instrument panel SUBARU LEGACY 1996 Service Owner's Manual

G5M0332
4) Remove steering wheel nut, then draw out steering
wheel from shaft using steering puller.
G4M0086
5) Remove universal joint bolts and then remove universal
joint.
CAUTION:
Scribe alignment marks on universal joint so that it can
be reassembled at the original serration.
6) Remove trim panel under instrument panel.
7) Disconnect connectors for ignition switch and combina-
tion switch wiring harness under instrument panel.
B4M0127A
8) Remove the two bolts under instrument panel securing
steering shaft.
9) Pull out steering shaft assembly from hole on toe board.
CAUTION:
Be sure to remove universal joint before removing
steering shaft assembly installing bolts when remov-
ing steering shaft assembly or when lowering it for
servicing of other parts.
B4M0555
B: DISASSEMBLY
Remove the four screws securing upper and lower steer-
ing column covers, and the two screws securing combina-
tion switch, then remove related parts.
NOTE:
Steering column assembly can not to be disassembled.
11
4-3SERVICE PROCEDURE
2. Tilt Steering Column

B4M0555
D: ASSEMBLY
1) Insert combination switch to upper column shaft, and
install lower column cover with tilt lever held in the lowered
position. Then route ignition key harness and combination
switch harness between column cover mounting bosses.
2) Fit upper column cover to lower column cover, and
tighten combination switch and column cover.
Tightening torque:
1.2±0.2 N⋅m (0.12±0.02 kg-m, 0.9±0.1 ft-lb)
CAUTION:
Don’t overtorque screw.
E: INSTALLATION
1) Insert end of steering shaft into toe board grommet.
2) Tighten steering shaft mounting bolts under instrument
panel.
Tightening torque:
25±5 N⋅m (2.5±0.5 kg-m, 18.1±3.6 ft-lb)
3) Connect ignition and combination switch connectors
under instrument panel.
4) Connect airbag system connector at harness spool.
NOTE:
Make sure to apply double lock.
5) Install universal joint.
(1) Align bolt hole on the long yoke side of universal
joint with the cutout at the serrated section of shaft end,
and insert universal joint.
(2) Align bolt hole on the short yoke side of universal
joint with the cutout at the serrated section of gearbox
assembly. Lower universal joint completely.
(3) Temporarily tighten bolt on the short yoke side.
Raise universal joint to make sure the bolt is properly
passing through the cutout at the serrated section.
(4) Tighten bolt on the long yoke side, then that on the
short yoke side.
Tightening torque:
24±3 N⋅m (2.4±0.3 kg-m, 17.4±2.2 ft-lb)
CAUTION:

Make sure that universal joint bolts is tightened
through notch in shaft serration.

Excessively large tightening torque of universal
joint bolts may lead to heavy steering wheel operation.
Standard clearance between gearbox to DOJ:
Over 15 mm (0.59 in)
13
4-3SERVICE PROCEDURE
2. Tilt Steering Column

B4M0622A
D: AIR BLEEDING CONTROL WITH SELECT
MONITOR
1) Connect select monitor to data link connector beside
driver’s seat instrument panel lower.

1Data link connector (for Subaru select monitor and
OBD-II general scan tool)

2Data link connector (for Subaru select monitor)
NOTE:
When using data link connector
1above, use ST.
ST 498357200 ADAPTER CABLE
2) Start the engine.
3) Change select monitor to TCS mode by pressing the
function key.
B4M0623
4) Press FD3 ENT key.
B4M0624
5) When the message shown in the figure is displayed,
press ENT key.
B4M0625
6) Air bleeding control operation starts.
91
4-4SERVICE PROCEDURE
19. Air Bleeding (With TCS model)

B4M1005
7) Remove bolt cover and bolt.
B4M1006
8) Remove ABSCM upper mounting bolt.
B4M1045A
9) Pull the lower part of the instrument panel rearward 5
cm (1.97 in).
CAUTION:
When pulled more than 6 cm (2.4 in), the instrument
panel may be deformed.
NOTE:
At this time, instrument panel securing clips can be
removed.
B4M1008
10) Remove two ABSCM lower mounting bolts from the
lower part of the instrument panel.
B4M1009A
11) While holding the lower part of instrument panel rear-
ward 5 cm (1.97 in) remove the ABSCM.
CAUTION:
When pulled more than 6 cm (2.4 in), the instrument
panel may be deformed.
12) Disconnect connector from ABSCM.
CAUTION:
Do not drop or bump ABSCM.
120
4-4SERVICE PROCEDURE
23. ABS Control Module (ABS 5.3 Type)

B: REMOVAL
1. ACCELERATOR PEDAL (LHD MODEL)
1) Disconnect ground cable from battery.
2) Disconnect accelerator cable from throttle body.
CAUTION:
Be careful not to kink accelerator cable.
3) Remove instrument panel lower cover from instrument
panel, and connector.
G4M0322
4) Disconnect accelerator cable from accelerator pedal
lever.
G4M0335
5) Working inside engine compartment, remove casing
cap out of the toe board by turning it clockwise.
6) Pull out the cable from the toe board hole.
G4M0321
7) Remove accelerator pedal connecting bolt from accel-
erator pedal bracket.
8
4-5SERVICE PROCEDURE
1. Pedal

2. BRAKE AND CLUTCH PEDAL (LHD MODEL)
1) Disconnect ground cable from battery.
2) Disconnect clutch cable from release lever.
3) Remove instrument panel lower cover from instrument
panel.
4) Disconnect the following parts from pedal bracket.
(1) Operating rod of brake booster
(2) Electrical connectors (for stop light switch, etc.)
5) Remove clevis pin which secures pedal to push rod.
B4M0154A
6) Remove bolts and nuts which secure brake and clutch
pedals, and remove pedal bracket and clutch cable as a
unit.
CAUTION:
Before removing clutch cable from toe board, remove
grommet. Slowly remove clutch cable, being careful
not to scratch it.
7) Depress clutch pedal, disconnect clutch cable from
clutch pedal.
G4M0324
3. BRAKE PEDAL (LHD MODEL)
1) Disconnect ground cable from battery.
2) Remove instrument panel lower cover from instrument
panel.
3) Remove clevis pin which secures brake pedal to brake
booster operating rod. Also disconnect stop light switch
connector.
4) Remove two bolts and four nuts which secure brake
pedal to pedal.
9
4-5SERVICE PROCEDURE
1. Pedal

4. ACCELERATOR AND BRAKE PEDAL (RHD
MODEL)
1) Disconnect negative cable from battery.
2) Disconnect accelerator cable from throttle body.
CAUTION:
Be careful not to kink accelerator cable.
3) Remove instrument panel lower cover from instrument
panel.
4) Remove clevis pin which secures brake pedal to brake
booster operating rod. Also disconnect electrical connec-
tors (for stop light switch, etc.).
G4M0322
5) Disconnect accelerator cable from accelerator pedal
lever.
B4M0156A
6) Remove the casing cap out of the toe board by turning
it clockwise.
7) Pull out the cable from the toe board hole.
10
4-5SERVICE PROCEDURE
1. Pedal

1. Supplemental Restraint System
“Airbag”
Airbag system wiring harness is routed near the instrument
panel, heater unit, blower motor and control unit.
CAUTION:

All Airbag system wiring harness and connectors
are colored yellow. Do not use electrical test equip-
ment on these circuit.

Be careful not to damage Airbag system wiring har-
ness when servicing the instrument panel, heater unit,
blower motor and control unit.
2. Heater Unit
A: REMOVAL AND INSTALLATION
1) Disconnect GND cable from battery.
2) Remove heater hoses (inlet, outlet) in engine compart-
ment.
NOTE:
Drain as much coolant from heater unit as possible, and
plug disconnected hose with cloth.
<Ref. to 2-5 [W1A0].>
3) Remove instrument panel.
<Ref. to 5-4 [W1A0].>
4) Remove steering support beam.
<Ref. to 5-1 [C600].>
5) Remove evaporator. (With A/C model)
<Ref. to 4-7 [W14A0].>
G4M0554
6) Remove heater unit.
11
4-6SERVICE PROCEDURE
1. Supplemental Restraint System“Airbag”- 2. Heater Unit

1. Supplemental Restraint System
“Airbag”
Airbag system wiring harness is routed near the instrument
panel, heater unit, blower motor and control unit.
CAUTION:

All Airbag system wiring harness and connectors
are colored yellow. Do not use electrical test equip-
ment on these circuit.

Be careful not to damage Airbag system wiring har-
ness when servicing the instrument panel, heater unit,
blower motor and control unit.
2. Heater Unit
A: REMOVAL AND INSTALLATION
1) Disconnect GND cable from battery.
2) Remove heater hoses (inlet, outlet) in engine compart-
ment.
NOTE:
Drain as much coolant from heater unit as possible, and
plug disconnected hose with cloth.
<Ref. to 2-5 [W1A0].>
3) Remove instrument panel.
<Ref. to 5-4 [W1A0].>
4) Remove steering support beam.
<Ref. to 5-1 [C600].>
5) Remove evaporator. (With A/C model)
<Ref. to 4-7 [W14A0].>
G4M0554
6) Remove heater unit.
11
4-6SERVICE PROCEDURE
1. Supplemental Restraint System“Airbag”- 2. Heater Unit

B4M0063
6. Mode Door Motor
A: REMOVAL
1) Remove instrument panel. <Ref. to 5-4 [W1A0].>
2) Remove mode door motor.
B4M0064A
B: INSPECTION
1) When approx. 12 V is applied to the mode door motor
terminals, mode door motor operates as follows:
LHD model
Terminal No.
Mode door motor
21
Polarity of power supply
terminalsMode door motor
operationDirection of linkage
rotation
+ VENT,DEF Clockwise
+ DEF,VENT Counterclockwise
RHD model
Terminal No.
Mode door motor
76
Polarity of power supply
terminalsMode door motor
operationDirection of linkage
rotation
+ VENT,DEF Clockwise
+ DEF,VENT Counterclockwise
2) Check mode door motor position switch.
When the mode door motor is moved to each mode posi-
tion by using the mode selector switch, check if continuity
exists between each terminal as follows:
LHD model
Mode selector switch
positionsTerminal No.
VENT 8 or 7
9 (GND) BI-LEV 6 or 7
HEAT 5or6
DEF/HEAT 4 or 5
DEF 3or4
18
4-6SERVICE PROCEDURE
6. Mode Door Motor