1997 SUBARU LEGACY contents

3. DEEP DAMAGE SUCH AS A BREAK OR HOLE
THAT REQUIRES FILLING
Much of the peripheral grained surface must be sacrificed
for repair, and the degree of restoration is not really worth
the expense. (The surface, however, will become almost
flush with adjacent areas.)
Recommended repair kit: PP Part Repair Kit (NRM)
Process
No.Process name Job contents
1 Bumper removal Remove bumper as required.
2 Parts removal Remove parts built into bumper as required.
3 Bumper placementPlace bumper on a paint work table as required.
It is recommended that contour of work table
accommodates internal shape of bumper.
G5M0164
4 Surface preparationRemove dust, oil, etc. from areas to be repaired and surrounding areas, using a suitable solvent
(NRM No. 900 precleno, white gasoline, or alcohol).
5 CuttingIf nature of damage are cracks or holes, cut a
guide slit of 20 to 30 mm (0.79 to 1.18 in) in
length along the crack or hole up to the bumper’s
base surface. Then, bevel or“vee-out”the
affected area using a knife or grinder.
G5M0165
6 Sanding (I) Grind beveled surface with sand paper (#40 to #60) to smooth finish.
7 Cleaning Clean the sanded surface with the same solvent as used in process No. 4.
8 Temporary weldingGrind the side just opposite the beveled area with sand paper (#40 to #60) and clean using a sol-
vent.
Temporarily spot-weld the side, using a PP welding rod and heater gun.
G5M0166
NOTE:

Do not melt welding rod until it flows out. This results in reduced strength.

Leave the welded spot unattended until it cools completely.
47
5-1SERVICE PROCEDURE
7. Repair Instructions for Colored PP Bumper

Process
No.Process name Job contents
9 WeldingUsing a heater gun and PP welding rod, weld the beveled spot while melting the rod and damaged
area.
G5M0167
NOTE:

Melt the sections indicated by hatched area.

Do not melt welding rod until it flows out, in order to provide strength.

Always keep the heater gun 1 to 2 cm (0.4 to 0.8 in) away from the welding spot.

Leave the welded spot unattended until it cools completely.
10 Sanding (II)Remove excess part of weld with a putty knife. If a drill or disc wheel is used instead of the knife,
operate it at a rate lower than 1,500 rpm and grind the excess part little by little. A higher rpm will
cause the PP substrate to melt from the heat.
G5M0168
Sand the welded spot smooth with #240 sand paper.
11 MaskingMask the black substrate section using masking tape.
Recommended masking tape: Nichiban No. 533 or equivalent
12 Cleaning/degreasing Completely clean the entire coated area, using solvent similar to that used in process No. 4.
13 Primer coatingApply a coat of primer to the repaired surface and its surrounding areas. Mask these areas, if neces-
sary.
Recommended primer: Mp/ 364 PP primer
NOTE:
Be sure to apply one coat of primer at a spraying pressure of 245 to 343 kPa (2.5 to 3.5 kg/cm
2,36
to 50 psi) with a spray gun.
14 Leave unattended.Leave the repaired area unattended at 20°C (68°F) for 10 to 15 minutes until primer is half-dry.
NOTE:
If dirt or dust comes in contact with the coated area, wipe it off with a cloth dampended with alcohol.
(Do not use thinner since the coated area tends to melt.)
15Primer surfacer
coatingApply a coat of primer surfacer to the repaired area two or three times at an interval of 3 to 5 min-
utes.
Recommended surfacer:
UPS 300 Flex primer

No. 303 UPS 300 Exclusive hardener

NPS 725 Exclusive reducer (thinner)

Mixing ratio:2:1(UPS 300: No. 303)

Viscosity: 12—14 sec/20°C (68°F)

Coated film thickness: 40—50µ
16 Drying Allow the coated surface to dry for 60 minutes at 20°C (68°F) [or 30 minutes at 60°C (140°F)].
17 Sanding (III) Sand the coated surface and its surrounding areas using #400 sand paper and water.
48
5-1SERVICE PROCEDURE
7. Repair Instructions for Colored PP Bumper

Process
No.Process name Job contents
18 Cleaning/degreasing Same as process No. 12.
19 Top coat (I)Solid color Metallic color
Use a“block”coating method.

Recommended paint:
Suncryl (SC)
No. 307 Flex hardener
SC reducer (thinner)

Mixing ratio:3:1
Suncryl (SC) vs. No. 307 Flex hardener

Viscosity: 11—13 sec/20°C (68°F)

Coated film thickness: 40—50µ

Spraying thickness: 245—343 kPa
(2.5—3.5 kg/cm
2,36—50 psi)Use a“block”coating method.

Recommended paint:
Suncryl (SC)
No. 307 Flex hardener
SC Reducer (thinner)

Mixing ratio:3:1
Suncryl (SC) vs. No. 307 Flex Hardener

Viscosity: 11—13 sec/20°C (68°F)

Coated film thickness: 20—30µ

Spraying thickness: 245—343 kPa
(2.5—3.5 kg/cm2,36—50 psi)
20 Leave unattended. Not required.Leave unattended at 20°C (68°F) for at least 10
minutes until the top coated area is half-dry.
NOTE:
Be careful to keep dust or dirt from coming in
contact with the affected area.
21 Top coat (II) Not required.Apply a clear coat three times at an interval of 3
to 5 minutes.

Recommended paint:
SC710 Overlay clear
No. 307 Flex hardener
SC reducer (thinner)

Mixing ratio:3:1
Suncryl (SC) vs. No. 307 Flex hardener

Viscosity: 10—13 sec/20°C (68°F)

Coated film thickness: 20—30µ

Spraying pressure: 245—343 kPa
(2.5—3.5 kg/cm
2,36—50 psi)
22 DryingAllow the coated surface to dry at 20°C (68°F) for two hours or 60°C (140°F) for 30 minutes.
NOTE:
Do not allow the temperature to exceed 80°C (176°F) since this will deform the PP substrate.
23 Inspection Carefully check the condition of the repaired area.
24 Masking removal Remove masking tape applied in process No. 11 and 13.
25 Parts installation Install parts on bumper in reverse order of removal.
26 Bumper installation Install bumper.
49
5-1SERVICE PROCEDURE
7. Repair Instructions for Colored PP Bumper

1. Precaution

Before disassembling or reassembling parts, always
disconnect battery ground cable. When repairing
radio, control modules, etc. which are provided with
memory functions, record memory contents before
disconnecting battery ground cable. Otherwise, these
contents are cancelled upon disconnection.

Reassemble parts in reverse order of disassembly
procedure unless otherwise indicated.

Adjust parts to specifications contained in this
manual if so designated.

Connect connectors and hoses securely during
reassembly.

After reassembly, ensure functional parts operate
smoothly.
CAUTION:

Airbag system wiring harness is routed near the
electrical parts and switch.

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 ignition key cylinder.
G6M0102
2. Battery
A: REMOVAL AND INSTALLATION
1. BATTERY
1) Disconnect the positive (+) terminal after disconnecting
the negative () terminal of battery.
2) Remove flange nuts from battery rods and take off bat-
tery holder.
3) Remove battery.
Tightening torque:
3.4±1.0 N⋅m (0.35±0.1 kg-m, 2.5±0.7 ft-lb)
NOTE:

Clean battery cable terminals and apply grease to retard
the formation of corrosion.

Connect the positive (+) terminal of battery and then the
negative () terminal of the battery.
4
6-2SERVICE PROCEDURE
1. Precaution - 2. Battery

1. Precaution

Before disassembling or reassembling parts, always
disconnect battery ground cable. When repairing
radio, control modules, etc. which are provided with
memory functions, record memory contents before
disconnecting battery ground cable. Otherwise, these
contents are cancelled upon disconnection.

Reassemble parts in reverse order of disassembly
procedure unless otherwise indicated.

Adjust parts to specifications contained in this
manual if so designated.

Connect connectors and hoses securely during
reassembly.

After reassembly, ensure functional parts operate
smoothly.
CAUTION:

Airbag system wiring harness is routed near the
electrical parts and switch.

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 ignition key cylinder.
G6M0102
2. Battery
A: REMOVAL AND INSTALLATION
1. BATTERY
1) Disconnect the positive (+) terminal after disconnecting
the negative () terminal of battery.
2) Remove flange nuts from battery rods and take off bat-
tery holder.
3) Remove battery.
Tightening torque:
3.4±1.0 N⋅m (0.35±0.1 kg-m, 2.5±0.7 ft-lb)
NOTE:

Clean battery cable terminals and apply grease to retard
the formation of corrosion.

Connect the positive (+) terminal of battery and then the
negative () terminal of the battery.
4
6-2SERVICE PROCEDURE
1. Precaution - 2. Battery

OBD0006F
B2M0433D
B: OBD-II GENERAL SCAN TOOL
1. HOW TO USE OBD-II GENERAL SCAN TOOL
1) Prepare a general scan tool (OBD-II general scan tool)
required by SAE J1978.
2) Open the cover and connect the OBD-II general scan
tool to the data link connector located in the lower portion
of the instrument panel (on the driver’s side), to the lower
cover.
3) Using the OBD-II general scan tool, call up diagnostic
trouble code(s) and freeze frame data.
OBD-II general scan tool functions consist of:
(1) MODE $01: Current powertrain diagnostic data
(2) MODE $02: Powertrain freeze frame data
(3) MODE $03: Emission-related powertrain diagnostic
trouble codes
(4) MODE $04: Clear/Reset emission-related diagnos-
tic information
(5) MODE $05: Oxygen sensor monitoring test results
Read out data according to repair procedures.
(For detailed operation procedures, refer to the OBD-II
General Scan Tool Operation Manual.)
NOTE:
For details concerning diagnostic trouble codes, refer to
the DIAGNOSTIC TROUBLE CODE (DTC) LIST. 2-7 [T10A0], [T11A0].>
H2M1280
2. DATA LINK CONNECTOR (FOR OBD-II GENERAL
SCAN TOOL AND SUBARU SELECT MONITOR)
1) This connector is used both for OBD-II general scan
tools and the Subaru Select Monitor.
2) Terminal No. 4 to No. 6 of the data link connector is
used for the Subaru Select Monitor signal.
CAUTION:
Do not connect any scan tools other than the OBD-II
general scan tools and the Subaru Select Monitor,
because the circuit for the Subaru Select Monitor may
be damaged.
Terminal No. Contents Terminal No. Contents
1 Power supply 9 Blank
2 Blank 10 K line of ISO 9141 CARB
3 Blank 11 Blank
4Subaru Select Monitor signal (ECM to Subaru
Select Monitor)*12 Ground
5Subaru Select Monitor signal (Subaru Select
Monitor to ECM)*13 Ground
6 Subaru Select Monitor clock* 14 Blank
7 Blank 15 Blank
8 Blank 16 Blank
*: Circuit only for Subaru Select Monitor
32
2-7ON-BOARD DIAGNOSTICS II SYSTEM
3. Diagnosis System

H2M1149
5. READ FREEZE FRAME DATA SHOWN ON
DISPLAY. (MODE FB3)
NOTE:

For items and contents shown on display, refer to“6.
READ DATA FUNCTION KEY LIST FOR ENGINE”. to 2-7 [T3C6].>

Freeze frame data will not erase without clearing
memory.
1) Select engine mode using function key.
Press the function key [0].
G3M0152
2) Designate mode using function key.
Press [F] [B] [3] [ENT] in that order.
B2M0636
3) Ensure freeze frame data(s) is (are) shown.
(1) When no trouble is detected, or after memory is
cleared.
B2M0636
(2) When a trouble occurs but the corresponding item
is not displayed.
B2M0638
(3) When only one trouble corresponding to the dis-
played item has occurred.

1Abbreviation

2Diagnostic trouble code of trouble occurred
40
2-7ON-BOARD DIAGNOSTICS II SYSTEM
3. Diagnosis System

6. READ DATA FUNCTION KEY LIST FOR ENGINE
Function mode Contents Abbreviation Unit of measure
F00 ROM ID number YEAR—
F01 Battery voltage VB V
F02 Vehicle speed signal VSP km/h, MPH
F03 Engine speed signal EREV rpm
F04 Engine coolant temperature signal TW°C,°F
F05 Ignition signal ADVS deg
F06 Mass air flow signal QA g/s, V
F07 Throttle position signal THV %, V
F08 Injector pulse width TIM mS
F09 Idle air control signal ISC %
F10 Load data LOAD %
F11 Front oxygen sensor output signal O2 V
F12 Front oxygen sensor maximum and minimum output signal O2max - min V, V
F13 Rear oxygen sensor output signal RO2 V
F14 Rear oxygen sensor maximum and minimum output signal RO2max - min V, V
F17 Short term fuel trim ALPHA %
F19 Knock sensor signal KNOCK deg
F20 Atmospheric absolute pressure signal BARO. P kPa, mmHg
F21 Intake manifold absolute pressure signal MANI. P kPa, mmHg
F29A/F correction coefficient [short term trim] by rear oxygen sen-
sorPHOS %
F30 Long term fuel trim [A/F learning correction coefficient] KBLRC %
F31 Long term fuel trim whole [A/F learning control coefficient] K0 %
F32 Front oxygen sensor heater current FO2H A
F33 Rear oxygen sensor heater current RO2H A
F35 Purge control solenoid valve duty ratio CPCD %
F36Maximum value of cylinder #1 misfire times during 100 rota-
tionsMF1 %
F37Maximum value of cylinder #2 misfire times during 100 rota-
tionsMF2 %
F38Maximum value of cylinder #3 misfire times during 100 rota-
tionsMF3 %
F39Maximum value of cylinder #4 misfire times during 100 rota-
tionsMF4 %
F42Maximum and minimum EGR system pressure value (AT
vehicles)EGRmax - min kPa
F43 Fuel tank pressure signal TNKP kPa, mmHg
F44 Fuel temperature signal TNKT°C,°F
F45 Fuel level signal FLEVEL V
FA 0 O N)OFF signal——
FA 1 O N)OFF signal——
FA 2 O N)OFF signal——
FA 3 O N)OFF signal——
FA 4 O N)OFF signal——
FA 5 O N)OFF signal——
FB0 Diagnostic trouble code (DTC) INSPECT—
FB1 Diagnostic trouble code (DTC) OBD—
42
2-7ON-BOARD DIAGNOSTICS II SYSTEM
3. Diagnosis System