pretensioner. - When painting or performing sheet metal work on the front part of the vehicle, including the front wheel apron, front fender, and front side frame, remove the front sub sensors and wire harness of the airbag system. Page 7229 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 4398 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 6454 B230-B283 Page 796 B134-B136 Specifications Valve Clearance: Specifications Valve clearance: STD Intake ............................................................................................................... ........................................................ 0.20 ± 0.02 mm (0.0079 ± 0.0008 inch) Exhaust ....................... ............................................................................................................................................. 0.35 ± 0.02 mm (0.0138 ± 0.0008 inch) Page 7423 Wiper Relay: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 2396 F21-F61 Page 618 B380-f6 Page 3382 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 2932 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 804 R72-R145 R148 Testing and Inspection Tailgate Release Handle: Testing and Inspection REAR GATE OUTER HANDLE INSPECTION 1. Inspect the rod for deformation. 2. Make sure the outer handle and cable move smoothly. Recall 07V043000: Occupant Sensor Wiring Harness Seat Occupant Sensor: Recalls Recall 07V043000: Occupant Sensor Wiring Harness MAKE/MODELS: MODEL/BUILD YEARS: Subaru/Forester 2006 Subaru/Impreza 2006 MANUFACTURER: Subaru of America, Inc. NHTSA CAMPAIGN ID NUMBER: 07V043000 MFG'S REPORT DATE: February 06, 2007 COMPONENT: Air Bags: Frontal POTENTIAL NUMBER OF UNITS AFFECTED: 7004 SUMMARY: On certain vehicles, the wiring harness for the air bag occupant detection system in the front passenger seat may have been pinched during production. Pinching of the wiring harness between the floor crossmember and the seat mounting bracket could result in a short circuit. CONSEQUENCE: The passenger's front air bag could become disabled and may not deploy in the event of a crash increasing the risk of injury to the seat occupant. Also an electrical short circuit could cause a fire. REMEDY: Dealers will inspect to see if the wiring had been incorrectly routed under the seat bracket. If so, the dealer will repair any damaged wiring, reroute and secure the wiring harness in the correct location, and re-calibrate the occupant detection system as necessary. The recall is expected to begin on or about March 5, 2007. Owners may contact Subaru at 1-800-782-2783. NOTES: Subaru recall No. WVC-13. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 6946 Trunk Lamp Switch: Testing and Inspection Trunk Room Light Switch TRUNK ROOM LIGHT SWITCH Measure the resistance between trunk room light switch terminals. Page 4811 Alternator: Testing and Inspection INSPECTION 1. DIODE CAUTION: Never use a mega tester (designed for reading high voltage) or any other similar instrument for this test; otherwise, the diodes may be damaged. 1. Checking positive diode Check for continuity between the diode lead and positive side heat sink. The positive diode is in good condition if resistance is 1 ohm or less only in the direction from the diode lead to heat sink. 2. Checking negative diode Check for continuity between the negative side heat sink and diode lead. The negative diode is in good condition if resistance is 1 ohm or less only in the direction from the heat sink to diode lead. 2. ROTOR 1. Slip ring surface Inspect the slip rings for contamination or any roughness on the sliding surface. Repair the slip ring surface using a lathe or sand paper. 2. Slip ring outer diameter Measure the slip ring outer diameter. If the slip ring is worn, replace the rotor assembly. Slip ring outer diameter: Standard: 22.7 mm (0.894 in) Limit: 22.1 mm (0.870 in) 3. Continuity test Page 4140 2) Remove the spring pin and lever. 3) Remove the clutch pedal and bushings. 4) Remove the stopper, clip, O-ring, rod S, and then remove the spring S and bushing S. Page 6460 R72-R145 R148 Page 2392 B136-B141 Page 1537 4. Remove the bolts which secure the power steering pump bracket. 5. Remove the power steering tank from the bracket by pulling it upward. 6. Place the power steering pump on the right side wheel apron. 12. Disconnect the emission hose (A) and connector (B) from the PCV hose assembly. Page 3399 B380-f6 Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 1903 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 2313 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 1474 B292-B317 Page 3232 Accelerator Pedal: Service and Repair Removal and Installation ACCELERATOR PEDAL REMOVAL: 1. Disconnect the ground cable from battery. 2. Disconnect the connector (A). 3. Remove the bolt (B) securing accelerator pedal assembly. INSTALLATION Install in the reverse order of removal. Tightening torque: 18 N-m (1.8 kgf-m, 13.0 ft-lb) Page 5900 Security System Locations Keyless Entry System Page 3261 F21-F61 Recall 07V043000: Occupant Sensor Wiring Harness Seat Occupant Classification Module - Air Bag: All Technical Service Bulletins Recall 07V043000: Occupant Sensor Wiring Harness MAKE/MODELS: MODEL/BUILD YEARS: Subaru/Forester 2006 Subaru/Impreza 2006 MANUFACTURER: Subaru of America, Inc. NHTSA CAMPAIGN ID NUMBER: 07V043000 MFG'S REPORT DATE: February 06, 2007 COMPONENT: Air Bags: Frontal POTENTIAL NUMBER OF UNITS AFFECTED: 7004 SUMMARY: On certain vehicles, the wiring harness for the air bag occupant detection system in the front passenger seat may have been pinched during production. Pinching of the wiring harness between the floor crossmember and the seat mounting bracket could result in a short circuit. CONSEQUENCE: The passenger's front air bag could become disabled and may not deploy in the event of a crash increasing the risk of injury to the seat occupant. Also an electrical short circuit could cause a fire. REMEDY: Dealers will inspect to see if the wiring had been incorrectly routed under the seat bracket. If so, the dealer will repair any damaged wiring, reroute and secure the wiring harness in the correct location, and re-calibrate the occupant detection system as necessary. The recall is expected to begin on or about March 5, 2007. Owners may contact Subaru at 1-800-782-2783. NOTES: Subaru recall No. WVC-13. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 2758 B54-B127 Page 3601 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 6838 B3-B12 Testing and Inspection Fog/Driving Lamp Relay: Testing and Inspection FRONT FOG LIGHT RELAY Measure the front fog light relay resistance between terminals when connecting terminal No. 4 to battery positive terminal and terminal No. 3 to battery ground terminal. Page 2747 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 460 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 5616 - When painting or performing sheet metal work on the side of the vehicle, including the side sill, center pillar, and front and rear doors, remove the side airbag sensors and wire harness of the airbag system. - When storing a removed airbag module, do not place any objects on it or pile airbag modules on top of each other. If the airbag inflates for some reason when it is placed with its pad side facing downward or under any object, a serious accident may result. Page 4196 12) Extract the companion flange using ST. ST 399703600 PULLER ASSY 13) Remove the oil seal using ST. ST 398527700 PULLER ASSY 14) Fit a new oil seal using ST. ST 498447120 INSTALLER 15) Install the companion flange. NOTE: Use a plastic hammer to install the companion flange. 16) Apply Lock Tite to the bolt threads of drive pinion shaft, and the seating surface of new self-locking nut. Lock Tite: THREE BOND 1324 (Part No. 004403042) 17) Tighten the self-locking nut within the specified torque range so that the preload of companion flange becomes the same as that before replacing oil seal. Except STI model Page 4899 Step 8 - 14 Page 522 B17-B20 Page 315 B3-B12 Page 3302 Fuel Pump Relay: Service and Repair Fuel Pump Relay REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the passenger's side front side sill cover. 3. Remove the bolt which holds the relay bracket on the body. 4. Disconnect the connectors from the main relay. 5. Remove the main relay from the mounting bracket. INSTALLATION Install in the reverse order of removal. Page 1167 Fluid - A/T: Service and Repair A/T Condition Check Automatic Transmission Fluid CONDITION CHECK NOTE: When replacing ATF, check the inside condition of the transmission body by inspecting the drained ATF. Page 1374 Piston: Service and Repair Cylinder Block CYLINDER BLOCK Page 6578 F61-R47 Service and Repair Headliner: Service and Repair Roof Trim A: Removal Caution: When removing the clip, use great car not to damage the roof trim 1. Sedan Model 1) Disconnect the ground terminal from battery. 2) Remove the sunroof switch (Model with sunroof) 3) Remove the spot map light. 4) Remove the room light. 5) Remove the sun visor and hook on right or left side or on both sides. 6) In the case of models with sunroof, remove the sunroof weather strip. Page 3722 B292-B317 Page 5225 DISASSEMBLY 1. Using the following table as a guide, verify the type of bushings. 2. Select the ST according to type of bushings used. Bushing ST: INSTALLER & REMOVER SET Bushing A927700000 Bushing B927690000 Bushing C927700000 3. Using the ST, press the bushing out of place. ASSEMBLY 1. Use the same ST that was used during disassembly. 2. If it is difficult to press the bushing into trailing link, apply water-diluted TIRE LUBE to the inner surface of ST as a lubricant. Specified lubricant: TIRE LUBE: water = 1: 3 Page 5322 Air Duct: Service and Repair Heater Vent Duct Heater Vent Duct REMOVAL 1. Remove the instrument panel. 2. Remove the screws. 3. Remove the heater vent duct. INSTALLATION Install in the reverse order of removal. Page 746 Disclaimer Page 4592 Page 3573 Ignition Coil: Service and Repair Ignition Coil and Ignitor Assembly REMOVAL Direct ignition type has been adopted. Refer to the "Spark Plug Removal" for removal procedure. INSTALLATION Install in the reverse order of removal. Tightening torque: 16 N.m (1.6 kgf-m, 11.7 ft-lb) Testing and Inspection Door Switch: Testing and Inspection DOOR SWITCH Measure the resistance between door switch terminals. Page 1049 2. Remove the belt idler No. 2. 3. Remove the automatic belt tension adjuster assembly. INSTALLATION 1. AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER 1. Preparation for installation of automatic belt tension adjuster assembly: CAUTION: ^ Always use a vertical type pressing tool to move the adjuster rod down. ^ Do not use a lateral type vise. ^ Push the adjuster rod vertically. ^ Press-in the push adjuster rod gradually taking more than 3 minutes. ^ Do not allow press pressure to exceed 9,807 Nm (1,000 kgf, 2,205 ft. lbs.). ^ Press the adjuster rod as far as the end surface of cylinder. Do not press the adjuster rod into the cylinder. Doing so may damage the cylinder. ^ Do not release the press pressure until stopper pin is completely inserted. 1. Attach the automatic belt tension adjuster assembly to the vertical pressing tool. 2. Slowly move the adjuster rod down with a pressure of 165 Nm (16.8 kgf,37.1 ft. lbs.) or more until the adjuster rod is aligned with the stopper pin hole in the cylinder. Locations Cruise Control Indicator Lamp: Locations Non-Turbo Model Testing and Inspection Horn Switch: Testing and Inspection INSPECTION Measure the resistance between horn switch terminal and airbag module bracket. Page 7232 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 2851 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 3102 B292-B317 Page 1372 5. Calculate the clearance between cylinder and piston. NOTE: Measurement should be performed at a temperature of 20°C (68°F). Cylinder to piston clearance at 20°C (68°F): Standard -0.010 - 0.010 mm (-0.0004 - 0.0004 inch) Limit 0.030 mm (0.0012 inch) 6. Boring and honing 1. If the value of taper, out-of-roundness, or cylinder-to-piston clearance measured exceeds the limit or if there is any damage on the cylinder wall, reboring it to use an oversize piston. CAUTION: ^ When any of the cylinders needs reboring, all other cylinders must be bored at the same time, and use oversize pistons. ^ Do not perform boring on one cylinder only, nor use an oversize piston for one cylinder only. 2. If the cylinder inner diameter exceeds the limit after boring and honing, replace the crankcase. NOTE: Immediately after reboring, the cylinder diameter may differ from its real diameter due to temperature rise. Thus, pay attention to this when measuring the cylinder diameter. Cylinder enlarging (boring) limit (dia): To 100.005 mm (3.937 inch) PISTON AND PISTON PIN 1. Check the pistons and piston pins for damage, cracks, and wear and the piston ring grooves for wear and damage. Replace if defective. 2. Measure the piston-to-cylinder clearance at each cylinder. If any of the clearances is not within specification, replace the piston or bore the cylinder to use an oversize piston. 3. Make sure that the piston pin can be inserted into the piston pin hole with a thumb at 20°C (68°F). Replace if defective. Standard clearance between piston pin and hole in piston: Standard 0.004 - 0.008 mm (0.0002 0.0003 inch) Limit 0.020 mm (0.0008 inch) Diagram Information and Instructions Parking Lamp: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 2255 R58-R69 Page 3282 5. Remove the power steering tank from the bracket by pulling it upward 6. Place the power steering pump on the right side wheel apron. 8. Remove the fuel pipe protector RH. 9. Disconnect the connector from the fuel injector. Page 4928 B380-f6 Page 4556 Brake Pad: Specifications SERVICE LIMIT Front brake 15" .................................................................................................................................... ......................................................................... 1.5 mm (0.059 in) 16" ................................................ ............................................................................................................................................................. 1.5 mm (0.059 in) 17" .......................................................................................................................... ................................................................................... 1.2 mm (0.047 in) Rear brake 14" .................................................................................................................................... ......................................................................... 1.5 mm (0.059 in) 15" ................................................ ............................................................................................................................................................. 1.5 mm (0.059 in) 17" .......................................................................................................................... ................................................................................... 1.2 mm (0.047 in) Page 1318 Camshaft: Service and Repair Camshaft CYLINDER HEAD AND CAMSHAFT Page 2458 B230-B283 Page 4728 Electrical Component Location Locations Electrical Components Location Front Washer Nozzle Windshield Washer Spray Nozzle: Testing and Inspection Front Washer Nozzle Front Washer Nozzle INSPECTION - Make sure the nozzle and hose are not clogged. - Make sure the hose is not bent. Page 877 Solenoid Valve, Actuator, Emission Control System Parts And Ignition System Parts (Part 5) Page 5064 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 6792 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Locations Fuel Temperature Sensor: Locations Page 4741 Electrical Component Location Page 2742 Page 133 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 915 Transmission Speed Sensor: Service and Repair Torque Converter Turbine Speed Sensor Torque Converter Turbine Speed Sensor REMOVAL When removing the torque converter turbine speed sensor, refer to "Front Vehicle Speed Sensor". INSTALLATION When installing the torque converter turbine speed sensor, refer to "Front Vehicle Speed Sensor" Page 5790 For vehicles under the Basic New Car Limited Warranty period, this repair may be claimed using the table. Disclaimer Page 2032 R58-R69 Page 6741 Fog/Driving Lamp Bulb: Service and Repair FRONT FOG LIGHT BULB REMOVAL 1. Disconnect the ground cable from battery. 2. Remove three clips, and then turn over the lower mud guard. 3. Remove the harness connector. 4. Remove the back cover (A). 5. Remove the spring retainer, and then detach the fog light bulb. INSTALLATION Install in the reverse order of removal. Page 4699 B292-B317 Page 900 4) Using the ST, tighten the bolts of inhibitor switch. ST 499267300 STOPPER PIN 5) Install the select cable to range select lever. 6) Install the plate assembly to transmission. 7) Install the washer and snap pin to range select lever. 8) Install the front and center exhaust pipes. (Non-turbo model) 9) Install the center exhaust pipe. (Turbo model) 10) Lower the vehicle. 11) Install the inhibitor switch connector from stay. 12) Connect the inhibitor switch connector. Page 478 Crankshaft Position, Camshaft Position And Knock Sensors Page 6133 B54-B127 Page 4271 Non-turbo model ^ Turbo model Turbo model 4) Replace defective parts. Page 4541 6. Position the boot in grooves on cylinder and piston. 7. Install the boot ring. Be careful not to scratch the boot. 3. 17 INCH TYPE 1. Clean the caliper body interior using brake fluid. 2. Apply a coat of brake fluid to the piston seal, and then install the piston seal in groove on caliper body. 3. Apply a coat of brake fluid to the entire inner surface of cylinder and outer surface of piston. 4. Apply a coat of specified grease to the boot and install it in the groove on piston. Grease: NIGLUBE RX-2 (Part No. K0779GA 102) 5. Insert the piston into cylinder. CAUTION: Do not force the piston into cylinder. 6. Position the boot in grooves on cylinder and piston. Page 3771 B230-B283 Page 3064 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 1211 Refrigerant: Testing and Inspection Refrigerant Leak Check INSPECTION 1. Operate the A/C system for approx. 10 minutes, and confirm that the high-pressure side shows at least 690 kPa (7.03 kg/ sq cm, 100 psi). Then stop the engine to start the leak test. 2. Starting from the connection between the high pressure pipe and evaporator, check the system for leaks along the high-pressure side through the compressor. The following items must be checked thoroughly. 3. Check the joint and seam between the pressure switch (dual pressure switch) and high-pressure pipe. 4. Check the connections between the condenser and pipes, and welded joints on the condenser. The leak tester may detect the oil on the condenser fins as a leak. 5. Check the joint between the compressor and hoses. 6. Check the machined area of compressor and other joints on the compressor. 7. Check the compressor shaft seal at the area near the center of compressor clutch pulley. Some shaft seals show a slight amount of leakage about 3 g (0.1 oz) per year. This is not a problem. 8. Starting from the connection between the low pressure pipe and evaporator, check the system for leakage along the low-pressure side through the compressor. The following items must be checked thoroughly. Connection between two parts - Connection between the pipe and plate 9. Visually check the rubber area of the flexible hose for cracks. Check the entire length of the flexible hose, especially the connection with the metal hose end. CAUTION: Carefully check the external surface of hoses and tubes at approx. 25 mm (0.98 in) per second. 10. Disconnect the drain hose from the heater case, and check the hose end for at least 10 seconds. After the test is finished, reconnect the drain hose. Diagram Information and Instructions Seat Heater: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. A/T Controls - DTC P0851/P0852 Set Neutral Safety Switch: Customer Interest A/T Controls - DTC P0851/P0852 Set NUMBER: 16-68-06 DATE: 10/09/06 APPLICABILITY: 2005~06MY Legacy, Outback, Impreza and Forester Vehicles Equipped with 4EAT SUBJECT: Diagnostic procedures for P0851/P0852 INTRODUCTION The purpose of this bulletin is to assist when diagnosing P0851 (Neutral Switch Input Circuit Low) and P0852 Neutral Switch Input Circuit High). If you encounter a vehicle with P0851 and/or P0852, use the following repair procedure. REPAIR PROCEDURE/INFORMATION Using the Subaru Select Monitor, check for diagnostic trouble codes stored in memory. If P0851 and/or P0852 are stored in memory, adjust the inhibitor switch and select cable. Note: Refer to the applicable Subaru Service Manual found on the STIS web-site for component removal to gain access to the inhibitor switch and select cable. It is critical that the following adjustments are performed correctly. Adjustment for inhibitor switch 1) Set the select lever to "N" range. 2) Loosen the three inhibitor switch securing bolts. 3) Insert ST (special tool) 499267300 Stopper Pin as vertical as possible into the holes in the inhibitor switch lever and switch body. 4) Tighten the three inhibitor switch securing bolts then remove special tool. Tightening torque: 3.4 N-m (0.35 kgf-m, 2.5 ft-lb) Adjustment for select cable Testing and Inspection Wiper Switch: Testing and Inspection COMBINATION SWITCH (WIPER) INSPECTION - Inspect the continuity between each connector terminal If continuity is not as specified, replace the switch. - Intermittent operation inspection (inspection of wiper switch unit) 1. Position the voltage meter between the connector terminals No. 7 (+) and No. 2 (-). 2. Connect the battery positive lead to connector terminal No. 17 and the negative lead to connector terminals No. 2 and No. 16. 3. Turn the wiper switch to INT. 4. Disconnect the battery negative lead from connector terminal No. 16. 5. Connect the battery positive lead to connector terminal No. 16 for 5 seconds. 6. Connect the battery negative lead to connector terminal No. 16, and check the voltage between the connector terminals No. 7 (+) and No. 2 (-). Locations Sensor Page 4902 5. Disconnect the connector and terminal from starter. 6. Remove the starter from transmission. INSTALLATION Install in the reverse order of removal. Tightening torque: 50 N.m (5.1 kgf-m, 37 ft-lb) Page 6295 R72-R145 R148 Locations Electrical Components Location Page 5686 Impact Sensor: Adjustments IMPACT SENSOR ADJUSTMENT 1. CHECK IMPACT SENSOR 1. Remove the key from ignition switch. 2. Close all windows. 3. Close all the doors, trunk lid and rear gate. Leave open the front hood. 4. Press the LOCK button of the transmitter from outside vehicle. 5. Check that the security indicator light blinks twice within 0.5 seconds in 2 seconds cycle after 30 seconds. 6. Hit the windshield with your palm continuously and check the security alarm operates. Lift up the front hood approx. 12 cm (4.7 in), and then drop it off to check the operation of security alarm. 7. If NG, adjust the impact sensitivity. 2. IMPACT SENSITIVITY ADJUSTMENT 1. Connect the Subaru Select Monitor to data link connector. 2. Turn the ignition switch to ON. 3. Select {Impact Sensor} from the main menu. 4. Make a {ECU customizing}. - Sensitivity can be adjusted in 11 levels (0 to 10). - Initial setting is 5. - Smaller number means more sensitive. - Larger number means less sensitive. 5. Turn the ignition switch to OFF, and then remove the Subaru Select Monitor. NOTE: Set the sensor so as not to let the alarm on normal vibration (reclining to the door, hit the ball and etc.). - Set the sensor to operate the alarm with hitting the door or window glass, etc. continuously like a mayhem by robbery. - Ask the customer about parking situation for setting, because the alarm operate when the vibration not only the burglar but also the construction etc. Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 7242 F21-F61 Description and Operation Front Door Panel: Description and Operation Door Trim Shock absorbing pads installed to the backside of the front and rear door trims attenuate the impact due to a secondary collision. Page 7215 (1) Open the hood and remove the check valve. (2) Attach valve cushion (86634SA000) around the modified check valve (86634AG000) for soundproofing. Page 800 B380-f6 Locations Clutch Switch: Locations Non-Turbo Model Page 2463 R58-R69 Page 654 B128-B134 Page 2389 B54-B127 Page 4621 2. Remove the piston boot. 3. Place a wooden block in caliper body as shown in the figure to prevent the piston from jumping out and avoid being damaged. 4. Gradually supply compressed air via the installation hole of brake hose to force the piston out. 5. Remove the piston seal from caliper body cylinder. CAUTION: Do not damage the cylinder and piston seal groove. 3. 17 INCH TYPE 1. Remove the piston boots from each piston end. Page 2337 Vehicle Speed Sensor: Service and Repair Vehicle Speed Sensor REMOVAL 1) Disconnect the ground cable from battery. 2) Lift-up the vehicle. 3) Remove the front, center and rear exhaust pipes and muffler. ^ Non-turbo model ^ Turbo model 4) Disconnect the connector from vehicle speed sensor. 5) Turn and remove the vehicle speed sensor. INSTALLATION NOTE: ^ When the vehicle speed sensor is removed, discard it and replace with a new one. ^ Ensure the sensor mounting hole is clean and free of foreign matter. ^ Align the tip end of key with key groove on end of speedometer shaft during installation. 1) Hand tighten the vehicle speed sensor. 2) Tighten the vehicle speed sensor using suitable tool. Tightening torque: 5.9 Nm (0.6 kgf-m, 4.3 ft. lbs.) 3) Connect the connector to vehicle speed sensor. 4) Install the front, center and rear exhaust pipes and muffler. ^ Non-turbo model ^ Turbo model 5) Lower the vehicle. 6) Connect the battery ground cable to battery. INSPECTION The vehicle speed sensor can not be inspected as a single unit. Check if speedometer operates normally. If it does not operate normally, inspect the combination meter system. A/T Fluid Inspection Fluid - A/T: Service and Repair A/T Fluid Inspection Automatic Transmission Fluid INSPECTION NOTE: 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 engine to raise ATF temperature to 70 - 80°C (158 - 176°F) on SUBARU Select Monitor. 2) Make sure the vehicle is level. 3) After selecting all positions (P, R, N, D, 3, 2, 1), set the select lever in "P" range. Measure the ATF level with the engine idling for one or two minutes. 4) Make sure that ATF level is between the upper level and lower level at HOT side. If the level is below the lower level, check for leaks in the transmission. If there are leaks, it is necessary to repair or replace gasket, oil seals, plugs or other parts. CAUTION: ^ Use care not to exceed the upper limit level. ^ Filling of ATF to the upper level when the transmission is cold will result in overfilling of ATF, causing a transmission failure. 5) Check ATF level after raising ATF temperature to 70 - 80°C (158 - 176°F) by driving the distance of 5 to 10 km (3 to 6 miles) or by idling the engine. Page 6482 B17-B20 Locations Electronic Throttle Actuator Relay: Locations Solenoid Valve, Actuator, Emission Control System Parts And Ignition System Parts (Part 5) Page 798 B230-B283 Description and Operation Glove Compartment: Description and Operation GLOVE BOX - The glove box is provided with a damper that controls the glove box lid to open slowly. - It is also provided with night illumination that operates in connection with the lighting system. Page 4820 2. Remove cover B. 3. Separate the brush from connection to remove. 10. Remove the rectifier as follows. 1. Remove the bolts which secure the rectifier. 2. Remove the cover of terminal B. Page 6280 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Diagrams Window Glass: Diagrams Fixed Glass (Sedan Model) Locations Main Relay (Computer/Fuel System): Locations Main Fuse Box (M/B) Solenoid Valve, Actuator, Emission Control System Parts And Ignition System Parts (Part 5) Page 1798 F61-R47 Page 2692 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 2130 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 2202 R58-R69 Page 888 1. Connect the inhibitor switch harness connector to inhibitor switch. 2. Install the inhibitor switch to transmission case. 3. Move the range select lever to neutral position. 4. Using the ST, tighten the bolts of inhibitor switch. ST 499267300 STOPPER PIN Tightening torque: 3.5 Nm (0.36 kgf-m, 2.6 ft. lbs.) 5. Install the select cable to range select lever. 6. Install the plate assembly to transmission. Tightening torque: T: 25 Nm (2.5 kgf-m, 18 ft. lbs.) Page 2382 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 1500 B3-B12 Recall 07V043000: Occupant Sensor Wiring Harness Seat Occupant Sensor: Recalls Recall 07V043000: Occupant Sensor Wiring Harness MAKE/MODELS: MODEL/BUILD YEARS: Subaru/Forester 2006 Subaru/Impreza 2006 MANUFACTURER: Subaru of America, Inc. NHTSA CAMPAIGN ID NUMBER: 07V043000 MFG'S REPORT DATE: February 06, 2007 COMPONENT: Air Bags: Frontal POTENTIAL NUMBER OF UNITS AFFECTED: 7004 SUMMARY: On certain vehicles, the wiring harness for the air bag occupant detection system in the front passenger seat may have been pinched during production. Pinching of the wiring harness between the floor crossmember and the seat mounting bracket could result in a short circuit. CONSEQUENCE: The passenger's front air bag could become disabled and may not deploy in the event of a crash increasing the risk of injury to the seat occupant. Also an electrical short circuit could cause a fire. REMEDY: Dealers will inspect to see if the wiring had been incorrectly routed under the seat bracket. If so, the dealer will repair any damaged wiring, reroute and secure the wiring harness in the correct location, and re-calibrate the occupant detection system as necessary. The recall is expected to begin on or about March 5, 2007. Owners may contact Subaru at 1-800-782-2783. NOTES: Subaru recall No. WVC-13. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 4304 ^ Install the lock wire to the stay groove. ^ Bend the extra wire to same direction of lock wire winding. 11) Check the swing torque of rod in relation to the gear shift lever. 12) Check that there is no excessive play and that parts move smoothly. INSPECTION 1) Check the removed parts (bushing, cushion rubber, spacer, boot, stay, rod, etc.) for deformation, damage and wear. Repair or replace any defective part. ^ 5MT Page 3056 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Capacity Specifications Engine Oil: Capacity Specifications Oil capacity .......................................................................................................................................... .................................... 4.0 L (4.2 US qt, 3.5 Imp qt) Page 4009 B17-B20 Page 2909 9. Remove the fuel sub level sensor. INSTALLATION Install in the reverse order of removal. NOTE: Use a new gasket. 1. Ensure the sealing portion is free from fuel foreign particles before installation. 2. Tighten the nuts and bolts to specified torque the order as shown in the figure. Page 1359 Crankshaft: Tools and Equipment Subaru Crankshaft Socket - AST Tool # SU499987500 Subaru Crankshaft Socket AST tool# SU499987500 Page 2147 Camshaft Position Sensor: Locations Sensor (Part 1) Page 2806 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 4702 F61-R47 Page 3592 B136-B141 Page 6134 B128-B134 Page 5663 B134-B136 Page 6325 R72-R145 R148 Page 2284 B134-B136 Page 2686 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 1024 Spark Plug: Testing and Inspection INSPECTION Check the electrodes and inner and outer ceramic insulator of plugs, noting the type of deposits and the degrees of electrode erosion. 1. Normal: Brown to grayish-tan deposits and slight electrode wear indicates correct spark plug heat range. 2. Carbon fouled: Dry fluffy carbon deposits on insulator and electrode are mostly caused by slow speed driving in city, weak ignition, too rich fuel mixture and dirty air cleaner, etc. Page 5539 Air Bag Control Module: Testing and Inspection INSPECTION Check for the following, and replace damaged parts with new parts. - Control module, connector, and mounting bracket are damaged. - Airbag is deployed. - Side airbag is deployed. Rear Door Trim Rear Door Panel: Service and Repair Rear Door Trim REAR DOOR TRIM Door Trim REMOVAL CAUTION: Do not apply excessive force to the clip. Otherwise the clip may be broken. 1. Disconnect the ground cable from battery. 2. Insert the flat tip screw driver into A part of inner remote cover, and then remove the lower hook with turning screw driver. Remove the upper hook with pulling inner remote cover, and then remove the inner remote cover. Page 2550 Air Flow Meter/Sensor: Service and Repair Mass Air Flow and Intake Air Temperature Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the connector from mass air flow and intake air temperature sensor. 3. Remove the mass air flow and intake air temperature sensor. INSTALLATION Install in the reverse order of removal. Tightening torque: 1.7 N.m (0.17 kgf-m, 1.3 ft-lb) Page 5227 5. Turn the lateral link upside down. Press the ST plunger in opposite direction that outlined in the former procedure until bushing is correctly positioned in trailing link. INSPECTION Visually check the lateral links for damage or bends. Page 2360 B292-B317 Page 4647 15) Read values indicated on the pressure gauges and check if they meet the standard value. 16) After checking, remove the pressure gauges from caliper bodies. 17) Connect the air bleeder screws to RL and RR caliper bodies. 18) Bleed air from the brake system. CHECKING THE HYDRAULIC UNIT ABS OPERATION WITH BRAKE TESTER 1) In the case of non-turbo AT model, install a spare fuse with the FWD connector in the main fuse box to simulate FWD model. NOTE: The AWD circuit of MT and turbo AT model can not be disabled. 2) Prepare for operating the ABS sequence control. 3) Set the front wheels or rear wheels on the brake tester and set the select lever's position at "N" range. 4) Operate the brake tester. 5) Perform the ABS sequence control. 6) Hydraulic unit begins to work; and check the following working sequence. (1) The FL side performs decompression, holding and compression in sequence, and subsequently the FR side repeats the cycle. (2) The RR side performs decompression, holding and compression in sequence, and subsequently the AL side repeats the cycle. Page 1567 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 720 B128-B134 Page 2734 P Code List (Partial list) Side Airbag Sensor Impact Sensor: Testing and Inspection Side Airbag Sensor Side Airbag Sensor INSPECTION Check for the following, and replace damaged parts with new parts. - Mounting bracket of side airbag sensor or connector is damaged. - Side airbag is deployed. Page 2208 2. Connect the knock sensor connector. 3. Install the intercooler. 4. Connect the battery ground cable to battery. Combination Switch (Light) Combination Switch: Service and Repair Combination Switch (Light) COMBINATION SWITCH (LIGHT) REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the instrument panel lower cover. 3. Remove the screws which secure the upper column cover to lower column cover. 4. Remove the screws which secure the upper column cover. 5. Disconnect the connector from combination switch. 6 Remove the screws which secure the switch, and then remove the switch. INSTALLATION Install in the reverse order of removal. Page 4075 11) Remove the clamp, and then remove the shift lock solenoid. INSTALLATION Install in the reverse order of removal. INSPECTION Step 1 - Step 4 Page 7329 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 2915 6. Disconnect the pressure hose from fuel tank pressure sensor. INSTALLATION Install in the reverse order of removal. Page 4191 Fluid - Differential: Fluid Type Specifications Differential Fluid NON STI Grade ................................................................................................................................... .......................................................................................... GL-5 Viscosity .......................................... .............................................................................................................................................................. ........... 80W-90 STI Grade .................................................................................................................. ........................................................................................................... GL-5 Viscosity ......................... .............................................................................................................................................................. ............................. SAE 90 Page 140 Engine Control Module (ECM) I/O Signal (Part 6) Page 715 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 5413 Hose/Line HVAC: Service and Repair Hose and Tube REMOVAL CAUTION: - When disconnecting/connecting hoses, do not apply excessive force to them. Confirm that no torsion and excessive tension exists after installing. - Seal the disconnected hose with a plug or vinyl tape to prevent contamination from entering. 1. Disconnect the ground cable from battery. 2. Using the refrigerant recovery system, discharge refrigerant. 3. Remove the evaporator unit mounting bolt (A). 4. Remove the low-pressure hose attaching bolts (B). 5. Disconnect the low-pressure hose from evaporator unit. 6. Disconnect the low-pressure hose from compressor. 7. Remove the low-pressure hose from vehicle. 8. Remove the high-pressure hose attaching bolts (C). 9. Disconnect the high-pressure hose from compressor. 10. Disconnect the high-pressure hose from condenser. 11. Remove the high-pressure hose from vehicle. 12. Remove the high-pressure tube attaching bolt (D). 13. Remove the high-pressure tube from vehicle. INSTALLATION CAUTION: - When disconnecting/connecting hoses, do not apply an excessive force to them. Confirm that no torsion and excessive tension exists after installing. - Seal the disconnected hose with a plug or vinyl tape to prevent contamination from entering. 1. Install in the reverse order of removal. 2. Charge refrigerant. Tightening torque: T1: 7.4 N.m (0.75 kgf-m, 5.4 ft-lb) T2: 15 N.m (1.5 kgf-m, 10.8 ft-lb) Page 3131 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 5665 B230-B283 Description and Operation Trim Panel: Description and Operation Trunk Room Trim Trunk lid trims and trunk lid arm covers are used to improve the feel of material. Page 7322 2. Make sure the wiper rubber is securely fastened to the pull stopper (A). 2. RESIN TYPE Resin Type 1. Insert the wiper rubber through the claw (B). 2. Insert the wiper rubber top until it protrudes about 20 mm (0.79 in) from the stopper (D). Page 3603 Ignition Control Module: Testing and Inspection INSPECTION For inspection, refer to IGNITION CONTROL SYSTEM, Diagnostics for Engine Starting Failure. Service and Repair Heat Shield: Service and Repair HEAT SHIELD COVER REMOVAL 1. CENTER HEAT SHIELD COVER 1. Remove the rear exhaust pipe and muffler. - Non-turbo model - Turbo model and STI model 2. Remove the propeller shaft. 3. Remove the four bolts to remove center heat shield cover. (Except STI model) 4. Remove the four nuts and two clips to remove center heat shield cover. (STI model) 2. REAR HEAT SHIELD COVER 1. Remove the muffler. 2. Remove the four bolts to remove rear heat shield cover. Page 5083 F61-R47 Page 5431 Refrigerant Oil: Service and Repair Compressor Oil PROCEDURE NOTE: Before making repairs, conduct the oil return operation to return the compressor oil in circulation with the refrigerant to compressor. 1. Increase engine to 1,500 rpm. 2. Turn the A/C switch to ON. 3. Turn the temperature control switch to MAX COOL. 4. Put in RECIRC position. 5. Turn the blower control switch to HI. 6. Leave in this condition for 10 minutes. REPLACEMENT NOTE: - If a component is replaced, add an appropriate amount of compressor oil. - When replacing the compressor, the new compressor will already have the specified amount of oil in it. Install the new compressor after removing the same amount of oil that is remaining in the compressor removed. Replacement parts Amount of oil replenishment Evaporator 114 ml (3.9 US fl oz, 4.0 Imp fl oz) Condenser 7 ml (0.24 US fl oz, 0.25 Imp fl oz) Hose 1 ml (0.03 US fl oz, 0.04 Imp fl oz) Page 7042 F61-R47 Front Wiper Motor and Link Wiper Motor: Service and Repair Front Wiper Motor and Link FRONT WIPER MOTOR AND LINK REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the cowl panel. 3. Disconnect the connector of motor. 4. Remove the bolts to remove wiper link. 5. Remove the bolts and nuts to remove motor. INSTALLATION 1. Connect the battery ground cable to battery. 2. To confirm that the motor is at auto stop position, connect the harness to motor and turn the wiper switch ON/OFF once. 3. Disconnect the ground cable from battery. 4. Tighten the nut where rod (A) and link plate (B) is aligned in a straight line. 5. Install in the reverse order of removal. Tightening torque: Nm (kgf-m, ft-lb) T1: 6.0 (0.61, 4.4) T2: 20 (2.0, 14.5) Page 2892 Crankshaft Position, Camshaft Position And Knock Sensors Page 992 NOTE: Thrust angle refers to a mean value of right and left rear wheel toe angles in relation to the vehicle body center line. Vehicle is driven straight in the thrust angle direction while swinging in the oblique direction depending on the degree of the mean thrust angle. Thrust angle: r = (a - B)/2 a: Right rear wheel toe-in angle B: Left rear wheel toe-in angle Here, use only positive toe-in values from each wheel to substitute for a and P in the equation. Page 299 Cruise Control Switch: Testing and Inspection INSPECTION Measure the cruise control command switch resistance. If NG, replace the cruise control command switch. Page 4723 2. Stop the engine and watch vacuum gauge. If the vacuum drop range is less than 3.3 kPa (25 mmHg, 0.98 inHg) within 15 seconds after stopping engine, the brake booster is functioning properly. If defective, refer to "AIR TIGHTNESS CHECK". 3. If any fault is found on brake booster, replace the brake booster with a new one. ^ Lack of boosting action check Turn off the engine, and set the vacuum gauge reading at "0". Then, check the fluid pressure when brake pedal is depressed. The pressure must be greater than the standard value listed. ^ Boosting action check Set the vacuum gauge reading at 66.7 kPa (500 mmHg, 19.69 inHg) by running engine. Then, check the fluid pressure when brake pedal is depressed. The pressure must be greater than the standard value listed. Page 3436 R58-R69 Page 7081 F21-F61 Page 2468 Knock Sensor: Service and Repair Knock Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the intercooler. 3. Disconnect the knock sensor connector. 4. Remove the knock sensor from the cylinder block. INSTALLATION 1. Install the knock sensor to the cylinder block. Tightening torque: 24 N.m (2.4 kgf-m, 17.4 ft-lb) NOTE: Extraction area of the knock sensor cord must be positioned at a 60 degrees angle relative to the engine rear. Page 1829 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 120 B17-B20 Page 1825 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 7332 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 7005 B292-B317 Diagram Information and Instructions Heated Glass Element: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 7389 Wiper Motor: Testing and Inspection Rear Wiper Motor Rear Wiper Motor INSPECTION 1. Connect the battery to wiper motor connector and confirm that the wiper motor operates. 2. Connect the battery to terminal of connector, and then remove the terminal connections with motor rotated, and stop the wiper motor through operation. 3. Connect the battery and confirm that the motor stops at automatic stop position after the motor operates at low speed again. Testing and Inspection Crankshaft Gear/Sprocket: Testing and Inspection INSPECTION 1. Check the crank sprocket teeth for abnormal wear and scratches. 2. Make sure there is no free play between crank sprocket and key. 3. Check the crank sprocket notch used for sensor for damage and contamination of foreign matter. Page 1615 B230-B283 Page 5522 7. Attach the repaired body wire harness to the area directly rearward of the wire clamp with insulating tape to prevent the wire from interfering with the seat rail. (See photos below for location of the wire and tape.) 8. Reinstall the floor carpet. Wrap the previously cut portion of carpet with 1.5 inch wide unwoven adhesive tape. 9. Reinstall the center console trim. Note: Be careful that switch wires attached to the center console trim are not pinched by the parking brake lever during installation. 10. Reinstall the passenger front seat. (Install the seat slide rail cover on Forester model.) 11. Reconnect the negative battery cable. (Reprogram the customer's radio stations presets.) 12. Perform Seat Occupant Detection System calibration. (See applicable service manual.) Note: Impreza models have the bladder type system which will require re-zeroing. Forester models have the load sensor type system which requires re-calibration. 13. Turn on the ignition switch and confirm that the seat heater switches and the air bag warning light works properly. SERVICE PROGRAM IDENTIFICATION LABEL Type or print the necessary information on a recall identification label. The completed label should be attached to the vehicle's upper radiator support. Page 2874 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 2478 Idle Speed: Testing and Inspection Idle Speed INSPECTION 1. Before checking the idle speed, check the following: 1. Ensure the air cleaner element is free from clogging, ignition timing is correct, spark plugs are in good condition, and that the hoses are connected properly. 2. Ensure the malfunction indicator light does not illuminate. 2. Warm-up the engine. 3. Stop the engine, and then turn the ignition switch to OFF. 4. Insert the cartridge to Subaru Select Monitor. 5. Connect the Subaru Select Monitor to data link connector. 6. Turn the ignition switch to ON, and Subaru Select Monitor power switch to ON. 7. Select the (2. Each System Check) in Main Menu. 8. Select the (Engine Control System) in Selection Menu. 9. Select the (1. Current Data Display & Save) in Engine Control System Diagnosis. 10. Select the (1. 12 Data Display) in Data Display Menu. 11. Start the engine, and then read the engine idle speed. 12. Check the idle speed when unloaded. (With headlights, heater fan, rear defroster, radiator fan, air conditioning, etc. OFF) Idle speed [No load and gears in neutral]. 700 ± 100 rpm 13. Check the idle speed when loaded. (Turn the air conditioning switch to "ON" and operate the compressor for at least 1 minute before measurement.) Idle speed [A/C "ON". no load and gears in neutral]: When the A/C refrigerant pressure is low MT. 725 ± 100 rpm AT. 750 ± 100 rpm When the A/C refrigerant pressure is high MT. 800 ± 100 rpm AT. 825 ± 100 rpm NOTE: As idle speed is controlled by the automatic adjustment type, it can not be adjusted manually. If the idle speed is out of specifications, refer to General On-board Diagnosis Table under "Engine Control System". Page 912 8) Install the front vehicle speed sensor and torque converter turbine speed sensor, and then fasten the harness. 9) Install the inlet pipe. NOTE: Be sure to use a new copper washer. 10) Install the transmission rear crossmember bolts. Tightening torque: 70 Nm (7.1 kgf-m, 51 ft. lbs.) 11) Install the propeller shaft. 12) Install the front, center, rear exhaust pipes and muffler. (Non-turbo model) 13) Install the center, rear exhaust pipes and muffler. (Turbo model) 14) Lower the vehicle. 15) Install the transmission connector to the stay. 16) Install the pitching stopper. 17) Install the air intake chamber. (Non-turbo model) 18) Install the intercooler. (Turbo model) Page 2279 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 7147 (1) Open the hood and remove the check valve. (2) Attach valve cushion (86634SA000) around the modified check valve (86634AG000) for soundproofing. Page 2123 B380-f6 Page 5423 Refrigerant: Testing and Inspection Refrigerant Leak Check INSPECTION 1. Operate the A/C system for approx. 10 minutes, and confirm that the high-pressure side shows at least 690 kPa (7.03 kg/ sq cm, 100 psi). Then stop the engine to start the leak test. 2. Starting from the connection between the high pressure pipe and evaporator, check the system for leaks along the high-pressure side through the compressor. The following items must be checked thoroughly. 3. Check the joint and seam between the pressure switch (dual pressure switch) and high-pressure pipe. 4. Check the connections between the condenser and pipes, and welded joints on the condenser. The leak tester may detect the oil on the condenser fins as a leak. 5. Check the joint between the compressor and hoses. 6. Check the machined area of compressor and other joints on the compressor. 7. Check the compressor shaft seal at the area near the center of compressor clutch pulley. Some shaft seals show a slight amount of leakage about 3 g (0.1 oz) per year. This is not a problem. 8. Starting from the connection between the low pressure pipe and evaporator, check the system for leakage along the low-pressure side through the compressor. The following items must be checked thoroughly. Connection between two parts - Connection between the pipe and plate 9. Visually check the rubber area of the flexible hose for cracks. Check the entire length of the flexible hose, especially the connection with the metal hose end. CAUTION: Carefully check the external surface of hoses and tubes at approx. 25 mm (0.98 in) per second. 10. Disconnect the drain hose from the heater case, and check the hose end for at least 10 seconds. After the test is finished, reconnect the drain hose. Diagnostic Aids Control Assembly: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 6117 4. Set the rear crossbar so that front direction mark on the right side top face of crossbar point in the direction of vehicle front. 5. Place the crossbar end support on a joint of rear roof rail support and roof rail. 6. lighten the end support and clamp using TORX(R) bolt T30. Page 3434 F21-F61 Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 3463 B54-B127 Page 4926 B230-B283 Page 3656 B134-B136 Page 7345 B380-f6 Testing and Inspection ABS Light: Testing and Inspection ABS Warning Light/Brake Warning Light Illumination Pattern INSPECTION 1. When the ABS warning light does not illuminate in accordance with this illumination pattern, there must be an electrical malfunction. 2. When the ABS warning light remains constantly OFF, repair the ABS warning light circuit or diagnosis circuit. NOTE: Even though the ABS warning light does not go out about 2 seconds after it illuminates, the ABS system operates normally when the warning light goes out while driving at approximately 12 km/h (7 MPH). However, the Antilock brakes do not work while ABS warning light is illuminated. Page 4812 Check the resistance between slip rings using circuit tester. If the resistance is not within the specified range, replace the rotor assembly. Specified resistance: Approx. 1.8 - 2.2 ohm 4. Insulation test Check the continuity between slip ring and rotor core or shaft. If resistance is 1 ohm or less, the rotor coil is grounded, and so replace the rotor assembly. 5. Ball bearing (rear side) Check the rear ball bearing. Replace if it is noisy or if the rotor does not turn smoothly. 3. STATOR 1. Continuity test Inspect the stator coil for continuity between each end of the lead wires. If resistance is 1 Mohm or more, the lead wire is broken, and so replace the stator assembly. 2. Insulation test Page 20 Antitheft Relay: Service and Repair INTERRUPT RELAY REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the audio instrument. 3. Remove the interrupt relay. INSTALLATION Install in the reverse order of removal. Page 3094 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 2117 B54-B127 Page 7377 B230-B283 Page 3925 Differential Fluid - A/T: Service and Repair Differential Fluid Replacement Differential Gear Oil REPLACEMENT 1) Lift-up the vehicle. 2) Remove the differential gear oil drain plug using TORX T70, and then drain the differential gear oil completely. CAUTION: ^ Directly after the vehicle has been running, the differential gear oil is hot. Therefore, be careful not to burn yourself. ^ Be careful not to spill the differential gear oil on exhaust pipe to prevent it from emitting smoke or fire. When the differential gear oil is spilled on exhaust pipe, wipe it away completely. 3) Replace the gasket with a new one, and then tighten the differential gear oil drain plug using TORX T70. Tightening torque: 44 Nm (4.5 kgf-m, 32.5 ft. lbs.) (Aluminum gasket) 70 Nm (7.1 kgf-m, 51.6 ft. lbs.) (Copper gasket) 4) Lower the vehicle. 5) Pour gear oil into the gauge hole. Recommended fluid. Gear oil capacity: 1.1 - 1.3 liters (1.2 - 1.4 US quarts, 1.0 - 1.1 Imp quarts) 6) Check the level of differential gear oil. Specifications Parking Lamp: Specifications Specifications Clearance/Parking/Front side marker light ............................................................................................................................................................ 12 V - 5 W Page 7038 B230-B283 Page 5876 4. Remove the power window control switch. 5. Remove the clips of trim panel using clip remover to remove trim panel. INSTALLATION Install in the reverse order of removal. Page 3003 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Diagnostic Aids Blower Motor: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Front Axle Axle Shaft Assembly: Diagrams Front Axle Front Axle Page 2445 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 7281 (1) Open the rear gate and remove the foam trim board on the left hand side from the cargo floor. (2) Remove the check valve. Note: Place rags or paper towels in the area. There is a chance that a small amount of washer fluid may leak out. (3) Attach valve cushion (86634SA000) around the modified check valve (86634AA010) for soundproofing. (4) Install the modified check valve and valve cushion. Page 1370 Piston: Testing and Inspection INSPECTION CYLINDER AND PISTON 1. The cylinder bore size is stamped on cylinder block's front upper surface. NOTE: ^ Measurement should be performed at a temperature of 20°C (68°F). ^ Standard sized pistons are classified into two grades, "A" and "B". These grades should be used as a guide line in selecting a standard piston. Standard diameter. 99.505 - 99.515 mm (3.9175 - 3.9179 inch) 99.495 - 99.505 mm (3.9171 - 3.9175 inch) 2. How to measure the inner diameter of each cylinder Measure the inner diameter of each cylinder in both the thrust and piston pin directions at the heights shown in the figure, using a cylinder bore gauge. NOTE: Measurement should be performed at a temperature of 20°C (68°F). Taper. Standard 0.015 mm (0.0006 inch) Limit 0.050 mm (0.0020 inch) Out-of-roundness: Standard 0.010 mm (0.0004 inch) Limit 0.050 mm (0.0020 inch) Restraints - Seat Belt Latch Slides To Lower Anchor Seat Belt: All Technical Service Bulletins Restraints - Seat Belt Latch Slides To Lower Anchor NUMBER: 17-06-01R DATE: 05/11/05 APPLICABILITY: 1995 MY and after Legacy 1998 MY and after Forester 1993MY and after Impreza 2003MY and after Baja 2006MY and after Tribeca SUBJECT: Seat Belt Latch Slides to the Lower Seat Belt Anchor DESCRIPTION In the event you encounter a customer complaint of the seat belt latch sliding down the v~ebbing to the lower seat belt anchor, it may be caused by the latch web stop button separating from the belt webbing. This stop button may become loose and fall off if the belt webbing is jammed between the body panel and door when the door is closed Use the chart to locate and order the correct repair kit for your application. REPAIR PROCEDURES 1) Inspect the belt webbing for damage. If damaged replace the seat belt assembly. 2) Remove any piece of broken stopper button from the belt webbing. 3) Lift the belt latch up and beyond the original stopper button location and hold in place using adhesive tape. 4) Locate the original stopper hole (about 500mm up from bottom anchor) in the webbing and insert the new male stopper button from the backside of the belt Push the other part of the button over the pin sticking through the front belt webbing. 5) Using a suitable tool, crimp the two parts together until the new button thickness is 4.5~5.0mm. 6) Remove the adhesive tape from the latch and confirm the stopper button holds the latch in the proper position. For vehicles within the Basic New Car Limited Warranty period this repair can be claimed using the table shown. Page 2196 B136-B141 Page 1672 Timing Cover: Service and Repair Timing Belt Cover REMOVAL a. Remove the V-belt. b. Remove the crank pulley. c. Remove the timing belt cover (LH) (A). d. Remove the timing belt cover (RH) (B). e. Remove the front timing belt cover (C). INSTALLATION a. Install the front timing belt cover (c). Tightening torque: 5 Nm (0.5 kgf-m, 3.6 ft. lbs.) b. Install the timing belt cover (RH) (B). Tightening torque: 5 Nm (0.5 kgf-m, 3.6 ft. lbs.) c. Install the timing belt cover (LH) (A). Tightening torque: 5 Nm (0.5 kgf-m, 3.6 ft. lbs.) d. Install the crank pulley. e. Install the V-belt. INSPECTION Make sure the cover is not damaged. Page 5279 For vehicles within the Basic New Car Limited Warranty period, this repair may be claimed using table. Disclaimer Page 5113 Additional labels are available through the Customer Dealer Services Department (CDS). CLAIM REIMBURSEMENT AND ENTRY PROCEDURES Credit to perform this recall will be based on the submission of properly completed repair order information. Dealers may enter the applicable claim information through their Dealer Communications System. Inspect - Use the applicable claim submission information for inspection of passenger front seat wire harness. Repair Wiring - Use the additional claim submission information for repair of the passenger front seat wire harness. Disclaimer Page 1316 g. Completely remove the plastigauge. 5. Check the cam face condition, and remove the minor faults by grinding with oil stone. Measure the cam height H. If it exceeds the limit or offset wear occurs, replace the camshaft. Cam height H. Standard Intake 46.55 - 46.65 mm (1.833 1.837 inch) Exhaust 46.75 - 46.85 mm (1.841 - 1.844 inch) Limit Intake 46.45 mm (1.829 inch) Exhaust 46.65 mm (1.837 inch) Cam base circle diameter 37.0 mm (1.457 inch) 6. Measure the thrust clearance of camshaft with dial gauge. If the thrust clearance exceeds the limit or offset wear occurs, replace the caps and cylinder head as a set. If necessary, replace the camshaft. Standard. 0.068 - 0.116 mm (0.0027 0.0046 inch) Limit. 0. 14 mm (0. 0055 inch) Page 4064 4) Remove intercooler. (Turbo model) TRANSMISSION REAR CROSSMEMBER AND REAR CUSHION RUBBER 1) Install the rear cushion rubber. Tightening torque: 39 Nm (4.0 kgf-m, 29 ft. lbs.) 2) Install the crossmember. 3) Remove the transmission jack. 4) Install the front, center, rear exhaust pipes and the muffler. (Non-turbo model) 5) Install center and rear exhaust pipes, and muffler. (Turbo model) INSPECTION Repair or replace parts if the results of the inspection below are not satisfactory. PITCHING STOPPER Make sure that the pitching stopper is not bent or damaged. Make sure that the rubber is not stiff, cracked, or otherwise damaged. TRANSMISSION REAR CROSSMEMBER AND REAR CUSHION RUBBER Make sure that the crossmember is not bent or damaged. Make sure that the cushion rubber is not stiff, cracked, or otherwise damaged. Page 4664 14) Detach the grommet from rear floor. 15) Remove the cable assembly from cabin by forcibly pulling it backward. 16) Detach the parking brake cable from cable guide at rear trailing link. INSTALLATION 1) Install in the reverse order of removal. NOTE: Be sure to pass the cable through cable guide inside the tunnel. 2) Be sure to adjust the lever stroke. Page 6831 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 4993 ownership. For affected vehicles sold after the date on the dealer's affected list, dealers are to contact those owners and provide them with a copy of the owner notification letter. They should also arrange to make the required correction according to the instructions in the service procedure section of this bulletin. Dealers are also to promptly perform the applicable service procedures defined in this bulletin to correct all affected vehicles in their inventory (new, used, demo). Additionally, whenever a vehicle subject to this recall is taken into dealer new or used inventory, or is in the dealership for service, necessary steps should be taken to ensure the service program correction has been made before selling or releasing the vehicle. PARTS INFORMATION Special Tools and Materials ^ Soldering gun and solder ^ Heat gun ^ 1.5 inch wide unwoven adhesive tape ^ Subaru Global Terminal Wiring Kit 1-47606 ^ Electrical tape ^ Electrical shrink wrap tubing SERVICE PROCEDURE This Recall will involve inspection of the front passenger seat wiring for proper routing. It will also involve repair of the affected wire harness if the inspection reveals pinched wiring. Service Procedure The first part of the procedure involves inspecting the wiring harness for proper routing and possible damage. (There are two separate procedures, one for each different vehicle.) If there is no damage to the wiring harness, no repair is necessary. If the wiring harness is found to be damaged, then follow the repair procedure. Forester Inspection Procedure (See Impreza inspection procedure.) 1. Slide the front passenger seat to the rear most position to expose the front of the slide rail. Page 3327 10. Disconnect the evaporation hoses from fuel pipes. 11. Remove the bolts which hold the fuel filler pipe bracket on the body. 12. Loosen the clamp and separate the fuel filler hose (A) from the fuel filler pipe. 13. Move the clip and separate the evaporation hose (B). 14. Remove the fuel filler pipe to under side of the vehicle. 15. Remove the evaporation pipe together with clip from the body. INSTALLATION 1. Open the fuel filler flap lid. 2. Set the fuel saucer (A) with rubber packing (C) and insert the fuel filler pipe into hole from the inner side of apron. Page 566 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Locations Secondary A/C Fuse Box Page 1878 Disclaimer Page 5192 12) Install a new holder to cylinder side of steering body. Tightening torque: 90 Nm (9.0 kgf-m, 65.1 ft. lbs.) 13) Install the ST to rack cylinder. Using a press, press the ST until its groove is aligned with end of holder. ST 34199FE000 INSTALLER & REMOVER 14) Using the ST, clinch steering body cylinder at a point less than 3 mm (0.12 inch) from holder. Page 890 Neutral Safety Switch: Service and Repair Neutral Position Switch NEUTRAL POSITION SWITCH REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the connector from neutral position switch, and then remove the switch. INSTALLATION Install in the reverse order of removal. Page 678 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Locations Main Fuse Box (M/B) Page 3874 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 5016 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 1626 Oil Pressure Sender: Testing and Inspection INSPECTION Step 1-Step 3 Make sure oil does not leak or seep from where the oil pressure switch is installed. Page 3284 8. Remove the purge control solenoid valve. 9. Remove the two bolts which hold the fuel injector pipe to the left side of intake manifold. 10. Remove the bolt which secure fuel injector pipe to intake manifold. 11. Remove the fuel injector while lifting up the fuel injector pipe. Page 1038 NOTE: If the measured value is not within specification, take notes of the value in order to adjust the valve clearance later on. 13. If necessary, adjust the valve clearance. 14. Further turn the crank pulley clockwise. Using the same procedures described previously, and then measure the valve clearances again. 1. Set the arrow mark on cam sprocket to position shown in the figure, and then measure the #2 cylinder exhaust valve and #3 cylinder intake valve clearances. 2. Set the arrow mark on cam sprocket to position shown in the figure, and then measure the #2 cylinder intake valve and #4 cylinder exhaust valve clearances. 3. Set the arrow mark on cam sprocket to position shown in the figure, and then measure the #1 cylinder exhaust valve and #4 cylinder intake valve clearances. 15. After inspection, install the related parts in the reverse order of removal. Tightening torque: 33 Nm (3.4 kgf-m, 25 ft. lbs.) Locations Electrical Components Location Page 2305 Transmission Position Switch/Sensor: Service and Repair AT Shift Lock Solenoid and "P" Range Switch AT Shift Lock Solenoid and "P" Range Switch REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the console box. 3) Disconnect the connector. 4) Remove the grip. 5) Remove the indicator bulb from indicator cover. 6) Remove the indicator cover. 7) Remove the blind. 8) Remove the cushion. 9) Remove the clip, and then remove the "P" range switch. 10) Remove the cover. Page 4535 5. Remove the caliper body from housing. 6. Clean mud and foreign particles from the caliper body assembly and support. 3. 17 INCH TYPE CAUTION: Do not allow brake fluid to come in contact with vehicle body; wash away immediately with water and wipe off completely if spilled. 1. Set the vehicle on a lift. 2. Loosen the wheel nuts. 3. Lift-up the vehicle, and then remove the front wheel. 4. Remove the brake pads from caliper body. 5. Remove the union bolt (1) and brake hose from caliper body assembly. 6. Remove installation bolts (2) from housing. 7. Clean mud and foreign particles from the caliper body assembly. INSTALLATION 1. 15 INCH TYPE 1. Install the support on housing. Tightening torque: 80 Nm (8.2 kgf-m, 59 ft. lbs.) 2. Apply thin coat of Molykote AS-880N (Part No. K0777YA010) to the frictional portion between pad and pad clip. 3. Apply thin coat of Molykote AS-880N (Part No. K0777YA010) to the frictional portion between pad and inner shim. 4. Install the pads on support. 5. Install the caliper body on support. Tightening torque: 26.5 Nm (2.7 kgf-m, 19.5 ft. lbs.) 6. Replace the brake hose gaskets with new ones, and then connect the brake hose. Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft. lbs.) Page 849 2) Check the clutch switch continuity. If the resistance is not as specified, replace the switch. (1) Disconnect the clutch switch connector. (2) Measure the resistance between 1 and 2 of switch terminal. ^ Clutch switch (Cruise control) ^ Clutch switch (Starter interlock) 3) Confirm that the engine does not start when the clutch pedal is not depressed. If the engine starts, adjust the clutch switch, and inspect the starter interlock circuit. 4) Confirm that the engine starts when the clutch pedal is fully depressed. If the engine does not start, adjust the clutch switch, and inspect the starter interlock circuit. ADJUSTMENT 1) Loosen the clutch switch mounting lock nut (Starter interlock). Page 3076 R58-R69 Page 1505 B136-B141 Page 1126 3) Temporarily connect the pipe C and D to gear box. 4) Temporarily install the clamp E on pipes C and D. NOTE: Ensure the letter "8" on each clamp are diagonally opposite each other as shown in the figure. Page 4799 Battery: Testing and Inspection INSPECTION WARNING: - Electrolyte has toxicity; be careful handling the fluid. - Avoid contact with skin, eyes or clothing. Especially at contact with eyes, flush with running water for 15 minutes and get prompt medical attention. - Batteries produce explosive gasses. Keep sparks, flame, cigarettes away. - Ventilate when charging or using in enclosed space. - For safety, in case an explosion does occur, wear eye protection or shield your eyes when working near any battery. Never lean over a battery. - Do not let the battery fluid contact eyes, skin, fabrics, or paint-work because battery fluid is corrosive acid. - To lessen the risk of sparks, remove rings, metal watch-bands, and other metal jewelry. Never allow metal tools to contact the positive battery terminal and anything connected to it while you are at the same time in contact with any other metallic portion of the vehicle. This may cause a short circuit. 1. EXTERNAL PARTS Check for the existence of dirt or cracks on battery case, top cover, vent plugs, and terminal posts. If necessary, clean with water and wipe with a dry cloth. Apply a thin coat of grease on the terminal posts to prevent corrosion. 2. ELECTROLYTE LEVEL Check the electrolyte level in each cell. If the level is below MIN LEVEL, bring the level to MAX LEVEL by pouring distilled water into the battery cell. Do not fill beyond MAX LEVEL. 3. SPECIFIC GRAVITY OF ELECTROLYTE 1. Measure the specific gravity of electrolyte using a hydrometer and a thermometer. Specific gravity varies with temperature of electrolyte so that it must be corrected at 20 °C (68 °F) using the following equation: S(20) = St + 0.0007 x (t - 20) S(20): Specific gravity corrected at electrolyte temperature of 20 °C St: Measured specific gravity t: Measured temperature (°C) Determine whether or not battery must be charged, according to corrected specific gravity. Standard specific gravity: 1.220 - 1.290 [at 20 °C (68 °F)] 2. Measuring the specific gravity of the electrolyte in battery will disclose the state of charge of battery. The relation between specific gravity and state of charge is as shown in the figure. MEASUREMENT WARNING: Do not bring an open flame close to the battery at this time. CAUTION - Prior to charging, corroded terminals should be cleaned with a brush and common caustic soda solution. - Be careful since the battery electrolyte overflows while charging the battery. - Observe the instructions when handling battery charger. - Before charging the battery on vehicle, disconnect battery ground terminal to prevent damage of generator diodes or other electrical units. 1. JUDGMENT OF BATTERY IN CHARGED CONDITION 1. Specific gravity of electrolyte is held within the specified range from 1.250 to 1.290 for more than one hour. 2. Voltage per battery cell is held at the specified range from 2.5 to 2.8 volts for more than one hour. Page 2293 Throttle Position Sensor: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 5594 Air Bag Control Module: Testing and Inspection INSPECTION Check for the following, and replace damaged parts with new parts. - Control module, connector, and mounting bracket are damaged. - Airbag is deployed. - Side airbag is deployed. Page 938 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Locations Electronic Throttle Actuator Relay: Locations Solenoid Valve, Actuator, Emission Control System Parts And Ignition System Parts (Part 5) Page 4002 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 899 12) Move the range select lever to parking position (left side). 13) Remove the inhibitor switch from transmission. 14) Disconnect the inhibitor switch harness connector from inhibitor switch. INSTALLATION 1) Connect the inhibitor switch harness connector to inhibitor switch. 2) Install the inhibitor switch to transmission case. 3) Move the range select lever to neutral position. Service and Repair Body Control Module: Service and Repair Body Integrated Module REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the lower cover. 3) Remove the knee bolster. 4) Disconnect the connector from body integrated module. 5) Remove the body integrated module. INSTALLATION Install in the reverse order of removal. Engine Controls - DTC P0340/P0345 After Camshaft R & R Camshaft Position Sensor: All Technical Service Bulletins Engine Controls - DTC P0340/P0345 After Camshaft R & R Number: 02-107-09 Date: 03/24/09 Applicability: 2004~06MY Baja 2.5L Turbo 2004~06MY Impreza 2.5L Turbo 2004~06MY Forester 2.5L Turbo 2004~06MY Legacy/Outback 2.5L Turbo SUBJECT: Intake Camshaft Replacement Introduction If you encounter a vehicle that has a CEL and P0340 or P0345 stored in memory immediately after replacing the intake camshaft(s), the air gap between the camshaft and camshaft position sensor may be out of specification. A modification was made to the plate area of the camshaft where the camshaft position sensor picks up the signal. Parts Information Repair Procedure/ Information Using a feeler (thickness) gauge, measure the gap between the camshaft and camshaft position sensor. The correct gap is between 0.15mm to 0.98mm (0.0059 to 0.0386 in.) If the gap is over 0.98mm (0.0386 in.) replace the camshaft position sensor. Refer to the applicable service manual. Warranty/Claim Information For vehicles within warranty, refer the Subaru Warranty Wizard for claim submission information. Page 7218 Claim Reimbursement/Warrant Information For vehicles under the Basic New Car Limited Warranty period, refer to the Subaru Warranty Wizard(C) for claim submission information. Disclaimer Service and Repair Sun Visor: Service and Repair SUN VISOR REMOVAL Remove the mounting screws, and then detach the sun visor (A) and hook (B). INSTALLATION Install in the reverse order of removal. Page 6324 R58-R69 Page 3006 CAUTION: When removing the front oxygen (A/F) sensor, wait until exhaust pipe cools, otherwise it will damage exhaust pipe. INSTALLATION 1. Before installing front oxygen (A/F) sensor, apply anti-seize compound only to the threaded portion of front oxygen (A/F) sensor to make the next removal easier. Anti-seize compound: NEVER-SEEZ NS-165 or equivalent CAUTION: Never apply anti-seize compound to protector of front oxygen (A/F) sensor. 2. Install the front oxygen (A/F) sensor. 3. Install the service hole cover. 4. Lower the vehicle. 5. Install the front right side wheel. 6. Connect the engine harness to the bracket (B) using clips (A). Page 3862 B128-B134 Page 3295 Fuel Pressure: Testing and Inspection Fuel Pressure INSPECTION WARNING: Before removing the fuel pressure gauge, release the fuel pressure. NOTE: If out of specification, check or replace the pressure regulator and pressure regulator vacuum hose. 1. Release the fuel pressure. 2. Disconnect the fuel delivery hoses from fuel damper, and then connect the fuel pressure gauge. 3. Connect the connector of fuel pump relay. 4. Start the engine. 5. Measure the fuel pressure while disconnecting the pressure regulator vacuum hose from intake manifold. Fuel pressure: Standard. 284 - 314 kPa (2.9 - 3.2 kgf/cm2, 41 - 46 psi) 6. After connecting the pressure regulator vacuum hose, measure the fuel pressure. Fuel pressure: Standard. 230 - 260 kPa (2.35 - 2.65 kgf/cm2, 33 - 38 psi) NOTE: The fuel pressure gauge registers 10 to 20 kPa (0.1 to 0.2 kgf/cm2, 1 to 3 psi) higher than standard values during high-altitude operations. Page 1911 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 1280 ^ Inspect the cone for any debris or damage and clean or replace as necessary ^ Perform the Centering Check® Procedure (software version 2.1 and higher) before each wheel is balanced PROCEDURE Always verify the concern with a test drive before beginning diagnosis and performing repairs. Drive the vehicle a minimum of 10 miles to eliminate any flat spots on the tires. Immediately after the road test, lift the vehicle into the air to minimize flat spotting. Adjust tire pressures according to the door label and inspect for any visible damage. If any damage is found, resolve these concerns before continuing with diagnosis. Tire dynamic imbalance should be measured first and adjusted to within 5 grams. Leave any remaining factory weights in place and remove weights that have been added afier production; be careful not to damage the wheel. If the assembly cannot be adjusted to within 5 grams, inspect for the following: ^ Improperly mounted tire or unseated tire bead ^ Improperly mounted assembly to the balancer ^ Damage to the wheel or tire ^ Damage to the tire balancer ^ Debris located inside the tire If a vibration can still be felt afier the wheels have been properly balanced, there is a possibility of excessive radial force variation (RFV) in the tire and wheel assembly. To address RFV concerns, a wheel balancer capable of measuring RFV must be used; Subaru Of America Inc. recommends the use of the Hunter GSP 9700 Road Force Measurement System. If a GSP 9700 is not available, locate the nearest machine through the Hunter Engineering web site (www.gsp9700.com). Measure and record the RFV readings of the wheel and tire assembly for R1H. Then perform the wheel runout measurements by following the on-screen instructions or by referring to the operating instructions; this will determine the individual tire and wheel RFV measurements. The following assembly RFV measurements can be used as a guide: ^ R1H on passenger tires - 8.0kg (17.6lbs) or less If higher than normal RFV measurements are found for the assembly, refer to the on-screen instructions or the operating instructions to match the tire and wheel to minimize the assembly RFV By matching the low spot of the tire to the high spot of the wheel, radial force can be reduced without replacing any components. After all RFV measurements are adjusted to the lowest possible level, install the wheels with the lowest RFV measurements on the front of the vehicle and road test to verify the concern has been reduced. Replacement of tires due to excessive assembly measurements may be unnecessary. If the concern still exists at an unacceptable level, contact the Subaru Technical HelpLine with the following information readily available: ^ Thorough description of customer's concern ^ VIN ^ Mileage ^ Tire manufacturer, size and condition ^ Completed "Dealer vibration Analysis Worksheet and Tire Analysis Worksheet" available under TechLine Pre-Call Worksheets on Subarunet. (All measurements should be in grams or kilograms) ^ Service history of vehicle WARRANTY/CLAIM INFORMATION Page 1746 A used toothbrush which has been cleaned works great. Manually open the negative pressure valve. Using clean water and a brush, thoroughly clean the valve (inner and outer surface) and the valve seal surface. Check the radiator cap valve opening pressure using a radiator cap tester to insure the cap is within specification (refer to the applicable Subaru Service Manual). Note: If the cap is out of specification replace it. 2. Coolant Reservoir Tank Cleaning Remove the reservoir tank (refer to the applicable Subaru Service Manual). Using clean water, thoroughly clean the inside of the reservoir tank. Reinstall reservoir tank. Fill with coolant to the Full mark. Note: Be sure to use genuine Subaru Super Coolant or Subaru Long Life Coolant, depending upon what type of coolant is currently in the system. 3. Coolant Reservoir Tank Hose Modification Page 446 B17-B20 Page 3726 R58-R69 Page 5154 8) Remove the bolt from the rear side of oil pump. 9) Disassemble the oil pump and bracket by inserting a flat tip screwdriver as shown in the figure. INSTALLATION 1) Install the oil pump to bracket. (1) Place the oil pump bracket in a vise. Tighten the bushing using a 12.7 mm (1/2") type 14 mm and 21 mm box wrench until it is in contact with the oil pump mounting surface. CAUTION: Do not place the oil pump bracket directly in the vise; use soft pads and hold oil pump lightly to protect the pump. Page 3897 B128-B134 Service and Repair Fuel Pump Control Unit: Service and Repair Fuel Pump Control Unit REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the rear quarter trim. 3. Disconnect the connector from the fuel pump control unit. 4. Remove the fuel pump control unit. INSTALLATION Install in the reverse order of removal. Page 2753 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 6719 Glove Box Lamp: Service and Repair GLOVE BOX LIGHT REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the glove box. 3. Disconnect the harness connector. 4. Remove the glove box light. INSTALLATION Install in the reverse order of removal. Page 3418 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 2861 B54-B127 Front Brake Pad: Service and Repair Front Front Brake Pad REMOVAL 1. 15 INCH TYPE 1. Set the vehicle on a lift. 2. Loosen the wheel nuts. 3. Lift-up the vehicle, and then remove the front wheel. 4. Remove the lower caliper bolt. 5. Raise the caliper body upward and support it. NOTE: Do not disconnect the brake hose from caliper body. 6. Remove the pad. NOTE: If the brake pad is difficult to remove, proceed as follows: 1. Remove the caliper body from support. 2. Remove the support. 3. Place a support in a vise between wooden blocks. 4. Attach a rod of less than 12 mm (0.47 inch) dia. to the shaded area of brake pad, and strike the rod with a hammer to drive brake pad out of place. 2. 16 INCH TYPE 1. Set the vehicle on a lift. 2. Loosen the wheel nuts. 3. Lift-up the vehicle, and then remove the front wheel. 4. Remove the M clip. Cooling System - Coolant Comes Out Of Reservoir Coolant Reservoir: All Technical Service Bulletins Cooling System - Coolant Comes Out Of Reservoir NUMBER: 08-52-08 DATE: 08/18/08 APPLICABILITY: 1999MY and later Impreza & Forester 2000MY and later Legacy & Outback 2006MY and later Tribeca SUBJECT: Coolant Overflow Introduction If you encounter a vehicle which experiences coolant coming out of the coolant reservoir tank, it may be caused by the radiator cap pressure valve being stuck open by debris sucked up through the reservoir tank hose. As the cooling system cools down, it sucks coolant back into the radiator. If there is debris that settles to the bottom of the reservoir tank, the hose is low enough to also suck them back into radiator. This causes the radiator cap not to seal, allowing excessive amount of coolant to escape overflowing the reservoir tank. If this condition continues over time, there will not be enough coolant in the system to maintain proper engine temperature. In order to correct the condition you need to clean (and test) or replace the radiator cap, clean out the reservoir tank, and shorten the hose slightly, following the repair procedure. Production Line Change The shorter coolant reservoir tank hose was used in production as shown above. Repair Procedure/Information 1. Radiator Cap Cleaning Many caps can be successfully cleaned. The important part is the thorough cleaning of the negative pressure valve. If this is not done completely, remaining debris may result in a repeat issue. If there is an excessive amount of debris or the sealing rubber on the cap appears to be pitted or damaged, replace the cap. Note: If replacing the cap, skip to Step 2. Using clean water and a brush, thoroughly clean the cap seal surface. Note: Service and Repair Evaporator Core: Service and Repair Evaporator REMOVAL 1. Remove the heater and cooling unit. 2. Loosen the screws and clip to remove the evaporator cover. 3. Remove the evaporator. 4. Loosen the two bolts to remove the expansion valve. CAUTION: If the evaporator is replaced, add appropriate amount of compressor oil to evaporator. INSTALLATION Install in the reverse order of removal. Diagnostic Aids Fuel Gauge Sender: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 5834 Capacity Specifications Coolant: Capacity Specifications Coolant capacity MT: ...................................................................................................................................................... ....................... 7.7 L (8.1 US qt, 6.8 Imp qt.) Page 425 Trunk Lamp Switch: Testing and Inspection Trunk Room Light Switch TRUNK ROOM LIGHT SWITCH Measure the resistance between trunk room light switch terminals. Page 5948 Trunk / Liftgate Lock: Service and Repair Trunk Lid Lock Assembly TRUNK LID LOCK ASSEMBLY REMOVAL 1. Remove the trunk lid key cylinder rod clamp. 2. Loosen two bolts to remove the trunk lid lock assembly. INSTALLATION Install in the reverse order of removal. NOTE: Apply grease to parts that rub. - Make sure the lock works properly after installation. Page 608 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 7419 F21-F61 Page 6385 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 3095 B3-B12 Page 1281 For vehicles within the Basic New Car Limited Warranty period, this repair may be claimed using table. Disclaimer Page 3257 B136-B141 Page 2743 P Code List (Partial list) Page 7364 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 5519 2. Pull up the seat slide rail cover from the center console side as indicated by the arrows. 3. Check visually and with your fingers in the area indicated by broken lines to confirm that the body wiring harness (for power to the occupant detection ECU) is not located and/or pinched around the seat bracket. 4. If the wire is found to be located properly (not pinched), reinstall the seat slide rail cover. No further action is required. If the wire is found to be pinched, proceed to the "Wiring Repair Procedure". Impreza Inspection Procedure 1. Remove the center console trim between the select lever and the parking brake lever. If necessary, refer to the applicable service manual for removal instructions. 2. Cut the cross section of floor carpet in the center and in front of the parking brake lever with scissors (as shown, below). Note: Be careful not to damage wires around the work area. ^ Pull up the floor carpet to inspect a section of the subject body wiring harness from the clamping point located behind the shifter console down to the front passenger seat slide rail as indicated in the photo to the left. ^ Check visually and with your fingers to confirm that the wire is not located around the seat bracket area as indicated by the arrow in the photo Page 6389 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 1486 4. Install the generator on bracket. Inspection 1. Make sure oil does not leak or seep from where the oil pressure switch is installed. Page 3738 Spark Plug: Application and ID Type ..................................................................................................................................................... ............................................................. Manufacturer ILFR6B ................................................................................................................................................ .......................................................................... NGK Gap ...................................................................................................................................................... ................................. 0.7 - 0.8 mm (0.028 - 0.031 in) Torque ................................................................................................................................................. ........................................................ 21 N.m (15 ft.lb) Page 3824 1. BACK-UP LIGHT SWITCH AND NEUTRAL POSITION SWITCH 1) Install the back-up light switch and neutral position switch with harness. Tightening torque: 32.3 Nm (3.3 kgf-m, 23.8 ft. lbs.) 2) Connect the connector of back-up light switch and neutral position switch. 3) Install the air intake duct and cleaner case. (Non-turbo model) 4) Install the intercooler. (Turbo model) 5) Connect the battery ground cable to battery. Neutral Switch & Backup Switch Testing Switches and Harness INSPECTION BACK-UP LIGHT SWITCH Inspect the back-up light switch. NEUTRAL POSITION SWITCH 1) Turn the ignition switch to OFF. 2) Disconnect the connector of neutral position switch. 3) Measure the resistance between neutral position switch terminals. Non-turbo model: Non-turbo model Turbo model: Turbo model ^ Non-turbo model Page 687 B134-B136 Page 3419 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Engine Controls - DTC P0340/P0345 After Camshaft R & R Camshaft Position Sensor: All Technical Service Bulletins Engine Controls - DTC P0340/P0345 After Camshaft R & R Number: 02-107-09 Date: 03/24/09 Applicability: 2004~06MY Baja 2.5L Turbo 2004~06MY Impreza 2.5L Turbo 2004~06MY Forester 2.5L Turbo 2004~06MY Legacy/Outback 2.5L Turbo SUBJECT: Intake Camshaft Replacement Introduction If you encounter a vehicle that has a CEL and P0340 or P0345 stored in memory immediately after replacing the intake camshaft(s), the air gap between the camshaft and camshaft position sensor may be out of specification. A modification was made to the plate area of the camshaft where the camshaft position sensor picks up the signal. Parts Information Repair Procedure/ Information Using a feeler (thickness) gauge, measure the gap between the camshaft and camshaft position sensor. The correct gap is between 0.15mm to 0.98mm (0.0059 to 0.0386 in.) If the gap is over 0.98mm (0.0386 in.) replace the camshaft position sensor. Refer to the applicable service manual. Warranty/Claim Information For vehicles within warranty, refer the Subaru Warranty Wizard for claim submission information. Page 5652 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 1585 R58-R69 Page 6286 B128-B134 Page 2934 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 6157 (2) Front seat back heater: Double-faced tape has been added. Note: The part number has changed. Disclaimer Page 3268 Air Flow Meter/Sensor: Service and Repair Mass Air Flow and Intake Air Temperature Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the connector from mass air flow and intake air temperature sensor. 3. Remove the mass air flow and intake air temperature sensor. INSTALLATION Install in the reverse order of removal. Tightening torque: 1.7 N.m (0.17 kgf-m, 1.3 ft-lb) Page 7156 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 3309 CAUTION: Be sure to inspect hoses and their connections for any leakage of fuel. 3. Connect the evaporation hose by inserting it into the pipe for 15 to 20 mm (0.59 to 0.79 in) in length. L = 17.5 ±2.5 mm (0.689 ±0.098 in) Page 7045 Power Window Switch: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 1827 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 6131 B3-B12 Page 4256 Flywheel: Service and Repair Flywheel REMOVAL 1) Remove the transmission assembly. 5MT: 6MT: 2) Remove the clutch cover and clutch disc. 3) Using the ST, remove the flywheel. ST 498497100 CRANKSHAFT STOPPER INSTALLATION 1) Install the flywheel and ST. ST 498497100 CRANKSHAFT STOPPER 2) Tighten the flywheel attaching bolts to the specified torque. Tightening Torque: Except STi Model 72 N.m (7.3 kgf-m, 52.8 ft-lb) STi Model 75 N.m (7.6 kgf-m, 55.3 ft-lb) NOTE: Tighten the flywheel installing bolts gradually. Each bolt should be tightened to the specified torque in a crisscross fashion. Page 1471 B134-B136 Page 7375 B134-B136 Page 3420 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS General Clock: Description and Operation General GENERAL The clock unit display can be switched to indicate outside air temperature, fuel efficiency, remaining travel distance or continuous driving time, by operating a button. The DISP button is used for switching the display, and the indicated information switches in the following sequence each time the button is pressed: outside temperature -> fuel efficiency at the instant -> average fuel efficiency remaining travel distance -> continuous driving time. These data are sent from the combination meter by means of digital communication. This clock unit is provided with a function to automatically display a failure; if the accessory power circuit is open it displays "Acc", and if the ignition power circuit is open it displays "ign". If an abnormality is detected in the communication between the combination meter and clock unit or in the received data, "Err" is displayed. If no data can be received, "Err" will always be displayed even when the indication is switched with the DISP button, but when only a specific data is not received, "Err" will be displayed only when the indication is switched to display that data. For example, if outside temperature data is not received "Err" will be displayed only when the thermometer feature is selected, and other indications such as the fuel efficiency meter will be displayed normally. Page 3068 B128-B134 Page 3158 Air Injection Control Valve: Testing and Inspection INSPECTION Make sure the hoses are not cracked or loose. Page 7074 B54-B127 Page 685 B54-B127 Page 1873 Remove the hose from the reservoir tank. Cut 20 mm from the bottom of the hose at a 45° angle. Reinstall hose in reservoir tank. Start engine and permit to fully warm up. Turn off engine and allow to fully cool down. Recheck coolant level in reservoir and add coolant if needed. Note: Be sure to use genuine Subaru Super Coolant or Subaru Long Life Coolant, depending upon what type of coolant is currently in the system. Warranty/Claim Information Page 7304 7. Perform the above steps from 1) to 6) at the MIN and MAX positions of intermittent control switch, and replace the wiper switch assembly if it does not operate as specified. Testing and Inspection Windshield Washer Switch: Testing and Inspection COMBINATION SWITCH (WIPER) INSPECTION - Inspect the continuity between each connector terminal If continuity is not as specified, replace the switch. - Intermittent operation inspection (inspection of wiper switch unit) 1. Position the voltage meter between the connector terminals No. 7 (+) and No. 2 (-). 2. Connect the battery positive lead to connector terminal No. 17 and the negative lead to connector terminals No. 2 and No. 16. 3. Turn the wiper switch to INT. 4. Disconnect the battery negative lead from connector terminal No. 16. 5. Connect the battery positive lead to connector terminal No. 16 for 5 seconds. 6. Connect the battery negative lead to connector terminal No. 16, and check the voltage between the connector terminals No. 7 (+) and No. 2 (-). Page 4905 2. Remove the ring, stopper and clutch from shaft. 2. BRUSH HOLDER NOTE: Only the brush holder of turbo MT model starter can be disassembled. Slightly open the metal fitting while holding the insulating plate against the brush holder. Remove the insulating plate. The brush and spring can be easily removed from the brush holder at this time. ASSEMBLY 1. Assemble in the reverse order of disassembly. 2. Apply grease to the following parts before assembly. - Front and rear bracket sleeve bearings - Armature shaft gear - Outer periphery of plunger - Mating surfaces of plunger and lever - Gear shaft splines - Mating surfaces of lever and clutch - Ball at armature shaft end - Planetary gear Front Sub Sensor Impact Sensor: Service and Repair Front Sub Sensor FRONT SUB SENSOR REMOVAL 1. Turn the ignition switch to OFF. 2. Disconnect the ground cable from battery, and wait for at least 20 seconds before starting work. 3. Remove the front bumper. 4. Remove the bolt, and then detach the front sub sensor. 5. Disconnect the connector from front sub sensor. B: INSTALLATION Install in the reverse order of removal. Tightening torque: Refer to "COMPONENT" in "General Description". See: Air Bag Systems/Locations Page 4151 Schematic drawings Page 1501 B17-B20 Page 6257 Non-Turbo Model Page 3776 R58-R69 Page 4029 Shifter A/T: Description and Operation Select Lever - The automatic transmission select lever can be moved to any of the 4 ranges and the transmission enters sports mode when the lever is moved laterally from D range, and further switches to sports shift mode (manual mode) when the lever is moved forward ("+" direction) or rearward ("-" direction). - The select lever makes shift direction (longitudinal) movements as well as select direction (lateral) movements. The select lever is guided by a gate to make these movements. - In the sports shift mode, the transmission upshifts when the selector lever is moved forward ("+" direction) and downshifts when the lever is moved rearward ("-" direction). - To transmit movements of the select lever to the transmission, a select cable is used. - The select lever mechanism has a detent spring. It ensures more precise positioning of the select lever Locations Sensor Cooling System - Coolant Comes Out Of Reservoir Coolant Line/Hose: All Technical Service Bulletins Cooling System - Coolant Comes Out Of Reservoir NUMBER: 08-52-08 DATE: 08/18/08 APPLICABILITY: 1999MY and later Impreza & Forester 2000MY and later Legacy & Outback 2006MY and later Tribeca SUBJECT: Coolant Overflow Introduction If you encounter a vehicle which experiences coolant coming out of the coolant reservoir tank, it may be caused by the radiator cap pressure valve being stuck open by debris sucked up through the reservoir tank hose. As the cooling system cools down, it sucks coolant back into the radiator. If there is debris that settles to the bottom of the reservoir tank, the hose is low enough to also suck them back into radiator. This causes the radiator cap not to seal, allowing excessive amount of coolant to escape overflowing the reservoir tank. If this condition continues over time, there will not be enough coolant in the system to maintain proper engine temperature. In order to correct the condition you need to clean (and test) or replace the radiator cap, clean out the reservoir tank, and shorten the hose slightly, following the repair procedure. Production Line Change The shorter coolant reservoir tank hose was used in production as shown above. Repair Procedure/Information 1. Radiator Cap Cleaning Many caps can be successfully cleaned. The important part is the thorough cleaning of the negative pressure valve. If this is not done completely, remaining debris may result in a repeat issue. If there is an excessive amount of debris or the sealing rubber on the cap appears to be pitted or damaged, replace the cap. Note: If replacing the cap, skip to Step 2. Using clean water and a brush, thoroughly clean the cap seal surface. Note: Page 3391 B3-B12 Service and Repair Fuel Pump Control Unit: Service and Repair Fuel Pump Control Unit REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the rear quarter trim. 3. Disconnect the connector from the fuel pump control unit. 4. Remove the fuel pump control unit. INSTALLATION Install in the reverse order of removal. Locations Crankshaft Position Sensor: Locations Sensor (Part 1) Page 5479 Step 1 - 5 Page 6456 B380-f6 Page 188 F21-F61 Page 556 Page 1552 21. Remove the intake duct from the intake manifold. 22. Remove the tumble generator valve assembly from the intake manifold. ASSEMBLY NOTE: Replace the gasket with a new one. 1. Install the tumble generator valve assembly the intake manifold. 2. Install the air intake duct to the intake manifold. Page 4412 5) Disconnect the inhibitor switch connector. 6) Remove the inhibitor switch connector from stay. 7) Lift-up the vehicle. 8) Remove the front and center exhaust pipes. 9) Remove the snap pin and washer from range select lever. 10) Remove the plate assembly from transmission case. 11) Remove the bolts. Page 148 Main Relay (Computer/Fuel System): Service and Repair Main Relay REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the passenger's side front side sill cover. 3. Remove the bolt which holds the relay bracket on the body. 4. Disconnect the connectors from the main relay. 5. Remove the main relay from the mounting bracket. INSTALLATION Install in the reverse order of removal. Page 1168 Fluid - A/T: Service and Repair Differential Fluid Level Check Differential Gear Oil 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 check the level. If the differential gear oil level is below the "L" line, add oil to bring the level up to the "F" line. 5) To prevent overfilling the differential gear oil, do not replenish oil above the "F" line. Page 3542 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the bolt which installs the crankshaft position sensor to cylinder block. 3. Remove the crankshaft position sensor, and disconnect the connector from it. INSTALLATION Install in the reverse order of removal. General Brake Master Cylinder: Description and Operation General Master Cylinder - The master cylinder consists of a brake fluid reservoir chamber that stores brake fluid, and a hydraulic chamber section that converts the force applied to the brake pedal into hydraulic pressure. - The hydraulic pressure generated in each of the two hydraulic chambers are sent to the brake caliper of each wheel through the 2 diagonally split brake circuits. Page 5287 Wheels: Service Precautions Aluminum Wheel CAUTION Aluminum wheels are easily scratched. To maintain their appearance and safety, do the following: 1. Do not damage the aluminum wheels during removal, installation, wheel balancing, etc. After removing, place them on a rubber mat, etc. 2. While the vehicle is being driven, be careful not to ride over sharp obstacles or allow the wheels to contact the shoulder of road. 3. When installing a tire chain, be sure to install it properly not to have slack; otherwise it may hit the wheel while driving. 4. When washing the aluminum wheel, use neutral synthetic detergent and water. Avoid using the cleanser including abrasive, hard brushes or an automatic car washer. Page 6760 - Do not leave the headlight without a bulb for a long time. Dust, and moisture, etc. entering the headlight may affect its performance. 1. Remove the ground cable from battery. 2. Remove the headlight assembly. 3. Remove the back cover. 4. Disconnect the harness connector. 5. Remove the light bulb retaining spring, and then remove the bulb. INSTALLATION Install in the reverse order of removal. CAUTION: Attach the rubber cap with letters TOP on the top so the drain hole will be on the lower side. Page 6150 - The sunshade automatically opens or closes together with the rear glass lid. However, when completely closing the sunroof, the sunshade will come to a stop at a position 170 mm (6.69 in) before the fully closed position even when the front glass lid is completely tilted down. Close the shade manually after the glass lid is completely closed. Page 3404 Air Flow Meter/Sensor: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 3098 B128-B134 Page 1197 The proper viscosity helps vehicle get good cold and hot starting by reducing viscous friction and thus increasing cranking speed. CAUTION: When replenishing oil, it does not matter if the oil to be added is a different brand from that in the engine; however, use oil having the API standard and SAE viscosity No. designated by SUBARU. NOTE: If the vehicle is used in areas with very high temperatures or for other heavy duty applications, the following viscosity oils may be used: API standard: SM or SL SAE Viscosity No.: 30, 40, 10W-50, 20W-40, 20W50. 7. Close the engine oil filler cap. 8. Start the engine and warm it up for a time. 9. After the engine stops, recheck the oil level. If necessary, add engine oil up to the upper level on level gauge. Page 7030 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. A/T Controls - DTC P0851/P0852 Set Neutral Safety Switch: All Technical Service Bulletins A/T Controls - DTC P0851/P0852 Set NUMBER: 16-68-06 DATE: 10/09/06 APPLICABILITY: 2005~06MY Legacy, Outback, Impreza and Forester Vehicles Equipped with 4EAT SUBJECT: Diagnostic procedures for P0851/P0852 INTRODUCTION The purpose of this bulletin is to assist when diagnosing P0851 (Neutral Switch Input Circuit Low) and P0852 Neutral Switch Input Circuit High). If you encounter a vehicle with P0851 and/or P0852, use the following repair procedure. REPAIR PROCEDURE/INFORMATION Using the Subaru Select Monitor, check for diagnostic trouble codes stored in memory. If P0851 and/or P0852 are stored in memory, adjust the inhibitor switch and select cable. Note: Refer to the applicable Subaru Service Manual found on the STIS web-site for component removal to gain access to the inhibitor switch and select cable. It is critical that the following adjustments are performed correctly. Adjustment for inhibitor switch 1) Set the select lever to "N" range. 2) Loosen the three inhibitor switch securing bolts. 3) Insert ST (special tool) 499267300 Stopper Pin as vertical as possible into the holes in the inhibitor switch lever and switch body. 4) Tighten the three inhibitor switch securing bolts then remove special tool. Tightening torque: 3.4 N-m (0.35 kgf-m, 2.5 ft-lb) Adjustment for select cable Page 319 B134-B136 Page 1387 Valve Clearance: Adjustments Adjustment CAUTION: Adjustment of the valve clearance should be performed while engine is cold. 1. Measure all valve clearances. NOTE: Record each valve clearance after it has been measured. 2. Remove the camshaft. 3. Remove the valve lifter. 4. Measure the thickness of valve lifter with a micrometer. 5. Select a shim of suitable thickness using measured valve clearance and valve lifter thickness, by referring to the following table. Service and Repair Spare Tire: Service and Repair "T-type" Tire NOTE "T-type" tire for temporary use is prepared as a spare tire. CAUTION: ^ Do not use a tire chain with the "T-type" tire. Because of the smaller tire size, a tire chain will not fit properly and will result in damage to the vehicle and the tire. ^ Do not drive at a speed greater than 80 km/h (50 MPH). ^ Drive as slowly as possible and avoid passing over bumps. REPLACEMENT Refer to Aluminum Wheel for removal and installation of T-type tires. CAUTION: Replace with a conventional tire as soon as possible since the T-type tire is only for temporary use. INSPECTION 1. Check the tire inflation pressure. Specification: 420 kPa (4.2 kg/cm2, 60 psi) 2. Take stones, glass, nails, etc. out of the tread groove. 3. Check the tires for deformation, cracks, partial or over limit wear. CAUTION: Replace the tire with a new one. Page 1037 Valve Clearance: Testing and Inspection VALVE CLEARANCE INSPECTION Inspection and adjustment of the valve clearance should be performed while engine is cold. 1. Set the vehicle on a lift. 2. Disconnect the ground cable from battery. 3. Remove the air intake duct. 4. Remove the bolts which secure the timing belt cover (RH). 5. Lift-up the vehicle. 6. Remove the under cover. 7. Loosen the remaining bolts which secure the timing belt cover (RH), and then remove the timing belt cover. 8. Lower the vehicle. 9. When inspecting the #1 and #3 cylinders: 1. Pull out the engine harness connector with bracket from air cleaner upper cover. 2. Remove the air cleaner case. 3. Disconnect the ignition coil connector. 4. Remove the ignition coil. 5. Place a suitable container under the vehicle. 6. Disconnect the PCV hose from rocker cover (RH). 7. Remove the bolts, and then remove the rocker cover (RH). 10. When inspecting the #2 and #4 cylinders: 1. Disconnect the battery cable, and then remove the battery and battery carrier. 2. Remove the secondary air pump. 3. Disconnect the ignition coil connector. 4. Remove the ignition coil. 5. Place a suitable container under the vehicle. 6. Disconnect the PCV hose from rocker cover (LH) 7. Remove the bolts, and then remove the rocker cover (LH). 11. Turn the crank pulley clockwise until arrow mark on the cam sprocket is set to position shown in the figure. NOTE: Turn the crankshaft using socket wrench. 12. Measure the #1 cylinder intake valve and #3 cylinder exhaust valve clearance by using thickness gauge (A). NOTE: ^ Insert the thickness gauge (A) in as horizontal a direction as possible with respect to the shim. ^ Measure the exhaust valve clearances while lifting-up the vehicle. Valve clearance: STD Intake: 0.20 ± 0.02 mm (0.0079 ± 0.0008 inch) Exhaust. 0.35 ± 0.02 mm (0.0138 ± 0.0008 inch) Page 5201 INPUT SHAFT PLAY TURNING RESISTANCE OF GEARBOX Using the ST, measure the gearbox turning resistance. ST 34099PA100 SPANNER Page 6400 F21-F61 Page 708 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 6452 B134-B136 Page 3331 Fuel Filler Hose: Service and Repair Disassembly and Assembly Fuel Filler Pipe DISASSEMBLY 1. Move the clamp, and disconnect the evaporation hose from the joint pipe. 2. Remove the bolt which installs the joint pipe on the fuel filler pipe. 3. Disconnect the evaporation hose from the fuel filler pipe. 4. Remove the shut valve from the fuel filler pipe. ASSEMBLY 1. Install the shut valve on the fuel filler pipe. 2. Connect the evaporation hose to the fuel filler pipe. Locations Electrical Component Location Page 2506 4. Remove the ignition coil and ignitor assembly. 5. Remove the spark plugs with the spark plug sockets. INSTALLATION RH SIDE Install in the reverse order of removal. Tightening torque (Spark plug): 21 N.m (2.1 kgf-m, 15.2 ft-lb) Tightening torque (Ignition coil and ignitor assembly): 16 N.m (1.6 kgf-m, 11.7 ft-lb) NOTE: - The above torque should be only applied to new spark plugs without oil on their threads. - In case their threads are lubricated, the torque should be reduced by approx. 1/3 of the specified torque in order to avoid over-stressing. LH SIDE Install in the reverse order of removal. Tightening torque (Spark plug): 21 N.m (2.1 kgf-m, 15.2 ft-lb) Tightening torque (Ignition coil and ignitor assembly): 16 N.m (1.6 kgf-m, 11.7 ft-lb) NOTE: - The above torque should be only applied to new spark plugs without oil on their threads. - In case their threads are lubricated, the torque should be reduced by approx. 1/3 of the specified torque in order to avoid over-stressing. Page 703 Fuel Temperature Sensor: Service and Repair Fuel Temperature Sensor REMOVAL Fuel temperature sensor and fuel level sensor are integrated into one unit; therefore, the removal procedure is the same as that for fuel level sensor. INSTALLATION Fuel temperature sensor and fuel level sensor are integrated into one unit; therefore, the installation procedure is the same as that for fuel level sensor. Page 6355 B380-f6 Page 7046 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 2347 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 5877 Front Door Panel: Service and Repair Front Sealing Cover FRONT SEALING COVER REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the front door trim. 3. Remove the front speaker. 4. Remove the door trim bracket. 5. Remove the sealing cover. NOTE: - Carefully remove the butyl tape. Excessive force will easily break the cover. - If the cover gets broken, replace it with a new one. INSTALLATION 1. Install in the reverse order of removal. 2. When replacing the sealing cover, use the butyl tape. 3. Press the butyl tape-applied area firmly to prevent any floating on surface. Butyl tape: 3M 8626 or equivalent NOTE: Apply a uniform bead of butyl tape. - Attach the sealing cover, keeping it from becoming wrinkled. - Breaks in the bead will allow water leakage and contamination. Page 2754 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Locations Wheel Speed Sensor: Locations Electrical Component Location Page 1291 8) Install the ABS wheel speed sensor on housing. Tightening torque: 33 Nm (3.4 kgf-m, 24 ft. lbs.) 9) Install the wheel and tighten the wheel nuts to specified torque. Tightening torque: 90 Nm (9.1 kgf-m, 65.7 ft. lbs.) DISASSEMBLY Using the ST and a hydraulic press, drive hub bolts out. ST 28399AG000 HUB STAND CAUTION: ^ Be careful not to hammer the hub bolts. This may deform the hub. ^ Do not reuse the hub bolt. NOTE: Since the hub unit bearing can not be disassembled, only hub bolts can be removed. ASSEMBLY 1) Attach the hub to ST securely. ST 28099PA080 HUB STAND 2) Using a press, Press new hub bolts until their seating surfaces contact the hub. NOTE: Use 12 mm (0.47 inch) dia. holes in HUB STAND to prevent bolts from tilting. INSPECTION Page 6288 B136-B141 Locations Secondary A/C Fuse Box Page 4707 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Engine Controls - DTC P0607 Diagnostic Information Engine Control Module: Customer Interest Engine Controls - DTC P0607 Diagnostic Information NUMBER: 11-91-08 DATE: 12/05/08 APPLICABILITY: 2004-2008MY Impreza 2004-2008MY Forester 2005-2008MY Legacy/Outback 2006-2007MY Tribeca SUBJECT: DTC P0607 Control Module Performance Introduction The purpose of the bulletin is for information purposes when diagnosing DTC P0607. The following checks and information is in addition to what is listed in the Subaru Service Manual. This information is to be used in conjunction with the service manual. Repair Procedure/Information Additional items to check: ^ Rapid drop of voltage from a dead battery ^ Loose battery terminals ^ Loose ECM ground terminal ^ A short or open to the power or ground circuit If the malfunction criteria are met, the CEL will illuminate, the vehicle will go into fail safe and the throttle valve opening will be fixed at 6°. Fail safe will recover to normal mode if the ECM judges the criteria "OK" at the time of the next engine start. The CEL will not turn off until the "OK" driving cycle is completed 3 times in a row. The judgment is decided by the ECM to keep the CEL On or Off at the time the ignition switch is turned from ON to OFF. The ECM keeps DTC P0607 in memory even after the indicator light goes out. Therefore, it is important to erase memory after the repair is completed. Detail list of applicable model and engine type. Page 3258 B230-B283 Page 1842 F61-R47 Page 5484 Solar Sensor: Testing and Inspection SUNLOAD SENSOR TROUBLE SYMPTOM: - Sensor identified that sunlight is at maximum. Then, A/C system is controlled to COOL side. - Sensor identified that sunlight is at minimum. Then, A/C system is controlled to HOT side. NOTE: When the sunload sensor is checked indoors or in the shade, it may be diagnosed as open circuit. Always check the sunload sensor at a place where sun shines directly on it. Wiring Diagram Engine Controls - A/F, O2 Sensor Diagnostic Information Oxygen Sensor: Technical Service Bulletins Engine Controls - A/F, O2 Sensor Diagnostic Information Bulletin Number: 11-92-08 Date: 01/05/09 APPLICABILITY: 1999MY and later Forester 1999MY and later Impreza 2000MY and later Legacy 2006MY and later Tribeca SUBJECT: Air/Fuel Ratio Sensor and Oxygen Sensor INTRODUCTION This bulletin is for information purposes only. REPAIR/SERVICE INFORMATION When performing diagnostics or reading Diagnostic Trouble Codes (DTC) for Air Fuel Ratio (A/F) sensors and Oxygen (O2) sensors use the following information to identify, locate and repair the appropriate sensor and sensor circuits: (1) Rarely will multiple sensors fail at the same time. (2) On vehicles with only one O2 sensor, the designation for that O2 sensor will be bank 1. (3) On vehicles with only one A/F sensor, the designation for that A/F sensor will be bank 1. (4) Any reference to sensor 1 is an A/F sensor. (5) Any reference to sensor 2 is an O2 sensor. (6) Early PZEV vehicles used an additional O2 sensor behind the rear catalyst and is designated sensor 3. (7) On vehicles with A/F and O2 sensors on the right (Passenger Side) and left (Driver side) of the vehicle, Bank 1 is the right side (Passenger Side) and Bank 2 is the left side (Driver side). Example: DTC P0030 HO2S HEATER CONTROL CIRCUIT (Bank 1 Sensor 1). This DTC is referring to the A/F sensor and since it is on a 2007 Forester there is only one A/F sensor and one O2 sensor. Example (as illustrated): DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (Bank 1 Sensor 2). This DTC is referring to the O2 sensor on the right side exhaust (or the O2 sensor of a vehicle with only one O2 sensor). Page 1529 Engine Oil Pressure: Testing and Inspection Engine Oil Pressure INSPECTION 1. Remove the oil pressure switch. 2. Connect the oil pressure gauge hose to cylinder block. 3. Connect the battery ground cable to battery. 4. Start the engine, and then measure the oil pressure. Oil pressure: 98 kPa (1.0 kgf/cm2, 14 psi) or more at 600 rpm 294 kPa (3.0 kgf/cm2, 43 psi) or more at 5,000 rpm CAUTION: ^ If the oil pressure is out of specification, check oil pump, oil filter and lubrication line. ^ If the oil pressure warning light is turned ON and oil pressure is in specification, replace the oil pressure switch. NOTE: The specified data is based on an engine oil temperature of 80°C (176°F). 5. After measuring the oil pressure, install the oil pressure switch. Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft. lbs.) Page 6646 Tire Monitoring System: Technical Service Bulletins Tire Monitor System - Valve Stem Cap Information 05 tire valve stem caps This is to remind you of the importance of the tire valve stem cap. These caps need to be installed on every tire, regardless if the vehicle is equipped with TPMS or not. Without these caps, dirt and moisture can interfere with the proper sealing of the tire valve stem. This can result in a gradual loss of tire pressure or interfere with adding air to the tire. In turn this may result in a TPMS lamp coming on and an inconvenienced customer. The cap is gray in color, part # S0A342LT09. The accessory SPT valve stem cap may also be used and will not affect the TPMS operation. Page 644 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 4547 2. Place a wooden block in caliper body as shown in the figure to prevent the piston from jumping out and avoid being damaged. 3. Gradually supply compressed air via the installation hole of brake hose to force the piston out. 4. Remove the piston seal from caliper body cylinder. CAUTION: Do not damage the cylinder and piston seal groove. ASSEMBLY 1. 14 INCH TYPE 1. Clean the caliper body interior using brake fluid. 2. Apply a coat of brake fluid to the piston seal and fit piston seal in groove on caliper body. 3. Apply a coat of brake fluid to the entire inner surface of cylinder and outer surface of piston. 4. Insert the piston into cylinder. CAUTION: Do not force piston into cylinder. 5. Apply a coat of specified grease to the boot and fit in groove on ends of cylinder and piston. Grease: NIGLUBE RX-2 (Part No. K0779GA 102) 6. Install the piston boot to caliper body, and then attach boot ring. Page 558 The list shown above is of A/F Sensor related DTCs. (This list is for example only. Refer to the applicable service manual for a complete list of DTCs.) Note: When the DTCs for A/F sensor are stored in memory, do not replace the oxygen sensor. The list above is of O2 Sensor related DTCs. (This list is for example only. Refer to the applicable service manual for a complete list of DTCs.) Note: When the DTCs for O2 sensor are stored in memory, do not replace the A/F sensor. Page 2984 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 1055 3. Tighten the bolts. Tightening torque: 9.75 Nm (1.0 kgf-m, 7.2 ft. lbs.) Tightening torque: 6.4 Nm (0.65 kgf-m, 4.7 ft. lbs.) Tightening torque: 6.4 Nm (0.65 kgf-m, 4.7 ft. lbs.) Tightening torque: 6.4 Nm (0.65 kgf-m, 4.7 ft. lbs.) Page 7279 (1) Open the hood and remove the check valve. (2) Attach valve cushion (86634SA000) around the modified check valve (86634AG000) for soundproofing. A/C, Interior - Seat Heater Relay Updated Seat Heater: Technical Service Bulletins A/C, Interior - Seat Heater Relay Updated change of seat heater relay In order to use a common seat heater relay with other models, FUT has changed the seat heater relay installed in Impreza and Forester vehicles from part number 8250TTC000 (brown) to 8250TFCT00 (black). The relay is located next to the fuse box under the lower dash panel on the driver side on vehicles equipped with seat heaters VIN breaks where the new relay has been installed are as shown. Diagnostic Aids Fuse: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 115 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 2169 Fuel Tank Pressure Sensor: Testing and Inspection INSPECTION Make sure the hoses are not cracked or loose. Locations Sensor Page 6387 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 4703 R58-R69 Page 3237 Air Filter Element: Service and Repair Air Cleaner Element REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the connector from mass air flow and intake air temperature sensor. 3. Loosen the clamp (A) which connects the air intake boot and intake duct. 4. Remove the clip (B) from air cleaner upper cover. 5. Remove the air cleaner upper cover. 6. Remove the air cleaner element. INSTALLATION Install in the reverse order of removal. NOTE: Before installing the air cleaner upper cover, align the holes with protruding portions of air cleaner lower case, then secure the upper cover to the lower case. Page 3088 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 979 Wiper Switch: Service and Repair COMBINATION SWITCH (WIPER) REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the instrument panel lower cover. 3. Loosen the screw to remove steering column cover lower. 4. Remove the screw to steering column cover upper. 5. Disconnect the connectors from combination switches. 6. Loosen the screw to remove combination switch. INSTALLATION Install in the reverse order of removal. Page 4607 Brake Caliper: Testing and Inspection Rear INSPECTION 1. Repair or replace the faulty parts. 2. Check the caliper body and piston for uneven wear, damage or rust. 3. Check the rubber parts for damage or deterioration. Locations Clutch Switch: Locations Non-Turbo Model Page 4053 INSTALLATION 1) Insert the reverse check cable to the hole of inner boots from underneath the vehicle. 2) Insert the reverse check cable to the gear shift lever assembly, then fix with the band clip. NOTE: ^ Cut off the extra band clip. ^ Make sure that the reverse check cable is inserted into gear shift lever assembly without any clearance. 3) Fix the slider and reverse check cable end with spring pin. NOTE: Apply grease to the sliding part of slider. 4) With the cable pulled (slider lowered), adjust the length between end of cable plate and reverse check cable to 84 mm (3.31 inch), and then tighten the lock nut. Page 499 Fuel Tank Pressure Sensor: Testing and Inspection INSPECTION Make sure the hoses are not cracked or loose. Locations Fuel Gauge Sender: Locations Page 379 8. Remove the bolts which install the fuel sub level sensor on the fuel tank. 9. Remove the fuel sub level sensor. INSTALLATION Install in the reverse order of removal. NOTE: Use a new gasket. 1. Ensure the sealing portion is free from fuel or foreign particles before installation. 2. Tighten the nuts and bolts to specified torque in order as shown in the figure. Page 2248 B134-B136 Page 3984 Transmission Speed Sensor: Service and Repair Rear Vehicle Speed Sensor Rear Vehicle Speed Sensor REMOVAL 1) Set the vehicle on a lift, and then lift-up the vehicle. 2) Disconnect the connector from rear vehicle speed sensor. ^ MP-T model MP-T model ^ VTD model VTD model 3) Remove the rear vehicle speed sensor. ^ MP-T model MP-T model ^ VTD model Page 5183 11) Align the ST pin to plug hole to install. Rotate the ST counterclockwise to remove plug. ST 34199AE090 PLUG WRENCH 12) Remove the valve assembly taking care not to scratch seal ring and valve housing inner surface. Page 4918 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 4008 B3-B12 Page 3020 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Specifications Differential Fluid - Transfer Case: Specifications The Subaru transmission incorporates the transfer case within the unit and lubricates from a common sump. For the fluid specification refer to Manual Transmission/Transaxle or Automatic Transmission/Transaxle. Page 6597 Fuel Gauge Sender: Service and Repair Fuel Sub Level Sensor Fuel Sub Level Sensor REMOVAL WARNING: - Place "NO FIRE" signs near the working area. - Be careful not to spill the fuel. 1. Disconnect the ground cable from battery. 2. Lift up the vehicle. 3. Drain the fuel from the fuel tank. 4. Remove the rear seat. 5. Remove the service hole cover. 6. Disconnect the connector from the fuel sub level sensor. 7. Disconnect the fuel jet pump hose. Page 4613 3. Remove the boot from piston end. 4. Place a wooden block in caliper body as shown in the figure to prevent the piston from jumping out and avoid being damaged. 5. Gradually supply compressed air via the installation hole of brake hose to force the piston out. 6. Remove the piston seal from caliper body cylinder. CAUTION: Do not damage the cylinder and piston seal groove. 3. 17 INCH TYPE 1. Clean mud and foreign particles from the caliper body assembly. CAUTION: Be careful not to allow foreign particles to enter the brake hose connector. Page 969 7. Perform the above steps from 1) to 6) at the MIN and MAX positions of intermittent control switch, and replace the wiper switch assembly if it does not operate as specified. Page 2276 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 1915 B128-B134 Page 2775 7. Connect the connector of front oxygen (A/F)sensor. 8. Connect the battery ground cable to battery. Locations Variable Induction Position Sensor: Locations Sensor (Part 1) Page 2084 B128-B134 Page 958 Power Window Switch: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 2271 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 2283 B128-B134 Page 1763 A used toothbrush which has been cleaned works great. Manually open the negative pressure valve. Using clean water and a brush, thoroughly clean the valve (inner and outer surface) and the valve seal surface. Check the radiator cap valve opening pressure using a radiator cap tester to insure the cap is within specification (refer to the applicable Subaru Service Manual). Note: If the cap is out of specification replace it. 2. Coolant Reservoir Tank Cleaning Remove the reservoir tank (refer to the applicable Subaru Service Manual). Using clean water, thoroughly clean the inside of the reservoir tank. Reinstall reservoir tank. Fill with coolant to the Full mark. Note: Be sure to use genuine Subaru Super Coolant or Subaru Long Life Coolant, depending upon what type of coolant is currently in the system. 3. Coolant Reservoir Tank Hose Modification Page 538 2. Connect the knock sensor connector. 3. Install the intercooler. 4. Connect the battery ground cable to battery. Page 4705 Parking Brake Warning Lamp: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 6277 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 555 Page 1355 O.D.: Outer Diameter 4. Measure the side clearance of crankshaft at center bearing. If the clearance exceeds the limit, replace the bearing. Crankshaft side clearance: Standard 0.030 - 0.115 mm (0.0012 - 0.0045 inch) Limit 0.25 mm (0.0098 inch) 5. Inspect individual crankshaft bearings for signs of flaking, seizure, melting, and wear. 6. Measure the oil clearance on each crankshaft bearing by means of plastigauge. If the measurement is not within the specification, replace the defective bearing with an undersize one, and replace or recondition the crankshaft as necessary. Crankshaft oil clearance: Standard 0.010 - 0.030 mm (0.0004 - 0.0012 inch) Limit 0.040 mm (0.0016 inch) Page 1605 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 2867 B380-f6 Page 4920 B3-B12 Page 2164 Fuel Level Sensor: Service and Repair Fuel Sub Level Sensor Fuel Sub Level Sensor REMOVAL WARNING: - Place "NO FIRE" signs near the working area. - Be careful not to spill fuel on the floor. 1. Disconnect the ground cable from battery. 2. Lift up the vehicle. 3. Drain the fuel from the fuel tank. 4. Remove the luggage floor mat. 5. Remove the service hole cover. 6. Disconnect the connector from the fuel sub level sensor. 7. Disconnect the fuel jet pump hose. 8. Remove the bolts which install the fuel sub level sensor on the fuel tank. Page 1834 B54-B127 M/T - Clutch Pedal Squeaking Noise Clutch Pedal Assembly: Technical Service Bulletins M/T - Clutch Pedal Squeaking Noise CLUTCH PEDAL SQUEAK If you encounter a manual transmission equipped vehicle with a clutch pedal squeak concern, and lubricating the pedal mechanism didn't fix the noise, check the clutch switch. We have had a few reports where this has been the source of the problem. The fix is to replace the clutch pedal switch. Page 2128 Air Flow Meter/Sensor: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 1555 - RH side 12. Tighten the two bolts which install the fuel injector pipes on the left side of intake manifold. 13. Connect the evaporation hoses to the purge valve. NOTE: Connect the evaporation hoses as shown in the figure. Page 2454 B54-B127 Service and Repair Throttle Body: Service and Repair Throttle Body REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the intercooler. 3. Disconnect the connector from the throttle position sensor (A) and manifold absolute pressure sensor (B). 4. Disconnect the engine coolant hoses from the throttle body. 5. Remove the bolts which secure the throttle body to intake manifold. INSTALLATION 1. Install in the reverse order of removal. NOTE: Always use a new gasket. Page 278 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the generator. 3. Drain the engine coolant. 4. Disconnect the connector from the engine coolant temperature sensor. 5. Remove the engine coolant temperature sensor. INSTALLATION Install in the reverse order of removal. NOTE: Use a new gasket. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb) Service and Repair Body Control Module: Service and Repair Body Integrated Module REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the lower cover. 3) Remove the knee bolster. 4) Disconnect the connector from body integrated module. 5) Remove the body integrated module. INSTALLATION Install in the reverse order of removal. Page 6017 - When checking, use a test harness (1). Do not directly apply the tester probe to any connector terminal of the airbag. Damage to the connector terminal may cause the airbag to activate erroneously. - Do not check continuity of either of the airbag modules for driver, passenger or side, or pretensioner. Page 2039 Engine Control Module (ECM) I/O Signal (Part 3) Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Torque Specifications Crank Pulley Bolt ........................................................................................................................................................... 180 Nm (18.4 kgf-m, 132.8 ft. lbs.) Engine - Turbocharger Oil Supply Mesh Screen Oil Line: Technical Service Bulletins Engine - Turbocharger Oil Supply Mesh Screen NUMBER: 02-103-07R DATE: 10/29/07 APPLICABILITY: All Turbo Equipped Vehicles SUBJECT: Turbocharger Oil Supply Mesh Screen INTRODUCTION This bulletin is for informational purposes only Turbocharged engines require proper maintenance especially when the vehicle is used under severe driving conditions such as moderate to hard acceleration and engine braking on a somewhat regular basis. In any case, it is recommended that the engine oil and filter be changed every 3,750 miles (6,000 km) or 3~3/4 months. In addition, the mesh screen which is located inside the banjo bolt that secures the turbocharger oil supply pipe to the back of the right side cylinder head should be checked to make sure it is not clogged or restricted especially if the condition of the oil is questionable or as to when the last oil change was performed. If clogged or restricted, it will reduce or cut off the oil supply to the turbo resulting in failure The oil supply pipe should also be checked to make sure that there are no obstructions. Note: The mesh screen is only available with a replacement banjo bolt ^ Make sure the mesh screen is installed in the proper direction; incorrect installation will cut off oil supply to the turbo. ^ Do not confuse the oil supply mesh screen with the Active Valve Control System (AVCS) union screw filter Refer to Service Bulletin 02-97-05 dated 10/06/05. ^ When the vehicle is used under severe driving conditions, the engine oil is consumed more quickly than under normal driving conditions due to high intake manifold vacuum during engine braking and higher temperatures; the engine oil level should be checked at every fuel fill up. For additional examples of severe driving conditions~ refer to the Warranty & Maintenance Booklet. Disclaimer Locations Fuel Tank Pressure Sensor: Locations Page 6853 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 249 Wiper Relay: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 655 B134-B136 Front Door Lock Actuator Power Door Lock Actuator: Testing and Inspection Front Door Lock Actuator FRONT DOOR LOCK ACTUATOR INSPECTION 1. Disconnect the front door lock actuator harness connector. 2. Connect the battery to front door lock actuator terminals. If NG, replace the door lock actuator. Page 6122 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 4542 Page 1462 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 7294 Windshield Washer Spray Nozzle: Testing and Inspection Rear Washer Rear Washer INSPECTION - Make sure the nozzle and hose are not clogged. - Make sure the hose is not bent. Page 1735 Coolant: Fluid Type Specifications The cooling system has been filled at the factory with a high quality, corrosion-inhibiting, year-round coolant which provides protection against freezing down to -33°F (-36°C). For adding, use genuine SUBARU coolant or an equivalent: a mixture of 50% soft water and 50% ethylene-glycol based coolant. Use of improper coolants may result in corrosion in the cooling system. It is important to maintain protection against freezing and corrosion, even if freezing temperatures are not expected. Never mix different kinds of coolant. Do not splash coolant on the vehicle's paint. Page 6513 B128-B134 Page 579 B136-B141 Page 2388 B17-B20 Page 3135 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 3189 INSTALLATION Install in the reverse order of removal. NOTE: Replace the gasket with a new one. Page 3397 B230-B283 Page 5073 B3-B12 Locations Main Relay (Computer/Fuel System): Locations Main Fuse Box (M/B) Solenoid Valve, Actuator, Emission Control System Parts And Ignition System Parts (Part 5) Page 943 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 6545 B230-B283 Page 125 B230-B283 Page 5755 Keyless Entry Transmitter: Technical Service Bulletins Keyless Entry - Remote Transmitter Modification NUMBER: 15-117-06 DATE: 04/06/06 APPLICABILITY: 2005MY Legacy and Outback 2005-06MY Forester and Impreza SUBJECT: Keyless Remote Transmitter Modification INTRODUCTION A modification has been made to the keyless remote transmitter to prevent unintentional activation. PRODUCTION LINE CHANGE The modified transmitter was used in 2006MY production with the following VINs: Existing transmitters can be modified using the following procedure. Note: Part # 88039AG02A contains an upper transmitter case, lock, unlock and trunk/rear gate button. Part # 88039FE050 contains an upper transmitter case, lock and unlock button. REPAIR PROCEDURE/INFORMATION: Note: To prevent static electricity, touch a metal object first before disassembling transmitter. Make sure that transmitter does not come in contact with oil, water or any other contaminates that could damage it. 1) Insert a flathead screwdriver that is wrapped by a cloth around the blade into the small gap and remove the upper cover. Be extremely careful not to scratch the case. 2) Remove the electrical circuit base with waterproof rubber by pushing on the unlock button. Be extremely careful not to touch the electrical circuit base. 3) Peel off the tape of the service parts (upper transmitter case and buttons) and assemble them in reverse steps of disassembly. CLAIM REIMBURSEMENT/WARRANTY INFORMATION Back-Up Light Switch (MT Model) Backup Lamp Switch: Testing and Inspection Back-Up Light Switch (MT Model) BACK-UP LIGHT SWITCH (MT MODEL) Measure the resistance between back-up light switch terminals. Page 7044 R72-R145 R148 Page 6164 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 1540 - RH side - LH side 22. Disconnect the engine harness fixed by clip (A) from the rocker cover. - RH side - LH side Testing and Inspection Grille: Testing and Inspection FRONT HOOD GRILLE INSPECTION Make sure that the clip is firmly engaged. Make sure that there is no abnormal gap at whole periphery of hood grille. Make sure that there is no damage on hood grille. Page 4589 Page 2387 B3-B12 Page 1916 B134-B136 Page 957 R72-R145 R148 Page 7401 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 3142 B230-B283 Page 2007 Engine Control Module: Locations Non-Turbo Model Locations Sensor Testing and Inspection Tail Lamp Relay: Testing and Inspection TAIL AND ILLUMINATION RELAY Measure the tail and illumination relay resistance between terminals when connecting terminal No. 4 to battery positive terminal and terminal No. 3 to battery ground terminal. Page 4816 INSTALLATION Install in the reverse order of removal. Tightening torque: 25 N.m (2.5 kgf-m, 18.1 ft-lb) CAUTION: Check and adjust the V-belt tension. Page 6403 R72-R145 R148 Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 2107 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 6506 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 2190 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 536 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 2947 R72-R145 R148 Page 4096 Liquid gasket: THREE BOND 1217B (Part No. K0877YA020) 6. Install the oil pan by equally tightening the bolts. Tightening torque: 5 Nm (0.5 kgf-cm, 3.7 ft. lbs.) 7. Pour ATF through the oil charge pipe. Capacity: Fill the same amount of the drained ATF. 8. Check the ATF level. 9. Perform the Clear Memory 2. 10. Perform the inspection with driving the vehicle et the end of repair work, and make sure there is no faulty as below; ^ Excessive shift shock ^ Oil leakage from transmission body and etc. ^ Occurrence of noise caused by interference etc. NOTE: If excessive shift shock is felt, execute the advance operation of learning control. INSPECTION Check each parts for holes, damages or other foreign matters. Page 4335 21) Remove the oil pan. 22) Disconnect the harness connector and transmission ground terminal. 23) Remove the harness assembly. INSTALLATION 1) Pass the harness assembly through the hole in the transmission case. 2) Connect the harness connector and transmission ground. Side Airbag Sensor Impact Sensor: Testing and Inspection Side Airbag Sensor Side Airbag Sensor INSPECTION Check for the following, and replace damaged parts with new parts. - Mounting bracket of side airbag sensor or connector is damaged. - Side airbag is deployed. Keyless Entry - Remote Transmitter Service Tip Keyless Entry Transmitter: Technical Service Bulletins Keyless Entry - Remote Transmitter Service Tip Keyless Entry Remote Inoperative Inspections of returned Keyless Entry Remotes for inoperative complaints found that many are due to oxidation on the contacts. Merely moving the battery itself disturbs this oxidation and the remotes then operate normally. This would be a very inexpensive first thing to check for an inoperative complaint. Check the battery and terminal condition and buff with a coarse cloth if either the battery or terminals are oxidized. Page 4933 Auxiliary Power Outlet: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 7087 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 7323 3. Insert the wiper rubber into the claw (A). Page 1976 INSTALLATION Install in the reverse order of removal. Page 4013 B136-B141 Page 2579 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the generator. 3. Drain the engine coolant. 4. Disconnect the connector from the engine coolant temperature sensor. 5. Remove the engine coolant temperature sensor. INSTALLATION Install in the reverse order of removal. NOTE: Use a new gasket. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb) Page 3899 B136-B141 Page 4104 3) Remove the ST. ST 499747100 CLUTCH DISC GUIDE 4) Install the transmission assembly. 5MT: Manual Transmission Assembly 6MT: Manual Transmission Assembly INSPECTION CLUTCH DISC 1) Facing wear Measure the depth of rivet head from the surface of facing. Replace if facings are worn locally or worn down to less than the specified value. NOTE: Do not wash the clutch disc with any cleaning fluid. 2) Hardened facing Correct by using emery paper or replace. 3) Oil leakage on facing Replace the clutch disc and inspect the transmission front oil seal, transmission case mating surface, engine rear oil seal and other points for oil leakage. Page 7160 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 6856 ILM(ES)-03 Diagrams: Other diagrams referred to by name within these diagrams (i.e. "REF. TO GND-01", etc) can be found at Diagrams by Diagram Name. See: Diagrams/Electrical Diagrams/Diagrams By Diagram Name Connector and Ground Locations: The locations of the Connectors or Grounds shown within these diagrams can be found via the connector or ground number at Vehicle Locations. See: Locations Page 5176 Turbo Model 3) Connect the pipe D first to gear box, and pipe C second. Tightening torque: 15 Nm (1.5 kgf-m, 10.8 ft. lbs.) 4) Install the universal joint. 5) Connect the tie-rod end and knuckle arm, and tighten with castle nut. Tightening torque (Castle nut): 27 Nm (2.75 kgf-m, 19.9 ft. lbs.) CAUTION: When connecting, do not hit the cap at bottom of tie-rod end with hammer. 6) After tightening the castle nut to specified torque, tighten it further within 60° until cotter pin hole is aligned with the slot in nut, and then bend the cotter pin to lock. Intercooler Removal and Installation Intercooler: Service and Repair Intercooler Removal and Installation Intercooler REMOVAL 1. Disconnect the PCV hoses from PCV pipe. 2. Remove the air by-pass valve from intercooler. 3. Remove the bolts which secure the intercooler to bracket. 4. Loosen the clamp (A) which connects the turbocharger to intercooler ducts. Page 3873 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 2936 B17-B20 Page 3664 R72-R145 R148 Page 5586 Side Air Bag: Service and Repair SIDE AIRBAG MODULE REMOVAL CAUTION: Before working on the airbag module, refer to the "CAUTION" in General Description. See: Service Precautions NOTE: Remove the passenger's side by referring to driver's side. 1. Turn the ignition switch to OFF. 2. Disconnect the ground cable from battery, and wait for at least 20 seconds before starting work. 3. Remove the front seats. 4. Remove the clip, and then remove the side airbag harness from slide rail IN (A) and reverse side of seat cushion assembly. 5. Remove the backrest cover. 6. Remove the side airbag harness from backrest frame assembly. 7. Remove the side airbag module (A) from backrest frame assembly. Page 5033 F21-F61 Page 3145 F21-F61 Locations Main Relay (Computer/Fuel System): Locations Main Fuse Box (M/B) Solenoid Valve, Actuator, Emission Control System Parts And Ignition System Parts (Part 5) Page 106 Non-Turbo Model Page 2465 Knock Sensor: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 5088 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 4599 Specified pedal stroke WRX model 105 mm (4.13 inch) Except WRX model 90 mm (3.54 inch) When depressing brake pedal with a 490 Nm (50 kgf, 110 lb ) load. 7. If the distance is more than the specifications, there is a possibility that air is in the brake line. Bleed the brake line until pedal stroke meets the specification. 8. Operate the hydraulic control unit in the sequence control mode. 9. Recheck the pedal stroke. 10. If the distance is more than specifications, there is a possibility air is in the inside of hydraulic unit. Repeat above steps (2) to (9) above until pedal stroke meets the specification. 11. Add brake fluid to the required level (MAX. level) of reservoir tank. 12. As a final step, test run the vehicle at low speed and apply brakes to ensure that brakes provide normal braking action. Page 5653 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 5673 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 7139 (3) Install the modified check valve and valve cushion. Rear Check Valve on Forester Page 7008 F61-R47 Page 7166 B17-B20 Page 7173 B380-f6 Page 6392 B17-B20 Inhibitor Switch Transmission Position Switch/Sensor: Service and Repair Inhibitor Switch Inhibitor Switch INSPECTION When the driving condition or starter motor operation is erroneous, first check the shift linkage for improper operation. If the shift linkage is functioning properly, check the inhibitor switch. 1) Disconnect the inhibitor switch connector. 2) Check continuity in inhibitor switch circuits with the select lever moved to each position. NOTE: ^ Also check that continuity in ignition circuit does not exist when the select lever is in "R", "D", "3", "2" and "1" ranges. ^ If the inhibitor switch is inoperative, check for poor contact of connector on transmission side. 3) Check if there is continuity at equal points when the select lever is tilted 1.5° in both directions from "N" range. If there is continuity in one direction and the continuity in the other or if there is continuity at unequal points, adjust the inhibitor switch. 4) Repeat the above checks. If there are abnormalities, adjust the select cable. REMOVAL 1) Set up the vehicle on a lift. 2) Move the select lever to "N" range. 3) Remove the air intake chamber (Non-turbo model). 4) Remove the intercooler. (Turbo model) Front Oxygen Sensor Oxygen Sensor: Service and Repair Front Oxygen Sensor Front Oxygen (A/F) Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the connector from the front oxygen (A/F) sensor. 3. Disconnect the engine harness fixed by clip (A) from the bracket (B). 4. Remove the front right side wheel. 5. Lift-up the vehicle. 6. Remove the service hole cover. 7. Apply spray type lubricant to the threaded portion of front oxygen (A/F) sensor, and leave it for one minute or more. 8. Remove the front oxygen (A/F) sensor. Page 2843 Main Relay (Computer/Fuel System): Service and Repair Main Relay REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the passenger's side front side sill cover. 3. Remove the bolt which holds the relay bracket on the body. 4. Disconnect the connectors from the main relay. 5. Remove the main relay from the mounting bracket. INSTALLATION Install in the reverse order of removal. Page 2768 R72-R145 R148 Page 4493 2. Check the position of pedal pad. Pedal height L: 148 mm (5.83 inch) Brake pedal free play 0.5 - 2.0 mm (0. 02 - 0.08 inch) [Depress brake pedal pad with a force of less than 10 Nm (1 kgf, 2 ft. lbs.).] 3. If it is not within specified value, adjust it by adjusting the brake booster operating rod length. Page 1511 R58-R69 Page 6605 Speedometer Head: Description and Operation SPEEDOMETER GENERAL - The speedometer system is an electrical type that uses electric signals from the ABS or vehicle dynamics control (VDC) control module. - Since the system does not use mechanical components such as rotating cable, there are no opportunities of occurring such problems as meter needle vibration and cable disconnection. Also, it does not constitute any means of mechanical noise transmission. - The odometer and trip meter readings appear on a liquid crystal display (LCD). - At the trip meter display, the illumination level and the following trouble information (abnormality of various control modules, communication system, vehicle speed signals, etc.) are shown in addition to the trip meter reading. OPERATION The ABS or VDC control module calculates the vehicle speed based on signals from the four wheel speed sensors and sends vehicle speed signals (4 pulses per rotation of wheel) to the speedometer drive circuit and odometer/trip meter drive circuit in the speedometer. NOTE: Signals from the ABS or VDC control module are also used by the engine control module, automatic transmission control module, etc. SPECIFICATIONS Page 6165 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Recall 07V043000: Occupant Sensor Wiring Harness Seat Occupant Sensor: All Technical Service Bulletins Recall 07V043000: Occupant Sensor Wiring Harness MAKE/MODELS: MODEL/BUILD YEARS: Subaru/Forester 2006 Subaru/Impreza 2006 MANUFACTURER: Subaru of America, Inc. NHTSA CAMPAIGN ID NUMBER: 07V043000 MFG'S REPORT DATE: February 06, 2007 COMPONENT: Air Bags: Frontal POTENTIAL NUMBER OF UNITS AFFECTED: 7004 SUMMARY: On certain vehicles, the wiring harness for the air bag occupant detection system in the front passenger seat may have been pinched during production. Pinching of the wiring harness between the floor crossmember and the seat mounting bracket could result in a short circuit. CONSEQUENCE: The passenger's front air bag could become disabled and may not deploy in the event of a crash increasing the risk of injury to the seat occupant. Also an electrical short circuit could cause a fire. REMEDY: Dealers will inspect to see if the wiring had been incorrectly routed under the seat bracket. If so, the dealer will repair any damaged wiring, reroute and secure the wiring harness in the correct location, and re-calibrate the occupant detection system as necessary. The recall is expected to begin on or about March 5, 2007. Owners may contact Subaru at 1-800-782-2783. NOTES: Subaru recall No. WVC-13. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 314 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 4157 2) Check the clutch switch continuity. If the resistance is not as specified, replace the switch. (1) Disconnect the clutch switch connector. (2) Measure the resistance between 1 and 2 of switch terminal. ^ Clutch switch (Cruise control) ^ Clutch switch (Starter interlock) 3) Confirm that the engine does not start when the clutch pedal is not depressed. If the engine starts, adjust the clutch switch, and inspect the starter interlock circuit. 4) Confirm that the engine starts when the clutch pedal is fully depressed. If the engine does not start, adjust the clutch switch, and inspect the starter interlock circuit. ADJUSTMENT 1) Loosen the clutch switch mounting lock nut (Starter interlock). Page 3069 B134-B136 Locations Secondary A/C Fuse Box Page 1345 Crankshaft Gear/Sprocket: Service and Repair Crank Sprocket REMOVAL a. Remove the V-belt. b. Remove the crank pulley. c. Remove the timing belt cover. d. Remove the timing belt. e. Remove the crank sprocket. INSTALLATION a. Install the crank sprocket. b. Install the timing belt. c. Install the timing belt cover. d. Install the crank pulley. e. Install the V-belt. INSPECTION a. Check the crank sprocket teeth for abnormal wear and scratches. b. Make sure there is no free play between crank sprocket and key. c. Check the crank sprocket notch used for sensor for damage and contamination of foreign matter. Page 3718 B128-B134 Page 5730 Alarm Module: Description and Operation SECURITY CONTROL UNIT PROCEDURE 1. FUNCTION SETTING (ECM CUSTOMIZING) 1. Connect the Subaru Select Monitor to data link connector. 2. Turn the ignition switch to ON. 3. On the display screen, select the {Each System Check} and press the [YES] key. 4. On the display screen, select the {Keyless Unit Mode} and press the [YES] key. 5. On the display screen, select the {ECM customizing} and press the [YES] key. 6. Change the setting with UP/DOWN key and press the [YES] key. - List of function setting item (ECM customizing) 7. After setting, make sure that vehicle equipment is same as the setting changed in the {Current Data Display & Save}. CAUTION: It is possible to control the original functions of vehicle when settings above are corresponded to vehicle equipment. - Do not change the settings except for setting above during operation of equipment setting. - Resetting is needed if installing a new keyless unit. - In passive mode, the system will automatically activate the alarm but WILL NOT automatically lock the doors. Failure to lock the doors manually will result in a higher security risk. NOTE: For details concerning operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. 8. Turn the ignition switch to OFF, and then remove the Subaru Select Monitor. 2. ALARM HISTORY REPORT MODE 1. Turn the ignition switch to ON. Page 997 Fuel Pressure: Testing and Inspection Fuel Pressure INSPECTION WARNING: Before removing the fuel pressure gauge, release the fuel pressure. NOTE: If out of specification, check or replace the pressure regulator and pressure regulator vacuum hose. 1. Release the fuel pressure. 2. Disconnect the fuel delivery hoses from fuel damper, and then connect the fuel pressure gauge. 3. Connect the connector of fuel pump relay. 4. Start the engine. 5. Measure the fuel pressure while disconnecting the pressure regulator vacuum hose from intake manifold. Fuel pressure: Standard. 284 - 314 kPa (2.9 - 3.2 kgf/cm2, 41 - 46 psi) 6. After connecting the pressure regulator vacuum hose, measure the fuel pressure. Fuel pressure: Standard. 230 - 260 kPa (2.35 - 2.65 kgf/cm2, 33 - 38 psi) NOTE: The fuel pressure gauge registers 10 to 20 kPa (0.1 to 0.2 kgf/cm2, 1 to 3 psi) higher than standard values during high-altitude operations. Page 3265 Air Flow Meter/Sensor: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 4328 11) Remove the clamp, and then remove the shift lock solenoid. INSTALLATION Install in the reverse order of removal. INSPECTION Step 1 - Step 4 Air Intake Duct Intake Air Duct: Service and Repair Air Intake Duct Air Intake Duct REMOVAL Remove the bolts which install the air intake duct on front side of body. INSTALLATION Install in the reverse order of removal. Page 458 Air Flow Meter/Sensor: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 2499 Spark Plug: Specifications Type ..................................................................................................................................................... ............................................................. Manufacturer ILFR6B ................................................................................................................................................ .......................................................................... NGK Gap ...................................................................................................................................................... ................................. 0.7 - 0.8 mm (0.028 - 0.031 in) Torque ................................................................................................................................................. ........................................................ 21 N.m (15 ft.lb) Specifications Valve Clearance: Specifications Valve clearance: STD Intake ............................................................................................................... ........................................................ 0.20 ± 0.02 mm (0.0079 ± 0.0008 inch) Exhaust ....................... ............................................................................................................................................. 0.35 ± 0.02 mm (0.0138 ± 0.0008 inch) Page 2908 Fuel Level Sensor: Service and Repair Fuel Sub Level Sensor Fuel Sub Level Sensor REMOVAL WARNING: - Place "NO FIRE" signs near the working area. - Be careful not to spill fuel on the floor. 1. Disconnect the ground cable from battery. 2. Lift up the vehicle. 3. Drain the fuel from the fuel tank. 4. Remove the luggage floor mat. 5. Remove the service hole cover. 6. Disconnect the connector from the fuel sub level sensor. 7. Disconnect the fuel jet pump hose. 8. Remove the bolts which install the fuel sub level sensor on the fuel tank. Page 4137 CLUTCH PEDAL Page 6095 Power Mirror Switch: Service and Repair REMOTE CONTROL MIRROR SWITCH REMOVAL Refer to Power Window Control Switch for removal procedure, because the remote control mirror switch is installed in power window control switch panel. INSTALLATION Refer to Power Window Control Switch for installation procedure, because the remote control mirror switch is installed in power window control switch panel. Page 4537 4. Remove the piston boot. 5. Remove the piston seal from caliper body cylinder. CAUTION: Do not damage the cylinder and piston seal groove. 6. Remove the guide pin and boot from caliper body. 2. 16 INCH TYPE 1. Clean mud and foreign particles from the caliper body assembly. CAUTION: Be careful not to allow foreign particles to enter the brake hose connector. 2. Using a standard screwdriver, remove the boot ring from piston. Page 3933 Fluid - A/T: Service and Repair A/T Fluid Replacement Automatic Transmission Fluid REPLACEMENT 1) Lift-up the vehicle. 2) Drain the ATF completely. 3) Check the ATF for condition. CAUTION: Directly after the vehicle has been running, the ATF is hot. Therefore, be careful not to burn yourself. 4) Replace with a new gasket, and then tighten the ATF drain plug. 5) Lower the vehicle. 6) Pour ATF through the oil charge pipe. Recommended fluid: Fluid capacity: Fill the same amount of ATF drained from drain plug hole. Capacity when transmission is overhauled: 9.3 - 9.6 liters (9.8 - 10.1 US quarts, 8.2 - 8.4 Imp quarts) 7) Check the level and leaks of ATF. Page 6991 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 6078 Power Door Lock Actuator: Service and Repair Front Door Lock Actuator FRONT DOOR LOCK ACTUATOR REMOVAL 1. Remove the front door latch assembly. 2. Remove the two screws to remove front door lock actuator. INSTALLATION Install in the reverse order of removal. NOTE: Make sure the lock works properly after installation. Page 7239 B230-B283 Page 5910 Rear Door Panel: Service and Repair Rear Sealing Cover REAR SEALING COVER REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the rear door trim. 3. Remove the rear speaker. 4. Remove the door trim bracket. 5. Remove the sealing cover. NOTE: - Carefully remove the butyl tape. Excessive force will easily break the cover. - If the cover gets broken, replace it with a new one. INSTALLATION 1. Install in the reverse order of removal. 2. When replacing the sealing cover, use butyl tape. 3. Press the butyl tape-applied area firmly to prevent any floating on surface. Butyl tape: 3M 8626 or equivalent NOTE: Apply an uniform bead of butyl tape. - Attach the sealing cover, keeping it from becoming wrinkled. - Breaks in the bead will allow water leakage and contamination. Service and Repair Exhaust Pipe: Service and Repair Exhaust Pipe Turbo model Turbo model Page 7233 B3-B12 Page 5025 B17-B20 Diagram Information and Instructions Wiper Relay: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 3001 Oxygen Sensor: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Fuel Level Sensor Fuel Level Sensor: Service and Repair Fuel Level Sensor Fuel Level Sensor REMOVAL WARNING: - Place "NO FIRE" signs near the working area. - Be careful not to spill the fuel. NOTE: Fuel level sensor is built in fuel pump assembly. 1. Remove the fuel pump assembly. 2. Disconnect the connector from the fuel pump bracket. 3. Remove the fuel temperature sensor. 4. Remove the bolt which installs the fuel level sensor on mounting bracket. INSTALLATION Install in the reverse order of removal. Removal and Installation Wiper Blade: Service and Repair Removal and Installation WIPER BLADE REMOVAL While pushing the locking clip (A) up, pull out the blade from arm to arrow direction. INSTALLATION 1. Install in the reverse order of removal. 2. Confirm that the clip is locked securely. Page 5022 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 6353 B230-B283 Page 1322 tighten to specified torque. Tightening torque: T1: 9.75 Nm (1.0 kgf-m, 7.2 ft. lbs.) T2: 20 Nm (2.0 kgf-m, 14.8 ft. lbs.) d. After tightening the camshaft cap, ensure the camshaft rotates only slightly while holding it at "base" circle. 3. Apply engine oil to the outer perimeter and lips of oil seal, and install the oil seal on camshaft using ST1 and ST2. NOTE: Use a new oil seal. ST1 499587600 OIL SEAL GUIDE ST2 499597200 OIL SEAL GUIDE 4. Rocker cover installation a. Install the gasket on rocker cover. Install the peripheral gasket and ignition coil gasket. b. Apply liquid gasket to the designated point of cylinder head. NOTE: Apply liquid gasket to the half moon plug portion with sticking out more than 5 mm (0.2 inch). Liquid gasket. THREE BOND 1215 (Part No. 004403007) or equivalent Page 4917 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 3438 Throttle Position Sensor: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 6594 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 3698 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 1839 B292-B317 Page 5082 F21-F61 Page 1444 Page 4416 Transmission Position Switch/Sensor: Service and Repair AT Shift Lock Solenoid and "P" Range Switch AT Shift Lock Solenoid and "P" Range Switch REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the console box. 3) Disconnect the connector. 4) Remove the grip. 5) Remove the indicator bulb from indicator cover. 6) Remove the indicator cover. 7) Remove the blind. 8) Remove the cushion. 9) Remove the clip, and then remove the "P" range switch. 10) Remove the cover. Page 5690 Impact Sensor: Service and Repair Impact Sensor IMPACT SENSOR REMOVAL 1. Remove the key from ignition switch. 2. Close all the doors, trunk lid and rear gate. 3. Press the UNLOCK button of transmitter. 4. Change the setting of impact sensor using Subaru Select Monitor. 5. Disconnect the ground cable from battery. 6. Remove the impact sensor. INSTALLATION 1. Remove the key from ignition switch. 2. Close all the doors, trunk lid and rear gate. 3. Press the UNLOCK button of transmitter. 4. Disconnect the ground cable from battery. 5. Install the impact sensor. 6. Connect the battery ground cable to battery. 7. Change the setting of impact sensor using Subaru Select Monitor. Page 7348 R58-R69 Page 936 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 243 B292-B317 Page 3151 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 268 Electrical Component Location Page 7179 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Front Oxygen Sensor Oxygen Sensor: Service and Repair Front Oxygen Sensor Front Oxygen (A/F) Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the connector from the front oxygen (A/F) sensor. 3. Disconnect the engine harness fixed by clip (A) from the bracket (B). 4. Remove the front right side wheel. 5. Lift-up the vehicle. 6. Remove the service hole cover. 7. Apply spray type lubricant to the threaded portion of front oxygen (A/F) sensor, and leave it for one minute or more. 8. Remove the front oxygen (A/F) sensor. Page 1959 STI model Page 6388 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 4737 Electrical Component Location Diagrams Trunk Lid And Rear Gate Lock Page 2679 General Tools Page 3902 B380-f6 Testing and Inspection Camshaft: Testing and Inspection Inspection 1. Measure the bend, and repair or replace if necessary. Limit. 0.020 mm (0.0008 inch) 2. Check the journal for damage and wear. Replace if faulty. 3. Measure the outside diameter of camshaft journal. If the journal diameter is not within standard, check the oil clearance. 4. Measurement of the camshaft journal oil clearance a. Clean the bearing caps and camshaft journals. b. Place the camshafts on cylinder head. (Without installing the valve rocker.) c. Place a plastigauge across each of the camshaft journals. d. Gradually tighten the cap in at least two stages in alphabetical sequence shown in the figure, and then tighten to specified torque. Do not turn the camshaft. Tightening torque: T1: 9.75 Nm (1.0 kgf-m, 7.2 ft. lbs.) T2: 20 Nm (2.0 kgf-m, 14.8 ft. lbs.) e. Remove the bearing caps. f. Measure the widest point of the plastigauge on each journal. If the oil clearance exceeds the limit, replace the camshaft. If necessary, replace the camshaft caps and cylinder head as a set. Standard. 0.037 - 0.072 mm (0. 00 15 - 0.0028 inch) Limit: 0.10 mm (0. 0039 inch) Page 6510 B3-B12 Page 4973 B134-B136 Page 4070 5) Disconnect the inhibitor switch connector. 6) Remove the inhibitor switch connector from stay. 7) Lift-up the vehicle. 8) Remove the front and center exhaust pipes. 9) Remove the snap pin and washer from range select lever. 10) Remove the plate assembly from transmission case. 11) Remove the bolts. Page 6676 Center Mounted Brake Lamp: Testing and Inspection HIGH-MOUNTED STOP LIGHT INSPECTION 1. Visually check the bulb for blow out. 2. If NG, replace the high-mounted stop light with a new one. Page 1492 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 2997 F21-F61 Specifications Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Rear Washer Windshield Washer Spray Nozzle: Service and Repair Rear Washer REAR WASHER REMOVAL 1. Remove the high-mount stop light. 2. Remove the washer hose from washer nozzle. 3. Open the clips on the underside of hood with a thin screwdriver or other tool, and then remove the washer nozzle. INSTALLATION 1. Install in the reverse order of removal. 2. Adjust the position of the washer liquid sprayer. Page 2539 B136-B141 Page 4789 7. Install the washer and snap pin to range select lever. 8. Install the front and center exhaust pipes. (Nonturbo model) 9. Install the center exhaust pipe. (Turbo model) 10. Lower the vehicle. 11. Install the inhibitor switch connector from stay. 12. Connect the inhibitor switch connector. 13. Install the air intake chamber. (Non-turbo model) 14. Install the intercooler. (Turbo model) 15. Inspect the inhibitor switch. Page 3623 B128-B134 Locations Sensor Page 1614 B136-B141 Rear Differential Front Oil Seal Seals and Gaskets: Service and Repair Rear Differential Front Oil Seal Rear Differential Front Oil Seal REPLACEMENT 1) Set the vehicle on a lift. 2) Disconnect the ground cable from battery. 3) Move the select lever or gear shift lever to "N". 4) Release the parking brake. 5) Remove the oil drain plug, and drain the gear oil. 6) Install the oil drain plug. NOTE: Apply liquid gasket to the drain plug. Liquid gasket: THREE BOND 1105 (Part No. 004403010) or equivalent. Tightening torque: 49 Nm (5.0 kgf-m, 36.2 ft. lbs.) 7) Lift-up the vehicle. 8) Remove the rear exhaust pipe and muffler. 9) Remove the propeller shaft from body. 10) Remove the self-locking nut while holding the companion flange with ST. Except STI model ST 498427200 FLANGE WRENCH STI model ST 18633AA000 WRENCH COMPL 11) Remove the center heat shield cover. Page 1194 Engine Oil: Fluid Type Specifications Recommended oil: ILSAC GF-4, which can be identified with the new API certification mark (Star burst mark) or API classification SM with the words "ENERGY CONSERVING" SAE viscosity 5W-30 preferred Recommended grade and viscosity for severe driving conditions - If the vehicle is used in desert areas, in areas with very high temperatures, or used for heavy-duty applications such as towing a trailer, use of oil with the following grade and viscosities is recommended. API Classification SM (or SL) SAE Viscosity 30, 40, 10W-50, 20W-40, 20W-50 Front Catalytic Converter Catalytic Converter: Service and Repair Front Catalytic Converter Front Catalytic Converter REMOVAL 1. Remove the center exhaust pipe. 2. Separate the front catalytic converter (A) from rear catalytic converter (B). INSTALLATION NOTE: - Replace the gaskets with new ones. - Install in the reverse order of removal. Page 3037 Throttle Position Sensor: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 234 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 1785 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 321 B230-B283 Page 6116 Roof Rack Frame: Service and Repair Crossbar CROSSBAR Crossbar REMOVAL 1. Remove the TORX(R) bolt T30 from each end support. 2. Rotate the lower clamp of each end support about 90° downward to remove the crossbar. CAUTION: Pay attention to avoid damage to the roof panel during removal or installation. INSTALLATION 1. Rotate the lower clamp of each end support about 90° downward. 2. Set the front crossbar so that front direction mark on the right side top face of crossbar point in the direction of vehicle front. 3. Place the crossbar end support in a position 76.2 mm (3 in) behind the joint of front roof rail support and roof rail. Testing and Inspection Drive Belt: Testing and Inspection Inspection 1. Replace the belts, if cracks, fraying or wear is found. 2. Check the V-belt tension and adjust it if necessary by changing generator installing position and idler pulley installing position. Belt tension (with belt tension gauge) (A) When installing new parts: 640 - 780 Nm (65 - 80 kgf, 144 - 175 ft. lbs.) At inspection: 490 - 640 Nm (50 - 65 kgf, 110 - 144 ft. lbs.) (B) When installing new parts: 740 - 880 Nm (75 - 90 kgf, 166 - 198 ft. lbs.) At inspection: 350 - 450 Nm (36 - 46 kgf, 79 101 ft. lbs.) Belt tension (without belt tension gauge) (A) When installing new parts: 7 - 9 mm (0.276 - 0.354 inch) At inspection: 9 - 11 mm (0.354 - 0.433 inch) (B) When installing new parts: 7.5 - 8.5 mm (0.295 - 0.335 inch) At inspection: 9.0 - 10.0 mm (0.354 - 0.394 inch) Testing and Inspection Fog/Driving Lamp Switch: Testing and Inspection FRONT FOG LIGHT SWITCH Measure the resistance between front fog light switch terminals. Page 5186 19) Set the ST on drawing dimension. ST 34199AE120 GEARBOX OIL SEAL REMOVER 20) Set the stopper to gear box, and then insert the tip of ST to gear box. Page 5508 - When painting or performing sheet metal work on the side of the vehicle, including the side sill, center pillar, and front and rear doors, remove the side airbag sensors and wire harness of the airbag system. - When storing a removed airbag module, do not place any objects on it or pile airbag modules on top of each other. If the airbag inflates for some reason when it is placed with its pad side facing downward or under any object, a serious accident may result. Page 139 Engine Control Module (ECM) I/O Signal (Part 5) Page 689 B230-B283 Page 7197 Wiper Switch: Service and Repair COMBINATION SWITCH (WIPER) REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the instrument panel lower cover. 3. Loosen the screw to remove steering column cover lower. 4. Remove the screw to steering column cover upper. 5. Disconnect the connectors from combination switches. 6. Loosen the screw to remove combination switch. INSTALLATION Install in the reverse order of removal. Locations Main Relay (Computer/Fuel System): Locations Main Fuse Box (M/B) Solenoid Valve, Actuator, Emission Control System Parts And Ignition System Parts (Part 5) Page 5121 3) Tighten two new self-locking nuts. Tightening torque: 175 Nm (17.8 kgf-m, 129 ft. lbs.) Recall 07V043000: Occupant Sensor Wiring Harness Seat Occupant Classification Module - Air Bag: Recalls Recall 07V043000: Occupant Sensor Wiring Harness MAKE/MODELS: MODEL/BUILD YEARS: Subaru/Forester 2006 Subaru/Impreza 2006 MANUFACTURER: Subaru of America, Inc. NHTSA CAMPAIGN ID NUMBER: 07V043000 MFG'S REPORT DATE: February 06, 2007 COMPONENT: Air Bags: Frontal POTENTIAL NUMBER OF UNITS AFFECTED: 7004 SUMMARY: On certain vehicles, the wiring harness for the air bag occupant detection system in the front passenger seat may have been pinched during production. Pinching of the wiring harness between the floor crossmember and the seat mounting bracket could result in a short circuit. CONSEQUENCE: The passenger's front air bag could become disabled and may not deploy in the event of a crash increasing the risk of injury to the seat occupant. Also an electrical short circuit could cause a fire. REMEDY: Dealers will inspect to see if the wiring had been incorrectly routed under the seat bracket. If so, the dealer will repair any damaged wiring, reroute and secure the wiring harness in the correct location, and re-calibrate the occupant detection system as necessary. The recall is expected to begin on or about March 5, 2007. Owners may contact Subaru at 1-800-782-2783. NOTES: Subaru recall No. WVC-13. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 4749 2) Check the clutch switch continuity. If the resistance is not as specified, replace the switch. (1) Disconnect the clutch switch connector. (2) Measure the resistance between 1 and 2 of switch terminal. ^ Clutch switch (Cruise control) ^ Clutch switch (Starter interlock) 3) Confirm that the engine does not start when the clutch pedal is not depressed. If the engine starts, adjust the clutch switch, and inspect the starter interlock circuit. 4) Confirm that the engine starts when the clutch pedal is fully depressed. If the engine does not start, adjust the clutch switch, and inspect the starter interlock circuit. ADJUSTMENT 1) Loosen the clutch switch mounting lock nut (Starter interlock). Page 2078 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 955 F61-R47 Page 7247 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Symptom Related Diagnostic Procedures Drive/Propeller Shaft: Symptom Related Diagnostic Procedures Drive Shaft INSPECTION NOTE: Vibration while cruising may be caused by an unbalanced tire, improper tire inflation pressure, improper wheel alignment, etc. Page 4974 B136-B141 Page 6458 F61-R47 Page 2935 B3-B12 Diagrams Page 731 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 4674 Parking Brake Shoe: Adjustments Parking Brake Assembly (Rear Disc Brake) ADJUSTMENT SHOE CLEARANCE 1) Return the parking brake completely. 2) Remove the adjusting hole cover from backplate. 3) Turn the adjusting screw using a flat tip screwdriver until brake shoe is in close contact with disc rotor. 4) Turn back (downward) the adjusting screw 3 or 4 notches. CAUTION: Be sure that the brake is not dragging. 5) Install the adjusting hole cover to back plate. 6) Adjust the parking brake lever stroke. LEVER STROKE 1) Before adjusting the lever stroke, adjust the shoe clearance. 2) Remove the console box lid. 3) Forcibly pull the parking brake lever 3 to 5 times. 4) Adjust the parking brake lever by turning adjuster until parking brake lever stroke is set at 7 to 8 notches with operating force of 196 N (20 kgf, 44 lbs.). 5) Tighten the lock nut. 6) Install the console box lid. Lever stroke: 7 to 8 notches when pulled with a force of 196N (20 kgf, 44 lbs.) Tightening torque (Lock nut): 6 Nm (0.6 kgf-m, 4.4 ft. lbs.) Page 6583 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 2631 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 1616 B292-B317 Page 1125 1) Temporarily tighten the two bolts fixing pipe C and D. (bolt A) NOTE: Visually check that the hose between tank and pipe D is free from bending or twisting. ^ Non-turbo model Non-turbo model ^ Turbo model and STI model Turbo model and STI model (1) Connect the pipe D to oil tank. (2) Using a new gasket, connect the pipe C to oil pump. (3) Tighten the two bolts fixing pipe C and D. (bolt A) 2) Install the coolant filler tank. (Turbo model) Recall 07V043000: Occupant Sensor Wiring Harness Seat Occupant Sensor: All Technical Service Bulletins Recall 07V043000: Occupant Sensor Wiring Harness MAKE/MODELS: MODEL/BUILD YEARS: Subaru/Forester 2006 Subaru/Impreza 2006 MANUFACTURER: Subaru of America, Inc. NHTSA CAMPAIGN ID NUMBER: 07V043000 MFG'S REPORT DATE: February 06, 2007 COMPONENT: Air Bags: Frontal POTENTIAL NUMBER OF UNITS AFFECTED: 7004 SUMMARY: On certain vehicles, the wiring harness for the air bag occupant detection system in the front passenger seat may have been pinched during production. Pinching of the wiring harness between the floor crossmember and the seat mounting bracket could result in a short circuit. CONSEQUENCE: The passenger's front air bag could become disabled and may not deploy in the event of a crash increasing the risk of injury to the seat occupant. Also an electrical short circuit could cause a fire. REMEDY: Dealers will inspect to see if the wiring had been incorrectly routed under the seat bracket. If so, the dealer will repair any damaged wiring, reroute and secure the wiring harness in the correct location, and re-calibrate the occupant detection system as necessary. The recall is expected to begin on or about March 5, 2007. Owners may contact Subaru at 1-800-782-2783. NOTES: Subaru recall No. WVC-13. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 5835 Page 2238 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 6770 Headlamp Relay: Testing and Inspection HEADLIGHT RELAY Measure the headlight relay resistance between terminals when connecting terminal No. 4 to battery positive terminal and terminal No. 3 to battery ground terminal. Page 6161 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 2870 R58-R69 Page 6173 B134-B136 Page 3132 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 1823 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 170 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 643 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 5040 Auxiliary Power Outlet: Electrical Diagrams Front Accessory Power Supply Socket System FAPS-01 Diagrams: Other diagrams referred to by name within these diagrams (i.e. "REF. TO GND-01", etc) can be found at Diagrams by Diagram Name. See: Diagrams/Electrical Diagrams/Diagrams By Diagram Name Connector and Ground Locations: The locations of the Connectors or Grounds shown within these diagrams can be found via the connector or ground number at Vehicle Locations. See: Locations Rear Accessory Power Supply System Page 941 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 5296 8) Install the ABS wheel speed sensor on housing. Tightening torque: 33 Nm (3.4 kgf-m, 24 ft. lbs.) 9) Install the wheel and tighten the wheel nuts to specified torque. Tightening torque: 90 Nm (9.1 kgf-m, 65.7 ft. lbs.) DISASSEMBLY Using the ST and a hydraulic press, drive hub bolts out. ST 28399AG000 HUB STAND CAUTION: ^ Be careful not to hammer the hub bolts. This may deform the hub. ^ Do not reuse the hub bolt. NOTE: Since the hub unit bearing can not be disassembled, only hub bolts can be removed. ASSEMBLY 1) Attach the hub to ST securely. ST 28099PA080 HUB STAND 2) Using a press, Press new hub bolts until their seating surfaces contact the hub. NOTE: Use 12 mm (0.47 inch) dia. holes in HUB STAND to prevent bolts from tilting. INSPECTION Page 5053 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Locations Data Link Connector: Locations Locations Cruise Control Switch: Locations Non-Turbo Model Locations Variable Induction Control Actuator: Locations Solenoid Valve, Actuator, Emission Control System Parts And Ignition System Parts (Part 1) Page 3864 B136-B141 Page 3137 B17-B20 Page 1478 R58-R69 Inhibitor Switch Transmission Position Switch/Sensor: Service and Repair Inhibitor Switch Inhibitor Switch INSPECTION When the driving condition or starter motor operation is erroneous, first check the shift linkage for improper operation. If the shift linkage is functioning properly, check the inhibitor switch. 1) Disconnect the inhibitor switch connector. 2) Check continuity in inhibitor switch circuits with the select lever moved to each position. NOTE: ^ Also check that continuity in ignition circuit does not exist when the select lever is in "R", "D", "3", "2" and "1" ranges. ^ If the inhibitor switch is inoperative, check for poor contact of connector on transmission side. 3) Check if there is continuity at equal points when the select lever is tilted 1.5° in both directions from "N" range. If there is continuity in one direction and the continuity in the other or if there is continuity at unequal points, adjust the inhibitor switch. 4) Repeat the above checks. If there are abnormalities, adjust the select cable. REMOVAL 1) Set up the vehicle on a lift. 2) Move the select lever to "N" range. 3) Remove the air intake chamber (Non-turbo model). 4) Remove the intercooler. (Turbo model) Page 6450 B54-B127 Page 5087 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 712 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 883 Neutral Safety Switch: Adjustments Inhibitor Switch ADJUSTMENT 1. Shift the select lever to N range. 2. Loosen the three inhibitor switch securing bolts. 3. Insert the ST as vertical as possible into the holes in inhibitor switch lever and switch body. ST 499267300 STOPPER PIN 4. Tighten the three inhibitor switch bolts. Tightening torque: 3.4 Nm (0.35 kgf-m, 2.5 ft. lbs.) 5. Repeat the above checks. If the inhibitor switch is determined to be faulty, replace it. Page 7065 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 2187 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 6553 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 2948 Knock Sensor: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 4197 ST 498427200 FLANGE WRENCH STI model ST 18633AA000 WRENCH COMPL NOTE: Use a new self-locking nut. 18) Hereafter, reassemble in the reverse order of disassembly. 19) Fill the differential carrier with gear oil to the bottom of filler plug hole after installing. Page 137 Engine Control Module (ECM) I/O Signal (Part 3) Page 615 B136-B141 Page 4715 Vacuum Brake Booster: Testing and Inspection INSPECTION 1. OPERATION CHECK (WITHOUT GAUGES) CAUTION: When checking operation, be sure to securely apply the parking brake. ^ Checking without gauges This method cannot determine the exact portion which has failed, but it can provide a rough understanding of the nature of failure if checking is conducted in accordance with the following procedures. ^ Air tightness check Start the engine, and run it for 1 to 2 minutes, then turn it off. Depress the brake pedal several times applying same pedal force as that used in ordinary braking operations. The pedal stroke should be greatest on 1st depression, and it should become smaller with each successive depression. If no change occurs in the pedal height while in a depressed state, the brake booster is faulty. NOTE: ^ In the event of defective operation, inspect the condition of check valve and vacuum hose. ^ Replace them if faulty and conduct the test again. ^ If no improvement is observed, check precisely with gauges. ^ Operation check 1. With the engine off, depress the brake pedal several times applying same pedal force and make sure that pedal height does not vary with each depression of pedal. 2. With the brake pedal depressed, start the engine. 3. As the engine starts, the brake pedal should move slightly toward the floor. If no change occurs in the pedal height, the brake booster is faulty. NOTE: If faulty, check precisely with gauges. ^ Loaded air tightness check Depress the brake pedal while engine is running, and turn off the engine while pedal is still depressed. Keep the pedal depressed for 30 seconds; if no change occurs in the pedal height, the brake booster is functioning normally; if the pedal height increases, it is faulty. Page 520 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 6779 Horn Switch: Service and Repair HORN SWITCH REMOVAL WARNING: Before servicing, be sure to read the notes in AB section for proper handling of driver's airbag module. NOTE: Horn switch forms a unit with the driver s airbag module. 1. Disconnect the ground cable from battery. 2. Remove the driver's airbag module. INSTALLATION Install in the reverse order of removal. Page 5803 Alarm Module: Service Precautions SECURITY CONTROL UNIT NOTE: The control of security system is performed by the keyless entry control unit. Page 7171 B230-B283 Capacity Specifications Fluid - A/T: Capacity Specifications Automatic Transmission Fluid Capacity .............................................................................................. ..................................................................... 9.5 liter (10.0 US qt, 8.4 Imp qt) Page 7050 Power Window Switch: Service and Repair POWER WINDOW CONTROL SWITCH REMOVAL 1. MAIN SWITCH 1. Disconnect the ground cable from battery. 2. Using a flat tip screwdriver, remove the screw cover. 3. Loosen the screw to remove the power window main switch. 4. Disconnect the connector. 2. SUB SWITCH 1. Disconnect the ground cable from battery. 2. Remove the screw which secures switch panel. 3. Remove the switch panel. Page 7236 B128-B134 Page 3422 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 4772 1) With the select lever already in the "N" range, loosen the adjusting nuts A and B on both sides. 2) Turn the adjusting nut B until it lightly touches the connector. 3) Use a spanner wrench to hold nut B so that it does not rotate and then tighten the adjusting nut A. Tightening torque: 7.5 N-m (0.76 kgf-m, 5.5 ft-lb) 4) Afier the completion of adjustment, confirm that the select lever operates normally at all ranges: ^ Move the select lever from "P" to "D" range. Check that the detents could be felt in each range. If the detents cannot be felt or the position pointer (dash indicator) is improperly aligned, re-adjust the cable. ^ Check if the starter motor rotates when the select lever is set to "P" range. Page 2302 12) Move the range select lever to parking position (left side). 13) Remove the inhibitor switch from transmission. 14) Disconnect the inhibitor switch harness connector from inhibitor switch. INSTALLATION 1) Connect the inhibitor switch harness connector to inhibitor switch. 2) Install the inhibitor switch to transmission case. 3) Move the range select lever to neutral position. Locations Manifold Pressure/Vacuum Sensor: Locations Sensor (Part 1) M/T - Clutch Pedal Squeaking Noise Clutch Pedal Position Sensor / Switch: Technical Service Bulletins M/T - Clutch Pedal Squeaking Noise CLUTCH PEDAL SQUEAK If you encounter a manual transmission equipped vehicle with a clutch pedal squeak concern, and lubricating the pedal mechanism didn't fix the noise, check the clutch switch. We have had a few reports where this has been the source of the problem. The fix is to replace the clutch pedal switch. Service and Repair Antitheft Antenna: Service and Repair IMMOBILIZER ANTENNA REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the instrument panel lower cover. 3. Remove the screws, separate upper column cover and lower column cover. 4. Disconnect the immobilizer antenna connector (A) from body harness. 5. Remove the screw, and detach the immobilizer antenna (B). INSTALLATION Install in the reverse order of removal. Page 2923 Crankshaft Position, Camshaft Position And Knock Sensors Page 1027 Spark Plug: Service and Repair Spark Plug REMOVAL CAUTION: All spark plugs installed on an engine, must be of the same heat range. Spark plug: NGK: ILFR6B RH SIDE 1. Disconnect the ground cable from battery. 2. Remove the air cleaner lower case. Page 4936 Auxiliary Power Outlet: Electrical Diagrams Front Accessory Power Supply Socket System FAPS-01 Diagrams: Other diagrams referred to by name within these diagrams (i.e. "REF. TO GND-01", etc) can be found at Diagrams by Diagram Name. See: Diagrams/Electrical Diagrams/Diagrams By Diagram Name Connector and Ground Locations: The locations of the Connectors or Grounds shown within these diagrams can be found via the connector or ground number at Vehicle Locations. See: Locations Rear Accessory Power Supply System Page 636 11) Remove the clamp, and then remove the shift lock solenoid. INSTALLATION Install in the reverse order of removal. INSPECTION Step 1 - Step 4 Page 7001 B128-B134 Page 5778 EXAMPLES OF PEELING LABELS PLEASE USE CAUTION WHEN USING YOUR GENUINE SUBARU IN-DASH CD CHANGER/PLAYER In-dash compact disc (CD) players are a great way to enjoy crystal-clear music in your Subaru. Subaru CD players are designed to play standard 4 3/4 inch diameter CDs, which carry the "Compact Disc Digital Audio" logo. Page 1069 REAR SIDE BELT 1. Install the belt, and tighten the slider bolt (B) so as to obtain the specified belt tension. 2. Tighten the lock nut (A). Tightening torque: Lock nut (A) 23 Nm (2.3 kgf-m, 17.0 ft. lbs.) Inspection 1. Replace the belts, if cracks, fraying or wear is found. 2. Check the V-belt tension and adjust it if necessary by changing generator installing position and idler pulley installing position. Belt tension (with belt tension gauge) (A) When installing new parts: 640 - 780 Nm (65 - 80 kgf, 144 - 175 ft. lbs.) At inspection: 490 - 640 Nm (50 - 65 kgf, 110 - 144 ft. lbs.) (B) When installing new parts: 740 - 880 Nm (75 - 90 kgf, 166 - 198 ft. lbs.) At inspection: 350 - 450 Nm (36 - 46 kgf, 79 - 101 ft. lbs.) Engine Controls - Engine Misfire Between 1600-1900 RPM PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Engine Misfire Between 1600-1900 RPM NUMBER: 11-88-08 DATE: 09/02/08 APPLICABILITY: 2006~07MY Impreza WRX 2.5L Turbo, AT and MT SUBJECT: Reprogramming Files for Engine Misfire Introduction This is to announce that ECM reprogramming files are now available to rectify engine misfire between 1,600 and 1,900 rpm during engine warm up. The condition only occurs when the vehicle is parked and the driver is attempting to warm up the engine quicker by increasing the RPM. Pack File Applicability Disclaimer Page 1502 B54-B127 Page 3586 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 2986 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 440 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 1389 6. Inspect all valves for clearance again at this stage. If the valve clearance is not correct, repeat the procedure over again from the first step. 7. After inspection, install the related parts in the reverse order of removal. Page 6086 Trunk / Liftgate Lock: Testing and Inspection Trunk Lid Lock Assembly TRUNK LID LOCK ASSEMBLY INSPECTION 1. Check the striker for bending or abnormal wear. 2. Check the safety lever for improper movement. 3. Check other levers and the spring for rust formation and unsmooth movement. Page 7034 B54-B127 Page 4829 2) Fully depress the clutch pedal. 3) Adjust the clutch pedal plate and clutch switch so that the gap between them is 3 - 3.5 mm (0. 12 - 0.14 inch). 4) Tighten the lock nut. Tightening torque: 8 Nm (0.8 kgf-m, 5.9 ft. lbs.) Page 2448 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 3164 Air Injection Pump: Testing and Inspection Secondary Air Pump INSPECTION Make sure the hoses are not cracked or loose. Page 2646 F21-F61 Page 7246 Windshield Washer Motor: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 6986 Disclaimer Page 1026 Spark Plug: Adjustments ADJUSTMENT Clean the spark plugs with a wire brush. Clean and remove the carbon or oxide deposits, but do not wear away ceramic insulator. If deposits are too stubborn, replace the plugs. After cleaning the spark plugs, correct the spark plug gap using a gap gauge. NOTE: Do not use spark plug cleaners, because the spark plugs are applied with iridium tips. Page 2456 B134-B136 Page 4481 Specified pedal stroke WRX model 105 mm (4.13 inch) Except WRX model 90 mm (3.54 inch) When depressing brake pedal with a 490 Nm (50 kgf, 110 lb ) load. 7. If the distance is more than the specifications, there is a possibility that air is in the brake line. Bleed the brake line until pedal stroke meets the specification. 8. Operate the hydraulic control unit in the sequence control mode. 9. Recheck the pedal stroke. 10. If the distance is more than specifications, there is a possibility air is in the inside of hydraulic unit. Repeat above steps (2) to (9) above until pedal stroke meets the specification. 11. Add brake fluid to the required level (MAX. level) of reservoir tank. 12. As a final step, test run the vehicle at low speed and apply brakes to ensure that brakes provide normal braking action. Page 4676 6) Remove the front shoe hold-down spring and pin with pliers. 7) Remove the strut and strut spring. 8) Remove the adjuster assembly from parking brake assembly. 9) Remove the brake shoe. 10) Remove the rear shoe hold-down spring and pin with pliers. 11) Remove the parking brake cable from parking brake lever. 12) Using a standard screwdriver, raise the retainer. Remove the parking brake lever and washer from brake shoe. INSTALLATION CAUTION: Be sure the lining surface is free from oil and grease contamination. 1) Apply brake grease to the following places. Brake grease:Brake Grease (Part No. 003602002) ^ Six contact surfaces of shoe rim and back plate packing ^ Contact surface of shoe wave and anchor pin ^ Contact surface of lever and strut ^ Contact surface of shoe wave and adjuster assembly ^ Contact surface of shoe wave and strut ^ Contact surface of lever and shoe wave ^ Insert the primary side brake shoe into anchor pin groove. 3) Secure the brake shoe with shoe hold-down pin and cup. Page 6451 B128-B134 Page 7362 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 495 9. Remove the fuel sub level sensor. INSTALLATION Install in the reverse order of removal. NOTE: Use a new gasket. 1. Ensure the sealing portion is free from fuel foreign particles before installation. 2. Tighten the nuts and bolts to specified torque the order as shown in the figure. Page 7225 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Transmission Gear Oil Inspection Fluid - M/T: Service and Repair Transmission Gear Oil Inspection Transmission Gear Oil INSPECTION 1) Park the vehicle on a level surface. 2) Turn the ignition switch to OFF, and then wait until the engine cools. 3) Remove the oil level gauge and wipe it clean. 4) Reinsert the level gauge all the way. Be sure the level gauge is correctly inserted and in the proper direction. 5) Pull out the oil level gauge again and check the oil level on it. If it is below the lower level, add oil through the oil level gauge hole to bring the level up to the upper level. Page 7048 Power Window Switch: Testing and Inspection POWER WINDOW CONTROL SWITCH INSPECTION 1. MAIN SWITCH 1. Remove the main switch. 2. Turn the window lock switch to UNLOCK. 3. Connect the battery and main switch as shown in the figure. 4. Measure the main switch resistance. 5. If NG, replace the main switch. 2. SUB SWITCH 1. Remove the sub switch. Page 6136 B136-B141 Page 6064 Keyless Entry Transmitter: Testing and Inspection TRANSMITTER INSPECTION 1. TRANSMITTER BATTERY Measure the voltage between the transmitter battery (+) terminal and (-) terminal. NOTE: Battery discharge occurs during measurement. Complete the measurement within 5 seconds. If NG, replace the battery. (Use CR2025 or equivalent.) Page 5491 Main Fuse Box (M/B) Secondary A/C Fuse Box Page 617 B292-B317 Page 3104 F21-F61 Description and Operation Temperature Sensor (Gauge): Description and Operation WATER TEMPERATURE GAUGE - Water temperature signals are generated at the engine coolant temperature sensor on the engine, and after converted into digital signals, these signals are sent via the body integrated unit to the combination meter. - The resistance of the engine coolant temperature sensor changes according to the engine coolant temperature. Therefore, the signals sent to the water temperature gauge also changes according to the engine coolant temperature. As the change in signals causes the magnetic force of the step motor to change, the gauge needle moves according to the engine coolant temperature. - When the coolant is at a normal operating temperature of approx. 85 to 100 degree C (158 to 212 degree F), the gauge needle stays in the middle of the indication range as shown in the figure. Page 874 Neutral Safety Switch: Locations Locations Fuel Gauge Sender: Locations Page 1323 c. Install the rocker cover on cylinder head. Ensure the gasket is properly positioned during installation. CAUTION: Use a new rocker cover gasket. d. Tighten the rocker cover tightening bolts in alphabetical sequence shown in the figure, and then tighten to specified torque. Tightening torque: 6.4 Nm (0.65 kgf-m, 4.7 ft. lbs.) 5. Install the oil pipe. NOTE: Installing location of the union screw varies depending on with or without filter. Be careful of this. Tightening torque: 29 Nm (3.0 kgf-m, 21.4 ft. lbs.) Page 1089 Fluid Filter - A/T: Service and Repair ATF Filter REMOVAL NOTE: The ATF filter is maintenance free. 1) Lift-up the vehicle. 2) Using ST, remove ATF filter. ST 498545400 OIL FILTER WRENCH INSTALLATION 1) Get new ATF filter and apply a thin coat of ATF to the oil seal. 2) Install ATF filter. Turn it by hand, being careful not to damage oil seal. 3) Using ST, tighten ATF filter. Calculate ATF filter torque specifications using the following formula. T2 = L2/(L1 + L2) x T1 T1: 14 Nm (1.4 kgf-m, 10.1 ft. lbs.) [Required torque setting] T2: Tightening torque L1: ST length 78 mm (3.07 inch) L2: Torque wrench length Example: NOTE: Align ST with torque wrench while tightening ATF filter. ST 498545400 OIL FILTER WRENCH 4) Add ATF. 5) Inspect level of ATF. INSPECTION Check for rust, hole, ATF leaks, and other damage. Page 6354 B292-B317 Page 6330 Schematic Drawings Service and Repair Fuel Pump Control Unit: Service and Repair Fuel Pump Control Unit REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the rear quarter trim. 3. Disconnect the connector from the fuel pump control unit. 4. Remove the fuel pump control unit. INSTALLATION Install in the reverse order of removal. Page 3622 B54-B127 Page 1152 Differential Fluid - A/T: Fluid Type Specifications Automatic Transmission Differential Gear Oil Fluid Capacity ...................................................................................................................................... ......................... 1.2 liter (1.3 US qt, 1.1 Imp qt) Fluid Type API GL-5 (See figure above for applicable viscosity) Page 3619 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 649 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 2217 Page 4461 5) Slowly remove the ABSCM upward from H/U. NOTE: To prevent damaging of coil part, remove the ABSCM straightly from H/U. 6) Ensure there are no dirt or damage on sealing surface of H/U. CAUTION: ^ Do not clean the ABSCM & H/U with applying compressed air. ^ Do not repair the damages of H/U sealing surface using file or metal scraper. To remove the sealing, use resin scraper. Do not use the chemical materials (thinner and etc.). 7) Position the coil of new ABSCM to align H/U valve. 8) To prevent deforming of ABSCM housing cover, hold the corner of ABSCM and install it to the H/U without tilting. 9) Using TORT BIT E5, tighten the screws stepwise in the order of (1) through (4). CAUTION: Always use new screws. Tightening torque:1.5 Nm (0.15 kgf-m, 1.1 ft. lbs.) 10) Check that there is no foreign matter in aligning part between ABSCM and H/U. 11) Using TORT BIT E5, tighten the screws stepwise in the order of (1) through (4) again. Tightening torque: 3 Nm (0.3 kgf-m, 2.2 ft. lbs.) 12) Check that there is no clearance in aligning part between ABSCM and H/U. 13) Install the ABSCM&H;/U to vehicle. INSPECTION 1) Check the connected and fixed condition of connector. Engine Controls - Engine Misfire Between 1600-1900 RPM PROM - Programmable Read Only Memory: Customer Interest Engine Controls - Engine Misfire Between 1600-1900 RPM NUMBER: 11-88-08 DATE: 09/02/08 APPLICABILITY: 2006~07MY Impreza WRX 2.5L Turbo, AT and MT SUBJECT: Reprogramming Files for Engine Misfire Introduction This is to announce that ECM reprogramming files are now available to rectify engine misfire between 1,600 and 1,900 rpm during engine warm up. The condition only occurs when the vehicle is parked and the driver is attempting to warm up the engine quicker by increasing the RPM. Pack File Applicability Disclaimer Page 1574 B3-B12 Page 5456 Step 1 - 6 Page 4178 Page 3400 F21-F61 Cooling System - Coolant Comes Out Of Reservoir Coolant Reservoir: Customer Interest Cooling System - Coolant Comes Out Of Reservoir NUMBER: 08-52-08 DATE: 08/18/08 APPLICABILITY: 1999MY and later Impreza & Forester 2000MY and later Legacy & Outback 2006MY and later Tribeca SUBJECT: Coolant Overflow Introduction If you encounter a vehicle which experiences coolant coming out of the coolant reservoir tank, it may be caused by the radiator cap pressure valve being stuck open by debris sucked up through the reservoir tank hose. As the cooling system cools down, it sucks coolant back into the radiator. If there is debris that settles to the bottom of the reservoir tank, the hose is low enough to also suck them back into radiator. This causes the radiator cap not to seal, allowing excessive amount of coolant to escape overflowing the reservoir tank. If this condition continues over time, there will not be enough coolant in the system to maintain proper engine temperature. In order to correct the condition you need to clean (and test) or replace the radiator cap, clean out the reservoir tank, and shorten the hose slightly, following the repair procedure. Production Line Change The shorter coolant reservoir tank hose was used in production as shown above. Repair Procedure/Information 1. Radiator Cap Cleaning Many caps can be successfully cleaned. The important part is the thorough cleaning of the negative pressure valve. If this is not done completely, remaining debris may result in a repeat issue. If there is an excessive amount of debris or the sealing rubber on the cap appears to be pitted or damaged, replace the cap. Note: If replacing the cap, skip to Step 2. Using clean water and a brush, thoroughly clean the cap seal surface. Note: Page 6799 B136-B141 Testing and Inspection ABS Light: Testing and Inspection ABS Warning Light/Brake Warning Light Illumination Pattern INSPECTION 1. When the ABS warning light does not illuminate in accordance with this illumination pattern, there must be an electrical malfunction. 2. When the ABS warning light remains constantly OFF, repair the ABS warning light circuit or diagnosis circuit. NOTE: Even though the ABS warning light does not go out about 2 seconds after it illuminates, the ABS system operates normally when the warning light goes out while driving at approximately 12 km/h (7 MPH). However, the Antilock brakes do not work while ABS warning light is illuminated. Page 6294 R58-R69 Page 3971 4) Using the ST, tighten the bolts of inhibitor switch. ST 499267300 STOPPER PIN 5) Install the select cable to range select lever. 6) Install the plate assembly to transmission. 7) Install the washer and snap pin to range select lever. 8) Install the front and center exhaust pipes. (Non-turbo model) 9) Install the center exhaust pipe. (Turbo model) 10) Lower the vehicle. 11) Install the inhibitor switch connector from stay. 12) Connect the inhibitor switch connector. Page 3430 B136-B141 Page 4654 Brake Master Cylinder: Description and Operation Brake Fluid Level Switch BRAKE FLUID LEVEL SWITCH The brake fluid level switch is located inside the brake fluid reservoir tank and causes the brake system warning light on the combination meter to come on when the fluid level has dropped below the predetermined level. The switch assembly consists of a reed switch (normally open) and a permanent magnet that is incorporated in a float. When the brake fluid level is normal, the float is far above the reed switch, so the force of the magnet is unable to act on the reed switch. The warning light circuit, therefore, remains open. When the brake fluid level drops to a level approximately 20 mm (0.79 in) below the maximum level and the float lowers accordingly, the magnet aligns with the reed switch, activating the reed switch contact. The warning light then comes on to warn the driver of the situation. The warning light may, although momentarily, illuminate even when the brake fluid level is normal if the vehicle tilts or swing largely. Testing and Inspection Map Light Bulb: Testing and Inspection SPOT MAP LIGHT INSPECTION SPOT MAP LIGHT BULB 1. Visually check the bulb for blow out. 2. Check the bulb specification. 3. If NG, replace the bulb with a new one. Service and Repair Power Transistor HVAC: Service and Repair Power Transistor (Auto A/C Model) REMOVAL 1. Remove the glove box. 2. Disconnect the power transistor connector. 3. Loosen the two screws to remove the power transistor. INSTALLATION Install in the reverse order of removal. Page 3894 B3-B12 Page 1747 Remove the hose from the reservoir tank. Cut 20 mm from the bottom of the hose at a 45° angle. Reinstall hose in reservoir tank. Start engine and permit to fully warm up. Turn off engine and allow to fully cool down. Recheck coolant level in reservoir and add coolant if needed. Note: Be sure to use genuine Subaru Super Coolant or Subaru Long Life Coolant, depending upon what type of coolant is currently in the system. Warranty/Claim Information Page 2937 B54-B127 Page 7089 2. Measure the sub switch resistance. 3. If NG, replace the sub switch. Service and Repair Cowl Moulding / Trim: Service and Repair COWL PANEL Cowl Panel REMOVAL 1. Open the front hood. 2. Remove the wiper arm. 3. Remove the front panel seal. 4. Disengage the clips (A) to remove the cowl panel. INSTALLATION Install in the reverse order of removal. Front Wiper Arm Wiper Arm: Adjustments Front Wiper Arm ADJUSTMENT Operate the wiper once. Align the wiper blade the ceramic print point mark (A) of front window panel. Page 1128 8) Install the jack-up plate. 9) Install the air intake duct. 10) Install the air intake duct, air cleaner upper cover and air intake boot. 11) Connect the battery ground cable to battery. 12) Feed the specified fluid. CAUTION: Never start the engine before feeding the fluid; otherwise vane pump might be seized up. 13) Finally check clearance between pipes and/or hoses, as shown above. If cruise control actuator-to-power steering hose clearance is less than 10 mm (0-39 inch), move the portion (A) secured by clamp to other portion, or bend portion (B) to adjust. INSPECTION Check all disassembled parts for wear, damage or other abnormalities. Repair or replace faulty parts as required. CAUTION: Although the surface layer materials of rubber hoses have excellent weathering resistance, heat resistance and resistance for low temperature brittleness, they are likely to be damaged chemically by brake fluid, battery electrolyte, engine oil and automatic transmission fluid and their service lives are to be very shortened. It is very important to keep the hoses free from before mentioned fluids and to wipe out immediately when the hoses are adhered with the fluids. Since the resistances for heat or low temperature brittleness are gradually declining according to time accumulation of hot or cold conditions for the Page 2443 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 1904 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 3314 7. Lift up the vehicle. 8. Disconnect the quick connector on fuel line. 1. Clean the pipe and connector, if they are covered with dust. 2. To prevent from damaging or entering foreign matter, wrap the pipes and connectors with plastic bag, etc. 3. Hold the connector (A) and push retainer (B) down. 4. Pull out the connector (A) from retainer (B). INSTALLATION 1. Connect the quick connector on fuel line. CAUTION: Use a new retainer except for use of engine compartment. - Make sure that the connected portion is not damaged or has dust. If necessary, clean seal surface of pipe. 1. Set the new retainer (B) to connector (A). Page 6786 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 1800 R72-R145 R148 Page 7209 Claim Reimbursement/Warrant Information For vehicles under the Basic New Car Limited Warranty period, refer to the Subaru Warranty Wizard(C) for claim submission information. Disclaimer Page 7024 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 2218 Page 3464 B128-B134 Page 1129 hoses and their service lives are shortening accordingly, it is necessary to perform the careful inspection frequently when the vehicle is used in hot weather areas, cold weather area and a driving condition in which many steering operations are required in short time. Particularly, continuous work of relief valve over 5 seconds causes to reduce service lives of the hoses, the oil pump, the fluid, etc. due to over heat. NOTE: It is likely that although one judges fluid leakage, there is actually no leakage. This is because the fluid spilt during the last maintenance was not completely wiped off. Be sure to wipe off spilt fluid thoroughly after maintenance. Page 6491 F61-R47 Page 7037 B136-B141 Testing and Inspection Camshaft Gear/Sprocket: Testing and Inspection INSPECTION 1. Check the cam sprocket teeth for abnormal wear and scratches. 2. Make sure there is no free play between cam sprocket and key. Page 4787 10. Remove the plate assembly from transmission case. 11. Remove the bolts. 12. Move the range select lever to parking position (left side). 13. Remove the inhibitor switch from transmission. 14. Disconnect the inhibitor switch harness connector from inhibitor switch. INSTALLATION Page 5119 CAMBER ^ Inspection 1) Place the front wheel on turning radius gauge. Make sure ground contacting surfaces of front and rear wheels are set at the same height. 2) Set the adapter into the center of wheel, and then install the wheel alignment gauge. Page 3772 B292-B317 Page 3036 R72-R145 R148 Page 2240 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 4027 Shifter A/T: Diagrams At Select Lever Page 6514 B134-B136 Page 6321 B380-f6 Page 5667 B380-f6 Page 5734 Alarm Module: Service and Repair Security Control Unit SECURITY CONTROL UNIT REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the instrument panel lower cover. 3. Remove the nut, and then remove the keyless entry control unit while disconnecting connector. 4. Disconnect the keyless entry control unit and other electrical control module. INSTALLATION Install in the reverse order of removal. Page 4230 17) Cut off the band with an allowance of about 10 mm (0.39 inch) left from clip, and bend this allowance over the clip. NOTE: Be careful so that the end of band is in close contact with clip. 18) Fix up the boot on EBJ in the same manner. 19) Extend and retract the DOJ to provide equal grease coating. Rear Drive Shaft Inspection INSPECTION Check the removed parts for damage, wear, corrosion, etc. If faulty, repair or replace. 1) DOJ (Double Offset Joint) Check seizure, corrosion, damage, wear and excessive play. 2) EDJ (High-efficiency compact double offset joint) Check for seizure, corrosion, damage, wear or excessive play. 3) Shaft Check excessive bending, twisting, damage and wear. 4) EBJ (High-efficiency compact ball fixed Joint) Check seizure, corrosion, damage and excessive play. 5) Boot Check for wear, warping, breakage or scratches. 6) Grease Check for discoloration or fluidity. Page 3244 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 7075 B128-B134 Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 3868 F21-F61 Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 6135 B134-B136 Page 3558 B54-B127 Page 6623 B17-B20 Page 2449 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Diagrams MASTER CYLINDER Page 4457 Electrical Component Location Locations Electrical Component Location Page 7084 R72-R145 R148 Page 6176 B292-B317 Page 1426 Engine Oil: Fluid Type Specifications Recommended oil: ILSAC GF-4, which can be identified with the new API certification mark (Star burst mark) or API classification SM with the words "ENERGY CONSERVING" SAE viscosity 5W-30 preferred Recommended grade and viscosity for severe driving conditions - If the vehicle is used in desert areas, in areas with very high temperatures, or used for heavy-duty applications such as towing a trailer, use of oil with the following grade and viscosities is recommended. API Classification SM (or SL) SAE Viscosity 30, 40, 10W-50, 20W-40, 20W-50 Intake Door Actuator Air Door Actuator / Motor: Testing and Inspection Intake Door Actuator INTAKE DOOR ACTUATOR TROUBLE SYMPTOM: FRESH/RECIRC mode is not changed. Wiring Diagram Page 7149 (1) Open the rear gate and remove the foam trim board on the left hand side from the cargo floor. (2) Remove the check valve. Note: Place rags or paper towels in the area. There is a chance that a small amount of washer fluid may leak out. (3) Attach valve cushion (86634SA000) around the modified check valve (86634AA010) for soundproofing. (4) Install the modified check valve and valve cushion. Page 6628 B230-B283 Page 2020 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 358 Refrigerant Pressure Sensor / Switch: Testing and Inspection Pressure Switch (Dual Switch) INSPECTION 1. Connect the manifold gauge to the service valve on high-pressure side. 2. Remove the pressure switch harness connector. Using a circuit tester, inspect the ON-OFF operation of pressure switch. Page 6393 B54-B127 Page 6581 Seat Belt Reminder Lamp: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 2184 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 6398 B292-B317 Page 691 B380-f6 Page 7376 B136-B141 Service and Repair Hydraulic Hose: Service and Repair Clutch Pipe and Hose REMOVAL 1) Remove the air intake chamber and air intake duct. (Non-turbo model) 2) Remove the intercooler. (Turbo model) 3) Drain the clutch fluid. 4) Remove the clutch pipe from the clutch hose and master cylinder. 5) Pull out the clamp, then remove the clutch hose from bracket. 6) Remove the hose from operating cylinder. 7) Remove the bracket. INSTALLATION Install in the reverse order of removal. NOTE: Bleed air of the clutch fluid. INSPECTION Check the pipes and hoses for cracks, breakage, or damage. Check the joints for fluid leakage. If any cracks, breakage, damage or leakage is found, Page 1195 Engine Oil: Testing and Inspection Engine Oil INSPECTION 1. Park the vehicle on a level surface. 2. After turning off the engine, wait a few minutes for oil to drain back into the oil pan before checking the level. 3. Just after driving or while the engine is warm, engine oil level may show in the range between the "F line and notch mark. This is caused by thermal expansion of engine oil. 4. Remove the oil level gauge and wipe it clean. 5. Reinsert the level gauge all the way. Be sure that the level gauge is correctly inserted and in proper orientation. 6. Remove it again and note the reading. If the engine oil level is below the "L" line, add oil to bring the level up to "F line. NOTE: To prevent overfilling the engine oil, do not add oil above "F line when the engine is cold. Page 6127 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 1320 9. Remove the timing belt cover No. 2 (RH). 10. Remove the spark plug cord. 11. Remove the oil level gauge guide. (LH side) 12. Remove the rocker cover and gasket. 13. Remove the oil pipe. 14. Loosen the oil flow control solenoid valve assembly and intake camshaft cap bolts equally, a little at a time in alphabetical sequence shown in the figure. 15. Loosen the exhaust camshaft cap bolts equally, a little at a time in alphabetical sequence shown in the figure. 16. Remove the oil flow control solenoid valve assembly, intake camshaft cap, and camshaft. 17. Remove the exhaust camshaft cap and camshaft. NOTE: Arrange the camshaft caps in order so that they can be installed in their original positions. Page 5207 Always refer to "Airbag System" before performing airbag module service. INSPECTION Check for wear, damage, or any other faults. If necessary, replace. Service limit: Universal joint play: 0 mm (0 inch) Maximum swing torque: 0.3 N (0.03 kgf, 0.07 lbs.) Measurement of swing torque of universal joint is as shown in the figures. Service limit: Maximum load. 3.8 N (0.39 kgf, 0.86 lbs.) or less Service limit: Maximum load. 3.8 N (0.39 kgf, 0.86 lbs.) or less Page 3093 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 4172 Page 1236 Fuse & Relay Box (F/B) Diagram Information and Instructions Oil Pressure Warning Lamp/Indicator: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 1848 Temperature Gauge: Electrical Diagrams Temperature Gauge C/TEMP-01 Diagrams: Other diagrams referred to by name within these diagrams (i.e. "REF. TO GND-01", etc) can be found at Diagrams by Diagram Name. See: Diagrams/Electrical Diagrams/Diagrams By Diagram Name Connector and Ground Locations: The locations of the Connectors or Grounds shown within these diagrams can be found via the connector or ground number at Vehicle Locations. See: Locations Additional/Related Diagrams For information regarding diagrams for this component, please refer to Instrument Panel, Gauges and Warning Indicators diagrams. See: Instrument Panel, Gauges and Warning Indicators/Diagrams/Electrical Diagrams Page 6717 ILM(ES)-03 Diagrams: Other diagrams referred to by name within these diagrams (i.e. "REF. TO GND-01", etc) can be found at Diagrams by Diagram Name. See: Diagrams/Electrical Diagrams/Diagrams By Diagram Name Connector and Ground Locations: The locations of the Connectors or Grounds shown within these diagrams can be found via the connector or ground number at Vehicle Locations. See: Locations Page 3798 11) Remove the clamp, and then remove the shift lock solenoid. INSTALLATION Install in the reverse order of removal. INSPECTION Step 1 - Step 4 Page 4912 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 6694 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 4644 3) Connect the brake pipes to their correct ABSCM&H;/U connections. Tightening torque:15 Nm (1.5 kgf-m, 10.8 ft. lbs.) 4) Using the cable clip, secure the ABSCM&H;/U harness to bracket. 5) Connect the connector to ABSCM&H;/U. NOTE: ^ Be sure to remove all foreign matter from inside of the connector before connecting. ^ Ensure that the ABSCM&H;/U connector is securely locked. 6) Connect the ground cable to ABSCM&H;/U, and then apply anti-corrosive wax. 7) Install the air cleaner case and air intake duct. 8) Bleed air from the brake system. REPLACEMENT CAUTION: ^ Because the seal of ABSCM cannot be replaced, do not pull or peel it with lifting up. ^ Because the screw part of H/U deteriorates in every replacement procedure, do not perform the replacement more than five times on it. When the malfunction is found though the replacement that performed is less than five times, replace the H/U body. ^ Use new screws for installation of ABSCM. ^ When the sealing surface of ABSCM or H/U is dirty or damaged and it cannot be removed or repaired, replace it with new one. 1) Remove the ABSCM&H;/U. 2) To prevent entering foreign matter and brake fluid leakage, plug the oil pressure port of ABSCM&H;/U using screw plug and etc. 3) Set the pump motor part of removed ABSCM&H;/U faces down in the vise. NOTE: Before securing a part on a vice, place cushioning material such as wood blocks, aluminum plate or cloth between the part and vice. 4) Using TORT BIT E5, remove the four screws of ABSCM. NOTE: Always use new screws. Page 6492 R58-R69 Page 7337 B3-B12 Page 5203 ^ If oil stops leaking from "f": The oil seal of rack housing is damaged. Replace the oil seal and the parts that are damaged during disassembly with new ones. ADJUSTMENT 1) Adjust the front toe. 2) Adjust the steering angle of wheels. 3) If the steering wheel spokes are not horizontal when wheels are set in the straight ahead position, and error is more than 50 on the periphery of steering wheel, correctly re-install the steering wheel. 4) If the steering wheel spokes are not horizontal with vehicle set in the straight ahead position after this adjustment, correct it by turning the right and left tie-rods in opposite direction by same angle. Page 1273 ^ Inspect the cone for any debris or damage and clean or replace as necessary ^ Perform the Centering Check® Procedure (software version 2.1 and higher) before each wheel is balanced PROCEDURE Always verify the concern with a test drive before beginning diagnosis and performing repairs. Drive the vehicle a minimum of 10 miles to eliminate any flat spots on the tires. Immediately after the road test, lift the vehicle into the air to minimize flat spotting. Adjust tire pressures according to the door label and inspect for any visible damage. If any damage is found, resolve these concerns before continuing with diagnosis. Tire dynamic imbalance should be measured first and adjusted to within 5 grams. Leave any remaining factory weights in place and remove weights that have been added afier production; be careful not to damage the wheel. If the assembly cannot be adjusted to within 5 grams, inspect for the following: ^ Improperly mounted tire or unseated tire bead ^ Improperly mounted assembly to the balancer ^ Damage to the wheel or tire ^ Damage to the tire balancer ^ Debris located inside the tire If a vibration can still be felt afier the wheels have been properly balanced, there is a possibility of excessive radial force variation (RFV) in the tire and wheel assembly. To address RFV concerns, a wheel balancer capable of measuring RFV must be used; Subaru Of America Inc. recommends the use of the Hunter GSP 9700 Road Force Measurement System. If a GSP 9700 is not available, locate the nearest machine through the Hunter Engineering web site (www.gsp9700.com). Measure and record the RFV readings of the wheel and tire assembly for R1H. Then perform the wheel runout measurements by following the on-screen instructions or by referring to the operating instructions; this will determine the individual tire and wheel RFV measurements. The following assembly RFV measurements can be used as a guide: ^ R1H on passenger tires - 8.0kg (17.6lbs) or less If higher than normal RFV measurements are found for the assembly, refer to the on-screen instructions or the operating instructions to match the tire and wheel to minimize the assembly RFV By matching the low spot of the tire to the high spot of the wheel, radial force can be reduced without replacing any components. After all RFV measurements are adjusted to the lowest possible level, install the wheels with the lowest RFV measurements on the front of the vehicle and road test to verify the concern has been reduced. Replacement of tires due to excessive assembly measurements may be unnecessary. If the concern still exists at an unacceptable level, contact the Subaru Technical HelpLine with the following information readily available: ^ Thorough description of customer's concern ^ VIN ^ Mileage ^ Tire manufacturer, size and condition ^ Completed "Dealer vibration Analysis Worksheet and Tire Analysis Worksheet" available under TechLine Pre-Call Worksheets on Subarunet. (All measurements should be in grams or kilograms) ^ Service history of vehicle WARRANTY/CLAIM INFORMATION Page 3475 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 5422 Refrigerant: Service Precautions REFRIGERANT - The CFC-12 refrigerant cannot be used in the HFC-134a A/C system. The HFC-134a refrigerant, also, cannot be used in the CFC-12 A/C system. - If an incorrect or no refrigerant is used, poor lubrication will result and the compressor itself may be damaged. HANDLING OF REFRIGERANT - The refrigerant boils at approx. -30 °C (-22 °F). When handling it, be sure to wear safety goggles and protective gloves. Direct contact of the refrigerant with skin may cause frostbite. If the refrigerant gets into your eye, avoid rubbing your eyes with your hands. Wash your eye with plenty of water, and receive medical treatment from an eye doctor. - Do not heat a service can. If a service can is directly heated, or put into boiling water, the inside pressure will become extremely high. This may cause the can to explode. If a service can must be warmed up, use hot water in 40 °C (104 °F) max. - Do not drop or impact a service can. (Observe the precautions and operation procedure described on the refrigerant can.) - When the engine is running, do not open the high-pressure valve of the manifold gauge. The high-pressure gas will back-flow resulting in an explosion of the can. - Provide good ventilation and do not work in a closed area. - In order to prevent global warning, avoid releasing HFC-134a into the atmosphere. Using a refrigerant recovery system, discharge and reuse it. Propeller Shaft Dimensions Drive/Propeller Shaft: Specifications Propeller Shaft Dimensions Propeller Shaft Dimensions 1 Propeller Shaft Dimensions 2 Page 2256 R72-R145 R148 Page 7013 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 7334 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Service and Repair Skid Plate: Service and Repair REAR DIFFERENTIAL PROTECTOR Rear Differential Protector REMOVAL 1. Remove the rear exhaust pipe and muffler. 2. Remove the differential front member installation bolts. 3. Loosen the nuts until the rear differential protector can be removed. Page 6426 - Do not allow water or oil to come in contact with the connector terminals. Do not touch the connector terminals. - Either of the airbag modules for driver, passenger or side, or pretensioner must not be disassembled. - The removed front seat with the airbag module must be kept at least 200 mm (8 in) away from walls and other objects. - Do not use the airbag or pretensioner parts from other vehicles. Always replace defective parts with new parts. - Never reuse a deployed airbag or pretensioner. - When painting or performing sheet metal work on the front part of the vehicle, including the front wheel apron, front fender, and front side frame, remove the front sub sensors and wire harness of the airbag system. Page 2315 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 913 Transmission Speed Sensor: Service and Repair Rear Vehicle Speed Sensor Rear Vehicle Speed Sensor REMOVAL 1) Set the vehicle on a lift, and then lift-up the vehicle. 2) Disconnect the connector from rear vehicle speed sensor. ^ MP-T model MP-T model ^ VTD model VTD model 3) Remove the rear vehicle speed sensor. ^ MP-T model MP-T model ^ VTD model Page 2031 F61-R47 Page 2545 R58-R69 Page 6414 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 4295 Shifter M/T: Service and Repair MT Gear Shift Lever REMOVAL 5MT 1) Set the vehicle on a lift. 2) Disconnect the ground cable from battery. 3) Remove the gear shift knob. 4) Remove the console box. 5) Remove the clamp. 6) Remove the boot and insulator assembly. 7) Remove the plate assembly from body. 8) Lift-up the vehicle. 9) Remove the rear exhaust pipe and muffler. ^ SOHC model ^ DOHC turbo model 10) Remove the stay from transmission bracket. Page 4545 2. Remove the piston boot. 3. Place a wooden block in caliper body as shown in the figure to prevent the piston from jumping out and avoid being damaged. 4. Gradually supply compressed air via the installation hole of brake hose to force the piston out. 5. Remove the piston seal from caliper body cylinder. CAUTION: Do not damage the cylinder and piston seal groove. 6. Remove the lock pin sleeve and boot from caliper body. 7. Remove the guide pin boot. 2. 15 INCH TYPE 1. Remove the boot ring. Adjustments Transmission Position Switch/Sensor: Adjustments Inhibitor Switch ADJUSTMENT 1) Move the select lever to "N" range. 2) Loosen the three inhibitor switch securing bolts. 3) Insert the ST as vertical as possible into the holes in inhibitor switch lever and switch body. ST 499267300 STOPPER PIN 4) Tighten the three inhibitor switch bolts. Tightening torque: 3.5 Nm (0.36 kgf-m, 2.6 ft. lbs.) 5) Repeat the above checks. If the inhibitor switch is determined to be "faulty", replace it. Page 437 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 901 13) Install the air intake chamber. (Non-turbo model) 14) Install the intercooler. (Turbo model) 15) Inspect the inhibitor switch. Page 3856 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 6898 3. If it is not within specified value, adjust it by adjusting position of stop light switch. CAUTION: Be careful not to rotate the stop light switch. ADJUSTMENT Loosen the lock nut, and adjust the stop light switch position until the clearance between threaded end of stop light switch and stopper (A) becomes 0.3 mm (0.012 inch). Then, tighten the lock nut. Tightening torque: 8 Nm (0.8 kgf-m, 5.8 ft. lbs.) NOTE: Tighten the lock nut B until the clearance between threaded end of stop light switch and stopper becomes 0 mm (0 inch). Hold the stop light switch to prevent turning, and then loosen the lock nut B approximately 60°. The clearance (A) will become 0.3 mm (0.012 inch). Page 571 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Locations Lateral Accelerometer: Locations Electrical Component Location Page 5429 Refrigerant Oil: Fluid Type Specifications COMPRESSOR OIL Use only the manufacturer-authorized compressor oil for the HFC-134a system; only use DH-PR. Page 4132 repair or replace the applicable pipe or hose. Page 2249 B136-B141 Page 607 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 4564 5. Remove the pad pins, then remove the cross spring. 6. Use a wrench to expand the pads, and then push the piston back. 7. Remove the pad. 3. 17 INCH TYPE 1. Set the vehicle on a lift. 2. Loosen the wheel nuts. 3. Lift-up the vehicle, and then remove the front wheel. 4. Remove the clip. Page 528 B292-B317 Page 476 Disclaimer Page 4624 3. 17 INCH TYPE 1. Clean the caliper body interior using brake fluid. 2. Apply a coat of brake fluid to the piston seal and install the piston seal in groove on caliper body. 3. Apply a coat of brake fluid to the entire inner surface of cylinder and outer surface of piston. 4. Apply a coat of specified grease to the boot and install it in the groove on piston. Grease: NIGLUBE RX-2 (Part No. K0779GA 102) 5. Insert the piston into cylinder. CAUTION: Do not force the piston into cylinder. 6. Position the boot in grooves on cylinder and piston. Page 2927 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 7234 B17-B20 Ignition System - Spark Plug Replacement Intervals Spark Plug: Technical Service Bulletins Ignition System - Spark Plug Replacement Intervals PLATINUM SPARK PLUG CHANGE INTERVALS The Techline occasionally gets calls concerning the change intervals on platinum plugs and why some need to be changed at 30,000 miles and others at 60,000 miles. The reason for this is the spark plugs on 2.5L NA engines, the electrode side of this plug is platinum but the plug core side is not platinum. Therefore, it is a maintenance interval every 30,000 miles. On the 2.5L Turbo and 3.OL engines, both the electrode side and the plug core side are platinum. Therefore, it is a maintenance interval every 60,000 miles. Specifications Piston Ring: Specifications PISTON RING Piston ring gap Top ring STD Outer circle side ........................................................................................................................................................... 0.20 - 0.25 mm (0.0079 - 0.0098 in.) Inner circle side ............................................................................................................................................................ 0.20 - 0.30 mm (0.0079 - 0.0117 in.) Limit .......................................................................................... ............................................................................................................... 1.0 mm (0.039 in.) Second ring STD .............................................................................................................................................. .................................... 0.37 - 0.52 mm (0.015 - 0.020 in.) Limit ......................................................... ................................................................................................................................................ 1.0 mm (0.039 in.) Oil ring STD ........................................................................................................................ ...................................................... 0.20 - 0.50 mm (0.0079 - 0.0197 in.) Limit ................................... .............................................................................................................................................................. ........ 1.5 mm (0.059 in.) Clearance between piston ring and piston ring groove Top ring STD .......... .............................................................................................................................................................. ...... 0.04 - 0.08 mm (0.0016 - 0.0031 in.) Limit ................................................................................... .................................................................................................................. 0.15 mm (0.0059 in.) Second ring STD ................................................................................................................................. ......................................... 0.030 - 0.070 mm (0.0012 - 0.0028 in.) Limit ............................................ ......................................................................................................................................................... 0.15 mm (0.0059 in.) Note: STD = Standard Page 2860 B17-B20 Page 4915 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 1434 3. Install the adapter B. 4. Contact the engine oil cooler stopper (A) to adapter B rib (B) to install engine oil cooler. 5. Apply liquid gasket to the plug thread when installing it. Liquid gasket. THREE BOND 1215 (Part No. 004403007) or equivalent Tightening torque: T1: 45 Nm (4.6 kgf-m, 33.2 ft. lbs.) T2: 6.4 Nm (0. 65 kgf-m, 4.7 ft. lbs.) T3: 54 Nm (5.5 kgf-m, 40 ft. lbs.) T4: 69 Nm (7.0 kgf-m, 50.9 ft. lbs.) NOTE: Always use new gasket and O-ring. Page 6895 Sensor Page 6542 B128-B134 Page 4377 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 5385 Evaporator Case: Service and Repair Heater and Cooling Unit REMOVAL 1. Disconnect the ground cable from battery. 2. Using the refrigerant recovery system, discharge refrigerant. 3. Drain LLC from the radiator. 4. Remove the bolt securing expansion valve and pipe in engine compartment. Release the heater hose clamps in engine compartment to remove the hoses. 5. Remove the instrument panel. 6. Remove the support beam. 7. Remove the blower motor unit assembly. 8. Disconnect the servo motor connectors. 9. Loosen the bolt and nuts to remove the heater and cooling unit. INSTALLATION 1. Install in the reverse order of removal. 2. Charge refrigerant. Tightening torque: T: 7.4 N.m (0.75 kgf-m, 5.4 ft-lb) Page 6440 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 577 B128-B134 A/T Controls - DTC P0851/P0852 Set Neutral Safety Switch: All Technical Service Bulletins A/T Controls - DTC P0851/P0852 Set NUMBER: 16-68-06 DATE: 10/09/06 APPLICABILITY: 2005~06MY Legacy, Outback, Impreza and Forester Vehicles Equipped with 4EAT SUBJECT: Diagnostic procedures for P0851/P0852 INTRODUCTION The purpose of this bulletin is to assist when diagnosing P0851 (Neutral Switch Input Circuit Low) and P0852 Neutral Switch Input Circuit High). If you encounter a vehicle with P0851 and/or P0852, use the following repair procedure. REPAIR PROCEDURE/INFORMATION Using the Subaru Select Monitor, check for diagnostic trouble codes stored in memory. If P0851 and/or P0852 are stored in memory, adjust the inhibitor switch and select cable. Note: Refer to the applicable Subaru Service Manual found on the STIS web-site for component removal to gain access to the inhibitor switch and select cable. It is critical that the following adjustments are performed correctly. Adjustment for inhibitor switch 1) Set the select lever to "N" range. 2) Loosen the three inhibitor switch securing bolts. 3) Insert ST (special tool) 499267300 Stopper Pin as vertical as possible into the holes in the inhibitor switch lever and switch body. 4) Tighten the three inhibitor switch securing bolts then remove special tool. Tightening torque: 3.4 N-m (0.35 kgf-m, 2.5 ft-lb) Adjustment for select cable Page 7424 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 2942 B292-B317 Page 4593 The tables shown above contain additional information for recommended materials listed in the repair manuals for individual models. For additional warranty submission information please refer the materials policy in Section 13.9 of the CDS Policies and Procedures Manual. Disclaimer Page 5689 Impact Sensor: Service and Repair Side Airbag Sensor SIDE AIRBAG SENSOR REMOVAL 1. Turn the ignition switch to OFF. 2. Disconnect the ground cable from battery, and wait for at least 20 seconds before starting work. 3. Remove the outer seat belt (FRONT). 4. Detach the side airbag sensor, and then disconnect the airbag connector. INSTALLATION Install in the reverse order of removal. Tightening torque: Refer to "COMPONENT" in "General Description". See: Air Bag Systems/Locations Page 4325 4) Using the ST, tighten the bolts of inhibitor switch. ST 499267300 STOPPER PIN 5) Install the select cable to range select lever. 6) Install the plate assembly to transmission. 7) Install the washer and snap pin to range select lever. 8) Install the front and center exhaust pipes. (Non-turbo model) 9) Install the center exhaust pipe. (Turbo model) 10) Lower the vehicle. 11) Install the inhibitor switch connector from stay. 12) Connect the inhibitor switch connector. Page 1350 O.D.: Outer Diameter 4. Measure the side clearance of crankshaft at center bearing. If the clearance exceeds the limit, replace the bearing. Crankshaft side clearance: Standard 0.030 - 0.115 mm (0.0012 - 0.0045 inch) Limit 0.25 mm (0.0098 inch) 5. Inspect individual crankshaft bearings for signs of flaking, seizure, melting, and wear. 6. Measure the oil clearance on each crankshaft bearing by means of plastigauge. If the measurement is not within the specification, replace the defective bearing with an undersize one, and replace or recondition the crankshaft as necessary. Crankshaft oil clearance: Standard 0.010 - 0.030 mm (0.0004 - 0.0012 inch) Limit 0.040 mm (0.0016 inch) Engine Controls - DTC P0340/P0345 After Camshaft R & R Camshaft Position Sensor: All Technical Service Bulletins Engine Controls - DTC P0340/P0345 After Camshaft R & R Number: 02-107-09 Date: 03/24/09 Applicability: 2004~06MY Baja 2.5L Turbo 2004~06MY Impreza 2.5L Turbo 2004~06MY Forester 2.5L Turbo 2004~06MY Legacy/Outback 2.5L Turbo SUBJECT: Intake Camshaft Replacement Introduction If you encounter a vehicle that has a CEL and P0340 or P0345 stored in memory immediately after replacing the intake camshaft(s), the air gap between the camshaft and camshaft position sensor may be out of specification. A modification was made to the plate area of the camshaft where the camshaft position sensor picks up the signal. Parts Information Repair Procedure/ Information Using a feeler (thickness) gauge, measure the gap between the camshaft and camshaft position sensor. The correct gap is between 0.15mm to 0.98mm (0.0059 to 0.0386 in.) If the gap is over 0.98mm (0.0386 in.) replace the camshaft position sensor. Refer to the applicable service manual. Warranty/Claim Information For vehicles within warranty, refer the Subaru Warranty Wizard for claim submission information. Page 4074 Transmission Position Switch/Sensor: Service and Repair AT Shift Lock Solenoid and "P" Range Switch AT Shift Lock Solenoid and "P" Range Switch REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the console box. 3) Disconnect the connector. 4) Remove the grip. 5) Remove the indicator bulb from indicator cover. 6) Remove the indicator cover. 7) Remove the blind. 8) Remove the cushion. 9) Remove the clip, and then remove the "P" range switch. 10) Remove the cover. Page 2252 B380-f6 Locations Lateral Accelerometer: Locations Electrical Component Location Page 4590 Wheels/Tires - Wheel Lock Installation/Removal Wheel Fastener: Technical Service Bulletins Wheels/Tires - Wheel Lock Installation/Removal NUMBER: 15-125-07 DATE: 08/29/07 APPLICABILITY: All Vehicles SUBJECT: Subaru Wheel Locks Introduction The purpose of this bulletin is to provide the proper procedure for removing and installing Subaru wheel locks. Failure to follow this procedure can cause damage to the wheel locks and/or wheels. Repair Procedure/Information 1) Remove one lug nut from each wheel. If wheel studs are dirty, clean with a wire brush prior to installing locks. Use extreme care to prevent damage to the wheel. 2) By hand, install one wheel lock on each wheel. 3) Using the special wheel lock key and a torque wrench, tighten each wheel lock to the proper lug nut torque specification (refer to the applicable Subaru Service Manual). NOTE: For ease of installation and removal, the wheel lock should always be the last lug nut tightened on each wheel and should always be the first one removed. WARNING: Use of an impact wrench may cause permanent damage to the wheel lock and key. Warranty Information Wheel locks and/or keys that are damaged due to improper installation and/or removal is not a matter for warranty. Disclaimer Page 2021 B3-B12 Page 5914 Rear Door Window Regulator: Service and Repair REAR REGULATOR AND MOTOR ASSEMBLY REMOVAL 1. Remove the rear door glass. 2. Remove the front sash. 3. Disconnect the motor connector. 4. Remove the four bolts and two nuts to remove regulator assembly. 5. Remove the screws to remove motor assembly. INSTALLATION 1. Install in the reverse order of removal. 2. Adjust the rear door glass. Tightening torque: Nm (kgf-m, ft-lb) T1: 7.4 (0.75, 5.5) T2: 13.7 (1.4, 10.1) Service and Repair Air Bag(s) Arming and Disarming: Service and Repair CAUTION: - When servicing a vehicle, be sure to turn the ignition switch to OFF, disconnect the ground cable from battery, and wait for more than 20 seconds before starting work. - The airbag system is fitted with a backup power source. If the airbag system is serviced within 20 seconds after the ground cable is disconnected, it may inflate. - If the airbag warning light illuminates, repair the vehicle immediately. Airbag or pretensioner may inflate incorrectly, or not inflate in collision. - If sensors, airbag module, airbag control module, pretensioner, and harness are deformed or damaged, replace them with new genuine parts. - When checking the airbag system, be sure to use a digital circuit tester. Infinitesimal electric current in an analog circuit tester may cause the airbag to activate erroneously. - When checking the airbag system, be sure to use a digital circuit tester. Infinitesimal electric current in an analog circuit tester may cause the airbag to activate erroneously. Page 3845 11) Remove the clamp, and then remove the shift lock solenoid. INSTALLATION Install in the reverse order of removal. INSPECTION Step 1 - Step 4 Page 3087 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 1920 B380-f6 Page 393 Brake Light Switch: Testing and Inspection BRAKE LIGHT SWITCH INSPECTION 1. If the stop light switch does not operate properly (or if it does not stop at the specified position), replace with a new one. Specified position L: 2 mm (0.079 inch) 2. Measure the clearance between threaded end of stop light switch and stopper. CAUTION: Be careful not to rotate stop light switch. Stop light switch clearance 0.3 mm (0.012 inch) 3. If it is not within specified value, adjust it by adjusting position of stop light switch. CAUTION: Be careful not to rotate the stop light switch. Page 5348 Blower Motor Resistor: Service and Repair Blower Resistor (Manual A/C Model) REMOVAL 1. Remove the glove box. 2. Disconnect the blower resistor connector. 3. Loosen the two screws to remove the blower resistor. INSTALLATION Install in the reverse order of removal. Page 56 Main Fuse Box (M/B) Secondary A/C Fuse Box Page 2636 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 6342 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 6613 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Testing and Inspection Fuel Supply Line: Testing and Inspection INSPECTION 1. Make sure that there are no cracks on the fuel pipes and fuel hoses. 2. Make sure that the fuel pipe and fuel hose connections are tight. Page 3636 Knock Sensor: Service and Repair Knock Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the intercooler. 3. Disconnect the knock sensor connector. 4. Remove the knock sensor from the cylinder block. INSTALLATION 1. Install the knock sensor to the cylinder block. Tightening torque: 24 N.m (2.4 kgf-m, 17.4 ft-lb) NOTE: Extraction area of the knock sensor cord must be positioned at a 60 degrees angle relative to the engine rear. Page 6703 B134-B136 Page 2232 Oxygen Sensor: Locations Location View Page 2203 R72-R145 R148 Locations Cooling System - Coolant Comes Out Of Reservoir Radiator Cap: Customer Interest Cooling System - Coolant Comes Out Of Reservoir NUMBER: 08-52-08 DATE: 08/18/08 APPLICABILITY: 1999MY and later Impreza & Forester 2000MY and later Legacy & Outback 2006MY and later Tribeca SUBJECT: Coolant Overflow Introduction If you encounter a vehicle which experiences coolant coming out of the coolant reservoir tank, it may be caused by the radiator cap pressure valve being stuck open by debris sucked up through the reservoir tank hose. As the cooling system cools down, it sucks coolant back into the radiator. If there is debris that settles to the bottom of the reservoir tank, the hose is low enough to also suck them back into radiator. This causes the radiator cap not to seal, allowing excessive amount of coolant to escape overflowing the reservoir tank. If this condition continues over time, there will not be enough coolant in the system to maintain proper engine temperature. In order to correct the condition you need to clean (and test) or replace the radiator cap, clean out the reservoir tank, and shorten the hose slightly, following the repair procedure. Production Line Change The shorter coolant reservoir tank hose was used in production as shown above. Repair Procedure/Information 1. Radiator Cap Cleaning Many caps can be successfully cleaned. The important part is the thorough cleaning of the negative pressure valve. If this is not done completely, remaining debris may result in a repeat issue. If there is an excessive amount of debris or the sealing rubber on the cap appears to be pitted or damaged, replace the cap. Note: If replacing the cap, skip to Step 2. Using clean water and a brush, thoroughly clean the cap seal surface. Note: Page 2533 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 4645 5) Slowly remove the ABSCM upward from H/U. NOTE: To prevent damaging of coil part, remove the ABSCM straightly from H/U. 6) Ensure there are no dirt or damage on sealing surface of H/U. CAUTION: ^ Do not clean the ABSCM & H/U with applying compressed air. ^ Do not repair the damages of H/U sealing surface using file or metal scraper. To remove the sealing, use resin scraper. Do not use the chemical materials (thinner and etc.). 7) Position the coil of new ABSCM to align H/U valve. 8) To prevent deforming of ABSCM housing cover, hold the corner of ABSCM and install it to the H/U without tilting. 9) Using TORT BIT E5, tighten the screws stepwise in the order of (1) through (4). CAUTION: Always use new screws. Tightening torque:1.5 Nm (0.15 kgf-m, 1.1 ft. lbs.) 10) Check that there is no foreign matter in aligning part between ABSCM and H/U. 11) Using TORT BIT E5, tighten the screws stepwise in the order of (1) through (4) again. Tightening torque: 3 Nm (0.3 kgf-m, 2.2 ft. lbs.) 12) Check that there is no clearance in aligning part between ABSCM and H/U. 13) Install the ABSCM&H;/U to vehicle. INSPECTION 1) Check the connected and fixed condition of connector. Page 2125 F61-R47 Page 3657 B136-B141 Recall - Front Seat Wiring Harness Routing Wiring Harness: All Technical Service Bulletins Recall - Front Seat Wiring Harness Routing NUMBER: WVC-13 DATE: March 2007 APPLICABILITY: 2006MY Subaru Forester & Impreza SUBJECT: Front Passenger Seat Wiring INTRODUCTION Subaru of America, Inc. (SOA) has determined that certain 2006 MY Subaru Forester and Impreza models may have been produced with an improperly routed electrical wiring harness. That harness could have been pinched against the passenger front seat mounting bolt during production. If the wiring harness was improperly installed, an electrical short could occur. There are two safety risks associated with this condition. The first is that the passenger's front air bag, which is connected to this wiring harness, could become disabled, in which case it would not deploy as designed in an accident and would therefore expose the right front passenger to the possibility of serious injuries. The second is that an electrical short circuit could, under some circumstances, cause a fire. If an electrical short circuit occurs in this wiring harness, fuse # 6 (located in the fuse panel on the lower left side of the dashboard) will "blow", disabling the passenger front air bag. This could occur at any time and without prior warning. But once it occurs, the driver will be alerted to this condition by the illumination of the air bag system warning light on the vehicle's instrument panel. Occupants will also be alerted to this condition if the passenger's frontal air bag ON/OFF indicator indicates "OFF" even if an adult passenger is occupying that seat. If fuse # 6 had previously blown and been replaced with no repair made to correct the underlying cause, there is a possibility that this wiring harness has already been damaged due to a short circuit. Under these circumstances, the new replacement fuse may not blow and a fire could occur at any time without warning. In Forester models, it could happen even if the ignition switch is in the "LOCK" (off) position. Vehicle owners will be advised in the Owner Notification Letter that if they encounter a blown fuse, an illuminated air bag system warning light, smell smoke, or have replaced a blown fuse # 6 without correcting the underlying problem, to not operate the vehicle. They will be advised to contact the nearest Subaru dealer as soon as possible for guidance. In these cases, dealers should arrange to have the vehicle towed and repairs performed immediately. This recall will involve inspection and possible repair of the front passenger seat wire harness. Please refer to the Service Procedure section of this bulletin for more details. AFFECTED VEHICLES ^ 2006 MY Subaru Forester and Impreza Potentially affected vehicles are identified in the VIN range chart below. Not all vehicles within the VIN range are affected. Prior to performing repairs, confirm coverage for potentially affected vehicles by using the Vehicle Coverage Inquiry in the Dealer Communication System (DCS). OWNER NOTIFICATION SOA will prepare and mail Owner Notification Letters to owners of affected vehicles on or around March 9, 2007. A copy of the Owner Notification Letter is included at the end of this bulletin. DEALER PROGRAM RESPONSIBILITY Dealers are to promptly service all vehicles subject to this recall at no charge to the vehicle owner regardless of mileage~ age of the vehicle~ or Page 4980 R58-R69 Page 4971 B54-B127 Page 4889 Starter Motor: Locations Page 443 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 4305 5MT Page 2451 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 5335 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Engine Controls - DTC P0340/P0345 After Camshaft R & R Camshaft Position Sensor: Customer Interest Engine Controls - DTC P0340/P0345 After Camshaft R&R Number: 02-107-09 Date: 03/24/09 Applicability: 2004~06MY Baja 2.5L Turbo 2004~06MY Impreza 2.5L Turbo 2004~06MY Forester 2.5L Turbo 2004~06MY Legacy/Outback 2.5L Turbo SUBJECT: Intake Camshaft Replacement Introduction If you encounter a vehicle that has a CEL and P0340 or P0345 stored in memory immediately after replacing the intake camshaft(s), the air gap between the camshaft and camshaft position sensor may be out of specification. A modification was made to the plate area of the camshaft where the camshaft position sensor picks up the signal. Parts Information Repair Procedure/ Information Using a feeler (thickness) gauge, measure the gap between the camshaft and camshaft position sensor. The correct gap is between 0.15mm to 0.98mm (0.0059 to 0.0386 in.) If the gap is over 0.98mm (0.0386 in.) replace the camshaft position sensor. Refer to the applicable service manual. Warranty/Claim Information For vehicles within warranty, refer the Subaru Warranty Wizard for claim submission information. Page 3617 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 107 Page 2862 B128-B134 Page 1847 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 4522 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 5666 B292-B317 Page 3383 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 2711 Knock Sensor: Service and Repair Knock Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the intercooler. 3. Disconnect the knock sensor connector. 4. Remove the knock sensor from the cylinder block. INSTALLATION 1. Install the knock sensor to the cylinder block. Tightening torque: 24 N.m (2.4 kgf-m, 17.4 ft-lb) NOTE: Extraction area of the knock sensor cord must be positioned at a 60 degrees angle relative to the engine rear. Description and Operation Malfunction Indicator Lamp: Description and Operation ACTIVATION OF MALFUNCTION INDICATOR LIGHT 1. When the ignition switch is turned to ON (engine off), the malfunction indicator light in the combination meter illuminates. NOTE: If the malfunction indicator light does not illuminate, perform diagnostics of the malfunction indicator light circuit or the combination meter circuit. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Diagnosis By Symptom/Malfunction Indicator Lamp (MIL) Does Not Come ON 2. After starting the engine, the malfunction indicator light goes out. If it does not, either the engine or the emission control system is malfunctioning. 3. If the diagnosis system senses a misfire which could damage the catalyzer, the malfunction indicator light will blink at a cycle of 1 Hz. Page 1908 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 693 F61-R47 Page 114 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS System Diagnosis Front Door Exterior Handle: Testing and Inspection FRONT OUTER HANDLE INSPECTION 1. Make sure the rod is not deformed. 2. Make sure the lever and rod work smoothly. Page 2366 Air Flow Meter/Sensor: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 951 B230-B283 Service and Repair Cruise Control Module: Service and Repair Cruise Control Unit REMOVAL The control of cruise control system is performed by Engine control module (ECM). Page 1779 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 7096 Front Door Glass Page 4278 8) Install the front drive shaft. ST 28399SA010 OIL SEAL PROTECTOR 9) Install the front and center exhaust pipe. (Non-turbo model) 10) Lower the vehicle. 11) Pour gear oil through the gauge hole. Page 1835 B128-B134 Page 4355 Non-turbo model ^ Turbo model Turbo model 4) Replace defective parts. Page 4221 NOTE: EBJ installation surface of EBJ boot shall be cleaned so as to be free from grease and other substances. 5) Install the boot projecting portion to EBJ groove. 6) Set the large boot band in place. 7) Install the boot projecting portion to shaft groove. 8) Tighten the boot bands using the ST, torque wrench and socket flex handle. ST 28099AC000 BOOT BAND PLIER Tightening torque: Large boot band 157 Nm (16.0 kgf-m, 116 ft. lbs.) or more Small boot band 133 Nm (13.6 kgf-m, 98 ft. lbs.) or more Page 2639 B54-B127 Inhibitor Switch Transmission Position Switch/Sensor: Service and Repair Inhibitor Switch Inhibitor Switch INSPECTION When the driving condition or starter motor operation is erroneous, first check the shift linkage for improper operation. If the shift linkage is functioning properly, check the inhibitor switch. 1) Disconnect the inhibitor switch connector. 2) Check continuity in inhibitor switch circuits with the select lever moved to each position. NOTE: ^ Also check that continuity in ignition circuit does not exist when the select lever is in "R", "D", "3", "2" and "1" ranges. ^ If the inhibitor switch is inoperative, check for poor contact of connector on transmission side. 3) Check if there is continuity at equal points when the select lever is tilted 1.5° in both directions from "N" range. If there is continuity in one direction and the continuity in the other or if there is continuity at unequal points, adjust the inhibitor switch. 4) Repeat the above checks. If there are abnormalities, adjust the select cable. REMOVAL 1) Set up the vehicle on a lift. 2) Move the select lever to "N" range. 3) Remove the air intake chamber (Non-turbo model). 4) Remove the intercooler. (Turbo model) Page 667 Vehicle Speed Sensor: Service and Repair Vehicle Speed Sensor REMOVAL 1) Disconnect the ground cable from battery. 2) Lift-up the vehicle. 3) Remove the front, center and rear exhaust pipes and muffler. ^ Non-turbo model ^ Turbo model 4) Disconnect the connector from vehicle speed sensor. 5) Turn and remove the vehicle speed sensor. INSTALLATION NOTE: ^ When the vehicle speed sensor is removed, discard it and replace with a new one. ^ Ensure the sensor mounting hole is clean and free of foreign matter. ^ Align the tip end of key with key groove on end of speedometer shaft during installation. 1) Hand tighten the vehicle speed sensor. 2) Tighten the vehicle speed sensor using suitable tool. Tightening torque: 5.9 Nm (0.6 kgf-m, 4.3 ft. lbs.) 3) Connect the connector to vehicle speed sensor. 4) Install the front, center and rear exhaust pipes and muffler. ^ Non-turbo model ^ Turbo model 5) Lower the vehicle. 6) Connect the battery ground cable to battery. INSPECTION The vehicle speed sensor can not be inspected as a single unit. Check if speedometer operates normally. If it does not operate normally, inspect the combination meter system. Page 7381 F61-R47 Page 3476 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Luggage Room Light Switch Trunk Lamp Switch: Testing and Inspection Luggage Room Light Switch Luggage Room Light LUGGAGE ROOM LIGHT SWITCH Measure the resistance between luggage room light terminals. Page 2913 Fuel Tank Pressure Sensor: Testing and Inspection INSPECTION Make sure the hoses are not cracked or loose. Page 2086 B136-B141 Page 6538 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 4389 B136-B141 Page 6836 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Service and Repair Fuel Pressure Release: Service and Repair Fuel PROCEDURE RELEASING OF FUEL PRESSURE WARNING: - Place "NO FIRE" signs near the working area. - Be careful not to spill the fuel. 1. Disconnect the connector from the fuel pump relay. 2. Start and run the engine until it stalls. 3. After the engine stalls, crank it for five more seconds. 4. Turn the ignition switch to OFF. Page 1284 Wheels: Service and Repair Aluminum Wheel REMOVAL 1. Apply parking brake, and position the select lever to P or LOW. 2. Set jacks or a lift to the specified point, and support the vehicle with its tires slightly contacting the floor. 3. Loosen the wheel nuts. 4. Raise the vehicle until its tires take off the ground using a jack or a lift. 5. Remove the wheel nuts and wheels. NOTE: ^ While removing the wheels, prevent the hub bolts from damage. ^ Place the wheels with their outer sides facing upward to prevent the wheels from damage. INSTALLATION 1. Remove dirt from the mating surface of wheel and brake rotor. 2. Attach the wheel to hub by aligning the wheel bolt hole with hub bolt. 3. Temporarily attach the wheel nuts to hub bolts, using SUBARU genuine wheel nut. 4. Manually tighten the nuts making sure the wheel hub hole is aligned correctly to guide portion of hub. 5. Tighten the wheel nuts in a diagonal selection to specified torque. Use a wheel nut wrench. Wheel nut tightening torque: 90 Nm (9.1 kgf-m, 65.7 ft. lbs.) CAUTION: ^ Tighten the wheel nuts in two or three steps by gradually increasing the torque and working diagonally, until the specified torque is reached. ^ Do not depress the wrench with foot; Always use both hands when tightening. ^ Make sure the bolt, nut and nut seating surface of the wheel are free from oils. 6. If a wheel is removed for replacement or for repair of a puncture, retighten the wheel nuts to the specified torque after running 1,000 km (600 miles). INSPECTION 1. Deformation or damage on the rim can cause air leakage. Check the rim flange for deformation, crack or damage, and repair or replace as necessary. 2. Jack-up the vehicle until tires clear the floor. 3. Slowly rotate the wheel to check the rim runout using a dial gauge. Page 38 Electrical Component Location Page 776 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 5968 Underbody Cover: Service and Repair Front Under Cover FRONT UNDER COVER Under Cover REMOVAL 1. Lift-up the vehicle. 2. Remove the bolts and clips to remove under cover. INSTALLATION Install in the reverse order of removal. Tightening torque: 14 N.m (1.4 kgf-m, 10.3 ft-lb) Page 3767 B54-B127 Testing and Inspection Marker Lamp Bulb: Testing and Inspection Front Side Marker Light Bulb INSPECTION 1. Visually check the bulb for blow out. 2. Check the bulb specification. 3. If NG, replace the bulb with a new one. Symptom Related Diagnostic Procedures Symptom Chart Page 6172 B128-B134 Page 2323 B54-B127 Page 4937 RAPS-01 Diagrams: Other diagrams referred to by name within these diagrams (i.e. "REF. TO GND-01", etc) can be found at Diagrams by Diagram Name. See: Diagrams/Electrical Diagrams/Diagrams By Diagram Name Connector and Ground Locations: The locations of the Connectors or Grounds shown within these diagrams can be found via the connector or ground number at Vehicle Locations. See: Locations Rear Accessory Power Supply Socket System Page 2770 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 6007 Carpet: Service and Repair Luggage Floor Mat LUGGAGE FLOOR MAT REMOVAL Remove the clips, and then detach the rear floor mats. INSTALLATION Install in the reverse order of removal. Page 6312 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 286 Non-Turbo Model Page 5246 INSPECTION Refer to Front Strut as a guide for inspection procedures. DISPOSAL Refer to Front Strut as a guide for disposal procedures. Adjustments Transmission Position Switch/Sensor: Adjustments Inhibitor Switch ADJUSTMENT 1) Move the select lever to "N" range. 2) Loosen the three inhibitor switch securing bolts. 3) Insert the ST as vertical as possible into the holes in inhibitor switch lever and switch body. ST 499267300 STOPPER PIN 4) Tighten the three inhibitor switch bolts. Tightening torque: 3.5 Nm (0.36 kgf-m, 2.6 ft. lbs.) 5) Repeat the above checks. If the inhibitor switch is determined to be "faulty", replace it. Page 719 B54-B127 Page 647 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 3646 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Service and Repair Cowl Moulding / Trim: Service and Repair COWL PANEL Cowl Panel REMOVAL 1. Open the front hood. 2. Remove the wiper arm. 3. Remove the front panel seal. 4. Disengage the clips (A) to remove the cowl panel. INSTALLATION Install in the reverse order of removal. Page 5725 Alarm Horn Relay: Service and Repair SECURITY HORN RELAY REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the mounting bolt and detach the security horn relay. INSTALLATION Install in the reverse order of removal. Page 789 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 4523 Brake Warning Indicator: Testing and Inspection ABS Warning Light/Brake Warning Light Illumination Pattern INSPECTION 1. When the ABS warning light does not illuminate in accordance with this illumination pattern, there must be an electrical malfunction. 2. When the ABS warning light remains constantly OFF, repair the ABS warning light circuit or diagnosis circuit. NOTE: Even though the ABS warning light does not go out about 2 seconds after it illuminates, the ABS system operates normally when the warning light goes out while driving at approximately 12 km/h (7 MPH). However, the Antilock brakes do not work while ABS warning light is illuminated. Page 4506 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Diagram Information and Instructions Oil Pressure Sender: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 6396 B136-B141 Page 6351 B134-B136 Page 4995 to the right. The proper wire location (not pinched) is indicated by broken lines in the photo to the right, below. ^ If the wire was found to be pinched, proceed to the "Wiring Repair Procedure" section, below. 3. If the wire was found to be located properly (not pinched), no repair is necessary. Reinstall the floor carpet. Wrap the previously cut portion of carpet with 1.5 inch wide unwoven adhesive tape. 4. Reinstall the center console trim. Note: Be careful that the seat heater switch is not pinched by the parking brake lever during reinstallation. 5. Confirm that switches, including the seat heater switch, work properly. Wiring Repair Procedure: Forester & Impreza 1. Disconnect the negative battery cable. Note: In the interest of customer satisfaction, please write down all radio preset stations prior to disconnecting the battery. The stations should be reset into the radio afier completion of the repair. 2. For Impreza models, proceed to step 4. Forester Models only: Remove the center console trim between the select lever and parking brake lever. 3. Forester only: Cut a cross section of floor carpet at the center in front of the parking brake lever with scissors as shown. Engine Controls - DTC P0607 Diagnostic Information Engine Control Module: Customer Interest Engine Controls - DTC P0607 Diagnostic Information NUMBER: 11-91-08 DATE: 12/05/08 APPLICABILITY: 2004-2008MY Impreza 2004-2008MY Forester 2005-2008MY Legacy/Outback 2006-2007MY Tribeca SUBJECT: DTC P0607 Control Module Performance Introduction The purpose of the bulletin is for information purposes when diagnosing DTC P0607. The following checks and information is in addition to what is listed in the Subaru Service Manual. This information is to be used in conjunction with the service manual. Repair Procedure/Information Additional items to check: ^ Rapid drop of voltage from a dead battery ^ Loose battery terminals ^ Loose ECM ground terminal ^ A short or open to the power or ground circuit If the malfunction criteria are met, the CEL will illuminate, the vehicle will go into fail safe and the throttle valve opening will be fixed at 6°. Fail safe will recover to normal mode if the ECM judges the criteria "OK" at the time of the next engine start. The CEL will not turn off until the "OK" driving cycle is completed 3 times in a row. The judgment is decided by the ECM to keep the CEL On or Off at the time the ignition switch is turned from ON to OFF. The ECM keeps DTC P0607 in memory even after the indicator light goes out. Therefore, it is important to erase memory after the repair is completed. Detail list of applicable model and engine type. Page 1578 B134-B136 Page 2761 B136-B141 Page 6775 Horn Relay: Testing and Inspection HORN RELAY INSPECTION Measure the horn relay resistance between terminals (indicated in table) when connecting the terminal No. 4 to battery positive terminal and terminal No. 3 to battery ground cable. Page 4243 Drive/Propeller Shaft: Specifications Front Drive Shaft Dimensions Front Drive Shaft Dimensions 1 Front Drive Shaft Dimensions 2 Page 3402 R58-R69 Service and Repair Fuel Cut Control Unit: Service and Repair Fuel Cut Valve REMOVAL 1. Remove the fuel tank. 2. Remove the protect cover. 3. Move the clip and disconnect the evaporation hose from fuel cut valve. 4. Remove the bolts which install the fuel cut valve. INSTALLATION Install in the reverse order of removal. NOTE: Use a new gasket. Page 4201 11) Insert the DOJ into rear differential. (1) Install the ST to rear differential. ST 28099PA090 OIL SEAL PROTECTOR (2) Install the spline shaft until the spline portion is inside the side oil seal using ST. ST 28099PA090 OIL SEAL PROTECTOR (3) Remove the ST. ST 28099PA090 OIL SEAL PROTECTOR 12) Hereafter, reassemble in the reverse order of disassembly. Locations Cabin Air Filter: Locations The Optional Cabin Air Filter is located in the Heater-A/C box behind the glove compartment. Page 2231 P Code List (Partial list) Page 4675 Parking Brake Shoe: Service and Repair Parking Brake Assembly (Rear Disc Brake) REMOVAL 1) Pull down and release the parking brake. 2) Remove the two mounting bolts and remove the brake caliper assembly. 3) Suspend the brake caliper assembly so that the hose is not stretched. 4) Remove the disc rotor. NOTE: If the disc rotor is difficult to remove, try the two following methods in order. (1) Turn the adjusting screw using a flat tip screwdriver until brake shoe gets away enough from the disc rotor. (2) If the disc rotor seizes up within hub, drive the disc rotor out by installing two 8-mm bolts in holes B on rotor. 5) Remove the shoe return spring from parking brake assembly. Recall - Front Seat Wiring Harness Routing Air Bag Harness: Recalls Recall - Front Seat Wiring Harness Routing NUMBER: WVC-13 DATE: March 2007 APPLICABILITY: 2006MY Subaru Forester & Impreza SUBJECT: Front Passenger Seat Wiring INTRODUCTION Subaru of America, Inc. (SOA) has determined that certain 2006 MY Subaru Forester and Impreza models may have been produced with an improperly routed electrical wiring harness. That harness could have been pinched against the passenger front seat mounting bolt during production. If the wiring harness was improperly installed, an electrical short could occur. There are two safety risks associated with this condition. The first is that the passenger's front air bag, which is connected to this wiring harness, could become disabled, in which case it would not deploy as designed in an accident and would therefore expose the right front passenger to the possibility of serious injuries. The second is that an electrical short circuit could, under some circumstances, cause a fire. If an electrical short circuit occurs in this wiring harness, fuse # 6 (located in the fuse panel on the lower left side of the dashboard) will "blow", disabling the passenger front air bag. This could occur at any time and without prior warning. But once it occurs, the driver will be alerted to this condition by the illumination of the air bag system warning light on the vehicle's instrument panel. Occupants will also be alerted to this condition if the passenger's frontal air bag ON/OFF indicator indicates "OFF" even if an adult passenger is occupying that seat. If fuse # 6 had previously blown and been replaced with no repair made to correct the underlying cause, there is a possibility that this wiring harness has already been damaged due to a short circuit. Under these circumstances, the new replacement fuse may not blow and a fire could occur at any time without warning. In Forester models, it could happen even if the ignition switch is in the "LOCK" (off) position. Vehicle owners will be advised in the Owner Notification Letter that if they encounter a blown fuse, an illuminated air bag system warning light, smell smoke, or have replaced a blown fuse # 6 without correcting the underlying problem, to not operate the vehicle. They will be advised to contact the nearest Subaru dealer as soon as possible for guidance. In these cases, dealers should arrange to have the vehicle towed and repairs performed immediately. This recall will involve inspection and possible repair of the front passenger seat wire harness. Please refer to the Service Procedure section of this bulletin for more details. AFFECTED VEHICLES ^ 2006 MY Subaru Forester and Impreza Potentially affected vehicles are identified in the VIN range chart below. Not all vehicles within the VIN range are affected. Prior to performing repairs, confirm coverage for potentially affected vehicles by using the Vehicle Coverage Inquiry in the Dealer Communication System (DCS). OWNER NOTIFICATION SOA will prepare and mail Owner Notification Letters to owners of affected vehicles on or around March 9, 2007. A copy of the Owner Notification Letter is included at the end of this bulletin. DEALER PROGRAM RESPONSIBILITY Dealers are to promptly service all vehicles subject to this recall at no charge to the vehicle owner regardless of mileage~ age of the vehicle~ or Page 505 Intake Air Temperature Sensor: Service and Repair Mass Air Flow and Intake Air Temperature Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the connector from mass air flow and intake air temperature sensor. 3. Remove the mass air flow and intake air temperature sensor. INSTALLATION Install in the reverse order of removal. Tightening torque: 1.7 N.m (0.17 kgf-m, 1.3 ft-lb) Page 876 Non-Turbo Model Adjustments Transmission Position Switch/Sensor: Adjustments Inhibitor Switch ADJUSTMENT 1) Move the select lever to "N" range. 2) Loosen the three inhibitor switch securing bolts. 3) Insert the ST as vertical as possible into the holes in inhibitor switch lever and switch body. ST 499267300 STOPPER PIN 4) Tighten the three inhibitor switch bolts. Tightening torque: 3.5 Nm (0.36 kgf-m, 2.6 ft. lbs.) 5) Repeat the above checks. If the inhibitor switch is determined to be "faulty", replace it. Page 4755 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 4289 1. BACK-UP LIGHT SWITCH AND NEUTRAL POSITION SWITCH 1) Install the back-up light switch and neutral position switch with harness. Tightening torque: 32.3 Nm (3.3 kgf-m, 23.8 ft. lbs.) 2) Connect the connector of back-up light switch and neutral position switch. 3) Install the air intake duct and cleaner case. (Non-turbo model) 4) Install the intercooler. (Turbo model) 5) Connect the battery ground cable to battery. Neutral Switch & Backup Switch Testing Switches and Harness INSPECTION BACK-UP LIGHT SWITCH Inspect the back-up light switch. NEUTRAL POSITION SWITCH 1) Turn the ignition switch to OFF. 2) Disconnect the connector of neutral position switch. 3) Measure the resistance between neutral position switch terminals. Non-turbo model: Non-turbo model Turbo model: Turbo model ^ Non-turbo model Page 3903 F21-F61 Page 2035 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 2992 B134-B136 Page 2982 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 4871 Non-Turbo Model Page 675 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 6620 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Testing and Inspection Resonator: Testing and Inspection INSPECTION 1. Inspect for cracks and loose connections. 2. Inspect that no foreign objects are mixed in resonator chamber. Page 645 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 914 VTD model INSTALLATION Install in the reverse order of removal. NOTE: Replace with a new O-ring. Tightening torque: 7 Nm (0. 7 kgf-m, 5. 1 ft. lbs.) Page 3066 B17-B20 Page 1617 B380-f6 Page 2275 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Testing and Inspection Fog/Driving Lamp Switch: Testing and Inspection FRONT FOG LIGHT SWITCH Measure the resistance between front fog light switch terminals. Page 3252 B3-B12 Specifications Exhaust Manifold: Specifications Torque Specifications Exhaust Manifold To Cylinder Head ................................................................................................................................. .................................... 40 Nm (4 kgf-m, 28.9 ft. lbs.) To Exhaust Pipe ............................................... ...................................................................................................................... 35 Nm (3.6 kgf-m, 26 ft. lbs.) Page 3097 B54-B127 Page 453 B380-f6 Page 1604 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 3913 Non-turbo model ^ Turbo model Turbo model 2) Install the air intake chamber. (Non-turbo model) 3) Install intercooler. (Turbo model) INSPECTION Make sure the hose is not cracked or clogged. Page 3795 4) Using the ST, tighten the bolts of inhibitor switch. ST 499267300 STOPPER PIN 5) Install the select cable to range select lever. 6) Install the plate assembly to transmission. 7) Install the washer and snap pin to range select lever. 8) Install the front and center exhaust pipes. (Non-turbo model) 9) Install the center exhaust pipe. (Turbo model) 10) Lower the vehicle. 11) Install the inhibitor switch connector from stay. 12) Connect the inhibitor switch connector. Page 394 Brake Light Switch: Service and Repair Stop Light Switch REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the stop light switch connector. 3. Loosen nuts, and unscrew stop light switch to remove. INSTALLATION 1. Screw the stop light switch onto a bracket and secure it temporarily with a nut. 2. Adjust the stop light switch position, and then tighten the nut. Tightening torque: 8 Nm (0.8 kgf-m, 5.8 ft. lbs.) INSPECTION 1. If the stop light switch does not operate properly (or if it does not stop at the specified position), replace with a new one. Specified position L: 2 mm (0.079 inch) 2. Measure the clearance between threaded end of stop light switch and stopper. CAUTION: Be careful not to rotate stop light switch. Stop light switch clearance 0.3 mm (0.012 inch) Page 2222 P Code List (Partial list) Page 1648 2. TIMING BELT 1. Preparation for installation of automatic belt tension adjuster assembly. 2. Crankshaft and cam sprocket alignment 1. Align mark (A) on the crank sprocket with mark on the oil pump cover at cylinder block. 2. Align single line mark (A) on the exhaust cam sprocket (RH) with notch (B) on timing belt cover. 3. Align single line mark (A) on the intake cam sprocket (RH) with notch (B) on timing belt cover. (Make sure double lines (c) on intake camshaft and exhaust cam sprockets are aligned.) 4. Align single line mark (A) on exhaust cam sprocket (LH) with notch (B) on timing belt cover by turning the sprocket counterclockwise (as viewed from front of engine). Page 6488 B292-B317 Page 3136 B3-B12 Page 6307 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 2706 R58-R69 Page 229 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 4696 B134-B136 Page 534 Knock Sensor: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 5656 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 5392 Evaporator Temperature Sensor / Switch: Testing and Inspection Wiring Diagram Page 2380 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Service and Repair Roll Connector: Service and Repair ROLL CONNECTOR REMOVAL 1. Turn the ignition switch to OFF. 2. Disconnect the ground cable from battery, and wait for at least 20 seconds before starting work. 3. Remove the driver's airbag module. 4. Remove the steering wheel. 5. Remove the steering column cover. 6. Remove the screws, and then remove the roll connector. INSTALLATION 1. Install in the reverse order of removal. 2. Before installing the steering wheel, be sure the direction of roll connector is adjusted with steering. Roll Connector ADJUSTMENT 1. Check that the front wheels are positioned in straight ahead direction. 2. Turn the roll connector pin (A) clockwise until it stops. 3. Turn the roll connector pin (A) counterclockwise approx. 3.25 turns until" /\" marks are aligned. Page 1448 Oil Pan: Service and Repair Oil Pan and Strainer Removal 1. Set the vehicle on a lift. 2. Remove the front wheels. 3. Disconnect the ground cable from battery. 4. Disconnect the connector from mass airflow and intake air temperature sensor. Page 3130 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 619 F21-F61 Specifications Fluid Pan: Specifications Install the oil pan. Tightening torque: ................................................................................................................................ ............................... 5 Nm (0.5 kgf-m, 3.6 ft. lbs.) Service and Repair Fuel Cut Control Unit: Service and Repair Fuel Cut Valve REMOVAL 1. Remove the fuel tank. 2. Remove the protect cover. 3. Move the clip and disconnect the evaporation hose from fuel cut valve. 4. Remove the bolts which install the fuel cut valve. INSTALLATION Install in the reverse order of removal. NOTE: Use a new gasket. M/T - Clutch Pedal Squeaking Noise Clutch Pedal Position Sensor / Switch: Technical Service Bulletins M/T - Clutch Pedal Squeaking Noise CLUTCH PEDAL SQUEAK If you encounter a manual transmission equipped vehicle with a clutch pedal squeak concern, and lubricating the pedal mechanism didn't fix the noise, check the clutch switch. We have had a few reports where this has been the source of the problem. The fix is to replace the clutch pedal switch. Locations Daytime Running Lamp Relay: Locations Area View Daytime Running Light Relay - (B102) Rear Gate Latch Lock Actuator Trunk / Liftgate Lock: Testing and Inspection Rear Gate Latch Lock Actuator REAR GATE LATCH LOCK ACTUATOR INSPECTION 1. Disconnect the rear gate latch lock actuator harness connector. 2. Connect the battery to rear gate latch lock actuator terminals. If NG, replace the rear gate latch lock actuator. Engine Controls - DTC P0607 Diagnostic Information Engine Control Module: Customer Interest Engine Controls - DTC P0607 Diagnostic Information NUMBER: 11-91-08 DATE: 12/05/08 APPLICABILITY: 2004-2008MY Impreza 2004-2008MY Forester 2005-2008MY Legacy/Outback 2006-2007MY Tribeca SUBJECT: DTC P0607 Control Module Performance Introduction The purpose of the bulletin is for information purposes when diagnosing DTC P0607. The following checks and information is in addition to what is listed in the Subaru Service Manual. This information is to be used in conjunction with the service manual. Repair Procedure/Information Additional items to check: ^ Rapid drop of voltage from a dead battery ^ Loose battery terminals ^ Loose ECM ground terminal ^ A short or open to the power or ground circuit If the malfunction criteria are met, the CEL will illuminate, the vehicle will go into fail safe and the throttle valve opening will be fixed at 6°. Fail safe will recover to normal mode if the ECM judges the criteria "OK" at the time of the next engine start. The CEL will not turn off until the "OK" driving cycle is completed 3 times in a row. The judgment is decided by the ECM to keep the CEL On or Off at the time the ignition switch is turned from ON to OFF. The ECM keeps DTC P0607 in memory even after the indicator light goes out. Therefore, it is important to erase memory after the repair is completed. Detail list of applicable model and engine type. Page 6696 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 614 B134-B136 Page 3440 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Specifications License Plate Lamp: Specifications Specifications License plate light................................................................................................................................. ..................................................................12 V - 5 W Page 2990 B54-B127 Page 2501 Spark Plug: Testing and Inspection INSPECTION Check the electrodes and inner and outer ceramic insulator of plugs, noting the type of deposits and the degrees of electrode erosion. 1. Normal: Brown to grayish-tan deposits and slight electrode wear indicates correct spark plug heat range. 2. Carbon fouled: Dry fluffy carbon deposits on insulator and electrode are mostly caused by slow speed driving in city, weak ignition, too rich fuel mixture and dirty air cleaner, etc. Page 5086 Grounding Point: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 2651 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 2833 Engine Control Module (ECM) I/O Signal (Part 4) Page 2518 6. Inspect all valves for clearance again at this stage. If the valve clearance is not correct, repeat the procedure over again from the first step. 7. After inspection, install the related parts in the reverse order of removal. Page 5196 22) Tighten the adjusting screw to specified torque. Tightening torque: 7.4 Nm (0.75 kgf-m, 5.4 ft. lbs.) 23) After tightening to the specified tightening torque, loosen it by 37°. 24) Remove the tie-rod. 25) Verify that play is within specified value. 26) Loosen the adjusting screw, and then apply liquid gasket to at least 1/3 of the entire perimeter of adjusting screw thread. Liquid gasket: THREE BOND 1141 (Part No. 004403006) 27) Tighten the adjusting screw. Tightening torque: 9.8 Nm (1.0 kgf-m, 7.2 ft. lbs.) 28) After tightening to the specified tightening torque, loosen it. 29) Tighten the adjusting screw. Tightening torque: 4.8 Nm (0.49 kgf-m, 3.5 ft. lbs.) 30) After tightening to the specified tightening torque, loosen it. 31) Tighten the adjusting screw. Tightening torque: 4.8 Nm (0.49 kgf-m, 3.5 ft. lbs.) 32) After tightening to the specified tightening torque, loosen it by 37°. 33) Install the lock nut. While holding the adjusting screw with a wrench, tighten lock nut using ST. ST 926230000 SPANNER Tightening torque (Lock nut): 40 Nm (4.1 kgf-m, 29.5 ft. lbs.) NOTE: Hold the adjusting screw with a wrench to prevent it from turning while tightening lock nut. 34) Install the tie-rod into rack. Tightening torque: 90 Nm (9.0 kgf-m, 65.1 ft. lbs.) Page 4012 B134-B136 Page 3057 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 2353 B3-B12 Page 5902 Rear Door Latch: Service and Repair REAR DOOR LATCH AND DOOR LOCK ACTUATOR ASSEMBLY REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the rear door trim. 3. Remove the sealing cover. 4. Remove the rear inner remote. 5. Remove three screws and a bolt. 6. Disconnect the connector, and then remove the rear door latch assembly. INSTALLATION Install in the reverse order of removal. NOTE: Make sure the lock works properly after installation. A/T - 4AT, Filter/Torque Specification Revision Fluid Filter - A/T: Technical Service Bulletins A/T - 4AT, Filter/Torque Specification Revision NUMBER: 16-75-09 DATE: 04/08/09 APPLICABILITY SUBJECT: 4AT Automatic Transmission Strainer Introduction The purpose of this bulletin is to inform you that the automatic transmission strainer has changed from being made out of metal to resin. The length of the bolts and the torque specification has also changed. Countermeasure in Production The new style strainer was used in production towards the end of October, 2008 starting with transmission # 374122. Part Information Page 4489 3. If it is not within specified value, adjust it by adjusting the brake booster operating rod length. Page 1681 Idle Speed: Testing and Inspection Idle Speed INSPECTION 1. Before checking the idle speed, check the following: 1. Ensure the air cleaner element is free from clogging, ignition timing is correct, spark plugs are in good condition, and that the hoses are connected properly. 2. Ensure the malfunction indicator light does not illuminate. 2. Warm-up the engine. 3. Stop the engine, and then turn the ignition switch to OFF. 4. Insert the cartridge to Subaru Select Monitor. 5. Connect the Subaru Select Monitor to data link connector. 6. Turn the ignition switch to ON, and Subaru Select Monitor power switch to ON. 7. Select the (2. Each System Check) in Main Menu. 8. Select the (Engine Control System) in Selection Menu. 9. Select the (1. Current Data Display & Save) in Engine Control System Diagnosis. 10. Select the (1. 12 Data Display) in Data Display Menu. 11. Start the engine, and then read the engine idle speed. 12. Check the idle speed when unloaded. (With headlights, heater fan, rear defroster, radiator fan, air conditioning, etc. OFF) Idle speed [No load and gears in neutral]. 700 ± 100 rpm 13. Check the idle speed when loaded. (Turn the air conditioning switch to "ON" and operate the compressor for at least 1 minute before measurement.) Idle speed [A/C "ON". no load and gears in neutral]: When the A/C refrigerant pressure is low MT. 725 ± 100 rpm AT. 750 ± 100 rpm When the A/C refrigerant pressure is high MT. 800 ± 100 rpm AT. 825 ± 100 rpm NOTE: As idle speed is controlled by the automatic adjustment type, it can not be adjusted manually. If the idle speed is out of specifications, refer to General On-board Diagnosis Table under "Engine Control System". Page 2397 F61-R47 Page 3719 B134-B136 Capacity Specifications Refrigerant: Capacity Specifications Capacity ............................................................................................................................................... .................................. 0.50 ± 0.05 kg (1.10 ± 0.11 lb) Page 2531 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 1417 Engine Oil Pressure: Testing and Inspection Engine Oil Pressure INSPECTION 1. Remove the oil pressure switch. 2. Connect the oil pressure gauge hose to cylinder block. 3. Connect the battery ground cable to battery. 4. Start the engine, and then measure the oil pressure. Oil pressure: 98 kPa (1.0 kgf/cm2, 14 psi) or more at 600 rpm 294 kPa (3.0 kgf/cm2, 43 psi) or more at 5,000 rpm CAUTION: ^ If the oil pressure is out of specification, check oil pump, oil filter and lubrication line. ^ If the oil pressure warning light is turned ON and oil pressure is in specification, replace the oil pressure switch. NOTE: The specified data is based on an engine oil temperature of 80°C (176°F). 5. After measuring the oil pressure, install the oil pressure switch. Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft. lbs.) Page 1705 3. Oil fouled: Wet black deposits show oil entrance into combustion chamber through worn rings and pistons or excessive clearance between valve guides and stems. 4. Overheating: White or light gray insulator with black or brown spots and bluish burnt electrodes indicates engine overheating. Moreover, the appearance results from incorrect ignition timing, loose spark plugs, wrong selection of fuel, hotter range plug, etc. Page 3650 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 2554 Intake Air Temperature Sensor: Service and Repair Mass Air Flow and Intake Air Temperature Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the connector from mass air flow and intake air temperature sensor. 3. Remove the mass air flow and intake air temperature sensor. INSTALLATION Install in the reverse order of removal. Tightening torque: 1.7 N.m (0.17 kgf-m, 1.3 ft-lb) Page 1826 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 6323 F61-R47 Front Vehicle Speed Sensor Transmission Speed Sensor: Service and Repair Front Vehicle Speed Sensor Front Vehicle Speed Sensor REMOVAL 1) Set up the vehicle on a lift. 2) Disconnect the ground cable from battery. 3) Remove the air intake chamber. (Non-turbo model) 4) Remove the intercooler. (Turbo model) 5) Disconnect the transmission connector. 6) Remove the pitching stopper. 7) Remove the transmission connector from stay. 8) Lift-up the vehicle. 9) Clean the transmission exterior. 10) Drain the ATF completely. NOTE: ^ Tighten the ATF drain plug after draining the ATF. ^ Use anew gasket. 11) Remove the front, center, exhaust pipes and muffler. (Non-turbo model) 12) Remove the center, rear exhaust pipe and muffler. (Turbo model) 13) Remove the propeller shaft. 14) Place the transmission jack under transmission. NOTE: Make sure that the support plates of transmission jack don't touch the crossmember. 15) Remove the transmission rear crossmember bolts. Page 6896 Brake Light Switch: Testing and Inspection BRAKE LIGHT SWITCH INSPECTION 1. If the stop light switch does not operate properly (or if it does not stop at the specified position), replace with a new one. Specified position L: 2 mm (0.079 inch) 2. Measure the clearance between threaded end of stop light switch and stopper. CAUTION: Be careful not to rotate stop light switch. Stop light switch clearance 0.3 mm (0.012 inch) 3. If it is not within specified value, adjust it by adjusting position of stop light switch. CAUTION: Be careful not to rotate the stop light switch. Page 2980 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 6067 Keyless Entry Transmitter: Service and Repair Replacement TRANSMITTER REPLACEMENT 1. REGISTRATION OF TRANSMITTER WITH SUBARU SELECT MONITOR NOTE: A maximum of four transmitters can be registered for each individual vehicle. - When replacing or adding the transmitter, new registration of transmitter is necessary. 1. Connect the Subaru Select Monitor to the vehicle. 2. Turn the ignition switch to ON. 3. From the on the Subaru Select Monitor, select the {2. Check individual system} -> {Keyless unit mode} -> {1. Keyless ID registration}, and press the [YES] key. 4. Input the 8-digit ID number from the left attached to the plastic bag of transmitter or circuit board inside transmitter. NOTE: Press the [/\] key on the Subaru Select Monitor to increase the number, and the [\/] key to decrease. Press the [<] key to move to the digit in the left, and [>] to the right. 5. The ID number you have entered will be shown. Make sure that the ID number shown is the same as that of plastic bag. 6. Press the [YES] key if the ID number is correct. Press the [NO] key if incorrect, to return to the step 3) and try again. 7. will be displayed and registration started. 8. will be shown when the process is done. 9. To end, select the , and press the [NO] key to return to {1. Keyless ID registration}. If there are additional transmitters to be registered, select the , and press the [YES] key to return to the step 3). NOTE: If the registration fails, will be shown. Press the [YES] key to return to the {1. Keyless ID registration} and retry from the step 2). - is shown on the Subaru Select Monitor when four transmitters have been registered. Press the [NO] key to return to {1. Keyless ID registration}. Diagnostic Aids Refrigerant Pressure Sensor / Switch: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 6841 B128-B134 Page 1709 4. Remove the ignition coil and ignitor assembly. 5. Remove the spark plugs with the spark plug sockets. INSTALLATION RH SIDE Install in the reverse order of removal. Tightening torque (Spark plug): 21 N.m (2.1 kgf-m, 15.2 ft-lb) Tightening torque (Ignition coil and ignitor assembly): 16 N.m (1.6 kgf-m, 11.7 ft-lb) NOTE: - The above torque should be only applied to new spark plugs without oil on their threads. - In case their threads are lubricated, the torque should be reduced by approx. 1/3 of the specified torque in order to avoid over-stressing. LH SIDE Install in the reverse order of removal. Tightening torque (Spark plug): 21 N.m (2.1 kgf-m, 15.2 ft-lb) Tightening torque (Ignition coil and ignitor assembly): 16 N.m (1.6 kgf-m, 11.7 ft-lb) NOTE: - The above torque should be only applied to new spark plugs without oil on their threads. - In case their threads are lubricated, the torque should be reduced by approx. 1/3 of the specified torque in order to avoid over-stressing. Page 2081 B3-B12 Page 682 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 780 Crankshaft Position, Camshaft Position And Knock Sensors Page 865 1) With the select lever already in the "N" range, loosen the adjusting nuts A and B on both sides. 2) Turn the adjusting nut B until it lightly touches the connector. 3) Use a spanner wrench to hold nut B so that it does not rotate and then tighten the adjusting nut A. Tightening torque: 7.5 N-m (0.76 kgf-m, 5.5 ft-lb) 4) Afier the completion of adjustment, confirm that the select lever operates normally at all ranges: ^ Move the select lever from "P" to "D" range. Check that the detents could be felt in each range. If the detents cannot be felt or the position pointer (dash indicator) is improperly aligned, re-adjust the cable. ^ Check if the starter motor rotates when the select lever is set to "P" range. Page 4021 Shift Solenoid: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 5294 Wheel Bearing: Service and Repair Front Hub Unit Bearing REMOVAL 1) Disconnect the ground cable from battery. 2) Lift-up the vehicle and remove the front wheels. 3) Unlock the axle nut. 4) Remove the axle nut using a socket wrench while depressing the brake pedal. CAUTION: Remove the wheel before loosening the axle nut. Failure to follow this rule may damage the wheel bearings. 5) Remove the disc brake caliper from housing, and suspend it from strut using a wire. 6) Remove the disc rotor from hub. NOTE: If the disc rotor seizes up within hub, drive disc rotor out by installing an 8-mm bolt in screw hole on rotor. 7) Remove the ABS wheel speed sensor assembly and harness. 8) Remove four bolts from housing. Page 5670 R58-R69 Page 1190 EXAMPLES Of FAILED TURBOCHARGERS Inadequate lubrication supplied to the turbocharger will cause damage to the turbine center shaft bearing. This will cause radial movement of the shaft permitting the compressor impellers to come in contact with the housing. Before replacing a damaged turbocharger, review the customer's maintenance history. If there is evidence that the engine was not properly maintained, follow the Engine Oil System Flush instructions prior to replacing the turbocharger to avoid a secondary failure. ENGINE OIL SYSTEM FLUSH INSTRUCTIONS 1) Make sure the engine oil level is "FULL" 2) Start the engine and bring to operating temperature 3) Turn the engine OFF 4) Add Engine Oil System Flush to the engine oil 5) Start the engine and let idle for 20 minutes 6) Turn the engine OFF and drain the old engine oil and Engine Oil System Flush from the oil pan 7) Replace the engine oil filter with a Genuine Subaru Oil Filter 8) Refill the engine oil with the proper engine oil as recommended in the vehicle's owner manual Page 3568 R72-R145 R148 Page 7230 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 5474 Refrigerant Pressure Sensor / Switch: Testing and Inspection Pressure Switch (Dual Switch) INSPECTION 1. Connect the manifold gauge to the service valve on high-pressure side. 2. Remove the pressure switch harness connector. Using a circuit tester, inspect the ON-OFF operation of pressure switch. Page 3316 CAUTION: Be sure to inspect hoses and their connections for any leakage of fuel. 3. Connect the evaporation hose by inserting it into the pipe for 15 to 20 mm (0.59 to 0.79 in) in length. L = 17.5 ±2.5 mm (0.689 ±0.098 in) Page 5554 Impact Sensor: Service and Repair Side Airbag Sensor SIDE AIRBAG SENSOR REMOVAL 1. Turn the ignition switch to OFF. 2. Disconnect the ground cable from battery, and wait for at least 20 seconds before starting work. 3. Remove the outer seat belt (FRONT). 4. Detach the side airbag sensor, and then disconnect the airbag connector. INSTALLATION Install in the reverse order of removal. Tightening torque: Refer to "COMPONENT" in "General Description". See: Locations Page 5374 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 2836 Engine Control Module: Service and Repair Engine Control Module (ECM) REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the lower inner trim of the passenger side. 3. Detach the floor mat of the front passenger seat. 4. Remove the protect cover. 5. Remove the nuts (A) which hold ECM to the bracket. 6. Remove the clip (B) from the bracket. 7. Disconnect the ECM connectors and take out the ECM. INSTALLATION Install in the reverse order of removal. CAUTION: - When replacing ECM, use of wrong spec. ECM may lead to damage to the fuel injection system. - When replacing ECM, do not damage the harnesses and connectors. Tightening torque: 5 N.m (0.5 kgf-m, 3.7 ft-lb) Page 4086 VTD model INSTALLATION Install in the reverse order of removal. NOTE: Replace with a new O-ring. Tightening torque: 7 Nm (0. 7 kgf-m, 5. 1 ft. lbs.) Page 5438 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 7252 8. Disconnect the hose. 9. Remove the bolt and nut, and then remove the washer tank. INSTALLATION Install in the reverse order of removal. Tightening torque: 6.0 N-m (0.61 kgf-m, 4.4 ft-lb) Page 4208 Rear Axle Page 6580 R72-R145 R148 Page 2699 B134-B136 Page 7331 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 294 Clutch Switch: Service and Repair CLUTCH SWITCH REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the connector from clutch switch, and then remove the switch. INSTALLATION Install in the reverse order of removal. Page 4701 F21-F61 Page 898 5) Disconnect the inhibitor switch connector. 6) Remove the inhibitor switch connector from stay. 7) Lift-up the vehicle. 8) Remove the front and center exhaust pipes. 9) Remove the snap pin and washer from range select lever. 10) Remove the plate assembly from transmission case. 11) Remove the bolts. Testing and Inspection Hazard Warning Switch: Testing and Inspection HAZARD SWITCH Measure the resistance between hazard switch terminals. Page 5020 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 3865 B230-B283 Locations Sensor Page 3554 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 1339 Connecting Rod: Testing and Inspection INSPECTION CONNECTING ROD 1. Replace the connecting rod, if the large or small end thrust surface is damaged. 2. Check for bend or twist using a connecting rod aligner. Replace the connecting rod if the bend or twist exceeds the limit. Limit of bend or twist per 100 mm (3.94 inch) in length: 0.10 mm (0. 0039 inch) 3. Install the connecting rod fitted with bearing to crankshaft, and then measure the side clearance (thrust clearance). Replace the connecting rod if the side clearance exceeds the specified limit. Connecting rod side clearance: Standard 0.070 - 0.330 mm (0.0028 - 0.0130 inch) Limit 0.4 mm (0.016 inch) 4. Inspect the connecting rod bearing for scar, peeling, seizure, melting, wear, etc. 5. Measure the oil clearance on individual connecting rod bearings by means of plastigauge. If any oil clearance is not within the specification, replace the defective bearing with a new one of standard size or undersize as necessary. (See the table below.) Connecting rod oil clearance: Standard 0.017 - 0.045 mm (0.0007 - 0.0018 inch) Locations Security Lamp/Indicator: Locations Security System Electrical Component Location Page 6401 F61-R47 Page 4207 Front Axle Page 4686 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 1792 B134-B136 Page 3947 8) Remove the oil cooler inlet and outlet pipes. NOTE: When removing outlet pipe, be careful not to lose ball and spring used with retaining screw. INSTALLATION 1) Install the oil cooler outlet and inlet pipes using a new aluminum washer. 2) Install ATF cooler pipe to frame. Page 2436 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 4964 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 6618 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 1570 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 7011 Heated Glass Element: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 123 B134-B136 Page 1794 B230-B283 Locations Keyless Entry System Page 4878 Neutral Safety Switch: Adjustments Inhibitor Switch ADJUSTMENT 1. Shift the select lever to N range. 2. Loosen the three inhibitor switch securing bolts. 3. Insert the ST as vertical as possible into the holes in inhibitor switch lever and switch body. ST 499267300 STOPPER PIN 4. Tighten the three inhibitor switch bolts. Tightening torque: 3.4 Nm (0.35 kgf-m, 2.5 ft. lbs.) 5. Repeat the above checks. If the inhibitor switch is determined to be faulty, replace it. Identification Oxygen Sensor: Locations Identification This article was updated by bulletin number: 11-92-08 Date: 01/05/09 APPLICABILITY: 1999MY and later Forester 1999MY and later Impreza 2000MY and later Legacy 2006MY and later Tribeca SUBJECT: Air/Fuel Ratio Sensor and Oxygen Sensor INTRODUCTION For information purposes only. REPAIR/SERVICE INFORMATION When performing diagnostics or reading Diagnostic Trouble Codes (DTC) for Air Fuel Ratio (A/F) sensors and Oxygen (O2) sensors use the following information to identify, locate and repair the appropriate sensor and sensor circuits: (1) Rarely will multiple sensors fail at the same time. (2) On vehicles with only one O2 sensor, the designation for that O2 sensor will be bank 1. (3) On vehicles with only one A/F sensor, the designation for that A/F sensor will be bank 1. (4) Any reference to sensor 1 is an A/F sensor. (5) Any reference to sensor 2 is an O2 sensor. (6) Early PZEV vehicles used an additional O2 sensor behind the rear catalyst and is designated sensor 3. (7) On vehicles with A/F and O2 sensors on the right (Passenger Side) and left (Driver side) of the vehicle, Bank 1 is the right side (Passenger Side) and Bank 2 is the left side (Driver side). Example: DTC P0030 HO2S HEATER CONTROL CIRCUIT (Bank 1 Sensor 1). This DTC is referring to the A/F sensor and since it is on a 2007 Forester there is only one A/F sensor and one O2 sensor. Example (as illustrated): DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (Bank 1 Sensor 2). This DTC is referring to the O2 sensor on the right side exhaust (or the O2 sensor of a vehicle with only one O2 sensor). Page 6477 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 5805 2. Security indicator light blinks. NOTE: If the ALARM/WARNING occurs in the ARM mode, the indicator light blinks when the ignition switch is turned to OFF -> ON at the next DISARM mode. - If ALARM/WARNING does not occur, the light does not blink. - More than one alarm or warning occurs, the most numbers of blinking times have priority to blink. - Anytime the ignition switch is turned to ON in the DISARM mode, it blinks. The memory will be updated at the next ARM mode. Page 1781 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Wipers/Washers - Poor Front/Rear Washer Nozzle Operation Windshield Washer Hose: Customer Interest Wipers/Washers - Poor Front/Rear Washer Nozzle Operation NUMBER: 07-55-06 DATE: 04/04/06 APPLICABILITY: 2006MY Forester and Impreza SUBJECT: Poor Windshield Washer Fluid Spray Introduction If you encounter a customer complaint that the windshield washer fluid does not spray properly from the front or rear washer nozzle, there is the possibility that the nozzle or check valve is clogged or the fluid hose could be pinched or bent. Use the following repair procedure to check and repair as necessary. Production Line Change The check valve was changed from a ball type to a rubber type to prevent clogging. The new style check valve was used in production starting in October, 2005 with the VINs shown. Parts Information Repair Procedure/Information 1) Check the washer nozzle for contamination. If the spray hole is clogged with wax, dust or foreign material, blow compressed air to the spray hole of the washer nozzle to clear the obstruction. 2) Check the washer nozzle fluid hose. Make sure the hose is not pinched, and that it does not have severe bends or kinks. 3) Check the rear washer hose running along the left sill, as well as the hose in the tailgate area, to ensure that the hose is not pinched or bent, restricting the flow. 4) If there is no problem found in step 1 or 2, install a modified check valve. Front check valve on Forester and Impreza Page 3247 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 455 F61-R47 Page 4425 3) Apply proper amount of liquid gasket to the entire oil pan mating surface. Liquid gasket: THREE BOND 1217B (Part No. K0877YA020) 4) Apply liquid gasket fully to three holes other than screw holes on transmission case. Liquid gasket: THREE BOND 1217B (Part No. K0877YA020) 5) Install the oil pan. Tightening torque: 5 Nm (0.5 kgf-m, 3.6 ft. lbs.) 6) Connect the connector of rear vehicle speed sensor. (MP-T model) 7) Connect the connector of rear vehicle speed sensor. (VTD model) Page 2129 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 2810 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 2705 F61-R47 Diagram Information and Instructions Fuel Gauge: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Front Brake Rotor/Disc: Service and Repair Front Front Disc Rotor REMOVAL 1. 15 INCH TYPE 1. Set the vehicle on a lift. 2. Loosen the wheel nuts. 3. Lift-up the vehicle, and then remove the front wheel. 4. Remove the caliper body and support from housing, and suspend it from strut using a wire. 5. Remove the disc rotor. NOTE: If the disc rotor seizes up within the hub, drive the disc rotor out by installing an 8-mm bolt in holes (B) on disc rotor. 6. Clean mud and foreign particles from the caliper body assembly and support. 2. 16 INCH TYPE & 17 INCH TYPE 1. Set the vehicle on a lift. 2. Loosen the wheel nut. 3. Lift-up the vehicle, and then remove the front wheel. 4. Remove the caliper body from housing, and suspend it from strut using a wire. 5. Remove the disc rotor from hub. NOTE: If the disc rotor seizes up within the hub, drive the disc rotor out by installing an 8-mm bolt in holes B on disc rotor. Page 3243 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Wipers/Washers - Poor Front/Rear Washer Nozzle Operation Windshield Washer Hose: All Technical Service Bulletins Wipers/Washers - Poor Front/Rear Washer Nozzle Operation NUMBER: 07-55-06 DATE: 04/04/06 APPLICABILITY: 2006MY Forester and Impreza SUBJECT: Poor Windshield Washer Fluid Spray Introduction If you encounter a customer complaint that the windshield washer fluid does not spray properly from the front or rear washer nozzle, there is the possibility that the nozzle or check valve is clogged or the fluid hose could be pinched or bent. Use the following repair procedure to check and repair as necessary. Production Line Change The check valve was changed from a ball type to a rubber type to prevent clogging. The new style check valve was used in production starting in October, 2005 with the VINs shown. Parts Information Repair Procedure/Information 1) Check the washer nozzle for contamination. If the spray hole is clogged with wax, dust or foreign material, blow compressed air to the spray hole of the washer nozzle to clear the obstruction. 2) Check the washer nozzle fluid hose. Make sure the hose is not pinched, and that it does not have severe bends or kinks. 3) Check the rear washer hose running along the left sill, as well as the hose in the tailgate area, to ensure that the hose is not pinched or bent, restricting the flow. 4) If there is no problem found in step 1 or 2, install a modified check valve. Front check valve on Forester and Impreza Page 6366 Non-Turbo Model Page 3616 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 1140 Clutch Fluid: Service and Repair Clutch Fluid INSPECTION 1) Park the vehicle on a level surface. 2) Inspect the fluid level using scale on the outside of the reservoir tank. If the level is below "MIN", add fluid to bring it up to "MAX", and also inspect for leakage. REPLACEMENT CAUTION: ^ The FMVSS No. 116, fresh DOT3 or 4 brake fluid must be used. ^ Cover the bleeder with waste cloth, when loosening it, to prevent brake fluid from being splashed over surrounding parts. ^ Avoid mixing different brands of brake fluid to prevent degrading the quality of the fluid. ^ Be careful not to allow dirt or dust to get into the reservoir tank. NOTE: ^ During bleeding operation, keep the clutch reservoir tank filled with brake fluid to eliminate entry of air. ^ Clutch pedal operating must be very slow. ^ Bleed air from the oil line with help of a co-worker. ^ The amount of brake fluid required is approximately 70 ml (2.4 US fl ounces, 2.5 Imp fl ounces) for total clutch system. 1) Remove the air intake chamber. (Non-turbo model) 2) Remove the intercooler. (Turbo model) 3) Either jack-up the vehicle and place a rigid racks under it, or lift-up the vehicle. 4) Drain brake fluid from the reservoir tank. 5) Refill the reservoir tank with recommended brake fluid. Recommended brake fluid: FMVSS No. 116, fresh DOT3 or 4 brake fluid 6) Drain all contaminated fluid in the same method as air bleeding. 7) Refill the brake fluid before reservoir tank becomes empty, and drain contaminated fluid again. 8) Repeat the above procedure until the contaminated fluid is completely drained. Page 2314 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 572 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 4072 4) Using the ST, tighten the bolts of inhibitor switch. ST 499267300 STOPPER PIN 5) Install the select cable to range select lever. 6) Install the plate assembly to transmission. 7) Install the washer and snap pin to range select lever. 8) Install the front and center exhaust pipes. (Non-turbo model) 9) Install the center exhaust pipe. (Turbo model) 10) Lower the vehicle. 11) Install the inhibitor switch connector from stay. 12) Connect the inhibitor switch connector. Page 3632 R72-R145 R148 Page 4510 B128-B134 Page 1625 Testing and Inspection Oil Pick Up/Strainer: Testing and Inspection Inspection By visual check, make sure the oil pan, oil strainer, oil strainer stay and baffle plate are not damaged. Page 2461 F21-F61 Luggage Room Light Switch Trunk Lamp Switch: Testing and Inspection Luggage Room Light Switch Luggage Room Light LUGGAGE ROOM LIGHT SWITCH Measure the resistance between luggage room light terminals. Page 7029 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Locations Security System Page 2572 Disclaimer Page 3571 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 6715 Glove Box Lamp: Electrical Diagrams ILM(ES)-01 Page 5486 Solar Sensor: Service and Repair Sunload Sensor (Auto A/C Model) REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the front defroster grille. 3. Disconnect the sunload sensor connector (A). CAUTION: Be careful not to damage the sensors and interior trims when removing them. INSTALLATION Install in the reverse order of removal. Page 470 Disclaimer Page 620 F61-R47 Page 3354 Intake Air Duct: Service and Repair Intake Duct Intake Duct REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the intake manifold. 3. Remove the sensor, engine harness and fuel pipe attached to intake manifold. 4. Remove the intake duct from intake manifold. INSTALLATION Install in the reverse order of removal. Tightening torque: 19 N ?m (1.9 kgf-m, 13.7 ft-lb) Page 1968 6. Secure the clip on crossmember. 7. Tighten the bolt which holds the center exhaust pipe bracket to transmission. Tightening torque: 30 Nm (3.1 kgf-m, 22.4 ft. lbs.) 8. Tighten the bolt which holds the center exhaust pipe to hanger bracket. Tightening torque: 35 Nm (3.6 kgf-m, 26 ft. lbs.) 9. Lower the vehicle. 10. Place the turbocharger lower cover, and tighten the bolts which install the upper side of lower cover. Tightening torque: 7.5 Nm (0.8 kgf-m, 5.5 ft. lbs.) Specifications Fluid - Transfer Case: Specifications The Subaru transmission incorporates the transfer case within the unit and lubricates from a common sump. For the fluid specification refer to Manual Transmission/Transaxle or Automatic Transmission/Transaxle. Locations Page 602 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 5134 Power Steering Fluid: Testing and Inspection Power Steering Fluid INSPECTION 1) Check the power steering fluid for deterioration or contamination. If the fluid is highly deteriorated or contaminated, drain it and refill with new fluid. 2) Check the joints and units for oil leakage. If any oil leaks are found, repair or replace the applicable part. 3) Inspect the fluid level on flat and level surface with engine "OFF" by indicator of reservoir tank. If the level is at MIN. point or below, add fluid to keep the level in the specified range of the indicator. If at MAX. point or above, drain fluid by using a syringe or the like. (1) Check at power steering fluid temperature 20°C (68°F); read the fluid level on the "COLD" side. (2) Check at power steering fluid temperature 80°C (176°F); read the fluid level on the "HOT" side. Page 7365 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 2931 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 3612 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Engine Controls - DTC P0607 Diagnostic Information Engine Control Module: All Technical Service Bulletins Engine Controls - DTC P0607 Diagnostic Information NUMBER: 11-91-08 DATE: 12/05/08 APPLICABILITY: 2004-2008MY Impreza 2004-2008MY Forester 2005-2008MY Legacy/Outback 2006-2007MY Tribeca SUBJECT: DTC P0607 Control Module Performance Introduction The purpose of the bulletin is for information purposes when diagnosing DTC P0607. The following checks and information is in addition to what is listed in the Subaru Service Manual. This information is to be used in conjunction with the service manual. Repair Procedure/Information Additional items to check: ^ Rapid drop of voltage from a dead battery ^ Loose battery terminals ^ Loose ECM ground terminal ^ A short or open to the power or ground circuit If the malfunction criteria are met, the CEL will illuminate, the vehicle will go into fail safe and the throttle valve opening will be fixed at 6°. Fail safe will recover to normal mode if the ECM judges the criteria "OK" at the time of the next engine start. The CEL will not turn off until the "OK" driving cycle is completed 3 times in a row. The judgment is decided by the ECM to keep the CEL On or Off at the time the ignition switch is turned from ON to OFF. The ECM keeps DTC P0607 in memory even after the indicator light goes out. Therefore, it is important to erase memory after the repair is completed. Detail list of applicable model and engine type. Page 1612 B128-B134 Page 622 R72-R145 R148 Page 4583 Brake Rotor/Disc: Service and Repair Rear Rear Disc Rotor REMOVAL 1. Set the vehicle on a lift. 2. Loosen the wheel nuts. 3. Lift-up the vehicle, and then remove the wheels. 4. Release the parking brake. 5. Remove the two mounting bolts, and then remove the disc brake assembly. 6. Suspend the disc brake assembly so that hose is not stretched. 7. Remove the disc rotor. NOTE: If the disc rotor is difficult to remove try following two methods in order. 1. Turn the adjusting screw using a flat tip screwdriver until brake shoe gets away enough from the disc rotor. 2. If the disc rotor seizes up within hub, drive the disc rotor out by installing an 8-mm bolt in holes B on disc rotor. INSTALLATION 1. Install in the reverse order of removal. 2. Adjust the parking brake. INSPECTION 1. Check bearing axial end play and hub runout before disc rotor runout limit inspection. 2. Secure the disc rotor by tightening five wheel nuts. Page 4502 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 1107 A used toothbrush which has been cleaned works great. Manually open the negative pressure valve. Using clean water and a brush, thoroughly clean the valve (inner and outer surface) and the valve seal surface. Check the radiator cap valve opening pressure using a radiator cap tester to insure the cap is within specification (refer to the applicable Subaru Service Manual). Note: If the cap is out of specification replace it. 2. Coolant Reservoir Tank Cleaning Remove the reservoir tank (refer to the applicable Subaru Service Manual). Using clean water, thoroughly clean the inside of the reservoir tank. Reinstall reservoir tank. Fill with coolant to the Full mark. Note: Be sure to use genuine Subaru Super Coolant or Subaru Long Life Coolant, depending upon what type of coolant is currently in the system. 3. Coolant Reservoir Tank Hose Modification Page 1379 Piston Ring: Testing and Inspection Inspection Piston Ring 1. If the piston ring is broken, damaged, or worn, or if its tension is insufficient, or when the piston is replaced, replace the piston ring with a new one of the same size as the piston. CAUTION: ^ Marks are shown on the end of top and second rings. When installing the rings to piston, face this mark upward. ^ Oil ring consists of upper rail, expander and lower rail. When installing on piston, be careful of each rail's direction. 2. Squarely place the piston ring and oil ring in cylinder, and then measure the piston ring closed gap with a thickness gauge. 3. Measure the clearance between piston ring and piston ring groove with a thickness gauge. NOTE: Before measuring the clearance, clean the piston ring groove and piston ring. Page 3794 12) Move the range select lever to parking position (left side). 13) Remove the inhibitor switch from transmission. 14) Disconnect the inhibitor switch harness connector from inhibitor switch. INSTALLATION 1) Connect the inhibitor switch harness connector to inhibitor switch. 2) Install the inhibitor switch to transmission case. 3) Move the range select lever to neutral position. Page 3385 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 1917 B136-B141 Service and Repair Evaporative Canister Filter: Service and Repair Drain Filter SPECIFICATION Drain filter is built in the canister, and it is a part which cannot be disassembled. Specifications Specifications Front Door Trim Front Door Panel: Service and Repair Front Door Trim FRONT DOOR TRIM Door Trim REMOVAL CAUTION: Do not apply excessive force to the clip. Otherwise the clip may be broken. 1. Disconnect the ground cable from battery. 2. Remove the gusset cover. 3. Insert the flat tip screw driver into A part of inner remote cover, and then remove the lower hook with turning screw driver. Remove the upper hook with pulling inner remote cover, and then remove the inner remote cover. Page 7282 Claim Reimbursement/Warrant Information For vehicles under the Basic New Car Limited Warranty period, refer to the Subaru Warranty Wizard(C) for claim submission information. Disclaimer Page 5685 Impact Sensor: Testing and Inspection Front Sub Sensor Front Sub Sensor INSPECTION Check for the following, and replace damaged parts with new parts. - Front sub sensor and connector are damaged. - Airbag is deployed. Page 3663 R58-R69 Page 3775 F61-R47 Page 3286 2. LH SIDE Page 5342 Blower Motor: Service and Repair Blower Motor Unit Assembly REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the glove box. 3. Loosen the nut to remove the support beam stay. 4. Disconnect the blower motor connector. 5. Disconnect the power transistor or blower resistor connector. 6. Loosen the bolt and nut to remove the blower motor unit assembly. INSTALLATION Install in the reverse order of removal. Page 5175 Non-Turbo Model ^ Turbo model Turbo Model INSTALLATION 1) Insert the gearbox into crossmember, being careful not to damage the gearbox boot. 2) Tighten the gearbox to crossmember bracket via clamp with bolts to specified torque. Tightening torque: 60 Nm (6.1 kgf-m, 44.3 ft. lbs.) ^ Non-turbo model Non-Turbo Model ^ Turbo model Page 7383 R72-R145 R148 Page 113 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 2038 Engine Control Module (ECM) I/O Signal (Part 2) Front Brake Caliper: Testing and Inspection Front INSPECTION 1. Repair or replace the faulty parts. 2. Check the caliper body and piston for uneven wear, damage or rust. 3. Check the rubber parts for damage or deterioration. Locations Keyless Entry System Diagrams Trunk Lid And Rear Gate Lock Page 4499 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 4011 B128-B134 Page 7407 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 3128 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. System Diagnosis Rear Door Window Regulator: Testing and Inspection REAR REGULATOR AND MOTOR ASSEMBLY INSPECTION 1. Make sure that the power window motor rotates properly when battery voltage is applied to terminals of motor connector. 2. Change polarity of battery connections to terminals to ensure that the motor rotates in reverse direction. Page 1460 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 6485 B134-B136 Page 2771 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 3134 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 5992 INSTALLATION Install in the reverse order of removal. Diagram Information and Instructions Ignition Control Module: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 2830 Engine Control Module: Testing and Inspection Engine Control Module (ECM) I/O Signal (Part 1) Page 3458 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 1047 4. Remove the timing belt guides. (MT model) 5. If the alignment mark and/or arrow mark (which indicates rotation direction) on timing belt fade away, put new marks before removing the timing belt as follows: 1. Turn the crankshaft using ST, and align the alignment marks on crank sprocket, intake cam sprocket (LH), exhaust cam sprocket (LH), intake cam sprocket (RH) and exhaust cam sprocket (RH) with notches of timing belt cover and cylinder block. ST 499987500 CRANKSHAFT SOCKET 2. Using white paint, put alignment and/or arrow marks on the timing belts in relation to the sprockets. Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 842 Seat Occupant Sensor: Description and Operation Occupant Detection System (From '06MY) GENERAL In '06MY, the occupant detection system was changed. The loadcell sensor that is located between the seat cushion and the seat frame consists of the bladder (bag) containing silicon gel and the pressure sensor connected with a hose. When the passenger sits in the passenger's seat, the silicon gel contained in the bladder is pushed. The loadcell sensor measures this pressure, and then it sends the signal to the occupant detection control module. The occupant detection control module detects the physique of the person sitting in the passenger's seat based on the signals, and then it sends the control signal to the airbag control module. The belt tension sensor was also added to the outer seat belt. The belt tension sensor detects the status that seat belt is continuously tensioning (when the child seat is attached to the passenger's seat, etc.), and then it sends the signal to the occupant detection control module. Page 7126 3. Clean the body with alcohol or white gasoline to remove thoroughly chips, dusts, and dirt from body face. 4. Install the dam rubber. 5. Fit the mark (B) on molding to the notch (A) of glass side, and install the molding to the whole glass edge. 6. Apply two kinds of primer to the adhesive layer of glass using sponge. Glass primer: Dow Automotive ESSEX U-401 (for undercoat) and ESSEX U-402 (for overcoat) or equivalent Locations Fuel Pump Relay: Locations Solenoid Valve, Actuator, Emission Control System Parts And Ignition System Parts (Part 5) Page 5008 7. Attach the repaired body wire harness to the area directly rearward of the wire clamp with insulating tape to prevent the wire from interfering with the seat rail. (See photos below for location of the wire and tape.) 8. Reinstall the floor carpet. Wrap the previously cut portion of carpet with 1.5 inch wide unwoven adhesive tape. 9. Reinstall the center console trim. Note: Be careful that switch wires attached to the center console trim are not pinched by the parking brake lever during installation. 10. Reinstall the passenger front seat. (Install the seat slide rail cover on Forester model.) 11. Reconnect the negative battery cable. (Reprogram the customer's radio stations presets.) 12. Perform Seat Occupant Detection System calibration. (See applicable service manual.) Note: Impreza models have the bladder type system which will require re-zeroing. Forester models have the load sensor type system which requires re-calibration. 13. Turn on the ignition switch and confirm that the seat heater switches and the air bag warning light works properly. SERVICE PROGRAM IDENTIFICATION LABEL Type or print the necessary information on a recall identification label. The completed label should be attached to the vehicle's upper radiator support. Page 4085 Transmission Speed Sensor: Service and Repair Rear Vehicle Speed Sensor Rear Vehicle Speed Sensor REMOVAL 1) Set the vehicle on a lift, and then lift-up the vehicle. 2) Disconnect the connector from rear vehicle speed sensor. ^ MP-T model MP-T model ^ VTD model VTD model 3) Remove the rear vehicle speed sensor. ^ MP-T model MP-T model ^ VTD model Page 4380 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 3587 B3-B12 Page 2455 B128-B134 Page 3712 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 527 B230-B283 Page 937 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 5505 - When checking, use a test harness (1). Do not directly apply the tester probe to any connector terminal of the airbag. Damage to the connector terminal may cause the airbag to activate erroneously. - Do not check continuity of either of the airbag modules for driver, passenger or side, or pretensioner. Page 1547 Intake Manifold: Service and Repair Disassembly and Assembly Intake Manifold DISASSEMBLY 1. Remove the fuel pipe protector RH. 2. Remove the fuel pipe protector LH. 3. Remove the engine ground terminal from the intake manifold. Page 886 If there is continuity in one direction and the continuity in the other or if there is continuity at unequal points, adjust the inhibitor switch. 4. Repeat the above checks. If there are abnormalities, adjust the select cable. REMOVAL 1. Set up the vehicle on a lift. 2. Move the select lever to N range. 3. Remove the air intake chamber. (Non-turbo model) 4. Remove the intercooler. (Turbo model) 5. Disconnect the inhibitor switch connector. 6. Remove the inhibitor switch connector from stay. 7. Lift-up the vehicle. 8. Remove the front and center exhaust pipes. 9. Remove the snap pin and washer from range select lever. Page 950 B136-B141 Page 2241 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 3659 B292-B317 Page 5582 Seat Occupant Sensor: Description and Operation Occupant Detection System (From '06MY) GENERAL In '06MY, the occupant detection system was changed. The loadcell sensor that is located between the seat cushion and the seat frame consists of the bladder (bag) containing silicon gel and the pressure sensor connected with a hose. When the passenger sits in the passenger's seat, the silicon gel contained in the bladder is pushed. The loadcell sensor measures this pressure, and then it sends the signal to the occupant detection control module. The occupant detection control module detects the physique of the person sitting in the passenger's seat based on the signals, and then it sends the control signal to the airbag control module. The belt tension sensor was also added to the outer seat belt. The belt tension sensor detects the status that seat belt is continuously tensioning (when the child seat is attached to the passenger's seat, etc.), and then it sends the signal to the occupant detection control module. Page 5221 INSTALLATION 1) Temporarily tighten the two bolts used to secure rear bushing of transverse link to body. NOTE: These bolts should be tightened to such an extent that they can still move back and forth in the oblong shaped hole in the bracket (which holds the bushing). 2) Install the bolts used to connect transverse link to crossmember and temporarily tighten with a new self-locking nut. 3) Insert the ball joint into housing. 4) Connect the stabilizer link to transverse link, and then temporarily tighten a new self-locking nut. ^ Sedan turbo model and STI model Sedan turbo model and STI model ^ Except Sedan turbo model and STI model Except Sedan turbo model and STI model 5) Tighten the following points in the order shown below when tires are in full contact with the ground and vehicle is curb weight. (1) Transverse link to stabilizer link, and stabilizer to stabilizer link (Sedan turbo model and STI model) Tightening torque: 45 Nm (4.6 kgf-m, 33 ft. lbs.) (2) Transverse link to stabilizer link, and stabilizer to stabilizer link (Except Sedan turbo model and STI model) Tightening torque: Transverse link to stabilizer link: 30 Nm (3.1 kgf-m, 22 ft. lbs.) Stabilizer to stabilizer link: 45 Nm (4.6 kgf-m, 33 ft. lbs.) (3) Transverse link and crossmember Page 2720 4. When the ignition switch is turned to ON (engine off) or to START with the test mode connector connected, the malfunction indicator light blinks at a cycle of 3 Hz. Page 1943 10. Install the timing belt. 11. Install the V-belts. 12. Install the radiator. Inspection 1. Check the water pump bearing for smooth rotation. 2. Check the water pump pulley for abnormalities. 3. Make sure the impeller is not deformed or damaged. 4. Check the clearance between impeller and pump case. ^ Clearance between impeller and pump case: ^ Standard 0.5 - 1.5 mm (0. 020 - 0.059 inch) 5. After water pump installation, check the pulley shaft for engine coolant leaks. If leaks are noted, replace the water pump assembly. Page 2929 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 963 Power Window Switch: Service and Repair POWER WINDOW CONTROL SWITCH REMOVAL 1. MAIN SWITCH 1. Disconnect the ground cable from battery. 2. Using a flat tip screwdriver, remove the screw cover. 3. Loosen the screw to remove the power window main switch. 4. Disconnect the connector. 2. SUB SWITCH 1. Disconnect the ground cable from battery. 2. Remove the screw which secures switch panel. 3. Remove the switch panel. Page 1541 23. Using ST, disconnect fuel hoses from fuel pipes. CAUTION: Be careful not to spill fuel. - Catch fuel from hoses using a container or cloth. ST 42099AE000 CONNECTOR REMOVER 24. Remove the bolts which secure the intake manifold to the cylinder heads. 25. Remove the intake manifold. INSTALLATION 1. Install the intake manifold onto cylinder heads. NOTE: Always use new gaskets. Page 2502 3. Oil fouled: Wet black deposits show oil entrance into combustion chamber through worn rings and pistons or excessive clearance between valve guides and stems. 4. Overheating: White or light gray insulator with black or brown spots and bluish burnt electrodes indicates engine overheating. Moreover, the appearance results from incorrect ignition timing, loose spark plugs, wrong selection of fuel, hotter range plug, etc. Page 6708 F21-F61 Page 7240 B292-B317 Page 1736 Coolant: Testing and Inspection Inspection Relationship Of Coolant Concentration And Freezing Temperature The concentration and safe operating temperature of the coolant is shown in the diagram. Measuring the temperature and specific gravity of the coolant will provide this information. ^ If the coolant temperature is 25°C (77°F) and its specific gravity is 1.054 and the concentration is 35% (point A), the safe operating temperature is -14°C (7°F) (point B), and the freezing temperature is -20°C (-4°F) (point C). Procedure To Adjust The Concentration Of The Coolant To adjust the concentration of the coolant according to temperature, find the proper fluid concentration in the above diagram and replace the necessary amount of coolant with an undiluted solution of SUBARU genuine coolant (concentration 50%). The amount of coolant that should be replaced can be determined using the diagram. ^ Assume that the coolant concentration must be increased from 25% to 40%. Find point A, where the 25% line of coolant concentration intersects with the 40% curve of the necessary coolant concentration, and read the scale on the vertical axis of the graph at height A. The quantity of coolant to be drained is 2.1 l (2.2 US qt, 1.8 Imp qt). Drain 2.1 l (2.2 US qt, 1.8 Imp qt) of coolant from the cooling system and add 2.1 l (2.2 US qt, 1.8 Imp qt) of the undiluted solution of SUBARU coolant. If a coolant concentration of 50% is needed, drain all the coolant and refill with the undiluted solution only. Page 6447 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 3454 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Locations Sensor Page 1349 Crankshaft Main Bearing: Testing and Inspection INSPECTION CRANKSHAFT AND CRANKSHAFT BEARING 1. Clean the crankshaft completely and check for cracks by means of liquid penetrant tester etc., and replace if defective. 2. Measure the crankshaft bend, and correct or replace if it exceeds the limit. NOTE: If a suitable V-block is not available, install the #1 and #5 crankshaft bearing on cylinder block, position the crankshaft on these bearings and measure the crankshaft bend using a dial gauge. Crankshaft bend limit. 0.035 mm (0.0014 inch) 3. Inspect the crank journal and crank pin for wear. If they are not within the specifications, replace the bearing with a suitable (undersize) one, and then replace or recondition the crankshaft as necessary. When grinding the crank journal or crank pin, finish them to specified dimensions according to the undersize bearing to be used. Crank pin: Out-of-roundness 0.003 mm (0.0001 inch) Cylindricality 0.004 mm (0.0002 inch) Grinding limit To 51.750 mm (2.0374 inch) dia. Crank journal: Out-of-roundness 0.005 mm (0.0002 inch) Cylindricality 0.006 mm (0.0002 inch) Grinding limit To 59.750 mm (2.3524 inch) dia. Page 4217 Axle Shaft Assembly: Overhaul Front Drive Shaft Disassembly DISASSEMBLY EBJ+PTJ TYPE 1) Place alignment marks on shaft and outer race. 2) Remove the PTJ boot band and boot. CAUTION: Be careful not to damage the boot. 3) Remove the circlip from PTJ outer race using a screwdriver. 4) Remove the PTJ outer race from shaft assembly. 5) Wipe off the grease. CAUTION: The grease is a special grease. Do not confuse with other greases. Service and Repair Control Module: Service and Repair Transmission Control Module (TCM) REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the lower cover and then disconnect the connector. 3) Remove the knee bolster. 4) Disconnect the connectors from TCM. 5) Remove the TCM. INSTALLATION 1) Install the TCM. 2) Connect the connectors to TCM. 3) Install in the reverse order of removal. 4) If replacing the TCM, execute the advance operation of learning control promotion. Page 6802 B380-f6 Page 6801 B292-B317 Page 535 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 1477 F61-R47 Page 7181 Wiper Relay: Testing and Inspection WIPER CONTROL RELAY INSPECTION 1. Disconnect the connector from wiper control relay. 2. Connect the positive (+) lead from the battery to terminal 8 and the negative (-) lead to terminal 6. Connect the positive (+) lead from the voltmeter to terminal 3 and the negative ( ) lead to ground. 3. Measure the voltage when the wiper relay is operated. If operation is not as specified, replace the switch. Page 2673 Fuel Tank Pressure Sensor: Testing and Inspection INSPECTION Make sure the hoses are not cracked or loose. Page 3534 Disclaimer Page 1797 F21-F61 Page 3216 Fuel Pressure: Testing and Inspection Fuel Pressure INSPECTION WARNING: Before removing the fuel pressure gauge, release the fuel pressure. NOTE: If out of specification, check or replace the pressure regulator and pressure regulator vacuum hose. 1. Release the fuel pressure. 2. Disconnect the fuel delivery hoses from fuel damper, and then connect the fuel pressure gauge. 3. Connect the connector of fuel pump relay. 4. Start the engine. 5. Measure the fuel pressure while disconnecting the pressure regulator vacuum hose from intake manifold. Fuel pressure: Standard. 284 - 314 kPa (2.9 - 3.2 kgf/cm2, 41 - 46 psi) 6. After connecting the pressure regulator vacuum hose, measure the fuel pressure. Fuel pressure: Standard. 230 - 260 kPa (2.35 - 2.65 kgf/cm2, 33 - 38 psi) NOTE: The fuel pressure gauge registers 10 to 20 kPa (0.1 to 0.2 kgf/cm2, 1 to 3 psi) higher than standard values during high-altitude operations. Page 7070 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 4250 Drive/Propeller Shaft: Service and Repair Propeller Shaft REMOVAL NOTE: ^ Before removing the propeller shaft, wrap the metal parts with a cloth or rubber material. ^ In case of EDJ type, before removing the propeller shaft, wrap the metal parts (installed at the rubber boot of center EDJ) with a cloth or rubber material, as shown in the figure. Rubber boot may be damaged due to interference with adjacent metal parts while bending the EDJ during removal. ^ Except STI model Except STI model ^ STI model STI model 1) Disconnect the ground cable from battery. 2) Move the select lever or gear shift lever to "N". 3) Release the parking brake. 4) Jack-up the vehicle and support it with sturdy racks. 5) Remove the center exhaust pipes. 6) Remove the rear exhaust pipe and muffler. 7) Remove the differential mount front cover. 8) Make matching marks on affected parts before removal. Page 7380 F21-F61 Page 7091 4. Disconnect the connector. INSTALLATION 1. MAIN SWITCH Install in the reverse order of removal. 2. SUB SWITCH Install in the reverse order of removal. Service and Repair Trailer Hitch: Service and Repair TRAILER HITCH Trailer Hitch REMOVAL CAUTION: Because the trailer hitch is heavy, two people are required to remove it. 1. Lift-up the vehicle. 2. Remove the cushion rubber from body. 3. Remove the canister. 4. Remove the trailer hitch installation bolts. Page 2800 Engine Control Module: Locations Non-Turbo Model Page 5837 Front Bumper: Removal and Replacement FRONT BUMPER Front Bumper REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the front grille RH and front grille LH. 3. Remove the clips inside the mounting portion of front grille RH and front grille LH. Wipers/Washers - Poor Front/Rear Washer Nozzle Operation Windshield Washer Spray Nozzle: All Technical Service Bulletins Wipers/Washers - Poor Front/Rear Washer Nozzle Operation NUMBER: 07-55-06 DATE: 04/04/06 APPLICABILITY: 2006MY Forester and Impreza SUBJECT: Poor Windshield Washer Fluid Spray Introduction If you encounter a customer complaint that the windshield washer fluid does not spray properly from the front or rear washer nozzle, there is the possibility that the nozzle or check valve is clogged or the fluid hose could be pinched or bent. Use the following repair procedure to check and repair as necessary. Production Line Change The check valve was changed from a ball type to a rubber type to prevent clogging. The new style check valve was used in production starting in October, 2005 with the VINs shown. Parts Information Repair Procedure/Information 1) Check the washer nozzle for contamination. If the spray hole is clogged with wax, dust or foreign material, blow compressed air to the spray hole of the washer nozzle to clear the obstruction. 2) Check the washer nozzle fluid hose. Make sure the hose is not pinched, and that it does not have severe bends or kinks. 3) Check the rear washer hose running along the left sill, as well as the hose in the tailgate area, to ensure that the hose is not pinched or bent, restricting the flow. 4) If there is no problem found in step 1 or 2, install a modified check valve. Front check valve on Forester and Impreza Fuel Level Sensor Fuel Level Sensor: Service and Repair Fuel Level Sensor Fuel Level Sensor REMOVAL WARNING: - Place "NO FIRE" signs near the working area. - Be careful not to spill the fuel. NOTE: Fuel level sensor is built in fuel pump assembly. 1. Remove the fuel pump assembly. 2. Disconnect the connector from the fuel pump bracket. 3. Remove the fuel temperature sensor. 4. Remove the bolt which installs the fuel level sensor on mounting bracket. INSTALLATION Install in the reverse order of removal. Page 6570 B54-B127 Page 313 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Locations Knock Sensor: Locations Sensor (Part 1) Locations Yaw Rate Sensor: Locations Electrical Component Location Cooling System - Coolant Comes Out Of Reservoir Coolant Line/Hose: Customer Interest Cooling System - Coolant Comes Out Of Reservoir NUMBER: 08-52-08 DATE: 08/18/08 APPLICABILITY: 1999MY and later Impreza & Forester 2000MY and later Legacy & Outback 2006MY and later Tribeca SUBJECT: Coolant Overflow Introduction If you encounter a vehicle which experiences coolant coming out of the coolant reservoir tank, it may be caused by the radiator cap pressure valve being stuck open by debris sucked up through the reservoir tank hose. As the cooling system cools down, it sucks coolant back into the radiator. If there is debris that settles to the bottom of the reservoir tank, the hose is low enough to also suck them back into radiator. This causes the radiator cap not to seal, allowing excessive amount of coolant to escape overflowing the reservoir tank. If this condition continues over time, there will not be enough coolant in the system to maintain proper engine temperature. In order to correct the condition you need to clean (and test) or replace the radiator cap, clean out the reservoir tank, and shorten the hose slightly, following the repair procedure. Production Line Change The shorter coolant reservoir tank hose was used in production as shown above. Repair Procedure/Information 1. Radiator Cap Cleaning Many caps can be successfully cleaned. The important part is the thorough cleaning of the negative pressure valve. If this is not done completely, remaining debris may result in a repeat issue. If there is an excessive amount of debris or the sealing rubber on the cap appears to be pitted or damaged, replace the cap. Note: If replacing the cap, skip to Step 2. Using clean water and a brush, thoroughly clean the cap seal surface. Note: Page 6707 B380-f6 Page 3962 Seals and Gaskets: Service and Repair Differential Side Retainer Oil Seal Differential Side Retainer Oil Seal INSPECTION Check the leakage of gear oil from differential side retainer oil seal part. If there is oil leakage, replace the oil seal. REPLACEMENT 1) Lift-up the vehicle. 2) Remove the front exhaust pipe and center exhaust pipe. Non-turbo model Turbo model 3) Drain the differential gear by removing differential gear oil drain plug. 4) Replace new gasket and tighten the differential oil drain plug. Tightening torque: 44 Nm (4.5 kgf-m, 32.5 ft. lbs.) (Aluminum gasket) 70 Nm (7.1 kgf-m, 51.6 ft. lbs.) (Copper gasket) 5) Separate the front drive shaft from transmission. 6) Remove the differential side retainer oil seal using driver which wrapped with vinyl tape or etc. 7) Using ST, install the differential side retainer oil seal by slightly tapping with hammer. ST 18675AA010 DIFFERENTIAL SIDE OIL SEAL INSTALLER 8) Apply oil to the oil seal lips. 9) Using the ST, install the front drive shaft. ST 28399SA010 OIL SEAL PROTECTOR 10) Install the front exhaust pipe and center exhaust pipe. Non-turbo model Turbo model 11) Lower the vehicle. 12) Pour differential gear oil into the gauge hole. Recommended gear oil: Refer to LUBRICANTS, RECOMMENDED MATERIALS. Differential gear oil capacity: 1.1 - 1.3 liters (1.3 - 1.4 US quarts, 1.0 - 1.1 Imp quarts) 13) Check the gear oil amount. Page 3688 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the connector from the camshaft position sensor RH. 3. Remove the camshaft position sensor RH from the rear side of cylinder head. 4. Remove the camshaft position sensor LH in the same procedure as RH side. INSTALLATION Install in the reverse order of removal. Tightening torque: Camshaft position sensor support: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) Camshaft position sensor: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) Locations Radiator Cooling Fan Motor Relay: Locations Main Fuse Box (M/B) Solenoid Valve, Actuator, Emission Control System Parts And Ignition System Parts (Part 5) Page 3766 B17-B20 Page 3580 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 6808 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 513 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Locations SRS Airbag Page 3729 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Front Door Latch and Door Lock Actuator Assembly Power Door Lock Actuator: Service and Repair Front Door Latch and Door Lock Actuator Assembly FRONT DOOR LATCH AND DOOR LOCK ACTUATOR ASSEMBLY REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the front door trim. 3. Remove the sealing cover. 4. Remove the front inner remote. 5. Remove three screws and a bolt. 6. Remove the front door latch assembly, and then disconnect the connector. INSTALLATION Install in the reverse order of removal. NOTE: Make sure the lock works properly after installation. Page 3709 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 6997 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 7192 Wiper Blade Heater Switch: Service and Repair WIPER DEICER SWITCH REMOVAL Remove the driver side lower cover, and then remove the wiper deicer switch. INSTALLATION Install in the reverse order of removal. Select Cable Shift Cable: Service and Repair Select Cable Select Cable REMOVAL 1) Set the vehicle on a lift. 2) Set the select lever to "N" range. 3) Disconnect negative cable from battery. 4) Lift-up the vehicle. 5) Remove front, center, rear exhaust pipe and muffler. (SOHC model) 6) Remove the center and rear exhaust pipes and muffler. (DOHC turbo model) 7) Remove the snap pin and washer from range select lever. 8) Remove the plate assembly from transmission case. 9) Disconnect the cable from select lever, and then remove the cable bracket. Page 2624 Non-Turbo Model Page 5840 INSTALLATION 1. Install in the reverse order of removal. 2. Align the front bumper mounting hole with the pawl of slider (A) to install. Tightening torque: Refer to COMPONENT in General Description. Page 5017 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 2098 Ignition Control Module: Service and Repair Ignition Coil and Ignitor Assembly REMOVAL Direct ignition type has been adopted. Refer to the "Spark Plug Removal" for removal procedure. INSTALLATION Install in the reverse order of removal. Tightening torque: 16 N.m (1.6 kgf-m, 11.7 ft-lb) Page 911 3) Apply proper amount of liquid gasket to the entire oil pan mating surface. Liquid gasket: THREE BOND 1217B (Part No. K0877YA020) 4) Apply liquid gasket fully to three holes other than screw holes on transmission case. Liquid gasket: THREE BOND 1217B (Part No. K0877YA020) 5) Install the oil pan. Tightening torque: 5 Nm (0.5 kgf-m, 3.6 ft. lbs.) 6) Connect the connector of rear vehicle speed sensor. (MP-T model) 7) Connect the connector of rear vehicle speed sensor. (VTD model) Page 3394 B128-B134 Page 3703 Crankshaft Position, Camshaft Position And Knock Sensors Page 3071 B230-B283 Page 2884 Disclaimer Page 2322 B17-B20 Page 1843 R58-R69 M/T - Clutch Pedal Squeaking Noise Clutch Pedal Position Sensor / Switch: Technical Service Bulletins M/T - Clutch Pedal Squeaking Noise CLUTCH PEDAL SQUEAK If you encounter a manual transmission equipped vehicle with a clutch pedal squeak concern, and lubricating the pedal mechanism didn't fix the noise, check the clutch switch. We have had a few reports where this has been the source of the problem. The fix is to replace the clutch pedal switch. Page 4218 6) Place alignment marks on roller kit and trunnion. 7) Remove the roller kit from trunnion. CAUTION: Be careful with the roller kit position. 8) Place an alignment mark on trunnion and shaft. 9) Remove the snap ring and trunnion. CAUTION: Be sure to wrap the shaft splines with vinyl tape to prevent the boot from scratches. 10) Remove the PTJ boot. 11) Place the drive shaft in a vise between wooden blocks. CAUTION: Do not place the drive shaft directly in a vise; use wooden block. Locations SRS Airbag Page 2504 Spark Plug: Service and Repair Spark Plug REMOVAL CAUTION: All spark plugs installed on an engine, must be of the same heat range. Spark plug: NGK: ILFR6B RH SIDE 1. Disconnect the ground cable from battery. 2. Remove the air cleaner lower case. Page 1115 Remove the hose from the reservoir tank. Cut 20 mm from the bottom of the hose at a 45° angle. Reinstall hose in reservoir tank. Start engine and permit to fully warm up. Turn off engine and allow to fully cool down. Recheck coolant level in reservoir and add coolant if needed. Note: Be sure to use genuine Subaru Super Coolant or Subaru Long Life Coolant, depending upon what type of coolant is currently in the system. Warranty/Claim Information M/T - Clutch Pedal Squeaking Noise Clutch Switch: Technical Service Bulletins M/T - Clutch Pedal Squeaking Noise CLUTCH PEDAL SQUEAK If you encounter a manual transmission equipped vehicle with a clutch pedal squeak concern, and lubricating the pedal mechanism didn't fix the noise, check the clutch switch. We have had a few reports where this has been the source of the problem. The fix is to replace the clutch pedal switch. Locations Fuel Tank Pressure Sensor: Locations Page 3139 B128-B134 Page 3386 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 7310 Wiper Arm: Adjustments Rear Wiper Arm Rear Wiper Arm ADJUSTMENT 1. Operate the rear wiper once. 2. Align the blade to rear defogger heat wire (A). Page 6183 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 537 Knock Sensor: Service and Repair Knock Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the intercooler. 3. Disconnect the knock sensor connector. 4. Remove the knock sensor from the cylinder block. INSTALLATION 1. Install the knock sensor to the cylinder block. Tightening torque: 24 N.m (2.4 kgf-m, 17.4 ft-lb) NOTE: Extraction area of the knock sensor cord must be positioned at a 60 degrees angle relative to the engine rear. Page 5312 Step 1 - 6 Page 5224 Control Arm: Service and Repair Rear Suspension Lateral link REMOVAL 1. Loosen the wheel nuts. Lift-up the vehicle and remove wheel. 2. Remove the stabilizers. 3. Remove the ABS wheel speed sensor harness from trailing link. 4. Remove the bolt securing trailing link to rear housing. 5. Remove the bolts which secure the lateral link assembly to rear housing. 6. Remove the DOJ from rear differential using ST. ST 28099PA100 DRIVE SHAFT REMOVER NOTE: The side spline shaft snap ring comes out together with the shaft. CAUTION: Be careful not to damage the side bearing retainer. Always use bolt shown in the figure, as supporting point for ST during removal. 7. Scribe an alignment mark on the rear lateral link adjusting bolt and crossmember. 8. Remove the bolts securing front and rear lateral links to crossmember, detach lateral links. CAUTION: To loosen the adjusting bolt, always loosen the nut while holding head of adjusting bolt. INSTALLATION Install in the reverse order of removal. Observe the following instructions. CAUTION: ^ Replace the self-locking nut and DOJ snap ring with new ones. ^ Always use the special tool not to allow the DOJ splines to damage the side oil seal. ST 28099PA090 OIL SEAL PROTECTOR ^ Always tighten the bushing location when tires are in full contact with the ground and vehicle is curb weight. ^ Secure the bolt head and tighten the nut when installing the adjusting bolt. NOTE: Check the wheel alignment and adjust if necessary. Page 1969 11. Place the turbocharger upper cover, and tighten the bolts which install the upper side of upper cover. Tightening torque: 7.5 Nm (0.8 kgf-m, 5.5 ft. lbs.) 12. Lift-up the vehicle. 13. Tighten the bolts which install the under side of turbocharger lower cover. Tightening torque: 7.5 Nm (0.8 kgf-m, 5.5 ft. lbs.) 14. Install the under cover. 15. Lower the vehicle. 16. Install the intercooler bracket. 17. Install the intercooler. Page 550 The list above is of O2 Sensor related DTCs. (This list is for example only. Refer to the applicable service manual for a complete list of DTCs.) Note: When the DTCs for O2 sensor are stored in memory, do not replace the A/F sensor. Page 1646 2. Remove the belt idler No. 2. 3. Remove the automatic belt tension adjuster assembly. INSTALLATION 1. AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER 1. Preparation for installation of automatic belt tension adjuster assembly: CAUTION: ^ Always use a vertical type pressing tool to move the adjuster rod down. ^ Do not use a lateral type vise. ^ Push the adjuster rod vertically. ^ Press-in the push adjuster rod gradually taking more than 3 minutes. ^ Do not allow press pressure to exceed 9,807 Nm (1,000 kgf, 2,205 ft. lbs.). ^ Press the adjuster rod as far as the end surface of cylinder. Do not press the adjuster rod into the cylinder. Doing so may damage the cylinder. ^ Do not release the press pressure until stopper pin is completely inserted. 1. Attach the automatic belt tension adjuster assembly to the vertical pressing tool. 2. Slowly move the adjuster rod down with a pressure of 165 Nm (16.8 kgf,37.1 ft. lbs.) or more until the adjuster rod is aligned with the stopper pin hole in the cylinder. Page 5285 ^ Inspect the cone for any debris or damage and clean or replace as necessary ^ Perform the Centering Check® Procedure (software version 2.1 and higher) before each wheel is balanced PROCEDURE Always verify the concern with a test drive before beginning diagnosis and performing repairs. Drive the vehicle a minimum of 10 miles to eliminate any flat spots on the tires. Immediately after the road test, lift the vehicle into the air to minimize flat spotting. Adjust tire pressures according to the door label and inspect for any visible damage. If any damage is found, resolve these concerns before continuing with diagnosis. Tire dynamic imbalance should be measured first and adjusted to within 5 grams. Leave any remaining factory weights in place and remove weights that have been added afier production; be careful not to damage the wheel. If the assembly cannot be adjusted to within 5 grams, inspect for the following: ^ Improperly mounted tire or unseated tire bead ^ Improperly mounted assembly to the balancer ^ Damage to the wheel or tire ^ Damage to the tire balancer ^ Debris located inside the tire If a vibration can still be felt afier the wheels have been properly balanced, there is a possibility of excessive radial force variation (RFV) in the tire and wheel assembly. To address RFV concerns, a wheel balancer capable of measuring RFV must be used; Subaru Of America Inc. recommends the use of the Hunter GSP 9700 Road Force Measurement System. If a GSP 9700 is not available, locate the nearest machine through the Hunter Engineering web site (www.gsp9700.com). Measure and record the RFV readings of the wheel and tire assembly for R1H. Then perform the wheel runout measurements by following the on-screen instructions or by referring to the operating instructions; this will determine the individual tire and wheel RFV measurements. The following assembly RFV measurements can be used as a guide: ^ R1H on passenger tires - 8.0kg (17.6lbs) or less If higher than normal RFV measurements are found for the assembly, refer to the on-screen instructions or the operating instructions to match the tire and wheel to minimize the assembly RFV By matching the low spot of the tire to the high spot of the wheel, radial force can be reduced without replacing any components. After all RFV measurements are adjusted to the lowest possible level, install the wheels with the lowest RFV measurements on the front of the vehicle and road test to verify the concern has been reduced. Replacement of tires due to excessive assembly measurements may be unnecessary. If the concern still exists at an unacceptable level, contact the Subaru Technical HelpLine with the following information readily available: ^ Thorough description of customer's concern ^ VIN ^ Mileage ^ Tire manufacturer, size and condition ^ Completed "Dealer vibration Analysis Worksheet and Tire Analysis Worksheet" available under TechLine Pre-Call Worksheets on Subarunet. (All measurements should be in grams or kilograms) ^ Service history of vehicle WARRANTY/CLAIM INFORMATION Page 403 Combination Switch: Service and Repair Combination Base Switch Assembly COMBINATION BASE SWITCH ASSEMBLY REMOVAL 1. Remove the driver s airbag module. 2. Remove the steering wheel. 3. Remove the steering column cover. 4. Remove the combination switch. 5. Loosen the four screws and remove the roll connector. 6. Loosen the three screws. 7. Disconnect the connector and remove the combination base switch assembly. INSTALLATION 1. Install in the reverse order of removal. 2. Align the attaching direction of roll connector with the steering wheel, before installation of steering wheel. Page 2091 F61-R47 Description and Operation Temperature Sensor (Gauge): Description and Operation WATER TEMPERATURE GAUGE - Water temperature signals are generated at the engine coolant temperature sensor on the engine, and after converted into digital signals, these signals are sent via the body integrated unit to the combination meter. - The resistance of the engine coolant temperature sensor changes according to the engine coolant temperature. Therefore, the signals sent to the water temperature gauge also changes according to the engine coolant temperature. As the change in signals causes the magnetic force of the step motor to change, the gauge needle moves according to the engine coolant temperature. - When the coolant is at a normal operating temperature of approx. 85 to 100 degree C (158 to 212 degree F), the gauge needle stays in the middle of the indication range as shown in the figure. Page 3853 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 6635 Temperature Gauge: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 4513 B230-B283 Locations Electrical Component Location Page 3202 Leak Detection Solenoid: Service and Repair Pressure Control Solenoid Valve REMOVAL 1. Set the vehicle on a lift. 2. Disconnect the ground cable from battery. 3. Lift up the vehicle. 4. Remove the canister. 5. Remove the bolt which installs the pressure control solenoid valve holding bracket on body. 6. Remove the pressure control solenoid valve with bracket. 7. Disconnect the connector from pressure control solenoid valve. 8. Disconnect the two evaporation hoses from pressure control solenoid valve. 9. Remove the pressure control solenoid valve from bracket. Page 3009 2. Install the rear oxygen sensor. - AT model - MT model 3. Connect the connector to the rear oxygen sensor. Page 4245 Propeller Shaft Page 2444 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 1052 5. Align the single line mark (A) on intake cam sprocket (LH) with notch (B) on timing belt cover by turning the sprocket clockwise (as viewed from front of engine). (Ensure the double lines (c) on intake and exhaust cam sprockets are aligned.) 6. Ensure the camshaft and crank sprockets are positioned properly. CAUTION: ^ Intake and exhaust camshafts for this DOHC engine can be independently rotated with the timing belts removed. As can be seen from the figure, if the intake and exhaust valves are lifted simultaneously, their heads will interfere with each other, resulting in bent valves. ^ When the timing belts are not installed, four camshafts are held at the "zero-lift" position, where all cams on camshafts do not push the intake and exhaust valves down. (Under this condition, all valves remain unlifted.) ^ When the camshafts are rotated to install the timing belts, #2 intake and #4 exhaust cam of camshafts (LH) are held to push their corresponding valves down. (Under this condition, these valves are held lifted.) Camshafts (RH) are held so that their cams do not push valves down. ^ Camshafts (LH) must be rotated from the "zero-lift" position to the position where the timing belt is to be installed at as small an angle as possible, in order to prevent mutual interference of intake and exhaust valve heads. ^ Do not allow the camshafts to rotate in the direction shown by the upper illustration in the figure as this causes both intake and exhaust valves to lift simultaneously, resulting in interference with their heads. Page 1202 Power Steering Fluid: Fluid Type Specifications P/S Fluid type ...................................................................................................................................... ........................................ Dexron (R) III A/T Fluid Page 1787 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 7346 F21-F61 Page 4019 R58-R69 Page 6075 Power Door Lock Actuator: Testing and Inspection Rear Door Lock Actuator REAR DOOR LOCK ACTUATOR INSPECTION 1. Disconnect the rear door lock actuator harness connector. 2. Connect the battery to rear door lock actuator terminals. If NG, replace the door lock actuator. Page 3079 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 6875 Headlamp Relay: Testing and Inspection HEADLIGHT RELAY Measure the headlight relay resistance between terminals when connecting terminal No. 4 to battery positive terminal and terminal No. 3 to battery ground terminal. Service and Repair Control Module: Service and Repair Transmission Control Module (TCM) REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the lower cover and then disconnect the connector. 3) Remove the knee bolster. 4) Disconnect the connectors from TCM. 5) Remove the TCM. INSTALLATION 1) Install the TCM. 2) Connect the connectors to TCM. 3) Install in the reverse order of removal. 4) If replacing the TCM, execute the advance operation of learning control promotion. Page 4042 INSPECTION 1) Inspect the removed parts for deformation, damage and wear. Correct or replace if defective. 2) Confirm the following parts for operating condition before assembly. Moving condition of the select lever assembly, it should move smoothly. Page 1479 R72-R145 R148 Page 2263 7. Connect the connector of front oxygen (A/F)sensor. 8. Connect the battery ground cable to battery. Page 3581 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 193 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 3727 R72-R145 R148 M/T - Clutch Pedal Squeaking Noise Clutch Pedal Position Sensor / Switch: Technical Service Bulletins M/T - Clutch Pedal Squeaking Noise CLUTCH PEDAL SQUEAK If you encounter a manual transmission equipped vehicle with a clutch pedal squeak concern, and lubricating the pedal mechanism didn't fix the noise, check the clutch switch. We have had a few reports where this has been the source of the problem. The fix is to replace the clutch pedal switch. Page 2825 R58-R69 Page 2200 F21-F61 Locations Page 2114 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 4007 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Testing and Inspection Fog/Driving Lamp Relay: Testing and Inspection FRONT FOG LIGHT RELAY Measure the front fog light relay resistance between terminals when connecting terminal No. 4 to battery positive terminal and terminal No. 3 to battery ground terminal. Page 680 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 2687 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 6079 Power Door Lock Actuator: Service and Repair Rear Door Latch and Door Lock Actuator Assembly REAR DOOR LATCH AND DOOR LOCK ACTUATOR ASSEMBLY REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the rear door trim. 3. Remove the sealing cover. 4. Remove the rear inner remote. 5. Remove three screws and a bolt. 6. Disconnect the connector, and then remove the rear door latch assembly. INSTALLATION Install in the reverse order of removal. NOTE: Make sure the lock works properly after installation. Page 4895 Measure the pinion gap while the pinion is pulled out as shown in the figure. Pinion gap: 0.5 - 2.0 mm (0.020 - 0.079 in) If the motor is running with the pinion forced endwise on shaft, disconnect the connector from terminal M of switch assembly, and then connect terminal M to ground terminal (-) of battery with a lead wire. Next, gently push the pinion back with your fingertips, and then measure the pinion gap. 8. PERFORMANCE TEST The starter should be submitted to performance tests whenever it has been overhauled, to assure its satisfactory performance when installed on the engine. Three performance tests, no-load test, load test, and lock test, are presented here; however, if the load test and lock test cannot be performed, carry out at least the no-load test. For these performance tests, use the circuit shown in figure. 1. No-load test With switch on, adjust the variable resistor to obtain 11 V, take the ammeter reading, and then measure the starter speed. Compare these values with the specifications. No-load test (standards): Voltage/Current Non-turbo, MT model MAX. 11 V/95 A Turbo, MT model MAX. 11 V/90 A AT model MAX. 11 V/90 Rotating speed Non-turbo, MT model More than 2,500 rpm Page 191 R72-R145 R148 Page 4464 7) Read values indicated on the brake tester and check if the fluctuation of values, while decompressed and compressed, meet the standard values. 8) After checking, also check if any irregular brake pedal tightness is felt. Page 2016 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 4277 Seals and Gaskets: Service and Repair Differential Side Retainer Oil Seal Differential Side Retainer Oil Seal INSPECTION Check leakage of gear oil from the differential side retainer oil seal part. If there is oil leakage, replace with a new oil seal, and check drive shaft. REPLACEMENT 1) Lift-up the vehicle. 2) Remove the drain plug using TORX BIT T70, and drain the differential gear oil completely. 3) Replace with a new gasket and tighten the drain plug using TORX BIT T70. 4) Remove the front and center exhaust pipe. (Non-turbo model) 5) Separate the front drive shaft from transmission. 6) Remove the differential side retainer oil seal. NOTE: ^ Be sure to replace the differential side retainer oil seal after the procedure of removing the front drive shaft from transmission. ^ When removing the oil seal, using the ST 398527700 PULLER ASSY. Also when using a flat tip screwdriver, be careful not to scratch the differential side retainer 7) Using the ST, install the differential side retainer by slightly tapping with a plastic hammer. ST 18675AA000 DIFFERENTIAL SIDE OIL SEAL INSTALLER NOTE: Apply oil to the oil seal lips. Page 2193 B54-B127 Page 2859 B3-B12 Testing and Inspection Fuel Injector: Testing and Inspection FUEL INJECTOR CIRCUIT CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Clearing Trouble Codes and Inspection Mode. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/DTC List - P Codes/List of Diagnostic Trouble Code (DTC) Wiring Diagram Page 4998 Additional labels are available through the Customer Dealer Services Department (CDS). CLAIM REIMBURSEMENT AND ENTRY PROCEDURES Credit to perform this recall will be based on the submission of properly completed repair order information. Dealers may enter the applicable claim information through their Dealer Communications System. Inspect - Use the applicable claim submission information for inspection of passenger front seat wire harness. Repair Wiring - Use the additional claim submission information for repair of the passenger front seat wire harness. Disclaimer Page 4656 Brake Master Cylinder: Service and Repair Master Cylinder REMOVAL CAUTION: Do not allow brake fluid to come in contact with vehicle body; wash away with water and wipe off completely if spilled. 1. Thoroughly drain brake fluid from reservoir tank. 2. Disconnect the fluid level indicator harness connector. 3. Remove the brake pipes from master cylinder. 4. Remove the master cylinder mounting nuts, and take out master cylinder from brake booster. INSTALLATION 1. To install the master cylinder to body, reverse the sequence of removal procedure. Tightening torque: Master cylinder mounting nut 15 Nm (1.5 kgf-m, 10.8 ft. lbs.) Piping flare nut 15 Nm (1.5 kgf-m, 10.8 ft. lbs.) CAUTION: Be sure to use recommended brake fluid. 2. Bleed air from the brake system. DISASSEMBLY 1. Remove mud and dirt from the surface of brake master cylinder. 2. Secure the master cylinder on a vise. 3. Remove the pin which secures reservoir tank to master cylinder, and then remove the reservoir tank and grommet. 4. Remove the cylinder pin with magnetic pick-up tool while pushing in primary piston by screwdriver which wrapped with tape. 5. Pry up the pawl, and then remove the piston retainer. Hold piston retainer tight, because the piston may jump out from master cylinder. 6. Extract the primary piston assembly and secondary piston assembly straight out, while taking care not to scratch the inner surface of cylinder. 7. Use brake fluid to wash the inside wall of cylinder, and piston assembly. If any damage, deformation, wear, rust, and other faults are found, replace the faulty part. ASSEMBLY 1. Apply recommended brake fluid to the inside wall of cylinder, and to outer surface of the piston assembly. 2. Ensure that the inside wall of cylinder, and piston assembly are free from dirt when assembling. Install the primary piston assembly and secondary piston assembly, while taking care not to damage, scratch, or dent the cylinder inside wall, and piston assembly. 3. Install the cylinder pin while pushing in primary piston by screwdriver which wrapped with tape. 4. Install the piston retainer, and then secure it by pressing the pawl. Page 6897 Brake Light Switch: Service and Repair Stop Light Switch REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the stop light switch connector. 3. Loosen nuts, and unscrew stop light switch to remove. INSTALLATION 1. Screw the stop light switch onto a bracket and secure it temporarily with a nut. 2. Adjust the stop light switch position, and then tighten the nut. Tightening torque: 8 Nm (0.8 kgf-m, 5.8 ft. lbs.) INSPECTION 1. If the stop light switch does not operate properly (or if it does not stop at the specified position), replace with a new one. Specified position L: 2 mm (0.079 inch) 2. Measure the clearance between threaded end of stop light switch and stopper. CAUTION: Be careful not to rotate stop light switch. Stop light switch clearance 0.3 mm (0.012 inch) Page 3058 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 882 Neutral Safety Switch: Testing and Inspection Inhibitor Switch (AT Model) INHIBITOR SWITCH (AT MODEL) Measure the resistance between inhibitor switch terminals. Diagrams Power Steering Pump: Diagrams OIL PUMP ^ TURBO MODEL AND STI MODEL TURBO MODEL AND STI MODEL Page 7177 R72-R145 R148 Page 4123 STI model 4) Remove the operating cylinder from transmission. ^ Non-turbo model Non-turbo model ^ Turbo model Turbo model ^ STI model Locations Secondary Air Combi Value Page 3872 Shift Solenoid: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 5455 Ambient Temperature Sensor / Switch HVAC: Testing and Inspection AMBIENT SENSOR TROUBLE SYMPTOM: Fan speed is not switched when the fan speed control dial is in AUTO position. Wiring Diagram Page 2540 B230-B283 Page 4177 Service and Repair Body Control Module: Service and Repair Body Integrated Module REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the lower cover. 3) Remove the knee bolster. 4) Disconnect the connector from body integrated module. 5) Remove the body integrated module. INSTALLATION Install in the reverse order of removal. Removal and Installation Keyless Entry Transmitter: Service and Repair Removal and Installation TRANSMITTER REMOVAL 1. TRANSMITTER BATTERY Remove the battery (1) from transmitter. NOTE: To prevent static electricity damage to transmitter printed circuit board, touch the steel area of building with hand to discharge the static electricity carried on body or clothes before disassembling transmitter. INSTALLATION 1. TRANSMITTER BATTERY Install in the reverse order of removal. Page 442 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Subaru Crank Pulley Wrench - AST Tool # SU499977100 Crankshaft: Tools and Equipment Subaru Crank Pulley Wrench - AST Tool # SU499977100 Subaru Crank Pulley Wrench AST tool# SU499977100 Used to hold the crankshaft. - Contact AST for pricing Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Page 5982 4. Remove the rear differential protector. INSTALLATION Install in the reverse order of removal. Tightening torque: 90 N.m (9.2 kgf-m, 66.4 ft-lb) NOTE: Install the protector between the nuts and differential rear member. Tightening torque: 70 N.m (7.1 kgf-m, 51.6 ft-lb) Page 11 Alarm Module: Service Precautions SECURITY CONTROL UNIT NOTE: The control of security system is performed by the keyless entry control unit. Page 3863 B134-B136 Page 3710 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Specifications Compression Check: Specifications Compression (at 200 - 300 rpm): Standard ................................................................................................................................................... 981 1,177 kPa (10 - 12 kgf1cni2, 142 - 171 psi) Difference between cylinders ....................................................................................................................................... Less than 49 kPa (0.5 kgf1cm, 7 psi) Page 4945 Fuse & Relay Box (F/B) Page 1360 Subaru Crankshaft Socket used to align crank to TDC while working with the timing belt. - Made in U.S.A - Call AST for pricing Subaru timing crank Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Service and Repair Maintenance Required Lamp/Indicator: Service and Repair The OEM does not provide a Maintenance Required Indicator for this model. Page 241 B136-B141 Page 6627 B136-B141 Page 7272 (1) Open the rear gate and remove the foam trim board on the left hand side from the cargo floor. (2) Remove the check valve. Note: Place rags or paper towels in the area. There is a chance that a small amount of washer fluid may leak out. (3) Attach valve cushion (86634SA000) around the modified check valve (86634AA010) for soundproofing. (4) Install the modified check valve and valve cushion. Inhibitor Switch Neutral Safety Switch: Service and Repair Inhibitor Switch Removal and Installation Inhibitor Switch REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the connector from inhibitor switch, and then remove the switch. INSTALLATION Install in the reverse order of removal. Inspection Inhibitor Switch INSPECTION When the driving condition or starter motor operation is erroneous, first check the shift linkage for improper operation. If the shift linkage is functioning properly, check the inhibitor switch. 1. Disconnect the inhibitor switch connector. 2. Check continuity in inhibitor switch circuits with the select lever moved to each position. NOTE: ^ Also check that continuity in ignition circuit does not exist when the select lever is in R, D, 3, 2 and 1 ranges. ^ If the inhibitor switch is inoperative, check for poor contact of connector on transmission side. 3. Check if there is continuity at equal points when the select lever is turned 1.5° in both directions from N range. Page 4127 Non-turbo Model ^ Except Non-turbo model and STI model Except Non-turbo model and STI model ASSEMBLY NOTE: ^ Keep applying working fluid to all the parts during assembly. ^ Assembly for operating cylinder of only 5MT model can be performed. That of 6MT model is a component that cannot be disassembled. Recommended clutch fluid: FMVSS No. 116, fresh DOT3 or 4 brake fluid 1) Install the piston spring to piston. ^ Non-turbo model Non-turbo Model ^ Except Non-turbo model and STI model Page 479 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the connector from the camshaft position sensor RH. 3. Remove the camshaft position sensor RH from the rear side of cylinder head. 4. Remove the camshaft position sensor LH in the same procedure as RH side. INSTALLATION Install in the reverse order of removal. Tightening torque: Camshaft position sensor support: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) Camshaft position sensor: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) Locations Electrical Component Location Page 6850 R72-R145 R148 Testing and Inspection Tail Light Bulb: Testing and Inspection TAIL/STOP LIGHT BULB INSPECTION 1. Visually check the bulb for blow out. 2. Check the bulb specification. 3. If NG, replace the bulb with a new one. Page 1475 B380-f6 Locations Sensor Page 3287 Install in the reverse order of removal. NOTE: Replace the O-ring and insulators with new ones. Page 189 F61-R47 Page 6340 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 3437 R72-R145 R148 Page 6698 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 3796 13) Install the air intake chamber. (Non-turbo model) 14) Install the intercooler. (Turbo model) 15) Inspect the inhibitor switch. Page 3073 B380-f6 Navigation System - Display Dimmer In Cold Temps Navigation Display: Technical Service Bulletins Navigation System - Display Dimmer In Cold Temps NAVIGATION DISPLAY ILLUMINATION IN COLD WEATHER There is a possibility that the navigation display illumination may become dark under low temperature conditions. The display will brighten as it warms up. This is a normal function and no repairs should be attempted. Page 6242 Cruise Control Switch: Service and Repair CRUISE CONTROL COMMAND SWITCH REMOVAL WARNING: Before servicing, be sure to read the notes in the AB section for proper handling of the driver's airbag module. 1. Set the front wheels in straight ahead position. 2. Turn the ignition switch to OFF. 3. Disconnect the ground cable from battery and wait for at least 20 seconds before starting work. 4. Using the TORX BIT T30 (Tamper resistant type), loosen the two TORX® bolts which secure driver's airbag module. 5. Disconnect the airbag module connector on back of airbag module. 6. Remove the steering wheel. 7. Remove four screws, and then remove the lower cover from steering wheel. 8. Remove the screw, and then remove the cruise control command switch from lower cover. INSTALLATION Install in the reverse order of removal. Page 4386 B54-B127 Page 986 3) Follow the wheel alignment gauge operation manual to measure camber angle. NOTE: Refer to the "SPECIFICATION" for camber values. Front: Rear: ^ Front Camber Adjustment 1) Loosen the two self-locking nuts located at lower front portion of strut. NOTE: When adjusting bolt needs to be loosened or tightened, hold its head with a wrench and turn self-locking nut. 2) Turn the camber adjusting bolt so that camber is set at the specification. NOTE: Moving the adjusting bolt by one scale graduation changes camber by approximately 0°10'. Page 2326 B136-B141 Page 2119 B134-B136 Engine Controls - DTC P0607 Diagnostic Information Engine Control Module: All Technical Service Bulletins Engine Controls - DTC P0607 Diagnostic Information NUMBER: 11-91-08 DATE: 12/05/08 APPLICABILITY: 2004-2008MY Impreza 2004-2008MY Forester 2005-2008MY Legacy/Outback 2006-2007MY Tribeca SUBJECT: DTC P0607 Control Module Performance Introduction The purpose of the bulletin is for information purposes when diagnosing DTC P0607. The following checks and information is in addition to what is listed in the Subaru Service Manual. This information is to be used in conjunction with the service manual. Repair Procedure/Information Additional items to check: ^ Rapid drop of voltage from a dead battery ^ Loose battery terminals ^ Loose ECM ground terminal ^ A short or open to the power or ground circuit If the malfunction criteria are met, the CEL will illuminate, the vehicle will go into fail safe and the throttle valve opening will be fixed at 6°. Fail safe will recover to normal mode if the ECM judges the criteria "OK" at the time of the next engine start. The CEL will not turn off until the "OK" driving cycle is completed 3 times in a row. The judgment is decided by the ECM to keep the CEL On or Off at the time the ignition switch is turned from ON to OFF. The ECM keeps DTC P0607 in memory even after the indicator light goes out. Therefore, it is important to erase memory after the repair is completed. Detail list of applicable model and engine type. Page 7067 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 6846 B380-f6 Service and Repair Air Bag(s) Arming and Disarming: Service and Repair CAUTION: - When servicing a vehicle, be sure to turn the ignition switch to OFF, disconnect the ground cable from battery, and wait for more than 20 seconds before starting work. - The airbag system is fitted with a backup power source. If the airbag system is serviced within 20 seconds after the ground cable is disconnected, it may inflate. - If the airbag warning light illuminates, repair the vehicle immediately. Airbag or pretensioner may inflate incorrectly, or not inflate in collision. - If sensors, airbag module, airbag control module, pretensioner, and harness are deformed or damaged, replace them with new genuine parts. - When checking the airbag system, be sure to use a digital circuit tester. Infinitesimal electric current in an analog circuit tester may cause the airbag to activate erroneously. - When checking the airbag system, be sure to use a digital circuit tester. Infinitesimal electric current in an analog circuit tester may cause the airbag to activate erroneously. Locations Page 818 Impact Sensor: Adjustments IMPACT SENSOR ADJUSTMENT 1. CHECK IMPACT SENSOR 1. Remove the key from ignition switch. 2. Close all windows. 3. Close all the doors, trunk lid and rear gate. Leave open the front hood. 4. Press the LOCK button of the transmitter from outside vehicle. 5. Check that the security indicator light blinks twice within 0.5 seconds in 2 seconds cycle after 30 seconds. 6. Hit the windshield with your palm continuously and check the security alarm operates. Lift up the front hood approx. 12 cm (4.7 in), and then drop it off to check the operation of security alarm. 7. If NG, adjust the impact sensitivity. 2. IMPACT SENSITIVITY ADJUSTMENT 1. Connect the Subaru Select Monitor to data link connector. 2. Turn the ignition switch to ON. 3. Select {Impact Sensor} from the main menu. 4. Make a {ECU customizing}. - Sensitivity can be adjusted in 11 levels (0 to 10). - Initial setting is 5. - Smaller number means more sensitive. - Larger number means less sensitive. 5. Turn the ignition switch to OFF, and then remove the Subaru Select Monitor. NOTE: Set the sensor so as not to let the alarm on normal vibration (reclining to the door, hit the ball and etc.). - Set the sensor to operate the alarm with hitting the door or window glass, etc. continuously like a mayhem by robbery. - Ask the customer about parking situation for setting, because the alarm operate when the vibration not only the burglar but also the construction etc. Page 318 B128-B134 Page 6670 Brake Light Switch: Testing and Inspection BRAKE LIGHT SWITCH INSPECTION 1. If the stop light switch does not operate properly (or if it does not stop at the specified position), replace with a new one. Specified position L: 2 mm (0.079 inch) 2. Measure the clearance between threaded end of stop light switch and stopper. CAUTION: Be careful not to rotate stop light switch. Stop light switch clearance 0.3 mm (0.012 inch) 3. If it is not within specified value, adjust it by adjusting position of stop light switch. CAUTION: Be careful not to rotate the stop light switch. Page 317 B54-B127 Page 3972 13) Install the air intake chamber. (Non-turbo model) 14) Install the intercooler. (Turbo model) 15) Inspect the inhibitor switch. Page 6519 F21-F61 Page 4833 Ignition Lock: Service and Repair IGNITION KEY LOCK REPLACEMENT 1. Remove the ground cable from battery. 2. Remove the steering column. 3. Secure the steering column in a vise. Remove the bolt with a drill. 4. Remove the ignition key lock. 5. Use a new torn bolt. Tighten the torn bolt to end of thread. Page 3338 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 2085 B134-B136 Page 1844 R72-R145 R148 Page 110 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 195 Ignition Control Module: Testing and Inspection INSPECTION For inspection, refer to IGNITION CONTROL SYSTEM, Diagnostics for Engine Starting Failure. Page 1169 Fluid - A/T: Service and Repair Differential Fluid Replacement Differential Gear Oil REPLACEMENT 1) Lift-up the vehicle. 2) Remove the differential gear oil drain plug using TORX T70, and then drain the differential gear oil completely. CAUTION: ^ Directly after the vehicle has been running, the differential gear oil is hot. Therefore, be careful not to burn yourself. ^ Be careful not to spill the differential gear oil on exhaust pipe to prevent it from emitting smoke or fire. When the differential gear oil is spilled on exhaust pipe, wipe it away completely. 3) Replace the gasket with a new one, and then tighten the differential gear oil drain plug using TORX T70. Tightening torque: 44 Nm (4.5 kgf-m, 32.5 ft. lbs.) (Aluminum gasket) 70 Nm (7.1 kgf-m, 51.6 ft. lbs.) (Copper gasket) 4) Lower the vehicle. 5) Pour gear oil into the gauge hole. Recommended fluid. Gear oil capacity: 1.1 - 1.3 liters (1.2 - 1.4 US quarts, 1.0 - 1.1 Imp quarts) 6) Check the level of differential gear oil. Locations Electrical Components Location Page 3867 B380-f6 Page 6326 Clock: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 4927 B292-B317 Page 2350 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 1565 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 5967 Diffuser Tightening torque Page 1980 STI model Page 5861 Front Door Exterior Handle: Service and Repair FRONT OUTER HANDLE REMOVAL 1. Remove the door trim. 2. Remove the sealing cover. 3. Remove the bolt (A). 4. Move the front door glass downward. Remove the bolt and rod clamp. 5. Remove the front outer handle. CAUTION: Do not use excessive force to remove the handle from door panel. This will deform it. INSTALLATION Install in the reverse order of removal. NOTE: Make sure the front outer handle works properly after installation. Page 5177 7) Install the front stabilizer to vehicle. 8) Install the front exhaust pipe assembly. (Non-turbo model) 9) Install the sub frame. 10) Install the under cover. 11) Align the center of roll connector. 12) Install the steering wheel. 13) Install the front wheels. 14) Tighten the wheel nuts to specified torque. Tightening torque: 90 Nm (9.0 kgf-m, 65.1 ft. lbs.) 15) Connect the battery ground cable to battery. 16) Pour fluid into the oil tank, and bleed air. 17) Check for fluid leaks. 18) Install the jack-up plate. 19) Lower the vehicle. 20) Check the fluid level in oil tank. 21) After adjusting the toe-in and steering angle, tighten the lock nut on tie-rod end. Tightening torque: 83 Nm (8.5 kgf-m, 61.5 ft. lbs.) NOTE: When adjusting the toe-in, hold boot as shown to prevent it from being rotated or twisted. If twisted, straighten it. Engine Controls - DTC P0340/P0345 After Camshaft R & R Camshaft Position Sensor: Customer Interest Engine Controls - DTC P0340/P0345 After Camshaft R&R Number: 02-107-09 Date: 03/24/09 Applicability: 2004~06MY Baja 2.5L Turbo 2004~06MY Impreza 2.5L Turbo 2004~06MY Forester 2.5L Turbo 2004~06MY Legacy/Outback 2.5L Turbo SUBJECT: Intake Camshaft Replacement Introduction If you encounter a vehicle that has a CEL and P0340 or P0345 stored in memory immediately after replacing the intake camshaft(s), the air gap between the camshaft and camshaft position sensor may be out of specification. A modification was made to the plate area of the camshaft where the camshaft position sensor picks up the signal. Parts Information Repair Procedure/ Information Using a feeler (thickness) gauge, measure the gap between the camshaft and camshaft position sensor. The correct gap is between 0.15mm to 0.98mm (0.0059 to 0.0386 in.) If the gap is over 0.98mm (0.0386 in.) replace the camshaft position sensor. Refer to the applicable service manual. Warranty/Claim Information For vehicles within warranty, refer the Subaru Warranty Wizard for claim submission information. Page 1606 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 6305 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 2259 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 7421 R58-R69 Page 2764 B380-f6 Page 549 Refer to the illustrations above for more details on locating the appropriate sensors. The list shown above is of A/F Sensor related DTCs. (This list is for example only. Refer to the applicable service manual for a complete list of DTCs.) Note: When the DTCs for A/F sensor are stored in memory, do not replace the oxygen sensor. Page 5185 16) Using the ST1 and ST2, repair the cylinder's clinched sections. ST1 34099FA080 PUNCH ST2 34199FE020 BASE 17) If the cylinder edge is deformed in a convex shape, repair using an oil stone. 18) Remove the oil seal using ST and press from plug. ST 34199AE100 PLUG OIL SEAL REMOVER NOTE: Do not apply force on the plug edge surface. Page 1940 Water Pump: Service and Repair Water Pump Removal 1. Remove the radiator. 2. Remove the V-belts. 3. Remove the timing belt. 4. Remove the automatic belt tension adjuster (A). 5. Remove the belt idler (B). 6. Remove the belt idler No. 2 (C). Page 3462 B17-B20 Page 7108 7. Operate the power window switch to move the glass to position shown in the figure, and then remove the two nuts from service holes. 8. Take out the door glass. CAUTION: Do not turn the regulator in closing direction after removal of the glass. Otherwise gear may be disengaged. - Avoid impact and damage to the glass. INSTALLATION 1. Install in the reverse order of removal. CAUTION: Make sure the slider (front) and roller (rear) of glass is placed securely in sash. 2. Adjust the front door glass. Tightening torque: Nm (kgf-m, ft-lb) T1: 7.4 (0.75, 5.5) T2: 13.7 (1.4, 10.1) Page 5120 3) Follow the wheel alignment gauge operation manual to measure camber angle. NOTE: Refer to the "SPECIFICATION" for camber values. Front: Rear: ^ Front Camber Adjustment 1) Loosen the two self-locking nuts located at lower front portion of strut. NOTE: When adjusting bolt needs to be loosened or tightened, hold its head with a wrench and turn self-locking nut. 2) Turn the camber adjusting bolt so that camber is set at the specification. NOTE: Moving the adjusting bolt by one scale graduation changes camber by approximately 0°10'. Page 6851 Parking Lamp: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Engine Controls - DTC P0340/P0345 After Camshaft R & R Camshaft Position Sensor: All Technical Service Bulletins Engine Controls - DTC P0340/P0345 After Camshaft R & R Number: 02-107-09 Date: 03/24/09 Applicability: 2004~06MY Baja 2.5L Turbo 2004~06MY Impreza 2.5L Turbo 2004~06MY Forester 2.5L Turbo 2004~06MY Legacy/Outback 2.5L Turbo SUBJECT: Intake Camshaft Replacement Introduction If you encounter a vehicle that has a CEL and P0340 or P0345 stored in memory immediately after replacing the intake camshaft(s), the air gap between the camshaft and camshaft position sensor may be out of specification. A modification was made to the plate area of the camshaft where the camshaft position sensor picks up the signal. Parts Information Repair Procedure/ Information Using a feeler (thickness) gauge, measure the gap between the camshaft and camshaft position sensor. The correct gap is between 0.15mm to 0.98mm (0.0059 to 0.0386 in.) If the gap is over 0.98mm (0.0386 in.) replace the camshaft position sensor. Refer to the applicable service manual. Warranty/Claim Information For vehicles within warranty, refer the Subaru Warranty Wizard for claim submission information. Page 7125 1. Disconnect the wiper deicer connector. (Model with wiper deicer) 2. Remove the cowl panel. 3. Remove the glass molding. 4. Tape the body side of circumference of windshield glass for protection. 5. Make a hole in adhesive layer using a drill or knife. 6. Pass the piano wire through hole, and attach securely both the piano wire ends to pieces of wood. 7. Pull the wire ends alternately to cut off the adhesive layer. CAUTION: Do not tightly pull the piano wire against the windshield glass edge. - Be careful not to damage the interior and exterior parts. - Do not cross piano wires. Otherwise they may be cut. - After removing the area near instrument panel, attach a protection plate to it. Use extreme care when removing. INSTALLATION 1. Clean the external circumference of windshield glass with alcohol or white gasoline. 2. Remove the adhesive layer on the body using cutter knife to obtain smooth face 2 mm (0.08 in) thick. CAUTION: Be careful not to damage the body and paint surface. Page 814 Impact Sensor: Description and Operation IMPACT SENSOR OPERATION 1. IMPACT SENSOR SETTING USING SUBARU SELECT MONITOR 1. Connect the Subaru Select Monitor to data link connector. 2. Turn the ignition switch to ON. 3. Select {Keyless Unit} from the main menu. 4. Select {ECU customizing}. 5. Make a impact monitor setting. - When installing: ON - When removing: OFF 6. Make a impact monitor ON/OFF setting. - When installing: ON - When removing: OFF 7. Turn the ignition switch to OFF, and then remove the Subaru Select Monitor. Page 5126 NOTE: Thrust angle refers to a mean value of right and left rear wheel toe angles in relation to the vehicle body center line. Vehicle is driven straight in the thrust angle direction while swinging in the oblique direction depending on the degree of the mean thrust angle. Thrust angle: r = (a - B)/2 a: Right rear wheel toe-in angle B: Left rear wheel toe-in angle Here, use only positive toe-in values from each wheel to substitute for a and P in the equation. Page 6522 R72-R145 R148 Diagnostic Aids Speedometer Head: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Service and Repair Air Bypass Valve: Service and Repair Air By-pass Valve REMOVAL 1. Remove the air by-pass valve from intercooler. 2. Disconnect the air by-pass hoses from air bypass valve. INSTALLATION Install in the reverse order of removal. NOTE: Do not let the O-ring bite. Testing and Inspection Hose/Line HVAC: Testing and Inspection Hose and Tube INSPECTION NOTE: If cracking, damage, or swelling is found on a hose, replace it with a new one. Page 4390 B230-B283 Page 4490 Brake Pedal Assy: Service and Repair Brake Pedal REMOVAL 1. MT MODEL 1. Remove the steering shaft. 2. Disconnect the connectors (for stop light switch, etc.) from pedal bracket. 3. Remove the clevis pin which secures the lever to push rod. 4. Remove the nut which secures the clutch master cylinder. 5. Remove the accelerator pedal. 6. Remove the bolts and nuts which the secure pedal bracket. 2. AT MODEL 1. Disconnect the ground cable from battery. 2. Remove the instrument panel lower cover from instrument panel. 3. Remove the clevis pin which secures the brake pedal to brake booster operating rod. Also disconnect the stop light switch connector. 4. Remove the four bolts and four nuts which secure the brake pedal to pedal. INSTALLATION 1. Install in the reverse order of removal. CAUTION: ^ If the cable clamp is damaged, replace it with a new one. ^ Never fail to cover the outer cable end with boot. ^ Always use new clevis pins. 2. Adjust the clutch pedal 3. Inspect the brake pedal after installation Testing and Inspection Leak Detection Solenoid: Testing and Inspection INSPECTION Make sure the hoses are not cracked or loose. Page 1638 Crankshaft Gear/Sprocket: Service and Repair Crank Sprocket REMOVAL a. Remove the V-belt. b. Remove the crank pulley. c. Remove the timing belt cover. d. Remove the timing belt. e. Remove the crank sprocket. INSTALLATION a. Install the crank sprocket. b. Install the timing belt. c. Install the timing belt cover. d. Install the crank pulley. e. Install the V-belt. INSPECTION a. Check the crank sprocket teeth for abnormal wear and scratches. b. Make sure there is no free play between crank sprocket and key. c. Check the crank sprocket notch used for sensor for damage and contamination of foreign matter. Diagram Information and Instructions Sunroof / Moonroof: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 5343 Tightening torque: T: 7.4 N.m (0.75 kgf-m, 5.4 ft-lb) Page 1651 5. After ensuring that the marks on the timing belt and sprockets are aligned, remove the stopper pin from tensioner adjuster. 6. Install the timing belt guide. (MT model) CAUTION: ^ Before installing the bolts, clean the threaded portion of timing belt cover. ^ Apply liquid gasket to the threaded portion of bolts. (Cam sprocket side only) Liquid gasket. THREE BOND 1324 (Part No. 004403042) or equivalent 1. Temporarily tighten the bolts. 2. Check and adjust the clearance between timing belt and timing belt guide. Clearance: 1.0 ± 0.5 mm (0.039 ± 0.020 inch) Page 5202 OIL LEAKING 1) Lift up the vehicle. 2) Even if the location of the leak can be easily found by observing the leaking condition, it is necessary to thoroughly remove the fluid from the suspected portion and turn the steering wheel from lock to lock about thirty to forty times with engine running, then make comparison of the suspected portion between immediately after and several hours after this operation. 3) Inspect leakage from "a". The oil seal is damaged. Replace the valve assembly with a new one. 4) Inspect leakage from "b". The torsion bar O-ring is damaged. Replace the valve assembly with a new one. 5) Inspect leakage from "c". The oil seal is damaged. Replace the valve assembly or oil seal with a new one. 6) Inspect leakage from "d". The pipe is damaged. Replace the faulty pipe or O-ring. 7) Inspect leakage from "g". The hose is damaged. Replace the hose with a new one. 8) If leak is other than a, b, c, d, or g, and if oil is leaking from the gearbox, move the right and left boots toward tie-rod end side, respectively, with the gearbox mounted to the vehicle, and remove fluid from the surrounding portions. Then, turn the steering wheel from lock to lock thirty to forty times with the engine running, then make comparison of the leaked portion immediately after and several hours after this operation. (1) Leakage from "e" The cylinder seal is damaged. Replace the rack bushing with a new one. (2) Leakage from 'T' There are two possible causes. Take the following step first. Remove the pipe assembly B from the valve housing, and close the circuit with ST. ST 926420000 PLUG Turn the steering wheel from lock to lock thirty to forty times with the engine running, then make comparison of the leaked portion between immediately after and several hours after this operation. ^ If leakage from 'T' is noted again: The oil seal of pinion and valve assembly is damaged. Replace the pinion and valve assembly with a new one. Or replace the oil seal and parts that are damaged during disassembly with new ones. Page 2655 Engine Control Module (ECM) I/O Signal (Part 3) Page 3121 11) Remove the clamp, and then remove the shift lock solenoid. INSTALLATION Install in the reverse order of removal. INSPECTION Step 1 - Step 4 Page 6489 B380-f6 Page 5198 38) After installing, check the boot end is positioned into groove on tie-rod. 39) If the tie-rod end was removed, screw in the lock nut and tie-rod end to screwed portion of tie rod, and then tighten the lock nut temporarily in a position as shown in the figure. Installed tie-rod length L: Sedan: 25 mm (0.98 inch) Wagon: 15 mm (0.59 inch) 40) Inspect the gearbox as follows: "A" Holding the tie-rod end, repeat lock to lock two or three times as quickly as possible. "B" Holding the tie-rod end, turn it slowly at a radius one or two times as large as possible. After all, make sure that the boot is installed in specified position without deflation. 41) Remove the gearbox from ST. ST 926200000 STAND 42) Install the four pipes on gearbox. (1) Connect the pipe A and B to gearbox. Tightening torque: Housing side 20 Nm (2.0 kgf-m, 14.5 ft. lbs.) Cylinder side 24 Nm (2.4 kgf-m, 17.4 ft. lbs.) (2) Connect the pipe G and H to gearbox. Tightening torque: 15 Nm (1.5 kgf-m, 10.8 ft. lbs.) Locations Manifold Pressure/Vacuum Sensor: Locations Sensor (Part 1) Page 714 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 5424 11. Turn the ignition key to ON position, and run the blower at high speed for 1 minute. Stop the blower to check the ventilation grille on the instrument panel. While moving the tester closer to the grille, run the blower for 1 or 2 seconds, then stop it. Check the grille at that point for at least 10 seconds. 12. Check the valve in the service port. 13. Visually check the rubber seal in service port cap. Page 1317 Page 4338 Transmission Speed Sensor: Service and Repair Rear Vehicle Speed Sensor Rear Vehicle Speed Sensor REMOVAL 1) Set the vehicle on a lift, and then lift-up the vehicle. 2) Disconnect the connector from rear vehicle speed sensor. ^ MP-T model MP-T model ^ VTD model VTD model 3) Remove the rear vehicle speed sensor. ^ MP-T model MP-T model ^ VTD model Page 6475 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 4492 4. Remove the brake pedal pad. ASSEMBLY 1. Attach the stop light switch, etc. to pedal bracket temporarily. 2. Clean the inside of bores of clutch pedal and brake pedal, apply grease, and set the bushings into bores. 3. Align bores of the pedal bracket, clutch pedal and brake pedal, attach the brake pedal return spring, and then install the pedal bolt. NOTE: Clean up the inside of bushings and apply grease before installing spacer. Tightening torque: T. 30 Nm (3.1 kgf-m, 22.1 ft. lbs.) 4. Adjust the stop light switch position after installing the brake pedal to vehicle. INSPECTION 1. Move the brake and clutch pedal pads in the lateral direction with a force of approximately 10 Nm (1 kgf, 2 ft. lbs.) to ensure pedal deflection is in specified range. CAUTION: If excessive deflection is noted, replace the bushings with new ones. Deflection of brake and clutch pedal. Service limit 5.0 mm (0. 197 inch) or less Page 752 Disclaimer Page 2643 B230-B283 Page 4719 CAUTION: If external force is applied from above when the brake booster is placed in this position, the resin portion as indicated by "P", may be damaged. INSTALLATION 1. Adjust the operating rod of brake booster. Standard L: 144.6 mm (5.69 inch) If it is not within specified value, adjust it by adjusting the brake booster operating rod. 2. Mount the brake booster in position. 3. Connect the operating rod to brake pedal with clevis pin and snap pin. Locations Crankshaft Position Sensor: Locations Sensor (Part 1) Page 4663 Parking Brake Cable: Service and Repair Parking Brake Cable REMOVAL 1) Lift up the vehicle. 2) Remove the rear wheels. 3) Remove the rear seat cushion. 4) Remove the console box. 5) Loosen the parking cable adjusting nut and console bracket. 6) Remove the parking brake lever. 7) Roll up the floor mat and remove clamps. 8) Remove the equalizer cover. 9) Remove the inner cable end from equalizer. 10) Remove the parking brake cable from rear brake. 11) Remove the clamp from rear brake. 12) Remove the bolt and bracket from trailing link bracket. 13) Remove the bolt and clamp from rear floor. Page 4914 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 3144 B380-f6 Page 1952 Catalytic Converter: Service and Repair Rear Catalytic Converter Rear Catalytic Converter REMOVAL 1. Remove the center exhaust pipe. 2. Separate the rear catalytic converter (B) from front catalytic converter (A). INSTALLATION NOTE: - Replace the gaskets with new ones. - Install in the reverse order of removal. Page 7072 B3-B12 Page 2352 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 6318 B136-B141 Page 1983 2. Remove the rubber cushions, and detach the muffler. CAUTION: Be careful not to drop the muffler during removal. NOTE: To facilitate removal, apply a coat of spray type lubricant to the mating area of rubber cushions in advance. INSTALLATION Install in the reverse order of removal. NOTE: Replace the gasket and self-locking nut with a new one. Tightening torque: 48 Nm (4.9 kgf-m, 35.4 ft. lbs.) INSPECTION 1. Make sure there are no exhaust leaks from connections and welds. 2. Make sure there are no holes or rusting. 3. Make sure the cushion rubber is not worn or cracked. Page 6439 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Specifications Wheel Bearing: Specifications Subaru does not specify a wheel bearing grease. Page 5523 Additional labels are available through the Customer Dealer Services Department (CDS). CLAIM REIMBURSEMENT AND ENTRY PROCEDURES Credit to perform this recall will be based on the submission of properly completed repair order information. Dealers may enter the applicable claim information through their Dealer Communications System. Inspect - Use the applicable claim submission information for inspection of passenger front seat wire harness. Repair Wiring - Use the additional claim submission information for repair of the passenger front seat wire harness. Disclaimer Service and Repair Gear Sensor/Switch: Service and Repair Switches and Harness REMOVAL 1. BACK-UP LIGHT AND NEUTRAL POSITION SWITCH 1) Disconnect the ground cable from battery. 2) Remove the air intake duct and cleaner case. (Non-turbo model) 3) Remove the intercooler. (Turbo model) 4) Disconnect the connector of back-up light switch and neutral position switch. ^ Non-turbo model Non-turbo model ^ Turbo model Turbo model 5) Lift-up the vehicle. 6) Remove the back-up light switch and neutral position switch with harness. INSTALLATION Page 5071 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 6995 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 6012 4. Remove the screws to remove console cover. 5. Remove the screws. 6. Remove the hook pawl of console side panel to remove console box. INSTALLATION Install in the reverse order of removal. Page 4463 15) Read values indicated on the pressure gauges and check if they meet the standard value. 16) After checking, remove the pressure gauges from caliper bodies. 17) Connect the air bleeder screws to RL and RR caliper bodies. 18) Bleed air from the brake system. CHECKING THE HYDRAULIC UNIT ABS OPERATION WITH BRAKE TESTER 1) In the case of non-turbo AT model, install a spare fuse with the FWD connector in the main fuse box to simulate FWD model. NOTE: The AWD circuit of MT and turbo AT model can not be disabled. 2) Prepare for operating the ABS sequence control. 3) Set the front wheels or rear wheels on the brake tester and set the select lever's position at "N" range. 4) Operate the brake tester. 5) Perform the ABS sequence control. 6) Hydraulic unit begins to work; and check the following working sequence. (1) The FL side performs decompression, holding and compression in sequence, and subsequently the FR side repeats the cycle. (2) The RR side performs decompression, holding and compression in sequence, and subsequently the AL side repeats the cycle. Page 5223 REAR BUSHING 1) Install the rear bushing to transverse link, and then align the aligning marks scribed on the two. 2) Tighten the new self-locking nut. NOTE: While holding the rear bushing so as not to change position of aligning marks, tighten the self-locking nut. Tightening torque: 190 Nm (19.4 kgf-m, 140 ft. lbs.) INSPECTION 1) Check the transverse link for wear, damage and cracks, and correct or replace if defective. 2) Check the bushings for large cracks, fatigue or damage. 3) Check the rear bushing for oil leaks. Page 3763 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 548 Page 3625 B136-B141 Page 2740 The list shown above is of A/F Sensor related DTCs. (This list is for example only. Refer to the applicable service manual for a complete list of DTCs.) Note: When the DTCs for A/F sensor are stored in memory, do not replace the oxygen sensor. The list above is of O2 Sensor related DTCs. (This list is for example only. Refer to the applicable service manual for a complete list of DTCs.) Note: When the DTCs for O2 sensor are stored in memory, do not replace the A/F sensor. Identification Oxygen Sensor: Locations Identification This article was updated by bulletin number: 11-92-08 Date: 01/05/09 APPLICABILITY: 1999MY and later Forester 1999MY and later Impreza 2000MY and later Legacy 2006MY and later Tribeca SUBJECT: Air/Fuel Ratio Sensor and Oxygen Sensor INTRODUCTION For information purposes only. REPAIR/SERVICE INFORMATION When performing diagnostics or reading Diagnostic Trouble Codes (DTC) for Air Fuel Ratio (A/F) sensors and Oxygen (O2) sensors use the following information to identify, locate and repair the appropriate sensor and sensor circuits: (1) Rarely will multiple sensors fail at the same time. (2) On vehicles with only one O2 sensor, the designation for that O2 sensor will be bank 1. (3) On vehicles with only one A/F sensor, the designation for that A/F sensor will be bank 1. (4) Any reference to sensor 1 is an A/F sensor. (5) Any reference to sensor 2 is an O2 sensor. (6) Early PZEV vehicles used an additional O2 sensor behind the rear catalyst and is designated sensor 3. (7) On vehicles with A/F and O2 sensors on the right (Passenger Side) and left (Driver side) of the vehicle, Bank 1 is the right side (Passenger Side) and Bank 2 is the left side (Driver side). Example: DTC P0030 HO2S HEATER CONTROL CIRCUIT (Bank 1 Sensor 1). This DTC is referring to the A/F sensor and since it is on a 2007 Forester there is only one A/F sensor and one O2 sensor. Example (as illustrated): DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (Bank 1 Sensor 2). This DTC is referring to the O2 sensor on the right side exhaust (or the O2 sensor of a vehicle with only one O2 sensor). Page 4081 16) Lower the AT jack. NOTE: Do not separate the AT jack and transmission. 17) Remove the oil cooler inlet and outlet pipe. NOTE: When removing the outlet pipe, be careful not to lose balls and springs used with retaining screws. 18) Remove the front and torque converter turbine speed sensor. 19) Disconnect the connector of rear vehicle speed sensor. (VTD model) 20) Disconnect the connector from rear vehicle speed sensor. (MP-T model) Page 186 B292-B317 Page 580 B230-B283 Page 4384 B3-B12 Page 253 Wiper Relay: Service and Repair WIPER CONTROL RELAY REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the right quarter lower trim. 3. Loosen the nut to remove control unit. INSTALLATION Install in the reverse order of removal. Page 7368 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 787 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 1491 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 2890 Disclaimer Diagram Information and Instructions Brake Warning Indicator: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 1831 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 6632 F61-R47 Page 3106 R58-R69 Page 2943 B380-f6 Locations Electrical Components Location Page 6536 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 2183 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 582 B380-f6 Page 3559 B128-B134 Page 4438 Clutch Pedal Position Sensor / Switch: Description and Operation OPERATION STARTER INTERLOCK MECHANISM When the clutch pedal is fully depressed, the stopper on the pedal pushes the clutch switch push rod inwards. When the pushrod is pressed in, the switch turns ON and connects the ignition switch to the starter circuit enabling engine start. Schematic Drawings Page 5534 Additional labels are available through the Customer Dealer Services Department (CDS). CLAIM REIMBURSEMENT AND ENTRY PROCEDURES Credit to perform this recall will be based on the submission of properly completed repair order information. Dealers may enter the applicable claim information through their Dealer Communications System. Inspect - Use the applicable claim submission information for inspection of passenger front seat wire harness. Repair Wiring - Use the additional claim submission information for repair of the passenger front seat wire harness. Disclaimer Page 1472 B136-B141 Page 6317 B134-B136 Page 4813 Inspect the stator coil for continuity between stator core and each end of lead wire. If resistance is 1 ohm or less, the stator coil is grounded, and so replace the stator assembly. 4. BRUSH 1. Measure the length of each brush. If wear exceeds the service limit, replace the brush. Each brush has the service limit mark (A) on it. Brush length: Standard: 18.5 mm (0.728 in) Service limit: 5.0 mm (0.197 in) 2. Checking brush spring for proper pressure Using a spring pressure indicator, push the brush into the brush holder until its tip protrudes 2 mm (0.08 in). Then measure the pressure of brush spring. If the pressure is less than 2.648 N (270 g, 9.52 oz), replace the brush spring with a new one. The new spring must have a pressure of 4.609 to 5.786 N (470 to 590 g, 16.58 to 20.810 oz). 5. BEARING (FRONT SIDE) Check the front ball bearing. If the resistance is felt while rotating, or if abnormal noise is heard, replace the ball bearing. Testing and Inspection Parking Brake Lever: Testing and Inspection Parking Brake Lever INSPECTION While pulling the parking brake lever upward, count the notches. Lever stroke: 7 to 8 notches when pulled with a force of 196 N (20 kgf, 44 lbs.) If not as specified, adjust the parking brake. Page 2730 Page 2120 B136-B141 Page 1603 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 6252 Brake Switch (Cruise Control): Testing and Inspection INSPECTION Measure the brake switch (A) and stop light switch (B) resistance. If NG, replace the stop light and brake switch. Page 6310 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 2988 B3-B12 Page 4022 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 6226 Brake Switch (Cruise Control): Testing and Inspection INSPECTION Measure the brake switch (A) and stop light switch (B) resistance. If NG, replace the stop light and brake switch. Steering Gearbox Removal Steering Gear: Service and Repair Steering Gearbox Removal Steering Gearbox REMOVAL 1) Set the vehicle on a lift. 2) Disconnect the ground cable from battery. 3) Loosen the front wheel nut. 4) Lift-up the vehicle, and then remove the front wheels. 5) Remove the under cover. 6) Remove the sub frame. 7) Remove the front exhaust pipe assembly. (Non-turbo model) WARNING: Be careful, the exhaust pipe is hot. 8) Using a puller, remove the tie-rod end from knuckle arm after pulling off cotter pin and removing castle nut. 9) Remove the jack-up plate and front stabilizer. 10) Remove the one pipe joint at center of gearbox, and connect vinyl hose to pipe and joint. Discharge fluid by turning the steering wheel fully clockwise and counterclockwise. Discharge fluid similarly from the other pipe. ^ Non-turbo model Page 4388 B134-B136 Page 808 Knock Sensor: Service and Repair Knock Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the intercooler. 3. Disconnect the knock sensor connector. 4. Remove the knock sensor from the cylinder block. INSTALLATION 1. Install the knock sensor to the cylinder block. Tightening torque: 24 N.m (2.4 kgf-m, 17.4 ft-lb) NOTE: Extraction area of the knock sensor cord must be positioned at a 60 degrees angle relative to the engine rear. Page 3107 R72-R145 R148 Page 7231 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Service and Repair Engine Mount: Service and Repair Engine Mounting ENGINE MOUNTING Removal 1. Remove the engine assembly. 2. Remove the engine mounting from engine assembly. Installation 1. Install in the reverse order of removal. Tightening torque: Engine mounting 35 Nm (3.6 kgf-m, 25.8 ft. lbs.) Inspection 1. Make sure there are no cracks or other damage. Page 1620 R58-R69 Page 6539 B3-B12 Page 1325 10. Install the tensioner bracket. Tightening torque: 24.5 Nm (2.5 kgf-m, 18.1 ft. lbs.) 11. Install the cam sprocket. 12. Install the timing belt. 13. Install the timing belt cover. 14. Install the crank pulley. 15. Install the V-belt. Inspection 1. Measure the bend, and repair or replace if necessary. Limit. 0.020 mm (0.0008 inch) 2. Check the journal for damage and wear. Replace if faulty. 3. Measure the outside diameter of camshaft journal. If the journal diameter is not within standard, check the oil clearance. 4. Measurement of the camshaft journal oil clearance a. Clean the bearing caps and camshaft journals. b. Place the camshafts on cylinder head. (Without installing the valve rocker.) c. Place a plastigauge across each of the camshaft journals. d. Gradually tighten the cap in at least two stages in alphabetical sequence shown in the figure, and then tighten to specified torque. Do not turn the camshaft. Tightening torque: T1: 9.75 Nm (1.0 kgf-m, 7.2 ft. lbs.) T2: 20 Nm (2.0 kgf-m, 14.8 ft. lbs.) Page 2272 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 6928 Trunk Lamp Switch: Testing and Inspection Trunk Room Light Switch TRUNK ROOM LIGHT SWITCH Measure the resistance between trunk room light switch terminals. Page 4296 11) Remove the rod from joint. 12) Remove the cushion rubber from body. 13) Extract the spring pin, and then remove the joint. 14) Lower the vehicle. Page 6508 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 6282 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 4370 11) Remove the clamp, and then remove the shift lock solenoid. INSTALLATION Install in the reverse order of removal. INSPECTION Step 1 - Step 4 Page 3096 B17-B20 Page 3536 Crankshaft Position, Camshaft Position And Knock Sensors Page 942 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 6879 Horn Relay: Testing and Inspection HORN RELAY INSPECTION Measure the horn relay resistance between terminals (indicated in table) when connecting the terminal No. 4 to battery positive terminal and terminal No. 3 to battery ground cable. Diagram Information and Instructions Power Window Switch: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 1572 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 7372 B17-B20 Page 6258 Clutch Switch: Testing and Inspection CLUTCH SWITCH INSPECTION Measure the clutch switch resistance. If NG, replace the clutch switch. Recall 07V043000: Occupant Sensor Wiring Harness Seat Occupant Sensor: All Technical Service Bulletins Recall 07V043000: Occupant Sensor Wiring Harness MAKE/MODELS: MODEL/BUILD YEARS: Subaru/Forester 2006 Subaru/Impreza 2006 MANUFACTURER: Subaru of America, Inc. NHTSA CAMPAIGN ID NUMBER: 07V043000 MFG'S REPORT DATE: February 06, 2007 COMPONENT: Air Bags: Frontal POTENTIAL NUMBER OF UNITS AFFECTED: 7004 SUMMARY: On certain vehicles, the wiring harness for the air bag occupant detection system in the front passenger seat may have been pinched during production. Pinching of the wiring harness between the floor crossmember and the seat mounting bracket could result in a short circuit. CONSEQUENCE: The passenger's front air bag could become disabled and may not deploy in the event of a crash increasing the risk of injury to the seat occupant. Also an electrical short circuit could cause a fire. REMEDY: Dealers will inspect to see if the wiring had been incorrectly routed under the seat bracket. If so, the dealer will repair any damaged wiring, reroute and secure the wiring harness in the correct location, and re-calibrate the occupant detection system as necessary. The recall is expected to begin on or about March 5, 2007. Owners may contact Subaru at 1-800-782-2783. NOTES: Subaru recall No. WVC-13. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Locations Horn Relay: Locations Main Fuse Box (M/B) Security System Page 722 B136-B141 Page 560 Page 1453 14. Install the intercooler. 15. Install the air intake boot and air cleaner upper cover. 16. Connect the connector to mass air flow and intake air temperature sensor. 17. Install the front wheels. 18. Connect the battery ground cable to battery. 19. Fill engine oil. Inspection 1. By visual check, make sure the oil pan, oil strainer, oil strainer stay and baffle plate are not damaged. Page 6481 B3-B12 Page 6463 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 5084 R58-R69 Page 6511 B17-B20 Page 970 Windshield Washer Switch: Service and Repair COMBINATION SWITCH (WIPER) REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the instrument panel lower cover. 3. Loosen the screw to remove steering column cover lower. 4. Remove the screw to steering column cover upper. 5. Disconnect the connectors from combination switches. 6. Loosen the screw to remove combination switch. INSTALLATION Install in the reverse order of removal. Page 449 B134-B136 Locations Fuel Temperature Sensor: Locations Page 2333 R72-R145 R148 Page 2510 Compression Check: Testing and Inspection Compression Inspection CAUTION: After warming-up, engine becomes very hot. Be careful not to burn yourself during measurement. 1. After warming-up the engine, turn the ignition switch to OFF. 2. Make sure that the battery is fully charged. 3. Release the fuel pressure. 4. Remove all the spark plugs. 5. Fully open the throttle valve. 6. Check the starter motor for satisfactory performance and operation. 7. Fix the compression gauge securely against spark plug hole. NOTE: The screw of screw-in type compression gauge (put into cylinder head spark plug hole) should be less than 18 mm (0.71 inch) long. 8. Crank the engine by means of starter motor, and then read the maximum value on the gauge when the gauge needle is steady. 9. Perform at least two measurements per cylinder, and make sure that the values are correct. Compression (at 200 - 300 rpm): Standard ............................................................................................................................................... 981 1,177 kPa (10 - 12 kgf/cm2, 142 - 171 psi) Difference between cylinders 2 Less than ........................................................................................... ..................................................................................... 49 kPa (0.5 kgf/cm2, 7 psi) Page 242 B230-B283 Page 692 F21-F61 Page 5750 Keyless Entry Module: Service and Repair KEYLESS ENTRY CONTROL UNIT REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the instrument panel lower cover. 3. Remove the nut, and then remove the keyless entry control unit while disconnecting connector. 4. Disconnect the keyless entry control unit and other electrical control module. INSTALLATION Install in the reverse order of removal. Capacity Specifications Refrigerant Oil: Capacity Specifications Compressor Oil REPLACEMENT NOTE: - If a component is replaced, add an appropriate amount of compressor oil. - When replacing the compressor, the new compressor will already have the specified amount of oil in it. Install the new compressor after removing the same amount of oil that is remaining in the compressor removed. Page 2245 B17-B20 Page 6617 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 164 Main Relay (Computer/Fuel System): Service and Repair Main Relay REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the passenger's side front side sill cover. 3. Remove the bolt which holds the relay bracket on the body. 4. Disconnect the connectors from the main relay. 5. Remove the main relay from the mounting bracket. INSTALLATION Install in the reverse order of removal. Page 4517 F61-R47 Page 3985 VTD model INSTALLATION Install in the reverse order of removal. NOTE: Replace with a new O-ring. Tightening torque: 7 Nm (0. 7 kgf-m, 5. 1 ft. lbs.) Page 6291 B380-f6 Page 2649 R72-R145 R148 Page 7420 F61-R47 Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 5500 Repairs and Inspections Required After a Collision: Service and Repair Seat Belt System INSPECTION LOCATIONS AFTER A COLLISION INSPECTION Check for the following, and then replace with new parts if necessary. - Center pillar lower garnish is discolored or cracked. - Wire harness and/or connector is damaged. Page 29 Keyless Entry Module: Service and Repair KEYLESS ENTRY CONTROL UNIT REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the instrument panel lower cover. 3. Remove the nut, and then remove the keyless entry control unit while disconnecting connector. 4. Disconnect the keyless entry control unit and other electrical control module. INSTALLATION Install in the reverse order of removal. Page 4566 3. Install the pads on support. 4. Install the caliper body on support. Tightening torque: 26.5 Nm (2.7 kgf-m, 19.5 ft. lbs.) NOTE: If it is difficult to push the piston during pad replacement, loosen the air bleeder screw to facilitate work. 2. 16 INCH TYPE 1. Apply thin coat of Molykote AS-880N (Part No. K0777YA010) to the frictional portion between pad and pad inner shim. 2. Install the pads on caliper body. 3. Install the pad pin on caliper body. 4. Install the M clip. 5. Install the cross spring. 3. 17 INCH TYPE 1. Apply thin coat of Molykote AS-880N (Part No. K0777YA010) to the frictional portion between pad and pad shim. 2. Install the pads on caliper body. 3. Install the cross spring. 4. Install the pad pins. 5. Install the clip. INSPECTION 1. 15 INCH TYPE Check the pad thickness A. Page 6211 Tailgate Latch: Service and Repair REAR GATE LATCH ASSEMBLY REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the rear gate trim. 3. Remove three bolts. 4. Disconnect the connectors, and then remove the rear gate latch assembly. INSTALLATION Install in the reverse order of removal. NOTE: Make sure the lock works properly after installation. Page 4954 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Wheels/Tires - Wheel Lock Installation/Removal Wheel Fastener: Technical Service Bulletins Wheels/Tires - Wheel Lock Installation/Removal NUMBER: 15-125-07 DATE: 08/29/07 APPLICABILITY: All Vehicles SUBJECT: Subaru Wheel Locks Introduction The purpose of this bulletin is to provide the proper procedure for removing and installing Subaru wheel locks. Failure to follow this procedure can cause damage to the wheel locks and/or wheels. Repair Procedure/Information 1) Remove one lug nut from each wheel. If wheel studs are dirty, clean with a wire brush prior to installing locks. Use extreme care to prevent damage to the wheel. 2) By hand, install one wheel lock on each wheel. 3) Using the special wheel lock key and a torque wrench, tighten each wheel lock to the proper lug nut torque specification (refer to the applicable Subaru Service Manual). NOTE: For ease of installation and removal, the wheel lock should always be the last lug nut tightened on each wheel and should always be the first one removed. WARNING: Use of an impact wrench may cause permanent damage to the wheel lock and key. Warranty Information Wheel locks and/or keys that are damaged due to improper installation and/or removal is not a matter for warranty. Disclaimer Page 2110 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 1919 B292-B317 Page 2036 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 6493 R72-R145 R148 Page 1960 Turbo model Page 1885 Radiator Cap: Testing and Inspection Radiator Cap Inspection 1. Attach the radiator cap to tester. 2. Increase the pressure until tester gauge pointer stops. Radiator cap is functioning properly if it holds the service limit pressure for 5 to 6 seconds. Coolant Filler Tank Side Standard pressure: .................................................................................................................................. 93 - 123 kPa (0.95 - 1.25 kgf/cm2, 14 - 18 psi) Service limit pressure: ....................................................................................................................................................... 83 kPa (0.85 kgf/cm2, 12 psi) Radiator Side Standard pressure: ............................................................................................................................... 1.22 - 152 kPa (1.24 - 1.55 kgf/cm2, 18 - 22 psi) Service limit pressure: .................................................................................................................................................... 112 kPa (1.14 kgf/cm,2, 16 psi) CAUTION: ^ Be sure to remove foreign matter and rust from the cap in advance. Otherwise, results of pressure test will be incorrect. ^ Do not mix up the coolant filler tank side cap with radiator side cap. Page 5032 B380-f6 Page 822 Impact Sensor: Service and Repair Impact Sensor IMPACT SENSOR REMOVAL 1. Remove the key from ignition switch. 2. Close all the doors, trunk lid and rear gate. 3. Press the UNLOCK button of transmitter. 4. Change the setting of impact sensor using Subaru Select Monitor. 5. Disconnect the ground cable from battery. 6. Remove the impact sensor. INSTALLATION 1. Remove the key from ignition switch. 2. Close all the doors, trunk lid and rear gate. 3. Press the UNLOCK button of transmitter. 4. Disconnect the ground cable from battery. 5. Install the impact sensor. 6. Connect the battery ground cable to battery. 7. Change the setting of impact sensor using Subaru Select Monitor. Page 2395 B380-f6 Page 807 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 3851 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 2131 Air Flow Meter/Sensor: Service and Repair Mass Air Flow and Intake Air Temperature Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the connector from mass air flow and intake air temperature sensor. 3. Remove the mass air flow and intake air temperature sensor. INSTALLATION Install in the reverse order of removal. Tightening torque: 1.7 N.m (0.17 kgf-m, 1.3 ft-lb) Page 6713 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Rear Gate Latch Switch Tailgate Latch: Testing and Inspection Rear Gate Latch Switch REAR GATE LATCH SWITCH Measure the resistance between rear gate latch switch terminals. Specifications Clutch Fluid: Specifications Fluid Type ........................................................................................................................................................ FMVSS No. 116 DOT 3 or 4 Brake Fluid Page 7138 (1) Open the hood and remove the check valve. (2) Attach valve cushion (86634SA000) around the modified check valve (86634AG000) for soundproofing. Page 4678 (3) Drive the vehicle for about 200 meter (0.12 mile) in this condition. (4) Wait 5 to 10 minutes for the parking brake to cool down. Repeat this procedure once more. (5) After breaking-in, re-adjust the parking brakes. Page 6348 B17-B20 Page 2515 NOTE: If the measured value is not within specification, take notes of the value in order to adjust the valve clearance later on. 13. If necessary, adjust the valve clearance. 14. Further turn the crank pulley clockwise. Using the same procedures described previously, and then measure the valve clearances again. 1. Set the arrow mark on cam sprocket to position shown in the figure, and then measure the #2 cylinder exhaust valve and #3 cylinder intake valve clearances. 2. Set the arrow mark on cam sprocket to position shown in the figure, and then measure the #2 cylinder intake valve and #4 cylinder exhaust valve clearances. 3. Set the arrow mark on cam sprocket to position shown in the figure, and then measure the #1 cylinder exhaust valve and #4 cylinder intake valve clearances. 15. After inspection, install the related parts in the reverse order of removal. Tightening torque: 33 Nm (3.4 kgf-m, 25 ft. lbs.) Page 1464 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 3667 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 6265 Cruise Control Switch: Service and Repair CRUISE CONTROL COMMAND SWITCH REMOVAL WARNING: Before servicing, be sure to read the notes in the AB section for proper handling of the driver's airbag module. 1. Set the front wheels in straight ahead position. 2. Turn the ignition switch to OFF. 3. Disconnect the ground cable from battery and wait for at least 20 seconds before starting work. 4. Using the TORX BIT T30 (Tamper resistant type), loosen the two TORX® bolts which secure driver's airbag module. 5. Disconnect the airbag module connector on back of airbag module. 6. Remove the steering wheel. 7. Remove four screws, and then remove the lower cover from steering wheel. 8. Remove the screw, and then remove the cruise control command switch from lower cover. INSTALLATION Install in the reverse order of removal. Service and Repair Shift Interlock Solenoid: Service and Repair AT Shift Lock Solenoid and "P" Range Switch REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the console box. 3) Disconnect the connector. 4) Remove the grip. 5) Remove the indicator bulb from indicator cover. 6) Remove the indicator cover. 7) Remove the blind. 8) Remove the cushion. 9) Remove the clip, and then remove the "P" range switch. 10) Remove the cover. Locations Electrical Components Location Service and Repair Air Bag(s) Arming and Disarming: Service and Repair CAUTION: - When servicing a vehicle, be sure to turn the ignition switch to OFF, disconnect the ground cable from battery, and wait for more than 20 seconds before starting work. - The airbag system is fitted with a backup power source. If the airbag system is serviced within 20 seconds after the ground cable is disconnected, it may inflate. - If the airbag warning light illuminates, repair the vehicle immediately. Airbag or pretensioner may inflate incorrectly, or not inflate in collision. - If sensors, airbag module, airbag control module, pretensioner, and harness are deformed or damaged, replace them with new genuine parts. - When checking the airbag system, be sure to use a digital circuit tester. Infinitesimal electric current in an analog circuit tester may cause the airbag to activate erroneously. - When checking the airbag system, be sure to use a digital circuit tester. Infinitesimal electric current in an analog circuit tester may cause the airbag to activate erroneously. Page 111 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 7343 B230-B283 Page 2759 B128-B134 Page 1177 Fluid - M/T: Service and Repair Transmission Gear Oil Replacement Transmission Gear Oil REPLACEMENT 1) Pull out the oil level gauge. 2) Lift-up the vehicle. 3) Remove the drain plug using TORX BIT T70, and drain the transmission gear oil completely. CAUTION: Directly after the engine has been running, the transmission gear oil is hot. Be careful not to burn yourself. NOTE: Tighten the transmission drain plug after draining the transmission gear oil. 4) Lower the vehicle. 5) Pour gear oil into the gauge hole. Recommended gear oil: Use GL-5 (75W-90) or equivalent. Gear oil capacity: 3.5 liters (3.7 US quarts, 3.1 Imp quarts) 6) Check the level of the transmission gear oil. CAUTION: When inserting the level gauge into transmission gear, align the protrusion on the top end of level gauge with the notch in the gauge hole. NOTE: The level should be within the specified range marked on the gauge. Page 1056 7. Install the timing belt cover. 8. Install the crank pulley. 9. Install the V-belt. INSPECTION 1. TIMING BELT 1. Check the timing belt teeth for breaks, cracks, and wear. If any fault is found, replace the belt. 2. Check the condition of backside of timing belt; if any crack is found, replace the timing belt. CAUTION: ^ Be careful not to let oil, grease or coolant contact the timing belt. Remove quickly and thoroughly if this happens. ^ Do not bend the timing belt sharply. Bending diameter h: 60 mm (2.36 inch) or more 2. AUTOMATIC BELT TENSION ADJUSTER 1. Visually check the oil seals for leaks, and rod ends for abnormal wear or scratches. If necessary, replace the automatic belt tension adjuster assembly. NOTE: Slight traces of oil at rod's oil seal does not indicate a problem. 2. Check that the adjuster rod does not move when a pressure of 294 Nm (30 kgf, 66 ft. lbs.) is applied to it. This is to check adjuster rod stiffness. 3. If the adjuster rod is not stiff and moves freely when applying 294 Nm (30 kgf, 66 ft. lbs.), check it using the following procedures: 1. Slowly press the adjuster rod down to the end surface of the cylinder. Repeat this motion 2 or 3 times. 2. With the adjuster rod moved all the way up, apply a pressure of 294 Nm (30 kgf, 66 ft. lbs.) to it. Check the adjuster rod stiffness. 3. If the adjuster rod is not stiff and moves down, replace the automatic belt tension adjuster assembly with a new one. CAUTION: Always use a vertical type pressing tool to move the adjuster rod down. ^ Do not use a lateral type vise. ^ Push the adjuster rod vertically. ^ Press-in the push adjuster rod gradually taking more than 3 minutes. ^ Do not allow press pressure to exceed 9,807 Nm (1,000 kgf, 2,205 ft. lbs.). ^ Press the adjuster rod as far as the end surface of the cylinder. Do not press the adjuster rod into the cylinder. Doing so may damage the cylinder. 4. Measure the extension of rod beyond the body. If it is not within specifications, replace with a new one. Page 552 P Code List (Partial list) Page 6140 F21-F61 Page 3029 B136-B141 Page 1507 B292-B317 Page 6011 Console: Service and Repair CONSOLE BOX Console Box REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the console front panel. 3. Remove the shift knob (MT model). Page 3453 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 2534 B3-B12 Page 4536 7. Bleed air from the brake system. 2. 16 INCH TYPE 1. Install the caliper body on housing. Tightening torque: 80 Nm (8.2 kgf-m, 59 ft. lbs.) 2. Apply thin coat of Molykote AS-880N (Part No. K0777YA010) to the frictional portion between pad and pad inner shim. 3. Install the pads on caliper body. 4. Install the pad pin and cross spring on caliper body. 5. Install the M clip. 6. Replace the brake hose gaskets with new ones, and then connect the brake hose. Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft. lbs.) 7. Bleed air from the brake system. 3. 17 INCH TYPE 1. Install the caliper body assembly on housing. Tightening torque: 155 Nm (15.8 kgf-m, 114.3 ft. lbs.) 2. Apply thin coat of Molykote AS-880N (Part No. K0777YA010) to the frictional portion between pad and pad shim. 3. Install the pads on caliper body. 4. Install the cross spring. 5. Install the pad pins. 6. Install the clip. 7. Replace the brake hose gaskets with new ones, and then connect the brake hose. Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft. lbs.) 8. Bleed air from the brake system. DISASSEMBLY 1. 15 INCH TYPE 1. Clean mud and foreign particles from the caliper body assembly and support. CAUTION: Be careful not to allow foreign particles to enter the brake hose connector. 2. Place a wooden block in caliper body as shown in the figure to prevent the piston from jumping out and avoid being damaged. 3. Gradually supply compressed air via the installation hole of brake hose to force the piston out. Page 4548 7. Apply a coat of specified grease to the guide pin, outer surface, sleeve outer surface, cylinder inner surface, and boot grooves. Grease: NIGLUBE RX-2 (Part No. K0779GA 102) 8. Install the guide pin boot on support. 9. Install the lock pin boot on support, and then insert the lock pin sleeve into place. 2. 15 INCH TYPE 1. Clean the caliper body interior using brake fluid. 2. Apply a coat of brake fluid to the piston seal and fit piston seal in groove on caliper body. 3. Apply a coat of brake fluid to the entire inner surface of cylinder and outer surface of piston. 4. Apply a coat of specified grease to the boot and install it in the groove on piston. Grease: NIGLUBE RX-2 (Part No. K0779GA 102) 5. Insert the piston into cylinder. CAUTION: Do not force the piston into cylinder. 6. Install the piston boot to caliper body, and then attach boot ring. Page 3032 B380-f6 Page 3472 R58-R69 Page 4032 12) Move the transmission to right side, and then remove the stay bolt and reverse check cable. NOTE: If the transmission is not moved, the stay bolt will contact body and damage may occur. 13) Raise the clip of stay, and then separate the stay and reverse check cable. 14) Remove the reverse check cable by pulling from underneath the vehicle. NOTE: Take care not to damage the inner boot. 15) Loosen the lock nut, then remove the reverse check cable from cable plate. Page 2674 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor REMOVAL WARNING: - Place "NO FIRE" signs near the working area. - Be careful not to spill fuel. 1. Remove the fuel tank. 2. Remove the protector cover. 3. Disconnect the connector from fuel tank pressure sensor. 4. Release the clips which hold fuel pipes onto fuel tank. 5. Remove the bolt and nut which hold the fuel tank pressure sensor onto the bracket. Page 3502 Diagram Information and Instructions Oil Pressure Sender: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 1935 Page 3620 B3-B12 Page 4376 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Diagram Information and Instructions Power Window Switch: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 3598 R58-R69 Page 1048 Z1: 54.5 tooth length Z2: 51 tooth length Z3: 28 tooth length 6. Remove the belt idler (A). 7. Remove the timing belt. CAUTION: After the timing belt has been removed, never rotate the intake and exhaust, cam sprocket. If the cam sprocket is rotated, the intake and exhaust valve heads strike together and valve stems are bent. 2. BELT IDLER AND AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY 1. Remove the belt idler (B) and (c). Testing and Inspection Ignition Lock: Testing and Inspection IGNITION KEY LOCK INSPECTION 1. Remove the instrument panel lower cover. 2. Remove the lower column cover. 3. Unfasten the hold-down clip which secures harness and disconnect the connector of ignition switch from body harness. 4. Turn the ignition key plate to each position and check the continuity between terminals of ignition connector. If NG, replace the ignition switch. Page 2864 B136-B141 Page 6315 B54-B127 Service and Repair Gear Sensor/Switch: Service and Repair Switches and Harness REMOVAL 1. BACK-UP LIGHT AND NEUTRAL POSITION SWITCH 1) Disconnect the ground cable from battery. 2) Remove the air intake duct and cleaner case. (Non-turbo model) 3) Remove the intercooler. (Turbo model) 4) Disconnect the connector of back-up light switch and neutral position switch. ^ Non-turbo model Non-turbo model ^ Turbo model Turbo model 5) Lift-up the vehicle. 6) Remove the back-up light switch and neutral position switch with harness. INSTALLATION Page 1312 2. Install the timing belt. 3. Install the timing belt cover. 4. Install the crank pulley. 5. Install the V-belt. Inspection 1. Check the cam sprocket teeth for abnormal wear and scratches. 2. Make sure there is no free play between cam sprocket and key. Page 177 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 1905 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 2628 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Recall 07V043000: Occupant Sensor Wiring Harness Seat Occupant Classification Module - Air Bag: All Technical Service Bulletins Recall 07V043000: Occupant Sensor Wiring Harness MAKE/MODELS: MODEL/BUILD YEARS: Subaru/Forester 2006 Subaru/Impreza 2006 MANUFACTURER: Subaru of America, Inc. NHTSA CAMPAIGN ID NUMBER: 07V043000 MFG'S REPORT DATE: February 06, 2007 COMPONENT: Air Bags: Frontal POTENTIAL NUMBER OF UNITS AFFECTED: 7004 SUMMARY: On certain vehicles, the wiring harness for the air bag occupant detection system in the front passenger seat may have been pinched during production. Pinching of the wiring harness between the floor crossmember and the seat mounting bracket could result in a short circuit. CONSEQUENCE: The passenger's front air bag could become disabled and may not deploy in the event of a crash increasing the risk of injury to the seat occupant. Also an electrical short circuit could cause a fire. REMEDY: Dealers will inspect to see if the wiring had been incorrectly routed under the seat bracket. If so, the dealer will repair any damaged wiring, reroute and secure the wiring harness in the correct location, and re-calibrate the occupant detection system as necessary. The recall is expected to begin on or about March 5, 2007. Owners may contact Subaru at 1-800-782-2783. NOTES: Subaru recall No. WVC-13. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 593 7. Connect the connector of front oxygen (A/F)sensor. 8. Connect the battery ground cable to battery. Page 3000 R72-R145 R148 Page 575 B17-B20 Page 494 Fuel Level Sensor: Service and Repair Fuel Sub Level Sensor Fuel Sub Level Sensor REMOVAL WARNING: - Place "NO FIRE" signs near the working area. - Be careful not to spill fuel on the floor. 1. Disconnect the ground cable from battery. 2. Lift up the vehicle. 3. Drain the fuel from the fuel tank. 4. Remove the luggage floor mat. 5. Remove the service hole cover. 6. Disconnect the connector from the fuel sub level sensor. 7. Disconnect the fuel jet pump hose. 8. Remove the bolts which install the fuel sub level sensor on the fuel tank. Page 2973 Page 2116 B17-B20 Page 1203 Power Steering Fluid: Testing and Inspection Power Steering Fluid INSPECTION 1) Check the power steering fluid for deterioration or contamination. If the fluid is highly deteriorated or contaminated, drain it and refill with new fluid. 2) Check the joints and units for oil leakage. If any oil leaks are found, repair or replace the applicable part. 3) Inspect the fluid level on flat and level surface with engine "OFF" by indicator of reservoir tank. If the level is at MIN. point or below, add fluid to keep the level in the specified range of the indicator. If at MAX. point or above, drain fluid by using a syringe or the like. (1) Check at power steering fluid temperature 20°C (68°F); read the fluid level on the "COLD" side. (2) Check at power steering fluid temperature 80°C (176°F); read the fluid level on the "HOT" side. Page 6566 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 1610 B17-B20 Diagnostic Aids Alternator: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 4051 Shift Cable: Service and Repair Reverse Check Cable Reverse Check Cable REMOVAL 1) Set the vehicle on a lift. 2) Remove the gear shift knob. 3) Remove the console box front. 4) Remove the spring pin from slider. 5) Remove the slider and spring. 6) Cut the band clip, and then separate the reverse check cable from gearshift lever. 7) Lift-up the vehicle. 8) Remove the under cover. 9) Remove the rear exhaust pipe and muffler. 10) Remove the crossmember. 11) Remove the snap pin and washer, and then separate the reverse check cable from reverse check lever. Page 4543 Brake Caliper: Service and Repair Rear 5GRear Disc Brake Assembly REMOVAL 1. 14 INCH TYPE CAUTION: Do not allow brake fluid to come in contact with vehicle body; wash away immediately with water and wipe off completely if spilled. 1. Set the vehicle on a lift. 2. Loosen the wheel nuts. 3. Lift-up the vehicle, and then remove the wheels. 4. Disconnect the brake hose from caliper body assembly. 5. Remove the bolt securing lock pin to caliper body. 6. Raise the caliper body and move it toward vehicle center to separate it from support. 7. Remove the support from housing. NOTE: Remove the support only when replacing it or the disc rotor. It need not be removed when servicing the caliper body assembly. 8. Clean mud and foreign particles from the caliper body assembly and support. CAUTION: Be careful not to allow foreign particles to enter brake hose connector. 2. 15 INCH TYPE CAUTION: Do not allow brake fluid to come in contact with vehicle body; wash away at once with water and wipe off completely if spilled. 1. Set the vehicle on a lift. 2. Loosen the wheel nuts. 3. Lift-up the vehicle, and then remove the wheels. 4. Remove the pads from caliper body. 5. Disconnect the brake hose from caliper body assembly. 6. Remove the caliper body from housing. 7. Clean mud and foreign particles from the caliper body assembly. CAUTION: Be careful not to allow foreign particles to enter brake hose connector. 3. 17 INCH TYPE CAUTION: Do not allow brake fluid to come in contact with vehicle body; wash away immediately with water and wipe off completely if spilled. Page 131 R72-R145 R148 Page 3693 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the bolt which installs the crankshaft position sensor to cylinder block. 3. Remove the crankshaft position sensor, and disconnect the connector from it. INSTALLATION Install in the reverse order of removal. Immobilizer Control Unit Alarm Module: Service and Repair Immobilizer Control Unit IMMOBILIZER CONTROL UNIT REMOVAL NOTE: Prepare the security ID plate. - Prepare all registered immobilizer keys for the model with immobilizer. - Make a registration of immobilizer when replacing the immobilizer control unit. New immobilizer key is required for registration. For detailed operation procedure, refer to "IMMOBILIZER REGISTRATION MANUAL - If the keys are added without replacing the immobilizer control unit, maximum 4 keys can be registered including new keys. 1. Disconnect the ground cable from battery. 2. Remove the instrument panel lower cover. 3. Disconnect the connector from immobilizer control unit. 4. Remove the immobilizer control unit. INSTALLATION Install in the reverse order of removal. Page 3651 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 4796 Disclaimer Page 6406 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 5947 Trunk / Liftgate Lock: Service and Repair Trunk Lid KEY LOCK CYLINDERS REPLACEMENT TRUNK LID 1. Remove the trunk lid release handle. 2. Remove the rod clamp. Remove the lock plate. Replace the key cylinder. Locations Electrical Components Location Page 5250 2. Using the ST, press the rear bushing out of place. ST 927730000 INSTALLER & REMOVER SET ASSEMBLY FRONT BUSHING Using the ST, press the bushing into trailing link. ST 927720000 INSTALLER & REMOVER SET CAUTION: Turn the ST plunger upside down and press it until the plunger end surface contacts the trailing link end surface. Page 1799 R58-R69 Page 990 Turbo model and STI model: 85 Nm (8.6 kgf-m, 62.2 ft. lbs.) NOTE: Correct the tie-rod boot, if it is twisted. REAR WHEEL TOE-IN ^ Inspection Toe-in: 0±3 mm (0±0. 12 inch) (tolerance) For rear toe-in inspection procedure, refer to FRONT WHEEL TOE-IN procedure. ^ Adjustment 1) Loosen the self-locking nut on inner side of link rear. NOTE: When loosening or tightening the adjusting bolt, hold the bolt head and turn self-locking nut. 2) Turn the adjusting bolt head until toe-in is at the specification. Toe-in: 0±2 mm (0±0.08 inch) (adjustment standard) NOTE: When the right and left wheels are adjusted for toe-in at the same time, the movement of one scale graduation changes toe-in by approximately 1.5 mm (0.6 inch). Page 2807 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 2766 F61-R47 Page 3904 F61-R47 Page 5925 Hood Latch: Adjustments FRONT HOOD LOCK ASSEMBLY ADJUSTMENT Loosen the bolt. Adjust the front hood lock assembly while moving it up and down. Page 6598 8. Remove the bolts which install the fuel sub level sensor on the fuel tank. 9. Remove the fuel sub level sensor. INSTALLATION Install in the reverse order of removal. NOTE: Use a new gasket. 1. Ensure the sealing portion is free from fuel or foreign particles before installation. 2. Tighten the nuts and bolts to specified torque in order as shown in the figure. Page 5036 R72-R145 R148 Page 6308 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 4643 Hydraulic Control Assembly - Antilock Brakes: Service and Repair ABS Control Module and Hydraulic Control Unit (ABSCM&H;/U) REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the air intake duct and air cleaner case from the engine compartment to facilitate removal of ABSCM&H;/U. 3) Use compressed air to get rid of water around the ABSCM&H;/U. NOTE: Contact will be insufficient if the terminal gets wet. 4) Disconnect the ABSCM&H;/U connector pulling up the lock lever. CAUTION: Do not pull the harness when disconnecting connector. 5) Remove the harness clip. 6) Disconnect the brake pipes from ABSCM&H;/U. 7) Wrap the brake pipe using a vinyl bag not to spill the brake fluid on the vehicle body. CAUTION: When brake fluid is attached to the vehicle body, wash it off with water and wipe the water. 8) Remove the nuts and remove the ABSCM&H;/U. CAUTION: ^ Do not drop or bump the ABSCM&H;/U. ^ Do not turn ABSCM&H;/U upside down or place it sideways for storage. ^ Be careful that no foreign objects are mixed in ABSCM&H;/U. ^ Be careful that no water enters inside the connectors. 9) Remove the ABSCM&H;/U bracket. INSTALLATION 1) Install the ABSCM&H;/U bracket. Tightening torque:33 Nm (3.3 kgf-m, 24 ft. lbs.) 2) Install the ABSCM&H;/U aligning the groove of damper on ABSCM&H;/U side with the pawl of bracket. NOTE: Check the identification mark of ABSCM&H;/U. Tightening torque:7.5 Nm (0.76 kgf-m, 5.5 ft. lbs.) Page 4766 ^ Check the back-up light illumination when the select lever is in "R" range. ^ Check the parking lock operation when the select lever is in "F" range. 5) Using the Subaru Select Monitor, clear the diagnostic trouble codes stored in memory. If the codes return afier the correct adjustments, refer to the diagnostic procedure found in the applicable Subaru Service Manual. WARRANTY/CLAIM INFORMATION For vehicles within the Basic New Car Limited Warranty period, refer to the Subaru Warranty Wizard for claim submission information. Disclaimer Page 710 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 1463 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. M/T - Clutch Pedal Squeaking Noise Clutch Switch: Technical Service Bulletins M/T - Clutch Pedal Squeaking Noise CLUTCH PEDAL SQUEAK If you encounter a manual transmission equipped vehicle with a clutch pedal squeak concern, and lubricating the pedal mechanism didn't fix the noise, check the clutch switch. We have had a few reports where this has been the source of the problem. The fix is to replace the clutch pedal switch. Testing and Inspection Headlamp Alignment Switch: Testing and Inspection HEADLIGHT BEAM LEVELER SYSTEM HEADLIGHT BEAM LEVELER SWITCH Measure the resistance between headlight beam leveler switch terminals. Page 2975 P Code List (Partial list) Page 3948 3) Connect ATF cooler hose to pipe transmission side. NOTE: ^ Install so that the hose is not folded over, excessively bent, or twisted. ^ Be careful to insert the hose to the specified position. 4) Connect ATF cooler hose to pipe of radiator side. NOTE: ^ Install so that the hose is not folded over, excessively bent, or twisted. ^ Be careful to insert the hose to the specified position. 5) Install the under cover. 6) Install battery and washer tank. 7) Fill ATF. NOTE: Make sure there are no ATF leaks in joints between the transmission, radiator, pipes, and hoses. INSPECTION Repair or replace any defective hoses, pipes, clamps, and washers found from the inspection below. Page 3999 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 2170 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor REMOVAL WARNING: - Place "NO FIRE" signs near the working area. - Be careful not to spill fuel. 1. Remove the fuel tank. 2. Remove the protector cover. 3. Disconnect the connector from fuel tank pressure sensor. 4. Release the clips which hold fuel pipes onto fuel tank. 5. Remove the bolt and nut which hold the fuel tank pressure sensor onto the bracket. Trunk Room Trim Trunk / Liftgate Interior Trim Panel: Service and Repair Trunk Room Trim TRUNK ROOM TRIM REMOVAL 1. Remove the rear seat backrest. 2. Remove the trunk room mat. 3. Remove the clip (A). 4. Remove the clips, and then detach the trunk rear trim (B). 5. Remove the clips to remove trunk side trim (C). INSTALLATION Install in the reverse order of removal. Page 6989 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 6852 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 2369 Air Flow Meter/Sensor: Service and Repair Mass Air Flow and Intake Air Temperature Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the connector from mass air flow and intake air temperature sensor. 3. Remove the mass air flow and intake air temperature sensor. INSTALLATION Install in the reverse order of removal. Tightening torque: 1.7 N.m (0.17 kgf-m, 1.3 ft-lb) Specifications Fuel Pressure: Specifications Fuel pressure: (disconnecting the pressure regulator) Standard ......................................................................................................................................................... 284 - 314 kPa (2.9 - 3.2 kgf/cm2, 41 - 46 psi) Fuel pressure: (connecting the pressure regulator) Standard ..................................................................................................................................................... 230 - 260 kPa (2.35 - 2.65 kgf/cm2, 33 - 38 psi) Page 4041 15) Remove the select lever assembly bushing from bracket. 16) Remove the bracket from select lever assembly. 17) Remove the bushing from bracket. ASSEMBLY 1) Clean all parts before assembly. 2) Apply grease to each select lever parts. Lock plate: SUNCALL GREASE (Part No. 002948040) Except lock plate: KOPR-KOTE (Part No. 003603001) or equivalent 3) Assembly is in the reverse order of disassembly. 4) After completion of fitting, transfer the select lever to range "P" - " 1 ", then check whether the indicator and select lever agree, whether the pointer and position mark agree and what the operating force is. Page 1727 7. Remove the camshaft position sensor. 8. Remove the cam sprockets (I-H) by using ST. 9. Remove the belt cover No. 2 (I-H). 10. Remove the tensioner bracket. 11. Disconnect the hose from water pump. 12. Remove the water pump. Installation 1. Install the water pump onto cylinder block (I-H). NOTE: ^ Replace the gasket with a new one. ^ When installing the water pump, tighten bolts in two stages in alphabetical sequence as shown in the figure. Tightening torque: First ...................................................................................................................................................... ............................. 12 Nm (1.2 kgf-m, 8.7 ft. lbs.) Second ................................................................... ............................................................................................................ 12 Nm (1.2 kgf-m, 8.7 ft. lbs.) Page 395 3. If it is not within specified value, adjust it by adjusting position of stop light switch. CAUTION: Be careful not to rotate the stop light switch. ADJUSTMENT Loosen the lock nut, and adjust the stop light switch position until the clearance between threaded end of stop light switch and stopper (A) becomes 0.3 mm (0.012 inch). Then, tighten the lock nut. Tightening torque: 8 Nm (0.8 kgf-m, 5.8 ft. lbs.) NOTE: Tighten the lock nut B until the clearance between threaded end of stop light switch and stopper becomes 0 mm (0 inch). Hold the stop light switch to prevent turning, and then loosen the lock nut B approximately 60°. The clearance (A) will become 0.3 mm (0.012 inch). Locations Crankshaft Position Sensor: Locations Sensor (Part 1) Locations Fuel Level Sensor: Locations Page 4458 Page 3566 F61-R47 Page 4610 5. Remove the caliper body from housing. 6. Clean mud and foreign particles from the caliper body assembly and support. 3. 17 INCH TYPE CAUTION: Do not allow brake fluid to come in contact with vehicle body; wash away immediately with water and wipe off completely if spilled. 1. Set the vehicle on a lift. 2. Loosen the wheel nuts. 3. Lift-up the vehicle, and then remove the front wheel. 4. Remove the brake pads from caliper body. 5. Remove the union bolt (1) and brake hose from caliper body assembly. 6. Remove installation bolts (2) from housing. 7. Clean mud and foreign particles from the caliper body assembly. INSTALLATION 1. 15 INCH TYPE 1. Install the support on housing. Tightening torque: 80 Nm (8.2 kgf-m, 59 ft. lbs.) 2. Apply thin coat of Molykote AS-880N (Part No. K0777YA010) to the frictional portion between pad and pad clip. 3. Apply thin coat of Molykote AS-880N (Part No. K0777YA010) to the frictional portion between pad and inner shim. 4. Install the pads on support. 5. Install the caliper body on support. Tightening torque: 26.5 Nm (2.7 kgf-m, 19.5 ft. lbs.) 6. Replace the brake hose gaskets with new ones, and then connect the brake hose. Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft. lbs.) Page 5901 Rear Door Latch: Testing and Inspection REAR DOOR LATCH AND DOOR LOCK ACTUATOR ASSEMBLY INSPECTION 1. Make sure the rod is not deformed. 2. Make sure the outer handle, rear remote handle and rod move smoothly. Specifications Fluid - Transfer Case: Specifications The Subaru transmission incorporates the transfer case within the unit and lubricates from a common sump. For the fluid specification refer to Manual Transmission/Transaxle or Automatic Transmission/Transaxle. Page 3665 Ignition Control Module: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Specifications Idle Speed: Specifications Idle speed [A/C "ON". no load and gears in neutral]: When the A/C refrigerant pressure is low MT .. .............................................................................................................................................................. ................................................. 725 ± 100 rpm AT .............................................................................. ..................................................................................................................................... 750 ± 100 rpm When the A/C refrigerant pressure is high MT .................................................................................... ............................................................................................................................. 800 ± 100 rpm AT .. .............................................................................................................................................................. ................................................... 825 ± 100 rpm Page 4894 Except DOHC turbo MT model 2.5 N (0.25 kgf, 0.56 lb) DOHC turbo MT model 5.9 N (0.6 kgf, 1.3 lb) 5. SWITCH ASSEMBLY Using a circuit tester (set in "ohm"), check that there is continuity between terminals S and M, and between terminal S and ground Also check to be sure there is no continuity between terminals M and B. Terminal/Specified resistance: S - M/Less than 1 ohm S - Ground/Less than 1 ohm M - B/More than 1 Mohm 6. SWITCH ASSEMBLY OPERATION 1. Connect the terminal S of switch assembly to positive terminal of battery with a lead wire, and starter body to ground terminal of battery. The pinion should be forced endwise on shaft. CAUTION: With the pinion forced endwise on shaft, the starter motor may rotate because current flows through the pull-in coil to motor, however, this is not a problem. 2. Disconnect the connector from terminal M, and then connect the positive terminal of battery and terminal M using a lead wire and ground terminal to starter body. In this test set up, the pinion should return to its original position even when it is pulled out with a screwdriver. 7. PINION GAP Page 130 R58-R69 Diagrams MASTER CYLINDER Page 1324 6. Connect the oil flow control solenoid valve connector. 7. Similarly, install the parts on RH side. 8. Install the timing belt cover No. 2 (RH). Tightening torque: 5 Nm (0.5 kgf-m, 3.6 ft. lbs.) 9. Install the timing belt cover No. 2 (LH). Tightening torque: 5 Nm (0.5 kgf-m, 3.6 ft. lbs.) Page 5821 5. Remove the trailer hitch while lowering exhaust pipe. INSTALLATION CAUTION: Because the trailer hitch is heavy, two people are required to install it. Install in the reverse order of removal. Tightening torque: Trailer hitch to body: 95 N.m (9.7 kgf-m, 70 ft-lb) Canister: 23 N.m (2.3 kgf-m, 17 ft-lb) Page 2257 Oxygen Sensor: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 2946 R58-R69 Page 568 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 4697 B136-B141 Page 5146 5) Tighten the clamp E firmly. 6) Tighten the joint nut. 7) Connect the pipes A and B to four pipe joints of gearbox. Connect the upper pipe B first, and lower pipe A second. ^ Non-turbo model Non-Turbo Model ^ Turbo model Turbo Model Page 4970 B17-B20 Page 5793 Speaker: Service and Repair Tweeter TWEETER REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the front door trim. 3. Remove the tweeter mounting screws. 4. Disconnect the harness connector and remove tweeter. INSTALLATION Install in the reverse order of removal. Page 7086 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Front Vehicle Speed Sensor Transmission Speed Sensor: Service and Repair Front Vehicle Speed Sensor Front Vehicle Speed Sensor REMOVAL 1) Set up the vehicle on a lift. 2) Disconnect the ground cable from battery. 3) Remove the air intake chamber. (Non-turbo model) 4) Remove the intercooler. (Turbo model) 5) Disconnect the transmission connector. 6) Remove the pitching stopper. 7) Remove the transmission connector from stay. 8) Lift-up the vehicle. 9) Clean the transmission exterior. 10) Drain the ATF completely. NOTE: ^ Tighten the ATF drain plug after draining the ATF. ^ Use anew gasket. 11) Remove the front, center, exhaust pipes and muffler. (Non-turbo model) 12) Remove the center, rear exhaust pipe and muffler. (Turbo model) 13) Remove the propeller shaft. 14) Place the transmission jack under transmission. NOTE: Make sure that the support plates of transmission jack don't touch the crossmember. 15) Remove the transmission rear crossmember bolts. Page 3626 B230-B283 Page 3390 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 4856 ^ Check the back-up light illumination when the select lever is in "R" range. ^ Check the parking lock operation when the select lever is in "F" range. 5) Using the Subaru Select Monitor, clear the diagnostic trouble codes stored in memory. If the codes return afier the correct adjustments, refer to the diagnostic procedure found in the applicable Subaru Service Manual. WARRANTY/CLAIM INFORMATION For vehicles within the Basic New Car Limited Warranty period, refer to the Subaru Warranty Wizard for claim submission information. Disclaimer Vehicle - Recommended Fluids/Chemicals Continuously Variable Transmission/Transaxle: Technical Service Bulletins Vehicle Recommended Fluids/Chemicals NUMBER: 01-067-08 DATE: 09/09/08 APPLICABILITY: All Subaru Vehicles SUBJECT: Recommended Materials Introduction Page 5532 Note: Be careful not to damage wires around the working area. 4. Impreza and Forester: Remove the passenger front seat and disconnect the body wire connector afier pulling up the floor carpet. Note: Check if the wire is pinched at the seat rail and damaged. 5. Repair the wire according to the extent of damage as indicated below. (1) When only the surface of the wire covering is damaged only: Wrap electrical tape around the damaged portion, proceed to Step 7. (2) When the core wire is cut or damaged: Cut and remove the damaged section of wire, as illustrated. (3) Peel the wire covering 5/8 inch (15 mm) from the tip of cut wire and expose the core wires, as illustrated. (4) Install heat shrink tubing on one side of the cut wiring. (5) Twist the core wires together so that they entwine each other. Be careful to ensure the tips of the wires are level and parallel. Otherwise~ the wire will break through the heat shrink tubing. (6) Solder the twisted wires and activate the heat shrink tubing with a heat gun. Confirm that no frayed wires are visible. 6. Reconnect the body wire connector. Page 5145 3) Temporarily connect the pipe C and D to gear box. 4) Temporarily install the clamp E on pipes C and D. NOTE: Ensure the letter "8" on each clamp are diagonally opposite each other as shown in the figure. Page 5892 Rear Door Exterior Handle: Service and Repair REAR OUTER HANDLE REMOVAL 1. Remove the rear door trim. 2. Remove the sealing cover. 3. Remove the rear inner remote. 4. Remove the rear door latch assembly. 5. Loosen two bolts and a nut to remove the rear outer handle. CAUTION: Do not use excessive force to remove the handle from door panel. This will deform it. INSTALLATION Install in the reverse order of removal. NOTE: Make sure the rear outer handle works properly after installation. Diagram Information and Instructions Outside Temperature Display: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 2286 B230-B283 Page 790 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 3264 R72-R145 R148 Page 1549 8. Disconnect the connector from the tumble generator valve sensor. 9. Disconnect the connector from the purge control solenoid valve. 10. Remove the purge control solenoid valve. 11. Disconnect the evaporation hose and purge valve from the intake manifold. 12. Remove the two bolts which hold the fuel pipes on the left side of intake manifold. 13. Remove the bolt which hold the fuel injector pipe onto intake manifold. Page 2850 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 7374 B128-B134 Page 2012 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Specifications Wiper Motor: Specifications SPECIFICATION Front wiper motor - Input ..................................................................................................................... .................................................... 12 V - 72 W or less Rear wiper motor - Input ................................. ......................................................................................................................................... 12 V - 42 W or less Page 4919 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 677 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 1385 Valve Clearance: Testing and Inspection VALVE CLEARANCE INSPECTION Inspection and adjustment of the valve clearance should be performed while engine is cold. 1. Set the vehicle on a lift. 2. Disconnect the ground cable from battery. 3. Remove the air intake duct. 4. Remove the bolts which secure the timing belt cover (RH). 5. Lift-up the vehicle. 6. Remove the under cover. 7. Loosen the remaining bolts which secure the timing belt cover (RH), and then remove the timing belt cover. 8. Lower the vehicle. 9. When inspecting the #1 and #3 cylinders: 1. Pull out the engine harness connector with bracket from air cleaner upper cover. 2. Remove the air cleaner case. 3. Disconnect the ignition coil connector. 4. Remove the ignition coil. 5. Place a suitable container under the vehicle. 6. Disconnect the PCV hose from rocker cover (RH). 7. Remove the bolts, and then remove the rocker cover (RH). 10. When inspecting the #2 and #4 cylinders: 1. Disconnect the battery cable, and then remove the battery and battery carrier. 2. Remove the secondary air pump. 3. Disconnect the ignition coil connector. 4. Remove the ignition coil. 5. Place a suitable container under the vehicle. 6. Disconnect the PCV hose from rocker cover (LH) 7. Remove the bolts, and then remove the rocker cover (LH). 11. Turn the crank pulley clockwise until arrow mark on the cam sprocket is set to position shown in the figure. NOTE: Turn the crankshaft using socket wrench. 12. Measure the #1 cylinder intake valve and #3 cylinder exhaust valve clearance by using thickness gauge (A). NOTE: ^ Insert the thickness gauge (A) in as horizontal a direction as possible with respect to the shim. ^ Measure the exhaust valve clearances while lifting-up the vehicle. Valve clearance: STD Intake: 0.20 ± 0.02 mm (0.0079 ± 0.0008 inch) Exhaust. 0.35 ± 0.02 mm (0.0138 ± 0.0008 inch) Page 4122 Clutch Slave Cylinder: Service and Repair Operating Cylinder REMOVAL 1) Remove the air intake chamber (Non-turbo model). 2) Remove the intercooler. (Turbo model) 3) Remove the clutch hose from operating cylinder. CAUTION: ^ Cover the hose joint to prevent clutch fluid from flowing out. ^ Do not loosen or remove the cap bolt. (Turbo model and STI model) ^ Non-turbo model Non-turbo model ^ Turbo model Turbo model ^ STI model Page 5251 CAUTION: Install the front bushing in the proper direction, as shown in the figure. REAR BUSHING 1. Using the ST, press the bushing into trailing link. ST 927730000 INSTALLER & REMOVER SET NOTE: If it is difficult to press the bushing into trailing link, apply water-diluted TIRE LUBE to the inner surface of ST as a lubricant. Specified lubricant: TIRE LUBE: water = 1: 3 Page 1726 Water Pump: Service and Repair Water Pump Removal 1. Remove the radiator. 2. Remove the V-belts. 3. Remove the timing belt. 4. Remove the automatic belt tension adjuster (A). 5. Remove the belt idler (B). 6. Remove the belt idler No. 2 (C). Page 2079 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 764 Crankshaft Position, Camshaft Position And Knock Sensors Page 3717 B54-B127 Page 3720 B136-B141 Page 6625 B128-B134 Combination Switch (Light) Combination Switch: Service and Repair Combination Switch (Light) COMBINATION SWITCH (LIGHT) REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the instrument panel lower cover. 3. Remove the screws which secure the upper column cover to lower column cover. 4. Remove the screws which secure the upper column cover. 5. Disconnect the connector from combination switch. 6 Remove the screws which secure the switch, and then remove the switch. INSTALLATION Install in the reverse order of removal. Page 4559 NOTE: ^ Always replace the pads for both right and left wheels at the same time. ^ Also replace the pad clips if they are twisted or worn. ^ A wear indicator is provided on the inner disc brake pad. If the pad wears down to such an extent that the end of wear indicator contacts disc rotor, a squeaking sound is produced as the wheel rotates. If this sound is heard, replace the pad. ^ Replace the pad if there is oil or grease on it. Page 187 B380-f6 Page 4876 Neutral Safety Switch: Testing and Inspection Neutral Position Switch NEUTRAL POSITION SWITCH INSPECTION Non-Turbo Model Turbo Model STI Model Measure the neutral position switch resistance. If NG, replace the neutral position switch. Page 4722 ^ Loaded air tightness check Depress the brake pedal while engine is running, and turn off the engine while pedal is still depressed. Keep the pedal depressed for 30 seconds; if no change occurs in the pedal height, the brake booster is functioning normally; if the pedal height increases, it is faulty. NOTE: If faulty, check precisely with gauges. 2. OPERATION CHECK (WITH GAUGES) CAUTION: When checking operation, be sure to securely apply the parking brake. ^ Checking with gauges Connect gauges as shown in the figure. After bleeding air from pressure gauges, proceed to each check. ^ Air tightness check 1. Start the engine and keep it running until a vacuum of 66.7 kPa (500 mmHg, 19.69 inHg) = point A is indicated on vacuum gauge. Do not depress the brake pedal. 2. Stop the engine and watch the gauge. If the vacuum drop range is less than 3.3 kPa (25 mmHg, 0.98 inHg) within 15 seconds after stopping engine, the brake booster is functioning properly. If defective, the cause may be one of those listed below. ^ Check valve malfunction ^ Leak from vacuum hose ^ Leak from the shell jointed portion or stud bolt welded portion ^ Damaged diaphragm ^ Leak from valve body seal and bearing portion ^ Leak from plate and seal assembly portion ^ Leak from poppet valve assembly portion ^ Loaded air tightness check 1. Start the engine and depress brake pedal with pedal force of 196 Nm (20 kgf, 44 ft. lbs.). Keep the engine running until a vacuum of 66.7 kPa (500 mmHg, 19.69 inHg) = point B is indicated on vacuum gauge while the pedal is still depressed. Page 3820 Schematic drawings Page 944 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 4573 NOTE: ^ Always replace the pads for both right and left wheels at the same time. ^ Also replace the pad clips if they are twisted or worn. ^ A wear indicator is provided on the inner disc brake pad. If the pad wears down to such an extent that the end of wear indicator contacts disc rotor, a squeaking sound is produced as the wheel rotates. If this sound is heard, replace the pad. ^ Replace the pad if there is oil or grease on it. Rear Door Glass Window Glass: Adjustments Rear Door Glass REAR DOOR GLASS ADJUSTMENT NOTE: The rear door glass, as a rule, should be adjusted in the same manner as front door glass, although they are different in dimension. Special notes for the rear glass are given. 1. Adjust the glass position using the following dimensions as a guide line. NOTE: If the dimensions are smaller than the given dimensions, glass may get caught in weather strip during lifting/lowering operation. In the worst case, it may cause the glass not to be opened fully. - After adjustment, move the glass up and down to check whether it is caught. 2. Set the ST on glass, and then adjust the contact degree of glass using the following dimensions as a guide line. ST 61299AE010 SPACER (For rear door glass of thickness 4 mm (0.157 in)) NOTE: If the contact degree of rear glass is higher than necessary, glass may get caught in weather strip of center pillar corner, resulting in early wear of weather strip. Be careful when adjusting. - After adjustment, move the glass up and down to check whether it is caught. Page 4677 4) Install the plate to anchor pin, and then assemble the primary return spring to anchor pin. 5) Install the parking brake cable to parking brake lever. 6) Assemble the strut and adjuster, and then secure the secondary side brake shoe with shoe holddown pin & cup. NOTE: ^ Install the strut spring of both right and left wheels facing vehicle front. ^ Install the adjuster assembly with screw on left side. 7) Install the secondary return spring and adjusting spring. 8) Adjust the parking brakes. 9) Drive the vehicle for parking brake lining "break-in". (1) Drive the vehicle at about 35 km/h (22 MPH). (2) With the parking brake release button pushed in, pull the parking brake lever gently. Page 3117 12) Move the range select lever to parking position (left side). 13) Remove the inhibitor switch from transmission. 14) Disconnect the inhibitor switch harness connector from inhibitor switch. INSTALLATION 1) Connect the inhibitor switch harness connector to inhibitor switch. 2) Install the inhibitor switch to transmission case. 3) Move the range select lever to neutral position. Testing and Inspection Hose/Line HVAC: Testing and Inspection Hose and Tube INSPECTION NOTE: If cracking, damage, or swelling is found on a hose, replace it with a new one. Page 1627 Oil Pressure Sender: Service and Repair Oil Pressure Switch Removal 1. Remove the generator from bracket. 2. Disconnect the terminal from oil pressure switch. 3. Remove the oil pressure switch. Installation 1. Apply liquid gasket to the oil pressure switch threads. ^ Liquid gasket. THREE BOND 1324 (Part No. 004403042) or equivalent 2. Install the oil pressure switch onto engine block. ^ Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft. lbs.) 3. Connect the terminal of oil pressure switch. Page 6630 B380-f6 Page 1971 4. Separate the rear exhaust pipe from muffler. CAUTION: Be careful not to pull down the rear exhaust pipe. 5. Remove the rear exhaust pipe. INSTALLATION NOTE: Replace the gaskets and self-locking nut with new ones. 1. Install the rear exhaust pipe to muffler. Tightening torque: 48 Nm (4.9 kgf-m, 35.4 ft. lbs.) 2. Install the rear exhaust pipe to center exhaust pipe. Tightening torque: 18 Nm (1.8 kgf-m, 13 ft. lbs.) Page 6622 B3-B12 Page 7169 B134-B136 Page 1366 e. Install the V-belt. INSPECTION a. Make sure the V-belt is not worn or otherwise damaged. b. Check the tension of the belt. Locations Daytime Running Lamp Relay: Locations Area View Daytime Running Light Relay - (B102) Page 6577 F21-F61 Page 561 P Code List (Partial list) Page 6845 B292-B317 Page 7076 B134-B136 Page 3465 B134-B136 Page 1512 R72-R145 R148 Page 3629 F21-F61 Page 6790 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 3633 Knock Sensor: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 1628 4. Install the generator on bracket. Inspection 1. Make sure oil does not leak or seep from where the oil pressure switch is installed. Page 3147 R58-R69 Ignition System - Spark Plug Replacement Intervals Spark Plug: Technical Service Bulletins Ignition System - Spark Plug Replacement Intervals PLATINUM SPARK PLUG CHANGE INTERVALS The Techline occasionally gets calls concerning the change intervals on platinum plugs and why some need to be changed at 30,000 miles and others at 60,000 miles. The reason for this is the spark plugs on 2.5L NA engines, the electrode side of this plug is platinum but the plug core side is not platinum. Therefore, it is a maintenance interval every 30,000 miles. On the 2.5L Turbo and 3.OL engines, both the electrode side and the plug core side are platinum. Therefore, it is a maintenance interval every 60,000 miles. Page 7405 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 7333 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 3725 F61-R47 Page 3489 Intercooler: Service and Repair Intercooler Disassembly and Assembly Intercooler DISASSEMBLY 1. Remove the intercooler ducts from intercooler. 2. Separate the intercooler ducts. ASSEMBLY Assemble in the reverse order of disassembly. NOTE: Do not let the O-ring bite. Page 5671 R72-R145 R148 Page 6804 F61-R47 Page 6693 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 3860 B17-B20 Page 3203 10. Disconnect the pressure control valve hose from pressure control solenoid valve. INSTALLATION Install in the reverse order of removal. Page 364 Solar Sensor: Service and Repair Sunload Sensor (Auto A/C Model) REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the front defroster grille. 3. Disconnect the sunload sensor connector (A). CAUTION: Be careful not to damage the sensors and interior trims when removing them. INSTALLATION Install in the reverse order of removal. Service and Repair Fuel Pressure Pulsation Damper: Service and Repair Fuel Damper Valve REMOVAL 1. Release the fuel pressure. 2. Remove the fuel damper valve from the fuel delivery line (A) and fuel return line (B). WARNING: Be careful not to spill fuel. - Catch the fuel from hoses using a container or cloth. INSTALLATION Install in the reverse order of removal. Tightening torque: 1.25 N.m (0.13 kgf-m, 0.94 ft-lb) Page 723 B230-B283 Page 3906 R72-R145 R148 Page 6361 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 530 F21-F61 Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 1429 The proper viscosity helps vehicle get good cold and hot starting by reducing viscous friction and thus increasing cranking speed. CAUTION: When replenishing oil, it does not matter if the oil to be added is a different brand from that in the engine; however, use oil having the API standard and SAE viscosity No. designated by SUBARU. NOTE: If the vehicle is used in areas with very high temperatures or for other heavy duty applications, the following viscosity oils may be used: API standard: SM or SL SAE Viscosity No.: 30, 40, 10W-50, 20W-40, 20W50. 7. Close the engine oil filler cap. 8. Start the engine and warm it up for a time. 9. After the engine stops, recheck the oil level. If necessary, add engine oil up to the upper level on level gauge. Page 4284 Clutch Pedal Position Sensor / Switch: Description and Operation OPERATION STARTER INTERLOCK MECHANISM When the clutch pedal is fully depressed, the stopper on the pedal pushes the clutch switch push rod inwards. When the pushrod is pressed in, the switch turns ON and connects the ignition switch to the starter circuit enabling engine start. Schematic Drawings Page 3251 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Service and Repair Fuel Pressure Release: Service and Repair Fuel PROCEDURE RELEASING OF FUEL PRESSURE WARNING: - Place "NO FIRE" signs near the working area. - Be careful not to spill the fuel. 1. Disconnect the connector from the fuel pump relay. 2. Start and run the engine until it stalls. 3. After the engine stalls, crank it for five more seconds. 4. Turn the ignition switch to OFF. Page 2919 Intake Air Temperature Sensor: Service and Repair Mass Air Flow and Intake Air Temperature Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the connector from mass air flow and intake air temperature sensor. 3. Remove the mass air flow and intake air temperature sensor. INSTALLATION Install in the reverse order of removal. Tightening torque: 1.7 N.m (0.17 kgf-m, 1.3 ft-lb) Page 2926 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 4303 7) Install the washer and snap ring. 8) Insert the gear shift lever and rod into boot hole. 9) Install the rod. 10) Install a new lock wire. NOTE: Page 624 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 3969 5) Disconnect the inhibitor switch connector. 6) Remove the inhibitor switch connector from stay. 7) Lift-up the vehicle. 8) Remove the front and center exhaust pipes. 9) Remove the snap pin and washer from range select lever. 10) Remove the plate assembly from transmission case. 11) Remove the bolts. Page 7335 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 1246 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Testing and Inspection Radiator: Testing and Inspection Radiator Inspection 1. Remove the coolant filler tank cap, top off coolant filler tank, and then attach the tester to coolant filler tank in place of cap. 2. Apply a pressure of 122 kPa (1.2 kgf/cm, 18 psi) to the coolant filler tank to check if: ^ Engine coolant leaks at/around radiator. ^ Engine coolant leaks at/around hoses or connections. CAUTION: ^ Inspection must be carried out at the side of coolant filler tank, not at the side of radiator. ^ Engine should be turned off. ^ Wipe engine coolant from check points in advance. ^ If engine coolant adheres to the exhaust pipe, wipe it off completely. ^ Be careful to prevent engine coolant from spurting out when removing the tester. ^ Be careful also not to deform the filler neck of coolant filler tank when installing or removing tester. Page 3416 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 1245 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 7422 R72-R145 R148 Wipers/Washers - Poor Front/Rear Washer Nozzle Operation Check Valve: All Technical Service Bulletins Wipers/Washers - Poor Front/Rear Washer Nozzle Operation NUMBER: 07-55-06 DATE: 04/04/06 APPLICABILITY: 2006MY Forester and Impreza SUBJECT: Poor Windshield Washer Fluid Spray Introduction If you encounter a customer complaint that the windshield washer fluid does not spray properly from the front or rear washer nozzle, there is the possibility that the nozzle or check valve is clogged or the fluid hose could be pinched or bent. Use the following repair procedure to check and repair as necessary. Production Line Change The check valve was changed from a ball type to a rubber type to prevent clogging. The new style check valve was used in production starting in October, 2005 with the VINs shown. Parts Information Repair Procedure/Information 1) Check the washer nozzle for contamination. If the spray hole is clogged with wax, dust or foreign material, blow compressed air to the spray hole of the washer nozzle to clear the obstruction. 2) Check the washer nozzle fluid hose. Make sure the hose is not pinched, and that it does not have severe bends or kinks. 3) Check the rear washer hose running along the left sill, as well as the hose in the tailgate area, to ensure that the hose is not pinched or bent, restricting the flow. 4) If there is no problem found in step 1 or 2, install a modified check valve. Front check valve on Forester and Impreza Page 7128 10. Fit the locating pins using suction rubber cup to install the windshield glass. 11. Lightly press the windshield glass for tight fit. 12. Make flush the adhesive surface jutted out using spatula. 13. Connect the wiper deicer connector. (Model with wiper deicer) 14. After completion of all work, allow the vehicle to stand for about 24 hours. NOTE: When the door is opened/closed after glass is bonded, always lower the door glass and then open/close it carefully. - Move the vehicle slowly. - For minimum drying time and time the vehicle must be left standing before driving after bonding, follow the instructions or instruction manual from adhesive manufacturer. 15. After curing of adhesive, pour water on external surface of vehicle to check that there are no water leaks. NOTE: When a vehicle is returned to the user, tell him or her that the vehicle should not be subjected to heavy impact for at least three days. 16. Install the cowl panel. Page 2503 Spark Plug: Adjustments ADJUSTMENT Clean the spark plugs with a wire brush. Clean and remove the carbon or oxide deposits, but do not wear away ceramic insulator. If deposits are too stubborn, replace the plugs. After cleaning the spark plugs, correct the spark plug gap using a gap gauge. NOTE: Do not use spark plug cleaners, because the spark plugs are applied with iridium tips. Page 2295 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 4015 B292-B317 Page 4568 NOTE: ^ Always replace the pads for both right and left wheels at the same time. ^ Also replace the pad clips if they are twisted or worn. ^ A wear indicator is provided on the inner disc brake pad. If the pad wears down to such an extent that the end of wear indicator contacts disc rotor, a squeaking sound is produced as the wheel rotates. If this sound is heard, replace the pad. ^ Replace the pad if there is oil or grease on it. Page 3018 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 6705 B230-B283 Page 2941 B230-B283 Page 3563 B292-B317 Page 457 R72-R145 R148 Page 4488 Brake Pedal Assy: Testing and Inspection INSPECTION 1. Move the brake and clutch pedal pads in the lateral direction with a force of approximately 10 Nm (1 kgf, 2 ft. lbs.) to ensure pedal deflection is in specified range. CAUTION: If excessive deflection is noted, replace the bushings with new ones. Deflection of brake and clutch pedal. Service limit 5.0 mm (0. 197 inch) or less 2. Check the position of pedal pad. Pedal height L: 148 mm (5.83 inch) Brake pedal free play 0.5 - 2.0 mm (0. 02 - 0.08 inch) [Depress brake pedal pad with a force of less than 10 Nm (1 kgf, 2 ft. lbs.).] Page 3432 B292-B317 Removal and Replacement Axle Shaft Assembly: Removal and Replacement Front Drive Shaft Removal Front Drive Shaft REMOVAL 1) Jack-up the vehicle, support it with rigid racks, and then remove the front wheel cap and wheels. 2) Raise the caulking portion of axle nut. 3) Depress the brake pedal and remove the axle nut using a socket wrench. CAUTION: Be sure to loosen the axle nut after removing the wheel from vehicle. Failure to follow this rule may damage the wheel bearings. 4) Remove the stabilizer link from transverse link. 5) Disconnect the transverse link from housing. 6) Remove the front drive shaft assembly. If it is hard to remove, use the ST1 and ST2. ST1 926470000 AXLE SHAFT PULLER ST2 28099PA110 AXLE SHAFT PULLER PLATE CAUTION: ^ Be careful not to damage the oil seal lip and tone wheel when removing the front drive shaft. ^ When the front drive shaft is to be replaced, also replace the inner oil seal. 7) Remove the front drive shaft from transmission using bar. CAUTION: Be careful not to damage the holder portion. Front Drive Shaft Installation Front Drive Shaft INSTALLATION 1) Using the ST, replace the differential side retainer oil seal with a new one. ST 18675AA000 DIFFERENTIAL SIDE OIL SEAL INSTALLER NOTE: After pulling out the drive shaft, be sure to replace with a new oil seal. 2) Insert the EBJ into hub splines. CAUTION: Page 3070 B136-B141 Floor Mat Carpet: Service and Repair Floor Mat FLOOR MAT REMOVAL 1. Remove the front seats. 2. Remove the rear seat cushion. 3. Remove the console box. 4. Remove the side sill front cover, side sill rear cover and center pillar lower trim. 5. Remove the foot rest. 6. Remove the clips from floor mat. 7. Remove the mat hook. 8. Remove the mat from toe board area. 9. Remove the mat from rear heater duct. 10. Roll the mat, and then take it out of opened rear door. INSTALLATION Install in the reverse order of removal. NOTE: - Secure the mat firmly with hook and Velcro tape. - Insert the mat edge firmly into the groove of side sill cover. Page 175 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Service and Repair Transmission Mount: Service and Repair Transmission Mounting System REMOVAL PITCHING STOPPER 1) Disconnect the ground cable from battery. 2) Remove the air intake chamber. (Non-turbo model) 3) Remove intercooler. (Turbo model) 4) Remove the throttle body. 5) Remove the pitching stopper. TRANSMISSION REAR CROSSMEMBER AND REAR CUSHION RUBBER 1) Disconnect the ground cable from battery. 2) Jack-up the vehicle and support it with sturdy racks. 3) Remove the front, center, rear exhaust pipes and muffler. (Non-turbo model) 4) Remove center and rear exhaust pipes, and muffler. (Turbo model) 5) Set the transmission jack under the transmission. Make sure that the support plates of transmission jack don't touch the oil pan. 6) Remove the transmission rear crossmember. 7) Remove the rear cushion rubber. INSTALLATION PITCHING STOPPER 1) Install the pitching stopper. 2) Install the throttle body. 3) Install the air intake chamber. (Non-turbo model) Page 586 R72-R145 R148 Page 2823 F21-F61 Testing and Inspection Courtesy Lamp Bulb: Testing and Inspection ROOM LIGHT INSPECTION ROOM LIGHT BULB 1. Visually check the bulb for blow out. 2. Check the bulb specification. 3. If NG, replace the bulb with a new one. Page 6019 - Do not allow water or oil to come in contact with the connector terminals. Do not touch the connector terminals. - Either of the airbag modules for driver, passenger or side, or pretensioner must not be disassembled. - The removed front seat with the airbag module must be kept at least 200 mm (8 in) away from walls and other objects. - Do not use the airbag or pretensioner parts from other vehicles. Always replace defective parts with new parts. - Never reuse a deployed airbag or pretensioner. - When painting or performing sheet metal work on the front part of the vehicle, including the front wheel apron, front fender, and front side frame, remove the front sub sensors and wire harness of the airbag system. Page 574 B3-B12 Page 1542 2. Connect the fuel delivery hose, return hose and evaporation hose. 3. Connect the connector to the oil pressure switch (B), crankshaft position sensor (C) and engine coolant temperature sensor (A). 4. Connect the connector to the knock sensor. 5. Connect the connector to the camshaft position sensor. 6. Connect the connector to the ignition coil and ignitor assembly. Locations Electrical Component Location Page 2852 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 3444 Variable Induction Position Sensor: Service and Repair NOTE: DO NOT remove the tumble generator valve position sensor from tumble generator valve assembly, since it cannot be adjusted during installation. Refer to "Tumble Generator Valve Assembly" for removal and installation procedures. Page 6479 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 3768 B128-B134 Page 1040 Page 194 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 3503 Variable Induction Control Actuator: Service and Repair Tumble Generator Valve Actuator REMOVAL RH SIDE 1. Release the fuel pressure. 2. Disconnect the ground cable from battery. 3. Open the fuel filler flap lid and remove the fuel filler cap. 4. Remove the intake manifold. 5. Disconnect the connector from tumble generator valve actuator RH. 6. Remove the tumble generator valve actuator RH. LH SIDE 1. Release the fuel pressure. 2. Disconnect the ground cable from battery. 3. Open the fuel filler flap lid and remove the fuel filler cap. 4. Remove the secondary air pump. 5. Disconnect the connector from tumble generator valve actuator LH. 6. Remove the tumble generator valve actuator LH. INSTALLATION RH SIDE Install in the reverse order of removal. LH SIDE Install in the reverse order of removal. Page 7417 B292-B317 Page 2695 B3-B12 Page 4903 Starter Motor: Service and Repair Disassembly and Assembly DISASSEMBLY 1. STARTER ASSEMBLY 1. Loosen the nut which holds the terminal M of switch assembly, and then disconnect the connector. 2. Remove the bolts which hold the switch assembly, and then remove switch assembly, plunger and plunger spring from starter as a unit. NOTE: Be careful because the pinion gap adjustment washer may sometimes be used on the mounting surface of switch assembly. 3. Remove both through-bolts and brush holder screws, and then detach the rear cover and brush holder. 4. Remove the armature and yoke from front bracket. The ball used as a bearing will come off from the armature end. NOTE: Before removal of the yoke, put alignment marks on the yoke and front bracket. Page 2179 Crankshaft Position, Camshaft Position And Knock Sensors Page 5873 Front Door Panel: Testing and Inspection FRONT SEALING COVER INSPECTION If the sealing cover is damaged, replace it with a new one. Page 3421 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 6283 B3-B12 Page 6495 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 6313 B3-B12 Page 1524 14. Install the intercooler. 15. Install the air intake boot and air cleaner upper cover. 16. Connect the connector to mass air flow and intake air temperature sensor. 17. Install the front wheels. 18. Connect the battery ground cable to battery. 19. Fill engine oil. Inspection 1. By visual check, make sure the oil pan, oil strainer, oil strainer stay and baffle plate are not damaged. Page 2536 B54-B127 Service and Repair Spare Tire: Service and Repair "T-type" Tire NOTE "T-type" tire for temporary use is prepared as a spare tire. CAUTION: ^ Do not use a tire chain with the "T-type" tire. Because of the smaller tire size, a tire chain will not fit properly and will result in damage to the vehicle and the tire. ^ Do not drive at a speed greater than 80 km/h (50 MPH). ^ Drive as slowly as possible and avoid passing over bumps. REPLACEMENT Refer to Aluminum Wheel for removal and installation of T-type tires. CAUTION: Replace with a conventional tire as soon as possible since the T-type tire is only for temporary use. INSPECTION 1. Check the tire inflation pressure. Specification: 420 kPa (4.2 kg/cm2, 60 psi) 2. Take stones, glass, nails, etc. out of the tread groove. 3. Check the tires for deformation, cracks, partial or over limit wear. CAUTION: Replace the tire with a new one. Page 6655 Backup Lamp Switch: Testing and Inspection Inhibitor Switch (AT Model) INHIBITOR SWITCH (AT MODEL) Measure the resistance between inhibitor switch terminals. Page 6638 Temperature Gauge: Electrical Diagrams Temperature Gauge C/TEMP-01 Diagrams: Other diagrams referred to by name within these diagrams (i.e. "REF. TO GND-01", etc) can be found at Diagrams by Diagram Name. See: Diagrams/Electrical Diagrams/Diagrams By Diagram Name Connector and Ground Locations: The locations of the Connectors or Grounds shown within these diagrams can be found via the connector or ground number at Vehicle Locations. See: Locations Additional/Related Diagrams For information regarding diagrams for this component, please refer to Instrument Panel, Gauges and Warning Indicators diagrams. See: Diagrams/Electrical Diagrams Page 1802 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 5007 Note: Be careful not to damage wires around the working area. 4. Impreza and Forester: Remove the passenger front seat and disconnect the body wire connector afier pulling up the floor carpet. Note: Check if the wire is pinched at the seat rail and damaged. 5. Repair the wire according to the extent of damage as indicated below. (1) When only the surface of the wire covering is damaged only: Wrap electrical tape around the damaged portion, proceed to Step 7. (2) When the core wire is cut or damaged: Cut and remove the damaged section of wire, as illustrated. (3) Peel the wire covering 5/8 inch (15 mm) from the tip of cut wire and expose the core wires, as illustrated. (4) Install heat shrink tubing on one side of the cut wiring. (5) Twist the core wires together so that they entwine each other. Be careful to ensure the tips of the wires are level and parallel. Otherwise~ the wire will break through the heat shrink tubing. (6) Solder the twisted wires and activate the heat shrink tubing with a heat gun. Confirm that no frayed wires are visible. 6. Reconnect the body wire connector. Page 4199 (5) Remove the bolts which secure trailing link to housing. (6) Remove the bolts which secure the front and rear lateral link to rear housing. (7) Remove the DOJ from the rear differential by using ST. NOTE: When removing the DOJ from rear differential, fit ST to the bolts as shown in the figure so as not to damage the side bearing retainer. ST 208099PA100 DRIVE SHAFT REMOVER Page 4220 5) Pry and remove the round circlip located at neck of DOJ outer race with a screwdriver. 6) Take out the DOJ outer race from shaft assembly. 7) Wipe off the grease, and then take out the balls. NOTE: ^ The grease is a special grease (grease for constant velocity joint). Do not confuse with other greases. ^ Disassemble with exercising care not to lose balls (6 pcs). 8) To remove the cage from inner race, turn the cage by a half pitch to the track groove of inner race, and shift the cage. 9) Remove the snap ring, which fixes the inner race to shaft, by using pliers. 10) Take out the DOJ inner race. 11) Take off the DOJ cage from shaft and remove the DOJ boot. 12) Wrap the shaft splines with vinyl tape. 13) Remove the BJ boot in the same procedure as DOJ boot. NOTE: Further disassembly of axle is impossible because the BJ cannot be disassembled. Front Drive Shaft Assembly ASSEMBLY EBJ+PTJ TYPE NOTE: Use specified grease. EBJ side: NTG2218-M (Part No. 28395AGO10) PTJ side: NKG302 (Part No. 28495AE00) 1) Place the EBJ boot and small boot band on EBJ side of shaft. CAUTION: Be sure to wrap the shaft splines with vinyl tape to prevent the boot from scratches. 2) Place the drive shaft in a vise. CAUTION: Do not place the drive shaft directly in a vise; use wooden blocks. 3) Apply a coat of specified grease [60 to 70 g (2.12 to 2.47 ounces)] to El3J. 4) Apply an even coat of specified grease [20 to 30 g (0.71 to 1.06 ounces)] to entire inner surface of boot. Also apply grease to shaft. Page 5669 F61-R47 Page 1918 B230-B283 Page 3048 13) Install the air intake chamber. (Non-turbo model) 14) Install the intercooler. (Turbo model) 15) Inspect the inhibitor switch. Page 452 B292-B317 Page 176 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 3428 B128-B134 Page 6830 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Diagram Information and Instructions Ignition Control Module: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 4004 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 2457 B136-B141 Identification Oxygen Sensor: Locations Identification This article was updated by bulletin number: 11-92-08 Date: 01/05/09 APPLICABILITY: 1999MY and later Forester 1999MY and later Impreza 2000MY and later Legacy 2006MY and later Tribeca SUBJECT: Air/Fuel Ratio Sensor and Oxygen Sensor INTRODUCTION For information purposes only. REPAIR/SERVICE INFORMATION When performing diagnostics or reading Diagnostic Trouble Codes (DTC) for Air Fuel Ratio (A/F) sensors and Oxygen (O2) sensors use the following information to identify, locate and repair the appropriate sensor and sensor circuits: (1) Rarely will multiple sensors fail at the same time. (2) On vehicles with only one O2 sensor, the designation for that O2 sensor will be bank 1. (3) On vehicles with only one A/F sensor, the designation for that A/F sensor will be bank 1. (4) Any reference to sensor 1 is an A/F sensor. (5) Any reference to sensor 2 is an O2 sensor. (6) Early PZEV vehicles used an additional O2 sensor behind the rear catalyst and is designated sensor 3. (7) On vehicles with A/F and O2 sensors on the right (Passenger Side) and left (Driver side) of the vehicle, Bank 1 is the right side (Passenger Side) and Bank 2 is the left side (Driver side). Example: DTC P0030 HO2S HEATER CONTROL CIRCUIT (Bank 1 Sensor 1). This DTC is referring to the A/F sensor and since it is on a 2007 Forester there is only one A/F sensor and one O2 sensor. Example (as illustrated): DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (Bank 1 Sensor 2). This DTC is referring to the O2 sensor on the right side exhaust (or the O2 sensor of a vehicle with only one O2 sensor). Page 298 Non-Turbo Model Page 1303 Compression Check: Testing and Inspection Compression Inspection CAUTION: After warming-up, engine becomes very hot. Be careful not to burn yourself during measurement. 1. After warming-up the engine, turn the ignition switch to OFF. 2. Make sure that the battery is fully charged. 3. Release the fuel pressure. 4. Remove all the spark plugs. 5. Fully open the throttle valve. 6. Check the starter motor for satisfactory performance and operation. 7. Fix the compression gauge securely against spark plug hole. NOTE: The screw of screw-in type compression gauge (put into cylinder head spark plug hole) should be less than 18 mm (0.71 inch) long. 8. Crank the engine by means of starter motor, and then read the maximum value on the gauge when the gauge needle is steady. 9. Perform at least two measurements per cylinder, and make sure that the values are correct. Compression (at 200 - 300 rpm): Standard ............................................................................................................................................... 981 1,177 kPa (10 - 12 kgf/cm2, 142 - 171 psi) Difference between cylinders 2 Less than ........................................................................................... ..................................................................................... 49 kPa (0.5 kgf/cm2, 7 psi) Differential Fluid Level Check Differential Fluid - A/T: Service and Repair Differential Fluid Level Check Differential Gear Oil 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 check the level. If the differential gear oil level is below the "L" line, add oil to bring the level up to the "F" line. 5) To prevent overfilling the differential gear oil, do not replenish oil above the "F" line. Page 3279 Step 1 - 6 Page 6478 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Service and Repair Gear Sensor/Switch: Service and Repair Switches and Harness REMOVAL 1. BACK-UP LIGHT AND NEUTRAL POSITION SWITCH 1) Disconnect the ground cable from battery. 2) Remove the air intake duct and cleaner case. (Non-turbo model) 3) Remove the intercooler. (Turbo model) 4) Disconnect the connector of back-up light switch and neutral position switch. ^ Non-turbo model Non-turbo model ^ Turbo model Turbo model 5) Lift-up the vehicle. 6) Remove the back-up light switch and neutral position switch with harness. INSTALLATION Page 7000 B54-B127 Page 7273 Claim Reimbursement/Warrant Information For vehicles under the Basic New Car Limited Warranty period, refer to the Subaru Warranty Wizard(C) for claim submission information. Disclaimer Page 4252 2) Align the matching marks, and then connect the flange yoke and rear differential. 3) Using new bolts, install the differential mount front cover. (1) Temporarily tighten the bolt (A) while pushing cover forward. (2) Tighten the bolt (B) to specified torque. (3) Tighten the bolt (A) to specified torque. (4) Tighten the remaining bolts to specified torque. 4) Install the center exhaust pipes. 5) Install the rear exhaust pipe and muffler. Page 3075 F61-R47 Service and Repair Air Bag(s) Arming and Disarming: Service and Repair CAUTION: - When servicing a vehicle, be sure to turn the ignition switch to OFF, disconnect the ground cable from battery, and wait for more than 20 seconds before starting work. - The airbag system is fitted with a backup power source. If the airbag system is serviced within 20 seconds after the ground cable is disconnected, it may inflate. - If the airbag warning light illuminates, repair the vehicle immediately. Airbag or pretensioner may inflate incorrectly, or not inflate in collision. - If sensors, airbag module, airbag control module, pretensioner, and harness are deformed or damaged, replace them with new genuine parts. - When checking the airbag system, be sure to use a digital circuit tester. Infinitesimal electric current in an analog circuit tester may cause the airbag to activate erroneously. - When checking the airbag system, be sure to use a digital circuit tester. Infinitesimal electric current in an analog circuit tester may cause the airbag to activate erroneously. Page 6448 B3-B12 Service and Repair Positive Crankcase Ventilation Valve: Service and Repair PCV Hose Assembly REMOVAL CAUTION: Removal is not allowed except for the damage of PCV hose, diagnosis connector and PCV valve. 1. Remove the intake manifold. 2. Clip the protrusion of clamp after aligning the concave portion of ST with protrusion of clamp, and then unlock the lock. 3. Remove the PCV hose assembly. ST 18353AA000 CLAMP PLIERS INSTALLATION NOTE: Replace the clamp with a new one. 1. Install the PCV hose assembly, and then lock the clamp with protrusion of clamp clipped by pliers. ST 18353AA000 CLAMP PLIERS 2. Install the intake manifold. Page 6811 ILM(ES)-02 Locations Page 5070 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 515 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 3774 F21-F61 Page 2379 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Locations Knock Sensor: Locations Sensor (Part 1) Fuel Level Sensor Fuel Gauge Sender: Service and Repair Fuel Level Sensor Fuel Level Sensor REMOVAL WARNING: - Place "NO FIRE" signs near the working area. - Be careful not to spill the fuel. NOTE: Fuel level sensor is built in fuel pump assembly. 1. Remove the fuel pump assembly. 2. Disconnect the connector from the fuel pump bracket. 3. Remove the fuel temperature sensor. 4. Remove the bolt which installs the fuel level sensor on mounting bracket. INSTALLATION Install in the reverse order of removal. Page 4237 Refer to "FRONT AXLE" for inspection procedures. CAUTION: If there is any fault in the bearing, replace hub unit bearing. Page 1584 F61-R47 Page 512 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 7095 Fixed Glass (Wagon Model) Page 947 B54-B127 Page 4518 R58-R69 Page 2962 Page 3602 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 2760 B134-B136 Page 4476 Electrical Component Location Testing and Inspection Canister Vent Valve: Testing and Inspection INSPECTION 1. Make sure that all hoses are installed securely. 2. Make sure that hoses are not cracked or loose. Page 4532 Brake Caliper: Testing and Inspection Rear INSPECTION 1. Repair or replace the faulty parts. 2. Check the caliper body and piston for uneven wear, damage or rust. 3. Check the rubber parts for damage or deterioration. Page 6704 B136-B141 Page 4224 4) Insert the DOJ cage onto shaft. NOTE: Insert the cage with cut-out portion facing the shaft end, since the cage has an orientation. 5) Install the DOJ inner race on shaft, and fit the snap ring with pliers. NOTE: Confirm the snap ring is completely fitted in shaft groove. 6) Install the cage, which was previously fitted, to inner race fixed upon shaft. NOTE: Fit the cage with protruded part aligned with the track on inner race, and then turn by a half pitch. 7) Fill 80 to 90 g (2.82 to 3.17 ounces) of specified grease into the interior of DOJ outer race. 8) Apply a coat of specified grease to cage pocket and six balls. 9) Insert six balls into cage pocket. Page 5444 Condenser Fan Motor Relay: Testing and Inspection INSPECTION While applying battery voltage to the terminal between (3) and (4), check continuity between (1) and (2). If no continuity exists, replace the relay with a new one. Engine - Engine Oil System Flushing Engine Oil: Technical Service Bulletins Engine - Engine Oil System Flushing NUMBER: 02-110-10 DATE: 01/05/11 APPLICABILITY: All Turbo Models SUBJECT: Subaru Genuine Engine Oil System Flush INTRODUCTION The purpose of this bulletin is to announce a new product that is now available through the Subaru Genuine Chemical Program, "Subaru Engine Oil System Flush" The main cause of turbocharger failure is lack of lubrication due to insufficient maintenance Currently, 2010MY and prior turbocharged engines require that the oil and filter be changed every 3,750 miles (6,000km) or 3-3/4 months All 2011MY turbocharged engines require that the oil and filter be changed every 7,500 miles (12,000 km) or 7.5 months Proper oil change maintenance is critical to the lubrication of engine components, especially in turbocharged engines When engine oil maintenance is not performed at required intervals, oil gelling (sludge) and deposits caused by deterioration of the oil will clog oil passages, causing excessive wear from lack of lubrication If the mesh filter screen located inside the banjo bolt that secures the turbocharger oil supply pipe to the back of the right cylinder head becomes clogged, the turbocharger will fail. In addition, this will also cause damage to the Active Valve Control System (AVCS) As a reference, refer to Service Bulletin 02-106-08R, Turbocharger Mesh Filter Screen Synthetic Oil Subaru of America Inc recommends using synthetic motor oil in all turbo charged engines. When using synthetic oil, you must use oil of the same classification, viscosity and grade shown in this Owner's Manual, and must follow the oil and filter changing intervals shown in the maintenance schedule. PART INFORMATION Page 6569 B17-B20 Page 2075 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 4301 8) Remove the boss from the joint. ASSEMBLY 5MT NOTE: ^ Clean all the parts before assembly. ^ Apply grease [KOPR-KOTE (Part No. 003603001) or equivalent] to each part. 1) Mount the bushing and cushion rubber on the stay. 2) Install the bushing and spacer to boss. Page 6279 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 2281 B17-B20 Page 4788 1. Connect the inhibitor switch harness connector to inhibitor switch. 2. Install the inhibitor switch to transmission case. 3. Move the range select lever to neutral position. 4. Using the ST, tighten the bolts of inhibitor switch. ST 499267300 STOPPER PIN Tightening torque: 3.5 Nm (0.36 kgf-m, 2.6 ft. lbs.) 5. Install the select cable to range select lever. 6. Install the plate assembly to transmission. Tightening torque: T: 25 Nm (2.5 kgf-m, 18 ft. lbs.) Locations Radiator Cooling Fan Motor Relay: Locations Main Fuse Box (M/B) Solenoid Valve, Actuator, Emission Control System Parts And Ignition System Parts (Part 5) Page 6793 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 5731 2. Security indicator light blinks. NOTE: If the ALARM/WARNING occurs in the ARM mode, the indicator light blinks when the ignition switch is turned to OFF -> ON at the next DISARM mode. - If ALARM/WARNING does not occur, the light does not blink. - More than one alarm or warning occurs, the most numbers of blinking times have priority to blink. - Anytime the ignition switch is turned to ON in the DISARM mode, it blinks. The memory will be updated at the next ARM mode. Page 4700 B380-f6 Page 1088 Torque Specification Interchangeability The strainers are interchangeable for the models listed; however the correct bolts and torque specification must be used depending upon what strainer is installed. Disclaimer Page 5197 NOTE: Check the mating face of rack and tie-rod for foreign material, dirt, dust and etc. If required, clean the mating face. 35) Apply a coat of grease to the tie-rod groove, and then install the boot to housing. NOTE: Make sure that the boot is installed without unusual inflation or deflation. 36) Caulk the boot so the space inside boot band caulking portion becomes 2 mm (0.08 inch) or less. NOTE: Use a new boot band. 37) Fix the boot end with clip (small). Page 5035 R58-R69 Page 5767 Step 1 - 4 2. CHECK KEY SWITCH CIRCUIT Locations Rear Door Latch: Locations Keyless Entry System Testing and Inspection Brake Light Bulb: Testing and Inspection TAIL/STOP LIGHT BULB INSPECTION 1. Visually check the bulb for blow out. 2. Check the bulb specification. 3. If NG, replace the bulb with a new one. Page 681 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 3973 Transmission Position Switch/Sensor: Service and Repair AT Shift Lock Solenoid and "P" Range Switch AT Shift Lock Solenoid and "P" Range Switch REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the console box. 3) Disconnect the connector. 4) Remove the grip. 5) Remove the indicator bulb from indicator cover. 6) Remove the indicator cover. 7) Remove the blind. 8) Remove the cushion. 9) Remove the clip, and then remove the "P" range switch. 10) Remove the cover. Page 3980 16) Lower the AT jack. NOTE: Do not separate the AT jack and transmission. 17) Remove the oil cooler inlet and outlet pipe. NOTE: When removing the outlet pipe, be careful not to lose balls and springs used with retaining screws. 18) Remove the front and torque converter turbine speed sensor. 19) Disconnect the connector of rear vehicle speed sensor. (VTD model) 20) Disconnect the connector from rear vehicle speed sensor. (MP-T model) Page 4960 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 1433 Oil Cooler: Service and Repair Engine Oil Cooler Removal 1. Lift-up the vehicle. 2. Remove the under cover. 3. Drain the engine oil. 4. Drain the engine coolant. 5. Remove the water by-pass pipe between oil cooler and water pump. 6. Remove the engine oil filter. 7. Remove the connector, and then remove the oil cooler. Installation 1. Install in the reverse order of removal. 2. Contact the knock pin (A) of adapter A to cylinder block rib (B) to install adapter A. Page 5208 Service limit: Maximum load. 7.3 N (0. 74 kgf, 1. 64 lbs.) or less Service limit: Maximum load. 7.3 N (0.74 kgf, 1.64 lbs.) or less Page 1914 B54-B127 Page 1588 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Testing and Inspection Wiper Blade Heater Switch: Testing and Inspection WIPER DEICER SWITCH INSPECTION Move wiper deicer switch to each position and check continuity between terminals. If NG, replace the switch. Page 1788 B3-B12 Diagram Information and Instructions Wiper Blade Heater: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 3647 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 4212 4) Remove the axle nut using a socket wrench with parking brake applied. CAUTION: Remove the axle nut with vehicle weight not applied on axle. 5) Disconnect the stabilizer link. ^ Except STI model Except STI model ^ STI model STI model 6) Remove the bolt which secures the trailing link to housing. 7) Remove the bolts which secure the front lateral link and rear lateral link to housing. Page 1866 Remove the hose from the reservoir tank. Cut 20 mm from the bottom of the hose at a 45° angle. Reinstall hose in reservoir tank. Start engine and permit to fully warm up. Turn off engine and allow to fully cool down. Recheck coolant level in reservoir and add coolant if needed. Note: Be sure to use genuine Subaru Super Coolant or Subaru Long Life Coolant, depending upon what type of coolant is currently in the system. Warranty/Claim Information Specifications Water Pump: Specifications When installing the water pump, tighten bolts in two stages in alphabetical sequence as shown in the figure. Tightening torque: First ........................................................................................................................ ................................................................ 12 Nm (1.2 kgf-m, 8.7 ft. lbs.) Second ................................ .................................................................................................................................................... 12 Nm (1.2 kgf-m, 8.7 ft. lbs.) Page 4913 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 12 Alarm Module: Description and Operation SECURITY CONTROL UNIT PROCEDURE 1. FUNCTION SETTING (ECM CUSTOMIZING) 1. Connect the Subaru Select Monitor to data link connector. 2. Turn the ignition switch to ON. 3. On the display screen, select the {Each System Check} and press the [YES] key. 4. On the display screen, select the {Keyless Unit Mode} and press the [YES] key. 5. On the display screen, select the {ECM customizing} and press the [YES] key. 6. Change the setting with UP/DOWN key and press the [YES] key. - List of function setting item (ECM customizing) 7. After setting, make sure that vehicle equipment is same as the setting changed in the {Current Data Display & Save}. CAUTION: It is possible to control the original functions of vehicle when settings above are corresponded to vehicle equipment. - Do not change the settings except for setting above during operation of equipment setting. - Resetting is needed if installing a new keyless unit. - In passive mode, the system will automatically activate the alarm but WILL NOT automatically lock the doors. Failure to lock the doors manually will result in a higher security risk. NOTE: For details concerning operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. 8. Turn the ignition switch to OFF, and then remove the Subaru Select Monitor. 2. ALARM HISTORY REPORT MODE 1. Turn the ignition switch to ON. Page 4572 NOTE: ^ Always replace the pads for both right and left wheels at the same time. ^ Also replace the pad clips if they are twisted or worn. ^ A wear indicator is provided on the inner disc brake pad. If the pad wears down to such an extent that the end of wear indicator contacts disc rotor, a squeaking sound is produced as the wheel rotates. If this sound is heard, replace the pad. ^ Replace the pad if there is oil or grease on it. 2. 15 INCH TYPE Check the pad thickness A. NOTE: ^ Always replace the pads for both right and left wheels at the same time. ^ Also replace the pad clips if they are twisted or worn. ^ A wear indicator is provided on the inner disc brake pad. If the pad wears down to such an extent that the end of wear indicator contacts disc rotor, a squeaking sound is produced as the wheel rotates. If this sound is heard, replace the pad. ^ Replace the pad if there is oil or grease on it. 3. 17 INCH TYPE Check the pad thickness A. Page 5026 B54-B127 Page 651 B3-B12 Service and Repair Clutch Disc: Service and Repair Clutch Disc and Cover REMOVAL 1) Remove the transmission assembly from vehicle body. 5MT: Manual Transmission 6MT: Manual Transmission 2) Install the ST on flywheel. ST 499747100 CLUTCH DISC GUIDE 3) Remove the clutch cover and clutch disc. NOTE: ^ Take care not to allow oil on the clutch disc facing. ^ Do not disassemble the clutch cover and clutch disc. ^ Be sure to put alignment marks on the flywheel and clutch cover before removing clutch cover. INSTALLATION 1) Insert the ST into clutch disc and install them on the flywheel by inserting the ST end into pilot bearing. NOTE: When installing the clutch disc, be careful to its direction. ST 499747100 CLUTCH DISC GUIDE 2) Install the clutch cover on flywheel and tighten the bolts to specified torque. NOTE: ^ When reinstalling, align the alignment marks. ^ When installing a new clutch cover, position the clutch cover so that there is a gap of 120° or more between "0" marks on the flywheel and clutch cover. ("0" marks indicate the directions of residual unbalance.) ^ Note the front and rear of the clutch disc when installing. ^ Tighten the clutch cover installing bolts gradually. Each bolt should be tightened to the specified torque in a crisscross order. Page 5191 9) Apply a coat of grease to the grooves in rack, sliding surface of sleeve and sealing surface of piston. Install the ST on end of steering body cylinder. Then insert the rack into steering body from cylinder side. ST 34199FE050 GUIDE CAUTION: Do not allow grease to block the air vent hole on rack. 10) Using the press, slowly press the inner side oil seal until distance between the ST and end of rack becomes 65 mm (2.56 inch). ST 34199FE050GUIDE CAUTION: Ensure the ST's inner wall is free of scratches since it may damage the oil seal. 11) Pass the ST2 and pipe through rack and press outer side oil seal until ST1 is in contact with ST2 using press. ST1 34199FE050 GUIDE ST2 34199FE060 INSTALLER Page 3981 21) Remove the oil pan. 22) Disconnect the harness connector and transmission ground terminal. 23) Remove the harness assembly. INSTALLATION 1) Pass the harness assembly through the hole in the transmission case. 2) Connect the harness connector and transmission ground. Capacity Specifications Engine Oil: Capacity Specifications Oil capacity .......................................................................................................................................... .................................... 4.0 L (4.2 US qt, 3.5 Imp qt) Page 6143 R72-R145 R148 Specifications Page 6163 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 2321 B3-B12 Page 6289 B230-B283 Page 2018 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Cooling System - Radiator Cap Radiator Cap: All Technical Service Bulletins Cooling System - Radiator Cap NUMBER: 09-45-06 DATE: 11/28/06 APPLICABILITY: All Models SUBJECT: Radiator Cap INTRODUCTION The purpose of this bulletin is to provide the inspection and cleaning procedure for the radiator cap. Whenever servicing the coolant/radiator, it is imperative that the filler neck and cap are clean of all contaminants and debris. If foreign material is left in the filler neck sealing area, it will become embedded in the rubber seal and will prevent the cap from sealing properly. Before making the determination that the radiator cap is faulty, perform the following repair procedure. REPAIR PROCEDURE/INFORMATION Caution: The engine cooling system is under pressure and may be extremely hot. To prevent personal injury or vehicle damage, be sure to take appropriate precautions while performing this procedure. 1) Wash and clean the rubber seal surface(s) "A" using clean water and a soft bristle brush. 2) Carefully open the negative pressure valve. Using clean water and a soft bristle brush wash and clean the mating surface "B" between the valve and the rubber seal. Note: Clean thoroughly. Failure to do so will prevent the cap from holding pressure. 3) After cleaning, check valve-opening pressure of cap using a cap tester according to the applicable service manual. 4) Clean the filler neck sealing surface of any and all contaminants. Note: If the valve opening pressure stays within the predetermined specification the cap is reusable. Only replace caps that failed the pressure test. Special note: If the vehicle has any record of overheating the cap may not be reusable even afier cleaning due to the deterioration of the sealing materials. WARRANTY/CLAIM INFORMATION For vehicles under the Basic New Car Limited Warranty period, this repair may be claimed using the table. Diagnostic Aids Refrigerant Pressure Sensor / Switch: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 7175 F61-R47 Page 6386 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 4955 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 3728 Knock Sensor: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 6544 B136-B141 Page 2253 F21-F61 Page 4048 10) Remove the select cable from plate assembly. INSTALLATION 1) install the select cable to plate assembly. Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft. lbs.) 2) Install the select cable to range select lever. 3) Install the plate assembly to transmission. 4) Install the washer and snap pin to range select lever. 5) Insert the thread portion of other inner cable and into connector hole of select lever, and fix the other outer cable end to the bracket. Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft. lbs.) 6) Move the select lever to "N" range, and then adjust the select cable position. 7) Install the front, center, rear exhaust pipe and muffler. (SOHC model) Page 2855 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 4821 3. Remove the nut of terminal B, and then remove the rectifier. ASSEMBLY Assemble in the reverse order of disassembly. 1. Pulling up brush Before assembling, press the brush down into brush holder, and then fix them in that position by passing a [1 mm (0.08 in) dia. 40 to 50 mm (1.6 to 2.0 in) long] wire through the hole as shown in the figure. CAUTION: Be sure to remove the wire after reassembly. 2. Install the ball bearing. 1. Set the ball bearing on the front cover, and then securely install an appropriate tool (such as a fit socket wrench) to the bearing outer race. 2. Press the ball bearing into the specified position using a press. 3. Install the bearing retainer. 3. Press the bearing (rear side) into the rotor shaft using a press to install. 4. Heat the bearing box in rear cover [50 to 60 °C (122 to 140 °F)], and then press the rear bearing into rear cover. CAUTION: Grease should not be applied to rear bearing. Remove the oil completely if it is found on bearing box. 5. After reassembly, turn the pulley by hand to check that rotor turns smoothly. Page 6395 B134-B136 Page 3358 Main Relay (Computer/Fuel System): Service and Repair Main Relay REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the passenger's side front side sill cover. 3. Remove the bolt which holds the relay bracket on the body. 4. Disconnect the connectors from the main relay. 5. Remove the main relay from the mounting bracket. INSTALLATION Install in the reverse order of removal. Page 6033 9) Remove the rear rail trim (A). 10) Remove the rear quarter upper trim (B) of both sides. Page 3426 B17-B20 Page 2171 6. Disconnect the pressure hose from fuel tank pressure sensor. INSTALLATION Install in the reverse order of removal. Locations Electrical Components Location Page 5661 B54-B127 Page 3255 B128-B134 Page 635 Transmission Position Switch/Sensor: Service and Repair AT Shift Lock Solenoid and "P" Range Switch AT Shift Lock Solenoid and "P" Range Switch REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the console box. 3) Disconnect the connector. 4) Remove the grip. 5) Remove the indicator bulb from indicator cover. 6) Remove the indicator cover. 7) Remove the blind. 8) Remove the cushion. 9) Remove the clip, and then remove the "P" range switch. 10) Remove the cover. Page 4982 Grounding Point: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 4884 7. Install the washer and snap pin to range select lever. 8. Install the front and center exhaust pipes. (Nonturbo model) 9. Install the center exhaust pipe. (Turbo model) 10. Lower the vehicle. 11. Install the inhibitor switch connector from stay. 12. Connect the inhibitor switch connector. 13. Install the air intake chamber. (Non-turbo model) 14. Install the intercooler. (Turbo model) 15. Inspect the inhibitor switch. Page 7280 (3) Install the modified check valve and valve cushion. Rear Check Valve on Forester Diagram Information and Instructions Compass: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 1654 Rod extension H. 5.7 ± 0.5 mm (0.224 ± 0.020 inch) 3. BELT TENSION PULLEY 1. Check the mating surfaces of timing belt and contact point of adjuster rod for abnormal wear or scratches. Replace the belt tension pulley if faulty. 2. Check the belt tension pulley for smooth rotation. Replace if noise or excessive play is noted. 3. Check the belt tension pulley for grease leakage. 4. BELT IDLER 1. Check the belt idler for smooth rotation. Replace if noise or excessive play is noted. 2. Check the outer contacting surfaces of idler pulley for abnormal wear and scratches. 3. Check the belt idler for grease leakage. Page 2996 B380-f6 Page 2106 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 3471 F61-R47 Diagnostic Aids Fuel Gauge Sender: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 665 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 1622 Oil Pressure Sender: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 3535 Camshaft Position Sensor: Locations Sensor (Part 1) Page 5027 B128-B134 Testing and Inspection Antenna Amplifier: Testing and Inspection ANTENNA AMPLIFIER INSPECTION Measure the antenna amplifier resistance. Page 1217 Refrigerant Oil: Fluid Type Specifications COMPRESSOR OIL Use only the manufacturer-authorized compressor oil for the HFC-134a system; only use DH-PR. Specifications Valve Clearance: Specifications Valve clearance: STD Intake ............................................................................................................... ........................................................ 0.20 ± 0.02 mm (0.0079 ± 0.0008 inch) Exhaust ....................... ............................................................................................................................................. 0.35 ± 0.02 mm (0.0138 ± 0.0008 inch) Page 956 R58-R69 Page 7107 Window Glass: Service and Repair Front Door Glass FRONT DOOR GLASS REMOVAL 1. Remove the front door trim. 2. Remove the sealing cover. 3. Remove the outer mirror assembly. 4. Remove the mirror gusset. 5. Remove the stabilizer (Inner) and stabilizer (Outer). 6. Remove the screw at the rear end of weather strip, and remove weather strip. Page 2865 B230-B283 Page 1962 6. Remove the bolts and nuts which hold the front exhaust pipe assembly to turbocharger joint pipe. 7. While holding the front exhaust pipe assembly with one hand, remove the nuts which hold the front exhaust pipe assembly to cylinder head exhaust port. 8. Remove the front exhaust pipe assembly. 9. Remove the covers from exhaust manifold and front exhaust pipe. 10. Separate the front exhaust pipe from exhaust manifolds. ^ Turbo model ^ STI model INSTALLATION NOTE: Replace the gaskets with new ones. 1. Assemble the front exhaust pipe and exhaust manifolds. Tightening torque: 35 Nm (3.6 kgf-m, 26 ft. lbs.) ^ Turbo model Page 7110 Window Glass: Service and Repair Rear Window Glass REAR WINDOW GLASS REMOVAL 1. Disconnect the electrical connectors from rear defogger terminals and antenna terminal. 2. Remove the glass in the same procedure as for windshield glass. INSTALLATION 1. Install the dam rubber. 2. Install the glass in the same procedure as for windshield glass. 3. Connect the rear defogger terminals and antenna terminal. 4. After completion of all work, allow the vehicle to stand for about 24 hours. NOTE: When the door is opened/closed after glass is bonded, always lower the door glass and then open/close door carefully. - Move the vehicle slowly. - For minimum drying time and time the vehicle must be left standing before driving after bonding, follow the instructions or instruction manual from adhesive manufacturer. 5. After curing of adhesive, pour water on external surface of vehicle to check that there are no water leaks. NOTE: When a vehicle is returned to user, tell him or her that the vehicle should not be subjected to heavy impact for at least three days. Page 1780 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 3025 B17-B20 Page 6701 B54-B127 Page 3907 Shift Solenoid: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 2089 B380-f6 Page 3002 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 5199 Steering Gear: Service and Repair Steering Gearbox Inspection INSPECTION BASIC INSPECTION 1) Clean all disassembled parts, and check for wear, damage, or any other faults, then repair or replace as necessary. 2) When disassembling, check the inside of gearbox for water. If any water is found, carefully check the boot for damage, input shaft dust seal, adjusting screw and boot clips for poor sealing. If faulty, replace with new parts. SERVICE LIMIT Make a measurement as follows. If it exceeds the specified service limit, adjust or replace. NOTE: When making a measurement, vise the gearbox by using ST. Never vise the gearbox by inserting aluminum plates, etc. between vise and gearbox. ST 926200000 STAND Page 5302 Wheel Fastener: Specifications Tighten the wheel nuts in a diagonal selection to specified torque. Use a wheel nut wrench. Wheel nut tightening torque ........................................................................................................................................... 90 Nm (9.1 kgf-m, 65.7 ft. lbs.) Locations Security System A/C, Interior - Seat Heater Relay Updated Seat Heater Relay: Technical Service Bulletins A/C, Interior - Seat Heater Relay Updated change of seat heater relay In order to use a common seat heater relay with other models, FUT has changed the seat heater relay installed in Impreza and Forester vehicles from part number 8250TTC000 (brown) to 8250TFCT00 (black). The relay is located next to the fuse box under the lower dash panel on the driver side on vehicles equipped with seat heaters VIN breaks where the new relay has been installed are as shown. Page 4171 4) Deflection on facing If deflection exceeds the specified value at the outer circumference of facing, repair or replace. ST 499747100 CLUTCH DISC GUIDE 5) If worn spline, loose rivets or damper spring failure is found, replace the clutch disc. CLUTCH COVER NOTE: Visually check for the following items without disassembling, and replace or repair if defective. 1) Loose thrust rivet 2) Damaged or worn bearing contact area at center of diaphragm spring Page 2762 B230-B283 Page 6788 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 949 B134-B136 Page 362 Solar Sensor: Testing and Inspection SUNLOAD SENSOR TROUBLE SYMPTOM: - Sensor identified that sunlight is at maximum. Then, A/C system is controlled to COOL side. - Sensor identified that sunlight is at minimum. Then, A/C system is controlled to HOT side. NOTE: When the sunload sensor is checked indoors or in the shade, it may be diagnosed as open circuit. Always check the sunload sensor at a place where sun shines directly on it. Wiring Diagram Page 3866 B292-B317 Page 5311 Air Door Actuator / Motor: Testing and Inspection Mode Door Actuator MODE DOOR ACTUATOR TROUBLE SYMPTOM: Air flow outlet is not changed. Wiring Diagram Page 5068 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 2250 B230-B283 Page 2236 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 4226 16) Tap on the clip with the punch provided at the end of ST. ST 925091000 BAND TIGHTENING TOOL NOTE: Tap to an extent that the boot underneath is not damaged. 17) Cut off the band with an allowance of about 10 mm (0.39 inch) left from clip, and bend this allowance over the clip. NOTE: Be careful so that the end of band is in close contact with clip. 18) Fix up the boot on BJ in the same manner. 19) Extend and retract the DOJ to provide equal grease coating. Front Drive Shaft Inspection INSPECTION Check the removed parts for damage, wear, corrosion etc. If faulty, repair or replace. 1) DOJ (Double Offset Joint) Check seizure, corrosion, damage, wear and excessive play. 2) PTJ (Pillow tripod Joint) Check seizure, corrosion, damage and excessive play. 3) Shaft Check excessive bending, twisting, damage and wear. 4) EBJ (High-efficiency compact ball fixed joint) Check seizure, corrosion, damage and excessive play. 5) Boot Check for wear, warping, breakage or scratches. 6) Grease Check for discoloration or fluidity. Rear Drive Shaft Disassembly DISASSEMBLY 1) Straighten the bent claw of larger end of DOJ boot. 2) Loosen the band by means of screwdriver or pliers with care of not damaging boot. 3) Remove the boot band on the small end of DOJ boot in the same manner. 4) Remove the larger end of DOJ boot from DOJ outer race. 5) Pry and remove the round circlip located at neck of DOJ outer race with a screwdriver. Page 1022 Spark Plug: Specifications Type ..................................................................................................................................................... ............................................................. Manufacturer ILFR6B ................................................................................................................................................ .......................................................................... NGK Gap ...................................................................................................................................................... ................................. 0.7 - 0.8 mm (0.028 - 0.031 in) Torque ................................................................................................................................................. ........................................................ 21 N.m (15 ft.lb) Page 2073 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 6671 Brake Light Switch: Service and Repair Stop Light Switch REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the stop light switch connector. 3. Loosen nuts, and unscrew stop light switch to remove. INSTALLATION 1. Screw the stop light switch onto a bracket and secure it temporarily with a nut. 2. Adjust the stop light switch position, and then tighten the nut. Tightening torque: 8 Nm (0.8 kgf-m, 5.8 ft. lbs.) INSPECTION 1. If the stop light switch does not operate properly (or if it does not stop at the specified position), replace with a new one. Specified position L: 2 mm (0.079 inch) 2. Measure the clearance between threaded end of stop light switch and stopper. CAUTION: Be careful not to rotate stop light switch. Stop light switch clearance 0.3 mm (0.012 inch) Page 7040 B380-f6 Page 2774 CAUTION: When removing the front oxygen (A/F) sensor, wait until exhaust pipe cools, otherwise it will damage exhaust pipe. INSTALLATION 1. Before installing front oxygen (A/F) sensor, apply anti-seize compound only to the threaded portion of front oxygen (A/F) sensor to make the next removal easier. Anti-seize compound: NEVER-SEEZ NS-165 or equivalent CAUTION: Never apply anti-seize compound to protector of front oxygen (A/F) sensor. 2. Install the front oxygen (A/F) sensor. 3. Install the service hole cover. 4. Lower the vehicle. 5. Install the front right side wheel. 6. Connect the engine harness to the bracket (B) using clips (A). Page 2633 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 6174 B136-B141 Locations Secondary A/C Fuse Box Page 293 Clutch Switch: Testing and Inspection CLUTCH SWITCH INSPECTION Measure the clutch switch resistance. If NG, replace the clutch switch. Page 5125 3) Tighten a new self-locking nut. Tightening torque: 100 Nm (10.2 kgf-m, 74 ft. lbs.) THRUST ANGLE ^ Inspection 1) Position the vehicle on a level surface. 2) Move the vehicle 3 to 4 m (10 to 13 ft.) directly forward. 3) Determine the center lines of loci of both front and rear axles. 4) Measure the distance "L" between center lines of loci of the axles. Thrust angle: 0°±30'(tolerance) Less than 30' when "L" is less than 22 mm (0. 9 inch). ^ Adjustment 1) Make the thrust angle adjustments by turning toe-in adjusting bolts of rear suspension equally in the same direction. 2) When one rear wheel is adjusted in a toe-in direction, adjust the other rear wheel equally in toe-out direction, in order to make thrust angle adjustment. 3) When the right and left adjusting bolts are turned incrementally by one graduation in the same direction, the thrust angle will change approximately 16' ["L" is almost equal to 12 mm (0.472 inch)]. Testing and Inspection Exterior Lighting Relay: Testing and Inspection TAIL AND ILLUMINATION RELAY Measure the tail and illumination relay resistance between terminals when connecting terminal No. 4 to battery positive terminal and terminal No. 3 to battery ground terminal. Page 4439 Schematic drawings Page 4429 Transmission Speed Sensor: Service and Repair Torque Converter Turbine Speed Sensor Torque Converter Turbine Speed Sensor REMOVAL When removing the torque converter turbine speed sensor, refer to "Front Vehicle Speed Sensor". INSTALLATION When installing the torque converter turbine speed sensor, refer to "Front Vehicle Speed Sensor" Page 959 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 3091 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 7168 B128-B134 Page 4571 6. Expand the pads and push piston back. 7. Remove the pad. INSTALLATION 1. 14 INCH TYPE 1. Apply a thin coat of Molykote AS-880N (Part No. K0777YA010) to the frictional portion between pad and pad clip. 2. Install the pads on support. 3. Install the caliper body on support. Tightening torque: 37 Nm (3.8 kgf-m, 27.5 ft. lbs.) NOTE: If it is difficult to push the piston during pad replacement, loosen the air bleeder screw to facilitate work. 2. 15 INCH TYPE 1. Apply a thin coat of Molykote AS-880N (Part No. K0777YA010) to the frictional portion between pad and pad inner shim. 2. Install the pads on caliper body. 3. Install the cross spring. 4. Install the pad pin on caliper body. 5. Install the M clip. 3. 17 INCH TYPE 1. Apply a thin coat of Molykote AS-880N (Part No. K0777YA010) to frictional portion between pad and pad inner shim. 2. Install the pads on caliper body. 3. Install the cross spring and pad pins. 4. Install the clip. INSPECTION 1. 14 INCH TYPE Check pad thickness A. Diagram Information and Instructions Parking Brake Warning Lamp: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 1713 Compression Check: Testing and Inspection Compression Inspection CAUTION: After warming-up, engine becomes very hot. Be careful not to burn yourself during measurement. 1. After warming-up the engine, turn the ignition switch to OFF. 2. Make sure that the battery is fully charged. 3. Release the fuel pressure. 4. Remove all the spark plugs. 5. Fully open the throttle valve. 6. Check the starter motor for satisfactory performance and operation. 7. Fix the compression gauge securely against spark plug hole. NOTE: The screw of screw-in type compression gauge (put into cylinder head spark plug hole) should be less than 18 mm (0.71 inch) long. 8. Crank the engine by means of starter motor, and then read the maximum value on the gauge when the gauge needle is steady. 9. Perform at least two measurements per cylinder, and make sure that the values are correct. Compression (at 200 - 300 rpm): Standard ............................................................................................................................................... 981 1,177 kPa (10 - 12 kgf/cm2, 142 - 171 psi) Difference between cylinders 2 Less than ........................................................................................... ..................................................................................... 49 kPa (0.5 kgf/cm2, 7 psi) Page 2235 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 259 Power Mirror Switch: Service and Repair REMOTE CONTROL MIRROR SWITCH REMOVAL Refer to Power Window Control Switch for removal procedure, because the remote control mirror switch is installed in power window control switch panel. INSTALLATION Refer to Power Window Control Switch for installation procedure, because the remote control mirror switch is installed in power window control switch panel. Page 6507 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 1647 3. With a 2 mm (0.08 inch) dia. stopper pin or a 2 mm (nominal) dia. hex bar wrench inserted into the stopper pin hole in the cylinder, secure the adjuster rod. 2. Install the automatic belt tension adjuster assembly. Tightening torque: 39 Nm (4.0 kgf-m, 28.9 ft. lbs.) 3. Install the belt idler No. 2. Tightening torque: 39 Nm (4.0 kgf-m, 28.9 ft. lbs.) 4. Install the belt idlers. Tightening torque: 39 Nm (4.0 kgf-m, 28.9 ft. lbs.) Page 6314 B17-B20 Page 3343 8. Remove the bolts which install the fuel sub level sensor on the fuel tank. 9. Remove the fuel sub level sensor. INSTALLATION Install in the reverse order of removal. NOTE: Use a new gasket. 1. Ensure the sealing portion is free from fuel or foreign particles before installation. 2. Tighten the nuts and bolts to specified torque in order as shown in the figure. Wheels/Tires - Highway Speed Vibration/Harshness/Noise Wheels: All Technical Service Bulletins Wheels/Tires - Highway Speed Vibration/Harshness/Noise NUMBER: 05-50-10R DATE: 02/03/11 APPLICABILITY: All Subaru Vehicles SUBJECT: Noise, Vibration and Harshness (NVH) at Highway Speeds Caused by a Tire Imbalance or Excessive Radial Force INTRODUCTION This bulletin is to serve as information only and is intended to help minimize steering wheel vibrations at highway speed. DESCRIPTION Some customers may describe a concern of a steering wheel vibration, oscillation or a "shimmy" condition at highway speeds that may be caused by improper tire and wheel balance or excessive radial force variation (RFV). Subaru of America Inc. (SOA) recommends the use of the Hunter GSP 9700 Wheel Balance and Road Force Measurement System to properly balance the wheel and tire assemblies "dynamically" and to measure the radial force variation of the wheel and tire assembly. While the majority of these conditions can be greatly reduced with proper wheel balancing, some road feel may be considered characteristic and can be compared to like model vehicles with similar mileage. Wheel Imbalance The two most common types of wheel imbalances are static (single weight plane) and dynamic (dual weight plane). A static imbalance is best described as a vertical imbalance when the assembly is mounted on the vehicle. A dynamic imbalance is defined as a vertical and inner/outer imbalance while the assembly is mounted on the vehicle. Wheel and tire assembly imbalance should be addressed first as this is the most common source of tire and wheel vibrations. A well maintained dual weight plane balancer (commonly known as a Dynamic Balancer) such as a Hunter G5P9700 should be used to achieve the best possible results. Balancer settings and proper maintenance are critical to obtaining the best results. Refer to the operating instructions as provided by the balancer manufacturer for setup and maintenance instructions. Radial Force Variation (RFV) Radial force variation is an industrial measurement describing the tire uniformity under load. These variations, or harmonics, are measured in kilograms, pounds or newtons. SOA asks that all weight measurements be reported using the metric system (grams, kilograms, etc.) The Hunter GSP 9700 Road Force Measurement System is capable of measuring these harmonics and displaying them as R1H (radial first harmonic), R2H (radial second harmonic) and R3H (radial third harmonic.) These different harmonic levels indicate the number of bad occurrences per revolution. Most commonly, radial first (R1H) harmonics are the cause of steering wheel or body related vibrations that can be felt at highway speeds. Radial force variation can be greatly affected if the vehicle has been parked for an extended period of time causing flat spots or by improper tire inflation. Before performing any diagnosis~ be sure to drive the vehicle at least 10 miles and adjust tire pressures as indicated on the door label. Machine Setup SOA recommends the use of the Hunter GSP 9700 Road Force Measurement System to properly balance and measure radial force on tire and wheel assemblies. To ensure the most accurate results, the following guidelines should be used: ^ Refer to the operating instructions to set the machine to measure in grams (for balancing) and kilograms (for radial force measurements) ^ Refer to the operating instructions to enable the dynamic balancing mode ^ Refer to the operating instructions to disable the Quickmatch(TM) function, if available. ^ Select the "Mixed Weights Balance" mode and measure the weight location carefully. ^ Calibration should be checked at least once per week ^ Ensure the arbor threads and base plate are clean and in good condition ^ Measure the wheel center bore and select the proper cone for mounting the wheel to the balancer Page 1218 Refrigerant Oil: Service Precautions COMPRESSOR OIL - HFC-134a compressor oil has no compatibility with that for CFC-12 system. - Use only the manufacturer-authorized compressor oil for the HFC-134a system; only use DH-PR. - Do not mix multiple compressor oils. If CFC-12 compressor oil is used in a HFC-134a A/ C system, the compressor may become stuck due to poor lubrication, or the refrigerant may leak due to swelling of rubber parts. On the other hand, if HFC-134a compressor oil is used in a CFC-12 A/C system, the durability of the A/C system will be lowered. - HFC-134a compressor oil is very hygroscopic. When replacing or installing/removing A/C parts, immediately isolate the oil from the atmosphere using a plug or tape. In order to avoid moisture, store the oil in a container with its cap tightly closed. Page 6496 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 3624 B134-B136 Page 697 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Service and Repair Fuel Pressure Release: Service and Repair Fuel PROCEDURE RELEASING OF FUEL PRESSURE WARNING: - Place "NO FIRE" signs near the working area. - Be careful not to spill the fuel. 1. Disconnect the connector from the fuel pump relay. 2. Start and run the engine until it stalls. 3. After the engine stalls, crank it for five more seconds. 4. Turn the ignition switch to OFF. Page 5355 Cabin Temperature Sensor / Switch: Testing and Inspection IN-VEHICLE SENSOR TROUBLE SYMPTOM: - When turning the AUTO switch to ON, blower fan speed, outlet port and inlet port is not changed. - If the switch LED indicates that the sensor is malfunctioning, replace the auto A/C control module. The in-vehicle sensor is built into the auto A/C control module and cannot be replaced as a single unit. Page 6547 B380-f6 Page 5174 Non-Turbo Model ^ Turbo model Turbo Model 11) Remove the universal joint. 12) Disconnect the lower pipe C from gear box first, and upper pipe D second. 13) Remove the clamp bolts securing the gearbox to crossmember, and then remove the gearbox. ^ Non-turbo model Page 6399 B380-f6 Page 3266 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 765 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the connector from the camshaft position sensor RH. 3. Remove the camshaft position sensor RH from the rear side of cylinder head. 4. Remove the camshaft position sensor LH in the same procedure as RH side. INSTALLATION Install in the reverse order of removal. Tightening torque: Camshaft position sensor support: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) Camshaft position sensor: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) Page 2192 B17-B20 Page 1484 Oil Pressure Sender: Testing and Inspection INSPECTION Step 1-Step 3 Make sure oil does not leak or seep from where the oil pressure switch is installed. Page 444 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 2500 Spark Plug: Application and ID Type ..................................................................................................................................................... ............................................................. Manufacturer ILFR6B ................................................................................................................................................ .......................................................................... NGK Gap ...................................................................................................................................................... ................................. 0.7 - 0.8 mm (0.028 - 0.031 in) Torque ................................................................................................................................................. ........................................................ 21 N.m (15 ft.lb) Page 5449 Main Fuse Box (M/B) Secondary A/C Fuse Box Page 2786 Electronic Throttle Actuator Relay: Service and Repair Electronic Throttle Control Relay REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the passenger's side front side sill cover. 3. Remove the bolt which holds the relay bracket on the body. 4. Disconnect the connectors from the main relay. 5. Remove the main relay from the mounting bracket. INSTALLATION Install in the reverse order of removal. Page 1865 A used toothbrush which has been cleaned works great. Manually open the negative pressure valve. Using clean water and a brush, thoroughly clean the valve (inner and outer surface) and the valve seal surface. Check the radiator cap valve opening pressure using a radiator cap tester to insure the cap is within specification (refer to the applicable Subaru Service Manual). Note: If the cap is out of specification replace it. 2. Coolant Reservoir Tank Cleaning Remove the reservoir tank (refer to the applicable Subaru Service Manual). Using clean water, thoroughly clean the inside of the reservoir tank. Reinstall reservoir tank. Fill with coolant to the Full mark. Note: Be sure to use genuine Subaru Super Coolant or Subaru Long Life Coolant, depending upon what type of coolant is currently in the system. 3. Coolant Reservoir Tank Hose Modification Page 2042 Engine Control Module (ECM) I/O Signal (Part 6) Page 4413 12) Move the range select lever to parking position (left side). 13) Remove the inhibitor switch from transmission. 14) Disconnect the inhibitor switch harness connector from inhibitor switch. INSTALLATION 1) Connect the inhibitor switch harness connector to inhibitor switch. 2) Install the inhibitor switch to transmission case. 3) Move the range select lever to neutral position. Page 7002 B134-B136 Page 2514 Valve Clearance: Testing and Inspection VALVE CLEARANCE INSPECTION Inspection and adjustment of the valve clearance should be performed while engine is cold. 1. Set the vehicle on a lift. 2. Disconnect the ground cable from battery. 3. Remove the air intake duct. 4. Remove the bolts which secure the timing belt cover (RH). 5. Lift-up the vehicle. 6. Remove the under cover. 7. Loosen the remaining bolts which secure the timing belt cover (RH), and then remove the timing belt cover. 8. Lower the vehicle. 9. When inspecting the #1 and #3 cylinders: 1. Pull out the engine harness connector with bracket from air cleaner upper cover. 2. Remove the air cleaner case. 3. Disconnect the ignition coil connector. 4. Remove the ignition coil. 5. Place a suitable container under the vehicle. 6. Disconnect the PCV hose from rocker cover (RH). 7. Remove the bolts, and then remove the rocker cover (RH). 10. When inspecting the #2 and #4 cylinders: 1. Disconnect the battery cable, and then remove the battery and battery carrier. 2. Remove the secondary air pump. 3. Disconnect the ignition coil connector. 4. Remove the ignition coil. 5. Place a suitable container under the vehicle. 6. Disconnect the PCV hose from rocker cover (LH) 7. Remove the bolts, and then remove the rocker cover (LH). 11. Turn the crank pulley clockwise until arrow mark on the cam sprocket is set to position shown in the figure. NOTE: Turn the crankshaft using socket wrench. 12. Measure the #1 cylinder intake valve and #3 cylinder exhaust valve clearance by using thickness gauge (A). NOTE: ^ Insert the thickness gauge (A) in as horizontal a direction as possible with respect to the shim. ^ Measure the exhaust valve clearances while lifting-up the vehicle. Valve clearance: STD Intake: 0.20 ± 0.02 mm (0.0079 ± 0.0008 inch) Exhaust. 0.35 ± 0.02 mm (0.0138 ± 0.0008 inch) Page 1340 Limit 0.05 mm (0.0020 inch) 6. Inspect the bushing at connecting rod small end, and replace if worn or damaged. Also measure the piston pin clearance at connecting rod small end. Clearance between piston pin and bushing: Standard 0 - 0.022 mm (0 - 0.0009 inch) Limit 0.030 mm (0.0012 inch) 7. Replacement procedure is as follows. 1. Remove the bushing from connecting rod with ST and press. 2. Press the bushing with ST after applying oil on the periphery of bushing. ST 499037100 CONNECTING ROD BUSHING REMOVER AND INSTALLER Page 3769 B134-B136 Page 5184 13) Remove the holder using a wrench (36 mm width across flats) or adjustable wrench. 14) Install the ST on valve side of rack and press outer side oil seal out taking care not to contact rack with steering body inner surface. ST 34199FEOOO INSTALLER & REMOVER NOTE: Block the pipe connection of steering body to prevent fluid from flowing out. 15) Insert the ST from valve side and press backup ring and oil seal out. ST 34199FE010 REMOVER Locations Cruise Control Switch: Locations Non-Turbo Model Page 2756 B3-B12 Page 4604 Disclaimer Diagnostic Aids Ignition Switch: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Locations Crankshaft Position Sensor: Locations Sensor (Part 1) Page 3762 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 1465 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 5321 Air Duct: Service and Repair Heater Duct Heater Duct REMOVAL 1. Remove the front seats. 2. Remove the console box. 3. Remove the side sill front cover, side sill rear cover and center pillar lower trim. 4. Remove the foot rest. 5. Remove the clips from floor mat. 6. Remove the mat hook. 7. Remove the mat from toe board area. 8. Remove the rear heater duct cover (A). Draw out the rear heater duct from the unit assembly and slide it forward to remove. INSTALLATION Install in the reverse order of removal. NOTE: - Secure the mat firmly with hook and Velcro tape. - Insert the mat edge firmly into the groove of side sill cover. Page 6407 Fuel Gauge: Description and Operation FUEL GAUGE GENERAL - The fuel gauge unit consists of a float and a potentiometer whose resistance varies depending on movement of the float. It is located inside the fuel tank and forms an integral part of the fuel pump. The fuel gauge indicates the fuel level in the tank when the ignition switch is in the ON position. When the trip knob is pushed, the fuel gauge illumination comes ON and the fuel level registered just before the ignition switch was turned OFF is indicated, even when the ignition switch is in the OFF position. - All models are equipped with two fuel level sensors. These sensors are installed in the fuel tank, one on the right side and the other on the left side. Two sensors are necessary because the fuel tank is divided into main and sub tank compartments. OPERATION The low fuel warning light operates as follows: - The signal from the fuel level sensor is converted into a digital signal at the body integrated unit, and then sent to the combination meter. The combination meter microprocessor continually monitors this signal. It turns on the low fuel warning light in the combination meter if a resistance value corresponding to the critical fuel level is detected for a certain time while driving. - This monitoring time has been decided to avoid false operation of the warning light, which may happen when a large part of remaining fuel is collected temporarily in the sub tank compartment. Page 6559 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 4145 Page 6993 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 185 B230-B283 Page 7109 Window Glass: Service and Repair Rear Gate Glass REAR GATE GLASS REMOVAL 1. Remove the rear wiper motor. 2. Disconnect the electrical connector from rear defogger terminal. 3. Remove the glass in the same procedure as for windshield glass. INSTALLATION 1. Apply adhesive in the same procedure as for windshield glass. 2. Insert the glass locating pin into the rear gate hole, and after pushing on the area around the locating pin to secure it, push lightly all around the area to seal it. 3. About one hour after installation, conduct a water leak test. 4. After completion of all work, allow the vehicle to stand for about 24 hours. NOTE: When the door is opened/closed after glass is bonded, always lower the door glass and then open/close it carefully. - Move the vehicle slowly. - For minimum drying time and time the vehicle must be left standing before driving after bonding, follow the instructions or instruction manual from adhesive manufacturer. - When a vehicle is returned to the user, tell him or her that the vehicle should not be subjected to heavy impact for at least three days. 5. Connect the rear defogger terminals. 6. Install the rear wiper. Page 6565 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS A/T - 4AT, Filter/Torque Specification Revision Fluid Filter - A/T: Technical Service Bulletins A/T - 4AT, Filter/Torque Specification Revision NUMBER: 16-75-09 DATE: 04/08/09 APPLICABILITY SUBJECT: 4AT Automatic Transmission Strainer Introduction The purpose of this bulletin is to inform you that the automatic transmission strainer has changed from being made out of metal to resin. The length of the bolts and the torque specification has also changed. Countermeasure in Production The new style strainer was used in production towards the end of October, 2008 starting with transmission # 374122. Part Information Page 3427 B54-B127 Page 7257 Windshield Washer Reservoir: Testing and Inspection WASHER TANK AND MOTOR INSPECTION Apply battery voltage to the connector terminal of the washer motor and make sure the motor operates. Page 3246 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Body - Front Power Window Motor/Harness Change Front Door Window Motor: Technical Service Bulletins Body - Front Power Window Motor/Harness Change NUMBER: 07-64-08 DATE: 12/04/08 APPLICABILITY: 2002-07MY Impreza SUBJECT: Power Window Motor Assembly, Front Introduction The purpose of this bulletin is to inform you that the wiring harness of the front door power window motor has been shortened. When replacing with the new style, it will be necessary to reroute and secure the harness. PART INFORMATION Immobilizer Control Unit Alarm Module: Service and Repair Immobilizer Control Unit IMMOBILIZER CONTROL UNIT REMOVAL NOTE: Prepare the security ID plate. - Prepare all registered immobilizer keys for the model with immobilizer. - Make a registration of immobilizer when replacing the immobilizer control unit. New immobilizer key is required for registration. For detailed operation procedure, refer to "IMMOBILIZER REGISTRATION MANUAL - If the keys are added without replacing the immobilizer control unit, maximum 4 keys can be registered including new keys. 1. Disconnect the ground cable from battery. 2. Remove the instrument panel lower cover. 3. Disconnect the connector from immobilizer control unit. 4. Remove the immobilizer control unit. INSTALLATION Install in the reverse order of removal. Testing and Inspection Canister Purge Solenoid: Testing and Inspection INSPECTION Make sure the hoses are not cracked or loose. Page 3485 Intercooler: Locations Secondary Air Pressure Sensor Sensor (Part 1) Page 3692 Crankshaft Position, Camshaft Position And Knock Sensors Page 5437 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 792 B3-B12 Page 4397 Shift Solenoid: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 3411 Fuel Temperature Sensor: Service and Repair Fuel Temperature Sensor REMOVAL Fuel temperature sensor and fuel level sensor are integrated into one unit; therefore, the removal procedure is the same as that for fuel level sensor. INSTALLATION Fuel temperature sensor and fuel level sensor are integrated into one unit; therefore, the installation procedure is the same as that for fuel level sensor. Page 3431 B230-B283 Page 5153 Power Steering Pump: Service and Repair Oil Pump REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the pulley belt cover. 3) Loosen the belt tension adjusting bolt and generator securing bolt, and then remove the power steering pump V-belt. 4) Disconnect the connector from power steering pump switch. 5) Disconnect the pipe C and suction hose from oil pump. CAUTION: ^ Do not allow fluid from the hose end to come into contact with pulley belt. ^ To prevent foreign matter from entering the hose, cover the open ends of them with a clean cloth. 6) Remove the bolts which install the power steering pump bracket. 7) Place the oil pump bracket in a vise, remove the two bolts from front side of oil pump. CAUTION: Do not place the oil pump bracket directly in the vise; use soft pads and hold oil pump lightly to protect the pump. Page 5337 Manual A/C Model Page 6795 B17-B20 Page 1482 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 5635 8. Remove the two bolts and adjustable anchor assembly. CAUTION: Do not drop or apply any impact to the pretensioner. - Pretensioner and bracket should be treated as an assembly. Do not attempt to disassemble it. 2. INNER SEAT BELT ASSEMBLY 1. Turn the ignition switch to OFF, disconnect the ground cable from battery, and wait for more than 20 seconds before starting work. 2. Remove the console box. 3. Disconnect the seat belt warning light connector under the seat. 4. Remove the clip of harness from seat rail. 5. Remove the anchor bolt, and then remove the inner seat belt assembly. INSTALLATION 1. OUTER SEAT BELT ASSEMBLY Install in the reverse order of removal. CAUTION: Parts of the driver and passenger sides are not identical. Before installation, make sure the correct part is used. - Be careful not to twist the seat belts during installation. 2. INNER SEAT BELT ASSEMBLY Install in the reverse order of removal. CAUTION: After driver s and passenger s inner seat belt assemblies installation, check that the seat belt buckle switch operates normally using Subaru Select Monitor on the {Status Data} of . Improper buckle switch function may cause airbag system malfunction. - Inner seat belt assembly harness (1) must be routed securely as shown in the figure, since it may affect the performances of seat position sensor and occupant detection system. Page 1163 Fluid - A/T: Fluid Type Specifications Automatic Transmission Recommended fluid Use one of the following types of automatic transmission fluid: Subaru ATF Type-HP IDEMITSU ATF HP Castrol Transmax J Pennzoil ATF J Page 4657 5. Install the seal to reservoir tank. 6. Install the reservoir tank to master cylinder and secure with pin. Page 4163 3) Apply grease to the spline portion. 4) Insert the release fork shaft into release fork. NOTE: Make sure the cutout portion of release fork shaft contacts spring pin. 5) Tighten the plug. Service and Repair Antitheft Antenna: Service and Repair IMMOBILIZER ANTENNA REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the instrument panel lower cover. 3. Remove the screws, separate upper column cover and lower column cover. 4. Disconnect the immobilizer antenna connector (A) from body harness. 5. Remove the screw, and detach the immobilizer antenna (B). INSTALLATION Install in the reverse order of removal. Page 447 B54-B127 Page 5297 Refer to "FRONT AXLE" for inspection procedures. CAUTION: If there is any fault in the bearing, replace hub unit bearing. Page 3245 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 3723 B380-f6 Page 7 Alarm Horn Relay: Service and Repair SECURITY HORN RELAY REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the mounting bolt and detach the security horn relay. INSTALLATION Install in the reverse order of removal. Page 2930 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 4561 NOTE: ^ Always replace the pads for both right and left wheels at the same time. ^ Also replace the pad clips if they are twisted or worn. ^ A wear indicator is provided on the inner disc brake pad. If the pad wears down to such an extent that the end of wear indicator contacts disc rotor, a squeaking sound is produced as the wheel rotates. If this sound is heard, replace the pad. ^ Replace the pad if there is oil or grease on it. Page 4428 VTD model INSTALLATION Install in the reverse order of removal. NOTE: Replace with a new O-ring. Tightening torque: 7 Nm (0. 7 kgf-m, 5. 1 ft. lbs.) Capacity Specifications Fluid - A/T: Capacity Specifications Automatic Transmission Fluid Capacity .............................................................................................. ..................................................................... 9.5 liter (10.0 US qt, 8.4 Imp qt) Locations Cruise Control Switch: Locations Non-Turbo Model Page 523 B54-B127 Removal and Installation Windshield Washer Reservoir: Service and Repair Removal and Installation WASHER TANK AND MOTOR REMOVAL 1. Open the hood. 2. Disconnect the ground cable from battery. 3. Remove the front bumper. 4. Remove the hose from L joint, and then drain washer fluid. 5. Remove the duct clip. 6. Remove the connector. 7. Remove the screw, and then remove the cover. Page 306 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 4399 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 2966 P Code List (Partial list) Page 4969 B3-B12 Page 5038 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 6894 Electrical Component Location Inhibitor Switch Neutral Safety Switch: Service and Repair Inhibitor Switch Removal and Installation Inhibitor Switch REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the connector from inhibitor switch, and then remove the switch. INSTALLATION Install in the reverse order of removal. Inspection Inhibitor Switch INSPECTION When the driving condition or starter motor operation is erroneous, first check the shift linkage for improper operation. If the shift linkage is functioning properly, check the inhibitor switch. 1. Disconnect the inhibitor switch connector. 2. Check continuity in inhibitor switch circuits with the select lever moved to each position. NOTE: ^ Also check that continuity in ignition circuit does not exist when the select lever is in R, D, 3, 2 and 1 ranges. ^ If the inhibitor switch is inoperative, check for poor contact of connector on transmission side. 3. Check if there is continuity at equal points when the select lever is turned 1.5° in both directions from N range. Testing and Inspection Crankshaft Gear/Sprocket: Testing and Inspection INSPECTION 1. Check the crank sprocket teeth for abnormal wear and scratches. 2. Make sure there is no free play between crank sprocket and key. 3. Check the crank sprocket notch used for sensor for damage and contamination of foreign matter. Page 3181 Canister Purge Solenoid: Service and Repair Purge Control Solenoid Valve REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the connector and hoses from purge control solenoid valve. 3. Remove the bolt which installs the purge control solenoid valve onto intake manifold. INSTALLATION Install in the reverse order of removal. NOTE: Connect the evaporation hoses as shown in the figure. Page 4692 B3-B12 Page 4487 By letting the brake pedal to move down along the catcher, the rearward movement of the brake pad is controlled. Page 4983 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 75 Headlamp Relay: Testing and Inspection HEADLIGHT RELAY Measure the headlight relay resistance between terminals when connecting terminal No. 4 to battery positive terminal and terminal No. 3 to battery ground terminal. Page 4633 CENTER AND REAR BRAKE PIPES AND HOSES Specifications Specification Page 1924 R72-R145 R148 Page 4923 B128-B134 Page 6718 Glove Box Lamp: Testing and Inspection GLOVE BOX LIGHT INSPECTION 1. Visually check the bulb for blow out. 2. Check the bulb specification. 3. If NG, replace the bulb with a new one. Locations Intake Air Temperature Sensor: Locations Sensor (Part 1) Page 6031 7) Remove the assist-grips (A). 8) Remove the upper inner trim. 9) Remove the quarter upper trim. 10) Remove the clips, and then remove the roof trim. 2. Wagon Model 1) Disconnect the ground terminal from battery. 2) Remove the sunroof switch (Model with sunroof) 3) Remove the room light. 4) Remove the sun visor and hook on right or left side or on both sides. Page 6843 B136-B141 Page 5625 Disclaimer Diagram Information and Instructions Temperature Gauge: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 6955 Combination Switch: Testing and Inspection Combination Base Switch Assembly INSPECTION COMBINATION BASE SWITCH ASSEMBLY Perform the inspection for the following items and replace with a new one, if any damage is found. Crack or deformation of combination base switch assembly or roll connector. Page 4870 Non-Turbo Model Specifications Idle Speed: Specifications Idle speed [A/C "ON". no load and gears in neutral]: When the A/C refrigerant pressure is low MT .. .............................................................................................................................................................. ................................................. 725 ± 100 rpm AT .............................................................................. ..................................................................................................................................... 750 ± 100 rpm When the A/C refrigerant pressure is high MT .................................................................................... ............................................................................................................................. 800 ± 100 rpm AT .. .............................................................................................................................................................. ................................................... 825 ± 100 rpm Page 6857 Parking Lamp: Testing and Inspection INSPECTION PARKING SWITCH Measure the resistance between parking switch terminals. Page 2517 Page 6615 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 4765 1) With the select lever already in the "N" range, loosen the adjusting nuts A and B on both sides. 2) Turn the adjusting nut B until it lightly touches the connector. 3) Use a spanner wrench to hold nut B so that it does not rotate and then tighten the adjusting nut A. Tightening torque: 7.5 N-m (0.76 kgf-m, 5.5 ft-lb) 4) Afier the completion of adjustment, confirm that the select lever operates normally at all ranges: ^ Move the select lever from "P" to "D" range. Check that the detents could be felt in each range. If the detents cannot be felt or the position pointer (dash indicator) is improperly aligned, re-adjust the cable. ^ Check if the starter motor rotates when the select lever is set to "P" range. Testing and Inspection Wiper Switch: Testing and Inspection COMBINATION SWITCH (WIPER) INSPECTION - Inspect the continuity between each connector terminal If continuity is not as specified, replace the switch. - Intermittent operation inspection (inspection of wiper switch unit) 1. Position the voltage meter between the connector terminals No. 7 (+) and No. 2 (-). 2. Connect the battery positive lead to connector terminal No. 17 and the negative lead to connector terminals No. 2 and No. 16. 3. Turn the wiper switch to INT. 4. Disconnect the battery negative lead from connector terminal No. 16. 5. Connect the battery positive lead to connector terminal No. 16 for 5 seconds. 6. Connect the battery negative lead to connector terminal No. 16, and check the voltage between the connector terminals No. 7 (+) and No. 2 (-). Page 2429 Crankshaft Position, Camshaft Position And Knock Sensors Page 6787 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 2707 R72-R145 R148 Page 6193 Power Mirror Switch: Service and Repair REMOTE CONTROL MIRROR SWITCH REMOVAL Refer to Power Window Control Switch for removal procedure, because the remote control mirror switch is installed in power window control switch panel. INSTALLATION Refer to Power Window Control Switch for installation procedure, because the remote control mirror switch is installed in power window control switch panel. Body - Front Power Window Motor/Harness Change Front Door Window Motor: Technical Service Bulletins Body - Front Power Window Motor/Harness Change NUMBER: 07-64-08 DATE: 12/04/08 APPLICABILITY: 2002-07MY Impreza SUBJECT: Power Window Motor Assembly, Front Introduction The purpose of this bulletin is to inform you that the wiring harness of the front door power window motor has been shortened. When replacing with the new style, it will be necessary to reroute and secure the harness. PART INFORMATION Page 5848 10. Remove the bolt. 11. Remove the three bolts, then remove the bumper beam. NOTE: In the case of right side, remove the canister first. Loosen the bolt, and then remove the bumper beam. 12. Remove the five clips, and then remove the bumper upper beam. 13. Remove the license plate light. Page 1717 Valve Clearance: Testing and Inspection VALVE CLEARANCE INSPECTION Inspection and adjustment of the valve clearance should be performed while engine is cold. 1. Set the vehicle on a lift. 2. Disconnect the ground cable from battery. 3. Remove the air intake duct. 4. Remove the bolts which secure the timing belt cover (RH). 5. Lift-up the vehicle. 6. Remove the under cover. 7. Loosen the remaining bolts which secure the timing belt cover (RH), and then remove the timing belt cover. 8. Lower the vehicle. 9. When inspecting the #1 and #3 cylinders: 1. Pull out the engine harness connector with bracket from air cleaner upper cover. 2. Remove the air cleaner case. 3. Disconnect the ignition coil connector. 4. Remove the ignition coil. 5. Place a suitable container under the vehicle. 6. Disconnect the PCV hose from rocker cover (RH). 7. Remove the bolts, and then remove the rocker cover (RH). 10. When inspecting the #2 and #4 cylinders: 1. Disconnect the battery cable, and then remove the battery and battery carrier. 2. Remove the secondary air pump. 3. Disconnect the ignition coil connector. 4. Remove the ignition coil. 5. Place a suitable container under the vehicle. 6. Disconnect the PCV hose from rocker cover (LH) 7. Remove the bolts, and then remove the rocker cover (LH). 11. Turn the crank pulley clockwise until arrow mark on the cam sprocket is set to position shown in the figure. NOTE: Turn the crankshaft using socket wrench. 12. Measure the #1 cylinder intake valve and #3 cylinder exhaust valve clearance by using thickness gauge (A). NOTE: ^ Insert the thickness gauge (A) in as horizontal a direction as possible with respect to the shim. ^ Measure the exhaust valve clearances while lifting-up the vehicle. Valve clearance: STD Intake: 0.20 ± 0.02 mm (0.0079 ± 0.0008 inch) Exhaust. 0.35 ± 0.02 mm (0.0138 ± 0.0008 inch) Page 451 B230-B283 Service and Repair Air Bag(s) Arming and Disarming: Service and Repair CAUTION: - When servicing a vehicle, be sure to turn the ignition switch to OFF, disconnect the ground cable from battery, and wait for more than 20 seconds before starting work. - The airbag system is fitted with a backup power source. If the airbag system is serviced within 20 seconds after the ground cable is disconnected, it may inflate. - If the airbag warning light illuminates, repair the vehicle immediately. Airbag or pretensioner may inflate incorrectly, or not inflate in collision. - If sensors, airbag module, airbag control module, pretensioner, and harness are deformed or damaged, replace them with new genuine parts. - When checking the airbag system, be sure to use a digital circuit tester. Infinitesimal electric current in an analog circuit tester may cause the airbag to activate erroneously. - When checking the airbag system, be sure to use a digital circuit tester. Infinitesimal electric current in an analog circuit tester may cause the airbag to activate erroneously. Page 5672 Seat Belt Reminder Lamp: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 2940 B136-B141 Page 4263 Fluid - M/T: Fluid Type Specifications Transmission Fluid Grade ................................................................................................................................................... ............................................. API classification GL-5 Above 0° C (38° F) ........................................... ......................................................................................................................................................... SAE 90 Above -30° C (-20° F) ............................................................................................................. .............................................................................. SAE 85W Below 30° C (83° F) ............................. .............................................................................................................................................................. ... SAE 80W All temperatures .............................................................................................................. .......................................................................................... 75W-90 Page 5398 Manual A/C Model Page 2854 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Diagram Information and Instructions Ignition Control Module: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 4290 Non-turbo model ^ Turbo model Turbo model 4) Replace defective parts. Blower Motor Unit Assembly Blower Motor: Testing and Inspection Blower Motor Unit Assembly INSPECTION Connect the motor connector terminal 1 from the battery to the positive (+) lead and terminal 2 to the negative (-) lead. Make sure the motor runs smoothly. Diagram Information and Instructions Radiator Cooling Fan Motor: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 117 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Locations Crankshaft Position Sensor: Locations Sensor (Part 1) Page 6233 Clutch Switch: Service and Repair CLUTCH SWITCH REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the connector from clutch switch, and then remove the switch. INSTALLATION Install in the reverse order of removal. Service and Repair Mud Flap: Service and Repair MUD GUARD REMOVAL 1. Lift-up the vehicle. 2. Remove the screws and clips to remove mud guard. INSTALLATION Insert the hook into body, and tighten it with screw and clip. Tightening torque: T: 4.5 N.m (0.46 kgf-m, 3.3 ft-lb) Diagnostic Aids Fuse: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Locations Variable Induction Position Sensor: Locations Sensor (Part 1) Page 6502 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 4039 7) Remove the clamp, and the remove the shift lock solenoid. 8) Remove the bolt securing lock plate B. 9) Remove the lock plates A, B, C and bushing. 10) Remove the cushion plate. Page 1556 14. Connect the evaporation hose and purge valve to the intake manifold. 15. Install the purge control solenoid valve. 16. Connect the hoses to the purge control solenoid valve. NOTE: Connect the evaporation hoses as shown in the figure. 17. Connect the connector to the purge control solenoid valve. Service and Repair Gear Sensor/Switch: Service and Repair Switches and Harness REMOVAL 1. BACK-UP LIGHT AND NEUTRAL POSITION SWITCH 1) Disconnect the ground cable from battery. 2) Remove the air intake duct and cleaner case. (Non-turbo model) 3) Remove the intercooler. (Turbo model) 4) Disconnect the connector of back-up light switch and neutral position switch. ^ Non-turbo model Non-turbo model ^ Turbo model Turbo model 5) Lift-up the vehicle. 6) Remove the back-up light switch and neutral position switch with harness. INSTALLATION Page 3389 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Service and Repair Fuel Pressure Release: Service and Repair Fuel PROCEDURE RELEASING OF FUEL PRESSURE WARNING: - Place "NO FIRE" signs near the working area. - Be careful not to spill the fuel. 1. Disconnect the connector from the fuel pump relay. 2. Start and run the engine until it stalls. 3. After the engine stalls, crank it for five more seconds. 4. Turn the ignition switch to OFF. Page 2083 B54-B127 Page 5651 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 5461 Cabin Temperature Sensor / Switch: Testing and Inspection IN-VEHICLE SENSOR TROUBLE SYMPTOM: - When turning the AUTO switch to ON, blower fan speed, outlet port and inlet port is not changed. - If the switch LED indicates that the sensor is malfunctioning, replace the auto A/C control module. The in-vehicle sensor is built into the auto A/C control module and cannot be replaced as a single unit. Page 2708 Knock Sensor: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Testing and Inspection Wiper Blade Heater Switch: Testing and Inspection WIPER DEICER SWITCH INSPECTION Move wiper deicer switch to each position and check continuity between terminals. If NG, replace the switch. Page 6062 Keyless Entry Transmitter: Technical Service Bulletins Keyless Entry - Remote Transmitter Modification NUMBER: 15-117-06 DATE: 04/06/06 APPLICABILITY: 2005MY Legacy and Outback 2005-06MY Forester and Impreza SUBJECT: Keyless Remote Transmitter Modification INTRODUCTION A modification has been made to the keyless remote transmitter to prevent unintentional activation. PRODUCTION LINE CHANGE The modified transmitter was used in 2006MY production with the following VINs: Existing transmitters can be modified using the following procedure. Note: Part # 88039AG02A contains an upper transmitter case, lock, unlock and trunk/rear gate button. Part # 88039FE050 contains an upper transmitter case, lock and unlock button. REPAIR PROCEDURE/INFORMATION: Note: To prevent static electricity, touch a metal object first before disassembling transmitter. Make sure that transmitter does not come in contact with oil, water or any other contaminates that could damage it. 1) Insert a flathead screwdriver that is wrapped by a cloth around the blade into the small gap and remove the upper cover. Be extremely careful not to scratch the case. 2) Remove the electrical circuit base with waterproof rubber by pushing on the unlock button. Be extremely careful not to touch the electrical circuit base. 3) Peel off the tape of the service parts (upper transmitter case and buttons) and assemble them in reverse steps of disassembly. CLAIM REIMBURSEMENT/WARRANTY INFORMATION Page 7009 R58-R69 Page 3262 F61-R47 Page 2014 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 2866 B292-B317 Testing and Inspection Antitheft Relay: Testing and Inspection INTERRUPT RELAY INSPECTION Measure the interrupt relay resistance between terminals (indicated in the table) when connecting terminal No. 3 to battery positive terminal and terminal No. 1 to battery ground terminal. If NG, replace the interrupt relay. CAUTION: Do not connect the terminals to battery positive terminal and ground terminal incorrectly. If this happens, replace the interrupt relay. Page 6844 B230-B283 Page 1503 B128-B134 Page 732 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Air Vent Grille Air Duct: Service and Repair Air Vent Grille Air Vent Grille REMOVAL 1. CENTER GRILLE 1. Disconnect the ground cable from battery. 2. Remove the console front panel. 3. Remove the center console panel. 4. Loosen the three screws to remove the center air vent grille (A). 2. SIDE GRILLE 1. Disconnect the ground cable from battery. 2. Remove the heater vent duct. 3. Loosen the screws to remove the side air vent grille. INSTALLATION Install in the reverse order of removal. Page 5480 Solar Sensor: Service and Repair Sunload Sensor (Auto A/C Model) REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the front defroster grille. 3. Disconnect the sunload sensor connector (A). CAUTION: Be careful not to damage the sensors and interior trims when removing them. INSTALLATION Install in the reverse order of removal. Page 1283 Wheels: Testing and Inspection Wheel Balancing REPLACEMENT 1. Remove the balance weights. 2. Using wheel balancer, measure the wheel balance. 3. Select a weight close to the value measured by wheel balancer. 4. Install the selected weight to the point designated by wheel balancer. 5. Using wheel balancer, measure the wheel balance again. Check the wheel balance is correctly adjusted. INSPECTION 1. Proper wheel balance may be lost if the tire is repaired or if it wears. Check the tire for dynamic balance, and repair as necessary. 2. To check for dynamic balance, use a wheel balancer. Drive in the balance weight on both the top and rear sides of rim. 3. Some types of balancer can cause damage to the wheel. Use an appropriate balancer when adjusting the wheel balance. 4. Use genuine balance weights. NOTE: ^ 55 g (1.94 oz) weight used with the aluminum wheel is not available. ^ Balance weights are available for use with any of 16 to 1 7-inch wheels. Adjustments Transmission Position Switch/Sensor: Adjustments Inhibitor Switch ADJUSTMENT 1) Move the select lever to "N" range. 2) Loosen the three inhibitor switch securing bolts. 3) Insert the ST as vertical as possible into the holes in inhibitor switch lever and switch body. ST 499267300 STOPPER PIN 4) Tighten the three inhibitor switch bolts. Tightening torque: 3.5 Nm (0.36 kgf-m, 2.6 ft. lbs.) 5) Repeat the above checks. If the inhibitor switch is determined to be "faulty", replace it. Page 2688 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 690 B292-B317 Page 557 Refer to the illustrations above for more details on locating the appropriate sensors. Page 6123 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Locations Keyless Entry System Page 6383 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 2546 R72-R145 R148 Page 3473 R72-R145 R148 Locations Fuel Temperature Sensor: Locations Page 6903 Combination Switch: Testing and Inspection Combination Base Switch Assembly INSPECTION COMBINATION BASE SWITCH ASSEMBLY Perform the inspection for the following items and replace with a new one, if any damage is found. Crack or deformation of combination base switch assembly or roll connector. Page 6541 B54-B127 Page 3583 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 4961 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 3855 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 182 B128-B134 Diagnostic Aids Fuse Block: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 4849 ^ Check the back-up light illumination when the select lever is in "R" range. ^ Check the parking lock operation when the select lever is in "F" range. 5) Using the Subaru Select Monitor, clear the diagnostic trouble codes stored in memory. If the codes return afier the correct adjustments, refer to the diagnostic procedure found in the applicable Subaru Service Manual. WARRANTY/CLAIM INFORMATION For vehicles within the Basic New Car Limited Warranty period, refer to the Subaru Warranty Wizard for claim submission information. Disclaimer Page 6344 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 4128 Except Non-turbo model and STI model 2) Insert the piston into operating cylinder. 3) Install the push rod to boot. 4) Install the boot and push rod to operating cylinder. ^ Non-turbo model Non-turbo Model ^ Except Non-turbo model and STI model Except Non-turbo model and STI model INSPECTION 1) Check the operating cylinder for damage. If operating cylinder is damaged, replace it. 2) Check the operating cylinder for fluid leakage or damage on boot. If any leakage or damage is found, replace the operating cylinder. Page 7003 B136-B141 Page 4508 B17-B20 Page 3765 B3-B12 Page 2157 Crankshaft Position, Camshaft Position And Knock Sensors Page 3553 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 4567 NOTE: ^ Always replace the pads for both right and left wheels at the same time. ^ Also replace the pad clips if they are twisted or worn. ^ A wear indicator is provided on the inner disc brake pad. If the pad wears down to such an extent that the end of wear indicator contacts disc rotor, a squeaking sound is produced as the wheel rotates. If this sound is heard, replace the pad. ^ Replace the pad if there is oil or grease on it. 2. 16 INCH TYPE Check the pad thickness A. NOTE: ^ Always replace the pads for both right and left wheels at the same time. ^ Also replace the pad clips if they are twisted or worn. ^ A wear indicator is provided on the inner disc brake pad. If the pad wears down to such an extent that the end of wear indicator contacts disc rotor, a squeaking sound is produced as the wheel rotates. If this sound is heard, replace the pad. ^ Replace the pad if there is oil or grease on it. 3. 17 INCH TYPE Check the pad thickness A. Page 3687 Crankshaft Position, Camshaft Position And Knock Sensors Page 3777 R72-R145 R148 Page 4324 12) Move the range select lever to parking position (left side). 13) Remove the inhibitor switch from transmission. 14) Disconnect the inhibitor switch harness connector from inhibitor switch. INSTALLATION 1) Connect the inhibitor switch harness connector to inhibitor switch. 2) Install the inhibitor switch to transmission case. 3) Move the range select lever to neutral position. Page 4302 3) Using new self-locking nuts, install the boss to the joint. 4) Install the snap ring to gear shift lever and install the bushing. NOTE: Apply grease to the bushing. 5) Apply grease to the bushing and O-ring, and then install to the gear shift lever. 6) Apply sufficient grease into boss, and then install the gear shift lever to the stay. Page 1311 Camshaft Gear/Sprocket: Service and Repair Cam Sprocket Removal 1. Remove the V-belt. 2. Remove the crank pulley. 3. Remove the timing belt cover. 4. Remove the timing belt. 5. Remove the cam sprockets. To lock the camshaft, use ST. ST 499207400 CAM SPROCKET WRENCH ST 499977500 CAM SPROCKET WRENCH Installation 1. Install the cam sprocket. To lock the camshaft, use ST. ST 499207400 CAM SPROCKET WRENCH Tightening torque: Tighten to 30 Nm (3.1 kgf-m, 22.1 ft. lbs.), then further tighten by 45° NOTE: Do not confuse the cam sprockets (RH) and (LH) intake side during installation. ST 499977500 CAM SPROCKET WRENCH Tightening torque: Tighten to 30 Nm (3.1 kgf-m, 22.1 ft. lbs.), then further tighten by 45° Page 5838 4. Remove the six clips on the upper part of bumper. 5. Remove the clips, which secure the front bumper to fender. 6. Remove the clips, and turn over the mud guard LH and RH. Page 3892 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 1470 B128-B134 Page 3593 B230-B283 Page 7063 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 6619 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Extension Case Oil Seal Seals and Gaskets: Service and Repair Extension Case Oil Seal Extension Case Oil Seal INSPECTION Make sure the ATF does not leak from the joint of transmission and propeller shaft. If so, replace the oil seal. REPLACEMENT 1) Clean the transmission exterior. 2) Drain the ATF completely. NOTE: ^ Tighten the ATF drain plug after draining the ATF. ^ Use anew gasket. 3) Remove the rear exhaust pipe and muffler. Non-turbo model Turbo model 4) Remove the propeller shaft. 5) Using the ST, remove the oil seal. ST 398527700 PULLER ASSY 6) Using the ST, install the oil seal. ST 498057300 INSTALLER 7) Install the propeller shaft. 8) Install the rear exhaust pipe and muffler. Non-turbo model Turbo model 9) Pour ATF and check the ATF level. Page 3778 Shift Solenoid: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 3254 B54-B127 Page 902 Transmission Position Switch/Sensor: Service and Repair AT Shift Lock Solenoid and "P" Range Switch AT Shift Lock Solenoid and "P" Range Switch REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the console box. 3) Disconnect the connector. 4) Remove the grip. 5) Remove the indicator bulb from indicator cover. 6) Remove the indicator cover. 7) Remove the blind. 8) Remove the cushion. 9) Remove the clip, and then remove the "P" range switch. 10) Remove the cover. Locations Intake Air Temperature Sensor: Locations Sensor (Part 1) Locations Daytime Running Lamp Relay: Locations Area View Daytime Running Light Relay - (B102) Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Testing and Inspection Alarm Horn Relay: Testing and Inspection SECURITY HORN RELAY INSPECTION Measure the security horn relay resistance between terminals (indicated in the table) when connecting terminal No. 4 to battery positive terminal and terminal No. 1 to battery ground terminal. If NG, replace the security horn relay. Page 514 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 2693 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 736 Variable Induction Position Sensor: Service and Repair NOTE: DO NOT remove the tumble generator valve position sensor from tumble generator valve assembly, since it cannot be adjusted during installation. Refer to "Tumble Generator Valve Assembly" for removal and installation procedures. Page 3666 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 4808 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 4549 3. 17 INCH TYPE 1. Clean the caliper body interior using brake fluid. 2. Apply a coat of brake fluid to the piston seal and install the piston seal in groove on caliper body. 3. Apply a coat of brake fluid to the entire inner surface of cylinder and outer surface of piston. 4. Apply a coat of specified grease to the boot and install it in the groove on piston. Grease: NIGLUBE RX-2 (Part No. K0779GA 102) 5. Insert the piston into cylinder. CAUTION: Do not force the piston into cylinder. 6. Position the boot in grooves on cylinder and piston. Page 3870 R58-R69 Page 1039 Valve Clearance: Adjustments Adjustment CAUTION: Adjustment of the valve clearance should be performed while engine is cold. 1. Measure all valve clearances. NOTE: Record each valve clearance after it has been measured. 2. Remove the camshaft. 3. Remove the valve lifter. 4. Measure the thickness of valve lifter with a micrometer. 5. Select a shim of suitable thickness using measured valve clearance and valve lifter thickness, by referring to the following table. Restraints - Seat Belt Latch Slides To Lower Anchor Seat Belt: Customer Interest Restraints - Seat Belt Latch Slides To Lower Anchor NUMBER: 17-06-01R DATE: 05/11/05 APPLICABILITY: 1995 MY and after Legacy 1998 MY and after Forester 1993MY and after Impreza 2003MY and after Baja 2006MY and after Tribeca SUBJECT: Seat Belt Latch Slides to the Lower Seat Belt Anchor DESCRIPTION In the event you encounter a customer complaint of the seat belt latch sliding down the v~ebbing to the lower seat belt anchor, it may be caused by the latch web stop button separating from the belt webbing. This stop button may become loose and fall off if the belt webbing is jammed between the body panel and door when the door is closed Use the chart to locate and order the correct repair kit for your application. REPAIR PROCEDURES 1) Inspect the belt webbing for damage. If damaged replace the seat belt assembly. 2) Remove any piece of broken stopper button from the belt webbing. 3) Lift the belt latch up and beyond the original stopper button location and hold in place using adhesive tape. 4) Locate the original stopper hole (about 500mm up from bottom anchor) in the webbing and insert the new male stopper button from the backside of the belt Push the other part of the button over the pin sticking through the front belt webbing. 5) Using a suitable tool, crimp the two parts together until the new button thickness is 4.5~5.0mm. 6) Remove the adhesive tape from the latch and confirm the stopper button holds the latch in the proper position. For vehicles within the Basic New Car Limited Warranty period this repair can be claimed using the table shown. Page 3810 Transmission Speed Sensor: Service and Repair Torque Converter Turbine Speed Sensor Torque Converter Turbine Speed Sensor REMOVAL When removing the torque converter turbine speed sensor, refer to "Front Vehicle Speed Sensor". INSTALLATION When installing the torque converter turbine speed sensor, refer to "Front Vehicle Speed Sensor" Page 2189 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Service and Repair Shift Interlock Solenoid: Service and Repair AT Shift Lock Solenoid and "P" Range Switch REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the console box. 3) Disconnect the connector. 4) Remove the grip. 5) Remove the indicator bulb from indicator cover. 6) Remove the indicator cover. 7) Remove the blind. 8) Remove the cushion. 9) Remove the clip, and then remove the "P" range switch. 10) Remove the cover. Page 4691 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 2464 R72-R145 R148 Page 7006 B380-f6 Page 925 Schematic drawings Reverse Check Cable Shifter A/T: Service and Repair Reverse Check Cable Reverse Check Cable REMOVAL 1) Set the vehicle on a lift. 2) Remove the gear shift knob. 3) Remove the console box front. 4) Remove the spring pin from slider. 5) Remove the slider and spring. 6) Cut the band clip, and then separate the reverse check cable from gearshift lever. 7) Lift-up the vehicle. 8) Remove the under cover. 9) Remove the rear exhaust pipe and muffler. 10) Remove the crossmember. 11) Remove the snap pin and washer, and then separate the reverse check cable from reverse check lever. Page 2447 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Capacity Specifications Fluid - M/T: Capacity Specifications M/T Fluid capacity 5SPD ................................................................................................................................................. 3.7 US qt (3.5 liters, 3.1 Imp qts) M/T Fluid capacity 6SPD ................................................................................................................................................. 4.3 US qt (4.1 liters, 3.6 Imp qts) Inhibitor Switch Neutral Safety Switch: Testing and Inspection Inhibitor Switch INHIBITOR SWITCH INSPECTION Measure the inhibitor switch resistance. If NG, replace the inhibitor switch. Page 3021 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 4781 Neutral Safety Switch: Testing and Inspection Neutral Position Switch NEUTRAL POSITION SWITCH INSPECTION Non-Turbo Model Turbo Model STI Model Measure the neutral position switch resistance. If NG, replace the neutral position switch. Engine Controls - DTC P0340/P0345 After Camshaft R & R Camshaft Position Sensor: Customer Interest Engine Controls - DTC P0340/P0345 After Camshaft R&R Number: 02-107-09 Date: 03/24/09 Applicability: 2004~06MY Baja 2.5L Turbo 2004~06MY Impreza 2.5L Turbo 2004~06MY Forester 2.5L Turbo 2004~06MY Legacy/Outback 2.5L Turbo SUBJECT: Intake Camshaft Replacement Introduction If you encounter a vehicle that has a CEL and P0340 or P0345 stored in memory immediately after replacing the intake camshaft(s), the air gap between the camshaft and camshaft position sensor may be out of specification. A modification was made to the plate area of the camshaft where the camshaft position sensor picks up the signal. Parts Information Repair Procedure/ Information Using a feeler (thickness) gauge, measure the gap between the camshaft and camshaft position sensor. The correct gap is between 0.15mm to 0.98mm (0.0059 to 0.0386 in.) If the gap is over 0.98mm (0.0386 in.) replace the camshaft position sensor. Refer to the applicable service manual. Warranty/Claim Information For vehicles within warranty, refer the Subaru Warranty Wizard for claim submission information. Testing and Inspection Condenser HVAC: Testing and Inspection Condenser INSPECTION 1. Confirm that no dust or insects are found on the condenser fins. Air-blow or flush fins with water as needed. 2. Confirm that no oil leaks from condenser. If a failure is found, replace the condenser with a new one. Page 1791 B128-B134 Page 6990 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 6408 SPECIFICATIONS Page 2225 Front Brake Caliper: Service and Repair Front Front Disc Brake Assembly REMOVAL 1. 15 INCH TYPE CAUTION: Do not allow brake fluid to come in contact with vehicle body; wash away immediately with water and wipe off completely if spilled. 1. Set the vehicle on a lift. 2. Loosen the wheel nuts. 3. Lift-up the vehicle, and then remove the front wheel. 4. Remove the union bolt, and then disconnect the brake hose from caliper body assembly. 5. Remove the bolt securing lock pin to caliper body. 6. Raise the caliper body, and then move it toward vehicle center to separate it from support. 7. Remove the support from housing. NOTE: Remove the support only when replacing it or the disc rotor. It need not be removed when servicing the caliper body assembly. 8. Clean mud and foreign particles from the caliper body assembly and support. 2. 16 INCH TYPE CAUTION: Do not allow brake fluid to come in contact with vehicle body; wash away at once with water and wipe off completely if spilled. 1. Set the vehicle on a lift. 2. Loosen the wheel nuts. 3. Lift-up the vehicle, and then remove the front wheel. 4. Remove the union bolt, and then disconnect the brake hose from caliper body assembly. Page 7249 Windshield Washer Motor: Testing and Inspection WASHER TANK AND MOTOR INSPECTION Apply battery voltage to the connector terminal of the washer motor and make sure the motor operates. Page 6434 4. When the ignition switch is turned to ON (engine off) or to START with the test mode connector connected, the malfunction indicator light blinks at a cycle of 3 Hz. Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 5812 Antitheft Relay: Service and Repair INTERRUPT RELAY REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the audio instrument. 3. Remove the interrupt relay. INSTALLATION Install in the reverse order of removal. Page 3645 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 5165 - Do not drop the airbag modulator parts, subject them to high temperature over 93 degrees C (199 degrees F), or let water, oil, or grease get on them; otherwise, the internal parts may be damaged and reliability greatly lowered. - If any damage, opening, or rust is found on the airbag system wire harness, do not attempt to repair using soldering equipment. Be sure to replace the faulty harness with a new genuine part. - Install the wire harness securely with the specified clips to avoid interference or tangled up with other parts. Page 2675 6. Disconnect the pressure hose from fuel tank pressure sensor. INSTALLATION Install in the reverse order of removal. Page 6603 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 308 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 6296 Brake Warning Indicator: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 785 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 4976 B292-B317 Page 181 B54-B127 Page 2981 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 5764 Security Lamp/Indicator: Testing and Inspection DIAGNOSTICS CHART FOR SECURITY INDICATOR LIGHT INSPECTION Wiring Diagram Page 6574 B230-B283 Page 2446 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Front Vehicle Speed Sensor Transmission Speed Sensor: Service and Repair Front Vehicle Speed Sensor Front Vehicle Speed Sensor REMOVAL 1) Set up the vehicle on a lift. 2) Disconnect the ground cable from battery. 3) Remove the air intake chamber. (Non-turbo model) 4) Remove the intercooler. (Turbo model) 5) Disconnect the transmission connector. 6) Remove the pitching stopper. 7) Remove the transmission connector from stay. 8) Lift-up the vehicle. 9) Clean the transmission exterior. 10) Drain the ATF completely. NOTE: ^ Tighten the ATF drain plug after draining the ATF. ^ Use anew gasket. 11) Remove the front, center, exhaust pipes and muffler. (Non-turbo model) 12) Remove the center, rear exhaust pipe and muffler. (Turbo model) 13) Remove the propeller shaft. 14) Place the transmission jack under transmission. NOTE: Make sure that the support plates of transmission jack don't touch the crossmember. 15) Remove the transmission rear crossmember bolts. Page 1789 B17-B20 Page 4623 7. Apply a coat of specified grease to the guide pin, outer surface, sleeve outer surface, cylinder inner surface, and boot grooves. Grease: NIGLUBE RX-2 (Part No. K0779GA 102) 8. Install the guide pin boot on support. 9. Install the lock pin boot on support, and then insert the lock pin sleeve into place. 2. 15 INCH TYPE 1. Clean the caliper body interior using brake fluid. 2. Apply a coat of brake fluid to the piston seal and fit piston seal in groove on caliper body. 3. Apply a coat of brake fluid to the entire inner surface of cylinder and outer surface of piston. 4. Apply a coat of specified grease to the boot and install it in the groove on piston. Grease: NIGLUBE RX-2 (Part No. K0779GA 102) 5. Insert the piston into cylinder. CAUTION: Do not force the piston into cylinder. 6. Install the piston boot to caliper body, and then attach boot ring. Diagram Information and Instructions Wiper Relay: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 5547 Impact Sensor: Description and Operation IMPACT SENSOR OPERATION 1. IMPACT SENSOR SETTING USING SUBARU SELECT MONITOR 1. Connect the Subaru Select Monitor to data link connector. 2. Turn the ignition switch to ON. 3. Select {Keyless Unit} from the main menu. 4. Select {ECU customizing}. 5. Make a impact monitor setting. - When installing: ON - When removing: OFF 6. Make a impact monitor ON/OFF setting. - When installing: ON - When removing: OFF 7. Turn the ignition switch to OFF, and then remove the Subaru Select Monitor. Page 2207 Knock Sensor: Service and Repair Knock Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the intercooler. 3. Disconnect the knock sensor connector. 4. Remove the knock sensor from the cylinder block. INSTALLATION 1. Install the knock sensor to the cylinder block. Tightening torque: 24 N.m (2.4 kgf-m, 17.4 ft-lb) NOTE: Extraction area of the knock sensor cord must be positioned at a 60 degrees angle relative to the engine rear. Specifications Pressure Plate: Specifications Pressure Plate ^ Tighten the clutch cover installing bolts gradually. Each bolt should be tightened to the specified torque in a crisscross order. Page 4444 Non-turbo model ^ Turbo model Turbo model 4) Replace defective parts. Description and Operation Front Bumper: Description and Operation Front Bumper Beam A bumper beam assembly is placed inside the front bumper. The beam assembly is fastened to the chassis frame and absorbs the shock energy in case of a front collision to enhance safety of the vehicle. Page 2266 4. Connect the clip to the crossmember. 5. Lower the vehicle. 6. Connect the battery ground cable to battery. Page 3859 B3-B12 Specifications Engine Oil Pressure: Specifications Oil pressure: 98 kPa (1.0 kgf/cm2, 14 psi) or more at 600 rpm 294 kPa (3.0 kgf/cm2, 43 psi) or more at 5,000 rpm Locations Sensor Page 3417 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 1292 Refer to "FRONT AXLE" for inspection procedures. CAUTION: If there is any fault in the bearing, replace hub unit bearing. Page 3468 B292-B317 Page 6425 - Do not drop the airbag modulator parts, subject them to high temperature over 93 degrees C (199 degrees F), or let water, oil, or grease get on them; otherwise, the internal parts may be damaged and reliability greatly lowered. - If any damage, opening, or rust is found on the airbag system wire harness, do not attempt to repair using soldering equipment. Be sure to replace the faulty harness with a new genuine part. - Install the wire harness securely with the specified clips to avoid interference or tangled up with other parts. Testing and Inspection Hazard Warning Switch: Testing and Inspection HAZARD SWITCH Measure the resistance between hazard switch terminals. Page 3887 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 4117 4) Remove the snap ring. CAUTION: Be careful when removing the snap ring to prevent the rod, washer, piston and return spring from flying out. 5) Remove the clutch damper. ASSEMBLY 1) Install the clutch damper. Tightening torque: 46.6 Nm (4.75 kgf-m, 34.4 ft. lbs.) 2) Apply a coat of grease to the contacting surfaces of the push rod and piston before installation. Grease: SILICONE GREASE G-40M (Part No. 004404003) 3) Assemble in the reverse order of disassembly. Tightening torque: 10 Nm (1.0 kgf-m, 7 ft. lbs.) INSPECTION If any damage, deformation, wear, swelling, rust or other faults are found on the cylinder, piston, push rod, fluid reservoir, return spring, gasket, clutch damper, cylinder boot and hose replace the faulty part. Page 7425 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 7342 B136-B141 Page 1427 Engine Oil: Testing and Inspection Engine Oil INSPECTION 1. Park the vehicle on a level surface. 2. After turning off the engine, wait a few minutes for oil to drain back into the oil pan before checking the level. 3. Just after driving or while the engine is warm, engine oil level may show in the range between the "F line and notch mark. This is caused by thermal expansion of engine oil. 4. Remove the oil level gauge and wipe it clean. 5. Reinsert the level gauge all the way. Be sure that the level gauge is correctly inserted and in proper orientation. 6. Remove it again and note the reading. If the engine oil level is below the "L" line, add oil to bring the level up to "F line. NOTE: To prevent overfilling the engine oil, do not add oil above "F line when the engine is cold. M/T - Clutch Pedal Squeaking Noise Clutch Switch: Technical Service Bulletins M/T - Clutch Pedal Squeaking Noise CLUTCH PEDAL SQUEAK If you encounter a manual transmission equipped vehicle with a clutch pedal squeak concern, and lubricating the pedal mechanism didn't fix the noise, check the clutch switch. We have had a few reports where this has been the source of the problem. The fix is to replace the clutch pedal switch. Page 2291 R58-R69 Page 2654 Engine Control Module (ECM) I/O Signal (Part 2) Page 4776 Non-Turbo Model Page 6636 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 235 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification System Diagnosis Rear Door Interior Handle: Testing and Inspection REAR INNER REMOTE INSPECTION 1. Make sure the rod is not deformed. 2. Make sure the lever and rod work smoothly. 3. Make sure the child safety lock work properly. Diagram Information and Instructions Temperature Gauge: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 7224 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Recall - Front Seat Wiring Harness Routing Wiring Harness: Recalls Recall - Front Seat Wiring Harness Routing NUMBER: WVC-13 DATE: March 2007 APPLICABILITY: 2006MY Subaru Forester & Impreza SUBJECT: Front Passenger Seat Wiring INTRODUCTION Subaru of America, Inc. (SOA) has determined that certain 2006 MY Subaru Forester and Impreza models may have been produced with an improperly routed electrical wiring harness. That harness could have been pinched against the passenger front seat mounting bolt during production. If the wiring harness was improperly installed, an electrical short could occur. There are two safety risks associated with this condition. The first is that the passenger's front air bag, which is connected to this wiring harness, could become disabled, in which case it would not deploy as designed in an accident and would therefore expose the right front passenger to the possibility of serious injuries. The second is that an electrical short circuit could, under some circumstances, cause a fire. If an electrical short circuit occurs in this wiring harness, fuse # 6 (located in the fuse panel on the lower left side of the dashboard) will "blow", disabling the passenger front air bag. This could occur at any time and without prior warning. But once it occurs, the driver will be alerted to this condition by the illumination of the air bag system warning light on the vehicle's instrument panel. Occupants will also be alerted to this condition if the passenger's frontal air bag ON/OFF indicator indicates "OFF" even if an adult passenger is occupying that seat. If fuse # 6 had previously blown and been replaced with no repair made to correct the underlying cause, there is a possibility that this wiring harness has already been damaged due to a short circuit. Under these circumstances, the new replacement fuse may not blow and a fire could occur at any time without warning. In Forester models, it could happen even if the ignition switch is in the "LOCK" (off) position. Vehicle owners will be advised in the Owner Notification Letter that if they encounter a blown fuse, an illuminated air bag system warning light, smell smoke, or have replaced a blown fuse # 6 without correcting the underlying problem, to not operate the vehicle. They will be advised to contact the nearest Subaru dealer as soon as possible for guidance. In these cases, dealers should arrange to have the vehicle towed and repairs performed immediately. This recall will involve inspection and possible repair of the front passenger seat wire harness. Please refer to the Service Procedure section of this bulletin for more details. AFFECTED VEHICLES ^ 2006 MY Subaru Forester and Impreza Potentially affected vehicles are identified in the VIN range chart below. Not all vehicles within the VIN range are affected. Prior to performing repairs, confirm coverage for potentially affected vehicles by using the Vehicle Coverage Inquiry in the Dealer Communication System (DCS). OWNER NOTIFICATION SOA will prepare and mail Owner Notification Letters to owners of affected vehicles on or around March 9, 2007. A copy of the Owner Notification Letter is included at the end of this bulletin. DEALER PROGRAM RESPONSIBILITY Dealers are to promptly service all vehicles subject to this recall at no charge to the vehicle owner regardless of mileage~ age of the vehicle~ or Page 138 Engine Control Module (ECM) I/O Signal (Part 4) Page 2857 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 4934 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 663 R72-R145 R148 Page 5190 6) Insert the ST-A with oil seal assembled, through gear side of rack. Remove the oil seal from ST-A near piston, and then remove the ST-A from rack. 7) Install the back-up washer from gear side of rack. 8) Equally apply a thin coat of grease to the rack, then install the oil seal. CAUTION: Be careful not to scratch the oil seal lips with piston's inner ring section. Page 4017 F21-F61 Page 1925 Temperature Gauge: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 2258 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 3308 2. Push the pipe into the connector completely. NOTE: At this time, two clicking sounds are heard. CAUTION: Pull the connector to ensure it is connected securely. - Ensure the two retainer pawls are engaged in their mating positions in the connector. - Be sure to inspect hoses and their connections for any leakage of fuel. 2. Connect the fuel delivery hose and return hose by inserting them into the pipe for 20 to 25 mm (0.79 to 0.98 in) in length. Type A: When the fitting length is specified. Type B: When the fitting length is not specified. l: 2.5 ±1.5 mm (0.098 ±0.059 in) L: 22.5 ±2.5 mm (0.886 ±0.098 in) Cooling System - Coolant Comes Out Of Reservoir Coolant Line/Hose: All Technical Service Bulletins Cooling System - Coolant Comes Out Of Reservoir NUMBER: 08-52-08 DATE: 08/18/08 APPLICABILITY: 1999MY and later Impreza & Forester 2000MY and later Legacy & Outback 2006MY and later Tribeca SUBJECT: Coolant Overflow Introduction If you encounter a vehicle which experiences coolant coming out of the coolant reservoir tank, it may be caused by the radiator cap pressure valve being stuck open by debris sucked up through the reservoir tank hose. As the cooling system cools down, it sucks coolant back into the radiator. If there is debris that settles to the bottom of the reservoir tank, the hose is low enough to also suck them back into radiator. This causes the radiator cap not to seal, allowing excessive amount of coolant to escape overflowing the reservoir tank. If this condition continues over time, there will not be enough coolant in the system to maintain proper engine temperature. In order to correct the condition you need to clean (and test) or replace the radiator cap, clean out the reservoir tank, and shorten the hose slightly, following the repair procedure. Production Line Change The shorter coolant reservoir tank hose was used in production as shown above. Repair Procedure/Information 1. Radiator Cap Cleaning Many caps can be successfully cleaned. The important part is the thorough cleaning of the negative pressure valve. If this is not done completely, remaining debris may result in a repeat issue. If there is an excessive amount of debris or the sealing rubber on the cap appears to be pitted or damaged, replace the cap. Note: If replacing the cap, skip to Step 2. Using clean water and a brush, thoroughly clean the cap seal surface. Note: Front Accessory Power Supply Socket Auxiliary Power Outlet: Service and Repair Front Accessory Power Supply Socket FRONT ACCESSORY POWER SUPPLY SOCKET REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the console front panel. 3. Disconnect the harness connectors and remove front accessory power supply socket. INSTALLATION Install in the reverse order of removal. Locations Electronic Brake Control Module: Locations Electrical Component Location Page 713 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 1059 7. Install the timing belt cover. 8. Install the crank pulley. 9. Install the V-belt. INSPECTION 1. TIMING BELT 1. Check the timing belt teeth for breaks, cracks, and wear. If any fault is found, replace the belt. 2. Check the condition of back side of belt; if any crack is found, replace the belt. CAUTION: ^ Be careful not to let oil, grease or coolant contact the timing belt. Remove quickly and thoroughly if this happens. ^ Do not bend the belt sharply. Bending radius h: 60 mm (2.36 inch) or more 2. AUTOMATIC BELT TENSION ADJUSTER 1. Visually check the oil seals for leaks, and rod ends for abnormal wear or scratches. If necessary, replace the automatic belt tension adjuster assembly. NOTE: Slight traces of oil at rod's oil seal does not indicate a problem. 2. Check that the adjuster rod does not move when a pressure of 294 Nm (30 kgf, 66 ft. lbs.) is applied to it. This is to check adjuster rod stiffness. 3. If the adjuster rod is not stiff and moves freely when applying 294 Nm (30 kgf, 66 ft. lbs.), check it using the following procedures: 1. Slowly press the adjuster rod down to the end surface of the cylinder. Repeat this motion 2 or 3 times. 2. With the adjuster rod moved all the way up, apply a pressure of 165 Nm (16.8 kgf, 37.1 ft. lbs.) to it. Check the adjuster rod stiffness. 3. If the adjuster rod is not stiff and moves down, replace the automatic belt tension adjuster assembly with a new one. CAUTION: ^ Always use a vertical type pressing tool to move the adjuster rod down. ^ Do not use a lateral type vise. ^ Push the adjuster rod vertically. ^ Press-in the push adjuster rod gradually taking more than 3 minutes. ^ Do not allow press pressure to exceed 9,807 Nm (1,000 kgf, 2,205 ft. lbs.). ^ Press the adjuster rod till the end of the surface of the cylinder. Do not press the adjuster rod into the cylinder. Doing so may damage the cylinder. Description and Operation Hydraulic Brake Booster: Description and Operation Brake Booster The brake booster is a tandem type that uses two diaphragms. By utilizing the differential pressure between the intake manifold vacuum and atmospheric pressure, a high braking force can be obtained even when the pedal depressing effort is small. The brake booster is installed between the brake pedal and master cylinder. This contributes to improve the response to the brake pedal. If it fails, the brake servo effect is lost requiring a larger pedal effort, however, the braking force is still maintained. Page 1147 Page 587 Oxygen Sensor: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 2526 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 2724 Manifold Pressure/Vacuum Sensor: Service and Repair Manifold Absolute Pressure Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the connectors from manifold absolute pressure sensor. 3. Remove the manifold absolute pressure sensor from the throttle body. INSTALLATION Install in the reverse order of removal. NOTE: Replace the O-rings for the manifold absolute pressure sensor with new ones. Tightening torque: 1.6 N.m (0.16 kgf-m, 1.2 ft-lb) Page 3198 Evaporative Shut Valve: Service and Repair Shut Valve REMOVAL WARNING: - Place "NO FIRE" signs near the working area. - Be careful not to spill fuel. 1. Remove the fuel filler pipe. 2. Disconnect the evaporation hoses from shut valve. 3. Remove the shut valve from fuel filler pipe. INSTALLATION Install in the reverse order of removal. Page 6813 License Plate Lamp: Testing and Inspection LICENSE PLATE LIGHT INSPECTION 1. Visually check the bulb for blow out. 2. Check the bulb specification. 3. If NG, replace the bulb with a new one. Page 1136 NOTE: Add brake fluid as necessary during replacement, in order to prevent the tank from running short of brake fluid. 9. After completing the replacement, hold brake pedal depressed and tighten screw and install air bleeder screw cap. Tightening torque (Air bleeder screw): Except 17 inch type: 8 Nm (0.8 kgf-m, 5.8 ft. lbs.) 17 inch type: 20 Nm (2.0 kgf-m, 14.5 ft. lbs.) 10. Replace brake fluid of each wheel cylinder using the same procedures as described in steps (6) through (8) above. 11. Depress the brake pedal with a force of approximately 294 Nm (30 kg, 66 ft. lbs.) and hold it there for approximately 20 seconds. At this time check for mix in air and pedal height change. Visually inspect the air bleeder screws and brake pipe joints to make sure that 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 make sure that brakes are operating properly. Page 1795 B292-B317 Page 4809 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 2304 13) Install the air intake chamber. (Non-turbo model) 14) Install the intercooler. (Turbo model) 15) Inspect the inhibitor switch. Page 3315 2. Push the pipe into the connector completely. NOTE: At this time, two clicking sounds are heard. CAUTION: Pull the connector to ensure it is connected securely. - Ensure the two retainer pawls are engaged in their mating positions in the connector. - Be sure to inspect hoses and their connections for any leakage of fuel. 2. Connect the fuel delivery hose and return hose by inserting them into the pipe for 20 to 25 mm (0.79 to 0.98 in) in length. Type A: When the fitting length is specified. Type B: When the fitting length is not specified. l: 2.5 ±1.5 mm (0.098 ±0.059 in) L: 22.5 ±2.5 mm (0.886 ±0.098 in) Page 4669 Parking Brake Lever: Service and Repair Parking Brake Lever REMOVAL 1) Lift up the vehicle. 2) Remove the rear wheel. 3) Remove the rear seat cushion. 4) Remove the console box. 5) Loosen the parking cable adjusting nut and console bracket. 6) Disconnect the connector of parking brake switch. 7) Remove the parking brake lever. 8) Unbend the parking brake lever pawls and remove cable. INSTALLATION 1) Install in the reverse order of removal. Tightening torque: Parking brake lever: 18 Nm (1.8 kgf-m, 13.0 ft. lbs.) Adjusting nut: 6 Nm (0.6 kgf-m, 4.4 ft. lbs.) 2) Be sure to adjust the lever stroke. Page 2015 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 5314 Step 1 - 6 Page 3034 F61-R47 Page 6552 Parking Brake Warning Lamp: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 5029 B136-B141 Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 4748 Clutch Switch: Service and Repair Clutch Switch REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the instrument panel lower cover. 3) Disconnect the connector from clutch switch. 4) Remove the clutch switch. INSTALLATION CLUTCH SWITCH (CRUISE CONTROL) 1) Move the clevis pin of the push rod right and left and hold where it moves smoothly, then measure stroke of clutch pedal. 2) If the clutch pedal stroke is out of specification, adjust the stroke. 3) Connect clutch switch connector. CLUTCH SWITCH (STARTER INTER LOCK) 1) Fully depress the clutch pedal. 2) Install the clutch pedal plate and clutch switch so that the gap between them is 3 - 3.5 mm (0. 12 0.14 inch), and then tighten the lock nut. 3) Connect the clutch switch connector. 4) Confirm that the engine does not start when the clutch pedal is released. 5) Confirm that the engine starts when the clutch pedal is fully depressed. INSPECTION 1) If the clutch switch (cruise control) does not operate properly (or if it does not stop at the specified position), replace with a new one. Page 132 Engine Control Module: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 6170 B17-B20 Rear Diffuser Underbody Cover: Service and Repair Rear Diffuser DIFFUSER REMOVAL 1. Lift-up the vehicle. 2. Loosen the five bolts to remove rear diffuser. 3. Remove the two bolts, and remove the diffuser bracket. INSTALLATION Install in the reverse order of removal. NOTE: Hang the back side of rear diffuser on diffuser bracket to install. Page 6322 F21-F61 Page 1354 Crankshaft: Testing and Inspection INSPECTION CRANKSHAFT AND CRANKSHAFT BEARING 1. Clean the crankshaft completely and check for cracks by means of liquid penetrant tester etc., and replace if defective. 2. Measure the crankshaft bend, and correct or replace if it exceeds the limit. NOTE: If a suitable V-block is not available, install the #1 and #5 crankshaft bearing on cylinder block, position the crankshaft on these bearings and measure the crankshaft bend using a dial gauge. Crankshaft bend limit. 0.035 mm (0.0014 inch) 3. Inspect the crank journal and crank pin for wear. If they are not within the specifications, replace the bearing with a suitable (undersize) one, and then replace or recondition the crankshaft as necessary. When grinding the crank journal or crank pin, finish them to specified dimensions according to the undersize bearing to be used. Crank pin: Out-of-roundness 0.003 mm (0.0001 inch) Cylindricality 0.004 mm (0.0002 inch) Grinding limit To 51.750 mm (2.0374 inch) dia. Crank journal: Out-of-roundness 0.005 mm (0.0002 inch) Cylindricality 0.006 mm (0.0002 inch) Grinding limit To 59.750 mm (2.3524 inch) dia. Page 6316 B128-B134 Page 5869 Front Door Latch: Service and Repair FRONT DOOR LATCH AND DOOR LOCK ACTUATOR ASSEMBLY REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the front door trim. 3. Remove the sealing cover. 4. Remove the front inner remote. 5. Remove three screws and a bolt. 6. Remove the front door latch assembly, and then disconnect the connector. INSTALLATION Install in the reverse order of removal. NOTE: Make sure the lock works properly after installation. Page 5952 Trunk / Liftgate Release Lever: Service and Repair TRUNK LID RELEASE HANDLE REMOVAL 1. Remove the five clips. 2. Remove the cable from trunk lid release handle. INSTALLATION Install in the reverse order of removal. Service and Repair Control Module: Service and Repair Transmission Control Module (TCM) REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the lower cover and then disconnect the connector. 3) Remove the knee bolster. 4) Disconnect the connectors from TCM. 5) Remove the TCM. INSTALLATION 1) Install the TCM. 2) Connect the connectors to TCM. 3) Install in the reverse order of removal. 4) If replacing the TCM, execute the advance operation of learning control promotion. Page 1645 Z1: 54.5 tooth length Z2: 51 tooth length Z3: 28 tooth length 6. Remove the belt idler (A). 7. Remove the timing belt. CAUTION: After the timing belt has been removed, never rotate the intake and exhaust, cam sprocket. If the cam sprocket is rotated, the intake and exhaust valve heads strike together and valve stems are bent. 2. BELT IDLER AND AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY 1. Remove the belt idler (B) and (c). Page 6672 3. If it is not within specified value, adjust it by adjusting position of stop light switch. CAUTION: Be careful not to rotate the stop light switch. ADJUSTMENT Loosen the lock nut, and adjust the stop light switch position until the clearance between threaded end of stop light switch and stopper (A) becomes 0.3 mm (0.012 inch). Then, tighten the lock nut. Tightening torque: 8 Nm (0.8 kgf-m, 5.8 ft. lbs.) NOTE: Tighten the lock nut B until the clearance between threaded end of stop light switch and stopper becomes 0 mm (0 inch). Hold the stop light switch to prevent turning, and then loosen the lock nut B approximately 60°. The clearance (A) will become 0.3 mm (0.012 inch). Page 6533 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 2355 B54-B127 Specifications Diagnostic Aids Fuel Gauge Sender: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 7351 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 57 System Relay: Testing and Inspection INSPECTION While applying battery voltage to the terminal between (3) and (4), check continuity between (1) and (2). If no continuity exists, replace the relay with a new one. Page 6178 F21-F61 Page 850 2) Fully depress the clutch pedal. 3) Adjust the clutch pedal plate and clutch switch so that the gap between them is 3 - 3.5 mm (0. 12 - 0.14 inch). 4) Tighten the lock nut. Tightening torque: 8 Nm (0.8 kgf-m, 5.9 ft. lbs.) Page 652 B17-B20 Page 300 Cruise Control Switch: Service and Repair CRUISE CONTROL COMMAND SWITCH REMOVAL WARNING: Before servicing, be sure to read the notes in the AB section for proper handling of the driver's airbag module. 1. Set the front wheels in straight ahead position. 2. Turn the ignition switch to OFF. 3. Disconnect the ground cable from battery and wait for at least 20 seconds before starting work. 4. Using the TORX BIT T30 (Tamper resistant type), loosen the two TORX® bolts which secure driver's airbag module. 5. Disconnect the airbag module connector on back of airbag module. 6. Remove the steering wheel. 7. Remove four screws, and then remove the lower cover from steering wheel. 8. Remove the screw, and then remove the cruise control command switch from lower cover. INSTALLATION Install in the reverse order of removal. Page 2096 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 6789 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Testing and Inspection Backup Light Bulb: Testing and Inspection BACK-UP LIGHT BULB INSPECTION 1. Visually check the bulb for blow out. 2. Check the bulb specification. 3. If NG, replace the bulb with a new one. Page 2875 Air Flow Meter/Sensor: Service and Repair Mass Air Flow and Intake Air Temperature Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the connector from mass air flow and intake air temperature sensor. 3. Remove the mass air flow and intake air temperature sensor. INSTALLATION Install in the reverse order of removal. Tightening torque: 1.7 N.m (0.17 kgf-m, 1.3 ft-lb) Page 7028 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 441 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 7382 R58-R69 Testing and Inspection Hazard Warning Switch: Testing and Inspection HAZARD SWITCH Measure the resistance between hazard switch terminals. Page 4996 Note: Be careful not to damage wires around the working area. 4. Impreza and Forester: Remove the passenger front seat and disconnect the body wire connector afier pulling up the floor carpet. Note: Check if the wire is pinched at the seat rail and damaged. 5. Repair the wire according to the extent of damage as indicated below. (1) When only the surface of the wire covering is damaged only: Wrap electrical tape around the damaged portion, proceed to Step 7. (2) When the core wire is cut or damaged: Cut and remove the damaged section of wire, as illustrated. (3) Peel the wire covering 5/8 inch (15 mm) from the tip of cut wire and expose the core wires, as illustrated. (4) Install heat shrink tubing on one side of the cut wiring. (5) Twist the core wires together so that they entwine each other. Be careful to ensure the tips of the wires are level and parallel. Otherwise~ the wire will break through the heat shrink tubing. (6) Solder the twisted wires and activate the heat shrink tubing with a heat gun. Confirm that no frayed wires are visible. 6. Reconnect the body wire connector. Page 1587 Oil Pressure Warning Lamp/Indicator: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 134 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Specifications Brake Rotor/Disc: Specifications SERVICE LIMIT Front Except 17" .................................................................................................................................. .................................................................. 22 mm (0.87 in) 17" .......................................................... ...................................................................................................................................................... 28 mm (1.10 in) Disc runout ..................................................................................................................... ...................................................................... 0.075 mm (0.0030 in Rear Disc thickness 14" ...................................................................................................................... ....................................................................................... 8.5 mm (0.335 in) 15" .................................. .............................................................................................................................................................. ................ 16 mm (0.63 in) 17" ............................................................................................................ .................................................................................................... 18 mm (0.71 in) Disc runout ........... .............................................................................................................................................................. ................... 0.07 mm (0.0028 in) Page 1452 7. Tighten the nuts which install the front cushion rubber onto front crossmember. Tightening torque: 83 Nm (8.5 kgf-m, 61 ft. lbs.) 8. Install the front exhaust pipe assembly. 9. Install the under cover. 10. Lower the vehicle. CAUTION: When lowering the vehicle, lower the lifting device and wire rope together. 11. Remove the lifting device and steel cables. 12. Install the pitching stopper. Tightening torque: T1: 50 Nm (5.1 kgf-m, 36.9 ft. lbs.) T2: 58 Nm (5.9 kgf-m, 42.8 ft. lbs.) 13. Install the radiator upper brackets. Page 6089 Trunk / Liftgate Lock: Service and Repair Trunk Lid KEY LOCK CYLINDERS REPLACEMENT TRUNK LID 1. Remove the trunk lid release handle. 2. Remove the rod clamp. Remove the lock plate. Replace the key cylinder. Page 2113 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 4150 Clutch Pedal Position Sensor / Switch: Description and Operation OPERATION STARTER INTERLOCK MECHANISM When the clutch pedal is fully depressed, the stopper on the pedal pushes the clutch switch push rod inwards. When the pushrod is pressed in, the switch turns ON and connects the ignition switch to the starter circuit enabling engine start. Schematic Drawings Page 1407 REAR SIDE BELT 1. Install the belt, and tighten the slider bolt (B) so as to obtain the specified belt tension. 2. Tighten the lock nut (A). Tightening torque: Lock nut (A) 23 Nm (2.3 kgf-m, 17.0 ft. lbs.) Inspection 1. Replace the belts, if cracks, fraying or wear is found. 2. Check the V-belt tension and adjust it if necessary by changing generator installing position and idler pulley installing position. Belt tension (with belt tension gauge) (A) When installing new parts: 640 - 780 Nm (65 - 80 kgf, 144 - 175 ft. lbs.) At inspection: 490 - 640 Nm (50 - 65 kgf, 110 - 144 ft. lbs.) (B) When installing new parts: 740 - 880 Nm (75 - 90 kgf, 166 - 198 ft. lbs.) At inspection: 350 - 450 Nm (36 - 46 kgf, 79 - 101 ft. lbs.) Page 4186 Differential Mount: Service and Repair Rear Differential Member REMOVAL When removing the differential front member, work the removal procedure as rear differential. INSTALLATION 1) Position the differential front member on body by passing it under the parking brake cable and securing to rear differential. NOTE: When installing the differential front member, do not confuse the installation sequence of the stopper. 2) Insert the DOJ of rear drive shaft into rear differential. NOTE: Before inserting, replace the differential side oil seal with a new one. ST 28099PA090 OIL SEAL PROTECTOR 3) Hereafter, install in the reverse order of removal. INSPECTION 1) Check the rear differential member for damage, bend, or corrosion. If damage, bend, or corrosion is excessive, replace the rear differential member. 2) Check the bushings of rear differential member for cracking, hardening, or damage. If cracking, hardening, or damage is excessive, replace the rear differential member. Procedures Front Bumper: Procedures FRONT BUMPER REPAIR 1. COATING METHOD FOR PP BUMPER 2. REPAIR INSTRUCTIONS FOR COLORED PP BUMPER NOTE: All PP bumpers are provided with a grained surface, and if the surface is damaged, it cannot normally be restored to its former condition. Damage limited to shallow scratches that cause only a change in the lustre of the base material or coating, can be almost fully restored. Before repairing a damaged area, explain this point to the customer and get an understanding about the matter. Repair methods are outlined below, based on a classification of the extent of damage. 1. Minor damage causing only a change in the lustre of the bumper due to a light touch Almost restorable. Page 1600 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Locations Electrical Components Location Page 4395 R58-R69 Service Precautions Information Bus: Service Precautions CAUTION - Before disassembling or reassembling parts, always disconnect the battery ground cable. When replacing radio, control module, and other parts provided with memory functions, record memory contents before disconnecting the battery ground cable. Otherwise, the memory will be erased. - Reassemble in the reverse order of disassembly, unless otherwise indicated. - Adjust parts to the given specifications. - Connect the connectors and hoses securely during reassembly. - After reassembly, make sure functional parts operate smoothly. Page 6664 Brake Light Bulb: Service and Repair TAIL/STOP LIGHT BULB REMOVAL 1. SEDAN MODEL 1. Remove the trunk side trim of rear portion. 2. Turn the socket and remove the bulb. 2. WAGON MODEL 1. Remove the rear combination light assembly. 2. Turn the socket and remove the bulb. INSTALLATION Install in the reverse order of removal. Testing and Inspection Power Mirror Switch: Testing and Inspection REMOTE CONTROL MIRROR SWITCH INSPECTION Move the rearview mirror switch to each position and check continuity between terminals. Change over switch right position Change over switch left position If NG, replace the switch. Locations Fuel Pump Relay: Locations Solenoid Valve, Actuator, Emission Control System Parts And Ignition System Parts (Part 5) Page 7356 Wiper Blade Heater Switch: Service and Repair WIPER DEICER SWITCH REMOVAL Remove the driver side lower cover, and then remove the wiper deicer switch. INSTALLATION Install in the reverse order of removal. Service and Repair Maintenance Required Lamp/Indicator: Service and Repair The OEM does not provide a Maintenance Required Indicator for this model. Page 1575 B17-B20 Page 288 Brake Switch (Cruise Control): Service and Repair STOP LIGHT AND BRAKE SWITCH REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the connector from stop and brake switch, and then remove the switch. INSTALLATION Install in the reverse order of removal. Page 4349 Clutch Pedal Position Sensor / Switch: Description and Operation OPERATION STARTER INTERLOCK MECHANISM When the clutch pedal is fully depressed, the stopper on the pedal pushes the clutch switch push rod inwards. When the pushrod is pressed in, the switch turns ON and connects the ignition switch to the starter circuit enabling engine start. Schematic Drawings Page 1033 Compression Check: Testing and Inspection Compression Inspection CAUTION: After warming-up, engine becomes very hot. Be careful not to burn yourself during measurement. 1. After warming-up the engine, turn the ignition switch to OFF. 2. Make sure that the battery is fully charged. 3. Release the fuel pressure. 4. Remove all the spark plugs. 5. Fully open the throttle valve. 6. Check the starter motor for satisfactory performance and operation. 7. Fix the compression gauge securely against spark plug hole. NOTE: The screw of screw-in type compression gauge (put into cylinder head spark plug hole) should be less than 18 mm (0.71 inch) long. 8. Crank the engine by means of starter motor, and then read the maximum value on the gauge when the gauge needle is steady. 9. Perform at least two measurements per cylinder, and make sure that the values are correct. Compression (at 200 - 300 rpm): Standard ............................................................................................................................................... 981 1,177 kPa (10 - 12 kgf/cm2, 142 - 171 psi) Difference between cylinders 2 Less than ........................................................................................... ..................................................................................... 49 kPa (0.5 kgf/cm2, 7 psi) Page 1515 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 1548 4. Disconnect the connector from the throttle position sensor (A) and manifold absolute pressure sensor (B). 5. Remove the throttle body from the intake manifold. 6. Disconnect the connector from the fuel injector. 7. Disconnect the connector from the tumble generator valve actuator. Service and Repair Brake Bleeding: Service and Repair AIR BLEEDING PROCEDURE CAUTION: ^ The FMVSS No. 116, fresh DOT3 or DOT4 brake fluid must be used. ^ Cover the air bleeder screw with waste cloth when loosening it to prevent brake fluid from being splashed over surrounding parts. ^ Do not allow brake fluid to come in contact with vehicle body; wash away with water and wipe off completely if spilled. ^ Avoid mixing different brands of brake fluid to prevent degrading the quality of the fluid. ^ Be careful not to allow dirt or dust to get into the reservoir tank. 1. MASTER CYLINDER NOTE: ^ If the master cylinder is disassembled or reservoir tank is empty, bleed the master cylinder. ^ During the bleeding operation, keep the brake reservoir tank filled with brake fluid to eliminate entry of air. ^ The brake pedal operating must be very slow. ^ For convenience and safety, two people should do the work. 1. Loosen the wheel nuts, jack-up the vehicle, support it with rigid racks, and remove the wheel. 2. Disconnect the brake line at primary and secondary sides. 3. Put a plastic bag cover on master cylinder. 4. Carefully depress and hold the brake pedal. 5. Close the outlet plug with your finger, and then release the brake pedal. 6. Repeat step (4) and (5) until the brake fluid is completely bled from outlet plug. 7. Remove the plastic bag. 8. Install the brake pipes to master cylinder. Tightening torque: 15 Nm (1.5 kgf-m, 10.8 ft. lbs.) 9. Bleed air from the brake line. 2. BRAKE LINE NOTE: ^ During the bleeding operation, keep the brake reservoir tank filled with brake fluid to eliminate entry of air. ^ The brake pedal operating must be very slow. ^ For convenience and safety, two people should do the work. 1. Make sure that there is no leak from the joints and connections of brake system. 2. Fit one end of vinyl tube into the air bleeder screw and put the other end into a brake fluid container. Page 5075 B54-B127 Page 1356 Crankshaft: Service and Repair CRANKSHAFT CRANKSHAFT AND PISTON Diagram Information and Instructions Seat Belt Reminder Lamp: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 6629 B292-B317 Page 6823 Marker Lamp Bulb: Service and Repair FRONT SIDE MARKER LIGHT BULB REMOVAL 1. When removing the turn signal light bulb, fully turn the direction of tire to the opposite direction of desired turn signal light bulb. 2. Remove the clip, and turn the mud guard inward. 3. Turn the socket (A) from wheel arch part, and then remove the front side marker light bulb. INSTALLATION Install in the reverse order of removal. Testing and Inspection Door Switch: Testing and Inspection DOOR SWITCH Measure the resistance between door switch terminals. Page 6490 F21-F61 Page 6797 B128-B134 Page 179 B3-B12 Page 4251 9) Remove the three bolts which hold the propeller shaft to rear differential. 10) Remove the remaining bolt. 11) Remove the two bolts which hold the center bearing to vehicle body. 12) Remove the propeller shaft from transmission. CAUTION: ^ Be careful not to damage the oil seals and frictional surface of sleeve yoke. ^ Cover the center exhaust pipe with a cloth to keep off any ATF or oil spilled from transmission when removing the propeller shaft. 13) Install the extension cap to transmission. NOTE: If the extension cap is not available, place a vinyl bag over opening and fasten it with string to prevent gear oil or ATF from leaking. INSTALLATION 1) Insert the sleeve yoke into transmission, and then attach the center bearing to body. Page 5099 to the right. The proper wire location (not pinched) is indicated by broken lines in the photo to the right, below. ^ If the wire was found to be pinched, proceed to the "Wiring Repair Procedure" section, below. 3. If the wire was found to be located properly (not pinched), no repair is necessary. Reinstall the floor carpet. Wrap the previously cut portion of carpet with 1.5 inch wide unwoven adhesive tape. 4. Reinstall the center console trim. Note: Be careful that the seat heater switch is not pinched by the parking brake lever during reinstallation. 5. Confirm that switches, including the seat heater switch, work properly. Wiring Repair Procedure: Forester & Impreza 1. Disconnect the negative battery cable. Note: In the interest of customer satisfaction, please write down all radio preset stations prior to disconnecting the battery. The stations should be reset into the radio afier completion of the repair. 2. For Impreza models, proceed to step 4. Forester Models only: Remove the center console trim between the select lever and parking brake lever. 3. Forester only: Cut a cross section of floor carpet at the center in front of the parking brake lever with scissors as shown. Page 1728 2. Connect the hose to water pump. 3. Install the tensioner bracket. Tightening torque: 24.5 Nm (2.5 kgf-m, 18.1 ft. lbs.) 4. Install the belt cover No. 2 (LH). Tightening torque: 5 Nm (0.5 kgf-m, 3.6 ft. lbs.) 5. Install the cam sprockets (LH) by using ST. 6. Install the camshaft position sensor. 7. Install the belt idler No. 2 (c). 8. Install the belt idler (B). 9. Install the automatic belt tension adjuster (A) which has tension rod held by pin. ^ Tightening torque: 39 Nm (4.0 kgf-m, 28.9 ft. lbs.) Locations Coolant Temperature Sensor/Switch (For Computer): Locations Sensor (Part 1) Page 183 B134-B136 Page 5159 Turbo model and STI model: 7,350 - 8,036 kPa (75 - 82 kgf/cm2, 1,067 - 1,165 psi) (4) If it is not within the specified value, replace the oil pump. 3) Measure the working pressure. (1) Using the STs, measure the working pressure. (2) Open the valve. (3) Measure the working pressure of control valve by turning wheel from stop to stop. ST1 925711000 PRESSURE GAUGE ST2 34099AC020 ADAPTER HOSE B ST3 34099AC010 ADAPTER HOSE A Service limit. Non-turbo model: 6,700 - 7,400 kPa (68 - 75 kgf/cm2, 972 - 1,073 psi) Turbo model and STI model: 7,350 - 8,036 kPa (75 - 82 kgf/cm2, 1,067 - 1,165 psi) (4) If it is within the specified value, measure the steering effort. Diagnostic Table.> If it is not within specified value, replace the control valve itself or control valve and pinion as a single unit with new ones. Page 2683 Crankshaft Position, Camshaft Position And Knock Sensors Page 1949 Catalytic Converter: Testing and Inspection Rear Catalytic Converter INSPECTION 1. Make sure there are no exhaust leaks from connections and welds. 2. Make sure there are no holes or rusting. Service and Repair Body Control Module: Service and Repair Body Integrated Module REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the lower cover. 3) Remove the knee bolster. 4) Disconnect the connector from body integrated module. 5) Remove the body integrated module. INSTALLATION Install in the reverse order of removal. Page 2274 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 7188 Windshield Washer Switch: Service and Repair COMBINATION SWITCH (WIPER) REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the instrument panel lower cover. 3. Loosen the screw to remove steering column cover lower. 4. Remove the screw to steering column cover upper. 5. Disconnect the connectors from combination switches. 6. Loosen the screw to remove combination switch. INSTALLATION Install in the reverse order of removal. Page 5241 Tightening torque: 175 Nm (17.8 kgf-m, 129 ft. lbs.) 3) Install the ABS wheel speed sensor harness to strut. Tightening torque: 33 Nm (3.3 kgf-m, 24 ft. lbs.) 4) Install the bolts which secure the brake hose to strut. Tightening torque: 33 Nm (3.4 kgf-m, 24.3 ft. lbs.) 5) Install the wheels. NOTE: Check the wheel alignment and adjust if necessary. DISASSEMBLY 1) Using a coil spring compressor, compress the coil spring. 2) Using the ST, remove the self-locking nut. ST 927760000 STRUT MOUNT SOCKET 3) Remove the strut mount, upper spring seat and rubber seat from strut. 4) Gradually decreasing the compression force of compressor, and then remove the coil spring. 5) Remove the dust cover and helper spring. ASSEMBLY 1) Before installing the coil spring, strut mount, etc., on strut, check for the presence of air in the damping force generating mechanism of strut since air prevents proper damping force from being produced. 2) Checking for the presence of air (1) Place the strut vertically with piston rod facing up. (2) Move the piston rod to center of its entire stroke. (3) While holding the piston rod end with fingertips, move the rod up and down. (4) If the piston rod moves at least 10 mm (0.39 inch) in the former step, purge air from the strut. 3) Air purging procedure (1) Place the strut vertically with piston rod facing up. (2) Fully extend the piston rod. (3) With the piston rod fully extended, place the piston rod side down. The strut must stand vertically. (4) Fully contract the piston rod. (5) Repeat three or four times from first step. NOTE: After completely purging air from strut, be sure to place the strut with piston rod facing up. If it is laid down, check for entry of air in the strut as outlined under "Checking for the presence of air". 4) Using a coil spring compressor, compress the coil spring. Specifications Timing Cover: Specifications Timing belt cover ................................................................................................................................. .................................... 5 Nm (0.5 kgf-m, 3.6 ft. lbs.) Page 6561 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 248 R72-R145 R148 Page 4963 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 2733 Page 4862 Disclaimer Page 2008 Non-Turbo Model Specifications Center Mounted Brake Lamp: Specifications Specifications HIGH-MOUNTED STOP LIGHT Sedan Standard type............................................................................................................................ .............................................................................12 V 21 W Rear spoiler built-in type........................ ...................................................................................................................................................12 V 1.2 W (LED) Wagon.................................................................................................................................................. .................................................................12 V 13 W Page 4073 13) Install the air intake chamber. (Non-turbo model) 14) Install the intercooler. (Turbo model) 15) Inspect the inhibitor switch. Page 2080 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 4511 B134-B136 Page 6572 B134-B136 Page 5334 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 6711 R72-R145 R148 Page 4143 ^ Model without cruise control ^ Model with cruise control Model With Cruise Control 6) Turn the push rod to lengthen until the clutch pedal contacts the stopper bolt (model without cruise control) or clutch switch (model with cruise control). 7) Turn the push rod further 270° to shorten (in the arrow direction as shown in the figure). 8) Move the clevis pin to the right and left to make sure it moves smoothly. 9) Tighten the push rod lock nut. Page 1553 3. Install the fuel pipe assembly and pressure regulator to the intake manifold. 4. Install the fuel injector pipe LH. 5. Connect the left side fuel hose LH to fuel injector pipe, and tighten the clamp screw. 6. Install the fuel injector pipe RH. 7. Connect the fuel hose RH to fuel injector pipe, and tighten the clamp screw. 8. Install the engine harness to the intake manifold. Page 2777 2. Install the rear oxygen sensor. - AT model - MT model 3. Connect the connector to the rear oxygen sensor. Page 4777 Solenoid Valve, Actuator, Emission Control System Parts And Ignition System Parts (Part 5) Page 6550 R58-R69 Page 3403 R72-R145 R148 Page 6483 B54-B127 Service and Repair Trailer Hitch: Service and Repair TRAILER HITCH Trailer Hitch REMOVAL CAUTION: Because the trailer hitch is heavy, two people are required to remove it. 1. Lift-up the vehicle. 2. Remove the cushion rubber from body. 3. Remove the canister. 4. Remove the trailer hitch installation bolts. Page 2696 B17-B20 Page 5533 7. Attach the repaired body wire harness to the area directly rearward of the wire clamp with insulating tape to prevent the wire from interfering with the seat rail. (See photos below for location of the wire and tape.) 8. Reinstall the floor carpet. Wrap the previously cut portion of carpet with 1.5 inch wide unwoven adhesive tape. 9. Reinstall the center console trim. Note: Be careful that switch wires attached to the center console trim are not pinched by the parking brake lever during installation. 10. Reinstall the passenger front seat. (Install the seat slide rail cover on Forester model.) 11. Reconnect the negative battery cable. (Reprogram the customer's radio stations presets.) 12. Perform Seat Occupant Detection System calibration. (See applicable service manual.) Note: Impreza models have the bladder type system which will require re-zeroing. Forester models have the load sensor type system which requires re-calibration. 13. Turn on the ignition switch and confirm that the seat heater switches and the air bag warning light works properly. SERVICE PROGRAM IDENTIFICATION LABEL Type or print the necessary information on a recall identification label. The completed label should be attached to the vehicle's upper radiator support. Page 7039 B292-B317 Page 2853 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Tire Monitor System - Valve Stem Torque Tool Tire Monitoring System: Technical Service Bulletins Tire Monitor System - Valve Stem Torque Tool TPMS VALVE CORE TOOL Over the past year, we've all come to find out just how sensitive the Tire Pressure Monitoring System (TPMS) is to pressure fluctuations. There is a new tool out there that will properly torque the valve stem when you put it back in so that it's not under or over torqued which could possibly result in a leak. The one tool that we know of is manufactured by Vacula Automotive, and will torque the valve stem to 4 in. lbs. The part number is 72-088-0020. Subaru does not endorse or require that you get this tool. We just wanted to make you aware of it. Page 699 Air Flow Meter/Sensor: Service and Repair Mass Air Flow and Intake Air Temperature Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the connector from mass air flow and intake air temperature sensor. 3. Remove the mass air flow and intake air temperature sensor. INSTALLATION Install in the reverse order of removal. Tightening torque: 1.7 N.m (0.17 kgf-m, 1.3 ft-lb) Specifications Engine Oil Pressure: Specifications Oil pressure: 98 kPa (1.0 kgf/cm2, 14 psi) or more at 600 rpm 294 kPa (3.0 kgf/cm2, 43 psi) or more at 5,000 rpm Diagrams Hood Lock And Remote Openers Combination Switch (Light) Combination Switch: Testing and Inspection Combination Switch (Light) INSPECTION Measure the resistance between combination switch terminals. 1. LIGHTING SWITCH 2. DIMMER AND PASSING SWITCH 3. TURN SIGNAL SWITCH Page 2748 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 4848 1) With the select lever already in the "N" range, loosen the adjusting nuts A and B on both sides. 2) Turn the adjusting nut B until it lightly touches the connector. 3) Use a spanner wrench to hold nut B so that it does not rotate and then tighten the adjusting nut A. Tightening torque: 7.5 N-m (0.76 kgf-m, 5.5 ft-lb) 4) Afier the completion of adjustment, confirm that the select lever operates normally at all ranges: ^ Move the select lever from "P" to "D" range. Check that the detents could be felt in each range. If the detents cannot be felt or the position pointer (dash indicator) is improperly aligned, re-adjust the cable. ^ Check if the starter motor rotates when the select lever is set to "P" range. Airbag Systems Repairs and Inspections Required After a Collision: Service and Repair Airbag Systems INSPECTION LOCATIONS AFTER A COLLISION REPLACEMENT When airbag system is deployed, replace the following parts. 1. FRONT COLLISION 1. Driver s airbag module 2. Passenger s airbag module 3. Driver s seat belt (pretensioner) 4. Passenger s seat belt (pretensioner) 5. Airbag control module 6. Front sub-sensor 7. Roll connector 2. SIDE COLLISION 1. Airbag control module 2. Side airbag module (operating side seat backrest) 3. Side airbag sensor (operating side) 3. INSPECTION OF OTHER PARTS Check for the following parts, replace the damaged parts with new ones. 1. Steering wheel and steering shaft Check the steering wheel and steering shaft for mounting condition and deflection of axial and radical, upward and downward direction. Check the steering shaft for deflection of axial and radical direction with tilt lever released. (After a collision, absorbing part of steering shaft may inflate.) 2. Check the direct type connector of driver s airbag module, pretensioner, etc. for damage, and also check each harness for pinch and connector damage. If damage is found, replace the harness as a unit. 3. Check the seat cushion frame, backrest, seat rail and headrest for deformation, distortion, crack, installing condition and play. 4. For passenger's seat, replace the seat cushion pad frame assembly with new one if the seat cushion frame assembly is deformed or cracked. 5. If the passenger's seat cushion cover is torn or frayed, replace the seat cushion cover with a new one. Otherwise, the occupant detection system may not operate properly. 6. Be sure to perform the system calibration for occupant detection system when the passenger s seat cushion cover has been removed or replaced. Failure to do so may cause improper activation of occupant detection system. 7. Check if the driver's seat position sensor, and the driver's and passenger's seatbelt buckle switches operate normally. INSPECTION If the vehicle is involved in a collision, even if it is a slight collision, be sure to check the following system parts. 1. DRIVER S AIRBAG MODULE 1. Check for the following, and replace damaged parts with new parts. - Airbag module is cracked or deformed. - Harness and/or connector is cracked, deformed or open. Lead wire is exposed. - The module surface is fouled with grease, oil, water or cleaning solvent. 2. When installing a new driver's airbag module, check the following, and replace the damaged parts with new ones. - The steering wheel is in the way, making it difficult to install the airbag module. - The clearance between the driver's airbag module and steering wheel is not constant. - The steering wheel deformation in axial and radial directions exceed limits. Specifications: Height deflection A Description and Operation Malfunction Indicator Lamp: Description and Operation ACTIVATION OF MALFUNCTION INDICATOR LIGHT 1. When the ignition switch is turned to ON (engine off), the malfunction indicator light in the combination meter illuminates. NOTE: If the malfunction indicator light does not illuminate, perform diagnostics of the malfunction indicator light circuit or the combination meter circuit. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Diagnosis By Symptom/Malfunction Indicator Lamp (MIL) Does Not Come ON 2. After starting the engine, the malfunction indicator light goes out. If it does not, either the engine or the emission control system is malfunctioning. 3. If the diagnosis system senses a misfire which could damage the catalyzer, the malfunction indicator light will blink at a cycle of 1 Hz. Wipers/Washers - Wiper Blade Information Wiper Blade: Technical Service Bulletins Wipers/Washers - Wiper Blade Information 12 WIPER BLADES - THE BASICS When presented with a complaint indicating worn or noisy windshield wipers, please keep the following checks in mind. First check the condition of the wiper's rubber inserts. They should not be cracked, split or torn. If damaged, the inserts must be replaced. In all cases the blade frame itself should be inspected to ensure that the pivot points move easily and that the frame is not bent or otherwise damaged. Wipers with physically damaged blade frames are not a matter for warranty. If the frame is in good shape, then only the rubber insert needs replacing. If the wiper and rubber inserts appear undamaged, check the wiper performance to determine if the blades are streaking, smearing or chattering as they go across the windshield. The following information is supplied to assist in your understanding of the causes of wiper streaking and chattering complaints and should be considered a maintenance tip. If you notice any of these concerns, many times they are due to residue on the wipers, windshield, or both. To correct these concerns, start by cleaning the windshield and the wiper blades rubber inserts. Clean the windshield and the wiper inserts with a neutral non-abrasive cleaner, such as washer solvent using a sponge or soft cloth. Do not use petroleum products, thinner, or other solvents, as these will dry and damage the rubber and possibly the windshield. In terms of warranty handling if physical damage is not present and if cleaning would not resolve the concern, only the wiper's rubber inserts should require replacement. In the event that a direct replacement insert for the original equipment blade is not available from Subaru, the wiper blade assembly should be replaced with a Genuine Subaru replacement blade assembly (denoted by a part number beginning with SOA such as S0A591U218). Please see June 05 Tech Tips for specific information relating to 05 Legacy and Outback applications. The chart shown below contains a list of the available replacement wiper inserts and blade assemblies from SOA Parts. Please refer to www.subarunet.com > Fixed Operations> Price Book/CD Instructions> Price Book - Front Section > Wiper Blades and Refills for the latest chart. Diagrams Washer Tank Page 2378 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 3549 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 2541 B292-B317 Page 5448 Electrical Components Location Page 3889 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 5779 The following CDs may cause problems when loading, playing, or ejecting due to the complexity of your CD player's internal mechanisms. Disclaimer Service and Repair Cowl Moulding / Trim: Service and Repair COWL PANEL Cowl Panel REMOVAL 1. Open the front hood. 2. Remove the wiper arm. 3. Remove the front panel seal. 4. Disengage the clips (A) to remove the cowl panel. INSTALLATION Install in the reverse order of removal. Page 4350 Schematic drawings Roof Rail Roof Rack Frame: Service and Repair Roof Rail ROOF RAIL Roof Rail REMOVAL 1. Remove the roof trim. 2. Remove the four mounting nuts, and then detach the roof rail carefully. INSTALLATION Install in the reverse order of removal. Page 2828 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 793 B17-B20 Page 1601 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 5142 5) Disconnect the pipe C and D from gear box. 6) Non-turbo model (1) Remove the air intake duct. (2) Remove the bolt A. (3) Disconnect the pipe C from oil pump. Disconnect the pipe D from return hose. CAUTION: ^ Do not allow fluid from the hose end to come into contact with pulley belt. ^ To prevent foreign matter from entering the hose and pipe, cover the open ends of them with a clean cloth. Locations Electrical Component Location Page 2615 Remove the hose from the reservoir tank. Cut 20 mm from the bottom of the hose at a 45° angle. Reinstall hose in reservoir tank. Start engine and permit to fully warm up. Turn off engine and allow to fully cool down. Recheck coolant level in reservoir and add coolant if needed. Note: Be sure to use genuine Subaru Super Coolant or Subaru Long Life Coolant, depending upon what type of coolant is currently in the system. Warranty/Claim Information Page 964 4. Disconnect the connector. INSTALLATION 1. MAIN SWITCH Install in the reverse order of removal. 2. SUB SWITCH Install in the reverse order of removal. Page 1838 B230-B283 Page 2535 B17-B20 Page 698 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 3398 B292-B317 Locations Locations Sensor Page 6494 Oil Pressure Warning Lamp/Indicator: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 5430 Refrigerant Oil: Service Precautions COMPRESSOR OIL - HFC-134a compressor oil has no compatibility with that for CFC-12 system. - Use only the manufacturer-authorized compressor oil for the HFC-134a system; only use DH-PR. - Do not mix multiple compressor oils. If CFC-12 compressor oil is used in a HFC-134a A/ C system, the compressor may become stuck due to poor lubrication, or the refrigerant may leak due to swelling of rubber parts. On the other hand, if HFC-134a compressor oil is used in a CFC-12 A/C system, the durability of the A/C system will be lowered. - HFC-134a compressor oil is very hygroscopic. When replacing or installing/removing A/C parts, immediately isolate the oil from the atmosphere using a plug or tape. In order to avoid moisture, store the oil in a container with its cap tightly closed. Page 4925 B136-B141 Page 1135 Brake Fluid: Service and Repair Brake Fluid INSPECTION 1. Check that the brake fluid level remains between "MIN" and "MAX". If out of the specified range, refill or drain fluid. If the fluid level becomes close to "MIN", refill the fluid. 2. Check the fluid for discoloration. If the fluid color has excessively changed, drain the fluid and refill with new fluid. REPLACEMENT CAUTION: ^ To always maintain the brake fluid characteristics, replace the brake fluid according to maintenance schedule or earlier than that when used in severe condition. ^ The FMVSS No. 116, fresh DOT3 or DOT4 brake fluid must be used. ^ Cover the air bleeder screw with waste cloth, when loosening it, to prevent brake fluid from being splashed over surrounding parts. ^ Do not allow brake fluid to come in contact with vehicle body; wash away with water and wipe off completely if spilled. ^ 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. NOTE: ^ During replacement, keep the brake reservoir tank filled with brake fluid to eliminate entry of air. ^ The brake pedal operating must be very slow. ^ For convenience and safety, two people should do the work. ^ The amount of brake fluid required is approximately 500 m l (16.9 US fl oz, 17.6 Imp fl oz) for total brake system. 1. Either lift-up the vehicle and place a rigid racks under it, or lift-up vehicle. 2. Remove both front and rear wheels. 3. Draw out the brake fluid from master cylinder with syringe. 4. Refill the reservoir tank with recommended brake fluid. Recommended brake fluid. FMVSS No. 116, fresh DOT3 or DOT4 brake fluid 5. Install one end of a vinyl tube onto the air bleeder screw and insert the other end of the tube into a container to collect the brake fluid. CAUTION: Brake fluid replacement sequence; (A) Front right -> (B) Rear left -> (C) Front left -> (D) Rear right 6. Instruct your co-worker to depress the brake pedal slowly two or three times and then hold it depressed. 7. Loosen the air bleeder screw approximately 1/4 turn until a small amount of brake fluid drains into container, and then quickly tighten the screw. 8. Release the brake pedal slowly. Repeat steps (6) through (8) until new fluid flows through vinyl tube. Page 3596 F21-F61 Page 4569 Brake Pad: Service and Repair Rear Rear Brake Pad REMOVAL 1. 14 INCH TYPE 1. Set the vehicle on a lift. 2. Loosen the wheel nuts. 3. Lift-up the vehicle, and then remove the rear wheel. 4. Remove the lower caliper bolt. 5. Raise the caliper body upward and support it. NOTE: Do not disconnect the brake hose from caliper body. 6. Remove the pad. NOTE: If the brake pad is difficult to remove, use the same procedure as for front disc brake pad. 2. 15 INCH TYPE 1. Set the vehicle on a lift. 2. Loosen the wheel nuts. 3. Lift-up the vehicle, and then remove the rear wheel. 4. Remove the M clip. 5. Remove the two pad pins. 6. Remove the cross spring. Description and Operation Malfunction Indicator Lamp: Description and Operation ACTIVATION OF MALFUNCTION INDICATOR LIGHT 1. When the ignition switch is turned to ON (engine off), the malfunction indicator light in the combination meter illuminates. NOTE: If the malfunction indicator light does not illuminate, perform diagnostics of the malfunction indicator light circuit or the combination meter circuit. See: Testing and Inspection/Symptom Related Diagnostic Procedures/Diagnosis By Symptom/Malfunction Indicator Lamp (MIL) Does Not Come ON 2. After starting the engine, the malfunction indicator light goes out. If it does not, either the engine or the emission control system is malfunctioning. 3. If the diagnosis system senses a misfire which could damage the catalyzer, the malfunction indicator light will blink at a cycle of 1 Hz. Page 6126 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 5799 Alarm Horn Relay: Service and Repair SECURITY HORN RELAY REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the mounting bolt and detach the security horn relay. INSTALLATION Install in the reverse order of removal. Page 2440 Crankshaft Position, Camshaft Position And Knock Sensors Page 4014 B230-B283 Page 3074 F21-F61 Fuel Level Sensor Fuel Gauge Sender: Service and Repair Fuel Level Sensor Fuel Level Sensor REMOVAL WARNING: - Place "NO FIRE" signs near the working area. - Be careful not to spill the fuel. NOTE: Fuel level sensor is built in fuel pump assembly. 1. Remove the fuel pump assembly. 2. Disconnect the connector from the fuel pump bracket. 3. Remove the fuel temperature sensor. 4. Remove the bolt which installs the fuel level sensor on mounting bracket. INSTALLATION Install in the reverse order of removal. Page 3263 R58-R69 Page 3756 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 1485 Oil Pressure Sender: Service and Repair Oil Pressure Switch Removal 1. Remove the generator from bracket. 2. Disconnect the terminal from oil pressure switch. 3. Remove the oil pressure switch. Installation 1. Apply liquid gasket to the oil pressure switch threads. ^ Liquid gasket. THREE BOND 1324 (Part No. 004403042) or equivalent 2. Install the oil pressure switch onto engine block. ^ Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft. lbs.) 3. Connect the terminal of oil pressure switch. Page 7174 F21-F61 Service and Repair Brake Bleeding: Service and Repair AIR BLEEDING PROCEDURE CAUTION: ^ The FMVSS No. 116, fresh DOT3 or DOT4 brake fluid must be used. ^ Cover the air bleeder screw with waste cloth when loosening it to prevent brake fluid from being splashed over surrounding parts. ^ Do not allow brake fluid to come in contact with vehicle body; wash away with water and wipe off completely if spilled. ^ Avoid mixing different brands of brake fluid to prevent degrading the quality of the fluid. ^ Be careful not to allow dirt or dust to get into the reservoir tank. 1. MASTER CYLINDER NOTE: ^ If the master cylinder is disassembled or reservoir tank is empty, bleed the master cylinder. ^ During the bleeding operation, keep the brake reservoir tank filled with brake fluid to eliminate entry of air. ^ The brake pedal operating must be very slow. ^ For convenience and safety, two people should do the work. 1. Loosen the wheel nuts, jack-up the vehicle, support it with rigid racks, and remove the wheel. 2. Disconnect the brake line at primary and secondary sides. 3. Put a plastic bag cover on master cylinder. 4. Carefully depress and hold the brake pedal. 5. Close the outlet plug with your finger, and then release the brake pedal. 6. Repeat step (4) and (5) until the brake fluid is completely bled from outlet plug. 7. Remove the plastic bag. 8. Install the brake pipes to master cylinder. Tightening torque: 15 Nm (1.5 kgf-m, 10.8 ft. lbs.) 9. Bleed air from the brake line. 2. BRAKE LINE NOTE: ^ During the bleeding operation, keep the brake reservoir tank filled with brake fluid to eliminate entry of air. ^ The brake pedal operating must be very slow. ^ For convenience and safety, two people should do the work. 1. Make sure that there is no leak from the joints and connections of brake system. 2. Fit one end of vinyl tube into the air bleeder screw and put the other end into a brake fluid container. Page 237 B17-B20 Page 729 R72-R145 R148 Page 7080 B380-f6 Specifications Clearance Lamp: Specifications Specifications Clearance/Parking/Front side marker light ............................................................................................................................................................ 12 V - 5 W Page 5529 ownership. For affected vehicles sold after the date on the dealer's affected list, dealers are to contact those owners and provide them with a copy of the owner notification letter. They should also arrange to make the required correction according to the instructions in the service procedure section of this bulletin. Dealers are also to promptly perform the applicable service procedures defined in this bulletin to correct all affected vehicles in their inventory (new, used, demo). Additionally, whenever a vehicle subject to this recall is taken into dealer new or used inventory, or is in the dealership for service, necessary steps should be taken to ensure the service program correction has been made before selling or releasing the vehicle. PARTS INFORMATION Special Tools and Materials ^ Soldering gun and solder ^ Heat gun ^ 1.5 inch wide unwoven adhesive tape ^ Subaru Global Terminal Wiring Kit 1-47606 ^ Electrical tape ^ Electrical shrink wrap tubing SERVICE PROCEDURE This Recall will involve inspection of the front passenger seat wiring for proper routing. It will also involve repair of the affected wire harness if the inspection reveals pinched wiring. Service Procedure The first part of the procedure involves inspecting the wiring harness for proper routing and possible damage. (There are two separate procedures, one for each different vehicle.) If there is no damage to the wiring harness, no repair is necessary. If the wiring harness is found to be damaged, then follow the repair procedure. Forester Inspection Procedure (See Impreza inspection procedure.) 1. Slide the front passenger seat to the rear most position to expose the front of the slide rail. Page 5265 Tire Monitoring System: Technical Service Bulletins Tire Monitor System - Valve Stem Cap Information 05 tire valve stem caps This is to remind you of the importance of the tire valve stem cap. These caps need to be installed on every tire, regardless if the vehicle is equipped with TPMS or not. Without these caps, dirt and moisture can interfere with the proper sealing of the tire valve stem. This can result in a gradual loss of tire pressure or interfere with adding air to the tire. In turn this may result in a TPMS lamp coming on and an inconvenienced customer. The cap is gray in color, part # S0A342LT09. The accessory SPT valve stem cap may also be used and will not affect the TPMS operation. Page 1297 Wheel Fastener: Specifications Tighten the wheel nuts in a diagonal selection to specified torque. Use a wheel nut wrench. Wheel nut tightening torque ........................................................................................................................................... 90 Nm (9.1 kgf-m, 65.7 ft. lbs.) Page 2659 Engine Control Module: Service and Repair Engine Control Module (ECM) REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the lower inner trim of the passenger side. 3. Detach the floor mat of the front passenger seat. 4. Remove the protect cover. 5. Remove the nuts (A) which hold ECM to the bracket. 6. Remove the clip (B) from the bracket. 7. Disconnect the ECM connectors and take out the ECM. INSTALLATION Install in the reverse order of removal. CAUTION: - When replacing ECM, use of wrong spec. ECM may lead to damage to the fuel injection system. - When replacing ECM, do not damage the harnesses and connectors. Tightening torque: 5 N.m (0.5 kgf-m, 3.7 ft-lb) Page 6304 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 4519 R72-R145 R148 Page 6328 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 7341 B134-B136 Page 387 Backup Lamp Switch: Testing and Inspection Inhibitor Switch (AT Model) INHIBITOR SWITCH (AT MODEL) Measure the resistance between inhibitor switch terminals. Page 4394 F61-R47 Page 247 R58-R69 Page 1520 5. Remove the air intake boot and air cleaner upper cover. 6. Remove the intercooler. 7. Remove the pitching stopper. 8. Remove the radiator upper brackets. 9. Support the engine with a lifting device and wire ropes. 10. Lift-up the vehicle. CAUTION: When lifting up the vehicle, rise up the wire rope together. Page 1174 Fluid - M/T: Fluid Type Specifications Transmission Fluid Grade ................................................................................................................................................... ............................................. API classification GL-5 Above 0° C (38° F) ........................................... ......................................................................................................................................................... SAE 90 Above -30° C (-20° F) ............................................................................................................. .............................................................................. SAE 85W Below 30° C (83° F) ............................. .............................................................................................................................................................. ... SAE 80W All temperatures .............................................................................................................. .......................................................................................... 75W-90 Specifications Fuel Pressure: Specifications Fuel pressure: (disconnecting the pressure regulator) Standard ......................................................................................................................................................... 284 - 314 kPa (2.9 - 3.2 kgf/cm2, 41 - 46 psi) Fuel pressure: (connecting the pressure regulator) Standard ..................................................................................................................................................... 230 - 260 kPa (2.35 - 2.65 kgf/cm2, 33 - 38 psi) Page 2088 B292-B317 Page 2230 Page 1319 CYLINDER HEAD AND CAMSHAFT Removal 1. Remove the V-belt. 2. Remove the crank pulley. 3. Remove the timing belt cover. 4. Remove the timing belt. 5. Remove the cam sprocket. 6. Disconnect the oil flow control solenoid valve assembly connector. 7. Remove the tensioner bracket. 8. Remove the timing belt cover No. 2 (LH). Page 5615 - Do not allow water or oil to come in contact with the connector terminals. Do not touch the connector terminals. - Either of the airbag modules for driver, passenger or side, or pretensioner must not be disassembled. - The removed front seat with the airbag module must be kept at least 200 mm (8 in) away from walls and other objects. - Do not use the airbag or pretensioner parts from other vehicles. Always replace defective parts with new parts. - Never reuse a deployed airbag or pretensioner. - When painting or performing sheet metal work on the front part of the vehicle, including the front wheel apron, front fender, and front side frame, remove the front sub sensors and wire harness of the airbag system. Page 5097 ownership. For affected vehicles sold after the date on the dealer's affected list, dealers are to contact those owners and provide them with a copy of the owner notification letter. They should also arrange to make the required correction according to the instructions in the service procedure section of this bulletin. Dealers are also to promptly perform the applicable service procedures defined in this bulletin to correct all affected vehicles in their inventory (new, used, demo). Additionally, whenever a vehicle subject to this recall is taken into dealer new or used inventory, or is in the dealership for service, necessary steps should be taken to ensure the service program correction has been made before selling or releasing the vehicle. PARTS INFORMATION Special Tools and Materials ^ Soldering gun and solder ^ Heat gun ^ 1.5 inch wide unwoven adhesive tape ^ Subaru Global Terminal Wiring Kit 1-47606 ^ Electrical tape ^ Electrical shrink wrap tubing SERVICE PROCEDURE This Recall will involve inspection of the front passenger seat wiring for proper routing. It will also involve repair of the affected wire harness if the inspection reveals pinched wiring. Service Procedure The first part of the procedure involves inspecting the wiring harness for proper routing and possible damage. (There are two separate procedures, one for each different vehicle.) If there is no damage to the wiring harness, no repair is necessary. If the wiring harness is found to be damaged, then follow the repair procedure. Forester Inspection Procedure (See Impreza inspection procedure.) 1. Slide the front passenger seat to the rear most position to expose the front of the slide rail. Testing and Inspection Air Filter Element: Testing and Inspection INSPECTION Inspect for cracks and loose connections. Page 3307 7. Lift up the vehicle. 8. Disconnect the quick connector on fuel line. 1. Clean the pipe and connector, if they are covered with dust. 2. To prevent from damaging or entering foreign matter, wrap the pipes and connectors with plastic bag, etc. 3. Hold the connector (A) and push retainer (B) down. 4. Pull out the connector (A) from retainer (B). INSTALLATION 1. Connect the quick connector on fuel line. CAUTION: Use a new retainer except for use of engine compartment. - Make sure that the connected portion is not damaged or has dust. If necessary, clean seal surface of pipe. 1. Set the new retainer (B) to connector (A). Page 6472 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 589 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 6352 B136-B141 Page 7408 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 2709 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 2897 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the generator. 3. Drain the engine coolant. 4. Disconnect the connector from the engine coolant temperature sensor. 5. Remove the engine coolant temperature sensor. INSTALLATION Install in the reverse order of removal. NOTE: Use a new gasket. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb) Page 4828 2) Check the clutch switch continuity. If the resistance is not as specified, replace the switch. (1) Disconnect the clutch switch connector. (2) Measure the resistance between 1 and 2 of switch terminal. ^ Clutch switch (Cruise control) ^ Clutch switch (Starter interlock) 3) Confirm that the engine does not start when the clutch pedal is not depressed. If the engine starts, adjust the clutch switch, and inspect the starter interlock circuit. 4) Confirm that the engine starts when the clutch pedal is fully depressed. If the engine does not start, adjust the clutch switch, and inspect the starter interlock circuit. ADJUSTMENT 1) Loosen the clutch switch mounting lock nut (Starter interlock). Page 5147 8) Install the jack-up plate. 9) Install the air intake duct. 10) Install the air intake duct, air cleaner upper cover and air intake boot. 11) Connect the battery ground cable to battery. 12) Feed the specified fluid. CAUTION: Never start the engine before feeding the fluid; otherwise vane pump might be seized up. 13) Finally check clearance between pipes and/or hoses, as shown above. If cruise control actuator-to-power steering hose clearance is less than 10 mm (0-39 inch), move the portion (A) secured by clamp to other portion, or bend portion (B) to adjust. INSPECTION Check all disassembled parts for wear, damage or other abnormalities. Repair or replace faulty parts as required. CAUTION: Although the surface layer materials of rubber hoses have excellent weathering resistance, heat resistance and resistance for low temperature brittleness, they are likely to be damaged chemically by brake fluid, battery electrolyte, engine oil and automatic transmission fluid and their service lives are to be very shortened. It is very important to keep the hoses free from before mentioned fluids and to wipe out immediately when the hoses are adhered with the fluids. Since the resistances for heat or low temperature brittleness are gradually declining according to time accumulation of hot or cold conditions for the Page 613 B128-B134 Page 821 Impact Sensor: Service and Repair Side Airbag Sensor SIDE AIRBAG SENSOR REMOVAL 1. Turn the ignition switch to OFF. 2. Disconnect the ground cable from battery, and wait for at least 20 seconds before starting work. 3. Remove the outer seat belt (FRONT). 4. Detach the side airbag sensor, and then disconnect the airbag connector. INSTALLATION Install in the reverse order of removal. Tightening torque: Refer to "COMPONENT" in "General Description". See: Restraint Systems/Air Bag Systems/Locations Front Catalytic Converter Catalytic Converter: Testing and Inspection Front Catalytic Converter INSPECTION 1. Make sure there are no exhaust leaks from connections and welds. 2. Make sure there are no holes or rusting. Page 5112 7. Attach the repaired body wire harness to the area directly rearward of the wire clamp with insulating tape to prevent the wire from interfering with the seat rail. (See photos below for location of the wire and tape.) 8. Reinstall the floor carpet. Wrap the previously cut portion of carpet with 1.5 inch wide unwoven adhesive tape. 9. Reinstall the center console trim. Note: Be careful that switch wires attached to the center console trim are not pinched by the parking brake lever during installation. 10. Reinstall the passenger front seat. (Install the seat slide rail cover on Forester model.) 11. Reconnect the negative battery cable. (Reprogram the customer's radio stations presets.) 12. Perform Seat Occupant Detection System calibration. (See applicable service manual.) Note: Impreza models have the bladder type system which will require re-zeroing. Forester models have the load sensor type system which requires re-calibration. 13. Turn on the ignition switch and confirm that the seat heater switches and the air bag warning light works properly. SERVICE PROGRAM IDENTIFICATION LABEL Type or print the necessary information on a recall identification label. The completed label should be attached to the vehicle's upper radiator support. Page 3194 Canister Vent Valve: Service and Repair Drain Valve REMOVAL 1. Set the vehicle on the lift. 2. Disconnect the ground cable from battery. 3. Lift up the vehicle. 4. Remove the canister. 5. Remove clip (A), and then remove drain valve (B) from canister. 6. Remove the filter from drain valve (B). INSTALLATION Install in the reverse order of removal. CAUTION: - Assemble the drain valve filter without any clearance. - Make sure the packing in the groove before assembling drain valve to canister. - Replace the clip with a new one. Page 3707 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 500 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor REMOVAL WARNING: - Place "NO FIRE" signs near the working area. - Be careful not to spill fuel. 1. Remove the fuel tank. 2. Remove the protector cover. 3. Disconnect the connector from fuel tank pressure sensor. 4. Release the clips which hold fuel pipes onto fuel tank. 5. Remove the bolt and nut which hold the fuel tank pressure sensor onto the bracket. Inhibitor Switch Neutral Safety Switch: Service and Repair Inhibitor Switch Removal and Installation Inhibitor Switch REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the connector from inhibitor switch, and then remove the switch. INSTALLATION Install in the reverse order of removal. Inspection Inhibitor Switch INSPECTION When the driving condition or starter motor operation is erroneous, first check the shift linkage for improper operation. If the shift linkage is functioning properly, check the inhibitor switch. 1. Disconnect the inhibitor switch connector. 2. Check continuity in inhibitor switch circuits with the select lever moved to each position. NOTE: ^ Also check that continuity in ignition circuit does not exist when the select lever is in R, D, 3, 2 and 1 ranges. ^ If the inhibitor switch is inoperative, check for poor contact of connector on transmission side. 3. Check if there is continuity at equal points when the select lever is turned 1.5° in both directions from N range. Page 5158 (5) Install the ST3 to end of pipe C removed from pump. (6) Replenish power steering fluid up to the specified level. (7) Open the valve, and start the engine. (8) Measure the regular pressure. ST1 925711000 PRESSURE GAUGE ST2 34099AC020 ADAPTER HOSE B ST3 34099AC010 ADAPTER HOSE A Service limit. 981 kPa (10 kgf/cm2, 142 psi) or less (9) If it is not within the specified value, replace the troubled part caused by the following symptoms; pipe or hose clogged, leaks from fluid line, and mix of foreign objects in fluid line. 2) Measure the relief pressure. (1) Using the STs, measure the relief pressure. (2) Close the valve. (3) Measure the relief pressure. ST1 925711000 PRESSURE GAUGE ST2 34099AC020 ADAPTER HOSE B ST3 34099AC010 ADAPTER HOSE A Service limit: Non-turbo model: 6,700 - 7,400 kPa (68 - 75 kgf/cm2, 972 - 1,073 psi) Adjustments Transmission Position Switch/Sensor: Adjustments Inhibitor Switch ADJUSTMENT 1) Move the select lever to "N" range. 2) Loosen the three inhibitor switch securing bolts. 3) Insert the ST as vertical as possible into the holes in inhibitor switch lever and switch body. ST 499267300 STOPPER PIN 4) Tighten the three inhibitor switch bolts. Tightening torque: 3.5 Nm (0.36 kgf-m, 2.6 ft. lbs.) 5) Repeat the above checks. If the inhibitor switch is determined to be "faulty", replace it. Page 5716 Antenna Amplifier: Service and Repair ANTENNA AMPLIFIER REMOVAL 1. SEDAN 1. Disconnect the ground cable from battery. 2. Remove the rear pillar upper trim. 3. Disconnect the harness connector and terminal. 4. Remove the mounting screw and bolt, and detach antenna amplifier. 2. WAGON 1. Disconnect the ground cable from battery. 2. Remove the rear quarter upper trim and roof trim. 3. Disconnect the harness connector and terminal. 4. Remove the mounting screws and detach the antenna amplifier. INSTALLATION Install in the reverse order of removal. Page 2938 B128-B134 Service and Repair Power Steering Line/Hose: Service and Repair Pipe Assembly REMOVAL 1) Disconnect the ground cable from battery. 2) Lift-up the vehicle, and then remove the jack-up plate. 3) Remove the one pipe joint at the center of gearbox, and then connect the vinyl hose to pipe and joint. Discharge fluid by turning steering wheel fully clockwise and counterclockwise. Discharge fluid similarly from the other pipe. ^ Non-turbo model Non-turbo model ^ Turbo model Turbo model 4) Remove the clamp E from pipes C and D. Page 3031 B292-B317 Page 1845 Temperature Gauge: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 6573 B136-B141 Page 3092 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 2809 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 51 Condenser Fan Motor Relay: Testing and Inspection INSPECTION While applying battery voltage to the terminal between (3) and (4), check continuity between (1) and (2). If no continuity exists, replace the relay with a new one. Page 2529 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 1704 Spark Plug: Testing and Inspection INSPECTION Check the electrodes and inner and outer ceramic insulator of plugs, noting the type of deposits and the degrees of electrode erosion. 1. Normal: Brown to grayish-tan deposits and slight electrode wear indicates correct spark plug heat range. 2. Carbon fouled: Dry fluffy carbon deposits on insulator and electrode are mostly caused by slow speed driving in city, weak ignition, too rich fuel mixture and dirty air cleaner, etc. Page 3090 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 4683 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 3764 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 7352 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 7208 (1) Open the rear gate and remove the foam trim board on the left hand side from the cargo floor. (2) Remove the check valve. Note: Place rags or paper towels in the area. There is a chance that a small amount of washer fluid may leak out. (3) Attach valve cushion (86634SA000) around the modified check valve (86634AA010) for soundproofing. (4) Install the modified check valve and valve cushion. Page 1228 - When checking, use a test harness (1). Do not directly apply the tester probe to any connector terminal of the airbag. Damage to the connector terminal may cause the airbag to activate erroneously. - Do not check continuity of either of the airbag modules for driver, passenger or side, or pretensioner. Page 6371 - When checking, use a test harness (1). Do not directly apply the tester probe to any connector terminal of the airbag. Damage to the connector terminal may cause the airbag to activate erroneously. - Do not check continuity of either of the airbag modules for driver, passenger or side, or pretensioner. Page 6626 B134-B136 Page 6487 B230-B283 Page 3825 Non-turbo model ^ Turbo model Turbo model 4) Replace defective parts. Page 2763 B292-B317 Page 4827 Clutch Switch: Service and Repair Clutch Switch REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the instrument panel lower cover. 3) Disconnect the connector from clutch switch. 4) Remove the clutch switch. INSTALLATION CLUTCH SWITCH (CRUISE CONTROL) 1) Move the clevis pin of the push rod right and left and hold where it moves smoothly, then measure stroke of clutch pedal. 2) If the clutch pedal stroke is out of specification, adjust the stroke. 3) Connect clutch switch connector. CLUTCH SWITCH (STARTER INTER LOCK) 1) Fully depress the clutch pedal. 2) Install the clutch pedal plate and clutch switch so that the gap between them is 3 - 3.5 mm (0. 12 0.14 inch), and then tighten the lock nut. 3) Connect the clutch switch connector. 4) Confirm that the engine does not start when the clutch pedal is released. 5) Confirm that the engine starts when the clutch pedal is fully depressed. INSPECTION 1) If the clutch switch (cruise control) does not operate properly (or if it does not stop at the specified position), replace with a new one. Page 5919 Fuel Door: Service and Repair REMOTE OPENERS FUEL FLAP OPENER REMOVAL 1. Remove the rear seat. 2. Remove the center pillar lower trim, and remove the side sill cover on passenger side. Remove the rear pillar lower trim. Pull back the floor mat. Remove the clip holding the cable. 3. Remove the bolt. Remove the pull handle assembly. 4. Remove the cable from pull handle assembly. 5. Remove the right rear quarter trim. 6. Rotate the fuel lock inside the quarter panel to left and remove. INSTALLATION Install in the reverse order of removal. Engine Controls - A/F, O2 Sensor Diagnostic Information Oxygen Sensor: Technical Service Bulletins Engine Controls - A/F, O2 Sensor Diagnostic Information Bulletin Number: 11-92-08 Date: 01/05/09 APPLICABILITY: 1999MY and later Forester 1999MY and later Impreza 2000MY and later Legacy 2006MY and later Tribeca SUBJECT: Air/Fuel Ratio Sensor and Oxygen Sensor INTRODUCTION This bulletin is for information purposes only. REPAIR/SERVICE INFORMATION When performing diagnostics or reading Diagnostic Trouble Codes (DTC) for Air Fuel Ratio (A/F) sensors and Oxygen (O2) sensors use the following information to identify, locate and repair the appropriate sensor and sensor circuits: (1) Rarely will multiple sensors fail at the same time. (2) On vehicles with only one O2 sensor, the designation for that O2 sensor will be bank 1. (3) On vehicles with only one A/F sensor, the designation for that A/F sensor will be bank 1. (4) Any reference to sensor 1 is an A/F sensor. (5) Any reference to sensor 2 is an O2 sensor. (6) Early PZEV vehicles used an additional O2 sensor behind the rear catalyst and is designated sensor 3. (7) On vehicles with A/F and O2 sensors on the right (Passenger Side) and left (Driver side) of the vehicle, Bank 1 is the right side (Passenger Side) and Bank 2 is the left side (Driver side). Example: DTC P0030 HO2S HEATER CONTROL CIRCUIT (Bank 1 Sensor 1). This DTC is referring to the A/F sensor and since it is on a 2007 Forester there is only one A/F sensor and one O2 sensor. Example (as illustrated): DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (Bank 1 Sensor 2). This DTC is referring to the O2 sensor on the right side exhaust (or the O2 sensor of a vehicle with only one O2 sensor). Diagnostic Aids Ignition Switch: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 5397 Auto A/C Model Page 4285 Schematic drawings Page 7270 (1) Open the hood and remove the check valve. (2) Attach valve cushion (86634SA000) around the modified check valve (86634AG000) for soundproofing. Page 1114 A used toothbrush which has been cleaned works great. Manually open the negative pressure valve. Using clean water and a brush, thoroughly clean the valve (inner and outer surface) and the valve seal surface. Check the radiator cap valve opening pressure using a radiator cap tester to insure the cap is within specification (refer to the applicable Subaru Service Manual). Note: If the cap is out of specification replace it. 2. Coolant Reservoir Tank Cleaning Remove the reservoir tank (refer to the applicable Subaru Service Manual). Using clean water, thoroughly clean the inside of the reservoir tank. Reinstall reservoir tank. Fill with coolant to the Full mark. Note: Be sure to use genuine Subaru Super Coolant or Subaru Long Life Coolant, depending upon what type of coolant is currently in the system. 3. Coolant Reservoir Tank Hose Modification Locations Yaw Rate Sensor: Locations Electrical Component Location Page 4118 Diagrams Rear Differential Mounting System Page 2019 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 2242 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 2704 F21-F61 Page 2115 B3-B12 Diagrams Page 4018 F61-R47 Page 2037 Engine Control Module: Testing and Inspection Engine Control Module (ECM) I/O Signal (Part 1) Page 1982 STI model REMOVAL 1. Separate the muffler from rear exhaust pipe. CAUTION: Be careful, the exhaust pipe is hot. Page 264 Electrical Component Location Page 6105 Keyless Entry Module: Service and Repair KEYLESS ENTRY CONTROL UNIT REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the instrument panel lower cover. 3. Remove the nut, and then remove the keyless entry control unit while disconnecting connector. 4. Disconnect the keyless entry control unit and other electrical control module. INSTALLATION Install in the reverse order of removal. Locations Knock Sensor: Locations Sensor (Part 1) Page 2175 Intake Air Temperature Sensor: Service and Repair Mass Air Flow and Intake Air Temperature Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the connector from mass air flow and intake air temperature sensor. 3. Remove the mass air flow and intake air temperature sensor. INSTALLATION Install in the reverse order of removal. Tightening torque: 1.7 N.m (0.17 kgf-m, 1.3 ft-lb) Page 6179 F61-R47 Page 2826 R72-R145 R148 Page 4868 Disclaimer Page 3105 F61-R47 Page 3804 16) Lower the AT jack. NOTE: Do not separate the AT jack and transmission. 17) Remove the oil cooler inlet and outlet pipe. NOTE: When removing the outlet pipe, be careful not to lose balls and springs used with retaining screws. 18) Remove the front and torque converter turbine speed sensor. 19) Disconnect the connector of rear vehicle speed sensor. (VTD model) 20) Disconnect the connector from rear vehicle speed sensor. (MP-T model) Page 5318 Air Duct: Testing and Inspection INSPECTION The direction and amount of air should be adjusted smoothly. The adjustment should be kept in each position. Page 7049 2. Measure the sub switch resistance. 3. If NG, replace the sub switch. Page 7100 Window Glass: Adjustments Front Door Glass FRONT DOOR GLASS ADJUSTMENT NOTE: Before adjustment, ensure that all adjusting nuts of stabilizer (inner), upper stopper, and sash are loosened and door glass is raised so that it is in contact with weather strip. 1. Temporarily tighten one adjusting bolt on one side of rear sash at the midpoint of slotted hole in the inner panel. 2. Temporarily tighten the regulator B-channel in a position at the top of slotted hole. 3. Lower the door glass 10 to 15 mm (0.39 to 0.59 in) from fully closed position. While applying outward pressure of 45.0±5.0 N (4.5±0.5 kgf, 9.9± 1.1 lbf) (F) to the upper edge of glass above midpoint of stabilizer (Outer), press the stabilizer (Inner) at pressure of 30±5 N (3.0±0.5 kgf, 6.6±1.1 lbf) to the glass, then secure it. 4. For adjustment of clearance between front glass and center pillar cover, loosen the nuts (A), and move the glass sash back and forward until clearance becomes the value shown. Specifications Crankshaft: Specifications CRANKSHAFT Bend limit ............................................................................................................................................. .............................................. 0.035 mm (0.0014 in.) Crank pin Out-of-roundness ................................................................................................................ ................................................................ 0.003 mm (0.0001 in.) Cylindricality ................................... ................................................................................................................................................... 0.004 mm (0.0002 in.) Grinding limit (diameter) ............................................................................................................................................................ To 51.750 mm (2.0374 in.) Crank journal Out-of-roundness .......................................................................................................... ...................................................................... 0.005 mm (0.0002 in.) Cylindricality ............................. ......................................................................................................................................................... 0.006 mm (0.0002 in.) Grinding limit (diameter) ............................................................................................................................................................ To 59.750 mm (2.3524 in.) Crank pin outer diameter STD ............................................................................................................. ......................................................... 51.984 - 52.000 mm (2.0466 - 2.0472 in.) 0.03 mm (0.0012 in.) US ..................................................................................................................................... 51.954 51.970 mm (2.0454 - 2.0461 in.) 0.05 mm (0.0020 in.) US ..................................................................................................................................... 51.934 51.950 mm (2.0447 - 2.0453 in.) 0.25 mm (0.0098 in.) US ..................................................................................................................................... 51.734 51.750 mm (2.0368 - 2.0374 in.) Crank journal outer diameter STD ..................................................................................................................................................... ................. 59.992 - 60.008 mm (2.3619 - 2.3625 in.) 0.03 mm (0.0012 in.) US ..................................................................................................................................... 59.962 59.978 mm (2.3607 - 2.3613 in.) 0.05 mm (0.0020 in.) US ..................................................................................................................................... 59.942 59.958 mm (2.3599 - 2.3605 in.) 0.25 mm (0.0098 in.) US ..................................................................................................................................... 59.742 59.758 mm (2.3520 - 2.3527 in.) Side clearance STD ............................................................................................................................. ............................................. 0.030 - 0.115 mm (0.0012 - 0.0045 in.) Limit ........................................ ............................................................................................................................................................. 0.25 mm (0.0098 in.) Oil clearance STD ............................................................................................................................... ........................................... 0.010 - 0.030 mm (0.0004 - 0.0012 in.) Limit .......................................... ........................................................................................................................................................... 0.40 mm (0.0016 in.) NOTE: US: Undersize OS: Oversize ID: Inside Diameter OD: Outside Diameter Page 6576 B380-f6 Page 2424 Crankshaft Position, Camshaft Position And Knock Sensors Page 5340 Blower Motor: Testing and Inspection Blower Fan Does Not Rotate BLOWER FAN DOES NOT ROTATE TROUBLE SYMPTOM: - Blower motor is not rotated. - Blower motor speed does not change. Wiring Diagram Page 3129 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 1650 3. Installation of timing belt Align the alignment mark on timing belt with marks on sprockets in alphabetical order shown in the figure. While aligning marks, position the timing belt properly. CAUTION: ^ Disengagement of more than three timing belt teeth may result in interference between the valve and piston. ^ Ensure the belt's rotating direction is correct. 4. Install the belt idler. Tightening torque: 39 Nm (4.0 kgf-m, 28.9 ft. lbs.) NOTE: Make sure that the marks on the timing belt and sprockets are aligned. Page 135 Engine Control Module: Testing and Inspection Engine Control Module (ECM) I/O Signal (Part 1) Wheels/Tires - Highway Speed Vibration/Harshness/Noise Wheels: Customer Interest Wheels/Tires - Highway Speed Vibration/Harshness/Noise NUMBER: 05-50-10R DATE: 02/03/11 APPLICABILITY: All Subaru Vehicles SUBJECT: Noise, Vibration and Harshness (NVH) at Highway Speeds Caused by a Tire Imbalance or Excessive Radial Force INTRODUCTION This bulletin is to serve as information only and is intended to help minimize steering wheel vibrations at highway speed. DESCRIPTION Some customers may describe a concern of a steering wheel vibration, oscillation or a "shimmy" condition at highway speeds that may be caused by improper tire and wheel balance or excessive radial force variation (RFV). Subaru of America Inc. (SOA) recommends the use of the Hunter GSP 9700 Wheel Balance and Road Force Measurement System to properly balance the wheel and tire assemblies "dynamically" and to measure the radial force variation of the wheel and tire assembly. While the majority of these conditions can be greatly reduced with proper wheel balancing, some road feel may be considered characteristic and can be compared to like model vehicles with similar mileage. Wheel Imbalance The two most common types of wheel imbalances are static (single weight plane) and dynamic (dual weight plane). A static imbalance is best described as a vertical imbalance when the assembly is mounted on the vehicle. A dynamic imbalance is defined as a vertical and inner/outer imbalance while the assembly is mounted on the vehicle. Wheel and tire assembly imbalance should be addressed first as this is the most common source of tire and wheel vibrations. A well maintained dual weight plane balancer (commonly known as a Dynamic Balancer) such as a Hunter G5P9700 should be used to achieve the best possible results. Balancer settings and proper maintenance are critical to obtaining the best results. Refer to the operating instructions as provided by the balancer manufacturer for setup and maintenance instructions. Radial Force Variation (RFV) Radial force variation is an industrial measurement describing the tire uniformity under load. These variations, or harmonics, are measured in kilograms, pounds or newtons. SOA asks that all weight measurements be reported using the metric system (grams, kilograms, etc.) The Hunter GSP 9700 Road Force Measurement System is capable of measuring these harmonics and displaying them as R1H (radial first harmonic), R2H (radial second harmonic) and R3H (radial third harmonic.) These different harmonic levels indicate the number of bad occurrences per revolution. Most commonly, radial first (R1H) harmonics are the cause of steering wheel or body related vibrations that can be felt at highway speeds. Radial force variation can be greatly affected if the vehicle has been parked for an extended period of time causing flat spots or by improper tire inflation. Before performing any diagnosis~ be sure to drive the vehicle at least 10 miles and adjust tire pressures as indicated on the door label. Machine Setup SOA recommends the use of the Hunter GSP 9700 Road Force Measurement System to properly balance and measure radial force on tire and wheel assemblies. To ensure the most accurate results, the following guidelines should be used: ^ Refer to the operating instructions to set the machine to measure in grams (for balancing) and kilograms (for radial force measurements) ^ Refer to the operating instructions to enable the dynamic balancing mode ^ Refer to the operating instructions to disable the Quickmatch(TM) function, if available. ^ Select the "Mixed Weights Balance" mode and measure the weight location carefully. ^ Calibration should be checked at least once per week ^ Ensure the arbor threads and base plate are clean and in good condition ^ Measure the wheel center bore and select the proper cone for mounting the wheel to the balancer Page 5135 Power Steering Fluid: Service and Repair Power Steering Fluid REPLACEMENT 1) Lift up the vehicle. 2) Remove the jack up plate. 3) Remove the pipe joint in center of gear box, and then install the vinyl hose to pipe and joint. Drain the fluid while turning steering wheel. 4) Set the ST on top of reservoir tank and fill it about half way with the specified fluid. ST 34199AE040 OIL CHARGE GUIDE 5) Continue to turn the steering wheel slowly from lock to lock until bubbles stop appearing on oil surface while keeping the fluid at that level. 6) If turning the steering wheel in low fluid level condition, air will be sucked in pipe. In this case, leave it about half an hour and then do the step 5) again. 7) Lift up the vehicle, start the engine and let it idle. 8) Continue to turn the steering wheel slowly from lock to lock again until bubbles stop appearing on oil surface while keeping the fluid at that level. It is normal that bubbles stop appearing after three times turning of steering wheel from lock to lock. 9) In case the bubbles do not stop appearing in the tank, leave it about half an hour and then do the step 4) all over again. 10) Lower the vehicle, and then idle the engine. 11) Continue to turn the steering wheel from lock to lock until bubbles stop appearing and change of the fluid level is within 3 mm (0.12 inch). 12) In case the following happens, leave it about half an hour and then do step 8) to 11) again. (1) The fluid level changes over 3 mm (0.12 inch). (2) Bubbles remain on the upper surface of the fluid. (3) Grinding noise is generated from oil pump. 13) Check the fluid leakage after turning steering wheel from lock to lock with engine running. Page 1926 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 5133 Power Steering Fluid: Fluid Type Specifications P/S Fluid type ...................................................................................................................................... ........................................ Dexron (R) III A/T Fluid Testing and Inspection Turn Signal Switch: Testing and Inspection INSPECTION Measure the resistance between combination switch terminals. 1. LIGHTING SWITCH 2. DIMMER AND PASSING SWITCH 3. TURN SIGNAL SWITCH Page 2228 The list shown above is of A/F Sensor related DTCs. (This list is for example only. Refer to the applicable service manual for a complete list of DTCs.) Note: When the DTCs for A/F sensor are stored in memory, do not replace the oxygen sensor. The list above is of O2 Sensor related DTCs. (This list is for example only. Refer to the applicable service manual for a complete list of DTCs.) Note: When the DTCs for O2 sensor are stored in memory, do not replace the A/F sensor. Page 2575 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the connector from the camshaft position sensor RH. 3. Remove the camshaft position sensor RH from the rear side of cylinder head. 4. Remove the camshaft position sensor LH in the same procedure as RH side. INSTALLATION Install in the reverse order of removal. Tightening torque: Camshaft position sensor support: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) Camshaft position sensor: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) Page 2204 Knock Sensor: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 4392 B380-f6 Page 2306 11) Remove the clamp, and then remove the shift lock solenoid. INSTALLATION Install in the reverse order of removal. INSPECTION Step 1 - Step 4 Page 3613 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 783 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 6297 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 3141 B136-B141 Page 6560 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Locations Electronic Throttle Actuator: Locations Sensor (Part 1) Combination Switch (Light) Combination Switch: Service and Repair Combination Switch (Light) COMBINATION SWITCH (LIGHT) REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the instrument panel lower cover. 3. Remove the screws which secure the upper column cover to lower column cover. 4. Remove the screws which secure the upper column cover. 5. Disconnect the connector from combination switch. 6 Remove the screws which secure the switch, and then remove the switch. INSTALLATION Install in the reverse order of removal. Page 5636 - Driver's seat (with seat heater) - Driver's seat (without seat heater) Page 2401 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 5789 2) Apply 3MTM Heavy Drip-Chek(TM) Sealer 08531 to the gap of the seam of the inner door panel (See figure 2, below). 3) Reinstall the sealing cover (if equipped with standard speakers perform countermeasure 2), speaker and door trim. 4) Verify that the chatter and/or vibration is eliminated. Countermeasure 2 1) Remove the door trim, speaker and sealing cover. 2) Install a new sealing cover using 3MTM Windo-Weld(TM) Round Ribbon Sealer 08625 (See figure 3, below). Make sure to use a uniform bead and press firmly to insure the sealing cover stays in place. Note: Breaks in the bead will allow water leakage and contamination. ^ Reinstall the speaker and door trim. ^ Verify that the chatter and/or vibration is eliminated. WARRANTY/CLAIM INFORMATION Page 3393 B54-B127 Page 2999 R58-R69 Page 4922 B54-B127 Page 5662 B128-B134 Page 3896 B54-B127 Page 5794 Speaker: Service and Repair Rear Speaker REAR SPEAKER REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the rear door trim. 3. Remove the rear speaker mounting screws. 4. Disconnect the harness connector and remove rear speaker INSTALLATION Install in the reverse order of removal. Page 3550 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 570 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 3564 B380-f6 Page 7157 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 4704 R72-R145 R148 Page 3570 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 533 R72-R145 R148 Page 2645 B380-f6 Page 7167 B54-B127 Locations Coolant Temperature Sensor/Switch (For Computer): Locations Sensor (Part 1) Testing and Inspection Camshaft Gear/Sprocket: Testing and Inspection INSPECTION 1. Check the cam sprocket teeth for abnormal wear and scratches. 2. Make sure there is no free play between cam sprocket and key. Page 1070 Belt tension (without belt tension gauge) (A) When installing new parts: 7 - 9 mm (0.276 - 0.354 inch) At inspection: 9 - 11 mm (0.354 - 0.433 inch) (B) When installing new parts: 7.5 - 8.5 mm (0.295 - 0.335 inch) At inspection: 9.0 - 10.0 mm (0.354 - 0.394 inch) Page 6319 B230-B283 Page 4055 8) Install the rear exhaust pipe and muffler. 9) Install the console box. INSPECTION 1) Verify whether the slider moves smoothly. If not, adjust the reverse check cable or check damage of slider. 2) Check that the gear can be shift to reverse, when the slider is pulled up. If the gear can not be shift to reverse, adjust the reverse check cable. 3) Check that the gear can not be shift to reverse, when the slider is not pulled up. If the gear can be shift to reverse, adjust or replace the reverse check cable. ADJUSTMENT 1) Set the vehicle on a lift. 2) Remove the under cover. 3) Remove the rear exhaust pipe and muffler. 4) Remove the crossmember. 5) Remove the snap pin and washer, and then separate the reverse check cable from reverse check lever. 6) Move the transmission to right side, and then remove the stay bolt and reverse check cable. NOTE: If the transmission is not moved, the stay bolt will contact body and damage may occur. Page 6669 Sensor Page 1001 Idle Speed: Testing and Inspection Idle Speed INSPECTION 1. Before checking the idle speed, check the following: 1. Ensure the air cleaner element is free from clogging, ignition timing is correct, spark plugs are in good condition, and that the hoses are connected properly. 2. Ensure the malfunction indicator light does not illuminate. 2. Warm-up the engine. 3. Stop the engine, and then turn the ignition switch to OFF. 4. Insert the cartridge to Subaru Select Monitor. 5. Connect the Subaru Select Monitor to data link connector. 6. Turn the ignition switch to ON, and Subaru Select Monitor power switch to ON. 7. Select the (2. Each System Check) in Main Menu. 8. Select the (Engine Control System) in Selection Menu. 9. Select the (1. Current Data Display & Save) in Engine Control System Diagnosis. 10. Select the (1. 12 Data Display) in Data Display Menu. 11. Start the engine, and then read the engine idle speed. 12. Check the idle speed when unloaded. (With headlights, heater fan, rear defroster, radiator fan, air conditioning, etc. OFF) Idle speed [No load and gears in neutral]. 700 ± 100 rpm 13. Check the idle speed when loaded. (Turn the air conditioning switch to "ON" and operate the compressor for at least 1 minute before measurement.) Idle speed [A/C "ON". no load and gears in neutral]: When the A/C refrigerant pressure is low MT. 725 ± 100 rpm AT. 750 ± 100 rpm When the A/C refrigerant pressure is high MT. 800 ± 100 rpm AT. 825 ± 100 rpm NOTE: As idle speed is controlled by the automatic adjustment type, it can not be adjusted manually. If the idle speed is out of specifications, refer to General On-board Diagnosis Table under "Engine Control System". Rear Gate Latch Lock Actuator Trunk / Liftgate Lock: Service and Repair Rear Gate Latch Lock Actuator REAR GATE LATCH LOCK ACTUATOR REMOVAL 1. Remove the rear gate latch assembly. 2. Loosen two screws to remove the rear gate lock actuator. INSTALLATION Install in the reverse order of removal. NOTE: Make sure the lock works properly after installation. Page 6149 Sunroof / Moonroof: Description and Operation Wagon Models WAGON MODELS DESCRIPTION The sunroof operates on an automatic opening/closing system, and the joined opening area consists of a tilting front glass lid and a sliding rear glass lid. - The sunroof openings are joined to form a single, wide opening (720 mm (28.35 in) long and 600 mm (23.62 in) wide), aiming to improve the "open and free" feeling to a great extent. - A motor with a built-in microprocessor is used for the sunroof motor, which provides one-touch automatic opening and closing functions with a jamming prevention feature. (The system operates in auto mode when the switch is pushed.) - The frame, glass lid and mechanism parts are refined to reduce considerable amount of weight. - The contour and tilt-up angle of the front glass lid are refined to enhance the effect as a deflector and reduce the wind blowing into the cabin when the sunroof is open. Also, the edge shape of the front glass lid is optimized to minimize unpleasant wind shearing noise. FUNCTION - Open and close operations When the switch is pushed rearwards, the rear edge of the front glass lid tilts up by 45 mm (1.77 in). - When the switch is pushed forwards, the front glass lid tilts down to the fully closed position and then stops. - When the sunroof switch is pushed rearwards while the front glass lid is fully closed, the rear end of the front glass lid stops at a position ready for tilting up. When the switch is pushed again, the rear end of the front glass lid further tilts up to a position of 70 mm (2.76 in), and the rear glass lid slides and opens to a position 410 mm (16.14 in) from the rear end of the front glass lid and stops. When the sunroof switch is pushed again, the rear glass lid opens to the wide-open position [550 mm (21.65 in) from the front glass lid rear end]. - When the sunroof switch is pushed forwards while the rear glass lid is at its wide-open position, the rear glass lid moves forward, and then comes to a stop when its front end reaches a position 150 mm (5.91 in) from the rear end of the front glass lid. When the sunroof switch is pushed again, the rear glass lid moves to the fully closed position, and the front glass lid closes until it reaches its tilted up position. When the sunroof switch is pushed once more, the front glass lid tilts down to the fully closed position . - Sunshade operation When the front glass lid tilts up, the shade opens at its front edge by 20 mm (0.79 in) in connection with the lid, to improve ventilation. However, when tilting down the shade will not move in connection with the front glass lid so the shade must be manually closed. Page 5326 Ambient Temperature Sensor / Switch HVAC: Testing and Inspection AMBIENT SENSOR TROUBLE SYMPTOM: Fan speed is not switched when the fan speed control dial is in AUTO position. Wiring Diagram Page 1483 Page 228 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 6404 Fuel Gauge: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 1119 Hose/Line HVAC: Service and Repair Hose and Tube REMOVAL CAUTION: - When disconnecting/connecting hoses, do not apply excessive force to them. Confirm that no torsion and excessive tension exists after installing. - Seal the disconnected hose with a plug or vinyl tape to prevent contamination from entering. 1. Disconnect the ground cable from battery. 2. Using the refrigerant recovery system, discharge refrigerant. 3. Remove the evaporator unit mounting bolt (A). 4. Remove the low-pressure hose attaching bolts (B). 5. Disconnect the low-pressure hose from evaporator unit. 6. Disconnect the low-pressure hose from compressor. 7. Remove the low-pressure hose from vehicle. 8. Remove the high-pressure hose attaching bolts (C). 9. Disconnect the high-pressure hose from compressor. 10. Disconnect the high-pressure hose from condenser. 11. Remove the high-pressure hose from vehicle. 12. Remove the high-pressure tube attaching bolt (D). 13. Remove the high-pressure tube from vehicle. INSTALLATION CAUTION: - When disconnecting/connecting hoses, do not apply an excessive force to them. Confirm that no torsion and excessive tension exists after installing. - Seal the disconnected hose with a plug or vinyl tape to prevent contamination from entering. 1. Install in the reverse order of removal. 2. Charge refrigerant. Tightening torque: T1: 7.4 N.m (0.75 kgf-m, 5.4 ft-lb) T2: 15 N.m (1.5 kgf-m, 10.8 ft-lb) Page 2737 Page 3922 Differential Fluid - A/T: Fluid Type Specifications Automatic Transmission Differential Gear Oil Fluid Capacity ...................................................................................................................................... ......................... 1.2 liter (1.3 US qt, 1.1 Imp qt) Fluid Type API GL-5 (See figure above for applicable viscosity) Page 3099 B134-B136 Locations Page 5072 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 6251 Non-Turbo Model Page 3662 F61-R47 Testing and Inspection Antitheft Relay: Testing and Inspection INTERRUPT RELAY INSPECTION Measure the interrupt relay resistance between terminals (indicated in the table) when connecting terminal No. 3 to battery positive terminal and terminal No. 1 to battery ground terminal. If NG, replace the interrupt relay. CAUTION: Do not connect the terminals to battery positive terminal and ground terminal incorrectly. If this happens, replace the interrupt relay. Page 2963 Refer to the illustrations above for more details on locating the appropriate sensors. The list shown above is of A/F Sensor related DTCs. (This list is for example only. Refer to the applicable service manual for a complete list of DTCs.) Note: When the DTCs for A/F sensor are stored in memory, do not replace the oxygen sensor. Page 3604 Ignition Control Module: Service and Repair Ignition Coil and Ignitor Assembly REMOVAL Direct ignition type has been adopted. Refer to the "Spark Plug Removal" for removal procedure. INSTALLATION Install in the reverse order of removal. Tightening torque: 16 N.m (1.6 kgf-m, 11.7 ft-lb) Page 3653 B17-B20 Page 1373 4. Check the snap ring installation groove (A) on piston for burr. If necessary, remove the burr from groove so that the piston pin can lightly move. 5. Check the piston pin snap ring for distortion, cracks and wear. Page 2226 Wheels/Tires - Highway Speed Vibration/Harshness/Noise Wheels: Customer Interest Wheels/Tires - Highway Speed Vibration/Harshness/Noise NUMBER: 05-50-10R DATE: 02/03/11 APPLICABILITY: All Subaru Vehicles SUBJECT: Noise, Vibration and Harshness (NVH) at Highway Speeds Caused by a Tire Imbalance or Excessive Radial Force INTRODUCTION This bulletin is to serve as information only and is intended to help minimize steering wheel vibrations at highway speed. DESCRIPTION Some customers may describe a concern of a steering wheel vibration, oscillation or a "shimmy" condition at highway speeds that may be caused by improper tire and wheel balance or excessive radial force variation (RFV). Subaru of America Inc. (SOA) recommends the use of the Hunter GSP 9700 Wheel Balance and Road Force Measurement System to properly balance the wheel and tire assemblies "dynamically" and to measure the radial force variation of the wheel and tire assembly. While the majority of these conditions can be greatly reduced with proper wheel balancing, some road feel may be considered characteristic and can be compared to like model vehicles with similar mileage. Wheel Imbalance The two most common types of wheel imbalances are static (single weight plane) and dynamic (dual weight plane). A static imbalance is best described as a vertical imbalance when the assembly is mounted on the vehicle. A dynamic imbalance is defined as a vertical and inner/outer imbalance while the assembly is mounted on the vehicle. Wheel and tire assembly imbalance should be addressed first as this is the most common source of tire and wheel vibrations. A well maintained dual weight plane balancer (commonly known as a Dynamic Balancer) such as a Hunter G5P9700 should be used to achieve the best possible results. Balancer settings and proper maintenance are critical to obtaining the best results. Refer to the operating instructions as provided by the balancer manufacturer for setup and maintenance instructions. Radial Force Variation (RFV) Radial force variation is an industrial measurement describing the tire uniformity under load. These variations, or harmonics, are measured in kilograms, pounds or newtons. SOA asks that all weight measurements be reported using the metric system (grams, kilograms, etc.) The Hunter GSP 9700 Road Force Measurement System is capable of measuring these harmonics and displaying them as R1H (radial first harmonic), R2H (radial second harmonic) and R3H (radial third harmonic.) These different harmonic levels indicate the number of bad occurrences per revolution. Most commonly, radial first (R1H) harmonics are the cause of steering wheel or body related vibrations that can be felt at highway speeds. Radial force variation can be greatly affected if the vehicle has been parked for an extended period of time causing flat spots or by improper tire inflation. Before performing any diagnosis~ be sure to drive the vehicle at least 10 miles and adjust tire pressures as indicated on the door label. Machine Setup SOA recommends the use of the Hunter GSP 9700 Road Force Measurement System to properly balance and measure radial force on tire and wheel assemblies. To ensure the most accurate results, the following guidelines should be used: ^ Refer to the operating instructions to set the machine to measure in grams (for balancing) and kilograms (for radial force measurements) ^ Refer to the operating instructions to enable the dynamic balancing mode ^ Refer to the operating instructions to disable the Quickmatch(TM) function, if available. ^ Select the "Mixed Weights Balance" mode and measure the weight location carefully. ^ Calibration should be checked at least once per week ^ Ensure the arbor threads and base plate are clean and in good condition ^ Measure the wheel center bore and select the proper cone for mounting the wheel to the balancer Page 5660 B17-B20 Engine Controls - A/F, O2 Sensor Diagnostic Information Oxygen Sensor: Technical Service Bulletins Engine Controls - A/F, O2 Sensor Diagnostic Information Bulletin Number: 11-92-08 Date: 01/05/09 APPLICABILITY: 1999MY and later Forester 1999MY and later Impreza 2000MY and later Legacy 2006MY and later Tribeca SUBJECT: Air/Fuel Ratio Sensor and Oxygen Sensor INTRODUCTION This bulletin is for information purposes only. REPAIR/SERVICE INFORMATION When performing diagnostics or reading Diagnostic Trouble Codes (DTC) for Air Fuel Ratio (A/F) sensors and Oxygen (O2) sensors use the following information to identify, locate and repair the appropriate sensor and sensor circuits: (1) Rarely will multiple sensors fail at the same time. (2) On vehicles with only one O2 sensor, the designation for that O2 sensor will be bank 1. (3) On vehicles with only one A/F sensor, the designation for that A/F sensor will be bank 1. (4) Any reference to sensor 1 is an A/F sensor. (5) Any reference to sensor 2 is an O2 sensor. (6) Early PZEV vehicles used an additional O2 sensor behind the rear catalyst and is designated sensor 3. (7) On vehicles with A/F and O2 sensors on the right (Passenger Side) and left (Driver side) of the vehicle, Bank 1 is the right side (Passenger Side) and Bank 2 is the left side (Driver side). Example: DTC P0030 HO2S HEATER CONTROL CIRCUIT (Bank 1 Sensor 1). This DTC is referring to the A/F sensor and since it is on a 2007 Forester there is only one A/F sensor and one O2 sensor. Example (as illustrated): DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (Bank 1 Sensor 2). This DTC is referring to the O2 sensor on the right side exhaust (or the O2 sensor of a vehicle with only one O2 sensor). Page 5757 Keyless Entry Transmitter: Testing and Inspection TRANSMITTER INSPECTION 1. TRANSMITTER BATTERY Measure the voltage between the transmitter battery (+) terminal and (-) terminal. NOTE: Battery discharge occurs during measurement. Complete the measurement within 5 seconds. If NG, replace the battery. (Use CR2025 or equivalent.) Front Turn Signal Light Bulb Turn Signal Bulb: Testing and Inspection Front Turn Signal Light Bulb FRONT TURN SIGNAL LIGHT BULB INSPECTION 1. Visually check the bulb for blow out. 2. Check the bulb specification. 3. If NG, replace the bulb with a new one. Page 3133 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 3061 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 4706 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Rear Door Glass Window Glass: Service and Repair Rear Door Glass REAR DOOR GLASS REMOVAL 1. Remove the rear door trim. 2. Remove the sealing cover. 3. Remove the stabilizer. 4. Remove the front end and rear end of weather strip. Ignition System - Spark Plug Replacement Intervals Spark Plug: Technical Service Bulletins Ignition System - Spark Plug Replacement Intervals PLATINUM SPARK PLUG CHANGE INTERVALS The Techline occasionally gets calls concerning the change intervals on platinum plugs and why some need to be changed at 30,000 miles and others at 60,000 miles. The reason for this is the spark plugs on 2.5L NA engines, the electrode side of this plug is platinum but the plug core side is not platinum. Therefore, it is a maintenance interval every 30,000 miles. On the 2.5L Turbo and 3.OL engines, both the electrode side and the plug core side are platinum. Therefore, it is a maintenance interval every 60,000 miles. Page 5156 Perform the following inspection procedures and repair or replace defective parts. SERVICE LIMIT Make a measurement as follows. If it exceeds the specified service limit, replace the parts with new ones. CAUTION: ^ Fix the oil pump on a vise to make a measurement. At this time, hold the oil pump with least possible force between two wood pieces. ^ Do not set outside of flow control valve or pulley on a vise; otherwise outside or pulley might be deformed. Select properly sized wood pieces. 1) Play of the pulley shaft Condition: P: When applying the force of 9.8 N (1.0 kgf, 2.2 lbs.) 2) Ditch deflection of pulley Service limit: Page 4507 B3-B12 Page 2312 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 3470 F21-F61 Service and Repair Trunk / Liftgate Shock / Support: Service and Repair REAR GATE DISPOSAL 1. REAR GATE DAMPER STAY CAUTION: Gas is colorless, odorless, and harmless. However, gas pressure may spray the cutting powder or oil. Be sure to wear dust-resistant goggles. 1. Cover with a vinyl case as shown in the figure. NOTE: Prevent the vinyl case from being caught by drill cutting edge 2. Lift the body side slightly with piston rods fully extended, and secure the body side on vise stand. Drill a hole in 2 to 3 mm (0.08 to 0.12 in) diameter at a point 10 to 200 mm (0.39 to 7.87 in) from door side, and bleed the rear gate damper stay completely. Page 573 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 5101 7. Attach the repaired body wire harness to the area directly rearward of the wire clamp with insulating tape to prevent the wire from interfering with the seat rail. (See photos below for location of the wire and tape.) 8. Reinstall the floor carpet. Wrap the previously cut portion of carpet with 1.5 inch wide unwoven adhesive tape. 9. Reinstall the center console trim. Note: Be careful that switch wires attached to the center console trim are not pinched by the parking brake lever during installation. 10. Reinstall the passenger front seat. (Install the seat slide rail cover on Forester model.) 11. Reconnect the negative battery cable. (Reprogram the customer's radio stations presets.) 12. Perform Seat Occupant Detection System calibration. (See applicable service manual.) Note: Impreza models have the bladder type system which will require re-zeroing. Forester models have the load sensor type system which requires re-calibration. 13. Turn on the ignition switch and confirm that the seat heater switches and the air bag warning light works properly. SERVICE PROGRAM IDENTIFICATION LABEL Type or print the necessary information on a recall identification label. The completed label should be attached to the vehicle's upper radiator support. Page 6391 B3-B12 Specifications Alignment: Specifications SPECIFICATION SPECIFICATION 1 SPECIFICATION 2 NOTE: ^ Front and rear toe-in and front camber can be adjusted. If toe-in or camber exceeds tolerance, adjust toe-in and camber to the adjustment standard. ^ The other items indicated in the specification table cannot be adjusted. If the other items exceed specifications, check suspension parts and connections for deformities; replace with new ones as required. Service and Repair Heater Core: Service and Repair Heater Core REMOVAL 1. Remove the heater and cooling unit. 2. Loosen the screws to remove the heater core cover. 3. Remove the heater core. INSTALLATION Install in the reverse order of removal. Engine Controls - DTC P0607 Diagnostic Information Engine Control Module: All Technical Service Bulletins Engine Controls - DTC P0607 Diagnostic Information NUMBER: 11-91-08 DATE: 12/05/08 APPLICABILITY: 2004-2008MY Impreza 2004-2008MY Forester 2005-2008MY Legacy/Outback 2006-2007MY Tribeca SUBJECT: DTC P0607 Control Module Performance Introduction The purpose of the bulletin is for information purposes when diagnosing DTC P0607. The following checks and information is in addition to what is listed in the Subaru Service Manual. This information is to be used in conjunction with the service manual. Repair Procedure/Information Additional items to check: ^ Rapid drop of voltage from a dead battery ^ Loose battery terminals ^ Loose ECM ground terminal ^ A short or open to the power or ground circuit If the malfunction criteria are met, the CEL will illuminate, the vehicle will go into fail safe and the throttle valve opening will be fixed at 6°. Fail safe will recover to normal mode if the ECM judges the criteria "OK" at the time of the next engine start. The CEL will not turn off until the "OK" driving cycle is completed 3 times in a row. The judgment is decided by the ECM to keep the CEL On or Off at the time the ignition switch is turned from ON to OFF. The ECM keeps DTC P0607 in memory even after the indicator light goes out. Therefore, it is important to erase memory after the repair is completed. Detail list of applicable model and engine type. Page 6264 Cruise Control Switch: Testing and Inspection INSPECTION Measure the cruise control command switch resistance. If NG, replace the cruise control command switch. Page 1254 4. When the ignition switch is turned to ON (engine off) or to START with the test mode connector connected, the malfunction indicator light blinks at a cycle of 3 Hz. Page 5009 Additional labels are available through the Customer Dealer Services Department (CDS). CLAIM REIMBURSEMENT AND ENTRY PROCEDURES Credit to perform this recall will be based on the submission of properly completed repair order information. Dealers may enter the applicable claim information through their Dealer Communications System. Inspect - Use the applicable claim submission information for inspection of passenger front seat wire harness. Repair Wiring - Use the additional claim submission information for repair of the passenger front seat wire harness. Disclaimer Page 3711 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 7079 B292-B317 Page 5085 R72-R145 R148 Page 2573 Camshaft Position Sensor: Locations Sensor (Part 1) Page 7321 Wiper Blade: Service and Repair Disassembly and Assembly WIPER BLADE DISASSEMBLY 1. METAL TYPE Pull on the side (A) of wiper rubber stopper, and then remove the rubber from blade assembly. 2. RESIN TYPE Pull the wiper rubber top slightly from the stopper (A) and pull it out fully. ASSEMBLY 1. METAL TYPE 1. Insert the wiper rubber onto blade so that the stopper is in the position shown. Page 1796 B380-f6 Page 307 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Specifications Idle Speed: Specifications Idle speed [A/C "ON". no load and gears in neutral]: When the A/C refrigerant pressure is low MT .. .............................................................................................................................................................. ................................................. 725 ± 100 rpm AT .............................................................................. ..................................................................................................................................... 750 ± 100 rpm When the A/C refrigerant pressure is high MT .................................................................................... ............................................................................................................................. 800 ± 100 rpm AT .. .............................................................................................................................................................. ................................................... 825 ± 100 rpm Page 6958 Combination Switch: Service and Repair Combination Base Switch Assembly COMBINATION BASE SWITCH ASSEMBLY REMOVAL 1. Remove the driver s airbag module. 2. Remove the steering wheel. 3. Remove the steering column cover. 4. Remove the combination switch. 5. Loosen the four screws and remove the roll connector. 6. Loosen the three screws. 7. Disconnect the connector and remove the combination base switch assembly. INSTALLATION 1. Install in the reverse order of removal. 2. Align the attaching direction of roll connector with the steering wheel, before installation of steering wheel. Page 4144 10) Depress and release the clutch pedal two to three times to ensure that clutch pedal and release fork operates smoothly. If the clutch pedal and release fork do not operate smoothly, bleed air from the clutch hydraulic system. 11) Measure the clutch pedal full stroke length again to ensure that it is within specifications. If it is not, repeat adjustment procedures again from the beginning. Clutch pedal full stroke: 130 - 135 mm (5.12 - 5.31 inch) 12) Push the release lever until operating cylinder push rod retracts. Ensure that clutch fluid level in reservoir tank increases. If the clutch fluid level increases, the hydraulic clutch is properly adjusted; if fluid level does not increase or push rod does not retract, replace the master cylinder with a new one. 13) Push the release lever until operating cylinder push rod retracts. Check that the clutch fluid level in reservoir tank increases. 14) If the clutch fluid level increases, hydraulic clutch play is correct. 15) If the clutch fluid level does not increase or push rod does not retract, clutch pedal must be readjusted. 16) Check the fluid level on the outside of the reservoir tank. If the level is below "MIN", add clutch fluid to bring it up to "MAX". Page 5244 STI MODEL CAUTION: ^ Before handling gas filled struts, be sure to wear goggles to protect eyes from gas, oil and filings. ^ Do not disassemble the strut damper or place into a fire. ^ Drill holes before disposing of gas filled struts. 1) Place the gas filled strut on a flat and level surface with damping tube fully extended. 2) Using a 2 to 3 mm (0.08 to 0.12 inch) dia. drill, make holes in (1), and then make a hole in (2). Testing and Inspection Trunk Light Bulb: Testing and Inspection Luggage Room Light INSPECTION LUGGAGE ROOM LIGHT BULB 1. Visually check the bulb for blow out. 2. Check the bulb specification. 3. If NG, replace the bulb with a new one. Page 5259 Refer to "FRONT AXLE" for inspection procedures. CAUTION: If there is any fault in the bearing, replace hub unit bearing. Locations Air Flow Meter/Sensor: Locations Sensor (Part 1) System Diagnosis Rear Door Window Regulator: Testing and Inspection REAR REGULATOR AND MOTOR ASSEMBLY INSPECTION 1. Make sure that the power window motor rotates properly when battery voltage is applied to terminals of motor connector. 2. Change polarity of battery connections to terminals to ensure that the motor rotates in reverse direction. Page 872 1) With the select lever already in the "N" range, loosen the adjusting nuts A and B on both sides. 2) Turn the adjusting nut B until it lightly touches the connector. 3) Use a spanner wrench to hold nut B so that it does not rotate and then tighten the adjusting nut A. Tightening torque: 7.5 N-m (0.76 kgf-m, 5.5 ft-lb) 4) Afier the completion of adjustment, confirm that the select lever operates normally at all ranges: ^ Move the select lever from "P" to "D" range. Check that the detents could be felt in each range. If the detents cannot be felt or the position pointer (dash indicator) is improperly aligned, re-adjust the cable. ^ Check if the starter motor rotates when the select lever is set to "P" range. System Diagnosis Front Door Latch: Testing and Inspection FRONT DOOR LATCH AND DOOR LOCK ACTUATOR ASSEMBLY INSPECTION 1. Make sure the rod is not deformed. 2. Make sure the lever and rod work smoothly. Page 4223 19) Put a new band through the clip and wind twice in alignment with band groove of boot. 20) Tighten the band by using the ST. ST 925091000 BAND TIGHTENING TOOL NOTE: Tighten the band until it cannot be moved by hand. 21) Tap on the clip with punch provided at the end of ST. ST 925091000 BAND TIGHTENING TOOL CAUTION: Tap to an extent that the boot underneath is not damaged. 22) Cut off the band with an allowance of about 10 mm (0.39 inch) left from clip, and bend this allowance over clip. CAUTION: Be careful so that the end of band is in close contact with clip. 23) Extend and retract the PTJ to provide equal grease coating. BJ+DOJ TYPE NOTE: Use specified grease. BJ side: NTG2218-M (Part No. 28395AG030) DOJ side: NKG205 (Part No. 28495AGO10) 1) Install the BJ boot in specified position, and fill it with 60 to 70 g (2.12 to 2.47 ounces) of specified grease. 2) Place the DOJ boot at the center of shaft. 3) Wrap the shaft splines with vinyl tape. Page 6571 B128-B134 Page 2273 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 4033 INSTALLATION 1) Insert the reverse check cable to the hole of inner boots from underneath the vehicle. 2) Insert the reverse check cable to the gear shift lever assembly, then fix with the band clip. NOTE: ^ Cut off the extra band clip. ^ Make sure that the reverse check cable is inserted into gear shift lever assembly without any clearance. 3) Fix the slider and reverse check cable end with spring pin. NOTE: Apply grease to the sliding part of slider. 4) With the cable pulled (slider lowered), adjust the length between end of cable plate and reverse check cable to 84 mm (3.31 inch), and then tighten the lock nut. Page 6814 License Plate Lamp: Service and Repair LICENSE PLATE LIGHT REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the license plate light mounting screw (A), and then remove the lens (B). 3. Remove the bulb. INSTALLATION Install in the reverse order of removal. Page 5521 Note: Be careful not to damage wires around the working area. 4. Impreza and Forester: Remove the passenger front seat and disconnect the body wire connector afier pulling up the floor carpet. Note: Check if the wire is pinched at the seat rail and damaged. 5. Repair the wire according to the extent of damage as indicated below. (1) When only the surface of the wire covering is damaged only: Wrap electrical tape around the damaged portion, proceed to Step 7. (2) When the core wire is cut or damaged: Cut and remove the damaged section of wire, as illustrated. (3) Peel the wire covering 5/8 inch (15 mm) from the tip of cut wire and expose the core wires, as illustrated. (4) Install heat shrink tubing on one side of the cut wiring. (5) Twist the core wires together so that they entwine each other. Be careful to ensure the tips of the wires are level and parallel. Otherwise~ the wire will break through the heat shrink tubing. (6) Solder the twisted wires and activate the heat shrink tubing with a heat gun. Confirm that no frayed wires are visible. 6. Reconnect the body wire connector. Page 2348 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 1566 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 2140 Disclaimer Page 7404 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 5039 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 5243 10) Loosen the coil spring carefully. INSPECTION Check the disassembled parts for cracks, damage and wear, and replace with new parts if defective. DAMPER STRUT 1) Check for oil leakage. 2) Move the piston rod up and down to check that it operates smoothly without any binding. 3) Play of piston rod ^ Measure the play as follows: Fix outer shell and fully extend the rod. Set a dial gauge at the end of rod: L [10 mm (0.39 inch)], then apply a force of W [20 N (2 kgf, 4 lbs.)] to threaded portion. With the force of 20 N (2 kgf, 4 lbs.) applied, read dial gauge indication: P1. Apply a force of 20 N (2 kgf, 4 lbs.) in the opposite direction of "W", then read dial gauge indication: P2. Limit of play (P1 + P2): 0.8 mm (0.031 inch) If the play is greater than limit, replace the strut. STRUT MOUNT Check the rubber part for large cracks, deformation and deterioration, and replace it with a new one if defective. DUST COVER If any large cracks or damage are found, replace it with a new one. COIL SPRING One having permanent strain should be replaced with a new one. When the vehicle posture is uneven, although there are no considerable reasons like tire puncture, uneven loading, etc., check the coil spring for its free length referring to specifications, cracks, etc., and replace it with a new one if defective. HELPER Replace it with a new one if cracked excessively or damaged. DISPOSAL EXCEPT STI MODEL CAUTION: ^ Before handling gas filled struts, be sure to wear goggles to protect eyes from gas, oil and filings. ^ Do not disassemble the strut damper or place into a fire. ^ Drill holes before disposing of gas filled struts. 1) Place the gas filled strut on a flat and level surface with piston rod fully extended. 2) Using a 2 to 3 mm (0.08 to 0.12 inch) dia. drill, make holes in areas shown in the figure. Page 127 B380-f6 Page 4591 Page 2566 Disclaimer Page 6890 Backup Lamp Switch: Testing and Inspection Inhibitor Switch (AT Model) INHIBITOR SWITCH (AT MODEL) Measure the resistance between inhibitor switch terminals. Page 725 B380-f6 Page 7004 B230-B283 Description and Operation Trunk / Liftgate Hinge: Description and Operation TRUNK LID ARM By minimizing the size of the trunk lid arm, the traveling radius of the arm is made smaller to acquire a wider cargo space. The trunk lid arm is stored inside the trunk trim when the trunk lid is closed. This prevents the luggage from interfering with the arm when closing the trunk. Page 4786 If there is continuity in one direction and the continuity in the other or if there is continuity at unequal points, adjust the inhibitor switch. 4. Repeat the above checks. If there are abnormalities, adjust the select cable. REMOVAL 1. Set up the vehicle on a lift. 2. Move the select lever to N range. 3. Remove the air intake chamber. (Non-turbo model) 4. Remove the intercooler. (Turbo model) 5. Disconnect the inhibitor switch connector. 6. Remove the inhibitor switch connector from stay. 7. Lift-up the vehicle. 8. Remove the front and center exhaust pipes. 9. Remove the snap pin and washer from range select lever. Page 3119 13) Install the air intake chamber. (Non-turbo model) 14) Install the intercooler. (Turbo model) 15) Inspect the inhibitor switch. Page 6964 Turn Signal Bulb: Testing and Inspection Rear Turn Signal Light Bulb REAR TURN SIGNAL LIGHT BULB INSPECTION 1. Visually check the bulb for blow out. 2. Check the bulb specification. 3. If NG, replace the bulb with a new one. Page 4810 Generator Locations Expansion Valve: Locations A/T Controls - DTC P0851/P0852 Set Neutral Safety Switch: All Technical Service Bulletins A/T Controls - DTC P0851/P0852 Set NUMBER: 16-68-06 DATE: 10/09/06 APPLICABILITY: 2005~06MY Legacy, Outback, Impreza and Forester Vehicles Equipped with 4EAT SUBJECT: Diagnostic procedures for P0851/P0852 INTRODUCTION The purpose of this bulletin is to assist when diagnosing P0851 (Neutral Switch Input Circuit Low) and P0852 Neutral Switch Input Circuit High). If you encounter a vehicle with P0851 and/or P0852, use the following repair procedure. REPAIR PROCEDURE/INFORMATION Using the Subaru Select Monitor, check for diagnostic trouble codes stored in memory. If P0851 and/or P0852 are stored in memory, adjust the inhibitor switch and select cable. Note: Refer to the applicable Subaru Service Manual found on the STIS web-site for component removal to gain access to the inhibitor switch and select cable. It is critical that the following adjustments are performed correctly. Adjustment for inhibitor switch 1) Set the select lever to "N" range. 2) Loosen the three inhibitor switch securing bolts. 3) Insert ST (special tool) 499267300 Stopper Pin as vertical as possible into the holes in the inhibitor switch lever and switch body. 4) Tighten the three inhibitor switch securing bolts then remove special tool. Tightening torque: 3.4 N-m (0.35 kgf-m, 2.5 ft-lb) Adjustment for select cable Page 4636 3. Position the disc in straight-forward direction and route brake hose through hole in bracket on wheel apron side. CAUTION: Be sure brake hose is not twisted. 4. Temporarily tighten the flare nut to connect brake pipe and hose. 5. Fix the brake hose with clamp at wheel apron bracket. 6. While holding the hexagonal part of brake hose fitting with a wrench, tighten the flare nut to the specified torque. Tightening torque (Brake pipe flare nut): 15 Nm (1.5 kgf-m, 10.8 ft. lbs.) 7. Bleed air from the brake system. 2. REAR BRAKE HOSE 1. Pass the brake hose through hole of bracket, and then lightly tighten the flare nut to connect brake pipe. 2. Insert the clamp upward to fix brake hose. 3. Install the brake hose to caliper body using a new gasket. Tightening torque (Union bolt): 18 Nm (1.8 kgf-m, 13.0 ft. lbs.) 4. While holding the hexagonal part of brake hose fitting with a wrench, tighten the flare nut to the specified torque. Tightening torque (Brake pipe flare nut): 15 Nm (1.5 kgf-m, 10.8 ft. lbs.) 5. Bleed air from the brake system. INSPECTION Ensure there are no cracks, breakage, or damage on the hoses. Check the joints for fluid leakage. If any cracks, breakage, damage or leakage is found, repair or replace the hose. Page 172 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 2818 B134-B136 Page 4236 8) Install the ABS wheel speed sensor on housing. Tightening torque: 33 Nm (3.4 kgf-m, 24 ft. lbs.) 9) Install the wheel and tighten the wheel nuts to specified torque. Tightening torque: 90 Nm (9.1 kgf-m, 65.7 ft. lbs.) DISASSEMBLY Using the ST and a hydraulic press, drive hub bolts out. ST 28399AG000 HUB STAND CAUTION: ^ Be careful not to hammer the hub bolts. This may deform the hub. ^ Do not reuse the hub bolt. NOTE: Since the hub unit bearing can not be disassembled, only hub bolts can be removed. ASSEMBLY 1) Attach the hub to ST securely. ST 28099PA080 HUB STAND 2) Using a press, Press new hub bolts until their seating surfaces contact the hub. NOTE: Use 12 mm (0.47 inch) dia. holes in HUB STAND to prevent bolts from tilting. INSPECTION Page 2221 Page 6445 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 6523 Outside Temperature Display: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 5179 4) Install the universal joint. 5) Connect the tie-rod end and knuckle arm, and tighten with castle nut. Tightening torque (Castle nut): 27 Nm (2.75 kgf-m, 19.9 ft. lbs.) CAUTION: When connecting, do not hit the cap at bottom of tie-rod end with hammer. 6) After tightening the castle nut to specified torque, tighten it further within 60° until cotter pin hole is aligned with the slot in nut, and then bend the cotter pin to lock. 7) Install the front stabilizer to vehicle. 8) Install the front exhaust pipe assembly. (Non-turbo model) 9) Install the sub frame. 10) Install the under cover. 11) Align the center of roll connector. 12) Install the steering wheel. 13) Install the front wheels. 14) Tighten the wheel nuts to specified torque. Tightening torque: 90 Nm (9.0 kgf-m, 65.1 ft. lbs.) 15) Connect the battery ground cable to battery. 16) Pour fluid into the oil tank, and bleed air. 17) Check for fluid leaks. Page 3661 F21-F61 Cooling System - Coolant Comes Out Of Reservoir Radiator Cap: All Technical Service Bulletins Cooling System - Coolant Comes Out Of Reservoir NUMBER: 08-52-08 DATE: 08/18/08 APPLICABILITY: 1999MY and later Impreza & Forester 2000MY and later Legacy & Outback 2006MY and later Tribeca SUBJECT: Coolant Overflow Introduction If you encounter a vehicle which experiences coolant coming out of the coolant reservoir tank, it may be caused by the radiator cap pressure valve being stuck open by debris sucked up through the reservoir tank hose. As the cooling system cools down, it sucks coolant back into the radiator. If there is debris that settles to the bottom of the reservoir tank, the hose is low enough to also suck them back into radiator. This causes the radiator cap not to seal, allowing excessive amount of coolant to escape overflowing the reservoir tank. If this condition continues over time, there will not be enough coolant in the system to maintain proper engine temperature. In order to correct the condition you need to clean (and test) or replace the radiator cap, clean out the reservoir tank, and shorten the hose slightly, following the repair procedure. Production Line Change The shorter coolant reservoir tank hose was used in production as shown above. Repair Procedure/Information 1. Radiator Cap Cleaning Many caps can be successfully cleaned. The important part is the thorough cleaning of the negative pressure valve. If this is not done completely, remaining debris may result in a repeat issue. If there is an excessive amount of debris or the sealing rubber on the cap appears to be pitted or damaged, replace the cap. Note: If replacing the cap, skip to Step 2. Using clean water and a brush, thoroughly clean the cap seal surface. Note: Inhibitor Switch Transmission Position Switch/Sensor: Service and Repair Inhibitor Switch Inhibitor Switch INSPECTION When the driving condition or starter motor operation is erroneous, first check the shift linkage for improper operation. If the shift linkage is functioning properly, check the inhibitor switch. 1) Disconnect the inhibitor switch connector. 2) Check continuity in inhibitor switch circuits with the select lever moved to each position. NOTE: ^ Also check that continuity in ignition circuit does not exist when the select lever is in "R", "D", "3", "2" and "1" ranges. ^ If the inhibitor switch is inoperative, check for poor contact of connector on transmission side. 3) Check if there is continuity at equal points when the select lever is tilted 1.5° in both directions from "N" range. If there is continuity in one direction and the continuity in the other or if there is continuity at unequal points, adjust the inhibitor switch. 4) Repeat the above checks. If there are abnormalities, adjust the select cable. REMOVAL 1) Set up the vehicle on a lift. 2) Move the select lever to "N" range. 3) Remove the air intake chamber (Non-turbo model). 4) Remove the intercooler. (Turbo model) Page 128 F21-F61 Page 3384 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 3631 R58-R69 Page 1708 3. Disconnect the connector from ignition coil and ignitor assembly. 4. Remove the ignition coil and ignitor assembly. 5. Remove the spark plugs with the spark plug sockets. LH SIDE 1. Remove the battery and battery carrier. 2. Remove the secondary air pump. 3. Disconnect the connector from ignition coil and ignitor assembly. Page 1406 Drive Belt: Service and Repair V-Belt Removal NOTE: Perform the following procedures with the engine installed to the body. FRONT SIDE BELT 1. Loosen the lock bolt (A). 2. Loosen the slider bolt (B). 3. Remove the front side belt (C). REAR SIDE BELT 1. Loosen the lock nut (A). 2. Loosen the slider bolt (B). 3. Remove the A/C belt. 4. Remove the A/C belt tensioner. Installation FRONT SIDE BELT NOTE: Wipe off any oil or water on the belt and pulley. 1. Install the V-belt (c), and tighten the slider bolt so as to obtain the specified belt tension. 2. Tighten the lock bolt (A). 3. Tighten the slider bolt (13). Tightening torque: Lock bolt through bolt 25 Nm (2.5 kgf-m, 18.4 ft. lbs.) Slider bolt: 8 Nm (0.8 kgf-m, 5.9 ft. lbs.) Page 6182 Seat Heater: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Inhibitor Switch Transmission Position Switch/Sensor: Service and Repair Inhibitor Switch Inhibitor Switch INSPECTION When the driving condition or starter motor operation is erroneous, first check the shift linkage for improper operation. If the shift linkage is functioning properly, check the inhibitor switch. 1) Disconnect the inhibitor switch connector. 2) Check continuity in inhibitor switch circuits with the select lever moved to each position. NOTE: ^ Also check that continuity in ignition circuit does not exist when the select lever is in "R", "D", "3", "2" and "1" ranges. ^ If the inhibitor switch is inoperative, check for poor contact of connector on transmission side. 3) Check if there is continuity at equal points when the select lever is tilted 1.5° in both directions from "N" range. If there is continuity in one direction and the continuity in the other or if there is continuity at unequal points, adjust the inhibitor switch. 4) Repeat the above checks. If there are abnormalities, adjust the select cable. REMOVAL 1) Set up the vehicle on a lift. 2) Move the select lever to "N" range. 3) Remove the air intake chamber (Non-turbo model). 4) Remove the intercooler. (Turbo model) Page 3936 Fluid - A/T: Service and Repair Differential Fluid Replacement Differential Gear Oil REPLACEMENT 1) Lift-up the vehicle. 2) Remove the differential gear oil drain plug using TORX T70, and then drain the differential gear oil completely. CAUTION: ^ Directly after the vehicle has been running, the differential gear oil is hot. Therefore, be careful not to burn yourself. ^ Be careful not to spill the differential gear oil on exhaust pipe to prevent it from emitting smoke or fire. When the differential gear oil is spilled on exhaust pipe, wipe it away completely. 3) Replace the gasket with a new one, and then tighten the differential gear oil drain plug using TORX T70. Tightening torque: 44 Nm (4.5 kgf-m, 32.5 ft. lbs.) (Aluminum gasket) 70 Nm (7.1 kgf-m, 51.6 ft. lbs.) (Copper gasket) 4) Lower the vehicle. 5) Pour gear oil into the gauge hole. Recommended fluid. Gear oil capacity: 1.1 - 1.3 liters (1.2 - 1.4 US quarts, 1.0 - 1.1 Imp quarts) 6) Check the level of differential gear oil. Page 1906 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 5166 - Do not allow water or oil to come in contact with the connector terminals. Do not touch the connector terminals. - Either of the airbag modules for driver, passenger or side, or pretensioner must not be disassembled. - The removed front seat with the airbag module must be kept at least 200 mm (8 in) away from walls and other objects. - Do not use the airbag or pretensioner parts from other vehicles. Always replace defective parts with new parts. - Never reuse a deployed airbag or pretensioner. - When painting or performing sheet metal work on the front part of the vehicle, including the front wheel apron, front fender, and front side frame, remove the front sub sensors and wire harness of the airbag system. Page 1895 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the generator. 3. Drain the engine coolant. 4. Disconnect the connector from the engine coolant temperature sensor. 5. Remove the engine coolant temperature sensor. INSTALLATION Install in the reverse order of removal. NOTE: Use a new gasket. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb) Page 124 B136-B141 Page 4695 B128-B134 Sedan Models Sunroof / Moonroof: Description and Operation Sedan Models SEDAN MODELS DESCRIPTION The sunroof operates on an automatic opening/closing system including tilt and slide mechanisms. - A motor with a built-in microprocessor is used for the sunroof motor, which provides one-touch automatic opening and closing functions with a jamming prevention feature. (The system operates in auto mode when the switch is pushed for more than 0.3 seconds.) - Reduced thickness of the sunroof provides extra overhead clearance in the passenger compartment. - The frame, glass lid and mechanism parts are refined to reduce considerable amount of weight. FUNCTION - Sunroof tilting and sliding operation With the glass lid fully closed, pushing the rear side of the tilt switch causes the rear end of the glass lid to rise by 30 mm (1.18 in). Pushing then the front side of the switch causes the lid to lower to the original position. - Pushing the OPEN/CLOSE switch rearward causes the glass lid to slide rearward and open. Pushing the switch forward causes the glass lid to move forward and stop at a point 150 mm (5.91 in) before the fully closed position. Pushing the switch again closes the lid completely. - Sunshade operation The sunshade can be opened or closed manually when the glass lid is closed. - The sunshade moves rearward together with the glass lid when the OPEN side of the OPEN/ CLOSE switch is pushed. (When closed, only the glass lid moves.) Page 7367 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 6357 F61-R47 Page 2656 Engine Control Module (ECM) I/O Signal (Part 4) Locations Secondary Air Pump Control Valve Body Valve Body: Service and Repair Control Valve Body Control Valve Body REMOVAL 1. Set the vehicle on a lift. 2. Disconnect the ground cable from battery. 3. Lift-up the vehicle. 4. Clean the transmission exterior. 5. Remove the ATF drain plug to drain ATF. CAUTION: Directly after the vehicle has been running or the engine has been long idle running, the ATF is hot. Be careful not to burn yourself. 6. Tighten the ATF drain plug. NOTE: Use a new gasket. Tightening torque: 25 Nm (2.5 kgf-cm, 18 ft. lbs.) 7. Remove the oil pan. CAUTION: Be sure to prevent the entering of dust and other foreign matters into oil pan. 8. Remove the magnet. 9. Clean the magnet. 10. Completely remove the remaining liquid gasket on the transmission case and oil pan. 11. Disconnect the control valve connector and front vehicle speed sensor connector. 12. Remove the control valve body. Page 606 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Procedures Rear Bumper: Procedures REAR BUMPER REPAIR Refer to description about repair of front bumper. Page 1965 5. Lift-up the vehicle. 6. Remove the under cover. 7. Remove the bolts which install the under side of turbocharger lower cover. CAUTION: Be careful, the turbocharger and exhaust pipe are hot. 8. Lower the vehicle. 9. Remove the turbocharger upper cover. 10. Remove the bolts which install the upper side of turbocharger lower cover, and remove it. 11. Separate the center exhaust pipe from turbocharger. Page 7349 R72-R145 R148 Service and Repair Shift Interlock Solenoid: Service and Repair AT Shift Lock Solenoid and "P" Range Switch REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the console box. 3) Disconnect the connector. 4) Remove the grip. 5) Remove the indicator bulb from indicator cover. 6) Remove the indicator cover. 7) Remove the blind. 8) Remove the cushion. 9) Remove the clip, and then remove the "P" range switch. 10) Remove the cover. Page 2653 Engine Control Module: Testing and Inspection Engine Control Module (ECM) I/O Signal (Part 1) Page 2548 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 272 Electrical Component Location Page 6020 - When painting or performing sheet metal work on the side of the vehicle, including the side sill, center pillar, and front and rear doors, remove the side airbag sensors and wire harness of the airbag system. - When storing a removed airbag module, do not place any objects on it or pile airbag modules on top of each other. If the airbag inflates for some reason when it is placed with its pad side facing downward or under any object, a serious accident may result. Page 2148 Crankshaft Position, Camshaft Position And Knock Sensors Page 3461 B3-B12 Page 2998 F61-R47 Service and Repair Steering Wheel: Service and Repair Steering Wheel REMOVAL 1) Disconnect the ground cable from battery. 2) Set the tires to straight-ahead position. 3) Remove the airbag module. WARNING: Always refer to "Airbag System" before performing airbag module service. 4) Make matching marks on the steering wheel and steering shaft. 5) Remove the steering wheel nut, and then draw out the steering wheel from shaft using steering puller. INSTALLATION WARNING: Always refer to "Airbag System" before performing airbag module service. 1) Align the center of roll connector. 2) Install in the reverse order of removal. NOTE: Align matching marks on the steering wheel and steering shaft. Tightening torque: 45 Nm (4.6 kgf-m, 33.2 ft. lbs.) Column cover-to-steering wheel clearance: 2 - 4 mm (0.08 - 0.16 inch) CAUTION: Insert the roll connector guide pin into guide hole on lower end of surface of steering wheel to prevent damage. INSPECTION 1) Check the steering wheel for deformation. If the deformation is excessive, replace steering wheel. 2) Check the splines on steering wheel for damage. If the damage is excessive, replace steering wheel. Page 3285 INSTALLATION RH SIDE Install in the reverse order of removal. NOTE: Replace the O-ring and insulators with new ones. Page 227 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 1964 ^ STI model Tightening torque: 35 Nm (3.6 kgf-m, 26 ft. lbs.) 6. Install the upper and lower exhaust manifold covers (LH). Tightening torque: Turbo model 7.5 Nm (0.8 kgf-m, 5.5 ft. lbs.) STI model 19 Nm (1.9 kgf-m, 13.7 ft. lbs.) 7. Install the lower exhaust manifold cover (RH). Tightening torque: Turbo model 7.5 Nm (0.8 kgf-m, 5.5 ft. lbs.) STI model 19 Nm (1.9 kgf-m, 13.7 ft. lbs.) 8. Install the front oxygen (A/F) sensor. 9. Install the under cover. 10. Connect the battery ground cable to battery. 3. Center Exhaust Pipe REMOVAL 1. Set the vehicle on a lift. 2. Disconnect the ground cable from battery. 3. Remove the intercooler. 4. Remove the intercooler bracket. Page 3063 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 3715 B3-B12 Page 4216 8) Using the ST1 and ST2, pull the rear drive shaft into place. ST1 922431000 AXLE SHAFT INSTALLER ST2 927390000 ADAPTER 9) Tighten a new axle nut to the specified torque with parking brake applied. Tightening torque: 190 Nm (19.4 kgf-m, 140 ft. lbs.) 10) Lock the axle nut. 11) Install the wheel. Tightening torque: 90 Nm (9.1 kgf-m, 65.7 ft. lbs.) 12) Make the tires contact the ground fully. CAUTION: Make the tires contact the ground fully and the vehicle be in curb weight whenever carrying out the tightening of bushing portions. 13) Tighten the installation bolt of rear housing assembly and lateral link assembly. Tightening torque: 140 Nm (14.3 kgf-m, 103 ft. lbs.) 14) Tighten the installation bolt of rear housing assembly and trailing link assembly. Tightening torque: 90 Nm (9.2 kgf-m, 66 ft. lbs.) Page 2822 B380-f6 Page 1224 Specified pedal stroke WRX model 105 mm (4.13 inch) Except WRX model 90 mm (3.54 inch) When depressing brake pedal with a 490 Nm (50 kgf, 110 lb ) load. 7. If the distance is more than the specifications, there is a possibility that air is in the brake line. Bleed the brake line until pedal stroke meets the specification. 8. Operate the hydraulic control unit in the sequence control mode. 9. Recheck the pedal stroke. 10. If the distance is more than specifications, there is a possibility air is in the inside of hydraulic unit. Repeat above steps (2) to (9) above until pedal stroke meets the specification. 11. Add brake fluid to the required level (MAX. level) of reservoir tank. 12. As a final step, test run the vehicle at low speed and apply brakes to ensure that brakes provide normal braking action. Page 592 CAUTION: When removing the front oxygen (A/F) sensor, wait until exhaust pipe cools, otherwise it will damage exhaust pipe. INSTALLATION 1. Before installing front oxygen (A/F) sensor, apply anti-seize compound only to the threaded portion of front oxygen (A/F) sensor to make the next removal easier. Anti-seize compound: NEVER-SEEZ NS-165 or equivalent CAUTION: Never apply anti-seize compound to protector of front oxygen (A/F) sensor. 2. Install the front oxygen (A/F) sensor. 3. Install the service hole cover. 4. Lower the vehicle. 5. Install the front right side wheel. 6. Connect the engine harness to the bracket (B) using clips (A). Page 6461 Oil Pressure Sender: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 2040 Engine Control Module (ECM) I/O Signal (Part 4) Page 2983 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 4655 Brake Master Cylinder: Testing and Inspection INSPECTION If any damage, deformation, wear, swelling, rust, and other faults are found on the primary piston assembly or secondary piston assembly, replace the faulty part. NOTE: ^ The primary and secondary pistons must be replaced as complete assemblies. ^ The service limit of clearance between each piston and the master cylinder inner dia. is 0.11 mm (0.0043 inch). Page 2532 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Locations Manifold Pressure/Vacuum Sensor: Locations Sensor (Part 1) Page 5632 Seat Belt: Testing and Inspection INSPECTION 1. OUTER SEAT BELT ASSEMBLY Check for the following, and replace with new parts if necessary. Pretensioner is cracked or deformed. - Seat belt is slackened, bent, or frayed. Seat belt is abnormally wound or extended. 2. INNER SEAT BELT ASSEMBLY Check for the following, and replace with new parts if necessary. Inner seat belt assembly is deformed or damaged. - Seat belt buckle is engaged improperly. Page 4662 Parking Brake Cable: Testing and Inspection Parking Brake Cable INSPECTION Check the removed cable and replace it if damaged, rusty or malfunctioning. 1) Check for smooth operation of the cable. 2) Check the inner cable for damage and rust. 3) Check the outer cable for damage, bends and cracks. 4) Check the boot for damage, cracks and deterioration. Page 4509 B54-B127 Page 694 R58-R69 Page 1923 R58-R69 Page 775 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 3699 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Diagrams Steering Gear: Diagrams POWER ASSISTED SYSTEM ^ TURBO MODEL AND STI MODEL TURBO MODEL AND STI MODEL Page 3259 B292-B317 Page 4443 1. BACK-UP LIGHT SWITCH AND NEUTRAL POSITION SWITCH 1) Install the back-up light switch and neutral position switch with harness. Tightening torque: 32.3 Nm (3.3 kgf-m, 23.8 ft. lbs.) 2) Connect the connector of back-up light switch and neutral position switch. 3) Install the air intake duct and cleaner case. (Non-turbo model) 4) Install the intercooler. (Turbo model) 5) Connect the battery ground cable to battery. Neutral Switch & Backup Switch Testing Switches and Harness INSPECTION BACK-UP LIGHT SWITCH Inspect the back-up light switch. NEUTRAL POSITION SWITCH 1) Turn the ignition switch to OFF. 2) Disconnect the connector of neutral position switch. 3) Measure the resistance between neutral position switch terminals. Non-turbo model: Non-turbo model Turbo model: Turbo model ^ Non-turbo model Page 5421 Refrigerant: Fluid Type Specifications Fluid Type ............................................................................................................................................ ......................................... HFC-134a (CH(2)FCF(3)) Page 6505 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 4798 Battery: Description and Operation Battery The battery is located in the left front part of the engine compartment. It is held on a tray by the battery holder. Page 4504 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Testing and Inspection Headlamp Alignment Switch: Testing and Inspection HEADLIGHT BEAM LEVELER SYSTEM HEADLIGHT BEAM LEVELER SWITCH Measure the resistance between headlight beam leveler switch terminals. Page 6455 B292-B317 Page 4468 Electrical Component Location Page 6453 B136-B141 Page 7085 Power Window Switch: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 3759 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 1833 B17-B20 Page 5278 ^ Inspect the cone for any debris or damage and clean or replace as necessary ^ Perform the Centering Check® Procedure (software version 2.1 and higher) before each wheel is balanced PROCEDURE Always verify the concern with a test drive before beginning diagnosis and performing repairs. Drive the vehicle a minimum of 10 miles to eliminate any flat spots on the tires. Immediately after the road test, lift the vehicle into the air to minimize flat spotting. Adjust tire pressures according to the door label and inspect for any visible damage. If any damage is found, resolve these concerns before continuing with diagnosis. Tire dynamic imbalance should be measured first and adjusted to within 5 grams. Leave any remaining factory weights in place and remove weights that have been added afier production; be careful not to damage the wheel. If the assembly cannot be adjusted to within 5 grams, inspect for the following: ^ Improperly mounted tire or unseated tire bead ^ Improperly mounted assembly to the balancer ^ Damage to the wheel or tire ^ Damage to the tire balancer ^ Debris located inside the tire If a vibration can still be felt afier the wheels have been properly balanced, there is a possibility of excessive radial force variation (RFV) in the tire and wheel assembly. To address RFV concerns, a wheel balancer capable of measuring RFV must be used; Subaru Of America Inc. recommends the use of the Hunter GSP 9700 Road Force Measurement System. If a GSP 9700 is not available, locate the nearest machine through the Hunter Engineering web site (www.gsp9700.com). Measure and record the RFV readings of the wheel and tire assembly for R1H. Then perform the wheel runout measurements by following the on-screen instructions or by referring to the operating instructions; this will determine the individual tire and wheel RFV measurements. The following assembly RFV measurements can be used as a guide: ^ R1H on passenger tires - 8.0kg (17.6lbs) or less If higher than normal RFV measurements are found for the assembly, refer to the on-screen instructions or the operating instructions to match the tire and wheel to minimize the assembly RFV By matching the low spot of the tire to the high spot of the wheel, radial force can be reduced without replacing any components. After all RFV measurements are adjusted to the lowest possible level, install the wheels with the lowest RFV measurements on the front of the vehicle and road test to verify the concern has been reduced. Replacement of tires due to excessive assembly measurements may be unnecessary. If the concern still exists at an unacceptable level, contact the Subaru Technical HelpLine with the following information readily available: ^ Thorough description of customer's concern ^ VIN ^ Mileage ^ Tire manufacturer, size and condition ^ Completed "Dealer vibration Analysis Worksheet and Tire Analysis Worksheet" available under TechLine Pre-Call Worksheets on Subarunet. (All measurements should be in grams or kilograms) ^ Service history of vehicle WARRANTY/CLAIM INFORMATION Page 1910 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 7066 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Adjustments Transmission Position Switch/Sensor: Adjustments Inhibitor Switch ADJUSTMENT 1) Move the select lever to "N" range. 2) Loosen the three inhibitor switch securing bolts. 3) Insert the ST as vertical as possible into the holes in inhibitor switch lever and switch body. ST 499267300 STOPPER PIN 4) Tighten the three inhibitor switch bolts. Tightening torque: 3.5 Nm (0.36 kgf-m, 2.6 ft. lbs.) 5) Repeat the above checks. If the inhibitor switch is determined to be "faulty", replace it. Page 5668 F21-F61 Page 6402 R58-R69 Page 5506 - Do not drop the airbag modulator parts, subject them to high temperature over 93 degrees C (199 degrees F), or let water, oil, or grease get on them; otherwise, the internal parts may be damaged and reliability greatly lowered. - If any damage, opening, or rust is found on the airbag system wire harness, do not attempt to repair using soldering equipment. Be sure to replace the faulty harness with a new genuine part. - Install the wire harness securely with the specified clips to avoid interference or tangled up with other parts. Page 7150 Claim Reimbursement/Warrant Information For vehicles under the Basic New Car Limited Warranty period, refer to the Subaru Warranty Wizard(C) for claim submission information. Disclaimer Page 2805 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 3260 B380-f6 Page 6047 INSTALLATION Install in the reverse order of removal. CAUTION: Be sure to securely hook the pawls of inner trim panel to body flange. NOTE: When installing the rear quarter upper trim, be sure to set the rear molding as shown in the figure. Page 4037 Shifter A/T: Service and Repair Select Lever Select Lever REMOVAL 1) Set the vehicle on a lift. 2) Disconnect the ground cable from battery. 3) Set the select lever to the "N" range. 4) Lift-up the vehicle. 5) Remove the rear exhaust pipe and muffler. ^ SOHC model ^ DOHC turbo model 6) Disconnect the cable from select lever, and then remove the cable bracket. 7) Lower the vehicle. 8) Remove the console box. 9) Disconnect the connectors, then remove the four bolts to take out the select lever from the body. INSTALLATION 1) Mount the select lever onto the vehicle body. 2) Tighten the four bolts to install the select lever to the vehicle body, then connect connector. 3) Install the console box. 4) Set location of the select lever at "N" range. 5) Lift-up the vehicle. 6) Set location of the range select lever to "N" range. Page 4213 8) Remove the rear ABS wheel speed sensor from back plate. 9) Remove the rear drive shaft from rear axle. If it is hard to remove, remove the brake disk rotor using the ST1 and ST2. ST1 926470000 AXLE SHAFT PULLER ST2 28099PA110 AXLE SHAFT PULLER PLATE CAUTION: ^ Do not hammer the drive shaft when removing. ^ Do not damage the oil seal and tone wheel. 10) Remove the rear drive shaft from rear differential using the ST. ST 28099PA100 DRIVE SHAFT REMOVER NOTE: Fit the ST to the bolt (A) as shown in the figure to avoid damage on the side bearing retainer. Page 4984 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Assembly and Disassembly Accelerator Pedal: Service and Repair Assembly and Disassembly DISASSEMBLY NOTE: Accelerator pedal cannot be disassembled. Page 2093 R72-R145 R148 Page 3716 B17-B20 Page 6397 B230-B283 Page 3721 B230-B283 Page 1677 Fuel Pressure: Testing and Inspection Fuel Pressure INSPECTION WARNING: Before removing the fuel pressure gauge, release the fuel pressure. NOTE: If out of specification, check or replace the pressure regulator and pressure regulator vacuum hose. 1. Release the fuel pressure. 2. Disconnect the fuel delivery hoses from fuel damper, and then connect the fuel pressure gauge. 3. Connect the connector of fuel pump relay. 4. Start the engine. 5. Measure the fuel pressure while disconnecting the pressure regulator vacuum hose from intake manifold. Fuel pressure: Standard. 284 - 314 kPa (2.9 - 3.2 kgf/cm2, 41 - 46 psi) 6. After connecting the pressure regulator vacuum hose, measure the fuel pressure. Fuel pressure: Standard. 230 - 260 kPa (2.35 - 2.65 kgf/cm2, 33 - 38 psi) NOTE: The fuel pressure gauge registers 10 to 20 kPa (0.1 to 0.2 kgf/cm2, 1 to 3 psi) higher than standard values during high-altitude operations. Page 230 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 6624 B54-B127 Page 3585 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 1058 Timing Belt: Service and Repair Part 2 The Contents of This Image/Article Reflects the Contents of 18-136-09 Manual Update dated 02/11/09. 3. Tighten the bolts. Tightening torque: 9.75 Nm (1.0 kgf-m, 7 ft. lbs.) Tightening torque: 6.4 Nm (0.65 kgf-m, 4.7 ft. lbs.) Tightening torque: 6.4 Nm (0.65 kgf-m, 4.7 ft. lbs.) Tightening torque:6.4 Nm (0.65 kgf-m, 4.7 ft. lbs.) Page 7370 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification System Diagnosis Rear Door Exterior Handle: Testing and Inspection REAR OUTER HANDLE INSPECTION 1. Make sure the rod is not deformed. 2. Make sure the outer handle and rod move smoothly. Page 7386 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 2318 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 2668 Fuel Level Sensor: Service and Repair Fuel Sub Level Sensor Fuel Sub Level Sensor REMOVAL WARNING: - Place "NO FIRE" signs near the working area. - Be careful not to spill fuel on the floor. 1. Disconnect the ground cable from battery. 2. Lift up the vehicle. 3. Drain the fuel from the fuel tank. 4. Remove the luggage floor mat. 5. Remove the service hole cover. 6. Disconnect the connector from the fuel sub level sensor. 7. Disconnect the fuel jet pump hose. 8. Remove the bolts which install the fuel sub level sensor on the fuel tank. Page 1513 Oil Pressure Warning Lamp/Indicator: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 1290 9) Remove the front hub unit bearing. If it is hard to remove, use STs. ST1 926470000 AXLE SHAFT PULLER ST2 28099PA110 AXLE SHAFT PULLER PLATE INSTALLATION 1) Tighten the front hub unit bearing to the housing with four bolts. 2) Install the front drive shaft. 3) Tighten the axle nut temporarily. 4) Install the disc rotor on hub. 5) Install the disc brake caliper on the housing. Tightening torque: 78 Nm (8.0 kgf-m, 57.9 ft. lbs.) 6) While depressing the brake pedal, tighten a new axle nut (olive color) to specified torque and lock it securely. Tightening torque: 220 Nm (22.4 kgf-m, 162 ft. lbs.) CAUTION: ^ Install the wheel after installation of the axle nut. Failure to follow this rule may damage the wheel bearing. ^ Do not overtighten it as this may damage wheel bearing. 7) After tightening the axle nut, lock it securely. Page 2425 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the connector from the camshaft position sensor RH. 3. Remove the camshaft position sensor RH from the rear side of cylinder head. 4. Remove the camshaft position sensor LH in the same procedure as RH side. INSTALLATION Install in the reverse order of removal. Tightening torque: Camshaft position sensor support: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) Camshaft position sensor: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) Page 1664 Timing Belt Tensioner: Testing and Inspection INSPECTION 2. AUTOMATIC BELT TENSION ADJUSTER 1. Visually check the oil seals for leaks, and rod ends for abnormal wear or scratches. If necessary, replace the automatic belt tension adjuster assembly. NOTE: Slight traces of oil at rod's oil seal does not indicate a problem. 2. Check that the adjuster rod does not move when a pressure of 294 Nm (30 kgf, 66 ft. lbs.) is applied to it. This is to check adjuster rod stiffness. 3. If the adjuster rod is not stiff and moves freely when applying 294 Nm (30 kgf, 66 ft. lbs.), check it using the following procedures: 1. Slowly press the adjuster rod down to the end surface of the cylinder. Repeat this motion 2 or 3 times. 2. With the adjuster rod moved all the way up, apply a pressure of 294 Nm (30 kgf, 66 ft. lbs.) to it. Check the adjuster rod stiffness. 3. If the adjuster rod is not stiff and moves down, replace the automatic belt tension adjuster assembly with a new one. CAUTION: Always use a vertical type pressing tool to move the adjuster rod down. ^ Do not use a lateral type vise. ^ Push the adjuster rod vertically. ^ Press-in the push adjuster rod gradually taking more than 3 minutes. ^ Do not allow press pressure to exceed 9,807 Nm (1,000 kgf, 2,205 ft. lbs.). ^ Press the adjuster rod as far as the end surface of the cylinder. Do not press the adjuster rod into the cylinder. Doing so may damage the cylinder. 4. Measure the extension of rod beyond the body. If it is not within specifications, replace with a new one. Rod extension H. 5.7 ± 0.5 mm (0.224 ± 0.020 inch) 3. BELT TENSION PULLEY 1. Check the mating surfaces of timing belt and contact point of adjuster rod for abnormal wear or scratches. Replace the belt tension pulley if faulty. 2. Check the belt tension pulley for smooth rotation. Replace if noise or excessive play is noted. 3. Check the belt tension pulley for grease leakage. Locations Fuel Gauge Sender: Locations Page 3457 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 5550 Impact Sensor: Testing and Inspection Front Sub Sensor Front Sub Sensor INSPECTION Check for the following, and replace damaged parts with new parts. - Front sub sensor and connector are damaged. - Airbag is deployed. Page 7164 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 1793 B136-B141 Page 2767 R58-R69 Page 6339 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 4622 2. Place a wooden block in caliper body as shown in the figure to prevent the piston from jumping out and avoid being damaged. 3. Gradually supply compressed air via the installation hole of brake hose to force the piston out. 4. Remove the piston seal from caliper body cylinder. CAUTION: Do not damage the cylinder and piston seal groove. ASSEMBLY 1. 14 INCH TYPE 1. Clean the caliper body interior using brake fluid. 2. Apply a coat of brake fluid to the piston seal and fit piston seal in groove on caliper body. 3. Apply a coat of brake fluid to the entire inner surface of cylinder and outer surface of piston. 4. Insert the piston into cylinder. CAUTION: Do not force piston into cylinder. 5. Apply a coat of specified grease to the boot and fit in groove on ends of cylinder and piston. Grease: NIGLUBE RX-2 (Part No. K0779GA 102) 6. Install the piston boot to caliper body, and then attach boot ring. Page 6593 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 3146 F61-R47 Locations Page 578 B134-B136 Page 232 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Cooling System - Radiator Cap Radiator Cap: All Technical Service Bulletins Cooling System - Radiator Cap NUMBER: 09-45-06 DATE: 11/28/06 APPLICABILITY: All Models SUBJECT: Radiator Cap INTRODUCTION The purpose of this bulletin is to provide the inspection and cleaning procedure for the radiator cap. Whenever servicing the coolant/radiator, it is imperative that the filler neck and cap are clean of all contaminants and debris. If foreign material is left in the filler neck sealing area, it will become embedded in the rubber seal and will prevent the cap from sealing properly. Before making the determination that the radiator cap is faulty, perform the following repair procedure. REPAIR PROCEDURE/INFORMATION Caution: The engine cooling system is under pressure and may be extremely hot. To prevent personal injury or vehicle damage, be sure to take appropriate precautions while performing this procedure. 1) Wash and clean the rubber seal surface(s) "A" using clean water and a soft bristle brush. 2) Carefully open the negative pressure valve. Using clean water and a soft bristle brush wash and clean the mating surface "B" between the valve and the rubber seal. Note: Clean thoroughly. Failure to do so will prevent the cap from holding pressure. 3) After cleaning, check valve-opening pressure of cap using a cap tester according to the applicable service manual. 4) Clean the filler neck sealing surface of any and all contaminants. Note: If the valve opening pressure stays within the predetermined specification the cap is reusable. Only replace caps that failed the pressure test. Special note: If the vehicle has any record of overheating the cap may not be reusable even afier cleaning due to the deterioration of the sealing materials. WARRANTY/CLAIM INFORMATION For vehicles under the Basic New Car Limited Warranty period, this repair may be claimed using the table. Rear Gate Latch Lock Actuator Trunk / Liftgate Lock: Testing and Inspection Rear Gate Latch Lock Actuator REAR GATE LATCH LOCK ACTUATOR INSPECTION 1. Disconnect the rear gate latch lock actuator harness connector. 2. Connect the battery to rear gate latch lock actuator terminals. If NG, replace the rear gate latch lock actuator. Oil Seal Seals and Gaskets: Service and Repair Oil Seal Oil Seal INSPECTION Check the oil seal portion for leakage. If leakage is found, replace the oil seal with a new one. REPLACEMENT 1) Clean the transmission exterior. 2) Remove the drain plug using TORX BIT T70, and drain the transmission gear oil completely. NOTE: Tighten the drain plug after draining gear oil. 3) Remove the rear exhaust pipe and muffler. ^ Non-turbo model ^ Turbo model 4) Remove the propeller shaft. 5) Using the ST, remove the oil seal. ST 398527700 PULLER ASSY 6) Using the ST, install the oil seal. ST 498057300 INSTALLER Locations Radiator Cooling Fan Motor Relay: Locations Main Fuse Box (M/B) Solenoid Valve, Actuator, Emission Control System Parts And Ignition System Parts (Part 5) Page 3321 Evaporative Shut Valve: Service and Repair Shut Valve REMOVAL WARNING: - Place "NO FIRE" signs near the working area. - Be careful not to spill fuel. 1. Remove the fuel filler pipe. 2. Disconnect the evaporation hoses from shut valve. 3. Remove the shut valve from fuel filler pipe. INSTALLATION Install in the reverse order of removal. Page 5640 4. Remove the seat belt lower anchor bolt. 5. Remove the anchor cover. Remove the bolt from pillar and remove shoulder anchor. 6. Remove the rear quarter trim. 7. Remove the bolts, and then detach the outer seat belt. 8. Remove the two bolts and remove adjustable anchor ASSEMBLY. 5. SHOULDER SEAT BELT CTR ASSEMBLY (WAGON MODEL) Page 91 Electronic Throttle Actuator Relay: Service and Repair Electronic Throttle Control Relay REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the passenger's side front side sill cover. 3. Remove the bolt which holds the relay bracket on the body. 4. Disconnect the connectors from the main relay. 5. Remove the main relay from the mounting bracket. INSTALLATION Install in the reverse order of removal. Page 292 Non-Turbo Model Page 1449 5. Remove the air intake boot and air cleaner upper cover. 6. Remove the intercooler. 7. Remove the pitching stopper. 8. Remove the radiator upper brackets. 9. Support the engine with a lifting device and wire ropes. 10. Lift-up the vehicle. CAUTION: When lifting up the vehicle, rise up the wire rope together. Specifications Glove Box Lamp: Specifications Specifications Glove box light...................................................................................................................................... ...............................................................12 V - 1.4 W Page 5157 1.0 mm (0.039 inch) or less NOTE: Read the value for one surface of V ditch, and then the value for another off the dial. 3) Resistance to rotation of pulley Service limit: Maximum load: 9.22 N (0.94 kgf, 2.07 lbs.) or less NOTE: ^ A rather higher value maybe indicated when pulley starts turning. ^ Measure the load during rotation and make a judgment. HYDRAULIC PRESSURE NOTE: ^ Be sure to complete all items aforementioned in "INSPECTION", prior to measuring hydraulic pressure. Otherwise, pressure can not be measured correctly. ^ Do not leave the valve of pressure gauge closed or hold the steering wheel at stop end for 5 seconds or more in any case, as the oil pump may be damaged due to long keep of these conditions. ^ Put a cotton cloth waste at a place where fluid drops before the pressure gauge is installed. Wipe off split fluid thoroughly after the measurement. 1) REGULAR PRESSURE MEASUREMENT (1) Connect the ST1, ST2 and ST3. ST1 925711000 PRESSURE GAUGE ST2 34099AC020 ADAPTER HOSE B ST3 34099AC010 ADAPTER HOSE A (2) Remove the air intake duct. (3) Disconnect the pipe C from the pump. (4) Using the gasket (Part No. 34621AC022) and bolt (Part No. 34620AC010), install the ST2 to the pump instead of pipe C. Page 6146 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Diagram Information and Instructions Ignition Control Module: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Rear Gate Latch Lock Actuator Trunk / Liftgate Lock: Service and Repair Rear Gate Latch Lock Actuator REAR GATE LATCH LOCK ACTUATOR REMOVAL 1. Remove the rear gate latch assembly. 2. Loosen two screws to remove the rear gate lock actuator. INSTALLATION Install in the reverse order of removal. NOTE: Make sure the lock works properly after installation. Page 2527 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 6372 - Do not drop the airbag modulator parts, subject them to high temperature over 93 degrees C (199 degrees F), or let water, oil, or grease get on them; otherwise, the internal parts may be damaged and reliability greatly lowered. - If any damage, opening, or rust is found on the airbag system wire harness, do not attempt to repair using soldering equipment. Be sure to replace the faulty harness with a new genuine part. - Install the wire harness securely with the specified clips to avoid interference or tangled up with other parts. Page 3880 11) Remove the clamp, and then remove the shift lock solenoid. INSTALLATION Install in the reverse order of removal. INSPECTION Step 1 - Step 4 Page 2965 Page 856 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 4505 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Brakes - Brake Pad Rust Prevention Brake Pad: Technical Service Bulletins Brakes - Brake Pad Rust Prevention PREVENTIVE MEASURE FOR SURFACE RUST AROUND DISK BRAKE PAD If you encounter a complaint that the brake pad is not sliding properly or that a squeaking type noise can be heard even though the brake performance is normal, and the vehicle is operated in the salt belt or coastal areas, there is a possibility the brake pad portion may have some surface rust on it. The cure is to apply a thin coat of grease (Molykote AS-880N or equivalent) to the parts as shown below. 1) Apply a thin coat of Molykote AS-880N (P/N: K0777YA010) or equivalent to frictional portion between pad and inner shim. Page 7373 B54-B127 Page 5530 2. Pull up the seat slide rail cover from the center console side as indicated by the arrows. 3. Check visually and with your fingers in the area indicated by broken lines to confirm that the body wiring harness (for power to the occupant detection ECU) is not located and/or pinched around the seat bracket. 4. If the wire is found to be located properly (not pinched), reinstall the seat slide rail cover. No further action is required. If the wire is found to be pinched, proceed to the "Wiring Repair Procedure". Impreza Inspection Procedure 1. Remove the center console trim between the select lever and the parking brake lever. If necessary, refer to the applicable service manual for removal instructions. 2. Cut the cross section of floor carpet in the center and in front of the parking brake lever with scissors (as shown, below). Note: Be careful not to damage wires around the work area. ^ Pull up the floor carpet to inspect a section of the subject body wiring harness from the clamping point located behind the shifter console down to the front passenger seat slide rail as indicated in the photo to the left. ^ Check visually and with your fingers to confirm that the wire is not located around the seat bracket area as indicated by the arrow in the photo Page 4056 7) With the cable pulled (slider lowered), adjust the length between end of cable plate and reverse check cable to 84 mm (3.31 inch), and then tighten the lock nut. 8) Move the transmission to right side, and then install the stay. 9) Install the crossmember. 10) Install the rear exhaust pipe and muffler. 11) Install the reverse check cable end, washer and snap pin to reverse check lever. NOTE: Take care to install the snap pin in proper direction. 12) Install the under cover. Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 2027 B230-B283 Page 4498 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 4515 B380-f6 Page 4869 Neutral Safety Switch: Locations Page 6320 B292-B317 Page 5123 FRONT WHEEL TOE-IN ^ Inspection Toe-in: 0±3 mm (0±0. 12 inch) (tolerance) 1) Set the toe-in gauge to rear sides of right and left front tires at height corresponding to center of spindle. 2) Mark each right and left tires at height corresponding to center of spindle and measure the distance "A" between marks. 3) Move the vehicle forward to rotate wheels 1800. NOTE: Whenever rotating the wheels, drive the vehicle forward. 4) Measure the distance "B" between right and left marks. Toe-in can then be obtained by the following equation: ^ Adjustment 1) Make sure that the right and left steering angles are within specified value. 2) Loosen the right and left side steering tie-rods lock nuts. 3) Turn the right and left tie rods equal amounts until the toe-in is at the specification. Toe-in: 0±2 mm (0±0.08 inch) (adjustment standard) Both the right and left tie-rods are right-hand threaded. To increase toe-in, turn both tie-rods clockwise equal amounts (as viewed from inside of the vehicle). 4) Tighten the tie-rod lock nut. Tightening torque: Non- turbo model: 83 Nm (8.5 kgf-m, 61.5 ft. lbs.) Page 3109 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Service and Repair Oil Filter: Service and Repair Engine Oil Filter REMOVAL 1. Lift-up the vehicle. 2. Remove the under cover. 3. Remove the oil filter with ST. ST 18332AA000 OIL FILTER WRENCH (Outer diameter: 68 mm (2.68 inch)) ST 18332AA010 OIL FILTER WRENCH (Outer diameter: 65 mm (2.56 inch)) NOTE: Standard oil filter is outer diameter of 68 mm (2.68 inch). However, SUBARU genuine oil filter having outer diameter of 65 mm (2.56 inch) can also be used. INSTALLATION 1. Get a new oil filter and apply a thin coat of engine oil to seal rubber. 2. Install the oil filter by turning it by hand, being careful not to damage seal rubber. ^ Tighten the oil filter 68 mm (2.68 inch) in diameter by approximately 1 rotation more after the seal rubber of oil filter comes in contact with cylinder block or oil cooler. If using a torque wrench, tighten it to 14 Nm (1.4 kgf-m, 10.3 ft. lbs.). ^ Tighten the oil filter 65 mm (2.56 inch) in diameter by approximately 2/3 - 3/4 rotation more after the seal rubber of oil filter comes in contact with cylinder block or oil cooler. If using a torque wrench, tighten it to 12 Nm (1.2 kgf-m, 8.7 ft. lbs.). CAUTION: Do not tighten excessively, or oil may leak. INSPECTION 1. After installing the oil filter, run the engine and make sure that no oil is leaking around seal rubber. NOTE: The filter element and filter case are permanently jointed; therefore, interior cleaning is not necessary. 2. Check the engine oil level. Page 2650 Engine Control Module: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 6358 R58-R69 Page 4115 Clutch Master Cylinder: Service and Repair Master Cylinder REMOVAL 1) Thoroughly drain the brake fluid from reservoir tank. 2) Remove the snap pin, clevis pin and separate the push rod of master cylinder from clutch pedal. 3) Remove the air intake chamber (Non-turbo model). 4) Remove the intercooler (Turbo model). 5) Disconnect the clutch pipe from master cylinder. 6) Remove the master cylinder and reservoir tank as a unit. CAUTION: Be extremely careful not to spill brake fluid. Brake fluid spilt on the vehicle body will harm the paint surface; wipe it off quickly if spilt. INSTALLATION 1) Install the master cylinder to body, and connect the clutch pipe to master cylinder. NOTE: Check that the pipe is routed properly. 2) Connect the push rod of master cylinder to clutch pedal, and install the clevis pin and snap pin. Page 4087 Transmission Speed Sensor: Service and Repair Torque Converter Turbine Speed Sensor Torque Converter Turbine Speed Sensor REMOVAL When removing the torque converter turbine speed sensor, refer to "Front Vehicle Speed Sensor". INSTALLATION When installing the torque converter turbine speed sensor, refer to "Front Vehicle Speed Sensor" Page 6887 Page 6203 2. Open the trunk lid. 3. Disconnect the connector of high mounted stop light. 4. Remove the mounting nuts of rear spoiler. 5. Remove the rear spoiler. CAUTION: Pay attention to avoid damage during removal or installation. INSTALLATION Install in the reverse order of removal. Tightening torque: Rear spoiler to trunk lid 7.5 ± 2 N.m (0.76 ± 0.20 kgf-m, 5.5 ± 1.4 ft-lb) Adjustments Transmission Position Switch/Sensor: Adjustments Inhibitor Switch ADJUSTMENT 1) Move the select lever to "N" range. 2) Loosen the three inhibitor switch securing bolts. 3) Insert the ST as vertical as possible into the holes in inhibitor switch lever and switch body. ST 499267300 STOPPER PIN 4) Tighten the three inhibitor switch bolts. Tightening torque: 3.5 Nm (0.36 kgf-m, 2.6 ft. lbs.) 5) Repeat the above checks. If the inhibitor switch is determined to be "faulty", replace it. Page 5465 Evaporator Temperature Sensor / Switch: Testing and Inspection Wiring Diagram Page 3281 Fuel Injector REMOVAL RH SIDE 1. Release the fuel pressure. 2. Disconnect the ground cable from battery. 3. Open the fuel filler flap lid and remove the fuel filler cap. 4. Remove the air cleaner upper cover and air intake boot. 5. Remove the air cleaner element. 6. Remove the coolant filler tank. 7. Remove the power steering pump. 1. Remove the front side V-belt. 2. Disconnect the power steering switch connector. 3. Remove the bolts which secure the power steering pipe brackets to the intake manifold. NOTE: Do not disconnect the power steering hose. 4. Remove the bolts which secure the power steering pump bracket. Page 7415 B136-B141 Page 4966 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 6175 B230-B283 Page 2390 B128-B134 Page 7336 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 5216 (3) Calculate plays from the following formula. S= l2 - l1 (4) When plays are larger than the following value, replace with a new one. FRONT BALL JOINT: Specified play for replacement S: Less than 0.3 mm (0.012 inch) 2) When the play is smaller than specified value, visually inspect the dust cover. 3) The ball joint and cover that have been removed must be checked for wear, damage or cracks, and any defective part must be replaced. 4) If the dust cover is damaged, replace with a new ball joint. Transmission Gear Oil Inspection Fluid - M/T: Service and Repair Transmission Gear Oil Inspection Transmission Gear Oil INSPECTION 1) Park the vehicle on a level surface. 2) Turn the ignition switch to OFF, and then wait until the engine cools. 3) Remove the oil level gauge and wipe it clean. 4) Reinsert the level gauge all the way. Be sure the level gauge is correctly inserted and in the proper direction. 5) Pull out the oil level gauge again and check the oil level on it. If it is below the lower level, add oil through the oil level gauge hole to bring the level up to the upper level. Recall 07V043000: Occupant Sensor Wiring Harness Seat Occupant Classification Module - Air Bag: All Technical Service Bulletins Recall 07V043000: Occupant Sensor Wiring Harness MAKE/MODELS: MODEL/BUILD YEARS: Subaru/Forester 2006 Subaru/Impreza 2006 MANUFACTURER: Subaru of America, Inc. NHTSA CAMPAIGN ID NUMBER: 07V043000 MFG'S REPORT DATE: February 06, 2007 COMPONENT: Air Bags: Frontal POTENTIAL NUMBER OF UNITS AFFECTED: 7004 SUMMARY: On certain vehicles, the wiring harness for the air bag occupant detection system in the front passenger seat may have been pinched during production. Pinching of the wiring harness between the floor crossmember and the seat mounting bracket could result in a short circuit. CONSEQUENCE: The passenger's front air bag could become disabled and may not deploy in the event of a crash increasing the risk of injury to the seat occupant. Also an electrical short circuit could cause a fire. REMEDY: Dealers will inspect to see if the wiring had been incorrectly routed under the seat bracket. If so, the dealer will repair any damaged wiring, reroute and secure the wiring harness in the correct location, and re-calibrate the occupant detection system as necessary. The recall is expected to begin on or about March 5, 2007. Owners may contact Subaru at 1-800-782-2783. NOTES: Subaru recall No. WVC-13. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 2400 Throttle Position Sensor: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 2087 B230-B283 Service and Repair Valve Cover: Service and Repair VALVE COVER CYLINDER HEAD AND CAMSHAFT Page 4582 6. Clean mud and foreign particles from the caliper body assembly. INSTALLATION 1. Install the disc rotor. 2. Install the caliper body and support to housing. Tightening torque: Except 17 inch type: 80 Nm (8.2 kgf-m, 59 ft. lbs.) 17 inch type: 155 Nm (15.8 kgf-m, 114.3 ft. lbs.) 3. Install the wheel. INSPECTION 1. Check front wheel bearing play and axle hub play before disc rotor runout limit inspection. 2. Secure the disc rotor by tightening five wheel nuts. 3. Set a dial gauge 10 mm (0.39 inch) inward of rotor outer perimeter. Turn the disc rotor to check runout. If the disc rotor runout exceeds the service limit, resurface the disc rotor. After resurfacing, check disc rotor thickness as in step 4. Disc rotor runout limit. 0.075 mm (0.0030 inch) 4. Set a micrometer 10 mm (0.39 inch) inward of the rotor outer perimeter, and then measure the disc rotor thickness. If the thickness of disc rotor exceeds the service limit, replace with a new disc rotor. Page 3797 Transmission Position Switch/Sensor: Service and Repair AT Shift Lock Solenoid and "P" Range Switch AT Shift Lock Solenoid and "P" Range Switch REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the console box. 3) Disconnect the connector. 4) Remove the grip. 5) Remove the indicator bulb from indicator cover. 6) Remove the indicator cover. 7) Remove the blind. 8) Remove the cushion. 9) Remove the clip, and then remove the "P" range switch. 10) Remove the cover. Page 5066 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 3888 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 5194 17) Apply grease on the oil seal circumference, and then press into the plug using ST and a press. Replace the plug circumference O-rings with new ones. ST 34199AE110 PLUG OIL SEAL INSTALLER CAUTION: Pay attention to the oil seal direction, and attaching position. 18) Using the ST, install the plug. ST 34199AE090PLUG WRENCH Tightening torque: 64 Nm (6.5 kgf-m, 47.0 ft. lbs.) Page 2191 B3-B12 Page 1772 Coolant Reservoir: Service and Repair Coolant Filler Tank Removal WARNING: The radiator is pressurized. Wait until the engine cools down before working on the radiator. 1. Drain the coolant about 3.0 liters (3.2 US qt, 2.6 Imp qt). 2. Remove the air cleaner upper cover and air intake boot. 3. Remove the air cleaner element. 4. Disconnect the engine coolant hoses from coolant filler tank. 5. Remove the bolts and nut which install the coolant filler tank. 6. Disconnect the engine coolant hose which connects the under side of coolant filler tank. 7. Remove the coolant filler tank. Installation 1. Install in the reverse order of removal. ^ Tightening torque: ^ T1 ...................................................................................................................................................... .................. 16 Nm (1.6 kgf-m, 11.8 ft. lbs.) ^ T2 ...................................................................................................................................................... .................... 13 Nm (1.3 kgf-m, 9.6 ft. lbs.) Page 6278 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Locations Hydraulic Control Assembly - Antilock Brakes: Locations Electrical Component Location Page 875 Non-Turbo Model Page 4387 B128-B134 Page 2109 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 1721 6. Inspect all valves for clearance again at this stage. If the valve clearance is not correct, repeat the procedure over again from the first step. 7. After inspection, install the related parts in the reverse order of removal. Page 3062 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 2124 F21-F61 Page 5375 Control Assembly: Exploded Views Auto A/C Model Page 2644 B292-B317 Page 400 Combination Switch: Testing and Inspection Combination Base Switch Assembly INSPECTION COMBINATION BASE SWITCH ASSEMBLY Perform the inspection for the following items and replace with a new one, if any damage is found. Crack or deformation of combination base switch assembly or roll connector. Page 1653 7. Install the timing belt cover. 8. Install the crank pulley. 9. Install the V-belt. INSPECTION 1. TIMING BELT 1. Check the timing belt teeth for breaks, cracks, and wear. If any fault is found, replace the belt. 2. Check the condition of backside of timing belt; if any crack is found, replace the timing belt. CAUTION: ^ Be careful not to let oil, grease or coolant contact the timing belt. Remove quickly and thoroughly if this happens. ^ Do not bend the timing belt sharply. Bending diameter h: 60 mm (2.36 inch) or more 2. AUTOMATIC BELT TENSION ADJUSTER 1. Visually check the oil seals for leaks, and rod ends for abnormal wear or scratches. If necessary, replace the automatic belt tension adjuster assembly. NOTE: Slight traces of oil at rod's oil seal does not indicate a problem. 2. Check that the adjuster rod does not move when a pressure of 294 Nm (30 kgf, 66 ft. lbs.) is applied to it. This is to check adjuster rod stiffness. 3. If the adjuster rod is not stiff and moves freely when applying 294 Nm (30 kgf, 66 ft. lbs.), check it using the following procedures: 1. Slowly press the adjuster rod down to the end surface of the cylinder. Repeat this motion 2 or 3 times. 2. With the adjuster rod moved all the way up, apply a pressure of 294 Nm (30 kgf, 66 ft. lbs.) to it. Check the adjuster rod stiffness. 3. If the adjuster rod is not stiff and moves down, replace the automatic belt tension adjuster assembly with a new one. CAUTION: Always use a vertical type pressing tool to move the adjuster rod down. ^ Do not use a lateral type vise. ^ Push the adjuster rod vertically. ^ Press-in the push adjuster rod gradually taking more than 3 minutes. ^ Do not allow press pressure to exceed 9,807 Nm (1,000 kgf, 2,205 ft. lbs.). ^ Press the adjuster rod as far as the end surface of the cylinder. Do not press the adjuster rod into the cylinder. Doing so may damage the cylinder. 4. Measure the extension of rod beyond the body. If it is not within specifications, replace with a new one. Page 6834 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Diagram Information and Instructions Temperature Gauge: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Locations Hydraulic Control Assembly - Antilock Brakes: Locations Electrical Component Location Testing and Inspection Timing Belt: Testing and Inspection Timing Belt Inspection 1. Check the timing belt teeth for breaks, cracks, and wear. If any fault is found, replace the belt. 2. Check the condition of backside of timing belt; if any crack is found, replace the timing belt. CAUTION: ^ Be careful not to let oil, grease or coolant contact the timing belt. Remove quickly and thoroughly if this happens. ^ Do not bend the timing belt sharply. ^ Bending diameter h: 60 mm (2.36 inch) or more Page 2757 B17-B20 Page 129 F61-R47 Page 5167 - When painting or performing sheet metal work on the side of the vehicle, including the side sill, center pillar, and front and rear doors, remove the side airbag sensors and wire harness of the airbag system. - When storing a removed airbag module, do not place any objects on it or pile airbag modules on top of each other. If the airbag inflates for some reason when it is placed with its pad side facing downward or under any object, a serious accident may result. Page 2025 B134-B136 Page 609 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 488 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the bolt which installs the crankshaft position sensor to cylinder block. 3. Remove the crankshaft position sensor, and disconnect the connector from it. INSTALLATION Install in the reverse order of removal. Page 802 F61-R47 Page 4266 Fluid - M/T: Service and Repair Transmission Gear Oil Replacement Transmission Gear Oil REPLACEMENT 1) Pull out the oil level gauge. 2) Lift-up the vehicle. 3) Remove the drain plug using TORX BIT T70, and drain the transmission gear oil completely. CAUTION: Directly after the engine has been running, the transmission gear oil is hot. Be careful not to burn yourself. NOTE: Tighten the transmission drain plug after draining the transmission gear oil. 4) Lower the vehicle. 5) Pour gear oil into the gauge hole. Recommended gear oil: Use GL-5 (75W-90) or equivalent. Gear oil capacity: 3.5 liters (3.7 US quarts, 3.1 Imp quarts) 6) Check the level of the transmission gear oil. CAUTION: When inserting the level gauge into transmission gear, align the protrusion on the top end of level gauge with the notch in the gauge hole. NOTE: The level should be within the specified range marked on the gauge. Page 2950 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 1497 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 519 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 1025 3. Oil fouled: Wet black deposits show oil entrance into combustion chamber through worn rings and pistons or excessive clearance between valve guides and stems. 4. Overheating: White or light gray insulator with black or brown spots and bluish burnt electrodes indicates engine overheating. Moreover, the appearance results from incorrect ignition timing, loose spark plugs, wrong selection of fuel, hotter range plug, etc. Page 5808 Alarm Module: Service and Repair Security Control Unit SECURITY CONTROL UNIT REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the instrument panel lower cover. 3. Remove the nut, and then remove the keyless entry control unit while disconnecting connector. 4. Disconnect the keyless entry control unit and other electrical control module. INSTALLATION Install in the reverse order of removal. Page 2811 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 3648 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 3660 B380-f6 Page 6115 CAUTION: Be careful not to scratch the body panels with roof rail stud bolts when removing and installing them. Tightening torque: 7.4 N.m (0.75 kgf-m, 5.46 ft-lb) Locations Wheel Speed Sensor: Locations Electrical Component Location Page 1927 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Inhibitor Switch Transmission Position Switch/Sensor: Service and Repair Inhibitor Switch Inhibitor Switch INSPECTION When the driving condition or starter motor operation is erroneous, first check the shift linkage for improper operation. If the shift linkage is functioning properly, check the inhibitor switch. 1) Disconnect the inhibitor switch connector. 2) Check continuity in inhibitor switch circuits with the select lever moved to each position. NOTE: ^ Also check that continuity in ignition circuit does not exist when the select lever is in "R", "D", "3", "2" and "1" ranges. ^ If the inhibitor switch is inoperative, check for poor contact of connector on transmission side. 3) Check if there is continuity at equal points when the select lever is tilted 1.5° in both directions from "N" range. If there is continuity in one direction and the continuity in the other or if there is continuity at unequal points, adjust the inhibitor switch. 4) Repeat the above checks. If there are abnormalities, adjust the select cable. REMOVAL 1) Set up the vehicle on a lift. 2) Move the select lever to "N" range. 3) Remove the air intake chamber (Non-turbo model). 4) Remove the intercooler. (Turbo model) Page 6360 Compass: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 4016 B380-f6 Page 4693 B17-B20 Page 1618 F21-F61 Page 3038 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 6480 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Locations Brake Light Switch: Locations Electrical Component Location Page 7427 Wiper Relay: Service and Repair WIPER CONTROL RELAY REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the right quarter lower trim. 3. Loosen the nut to remove control unit. INSTALLATION Install in the reverse order of removal. Page 7012 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 6803 F21-F61 Service and Repair Rear Cross-Member: Service and Repair Rear Crossmember REMOVAL CAUTION: Do not subject the ABS wheel speed sensor harness to excessive tension. 1. Separate the front exhaust pipe and rear exhaust pipe. 2. Remove the rear exhaust pipe and muffler. 3. Remove the rear differential. 4. Place the transmission jack under rear crossmember. 5. Remove the bolts securing crossmember to vehicle body, and then remove the crossmember. 6. Scribe an alignment mark on the rear lateral link cam bolt and crossmember. 7. Remove the front and rear lateral links by loosening nuts. INSTALLATION NOTE: ^ Discard the loosened self-locking nut and replace it with a new one. ^ Always secure the bolt head and tighten the nut when tightening the adjusting bolt. 1. Install in the reverse order of removal. 2. For installation and tightening torque of rear differential. 3. Always tighten the rubber bushing when tires are in full contact with the ground and vehicle is curb weight. 4. Check the wheel alignment and adjust if necessary. INSPECTION Check the removed parts for wear, damage and cracks, and correct or replace if defective. Page 2028 B292-B317 Page 5024 B3-B12 Page 2817 B128-B134 Page 721 B134-B136 Page 6210 Tailgate Latch: Testing and Inspection Rear Gate Latch Assembly REAR GATE LATCH ASSEMBLY INSPECTION 1. Make sure the rod is not deformed. 2. Make sure the outer handle and cable move smoothly. Page 4817 Alternator: Service and Repair Disassembly and Assembly DISASSEMBLY 1. Remove the four through-bolts. 2. Heat portion (A) of rear cover to 50 °C (122 °F) with a heater drier. 3. Then insert the tip of a flat tip screwdriver into the gap between stator core and front cover. Pry them apart to disassemble. 4. Hold the rotor with a vise and remove pulley nut. Page 6449 B17-B20 Page 4646 2) Check specifications of the mark with ABSCM&H;/U. CHECKING THE HYDRAULIC UNIT ABS OPERATION BY PRESSURE GAUGE 1) Lift-up the vehicle and remove the wheels. 2) Disconnect the air bleeder screws from the FL and FR caliper bodies. 3) Connect two pressure gauges to the FL and FR caliper bodies. CAUTION: ^ Pressure gauges used exclusively for brake fluid must be used. ^ Do not employ pressure gauge previously used for transmission oil pressure since the piston seal is expanded which may lead to malfunction of the brake. NOTE: Wrap sealing tape around the pressure gauge. 4) Bleed air from the pressure gauges. 5) Perform the ABS sequence control. 6) When the hydraulic unit begins to work and first the FL side performs decompression, holding and compression, and then the FR side performs decompression, holding and compression. 7) Read values indicated on the pressure gauge and check if the fluctuation of the values between decompression and compression meets the standard values. Also check if any irregular brake pedal tightness is felt. 8) Remove the pressure gauges from FL and FR caliper bodies. 9) Remove the air bleeder screws from the RL and RR caliper bodies. 10) Connect the air bleeder screws to the FL and FR caliper bodies. 11) Connect two pressure gauges to the RL and RR caliper bodies. 12) Bleed air from the FL and FR caliper bodies. 13) Perform the ABS sequence control. 14) When the hydraulic unit begins to work, at first the RR side performs decompression, holding and compression, and then the RL side performs decompression, holding and compression. Page 2398 R58-R69 Page 991 3) Tighten a new self-locking nut. Tightening torque: 100 Nm (10.2 kgf-m, 74 ft. lbs.) THRUST ANGLE ^ Inspection 1) Position the vehicle on a level surface. 2) Move the vehicle 3 to 4 m (10 to 13 ft.) directly forward. 3) Determine the center lines of loci of both front and rear axles. 4) Measure the distance "L" between center lines of loci of the axles. Thrust angle: 0°±30'(tolerance) Less than 30' when "L" is less than 22 mm (0. 9 inch). ^ Adjustment 1) Make the thrust angle adjustments by turning toe-in adjusting bolts of rear suspension equally in the same direction. 2) When one rear wheel is adjusted in a toe-in direction, adjust the other rear wheel equally in toe-out direction, in order to make thrust angle adjustment. 3) When the right and left adjusting bolts are turned incrementally by one graduation in the same direction, the thrust angle will change approximately 16' ["L" is almost equal to 12 mm (0.472 inch)]. Page 173 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 576 B54-B127 Page 4688 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 3494 Page 6349 B54-B127 Page 2738 Page 1644 4. Remove the timing belt guides. (MT model) 5. If the alignment mark and/or arrow mark (which indicates rotation direction) on timing belt fade away, put new marks before removing the timing belt as follows: 1. Turn the crankshaft using ST, and align the alignment marks on crank sprocket, intake cam sprocket (LH), exhaust cam sprocket (LH), intake cam sprocket (RH) and exhaust cam sprocket (RH) with notches of timing belt cover and cylinder block. ST 499987500 CRANKSHAFT SOCKET 2. Using white paint, put alignment and/or arrow marks on the timing belts in relation to the sprockets. Page 4975 B230-B283 Locations Yaw Rate Sensor: Locations Electrical Component Location Page 7101 5. For adjustment of upper and lower ends of center pillar, loosen the adjusting nut (A) of B-channel (B). 6. Adjust so that the upper and lower ends of center pillar are the same size. 7. For glass stroke adjustment, set the ST on glass and close the door, raise glass until positional relationship between glass and weather strip becomes as shown. And secure the glass so that the upper stopper lightly touches the glass holder. ST 61299AE000 SPACER (For front door glass of thickness 5 mm (0.197 in)) Page 3741 Spark Plug: Adjustments ADJUSTMENT Clean the spark plugs with a wire brush. Clean and remove the carbon or oxide deposits, but do not wear away ceramic insulator. If deposits are too stubborn, replace the plugs. After cleaning the spark plugs, correct the spark plug gap using a gap gauge. NOTE: Do not use spark plug cleaners, because the spark plugs are applied with iridium tips. Page 516 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 2095 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 3120 Transmission Position Switch/Sensor: Service and Repair AT Shift Lock Solenoid and "P" Range Switch AT Shift Lock Solenoid and "P" Range Switch REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the console box. 3) Disconnect the connector. 4) Remove the grip. 5) Remove the indicator bulb from indicator cover. 6) Remove the indicator cover. 7) Remove the blind. 8) Remove the cushion. 9) Remove the clip, and then remove the "P" range switch. 10) Remove the cover. Page 6018 - Do not drop the airbag modulator parts, subject them to high temperature over 93 degrees C (199 degrees F), or let water, oil, or grease get on them; otherwise, the internal parts may be damaged and reliability greatly lowered. - If any damage, opening, or rust is found on the airbag system wire harness, do not attempt to repair using soldering equipment. Be sure to replace the faulty harness with a new genuine part. - Install the wire harness securely with the specified clips to avoid interference or tangled up with other parts. Page 7196 7. Perform the above steps from 1) to 6) at the MIN and MAX positions of intermittent control switch, and replace the wiper switch assembly if it does not operate as specified. Page 6356 F21-F61 Page 4156 Clutch Switch: Service and Repair Clutch Switch REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the instrument panel lower cover. 3) Disconnect the connector from clutch switch. 4) Remove the clutch switch. INSTALLATION CLUTCH SWITCH (CRUISE CONTROL) 1) Move the clevis pin of the push rod right and left and hold where it moves smoothly, then measure stroke of clutch pedal. 2) If the clutch pedal stroke is out of specification, adjust the stroke. 3) Connect clutch switch connector. CLUTCH SWITCH (STARTER INTER LOCK) 1) Fully depress the clutch pedal. 2) Install the clutch pedal plate and clutch switch so that the gap between them is 3 - 3.5 mm (0. 12 0.14 inch), and then tighten the lock nut. 3) Connect the clutch switch connector. 4) Confirm that the engine does not start when the clutch pedal is released. 5) Confirm that the engine starts when the clutch pedal is fully depressed. INSPECTION 1) If the clutch switch (cruise control) does not operate properly (or if it does not stop at the specified position), replace with a new one. Removal and Installation Starter Motor: Service and Repair Removal and Installation Starter REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the air cleaner case. (Non-turbo model) 3. Remove the intercooler. (Turbo model) 4. Remove the air cleaner case stay. (Non-turbo model) - MT Model - AT Model Page 3019 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Engine - Sodium Filled Valve Handling Precautions Valve: Technical Service Bulletins Engine - Sodium Filled Valve Handling Precautions SAFE HANDLING OF SODIUM FILLED VALVES Sodium filled exhaust valves were introduced in all 2004 model year 2.5L DOHC engines. Sodium has a high thermal conductivity and liquefies at high temperatures. Once liquefied it moves within the valve to promote faster cooling of the valve head by transferring heat to the valve stem. When working on Subaru engines with sodium filled valves, take a few moments to review the cautions listed in the Subaru service manual for safe handling. Sodium is a highly alkaline and very reactive substance that will react severely when exposed to moisture. Never attempt to disassemble these valves as injury may result. Valves that are damaged due to accidents or other sources of engine damage may expose the sodium they contain to the atmosphere. In these cases appropriate handling of these valves is require to prevent personal injury or property damage. The Subaru service manual outlines these precautions in depth. This information can be found quickly using STIS and searching for "sodium within the appropriate service manual. Disposal requirements for damaged valves are also discussed. Always comply with all applicable local, state, and federal laws and regulations when disposing of these parts. Page 2951 Knock Sensor: Service and Repair Knock Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the intercooler. 3. Disconnect the knock sensor connector. 4. Remove the knock sensor from the cylinder block. INSTALLATION 1. Install the knock sensor to the cylinder block. Tightening torque: 24 N.m (2.4 kgf-m, 17.4 ft-lb) NOTE: Extraction area of the knock sensor cord must be positioned at a 60 degrees angle relative to the engine rear. Page 1166 Fluid - A/T: Service and Repair A/T Fluid Replacement Automatic Transmission Fluid REPLACEMENT 1) Lift-up the vehicle. 2) Drain the ATF completely. 3) Check the ATF for condition. CAUTION: Directly after the vehicle has been running, the ATF is hot. Therefore, be careful not to burn yourself. 4) Replace with a new gasket, and then tighten the ATF drain plug. 5) Lower the vehicle. 6) Pour ATF through the oil charge pipe. Recommended fluid: Fluid capacity: Fill the same amount of ATF drained from drain plug hole. Capacity when transmission is overhauled: 9.3 - 9.6 liters (9.8 - 10.1 US quarts, 8.2 - 8.4 Imp quarts) 7) Check the level and leaks of ATF. Page 5555 Impact Sensor: Service and Repair Impact Sensor IMPACT SENSOR REMOVAL 1. Remove the key from ignition switch. 2. Close all the doors, trunk lid and rear gate. 3. Press the UNLOCK button of transmitter. 4. Change the setting of impact sensor using Subaru Select Monitor. 5. Disconnect the ground cable from battery. 6. Remove the impact sensor. INSTALLATION 1. Remove the key from ignition switch. 2. Close all the doors, trunk lid and rear gate. 3. Press the UNLOCK button of transmitter. 4. Disconnect the ground cable from battery. 5. Install the impact sensor. 6. Connect the battery ground cable to battery. 7. Change the setting of impact sensor using Subaru Select Monitor. Page 7178 Wiper Relay: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 5964 Underbody Cover: Description and Operation Fuel Tank Protector FUEL TANK PROTECTOR - A fuel tank protector is installed to prevent damage to the fuel tank by flying stones etc. during driving. - Taking recycling reasons into account, polypropylene (PP) material is used. Page 4611 7. Bleed air from the brake system. 2. 16 INCH TYPE 1. Install the caliper body on housing. Tightening torque: 80 Nm (8.2 kgf-m, 59 ft. lbs.) 2. Apply thin coat of Molykote AS-880N (Part No. K0777YA010) to the frictional portion between pad and pad inner shim. 3. Install the pads on caliper body. 4. Install the pad pin and cross spring on caliper body. 5. Install the M clip. 6. Replace the brake hose gaskets with new ones, and then connect the brake hose. Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft. lbs.) 7. Bleed air from the brake system. 3. 17 INCH TYPE 1. Install the caliper body assembly on housing. Tightening torque: 155 Nm (15.8 kgf-m, 114.3 ft. lbs.) 2. Apply thin coat of Molykote AS-880N (Part No. K0777YA010) to the frictional portion between pad and pad shim. 3. Install the pads on caliper body. 4. Install the cross spring. 5. Install the pad pins. 6. Install the clip. 7. Replace the brake hose gaskets with new ones, and then connect the brake hose. Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft. lbs.) 8. Bleed air from the brake system. DISASSEMBLY 1. 15 INCH TYPE 1. Clean mud and foreign particles from the caliper body assembly and support. CAUTION: Be careful not to allow foreign particles to enter the brake hose connector. 2. Place a wooden block in caliper body as shown in the figure to prevent the piston from jumping out and avoid being damaged. 3. Gradually supply compressed air via the installation hole of brake hose to force the piston out. Page 3342 Fuel Gauge Sender: Service and Repair Fuel Sub Level Sensor Fuel Sub Level Sensor REMOVAL WARNING: - Place "NO FIRE" signs near the working area. - Be careful not to spill the fuel. 1. Disconnect the ground cable from battery. 2. Lift up the vehicle. 3. Drain the fuel from the fuel tank. 4. Remove the rear seat. 5. Remove the service hole cover. 6. Disconnect the connector from the fuel sub level sensor. 7. Disconnect the fuel jet pump hose. Testing and Inspection Headlamp Alignment Actuator: Testing and Inspection HEADLIGHT BEAM LEVELER SYSTEM HEADLIGHT BEAM LEVELER ACTUATOR 1. Turn on the headlights. 2. Confirm the headlight beam level is lowered by changing the switch position to 0 - 1 - 2 - 3. 2. Page 4978 F21-F61 Locations Coolant Temperature Sensor/Switch (For Computer): Locations Sensor (Part 1) Page 4297 15) Remove the gear shift lever. INSTALLATION 5MT 1) Install the joint to the transmission and secure with the spring pin. 2) Insert gear shift lever from room side. NOTE: After inserting rod and stay, position them onto transmission mount. 3) Lift-up the vehicle. 4) Install the joint to shifter arm. 5) Insert the spring pin. 6) Mount the cushion rubber on body. Page 5347 Blower Motor Resistor: Testing and Inspection Blower Resistor (Manual A/C Model) INSPECTION Measure the blower resistor resistance. Terminal No. Standard 3 and 1 Approx. 0.51 ohms 3 and 2 Approx. 2.70 ohms 3 and 4 Approx. 1.43 ohms If NG, replace the blower resistor. Page 1576 B54-B127 Page 5613 - When checking, use a test harness (1). Do not directly apply the tester probe to any connector terminal of the airbag. Damage to the connector terminal may cause the airbag to activate erroneously. - Do not check continuity of either of the airbag modules for driver, passenger or side, or pretensioner. Page 4276 7) Install the propeller shaft. 8) Install the rear exhaust pipe and muffler. ^ Non-turbo model ^ Turbo model 9) Pour gear oil and check the oil level. Page 3143 B292-B317 Page 2914 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor REMOVAL WARNING: - Place "NO FIRE" signs near the working area. - Be careful not to spill fuel. 1. Remove the fuel tank. 2. Remove the protector cover. 3. Disconnect the connector from fuel tank pressure sensor. 4. Release the clips which hold fuel pipes onto fuel tank. 5. Remove the bolt and nut which hold the fuel tank pressure sensor onto the bracket. Page 6543 B134-B136 Page 855 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 2422 Disclaimer Page 666 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 6563 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 122 B128-B134 Page 3049 Transmission Position Switch/Sensor: Service and Repair AT Shift Lock Solenoid and "P" Range Switch AT Shift Lock Solenoid and "P" Range Switch REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the console box. 3) Disconnect the connector. 4) Remove the grip. 5) Remove the indicator bulb from indicator cover. 6) Remove the indicator cover. 7) Remove the blind. 8) Remove the cushion. 9) Remove the clip, and then remove the "P" range switch. 10) Remove the cover. Diagrams Heater Core Case: Diagrams Auto A/C Model Page 2024 B128-B134 Page 1408 Belt tension (without belt tension gauge) (A) When installing new parts: 7 - 9 mm (0.276 - 0.354 inch) At inspection: 9 - 11 mm (0.354 - 0.433 inch) (B) When installing new parts: 7.5 - 8.5 mm (0.295 - 0.335 inch) At inspection: 9.0 - 10.0 mm (0.354 - 0.394 inch) Page 2808 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 2970 Page 6837 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 581 B292-B317 Page 192 Ignition Control Module: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Engine Controls - DTC P0340/P0345 After Camshaft R & R Camshaft Position Sensor: All Technical Service Bulletins Engine Controls - DTC P0340/P0345 After Camshaft R & R Number: 02-107-09 Date: 03/24/09 Applicability: 2004~06MY Baja 2.5L Turbo 2004~06MY Impreza 2.5L Turbo 2004~06MY Forester 2.5L Turbo 2004~06MY Legacy/Outback 2.5L Turbo SUBJECT: Intake Camshaft Replacement Introduction If you encounter a vehicle that has a CEL and P0340 or P0345 stored in memory immediately after replacing the intake camshaft(s), the air gap between the camshaft and camshaft position sensor may be out of specification. A modification was made to the plate area of the camshaft where the camshaft position sensor picks up the signal. Parts Information Repair Procedure/ Information Using a feeler (thickness) gauge, measure the gap between the camshaft and camshaft position sensor. The correct gap is between 0.15mm to 0.98mm (0.0059 to 0.0386 in.) If the gap is over 0.98mm (0.0386 in.) replace the camshaft position sensor. Refer to the applicable service manual. Warranty/Claim Information For vehicles within warranty, refer the Subaru Warranty Wizard for claim submission information. Page 239 B128-B134 Page 3328 3. Align the holes in fuel filler pipe neck and set the cup (B), and tighten the screws. NOTE: If the edges of rubber packing are folded toward the inside, straighten it with a screwdriver. 4. Install the evaporation pipe. 5. Connect the evaporation hoses to fuel pipes. 6. Insert the fuel filler hose (A) approximately 35 to 40 mm (1.38 to 1.57 in) over the lower end of fuel filler pipe and tighten the clamp. Page 763 Camshaft Position Sensor: Locations Sensor (Part 1) Page 4164 6) Install the transmission assembly. INSPECTION RELEASE BEARING CAUTION: Since this bearing is grease sealed and is of a non-lubrication type, do not wash with gasoline or any solvent when servicing the clutch. 1) Check the bearing for smooth movement by applying force in the radial direction. 2) Check the bearing for smooth rotation by applying pressure in the thrust direction. 3) Check wear and damage of the bearing case surface contacting with lever. RELEASE LEVER Check the lever pivot portion and the point of contact with release bearing case for wear. Page 4614 2. Remove the piston boots from each piston end. 3. Place a wooden block in caliper body as shown in the figure to prevent the piston from jumping out and avoid being damaged. 4. Gradually supply compressed air via the installation hole of brake hose to force the piston out. 5. Remove the piston seal from caliper body cylinder. CAUTION: Do not damage the cylinder and piston seal groove. ASSEMBLY 1. 15 INCH TYPE 1. Clean the caliper body interior using brake fluid. 2. Apply a coat of brake fluid to the piston seal and fit piston seal in groove on caliper body. 3. Apply a coat of brake fluid to the entire inner surface of cylinder and outer surface of piston. 4. Apply a coat of specified grease to the boot and install the piston boot to the groove on ends of cylinder. Grease: NIGLUBE RX-2 (Part No. K0779GA 102) 5. Insert the piston into cylinder. CAUTION: Do not force the piston into cylinder. Page 2319 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Locations Intake Air Temperature Sensor: Locations Sensor (Part 1) Page 517 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Locations Knock Sensor: Locations Sensor (Part 1) Page 4106 Page 6832 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Fuel Level Sensor Fuel Level Sensor: Service and Repair Fuel Level Sensor Fuel Level Sensor REMOVAL WARNING: - Place "NO FIRE" signs near the working area. - Be careful not to spill the fuel. NOTE: Fuel level sensor is built in fuel pump assembly. 1. Remove the fuel pump assembly. 2. Disconnect the connector from the fuel pump bracket. 3. Remove the fuel temperature sensor. 4. Remove the bolt which installs the fuel level sensor on mounting bracket. INSTALLATION Install in the reverse order of removal. Page 5187 21) By fixing the 2-surface width, press in by rotating the rod and attach to oil seal. 22) While fixing the 2-surface width, pull out the oil seal by rotating nut. CAUTION: Take care not to scratch the gear box inner surface. Diagram Information and Instructions Grounding Point: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Locations Air Bag Control Module: Locations Electrical Component Location Page 6525 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Locations Brake Switch (Cruise Control): Locations Non-Turbo Model Page 3024 B3-B12 Page 236 B3-B12 Page 6709 F61-R47 Page 5994 INSTALLATION 1. Replace the four clips with new ones. 2. Engage the four clips of hood grille to front hood panel. CAUTION: Make sure that the anchor portion of each clip is firmly engaged. 3. Install the six nuts. Tightening torque: 4.5 N.m (0.46 kgf-m, 3.32 ft-lb) 4. Catch the two hooks (A) of hood duct to hood holes. Page 1933 Thermostat: Service and Repair Thermostat Removal 1. Set the vehicle on a lift. 2. Lift-up the vehicle. 3. Remove the under cover. 4. Drain the engine coolant completely. 5. Disconnect the radiator outlet hose. 6. Remove the thermostat cover, and then remove the gasket and thermostat. Installation 1. Install the gasket to thermostat, and install the thermostat and gasket to water pump as a unit. NOTE: Front Suspension Control Arm: Service and Repair Front Suspension Front Transverse Link REMOVAL 1) Set the vehicle on a lift. 2) Lift-up the vehicle and remove the wheel. 3) Remove the sub frame. 4) Disconnect the stabilizer link from transverse link. 5) Remove the bolt securing ball joint of transverse link to housing. ^ Sedan turbo model and STI model Sedan turbo model and STI model ^ Except Sedan turbo model and STI model Except Sedan turbo model and STI model 6) Remove the nut (do not remove bolt) securing transverse link to crossmember. 7) Remove the two bolts securing bushing bracket of transverse link to the vehicle body at rear bushing location. 8) Extract the ball joint from housing. 9) Remove the bolt securing transverse link to crossmember, and then extract the transverse link from crossmember. Locations Main Relay (Computer/Fuel System): Locations Main Fuse Box (M/B) Solenoid Valve, Actuator, Emission Control System Parts And Ignition System Parts (Part 5) Page 7182 Wiper Relay: Service and Repair WIPER CONTROL RELAY REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the right quarter lower trim. 3. Loosen the nut to remove control unit. INSTALLATION Install in the reverse order of removal. Page 5288 Wheels: Testing and Inspection Wheel Balancing REPLACEMENT 1. Remove the balance weights. 2. Using wheel balancer, measure the wheel balance. 3. Select a weight close to the value measured by wheel balancer. 4. Install the selected weight to the point designated by wheel balancer. 5. Using wheel balancer, measure the wheel balance again. Check the wheel balance is correctly adjusted. INSPECTION 1. Proper wheel balance may be lost if the tire is repaired or if it wears. Check the tire for dynamic balance, and repair as necessary. 2. To check for dynamic balance, use a wheel balancer. Drive in the balance weight on both the top and rear sides of rim. 3. Some types of balancer can cause damage to the wheel. Use an appropriate balancer when adjusting the wheel balance. 4. Use genuine balance weights. NOTE: ^ 55 g (1.94 oz) weight used with the aluminum wheel is not available. ^ Balance weights are available for use with any of 16 to 1 7-inch wheels. Page 6476 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 7396 Wiper Motor Linkage: Service and Repair FRONT WIPER MOTOR AND LINK REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the cowl panel. 3. Disconnect the connector of motor. 4. Remove the bolts to remove wiper link. 5. Remove the bolts and nuts to remove motor. INSTALLATION 1. Connect the battery ground cable to battery. 2. To confirm that the motor is at auto stop position, connect the harness to motor and turn the wiper switch ON/OFF once. 3. Disconnect the ground cable from battery. 4. Tighten the nut where rod (A) and link plate (B) is aligned in a straight line. 5. Install in the reverse order of removal. Tightening torque: Nm (kgf-m, ft-lb) T1: 6.0 (0.61, 4.4) T2: 20 (2.0, 14.5) Locations Coolant Temperature Sensor/Switch (For Computer): Locations Sensor (Part 1) Page 1538 13. Disconnect the engine coolant hoses from the throttle body. 14. Disconnect the brake booster vacuum hose. 15. Disconnect the pressure hose from the intake duct. 16. Disconnect the engine harness connectors from the bulkhead harness connectors. Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 910 21) Remove the oil pan. 22) Disconnect the harness connector and transmission ground terminal. 23) Remove the harness assembly. INSTALLATION 1) Pass the harness assembly through the hole in the transmission case. 2) Connect the harness connector and transmission ground. Page 6374 - When painting or performing sheet metal work on the side of the vehicle, including the side sill, center pillar, and front and rear doors, remove the side airbag sensors and wire harness of the airbag system. - When storing a removed airbag module, do not place any objects on it or pile airbag modules on top of each other. If the airbag inflates for some reason when it is placed with its pad side facing downward or under any object, a serious accident may result. Page 1773 2. Fill engine coolant. Page 439 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Locations Intake Air Temperature Sensor: Locations Sensor (Part 1) Page 6418 Fuel Gauge Sender: Service and Repair Fuel Sub Level Sensor Fuel Sub Level Sensor REMOVAL WARNING: - Place "NO FIRE" signs near the working area. - Be careful not to spill the fuel. 1. Disconnect the ground cable from battery. 2. Lift up the vehicle. 3. Drain the fuel from the fuel tank. 4. Remove the rear seat. 5. Remove the service hole cover. 6. Disconnect the connector from the fuel sub level sensor. 7. Disconnect the fuel jet pump hose. Diagnostic Aids Fuse: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Specifications Fuel Pressure: Specifications Fuel pressure: (disconnecting the pressure regulator) Standard ......................................................................................................................................................... 284 - 314 kPa (2.9 - 3.2 kgf/cm2, 41 - 46 psi) Fuel pressure: (connecting the pressure regulator) Standard ..................................................................................................................................................... 230 - 260 kPa (2.35 - 2.65 kgf/cm2, 33 - 38 psi) Page 3935 Fluid - A/T: Service and Repair Differential Fluid Level Check Differential Gear Oil 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 check the level. If the differential gear oil level is below the "L" line, add oil to bring the level up to the "F" line. 5) To prevent overfilling the differential gear oil, do not replenish oil above the "F" line. Page 6548 F21-F61 Page 5650 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 5788 If the speakers still chatter and/or vibrate, perform the following countermeasure(s): [A] Standard speaker, perform Countermeasure 1 & 2. [B] High-grade speaker, perform Countermeasure 1. ^ Sealing covers with urethane are used with high-grade speakers; therefore countermeasure 2 does not need to be performed. How to distinguish between Standard speaker and High-grade speaker Vehicles equipped with standard speakers use a sealing cover without urethane. Vehicles equipped with high-grade speakers use a sealing cover with urethane. Countermeasure 1 1) Remove the door trim speaker and sealing cover (see figure 1, below). Page 3080 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 650 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Locations Air Flow Meter/Sensor: Locations Sensor (Part 1) Page 5015 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 1624 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 2755 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 1209 Refrigerant: Fluid Type Specifications Fluid Type ............................................................................................................................................ ......................................... HFC-134a (CH(2)FCF(3)) Page 2483 Air Filter Element: Service and Repair Air Cleaner Element REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the connector from mass air flow and intake air temperature sensor. 3. Loosen the clamp (A) which connects the air intake boot and intake duct. 4. Remove the clip (B) from air cleaner upper cover. 5. Remove the air cleaner upper cover. 6. Remove the air cleaner element. INSTALLATION Install in the reverse order of removal. NOTE: Before installing the air cleaner upper cover, align the holes with protruding portions of air cleaner lower case, then secure the upper cover to the lower case. Locations Knock Sensor: Locations Sensor (Part 1) Page 6631 F21-F61 Page 3582 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 7140 (1) Open the rear gate and remove the foam trim board on the left hand side from the cargo floor. (2) Remove the check valve. Note: Place rags or paper towels in the area. There is a chance that a small amount of washer fluid may leak out. (3) Attach valve cushion (86634SA000) around the modified check valve (86634AA010) for soundproofing. (4) Install the modified check valve and valve cushion. Page 1023 Spark Plug: Application and ID Type ..................................................................................................................................................... ............................................................. Manufacturer ILFR6B ................................................................................................................................................ .......................................................................... NGK Gap ...................................................................................................................................................... ................................. 0.7 - 0.8 mm (0.028 - 0.031 in) Torque ................................................................................................................................................. ........................................................ 21 N.m (15 ft.lb) Page 2243 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 6130 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 2750 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 1506 B230-B283 Page 7121 Rear Door Window Regulator: Service and Repair REAR REGULATOR AND MOTOR ASSEMBLY REMOVAL 1. Remove the rear door glass. 2. Remove the front sash. 3. Disconnect the motor connector. 4. Remove the four bolts and two nuts to remove regulator assembly. 5. Remove the screws to remove motor assembly. INSTALLATION 1. Install in the reverse order of removal. 2. Adjust the rear door glass. Tightening torque: Nm (kgf-m, ft-lb) T1: 7.4 (0.75, 5.5) T2: 13.7 (1.4, 10.1) Testing and Inspection Air Filter Element: Testing and Inspection INSPECTION Inspect for cracks and loose connections. Page 4617 Page 6184 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 686 B128-B134 Testing and Inspection Door Switch: Testing and Inspection DOOR SWITCH Measure the resistance between door switch terminals. Page 419 Horn Switch: Service and Repair HORN SWITCH REMOVAL WARNING: Before servicing, be sure to read the notes in AB section for proper handling of driver's airbag module. NOTE: Horn switch forms a unit with the driver s airbag module. 1. Disconnect the ground cable from battery. 2. Remove the driver's airbag module. INSTALLATION Install in the reverse order of removal. Page 4337 8) Install the front vehicle speed sensor and torque converter turbine speed sensor, and then fasten the harness. 9) Install the inlet pipe. NOTE: Be sure to use a new copper washer. 10) Install the transmission rear crossmember bolts. Tightening torque: 70 Nm (7.1 kgf-m, 51 ft. lbs.) 11) Install the propeller shaft. 12) Install the front, center, rear exhaust pipes and muffler. (Non-turbo model) 13) Install the center, rear exhaust pipes and muffler. (Turbo model) 14) Lower the vehicle. 15) Install the transmission connector to the stay. 16) Install the pitching stopper. 17) Install the air intake chamber. (Non-turbo model) 18) Install the intercooler. (Turbo model) Page 4141 5) Remove the stoppers from clutch pedal. 6) Remove the clutch pedal pad. (Non-turbo model) ASSEMBLY 1) Attach the stopper, etc. to pedal bracket temporarily. 2) Clean inside of bores of clutch pedal and brake pedal, apply grease, and set bushings into bores. Grease: SUNLIGHT 2 (Part No. 003602010) or equivalent 3) Align bores of pedal bracket, clutch pedal and brake pedal, attach the brake pedal return spring, assist rods, spring, and bushing. NOTE: Clean up inside of bushings and apply grease before installing the spacer. INSPECTION Move the clutch pedal pads in the lateral direction with a force of approximately 10 N (1 kgf, 2 lbs.) to ensure pedal play is in specified range. CAUTION: If excessive movement is noted, replace the bushings with new ones. ADJUSTMENT 1) Turn the lock nuts until clutch pedal full stroke length is within specifications. CAUTION: Do not attempt to turn the clutch switch to adjust clutch pedal full stroke length. NOTE: If lock nuts cannot adjust the clutch pedal full stroke length to specifications, turn the master cylinder push rod to adjust it. Page 3138 B54-B127 Page 794 B54-B127 Page 5079 B230-B283 Page 1928 Temperature Gauge: Electrical Diagrams Temperature Gauge C/TEMP-01 Diagrams: Other diagrams referred to by name within these diagrams (i.e. "REF. TO GND-01", etc) can be found at Diagrams by Diagram Name. See: Diagrams/Electrical Diagrams/Diagrams By Diagram Name Connector and Ground Locations: The locations of the Connectors or Grounds shown within these diagrams can be found via the connector or ground number at Vehicle Locations. See: Locations Additional/Related Diagrams For information regarding diagrams for this component, please refer to Instrument Panel, Gauges and Warning Indicators diagrams. See: Instrument Panel, Gauges and Warning Indicators/Diagrams/Electrical Diagrams Page 6125 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 3118 4) Using the ST, tighten the bolts of inhibitor switch. ST 499267300 STOPPER PIN 5) Install the select cable to range select lever. 6) Install the plate assembly to transmission. 7) Install the washer and snap pin to range select lever. 8) Install the front and center exhaust pipes. (Non-turbo model) 9) Install the center exhaust pipe. (Turbo model) 10) Lower the vehicle. 11) Install the inhibitor switch connector from stay. 12) Connect the inhibitor switch connector. Page 3366 Fuel Pump Relay: Service and Repair Fuel Pump Relay REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the passenger's side front side sill cover. 3. Remove the bolt which holds the relay bracket on the body. 4. Disconnect the connectors from the main relay. 5. Remove the main relay from the mounting bracket. INSTALLATION Install in the reverse order of removal. Page 4378 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Locations Clutch Switch: Locations Non-Turbo Model Page 6415 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 2700 B136-B141 Page 4375 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 2237 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 2127 R72-R145 R148 Page 7032 B3-B12 Service and Repair Fuel Pressure Release: Service and Repair Fuel PROCEDURE RELEASING OF FUEL PRESSURE WARNING: - Place "NO FIRE" signs near the working area. - Be careful not to spill the fuel. 1. Disconnect the connector from the fuel pump relay. 2. Start and run the engine until it stalls. 3. After the engine stalls, crank it for five more seconds. 4. Turn the ignition switch to OFF. Locations Page 2205 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 611 B17-B20 Page 6554 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 7051 4. Disconnect the connector. INSTALLATION 1. MAIN SWITCH Install in the reverse order of removal. 2. SUB SWITCH Install in the reverse order of removal. Page 6692 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 6906 Combination Switch: Service and Repair Combination Base Switch Assembly COMBINATION BASE SWITCH ASSEMBLY REMOVAL 1. Remove the driver s airbag module. 2. Remove the steering wheel. 3. Remove the steering column cover. 4. Remove the combination switch. 5. Loosen the four screws and remove the roll connector. 6. Loosen the three screws. 7. Disconnect the connector and remove the combination base switch assembly. INSTALLATION 1. Install in the reverse order of removal. 2. Align the attaching direction of roll connector with the steering wheel, before installation of steering wheel. Page 7007 F21-F61 Page 2384 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Description and Operation Rear Door Panel: Description and Operation Door Trim Shock absorbing pads installed to the backside of the front and rear door trims attenuate the impact due to a secondary collision. Page 2301 5) Disconnect the inhibitor switch connector. 6) Remove the inhibitor switch connector from stay. 7) Lift-up the vehicle. 8) Remove the front and center exhaust pipes. 9) Remove the snap pin and washer from range select lever. 10) Remove the plate assembly from transmission case. 11) Remove the bolts. Page 1509 F21-F61 Page 1219 Refrigerant Oil: Service and Repair Compressor Oil PROCEDURE NOTE: Before making repairs, conduct the oil return operation to return the compressor oil in circulation with the refrigerant to compressor. 1. Increase engine to 1,500 rpm. 2. Turn the A/C switch to ON. 3. Turn the temperature control switch to MAX COOL. 4. Put in RECIRC position. 5. Turn the blower control switch to HI. 6. Leave in this condition for 10 minutes. REPLACEMENT NOTE: - If a component is replaced, add an appropriate amount of compressor oil. - When replacing the compressor, the new compressor will already have the specified amount of oil in it. Install the new compressor after removing the same amount of oil that is remaining in the compressor removed. Replacement parts Amount of oil replenishment Evaporator 114 ml (3.9 US fl oz, 4.0 Imp fl oz) Condenser 7 ml (0.24 US fl oz, 0.25 Imp fl oz) Hose 1 ml (0.03 US fl oz, 0.04 Imp fl oz) Page 3537 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the connector from the camshaft position sensor RH. 3. Remove the camshaft position sensor RH from the rear side of cylinder head. 4. Remove the camshaft position sensor LH in the same procedure as RH side. INSTALLATION Install in the reverse order of removal. Tightening torque: Camshaft position sensor support: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) Camshaft position sensor: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) Page 3250 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 940 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 121 B54-B127 Page 2689 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 4034 5) Move the transmission to right side, and then install the stay. 6) Install the reverse check cable end, washer and snap pin to reverse check lever. NOTE: Take care to install the snap pin in proper direction. 7) Fix the reverse check cable to clip of stay. NOTE: Install the reverse check cable to upper side of stay. Page 3858 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 662 R58-R69 Service and Repair Windshield: Service and Repair WINDSHIELD GLASS REMOVAL 1. USING WINDSHIELD KNIFE 1. Disconnect the wiper deicer connector. (Model with wiper deicer) 2. Remove the cowl panel. 3. Remove the glass molding. 4. Tape the body side of the circumference of windshield glass for protection. 5. Apply sufficient amount of soapy water to the adhesive layer. 6. Insert the windshield knife into the adhesive layer. 7. While holding the knife edge and windshield glass edge at a right angle, move the windshield knife in parallel to the windshield glass edge along face and edge of windshield glass to cut the adhesive layer. NOTE: Do not twist the windshield knife. - Cutting of adhesive layer shall be started with wider gap between windshield glass and body. - Because the locating pins are bonded to corners of glass, use piano wire to cut the pin. 2. USING PIANO WIRE Page 3809 VTD model INSTALLATION Install in the reverse order of removal. NOTE: Replace with a new O-ring. Tightening torque: 7 Nm (0. 7 kgf-m, 5. 1 ft. lbs.) Page 3148 R72-R145 R148 Page 6441 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 2282 B54-B127 Page 6621 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 6231 Non-Turbo Model Page 203 Air Bag Control Module: Service and Repair AIRBAG CONTROL MODULE REMOVAL CAUTION: - Do not disassemble the airbag control module. - If the airbag control module is deformed or if water damage is suspected, replace the airbag control module with a new one. - Do not drop the airbag control module. - After removal, keep the airbag control module on a dry, clean surface away from moisture, heat, and dust. 1. Turn the ignition switch to OFF. 2. Disconnect the ground cable from battery, and wait for at least 20 seconds before starting work. 3. Remove the console cover. 4. Remove the center console panel. 5. Disconnect the connector from airbag control module. 6. Remove the four bolts and remove airbag control module. INSTALLATION CAUTION: Use new bolts (for airbag control module only) during installation. Install in the reverse order of removal. Tightening torque: Refer to "COMPONENT" in "General Description". See: Restraint Systems/Air Bag Systems/Locations Service and Repair Power Steering Fluid Reservoir: Service and Repair Reservoir Tank REMOVAL 1) Remove the air intake duct. 2) Drain fluid from the reservoir tank. 3) Disconnect the pipe D from return hose and suction hose from oil pump. CAUTION: ^ Do not allow fluid from the hose end to come into contact with pulley belt. ^ To prevent foreign matter from entering the hose and pipe, cover the open ends of them with a clean cloth. 4) Remove the reservoir tank from bracket by pulling it upwards. INSTALLATION 1) Install the reservoir tank to bracket. 2) Connect the pipes D to return hose and suction hose to oil pump. 3) Feed the power steering fluid to the specified level. INSPECTION Check the reservoir tank for cracks, breakage, or damage. If any cracks, breakage, or damage is found, replace the reservoir tank. Audio System - Noise With Rear Defogger ON Heated Glass Element: All Technical Service Bulletins Audio System - Noise With Rear Defogger ON NUMBER: 15-126-07 DATE: 02/13/08 APPLICABILITY: All Models SUBJECT: Radio Static When Rear Window Defogger Is On INTRODUCTION If you encounter a customer complaint of radio static when the radio and rear window defogger are on at the same time, there is the possibility of a break in one or more of the defogger grids. When the grid is broken, a high resistance field is created at the break point which can create static on some radio stations. The level of resistance is usually high enough to create a field of interference which projects out from the glass. The break can be detected visually or by using a portable radio. PART INFORMATION Permatex(R) Quick Grid(TM) Rear Window Defogger Repair Kit, part If 15067, used for repairing damaged rear window defogger grids, is available at local automotive parts stores REPAIR PROCEDURE/INFORMATION Note: There are certain factors that could lead to unsuccessful testing. Examples are: overhead fluorescent lights, telegraph poles, high tension lines, weather conditions, etc. Testing should be performed outdoors on a clear day. Also, there is the possibility that the static may not be duplicated due to the location of the vehicle. If that is the case, you may want to move the vehicle to a different location when testing. We highly discourage the use of accessory window tinting. If the vehicle is equipped with it, do not continue with the procedure. ^ Using a portable radio, set the radio to the same frequency and station being disturbed by static. From the outside of the vehicle, slowly move the radio's antenna across the defogger grids. When interference is encountered, inspect that specific area closely for a break. Depending upon the size of the break, a magnifying glass and/or eyeloupe may be required. ^ Once the break is identified, it should be repaired using the Permatex(R) repair kit instead of replacing the rear glass. Note: Make sure to carefully read and follow the instructions and precautions that are included with the Permatex(R) repair kit. ^ The repaired area must be completely opaque and have a resistance reading of essentially zero (0) ohms across the repair. ^ There may be more than one break. If the first break repair does not eliminate the static, re-inspect and repair any other breaks as necessary. WARRANTY/CLAIM INFORMATION Note: For vehicles within the Basic New Car Limited Warranty period the warranty covers repairs needed to correct defects in material or workmanship. Damage to the rear window defogger/antenna grid which is the result of an outside influence is not covered under warranty Examples are: improper cleaning of the glass, window tinting, scratches and/or cuts from objects coming in contact with the grids, etc For vehicles within the Basic New Car Limited Warranty period, this repair can be claimed using the table above. Locations Fuel Tank Pressure Sensor: Locations Page 3611 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Testing and Inspection Wiper Motor Linkage: Testing and Inspection FRONT WIPER MOTOR AND LINK INSPECTION 1. When the battery is connected to the terminal of connectors, confirm that the motor operates at low speed. 2. When the battery is connected to the terminal of connectors, confirm that the motor operates at high speed. 3. Connect the battery to terminals of connector, and then remove the terminal connection with motor rotated at low speed, and stop the wiper motor through operation. 4. Connect the battery and confirm that the motor stops at automatic stop position after the motor operates at low speed again. Page 4967 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 2334 Vehicle Speed Sensor: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 2394 B292-B317 Page 2264 Oxygen Sensor: Service and Repair Rear Oxygen Sensor Rear Oxygen Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Lift-up the vehicle. 3. Disconnect the connector from the rear oxygen sensor. 4. Remove the clip by pulling out from the upper side of crossmember. 5. Apply spray type lubricant to the threaded portion of rear oxygen sensor, and leave it for one minute or more. 6. Remove the rear oxygen sensor. CAUTION: When removing the rear oxygen sensor, wait until exhaust pipe cools, otherwise it will damage exhaust pipe. INSTALLATION 1. Before installing rear oxygen sensor, apply antiseize compound only to the threaded portion of rear oxygen sensor to make the next removal easier. CAUTION: Never apply anti-seize compound to protector of rear oxygen sensor. Anti-seize compound: NEVER-SEEZ NS-165 or equivalent Page 3595 B380-f6 Page 1321 18. Similarly, remove the camshafts (RH) and related parts. Installation 1. Camshaft installation Apply engine oil to the cylinder head at camshaft bearing installing location before installing the camshaft. Install the camshaft so that each valve is close to or in contact with "base circle" of cam lobe. NOTE: ^ When the camshafts are positioned as shown in the figure, camshaft (LH) needs to be rotated at a minimum to align with the timing belt during installation. ^ Camshaft (RH) need not be rotated when set at the position shown in the figure. Intake camshaft (LH): Rotate 80° clockwise. Exhaust camshaft (LH): Rotate 45° counterclockwise. 2. Camshaft cap and oil flow control solenoid valve assembly installation a. Apply small amount of liquid gasket to the cap mating surface. NOTE: Do not apply liquid gasket excessively. Otherwise, the excessive liquid gasket may come out and flow toward oil seal, resulting in oil leaks. Liquid gasket. THREE BOND 1215 (Part No. 004403007) or equivalent b. Apply engine oil to the cap bearing surface, and install the cap on camshaft as shown by identification mark. c. Gradually tighten the camshaft cap and oil control valve assembly in at least two stages in alphabetical sequence shown in the figure, and then Page 4227 6) Take out the DOJ outer race from shaft assembly. 7) Wipe off the grease, and then take out the balls. NOTE: ^ The grease is a special grease (grease for constant velocity joint). Do not confuse with other greases. ^ Disassemble with exercising care not to lose balls (6 pcs). 8) To remove the cage from inner race, turn the cage by a half pitch to the track groove of inner race, and shift the cage. 9) Remove the snap ring, which fixes the inner race to shaft, by using pliers. 10) Take out the DOJ inner race. 11) Take off the DOJ cage from shaft and remove the DOJ boot. 12) Wrap the shaft splines with vinyl tape. 13) Remove the EBJ boot in the same procedure as DOJ boot. NOTE: Further disassembly of axle is impossible because the EBJ cannot be disassembled. Rear Drive Shaft Assembly ASSEMBLY NOTE: Use specified grease. EBJ side: NTG2218-M (Part No. 28395AGO10) DOJ side: Except STI model NKG205 (Part No. 28495AGOOO) EDJ side: STI model NKG205 (Part No. 28495AG010) 1) Install the EBJ boot in specified position, and fill it with 60 to 70 g (2.12 to 2.47 ounces) of specified grease. 2) Place the DOJ boot at the center of shaft. 3) Wrap the shaft splines with vinyl tape. 4) Insert the DOJ cage onto shaft. NOTE: Insert the cage with cut-out portion facing the shaft end, since the cage has an orientation. Page 2974 Page 2701 B230-B283 Page 1581 B292-B317 Page 1155 Differential Fluid - A/T: Service and Repair Differential Fluid Replacement Differential Gear Oil REPLACEMENT 1) Lift-up the vehicle. 2) Remove the differential gear oil drain plug using TORX T70, and then drain the differential gear oil completely. CAUTION: ^ Directly after the vehicle has been running, the differential gear oil is hot. Therefore, be careful not to burn yourself. ^ Be careful not to spill the differential gear oil on exhaust pipe to prevent it from emitting smoke or fire. When the differential gear oil is spilled on exhaust pipe, wipe it away completely. 3) Replace the gasket with a new one, and then tighten the differential gear oil drain plug using TORX T70. Tightening torque: 44 Nm (4.5 kgf-m, 32.5 ft. lbs.) (Aluminum gasket) 70 Nm (7.1 kgf-m, 51.6 ft. lbs.) (Copper gasket) 4) Lower the vehicle. 5) Pour gear oil into the gauge hole. Recommended fluid. Gear oil capacity: 1.1 - 1.3 liters (1.2 - 1.4 US quarts, 1.0 - 1.1 Imp quarts) 6) Check the level of differential gear oil. Page 3008 Oxygen Sensor: Service and Repair Rear Oxygen Sensor Rear Oxygen Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Lift-up the vehicle. 3. Disconnect the connector from the rear oxygen sensor. 4. Remove the clip by pulling out from the upper side of crossmember. 5. Apply spray type lubricant to the threaded portion of rear oxygen sensor, and leave it for one minute or more. 6. Remove the rear oxygen sensor. CAUTION: When removing the rear oxygen sensor, wait until exhaust pipe cools, otherwise it will damage exhaust pipe. INSTALLATION 1. Before installing rear oxygen sensor, apply antiseize compound only to the threaded portion of rear oxygen sensor to make the next removal easier. CAUTION: Never apply anti-seize compound to protector of rear oxygen sensor. Anti-seize compound: NEVER-SEEZ NS-165 or equivalent Page 4480 CAUTION: Brake fluid replacement sequence; (A) Front right -> (B) Rear left -> (C) Front left -> (D) Rear right 3. Slowly depress the brake pedal and keep it depressed. Then, open the air bleeder screw to discharge air together with the fluid. Release the air bleeder screw for 1 to 2 seconds. Next, with the air bleeder screw closed, slowly release the brake pedal. Repeat these steps until there are no more air bubbles in the vinyl tube. Allow 3 to 4 seconds between two brake pedal operations. CAUTION: Cover the air bleeder screw with waste cloth, when loosening it, to prevent brake fluid from being splashed over surrounding parts. NOTE: The brake pedal operating must be very slow. 4. Tighten the air bleeder screw securely when no air bubbles are visible. Tightening torque: Except 17 inch type: 8 Nm (0.8 kgf-m, 5.8 ft. lbs.) 17 inch type: 20 Nm (2.0 kgf-m, 14.5 ft. lbs.) NOTE: For 17 inch type, do not allow brake fluid come in contact with caliper body; wash away with water. (Especially for air bleeder screw.) 5. Perform these steps for the brakes connecting to secondary chamber of master cylinder, first, and then for the ones connecting to primary chamber. With all procedures completed, fully depress the brake pedal and keep it in that position for approximately 20 seconds to make sure that there is no leak evident in the entire system. 6. Check the pedal stroke. While the engine is idling, depress the brake pedal with a 490 Nm (50 kgf, 110 ft. lbs.) load and measure the distance between 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 not be more than specified. Page 648 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 5313 Air Door Actuator / Motor: Testing and Inspection Air Mix Door Actuator AIR MIX DOOR ACTUATOR TROUBLE SYMPTOM: Outlet air temperature is not changed. Wiring Diagram Page 5926 Hood Latch: Service and Repair FRONT HOOD LOCK ASSEMBLY REMOVAL 1. Open the front hood. 2. Remove the bolts. Remove the hood lock assembly. 3. Remove the release cable from front hood lock assembly. INSTALLATION Install in the reverse order of removal. NOTE: - Apply grease to parts that rub. - Make sure the release cable works properly after installation. Page 3628 B380-f6 Page 4898 Step 1 - 7 Page 6181 R72-R145 R148 Page 5531 to the right. The proper wire location (not pinched) is indicated by broken lines in the photo to the right, below. ^ If the wire was found to be pinched, proceed to the "Wiring Repair Procedure" section, below. 3. If the wire was found to be located properly (not pinched), no repair is necessary. Reinstall the floor carpet. Wrap the previously cut portion of carpet with 1.5 inch wide unwoven adhesive tape. 4. Reinstall the center console trim. Note: Be careful that the seat heater switch is not pinched by the parking brake lever during reinstallation. 5. Confirm that switches, including the seat heater switch, work properly. Wiring Repair Procedure: Forester & Impreza 1. Disconnect the negative battery cable. Note: In the interest of customer satisfaction, please write down all radio preset stations prior to disconnecting the battery. The stations should be reset into the radio afier completion of the repair. 2. For Impreza models, proceed to step 4. Forester Models only: Remove the center console trim between the select lever and parking brake lever. 3. Forester only: Cut a cross section of floor carpet at the center in front of the parking brake lever with scissors as shown. Page 1652 3. Tighten the bolts. Tightening torque: 9.75 Nm (1.0 kgf-m, 7.2 ft. lbs.) Tightening torque: 6.4 Nm (0.65 kgf-m, 4.7 ft. lbs.) Tightening torque: 6.4 Nm (0.65 kgf-m, 4.7 ft. lbs.) Tightening torque: 6.4 Nm (0.65 kgf-m, 4.7 ft. lbs.) Page 7187 7. Perform the above steps from 1) to 6) at the MIN and MAX positions of intermittent control switch, and replace the wiper switch assembly if it does not operate as specified. Page 4929 F21-F61 Page 7344 B292-B317 Page 6306 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 3886 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 1754 Remove the hose from the reservoir tank. Cut 20 mm from the bottom of the hose at a 45° angle. Reinstall hose in reservoir tank. Start engine and permit to fully warm up. Turn off engine and allow to fully cool down. Recheck coolant level in reservoir and add coolant if needed. Note: Be sure to use genuine Subaru Super Coolant or Subaru Long Life Coolant, depending upon what type of coolant is currently in the system. Warranty/Claim Information Page 3047 4) Using the ST, tighten the bolts of inhibitor switch. ST 499267300 STOPPER PIN 5) Install the select cable to range select lever. 6) Install the plate assembly to transmission. 7) Install the washer and snap pin to range select lever. 8) Install the front and center exhaust pipes. (Non-turbo model) 9) Install the center exhaust pipe. (Turbo model) 10) Lower the vehicle. 11) Install the inhibitor switch connector from stay. 12) Connect the inhibitor switch connector. Page 141 Engine Control Module: Service and Repair Engine Control Module (ECM) REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the lower inner trim of the passenger side. 3. Detach the floor mat of the front passenger seat. 4. Remove the protect cover. 5. Remove the nuts (A) which hold ECM to the bracket. 6. Remove the clip (B) from the bracket. 7. Disconnect the ECM connectors and take out the ECM. INSTALLATION Install in the reverse order of removal. CAUTION: - When replacing ECM, use of wrong spec. ECM may lead to damage to the fuel injection system. - When replacing ECM, do not damage the harnesses and connectors. Tightening torque: 5 N.m (0.5 kgf-m, 3.7 ft-lb) Page 2393 B230-B283 Page 3067 B54-B127 Page 1050 3. With a 2 mm (0.08 inch) dia. stopper pin or a 2 mm (nominal) dia. hex bar wrench inserted into the stopper pin hole in the cylinder, secure the adjuster rod. 2. Install the automatic belt tension adjuster assembly. Tightening torque: 39 Nm (4.0 kgf-m, 28.9 ft. lbs.) 3. Install the belt idler No. 2. Tightening torque: 39 Nm (4.0 kgf-m, 28.9 ft. lbs.) 4. Install the belt idlers. Tightening torque: 39 Nm (4.0 kgf-m, 28.9 ft. lbs.) Page 1468 B17-B20 Page 6521 R58-R69 Page 4083 3) Apply proper amount of liquid gasket to the entire oil pan mating surface. Liquid gasket: THREE BOND 1217B (Part No. K0877YA020) 4) Apply liquid gasket fully to three holes other than screw holes on transmission case. Liquid gasket: THREE BOND 1217B (Part No. K0877YA020) 5) Install the oil pan. Tightening torque: 5 Nm (0.5 kgf-m, 3.6 ft. lbs.) 6) Connect the connector of rear vehicle speed sensor. (MP-T model) 7) Connect the connector of rear vehicle speed sensor. (VTD model) Page 4819 7. Unsolder connection between rectifier and stator coil to remove the stator coil. CAUTION: Do not allow a 180 - 270 W soldering iron to contact the terminals for more than 5 seconds at once because the rectifier cannot withstand so much heat. 8. Remove the IC regulator as follows. 1. Remove the screws which secure IC regulator to rear cover. 2. Unsolder the connection between IC regulator and rectifier to remove the IC regulator. 9. Remove the brush as follows. 1. Remove cover A. Locations Air Flow Meter/Sensor: Locations Sensor (Part 1) Page 4790 Neutral Safety Switch: Service and Repair Neutral Position Switch NEUTRAL POSITION SWITCH REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the connector from neutral position switch, and then remove the switch. INSTALLATION Install in the reverse order of removal. Diagnostic Aids Fuel Gauge Sender: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 4415 13) Install the air intake chamber. (Non-turbo model) 14) Install the intercooler. (Turbo model) 15) Inspect the inhibitor switch. Page 1771 Remove the hose from the reservoir tank. Cut 20 mm from the bottom of the hose at a 45° angle. Reinstall hose in reservoir tank. Start engine and permit to fully warm up. Turn off engine and allow to fully cool down. Recheck coolant level in reservoir and add coolant if needed. Note: Be sure to use genuine Subaru Super Coolant or Subaru Long Life Coolant, depending upon what type of coolant is currently in the system. Warranty/Claim Information Page 3028 B134-B136 Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 6048 Trim Panel: Service and Repair Upper Inner Trim UPPER INNER TRIM REMOVAL 1. Remove the lower inner trim. 2. Remove the front molding (A). 3. Remove the front pillar upper trim (B). 4. Detach the front seat belt shoulder anchor, and then remove the center pillar upper trim (C). INSTALLATION Install in the reverse order of removal. CAUTION: Be sure to securely hook the pawls of inner trim panel to body flange. NOTE: When installing the center pillar upper trim and front pillar upper trim, be sure to set the front molding as shown in the figure. Page 5189 Steering Gear: Service and Repair Steering Gearbox Assembly TURBO MODEL AND STI MODEL 1) Using a press, install the bushing to gearbox installation portion. 2) Apply a coat of grease to inside and outside of new oil seal. Specified steering grease: VALIANT GREASE M-2 (Part No. 003608001) 3) Verify the oil seal direction and installation position. Using the ST and press, press fit the oil seal to gearbox. ST 34199AE130 GEARBOX OIL SEAL INSTALLER 4) Using a C-clamp, attach the steering body as shown in the figure. Apply a coat of grease to needle bearing. CAUTION: Ensure the needle bearing is free from defects. If it is faulty, replace the steering body with a new one. 5) Using the ST-B and ST-C, attach the oil seal to ST.A. ST 34199FE040INSTALLER A, B, C NOTE: Face the oil seal in direction shown in the figure. Page 2108 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 1196 Engine Oil: Service and Repair REPLACEMENT 1. Open the engine oil filler cap for quick draining of engine oil. 2. Drain the engine oil by loosening the engine oil drain plug. 3. Replace the drain plug gasket. 4. Tighten the engine oil drain plug after draining engine oil. Tightening torque: 44 Nm (4.5 kgf-m, 32.5 ft. lbs.) 5. Install the service hole cover. 6. Use the engine oil of proper quality and viscosity, fill engine oil through the oil filler duct up to upper level on level gauge. Make sure that the vehicle is placed level when checking oil level. Recommended oil. API standard SM with the "Energy Conserving" logo is printed. ILSAC standard, GF4 "Star burst mark" label is on the container. Engine oil capacity. Upper level 4.0 L (4.2 US qt, 3.5 Imp qt) Lower level 3.0 L (3.2 US qt, 2.6 Imp qt) Page 6855 ILM(ES)-02 Page 3460 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 1559 25. Install the fuel pipe protector LH. Specifications Differential Fluid - Transfer Case: Specifications The Subaru transmission incorporates the transfer case within the unit and lubricates from a common sump. For the fluid specification refer to Manual Transmission/Transaxle or Automatic Transmission/Transaxle. Page 585 R58-R69 Page 2288 B380-f6 Page 3039 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 2829 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 1409 Locations Daytime Running Lamp Control Unit: Locations Area View Daytime Running Light Control Module - (B96, B242) Identification Oxygen Sensor: Locations Identification This article was updated by bulletin number: 11-92-08 Date: 01/05/09 APPLICABILITY: 1999MY and later Forester 1999MY and later Impreza 2000MY and later Legacy 2006MY and later Tribeca SUBJECT: Air/Fuel Ratio Sensor and Oxygen Sensor INTRODUCTION For information purposes only. REPAIR/SERVICE INFORMATION When performing diagnostics or reading Diagnostic Trouble Codes (DTC) for Air Fuel Ratio (A/F) sensors and Oxygen (O2) sensors use the following information to identify, locate and repair the appropriate sensor and sensor circuits: (1) Rarely will multiple sensors fail at the same time. (2) On vehicles with only one O2 sensor, the designation for that O2 sensor will be bank 1. (3) On vehicles with only one A/F sensor, the designation for that A/F sensor will be bank 1. (4) Any reference to sensor 1 is an A/F sensor. (5) Any reference to sensor 2 is an O2 sensor. (6) Early PZEV vehicles used an additional O2 sensor behind the rear catalyst and is designated sensor 3. (7) On vehicles with A/F and O2 sensors on the right (Passenger Side) and left (Driver side) of the vehicle, Bank 1 is the right side (Passenger Side) and Bank 2 is the left side (Driver side). Example: DTC P0030 HO2S HEATER CONTROL CIRCUIT (Bank 1 Sensor 1). This DTC is referring to the A/F sensor and since it is on a 2007 Forester there is only one A/F sensor and one O2 sensor. Example (as illustrated): DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (Bank 1 Sensor 2). This DTC is referring to the O2 sensor on the right side exhaust (or the O2 sensor of a vehicle with only one O2 sensor). Side Airbag Sensor Impact Sensor: Testing and Inspection Side Airbag Sensor Side Airbag Sensor INSPECTION Check for the following, and replace damaged parts with new parts. - Mounting bracket of side airbag sensor or connector is damaged. - Side airbag is deployed. Page 1054 5. After ensuring that the marks on the timing belt and sprockets are aligned, remove the stopper pin from tensioner adjuster. 6. Install the timing belt guide. (MT model) CAUTION: ^ Before installing the bolts, clean the threaded portion of timing belt cover. ^ Apply liquid gasket to the threaded portion of bolts. (Cam sprocket side only) Liquid gasket. THREE BOND 1324 (Part No. 004403042) or equivalent 1. Temporarily tighten the bolts. 2. Check and adjust the clearance between timing belt and timing belt guide. Clearance: 1.0 ± 0.5 mm (0.039 ± 0.020 inch) Page 3983 8) Install the front vehicle speed sensor and torque converter turbine speed sensor, and then fasten the harness. 9) Install the inlet pipe. NOTE: Be sure to use a new copper washer. 10) Install the transmission rear crossmember bolts. Tightening torque: 70 Nm (7.1 kgf-m, 51 ft. lbs.) 11) Install the propeller shaft. 12) Install the front, center, rear exhaust pipes and muffler. (Non-turbo model) 13) Install the center, rear exhaust pipes and muffler. (Turbo model) 14) Lower the vehicle. 15) Install the transmission connector to the stay. 16) Install the pitching stopper. 17) Install the air intake chamber. (Non-turbo model) 18) Install the intercooler. (Turbo model) Page 7235 B54-B127 Page 603 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 6124 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 5882 REPAIR INFORMATION/PROCEDURE Page 7261 Windshield Washer Reservoir: Service and Repair Disassembly and Assembly WASHER TANK AND MOTOR DISASSEMBLY Pull out the washer motor from tank. ASSEMBLY 1. Assemble in the reverse order of disassembly. 2. Confirm that water does not leak from installation area of motor. Page 2365 R72-R145 R148 Locations Shift Control Page 6329 Clock: Electrical Diagrams Electrical Diagrams CLOCK-01 Diagrams: Other diagrams referred to by name within these diagrams (i.e. "REF. TO GND-01", etc) can be found at Diagrams by Diagram Name. See: Diagrams/Electrical Diagrams/Diagrams By Diagram Name Connector and Ground Locations: The locations of the Connectors or Grounds shown within these diagrams can be found via the connector or ground number at Vehicle Locations. See: Locations Page 3941 Torque Specification Interchangeability The strainers are interchangeable for the models listed; however the correct bolts and torque specification must be used depending upon what strainer is installed. Disclaimer Testing and Inspection Side Air Bag: Testing and Inspection INSPECTION CAUTION: Before working on the airbag module, refer to the "CAUTION" in General Description. See: Service Precautions Perform the inspection of following items, and replace the damaged parts with new ones. 1. With side clash (when side airbag is deployed) - Side airbag module assembly - Backrest pad assembly - Backrest frame assembly - Backrest cover assembly 2. Other replacement parts, which found to be damaged by visual check - Headrest assembly - Bushing - Slide rail OUT - Slide rail IN - Seat hinge cover - Seat lifter lever - Reclining lever - Side airbag harness and connector (body side) 3. With side clash (when side airbag is not deployed) Check the seat and airbag module visually, and then replace them with new ones if damaged or cracked. Specially inspect the damage of airbag module body, installing bracket, harness connector. 4. Without side clash (dirt and damage of cover) Replace the corresponding part with a new one. Page 2474 Fuel Pressure: Testing and Inspection Fuel Pressure INSPECTION WARNING: Before removing the fuel pressure gauge, release the fuel pressure. NOTE: If out of specification, check or replace the pressure regulator and pressure regulator vacuum hose. 1. Release the fuel pressure. 2. Disconnect the fuel delivery hoses from fuel damper, and then connect the fuel pressure gauge. 3. Connect the connector of fuel pump relay. 4. Start the engine. 5. Measure the fuel pressure while disconnecting the pressure regulator vacuum hose from intake manifold. Fuel pressure: Standard. 284 - 314 kPa (2.9 - 3.2 kgf/cm2, 41 - 46 psi) 6. After connecting the pressure regulator vacuum hose, measure the fuel pressure. Fuel pressure: Standard. 230 - 260 kPa (2.35 - 2.65 kgf/cm2, 33 - 38 psi) NOTE: The fuel pressure gauge registers 10 to 20 kPa (0.1 to 0.2 kgf/cm2, 1 to 3 psi) higher than standard values during high-altitude operations. Page 7172 B292-B317 Page 1656 7. Install the timing belt cover. 8. Install the crank pulley. 9. Install the V-belt. INSPECTION 1. TIMING BELT 1. Check the timing belt teeth for breaks, cracks, and wear. If any fault is found, replace the belt. 2. Check the condition of back side of belt; if any crack is found, replace the belt. CAUTION: ^ Be careful not to let oil, grease or coolant contact the timing belt. Remove quickly and thoroughly if this happens. ^ Do not bend the belt sharply. Bending radius h: 60 mm (2.36 inch) or more 2. AUTOMATIC BELT TENSION ADJUSTER 1. Visually check the oil seals for leaks, and rod ends for abnormal wear or scratches. If necessary, replace the automatic belt tension adjuster assembly. NOTE: Slight traces of oil at rod's oil seal does not indicate a problem. 2. Check that the adjuster rod does not move when a pressure of 294 Nm (30 kgf, 66 ft. lbs.) is applied to it. This is to check adjuster rod stiffness. 3. If the adjuster rod is not stiff and moves freely when applying 294 Nm (30 kgf, 66 ft. lbs.), check it using the following procedures: 1. Slowly press the adjuster rod down to the end surface of the cylinder. Repeat this motion 2 or 3 times. 2. With the adjuster rod moved all the way up, apply a pressure of 165 Nm (16.8 kgf, 37.1 ft. lbs.) to it. Check the adjuster rod stiffness. 3. If the adjuster rod is not stiff and moves down, replace the automatic belt tension adjuster assembly with a new one. CAUTION: ^ Always use a vertical type pressing tool to move the adjuster rod down. ^ Do not use a lateral type vise. ^ Push the adjuster rod vertically. ^ Press-in the push adjuster rod gradually taking more than 3 minutes. ^ Do not allow press pressure to exceed 9,807 Nm (1,000 kgf, 2,205 ft. lbs.). ^ Press the adjuster rod till the end of the surface of the cylinder. Do not press the adjuster rod into the cylinder. Doing so may damage the cylinder. Page 2381 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Recall - Front Seat Wiring Harness Routing Air Bag Harness: All Technical Service Bulletins Recall - Front Seat Wiring Harness Routing NUMBER: WVC-13 DATE: March 2007 APPLICABILITY: 2006MY Subaru Forester & Impreza SUBJECT: Front Passenger Seat Wiring INTRODUCTION Subaru of America, Inc. (SOA) has determined that certain 2006 MY Subaru Forester and Impreza models may have been produced with an improperly routed electrical wiring harness. That harness could have been pinched against the passenger front seat mounting bolt during production. If the wiring harness was improperly installed, an electrical short could occur. There are two safety risks associated with this condition. The first is that the passenger's front air bag, which is connected to this wiring harness, could become disabled, in which case it would not deploy as designed in an accident and would therefore expose the right front passenger to the possibility of serious injuries. The second is that an electrical short circuit could, under some circumstances, cause a fire. If an electrical short circuit occurs in this wiring harness, fuse # 6 (located in the fuse panel on the lower left side of the dashboard) will "blow", disabling the passenger front air bag. This could occur at any time and without prior warning. But once it occurs, the driver will be alerted to this condition by the illumination of the air bag system warning light on the vehicle's instrument panel. Occupants will also be alerted to this condition if the passenger's frontal air bag ON/OFF indicator indicates "OFF" even if an adult passenger is occupying that seat. If fuse # 6 had previously blown and been replaced with no repair made to correct the underlying cause, there is a possibility that this wiring harness has already been damaged due to a short circuit. Under these circumstances, the new replacement fuse may not blow and a fire could occur at any time without warning. In Forester models, it could happen even if the ignition switch is in the "LOCK" (off) position. Vehicle owners will be advised in the Owner Notification Letter that if they encounter a blown fuse, an illuminated air bag system warning light, smell smoke, or have replaced a blown fuse # 6 without correcting the underlying problem, to not operate the vehicle. They will be advised to contact the nearest Subaru dealer as soon as possible for guidance. In these cases, dealers should arrange to have the vehicle towed and repairs performed immediately. This recall will involve inspection and possible repair of the front passenger seat wire harness. Please refer to the Service Procedure section of this bulletin for more details. AFFECTED VEHICLES ^ 2006 MY Subaru Forester and Impreza Potentially affected vehicles are identified in the VIN range chart below. Not all vehicles within the VIN range are affected. Prior to performing repairs, confirm coverage for potentially affected vehicles by using the Vehicle Coverage Inquiry in the Dealer Communication System (DCS). OWNER NOTIFICATION SOA will prepare and mail Owner Notification Letters to owners of affected vehicles on or around March 9, 2007. A copy of the Owner Notification Letter is included at the end of this bulletin. DEALER PROGRAM RESPONSIBILITY Dealers are to promptly service all vehicles subject to this recall at no charge to the vehicle owner regardless of mileage~ age of the vehicle~ or Page 5037 Auxiliary Power Outlet: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 1124 7) Turbo model (1) Remove the air cleaner. (2) Remove the coolant filler tank. (3) Remove the two bolts fixing pipe C and D. (bolt A) (4) Disconnect the pipe C from oil pump. Disconnect the pipe D from return hose. CAUTION: ^ Do not allow fluid from the hose end to come into contact with pulley belt. ^ To prevent foreign matter from entering the hose and pipe, cover the open ends of them with a clean cloth. INSTALLATION Diagrams Evaporator Case: Diagrams Auto A/C Model Page 7117 Front Door Window Regulator: Service and Repair FRONT REGULATOR AND MOTOR ASSEMBLY REMOVAL 1. Remove the door glass. 2. Loosen the nuts to remove the rear sash. 3. Disconnect the motor connector. 4. Loosen the four bolts and two nuts to remove the regulator assembly. 5. Loosen the screw to remove motor assembly. INSTALLATION 1. Install in the reverse order of removal. 2. Adjust the front door glass. Tightening torque: Nm (kgf-m, ft-lb) T1: 7.4 (0.75, 5.5) T2: 13.7 (1.4, 10.1) Page 1811 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the generator. 3. Drain the engine coolant. 4. Disconnect the connector from the engine coolant temperature sensor. 5. Remove the engine coolant temperature sensor. INSTALLATION Install in the reverse order of removal. NOTE: Use a new gasket. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb) Page 5124 Turbo model and STI model: 85 Nm (8.6 kgf-m, 62.2 ft. lbs.) NOTE: Correct the tie-rod boot, if it is twisted. REAR WHEEL TOE-IN ^ Inspection Toe-in: 0±3 mm (0±0. 12 inch) (tolerance) For rear toe-in inspection procedure, refer to FRONT WHEEL TOE-IN procedure. ^ Adjustment 1) Loosen the self-locking nut on inner side of link rear. NOTE: When loosening or tightening the adjusting bolt, hold the bolt head and turn self-locking nut. 2) Turn the adjusting bolt head until toe-in is at the specification. Toe-in: 0±2 mm (0±0.08 inch) (adjustment standard) NOTE: When the right and left wheels are adjusted for toe-in at the same time, the movement of one scale graduation changes toe-in by approximately 1.5 mm (0.6 inch). Page 3387 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 4323 5) Disconnect the inhibitor switch connector. 6) Remove the inhibitor switch connector from stay. 7) Lift-up the vehicle. 8) Remove the front and center exhaust pipes. 9) Remove the snap pin and washer from range select lever. 10) Remove the plate assembly from transmission case. 11) Remove the bolts. Locations Wheel Speed Sensor: Locations Electrical Component Location Locations Brake Light Switch: Locations Electrical Component Location Page 79 Horn Relay: Testing and Inspection HORN RELAY INSPECTION Measure the horn relay resistance between terminals (indicated in table) when connecting the terminal No. 4 to battery positive terminal and terminal No. 3 to battery ground cable. Page 4628 Brake Fluid: Service and Repair Brake Fluid INSPECTION 1. Check that the brake fluid level remains between "MIN" and "MAX". If out of the specified range, refill or drain fluid. If the fluid level becomes close to "MIN", refill the fluid. 2. Check the fluid for discoloration. If the fluid color has excessively changed, drain the fluid and refill with new fluid. REPLACEMENT CAUTION: ^ To always maintain the brake fluid characteristics, replace the brake fluid according to maintenance schedule or earlier than that when used in severe condition. ^ The FMVSS No. 116, fresh DOT3 or DOT4 brake fluid must be used. ^ Cover the air bleeder screw with waste cloth, when loosening it, to prevent brake fluid from being splashed over surrounding parts. ^ Do not allow brake fluid to come in contact with vehicle body; wash away with water and wipe off completely if spilled. ^ 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. NOTE: ^ During replacement, keep the brake reservoir tank filled with brake fluid to eliminate entry of air. ^ The brake pedal operating must be very slow. ^ For convenience and safety, two people should do the work. ^ The amount of brake fluid required is approximately 500 m l (16.9 US fl oz, 17.6 Imp fl oz) for total brake system. 1. Either lift-up the vehicle and place a rigid racks under it, or lift-up vehicle. 2. Remove both front and rear wheels. 3. Draw out the brake fluid from master cylinder with syringe. 4. Refill the reservoir tank with recommended brake fluid. Recommended brake fluid. FMVSS No. 116, fresh DOT3 or DOT4 brake fluid 5. Install one end of a vinyl tube onto the air bleeder screw and insert the other end of the tube into a container to collect the brake fluid. CAUTION: Brake fluid replacement sequence; (A) Front right -> (B) Rear left -> (C) Front left -> (D) Rear right 6. Instruct your co-worker to depress the brake pedal slowly two or three times and then hold it depressed. 7. Loosen the air bleeder screw approximately 1/4 turn until a small amount of brake fluid drains into container, and then quickly tighten the screw. 8. Release the brake pedal slowly. Repeat steps (6) through (8) until new fluid flows through vinyl tube. Specifications Fuel Pressure: Specifications Fuel pressure: (disconnecting the pressure regulator) Standard ......................................................................................................................................................... 284 - 314 kPa (2.9 - 3.2 kgf/cm2, 41 - 46 psi) Fuel pressure: (connecting the pressure regulator) Standard ..................................................................................................................................................... 230 - 260 kPa (2.35 - 2.65 kgf/cm2, 33 - 38 psi) Page 2034 Engine Control Module: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 6444 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 1546 3. Install the power steering pump, and tighten the bolts. 4. Install the power steering pipe brackets on the intake manifold RH. 5. Install the front side V-belt. 15. Install the coolant filler tank. 16. Install the intercooler. 17. Install the air cleaner element. 18. Install the air cleaner upper cover and air intake duct as a unit. 19. Connect the connector to the fuel pump relay. 20. Connect the battery ground cable to battery. 21. Lift up the vehicle. 22. Install the under cover. 23. Fill the engine coolant. Page 4050 8) After completion of fitting, make sure that the select lever operates smoothly all across the operating range. 9) Install in the reverse order of removal. Locations Electrical Component Location Page 7410 B3-B12 Page 1274 For vehicles within the Basic New Car Limited Warranty period, this repair may be claimed using table. Disclaimer Page 1459 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 3986 Transmission Speed Sensor: Service and Repair Torque Converter Turbine Speed Sensor Torque Converter Turbine Speed Sensor REMOVAL When removing the torque converter turbine speed sensor, refer to "Front Vehicle Speed Sensor". INSTALLATION When installing the torque converter turbine speed sensor, refer to "Front Vehicle Speed Sensor" Page 2872 Air Flow Meter/Sensor: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 4560 Brake Pad: Testing and Inspection Rear INSPECTION 1. 14 INCH TYPE Check pad thickness A. NOTE: ^ Always replace the pads for both right and left wheels at the same time. ^ Also replace the pad clips if they are twisted or worn. ^ A wear indicator is provided on the inner disc brake pad. If the pad wears down to such an extent that the end of wear indicator contacts disc rotor, a squeaking sound is produced as the wheel rotates. If this sound is heard, replace the pad. ^ Replace the pad if there is oil or grease on it. 2. 15 INCH TYPE Check the pad thickness A. NOTE: ^ Always replace the pads for both right and left wheels at the same time. ^ Also replace the pad clips if they are twisted or worn. ^ A wear indicator is provided on the inner disc brake pad. If the pad wears down to such an extent that the end of wear indicator contacts disc rotor, a squeaking sound is produced as the wheel rotates. If this sound is heard, replace the pad. ^ Replace the pad if there is oil or grease on it. 3. 17 INCH TYPE Check the pad thickness A. Page 7103 13. During adjustments, loosen the other three clamping bolts. 14. After adjustment, tighten the bolts and nuts. Page 3267 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Specifications Fuel Pressure: Specifications Fuel pressure: (disconnecting the pressure regulator) Standard ......................................................................................................................................................... 284 - 314 kPa (2.9 - 3.2 kgf/cm2, 41 - 46 psi) Fuel pressure: (connecting the pressure regulator) Standard ..................................................................................................................................................... 230 - 260 kPa (2.35 - 2.65 kgf/cm2, 33 - 38 psi) Page 2944 F21-F61 Page 4721 10. Bleed air from the brake system. Tightening torque (Air bleeder screw): Except 17 inch type: 8 Nm (0.8 kgf-m, 5.8 ft. lbs.) 17 inch type: 20 Nm (2.0 kgf-m, 14.5 ft. lbs.) 11. Conduct road tests to ensure brakes do not drag. INSPECTION 1. OPERATION CHECK (WITHOUT GAUGES) CAUTION: When checking operation, be sure to securely apply the parking brake. ^ Checking without gauges This method cannot determine the exact portion which has failed, but it can provide a rough understanding of the nature of failure if checking is conducted in accordance with the following procedures. ^ Air tightness check Start the engine, and run it for 1 to 2 minutes, then turn it off. Depress the brake pedal several times applying same pedal force as that used in ordinary braking operations. The pedal stroke should be greatest on 1st depression, and it should become smaller with each successive depression. If no change occurs in the pedal height while in a depressed state, the brake booster is faulty. NOTE: ^ In the event of defective operation, inspect the condition of check valve and vacuum hose. ^ Replace them if faulty and conduct the test again. ^ If no improvement is observed, check precisely with gauges. ^ Operation check 1. With the engine off, depress the brake pedal several times applying same pedal force and make sure that pedal height does not vary with each depression of pedal. 2. With the brake pedal depressed, start the engine. 3. As the engine starts, the brake pedal should move slightly toward the floor. If no change occurs in the pedal height, the brake booster is faulty. NOTE: If faulty, check precisely with gauges. Page 3630 F61-R47 Description and Operation Transmission Mounting Page 5836 Page 4257 3) Install the clutch disc and cover. 4) Install the transmission assembly. 5MT: Manual Transmission 6MT: Manual Transmission INSPECTION CAUTION: Since this bearing is grease sealed and is of a non-lubrication type, do not wash with gasoline or any solvent. 1) Damage on sliding surface of facing and ring gear If defective, replace the flywheel. 2) Smoothness of rotation Rotate the ball bearing applying pressure in thrust direction. 3) If noise or excessive play is noted, replace the flywheel. Page 4003 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 3643 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 1239 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 6633 R58-R69 Page 7025 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 6810 License Plate Lamp: Electrical Diagrams ILM(ES)-01 Page 2121 B230-B283 Page 3930 Fluid - A/T: Fluid Type Specifications Automatic Transmission Recommended fluid Use one of the following types of automatic transmission fluid: Subaru ATF Type-HP IDEMITSU ATF HP Castrol Transmax J Pennzoil ATF J Page 5551 Impact Sensor: Adjustments IMPACT SENSOR ADJUSTMENT 1. CHECK IMPACT SENSOR 1. Remove the key from ignition switch. 2. Close all windows. 3. Close all the doors, trunk lid and rear gate. Leave open the front hood. 4. Press the LOCK button of the transmitter from outside vehicle. 5. Check that the security indicator light blinks twice within 0.5 seconds in 2 seconds cycle after 30 seconds. 6. Hit the windshield with your palm continuously and check the security alarm operates. Lift up the front hood approx. 12 cm (4.7 in), and then drop it off to check the operation of security alarm. 7. If NG, adjust the impact sensitivity. 2. IMPACT SENSITIVITY ADJUSTMENT 1. Connect the Subaru Select Monitor to data link connector. 2. Turn the ignition switch to ON. 3. Select {Impact Sensor} from the main menu. 4. Make a {ECU customizing}. - Sensitivity can be adjusted in 11 levels (0 to 10). - Initial setting is 5. - Smaller number means more sensitive. - Larger number means less sensitive. 5. Turn the ignition switch to OFF, and then remove the Subaru Select Monitor. NOTE: Set the sensor so as not to let the alarm on normal vibration (reclining to the door, hit the ball and etc.). - Set the sensor to operate the alarm with hitting the door or window glass, etc. continuously like a mayhem by robbery. - Ask the customer about parking situation for setting, because the alarm operate when the vibration not only the burglar but also the construction etc. Page 4538 3. Remove the boot from piston end. 4. Place a wooden block in caliper body as shown in the figure to prevent the piston from jumping out and avoid being damaged. 5. Gradually supply compressed air via the installation hole of brake hose to force the piston out. 6. Remove the piston seal from caliper body cylinder. CAUTION: Do not damage the cylinder and piston seal groove. 3. 17 INCH TYPE 1. Clean mud and foreign particles from the caliper body assembly. CAUTION: Be careful not to allow foreign particles to enter the brake hose connector. Page 4125 STI model NOTE: ^ Be sure to install the clutch hose with the mark side facing upward. ^ Be careful not to twist the clutch hose during installation. 2) After bleeding air from the operating cylinder, ensure that clutch operates properly. DISASSEMBLY NOTE: Disassembly for operating cylinder of only 5MT model can be performed. That of 6MT model is a component that cannot be disassembled. 1) Remove the boot and push rod. ^ Non-turbo model Non-turbo model ^ Except Non-turbo model and STI model Page 952 B292-B317 Page 445 B3-B12 Page 2873 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 3455 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 3994 11) Remove the clamp, and then remove the shift lock solenoid. INSTALLATION Install in the reverse order of removal. INSPECTION Step 1 - Step 4 Page 6503 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 2462 F61-R47 Page 3103 B380-f6 Testing and Inspection Air Filter Element: Testing and Inspection INSPECTION Inspect for cracks and loose connections. Page 1450 11. Remove the under cover. 12. Drain the engine oil. 13. Remove the front exhaust pipe assembly. 14. Remove the nuts which install the front cushion rubber onto front crossmember. 15. Remove the bolts which install the oil pan on cylinder block while raising up engine. 16. Insert the oil pan cutter blade between cylinder block-to-oil pan clearance. CAUTION: Do not use a screwdriver or similar tool in place of oil pan cutter. 17. Remove the oil strainer. 18. Remove the baffle plate. Installation CAUTION: Before installing the oil pan, clean sealant from oil pan and engine block. 1. Check the seal (A) is securely installed in baffle plate in the direction as shown in the figure. Page 4965 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 5028 B134-B136 Page 2126 R58-R69 Page 3730 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 3065 B3-B12 Inhibitor Switch Neutral Safety Switch: Testing and Inspection Inhibitor Switch INHIBITOR SWITCH INSPECTION Measure the inhibitor switch resistance. If NG, replace the inhibitor switch. Page 6854 Parking Lamp: Electrical Diagrams ILM(ES)-01 Page 1607 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 4648 7) Read values indicated on the brake tester and check if the fluctuation of values, while decompressed and compressed, meet the standard values. 8) After checking, also check if any irregular brake pedal tightness is felt. Page 2327 B230-B283 Testing and Inspection Headlamp Alignment Switch: Testing and Inspection HEADLIGHT BEAM LEVELER SYSTEM HEADLIGHT BEAM LEVELER SWITCH Measure the resistance between headlight beam leveler switch terminals. Page 6309 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 5896 Rear Door Interior Handle: Service and Repair REAR INNER REMOTE REMOVAL 1. Remove the rear door trim. 2. Remove the sealing cover. 3. Remove a screw and two rod joints. 4. Remove the rear inner remote. INSTALLATION Install in the reverse order of removal. NOTE: Make sure the rear inner remote works properly after installation. Page 4379 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Keyless Entry - Remote Transmitter Service Tip Keyless Entry Transmitter: Technical Service Bulletins Keyless Entry - Remote Transmitter Service Tip Keyless Entry Remote Inoperative Inspections of returned Keyless Entry Remotes for inoperative complaints found that many are due to oxidation on the contacts. Merely moving the battery itself disturbs this oxidation and the remotes then operate normally. This would be a very inexpensive first thing to check for an inoperative complaint. Check the battery and terminal condition and buff with a coarse cloth if either the battery or terminals are oxidized. Page 6794 B3-B12 Page 4801 Battery: Service and Repair BATTERY REMOVAL 1. Disconnect the positive (+) cable after disconnecting the ground (-) cable of battery. 2. Remove the flange nuts from battery rods, and then take off the battery holder. 3. Remove the battery. INSTALLATION Install in the reverse order of removal. Tightening torque: 3.4 N.m (0.35 kgf-m, 2.5 ft-lb) NOTE - Clean the battery cable terminals, and then apply grease to retard formation of corrosion. - Connect the positive (+) cable of battery and then the ground (-) cable of battery. Page 3555 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 2023 B54-B127 Specifications Specification Page 5182 6) Using the ST, loosen lock nut. ST 926230000 SPANNER 7) Tighten the adjusting screw until it no longer tightens. 8) Using a wrench (32 mm width across flats) or adjustable wrench with cinching boot, remove the tie rod. 9) Loosen the adjusting screw, and then remove the spring and sleeve. 10) Clean the dirt of input shaft. Remove the dust cover taking care not to scratch the housing or input shaft and allow foreign matter to enter gear box interior. Front Vehicle Speed Sensor Transmission Speed Sensor: Service and Repair Front Vehicle Speed Sensor Front Vehicle Speed Sensor REMOVAL 1) Set up the vehicle on a lift. 2) Disconnect the ground cable from battery. 3) Remove the air intake chamber. (Non-turbo model) 4) Remove the intercooler. (Turbo model) 5) Disconnect the transmission connector. 6) Remove the pitching stopper. 7) Remove the transmission connector from stay. 8) Lift-up the vehicle. 9) Clean the transmission exterior. 10) Drain the ATF completely. NOTE: ^ Tighten the ATF drain plug after draining the ATF. ^ Use anew gasket. 11) Remove the front, center, exhaust pipes and muffler. (Non-turbo model) 12) Remove the center, rear exhaust pipe and muffler. (Turbo model) 13) Remove the propeller shaft. 14) Place the transmission jack under transmission. NOTE: Make sure that the support plates of transmission jack don't touch the crossmember. 15) Remove the transmission rear crossmember bolts. Page 3249 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 612 B54-B127 Page 6394 B128-B134 Specifications Oil Pan: Specifications Oil Pan Bolts ........................................................................................................................................ .................................... 5 Nm (0.5 kgf-m, 3.6 ft. lbs.) Page 1029 4. Remove the ignition coil and ignitor assembly. 5. Remove the spark plugs with the spark plug sockets. INSTALLATION RH SIDE Install in the reverse order of removal. Tightening torque (Spark plug): 21 N.m (2.1 kgf-m, 15.2 ft-lb) Tightening torque (Ignition coil and ignitor assembly): 16 N.m (1.6 kgf-m, 11.7 ft-lb) NOTE: - The above torque should be only applied to new spark plugs without oil on their threads. - In case their threads are lubricated, the torque should be reduced by approx. 1/3 of the specified torque in order to avoid over-stressing. LH SIDE Install in the reverse order of removal. Tightening torque (Spark plug): 21 N.m (2.1 kgf-m, 15.2 ft-lb) Tightening torque (Ignition coil and ignitor assembly): 16 N.m (1.6 kgf-m, 11.7 ft-lb) NOTE: - The above torque should be only applied to new spark plugs without oil on their threads. - In case their threads are lubricated, the torque should be reduced by approx. 1/3 of the specified torque in order to avoid over-stressing. Page 118 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 6967 Turn Signal Bulb: Service and Repair Rear Turn Signal Light Bulb REAR TURN SIGNAL LIGHT BULB REMOVAL 1. SEDAN MODEL 1. Remove the trunk side trim of rear portion. 2. Turn the socket and remove the bulb. 2. WAGON MODEL 1. Remove the rear combination light assembly. 2. Turn the socket and remove the bulb. INSTALLATION Install in the reverse order of removal. Diagram Information and Instructions Parking Brake Warning Lamp: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 6293 F61-R47 Page 806 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 5045 Auxiliary Power Outlet: Service and Repair Rear Accessory Power Supply Socket REAR ACCESSORY POWER SUPPLY SOCKET REMOVAL 1. FRONT 1. Disconnect the ground cable from battery. 2. Remove the console cover. 3. Disconnect the harness connectors and remove accessory power supply socket. INSTALLATION Install in the reverse order of removal. Wipers/Washers - Front Washer Nozzle Won't Spray Windshield Washer Spray Nozzle: All Technical Service Bulletins Wipers/Washers - Front Washer Nozzle Won't Spray FRONT WASHER NOZZLE DOES NOT SPRAY PROPERLY Failure of the front washer nozzle to spray properly may be caused by something blocking the nozzle outlet. Try to eliminate dust and foreign matter from front washer nozzle using the following procedure. If the washer nozzle spraying does not change after the repair, then it will be necessary to replace with a new nozzle or inspect other parts on the washer system. 1) Open the front hood 2) Remove the washer nozzle 3) Blow compressed air in the spray hole of the washer nozzle and the installation hole for washer hose to eliminate dust and foreign matter. 4) Install the hose to washer nozzle and install the washer nozzle. 5) Check if front washer sprays properly. If no change, replace with a new nozzle. A Technical Service Bulletin will be forthcoming with additional information on this subject. Page 4565 5. Remove the pad pins and cross spring. 6. Use a wrench to expand the pads, and then push the piston back. 7. Remove the pad. INSTALLATION 1. 15 INCH TYPE 1. Apply thin coat of Molykote AS-880N (Part No. K0777YA010) to the frictional portion between pad and pad clip. 2. Apply thin coat of Molykote AS-880N (Part No. K0777YA010) to the frictional portion between pad and pad inner shim. Page 3805 21) Remove the oil pan. 22) Disconnect the harness connector and transmission ground terminal. 23) Remove the harness assembly. INSTALLATION 1) Pass the harness assembly through the hole in the transmission case. 2) Connect the harness connector and transmission ground. Page 6842 B134-B136 Front Vehicle Speed Sensor Transmission Speed Sensor: Service and Repair Front Vehicle Speed Sensor Front Vehicle Speed Sensor REMOVAL 1) Set up the vehicle on a lift. 2) Disconnect the ground cable from battery. 3) Remove the air intake chamber. (Non-turbo model) 4) Remove the intercooler. (Turbo model) 5) Disconnect the transmission connector. 6) Remove the pitching stopper. 7) Remove the transmission connector from stay. 8) Lift-up the vehicle. 9) Clean the transmission exterior. 10) Drain the ATF completely. NOTE: ^ Tighten the ATF drain plug after draining the ATF. ^ Use anew gasket. 11) Remove the front, center, exhaust pipes and muffler. (Non-turbo model) 12) Remove the center, rear exhaust pipe and muffler. (Turbo model) 13) Remove the propeller shaft. 14) Place the transmission jack under transmission. NOTE: Make sure that the support plates of transmission jack don't touch the crossmember. 15) Remove the transmission rear crossmember bolts. Ignition System - Spark Plug Replacement Intervals Spark Plug: Technical Service Bulletins Ignition System - Spark Plug Replacement Intervals PLATINUM SPARK PLUG CHANGE INTERVALS The Techline occasionally gets calls concerning the change intervals on platinum plugs and why some need to be changed at 30,000 miles and others at 60,000 miles. The reason for this is the spark plugs on 2.5L NA engines, the electrode side of this plug is platinum but the plug core side is not platinum. Therefore, it is a maintenance interval every 30,000 miles. On the 2.5L Turbo and 3.OL engines, both the electrode side and the plug core side are platinum. Therefore, it is a maintenance interval every 60,000 miles. Locations Main Fuse Box (M/B) Page 2544 F61-R47 Page 4774 Neutral Safety Switch: Locations Page 5290 4. If the rim runout exceeds specifications, remove the tire from rim and check runout while attaching the dial gauge to positions shown in the figure. 5. If the measured runout still exceeds specifications, replace the wheel. Page 4453 Electrical Component Location Page 384 Engine - Engine Oil System Flushing Engine Oil: Technical Service Bulletins Engine - Engine Oil System Flushing NUMBER: 02-110-10 DATE: 01/05/11 APPLICABILITY: All Turbo Models SUBJECT: Subaru Genuine Engine Oil System Flush INTRODUCTION The purpose of this bulletin is to announce a new product that is now available through the Subaru Genuine Chemical Program, "Subaru Engine Oil System Flush" The main cause of turbocharger failure is lack of lubrication due to insufficient maintenance Currently, 2010MY and prior turbocharged engines require that the oil and filter be changed every 3,750 miles (6,000km) or 3-3/4 months All 2011MY turbocharged engines require that the oil and filter be changed every 7,500 miles (12,000 km) or 7.5 months Proper oil change maintenance is critical to the lubrication of engine components, especially in turbocharged engines When engine oil maintenance is not performed at required intervals, oil gelling (sludge) and deposits caused by deterioration of the oil will clog oil passages, causing excessive wear from lack of lubrication If the mesh filter screen located inside the banjo bolt that secures the turbocharger oil supply pipe to the back of the right cylinder head becomes clogged, the turbocharger will fail. In addition, this will also cause damage to the Active Valve Control System (AVCS) As a reference, refer to Service Bulletin 02-106-08R, Turbocharger Mesh Filter Screen Synthetic Oil Subaru of America Inc recommends using synthetic motor oil in all turbo charged engines. When using synthetic oil, you must use oil of the same classification, viscosity and grade shown in this Owner's Manual, and must follow the oil and filter changing intervals shown in the maintenance schedule. PART INFORMATION Page 7253 Windshield Washer Motor: Service and Repair Disassembly and Assembly WASHER TANK AND MOTOR DISASSEMBLY Pull out the washer motor from tank. ASSEMBLY 1. Assemble in the reverse order of disassembly. 2. Confirm that water does not leak from installation area of motor. Page 378 Fuel Gauge Sender: Service and Repair Fuel Sub Level Sensor Fuel Sub Level Sensor REMOVAL WARNING: - Place "NO FIRE" signs near the working area. - Be careful not to spill the fuel. 1. Disconnect the ground cable from battery. 2. Lift up the vehicle. 3. Drain the fuel from the fuel tank. 4. Remove the rear seat. 5. Remove the service hole cover. 6. Disconnect the connector from the fuel sub level sensor. 7. Disconnect the fuel jet pump hose. Page 4673 Parking Brake Shoe: Testing and Inspection Parking Brake Assembly (Rear Disc Brake) INSPECTION 1) Measure the brake disc rotor inside diameter. If the disc is scored or worn, replace the brake disc rotor.Disc rotor inside diameter: Standard Except STi model 170 mm (6.69 inch) STi model 190 mm (7.48 inch) Service limit Except STi model 171 mm (6.73 inch) STi model 191 mm (7.52 inch) 2) Measure the lining thickness. If it exceeds the limit, replace the shoe assembly.Lining thickness: Standard3.2 mm (0.126 inch) Service limit1.5 mm (0.059 inch) NOTE: Replace the right and left brake shoes at the same time. Page 6839 B17-B20 Page 4512 B136-B141 Page 3406 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 2744 Oxygen Sensor: Locations Location View Page 3584 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 1071 Page 2994 B230-B283 Page 5478 Solar Sensor: Testing and Inspection SUNLOAD SENSOR TROUBLE SYMPTOM: - Sensor identified that sunlight is at maximum. Then, A/C system is controlled to COOL side. - Sensor identified that sunlight is at minimum. Then, A/C system is controlled to HOT side. NOTE: When the sunload sensor is checked indoors or in the shade, it may be diagnosed as open circuit. Always check the sunload sensor at a place where sun shines directly on it. Wiring Diagram Page 6443 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 1097 Oil Filter: Tools and Equipment Oil Filter Wrench AST tool# 5040 66.5mm, 14 flats, Oil Filter Wrench for Subaru. Fits all 2.5L 4-cylinder motors (except Justy and Loyale). Fits both Subaru factory filter #15208AA100 and Suzuki factory filter #16510-03G00. Also fits 2008 U.S. model Smart Car. - 66.5mm with 14 Flats - Applicable to Subaru 2.5L 4-Cylinder Motors (except Justy and Loyale) - Fits Suzuki factory filter# 16510-03G00 - Fits 2008 U.S. Model Smart Car - Made in USA Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Page 2956 Manifold Pressure/Vacuum Sensor: Service and Repair Manifold Absolute Pressure Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the connectors from manifold absolute pressure sensor. 3. Remove the manifold absolute pressure sensor from the throttle body. INSTALLATION Install in the reverse order of removal. NOTE: Replace the O-rings for the manifold absolute pressure sensor with new ones. Tightening torque: 1.6 N.m (0.16 kgf-m, 1.2 ft-lb) Testing and Inspection Door Switch: Testing and Inspection DOOR SWITCH Measure the resistance between door switch terminals. Page 2368 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Locations Knock Sensor: Locations Sensor (Part 1) Specifications BRAKE BOOSTER Page 5188 23) Using a press, remove the bushing of gearbox installation portion. Page 1060 4. Measure the extension of rod beyond the body. If it is not within specifications, replace with a new one. Rod extension H. 5.7 ± 0.5 mm (0.224 ± 0.020 inch) 3. BELT TENSION PULLEY 1. Check the mating surfaces of timing belt and contact point of adjuster rod for abnormal wear or scratches. Replace the belt tension pulley if faulty. 2. Check the belt tension pulley for smooth rotation. Replace if noise or excessive play is noted. 3. Check the belt tension pulley for grease leakage. 4. BELT IDLER 1. Check the belt idler for smooth rotation. Replace if noise or excessive play is noted. 2. Check the outer contacting surfaces of idler pulley for abnormal wear and scratches. 3. Check the belt idler for grease leakage. Page 805 Knock Sensor: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 6144 Sunroof / Moonroof: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 4544 1. Set the vehicle on a lift. 2. Loosen the wheel nuts. 3. Lift-up the vehicle, and then remove the wheels. 4. Remove the brake pads from caliper body. 5. Disconnect the brake hose from caliper body. 6. Remove the caliper body from housing. 7. Clean mud and foreign particles from the caliper body. CAUTION: Be careful not to allow foreign particles to enter brake hose connector. INSTALLATION 1. 14 INCH TYPE 1. Install the support on housing. Tightening torque: 53 Nm (5.4 kgf-m, 39.1 ft. lbs.) 2. Apply thin coat of Molykote AS-880N (Part No. K0777YA010) to the frictional portion between pad and pad clip. 3. Install the pads on support. 4. Install the caliper body on support. Tightening torque: 37 Nm (3.8 kgf-m, 27.5 ft. lbs.) 5. Replace the brake hose gaskets with new ones, and then connect the brake hose. Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft. lbs.) 6. Bleed air from the brake system. 2. 15 INCH TYPE 1. Install the caliper body on housing. Tightening torque: 53 Nm (5.4 kgf-m, 39.1 ft. lbs.) 2. Apply a thin coat of Molykote AS-880N (Part No. K0777YA010) to the frictional portion between pad and pad clip. 3. Install the pads on caliper body. 4. Replace the brake hose gaskets with new ones, and then connect the brake hose. Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft. lbs.) 5. Bleed air from the brake system. 3. 17 INCH TYPE 1. Install the caliper body on housing. Tightening torque: 65 Nm (6.6 kgf-m, 47.9 ft. lbs.) 2. Install the pads on caliper body. 3. Replace the brake hose gaskets with new ones, and then connect the brake hose. Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft. lbs.) 4. Bleed air from the brake system. DISASSEMBLY 1. 14 INCH TYPE 1. Remove the boot ring. Page 7111 Window Glass: Service and Repair Rear Quarter Glass REAR QUARTER GLASS REMOVAL Remove the glass in the same procedure as for windshield glass. INSTALLATION 1. Cut off the nozzle tip as shown in the figure. 2. Install the glass in the same procedure as for windshield glass. 3. After completion of all work, allow the vehicle to stand for about 24 hours. NOTE: When the door is opened/closed after glass is bonded, always lower the door glass and then open/close it carefully. Testing and Inspection Exterior Lighting Relay: Testing and Inspection TAIL AND ILLUMINATION RELAY Measure the tail and illumination relay resistance between terminals when connecting terminal No. 4 to battery positive terminal and terminal No. 3 to battery ground terminal. Subaru 2.5L Cam Alignment Bar - Ast [SU499207300] Camshaft: Tools and Equipment Subaru 2.5L Cam Alignment Bar - Ast [SU499207300] Subaru 2.5L Cam Alignment Bar AST tool# SU499207300 - Made in the U.S.A. Subaru 2.5L Cam Alignment Bar 2008 suggested user price: Call AST for pricing Assenmacher Specialty Tools 1 800 525 2943 Page 1130 Page 5657 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 2149 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the connector from the camshaft position sensor RH. 3. Remove the camshaft position sensor RH from the rear side of cylinder head. 4. Remove the camshaft position sensor LH in the same procedure as RH side. INSTALLATION Install in the reverse order of removal. Tightening torque: Camshaft position sensor support: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) Camshaft position sensor: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) Page 5765 Step 1 - 6 1. CHECK SECURITY INDICATOR LIGHT CIRCUIT Page 7243 F61-R47 Testing and Inspection Door Switch: Testing and Inspection DOOR SWITCH Measure the resistance between door switch terminals. Page 3949 1) Check for ATF leaks in joints between the transmission, radiator, pipes, and hoses. 2) Check for deformed clamps. 3) Lightly bend the hose and check for cracks in the surface and other damage. 4) Pinch the hose with your fingers and check for poor elasticity. Also check for poor elasticity in the parts where the clamp was by pressing with your fingernail. 5) Check for peeling, cracks, and deformation at the tip of the hose. Page 588 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Intercooler Intercooler Engine - Turbocharger Oil Supply Mesh Screen Oil Line: Technical Service Bulletins Engine - Turbocharger Oil Supply Mesh Screen NUMBER: 02-103-07R DATE: 10/29/07 APPLICABILITY: All Turbo Equipped Vehicles SUBJECT: Turbocharger Oil Supply Mesh Screen INTRODUCTION This bulletin is for informational purposes only Turbocharged engines require proper maintenance especially when the vehicle is used under severe driving conditions such as moderate to hard acceleration and engine braking on a somewhat regular basis. In any case, it is recommended that the engine oil and filter be changed every 3,750 miles (6,000 km) or 3~3/4 months. In addition, the mesh screen which is located inside the banjo bolt that secures the turbocharger oil supply pipe to the back of the right side cylinder head should be checked to make sure it is not clogged or restricted especially if the condition of the oil is questionable or as to when the last oil change was performed. If clogged or restricted, it will reduce or cut off the oil supply to the turbo resulting in failure The oil supply pipe should also be checked to make sure that there are no obstructions. Note: The mesh screen is only available with a replacement banjo bolt ^ Make sure the mesh screen is installed in the proper direction; incorrect installation will cut off oil supply to the turbo. ^ Do not confuse the oil supply mesh screen with the Active Valve Control System (AVCS) union screw filter Refer to Service Bulletin 02-97-05 dated 10/06/05. ^ When the vehicle is used under severe driving conditions, the engine oil is consumed more quickly than under normal driving conditions due to high intake manifold vacuum during engine braking and higher temperatures; the engine oil level should be checked at every fuel fill up. For additional examples of severe driving conditions~ refer to the Warranty & Maintenance Booklet. Disclaimer Diagram Information and Instructions Ignition Coil: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 5110 to the right. The proper wire location (not pinched) is indicated by broken lines in the photo to the right, below. ^ If the wire was found to be pinched, proceed to the "Wiring Repair Procedure" section, below. 3. If the wire was found to be located properly (not pinched), no repair is necessary. Reinstall the floor carpet. Wrap the previously cut portion of carpet with 1.5 inch wide unwoven adhesive tape. 4. Reinstall the center console trim. Note: Be careful that the seat heater switch is not pinched by the parking brake lever during reinstallation. 5. Confirm that switches, including the seat heater switch, work properly. Wiring Repair Procedure: Forester & Impreza 1. Disconnect the negative battery cable. Note: In the interest of customer satisfaction, please write down all radio preset stations prior to disconnecting the battery. The stations should be reset into the radio afier completion of the repair. 2. For Impreza models, proceed to step 4. Forester Models only: Remove the center console trim between the select lever and parking brake lever. 3. Forester only: Cut a cross section of floor carpet at the center in front of the parking brake lever with scissors as shown. Page 1782 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 2547 Air Flow Meter/Sensor: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 1619 F61-R47 A/C, Interior - Seat Heater Relay Updated Seat Heater Relay: Technical Service Bulletins A/C, Interior - Seat Heater Relay Updated change of seat heater relay In order to use a common seat heater relay with other models, FUT has changed the seat heater relay installed in Impreza and Forester vehicles from part number 8250TTC000 (brown) to 8250TFCT00 (black). The relay is located next to the fuse box under the lower dash panel on the driver side on vehicles equipped with seat heaters VIN breaks where the new relay has been installed are as shown. Page 567 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Service and Repair Shift Interlock Solenoid: Service and Repair AT Shift Lock Solenoid and "P" Range Switch REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the console box. 3) Disconnect the connector. 4) Remove the grip. 5) Remove the indicator bulb from indicator cover. 6) Remove the indicator cover. 7) Remove the blind. 8) Remove the cushion. 9) Remove the clip, and then remove the "P" range switch. 10) Remove the cover. Page 2640 B128-B134 Capacity Specifications Refrigerant: Capacity Specifications Capacity ............................................................................................................................................... .................................. 0.50 ± 0.05 kg (1.10 ± 0.11 lb) Page 5638 Seat Belt: Service and Repair Rear Seat Belt REAR SEAT BELT REMOVAL 1. OUTER SEAT BELT RH ASSEMBLY AND LH ASSEMBLY (SEDAN MODEL) 1. Remove the rear seat. 2. Remove the side sill rear lower cover. 3. Remove the seat belt lower anchor bolt. 4. Remove the anchor cover. Remove the bolt from pillar and remove shoulder anchor. 5. Remove the quarter pillar trim. 6. Remove the bolts, and then detach the outer seat belt assembly. 7. Remove the two bolts and remove adjustable anchor ASSY. Page 5639 2. SHOULDER SEAT BELT CTR ASSEMBLY (SEDAN MODEL) 1. Remove the rear seat cushion. 2. Remove the seat belt lower anchor bolt. 3. Remove the quarter pillar trim. 4. Remove the rear shelf trim. 5. Remove the bolts, and then detach the shoulder seat belt assembly. 3. CENTER SEAT BELT LH ASSEMBLY (SEDAN MODEL) 1. Remove the rear seat cushion. 2. Remove the bolts, and then detach the center seat belt LH assembly. 4. OUTER SEAT BELT RH ASSEMBLY AND LH ASSEMBLY (WAGON MODEL) 1. Remove the luggage floor mat. 2. Remove the rear seat cushion. 3. Remove the side sill rear lower cover. Page 1703 Spark Plug: Application and ID Type ..................................................................................................................................................... ............................................................. Manufacturer ILFR6B ................................................................................................................................................ .......................................................................... NGK Gap ...................................................................................................................................................... ................................. 0.7 - 0.8 mm (0.028 - 0.031 in) Torque ................................................................................................................................................. ........................................................ 21 N.m (15 ft.lb) Page 1041 6. Inspect all valves for clearance again at this stage. If the valve clearance is not correct, repeat the procedure over again from the first step. 7. After inspection, install the related parts in the reverse order of removal. Page 1326 e. Remove the bearing caps. f. Measure the widest point of the plastigauge on each journal. If the oil clearance exceeds the limit, replace the camshaft. If necessary, replace the camshaft caps and cylinder head as a set. Standard. 0.037 - 0.072 mm (0. 00 15 - 0.0028 inch) Limit: 0.10 mm (0. 0039 inch) g. Completely remove the plastigauge. 5. Check the cam face condition, and remove the minor faults by grinding with oil stone. Measure the cam height H. If it exceeds the limit or offset wear occurs, replace the camshaft. Cam height H. Standard Intake 46.55 - 46.65 mm (1.833 1.837 inch) Exhaust 46.75 - 46.85 mm (1.841 - 1.844 inch) Limit Intake 46.45 mm (1.829 inch) Exhaust 46.65 mm (1.837 inch) Cam base circle diameter 37.0 mm (1.457 inch) Page 7064 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 3108 Throttle Position Sensor: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 6848 F61-R47 Page 2710 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Cooling System - Coolant Comes Out Of Reservoir Coolant Line/Hose: All Technical Service Bulletins Cooling System - Coolant Comes Out Of Reservoir NUMBER: 08-52-08 DATE: 08/18/08 APPLICABILITY: 1999MY and later Impreza & Forester 2000MY and later Legacy & Outback 2006MY and later Tribeca SUBJECT: Coolant Overflow Introduction If you encounter a vehicle which experiences coolant coming out of the coolant reservoir tank, it may be caused by the radiator cap pressure valve being stuck open by debris sucked up through the reservoir tank hose. As the cooling system cools down, it sucks coolant back into the radiator. If there is debris that settles to the bottom of the reservoir tank, the hose is low enough to also suck them back into radiator. This causes the radiator cap not to seal, allowing excessive amount of coolant to escape overflowing the reservoir tank. If this condition continues over time, there will not be enough coolant in the system to maintain proper engine temperature. In order to correct the condition you need to clean (and test) or replace the radiator cap, clean out the reservoir tank, and shorten the hose slightly, following the repair procedure. Production Line Change The shorter coolant reservoir tank hose was used in production as shown above. Repair Procedure/Information 1. Radiator Cap Cleaning Many caps can be successfully cleaned. The important part is the thorough cleaning of the negative pressure valve. If this is not done completely, remaining debris may result in a repeat issue. If there is an excessive amount of debris or the sealing rubber on the cap appears to be pitted or damaged, replace the cap. Note: If replacing the cap, skip to Step 2. Using clean water and a brush, thoroughly clean the cap seal surface. Note: Page 1240 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Service and Repair Muffler: Service and Repair Muffler Turbo model Turbo model Page 6512 B54-B127 Page 1077 Air Filter Element: Service and Repair Air Cleaner Element REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the connector from mass air flow and intake air temperature sensor. 3. Loosen the clamp (A) which connects the air intake boot and intake duct. 4. Remove the clip (B) from air cleaner upper cover. 5. Remove the air cleaner upper cover. 6. Remove the air cleaner element. INSTALLATION Install in the reverse order of removal. NOTE: Before installing the air cleaner upper cover, align the holes with protruding portions of air cleaner lower case, then secure the upper cover to the lower case. Page 4514 B292-B317 Page 1380 Page 660 F21-F61 Page 7090 Power Window Switch: Service and Repair POWER WINDOW CONTROL SWITCH REMOVAL 1. MAIN SWITCH 1. Disconnect the ground cable from battery. 2. Using a flat tip screwdriver, remove the screw cover. 3. Loosen the screw to remove the power window main switch. 4. Disconnect the connector. 2. SUB SWITCH 1. Disconnect the ground cable from battery. 2. Remove the screw which secures switch panel. 3. Remove the switch panel. Locations Brake Switch (Cruise Control): Locations Non-Turbo Model Locations Electrical Components Location Page 7271 (3) Install the modified check valve and valve cushion. Rear Check Valve on Forester Diagram Information and Instructions Brake Warning Indicator: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 1840 B380-f6 Page 5242 NOTE: Make sure that the installing direction of coil spring is as shown in the figure. 5) Set the coil spring correctly so that its end face fits well into the spring seat as shown in the figure. 6) Install the helper and dust cover to the piston rod. 7) Pull the piston rod fully upward, and install the rubber seat and spring seat. NOTE: Ensure that the upper spring seat is positioned as shown in the figure. 8) Install the strut mount to the piston rod, and then tighten a new self-locking nut temporarily. 9) Using a hexagon wrench to prevent strut rod from turning, tighten the self-locking nut with ST. ST 927760000 STRUT MOUNT SOCKET Locations System Relay: Locations Main Fuse Box (M/B) Tire Monitor System - Valve Stem Torque Tool Tire Monitoring System: Technical Service Bulletins Tire Monitor System - Valve Stem Torque Tool TPMS VALVE CORE TOOL Over the past year, we've all come to find out just how sensitive the Tire Pressure Monitoring System (TPMS) is to pressure fluctuations. There is a new tool out there that will properly torque the valve stem when you put it back in so that it's not under or over torqued which could possibly result in a leak. The one tool that we know of is manufactured by Vacula Automotive, and will torque the valve stem to 4 in. lbs. The part number is 72-088-0020. Subaru does not endorse or require that you get this tool. We just wanted to make you aware of it. Page 250 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 6384 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 4979 F61-R47 Page 1057 Rod extension H. 5.7 ± 0.5 mm (0.224 ± 0.020 inch) 3. BELT TENSION PULLEY 1. Check the mating surfaces of timing belt and contact point of adjuster rod for abnormal wear or scratches. Replace the belt tension pulley if faulty. 2. Check the belt tension pulley for smooth rotation. Replace if noise or excessive play is noted. 3. Check the belt tension pulley for grease leakage. 4. BELT IDLER 1. Check the belt idler for smooth rotation. Replace if noise or excessive play is noted. 2. Check the outer contacting surfaces of idler pulley for abnormal wear and scratches. 3. Check the belt idler for grease leakage. Page 2583 Crankshaft Position, Camshaft Position And Knock Sensors Locations Fuse: Locations Main Fuse Box (M/B) Fuse & Relay Box (F/B) Main Fuse Box (M/B) Secondary A/C Fuse Box Page 6462 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 634 13) Install the air intake chamber. (Non-turbo model) 14) Install the intercooler. (Turbo model) 15) Inspect the inhibitor switch. Locations Sensor Page 2858 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 1932 Thermostat: Testing and Inspection Thermostat Inspection 1. Replace the thermostat if the valve does not close completely at an ambient temperature or if the following test shows unsatisfactory results. 2. Immerse the thermostat and thermometer in water. Raise water temperature gradually, and measure the temperature and valve lift when the valve begins to open and when the valve is fully opened. During the test, agitate the water for even temperature distribution. The measurement should be to the specification. NOTE: ^ Leave the thermostat in a boiled water for more than five minutes before measuring the valve lift. ^ Hold the thermostat with a wire or the like to avoid contacting with the bottom of container. Starts to open: ..................................................................................................................................... ................................... 76 - 80°C (169 - 176°F) Fully opens: ............................................................... ............................................................................................................................. 91°C (196°F) Valve lift. ........................................................................................................................................................ ................ 9.0 mm (0.35 inch) or more Page 2824 F61-R47 Page 7245 R72-R145 R148 Fuel Level Sensor Fuel Level Sensor: Service and Repair Fuel Level Sensor Fuel Level Sensor REMOVAL WARNING: - Place "NO FIRE" signs near the working area. - Be careful not to spill the fuel. NOTE: Fuel level sensor is built in fuel pump assembly. 1. Remove the fuel pump assembly. 2. Disconnect the connector from the fuel pump bracket. 3. Remove the fuel temperature sensor. 4. Remove the bolt which installs the fuel level sensor on mounting bracket. INSTALLATION Install in the reverse order of removal. Page 4783 Neutral Safety Switch: Adjustments Inhibitor Switch ADJUSTMENT 1. Shift the select lever to N range. 2. Loosen the three inhibitor switch securing bolts. 3. Insert the ST as vertical as possible into the holes in inhibitor switch lever and switch body. ST 499267300 STOPPER PIN 4. Tighten the three inhibitor switch bolts. Tightening torque: 3.4 Nm (0.35 kgf-m, 2.5 ft. lbs.) 5. Repeat the above checks. If the inhibitor switch is determined to be faulty, replace it. Page 171 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 3982 3) Apply proper amount of liquid gasket to the entire oil pan mating surface. Liquid gasket: THREE BOND 1217B (Part No. K0877YA020) 4) Apply liquid gasket fully to three holes other than screw holes on transmission case. Liquid gasket: THREE BOND 1217B (Part No. K0877YA020) 5) Install the oil pan. Tightening torque: 5 Nm (0.5 kgf-m, 3.6 ft. lbs.) 6) Connect the connector of rear vehicle speed sensor. (MP-T model) 7) Connect the connector of rear vehicle speed sensor. (VTD model) Page 2212 Manifold Pressure/Vacuum Sensor: Service and Repair Manifold Absolute Pressure Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the connectors from manifold absolute pressure sensor. 3. Remove the manifold absolute pressure sensor from the throttle body. INSTALLATION Install in the reverse order of removal. NOTE: Replace the O-rings for the manifold absolute pressure sensor with new ones. Tightening torque: 1.6 N.m (0.16 kgf-m, 1.2 ft-lb) Page 438 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 2952 2. Connect the knock sensor connector. 3. Install the intercooler. 4. Connect the battery ground cable to battery. Page 2752 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 1909 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 2588 Data Link Connector: Diagrams Data Link Connector NOTE: This connector is used both for the general scan tools and Subaru Select Monitor. CAUTION: Do not connect any scan tools other than the general scan tools and Subaru Select Monitor, because the circuit for Subaru Select Monitor may be damaged. Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 3668 Ignition Control Module: Testing and Inspection INSPECTION For inspection, refer to IGNITION CONTROL SYSTEM, Diagnostics for Engine Starting Failure. Testing and Inspection Fuel Return Line: Testing and Inspection INSPECTION 1. Make sure that there are no cracks on the fuel pipes and fuel hoses. 2. Make sure that the fuel pipe and fuel hose connections are tight. Specifications Water Pump: Specifications When installing the water pump, tighten bolts in two stages in alphabetical sequence as shown in the figure. Tightening torque: First ........................................................................................................................ ................................................................ 12 Nm (1.2 kgf-m, 8.7 ft. lbs.) Second ................................ .................................................................................................................................................... 12 Nm (1.2 kgf-m, 8.7 ft. lbs.) Page 4935 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 7026 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 6798 B134-B136 Page 2402 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 5457 Ambient Temperature Sensor / Switch HVAC: Service and Repair Ambient Sensor REMOVAL 1. Open the front hood. 2. Disconnect the ground cable from battery. 3. Disconnect the ambient sensor connector. 4. Remove the ambient sensor from radiator lower panel. INSTALLATION Install in the reverse order of removal. Page 3439 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 6156 Seat Heater: Technical Service Bulletins A/C - Seat Heater Anchor Point Modification NUMBER: 07-57-06 DATE: 08/24/06 APPLICABILITY: 2006MY Forester and Impreza SUBJECT: Seat Heater Anchor Point Modification INTRODUCTION The purpose of this bulletin is to inform you that the number of seat cushion heater anchor points has been increased to improve the fit of the seat cushion heater and double-faced tape has been added to the seat back heater. PRODUCTION LINE CHANGE The modification was used in production November, 2005 with the following VINs: PART INFORMATION SERVICE INFORMATION (1) Front seat cushion heater: Anchor points have been increased. Note: The part number has not been changed. Page 3351 Intake Air Duct: Testing and Inspection INSPECTION 1. Inspect for cracks and loose connections. 2. Inspect that no foreign objects are mixed in intake duct. Page 5118 Alignment: Service and Repair Wheel Alignment INSPECTION Check the following items before taking wheel alignment measurement. Check items before taking wheel alignment measurement: tire air pressure ^ unbalanced right and left tire wear, size difference ^ tire run-out ^ ball joint excessive play, wear ^ tie rod end excessive play, wear ^ wheel bearing excessive play ^ right and left wheel base imbalance ^ steering link part deformed, excessive play ^ suspension part deformed, excessive play Check, adjust and/or measure the wheel alignment in accordance with procedures indicated in the figure: WHEEL ARCH HEIGHT 1) Set the vehicle on a level surface. 2) Set the vehicle to "curb weight" conditions. (Empty luggage compartment, install spare tire, jack, service tools, and top up fuel tank.) 3) Set the steering wheel in a straight line, then remove the vehicle straight ahead more than 5 m (16 ft.) to settle the suspension. 4) Suspend the thread from wheel arch (point "A" in figure below) to determine a point directly above center of wheel. 5) Measure the distance between measuring point "A" and center of wheel. Page 6215 Tailgate Release Handle: Service and Repair REAR GATE OUTER HANDLE REMOVAL 1. Remove the rear gate trim. 2. Remove the rear gate latch assembly. 3. Remove the two nuts to remove the rear gate outer handle. INSTALLATION Install in the reverse order of removal. NOTE: Make sure the rear gate outer handle works properly after installation. Page 1365 Harmonic Balancer - Crankshaft Pulley: Service and Repair Crank Pulley REMOVAL a. Remove the V-belt. b. Remove the crank pulley bolt. To lock the crankshaft, use ST. ST 499977100 CRANK PULLEY WRENCH c. Remove the crank pulley. INSTALLATION a. install the crank pulley. b. Install the pulley bolt. To lock the crankshaft, use ST. ST 499977100 CRANK PULLEY WRENCH 1. Clean the crank pulley thread using compressed air. 2. Apply engine oil to the crank pulley bolt seat and thread. 3. Tighten the bolts temporarily with tightening torque of 44 Nm (4.5 kgf-m, 33 ft. lbs.). 4. Tighten the crank pulley bolts. Tightening torque: 180 Nm (18.4 kgf-m, 132.8 ft. lbs.) c. Confirm that the tightening angle of crank pulley bolt is 65 degrees or more. If the tightening angle of crank pulley bolt is less than 65 degrees, conduct the following procedures. CAUTION: If the tightening angle of crank pulley bolt is less than 65 degrees, the bolt should be damaged. In this case, the bolt must be replaced. 1. Replace the crank pulley bolts and clean them. Crank pulley bolt: 12369AA011 2. Clean the crankshaft thread using compressed air. 3. Tighten the bolts temporarily with tightening torque of 44 Nm (4.5 kgf-m, 33 ft. lbs.). 4. Tighten the crank pulley bolts keeping them in an angle between 65 degrees and 75 degrees. NOTE: Conduct the tightening procedures by confirming the turning angle of crank pulley bolt referring to the gauge indicated on timing belt cover. d. Install the A/C belt tensioner. Control Unit (Manual A/C Model) Control Assembly: Service and Repair Control Unit (Manual A/C Model) Control Unit (Manual A/C Model) REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the glove box. 3. Remove the lower panel. 4. Remove the control wires. 5. Remove the console front panel. 6. Remove the center console panel. Page 6459 R58-R69 Page 4972 B128-B134 Page 1853 11. Remove the V-belt covers. 12. Disconnect the overflow hose. 13. Remove the reservoir tank. 14. Disconnect the radiator inlet hose (A) and water tank hose (B) from radiator. 15. Remove the radiator upper brackets. 16. While lifting the radiator up, slide it to the left. 17. Lift-up the radiator, and then remove it from vehicle. Page 4911 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Specifications Specification Page 7412 B54-B127 Page 2961 Page 1582 B380-f6 Page 4616 6. Position the boot in grooves on cylinder and piston. 7. Install the boot ring. Be careful not to scratch the boot. 3. 17 INCH TYPE 1. Clean the caliper body interior using brake fluid. 2. Apply a coat of brake fluid to the piston seal, and then install the piston seal in groove on caliper body. 3. Apply a coat of brake fluid to the entire inner surface of cylinder and outer surface of piston. 4. Apply a coat of specified grease to the boot and install it in the groove on piston. Grease: NIGLUBE RX-2 (Part No. K0779GA 102) 5. Insert the piston into cylinder. CAUTION: Do not force the piston into cylinder. 6. Position the boot in grooves on cylinder and piston. Page 3227 Page 656 B136-B141 Page 1783 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 5148 hoses and their service lives are shortening accordingly, it is necessary to perform the careful inspection frequently when the vehicle is used in hot weather areas, cold weather area and a driving condition in which many steering operations are required in short time. Particularly, continuous work of relief valve over 5 seconds causes to reduce service lives of the hoses, the oil pump, the fluid, etc. due to over heat. NOTE: It is likely that although one judges fluid leakage, there is actually no leakage. This is because the fluid spilt during the last maintenance was not completely wiped off. Be sure to wipe off spilt fluid thoroughly after maintenance. Page 5363 Condenser HVAC: Service and Repair Condenser REMOVAL 1. Using the refrigerant recovery system, discharge refrigerant. 2. Disconnect the ground cable from battery. 3. Remove the front bumper. 4. Disconnect the pressure hose and pipe from condenser. 5. Remove the radiator bracket (A). 6. Remove the two bolts. While lifting the condenser, pull it out through the space between radiator and radiator panel. CAUTION: Be careful not to damage the condenser fins. If a damaged fin is found, repair it using a thin screwdriver. - If the condenser is replaced, add appropriate amount of compressor oil to the compressor. INSTALLATION 1. Install in the reverse order of removal. Testing and Inspection Alarm Horn Relay: Testing and Inspection SECURITY HORN RELAY INSPECTION Measure the security horn relay resistance between terminals (indicated in the table) when connecting terminal No. 4 to battery positive terminal and terminal No. 1 to battery ground terminal. If NG, replace the security horn relay. Page 310 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 3467 B230-B283 Page 4298 7) Connect the rod to the joint. 8) Connect the stay to transmission bracket. 9) Install the rear exhaust pipe and muffler. ^ SOHC model ^ DOHC turbo model 10) Lower the vehicle. 11) Install the plate assembly to body. Page 878 Solenoid Valve And Switch (AT Model) Solenoid Valve And Switch (MT Model) Locations Electrical Components Location Page 1737 Locations Security System Testing and Inspection Tail Lamp Relay: Testing and Inspection TAIL AND ILLUMINATION RELAY Measure the tail and illumination relay resistance between terminals when connecting terminal No. 4 to battery positive terminal and terminal No. 3 to battery ground terminal. Page 3679 Disclaimer Page 6532 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 6177 B380-f6 Page 5409 Heater Core Case: Service and Repair Heater and Cooling Unit REMOVAL 1. Disconnect the ground cable from battery. 2. Using the refrigerant recovery system, discharge refrigerant. 3. Drain coolant from the radiator. 4. Remove the bolt securing expansion valve and pipe in engine compartment. Release the heater hose clamps in engine compartment to remove the hoses. 5. Remove the instrument panel. 6. Remove the support beam. 7. Remove the blower motor unit assembly. 8. Disconnect the servo motor connectors. 9. Loosen the bolt and nuts to remove the heater and cooling unit. INSTALLATION 1. Install in the reverse order of removal. 2. Charge refrigerant. Tightening torque: T: 7.4 N.m (0.75 kgf-m, 5.4 ft-lb) Diagrams Brake Hose/Line: Diagrams FRONT BRAKE PIPES AND HOSE Page 1942 2. Connect the hose to water pump. 3. Install the tensioner bracket. Tightening torque: 24.5 Nm (2.5 kgf-m, 18.1 ft. lbs.) 4. Install the belt cover No. 2 (LH). Tightening torque: 5 Nm (0.5 kgf-m, 3.6 ft. lbs.) 5. Install the cam sprockets (LH) by using ST. 6. Install the camshaft position sensor. 7. Install the belt idler No. 2 (c). 8. Install the belt idler (B). 9. Install the automatic belt tension adjuster (A) which has tension rod held by pin. ^ Tightening torque: 39 Nm (4.0 kgf-m, 28.9 ft. lbs.) Page 1568 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 3375 Install in the reverse order of removal. Combination Switch (Light) Combination Switch: Testing and Inspection Combination Switch (Light) INSPECTION Measure the resistance between combination switch terminals. 1. LIGHTING SWITCH 2. DIMMER AND PASSING SWITCH 3. TURN SIGNAL SWITCH Page 4620 2. Remove the piston boot. 3. Place a wooden block in caliper body as shown in the figure to prevent the piston from jumping out and avoid being damaged. 4. Gradually supply compressed air via the installation hole of brake hose to force the piston out. 5. Remove the piston seal from caliper body cylinder. CAUTION: Do not damage the cylinder and piston seal groove. 6. Remove the lock pin sleeve and boot from caliper body. 7. Remove the guide pin boot. 2. 15 INCH TYPE 1. Remove the boot ring. Page 4773 ^ Check the back-up light illumination when the select lever is in "R" range. ^ Check the parking lock operation when the select lever is in "F" range. 5) Using the Subaru Select Monitor, clear the diagnostic trouble codes stored in memory. If the codes return afier the correct adjustments, refer to the diagnostic procedure found in the applicable Subaru Service Manual. WARRANTY/CLAIM INFORMATION For vehicles within the Basic New Car Limited Warranty period, refer to the Subaru Warranty Wizard for claim submission information. Disclaimer Page 6427 - When painting or performing sheet metal work on the side of the vehicle, including the side sill, center pillar, and front and rear doors, remove the side airbag sensors and wire harness of the airbag system. - When storing a removed airbag module, do not place any objects on it or pile airbag modules on top of each other. If the airbag inflates for some reason when it is placed with its pad side facing downward or under any object, a serious accident may result. Page 3627 B292-B317 Page 5144 1) Temporarily tighten the two bolts fixing pipe C and D. (bolt A) NOTE: Visually check that the hose between tank and pipe D is free from bending or twisting. ^ Non-turbo model Non-turbo model ^ Turbo model and STI model Turbo model and STI model (1) Connect the pipe D to oil tank. (2) Using a new gasket, connect the pipe C to oil pump. (3) Tighten the two bolts fixing pipe C and D. (bolt A) 2) Install the coolant filler tank. (Turbo model) Page 4211 Be careful not to damage the inner oil seal lip and tone wheel. 3) Using the ST1 and ST2, pull the drive shaft into place. ST1 922431000 AXLE SHAFT INSTALLER ST2 927390000 ADAPTER 4) Tighten the axle nut temporarily. 5) Using the ST, install the front drive shaft to transmission. ST 28399SA010 OIL SEAL PROTECTOR 6) Connect the transverse link to housing. Tightening torque: 50 Nm (5.1 kgf-m, 37 ft. lbs.) 7) Install the stabilizer bracket. 8) While depressing the brake pedal, tighten the axle nut to specified torque. Tightening torque: 220 Nm (22.4 kgf-m, 162 ft. lbs.) CAUTION: ^ Always tighten the axle nut before installing wheel on vehicle. If the tire is installed and comes in contact with ground when axle nut is loose, wheel bearings may be damaged. ^ Do not overtighten it as this may damage the wheel bearing. 9) After tightening the axle nut, caulk and lock it. Rear Drive Shaft Removal Rear Drive Shaft REMOVAL 1) Disconnect the ground cable from battery. 2) Lift-up the vehicle, and remove the rear wheel. 3) Unlock the axle nut. Front Turn Signal Light Bulb Turn Signal Bulb: Service and Repair Front Turn Signal Light Bulb FRONT TURN SIGNAL LIGHT BULB REMOVAL 1. When removing the turn signal light bulb, fully turn the direction of tire to the opposite side of desired turn signal light bulb. 2. Remove the clip, and turn the mud guard inward. 3. Turn the socket (A) from wheel arch part, and then remove the front turn signal light bulb. INSTALLATION Install in the reverse order of removal. Page 1282 Wheels: Service Precautions Aluminum Wheel CAUTION Aluminum wheels are easily scratched. To maintain their appearance and safety, do the following: 1. Do not damage the aluminum wheels during removal, installation, wheel balancing, etc. After removing, place them on a rubber mat, etc. 2. While the vehicle is being driven, be careful not to ride over sharp obstacles or allow the wheels to contact the shoulder of road. 3. When installing a tire chain, be sure to install it properly not to have slack; otherwise it may hit the wheel while driving. 4. When washing the aluminum wheel, use neutral synthetic detergent and water. Avoid using the cleanser including abrasive, hard brushes or an automatic car washer. Page 3658 B230-B283 Page 6829 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 3078 Vehicle Speed Sensor: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 5065 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Diagram Information and Instructions Clock: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 5077 B134-B136 Page 6240 Non-Turbo Model Tire Monitor System - Valve Stem Torque Tool Tire Monitoring System: Technical Service Bulletins Tire Monitor System - Valve Stem Torque Tool TPMS VALVE CORE TOOL Over the past year, we've all come to find out just how sensitive the Tire Pressure Monitoring System (TPMS) is to pressure fluctuations. There is a new tool out there that will properly torque the valve stem when you put it back in so that it's not under or over torqued which could possibly result in a leak. The one tool that we know of is manufactured by Vacula Automotive, and will torque the valve stem to 4 in. lbs. The part number is 72-088-0020. Subaru does not endorse or require that you get this tool. We just wanted to make you aware of it. Page 3942 Fluid Filter - A/T: Service and Repair ATF Filter REMOVAL NOTE: The ATF filter is maintenance free. 1) Lift-up the vehicle. 2) Using ST, remove ATF filter. ST 498545400 OIL FILTER WRENCH INSTALLATION 1) Get new ATF filter and apply a thin coat of ATF to the oil seal. 2) Install ATF filter. Turn it by hand, being careful not to damage oil seal. 3) Using ST, tighten ATF filter. Calculate ATF filter torque specifications using the following formula. T2 = L2/(L1 + L2) x T1 T1: 14 Nm (1.4 kgf-m, 10.1 ft. lbs.) [Required torque setting] T2: Tightening torque L1: ST length 78 mm (3.07 inch) L2: Torque wrench length Example: NOTE: Align ST with torque wrench while tightening ATF filter. ST 498545400 OIL FILTER WRENCH 4) Add ATF. 5) Inspect level of ATF. INSPECTION Check for rust, hole, ATF leaks, and other damage. Page 4423 16) Lower the AT jack. NOTE: Do not separate the AT jack and transmission. 17) Remove the oil cooler inlet and outlet pipe. NOTE: When removing the outlet pipe, be careful not to lose balls and springs used with retaining screws. 18) Remove the front and torque converter turbine speed sensor. 19) Disconnect the connector of rear vehicle speed sensor. (VTD model) 20) Disconnect the connector from rear vehicle speed sensor. (MP-T model) Page 3081 Vehicle Speed Sensor: Service and Repair Vehicle Speed Sensor REMOVAL 1) Disconnect the ground cable from battery. 2) Lift-up the vehicle. 3) Remove the front, center and rear exhaust pipes and muffler. ^ Non-turbo model ^ Turbo model 4) Disconnect the connector from vehicle speed sensor. 5) Turn and remove the vehicle speed sensor. INSTALLATION NOTE: ^ When the vehicle speed sensor is removed, discard it and replace with a new one. ^ Ensure the sensor mounting hole is clean and free of foreign matter. ^ Align the tip end of key with key groove on end of speedometer shaft during installation. 1) Hand tighten the vehicle speed sensor. 2) Tighten the vehicle speed sensor using suitable tool. Tightening torque: 5.9 Nm (0.6 kgf-m, 4.3 ft. lbs.) 3) Connect the connector to vehicle speed sensor. 4) Install the front, center and rear exhaust pipes and muffler. ^ Non-turbo model ^ Turbo model 5) Lower the vehicle. 6) Connect the battery ground cable to battery. INSPECTION The vehicle speed sensor can not be inspected as a single unit. Check if speedometer operates normally. If it does not operate normally, inspect the combination meter system. Page 4180 Service and Repair Fuel Cut Control Unit: Service and Repair Fuel Cut Valve REMOVAL 1. Remove the fuel tank. 2. Remove the protect cover. 3. Move the clip and disconnect the evaporation hose from fuel cut valve. 4. Remove the bolts which install the fuel cut valve. INSTALLATION Install in the reverse order of removal. NOTE: Use a new gasket. Page 7161 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 4071 12) Move the range select lever to parking position (left side). 13) Remove the inhibitor switch from transmission. 14) Disconnect the inhibitor switch harness connector from inhibitor switch. INSTALLATION 1) Connect the inhibitor switch harness connector to inhibitor switch. 2) Install the inhibitor switch to transmission case. 3) Move the range select lever to neutral position. Page 6520 F61-R47 Diagnostic Aids Ignition Switch: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 6805 R58-R69 Page 5538 SRS Airbag Page 6809 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 3176 Catalytic Converter: Service and Repair Rear Catalytic Converter Rear Catalytic Converter REMOVAL 1. Remove the center exhaust pipe. 2. Separate the rear catalytic converter (B) from front catalytic converter (A). INSTALLATION NOTE: - Replace the gaskets with new ones. - Install in the reverse order of removal. Locations Electrical Components Location Page 3150 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 1939 Water Pump: Testing and Inspection Water Pump Inspection 1. Check the water pump bearing for smooth rotation. 2. Check the water pump pulley for abnormalities. 3. Check the impeller for damage or abnormal deformation. 4. Check the clearance between impeller and pump case. ^ Clearance between impeller and pump case: ^ Standard ........................................................................................................................................... .................... 0.5 - 1.5 mm (0.020 - 0.060 in) 5. After water pump installation, check the pulley shaft for engine coolant leaks. If leaks are noted, replace the water pump assembly. Locations Knock Sensor: Locations Sensor (Part 1) Page 2543 F21-F61 Page 1473 B230-B283 Page 6338 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 4893 armature. A short-circuited armature will cause the iron sheet to vibrate and to be attracted to core. If the iron sheet is attracted or vibrates, the armature, which is short-circuited, must be replaced or repaired. 5. Using a circuit tester, touch one probe to the commutator segment and the other to shaft. There should be no continuity. If there is continuity, the armature is grounded. Replace the armature if it is grounded. 2. YOKE Make sure the pole is set in position. 3. OVERRUNNING CLUTCH Inspect the teeth of pinion for wear and damage. Replace if it is damaged. It is normal if the pinion rotates smoothly in direction of rotation (counterclockwise) and does not rotate in the opposite direction. CAUTION: Do not clean the overrunning clutch with oil to prevent grease from flowing out. 4. BRUSH AND BRUSH HOLDER 1. Brush length Measure the brush length, and then replace if it is worn down to under the service limit. Replace if abnormal wear or cracks are noticed.. Brush length: Standard: 12.3 mm (0.484 in) Service limit: 7.0 mm (0.276 in) 2. Brush movement Be sure the brush moves smoothly inside brush holder. 3. Brush spring force Measure the brush spring force with a spring scale. If it is less than the service limit, replace the brush holder. Brush spring force: Standard Except DOHC turbo MT model 15.9 - 19.5 N (1.62 - 1.99 kgf, 3.57 4.38 lb) (when new) DOHC turbo MT model 21.6 N (2.2 kgf, 4.9 lb) (when new) Service limit Page 4327 Transmission Position Switch/Sensor: Service and Repair AT Shift Lock Solenoid and "P" Range Switch AT Shift Lock Solenoid and "P" Range Switch REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the console box. 3) Disconnect the connector. 4) Remove the grip. 5) Remove the indicator bulb from indicator cover. 6) Remove the indicator cover. 7) Remove the blind. 8) Remove the cushion. 9) Remove the clip, and then remove the "P" range switch. 10) Remove the cover. Page 1579 B136-B141 Page 866 ^ Check the back-up light illumination when the select lever is in "R" range. ^ Check the parking lock operation when the select lever is in "F" range. 5) Using the Subaru Select Monitor, clear the diagnostic trouble codes stored in memory. If the codes return afier the correct adjustments, refer to the diagnostic procedure found in the applicable Subaru Service Manual. WARRANTY/CLAIM INFORMATION For vehicles within the Basic New Car Limited Warranty period, refer to the Subaru Warranty Wizard for claim submission information. Disclaimer Page 2863 B134-B136 Page 2632 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 5181 Steering Gear: Service and Repair Steering Gearbox Disassembly DISASSEMBLY TURBO MODEL 1) Disconnect the pipes A and B from steering body and control valve housing. 2) Secure the gearbox removed from vehicle using a C-clamp. 3) Remove the tie-rod end and lock nut from gearbox. 4) Remove the clip on outside of boot using pliers, and then slide the boot to tie-rod end side. 5) Using flat tip screwdriver, remove the band from boot. NOTE: Check the boot for crack, damage or deterioration. Replace the boot with a new one if necessary. Page 2287 B292-B317 Recall 07V043000: Occupant Sensor Wiring Harness Seat Occupant Classification Module - Air Bag: Recalls Recall 07V043000: Occupant Sensor Wiring Harness MAKE/MODELS: MODEL/BUILD YEARS: Subaru/Forester 2006 Subaru/Impreza 2006 MANUFACTURER: Subaru of America, Inc. NHTSA CAMPAIGN ID NUMBER: 07V043000 MFG'S REPORT DATE: February 06, 2007 COMPONENT: Air Bags: Frontal POTENTIAL NUMBER OF UNITS AFFECTED: 7004 SUMMARY: On certain vehicles, the wiring harness for the air bag occupant detection system in the front passenger seat may have been pinched during production. Pinching of the wiring harness between the floor crossmember and the seat mounting bracket could result in a short circuit. CONSEQUENCE: The passenger's front air bag could become disabled and may not deploy in the event of a crash increasing the risk of injury to the seat occupant. Also an electrical short circuit could cause a fire. REMEDY: Dealers will inspect to see if the wiring had been incorrectly routed under the seat bracket. If so, the dealer will repair any damaged wiring, reroute and secure the wiring harness in the correct location, and re-calibrate the occupant detection system as necessary. The recall is expected to begin on or about March 5, 2007. Owners may contact Subaru at 1-800-782-2783. NOTES: Subaru recall No. WVC-13. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 953 B380-f6 Page 2634 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 6486 B136-B141 Page 4139 Clutch Pedal Assembly: Service and Repair Clutch Pedal REMOVAL 1) Remove the steering column. 2) Disconnect the connectors from stop light and clutch switches. 3) Remove the snap pins which secure lever to push rod and operating rod. 4) Remove the clevis pins which secure lever to push rod and operating rod. 5) Remove the air intake chamber. (Non-turbo model) 6) Remove the intercooler. (Turbo model) 7) Remove the nut which secures clutch master cylinder. 8) Remove the bolts and nuts which secure brake and clutch pedals, and remove the pedal assembly. INSTALLATION 1) Install in the reverse order of removal. NOTE: Always use new clevis pins. 2) Adjust the clutch pedal after installation. 3) Adjust the clutch switch (Starter interlock). DISASSEMBLY 1) Remove the clips, assist spring, rod and bushing. Page 3714 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Diagnostic Aids Ignition Switch: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 4310 2) Install the throttle body. ^ Non-turbo model ^ Turbo model 3) Install the air intake duct and cleaner case. (Non-turbo model) 4) Install the intercooler. (Turbo model) 5) Connect the battery ground cable to battery. CROSSMEMBER AND CUSHION RUBBER 1) Install the rear cushion rubber. Tightening torque: 35 Nm (3.6 kgf-m, 26 ft. lbs.) 2) Install the rear crossmember. 3) Remove the transmission jack. 4) Install the front and center exhaust pipes. (Non-turbo model) 5) Install the center exhaust pipe. (Turbo model) 6) Install the rear exhaust pipe and muffler. ^ Non-turbo model ^ Turbo model INSPECTION Repair or replace parts if the results of the inspection below are not satisfactory. PITCHING STOPPER Make sure the pitching stopper is not bent or damaged. Make sure the rubber is not stiff, cracked, or otherwise damaged. CROSSMEMBER AND CUSHION RUBBER Make sure the crossmember is not bent or damaged. Make sure the cushion rubber is not stiff, cracked, or otherwise damaged. Front Catalytic Converter Catalytic Converter: Testing and Inspection Front Catalytic Converter INSPECTION 1. Make sure there are no exhaust leaks from connections and welds. 2. Make sure there are no holes or rusting. Page 112 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Testing and Inspection Door Switch: Testing and Inspection DOOR SWITCH Measure the resistance between door switch terminals. Page 6299 Brake Warning Indicator: Testing and Inspection ABS Warning Light/Brake Warning Light Illumination Pattern INSPECTION 1. When the ABS warning light does not illuminate in accordance with this illumination pattern, there must be an electrical malfunction. 2. When the ABS warning light remains constantly OFF, repair the ABS warning light circuit or diagnosis circuit. NOTE: Even though the ABS warning light does not go out about 2 seconds after it illuminates, the ABS system operates normally when the warning light goes out while driving at approximately 12 km/h (7 MPH). However, the Antilock brakes do not work while ABS warning light is illuminated. Page 4924 B134-B136 Inhibitor Switch Neutral Safety Switch: Testing and Inspection Inhibitor Switch INHIBITOR SWITCH INSPECTION Measure the inhibitor switch resistance. If NG, replace the inhibitor switch. Page 3248 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 4460 3) Connect the brake pipes to their correct ABSCM&H;/U connections. Tightening torque:15 Nm (1.5 kgf-m, 10.8 ft. lbs.) 4) Using the cable clip, secure the ABSCM&H;/U harness to bracket. 5) Connect the connector to ABSCM&H;/U. NOTE: ^ Be sure to remove all foreign matter from inside of the connector before connecting. ^ Ensure that the ABSCM&H;/U connector is securely locked. 6) Connect the ground cable to ABSCM&H;/U, and then apply anti-corrosive wax. 7) Install the air cleaner case and air intake duct. 8) Bleed air from the brake system. REPLACEMENT CAUTION: ^ Because the seal of ABSCM cannot be replaced, do not pull or peel it with lifting up. ^ Because the screw part of H/U deteriorates in every replacement procedure, do not perform the replacement more than five times on it. When the malfunction is found though the replacement that performed is less than five times, replace the H/U body. ^ Use new screws for installation of ABSCM. ^ When the sealing surface of ABSCM or H/U is dirty or damaged and it cannot be removed or repaired, replace it with new one. 1) Remove the ABSCM&H;/U. 2) To prevent entering foreign matter and brake fluid leakage, plug the oil pressure port of ABSCM&H;/U using screw plug and etc. 3) Set the pump motor part of removed ABSCM&H;/U faces down in the vise. NOTE: Before securing a part on a vice, place cushioning material such as wood blocks, aluminum plate or cloth between the part and vice. 4) Using TORT BIT E5, remove the four screws of ABSCM. NOTE: Always use new screws. Page 1786 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 2077 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Locations Sensor Page 5588 airbag harness. Page 3060 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 5102 Additional labels are available through the Customer Dealer Services Department (CDS). CLAIM REIMBURSEMENT AND ENTRY PROCEDURES Credit to perform this recall will be based on the submission of properly completed repair order information. Dealers may enter the applicable claim information through their Dealer Communications System. Inspect - Use the applicable claim submission information for inspection of passenger front seat wire harness. Repair Wiring - Use the additional claim submission information for repair of the passenger front seat wire harness. Disclaimer Page 4309 Transmission Mount: Service and Repair Transmission Mounting System REMOVAL PITCHING STOPPER 1) Disconnect the ground cable from battery. 2) Remove the air intake duct. (Non-turbo model) 3) Remove the air cleaner case. (Non-turbo model) 4) Remove the intercooler. (Turbo model) 5) Remove the throttle body. ^ Non-turbo model ^ Turbo model 6) Remove the pitching stopper. CROSSMEMBER AND CUSHION RUBBER 1) Disconnect the ground cable from battery. 2) Jack-up the vehicle and support it with rigid racks. 3) Remove the front and center exhaust pipes. (Non-turbo model) 4) Remove the center exhaust pipe. (Turbo model) 5) Remove the rear exhaust pipe and muffler. ^ Non-turbo model ^ Turbo model 6) Set the transmission jack under the transmission body. CAUTION: Always support the transmission case with a transmission jack. 7) Remove the rear crossmember. 8) Remove the rear cushion rubber. INSTALLATION PITCHING STOPPER 1) Install the pitching stopper. Page 6568 B3-B12 Page 1837 B136-B141 Page 320 B136-B141 Page 3708 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 7244 R58-R69 Page 788 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 2891 Camshaft Position Sensor: Locations Sensor (Part 1) Page 5336 Blower Motor: Exploded Views Auto A/C Model Page 2972 The list shown above is of A/F Sensor related DTCs. (This list is for example only. Refer to the applicable service manual for a complete list of DTCs.) Note: When the DTCs for A/F sensor are stored in memory, do not replace the oxygen sensor. The list above is of O2 Sensor related DTCs. (This list is for example only. Refer to the applicable service manual for a complete list of DTCs.) Note: When the DTCs for O2 sensor are stored in memory, do not replace the A/F sensor. Page 2320 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 3548 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 6474 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 4503 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Service and Repair Rear Cross-Member: Service and Repair Rear Crossmember REMOVAL CAUTION: Do not subject the ABS wheel speed sensor harness to excessive tension. 1. Separate the front exhaust pipe and rear exhaust pipe. 2. Remove the rear exhaust pipe and muffler. 3. Remove the rear differential. 4. Place the transmission jack under rear crossmember. 5. Remove the bolts securing crossmember to vehicle body, and then remove the crossmember. 6. Scribe an alignment mark on the rear lateral link cam bolt and crossmember. 7. Remove the front and rear lateral links by loosening nuts. INSTALLATION NOTE: ^ Discard the loosened self-locking nut and replace it with a new one. ^ Always secure the bolt head and tighten the nut when tightening the adjusting bolt. 1. Install in the reverse order of removal. 2. For installation and tightening torque of rear differential. 3. Always tighten the rubber bushing when tires are in full contact with the ground and vehicle is curb weight. 4. Check the wheel alignment and adjust if necessary. INSPECTION Check the removed parts for wear, damage and cracks, and correct or replace if defective. Page 1127 5) Tighten the clamp E firmly. 6) Tighten the joint nut. 7) Connect the pipes A and B to four pipe joints of gearbox. Connect the upper pipe B first, and lower pipe A second. ^ Non-turbo model Non-Turbo Model ^ Turbo model Turbo Model Page 2194 B128-B134 Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 1539 17. Remove the engine harness connector from front harness connector. 18. Disconnect the connectors from the engine coolant temperature sensor (A), oil pressure switch (B) and crankshaft position sensor (C). 19. Disconnect the knock sensor connector. 20. Disconnect the connector from the camshaft position sensor. 21. Disconnect the connector from the ignition coil and ignitor assembly. Engine Controls - DTC P0340/P0345 After Camshaft R & R Camshaft Position Sensor: Customer Interest Engine Controls - DTC P0340/P0345 After Camshaft R&R Number: 02-107-09 Date: 03/24/09 Applicability: 2004~06MY Baja 2.5L Turbo 2004~06MY Impreza 2.5L Turbo 2004~06MY Forester 2.5L Turbo 2004~06MY Legacy/Outback 2.5L Turbo SUBJECT: Intake Camshaft Replacement Introduction If you encounter a vehicle that has a CEL and P0340 or P0345 stored in memory immediately after replacing the intake camshaft(s), the air gap between the camshaft and camshaft position sensor may be out of specification. A modification was made to the plate area of the camshaft where the camshaft position sensor picks up the signal. Parts Information Repair Procedure/ Information Using a feeler (thickness) gauge, measure the gap between the camshaft and camshaft position sensor. The correct gap is between 0.15mm to 0.98mm (0.0059 to 0.0386 in.) If the gap is over 0.98mm (0.0386 in.) replace the camshaft position sensor. Refer to the applicable service manual. Warranty/Claim Information For vehicles within warranty, refer the Subaru Warranty Wizard for claim submission information. Page 184 B136-B141 Page 3869 F61-R47 Page 2467 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 5379 7. Remove four screws. 8. Pull out the control unit and disconnect connectors. INSTALLATION Install in the reverse order of removal. Diagram Information and Instructions Oil Pressure Warning Lamp/Indicator: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 565 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Locations Main Fuse Box (M/B) Page 7350 Wiper Blade Heater: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Service and Repair Fuel Pressure Release: Service and Repair Fuel PROCEDURE RELEASING OF FUEL PRESSURE WARNING: - Place "NO FIRE" signs near the working area. - Be careful not to spill the fuel. 1. Disconnect the connector from the fuel pump relay. 2. Start and run the engine until it stalls. 3. After the engine stalls, crank it for five more seconds. 4. Turn the ignition switch to OFF. Page 2391 B134-B136 Page 2399 R72-R145 R148 Locations Fuel Level Sensor: Locations Page 1725 Water Pump: Testing and Inspection Water Pump Inspection 1. Check the water pump bearing for smooth rotation. 2. Check the water pump pulley for abnormalities. 3. Check the impeller for damage or abnormal deformation. 4. Check the clearance between impeller and pump case. ^ Clearance between impeller and pump case: ^ Standard ........................................................................................................................................... .................... 0.5 - 1.5 mm (0.020 - 0.060 in) 5. After water pump installation, check the pulley shaft for engine coolant leaks. If leaks are noted, replace the water pump assembly. Page 7297 Windshield Washer Spray Nozzle: Adjustments Front Washer Nozzle FRONT WASHER NOZZLE ADJUSTMENT 1. Turn the wiper switch to OFF position. 2. When the vehicle stops, adjust the washer fluid injection position as shown in the figure. Page 3740 3. Oil fouled: Wet black deposits show oil entrance into combustion chamber through worn rings and pistons or excessive clearance between valve guides and stems. 4. Overheating: White or light gray insulator with black or brown spots and bluish burnt electrodes indicates engine overheating. Moreover, the appearance results from incorrect ignition timing, loose spark plugs, wrong selection of fuel, hotter range plug, etc. Page 3724 F21-F61 Page 5846 Rear Bumper: Removal and Replacement REAR BUMPER Rear Bumper REMOVAL 1. WAGON MODEL 1. Disconnect the ground cable from battery. 2. Remove the bolt inside wheel house (both sides), and the clips on lower side of bumper. Combination Switch (Light) Combination Switch: Testing and Inspection Combination Switch (Light) INSPECTION Measure the resistance between combination switch terminals. 1. LIGHTING SWITCH 2. DIMMER AND PASSING SWITCH 3. TURN SIGNAL SWITCH Page 5658 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Front Catalytic Converter Catalytic Converter: Service and Repair Front Catalytic Converter Front Catalytic Converter REMOVAL 1. Remove the center exhaust pipe. 2. Separate the front catalytic converter (A) from rear catalytic converter (B). INSTALLATION NOTE: - Replace the gaskets with new ones. - Install in the reverse order of removal. Locations Crankshaft Position Sensor: Locations Sensor (Part 1) Page 6145 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 6546 B292-B317 Page 1051 2. TIMING BELT 1. Preparation for installation of automatic belt tension adjuster assembly. 2. Crankshaft and cam sprocket alignment 1. Align mark (A) on the crank sprocket with mark on the oil pump cover at cylinder block. 2. Align single line mark (A) on the exhaust cam sprocket (RH) with notch (B) on timing belt cover. 3. Align single line mark (A) on the intake cam sprocket (RH) with notch (B) on timing belt cover. (Make sure double lines (c) on intake camshaft and exhaust cam sprockets are aligned.) 4. Align single line mark (A) on exhaust cam sprocket (LH) with notch (B) on timing belt cover by turning the sprocket counterclockwise (as viewed from front of engine). Page 5149 Locations Electrical Components Location Locations Sensor Service and Repair Air Bag(s) Arming and Disarming: Service and Repair CAUTION: - When servicing a vehicle, be sure to turn the ignition switch to OFF, disconnect the ground cable from battery, and wait for more than 20 seconds before starting work. - The airbag system is fitted with a backup power source. If the airbag system is serviced within 20 seconds after the ground cable is disconnected, it may inflate. - If the airbag warning light illuminates, repair the vehicle immediately. Airbag or pretensioner may inflate incorrectly, or not inflate in collision. - If sensors, airbag module, airbag control module, pretensioner, and harness are deformed or damaged, replace them with new genuine parts. - When checking the airbag system, be sure to use a digital circuit tester. Infinitesimal electric current in an analog circuit tester may cause the airbag to activate erroneously. - When checking the airbag system, be sure to use a digital circuit tester. Infinitesimal electric current in an analog circuit tester may cause the airbag to activate erroneously. Page 4883 1. Connect the inhibitor switch harness connector to inhibitor switch. 2. Install the inhibitor switch to transmission case. 3. Move the range select lever to neutral position. 4. Using the ST, tighten the bolts of inhibitor switch. ST 499267300 STOPPER PIN Tightening torque: 3.5 Nm (0.36 kgf-m, 2.6 ft. lbs.) 5. Install the select cable to range select lever. 6. Install the plate assembly to transmission. Tightening torque: T: 25 Nm (2.5 kgf-m, 18 ft. lbs.) Page 2328 B292-B317 Removal and Installation Windshield Washer Motor: Service and Repair Removal and Installation WASHER TANK AND MOTOR REMOVAL 1. Open the hood. 2. Disconnect the ground cable from battery. 3. Remove the front bumper. 4. Remove the hose from L joint, and then drain washer fluid. 5. Remove the duct clip. 6. Remove the connector. 7. Remove the screw, and then remove the cover. Page 3637 2. Connect the knock sensor connector. 3. Install the intercooler. 4. Connect the battery ground cable to battery. Service and Repair Air Bag(s) Arming and Disarming: Service and Repair CAUTION: - When servicing a vehicle, be sure to turn the ignition switch to OFF, disconnect the ground cable from battery, and wait for more than 20 seconds before starting work. - The airbag system is fitted with a backup power source. If the airbag system is serviced within 20 seconds after the ground cable is disconnected, it may inflate. - If the airbag warning light illuminates, repair the vehicle immediately. Airbag or pretensioner may inflate incorrectly, or not inflate in collision. - If sensors, airbag module, airbag control module, pretensioner, and harness are deformed or damaged, replace them with new genuine parts. - When checking the airbag system, be sure to use a digital circuit tester. Infinitesimal electric current in an analog circuit tester may cause the airbag to activate erroneously. - When checking the airbag system, be sure to use a digital circuit tester. Infinitesimal electric current in an analog circuit tester may cause the airbag to activate erroneously. Page 6090 Trunk / Liftgate Lock: Service and Repair Trunk Lid Lock Assembly TRUNK LID LOCK ASSEMBLY REMOVAL 1. Remove the trunk lid key cylinder rod clamp. 2. Loosen two bolts to remove the trunk lid lock assembly. INSTALLATION Install in the reverse order of removal. NOTE: Apply grease to parts that rub. - Make sure the lock works properly after installation. Page 2239 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 2406 Variable Induction Position Sensor: Service and Repair NOTE: DO NOT remove the tumble generator valve position sensor from tumble generator valve assembly, since it cannot be adjusted during installation. Refer to "Tumble Generator Valve Assembly" for removal and installation procedures. Locations Electrical Component Location Page 7165 B3-B12 Page 7041 F21-F61 Page 2928 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 4391 B292-B317 Page 2344 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 3407 Air Flow Meter/Sensor: Service and Repair Mass Air Flow and Intake Air Temperature Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the connector from mass air flow and intake air temperature sensor. 3. Remove the mass air flow and intake air temperature sensor. INSTALLATION Install in the reverse order of removal. Tightening torque: 1.7 N.m (0.17 kgf-m, 1.3 ft-lb) A/C, Interior - Seat Heater Relay Updated Seat Heater Relay: Technical Service Bulletins A/C, Interior - Seat Heater Relay Updated change of seat heater relay In order to use a common seat heater relay with other models, FUT has changed the seat heater relay installed in Impreza and Forester vehicles from part number 8250TTC000 (brown) to 8250TFCT00 (black). The relay is located next to the fuse box under the lower dash panel on the driver side on vehicles equipped with seat heaters VIN breaks where the new relay has been installed are as shown. Front Grille Grille: Service and Repair Front Grille FRONT GRILLE REMOVAL 1. Remove the six clips (A). 2. Remove the clip on the upper side and the hooks on the right, left and lower sides, and remove the grille LH, grille RH and grille center. 3. Remove the screw and disassemble front grille. Page 2361 B380-f6 Testing and Inspection Fog/Driving Lamp Relay: Testing and Inspection FRONT FOG LIGHT RELAY Measure the front fog light relay resistance between terminals when connecting terminal No. 4 to battery positive terminal and terminal No. 3 to battery ground terminal. Page 4459 Hydraulic Control Assembly - Antilock Brakes: Service and Repair ABS Control Module and Hydraulic Control Unit (ABSCM&H;/U) REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the air intake duct and air cleaner case from the engine compartment to facilitate removal of ABSCM&H;/U. 3) Use compressed air to get rid of water around the ABSCM&H;/U. NOTE: Contact will be insufficient if the terminal gets wet. 4) Disconnect the ABSCM&H;/U connector pulling up the lock lever. CAUTION: Do not pull the harness when disconnecting connector. 5) Remove the harness clip. 6) Disconnect the brake pipes from ABSCM&H;/U. 7) Wrap the brake pipe using a vinyl bag not to spill the brake fluid on the vehicle body. CAUTION: When brake fluid is attached to the vehicle body, wash it off with water and wipe the water. 8) Remove the nuts and remove the ABSCM&H;/U. CAUTION: ^ Do not drop or bump the ABSCM&H;/U. ^ Do not turn ABSCM&H;/U upside down or place it sideways for storage. ^ Be careful that no foreign objects are mixed in ABSCM&H;/U. ^ Be careful that no water enters inside the connectors. 9) Remove the ABSCM&H;/U bracket. INSTALLATION 1) Install the ABSCM&H;/U bracket. Tightening torque:33 Nm (3.3 kgf-m, 24 ft. lbs.) 2) Install the ABSCM&H;/U aligning the groove of damper on ABSCM&H;/U side with the pawl of bracket. NOTE: Check the identification mark of ABSCM&H;/U. Tightening torque:7.5 Nm (0.76 kgf-m, 5.5 ft. lbs.) Specifications Wheel Bearing: Specifications Subaru does not specify a wheel bearing grease. Page 2525 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 6473 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 3152 Vehicle Speed Sensor: Service and Repair Vehicle Speed Sensor REMOVAL 1) Disconnect the ground cable from battery. 2) Lift-up the vehicle. 3) Remove the front, center and rear exhaust pipes and muffler. ^ Non-turbo model ^ Turbo model 4) Disconnect the connector from vehicle speed sensor. 5) Turn and remove the vehicle speed sensor. INSTALLATION NOTE: ^ When the vehicle speed sensor is removed, discard it and replace with a new one. ^ Ensure the sensor mounting hole is clean and free of foreign matter. ^ Align the tip end of key with key groove on end of speedometer shaft during installation. 1) Hand tighten the vehicle speed sensor. 2) Tighten the vehicle speed sensor using suitable tool. Tightening torque: 5.9 Nm (0.6 kgf-m, 4.3 ft. lbs.) 3) Connect the connector to vehicle speed sensor. 4) Install the front, center and rear exhaust pipes and muffler. ^ Non-turbo model ^ Turbo model 5) Lower the vehicle. 6) Connect the battery ground cable to battery. INSPECTION The vehicle speed sensor can not be inspected as a single unit. Check if speedometer operates normally. If it does not operate normally, inspect the combination meter system. Page 2528 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 4962 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 2280 B3-B12 Page 1633 Camshaft Gear/Sprocket: Service and Repair Cam Sprocket Removal 1. Remove the V-belt. 2. Remove the crank pulley. 3. Remove the timing belt cover. 4. Remove the timing belt. 5. Remove the cam sprockets. To lock the camshaft, use ST. ST 499207400 CAM SPROCKET WRENCH ST 499977500 CAM SPROCKET WRENCH Installation 1. Install the cam sprocket. To lock the camshaft, use ST. ST 499207400 CAM SPROCKET WRENCH Tightening torque: Tighten to 30 Nm (3.1 kgf-m, 22.1 ft. lbs.), then further tighten by 45° NOTE: Do not confuse the cam sprockets (RH) and (LH) intake side during installation. ST 499977500 CAM SPROCKET WRENCH Tightening torque: Tighten to 30 Nm (3.1 kgf-m, 22.1 ft. lbs.), then further tighten by 45° Page 1828 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 2358 B136-B141 Page 6034 9) Remove the clips, and then remove the roof trim. B: Installation Install in the reverse order of removal. Page 1702 Spark Plug: Specifications Type ..................................................................................................................................................... ............................................................. Manufacturer ILFR6B ................................................................................................................................................ .......................................................................... NGK Gap ...................................................................................................................................................... ................................. 0.7 - 0.8 mm (0.028 - 0.031 in) Torque ................................................................................................................................................. ........................................................ 21 N.m (15 ft.lb) Page 683 B3-B12 Page 3347 Fuel Temperature Sensor: Service and Repair Fuel Temperature Sensor REMOVAL Fuel temperature sensor and fuel level sensor are integrated into one unit; therefore, the removal procedure is the same as that for fuel level sensor. INSTALLATION Fuel temperature sensor and fuel level sensor are integrated into one unit; therefore, the installation procedure is the same as that for fuel level sensor. Page 974 Wiper Blade Heater Switch: Service and Repair WIPER DEICER SWITCH REMOVAL Remove the driver side lower cover, and then remove the wiper deicer switch. INSTALLATION Install in the reverse order of removal. Page 2022 B17-B20 Antitheft System - False Shock Sensor Activation Antitheft Motion Sensor: Technical Service Bulletins Antitheft System - False Shock Sensor Activation 15 FALSE SHOCK SENSOR ACTIVATION We have found that both the 06 MY Forester and 06 MY Impreza shock sensors can be activated using the select monitor without a shock sensor installed in the vehicle. In other words, the individual using the select monitor can access the screen to change the sensor setting from "off" to "on" status even though no sensor module has been installed. If this occurs, upon function testing the system: 1) After the normal 30 second interval the system will arm (as indicated with the change in the security system indicator light sequence) 2) At approximately a 3 - 4 second time period after system arming completion, the security alarm system will beep several times and then the alarm fully activates. If a security system shock system is erroneously activated without a sensor module actually installed, there is the possibility that the individual performing a system function test may be mislead into thinking that the system is operating normally upon hitting the steering wheel repeatedly as soon as the system arms. The system may automatically activate at the same time as shocks are applied by hitting the steering wheel. Upon discovering this possibility, we now caution all dealers that all shock sensor function testing is to occur only after waiting a period of at least six seconds after the security system is armed. This will identify any systems possibly missing shock sensor modules or modules that may be installed but not functioning correctly. Page 357 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 4038 7) Insert the thread portion of the other inner cable and into the connector hole of the select lever, and fix the other outer cable end to the bracket. Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft. lbs.) 8) Adjust the select cable position. 9) After completion of fitting, make sure that the select lever operates smoothly all across the operating range. 10) Install the rear exhaust pipe and muffler. ^ SOHC model ^ DOHC turbo model 11) Inspect the following items. If the following inspection reveals faults, adjust the select cable and inhibitor switch. (1) The engine starts operating when select lever is in range "P" and "N", but not in other ranges. (2) The back-up light is lit when the select lever is in range "R", but not in other ranges. (3) Select lever and indicator ranges are matched. DISASSEMBLY 1) Remove the packing. 2) Remove the grip. 3) Remove the indicator light, and then remove the indicator cover. NOTE: Be careful not to break the indicator light during removal. 4) Remove the blind. 5) Remove the cover. 6) Remove the clips, and then remove the guide plate. ATF Cooler Pipe and Hose Fluid Line/Hose: Service and Repair ATF Cooler Pipe and Hose ATF Cooler Pipe and Hose REMOVAL 1) Set the vehicle on a lift. 2) Remove battery and washer tank. 3) Lift-up the vehicle. 4) Remove the under cover. 5) Disconnect ATF cooler hose from radiator. NOTE: ^ Do not remove with a screwdriver or other pointed tools. ^ When the hose is difficult to remove, wrap a shop cloth around the hose to protect it. Turn it with pliers, and then pull directly out with your hand. 6) Disconnect ATF cooler hoses from pipes. NOTE: ^ Do not remove with a screwdriver or other pointed tools. ^ When the hose is difficult to remove, wrap a shop cloth around the hose to protect it. Turn it with pliers, and then pull directly out with your hand. 7) Remove ATF cooler pipe from frame. Page 2979 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 889 7. Install the washer and snap pin to range select lever. 8. Install the front and center exhaust pipes. (Nonturbo model) 9. Install the center exhaust pipe. (Turbo model) 10. Lower the vehicle. 11. Install the inhibitor switch connector from stay. 12. Connect the inhibitor switch connector. 13. Install the air intake chamber. (Non-turbo model) 14. Install the intercooler. (Turbo model) 15. Inspect the inhibitor switch. Page 244 B380-f6 Page 2383 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 6999 B17-B20 Page 3423 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 2976 Oxygen Sensor: Locations Location View Page 4116 NOTE: Apply grease to the clevis pin. 3) After bleeding air from the clutch system, ensure that clutch operates properly. 4) Install the air intake chamber. (Non-turbo model) 5) Install the intercooler. (Turbo model) DISASSEMBLY 1) Remove the straight pin and reservoir tank. 2) Remove the oil seal. 3) Move the cylinder boot backward. Page 3898 B134-B136 Page 4642 Page 4873 Solenoid Valve And Switch (AT Model) Solenoid Valve And Switch (MT Model) Page 7023 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Removal and Installation Intake Manifold: Service and Repair Removal and Installation Intake Manifold (Part 1) Page 4615 6. Position the boot in grooves on cylinder and piston. 7. Apply a coat of specified grease to the lock pin and guide pin outer surface, cylinder inner surface, and boot grooves. Grease: NIGLUBE RX-2 (Part No. K0779GA 102) 8. Install the lock and guide pin boot on support. 2. 16 INCH TYPE 1. Clean the caliper body interior using brake fluid. 2. Apply a coat of brake fluid to the piston seal and fit piston seal in groove on caliper body. 3. Apply a coat of brake fluid to the entire inner surface of cylinder and outer surface of piston. 4. Apply a coat of specified grease to the boot and fit in groove on ends of cylinder and piston. Grease: NIGLUBE RX-2 (Part No. K0779GA 102) 5. Insert the piston into cylinder. CAUTION: Do not force the piston into cylinder. Page 6204 Spoiler: Service and Repair Roof Spoiler ROOF SPOILER Roof Spoiler REMOVAL 1. Remove the bolt cap, and then remove the two bolts. 2. Remove the roof spoiler. INSTALLATION Install in the reverse order of removal. Tightening torque: 7.5 N.m (0.76 kgf-m, 5.5 ft-lb) Page 5499 8. STEERING SHAFT Check for the following, and replace damaged parts with new parts. Overall length of steering column should be within specifications. Specifications: Overall length L 818.7 ±1.5 mm (32.23 ±0.06 in) 9. DRIVER'S SEAT Check the following items and replace the damaged parts with new one. Seat belt buckle or seat position sensor body/bracket is cracked or deformed. - Harness or connector is cracked, deformed or disconnected. Harness wire is exposed. CAUTION: Do not remove the seat position sensor from seat rail. 10. PASSENGER'S SEAT 1. Check the following items and replace the damaged parts with new one. - Seat belt buckle body/bracket has scratch, crack or deformation. - Backrest frame has crack or deformation. - Headrest has deformation or play. - If the seat cushion cover or seat back cover is torn or frayed, replace the cover with new one and perform the system calibration. CAUTION: Check the following items, and if faulty, replace the seat cushion pad and frame as assembly. Never disassemble. - Seat cushion frame or seat cushion pad has crack or deformation. - Occupant detection system pressure sensor hose, occupant detection control module or its installing bracket has scratch, crack or deformation. - Harness or connector is cracked, deformed or disconnected. Harness wire is exposed. 2. After checking the installing condition of passenger s seat, perform the system calibration of occupant detection system. 11. BELT TENSION SENSOR Check the following items, and replace the damaged parts with new one. Belt tension sensor has scratch, crack or deformation. - Harness or connector is cracked, deformed or disconnected. Harness wire is exposed. Testing and Inspection Wiper Switch: Testing and Inspection COMBINATION SWITCH (WIPER) INSPECTION - Inspect the continuity between each connector terminal If continuity is not as specified, replace the switch. - Intermittent operation inspection (inspection of wiper switch unit) 1. Position the voltage meter between the connector terminals No. 7 (+) and No. 2 (-). 2. Connect the battery positive lead to connector terminal No. 17 and the negative lead to connector terminals No. 2 and No. 16. 3. Turn the wiper switch to INT. 4. Disconnect the battery negative lead from connector terminal No. 16. 5. Connect the battery positive lead to connector terminal No. 16 for 5 seconds. 6. Connect the battery negative lead to connector terminal No. 16, and check the voltage between the connector terminals No. 7 (+) and No. 2 (-). Page 3395 B134-B136 Locations Daytime Running Lamp Control Unit: Locations Area View Daytime Running Light Control Module - (B96, B242) Page 487 Crankshaft Position, Camshaft Position And Knock Sensors Page 4299 12) Pay attention to the direction of boot and insulator assembly and install them to the vehicle. 13) Install the clamp. 14) Install console box. DISASSEMBLY 5MT 1) Disassemble the lock wire. 2) Remove the rod from lever. Page 881 Neutral Safety Switch: Testing and Inspection Neutral Position Switch NEUTRAL POSITION SWITCH INSPECTION Non-Turbo Model Turbo Model STI Model Measure the neutral position switch resistance. If NG, replace the neutral position switch. Page 3374 Resonator: Service and Repair Resonator Chamber REMOVAL 1. Set the vehicle on a lift. 2. Remove the air intake duct. 3. Remove the air cleaner lower case. 4. Remove the resonator chamber mounting nut on right side of engine compartment. 5. Remove the front wheel RH, and lift up the vehicle. 6. Remove the front mud guard RH. 7. Remove the resonator chamber from the inside front fender. INSTALLATION Page 1498 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Locations Crankshaft Position Sensor: Locations Sensor (Part 1) Page 309 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Front Oxygen Sensor Oxygen Sensor: Service and Repair Front Oxygen Sensor Front Oxygen (A/F) Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the connector from the front oxygen (A/F) sensor. 3. Disconnect the engine harness fixed by clip (A) from the bracket (B). 4. Remove the front right side wheel. 5. Lift-up the vehicle. 6. Remove the service hole cover. 7. Apply spray type lubricant to the threaded portion of front oxygen (A/F) sensor, and leave it for one minute or more. 8. Remove the front oxygen (A/F) sensor. System Diagnosis Front Door Interior Handle: Testing and Inspection FRONT INNER REMOTE INSPECTION 1. Make sure the rod is not deformed. 2. Make sure the lever and rod work smoothly. Page 5642 4. OUTER SEAT BELT RH ASSEMBLY AND LH ASSEMBLY (WAGON MODEL) Install in the reverse order of removal. CAUTION: During installation, make sure that the seat belts are not twisted. - After installation, make sure that the seat belts can be smoothly extended and wound. 5. SHOULDER SEAT BELT CTR ASSEMBLY (WAGON MODEL) Install in the reverse order of removal. CAUTION: During installation, make sure that the seat belts are not twisted. - After installation, make sure that the seat belts are smoothly extended and wound. 6. CENTER SEAT BELT RH ASSEMBLY AND LH ASSEMBLY (WAGON MODEL) Install in the reverse order of removal. CAUTION: During installation, make sure that the seat belts are not twisted. INSPECTION 1. OUTER SEAT BELT RH ASSEMBLY AND LH ASSEMBLY (SEDAN MODEL) Check for the following, and replace with new parts if necessary. Seat belt is slackened, bent, or frayed. Seat belt is abnormally wound or extended. 2. SHOULDER SEAT BELT CTR ASSEMBLY (SEDAN MODEL) Check for the following, and replace with new parts if necessary. Seat belt is slackened, bent, or frayed. Seat belt is abnormally wound or extended. 3. CENTER SEAT BELT LH ASSEMBLY (SEDAN MODEL) Check for the following, and replace with new parts if necessary. Inner belt is deformed or damaged. - Seat belt buckle is engaged improperly. 4. OUTER SEAT BELT RH ASSEMBLY AND LH ASSEMBLY (WAGON MODEL) Check for the following, and replace with new parts if necessary. Seat belt is slackened, bent, or frayed. Seat belt is abnormally wound or extended. 5. SHOULDER SEAT BELT CTR ASSEMBLY (WAGON MODEL) Check for the following, and replace with new parts if necessary. Seat belt is slackened, bent, or frayed. Seat belt is abnormally wound or extended. 6. CENTER SEAT BELT RH ASSEMBLY AND LH ASSEMBLY (WAGON MODEL) Check for the following, and replace with new parts if necessary. - Inner belt is deformed or damaged. - Seat belt buckle is engaged improperly. Page 5098 2. Pull up the seat slide rail cover from the center console side as indicated by the arrows. 3. Check visually and with your fingers in the area indicated by broken lines to confirm that the body wiring harness (for power to the occupant detection ECU) is not located and/or pinched around the seat bracket. 4. If the wire is found to be located properly (not pinched), reinstall the seat slide rail cover. No further action is required. If the wire is found to be pinched, proceed to the "Wiring Repair Procedure". Impreza Inspection Procedure 1. Remove the center console trim between the select lever and the parking brake lever. If necessary, refer to the applicable service manual for removal instructions. 2. Cut the cross section of floor carpet in the center and in front of the parking brake lever with scissors (as shown, below). Note: Be careful not to damage wires around the work area. ^ Pull up the floor carpet to inspect a section of the subject body wiring harness from the clamping point located behind the shifter console down to the front passenger seat slide rail as indicated in the photo to the left. ^ Check visually and with your fingers to confirm that the wire is not located around the seat bracket area as indicated by the arrow in the photo Page 6281 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 4229 11) Install the circlip in the groove on DOJ outer race. NOTE: ^ Assure the balls, cage and inner race are completely fitted in the outer race of DOJ. ^ Exercise care not to place the matched position of circlip in ball groove of outer race. ^ Pull the shaft lightly and assure that the circlip is completely fitted in groove. 12) Apply an even coat of the specified grease [20 to 30 g (0.71 to 1.06 ounces)] to the entire inner surface of boot. Also apply grease to shaft. 13) Install the DOJ boot taking care not to twist it. NOTE: ^ Inside of the larger end of DOJ boot and boot groove shall be cleaned so as to be free from grease and other substances. ^ When installing the DOJ boot, position the outer race of DOJ at center of its travel. 14) Put a new band through the clip and wind twice in alignment with band groove of boot. NOTE: When tightening the boot, exercise care so that air within boot is appropriate. 15) Tighten the band using the ST. ST 925091000 BAND TIGHTENING TOOL NOTE: Tighten the band until it cannot be moved by hand. 16) Tap on the clip with the punch provided at the end of ST. ST 92509looo BAND TIGHTENING TOOL NOTE: Tap to an extent that the boot underneath is not damaged. Page 1006 Air Filter Element: Service and Repair Air Cleaner Element REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the connector from mass air flow and intake air temperature sensor. 3. Loosen the clamp (A) which connects the air intake boot and intake duct. 4. Remove the clip (B) from air cleaner upper cover. 5. Remove the air cleaner upper cover. 6. Remove the air cleaner element. INSTALLATION Install in the reverse order of removal. NOTE: Before installing the air cleaner upper cover, align the holes with protruding portions of air cleaner lower case, then secure the upper cover to the lower case. Page 190 R58-R69 Locations Air Flow Meter/Sensor: Locations Sensor (Part 1) Page 2537 B128-B134 Specifications Idle Speed: Specifications Idle speed [A/C "ON". no load and gears in neutral]: When the A/C refrigerant pressure is low MT .. .............................................................................................................................................................. ................................................. 725 ± 100 rpm AT .............................................................................. ..................................................................................................................................... 750 ± 100 rpm When the A/C refrigerant pressure is high MT .................................................................................... ............................................................................................................................. 800 ± 100 rpm AT .. .............................................................................................................................................................. ................................................... 825 ± 100 rpm Page 5849 14. Remove the six clips, and then remove the bumper side cover. 15. Remove the upper bracket from body. 2. SEDAN MODEL Refer to description about removal of rear bumper of wagon model. INSTALLATION 1. WAGON MODEL Install in the reverse order of removal. Tightening torque: Refer to COMPONENT in General Description. 2. SEDAN MODEL Install in the reverse order of removal. Tightening torque: Refer to COMPONENT in General Description. Page 2346 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 2729 Page 3578 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 4579 Brake Rotor/Disc: Testing and Inspection Rear INSPECTION 1. Check bearing axial end play and hub runout before disc rotor runout limit inspection. 2. Secure the disc rotor by tightening five wheel nuts. 3. Set a dial gauge 10 mm (0.39 inch) inward of rotor outer perimeter. Turn the disc rotor to check runout. If the disc rotor runout exceeds the service limit, resurface the disc rotor. After resurfacing, check disc rotor thickness as in step 4. Disc rotor runout limit. 0.070 mm (0.0028 inch) 4. Set a micrometer 10 mm (0.39 inch) inward of the rotor outer perimeter, and then measure the disc rotor thickness. If the thickness of disc rotor exceeds the service limit, replace with a new disc rotor. Page 4052 12) Move the transmission to right side, and then remove the stay bolt and reverse check cable. NOTE: If the transmission is not moved, the stay bolt will contact body and damage may occur. 13) Raise the clip of stay, and then separate the stay and reverse check cable. 14) Remove the reverse check cable by pulling from underneath the vehicle. NOTE: Take care not to damage the inner boot. 15) Loosen the lock nut, then remove the reverse check cable from cable plate. Page 1972 3. Lower the vehicle. 4. Connect the battery ground cable to battery. INSPECTION 1. Make sure there are no exhaust leaks from connections and welds. 2. Make sure there are no holes or rusting. 3. Make sure the cushion rubber is not worn or cracked. Page 4896 Turbo, MT model More than 2,860 rpm AT model More than 2,000 rpm 2. Load test Apply the specified braking torque to starter. The condition is satisfactory if the current draw and starter speed are within the specifications. Load test (standards): Voltage/Load Non-turbo, MT model 8 V/8.5 N.m (0.87 kgf-m, 6.3 ft-lb) Turbo, MT model 8 V/9.3 N.m (0.95 kgf-m, 6.9 ft-lb) AT model 8 V/9.8 N.m (1.0 kgf-m, 7.2 ft-lb) Current/Speed Non-turbo, MT model More than 280 A/970 rpm Turbo, MT model More than 280 A/860 rpm AT model More than 280 A/1,000 rpm 3. Lock test With the starter stalled, or not rotating, measure the torque developed and current draw when the voltage is adjusted to the specified voltage. Lock test (standards): Voltage/Current Non-turbo, MT model Less than 4 V/680 A Turbo, MT model Less than 4 V/515 A AT model Less than 3.5 V/960 A Torque Non-turbo, MT model 17 N.m (1.73 kgf-m, 12.5 ft-lb) Turbo, MT model 16 N.m (1.63 kgf-m, 11.8 ft-lb) AT model 31 N.m (3.16 kgf-m, 22.9 ft-lb) Testing and Inspection Trunk / Liftgate Release Lever: Testing and Inspection TRUNK LID RELEASE HANDLE INSPECTION 1. Make sure the cable is not deformed. 2. Make sure the lever works smoothly. Page 2625 Page 3228 Accelerator Pedal: Service Precautions CAUTION: - Wear work clothing, including a cap, protective goggles and protective shoes during operation. - Remove contamination including dirt and corrosion before removal, installation or disassembly. - Keep the disassembled parts in order and protect them from dust and dirt. - Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. - Be careful not to burn yourself, because each part on the vehicle is hot after running. - Be sure to tighten fasteners including bolts and nuts to the specified torque. - Place shop jacks or rigid racks at the specified points. - Before disconnecting electrical connectors of sensors or units, be sure to disconnect the ground cable from battery. Page 2112 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 5295 9) Remove the front hub unit bearing. If it is hard to remove, use STs. ST1 926470000 AXLE SHAFT PULLER ST2 28099PA110 AXLE SHAFT PULLER PLATE INSTALLATION 1) Tighten the front hub unit bearing to the housing with four bolts. 2) Install the front drive shaft. 3) Tighten the axle nut temporarily. 4) Install the disc rotor on hub. 5) Install the disc brake caliper on the housing. Tightening torque: 78 Nm (8.0 kgf-m, 57.9 ft. lbs.) 6) While depressing the brake pedal, tighten a new axle nut (olive color) to specified torque and lock it securely. Tightening torque: 220 Nm (22.4 kgf-m, 162 ft. lbs.) CAUTION: ^ Install the wheel after installation of the axle nut. Failure to follow this rule may damage the wheel bearing. ^ Do not overtighten it as this may damage wheel bearing. 7) After tightening the axle nut, lock it securely. Removal and Installation Alternator: Service and Repair Removal and Installation GENERATOR REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the connector and terminal from generator. - Non-Turbo model - Turbo model 3. Remove the V-belt cover. 4. Remove the front side V-belt. 5. Remove the bolts which install generator onto bracket. Page 2816 B54-B127 Page 5593 SRS Airbag Page 6139 B380-f6 Page 6100 2006 IMPREZA PAINT CODES Page 1476 F21-F61 Page 1934 ^ When reinstalling the thermostat, use a new gasket. ^ The thermostat must be installed with the jiggle pin (D) facing upward. ^ Tightening torque: 12 Nm (1.2 kgf-m, 8.7 ft. lbs.) 2. Fill engine coolant. Inspection 1. Replace the thermostat if the valve does not close completely at an ambient temperature or if the following test shows unsatisfactory results. 2. Immerse the thermostat and thermometer in water. Raise water temperature gradually, and measure the temperature and valve lift when the valve begins to open and when the valve is fully opened. During the test, agitate the water for even temperature distribution. The measurement should be to the specification. NOTE: ^ Leave the thermostat in a boiled water for more than five minutes before measuring the valve lift. ^ Hold the thermostat with a wire or the like to avoid contacting with the bottom of container. Starts to open: ..................................................................................................................................... ......................................... 76 - 80°C (169 - 176°F) Fully opens: ......................................................... ......................................................................................................................................... 91°C (196°F) Valve lift. ................................................................................................................................. ............................................. 9.0 mm (0.35 inch) or more Specifications Connecting Rod: Specifications CONNECTING ROD Bend twist per 100 mm (3.94 in) in length Limit .................................................................................. ................................................................................................................... 0.10 mm (0.0039 in.) Side clearance STD ............................................................................................................................. ............................................. 0.070 - 0.330 mm (0.0028 - 0.0130 in.) Limit ........................................ .............................................................................................................................................................. ... 0.4 mm (0.016 in.) Connecting Rod Cap Bolts Tighten ..................................................................................................... ............................................................................ 52 Nm (5.3 kgf-m, 38.4 ft. lbs.) NOTE: US: Undersize OS: Oversize ID: Inside Diameter OD: Outside Diameter Page 1204 Power Steering Fluid: Service and Repair Power Steering Fluid REPLACEMENT 1) Lift up the vehicle. 2) Remove the jack up plate. 3) Remove the pipe joint in center of gear box, and then install the vinyl hose to pipe and joint. Drain the fluid while turning steering wheel. 4) Set the ST on top of reservoir tank and fill it about half way with the specified fluid. ST 34199AE040 OIL CHARGE GUIDE 5) Continue to turn the steering wheel slowly from lock to lock until bubbles stop appearing on oil surface while keeping the fluid at that level. 6) If turning the steering wheel in low fluid level condition, air will be sucked in pipe. In this case, leave it about half an hour and then do the step 5) again. 7) Lift up the vehicle, start the engine and let it idle. 8) Continue to turn the steering wheel slowly from lock to lock again until bubbles stop appearing on oil surface while keeping the fluid at that level. It is normal that bubbles stop appearing after three times turning of steering wheel from lock to lock. 9) In case the bubbles do not stop appearing in the tank, leave it about half an hour and then do the step 4) all over again. 10) Lower the vehicle, and then idle the engine. 11) Continue to turn the steering wheel from lock to lock until bubbles stop appearing and change of the fluid level is within 3 mm (0.12 inch). 12) In case the following happens, leave it about half an hour and then do step 8) to 11) again. (1) The fluid level changes over 3 mm (0.12 inch). (2) Bubbles remain on the upper surface of the fluid. (3) Grinding noise is generated from oil pump. 13) Check the fluid leakage after turning steering wheel from lock to lock with engine running. Page 3425 B3-B12 Page 532 R58-R69 Page 1855 8. Install the air intake duct. 9. Lift-up the vehicle. 10. Connect the ATF cooler hoses. (AT model). 11. Connect the radiator outlet hose. 12. Connect the connectors to radiator main fan motor (A) and sub fan motor (B). 13. Install the undercover. 14. Lower the vehicle. 15. Connect the battery ground cable to battery. 16. Fill engine coolant. Specifications Compression Check: Specifications Compression (at 200 - 300 rpm): Standard ................................................................................................................................................... 981 1,177 kPa (10 - 12 kgf1cni2, 142 - 171 psi) Difference between cylinders ....................................................................................................................................... Less than 49 kPa (0.5 kgf1cm, 7 psi) Page 6292 F21-F61 Page 2043 Engine Control Module: Service and Repair Engine Control Module (ECM) REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the lower inner trim of the passenger side. 3. Detach the floor mat of the front passenger seat. 4. Remove the protect cover. 5. Remove the nuts (A) which hold ECM to the bracket. 6. Remove the clip (B) from the bracket. 7. Disconnect the ECM connectors and take out the ECM. INSTALLATION Install in the reverse order of removal. CAUTION: - When replacing ECM, use of wrong spec. ECM may lead to damage to the fuel injection system. - When replacing ECM, do not damage the harnesses and connectors. Tightening torque: 5 N.m (0.5 kgf-m, 3.7 ft-lb) Page 1123 5) Disconnect the pipe C and D from gear box. 6) Non-turbo model (1) Remove the air intake duct. (2) Remove the bolt A. (3) Disconnect the pipe C from oil pump. Disconnect the pipe D from return hose. CAUTION: ^ Do not allow fluid from the hose end to come into contact with pulley belt. ^ To prevent foreign matter from entering the hose and pipe, cover the open ends of them with a clean cloth. Page 676 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 1439 Oil Filter: Tools and Equipment Oil Filter Wrench AST tool# 5040 66.5mm, 14 flats, Oil Filter Wrench for Subaru. Fits all 2.5L 4-cylinder motors (except Justy and Loyale). Fits both Subaru factory filter #15208AA100 and Suzuki factory filter #16510-03G00. Also fits 2008 U.S. model Smart Car. - 66.5mm with 14 Flats - Applicable to Subaru 2.5L 4-Cylinder Motors (except Justy and Loyale) - Fits Suzuki factory filter# 16510-03G00 - Fits 2008 U.S. Model Smart Car - Made in USA Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Page 1480 Oil Pressure Sender: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 6274 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 786 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 3900 B230-B283 Page 3405 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 4690 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 6994 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 2813 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 3072 B292-B317 Page 3905 R58-R69 Page 7083 R58-R69 Page 909 16) Lower the AT jack. NOTE: Do not separate the AT jack and transmission. 17) Remove the oil cooler inlet and outlet pipe. NOTE: When removing the outlet pipe, be careful not to lose balls and springs used with retaining screws. 18) Remove the front and torque converter turbine speed sensor. 19) Disconnect the connector of rear vehicle speed sensor. (VTD model) 20) Disconnect the connector from rear vehicle speed sensor. (MP-T model) Page 6504 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. A/T Controls - DTC P0851/P0852 Set Neutral Safety Switch: Customer Interest A/T Controls - DTC P0851/P0852 Set NUMBER: 16-68-06 DATE: 10/09/06 APPLICABILITY: 2005~06MY Legacy, Outback, Impreza and Forester Vehicles Equipped with 4EAT SUBJECT: Diagnostic procedures for P0851/P0852 INTRODUCTION The purpose of this bulletin is to assist when diagnosing P0851 (Neutral Switch Input Circuit Low) and P0852 Neutral Switch Input Circuit High). If you encounter a vehicle with P0851 and/or P0852, use the following repair procedure. REPAIR PROCEDURE/INFORMATION Using the Subaru Select Monitor, check for diagnostic trouble codes stored in memory. If P0851 and/or P0852 are stored in memory, adjust the inhibitor switch and select cable. Note: Refer to the applicable Subaru Service Manual found on the STIS web-site for component removal to gain access to the inhibitor switch and select cable. It is critical that the following adjustments are performed correctly. Adjustment for inhibitor switch 1) Set the select lever to "N" range. 2) Loosen the three inhibitor switch securing bolts. 3) Insert ST (special tool) 499267300 Stopper Pin as vertical as possible into the holes in the inhibitor switch lever and switch body. 4) Tighten the three inhibitor switch securing bolts then remove special tool. Tightening torque: 3.4 N-m (0.35 kgf-m, 2.5 ft-lb) Adjustment for select cable Page 4877 Neutral Safety Switch: Testing and Inspection Inhibitor Switch (AT Model) INHIBITOR SWITCH (AT MODEL) Measure the resistance between inhibitor switch terminals. Front Brake Pad: Testing and Inspection Front INSPECTION 1. 15 INCH TYPE Check the pad thickness A. NOTE: ^ Always replace the pads for both right and left wheels at the same time. ^ Also replace the pad clips if they are twisted or worn. ^ A wear indicator is provided on the inner disc brake pad. If the pad wears down to such an extent that the end of wear indicator contacts disc rotor, a squeaking sound is produced as the wheel rotates. If this sound is heard, replace the pad. ^ Replace the pad if there is oil or grease on it. 2. 16 INCH TYPE Check the pad thickness A. NOTE: ^ Always replace the pads for both right and left wheels at the same time. ^ Also replace the pad clips if they are twisted or worn. ^ A wear indicator is provided on the inner disc brake pad. If the pad wears down to such an extent that the end of wear indicator contacts disc rotor, a squeaking sound is produced as the wheel rotates. If this sound is heard, replace the pad. ^ Replace the pad if there is oil or grease on it. 3. 17 INCH TYPE Check the pad thickness A. Page 2538 B134-B136 Page 2165 9. Remove the fuel sub level sensor. INSTALLATION Install in the reverse order of removal. NOTE: Use a new gasket. 1. Ensure the sealing portion is free from fuel foreign particles before installation. 2. Tighten the nuts and bolts to specified torque the order as shown in the figure. Testing and Inspection Turn Signal Switch: Testing and Inspection INSPECTION Measure the resistance between combination switch terminals. 1. LIGHTING SWITCH 2. DIMMER AND PASSING SWITCH 3. TURN SIGNAL SWITCH Page 7170 B136-B141 Page 962 2. Measure the sub switch resistance. 3. If NG, replace the sub switch. Engine Controls - DTC P0340/P0345 After Camshaft R & R Camshaft Position Sensor: Customer Interest Engine Controls - DTC P0340/P0345 After Camshaft R&R Number: 02-107-09 Date: 03/24/09 Applicability: 2004~06MY Baja 2.5L Turbo 2004~06MY Impreza 2.5L Turbo 2004~06MY Forester 2.5L Turbo 2004~06MY Legacy/Outback 2.5L Turbo SUBJECT: Intake Camshaft Replacement Introduction If you encounter a vehicle that has a CEL and P0340 or P0345 stored in memory immediately after replacing the intake camshaft(s), the air gap between the camshaft and camshaft position sensor may be out of specification. A modification was made to the plate area of the camshaft where the camshaft position sensor picks up the signal. Parts Information Repair Procedure/ Information Using a feeler (thickness) gauge, measure the gap between the camshaft and camshaft position sensor. The correct gap is between 0.15mm to 0.98mm (0.0059 to 0.0386 in.) If the gap is over 0.98mm (0.0386 in.) replace the camshaft position sensor. Refer to the applicable service manual. Warranty/Claim Information For vehicles within warranty, refer the Subaru Warranty Wizard for claim submission information. Page 6276 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 201 SRS Airbag Page 3806 3) Apply proper amount of liquid gasket to the entire oil pan mating surface. Liquid gasket: THREE BOND 1217B (Part No. K0877YA020) 4) Apply liquid gasket fully to three holes other than screw holes on transmission case. Liquid gasket: THREE BOND 1217B (Part No. K0877YA020) 5) Install the oil pan. Tightening torque: 5 Nm (0.5 kgf-m, 3.6 ft. lbs.) 6) Connect the connector of rear vehicle speed sensor. (MP-T model) 7) Connect the connector of rear vehicle speed sensor. (VTD model) Specifications Brake Fluid: Specifications Fluid Type ......................................................................................................................................................... FMVSS No. 116 DOT 3or 4 Brake Fluid Page 4486 Brake Pedal Assy: Description and Operation Brake Pedal The brake pedal is provided with a mechanism to control movement to the rear in case of a frontal collision to minimize injury to the driver's legs. If the brake pedal is pushed rearwards in case of a frontal collision, the brake pedal comes in contact with the catcher. If the brake pedal is pressed further, the brake pedal will come apart from the pedal side bracket. The brake pedal will move along the brake catcher. Diagrams OPERATING CYLINDER Page 4215 6) Install the stabilizer link. ^ Except STI model Except STI model ^ STI model STI model 7) Install the ABS wheel speed sensor. Page 7406 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 657 B230-B283 Page 2362 F21-F61 Page 1671 Timing Cover: Testing and Inspection INSPECTION Make sure the cover is not damaged. Page 3033 F21-F61 Front Oxygen Sensor Oxygen Sensor: Service and Repair Front Oxygen Sensor Front Oxygen (A/F) Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the connector from the front oxygen (A/F) sensor. 3. Disconnect the engine harness fixed by clip (A) from the bracket (B). 4. Remove the front right side wheel. 5. Lift-up the vehicle. 6. Remove the service hole cover. 7. Apply spray type lubricant to the threaded portion of front oxygen (A/F) sensor, and leave it for one minute or more. 8. Remove the front oxygen (A/F) sensor. Page 6840 B54-B127 Page 5074 B17-B20 Page 5682 Impact Sensor: Description and Operation IMPACT SENSOR OPERATION 1. IMPACT SENSOR SETTING USING SUBARU SELECT MONITOR 1. Connect the Subaru Select Monitor to data link connector. 2. Turn the ignition switch to ON. 3. Select {Keyless Unit} from the main menu. 4. Select {ECU customizing}. 5. Make a impact monitor setting. - When installing: ON - When removing: OFF 6. Make a impact monitor ON/OFF setting. - When installing: ON - When removing: OFF 7. Turn the ignition switch to OFF, and then remove the Subaru Select Monitor. Locations Coolant Temperature Sensor/Switch (For Computer): Locations Sensor (Part 1) Page 6465 Oil Pressure Sender: Testing and Inspection INSPECTION Step 1-Step 3 Make sure oil does not leak or seep from where the oil pressure switch is installed. Page 2122 B292-B317 Service and Repair Control Module: Service and Repair Transmission Control Module (TCM) REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the lower cover and then disconnect the connector. 3) Remove the knee bolster. 4) Disconnect the connectors from TCM. 5) Remove the TCM. INSTALLATION 1) Install the TCM. 2) Connect the connectors to TCM. 3) Install in the reverse order of removal. 4) If replacing the TCM, execute the advance operation of learning control promotion. Page 1922 F61-R47 Page 1613 B134-B136 Specifications Valve Clearance: Specifications Valve clearance: STD Intake ............................................................................................................... ........................................................ 0.20 ± 0.02 mm (0.0079 ± 0.0008 inch) Exhaust ....................... ............................................................................................................................................. 0.35 ± 0.02 mm (0.0138 ± 0.0008 inch) Page 3852 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 4618 Brake Caliper: Service and Repair Rear 5GRear Disc Brake Assembly REMOVAL 1. 14 INCH TYPE CAUTION: Do not allow brake fluid to come in contact with vehicle body; wash away immediately with water and wipe off completely if spilled. 1. Set the vehicle on a lift. 2. Loosen the wheel nuts. 3. Lift-up the vehicle, and then remove the wheels. 4. Disconnect the brake hose from caliper body assembly. 5. Remove the bolt securing lock pin to caliper body. 6. Raise the caliper body and move it toward vehicle center to separate it from support. 7. Remove the support from housing. NOTE: Remove the support only when replacing it or the disc rotor. It need not be removed when servicing the caliper body assembly. 8. Clean mud and foreign particles from the caliper body assembly and support. CAUTION: Be careful not to allow foreign particles to enter brake hose connector. 2. 15 INCH TYPE CAUTION: Do not allow brake fluid to come in contact with vehicle body; wash away at once with water and wipe off completely if spilled. 1. Set the vehicle on a lift. 2. Loosen the wheel nuts. 3. Lift-up the vehicle, and then remove the wheels. 4. Remove the pads from caliper body. 5. Disconnect the brake hose from caliper body assembly. 6. Remove the caliper body from housing. 7. Clean mud and foreign particles from the caliper body assembly. CAUTION: Be careful not to allow foreign particles to enter brake hose connector. 3. 17 INCH TYPE CAUTION: Do not allow brake fluid to come in contact with vehicle body; wash away immediately with water and wipe off completely if spilled. Page 2637 B3-B12 Page 4235 9) Remove the front hub unit bearing. If it is hard to remove, use STs. ST1 926470000 AXLE SHAFT PULLER ST2 28099PA110 AXLE SHAFT PULLER PLATE INSTALLATION 1) Tighten the front hub unit bearing to the housing with four bolts. 2) Install the front drive shaft. 3) Tighten the axle nut temporarily. 4) Install the disc rotor on hub. 5) Install the disc brake caliper on the housing. Tightening torque: 78 Nm (8.0 kgf-m, 57.9 ft. lbs.) 6) While depressing the brake pedal, tighten a new axle nut (olive color) to specified torque and lock it securely. Tightening torque: 220 Nm (22.4 kgf-m, 162 ft. lbs.) CAUTION: ^ Install the wheel after installation of the axle nut. Failure to follow this rule may damage the wheel bearing. ^ Do not overtighten it as this may damage wheel bearing. 7) After tightening the axle nut, lock it securely. Page 2146 Disclaimer Wheels/Tires - Highway Speed Vibration/Harshness/Noise Wheels: All Technical Service Bulletins Wheels/Tires - Highway Speed Vibration/Harshness/Noise NUMBER: 05-50-10R DATE: 02/03/11 APPLICABILITY: All Subaru Vehicles SUBJECT: Noise, Vibration and Harshness (NVH) at Highway Speeds Caused by a Tire Imbalance or Excessive Radial Force INTRODUCTION This bulletin is to serve as information only and is intended to help minimize steering wheel vibrations at highway speed. DESCRIPTION Some customers may describe a concern of a steering wheel vibration, oscillation or a "shimmy" condition at highway speeds that may be caused by improper tire and wheel balance or excessive radial force variation (RFV). Subaru of America Inc. (SOA) recommends the use of the Hunter GSP 9700 Wheel Balance and Road Force Measurement System to properly balance the wheel and tire assemblies "dynamically" and to measure the radial force variation of the wheel and tire assembly. While the majority of these conditions can be greatly reduced with proper wheel balancing, some road feel may be considered characteristic and can be compared to like model vehicles with similar mileage. Wheel Imbalance The two most common types of wheel imbalances are static (single weight plane) and dynamic (dual weight plane). A static imbalance is best described as a vertical imbalance when the assembly is mounted on the vehicle. A dynamic imbalance is defined as a vertical and inner/outer imbalance while the assembly is mounted on the vehicle. Wheel and tire assembly imbalance should be addressed first as this is the most common source of tire and wheel vibrations. A well maintained dual weight plane balancer (commonly known as a Dynamic Balancer) such as a Hunter G5P9700 should be used to achieve the best possible results. Balancer settings and proper maintenance are critical to obtaining the best results. Refer to the operating instructions as provided by the balancer manufacturer for setup and maintenance instructions. Radial Force Variation (RFV) Radial force variation is an industrial measurement describing the tire uniformity under load. These variations, or harmonics, are measured in kilograms, pounds or newtons. SOA asks that all weight measurements be reported using the metric system (grams, kilograms, etc.) The Hunter GSP 9700 Road Force Measurement System is capable of measuring these harmonics and displaying them as R1H (radial first harmonic), R2H (radial second harmonic) and R3H (radial third harmonic.) These different harmonic levels indicate the number of bad occurrences per revolution. Most commonly, radial first (R1H) harmonics are the cause of steering wheel or body related vibrations that can be felt at highway speeds. Radial force variation can be greatly affected if the vehicle has been parked for an extended period of time causing flat spots or by improper tire inflation. Before performing any diagnosis~ be sure to drive the vehicle at least 10 miles and adjust tire pressures as indicated on the door label. Machine Setup SOA recommends the use of the Hunter GSP 9700 Road Force Measurement System to properly balance and measure radial force on tire and wheel assemblies. To ensure the most accurate results, the following guidelines should be used: ^ Refer to the operating instructions to set the machine to measure in grams (for balancing) and kilograms (for radial force measurements) ^ Refer to the operating instructions to enable the dynamic balancing mode ^ Refer to the operating instructions to disable the Quickmatch(TM) function, if available. ^ Select the "Mixed Weights Balance" mode and measure the weight location carefully. ^ Calibration should be checked at least once per week ^ Ensure the arbor threads and base plate are clean and in good condition ^ Measure the wheel center bore and select the proper cone for mounting the wheel to the balancer Page 2629 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 770 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the bolt which installs the crankshaft position sensor to cylinder block. 3. Remove the crankshaft position sensor, and disconnect the connector from it. INSTALLATION Install in the reverse order of removal. Page 7228 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Capacity Specifications Differential Fluid - A/T: Capacity Specifications Automatic Transmission Differential Gear Oil Fluid Capacity ...................................................................................................................................... ......................... 1.2 liter (1.3 US qt, 1.1 Imp qt) Fluid Type API GL-5 (See figure above for applicable viscosity) Page 3591 B134-B136 Page 6290 B292-B317 Page 2254 F61-R47 Page 4994 2. Pull up the seat slide rail cover from the center console side as indicated by the arrows. 3. Check visually and with your fingers in the area indicated by broken lines to confirm that the body wiring harness (for power to the occupant detection ECU) is not located and/or pinched around the seat bracket. 4. If the wire is found to be located properly (not pinched), reinstall the seat slide rail cover. No further action is required. If the wire is found to be pinched, proceed to the "Wiring Repair Procedure". Impreza Inspection Procedure 1. Remove the center console trim between the select lever and the parking brake lever. If necessary, refer to the applicable service manual for removal instructions. 2. Cut the cross section of floor carpet in the center and in front of the parking brake lever with scissors (as shown, below). Note: Be careful not to damage wires around the work area. ^ Pull up the floor carpet to inspect a section of the subject body wiring harness from the clamping point located behind the shifter console down to the front passenger seat slide rail as indicated in the photo to the left. ^ Check visually and with your fingers to confirm that the wire is not located around the seat bracket area as indicated by the arrow in the photo Page 6562 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 6575 B292-B317 Page 3392 B17-B20 Page 2094 Ignition Control Module: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 5049 Fuse & Relay Box (F/B) Page 4035 8) Install the rear exhaust pipe and muffler. 9) Install the console box. INSPECTION 1) Verify whether the slider moves smoothly. If not, adjust the reverse check cable or check damage of slider. 2) Check that the gear can be shift to reverse, when the slider is pulled up. If the gear can not be shift to reverse, adjust the reverse check cable. 3) Check that the gear can not be shift to reverse, when the slider is not pulled up. If the gear can be shift to reverse, adjust or replace the reverse check cable. ADJUSTMENT 1) Set the vehicle on a lift. 2) Remove the under cover. 3) Remove the rear exhaust pipe and muffler. 4) Remove the crossmember. 5) Remove the snap pin and washer, and then separate the reverse check cable from reverse check lever. 6) Move the transmission to right side, and then remove the stay bolt and reverse check cable. NOTE: If the transmission is not moved, the stay bolt will contact body and damage may occur. Page 126 B292-B317 Locations Sensor Page 526 B136-B141 Page 2292 R72-R145 R148 Page 2698 B128-B134 Page 5226 3. Using the ST, press the bushing into place. 4. Press the ST plunger until bushing flange protrudes beyond lateral link. Page 180 B17-B20 Engine Controls - DTC P0340/P0345 After Camshaft R & R Camshaft Position Sensor: All Technical Service Bulletins Engine Controls - DTC P0340/P0345 After Camshaft R & R Number: 02-107-09 Date: 03/24/09 Applicability: 2004~06MY Baja 2.5L Turbo 2004~06MY Impreza 2.5L Turbo 2004~06MY Forester 2.5L Turbo 2004~06MY Legacy/Outback 2.5L Turbo SUBJECT: Intake Camshaft Replacement Introduction If you encounter a vehicle that has a CEL and P0340 or P0345 stored in memory immediately after replacing the intake camshaft(s), the air gap between the camshaft and camshaft position sensor may be out of specification. A modification was made to the plate area of the camshaft where the camshaft position sensor picks up the signal. Parts Information Repair Procedure/ Information Using a feeler (thickness) gauge, measure the gap between the camshaft and camshaft position sensor. The correct gap is between 0.15mm to 0.98mm (0.0059 to 0.0386 in.) If the gap is over 0.98mm (0.0386 in.) replace the camshaft position sensor. Refer to the applicable service manual. Warranty/Claim Information For vehicles within warranty, refer the Subaru Warranty Wizard for claim submission information. Page 595 2. Install the rear oxygen sensor. - AT model - MT model 3. Connect the connector to the rear oxygen sensor. Page 5408 Manual A/C Model Page 4294 5MT Gearshift Lever Page 848 Clutch Switch: Service and Repair Clutch Switch REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the instrument panel lower cover. 3) Disconnect the connector from clutch switch. 4) Remove the clutch switch. INSTALLATION CLUTCH SWITCH (CRUISE CONTROL) 1) Move the clevis pin of the push rod right and left and hold where it moves smoothly, then measure stroke of clutch pedal. 2) If the clutch pedal stroke is out of specification, adjust the stroke. 3) Connect clutch switch connector. CLUTCH SWITCH (STARTER INTER LOCK) 1) Fully depress the clutch pedal. 2) Install the clutch pedal plate and clutch switch so that the gap between them is 3 - 3.5 mm (0. 12 0.14 inch), and then tighten the lock nut. 3) Connect the clutch switch connector. 4) Confirm that the engine does not start when the clutch pedal is released. 5) Confirm that the engine starts when the clutch pedal is fully depressed. INSPECTION 1) If the clutch switch (cruise control) does not operate properly (or if it does not stop at the specified position), replace with a new one. Page 1872 A used toothbrush which has been cleaned works great. Manually open the negative pressure valve. Using clean water and a brush, thoroughly clean the valve (inner and outer surface) and the valve seal surface. Check the radiator cap valve opening pressure using a radiator cap tester to insure the cap is within specification (refer to the applicable Subaru Service Manual). Note: If the cap is out of specification replace it. 2. Coolant Reservoir Tank Cleaning Remove the reservoir tank (refer to the applicable Subaru Service Manual). Using clean water, thoroughly clean the inside of the reservoir tank. Reinstall reservoir tank. Fill with coolant to the Full mark. Note: Be sure to use genuine Subaru Super Coolant or Subaru Long Life Coolant, depending upon what type of coolant is currently in the system. 3. Coolant Reservoir Tank Hose Modification Page 4383 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 3007 7. Connect the connector of front oxygen (A/F)sensor. 8. Connect the battery ground cable to battery. Page 3100 B136-B141 Page 6517 B292-B317 Specifications Wheel Bearing: Specifications Subaru does not specify a wheel bearing grease. Page 5019 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 6298 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Locations Keyless Entry System Service and Repair Torque Converter Clutch: Service and Repair Torque Converter Clutch Assembly REMOVAL 1) Remove the transmission assembly from the vehicle. 2) Extract the torque converter clutch and oil pump shaft horizontally. NOTE: Be careful not to scratch the bushing inside the oil pump shaft. 3) Remove the input shaft. NOTE: When the torque converter clutch assembly is removed, the input shaft will come out. 4) Remove the clip from torque converter clutch. INSTALLATION 1) Install the clip to torque converter clutch. 2) Install the oil pump shaft to the torque converter clutch, and then check the clip fits securely in its groove. 3) Insert the input shaft while rotating it lightly by hand, and then check the protrusion amount. 4) Holding the torque converter clutch assembly by hand, carefully install it to the converter case. Be careful not to damage the bushing. Also avoid undue contact between the oil pump shaft bushing and stator shaft portion of the oil pump cover. 5) Rotate the shaft lightly by hand to engage the splines securely. Page 2949 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 4800 2. STATE OF CHARGE CHECK USING A HYDROMETER 3. NORMAL CHARGING Charge the battery at current value specified by manufacturer or at approx. 1/10 of the battery's ampere-hour rating. 4. QUICK CHARGING Quick charging is a method in which the battery is charged in a short period of time with a relatively large current by using a quick charger. Since a large current flow raises electrolyte temperature, the battery is subject to damage if large current is used for prolonged time. For this reason, the quick charging must be carried out within a current range that will not increase the electrolyte temperature above 40 °C (104 °F). It should be also remembered that the quick charging is a temporary means to bring battery voltage up to a fair value and, as a rule, a battery should be charged slowly with a low current. CAUTION Observe the items in 3. NORMAL CHARGING. - Never use more than 10 amperes when charging the battery because that will shorten battery life. Page 4462 2) Check specifications of the mark with ABSCM&H;/U. CHECKING THE HYDRAULIC UNIT ABS OPERATION BY PRESSURE GAUGE 1) Lift-up the vehicle and remove the wheels. 2) Disconnect the air bleeder screws from the FL and FR caliper bodies. 3) Connect two pressure gauges to the FL and FR caliper bodies. CAUTION: ^ Pressure gauges used exclusively for brake fluid must be used. ^ Do not employ pressure gauge previously used for transmission oil pressure since the piston seal is expanded which may lead to malfunction of the brake. NOTE: Wrap sealing tape around the pressure gauge. 4) Bleed air from the pressure gauges. 5) Perform the ABS sequence control. 6) When the hydraulic unit begins to work and first the FL side performs decompression, holding and compression, and then the FR side performs decompression, holding and compression. 7) Read values indicated on the pressure gauge and check if the fluctuation of the values between decompression and compression meets the standard values. Also check if any irregular brake pedal tightness is felt. 8) Remove the pressure gauges from FL and FR caliper bodies. 9) Remove the air bleeder screws from the RL and RR caliper bodies. 10) Connect the air bleeder screws to the FL and FR caliper bodies. 11) Connect two pressure gauges to the RL and RR caliper bodies. 12) Bleed air from the FL and FR caliper bodies. 13) Perform the ABS sequence control. 14) When the hydraulic unit begins to work, at first the RR side performs decompression, holding and compression, and then the RL side performs decompression, holding and compression. Page 6382 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 3895 B17-B20 Page 6710 R58-R69 Recall - Front Seat Wiring Harness Routing Wiring Harness: Recalls Recall - Front Seat Wiring Harness Routing NUMBER: WVC-13 DATE: March 2007 APPLICABILITY: 2006MY Subaru Forester & Impreza SUBJECT: Front Passenger Seat Wiring INTRODUCTION Subaru of America, Inc. (SOA) has determined that certain 2006 MY Subaru Forester and Impreza models may have been produced with an improperly routed electrical wiring harness. That harness could have been pinched against the passenger front seat mounting bolt during production. If the wiring harness was improperly installed, an electrical short could occur. There are two safety risks associated with this condition. The first is that the passenger's front air bag, which is connected to this wiring harness, could become disabled, in which case it would not deploy as designed in an accident and would therefore expose the right front passenger to the possibility of serious injuries. The second is that an electrical short circuit could, under some circumstances, cause a fire. If an electrical short circuit occurs in this wiring harness, fuse # 6 (located in the fuse panel on the lower left side of the dashboard) will "blow", disabling the passenger front air bag. This could occur at any time and without prior warning. But once it occurs, the driver will be alerted to this condition by the illumination of the air bag system warning light on the vehicle's instrument panel. Occupants will also be alerted to this condition if the passenger's frontal air bag ON/OFF indicator indicates "OFF" even if an adult passenger is occupying that seat. If fuse # 6 had previously blown and been replaced with no repair made to correct the underlying cause, there is a possibility that this wiring harness has already been damaged due to a short circuit. Under these circumstances, the new replacement fuse may not blow and a fire could occur at any time without warning. In Forester models, it could happen even if the ignition switch is in the "LOCK" (off) position. Vehicle owners will be advised in the Owner Notification Letter that if they encounter a blown fuse, an illuminated air bag system warning light, smell smoke, or have replaced a blown fuse # 6 without correcting the underlying problem, to not operate the vehicle. They will be advised to contact the nearest Subaru dealer as soon as possible for guidance. In these cases, dealers should arrange to have the vehicle towed and repairs performed immediately. This recall will involve inspection and possible repair of the front passenger seat wire harness. Please refer to the Service Procedure section of this bulletin for more details. AFFECTED VEHICLES ^ 2006 MY Subaru Forester and Impreza Potentially affected vehicles are identified in the VIN range chart below. Not all vehicles within the VIN range are affected. Prior to performing repairs, confirm coverage for potentially affected vehicles by using the Vehicle Coverage Inquiry in the Dealer Communication System (DCS). OWNER NOTIFICATION SOA will prepare and mail Owner Notification Letters to owners of affected vehicles on or around March 9, 2007. A copy of the Owner Notification Letter is included at the end of this bulletin. DEALER PROGRAM RESPONSIBILITY Dealers are to promptly service all vehicles subject to this recall at no charge to the vehicle owner regardless of mileage~ age of the vehicle~ or Locations Manifold Pressure/Vacuum Sensor: Locations Sensor (Part 1) Page 3059 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 1824 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Inhibitor Switch Transmission Position Switch/Sensor: Service and Repair Inhibitor Switch Inhibitor Switch INSPECTION When the driving condition or starter motor operation is erroneous, first check the shift linkage for improper operation. If the shift linkage is functioning properly, check the inhibitor switch. 1) Disconnect the inhibitor switch connector. 2) Check continuity in inhibitor switch circuits with the select lever moved to each position. NOTE: ^ Also check that continuity in ignition circuit does not exist when the select lever is in "R", "D", "3", "2" and "1" ranges. ^ If the inhibitor switch is inoperative, check for poor contact of connector on transmission side. 3) Check if there is continuity at equal points when the select lever is tilted 1.5° in both directions from "N" range. If there is continuity in one direction and the continuity in the other or if there is continuity at unequal points, adjust the inhibitor switch. 4) Repeat the above checks. If there are abnormalities, adjust the select cable. REMOVAL 1) Set up the vehicle on a lift. 2) Move the select lever to "N" range. 3) Remove the air intake chamber (Non-turbo model). 4) Remove the intercooler. (Turbo model) Page 5108 ownership. For affected vehicles sold after the date on the dealer's affected list, dealers are to contact those owners and provide them with a copy of the owner notification letter. They should also arrange to make the required correction according to the instructions in the service procedure section of this bulletin. Dealers are also to promptly perform the applicable service procedures defined in this bulletin to correct all affected vehicles in their inventory (new, used, demo). Additionally, whenever a vehicle subject to this recall is taken into dealer new or used inventory, or is in the dealership for service, necessary steps should be taken to ensure the service program correction has been made before selling or releasing the vehicle. PARTS INFORMATION Special Tools and Materials ^ Soldering gun and solder ^ Heat gun ^ 1.5 inch wide unwoven adhesive tape ^ Subaru Global Terminal Wiring Kit 1-47606 ^ Electrical tape ^ Electrical shrink wrap tubing SERVICE PROCEDURE This Recall will involve inspection of the front passenger seat wiring for proper routing. It will also involve repair of the affected wire harness if the inspection reveals pinched wiring. Service Procedure The first part of the procedure involves inspecting the wiring harness for proper routing and possible damage. (There are two separate procedures, one for each different vehicle.) If there is no damage to the wiring harness, no repair is necessary. If the wiring harness is found to be damaged, then follow the repair procedure. Forester Inspection Procedure (See Impreza inspection procedure.) 1. Slide the front passenger seat to the rear most position to expose the front of the slide rail. Locations Variable Induction Position Sensor: Locations Sensor (Part 1) Page 2195 B134-B136 Page 2345 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Engine Controls - DTC P0340/P0345 After Camshaft R & R Camshaft Position Sensor: All Technical Service Bulletins Engine Controls - DTC P0340/P0345 After Camshaft R & R Number: 02-107-09 Date: 03/24/09 Applicability: 2004~06MY Baja 2.5L Turbo 2004~06MY Impreza 2.5L Turbo 2004~06MY Forester 2.5L Turbo 2004~06MY Legacy/Outback 2.5L Turbo SUBJECT: Intake Camshaft Replacement Introduction If you encounter a vehicle that has a CEL and P0340 or P0345 stored in memory immediately after replacing the intake camshaft(s), the air gap between the camshaft and camshaft position sensor may be out of specification. A modification was made to the plate area of the camshaft where the camshaft position sensor picks up the signal. Parts Information Repair Procedure/ Information Using a feeler (thickness) gauge, measure the gap between the camshaft and camshaft position sensor. The correct gap is between 0.15mm to 0.98mm (0.0059 to 0.0386 in.) If the gap is over 0.98mm (0.0386 in.) replace the camshaft position sensor. Refer to the applicable service manual. Warranty/Claim Information For vehicles within warranty, refer the Subaru Warranty Wizard for claim submission information. Page 2303 4) Using the ST, tighten the bolts of inhibitor switch. ST 499267300 STOPPER PIN 5) Install the select cable to range select lever. 6) Install the plate assembly to transmission. 7) Install the washer and snap pin to range select lever. 8) Install the front and center exhaust pipes. (Non-turbo model) 9) Install the center exhaust pipe. (Turbo model) 10) Lower the vehicle. 11) Install the inhibitor switch connector from stay. 12) Connect the inhibitor switch connector. Page 2246 B54-B127 Locations SRS Airbag Page 6467 4. Install the generator on bracket. Inspection 1. Make sure oil does not leak or seep from where the oil pressure switch is installed. Diagram Information and Instructions Grounding Point: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 1544 8. Connect the engine harness connector to front harness connector. 9. Connect the engine harness connector to the bulkhead harness connectors. 10. Connect the brake booster 11. Connect the engine coolant hoses to the throttle body. Description and Operation Drink Holders: Description and Operation CUP HOLDER FOR FRONT SEAT PASSENGERS - Provided with a shutter type lid that can be closed when the cup holder is not used. - The cup holder can hold a container up to a 500 cc size plastic bottle or an L size paper cup. Page 3433 B380-f6 Page 695 R72-R145 R148 Page 5865 Front Door Interior Handle: Service and Repair FRONT INNER REMOTE REMOVAL 1. Remove the door trim. 2. Remove the sealing cover. 3. Remove a screw and two rod joints. 4. Remove the front inner remote. INSTALLATION Install in the reverse order of removal. NOTE: Make sure the front inner remote works properly after installation. Capacity Specifications Refrigerant Oil: Capacity Specifications Compressor Oil REPLACEMENT NOTE: - If a component is replaced, add an appropriate amount of compressor oil. - When replacing the compressor, the new compressor will already have the specified amount of oil in it. Install the new compressor after removing the same amount of oil that is remaining in the compressor removed. Description and Operation Temperature Sensor (Gauge): Description and Operation WATER TEMPERATURE GAUGE - Water temperature signals are generated at the engine coolant temperature sensor on the engine, and after converted into digital signals, these signals are sent via the body integrated unit to the combination meter. - The resistance of the engine coolant temperature sensor changes according to the engine coolant temperature. Therefore, the signals sent to the water temperature gauge also changes according to the engine coolant temperature. As the change in signals causes the magnetic force of the step motor to change, the gauge needle moves according to the engine coolant temperature. - When the coolant is at a normal operating temperature of approx. 85 to 100 degree C (158 to 212 degree F), the gauge needle stays in the middle of the indication range as shown in the figure. Page 3466 B136-B141 Page 4733 Electrical Component Location Service and Repair Heater Core: Service and Repair Heater Core REMOVAL 1. Remove the heater and cooling unit. 2. Loosen the screws to remove the heater core cover. 3. Remove the heater core. INSTALLATION Install in the reverse order of removal. Page 1545 12. Connect the emission hose (A) and connector (B) to the PCV hose assembly. 13. Connect the pressure hose to the intake duct. 14. Install the power steering pump. 1. Install the power steering tank on the bracket. 2. Connect the connector to the power steering pump switch. Back-Up Light Switch (MT Model) Backup Lamp Switch: Testing and Inspection Back-Up Light Switch (MT Model) BACK-UP LIGHT SWITCH (MT MODEL) Measure the resistance between back-up light switch terminals. Page 1182 Fluid - Differential: Fluid Type Specifications Differential Fluid NON STI Grade ................................................................................................................................... .......................................................................................... GL-5 Viscosity .......................................... .............................................................................................................................................................. ........... 80W-90 STI Grade .................................................................................................................. ........................................................................................................... GL-5 Viscosity ......................... .............................................................................................................................................................. ............................. SAE 90 Specifications Compression Check: Specifications Compression (at 200 - 300 rpm): Standard ................................................................................................................................................... 981 1,177 kPa (10 - 12 kgf1cni2, 142 - 171 psi) Difference between cylinders ....................................................................................................................................... Less than 49 kPa (0.5 kgf1cm, 7 psi) Page 4500 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Locations Backup Lamp Switch: Locations Solenoid Valve And Switch (AT Model) Solenoid Valve, Actuator, Emission Control System Parts And Ignition System Parts (Part 5) Page 5655 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 5993 Grille: Service and Repair Front Hood Grille FRONT HOOD GRILLE Front Hood Grille REMOVAL 1. Open the front hood. 2. Remove the intercooler water spray hose. (STI model) 3. Remove the seven bolts and clip (A) to remove the hood duct. 4. Loosen the six nuts (B), remove the four clips (A), and then remove the hood grille. Page 6759 Headlamp Bulb: Service and Repair HEADLIGHT BULB REMOVAL 1. HIGH BEAM AND HALOGEN TYPE LOW BEAM CAUTION: Because the halogen bulb operates at a high temperature, dirt and oil on the bulb surface reduces the bulb s service life. Hold the flange portion when replacing the bulb. Never touch the glass portion. - Do not leave the headlight without a bulb for a long time. Dust, moisture, etc. entering the headlight may affect its performance. 1 Disconnect the ground cable from battery. 2 Remove the air intake duct (A) (when right side headlight bulb is removed). 3. Disconnect the harness connector. 4. Remove the bulb assembly. To remove the low beam, remove the back cover and go to Step 5. 5. Remove the light bulb retaining spring (A) to remove the bulb. 2. HID TYPE LOW BEAM CAUTION: Do not operate with wet hands. - As the lightening circuit uses high voltage, be sure to confirm that the power supply is turned off before operation. - When replacing the bulb, hold the flange portion and never touch the glass portion. Page 6137 B230-B283 Page 6518 B380-f6 Page 803 R58-R69 Page 6800 B230-B283 Page 7366 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 5058 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 7363 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Engine Controls - DTC P0340/P0345 After Camshaft R & R Camshaft Position Sensor: Customer Interest Engine Controls - DTC P0340/P0345 After Camshaft R&R Number: 02-107-09 Date: 03/24/09 Applicability: 2004~06MY Baja 2.5L Turbo 2004~06MY Impreza 2.5L Turbo 2004~06MY Forester 2.5L Turbo 2004~06MY Legacy/Outback 2.5L Turbo SUBJECT: Intake Camshaft Replacement Introduction If you encounter a vehicle that has a CEL and P0340 or P0345 stored in memory immediately after replacing the intake camshaft(s), the air gap between the camshaft and camshaft position sensor may be out of specification. A modification was made to the plate area of the camshaft where the camshaft position sensor picks up the signal. Parts Information Repair Procedure/ Information Using a feeler (thickness) gauge, measure the gap between the camshaft and camshaft position sensor. The correct gap is between 0.15mm to 0.98mm (0.0059 to 0.0386 in.) If the gap is over 0.98mm (0.0386 in.) replace the camshaft position sensor. Refer to the applicable service manual. Warranty/Claim Information For vehicles within warranty, refer the Subaru Warranty Wizard for claim submission information. Page 4023 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 7077 B136-B141 Page 6540 B17-B20 Page 4214 Rear Drive Shaft Installation INSTALLATION 1) Insert the rear drive shaft into rear axle. 2) Temporarily tighten the axle nut. 3) Install the rear drive shaft to rear differential using the ST. ST 28099PA090 OIL SEAL PROTECTOR 4) Temporarily tighten the front lateral link and rear lateral link to housing using a new self-locking nuts. 5) Temporarily tighten the trailing link to housing using a new self-locking nut. Page 6232 Clutch Switch: Testing and Inspection CLUTCH SWITCH INSPECTION Measure the clutch switch resistance. If NG, replace the clutch switch. Page 6141 F61-R47 Page 3744 4. Remove the ignition coil and ignitor assembly. 5. Remove the spark plugs with the spark plug sockets. INSTALLATION RH SIDE Install in the reverse order of removal. Tightening torque (Spark plug): 21 N.m (2.1 kgf-m, 15.2 ft-lb) Tightening torque (Ignition coil and ignitor assembly): 16 N.m (1.6 kgf-m, 11.7 ft-lb) NOTE: - The above torque should be only applied to new spark plugs without oil on their threads. - In case their threads are lubricated, the torque should be reduced by approx. 1/3 of the specified torque in order to avoid over-stressing. LH SIDE Install in the reverse order of removal. Tightening torque (Spark plug): 21 N.m (2.1 kgf-m, 15.2 ft-lb) Tightening torque (Ignition coil and ignitor assembly): 16 N.m (1.6 kgf-m, 11.7 ft-lb) NOTE: - The above torque should be only applied to new spark plugs without oil on their threads. - In case their threads are lubricated, the torque should be reduced by approx. 1/3 of the specified torque in order to avoid over-stressing. Locations Backup Lamp Switch: Locations Solenoid Valve And Switch (AT Model) Solenoid Valve, Actuator, Emission Control System Parts And Ignition System Parts (Part 5) Page 4095 NOTE: Replace the control valve body as assembly, because it is non-disassemble part. INSTALLATION 1. Check the control valve body for dust and other foreign matters. 2. Install the control valve body to transmission by equally tightening the bolts. Tightening torque: 8 Nm (0.8 kgf-cm, 5.8 ft. lbs.) 3. Connect the control valve connector. 4. Attach the magnet at the specified position of oil pan. 5. Apply liquid gasket to the oil pan. Page 3685 Disclaimer Page 1371 3. When the piston is to be replaced due to general or cylinder wear, determine a suitable sized piston by measuring the piston clearance. 4. How to measure the outer diameter of each piston: Measure the outer diameter of each piston at the height shown in the figure. (Thrust direction) NOTE: Measurement should be performed at a temperature of 200C (680F). Piston grade point H. 38.2 mm (1.50 inch) Piston outer diameter. Standard 99.505 - 99.515 mm (3.9175 - 3.9179 inch) 99.495 - 99.505 mm (3.9171 - 3.9175 inch) 0.25 mm (0.0098 inch) oversize 99.745 - 99.765 mm (3.9270 - 3.9278 inch) 0.50 mm (0.0197 inch) oversize 99.995 - 100.015 mm (3.9368 - 3.9376 inch) Page 4126 Except Non-turbo model And STI Model 2) Apply compressed air through the clutch hose attaching hole. NOTE: Face the piston hole downward and place a wooden block to prevent the piston from jumping out. ^ Non-turbo model Non-turbo model ^ Except Non-turbo model and STI model Except Non-turbo model and STI model 3) Separate the piston and piston spring. ^ Non-turbo model Page 3758 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 1634 2. Install the timing belt. 3. Install the timing belt cover. 4. Install the crank pulley. 5. Install the V-belt. Inspection 1. Check the cam sprocket teeth for abnormal wear and scratches. 2. Make sure there is no free play between cam sprocket and key. Page 2066 Main Relay (Computer/Fuel System): Service and Repair Main Relay REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the passenger's side front side sill cover. 3. Remove the bolt which holds the relay bracket on the body. 4. Disconnect the connectors from the main relay. 5. Remove the main relay from the mounting bracket. INSTALLATION Install in the reverse order of removal. Page 596 4. Connect the clip to the crossmember. 5. Lower the vehicle. 6. Connect the battery ground cable to battery. Page 5924 Hood Latch: Testing and Inspection FRONT HOOD LOCK ASSEMBLY INSPECTION 1. Check the striker for bending or abnormal wear. 2. Check the safety lever for improper movement. 3. Check other levers and the spring for rust formation and unsmooth movement. Page 616 B230-B283 Page 3706 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 1533 Intake Manifold: Testing and Inspection INSPECTION Make sure the fuel pipe and fuel hoses are not cracked and the connections are tightened. Page 4930 F61-R47 Page 525 B134-B136 Testing and Inspection Air Filter Element: Testing and Inspection INSPECTION Inspect for cracks and loose connections. Page 3970 12) Move the range select lever to parking position (left side). 13) Remove the inhibitor switch from transmission. 14) Disconnect the inhibitor switch harness connector from inhibitor switch. INSTALLATION 1) Connect the inhibitor switch harness connector to inhibitor switch. 2) Install the inhibitor switch to transmission case. 3) Move the range select lever to neutral position. Page 978 7. Perform the above steps from 1) to 6) at the MIN and MAX positions of intermittent control switch, and replace the wiper switch assembly if it does not operate as specified. Page 4426 8) Install the front vehicle speed sensor and torque converter turbine speed sensor, and then fasten the harness. 9) Install the inlet pipe. NOTE: Be sure to use a new copper washer. 10) Install the transmission rear crossmember bolts. Tightening torque: 70 Nm (7.1 kgf-m, 51 ft. lbs.) 11) Install the propeller shaft. 12) Install the front, center, rear exhaust pipes and muffler. (Non-turbo model) 13) Install the center, rear exhaust pipes and muffler. (Turbo model) 14) Lower the vehicle. 15) Install the transmission connector to the stay. 16) Install the pitching stopper. 17) Install the air intake chamber. (Non-turbo model) 18) Install the intercooler. (Turbo model) Service and Repair Ball Joint: Service and Repair Front Ball Joint REMOVAL 1) Remove the wheel. 2) Pull out the cotter pin from ball stud, remove the castle nut, and extract the ball stud from transverse link. 3) Remove the bolt securing ball joint to housing. 4) Extract the ball joint from housing. INSTALLATION 1) Install the ball joint onto housing. Tightening torque (Bolt): 50 Nm (5.1 kgf-m, 37 ft. lbs.) CAUTION: Do not apply grease to tapered portion of ball stud. 2) Connect the ball joint to transverse link. Tightening torque (Castle nut): Sedan turbo model and STI model: 30 Nm (3.1 kgf-m, 22 ft. lbs.) Except Sedan turbo model and STI model: 40 Nm (4.1 kgf-m, 30 ft. lbs.) 3) Retighten the castle nut further within 600 until a slot in castle nut is aligned with the hole in ball stud end, then insert a new cotter pin and bend it around castle nut. 4) Install the front wheel. INSPECTION 1) Measure the play of ball joint by the following procedures. Replace with a new one when the play exceeds specified value. (1) With 686 N (70 kgf, 154 lbs.) loaded in direction shown in the figure, measure the dimension l1. (2) With 686 N (70 kgf, 154 lbs.) loaded in opposite direction shown in the figure, measure the dimension l2. Page 1341 3. Make two 3 mm (0.12 inch) holes in bushing. Ream the inside of bushing. 4. After the completion of reaming, clean the bushing to remove chips. Page 1028 3. Disconnect the connector from ignition coil and ignitor assembly. 4. Remove the ignition coil and ignitor assembly. 5. Remove the spark plugs with the spark plug sockets. LH SIDE 1. Remove the battery and battery carrier. 2. Remove the secondary air pump. 3. Disconnect the connector from ignition coil and ignitor assembly. Page 7402 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Locations Air Flow Meter/Sensor: Locations Sensor (Part 1) Page 2821 B292-B317 Page 2652 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 3779 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Testing and Inspection Headlamp Bulb: Testing and Inspection Headlight Bulb INSPECTION 1. HALOGEN TYPE 1. Visually check the bulb for blow out. 2. Check the bulb specification. 3. If NG, replace the bulb with a new one. 2. HID TYPE CAUTION: Do not operate with wet hands. - Do not touch the harness, inner headlight, or any metallic portion of the headlight when the light is illuminated (when the lighting switch is turned on). - When performing a lighting test, make sure that the headlight is mounted on the vehicle, and the power supply is connected to the connector on the vehicle's side. 1. Check the bulb specification. 2. Use a normal HID bulb for headlight lighting test. 3. If the headlight does not illuminate, replace the bulb with a new one. DISPOSAL 1. HID TYPE CAUTION: HID type light bulb contains mercury. Dispose the bulb according to regional regulation and contact SOA Service Center. Page 2072 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 7162 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Wipers/Washers - Poor Front/Rear Washer Nozzle Operation Windshield Washer Spray Nozzle: Customer Interest Wipers/Washers - Poor Front/Rear Washer Nozzle Operation NUMBER: 07-55-06 DATE: 04/04/06 APPLICABILITY: 2006MY Forester and Impreza SUBJECT: Poor Windshield Washer Fluid Spray Introduction If you encounter a customer complaint that the windshield washer fluid does not spray properly from the front or rear washer nozzle, there is the possibility that the nozzle or check valve is clogged or the fluid hose could be pinched or bent. Use the following repair procedure to check and repair as necessary. Production Line Change The check valve was changed from a ball type to a rubber type to prevent clogging. The new style check valve was used in production starting in October, 2005 with the VINs shown. Parts Information Repair Procedure/Information 1) Check the washer nozzle for contamination. If the spray hole is clogged with wax, dust or foreign material, blow compressed air to the spray hole of the washer nozzle to clear the obstruction. 2) Check the washer nozzle fluid hose. Make sure the hose is not pinched, and that it does not have severe bends or kinks. 3) Check the rear washer hose running along the left sill, as well as the hose in the tailgate area, to ensure that the hose is not pinched or bent, restricting the flow. 4) If there is no problem found in step 1 or 2, install a modified check valve. Front check valve on Forester and Impreza Page 679 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 3857 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 3010 4. Connect the clip to the crossmember. 5. Lower the vehicle. 6. Connect the battery ground cable to battery. Page 2466 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Testing and Inspection Evaporative Shut Valve: Testing and Inspection INSPECTION Make sure the hoses are not cracked or loose. Page 3016 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 1609 B3-B12 Page 2331 F61-R47 Page 2153 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the generator. 3. Drain the engine coolant. 4. Disconnect the connector from the engine coolant temperature sensor. 5. Remove the engine coolant temperature sensor. INSTALLATION Install in the reverse order of removal. NOTE: Use a new gasket. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb) Page 4839 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 3819 Clutch Pedal Position Sensor / Switch: Description and Operation OPERATION STARTER INTERLOCK MECHANISM When the clutch pedal is fully depressed, the stopper on the pedal pushes the clutch switch push rod inwards. When the pushrod is pressed in, the switch turns ON and connects the ignition switch to the starter circuit enabling engine start. Schematic Drawings Page 3023 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 6677 Center Mounted Brake Lamp: Service and Repair HIGH-MOUNTED STOP LIGHT REMOVAL 1. SEDAN MODEL (STANDARD TYPE) 1. Disconnect the ground cable from battery. 2. Disconnect the connector of high-mounted stop light from body harness. 3. Remove the bolts, then detach the high-mounted stop light assembly. 2. SEDAN MODEL (REAR SPOILER BUILT-IN TYPE) 1. Disconnect the ground cable from battery. 2. Remove the bolts, then detach the high-mounted stop light assembly. 3. Disconnect the connector of high-mounted stop light from body harness. 3. WAGON MODEL 1. Disconnect the ground cable from battery. 2. Remove the cap (a) by prying on the edge with screwdriver. 3. Remove the screws (b), and then the detach cover (c). 4. Remove screws (d), and then detach the highmounted stop light while disconnecting connector. INSTALLATION Install in the reverse order of removal. Page 7027 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 4584 3. Set a dial gauge 10 mm (0.39 inch) inward of rotor outer perimeter. Turn the disc rotor to check runout. If the disc rotor runout exceeds the service limit, resurface the disc rotor. After resurfacing, check disc rotor thickness as in step 4. Disc rotor runout limit. 0.070 mm (0.0028 inch) 4. Set a micrometer 10 mm (0.39 inch) inward of the rotor outer perimeter, and then measure the disc rotor thickness. If the thickness of disc rotor exceeds the service limit, replace with a new disc rotor. Service and Repair Cruise Control Module: Service and Repair Cruise Control Unit REMOVAL The control of cruise control system is performed by Engine control module (ECM). Capacity Specifications Power Steering Fluid: Capacity Specifications Power Steering Gear Fluid Fluid Capacity .............................................................................................................................................................. 0.7 liter (0.7 US qt, 0.6 Imp qt) Locations Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 3562 B230-B283 Page 6345 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 4941 Auxiliary Power Outlet: Service and Repair Rear Accessory Power Supply Socket REAR ACCESSORY POWER SUPPLY SOCKET REMOVAL 1. FRONT 1. Disconnect the ground cable from battery. 2. Remove the console cover. 3. Disconnect the harness connectors and remove accessory power supply socket. INSTALLATION Install in the reverse order of removal. Page 4775 Non-Turbo Model System Diagnosis Front Door Window Regulator: Testing and Inspection FRONT REGULATOR AND MOTOR ASSEMBLY INSPECTION 1. Make sure the power window motor rotates properly when battery voltage is applied to the terminals of motor connector. 2. Change polarity of battery connections to terminals to ensure the motor rotates in reverse direction. Page 7112 - Move the vehicle slowly. - For minimum drying time and time the vehicle must be left standing before driving after bonding, follow the instructions or instruction manual from adhesive manufacturer. 4. After curing of adhesive, pour water on external surface of vehicle to check that there are no water leaks. NOTE: When a vehicle is returned to user, tell him or her that the vehicle should not be subjected to heavy impact for at least three days. Page 1230 - Do not allow water or oil to come in contact with the connector terminals. Do not touch the connector terminals. - Either of the airbag modules for driver, passenger or side, or pretensioner must not be disassembled. - The removed front seat with the airbag module must be kept at least 200 mm (8 in) away from walls and other objects. - Do not use the airbag or pretensioner parts from other vehicles. Always replace defective parts with new parts. - Never reuse a deployed airbag or pretensioner. - When painting or performing sheet metal work on the front part of the vehicle, including the front wheel apron, front fender, and front side frame, remove the front sub sensors and wire harness of the airbag system. Electrical - Low Battery Voltage Affects Other Systems Battery: Technical Service Bulletins Electrical - Low Battery Voltage Affects Other Systems LOW BATTERY VOLTAGE If you should encounter a dead battery, especially if the voltage had dropped below 7 volts, there is a possibility that other components may have been affected. Charge the baffery following established procedure using the Midtronics test equipment. Pay affention to the electrical equipment such as relays, radio, horns, lights and other like equipment. All items should be checked for proper operation prior to releasing the vehicle back to the customer. Page 240 B134-B136 Page 7069 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Specifications Flywheel: Specifications Tightening Torque: Except STi Model 72 N.m (7.3 kgf-m, 52.8 ft-lb) STi Model 75 N.m (7.6 kgf-m, 55.3 ft-lb) NOTE: Tighten the flywheel installing bolts gradually. Each bolt should be tightened to the specified torque in a crisscross fashion. Page 6980 Disclaimer Page 6457 F21-F61 Page 5439 Refrigerant Pressure Sensor / Switch: Testing and Inspection Pressure Switch (Dual Switch) INSPECTION 1. Connect the manifold gauge to the service valve on high-pressure side. 2. Remove the pressure switch harness connector. Using a circuit tester, inspect the ON-OFF operation of pressure switch. Page 711 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 4931 R58-R69 Page 4797 Specification Page 5289 Wheels: Service and Repair Aluminum Wheel REMOVAL 1. Apply parking brake, and position the select lever to P or LOW. 2. Set jacks or a lift to the specified point, and support the vehicle with its tires slightly contacting the floor. 3. Loosen the wheel nuts. 4. Raise the vehicle until its tires take off the ground using a jack or a lift. 5. Remove the wheel nuts and wheels. NOTE: ^ While removing the wheels, prevent the hub bolts from damage. ^ Place the wheels with their outer sides facing upward to prevent the wheels from damage. INSTALLATION 1. Remove dirt from the mating surface of wheel and brake rotor. 2. Attach the wheel to hub by aligning the wheel bolt hole with hub bolt. 3. Temporarily attach the wheel nuts to hub bolts, using SUBARU genuine wheel nut. 4. Manually tighten the nuts making sure the wheel hub hole is aligned correctly to guide portion of hub. 5. Tighten the wheel nuts in a diagonal selection to specified torque. Use a wheel nut wrench. Wheel nut tightening torque: 90 Nm (9.1 kgf-m, 65.7 ft. lbs.) CAUTION: ^ Tighten the wheel nuts in two or three steps by gradually increasing the torque and working diagonally, until the specified torque is reached. ^ Do not depress the wrench with foot; Always use both hands when tightening. ^ Make sure the bolt, nut and nut seating surface of the wheel are free from oils. 6. If a wheel is removed for replacement or for repair of a puncture, retighten the wheel nuts to the specified torque after running 1,000 km (600 miles). INSPECTION 1. Deformation or damage on the rim can cause air leakage. Check the rim flange for deformation, crack or damage, and repair or replace as necessary. 2. Jack-up the vehicle until tires clear the floor. 3. Slowly rotate the wheel to check the rim runout using a dial gauge. Page 7384 Wiper Motor: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 4720 4. Connect the vacuum hose to brake booster. 5. Mount the master cylinder onto brake booster. 6. Connect the brake pipes to master cylinder. 7. Connect the electric connector for brake fluid level indicator. 8. Measure the clearance between threaded end of stop light switch and stopper. If it is not within specified value, adjust it by adjusting the position of stop light switch. CAUTION: Be careful not to rotate the stop light switch. Stop light switch clearance 0.3 mm (0.012 inch) 9. Apply grease to operating rod connecting pin to prevent it from wearing. Page 2227 Refer to the illustrations above for more details on locating the appropriate sensors. Page 4219 12) Raise the boot band claws by means of screwdriver and hammer. 13) Cut and remove the boot. CAUTION: The boot must be replaced with a new one whenever it is removed. NOTE: Further disassembly of axle is impossible because the EBJ cannot be disassembled. BJ+DOJ TYPE 1) Straighten the bent claw of larger end of DOJ boot. 2) Loosen the band by means of screwdriver or pliers with care of not damaging boot. 3) Remove the boot band on the small end of DOJ boot in the same manner. 4) Remove the larger end of DOJ boot from DOJ outer race. Page 2801 Non-Turbo Model Page 5935 Trunk / Liftgate Interior Trim Panel: Service and Repair Rear Gate Trim REAR GATE TRIM REMOVAL CAUTION: Be careful not to damage the clips or their holes. Remove the clips, and then detach the rear gate trim. INSTALLATION Install in the reverse order of removal. Page 1608 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 6534 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 6202 Large-sized rear spoiler: Twelve tightening positions, four clips INSTALLATION 1. Install in the reverse order of removal. 2. Clean the mounting surfaces of trunk lid and spoiler before installation. Tightening torque: 7.5 N.m (0.76 kgf-m, 5.5 ft-lb) Option Parts REAR SPOILER Rear Spoiler REMOVAL 1. Disconnect the ground cable from battery. Locations System Relay: Locations Main Fuse Box (M/B) Page 6714 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 6807 License Plate Lamp: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 924 Clutch Pedal Position Sensor / Switch: Description and Operation OPERATION STARTER INTERLOCK MECHANISM When the clutch pedal is fully depressed, the stopper on the pedal pushes the clutch switch push rod inwards. When the pushrod is pressed in, the switch turns ON and connects the ignition switch to the starter circuit enabling engine start. Schematic Drawings Page 6690 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 3022 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 3654 B54-B127 Page 661 F61-R47 Diagrams Heater Duct Page 7016 Heated Glass Element: Component Tests and General Diagnostics REAR WINDOW DEFOGGER INSPECTION CAUTION: When wiping stain on glass off with cloth, use a dry and soft cloth and move it along the heat wire to avoid damage to heat wire. 1. Turn the ignition switch to ON. 2. Turn the defogger switch to ON. 3. Wrap the tips of tester pins with aluminum foil to avoid damage to heat wire. 4. Measure the voltage at wire center with DC voltmeter. Standard voltage: Approx. 6 V NOTE: If the measured value is 12 volts, heat wire is open between wire center and positive (+) end. - If zero volt, heat wire is open between wire center and ground. 5. Apply positive lead of voltmeter to positive terminal of voltmeter, and then move the negative lead along the wire up to negative terminal end. If voltage changes from zero to several volts during movement of lead, heat wire is open at the voltage change point. Page 2647 F61-R47 Page 7392 Wiper Motor: Service and Repair Rear Wiper Motor REAR WIPER MOTOR REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the rear wiper arm. 3. Remove the rear gate lower trim. 4. Unclip the clip of harness, and then disconnect the connector of wiper motor. 5. Loosen the bolts to remove the wiper motor assembly (A). 6. Remove rear wiper cushion. INSTALLATION 1. Install in the reverse order of removal. 2. Install the rear wiper cushion with the arrow mark facing up, as shown in the figure. Tightening torque: Nm (kgf-m, ft-lb) T1: 6.0 (0.61, 4.4) T2: 8.0 (0.82, 5.9) Page 4414 4) Using the ST, tighten the bolts of inhibitor switch. ST 499267300 STOPPER PIN 5) Install the select cable to range select lever. 6) Install the plate assembly to transmission. 7) Install the washer and snap pin to range select lever. 8) Install the front and center exhaust pipes. (Non-turbo model) 9) Install the center exhaust pipe. (Turbo model) 10) Lower the vehicle. 11) Install the inhibitor switch connector from stay. 12) Connect the inhibitor switch connector. Service and Repair Oil Filter: Service and Repair Engine Oil Filter REMOVAL 1. Lift-up the vehicle. 2. Remove the under cover. 3. Remove the oil filter with ST. ST 18332AA000 OIL FILTER WRENCH (Outer diameter: 68 mm (2.68 inch)) ST 18332AA010 OIL FILTER WRENCH (Outer diameter: 65 mm (2.56 inch)) NOTE: Standard oil filter is outer diameter of 68 mm (2.68 inch). However, SUBARU genuine oil filter having outer diameter of 65 mm (2.56 inch) can also be used. INSTALLATION 1. Get a new oil filter and apply a thin coat of engine oil to seal rubber. 2. Install the oil filter by turning it by hand, being careful not to damage seal rubber. ^ Tighten the oil filter 68 mm (2.68 inch) in diameter by approximately 1 rotation more after the seal rubber of oil filter comes in contact with cylinder block or oil cooler. If using a torque wrench, tighten it to 14 Nm (1.4 kgf-m, 10.3 ft. lbs.). ^ Tighten the oil filter 65 mm (2.56 inch) in diameter by approximately 2/3 - 3/4 rotation more after the seal rubber of oil filter comes in contact with cylinder block or oil cooler. If using a torque wrench, tighten it to 12 Nm (1.2 kgf-m, 8.7 ft. lbs.). CAUTION: Do not tighten excessively, or oil may leak. INSPECTION 1. After installing the oil filter, run the engine and make sure that no oil is leaking around seal rubber. NOTE: The filter element and filter case are permanently jointed; therefore, interior cleaning is not necessary. 2. Check the engine oil level. Page 6695 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 7379 B380-f6 Page 3313 Fuel Supply Line: Service and Repair Fuel Delivery, Return and Evaporation lines REMOVAL 1. Set the vehicle on a lift. 2. Release the fuel pressure. 3. Open the fuel filler flap lid and remove the fuel filler cap. 4. Remove the floor mat. 5. Disconnect the fuel delivery pipes and hoses, and disconnect the fuel return pipes and hoses, evaporation pipes and hoses. 6. In engine compartment, detach the fuel delivery hoses, return hoses and evaporation hose. 1. Disconnect the quick connectors of fuel delivery line and return line by pushing the ST to the direction of arrow. ST 42099AE000 CONNECTOR REMOVER 2. Remove the clip, and disconnect the evaporation hose from pipe. WARNING: - Be careful not to spill fuel. - Catch the fuel from hoses using a container or cloth. Page 5171 Page 4546 2. Remove the piston boot. 3. Place a wooden block in caliper body as shown in the figure to prevent the piston from jumping out and avoid being damaged. 4. Gradually supply compressed air via the installation hole of brake hose to force the piston out. 5. Remove the piston seal from caliper body cylinder. CAUTION: Do not damage the cylinder and piston seal groove. 3. 17 INCH TYPE 1. Remove the piston boots from each piston end. Locations Electronic Throttle Actuator Relay: Locations Solenoid Valve, Actuator, Emission Control System Parts And Ignition System Parts (Part 5) Capacity Specifications Fluid - Differential: Capacity Specifications Rear Differential Gear Oil Non STI Model Fluid Capacity ................................................................... .................................................................................................. 0.8 liter (0.8 US qt, 0.7 Imp qt) Rear Differential Gear Oil STI Model Only Fluid Capacity ................................................................... .................................................................................................. 1.0 liter (1.1 US qt, 0.9 Imp qt) Fluid Type API GL-5 ..................................................................................................................................... ........................................................... SAE 90 Diagnostic Aids Fuse Block: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 4795 Battery: Technical Service Bulletins Electrical - Parasitic Battery Draw Information NUMBER: 07-62-07 DATE: 01/17/08 APPLICABILITY: All Models SUBJECT: Dark Current or Excessive Battery Draw INTRODUCTION The purpose of this bulletin is to provide the diagnostic procedure when checking for excessive battery draw REPAIR PROCEDURE/INFORMATION PRIOR to beginning the test: ^ Be certain the vehicle battery is fully charged ^ The battery posts and cable ends are free of corrosion, dirt, sealer, and in good condition. ^ Be sure to record the customer's radio station, and satellite radio station pre-sets as they will be lost during the test, along with any seat memory settings. ^ You may NOT use an aftermarket 9V memory device in the power outlet to retain any ECU memory. ^ Any aftermarket accessories will also need to be disconnected. These items will affect the test results and may cause false readings or misdiagnosis. Items required for test: ^ Pen and paper for recording radio and satellite radio pre-sets ^ Digital Volt Ohm Meter ^ 10 MM wrench ^ 16 gauge by-pass wire, about 12 inches long, w/ proper securing attachments at each end Test Procedure: 1) Remove battery negative cable 2) Connect one end of by-pass wire to the battery's negative post then connect the other end to negative battery cable end Simply wrapping then twisting the stripped back ends of the by-pass wire around the post and terminal will be sufficient Reinstall the negative cable on the battery post 3) Wait 5 minutes before proceeding to the next step. This will allow the system voltage to stabilize. During this time, be sure the glove box door, trunk, tailgate, and all vehicle doors are closed and their corresponding lamps are off. Also, be sure that the head lamps, fog lamps, and all switches are off. The ignition key needs to be removed, and the doors must be locked (make sure not to lock the keys in the car). Remove the negative battery cable, making sure the by-pass wire has not lost contact. If contact is lost, you will need to start at step # 2 again. 4) Make sure your voltmeter is set to milliamp (mA) setting. Connect the test leads of your voltmeter to the negative battery cable and the negative battery post. Remove the by-pass wire you installed in steps # 2 and # 3 and measure the current draw. After the 5 minute stabilization period, the measured draw should be a maximum of 150 milli-amps. This maximum draw value is read with the key out of the ignition switch. If your results are greater than the above specification, further diagnosis will be necessary to determine the source of the excessive current draw. This should be done using normal electrical circuit testing until the source of this excessive draw is determined and repaired. After confirming the repair, the customer's radio presets and clock time should be reset properly. Page 1941 7. Remove the camshaft position sensor. 8. Remove the cam sprockets (I-H) by using ST. 9. Remove the belt cover No. 2 (I-H). 10. Remove the tensioner bracket. 11. Disconnect the hose from water pump. 12. Remove the water pump. Installation 1. Install the water pump onto cylinder block (I-H). NOTE: ^ Replace the gasket with a new one. ^ When installing the water pump, tighten bolts in two stages in alphabetical sequence as shown in the figure. Tightening torque: First ...................................................................................................................................................... ............................. 12 Nm (1.2 kgf-m, 8.7 ft. lbs.) Second ................................................................... ............................................................................................................ 12 Nm (1.2 kgf-m, 8.7 ft. lbs.) Locations Fuel Tank Pressure Sensor: Locations Page 1514 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Description and Operation Rear Bumper: Description and Operation Rear Bumper Beam - A bumper beam assembly is placed inside the rear bumper. The beam assembly is fastened to the chassis frame and absorbs the shock energy in case of a rear collision, etc. to reduce damage to the vehicle. - The rear bumper assembly consists of a bumper face bracket, main beam, main beam bracket, and energy absorber foam made of PP foam. Capacity Specifications Fluid - M/T: Capacity Specifications M/T Fluid capacity 5SPD ................................................................................................................................................. 3.7 US qt (3.5 liters, 3.1 Imp qts) M/T Fluid capacity 6SPD ................................................................................................................................................. 4.3 US qt (4.1 liters, 3.6 Imp qts) Page 3173 Catalytic Converter: Testing and Inspection Rear Catalytic Converter INSPECTION 1. Make sure there are no exhaust leaks from connections and welds. 2. Make sure there are no holes or rusting. Page 1422 EXAMPLES Of FAILED TURBOCHARGERS Inadequate lubrication supplied to the turbocharger will cause damage to the turbine center shaft bearing. This will cause radial movement of the shaft permitting the compressor impellers to come in contact with the housing. Before replacing a damaged turbocharger, review the customer's maintenance history. If there is evidence that the engine was not properly maintained, follow the Engine Oil System Flush instructions prior to replacing the turbocharger to avoid a secondary failure. ENGINE OIL SYSTEM FLUSH INSTRUCTIONS 1) Make sure the engine oil level is "FULL" 2) Start the engine and bring to operating temperature 3) Turn the engine OFF 4) Add Engine Oil System Flush to the engine oil 5) Start the engine and let idle for 20 minutes 6) Turn the engine OFF and drain the old engine oil and Engine Oil System Flush from the oil pan 7) Replace the engine oil filter with a Genuine Subaru Oil Filter 8) Refill the engine oil with the proper engine oil as recommended in the vehicle's owner manual Page 2893 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the connector from the camshaft position sensor RH. 3. Remove the camshaft position sensor RH from the rear side of cylinder head. 4. Remove the camshaft position sensor LH in the same procedure as RH side. INSTALLATION Install in the reverse order of removal. Tightening torque: Camshaft position sensor support: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) Camshaft position sensor: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) Brake Hose Brake Hose/Line: Service and Repair Brake Hose Brake Hose REMOVAL 1. FRONT BRAKE HOSE 1. Separate the brake pipe from brake hose. (Always use the flare nut wrench and be careful not to deform the flare nut.) 2. Pull out the clamp to remove brake hose. 3. Remove the bolt at strut and union bolt. 2. REAR BRAKE HOSE 1. Separate the brake pipe from brake hose. NOTE: Always use the flare nut wrench and be careful not to deform the flare nut. 2. Remove the clamp and union bolt. INSTALLATION 1. FRONT BRAKE HOSE 1. Secure the brake hose to strut mount. Tightening torque: 33 Nm (3.4 kgf-m, 25 ft. lbs.) 2. Install the brake hose to caliper body using a new gasket. Tightening torque (Union bolt): 18 Nm (1.8 kgf-m, 13.0 ft. lbs.) Page 6509 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 3541 Crankshaft Position, Camshaft Position And Knock Sensors Page 5164 - When checking, use a test harness (1). Do not directly apply the tester probe to any connector terminal of the airbag. Damage to the connector terminal may cause the airbag to activate erroneously. - Do not check continuity of either of the airbag modules for driver, passenger or side, or pretensioner. Brakes - Rear Brake Caliper Modification Brake Caliper: Technical Service Bulletins Brakes - Rear Brake Caliper Modification NUMBER: 06-36-06 DATE: 06/23/06 APPLICABILITY: 2001 MY and later Impreza WRX SUBJECT: Modification to Rear Brake Caliper INTRODUCTION This bulletin is for informational purposes only. A production change was made to the rear brake caliper on 01MY and newer Impreza WRX. The washer between the caliper body and the backing plate has been discontinued. A change has been made to the caliper body to maintain the correct geometry, although the part numbers have not changed. PRODUCTION LINE CHANGE Production line changes have been incorporated into the VINs shown. PART INFORMATION REPAIR PROCEDURE/INFORMATION Refer to the applicable Subaru Service Manual located on the STIS (Subaru Technical Information System) web site. CLAIM REIMBURSEMENT/WARRANTY INFORMATION For vehicles within the basic New Car Limited Warranty period, refer to the Subaru Warranty Wizard(R) for claim submission information. Locations Electronic Throttle Actuator Relay: Locations Solenoid Valve, Actuator, Emission Control System Parts And Ignition System Parts (Part 5) Page 5122 CASTER ^ Inspection 1) Place the front wheel on turning radius gauge. Make sure ground contacting surfaces of front and rear wheels are set at the same height. 2) Set the adapter into center of wheel, and then install the wheel alignment gauge. 3) Follow the wheel alignment gauge operation manual to measure caster angle. NOTE: Refer to "SPECIFICATION" for caster values. STEERING ANGLE ^ Inspection 1) Place the vehicle on a turning radius gauge. 2) While depressing the brake pedal, turn the steering wheel fully to the right and left. With the steering wheel held at each fully turned position, measure both the inner and outer wheel steering angle. Steering angle: ^ Adjustment 1) Turn the tie-rod to adjust steering angle of both inner and outer wheels. 2) Check the toe-in. NOTE: Correct the boot if it is twisted. Page 4619 1. Set the vehicle on a lift. 2. Loosen the wheel nuts. 3. Lift-up the vehicle, and then remove the wheels. 4. Remove the brake pads from caliper body. 5. Disconnect the brake hose from caliper body. 6. Remove the caliper body from housing. 7. Clean mud and foreign particles from the caliper body. CAUTION: Be careful not to allow foreign particles to enter brake hose connector. INSTALLATION 1. 14 INCH TYPE 1. Install the support on housing. Tightening torque: 53 Nm (5.4 kgf-m, 39.1 ft. lbs.) 2. Apply thin coat of Molykote AS-880N (Part No. K0777YA010) to the frictional portion between pad and pad clip. 3. Install the pads on support. 4. Install the caliper body on support. Tightening torque: 37 Nm (3.8 kgf-m, 27.5 ft. lbs.) 5. Replace the brake hose gaskets with new ones, and then connect the brake hose. Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft. lbs.) 6. Bleed air from the brake system. 2. 15 INCH TYPE 1. Install the caliper body on housing. Tightening torque: 53 Nm (5.4 kgf-m, 39.1 ft. lbs.) 2. Apply a thin coat of Molykote AS-880N (Part No. K0777YA010) to the frictional portion between pad and pad clip. 3. Install the pads on caliper body. 4. Replace the brake hose gaskets with new ones, and then connect the brake hose. Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft. lbs.) 5. Bleed air from the brake system. 3. 17 INCH TYPE 1. Install the caliper body on housing. Tightening torque: 65 Nm (6.6 kgf-m, 47.9 ft. lbs.) 2. Install the pads on caliper body. 3. Replace the brake hose gaskets with new ones, and then connect the brake hose. Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft. lbs.) 4. Bleed air from the brake system. DISASSEMBLY 1. 14 INCH TYPE 1. Remove the boot ring. Page 3429 B134-B136 Page 7207 (3) Install the modified check valve and valve cushion. Rear Check Valve on Forester Page 4689 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 6515 B136-B141 Page 6346 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 5833 2. Deep damage caused by scratching fences, etc. A dent cannot be repaired but a whitened or swelled part can be removed. 3. Deep damage such as a break or hole that requires filling Much of the peripheral grained surface must be sacrificed for repair, and the degree of restoration is not really worth the expense. (The surface, however, will become almost flush with adjacent areas.) Recommended repair kit: PP Part Repair Kit (NRM) Locations Sensor Page 929 1. BACK-UP LIGHT SWITCH AND NEUTRAL POSITION SWITCH 1) Install the back-up light switch and neutral position switch with harness. Tightening torque: 32.3 Nm (3.3 kgf-m, 23.8 ft. lbs.) 2) Connect the connector of back-up light switch and neutral position switch. 3) Install the air intake duct and cleaner case. (Non-turbo model) 4) Install the intercooler. (Turbo model) 5) Connect the battery ground cable to battery. Neutral Switch & Backup Switch Testing Switches and Harness INSPECTION BACK-UP LIGHT SWITCH Inspect the back-up light switch. NEUTRAL POSITION SWITCH 1) Turn the ignition switch to OFF. 2) Disconnect the connector of neutral position switch. 3) Measure the resistance between neutral position switch terminals. Non-turbo model: Non-turbo model Turbo model: Turbo model ^ Non-turbo model Page 5252 2. Press the ST plunger until the bushing flange protrudes beyond trailing link. ST 927730000 INSTALLER & REMOVER SET 3. Turn the trailing link upside down. Press the ST plunger in the opposite direction that outlines in the former procedure until bushing is correctly positioned in trailing link. ST 927730000 INSTALLER & REMOVER SET 4. Install the housing. INSPECTION Check the trailing links for bends, corrosion or damage. Page 4111 Clutch Fluid: Service and Repair Clutch Fluid INSPECTION 1) Park the vehicle on a level surface. 2) Inspect the fluid level using scale on the outside of the reservoir tank. If the level is below "MIN", add fluid to bring it up to "MAX", and also inspect for leakage. REPLACEMENT CAUTION: ^ The FMVSS No. 116, fresh DOT3 or 4 brake fluid must be used. ^ Cover the bleeder with waste cloth, when loosening it, to prevent brake fluid from being splashed over surrounding parts. ^ Avoid mixing different brands of brake fluid to prevent degrading the quality of the fluid. ^ Be careful not to allow dirt or dust to get into the reservoir tank. NOTE: ^ During bleeding operation, keep the clutch reservoir tank filled with brake fluid to eliminate entry of air. ^ Clutch pedal operating must be very slow. ^ Bleed air from the oil line with help of a co-worker. ^ The amount of brake fluid required is approximately 70 ml (2.4 US fl ounces, 2.5 Imp fl ounces) for total clutch system. 1) Remove the air intake chamber. (Non-turbo model) 2) Remove the intercooler. (Turbo model) 3) Either jack-up the vehicle and place a rigid racks under it, or lift-up the vehicle. 4) Drain brake fluid from the reservoir tank. 5) Refill the reservoir tank with recommended brake fluid. Recommended brake fluid: FMVSS No. 116, fresh DOT3 or 4 brake fluid 6) Drain all contaminated fluid in the same method as air bleeding. 7) Refill the brake fluid before reservoir tank becomes empty, and drain contaminated fluid again. 8) Repeat the above procedure until the contaminated fluid is completely drained. Page 1921 F21-F61 Page 1655 Timing Belt: Service and Repair Part 2 The Contents of This Image/Article Reflects the Contents of 18-136-09 Manual Update dated 02/11/09. 3. Tighten the bolts. Tightening torque: 9.75 Nm (1.0 kgf-m, 7 ft. lbs.) Tightening torque: 6.4 Nm (0.65 kgf-m, 4.7 ft. lbs.) Tightening torque: 6.4 Nm (0.65 kgf-m, 4.7 ft. lbs.) Tightening torque:6.4 Nm (0.65 kgf-m, 4.7 ft. lbs.) Page 2690 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 939 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 769 Crankshaft Position, Camshaft Position And Knock Sensors Page 6390 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Testing and Inspection Exterior Lighting Relay: Testing and Inspection TAIL AND ILLUMINATION RELAY Measure the tail and illumination relay resistance between terminals when connecting terminal No. 4 to battery positive terminal and terminal No. 3 to battery ground terminal. Page 7385 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 3556 B3-B12 Page 4554 2) Apply a thin coat of Molykote AS-880N or equivalent to both faces of inner shim. 3) Apply a thin coat of Molykote M7439 or equivalent to pad clip Page 653 B54-B127 Page 7238 B136-B141 Service and Repair Gear Sensor/Switch: Service and Repair Switches and Harness REMOVAL 1. BACK-UP LIGHT AND NEUTRAL POSITION SWITCH 1) Disconnect the ground cable from battery. 2) Remove the air intake duct and cleaner case. (Non-turbo model) 3) Remove the intercooler. (Turbo model) 4) Disconnect the connector of back-up light switch and neutral position switch. ^ Non-turbo model Non-turbo model ^ Turbo model Turbo model 5) Lift-up the vehicle. 6) Remove the back-up light switch and neutral position switch with harness. INSTALLATION Page 3452 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 2702 B292-B317 Rear Spoiler Spoiler: Service and Repair Rear Spoiler Exterior/Interior Trim REAR SPOILER Rear Spoiler REMOVAL 1. Disconnect the ground cable from battery. 2. Open the trunk lid. 3. Remove the electrical connector (A) of high mount stop light. 4. Loosen the mounting nut of rear spoiler to remove rear spoiler. CAUTION: When removing the nut, do not drop it into trunk lid. - Pay attention to avoid damage during removal or installation. Small-sized rear spoiler: Four tightening positions, two clips Page 5178 Steering Gear: Service and Repair Steering Gearbox Installation Steering Gearbox INSTALLATION 1) Insert the gearbox into crossmember, being careful not to damage the gearbox boot. 2) Tighten the gearbox to crossmember bracket via clamp with bolts to specified torque. Tightening torque: 60 Nm (6.1 kgf-m, 44.3 ft. lbs.) ^ Non-turbo model Non-Turbo Model ^ Turbo model Turbo Model 3) Connect the pipe D first to gear box, and pipe C second. Tightening torque: 15 Nm (1.5 kgf-m, 10.8 ft. lbs.) Page 5052 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 1846 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 4424 21) Remove the oil pan. 22) Disconnect the harness connector and transmission ground terminal. 23) Remove the harness assembly. INSTALLATION 1) Pass the harness assembly through the hole in the transmission case. 2) Connect the harness connector and transmission ground. Diagram Information and Instructions Wiper Motor: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 633 4) Using the ST, tighten the bolts of inhibitor switch. ST 499267300 STOPPER PIN 5) Install the select cable to range select lever. 6) Install the plate assembly to transmission. 7) Install the washer and snap pin to range select lever. 8) Install the front and center exhaust pipes. (Non-turbo model) 9) Install the center exhaust pipe. (Turbo model) 10) Lower the vehicle. 11) Install the inhibitor switch connector from stay. 12) Connect the inhibitor switch connector. Page 5507 - Do not allow water or oil to come in contact with the connector terminals. Do not touch the connector terminals. - Either of the airbag modules for driver, passenger or side, or pretensioner must not be disassembled. - The removed front seat with the airbag module must be kept at least 200 mm (8 in) away from walls and other objects. - Do not use the airbag or pretensioner parts from other vehicles. Always replace defective parts with new parts. - Never reuse a deployed airbag or pretensioner. - When painting or performing sheet metal work on the front part of the vehicle, including the front wheel apron, front fender, and front side frame, remove the front sub sensors and wire harness of the airbag system. Page 4222 9) Place the PTJ boot at the center of shaft. 10) Align the alignment marks, and then install the trunnion on shaft. 11) Install the snap ring to shaft. CAUTION: Confirm that the snap ring is completely fitted in shaft groove. 12) Fill 100 to 110 g (3.53 to 3.88 ounces) of specified grease into the interior of PTJ outer race. 13) Apply a coat of specified grease to roller kit and trunnion. 14) Align the alignment marks on roller kit and trunnion, and then install the free ring. CAUTION: Be careful with the roller kit position. 15) Align the alignment marks on shaft and outer race, and then install the outer race. 16) Install the circlip in the groove on PTJ outer race. CAUTION: Pull the shaft lightly and assure the circlip is completely fitted in groove. 17) Apply an even coat of the specified grease 30 to 40 g (1.06 to 1.41 ounces) to the entire inner surface of boot. 18) Install the PTJ boot taking care not to twist it. CAUTION: ^ PTJ installation surface of PTJ boot shall be cleaned so as to be free from grease and other substances. ^ When installing the PTJ boot, position the outer race of PTJ at center of its travel. Page 3579 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 1191 Note: Remember to always replace the banjo bolt and mesh filter screen when replacing the turbocharger. Proper vehicle maintenance should be reviewed with the customer to avoid a recurring problem in the future. Front Sub Sensor Impact Sensor: Service and Repair Front Sub Sensor FRONT SUB SENSOR REMOVAL 1. Turn the ignition switch to OFF. 2. Disconnect the ground cable from battery, and wait for at least 20 seconds before starting work. 3. Remove the front bumper. 4. Remove the bolt, and then detach the front sub sensor. 5. Disconnect the connector from front sub sensor. B: INSTALLATION Install in the reverse order of removal. Tightening torque: Refer to "COMPONENT" in "General Description". See: Locations Page 4020 R72-R145 R148 Page 1963 ^ STI model 2. Install the front exhaust pipe covers. Tightening torque: Turbo model 7.5 Nm (0.8 kgf-m, 5.5 ft. lbs.) STI model 25 Nm (2.5 kgf-m, 18.1 ft. lbs.) 3. Install the upper exhaust manifold cover (RH). Tightening torque: Turbo model 7.5 Nm (0.8 kgf-m, 5.5 ft. lbs.) STI model 19 Nm (1. 9 kgf-m, 13.7 ft. lbs.) 4. Install the front exhaust pipe assembly. Tightening torque: 35 Nm (3.6 kgf-m, 26 ft. lbs.) 5. Connect the exhaust manifold (RH) to turbocharger joint pipe. ^ Turbo model Tightening torque: T1: 35 Nm (3.6 kgf-m, 26 ft. lbs.) T2: 40 Nm (4 kgf-m, 28.9 ft. lbs.) Page 6424 - When checking, use a test harness (1). Do not directly apply the tester probe to any connector terminal of the airbag. Damage to the connector terminal may cause the airbag to activate erroneously. - Do not check continuity of either of the airbag modules for driver, passenger or side, or pretensioner. Page 4138 Clutch Pedal Assembly: Description and Operation CONSTRUCTION - The hydraulic clutch pedal is connected to the master cylinder via a rod. - The clutch pedal and brake pedal are mounted on the same bracket. - The clutch pedal has a mechanism that reduces (assists) the force required to depress the clutch pedal and reduce the initial pedal depressing force. - A starter interlock mechanism is provided to prevent the engine from starting unless the clutch pedal is pressed. Page 984 Alignment: Service and Repair Wheel Alignment INSPECTION Check the following items before taking wheel alignment measurement. Check items before taking wheel alignment measurement: tire air pressure ^ unbalanced right and left tire wear, size difference ^ tire run-out ^ ball joint excessive play, wear ^ tie rod end excessive play, wear ^ wheel bearing excessive play ^ right and left wheel base imbalance ^ steering link part deformed, excessive play ^ suspension part deformed, excessive play Check, adjust and/or measure the wheel alignment in accordance with procedures indicated in the figure: WHEEL ARCH HEIGHT 1) Set the vehicle on a level surface. 2) Set the vehicle to "curb weight" conditions. (Empty luggage compartment, install spare tire, jack, service tools, and top up fuel tank.) 3) Set the steering wheel in a straight line, then remove the vehicle straight ahead more than 5 m (16 ft.) to settle the suspension. 4) Suspend the thread from wheel arch (point "A" in figure below) to determine a point directly above center of wheel. 5) Measure the distance between measuring point "A" and center of wheel. Page 2201 F61-R47 Page 6466 Oil Pressure Sender: Service and Repair Oil Pressure Switch Removal 1. Remove the generator from bracket. 2. Disconnect the terminal from oil pressure switch. 3. Remove the oil pressure switch. Installation 1. Apply liquid gasket to the oil pressure switch threads. ^ Liquid gasket. THREE BOND 1324 (Part No. 004403042) or equivalent 2. Install the oil pressure switch onto engine block. ^ Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft. lbs.) 3. Connect the terminal of oil pressure switch. Engine Controls - A/F, O2 Sensor Diagnostic Information Oxygen Sensor: Technical Service Bulletins Engine Controls - A/F, O2 Sensor Diagnostic Information Bulletin Number: 11-92-08 Date: 01/05/09 APPLICABILITY: 1999MY and later Forester 1999MY and later Impreza 2000MY and later Legacy 2006MY and later Tribeca SUBJECT: Air/Fuel Ratio Sensor and Oxygen Sensor INTRODUCTION This bulletin is for information purposes only. REPAIR/SERVICE INFORMATION When performing diagnostics or reading Diagnostic Trouble Codes (DTC) for Air Fuel Ratio (A/F) sensors and Oxygen (O2) sensors use the following information to identify, locate and repair the appropriate sensor and sensor circuits: (1) Rarely will multiple sensors fail at the same time. (2) On vehicles with only one O2 sensor, the designation for that O2 sensor will be bank 1. (3) On vehicles with only one A/F sensor, the designation for that A/F sensor will be bank 1. (4) Any reference to sensor 1 is an A/F sensor. (5) Any reference to sensor 2 is an O2 sensor. (6) Early PZEV vehicles used an additional O2 sensor behind the rear catalyst and is designated sensor 3. (7) On vehicles with A/F and O2 sensors on the right (Passenger Side) and left (Driver side) of the vehicle, Bank 1 is the right side (Passenger Side) and Bank 2 is the left side (Driver side). Example: DTC P0030 HO2S HEATER CONTROL CIRCUIT (Bank 1 Sensor 1). This DTC is referring to the A/F sensor and since it is on a 2007 Forester there is only one A/F sensor and one O2 sensor. Example (as illustrated): DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (Bank 1 Sensor 2). This DTC is referring to the O2 sensor on the right side exhaust (or the O2 sensor of a vehicle with only one O2 sensor). Page 2987 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 3507 Install in the reverse order of removal. NOTE: Always use new gaskets. Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Locations Air Flow Meter/Sensor: Locations Sensor (Part 1) Page 2835 Engine Control Module (ECM) I/O Signal (Part 6) Service and Repair Power Steering Line/Hose: Service and Repair Pipe Assembly REMOVAL 1) Disconnect the ground cable from battery. 2) Lift-up the vehicle, and then remove the jack-up plate. 3) Remove the one pipe joint at the center of gearbox, and then connect the vinyl hose to pipe and joint. Discharge fluid by turning steering wheel fully clockwise and counterclockwise. Discharge fluid similarly from the other pipe. ^ Non-turbo model Non-turbo model ^ Turbo model Turbo model 4) Remove the clamp E from pipes C and D. Page 5257 9) Remove the front hub unit bearing. If it is hard to remove, use STs. ST1 926470000 AXLE SHAFT PULLER ST2 28099PA110 AXLE SHAFT PULLER PLATE INSTALLATION 1) Tighten the front hub unit bearing to the housing with four bolts. 2) Install the front drive shaft. 3) Tighten the axle nut temporarily. 4) Install the disc rotor on hub. 5) Install the disc brake caliper on the housing. Tightening torque: 78 Nm (8.0 kgf-m, 57.9 ft. lbs.) 6) While depressing the brake pedal, tighten a new axle nut (olive color) to specified torque and lock it securely. Tightening torque: 220 Nm (22.4 kgf-m, 162 ft. lbs.) CAUTION: ^ Install the wheel after installation of the axle nut. Failure to follow this rule may damage the wheel bearing. ^ Do not overtighten it as this may damage wheel bearing. 7) After tightening the axle nut, lock it securely. Page 7127 7. Apply primer to adhesive layer of body. Painted surface primer: Dow Automotive ESSEX U-413 or equivalent NOTE: Primer once attached to painted surface of the body and internal trim is hard to wipe off. Mask the circumference of such areas. - Let the primer dry for about ten minutes before installing the glass. - Do not touch the surface coated with primer. 8. Cut off the cartridge nozzle tip as shown and set it in sealant gun. 9. Apply adhesive to the glass end surface as shown. Page 7035 B128-B134 Page 5631 Disclaimer Page 6785 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 2648 R58-R69 Page 4485 AT MODEL Page 7300 Windshield Washer Spray Nozzle: Service and Repair Front Washer Nozzle FRONT WASHER NOZZLE REMOVAL 1. Remove the washer hose from the washer nozzle. 2. Open the clips on the underside of the hood with a thin screwdriver or other tool, and remove the washer nozzle. INSTALLATION 1. Install in the reverse order of removal. 2. Adjust the position of the washer liquid sprayer. Page 6168 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Application and ID Paint: Application and ID Note: This is the most accurate information at the time of printing. The various paint manufacturers designate their own stock numbers and their formulas are updated on a continual basis. Some vendors may have different color names than the ones provided by SOA. Double check vendor numbers for accurate color match. If there are any problems with the listed vendor numbers, please have body shop personnel contact the specific paint vendor for updated information. The paint codes can be found on the vehicle's VIN plate located either on the left (driver-side) strut tower or at the base of the left "B" pillar in the opening between the front and rear door~ The color codes will be 3 characters for either a solid color or Two-Tone. Examples: 32J - Obsidian Black Pearl (monotone) 4NJ - Obsidian Black Pearl / Steel Gray Metallic (two-tone) As always, contact the SOA Tech Support Line if you need further assistance. Page 7340 B128-B134 Page 4921 B17-B20 Page 3652 B3-B12 Floor Under Cover Underbody Cover: Description and Operation Floor Under Cover FLOOR UNDER COVER - A floor under cover is installed to both sides of the vehicle's floor part to improve the aerodynamic characteristics at the underside of the vehicle. - Taking recycling reasons into account, polypropylene (PP) material is used. Page 6057 Keyless Entry Module: Service and Repair KEYLESS ENTRY CONTROL UNIT REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the instrument panel lower cover. 3. Remove the nut, and then remove the keyless entry control unit while disconnecting connector. 4. Disconnect the keyless entry control unit and other electrical control module. INSTALLATION Install in the reverse order of removal. Page 5368 Condenser Fan Motor Relay: Testing and Inspection INSPECTION While applying battery voltage to the terminal between (3) and (4), check continuity between (1) and (2). If no continuity exists, replace the relay with a new one. Page 1289 Wheel Bearing: Service and Repair Front Hub Unit Bearing REMOVAL 1) Disconnect the ground cable from battery. 2) Lift-up the vehicle and remove the front wheels. 3) Unlock the axle nut. 4) Remove the axle nut using a socket wrench while depressing the brake pedal. CAUTION: Remove the wheel before loosening the axle nut. Failure to follow this rule may damage the wheel bearings. 5) Remove the disc brake caliper from housing, and suspend it from strut using a wire. 6) Remove the disc rotor from hub. NOTE: If the disc rotor seizes up within hub, drive disc rotor out by installing an 8-mm bolt in screw hole on rotor. 7) Remove the ABS wheel speed sensor assembly and harness. 8) Remove four bolts from housing. Page 4228 5) Install the DOJ inner race on shaft, and fit the snap ring with pliers. NOTE: Confirm the snap ring is completely fitted in shaft groove. 6) Install the cage, which was previously fitted, to inner race fixed upon shaft. NOTE: Fit the cage with protruded part aligned with the track on inner race, and then turn by a half pitch. 7) Fill 80 to 90 g (2.82 to 3.17 ounces) of specified grease into the interior of DOJ outer race. 8) Apply a coat of specified grease to cage pocket and six balls. 9) Insert six balls into cage pocket. 10) Align the outer race track and ball positions and place in the part where shaft, inner race, cage and balls are previously installed, and then fit the outer race. Service and Repair Radio/Stereo Noise Filter: Service and Repair NOISE SUPPRESSOR REMOVAL 1. SEDAN 1. Disconnect the ground cable from battery. 2. Remove the rear pillar upper trim. 3. Remove the rear shelf trim. 4. Disconnect the feeder cord connector from antenna amplifier. 5. Disconnect the harness connector of noise suppressor from terminal on glass antenna. 6. Remove the harness clip. 7. Remove the mounting nut and detach the noise suppressor. 2. WAGON 1. Disconnect the ground cable from battery. 2. Remove the rear gate trim. 3. Disconnect the connector from noise suppressor. 4. Remove the mounting nut and detach the noise suppressor. INSTALLATION Install in the reverse order of removal. Page 2009 Page 1589 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 4393 F21-F61 Page 1146 Coolant: Testing and Inspection Inspection Relationship Of Coolant Concentration And Freezing Temperature The concentration and safe operating temperature of the coolant is shown in the diagram. Measuring the temperature and specific gravity of the coolant will provide this information. ^ If the coolant temperature is 25°C (77°F) and its specific gravity is 1.054 and the concentration is 35% (point A), the safe operating temperature is -14°C (7°F) (point B), and the freezing temperature is -20°C (-4°F) (point C). Procedure To Adjust The Concentration Of The Coolant To adjust the concentration of the coolant according to temperature, find the proper fluid concentration in the above diagram and replace the necessary amount of coolant with an undiluted solution of SUBARU genuine coolant (concentration 50%). The amount of coolant that should be replaced can be determined using the diagram. ^ Assume that the coolant concentration must be increased from 25% to 40%. Find point A, where the 25% line of coolant concentration intersects with the 40% curve of the necessary coolant concentration, and read the scale on the vertical axis of the graph at height A. The quantity of coolant to be drained is 2.1 l (2.2 US qt, 1.8 Imp qt). Drain 2.1 l (2.2 US qt, 1.8 Imp qt) of coolant from the cooling system and add 2.1 l (2.2 US qt, 1.8 Imp qt) of the undiluted solution of SUBARU coolant. If a coolant concentration of 50% is needed, drain all the coolant and refill with the undiluted solution only. Page 1557 18. Connect the connector to the tumble generator valve sensor. 19. Connect the connector to the tumble generator valve actuator. 20. Connect the connector to the fuel injector. 21. Install the throttle body to the intake manifold. NOTE: Replace the gasket with a new one. Page 5041 RAPS-01 Diagrams: Other diagrams referred to by name within these diagrams (i.e. "REF. TO GND-01", etc) can be found at Diagrams by Diagram Name. See: Diagrams/Electrical Diagrams/Diagrams By Diagram Name Connector and Ground Locations: The locations of the Connectors or Grounds shown within these diagrams can be found via the connector or ground number at Vehicle Locations. See: Locations Rear Accessory Power Supply Socket System Page 2092 R58-R69 Page 3589 B54-B127 Page 3739 Spark Plug: Testing and Inspection INSPECTION Check the electrodes and inner and outer ceramic insulator of plugs, noting the type of deposits and the degrees of electrode erosion. 1. Normal: Brown to grayish-tan deposits and slight electrode wear indicates correct spark plug heat range. 2. Carbon fouled: Dry fluffy carbon deposits on insulator and electrode are mostly caused by slow speed driving in city, weak ignition, too rich fuel mixture and dirty air cleaner, etc. Page 1327 6. Measure the thrust clearance of camshaft with dial gauge. If the thrust clearance exceeds the limit or offset wear occurs, replace the caps and cylinder head as a set. If necessary, replace the camshaft. Standard. 0.068 - 0.116 mm (0.0027 0.0046 inch) Limit. 0. 14 mm (0. 0055 inch) Page 5393 Step 1 - 6 Page 1707 Spark Plug: Service and Repair Spark Plug REMOVAL CAUTION: All spark plugs installed on an engine, must be of the same heat range. Spark plug: NGK: ILFR6B RH SIDE 1. Disconnect the ground cable from battery. 2. Remove the air cleaner lower case. Page 3015 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 903 11) Remove the clamp, and then remove the shift lock solenoid. INSTALLATION Install in the reverse order of removal. INSPECTION Step 1 - Step 4 Page 3253 B17-B20 Page 5364 CAUTION: Replace the O-rings on hoses or pipes with new ones, and then apply compressor oil. Confirm that lower guide of condenser (A) has been fitted into holes on radiator panel. 2. Charge refrigerant. Tightening torque: T1: 7.4 N.m (0.75 kgf-m, 5.4 ft-lb) T2: 15 N.m (1.5 kgf-m, 10.8 ft-lb) Page 2834 Engine Control Module (ECM) I/O Signal (Part 5) Page 1519 Oil Pick Up/Strainer: Service and Repair Oil Pan and Strainer Removal 1. Set the vehicle on a lift. 2. Remove the front wheels. 3. Disconnect the ground cable from battery. 4. Disconnect the connector from mass airflow and intake air temperature sensor. Page 356 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 5654 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Locations Fuel Pump Relay: Locations Solenoid Valve, Actuator, Emission Control System Parts And Ignition System Parts (Part 5) Page 2856 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Service and Repair Control Module: Service and Repair Transmission Control Module (TCM) REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the lower cover and then disconnect the connector. 3) Remove the knee bolster. 4) Disconnect the connectors from TCM. 5) Remove the TCM. INSTALLATION 1) Install the TCM. 2) Connect the connectors to TCM. 3) Install in the reverse order of removal. 4) If replacing the TCM, execute the advance operation of learning control promotion. Page 1145 Coolant: Fluid Type Specifications The cooling system has been filled at the factory with a high quality, corrosion-inhibiting, year-round coolant which provides protection against freezing down to -33°F (-36°C). For adding, use genuine SUBARU coolant or an equivalent: a mixture of 50% soft water and 50% ethylene-glycol based coolant. Use of improper coolants may result in corrosion in the cooling system. It is important to maintain protection against freezing and corrosion, even if freezing temperatures are not expected. Never mix different kinds of coolant. Do not splash coolant on the vehicle's paint. Front Accessory Power Supply Socket Auxiliary Power Outlet: Service and Repair Front Accessory Power Supply Socket FRONT ACCESSORY POWER SUPPLY SOCKET REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the console front panel. 3. Disconnect the harness connectors and remove front accessory power supply socket. INSTALLATION Install in the reverse order of removal. Specifications Piston: Specifications PISTON Outer diameter STD A ......................................................................................................................... ................................................. 99.505 - 99.515 mm (3.9175 - 3.9179 in.) B ...................................... .................................................................................................................................... 99.495 99.505 mm (3.9171 - 3.9175 in.) 0.25 mm (0.0098 in.) OS ..................................................................................................................................... 99.745 99.765 mm (3.9270 - 3.9278 in.) 0.50 mm (0.0197 in.) OS ................................................................................................................................... 99.995 100.015 mm (3.9368 - 3.9376 in.) Piston pin Standard clearance between piston pin and hole in piston STD ..................................................................................................................................................... ..................... 0.004 - 0.008 mm (0.0002 - 0.0003 in.) Limit ................................................................ ................................................................................................................................... 0.020 mm (0.0008 in.) Degree of fit Piston pin must be fitted into position with thumb at 20°C (68°F). Note: STD = Standard OS = Oversized Page 1494 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 3737 Spark Plug: Specifications Type ..................................................................................................................................................... ............................................................. Manufacturer ILFR6B ................................................................................................................................................ .......................................................................... NGK Gap ...................................................................................................................................................... ................................. 0.7 - 0.8 mm (0.028 - 0.031 in) Torque ................................................................................................................................................. ........................................................ 21 N.m (15 ft.lb) Page 2367 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 7176 R58-R69 Page 5245 Suspension Strut / Shock Absorber: Service and Repair Rear Suspension Rear Strut REMOVAL 1. Remove the rear seat cushion and backrest. (Sedan model) 2. Remove the strut cap of quarter trim. (Wagon model) 3. Loosen the rear wheel nuts. 4. Lift-up the vehicle, and remove rear wheels. 5. Remove the brake hose clip, and then remove the brake hose from rear strut. 6. Remove the bolts which secure the rear strut to housing. 7. Remove the nuts securing strut mount to body. INSTALLATION 1. Secure the strut mount to vehicle body using a new self-locking nut. Tightening torque: 20 Nm (2.0 kgf-m, 14.5 ft. lbs.) 2. Secure the rear strut to housing using a new self-locking nut. Tightening torque: 200 Nm (20.0 kgf-m, 145 ft. lbs.) 3. Install the brake hose to lower side of strut, then insert the brake hose clip. CAUTION: ^ Check the hose clip is positioned properly. ^ Check the brake hose for twisting, or excessive tension. ^ Do not subject the ABS wheel speed sensor harness to excessive tension. 4. Lower the vehicle and tighten wheel nut. Tightening torque: 90 Nm (9.2 kgf-m, 66 ft. lbs.) 5. Install the rear seat backrest and rear seat cushion. (Sedan model) 6. Install the strut cap to rear quarter trim. (Wagon model) NOTE: Check the wheel alignment and adjust if necessary. DISASSEMBLY For disassembly of rear strut, refer to procedures outlined under front strut as a guide. ASSEMBLY Refer to Front Strut as a guide for assembly procedures. Page 724 B292-B317 Page 7043 R58-R69 Page 3160 SECONDARY AIR COMBI VALVE LH Install in the reverse order of removal. NOTE: Use a new gasket. SECONDARY AIR COMBI VALVE RH Install in the reverse order of removal. NOTE: Use a new gasket. Page 6564 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 5595 Air Bag Control Module: Service and Repair AIRBAG CONTROL MODULE REMOVAL CAUTION: - Do not disassemble the airbag control module. - If the airbag control module is deformed or if water damage is suspected, replace the airbag control module with a new one. - Do not drop the airbag control module. - After removal, keep the airbag control module on a dry, clean surface away from moisture, heat, and dust. 1. Turn the ignition switch to OFF. 2. Disconnect the ground cable from battery, and wait for at least 20 seconds before starting work. 3. Remove the console cover. 4. Remove the center console panel. 5. Disconnect the connector from airbag control module. 6. Remove the four bolts and remove airbag control module. INSTALLATION CAUTION: Use new bolts (for airbag control module only) during installation. Install in the reverse order of removal. Tightening torque: Refer to "COMPONENT" in "General Description". See: Air Bag Systems/Locations Front Speaker Speaker: Service and Repair Front Speaker FRONT SPEAKER REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the front door trim. 3. Remove the front speaker mounting screws. 4. Disconnect the harness connector and remove front speaker. INSTALLATION Install in the reverse order of removal. Page 1428 Engine Oil: Service and Repair REPLACEMENT 1. Open the engine oil filler cap for quick draining of engine oil. 2. Drain the engine oil by loosening the engine oil drain plug. 3. Replace the drain plug gasket. 4. Tighten the engine oil drain plug after draining engine oil. Tightening torque: 44 Nm (4.5 kgf-m, 32.5 ft. lbs.) 5. Install the service hole cover. 6. Use the engine oil of proper quality and viscosity, fill engine oil through the oil filler duct up to upper level on level gauge. Make sure that the vehicle is placed level when checking oil level. Recommended oil. API standard SM with the "Energy Conserving" logo is printed. ILSAC standard, GF4 "Star burst mark" label is on the container. Engine oil capacity. Upper level 4.0 L (4.2 US qt, 3.5 Imp qt) Lower level 3.0 L (3.2 US qt, 2.6 Imp qt) Page 6128 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 2198 B292-B317 Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 1586 R72-R145 R148 Page 4641 Electrical Component Location Page 4158 2) Fully depress the clutch pedal. 3) Adjust the clutch pedal plate and clutch switch so that the gap between them is 3 - 3.5 mm (0. 12 - 0.14 inch). 4) Tighten the lock nut. Tightening torque: 8 Nm (0.8 kgf-m, 5.9 ft. lbs.) Page 3893 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Diagram Information and Instructions Oil Pressure Warning Lamp/Indicator: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 3742 Spark Plug: Service and Repair Spark Plug REMOVAL CAUTION: All spark plugs installed on an engine, must be of the same heat range. Spark plug: NGK: ILFR6B RH SIDE 1. Disconnect the ground cable from battery. 2. Remove the air cleaner lower case. Page 5674 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 6263 Non-Turbo Model Page 7414 B134-B136 Front Suspension Suspension Strut / Shock Absorber: Service and Repair Front Suspension Front Strut REMOVAL 1) Remove the wheel. 2) Remove the bolt securing the brake hose from strut. 3) Scribe an alignment mark on the camber adjusting bolt which secures the strut to housing. 4) Remove the bolt securing ABS wheel speed sensor harness. 5) Remove the two bolts securing housing to strut. NOTE: While holding the head of adjusting bolt, loosen self-locking nut. 6) Remove the three nuts securing the strut mount to body. INSTALLATION 1) Install the strut mount at upper side of strut to body, and then tighten with the nuts. Tightening torque: 20 Nm (2.0 kgf-m, 14.5 ft. lbs.) 2) Position the aligning mark on camber adjustment bolt with aligning mark on lower side of strut. Install the strut to housing with a new self-locking nut. NOTE: While holding the head of adjusting bolt, tighten the self-locking nut. Page 5766 Wiring Diagram Page 658 B292-B317 Page 2188 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Specifications Crankshaft Main Bearing: Specifications MAIN BEARING Thickness at center #1, #3 STD .......................................................................................................... ................................................................ 1.998 - 2.011 mm (0.0787 - 0.0792 in.) 0.03 mm (0.0012 in.) US ......................................................................................................................................... 2.017 - 2.020 mm (0.0794 - 0.0795 in.) 0.05 mm (0.0020 in.) US ......................................................................................................................................... 2.027 2.030 mm (0.0798 - 0.0799 in.) 0.25 mm (0.0098 in.) US ......................................................................................................................................... 2.127 2.130 mm (0.0837 - 0.0839 in.) #2, #4, #5 STD .................................................................................................................................... ...................................... 2.000 - 2.013 mm (0.0787 - 0.0793 in.) 0.03 mm (0.0012 in.) US ......................................................................................................................................... 2.019 2.022 mm (0.0795 - 0.0796 in.) 0.05 mm (0.0020 in.) US ......................................................................................................................................... 2.029 2.032 mm (0.0799 - 0.0800 in.) 0.25 mm (0.0098 in.) US ......................................................................................................................................... 2.129 2.132 mm (0.0838 - 0.0839 in.) NOTE: US: Undersize OS: Oversize ID: Inside Diameter OD: Outside Diameter Page 3089 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 2703 B380-f6 Page 1830 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 2030 F21-F61 Page 1229 - Do not drop the airbag modulator parts, subject them to high temperature over 93 degrees C (199 degrees F), or let water, oil, or grease get on them; otherwise, the internal parts may be damaged and reliability greatly lowered. - If any damage, opening, or rust is found on the airbag system wire harness, do not attempt to repair using soldering equipment. Be sure to replace the faulty harness with a new genuine part. - Install the wire harness securely with the specified clips to avoid interference or tangled up with other parts. Engine Controls - DTC P0340/P0345 After Camshaft R & R Camshaft Position Sensor: Customer Interest Engine Controls - DTC P0340/P0345 After Camshaft R&R Number: 02-107-09 Date: 03/24/09 Applicability: 2004~06MY Baja 2.5L Turbo 2004~06MY Impreza 2.5L Turbo 2004~06MY Forester 2.5L Turbo 2004~06MY Legacy/Outback 2.5L Turbo SUBJECT: Intake Camshaft Replacement Introduction If you encounter a vehicle that has a CEL and P0340 or P0345 stored in memory immediately after replacing the intake camshaft(s), the air gap between the camshaft and camshaft position sensor may be out of specification. A modification was made to the plate area of the camshaft where the camshaft position sensor picks up the signal. Parts Information Repair Procedure/ Information Using a feeler (thickness) gauge, measure the gap between the camshaft and camshaft position sensor. The correct gap is between 0.15mm to 0.98mm (0.0059 to 0.0386 in.) If the gap is over 0.98mm (0.0386 in.) replace the camshaft position sensor. Refer to the applicable service manual. Warranty/Claim Information For vehicles within warranty, refer the Subaru Warranty Wizard for claim submission information. Locations Main Relay (Computer/Fuel System): Locations Main Fuse Box (M/B) Solenoid Valve, Actuator, Emission Control System Parts And Ignition System Parts (Part 5) Page 727 F61-R47 Page 3149 Vehicle Speed Sensor: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 2778 4. Connect the clip to the crossmember. 5. Lower the vehicle. 6. Connect the battery ground cable to battery. Front Brake Caliper: Service and Repair Front Front Disc Brake Assembly REMOVAL 1. 15 INCH TYPE CAUTION: Do not allow brake fluid to come in contact with vehicle body; wash away immediately with water and wipe off completely if spilled. 1. Set the vehicle on a lift. 2. Loosen the wheel nuts. 3. Lift-up the vehicle, and then remove the front wheel. 4. Remove the union bolt, and then disconnect the brake hose from caliper body assembly. 5. Remove the bolt securing lock pin to caliper body. 6. Raise the caliper body, and then move it toward vehicle center to separate it from support. 7. Remove the support from housing. NOTE: Remove the support only when replacing it or the disc rotor. It need not be removed when servicing the caliper body assembly. 8. Clean mud and foreign particles from the caliper body assembly and support. 2. 16 INCH TYPE CAUTION: Do not allow brake fluid to come in contact with vehicle body; wash away at once with water and wipe off completely if spilled. 1. Set the vehicle on a lift. 2. Loosen the wheel nuts. 3. Lift-up the vehicle, and then remove the front wheel. 4. Remove the union bolt, and then disconnect the brake hose from caliper body assembly. Page 4684 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 3469 B380-f6 Page 2041 Engine Control Module (ECM) I/O Signal (Part 5) Page 6847 F21-F61 Page 2991 B128-B134 Page 518 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 2630 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 3901 B292-B317 Page 4396 R72-R145 R148 Page 3808 Transmission Speed Sensor: Service and Repair Rear Vehicle Speed Sensor Rear Vehicle Speed Sensor REMOVAL 1) Set the vehicle on a lift, and then lift-up the vehicle. 2) Disconnect the connector from rear vehicle speed sensor. ^ MP-T model MP-T model ^ VTD model VTD model 3) Remove the rear vehicle speed sensor. ^ MP-T model MP-T model ^ VTD model Page 954 F21-F61 Page 6716 ILM(ES)-02 Page 5341 Step 1 - 5 Inhibitor Switch Transmission Position Switch/Sensor: Service and Repair Inhibitor Switch Inhibitor Switch INSPECTION When the driving condition or starter motor operation is erroneous, first check the shift linkage for improper operation. If the shift linkage is functioning properly, check the inhibitor switch. 1) Disconnect the inhibitor switch connector. 2) Check continuity in inhibitor switch circuits with the select lever moved to each position. NOTE: ^ Also check that continuity in ignition circuit does not exist when the select lever is in "R", "D", "3", "2" and "1" ranges. ^ If the inhibitor switch is inoperative, check for poor contact of connector on transmission side. 3) Check if there is continuity at equal points when the select lever is tilted 1.5° in both directions from "N" range. If there is continuity in one direction and the continuity in the other or if there is continuity at unequal points, adjust the inhibitor switch. 4) Repeat the above checks. If there are abnormalities, adjust the select cable. REMOVAL 1) Set up the vehicle on a lift. 2) Move the select lever to "N" range. 3) Remove the air intake chamber (Non-turbo model). 4) Remove the intercooler. (Turbo model) Page 4249 Page 3077 R72-R145 R148 Page 6992 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 2363 F61-R47 Specifications Camshaft Bearing: Specifications Camshaft cap Gradually tighten the camshaft cap and oil control valve assembly in at least two stages in alphabetical sequence shown in the figure, and then tighten to specified torque. Tightening torque: T1: ....................................................................................................................................................... ................................ 9.75 Nm (1.0 kgf-m, 7.2 ft. lbs.) T2: .................................................................... .................................................................................................................... 20 Nm (2.0 kgf-m, 14.8 ft. lbs.) Page 6285 B54-B127 Page 1832 B3-B12 Page 3459 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 4997 7. Attach the repaired body wire harness to the area directly rearward of the wire clamp with insulating tape to prevent the wire from interfering with the seat rail. (See photos below for location of the wire and tape.) 8. Reinstall the floor carpet. Wrap the previously cut portion of carpet with 1.5 inch wide unwoven adhesive tape. 9. Reinstall the center console trim. Note: Be careful that switch wires attached to the center console trim are not pinched by the parking brake lever during installation. 10. Reinstall the passenger front seat. (Install the seat slide rail cover on Forester model.) 11. Reconnect the negative battery cable. (Reprogram the customer's radio stations presets.) 12. Perform Seat Occupant Detection System calibration. (See applicable service manual.) Note: Impreza models have the bladder type system which will require re-zeroing. Forester models have the load sensor type system which requires re-calibration. 13. Turn on the ignition switch and confirm that the seat heater switches and the air bag warning light works properly. SERVICE PROGRAM IDENTIFICATION LABEL Type or print the necessary information on a recall identification label. The completed label should be attached to the vehicle's upper radiator support. Page 2971 Refer to the illustrations above for more details on locating the appropriate sensors. Testing and Inspection Horn Switch: Testing and Inspection INSPECTION Measure the resistance between horn switch terminal and airbag module bracket. Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 119 B3-B12 Page 1753 A used toothbrush which has been cleaned works great. Manually open the negative pressure valve. Using clean water and a brush, thoroughly clean the valve (inner and outer surface) and the valve seal surface. Check the radiator cap valve opening pressure using a radiator cap tester to insure the cap is within specification (refer to the applicable Subaru Service Manual). Note: If the cap is out of specification replace it. 2. Coolant Reservoir Tank Cleaning Remove the reservoir tank (refer to the applicable Subaru Service Manual). Using clean water, thoroughly clean the inside of the reservoir tank. Reinstall reservoir tank. Fill with coolant to the Full mark. Note: Be sure to use genuine Subaru Super Coolant or Subaru Long Life Coolant, depending upon what type of coolant is currently in the system. 3. Coolant Reservoir Tank Hose Modification Page 4270 1. BACK-UP LIGHT SWITCH AND NEUTRAL POSITION SWITCH 1) Install the back-up light switch and neutral position switch with harness. Tightening torque: 32.3 Nm (3.3 kgf-m, 23.8 ft. lbs.) 2) Connect the connector of back-up light switch and neutral position switch. 3) Install the air intake duct and cleaner case. (Non-turbo model) 4) Install the intercooler. (Turbo model) 5) Connect the battery ground cable to battery. Neutral Switch & Backup Switch Testing Switches and Harness INSPECTION BACK-UP LIGHT SWITCH Inspect the back-up light switch. NEUTRAL POSITION SWITCH 1) Turn the ignition switch to OFF. 2) Disconnect the connector of neutral position switch. 3) Measure the resistance between neutral position switch terminals. Non-turbo model: Non-turbo model Turbo model: Turbo model ^ Non-turbo model Page 6535 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 584 F61-R47 Service and Repair Evaporative Canister Filter: Service and Repair Drain Filter SPECIFICATION Drain filter is built in the canister, and it is a part which cannot be disassembled. Page 1602 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 6311 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 1854 Installation 1. Attach the radiator mounting cushions to the holes on vehicle. 2. Install the radiator to vehicle. NOTE: Fit the pins on lower side of radiator into the cushions on body side. 3. Install the radiator brackets, and then tighten the bolts. ^ Tightening torque: ............................................................................................................................................... 18 Nm (1.8 kgf-m, 13.0 ft. lbs.) 4. Connect the radiator inlet hose (A) and water tank hose (B). 5. Install the reservoir tank. 6. Connect the overflow hose. 7. Install the V-belt cover. Page 5286 For vehicles within the Basic New Car Limited Warranty period, this repair may be claimed using table. Disclaimer Page 3615 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 6616 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 791 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 795 B128-B134 Page 5847 3. Remove the rear combination light assembly. 4. Remove the screw and two clips (both sides). 5. Remove the floor box. 6. Remove the rear skirt trim. 7. Turn over the rear quarter lower trims on both sides, and then loosen the four nuts. 8. Disconnect the license plate light connector, and then remove the rear bumper. 9. Remove the E/A FORM from bumper beam. CAUTION: E/A FORM may easily break. Do not apply excessive force to it during removal. Testing and Inspection Drive Belt: Testing and Inspection Inspection 1. Replace the belts, if cracks, fraying or wear is found. 2. Check the V-belt tension and adjust it if necessary by changing generator installing position and idler pulley installing position. Belt tension (with belt tension gauge) (A) When installing new parts: 640 - 780 Nm (65 - 80 kgf, 144 - 175 ft. lbs.) At inspection: 490 - 640 Nm (50 - 65 kgf, 110 - 144 ft. lbs.) (B) When installing new parts: 740 - 880 Nm (75 - 90 kgf, 166 - 198 ft. lbs.) At inspection: 350 - 450 Nm (36 - 46 kgf, 79 101 ft. lbs.) Belt tension (without belt tension gauge) (A) When installing new parts: 7 - 9 mm (0.276 - 0.354 inch) At inspection: 9 - 11 mm (0.354 - 0.433 inch) (B) When installing new parts: 7.5 - 8.5 mm (0.295 - 0.335 inch) At inspection: 9.0 - 10.0 mm (0.354 - 0.394 inch) Page 4501 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 7163 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 2186 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Locations Brake Switch (Cruise Control): Locations Non-Turbo Model Page 3256 B134-B136 Page 718 B17-B20 Page 1718 NOTE: If the measured value is not within specification, take notes of the value in order to adjust the valve clearance later on. 13. If necessary, adjust the valve clearance. 14. Further turn the crank pulley clockwise. Using the same procedures described previously, and then measure the valve clearances again. 1. Set the arrow mark on cam sprocket to position shown in the figure, and then measure the #2 cylinder exhaust valve and #3 cylinder intake valve clearances. 2. Set the arrow mark on cam sprocket to position shown in the figure, and then measure the #2 cylinder intake valve and #4 cylinder exhaust valve clearances. 3. Set the arrow mark on cam sprocket to position shown in the figure, and then measure the #1 cylinder exhaust valve and #4 cylinder intake valve clearances. 15. After inspection, install the related parts in the reverse order of removal. Tightening torque: 33 Nm (3.4 kgf-m, 25 ft. lbs.) Page 4838 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 3223 Idle Speed: Testing and Inspection Idle Speed INSPECTION 1. Before checking the idle speed, check the following: 1. Ensure the air cleaner element is free from clogging, ignition timing is correct, spark plugs are in good condition, and that the hoses are connected properly. 2. Ensure the malfunction indicator light does not illuminate. 2. Warm-up the engine. 3. Stop the engine, and then turn the ignition switch to OFF. 4. Insert the cartridge to Subaru Select Monitor. 5. Connect the Subaru Select Monitor to data link connector. 6. Turn the ignition switch to ON, and Subaru Select Monitor power switch to ON. 7. Select the (2. Each System Check) in Main Menu. 8. Select the (Engine Control System) in Selection Menu. 9. Select the (1. Current Data Display & Save) in Engine Control System Diagnosis. 10. Select the (1. 12 Data Display) in Data Display Menu. 11. Start the engine, and then read the engine idle speed. 12. Check the idle speed when unloaded. (With headlights, heater fan, rear defroster, radiator fan, air conditioning, etc. OFF) Idle speed [No load and gears in neutral]. 700 ± 100 rpm 13. Check the idle speed when loaded. (Turn the air conditioning switch to "ON" and operate the compressor for at least 1 minute before measurement.) Idle speed [A/C "ON". no load and gears in neutral]: When the A/C refrigerant pressure is low MT. 725 ± 100 rpm AT. 750 ± 100 rpm When the A/C refrigerant pressure is high MT. 800 ± 100 rpm AT. 825 ± 100 rpm NOTE: As idle speed is controlled by the automatic adjustment type, it can not be adjusted manually. If the idle speed is out of specifications, refer to General On-board Diagnosis Table under "Engine Control System". Page 7330 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 5080 B292-B317 Page 7339 B54-B127 Luggage Room Light Switch Trunk Lamp Switch: Testing and Inspection Luggage Room Light Switch Luggage Room Light LUGGAGE ROOM LIGHT SWITCH Measure the resistance between luggage room light terminals. Page 1495 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Service and Repair Fuel Cut Control Unit: Service and Repair Fuel Cut Valve REMOVAL 1. Remove the fuel tank. 2. Remove the protect cover. 3. Move the clip and disconnect the evaporation hose from fuel cut valve. 4. Remove the bolts which install the fuel cut valve. INSTALLATION Install in the reverse order of removal. NOTE: Use a new gasket. Page 7158 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 5376 Manual A/C Model Page 945 B3-B12 Page 3761 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 4694 B54-B127 Page 3655 B128-B134 Diagram Information and Instructions License Plate Lamp: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 7227 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 5327 Step 1 - 6 Page 7418 B380-f6 Page 3760 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 6446 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 1573 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 5222 Tightening torque: 95 Nm (9.7 kgf-m, 70.1 ft. lbs.) (4) Transverse link rear bushing and body Tightening torque: 250 Nm (25.5 kgf-m, 184 ft. lbs.) NOTE: Move the rear bushing back and forth until transverse link-to-rear bushing clearance is established (as indicated in the figure) before tightening. 6) Check the wheel alignment and adjust if necessary. DISASSEMBLY FRONT BUSHING Using the ST, press the front bushing out of place. ST 927680000 INSTALLER & REMOVER SET REAR BUSHING 1) Scribe an aligning mark on the transverse link and rear bushing. 2) Loosen the nut, and then remove the rear bushing. ASSEMBLY FRONT BUSHING Assemble in the reverse order of disassembly. CAUTION: Install the front bushing in correct direction, as shown in the figure. Page 6027 Glove Compartment: Service and Repair GLOVE BOX REMOVAL 1. Open the glove box. 2. Remove the screws to remove glove box. INSTALLATION Install in the reverse order of removal. Page 7328 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Service and Repair Gear Sensor/Switch: Service and Repair Switches and Harness REMOVAL 1. BACK-UP LIGHT AND NEUTRAL POSITION SWITCH 1) Disconnect the ground cable from battery. 2) Remove the air intake duct and cleaner case. (Non-turbo model) 3) Remove the intercooler. (Turbo model) 4) Disconnect the connector of back-up light switch and neutral position switch. ^ Non-turbo model Non-turbo model ^ Turbo model Turbo model 5) Lift-up the vehicle. 6) Remove the back-up light switch and neutral position switch with harness. INSTALLATION Page 2776 Oxygen Sensor: Service and Repair Rear Oxygen Sensor Rear Oxygen Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Lift-up the vehicle. 3. Disconnect the connector from the rear oxygen sensor. 4. Remove the clip by pulling out from the upper side of crossmember. 5. Apply spray type lubricant to the threaded portion of rear oxygen sensor, and leave it for one minute or more. 6. Remove the rear oxygen sensor. CAUTION: When removing the rear oxygen sensor, wait until exhaust pipe cools, otherwise it will damage exhaust pipe. INSTALLATION 1. Before installing rear oxygen sensor, apply antiseize compound only to the threaded portion of rear oxygen sensor to make the next removal easier. CAUTION: Never apply anti-seize compound to protector of rear oxygen sensor. Anti-seize compound: NEVER-SEEZ NS-165 or equivalent Page 5839 7. Remove the three clips in the center, right and left part of bumper. 8. Remove the fog light. 9. Remove the bumper from body. 10. Remove the energy absorber foam from front bumper beam. 11. Loosen the bolt and nut, and then remove the bumper beam from body. Page 3159 Air Injection Control Valve: Service and Repair Secondary Air Combi Valve REMOVAL SECONDARY AIR COMBI VALVE LH 1. Disconnect the ground cable from battery. 2. Remove the intercooler. 3. Disconnect the connector from secondary air combi valve LH. 4. Disconnect the air duct. 5. Disconnect the pipe LH. 6. Remove the secondary air combi valve LH. SECONDARY AIR COMBI VALVE RH 1. Disconnect the ground cable from battery. 2. Remove the intercooler. 3. Remove the secondary air combi valve LH. 4. Remove the intake manifold. 5. Disconnect the connector from secondary air combi valve RH. 6. Disconnect the pipe RH. 7. Remove the secondary air combi valve RH. INSTALLATION Page 961 Power Window Switch: Testing and Inspection POWER WINDOW CONTROL SWITCH INSPECTION 1. MAIN SWITCH 1. Remove the main switch. 2. Turn the window lock switch to UNLOCK. 3. Connect the battery and main switch as shown in the figure. 4. Measure the main switch resistance. 5. If NG, replace the main switch. 2. SUB SWITCH 1. Remove the sub switch. Page 6691 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 2289 F21-F61 Specifications Connecting Rod Bearing: Specifications CONNECTING ROD BEARING Oil clearance STD ............................................................................................................................... ........................................... 0.017 - 0.045 mm (0.0007 - 0.0018 in.) Limit .......................................... ........................................................................................................................................................... 0.05 mm (0.0020 in.) Thickness at center portion STD ......................................................................................................... ............................................................... 1.490 - 1.502 mm (0.0587 - 0.0591 mm) 0.03 mm (0.0012 in.) US ......................................................................................................................................... 1.504 - 1.512 mm (0.0592 - 0.0595 in.) 0.05 mm (0.0020 in.) US ......................................................................................................................................... 1.514 1.522 mm (0.0596 - 0.0599 in.) 0.25 mm(0.0098 in.) US .......................................................................................................................................... 1.614 1.622 mm (0.0635 - 0.0639 in.) Connecting rod bushing Clearance between piston pin and bushing STD ......................................... ................................................................................................................................................. 0 0.022 mm (0 - 0.0009 in.) Limit ............................................................................................................ ....................................................................................... 0.030 mm (0.0012 in.) NOTE: US: Undersize OS: Oversize ID: Inside Diameter OD: Outside Diameter Page 621 R58-R69 Page 960 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 3861 B54-B127 Page 450 B136-B141 Page 6849 R58-R69 System Diagnosis Front Door Window Regulator: Testing and Inspection FRONT REGULATOR AND MOTOR ASSEMBLY INSPECTION 1. Make sure the power window motor rotates properly when battery voltage is applied to the terminals of motor connector. 2. Change polarity of battery connections to terminals to ensure the motor rotates in reverse direction. Page 501 6. Disconnect the pressure hose from fuel tank pressure sensor. INSTALLATION Install in the reverse order of removal. Page 5986 5. Remove the trailer hitch while lowering exhaust pipe. INSTALLATION CAUTION: Because the trailer hitch is heavy, two people are required to install it. Install in the reverse order of removal. Tightening torque: Trailer hitch to body: 95 N.m (9.7 kgf-m, 70 ft-lb) Canister: 23 N.m (2.3 kgf-m, 17 ft-lb) Service and Repair Cruise Control Module: Service and Repair Cruise Control Unit REMOVAL The control of cruise control system is performed by Engine control module (ECM). Description and Operation Temperature Sensor (Gauge): Description and Operation WATER TEMPERATURE GAUGE - Water temperature signals are generated at the engine coolant temperature sensor on the engine, and after converted into digital signals, these signals are sent via the body integrated unit to the combination meter. - The resistance of the engine coolant temperature sensor changes according to the engine coolant temperature. Therefore, the signals sent to the water temperature gauge also changes according to the engine coolant temperature. As the change in signals causes the magnetic force of the step motor to change, the gauge needle moves according to the engine coolant temperature. - When the coolant is at a normal operating temperature of approx. 85 to 100 degree C (158 to 212 degree F), the gauge needle stays in the middle of the indication range as shown in the figure. Page 717 B3-B12 Page 6225 Non-Turbo Model Page 2359 B230-B283 Page 6567 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 6996 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 2074 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 4520 Brake Warning Indicator: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 7313 Wiper Arm: Service and Repair Rear Wiper Arm REAR WIPER ARM REMOVAL 1. Remove the wiper arm cover (A). 2. Remove the nut to remove wiper arm. INSTALLATION 1. Install in the reverse order of removal. 2. Operate the rear wiper once. 3. Align the blade to rear defogger heat wire (A). Tightening torque: Nm (kgf-m, ft-lb) T1: 6.0 (0.61, 4.4) T2: 8.0 (0.82, 5.9) Page 3396 B136-B141 Page 2622 Remove the hose from the reservoir tank. Cut 20 mm from the bottom of the hose at a 45° angle. Reinstall hose in reservoir tank. Start engine and permit to fully warm up. Turn off engine and allow to fully cool down. Recheck coolant level in reservoir and add coolant if needed. Note: Be sure to use genuine Subaru Super Coolant or Subaru Long Life Coolant, depending upon what type of coolant is currently in the system. Warranty/Claim Information Page 1481 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 4082 21) Remove the oil pan. 22) Disconnect the harness connector and transmission ground terminal. 23) Remove the harness assembly. INSTALLATION 1) Pass the harness assembly through the hole in the transmission case. 2) Connect the harness connector and transmission ground. Page 1571 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 6132 B17-B20 Page 4142 2) If the full stroke is out of specifications, loosen the clutch stopper nut (model without cruise control) or clutch switch lock nut (model with cruise control) to adjust. Tightening torque: 8 Nm (0.8 kgf-m, 5.8 ft. lbs.) 3) Loosen the push rod lock nut. 4) Turn the push rod to adjust. (1) Make sure that the clutch pedal contacts the stopper bolt side (model without cruise control) or the clutch switch side (model with cruise control) when releasing the clutch pedal. (2) Make sure that the clutch pedal contacts clutch pedal bracket stopper, when fully depressing the clutch pedal. 5) Turn the push rod to shorten until the clearance is made at the stopper bolt side (model without cruise control) or the clutch switch side (model with cruise control). Service and Repair Fuel Pressure Release: Service and Repair Fuel PROCEDURE RELEASING OF FUEL PRESSURE WARNING: - Place "NO FIRE" signs near the working area. - Be careful not to spill the fuel. 1. Disconnect the connector from the fuel pump relay. 2. Start and run the engine until it stalls. 3. After the engine stalls, crank it for five more seconds. 4. Turn the ignition switch to OFF. Page 459 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Locations Cabin Air Filter: Locations The Optional Cabin Air Filter is located in the Heater-A/C box behind the glove compartment. Page 6549 F61-R47 Page 2995 B292-B317 Page 2097 Ignition Control Module: Testing and Inspection INSPECTION For inspection, refer to IGNITION CONTROL SYSTEM, Diagnostics for Engine Starting Failure. Page 3599 R72-R145 R148 Page 3713 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 1611 B54-B127 Capacity Specifications Coolant: Capacity Specifications Coolant capacity MT: ...................................................................................................................................................... ....................... 7.7 L (8.1 US qt, 6.8 Imp qt.) Page 2731 Refer to the illustrations above for more details on locating the appropriate sensors. The list shown above is of A/F Sensor related DTCs. (This list is for example only. Refer to the applicable service manual for a complete list of DTCs.) Note: When the DTCs for A/F sensor are stored in memory, do not replace the oxygen sensor. Page 2050 Main Relay (Computer/Fuel System): Service and Repair Main Relay REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the passenger's side front side sill cover. 3. Remove the bolt which holds the relay bracket on the body. 4. Disconnect the connectors from the main relay. 5. Remove the main relay from the mounting bracket. INSTALLATION Install in the reverse order of removal. Page 1461 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 363 Step 1 - 5 Description and Operation Accessory Compartment: Description and Operation CENTER POCKET - A pocket with a lid is provided at the center of the instrument panel. - Night illumination, which operates in connection with the lighting system, is provided. Page 5100 Note: Be careful not to damage wires around the working area. 4. Impreza and Forester: Remove the passenger front seat and disconnect the body wire connector afier pulling up the floor carpet. Note: Check if the wire is pinched at the seat rail and damaged. 5. Repair the wire according to the extent of damage as indicated below. (1) When only the surface of the wire covering is damaged only: Wrap electrical tape around the damaged portion, proceed to Step 7. (2) When the core wire is cut or damaged: Cut and remove the damaged section of wire, as illustrated. (3) Peel the wire covering 5/8 inch (15 mm) from the tip of cut wire and expose the core wires, as illustrated. (4) Install heat shrink tubing on one side of the cut wiring. (5) Twist the core wires together so that they entwine each other. Be careful to ensure the tips of the wires are level and parallel. Otherwise~ the wire will break through the heat shrink tubing. (6) Solder the twisted wires and activate the heat shrink tubing with a heat gun. Confirm that no frayed wires are visible. 6. Reconnect the body wire connector. Page 4124 STI model INSTALLATION 1) Install in the reverse order of removal. NOTE: ^ Before installing the operating cylinder, apply grease (KOPR-KOTE: Part No. 003603001)to contact point of the release lever and operating cylinder. ^ For turbo model, bleed air with the operating cylinder attached to clutch hose, and then install it to vehicle. ^ Non-turbo model Non-turbo model ^ Turbo model Turbo model ^ STI model Page 5641 1. Remove the shoulder anchor bolt, and then detach the shoulder anchor from quarter pillar. 2. Remove the quarter trim. 3. Remove the three bolts, and then detach the seat belt assembly. 6. CENTER SEAT BELT RH ASSEMBLY AND LH ASSEMBLY (WAGON MODEL) 1. Remove the rear seat cushion. 2. Remove the bolt, and then detach the center seat belt assembly. INSTALLATION 1. OUTER SEAT BELT RH ASSEMBLY AND LH ASSEMBLY (SEDAN MODEL) Install in the reverse order of removal. CAUTION: During installation, make sure that the seat belts are not twisted. - After installation, make sure that the seat belts can be smoothly extended and wound. 2. SHOULDER SEAT BELT CTR ASSEMBLY (SEDAN MODEL) Install in the reverse order of removal. CAUTION: During installation, make sure that the seat belts are not twisted. - After installation, make sure that the seat belts can be smoothly extended and wound. 3. CENTER SEAT BELT LH ASSEMBLY (SEDAN MODEL) Install in the reverse order of removal. CAUTION: During installation, make sure that the seat belts are not twisted. Page 2332 R58-R69 Brakes - Rear Brake Caliper Modification Brake Caliper: Technical Service Bulletins Brakes - Rear Brake Caliper Modification NUMBER: 06-36-06 DATE: 06/23/06 APPLICABILITY: 2001 MY and later Impreza WRX SUBJECT: Modification to Rear Brake Caliper INTRODUCTION This bulletin is for informational purposes only. A production change was made to the rear brake caliper on 01MY and newer Impreza WRX. The washer between the caliper body and the backing plate has been discontinued. A change has been made to the caliper body to maintain the correct geometry, although the part numbers have not changed. PRODUCTION LINE CHANGE Production line changes have been incorporated into the VINs shown. PART INFORMATION REPAIR PROCEDURE/INFORMATION Refer to the applicable Subaru Service Manual located on the STIS (Subaru Technical Information System) web site. CLAIM REIMBURSEMENT/WARRANTY INFORMATION For vehicles within the basic New Car Limited Warranty period, refer to the Subaru Warranty Wizard(R) for claim submission information. Page 2277 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Adjustments Transmission Position Switch/Sensor: Adjustments Inhibitor Switch ADJUSTMENT 1) Move the select lever to "N" range. 2) Loosen the three inhibitor switch securing bolts. 3) Insert the ST as vertical as possible into the holes in inhibitor switch lever and switch body. ST 499267300 STOPPER PIN 4) Tighten the three inhibitor switch bolts. Tightening torque: 3.5 Nm (0.36 kgf-m, 2.6 ft. lbs.) 5) Repeat the above checks. If the inhibitor switch is determined to be "faulty", replace it. Page 1331 Constructed from lightweight aluminum Comparable to Subaru tool # 499207300 Camshaft alignment tool for Subaru. Constructed from lightweight aluminum. Applicable to: 2.5L DOHC non-turbo engines. Contact AST for Pricing Assenmacher Specialty Tools 1 800 525 2943 Page 784 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 2901 Crankshaft Position, Camshaft Position And Knock Sensors Page 7226 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 4981 R72-R145 R148 Diagram Information and Instructions Oil Pressure Sender: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 2262 CAUTION: When removing the front oxygen (A/F) sensor, wait until exhaust pipe cools, otherwise it will damage exhaust pipe. INSTALLATION 1. Before installing front oxygen (A/F) sensor, apply anti-seize compound only to the threaded portion of front oxygen (A/F) sensor to make the next removal easier. Anti-seize compound: NEVER-SEEZ NS-165 or equivalent CAUTION: Never apply anti-seize compound to protector of front oxygen (A/F) sensor. 2. Install the front oxygen (A/F) sensor. 3. Install the service hole cover. 4. Lower the vehicle. 5. Install the front right side wheel. 6. Connect the engine harness to the bracket (B) using clips (A). Page 3370 Main Relay (Computer/Fuel System): Service and Repair Main Relay REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the passenger's side front side sill cover. 3. Remove the bolt which holds the relay bracket on the body. 4. Disconnect the connectors from the main relay. 5. Remove the main relay from the mounting bracket. INSTALLATION Install in the reverse order of removal. Page 7206 (1) Open the hood and remove the check valve. (2) Attach valve cushion (86634SA000) around the modified check valve (86634AG000) for soundproofing. Page 2430 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the bolt which installs the crankshaft position sensor to cylinder block. 3. Remove the crankshaft position sensor, and disconnect the connector from it. INSTALLATION Install in the reverse order of removal. Service Precautions Intake Manifold: Service Precautions CAUTION - Wear work clothing, including a cap, protective goggles, and protective shoes during operation. - Remove contamination including dirt and corrosion before removal, installation or disassembly. - Keep the disassembled parts in order and protect them from dust and dirt. - Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly, and replacement. - Be careful not to burn yourself, because each part on the vehicle is hot after running. - Be sure to tighten fasteners including bolts and nuts to the specified torque. - Place shop jacks or rigid racks at the specified points. - Before disconnecting electrical connectors of sensor or units, be sure to disconnect the ground cable from battery. Locations Brake Light Switch: Locations Electrical Component Location Page 5804 Alarm Module: Description and Operation SECURITY CONTROL UNIT PROCEDURE 1. FUNCTION SETTING (ECM CUSTOMIZING) 1. Connect the Subaru Select Monitor to data link connector. 2. Turn the ignition switch to ON. 3. On the display screen, select the {Each System Check} and press the [YES] key. 4. On the display screen, select the {Keyless Unit Mode} and press the [YES] key. 5. On the display screen, select the {ECM customizing} and press the [YES] key. 6. Change the setting with UP/DOWN key and press the [YES] key. - List of function setting item (ECM customizing) 7. After setting, make sure that vehicle equipment is same as the setting changed in the {Current Data Display & Save}. CAUTION: It is possible to control the original functions of vehicle when settings above are corresponded to vehicle equipment. - Do not change the settings except for setting above during operation of equipment setting. - Resetting is needed if installing a new keyless unit. - In passive mode, the system will automatically activate the alarm but WILL NOT automatically lock the doors. Failure to lock the doors manually will result in a higher security risk. NOTE: For details concerning operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. 8. Turn the ignition switch to OFF, and then remove the Subaru Select Monitor. 2. ALARM HISTORY REPORT MODE 1. Turn the ignition switch to ON. Page 2335 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 477 Camshaft Position Sensor: Locations Sensor (Part 1) Diagram Information and Instructions Power Window Switch: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 6180 R58-R69 Page 594 Oxygen Sensor: Service and Repair Rear Oxygen Sensor Rear Oxygen Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Lift-up the vehicle. 3. Disconnect the connector from the rear oxygen sensor. 4. Remove the clip by pulling out from the upper side of crossmember. 5. Apply spray type lubricant to the threaded portion of rear oxygen sensor, and leave it for one minute or more. 6. Remove the rear oxygen sensor. CAUTION: When removing the rear oxygen sensor, wait until exhaust pipe cools, otherwise it will damage exhaust pipe. INSTALLATION 1. Before installing rear oxygen sensor, apply antiseize compound only to the threaded portion of rear oxygen sensor to make the next removal easier. CAUTION: Never apply anti-seize compound to protector of rear oxygen sensor. Anti-seize compound: NEVER-SEEZ NS-165 or equivalent Page 5756 For vehicles within the Basic New Car Limited Warranty period, this repair can be claimed using the table shown. Disclaimer Page 4949 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 5258 8) Install the ABS wheel speed sensor on housing. Tightening torque: 33 Nm (3.4 kgf-m, 24 ft. lbs.) 9) Install the wheel and tighten the wheel nuts to specified torque. Tightening torque: 90 Nm (9.1 kgf-m, 65.7 ft. lbs.) DISASSEMBLY Using the ST and a hydraulic press, drive hub bolts out. ST 28399AG000 HUB STAND CAUTION: ^ Be careful not to hammer the hub bolts. This may deform the hub. ^ Do not reuse the hub bolt. NOTE: Since the hub unit bearing can not be disassembled, only hub bolts can be removed. ASSEMBLY 1) Attach the hub to ST securely. ST 28099PA080 HUB STAND 2) Using a press, Press new hub bolts until their seating surfaces contact the hub. NOTE: Use 12 mm (0.47 inch) dia. holes in HUB STAND to prevent bolts from tilting. INSPECTION Page 1053 3. Installation of timing belt Align the alignment mark on timing belt with marks on sprockets in alphabetical order shown in the figure. While aligning marks, position the timing belt properly. CAUTION: ^ Disengagement of more than three timing belt teeth may result in interference between the valve and piston. ^ Ensure the belt's rotating direction is correct. 4. Install the belt idler. Tightening torque: 39 Nm (4.0 kgf-m, 28.9 ft. lbs.) NOTE: Make sure that the marks on the timing belt and sprockets are aligned. Page 2815 B17-B20 Page 2013 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Immobilizer Control Unit Alarm Module: Service and Repair Immobilizer Control Unit IMMOBILIZER CONTROL UNIT REMOVAL NOTE: Prepare the security ID plate. - Prepare all registered immobilizer keys for the model with immobilizer. - Make a registration of immobilizer when replacing the immobilizer control unit. New immobilizer key is required for registration. For detailed operation procedure, refer to "IMMOBILIZER REGISTRATION MANUAL - If the keys are added without replacing the immobilizer control unit, maximum 4 keys can be registered including new keys. 1. Disconnect the ground cable from battery. 2. Remove the instrument panel lower cover. 3. Disconnect the connector from immobilizer control unit. 4. Remove the immobilizer control unit. INSTALLATION Install in the reverse order of removal. Page 3528 Disclaimer Page 3229 Accelerator Pedal: Description and Operation General An electronically controlled throttle is adopted. The movement of the accelerator pedal is converted into electrical signals by the accelerator pedal position sensor and these signals are sent to the ECM. The ECM controls the operation of the throttle body based on the signals from the accelerator pedal position sensor and on other driving conditions. Page 1621 R72-R145 R148 Page 5498 Less than 6 mm (0.24 in) O.D. deflection L Less than 7 mm (0.28 in) 2. PASSENGER'S AIRBAG MODULE Check for the following, and replace damaged parts with new parts. Airbag module is cracked or deformed. - Harness and/or connector is cracked, deformed or open. Lead wire is exposed. - Mounting bracket is cracked or deformed. 3. SIDE AIRBAG MODULE Check for the following, and replace damaged parts with new parts. Front seat, airbag module and mounting bracket are damaged or deformed. - Harness and/or connector is cracked, deformed or open. Lead wire is exposed. 4. AIRBAG CONTROL MODULE Check for the following, and replace damaged parts with new parts. Control module is cracked or deformed. - Mounting bracket is cracked or deformed. - Connector is scratched, cracked or deformed. - Airbag is deployed. - Side airbag is deployed. 5. FRONT SUB SENSOR If the front section of vehicle as shown in the figure is damaged, check for the following, and replace damaged parts with new parts. Front sub sensor is cracked or deformed. - Mounting bracket is cracked or deformed. - Connector is scratched, cracked or deformed. - Airbag is deployed. 6. SIDE AIRBAG SENSOR If the side section of vehicle as shown in the figure is damaged, check for the following, and replace damaged parts with new parts. Side airbag sensor is cracked or deformed. - Mounting bracket is cracked or deformed. - Connector is scratched, cracked or deformed. - Side airbag is deployed. (operating side) 7. ROLL CONNECTOR Check for the following, and replace damaged parts with new parts. Combination switch or steering roll connector is cracked or deformed. Page 5450 System Relay: Testing and Inspection INSPECTION While applying battery voltage to the terminal between (3) and (4), check continuity between (1) and (2). If no continuity exists, replace the relay with a new one. Page 6796 B54-B127 Page 6442 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Specifications Compression Check: Specifications Compression (at 200 - 300 rpm): Standard ................................................................................................................................................... 981 1,177 kPa (10 - 12 kgf1cni2, 142 - 171 psi) Difference between cylinders ....................................................................................................................................... Less than 49 kPa (0.5 kgf1cm, 7 psi) Page 6551 R72-R145 R148 Page 105 Engine Control Module: Locations Non-Turbo Model Testing and Inspection Timing Belt: Testing and Inspection Timing Belt Inspection 1. Check the timing belt teeth for breaks, cracks, and wear. If any fault is found, replace the belt. 2. Check the condition of backside of timing belt; if any crack is found, replace the timing belt. CAUTION: ^ Be careful not to let oil, grease or coolant contact the timing belt. Remove quickly and thoroughly if this happens. ^ Do not bend the timing belt sharply. ^ Bending diameter h: 60 mm (2.36 inch) or more Page 1856 17. Check the ATF level. Inspection 1. Remove the coolant filler tank cap, top off coolant filler tank, and then attach the tester to coolant filler tank in place of cap. 2. Apply a pressure of 122 kPa (1.2 kgf/cm, 18 psi) to the coolant filler tank to check if: ^ Engine coolant leaks at/around radiator. ^ Engine coolant leaks at/around hoses or connections. CAUTION: ^ Inspection must be carried out at the side of coolant filler tank, not at the side of radiator. ^ Engine should be turned off. ^ Wipe engine coolant from check points in advance. ^ If engine coolant adheres to the exhaust pipe, wipe it off completely. ^ Be careful to prevent engine coolant from spurting out when removing the tester. ^ Be careful also not to deform the filler neck of coolant filler tank when installing or removing tester. Back-Up Light Switch (MT Model) Backup Lamp Switch: Testing and Inspection Back-Up Light Switch (MT Model) BACK-UP LIGHT SWITCH (MT MODEL) Measure the resistance between back-up light switch terminals. Service and Repair Body Control Module: Service and Repair Body Integrated Module REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the lower cover. 3) Remove the knee bolster. 4) Disconnect the connector from body integrated module. 5) Remove the body integrated module. INSTALLATION Install in the reverse order of removal. Page 252 Wiper Relay: Testing and Inspection WIPER CONTROL RELAY INSPECTION 1. Disconnect the connector from wiper control relay. 2. Connect the positive (+) lead from the battery to terminal 8 and the negative (-) lead to terminal 6. Connect the positive (+) lead from the voltmeter to terminal 3 and the negative ( ) lead to ground. 3. Measure the voltage when the wiper relay is operated. If operation is not as specified, replace the switch. Engine Controls - DTC P0340/P0345 After Camshaft R & R Camshaft Position Sensor: All Technical Service Bulletins Engine Controls - DTC P0340/P0345 After Camshaft R & R Number: 02-107-09 Date: 03/24/09 Applicability: 2004~06MY Baja 2.5L Turbo 2004~06MY Impreza 2.5L Turbo 2004~06MY Forester 2.5L Turbo 2004~06MY Legacy/Outback 2.5L Turbo SUBJECT: Intake Camshaft Replacement Introduction If you encounter a vehicle that has a CEL and P0340 or P0345 stored in memory immediately after replacing the intake camshaft(s), the air gap between the camshaft and camshaft position sensor may be out of specification. A modification was made to the plate area of the camshaft where the camshaft position sensor picks up the signal. Parts Information Repair Procedure/ Information Using a feeler (thickness) gauge, measure the gap between the camshaft and camshaft position sensor. The correct gap is between 0.15mm to 0.98mm (0.0059 to 0.0386 in.) If the gap is over 0.98mm (0.0386 in.) replace the camshaft position sensor. Refer to the applicable service manual. Warranty/Claim Information For vehicles within warranty, refer the Subaru Warranty Wizard for claim submission information. Page 1852 Radiator: Service and Repair Radiator And Radiator Fan Removal WARNING: The radiator is pressurized. Wait until the engine cools down before working on the radiator. 1. Set the vehicle on a lift. 2. Disconnect the ground cable from battery. 3. Lift-up the vehicle. 4. Remove the under cover. 5. Drain the engine coolant completely. 6. Disconnect the connectors of radiator main fan motor (A) and sub fan motor (B). 7. Disconnect the ATF cooler hose from ATF pipe. (AT model) Plug the openings in the hose and radiator with caps in order to prevent ATF from leaking. 8. Disconnect the radiator outlet hose from thermostat cover. 9. Lower the vehicle. 10. Remove the air intake duct. Page 1466 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 5005 2. Pull up the seat slide rail cover from the center console side as indicated by the arrows. 3. Check visually and with your fingers in the area indicated by broken lines to confirm that the body wiring harness (for power to the occupant detection ECU) is not located and/or pinched around the seat bracket. 4. If the wire is found to be located properly (not pinched), reinstall the seat slide rail cover. No further action is required. If the wire is found to be pinched, proceed to the "Wiring Repair Procedure". Impreza Inspection Procedure 1. Remove the center console trim between the select lever and the parking brake lever. If necessary, refer to the applicable service manual for removal instructions. 2. Cut the cross section of floor carpet in the center and in front of the parking brake lever with scissors (as shown, below). Note: Be careful not to damage wires around the work area. ^ Pull up the floor carpet to inspect a section of the subject body wiring harness from the clamping point located behind the shifter console down to the front passenger seat slide rail as indicated in the photo to the left. ^ Check visually and with your fingers to confirm that the wire is not located around the seat bracket area as indicated by the arrow in the photo Audio System - Noise With Rear Defogger ON Heated Glass Element: Customer Interest Audio System - Noise With Rear Defogger ON NUMBER: 15-126-07 DATE: 02/13/08 APPLICABILITY: All Models SUBJECT: Radio Static When Rear Window Defogger Is On INTRODUCTION If you encounter a customer complaint of radio static when the radio and rear window defogger are on at the same time, there is the possibility of a break in one or more of the defogger grids. When the grid is broken, a high resistance field is created at the break point which can create static on some radio stations. The level of resistance is usually high enough to create a field of interference which projects out from the glass. The break can be detected visually or by using a portable radio. PART INFORMATION Permatex(R) Quick Grid(TM) Rear Window Defogger Repair Kit, part If 15067, used for repairing damaged rear window defogger grids, is available at local automotive parts stores REPAIR PROCEDURE/INFORMATION Note: There are certain factors that could lead to unsuccessful testing. Examples are: overhead fluorescent lights, telegraph poles, high tension lines, weather conditions, etc. Testing should be performed outdoors on a clear day. Also, there is the possibility that the static may not be duplicated due to the location of the vehicle. If that is the case, you may want to move the vehicle to a different location when testing. We highly discourage the use of accessory window tinting. If the vehicle is equipped with it, do not continue with the procedure. ^ Using a portable radio, set the radio to the same frequency and station being disturbed by static. From the outside of the vehicle, slowly move the radio's antenna across the defogger grids. When interference is encountered, inspect that specific area closely for a break. Depending upon the size of the break, a magnifying glass and/or eyeloupe may be required. ^ Once the break is identified, it should be repaired using the Permatex(R) repair kit instead of replacing the rear glass. Note: Make sure to carefully read and follow the instructions and precautions that are included with the Permatex(R) repair kit. ^ The repaired area must be completely opaque and have a resistance reading of essentially zero (0) ohms across the repair. ^ There may be more than one break. If the first break repair does not eliminate the static, re-inspect and repair any other breaks as necessary. WARRANTY/CLAIM INFORMATION Note: For vehicles within the Basic New Car Limited Warranty period the warranty covers repairs needed to correct defects in material or workmanship. Damage to the rear window defogger/antenna grid which is the result of an outside influence is not covered under warranty Examples are: improper cleaning of the glass, window tinting, scratches and/or cuts from objects coming in contact with the grids, etc For vehicles within the Basic New Car Limited Warranty period, this repair can be claimed using the table above. Page 5485 Step 1 - 5 Page 4049 8) Install center and rear exhaust pipes and muffler. (DOHC turbo model) INSPECTION Check the removed cable and replace if damaged, rusty, or malfunctioning. 1) Check for smooth operation of the cable. 2) Check the inner cable for damage and rust. 3) Check the outer cable for damage, bends, and cracks. 4) Check the boot for damage, cracks, and deterioration. 5) Move the select lever from "P" range to "1" range. You should be able to feel the detents in each range. If the detents cannot be felt or the range pointer is improperly aligned, adjust the cable. ADJUSTMENT 1) Set the vehicle on a lift. 2) Set the select lever to "N" range. 3) Lift-up the vehicle. 4) Remove the rear exhaust pipe and muffler. ^ SOHC model ^ DOHC turbo model 5) Loosen the adjusting nut on each side. 6) Turn the adjusting nut B until it lightly touches the connector. 7) While preventing the adjusting nut B from moving with a wrench, tighten the adjusting nut A. Service and Repair Clutch Release Bearing: Service and Repair Release Bearing and Lever REMOVAL EXCEPT STI MODEL 1) Remove the transmission assembly from vehicle body. 2) Remove the two clips from release lever and remove the release bearing. (Non-turbo model) CAUTION: Be careful not to deform clips. 3) Remove the release bearing from release lever. (Turbo model) 4) Remove the dust cover. 5) Remove the lever spring from pivot with a screwdriver by accessing it through clutch housing release lever hole. Then remove the release lever. STI MODEL 1) Remove the transmission assembly from vehicle body. 2) Remove the release lever from transmission. 3) Put the release bearing in engine side. 4) Remove the release bearing from the clutch cover using flat-type screwdriver. Page 4417 11) Remove the clamp, and then remove the shift lock solenoid. INSTALLATION Install in the reverse order of removal. INSPECTION Step 1 - Step 4 Page 3326 3. Remove the screws holding packing in place. 4. Lift up the vehicle. 5. Remove the rear right side wheel nuts. 6. Remove the rear right side wheel. 7. Drain the fuel from the fuel tank. 8. Remove the fuel filler pipe protector. 9. Separate the evaporation hoses from the clip of fuel filler pipe. Page 5918 Fuel Door: Testing and Inspection REMOTE OPENERS INSPECTION Make sure the fuel filler flap lid opens and closes smoothly. Page 1210 Refrigerant: Service Precautions REFRIGERANT - The CFC-12 refrigerant cannot be used in the HFC-134a A/C system. The HFC-134a refrigerant, also, cannot be used in the CFC-12 A/C system. - If an incorrect or no refrigerant is used, poor lubrication will result and the compressor itself may be damaged. HANDLING OF REFRIGERANT - The refrigerant boils at approx. -30 °C (-22 °F). When handling it, be sure to wear safety goggles and protective gloves. Direct contact of the refrigerant with skin may cause frostbite. If the refrigerant gets into your eye, avoid rubbing your eyes with your hands. Wash your eye with plenty of water, and receive medical treatment from an eye doctor. - Do not heat a service can. If a service can is directly heated, or put into boiling water, the inside pressure will become extremely high. This may cause the can to explode. If a service can must be warmed up, use hot water in 40 °C (104 °F) max. - Do not drop or impact a service can. (Observe the precautions and operation procedure described on the refrigerant can.) - When the engine is running, do not open the high-pressure valve of the manifold gauge. The high-pressure gas will back-flow resulting in an explosion of the can. - Provide good ventilation and do not work in a closed area. - In order to prevent global warning, avoid releasing HFC-134a into the atmosphere. Using a refrigerant recovery system, discharge and reuse it. Page 4385 B17-B20 Page 6080 Power Door Lock Actuator: Service and Repair Rear Door Lock Actuator REAR DOOR LOCK ACTUATOR REMOVAL 1. Remove the rear door latch assembly. 2. Loosen two screws to remove rear door lock actuator. INSTALLATION Install in the reverse order of removal. NOTE: Make sure the lock works properly after installation. Page 674 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Diagram Information and Instructions Wiper Relay: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 1657 4. Measure the extension of rod beyond the body. If it is not within specifications, replace with a new one. Rod extension H. 5.7 ± 0.5 mm (0.224 ± 0.020 inch) 3. BELT TENSION PULLEY 1. Check the mating surfaces of timing belt and contact point of adjuster rod for abnormal wear or scratches. Replace the belt tension pulley if faulty. 2. Check the belt tension pulley for smooth rotation. Replace if noise or excessive play is noted. 3. Check the belt tension pulley for grease leakage. 4. BELT IDLER 1. Check the belt idler for smooth rotation. Replace if noise or excessive play is noted. 2. Check the outer contacting surfaces of idler pulley for abnormal wear and scratches. 3. Check the belt idler for grease leakage. Engine Controls - DTC P0607 Diagnostic Information Engine Control Module: Customer Interest Engine Controls - DTC P0607 Diagnostic Information NUMBER: 11-91-08 DATE: 12/05/08 APPLICABILITY: 2004-2008MY Impreza 2004-2008MY Forester 2005-2008MY Legacy/Outback 2006-2007MY Tribeca SUBJECT: DTC P0607 Control Module Performance Introduction The purpose of the bulletin is for information purposes when diagnosing DTC P0607. The following checks and information is in addition to what is listed in the Subaru Service Manual. This information is to be used in conjunction with the service manual. Repair Procedure/Information Additional items to check: ^ Rapid drop of voltage from a dead battery ^ Loose battery terminals ^ Loose ECM ground terminal ^ A short or open to the power or ground circuit If the malfunction criteria are met, the CEL will illuminate, the vehicle will go into fail safe and the throttle valve opening will be fixed at 6°. Fail safe will recover to normal mode if the ECM judges the criteria "OK" at the time of the next engine start. The CEL will not turn off until the "OK" driving cycle is completed 3 times in a row. The judgment is decided by the ECM to keep the CEL On or Off at the time the ignition switch is turned from ON to OFF. The ECM keeps DTC P0607 in memory even after the indicator light goes out. Therefore, it is important to erase memory after the repair is completed. Detail list of applicable model and engine type. Page 6063 For vehicles within the Basic New Car Limited Warranty period, this repair can be claimed using the table shown. Disclaimer Page 4968 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 4890 Starter (DOHC Turbo MT Model) Page 2542 B380-f6 Page 2435 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 4162 INSTALLATION EXCEPT STI MODEL NOTE: Before or during assembling, lubricate the following points with a light coat of grease. ^ Contact surface of lever and pivot ^ Contact surface of lever and bearing ^ Transmission main shaft spline (Use grease containing molybdenum disulphide.) 1) While pushing the release lever to pivot and twisting it to both sides, fit the lever spring onto the constricted portion of pivot. NOTE: ^ Apply grease (KOPR-KOTE: Part No. 003603001) to the contact point of release lever and operating cylinder. ^ Confirm that the lever spring is securely fitted by observing it through the main case hole. 2) Install the release bearing and fasten it with two clips. (Non-turbo model) 3) Install the release bearing. (Turbo model) 4) Install the dust cover. 5) Check smooth movement of the bearing with operating release lever. 6) Install the transmission assembly. ST1 MODEL 1) Install the release bearing on transmission. 2) Insert the release fork into release bearing tab. Page 174 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 4040 11) Remove the clip, and then remove the "P" range switch. 12) Remove the grommet, and then extract spring pin. 13) Remove the select lever arm, and then take away the select lever assembly from plate. 14) Remove the detent spring, and then remove the detent arm. Page 4181 The tables shown above contain additional information for recommended materials listed in the repair manuals for individual models. For additional warranty submission information please refer the materials policy in Section 13.9 of the CDS Policies and Procedures Manual. Disclaimer Page 1405 Page 7416 B230-B283 Page 6362 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 6579 R58-R69 Inhibitor Switch Transmission Position Switch/Sensor: Service and Repair Inhibitor Switch Inhibitor Switch INSPECTION When the driving condition or starter motor operation is erroneous, first check the shift linkage for improper operation. If the shift linkage is functioning properly, check the inhibitor switch. 1) Disconnect the inhibitor switch connector. 2) Check continuity in inhibitor switch circuits with the select lever moved to each position. NOTE: ^ Also check that continuity in ignition circuit does not exist when the select lever is in "R", "D", "3", "2" and "1" ranges. ^ If the inhibitor switch is inoperative, check for poor contact of connector on transmission side. 3) Check if there is continuity at equal points when the select lever is tilted 1.5° in both directions from "N" range. If there is continuity in one direction and the continuity in the other or if there is continuity at unequal points, adjust the inhibitor switch. 4) Repeat the above checks. If there are abnormalities, adjust the select cable. REMOVAL 1) Set up the vehicle on a lift. 2) Move the select lever to "N" range. 3) Remove the air intake chamber (Non-turbo model). 4) Remove the intercooler. (Turbo model) Page 4629 NOTE: Add brake fluid as necessary during replacement, in order to prevent the tank from running short of brake fluid. 9. After completing the replacement, hold brake pedal depressed and tighten screw and install air bleeder screw cap. Tightening torque (Air bleeder screw): Except 17 inch type: 8 Nm (0.8 kgf-m, 5.8 ft. lbs.) 17 inch type: 20 Nm (2.0 kgf-m, 14.5 ft. lbs.) 10. Replace brake fluid of each wheel cylinder using the same procedures as described in steps (6) through (8) above. 11. Depress the brake pedal with a force of approximately 294 Nm (30 kg, 66 ft. lbs.) and hold it there for approximately 20 seconds. At this time check for mix in air and pedal height change. Visually inspect the air bleeder screws and brake pipe joints to make sure that 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 make sure that brakes are operating properly. Suspension - Rear Stabilizer Link Positioning Stabilizer Link: Technical Service Bulletins Suspension - Rear Stabilizer Link Positioning 05 REAR STABILIZER LINK POSITIONING (2004MY and after Impreza Vehicles; 2003MY and after Forester Vehicles) When you are servicing or replacing rear suspension components there is the possibility that the position of the rear stabilizer link can change unintentionally. Make sure the rear stabilizer link is positioned properly; failure to do so could cause damage to the link. Page 6812 ILM(ES)-03 Diagrams: Other diagrams referred to by name within these diagrams (i.e. "REF. TO GND-01", etc) can be found at Diagrams by Diagram Name. See: Diagrams/Electrical Diagrams/Diagrams By Diagram Name Connector and Ground Locations: The locations of the Connectors or Grounds shown within these diagrams can be found via the connector or ground number at Vehicle Locations. See: Locations Lower Inner Trim Trim Panel: Service and Repair Lower Inner Trim LOWER INNER TRIM REMOVAL 1. Remove the side sill front cover (A). 2. Remove the rear seat cushion, and then remove side sill rear cover (B). 3. Remove the center pillar lower trim (C). INSTALLATION Install in the reverse order of removal. CAUTION: Be sure to securely hook pawls of inner trim panel to body flange. Page 2642 B136-B141 Page 6129 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 946 B17-B20 Page 684 B17-B20 Page 2814 B3-B12 Page 6162 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 3850 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 2469 2. Connect the knock sensor connector. 3. Install the intercooler. 4. Connect the battery ground cable to battery. Page 1981 Turbo model Wipers/Washers - Poor Front/Rear Washer Nozzle Operation Check Valve: Customer Interest Wipers/Washers - Poor Front/Rear Washer Nozzle Operation NUMBER: 07-55-06 DATE: 04/04/06 APPLICABILITY: 2006MY Forester and Impreza SUBJECT: Poor Windshield Washer Fluid Spray Introduction If you encounter a customer complaint that the windshield washer fluid does not spray properly from the front or rear washer nozzle, there is the possibility that the nozzle or check valve is clogged or the fluid hose could be pinched or bent. Use the following repair procedure to check and repair as necessary. Production Line Change The check valve was changed from a ball type to a rubber type to prevent clogging. The new style check valve was used in production starting in October, 2005 with the VINs shown. Parts Information Repair Procedure/Information 1) Check the washer nozzle for contamination. If the spray hole is clogged with wax, dust or foreign material, blow compressed air to the spray hole of the washer nozzle to clear the obstruction. 2) Check the washer nozzle fluid hose. Make sure the hose is not pinched, and that it does not have severe bends or kinks. 3) Check the rear washer hose running along the left sill, as well as the hose in the tailgate area, to ensure that the hose is not pinched or bent, restricting the flow. 4) If there is no problem found in step 1 or 2, install a modified check valve. Front check valve on Forester and Impreza Page 1536 Intake Manifold (Part 2) Intake Manifold REMOVAL 1. Release the fuel pressure. 2. Disconnect the ground cable from battery. 3. Open the fuel filler flap lid and remove the fuel filler cap. 4. Lift up the vehicle. 5. Remove the under cover. 6. Drain the engine coolant about 3.0L (3.2 US qt, 2.6 Imp qt). 7. Remove the air cleaner upper cover and air intake boot. 8. Remove the air cleaner element. 9. Remove the intercooler. 10. Remove the coolant filler tank. 11. Remove the power steering pump. 1. Remove the front side V-belt. 2. Disconnect the power steering switch connector. 3. Remove the bolts which secure the power steering pipe brackets to the intake manifold. NOTE: Do not disconnect the power steering hose. Page 245 F21-F61 Locations Electrical Components Location Page 2739 Refer to the illustrations above for more details on locating the appropriate sensors. Page 1686 Air Filter Element: Service and Repair Air Cleaner Element REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the connector from mass air flow and intake air temperature sensor. 3. Loosen the clamp (A) which connects the air intake boot and intake duct. 4. Remove the clip (B) from air cleaner upper cover. 5. Remove the air cleaner upper cover. 6. Remove the air cleaner element. INSTALLATION Install in the reverse order of removal. NOTE: Before installing the air cleaner upper cover, align the holes with protruding portions of air cleaner lower case, then secure the upper cover to the lower case. Page 2614 A used toothbrush which has been cleaned works great. Manually open the negative pressure valve. Using clean water and a brush, thoroughly clean the valve (inner and outer surface) and the valve seal surface. Check the radiator cap valve opening pressure using a radiator cap tester to insure the cap is within specification (refer to the applicable Subaru Service Manual). Note: If the cap is out of specification replace it. 2. Coolant Reservoir Tank Cleaning Remove the reservoir tank (refer to the applicable Subaru Service Manual). Using clean water, thoroughly clean the inside of the reservoir tank. Reinstall reservoir tank. Fill with coolant to the Full mark. Note: Be sure to use genuine Subaru Super Coolant or Subaru Long Life Coolant, depending upon what type of coolant is currently in the system. 3. Coolant Reservoir Tank Hose Modification Page 4105 4) Deflection on facing If deflection exceeds the specified value at the outer circumference of facing, repair or replace. ST 499747100 CLUTCH DISC GUIDE 5) If worn spline, loose rivets or damper spring failure is found, replace the clutch disc. CLUTCH COVER NOTE: Visually check for the following items without disassembling, and replace or repair if defective. 1) Loose thrust rivet 2) Damaged or worn bearing contact area at center of diaphragm spring Page 4977 B380-f6 Recall - Front Seat Wiring Harness Routing Wiring Harness: All Technical Service Bulletins Recall - Front Seat Wiring Harness Routing NUMBER: WVC-13 DATE: March 2007 APPLICABILITY: 2006MY Subaru Forester & Impreza SUBJECT: Front Passenger Seat Wiring INTRODUCTION Subaru of America, Inc. (SOA) has determined that certain 2006 MY Subaru Forester and Impreza models may have been produced with an improperly routed electrical wiring harness. That harness could have been pinched against the passenger front seat mounting bolt during production. If the wiring harness was improperly installed, an electrical short could occur. There are two safety risks associated with this condition. The first is that the passenger's front air bag, which is connected to this wiring harness, could become disabled, in which case it would not deploy as designed in an accident and would therefore expose the right front passenger to the possibility of serious injuries. The second is that an electrical short circuit could, under some circumstances, cause a fire. If an electrical short circuit occurs in this wiring harness, fuse # 6 (located in the fuse panel on the lower left side of the dashboard) will "blow", disabling the passenger front air bag. This could occur at any time and without prior warning. But once it occurs, the driver will be alerted to this condition by the illumination of the air bag system warning light on the vehicle's instrument panel. Occupants will also be alerted to this condition if the passenger's frontal air bag ON/OFF indicator indicates "OFF" even if an adult passenger is occupying that seat. If fuse # 6 had previously blown and been replaced with no repair made to correct the underlying cause, there is a possibility that this wiring harness has already been damaged due to a short circuit. Under these circumstances, the new replacement fuse may not blow and a fire could occur at any time without warning. In Forester models, it could happen even if the ignition switch is in the "LOCK" (off) position. Vehicle owners will be advised in the Owner Notification Letter that if they encounter a blown fuse, an illuminated air bag system warning light, smell smoke, or have replaced a blown fuse # 6 without correcting the underlying problem, to not operate the vehicle. They will be advised to contact the nearest Subaru dealer as soon as possible for guidance. In these cases, dealers should arrange to have the vehicle towed and repairs performed immediately. This recall will involve inspection and possible repair of the front passenger seat wire harness. Please refer to the Service Procedure section of this bulletin for more details. AFFECTED VEHICLES ^ 2006 MY Subaru Forester and Impreza Potentially affected vehicles are identified in the VIN range chart below. Not all vehicles within the VIN range are affected. Prior to performing repairs, confirm coverage for potentially affected vehicles by using the Vehicle Coverage Inquiry in the Dealer Communication System (DCS). OWNER NOTIFICATION SOA will prepare and mail Owner Notification Letters to owners of affected vehicles on or around March 9, 2007. A copy of the Owner Notification Letter is included at the end of this bulletin. DEALER PROGRAM RESPONSIBILITY Dealers are to promptly service all vehicles subject to this recall at no charge to the vehicle owner regardless of mileage~ age of the vehicle~ or Page 809 2. Connect the knock sensor connector. 3. Install the intercooler. 4. Connect the battery ground cable to battery. Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 7403 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 1499 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 3871 R72-R145 R148 Page 4427 Transmission Speed Sensor: Service and Repair Rear Vehicle Speed Sensor Rear Vehicle Speed Sensor REMOVAL 1) Set the vehicle on a lift, and then lift-up the vehicle. 2) Disconnect the connector from rear vehicle speed sensor. ^ MP-T model MP-T model ^ VTD model VTD model 3) Remove the rear vehicle speed sensor. ^ MP-T model MP-T model ^ VTD model Page 2251 B292-B317 Page 5109 2. Pull up the seat slide rail cover from the center console side as indicated by the arrows. 3. Check visually and with your fingers in the area indicated by broken lines to confirm that the body wiring harness (for power to the occupant detection ECU) is not located and/or pinched around the seat bracket. 4. If the wire is found to be located properly (not pinched), reinstall the seat slide rail cover. No further action is required. If the wire is found to be pinched, proceed to the "Wiring Repair Procedure". Impreza Inspection Procedure 1. Remove the center console trim between the select lever and the parking brake lever. If necessary, refer to the applicable service manual for removal instructions. 2. Cut the cross section of floor carpet in the center and in front of the parking brake lever with scissors (as shown, below). Note: Be careful not to damage wires around the work area. ^ Pull up the floor carpet to inspect a section of the subject body wiring harness from the clamping point located behind the shifter console down to the front passenger seat slide rail as indicated in the photo to the left. ^ Check visually and with your fingers to confirm that the wire is not located around the seat bracket area as indicated by the arrow in the photo Page 1907 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 3934 Fluid - A/T: Service and Repair A/T Condition Check Automatic Transmission Fluid CONDITION CHECK NOTE: When replacing ATF, check the inside condition of the transmission body by inspecting the drained ATF. Page 2868 F21-F61 Page 3908 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 3474 Throttle Position Sensor: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Front Seat Belt Seat Belt: Service and Repair Front Seat Belt FRONT SEAT BELT REMOVAL 1. OUTER SEAT BELT ASSEMBLY 1. Turn the ignition switch to OFF, disconnect the ground cable from battery, and wait for more than 20 seconds. 2. Fold backrest all the way forward, and then move front seat all the way forward. 3. Remove the center pillar lower trim. 4. Remove the anchor cover. Loosen the shoulder anchor bolt, and then detach the shoulder anchor from center pillar. 5. Turn over the floor mat to disconnect the connector of belt tension sensor. (Passenger s side). 6. Turn over the floor mat to disconnect the connector (A) of pretensioner, and then loosen the three bolts to remove the outer seat belt assembly. 7. Remove the center pillar upper trim. Page 547 Page 2118 B128-B134 Locations Fuse: Locations Main Fuse Box (M/B) Fuse & Relay Box (F/B) Main Fuse Box (M/B) Secondary A/C Fuse Box Page 2621 A used toothbrush which has been cleaned works great. Manually open the negative pressure valve. Using clean water and a brush, thoroughly clean the valve (inner and outer surface) and the valve seal surface. Check the radiator cap valve opening pressure using a radiator cap tester to insure the cap is within specification (refer to the applicable Subaru Service Manual). Note: If the cap is out of specification replace it. 2. Coolant Reservoir Tank Cleaning Remove the reservoir tank (refer to the applicable Subaru Service Manual). Using clean water, thoroughly clean the inside of the reservoir tank. Reinstall reservoir tank. Fill with coolant to the Full mark. Note: Be sure to use genuine Subaru Super Coolant or Subaru Long Life Coolant, depending upon what type of coolant is currently in the system. 3. Coolant Reservoir Tank Hose Modification Page 5031 B292-B317 Page 2669 9. Remove the fuel sub level sensor. INSTALLATION Install in the reverse order of removal. NOTE: Use a new gasket. 1. Ensure the sealing portion is free from fuel foreign particles before installation. 2. Tighten the nuts and bolts to specified torque the order as shown in the figure. Page 7216 (3) Install the modified check valve and valve cushion. Rear Check Valve on Forester Page 5944 Trunk / Liftgate Lock: Testing and Inspection Trunk Lid Lock Assembly TRUNK LID LOCK ASSEMBLY INSPECTION 1. Check the striker for bending or abnormal wear. 2. Check the safety lever for improper movement. 3. Check other levers and the spring for rust formation and unsmooth movement. Page 3773 B380-f6 Page 4916 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Locations Lateral Accelerometer: Locations Electrical Component Location Page 4698 B230-B283 Page 6922 Horn Switch: Service and Repair HORN SWITCH REMOVAL WARNING: Before servicing, be sure to read the notes in AB section for proper handling of driver's airbag module. NOTE: Horn switch forms a unit with the driver s airbag module. 1. Disconnect the ground cable from battery. 2. Remove the driver's airbag module. INSTALLATION Install in the reverse order of removal. Page 3621 B17-B20 Testing and Inspection Evaporative Shut Valve: Testing and Inspection INSPECTION Make sure the hoses are not cracked or loose. Page 5059 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 2869 F61-R47 Engine - Valve Guide Oil Seal Identification Valve Guide Seal: Technical Service Bulletins Engine - Valve Guide Oil Seal Identification Valve stem oil seals The Techline occasionally gets calls concerning the color of valve stem oil seals and what colors are for what valves. The green seals are for the exhaust valves. The gray/black seals are for the intake valves. We hope this helps alleviate some confusion. Page 1790 B54-B127 Page 2351 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 2902 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the bolt which installs the crankshaft position sensor to cylinder block. 3. Remove the crankshaft position sensor, and disconnect the connector from it. INSTALLATION Install in the reverse order of removal. Page 4006 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 2749 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 4334 16) Lower the AT jack. NOTE: Do not separate the AT jack and transmission. 17) Remove the oil cooler inlet and outlet pipe. NOTE: When removing the outlet pipe, be careful not to lose balls and springs used with retaining screws. 18) Remove the front and torque converter turbine speed sensor. 19) Disconnect the connector of rear vehicle speed sensor. (VTD model) 20) Disconnect the connector from rear vehicle speed sensor. (MP-T model) Page 3909 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 3634 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 2385 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 1803 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 2330 F21-F61 Page 7217 (1) Open the rear gate and remove the foam trim board on the left hand side from the cargo floor. (2) Remove the check valve. Note: Place rags or paper towels in the area. There is a chance that a small amount of washer fluid may leak out. (3) Attach valve cushion (86634SA000) around the modified check valve (86634AA010) for soundproofing. (4) Install the modified check valve and valve cushion. Service and Repair Trailing Arm: Service and Repair Rear Trailing Link REMOVAL 1. Loosen the rear wheel nuts. 2. Lift-up the vehicle, and then remove the rear wheels. 3. Remove both the rear parking brake clamp and ABS wheel speed sensor harness. 4. Remove the bolt which secures the trailing link to trailing link bracket. 5. Remove the bolt which secures the trailing link to rear housing. INSTALLATION 1. Install in the reverse order of removal. 2. Always tighten the bushing location when tires are in full contact with the ground and the vehicle is at curb weight condition. NOTE: Check the wheel alignment and adjust if necessary. DISASSEMBLY FRONT BUSHING Using the ST, press the front bushing out of place. ST 927720000 INSTALLER & REMOVER SET REAR BUSHING 1. Remove the housing. Page 799 B292-B317 Page 1521 11. Remove the under cover. 12. Drain the engine oil. 13. Remove the front exhaust pipe assembly. 14. Remove the nuts which install the front cushion rubber onto front crossmember. 15. Remove the bolts which install the oil pan on cylinder block while raising up engine. 16. Insert the oil pan cutter blade between cylinder block-to-oil pan clearance. CAUTION: Do not use a screwdriver or similar tool in place of oil pan cutter. 17. Remove the oil strainer. 18. Remove the baffle plate. Installation CAUTION: Before installing the oil pan, clean sealant from oil pan and engine block. 1. Check the seal (A) is securely installed in baffle plate in the direction as shown in the figure. Wipers/Washers - Front Washer Nozzle Won't Spray Windshield Washer Spray Nozzle: All Technical Service Bulletins Wipers/Washers - Front Washer Nozzle Won't Spray FRONT WASHER NOZZLE DOES NOT SPRAY PROPERLY Failure of the front washer nozzle to spray properly may be caused by something blocking the nozzle outlet. Try to eliminate dust and foreign matter from front washer nozzle using the following procedure. If the washer nozzle spraying does not change after the repair, then it will be necessary to replace with a new nozzle or inspect other parts on the washer system. 1) Open the front hood 2) Remove the washer nozzle 3) Blow compressed air in the spray hole of the washer nozzle and the installation hole for washer hose to eliminate dust and foreign matter. 4) Install the hose to washer nozzle and install the washer nozzle. 5) Check if front washer sprays properly. If no change, replace with a new nozzle. A Technical Service Bulletin will be forthcoming with additional information on this subject. Page 2638 B17-B20 Page 4717 2. Stop the engine and watch vacuum gauge. If the vacuum drop range is less than 3.3 kPa (25 mmHg, 0.98 inHg) within 15 seconds after stopping engine, the brake booster is functioning properly. If defective, refer to "AIR TIGHTNESS CHECK". 3. If any fault is found on brake booster, replace the brake booster with a new one. ^ Lack of boosting action check Turn off the engine, and set the vacuum gauge reading at "0". Then, check the fluid pressure when brake pedal is depressed. The pressure must be greater than the standard value listed. ^ Boosting action check Set the vacuum gauge reading at 66.7 kPa (500 mmHg, 19.69 inHg) by running engine. Then, check the fluid pressure when brake pedal is depressed. The pressure must be greater than the standard value listed. Page 1583 F21-F61 Page 4005 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 374 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 3165 Air Injection Pump: Service and Repair Secondary Air Pump REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the connector (A) from secondary air pump. 3. Disconnect the hose (B) from secondary air pump. 4. Remove the bolt (C) which secures the secondary air pump to the vehicle. INSTALLATION Install in the reverse order of removal. Tightening torque: 5 N.m (0.5 kgf-m, 3.7 ft-lb) Page 2751 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 2989 B17-B20 Page 1784 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Diagram Information and Instructions Glove Box Lamp: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Locations Keyless Entry System Page 5492 System Relay: Testing and Inspection INSPECTION While applying battery voltage to the terminal between (3) and (4), check continuity between (1) and (2). If no continuity exists, replace the relay with a new one. Page 2364 R58-R69 Page 3635 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 3101 B230-B283 Locations Horn Relay: Locations Main Fuse Box (M/B) Security System Testing and Inspection Power Mirror Switch: Testing and Inspection REMOTE CONTROL MIRROR SWITCH INSPECTION Move the rearview mirror switch to each position and check continuity between terminals. Change over switch right position Change over switch left position If NG, replace the switch. Page 1966 12. Lift-up the vehicle. 13. Disconnect the connector from rear oxygen sensor. 14. Vertically draw out the clip from crossmember. 15. Separate the center exhaust pipe from rear exhaust pipe. 16. Remove the bolt which holds the center exhaust pipe bracket to transmission. 17. Remove the intercooler bracket. 18. Remove the bolt which holds the center exhaust pipe to hanger bracket. CAUTION: Be careful not to pull down the center exhaust pipe. Page 716 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 3424 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 1469 B54-B127 Page 7237 B134-B136 Page 5710 Seat Occupant Sensor: Description and Operation Occupant Detection System (From '06MY) GENERAL In '06MY, the occupant detection system was changed. The loadcell sensor that is located between the seat cushion and the seat frame consists of the bladder (bag) containing silicon gel and the pressure sensor connected with a hose. When the passenger sits in the passenger's seat, the silicon gel contained in the bladder is pushed. The loadcell sensor measures this pressure, and then it sends the signal to the occupant detection control module. The occupant detection control module detects the physique of the person sitting in the passenger's seat based on the signals, and then it sends the control signal to the airbag control module. The belt tension sensor was also added to the outer seat belt. The belt tension sensor detects the status that seat belt is continuously tensioning (when the child seat is attached to the passenger's seat, etc.), and then it sends the signal to the occupant detection control module. Page 3027 B128-B134 Page 3891 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 817 Impact Sensor: Testing and Inspection Front Sub Sensor Front Sub Sensor INSPECTION Check for the following, and replace damaged parts with new parts. - Front sub sensor and connector are damaged. - Airbag is deployed. Page 3890 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 6700 B17-B20 Page 2459 B292-B317 Testing and Inspection Antitheft Relay: Testing and Inspection INTERRUPT RELAY INSPECTION Measure the interrupt relay resistance between terminals (indicated in the table) when connecting terminal No. 3 to battery positive terminal and terminal No. 1 to battery ground terminal. If NG, replace the interrupt relay. CAUTION: Do not connect the terminals to battery positive terminal and ground terminal incorrectly. If this happens, replace the interrupt relay. Page 930 Non-turbo model ^ Turbo model Turbo model 4) Replace defective parts. Page 4472 Electrical Component Location Page 4340 Transmission Speed Sensor: Service and Repair Torque Converter Turbine Speed Sensor Torque Converter Turbine Speed Sensor REMOVAL When removing the torque converter turbine speed sensor, refer to "Front Vehicle Speed Sensor". INSTALLATION When installing the torque converter turbine speed sensor, refer to "Front Vehicle Speed Sensor" Locations Intake Duct Engine Controls - DTC P0340/P0345 After Camshaft R & R Camshaft Position Sensor: Customer Interest Engine Controls - DTC P0340/P0345 After Camshaft R&R Number: 02-107-09 Date: 03/24/09 Applicability: 2004~06MY Baja 2.5L Turbo 2004~06MY Impreza 2.5L Turbo 2004~06MY Forester 2.5L Turbo 2004~06MY Legacy/Outback 2.5L Turbo SUBJECT: Intake Camshaft Replacement Introduction If you encounter a vehicle that has a CEL and P0340 or P0345 stored in memory immediately after replacing the intake camshaft(s), the air gap between the camshaft and camshaft position sensor may be out of specification. A modification was made to the plate area of the camshaft where the camshaft position sensor picks up the signal. Parts Information Repair Procedure/ Information Using a feeler (thickness) gauge, measure the gap between the camshaft and camshaft position sensor. The correct gap is between 0.15mm to 0.98mm (0.0059 to 0.0386 in.) If the gap is over 0.98mm (0.0386 in.) replace the camshaft position sensor. Refer to the applicable service manual. Warranty/Claim Information For vehicles within warranty, refer the Subaru Warranty Wizard for claim submission information. Page 4244 Drive/Propeller Shaft: Specifications Rear Drive Shaft Dimensions Rear Drive Shaft Dimensions 1 Rear Drive Shaft Dimensions 2 Page 251 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 3757 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 7305 Windshield Washer Switch: Service and Repair COMBINATION SWITCH (WIPER) REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the instrument panel lower cover. 3. Loosen the screw to remove steering column cover lower. 4. Remove the screw to steering column cover upper. 5. Disconnect the connectors from combination switches. 6. Loosen the screw to remove combination switch. INSTALLATION Install in the reverse order of removal. Page 233 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 797 B136-B141 Locations Coolant Temperature Sensor/Switch (For Computer): Locations Sensor (Part 1) Page 5328 Ambient Temperature Sensor / Switch HVAC: Service and Repair Ambient Sensor REMOVAL 1. Open the front hood. 2. Disconnect the ground cable from battery. 3. Disconnect the ambient sensor connector. 4. Remove the ambient sensor from radiator lower panel. INSTALLATION Install in the reverse order of removal. Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 238 B54-B127 Page 136 Engine Control Module (ECM) I/O Signal (Part 2) Page 5466 Step 1 - 6 Page 2969 Page 2158 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the bolt which installs the crankshaft position sensor to cylinder block. 3. Remove the crankshaft position sensor, and disconnect the connector from it. INSTALLATION Install in the reverse order of removal. Inhibitor Switch Transmission Position Switch/Sensor: Service and Repair Inhibitor Switch Inhibitor Switch INSPECTION When the driving condition or starter motor operation is erroneous, first check the shift linkage for improper operation. If the shift linkage is functioning properly, check the inhibitor switch. 1) Disconnect the inhibitor switch connector. 2) Check continuity in inhibitor switch circuits with the select lever moved to each position. NOTE: ^ Also check that continuity in ignition circuit does not exist when the select lever is in "R", "D", "3", "2" and "1" ranges. ^ If the inhibitor switch is inoperative, check for poor contact of connector on transmission side. 3) Check if there is continuity at equal points when the select lever is tilted 1.5° in both directions from "N" range. If there is continuity in one direction and the continuity in the other or if there is continuity at unequal points, adjust the inhibitor switch. 4) Repeat the above checks. If there are abnormalities, adjust the select cable. REMOVAL 1) Set up the vehicle on a lift. 2) Move the select lever to "N" range. 3) Remove the air intake chamber (Non-turbo model). 4) Remove the intercooler. (Turbo model) Page 5906 Rear Door Panel: Testing and Inspection REAR SEALING COVER INSPECTION If the sealing cover is damaged, replace it with a new one. Page 6998 B3-B12 Page 2336 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Service and Repair Brake Bleeding: Service and Repair AIR BLEEDING PROCEDURE CAUTION: ^ The FMVSS No. 116, fresh DOT3 or DOT4 brake fluid must be used. ^ Cover the air bleeder screw with waste cloth when loosening it to prevent brake fluid from being splashed over surrounding parts. ^ Do not allow brake fluid to come in contact with vehicle body; wash away with water and wipe off completely if spilled. ^ Avoid mixing different brands of brake fluid to prevent degrading the quality of the fluid. ^ Be careful not to allow dirt or dust to get into the reservoir tank. 1. MASTER CYLINDER NOTE: ^ If the master cylinder is disassembled or reservoir tank is empty, bleed the master cylinder. ^ During the bleeding operation, keep the brake reservoir tank filled with brake fluid to eliminate entry of air. ^ The brake pedal operating must be very slow. ^ For convenience and safety, two people should do the work. 1. Loosen the wheel nuts, jack-up the vehicle, support it with rigid racks, and remove the wheel. 2. Disconnect the brake line at primary and secondary sides. 3. Put a plastic bag cover on master cylinder. 4. Carefully depress and hold the brake pedal. 5. Close the outlet plug with your finger, and then release the brake pedal. 6. Repeat step (4) and (5) until the brake fluid is completely bled from outlet plug. 7. Remove the plastic bag. 8. Install the brake pipes to master cylinder. Tightening torque: 15 Nm (1.5 kgf-m, 10.8 ft. lbs.) 9. Bleed air from the brake line. 2. BRAKE LINE NOTE: ^ During the bleeding operation, keep the brake reservoir tank filled with brake fluid to eliminate entry of air. ^ The brake pedal operating must be very slow. ^ For convenience and safety, two people should do the work. 1. Make sure that there is no leak from the joints and connections of brake system. 2. Fit one end of vinyl tube into the air bleeder screw and put the other end into a brake fluid container. Page 2450 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 1706 Spark Plug: Adjustments ADJUSTMENT Clean the spark plugs with a wire brush. Clean and remove the carbon or oxide deposits, but do not wear away ceramic insulator. If deposits are too stubborn, replace the plugs. After cleaning the spark plugs, correct the spark plug gap using a gap gauge. NOTE: Do not use spark plug cleaners, because the spark plugs are applied with iridium tips. Page 1386 NOTE: If the measured value is not within specification, take notes of the value in order to adjust the valve clearance later on. 13. If necessary, adjust the valve clearance. 14. Further turn the crank pulley clockwise. Using the same procedures described previously, and then measure the valve clearances again. 1. Set the arrow mark on cam sprocket to position shown in the figure, and then measure the #2 cylinder exhaust valve and #3 cylinder intake valve clearances. 2. Set the arrow mark on cam sprocket to position shown in the figure, and then measure the #2 cylinder intake valve and #4 cylinder exhaust valve clearances. 3. Set the arrow mark on cam sprocket to position shown in the figure, and then measure the #1 cylinder exhaust valve and #4 cylinder intake valve clearances. 15. After inspection, install the related parts in the reverse order of removal. Tightening torque: 33 Nm (3.4 kgf-m, 25 ft. lbs.) Page 1912 B3-B12 Page 1569 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 3608 Crankshaft Position, Camshaft Position And Knock Sensors Page 1884 Disclaimer Page 3140 B134-B136 Page 1623 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 6659 Backup Light Bulb: Service and Repair BACK-UP LIGHT BULB REMOVAL 1. SEDAN MODEL 1. Remove the trunk side trim of rear portion. 2. Turn the socket and remove the bulb. 2. WAGON MODEL 1. Remove the rear combination light assembly. 2. Turn the socket and remove the bulb. INSTALLATION Install in the reverse order of removal. Page 3560 B134-B136 Page 6138 B292-B317 Engine Controls - DTC P0340/P0345 After Camshaft R & R Camshaft Position Sensor: All Technical Service Bulletins Engine Controls - DTC P0340/P0345 After Camshaft R & R Number: 02-107-09 Date: 03/24/09 Applicability: 2004~06MY Baja 2.5L Turbo 2004~06MY Impreza 2.5L Turbo 2004~06MY Forester 2.5L Turbo 2004~06MY Legacy/Outback 2.5L Turbo SUBJECT: Intake Camshaft Replacement Introduction If you encounter a vehicle that has a CEL and P0340 or P0345 stored in memory immediately after replacing the intake camshaft(s), the air gap between the camshaft and camshaft position sensor may be out of specification. A modification was made to the plate area of the camshaft where the camshaft position sensor picks up the signal. Parts Information Repair Procedure/ Information Using a feeler (thickness) gauge, measure the gap between the camshaft and camshaft position sensor. The correct gap is between 0.15mm to 0.98mm (0.0059 to 0.0386 in.) If the gap is over 0.98mm (0.0386 in.) replace the camshaft position sensor. Refer to the applicable service manual. Warranty/Claim Information For vehicles within warranty, refer the Subaru Warranty Wizard for claim submission information. Page 4000 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 7047 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 3552 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 7411 B17-B20 Page 664 Vehicle Speed Sensor: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 531 F61-R47 Page 2185 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 4001 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 6227 Brake Switch (Cruise Control): Service and Repair STOP LIGHT AND BRAKE SWITCH REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the connector from stop and brake switch, and then remove the switch. INSTALLATION Install in the reverse order of removal. Page 5760 Keyless Entry Transmitter: Service and Repair Replacement TRANSMITTER REPLACEMENT 1. REGISTRATION OF TRANSMITTER WITH SUBARU SELECT MONITOR NOTE: A maximum of four transmitters can be registered for each individual vehicle. - When replacing or adding the transmitter, new registration of transmitter is necessary. 1. Connect the Subaru Select Monitor to the vehicle. 2. Turn the ignition switch to ON. 3. From the on the Subaru Select Monitor, select the {2. Check individual system} -> {Keyless unit mode} -> {1. Keyless ID registration}, and press the [YES] key. 4. Input the 8-digit ID number from the left attached to the plastic bag of transmitter or circuit board inside transmitter. NOTE: Press the [/\] key on the Subaru Select Monitor to increase the number, and the [\/] key to decrease. Press the [<] key to move to the digit in the left, and [>] to the right. 5. The ID number you have entered will be shown. Make sure that the ID number shown is the same as that of plastic bag. 6. Press the [YES] key if the ID number is correct. Press the [NO] key if incorrect, to return to the step 3) and try again. 7. will be displayed and registration started. 8. will be shown when the process is done. 9. To end, select the , and press the [NO] key to return to {1. Keyless ID registration}. If there are additional transmitters to be registered, select the , and press the [YES] key to return to the step 3). NOTE: If the registration fails, will be shown. Press the [YES] key to return to the {1. Keyless ID registration} and retry from the step 2). - is shown on the Subaru Select Monitor when four transmitters have been registered. Press the [NO] key to return to {1. Keyless ID registration}. M/T - Clutch Pedal Squeaking Noise Clutch Switch: Technical Service Bulletins M/T - Clutch Pedal Squeaking Noise CLUTCH PEDAL SQUEAK If you encounter a manual transmission equipped vehicle with a clutch pedal squeak concern, and lubricating the pedal mechanism didn't fix the noise, check the clutch switch. We have had a few reports where this has been the source of the problem. The fix is to replace the clutch pedal switch. Page 3488 5. Loosen the clamp (B) which connects the throttle body to intercooler. 6. Remove the intercooler air duct from turbocharger. 7. Remove the intercooler from throttle body. INSTALLATION Install in the reverse order of removal. Page 6702 B128-B134 Service and Repair Door Locks: Service and Repair KEY LOCK CYLINDERS REPLACEMENT FRONT DOOR 1. Remove the door trim. 2. Pull back the sealing cover. 3. Move the front door glass downward. 4. Remove the rod clamp. Remove the bolt. Replace the key cylinder. Page 604 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 4354 1. BACK-UP LIGHT SWITCH AND NEUTRAL POSITION SWITCH 1) Install the back-up light switch and neutral position switch with harness. Tightening torque: 32.3 Nm (3.3 kgf-m, 23.8 ft. lbs.) 2) Connect the connector of back-up light switch and neutral position switch. 3) Install the air intake duct and cleaner case. (Non-turbo model) 4) Install the intercooler. (Turbo model) 5) Connect the battery ground cable to battery. Neutral Switch & Backup Switch Testing Switches and Harness INSPECTION BACK-UP LIGHT SWITCH Inspect the back-up light switch. NEUTRAL POSITION SWITCH 1) Turn the ignition switch to OFF. 2) Disconnect the connector of neutral position switch. 3) Measure the resistance between neutral position switch terminals. Non-turbo model: Non-turbo model Turbo model: Turbo model ^ Non-turbo model Page 631 5) Disconnect the inhibitor switch connector. 6) Remove the inhibitor switch connector from stay. 7) Lift-up the vehicle. 8) Remove the front and center exhaust pipes. 9) Remove the snap pin and washer from range select lever. 10) Remove the plate assembly from transmission case. 11) Remove the bolts. Page 196 Ignition Control Module: Service and Repair Ignition Coil and Ignitor Assembly REMOVAL Direct ignition type has been adopted. Refer to the "Spark Plug Removal" for removal procedure. INSTALLATION Install in the reverse order of removal. Tightening torque: 16 N.m (1.6 kgf-m, 11.7 ft-lb) Diagrams Hood Lock And Remote Openers Page 6939 Tail Light Bulb: Service and Repair TAIL/STOP LIGHT BULB REMOVAL 1. SEDAN MODEL 1. Remove the trunk side trim of rear portion. 2. Turn the socket and remove the bulb. 2. WAGON MODEL 1. Remove the rear combination light assembly. 2. Turn the socket and remove the bulb. INSTALLATION Install in the reverse order of removal. Page 4687 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 1543 - RH side - LH side 7. Connect the engine harness with clip (A) to the rocker cover. - RH side - LH side Page 3669 Ignition Control Module: Service and Repair Ignition Coil and Ignitor Assembly REMOVAL Direct ignition type has been adopted. Refer to the "Spark Plug Removal" for removal procedure. INSTALLATION Install in the reverse order of removal. Tightening torque: 16 N.m (1.6 kgf-m, 11.7 ft-lb) Page 873 ^ Check the back-up light illumination when the select lever is in "R" range. ^ Check the parking lock operation when the select lever is in "F" range. 5) Using the Subaru Select Monitor, clear the diagnostic trouble codes stored in memory. If the codes return afier the correct adjustments, refer to the diagnostic procedure found in the applicable Subaru Service Manual. WARRANTY/CLAIM INFORMATION For vehicles within the Basic New Car Limited Warranty period, refer to the Subaru Warranty Wizard for claim submission information. Disclaimer Page 1330 Camshaft: Tools and Equipment Camshaft Alignment Bar AST (SU 250) Subaru 2.5L Cam Alignment Bar AST tool# SU 250 Page 454 F21-F61 Page 1396 CYLINDER HEAD AND CAMSHAFT Page 178 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 2658 Engine Control Module (ECM) I/O Signal (Part 6) Description and Operation Tachometer: Description and Operation TACHOMETER The tachometer drive circuit is connected to the engine speed sensing circuit in the engine control module. When the engine speed increases or decreases, the voltage of the circuit also increases or decreases, changing the magnetic force of the tachometer drive coil. The tachometer needle then moves in accordance with change in the engine speed. Page 3283 10. Remove the bolts which hold the injector pipe to intake manifold. 11. Remove the fuel injector while lifting up the fuel injector pipe. LH SIDE 1. Release the fuel pressure. 2. Disconnect the ground cable from battery. 3. Open the fuel filler flap lid and remove the fuel filler cap. 4. Remove the intake manifold. 5. Remove the fuel pipe protector LH. 6. Disconnect the connector from the fuel injector. 7. Disconnect the connector from purge control solenoid valve. Page 5637 - Passenger's seat Service and Repair Steering Shaft Coupler: Service and Repair Universal Joint REMOVAL 1) Remove the steering wheel. 2) Make matching mark on the universal joint. 3) Remove the universal joint bolts, and then remove the universal joint. INSTALLATION 1) Align the cutout at serrated section of the column shaft and yoke, and then insert the universal joint into column shaft. 2) Align the matching marks, and then insert the universal joint to serrated section of gear box assembly. 3) Tighten the bolt. Tightening torque: 24 Nm (2.4 kgf-m, 17.4 ft. lbs.) CAUTION: Excessively large tightening torque of the universal joint bolts may lead to heavy steering wheel operation. Standard clearance between gearbox to DOJ: Over 14 mm (0.55 inch) 4) Align the center of roll connector. 5) Install the steering wheel and airbag module. WARNING: Page 5111 Note: Be careful not to damage wires around the working area. 4. Impreza and Forester: Remove the passenger front seat and disconnect the body wire connector afier pulling up the floor carpet. Note: Check if the wire is pinched at the seat rail and damaged. 5. Repair the wire according to the extent of damage as indicated below. (1) When only the surface of the wire covering is damaged only: Wrap electrical tape around the damaged portion, proceed to Step 7. (2) When the core wire is cut or damaged: Cut and remove the damaged section of wire, as illustrated. (3) Peel the wire covering 5/8 inch (15 mm) from the tip of cut wire and expose the core wires, as illustrated. (4) Install heat shrink tubing on one side of the cut wiring. (5) Twist the core wires together so that they entwine each other. Be careful to ensure the tips of the wires are level and parallel. Otherwise~ the wire will break through the heat shrink tubing. (6) Solder the twisted wires and activate the heat shrink tubing with a heat gun. Confirm that no frayed wires are visible. 6. Reconnect the body wire connector. Page 4778 Solenoid Valve And Switch (AT Model) Solenoid Valve And Switch (MT Model) Locations Variable Induction Position Sensor: Locations Sensor (Part 1) Page 524 B128-B134 Page 4540 6. Position the boot in grooves on cylinder and piston. 7. Apply a coat of specified grease to the lock pin and guide pin outer surface, cylinder inner surface, and boot grooves. Grease: NIGLUBE RX-2 (Part No. K0779GA 102) 8. Install the lock and guide pin boot on support. 2. 16 INCH TYPE 1. Clean the caliper body interior using brake fluid. 2. Apply a coat of brake fluid to the piston seal and fit piston seal in groove on caliper body. 3. Apply a coat of brake fluid to the entire inner surface of cylinder and outer surface of piston. 4. Apply a coat of specified grease to the boot and fit in groove on ends of cylinder and piston. Grease: NIGLUBE RX-2 (Part No. K0779GA 102) 5. Insert the piston into cylinder. CAUTION: Do not force the piston into cylinder. Page 3950 Fluid Line/Hose: Service and Repair Oil Charge Pipe Oil Charge Pipe REMOVAL 1) Remove the air intake chamber. (Non-turbo model) 2) Remove intercooler. (Turbo model) 3) Remove the oil charge pipe, and remove the O-ring from the flange face. INSTALLATION 1) Install the oil charge pipe with new O-ring. 2) Install the air intake chamber. (Non-turbo model) 3) Install intercooler. (Turbo model) INSPECTION Make sure the oil charge pipe is not deformed or otherwise damaged. Locations Knock Sensor: Locations Sensor (Part 1) Page 3807 8) Install the front vehicle speed sensor and torque converter turbine speed sensor, and then fasten the harness. 9) Install the inlet pipe. NOTE: Be sure to use a new copper washer. 10) Install the transmission rear crossmember bolts. Tightening torque: 70 Nm (7.1 kgf-m, 51 ft. lbs.) 11) Install the propeller shaft. 12) Install the front, center, rear exhaust pipes and muffler. (Non-turbo model) 13) Install the center, rear exhaust pipes and muffler. (Turbo model) 14) Lower the vehicle. 15) Install the transmission connector to the stay. 16) Install the pitching stopper. 17) Install the air intake chamber. (Non-turbo model) 18) Install the intercooler. (Turbo model) Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 1970 4. Joint Pipe REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the front oxygen (A/F) sensor. 3. Remove the under cover. 4. Remove the exhaust manifold lower cover (RH). 5. Remove the nuts which hold the front exhaust manifold to joint pipe. 6. Remove the center exhaust pipe. 7. Remove the turbocharger. 8. Take off the joint pipe in the upward direction. INSTALLATION Install in the reverse order of removal. Tightening torque: T. 35 Nm (3.6 kgf-m, 26 ft. lbs.) 5. Rear Exhaust Pipe REMOVAL 1. Disconnect the ground cable from battery. 2. Lift-up the vehicle. 3. Separate the rear exhaust pipe from center exhaust pipe. CAUTION: Be careful, the exhaust pipe is hot. Specifications Page 4539 2. Remove the piston boots from each piston end. 3. Place a wooden block in caliper body as shown in the figure to prevent the piston from jumping out and avoid being damaged. 4. Gradually supply compressed air via the installation hole of brake hose to force the piston out. 5. Remove the piston seal from caliper body cylinder. CAUTION: Do not damage the cylinder and piston seal groove. ASSEMBLY 1. 15 INCH TYPE 1. Clean the caliper body interior using brake fluid. 2. Apply a coat of brake fluid to the piston seal and fit piston seal in groove on caliper body. 3. Apply a coat of brake fluid to the entire inner surface of cylinder and outer surface of piston. 4. Apply a coat of specified grease to the boot and install the piston boot to the groove on ends of cylinder. Grease: NIGLUBE RX-2 (Part No. K0779GA 102) 5. Insert the piston into cylinder. CAUTION: Do not force the piston into cylinder. Page 461 Air Flow Meter/Sensor: Service and Repair Mass Air Flow and Intake Air Temperature Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the connector from mass air flow and intake air temperature sensor. 3. Remove the mass air flow and intake air temperature sensor. INSTALLATION Install in the reverse order of removal. Tightening torque: 1.7 N.m (0.17 kgf-m, 1.3 ft-lb) Page 1504 B134-B136 Page 316 B17-B20 Page 2635 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. A/T Fluid Inspection Fluid - A/T: Service and Repair A/T Fluid Inspection Automatic Transmission Fluid INSPECTION NOTE: 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 engine to raise ATF temperature to 70 - 80°C (158 - 176°F) on SUBARU Select Monitor. 2) Make sure the vehicle is level. 3) After selecting all positions (P, R, N, D, 3, 2, 1), set the select lever in "P" range. Measure the ATF level with the engine idling for one or two minutes. 4) Make sure that ATF level is between the upper level and lower level at HOT side. If the level is below the lower level, check for leaks in the transmission. If there are leaks, it is necessary to repair or replace gasket, oil seals, plugs or other parts. CAUTION: ^ Use care not to exceed the upper limit level. ^ Filling of ATF to the upper level when the transmission is cold will result in overfilling of ATF, causing a transmission failure. 5) Check ATF level after raising ATF temperature to 70 - 80°C (158 - 176°F) by driving the distance of 5 to 10 km (3 to 6 miles) or by idling the engine. Page 6634 R72-R145 R148 Page 6464 Locations Fuel Pump Relay: Locations Solenoid Valve, Actuator, Emission Control System Parts And Ignition System Parts (Part 5) Page 4326 13) Install the air intake chamber. (Non-turbo model) 14) Install the intercooler. (Turbo model) 15) Inspect the inhibitor switch. Page 483 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the generator. 3. Drain the engine coolant. 4. Disconnect the connector from the engine coolant temperature sensor. 5. Remove the engine coolant temperature sensor. INSTALLATION Install in the reverse order of removal. NOTE: Use a new gasket. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb) Page 6074 Power Door Lock Actuator: Testing and Inspection Rear Door Latch and Door Lock Actuator Assembly REAR DOOR LATCH AND DOOR LOCK ACTUATOR ASSEMBLY INSPECTION 1. Make sure the rod is not deformed. 2. Make sure the outer handle, rear remote handle and rod move smoothly. Testing and Inspection Alarm Horn Relay: Testing and Inspection SECURITY HORN RELAY INSPECTION Measure the security horn relay resistance between terminals (indicated in the table) when connecting terminal No. 4 to battery positive terminal and terminal No. 1 to battery ground terminal. If NG, replace the security horn relay. Page 7413 B128-B134 Page 5143 7) Turbo model (1) Remove the air cleaner. (2) Remove the coolant filler tank. (3) Remove the two bolts fixing pipe C and D. (bolt A) (4) Disconnect the pipe C from oil pump. Disconnect the pipe D from return hose. CAUTION: ^ Do not allow fluid from the hose end to come into contact with pulley belt. ^ To prevent foreign matter from entering the hose and pipe, cover the open ends of them with a clean cloth. INSTALLATION Page 7068 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Diagrams Brake Pedal Assy: Diagrams MT MODEL Page 3600 Ignition Control Module: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 5614 - Do not drop the airbag modulator parts, subject them to high temperature over 93 degrees C (199 degrees F), or let water, oil, or grease get on them; otherwise, the internal parts may be damaged and reliability greatly lowered. - If any damage, opening, or rust is found on the airbag system wire harness, do not attempt to repair using soldering equipment. Be sure to replace the faulty harness with a new genuine part. - Install the wire harness securely with the specified clips to avoid interference or tangled up with other parts. Page 6419 8. Remove the bolts which install the fuel sub level sensor on the fuel tank. 9. Remove the fuel sub level sensor. INSTALLATION Install in the reverse order of removal. NOTE: Use a new gasket. 1. Ensure the sealing portion is free from fuel or foreign particles before installation. 2. Tighten the nuts and bolts to specified torque in order as shown in the figure. Page 4685 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 3435 F61-R47 Testing and Inspection Turn Signal Switch: Testing and Inspection INSPECTION Measure the resistance between combination switch terminals. 1. LIGHTING SWITCH 2. DIMMER AND PASSING SWITCH 3. TURN SIGNAL SWITCH M/T - Clutch Pedal Squeaking Noise Clutch Pedal Position Sensor / Switch: Technical Service Bulletins M/T - Clutch Pedal Squeaking Noise CLUTCH PEDAL SQUEAK If you encounter a manual transmission equipped vehicle with a clutch pedal squeak concern, and lubricating the pedal mechanism didn't fix the noise, check the clutch switch. We have had a few reports where this has been the source of the problem. The fix is to replace the clutch pedal switch. Page 6712 Glove Box Lamp: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 6806 R72-R145 R148 Page 436 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 887 10. Remove the plate assembly from transmission case. 11. Remove the bolts. 12. Move the range select lever to parking position (left side). 13. Remove the inhibitor switch from transmission. 14. Disconnect the inhibitor switch harness connector from inhibitor switch. INSTALLATION Page 3330 11. Install the rear right wheel. 12. Lower the vehicle. 13. Tighten the wheel nuts. 14. Connect the battery ground cable to battery. Page 4054 5) Move the transmission to right side, and then install the stay. 6) Install the reverse check cable end, washer and snap pin to reverse check lever. NOTE: Take care to install the snap pin in proper direction. 7) Fix the reverse check cable to clip of stay. NOTE: Install the reverse check cable to upper side of stay. Page 605 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 3046 12) Move the range select lever to parking position (left side). 13) Remove the inhibitor switch from transmission. 14) Disconnect the inhibitor switch harness connector from inhibitor switch. INSTALLATION 1) Connect the inhibitor switch harness connector to inhibitor switch. 2) Install the inhibitor switch to transmission case. 3) Move the range select lever to neutral position. Page 1458 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 5155 2) Tighten the bolts which install the power steering pump bracket. 3) Interconnect the pipe C and suction hose. Tightening torque: Eye bolt 40 Nm (4.1 kgf-m, 29.5 ft. lbs.) CAUTION: If a hose is twisted at this step, the hose may come into contact with some other parts. 4) Connect the connector to power steering pump switch. 5) Install the pulley belt to oil pump. 6) Check the pulley belt tension. 7) Tighten the bolt of belt tension. Tightening torque: 25 Nm (2.5 kgf-m, 18. 1 ft. lbs.) 8) Install the pulley belt cover. 9) Connect the battery ground cable to battery. 10) Feed the specified power steering fluid. CAUTION: Never start the engine before feeding the fluid; otherwise vane pump might be seized up. INSPECTION BASIC INSPECTION Page 562 Oxygen Sensor: Locations Location View Page 2324 B128-B134 Page 5081 B380-f6 Page 7318 Wiper Blade: Testing and Inspection INSPECTION 1. When the wiper does not perform well, inspect the following: - Make sure the movable part of the blade assembly moves smoothly. - Make sure the wiper rubber is not deformed or damaged. 2. Replace them with new parts if damaged. Page 2769 Oxygen Sensor: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 1068 Drive Belt: Service and Repair V-Belt Removal NOTE: Perform the following procedures with the engine installed to the body. FRONT SIDE BELT 1. Loosen the lock bolt (A). 2. Loosen the slider bolt (B). 3. Remove the front side belt (C). REAR SIDE BELT 1. Loosen the lock nut (A). 2. Loosen the slider bolt (B). 3. Remove the A/C belt. 4. Remove the A/C belt tensioner. Installation FRONT SIDE BELT NOTE: Wipe off any oil or water on the belt and pulley. 1. Install the V-belt (c), and tighten the slider bolt so as to obtain the specified belt tension. 2. Tighten the lock bolt (A). 3. Tighten the slider bolt (13). Tightening torque: Lock bolt through bolt 25 Nm (2.5 kgf-m, 18.4 ft. lbs.) Slider bolt: 8 Nm (0.8 kgf-m, 5.9 ft. lbs.) Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 4381 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 1841 F21-F61 Page 2945 F61-R47 Page 625 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 4948 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Specifications Timing Belt Tensioner: Specifications Automatic belt tension adjuster ............................................................................................................................................ 39 Nm (4.0 kgf-m, 28.9 ft. lbs.) Page 1231 - When painting or performing sheet metal work on the side of the vehicle, including the side sill, center pillar, and front and rear doors, remove the side airbag sensors and wire harness of the airbag system. - When storing a removed airbag module, do not place any objects on it or pile airbag modules on top of each other. If the airbag inflates for some reason when it is placed with its pad side facing downward or under any object, a serious accident may result. Service and Repair Shift Interlock Solenoid: Service and Repair AT Shift Lock Solenoid and "P" Range Switch REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the console box. 3) Disconnect the connector. 4) Remove the grip. 5) Remove the indicator bulb from indicator cover. 6) Remove the indicator cover. 7) Remove the blind. 8) Remove the cushion. 9) Remove the clip, and then remove the "P" range switch. 10) Remove the cover. Page 2285 B136-B141 Page 3567 R58-R69 Page 6032 5) In the case of models with sunroof, remove the sunroof weather strip. 6) Remove the assist-grips (A). 7) Remove the upper inner trim. 8) Remove the rear quarter upper trim. Page 4872 Solenoid Valve, Actuator, Emission Control System Parts And Ignition System Parts (Part 5) Page 2090 F21-F61 Page 6333 Clock: Description and Operation Operation OPERATION CLOCK DISPLAY The clock shows time when the ignition switch is turned to ACC or further from OFF. INSTANT FUEL EFFICIENCY, AVERAGE FUEL EFFICIENCY, REMAINING TRAVEL DISTANCE AND CONTINUOUS DRIVING TIME DISPLAY The combination meter microprocessor performs calculations based on vehicle speed signals from the ABS/VDC control module, remaining fuel signals from the body integrated unit, fuel efficiency signals from the engine control module, and engine start signals, and then sends the data to the clock unit. - Average fuel efficiency The value is calculated from the distance and total amount of consumed fuel since the trip meter has been reset the last time. - Instant fuel efficiency The value is calculated during driving, based on the traveled distance and amount of consumed fuel recorded for a certain period. - Remaining travel distance The value is calculated from the average fuel efficiency in recent 30 km (18.8 miles) and the amount of remaining fuel. - Continuous driving time Indicates the total time since the engine has been started. OUTSIDE AIR TEMPERATURE DISPLAY The body integrated unit performs calculations based on outside air temperature signals from the ambient sensor and vehicle speed signals from the ABS/VDC control module, and then sends the data via the combination meter to the clock unit. BRIGHT (DIMMER CANCELING) FUNCTION The dimmer can be cancelled by pushing the BRIGHT button when the lighting switch is ON. The lights returns to the dimmed state when the button is pushed again. PASSENGER'S SEAT AIRBAG INDICATOR When this indicator (a mark on vehicles for Canada) is ON, the passenger's seat airbag will deploy in case of a front collision that should cause the airbag system to activate. When the indicator (a mark on vehicles for Canada) is OFF the passengers seat airbag will not deploy. Page 1435 Inspection 1. Check the coolant passages are not clogged using air blow method. 2. Check the mating surfaces of cylinder block, 0ring groove and oil filter for damage. Page 1364 Harmonic Balancer - Crankshaft Pulley: Testing and Inspection INSPECTION 1. Make sure the V-belt is not worn or otherwise damaged. 2. Check the tension of the belt. Page 4882 10. Remove the plate assembly from transmission case. 11. Remove the bolts. 12. Move the range select lever to parking position (left side). 13. Remove the inhibitor switch from transmission. 14. Disconnect the inhibitor switch harness connector from inhibitor switch. INSTALLATION Capacity Specifications Fluid - Differential: Capacity Specifications Rear Differential Gear Oil Non STI Model Fluid Capacity ................................................................... .................................................................................................. 0.8 liter (0.8 US qt, 0.7 Imp qt) Rear Differential Gear Oil STI Model Only Fluid Capacity ................................................................... .................................................................................................. 1.0 liter (1.1 US qt, 0.9 Imp qt) Fluid Type API GL-5 ..................................................................................................................................... ........................................................... SAE 90 Locations Fuse: Locations Main Fuse Box (M/B) Fuse & Relay Box (F/B) Main Fuse Box (M/B) Secondary A/C Fuse Box Page 5664 B136-B141 Page 4036 7) With the cable pulled (slider lowered), adjust the length between end of cable plate and reverse check cable to 84 mm (3.31 inch), and then tighten the lock nut. 8) Move the transmission to right side, and then install the stay. 9) Install the crossmember. 10) Install the rear exhaust pipe and muffler. 11) Install the reverse check cable end, washer and snap pin to reverse check lever. NOTE: Take care to install the snap pin in proper direction. 12) Install the under cover. Page 3743 3. Disconnect the connector from ignition coil and ignitor assembly. 4. Remove the ignition coil and ignitor assembly. 5. Remove the spark plugs with the spark plug sockets. LH SIDE 1. Remove the battery and battery carrier. 2. Remove the secondary air pump. 3. Disconnect the connector from ignition coil and ignitor assembly. Page 5520 to the right. The proper wire location (not pinched) is indicated by broken lines in the photo to the right, below. ^ If the wire was found to be pinched, proceed to the "Wiring Repair Procedure" section, below. 3. If the wire was found to be located properly (not pinched), no repair is necessary. Reinstall the floor carpet. Wrap the previously cut portion of carpet with 1.5 inch wide unwoven adhesive tape. 4. Reinstall the center console trim. Note: Be careful that the seat heater switch is not pinched by the parking brake lever during reinstallation. 5. Confirm that switches, including the seat heater switch, work properly. Wiring Repair Procedure: Forester & Impreza 1. Disconnect the negative battery cable. Note: In the interest of customer satisfaction, please write down all radio preset stations prior to disconnecting the battery. The stations should be reset into the radio afier completion of the repair. 2. For Impreza models, proceed to step 4. Forester Models only: Remove the center console trim between the select lever and parking brake lever. 3. Forester only: Cut a cross section of floor carpet at the center in front of the parking brake lever with scissors as shown. Page 5518 ownership. For affected vehicles sold after the date on the dealer's affected list, dealers are to contact those owners and provide them with a copy of the owner notification letter. They should also arrange to make the required correction according to the instructions in the service procedure section of this bulletin. Dealers are also to promptly perform the applicable service procedures defined in this bulletin to correct all affected vehicles in their inventory (new, used, demo). Additionally, whenever a vehicle subject to this recall is taken into dealer new or used inventory, or is in the dealership for service, necessary steps should be taken to ensure the service program correction has been made before selling or releasing the vehicle. PARTS INFORMATION Special Tools and Materials ^ Soldering gun and solder ^ Heat gun ^ 1.5 inch wide unwoven adhesive tape ^ Subaru Global Terminal Wiring Kit 1-47606 ^ Electrical tape ^ Electrical shrink wrap tubing SERVICE PROCEDURE This Recall will involve inspection of the front passenger seat wiring for proper routing. It will also involve repair of the affected wire harness if the inspection reveals pinched wiring. Service Procedure The first part of the procedure involves inspecting the wiring harness for proper routing and possible damage. (There are two separate procedures, one for each different vehicle.) If there is no damage to the wiring harness, no repair is necessary. If the wiring harness is found to be damaged, then follow the repair procedure. Forester Inspection Procedure (See Impreza inspection procedure.) 1. Slide the front passenger seat to the rear most position to expose the front of the slide rail. Page 1558 22. Connect the connector to the throttle position sensor (A) and manifold absolute pressure sensor B). 23. Install the engine ground terminal to the intake manifold. 24. Install the fuel pipe protector RH. Page 4855 1) With the select lever already in the "N" range, loosen the adjusting nuts A and B on both sides. 2) Turn the adjusting nut B until it lightly touches the connector. 3) Use a spanner wrench to hold nut B so that it does not rotate and then tighten the adjusting nut A. Tightening torque: 7.5 N-m (0.76 kgf-m, 5.5 ft-lb) 4) Afier the completion of adjustment, confirm that the select lever operates normally at all ranges: ^ Move the select lever from "P" to "D" range. Check that the detents could be felt in each range. If the detents cannot be felt or the position pointer (dash indicator) is improperly aligned, re-adjust the cable. ^ Check if the starter motor rotates when the select lever is set to "P" range. Page 3974 11) Remove the clamp, and then remove the shift lock solenoid. INSTALLATION Install in the reverse order of removal. INSPECTION Step 1 - Step 4 Page 6253 Brake Switch (Cruise Control): Service and Repair STOP LIGHT AND BRAKE SWITCH REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the connector from stop and brake switch, and then remove the switch. INSTALLATION Install in the reverse order of removal. Inspection Starter Motor: Testing and Inspection Inspection INSPECTION 1. ARMATURE 1. Check the commutator for any sign of burns of rough surfaces or stepped wear. If wear is of a minor nature, correct it by using sand paper. 2. Run-out test Check the commutator run-out, and then replace if it exceeds the limit. Commutator run-out: Standard: 0.05 mm (0.0020 in) Service limit: Less than 0.10 mm (0.0039 in) 3. Depth of segment mold Check the depth of segment mold. Depth of segment mold: 0.5 mm (0.020 in) 4. Armature short-circuit test Check the armature for short-circuit by placing it on a growler tester. Hold an iron sheet against the armature core while slowly rotating Page 6835 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 2182 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 5034 F61-R47 Page 2574 Crankshaft Position, Camshaft Position And Knock Sensors Testing and Inspection Air Filter Element: Testing and Inspection INSPECTION Inspect for cracks and loose connections. Page 4716 NOTE: If faulty, check precisely with gauges. 2. OPERATION CHECK (WITH GAUGES) CAUTION: When checking operation, be sure to securely apply the parking brake. ^ Checking with gauges Connect gauges as shown in the figure. After bleeding air from pressure gauges, proceed to each check. ^ Air tightness check 1. Start the engine and keep it running until a vacuum of 66.7 kPa (500 mmHg, 19.69 inHg) = point A is indicated on vacuum gauge. Do not depress the brake pedal. 2. Stop the engine and watch the gauge. If the vacuum drop range is less than 3.3 kPa (25 mmHg, 0.98 inHg) within 15 seconds after stopping engine, the brake booster is functioning properly. If defective, the cause may be one of those listed below. ^ Check valve malfunction ^ Leak from vacuum hose ^ Leak from the shell jointed portion or stud bolt welded portion ^ Damaged diaphragm ^ Leak from valve body seal and bearing portion ^ Leak from plate and seal assembly portion ^ Leak from poppet valve assembly portion ^ Loaded air tightness check 1. Start the engine and depress brake pedal with pedal force of 196 Nm (20 kgf, 44 ft. lbs.). Keep the engine running until a vacuum of 66.7 kPa (500 mmHg, 19.69 inHg) = point B is indicated on vacuum gauge while the pedal is still depressed. Page 7260 8. Disconnect the hose. 9. Remove the bolt and nut, and then remove the washer tank. INSTALLATION Install in the reverse order of removal. Tightening torque: 6.0 N-m (0.61 kgf-m, 4.4 ft-lb) Front Wiper Arm Wiper Arm: Service and Repair Front Wiper Arm FRONT WIPER ARM REMOVAL 1. Open the hood. 2. Remove the cap. 3. Remove the nut to remove arm. INSTALLATION 1. Install in the reverse order of removal. 2. Operate the wiper once. 3. Align the wiper blade to the ceramic print point mark (A) of front window panel. Tightening torque: Nm (kgf-m, ft-lb) T1: 6.0 (0.61, 4.4) T2: 20 (2.0, 14.5) Page 2317 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Testing and Inspection Hazard Warning Flasher: Testing and Inspection TURN SIGNAL AND HAZARD MODULE Connect the battery and turn signal light bulb to the module, as shown in the figure. The module is properly functioning if it blinks when power is supplied to the circuit. Page 5373 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Fuel Level Sensor Fuel Gauge Sender: Service and Repair Fuel Level Sensor Fuel Level Sensor REMOVAL WARNING: - Place "NO FIRE" signs near the working area. - Be careful not to spill the fuel. NOTE: Fuel level sensor is built in fuel pump assembly. 1. Remove the fuel pump assembly. 2. Disconnect the connector from the fuel pump bracket. 3. Remove the fuel temperature sensor. 4. Remove the bolt which installs the fuel level sensor on mounting bracket. INSTALLATION Install in the reverse order of removal. Page 202 Air Bag Control Module: Testing and Inspection INSPECTION Check for the following, and replace damaged parts with new parts. - Control module, connector, and mounting bracket are damaged. - Airbag is deployed. - Side airbag is deployed. Page 3127 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Locations Crankshaft Position Sensor: Locations Sensor (Part 1) Testing and Inspection Power Mirror Switch: Testing and Inspection REMOTE CONTROL MIRROR SWITCH INSPECTION Move the rearview mirror switch to each position and check continuity between terminals. Change over switch right position Change over switch left position If NG, replace the switch. Page 3854 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Testing and Inspection Horn Switch: Testing and Inspection INSPECTION Measure the resistance between horn switch terminal and airbag module bracket. Page 2111 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 5384 Manual A/C Model Page 6341 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 5816 Keyless Entry Module: Service and Repair KEYLESS ENTRY CONTROL UNIT REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the instrument panel lower cover. 3. Remove the nut, and then remove the keyless entry control unit while disconnecting connector. 4. Disconnect the keyless entry control unit and other electrical control module. INSTALLATION Install in the reverse order of removal. Page 3649 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 4521 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 3565 F21-F61 A/T Controls - DTC P0851/P0852 Set Neutral Safety Switch: Customer Interest A/T Controls - DTC P0851/P0852 Set NUMBER: 16-68-06 DATE: 10/09/06 APPLICABILITY: 2005~06MY Legacy, Outback, Impreza and Forester Vehicles Equipped with 4EAT SUBJECT: Diagnostic procedures for P0851/P0852 INTRODUCTION The purpose of this bulletin is to assist when diagnosing P0851 (Neutral Switch Input Circuit Low) and P0852 Neutral Switch Input Circuit High). If you encounter a vehicle with P0851 and/or P0852, use the following repair procedure. REPAIR PROCEDURE/INFORMATION Using the Subaru Select Monitor, check for diagnostic trouble codes stored in memory. If P0851 and/or P0852 are stored in memory, adjust the inhibitor switch and select cable. Note: Refer to the applicable Subaru Service Manual found on the STIS web-site for component removal to gain access to the inhibitor switch and select cable. It is critical that the following adjustments are performed correctly. Adjustment for inhibitor switch 1) Set the select lever to "N" range. 2) Loosen the three inhibitor switch securing bolts. 3) Insert ST (special tool) 499267300 Stopper Pin as vertical as possible into the holes in the inhibitor switch lever and switch body. 4) Tighten the three inhibitor switch securing bolts then remove special tool. Tightening torque: 3.4 N-m (0.35 kgf-m, 2.5 ft-lb) Adjustment for select cable Locations Fuel Gauge Sender: Locations Locations Keyless Entry System Page 6347 B3-B12 Page 2697 B54-B127 Page 24 Keyless Entry Module: Service and Repair KEYLESS ENTRY CONTROL UNIT REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the instrument panel lower cover. 3. Remove the nut, and then remove the keyless entry control unit while disconnecting connector. 4. Disconnect the keyless entry control unit and other electrical control module. INSTALLATION Install in the reverse order of removal. Page 7058 REPAIR INFORMATION/PROCEDURE Adjustments Transmission Position Switch/Sensor: Adjustments Inhibitor Switch ADJUSTMENT 1) Move the select lever to "N" range. 2) Loosen the three inhibitor switch securing bolts. 3) Insert the ST as vertical as possible into the holes in inhibitor switch lever and switch body. ST 499267300 STOPPER PIN 4) Tighten the three inhibitor switch bolts. Tightening torque: 3.5 Nm (0.36 kgf-m, 2.6 ft. lbs.) 5) Repeat the above checks. If the inhibitor switch is determined to be "faulty", replace it. Page 2505 3. Disconnect the connector from ignition coil and ignitor assembly. 4. Remove the ignition coil and ignitor assembly. 5. Remove the spark plugs with the spark plug sockets. LH SIDE 1. Remove the battery and battery carrier. 2. Remove the secondary air pump. 3. Disconnect the connector from ignition coil and ignitor assembly. Page 2265 2. Install the rear oxygen sensor. - AT model - MT model 3. Connect the connector to the rear oxygen sensor. Page 728 R58-R69 Recall 07V043000: Occupant Sensor Wiring Harness Seat Occupant Sensor: Recalls Recall 07V043000: Occupant Sensor Wiring Harness MAKE/MODELS: MODEL/BUILD YEARS: Subaru/Forester 2006 Subaru/Impreza 2006 MANUFACTURER: Subaru of America, Inc. NHTSA CAMPAIGN ID NUMBER: 07V043000 MFG'S REPORT DATE: February 06, 2007 COMPONENT: Air Bags: Frontal POTENTIAL NUMBER OF UNITS AFFECTED: 7004 SUMMARY: On certain vehicles, the wiring harness for the air bag occupant detection system in the front passenger seat may have been pinched during production. Pinching of the wiring harness between the floor crossmember and the seat mounting bracket could result in a short circuit. CONSEQUENCE: The passenger's front air bag could become disabled and may not deploy in the event of a crash increasing the risk of injury to the seat occupant. Also an electrical short circuit could cause a fire. REMEDY: Dealers will inspect to see if the wiring had been incorrectly routed under the seat bracket. If so, the dealer will repair any damaged wiring, reroute and secure the wiring harness in the correct location, and re-calibrate the occupant detection system as necessary. The recall is expected to begin on or about March 5, 2007. Owners may contact Subaru at 1-800-782-2783. NOTES: Subaru recall No. WVC-13. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 2516 Valve Clearance: Adjustments Adjustment CAUTION: Adjustment of the valve clearance should be performed while engine is cold. 1. Measure all valve clearances. NOTE: Record each valve clearance after it has been measured. 2. Remove the camshaft. 3. Remove the valve lifter. 4. Measure the thickness of valve lifter with a micrometer. 5. Select a shim of suitable thickness using measured valve clearance and valve lifter thickness, by referring to the following table. Page 2453 B17-B20 Page 6582 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 4225 10) Align the outer race track and ball positions and place in the part where shaft, inner race, cage and balls are previously installed, and then fit the outer race. 11) Install the circlip in the groove on DOJ outer race. NOTE: ^ Assure the balls, cage and inner race are completely fitted in the outer race of DOJ. ^ Exercise care not to place the matched position of circlip in ball groove of outer race. ^ Pull the shaft lightly and assure that the circlip is completely fitted in groove. 12) Apply an even coat of the specified grease [20 to 30 g (0.71 to 1.06 ounces)] to the entire inner surface of boot. Also apply grease to shaft. 13) Install the DOJ boot taking care not to twist it. NOTE: ^ Inside of the larger end of DOJ boot and boot groove shall be cleaned so as to be free from grease and other substances. ^ When installing the DOJ boot, position the outer race of DOJ at center of its travel. 14) Put a new band through the clip and wind twice in alignment with band groove of boot. NOTE: When tightening the boot, exercise care so that air within boot is appropriate. 15) Tighten the band using the ST. ST 925091000 BAND TIGHTENING TOOL NOTE: Tighten the band until it cannot be moved by hand. Page 2386 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Locations Fuel Level Sensor: Locations Specifications Fuel: Specifications The turbo engine is designed to operate using premium unleaded gasoline with an octane rating of 91 AKI or higher. If premium gasoline is not available, regular gasoline with an octane rating of 87 AKI or higher may be temporarily used. For optimum engine performance, it is recommended that you use premium grade unleaded gasoline. Page 4200 8) Suspend the rear drive shaft to the rear crossmember using wire. 9) Remove the oil seal using ST. ST 398527700 PULLER ASSY 10) Drive in a new side oil seal using ST. NOTE: Apply chassis grease between the oil seal lips. ST 398437700 DRIFT Page 6604 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 6614 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 726 F21-F61 Page 4612 4. Remove the piston boot. 5. Remove the piston seal from caliper body cylinder. CAUTION: Do not damage the cylinder and piston seal groove. 6. Remove the guide pin and boot from caliper body. 2. 16 INCH TYPE 1. Clean mud and foreign particles from the caliper body assembly. CAUTION: Be careful not to allow foreign particles to enter the brake hose connector. 2. Using a standard screwdriver, remove the boot ring from piston. Page 4234 Wheel Bearing: Service and Repair Front Hub Unit Bearing REMOVAL 1) Disconnect the ground cable from battery. 2) Lift-up the vehicle and remove the front wheels. 3) Unlock the axle nut. 4) Remove the axle nut using a socket wrench while depressing the brake pedal. CAUTION: Remove the wheel before loosening the axle nut. Failure to follow this rule may damage the wheel bearings. 5) Remove the disc brake caliper from housing, and suspend it from strut using a wire. 6) Remove the disc rotor from hub. NOTE: If the disc rotor seizes up within hub, drive disc rotor out by installing an 8-mm bolt in screw hole on rotor. 7) Remove the ABS wheel speed sensor assembly and harness. 8) Remove four bolts from housing. Cooling System - Coolant Comes Out Of Reservoir Coolant Line/Hose: Customer Interest Cooling System - Coolant Comes Out Of Reservoir NUMBER: 08-52-08 DATE: 08/18/08 APPLICABILITY: 1999MY and later Impreza & Forester 2000MY and later Legacy & Outback 2006MY and later Tribeca SUBJECT: Coolant Overflow Introduction If you encounter a vehicle which experiences coolant coming out of the coolant reservoir tank, it may be caused by the radiator cap pressure valve being stuck open by debris sucked up through the reservoir tank hose. As the cooling system cools down, it sucks coolant back into the radiator. If there is debris that settles to the bottom of the reservoir tank, the hose is low enough to also suck them back into radiator. This causes the radiator cap not to seal, allowing excessive amount of coolant to escape overflowing the reservoir tank. If this condition continues over time, there will not be enough coolant in the system to maintain proper engine temperature. In order to correct the condition you need to clean (and test) or replace the radiator cap, clean out the reservoir tank, and shorten the hose slightly, following the repair procedure. Production Line Change The shorter coolant reservoir tank hose was used in production as shown above. Repair Procedure/Information 1. Radiator Cap Cleaning Many caps can be successfully cleaned. The important part is the thorough cleaning of the negative pressure valve. If this is not done completely, remaining debris may result in a repeat issue. If there is an excessive amount of debris or the sealing rubber on the cap appears to be pitted or damaged, replace the cap. Note: If replacing the cap, skip to Step 2. Using clean water and a brush, thoroughly clean the cap seal surface. Note: Page 1836 B134-B136 Page 2026 B136-B141 Page 7338 B17-B20 Locations Fuel Level Sensor: Locations Page 2316 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 1508 B380-f6 Page 3572 Ignition Coil: Testing and Inspection INSPECTION For inspection, refer to IGNITION CONTROL SYSTEM, Diagnostics for Engine Starting Failure. Page 688 B136-B141 Page 5030 B230-B283 Page 4718 Vacuum Brake Booster: Service and Repair Brake Booster REMOVAL 1. Remove or disconnect the following parts at engine compartment. 1. Disconnect the connector for brake fluid level indicator. 2. Remove the brake pipes from master cylinder. 3. Remove the master cylinder installing nuts. 4. Disconnect the vacuum hose from brake booster. 2. Remove the following parts from pedal bracket. 1. Snap pin and clevis pin 2. Four brake booster installing nuts 3. Remove the brake booster while shunning brake pipes. NOTE: ^ Be careful not to drop the brake booster. The brake booster should be discarded if it has been dropped. ^ Use special care when handling the operating rod. If excessive force is applied to the operating rod, sufficient to cause a change in the angle in excess of ±30, it may result in damage to the power piston cylinder. ^ Use care when placing the brake booster on floor. ^ Do not change the push rod length. If it has been changed, reset the projected length "L" to standard length. Standard L: 10.05 mm (0.40 inch) Page 7036 B134-B136 Page 3597 F61-R47 Specifications Windshield Washer Motor: Specifications SPECIFICATION Front washer motor Pump type ........................................................................................................... ................................................................................................... Centrifugal Input .............................. .............................................................................................................................................................. ............. 12 V - 36 W or less Rear washer motor Pump type ............................................................................................................ .................................................................................................. Centrifugal Input ............................... .............................................................................................................................................................. ............ 12 V - 36 W or less Locations Coolant Temperature Sensor/Switch (For Computer): Locations Sensor (Part 1) Page 4198 Seals and Gaskets: Service and Repair Rear Differential Side Oil Seal Rear Differential Side Oil Seal INSPECTION Make sure that there is no oil leakage from side oil seal. If there is any oil leakage, replace the oil seal. REPLACEMENT 1) Move the select lever or gear shift lever to "N". 2) Release the parking brake. 3) Loosen both wheel nuts. 4) Lift-up the vehicle. 5) Remove the wheels. 6) Remove the rear exhaust pipe and muffler. ^ Non-turbo model ^ Turbo model and STI model 7) Remove the DOJ of rear drive shaft from rear differential. (1) Remove the ABS wheel speed sensor cable clamp and parking brake cable clamp from bracket. (2) Remove the ABS wheel speed sensor cable clamp from trailing link. (3) Remove the ABS wheel speed sensor cable clamp and parking brake cable guide from trailing link. (4) Remove the rear stabilizer link. Diagram Information and Instructions Oil Pressure Sender: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Differential Fluid Level Check Differential Fluid - A/T: Service and Repair Differential Fluid Level Check Differential Gear Oil 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 check the level. If the differential gear oil level is below the "L" line, add oil to bring the level up to the "F" line. 5) To prevent overfilling the differential gear oil, do not replenish oil above the "F" line. Page 529 B380-f6 Page 2549 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 4491 DISASSEMBLY 1. MT MODEL 1. Remove the brake switch. 2. Remove the clutch pedal. 3. Remove the clutch master cylinder bracket. 4. Remove the bushing, spring and stopper. 5. Remove the brake pedal pad. 2. AT MODEL 1. Remove the brake switch. 2. Unbolt, and then remove the brake pedal. 3. Remove the bushing, spacer and spring. Page 2716 Main Relay (Computer/Fuel System): Service and Repair Main Relay REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the passenger's side front side sill cover. 3. Remove the bolt which holds the relay bracket on the body. 4. Disconnect the connectors from the main relay. 5. Remove the main relay from the mounting bracket. INSTALLATION Install in the reverse order of removal. Diagnostic Aids Ignition Switch: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Testing and Inspection Windshield Washer Switch: Testing and Inspection COMBINATION SWITCH (WIPER) INSPECTION - Inspect the continuity between each connector terminal If continuity is not as specified, replace the switch. - Intermittent operation inspection (inspection of wiper switch unit) 1. Position the voltage meter between the connector terminals No. 7 (+) and No. 2 (-). 2. Connect the battery positive lead to connector terminal No. 17 and the negative lead to connector terminals No. 2 and No. 16. 3. Turn the wiper switch to INT. 4. Disconnect the battery negative lead from connector terminal No. 16. 5. Connect the battery positive lead to connector terminal No. 16 for 5 seconds. 6. Connect the battery negative lead to connector terminal No. 16, and check the voltage between the connector terminals No. 7 (+) and No. 2 (-). Page 2199 B380-f6 Diagnostic Aids Ignition Switch: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 16 Alarm Module: Service and Repair Security Control Unit SECURITY CONTROL UNIT REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the instrument panel lower cover. 3. Remove the nut, and then remove the keyless entry control unit while disconnecting connector. 4. Disconnect the keyless entry control unit and other electrical control module. INSTALLATION Install in the reverse order of removal. Service and Repair Fuel Pump Control Unit: Service and Repair Fuel Pump Control Unit REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the rear quarter trim. 3. Disconnect the connector from the fuel pump control unit. 4. Remove the fuel pump control unit. INSTALLATION Install in the reverse order of removal. Page 5042 RAPS-01 Diagrams: Other diagrams referred to by name within these diagrams (i.e. "REF. TO GND-01", etc) can be found at Diagrams by Diagram Name. See: Diagrams/Electrical Diagrams/Diagrams By Diagram Name Connector and Ground Locations: The locations of the Connectors or Grounds shown within these diagrams can be found via the connector or ground number at Vehicle Locations. See: Locations Page 3590 B128-B134 Page 6259 Clutch Switch: Service and Repair CLUTCH SWITCH REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the connector from clutch switch, and then remove the switch. INSTALLATION Install in the reverse order of removal. Page 2641 B134-B136 Page 2452 B3-B12 Page 6699 B3-B12 Page 2460 B380-f6 Specifications Compressor Clutch: Specifications Magnetic Clutch Clearance.................................................................................................................. ............................0.45 ±0.15 mm (0.0177 ±0.0059 in) Page 5587 INSTALLATION CAUTION: - Before working on the airbag module, refer to the "CAUTION" in General Description. See: Service Precautions - Be sure to perform the system calibration for occupant detection system after passenger's seat installation. 1. Ensure there are no foreign particles on side airbag module. 2. Install the side airbag module (A) to backrest frame assembly. Tightening torque: 5.9 N-m (0.60 kgf-m, 4.4 ft-lb) 3. Install the side airbag harness to backrest frame assembly. NOTE: Secure the harness to its original position of seat. 4. Install the backrest cover. 5. Install the side airbag harness to slide rail IN (A), and then secure the connector to the bracket on the back side of seat cushion assembly. 6. Recline the seat or slide it backward and forward. Check there is no contact between seat backrest assembly, cushion cover assembly and side Capacity Specifications Power Steering Fluid: Capacity Specifications Power Steering Gear Fluid Fluid Capacity .............................................................................................................................................................. 0.7 liter (0.7 US qt, 0.6 Imp qt) Page 610 B3-B12 Page 1764 Remove the hose from the reservoir tank. Cut 20 mm from the bottom of the hose at a 45° angle. Reinstall hose in reservoir tank. Start engine and permit to fully warm up. Turn off engine and allow to fully cool down. Recheck coolant level in reservoir and add coolant if needed. Note: Be sure to use genuine Subaru Super Coolant or Subaru Long Life Coolant, depending upon what type of coolant is currently in the system. Warranty/Claim Information Page 2294 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 4097 Valve Body: Service and Repair Transmission Control Device Transmission Control Device REMOVAL 1) Remove the transmission assembly from the vehicle. 2) Extract the torque converter clutch assembly. 3) Remove the input shaft. 4) Lift-up lever behind the transmission harness connector and disconnect it from stay. 5) Disconnect the air breather hoses. 6) Disconnect inhibitor switch connector from stay. 7) Wrap vinyl tape around the nipple attached to the air breather hose. 8) Remove pitching stopper bracket. 9) Remove the inhibitor switch. 10) Remove control valve body assembly. 11) Pull off the straight pin of manual plate. 12) Remove bolt securing select lever, then remove select lever, manual plate and parking rod. NOTE: Be careful not to damage the lips of the press-fitted oil seal in the case. 13) Remove the detent spring. Front Brake Rotor/Disc: Testing and Inspection Front INSPECTION 1. Check front wheel bearing play and axle hub play before disc rotor runout limit inspection. 2. Secure the disc rotor by tightening five wheel nuts. 3. Set a dial gauge 10 mm (0.39 inch) inward of rotor outer perimeter. Turn the disc rotor to check runout. If the disc rotor runout exceeds the service limit, resurface the disc rotor. After resurfacing, check disc rotor thickness as in step 4. Disc rotor runout limit. 0.075 mm (0.0030 inch) 4. Set a micrometer 10 mm (0.39 inch) inward of the rotor outer perimeter, and then measure the disc rotor thickness. If the thickness of disc rotor exceeds the service limit, replace with a new disc rotor. Page 4336 3) Apply proper amount of liquid gasket to the entire oil pan mating surface. Liquid gasket: THREE BOND 1217B (Part No. K0877YA020) 4) Apply liquid gasket fully to three holes other than screw holes on transmission case. Liquid gasket: THREE BOND 1217B (Part No. K0877YA020) 5) Install the oil pan. Tightening torque: 5 Nm (0.5 kgf-m, 3.6 ft. lbs.) 6) Connect the connector of rear vehicle speed sensor. (MP-T model) 7) Connect the connector of rear vehicle speed sensor. (VTD model) Page 3793 5) Disconnect the inhibitor switch connector. 6) Remove the inhibitor switch connector from stay. 7) Lift-up the vehicle. 8) Remove the front and center exhaust pipes. 9) Remove the snap pin and washer from range select lever. 10) Remove the plate assembly from transmission case. 11) Remove the bolts. Page 3329 7. Insert the evaporation hose (B) approximately 5 to 30 mm (0.98 to 1.18 in) into the lower end of evaporation pipe and hold the clip. CAUTION: Do not allow clips to touch evaporation hose (B) and rear suspension crossmember. 8. Tighten the bolt which holds the fuel filler pipe bracket on the body. 9. Secure the evaporation hose to clip of fuel filler pipe. 10. Install the fuel filler pipe protector. Page 6791 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 521 B3-B12 Page 3035 R58-R69 Page 3547 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 7102 For preventing wind noise, adjust the glass at the position where tip of gusset is raised up a little. 8. After stabilizer adjustment, carry out the glass crimp adjustment. First, visually ensure positional relationship between retainer & molding and glass of the roof side, and then begin with rear sash adjustment. Set the ST on glass, and then adjust two adjusting bolts alternately step by step to obtain dimensions shown below (cross-section A). ST 61299AE000 SPACER (For front door glass of thickness 5 mm (0.197 in)) NOTE: If two nuts are loosened at the same time, sash moves back and forth. Therefore, when one nut is adjusted, leave the other secured. 9. Make the same adjustment of two adjusting bolts of rear sash. NOTE:Do not tilt the sash bracket to inner panel during adjustment. Otherwise smooth regulator operation cannot be achieved. 10. Make adjustment of front sash in the same manner as that of rear sash. NOTE: Although front and rear sashes must, as a rule, be adjusted in the same manner, in some door installation, the adjustment in a different manner may be required. However, adjustment of one sash to the maximum amount and the other to the minimum amount is not permitted. Such adjustment may result in application of excessive load to regulator. 11. After adjustments, tighten the nuts. 12. After adjustment to glass, close the door. If there is a gap between outer lip of gusset and glass surface, adjust the gap with adjusting bolt (A) in lower fitting part of the gusset to prevent generation of wind noise. Specifications Brake Fluid: Specifications Fluid Type ......................................................................................................................................................... FMVSS No. 116 DOT 3or 4 Brake Fluid Page 2076 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Recall 07V043000: Occupant Sensor Wiring Harness Seat Occupant Classification Module - Air Bag: All Technical Service Bulletins Recall 07V043000: Occupant Sensor Wiring Harness MAKE/MODELS: MODEL/BUILD YEARS: Subaru/Forester 2006 Subaru/Impreza 2006 MANUFACTURER: Subaru of America, Inc. NHTSA CAMPAIGN ID NUMBER: 07V043000 MFG'S REPORT DATE: February 06, 2007 COMPONENT: Air Bags: Frontal POTENTIAL NUMBER OF UNITS AFFECTED: 7004 SUMMARY: On certain vehicles, the wiring harness for the air bag occupant detection system in the front passenger seat may have been pinched during production. Pinching of the wiring harness between the floor crossmember and the seat mounting bracket could result in a short circuit. CONSEQUENCE: The passenger's front air bag could become disabled and may not deploy in the event of a crash increasing the risk of injury to the seat occupant. Also an electrical short circuit could cause a fire. REMEDY: Dealers will inspect to see if the wiring had been incorrectly routed under the seat bracket. If so, the dealer will repair any damaged wiring, reroute and secure the wiring harness in the correct location, and re-calibrate the occupant detection system as necessary. The recall is expected to begin on or about March 5, 2007. Owners may contact Subaru at 1-800-782-2783. NOTES: Subaru recall No. WVC-13. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 2033 R72-R145 R148 Locations Electronic Brake Control Module: Locations Electrical Component Location Page 2712 2. Connect the knock sensor connector. 3. Install the intercooler. 4. Connect the battery ground cable to battery. Page 2802 Page 730 Throttle Position Sensor: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 6287 B134-B136 Locations Fuel Temperature Sensor: Locations Page 3401 F61-R47 Page 4756 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 2244 B3-B12 Page 246 F61-R47 Page 2278 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Locations Air Flow Meter/Sensor: Locations Sensor (Part 1) Page 4170 3) Remove the ST. ST 499747100 CLUTCH DISC GUIDE 4) Install the transmission assembly. 5MT: Manual Transmission Assembly 6MT: Manual Transmission Assembly INSPECTION CLUTCH DISC 1) Facing wear Measure the depth of rivet head from the surface of facing. Replace if facings are worn locally or worn down to less than the specified value. NOTE: Do not wash the clutch disc with any cleaning fluid. 2) Hardened facing Correct by using emery paper or replace. 3) Oil leakage on facing Replace the clutch disc and inspect the transmission front oil seal, transmission case mating surface, engine rear oil seal and other points for oil leakage. Front Vehicle Speed Sensor Transmission Speed Sensor: Service and Repair Front Vehicle Speed Sensor Front Vehicle Speed Sensor REMOVAL 1) Set up the vehicle on a lift. 2) Disconnect the ground cable from battery. 3) Remove the air intake chamber. (Non-turbo model) 4) Remove the intercooler. (Turbo model) 5) Disconnect the transmission connector. 6) Remove the pitching stopper. 7) Remove the transmission connector from stay. 8) Lift-up the vehicle. 9) Clean the transmission exterior. 10) Drain the ATF completely. NOTE: ^ Tighten the ATF drain plug after draining the ATF. ^ Use anew gasket. 11) Remove the front, center, exhaust pipes and muffler. (Non-turbo model) 12) Remove the center, rear exhaust pipe and muffler. (Turbo model) 13) Remove the propeller shaft. 14) Place the transmission jack under transmission. NOTE: Make sure that the support plates of transmission jack don't touch the crossmember. 15) Remove the transmission rear crossmember bolts. Audio System - CD Player Information/Precautions Compact Disc Player (CD): Technical Service Bulletins Audio System - CD Player Information/Precautions NUMBER: 15-120-07 DATE: 03/07/07 APPLICABILITY: All Models Equipped with an In-dash CD Changer/Player SUBJECT: In-dash CD Changer/Player Discs INTRODUCTION The purpose of this bulletin is to inform of cautions concerning compact discs. There have been an increasing number of changers/players being replaced under warranty. We have found that the majority of all failures are the result of the use of damaged CDs, non-compatible user-created CDs and labels, or multiple CDs inserted at the same time jamming the player or damaging the CD. The resultant damage to the player is generally not detected until after the audio exchange has been completed. Customers coming in with CD changer/player issues should be reminded at the time of the unit exchange that the use of CDs as described above are the potential causes of problems. We encourage you to make a copy of the In-dash CD Changer/Player page in this bulletin and provide it to your customers when an exchange unit is installed. Page 5490 Electrical Components Location Page 2423 Camshaft Position Sensor: Locations Sensor (Part 1) Fuel Level Sensor Fuel Gauge Sender: Service and Repair Fuel Level Sensor Fuel Level Sensor REMOVAL WARNING: - Place "NO FIRE" signs near the working area. - Be careful not to spill the fuel. NOTE: Fuel level sensor is built in fuel pump assembly. 1. Remove the fuel pump assembly. 2. Disconnect the connector from the fuel pump bracket. 3. Remove the fuel temperature sensor. 4. Remove the bolt which installs the fuel level sensor on mounting bracket. INSTALLATION Install in the reverse order of removal. Page 1577 B128-B134 Page 7033 B17-B20 Page 3026 B54-B127 Service and Repair Wastegate Solenoid: Service and Repair Wastegate Control Solenoid Valve REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the engine harness connector (A) from bracket. 3. Disconnect the connector (B) from wastegate control solenoid valve. 4. Remove the bracket from body. 5. Disconnect the pressure hoses (C) from wastegate control solenoid valve. 6. Remove the wastegate control solenoid valve from bracket. INSTALLATION Install in the reverse order of removal. Specifications Clutch Fluid: Specifications Fluid Type ........................................................................................................................................................ FMVSS No. 116 DOT 3 or 4 Brake Fluid Page 2082 B17-B20 Front Brake Caliper: Testing and Inspection Front INSPECTION 1. Repair or replace the faulty parts. 2. Check the caliper body and piston for uneven wear, damage or rust. 3. Check the rubber parts for damage or deterioration. Specifications Thermostat: Specifications Starts to open ...................................................................................................................................... ............................................. 76 - 80°C (169 - 176°F) Fully opens ...................................................... ................................................................................................................................................. 91°C (196°F) Valve lift .................................................................................................................................. ................................................... 9.0 mm (0.35 inch) or more Page 7159 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 1719 Valve Clearance: Adjustments Adjustment CAUTION: Adjustment of the valve clearance should be performed while engine is cold. 1. Measure all valve clearances. NOTE: Record each valve clearance after it has been measured. 2. Remove the camshaft. 3. Remove the valve lifter. 4. Measure the thickness of valve lifter with a micrometer. 5. Select a shim of suitable thickness using measured valve clearance and valve lifter thickness, by referring to the following table. Page 5018 - Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF. Page 6652 Page 4881 If there is continuity in one direction and the continuity in the other or if there is continuity at unequal points, adjust the inhibitor switch. 4. Repeat the above checks. If there are abnormalities, adjust the select cable. REMOVAL 1. Set up the vehicle on a lift. 2. Move the select lever to N range. 3. Remove the air intake chamber. (Non-turbo model) 4. Remove the intercooler. (Turbo model) 5. Disconnect the inhibitor switch connector. 6. Remove the inhibitor switch connector from stay. 7. Lift-up the vehicle. 8. Remove the front and center exhaust pipes. 9. Remove the snap pin and washer from range select lever. Page 1285 4. If the rim runout exceeds specifications, remove the tire from rim and check runout while attaching the dial gauge to positions shown in the figure. 5. If the measured runout still exceeds specifications, replace the wheel. Page 1212 11. Turn the ignition key to ON position, and run the blower at high speed for 1 minute. Stop the blower to check the ventilation grille on the instrument panel. While moving the tester closer to the grille, run the blower for 1 or 2 seconds, then stop it. Check the grille at that point for at least 10 seconds. 12. Check the valve in the service port. 13. Visually check the rubber seal in service port cap. Adjustments Transmission Position Switch/Sensor: Adjustments Inhibitor Switch ADJUSTMENT 1) Move the select lever to "N" range. 2) Loosen the three inhibitor switch securing bolts. 3) Insert the ST as vertical as possible into the holes in inhibitor switch lever and switch body. ST 499267300 STOPPER PIN 4) Tighten the three inhibitor switch bolts. Tightening torque: 3.5 Nm (0.36 kgf-m, 2.6 ft. lbs.) 5) Repeat the above checks. If the inhibitor switch is determined to be "faulty", replace it. Locations Air Flow Meter/Sensor: Locations Sensor (Part 1) Page 3561 B136-B141 Page 13 2. Security indicator light blinks. NOTE: If the ALARM/WARNING occurs in the ARM mode, the indicator light blinks when the ignition switch is turned to OFF -> ON at the next DISARM mode. - If ALARM/WARNING does not occur, the light does not blink. - More than one alarm or warning occurs, the most numbers of blinking times have priority to blink. - Anytime the ignition switch is turned to ON in the DISARM mode, it blinks. The memory will be updated at the next ARM mode. Page 5004 ownership. For affected vehicles sold after the date on the dealer's affected list, dealers are to contact those owners and provide them with a copy of the owner notification letter. They should also arrange to make the required correction according to the instructions in the service procedure section of this bulletin. Dealers are also to promptly perform the applicable service procedures defined in this bulletin to correct all affected vehicles in their inventory (new, used, demo). Additionally, whenever a vehicle subject to this recall is taken into dealer new or used inventory, or is in the dealership for service, necessary steps should be taken to ensure the service program correction has been made before selling or releasing the vehicle. PARTS INFORMATION Special Tools and Materials ^ Soldering gun and solder ^ Heat gun ^ 1.5 inch wide unwoven adhesive tape ^ Subaru Global Terminal Wiring Kit 1-47606 ^ Electrical tape ^ Electrical shrink wrap tubing SERVICE PROCEDURE This Recall will involve inspection of the front passenger seat wiring for proper routing. It will also involve repair of the affected wire harness if the inspection reveals pinched wiring. Service Procedure The first part of the procedure involves inspecting the wiring harness for proper routing and possible damage. (There are two separate procedures, one for each different vehicle.) If there is no damage to the wiring harness, no repair is necessary. If the wiring harness is found to be damaged, then follow the repair procedure. Forester Inspection Procedure (See Impreza inspection procedure.) 1. Slide the front passenger seat to the rear most position to expose the front of the slide rail. Page 3569 Ignition Coil: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 3885 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 3030 B230-B283 Page 5180 18) Install the jack-up plate. 19) Lower the vehicle. 20) Check the fluid level in oil tank. 21) After adjusting the toe-in and steering angle, tighten the lock nut on tie-rod end. Tightening torque: 83 Nm (8.5 kgf-m, 61.5 ft. lbs.) NOTE: When adjusting the toe-in, hold boot as shown to prevent it from being rotated or twisted. If twisted, straighten it. Service and Repair Mud Guard Page 4179 Page 2329 B380-f6 Page 3306 Fuel Return Line: Service and Repair Fuel Delivery, Return and Evaporation lines REMOVAL 1. Set the vehicle on a lift. 2. Release the fuel pressure. 3. Open the fuel filler flap lid and remove the fuel filler cap. 4. Remove the floor mat. 5. Disconnect the fuel delivery pipes and hoses, and disconnect the fuel return pipes and hoses, evaporation pipes and hoses. 6. In engine compartment, detach the fuel delivery hoses, return hoses and evaporation hose. 1. Disconnect the quick connectors of fuel delivery line and return line by pushing the ST to the direction of arrow. ST 42099AE000 CONNECTOR REMOVER 2. Remove the clip, and disconnect the evaporation hose from pipe. WARNING: - Be careful not to spill fuel. - Catch the fuel from hoses using a container or cloth. Rear Washer Windshield Washer Spray Nozzle: Adjustments Rear Washer Rear Washer ADJUSTMENT 1. Turn the wiper switch to OFF position. 2. When the vehicle stops, adjust the washer fluid injection position as shown in the figure. Page 7088 Power Window Switch: Testing and Inspection POWER WINDOW CONTROL SWITCH INSPECTION 1. MAIN SWITCH 1. Remove the main switch. 2. Turn the window lock switch to UNLOCK. 3. Connect the battery and main switch as shown in the figure. 4. Measure the main switch resistance. 5. If NG, replace the main switch. 2. SUB SWITCH 1. Remove the sub switch. Page 7347 F61-R47 Page 2219 Refer to the illustrations above for more details on locating the appropriate sensors. The list shown above is of A/F Sensor related DTCs. (This list is for example only. Refer to the applicable service manual for a complete list of DTCs.) Note: When the DTCs for A/F sensor are stored in memory, do not replace the oxygen sensor. Page 6275 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Locations Sensor Testing and Inspection Timing Belt Idler Pulley: Testing and Inspection Belt Idler 1. Check the belt idler for smooth rotation. Replace if noise or excessive play is noted. 2. Check the outer contacting surfaces of idler pulley for abnormal wear and scratches. 3. Check the belt idler for grease leakage. Diagnostic Aids Fuse Block: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 3732 2. Connect the knock sensor connector. 3. Install the intercooler. 4. Connect the battery ground cable to battery. Page 7431 7. Perform the above steps from 1) to 6) at the MIN and MAX positions of intermittent control switch, and replace the wiper switch assembly if it does not operate as specified. Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 7148 (3) Install the modified check valve and valve cushion. Rear Check Valve on Forester Page 2623 Engine Control Module: Locations Non-Turbo Model Page 7106 5. Remove the two screws to remove the weather strip outer. 6. Operate the power window switch to move the glass to position shown in the figure, and then remove two nuts from service holes. 7. Remove the two rear sash installation nuts, and then move the rear sash backward. 8. Remove the glass. CAUTION: Avoid impact and damage to the glass. INSTALLATION 1. Install in the reverse order of removal. NOTE: Make sure the slider (front) and roller (rear) of glass stay is placed securely in front and rear sash. 2. Adjust the rear door glass. Tightening torque: Nm (kgf-m, ft-lb) T1: 7.4 (0.75, 5.5) T2: 13.7 (1.4, 10.1) Page 2831 Engine Control Module (ECM) I/O Signal (Part 2) Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Front Sub Sensor Impact Sensor: Service and Repair Front Sub Sensor FRONT SUB SENSOR REMOVAL 1. Turn the ignition switch to OFF. 2. Disconnect the ground cable from battery, and wait for at least 20 seconds before starting work. 3. Remove the front bumper. 4. Remove the bolt, and then detach the front sub sensor. 5. Disconnect the connector from front sub sensor. B: INSTALLATION Install in the reverse order of removal. Tightening torque: Refer to "COMPONENT" in "General Description". See: Restraint Systems/Air Bag Systems/Locations Page 448 B128-B134 Page 7371 B3-B12 Page 4010 B54-B127 Front Wiper Motor and Link Wiper Motor: Testing and Inspection Front Wiper Motor and Link FRONT WIPER MOTOR AND LINK INSPECTION 1. When the battery is connected to the terminal of connectors, confirm that the motor operates at low speed. 2. When the battery is connected to the terminal of connectors, confirm that the motor operates at high speed. 3. Connect the battery to terminals of connector, and then remove the terminal connection with motor rotated at low speed, and stop the wiper motor through operation. 4. Connect the battery and confirm that the motor stops at automatic stop position after the motor operates at low speed again. Page 6501 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Page 4904 5. Remove packing A, planetary gears, packing B and plate. 6. Remove the shaft assembly and overrunning clutch as a unit. NOTE: Note the direction of the lever before removing. 7. Remove the overrunning clutch from shaft assembly as follows: 1. Remove the stopper from ring by lightly tapping the stopper with an appropriate tool (such as a fit socket wrench). Page 1467 B3-B12 Page 3780 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 3551 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 312 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 2356 B128-B134 Page 1510 F61-R47 Page 6166 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 2530 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 4099 5) Install control valve assembly and oil pan. 6) Turn over the transmission case to its original position. 7) Install pitching stopper bracket. Tightening torque: 41 Nm (4.2 kgf-m, 30.2 ft. lbs.) 8) Install inhibitor switch and adjust the inhibitor switch. 9) Insert inhibitor switch and transmission connector into stay. 10) Install air breather hose. 11) Insert the input shaft while rotating it lightly by hand, and then check the protrusion amount. 12) Install the torque converter clutch assembly. 13) Install the transmission assembly to the vehicle. INSPECTION Make sure the manual lever and detent spring are not worn or otherwise damaged. Page 646 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS M/T - Clutch Pedal Squeaking Noise Clutch Pedal Position Sensor / Switch: Technical Service Bulletins M/T - Clutch Pedal Squeaking Noise CLUTCH PEDAL SQUEAK If you encounter a manual transmission equipped vehicle with a clutch pedal squeak concern, and lubricating the pedal mechanism didn't fix the noise, check the clutch switch. We have had a few reports where this has been the source of the problem. The fix is to replace the clutch pedal switch. Testing and Inspection Windshield Washer Switch: Testing and Inspection COMBINATION SWITCH (WIPER) INSPECTION - Inspect the continuity between each connector terminal If continuity is not as specified, replace the switch. - Intermittent operation inspection (inspection of wiper switch unit) 1. Position the voltage meter between the connector terminals No. 7 (+) and No. 2 (-). 2. Connect the battery positive lead to connector terminal No. 17 and the negative lead to connector terminals No. 2 and No. 16. 3. Turn the wiper switch to INT. 4. Disconnect the battery negative lead from connector terminal No. 16. 5. Connect the battery positive lead to connector terminal No. 16 for 5 seconds. 6. Connect the battery negative lead to connector terminal No. 16, and check the voltage between the connector terminals No. 7 (+) and No. 2 (-). Testing and Inspection Oil Cooler: Testing and Inspection Inspection 1. Check the coolant passages are not clogged using air blow method. 2. Check the mating surfaces of cylinder block, 0ring groove and oil filter for damage. Page 7078 B230-B283 Page 4555 4) Apply a thin coat of Molykote M7439 or equivalent to caliper support. Page 7248 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 6484 B128-B134 Page 3686 Camshaft Position Sensor: Locations Sensor (Part 1) Service and Repair Rear Shelf: Service and Repair REAR SHELF TRIM REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the high-mounted stop light. 3. Remove the rear quarter upper trim. 4. Remove the seat belt center anchor lower bolt. 5. Remove the rear shelf trim. INSTALLATION Install in the reverse order of removal. Page 542 Manifold Pressure/Vacuum Sensor: Service and Repair Manifold Absolute Pressure Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the connectors from manifold absolute pressure sensor. 3. Remove the manifold absolute pressure sensor from the throttle body. INSTALLATION Install in the reverse order of removal. NOTE: Replace the O-rings for the manifold absolute pressure sensor with new ones. Tightening torque: 1.6 N.m (0.16 kgf-m, 1.2 ft-lb) Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 3731 Knock Sensor: Service and Repair Knock Sensor REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the intercooler. 3. Disconnect the knock sensor connector. 4. Remove the knock sensor from the cylinder block. INSTALLATION 1. Install the knock sensor to the cylinder block. Tightening torque: 24 N.m (2.4 kgf-m, 17.4 ft-lb) NOTE: Extraction area of the knock sensor cord must be positioned at a 60 degrees angle relative to the engine rear. Page 391 Electrical Component Location Page 659 B380-f6 Page 2691 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 6706 B292-B317 Page 6637 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 7369 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Part 1 Timing Belt: Service and Repair Part 1 Timing Belt The Contents of This Image/Article Reflects the Contents of 18-136-09 Manual Update dated 02/11/09. TIMING BELT REMOVAL 1. TIMING BELT 1. Remove the V-belt. 2. Remove the crank pulley. 3. Remove the timing belt cover. Page 1375 CYLINDER BLOCK Page 5659 B3-B12 Page 1551 14. Remove the fuel injector. 15. Remove the harness bracket which holds the engine harness onto intake manifold. 16. Remove the engine harness from the intake manifold. 17. Loosen the clamp which holds the front left side fuel hose to fuel injector pipe and remove the pipe from clamp. 18. Loosen the clamp which hold RH side fuel hose to fuel injector pipe, and remove the fuel injector pipe from clamp. 19. Remove the bolts which install the fuel pipe assembly on intake manifold. 20. Remove the fuel pipe assembly and pressure regulator, from the intake manifold. Page 4750 2) Fully depress the clutch pedal. 3) Adjust the clutch pedal plate and clutch switch so that the gap between them is 3 - 3.5 mm (0. 12 - 0.14 inch). 4) Tighten the lock nut. Tightening torque: 8 Nm (0.8 kgf-m, 5.9 ft. lbs.) Page 4248 Drive/Propeller Shaft: Component Tests and General Diagnostics Propeller Shaft INSPECTION NOTE: Do not disassemble the propeller shaft. Check the following and replace if necessary. 1) Tube surfaces for dents or cracks 2) Splines for deformation or abnormal wear 3) Joints for non-smooth operation or abnormal noise 4) Center bearing for free play, noise or nonsmooth operation 5) Oil seals for abnormal wear or damage 6) Center bearing for breakage Check the following points with propeller shaft installed in vehicle. JOINTS AND CONNECTIONS 1) Remove the center exhaust pipes. 2) Check for any looseness of the yoke flange mounting bolts which connect to rear differential and center bearing bracket mounting bolts. SPLINES AND BEARING LOCATIONS 1) Remove the center exhaust pipes. 2) Remove the rear exhaust pipe and muffler. 3) Turn the propeller shaft by hand to see if abnormal free play exists at splines. Also move the yokes to see if abnormal free play exists at spiders and bearings. RUNOUT OF PROPELLER SHAFT 1) Remove the center exhaust pipes. 2) Remove the rear exhaust pipe and muffler. 3) Set the dial gauge with its indicator stem at center of propeller shaft tube. 4) Turn the propeller shaft slowly by hands to check for "runout" of propeller shaft. CENTER BEARING FREE PLAY 1) Remove the front and center exhaust pipes. 2) Remove the rear exhaust pipe and muffler. 3) Move the propeller shaft near center bearing up and down, and left and right with your hand to check for any abnormal bearing free play. Recall 07V043000: Occupant Sensor Wiring Harness Seat Occupant Classification Module - Air Bag: Recalls Recall 07V043000: Occupant Sensor Wiring Harness MAKE/MODELS: MODEL/BUILD YEARS: Subaru/Forester 2006 Subaru/Impreza 2006 MANUFACTURER: Subaru of America, Inc. NHTSA CAMPAIGN ID NUMBER: 07V043000 MFG'S REPORT DATE: February 06, 2007 COMPONENT: Air Bags: Frontal POTENTIAL NUMBER OF UNITS AFFECTED: 7004 SUMMARY: On certain vehicles, the wiring harness for the air bag occupant detection system in the front passenger seat may have been pinched during production. Pinching of the wiring harness between the floor crossmember and the seat mounting bracket could result in a short circuit. CONSEQUENCE: The passenger's front air bag could become disabled and may not deploy in the event of a crash increasing the risk of injury to the seat occupant. Also an electrical short circuit could cause a fire. REMEDY: Dealers will inspect to see if the wiring had been incorrectly routed under the seat bracket. If so, the dealer will repair any damaged wiring, reroute and secure the wiring harness in the correct location, and re-calibrate the occupant detection system as necessary. The recall is expected to begin on or about March 5, 2007. Owners may contact Subaru at 1-800-782-2783. NOTES: Subaru recall No. WVC-13. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 4782 Neutral Safety Switch: Testing and Inspection Inhibitor Switch (AT Model) INHIBITOR SWITCH (AT MODEL) Measure the resistance between inhibitor switch terminals. Page 4938 RAPS-01 Diagrams: Other diagrams referred to by name within these diagrams (i.e. "REF. TO GND-01", etc) can be found at Diagrams by Diagram Name. See: Diagrams/Electrical Diagrams/Diagrams By Diagram Name Connector and Ground Locations: The locations of the Connectors or Grounds shown within these diagrams can be found via the connector or ground number at Vehicle Locations. See: Locations Page 7073 B17-B20 Page 3188 Evaporative Check Valve: Service and Repair Vent Valve REMOVAL WARNING: - Place"NO FIR" signs near the working area. - Be careful not to spill fuel. 1. Remove the fuel tank. 2. Remove the protector cover. 3. Remove the clips, and disconnect the hoses from vent valve. 4. Remove the nuts and then remove the vent valve. Page 311 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 1967 19. Remove the center exhaust pipe. INSTALLATION NOTE: Replace the gaskets with new ones. 1. Install the center exhaust pipe and temporarily tighten the bolt which holds the center exhaust pipe to hanger bracket. 2. Temporarily tighten the bolt which holds the center pipe to transmission. 3. Connect the center exhaust pipe to turbocharger. Tightening torque: 35 Nm (3.6 kgf-m, 26 ft. lbs.) 4. Install the center exhaust pipe to rear exhaust pipe. Tightening torque: 18 Nm (1.8 kgf-m, 13 ft. lbs.) 5. Connect the connector to rear oxygen sensor. Page 2595 Electronic Throttle Actuator Relay: Service and Repair Electronic Throttle Control Relay REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the passenger's side front side sill cover. 3. Remove the bolt which holds the relay bracket on the body. 4. Disconnect the connectors from the main relay. 5. Remove the main relay from the mounting bracket. INSTALLATION Install in the reverse order of removal. Page 4382 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 2357 B134-B136 Page 6516 B230-B283 Page 709 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 2832 Engine Control Module (ECM) I/O Signal (Part 3) Page 559 Page 4668 Parking Brake Lever: Adjustments Parking Brake Lever ADJUSTMENT 1) Remove the console cover. 2) Forcibly pull the parking brake lever 3 to 5 times. 3) Adjust the parking brake lever by turning adjuster until parking brake lever stroke is set at 7 to 8 notches with operating force of 196 N (20 kgf, 44 lbs.). 4) Tighten the lock nut. Lever stroke: 7 to 8 notches when pulled with a force of 196 N (20 kgf, 44 lbs.) Tightening torque (Lock nut): 6 Nm (0.6 kgf-m, 4.4 ft. lbs.) 5) Install the console cover. Page 5006 to the right. The proper wire location (not pinched) is indicated by broken lines in the photo to the right, below. ^ If the wire was found to be pinched, proceed to the "Wiring Repair Procedure" section, below. 3. If the wire was found to be located properly (not pinched), no repair is necessary. Reinstall the floor carpet. Wrap the previously cut portion of carpet with 1.5 inch wide unwoven adhesive tape. 4. Reinstall the center console trim. Note: Be careful that the seat heater switch is not pinched by the parking brake lever during reinstallation. 5. Confirm that switches, including the seat heater switch, work properly. Wiring Repair Procedure: Forester & Impreza 1. Disconnect the negative battery cable. Note: In the interest of customer satisfaction, please write down all radio preset stations prior to disconnecting the battery. The stations should be reset into the radio afier completion of the repair. 2. For Impreza models, proceed to step 4. Forester Models only: Remove the center console trim between the select lever and parking brake lever. 3. Forester only: Cut a cross section of floor carpet at the center in front of the parking brake lever with scissors as shown. Testing and Inspection Tail Lamp Relay: Testing and Inspection TAIL AND ILLUMINATION RELAY Measure the tail and illumination relay resistance between terminals when connecting terminal No. 4 to battery positive terminal and terminal No. 3 to battery ground terminal. Locations Horn Relay: Locations Main Fuse Box (M/B) Security System Page 7097 Rear Door Glass Page 55 Electrical Components Location Page 1108 Remove the hose from the reservoir tank. Cut 20 mm from the bottom of the hose at a 45° angle. Reinstall hose in reservoir tank. Start engine and permit to fully warm up. Turn off engine and allow to fully cool down. Recheck coolant level in reservoir and add coolant if needed. Note: Be sure to use genuine Subaru Super Coolant or Subaru Long Life Coolant, depending upon what type of coolant is currently in the system. Warranty/Claim Information Page 3456 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 4060 6) Install the transmission assembly to vehicle. INSPECTION Make sure the ring gear is not damaged and that the protrusion on the edge of the torque converter clutch is not deformed or otherwise damaged. Page 1801 Radiator Cooling Fan Motor: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 6169 B3-B12 Page 3618 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 5473 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Description and Operation Ash Tray: Description and Operation ASHTRAY AND CIGARETTE LIGHTER FOR FRONT SEAT PASSENGERS - These are located at the lower part of the center panel and can be opened in one-push action. - The ashtray and cigarette lighter are provided with night illumination, which operates in connection with the lighting system. Page 5256 Wheel Bearing: Service and Repair Front Hub Unit Bearing REMOVAL 1) Disconnect the ground cable from battery. 2) Lift-up the vehicle and remove the front wheels. 3) Unlock the axle nut. 4) Remove the axle nut using a socket wrench while depressing the brake pedal. CAUTION: Remove the wheel before loosening the axle nut. Failure to follow this rule may damage the wheel bearings. 5) Remove the disc brake caliper from housing, and suspend it from strut using a wire. 6) Remove the disc rotor from hub. NOTE: If the disc rotor seizes up within hub, drive disc rotor out by installing an 8-mm bolt in screw hole on rotor. 7) Remove the ABS wheel speed sensor assembly and harness. 8) Remove four bolts from housing. Page 7031 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 5729 Alarm Module: Service Precautions SECURITY CONTROL UNIT NOTE: The control of security system is performed by the keyless entry control unit. Page 988 CASTER ^ Inspection 1) Place the front wheel on turning radius gauge. Make sure ground contacting surfaces of front and rear wheels are set at the same height. 2) Set the adapter into center of wheel, and then install the wheel alignment gauge. 3) Follow the wheel alignment gauge operation manual to measure caster angle. NOTE: Refer to "SPECIFICATION" for caster values. STEERING ANGLE ^ Inspection 1) Place the vehicle on a turning radius gauge. 2) While depressing the brake pedal, turn the steering wheel fully to the right and left. With the steering wheel held at each fully turned position, measure both the inner and outer wheel steering angle. Steering angle: ^ Adjustment 1) Turn the tie-rod to adjust steering angle of both inner and outer wheels. 2) Check the toe-in. NOTE: Correct the boot if it is twisted. Page 3017 - The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40 degrees C (104 degrees F). - The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used. - Each unit is either directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems. - The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected. Page 5472 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 1961 STI model 2. Front Exhaust Pipe REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the front oxygen (A/F) sensor. 3. Remove the under cover. 4. Remove the lower exhaust manifold cover (RH). 5. Remove the lower and upper exhaust manifold covers (I-H). Page 2197 B230-B283 Page 6327 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 2017 A number of symbols are used in each wiring diagram to easily identify parts or circuits. 1. RELAY A symbol used to indicate a relay. 2. CONNECTOR-1 The sketch of the connector indicates the one-pole types. 3. WIRING CONNECTION Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols. (When two pages are needed for clear indication) 4. FUSE NO. & RATING The "FUSE No. & RATING" corresponds with that used in the fuse box (main fuse box, fuse and joint box). 5. CONNECTOR 2 - Each connector is indicated by a symbol. - Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. - For example, terminal number "G4" refers to No. 4 terminal of connector (G: F41) shown in the connector sketch. 6. CONNECTOR SKETCH - Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. - When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used. 7. GROUND Each grounding point can be located easily by referring to the corresponding wiring harness. Page 2657 Engine Control Module (ECM) I/O Signal (Part 5) Page 1770 A used toothbrush which has been cleaned works great. Manually open the negative pressure valve. Using clean water and a brush, thoroughly clean the valve (inner and outer surface) and the valve seal surface. Check the radiator cap valve opening pressure using a radiator cap tester to insure the cap is within specification (refer to the applicable Subaru Service Manual). Note: If the cap is out of specification replace it. 2. Coolant Reservoir Tank Cleaning Remove the reservoir tank (refer to the applicable Subaru Service Manual). Using clean water, thoroughly clean the inside of the reservoir tank. Reinstall reservoir tank. Fill with coolant to the Full mark. Note: Be sure to use genuine Subaru Super Coolant or Subaru Long Life Coolant, depending upon what type of coolant is currently in the system. 3. Coolant Reservoir Tank Hose Modification Page 3770 B136-B141 Page 3339 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 3594 B292-B317 Page 1993 Electronic Throttle Actuator Relay: Service and Repair Electronic Throttle Control Relay REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the passenger's side front side sill cover. 3. Remove the bolt which holds the relay bracket on the body. 4. Disconnect the connectors from the main relay. 5. Remove the main relay from the mounting bracket. INSTALLATION Install in the reverse order of removal. Page 1523 7. Tighten the nuts which install the front cushion rubber onto front crossmember. Tightening torque: 83 Nm (8.5 kgf-m, 61 ft. lbs.) 8. Install the front exhaust pipe assembly. 9. Install the under cover. 10. Lower the vehicle. CAUTION: When lowering the vehicle, lower the lifting device and wire rope together. 11. Remove the lifting device and steel cables. 12. Install the pitching stopper. Tightening torque: T1: 50 Nm (5.1 kgf-m, 36.9 ft. lbs.) T2: 58 Nm (5.9 kgf-m, 42.8 ft. lbs.) 13. Install the radiator upper brackets. Page 1067 Page 4637 Brake Hose/Line: Service and Repair Brake Pipe Brake Pipe REMOVAL NOTE: Airbag system wiring harness is routed near the center brake pipe. CAUTION: ^ Airbag system connectors are colored yellow. Do not use electrical test equipment on these circuits. ^ Be careful not to damage the airbag system wiring harness when servicing the center brake pipe. ^ When removing the brake pipe, use flare nut wrench. ^ When removing the brake pipe, make sure that it is not bent. INSTALLATION NOTE: Airbag system wiring harness is routed near the center brake pipe. CAUTION: ^ Airbag system connectors are colored yellow. Do not use electrical test equipment on these circuits. ^ Be careful not to damage the airbag system wiring harness when servicing the center brake pipe. ^ When installing the brake pipe, use flare nut wrench. ^ When installing the brake pipe, make sure that it is not bent. ^ After installing the brake pipe and hose, bleed the air. ^ After installing the brake hose, make sure that it does not touch the tire or suspension assembly, etc. Tightening torque (Brake pipe): 15 Nm (1.5 kgf-m, 10.8 ft. lbs.) INSPECTION Ensure there are no cracks, breakage, or damage on pipes. Check the joints for fluid leakage. If any cracks, breakage, damage or leakage is found, repair or replace the pipe. NOTE: Use a mirror when inspecting low-visible part or back side. Service and Repair Variable Induction Control Valve: Service and Repair Tumble Generator Valve Assembly REMOVAL 1. Release the fuel pressure. 2. Disconnect the ground cable from battery. 3. Open the fuel filler flap lid and remove the fuel filler cap. 4. Remove the intake manifold. 5. Disconnect the connector from the tumble generator valve sensor 6. Disconnect the connector from the tumble generator valve actuator. 7. Remove the fuel injector. 8. Remove the tumble generator valve body from the intake manifold. INSTALLATION Page 3388 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 5310 Step 1 - 6 Page 3086 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Specifications Dome Lamp: Specifications Specifications Room light............................................................................................................................................ ...................................................................12 V - 8 W Page 5200 RACK SHAFT PLAY IN RADIAL DIRECTION Page 2985 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Removal and Installation Keyless Entry Transmitter: Service and Repair Removal and Installation TRANSMITTER REMOVAL 1. TRANSMITTER BATTERY Remove the battery (1) from transmitter. NOTE: To prevent static electricity damage to transmitter printed circuit board, touch the steel area of building with hand to discharge the static electricity carried on body or clothes before disassembling transmitter. INSTALLATION 1. TRANSMITTER BATTERY Install in the reverse order of removal. Page 5909 3. Remove the power window control switch. 4. Remove the clips of trim panel using clip remover to remove trim panel. INSTALLATION Install in the reverse order of removal. Page 1451 2. Install the baffle plate. Tightening torque: 6.4 Nm (0.65 kgf-m, 4.7 ft. lbs.) 3. Install the oil strainer onto baffle plate. NOTE: Replace the O-ring with a new one. Tightening torque: 10 Nm (1.0 kgf-m, 7.2 ft. lbs.) 4. Apply liquid gasket to the mating surfaces, and then install the oil pan. Liquid gasket. THREE BOND 1207C (Part No. 004403012) or equivalent 5. Tighten the bolts which install the oil pan onto engine block. Tightening torque: 5 Nm (0.5 kgf-m, 3.6 ft. lbs.) 6. Lower the engine onto front crossmember. Diagram Information and Instructions Windshield Washer Motor: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 5021 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Page 1554 9. Install the harness bracket which holds the engine harness onto intake manifold. 10. Install the fuel injector. 11. Tighten the bolts which install the fuel injector pipe onto intake manifold. - LH side Page 623 Throttle Position Sensor: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 7010 R72-R145 R148 Page 7241 B380-f6 Page 2354 B17-B20 Page 5078 B136-B141 Page 1913 B17-B20 Audio System - Vibration from Front Door Speakers Speaker: Technical Service Bulletins Audio System - Vibration from Front Door Speakers NUMBER: 15-119-06 DATE: 11/29/06 APPLICABILITY: 2002MY and Later Impreza SUBJECT: Chattering/Vibration from Front Door Speakers INTRODUCTION If you encounter a customer complaint that the front door speaker(s) chatter and/or vibrate when the volume is set high, refer to the following repair procedure. PARTS/MATERIAL INFORMATION Countermeasure 1 3M(TM) Heavy Drip-Chek(TM) Sealer 08531 Countermeasure 2 S0A part # 61244FE100, Sealing Cover (with urethane) F Door; RH SOA part # 61244FE110, Sealing Cover (with urethane) F Door, LH 3M(TM) Windo-Weld(TM) Round Ribbon Sealer 08625 or butyl tape as an equivalent. Caution: Make sure to read and follow the directions, precautions. warnings, etc of the 3M(TM) products. REPAIR PROCEDURE/INFORMATION Verify the customer's complaint by playing a commercially purchased CD and/or the radio. Note: It is not advisable to play a burned (home made) CD, due to the fact the recording levels may have been set extremely high, which may cause undesirable chattering, vibration and/or distortion. 1) Check to make sure there is nothing in the door pockets that could cause chattering and/or vibrations. If there is, remove the objects. 2) Remove the door trim (refer to the applicable service manual) and check for loose or missing screws, broken or missing clips. Replace if necessary. 3) Check to make sure that the sealing cover is properly applied (no peeling, no misalignment, no breakage). Repair and/or replace as necessary. Page 1423 Note: Remember to always replace the banjo bolt and mesh filter screen when replacing the turbocharger. Proper vehicle maintenance should be reviewed with the customer to avoid a recurring problem in the future. Page 4169 Pressure Plate: Service and Repair Clutch Disc and Cover REMOVAL 1) Remove the transmission assembly from vehicle body. 5MT: Manual Transmission 6MT: Manual Transmission 2) Install the ST on flywheel. ST 499747100 CLUTCH DISC GUIDE 3) Remove the clutch cover and clutch disc. NOTE: ^ Take care not to allow oil on the clutch disc facing. ^ Do not disassemble the clutch cover and clutch disc. ^ Be sure to put alignment marks on the flywheel and clutch cover before removing clutch cover. INSTALLATION 1) Insert the ST into clutch disc and install them on the flywheel by inserting the ST end into pilot bearing. NOTE: When installing the clutch disc, be careful to its direction. ST 499747100 CLUTCH DISC GUIDE 2) Install the clutch cover on flywheel and tighten the bolts to specified torque. NOTE: ^ When reinstalling, align the alignment marks. ^ When installing a new clutch cover, position the clutch cover so that there is a gap of 120° or more between "0" marks on the flywheel and clutch cover. ("0" marks indicate the directions of residual unbalance.) ^ Note the front and rear of the clutch disc when installing. ^ Tighten the clutch cover installing bolts gradually. Each bolt should be tightened to the specified torque in a crisscross order. Page 2220 The list above is of O2 Sensor related DTCs. (This list is for example only. Refer to the applicable service manual for a complete list of DTCs.) Note: When the DTCs for O2 sensor are stored in memory, do not replace the A/F sensor. Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions How to Read Wiring Diagrams HOW TO READ WIRING DIAGRAMS 1.WIRING DIAGRAM The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: - Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front. - The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles. Page 287 Brake Switch (Cruise Control): Testing and Inspection INSPECTION Measure the brake switch (A) and stop light switch (B) resistance. If NG, replace the stop light and brake switch. Page 160 Fuel Pump Relay: Service and Repair Fuel Pump Relay REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the passenger's side front side sill cover. 3. Remove the bolt which holds the relay bracket on the body. 4. Disconnect the connectors from the main relay. 5. Remove the main relay from the mounting bracket. INSTALLATION Install in the reverse order of removal. Page 4598 CAUTION: Brake fluid replacement sequence; (A) Front right -> (B) Rear left -> (C) Front left -> (D) Rear right 3. Slowly depress the brake pedal and keep it depressed. Then, open the air bleeder screw to discharge air together with the fluid. Release the air bleeder screw for 1 to 2 seconds. Next, with the air bleeder screw closed, slowly release the brake pedal. Repeat these steps until there are no more air bubbles in the vinyl tube. Allow 3 to 4 seconds between two brake pedal operations. CAUTION: Cover the air bleeder screw with waste cloth, when loosening it, to prevent brake fluid from being splashed over surrounding parts. NOTE: The brake pedal operating must be very slow. 4. Tighten the air bleeder screw securely when no air bubbles are visible. Tightening torque: Except 17 inch type: 8 Nm (0.8 kgf-m, 5.8 ft. lbs.) 17 inch type: 20 Nm (2.0 kgf-m, 14.5 ft. lbs.) NOTE: For 17 inch type, do not allow brake fluid come in contact with caliper body; wash away with water. (Especially for air bleeder screw.) 5. Perform these steps for the brakes connecting to secondary chamber of master cylinder, first, and then for the ones connecting to primary chamber. With all procedures completed, fully depress the brake pedal and keep it in that position for approximately 20 seconds to make sure that there is no leak evident in the entire system. 6. Check the pedal stroke. While the engine is idling, depress the brake pedal with a 490 Nm (50 kgf, 110 ft. lbs.) load and measure the distance between 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 not be more than specified. Page 2029 B380-f6 Page 1550 - LH side - RH side Page 3511 Variable Induction Position Sensor: Service and Repair NOTE: DO NOT remove the tumble generator valve position sensor from tumble generator valve assembly, since it cannot be adjusted during installation. Refer to "Tumble Generator Valve Assembly" for removal and installation procedures. Page 1522 2. Install the baffle plate. Tightening torque: 6.4 Nm (0.65 kgf-m, 4.7 ft. lbs.) 3. Install the oil strainer onto baffle plate. NOTE: Replace the O-ring with a new one. Tightening torque: 10 Nm (1.0 kgf-m, 7.2 ft. lbs.) 4. Apply liquid gasket to the mating surfaces, and then install the oil pan. Liquid gasket. THREE BOND 1207C (Part No. 004403012) or equivalent 5. Tighten the bolts which install the oil pan onto engine block. Tightening torque: 5 Nm (0.5 kgf-m, 3.6 ft. lbs.) 6. Lower the engine onto front crossmember. Page 642 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Locations Main Relay (Computer/Fuel System): Locations Main Fuse Box (M/B) Solenoid Valve, Actuator, Emission Control System Parts And Ignition System Parts (Part 5) Page 7426 Wiper Relay: Testing and Inspection WIPER CONTROL RELAY INSPECTION 1. Disconnect the connector from wiper control relay. 2. Connect the positive (+) lead from the battery to terminal 8 and the negative (-) lead to terminal 6. Connect the positive (+) lead from the voltmeter to terminal 3 and the negative ( ) lead to ground. 3. Measure the voltage when the wiper relay is operated. If operation is not as specified, replace the switch. Page 392 Sensor Locations Daytime Running Lamp Control Unit: Locations Area View Daytime Running Light Control Module - (B96, B242) Page 2765 F21-F61 Page 551 Specifications Alignment: Specifications SPECIFICATION SPECIFICATION 1 SPECIFICATION 2 NOTE: ^ Front and rear toe-in and front camber can be adjusted. If toe-in or camber exceeds tolerance, adjust toe-in and camber to the adjustment standard. ^ The other items indicated in the specification table cannot be adjusted. If the other items exceed specifications, check suspension parts and connections for deformities; replace with new ones as required. Page 5076 B128-B134 Description and Operation Console: Description and Operation CONSOLE BOX - An accessory socket is provided in the console box. - When using the socket, the cable can be routed out from the front of the console box so that the cable will not be trapped even when the console lid is closed. Page 6046 Trim Panel: Service and Repair Rear Quarter Trim REAR QUARTER TRIM REMOVAL 1. SEDAN MODEL 1. Remove the rear seat. 2. Remove the side sill rear cover. 3. Remove the rear pillar lower cover (A). 4. Remove the seat belt lower anchor bolt, and then remove the rear pillar upper trim (B). 2. WAGON MODEL 1. Remove the rear seat. 2. Remove the side sill rear cover. 3. Remove the rear rail trim (A). 4. Loosen the screws and clips to remove the rear quarter upper trim (B). 5. Remove the rear skirt trim (C). 6. Remove the bolts and clips to remove the rear quarter lower trim (D). 7. Remove the nut, and remove the luggage compartment side rail. Page 2373 Fuel Temperature Sensor: Service and Repair Fuel Temperature Sensor REMOVAL Fuel temperature sensor and fuel level sensor are integrated into one unit; therefore, the removal procedure is the same as that for fuel level sensor. INSTALLATION Fuel temperature sensor and fuel level sensor are integrated into one unit; therefore, the installation procedure is the same as that for fuel level sensor. Locations Electronic Brake Control Module: Locations Electrical Component Location Page 948 B128-B134 Page 3644 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 2247 B128-B134 Page 116 8. DIODE A symbol is used to indicate a diode. 9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A <- -> A, B <- -> B 10. SYMBOLS OF WIRE CONNECTION AND CROSSING 11. POWER SUPPLY CIRCUIT A symbol is used to indicate the power supply in each wiring diagram. "MB - 5", "MB - 6", etc., which are used as power-supply symbols throughout the text, correspond with those shown in the "POWER SUPPLY CIRCUIT" in the wiring diagram. Accordingly, using the "POWER SUPPLY CIRCUIT" and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system. 12. CLASSIFICATION BY SPECIFICATION - When the wiring diagram differ according to vehicle specifications, the specification difference is described by using abbreviations. 13. HARNESS REPAIR KIT The connector adapting to Harness repair kit is shown as "HR" in the right-upper of connector number. Connector Symbols CONNECTOR SYMBOL IN WIRING HARNESS Testing and Inspection Fog/Driving Lamp Switch: Testing and Inspection FRONT FOG LIGHT SWITCH Measure the resistance between front fog light switch terminals. Part 1 Timing Belt: Service and Repair Part 1 Timing Belt The Contents of This Image/Article Reflects the Contents of 18-136-09 Manual Update dated 02/11/09. TIMING BELT REMOVAL 1. TIMING BELT 1. Remove the V-belt. 2. Remove the crank pulley. 3. Remove the timing belt cover. Page 7378 B292-B317 Page 1580 B230-B283 Page 2871 R72-R145 R148 Page 4885 Neutral Safety Switch: Service and Repair Neutral Position Switch NEUTRAL POSITION SWITCH REMOVAL 1. Disconnect the ground cable from battery. 2. Disconnect the connector from neutral position switch, and then remove the switch. INSTALLATION Install in the reverse order of removal. Page 632 12) Move the range select lever to parking position (left side). 13) Remove the inhibitor switch from transmission. 14) Disconnect the inhibitor switch harness connector from inhibitor switch. INSTALLATION 1) Connect the inhibitor switch harness connector to inhibitor switch. 2) Install the inhibitor switch to transmission case. 3) Move the range select lever to neutral position. Locations Backup Lamp Switch: Locations Solenoid Valve And Switch (AT Model) Solenoid Valve, Actuator, Emission Control System Parts And Ignition System Parts (Part 5) Page 6359 R72-R145 R148 Page 6537 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 3751 11) Remove the clamp, and then remove the shift lock solenoid. INSTALLATION Install in the reverse order of removal. INSPECTION Step 1 - Step 4 Page 6531 - The given color codes are used to indicate the colors of the wires. - The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter. Page 1223 CAUTION: Brake fluid replacement sequence; (A) Front right -> (B) Rear left -> (C) Front left -> (D) Rear right 3. Slowly depress the brake pedal and keep it depressed. Then, open the air bleeder screw to discharge air together with the fluid. Release the air bleeder screw for 1 to 2 seconds. Next, with the air bleeder screw closed, slowly release the brake pedal. Repeat these steps until there are no more air bubbles in the vinyl tube. Allow 3 to 4 seconds between two brake pedal operations. CAUTION: Cover the air bleeder screw with waste cloth, when loosening it, to prevent brake fluid from being splashed over surrounding parts. NOTE: The brake pedal operating must be very slow. 4. Tighten the air bleeder screw securely when no air bubbles are visible. Tightening torque: Except 17 inch type: 8 Nm (0.8 kgf-m, 5.8 ft. lbs.) 17 inch type: 20 Nm (2.0 kgf-m, 14.5 ft. lbs.) NOTE: For 17 inch type, do not allow brake fluid come in contact with caliper body; wash away with water. (Especially for air bleeder screw.) 5. Perform these steps for the brakes connecting to secondary chamber of master cylinder, first, and then for the ones connecting to primary chamber. With all procedures completed, fully depress the brake pedal and keep it in that position for approximately 20 seconds to make sure that there is no leak evident in the entire system. 6. Check the pedal stroke. While the engine is idling, depress the brake pedal with a 490 Nm (50 kgf, 110 ft. lbs.) load and measure the distance between 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 not be more than specified. Locations Air Bag Control Module: Locations Electrical Component Location Page 2062 Fuel Pump Relay: Service and Repair Fuel Pump Relay REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the passenger's side front side sill cover. 3. Remove the bolt which holds the relay bracket on the body. 4. Disconnect the connectors from the main relay. 5. Remove the main relay from the mounting bracket. INSTALLATION Install in the reverse order of removal. Page 3116 5) Disconnect the inhibitor switch connector. 6) Remove the inhibitor switch connector from stay. 7) Lift-up the vehicle. 8) Remove the front and center exhaust pipes. 9) Remove the snap pin and washer from range select lever. 10) Remove the plate assembly from transmission case. 11) Remove the bolts. Page 2819 B136-B141 Page 6171 B54-B127 Page 5193 CAUTION: Be careful not to deform the holder. ST 34099FA060 PUNCH HOLDER 15) Roll the vinyl tape on serration part of valve assembly, and then apply grease on the tape surface. 16) Apply a coat of grease on the gear teeth of valve assembly, and then attach the valve assembly taking care not to scratch oil seal and seal ring. Page 2939 B134-B136 Page 7409 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 2820 B230-B283 Page 696 Air Flow Meter/Sensor: Diagnostic Aids Basic Procedures BASIC PROCEDURES 1. GENERAL DESCRIPTION The most important purpose of diagnostics is to quickly determine which part is malfunctioning, to save time and labor. 2. IDENTIFICATION OF TROUBLE SYMPTOM Determine what the problem is based on the symptom. 3. PROBABLE CAUSE OF TROUBLE Look at the wiring diagram and check the system's circuit. Then check the switch, relay, fuse, ground, etc. 4. LOCATION AND REPAIR OF TROUBLE 1. Using the diagnostics, narrow down the causes. 2. If necessary, use a voltmeter, ohmmeter, etc. 3. Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problem is encountered, check the component parts. 5. SYSTEM OPERATION CHECK After repairing, ensure that the system operates properly. Basic Inspection BASIC INSPECTION 1. VOLTAGE MEASUREMENT 1. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2. Contact the positive lead of the voltmeter on connector (A). The voltmeter will indicate a voltage. 3. Shift the positive lead to connector (B). The voltmeter will indicate no voltage. 4. With the test set-up held as it is, turn the switch to ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5. The circuit is in good order. If a problem such as a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction. 2. CIRCUIT CONTINUITY CHECKS 1. Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2. Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Page 4098 INSTALLATION 1) Install detent spring to transmission case. 2) Insert range select lever, and tighten bolt. 3) Install the manual plate and parking rod. 4) Insert spring pin to manual plate. Page 6833 - Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a "F" for F8, "i" for i16, etc.) and the type of wiring harness. The first character of each connector number corresponds to the area or system of the vehicle. Symbols In Wiring Diagrams SYMBOLS IN WIRING DIAGRAMS Page 1649 5. Align the single line mark (A) on intake cam sprocket (LH) with notch (B) on timing belt cover by turning the sprocket clockwise (as viewed from front of engine). (Ensure the double lines (c) on intake and exhaust cam sprockets are aligned.) 6. Ensure the camshaft and crank sprockets are positioned properly. CAUTION: ^ Intake and exhaust camshafts for this DOHC engine can be independently rotated with the timing belts removed. As can be seen from the figure, if the intake and exhaust valves are lifted simultaneously, their heads will interfere with each other, resulting in bent valves. ^ When the timing belts are not installed, four camshafts are held at the "zero-lift" position, where all cams on camshafts do not push the intake and exhaust valves down. (Under this condition, all valves remain unlifted.) ^ When the camshafts are rotated to install the timing belts, #2 intake and #4 exhaust cam of camshafts (LH) are held to push their corresponding valves down. (Under this condition, these valves are held lifted.) Camshafts (RH) are held so that their cams do not push valves down. ^ Camshafts (LH) must be rotated from the "zero-lift" position to the position where the timing belt is to be installed at as small an angle as possible, in order to prevent mutual interference of intake and exhaust valve heads. ^ Do not allow the camshafts to rotate in the direction shown by the upper illustration in the figure as this causes both intake and exhaust valves to lift simultaneously, resulting in interference with their heads. Page 1729 10. Install the timing belt. 11. Install the V-belts. 12. Install the radiator. Inspection 1. Check the water pump bearing for smooth rotation. 2. Check the water pump pulley for abnormalities. 3. Make sure the impeller is not deformed or damaged. 4. Check the clearance between impeller and pump case. ^ Clearance between impeller and pump case: ^ Standard 0.5 - 1.5 mm (0. 020 - 0.059 inch) 5. After water pump installation, check the pulley shaft for engine coolant leaks. If leaks are noted, replace the water pump assembly. Page 6160 - When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined. - WIRING DIAGRAM: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. - The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in the figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal. - In the wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally. Service and Repair Case: Service and Repair Air Breather Hose REMOVAL 1) Remove the air intake chamber. (Non-turbo model) 2) Remove intercooler. (Turbo model) 3) Disconnect the air breather hoses. ^ Non-turbo model Non-turbo model ^ Turbo model Turbo model INSTALLATION 1) Install air breather hoses. NOTE: Install so that the hose is not folded over, excessively bent, or twisted. ^ Non-turbo model Page 7141 Claim Reimbursement/Warrant Information For vehicles under the Basic New Car Limited Warranty period, refer to the Subaru Warranty Wizard(C) for claim submission information. Disclaimer Page 4084 8) Install the front vehicle speed sensor and torque converter turbine speed sensor, and then fasten the harness. 9) Install the inlet pipe. NOTE: Be sure to use a new copper washer. 10) Install the transmission rear crossmember bolts. Tightening torque: 70 Nm (7.1 kgf-m, 51 ft. lbs.) 11) Install the propeller shaft. 12) Install the front, center, rear exhaust pipes and muffler. (Non-turbo model) 13) Install the center, rear exhaust pipes and muffler. (Turbo model) 14) Lower the vehicle. 15) Install the transmission connector to the stay. 16) Install the pitching stopper. 17) Install the air intake chamber. (Non-turbo model) 18) Install the intercooler. (Turbo model) Page 3557 B17-B20 Page 3050 11) Remove the clamp, and then remove the shift lock solenoid. INSTALLATION Install in the reverse order of removal. INSPECTION Step 1 - Step 4 Page 4165 Page 6241 Cruise Control Switch: Testing and Inspection INSPECTION Measure the cruise control command switch resistance. If NG, replace the cruise control command switch. Page 1720 Page 1388 Page 7017 Heated Glass Element: Service and Repair REAR WINDOW DEFOGGER REPAIR 1. Clean the broken portion with alcohol or white gasoline. 2. Mask both side of wire with thin film. 3. Apply conductive silver composition (DUPONT No. 4817) to broken portion. 4. After repair, check the wire. Page 375 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 6142 R58-R69 Page 5023 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 2732 The list above is of O2 Sensor related DTCs. (This list is for example only. Refer to the applicable service manual for a complete list of DTCs.) Note: When the DTCs for O2 sensor are stored in memory, do not replace the A/F sensor. Page 6524 3. The symbol "O--O" indicates that continuity exists between two points or terminals. For example, when a switch position is at "3", continuity exists among terminals 1, 3 and 6, as shown in the table below. 3. HOW TO DETERMINE AN OPEN CIRCUIT 1. WITH VOLTMETER: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open. 2. WITH OHMMETER: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates "infinite", the wiring is open. 4. HOW TO DETERMINE A SHORT CIRCUIT 1. WITH TEST LIGHT: Connect a test light (rated at approx. 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one Page 2741 Page 2206 connector at a time from the circuit. Starting with the one located farthest from the power supply. If the test light goes out when a connector is disconnected, the wiring between that connector and the next connector (farther from the power supply) is shorted. 2. WITH OHMMETER: Disconnect all affected connectors, and check continuity between each connector and ground. When the ohmmeter indicates continuity between a particular connector and a ground, that connector is shorted. Page 5540 Air Bag Control Module: Service and Repair AIRBAG CONTROL MODULE REMOVAL CAUTION: - Do not disassemble the airbag control module. - If the airbag control module is deformed or if water damage is suspected, replace the airbag control module with a new one. - Do not drop the airbag control module. - After removal, keep the airbag control module on a dry, clean surface away from moisture, heat, and dust. 1. Turn the ignition switch to OFF. 2. Disconnect the ground cable from battery, and wait for at least 20 seconds before starting work. 3. Remove the console cover. 4. Remove the center console panel. 5. Disconnect the connector from airbag control module. 6. Remove the four bolts and remove airbag control module. INSTALLATION CAUTION: Use new bolts (for airbag control module only) during installation. Install in the reverse order of removal. Tightening torque: Refer to "COMPONENT" in "General Description". See: Locations Page 583 F21-F61 Locations Main Relay (Computer/Fuel System): Locations Main Fuse Box (M/B) Solenoid Valve, Actuator, Emission Control System Parts And Ignition System Parts (Part 5) Page 7071 OE Harness Connector Repair Kits HARNESS REPAIR KIT Specification Page 6073 Power Door Lock Actuator: Testing and Inspection Front Door Latch and Door Lock Actuator Assembly FRONT DOOR LATCH AND DOOR LOCK ACTUATOR ASSEMBLY INSPECTION 1. Make sure the rod is not deformed. 2. Make sure the lever and rod work smoothly. Page 2416 Disclaimer Page 6167 A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors. Page 5380 Control Assembly: Service and Repair Control Unit (Auto A/C Model) Control Unit (Auto A/C Model) REMOVAL 1. Disconnect the ground cable from battery. 2. Remove the console front panel. 3. Remove the center console panel. 4. Disconnect the connector and aspirator hose (A). INSTALLATION Install in the reverse order of removal. Removal and Installation Fuel Filler Hose: Service and Repair Removal and Installation Fuel Filler Pipe Fuel Filler Pipe REMOVAL WARNING: - Place "NO FIRE" signs near the working area. - Be careful not to spill fuel . 1. Disconnect the ground cable from battery. 2. Open the fuel filler flap lid and remove the filler cap. Page 5886 Front Door Window Regulator: Service and Repair FRONT REGULATOR AND MOTOR ASSEMBLY REMOVAL 1. Remove the door glass. 2. Loosen the nuts to remove the rear sash. 3. Disconnect the motor connector. 4. Loosen the four bolts and two nuts to remove the regulator assembly. 5. Loosen the screw to remove motor assembly. INSTALLATION 1. Install in the reverse order of removal. 2. Adjust the front door glass. Tightening torque: Nm (kgf-m, ft-lb) T1: 7.4 (0.75, 5.5) T2: 13.7 (1.4, 10.1)

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