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Subaru LEGACY 2003 Service Manual

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2003 LEGACY SERVICE MANUAL
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.
FUJI HEAVY INDUSTRIES LTD.
QUICK REFERENCE INDEX
FRONT SUSPENSION
REAR SUSPENSION
WHEEL AND TIRE SYSTEM
DIFFERENTIALS
TRANSFER CASE
DRIVE SHAFT SYSTEM
ABS
ABS (DIAGNOSTICS)
VDC
VDC (DIAGNOSTICS)
BRAKE
PARKING BRAKE
POWER ASSISTED SYSTEM
(POWER STEERING)
FS
RS
WT
DI
TC
DS
ABS
ABS
VDC
VDC
BR
PB
PS
G2300GE6

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Summary of Contents for Subaru LEGACY 2003

  • Page 1 FRONT SUSPENSION REAR SUSPENSION WHEEL AND TIRE SYSTEM DIFFERENTIALS This service manual has been prepared to provide SUBARU service personnel TRANSFER CASE with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. DRIVE SHAFT SYSTEM...

  • Page 3: Table Of Contents

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

  • Page 4: General Description

    GENERAL DESCRIPTION 1. General Description A: SPECIFICATIONS Item Standard or remarks Front 0.3 — 0.8 mm (0.012 — 0.031 in) ABS sensor gap Rear 0.44 — 0.94 mm (0.0173 — 0.0370 in) ABS sensor resistance 1.25±0.25 kΩ Front LH Except OUTBACK Yellow OUTBACK Brown...
  • Page 5 GENERAL DESCRIPTION B: COMPONENT 1. ABS SENSOR ( 2 ) ( 3 ) ( 1 ) ( 4 ) ( 5 ) ( 7 ) ( 6 ) ( 3 ) VDC00069 (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)
  • Page 6 GENERAL DESCRIPTION 2. YAW RATE AND LATERAL G SENSOR ( 1 ) VDC00070 (1) Yaw rate and lateral G sensor Tightening torque: N·m (kgf-m, ft-lb) T: 7.5 (0.76, 5.5) 3. STEERING ANGLE SENSOR ( 2 ) ( 3 ) ( 1 ) VDC00189 (1) Steering angle sensor (2) Roll connector...
  • Page 7 GENERAL DESCRIPTION 4. VDC CONTROL MODULE (VDCCM) • LHD model ( 1 ) VDC00072 (1) VDC control module Tightening torque: N·m (kgf-m, ft-lb) T: 7.5 (0.76, 5.5) • RHD model ( 1 ) VDC00158 (1) VDC control module Tightening torque: N·m (kgf-m, ft-lb) T: 7.5 (0.76, 5.5) VDC-5...
  • Page 8 GENERAL DESCRIPTION 5. HYDRAULIC CONTROL UNIT (H/U) ( 4 ) (11) (12) (13) (14) ( 8 ) ( 7 ) ( 6 ) ( 3 ) (15) (16) ( 2 ) ( 1 ) ( 9 ) ( 7 ) ( 7 ) (10) ( 8 )
  • Page 9 GENERAL DESCRIPTION C: CAUTION • Be careful not to burn your hands, because each part on the vehicle is hot after running. • Wear working clothing, including, a cap, protec- • Be sure to tighten fasteners including bolts and tive goggles, and protective shoes during opera- nuts to the specified torque.

  • Page 10: Vdc Control Module (Vdccm)

    VDC CONTROL MODULE (VDCCM) 2. VDC Control Module (VDC- RHD model A: REMOVAL 1) Disconnect battery ground cable. VDC00159 4) Remove two bolts which install VDCCM onto body side bracket. LHD model FU-00009 2) Remove lower cover of instrument panel and disconnect connectors on the back side of the cov- VDC00076 RHD model...
  • Page 11 Vehicle specifications VDCCM identi- 3) Set the SUBARU SELECT MONITOR on the ve- fication mark hicle and select “Set Mode Str.A.Sen.N & Lat.Gs- Except OUTBACK en.0p” in “Function Check Sequence” display Except Austra- Except 3.0...

  • Page 12: Hydraulic Control Unit (H/U)

    HYDRAULIC CONTROL UNIT (H/U) 3. Hydraulic Control Unit (H/U) 2. RELAY BOX 1) Disconnect ground cable from battery. A: REMOVAL 2) Remove air intake duct from engine compart- 1. HYDRAULIC UNIT (H/U) ment to facilitate removal of relay box. 3) Disconnect connector from relay box. 1) Disconnect ground cable from battery.
  • Page 13 HYDRAULIC CONTROL UNIT (H/U) B: INSTALLATION 2. RELAY BOX 1) Install relay box and connector bracket. 1. HYDRAULIC UNIT (H/U) Tightening torque: 1) Install hydraulic unit. 13 N·m (1.3 kgf-m, 9.4 ft-lb) VDC00079 VDC00080 Tightening torque: 2) Secure relay box connector to connector brack- 18 N·m (1.8 kgf-m, 13.0 ft-lb) 2) Connect hydraulic unit ground cable to body.
  • Page 14 HYDRAULIC CONTROL UNIT (H/U) C: INSPECTION 1) Check connected and fixed condition of connector. 2) Check valve relay and motor relay for discontinuity or short circuits. Condition Terminal number Standard Diagram Terminal location 103±10 Ω 85 — 86 Turning off elec- Less than 0.5 Ω...
  • Page 15 HYDRAULIC CONTROL UNIT (H/U) 7) Read values indicated on the pressure gauge 2. CHECKING THE HYDRAULIC UNIT ABS and check if the fluctuation of the values between OPERATION WITH BRAKE TESTER decompression and compression meets the stan- 1) Prepare for operating ABS sequence control. dard values.
  • Page 16 HYDRAULIC CONTROL UNIT (H/U) 6) Read values indicated on the brake tester and 7) Read values indicated on the pressure gauge check if the fluctuation of values, when decom- and check if the fluctuation of the values between pressed and compressed, meet the standard val- decompression and compression meets the stan- ues.
  • Page 17 HYDRAULIC CONTROL UNIT (H/U) 4. CHECKING THE HYDRAULIC UNIT VDC 7) After checking, also check if any irregular brake pedal tightness is felt. OPERATION WITH BRAKE TESTER 1) Prepare for operating VDC sequence control. <Ref. to VDC-19, VDC Sequence Control.> 2) Set the front wheels or rear wheels on the brake tester and set the select lever's position at “neutral”.

  • Page 18: Abs Sequence Control

    ABS SEQUENCE CONTROL 4. ABS Sequence Control 2. ABS SEQUENCE CONTROL WITH SE- LECT MONITOR A: OPERATION NOTE: 1) Under the ABS sequence control, after the hy- • In the event of any trouble, the sequence control draulic unit solenoid valve is driven, the operation may not be operative.
  • Page 19 ABS SEQUENCE CONTROL 3. CONDITIONS FOR ABS SEQUENCE CONTROL 2.75 km/h (2 MPH) or less 10 km/h (6 MPH) or less Speed of all wheels Terminal No. 5 and No. 8 Ignition key switch 1.5s 1.5s 1.4s 1.0s 1.4s 0.6s Point A LIGHT ABS warning light...
  • Page 20 ABS SEQUENCE CONTROL B: SPECIFICATION 1. CONDITIONS FOR COMPLETION OF ABS SEQUENCE CONTROL When the following conditions develop, the ABS sequence control stops and ABS operation is re- turned to the normal control mode. 1) When the speed of at least one wheel reaches 10 km/h (6 MPH).

  • Page 21: Vdc Sequence Control

    VDC SEQUENCE CONTROL 5. VDC Sequence Control 2. VDC SEQUENCE CONTROL WITH SE- LECT MONITOR A: OPERATION NOTE: 1) Under the VDC sequence control, after the hy- • In the event of any trouble, the sequence control draulic unit solenoid valve is driven, the operation may not be operative.
  • Page 22 VDC SEQUENCE CONTROL 3. CONDITIONS FOR VDC SEQUENCE CONTROL 2.75 km/h (2 MPH) or less 10 km/h (6 MPH) or less Speed of all wheels Terminal No. 5 and No. 8 ON (Engine run) Ignition key switch Point A 1.5s 3.4s 3.4s 1.6s...
  • Page 23 VDC SEQUENCE CONTROL B: SPECIFICATION 1. CONDITIONS FOR COMPLETION OF VDC SEQUENCE CONTROL When the following conditions develop, the VDC sequence control stops and VDC operation is re- turned to the normal control mode. 1) When the speed of at least one wheel reaches 10 km/h (6 MPH).

  • Page 24: Yaw Rate And Lateral G Sensor

    YAW RATE AND LATERAL G SENSOR 6. Yaw Rate and Lateral G Sen- B: INSTALLATION Install in the reverse order of removal. NOTE: A: REMOVAL Do not install yaw rate and lateral G sensor in the 1) Disconnect battery ground cable. wrong direction.
  • Page 25 YAW RATE AND LATERAL G SENSOR C: INSPECTION 1. LATERAL G SENSOR SIGNAL Step Value CHECK SUBARU SELECT MONITOR. Do you have SUBARU select Go to step 5. Go to step 2. Monitor? CHECK YAW RATE AND LATERAL G SEN- 2.5±0.2 V Go to step 3.
  • Page 26 YAW RATE AND LATERAL G SENSOR Step Value CHECK YAW RATE AND LATERAL G SEN- 2.5±0.2 V Go to step 6. Replace yaw rate SOR. and lateral G sen- 1) Turn ignition switch to OFF. sor. 2) Connect select monitor connector to data link connector.
  • Page 27 YAW RATE AND LATERAL G SENSOR 2. YAW RATE SENSOR SIGNAL Step Value CHECK YAW RATE AND LATERAL G SEN- 2.1 V — 2.9 V Go to step 2. Replace yaw rate SOR USING OSCILLOSCOPE. and lateral G sen- 1) Connect all connectors. sor is normal.

  • Page 28: Steering Angle Sensor

    STEERING ANGLE SENSOR 7. Steering Angle Sensor A: REMOVAL The steering angle sensor must be always replace as assembly with combination base switch,if any problem is found,because this sensor can not be disassembled. Remove combination base switch assembly and refer to LI section for installation.<Ref. to LI-xx, Combination Base Switch Assembly.>...

  • Page 29: Front Abs Sensor

    FRONT ABS SENSOR 8. Front ABS Sensor A: NOTE The ABS sensor installed on VDC equipped vehi- cles is the same as the one on ABS equipped vehi- cles. Therefore, for removal, inspection and installation, refer to “ABS” section. <Ref. to ABS-12, Front ABS Sensor.> VDC-27...

  • Page 30: Rear Abs Sensor

    REAR ABS SENSOR 9. Rear ABS Sensor A: NOTE The ABS sensor installed on VDC equipped vehi- cles is the same as the one on ABS equipped vehi- cles. Therefore, for removal, inspection and installation, refer to “ABS” section. <Ref. to ABS-15, Rear ABS Sensor.> VDC-28...

  • Page 31: Front Tone Wheel

    FRONT TONE WHEEL 10.Front Tone Wheel A: NOTE As front tone wheel is integrated with front drive shaft, refer to “DS section” for removal, installation, and inspection procedures. <Ref. to DS-28, Front Drive Shaft.> VDC-29...

  • Page 32: Rear Tone Wheel

    REAR TONE WHEEL 11.Rear Tone Wheel A: NOTE As rear tone wheel is integrated with rear drive shaft, refer to “DS section” for removal, installation, and inspection procedures. <Ref. to DS-34, Rear Drive Shaft.> VDC-30...

  • Page 33: Vdc Off Switch

    VDC OFF SWITCH 12.VDC Off Switch 7) Remove VDC off switch by pushing it outward. A: REMOVAL 1. LHD MODEL 1) Remove screws and clip from instrument panel lower cover. 2) Remove front cover (A) while disconnecting con- nector. 3) Remove two screws (B) and then remove center panel (C) while disconnecting connector.
  • Page 34 VDC OFF SWITCH C: INSPECTION Off switch side VDC00103 Check continuity between VDC off switch termi- nals. Switch position Tester connection Specified condition 6 — 5 More than 1 MΩ Less than 1 Ω 6 — 5 If NG, replace VDC off switch. VDC-32...

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