1997 SUBARU LEGACY contents

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

BRAKES
[ABS
5
.31
TYPE]
'
[T501]
4-4d

5
.
Control
Module
I/O
Signal

Terminal

N
Input/Output
signal
Contents
o
.

_)
Measured
value
andmeasuring
conditions

ABS
Front
left
wheel
9-10

sensor'2
Front
right
wheel
11-12
0
.12
-
1
V
(Wheel

speed
Rear
left
wheel
7-8
(When
it
is
20Hz
.)

sensor)
Rear
right
wheel
14-15

Valve
relay
power
supply
24-23
10
-
15
Vwhen
ignition
switch
is
ON
.

Motor
relay
power
supply
25-23
10
-
15
Vwhen
ignition
switch
is
ON
.

G
sensor'2
Power
supply
30-28
4
.75
-
5
.25
V

(AWD
model
ground
28
-

only)
output
6-28
2
.3f0
.2
V
when
vehicle
isin
horizontal
position
.

Stop
light
switch*1
2-23
Less
than
1
.5
V
when
the
stop
light
is
OFF
and,10
-
15
V

when
thestop
light
is
ON
.

ABS
warning
light`2
21-23
Less
than
1.5
V
during
1
.5
seconds
when
ignition
switch
is

ON,and
10
-
15
V
after
1.5
seconds
.

AT
ABS
signal'2

(AT
model
only)
31-23
Less
than
1
.5
V
when
the
ABS
control
does
not
operate
still

and
more
than5
.5
V
when
ABS
operates
.

ABS
operation
signal
monitor*2
3--23
Less
than
1
.5
V
when
the
ABS
control
does
not
operate
still

and
more
than5
.5
V
when
ABS
operates
.

Select
Data
is
received
.
20-23
Less
than
1
.5
V
when
no
data
is
received
.

monitor'2
Data
is
sent
.
5--23
4
.75
-
5
.25
V
when
no
data
is
sent
.

ABS
Terminal
No
.
3
29-23
10
-
15
V
when
ignition
switch
is
ON
.
diagnosis

connector*2
Terminal
No
.
6
4-23
10
-
15
V
when
ignition
switch
is
ON
.

Power
supply'1
1-23
10
-
15
V
when
ignition
switch
is
ON
.

Grounding
line
23
-

Grounding
line
~26

*1
:
Measure
the
I/O
signal
voltage
after
removing
the
connector
from
the
ABSCM&H/U
terminal
.
'2
:
Measure
the
I/O
signal
voltage
at
connector
(F2)
or
(Fi)
.

9

4-4a
[TBAO1
BRAKES
[ABS
5
.31
TYPE]

8
.
Diagnostics
Chart
with
Trouble
Code
by
ABS
Warning
Light

8
.
Diagnostics
Chart
with
Trouble
Code

by
ABS
Warning
Light

A
:
LIST
OF
TROUBLE
CODE

Trouble
code
Contents
of
diagnosis
Ref
.
to
11

Start
code

e
Trouble
code
is
shown
afterstart
code
.

*
Only
start
code
is
shown
in
normal
condition
.

-

21
Front
right
ABS
sensor
[T8B0]*10

23
Abnormal
ABS
sensor
Front
left
ABS
sensor
[T8C0]*10

25
(Open
circuit
or
input
voltage
too
high)
Rear
right
ABS
sensor
[T8D0]*10

27
Rear
left
ABS
sensor
[T8E0]x10

22
Front
right
ABS
sensor
[T8F0]*10

24
Front
left
ABS
sensor
[T8G0]dr10

26
Abnormal
ABS
sensor

(Abnormal
ABS
sensor
signal)
Rear
right
ABS
sensor
[T8H0]*10

28
Rear
left
ABS
sensor
[T810]*10

29
Any
one
of
four
[T8J0]*10

31Front
rightinlet
valve
[T8K0]*10

32
Front
right
outlet
valve
[7800]*10

33
Front
left
inlet
valve
[TSLO]*10

34
Abnormal
solenoid
valve
circuit(s)
in
Front
left
outlet
valve
[T8PO]*10

35
ABS
control
module
and
hydraulic
unit
Rear
right
inlet
valve
[T8M0]*10

36Rear
right
outlet
valve
[T8QOj*10

37
Rear
left
inlet
valve
[T8N0]x10

38Rear
left
outlet
valve
[T8R0]*10

41
Abnormal
ABS
control
module
[T8SO1*10

42
Source
voltage
is
abnormal
.
[7870]*10

44
A
combination
of
AT
control
abnormal
[T8U0]t`r10

51
Abnormal
valve
relay
[T8V0]*10

52
Abnormal
motor
and/or
motor
relay
[T8W0]*10

54
Abnormal
stop
light
switch
(78X0]*10

56
Abnormal
G
sensor
output
voltage
[T8Y0)*10

30

BRAKES
[ABS
5
.31
TYPE]
[T9A3]
4-4d

9
.
Select
Monitor
Function
Mode

2
.
FA
MODE
(ON/OFF
DATA
ARE
DISPLAYED
.)

Function
code
M
it
i
b
i
C
l
Code
Abbreviation
easur
ng
ems
ontents
to
e
mon
toredScrol
Ref
.
to

131
Stop
light
switch
LED
1
comes
on
withthe
switch
on
(with
the

brake
pedal
down)
.

VR
Valve
relay
signal
LED
2
comes
on
withthevalverelay
off
.

MR
Motor
relay
signal
LED
3
comes
on
with
the
motor
on
.

FAO
ATAT
ABS
signal
LED
4
comesonwhen
ABS
control
is
on
.
Possible
[T910]*10

AW
ABS
warning
light
LED
6
comes
on
when
the
warning
light
is
on
.

VM
Valve
relay
monitor
LED
1
comes
on
with
thevalverelay
off
.

MM
Motor
relay
monitor
LED
8
comes
on
when
the
motor
relay
is
on
.

CM
CCM
signal
LED
9
comes
on
when
ABS
control
is
on
.

3
.
FB
MODE
(TROUBLE
CODES
ARE
DISPLAYED
.)

Function
code
M
i
s
easuring
tem
Contents
to
be
monitored
Scroll
Ref
.
to
Code
Abbreviation

D~ALL
A
maximum
of
3
trouble
codes
are
displayed
in

order
of
occurrence
.

D~NEW
The
most
recent
trouble
code
appears
on
the

select
monitor
display
.

FB1
D~MID
Historyoftrouble
The
second
most
recent
trouble
code
appears
Possible
[T10B0]*10codes
is
displayed
.
on
the
select
monitor
display
.

D~OLDThe
third
most
recent
trouble
code
appears
on

the
select
monitor
display
.

D~REF
A
specified
period
of
time
proceeding
trouble

code
appears
on
the
select
monitor
display
.

Do
*a*
22?(FB1)

FR
.
SS
SOFT

84M0919

NOTE
:

9
If
a
particular
trouble
code
is
notproperly
stored
in

memory
(due
to
a
drop
in
ABSCM&H/U
power
supply,
etc
.)

when
a
problem
occurs,
the
trouble
code,
followed
bya

question
mark
"?",
appears
on
the
select
monitor
display
.

This
shows
it
may
be
an
unreliable
reading
.

9*
a*
refers
to
the
troubles
in
order
of
occurrence
(NEW
.

MID,
OLD
and
REF)
.

91

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

9
.
Select
Monitor
Function
Mode

4
.
FC
MODE
(TROUBLE
CODES
ARE
ERASED
.)

Function
code

Code
Abbreviation
Measuring
items
Contents
to
be
monitored
Scroll
Ref
.
to

Historyoftrouble
FCOD~CLR
Function
of
clearing
trouble
code
.
Possible
[T9J0]*10
codes
is
erased
.

5
.
FD
MODE
(ABS
SEQUENCE
CONTROL
MODE)

Function
code
M
i
Code
Abbreviation
easurng
items
Contents
to
be
monitored
Scroll
Ref
.
to

FD1A~CHK
ABS
sequence
con-
Perform
ABS
sequence
control
by
operating
impossible
4-4

tral
valve
and
pump
motor
sequentially
.
[W25D2]*10
6
.
FE
MODE
(FREEZE
FRAME
DATA)

NOTE
:

9
Data
stored
at
the
time
of
trouble
occurrence
is
shown

on
display
.

Each
time
trouble
occurs,
the
latest
information
is

stored
in
the
freeze
frame
data
in
memory
.

Function
code
Measuring
items
Contents
to
be
monitored
Scroll
Ref
.
to
Code
Abbreviation

FE1
FR
FR
wheel
speedWheelspeed
detected
by
the
FR
ABS
sensor
is
possible
[T9K0]*10
(milelh)
displayed
in
mile/h
.

FE2
FL
FL
wheelspeed
Wheelspeed
detected
by
the
FL
ABS
sensor
is
possible
[T9L0]*10
(mile/h)
displayed
in
mile/h
.

FE3
RRRR
wheelspeed
Wheelspeed
detected
by
the
RR
ABS
sensor
is
possible
[T9MO]*10
(milelh)
displayed
in
mite/h
.

FE4
RLRL
wheel
speedWheel
speed
detected
by
the
RL
ABS
sensor
is
possible
[T91V0]*10
(mile/h)
displayed
in
mite/h
.

FE5
FRFR
wheel
speedWheelspeed
detected
by
the
FR
ABS
sensor
is
possible
[T9K0]fr10
(km/h)
displayed
in
km/h
.

FE6
FL
Ft
wheel
speed
Wheel
speed
detected
by
the
FL
ABS
sensor
is
Possible
[T9L0]~10
(km/h)
displayed
in
km/h
.

FE7
RRRR
wheel
speed
Wheel
speed
detected
by
the
RR
RBS
sensor
is
possible
[T9M0]*10
(km/h)
displayed
in
km/h
.

FE8
RLRL
wheel
speedWheelspeed
detected
by
the
RL
ABS
sensor
is
possible
[T9N0]t`r10
(km/h)
displayed
in
km/h
.

FE13
POWER
ABSCM&H/U
power
Power
(in
volts)
supplied
to
ABSCM&H/U
Possible
[T900]*10
supply
voltage
(V)
appears
on
the
select
monitor
display
.

G
sensor
output
Refers
to
vehicleacceleration
detected
by
the

FE14
G-SENS
voltage
(V)
analog
G
sensor
.
It
appears
on
the
select
moni-
Possible
[T9P0]*10

for
display
in
volts
.

MM
Motor
relay
monitor
LED
1
comes
on
when
motor
relay
is
on
.

131
Stop
light
switch
LED
2
comes
on
with
the
stop
light
switch
on
(with
the
brakepedal
depressed)
.
FE15
ATAT
ABS
signal
LED
3
comes
an
when
ABS
control
is
on
.
Possible
[T9Q0]~10

CM
CCM
signal
LED
4
comes
on
when
ABS
control
is
on
.

AO
ABS
control
LED
5
comes
on
when
ABS
control
is
on
.

FE16
CODE
trouble
code
The
most
recent
trouble
code
appears
on
select
Possible
(T9R0]*10
monitor
display
.

92

BRAKES
[ABS
5
.31
TYPE]
[T10B0]
4-4d

10
.
Diagnostics
Chart
with
Select
Monitor

B
:
LIST
OF
TROUBLE
CODE

Code
Display
screen
(FBi)
Contents
of
diagnosis
Ref
.
to

-
ERROR
3
(1)
Select
monitor
communication
failure
[T10COJ*10

11
NO
TROUBLE
Although
no
trouble
appears
on
the
select
monitor
display,
the
ABS
warning
light
remains
on
.
[T10D0]*10

21
FR
.
SS
HARD
Open
circuit
orinput
voltage
too
high
of
FR
sensor
[T10E0]*10

22
FR
.
SS
SOFT
Abnormal
ABS
sensor
signal
of
FRsensor
[T1010J*10

23FL
.
SS
HARD
Open
circuit
orinput
voltage
too
high
of
FLsensor
[T10F0]*10

24FL
.
SS
SOFT
Abnormal
ABS
sensor
signal
of
FL
sensor
[T10J0]*10

25
RR
.
SS
HARD
Open
circuit
orinput
voltage
too
high
of
RR
sensor[T10G0]*10
26
RR
.
SS
SOFT
Abnormal
ABS
sensor
signal
of
RR
sensor[T10K0]*10
27
RL
.
SS
HARD
Open
circuit
orinput
voltage
too
high
of
RL
sensor
[T10H0]tr10

28
RL
.
SS
SOFT
Abnormal
ABS
sensor
signal
of
RL
sensor
[T10L0]*10

29
EITHER
.
SS
SOFT
Abnormal
ABS
sensor
signal
(any
one
of
four)
JT10M0]{r10

31
FR
.
EV
VALVE
Abnormal
FR
inlet
valve
[T10N0]*10

32
FR
.
AV
VALVE
Abnormal
FR
outlet
valve
[T10R0]*10

33
FL
.
EV
VALVE
Abnormal
FL
inlet
valve
[T1000]*10

34
FL
.
AV
VALVE
Abnormal
FL
outlet
valve
[T10S0]xr10

35
RR
.
EV
VALVE
Abnormal
RR
inlet
valve
[T10P0]*10

36
RR
.
AV
VALVE
Abnormal
RR
outlet
valve
[T10T0]*10

37
RL
.
EV
VALVE
Abnormal
RL
inlet
valve
[T10QO]*10

38
RL
.
AV
VALVE
Abnormal
RL
outlet
valve[T10U0]tr10

41
ECU
Abnormal
ABSCM&H/U
[T10V0)*10

42
LOW
VOLTAGE
Source
voltage
is
low
.
[T10W0]tr10

HIGH
VOLTAGE
Source
voltage
is
high
.
[T10X0]*10

44
CCM
LINE
A
combination
of
AT
control
abnormals
(ABS
not
in
control)
[T10Y0]*10

CCM
OPEN
A
combination
of
AT
control
abnormals
(ABS
in
control)
[T10Z0]*10

V
.
RELAY
Abnormal
valve
relay
[T10AA0]*10
51
V
.
RELAY
ON
Valve
relay
ON
failure
[T10AB0]*10

M
.
RELAY
OPEN
Open
circuit
of
motor
relay
[T10AC0]*10

52
M
.
RELAY
ON
Motor
relay
ON
failure
[T10AD0]tr10

MOTOR
Abnormal
motor
[T10AE0]*10

54
BLS
Abnormal
stop
light
switch
[T10AF0]*10

G
SENSOR
LINE
Open
or
short
circuit
of
G
sensor
[T10AG0]*10

G
SENSOR
+B
Battery
short
of
G
sensor
[T10AH0]*10
56
G
SENSOR
H
~x
Abnormal
G
sensor
high
V
output
[T10A10]*10

G
SENSOR
STICK
I
G
sensor
output
is
stuck
.
[T10AJ0]*10

NOTE
:

High
~t
means
high
friction
coefficient
against
road

surface
.

103

6. Coating Method for PP Bumper
1. PROCESS STEPS
Process
No.Process name Job contents
1 Bumper mountingSet bumper on paint work table if required. Use
paint work table conforming to inner shape of
bumper when possible.
G5M0164
2 MaskingMask specified part (black base) with masking tape. Use masking tape for PP (e.g., Nichiban No.
533, etc.).
3Degreasing, clean-
ingClean all parts to be painted with white gasoline, normal alcohol, etc. to remove dirt, oil, fat, etc.
4 Primer paint First, apply one coat of primer to all parts to be painted, using air gun. Use primer (clear).
5 DryingDry at normal temperature [10 to 15 min. at 20°C (68°F)].
In half-dried condition, PP primer paint is dissolved by solvent, e.g. thinner, etc.
Therefore, if dust or dirt must be removed, use ordinary alcohol, etc.
6 Top coat paint (I)Solid color Metallic color
Use section (block) paint for top coat.

Paint in use (for each color):
Solid paint
Hardener PB
Thinner T-301

Mixing ratio:
Main agent vs. hardener = 4:1

Viscosity: 10—13 sec/20°C (68°F)

Film thickness: 35—45µ

Spraying pressure: 245—343 kPa
(2.5—3.5 kg/cm
2,36—50 psi)Use section (block) paint for top coat.

Paint in use (for each color):
Metallic paint
Hardener PB
Thinner T-306

Mixing ratio:
Main agent vs. hardener = 10:1

Viscosity: 10—13 sec/20°C (68°F)

Film thickness: 15—20µ

Spraying pressure: 245—343 kPa
(2.5—3.5 kg/cm2,36—50 psi)
7 Drying Not required.Dry at normal temperature [10 min. or more at
20°C (68°F)].
In half-dried condition, avoid dust, dirt.
8 Top coat paint (II) Not required.Apply a clear coat to parts with top coat paint (I),
three times, at 5—7 minutes intervals.

Paint in use:
Metallic paint
Hardener PB
Thinner T-301

Mixing ratio: Clear vs. hardener = 6:1

Viscosity: 14—16 sec/20°C (68°F)

Film thickness: 25—30µ

Spraying pressure: 245—343 kPa
(2.5—3.5 kg/cm
2,36—50 psi)
9 Drying60°C (140°F), 60 min. or 80°C (176°F), 30 min.
If higher than 80°C (176°F), PP may be deformed. Keep maximum temperature of 80°C (176°F).
10 Inspection Paint check
11 Masking removal Remove masking in process No. 2.
45
5-1SERVICE PROCEDURE
6. Coating Method for PP Bumper

7. Repair Instructions for Colored PP
Bumper
All PP bumpers are provided with a grained surface, and if
the surface is damaged, it cannot normally be restored to
its former condition. Damage limited to shallow scratches
that cause only a change in the lustre of the base material
or coating, can be almost fully restored. Before repairing a
damaged area, explain this point to the customer and get
an understanding about the matter.
Repair methods are outlined below, based on a classifica-
tion of the extent of damage.
1. MINOR DAMAGE CAUSING ONLY A CHANGE IN
THE LUSTRE OF THE BUMPER DUE TO A LIGHT
TOUCH
It is almost restorable as follows:
Process
No.Process name Job contents
1 Cleaning Clean the area to be repaired using water.
2 Sanding Grind the repairing area with #500 sand paper in a“feathering”motion.
3 FinishResin section Coated section
Repeatedly apply wax to the affected area using
a soft cloth (such as flannel).
Recommended wax: NITTO KASEI Soft 99 TIRE
WAX BLACK, or equivalent.Perform either the same operation as for the
resin section or process No. 18 and subsequent
operations in the“3.”section, depending on the
degree and nature of damage.
Polish the waxed area with a clean cloth after 5
to 10 minutes.
2. DEEP DAMAGE CAUSED BY SCRATCHING
FENCES, ETC.
A dent cannot be repaired but a whitened or swelled part
can be removed.
Process
No.Process name Job contents
1 Cleaning Clean damaged area with water.
2Removal of dam-
aged areaCut off protruding area, if any, due to collision, using a putty knife.
3 Sanding Grind the affected area with #100 to #500 sand paper.
4 FinishResin section Coated section
Same as process No. 3 in the“1.”section.Perform process No. 12 and subsequent opera-
tions in the“3.”section.
46
5-1SERVICE PROCEDURE
7. Repair Instructions for Colored PP Bumper