engine SUBARU LEGACY 1997 Service Repair Manual

Overrunning clutch
Drive pinion
Crown gear
Axle shaft
Differential gear
Final gear
Seal pipe
Oil pump
High clutch
Band brake
Low & reverse clutch
Reverse clutch
One-way clutch (1-2)
One-way clutch (3-4)
Double oil seal
Input shaft
Output shaft
Planetary gear
Reduction gear
Drive plate
Torque converter one-way clutch
Lock-up facing
Lock-up damper
ATF deterioration
ATF level too high or too low
Differential gear oil level too high or too low
Engine performance
Engine speed signal
Parking brake mechanism
Problem parts
30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 Symptom
Starter does not rotate when select lever is
in“P”or“N.”; starter rotates when select
lever is“R”,“D”,“3”or“2.”
XXXAbnormal noise when select lever is in“P”or
“N.”
X Hissing noise occurs during standing starts.
X X X X Noise occurs while driving in“D
1”range.
X X X X Noise occurs while driving in“D
2”range.
X X X Noise occurs while driving in“D
3”range.
X X X X Noise occurs while driving in“D
4”range.
XXEngine stalls while shifting from one range to
another.
Vehicle moves when select lever is in“N.”
XShock occurs when select lever is moved
from“N”to“D.”
Excessive time lag occurs when select lever
is moved from“N”to“D.”
XShock occurs when select lever is moved
from“N”to“R.”
XXExcessive time lag occurs when select lever
is moved from“N”to“R.”
XXXX X XXX X XVehicle does not start in any shift range
(engine revving up).
XVehicle does not start in any shift range
(engine stall).
XXVehicle does not start in“R”range only
(engine revving up).
XXVehicle does not start in“R”range only
(engine stall).
XVehicle does not start in“D”or“3”range
(engine revving up).
Vehicle does not start in“D”,“3”or“2”range
(engine revving up).
XVehicle does not start in“D”,“3”or“2”range
(engine stall).
Vehicle starts in“R”range only (engine rev-
ving up).
XXAcceleration during standing starts is poor
(high stall rpm).
XXXAcceleration during standing starts is poor
(low stall rpm).
XX XAcceleration is poor when select lever is in
“D”,“3”or“2”range (normal stall rpm).
XXXXAcceleration is poor when select lever is in
“R”(normal stall rpm).
XNo shift occurs from 1st to 2nd gear.
X X No shift occurs from 2nd to 3rd gear.
XNo shift occurs from 3rd to 4th gear.
No“kick-down”shifts occur.
Engine brake is not effected when select
lever is in“3”range.
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3-2AUTOMATIC TRANSMISSION AND DIFFERENTIAL
9. General Diagnostic Table

Problem parts
Inhibitor switch
Control module
Vehicle speed sensor 1
Vehicle speed sensor 2
Select cable
Select lever
FWD switch
Starter motor and harness
Throttle position sensor
Diagnosis switch
Accumulator (“N”—“D”)
Accumulator (2A)
Accumulator (4A)
Accumulator (3R)
ATF temperature sensor
Strainer
Duty solenoid A
Duty solenoid B
Shift solenoid 1
Shift solenoid 2
Shift solenoid 3
Control valve
Detent spring
Manual plate
Transfer clutch
Transfer valve
Transfer pipe
Duty solenoid C
Forward clutch
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Engine brake is not effected when select
lever is in“3”or“2”range.
Engine brake is not effected when select
lever is in“1”range.X
Shift characteristics are erroneous.XXXX X X
No lock-up occurs. X X X X
Vehicle cannot be set in“D”range power
mode.XX
“D”range power mode cannot be released. X X X
Parking brake is not effected. X X
Shift lever cannot be moved or is hard to
move from“P”range.XX
Select lever is hard to move. X X X X
Select lever is too light to move (unreason-
able resistance).XX
ATF spurts out.
Differential oil spurts out.
Differential oil level changes excessively.
Odor is produced from oil supply pipe.XX
Shock occurs when select lever is moved
from“1”to“2”range.X XXXX X
Slippage occurs when select lever is moved
from“1”to“2”range.X XXXX X
Shock occurs when select lever is moved
from“2”to“3”range.XXXXXX
Slippage occurs when select lever is moved
from“2”to“3”range.XXXXXX
Shock occurs when select lever is moved
from“3”to“4”range.X X XXX X
Slippage occurs when select lever is moved
from“3”to“4”range.X X XXX X
Shock occurs when select lever is moved
from“3”to“2”range.XXXXX
Shock occurs when select lever is moved
from“D”to“1”range.XXXXX
Shock occurs when select lever is moved
from“2”to“1”range.XXXXX
Shock occurs when accelerator pedal is
released at medium speeds.XXXXX
Vibration occurs during straight-forward
operation.XX
Select lever slips out of position during
acceleration or while driving on rough terrain.XX XX
Vibration occurs during turns (tight corner
“braking”phenomenon).XXX X X XX X
Front wheel slippage occurs during standing
starts.X X X X X X XXXX
Vehicle is not set in FWD mode. X XXX X
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3-2AUTOMATIC TRANSMISSION AND DIFFERENTIAL
9. General Diagnostic Table

Overrunning clutch
Drive pinion
Crown gear
Axle shaft
Differential gear
Final gear
Seal pipe
Oil pump
High clutch
Band brake
Low & reverse clutch
Reverse clutch
One-way clutch (1-2)
One-way clutch (3-4)
Double oil seal
Input shaft
Output shaft
Planetary gear
Reduction gear
Drive plate
Torque converter one-way clutch
Lock-up facing
Lock-up damper
ATF deterioration
ATF level too high or too low
Differential gear oil level too high or too low
Engine performance
Engine speed signal
Parking brake mechanism
Problem parts
30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 Symptom
XEngine brake is not effected when select
lever is in“3”or“2”range.
XEngine brake is not effected when select
lever is in“1”range.
Shift characteristics are erroneous.
X X No lock-up occurs.
Vehicle cannot be set in“D”range power
mode.
“D”range power mode cannot be released.
X Parking brake is not effected.
XShift lever cannot be moved or is hard to
move from“P”range.
Select lever is hard to move.
Select lever is too light to move (unreason-
able resistance).
X ATF spurts out.
X Differential oil spurts out.
X X Differential oil level changes excessively.
X XXXX X XOdor is produced from oil supply pipe.
XXXShock occurs when select lever is moved
from“1”to“2”range.
XSlippage occurs when select lever is moved
from“1”to“2”range.
XX X XShock occurs when select lever is moved
from“2”to“3”range.
XXSlippage occurs when select lever is moved
from“2”to“3”range.
XX XXShock occurs when select lever is moved
from“3”to“4”range.
XSlippage occurs when select lever is moved
from“3”to“4”range.
XX XShock occurs when select lever is moved
from“3”to“2”range.
XShock occurs when select lever is moved
from“D”to“1”range.
XXShock occurs when select lever is moved
from“2”to“1”range.
XXShock occurs when accelerator pedal is
released at medium speeds.
XXVibration occurs during straight-forward
operation.
Select lever slips out of position during
acceleration or while driving on rough terrain.
XVibration occurs during turns (tight corner
“braking”phenomenon).
Front wheel slippage occurs during standing
starts.
Vehicle is not set in FWD mode.
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3-2AUTOMATIC TRANSMISSION AND DIFFERENTIAL
9. General Diagnostic Table

3. Electrical Components Location
B4M0373A
1Hydraulic control unit

2Engine control module

3AT control module

4TCS warning light

5ABS warning light

6Diagnosis connector

7TCS operating indicator light

8TCS OFF indicator light
9TCS OFF switch

10Data link connector (for Subaru select monitor)

11Data link connector (for Subaru select monitor and OBD-II
general scan tool)

12Tone wheel

13ABS sensor

14Stroke sensor

15ABS/TCS control module
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3. Electrical Components Location

4. Schematic
B4M0380A
1Hydraulic control unit

2Valve relay

3Motor relay

4Motor

5Motor sensor

6Front left inlet solenoid valve

7Front left outlet solenoid valve

8Rear right inlet solenoid valve

9Rear right outlet solenoid valve

10TCS solenoid valve 2

11Front right inlet solenoid valve

12Front right outlet solenoid valve

13Rear left inlet solenoid valve
14Rear left outlet solenoid valve

15TCS solenoid valve 1

16Pressure switch

17Data link connector

18ABS/TCS control module

19ABS warning light

20TCS operating indicator light

21TCS OFF indicator light

22TCS warning light

23Stroke sensor

24TCS OFF switch

25Diagnosis connector
26Engine control module

27Rear right ABS sensor

28Front right ABS sensor

29Front left ABS sensor

30Rear left ABS sensor

31Brake warning light

32Parking brake switch

33Brake fluid level sensor

34Generator

35Stop lamp switch

36Stop lamp

37AT control module
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4. Schematic

Contents Connector No. Terminal No.Input/Output signals
Measured value and measuring conditions
TCS
control
unit ECM
commun-
icationTCS,ECM communication
(torque command)P6 14—GNDLess than 0.7 V when the vehicle stands
still.
TCS,ECM communication
(torque command)P6 5—GNDLess than 5 V when the vehicle stands
still.
TCS,ECM communication
(TCS operates)P6 12—GND4—5.4 V when TCS controls no
operations. Less than 0.7 V when it
controls operations.
ECM,TCS communication
(engine control)P6 4—GNDH/L toggle signal with the accelerator
pedal off (Cycle 20 mS, H: 10—14 V, L:
less than 0.7 V). Less than 2.0 V with the
accelerator pedal depressed. Also when
TCS OFF indicator light comes on by TCS
OFF switch.
ABS operation signal P6 13—GND10—14 V when the ABS control does not
operate still and less than 0.7 V when
ABS operates.
Fluid level sensor P7 20—GNDLess than2VwhenIGNisONand10—
14 V when idling.
Select
monitorData is received. P7 9—GND 4—4.5 V when no data is received.
Data is sent. P7 19—GND 4—4.5 V when no data is sent.
Diagnosis connector P7 8—GND 10—14 V when IGN is ON.
Power
supplyIgnition P5 1—GND 10—14 V when IGN is ON.
Battery P5 4—GND 10—14 V
Grounding
linePower P5 5—body 1Ωor less
Digital P7 15—body 1Ωor less
Power P4 6—body 1Ωor less
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5. Control Module I/O Signal

B: CHECK LIST FOR INTERVIEW
Check the following items about the vehicle’s state.
1. THE STATE OF THE WARNING LIGHTS
a. ABS warning light

1Is always on.2Sometimes comes on.3Comes on only once.4Does not come on.
When/how long does it come on?
Ignition key
position
1Lock2Acc3On (before starting engine)4Start5On after starting (Engine: run)
6On after starting (Engine: stop)
Timing
1Immediately after ignition is on.2Immediately after ignition starts.
3When advancing (Speedmiles/h,miles/h)4While traveling at a constant speed (Speedmiles/h)
5When decelerating (Speedmiles/h,miles/h)
6When turning (To right, to left, steering angledeg., steering timesec)
7When other electrical parts move (Part name:, Operating condition)
8When moving other electrical parts (Part name:, Operating condition)
b. TCS warning light

1Is always on.2Sometimes comes on.3Comes on only once.4Does not come on.
When does it come on?
Ignition key
position
1Lock2Acc3On (before starting engine)4Start5On after starting (Engine: run)
6On after starting (Engine: stop)
Timing
1Immediately after ignition is on.2Immediately after ignition starts.
3When advancing (Speedmiles/h,miles/h)4While traveling at a constant speed (Speedmiles/h)
5When decelerating (Speedmiles/h,miles/h)
6When turning (To right, to left, steering angledeg., steering timesec)
7When other electrical parts move (Part name:, Operating condition)
8When moving other electrical parts (Part name:, Operating condition)
c. TCS OFF indicator light

1Is always on.2Sometimes comes on.3Comes on only once.4Does not come on.
When/how long does it come on?
Ignition key
position
1Lock2Acc3On (before starting engine)4Start5On after starting (Engine: run)
6On after starting (Engine: stop)
Timing
1Immediately after ignition is on.2Immediately after ignition starts.
3When advancing (Speedmiles/h,miles/h)4While traveling at a constant speed (Speedmiles/h)
5When decelerating (Speedmiles/h,miles/h)
6When turning (To right, to left, steering angledeg., steering timesec)
7When other electrical parts move (Part name:, Operating condition)
8When moving other electrical parts (Part name:, Operating condition)
d. TCS operation indicator light

1Is always on.2Sometimes comes on.3Comes on only once.4Does not come on.
When does it come on?
Ignition key
position
1Lock2Acc3On (before starting engine)4Start5On after starting (Engine: run)
6On after starting (Engine: stop)
Timing
1Immediately after ignition is on.2Immediately after ignition starts.
3When advancing (Speedmiles/h,miles/h)4While traveling at a constant speed (Speedmiles/h)
5When decelerating (Speedmiles/h,miles/h)
6When turning (To right, to left, steering angledeg., steering timesec)
7When other electrical parts move (Part name:, Operating condition)
8When moving other electrical parts (Part name:, Operating condition)
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6. Diagnostics Chart for On-board Diagnosis System

e. Malfunction indicator light

1Is always on.2Sometimes comes on.3Comes on only once.4Does not come on.
When does it come on?
Ignition key
position
1Lock2Acc3On (before starting engine)4Start5On after starting (Engine: run)
6On after starting (Engine: stop)
Timing
1Immediately after ignition is on.2Immediately after ignition starts.
3When advancing (Speedmiles/h,miles/h)4While traveling at a constant speed (Speedmiles/h)
5When decelerating (Speedmiles/h,miles/h)
6When turning (To right, to left, steering angledeg., steering timesec)
7When other electrical parts move (Part name:, Operating condition)
8When moving other electrical parts (Part name:, Operating condition)
2. SYMPTOMS
ABS operating
condition1Performs no work.2Operates only when abruptly applying brakes. (Conditions: vehicle speedmiles/h, how to step
on brake pedal)
3Operating time (sec., etc.)4Operating noise (Produced/Not produced)
5What kind of noise? (Knock, gong gong, bong, buzz, gong gong buzz, etc.)
6Reaction force of brake pedal (Stick, pressed down once with a clunk, pressed and released, etc.)
TCS operating
condition
1Performs no work.2Operates only when abruptly accelerating. (Conditions: vehicle speedmiles/h, how to step on
accelerator pedal)
3Operating time (sec., etc.)4Operating noise (Produced/Not produced)
5What kind of noise? (Knock, gong gong, bong, buzz, gong gong buzz, etc.)
6Whether or not operation indicator light comes on. (Come on/Does not come on, Others)
Behavior of
vehicle
1Directional stability cannot be obtained or steering arm refuses to work when applying brakes (vehicle turns to right, turns
to left, spins, etc.).
2Directional stability cannot be obtained or steering arm refuses to work when accelerating (vehicle turns to right, turns to
left, spins, etc.).
3Brakes are out of order (braking distance is long, brakes lock or drag, pedal stroke is long, pedal sticks, etc.).
4Poor acceleration (fails to accelerate, engine stalls, etc.).
5Vibration, abnormal noise (operating noise is loud, noise is produced during operation from the front of vehicle (right, left)
(tones:), noise is produced during operation from the rear of vehicle (tones:, others)
6Other phenomena (concrete symptoms)
3. CONDITIONS UNDER WHICH TROUBLE OCCURS
Environment1Weather (fine, cloudy, rain, snow, etc.)
2Ambient temperature (°C/°F)
3Road (urban area, suburbs, highway, general road, ascending slope, descending slope, paved road, gravel road, muddy
road, sandy place, etc.)
4Road surface (dry, wet, new-fallen snow, compressed snow, frozen slope, etc.)
Conditions
1Brakes (decelerationg, continuous/intermittent)2Accelerator (accelerationg, continuous/intermittent)
3Travel speed (miles, advancing, accelerating, reducing speed, low speed, turning, etc.)
4Condition of tire of each wheel (air pressure, degree of wear, whether or not genuine parts are used, whether
or not chain is passed around tires, whether or not T tire is used.) others ()
5Condition of suspension alignment ()
6Loading state ()
4. REPAIRED PARTS ARE USED OR NOT
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6. Diagnostics Chart for On-board Diagnosis System

7. Diagnostics Chart for Warning Light
Circuit Failure
A: TROUBLE CODE DOES NOT APPEAR.
—TCS WARNING LIGHT COMES ON WHEN
STARTING THE ENGINE.—
1. Check TCS warning light.
OK
Not OK
Repair harness.
2. Check diagnosis terminal.
OK
Not OK
Repair harness.
3. Check diagnosis connector.
OK
Not OK
Repair harness/connector.
Replace ABS/TCS control module.
B4M0385



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7. Diagnostics Chart for Warning Light Circuit Failure

B: ABS AND TCS WARNING LIGHT DO NOT
GO OFF.
—TCS OFF AND TCS OPERATING
INDICATOR LIGHTS COME ON AND GO OFF
PROPERLY WHEN STARTING THE ENGINE,
WHILE ABS WARNING AND TCS WARNING
LIGHTS KEEP ON.—
1. Check brake fluid level.
OK
Not OK
Add to brake fluid.
2. Check brake fluid level sensor.
OK
Not OK
Replace master cylinder.
3. Check harness connector between ABS/TCS
control module and alternator.
OK
Not OK
Replace harness connector.
Replace ABS/TCS control module.
B4M0389



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7. Diagnostics Chart for Warning Light Circuit Failure