Subaru 2003 Legacy User manual

FUJI HEAVY INDUSTRIES LTD. G2300GE6
2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX
CHASSIS SECTION
This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.
All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.
FRONT SUSPENSION FS
REAR SUSPENSION RS
WHEEL AND TIRE SYSTEM WT
DIFFERENTIALS DI
TRANSFER CASE TC
DRIVE SHAFT SYSTEM DS
ABS ABS
ABS (DIAGNOSTICS) ABS
VDC VDC
VDC (DIAGNOSTICS) VDC
BRAKE BR
PARKING BRAKE PB
POWER ASSISTED SYSTEM
(POWER STEERING) PS

VDC VDC
Page
1. General Description ....................................................................................2
2. VDC Control Module (VDCCM)...................................................................8
3. Hydraulic Control Unit (H/U)......................................................................10
4. ABS Sequence Control.............................................................................16
5. VDC Sequence Control.............................................................................19
6. Yaw Rate and Lateral G Sensor ...............................................................22
7. Steering Angle Sensor..............................................................................26
8. Front ABS Sensor.....................................................................................27
9. Rear ABS Sensor......................................................................................28
10. Front Tone Wheel .....................................................................................29
11. Rear Tone Wheel......................................................................................30
12. VDC Off Switch.........................................................................................31

VDC-2
VDC GENERAL DESCRIPTION
1. General Description
A: SPECIFICATIONS
Item Standard or remarks
ABS sensor
ABS sensor gap Front 0.3 —0.8 mm (0.012 —0.031 in)
Rear 0.44 —0.94 mm (0.0173 —0.0370 in)
ABS sensor resistance 1.25±0.25 kΩ
Marks
of the
harness
Front LH Except OUTBACK Yellow
OUTBACK Brown
Front
RH Except OUTBACK White
OUTBACK Light blue
Rear LH Except OUTBACK Yellow
OUTBACK Yellow
Rear RH Except OUTBACK White
OUTBACK White
Yaw rate and
lateral G sensor Lateral G sensor voltage 2.5±0.2 V
VDC hydraulic control unit marks D2
VDC control
module marks
Except Australia
spec.
Except OUTBACK K
OUTBACK Except 3.0 L model M
3.0 L model N
Australia spec. Except OUTBACK J
OUTBACK Y

VDC-3
VDC
GENERAL DESCRIPTION
B: COMPONENT
1. ABS SENSOR
(1) Clip (5) Housing Tightening torque: N·m (kgf-m, ft-lb)
(2) Rear ABS sensor (6) Front ABS sensor T: 33 (3.3, 24)
(3) ABS spacer (7) Tone wheel (Front)
(4) Tone wheel (Rear)
VDC00069
( 7 ) ( 6 ) ( 3 )
( 5 )
( 4 )
( 3 )
( 2 )
( 1 )
T
T
T
T
T

VDC-4
VDC GENERAL DESCRIPTION
2. YAW RATE AND LATERAL G SENSOR
3. STEERING ANGLE SENSOR
(1) Yaw rate and lateral G sensor Tightening torque: N·m (kgf-m, ft-lb)
T: 7.5 (0.76, 5.5)
VDC00070
( 1 )
T
T
(1) Steering angle sensor (2) Roll connector (3) Combination base switch
( 1 )
( 2 )
( 3 )
VDC00189

VDC-5
VDC
GENERAL DESCRIPTION
4. VDC CONTROL MODULE (VDCCM)
•LHD model
•RHD model
(1) VDC control module Tightening torque: N·m (kgf-m, ft-lb)
T: 7.5 (0.76, 5.5)
(1) VDC control module Tightening torque: N·m (kgf-m, ft-lb)
T: 7.5 (0.76, 5.5)
VDC00072
( 1 )
T
T
T
VDC00158
( 1 )
T
T
T

VDC-6
VDC GENERAL DESCRIPTION
5. HYDRAULIC CONTROL UNIT (H/U)
(1) Relay box (9) Pressure sensor Tightening torque: N·m (kgf-m, ft-lb)
(2) Motor relay (10) Ground terminal T1: 13 (1.3, 9.4)
(3) Valve relay (11) Front-LH outlet T2: 18 (1.8, 13.0)
(4) Cap (12) Secondary inlet T3: 33 (3.3, 24)
(5) Bracket (13) Front-RH outlet T4: 38 (3.9, 28)
(6) Hydraulic control unit (14) Primary inlet
(7) Damper (15) Rear-LH outlet
(8) Stud bolt (16) Rear-RH outlet
( 4 )
VDC00073
( 3 )
( 2 )
( 1 )
( 5 )
( 6 ) ( 7 ) ( 8 )
( 9 )
( 8 )
( 7 )
( 7 )
(11) (12) (13) (14)
(15)
(16)
(10)
T2
T4
T1
T2
T3
T3

VDC-7
VDC
GENERAL DESCRIPTION
C: CAUTION
•Wear working clothing, including, a cap, protec-
tive goggles, and protective shoes during opera-
tion.
•Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
•Keep the disassembled parts in order and pro-
tect them from dust or dirt.
•Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly, and replacement.
•Be careful not to burn your hands, because each
part on the vehicle is hot after running.
•Be sure to tighten fasteners including bolts and
nuts to the specified torque.
•Place shopjacks or safetystands at thespecified
points.
•Before disconnecting electrical connectors of
sensors or units, be sure to disconnect ground ca-
ble from battery.
D: PREPARATION TOOL
1. SPECIAL TOOLS
2. GENERAL PURPOSE TOOLS
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
24082AA210 CARTRIDGE Troubleshooting for electrical systems.
22771AA030 SELECT MONI-
TOR KIT Troubleshooting for electrical systems. •English: 22771AA030 (Without printer)
•German: 22771AA070 (Without printer)
•French: 22771AA080 (Without printer)
•Spanish: 22771AA090 (Without printer)
TOOL NAME REMARKS
Circuit Tester Used for measuring resistance, voltage and ampere.
Pressure Gauge Used for measuring oil pressure.
Oscilloscope Used for measuring sensor.
ST24082AA210
ST22771AA030

VDC-8
VDC VDC CONTROL MODULE (VDCCM)
2. VDC Control Module (VDC-
CM)
A: REMOVAL
1) Disconnect battery ground cable.
2) Remove lower cover of instrument panel and
disconnect connectors on the back side of the cov-
er.
3) Remove three bolts which secure the fuse box
onto body side, then move the fuse box aside.
LHD model
RHD model
4) Remove two bolts which install VDCCM onto
body side bracket.
LHD model
RHD model
5) Disconnect connector from VDCCM by pulling
up the securing holder.
6) Remove VDCCM.
FU-00009
VDC00074
VDC00075
VDC00159
VDC00076
VDC00160
VDC00077