Sus Tips 0309 - March 2009 Tech Tips (TIPS 0309-01)

SUS TIPS 0309 - MARCH 2009 TECH TIPS

TECHNICAL SERVICE BULLETIN

LEGACY/OUTBACK 3.0L 5AT

Please note, the transmission drive plate (torque converter to flex plate) bolts have been changed back to a hexagon head from a socket-head style bolt. Either style can be used as they are interchangeable and the torque specifications are the same for both.

DTC P1714 (4AT) THROTTLE POSITION SENSOR (TPS) POWER SUPPLY CIRCUIT

As a reminder, when diagnosing (but not limited to) this DTC, be sure to check those grounds! An item often overlooked is an oxidized (dirty) ground terminal. In addition to checking to see if the bolts are tight, the transmission harness ground terminal(s) should be inspected, cleaned then re-tightened to eliminate the possibility of a poor contact.

2009MY FORESTER REAR COMBINATION LAMPS

Before replacing a rear combination lamp that may appear cracked, check to make sure it's not water causing an illusion. The photo to the right shows a "lip" around the edge of the lens that may accumulate water causing the illusion. Without using excessive pressure, carefully use an air nozzle to remove any accumulated water then reinspect.

AUDIO/NAV UNIT REMOVAL PRECAUTIONS

Please review the photos below regarding Navigation head unit removal on 2009 Forester and 2008-09 Impreza models. Due to the limited length of the wiring harness, it can be very difficult to access the connectors on the back of the unit. Not exercising caution can lead to an increased potential for damaging the surrounding dash trim area. Taping off the surrounding area with multiple layers of masking tape (or equivalent) will help minimize the possibility of damage. Inspect the harness and connectors to ensure that no damage was incurred during removal before re-installing the unit. Inspection of these components may also be a good place to start if you receive a customer concern of NAV screen or audio system problems.

IMPORTANT SHORT/LONG-BLOCK REPLACEMENT REMINDER

Whenever replacing a long block, short block, or performing a major engine repair involving a catastrophic engine component failure, be sure to perform all of the following checks:

• Remove the throttle body assembly from the intake manifold and thoroughly inspect the throttle body and intake manifold for any debris.
• Remove the tumble generator valve assemblies from both sides of the intake (if equipped). Both valves and the intake need to be inspected closely for debris.
IMPORTANT: Debris found in any component of the intake must be thoroughly cleaned before re-assembly.
• Remove the exhaust and thoroughly inspect for any debris that may have passed through and become trapped by the front catalyst(s).

When performing the above checks, follow the service procedure(s) outlined in the appropriate Service Manual. Always use new gaskets when re-assembling the intake manifold assembly and exhaust system.

Failure to perform these checks can leave debris that can re-enter the engine causing secondary failures, which would not be a matter for warranty.

BREMBO EQUIPPED DISC BRAKE NOISE

If you encounter a customer concern of a grinding or groaning type noise coming from the front brakes just prior to coming to a complete stop, chances are the noise is coming from the brake pads. Different brake pads were used for 2008~09 models. Using brake pads for a 2007 model should eliminate the noise. Keep in mind that using the earlier pads will not address other noises associated with scored or glazed brake rotors, worn pads, brake dust, wear indicators, etc.

The part number for the 2007 model brake pads is 26296FE100.

2009 FORESTER TAILGATE GROMMET REMOVAL

The following information is not in the Service Manual. If the tailgate plastic grommets need to be removed, using a white plastic trim tool will prevent damage to the paint. A flat blade screwdriver should NOT be used as damage to the grommet and/or the paint will likely result.

Using a white plastic trim tool, push in on one tab of the grommet and lift up. Repeat the procedure on the other 2 tabs. It helps to push down slightly on the tailgate to remove the grommet completely. When re-installing, make sure the grommet and rubber boot are fully seated all the way around properly to prevent water leaks.

REPLACEMENT CABLES FOR SUBARU DIAGNOSTIC SYSTEM (SDS)

Many dealers have found after 3+ years of daily use of their SDS, it has become necessary to replace the Data Link Cable (DLC) that connects the SDI Box to the vehicle. The DLC is a specialized proprietary cable with heavier-duty design from the "printer style" SDI Box connector end to the wire diameter and the other OBDII cable end that connects to the vehicle. The DLC is not available at local Computer stores.

Up to now, the procedure for obtaining a replacement DLC has been to purchase it from SPX but, due to current demand, many DLC's were back-ordered due to very limited availability. To counteract this issue, SOA located an alternative source for the cable that can provide them at a reduced price and provide a better warranty and a more continuous supply. The new replacement DLC is $225 (plus shipping and applicable taxes) or 30% lower cost versus the OEM cable from SPX at $319.00 (plus shipping and applicable taxes). The new DLC carries a 1 year warranty against manufacturer defects (vs. 90 days for the SPX version).

Once the new inventory is available, any dealer that has not yet ordered a replacement DLC from SPX will be shipped a new one automatically as part of a direct tool shipment starting sometime in April, 2009. Each dealer will be billed on their monthly parts statement for the cost.

Details for future ordering of the alternatively sourced DLC will be released soon. SPX will continue to process orders for the original equipment DLC.

2009MY FORESTER POWER WINDOW INFORMATION

We have received calls on the Techline about 2009MY Forester door rattles and concerns that the door windows do not close fast enough. In regard to the door rattles, there have been instances of bolts securing the door motor to the inner frame not being fully tightened. The bolts in question are shown below and the torque specification is 7.5 Nm or 5.5 ft. lbs.

We have also identified instances of the door glass run rubber (weather stripping) coming loose or becoming twisted in the front glass sash inside the doors. When the rubber is out of position, it places excessive resistance on the glass as it travels up and down. Because gravity helps with the "down" motion, the "up" function is where the concerns of slow operation arise. Use 5 seconds as a guideline for travel time from fully open to fully closed (with the engine running). In most cases, the rubber can be re-installed into the sash to complete the repair but in the event that it has become deformed or will not stay in the sash properly, it will need to be replaced. The photo on the left shows the stripping properly installed into the sash while the photo on the right shows it out of position.

TAPPING OR CLICKING NOISE, 2008-09MY IMPREZA

If you experience a Customer concern about a one-time "tap" or "click" noise from the car after a cold start, it may be a metal brake line contacting the under-body. The ABS system does a self-test on start-up approximately 10-15 seconds after engine start and speed sensor input is detected. The actuation of the internal valving of the ABS during this self-test sends a pulse of brake fluid pressure throughout the brake system. The tap or click noise can come from brake piping contacting the underside of the floor or body of the car when this pulse occurs. Insulating or re-positioning the brake piping for added clearance will eliminate the noise.