SUBARU LEGACY 1997 Service Repair Manual

In this manual, the following symbols are used.
*: Selective part

: Replacement part
: Should be lubricated with oil.
: Should be lubricated with grease.
: Sealing point
: Tightening torque

WARNING, CAUTION, NOTE

WARNING: Indicates the item which must be observed precisely during performance of maintenance ser-
vices in order to avoid injury to the mechanics and other persons.

CAUTION: Indicates the item which must be followed precisely during performance of maintenance ser-
vices so as to avoid damage and breakage to the vehicle and its parts and components.

NOTE: Indicates the hints, knacks, etc. which make the maintenance job easier.

SPECIAL TOOLS
When any special tool is required to perform the job, it is identified by“ST”in the applicable illustration and its
part number is shown in the manual.
M1H0120
1. Procedures for adjusting backlash
1) Set steering wheel to the straight-ahead position.
2) Remove the exhaust pipe
3) Loosen the lock nut with ST.


{ST1 921650000 STEERING GEARBOX WRENCH
ST2 921550000 STEERING GEARBOX WRENCH
Description
(of job method)
Shows the part name
Shows the part number
Tells that two kinds of special tools are required.
When two or more kinds of special tools are required to do
a job, they are identified by ST1, ST2,......respectively.


5

1. Important Safety Notice

Providing appropriate service and repair is a matter of great importance in the serviceman’s safety
maintenance and safe operation, function and performance which the SUBARU vehicle possesses.

In case the replacement of parts or replenishment of consumables is required, genuine SUBARU parts
whose parts numbers are designated or their equivalents must be utilized.

It must be made well known that the safety of the serviceman and the safe operation of the vehicle would
be jeopardized if he used any service parts, consumables, special tools and work procedure manuals which
are not approved or designated by SUBARU.
All right reserved. This book may not be reproduced
or copied, in whole or in part, without the written per-
mission of FUJI HEAVY INDUSTRIES LTD., TOKYO
JAPAN.
SUBARU,
andare trademarks of
FUJI HEAVY INDUSTRIES LTD.
© Copyright 1996 FUJI HEAVY INDUSTRIES LTD.
2
FOREWORD [T100]FOREWORD
1. Important Safety Notice

2. How to Use this Manual

This Service Manual is divided into four volumes by section so that it can be used with ease at work.
Refer to the Table of Contents, select and use the necessary section.

GENERAL INFORMATION SECTION

REPAIR SECTION

DIAGNOSTICS SECTION

WIRING DIAGRAM SECTION

The description of each area is provided with four types of titles different in size as shown below. The
Title No. or Symbol prefixes each title in order that the construction of the article and the flow of explana-
tion can be easily understood.
[Example of each title]

Area title: T. DIAGNOSTICS

Large title (Heading): 1. Diagnostics Chart with Select Monitor (to denote the main item of explanation.)

Medium title (Section): A: BASIC DIAGNOSTICS CHART (to denote the type of work in principle.)

Small title (Sub-section): 1. CHECK INPUT SIGNAL FOR ECM (to denote a derivative item of explanation.)
3
[T200] FOREWORDFOREWORD
2. How to Use this Manual

The Title Index No. is indicated on the top left (or right) side of the page as the book is opened. This is
useful for retrieving the necessary portion.
B0M0001
4
FOREWORD [T200]FOREWORD
2. How to Use this Manual

In this manual, the following symbols are used.
Character Description
B0M0002
Circuit tester

Voltage measurement
B0M0003
Circuit tester

Resistance measurement
B0M0004
The arrow indicates that insertion of the probe or numbering of the connector pins
is made from the side.
B0M0005
The arrow indicates that insertion of the probe or numbering of the connector pins
is made from the side.
B0M0006
Oscilloscope
B0M0007
Oscilloscope positive probe
B0M0008
Oscilloscope earth head

WARNING,CAUTION, NOTE

WARNING:Indicates the item which must be observed precisely during performance of maintenance
services in order to avoid injury to the mechanics and other persons.

CAUTION:Indicates that item which must be followed precisely during performance of maintenance
services so as to avoid damage and breakage to the vehicle and its parts and compo-
nents.

NOTE: Indicates the hints, knacks, etc. which make the maintenance job easier.
5
[T200] FOREWORDFOREWORD
2. How to Use this Manual

B0M0009
3. Basic Checks
A: DISCONNECTING CONNECTORS

Always hold the connector itself.
CAUTION:
Don’t pull the harness.
B0M0010

Inspect a connector by pushing it all the way in. If the con-
nector is equipped with a locking device, push it in until a
clicking sound is heard.
B0M0011

To disconnect a locking connector, first release the lock,
then pull the connector off.
<Unlock by pulling the locking tab.>
B0M0012
<Unlock by pushing the locking tab.>
B0M0013A
B: INSERTING A PROBE

Generally, probes are inserted into connectors from the
rear side (wire side).

When removing the shock protector take care not to deform
it; this also applies to waterproof connectors, which cannot be
tested from the wire side.
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FOREWORD [T3A0]FOREWORD
3. Basic Checks

B0M0014A

Connectors equipped with shock protectors must be
checked with a mini probe (thin), or it will be necessary to
remove the shock protector.
B0M0015A

When the connector has a back plate, remove the plate
after removing the projection of the plate first. (Be careful not
to use excessive force, since the terminals might brake off.)
B0M0016A
C: CHECKING FOR POOR CONTACT ON
PLUG-IN CONNECTORS
1. POOR CONTACT
Poor contact is frequently caused by corroded terminals, dirt,
foreign substances, weak contact points between male and
female connectors, etc. Quite often a plug with poor contact
will work perfectly again after it has been pulled off and recon-
nected. If harness and connector checks do not reveal any
defect, it can be assumed that an intermittent contact in a
connector is the source of trouble.
B0M0017A
2. VISUAL INSPECTION
1) Disconnect the two connector halves.
2) Check the connector pins for signs of corrosion or foreign
material.
3) Check the connector for loose and damaged terminals,
and make sure they are set correctly in the connector.
NOTE:
When the harness is pulled lightly, the terminals should not
come out.
B0M0018A
4) Insert the male pin of the connector into the female pin,
then pull it out.
NOTE:
If one of the pins allows to pull out easily, it is a likely source
of a malfunction.
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[T3C2] FOREWORDFOREWORD
3. Basic Checks

B0M0019A
5) Shake lightly the connector and the harness, and check for
sudden changes in voltage or resistance.
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FOREWORD [T3C2]FOREWORD
3. Basic Checks

B0M0020
4. Diagnosis and Checking Procedure
Using Instruments
A: USING A CIRCUIT TESTER
1. VOLTAGE CHECK (range set to DC V)
Connect the positive probe to the terminal to be tested, and
the negative probe to body ground. (or the ground terminal of
the ECM)
B0M0021
2. CHECKING THE CONNECTION (range set toΩ)
Measure the resistance and check for open or shorted wire in
the harness or the connector.
NOTE:
This check must be carried out with both connectors discon-
nected.
(This avoids by-passing the connection through other cir-
cuits.)
1) Check for open circuit. (range:Ωx 1K)
Measure the resistance between the respective pins in both
connectors.
Specified resistance:
More than 1 MΩ(No continuity) Open circuit
Less than 10Ω(Continuity) O.K.
2) Check for correct insulation value. (range:Ωx 1K)
Measure the resistance between the pins in both connectors,
as well as between the suspected pin and the body. (body
short)
Specified resistance:
More than 1 MΩ(No continuity) O.K.
Less than 10Ω(Continuity) Short circuit
3) Resistance measurement (range set toΩ)
Measuring the internal resistance of sensors, solenoid valves
etc. to check the operating condition of components.
NOTE:

Select the appropriate range for measuring the internal
resistance, or the measurement will result in an incorrect
reading.

Before changing the measurement range the gauge must
be reset to zero.
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[T4A2] FOREWORDFOREWORD
4. Diagnosis and Checking Procedure Using Instruments

B: USING A SUBARU SELECT MONITOR
With this testing procedure the defective component can be
determined by directly monitoring input/output signals of the
ECM or the trouble codes.
1. FEATURES

A variety of data can be checked without movements from
the drivers seat, passenger’s seat or from outside the vehicle.

This unit allows the identification of the type of malfunction,
for example whether the cause is an open or shorted wire in
the input/output signal line, or whether the breakdown of a
component is caused by a lack of maintenance.
2. DIAGNOSIS

Refer to the reference values for input/output and control
data to determine whether the malfunction is caused by a
worn out component, an open wire, a short etc.

Perform the diagnostics procedure as described in chapter
“Check based on trouble codes”by monitoring the trouble
codes.
NOTE:
It will be easier to determine a malfunction if the vehicle data
for normal conditions are available for comparison.
G2H0054
3. CONNECT SELECT MONITOR.
1) Connect select monitor to data link connector located
under instrument panel. (on driver’s side)
G3M0150
2) Insert cartridge into select monitor.
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FOREWORD [T4B0]FOREWORD
4. Diagnosis and Checking Procedure Using Instruments