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Subaru LEGACY 2003 Service Manual

Chassis section
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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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  • 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 Page General Description ..................2 ABS Control Module and Hydraulic Control Unit (ABSCM&H/U)....6 ABS Sequence Control ................9 Front ABS Sensor ..................12 Rear ABS Sensor..................15 Front Tone Wheel ..................19 Rear Tone Wheel ..................20 G Sensor ....................21...

  • 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 Except OUTBACK Yellow Front LH ABS sensor OUTBACK...
  • Page 5 GENERAL DESCRIPTION B: COMPONENT 1. SENSOR ( 3 ) ( 4 ) ( 1 ) ( 2 ) ( 5 ) ( 6 ) ( 8 ) ( 7 ) ( 4 ) ABS00327 (1) G sensor (5) Tone wheel (Rear) Tightening torque: N.m (kgf-m, ft-lb) (2) Clip (6) Housing...
  • Page 6 GENERAL DESCRIPTION 2. ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U) ( 4 ) ( 5 ) ( 6 ) ( 7 ) ( 2 ) ( 1 ) ( 3 ) ( 8 ) ( 9 ) ( 2 ) ( 1 ) ( 2 ) (10)
  • Page 7 GENERAL DESCRIPTION C: CAUTION • Be careful not to burn your hands, because each part in 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 8: Abs Control Module And Hydraulic Control Unit (Abscm&H/U)

    ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U) 2. ABS Control Module and Hy- 9) Remove ABSCM&H/U from engine compart- ment. draulic Control Unit (AB- CAUTION: SCM&H/U) • ABSCM&H/U cannot be disassembled. Do not attempt to loosen bolts and nuts. A: REMOVAL •...
  • Page 9 ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U) 4) Using cable clip, secure ABSCM&H/U harness NOTE: to bracket. Wrap sealing tape around the pressure gauge. 5) Connect connector to ABSCM&H/U. CAUTION: • Be sure to remove all foreign matter from in- side the connector before connecting.
  • Page 10 ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U) 17) Connect the air bleeder screws to RL and RR 4) Operate the brake tester. caliper bodies. 5) Perform ABS sequence control. 18) Bleed air from brake line. <Ref. to ABS-9, ABS Sequence Control.> 6) Hydraulic unit begins to work;...

  • Page 11: Abs Sequence Control

    ABS SEQUENCE CONTROL 3. 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 12 ABS SEQUENCE CONTROL 3. CONDITIONS FOR ABS SEQUENCE CONTROL Unit: second 4 km/h (2 MPH) 10 km/h (6 MPH) or less or less Speed of all wheels Either HI or LO possible, if using select monitor. HIGH Terminal No.5 and No.8 Operational guide line of Ignition key switch...
  • Page 13 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 14: Front Abs Sensor

    FRONT ABS SENSOR 4. Front ABS Sensor B: INSTALLATION 1) Temporarily install front ABS sensor on housing. A: REMOVAL CAUTION: 1) Disconnect battery ground cable. Be careful not to strike ABS sensor's pole piece 2) Disconnect front ABS sensor connector located and tone wheel's teeth against adjacent metal next to front strut mounting house in engine com- parts during installation.
  • Page 15 FRONT ABS SENSOR 3) Place a thickness gauge between ABS sensor's C: INSPECTION pole piece and tone wheel's tooth face. After stan- 1. ABS SENSOR dard clearance is obtained over the entire perime- ter, tighten ABS sensor on housing to specified 1) Check pole piece of ABS sensor for foreign par- torque.
  • Page 16 FRONT ABS SENSOR 2. SENSOR GAP 3. OUTPUT VOLTAGE 1) Measure the distance “A” between ABS sensor Output voltage can be checked by the following surface and sensor pole face. method. Install resistor and condenser, then rotate wheel about 2.75 km/h (2 MPH) or equivalent. NOTE: Regarding terminal No., please refer to item 1.

  • Page 17: Rear Abs Sensor

    REAR ABS SENSOR 5. Rear ABS Sensor 6) Remove bolts which hold rear sensor harness brackets. A: REMOVAL 1) Disconnect battery ground cable. 2) Lift-up the vehicle. 3) Remove fuel tank cover. ABS00166 ABS00163 4) Disconnect rear ABS sensor connector. ABS00167 ABS00164 5) Remove rear sensor harness from clip on body...
  • Page 18 REAR ABS SENSOR 8) When inspecting rear tone wheel, remove rear 3) Install rear sensor harness brackets in the origi- drive shaft as rear tone wheel is unitized with BJ as- nal positions and install harness on the clip. sembly of rear drive shaft. Tightening torque: <Ref.
  • Page 19 REAR ABS SENSOR 4) Place a thickness gauge between ABS sensor's C: INSPECTION and tone wheel's tooth face. After standard clear- 1. ABS SENSOR ance is obtained over the entire perimeter, tighten ABS sensor on rear arm to specified torque. 1) Check pole piece of ABS sensor for foreign par- ticles or damage.
  • Page 20 REAR ABS SENSOR 2. SENSOR GAP 3. OUTPUT VOLTAGE 1) Measure the distance “A” between ABS sensor Output voltage can be checked by the following surface and sensor pole face. method. Install resistor and condenser, then rotate wheel about 2.75 km/h (2 MPH) or equivalent. NOTE: Regarding terminal No., refer to item 1.

  • Page 21: Front Tone Wheel

    FRONT TONE WHEEL 6. Front Tone Wheel A: REMOVAL Refer to Front Drive Shaft, because front tone wheel is integrated with front drive shaft. <Ref. to DS-28, REMOVAL, Front Drive Shaft.> B: INSTALLATION Refer to Front Drive Shaft, because front tone wheel is integrated with front drive shaft.

  • Page 22: Rear Tone Wheel

    REAR TONE WHEEL 7. Rear Tone Wheel A: REMOVAL Refer to Rear Drive Shaft, because rear tone wheel is integrated with rear drive shaft. <Ref. to DS-34, REMOVAL, Rear Drive Shaft.> B: INSTALLATION Refer to Rear Drive Shaft, because rear tone wheel is integrated with rear drive shaft.

  • Page 23: G Sensor

    G SENSOR 8. G Sensor A: REMOVAL 1) Disconnect battery ground cable. ABS00150 2) Remove console cover. <Ref. to EI-34, REMOVAL, Console Box.> 3) Disconnect connector from G sensor. 4) Remove G sensor from body. CAUTION: Do not drop or bump G sensor. ABS00171 B: INSTALLATION 1) Install in the reverse order of removal.
  • Page 24 G SENSOR C: INSPECTION Step Value DO YOU HAVE SUBARU SELECT Available. Go to step 5. Go to step 2. MONITOR? CHECK G SENSOR. 2.1 — 2.5 V Go to step 3. Replace G sensor. 1) Turn ignition switch to OFF.

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