Emission Control System Subaru BRZ ZC

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1. Visual check of hose, connection and gasket Check the hoses for cracks, leakage or damage. NOTE: Removing the oil level gauge, oil filler cap, ventilation hose, etc. causes an engine trouble or engine stall. If any of the parts between the throttle body and cylinder head are not installed, loose or cracked, the engine intakes secondary air and this causes an engine trouble or engine stall.

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1. REMOVE REAR DIFFERENTIAL CARRIER ASSEMBLY (Refer to «REMOVAL»(ref-619162-S32187261582014053000000) )
2. REMOVE REAR SUSPENSION MEMBER SUB-ASSEMBLY (Refer to «REMOVAL»(ref-619196-S38511925982014053000000) )
3. REMOVE CANISTER PUMP MODULE Disconnect the drain tube B as indicated by the arrows, in the order shown in the illustration. Disconnect the drain tube A as indicated by the arrows, in the order shown in the illustration. Disconnect the evaporation hose from the fuel filler pipe assembly. Disengage the clip. Remove the 3 bolts and canister pump module. Disengage the clip. Disengage the clamp. Remove the nut and bracket B. Remove the 2 nuts and bracket A. Disconnect the drain tube A and drain tube B as indicated by the arrows, in the order shown in the illustration. Disconnect the 2 quick connector as indicated by the arrows, in the order shown in the illustration, and remove the drain tube C.
4. REMOVE CHARCOAL CANISTER ASSEMBLY Disconnect the fuel tank vent tube as indicated by the arrows, in the order shown in the illustration. Disconnect the purge tube as indicated by the arrows, in the order shown in the illustration. Remove the nut. Remove the 2 bolts and charcoal canister assembly along with the canister bracket B. Remove the 2 nuts and canister bracket B.

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1. INSPECT CHARCOAL CANISTER ASSEMBLY CAUTION: When applying vacuum, the needle may waver but, as long as the needle returns to its initial position immediately, it is not a malfunction. Visually check the charcoal canister assembly for cracks or damage. If cracks or damage is found, replace the charcoal canister assembly. Check the air flow. Using a vacuum pump, check the air flow according to the procedures below. Measurement Condition Specified Condition Ports B and C closed, and vacuum applied to port A (2 kPa (15 mmHg, 0.590 in.Hg)) No air leaks Port C closed, and vacuum applied to port A (2 kPa (15 mmHg, 0.590 in.Hg)) Air flows from port B Port C closed and air blown into port A (5 kPa (0.1 kgf/cm 2 , 0.725 psi)) Air flows from port B Measurement Condition Specified Condition Air blown into port A (5 kPa (0.1 kgf/cm 2 , 0.725 psi)) Air flows from ports B and C If the result is not as specified, replace the charcoal canister assembly.
2. INSPECT CANISTER PUMP MODULE Measure the resistance according to the value in the table below. STANDARD RESISTANCE Tester Connection Condition Specified Condition 1 - 5 20°C (68°F) 25 to 30 ohms 1 - 5 60°C (140°F) 27 to 35 ohms Check the operation of the check valve. Install a clean hose to the purge control solenoid valve. Check that air flows from port A to port B. Connect the positive (+) lead of the battery to terminal 5 and the negative (-) lead to terminal 1. Check that air does not flow from port A to port B. Connect the positive (+) lead of the battery to terminal 3 and the negative (-) lead to terminal 4. Check that the vacuum pump operates. CAUTION: Do not operate vacuum pump for 5 minutes or more. Connect the positive (+) lead of the battery to terminal 6 and the negative (-) lead to terminal 8. NOTE: Use new dry-cell batteries. Using a circuit tester, check that the initial voltage of a single dry-cell battery is 1.6 V or more. Also check that the voltage of the three batteries in position is within the range from 4.8 to 5.2 V. Measure the voltage according to the value in the table below. STANDARD VOLTAGE Tester Connection Condition Specified Condition 7 - 8 25°C (77°F) Approx. 3.5 V Connect the positive (+) lead of the battery to terminal 6 and the negative (-) lead to terminal 8. NOTE: Use new dry-cell batteries. Using a circuit tester, check that the initial voltage of a single dry-cell battery is 1.6 V or more. Also check that the voltage of the three batteries in position is within the range from 4.8 to 5.2 V. Connect the positive (+) lead of the battery to terminal 3 and the negative (-) lead to terminal 4. Check that the voltage drops slightly from 3.5 volts.

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1. INSTALL CHARCOAL CANISTER ASSEMBLY Install the canister bracket B to the charcoal canister assembly with 2 nuts. Standard value: T=8.0N.m {82kgf.cm} {5.9ft.lbf} Install the charcoal canister assembly with canister bracket B with the 2 bolts and the nut. Standard value: Bolt T=7.5N.m {76kgf.cm} {5.5ft.lbf} Nut T=8.0N.m {82kgf.cm} {5.9ft.lbf} Connect the fuel tank vent tube as indicated by the arrows, in the order shown in the illustration. Connect the purge tube as shown in the illustration.
2. INSTALL CANISTER PUMP MODULE Install the drain tube C. Connect the drain tube A and the drain tube B. Engage the clamp. Install the nuts and bracket B. Standard value: T=18N.m {184kgf.cm} {13.3ft.lbf} Install the 2 nuts and bracket A. Standard value: T=18N.m {184kgf.cm} {13.3ft.lbf} Engage the clip. Install the canister pump module with 3 bolts. Standard value: T=7.5N.m {77kgf.cm} {5.5ft.lbf} Connect the evaporation hose to the fuel pipe assembly. Engage the clip. Connect the drain tube A to the fuel filler pipe. Connect the drain tube B to the charcoal canister assembly.
3. INSTALL REAR SUSPENSION MEMBER SUB-ASSEMBLY (Refer to «INSTALLATION»(ref-619196-S42005376352014053000000) )
4. INSTALL REAR DIFFERENTIAL CARRIER ASSEMBLY (Refer to «INSTALLATION»(ref-619162-S42636695922014053000000) )

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1. Removal of engine cover sub-assembly No. 1 (Refer to «REMOVAL»(ref-619189-S39005489712014053000000) )
2. Removal of purge control solenoid valve While holding the purge control solenoid valve by hand, remove the nut. Disconnect the connector for the purge control solenoid valve. Disconnect the vacuum sensor connector. Disconnect the ventilation hose NO. 2 from the air intake boot. Disconnect the fuel vapor feed hose No. 1 and fuel vapor feed hose No. 2, and remove the purge control solenoid valve. Disconnect the joint wire harness connector from the purge control solenoid valve.

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1. Installation of purge control solenoid valve Connect the joint wire harness connector to the purge control solenoid valve. Connect the fuel vapor feed hose No. 1 and fuel vapor feed hose No. 2 to the purge control solenoid valve. Connect the ventilation hose NO. 1 to the air intake boot. Connect the vacuum sensor connector. Connect the purge control solenoid valve connector. Using the nut, install the purge control solenoid valve. Standard value: T=6.4N.m {65kgf.cm} {4.7ft.lbf}
2. Installation of engine cover sub-assembly No. 1 (Refer to «INSTALLATION»(ref-619189-S11634536132014053000000) )

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1. Inspection of purge control solenoid valve Resistance check Measure the resistance between the terminals. RESISTANCE Inspection terminals Inspection conditions Standard value 1 - 2 20°C {68°F} 21 to 27 ohms 1 - chassis ground Always 10 Mohms or more 2 - chassis ground Always 10 Mohms or more NOTE: If it is out of standard value, replace the purge control solenoid valve. Operation check Apply the battery voltage between the terminals of the purge control solenoid valve, and check if air flow is present between the ports E and F when the coil is energized or de-energized. CRITERIA Measurement condition Criteria Energized Air vent present Not energized No air vent NOTE: If it is out of standard value, replace the purge control solenoid valve.

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1. Check fuel tank ASSY check Visually check the cap gasket for distortion or damage.

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1. Removal of intake manifold (Refer to «DISASSEMBLY»(ref-619189-S01395914062014053000000) )
2. Removal of PCV valve Remove the ventilation hose. Remove the PCV valve from the cylinder head RH.

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1. Installation of PCV valve Apply THREE BOND 1324 to the PCV valve. Install the PCV valve to the cylinder head RH. Standard value: T=23N.m {235kgf.cm} {17.0ft.lbf} Connect the ventilation hose to the PCV valve.
2. Installation of intake manifold (Refer to «INSTALLATION»(ref-619189-S11634536132014053000000) )

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1. PCV valve inspection Operation check Install the hose to the PCV valve. Check that air comes out easily when air is blown into the hose from the cylinder head side. Check that air does not comes out easily when air is blown into the valve from the intake manifold side. Remove the hose from the PCV valve.