Subaru S209 2019 Service Manual Download Page 122 | Manualshive

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FS-28

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.

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).

NOTE:
Use HellermannTyton GalvaLok GL150 or equivalent tie-wraps.

11) Tighten the bolts which hold the strut tower bar to the strut tower bar bracket LH.

AA-13008

(A)

(A)

AA-13045

(a)

(A)

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Summary of Contents for S209 2019

Page 1: ...perienced 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 duri...

Page 2: ......

Page 3: ...FOREWORD FW Page 1 Foreword 2...

Page 4: ...hese 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 specific...

Page 5: ...SPECIFICATIONS SPC Page 1 S209 2...

Page 6: ...L DOHC high power turbo Engine type Horizontally opposed liquid cooled 4 cylinder 4 stroke gasoline engine Valve arrangement DOHC Bore stroke mm in 99 5 79 0 3 92 3 11 Displacement cm3 cu in 2 457 150...

Page 7: ...4 2 059 Rear kg lb 647 1 426 Gross vehicle weight G V W kg lb 2 000 4 409 Maximum permissible axle weight G A W Front kg lb 1 075 2 370 Rear kg lb 1 040 2 293 Option Genuine leather seat RECARO seat C...

Page 8: ...SPC 4 S209 SPECIFICATIONS...

Page 9: ...IDENTIFICATION ID Page 1 Identification 2...

Page 10: ...ORATION made 4 V Car line V WRX 5 A Body type A Sedan 6 2 Displacement class 2 2 5 L AWD high power turbo 4 CYLINDERS GASOLINE 7 Z Grade Z S209 8 6 Restraint 6 Manual belts dual airbag side airbag for...

Page 11: ...d 2 EJ Engine type symbol EJ 4 cylinders 3 and 4 25 Displacement 25 2 5 L 5 7 Fuel feed device 7 MFI single scroll high power turbo 6 X Exhaust regulations X North America Tier 3 LEV III 7 G Mounted t...

Page 12: ...ID 4 Identification IDENTIFICATION...

Page 13: ...RECOMMENDED MATERIALS RM Page 1 Recommended Materials 2...

Page 14: ...RM 2 Recommended Materials RECOMMENDED MATERIALS 1 Recommended Materials A RECOMMENDED MATERIALS 1 LUBRICANT Item Recommended materials Remarks Engine oil MOTUL 300V Power 5W 40...

Page 15: ...PRE DELIVERY INSPECTION PI Page 1 Pre delivery Inspection 2...

Page 16: ...ll vehicles to make sure to take responsibility B PRE DELIVERY INSPECTION PDI PROCEDURE Static checks just after vehicle receipt Checks with the engine running 1 ACCESSORY Check that the following acc...

Page 17: ...ion 1 Turn the ignition switch to ON and check that the intercooler water spray warning light illuminates 2 Start the engine and check that the intercooler water spray warning light goes off 3 If the...

Page 18: ...PI 4 Pre delivery Inspection PRE DELIVERY INSPECTION...

Page 19: ...PERIODIC MAINTENANCE SERVICES PM Page 1 Schedule 2 2 Air Cleaner Element 5...

Page 20: ...Fuel filter Note 2 Note 5 8 Air cleaner ele ment R R Note 6 9 Cooling system I I Note 8 10 Engine coolant Replace after the first 11 years or 220 000 km 137 500 miles and every six years or 120 000 k...

Page 21: ...6 211 2 1 000 miles 72 78 84 90 96 102 108 114 120 126 132 1 Engine oil Perform every 4 800 km 3 000 miles Note 1 2 Engine oil filter R R R R R R R R R R R Note 1 3 Spark plug R 4 V belt I I 5 Timing...

Page 22: ...cators 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 Exam...

Page 23: ...e marking a of air cleaner case upper with the marking b of air cleaner element NOTE Check that there is no dirt or dust within the air cleaner case If any dirt or dust is found clean it 1 Disconnect...

Page 24: ...PM 6 Air Cleaner Element PERIODIC MAINTENANCE SERVICES...

Page 25: ...s 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 repl...

Page 26: ......

Page 27: ...FUEL INJECTION FUEL SYSTEMS FU Page 1 General Description 2...

Page 28: ...TION Fuel tank Capacity 60 L 15 9 US gal 13 2 Imp gal Location Under rear seat Fuel pump Type Impeller Shutoff discharge pressure 900 kPa 9 18 kg cm2 130 5 psi or less Discharge rate 230 L 60 8 US gal...

Page 29: ...COMPONENT 1 INTAKE MANIFOLD 2 2 30 3 3 30 1 5 2 3 4 14 11 12 20 8 7 17 29 18 7 10 10 11 12 8 9 15 19 22 8 21 26 25 16 9 11 T5 T5 T2 T3 T5 T2 T4 T3 T6 T6 T1 T2 T1 T5 T5 T5 T5 T5 T6 13 T5 T5 T5 23 6 24...

Page 30: ...hose A 18 Intake manifold 6 Vacuum control hose 19 Wastegate control solenoid valve Tightening torque N m kgf m ft lb 7 Intake manifold gasket 20 Nipple T1 1 25 0 1 0 9 8 Guide pin 21 Nipple T2 6 4 0...

Page 31: ...se 10 5 Air Intake Duct 11 6 Intake Duct 12 7 Turbocharger 13 8 Intercooler Water Spray Tank Motor 19 9 Intercooler Water Spray Nozzle 21 10 Intercooler Water Spray Hose 23 11 Intercooler Water Spray...

Page 32: ...Air cleaner case bracket 7 Air cleaner case upper Tightening torque N m kgf m ft lb 2 Cushion 8 Mass air flow and intake air tem perature sensor T1 1 0 1 0 7 3 Air cleaner case lower 9 Clamp T2 2 5 0...

Page 33: ...l Description INTAKE INDUCTION 2 INTAKE DUCT 1 Clamp 4 Vacuum hose B Tightening torque N m kgf m ft lb 2 PCV hose ASSY 5 Intake duct T1 3 0 3 2 2 3 Vacuum hose A 6 Clamp T2 17 1 7 12 5 AA 15018 6 4 3...

Page 34: ...arger ASSY T1 6 4 0 7 4 7 3 Gasket 11 Air control hose ASSY T2 16 1 6 11 8 4 Union bolt 12 Clip T3 23 2 3 17 0 5 Turbocharger oil pipe 13 Oil outlet hose T4 31 5 3 2 23 2 6 Gasket 14 Turbocharger stay...

Page 35: ...IN 5 General Description INTAKE INDUCTION 4 INTERCOOLER WATER SPRAY AA 14000 T1 T2 T1 T3 4 1 3 5 6 7 T3 2 C C T1 A B 21 18 18 17 T1 11 10 10 10 10 12 10 8 A B 17 9 19 21 20 19 20 13 14 15 16...

Page 36: ...he removed parts in order and protect them from dust and dirt All removed parts if to be reused should be reinstalled in the original positions with attention to the correct directions etc Bolts nuts...

Page 37: ...1 4 AD106 3 2 1 9 10 8 AD107 ST16 1 2 3 4 3 4 2 1 5 6 7 13 14 11 12 9 10 8 B68 AD102 3 2 1 AD104 B41 MB 30 SBF 4 B 6 9 8 7 2 1 1 3 R3 B99 1 AD100 R10 D22 AD103 1 AD105 i375 i10 I F I F 40 20 38 7 3 B...

Page 38: ...er water spray level switch Does the intercooler water spray level switch operate prop erly Go to step 3 Replace the inter cooler water spray tank assembly 3 CHECK HARNESS BETWEEN COMBINA TION METER C...

Page 39: ...ment depending on the engine type when re placing the air cleaner elements Using other air cleaner element may affect the engine perfor mance Be sure to align the marking a of air cleaner case upper...

Page 40: ...ips 2 Install the nut a of the air cleaner case bracket NOTE Tighten while pulling the air cleaner case bracket a upward of the vehicle Tightening torque 7 5 N m 0 8 kgf m 5 5 ft lb 3 Tighten the bolt...

Page 41: ...hich secures the air intake duct and remove the air intake duct 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...

Page 42: ...from the intake manifold 4 Remove the intake duct from intake manifold B INSTALLATION Install in the reverse order of removal Tightening torque 17 N m 1 7 kgf m 12 5 ft lb C INSPECTION 1 LEAK DIAGNOS...

Page 43: ...ngine coolant hose from the water pipe 9 Remove the oil inlet pipe from the turbocharger CAUTION In order to prevent damaging the oil pipe on the cylinder head side fix the section a shown in the figu...

Page 44: ...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 2 Make the marking b at a position of 25 mm 1 0 in a from the lower end of oil outlet pipe 3 Set the turbo charg...

Page 45: ...re nuts are seated check for looseness while moving the pipe portion of the oil inlet pipe 7 Tighten the flare nuts which secure the turbo charger oil pipe to the oil inlet pipe CAUTION In order to pr...

Page 46: ...a new gasket Install so that the claw a of the water pipe con tacts the side face b of the housing Check the turbocharger and the water pipe for in terference Tightening torque 23 N m 2 3 kgf m 17 0...

Page 47: ...ed parts C INSPECTION 1 WASTE GATE ACTUATOR 1 Remove the intercooler 2 Remove the turbocharger upper cover 3 Remove the boost hose B from the waste gate actuator A of the turbocharger and connect the...

Page 48: ...n or more When replacing the tie wrap a with a new part use HellermannTyton GalvaLok GL150 or equivalent Tightening torque 7 5 N m 0 8 kgf m 5 5 ft lb 2 OTHER INSPECTIONS 1 Check that the turbocharger...

Page 49: ...nside may dam age the sub trunk 4 Disconnect the connector a and remove the bolts securing the intercooler water spray tank as sembly 5 Prepare a container and disconnect the inter cooler water spray...

Page 50: ...4 5 N m 0 5 kgf m 3 3 ft lb 6 Thereafter install in the reverse order of remov al Tightening torque T1 4 5 N m 0 5 kgf m 3 3 ft lb T2 7 5 N m 0 8 kgf m 5 5 ft lb C INSPECTION 1 INTERCOOLER WATER SPRAY...

Page 51: ...efore always replace with a new part 3 Remove the intercooler water spray duct hose assembly from the intercooler water spray nozzle 4 Remove the duct inner front hood 5 Press the two claws on the noz...

Page 52: ...stall the NOZZLE BRKT with bolts 4 Adjust the position so that the center of the bolt a and the center of the attachment area b align in a straight line 5 Pull the masking tape attached in step 2 to r...

Page 53: ...he sensor when working with the rear seat cushion removed NOTE Record the tie wrap installation positions 1 Open the front hood 2 Disconnect the ground terminal from battery and wait for at least 60 s...

Page 54: ...assembly from the intercooler water spray front hose as sembly 6 Remove the intercooler water spray duct hose assembly from the duct inner front hood 7 Remove the mud guard front LH 8 Cut the tie wrap...

Page 55: ...ooler water spray front hose assembly remove the string tied to the intercooler water spray front hose assembly in step 10 12 Release the claws and then remove the cover side sill front INN LH CAUTION...

Page 56: ...over catcher LH NOTE Remove the cover catcher LH by using a plastic remover 18 Remove the clips and remove the trim panel rear pillar UPR LH 19 Remove the trim panel rear pillar LWR LH 1 Remove the cl...

Page 57: ...IN 27 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...

Page 58: ...IN 28 Intercooler Water Spray Hose INTAKE INDUCTION AA 14017 AA 14018 AA 14019...

Page 59: ...the intercooler water spray side hose assembly in step 27 29 Remove the intercooler water spray side hose assembly from the vehicle B INSTALLATION Install in the reverse order of removal NOTE Install...

Page 60: ...pray level switch is integrated into the intercooler water spray tank assembly there fore refer to Intercooler Water Spray Tank Motor for installation procedure C INSPECTION 1 Check that the intercool...

Page 61: ...Set the tire to the straight ahead position 3 Remove the driver s airbag module 4 Remove the steering wheel CAUTION Always use the steering wheel puller for removal to avoid deforming the steering wh...

Page 62: ...ng Mode of the VDC Securely install the switch Improper insertion of the pin or claw of the switch may cause improper installation NOTE When installing a new intercooler water spray switch perform the...

Page 63: ...el off the mounting paper of I C SPRAY SW LABEL and press fit the I C SPRAY SW LABEL again with your fingers NOTE The part with sharp angle a of the I C SPRAY SW LABEL comes off easily so press it fir...

Page 64: ...oler water spray switch if the inspection result is not within the standard value Terminal No Inspection conditions Standard 3 4 Operate the RH side of the intercooler water spray switch assembly and...

Page 65: ...its center area with both hands Holding the corner part a with something stored inside may dam age the sub trunk 4 Remove the intercooler water spray relay from the BRKT UPR TANK B INSTALLATION Instal...

Page 66: ...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 Terminal No Standard 1...

Page 67: ...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 a...

Page 68: ...e bolts and remove the intercooler water spray timer 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...

Page 69: ...MECHANICAL ME Page 1 General Description 2 2 Cylinder Head 3...

Page 70: ...shaft and piston is SHORT BLOCK ENG only Valve spring Free length refer ence mm in Intake 53 48 2 1055 Exhaust 44 03 1 7335 Tension spring height N kgf lb mm in Set Intake 204 6 235 4 20 86 24 00 46 0...

Page 71: ...in you may get burned severely or if it touches flame fire may be caused by chemical reaction Therefore do not disassemble the exhaust valve It is safe when the metallic sodium encapsu lated in the ex...

Page 72: ...e broken exhaust valve in the water Hydrogen gas is produced by the chemical reaction Therefore always keep the container away from open flames such as sparks Because the severe chemical reaction is d...

Page 73: ...LUBRICATION LU Page 1 General Description 2...

Page 74: ...ription 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 increase...

Page 75: ...omponents 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 opt...

Page 76: ......

Page 77: ...CONTROL SYSTEMS CS Page 1 General Description 2 2 MT Gear Shift Lever 4...

Page 78: ...or less 1 Gear shift knob 8 Spacer 15 Joint 2 Cover shift lever 9 Cushion rubber 16 Boss 3 Boot and insulator ASSY 10 Reverse check lever 4 Clamp 11 Washer Tightening torque N m kgf m ft lb 5 Plate CO...

Page 79: ...fluid grease etc or equivalent Do not mix fluid grease etc of different grades or manufacturers Be sure to tighten fasteners including bolts and nuts to the specified torque Apply grease onto sliding...

Page 80: ...nect 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...

Page 81: ...CS 5 MT Gear Shift Lever CONTROL SYSTEMS 8 Remove the harness clamp 9 Remove the plate COMPL 10 Lift up the vehicle 11 Remove the center exhaust pipe rear CS 01786 CS 01787...

Page 82: ...over 13 Remove the crossmember 14 Remove the snap pin and washer and remove the reverse check cable 15 Move the transmission to the right side and remove the joint COMPL stay bolts and reverse check c...

Page 83: ...ever B INSTALLATION 1 Insert the gear shift lever from the bottom of the vehicle NOTE After inserting the rod and stay temporarily put them onto transmission mount 2 Install the cushion rubber Tighten...

Page 84: ...rection of the snap ring 5 Make sure the hole of extension case is aligned with that of reverse check lever If the hole positions are not aligned adjust the reverse check cable NOTE Check that the M3...

Page 85: ...t pipe rear 9 Install the plate COMPL NOTE Be careful not to twist the inner boot when installing Tightening torque 18 N m 1 8 kgf m 13 3 ft lb 1 Set the plate COMPL to the vehicle 2 Temporarily tight...

Page 86: ...hift 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 CAUTION Do not turn the gear...

Page 87: ...pacer from the boss 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 2 Install the boss to the rod...

Page 88: ...mage and wear If necessary correct or replace faulty parts Compare the removed parts with new parts to judge if there are damages or not 2 Check the swing torque of rod linked with the gear shift leve...

Page 89: ...CS 13 MT Gear Shift Lever CONTROL SYSTEMS Swing torque 3 7 N 0 38 kgf 0 83 lbf or less A Pivot B Swing torque CS 01814 A B...

Page 90: ...CS 14 MT Gear Shift Lever CONTROL SYSTEMS...

Page 91: ...CLUTCH SYSTEM CL Page 1 General Description 2...

Page 92: ...9 45 6 30 0 138 Flywheel side 240 160 3 2 9 45 6 30 0 126 Spline outer diameter mm in 25 2 0 992 number of teeth 24 Depth of rivet head mm in Clutch cover side 1 65 2 25 0 065 0 089 Flywheel side 1 35...

Page 93: ...f 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...

Page 94: ......

Page 95: ...FRONT SUSPENSION FS Page 1 General Description 2 2 Wheel Alignment 7 3 Front Crossmember Support Plate 17 4 Strut Tower Bar Front 19 5 Front Flexible Draw Stiffener 31...

Page 96: ...ication chart check the suspension parts and con nections for deformation If defective replace with new parts A B Positive Toe in Negative Toe out Tire size 265 35R19 Wheel arch height Tolerance 12 mm...

Page 97: ...FS 3 General Description FRONT SUSPENSION Individual toe angles...

Page 98: ...SPENSION B COMPONENT 1 FRONT SUSPENSION 6 2 2 18 19 T11 T12 11 13 20 22 T8 T6 6 T7 T13 17 16 2 15 14 2 1 8 10 9 6 3 2 T4 T4 6 T8 T9 T9 21 5 33 34 T3 T2 32 12 30 T8 T8 T8 T8 T10 30 T8 T5 4 31 29 24 25...

Page 99: ...r oil etc If any grease or oil spills wipe it off and clean immedi ately to prevent from penetrating into floor or flowing outside Follow all government and local regulations concerning disposal of re...

Page 100: ...shooting for electrical system NOTE For detailed operation procedures of Subaru Se lect Monitor 4 refer to Application help TOOL NAME REMARKS DST i Used together with Subaru Select Monitor 4 Alignmen...

Page 101: ...CAMBER ADJUST MENT Wheel Alignment Camber rear wheel Inspection Ref to FS 13 REAR WHEEL TOE IN ADJUST MENT Wheel Alignment NOTE Rear camber cannot be adjusted If the value exceeds the lat eral toleran...

Page 102: ...directly above the center of wheel 5 Measure the distance between the point A and the center of wheel 2 CAMBER 1 Place the front wheel on the turning radius gauge NOTE Make sure the ground contact su...

Page 103: ...with the operation manual for wheel alignment gauge 4 STEERING ANGLE 1 Place the vehicle on turning radius gauge 2 While depressing the brake pedal turn the steering wheel fully to the left and right...

Page 104: ...te the tires in the forward direction 4 Measure the distance B between the left and right marks Find toe in using the following calculation A B Toe in 6 REAR WHEEL TOE IN Refer to the FRONT WHEEL TOE...

Page 105: ...form the following adjustment 1 FRONT CAMBER 1 Adjust the camber angle to the following value 2 Loosen the two flange nuts while holding the strut bolts 3 Turn the camber adjusting bolt so that the ca...

Page 106: ...ASSY d Outer direction g Camber is decreased b Adjusting bolt e Inner direction c Front axle housing f Camber is increased To increase camber Rotate the left side counterclockwise Rotate the right si...

Page 107: ...teering angle sensor output 0 deg 3 FRONT WHEEL TOE IN When adjusting the toe in adjust it to the following value Toe in Adjustment value OUT 2 2 mm OUT 0 08 0 08 in 1 Check that the left and right wh...

Page 108: ...ls are adjusted for toe in at the same time the movement of one scale gradua tion changes toe in by approx 6 0 mm 0 24 in 3 Attach and tighten a new self locking nut Tightening torque 100 N m 10 2 kgf...

Page 109: ...uspension equally in the same direction 2 When one rear wheel is adjusted in a toe in direction adjust the other rear wheel equally in toe out direc tion in order to make the thrust angle adjustment 3...

Page 110: ...the oblique direction depending on the degree of the mean thrust angle Thrust angle 2 Rear RH wheel toe in angle Rear LH wheel toe in angle Substitute only the positive toe in values from each wheel i...

Page 111: ...LATION CAUTION For parts which are not reusable always use new parts Install the under cover front so that the front end of the under cover b comes inside the bumper face front a 1 Install the front c...

Page 112: ...FS 18 Front Crossmember Support Plate FRONT SUSPENSION 5 Lower the vehicle...

Page 113: ...CKET IS NOT REMOVED FROM THE VEHICLE 1 Attach a tape to the strut tower bar along the end face of the strut tower bar bracket LH and RH 2 Make an alignment mark b on the tape according to the alignmen...

Page 114: ...RUT 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 al...

Page 115: ...e strut tower bar brackets LH and RH to the strut mount 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...

Page 116: ...cessively may damage the pillow balls 1 WHEN THE STRUT TOWER BAR BRACKET IS NOT REMOVED FROM THE VEHICLE 1 Make sure that the alignment marks a on both ends rear side of the rubber boot at the strut t...

Page 117: ...ulting in fuel leakage 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 4 Confirm that the clearance A between t...

Page 118: ...s LH and RH Tightening torque 15 N m 1 5 kgf m 11 1 ft lb 6 Peel off the tape for position alignment from the strut tower bar 2 WHEN REMOVING THE STRUT TOWER BAR BRACKET FROM THE VEHICLE WHEN RE PLACI...

Page 119: ...from the strut tower bar assembly Only when replacing with a new strut tower bar 4 Make sure that the alignment marks a on both ends rear side of the rubber boot at the strut tower bar center positio...

Page 120: ...ket 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 WARNING Take care not to contact to the fuel pipe The fuel p...

Page 121: ...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 A...

Page 122: ...both the left and right sides 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 NOTE Use HellermannTyton...

Page 123: ...ENSION Tightening torque 15 N m 1 5 kgf m 11 1 ft lb 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...

Page 124: ...FS 30 Strut Tower Bar Front FRONT SUSPENSION RH side 13 Peel off the tape for position alignment from the strut tower bar AA 13053 b c a...

Page 125: ...ul not to damage the boot of the link ball 1 Lift up the vehicle 2 Loosen the lock nut a 3 Rotate the rod b to adjust until the adjustment scale position A becomes 0 mm CAUTION Do not disassemble or f...

Page 126: ...B INSTALLATION CAUTION Be careful not to damage the boot of the link ball 1 Install the front bracket Tightening torque 60 N m 6 1 kgf m 44 3 ft lb 2 Install the rear bracket NOTE If the bolt mountin...

Page 127: ...length B of the threaded portion for adjustment is in a range from 1 to 14 mm 0 039 to 0 551 in CAUTION If the exposed length B of the threaded portion for adjustment is not within specification re a...

Page 128: ...e front and rear brackets from the flexible draw stiffener front D ASSEMBLY CAUTION Be careful not to damage the boot of the link ball Install the front and rear brackets to the flexible draw stiffene...

Page 129: ...REAR SUSPENSION RS Page 1 General Description 2 2 Rear Sub Frame 8 3 Front Lateral Link 14 4 Rear Lateral Link 16 5 Rear Shock Absorber 18 6 Rear Flexible Draw Stiffener 22...

Page 130: ...n and front camber that are described in the specification chart cannot be adjusted If other items exceed the tolerance range of the specification chart check the suspension parts and con nections for...

Page 131: ...4 Stabilizer link T3 70 7 1 51 6 5 Bushing A trailing link 15 Rear shock absorber ASSY T4 80 8 2 59 6 Trailing link 16 Rear lateral link ASSY T5 90 9 2 66 4 7 Flange bolt B 17 Rear axle housing T6 110...

Page 132: ...ear upper arm ASSY 11 Bushing B rear axle housing T2 60 6 1 44 3 4 Snap pin 12 Flange nut T3 80 8 2 59 5 Lateral link ASSY front 13 Trailing link T4 90 9 2 66 4 6 Adjusting washer 14 Flange bolt T5 10...

Page 133: ...BER 1 Flange nut 5 Dust cover rear shock Tightening torque N m kgf m ft lb 2 Self locking nut 6 Helper rear T1 25 2 5 18 4 3 Shock mount rear 7 Coil spring rear T2 35 3 6 25 8 4 Rubber seat shock UPR...

Page 134: ...e been removed or replaced perform VSC VDC Center ing Mode of the VDC For parts which are not reusable always use new parts Other parts should be replaced with new parts as required When handling oil...

Page 135: ...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 Ti...

Page 136: ...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 CAUTION Be careful not to damage the sensor Do n...

Page 137: ...ve the bolts and nuts from the lower side of rear shock absorber assembly 2 Support the rear sub frame assembly using a transmission jack CAUTION The rear sub frame assembly is heavy Make sure that it...

Page 138: ...king of ABS wheel speed sensor harness does not twist 1 Check the removed parts for wear damage and crack and repair or replace them if faulty 2 Install each part to the rear sub frame assembly Tighte...

Page 139: ...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 3 Temporarily tighten the bolts on the body side of the rear support sub frame T1 T1 T2 T2 AA...

Page 140: ...the sensor assembly headlight beam leveler or forcibly move the arm Doing so may cause sensor damage and malfunction Tightening torque 7 5 N m 0 8 kgf m 5 5 ft lb 7 Install the clamp of the sub rear h...

Page 141: ...he 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 s...

Page 142: ...k assembly front and on the rear sub frame assembly 4 Remove the adjusting bolt d and remove the lateral link assembly front and the washer A CAUTION When removing the adjusting bolt d make sure to fi...

Page 143: ...ateral link assembly front and on the rear sub frame assembly Tightening torque T1 60 N m 6 1 kgf m 44 3 ft lb T2 100 N m 10 2 kgf m 73 8 ft lb 3 Install the nuts and install the cable assembly parkin...

Page 144: ...ral link assembly rear and the washer A B INSTALLATION CAUTION For parts which are not reusable always use new parts Always tighten the bushing in the state where the vehicle is at curb weight and the...

Page 145: ...the arm Doing so may cause sensor damage and malfunction Tightening torque 7 5 N m 0 8 kgf m 5 5 ft lb 4 Install the rear wheels and lower the vehicle Tightening torque 120 N m 12 2 kgf m 88 5 ft lb 5...

Page 146: ...veler 4 Remove the bolts and nuts and lower the lateral link assembly rear 1 Remove the nut and disconnect the rear stabilizer link 2 Remove the bolts from the lower side of rear shock absorber assemb...

Page 147: ...e where the vehicle is at curb weight and the wheels are in full contact with the ground 1 Install the rear shock absorber assembly 1 Lower the lateral link assembly rear and place the rear shock abso...

Page 148: ...dlight beam leveler or forcibly move the arm Doing so may cause sensor damage and malfunction Tightening torque 7 5 N m 0 8 kgf m 5 5 ft lb 2 Install the clips and install the trim panel trunk side 3...

Page 149: ...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 R...

Page 150: ...y 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 6 Disconnect the connector of the rear antenna assembly interior 7...

Page 151: ...TION Do not disassemble or further tighten the section c shown in the figure 10 Remove the nuts and then remove the flexible draw stiffener rear 11 Remove the nut plate a and the flexible draw stiffen...

Page 152: ...ffener rear bracket and temporarily tighten the bolts NOTE Install the nut plate with its cutout portion a facing the lower side 2 Adjust the gap A between the flexible draw stiffener rear bracket a a...

Page 153: ...further tighten the section c shown in the figure 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...

Page 154: ...ng torque 3 N m 0 3 kgf m 2 2 ft lb 8 Connect the connector of the rear antenna assembly interior 9 Install the trim panel trunk side 10 Install the trim panel trunk rear 11 Install the mat trunk 12 R...

Page 155: ...Rear Flexible Draw Stiffener REAR SUSPENSION CAUTION Do not disassemble or further tighten the section c shown in the figure 3 Tighten the lock nut Tightening torque 6 N m 0 6 kgf m 4 4 ft lb AA 13012...

Page 156: ...RS 28 Rear Flexible Draw Stiffener REAR SUSPENSION...

Page 157: ...WHEEL AND TIRE SYSTEM WT Page 1 General Description 2 2 Tire Repair Kit 3...

Page 158: ...ressure label attached to the body side of the driver s door 2 STANDARD EQUIPMENT TIRE WHEEL 3 SERVICE DATA WT 00001 1 Inset 2 P C D Tire size Wheel size Inset mm in P C D mm in Tire inflation pressur...

Page 159: ...space During the operation use appropriate protection tools to prevent the sealant from adhering to eyes skin and clothes After work wash hands face etc well to wash away the sealant completely If the...

Page 160: ...NT OF TIRE PUNCTURE REPAIR KIT CAUTION After using the puncture repair kit replace the repair sealant and the speed limit seal Set the new tire puncture repair kit at the specified position of the veh...

Page 161: ...BRAKE BR Page 1 General Description 2 2 Front Brake Pad 6 3 Rear Brake Pad 9...

Page 162: ...1 02 Rotor size O D Thickness mm in 340 30 13 39 1 18 Disc thickness mm in Standard 30 1 18 Limit 28 1 1 Disc runout mm in Standard Limit 0 075 0 003 Clearance adjustment Automatic adjustment Item Spe...

Page 163: ...lb 2 Bleeder screw 9 Pad clip nut T1 20 2 14 8 3 Cap bleeder 10 Piston seal T2 30 3 1 22 1 4 Cross spring 11 Piston disc brake T3 120 12 2 88 5 5 Pad disc brake front inner 12 Piston boot 6 Pad disc...

Page 164: ...r 27 Disc rotor solid type 4 Pin disc brake 16 Parking brake shoe secondary 5 Cross spring 17 Pin parking lever Tightening torque N m kgf m ft lb 6 Pad disc brake rear inner 18 Spring secondary shoe r...

Page 165: ...manufacturers Be sure to tighten fasteners including bolts and nuts to the specified torque Always use the jack up point when the shop jacks or rigid racks are used to support the vehicle Apply greas...

Page 166: ...a thin coat of grease to the side surface of the pad disc brake front Preparation items Grease An item contained in the pad kit or equivalent 2 Press back the piston disc brake with a tool as needed C...

Page 167: ...g 6 Install the pin disc brake 7 Install the front wheels Tightening torque 120 N m 12 2 kgf m 88 5 ft lb C INSPECTION 1 Check the thickness A of the pad disc brake front NOTE Always replace the pads...

Page 168: ...n the pad disc brake front outer and a squeaking sound is heard if the pad is worn to the limit 2 If the wear limit is exceeded in the inspection replace the pad disc brake front Standard a Wear limit...

Page 169: ...eplace pad clips if they are twisted or worn Replace the pad if there is oil or grease on it Wear indicators are installed on the pad disc brake rear outer and a squeaking sound is heard if the pad is...

Page 170: ...BR 10 Rear Brake Pad BRAKE...

Page 171: ...POWER ASSISTED SYSTEM POWER STEERING PS Page 1 General Description 2 2 Steering Gearbox 4 3 Pipe Assembly 5...

Page 172: ...ange r min 560 9 600 Direction of rotation Clockwise Power steering fluid Description SUBARU ATF or ATF DEXRON III Capacity L US qt Imp qt Oil tank 0 2 0 2 0 2 Whole system 0 7 0 7 0 6 Free play mm in...

Page 173: ...less At standstill on paved road with engine stalled N kgf lbf 294 2 29 9 66 2 or less SUBARU ATF or ATF DEXRON III 1 Reservoir tank 10 Suction connector Tightening torque N m kgf m ft lb 2 Cap 11 O...

Page 174: ...et in the straight ahead position or error is more than 5 on the periphery of the steering wheel correctly re install the steering wheel 4 If the steering wheel spokes are not horizontal with vehicle...

Page 175: ...move the one pipe joint at the center of the gearbox and connect the vinyl hose to the pipe and the joint Discharge the fluid by turning the steering wheel fully clockwise and counterclockwise Dischar...

Page 176: ...hose from return pipe and disconnect the pressure hose from feed pipe 7 Remove the air intake duct 8 Disconnect the suction hose and pressure hose from oil pump PS 00538 4 3 2 1 1 Feed pipe 2 Return...

Page 177: ...k 10 Remove the hose bracket and take out the hose assembly from vehicle B INSTALLATION CAUTION Install the under cover front so that the front end of the under cover b comes inside the bumper face fr...

Page 178: ...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 3 Wrap the protective cover to the area b shown in...

Page 179: ...t the slit faces downward 4 Attach a tie wrap to the position b shown in the figure and fix the protective cover a 5 Connect the suction hose and return hose to the reservoir tank a Protector b Area w...

Page 180: ...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 Tighten the eyebolt of pressure hose Tightening torque 40 N m 4 1 kgf...

Page 181: ...tioned on the opposite side as shown in the figure 9 Tighten clamp E Tightening torque 7 5 N m 0 8 kgf m 5 5 ft lb 10 Tighten the pressure hose to feed pipe and return hose to return pipe Tightening t...

Page 182: ...Tighten the bolts which hold the hose bracket Tightening torque 10 N m 1 kgf m 7 4 ft lb 16 Install the air intake duct 17 Connect the battery ground terminal 18 Fill with the specified fluid CAUTION...

Page 183: ...or 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 replace...

Page 184: ......

Page 185: ...INSTRUMENTATION DRIVER INFO IDI Page 1 General Description 2...

Page 186: ...start assist warning light VDC warning light VDC operation indicator light VDC OFF indicator light VDC traction mode indicator light High beam indicator light Front fog light indicator light Lighting...

Page 187: ...ntervention display Warning and indicator display Door partially latched Engine oil level BSD RCTA BSD RCTA OFF Washer fluid level Low ambient temperature High Beam Assist Access key RAB RAB OFF SRH O...

Page 188: ...IDI 4 General Description INSTRUMENTATION DRIVER INFO...

Page 189: ...EXTERIOR INTERIOR TRIM EI Page 1 General Description 2 2 Mud Guard 8 3 Front Bumper 14 4 Rear Bumper 24 5 Side Garnish Side Spoiler 40 6 Rear Spoiler 64 7 Lower Inner Trim 68 8 Trunk Room Trim 73...

Page 190: ...eneral Description EXTERIOR INTERIOR TRIM 1 General Description A COMPONENT 1 MUD GUARD 1 Under cover front 3 Mud guard front 5 Plate air flap rear 2 Plate air flap front 4 Mud guard rear 1 2 4 3 5 AA...

Page 191: ...EI 3 General Description EXTERIOR INTERIOR TRIM 2 FRONT GRILLE 1 Front grille emblem 3 Ornament 5 Spacer grille front 2 Cover grille front 4 Front grille ASSY 1 2 3 4 5 AA 10107...

Page 192: ...1 3 Bumper face front 11 Bracket UPR COMPL T2 2 0 0 2 1 48 4 Cover hook front 12 Bracket front bumper corner T3 4 5 0 46 3 32 5 Cover intake front 13 Energy absorber foam T4 7 5 0 8 5 5 6 Bumper side...

Page 193: ...umper beam COMPL rear 6 Bumper face rear Tightening torque N m kgf m ft lb 2 Bracket rear bumper side 7 Rear bumper extension T1 2 0 0 2 1 48 3 Bracket rear bumper corner 8 Cover outlet T2 3 5 0 4 2 6...

Page 194: ...he back side 1 Garnish ASSY fender 5 Rear quarter garnish Tightening torque N m kgf m ft lb 2 Molding garnish 6 Spoiler ASSY side T1 0 35 0 04 0 26 3 S209 emblem 7 Side under spoiler T2 1 0 0 1 0 7 4...

Page 195: ...pillar UPR 8 Cover catcher 14 Side sill plate rear 3 Cover side sill front 9 Cover side sill rear INN 4 Cover side sill front INN 10 Trim panel rear pillar LWR Tightening torque N m kgf m ft lb 5 Clip...

Page 196: ...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 2 Relea...

Page 197: ...he work for installing the mud guard rear 1 Disconnect the ground terminal from battery 2 Remove the bumper face rear 3 Remove the muffler 4 Remove the mud guard rear 5 Cover the area around the reinf...

Page 198: ...n the pattern paper a to the holes and trim lines on the vehicle shown in the figure and attach masking tapes b 8 Stamp a mark with a punch at the position a shown in the figure a Pattern paper LH b M...

Page 199: ...along the outer boundary of the pattern paper a 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...

Page 200: ...14 Smoothen the cut section of the reinforce wheel apron with a sandpaper CAUTION Remove any burrs on the cut section to avoid damaging the vehicle 15 Clean and degrease the cut section of the reinfor...

Page 201: ...EI 13 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...

Page 202: ...ove the front under spoiler 1 Remove the bolts c and washers d securing the front under spoiler b from the bumper face front a 2 Remove the clips a b and c and then remove the front under spoiler d B...

Page 203: ...ble sided tape is difficult to remove warm it with a hairdryer etc to make the removal easier D ASSEMBLY NOTE When installing a new bumper face front perform the following steps Perform the procedures...

Page 204: ...e pattern papers a b and c a Pattern paper FR BMP EXT c Pattern paper FR BMP EXT e Alignment position for convex angle b Pattern paper FR BMP EXT d Masking tape f Alignment position for trim line a Pa...

Page 205: ...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 CAUTION Be sure to make a hole of a specified diameter The front bumper extension may not be ins...

Page 206: ...Bumper EXTERIOR INTERIOR TRIM 2 Attach the pattern paper a while bending it toward the arrow directions 3 Make a mark off line for drilling hole b according to the pattern paper a AA 10120 c a b a AA...

Page 207: ...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 bumper face front and cause d...

Page 208: ...sure to make a hole of a specified diameter The front under spoiler may not be installed if the hole diameter is large 8 Make a pilot hole of 3 mm 0 12 in diameter at the mark off line position b usin...

Page 209: ...f the bumper face front 3 Install the front bumper extension 1 Clean and degrease the front bumper extension attachment area on the bumper face front NOTE When the ambient temperature is 15 C 59 F or...

Page 210: ...porarily install it with nut b and screws d and e CAUTION Screws are different in length Be sure to check the length before installation 4 Remove the mud guard front 5 Install the bumper face front to...

Page 211: ...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 9 Install the mud guard front a Dotted line c Front fe...

Page 212: ...the screws on the bumper face rear 2 Remove the screws in the wheel house 3 Remove the clips at the lower side of the bumper face rear 4 Detach b and c while pulling up a of the bumper face rear 5 Det...

Page 213: ...ot reuse the rear bumper extension 1 Remove the nut 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 et...

Page 214: ...ng a new bumper face rear perform the following steps Perform the procedures for the right side in the same way as for the left side 1 Perform the work for installing the muffler 1 Print out and cut t...

Page 215: ...d b 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 2 Perform the work for installing the rear quarter...

Page 216: ...shape mating surface b 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 3 Prepare a stopper by wrapping a cloth adhesive ta...

Page 217: ...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 CAUTION Be sure to make a hole of a specified diameter The rear quarter spoiler m...

Page 218: ...ut and cut the pattern papers named as RR BMPR EXT Patern paper LH CAUTION Confirm that the pattern paper is printed out with accurate size 2 Press the pattern paper a against the bumper face rear and...

Page 219: ...g to the pattern paper a 4 Press the pattern papers a and b against the bumper face rear and attach masking tapes c a Pattern paper RR BMP EXT 1 b Mark off line position a Pattern paper RR BMP EXT 2 b...

Page 220: ...according to pattern papers a and b 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 a Pattern paper RR BMP EX...

Page 221: ...ing a drill CAUTION Be sure to make a hole of a specified diameter The rear bumper extension may not be installed if the hole diameter is large 4 Install the bumper face rear 5 Clean and degrease the...

Page 222: ...OR INTERIOR TRIM Heating a particular small area will cause deformation of the parts 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...

Page 223: ...IOR 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 3 Temporarily install the rear quarter spoiler a with screws b a a AA 10100 a...

Page 224: ...sition adjustment easier 6 Peel off the backing sheet b on the rear quarter spoiler in the direction of the arrow c in numerical order as shown in the figure CAUTION Be careful not to cut off the back...

Page 225: ...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 Heating a particular small area will cause defo...

Page 226: ...2 6 ft lb 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...

Page 227: ...e rear bumper extension 7 Tighten the screws temporarily installed in step 4 Tightening torque 2 0 N m 0 2 kgf m 1 48 ft lb 10 Install the bumper face rear in the reverse order of removal Tightening t...

Page 228: ...reuse the side under spoiler 1 Remove the bolts c and washers d securing the side under spoiler b from the spoiler assembly side a 1 Garnish ASSY fender 5 Rear quarter garnish Tightening torque N m k...

Page 229: ...o make the removal easier 2 MOLDING WITH S209 LOGO 1 Remove the spoiler assembly side from the vehicle 2 Remove the garnish assembly fender from the front fender 3 Remove the double sided tape and rem...

Page 230: ...garnish NOTE If the double sided tape is difficult to remove warm it with a hairdryer etc to make the removal easier 3 REAR QUARTER GARNISH 1 Disconnect the ground terminal from battery 2 Remove the r...

Page 231: ...dryer etc to make the removal easier 4 REAR DOOR GARNISH 1 Remove the double sided tape and remove the rear door garnish a CAUTION Do not reuse the rear door garnish NOTE If the double sided tape is d...

Page 232: ...ines for drilling holes b according to the pattern pa pers d through k a Spoiler ASSY side e Pattern paper B i Pattern paper F b Mark off line position f Pattern paper C j Pattern paper G c Shape matc...

Page 233: ...ge 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 pilot hole of 6 mm 0 24 in diameter 5 Make a hole of 9 5 mm 0 37 in diameter a and a hol...

Page 234: ...e and clean the part 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 CAUTION Be sure to make a hole of a spec...

Page 235: ...re 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 Heating a particular small area will ca...

Page 236: ...poiler 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 3 Temporarily install the side under spoiler a with clips b AA 100...

Page 237: ...merical order as shown in the figure CAUTION Be careful not to cut off the backing sheet while peeling it off Confirm that the molding of the side under spoiler is not caught in and deformed 6 Press f...

Page 238: ...NOTE When installing a new garnish assembly fender perform the following steps 1 Print out and cut the pattern papers named as FENDER MOL Patern paper LH CAUTION Confirm that the pattern paper is pri...

Page 239: ...TRIM 3 Cut the upper part a of the garnish assembly fender shown in the figure 4 Make mark off lines for drilling holes b at 2 locations according to the pattern paper a a Pattern paper FR MLDG 3 LH...

Page 240: ...garnish attachment area on the garnish assembly 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 between 25 C...

Page 241: ...arnish 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 10...

Page 242: ...OR TRIM 3 Push the guide pin a of molding garnish against the rear end b of the oval hole of garnish assembly fender 4 Align the molding garnish a to the rear edge of the garnish assembly fender b and...

Page 243: ...nder CAUTION Confirm that there are no cracks on the vehicle body installation clips or deformations on the garnish assembly fender 5 Install the S209 emblem 1 Clean and degrease the S209 emblem attac...

Page 244: ...w rear quarter outer perform the following procedures 1 Disconnect the ground terminal from battery 2 Remove the rear tires 3 Remove the bumper face rear 4 Remove the mud guard rear 5 Remove the spoil...

Page 245: ...k off line position f using a drill e and then make a pilot hole of 6 mm 0 24 in diameter Finally make a hole of 9 5 mm 0 37 in diameter CAUTION Be sure to make a hole of a specified diameter The rear...

Page 246: ...burrs on the rear quarter outer and the arch rear inner to avoid damaging the vehicle 12 Clean and degrease the peripheral area around the drilled hole a completely using cloth with de greasing agent...

Page 247: ...lled wipe it off 2 Clean and degrease the rear quarter garnish attachment area on the rear quarter outer NOTE When the ambient temperature is 15 C 59 F or less heat the entire part of double sided tap...

Page 248: ...igning its line to the line a of the rear quarter out er 5 Peel off the backing sheet and press fit to the rear quarter outer 6 Remove the masking tape of the bolt tip temporarily attached in step 1 7...

Page 249: ...ll the mud guard rear 13 Install the bumper face rear 14 Install the rear tires 15 Connect the battery ground terminal 4 REAR DOOR GARNISH NOTE Install the rear door garnish with the rear quarter garn...

Page 250: ...h accurate size 2 Press the pattern papers a and b against the rear door panel and attach masking tapes c 3 Peel off the backing sheet a on the rear door garnish 4 Peel off 38 5 mm 1 52 in of the back...

Page 251: ...quarter garnish when opening closing the rear door otherwise the related parts may be damaged 6 Peel off the backing sheet on the rear door garnish 7 Press fit the rear door garnish a Rear door garnis...

Page 252: ...to allow the rear spoiler to fall off Be careful not to damage the vehicle body during removal and installation Be careful that the reactive force of trunk lid increases when the rear spoiler is remov...

Page 253: ...to the trunk lid inner panel 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 t...

Page 254: ...rily install the reinforcement rear c 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 NOTE Align the center positions on the left an...

Page 255: ...ment front and install it temporarily with nut a and bolt b 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 9 Install the tr...

Page 256: ...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 Rear B INSTALLA...

Page 257: ...he cover side sill front INN a toward the front side of the vehicle 2 Attach the backing sheet d on vehicle inside and the backing sheet e on vehicle outside to the front side with masking tape c NOTE...

Page 258: ...nside of the side sill plate front 5 Press fit the side sill plate front 6 Peel off the backing sheet on vehicle outside of the side sill plate front 7 Press fit the side sill plate front 3 Attach the...

Page 259: ...plied in step 1 CAUTION Make sure there are no gaps between the side sill plate rear and the cover side sill rear INN If there is a gap adjust the application position of the side sill plate rear to t...

Page 260: ...R 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...

Page 261: ...in shape However procedures for the left side can be performed in the same way as for the right side 1 Perform the work for installing the flexible draw stiffener rear 1 Print out and cut the pattern...

Page 262: ...to the cutting plane line a 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...

Page 263: ...im panel trunk side NOTE Margin A for the EPT sealer is 3 mm 0 118 mm 2 Install the trim panel trunk side 3 Install the trim panel trunk rear 4 Install the mat trunk 5 Return the rear seat backrest to...

Page 264: ...EI 76 Trunk Room Trim EXTERIOR INTERIOR TRIM...

Page 265: ...EXTERIOR BODY PANELS EB Page 1 Front Fender 2...

Page 266: ...e 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 to make the removal easier 3 Remove the double side...

Page 267: ...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 Heating a particular small area will cause deformation of the parts 2 Install the front fende...

Page 268: ...EB 4 Front Fender EXTERIOR BODY PANELS 4 Install the front fender air outlet outer a 5 Press fit the front fender air outlet outer 3 Install the cover front fender AA 10119 a...

Page 269: ...tment 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 vehi...

Page 270: ......

Page 271: ...WIRING SYSTEM WI Page 1 Intercooler Water Spray System 2 2 Instrument Panel Wiring Harness LH 4 3 Rear Wiring Harness LH 6 4 Rear Wiring Harness and Trunk Lid Cord 8...

Page 272: ...8 7 3 4 1 2 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 5 6 7 B99 B41 2 1 B225 i10 i229 i375 a a WI 86700 B B 6 G B 9 G B 8 W 7 B W 2 W 1 B W G B 1 G B R 3 G B G R3 B99 1 R G B AD100 R10 D22 AD1...

Page 273: ...D104 Gr Gr b b WI 86701 L 3 R 1 G 2 B 5 AD107 GB 14 AD108 L 3 R 1 R 4 G 2 B 5 B 6 R 2 G 4 W 1 B 3 B B 1 8 2 L G L ST16 LH RH 3 1 4 AD102 ST1 2 R L 2 B G B68 AD99 3 W W A W 1 R R AD101 AD104 B R AD106...

Page 274: ...nstrument Panel Wiring Harness LH A LOCATION Connector Connecting to No Pole Color Area No Description AD99 14 C 5 B68 Bulkhead wiring harness AD102 14 C 5 ST1 Roll connector i10 40 B 3 Combination me...

Page 275: ...WI 5 Instrument Panel Wiring Harness LH WIRING SYSTEM RH WI 86702 1 2 3 4 5 1 2 3 4 5 A B C D A B C D i10 AD99 AD102 i375...

Page 276: ...IRING SYSTEM 3 Rear Wiring Harness LH A LOCATION Connector Connecting to No Pole Color Area No Description AD100 8 B 4 R10 Rear wiring harness LH AD103 8 B 4 D22 Rear door cord LH AD105 1 C 2 i375 Ins...

Page 277: ...WI 7 Rear Wiring Harness LH WIRING SYSTEM AD105 AD103 AD100 WI 86703 1 2 3 4 5 1 2 3 4 5 A B C D A B C D...

Page 278: ...Cord A LOCATION Connector Connecting to No Pole Color Area No Description AD101 3 C 2 AD104 Adapter cord intercooler water spray AD104 3 C 2 AD101 AD106 5 Gr C 4 Intercooler water spray relay AD107 6...

Page 279: ...WI 9 Rear Wiring Harness and Trunk Lid Cord WIRING SYSTEM 1 2 3 4 5 1 2 3 4 5 A B C D A B C D WI 86704 GB 14 AD104 AD101 AD107 AD108 AD106...

Page 280: ...WI 10 Rear Wiring Harness and Trunk Lid Cord WIRING SYSTEM...

Page 281: ...tment 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 vehi...

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