General Information & Specifications: Overview Subaru BRZ ZC

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1. Explanation scope of repair procedures The repair procedures are divided into the following three main types of procedures: [Diagnosis], [Removal/Installation, Replacement, Disassembly/Assembly and Inspection/Adjustment], and [Final Inspection]. Although a description of the following elemental procedures has been omitted from this Service Information, they should be performed with the actual procedures. Jacking and lifting procedures Cleaning of removed parts as necessary Visual inspection
2. Preparation items The preparation items that should be prepared before starting the procedures, such as SSTs, general tools and lubricant are listed in the preparation items article. However, preparation items that are considered to be of general use for repair procedures (such as tool stands, jacks and rigid racks) are omitted.
3. Procedures The exploded view shows the corresponding Service Information and titles as necessary. The exploded view includes descriptions of non-reusable parts, grease application locations, pre-coated bolts and tightening torques. Tightening torque, lubrication locations and non-reusable parts are described as the essential points of the procedures. CAUTION: If the above items can only be indicated in an illustration, an exploded view with these essentials is included. In such cases, all information such as torque and lubrication is included within the illustration. Procedures only describe essential items, with the location and contents of procedures included in an illustration, as well as detailed procedures, standard values, or precautions explained using text. In some cases, a single illustration is common to various similar models. For that reason, the actual vehicle may differ in their exact details.
4. How to read the repair standard values Standard values and limits are printed in bold text.
5. Definitions of terms Standard value Indicates the tolerance range during inspection and adjustment. Limit Indicates the maximum or minimum value that cannot be surpassed during inspection and adjustment. Reference value If the measurement method for determining the standard value is quite difficult, this indicates a standard value for an easy measurement method when there is no possibility that a malfunction will occur. < Warning > Used to indicate that there is a danger of injury to the personnel performing the procedures or other personnel, and indicate that there is a danger of injury or accident if the instructions are not followed. < Caution > Used to indicate special precautions that must be taken regarding items and procedures that must be performed because failure to perform them will result in damage to the vehicle or parts. < Reference > Used to indicate supplemental explanations separate from the current text in order to make procedures easier to perform/understand.
6. SI units The units used in this Service Information are SI units (International System of Units), and are as described in the following format of meters and yards/pounds. (Ex.) Standard value: T=28N.m {286kgf.cm} {20.7ft.lbf} SI UNITS CONVERSION FACTORS TABLE Item SI unit Traditional unit SI unit conversion factor Speed m/s 2 G 9.80665 Torque, moment N.m kgf/cm 0.0980665 Power N kgf 9.80665 Pressure MPa kgf/cm 2 0.0980665 kPa mmHg 0.133322 Power (work rate), work efficiency kW PS 0.735499 W kcal/h 1.16279 Cubic volume cm 3 cc 1 Spring constant N/mm kgf/mm 9.80665 SI PREFIXES M (mega) 10 6 d (deci) 10 -1 =0.1 K (kilo) 10 3 c (centi) 10 -2 =0.01 H (hecto) 10 2 m (milli) 10 -3 =0.001 Da (deca) 10 1 μ(micro) 10 -6 =0.000001

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1. SRS airbags and seat-belt pretensioner Precautions for handling and procedures Failure to properly perform work according to procedures for the SRS airbag and pretensioner system can result in these components operating while handling them and cause a serious life-threatening accident. Additionally, failure to repair this system correctly can result in the inability to function properly. Read the following items carefully before servicing a vehicle (removal/installation, inspection, or replacement of parts) and perform the proper procedures as described in this Service Information. Disconnection of the battery ground terminal CAUTION: Power windows have an index function that slightly opens/closes window glass when a door is opened/closed. Disconnect the battery ground (negative) terminal with the driver's and passenger's doors opened (window glass lowered to a position where door opening/closing is not a problem). The molding will be damaged if the battery ground terminal is disconnected with the window glass completely closed and a door is opened/closed. Procedures consist of checking the diagnostic code, turning the key to IG OFF, disconnecting the battery ground terminal, and waiting 60 seconds or more before starting any other procedure. An airbag could operate if any procedures are performed within 60 seconds of disconnecting the battery ground terminal because the SRS airbag and pretensioner system is equipped with a backup power source. Make note of the memory contents of each system before disconnecting the battery ground terminal as the memory of some systems might be deleted when disconnected. Restore the system setting after the service procedure. General precautions regarding the SRS airbag and pretensioner system Use an electrical tester for electrical inspections. Precautions for system surroundings are as indicated on corresponding labels. Never disassemble this system. Replace any parts with new genuine parts if they have been dropped, cracked, dented, chipped or deformed in any way. Never use SRS airbag and pretensioner parts from other vehicles. Be sure to always replace with new parts if replacement is necessary. Do not directly expose to high heat or open flame. Always inspect using diagnostics even if SRS airbag and pretensioner parts have not operated in a collision. Do not allow grease, cleanser, oil, water or other substances to adhere to system parts. If any substance adheres, wipe off immediately using a dry soft cloth. Store and handle in locations not subject to high temperature (85°C {185°F} or more) or high humidity, and where less affected by electrical noise. Always use the SSTs to make SRS airbag and pretensioner operate when disposing of a vehicle or individual parts. NOTE: Disposal of driver's airbag module Disposal of passenger's airbag module Disposal of curtain airbag module Disposal of side airbag module Disposal of seat-belt pretensioner Never measure the resistance of SRS airbag and pretensioner parts. WARNING: Doing so is extremely dangerous as the tester current could result in SRS airbag and pretensioner operation. Always inspect the airbag warning light after inspecting, removing/installing or replacing SRS airbags and sensors. Precautions regarding disposal of SRS airbag and pretensioner (before operating) Never dispose of any parts that have not operated. Perform SRS airbag and pretensioner operations outdoors on level ground where safety can be ensured. Try to avoid performing operations in residential and similar areas. Before operating, advise all persons nearby as operation of an SRS airbag and pretensioner results in a loud noise. Use the corresponding SSTs if operating an SRS airbag and pretensioner, and remain at a distance of five meters or more from the SRS airbag and pretensioner. Before performing procedures, touch a water pipe or steel frame with a bare hand to discharge any static electricity as it could cause the SRS airbag and pretensioner to operate. Be careful to prevent the deploying side of an airbag to be operated to face downward. Precautions regarding disposal of SRS airbag and pretensioner (after operating) Leave an operated SRS airbag and pretensioner as is for 30 minutes or more as some parts can reach extremely high temperatures (few hundred C° or more). Do not sprinkle water or otherwise try to cool an operated SRS airbag and pretensioner. IN Wear dustproof safety goggles and gloves when handling an operated SRS airbag and pretensioner. Place an operated SRS airbag and pretensioner in a strong clear vinyl bag and seal the bag before disposal. Be sure to always wash your hands after performing disposal procedures. Precautions for driver's, passenger's, side and curtain airbag modules Always maintain removed airbags with the deployment side facing upward even if removed for a short time. WARNING: Operation of an airbag for any reason with the deployment side facing downward can result in a serious life-threatening accident. When storing, do not place anything on top of an airbag and do not stack airbags on top of each other. Precautions for seatbelt pretensioners Do not touch the area around the belt winding parts even if removed for a short time. WARNING: Operation of a pretensioner for any reason can cause the belt to be wound resulting in a serious life-threatening accident. When storing, do not place anything on top of a pretensioner and do not stack pretensioners on top of each other. Precautions for roll connectors Always perform roll connector centering when installing a roll connector or removing/installing the steering wheel. CAUTION: The roll connector could suffer an open circuit if the steering wheel is operated without performing centering. Precautions for airbag CM, front sub-sensor, side airbag sensor ASSY, airbag door sensor, side airbag sensor and satellite safing sensor Always replace the sensor ASSY (airbag CM, front sub-sensor, side airbag sensor and satellite safing sensor) if an SRS airbag and pretensioner have operated (including if only the SRS airbag or pretensioner has operated) due to collision. Precautions for wire harnesses and connectors Wire harnesses have a uniform yellow color except for hidden portion in the engine room. Be very careful when handling special connectors that have been adopted. Handling of vehicles that have been in crashes or otherwise subjected to collision If using electrical welding equipment, remove the SRS airbags and pretensioners before performing any work. Remove the airbag CM, front sub-sensor, side airbag sensor and satellite safing sensor before performing work if these might be subject an impact. Do not expose the airbag CM, front sub-sensor, side airbag sensor and satellite safing sensor to high temperatures. Check surrounding wire harnesses and connectors for damage and melt as an SRS airbag and pretensioner become extremely hot (few hundred °C or more) in some parts when operated. Cases where it is necessary to inspect an SRS airbag and pretensioner If a vehicle has been damaged such as due to a collision including cases where the SRS airbags and pretensioners have not operated. Cases where a diagnostic code for the SRS airbag system has been output.
2. Basic items Battery terminal removal/installation CAUTION: Power windows have an index function that slightly opens/closes window glass when a door is opened/closed. Disconnect the battery ground (negative) terminal with the driver's and passenger's doors opened (window glass lowered to a position where door opening/closing is not a problem). The molding will be damaged if the battery ground terminal is disconnected with the window glass completely closed and a door is opened/closed. If performing any electric system procedures, disconnect the battery ground terminal before starting in order to prevent burn out caused by short circuit. If removing/installing the battery ground terminal, turn the key to IG OFF and the lighting switch to OFF, and completely loosen the terminal nut so as not to pry the terminal. Make note of the memory contents before disconnect the battery ground terminal as doing so deletes the memory of the diagnostic and other systems. Reconnect the battery ground terminal. Standard value: T=6.0N.m {61kgf.cm} {4.4 ft.lbf} Pre-coated bolts Pre-coated bolts are bolts to which a thread-locking agent has been applied on the bolt thread. Use the specified adhesive to pre-coat a bolt when re-tightening, loosening or otherwise moving one. CAUTION: A torque check is performed using the lower limit value of the tightening torque tolerance range. If reusing a pre-coated part, remove all old adhesive from bolts and threaded holes, degrease, and dry using compressed air. Apply the specified thread-locking agent to the bolt thread and tighten to the specified torque. Depending on the thread-locking agent that is applied, some time might be required to allow the agent to harden. Gasket Use sealant with gaskets as necessary to prevent leakage. Bolts, nuts and screws Check the tightening torques of bolts, nuts and screws, and always use a torque wrench to tighten. Check for foreign material (such as burrs or film) on the tightening seating surface. Tightening when using a torque wrench extension If the overall length when tightening is increased due to using a torque wrench in combination with an SST or other tool, the actual torque will be excessive if you tighten it to the specified torque shown on the torque wrench. This Service Information only indicates the specified tightening torque. If using an SST or extension, it is necessary to use the following formula to calculate the proper torque wrench reading. Formula T'=TxL2/(L1+L2) T' Torque wrench reading [N.m{kgf/cm}] T Specified tightening torque [N.m{kgf/cm}] L1 Length of SST or tool [cm] L2 Torque wrench length [cm] Removal/Installation of fuel system parts Location for removal/installation of fuel system parts Perform procedures in a location with good ventilation, and where there are no sources of flame/sparks present nearby such as welding equipment, grinders, drill, electric motors or heaters. Do not perform procedures in or near a pit as it can become filled with vaporized fuel. Removal/Installation of fuel system parts Prepare a fire extinguisher before starting procedures. In order to prevent static electricity discharge, attach a grounding wire to the fuel changer, vehicle, fuel tank or similar part and sprinkle a small amount of water underfoot (not enough to be slippery) Do not use electrical equipment such as an electric pump or work lights, as these can generate sparks or cause high temperature. Do not use a steel hammer or similar tool as these can generate sparks. Keep cloths with fuel adhered separate from other cloths, and then dispose properly. Hose clamp handling Before removing a hose, check the hose insertion depth and clamp position so that it can be securely restored. Replace any deformed or deteriorated clamps with a new part. If reusing a hose, install the clamp in alignment with the clamp marks on the hose. After installation of a plate-spring clamp, apply force in the directions of the arrows to make the clamp well fitted.

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