Subaru LEGACY User manual

FUJI HEAVY INDUSTRIES LTD. G2320GE6
2004 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(diag)
VEHICLE DYNAMICS CONTROL (VDC) VDC
VEHICLE DYNAMICS CONTROL (VDC)
(DIAGNOSTICS) VDC(diag)
BRAKE BR
PARKING BRAKE PB
POWER ASSISTED SYSTEM
(POWER STEERING) PS

ABS (DIAGNOSTICS)ABS(diag)
Page
1. Basic Diagnostic Procedure........................................................................2
2. Check List for Interview...............................................................................4
3. General Description ....................................................................................8
4. Electrical Component Location .................................................................10
5. Control Module I/O Signal.........................................................................12
6. Subaru Select Monitor...............................................................................15
7. Read Diagnostic Trouble Code (DTC)......................................................25
8. Inspection Mode........................................................................................26
9. Clear Memory Mode..................................................................................27
10. ABS Warning Light / Brake Warning Light Illumination Pattern ................28
11. List of Diagnostic Trouble Code (DTC).....................................................39
12. Diagnostic Procedure with Diagnostic Trouble Code (DTC).....................42
13. General Diagnostic Table..........................................................................82

ABS(diag)-2
ABS (DIAGNOSTICS) Basic Diagnostic Procedure
1. Basic Diagnostic Procedure
A: PROCEDURE
CAUTION:
Remove foreign matters (dust, water, oil, etc.) from the ABSCM&H/U connector during removal and
installation.
NOTE:
• To check harness for broken wires or short circuits, shake trouble spot or connector.
• Refer to “Check List for Interview”. <Ref. to ABS(diag)-4, Check List for Interview.>
Step Check Yes No
1 CHECK PRE-INSPECTION.
1) Ask the customer when and how the trou-
ble occurred using interview checklist. <Ref. to
ABS(diag)-4, Check List for Interview.>
2) Before performing diagnostics, check the
component which might affect ABS problems.
<Ref. to ABS(diag)-8, INSPECTION, General
Description.>
Is the component that might
influence the ABS problem
normal?
Go to step 2. Repair or replace
each unit.
2 CHECK INDICATION OF DTC ON SCREEN.
1) Turn the ignition switch to OFF.
2) Connect the Subaru Select Monitor to data
link connector.
3) Turn the ignition switch to ON and Subaru
Select Monitor to ON.
NOTE:
If the communication function of the Subaru Se-
lect Monitor cannot be executed normally,
check the communication circuit. <Ref. to
ABS(diag)-18, COMMUNICATION FOR INI-
TIALIZING IMPOSSIBLE, INSPECTION, Sub-
aru Select Monitor.>
4) Read the DTC. <Ref. to ABS(diag)-25,
OPERATION, Read Diagnostic Trouble Code
(DTC).>
5) Record all DTCs and Freeze Frame Data.
Is DTC displayed? Go to step 4. Go to step 3.
3 PERFORM THE GENERAL DIAGNOSTICS.
1) Inspect using “General Diagnostic Table”.
<Ref. to ABS(diag)-82, General Diagnostic
Table.>
2) Perform clear memory mode. <Ref. to
ABS(diag)-17, CLEAR MEMORY MODE,
OPERATION, Subaru Select Monitor.>
3) Perform the inspection mode. <Ref. to
ABS(diag)-26, Inspection Mode.>
4) Read the DTC. <Ref. to ABS(diag)-15,
READ DIAGNOSTIC TROUBLE CODE (DTC),
OPERATION, Subaru Select Monitor.>
Check the DTC does not displayed.
Does the ABS warning light go
off after turning the ignition
switch to ON?
Finish the diagno-
sis. Check in accor- dance with “Diag-
nostic Procedure
for ABS”. <Ref. to
ABS(diag)-21,
WITHOUT DTC,
INSPECTION,
Subaru Select
Monitor.>

ABS(diag)-3
ABS (DIAGNOSTICS)
Basic Diagnostic Procedure
4 PERFORM THE DIAGNOSIS.
1) Refer to the “List of Diagnostic Trouble
Code (DTC)”. <Ref. to ABS(diag)-39,LIST, List
of Diagnostic Trouble Code (DTC).>
2) Fix the wrong part.
3) Perform clear memory mode. <Ref. to
ABS(diag)-17, CLEAR MEMORY MODE,
OPERATION, Subaru Select Monitor.>
4) Perform the inspection mode. <Ref. to
ABS(diag)-26, Inspection Mode.>
5) Read the DTC. <Ref. to ABS(diag)-15,
READ DIAGNOSTIC TROUBLE CODE (DTC),
OPERATION, Subaru Select Monitor.>
Is DTC displayed? Repeat step 1 to 4
until DTC is not
shown.
Finish the diagno-
sis.
Step Check Yes No

ABS(diag)-4
ABS (DIAGNOSTICS) Check List for Interview
2. Check List for Interview
A: CHECK
Check the following items about the vehicle’s state.
1. STATE OF ABS WARNING LIGHT
2. STATE OF BRAKE WARNING LIGHT
ABS warning light
comes on. ❏Always ❏Sometimes
❏Only once
❏Not come on
•When / how long does it come on?
Ignition key position ❏LOCK
❏ACC
❏ON (before starting engine)
❏START
❏ON (after Engine starting, engine is running)
❏ON (after Engine starting, engine is at a standstill)
Timing ❏Immediately after turning the ignition to ON
❏Immediately after turning the ignition to START
❏When accelerating — km/h
—MPH
❏When driving at a constant speed km/h MPH
❏When decelerating — km/h
—MPH
❏When turning to the right Steering angle: deg
Steering time: Sec.
❏When turning to the left Steering angle: deg
Steering time: Sec.
❏When operating other electrical parts
•Parts name:
•Operating condition:
Brake warning light
comes on. ❏Always ❏Sometimes
❏Only once
❏Not come on
❏When pulling the parking brake lever up.
❏When releasing the parking brake lever down.
•When / how long does it come on?
Ignition key position ❏LOCK
❏ACC
❏ON (before starting engine)
❏START
❏ON (after Engine starting, engine is running)
❏ON (after Engine starting, engine is at a standstill)

ABS(diag)-5
ABS (DIAGNOSTICS)
Check List for Interview
3. SYMPTOMS
Timing ❏Immediately after turning the ignition to ON
❏Immediately after turning the ignition to START
❏When accelerating — km/h
—MPH
❏When driving at a constant speed km/h MPH
❏When decelerating — km/h
—MPH
❏When turning to the right Steering angle: deg
Steering time: Sec.
❏When turning to the left Steering angle: deg
Steering time: Sec.
❏When operating other electrical parts
•Parts name:
•Operating condition:
ABS operating condi-
tion ❏Does not move.
❏Operates only when applying an abrupt brake. Vehicle speed: km/h
MPH
•How to step on brake pedal:
a) Operating time: Sec.
b) Operating noise: ❏Occurs. / ❏Does not occur.
•What kind of noise? ❏Knocking
❏Gong gong
❏Bong
❏Buzz
❏Gong gong buzz
❏Others:
c) Reaction force of brake pedal
❏Stick
❏Weak pedal resistance
❏Strong pedal resistance
❏Others:

ABS(diag)-6
ABS (DIAGNOSTICS) Check List for Interview
4. CONDITIONS UNDER WHICH TROUBLE OCCURS
Behavior of vehicle a) Directional stability cannot be obtained or the steering refuses to work when applying brakes:
❏Yes / ❏No
•When: ❏When turning to the right
❏When turning to the left
❏When spinning
❏Others:
a) Directional stability cannot be obtained or the steering refuses to work when accelerating:
❏Yes / ❏No
•When: ❏When turning to the right
❏When turning to the left
❏When spinning
❏Others:
c) Poor brake performance: ❏Yes / ❏No
•What kind: ❏Long braking/stopping distance
❏Brakes lock or drag
❏Long pedal stroke
❏Pedal sticks.
❏Others:
d) Poor acceleration: ❏Yes / ❏No
•What kind: ❏Not accelerate
❏Engine stalls.
❏Others:
e) Occurrence of vibration: ❏Yes / ❏No
•Where
•What kind:
f) Occurrence of noise: ❏Yes / ❏No
•Where
•What kind:
g) Other troubles occurred: ❏Yes / ❏No
•What kind:
Environment a) Weather ❏Fine
❏Cloudy
❏Rainy
❏Snowy
❏Others:
b) Ambient temperature °C (°F)
c) Road ❏Inner city
❏Suburbs
❏Highway
❏Local street
❏Uphill
❏Downhill
❏Paved road
❏Gravel road
❏Muddy road
❏Sandy place
❏Others:
d) Road surface ❏Dried
❏Wet
❏Covered with fresh snow
❏Covered with hardened snow
❏Frozen slope
❏Others:

ABS(diag)-7
ABS (DIAGNOSTICS)
Check List for Interview
Condition a) Brakes Deceleration: G
❏Intermittent / ❏Temporary
b) Accelerator Acceleration: G
❏Intermittent / ❏Temporary
c) Vehicle speed km/h MPH
❏Advancing
❏When accelerating
❏When decelerating
❏At low speed
❏When turning
❏Others:
d) Tire inflation pressure Front RH tire: kPa
Front LH tire: kPa
Rear RH tire: kPa
Rear LH tire: kPa
e) Degree of wear Front RH tire:
Front LH tire:
Rear RH tire:
Rear LH tire:
f) Genuine parts are used.: ❏Yes / ❏No
g) Tire chain is attached.: ❏Yes / ❏No
h) T-type tire is used.: ❏Yes / ❏No
i) Condition of suspension alignment:
j) Loading state:
k) Repair parts are used.: ❏Yes / ❏No
•Contents:
l) Others:

ABS(diag)-8
ABS (DIAGNOSTICS) General Description
3. General Description
A: CAUTION
1. SUPPLEMENTAL RESTRAINT SYSTEM
“AIRBAG”
Airbag system wiring harness is routed near the
ABS wheel speed sensor and ABSCM&H/U.
CAUTION:
• All airbag system wiring harness and con-
nectors are colored yellow. Do not use the elec-
trical test equipment on these circuits.
• Be careful not to damage the airbag system
wiring harness when servicing the ABS wheel
speed sensor and ABSCM&H/U.
B: INSPECTION
Before performing diagnosis, check the following
items which might affect ABS problems.
1. BATTERY
Measure battery voltage and check electrolyte.
Standard voltage: 12 V or more
Specific gravity: More than 1.260
2. BRAKE FLUID
1) Check the brake fluid level.
2) Check the brake fluid for leaks.
3. HYDRAULIC UNIT
Check the hydraulic unit.
• With brake tester <Ref. to ABS-8, CHECKING
THE HYDRAULIC UNIT ABS OPERATION WITH
BRAKE TESTER, INSPECTION, ABS Control
Module and Hydraulic Control Unit (ABSCM&H/
U).>
• Without brake tester <Ref. to ABS-7, CHECK-
ING THE HYDRAULIC UNIT ABS OPERATION
BY PRESSURE GAUGE, INSPECTION, ABS
Control Module and Hydraulic Control Unit (AB-
SCM&H/U).>
4. BRAKE DRAG
Check for brake drag.
5. BRAKE PAD AND ROTOR
Check the brake pad and rotor.
• FRONT <Ref. to BR-18, INSPECTION, Front
Brake Pad.> <Ref. to BR-19, INSPECTION, Front
Disc Rotor.>
• REAR <Ref. to BR-25, INSPECTION, Rear
Brake Pad.> <Ref. to BR-26, INSPECTION, Rear
Disc Rotor.>
6. TIRE
Check the tire specifications, tire wear and air pres-
sure. <Ref. to WT-2, SPECIFICATION, General
Description.>

ABS(diag)-9
ABS (DIAGNOSTICS)
General Description
C: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
24082AA230 CARTRIDGE Troubleshooting for electrical system.
22771AA030 SUBARU SELECT
MONITOR KIT Troubleshooting for electrical system. • 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.
Oscilloscope Used for measuring sensor.
ST24082AA23
0
ST22771AA03
0