engine SUBARU LEGACY 1996 Service Repair Manual

F: TCS SEQUENCE CONTROL
1) Under the TCS sequence control, after the hydraulic
unit solenoid valve is driven, the operation of the hydraulic
unit can be checked by means of the brake tester or pres-
sure gauge.
2) TCS sequence control can be started by diagnosis con-
nector or select monitor.
B4M0082C
1. OPERATIONAL GUIDELINES OF THE TCS
SEQUENCE CONTROL WITH DIAGNOSIS
CONNECTOR
1) Connect diagnosis terminals to terminal No. 4 of the
diagnosis connector beside driver seat heater unit.
2) Ignition switch is turned to ON.
3) Make sure only the start code (code 11) is shown in
normal condition.
NOTE:
When trouble codes are stored in memory, repair the faulty
parts.
4) Set the speed of all wheels at 10 km/h (6 MPH) or less.
5) Turn ignition switch OFF.
6) Start engine, and within 0.5 seconds after the ABS
warning light and TCS warning light go out, press TCS OFF
switch. Within 1.0 second thereafter, release and press the
switch again. Then, keep the switch pressed.
NOTE:

When the TCS sequence control is set to on, the brake
pedal must not be depressed.

Engine must operate.

When TCS OFF switch is not depressed within 0.5 sec-
onds after ABS and TCS warning lights turn off, the trouble
code mode comes on.
7) After completion of TCS sequence control, turn ignition
switch OFF.
103
4-4SERVICE PROCEDURE
20. Hydraulic Unit for ABS/TCS System

2. OPERATIONAL GUIDELINES OF THE TCS
SEQUENCE CONTROL WITH SELECT MONITOR
1) Connect select monitor to data link connector beside
driver’s seat heater unit.
2) Engine starts.
3) Put select monitor to TCS mode.
4) Put select monitor to FBI mode. Make sure code 11 is
indicated.
NOTE:
When trouble codes are stored in memory, repair the faulty
parts.
B4M0639
5) Press FD2 ENT key.
B4M0624
6) When the message shown in the figure is displayed,
press ENT key.
7) Checked portions will be displayed on select monitor.
B4M0627
8) When TCS sequence control cannot be started (by sys-
tem malfunction, etc.), the message shown in the figure will
be displayed.
NOTE:
Read the trouble codes. Repair faulty parts.
104
4-4SERVICE PROCEDURE
20. Hydraulic Unit for ABS/TCS System

22. Hydraulic Unit for ABS System
(ABS 5.3 Type)
B4M0994A
1Hydraulic control unit

2Damper

3Stud bolt

4Rear-RH outlet

5Rear-LH outlet

6Secondary inlet

7Primary inlet

8Front-LH outlet
9Front-RH outlet

10Cable clip

11Bracket

12Relay box

13Motor relay

14Valve relay

15Cap

16Connector bracket
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 18±5 (1.8±0.5, 13.0±3.6)
T2: 29±7 (3.0±0.7, 21.7±5.1)
T3: 32±10 (3.3±1.0, 24±7)
A: REMOVAL
1. HYDRAULIC UNIT
1) Disconnect ground cable from battery.
2) Remove air intake duct and canister from engine com-
partment to facilitate removal of hydraulic unit.
3) Disconnect connector from hydraulic unit.
4) Unlock cable clip.
5) Disconnect brake pipes from hydraulic unit.
CAUTION:
Wrap brake pipes with vinyl bag to avoid spilling brake
fluid on vehicle body.
109
4-4SERVICE PROCEDURE
22. Hydraulic Unit for ABS System (ABS 5.3 Type)

B4M0996
6) Remove nuts and bolt which secure hydraulic unit
bracket, and remove hydraulic unit from engine compart-
ment.
CAUTION:

Hydraulic unit cannot be disassembled. Do not
attempt to loosen bolts and nuts.

Do not drop or bump hydraulic unit.

Do not turn the hydraulic unit upside down or place
it on its side.

Be careful to prevent foreign particles from getting
into hydraulic unit.

When a new hydraulic unit is installed, apply a coat
of rust-preventive wax (Nippeco LT or GB) to bracket
attaching bolt after tightening.

Do not pull harness disconnecting harness connec-
tor.
2. RELAY BOX
1) Disconnect ground cable from battery.
2) Remove air intake duct and canister from engine com-
partment to facilitate removal of relay box.
B4M1029
3) Disconnect connector from relay box.
4) Unlock cable clip.
5) Remove nuts which secure relay box, and remove relay
box and connector bracket.
CAUTION:
Do not drop or bump relay box.
11 0
4-4SERVICE PROCEDURE
22. Hydraulic Unit for ABS System (ABS 5.3 Type)

G4M0462
2. CHECKING THE HYDRAULIC UNIT ABS
OPERATION WITH BRAKE TESTER
1) In the case of AWD AT vehicles, install a spare fuse with
the FWD connector in the engine compartment to simulate
FWD vehicles.
2) Prepare for operating ABS sequence control. 4-4 [W22D1] or 4-4 [W22D2].>
G4M0464
3) Set the front wheels or rear wheels on the brake tester
and set the select lever’s position at“neutral”.
4) Operate the brake tester.
5) Perform ABS sequence control. step 1 or 4-4 [W22D2] 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 fluctuation of values, when decompressed and
compressed, meet the standard values.
Unit: N (kg, lb)
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.
11 3
4-4SERVICE PROCEDURE
22. Hydraulic Unit for ABS System (ABS 5.3 Type)

D: ABS SEQUENCE CONTROL
1) Under the ABS sequence control, after the hydraulic
unit solenoid valve is driven, the operation of the hydraulic
unit can be checked by means of the brake tester or pres-
sure gauge.
2) ABS sequence control can be started by diagnosis con-
nector or select monitor.
B4M0082D
1. OPERATIONAL GUIDELINES OF THE ABS
SEQUENCE CONTROL WITH DIAGNOSIS
CONNECTOR
1) Connect diagnosis terminals to terminals No. 3 and No.
6 of the diagnosis connector beside driver’s seat heater
unit.
2) Set the 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 set to 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
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.
B4M0635
4) PressFD1ENTkey.
11 4
4-4SERVICE PROCEDURE
22. Hydraulic Unit for ABS System (ABS 5.3 Type)

G4M0319
2) If it is not in specified value, adjust it by turning adjust-
ing nut on engine side end of clutch cable.
Free play: L
3—4 mm (0.12—0.16 in)
Full stroke: A
25.5—27 mm (1.004—1.063 in)
3) Apply grease to connecting portion of clutch pedal and
clutch cable.


1Lock nut


2Adjusting nut


3Release fork
Lock nut tightening torque:
5.9±1.5 N⋅m (0.60±0.15 kg-m, 4.3±1.1 ft-lb)
G4M0320
3. ACCELERATOR PEDAL
Check pedal stroke and free play by operating accelerator
pedal by hand.
If it is not within specified value, adjust it by turning nut
connecting accelerator cable to throttle body.
Free play at pedal pad: L
1—4 mm (0.04—0.16 in)
Stroke at pedal pad: A
50—55 mm (1.97—2.17 in)


1Accelerator pedal


2Toe board


3Accelerator cable
Accelerator cable lock nut tightening torque:
14±4 N⋅m (1.4±0.4 kg-m, 10.1±2.9 ft-lb)
7
4-5SERVICE PROCEDURE
1. Pedal

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

A: REMOVAL
1) Disconnect accelerator cable from connector inside
engine compartment first.
G2M0280
2) Remove lock nut from accelerator cable bracket.
3) Separate accelerator cable

1from bracket, then unlock
inner cable.
4) Remove cable end from throttle cam using your finger-
tips.
CAUTION:
Be careful not to bend inner cable.
5) Disconnect cable end from accelerator cable bracket
inside driver compartment.
6) Remove clip inside engine compartment.
G4M0335
7) Working inside engine compartment, remove the casing
cap out of the toe board by turning it clockwise.
8) Pull out the cable from the toe board hole.
B: INSTALLATION
1) Installation is in the reverse order of removal proce-
dures.
CAUTION:
Be careful not to kink accelerator cable.
Make sure that holder and casing cap are securely
connected.
B4M0159A

1Casing cap


2Accelerator cable


3Toe board


4Accelerator pedal bracket


5Holder
2) Adjustment after cable installation.

17
4-5SERVICE PROCEDURE
3. Accelerator Cable

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.

3) Remove instrument panel.

4) Remove steering support beam.

5) Remove evaporator. (With A/C model)

G4M0554
6) Remove heater unit.
11
4-6SERVICE PROCEDURE
1. Supplemental Restraint System“Airbag”- 2. Heater Unit