Subaru Impreza 2007 User Manual

Download

Page 1

asieps_tobira_IM_US.book 2 ページ２０１２年１月１７日　火曜日　午後３時４８分

Foreword

FOREWORD

1. Foreword

A: FOREWORD

These manuals are used when performing maintenance, repair or diagnosis of Subaru IMPREZA. Applicable model: 2007MY GD*****, GG***** The manuals contain the latest information at the time of publication. Changes in the specifications, methods, etc. may be made without notice.

FW-2

Page 2

asieps_tobira_IM_US.book 1 ページ２０１２年１月１７日　火曜日　午後３時４８分

HOW TO USE THIS MANUALS

1. How to Use This Manuals ..........................................................................2

Page

Page 3

asieps_tobira_IM_US.book 2 ページ２０１２年１月１７日　火曜日　午後３時４８分

How to Use This Manuals

HOW TO USE THIS MANUALS

1. How to Use This Manuals

A: HOW TO USE THIS MANUALS

1. STRUCTURE

Each section consists of SCT that are broken down into SC that are divided into sections for each component. The specification, maintenance and other information for the components are included, and the diagnostic information has also been added where necessary.

2. CONTENTS

The first page has an index with tabs.

3. COMPONENT

Illustrations are provided for each component. The information necessary for repair work (tightening torque, grease up points, etc.) is described on these illustrations. Information is described using symbol. To order parts, refer to parts catalogue.

HU-2

Page 4

asieps_tobira_IM_US.book 3 ページ２０１２年１月１７日　火曜日　午後３時４８分

How to Use This Manuals

Example:

(5)

(8)

(7)

(10)

(16)

(10)

(14)

(3)

(15)

T11

(4)

T10

(23)

(18)

(1)

(17)

(4)

(2)

(9)

(10)

(22)

(13)

(21)

(4)

(3)

(24)

(25)

(12)

(24)

(28)

(10)

(29)

(25)

(6)

(11)

(26)

(30)

(2)

(1)

(9)

(10)

(11)

(27)

(31)

:Selective part

:Replacement part

:Sealing point

HOW TO USE THIS MANUALS

(6)

(12)

(17)

(32)

(37)

(14)

(19)

(3)

(4)

(22)

(34)

(5)

(33)

(7)

(8)

(20)

(21)

(23)

(16)

(18)

(35)

(13)

(15)

(36)

(20)

(19)

4. SPECIFICATION

If necessary, specifications are also included.

5. INSPECTION

Inspections to be carried out before and after maintenance are included.

HU-3

:Should be lubricated with oil.

:Should be lubricated with grease.

....

:Tightening torque

HU-00017

Page 5

asieps_tobira_IM_US.book 4 ページ２０１２年１月１７日　火曜日　午後３時４８分

How to Use This Manuals

HOW TO USE THIS MANUALS

6. MAINTENANCE

•Maintenance instructions for serviceable parts describe work area and detailed step with illustration. It also describes the use of special tool, tightening torque, caution for each procedure.

•If many serviceable parts are included in one service procedure, appropriate reference is provided for each parts.

Example:

15.Main Shaft Assembly for Single-Range

A: REMOVAL

1) Remove the manual transmission assembly

from vehicle. <Ref. to MT-33, REMOVAL, Manual Transmission Assembly.>

11) Tighten the lock nuts to the specified torque us-

ing ST1 and ST2.

NOTE: Secure the lock nuts in two places after tightening.

ST1 498937000 TRANSMISSION HOLDER ST2 499987003 SOCKET WRENCH (35)

Tightening torque:

118 N m (12.0 kgf-m, 86.8 ft-lb)

(E) (F)

(A)

(B)

(C)

(D)

(G)

(H)

ST2

(A) Component (D) Cautions (G) Tightening torque (B) Process (E) Tool number of special tool (H) Illustration (C) Reference (F) Name of special tool

ST1

HU-00020

7. DIAGNOSIS

Tables showing a step-by-step process make it easy to conduct diagnosis.

8. SI UNITS

Measurements in these manuals are according to the SI units. Metric and yard/pound measurements are also included.

Example:

Tightening torque:

44 N·m (4.5 kgf-m, 33 ft-lb)

HU-4

Page 6

asieps_tobira_IM_US.book 5 ページ２０１２年１月１７日　火曜日　午後３時４８分

How to Use This Manuals

HOW TO USE THIS MANUALS

9. EXPLANATION OF TERMINOLOGY

• List

AAI : Air Assist Injection I/O : Input / Output A/B : Airbag ISC : Idle Speed Control ABS : Anti-lock Brake System LED : Light Emitting Diode A/C : Air Conditioner ACC : Accessory LH : LH (Left Hand) A/F : Air Fuel Ratio LSD : Limited Slip Differential ALT : Generator M/B : Main Fuse & Relay Box ASSY : Assembly MD : Mini Disc AT : A ut o m at i c Tr a n sm i s si o n M FI : Multipoint Fuel Injection AT F : A u to m a ti c Tra n s mi s s io n Fl u i d M P-T : M u l ti - P la t e Tr a n sf e r AVC S : Ac tive Val ve Co ntrol System MT : Ma nual Tra nsmiss ion AWD : All Wheel Drive NA : Natural Aspiration BATT : Battery NC : Normal Close (Relay) CAN : Controller Area Network NO : Normal Open (Relay) CD-R/

RW COMPL : Complete OBD : On-Board Diagnosis CPU : Central Processing Unit P/S : Power Steering DCCD : Driver’s Control Center Differential P/W : Power Window DOHC : Double Overhead Camshaft PCD : Pitch Circle Diameter DTC : Diagnosis Trouble Code PCV : Positive Crankcase Ventilation DOJ : Double Offset Joint PID :Parameter Identification DVD : D igital Versat ile Di sc or Digital V ideo D isc RA M : R andom Acces s Memo ry

EBD : Electric Brake Distribution ROM : Read Only Memory

ECM : Engine Control Module SOHC : Single Overhead Camshaft EGI : Electronic Gasoline Injection SRS : Supplemental Restraint System E/G : Engine EGR : Exhaust Gas Recirculation SSM : Subaru Select Monitor ELR : Emergency Locking Retractor ST : Special Tool EX : Exhaust STD : Standard ETC : Electronic Throttle Control SW : Switch

F/B : Fuse & Joint Box TGV : Tumble Generator Valve FL : Fusible Link T/M : Transmission FWD : Front Wheel Drive UV : Ultraviolet GPS : Global Positioning System V.I.N. : Vehicle Identification Number HID : High-Intensity Discharge ViS-C : Viscous Coupling

H/U : Hydraulic Unit VTD : Variable Torque Distribution IG : Ignition W/H : Wiring Harness IN : Intake Pr : Primary INT : Intermittent 2ndr : Secondary

:CD Recordable/Rewritable OP :Option Parts

RH : RH (Right Hand)

rpm : Revolution Per Minute

T/B : Turbo charger

VSV : Vacuum Switching Valve

HU-5

Page 7

asieps_tobira_IM_US.book 6 ページ２０１２年１月１７日　火曜日　午後３時４８分

How to Use This Manuals

HOW TO USE THIS MANUALS

HU-6

Page 8

asieps_tobira_IM_US.book 1 ページ２０１２年１月１７日　火曜日　午後３時４８分

SPECIFICATIONS

1. Impreza ......................................................................................................2

SPC

Page

Page 9

asieps_tobira_IM_US.book 2 ページ２０１２年１月１７日　火曜日　午後３時４８分

Impreza

SPECIFICATIONS

1. Impreza

A: DIMENSION

Model Sedan Wagon OUTBACK STI Overall length mm (in) 4,465 (175.8) Overall width mm (in) 1,740 (68.5) 1,695 (66.7) 1,710 (67.3) 1,740 (68.5)

Overall height (at C.W.) mm (in) 1,440 (56.7)

Length mm (in) 1,890 (74.4) 1,845 (72.6) 1,890 (74.4)

Compartment

Wheelbase mm (in) 2,525 (99.4)

Tr e ad

Minimum road clearance mm (in) 160 (6.3) 160 (6.3) 170 (6.7) 145 (5.7)

Width mm (in) 1,380 (54.3)

Height mm (in)

Front mm (in) 1,485 (58.5) 1,465 (57.7) 1,460 (57.5) 1,490 (58.7)

Rear mm (in)

1,180 (46.5),

1,125 (44.3)

1,475 (58.1),

1,480 (58.3)

1,465 (57.7),

1,485 (58.5)

1,200 (47.2),

1,150 (45.3)

1,455 (57.3) 1,455 (57.3) 1,495 (58.9)

1,475 (58.1),

1,495 (58.9)

1,200 (47.2),

1,150 (45.3)

1,430 (56.3)

1,180 (46.5)

:WRX

: With sunroof

: With roof rail

B: ENGINE

Model 2.5 L Turbo 2.5 L STI Engine type Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine Val ve arrangem ent DOHC SO HC DO HC Bore × stroke mm (in) 99.5 × 79 (3.92 × 3.11) Displacement cm Compression ratio 8.4±0.2 10.0±0.2 8.2±0.2 Ignition order 1 — 3 — 2 — 4 Idle speed at Park or Neutral

position Maximum output kW (HP)/rpm 167 (224)/5,600 129 (173)/6,000 219 (293)/6,000 Maximum torque N·m (kgf-m, ft-lb)/rpm 307 (31.3, 226)/3,600 226 (23.0, 166)/4,400 394 (40.2, 290)/4,000

(cu in) 2,457 (149.94)

rpm 700±100

MT: 650±100

AT : 7 0 0±100

700±100

C: ELECTRICAL

Model 2.5 L Turbo 2.5 L STI

Ignition timing (at idling) BTDC 17°±10°

Spark plug Type and manufacturer NGK: ILFR6B NGK: FR5AP-11 NGK: ILFR6B Generator 12V — 110A 12 V — 90 A 12V — 110A

Battery Type and capacity (5HR)

AT : 1 2 V — 52 A H (75 D 2 3L) MT:12 V — 48 AH (55D23L)

MT: 10°±8°

AT : 1 5 °±8°

17°±10°

12 V — 48 AH

(55D23L)

SPC-2

Page 10

asieps_tobira_IM_US.book 3 ページ２０１２年１月１７日　火曜日　午後３時４８分

Impreza

SPECIFICATIONS

D: TRANSMISSION

Model 2.5 L Turbo 2.5 L STI Tr a ns m i s si o n ty p e 5M T 4 AT 5 M T 4 AT 6 MT Clutch type DSPD TCC DSPD TCC DSPD

1st 3.454 2.785 3.454 2.785 3.636 2nd 1.947 1.545 2.062 1.545 2.235 3rd 1.366 1.000 1.448 1.000 1.521

Gear ratio

Reduction gear (Front)

Reduction gear (Rear)

1st reduction

Final reduction

Tr a ns f e r r e d uc t i o n

Final reduction

4th 0.972 0.694 1.088 0.694 1.137 5th 0.738 — 0.780 — 0.971 6th — — — — 0.756 Rev. 3.333 2.272 3.333 2.272 3.545 Type of gear — Helical — Helical — Gear ratio — 1.000 — 1.000 — Type of gear Hypoid Hypoid Hypoid Hypoid Hypoid Gear ratio 3.700 3.900 3.900 4.111 3.900 Type of gear Helical — Helical — Helical Gear ratio 1.000 — 1.000 — 1.100 Type of gear Hypoid Hypoid Hypoid Hypoid Hypoid Gear ratio 3.700 3.900 3.900 4.111 3.545

5MT: 5-forward speeds with synchromesh and 1-reverse 4AT: Electronically controlled fully-automatic, 4-forward speeds and 1-reverse 6MT: 6-forward speeds with synchromesh and 1-reverse DSPD: Dry Single Plate Diaphragm TCC: Torque Converter Clutch

E: STEERING

Model 2.5i, OUTBACK WRX STI Type Rack and pinion Turns, lock to lock 3.0 2.7 2.6

Minimum turning radius m (ft)

Curb to curb 10.8 (35.4) 11.4 (37.4)

Wall to wall 11.6 (38.1) 12.0 (39.4)

F: SUSPENSION

Front Macpherson strut type suspension Rear Dual-link strut type suspension

G: BRAKE

Model 2.5i, OUTBACK WRX STI Service brake system Dual circuit hydraulic with vacuum suspended power unit Front Ventilated d isc bra ke Rear Disc brake Ventilated disc brake Parking brake Mechanical on rear brakes

H: TIRE

Model 2.5i, OUTBACK WRX STI Rim size 16 × 6 Tire size P205/55R16 89V 215/45R17 91W 225/45R17 90W Type Tubeless, Steel belted radial

/2JJ 17 × 7JJ 17 × 8JJ

SPC-3

Page 11

asieps_tobira_IM_US.book 4 ページ２０１２年１月１７日　火曜日　午後３時４８分

Impreza

SPECIFICATIONS

I: CAPACITY

Model

Fuel tank 2 (US gal, Imp gal) 60 (15.9, 13.2)

Capacity (at overhaul)

When replacing

Engine oil

Tr a ns m i s si o n ge a r oi l 2 (US qt, Imp qt) 3.5 (3.7, 3.1) — 3.5 (3.7, 3.1) — 4.1 (4.3, 3.6)

AT F 2 (US qt, Imp qt) —

Front differential gear oil 2 (US qt, Imp qt) —

Rear differential gear oil 2 (US qt, Imp qt) 0.8 (0.8, 0.7) 1.0 (1.1, 0.9) Power steering fluid 2 (US qt, Imp qt) 0.7 (0.7, 0.6) Engine coolant 2 (US qt, Imp qt) 7.7 (8.1, 6.8) 7.6 (8.0, 6.7) 7.0 (7.4, 6.2) 6.9 (7.3, 6.1) 7.7 (8.1, 6.8)

engine oil and oil filter

When replacing engine oil only

2 (US qt, Imp qt) 5.0 (5.3, 4.4)

2 (US qt, Imp qt) 4.3 (4.5, 3.8) 4.2 (4.4, 3.7) 4.3 (4.5, 3.8)

2 (US qt, Imp qt) 4.0 (4.2, 3.5)

2.5 L Turbo 2.5 L STI

5MT 4AT 5MT 4AT 6MT

9.3 — 9.6

(9.8 — 10.1,

8.2 — 8.4)

1.1 — 1.3

(1.2 — 1.4,

1.0 — 1.1)

—

9.3 — 9.6

(9.8 — 10.1,

8.2 — 8.4)

1.1 — 1.3

(1.2 — 1.4,

1.0 — 1.1)

—

SPC-4

Page 12

asieps_tobira_IM_US.book 5 ページ２０１２年１月１７日　火曜日　午後３時４８分

Impreza

J: WEIGHT

1. US MODEL

Sedan

Non-Turbo Turbo

Model

Front kg (lb) 792 (1,746) 818 (1,803) 861 (1,898) 870 (1,918) 869 (1,916) 861 (1,898)

Curb weight (C.W.)

Gross axle weight (G.A.W.)

Gross vehicle weight (G.V.W.) kg (lb)

Option

Rear kg (lb) 576 (1,270) 573 (1,263) 587 (1,294) 599 (1,321) 598 (1,318) 587 (1,294)

To ta l k g ( l b)

Front kg (lb) 939 (2,070) 939 (2,070) 998 (2,200) 998 (2,200) 998 (2,200) 998 (2,200) Rear kg (lb) 907 (2,000) 907 (2,000) 916 (2,020) 916 (2,020) 916 (2,020) 916 (2,020)

Power window Power door lock Cruise control ABS Front LSD — — — — — — Driver’s control center

differential (Auto) Cold W package — — — — —

Aluminum wheel

Air conditioner Sunroof — — — — Dual airbags Side airbag Rear spoiler — — — — — Leather seats — — — — —

Gold color — — — — — — Silver color — — — — — —

(3,016)

(3,920)

2.5 i WRX WRX-TR

5MT 4AT 5MT

1,368

1,778

— — — — — —

1,391

(3,067)

1,778

(3,920)

1,448

(3,192)

1,850

(4,079)

1,469

(3,239)

1,850

(4,079)

SPECIFICATIONS

1,467

(3,234)

1,850

(4,079)

1,448

(3,192)

1,850

(4,079)

SPC-5

Page 13

asieps_tobira_IM_US.book 6 ページ２０１２年１月１７日　火曜日　午後３時４８分

Impreza

SPECIFICATIONS

Tu rb o

Model

Curb weight (C.W.)

Gross axle weight (G.A.W.)

Gross vehicle weight (G.V.W.) kg (lb) 1,870 (4,128) 1,870 (4,128) 1,900 (4,189) 1,900 (4,189)

Option

Front kg (lb) 893 (1,969) 895 (1,973) 886 (1,953) 886 (1,953) Rear kg (lb) 580 (1,279) 600 (1,323) 634 (1,398) 634 (1,398) Total kg (lb) 1,473 (3,247) 1,495 (3,296) 1,520 (3,351) 1,520 (3,351) Front kg (lb) 998 (2,200) 998 (2,200) 1,030 (2,271) 1,030 (2,271) Rear kg (lb) 916 (2,020) 916 (2,020) 920 (2,028) 920 (2,028)

Power window Power door lock Cruise control ABS Front LSD — — Driver’s control center

differential (Auto) Cold W package — — —

Aluminum wheel

Air conditioner Sunroof — — — Dual airbags Side airbag Rear spoiler — — — Leather seats — — —

Gold color — — — Silver color — — —

WRX STI

4AT 6MT

— —

SPC-6

Page 14

asieps_tobira_IM_US.book 7 ページ２０１２年１月１７日　火曜日　午後３時４８分

Impreza

Wagon

Model

Front kg (lb) 786 (1,733) 806 (1,777) 788 (1,737) 811 (1,788) 788 (1,737) 811 (1,788)

Curb weight (C.W.)

Gross axle weight (G.A.W.)

Gross vehicle weight (G.V.W.) kg (lb)

Option

Rear kg (lb) 607 (1,338) 609 (1,343) 603 (1,329) 604 (1,332) 603 (1,329) 604 (1,332)

To ta l k g ( l b)

Front kg (lb) 939 (2,070) 939 (2,070) 939 (2,070) 939 (2,070) 939 (2,070) 939 (2,070) Rear kg (lb) 953 (2,100) 953 (2,100) 953 (2,100) 953 (2,100) 953 (2,100) 953 (2,100)

Power window Power door lock Cruise control ABS Front LSD — — — — — — Driver’s control center

differential (Auto) Cold W package — — — — — —

Aluminum wheel

Air conditioner Sunroof — — — — — — Dual airbags Side airbag Rear spoiler — — — — — — Leather seats — — — — — —

Gold color — — — — — — Silver color — — — — — —

(3,071)

(4,041)

2.5 i OUTBACK OUTBACK-SE

5MT 4AT 5MT 4AT 5MT 4AT

1,393

1,833

— — — — — —

1,415

(3,120)

1,833

(4,041)

Non-Turbo

1,391

(3,067)

1,833

(4,041)

1,415

(3,120)

1,833

(4,041)

SPECIFICATIONS

1,391

(3,067)

1,833

(4,041)

1,415

(3,120)

1,833

(4,041)

SPC-7

Page 15

asieps_tobira_IM_US.book 8 ページ２０１２年１月１７日　火曜日　午後３時４８分

Impreza

SPECIFICATIONS

Tu rb o

Model

5MT 4AT

Curb weight (C.W.)

Gross axle weight (G.A.W.)

Gross vehicle weight (G.V.W.) kg (lb) 1,910 (4,211) 1,910 (4,211) 1,930 (4,255) 1,930 (4,255)

Option

Front kg (lb) 856 (1,887) 863 (1,903) 881 (1,942) 888 (1,958) Rear kg (lb) 619 (1,365) 631 (1,391) 619 (1,365) 630 (1,389) Total kg (lb) 1,475 (3,252) 1,494 (3,294) 1,500 (3,307) 1,518 (3,347) Front kg (lb) 998 (2,200) 998 (2,200) 998 (2,200) 998 (2,200) Rear kg (lb) 953 (2,100) 953 (2,100) 953 (2,100) 953 (2,100)

Power window Power door lock Cruise control ABS Front LSD — — — — Driver’s control center

differential (Auto) Cold W package — —

Aluminum wheel

Air conditioner Sunroof — — Dual airbags Side airbag Rear spoiler — — — — Leather seats — —

Gold color — — — — Silver color — — — —

— — — —

WRX

SPC-8

Page 16

asieps_tobira_IM_US.book 9 ページ２０１２年１月１７日　火曜日　午後３時４８分

Impreza

2. CANADA MODEL

Sedan

Non-Turbo Turbo

Model

Front kg (lb) 792 (1,746) 818 (1,803) 862 (1,902) 870 (1,918) 869 (1,916) 861 (1,898)

Curb weight (C.W.)

Gross axle weight (G.A.W.)

Gross vehicle weight (G.V.W.) kg (lb)

Option

Rear kg (lb) 576 (1,270) 573 (1,263) 590 (1,300) 599 (1,321) 598 (1,318) 587 (1,294)

To ta l k g ( l b)

Front kg (lb) 939 (2,070) 939 (2,070) 998 (2,200) 998 (2,200) 998 (2,200) 998 (2,200) Rear kg (lb) 907 (2,000) 907 (2,000) 916 (2,020) 916 (2,020) 916 (2,020) 916 (2,020)

Power window Power door lock Cruise control ABS Front LSD — — — — — — Driver’s control center

differential (Auto) Cold W package — — —

Aluminum wheel

Air conditioner Sunroof — — — — Dual airbags Side airbag Rear spoiler — — — — Leather seats — — — — — —

Gold color — — — — — — Silver color — — — — — —

(3,016)

(3,920)

2.5 i WRX WRX-TR

5MT 4AT 5MT

1,368

1,778

— — — — — —

1,391

(3,067)

1,778

(3,920)

1,452

(3,202)

1,850

(4,079)

1,469

(3,239)

1,850

(4,079)

SPECIFICATIONS

1,467

(3,234)

1,850

(4,079)

1,448

(3,192)

1,850

(4,079)

SPC-9

Page 17

asieps_tobira_IM_US.book 10 ページ２０１２年１月１７日　火曜日　午後３時４８分

Impreza

SPECIFICATIONS

Tu rb o

Model

Curb weight (C.W.)

Gross axle weight (G.A.W.)

Gross vehicle weight (G.V.W.) kg (lb) 1,870 (4,128) 1,870 (4,128) 1,870 (4,128) 1,900 (4,189) 1,900 (4,189)

Option

Front kg (lb) 889 (1,960) 895 (1,973) 888 (1,958) 886 (1,953) 886 (1,953) Rear kg (lb) 589 (1,299) 599 (1,321) 588 (1,296) 634 (1,398) 634 (1,398) Total kg (lb) 1,478 (3,259) 1,494 (3,294) 1,476 (3,254) 1,520 (3,351) 1,520 (3,351) Front kg (lb) 998 (2,200) 998 (2,200) 998 (2,200) 1,030 (2,271) 1,030 (2,271) Rear kg (lb) 916 (2,020) 916 (2,020) 916 (2,020) 920 (2,028) 920 (2,028)

Power window Power door lock Cruise control ABS Front LSD — — — Driver’s control center

differential (Auto) Cold W package — — —

Aluminum wheel

Air conditioner Sunroof — — — — Dual airbags Side airbag Rear spoiler — — — Leather seats — — — — —

Gold color — — — — Silver color — — — —

— — —

WRX STI

4AT 6MT

SPC-10

Page 18

asieps_tobira_IM_US.book 11 ページ２０１２年１月１７日　火曜日　午後３時４８分

Impreza

Wagon

Model

Front kg (lb) 786 (1,733) 806 (1,777) 788 (1,737) 811 (1,788) 788 (1,737) 811 (1,788)

Curb weight (C.W.)

Gross axle weight (G.A.W.)

Gross vehicle weight (G.V.W.) kg (lb)

Option

Rear kg (lb) 607 (1,338) 609 (1,343) 603 (1,329) 604 (1,332) 603 (1,329) 604 (1,332)

To ta l k g ( l b)

Front kg (lb) 939 (2,070) 939 (2,070) 939 (2,070) 939 (2,070) 939 (2,070) 939 (2,070) Rear kg (lb) 953 (2,100) 953 (2,100) 953 (2,100) 953 (2,100) 953 (2,100) 953 (2,100)

Power window Power door lock Cruise control ABS Front LSD — — — — — — Driver’s control center

differential (Auto) Cold W package — — — — — —

Aluminum wheel

Air conditioner Sunroof — — — — — — Dual airbags Side airbag Rear spoiler — — — — — — Leather seats — — — — — —

Gold color — — — — — — Silver color — — — — — —

(3,071)

(4,041)

2.5 i OUTBACK OUTBACK-SE

5MT 4AT 5MT 4AT 5MT 4AT

1,393

1,833

— — — — — —

1,415

(3,120)

1,833

(4,041)

Non-Turbo

1,391

(3,067)

1,833

(4,041)

1,415

(3,120)

1,833

(4,041)

SPECIFICATIONS

1,391

(3,067)

1,833

(4,041)

1,415

(3,120)

1,833

(4,041)

SPC-11

Page 19

asieps_tobira_IM_US.book 12 ページ２０１２年１月１７日　火曜日　午後３時４８分

Impreza

SPECIFICATIONS

Tu rb o

Model

5MT 4AT

Curb weight (C.W.)

Gross axle weight (G.A.W.)

Gross vehicle weight (G.V.W.) kg (lb) 1,910 (4,211) 1,910 (4,211) 1,910 (4,211) 1,930 (4,255)

Option

Front kg (lb) 857 (1,889) 863 (1,902) 856 (1,887) 882 (1,944) Rear kg (lb) 620 (1,368) 630 (1,390) 619 (1,365) 620 (1,368) Total kg (lb) 1,477 (3,257) 1,493 (3,292) 1,475 (3,252) 1,502 (3,312) Front kg (lb) 998 (2,200) 998 (2,200) 998 (2,200) 998 (2,200) Rear kg (lb) 953 (2,100) 953 (2,100) 953 (2,100) 953 (2,100)

Power window Power door lock Cruise control ABS Front LSD — — — — Driver’s control center

differential (Auto) Cold W package —

Aluminum wheel

Air conditioner Sunroof — — — Dual airbags Side airbag Rear spoiler — Leather seats — — — —

Gold color — — — — Silver color — — — —

— — — —

WRX

SPC-12

Page 20

asieps_tobira_IM_US.book 1 ページ２０１２年１月１７日　火曜日　午後３時４８分

PRECAUTION

1. Precaution ..................................................................................................2

Page

Page 21

asieps_tobira_IM_US.book 2 ページ２０１２年１月１７日　火曜日　午後３時４８分

Precaution

PRECAUTION

1. Precaution

A: CAUTION

Please clearly understand and adhere to the following general precautions for environmental protection and to avoid minor or serious injury to the person doing the work or people in the area.

1. ABS

Handle the ABS as a total system. Do not disassemble or attempt to repair parts which are not instructed in this manual. Follow the directions in this manual when performing maintenance on the ABSCM&H/U. When parts other than those specified are disassembled, it is possible that the ABS system will not operate when needed or cause it to operate incorrectly and result in injury.

2. BRAKE FLUID

If brake fluid gets in your eyes or on your skin, do the following:

•Wash eyes and seek immediate medical attention.

•Wash your skin with soap and then rinse thoroughly with water.

3. RADIATOR FAN

The radiator fan may rotate without warning, even when the engine is not ON. Do not place your hand, cloth, tools or other items near the fan at any time.

4. ROAD TEST

Always conduct road tests in accordance with traffic rules and regulations to avoid bodily injury and interrupting traffic.

5. AIRBAG

To prevent bodily injury from unexpected deployment of airbags and unnecessary maintenance, follow the instructions in this manual when performing maintenance on or near the airbag components and the airbag wiring harnesses. To prevent unexpected deployment, perform the following steps for discharging the battery and then wait for at least 20 seconds before starting work.

•Step 1: Turn the ignition switch to OFF.

•Step 2: Disconnect the ground cable from the battery.

7. AIRBAG MODULE

Adhere to the following when handing and storing the airbag module to prevent bodily injury from unexpected deployment:

•Do not hold the harnesses or connectors to carry the module.

•Do not face the bag in the direction that it opens towards yourself or other people.

•Do not face the bag in the direction that it opens towards the floor or walls.

8. AIRBAG SPECIAL TOOL

To prevent unexpected deployment, only use special tools.

9. WINDOW

Always wear safety glasses when working around any glass to prevent glass fragments from damaging your eyes.

10.WINDOW ADHESIVE

Always use the recommended or equivalent adhesive when attaching glass to prevent it from coming falling, resulting in accidents and injury.

11.OIL

When handling oil, adhere to the following to prevent from unexpected accident.

•Prepare a container and cloth when performing work which oil possibly spills. If oil spills, wipe it off immediately to prevent from penetrating into floor or flowing out for environmental protection.

•Follow all government and local regulations concerning disposal of refuse when disposing.

12.FUEL

When handling and storing fuel, adhere to the following to prevent from unexpected accident.

•Be careful with fire.

•Prepare a container and cloth to prevent scattering of fuels when performing work where fuels can be spilled. If the fuel spills, wipe it off immediately to prevent from penetrating into floor or flowing out for environmental protection.

•Follow all government and local regulations concerning disposal of refuse when disposing.

6. AIRBAG DISPOSAL

To prevent bodily injury from unexpected airbag deployment, do not dispose the airbag modules in the same way as other waste. Follow all government regulations concerning disposal of refuse.

PC-2

Page 22

asieps_tobira_IM_US.book 3 ページ２０１２年１月１７日　火曜日　午後３時４８分

Precaution

PRECAUTION

13.ENGINE COOLANT

When handling engine coolant, adhere to the following to prevent from unexpected accident.

•Never remove the radiator cap since engine coolant may blow out when it is hot.

•Prepare a container and cloth to prevent scattering of engine coolant when performing work where engine coolant can be spilled. If the fuel spills, wipe it off immediately to prevent from penetrating into floor or flowing out for environmental protection.

•Follow all government and local regulations concerning disposal of refuse when disposing.

14.AIR CONDITIONER REFRIGERANT

In order to prevent from global warming, avoid releasing air conditioner refrigerant into the atmosphere. Using a refrigerant recovery system, discharge and recycle it.

15.HOSE REMOVAL/INSTALLATION PROCEDURES

1. Hose Removal/Installation Pre-Procedures

•Be careful to inspect hoses so as not to use damaged or deformed hoses. Using such hoses could cause leakage or loss of oil, with leaked oil splashing on exhaust pipes or other hot parts, resulting in smoke or fire.

•Always remove hoses when performing work. Not removing the hoses and moving parts out of the way when performing procedures may damage the inside of hoses and cause other negative affects.

2. Hose Removal/Installation Procedures and Inspection

• Remove hoses according to the following instructions.

•If using the hose remover (general tool), do not use the sharp-pointed hose remover (hose plucker) as it may damage pipe surfaces or hoses.

(1)

PC-00065

(1) Hose remover

•When using pliers to make hose removal easier, always be sure to use a cloth to protect the hose, slightly rotate the hose, and then pull straight out by hand.

PC-3

Page 23

asieps_tobira_IM_US.book 4 ページ２０１２年１月１７日　火曜日　午後３時４８分

Precaution

PRECAUTION

• Inspect the following points in continuous

use, and replace any hoses that are damaged or defective with new parts.

•Replace any hoses that are riding over the stay or spool with new parts.

(1)

PC-00067

(1) Hose riding over a stay

(1)

PC-00068

(1) Hose riding over a spool

•Check the inner and outer surfaces of the hose for damage, cracks, breakage, hardening/ softening/swelling of rubber, internal peeling, and that there are no deformations caused by infiltration/adhesion of foreign matter, and no twisted hoses. Replace any defective hoses with new parts.

• Install hoses according to the following in-

structions.

•Carefully check the installation positions.

•Do not use any lubricants.

•Securely insert until the specified positions (until contacting spool).

(2) (1)

(1)

PC-00070

(1) Contacting the spool. (Do not excessively insert

the hose to prevent the hose from becoming wrinkled up.)

(2) Apply an equal clamping force all around the

hose periphery.

•Check that the position and orientation of hose clamps, and the hose layout are correct. (Check that the position and orientation are matching, they are not excessively short/long, there are no differences with before performing the procedures, and that there is clearance between hoses and surrounding parts.)

•After installing, check that there are no disconnection of hoses or leakage from hoses. (Check that hoses are securely fixed by the clamps.)

• Inspect the hose clips and clamps according

to the following points, and replace any parts that are damaged or defective with new parts.

•Check for deformations, rust, damage, and adhering of foreign matter.

•For clips, check that the spring functions and has clamping force.

•For clamps, check that the screw can clinch, the clamp has not become oval shaped, and the screw is not damaged.

• Inspect the pipes according to the following

points, and replace any parts that are damaged or defective with new parts.

Check that the pipes do not have any damage, rust, peeling (including peeling plating), foreign matter adhering, twisting, crushing, bending, or cracks.

• Replace the following parts with new parts if

the hoses have been removed or their installation positions have been changed.

ATF cooler hose, engine oil cooler hose, MT oil cooler hose, power steering suction hose, and power steering return hose.

PC-00069

PC-4

Page 24

asieps_tobira_IM_US.book 1 ページ２０１２年１月１７日　火曜日　午後３時４８分

NOTE

1. Note ............................................................................................................2

Page

Page 25

asieps_tobira_IM_US.book 2 ページ２０１２年１月１７日　火曜日　午後３時４８分

Note

NOTE

1. Note

A: NOTE

This information will improve the efficiency of maintenance and assure that the finished work is of a good quality.

1. FASTENERS NOTICE

Fasteners are used to prevent the parts from damage, dislocation and play due to looseness. Fasteners must be tightened to the specified torque. Do not apply paint, lubricant, rust retardant or other substance to the surface around bolts, nuts, etc. Doing so will make it difficult to obtain the correct torque and result in looseness and other problem.

2. STATIC ELECTRICITY DAMAGE

Do not touch the control modules, connectors, logic boards and other such parts when there is a risk of static electricity. Always use a static electricity prevention cord or touch grounded metal for the elimination of static electricity before conducting work.

3. BATTERY

When removing the battery cables, always be sure to turn the ignition switch to OFF to prevent electrical damage to the control module from overcurrent.

4. SERVICE PARTS

Use genuine parts for maximum performance and maintenance when conducting repairs. Subaru/FHI will not be responsible for poor performance resulting from the use of parts except for genuine parts.

5. PROTECTING VEHICLE UNDER MAINTENANCE

Make sure to attach the fender cover, seat covers, etc. before work.

6. ENSURING SECURITY DURING WORK

When working in a group of two or more, perform the work with calling each other to ensure mutual safety.

NT-2

Page 26

asieps_tobira_IM_US.book 3 ページ２０１２年１月１７日　火曜日　午後３時４８分

Note

7. LIFT AND JACK

When using a lift or shop jack to raise a vehicle or using rigid rack to support a vehicle, always follow instructions concerning jack-up points and weight limits to prevent the vehicle from falling, which could result in injury. Be especially careful that the vehicle is balanced before raising it. Be sure to set the wheel stoppers when jacking-up only the front or rear side of the vehicle.

(1)

(5)

(6)

(2)

NOTE

(3)

(4)

NT-00141

(1) Supporting locations (3) Lift (5) Without side sill cover (2) Pantograph jack (4) Rigid racks (6) With side sill cover

NT-3

Page 27

asieps_tobira_IM_US.book 4 ページ２０１２年１月１７日　火曜日　午後３時４８分

Note

NOTE

(A)

(B)

(1)

(2)

NT-00142

(A) Front (B) Rear

(1) Front crossmember (2) Rear differential

NT-4

Page 28

asieps_tobira_IM_US.book 5 ページ２０１２年１月１７日　火曜日　午後３時４８分

Note

8. TIE-DOWNS

Tie-downs are used when transporting vehicles and when using the chassis dynamo. Attach tie-down only to the specified place on the vehicle.

Tie-down location

NOTE

(1)

(1) Hook for tie-down (2) Hook for tie-down and towing

(2)

NT-00143

Chain direction at tie-down condition Chain pulling range at tie-down condition

20˚ 20˚

45˚ 45˚

(1) Chain pulling range at tie-down condition

45˚ 45˚

: (1)

20˚ 20˚

NT-00064

Vehicle sinking volume at tie-down condition

Measure the distance “L” between the highest tire point and highest arch point before and after tiedown. Difference of measured values (sinking volume) should be within 50 mm (1.97 in) and make sure to fix the vehicle securely.

NT-00038

NT-5

NT-00144

Page 29

asieps_tobira_IM_US.book 6 ページ２０１２年１月１７日　火曜日　午後３時４８分

Note

NOTE

9. TOWING

Avoid towing vehicles except when the vehicle cannot be driven. For models with AWD, AT or VTD, use a loader instead of towing. When towing other vehicles, pay attention to the following to prevent hook or vehicle damage resulting from excessive weight.

•Do not install the hook except when towing.

•Do not tow other vehicles with a front tie-down hook.

•Make sure the vehicle towing is heavier than the vehicle being towed.

Front

(1)

(1) Eye bolt (2) Jack handle

Rear

(2)

NT-00145

NT-00146

NT-6

Page 30

asieps_tobira_IM_US.book 7 ページ２０１２年１月１７日　火曜日　午後３時４８分

Note

10.FRONT HOOD STAY INSTALLATION

At the check and general maintenance

NOTE

When wider hood opening is necessary

1) Remove the hood stay.

2) Set the stay into the hole of front hood inner.

3) Remove the grommet in the wheel apron, and set the lower end of stay into hole.

NT-00147

NT-00148

11.TRAINING

For an information about training, contact a dealer or agent.

12.GENERAL SCAN TOOL

Using general scan tools will greatly improve the efficiency of repairing engine electronic controls. Subaru Select Monitor can be used to diagnose the engine, ABS, AT and other electronically controlled parts.

NT-7

Page 31

asieps_tobira_IM_US.book 8 ページ２０１２年１月１７日　火曜日　午後３時４８分

Note

NOTE

NT-8

Page 32

asieps_tobira_IM_US.book 1 ページ２０１２年１月１７日　火曜日　午後３時４８分

IDENTIFICATION

1. Identification ...............................................................................................2

Page

Page 33

asieps_tobira_IM_US.book 2 ページ２０１２年１月１７日　火曜日　午後３時４８分

Identification

IDENTIFICATION

1. Identification

A: IDENTIFICATION

1. IDENTIFICATION NUMBER & LABEL LOCATIONS

The V.I.N. (Vehicle Identification Numbers) is used to classify the vehicle.

• POSITIONING OF THE PLATE LABEL FOR IDENTIFICATION

(2)

(1)

(3)

(4)

(5)

(1)

(6)

(1) Vehicle identification number

(V.I.N.)

(2) Emission control label

(3) Tire inflation pressure label (5) Barcode label (USA model) (4) Approval plate (6) Model number plate

• ENGINE • AUTOMATIC TRANSMISSION

(1)

(2)

ID-00059

(1)

ID-00121

ID-00143

(1) Engine serial number (2) Engine type (crankcase upper side)

(1) AT type label

ID-2

Page 34

asieps_tobira_IM_US.book 3 ページ２０１２年１月１７日　火曜日　午後３時４８分

Identification

IDENTIFICATION

• MANUAL TRANSMISSION (5MT)

(1) MT type label

• MANUAL TRANSMISSION (6MT)

(2)

(1)

ID-00122

(1)

• REAR DIFFERENTIAL

(1)

DI-00502

(1) Type (white paint)

(1) Transmission serial No. (2) MT type label

• MODEL NUMBER PLATE

ID-00144

ID-00194

ID-3

Page 35

asieps_tobira_IM_US.book 4 ページ２０１２年１月１７日　火曜日　午後３時４８分

Identification

IDENTIFICATION

2. MEANING OF V.I.N.

The meaning of the V.I.N. is as follows:

]JF1GG616X7G800001[

The large parentheses (][) located in front and back are stop marks.

Digits Code Meaning Details 1 — 3 JF1 Manufacturer body area JF1: Passenger car, FHI made 4G Car line IMPREZA 5G Body typeD: 4 door sedan

G: Wagon

6 6 Displacement 6: 2.5 L AWD

7: 2.5 L AWD turbo

71 Grade 1: 2.5 i

2: OUTBACK 3: OUTBACK-SE 4: WRX 5: WRX-TR 6: STI

7: STI LIMITED 86 Restraint6: Manual belts, dual airbag, side airbag 9X Check digit0 — 9&X 10 7 Model year 7: 2007MY

8: 2008MY

9: 2009MY 11 G Transmission type G: Full-time AWD 5MT Single range

H: Full-time AWD 4 Speed AT

L: Full-time AWD 6MT Single range 12 — 17 800001 Serial number From 500001: 4 door sedan

From 800001: Wagon

3. MODEL NUMBER PLATE

The model number plate indicates: the applied model, the option code, the trim code, the engine type, the transmission type, and the exterior color code. This information is helpful when placing orders for parts.

GGEFY6J

Digits Code Meaning Details 1G Series IMPREZA 2G Body typeD: 4 door sedan

G: Wagon

3E Engine displacement

Drive system

Suspension system 4F Model yearF: 2007MY 5Y DestinationY: U.S., Canada 66 Grade 6: 2.5 i

7J Transmission, fuel feed

system

E: 2.5 L AWD F: 2.5 L AWD High power turbo G: 2.5 L AWD turbo

7: OUTBACK 8: WRX 9: WRX-TR B: OUTBACK-SE E: STI H: STI-B

R: SOHC MFI 4AT P: DOHC B MFI 4AT J: SOHC MFI 5MT AWD D: DOHC B MFI 5MT AWD H: DOHC B MFI 6MT AWD

The engine and transmission type are as follows.

ID-4

Page 36

asieps_tobira_IM_US.book 5 ページ２０１２年１月１７日　火曜日　午後３時４８分

Identification

IDENTIFICATION

Engine EJ253BS9FB

Digits Code Meaning Details 1 and 2 EJ Engine type EJ: 4 cylinder 3 and 4 25 Displacement 25: 2.5 L 53 Fuel feed system3: MFI-NA(SOHC)

5: MFI turbo

7: MFI High power turbo 6B Exhaust regulationsB: U.S. (FED, CAL) 7S TransmissionE: 5MT

G: 6MT

P: AT

S: 5MT 89 Minor change9: 9 is stamped on the vehicle. 9 — 10 FB Detailed specifications Used when ordering parts. See the parts catalog for details.

Transmission TY754VC7AA

Digits Code Meaning Details 1T TransmissionT: Transmission 2Y Transmission typeY: Full-time AWD MT center differential

V: Full-time AWD AT center differential Z: Full-time AWD AT MP-T

3 and 4 75 Classification 75: 5MT

85: 6MT 1B: AT (direct control method)

54 Series MT4: 5MT

6: 6MT

AT 4 : AT

6V Transmission

specifications

7C Engine typeC: 925 SOHC

8 — 10 7AA Detailed specifications Used when ordering parts. See the parts catalog for details.

V: Full-time AWD 5MT single range with viscous coupling center differential W: Full-time AWD 6MT single range L: Full-time AWD with MP-T 4AT (direct control method) M: Full-time AWD with VTD 4AT (direct control method)

W: 925 DOHC turbo

Rear differential EG

Code Reduction gear ratio LSD EG 3.900 None EH 4.111 None ER 3.700 Viscous P1 3.900 Viscous HR 3.545 Torsen

Option code U4NG

Digits Code Meaning Details

1 — 2 U4 Destination U4: U.S. (FED, CAL)

CO: Canada

3 — 4 NG Main optional parts of

the vehicle

ID-5

—

Page 37

asieps_tobira_IM_US.book 6 ページ２０１２年１月１７日　火曜日　午後３時４８分

Identification

IDENTIFICATION

ID-6

Page 38

asieps_tobira_IM_US.book 1 ページ２０１２年１月１７日　火曜日　午後３時４８分

RECOMMENDED MATERIALS

1. Recommended Materials ...........................................................................2

Page

Page 39

asieps_tobira_IM_US.book 2 ページ２０１２年１月１７日　火曜日　午後３時４８分

Recommended Materials

RECOMMENDED MATERIALS

1. Recommended Materials

A: RECOMMENDED MATERIALS

1. GENERAL

To insure the best performance, always use the specified oil, gasoline, adhesive, sealant, etc. or a substitute of equivalent quality.

2. FUEL

Always use gasoline of the same or higher octane value than specified in the owner’s manual. Ignoring the specifications below will result in damage or poor performance of engine and fuel injection system. Use the specified gasoline to correct performance.

Unleaded gasoline

In order to reduce air pollution, use unleaded gasoline for the vehicle equipped with catalytic converter. Using leaded gasoline may damage the catalytic converter.

3. LUBRICANTS

Use either lubricants in the table below or equivalent. See the table below to choose the correct SAE viscosity.

Lubricant

Engine oil SM “Energy conserving” GF-4

API standard ILSAC standard

SAE

5W-30

Manual Transmission Oil GL-5 — AT front d i ffe r e nt i a l g e ar o il G L-5 — Rear differential gear oil GL-5 —

Recommended materials

RM-00049

FOR

GASOLINE

ENGINES

RM-00002

RM-2

Page 40

asieps_tobira_IM_US.book 3 ページ２０１２年１月１７日　火曜日　午後３時４８分

Recommended Materials

SAE viscosity No. and applicable temperature

Engine oil

RECOMMENDED MATERIALS

(˚C)

(˚F)

(˚C)

10 20 30 40

–30

–22

–20 –10

–4 14 50 6886104

10W-30 or 10W-40

5W-30 Recommend

RM-00059

Manual transmission oil, front differential gear oil and rear differential gear oil

10 20 30 40

–30 –20 –10

–22 –4 14 50 6886104

85W

80W

75W-90

4. FLUID

Use the fluids specified in the table below. Do not mix two different kinds or makes of fluid.

Fluid Recommended materials Alternative Remarks

Automatic transmission fluid SUBARU ATF HP

Power steering fluid SUBARU ATF HP DEXRON III — Brake fluid FMVSS No. 116 DOT3 FMVSS No. 116 DOT4 — Clutch fluid FMVSS No. 116 DOT3 FMVSS No. 116 DOT4 —

IDEMITSU: ATF HP Castrol: Transmax J

RM-00058

—

RM-3

Page 41

asieps_tobira_IM_US.book 4 ページ２０１２年１月１７日　火曜日　午後３時４８分

Recommended Materials

RECOMMENDED MATERIALS

5. COOLANT

Use the coolants specified in the table below to protect the engine.

Coolant Recommended materials Item number Alternative

Coolant SUBARU coolant 000016218

Water for dilution Distilled water — Tap water (Soft water) Cooling system protective agent Cooling system conditioner SOA345001 No

6. REFRIGERANT

Standard air conditioners on Subaru vehicles use HFC134a refrigerant. Do not mix it with other refrigerants. Also, do not use any compressor oil except for DH-PR.

Air conditioner Recommended materials Item number Alternative Refrigerant HFC134a — None Compressor oil DH-PR — None

7. GREASE

Use grease and supplementary lubricants shown in the table below.

Phosphoric acid (non-amine)

type

Grease Application point Recommended materials Item number Alternative

Supplementary lubricants • Oxygen sensor

• Bolts etc.

Grease MT main shaft NICHIMOLY N-130 — —

Clutch master cylinder push rod

•Gear shift lever

•Clutch activating cylinder

•Clutch pedal

•Brake pedal

•Clutch bearing

•Clutch release lever

•Select lever

•Steering shaft bearing

Select lever (lock plate unit)

Steering gearbox VALIANT GREASE M-2 003608001 ONE LUBER SG

Disc brake NIGLUBE RX-2 K0779GA102 — Brake pad Molykote AS-880N K0777YA010 — Front axle PTJ NKG302 28495AE010 — Rear axle EBJ NTG2218-M 28395AG010 — Front axle BJ NTG2218-M 28395AG030 —

• Front axle DOJ (STI model)

•Rear axle EDJ (STI model)

Rear axle DOJ (except for STI model)

•Door latch

•Door striker

Spray type lubricant 004301003 —

SILICONE GREASE G-40M 004404003 —

KOPR-KOTE 003603001 —

Suncall GLO-224 002948040 —

ONE LUBER MO

NKG205 28495AG010 —

NKG205 28495AG000 —

SILICONE GREASE

G-30M

004404002 —

RM-4

Page 42

asieps_tobira_IM_US.book 5 ページ２０１２年１月１７日　火曜日　午後３時４８分

Recommended Materials

8. ADHESIVE

Use the adhesives shown in the table below, or equivalent.

Adhesive Application point Recommended materials Item number Alternative

Adhesive Windshield, rear window

glass, rear quarter glass, rear gate and body

Rearview mirror base REPAIR KIT IN MR 65029FC000 — Soft vinyl CEMEDINE 540 — 3M’s EC-776, EC-847 or

Momentary sealant CEMEDINE 3000 — ARMSTRONG’s Eastman 910

9. SEAL MATERIAL

Use the seal material shown in the table below, or equivalent.

Seal material Application point Recommended materials Item number Alternative

Seal material • Cylinder block

•Torque converter clutch case

•Transmission case

•Transmission oil pan (6MT model)

•Oil pump

• DOHC rocker cover Tr an s m is s ion o i l p a n ( AT mo d e l) T HR E E B O ND 1 2 1 7B K 0 8 77 YA 0 20 —

•Rear differential

•Oil pressure switch

•Rear differential

•Service hole plug Steering adjusting screw THREE BOND 1141 004403006 — Camshaft cap Non-turbo model THREE BOND 1280B K0877YA018 —

Tu r bo m o de l T H REE BON D 1 2 1 5 0 0 44 0 3 0 07 —

•Front sealing cover

•Rear sealing cover Engine oil pan THREE BOND 1207C 004403012 —

•Separator cover

•DOHC semicircular plug

Dow Automotive Adhesive: ESSEX U-400HV or equivalent Glass primer: U-401 and U-402 Painted surface primer: U-413

THREE BOND 1215 004403007 DOW CORNING No. 7038

THREE BOND 1324 004403042 —

THREE BOND 1105 004403010 DOW CORNING No. 7038

3M Butyl Rubber 8626 — —

THREE BOND 1280B K0877YA018 —

RECOMMENDED MATERIALS

— —

EC-1022 (Spray type)

RM-5

Page 43

asieps_tobira_IM_US.book 6 ページ２０１２年１月１７日　火曜日　午後３時４８分

Recommended Materials

RECOMMENDED MATERIALS

RM-6

Page 44

asieps_tobira_IM_US.book 1 ページ２０１２年１月１７日　火曜日　午後３時４８分

PRE-DELIVERY INSPECTION

1. Pre-delivery Inspection ...............................................................................2

Page

Page 45

asieps_tobira_IM_US.book 2 ページ２０１２年１月１７日　火曜日　午後３時４８分

Pre-delivery Inspection

PRE-DELIVERY INSPECTION

1. Pre-delivery Inspection

A: GENERAL DESCRIPTION

The purposes of the pre-delivery inspection (PDI) are as follows.

•Remove the additional parts used for ensuring the vehicle quality during transportation and restore the vehicle to its normal condition.

•Check the vehicle before delivery is in normal condition.

•Check the vehicle or parts for any damage occurred during transportation or storage.

•Check the vehicle after repair is in normal condition.

•Make sure to provide a complete vehicle to customer. For above reasons, all SOAs (dealerships) must carry out the PDIs before delivery of vehicle. Refer to this manual unless otherwise specified.

PI-2

Page 46

asieps_tobira_IM_US.book 3 ページ２０１２年１月１７日　火曜日　午後３時４８分

Pre-delivery Inspection

PRE-DELIVERY INSPECTION

B: PRE-DELIVERY INSPECTION (PDI) PROCEDURE

Perform the procedures indicated in the table below.

Static Checks Just After Vehicle Receipt

Operation Check point

1. Appearance check 1. If the vehicle is covered with protective coating, visually check the vehicle body for

damage and dents. If the protective coating has been removed, visually check the painted body surfaces in detail for damage or rust.

2. Visually check the glass and light lenses for any damage, cracks or excessive gaps between body sheet metal.

3. Visually check the plated parts for any damage.

2. Tire check 1. Check the tires for damage, defective, and dents on wheels.

2. Check the tire air pressure.

3. Fuse installation If the vehicle is about to be delivered to customer, attach the room lamp fuse.

4. Air conditioner harness connection If the vehicle is about to be delivered to the customer, connect the air conditioner harness.

5. Lock/unlock and open/close operation checks of doors

6. Operation check of child safety lock system

7. Open/close operation checks of trunk lid

8. Check the rear gate for lock/unlock and open/close operations.

9. Operation check of trunk lid release lever

10. Operation check of fuel lid opener lock release lever

11. Accessory check Check that the following accessories are equipped.

12. Operation check of front hood lock release system

13. Battery Check the battery for any abnormal conditions such as rust or traces of battery fluid leaks.

14. Brake fluid Check the fluid level.

15. Engine oil Check the engine oil level.

16. Transmission fluid Check the fluid level.

17. AT front differential oil Check the AT front differential oil amount.

18. Engine coolant Check the engine coolant level.

19. Clutch fluid Check the clutch fluid amount.

20. Window washer fluid Check the window washer fluid amount.

21. Front hood latch check Check that the hood closes properly and that it can be locked securely.

22. Keyless entry system Check that the keyless entry system operates normally.

23. Security system Check that the security system operates normally.

24. Seat 1. Check the seat surfaces for stains or dirt.

25. Seat belt Check the seat belt installation conditions and functionality.

1. Using the key, check the trunk lid can be locked or unlocked normally.

2. Open and close all doors to check that there are no problems.

3. Operate the power door lock switch to check that the rear gate locks and unlocks normally.

Check the child safety lock system operates normally.

1. Using the key, check that the trunk lid can be locked or unlocked normally.

2. Operate the trunk lock release lever to check that the trunk lid opens normally.

3. Use the valet key to check that the lock cannot be released.

4. Open and close the trunk lid to check that there are no problems.

1. Check if the rear gate can be unlocked normally through the emergency hole.

2. Open and close the rear gate to check that there are no problems. Operate the trunk lid release lever to check that the trunk lock is unlocked normally.

Operate the fuel lid opener to check that the fuel filler lid can be unlocked normally.

• Owner’s manual

•Warranty booklet

•Maintenance note

•Spare key

• Key No. plate

•Jack

•Tool set

•Spare tire Operate the front hood lock release lever to check that the front hood opens normally.

2. Check the seat installation conditions and functionality.

PI-3

Page 47

asieps_tobira_IM_US.book 4 ページ２０１２年１月１７日　火曜日　午後３時４８分

Pre-delivery Inspection

PRE-DELIVERY INSPECTION

Checks with the Engine Running

Operation Check point

26. Test mode connector Test mode connector

27. Immobilizer system 1. Check that the engine starts with all keys that are equipped on vehicle.

2. 60 seconds after turning ignition switch from ON to ACC or OFF, or immediately after removing the key, check that the security indicator light is blinking.

28. Starting condition Start the engine and check that the engine starts smoothly.

29. Exhaust system Check that the exhaust noise is normal and no leaks are found.

30. Indicator and warning lights Check that all indicator lights and warning lights are operating correctly.

31. Heater & ventilation Check that the heater & ventilation system operates normally.

32. Air conditioner Check that the air conditioner operates normally.

33. Clock Check that the clock operates normally.

34. Radio Check the radio and AUX for proper operation.

35. Front accessory power supply socket

36. Lighting system Check that the lighting system operates normally.

37. Window washer Check that the window washer system operates normally.

38. Wiper Check that the wiper system operates normally.

39. Power window operation check Check that the power window operations normally.

40. Driver’s control center differential Check that the indicator light operations normally.

Check that the front accessory power socket operates normally.

Dynamic Test with the Vehicle Running

Operation Check point

41. Brake test Check the foot brake for normal operations.

42. Parking brake Check the parking brake for normal operations.

43. AT shift control Check that the AT shift patterns are correct.

44. Cruise control Check that the cruise control system operates normally.

Checks after Dynamic Test

Operation Check point

45. ATF level Check that the ATF level is correct.

46. Power steering fluid level Check that the power steering fluid level is normal.

47. Fluid leak check Check for fluid/oil leaks.

48. Water leak inspection Spray the vehicle with water and check for water leaks.

49. Appearance check 2 1. Remove the protective coating (if equipped).

2. Check the body paints for damage and stain.

3. Check the plated parts for damage and rust.

PI-4

Page 48

asieps_tobira_IM_US.book 5 ページ２０１２年１月１７日　火曜日　午後３時４８分

Pre-delivery Inspection

PRE-DELIVERY INSPECTION

1. APPEARANCE CHECK

•If the vehicle is covered with protective coating, visually check the vehicle body for damage and dents.

•If there is no protective coat, check the painted surface of the vehicle body for damage or rust, and repair as necessary.

•Check the window glass, door glass, and lights for any cracks or damage, and replace as necessary.

•Visually check the plated parts, such as the grilles and door knobs, for damage or loss of gloss and replace the parts as necessary.

2. TIRE CHECK

•Check for damage on the outside surface of the tires.

•Refer to the following table and inspect the tire air pressure.

Tire inflation pressure

Tire size

P205/55R16 230 (2.3, 33) 210 (2.1, 30) 215/45R17 230 (2.3, 33) 220 (2.2, 32) 225/45R17 240 (2.4, 35) 200 (2.0, 29)

kPa (kgf/cm2, psi)

Front Rear

3. FUSE INSTALLATION

Fuses for the room light circuit on initially delivered vehicles are removed to prevent battery discharge. Attach the 20 A fuse (A) as shown in the figure.

5. LOCK/UNLOCK AND OPEN/CLOSE OPERATION CHECKS OF DOORS

1) Using the key, lock and unlock the door several times to check for normal operation. Open and close the door several times for smooth movement.

(A)

(B)

PI-00153

(A) Unlock (B) Lock

2) Close the door of driver seat completely, and place the door lock knob (A) to the lock position. Then pull the inner remote (B) to ensure that doors will not open. For other doors, place the door lock knob (A) to lock position and then pull the inner remote (B) to ensure that doors will not open.

(A)

PI-00316

4. AIR CONDITIONER HARNESS CONNECTION

Disconnect the air conditioner harness immediately after vehicle delivery to protect the air conditioner compressor. Connect the harness as shown in the figure.

PI-00139

(B)

PI-00004

(A) Door lock knob (B) Inner remote

PI-5

Page 49

asieps_tobira_IM_US.book 6 ページ２０１２年１月１７日　火曜日　午後３時４８分

Pre-delivery Inspection

PRE-DELIVERY INSPECTION

3) Close all doors, and press the lock side of power door lock switch (A) on the driver’s side and passenger side. Check that all doors including rear gate are locked.

• Driver’s side

(A)

PI-00359

•Passenger’s side

(A)

6. CHECK THE OPERATION OF CHILD SAFETY LOCK SYSTEM

1) Set the child safety lock on both rear doors to the lock position.

2) Close the rear doors completely.

3) Check that the lock levers of the rear doors are in the unlock position. Then, pull inner remote of rear doors to ensure that doors will not open.

4) Pull the outer handles to ensure that doors will open.

(A)

(B)

PI-00157

(A) Unlock (B) Lock

PI-00360

4) Press the unlock side of the power door lock switch on the driver and passenger sides. Check that all doors including rear gate are unlocked.

• Driver’s side

PI-00243

•Passenger’s side

7. OPEN/CLOSE OPERATION CHECKS OF TRUNK LID

1) Operate the trunk lock release lever to check that the trunk lid opens.

2) Using the key, unlock the door several times to check for normal operation.

3) Open and close the trunk lid several times for smooth movement.

PI-00144

4) Use the valet key to make sure that the trunk lid and glove box cannot be opened.

PI-00156

PI-6

Page 50

asieps_tobira_IM_US.book 7 ページ２０１２年１月１７日　火曜日　午後３時４８分

Pre-delivery Inspection

PRE-DELIVERY INSPECTION

5) Set the trunk lid release lever to the cancel position, and check that the trunk lid can only be opened with the key.

PI-00149

8. CHECK THE REAR GATE FOR LOCK/ UNLOCK AND OPEN/CLOSE OPERATIONS

1) Open and close the rear gate several times for smooth movement.

2) Operate the rear gate emergency release lever to check that the rear gate can be locked and unlocked properly.

(1) Remove the cover inside the rear gate.

9. OPERATION CHECK OF TRUNK LID RELEASE HANDLE

1) Use a flat tip screwdriver. Slide the screwdriver blade from the slit aperture of the lock assembly fully to the end until you hear a click. This places the latch in the locked position.

PI-00147

(2) Operate the lever to check that the rear gate is locked and unlocked normally.

PI-00148

PI-00092

2) Move the release handle from outside the vehicle in the direction of the arrow to check if the latch is released.

PI-7

PI-00093

Page 51

asieps_tobira_IM_US.book 8 ページ２０１２年１月１７日　火曜日　午後３時４８分

Pre-delivery Inspection

PRE-DELIVERY INSPECTION

10.OPERATION CHECK OF FUEL LID OPENER LOCK RELEASE LEVER

Operate the fuel lid opener to check that the fuel lid is unlocked normally. Check that the filler cap is securely closed.

11.ACCESSORY CHECK

Check that the following accessories are provided.

•Owner’s manual

•Warranty booklet

•Maintenance note

•Spare key

•Jack

•Tool set

•Spare tire

(A)

(B)

(A)

PI-00145

Operate the lever (A) and check that the front hood is opened normally. Support the front hood with hood stay.

(A)

PI-00311

13.BATTERY

Check the battery terminals to make sure that there are no rust or corrosions due to fluid leaks. Check that the battery caps are securely tightened.

(B)

(A) Jack (B) Jack handle

PI-00146

12.OPERATION CHECK OF FRONT HOOD LOCK RELEASE SYSTEM

Operate the front hood release knob to check that the front hood will unlock properly.

PI-00071

(A)

(B)

(C)

PI-00012

(A) Cap (B) Upper level

14.BRAKE FLUID

Check the brake fluid amount. If the amount is insufficient, carry out a brake line test to identify brake fluid leaks and check the brake operation. After that, refill the brake fluid tank with the specified type of fluid.

PI-8

Page 52

asieps_tobira_IM_US.book 9 ページ２０１２年１月１７日　火曜日　午後３時４８分

Pre-delivery Inspection

PRE-DELIVERY INSPECTION

15.ENGINE OIL

Check the engine oil amount. If the amount of oil is insufficient, check that no leaks are found. Then, add the necessary amount of the specified engine oil.

(A)

(A) Oil level gauge (B) Engine oil filler cap (C) Upper level (D) Lower level (E) Approx. 1.0 2 (1.1 US qt, 0.9 Imp qt) (F) Notch mark

(B)

(F)

(C)

(E)

(D)

PM-00362

16.TRANSMISSION FLUID

Check the amount of transmission fluid. If the amount of fluid is insufficient, check for leaks. Then, add the necessary amount of specified fluid.

(A)

17.AT FRONT DIFFERENTIAL OIL

Check the AT front differential oil amount. If the amount of oil is insufficient, check for leaks. Then, add the necessary amount of the specified AT front differential oil.

(A)

(B)

(C)

(A) Oil level gauge (B) Upper level

(A)

PI-00183

18.ENGINE COOLANT

Check the coolant amount on the reservoir. If the amount of engine coolant is insufficient, check that no leaks are found. Then, add the necessary amount of coolant with the specified concentration.

19.CLUTCH FLUID

Check the clutch fluid amount. If the amount of fluid is insufficient, check that no leaks are found. Then, add the necessary amount of specified fluid.

(A) Oil level gauge (B) Upper level (C) Lower level

(B) (C)

PM-00030

(A)

(C)

(B)

PM-00076

(A) Reservoir tank (B) MIN. level

20.WINDOW WASHER FLUID

Check the window washer fluid amount. If the amount is insufficient, check that no leaks are found. Then, add the necessary amount of washer fluid.

21.FRONT HOOD LATCH CHECK

Retract the front hood stay and close the front hood. Check that the front hood is completely latched.

PI-9

Page 53

asieps_tobira_IM_US.book 10 ページ２０１２年１月１７日　火曜日　午後３時４８分

Pre-delivery Inspection

PRE-DELIVERY INSPECTION

22.KEYLESS ENTRY SYSTEM

Check the keyless entry system operations as follows:

•Fully open all the door windows.

•Remove the key from the ignition switch and close all the doors including rear gate.

•Press the “LOCK/ARM” button momentarily on the keyless transmitter. Check that all the doors become locked, the buzzer sounds once, and the hazard lights flash once.

PI-00357

•Press the “UNLOCK/DISARM” button momentarily on the keyless transmitter. Check that the driver’s door is unlocked, the buzzer sounds twice, and the hazard lights flash twice.

•With one of the doors open (including the rear gate), press the “LOCK” side (A) of the power door lock switch. Next, close all the doors including rear gate. Check if all the doors are locked and buzzer sounds once and the hazard light flashes once.

•Driver’s side

(A)

PI-00359

•Passenger’s side

(A)

PI-00358

•Within 5 seconds, press the “UNLOCK/DISARM” button momentarily on the keyless transmitter. Check that all the doors including rear gate are unlocked.

•Hold down the “LOCK/ARM” button on the keyless transmitter for approximately two seconds. Check that the panic mode (the horn keeps sounding) is initiated. Also, check that this condition continues for 30 seconds or until when any of the buttons on the keyless transmitter are pressed.

•Press the “LOCK/ARM” button momentarily on the keyless transmitter with one of the doors (including the rear gate) opened. Check that the buzzer sounds 5 times, and the hazard lamp flashes 5 times to notify the door not being fully closed. Next, close all the doors including rear gate. Check if all the doors are locked and buzzer sounds once and the hazard light flashes once.

PI-00360

Alarm sound operational check

•The system uses the buzzer and sounds the alarm when the door is locked or unlocked. The alarm sound can be turned OFF. To turn the alarm sound from ON to OFF, close all doors, (with the key not inserted in the key cylinder), hold down the “UNLOCK” side of the power door lock switch and insert the key in the key cylinder. Within 10 seconds, insert and take out the key for 5 times or more, and within 10 seconds after that, open and close the door. With the door closed, the hazard light will flash 3 times, indicating that the alarm sound has been turned OFF. To turn the alarm sound from OFF to ON, perform this procedure again. The hazard lamp will flash 3 times, indicating that the alarm has been turned ON.

PI-10

Page 54

asieps_tobira_IM_US.book 11 ページ２０１２年１月１７日　火曜日　午後３時４８分

Pre-delivery Inspection

PRE-DELIVERY INSPECTION

23.SECURITY SYSTEM

Check that the security system operates as indicated below.

1) Fully open all the door windows.

2) Remove the key from the ignition switch and close all the doors including rear gate.

3) Press the “LOCK/ARM” button on the keyless transmitter once.

PI-00357

4) If all doors lock, buzzer sounds once, the hazard light flashes once, and the security display light flashes as indicated below, the alarm system is in the monitoring condition.

5) Check that the system enters monitoring condition 30 seconds after the condition in 4).

•Alarm system monitoring condition (all models)

(A)

(B)

(C)

PI-00265

(A) Light ON (B) Light OFF

6) Press the “UNLOCK/DISARM” button on the keyless transmitter once.

PI-00264

•Alarm system monitoring prepared condition

(A)

(B)

(C)

PI-00315

(A) Light ON (B) Light OFF (C) 2 seconds

PI-00358

7) The alarm system is in the non-monitoring conditions if the driver’s side door is unlocked, the buzzer sounds twice, the hazard light flashes twice, the room light turns on, and the security display light turns off.

NOTE: On models without the immobilizer feature, the security display light does not flash after the “UNLOCK/DISARM” of the keyless transmitter is pressed.

PI-00264

PI-11

Page 55

asieps_tobira_IM_US.book 12 ページ２０１２年１月１７日　火曜日　午後３時４８分

Pre-delivery Inspection

PRE-DELIVERY INSPECTION

•Alarm system non-monitoring condition (models with immobilizer)

(A)

(B)

(C)

PI-00266

(A) Light ON (B) Light OFF (C) 3 seconds

8) Press the “LOCK/ARM” button once on the keyless transmitter with one of the doors (including the rear gate) opened.

12) Check that the system enters monitoring condition 30 seconds after the condition in 11).

(A)

(B)

(C)

PI-00265

(A) Light ON (B) Light OFF

13) With one of the all doors open (including the rear gate), press the “LOCK” side (A) of the power door lock switch.

•Driver’s side

(A)

PI-00357

9) Check that the buzzer sounds 5 times to give the door not fully closed warning.

10) Close all the doors including rear gate.

11) Check that the system is in the monitoring condition (all the doors become locked and the buzzer sounds once, and the hazard light flashes once).

•Alarm system monitoring prepared condition

(A)

(B)

(C)

PI-00315

(A) Light ON (B) Light OFF (C) 2 seconds

PI-00359

•Passenger’s side

(A)

PI-00360

14) Close all the doors including rear gate.

PI-12

Page 56

asieps_tobira_IM_US.book 13 ページ２０１２年１月１７日　火曜日　午後３時４８分

Pre-delivery Inspection

PRE-DELIVERY INSPECTION

15) If all doors become locked, the buzzer sounds once, and the hazard light flashes once, the alarm system is in the monitoring prepared condition.

•Alarm system monitoring prepared condition

(A)

(B)

(C)

PI-00315

(A) Light ON (B) Light OFF (C) 2 seconds

16) Check that the system enters monitoring condition 30 seconds after the condition in 15).

24.SEAT

1) Check that each seat provides full functionality in sliding and reclining. Check all available functions of the rear seat such as a trunk-through center armrest.

2) Check the passenger’s seat occupant detection system.

(1) Turn the ignition switch to ON. (2) Check that the passenger airbag ON/OFF indicator lights both turn on simultaneously for approximately six seconds, and after turning off for two seconds, only the OFF light illuminates.

(A)

(B)

PI-00325

(A) Airbag ON/OFF indicator light (U.S. model) (B) Airbag ON/OFF indicator light (Canada model)

(A)

(B)

(C)

PI-00265

(A) Light ON (B) Light OFF (C) 2 seconds

17) When the alarm system is in the monitoring condition, use the inner lock knob or the key to unlock the door, and open the door.

18) Check that the alarm condition occurs (horn sounds continuously, hazard light flashes, security indicator illuminates).

19) Check that the condition in 18) continues for 30 seconds or more, or until the “UNLOCK/DISARM” button of the keyless transmitter is pressed.

20) Check that in the monitoring condition, even if the ignition key is turned to the “START” position, the starter motor does not turn, and that the engine does not start.

21) On models equipped with an impact sensor, hit the front glass with your hand with the alarm system in the monitoring condition, to check that the alarm condition occurs.

22) When none of above is applicable, perform troubleshooting for the security system. <Ref. to SL-22, INSPECTION, Security System.>

3) With a person weighing approximately 70 kg (155 lb) or more sitting in the passenger’s seat, check whether the ON light of the passenger’s airbag ON/OFF indicator illuminates or not.

4) Have the passenger get out of the passenger’s seat, and check whether the OFF light of the passenger side airbag ON/OFF indicator illuminates.

25.SEAT BELT

1) Pull out the seat belt and then release it. Check that the belt retracts smoothly.

2) Check that the ALR seat belt operates properly.

26.TEST MODE CONNECTOR

Turn the ignition switch to ON and check that the malfunction indicator light starts blinking. If the light blinks, return the ignition key to LOCK and disconnect the test mode connector. Then, turn the ignition key to ON again. If the malfunction indicator light blinks at that time in spite of the disconnected test mode connector, carry out an engine diagnosis.

(A)

PI-00261

(A) Test mode connector (green)

PI-13

Page 57

asieps_tobira_IM_US.book 14 ページ２０１２年１月１７日　火曜日　午後３時４８分

Pre-delivery Inspection

PRE-DELIVERY INSPECTION

27.IMMOBILIZER SYSTEM

1) Check that the engine starts with all keys that are equipped on vehicle.

2) 60 seconds after turning ignition switch from ON to ACC or OFF, or immediately after removing the key, check that the security indicator light is blinking.

28.STARTING CONDITION

Start the engine and check that the engine starts smoothly. If the battery voltage is low, recharge or replace the battery. If any noises are observed, immediately stop the engine and check and repair the abnormal components.

29.EXHAUST SYSTEM

Listen to the exhaust noise to see if no noises are observed.

30.INDICATOR AND WARNING LIGHTS

Check that all indicator lights and warning lights are operating correctly.

31.HEATER & VENTILATION

Operate the heater & ventilation system to check for normal airflow outlet control, air inlet control, airflow capacity and heating performance.

32.AIR CONDITIONER

Operate the air conditioner. Check that the A/C compressor operates normally and enough cooling is provided.

NOTE: To prevent the insufficient lubrication of air conditioner, operate the air conditioner for 5 minutes at idling.

33.CLOCK

Check the clock for normal operations and enough accuracy.

34.RADIO

Check the radio for full functionality and normal noise level. Check the CD unit and AUX operations.

35.FRONT ACCESSORY POWER SUPPLY SOCKET

Check the operation of the front accessory power socket.

36.LIGHTING SYSTEM

1) Check the headlight operations.

2) Check the stop light operation.

3) Check other lights for normal operations.

37.WINDOW WASHER

Check that the window washer system injects washer fluid to the specified area of the windshield shown in the figure.

Front spray position:

A: 257 mm (10.12 in) B: 512 mm (20.16 in)

(1)

(1) Nozzle

PI-00133

Rear spray position:

A: 39 mm (1.53 in) B: 72°

PI-00104

38.WIPER

Check the front and rear wipers for normal operations.

39.POWER WINDOW OPERATION CHECK

Operate the power window switches one by one to check that each of the power windows goes up and down without noises.

40.DRIVER’S CONTROL CENTER DIFFERENTIAL

Check that the indicator light operations normally.

41.BRAKE TEST

Check the foot brake for normal operations.

42.PARKING BRAKE

Check the parking brake for normal operations. When pulling the parking brake lever with a force of 196 N (20 kgf, 44 lb), check that the lever stroke of parking brake lever is 7 to 8 notches.

PI-14

Page 58

asieps_tobira_IM_US.book 15 ページ２０１２年１月１７日　火曜日　午後３時４８分

Pre-delivery Inspection

PRE-DELIVERY INSPECTION

43.AT SHIFT CONTROL

1) Turn the ignition switch to ON.

2) While brake pedal is not depressed, check if the select lever does not move from “P” range.

3) While brake pedal is depressed, check if the select lever moves from “P” range.

4) Set the select lever to except for “P” range.

5) When the ignition switch is turned to OFF, check if the ignition key switch cannot be removed.

6) Set the AT selector lever to each gear position and check the shifting while driving the vehicle.

R N

D 3 2 1

Selector position

DOKOKOKOK

3 OK OK OK — 2 — OK — — 1OK — — —

1st 2nd 3rd 4th

Gear position

PI-00077

44.CRUISE CONTROL

Operate the cruise control system. Check that the system is activated and deactivated correctly.

45.ATF LEVEL

After selecting all positions (P, R, N, D, 3, 2, 1), set the select lever in “P” range. Idle the engine for 1 — 2 minutes, and measure the ATF level. If the amount is insufficient, check that no leaks are found. Then, add the necessary amount of the specified ATF.

(A)

(C)

(D)

(E)

(A) Level gauge (B) Inspection position when “HOT”

70 — 80°C (158 — 176°F) (C) Upper level (D) Lower level (E) Inspection position when “COLD”

[20 — 30°C (68 — 86°F)

(B)

HOT

(C)

COLD

(D)

PI-00105

46.POWER STEERING FLUID LEVEL

Check that the power steering fluid level is normal. If insufficient, check for leaks. Then add the necessary amount of the specified power steering fluid.

(A)

(C)

(B)

PM-00335

(A) Reservoir tank (B) MIN. level

47.FLUID LEAK CHECK

Check entire areas of the vehicle for any trace of coolant/oil/fluid leaks.

48.WATER LEAK TEST

Spray the vehicle with water using a hose and check that no water enters the passenger compartment.

•Before performing the water leakage test, remove anything that may obstruct the operation or which must be kept dry.

•Close all the windows and doors securely. Close the front hood, trunk lid and rear gate before starting the test.

•Connect a hose to a tap, and spray water on the vehicle. The rate of water spray must be approx. 20 to 25 2 (5.3 — 6.6 US gal, 4.4 — 5.5 Imp gal) per minute. When spraying water on areas adjacent to the floor and wheel house, increase the pressure. When spraying water on areas other than the floor and wheel house, decrease the pressure. But the force of water must be made strong occasionally by pressing the end of the hose.

NOTE: Be sure to keep the hose at least 10 cm (3.9 in) away from vehicle. Check the following areas.

•Front window and body framework mating portion

•Door mating portions

•Glass mating portions

•Rear quarter window mating portions

•Rear window and body framework mating portion

•Around roof drips If any dampness in the compartments is discovered after the water has been applied, carefully check all the areas that may have possibly contributed to the leak.

PI-15

Page 59

asieps_tobira_IM_US.book 16 ページ２０１２年１月１７日　火曜日　午後３時４８分

Pre-delivery Inspection

PRE-DELIVERY INSPECTION

49.APPEARANCE CHECK 2

1) If protective coating (lap guard) is applied, remove it.

NOTE:

•When removing the lap guard, using steam will make it easier to remove.

•Vehicle left for a extended periods or at low temperatures, spray the vehicle with water heated 50 — 60°C (122 — 140°F) to raise the surface temperature before peeling off the wrap guard. Do not use the water heated to over 60°C (140°F).

•If the adhesive remains exist on the coated surface, soak a flannel rag, etc. with a small amount of coating wax or solvent such as oil benzene and IPA, put the soaked cloth on the remains lightly, and then wipe them off with a flannel rag etc.

•Keep solvent from touching the resin or rubber parts. Do not use coating wax or solvents while the component surface temperature is hot due to hot weather etc.

•If the coated surface is swollen out due to seams or moisture, expose the vehicle to the sunlight for a few hours or heat the seam and swollen portions using a dryer etc.

•Dispose of the peeled wrap guard as burnable industrial garbage.

2) Check the whole vehicle body for flaking paint, damage by transportation, corrosion, dirt, cracks or blisters.

NOTE:

•It is better to determine an inspection pattern in order to avoid missing an area, since the total inspection area is wide.

•Do not repair the body paint unless absolutely necessary. Also, if the vehicle is in need of repair to remove scratches or corroded paint, the repair area must be limited to the minimum. Re-painting and spray painting must be avoided as much as possible.

3) Check each window glass for scratches carefully. Slight damage may be removed by polishing with cerium oxide. (Fill a cup half with cerium oxide, and add warm water to it. Then agitate the content until it turns to wax. Apply this wax to a soft cloth, and polish the glass with it.)

4) Check each portion of the vehicle body and underside components for the formation of rust. If rust is discovered, remove it with sandpaper of #80 to #180 and treat the surface with rust preventive. After this treatment is completed, flush the portion thoroughly, and prepare the surface for repair painting.

5) Check each portion of body and all of the chrome parts for deformation or distortion. Also, check each light lens for cracks.

PI-16

Page 60

asieps_tobira_IM_US.book 1 ページ２０１２年１月１７日　火曜日　午後３時４８分

PERIODIC MAINTENANCE SERVICES

1. General Description ...................................................................................2

2. Schedule ....................................................................................................3

3. Engine Oil ...................................................................................................6

4. Engine Oil Filter ..........................................................................................8

5. Spark Plug ..................................................................................................9

6. V-belt ........................................................................................................10

7. Timing Belt ...............................................................................................12

8. Fuel Line ..................................................................................................15

9. Fuel Filter .................................................................................................16

10. Air Cleaner Element .................................................................................17

11. Cooling System ........................................................................................18

12. Engine Coolant .........................................................................................20

13. Clutch System ..........................................................................................22

14. Transmission Gear Oil .............................................................................23

15. ATF ..........................................................................................................24

16. Front & Rear Differential Gear Oil ............................................................26

17. Brake Line ................................................................................................28

18. Brake Fluid ...............................................................................................30

19. Disc Brake Pad and Disc .........................................................................31

20. Parking Brake ...........................................................................................32

21. Suspension ..............................................................................................33

22. Wheel Bearing ..........................................................................................35

23. Axle Boots & Joints ..................................................................................36

24. Tire Rotation .............................................................................................37

25. Steering System (Power Steering) ...........................................................38

Page

Page 61

asieps_tobira_IM_US.book 2 ページ２０１２年１月１７日　火曜日　午後３時４８分

General Description

COOLING

1. General Description

A: SPECIFICATION

Cooling system Electric fan + Forced engine coolant circulation system

To t al e n gi n e cool an t c ap a c i ty 2 (US qt, Imp qt)

Type Centrifugal impeller type

Discharge rate 20 2 (5.3 US gal, 4.4 Imp gal)/min. Pump speed — Discharge pressure 760 rpm — 2.9 kPa (0.3 mAq) Engine coolant temperature 80°C (176°F) Discharge rate 100 2 (26.4 US gal, 22.0 Imp gal)/min. Pump speed — Discharge pressure 3,000 rpm — 49.0 kPa (5.0 mAq) Engine coolant temperature 80°C (176°F) Discharge rate 200 2 (52.8 US gal, 44.0 Imp gal)/min. Pump speed — Discharge pressure 6,000 rpm — 225.4 kPa (23.0 mAq) Engine coolant temperature 80°C (176°F)

Standard 0.5 — 1.5 mm (0.020 — 0.060 in)

Main fan 120 W Sub fan 120 W

Water pump

Thermostat

Radiator fan

Radiator

Reservoir tank

Discharge performance I

Discharge performance II

Discharge performance III

Impeller diameter 76 mm (2.99 in) Number of impeller vanes 8 Pump pulley diameter 60 mm (2.36 in) Clearance between

impeller and case Type Wax pellet type Starts to open 80 — 84°C (176 — 183°F) Fully opens 95°C (203°F) Val ve l ift 9. 0 mm (0.3 54 in ) or more Val ve b ore 35 mm (1.38 in )

Motor input

Fan diameter / Blade

Type Down flow

Core dimensions Width × Height × Thickness

Pressure range in which cap valve is open

Fins Corrugated fin type

Capacity 0.5 2 (0.5 US qt, 0.4 Imp qt)

AT model: approx. 6.9 (7.3, 6.1)

MT model: approx. 7.0 (7.4, 6.2)

320 mm (12.60 in) /5 (main fan)

320 mm (12.60 in) / 7 (sub fan)

691.5 × 340 × 16 mm

(27.22 × 13.39 × 0.63 in)

Above: 108±15 kPa

(1.1±0.15 kgf/cm

Below: –1.0 — –4.9 kPa

(–0.01 — –0.05 kg/cm2, –0.1 — –0.7 psi)

, 16±2 psi)

Coolant Recommended materials Item number Alternative Coolant SUBARU coolant 000016218 Phosphoric acid (non-amine) type Water for dilution Distilled water — Soft water or tap water Cooling system protective agent Cooling system conditioner SOA345001 None

CO(H4SO)-2

Page 62

asieps_tobira_IM_US.book 3 ページ２０１２年１月１７日　火曜日　午後３時４８分

General Description

B: COMPONENT

1. WATER PUMP

(2)

(1)

COOLING

(3)

(4)

(6)

(1) Water pump ASSY (4) Thermostat Tightening torque:N·m (kgf-m, ft-lb) (2) Gasket (5) Gasket T1: First 12 (1.2, 8.7) (3) Heater by-pass hose (6) Thermostat cover

(5)

CO-00265

Second 12 (1.2, 8.7)

T2: 12 (1.2, 8.7)

CO(H4SO)-3

Page 63

asieps_tobira_IM_US.book 4 ページ２０１２年１月１７日　火曜日　午後３時４８分

General Description

COOLING

2. RADIATOR AND RADIATOR FAN

(6)

(5)

(10)

(8)

(12)

(7)

(4)

(24)

(3)

(5)

(23)

(1)

(25)

(2)

(11)

(5)

(16)

(14)

(20)

(21)

(16)

(15)

(13)

(16)

(18)

(9)

(17)

(16)

(19)

(22)

CO-02325

(1) Radiator lower cushion (12) Radiator sub fan motor (23) Radiator lower bracket (2) Radiator (13) Radiator main fan shroud (24) Radiator drain plug (3) Radiator upper cushion (14) Radiator main fan (25) Radiator cap (4) Radiator upper bracket (15) Radiator main fan motor (5) Clamp (16) ATF hose clamp (AT model) Tightening torque:N·m (kgf-m, ft-lb) (6) Radiator inlet hose (17) ATF hose A (AT model) T1: 4.4 (0.45, 3.3) (7) Engine coolant reservoir tank cap (18) ATF hose B (AT model) T2: 12 (1.2, 8.7) (8) Over flow hose (19) ATF pipe (AT model) T3: 18 (1.8, 13.0)

(9) Engine coolant reservoir tank (20) ATF hose C (AT model) T4: 3.4 (0.35, 2.5) (10) Radiator sub fan shroud (21) ATF hose D (AT model) T5: 4.9 (0.50, 3.6) (11) Radiator sub fan (22) Radiator outlet hose

CO(H4SO)-4

Page 64

asieps_tobira_IM_US.book 5 ページ２０１２年１月１７日　火曜日　午後３時４８分

General Description

C: CAUTION

•Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work.

•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.

•Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts.

•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 connectors of sensors or units, be sure to disconnect the ground cable from the battery.

COOLING

D: PREPARATION TOOL

1. SPECIAL TOOL

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

499977100 CRANK PULLEY

ST-499977100

18231AA010 CAM SPROCKET

WRENCH

Used for stopping the rotation of crank shaft pulley when removing and tightening the crank pulley bolt.

•Used for removing and installing cam sprocket.

•CAM SPROCKET WRENCH (499207100) can also be used.

ST18231AA010

CO(H4SO)-5

Page 65

asieps_tobira_IM_US.book 6 ページ２０１２年１月１７日　火曜日　午後３時４８分

Radiator Main Fan System

COOLING

2. Radiator Main Fan System

A: WIRING DIAGRAM

SBF-1 SBF-4

A/C RELAY HOLDER

20A

MAIN FAN RELAY 1

MAIN FAN RELAY 2

MAIN FAN MOTOR

F27

F17

IGNITION SWITCH

No.18

31 34 32 30

28 25 27 29

F45

B62

No.17

A/C RELAY HOLDER

5 7 9

21 24 22 20

F27

SUB FAN MOTER

F16

20A

SUB FAN RELAY 1

SUB FAN RELAY 2

F16

F17

12 34

F45

3412 89

12 13 14 15 16 17 18 19 20 21 22 23 24

567

10 11

B136

1 2 3 4

987

17 18 19 202821 22 23

CO(H4SO)-6

3231

5 6

2524 33 34 35

18 29

F27

5 6

1610 11 12 13 14 15 2726

1 2

3 4

10 11

13 14

17 18 19

20 21

222324

B136

ECM

26 28 29

32 33 34

CO-02326

Page 66

asieps_tobira_IM_US.book 7 ページ２０１２年１月１７日　火曜日　午後３時４８分

Radiator Main Fan System

B: INSPECTION

DETECTING CONDITION:

•Engine coolant temperature is 96°C (205°F) or more.

•A/C compressor is rotating.

•Vehicle speed is 19 km/h (12 MPH) or less.

TROUBLE SYMPTOMS:

•Radiator main fan does not rotate under the above conditions.

•Radiator main fan does not rotate at high speed when the following conditions are met at the same time.

1. Engine coolant temperature is 90°C (194°F) or more.

2. A/C is ON.

Step Check Yes No

1CHECK RADIATOR OPERATION.

1) Warm-up the engine. (When vehicle is parked)

2) Turn the A/C switch to OFF.

3) Raise the engine coolant temperature to 96°C (205°F) or above.

2CHECK RADIATOR OPERATION.

Tu r n th e A /C sw i tc h t o O N u nder t h e co n diti o n of step 1.

3CHECK POWER SUPPLY TO MAIN FAN MO-

TOR. CAUTION:

Be careful not to overheat the engine during repair.

1) Turn the ignition switch to OFF.

2) Disconnect the connector from the main fan motor.

3) Start and warm up the engine until engine coolant temperature raises to 96°C (205°F) or above.

4) Stop the engine, and turn the ignition switch to ON.

5) Measure the voltage between main fan motor connector and chassis ground.

Connector & terminal

(F17) No. 1 (+) — Chassis ground (–):

4CHECK GROUND CIRCUIT OF MAIN FAN

MOTOR.

1) Turn the ignition switch to OFF.

2) Measure the resistance between main fan motor connector and chassis ground.

Connector & terminal

(F17) No. 3 — Chassis ground: (F17) No. 4 — Chassis ground:

5CHECK POOR CONTACT.

Check poor contact of main fan motor connector.

6CHECK MAIN FAN MOTOR.

Connect the battery positive (+) terminal to terminal No. 1, and the ground (–) terminal to terminal No. 3 or 4 of the main fan motor connector.

Does the radiator main fan rotate?

Does the radiator main fan rotate at high speed when the A/C compressor is operating?

Is the voltage 10 V or more? Go to step 4.Go to step 7.

Is the resistance less than 5 Ω?Go to step 5.Repair the open

Is there poor contact in the main fan motor connector?

Does the main fan rotate? Repair the poor

Go to step 2.Go to step 3.

Radiator main fan system is normal.

Repair the poor contact of main fan motor connector.

contact of main fan motor connector.

Go to step 17.

circuit of the harness between main fan motor connector and chassis ground.

Go to step 6.

Replace the main fan motor with a new part.

COOLING

CO(H4SO)-7

Page 67

asieps_tobira_IM_US.book 8 ページ２０１２年１月１７日　火曜日　午後３時４８分

Radiator Main Fan System

COOLING

Step Check Yes No

7CHECK POWER SUPPLY TO MAIN FAN RE-

LAY 1.

1) Turn the ignition switch to OFF.

2) Remove the main fan relay 1 from A/C relay holder.

3) Measure the voltage between main fan relay 1 terminal and chassis ground.

Connector & terminal

(F27) No. 31 (+) — Chassis ground (–):

8CHECK POWER SUPPLY TO MAIN FAN RE-

LAY 1.

1) Turn the ignition switch to ON.

2) Measure the voltage between main fan relay 1 terminal and chassis ground.

Connector & terminal

(F27) No. 34 (+) — Chassis ground (–):

9CHECK 20 A FUSE.

1) Remove the 20 A fuse from the A/C relay holder.

2) Check the condition of fuse.

10 CHECK POWER SUPPLY TO A/C RELAY

HOLDER 20 A FUSE TERMINAL.

Measure the voltage of harness between A/C relay holder 20 A fuse terminal and chassis ground.

Connector & terminal

(F27) No. 1 (+) — Chassis ground (–):

11 CHECK FUSE.

1) Turn the ignition switch to OFF.

2) Remove the fuse No. 18 from the joint box.

3) Check the condition of fuse.

12 CHECK MAIN FAN RELAY 1.

1) Turn the ignition switch to OFF.

2) Remove the main fan relay 1.

3) Measure the resistance of main fan relay 1.

Terminals

No. 30 — No. 31:

13 CHECK MAIN FAN RELAY 1.

1) Connect the battery to terminals No. 34 and No. 32 of the main fan relay 1.

2) Measure the resistance of main fan relay 1.

Terminals

No. 30 — No. 31:

14 CHECK HARNESS BETWEEN MAIN FAN

RELAY 1 TERMINAL AND MAIN FAN MOTOR CONNECTOR.

Measure the resistance of harness between main fan motor connector and main fan relay 1 terminal.

Connector & terminal

(F17) No. 1 — (F27) No. 30:

Is the voltage 10 V or more? Go to step 8.Go to step 9.

Is the voltage 10 V or more? Go to step 12.Go to step 11.

Is the fuse blown out? Replace the fuse. Go to step 10.

Is the voltage 10 V or more? Repair the open

Is the fuse blown out? Replace the fuse. Repair the open

Is the resistance 1 MΩ or more?

Is the resistance less than 1 Ω?Go to step 14. Replace the main

Is the resistance less than 1 Ω?Go to step 15.Repair the open

Repair the open circuit of harness between 20 A fuse and main fan relay terminal.

Go to step 13. Replace the main

circuit of harness

between main fuse

box connector and

20 A fuse terminal.

circuit of harness

between main fan

relay 1 and ignition

switch.

fan relay 1.

circuit of harness

between main fan

motor connector

and main fan relay

1 terminal.

CO(H4SO)-8

Page 68

asieps_tobira_IM_US.book 9 ページ２０１２年１月１７日　火曜日　午後３時４８分

Radiator Main Fan System

Step Check Yes No

15 CHECK HARNESS BETWEEN MAIN FAN

RELAY 1 AND ECM.

1) Turn the ignition switch to OFF.

2) Disconnect the connectors from the ECM.

3) Measure the resistance of harness between main fan relay 1 connector and ECM connector.

Connector & terminal

(F27) No. 32 — (B136) No. 18:

16 CHECK POOR CONTACT.

Repair the open circuit of harness between main fan relay and ECM.

17 CHECK POWER SUPPLY TO MAIN FAN MO-

TOR. CAUTION:

Be careful not to overheat the engine during repair.

1) Turn the ignition switch to OFF.

2) Disconnect the connector from the main fan motor.

3) Start and warm up the engine until engine coolant temperature raises to 96°C (205°F) or above.

4) Turn on the A/C switch.

5) Measure the voltage while the A/C compressor is operating.

6) Measure the voltage between main fan motor connector and chassis ground.

Connector & terminal

(F17) No. 2 (+) — Chassis ground (–):

18 CHECK POOR CONTACT.

Check poor contact of the main fan motor connector.

19 CHECK MAIN FAN MOTOR.

Connect the battery positive (+) terminal to terminal No. 2, and the ground (–) terminal to terminal No. 3 or No. 4 of the main fan motor connector.

20 CHECK POWER SUPPLY TO MAIN FAN RE-

LAY 2.

1) Turn the ignition switch to OFF.

2) Remove the main fan relay 2 from A/C relay holder.

3) Measure the voltage between main fan relay 2 terminal and chassis ground.

Connector & terminal

(F27) No. 28 (+) — Chassis ground (–):

21 CHECK POWER SUPPLY TO MAIN FAN RE-

LAY 2.

1) Turn the ignition switch to ON.

2) Measure the voltage between main fan relay 2 terminal and chassis ground.

Connector & terminal

(F27) No. 25 (+) — Chassis ground (–):

Is the resistance less than 1 Ω?Go to step 16.Repair the open

Is there poor contact in connector between main fan motor and ECM?

Is the voltage 10 V or more? Go to step 18.Go to step 20.

Is there poor contact in the main fan motor connector?

Does the main fan rotate? Repair the poor

Is the voltage 10 V or more? Go to step 21.Go to step 22.

Is the voltage 10 V or more? Go to step 25.Go to step 24.

Repair the poor contact of connector.

Repair the poor contact of main fan motor connector.

contact of main fan motor connector.

COOLING

circuit of harness

between main fan

relay 1 and ECM.

Check the DTC.

Repair the trouble

cause. <Ref. to

EN(H4SO)(diag)-

37, Read Diagnos-

tic Trouble Code

(DTC).>

Go to step 19.

Replace the main

fan motor with a

new part.

CO(H4SO)-9

Page 69

asieps_tobira_IM_US.book 10 ページ２０１２年１月１７日　火曜日　午後３時４８分

Radiator Main Fan System

COOLING

Step Check Yes No

22 CHECK 20 A FUSE.

1) Remove the 20 A fuse from the A/C relay holder.

2) Check the condition of fuse.

23 CHECK POWER SUPPLY TO A/C RELAY

HOLDER 20 A FUSE TERMINAL.

Measure the voltage of harness between A/C relay holder 20 A fuse terminal and chassis ground.

Connector & terminal

(F27) No. 1 (+) — Chassis ground (–):

24 CHECK FUSE.

1) Turn the ignition switch to OFF.

2) Remove the fuse No. 18 from the joint box.

3) Check the condition of fuse.

25 CHECK MAIN FAN RELAY 2.

1) Turn the ignition switch to OFF.

2) Remove the main fan relay 2.

3) Measure the resistance of main fan relay 2.

Terminals

No. 28 — No. 29:

26 CHECK MAIN FAN RELAY 2.

1) Connect the battery to terminals No. 25 and No. 27 of the main fan relay 2.

2) Measure the resistance of main fan relay 2.

Terminals

No. 28 — No. 29:

27 CHECK HARNESS BETWEEN MAIN FAN

RELAY 2 TERMINAL AND MAIN FAN MOTOR CONNECTOR.

Measure the resistance of harness between main fan motor connector and main fan relay 2 terminal.

Connector & terminal

(F17) No. 2 — (F27) No. 29:

28 CHECK HARNESS BETWEEN MAIN FAN

RELAY 2 AND ECM.

1) Turn the ignition switch to OFF.

2) Disconnect the connectors from the ECM.

3) Measure the resistance of harness between main fan relay 2 connector and ECM connector.

Connector & terminal

(F27) No. 27 — (B136) No. 29:

29 CHECK POOR CONTACT.

Repair the open circuit of harness between main fan relay and ECM.

Is the fuse blown out? Replace the fuse. Go to step 23.

Is the voltage 10 V or more? Repair the open

Is the fuse blown out? Replace the fuse. Repair the open

Is the resistance 1 MΩ or more?

Is the resistance less than 1 Ω?Go to step 27. Replace the main

Is the resistance less than 1 Ω?Go to step 28.Repair the open

Is the resistance less than 1 Ω?Go to step 29.Repair the open

Is there poor contact in connector between main fan motor and ECM?

Repair the open circuit of harness between 20 A fuse and main fan relay terminal.

Go to step 26. Replace the main

Repair the poor contact of connector.

circuit of harness

between main fuse

box connector and

20 A fuse terminal.

circuit of harness

between main fan

relay 2 and ignition

switch.

fan relay 2.

circuit of harness

between main fan

motor connector

and main fan relay

2 terminal.

circuit of harness

between main fan

relay 2 and ECM.

Check the DTC.

Repair the trouble

cause. <Ref. to

EN(H4SO)(diag)-

37, Read Diagnos-

tic Trouble Code

(DTC).>

CO(H4SO)-10

Page 70

asieps_tobira_IM_US.book 11 ページ２０１２年１月１７日　火曜日　午後３時４８分

Radiator Sub Fan System

3. Radiator Sub Fan System

A: WIRING DIAGRAM

COOLING

SBF-1 SBF-4

A/C RELAY HOLDER

20A

MAIN FAN RELAY 1

MAIN FAN RELAY 2

MAIN FAN MOTOR

F27

F17

IGNITION SWITCH

No.18

31 34 32 30

28 25 27 29

F45

B62

No.17

A/C RELAY HOLDER

5 7 9

21 24 22 20

F27

SUB FAN MOTER

F16

20A

SUB FAN RELAY 1

SUB FAN RELAY 2

F16

F17

12 34

F45

3412 89

12 13 14 15 16 17 18 19 20 21 22 23 24

567

10 11

B136

1 2 3 4

987

17 18 19 202821 22 23

3231

CO(H4SO)-11

5 6

2524 33 34 35

18 29

F27

5 6

1610 11 12 13 14 15 2726

1 2

3 4

10 11 13 14

17 18 19

20 21

222324

B136

ECM

26 28 29

32 33 34

CO-02326

Page 71

asieps_tobira_IM_US.book 12 ページ２０１２年１月１７日　火曜日　午後３時４８分

Radiator Sub Fan System

COOLING

B: INSPECTION

DETECTING CONDITION:

•Engine coolant temperature is 96°C (205°F) or more.

•A/C compressor is rotating.

•Vehicle speed is 19 km/h (12 MPH) or less.

TROUBLE SYMPTOMS:

•Radiator sub fan does not rotate under the above conditions.

•Radiator sub fan does not rotate at high speed when the following conditions are met at the same time.

1. Engine coolant temperature is 90°C (194°F) or more.

2. A/C is ON.

Step Check Yes No

1CHECK RADIATOR OPERATION.

1) Run the engine at idle. (When vehicle is parked)

2) Turn the A/C switch to OFF.

3) Raise the engine coolant temperature to 96°C (205°F) or above.

2CHECK RADIATOR OPERATION.

Tu r n th e A /C sw i tc h t o O N u nder t h e co n diti o n of step 1.

3CHECK POWER SUPPLY TO SUB FAN MO-

TOR. CAUTION:

Be careful not to overheat the engine during repair.

1) Turn the ignition switch to OFF.

2) Disconnect the connector from the sub fan motor.

3) Start and warm up the engine until engine coolant temperature raises to 96°C (205°F) or above.

4) Stop the engine, and turn the ignition switch to ON.

5) Measure the voltage between sub fan motor connector and chassis ground.

Connector & terminal

(F16) No. 1 (+) — Chassis ground (–):

4CHECK GROUND CIRCUIT OF SUB FAN

MOTOR.

1) Turn the ignition switch to OFF.

2) Measure the resistance between the sub fan motor connector and chassis ground.

Connector & terminal

(F16) No. 3 — Chassis ground: (F16) No. 4 — Chassis ground:

5CHECK POOR CONTACT.

Check for poor contact of sub fan motor connector.

6CHECK SUB FAN MOTOR.

Connect the battery positive (+) terminal to terminal No. 1, and the ground (–) terminal to terminal No. 3 or 4 of the sub fan motor connector.

Does the radiator sub fan rotate?

Does the radiator sub fan rotate at high speed when the A/C compressor is operating?

Is the voltage 10 V or more? Go to step 4.Go to step 7.

Is the resistance less than 5 Ω?Go to step 5.Repair the open

Is there poor contact in the sub fan motor connector?

Does the sub fan rotate? Repair the poor

Go to step 2.Go to step 3.

Radiator sub fan system is normal.

Repair the poor contact of sub fan motor connector.

contact of sub fan motor connector.

Go to step 17.

circuit of harness between sub fan motor connector and chassis ground.

Go to step 6.

Replace the sub fan motor with a new part.

CO(H4SO)-12

Page 72

asieps_tobira_IM_US.book 13 ページ２０１２年１月１７日　火曜日　午後３時４８分

Radiator Sub Fan System

Step Check Yes No

7CHECK POWER SUPPLY TO SUB FAN RE-

LAY 1.

1) Turn the ignition switch to OFF.

2) Remove the sub fan relay 1 from the A/C relay holder.

3) Measure the voltage between the sub fan relay 1 terminal and chassis ground.

Connector & terminal

(F27) No. 8 (+) — Chassis ground (–):

8CHECK POWER SUPPLY TO SUB FAN RE-

LAY 1.

1) Turn the ignition switch to ON.

2) Measure the voltage between the sub fan relay 1 terminal and chassis ground.

Connector & terminal

(F27) No. 5 (+) — Chassis ground (–):

9CHECK 20 A FUSE.

1) Remove the 20 A fuse from the A/C relay holder.

2) Check the condition of fuse.

10 CHECK POWER SUPPLY TO A/C RELAY

HOLDER 20 A FUSE TERMINAL.

Measure the voltage of harness between A/C relay holder 20 A fuse terminal and chassis ground.

Connector & terminal

(F27) No. 3 (+) — Chassis ground (–):

11 CHECK FUSE.

1) Turn the ignition switch to OFF.

2) Remove the fuse No. 17 from the joint box.

3) Check the condition of fuse.

12 CHECK SUB FAN RELAY 1.

1) Turn the ignition switch to OFF.

2) Remove the sub fan relay 1.

3) Measure the resistance of the sub fan relay

Terminals

No. 8 — No. 9:

13 CHECK SUB FAN RELAY 1.

1) Connect battery to the terminals No. 5 and No. 7 of sub fan relay 1.

2) Measure the resistance of the sub fan relay.

Terminals

No. 8 — No. 9:

14 CHECK HARNESS BETWEEN SUB FAN RE-

LAY 1 TERMINAL AND SUB FAN MOTOR CONNECTOR.

Measure the resistance of harness between sub fan motor connector and sub fan relay 1 terminal.

Connector & terminal

(F16) No. 1 — (F27) No. 9:

Is the voltage 10 V or more? Go to step 8.Go to step 9.

Is the voltage 10 V or more? Go to step 12.Go to step 11.

Is the fuse blown out? Replace the fuse. Go to step 10.

Is the voltage 10 V or more? Repair the harness

Is the fuse blown out? Replace the fuse. Repair the open

Is the resistance 1 MΩ or more?

Is the resistance less than 1 Ω?Go to step 14. Replace the sub

Is the resistance less than 1 Ω?Go to step 15.Repair the open

COOLING

Repair the open circuit between 20 A fuse and sub fan relay terminal.

Go to step 13. Replace the sub

circuit of harness

between sub fuse

box connector and

20 A fuse terminal.

circuit of harness

between sub fan

relay 1 and ignition

switch.

fan relay 1.

circuit of harness

between sub fan

motor connector

and sub fan relay 1

terminal.

CO(H4SO)-13

Page 73

asieps_tobira_IM_US.book 14 ページ２０１２年１月１７日　火曜日　午後３時４８分

Radiator Sub Fan System

COOLING

Step Check Yes No

15 CHECK HARNESS BETWEEN SUB FAN RE-

LAY 1 AND ECM.

1) Turn the ignition switch to OFF.

2) Disconnect the connectors from the ECM.

3) Measure the resistance of harness between sub fan relay 1 connector and ECM connector.

Connector & terminal

(F27) No. 7 — (B136) No. 18:

16 CHECK POOR CONTACT.

Repair the open circuit of harness between sub fan relay and ECM.

17 CHECK POWER SUPPLY TO SUB FAN MO-

TOR. CAUTION:

Be careful not to overheat the engine during repair.

1) Turn the ignition switch to OFF.

2) Disconnect the connector from the sub fan motor.

3) Start and warm up the engine until engine coolant temperature raises to 96°C (205°F) or above.

4) Turn on the A/C switch.

5) Measure the voltage while the A/C compressor is operating.

6) Measure the voltage between sub fan motor connector and chassis ground.

Connector & terminal

(F16) No. 2 (+) — Chassis ground (–):

18 CHECK POOR CONTACT.

Check for poor contact of sub fan motor connector.

19 CHECK SUB FAN MOTOR.

Connect the battery positive (+) terminal to terminal No. 2, and the ground (–) terminal to terminal No. 3 or 4 of the sub fan motor connector.

20 CHECK POWER SUPPLY TO SUB FAN RE-

LAY 2.

1) Turn the ignition switch to OFF.

2) Remove the sub fan relay 2 from the A/C relay holder.

3) Measure the voltage between the sub fan relay 2 terminal and chassis ground.

Connector & terminal

(F27) No. 21 (+) — Chassis ground (–):

21 CHECK POWER SUPPLY TO SUB FAN RE-

LAY 2.

1) Turn the ignition switch to ON.

2) Measure the voltage between the sub fan relay 2 terminal and chassis ground.

Connector & terminal

(F27) No. 24 (+) — Chassis ground (–):

Is the resistance less than 1 Ω?Go to step 16.Repair the open

Is there poor contact in connector between sub fan motor and ECM?

Is the voltage 10 V or more? Go to step 18.Go to step 20.

Is there poor contact in the sub fan motor connector?

Does the sub fan rotate? Repair the poor

Is the voltage 10 V or more? Go to step 21.Go to step 22.

Is the voltage 10 V or more? Go to step 25.Go to step 24.

Repair the poor contact of connector.

Repair the poor contact of sub fan motor connector.

contact of sub fan motor connector.

circuit of harness

between sub fan

relay 1 and ECM.

Check the DTC.

Repair the trouble

cause. <Ref. to

EN(H4SO)(diag)-

37, Read Diagnos-

tic Trouble Code

(DTC).>

Go to step 19.

Replace the sub

fan motor with a

new part.

CO(H4SO)-14

Page 74

asieps_tobira_IM_US.book 15 ページ２０１２年１月１７日　火曜日　午後３時４８分

Radiator Sub Fan System

Step Check Yes No

22 CHECK 20 A FUSE.

1) Remove the 20 A fuse from the A/C relay holder.

2) Check the condition of fuse.

23 CHECK POWER SUPPLY TO A/C RELAY

HOLDER 20 A FUSE TERMINAL.

Measure the voltage of harness between A/C relay holder 20 A fuse terminal and chassis ground.

Connector & terminal

(F27) No. 3 (+) — Chassis ground (–):

24 CHECK FUSE.

1) Turn the ignition switch to OFF.

2) Remove the fuse No. 17 from the joint box.

3) Check the condition of fuse.

25 CHECK SUB FAN RELAY 2.

1) Turn the ignition switch to OFF.

2) Remove the sub fan relay 2.

3) Measure the resistance of the sub fan relay

Terminals

No. 20 — No. 21:

26 CHECK SUB FAN RELAY 2.

1) Connect battery to the terminals No. 22 and No. 24 of sub fan relay 2.

2) Measure the resistance of the sub fan relay

Terminals

No. 20 — No. 21:

27 CHECK HARNESS BETWEEN SUB FAN RE-

LAY 2 TERMINAL AND SUB FAN MOTOR CONNECTOR.

Measure the resistance of harness between sub fan motor connector and sub fan relay 2 terminal.

Connector & terminal

(F16) No. 2 — (F27) No. 20:

28 CHECK HARNESS BETWEEN SUB FAN RE-

LAY 2 AND ECM.

1) Turn the ignition switch to OFF.

2) Disconnect the connectors from the ECM.

3) Measure the resistance of harness between sub fan relay 2 connector and ECM connector.

Connector & terminal

(F27) No. 22 — (B136) No. 29:

29 CHECK POOR CONTACT.

Repair the open circuit of harness between sub fan relay and ECM.

Is the fuse blown out? Replace the fuse. Go to step 23.

Is the voltage 10 V or more? Repair the open

Is the fuse blown out? Replace the fuse. Repair the open

Is the resistance 1 MΩ or more?

Is the resistance less than 1 Ω?Go to step 27. Replace the sub

Is the resistance less than 1 Ω?Go to step 28.Repair the open

Is the resistance less than 1 Ω?Go to step 29.Repair the open

Is there poor contact in connector between sub fan motor and ECM?

COOLING

Repair the open circuit of harness between 20 A fuse and sub fan relay terminal.

Go to step 26. Replace the sub

Repair the poor contact of connector.

circuit of harness

between sub fuse

box connector and

20 A fuse terminal.

circuit of harness

between sub fan

relay 2 and ignition

switch.

fan relay 2.

circuit of harness

between sub fan

motor connector

and sub fan relay 2

terminal.

circuit of harness

between sub fan

relay 2 and ECM.

Check the DTC.

Repair the trouble

cause. <Ref. to

EN(H4SO)(diag)-

37, Read Diagnos-

tic Trouble Code

(DTC).>

CO(H4SO)-15

Page 75

asieps_tobira_IM_US.book 16 ページ２０１２年１月１７日　火曜日　午後３時４８分

Engine Coolant

COOLING

4. Engine Coolant

A: REPLACEMENT

1. DRAINING OF ENGINE COOLANT

1) Set the vehicle on a lift.

2) Lift up the vehicle.

3) Remove the under cover.

4) Remove the drain plug to drain engine coolant into container.

NOTE: Remove the radiator cap so that engine coolant will drain faster.

CO-00009

5) Install the drain plug.

2. FILLING OF ENGINE COOLANT

1) Pour cooling system conditioner through the filler neck.

Cooling system protective agent:

Refer to “SPECIFICATION” for the cooling system protective agent. <Ref. to CO(H4SO)2, SPECIFICATION, General Description.>

2) Pour engine coolant into the radiator up to the filler neck position.

Recommended engine coolant:

Refer to “SPECIFICATION” for the recommended engine coolant. <Ref. to CO(H4SO)2, SPECIFICATION, General Description.>

Coolant level:

Refer to “SPECIFICATION” for the recommended engine coolant. <Ref. to CO(H4SO)2, SPECIFICATION, General Description.>

3) Fill engine coolant into the reservoir tank up to “FULL” level.

FULL

LOW

CO-00010

4) Close the radiator cap and start the engine. Race 5 to 6 times at 3,000 rpm or less, then stop the engine. (Complete this operation within 40 seconds.)

5) Wait for one minute after the engine stops, open the radiator cap. If the engine coolant level drops, add engine coolant into radiator up to the filler neck position.

6) Perform the procedures 4) and 5) again.

7) Attach the radiator cap and reservoir tank cap properly.

8) Start the engine and operate the heater at maximum hot position and the blower speed setting at “LO”.

9) Run the engine at 2,000 rpm or less until radiator fan starts and stops.

NOTE: Be careful with the engine coolant temperature gauge to prevent overheating.

10) Stop the engine and wait until the engine coolant temperature drops to 30°C (86°F) or less.

11) Open the radiator cap. If the engine coolant level drops, add engine coolant into radiator up to the filler neck position and reservoir tank to the “FULL” level.

12) Attach the radiator cap and reservoir tank cap properly.

13) Set the heater setting to maximum hot position and the blower speed setting to “LO” and start the engine. Perform racing at 3,000 rpm or less. If the flowing sound is heard from heater core, repeat the procedures from step 9).

CO(H4SO)-16

Page 76

asieps_tobira_IM_US.book 17 ページ２０１２年１月１７日　火曜日　午後３時４８分

Engine Coolant

COOLING

B: INSPECTION

1. RELATIONSHIP OF ENGINE COOLANT CONCENTRATION AND FREEZING TEMPERATURE

The concentration and safe operating temperature of engine coolant is shown in the diagram. Measuring the temperature and specific gravity of the coolant will provide this information. [Example] If the coolant temperature is 25°C (77°F) and its specific gravity is 1.054, 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).

•Diagram 1

Safe operating temperature

Concentration of coolant

Specific gravity

of coolant

1.100

1.090

1.080

60%

2. PROCEDURE TO ADJUST THE CONCENTRATION OF THE COOLANT

To adjust the concentration of coolant according to temperature, find the proper engine coolant concentration in the diagram 1 and replace the necessary amount of coolant with an undiluted solution of engine coolant (concentration 50%). The amount of engine coolant that should be replaced can be determined using the diagram 2. [Example] Assume that the engine coolant concentration must be increased from 25% to 40%. Find point A, where the 25% line of engine coolant concentration intersects with the 40% curve of the necessary engine 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 2 (2.2 US qt, 1.8 Imp qt). Drain 2.1 2 (2.2 US qt, 1.8 Imp qt) of coolant from the cooling system and add 2.1 2 (2.2 US qt,

1.8 Imp qt) undiluted coolant solution. If a coolant concentration of 50% is needed, drain all the coolant and refill with the undiluted solution only.

•Diagram 2

1.070

1.060

1.050

1.040

1.030

1.020

1.010

1.000

(1.054)

Freezing temperature

-40

(-40) (-22)

-20 -10

-30 (-4)

Coolant temperature

25 C

010203040

(50) (68) (86)

(32)

(14)

( F)

(77 F)

50%

40%

30%

20%

10%

(104)

CO-02172

Necessary Concentration

Quantity of coolant to be

drained (US qt, Imp qt)

(3.2,

2.6)

(2.1,

1.8) 1

(1.1,

0.9)

10%

Concentration of coolant in the vehicie cooling system %

Concentration of coolant in vehicie and quantity to be drained

of coolant

30%

25%

20%

15%

20 30 40 50

35%

45%

40%

CO-00012

CO(H4SO)-17

Page 77

asieps_tobira_IM_US.book 18 ページ２０１２年１月１７日　火曜日　午後３時４８分

Water Pump

COOLING

5. Water Pump

A: REMOVAL

1) Remove the radiator. <Ref. to CO(H4SO)-23, REMOVAL, Radiator.>

2) Remove the V-belts. <Ref. to ME(H4SO)-39, REMOVAL, V-belt.>

3) Remove the crank pulley. <Ref. to ME(H4SO)-41, REMOVAL, Crank Pulley.>

4) Remove the timing belt. <Ref. to ME(H4SO)-43, TIMING BELT, REMOVAL, Timing Belt.>

5) Remove the automatic belt tension adjuster.

CO-00016

6) Remove the belt idler No. 2.

8) Remove the belt cover (LH) No. 2.

CO-00019

9) Remove the tensioner bracket.

CO-00020

10) Disconnect the hose from water pump.

11) Remove the water pump.

CO-00017

7) Remove the cam sprocket (LH) using ST. ST 18231AA010 CAM SPROCKET WRENCH

NOTE: CAMSHAFT SPROCKET WRENCH (499207100) can also be used.

CO-00018

CO(H4SO)-18

CO-00021

Page 78

asieps_tobira_IM_US.book 19 ページ２０１２年１月１７日　火曜日　午後３時４８分

Water Pump

COOLING

B: INSTALLATION

1) Install the water pump onto cylinder block (LH). NOTE:

•Use a new gasket.

•When installing the water pump, tighten the bolts in two stages in alphabetical sequence as shown in figure.

Tightening torque:

First:

12 N·m (1.2 kgf-m, 8.7 ft-lb)

Second:

12 N·m (1.2 kgf-m, 8.7 ft-lb)

(B)

(C)

(D)

(E)

2) Install the hose to the water pump.

3) Install the tensioner bracket.

(A)

(F)

ME-02463

5) Install the cam sprocket (LH) using ST. ST 18231AA010 CAM SPROCKET WRENCH

NOTE: CAMSHAFT SPROCKET WRENCH (499207100) can also be used.

Tightening torque:

78 N·m (8.0 kgf-m, 57.9 ft-lb)

CO-00018

6) Install the belt idler No. 2.

Tightening torque:

39 N·m (4.0 kgf-m, 28.9 ft-lb)

Tightening torque:

24.5 N·m (2.5 kgf-m, 18.1 ft-lb)

4) Install the belt cover No. 2 (LH).

Tightening torque:

5 N·m (0.5 kgf-m, 3.6 ft-lb)

CO-00020

CO-00017

7) Install an automatic belt tension adjuster with the tension rod held by a pin. <Ref. to ME(H4SO)-44, AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER, INSTALLATION, Timing Belt.>

8) Install the timing belt. <Ref. to ME(H4SO)-45, TIMING BELT, INSTALLATION, Timing Belt.>

9) Install the crank pulley. <Ref. to ME(H4SO)-41, INSTALLATION, Crank Pulley.>

10) Install the V-belts. <Ref. to ME(H4SO)-39, INSTALLATION, V-belt.>

11) Install the radiator. <Ref. to CO(H4SO)-24, INSTALLATION, Radiator.>

CO-00019

CO(H4SO)-19

Page 79

asieps_tobira_IM_US.book 20 ページ２０１２年１月１７日　火曜日　午後３時４８分

Water Pump

COOLING

C: 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) Inspect the clearance between impeller and pump case.

Clearance between impeller and pump case:

Standard

0.5 — 1.5 mm (0.020 — 0.060 in)

CO-00293

5) After water pump installation, check pulley shaft for engine coolant leaks or noise. If leaks or noise are noted, replace the water pump assembly.

CO(H4SO)-20

Page 80

asieps_tobira_IM_US.book 21 ページ２０１２年１月１７日　火曜日　午後３時４８分

Thermostat

COOLING

6. Thermostat

A: REMOVAL

1) Set the vehicle on a lift.

2) Lift up the vehicle.

3) Remove the under cover.

4) Drain engine coolant completely. <Ref. to CO(H4SO)-16, DRAINING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>

CO-00009

5) Disconnect the radiator outlet hose from thermostat cover.

6) Remove the thermostat cover, and then remove the gasket and thermostat.

(C)

(B)

(A)

CO-00271

CO-00270

(A) Thermostat cover (B) Gasket

CO(H4SO)-21

Page 81

asieps_tobira_IM_US.book 22 ページ２０１２年１月１７日　火曜日　午後３時４８分

Thermostat

COOLING

B: INSTALLATION

1) Install a gasket to thermostat. NOTE:

Use a new gasket.

2) Install the thermostat and thermostat cover.

NOTE: The thermostat must be installed with the jiggle pin facing upward.

Tightening torque:

12 N·m (1.2 kgf-m, 8.7 ft-lb)

(D)

C: INSPECTION

Replace the thermostat if the valve does not close completely at an ambient temperature or if the following test shows unsatisfactory results.

•Inspection method Immerse the thermostat and a 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 measured value should meet the specification.

NOTE:

•Leave the thermostat in the boiling water for five minutes or more before measuring valve lift.

•Hold the thermostat with a wire or the like to avoid contacting with container bottom.

Opening start temperature:

80 — 84°C (176 — 183°F)

Full open temperature:

95°C (203°F)

Valve lift:

9.0 mm (0.354 in) or more

(C)

(B)

(A)

CO-02221

(A) Thermostat cover (B) Gasket (C) Thermostat (D) Jiggle pin

3) Connect the radiator outlet hose to thermostat cover.

4) Install the under cover.

5) Lower the vehicle.

6) Fill engine coolant. <Ref. to CO(H4SO)-16, FILLING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>

(A)

(B)

CO-00033

(A) Thermometer (B) Thermostat

CO(H4SO)-22

Page 82

asieps_tobira_IM_US.book 23 ページ２０１２年１月１７日　火曜日　午後３時４８分

Radiator

COOLING

7. Radiator

A: REMOVAL

CAUTION: The radiator is pressurized. Wait until engine cools down before working on the radiator.

1) Set the vehicle on a lift.

2) Disconnect the ground cable from the battery.

FU-00009

3) Lift up the vehicle.

4) Remove the under cover.

5) Drain engine coolant completely. <Ref. to CO(H4SO)-16, DRAINING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>

6) Disconnect the connectors of radiator main fan (A) and sub fan motor (B).

(A)

7) Disconnect the radiator outlet hose from thermostat cover.

CO-02249

8) Disconnect the ATF cooler hoses from ATF pipes. (AT model) Apply the cap to prevent ATF leaks.

CO-02250

9) Lower the vehicle.

10) Disconnect the over flow hose.

11) Remove the reservoir tank. <Ref. to CO(H4SO)-31, REMOVAL, Reservoir Tank.>

12) Remove the air intake duct.

13) Disconnect the radiator inlet hoses from the engine.

(B)

CO-00274

CO-02251

14) Remove the radiator upper brackets.

CO-00225

CO-00090

CO(H4SO)-23

Page 83

asieps_tobira_IM_US.book 24 ページ２０１２年１月１７日　火曜日　午後３時４８分

Radiator

COOLING

15) Detach the power steering hose from the clip on the radiator.

CO-00037

16) Lift the radiator up and away from vehicle.

B: INSTALLATION

1) Attach the radiator lower cushion to the hole on the radiator lower bracket.

CO-00041

2) Install the radiator to vehicle. NOTE:

Make pins on the lower side of radiator be fitted into the radiator lower cushions on body side.

3) Install the radiator upper brackets and tighten the bolts.

4) Attach the power steering hose to the radiator.

CO-00037

5) Connect the radiator inlet hose.

CO-02251

6) Install the air intake duct.

7) Install the reservoir tank. <Ref. to CO(H4SO)31, INSTALLATION, Reservoir Tank.>

8) Connect the over flow hose.

9) Lift up the vehicle.

10) Connect the ATF cooler hoses. (AT model)

Tightening torque:

18 N·m (1.8 kgf-m, 13.0 ft-lb)

CO-02250

11) Connect the radiator outlet hose.

CO-00090

CO-02249

CO(H4SO)-24

Page 84

asieps_tobira_IM_US.book 25 ページ２０１２年１月１７日　火曜日　午後３時４８分

Radiator

COOLING

12) Connect the connectors to the radiator main fan motor (A) and sub fan motor (B).

(A)

CO-00224

(B)

CO-00225

13) Install the under cover.

14) Lower the vehicle.

15) Connect the ground cable to the battery.

C: INSPECTION

1) Remove the radiator cap, fill the radiator with engine coolant, and then install the tester to the installation position of cap.

CO-00094

2) Apply a pressure of 157 kPa (1.6 kgf/cm psi) to the radiator and check the following items:

•Leakage from the radiator or its vicinity

•Leakage from the hose or its connections

CAUTION:

•Engine should be turned off.

•Wipe engine coolant from check points in advance.

•Be careful to prevent engine coolant from spurting out when removing tester.

•Be careful not to deform the filler neck of radiator when installing and removing the tester.

, 23

FU-00009

16) Fill engine coolant. <Ref. to CO(H4SO)-16, FILLING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>

17) Check the ATF level. <Ref. to 4AT-28, INSPECTION, Automatic Transmission Fluid.>

CO(H4SO)-25

Page 85

asieps_tobira_IM_US.book 26 ページ２０１２年１月１７日　火曜日　午後３時４８分

Radiator Cap

COOLING

8. Radiator Cap

A: INSPECTION

1) Attach the radiator cap to tester.

CO-00044

2) Increase pressure until the tester gauge pointer stops. Radiator cap is functioning properly if it holds the service limit pressure for five to six seconds. Replace the radiator cap if it is opened under a pressure less than the service limit value.

Standard:

93 — 123 kPa (0.95 — 1.25 kgf/cm2, 14 — 18 psi)

Service limit:

83 kPa (0.85 kgf/cm

CAUTION: Be sure to remove foreign matter and rust from the cap in advance. Otherwise, results of pressure test will be incorrect.

, 12 psi)

CO(H4SO)-26

Page 86

asieps_tobira_IM_US.book 27 ページ２０１２年１月１７日　火曜日　午後３時４８分

Radiator Main Fan and Fan Motor

COOLING

9. Radiator Main Fan and Fan Motor

A: REMOVAL

1) Set the vehicle on a lift.

2) Disconnect the ground cable from the battery.

FU-00009

3) Lift up the vehicle.

4) Remove the under cover.

5) Disconnect the connector of main fan motor (A).

B: INSTALLATION

Install in the reverse order of removal. NOTE:

If the installation of the radiator main fan motor assembly is difficult, attempt installation after loosening the bolts which hold the radiator sub fan motor assembly.

Tightening torque:

7.5 N·m (0.76 kgf-m, 5.5 ft-lb)

CO-00096

C: DISASSEMBLY

1) Remove the clip which holds the fan motor connector onto the shroud.

2) Remove the nut which holds the fan to the fan motor.

(A)

CO-00274

6) Remove the ATF hose from the clip of the radia-

tor main fan motor assembly. (AT model)

7) Lower the vehicle.

8) Disconnect the over flow hose.

9) Remove the reservoir tank. <Ref. to CO(H4SO)-

31, REMOVAL, Reservoir Tank.>

10) Remove the bolts which hold the radiator main

fan shroud to the radiator.

CO-00096

11) Remove the radiator main fan motor assembly.

CO-00047

3) Remove the bolts which hold fan motor onto shroud.

CO-00048

CO(H4SO)-27

Page 87

asieps_tobira_IM_US.book 28 ページ２０１２年１月１７日　火曜日　午後３時４８分

Radiator Main Fan and Fan Motor

COOLING

D: ASSEMBLY

Assemble in the reverse order of disassembly.

Tightening torque:

4.4 N·m (0.45 kgf-m, 3.3 ft-lb)

CO-00048

Tightening torque:

3.4 N·m (0.35 kgf-m, 2.5 ft-lb)

CO-00047

CO(H4SO)-28

Page 88

asieps_tobira_IM_US.book 29 ページ２０１２年１月１７日　火曜日　午後３時４８分

Radiator Sub Fan and Fan Motor

COOLING

10.Radiator Sub Fan and Fan Motor

A: REMOVAL

1) Set the vehicle on a lift.

2) Disconnect the ground cable from the battery.

FU-00009

3) Lift up the vehicle.

4) Remove the under cover.

5) Remove the connector of sub fan motor (B).

B: INSTALLATION

Install in the reverse order of removal.

Tightening torque:

7.5 N·m (0.76 kgf-m, 5.5 ft-lb)

CO-00101

C: DISASSEMBLY

1) Remove the clip which holds the fan motor connector onto the shroud.

2) Remove the nut which holds the fan to the fan motor.

(B)

CO-00225

6) Remove the ATF hose from the clip of the radia-

tor sub fan motor assembly. (AT model)

7) Lower the vehicle.

8) Remove the air intake duct.

9) Remove the bolts which hold the radiator sub fan

shroud to the radiator.

CO-00101

10) Remove the radiator sub fan motor assembly

from underneath the vehicle.

CO-00049

3) Remove the bolts which hold fan motor onto shroud.

CO-00050

CO(H4SO)-29

Page 89

asieps_tobira_IM_US.book 30 ページ２０１２年１月１７日　火曜日　午後３時４８分

Radiator Sub Fan and Fan Motor

COOLING

D: ASSEMBLY

Assemble in the reverse order of disassembly.

Tightening torque:

4.4 N·m (0.45 kgf-m, 3.3 ft-lb)

CO-00050

Tightening torque:

3.4 N·m (0.35 kgf-m, 2.5 ft-lb)

CO-00049

CO(H4SO)-30

Page 90

asieps_tobira_IM_US.book 31 ページ２０１２年１月１７日　火曜日　午後３時４８分

Reservoir Tank

11.Reservoir Tank

A: REMOVAL

1) Disconnect the over flow hose from the radiator

filler neck position.

2) Push the claw (A) and pull the reservoir tank in

the direction of the arrow to remove.

(A)

CO-00226

COOLING

B: INSTALLATION

Install in the reverse order of removal.

C: INSPECTION

Make sure the engine coolant level is between “FULL” and “LOW”.

CO(H4SO)-31

Page 91

asieps_tobira_IM_US.book 32 ページ２０１２年１月１７日　火曜日　午後３時４８分

Engine Cooling System Trouble in General

COOLING

12.Engine Cooling System Trouble in General

A: INSPECTION

Tr o ub l e Po s s ib l e cause C o r r ecti ve a ct i o n

Replenish engine coolant, inspect for leakage, and repair it if necessary.

Inspect and repair ignition control system. <Ref. to EN(H4SO)(diag)-2, Basic Diagnostic Procedure.>

Replace the engine coolant. If it is ineffective, inspect and repair the engine side.

Inspect and repair the fuel injection system. <Ref. to EN(H4SO)(diag)-2, Basic Diagnostic Procedure.>

Inspect the radiator fan relay, engine coolant temperature sensor or fan motor and replace them.

Overheating

Over-cooling

Engine coolant leaks

Abnormal noise

a. Insufficient engine coolant

b. Loose timing belt Repair or replace timing belt tensioner. c. Oil on timing belt Replace. d. Malfunction of thermostat Replace. e. Malfunction of water pump Replace. f. Clogged engine coolant passage Clean.

g. Improper ignition timing

h. Clogged or leaking radiator Clean, repair or replace.

i. Engine oil mixed in engine coolant

j. Air/fuel mixture ratio too lean

k. Excessive back pressure in exhaust system Clean or replace. l. Insufficient clearance between piston and cylinder Adjust or replace. m. Slipping clutch Repair or replace. n. Dragging brake Adjust.

o. Defective radiator fan

a. Ambient temperature extremely lowPartly cover radiator front area. b. Defective thermostat Replace. a. Loosened or damaged connecting units on hoses Repair or replace. b. Leakage from water pump Replace. c. Leakage from water pipe Repair or replace. d. Leakage around cylinder head gasket Retighten the cylinder head bolts or replace the gasket. e. Cylinder head and block damaged or cracked Repair or replace. f. Damaged or cracked thermostat case Repair or replace. g. Leakage from radiator Repair or replace. a. Timing belt problem Replace. b. Defective radiator fan Replace. c. Defective water pump bearing Replace water pump. d. Defective water pump mechanical seal Replace water pump.

CO(H4SO)-32

Page 92

asieps_tobira_IM_US.book 1 ページ２０１２年１月１７日　火曜日　午後３時４８分

LUBRICATION

1. General Description ...................................................................................2

2. Oil Pressure System ..................................................................................6

3. Engine Oil ...................................................................................................8

4. Oil Pump ..................................................................................................10

5. Oil Pan and Strainer .................................................................................15

6. Oil Pressure Switch ..................................................................................19

7. Engine Oil Filter ........................................................................................20

8. Engine Lubrication System Trouble in General ........................................21

LU(H4SO)

Page

Page 93

asieps_tobira_IM_US.book 2 ページ２０１２年１月１７日　火曜日　午後３時４８分

General Description

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

1. General Description

A: CAUTION

•Wear appropriate work clothing, including a cap,

protective goggles and protective shoes when performing any work.

•Remove contamination including dirt and corro-

sion before removal, installation or disassembly.

•Keep the disassembled parts in order and pro-

tect them from dust and dirt.

•Before removal, installation or disassembly, be

sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement.

•Vehicle components are extremely hot after driv-

ing. Be wary of receiving burns from heated parts.

•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 connectors of sensors or

units, be sure to disconnect the ground cable from the battery.

B: PREPARATION TOOL

1. SPECIAL TOOL

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

18353AA000 CLAMP PLIERS • Used for removing and installing the PCV

ST18353AA000

hose.

• This is a general tool made by the French company CAILLAU. (Code: 54.0.000.205) To m a k e t h i s e a sie r t o o b t ai n i n t h e s a me w ay as genuine Subaru parts, it has been provided with a tool number as an ST.

EC(H4SO)-2

Page 94

asieps_tobira_IM_US.book 3 ページ２０１２年１月１７日　火曜日　午後３時４８分

Front Catalytic Converter

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

2. Front Catalytic Converter

A: REMOVAL

The front catalytic converter is integrated into the front exhaust pipe. Refer to “Front Exhaust Pipe” for removal procedures. <Ref. to EX(H4SO)-4, REMOVAL, Front Exhaust Pipe.>

B: INSTALLATION

The front catalytic converter is integrated into the front exhaust pipe. Refer to “Front Exhaust Pipe” for the installation procedures. <Ref. to EX(H4SO)5, INSTALLATION, Front Exhaust Pipe.>

C: INSPECTION

1) Check the connections and welds for exhaust

leaks.

2) Make sure there are no holes or rusting.

EC(H4SO)-3

Page 95

asieps_tobira_IM_US.book 4 ページ２０１２年１月１７日　火曜日　午後３時４８分

Rear Catalytic Converter

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

3. Rear Catalytic Converter

A: REMOVAL

The rear catalytic converter is integrated into the center exhaust pipe. Refer to “Center Exhaust Pipe” for removal procedures. <Ref. to EX(H4SO)7, REMOVAL, Center Exhaust Pipe.>

B: INSTALLATION

The rear catalytic converter is integrated into the center exhaust pipe. Refer to “Center Exhaust Pipe” for installation procedures. <Ref. to EX(H4SO)-7, INSTALLATION, Center Exhaust Pipe.>

C: INSPECTION

1) Check the connections and welds for exhaust

leaks.

2) Make sure there are no holes or rusting.

EC(H4SO)-4

Page 96

asieps_tobira_IM_US.book 5 ページ２０１２年１月１７日　火曜日　午後３時４８分

EGR Valve

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

4. EGR Valve

A: SPECIFICATION

Refer to “EGR Valve” for removal and installation procedures. <Ref. to FU(H4SO)-29, EGR Valve.>

EC(H4SO)-5

Page 97

asieps_tobira_IM_US.book 6 ページ２０１２年１月１７日　火曜日　午後３時４８分

Canister

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

5. Canister

A: REMOVAL

1) Set the vehicle on a lift.

2) Disconnect the ground cable from the battery.

FU-00009

3) Lift up the vehicle.

4) Disconnect the connector (A) from the drain

valve.

5) Disconnect the evaporation hoses (B) and (C)

from the canister.

8) Remove the canister from the vehicle body.

EC-02073

B: INSTALLATION

Install in the reverse order of removal. NOTE:

Replace the retainer of the quick connector with a new part.

Tightening torque:

23 N·m (2.3 kgf-m, 17 ft-lb)

(A)

(C)

(B)

EC-02119

6) Disconnect the quick connector (A) from the

canister.

7) Disconnect the drain hose (B) from the canister.

(B)

(A)

EC-02120

EC-02073

C: INSPECTION

Make sure the canister and canister hoses are not cracked or loose.

EC(H4SO)-6

Page 98

asieps_tobira_IM_US.book 7 ページ２０１２年１月１７日　火曜日　午後３時４８分

Purge Control Solenoid Valve

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

6. Purge Control Solenoid Valve

A: REMOVAL

1) Disconnect the ground cable from the battery.

FU-00009

2) Disconnect the connector and hoses of purge

control solenoid valve, and then remove the purge control solenoid valve.

B: INSTALLATION

Install in the reverse order of removal.

Tightening torque:

19 N·m (1.9 kgf-m, 14.0 ft-lb)

EC-00223

NOTE: Connect the evaporation hose as shown in the following.

EC-00223

(B)

(A)

EC-00224

(A) To fuel pipe (evaporation line) (B) To intake manifold

C: INSPECTION

Make sure the hoses are not cracked or loose.

EC(H4SO)-7

Page 99

asieps_tobira_IM_US.book 8 ページ２０１２年１月１７日　火曜日　午後３時４８分

Fuel Level Sensor

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

7. Fuel Level Sensor

A: REMOVAL

Refer to “Fuel Level Sensor” for removal procedure. <Ref. to FU(H4SO)-53, REMOVAL, Fuel Level Sensor.>

B: INSTALLATION

Refer to “Fuel Level Sensor” for installation procedure. <Ref. to FU(H4SO)-53, INSTALLATION, Fuel Level Sensor.>

EC(H4SO)-8

Page 100

asieps_tobira_IM_US.book 9 ページ２０１２年１月１７日　火曜日　午後３時４８分

Fuel Temperature Sensor

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

8. Fuel Temperature Sensor

A: REMOVAL

The fuel temperature sensor and fuel level sensor are integrated into one unit; therefore, refer to “Fuel Level Sensor” for removal procedure. <Ref. to FU(H4SO)-53, REMOVAL, Fuel Level Sensor.>

B: INSTALLATION

The fuel temperature sensor and fuel level sensor are integrated into one unit; therefore, refer to “Fuel Level Sensor” for installation procedure. <Ref. to FU(H4SO)-53, INSTALLATION, Fuel Level Sensor.>

EC(H4SO)-9