Tech Tips May 2016 (TIPS 0516)

Publication date: 2016-05-26
Reference number: TIPS 0516

TECH TIPS MAY 2016

TECHNICAL SERVICE BULLETIN

Reference Number(s): TIPS 0516, Date of Issue: May 26, 2016

SUBARU:

All Models

03 P2751 AND NO CVT ENGAGEMENT

Techline has received limited reports of CVT-equipped vehicles with the AT Oil Temp light illuminated, MIL illuminated, and the vehicle will not move. After an inspection for DTCs, Technicians find P2751 Intermediate Shaft Speed Sensor "C" Circuit No Signal, which needs to be saved electronically along with the freeze frame data. Reviewing the General Description in Figure 1, we can see in order for this DTC to be detected, battery voltage must be greater than or equal to 9V, the CVT in drive or reverse, and the measured primary pulley shaft speed greater than or equal to 1000 rpm.

Under the conditions of the DTC General Description, once all of the enable conditions are met and the measured secondary pulley shaft speed remains at 0 rpm, the DTC is set and stored in the TCM memory. If by following the Trouble Tree for DTC P2751 all electrical inspections are within acceptable limits, do not forget the Variator Chain which is the link between the primary pulley and secondary pulley. Knowing that our secondary speed sensor circuit has everything required to operate, there is a possibility the Variator Chain has broken causing there to be no secondary pulley speed and no movement. Removal of the CVT unit oil pan for an inspection is required and if chain components are found, replacement of the CVT unit is necessary to correct the concern.

07 GR8-1100 EST BATTERY DIAGNOSTIC STATION, POWER SUPPLY MODE

Techline has been receiving calls on issues encountered during or after reprogramming a control module. Technicians report communication and power supply failures which often lead to control module replacement. Whenever reprogramming a control module, Subaru highly recommends connecting the GR8-1100 EST Battery Diagnostic Station to the vehicle and using the Power Supply Mode. Recently, we have started reprogramming new modules like the VDCCM, DCM and DMCM. Reprogramming these control modules can take longer than in the past and if not done correctly, the module can be affected. Never use any other type of "generic" power supply. The GR8 in Power Supply Mode will keep the voltage steady at all times. Confirm all electrical loads such as lights, audio, HVAC, seat heaters, and rear defroster are all switched off before setting up for Power Supply Mode. If the "Charge Battery" warning appears, the battery be must be charged before attempting reprogramming. This will happen if the battery charge level is too low and the GR8 cannot sustain the needed power supply. If required, always allow the GR8 to charge the battery as needed. Once completed, enter Power Supply Mode and perform the reprogramming. Do not connect the DSTi or SDI until the GR8 Power Supply Mode has completed its battery test mode and the Charging Voltage has dropped to a steady 13.5 Volts on the display (this may take up to 2 minutes if the battery is sufficiently charged). If a valid VIN is not entered, the GR8 will request an alternator rating. Enter 100 Amps as the default value.

REMINDER: Control module failures as a result of battery discharge during reprogramming are not a matter for warranty. Should any DTCs reset after the reprogramming is performed, diagnose per the corresponding procedure in the applicable Service Manual.

Directions for power supply mode use are below.

Confirm all electrical loads such as lights, audio, HVAC, seat heaters, and rear defroster are all switched OFF before setting up for Power Supply Mode.

Select the correct battery type (Flooded, AGM or AGM Spiral).
Select the CCA which matches the vehicle's battery
NOTE: (OE and replacement batteries have different CCA ratings. Always confirm the battery rating before proceeding.)
The GR8 will now run a quick test. After the test, if a manual VIN entry is requested, select back and select "Use CVG".
If a valid VIN is not entered, the GR8 will request an alternator rating. Enter 100 Amps as a default value.
If the "Charge Battery" WARNING appears, the battery MUST be charged before attempting reprogramming.
DO NOT connect the DSTi or SDI until the GR8 Power Supply Mode has completed its battery test mode and the Charging Voltage has dropped to a steady 13.5 Volts on the display. (this may take up to 2 minutes if the battery is sufficiently charged)
If the GR8 "beeps" or the Status Light flashes, a Diagnostic Charge Test should be performed on the battery before proceeding further.
Once Power Supply Mode reaches a steady 13.5 volts, connect the DSTi or SDI to the OBD connector and initiate the reprogramming process.
Amperage will fluctuate based upon the vehicle's demand for power.
NOTE: If the voltage rises beyond 14V while programming is in process, the reflash procedure will abort. This can indicate a need to test or charge the vehicle battery before any further attempt at programming.

IMPORTANT: This information is applicable to the Midtronics GR8 Diagnostic Battery Charger ONLY . It does not apply to any other brand / type of "generic" battery charger whatsoever. ONLY the GR8 and its Power Supply Mode feature has been tested and approved by SOA.

Once the GR8 is connected to the vehicle, as long as the battery is sufficiently charged , it takes less than 3 minutes to boot-up the charger, select Power Supply Mode , and have the battery voltage stabilized and ready for reprogramming.

15 DCM REMOVAL PRECAUTIONS

When removing the DCM from a vehicle, be sure not to place any excessive tension on the antenna harness when repositioning the DCM/Audio stack for connector removal. Figure 1 shows the rear view of the DCM with connector AN41 seated into the DCM with no antenna wire, and figure 2 shows the wire and pin removed from connector AN41. Both photos were the cause of a red LED in the overhead console, and DTC B2A01 stored in the Telematics system. If you encounter this DTC, always follow the proper Troubleshooting Tree and review the vehicle's service history. There is a possibility the DCM/Audio stack may have been removed previously for repairs or accessory installation, and as a result, the wiring could be damaged from mishandling. In the event you need to remove the DCM from a vehicle, please refer to Service Bulletin 15-195-16 for necessary servicing information.

When removing the DCM/Audio stack from the vehicle for any reason, follow the precautions outlined below:

Perform the removal procedures outlined in the applicable Service Manual.
Carefully pull the Audio stack forward not exceeding 6 inches as show in Figure 3.

Once the Audio stack has been repositioned to Figure 3, tilt the Audio/Navigation unit slightly downward and begin disconnecting the connectors as shown in Figure 4.
After the accessible connectors are disconnected, reach back and verify no harnesses are positioned around obstacles preventing unit repositioning.
Rotate the Audio stack slightly to reveal the existing connections as shown in Figure 5. Verify you have not placed excessive tension on the harnesses.
Begin disconnecting the remaining connections and remove the unit.
Once the unit has been removed, inspect all connections for damage.
Once repairs are completed, reinstall all removed components in reverse order.
Be sure to follow the installation procedures outlined in the applicable Service Manual.

Verify the customer is subscribed with STARLINK by checking the Vehicle Inquiry through Subarunet.
If subscribed, verify the green LED is illuminated in the overhead console.
Make a phone call by pressing the "i" button (shown in Figure 6) and confirm an operator connects, and then perform the same procedure with the SOS button. Advise each operator that this is just a test to confirm the unit's function.

15 2013 WRX OR STI SPECIAL EDITION GRAPHICS

Instructions for Subaru Retailers that need to order Replacement 2013 WRX or STI Special Edition Graphics from 3M original Wraps.

Please call the 3M Original Wraps dedicated Subaru Customer Service line at 1-888-551-9750.
Inform the Customer Service Representative that your retailer needs to order replacement WRX/STI Special edition graphics.
Pricing for the WRX design and the STI design is
- $82.45 - part only (only sold as full kit)
- $297.45 - installed part (3M will coordinate installation)
3M Original Wraps will deliver the replacement graphics within 10 business days and will coordinate installation if needed.

15 DOOR EDGE GUARDS / INSTALLATION TIPS AND BEST PRACTICES

We have received requests from the retailers for Door Edge Guard installation videos which detail the required steps to properly install the accessory in addition to the installation instructions provided by the supplier on STIS.

Five videos have been prepared and are provided below which to show the Door Edge Guard Installation from beginning to completion including tips to remove the door edge guard if damaged.

DOOR EDGE GUARD VIDEO KEY POINTS:

NOTE: To view the linked videos a Gmail account is required. An account maybe set-up by going to Door Edge Guard Removal https://mail.google.com

Required Special Tool Note:

To properly install the Door Edge Guard Accessory Kit a "Door Edge Guard Sealant Adjustment Special Tool" is required. In the event that factory applied door seam sealer needs to be adjusted to allow the Door Edge Guard to properly fit to the vehicle's door edge, this special tool is required. The special "Door Edge Guard Sealant Adjustment" tool is available through normal Subaru Parts channels using part number SOA801AT000 .

NOTE: the Door Edge Guard (DEG) seam sealer checking and adjusting tools shown in the videos have changed. The functionality and use instruction remains the same as shown in the video material. All tools and templates are subject to change without notice for product improvements, etc.

The new DEG tools are available in the Subaru Retail Parts Management (RPM) system on Subarunet using the part numbers listed below;

SOA801AT000 (white) DEG Tool applies to Legacy / Outback, WRX / STI, and Forester Rear Doors Only.
SOA801AT010 (black) DEG Tool is exclusively for the Forester Front Doors Only.

The new D.E.G. tool products are now being made of a higher durability nylon plastic material to reduce the possibility of breakage during multiple seam sealer adjustment use.

Video Material Disclaimer:

The Door Edge Guard (DEG) installation videos were created exclusively for use at the Subaru Ports of Entry where Genuine Subaru accessories are installed by specially trained installers at our USA port locations. The (DEG) installation process follows the Genuine Subaru Door Edge Guard Installation Instructions found on STIS. In this case, the specialty produced "magnetic templates" shown in the videos are only available to Subaru port facilities and not to retailers. The Genuine Subaru Door Edge Guard Installation Instructions include "paper templates" which perform the same function when installing the Door Edge Guard accessory kit and are available to the Subaru Retailers and Subaru Customers alike on STIS.