SUBARU LEGACY 1996 Service Repair Manual

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
partsor
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
thevehicle
would

be
jeopardized
if
heused
any
service
parts,
consumables,
special
tools
and
work
procedure
manuals
which

are
not
approved
or
designated
by
SUBARU
.

How
to
use
this
manual

Service
Manual
is
divided
into
six
volumes
bysection
.
Refer
to
the
Table
of
Contents,
select
anduse
the
nec-

essary
section
.

This
supplement
includes
corrective
and/or
additional
information
in
relationto
the
above
six
service
manual

volumes
.
Please
place
it
in
a
handy
place
for
ready
reference
.

For
informationnot
covered
in
this
supplement,
refer
to
1992
SERVICE
MANUALS
(Pub
.
No
.
G205BE
and
G206BE)

and
1993
SERVICE
MANUAL
(Pub
.
No
.
G210BE)
.

Each
chapter
in
the
manual
is
basically
made
of
the
following
five
types
of
areas
.

M
:
Mechanism
and
function

C
:
Component
parts

W
:
Service
procedure

(X
:
Service
procedure)

(Y
:
Service
procedure)

T
:
Troubleshooting

~
The
description
of
each
area
is
provided
withfour
types
of
titles
different
in
size
as
shown
below
.
The
Title
No
.

or
Symbol
prefixes
each
title
in
order
that
the
construction
ofthe
article
and
theflow
of
explanation
can
be
easily

understood
.

[Example
of
each
title]

"
Area
title
:
W
.
Service
procedure
(one
of
the
five
types
of
areas)

"
Large
title
(Heading)
:
1
.
Oil
Pump
(to
denotethe
main
item
of
explanation)

"
Medium
title
(Section)
:
A
.
REMOVAL
(to
denote
thetype
of
work
in
principle)

"
Small
title
(Sub-section)
:
1
.
INNER
ROTATOR
(to
denote
a
derivative
item
of
explanation)

2

~
The
Title
Index
No
.
is
indicated
on
thetop
left
(or
right)
side
of
the
page
asthe
book
is
opened
.
This
is
useful

for
retrieving
the
necessary
portion
.

(Example
of
usage)

Refer
to
2
-
4
[
W
1
B
1

7
77
Small
title
(Sub-section)

2-tOfwI
no

Medium
title
(Section)

Large
title
(Heading)

Area
title

Chapter
Na

of
title
placement

CLUTCH

SERVICE
PROCEDURE

Large
title
.General

11
A
:
PRECAUTION
I

When
servicing
clutch
system,
pay
attention
tothe
following
items
.
t)
Check
the
routing
ofclutch
cable
for
smoothness
.
2)
Excessive
tighteness
or
looseness
of
clutch
cable
have
a
bad
influence
upon
the
cable
durability
.
3)
Apply
grease
sufficiently
to
the
connecting
portion
ofclutch
pedal
.
4)
Apply
grease
sufficiently
to
the
release
leverportion
.
5)
Position
clutch
cable
through
the
center
of
toBboard
hole
-
'
`
A
.+anstment
is
done
by

In
this
manual,
thefollowing
symbols
are
used
.

Shouldbe
lubricated
with
oil
.

Shouldbe
lubricated
with
grease
.

Sealing
point

Tightening
torque

Small
title

2
.RELEASE
LEVER
Check
leverpivot
portion
and
the
point
of
contact
with
holder
for
wear
.

2
.Release
Bearing
and
Lever

A
:
REMOVAL

2)
Seal

3

2-7
[T2A2]
ON-BOARD
DIAGNOSTICS
II
SYSTEM

2
.
Electrical
Components
Location
2
.
Electrical
Components
Location

A
:
ENGINE

2
.
SENSOR

Fuel
level
sensor
~3
Fueltank
pressure
sensor

~2
Fuel
temperature
sensor
~4
Fuel
sub
level
sensor

r
B2M0921A

3

B2M0922A

B2M0946A

ON-BOARD
DIAGNOSTICS
II
SYSTEM
R2a31
2-7'

2
.
Electrical
Components
Location
3
3
.
SOLENOID
VALVE,
EMISSION
CONTROL
SYSTEM
PARTS
AND
IGNITION
SYSTEM
PARTS

~8
Pressure
control
solenoid
valve
~o
Canister

Vent
control
solenoid
valve

2-7
[reioi
ON-BOARD
DIAGNOSTICS
II
SYSTEM

8
.
Diagnostics
for
Engine
Starting
Failure

8
.
Diagnostics
for
Engine
Starting

Failure

I:
FUEL
PUMP
CIRCUIT
(2200
cc
AWD
EXCEPT
TAIWANMODEL)

811
Check
operating
sound
offuel
pump
.

812
Checkground
circuit
offuel
pump
.

I

__
813
Check
power
supply
to
fuel
pump
.
1

814
Check
harness
between
fuel
pump
and

fuel
pump
relay
connector
.

815
[
Check
fuel
pump
relay
.

816
Check
harness
between
ECM
and
fuel

pump
relay
connector
.

CAUTION
:

After
repair
or
replacement
of
faulty
parts,
conduct

CLEAR
MEMORY
and
INSPECTION
MODES
.

Ref
.
to
2-7
[T3D0]
and
[T3E0]
.*2
and
*4
>

4

ON-BOARD
DIAGNOSTICS
II
SYSTEM
[rsi2]
2-7
8
.
Diagnostics
for
Engine
Starting
Failure

WIRING
DIAGRAM
:

Fuel
pump

M

R58
S
.M
.J
.

R67R46
R1
897

E

B84

ECM

Fuel
pump
relay

0

846

SBF-2

No
.16
~b---

862F45

884

9
10
1112
13141516
R58
R61B46

3132
333435363738
39
40
4142
43
44585960
6162
6364
6566
6768
6910
1
2
3
~1
]
M34
1
84
1
8
51
86
1
871
88
1
89
1
90
1
91
1
92
1
93
1
94
1
95
1
96
1
4
56~J

82M
1014

PUMpK

OPERATING
SOUND
OFFUEL
811
CHEC

R58

OBD0132A

Make
sure
that
fuel
pump
isin
operation
for
two
seconds

when
turning
ignition
switch
to
ON
.

CHECK
:
Does
fuel
pump
produce
operating
sound?

NOTE
:

Fuel
pump
operation
check
can
also
beexecuted
using

Subaru
Select
Monitor
(Function
mode
:
FD01)
.

For
the
procedure,
referto
"COMPULSORY
VALVE
OPER-
ATION
CHECK
MODE"
2-7
[T3F0]*4
.

,res
:
Check
fuel
injector
circuit
.
<
Ref
.
to
2-7

[T10Q0].*2
>

No
:
Go
to
step
812
.
1
812
CHECK
GROUND
CIRCUIT
OF
FUEL
PUMP
.

1)
Turn
ignition
switch
to
OFF
.

2)
Disconnect
connector
from
fuel
pump
.

3)
Measure
resistance
of
harness
connector
between
fuel

pump
and
chassis
ground
.

CHECK
:
Connector
&
terminal

(R58)
No
.
4
-
Chassis
ground
:

Is
the
resistance
less
than
5
S2?

5

2-7
trsi31
ON-BOARD
DIAGNOSTICS
II
SYSTEM

8
.
Diagnostics
for
Engine
Starting
Failure

R58
Bog

1
23
2
1
L

11

5
643

D

S2

B2M0526A

,rES
:
Go
to
step
813
.

No
:
Repair
open
circuit
in
fuel
pump
ground
circuit
.

813
I
CHECK
POWER
SUPPLY
TOFUEL
PUMP
.

1)
Turn
ignition
switch
to
ON
.

2)
Measure
voltage
of
power
supply
circuit
between
fuel

pump
connector
and
chassis
ground
.

CHECK
:
Connector
&
terminal

(R58)
No
.
1
(+)
-
Chassis
ground
(
)
:

Is
the
voltage
more
than10
V?

,rES
:
Replace
fuel
pump
.

No
:
Go
to
step
814
.

814
CHECK
HARNESS
BETWEEN
FUEL
PUMP

AND
FUEL
PUMP
RELAY
CONNECTOR
.

1)
Turn
ignition
switch
to
OFF
.

2)
Measure
resistance
of
harness
connector
between
fuel

pump
and
fuel
pump
relay
.

CHECK
:
Connector
&
terminal

(R58)
No
.
1
-
(B46)
No
.
4
:

Is
the
resistance
less
than
1
S2?

,rES
:
Go
to
next
CHECK

No
:
Repair
open
circuit
in
harness
between
fuel
pump

and
fuel
pump
relay
connector
.

CHECK
:
Connector
&
terminal

(R58)
No
.
1
-
Chassis
ground
:

Is
the
resistance
more
than
1
MS2?

,res
:
Go
to
step
815
.

No
:
Repair
short
circuit
in
harness
between
fuel
pump

and
fuel
pump
relay
connector
.

6

ON-BOARD
DIAGNOSTICS
II
SYSTEM
[Tsisl
2-7

8
.
Diagnostics
for
Engine
Starting
Failure

815
1
CHECK
FUEL
PUMP
RELAY
.

1)
Disconnectconnectors
from
fuel
pump
relay
and
main

relay
.

2)
Remove
fuel
pump
relay
and
main
relay
with
bracket
.

3)
Connect
battery
to
fuel
pump
relay
connector
terminals

No
.
1
and
No
.
3
.

4)
Measure
resistance
between
connector
terminals
of

fuel
pump
relay
.

CHECK
;
Terminals

No
.
2
-
No
.
4
:

Is
the
resistance
less
than10
92?

YES
:
Go
tostep
816
.

No
:
Replace
fuel
pump
relay
.

816
CHECK
HARNESS
BETWEEN
ECM

FUEL
PUMP
RELAY
CONNECTOR
.

AND

1)
Disconnectconnectors
from
ECM
.

2)
Measure
resistanceof
harness
between
ECM
and
fuel

pump
relay
connector
.

CHECK
:
Connector
&
terminal

(B84)
No
.
32
-
(B46)
No
.
3
:

Is
the
resistance
less
than
1
0?

YES
.
Go
to
next
CHECK

No
:
Repair
harness
between
ECM
and
fuel
pump

relay
connector
.

CHECK
:
Is
there
poor
contact
in
ECM
connector?

vES
:
Repair
poor
contact
in
ECM
connector
.

No
:
Check
fuel
injector
circuit
.
<
Ref
.
to
2-7

[T8F0]
.*2
>

7

2_7
[T10A0]
ON-BOARD
DIAGNOSTICS
11
SYSTEM
10
.
Diagnostics
Chart
with
Trouble
Code

10
.
Diagnostics
Chart
with
Trouble
Code

A
:
DIAGNOSTIC
TROUBLE
CODE
(DTC)
LIST

DTC

No
.

Abbreviation

(Subaru
select
monitor)Item
Page

P0100
QA
Mass
air
flow
sensor
circuit
malfunction
'1

P0101
QA
-
R
Mass
air
flow
sensor
circuit
range/performance
problem
`1

P0105
P
-
S
Pressure
sensor
circuit
malfunction
*1

P0106
PS
-
R
Pressure
sensor
circuit
range/performance
problem
*1

P0115
TW
Engine
coolant
temperature
sensor
circuit
malfunction
'1

P0120
THV
Throttle
position
sensor
circuit
malfunction
'1

P0121
TH
-
R
Throttle
position
sensor
circuit
range/performance
problem
'1

P0125
TW
-
CL
Insufficient
coolant
temperature
for
closed
loop
fuel
control
'1

P0130
F02
-
V
Front
oxygen
sensor
circuit
malfunction
*1

P0133
F02
-
R
Front
oxygen
sensor
circuit
slowresponse
'1

P0135
F02H
Front
oxygen
sensor
heater
circuit
malfunction
*1

P0136
R02
-
V
Rear
oxygen
sensor
circuit
malfunction
'1

P0139
R02
-
R
Rear
oxygen
sensor
circuit
slowresponse
*1

P0141
R02H
Rear
oxygen
sensor
heater
circuit
malfunction
*1

P0170
FUEL
Fuel
trim
malfunction
'1

P0180
TNKT
Fuel
temperature
sensor
A
circuit
malfunction
10

P0181
TNKT-
FFuel
temperature
sensor
A
circuit
range/performance
problem
16

P0201
INJ1
Fuel
injector
circuit
malfunction
-
#1

P0202
INJ2Fuel
injector
circuit
malfunction
-
#2
"
1
P0203
INJ3Fuel
injector
circuit
malfunction
-
#3

P0204
INJ4Fuel
injector
circuit
malfunction
-
#4

P0301
MIS
-
1
Cylinder
1
misfire
detected

P0302
MIS
-
2Cylinder2
misfire
detected

P0303
MIS
-
3
Cylinder
3
misfire
detected

P0304
MIS
-
4
Cylinder
4
misfire
detected

P0325
KNOCK
Knock
sensor
circuit
malfunction
'1

P0335
CRANK
Crankshaft
position
sensor
circuit
malfunction
'1

P0340
CAM
Camshaft
position
sensor
circuit
malfunction
'1

P0400
EGR
Exhaust
gas
recirculation
flow
malfunction
`1

P0403
EGRSOL
Exhaust
gas
recirculation
circuit
malfunction
'1

P0420
CAT
Catalyst
system
efficiency
below
threshold
'1

P0440
EVAP
Evaporative
emission
control
system
malfunction
18

P0441
CPC
-
F
Evaporative
emission
control
system
incorrect
purge
flow
'1

P0443
CPC
Evaporative
emission
control
system
purge
control
valve
circuit
malfunction
'1

P0446
VCMSOL
Evaporative
emission
control
system
vent
control
malfunction
22

P0450
TNKP
Evaporative
emission
control
system
pressure
sensor
malfunction
28

P0451
TNKP
-
F
Evaporative
emission
control
system
pressure
sensor
range/performance

problem
36

'1
:
.
to
2-7
[T11A0]
.*4>

ON-BOARD
DIAGNOSTICS
11
SYSTEM
[T10A0]
2-7

10
.
Diagnostics
Chart
with
Trouble
Code

DTC

No
.

Abbreviation

(Subaru
select
monitor)Item
Page

P0500
VSP
Vehicle
speed
sensor
malfunction
'1

P0505
ISC
Idle
control
system
malfunction
`1

P0506
ISC
-
L
Idle
control
system
RPM
lower
than
expected
'1

P0507
ISC
-
H
Idle
control
system
RPM
higher
than
expected
'1

P0600
-
Serial
communication
link
malfunction
`1

P0601
RAM
Internal
control
module
memory
check
sum
error
'1

P0703
ATBRK
Brake
switch
input
malfunction
'1

P0705
ATRNG
Transmissionrange
sensor
circuit
malfunction
`1

P0710
ATF
Transmission
fluid
temperature
sensor
circuit
malfunction
'1

P0720
ATVSP
Output
speed
sensor
(vehicle
speed
sensor
1)
circuit
malfunction
'1

P0725
ATNE
Engine
speed
input
circuit
malfunction
'1

P0731
ATGR1
Gear
1
incorrect
ratio

P0732
ATGR2
Gear
2
incorrect
ratio
"
1
P0733
ATGR3
Gear
3
incorrect
ratio

P0734
ATGR4
Gear
4
incorrect
ratio

P0740
ATLU
-
F
Torque
converter
clutch
system
malfunction
1

P0743
ATLU
Torque
converter
clutch
system
electrical
*1

P0748
ATPL
Pressure
control
solenoid
electrical
'1

P0753
ATSFTi
Shift
solenoid
A
electrical
`1

P0758
ATSFT2
Shift
solenoid
B
electrical
'1

P0760
ATOVR
-
F
Shift
solenoid
C
malfunction
'1

P0763
ATOVR
Shift
solenoid
C
electrical
'1

P1100
ST-SW
Starter
switch
circuit
malfunction
'1

P1101
N/P
-
SW
Neutral
position
switch
circuit
malfunction
[MT
vehicles]
'1

P1101
N/P
-
SW
Neutral
position
switch
circuit
malfunction
[AT
vehicles]
1

P1102
BR
Pressure
sources
switching
solenoid
valve
circuit
malfunction
'1

P1103
TRQ
Engine
torque
control
signal
circuit
malfunction
`1

P1400
PCVSOL
Fueltank
pressure
control
solenoid
valve
circuit
malfunction
38

P1401
PCV
-
FFueltank
pressure
control
system
function
problem
44

P1402
FIVL
Fuel
level
sensor
circuit
malfunction
46

P1500
FAN
-
1
Radiator
fan
relay
1
circuit
malfunction
'1

P1502
FAN
-
F
Radiator
fan
function
problem
'1

P1700
ATTH
Throttle
position
sensor
circuit
malfunction
for
automatic
transmission
'1

P1701
ATCRS
Cruise
control
set
signal
circuit
malfunction
for
automatic
transmission
'1

P1702
ATDIAG
Automatic
transmission
diagnosis
inputsignal
circuit
malfunction
'1

P0461'2
EXERR22
Fuel
level
sensor
circuit
range/performance
problem
56

"1
:
<
Ref
.
to
2-7
[T11A0]
.*4
>

'2
:
Only
OBD-II
general
scan
tool
displays
DTC
.