Tech Tips November 2016 (TIPS 1116)

TECH TIPS NOVEMBER 2016

TECHNICAL SERVICE BULLETIN

03 CLUTCH RELEASE COMPONENT LUBRICATION AND INSPECTION REVISITED

Below are images labeled 1, 2, 3, and 4 that correspond with Figure 1. Each image shows the required lubrication point in detail. You can use these images as a reference when applying the approved lubricant. To locate the correct lubricant (grease), review the applicable Service Manual and if necessary use Service Bulletin 01-167-08R for approved equivalents.

Example below is from the 2017 MY impresa service manual. 

Inspect the clutch release fork for abnormal wear in the following locations: 

Each location point should be thoroughly inspected for wear that would prevent smooth operation of the release fork and release bearing. Each point should also be lubricated accordingly, as shown in the images labeled 1, 2, 3, and 4. Below, in the figure labeled Excessive Wear,  is an example of excessive release fork wear that caused a squeaking noise while the engine was running.

07 FUEL GAUGE DIAGNOSIS REVISITED

Should you receive a customer complaint stating their fuel gauge is not reading accurately or not going all the way up to the full position on any model Subaru equipped with a BIU (Body Integrated Unit), NEVER ground any of the wiring at the BIU. The proper way to diagnose both fuel sending units, BIU and combination meter can be found in the Service Manual for the particular model year you are working on. Generally, the BIU looks at both fuel tank sending units for a combined resistance value. This value varies from model year to model year. For example, if you where troubleshooting a 2009 Forester with a customer complaint of their fuel gauge not going all the way to the full mark after filling their fuel tank, the first step should be to check for any DTCs (Diagnostic Trouble Codes). Assume the vehicle had a P0462 Fuel Level Sensor Circuit High Input DTC. After choosing a 2009 Forester on STIS and searching for the DTC P0462, you will see a search link stating to check the combination meter. If you click on the corresponding link, it will take you to a flow chart showing you what each sending unit resistance value should be at both the Full and Empty positions. In this particular case, the main sending unit value should be 1 to 3 ohms with a full tank and 31 to 33 ohms with an empty tank. The sub-level sending unit should be 1 to 3 ohms with a full tank and 61 to 63 ohms with an empty tank. The BIU is looking for a combined resistance of 90 ohms for the gauge to read properly.

The key points to remember are, never ground out any of the wiring to make the gauge read full or empty and the combined resistance value the BIU is looking for can vary from different model years. Another point to remember is, always ask the Customer if they are fueling up the vehicle with the ignition key in the on position or with the engine running? If they are, doing so can create a situation where the BIU will not recognize the resistance changes for several key cycles causing the gauge to not move. The customer will interpret this as a problem because they do not see any gauge movement. A good way to test for this is to check where the gauge is reading then perform a battery capacitive discharge. If the gauge moves to a reading very close to the suspected fuel level, there is likely no problem other than fueling the vehicle with the ignition powered up.

14 NEW FUNCTION SSM4 OCTOBER VERSION

1. Improvement of "Project Information" 

   Add the new contents in "Project list" 

   Add new project searching function 

2. Improvement of "Individual data list" 

   Add the new sorting modes 

   Add the new sort function 

   Add the marking function 

15 RES INOPERATIVE? CHECK THE RES ANTENNA

Techline has received calls regarding inoperative Remote Engine Start systems after installation. Although Technicians are able to successfully register the system, when attempting to start the vehicle with the RES transmitters, there is no response from the vehicle. A quick check of the RES antenna will most likely show the connection is not fully seated as shown in Figure 1. 

When routing the RES antenna harness, verify there is enough slack in the harness to tuck it under the headliner. If there is not enough slack, excessive pressure will be applied against the harness and disconnect the antenna causing the inoperative condition. Please review the applicable installation instructions for correct installation practices. Figure 2  shows the RES antenna connection fully seated.

16 BINDING ON TURNS AND OTHER TRANSMISSION ISSUES

The Techline continues to receive calls from Technicians who have performed all types of unsuccessful repairs to transmissions with a "binding on turns" or "vehicle does not shift properly" concern from the Customer. One of the first questions we will ask is whether or not the tire circumferences have been measured. All too often, the answer is no. It is extremely important when diagnosing this type of transmission concern to make the tires one of the first variables you rule out. A difference as little as approximately 1/4" in circumference could cause binding and shifting issues due to the ratio imbalance caused by mis-matched tires. A solid method of measurement is to use a piece of rope and a tape measure. Adjust the tire pressures to specification. Next wrap the rope around the center of the tread and mark it. Repeat on all four tires then measure the difference between marks. Another method is to use a rope style tape measure. A quick keyword search on STIS of "Binding on Turns" will return a list of other bulletins and TIPS articles on this subject.