Subaru S209 2019 Service Manual
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Subaru S209 2019 Service Manual

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2019 S209 SERVICE MANUAL
GENERAL INFORMATION
SECTION
This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.
All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.
For information on sections that remain
unchanged, refer to 19MY WRX STI
service manual.
SUBARU TECNICA INTERNATIONAL INC.
QUICK REFERENCE INDEX
FOREWORD
SPECIFICATIONS
IDENTIFICATION
RECOMMENDED MATERIALS
PRE-DELIVERY INSPECTION
PERIODIC MAINTENANCE SERVICES
FW
SPC
ID
RM
PI
PM
SGV191101

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  • Page 1 SECTION FOREWORD SPECIFICATIONS IDENTIFICATION RECOMMENDED MATERIALS This service manual has been prepared to provide SUBARU service personnel PRE-DELIVERY INSPECTION with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. PERIODIC MAINTENANCE SERVICES This manual includes the procedures...
  • Page 3 FOREWORD Page Foreword ....................2...
  • Page 4 Foreword FOREWORD 1. Foreword A: FOREWORD These manuals are used when performing maintenance, repair or diagnosis of S209. Applicable model: 2019 MY VAF**** 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 5 SPECIFICATIONS Page S209 ......................2...
  • Page 6 S209 SPECIFICATIONS 1. S209 A: DIMENSION Model 2.5 L DOHC high power turbo Overall length mm (in) 4,620 (181.9) Overall width mm (in) 1,840 (72.4) Overall height mm (in) 1,475 (58.1) Length mm (in) 2,005 (78.9) Compartment Width mm (in) 1,490 (58.7) Height mm (in)
  • Page 7 S209 SPECIFICATIONS E: WEIGHT Sedan 2.5 L DOHC high power turbo Model S209 OP code Total kg (lb) 1,581 (3,485) Curb weight Front kg (lb) 934 (2,059) (C.W.) Rear kg (lb) 647 (1,426) Gross vehicle weight (G.V.W.) kg (lb) 2,000 (4,409) Front kg (lb) 1,075 (2,370)
  • Page 8 S209 SPECIFICATIONS SPC-4...
  • Page 9 IDENTIFICATION Page Identification ....................2...
  • Page 10 The starting and ending brackets ( ] [ ) are stop marks. Digits Code Meaning Details 1 — 3 Manufacturer body area JF1: Passenger car, SUBARU CORPORATION made Car line V: WRX Body type A: Sedan Displacement class 2: 2.5 L AWD high power turbo 4-CYLINDERS GASOLINE...
  • Page 11 Identification IDENTIFICATION The engine type is as follows. • Engine EJ257XG5LB Digits Code Meaning Details 1 and 2 Engine type symbol EJ: 4 cylinders 3 and 4 Displacement 25: 2.5 L Fuel feed device 7: MFI - single scroll high power turbo Exhaust regulations X: North America (Tier 3/LEV III) Mounted transmission...
  • Page 12 Identification IDENTIFICATION ID-4...
  • Page 13 RECOMMENDED MATERIALS Page Recommended Materials ................2...
  • Page 14 Recommended Materials RECOMMENDED MATERIALS 1. Recommended Materials A: RECOMMENDED MATERIALS 1. LUBRICANT Item Recommended materials Remarks Engine oil MOTUL 300V Power 5W-40 RM-2...
  • Page 15 PRE-DELIVERY INSPECTION Page Pre-delivery Inspection ................2...
  • Page 16 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 vehicle protective parts for transportation. • Check that the vehicle or parts before delivery are not damaged during transportation or storage. •...
  • Page 17 Pre-delivery Inspection PRE-DELIVERY INSPECTION • Front under spoiler AA-16000 (A) Jack (B) Jack handle (C) Tire repair kit (D) Screwdriver (E) Towing hook (eyebolt) 2. INTERCOOLER WATER SPRAY TANK NOTE: • Use pure water. • When the water level in the intercooler water spray tank is approx. 0.3 L (0.3 US qt, 0.3 Imp qt) or lower, the intercooler water spray warning light on the combination meter will illuminate.
  • Page 18 Pre-delivery Inspection PRE-DELIVERY INSPECTION PI-4...
  • Page 19 PERIODIC MAINTENANCE SERVICES Page Schedule ....................2 Air Cleaner Element ...................5...
  • Page 20 Schedule PERIODIC MAINTENANCE SERVICES 1. Schedule A: MAINTENANCE SCHEDULE 1. MODEL WITH US SPECIFICATION Maintenance item Maintenance interval [Number of months or km (miles), whichever occurs first] Months To be contin- ued to the next table. Remarks × 1,000 km 19.2 28.8 38.4...
  • Page 21 Schedule PERIODIC MAINTENANCE SERVICES Maintenance item Maintenance interval [Number of months or km (miles), whichever occurs first] Months Continued from previous table Remarks × 1,000 km 115.2 124.8 134.4 153.6 163.2 172.8 182.4 201.6 211.2 × 1,000 miles Engine oil Perform every 4,800 km (3,000 miles).
  • Page 22 7. A tire should be replaced when the tread wear indicator appears as a solid band across the tread. The indicators appear when the remaining tread has been worn to 1.6 mm (0.063 in) or less. 8. To prevent cooling system leakage, be sure to add SUBARU genuine cooling system conditioner when replacing coolant. Examples of severe conditions a.
  • Page 23 Air Cleaner Element PERIODIC MAINTENANCE SERVICES 2. Air Cleaner Element 4) Remove the air cleaner element. A: REPLACEMENT CAUTION: • Be sure to use STi genuine air cleaner ele- ment depending on the engine type when re- placing the air cleaner elements. Using other air cleaner element may affect the engine perfor- mance.
  • Page 24 Air Cleaner Element PERIODIC MAINTENANCE SERVICES PM-6...
  • Page 25 FUEL INJECTION (FUEL SYSTEMS) INTAKE (INDUCTION) MECHANICAL LUBRICATION This service manual has been prepared to provide SUBARU service personnel with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. This manual includes the procedures for maintenance, disassembling, reas-...
  • Page 27 FUEL INJECTION (FUEL SYSTEMS) Page General Description ...................2...
  • Page 28 General Description FUEL INJECTION (FUEL SYSTEMS) 1. General Description A: SPECIFICATION Capacity 60 L (15.9 US gal, 13.2 Imp gal) Fuel tank Location Under rear seat Type Impeller Shutoff discharge pressure 900 kPa (9.18 kg/cm , 130.5 psi) or less Fuel pump 230 L (60.8 US gal, 50.6 Imp gal)/h or more Discharge rate...
  • Page 29 General Description FUEL INJECTION (FUEL SYSTEMS) B: COMPONENT 1. INTAKE MANIFOLD (22) (15) (29) (17) (13) (26) (27) (25) (28) (19) (21) (11) (27) (28) (11) (20) (12) (10) (18) (16) (10) (23) (24) (14) (27) (28) (30) (11) (12) (30) AA-14035 FU-3...
  • Page 30 General Description FUEL INJECTION (FUEL SYSTEMS) Fuel pipe ASSY (14) Fuel injector pipe LH (27) O-ring Fuel hose (15) Fuel pipe protector RH (28) Rubber Clamp (16) Fuel pipe protector LH (29) Clip Purge control solenoid valve 1 (17) Solenoid valve bracket (30) Protector Vacuum hose A...

  • Page 31: Table Of Contents

    INTAKE (INDUCTION) Page General Description ...................2 Intercooler Water Spray System ..............7 Air Cleaner Element ...................9 Air Cleaner Case ..................10 Air Intake Duct ..................11 Intake Duct ....................12 Turbocharger ....................13 Intercooler Water Spray Tank & Motor .............19 Intercooler Water Spray Nozzle ...............21 Intercooler Water Spray Hose ..............23 Intercooler Water Spray Level Switch ............30 Intercooler Water Spray Switch ..............31...

  • Page 32: General Description

    General Description INTAKE (INDUCTION) 1. General Description A: SPECIFICATION Pump type Centrifugal Intercooler water spray motor Input 12 V — 36 W or less B: COMPONENT 1. AIR CLEANER (10) (11) (12) AA-15017 Air cleaner case bracket Air cleaner case (upper) Tightening torque: N·m (kgf-m, ft-lb) Cushion Mass air flow and intake air tem-...
  • Page 33 General Description INTAKE (INDUCTION) 2. INTAKE DUCT AA-15018 Clamp Vacuum hose B Tightening torque: N·m (kgf-m, ft-lb) PCV hose ASSY Intake duct T1: 3 (0.3, 2.2) Vacuum hose A Clamp T2: 17 (1.7, 12.5) IN-3...
  • Page 34 General Description INTAKE (INDUCTION) 3. TURBOCHARGER (10) (12) (13) (12) (11) (14) (15) AA-15016 Oil inlet pipe Gasket Tightening torque:N·m (kgf-m, ft-lb) Union bolt (10) Turbocharger ASSY T1: 6.4 (0.7, 4.7) Gasket (11) Air control hose ASSY T2: 16 (1.6, 11.8) Union bolt (12) Clip...
  • Page 35 General Description INTAKE (INDUCTION) 4. INTERCOOLER WATER SPRAY (21) (19) (20) (21) (20) (19) (18) (18) (17) (17) (16) (10) (15) (10) (10) (14) (10) (13) (12) (11) (10) AA-14000 IN-5...
  • Page 36 General Description INTAKE (INDUCTION) Intercooler water spray tank ASSY (10) Clip (19) JOINT L Intercooler water spray relay (11) Intercooler water spray front hose (20) NOZZLE HOSE ASSY Intercooler water spray tank (12) VALVE F (21) Intercooler water spray nozzle bracket Intercooler water spray timer (13)

  • Page 37: Intercooler Water Spray System

    Intercooler Water Spray System INTAKE (INDUCTION) 2. Intercooler Water Spray System A: WIRING DIAGRAM Refer to “Intercooler Water Spray System” in WI section. INTERCOOLER WATER MB-30 FB-42 FB-18 FB-12 SPRAY RELAY SBF-4 F/B FUSE NO. 26 F/B FUSE NO. 7 F/B FUSE NO.
  • Page 38 Intercooler Water Spray System INTAKE (INDUCTION) B: INSPECTION Diagnosis: 1. CHECK INTERCOOLER WATER SPRAY WARNING LIGHT Step Check CHECK COMBINATION METER. Does the warning light illumi- Go to step 2. Repair or replace 1) Turn the ignition switch to ON. (Engine OFF) nate at ignition switch ON, and the combination 2) Turn the ignition switch to OFF.

  • Page 39: Air Cleaner Element

    Air Cleaner Element INTAKE (INDUCTION) 3. Air Cleaner Element • Be sure to align the marking (a) of air cleaner case (upper) with the marking (b) of air cleaner A: REMOVAL element. 1) Disconnect the ground terminal from battery. 2) Remove the air cleaner case. 3) Remove the air cleaner case (lower).

  • Page 40: Air Cleaner Case

    Air Cleaner Case INTAKE (INDUCTION) 4. Air Cleaner Case Tightening torque: 7.5 N·m (0.8 kgf-m, 5.5 ft-lb) A: REMOVAL 3) Tighten the bolt (b). 1) Disconnect the ground terminal from battery. Tightening torque: 2) Remove the air intake duct. 6.5 N·m (0.7 kgf-m, 5.2 ft-lb) 3) Disconnect the connector (a) from the mass air 4) Tighten the clamp (c) of the air intake boot, and flow and intake air temperature sensor, and re-...

  • Page 41: Air Intake Duct

    Air Intake Duct INTAKE (INDUCTION) 5. Air Intake Duct A: REMOVAL Remove the clip which secures the air intake duct, and remove the air intake duct. AA-15004 B: INSTALLATION Install in the reverse order of removal. C: INSPECTION 1) Check that the air intake duct has no deforma- tion, cracks or other damages.

  • Page 42: Intake Duct

    Intake Duct INTAKE (INDUCTION) 6. Intake Duct A: REMOVAL 1) Disconnect the ground terminal from battery. 2) Remove the intake manifold. 3) Remove the sensor, engine harness and fuel pipe from the intake manifold. 4) Remove the intake duct from intake manifold. AA-15003 B: INSTALLATION Install in the reverse order of removal.

  • Page 43: Turbocharger

    Turbocharger INTAKE (INDUCTION) 7. Turbocharger CAUTION: In order to prevent damaging the oil pipe on the A: REMOVAL cylinder head side, fix the section (a) shown in the figure when loosing the oil inlet pipe flare 1) Disconnect the ground terminal from battery. nut, and avoid the part from rotating together 2) Drain approximately 3.0 L (3.2 US qt, 2.6 Imp qt) while loosening the nut.
  • Page 44 Turbocharger INTAKE (INDUCTION) 12) Disconnect the air control hose (a), and loosen B: INSTALLATION the clamp holding the intake duct to the turbocharg- 1) Install the turbocharger stay. Tightening torque: T1: 33 N·m (3.4 kgf-m, 24.3 ft-lb) T2: 42.5 N·m (4.3 kgf-m, 31.3 ft-lb) AA-15001 13) Disconnect the oil outlet pipe from the oil outlet hose, and remove the turbocharger.
  • Page 45 Turbocharger INTAKE (INDUCTION) NOTE: 6) Temporarily tighten the flare nuts which secure the turbocharger oil pipe to the oil inlet pipe until Use a new gasket. they are seated. CAUTION: • Tighten the flare nuts by hand. • After the flare nuts are seated, check for looseness while moving the pipe portion of the oil inlet pipe.
  • Page 46 Turbocharger INTAKE (INDUCTION) Tightening torque: • Check the turbocharger and the water pipe for in- terference. 42.5 N·m (4.3 kgf-m, 31.3 ft-lb) AA-15101 AA-15002 10) Tighten the union bolts which secure the oil in- Tightening torque: let pipe to the turbocharger. 23 N·m (2.3 kgf-m, 17.0 ft-lb) Tightening torque: 16 N·m (1.6 kgf-m, 11.8 ft-lb)
  • Page 47 Turbocharger INTAKE (INDUCTION) 15) Lower the vehicle. 3) Remove the boost hose (B) from the waste gate actuator (A) of the turbocharger, and connect the 16) Install the intercooler stay RH No. 2. Mighty Vac to the waste gate actuator (A). Tightening torque: 16 N·m (1.6 kgf-m, 11.8 ft-lb) AA-15015...
  • Page 48 Turbocharger INTAKE (INDUCTION) 5) After inspection, install the related parts in the reverse order of removal. NOTE: • After installing the vacuum hose, make sure that the clearance (A) between the strut tower bar and the vac- uum hose is 15 mm (0.591 in) or more. •...

  • Page 49: Intercooler Water Spray Tank & Motor

    Intercooler Water Spray Tank & Motor INTAKE (INDUCTION) 8. Intercooler Water Spray Tank 7) Remove the intercooler water spray relay. 8) Remove the bolts, and then remove the ground & Motor terminal. A: REMOVAL 1) Disconnect the ground terminal from battery. 2) Open the trunk, and remove the mat - trunk.
  • Page 50 Intercooler Water Spray Tank & Motor INTAKE (INDUCTION) B: INSTALLATION Tightening torque: T1: 4.5 N·m (0.5 kgf-m, 3.3 ft-lb) 1) When using a new intercooler water spray tank T2: 7.5 N·m (0.8 kgf-m, 5.5 ft-lb) assembly, remove the unnecessary bracket (a). AA-14028 AA-14022 C: INSPECTION...

  • Page 51: Intercooler Water Spray Nozzle

    Intercooler Water Spray Nozzle INTAKE (INDUCTION) 9. Intercooler Water Spray Noz- 6) Remove the nuts, and remove the NOZZLE BRKT. A: REMOVAL 1) Open the front hood. 2) Remove the clips, and remove the insulator - front hood from the front hood. CAUTION: Do not reuse any clips damaged during remov- al.
  • Page 52 Intercooler Water Spray Nozzle INTAKE (INDUCTION) CAUTION: (5) Pull the masking tape attached in step (2) to remove the backing sheet, and press-fit the When installing the NOZZLE BRKT, hold the NOZZLE BRKT. NOZZLE BRKT while tightening so that it does not rotate.

  • Page 53: Intercooler Water Spray Hose

    Intercooler Water Spray Hose INTAKE (INDUCTION) 10.Intercooler Water Spray Hose A: REMOVAL CAUTION: • Before handling the airbag system components, refer to “CAUTION” of “General Description” in “AIRBAG SYSTEM”. • Airbag system satellite safing sensor is located under the front center of the rear seat cushion. Be careful not to affect the sensor when working with the rear seat cushion removed.
  • Page 54 Intercooler Water Spray Hose INTAKE (INDUCTION) 5) Disconnect the intercooler water spray duct hose assembly from the intercooler water spray front hose as- sembly. AA-14012 6) Remove the intercooler water spray duct hose assembly from the duct - inner front hood. 7) Remove the mud guard - front LH.
  • Page 55 Intercooler Water Spray Hose INTAKE (INDUCTION) 9) Disconnect the intercooler water spray front hose assembly from the intercooler water spray side hose as- sembly. AA-14025 10) Tie a string to the front hood side of the intercooler water spray front hose assembly, and pull it out to the front fender side from the front hood.
  • Page 56 Intercooler Water Spray Hose INTAKE (INDUCTION) (1) Release the clip by pulling the trim panel - center pillar LWR LH toward you. (2) Expand the claws of the trim panel - center pillar LWR LH outward, and remove it from the trim panel - center pillar UPR LH.
  • Page 57 Intercooler Water Spray Hose INTAKE (INDUCTION) 25) Cut the tie-wrap securing the intercooler water spray side hose assembly using a pair of nippers, etc. AA-14015 AA-14016 IN-27...
  • Page 58 Intercooler Water Spray Hose INTAKE (INDUCTION) AA-14017 AA-14018 AA-14019 IN-28...
  • Page 59 Intercooler Water Spray Hose INTAKE (INDUCTION) 26) Prepare a container, and disconnect the intercooler water spray side hose assembly to drain water in the intercooler water spray side hose assembly. AA-14020 27) Tie a string to the front fender side of the intercooler water spray side hose assembly, and pull it out to the passenger room side.

  • Page 60: Intercooler Water Spray Level Switch

    Intercooler Water Spray Level Switch INTAKE (INDUCTION) 11.Intercooler Water Spray Level Switch A: REMOVAL The intercooler water spray level switch is integrated into the intercooler water spray tank assembly; there- fore, refer to “Intercooler Water Spray Tank & Motor” for removal procedure. B: INSTALLATION The intercooler water spray level switch is integrated into the intercooler water spray tank assembly;...

  • Page 61: Intercooler Water Spray Switch

    Intercooler Water Spray Switch INTAKE (INDUCTION) 12.Intercooler Water Spray Switch A: REMOVAL CAUTION: Before handling the airbag system components, always refer to “CAUTION” of “General Description” in “AIRBAG SYSTEM”. 1) Disconnect the ground terminal from battery and wait for at least 60 seconds before starting work. 2) Set the tire to the straight-ahead position.
  • Page 62 Intercooler Water Spray Switch INTAKE (INDUCTION) 5) Remove the screw, disconnect the connector and remove the intercooler water spray switch. PS-01719 B: INSTALLATION CAUTION: • Before handling the airbag system components, refer to “CAUTION” of “General Description” in “AIRBAG SYSTEM”. •...
  • Page 63 Intercooler Water Spray Switch INTAKE (INDUCTION) 3) Adhere the I/C SPRAY SW LABEL with its aligning position (a) fitted to the aligning position (b) on the in- tercooler water spray switch. AA-14038 4) Press-fit the I/C SPRAY SW LABEL using a squeegee over a mounting paper. Preparation tool: Squeegee 5) Peel off the mounting paper of I/C SPRAY SW LABEL, and press-fit the I/C SPRAY SW LABEL again with...
  • Page 64 Intercooler Water Spray Switch INTAKE (INDUCTION) 9) Install the driver’s airbag module. 10) Connect the battery ground terminal. C: INSPECTION 1) Measure the resistance between connector terminals. AA-14021 Terminal No. Inspection conditions Standard Operate the RH side of the intercooler water spray switch Less than 10 ...

  • Page 65: Intercooler Water Spray Relay

    Intercooler Water Spray Relay INTAKE (INDUCTION) 13.Intercooler Water Spray Re- 2) Measure the resistance between intercooler wa- ter spray relay terminals. A: REMOVAL 1) Disconnect the ground terminal from battery. 2) Open the trunk, and remove the mat - trunk. 3) Remove the sub trunk.
  • Page 66 Intercooler Water Spray Relay INTAKE (INDUCTION) 3) Connect battery positive terminal to terminal No. 3 and battery ground terminal to terminal No. 4, and measure the resistance between the intercooler water spray relay terminals. FU-04077 Terminal No. Standard Less than 1  1 and 2 IN-36...

  • Page 67: Intercooler Water Spray Timer

    Intercooler Water Spray Timer INTAKE (INDUCTION) 14.Intercooler Water Spray Timer A: REMOVAL 1) Disconnect the ground terminal from battery. 2) Open the trunk, and remove the mat - trunk. 3) Remove the sub trunk. CAUTION: Remove any luggage, etc. stored in the trunk room to outside of the vehicle, and then remove/install the sub trunk while holding its center area with both hands.
  • Page 68 Intercooler Water Spray Timer INTAKE (INDUCTION) 5) Remove the bolts, and remove the intercooler water spray timer. AA-14002 B: INSTALLATION Install in the reverse order of removal. Tightening torque: 4.5 N·m (0.5 kgf-m, 3.3 ft-lb) C: INSPECTION Check that the intercooler water spray timer has no deformation, cracks or other damages. IN-38...
  • Page 69 MECHANICAL Page General Description ...................2 Cylinder Head ....................3...
  • Page 70 General Description MECHANICAL 1. General Description A: SPECIFICATION Intake 53.48 (2.1055) Free length (refer- mm (in) ence) Exhaust 44.03 (1.7335) 204.6 — 235.4 Intake (20.86 — 24.00, 46.00 — 52.93)/36.0 (1.4173) 182 — 210 Exhaust (18.56 — 21.41, 40.92 — 47.22)/33.0 (1.2992) Tension/spring N (kgf, lb)/mm Valve spring...
  • Page 71 Cylinder Head MECHANICAL 2. Cylinder Head B: DISPOSAL WARNING: A: INSPECTION • Metallic sodium is encapsulated in the ex- 1. VALVE SPRING haust valve. Metallic sodium is a strong alkaline material and poses a risk of causing a severe 1) Check the valve springs for damage, free length chemical reaction.
  • Page 72 Cylinder Head MECHANICAL • When the exhaust valve is broken, remove it CAUTION: from the cylinder head, perform appropriate • Concerning the liquid waste disposal of the processing in the same manner as the general liquid (sodium hydrate) produced in a chemical steel material.
  • Page 73 LUBRICATION Page General Description ...................2...
  • Page 74 General Description LUBRICATION 1. General Description A: SPECIFICATION Recommended oil: MOTUL 300V Power (5W-40) CAUTION: Use 5W-40 (100% synthetic). NOTE: The proper viscosity oil helps the engine maintain its ideal temperature, and cranking speed increased by re- ducing viscosity friction in hot condition. LU-2...
  • Page 75 QUICK REFERENCE INDEX TRANSMISSION SECTION CONTROL SYSTEMS CLUTCH SYSTEM This service manual has been prepared to provide SUBARU service personnel with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. This manual includes the procedures...
  • Page 77 CONTROL SYSTEMS Page General Description ...................2 MT Gear Shift Lever ...................4...
  • Page 78 General Description CONTROL SYSTEMS 1. General Description A: SPECIFICATION Item Specifications Swing torque of rod against lever N (kgf, lbf) 3.7 (0.38, 0.83) or less B: COMPONENT 1. 6MT GEAR SHIFT LEVER (14) (15) (16) (10) (11) (13) (12) AA-12000 Gear shift knob Spacer (15)
  • Page 79 • Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, in- stallation, disassembly and replacement. • Use SUBARU genuine fluid, grease etc. or equivalent. Do not mix fluid, grease, etc. of different grades or manufacturers.
  • Page 80 MT Gear Shift Lever CONTROL SYSTEMS 2. MT Gear Shift Lever A: REMOVAL 1) Disconnect the ground terminal from battery. 2) Remove the gear shift knob by turning it counterclockwise. 3) Remove the console box assembly. 4) Remove the cover - shift lever. 5) Remove the panel center LWR LH and RH.
  • Page 81 MT Gear Shift Lever CONTROL SYSTEMS 8) Remove the harness clamp. CS-01786 9) Remove the plate COMPL. CS-01787 10) Lift up the vehicle. 11) Remove the center exhaust pipe (rear). CS-5...
  • Page 82 MT Gear Shift Lever CONTROL SYSTEMS 12) Remove the center exhaust cover. CS-01630 13) Remove the crossmember. 14) Remove the snap pin and washer, and remove the reverse check cable. CS-01788 Snap pin Washer Reverse check cable 15) Move the transmission to the right side, and remove the joint COMPL, stay bolts and reverse check ca- ble.
  • Page 83 MT Gear Shift Lever CONTROL SYSTEMS NOTE: If the transmission is not moved aside, the joint COMPL and stay bolts may contact the body and cause dam- age. CS-01789 Joint COMPL bolt Stay bolt Reverse check cable 16) Remove the cushion rubber. CS-01790 17) Remove the gear shift lever.
  • Page 84 MT Gear Shift Lever CONTROL SYSTEMS Tightening torque: T1: 12 N·m (1.2 kgf-m, 8.9 ft-lb) T2: 32 N·m (3.3 kgf-m, 23.6 ft-lb) CS-01791 Reverse check cable 4) Install the reverse check cable, washer and snap pin. NOTE: Pay attention to the installing direction of the snap ring. CS-01792 Reverse check cable Snap pin...
  • Page 85 MT Gear Shift Lever CONTROL SYSTEMS • When checking visually, confirm that the gap of hole positions is 0.5 mm (0.02 in) or less. CS-01793 Hole of reverse check lever Hole of extension case 6) Install the crossmember. 7) Install the center exhaust cover. 8) Install the center exhaust pipe (rear).
  • Page 86 MT Gear Shift Lever CONTROL SYSTEMS 11) Install the boot and insulator assembly, and secure with a clamp. 12) Install the panel center LWR LH and RH. 13) Install the cover - shift lever. 14) Install the console box assembly. 15) Install the gear shift knob by rotating it clockwise from 14 to 18 turns so that the distance (A) from the gear shift knob end surface to the slider end surface becomes 10 mm (0.394 in) or more.
  • Page 87 MT Gear Shift Lever CONTROL SYSTEMS 2) Remove the bushing and spacer from the boss. CS-01808 Bushing Spacer D: ASSEMBLY NOTE: • Clean all the parts before assembly. • Apply NIGTIGHT LTS No. 2 grease or equivalent to each part. 1) Install the bushing and spacer to boss.
  • Page 88 MT Gear Shift Lever CONTROL SYSTEMS Tightening torque: 12 N·m (1.2 kgf-m, 8.9 ft-lb) CS-01802 Boss E: INSPECTION 1) Check the parts (bushing, cushion rubber, spacer, boot, stay and rod, etc.) for deformation, damage and wear. If necessary, correct or replace faulty parts. Compare the removed parts with new parts to judge if there are damages or not.
  • Page 89 MT Gear Shift Lever CONTROL SYSTEMS Swing torque: 3.7 N (0.38 kgf, 0.83 lbf) or less CS-01814 Pivot Swing torque CS-13...
  • Page 90 MT Gear Shift Lever CONTROL SYSTEMS CS-14...
  • Page 91 CLUTCH SYSTEM Page General Description ...................2...
  • Page 92 General Description CLUTCH SYSTEM 1. General Description A: SPECIFICATION Transmission type Type Pull type Clutch cover Diaphragm set load N (kgf, lbf) 10,000 (1020, 2248) Facing material Woven (non-asbestos) Clutch cover side 240 × 160 × 3.5 (9.45 × 6.30 × 0.138) O.D.
  • Page 93 FRONT SUSPENSION REAR SUSPENSION WHEEL AND TIRE SYSTEM BRAKE This service manual has been prepared to provide SUBARU service personnel POWER ASSISTED SYSTEM with the necessary information and data (POWER STEERING) for the correct maintenance and repair of SUBARU vehicles.
  • Page 95 FRONT SUSPENSION Page General Description ...................2 Wheel Alignment ..................7 Front Crossmember Support Plate ............17 Strut Tower Bar Front ................19 Front Flexible Draw Stiffener ..............31...

  • Page 96: General Description

    General Description FRONT SUSPENSION 1. General Description A: SPECIFICATION 1. FRONT ALIGNMENT (INSPECTION VALUE) Tire size 265/35R19 Wheel arch height mm (in) 359 (14.13) +12 mm +0.47 in (Tolerance: –24 mm –0.94 in Camber (tolerance: 0°30 Differences between RH and LH: 35 or –1°05...
  • Page 97 General Description FRONT SUSPENSION  = Individual toe angles FS-3...
  • Page 98 General Description FRONT SUSPENSION B: COMPONENT 1. FRONT SUSPENSION (32) (34) (13) (33) (23) (14) (12) (15) (11) (17) (26) (18) (19) (25) (35) (20) (24) (30) (21) (28) (16) (22) (29) (27) (10) (31) (30) AA-13010 FS-4...
  • Page 99 • When performing a repair, identify the cause of trouble and avoid unnecessary removal, disassembly and replacement. • Use SUBARU genuine grease, the recommended or equivalent. Do not mix grease etc. of different grades or manufacturers. • Do not secure a part in a vise directly. Place cushioning materials such as wood pieces, blocks, aluminum plates, or waste cloth between the part and the vise.
  • Page 100 — SUBARU SELECT Used for setting of each function and trouble- MONITOR 4 shooting for electrical system. NOTE: For detailed operation procedures of Subaru Se- lect Monitor 4, refer to “Application help”. STSSM4 2. GENERAL TOOL TOOL NAME REMARKS DST-i Used together with Subaru Select Monitor 4.

  • Page 101: Wheel Alignment

    Wheel Alignment FRONT SUSPENSION 2. Wheel Alignment A: INSPECTION Check the following items before performing the wheel alignment measurement. • Tire inflation pressure • Uneven wear of RH and LH tires, or difference of sizes • Tire runout • Excessive play and wear of ball joint •...
  • Page 102 Wheel Alignment FRONT SUSPENSION NOTE: Empty the trunk or luggage room, load the spare tire, jack and service tools, and fill up the fuel tank. 3) Set the steering wheel in a straight-ahead position, and stabilize the suspension by moving the vehicle in a straight line for 5 m (16 ft) or more.
  • Page 103 Wheel Alignment FRONT SUSPENSION 2) Set the adapter into the center of wheel, and then set the wheel alignment gauge. FS-00213 (1) Alignment gauge (2) Turning radius gauge (3) Adapter 3) Measure the camber angle in accordance with the operation manual for wheel alignment gauge. Front camber (difference between RH Rear camber (difference between RH and Tire size...
  • Page 104 Wheel Alignment FRONT SUSPENSION 5. FRONT WHEEL TOE-IN Toe-in: Inspection value   OUT 2 3 mm (OUT 0.08 0.12 in) 1) Set the toe-in gauge in the position at wheel axis center height behind the right and left front tires. 2) Place a mark at the center of both left and right tires, and measure distance “A”...
  • Page 105 Wheel Alignment FRONT SUSPENSION Thrust angle: Inspection value   0°  Less than 30 when “L” is 23 mm (0.9 in) or less FS-00658 Center line of loci (front axle) Center line of loci (rear axle) B: ADJUSTMENT CAUTION: When the wheel alignment has been adjusted, perform the following adjustment.
  • Page 106 Wheel Alignment FRONT SUSPENSION NOTE: Moving the adjusting bolt by one scale changes the camber by approximately 0°15. FS-00513 Strut ASSY Outer direction Camber is decreased. Adjusting bolt Inner direction Front axle housing Camber is increased. To increase camber. Rotate the left side counterclockwise. Rotate the right side clockwise.
  • Page 107 NOTE: Using of the steering wheel angle sensor output values shown on Subaru Select Monitor will facilitate your work. 2) Before adjusting toe-in, be sure to adjust the steering wheel in the straight-ahead position (steering angle sensor output: 0 deg).
  • Page 108 Wheel Alignment FRONT SUSPENSION 1) Loosen the self-locking nut after holding the bolt head section of lateral link assembly - front. RS-00536 2) Turn the adjusting bolt until toe-in is within the specification. NOTE: When the left and right wheels are adjusted for toe-in at the same time, the movement of one scale gradua- tion changes toe-in by approx.
  • Page 109 Wheel Alignment FRONT SUSPENSION NOTE: While holding the adjusting bolt side, tighten the nut side. 5. THRUST ANGLE When adjusting, adjust it to the following value. Thrust angle: Adjustment value   0°  Less than 20 when “L” is 15 mm (0.6 in) or less FS-00658 Center line of loci (front axle) Center line of loci (rear axle)
  • Page 110 Wheel Alignment FRONT SUSPENSION Vehicle is driven straight in the thrust angle direction while slanting in the oblique direction depending on the degree of the mean thrust angle. FS-00659 Thrust angle Body center line Thrust angle:    – : Rear RH wheel toe-in angle : Rear LH wheel toe-in angle Substitute only the positive toe-in values from each wheel into ...

  • Page 111: Front Crossmember Support Plate

    Front Crossmember Support Plate FRONT SUSPENSION 3. Front Crossmember Support Plate A: REMOVAL 1) Lift up the vehicle. 2) Remove the under cover - front. 3) Remove the front support. 4) Remove the flexible draw stiffener - front. 5) Remove the bolt, and remove the front crossmember support, support crossmember front and the support arm front.
  • Page 112 Front Crossmember Support Plate FRONT SUSPENSION 5) Lower the vehicle. FS-18...

  • Page 113: Strut Tower Bar Front

    Strut Tower Bar Front FRONT SUSPENSION 4. Strut Tower Bar Front A: REMOVAL CAUTION: Do not apply an overload to the rubber boot with the strut tower bar bended to its maximum. Pillow balls are contained inside the rubber boot, and therefore bending the strut tower bar excessively may damage the pillow balls.
  • Page 114 Strut Tower Bar Front FRONT SUSPENSION WARNING: Take care not to contact to the fuel pipe. The fuel pipe may be damaged, resulting in fuel leakage. AA-13057 2. WHEN THE STRUT TOWER BAR BRACKET IS REMOVED FROM THE VEHICLE 1) Attach a tape to the strut tower bar along the end face of the strut tower bar bracket LH. 2) Make an alignment mark (b) on the tape according to the alignment mark (a) on the strut tower bar bracket AA-13000 3) Remove the bolts which hold the strut tower bar to the strut tower bar bracket LH.
  • Page 115 Strut Tower Bar Front FRONT SUSPENSION 4) Remove the flange nuts which hold the strut tower bar brackets LH and RH to the strut mount. AA-13003 5) Remove the strut tower bar toward the VDC control module side through the back side of the intercooler. WARNING: Take care not to contact to the fuel pipe.
  • Page 116 Strut Tower Bar Front FRONT SUSPENSION 6) Remove the strut tower bar bracket LH from the strut mount. AA-13005 B: INSTALLATION CAUTION: • For parts which are not reusable, always use new parts. • Do not apply an overload to the rubber boot with the strut tower bar bended to its maximum. Pillow balls are contained inside the rubber boot, and therefore bending the strut tower bar excessively may damage the pillow balls.
  • Page 117 Strut Tower Bar Front FRONT SUSPENSION WARNING: Take care not to contact to the fuel pipe. The fuel pipe may be damaged, resulting in fuel leakage. AA-13002 3) Align the alignment marks (a) and (b) on the strut tower bar and the strut tower bar brackets LH and RH, and temporarily tighten with bolts.
  • Page 118 Strut Tower Bar Front FRONT SUSPENSION NOTE: Use HellermannTyton GalvaLok GL150 or equivalent tie-wraps. AA-13045 5) Tighten the bolts which hold the strut tower bar to the strut tower bar brackets LH and RH. Tightening torque: 15 N·m (1.5 kgf-m, 11.1 ft-lb) AA-13001 6) Peel off the tape for position alignment from the strut tower bar.
  • Page 119 Strut Tower Bar Front FRONT SUSPENSION 2) Make an alignment mark (b) on the tape according to the alignment mark (a) on the strut tower bar bracket LH. (Only when replacing with a new strut tower bar) AA-13000 3) Remove the strut tower bar bracket LH from the strut tower bar assembly. (Only when replacing with a new strut tower bar) AA-13033 4) Make sure that the alignment marks (a) on both ends (rear side) of the rubber boot at the strut tower bar...
  • Page 120 Strut Tower Bar Front FRONT SUSPENSION 5) Install the strut tower bar bracket LH to the strut mount, and temporarily tighten the new flange nut. AA-13034 6) Install the strut tower bar and the strut tower bar bracket RH from the VDC control module side so that it goes through the back side of the intercooler, and temporarily tighten the new flange nut.
  • Page 121 Strut Tower Bar Front FRONT SUSPENSION 8) Confirm that the clearance (A) between the strut tower bar assembly and the intercooler and the clearance (B) between the strut tower bar assembly and the cowl panel are secured. AA-13035 AA-13007 FS-27...
  • Page 122 Strut Tower Bar Front FRONT SUSPENSION 9) Confirm that the clearance (A) between the strut tower bar assembly and the bulkhead is secured equally on both the left and right sides. AA-13008 10) Confirm that the clearance (A) between the strut tower bar and the vacuum hose is 15 mm (0.591 in) or more, and fix the vacuum hose with tie-wrap (a).
  • Page 123 Strut Tower Bar Front FRONT SUSPENSION Tightening torque: 15 N·m (1.5 kgf-m, 11.1 ft-lb) AA-13001 12) Tighten the flange nuts of the strut tower bar bracket in the alphabetical order as shown in the figure. Tightening torque: 20 N·m (2.0 kgf-m, 14.8 ft-lb) •...
  • Page 124 Strut Tower Bar Front FRONT SUSPENSION • RH side AA-13053 13) Peel off the tape for position alignment from the strut tower bar. FS-30...

  • Page 125: Front Flexible Draw Stiffener

    Front Flexible Draw Stiffener FRONT SUSPENSION 5. Front Flexible Draw Stiffener A: REMOVAL CAUTION: Be careful not to damage the boot of the link ball. 1) Lift up the vehicle. 2) Loosen the lock nut (a). AA-13030 3) Rotate the rod (b) to adjust until the adjustment scale position (A) becomes 0 mm. CAUTION: Do not disassemble or further tighten the section (c) shown in the figure.
  • Page 126 Front Flexible Draw Stiffener FRONT SUSPENSION 5) Remove the rear bracket. AA-13014 6) Remove the front bracket, and remove the flexible draw stiffener - front and the front/rear brackets as a unit. AA-13015 B: INSTALLATION CAUTION: Be careful not to damage the boot of the link ball. 1) Install the front bracket.
  • Page 127 Front Flexible Draw Stiffener FRONT SUSPENSION Tightening torque: 100 N·m (10.2 kgf-m, 73.8 ft-lb) 4) Rotate the rod (b) to adjust until the adjustment scale position (A) becomes 2.5 — 3 mm (0.098 — 0.118 in). CAUTION: Do not disassemble or further tighten the section (c) shown in the figure. AA-13012 5) Check that the exposed length (B) of the threaded portion for adjustment is in a range from 1 to 14 mm (0.039 to 0.551 in).
  • Page 128 Front Flexible Draw Stiffener FRONT SUSPENSION Remove the front and rear brackets from the flexible draw stiffener - front. AA-13032 D: ASSEMBLY CAUTION: Be careful not to damage the boot of the link ball. Install the front and rear brackets to the flexible draw stiffener - front. Tightening torque: 60 N·m (6.1 kgf-m, 44.3 ft-lb) FS-34...
  • Page 129 REAR SUSPENSION Page General Description ...................2 Rear Sub Frame ..................8 Front Lateral Link ..................14 Rear Lateral Link ..................16 Rear Shock Absorber ................18 Rear Flexible Draw Stiffener ..............22...

  • Page 130: General Description

    General Description REAR SUSPENSION 1. General Description A: SPECIFICATION Tire size 265/35R19 Wheel arch height mm (in) 351 (13.82) +12 mm +0.47 in (Tolerance: –24 mm –0.94 in Camber (tolerance: 0°45 Differences between RH and LH: 45 or less) –1°50 03 (00.12) Toe-in mm (in)
  • Page 131 General Description REAR SUSPENSION B: COMPONENT 1. REAR SUSPENSION (11) (12) (15) (10) (13) (14) (10) (20) (19) (16) (17) (18) AA-13016 Rear sub frame ASSY (11) Rear stabilizer Tightening torque: N·m (kgf-m, ft-lb) Stopper UPR (12) Bushing - stabilizer T1: 30 (3.1, 22.1) Support - sub frame (13)
  • Page 132 General Description REAR SUSPENSION (10) (12) (14) (15) (11) (13) AA-13017 Rear sub frame ASSY Lateral link ASSY - rear Tightening torque: N·m (kgf-m, ft-lb) Self-locking nut (10) Rear axle housing T1: 7.5 (0.8, 5.5) Rear upper arm ASSY (11) Bushing B - rear axle housing T2: 60 (6.1, 44.3) Snap pin...
  • Page 133 General Description REAR SUSPENSION 2. REAR SHOCK ABSORBER RS-00541 Flange nut Dust cover - rear shock Tightening torque: N·m (kgf-m, ft-lb) Self-locking nut Helper - rear T1: 25 (2.5, 18.4) Shock mount - rear Coil spring - rear T2: 35 (3.6, 25.8) Rubber seat - shock UPR Shock absorber COMPL - rear RS-5...
  • Page 134 • When performing a repair, identify the cause of trouble and avoid unnecessary removal, disassembly and replacement. • Use SUBARU genuine grease, the recommended or equivalent. Do not mix grease etc. of different grades or manufacturers. • Do not secure a part in a vise directly. Place cushioning materials such as wood blocks, aluminum plates, or waste cloth between the part and the vise.
  • Page 135 General Description REAR SUSPENSION D: PREPARATION TOOL 1. GENERAL TOOL TOOL NAME REMARKS Alignment tester Used for measuring wheel alignment. Toe-in gauge Used for toe-in measurement. Jack Used for removing and installing suspension. Bearing puller Used for removing bushings. Tie-rod ball joint puller Used for disconnecting the lateral link assembly - front.

  • Page 136: Rear Sub Frame

    Rear Sub Frame REAR SUSPENSION 2. Rear Sub Frame A: REMOVAL 1) Disconnect the ground terminal from battery. 2) Lift up the vehicle, and then remove the rear wheels. 3) Remove the rear exhaust pipe. 4) Remove the propeller shaft assembly. 5) Remove the clip and bolt on the harness clamp, and remove the rear ABS wheel speed sensor.
  • Page 137 Rear Sub Frame REAR SUSPENSION 8) Remove the clamp of the sub rear harness. RS-00484 9) Remove the sensor assembly - headlight beam leveler. 10) Remove the fuel tank protector. 11) Remove the rear sub frame assembly. (1) Remove the bolts and nuts from the lower side of rear shock absorber assembly. RS-00352 (2) Support the rear sub frame assembly using a transmission jack.
  • Page 138 Rear Sub Frame REAR SUSPENSION CAUTION: While checking there is no dragging of harness and wire, lower it slowly with a transmission jack. AA-13021 12) As necessary, remove each part from the rear sub frame assembly. B: INSTALLATION CAUTION: • For parts which are not reusable, always use new parts. •...
  • Page 139 Rear Sub Frame REAR SUSPENSION Tightening torque: T1: 70 N·m (7.1 kgf-m, 51.6 ft-lb) T2: 145 N·m (14.8 kgf-m, 106.9 ft-lb) AA-13020 (3) Temporarily tighten the bolts on the body side of the rear support sub frame. AA-13022 RS-11...
  • Page 140 Rear Sub Frame REAR SUSPENSION (4) Temporarily tighten the bolts on the rear sub frame side of the rear support sub frame. AA-13023 (5) Tighten the bolts on the body side. Tightening torque: 70 N·m (7.1 kgf-m, 51.6 ft-lb) (6) Tighten the bolts on the rear sub frame side. Tightening torque: 145 N·m (14.8 kgf-m, 106.9 ft-lb) 4) Install the bolts and nuts on the lower side of rear shock absorber assembly.
  • Page 141 Rear Sub Frame REAR SUSPENSION 14) Inspect the wheel alignment and adjust if necessary. CAUTION: When the wheel alignment has been adjusted, perform adjustment of the VDC sensor midpoint set- ting mode. 15) Connect the battery ground terminal. 16) Perform reinitialization of the auto headlight beam leveler system. C: INSPECTION Check the removed parts for wear, damage and crack, and repair or replace them if faulty.

  • Page 142: Front Lateral Link

    Front Lateral Link REAR SUSPENSION 3. Front Lateral Link A: REMOVAL 1) Lift up the vehicle, and then remove the rear wheels. 2) Remove the trailing link. 3) Remove the nuts, and remove the cable assembly - parking brake. RS-00535 4) Remove the lateral link assembly - front.
  • Page 143 Front Lateral Link REAR SUSPENSION • Check the pillow ball bushing for looseness. • Visually check the boot on the ball joint for abnormal cracks, fatigue or damage. 2) Install the lateral link assembly - front. CAUTION: • When installing the lateral link assembly - front, install the washer A on the nut side of the pillow ball bushing.

  • Page 144: Rear Lateral Link

    Rear Lateral Link REAR SUSPENSION 4. Rear Lateral Link A: REMOVAL 1) Disconnect the ground terminal from battery. 2) Lift up the vehicle, and then remove the rear wheels. 3) Remove the sensor assembly - headlight beam leveler. 4) Remove the lateral link assembly - rear. (1) Remove the nut and disconnect the rear stabilizer link.
  • Page 145 Rear Lateral Link REAR SUSPENSION Tightening torque: T1: 38 N·m (3.9 kgf-m, 28 ft-lb) T2: 80 N·m (8.2 kgf-m, 59 ft-lb) T3: 90 N·m (9.2 kgf-m, 66.4 ft-lb) AA-13029 3) Install the sensor assembly - headlight beam leveler. CAUTION: Do not apply impact to the sensor assembly - headlight beam leveler or forcibly move the arm. Doing so may cause sensor damage and malfunction.

  • Page 146: Rear Shock Absorber

    Rear Shock Absorber REAR SUSPENSION 5. Rear Shock Absorber A: REMOVAL 1) Disconnect the ground terminal from battery. 2) Lift up the vehicle, and then remove the rear wheels. 3) Remove the sensor assembly - headlight beam leveler. 4) Remove the bolts and nuts, and lower the lateral link assembly - rear. (1) Remove the nut and disconnect the rear stabilizer link.
  • Page 147 Rear Shock Absorber REAR SUSPENSION 8) Remove the nuts on the upper side of rear shock absorber assembly. RS-00408 9) Lower the lateral link assembly - rear, and remove the rear shock absorber assembly. B: INSTALLATION CAUTION: • For parts which are not reusable, always use new parts. •...
  • Page 148 Rear Shock Absorber REAR SUSPENSION Tightening torque: T1: 38 N·m (3.9 kgf-m, 28 ft-lb) T2: 80 N·m (8.2 kgf-m, 59 ft-lb) T3: 90 N·m (9.2 kgf-m, 66.4 ft-lb) AA-13029 (5) Install the sensor assembly - headlight beam leveler. CAUTION: Do not apply impact to the sensor assembly - headlight beam leveler or forcibly move the arm. Doing so may cause sensor damage and malfunction.
  • Page 149 Rear Shock Absorber REAR SUSPENSION CAUTION: When the wheel alignment has been adjusted, perform adjustment of the VDC sensor midpoint set- ting mode. 6) Connect the battery ground terminal. 7) Perform reinitialization of the auto headlight beam leveler system. C: INSPECTION Refer to “Front Strut”...

  • Page 150: Rear Flexible Draw Stiffener

    Rear Flexible Draw Stiffener REAR SUSPENSION 6. Rear Flexible Draw Stiffener A: REMOVAL CAUTION: Be careful not to damage the boot of the link ball. 1) Disconnect the ground terminal from battery. 2) Tilt the rear seat backrest forward. 3) Remove the mat - trunk. 4) Remove the trim panel - trunk rear.
  • Page 151 Rear Flexible Draw Stiffener REAR SUSPENSION CAUTION: Do not disassemble or further tighten the section (c) shown in the figure. AA-13012 10) Remove the nuts, and then remove the flexible draw stiffener - rear. AA-13025 11) Remove the nut plate (a) and the flexible draw stiffener - rear bracket (b). AA-13026 RS-23...
  • Page 152 Rear Flexible Draw Stiffener REAR SUSPENSION B: INSTALLATION CAUTION: • For parts which are not reusable, always use new parts. • Be careful not to damage the boot of the link ball. NOTE: For work procedures of installing a new trim panel - trunk side, refer to “Trunk Room Trim” of “EXTERIOR/ INTERIOR TRIM”...
  • Page 153 Rear Flexible Draw Stiffener REAR SUSPENSION CAUTION: Do not disassemble or further tighten the section (c) shown in the figure. AA-13012 6) Tighten the lock nut. Tightening torque: 6 N·m (0.6 kgf-m, 4.4 ft-lb) 7) Install the flexible draw stiffener - rear guard. (1) Temporarily tighten the bolts at 2 locations on the outer side (lower side) of the vehicle.
  • Page 154 Rear Flexible Draw Stiffener REAR SUSPENSION (2) Temporarily tighten the bolts at 2 locations on the inner side (rear side) of the vehicle. AA-13048 (3) Tighten at 4 locations equally, a little at a time, to apply the torque evenly. Tightening torque: 5 N·m (0.5 kgf-m, 3.7 ft-lb) (4) Further tighten all the bolts.
  • Page 155 Rear Flexible Draw Stiffener REAR SUSPENSION CAUTION: Do not disassemble or further tighten the section (c) shown in the figure. AA-13012 3) Tighten the lock nut. Tightening torque: 6 N·m (0.6 kgf-m, 4.4 ft-lb) RS-27...
  • Page 156 Rear Flexible Draw Stiffener REAR SUSPENSION RS-28...
  • Page 157 WHEEL AND TIRE SYSTEM Page General Description ...................2 Tire Repair Kit ....................3...
  • Page 158 General Description WHEEL AND TIRE SYSTEM 1. General Description A: SPECIFICATION 1. NOTE WT-00001 (1) Inset (2) P.C.D. NOTE: Size and inflation pressure of the standard equipment tire and other appropriate tires for equipment are de- scribed on the “Tire inflation pressure” label attached to the body side of the driver’s door. 2.
  • Page 159 Tire Repair Kit WHEEL AND TIRE SYSTEM 2. Tire Repair Kit A: NOTE • Refer to the owner’s manual for the tire puncture repair. • Replace the expired sealant with a new part. • The expiration date of a tire puncture repair sealant is shown on the label of the sealant bottle. The expired sealant is not included in the warranty.
  • Page 160 Tire Repair Kit WHEEL AND TIRE SYSTEM 2. REPLACEMENT OF TIRE PUNCTURE REPAIR KIT CAUTION: After using the puncture repair kit, replace the repair sealant and the speed limit seal. WT-10027 (1) Compressor (2) Repair sealant bottle Set the new tire puncture repair kit at the specified position of the vehicle. WT-4...
  • Page 161 BRAKE Page General Description ...................2 Front Brake Pad ..................6 Rear Brake Pad ..................9...
  • Page 162 General Description BRAKE 1. General Description A: SPECIFICATION NOTE: Refer to “PARKING BRAKE” for parking brake specifications. 1. FRONT DISC BRAKE Item Specification Size 18-inch Opposed 6-POT piston type Type Ventilated disc (Brembo) 30 × 2,34 × 2, 38 × 2 Effective cylinder diameter mm (in) (1.181 ×...
  • Page 163 General Description BRAKE B: COMPONENT 1. FRONT DISC BRAKE (13) (10) (11) ( 1 2 ) ( 1 2 ) (11) (10) BR-10300 Caliper body Pin - disc brake Tightening torque: N·m (kgf-m, ft-lb) Bleeder - screw Pad clip nut T1: 20 (2, 14.8) Cap - bleeder (10)
  • Page 164 General Description BRAKE 2. REAR DISC BRAKE (DRUM IN DISC TYPE) ( 3 ) ( 2 ) ( 5 ) ( 1 ) (10) (10) ( 1 2 ) ( 1 4 ) ( 1 3 ) ( 11 ) ( 1 5 ) ( 1 6 ) ( 1 7 )
  • Page 165 • Some vehicle components are extremely hot immediately after driving. Be wary of receiving burns from heated parts. • Use SUBARU genuine grease, the recommended or equivalent. Do not mix grease etc. of different grades or manufacturers. • Be sure to tighten fasteners including bolts and nuts to the specified torque.
  • Page 166 Front Brake Pad BRAKE 2. Front Brake Pad A: REMOVAL 1) Lift up the vehicle, and then remove the front wheels. 2) Remove the pad - disc brake front. (1) Remove the pin - disc brake (a), cross spring (b) and pad clip bolt (c). (2) Remove the pad - disc brake front.
  • Page 167 Front Brake Pad BRAKE 3) Install the pad - disc brake front. NOTE: Install the parts with the pad wear indicator facing upward. AA-13041 (a) Pad - disc brake front outer (b) Pad - disc brake front inner (c) Pad wear indicator 4) Install the pad clip bolt.
  • Page 168 Front Brake Pad BRAKE • Wear indicators are installed on the pad - disc brake front outer, and a squeaking sound is heard if the pad is worn to the limit. AA-13042 Standard (a) Wear limit (b) Pad thickness 9.5 mm (0.37 in) 2 mm (0.08 in) 2) If the wear limit is exceeded in the inspection, replace the pad - disc brake front.
  • Page 169 Rear Brake Pad BRAKE 3. Rear Brake Pad A: INSPECTION 1) Check the thickness of the pad - disc brake rear. NOTE: • Always replace the pads of both wheels and both sides as a set. • Replace pad clips if they are twisted or worn. •...
  • Page 170 Rear Brake Pad BRAKE BR-10...
  • Page 171 POWER ASSISTED SYSTEM (POWER STEERING) Page General Description ...................2 Steering Gearbox ..................4 Pipe Assembly ...................5...
  • Page 172 Operation flow rate: L (US qt, Imp qt) 3,000 r/min: 7.3 (7.7, 6.4) Revolution speed range: r/min 560 — 9,600 Direction of rotation Clockwise SUBARU ATF Description ATF DEXRON III Power steering fluid Oil tank: 0.2 (0.2, 0.2) Capacity: L (US qt, Imp qt) Whole system: 0.7 (0.7, 0.6)
  • Page 173 31 (3.16, 7) or less At standstill on paved road with engine stalled: N (kgf, lbf) 294.2 (29.9, 66.2) or less Recommended power steering fluid SUBARU ATF or ATF DEXRON III B: COMPONENT 1. HOSE AND TANK (13) (17) (16)
  • Page 174 Steering Gearbox POWER ASSISTED SYSTEM (POWER STEERING) 2. Steering Gearbox A: ADJUSTMENT 1) Adjust the front toe-in. PS-00107 (1) Lock nut 2) Check the steering angle of the wheels. Standard of steering angle: Inner wheel Outer wheel 32.0°1.5° 28.6°1.5° 3) If the steering wheel spokes are not horizontal when wheels are set in the straight ahead position, or error is more than 5°...
  • Page 175 Pipe Assembly POWER ASSISTED SYSTEM (POWER STEERING) 3. Pipe Assembly A: REMOVAL 1) Disconnect the ground terminal from battery. 2) Remove the under cover. 3) Lift up the vehicle, and remove the front crossmember support plate. PS-00445 (1) Front crossmember support plate 4) Remove the one pipe joint at the center of the gearbox, and connect the vinyl hose to the pipe and the joint.
  • Page 176 Pipe Assembly POWER ASSISTED SYSTEM (POWER STEERING) 6) Disconnect the return hose from return pipe and disconnect the pressure hose from feed pipe. PS-00538 (1) Feed pipe (2) Return pipe (3) Pressure hose (4) Return hose 7) Remove the air intake duct. 8) Disconnect the suction hose and pressure hose from oil pump.
  • Page 177 Pipe Assembly POWER ASSISTED SYSTEM (POWER STEERING) 9) Disconnect the suction hose and return hose from the reservoir tank. PS-00799 (1) Reservoir tank (2) Suction hose (3) Return hose 10) Remove the hose bracket and take out the hose assembly from vehicle. PS-00624 (1) Hose ASSY (2) Hose bracket...
  • Page 178 Pipe Assembly POWER ASSISTED SYSTEM (POWER STEERING) NOTE: When installing a new suction hose, perform the following steps 2) through 4). 1) Temporarily tighten the hose bracket bolt. PS-00624 (1) Hose ASSY (2) Hose bracket 2) Install a new clip band (a) to the pressure hose (d) and suction hose (c). CAUTION: Align the installation position of the clip band (a) with the protector edge (e) of the suction hose (c).
  • Page 179 Pipe Assembly POWER ASSISTED SYSTEM (POWER STEERING) NOTE: Set the protective cover so that the slit faces downward. AA-13051 (a) Protector (b) Area wrapped by the protective cover 4) Attach a tie-wrap to the position (b) shown in the figure and fix the protective cover (a). AA-13052 (a) Protective cover (b) Tie-wrap...
  • Page 180 Pipe Assembly POWER ASSISTED SYSTEM (POWER STEERING) CAUTION: Firmly insert the plastic clip of return hose to the bracket. PS-01212 (1) Reservoir tank (2) Suction hose (3) Return hose (4) Plastic clip 6) Tighten the hose bracket bolt. Tightening torque: 18 N·m (1.8 kgf-m, 13.3 ft-lb) 7) Connect the suction hose and pressure hose to the oil pump.
  • Page 181 Pipe Assembly POWER ASSISTED SYSTEM (POWER STEERING) 8) Temporarily connect the pressure hose to feed pipe and return hose to return pipe. Temporarily tighten the bolt of clamp E. PS-00847 (1) Return hose (2) Pressure hose (3) Clamp E (4) Return pipe (5) Feed pipe NOTE: Make sure that the character “8”...
  • Page 182 Pipe Assembly POWER ASSISTED SYSTEM (POWER STEERING) Tightening torque: Cylinder side: 27 N·m (2.8 kgf-m, 19.9 ft-lb) Gear housing side: 17 N·m (1.7 kgf-m, 12.5 ft-lb) PS-00553 (1) Pipe A (2) Pipe B 12) Install the front crossmember support plate and jack-up plate. 13) Install the under cover.
  • Page 183 BODY SECTION INSTRUMENTATION/DRIVER INFO EXTERIOR/INTERIOR TRIM EXTERIOR BODY PANELS This service manual has been prepared to provide SUBARU service personnel with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. This manual includes the procedures...
  • Page 185 INSTRUMENTATION/DRIVER INFO Page General Description ...................2...
  • Page 186 General Description INSTRUMENTATION/DRIVER INFO 1. General Description A: SPECIFICATION 1. COMBINATION METER ASSEMBLY When checking the Operation method, indicator needle Meter, display Drive control display method operation/needle reading operation Speedometer Tachometer Stepping motor type Combination meter — Engine coolant temperature gauge Fuel gauge ABS warning light Driver’s seat belt warning light...
  • Page 187 General Description INSTRUMENTATION/DRIVER INFO When checking the Operation method, indicator needle Meter, display Drive control display method operation/needle reading operation ODO indicator Trip indicator ECO gauge SI-DRIVE mode indicator Information (intervention) display Warning and indicator display • Door partially latched •...
  • Page 188 General Description INSTRUMENTATION/DRIVER INFO IDI-4...
  • Page 189 EXTERIOR/INTERIOR TRIM Page General Description ...................2 Mud Guard ....................8 Front Bumper ...................14 Rear Bumper ....................24 Side Garnish & Side Spoiler ..............40 Rear Spoiler .....................64 Lower Inner Trim ..................68 Trunk Room Trim ..................73...

  • Page 190: General Description

    General Description EXTERIOR/INTERIOR TRIM 1. General Description A: COMPONENT 1. MUD GUARD AA-10106 Under cover - front Mud guard - front Plate air flap - rear Plate air flap - front Mud guard - rear EI-2...
  • Page 191 General Description EXTERIOR/INTERIOR TRIM 2. FRONT GRILLE AA-10107 Front grille emblem Ornament Spacer grille - front Cover - grille front Front grille ASSY EI-3...
  • Page 192 General Description EXTERIOR/INTERIOR TRIM 3. FRONT BUMPER (11) (10) (14) (13) (12) (15) AA-10112 Sealing bumper - front Cover UPR - front Tightening torque: N·m (kgf-m, ft-lb) Plate UPR - front (10) Energy absorber plate - front T1: 1.5 (0.15, 1.11) Bumper face - front (11) Bracket UPR - COMPL...
  • Page 193 General Description EXTERIOR/INTERIOR TRIM 4. FRONT UNDER SPOILER AA-10113 Bumper face - front Well nut Tightening torque: N·m (kgf-m, ft-lb) Front under spoiler T: 1.0 (0.1, 0.7) 5. REAR BUMPER (10) AA-10110 Bumper beam COMPL - rear Bumper face - rear Tightening torque: N·m (kgf-m, ft-lb) Bracket - rear bumper side Rear bumper extension...
  • Page 194 General Description EXTERIOR/INTERIOR TRIM 6. SIDE GARNISH & SIDE SPOILER AA-10111 Garnish ASSY - fender Rear quarter garnish Tightening torque: N·m (kgf-m, ft-lb) Molding garnish Spoiler ASSY - side T1: 0.35 (0.04, 0.26) S209 emblem Side under spoiler T2: 1.0 (0.1, 0.7) Rear door garnish 7.
  • Page 195 General Description EXTERIOR/INTERIOR TRIM 8. INNER TRIM (11) (12) (14) (13) (10) AA-10116 Tether clip Trim panel - center pillar LWR (13) Side sill plate - front Trim panel - front pillar UPR Cover - catcher (14) Side sill plate - rear Cover side sill - front Cover side sill - rear INN Cover side sill - front INN...

  • Page 196: Mud Guard

    Mud Guard EXTERIOR/INTERIOR TRIM 2. Mud Guard A: REMOVAL 1. MUD GUARD - REAR 1) Disconnect the ground terminal from battery. 2) Remove the rear tires. 3) Remove the bumper face - rear. 4) Remove the mud guard - rear. (1) Release the clip (a) of the spoiler assembly - side.
  • Page 197 Mud Guard EXTERIOR/INTERIOR TRIM (3) Remove the clip (a), then remove the mud guard - rear. AA-10089 B: INSTALLATION 1. MUD GUARD - REAR NOTE: • When using a new reinforce wheel apron, perform the work described in step 1). •...
  • Page 198 Mud Guard EXTERIOR/INTERIOR TRIM NOTE: Align the pattern paper (a) to the holes and trim lines on the vehicle shown in the figure, and attach masking tapes (b). AA-10134 Pattern paper LH Masking tape (8) Stamp a mark with a punch at the position (a) shown in the figure. AA-10135 EI-10...
  • Page 199 Mud Guard EXTERIOR/INTERIOR TRIM (9) Put markings with white marker pen, etc. along the outer boundary of the pattern paper (a). AA-10136 Pattern paper LH Marking position (10) Remove the pattern paper. (11) Using a drill, make a pilot hole of 3 mm (0.12 in) diameter at the position marked in step (9), and then make a pilot hole of 6 mm (0.24 in) diameter.
  • Page 200 Mud Guard EXTERIOR/INTERIOR TRIM (12) Make a hole of 10 mm (0.39 in) to the position where the pilot hole is created using a drill. AA-10138 (13) By using an air saw in the numerical order shown in the figure, cut the reinforce wheel apron along the marking.
  • Page 201 Mud Guard EXTERIOR/INTERIOR TRIM (19) If the NOX-RUST (7703WJ) or equivalent is spilled, wipe it off and clean the area. 2) Install the mud guard - rear in the reverse order of removal. EI-13...

  • Page 202: Front Bumper

    Front Bumper EXTERIOR/INTERIOR TRIM 3. Front Bumper A: REMOVAL 1. FRONT UNDER SPOILER NOTE: Perform the procedures for the right side in the same way as for the left side. 1) Remove the front under spoiler. (1) Remove the bolts (c) and washers (d) securing the front under spoiler (b) from the bumper face - front (a).
  • Page 203 Front Bumper EXTERIOR/INTERIOR TRIM C: DISASSEMBLY 1. FRONT BUMPER EXTENSION 1) Remove the front bumper extension. CAUTION: Do not reuse the front bumper extension. (1) Remove the nuts (a) and screws (b). AA-10032 (2) Remove the double-sided tape, and remove the front bumper extension. NOTE: If the double-sided tape is difficult to remove, warm it with a hairdryer, etc.
  • Page 204 Front Bumper EXTERIOR/INTERIOR TRIM (2) Attach the pattern papers (a), (b) and (c) to the bumper face - front. (d) (d) AA-10140 Pattern paper FR BMP EXT Pattern paper FR BMP EXT Alignment position for convex angle Pattern paper FR BMP EXT Masking tape Alignment position for trim line (3) Make mark-off lines for drilling holes (d) at 3 locations according to the pattern papers (a), (b) and (c).
  • Page 205 Front Bumper EXTERIOR/INTERIOR TRIM (4) Make a pilot hole of 3 mm (0.12 in) diameter at the mark-off line position (a) using a drill, and then make a pilot hole of 6 mm (0.24 in) diameter. AA-10042 (5) Make a hole of 10 mm (0.39 in) diameter (a) and a hole of 12 mm (0.47 in) diameter (b) at the locations shown in the figure.
  • Page 206 Front Bumper EXTERIOR/INTERIOR TRIM (2) Attach the pattern paper (a) while bending it toward the arrow directions. AA-10120 (3) Make a mark-off line for drilling hole (b) according to the pattern paper (a). AA-10121 EI-18...
  • Page 207 Front Bumper EXTERIOR/INTERIOR TRIM (4) Make mark-off lines for drilling holes (b) at 7 locations shown in the figure using a straight pick (d) or similar. Ft UP AA-10044 Bumper mark-off line (5 mm (0.2 Bumper face - front Straight pick in)) Mark-off line position (5) Prepare a stopper by wrapping a cloth adhesive tape, etc.
  • Page 208 Front Bumper EXTERIOR/INTERIOR TRIM (6) Make a pilot hole of 3 mm (0.12 in) diameter at the mark-off line position (d) using a drill (c), and then make a pilot hole of 7 mm (0.28 in) diameter. Ft UP AA-10045 Bumper face - front Drill Mark-off line position...
  • Page 209 Front Bumper EXTERIOR/INTERIOR TRIM • Be sure to make a hole of a specified diameter. The front under spoiler may not be installed if the hole diameter is large. AA-10122 (9) Remove the clip (a) on vehicle, and insert the well nuts (b) to the hole positions (c) on lower side of the bumper face - front.
  • Page 210 Front Bumper EXTERIOR/INTERIOR TRIM (2) Peel off the backing sheet (a) on the front bumper extension by 38.5 mm (1.52 in), and then remove the whole backing sheet (b). AA-10033 (3) Set the front bumper extension (f) to the bumper face - front, and temporarily install it with nut (b) and screws (d) and (e).
  • Page 211 Front Bumper EXTERIOR/INTERIOR TRIM AA-10035 Dotted line Front fender 0.8 mm (0.03 in) Front bumper extension Bumper face - front (7) Peel off the backing sheet, and press-fit the front bumper extension. (8) Tighten the nuts and screws. Tightening torque: T1: 1.5 N·m (0.15 kgf-m, 1.11 ft-lb) T2: 2.0 N·m (0.2 kgf-m, 1.48 ft-lb) T3: 4.5 N·m (0.46 kgf-m, 3.32 ft-lb)

  • Page 212: Rear Bumper

    Rear Bumper EXTERIOR/INTERIOR TRIM 4. Rear Bumper A: REMOVAL 1) Disconnect the ground terminal from battery. 2) Remove the mat - trunk. 3) Remove the trim panel - trunk rear. 4) Remove the light assembly - rear combination. 5) Remove the bumper face - rear. (1) Remove the screws on the bumper face - rear.
  • Page 213 Rear Bumper EXTERIOR/INTERIOR TRIM CAUTION: Pulling with excessive force may damage the bracket. AA-10097 6) Remove the rear bumper extension. CAUTION: Do not reuse the rear bumper extension. (1) Remove the nut. AA-10084 (2) Remove the double-sided tape, and remove the rear bumper extension. NOTE: If the double-sided tape is difficult to remove, warm it with a hairdryer, etc.
  • Page 214 Rear Bumper EXTERIOR/INTERIOR TRIM (1) Remove screws (b) of the rear quarter spoiler (a). AA-10072 (2) Remove the double-sided tape, and remove the rear quarter spoiler. NOTE: If the double-sided tape is difficult to remove, warm it with a hairdryer, etc. to make the removal easier. B: INSTALLATION NOTE: •...
  • Page 215 Rear Bumper EXTERIOR/INTERIOR TRIM (3) Make a mark-off line (c) according to pattern papers (a) and (b). AA-10154 Pattern paper LH OUT Pattern paper LH IN Mark-off line (4) Cut the lower part of the bumper face - rear along the mark-off line. CAUTION: Remove any burrs on the cut sections (a) to avoid damaging the vehicle.
  • Page 216 Rear Bumper EXTERIOR/INTERIOR TRIM (1) Attach the pattern paper (a) so that it fits the fender arch shape mating surface (b). AA-10123 (2) Using a straight pick (c) or similar, make mark-off lines for drilling holes (b) at 2 locations according to the pattern paper (a).
  • Page 217 Rear Bumper EXTERIOR/INTERIOR TRIM CAUTION: Be sure to prepare a stopper; otherwise, the drill may interfere with the bumper face - rear and cause damage. AA-10027 5 mm (0.2 in) Drill bit Adhesive tape (4) Make a pilot hole of 3 mm (0.12 in) diameter at the mark-off line position (b) using a drill (a), and then make a hole of 6 mm (0.24 in) diameter.
  • Page 218 Rear Bumper EXTERIOR/INTERIOR TRIM CAUTION: Be sure to confirm the direction of installation. If the installation direction is not correct, the rear quarter spoiler may not be installed. AA-10066 J nut Bumper face - rear Hole position 3) Perform the work for installing the rear bumper extension. (1) Print out and cut the pattern papers named as “RR BMPR EXT, Patern paper LH”.
  • Page 219 Rear Bumper EXTERIOR/INTERIOR TRIM (3) Make a mark-off line for drilling hole (b) according to the pattern paper (a). AA-10144 Pattern paper RR BMP EXT (1) Mark-off line position (4) Press the pattern papers (a) and (b) against the bumper face - rear, and attach masking tapes (c). AA-10145 Pattern paper RR BMP EXT (2) Pattern paper RR BMP EXT (3)
  • Page 220 Rear Bumper EXTERIOR/INTERIOR TRIM (5) Make a mark-off line for drilling (c) according to pattern papers (a) and (b). AA-10146 Pattern paper RR BMP EXT (2) Pattern paper RR BMP EXT (3) Mark-off line (6) Cut the end part (a) of the bumper face - rear shown in the figure. CAUTION: Remove any burrs on the cut section to avoid damaging the vehicle.
  • Page 221 Rear Bumper EXTERIOR/INTERIOR TRIM (7) Make a pilot hole of 3 mm (0.12 in) diameter at the mark-off line position (a) using a drill, and then make a pilot hole of 6 mm (0.24 in) diameter. AA-10069 (8) Make a hole of 12 mm (0.47 in) diameter at the position (a) where the pilot hole is created using a drill. CAUTION: Be sure to make a hole of a specified diameter.
  • Page 222 Rear Bumper EXTERIOR/INTERIOR TRIM • Heating a particular small area will cause deformation of the parts. AA-10073 6) Install the rear quarter spoiler. (1) Peel off 38.5 mm (1.52 in) of the backing sheet (b) on the rear quarter spoiler (a). AA-10074 EI-34...
  • Page 223 Rear Bumper EXTERIOR/INTERIOR TRIM (2) Attach the backing sheet that was peeled off by 38.5 mm (1.52 in) to the front side with masking tape (a). AA-10100 (3) Temporarily install the rear quarter spoiler (a) with screws (b). AA-10075 EI-35...
  • Page 224 Rear Bumper EXTERIOR/INTERIOR TRIM (4) Install the washer (c) and the clip (d). AA-10076 Rear quarter spoiler Washer Clip Bumper face - rear (5) Adjust the position of rear quarter spoiler end according to the bumper face - rear. NOTE: A marking with a masking tape, etc.
  • Page 225 Rear Bumper EXTERIOR/INTERIOR TRIM • Confirm that the molding (f) of the rear quarter spoiler (a) is not caught in and deformed. AA-10078 Rear quarter spoiler Direction of peeling off the backing Opening paper Backing sheet Bumper face - rear Molding (7) Press-fit the rear quarter spoiler.
  • Page 226 Rear Bumper EXTERIOR/INTERIOR TRIM Tightening torque: 3.5 N·m (0.4 kgf-m, 2.6 ft-lb) AA-10086 (3) Install the bumper face - rear to the vehicle. (4) Temporarily install the rear bumper extension (a) and the rear quarter garnish (b) with screws (c). NOTE: Confirm the position of arch sections on the rear quarter garnish and the rear bumper extension.
  • Page 227 Rear Bumper EXTERIOR/INTERIOR TRIM (5) Align the arch section of the rear bumper extension to the position shown as dotted line (d). AA-10087 Rear bumper extension Rear quarter garnish Bumper face - rear Rear quarter outer Dotted line (6) Peel off the backing sheet, and press-fit the rear bumper extension. (7) Tighten the screws temporarily installed in step (4).

  • Page 228: Side Garnish & Side Spoiler

    Side Garnish & Side Spoiler EXTERIOR/INTERIOR TRIM 5. Side Garnish & Side Spoiler A: REMOVAL AA-10111 Garnish ASSY - fender Rear quarter garnish Tightening torque: N·m (kgf-m, ft-lb) Molding garnish Spoiler ASSY - side T1: 0.35 (0.04, 0.26) S209 emblem Side under spoiler T2: 1.0 (0.1, 0.7) Rear door garnish...
  • Page 229 Side Garnish & Side Spoiler EXTERIOR/INTERIOR TRIM (2) Remove the clips (a). AA-10011 (3) Remove the double-sided tape, and remove the side under spoiler. NOTE: If the double-sided tape is difficult to remove, warm it with a hairdryer, etc. to make the removal easier. 2.
  • Page 230 Side Garnish & Side Spoiler EXTERIOR/INTERIOR TRIM (1) Disconnect the tie-wrap (a). AA-10005 (2) Remove the double-sided tape, and remove the molding garnish (a). CAUTION: Do not reuse the molding garnish. NOTE: If the double-sided tape is difficult to remove, warm it with a hairdryer, etc. to make the removal easier. AA-10006 3.
  • Page 231 Side Garnish & Side Spoiler EXTERIOR/INTERIOR TRIM (1) Remove the hexagon cap nut and washer (b) from the rear quarter garnish (a). AA-10048 (2) Remove the double-sided tape, and remove the rear quarter garnish. NOTE: If the double-sided tape is difficult to remove, warm it with a hairdryer, etc. to make the removal easier. 4.
  • Page 232 Side Garnish & Side Spoiler EXTERIOR/INTERIOR TRIM (1) Attach the pattern papers (d) through (k) to the spoiler assembly - side (a) along the shape-matching positions (c). (2) Using a straight pick or similar, make mark-off lines for drilling holes (b) according to the pattern pa- pers (d) through (k).
  • Page 233 Side Garnish & Side Spoiler EXTERIOR/INTERIOR TRIM (3) Prepare a stopper by wrapping a cloth adhesive tape, etc. around the drill bit at the position 5 mm (0.2 in) from the tip end. CAUTION: Be sure to prepare a stopper; otherwise, the drill may interfere with the spoiler assembly - side and cause damage.
  • Page 234 Side Garnish & Side Spoiler EXTERIOR/INTERIOR TRIM • Remove any burrs on the spoiler assembly - side to avoid damaging the vehicle, and clean the part. AA-10029 (6) Make a pilot hole of 3 mm (0.12 in) diameter at the mark-off line position (b) using a drill (a), and then make a hole of 6 mm (0.24 in) diameter.
  • Page 235 Side Garnish & Side Spoiler EXTERIOR/INTERIOR TRIM (7) Insert the well nut (b) at the position (a) shown in the figure. AA-10031 2) Clean and degrease the side under spoiler attachment area on the spoiler assembly - side. NOTE: • When the ambient temperature is 15°C (59°F) or less, heat the entire part of double-sided tape and the at- tachment area to approx.
  • Page 236 Side Garnish & Side Spoiler EXTERIOR/INTERIOR TRIM (2) Attach the backing sheet that was peeled off by 38.5 mm (1.52 in) to the front side with masking tape (a). AA-10090 (3) Temporarily install the side under spoiler (a) with clips (b). AA-10013 EI-48...
  • Page 237 Side Garnish & Side Spoiler EXTERIOR/INTERIOR TRIM (4) Temporarily install the side under spoiler (a) with washer (b) and bolt (c). AA-10014 (5) Peel off the backing sheet (b) on the side under spoiler (a) in the direction of the arrow (c), in numerical order as shown in the figure.
  • Page 238 Side Garnish & Side Spoiler EXTERIOR/INTERIOR TRIM (7) Tighten the bolts temporarily installed in step (4). Tightening torque: 1.0 N·m (0.1 kgf-m, 0.7 ft-lb) 4) Install the spoiler assembly - side in the reverse order of removal. 2. MOLDING WITH S209 LOGO 1) Perform the work for installing the molding with S209 logo.
  • Page 239 Side Garnish & Side Spoiler EXTERIOR/INTERIOR TRIM (3) Cut the upper part (a) of the garnish assembly - fender shown in the figure. AA-10001 (4) Make mark-off lines for drilling holes (b) at 2 locations according to the pattern paper (a). AA-10148 Pattern paper FR MLDG (3): LH Mark-off line position...
  • Page 240 Side Garnish & Side Spoiler EXTERIOR/INTERIOR TRIM (5) Make a pilot hole of 3 mm (0.12 in) diameter at the mark-off line position (a) using a drill, and then make a hole of 5 mm (0.2 in) diameter. AA-10149 2) Clean and degrease the molding garnish attachment area on the garnish assembly - fender. NOTE: •...
  • Page 241 Side Garnish & Side Spoiler EXTERIOR/INTERIOR TRIM (2) Align the guide pin (a) of molding garnish and the lower end of guide flange (b) with the oval hole (c) of garnish assembly - fender and the flange portion (d). AA-10161 EI-53...
  • Page 242 Side Garnish & Side Spoiler EXTERIOR/INTERIOR TRIM (3) Push the guide pin (a) of molding garnish against the rear end (b) of the oval hole of garnish assembly - fender. AA-11000 (4) Align the molding garnish (a) to the rear edge of the garnish assembly - fender (b), and press-fit the parts.
  • Page 243 Side Garnish & Side Spoiler EXTERIOR/INTERIOR TRIM (5) Pass the tie-wrap (c) of the garnish assembly - fender (b) to the molding garnish (a). CAUTION: Be careful not to let the tie-wrap come off. AA-10081 (6) Tighten the tie-wrap (a), and cut the excess part. CAUTION: Cut it so that the tie-wrap does not come out from the emblem application position.
  • Page 244 Side Garnish & Side Spoiler EXTERIOR/INTERIOR TRIM (3) Attach the S209 emblem (a) while aligning it to the position shown as dotted line (b). AA-10080 (4) Press-fit the S209 emblem. 3. REAR QUARTER GARNISH 1) Perform the work for installing the rear quarter garnish. NOTE: When using a new rear quarter outer, perform the following procedures.
  • Page 245 Side Garnish & Side Spoiler EXTERIOR/INTERIOR TRIM CAUTION: Attach the pattern paper along the arch section. AA-10150 Pattern paper RQ GARN Masking tape Alignment position for radius curve Pattern paper RQ GARN (8) Make mark-off lines for drilling holes (c) at 3 locations according to the pattern papers (a) and (b). AA-10151 Pattern paper RQ GARN Pattern paper RQ GARN...
  • Page 246 Side Garnish & Side Spoiler EXTERIOR/INTERIOR TRIM • When drilling a hole, make a through-hole to the rear quarter outer and the arch rear inner. AA-10052 Outer side Rear quarter outer Drill Inner side Arch rear inner Mark-off line position (11) Smoothen the area around the drilled hole with a sandpaper.
  • Page 247 Side Garnish & Side Spoiler EXTERIOR/INTERIOR TRIM CAUTION: Apply EPICON primer or equivalent to the scratched area using a brush. AA-10054 Rear quarter outer side Hole of 9.5 mm (0.37 in) diameter Arch rear inner EPICON primer application area Rear quarter outer (14) Dry the EPICON primer or equivalent well.
  • Page 248 Side Garnish & Side Spoiler EXTERIOR/INTERIOR TRIM (3) Peel off 38.5 mm (1.52 in) of the backing sheet (b) on the rear quarter garnish. AA-10055 (4) Temporarily install the rear quarter garnish while aligning its line to the line (a) of the rear quarter out- AA-10057 (5) Peel off the backing sheet, and press-fit to the rear quarter outer.
  • Page 249 Side Garnish & Side Spoiler EXTERIOR/INTERIOR TRIM Tightening torque: 0.35 N·m (0.04 kgf-m, 0.26 ft-lb) AA-10059 (9) Apply NOX-RUST (7703WJ) or equivalent to the peripheral area of nut installation (a) shown in the fig- ure. AA-10060 (10) If the NOX-RUST (7703WJ) or equivalent is spilled, wipe it off and clean the area. (11) Install the spoiler assembly - side.
  • Page 250 Side Garnish & Side Spoiler EXTERIOR/INTERIOR TRIM • Heating a particular small area will cause deformation of the parts. 2) Install the rear door garnish. (1) Print out and cut the pattern papers named as “RR DOOR GARN Patern paper LH”. CAUTION: Confirm that the pattern paper is printed out with accurate size.
  • Page 251 Side Garnish & Side Spoiler EXTERIOR/INTERIOR TRIM CAUTION: Confirm that there are no contact of the rear door garnish and the rear quarter garnish when opening/ closing the rear door; otherwise, the related parts may be damaged. AA-10103 Rear door garnish Rear quarter garnish Rear door panel Upper end alignment position...

  • Page 252: Rear Spoiler

    Rear Spoiler EXTERIOR/INTERIOR TRIM 6. Rear Spoiler A: REMOVAL 1) Remove the trim panel - trunk lid. 2) Remove the nuts (a) and (b), and then remove the rear spoiler assembly. CAUTION: • When removing the nut, be careful not to drop the nut inside the trunk lid panel. •...
  • Page 253 Rear Spoiler EXTERIOR/INTERIOR TRIM 2) Install the spring nut (a) to the trunk lid inner panel. AA-10021 3) Temporarily attach the reinforcement rear (d) with bolt (b) and nut (c), while aligning the center position with the trunk lid outer panel hole (a). NOTE: Left and right parts of the reinforcement rear differ in shape.
  • Page 254 Rear Spoiler EXTERIOR/INTERIOR TRIM 4) Set the rear spoiler assembly to the trunk lid, and install the nut (b) to the upper side stud bolt (a) to tem- porarily install the reinforcement rear (c). AA-10023 5) Adjust so that the center of the bolt (b) is aligned to the center of a 10 mm (0.39 in) diameter (a) on the low- er side.
  • Page 255 Rear Spoiler EXTERIOR/INTERIOR TRIM 7) Set the reinforcement front, and install it temporarily with nut (a) and bolt (b). AA-10025 8) Tighten the bolts and nuts in the numerical order shown in the figure below. Tightening torque: 7.5 N·m (0.8 kgf-m, 5.5 ft-lb) (8) (7) AA-10026 9) Install the trim panel - trunk lid.

  • Page 256: Lower Inner Trim

    Lower Inner Trim EXTERIOR/INTERIOR TRIM 7. Lower Inner Trim A: REMOVAL 1. SIDE SILL PLATE Remove the double-sided tape, and remove the side sill plate (a). CAUTION: Do not reuse the side sill plate. NOTE: If the double-sided tape is difficult to remove, warm it with a hairdryer, etc. to make the removal easier. Front AA-10070 Rear...
  • Page 257 Lower Inner Trim EXTERIOR/INTERIOR TRIM NOTE: • When the ambient temperature is 15°C (59°F) or less, heat the entire part of double-sided tape and the at- tachment area to approx. between 25°C and 40°C (77°F and 104°F) using a heat light, etc. •...
  • Page 258 Lower Inner Trim EXTERIOR/INTERIOR TRIM (3) Align the side sill plate - front to the position of the masking tape applied in step (1). CAUTION: • Make sure there are no gaps between the side sill plate - front and the cover side sill - front INN. •...
  • Page 259 Lower Inner Trim EXTERIOR/INTERIOR TRIM NOTE: To facilitate the work, peel off approx. 80 mm (3.15 in) of the backing sheet (d) on vehicle inside and attach it to the front side. And then peel off approx. 50 mm (1.97 in) of the backing sheet (e) on vehicle outside and attach it to the front side.
  • Page 260 Lower Inner Trim EXTERIOR/INTERIOR TRIM (5) Press-fit the side sill plate - rear. (6) Peel off the backing sheet on vehicle outside of the side sill plate - rear. (7) Press-fit the side sill plate - rear. 4) Remove the masking tape, and peel off the protection seal of the side sill plate. EI-72...

  • Page 261: Trunk Room Trim

    Trunk Room Trim EXTERIOR/INTERIOR TRIM 8. Trunk Room Trim A: REMOVAL 1) Remove the trim panel - trunk lid. 2) Tilt the rear seat backrest forward. 3) Remove the mat - trunk. 4) Remove the trim panel - trunk rear. 5) Remove the trim panel - trunk side.
  • Page 262 Trunk Room Trim EXTERIOR/INTERIOR TRIM (3) Make a mark-off line according to the cutting plane line (a). AA-13046 Cutting plane line (4) Remove the pattern paper. (5) Cut the trim panel - trunk side along the mark-off line (a). CAUTION: Be careful not to cut the sound proofing material on the back side of the trim panel - trunk side.
  • Page 263 Trunk Room Trim EXTERIOR/INTERIOR TRIM (6) Cut the EPT sealer (5.0t) to 70 mm × 50 mm (2.756 in × 1.969 in) (a) and to 70 mm × 30 mm (2.756 in × 1.181 in) (b). AA-13039 (a) 70 mm × 50 mm (2.756 in × 1.969 in) (b) 70 mm ×...
  • Page 264 Trunk Room Trim EXTERIOR/INTERIOR TRIM EI-76...
  • Page 265 EXTERIOR BODY PANELS Page Front Fender ....................2...
  • Page 266 Front Fender EXTERIOR BODY PANELS 1. Front Fender A: REMOVAL 1. FRONT FENDER AIR OUTLET CAUTION: Do not reuse the front fender air outlet. 1) Remove the cover - front fender. 2) Remove the double-sided tape, and remove the front fender air outlet outer (a). NOTE: If the double-sided tape is difficult to remove, warm it with a hairdryer, etc.
  • Page 267 Front Fender EXTERIOR BODY PANELS B: INSTALLATION 1. FRONT FENDER AIR OUTLET 1) Clean and degrease the front fender air outlet attachment area on the front fender. NOTE: • When the ambient temperature is 15°C (59°F) or less, heat the entire part of double-sided tape and the at- tachment area to approx.
  • Page 268 Front Fender EXTERIOR BODY PANELS (4) Install the front fender air outlet outer (a). AA-10119 (5) Press-fit the front fender air outlet outer. 3) Install the cover - front fender. EB-4...
  • Page 269 2019 S209 SERVICE MANUAL QUICK REFERENCE INDEX WIRING SYSTEM SECTION WIRING SYSTEM This service manual has been prepared to provide SUBARU service personnel with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. This manual includes the procedures...
  • Page 271 WIRING SYSTEM Page Intercooler Water Spray System ..............2 Instrument Panel Wiring Harness LH ............4 Rear Wiring Harness LH ................6 Rear Wiring Harness and Trunk Lid Cord ..........8...

  • Page 272: Intercooler Water Spray System

    Intercooler Water Spray System WIRING SYSTEM 1. Intercooler Water Spray System A: WIRING DIAGRAM FB-18 FB-12 MB-30 FB-42 SBF-4 F/B FUSE NO. 26 F/B FUSE NO. 7 F/B FUSE NO. 2 (IG) (IG) B551 i229 POWER WINDOW CIRCUIT BREAKER POWER SUPPLY CIRCUIT COMBINATION METER MICRO COMPUTER...
  • Page 273 Intercooler Water Spray System WIRING SYSTEM INTERCOOLER WATER SPRAY RELAY AD104 AD101 AD106 INTERCOOLER WATER ST16 AD102 SPRAY TIMER AD99 INTERCOOLER WATER ROLL SPRAY SWITCH CONNECTOR AD107 INTERCOOLER WATER SPRAY MOTOR & LEVEL SWITCH AD108 REF. TO GND [b] GB-14 AD102 AD104 AD106...

  • Page 274: Instrument Panel Wiring Harness Lh

    Instrument Panel Wiring Harness LH WIRING SYSTEM 2. Instrument Panel Wiring Harness LH A: LOCATION Connector Connecting to Pole Color Area Description AD99 Bulkhead wiring harness AD102 Roll connector Combination meter i375 AD105 Adapter cord (intercooler water spray) WI-4...
  • Page 275 Instrument Panel Wiring Harness LH WIRING SYSTEM AD99 AD102 i375 WI-86702 WI-5...

  • Page 276: Rear Wiring Harness Lh

    Rear Wiring Harness LH WIRING SYSTEM 3. Rear Wiring Harness LH A: LOCATION Connector Connecting to Pole Color Area Description AD100 Rear wiring harness LH AD103 Rear door cord LH AD105 i375 Instrumenta panel wiring harness WI-6...
  • Page 277 Rear Wiring Harness LH WIRING SYSTEM AD103 AD100 AD105 WI-86703 WI-7...

  • Page 278: Rear Wiring Harness And Trunk Lid Cord

    Rear Wiring Harness and Trunk Lid Cord WIRING SYSTEM 4. Rear Wiring Harness and Trunk Lid Cord A: LOCATION Connector Connecting to Pole Color Area Description AD101 AD104 Adapter cord (intercooler water spray) AD104 AD101 AD106 Intercooler water spray relay AD107 Intercooler water spray timer AD108...
  • Page 279 Rear Wiring Harness and Trunk Lid Cord WIRING SYSTEM AD104 AD101 AD107 AD108 GB-14 AD106 WI-86704 WI-9...
  • Page 280 Rear Wiring Harness and Trunk Lid Cord WIRING SYSTEM WI-10...
  • Page 281 2019 S209 SERVICE MANUAL QUICK REFERENCE INDEX PATTERN PAPER SECTION PATTERN PAPER This service manual has been prepared to provide SUBARU service personnel with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. This manual includes the procedures...
  • Page 289 50mm 50mm...
  • Page 290 50mm 50mm...

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