engine SUBARU LEGACY 1997 Service Repair Manual

TABLE
OFCONTENTS

2-1
~************

2-2
*********~k**

2-3
tE**tE*ylr****t1~~t

2-3b
*******tlr~~ylr**

2-4
~t~~t~t1E7E~t~lr~lr~t~t~t~t

2-5
*yt***********
ENGINE
SECTION
2-6
*~~**********

2-7
*************

2-8
*****yt**ytyt*~*

2-9
*******~t*~*~*

2-10
**It~**yt**~*yt*

2-11
**~**********

3-1
**~t******~k*yt*

TRANSMISSION
AND
DIFFERENTIAL
3'2
**********'k**

SECTION
3-3
tf*~yt*yt*ytyt~t*yt~t

3-4
*yttt~*~~******

4-1
~t***~~~yt~k*~~*

4-2
~t*~t~**yttt***~k*

4-3
~**~k**~**~~~~

MECHANICAL
COMPONENTS
4-4
Brakes
SECTION

4-5
**~t~t~t~~~t**~~r*

4-6
*************

4-7
*tt**7f~*~k*****

5-1
*******~*****

5-2
*************

5-3
***********ytyt
BODY
SECTION
5-4
*skateboards*
с*

5-5
y1r*******~****

5-5b
**~t**********

6-1
**~~****yt****
ELECTRICAL
SECTION
6-2
~****~t**~t**1f~

All
right
reserved
.
This
book
may
not
bereproduced

or
copied,
in
whole
or
in
part,
withoutthe
written

permission
of
FUJI
HEAVY
INDUSTRIES
LTD
.,

TOKYO
JAPAN
.

SUBARU,
++
and
O
are
trademarks
of

FUJI
HEAVY
INDUSTRIES
LTD
.

@
Copyright
1996
FUJI
HEAVY
INDUSTRIES
LTD
.

2

SERVICE
PROCEDURE
[w2sao1
4-4

25
.
ABS
Control
Module
and
Hydraulic
Control
Unit
(ABSCM&H/U)
[ABS
5
.3i
Type]

A
:
REMOVAL

1)
Disconnect
ground
cablefrom
battery
.

2)
Remove
air
intake
duct
fromengine
compartment
to

facilitate
removal
of
ABSCM&H/U
.

3)
Use
an
air-gun
to
get
rid
of
water
around
the

ABSCM&H/U
.

CAUTION
:

The
contact
will
be
insufficient
if
the
terminal
gets
wet
.

4)
Pull
on
the
lock
of
the
ABSCM&H/U
connector
to

remove
it
.

5)
Disconnect
connector
from
ABSCM&H/U
.

CAUTION
:

Be
careful
not
tolet
water
or
other
foreign
matter
con-

tact
the
ABSCM&H/U
terminal

6)
Unlock
cable
clip
.

7)
Disconnect
brake
pipes
from
ABSCM&H/U
.

CAUTION
:

Wrap
brake
pipes
with
vinyl
bag
to
avoid
spilling
brake

fluid
on
vehicle
body
.

8)
Remove
ABSCM&H/U
fromengine
compartment
.

CAUTION
:

9
ABSCM&H/U
cannotbe
disassembled
.
Do
not
attempt

to
loosen
bolts
and
nuts
.

"
Do
not
drop
or
bump
ABSCM&H/U
.

"
Do
not
turn
the
ABSCM&H/U
upside
down
or
place
it

on
its
side
.

*
Be
careful
to
prevent
foreign
particles
from
getting

into
ABSCM&H/U
.

9
Apply
acoat
of
rust-preventive
wax
(Nippeco
LT
or

GB)
to
bracket
attaching
bolt
after
tightening
.

*
Do
not
pull
harness
disconnecting
harness
connector
.

7

4-4
[wzsc2]
SERVICE
PROCEDURE

25
.
ABS
Control
Module
and
Hydraulic
Control
Unit
(ABSCM&H/U)
(ABS
5
.3i
Type]

{~~Y+)~

_~00

G4M0464

2
.
CHECKINGTHE
HYDRAULIC
UNIT
ABS
OPERATION

WITH
BRAKE
TESTER

1)
In
the
case
of
AWD
AT
vehicles,
install
aspare
fuse
with

the
FWD
connector
in
the
engine
compartment
to
simu-

late
FWD
vehicles
.

2)
Prepare
for
operating
ABS
sequence
control
.
<
Ref,to

[W25D1
]*10
or
[W25D2]
.*10
>

3)
Setthe
front
wheels
orrear
wheels
on
the
brake
tester

and
set
the
select
lever's
position
at
"neutral"
.

4)
Operate
the
brake
tester
.

5)
Perform
ABS
sequence
control
.
<
Ref
.
to
[W25D1]*10

step
1
or
[W25D2]*10
step
1
.
>

6)
Hydraulic
unit
begins
to
work
;
and
check
the
following

working
sequence
.

(1)
The
FL
wheel
performs
decompression,
holding,

and
compression
in
sequence,
and
subsequently
the

FR
wheel
repeats
the
cycle
.

(2)
The
RR
wheel
performs
decompression,
holding,

and
compression
in
sequence,
and
subsequently
the

RL
wheel
repeats
the
cycle
.

7)
Read
values
indicated
on
the
brake
tester
and
check

if
the
fluctuationof
values,
when
decompressed
and

compressed,
meet
the
standard
values
.

Unit
:
N
(kg,
Ib)

Initial
value
When
decompressed
When
compressed

Front
wheel
981
(100,
221)
490
(50,
110)or
less
981
(100,
221)
or
more

Rear
wheel
981
(100,
221)
490
(50,
110)
or
less
981
(100,
221)or
more

8)
After
checking,
also
check
if
any
irregular
brake
pedal

tightness
is
felt
.

10

SERVICE
PROCEDURE
[W25D21
4-4

25
.
ABS
Control
Module
and
Hydraulic
Control
Unit
(ABSCM&H/U)
[ABS
5
.3i
Type]

Diagnosis
connector
--J

1

I`

--~
~
''-
Diagnosis
terminals

3
terminal
6
terminal
-
/

B4M0082D
D
:
ABS
SEQUENCE
CONTROL

1)
Under
the
ABS
sequence
control,
after
thehydraulic

unit
solenoid
valve
is
driven,
theoperation
of
thehydrau-

lic
unit
can
be
checked
by
means
of
the
brake
tester
or

pressure
gauge
.

2)
ABS
sequence
control
can
be
started
by
diagnosis

connector
or
select
monitor
.

1
.
OPERATIONAL
GUIDELINES
OF
THE
ABS

SEQUENCE
CONTROL
WITH
DIAGNOSIS
CONNECTOR

1)
Connect
diagnosis
terminals
to
terminals
No
.
3
andNo
.

6
of
the
diagnosis
connector
beside
driver's
seat
heater

unit
.

2)
Setthe
speed
of
all
wheels
at
4
km/h
(2
MPH)
or
less
.

3)
Turn
ignition
switch
OFF
.

4)
Within
0
.5
seconds
after
the
ABS
warning
light
goes

out,
depress
the
brake
pedal
and
hold
it
immediately
after

ignition
switch
is
turned
to
ON
.

CAUTION
:

Do
not
depress
the
clutch
pedal
.

NOTE
:

*
When
the
ignition
switch
is
setto
on,the
brake
pedal

must
not
be
depressed
.

Engine
must
not
operate
.

5)
After
completion
of
ABS
sequence
control,
turn
ignition

switch
OFF
.

2
.
OPERATIONAL
GUIDELINES
OF
THE
ABS

SEQUENCE
CONTROL
WITH
SELECT
MONITOR

NOTE
:

In
the
event
of
any
trouble,
the
sequence
control
may
not

be
operative
.
In
such
a
case,
activate
the
sequence

control,
referring
to
"OPERATIONAL
GUIDELINES
OF
THE

ABS
SEQUENCE
CONTROL
WITHDIAGNOSIS
CONNEC-

TOR
"
.
<
Ref
.
to
4-4
[W25D1],*10>

1)
Connect
select
monitor
to
data
link
connector
beside

driver's
seat
heater
unit
.

2)
Turn
ignition
switch
ON
.

3)
Put
select
monitor
to
ABS
mode
.

11

4-4d
[TSBO]
BRAKES
[ABS
5
.31
TYPE]

6
.
Diagnostics
Chart
for
On-board
Diagnosis
System

B
:
CHECK
LIST
FOR
INTERVIEW

Check
the
following
items
about
the
vehicle's
state
.

1
.
THE
STATE
OF
THE
ABS
WARNING
LIGHT

ABS
warning
light
O
Always

comes
on
.
D
Sometimes

O
Onlyonce

O
Does
not
come
on
o
When
/how
long
does
it
come
on?
:

Ignition
key
position
O
LOCK

D
ACC

OON
(before
starting
engine)

D
START

O
On
afterstarting
(Engine
is
running)

O
On
after
starting
(Engine
is
stop)

Timing
O
Immediately
afterignition
is
ON
.
O
Immediately
after
ignition
starts
.

O
When
advancing
km/h
to
km/h

MPH
to
MPH

D
While
traveling
at
a
constant
speed
km/h
MPH

D
When
decelerating
km/h
to
km/h

MPH
to
MPH
OWhen
turning
to
right
Steering
angle
:
deg

Steering
time
:
sec

D
When
turning
to
left
Steering
angle
:
deg

Steering
time
:
sec

D
When
moving
other
electrical
parts
Parts
name
Operating
condition

2
.
SYMPTOMS

ABS
operating
D
Performsno
work
.

condition
D
Operates
only
when
abruptly
applying
brakes
.
Vehicle
speed
:
km/h

MPH

~
How
to
step
on
brake
pedal

a)
Operating
time
:
sec

b)
Operating
noise
:
O
Produce
/
D
Does
not
produce

oWhat
kind
of
noise?
O
Knock

O
Gong
gong

D
Bong

a
Buzz

D
Gong
gong
buzz

O
Others

c)
Reaction
force
of
brake
pedal

O
Stick
O
Press
down
once
with
a
clunk

O
Press
and
released

D
Others

12

BRAKES
[ABS
5
.31
TYPE]
[MO]
4-4d

6
.
DiagnosticsChart
for
On-board
Diagnosis
System

Behavior
of
vehicle
a)
Directional
stability
cannotbe
obtained
or
steering
arm
refuses
to
work
when
applying
brakes

O
Yes
/
ONo

When
:
D
Vehicle
turns
to
right

o
Vehicle
turns
to
left

D
Spins

D
Others

b)
Directional
stability
cannot
be
obtained
orsteering
arm
refuses
to
work
when
accelerating

O
Yes
/
O
No

When
:
O
Vehicle
turns
to
right

O
Vehicle
turns
to
left

D
Spins

O
Others

c)
Brakes
areout
of
order
:
O
Yes
/
ONo

What
:
O
Braking
distance
is
long

O
Brakes
lockor
drag

D
Pedal
stroke
is
long

D
Pedal
sticks

O
Others

d)
Poor
acceleration
:
D
Yes
/
ONo

What
:
D
Fails
to
accelerate

o
Engine
stalls

o
Others

e)
Occurrence
of
vibration
:
D
Yes
/
[]No

Where
What
kind

f)
Occurrence
of
abnormal
noise
:
O
Yes
/
DNo

Where

What
kind

g)
Occurrence
of
other
phenomena
:
D
Yes
/
ONo

What
kind
3
.
CONDITIONS
UNDER
WHICH
TROUBLE
OCCURS

Environment
a)
Weather
D
Fine

O
Cloudy

O
Rainy

D
Snowy

O
Various/Others

b)
Ambient
temperature
F(°C)

c)
Road
D
Urban
area

D
Suburbs

O
Highway

O
General
road

D
Ascending
slope

O
Descending
slope

O
Paved
road

O
Gavel
road

O
Muddy
road

O
Sandy
place

Cl
Others

d)
Road
surface
D
Dry

D
Wet

O
New-fallen
snow

O
Compressed
snow

O
Frozen
slope

O
Others

13

4-4d
R7ao1
BRAKES
[ABS
5
.3i
TYPE]

7
.
Diagnostics
Chart
for
ABS
Warning
Light
Circuit
and
Diagnosis
Circuit
Failure

7
.
Diagnostics
Chart
for
ABS
Warning

Light
Circuit
and
Diagnosis
Circuit

Failure

A
:
ABS
WARNING
LIGHT
DOES
NOT
COME

ON
.

DIAGNOSIS
:

e
ABS
warning
light
circuit
is
open
or
shorted
.

TROUBLE
SYMPTOM
:

e
When
ignition
switch
is
turned
ON
(engine
OFF),
ABS

warning
light
does
not
come
on
.

WIRING
DIAGRAM
:

Fuse

No
.
12

Fuse

F49
f2
B100

ABS
control
module
and
hydraulic
control
unit

c
:
i14
No
.15

L
ABS

Combination
meter

881
0
Diagnosis
°
E
connector

Diagnosis
terminal

IGNsw
SBF-4
FL1.25B

Fuse
SBF-3

No
.19

882
8100

01
11
12
11
1
1
ID
M
131415161

i2
1
4
10
11
1
13141
1

i14

1
11
11

f49

123456789101112131415
16171819
20
2122
23
24252627
1
28
1
29
1
30
13
11

rw
am

84M1230

18

BRAKES
[ABS
5
.31
TYPE]
[T7A3]
4-4d

7
.
Diagnostics
Chart
for
ABS
Warning
Light
Circuit
and
Diagnosis
Circuit
Failure

B1
2345
678910
1112
1
13
1
14
1
15
1
16
1
17
1
18
1
19
.
)

D

V

-
B4M1273A

I7A1
ICHONECK
IF
OTHER
WARNING
LIGHTS
TURN

Turn
ignition
switch
to
ON
(engine
OFF)
.

CHECK
:
Do
other
warning
lights
turn
on?

,rES
:
Go
to
step
7A2
.

No
:
Repair
combination
meter
.

7A2
I
CHECK
ABS
WARNING
LIGHT
BULB
.

1)
Turn
ignition
switch
to
OFF
.

2)
Remove
combination
meter
.

3)
Remove
ABS
warning
light
bulb
from
combination

meter
.

CHECK
:
Is
ABS
warning
light
bulb
OK?

,mss
:
Go
to
step
7A3
.

No
:
Replace
ABS
warning
light
bulb
.

7A3
CHECK
BATTERY

NG
LIGHT
HARNESS

SHO
RT
OF
ABS
WARN-

1)
Disconnect
connector
(B100)
from
connector
(F2)
.

2)
Measure
voltage
between
connector
(B100)
and
chas-

sis
ground
.

Connector
&
terminal
(B100)
No
.
9
(+)
-
Chassis
ground
(
)
:

CHECK
:
Is
thevoltage
less
than
3
V?

vES
:
Go
to
step
7A4
.

No
:
Repair
warning
light
harness
.

19

4-4d
[T7BO1
BRAKES
[ABS
5
.31
TYPE]

7
.
Diagnostics
Chart
for
ABS
Warning
Light
Circuit
and
Diagnosis
Circuit
Failure

B
:
ABS
WARNING
LIGHT
DOES
NOT
GO
OFF
.

DIAGNOSIS
:

e
ABS
warning
light
circuit
is
open
or
shorted
.

TROUBLE
SYMPTOM
:

e
When
starting
the
engine
and
while
ABS
warning
light

is
kept
ON
.

WIRING
DIAGRAM
:

F49
F2
8100

ABS
control
module
and
hydraulic
control
unit
Fuse

No
.18

Fuse

C
:0
No
.
5

837
i2
ABS

Combination
meter

O
Diagnosis
°
E
connector
gg~

Diagnosis
terminal

IGNsw
SBF-4
FL1.25B

w

Q
m

Fuse
SBF-3

No
.
19

882
8100

1
11
1213141
161
11
10

i1

1
11213141
9
10
11134111181920212

0

1
10111
1

F49

12345678910111131415
16171819
20
2122
2324
25
2627
1
28
1
29
1
30
1
31
1

B4M1230

24

4-4d
[T7BaI
BRAKES
[ABS
5
.3i
TYPE]

7
.
Diagnostics
Chart
for
ABS
Warning
Light
Circuit
and
Diagnosis
Circuit
Failure

1~
\

MV

B4M0430

71134
CHECKGENERATOR
.

1)
Start
the
engine
.

2)
Idle
theengine
.

3)
Measure
voltage
between
generator
and
chassis

ground
.

Terminal

Generator
8
terminal
(+)
-
Chassis
ground
(
)
:

CHECK
;
Is
the
voltage
between
10
and
15
V?

vES
:
Go
to
step
7B5
.

No
:
Repair
generator
.

7B5
CHECK
BATTERY
TERMINAL
.

Turn
ignition
switch
to
OFF
.

CHECK
:
Is
there
poor
contact
at
battery
terminal?

,rES
:
Repair
battery
terminal
.

No
:
Go
to
step
7B6
.

71136
CHECK
POWER
SUPPLY
OF
ABSCM
.

1)
Disconnect
connector
from
ABSCM&H/U
.

2)
Start
engine
.

3)
Idle
the
engine
.

4)
Measure
voltage
between
ABSCM&H/U
connector
and

chassis
ground
.

Connector
&
terminal

(F49)
No
.
1
(+)
-
Chassis
ground
(-)
:

CHECK
:
Is
thevoltage
between
10
and
15
V?

ves
:
Go
to
step
71137
.

No
:
Repair
ABSCM&H/U
power
supply
circuit
.

71137
1
CHECK
WIRING
HARNESS
.

1)
Disconnect
connector
(F2)
from
connector
(B100)
.

2)
Turn
ignition
switch
to
ON
.

CHECK
:
Does
the
ABS
warning
light
remain
off?

S
:
Go
to
step
7B8
.

No
:
Repair
front
wiring
harness
.

26