Subaru BRZ 2016 User manual

2016 AUGUST BRZ SERVICE MANUAL QUICK REFERENCE INDEX
FUJI HEAVY INDUSTRIES LTD. G4440GE
GENERAL INFORMATION
SECTION
This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.
All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.
FOREWORD FW
HOW TO USE THIS MANUAL HU
SPECIFICATIONS SPC
PRECAUTION PC
NOTE NT
IDENTIFICATION ID
RECOMMENDED MATERIALS RM
PRE-DELIVERY INSPECTION PI
PERIODIC MAINTENANCE SERVICES PM
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17BRZ_EU_EN.book 2 ページ ２０１６年６月２８日 火曜日 午前１０時２２分

FOREWORD
FW
Page
1. Foreword ....................................................................................................2
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FW-2
Foreword
FOREWORD
1. Foreword
A: FOREWORD
These manuals are used when performing mainte-
nance, repair or diagnosis of Subaru BRZ.
Applicable model:
2017 MY ZC*****
The manuals contain the latest information at the
time of publication. Changes in the specifications,
methods, etc. may be made without notice.
NOTE:
“SUBARU” means Fuji Heavy Industry Ltd. and its
affiliates and subsidiaries.
“SUBARU dealer” means an authorized SUBARU
dealer and/or repairer.
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HOW TO USE THIS MANUAL
HU
Page
1. How to Use This Manual ............................................................................2
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HU-2
How to Use This Manual
HOW TO USE THIS MANUAL
1. How to Use This Manual
A: HOW TO USE THIS MANUAL
1. STRUCTURE
Each section consists of SCT that are broken down into SC that are divided into sections for each compo-
nent. The specification, maintenance and other information for the components are included, and the diag-
nostic information has also been added where necessary.
2. CONTENTS
The first page has an index with tabs.
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HU-3
How to Use This Manual
HOW TO USE THIS MANUAL
3. COMPONENT
Illustrations are provided for each component. The information necessary for repair work (tightening torque,
grease up points, etc.) is described on these illustrations. Information is described using symbol.
To order parts, refer to parts catalogue.
Example:
HU-00017
(14)
(9)
(8)
(7)
(6)
(10)
(4) (10)
(22)
(11)
(19)
(17)
(15)
(13)
(12)
(18)
(16)
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(11)
(10)
(9)
(12)
(13)
(19)
(18)
(20)
(17)
(16)
(24)
(10)
(25)
(5)
(4)
(4)
(4)
(3)
(3)
(3)
(2)
(1)
(21)
(15)
(23)
T7
T2
T2
T2
T2
T2
T2
T4
T5
T5
T8
T6
T6
T6
T11
T10
T1
T1
T3
T3
T3
T1
T9
T4
T5
T5 T3
T4
T3
T2
T4
T2
T1
T3
(20)
(21)
(23)
(22)
(10)
(24)
(25)
(26)
(35)
(34)
(27)
(14)
(28)
(29)
(31)
(32)
(37)
(30)
(33)
(36)
T3
T2
T1 ....
,
: Selective part
: Replacement part
: Sealing point
: Should be lubricated with oil.
: Should be lubricated with grease.
: Tightening torque
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HU-4
How to Use This Manual
HOW TO USE THIS MANUAL
4. DEFINITIONS OF “NOTE”, “CAUTION”, AND “WARNING”
•NOTE:
Describes additional information to make works easier.
•CAUTION:
Describes prohibited matters to prevent vehicle or parts damage, or matters that requires special attention
during work.
• WARNING:
Describes matters that may cause serious damage to the operator or other person, or that may cause dam-
age or accident.
5. SPECIFICATIONS
If necessary, specifications are also included.
6. INSPECTION
Inspections to be carried out before and after maintenance are included.
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HU-5
How to Use This Manual
HOW TO USE THIS MANUAL
7. MAINTENANCE
• Maintenance instructions for serviceable parts describe work area and detailed step with illustration. It also
describes the use of special tool, tightening torque, caution for each procedure.
• If many serviceable parts are included in one service procedure, appropriate reference is provided for each
part.
Example:
8. DIAGNOSIS
Step-by-step process is employed for easier diagnosis.
(A) Component (D) Cautions (G) Tightening torque
(B) Process (E) Tool number of special tool (H) Illustration
(C) Reference (F) Name of special tool
HU-00020
1) Remove the manual transmission assembly
from vehicle. <Ref. to MT-33, REMOVAL, Manual
Transmission Assembly.>
15.Main Shaft
A: REMOVAL
11) Tighten the lock nuts to the specified torque us-
ing ST1 and ST2.
NOTE:
Secure the lock nuts in two places after tightening.
ST1 498937000 TRANSMISSION HOLDER
(A)
(B)
(C)
(D)
(G)
(E) (F)
(H)
Tightening torque:
120 N m (12.2 kgf-m, 88.5 ft-lb)
ST1
ST2
ST2 499987003 SOCKET WRENCH (35)
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HU-6
How to Use This Manual
HOW TO USE THIS MANUAL
9. SI UNITS
Measurements in these manuals are according to the SI units. Metric and yard/pound measurements are
also included.
Example:
Tightening torque:
44 N·m (4.5 kgf-m, 33 ft-lb)
The figure used in these manuals are described in the SI units and conventional units are described in ( ).
List of SI unit
Item SI units Conventional unit Remarks
Force N (Newton) kgf 1 kgf = 9.807 N
Mass (Weight) kg, g kg, g
Capacity L, mL or cm3L or cc 1 cc = 1 cm3= 1 mL
Torque N·m kgf-m, kgf-cm 1 kgf-m = 9.807 N·m
Rotating speed r/min rpm
Pressure kPa (Kilopascal) kgf/cm21 kgf/cm2= 98.07 kPa
mmHg 1 mmHg = 0.1333 kPa
Power W PS 1 PS = 0.7355 kW
Calorie W·h cal 1 kcal = 1.163 W·h
Fuel consumption rate g/kW·h g/PS·h 1 g/PS·h = 1.3596 g/kW·h
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HU-7
How to Use This Manual
HOW TO USE THIS MANUAL
10.EXPLANATION OF TERMINOLOGY
List
2ndr Secondary
AAI Air Assist Injection
AAR Angular Adjusted Roller
A/B Airbag
ABS Anti-lock Brake System
A/C Air Conditioner
AC Angular Contact
ACC Accessory
A/F Air Fuel Ratio
ALT Generator
APS Accessory Power Supply Socket
ASSY Assembly
AT Automatic Transmission
ATF Automatic Transmission Fluid
AUX Auxiliary Storage Unit (External storage)
AVCS Active Valve Control System
AWD All Wheel Drive
BATT Battery
BCM Brake Control Module
BJ Bell Joint
BRKT Bracket
CAN Controller Area Network
CCA Cold Cranking Ampere
CD Compact Disc
CDI Common Rail Direct Injection
CD-R/RW CD Recordable/Rewritable
COMPL Complete
CPC Canister Purge Control Solenoid Valve
CPU Central Processing Unit
CTR Center
CM Control Module
CVT Continuously Variable Transmission
CVTF Continuously Variable Transmission Fluid
CWP Cold Weather Package
DCC Delivery Check Connector
DCCD Driver’s Control Center Differential
DOHC Double Overhead Camshaft
DOJ Double Offset Joint
DPF Diesel Particulate Filter (Exhaust gas puri-
fication system)
D/R Dual-range
DTC Diagnosis Trouble Code
DU Drive Unit
DVD Digital Versatile Disc or Digital Video Disc
EBD Electronic Brake Distribution
EBJ High-Efficiency Compact Ball Fixed Joint
ECM Engine Control Module
EDJ High-Efficiency Compact Double Offset
Joint
E/G Engine
EGI Electronic Gasoline Injection
EGR Exhaust Gas Recirculation
ELR Emergency Locking Retractor
EPB Electronic Parking Brake
ETC Electronic Throttle Control
EX Exhaust
F/B Fuse & Joint Box
FL Fusible Link
Ft Front
FWD Front Wheel Drive
GPS Global Positioning System
HBA High Beam Assist
HI High
HID High-Intensity Discharge
H/K Harman/Kardon Audio
H/L Headlight
H/U Hydraulic Unit
HVAC Heater, Ventilator and Air Conditioner
ICR Inrush Current Reduction
I/F Interface
IG Ignition
IN Intake
INT Intermittent
I/O Input/Output
IR Infrared Ray
ISC Idle Speed Control
K/A Keyless access
LAN Local Area Network
LCD Liquid Crystal Display
LED Light Emitting Diode
LH LH (Left Hand)
LHD Left Hand Drive
Lo Low
LSD Limited Slip Differential
LWR Lower
M/B Main Fuse & Relay Box
MD Mini Disc
MID Multi Information Display
MFI Multi-Point Fuel Injection
MP-T Multi-Plate Transfer
M/R Moon Roof
MT Manual Transmission
NA Natural Aspiration
NC Normal Close (Relay)
NO Normal Open (Relay)
OBD On-Board Diagnosis
OP Option Parts
PC Personal Computer
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HU-8
How to Use This Manual
HOW TO USE THIS MANUAL
PCD Pitch Circle Diameter
PCV Positive Crankcase Ventilation
PID Parameter Identification
PM Particulate Matter
Pr Primary
PRG Power Rear Gate
P/S Power Steering
PTJ Pillow Tripod Joint
P/W Power Window
RAM Random Access Memory
RH RH (Right Hand)
RHD Right Hand Drive
ROM Read Only Memory
Rr Rear
SDI Subaru Diagnostic Interface
SI Subaru Intelligent
SOHC Single Overhead Camshaft
SRH Steering Responsive Headlight
SRS Supplemental Restraint System
SRVD Subaru Rear Vehicle Detection
SSM Subaru Select Monitor
ST Special Tool
STD Standard
SVM Side View Monitor
SW Switch
T/B Turbocharger
TCS Traction Control System
TCM Transmission Control Module
TGV Tumble Generator Valve
T/M Transmission
TPMS Tire Pressure Monitoring System
UJ Universal Joint
UPR Upper
UV Ultraviolet
VDC Vehicle Dynamics Control
V.I.N. Vehicle Identification Number
ViS-C Viscous Coupling
VSV Vacuum Switching Valve
VTD Variable Torque Distribution
W/H Wiring Harness
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SPECIFICATIONS
SPC
Page
1. BRZ ............................................................................................................2
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SPC-2
BRZ
SPECIFICATIONS
1. BRZ
A: DIMENSION
*: EH, ET and MT model except for KA
B: ENGINE
*: MT model for KA
C: ELECTRICAL
*1: LHD model
*2: RHD model
Model 2.0 L DOHC non-turbo
Overall length mm (in) 4,240 (166.9)
Overall width mm (in) 1,775 (69.9)
Overall height mm (in) 1,320 (52.0)
Compartment
Length mm (in) 1,615 (63.6)
Width mm (in) 1,490 (58.7)
Height mm (in) 1,060 (41.7)
Wheelbase mm (in) 2,570 (101.2)
Tr e a d Front mm (in) 1,520 (59.8)
Rear mm (in) 1,540 (60.6)
Minimum road clearance mm (in) 130 (5.1),120 (4.7)*
Model 2.0 L DOHC non-turbo
MT AT
Engine type Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine
Valve arrangement DOHC
Bore × stroke mm (in) 86 × 86 (3.4 × 3.4)
Displacement cm3(cu in) 1,998 (121.9)
Compression ratio 12.5
Ignition order 1 — 3 — 2 — 4
Idle speed at Park or Neutral position r/min 650±100 700±100
Maximum output kW (PS)/(r/min) 147 (200)/7,000, 152 (207)/7,000*
Maximum torque N·m (kgf-m, lb-ft)/(r/min) 205 (20.9, 151.2)/6,400 — 6,600, 212 (21.6, 156.4)/6,400 — 6,800*
Model 2.0 L DOHC non-turbo
MT AT
Ignition timing/Idle speed BTDC/(r/min) 12°±10°/650 12°±10°/700
Spark plug Type and manufacturer DENSO: ZXE27HBR8
Generator 12 V — 130 A
Battery
Type 12 V — 48AH (55D23L)*1
12 V — 48AH (55D23R)*2
Nominal capacity 5 HR: 40 Ah [25°C (77°F)]
Nominal voltage 12 V
CCA 390 A
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SPC-3
BRZ
SPECIFICATIONS
D: TRANSMISSION
1. MT
6MT: 6-forward speeds and 1-reverse with synchromesh
DSPD: Dry Single Plate Diaphragm
*: MT model for KA
2. AT
6AT: Electronically controlled fully-automatic, 6-forward speeds and 1-reverse
TCC: Torque Converter Clutch
E: STEERING
F: SUSPENSION
Model 2.0 L DOHC non-turbo
Transmission 6MT
Clutch type DSPD
Gear ratio
1st 3.626
2nd 2.188
3rd 1.541
4th 1.213
5th 1.000
6th 0.767
Rev. 3.437
Reduction gear (Rear) Final reduction Type of gear Hypoid
Gear ratio 4.100 4.300*
Model 2.0 L DOHC non-turbo
Transmission 6AT
Clutch type TCC
Gear ratio
1st 3.538
2nd 2.060
3rd 1.404
4th 1.000
5th 0.713
6th 0.582
Reverse 3.168
Reduction gear (Rear) Final reduction Type of gear Hypoid
Gear ratio 4.100
Model 2.0 L DOHC non-turbo
Ty p e Rack and pinion
Electric power steering
Turns, lock to lock 2.4
Minimum turning radius m (ft) 5.4 (17.7)
Model 2.0 L DOHC non-turbo
Front Macpherson strut type suspension
Rear Double-wishbone type suspension
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SPC-4
BRZ
SPECIFICATIONS
G: BRAKE
H: TIRE
I: CAPACITY
Model 2.0 L DOHC non-turbo
Service brake system Dual circuit hydraulic with vacuum suspended power unit
Front Ventilated disc brake
Rear Solid disc brake Ventilated disc brake
Parking brake Mechanical on rear brakes
Model 2.0 L DOHC non-turbo
Wheel size 16 × 6 1/2J 17 × 7J
17 × 7 1/2J
Tire size 205/55R16 91V 215/45R17 87W
Type Tubeless, Steel belted radial
Model 2.0 L DOHC non-turbo
MT AT
Fuel tank L (US gal, Imp gal) 50 (13.2, 11.0)
Engine oil
Filling amount of engine oil
L (US qt, Imp qt)
When replacing engine oil and oil filter 5.4 (5.7, 4.8)
When replacing engine oil only 5.2 (5.5, 4.6)
Total capacity
(at overhaul) L (US qt, Imp qt) 6.3 (6.7, 5.5)
Transmission gear oil L (US qt, Imp qt) 2.2
(2.3, 1.9) —
ATF L (US qt, Imp qt) — 7.5
(7.9, 6.6)
Rear differential gear oil L (US qt, Imp qt) 1.1 — 1.2 (1.1 — 1.3, 1.0 — 1.1)
Engine coolant L (US qt, Imp qt) 7.2
(7.6, 6.3)
7.5
(7.9, 6.6)
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SPC-5
BRZ
SPECIFICATIONS
J: WEIGHT
LHD model
Model 2 door
BRZ Limited
Transmission MT
OP code E1 E2 E3 EA
ZF ZC ZF ZC ZM ZE PD PA ZF ZC
Curb weight
(C.W.)
Total kg (lb) 1,261
(2,781)
1,263
(2,785)
1,259
(2,776)
1,261
(2,781)
1,261
(2,781)
1,263
(2,785)
1,258
(2,774)
1,260
(2,778)
1,261
(2,781)
1,263
(2,785)
Front kg (lb) 690
(1,521)
691
(1,524)
688
(1,517)
689
(1,519)
690
(1,521)
691
(1,524)
690
(1,521)
691
(1,524)
690
(1,521)
691
(1,524)
Rear kg (lb) 571
(1,259)
572
(1,261)
571
(1,259)
572
(1,261)
571
(1,259)
572
(1,261)
568
(1,252)
569
(1,255)
571
(1,259)
572
(1,261)
Maximum permissible
weight (M.P.W.) kg (lb) 1,670
(3,682)
1,670
(3,682)
1,670
(3,682)
1,670
(3,682)
1,670
(3,682)
1,670
(3,682)
1,670
(3,682)
1,670
(3,682)
1,670
(3,682)
1,670
(3,682)
Maximum
permissible
axle weight
(M.P.A.W.)
Front kg (lb) 876
(1,932)
876
(1,932)
876
(1,932)
876
(1,932)
876
(1,932)
876
(1,932)
876
(1,932)
876
(1,932)
876
(1,932)
876
(1,932)
Rear kg (lb) 943
(2,079)
943
(2,079)
943
(2,079)
943
(2,079)
943
(2,079)
943
(2,079)
943
(2,079)
943
(2,079)
943
(2,079)
943
(2,079)
Option
17-inch summer tire
17-inch 7.5J sum-
mer tire — — — — — — — — — —
Brand brake — — — — — — — — — —
Large diameter
brake 16-V
Ty p e B
— — — — — — — —
Spare tire
Brand damper — — — — — — — — — —
LSD
A package
Leather package
Leather seat — — — — —
Medium size spoiler — —
Display audio — — — — — — — —
Special edition — — — — — — — — — —
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SPC-6
BRZ
SPECIFICATIONS
Model 2 door
BRZ Limited
Transmission MT
OP code ET K4 KF KS
BA BD BC BF PD PA PD PA PD PA PF PC
Curb weight
(C.W.)
Total kg (lb) 1,249
(2,754)
1,247
(2,750)
1,253
(2,763)
1,251
(2,758)
1,258
(2,774)
1,260
(2,778)
1,258
(2,774)
1,260
(2,778)
1,258
(2,774)
1,260
(2,778)
1,262
(2,783)
1,264
(2,787)
Front kg (lb) 683
(1,506)
682
(1,504)
682
(1,504)
681
(1,502
690
(1,521)
691
(1,524)
690
(1,521)
691
(1,524)
690
(1,521)
691
(1,524)
689
(1,519)
690
(1,521)
Rear kg (lb) 566
(1,248)
565
(1,246)
571
(1,259)
570
(1,257)
568
(1,252)
569
(1,255)
568
(1,252)
569
(1,255)
568
(1,252)
569
(1,255)
573
(1,263)
574
(1,266)
Maximum permissi-
ble weight (M.P.W.) kg (lb) 1,670 (3,682)
1,670
(3,682)
1,670
(3,682)
1,670
(3,682)
1,670
(3,682)
1,670
(3,682)
1,670
(3,682)
1,670
(3,682)
1,670
(3,682)
1,670
(3,682)
1,670
(3,682)
1,670
(3,682)
Maximum
permissible
axle weight
(M.P.A.W.)
Front kg (lb) 876
(1,932)
876
(1,932)
876
(1,932)
876
(1,932)
876
(1,932)
876
(1,932)
876
(1,932)
876
(1,932)
876
(1,932)
876
(1,932)
876
(1,932)
876
(1,932)
Rear kg (lb) 943
(2,079)
943
(2,079)
943
(2,079)
943
(2,079)
943
(2,079)
943
(2,079)
943
(2,079)
943
(2,079)
943
(2,079)
943
(2,079)
943
(2,079)
943
(2,079)
Option
17-inch sum-
mer tire — — — —
17-inch 7.5J
summer tire — — — — — — — — — — — —
Brand brake — — — — — — — — — — — —
Large diameter
brake 16-V
Ty p e B
— — — —
Spare tire
Brand damper — — — — — — — — — — — —
LSD
A package
Leather pack-
age
Leather seat — — — — — —
Medium size
spoiler — — — — — — — —
Display audio — — — — — — — — — — — —
Special edition — — — — — — — — — — — —
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SPC-7
BRZ
SPECIFICATIONS
Model 2 door
BRZ Limited
Transmission MT
OP code EC EP
OF OC OM OE OF OC OM OE
Curb weight
(C.W.)
Total kg (lb) 1,241
(2,736)
1,243
(2,741)
1,243
(2,741)
1,245
(2,745)
1,241
(2,736)
1,243
(2,741)
1,243
(2,741)
1,245
(2,745)
Front kg (lb) 688
(1,517)
689
(1,519)
690
(1,521)
691
(1,524
688
(1,517)
689
(1,519)
690
(1,521)
691
(1,524)
Rear kg (lb) 553
(1,219)
554
(1,222)
553
(1,219)
554
(1,222)
553
(1,219)
554
(1,222)
553
(1,219)
554
(1,222)
Maximum permissible
weight (M.P.W.) kg (lb) 1,670 (3,682)
1,670
(3,682)
1,670
(3,682)
1,670
(3,682)
1,670
(3,682)
1,670
(3,682)
1,670
(3,682)
1,670
(3,682)
Maximum
permissible
axle weight
(M.P.A.W.)
Front kg (lb) 876
(1,932)
876
(1,932)
876
(1,932)
876
(1,932)
876
(1,932)
876
(1,932)
876
(1,932)
876
(1,932)
Rear kg (lb) 943
(2,079)
943
(2,079)
943
(2,079)
943
(2,079)
943
(2,079)
943
(2,079)
943
(2,079)
943
(2,079)
Option
17-inch summer tire
17-inch 7.5J sum-
mer tire — — — — — — — —
Brand brake — — — — — — — —
Large diameter
brake 16-V
Ty p e B
— — — — — — — —
Spare tire — — — — — — — —
Brand damper — — — — — — — —
LSD
A package
Leather package
Leather seat — — — —
Medium size spoiler
Display audio — — — —
Special edition — — — — — — — —
17BRZ_EU_EN.book 7 ページ ２０１６年６月２８日 火曜日 午前１０時２２分

SPC-8
BRZ
SPECIFICATIONS
Model 2 door
BRZ Limited
Transmission MT
OP code KR E9 EH
PD PA PF PC PD PA BA BD BC BF
Curb weight
(C.W.)
Total kg (lb) 1,258
(2,774)
1,260
(2,778)
1,262
(2,783)
1,264
(2,787)
1,258
(2,774)
1,260
(2,778)
1,249
(2,754)
1,247
(2,750)
1,253
(2,763)
1,251
(2,758)
Front kg (lb) 690
(1,521)
691
(1,524)
689
(1,519)
690
(1,521)
690
(1,521)
691
(1,524)
683
(1,506)
682
(1,504)
682
(1,504)
681
(1,502)
Rear kg (lb) 568
(1,252)
569
(1,255)
573
(1,263)
574
(1,266)
568
(1,252)
569
(1,255)
566
(1,248)
565
(1,246)
571
(1,259)
570
(1,257)
Maximum permissible
weight (M.P.W.) kg (lb) 1,670 (3,682)
1,670
(3,682)
1,670
(3,682)
1,670
(3,682)
1,670
(3,682)
1,670
(3,682)
1,670
(3,682)
1,670
(3,682)
1,670
(3,682)
1,670
(3,682)
Maximum
permissible
axle weight
(M.P.A.W.)
Front kg (lb) 876
(1,932)
876
(1,932)
876
(1,932)
876
(1,932)
876
(1,932)
876
(1,932)
876
(1,932)
876
(1,932)
876
(1,932)
876
(1,932)
Rear kg (lb) 943
(2,079)
943
(2,079)
943
(2,079)
943
(2,079)
943
(2,079)
943
(2,079)
943
(2,079)
943
(2,079)
943
(2,079)
943
(2,079)
Option
17-inch summer tire — — — —
17-inch 7.5J sum-
mer tire — — — — — — — — — —
Brand brake — — — — — — — — — —
Large diameter
brake 16-V
Ty p e B
— — — —
Spare tire
Brand damper — — — — — — — — — —
LSD
A package
Leather package
Leather seat — — — — —
Medium size spoiler — — — — — —
Display audio — — — — — — — — — —
Special edition — — — — — — — — — —
17BRZ_EU_EN.book 8 ページ ２０１６年６月２８日 火曜日 午前１０時２２分