Subaru LEGACY 2004 Service Manual
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Subaru LEGACY 2004 Service Manual

Chassis section
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Table of Contents

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Download this manual See also: Service Manual, Owner's Manual
2004 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)
VEHICLE DYNAMICS CONTROL (VDC)
VEHICLE DYNAMICS CONTROL (VDC)
(DIAGNOSTICS)
BRAKE
PARKING BRAKE
POWER ASSISTED SYSTEM
(POWER STEERING)
FS
RS
WT
DI
TC
DS
ABS
ABS(diag)
VDC
VDC(diag)
BR
PB
PS
G2320GE6

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Summary of Contents for Subaru LEGACY 2004

  • 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 2: Table Of Contents

    FRONT SUSPENSION Page General Description ..................2 Wheel Alignment ..................8 Front Crossmember Support Plate ............15 Front Stabilizer ..................16 Front Ball Joint ..................17 Front Arm ....................19 Front Strut ....................22 Front Crossmember ..................26 General Diagnostic Table................27...

  • Page 3: General Description

    General Description FRONT SUSPENSION 1. General Description A: SPECIFICATION Sedan Wagon OUTBACK Model 2.5 i, 2.0 i 2.5 i 2.0 GT 3.0 R 2.0 i 2.5 i 2.0 GT 3.0 R OUTBACK 3.0 R Wheel arch height [Tolerance: mm (in) 376 (14.8) 381 (15.0) 376 (14.8)
  • Page 4 General Description FRONT SUSPENSION NOTE: • Front and rear toe-ins and front camber can be adjusted. If the toe-in or camber tolerance exceeds specifications, adjust them. • Other items indicated in the specification table cannot be adjusted. If those items exceed specifi- cations, check suspension parts and connections for deformities;...
  • Page 5 General Description FRONT SUSPENSION B: COMPONENT (16) (25) (17) (15) (18) (25) (19) (25) (20) (24) (21) (13) (26) (12) (25) (25) (22) (23) (11) (10) (14) (25) (25) FS-00131 ⋅ Front crossmember (14) Crossmember support plate Tightening torque: N m (kgf-m, ft-lb) (Small type) Housing...
  • Page 6 • Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary re- moval, installation, disassembly and replacement. • Use SUBARU genuine grease or the equivalent. Do not mix grease, etc. with that of another grade or from other manufacturers.

  • Page 7: Special Tool

    General Description FRONT SUSPENSION D: PREPARATION TOOL 1. SPECIAL TOOL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 927380002 ADAPTER Used as an adapter for camber & caster gauge when measuring camber and caster. (1) 28199AC000 PLATE (2) 28199AC010 BOLT ST-927380002 927680000 INSTALLER & Used for replacing the front arm front bushing.
  • Page 8 General Description FRONT SUSPENSION ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 20299AG020 STUD BOLT Used for removing and installing the stud bolt for (Newly adopted tool) SOCKET front arm installing portion. ST20299AG020 20399AG000 STRUT MOUNT Used for disassembling and assembling the strut (Newly adopted tool) SOCKET mount.

  • Page 9: Wheel Alignment

    Wheel Alignment FRONT SUSPENSION 2. Wheel Alignment A: INSPECTION Check the following items before taking wheel alignment measurement. Check items before taking wheel alignment measurement: • Tire inflation pressure • Unbalanced right and left tire wear, size difference • Tire runout •...
  • Page 10 Wheel Alignment FRONT SUSPENSION 1. WHEEL ARCH HEIGHT 3) Set the steering wheel in a straight-ahead posi- tion, and stabilize the suspensions by moving the 1) Park the vehicle on a level surface. vehicle straight more than 5 m (16 ft). 2) Set the vehicle under “curb weight”...
  • Page 11 Wheel Alignment FRONT SUSPENSION 2. CAMBER 3) Turn the camber adjusting bolt so that the cam- ber is set at specification. • INSPECTION NOTE: 1) Place the front wheel on turning radius gauge. Moving the adjusting bolt by one scale changes the Make sure the ground contacting surfaces of front camber by approx.
  • Page 12 Wheel Alignment FRONT SUSPENSION To increase camber. Rotate the left side counterclockwise. Rotate the right side clockwise. FS-00009 FS-00010 To decrease camber. Rotate the left side clockwise. Rotate the right side counterclockwise. FS-00010 FS-00009 4) Tighten two new self-locking nuts. 3) Measure the caster angle in accordance with the operation manual for wheel alignment gauge.
  • Page 13 Wheel Alignment FRONT SUSPENSION • ADJUSTMENT • ADJUSTMENT 1) Turn the tie-rod to adjust the steering angle of When adjusting the toe-in, adjust it to the following both inner and outer wheels. value. 2) Check the toe-in. Toe-in: ± ± NOTE: 2 mm (0 0.08 in)
  • Page 14 Wheel Alignment FRONT SUSPENSION 1) Loosen the self-locking nut on the inner side of 2) Turn the adjusting bolt until toe-in is at the spec- rear link. ification. NOTE: NOTE: When loosening or tightening the adjusting bolt, When the left and right wheels are adjusted for toe- hold the bolt head and turn self-locking nut.
  • Page 15 Wheel Alignment FRONT SUSPENSION 7. THRUST ANGLE 3) When the left and right adjusting bolts are turned by one graduation, the thrust angle will change ap- • INSPECTION prox. 17′ [“L” is approx. 13 mm (0.51 in)]. 1) Park the vehicle on a level surface. NOTE: 2) Move the vehicle 3 to 4 meters (10 to 13 feet) di- Thrust angle refers to a mean value of left and right...

  • Page 16: Front Crossmember Support Plate

    Front Crossmember Support Plate FRONT SUSPENSION 3. Front Crossmember Support Plate A: REMOVAL 1) Lift-up the vehicle. 2) Remove the front under cover. <Ref. to EI-26, REMOVAL, Front Under Cover.> 3) Remove the bolt and remove front crossmember support plate. •...

  • Page 17: Front Stabilizer

    Front Stabilizer FRONT SUSPENSION 4. Front Stabilizer • Stabilizer bracket has an orientation, so install it with the arrow mark faced to the front side of vehi- A: REMOVAL cle. 1) Lift-up the vehicle, and then remove the front wheels. 2) Remove the front under cover.

  • Page 18: Front Ball Joint

    Front Ball Joint FRONT SUSPENSION 5. Front Ball Joint NOTE: Stabilizer bracket has an orientation, so install it A: REMOVAL with the arrow mark faced to the front side of vehi- 1) Lift-up the vehicle and remove the front wheels. cle.
  • Page 19 Front Ball Joint FRONT SUSPENSION (4) Replace with a new one when the play ex- ceeds specified value. FRONT BALL JOINT Specified play for replacement S: Less than 0.3 mm (0.012 in) 2) When the play is within specified value, visually check the dust cover.

  • Page 20: Front Arm

    Front Arm FRONT SUSPENSION 6. Front Arm CAUTION: Do not remove the stud bolt without necessity. A: REMOVAL Always replace the parts with new ones when 1) Lift-up the vehicle, and then remove the front removed. wheels. 2) Remove the front crossmember support plate. <Ref.
  • Page 21 Front Arm FRONT SUSPENSION C: DISASSEMBLY 2) Using the ST and a press, remove the rear bush- ing. 1. FRONT BUSHING ST1 20299AG000 REMOVER ST2 20299AG010 BASE Using the ST and a press, remove the front bush- ing. ST 927680000 INSTALLER &...
  • Page 22 Front Arm FRONT SUSPENSION 2. REAR BUSHING 3) Using the ST and a press, install the rear bush- ing. 1) Install the rear bushing with its longer inner cyl- ST1 20299AG000 REMOVER inder faced upward and its shorter one faced down- ST2 20299AG010 BASE ward and protruding part rearward as shown in the figure.

  • Page 23: Front Strut

    Front Strut FRONT SUSPENSION 7. Front Strut 6) Remove the three nuts securing strut mount to body. A: REMOVAL 1) Lift-up the vehicle, and then remove the front wheels. 2) Scribe an alignment mark on the camber adjust- ing bolt and strut. 3) Remove the bolt securing brake hose from strut.
  • Page 24 Front Strut FRONT SUSPENSION C: DISASSEMBLY (5) Repeat 3 to 4 times from the step (1). 1) Using a coil spring compressor, compress the NOTE: coil spring. After completely purging air from the strut, be sure to place the strut with the piston rod facing up. If the strut is laid down and set, check for the entry of air in accordance with “Check for presence of air”.
  • Page 25 Front Strut FRONT SUSPENSION 7) Pull the piston rod fully upward, and install the E: INSPECTION spring seat. Check the removed part for wear, damage or cracks, and then repair or replace it if defective. NOTE: Ensure the upper spring seat is positioned as 1.
  • Page 26 Front Strut FRONT SUSPENSION F: DISPOSAL CAUTION: • Before handling struts, be sure to wear gog- gles to protect eyes from gas, oil and cutting powder. • Do not disassemble the strut damper or place into a fire. • Drill a hole into struts in case of discarding struts filled with gas.

  • Page 27: Front Crossmember

    Front Crossmember FRONT SUSPENSION 8. Front Crossmember B: INSTALLATION 1) Install in the reverse order of removal. A: REMOVAL NOTE: 1) Lift-up the vehicle, and then remove the front • Use a new bolt and self-locking nut. For the parts wheels.

  • Page 28: General Diagnostic Table

    General Diagnostic Table FRONT SUSPENSION 9. General Diagnostic Table A: INSPECTION 1. IMPROPER VEHICLE POSTURE OR IMPROPER WHEEL ARCH HEIGHT Possible cause Corrective action (1) Permanent distortion or breakage of coil spring Replace. (2) Rough operation of damper strut or shock absorber Replace.
  • Page 29 General Diagnostic Table FRONT SUSPENSION FS-28...
  • Page 30 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 31 REAR SUSPENSION Page General Description ..................2 Wheel Alignment ..................8 Rear Stabilizer.....................9 Rear Arm....................10 Upper Link....................14 Rear Shock Absorber................16 Front Link ....................18 Rear Link....................19 Sub Frame Support Arm ................21 Sub Frame Support Plate................22 Rear Sub Frame..................23 Helper......................24 General Diagnostic Table................25...

  • Page 32: General Description

    General Description REAR SUSPENSION 1. General Description A: SPECIFICATION Sedan Wagon Model OUTBACK 2.5 i, 2.0 i, 2.5 i 2.0 GT, 3.0 R 2.0 i 2.5 i OUTBACK 3.0 R Wheel arch height +12 mm [Tolerance: −24 mm (in) 360 (14.2) 375 (14.8) 430 (16.9) +0.47 in...

  • Page 33: Rear Suspension

    General Description REAR SUSPENSION B: COMPONENT 1. REAR SUSPENSION (21) (23) (10) (11) (20) (18) (12) (17) (16) (14) (19) (13) (15) (22) RS-00137 ⋅ Shock absorber (14) Rear arm bracket Tightening torque: N m (kgf-m, ft-lb) Self-locking nut (15) Hub bearing unit T1: 30 (3.1, 22.4) Stabilizer...
  • Page 34 • Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary re- moval, installation, disassembly and replacement. • Use SUBARU genuine grease etc. or the equiv- alent. Do not mix grease, etc. with that of another grade or from other manufacturers.
  • Page 35 General Description REAR SUSPENSION D: PREPARATION TOOL 1. SPECIAL TOOL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 927380002 ADAPTER Used for an adapter of camber & caster gauge when measuring the camber and caster. (1) 28199AC000 PLATE (2) 28199AC010 BOLT ST-927380002 20099AE000 INSTALLER &...
  • Page 36 General Description REAR SUSPENSION ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 20099AE040 INSTALLER & Used for replacing the rear arm rear bushing. REMOVER SET ST20099AE040 20099AE030 HELPER SOCKET Used for replacing the helper. WRENCH ST20099AE030 20399AG000 STRUT MOUNT Used for removing and installing the shock (New adopted tool) SOCKET mount.
  • Page 37 General Description REAR SUSPENSION ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 28099PA100 REMOVER Used for removal of DOJ. ST28099PA100 2. GENERAL TOOL TOOL NAME REMARKS Alignment gauge Used for wheel alignment measurement. Turning radius gauge Used for wheel alignment measurement. Toe-in gauge Used for toe-in measurement.

  • Page 38: Wheel Alignment

    Wheel Alignment REAR SUSPENSION 2. Wheel Alignment A: INSPECTION NOTE: Measure and adjust the front and rear wheel align- ment at a time. Refer to “FS” section for measure- ment and adjustment of wheel alignment. <Ref. to FS-8, INSPECTION, Wheel Alignment.> RS-8...

  • Page 39: Rear Stabilizer

    Rear Stabilizer REAR SUSPENSION 3. Rear Stabilizer 2) Always tighten the stabilizer bushing in the state that wheels are in full contact with the ground and A: REMOVAL the vehicle is curb weight. 1) Lift-up the vehicle, and then remove the rear Tightening torque: wheels.

  • Page 40: Rear Arm

    Rear Arm REAR SUSPENSION 4. Rear Arm 7) Remove the bolts which secure the brake hose bracket to rear arm. Remove the bolts which se- A: REMOVAL cure the ABS wheel speed sensor to rear arm. 1) Lift-up the vehicle, and then remove the rear wheels.

  • Page 41: Rear Arm

    Rear Arm REAR SUSPENSION 11) Remove the nuts which hold the rear arm to 14) Loosen the nut which hold the upper link to rear bracket. Remove the rear arm bracket. arm. RS-00050 15) Remove the bolt which secure the rear arm to the link, and then remove the rear arm.
  • Page 42 Rear Arm REAR SUSPENSION 8) Using the transmission jack, support the rear 3) Place the ST B on bushing, and push the bush- arm horizontally. ing out. 9) Tighten the nuts and bolts which hold the rear ST A 20099AE020 INSTALLER & REMOVER arm, front link, rear link, upper link and shock ab- sorber.
  • Page 43 Rear Arm REAR SUSPENSION 4) Place the ST B on bushing, and press-fit until E: INSPECTION each edge surface of bushing and rear arm comes Check the rear arm for bend, corrosion or damage. to be aligned. ST A 20099AE020 INSTALLER & REMOVER ST B 20099AE020 INSTALLER &...

  • Page 44: Upper Link

    Upper Link REAR SUSPENSION 5. Upper Link 2) Using new self-locking nuts, install the upper link. A: REMOVAL 1) Lift-up the vehicle, and then remove the rear wheels. 2) Using the transmission jack, support the rear arm horizontally. RS-00052 (1) Rear arm (2) Transmission jack NOTE: RS-00052...
  • Page 45 Upper Link REAR SUSPENSION CAUTION: Outer side bushing has an orientation. Assem- ble it with the longer protrusion faced to the rear side of vehicle. RS-00121 (1) Rear arm (2) Rear sub frame (3) Rear side of vehicle E: INSPECTION 1) Visually check the upper link for damage and de- formation.

  • Page 46: Rear Shock Absorber

    Rear Shock Absorber REAR SUSPENSION 6. Rear Shock Absorber CAUTION: Protect the rear link and sub frame from scratch A: REMOVAL in the way of putting a shop cloth between the 1) Remove the luggage floor mat. (Wagon model) jack and the mating portion. 2) Roll up the trunk side trim.
  • Page 47 Rear Shock Absorber REAR SUSPENSION F: DISPOSAL CAUTION: • Before handling shock absorbers, be sure to wear goggles to protect eyes from gas, oil and cutting powder. • Do not disassemble the shock absorber or place it into a fire. •...

  • Page 48: Front Link

    Front Link REAR SUSPENSION 7. Front Link 2) Using new self-locking nuts, install the front link. A: REMOVAL 1) Lift-up the vehicle, and then remove the rear wheels. 2) Using the transmission jack, support the rear arm horizontally. RS-00052 (1) Rear arm (2) Transmission jack CAUTION: Install the front link with the protrusion side...

  • Page 49: Rear Link

    Rear Link REAR SUSPENSION 8. Rear Link B: INSTALLATION 1) Using the transmission jack, support the rear A: REMOVAL arm horizontally. 1) Lift-up the vehicle, and then remove the rear 2) Using new self-locking nuts, install the rear link. wheels. 2) Remove the rear stabilizer.
  • Page 50 Rear Link REAR SUSPENSION D: ASSEMBLY Using the ST A and ST B, press-fit the bushing. ST A 20099AE000 INSTALLER & REMOVER ST B 20099AE000 INSTALLER & REMOVER ST-A ST-B RS-00083 E: INSPECTION Visually check the rear link for damage and defor- mation.

  • Page 51: Sub Frame Support Arm

    Sub Frame Support Arm REAR SUSPENSION 9. Sub Frame Support Arm A: REMOVAL 1) Lift-up the vehicle, and support the rear sub frame with support stand. 2) Remove the sub frame support arm. RS-00088 B: INSTALLATION Install in the reverse order of removal. Tightening torque: Sub frame support arm to Rear arm bracket ⋅...

  • Page 52: Sub Frame Support Plate

    Sub Frame Support Plate REAR SUSPENSION 10.Sub Frame Support Plate A: REMOVAL 1) Lift-up the vehicle, and support the rear sub frame with support stand. 2) Remove the sub frame support plate. FU-01134 B: INSTALLATION Install in the reverse order of removal. Tightening torque: Support plate to Sub frame ⋅...

  • Page 53: Rear Sub Frame

    Rear Sub Frame REAR SUSPENSION 11.Rear Sub Frame 3) Using the transmission jack, support the rear arm horizontally. Then tighten the nuts and bolts A: REMOVAL which hold the rear arm, front link, rear link, upper 1) Separate the front exhaust pipe from rear ex- link and shock absorber.

  • Page 54: Helper

    Helper REAR SUSPENSION 12.Helper A: REMOVAL 1) Lift-up the vehicle, and then remove the rear wheels. 2) Remove the helper using ST. ST 20099AE030 HELPER SOCKET WRENCH RS-00087 B: INSTALLATION Install in the reverse order of removal. Tightening torque: ⋅ 32 N m (3.3 kgf-m, 24 ft-lb) C: INSPECTION...

  • Page 55: General Diagnostic Table

    General Diagnostic Table REAR SUSPENSION 13.General Diagnostic Table A: INSPECTION 1. IMPROPER VEHICLE POSTURE OR IMPROPER WHEEL ARCH HEIGHT Possible cause Corrective action (1) Permanent distortion or breakage of coil spring Replace. (2) Rough operation of damper strut or shock absorber Replace.
  • Page 56 General Diagnostic Table REAR SUSPENSION RS-26...
  • Page 57 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 58 WHEEL AND TIRE SYSTEM Page General Description ..................2 Tire ......................4 Steel Wheel....................5 Aluminum Wheel ..................6 Wheel Balancing ..................7 “T-type” Tire ....................9 General Diagnostic Table................10...

  • Page 59: General Description

    General Description WHEEL AND TIRE SYSTEM 1. General Description A: SPECIFICATION 1. WHEEL AND TIRE SIZE WT-00001 (1) Offset (2) P.C.D. Tire inflation pressure Offset P.C.D. Specification Tire size Wheel size kPa (kgf/cm , psi) mm (in) mm (in) Front wheel Rear wheel ×...
  • Page 60 General Description WHEEL AND TIRE SYSTEM 2. SERVICE DATA Balance weight part number (Adhesive type weight for alumi- Weight Part Axial runout Radial runout num wheel) Steel wheel 1.5 mm (0.059 in) 28101AG000 5 g (0.18 oz) Aluminum wheel 1.0 mm (0.039 in) 28101AG010 7.5 g (0.26 oz) 28101AG020...

  • Page 61: Tire

    Tire WHEEL AND TIRE SYSTEM 2. Tire A: INSPECTION 1) Take stones, glass, nails etc. out of the tread groove. 2) Replace the tire if as follows. CAUTION: When replacing a tire, make sure to use only the same size, construction and load range as originally installed.

  • Page 62: Steel Wheel

    Steel Wheel WHEEL AND TIRE SYSTEM 3. Steel Wheel 3) Slowly rotate the wheel to check rim “runout” us- ing a dial gauge. A: REMOVAL 1) Apply the parking brake, and position the select lever to “P” or “LOW”. 2) Set the shop jacks or a lift to specified point, and support the vehicle with its wheels slightly contact- ing the floor.

  • Page 63: Aluminum Wheel

    Aluminum Wheel WHEEL AND TIRE SYSTEM 4. Aluminum Wheel A: REMOVAL Refer to “Steel Wheel” for removal procedure of aluminum wheels. <Ref. to WT-5, REMOVAL, Steel Wheel.> B: INSTALLATION Refer to “Steel Wheel” for installation procedure of aluminum wheels. <Ref. to WT-5, INSTALLATION, Steel Wheel.>...

  • Page 64: Wheel Balancing

    32.5 g (1.15 oz) wheel balancer. 28101AG120 35 g (1.23 oz) CAUTION: 28101AG130 37.5 g (1.32 oz) Use SUBARU genuine balance weight. 28101AG140 40 g (1.41 oz) 28101AG150 42.5 g (1.50 oz) Balance weight part number 28101AG160 45 g (1.59 oz)

  • Page 65: Wheel Balancing

    Wheel Balancing WHEEL AND TIRE SYSTEM 5) Using the wheel balancer, measure the wheel balance again. Check that wheel balance is cor- rectly adjusted. NOTE: • 55 g (1.94 oz) knock-on type weight used with aluminum wheel is not available. •...

  • Page 66: T-Type" Tire

    “T-type” Tire WHEEL AND TIRE SYSTEM 6. “T-type” Tire A: NOTE “T-type” tire for temporary use is prepared as a spare tire. (Except for KA, KS model) CAUTION: • Do not use a tire chain with the “T-type” tire. Because of the smaller tire size, a tire chain will not fit properly and will result in damage to the vehicle and the tire.

  • Page 67: General Diagnostic Table

    General Diagnostic Table WHEEL AND TIRE SYSTEM 7. General Diagnostic Table A: INSPECTION Symptom Possible cause Corrective action Wheel wobble. Improperly inflated tire. Adjust the tire pressure. Uneven wear Check the tire referring to Abnormal tire wear in this table, carry out the procedure and replace the tire.
  • Page 68 General Diagnostic Table WHEEL AND TIRE SYSTEM Symptom Possible cause Corrective action Abnormal tire wear Improperly inflated tire. Adjust the tire pressure. Improper wheel balancing Check the wheel balance. <Ref. to WT-7, ADJUSTMENT, Wheel Bal- ancing.> Front wheel alignment Check the front wheel alignments. <Ref.
  • Page 69 General Diagnostic Table WHEEL AND TIRE SYSTEM WT-12...
  • Page 70 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 71 DIFFERENTIALS Page General Description ..................2 Differential Gear Oil...................26 Front Differential Assembly ...............28 Rear Differential (T-type)................29 Rear Differential (VA-type) ................46 Rear Differential Front Oil Seal ..............72 Rear Differential Side Oil Seal ..............74 Rear Differential Front Member..............75 General Diagnostic Table................76...

  • Page 72: General Description

    General Description DIFFERENTIALS 1. General Description A: SPECIFICATION 1. REAR DIFFERENTIAL When replacing a rear differential assembly, select the correct one according to the following table. NOTE: • Using the different rear differential assembly causes the drive line and tires to “drag” or emit noise. •...

  • Page 73: Rear Differential Gear Oil

    General Description DIFFERENTIALS 2. CLASSIFICATION • VA2-type Identification label positions are shown in the fol- lowing figures. For details concerning identification, refer to “ID” section. • T-type DI-00397 (1) Identification 3. REAR DIFFERENTIAL GEAR OIL ID-00056 Recommended gear oil: GL-5 (75W-90) (1) Identification NOTE: •...
  • Page 74 General Description DIFFERENTIALS 5. ADJUSTING PART • T-type Drive pinion bearing preload (at companion 18.1 — 38.8 (1.8 — 4.0, 4.1 — 8.7) flange bolt hole) N (kgf, lb) Part No. Length mm (in) 383695201 56.2 (2.213) 383695202 56.4 (2.220) Preload adjusting collar 383695203 56.6 (2.228)
  • Page 75 General Description DIFFERENTIALS Part No. Thickness mm (in) 383445201 0.75 — 0.80 (0.0295 — 0.0315) Side gear thrust washer (Model without LSD) 383445202 0.80 — 0.85 (0.0315 — 0.0335) 383445203 0.85 — 0.90 (0.0335 — 0.0354) Side bearing standard width mm (in) —...
  • Page 76 General Description DIFFERENTIALS • VA1-type Drive pinion bearing preload (at companion 12.7 — 32.4 (1.3 — 3.3, 2.9 — 7.3) flange bolt hole) N (kgf, lb) Part No. Length mm (in) 32288AA040 52.3 (2.059) 32288AA050 52.5 (2.067) 31454AA100 52.6 (2.071) 32288AA060 52.7 (2.075) Preload adjusting collar...
  • Page 77 General Description DIFFERENTIALS • VA2-type Drive pinion bearing preload (at companion 12.7 — 32.4 (1.3 — 3.9, 2.9 — 7.3) flange bolt hole) N (kgf, lb) Part No. Length mm (in) 31454AA250 51.05 (2.010) 31454AA260 51.25 (2.018) 31454AA270 51.35 (2.022) 31454AA280 51.45 (2.026) Preload adjusting collar...
  • Page 78 General Description DIFFERENTIALS B: COMPONENT 1. REAR DIFFERENTIAL WITHOUT LSD (T-TYPE) ( 1 ) (18) (19) (21) ( 2 ) (20) ( 3 ) ( 4 ) (19) ( 5 ) (20) (18) (21) ( 1 ) (23) (22) (25) (26) (27) (16)
  • Page 79 General Description DIFFERENTIALS 2. REAR DIFFERENTIAL WITH LSD (T-TYPE) (21) (22) (23) (20) (15) (19) (24) (13) (17) (18) (16) (14) (14) (15) (13) (16) (17) (10) (11) (12) DI-00002 Hypoid driven gear and drive pin- (11) Companion flange (22) Stud bolt ion set (12)
  • Page 80 General Description DIFFERENTIALS 3. REAR DIFFERENTIAL (VA1-TYPE) (18) (19) (20) (19) (17) (16) (15) (14) (30) (13) (10) (11) (12) DI-00296 Hypoid driven gear and drive pin- (13) Lock plate (26) Gasket ion set (14) Side bearing (27) Oil filler plug Pinion height adjusting washer (15) O-ring...
  • Page 81 General Description DIFFERENTIALS 4. REAR DIFFERENTIAL (VA2-TYPE) (17) (16) (18) (15) (14) (20) (25) (19) (23) (13) (22) (21) (21) (24) (13) (14) (15) (16) (17) (10) (11) (12) DI-00349 Hypoid driven gear and drive pin- (11) Companion flange (22) Oil filler plug ion set (12)
  • Page 82 General Description DIFFERENTIALS 5. REAR DIFFERENTIAL MOUNTING SYSTEM DI-00350 ⋅ Rear differential front member Sub frame Tightening torque: N m (kgf-m, ft-lb) Rear differential member plate Self-locking nut T1: 52 (5.3, 38) Rear differential ASSY T2: 70 (7.1, 51) T3: 110 (11.2, 81) DI-12...
  • Page 83 • Avoid damaging the mating surface of the case. • Use SUBARU genuine gear oil, grease etc. or the equivalent. Do not mix gear oil, grease etc. with that of another grade or from other manufacturers.
  • Page 84 General Description DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 498447120 INSTALLER Used for installing front oil seal. ST-498447120 498427200 FLANGE WRENCH Used for stopping rotation of companion flange when removing and tightening self-locking nut. ST-498427200 398467700 DRIFT • Used for removing pinion, pilot bearing and front bearing cone.
  • Page 85 General Description DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 899580100 INSTALLER Used for press-fitting front bearing cone and pilot bearing. ST-899580100 899904100 STRAIGHT PIN Used for driving out differential pinion shaft lock REMOVER pin. ST-899904100 498247001 MAGNET BASE • Used for measuring backlash between side gear and pinion, and hypoid gear.
  • Page 86 General Description DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 398507704 BLOCK • Used for adjusting pinion height and preload. • For T-type and VA1-type ST-398507704 398177700 INSTALLER • Used for installing rear bearing cone. • For T-type and VA2-type ST-398177700 398457700 ATTACHMENT •...
  • Page 87 General Description DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 398437700 DRIFT • Used for installing side oil seal. • For T-type and VA2-type ST-398437700 398507702 DUMMY SHAFT • Used for adjusting pinion height and preload. • For T-type ST-398507702 398507703 DUMMY COLLAR •...
  • Page 88 General Description DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 398487700 DRIFT • Used for press-fitting side bearing cone. • For T-type and VA2-type ST-398487700 398507701 DIFFERENTIAL • Used for adjusting pinion height. CARRIER GAUGE • For T-type ST-398507701 398527700 PULLER ASSY •...
  • Page 89 General Description DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 28099PA090 OIL SEAL PROTEC- • Used for installing the rear drive shaft to rear differential. • For oil seal protection ST28099PA090 398237700 DRIFT • Used for installing side bearing. • For T-type ST-398237700 28099PA100 DRIVE SHAFT...
  • Page 90 General Description DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 899874100 INSTALLER Used for installing companion flange. ST-899874100 498077000 REMOVER • Used for removing side bearing cone from dif- ferential. • For VA2-type ST-498077000 899864100 REMOVER Used for removing differential side bearing. ST-899864100 499277200 INSTALLER...
  • Page 91 General Description DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 18758AA000 PULLER • Used for removing side bearing cup. • For VA2-type ST18758AA000 18759AA000 PULLER ASSY • Used for removing differential from side bear- (Newly adopted tool) ing cone. • For T-type ST18759AA000 18678AA000 DUMMY SHAFT...
  • Page 92 General Description DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 18630AA010 WRENCH ASSY • Used for removing and installing side oil seal (Newly adopted tool) holder. • For VA2-type NOTE: Also available for VA1-type. ST18630AA010 498175500 INSTALLER • Used for installing rear bearing cone. •...
  • Page 93 General Description DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 399520105 SEAT • Used for removing side bearing cone. • Used with PULLER SET (899524100). • For VA-type ST-399520105 498485400 DRIFT • Used for installing side bearing cone. • For VA1-type ST-498485400 498505501 DIFFERENTIAL •...
  • Page 94 General Description DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 498447150 DUMMY SHAFT • Used for adjusting pinion height and preload. • For VA1-type ST-498447150 498515500 REPLACER • Used for removing rear bearing cone. • For VA1-type ST-498515500 32285AA000 DUMMY COLLAR • Used for adjusting pinion height and preload. •...
  • Page 95 General Description DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499705401 PULLER ASSY • Used for removing side bearing race. • Used with SEAT (499705404). • For VA-type ST-499705401 2. GENERAL PURPOSE TOOL TOOL NAME REMARKS Transmission jack Used for assembly/disassembly of rear differential. Puller Used for removal of side bearing retainer.

  • Page 96: Differential Gear Oil

    Differential Gear Oil DIFFERENTIALS 2. Differential Gear Oil • Except for VA2-type A: INSPECTION 1) Remove the filler plug, and then check the gear oil. If it is contaminated or deteriorated, replace the gear oil. <Ref. to DI-26, REPLACEMENT, Differen- tial Gear Oil.>...
  • Page 97 Differential Gear Oil DIFFERENTIALS Recommended gear oil: <Ref. to DI-2, SPECIFICATION, General De- scription.> Oil capacity: 0.8 2 (0.8 US qt, 0.7 Imp qt) • Except for VA2-type DI-00391 (A) Filler plug (B) Drain plug • VA2-type DI-00355 (A) Filler plug (B) Drain plug 5) Install the filler plug.

  • Page 98: Front Differential Assembly

    Front Differential Assembly DIFFERENTIALS 3. Front Differential Assembly A: NOTE 1. AT MODEL • 4AT For front differential of 4AT model, refer to “4AT” section. <Ref. to 4AT-113, Front Differential As- sembly.> • 5AT For front differential of 5AT model, refer to “5AT” section.

  • Page 99: Rear Differential (T-Type)

    Rear Differential (T-type) DIFFERENTIALS 4. Rear Differential (T-type) ST 28099PA100 DRIVE SHAFT REMOVER A: REMOVAL 1) Disconnect the ground cable from battery. 2) Move the select lever or gear shift lever to neu- tral. 3) Loosen the wheel nuts. 4) Release the parking brake. 5) Jack-up the vehicle and support it with rigid racks.
  • Page 100 Rear Differential (T-type) DIFFERENTIALS 20) Secure the rear drive shaft to lateral link using NOTE: wire. When removing the stud bolt, carefully adjust the angle and location of transmission jack and jack stand, if necessary. DI-00277 21) Remove the rear differential member plate from rear differential.
  • Page 101 Rear Differential (T-type) DIFFERENTIALS 3) Install the ST to rear differential. 8) After inserting the rear differential stud bolt into rear crossmember bushing, lift up the transmission ST 28099PA090 OIL SEAL PROTECTOR jack and align the rear differential with its own posi- tion.
  • Page 102 Rear Differential (T-type) DIFFERENTIALS 12) Tighten the self-locking nut. C: DISASSEMBLY To detect the real cause of trouble, inspect the fol- Tightening torque: ⋅ lowing items before disassembling. 70 N m (7.1 kgf-m, 51 ft-lb) • Tooth contact of hypoid driven gear and drive pinion, and backlash •...
  • Page 103 Rear Differential (T-type) DIFFERENTIALS 4) Remove the bolts, and then remove the rear 7) When replacing the side bearing, remove the cover. bearing cup from side bearing retainer using ST. ST 398527700 PULLER ASSY NOTE: Remove it by tapping with plastic hammer. DI-00066 8) Extract the bearing cone with ST.
  • Page 104 Rear Differential (T-type) DIFFERENTIALS ST 899904100 STRAIGHT PIN REMOVER 13) Extract the companion flange with a puller. DI-00237 DI-00072 11) Draw out the pinion mate shaft and remove pin- 14) Press the end of drive pinion shaft and extract it ion mate gears, side gears and thrust washers.
  • Page 105 Rear Differential (T-type) DIFFERENTIALS 16) Remove the front oil seal from differential carri- D: ASSEMBLY er using ST. NOTE: ST 398527700 PULLER ASSY • Assemble in the reverse order of disassembly. • Check and adjust each part during assembly. • Keep the shims and washers in order, so that they are not improperly installed.
  • Page 106 Rear Differential (T-type) DIFFERENTIALS (3) Measure and record the thickness of pinion • Measure the preload in direction of tangent to height adjust washer. flange. ST1 398507702 DUMMY SHAFT NOTE: ST2 398507704 BLOCK If tooth contact (drive pinion, hypoid driven gear) is normal in the inspection before disassembling, ver- Tightening torque: ify that the washer is not deformed, and then re-use...
  • Page 107 Rear Differential (T-type) DIFFERENTIALS NOTE: Part No. Length mm (in) Use copies of this page. 383695201 56.2 (2.213) 383695202 56.4 (2.220) Thickness of pinion height adjusting Preload adjusting 383695203 56.6 (2.228) washer mm (in) collar 383695204 56.8 (2.236) Thickness of washer temporally 383695205 57.0 (2.244) inserted mm (in)
  • Page 108 Rear Differential (T-type) DIFFERENTIALS 3) Install the selected pinion height adjusting wash- 6) Insert the collar, then press-fit the pilot bearing er on drive pinion, and press the rear bearing cone with ST1 and ST2. into position with ST. ST1 399780104 WEIGHT ST 398177700 INSTALLER...
  • Page 109 Rear Differential (T-type) DIFFERENTIALS 9) Install a new self-locking nut and secure the (1) Measure the side gear backlash. companion flange using ST and tighten the nut. Side gear backlash: ST 498427200 FLANGE WRENCH 0.10 — 0.20 mm (0.0039 — 0.0079 in) Tightening torque: ⋅...
  • Page 110 Rear Differential (T-type) DIFFERENTIALS 12) Press the side bearing into differential case us- (4) Align the arrow mark on differential carrier ing ST. with the mark on side retainer during installation. ST 398227700 DRIFT NOTE: Be careful that side bearing outer race is not dam- aged by bearing roller.
  • Page 111 Rear Differential (T-type) DIFFERENTIALS Backlash: Hypoid driven gear runout on its back surface: 0.10 — 0.20 mm (0.0039 — 0.0079 in) 0.05 mm (0.0020 in) DI-00099 DI-00101 (7) At the same time, measure the total preload 17) Checking and adjusting the tooth contact of hy- of drive pinion.
  • Page 112 Rear Differential (T-type) DIFFERENTIALS • Face contact • Toe contact (inside end contact) Checking item: Backlash is too large. Checking item: Contact areas is small Contact pattern Contact pattern AT-00208 AT-00210 Corrective action: Increase thickness of drive pin- Corrective action: Reduce thickness of drive pinion ion height adjusting washer in order to bring drive height adjusting washer in order to bring drive pin- pinion close to hypoid driven gear.
  • Page 113 Rear Differential (T-type) DIFFERENTIALS 18) If proper tooth contact is not obtained, once 25) Install the breather cap. again adjust the drive pinion height by changing RH 26) Install the drain plug and filler plug. and LH side bearing retainer shims and the hypoid Tightening torque: gear backlash.
  • Page 114 Rear Differential (T-type) DIFFERENTIALS If the side gear backlash is not within the specifica- 4. TOOTH CONTACT BETWEEN HYPOID tion, adjust it as specified by selecting side gear DRIVEN GEAR AND DRIVE PINION thrust washer. Inspect the tooth contact between hypoid driven gear and drive pinion.
  • Page 115 Rear Differential (T-type) DIFFERENTIALS 3) Set the gauge inside of the companion flange, and measure the runout. Limit of runout: 0.08 mm (0.0031 in) DI-00361 4) If either runout exceeds the limit, move the phase of companion flange and drive pinion 90° each, and find the point where the runout is within the limit.

  • Page 116: Rear Differential (Va-Type)

    Rear Differential (VA-type) DIFFERENTIALS 5. Rear Differential (VA-type) 12) Remove the DOJ of rear drive shaft from rear differential. A: REMOVAL 1) Disconnect the ground cable from battery. 2) Move the select lever or gear shift lever to neu- tral. 3) Loosen the wheel nuts.
  • Page 117 Rear Differential (VA-type) DIFFERENTIALS 18) Remove the rear differential stud bolt from rear 22) Secure the rear drive shaft to lateral link using crossmember bushing. wire. NOTE: When removing the stud bolt, carefully adjust the angle and location of transmission jack and jack stand, if necessary.
  • Page 118 Rear Differential (VA-type) DIFFERENTIALS 3) Install the ST to rear differential. 8) After inserting the rear differential stud bolt into rear crossmember bushing, lift up the transmission ST 28099PA090 OIL SEAL PROTECTOR jack and align the rear differential to the height of rear differential.
  • Page 119 Rear Differential (VA-type) DIFFERENTIALS 12) Tighten the self-locking nut. 3) Remove the rear cover by loosening retaining bolts. Tightening torque: ⋅ 70 N m (7.1 kgf-m, 51 ft-lb) DI-00130 4) Remove the air breather cap. DI-00269 NOTE: 13) Lower the transmission jack. •...
  • Page 120 Rear Differential (VA-type) DIFFERENTIALS 6) Remove the holder RH and LH with ST. NOTE: ST 499785500 WRENCH ASSY Perform this operation only when changing oil seal. DI-00133 DI-00136 7) Pull out the differential case assembly from dif- 10) Extract the bearing cone with ST1 and ST2. ferential carrier.
  • Page 121 Rear Differential (VA-type) DIFFERENTIALS ST 899904100 STRAIGHT PIN REMOVER 15) Extract the companion flange with a puller. DI-00237 DI-00142 13) Draw out the pinion mate shaft and remove pin- (A) Companion flange ion mate gears, side gears and thrust washers. (B) Puller NOTE: 16) Press the end of drive pinion shaft and extract it...
  • Page 122 Rear Differential (VA-type) DIFFERENTIALS 18) Remove the front oil seal from differential carri- 2. VA2-TYPE er using ST. To detect the real cause of trouble, inspect the fol- ST 398527700 PULLER SET lowing items before disassembling. • Tooth contact and backlash between hypoid driv- en gear and drive pinion •...
  • Page 123 Rear Differential (VA-type) DIFFERENTIALS 5) Remove the holder RH and LH with ST. • Set the puller so that its claws catch the groove of holder. ST 18630AA010 WRENCH DI-00367 DI-00365 6) Pull out the differential case assembly from dif- (A) Groove ferential carrier.
  • Page 124 Rear Differential (VA-type) DIFFERENTIALS ST1 498077000 REMOVER 13) Removes the drive pinion shaft. ST2 399520105 SEAT 14) Remove the rear bearing cone from drive pin- ST3 899864100 REMOVER ion by supporting cone with ST. NOTE: Place the replacer so that its center-recessed side faces the pinion gear.
  • Page 125 Rear Differential (VA-type) DIFFERENTIALS D: ASSEMBLY ST1 398477701 HANDLE ST2 498447110 DRIFT 1. VA1-TYPE (3) Insert the front bearing cone. NOTE: NOTE: • Assemble in the reverse order of disassembly. Use new front bearing cone. • Check and adjust each part during assembly. (4) Measure and record the thickness of pinion •...
  • Page 126 Rear Differential (VA-type) DIFFERENTIALS NOTE: Part No. Length mm (in) • Use a new self-locking nut. 32288AA040 52.3 (2.059) • Be careful not to give excessive preload. 32288AA050 52.5 (2.067) • When tightening the self-locking nut, lock ST1 31454AA100 52.6 (2.071) with ST2 as shown in the figure.
  • Page 127 Rear Differential (VA-type) DIFFERENTIALS (3) Obtain the thickness of pinion height adjust- 4) Insert the drive pinion into differential carrier, in- ing washer to be inserted from the following for- stall the selected bearing preload adjusting collar mula, and replace the temporarily installed and washer.
  • Page 128 Rear Differential (VA-type) DIFFERENTIALS ST 498447120 INSTALLER • Insert the pinion mate shaft into the differential case by aligning the lock pin holes. DI-00089 8) Press-fit the companion flange with ST1 and ST2. NOTE: Be careful not to damage the bearing. ST1 899874100 INSTALLER ST2 399780104...
  • Page 129 Rear Differential (VA-type) DIFFERENTIALS 11) Install the hypoid driven gear on differential (2) Install the bearing race into holder RH and case. ST 398477702 DRIFT NOTE: • Before installing bolts, apply Lock Tite to bolt CAUTION: threads. Make sure that the oil seal, bearing outer race and cone are properly assembled.
  • Page 130 Rear Differential (VA-type) DIFFERENTIALS (2) Screw in the side holder LH until light con- Backlash: tact is made with ST. 0.10 — 0.15 mm (0.0039 — 0.0059 in) ST 499785500 WRENCH DI-00172 DI-00133 15) Draw a matching mark on both differential car- (3) Back off the side (hypoid driven gear side) rier and holder.
  • Page 131 Rear Differential (VA-type) DIFFERENTIALS 17) Recheck the hypoid driven gear to pinion back- • Face contact lash. Checking item: Backlash is too large. Contact pattern Backlash: 0.10 — 0.15 mm (0.0039 — 0.0059 in) AT-00208 Corrective action: Increase thickness of drive pin- DI-00172 ion height adjusting washer in order to bring drive 18) Checking and adjusting the tooth contact of hy-...
  • Page 132 Rear Differential (VA-type) DIFFERENTIALS • Toe contact (inside end contact) 19) If proper tooth contact is not obtained, once again adjust the drive pinion height and the differ- Checking item: Contact areas is small ential side bearing preload (already mentioned) Contact pattern and the hypoid gear backlash.
  • Page 133 Rear Differential (VA-type) DIFFERENTIALS 1) Adjusting preload for front and rear bearings: ST1 18678AA000 DUMMY SHAFT Adjust the bearing preload with collar and washer between front and rear bearings. Pinion height ad- justing washer are not affected by this adjustment. The adjustment must be carried out without oil seal inserted.
  • Page 134 Rear Differential (VA-type) DIFFERENTIALS Tightening torque: 2) Adjusting drive pinion height: ⋅ 191 N m (19.5 kgf-m, 141 ft-lb) Adjust the drive pinion height with washer installed between the rear bearing cone and the back of pin- ion gear. (1) Install the ST2. ST1 18678AA000 DUMMY SHAFT ST2 18831AA010 DIFFERENTIAL CARRIER GAUGE...
  • Page 135 Rear Differential (VA-type) DIFFERENTIALS (4) Obtain the thickness of pinion height adjust- 4) Insert the drive pinion into differential carrier, in- ing washer to be inserted from the following for- stall the previously selected bearing preload adjust- mula, and replace the temporarily installed ing collar and washer.
  • Page 136 Rear Differential (VA-type) DIFFERENTIALS 7) Fit a new oil seal with ST. 10) Install the hypoid driven gear on differential case. NOTE: NOTE: • Press-fit until end of oil seal is 1 mm (0.04 in) in- ward from end of carrier. •...
  • Page 137 Rear Differential (VA-type) DIFFERENTIALS (2) Install the bearing race into holder RH and (2) Screw in the side holder LH until light con- tact is made with ST. ST 398487700 DRIFT ST 18630AA010 WRENCH CAUTION: Make sure that the oil seal, bearing outer race and cone are properly assembled.
  • Page 138 Rear Differential (VA-type) DIFFERENTIALS Backlash: 16) Recheck the hypoid driven gear to pinion back- lash. 0.10 — 0.15 mm (0.0039 — 0.0059 in) Backlash: 0.10 — 0.15 mm (0.0039 — 0.0059 in) DI-00172 14) Draw a matching mark on both differential car- rier and holder.
  • Page 139 Rear Differential (VA-type) DIFFERENTIALS • Face contact • Toe contact (inside end contact) Checking item: Backlash is too large. Checking item: Contact areas is small Contact pattern Contact pattern AT-00208 AT-00210 Corrective action: Increase thickness of drive pin- Corrective action: Reduce thickness of drive pinion ion height adjusting washer in order to bring drive height adjusting washer in order to bring drive pin- pinion close to hypoid driven gear.
  • Page 140 Rear Differential (VA-type) DIFFERENTIALS 18) If proper tooth contact is not obtained, once 1. SIDE GEAR BACKLASH again adjust the drive pinion height and the differ- Using a dial gauge, check the backlash of the side ential side bearing preload (already mentioned) gear.
  • Page 141 Rear Differential (VA-type) DIFFERENTIALS Limit of runout: 3. TOOTH CONTACT BETWEEN HYPOID 0.08 mm (0.003 in) DRIVEN GEAR AND DRIVE PINION Adjust the tooth contact between hypoid driven gear and drive pinion gear. <Ref. to DI-55, ASSEMBLY, Rear Differential (VA- type).>...

  • Page 142: Rear Differential Front Oil Seal

    Rear Differential Front Oil Seal DIFFERENTIALS 6. Rear Differential Front Oil Tightening torque: T-type: Seal ⋅ 49 N m (5.0 kgf-m, 36.2 ft-lb) VA1-type: A: INSPECTION ⋅ 34 N m (3.5 kgf-m, 25.3 ft-lb) Make sure that there is no leakage from front oil For VA2-type: seal portion.
  • Page 143 Rear Differential Front Oil Seal DIFFERENTIALS 12) Install a new oil seal with ST. ST 498447120 OIL SEAL INSTALLER DI-00292 13) Install the companion flange. NOTE: Use a plastic hammer to install companion flange. 14) Tighten the self-locking nut within the specified torque range so that the turning resistance of com- panion flange becomes the same as that of before oil seal replacement.

  • Page 144: Rear Differential Side Oil Seal

    Rear Differential Side Oil Seal DIFFERENTIALS 7. Rear Differential Side Oil Seal A: INSPECTION Make sure that there is no leakage from side oil seal. If there is any leakage, replace the oil seal. B: REPLACEMENT 1) Remove the rear differential. <Ref. to DI-29, RE- MOVAL, Rear Differential (T-type).>...

  • Page 145: Rear Differential Front Member

    Rear Differential Front Member DIFFERENTIALS 8. Rear Differential Front Mem- A: REMOVAL 1) Disconnect the ground cable from battery. 2) Lift-up the vehicle. 3) Support the rear differential using transmission jack, and then remove the rear differential front member. DI-00293 (A) Rear differential front member B: INSTALLATION Install the rear differential front member with a new...

  • Page 146: General Diagnostic Table

    General Diagnostic Table DIFFERENTIALS 9. General Diagnostic Table A: INSPECTION Symptom or trouble Possible cause Remedy 1. Oil leakage (1) Worn, scratched or incorrectly seated Correct or replace. front or side oil seal. Scored, battered or excessively worn sliding surface of com- panion flange.
  • Page 147 General Diagnostic Table DIFFERENTIALS Symptom or trouble Possible cause Remedy 6. Gear noise (1) Improper tooth contact of hypoid gear. Readjust or replace hypoid gear set. NOTE: (2) Improper backlash for hypoid gear. Readjust. Since noises from engine, muffler, trans- (3) Scored or chipped teeth of hypoid Replace hypoid gear set.
  • Page 148 General Diagnostic Table DIFFERENTIALS DI-78...
  • Page 149 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 150 TRANSFER CASE Page General Description ..................2 Transfer Case and Extension Case Assembly..........3 Transfer Clutch....................4 Extension Case ...................5 Extension Case and Intermediate Case............6 Oil Seal......................7 Transfer Drive Gear ..................8 Transfer Driven Gear ..................9 Reduction Drive Gear................10 Center Differential Carrier .................11 Reduction Driven Gear................12 Center Differential ..................13 Transfer Clutch Pressure Test ..............14...

  • Page 151: General Description

    General Description TRANSFER CASE 1. General Description A: NOTE For general description, refer to “4AT”, “5AT” or “5MT” section. 4AT model: <Ref. to 4AT-2, General Description.> 5AT model: <Ref. to 5AT-2, General Description.> 5MT model: <Ref. to 5MT-2, General Description.> TC-2...

  • Page 152: Transfer Case And Extension Case Assembly

    Transfer Case and Extension Case Assembly TRANSFER CASE 2. Transfer Case and Extension Case Assembly A: NOTE For removal, installation and inspection, refer to “5MT” section. <Ref. to 5MT-44, Transfer Case and Extension Case Assembly.> TC-3...

  • Page 153: Transfer Clutch

    Transfer Clutch TRANSFER CASE 3. Transfer Clutch A: NOTE For removal, installation and inspection, refer to “4AT” or “5AT” section. 4AT model: <Ref. to 4AT-86, Transfer Clutch.> 5AT model: <Ref. to 5AT-74, Transfer Clutch.> TC-4...

  • Page 154: Extension Case

    Extension Case TRANSFER CASE 4. Extension Case A: NOTE For removal, installation and inspection, refer to “4AT” section. <Ref. to 4AT-82, Extension Case.> TC-5...

  • Page 155: Extension Case And Intermediate Case

    Extension Case and Intermediate Case TRANSFER CASE 5. Extension Case and Interme- diate Case A: NOTE For removal, installation and inspection, refer to “5AT” section. <Ref. to 5AT-72, Extension Case & Intermediate Case.> TC-6...

  • Page 156: Oil Seal

    Oil Seal TRANSFER CASE 6. Oil Seal A: NOTE For replacement and inspection, refer to “4AT”, “5AT” or “5MT” section. 4AT model: <Ref. to 4AT-50, Extension Case Oil Seal.> <Ref. to 4AT-51, Differential Side Retainer Oil Seal.> 5AT model: <Ref. to 5AT-49, Extension Case Oil Seal.> <Ref. to 5AT-50, Differential Side Retainer Oil Seal.>...

  • Page 157: Transfer Drive Gear

    Transfer Drive Gear TRANSFER CASE 7. Transfer Drive Gear A: NOTE For removal, installation and inspection, refer to “5MT” section. <Ref. to 5MT-48, Transfer Drive Gear.> TC-8...

  • Page 158: Transfer Driven Gear

    Transfer Driven Gear TRANSFER CASE 8. Transfer Driven Gear A: NOTE For removal, installation and inspection, refer to “5MT” section. <Ref. to 5MT-50, Transfer Driven Gear.> TC-9...

  • Page 159: Reduction Drive Gear

    Reduction Drive Gear TRANSFER CASE 9. Reduction Drive Gear A: NOTE For removal, installation and inspection, refer to “4AT” section. <Ref. to 4AT-96, Reduction Drive Gear.> TC-10...

  • Page 160: Center Differential Carrier

    Center Differential Carrier TRANSFER CASE 10.Center Differential Carrier A: NOTE For removal, installation and inspection, refer to “4AT” or “5AT” section. 4AT model: <Ref. to 4AT-98, Center Differential Carrier.> 5AT model: <Ref. to 5AT-80, Center Differential Carrier.> TC-11...

  • Page 161: Reduction Driven Gear

    Reduction Driven Gear TRANSFER CASE 11.Reduction Driven Gear A: NOTE For removal, installation and inspection, refer to “4AT” or “5AT” section. 4AT model: <Ref. to 4AT-94, Reduction Driven Gear.> 5AT model: <Ref. to 5AT-78, Reduction Driven Gear.> TC-12...

  • Page 162: Center Differential

    Center Differential TRANSFER CASE 12.Center Differential A: NOTE For removal, installation and inspection, refer to “5MT” section. <Ref. to 5MT-52, Center Differen- tial.> TC-13...

  • Page 163: Transfer Clutch Pressure Test

    Transfer Clutch Pressure Test TRANSFER CASE 13.Transfer Clutch Pressure Test A: NOTE For inspection, refer to “4AT” or “5AT” section. 4AT model: <Ref. to 4AT-39, Transfer Clutch Pressure Test.> 5AT model: <Ref. to 5AT-36, Transfer Clutch Pressure Test.> TC-14...
  • Page 164 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 165 DRIVE SHAFT SYSTEM Page General Description ..................2 Propeller Shaft ..................10 Front Axle....................13 Front Hub Unit Bearing ................17 Rear Hub Unit Bearing ................19 Front Drive Shaft ..................22 Rear Drive Shaft..................26 General Diagnostic Table................30...

  • Page 166: General Description

    General Description DRIVE SHAFT SYSTEM 1. General Description A: SPECIFICATION 1. PROPELLER SHAFT Model Propeller shaft type Propeller shaft length: L mm (in) 1490 (58.66) 1430 (56.30) 1317 (51.85) Front propeller shaft Joint-to-joint length: L mm (in) 735 (28.9) 675 (26.6) 562 (22.1) Rear propeller shaft Joint-to-Joint length: L mm (in)
  • Page 167 General Description DRIVE SHAFT SYSTEM 2. FRONT DRIVE SHAFT ASSEMBLY Axle diameter φ D Axle length L Model Type of drive shaft mm (in) mm (in) Turbo AT, 3.0 L EBJ87+PTJ82 32 (1.3) 349.6 (13.76) Except turbo AT, 3.0 L EBJ87+PTJ82 26 (1.0) 349.6 (13.76)
  • Page 168 General Description DRIVE SHAFT SYSTEM B: COMPONENT 1. PROPELLER SHAFT DS-00229 ⋅ Propeller shaft Rear differential (T-type) Tightening torque: N m (kgf-m, ft-lb) Bushing Rear differential (VA2-type) T1: 31 (3.2, 23.1) Rear differential (VA1-type) T2: 52 (5.3, 38.3) DS-4...
  • Page 169 General Description DRIVE SHAFT SYSTEM 2. FRONT AXLE (10) (14) (11) (12) (13) DS-00232 Spring pin Boot band (13) Front hub unit bearing Baffle plate Boot (PTJ) (14) Axle nut Outer race (PTJ) Boot (EBJ) ⋅ Snap ring (10) EBJ shaft ASSY Tightening torque: N m (kgf-m, ft-lb) Trunnion...

  • Page 170: Rear Axle

    General Description DRIVE SHAFT SYSTEM 3. REAR AXLE (10) (11) (12) (13) (14) DS-00233 Baffle plate (DOJ) Boot band (12) Rear hub unit bearing Outer race (DOJ) Boot (DOJ) (13) Hub bolt Snap ring (10) Boot (BJ) (14) Axle nut (olive color) Inner race (11) BJ shaft ASSY (2.0 L Non-turbo...
  • Page 171 General Description DRIVE SHAFT SYSTEM C: CAUTION • Use SUBARU genuine grease etc. or the equiv- alent. Do not mix grease, etc. with that of another • Wear work clothing, including a cap, protective grade or from other manufacturers. goggles, and protective shoes during operation.
  • Page 172 General Description DRIVE SHAFT SYSTEM ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 18675AA000 DIFFERENTIAL Used for installing differential side retainer oil SIDE OIL SEAL seal. INSTALLER ST18675AA000 927080000 HUB STAND Used for assembling hub bolt in hub. ST-927080000 927140000 AXLE SHAFT Same as plate 2 included in AXLE SHAFT PULLER PLATE PULLER (926470000).
  • Page 173 General Description DRIVE SHAFT SYSTEM ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 28399SA010 OIL SEAL PROTEC- • Used for installing front drive shaft into front differential. • For protecting oil seal. ST28399SA010 28399AG000 HUB STAND Used for extracting hub bolt. (New adopted tool) ST28399AG000 2.

  • Page 174: Propeller Shaft

    Propeller Shaft DRIVE SHAFT SYSTEM 2. Propeller Shaft 8) Make matching marks on the flange yoke and rear differential before removal. A: REMOVAL NOTE: • Before removing propeller shaft, wrap metal parts with a cloth or rubber material. • In case of DOJ type, before removing propeller shaft, wrap metal parts (installed at the rubber boot of center DOJ) with a cloth or rubber material, as shown in the figure.
  • Page 175 Propeller Shaft DRIVE SHAFT SYSTEM 7) Connect the battery ground cable to battery. NOTE: If extension cap is not available, place vinyl bag C: INSPECTION over opening and fasten with string to prevent gear NOTE: oil or ATF from leaking. Do not disassemble propeller shaft.
  • Page 176 Propeller Shaft DRIVE SHAFT SYSTEM Runout: Service limit 0.6 mm (0.024 in) DS-00036 (A) Propeller shaft (B) Dial gauge 4. CENTER BEARING FREE PLAY 1) Remove the front and center exhaust pipe. 2) Remove the rear exhaust pipe and muffler. 3) Remove the heat shield cover.

  • Page 177: Front Axle

    Front Axle DRIVE SHAFT SYSTEM 3. Front Axle 8) Remove the cotter pin and castle nut which se- cure tie-rod end to housing knuckle arm. A: REMOVAL 1) Disconnect the ground cable from battery. 2) Lift-up the vehicle and remove the front wheels. 3) Unlock the axle nut.
  • Page 178 Front Axle DRIVE SHAFT SYSTEM 12) Remove the front arm ball joint from housing. 3) Install the front arm ball joint to housing. Tightening torque: ⋅ 49 N m (5.0 kgf-m, 36 ft-lb) 4) Install the ABS wheel speed sensor harness to strut.
  • Page 179 Front Axle DRIVE SHAFT SYSTEM 12) After tightening the axle nut, lock it securely. D: ASSEMBLY 1) Assemble the front hub unit bearing. <Ref. to DS-18, ASSEMBLY, Front Hub Unit Bearing.> 2) Place the disc cover between housing and front hub unit, and tighten the four bolts.
  • Page 180 Front Axle DRIVE SHAFT SYSTEM 2) Inspect the lean of axis direction using a dial gauge. Replace the bearing if the load range ex- ceeds the limitation. Service limit: Maximum: 0.05 mm (0.0020 in) DS-00062 DS-16...

  • Page 181: Front Hub Unit Bearing

    Front Hub Unit Bearing DRIVE SHAFT SYSTEM 4. Front Hub Unit Bearing CAUTION: • Do not get closer the tool which charged A: REMOVAL magnetism to magnetic encorder. 1) Disconnect the ground cable from battery. • Be careful not to damage the magnetic en- 2) Lift-up the vehicle and remove the front wheels.
  • Page 182 Front Hub Unit Bearing DRIVE SHAFT SYSTEM 2) Install the front drive shaft. <Ref. to DS-22, IN- NOTE: STALLATION, Front Drive Shaft.> Since the hub unit bearing can not be disassem- 3) Tighten the axle nut temporarily. bled, only hub bolts can be removed. 4) Install the disc rotor on hub.

  • Page 183: Rear Hub Unit Bearing

    Rear Hub Unit Bearing DRIVE SHAFT SYSTEM 5. Rear Hub Unit Bearing • If the disc rotor seizes up within hub, drive the disc rotor out by installing an 8-mm bolt in screw A: REMOVAL hole on rotor. 1) Disconnect the ground cable from battery. 9) Remove the four bolts from rear arm.
  • Page 184 Rear Hub Unit Bearing DRIVE SHAFT SYSTEM 2) Tighten the four bolts to the back plate. NOTE: If it is hard to remove, use STs. Tightening torque: ⋅ ST1 926470000 AXLE SHAFT PULLER 65 N m (6.6 kgf-m, 47.9 ft-lb) ST2 927140000 AXLE SHAFT PULLER PLATE...
  • Page 185 Rear Hub Unit Bearing DRIVE SHAFT SYSTEM 10) While applying the parking brake and depress- D: ASSEMBLY ing the brake pedal, tighten a new axle nut (olive 1) Attach the hub to ST securely. color) to the specified torque and lock it securely. ST 927080000 HUB STAND Tightening torque:...

  • Page 186: Front Drive Shaft

    Front Drive Shaft DRIVE SHAFT SYSTEM 6. Front Drive Shaft NOTE: After pulling out the drive shaft, be sure to replace A: REMOVAL with a new oil seal. 1) Disconnect the ground cable from battery. 2) Lift-up the vehicle and remove the front wheels. 3) Unlock the axle nut.
  • Page 187 Front Drive Shaft DRIVE SHAFT SYSTEM C: DISASSEMBLY 6) Place alignment marks on the roller kit and trun- nion. 1) Place alignment marks on the shaft and outer race. DS-00106 2) Remove the PTJ boot band and boot. CAUTION: Be careful not to damage boot. DS-00109 7) Remove the roller kit from trunnion.
  • Page 188 Front Drive Shaft DRIVE SHAFT SYSTEM 10) Remove the PTJ boot. 7) Align alignment marks on the shaft and outer race, and install outer race. NOTE: Further disassembly of axle is impossible because the BJ cannot be disassembled. D: ASSEMBLY 1) Place the PTJ boot at the center of shaft.
  • Page 189 Front Drive Shaft DRIVE SHAFT SYSTEM 14) Tap on the clip with the punch provided at the end of ST. ST 925091000 BAND TIGHTENING TOOL CAUTION: Tap to an extent that the boot underneath is not damaged. DS-00133 15) Cut off the band with an allowance of about 10 mm (0.39 in) left from the clip and bend this allow- ance over the clip.

  • Page 190: Rear Drive Shaft

    Rear Drive Shaft DRIVE SHAFT SYSTEM 7. Rear Drive Shaft B: INSTALLATION 1) Insert the BJ or EBJ into rear hub splines. A: REMOVAL CAUTION: 1) Disconnect the ground cable from battery. • Be careful not to damage the magnetic en- 2) Lift-up the vehicle, and then remove the rear coder.
  • Page 191 Rear Drive Shaft DRIVE SHAFT SYSTEM 6) Lock the axle nut securely. 7) Wipe off the grease and take out balls. CAUTION: The grease is a special grease (grease for con- stant velocity joint). Do not confuse with other greases. NOTE: Disassemble exercising care not to lose balls (6 pcs).
  • Page 192 Rear Drive Shaft DRIVE SHAFT SYSTEM 2) Place the DOJ boot at the center of shaft. 5) Install the cage to inner race fixed upon shaft. CAUTION: NOTE: Be sure to wrap shaft splines with vinyl tape to Fit the cage with the protruded part aligned with the prevent boot from scratches.
  • Page 193 Rear Drive Shaft DRIVE SHAFT SYSTEM • Pull the shaft lightly and assure that the circlip is 16) Tap on the clip with the punch provided at the completely fitted in the groove. end of ST. ST 925091000 BAND TIGHTENING TOOL NOTE: Tap to an extent that the boot underneath is not damaged.

  • Page 194: General Diagnostic Table

    General Diagnostic Table DRIVE SHAFT SYSTEM 8. General Diagnostic Table A: INSPECTION NOTE: Vibration while cruising may be caused by an unbalanced tire, improper tire inflation pressure, improper wheel alignment, etc. Symptom Possible cause Corrective action Noise or vibration from propeller shaft Center bearing Check the center bearing.
  • Page 195 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 196 Page General Description ..................2 ABS Control Module and Hydraulic Control Unit (ABSCM&H/U)............6 ABS Sequence Control ................10 Front ABS Wheel Speed Sensor...............13 Rear ABS Wheel Speed Sensor ...............15 Front Magnetic Encoder................16 Rear Magnetic Encoder ................17 G Sensor ....................18...

  • Page 197: General Description

    General Description 1. General Description A: SPECIFICATION Item Standard value or identification Front 0.77 — 1.43 mm (0.030 — 0.056 in) ABS wheel speed sensor gap (for refer- ence) Rear 0.64 — 1.56 mm (0.025 — 0.061 in) K1 (White) ABS wheel speed sensor Front K2 (Yellow)
  • Page 198 General Description B: COMPONENT 1. ABS WHEEL SPEED SENSOR ABS00380 ⋅ G sensor Rear ABS wheel speed sensor LH Tightening torque: N m (kgf-m, ft-lb) Front ABS wheel speed sensor LH Hub unit bearing T1: 7.5 (0.76, 5.5) Front housing Magnetic encoder T2: 33 (3.3, 24) ABS-3...
  • Page 199 General Description 2. ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U) (10) (11) ABS00381 ABS control module and hydraulic Primary inlet (11) Bracket control unit (ABSCM&H/U) Secondary inlet ⋅ Front outlet RH Damper Tightening torque: N m (kgf-m, ft-lb) Rear outlet LH Spacer T1: 7.5 (0.76, 5.5) Rear outlet RH...
  • Page 200 TOOL NUMBER DESCRIPTION REMARKS 24082AA230 CARTRIDGE Troubleshooting for electrical system. ST24082AA230 22771AA030 SUBARU SELECT Troubleshooting for electrical system. MONITOR KIT • English: 22771AA030 (Without printer) • German: 22771AA070 (Without printer) • French: 22771AA080 (Without printer) • Spanish: 22771AA090 (Without printer) ST22771AA030 2.

  • Page 201: 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- 8) Remove the ABSCM&H/U bracket. B: INSTALLATION draulic Control Unit (AB- 1) Install the ABSCM&H/U bracket. SCM&H/U) Tightening torque: A: REMOVAL ⋅ 33 N m (3.3 kgf-m, 24 ft-lb) 1) Disconnect the ground cable from battery.
  • Page 202 ABS Control Module and Hydraulic Control Unit (ABSCM&H/U) Refer to “SPECIFICATION” for mark. <Ref. to 7) Read values indicated on the pressure gauge ABS-2, SPECIFICATION, General Description.> and check if the fluctuation of the values between decompression and compression meets the stan- dard values.
  • Page 203 ABS Control Module and Hydraulic Control Unit (ABSCM&H/U) 2. CHECKING THE HYDRAULIC UNIT ABS (1) The FL wheel performs decompression, holding and compression in sequence, and sub- OPERATION WITH BRAKE TESTER sequently the FR wheel repeats the cycle. 1) Install the spare fuse to the FWD connector lo- (2) The RR wheel performs decompression, cated in the main fuse box for the model without AT holding and compression in sequence, and sub-...
  • Page 204 ABS Control Module and Hydraulic Control Unit (ABSCM&H/U) NOTE: CAUTION: Before securing a part on a vice, place cushioning Always use new screws. material such as wood blocks, aluminum plate or Tightening torque: cloth between the part and vice. ⋅ 1.5 N m (0.15 kgf-m, 1.1 ft-lb) ABS00430...

  • Page 205: Abs Sequence Control

    NOTE: In the event of any trouble, the ABS sequence con- trol is not operated. 1) Connect the Subaru Select Monitor to data link connector under the driver’s side instrument panel lower cover. 2) Turn the ignition switch to ON.
  • Page 206 ABS Sequence Control 3. CONDITIONS FOR ABS SEQUENCE CONTROL V max < 4 km/h (2.5 MPH) V max < 10 km/h (6 MPH) (16) (17) (18) (21) (22) (23) (22) (23) (24) (19) (19) (19) (19) (20) (20) (20) (25) (22) (25) (22)
  • Page 207 (32) RL wheel cylinder pressure NOTE: When using the Subaru Select Monitor, the control operation starts from point A. The patterns from ig- nition key ON to the point A show that operation is started by diagnosis connector. (However, it is re- quired to turn the stop light switch to ON before point A.)

  • Page 208: Front Abs Wheel Speed Sensor

    4) Remove the sensor harness bracket. C: INSPECTION 1. INSPECTION WITH SUBARU SELECT MONITOR 1) Connect the Subaru Select Monitor to data link connector. 2) Select {Current Data Display & Save}. Check if the speed indicated on the display change in re-...
  • Page 209 Front ABS Wheel Speed Sensor 2) Charge a 12 V power supply to the No. 2 termi- nal of sensor connector as shown in the figure, and then install the resistance to No. 1 terminal. Rotate the wheel about 2.75 km/h (2 MPH) or equivalent, measure the voltage using oscilloscope.

  • Page 210: Rear Abs Wheel Speed Sensor

    Rear ABS Wheel Speed Sensor 5. Rear ABS Wheel Speed Sen- CAUTION: • Be careful not to damage the sensor portion. • Do not apply excessive force to the sensor A: REMOVAL harness. 1) Disconnect the ground cable from battery. 2) Disconnect the connector from rear ABS wheel speed sensor.

  • Page 211: Front Magnetic Encoder

    Front Magnetic Encoder 6. Front Magnetic Encoder A: REMOVAL Refer to “Front Hub Bearing” for removal, because the front magnetic encoder is integrated with front hub bearing. <Ref. to DS-17, REMOVAL, Front Hub Unit Bear- ing.> B: INSTALLATION Refer to “Front Hub Bearing” for installation, be- cause the front magnetic encoder is integrated with front hub bearing.

  • Page 212: Rear Magnetic Encoder

    Rear Magnetic Encoder 7. Rear Magnetic Encoder A: REMOVAL Refer to “Rear Hub Unit Bearing” for removal, be- cause the rear magnetic encoder is integrated with rear hub unit bearing. <Ref. to DS-19, REMOVAL, Rear Hub Unit Bear- ing.> B: INSTALLATION Refer to “Rear Hub Unit Bearing”...

  • Page 213: G Sensor

    G Sensor 8. G Sensor A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the console box. <Ref. to EI-53, REMOVAL, Console Box.> 3) Disconnect the connector from G sensor. 4) Remove the G sensor from body. CAUTION: •...
  • Page 214 2) Connect the Subaru Select Monitor to data between G sensor tal position? link connector. and ABSCM&H/U. 3) Set the Subaru Select Monitor to the {Brake Or replace G sen- Control} mode. sor. 4) Set the display in the {Current Data Display &...
  • Page 215 G Sensor ABS-20...
  • Page 216 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 217 Check List for Interview................4 General Description ..................8 Electrical Component Location ..............10 Control Module I/O Signal .................12 Subaru Select Monitor................15 Read Diagnostic Trouble Code (DTC) ............25 Inspection Mode..................26 Clear Memory Mode..................27 ABS Warning Light / Brake Warning Light Illumination Pattern ....28 List of Diagnostic Trouble Code (DTC) .............39...

  • Page 218: Basic Diagnostic Procedure

    Go to step 3. 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.
  • Page 219 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.>...

  • Page 220: Check List For Interview

    Check List for Interview ABS (DIAGNOSTICS) 2. Check List for Interview A: CHECK Check the following items about the vehicle’s state. 1. STATE OF ABS WARNING LIGHT ❏ Always ABS warning light ❏ Sometimes comes on. ❏ Only once ❏ Not come on •...
  • Page 221 Check List for Interview ABS (DIAGNOSTICS) ❏ Immediately after turning the ignition to ON Timing ❏ Immediately after turning the ignition to START ❏ When accelerating — km/h — ❏ When driving at a constant speed km/h ❏ When decelerating —...
  • Page 222 Check List for Interview ABS (DIAGNOSTICS) 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 ❏...
  • Page 223 Check List for Interview ABS (DIAGNOSTICS) Condition a) Brakes Deceleration: ❏ Intermittent / ❏ Temporary b) Accelerator Acceleration: ❏ Intermittent / ❏ Temporary c) Vehicle speed km/h ❏ Advancing ❏ When accelerating ❏ When decelerating ❏ At low speed ❏ When turning ❏...

  • Page 224: General Description

    General Description ABS (DIAGNOSTICS) 3. General Description 6. TIRE Check the tire specifications, tire wear and air pres- A: CAUTION sure. <Ref. to WT-2, SPECIFICATION, General 1. SUPPLEMENTAL RESTRAINT SYSTEM Description.> “AIRBAG” Airbag system wiring harness is routed near the ABS wheel speed sensor and ABSCM&H/U.
  • Page 225 TOOL NUMBER DESCRIPTION REMARKS 24082AA230 CARTRIDGE Troubleshooting for electrical system. ST24082AA230 22771AA030 SUBARU SELECT Troubleshooting for electrical system. MONITOR KIT • English: 22771AA030 (Without printer) • German: 22771AA070 (Without printer) • French: 22771AA080 (Without printer) • Spanish: 22771AA090 (Without printer) ST22771AA030 2.

  • Page 226: Electrical Component Location

    (10) (11) (12) ABS00458 ABS control module and hydraulic Data link connector Caliper body control unit (ABSCM&H/U) (For Subaru Select Monitor) (10) G sensor Two-way connector Transmission control module (11) Stop light switch (TCM) (AT model) Diagnosis connector (Used for...
  • Page 227 Electrical Component Location ABS (DIAGNOSTICS) ABS00405 ABS00106 (13) ABS00438 ABS00464 REAR FRONT ABS00408 ABS00407 (10) ABS00406 ABS(diag)-11...

  • Page 228: Control Module I/O Signal

    Control Module I/O Signal ABS (DIAGNOSTICS) 5. Control Module I/O Signal A: ELECTRICAL SPECIFICATION B301 7 8 9 10 11 16 17 18 22 23 24 25 26 ABS00409 ABS control module and hydraulic control unit (ABSCM&H/U) con- nector NOTE: •...
  • Page 229 8 — 15 1.5 seconds and less than 1.5 V after 1.5 seconds passed. Less than 1.5 V when no data is received. Subaru Select Monitor 7 — 15 0 ←→ 12 V pulse (in communication) ABS diagnosis connector 25 — 15 When the ignition switch is ON, 10 —...
  • Page 230 Control Module I/O Signal ABS (DIAGNOSTICS) B: WIRING DIAGRAM (16) (30) (31) (17) (18) (19) (20) (28) (29) (21) (22) (23) (10) (11) (12) (24) (13) (25) (14) (26) (15) (27) ABS00470 Battery (12) Rear inlet solenoid valve LH (24) Front ABS wheel speed sensor LH Ignition switch (13)

  • Page 231: Subaru Select Monitor

    5) Turn the ignition switch to ON (engine OFF) and 1. READ DIAGNOSTIC TROUBLE CODE turn the Subaru Select Monitor switch to ON. (DTC) 1) Prepare the Subaru Select Monitor kit. <Ref. to ABS(diag)-9, SPECIAL TOOL, PREPARATION TOOL, General Description.> ABS00114 (1) Power switch 6) On the «Main Menu»...
  • Page 232 Voltage supplied to ABSCM&H/U is displayed. ABS Control Flag ABS control condition is displayed. ON or OFF ABS OK B Signal ABS system normal/abnormal is displayed. OK or NG NOTE: For details concerning operation procedure, refer to the “SUBARU SELECT MONITOR OPERATION MAN- UAL”. ABS(diag)-16...
  • Page 233 Whether abnormal voltage occurred or Failure not is displayed during malfunction. 5) When “Done” and “Turn ignition switch OFF” are shown on the display screen, turn the Subaru Se- lect Monitor and ignition switch to OFF. NOTE: For details concerning operation procedure, refer to the “SUBARU SELECT MONITOR OPERATION...
  • Page 234 Subaru Select Monitor ABS (DIAGNOSTICS) B: INSPECTION 1. COMMUNICATION FOR INITIALIZING IMPOSSIBLE DETECTING CONDITION: Defective harness connector TROUBLE SYMPTOM: Communication is impossible between ABS and Subaru Select Monitor. WIRING DIAGRAM: BATTERY IGNITION SWITCH DATA LINK CONNECTOR B301 ABSCM & H/U...
  • Page 235 MUNICATION. year displayed on Subaru 1) Turn the ignition switch to ON. Select Monitor? 2) Using Subaru Select Monitor, check whether communication to other system can be executed normally. CHECK SUBARU SELECT MONITOR COM- Is the system name and model Replace Go to step 6.
  • Page 236 Subaru Select Monitor ABS (DIAGNOSTICS) Step Check CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 0.5 Go to step 12. Repair the open Ω? ABSCM&H/U AND CHASSIS GROUND. circuit in harness 1) Turn the ignition switch to OFF. between 2) Disconnect the connector from ABSCM&H/...
  • Page 237 • ABS warning light does not go off. • “NO TROUBLE CODE” will be displayed on the Subaru Select Monitor. NOTE: When the ABS warning light is OFF and “NO TROUBLE CODE” is displayed on Subaru Select Monitor, the system is in normal condition. ABS(diag)-21...
  • Page 238 Subaru Select Monitor ABS (DIAGNOSTICS) WIRING DIAGRAM: • LHD model BATTERY SBF-1 IGNITION SWITCH No.5 COMBINATION METER GROUND TERMINAL B301 ABSCM & H/U B301 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11...
  • Page 239 Subaru Select Monitor ABS (DIAGNOSTICS) • RHD model BATTERY SBF-1 IGNITION SWITCH No.5 COMBINATION METER GROUND TERMINAL B301 ABSCM & H/U B301 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 3 4 5 6...
  • Page 240 Subaru Select Monitor ABS (DIAGNOSTICS) Step Check DATA CHECK SUBARU SELECT MONITOR. Is “ON” indicated? Replace the Go to step 2. 1) Select {Current Data Display & Save} in ABSCM only. Subaru Select Monitor. <Ref. to ABS-8, 2) Read the condition of “ABS warning light”.

  • Page 241: Read Diagnostic Trouble Code (Dtc)

    Read Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) 7. Read Diagnostic Trouble Code (DTC) A: OPERATION For details about reading of DTCs, refer to “Subaru Select Monitor”. <Ref. to ABS(diag)-15, Subaru Se- lect Monitor.> ABS(diag)-25...

  • Page 242: Inspection Mode

    Inspection Mode ABS (DIAGNOSTICS) 8. Inspection Mode A: PROCEDURE Reproduce the malfunction occurrence condition as possible. Drive the vehicle at a speed more than 40 km/h (25 MPH) for at least one minute. ABS(diag)-26...

  • Page 243: Clear Memory Mode

    Clear Memory Mode ABS (DIAGNOSTICS) 9. Clear Memory Mode A: OPERATION For details concerning DTC clear operation, refer to “Subaru Select Monitor”. <Ref. to ABS(diag)-15, Subaru Select Monitor.> ABS(diag)-27...

  • Page 244: Abs Warning Light / Brake Warning Light Illumination Pattern

    ABS Warning Light / Brake Warning Light Illumination Pattern ABS (DIAGNOSTICS) 10.ABS Warning Light / Brake Warning Light Illumination Pattern A: INSPECTION (10) (11) ABS00442 Ignition switch ABS warning light Brake warning light (EBD warning light) Light OFF Light ON (10) Parking brake Start...
  • Page 245 ABS Warning Light / Brake Warning Light Illumination Pattern ABS (DIAGNOSTICS) 1) When the ABS warning light and brake warning light do not illuminate in accordance with this illumination pattern, there must be an electrical malfunction. 2) When ABS warning light remains constantly OFF, check the combination meter circuit. <Ref. to ABS(di- ag)-30, ABS WARNING LIGHT DOES NOT COME ON, ABS Warning Light / Brake Warning Light Illumina- tion Pattern.>...
  • Page 246 ABS Warning Light / Brake Warning Light Illumination Pattern ABS (DIAGNOSTICS) B: ABS WARNING LIGHT DOES NOT COME ON DETECTING CONDITION: • Defective combination meter • Defective harness TROUBLE SYMPTOM: When the ignition switch is turned to ON (engine OFF), ABS warning light does not come on. WIRING DIAGRAM: •...
  • Page 247 ABS Warning Light / Brake Warning Light Illumination Pattern ABS (DIAGNOSTICS) • RHD model BATTERY SBF-1 IGNITION SWITCH No.5 COMBINATION METER GROUND TERMINAL B301 ABSCM & H/U B301 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 3 4 5 6 16 17 18 19 20 21 22 23 24 25 26 5 6 7 8 9 10...
  • Page 248 ABS Warning Light / Brake Warning Light Illumination Pattern ABS (DIAGNOSTICS) Step Check CHECK ILLUMINATION OF OTHER LIGHTS. Do other warning lights illumi- Go to step 2. Check the combi- Turn the ignition switch to ON. (engine OFF) nate? nation meter. READ DTC.
  • Page 249 ABS Warning Light / Brake Warning Light Illumination Pattern ABS (DIAGNOSTICS) C: ABS WARNING LIGHT DOES NOT GO OFF DETECTING CONDITION: • Defective combination meter • Open in harness TROUBLE SYMPTOM: When starting the engine, the ABS warning light is kept on. WIRING DIAGRAM: •...
  • Page 250 ABS Warning Light / Brake Warning Light Illumination Pattern ABS (DIAGNOSTICS) • RHD model BATTERY SBF-1 IGNITION SWITCH No.5 COMBINATION METER GROUND TERMINAL B301 ABSCM & H/U B301 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 3 4 5 6 16 17 18 19 20 21 22 23 24 25 26 5 6 7 8 9 10...
  • Page 251 ABS Warning Light / Brake Warning Light Illumination Pattern ABS (DIAGNOSTICS) Step Check READ DTC. Is DTC displayed? Perform the diag- Go to step 2. Read the DTC. <Ref. to ABS(diag)-25, Read nosis according to Diagnostic Trouble Code (DTC).> DTC. CHECK WIRING HARNESS.
  • Page 252 ABS Warning Light / Brake Warning Light Illumination Pattern ABS (DIAGNOSTICS) D: BRAKE WARNING LIGHT DOES NOT GO OFF DETECTING CONDITION: • Brake warning light circuit is shorted. • Defective sensor/connector TROUBLE SYMPTOM: After starting the engine, the brake warning light is kept on though the parking lever is released. WIRING DIAGRAM: •...
  • Page 253 ABS Warning Light / Brake Warning Light Illumination Pattern ABS (DIAGNOSTICS) • RHD model BATTERY SBF-1 IGNITION SWITCH NO.5 BRAKE FLUID LEVEL SWITCH B301 ABSCM & H/U B229 PARKING BRAKE SWITCH B301 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 16 17 18 19 20 21 22 23 24 25 26 5 6 7 8 9 10 B229...
  • Page 254 ABS Warning Light / Brake Warning Light Illumination Pattern ABS (DIAGNOSTICS) Step Check CHECK INSTALLATION OF ABSCM&H/U Is the connector correctly Go to step 2. Insert the CONNECTOR. inserted? ABSCM&H/U con- 1) Turn the ignition switch to OFF. nector until the 2) Check that the ABSCM&H/U connector is clamp locks onto inserted to ABSCM&H/U until the clamp locks...

  • Page 255: List Of Diagnostic Trouble Code (Dtc)

    List of Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) 11.List of Diagnostic Trouble Code (DTC) A: LIST Content of diagnosis Display Reference target <Ref. to ABS(diag)-42, DTC C0101 ABS Rear Right ABS Sen- WHEEL SPEED SENSOR RR MALFUNC- Rear ABS wheel C0101 sor Circuit Open or TION (BROKEN WIRE, INPUT VOLTAGE...
  • Page 256 List of Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Content of diagnosis Display Reference target <Ref. to ABS(diag)-51, DTC C0115 ABS ABS wheel speed sen- Abnormal ABS wheel WHEEL SPEED SENSOR SIGNAL MAL- sor malfunction (ABS Any One of Four ABS C0115 speed sensor on any FUNCTION IN ONE OF FOUR WHEELS,...
  • Page 257 List of Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Content of diagnosis Display Reference target <Ref. to ABS(diag)-60, DTC C0127 REAR OUTLET SOLENOID VALVE RH MAL- Outlet valve malfunc- RR Pressure Reduc- FUNCTION IN ABS CONTROL MODULE C0127 Rear outlet valve RH tion in hydraulic unit ing Valve malfunction AND HYDRAULIC CONTROL UNIT...

  • Page 258: Diagnostic Procedure With Diagnostic Trouble Code (Dtc)

    Diagnostic Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) 12.Diagnostic Procedure with Diagnostic Trouble Code (DTC) A: DTC C0101 ABS WHEEL SPEED SENSOR RR MALFUNCTION (BROKEN WIRE, INPUT VOLTAGE TOO HIGH) NOTE: For the diagnostic procedure, refer to DTC C0104. <Ref. to ABS(diag)-43, DTC C0104 ABS WHEEL SPEED SENSOR FL MALFUNCTION (BROKEN WIRE, INPUT VOLTAGE TOO HIGH), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>...
  • Page 259 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) D: DTC C0104 ABS WHEEL SPEED SENSOR FL MALFUNCTION (BROKEN WIRE, INPUT VOLTAGE TOO HIGH) DTC DETECTING CONDITION: • Defective ABS wheel speed sensor (broken wire, input voltage too high) • Defective harness connector TROUBLE SYMPTOM: ABS does not operate.
  • Page 260 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) • RHD model B301 ABSCM & H/U FRONT ABS FRONT ABS REAR ABS REAR ABS WHEEL SPEED WHEEL SPEED WHEEL SPEED WHEEL SPEED SENSOR LH SENSOR RH SENSOR LH SENSOR RH B301 1 2 3 4 5 6 7 8 9...
  • Page 261 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK POOR CONTACT IN CONNECTOR. Is there poor contact? Repair the con- Go to step 2. Check the poor contact between ABSCM&H/U nector. and ABS wheel speed sensor. CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 0.5 Go to step 3.
  • Page 262 2) Erase the memory. <Ref. to ABS-8, 3) Perform the inspection mode. <Ref. to REPLACEMENT, ABS(diag)-17, CLEAR MEMORY MODE, ABS Control Mod- OPERATION, Subaru Select Monitor.> ule and Hydraulic 4) Read the DTC. Control Unit (ABSCM&H/U).> CHECK ANY OTHER DTC ON DISPLAY.
  • Page 263 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) H: DTC C0108 ABS WHEEL SPEED SENSOR FL MALFUNCTION (ABS WHEEL SPEED SENSOR ABNORMAL SIGNAL) DTC DETECTING CONDITION: • Defective ABS wheel speed sensor signal (noise, abnormal signal, etc.) • Defective harness connector TROUBLE SYMPTOM: ABS does not operate.
  • Page 264 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) • RHD model B301 ABSCM & H/U FRONT ABS FRONT ABS REAR ABS REAR ABS WHEEL SPEED WHEEL SPEED WHEEL SPEED WHEEL SPEED SENSOR LH SENSOR RH SENSOR LH SENSOR RH B301 1 2 3 4 5 6 7 8 9...
  • Page 265 2) Read the ABS wheel speed sensor output in the straight-ahead position? corresponding to the faulty wheel in Subaru Select Monitor data display mode. CHECK POOR CONTACT IN CONNECTOR. Is there poor contact in con- Repair the con- Go to step 3.
  • Page 266 2) Erase the memory. <Ref. to ABS-8, 3) Perform the inspection mode. <Ref. to REPLACEMENT, ABS(diag)-17, CLEAR MEMORY MODE, ABS Control Mod- OPERATION, Subaru Select Monitor.> ule and Hydraulic 4) Read the DTC. Control Unit (ABSCM&H/U).> CHECK ANY OTHER DTC ON DISPLAY.
  • Page 267 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) I: DTC C0115 ABS WHEEL SPEED SENSOR SIGNAL MALFUNCTION IN ONE OF FOUR WHEELS DTC DETECTING CONDITION: • Defective ABS wheel speed sensor signal (noise, abnormal signal, etc.) • Defective magnetic encoder •...
  • Page 268 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) WIRING DIAGRAM: • LHD model B301 ABSCM & H/U FRONT ABS FRONT ABS REAR ABS REAR ABS WHEEL SPEED WHEEL SPEED WHEEL SPEED WHEEL SPEED SENSOR LH SENSOR RH SENSOR LH SENSOR RH B301 4 5 6 7...
  • Page 269 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) • RHD model B301 ABSCM & H/U FRONT ABS FRONT ABS REAR ABS REAR ABS WHEEL SPEED WHEEL SPEED WHEEL SPEED WHEEL SPEED SENSOR LH SENSOR RH SENSOR LH SENSOR RH B301 1 2 3 4 5 6 7 8 9...
  • Page 270 1) Connect all the connectors. ABSCM only. 2) Erase the memory. <Ref. to ABS-8, 3) Perform the inspection mode. <Ref. to REPLACEMENT, ABS(diag)-17, CLEAR MEMORY MODE, ABS Control Mod- OPERATION, Subaru Select Monitor.> ule and Hydraulic 4) Read the DTC. Control Unit (ABSCM&H/U).> ABS(diag)-54...
  • Page 271 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Perform the diag- It results from a nosis according to temporary noise DTC. interference. NOTE: Though ABS warn- ing light remains to illuminate at this time, it is normal.
  • Page 272 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) M: DTC C0126 REAR INLET SOLENOID VALVE RH MALFUNCTION IN ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U) DTC DETECTING CONDITION: • Defective harness connector • Defective inlet solenoid valve in ABSCM&H/U TROUBLE SYMPTOM: •...
  • Page 273 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) WIRING DIAGRAM: BATTERY GENERATOR IGNITION SWITCH B301 ABSCM & H/U B301 1 2 3 4 5 6 7 8 9 10 11 16 17 18 19 20 21 22 23 24 25 26 ABS00414 ABS(diag)-57...
  • Page 274 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK INPUT VOLTAGE OF ABSCM&H/U. Is the voltage 10 — 15 V? Go to step 2. Repair the 1) Turn the ignition switch to OFF. ABSCM&H/U 2) Disconnect the connector from ABSCM&H/ power circuit.
  • Page 275 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) N: DTC C0121 FRONT OUTLET SOLENOID VALVE LH MALFUNCTION IN ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U) NOTE: For the diagnostic procedure, refer to DTC C0127. <Ref. to ABS(diag)-60, DTC C0127 REAR OUTLET SO- LENOID VALVE RH MALFUNCTION IN ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>...
  • Page 276 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Q: DTC C0127 REAR OUTLET SOLENOID VALVE RH MALFUNCTION IN ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U) DTC DETECTING CONDITION: • Defective harness connector • Defective outlet solenoid valve in ABSCM&H/U TROUBLE SYMPTOM: •...
  • Page 277 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) WIRING DIAGRAM: BATTERY GENERATOR IGNITION SWITCH B301 ABSCM & H/U B301 1 2 3 4 5 6 7 8 9 10 11 16 17 18 19 20 21 22 23 24 25 26 ABS00414 ABS(diag)-61...
  • Page 278 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK INPUT VOLTAGE OF ABSCM&H/U. Is the voltage 10 — 15 V? Go to step 2. Repair the 1) Turn the ignition switch to OFF. ABSCM&H/U 2) Disconnect the connector from ABSCM&H/ power circuit.
  • Page 279 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) R: DTC C0110 ABS CONTROL MODULE MALFUNCTION DTC DETECTING CONDITION: Defective ABSCM&H/U TROUBLE SYMPTOM: • ABS does not operate. • EBD does not operate. NOTE: Brake warning light comes on as well as ABS warning light. WIRING DIAGRAM: B301 ABSCM &...
  • Page 280 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK GROUND CIRCUIT OF ABSCM&H/U. Is the resistance less than 0.5 Go to step 2. Repair the Ω? 1) Turn the ignition switch to OFF. ABSCM&H/U 2) Disconnect the connector from ABSCM&H/ ground harness.
  • Page 281 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) S: DTC C0109 POWER VOLTAGE MALFUNCTION DTC DETECTING CONDITION: Power voltage of the ABSCM&H/U is too low or too high. TROUBLE SYMPTOM: • ABS does not operate. • EBD may not operate. NOTE: If EBD does not operate, brake warning light comes on as well as ABS warning light.
  • Page 282 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) WIRING DIAGRAM: BATTERY GENERATOR IGNITION SWITCH B301 ABSCM & H/U B301 1 2 3 4 5 6 7 8 9 10 11 16 17 18 19 20 21 22 23 24 25 26 ABS00414 ABS(diag)-66...
  • Page 283 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK GENERATOR. Is the voltage 10 — 15 V? Go to step 2. Repair the genera- 1) Start the engine. tor. 2) Run the engine at idle after warming up. 3) Measure the voltage between generator B terminal and chassis ground.
  • Page 284 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) T: DTC C0140 CAN COMMUNICATION MALFUNCTION DTC DETECTING CONDITION: Defective CAN communication TROUBLE SYMPTOM: Possibly the vehicle speed cannot output on CAN. Step Check CHECK LAN SYSTEM. Is there any fault in LAN sys- Repair it according Replace the Perform the diagnosis for LAN system.
  • Page 285 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) U: DTC C0114 VALVE RELAY MALFUNCTION DTC DETECTING CONDITION: Defective valve relay TROUBLE SYMPTOM: • ABS does not operate. • EBD does not operate depending on the trouble contents. NOTE: Brake warning light comes on as well as ABS warning light when EBD does not operate. WIRING DIAGRAM: BATTERY SBF-1...
  • Page 286 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK INPUT VOLTAGE OF ABSCM&H/U. Is the voltage 10 — 15 V? Go to step 2. Repair the har- 1) Turn the ignition switch to OFF. ness connector 2) Disconnect the connector from ABSCM&H/ between battery and ABSCM&H/U.
  • Page 287 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) V: DTC C0111 MOTOR/MOTOR RELAY MALFUNCTION DTC DETECTING CONDITION: • Defective motor • Defective motor relay • Defective harness connector TROUBLE SYMPTOM: ABS does not operate. WIRING DIAGRAM: BATTERY SBF-1 SBF-2 IGNITION SWITCH B301...
  • Page 288 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK INPUT VOLTAGE OF ABSCM&H/U. Is the voltage 10 — 15 V? Go to step 2. Repair the har- 1) Turn the ignition switch to OFF. ness connector 2) Disconnect the connector from ABSCM&H/ between battery and ABSCM&H/U.
  • Page 289 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK ANY OTHER DTC ON DISPLAY. Is any other DTC displayed? Inspect the DTC Temporary poor using “List of Diag- contact occurs. nostic Trouble NOTE: Code (DTC)”. Though ABS warn- <Ref.
  • Page 290 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) W: DTC C0116 FAULTY STOP LIGHT SWITCH DTC DETECTING CONDITION: Defective stop light switch WIRING DIAGRAM: BATTERY STOP LIGHT SWITCH B64 : OC B65 : WC B159 : WITH CRUISE CONTROL : WITHOUT CRUISE CONTROL B301 ABSCM &...
  • Page 291 1) Select {Current Data Display & Save} in Subaru Select Monitor. 2) Release the brake pedal. 3) Read the stop light switch signal in Subaru Select Monitor. CHECK OUTPUT OF STOP LIGHT SWITCH Is “ON” displayed on the dis- Go to step 5.
  • Page 292 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) X: DTC C0118 G SENSOR OUTPUT VOLTAGE MALFUNCTION DTC DETECTING CONDITION: Defective G sensor TROUBLE SYMPTOM: ABS does not operate. WIRING DIAGRAM: B301 ABSCM & H/U B292 ABS G SENSOR B292 B301 1 2 3 4 5 6 7 8 9 10 11 1 2 3...
  • Page 293 SUBARU SELECT MONITOR. 1) Select {Current Data Display & Save} in sensor is horizontal? Subaru Select Monitor. 2) Read the G sensor output on Subaru Select Monitor. CHECK POOR CONTACT IN CONNECTOR. Is there poor contact in con- Repair the con- Go to step 3.
  • Page 294 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK G SENSOR. Is the voltage 3.6 — 4.1 V Go to step 10. Replace G sen- Measure the voltage between G sensor con- when G sensor is inclined for- sor.
  • Page 295 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Y: DTC C0119 G SENSOR OUTPUT VOLTAGE MALFUNCTION DTC DETECTING CONDITION: Defective G sensor output signal TROUBLE SYMPTOM: ABS does not operate. WIRING DIAGRAM: B301 ABSCM & H/U B292 ABS G SENSOR B292 B301 1 2 3 4 5 6 7 8 9 10 11...
  • Page 296 SUBARU SELECT MONITOR. 1) Select {Current Data Display & Save} in sensor is on a level? Subaru Select Monitor. 2) Read the Subaru Select Monitor display. CHECK OUTPUT OF G SENSOR USING Is the reading indicated on dis- Go to step 4.
  • Page 297 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK G SENSOR. Is the voltage 2.1 — 2.5 V Go to step 11. Replace G sen- 1) Remove the console box. when G sensor is on a level? sor.

  • Page 298: General Diagnostic Table

    General Diagnostic Table ABS (DIAGNOSTICS) 13.General Diagnostic Table A: INSPECTION Symptom Problem parts • ABSCM&H/U (solenoid valve) • ABS wheel speed sensor • Brake (caliper, piston and pads) Vehicle is pulled to either right or • Wheel Alignment left side. •...
  • Page 299 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 300 VEHICLE DYNAMICS CONTROL (VDC) Page General Description ..................2 VDC Control Module & Hydraulic Control Unit (VDCCM&H/U)....7 ABS Sequence Control ................10 VDC Sequence Control................11 Yaw Rate & Lateral G Sensor ..............14 Steering Angle Sensor ................16 Front ABS Wheel Speed Sensor...............18 Rear ABS Wheel Speed Sensor ...............19 Front Magnetic Encoder................20 Rear Magnetic Encoder ................21 VDC OFF Switch..................22...

  • Page 301: General Description

    General Description VEHICLE DYNAMICS CONTROL (VDC) 1. General Description A: SPECIFICATION Item Standard values or identification Front 0.77 — 1.43 mm (0.030 — 0.056 in) ABS wheel speed sensor gap (for reference) Rear 0.64 — 1.56 mm (0.025 — 0.061 in) K1 (White) ABS wheel speed Front...
  • Page 302 General Description VEHICLE DYNAMICS CONTROL (VDC) B: COMPONENT 1. ABS WHEEL SPEED SENSOR VDC00194 ⋅ Front ABS wheel speed sensor Hub unit bearing Tightening torque: N m (kgf-m, ft-lb) Front housing Magnetic encoder T1: 7.5 (0.76, 5.5) Rear ABS wheel speed sensor T2: 33 (3.4, 24) VDC-3...
  • Page 303 General Description VEHICLE DYNAMICS CONTROL (VDC) 2. YAW RATE & LATERAL G SENSOR VDC00195 ⋅ Yaw rate & lateral G sensor Bracket Tightening torque: N m (kgf-m, ft-lb) T: 7.5 (0.76, 5.5) 3. STEERING ANGLE SENSOR VDC00196 (1) Steering angle sensor VDC-4...
  • Page 304 General Description VEHICLE DYNAMICS CONTROL (VDC) 4. VDC CONTROL MODULE & HYDRAULIC CONTROL UNIT (VDCCM&H/U) (8) (7) (10) (11) VDC00197 VDC control module and hydraulic Rear LH outlet (10) Pressure sensor control unit (VDCCM&H/U) Secondary inlet (11) Damper Clip Primary inlet ⋅...
  • Page 305 TOOL NUMBER DESCRIPTION REMARKS 24082AA230 CARTRIDGE Troubleshooting for electrical system. ST24082AA230 22771AA030 SUBARU SELECT Troubleshooting for electrical system. MONITOR KIT • English: 22771AA030 (Without printer) • German: 22771AA070 (Without printer) • French: 22771AA080 (Without printer) • Spanish: 22771AA090 (Without printer) ST22771AA030 2.

  • Page 306: Vdc Control Module & Hydraulic Control Unit (Vdccm&H/U)

    VDC Control Module & Hydraulic Control Unit (VDCCM&H/U) VEHICLE DYNAMICS CONTROL (VDC) 2. VDC Control Module & Hy- 7) Remove the clips, and then remove the VDC- CM&H/U. draulic Control Unit (VDC- CM&H/U) A: REMOVAL 1) Disconnect the ground cable from battery. 2) Use compressed air to get rid of water and dust around the VDCCM&H/U.
  • Page 307 VDC Control Module & Hydraulic Control Unit (VDCCM&H/U) VEHICLE DYNAMICS CONTROL (VDC) 4) Connect the brake pipes to their specified VDC- CAUTION: CM&H/U positions. • Pressure gauges used exclusively for brake fluid must be used. Tightening torque: ⋅ • Do not use the pressure gauge for the mea- 15 N m (1.5 kgf-m, 11.1 ft-lb) surement of transmission oil pressure since...
  • Page 308 (When the center position is not correct, ad- ABS00136 just the wheel alignment.) 3) Set the Subaru Select Monitor to vehicle, select the {Set up mode for Neutral of Steering Angle Sensor & Lateral G Sensor 0 point} on «Function check sequence»...

  • Page 309: Abs Sequence Control

    ABS Sequence Control.> 2. ABS SEQUENCE CONTROL WITH SUB- ARU SELECT MONITOR <Ref. to ABS-10, ABS SEQUENCE CONTROL WITH SUBARU SELECT MONITOR, OPERA- TION, ABS Sequence Control.> 3. CONDITIONS FOR ABS SEQUENCE CONTROL <Ref. to ABS-11, CONDITIONS FOR ABS SE- QUENCE CONTROL, OPERATION, ABS Se- quence Control.>...

  • Page 310: Vdc Sequence Control

    YES key. using the brake tester or pressure gauge after the 7) Operation points will be displayed on the Subaru hydraulic unit solenoid valve is operated. Select Monitor. 2) VDC sequence control can be started by diagno- sis connector or Subaru Select Monitor.
  • Page 311 VDC Sequence Control VEHICLE DYNAMICS CONTROL (VDC) 3. CONDITIONS FOR VDC SEQUENCE CONTROL V max < 4 km/h (2.5 MPH) V max < 10 km/h (6 MPH) (21) (35) (22) ON (23) (24) (27) (28) (27) (29) (25) (25) (25) (25) (26) (26)
  • Page 312 FR compression valve (29) 1.6 sec. NOTE: When using the Subaru Select Monitor, the control operation starts from point A. The patterns from ig- nition key ON to the point A show that operation is started by diagnosis connector. B: SPECIFICATION 1.

  • Page 313: Yaw Rate & Lateral G Sensor

    Yaw Rate & Lateral G Sensor VEHICLE DYNAMICS CONTROL (VDC) 5. Yaw Rate & Lateral G Sensor CAUTION: After completion of installation, set the follow- A: REMOVAL ing two positions. 1) Disconnect the ground cable from battery. • Positioning to the center of steering angle 2) Remove the console box.
  • Page 314 & lateral G sensor 3) Turn the ignition switch to ON. and VDCCM&H/U. Yaw rate sensor: −4 — 4 deg/ 4) Set the Subaru Select Monitor connector to Or replace the yaw the {Brake Control} mode. rate & lateral G 5) Select {Current Data Display &...

  • Page 315: Steering Angle Sensor

    Steering Angle Sensor VEHICLE DYNAMICS CONTROL (VDC) 6. Steering Angle Sensor 9) Remove the steering angle sensor from roll con- nector. A: REPLACEMENT CAUTION: • Do not perform the removal except when the replacement. • When replacing more than three times, re- place the combination switch as assembly to protect screw part.
  • Page 316 Steering Angle Sensor VEHICLE DYNAMICS CONTROL (VDC) 12) Apply thin coat of grease which is enclosed 17) Connect the battery ground cable to battery. with new part to the protruding parts (four) of steer- CAUTION: ing angle sensor. After completion of installation, adjust the fol- lowing two positions.

  • Page 317: Front Abs Wheel Speed Sensor

    Front ABS Wheel Speed Sensor VEHICLE DYNAMICS CONTROL (VDC) 7. Front ABS Wheel Speed Sen- A: NOTE For the vehicle equipped with VDC, it has the same ABS wheel speed sensor as installed to the vehicle equipped with ABS. For removal, installation and inspection procedure, refer to ABS section.

  • Page 318: Rear Abs Wheel Speed Sensor

    Rear ABS Wheel Speed Sensor VEHICLE DYNAMICS CONTROL (VDC) 8. Rear ABS Wheel Speed Sen- A: NOTE For the vehicle equipped with VDC, it has the same ABS wheel speed sensor as installed to the vehicle equipped with ABS. For removal, installation and inspection procedure, refer to ABS section.

  • Page 319: Front Magnetic Encoder

    Front Magnetic Encoder VEHICLE DYNAMICS CONTROL (VDC) 9. Front Magnetic Encoder A: NOTE For the vehicle equipped with VDC, it has the same magnetic encoder as installed to the vehicle equipped with ABS. For removal, installation and inspection procedure, refer to ABS section. <Ref.

  • Page 320: Rear Magnetic Encoder

    Rear Magnetic Encoder VEHICLE DYNAMICS CONTROL (VDC) 10.Rear Magnetic Encoder A: NOTE For the vehicle equipped with VDC, it has the same magnetic encoder as installed to the vehicle equipped with ABS. For removal, installation and inspection procedure, refer to ABS section. <Ref.

  • Page 321: Vdc Off Switch

    VDC OFF Switch VEHICLE DYNAMICS CONTROL (VDC) 11.VDC OFF Switch A: REMOVAL 1) Remove the instrument panel lower cover. 2) Remove the screws, and then remove the VDC OFF switch. • RHD model 4 3 2 1 VDC00210 • LHD model 7 6 5 4 3 2 1 14 13 12 11 10...
  • Page 322 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 323 Basic Diagnostic Procedure ................2 Check List for Interview................4 General Description ..................8 Electrical Component Location ..............10 Control Module I/O Signal .................12 Subaru Select Monitor................16 Read Diagnostic Trouble Code (DTC) ............22 Inspection Mode..................23 Clear Memory Mode..................24 Warning Light Illumination Pattern ............25 List of Diagnostic Trouble Code (DTC) .............37 Diagnostic Procedure with Diagnostic Trouble Code (DTC) .....43...

  • Page 324: Basic Diagnostic Procedure

    Subaru Select Monitor while driving, because the ABS and VDC functions are disabled. Care- fully drive the vehicle, when you have to communicate with the Subaru Select Monitor. When the data is displayed by the {Current Data Display & Save} menu, both the ABS and VDC warning lights are turned off and ABS and VDC functions are enabled.
  • Page 325 Basic Diagnostic Procedure VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Step Check PERFORM DIAGNOSIS. Is DTC displayed? Repeat step 4 until Finish the diagno- 1) Refer to “List of Diagnostic Trouble Code DTC is not shown. sis. (DTC)”. NOTE: For the DTC list, refer to “List of Diagnostic Trouble Code (DTC)”.

  • Page 326: Check List For Interview

    Check List for Interview VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) 2. Check List for Interview A: CHECK Check the following items about the vehicle’s state. 1. STATE OF ABS WARNING LIGHT ❏ Always ABS warning light ❏ Sometimes come on. ❏ Only once ❏...
  • Page 327 Check List for Interview VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) 2. STATE OF VDC WARNING LIGHT AND VDC OFF INDICATOR LIGHT ❏ Always VDC warning light ❏ Sometimes and VDC OFF indi- ❏ Only once cator light come on. ❏ Not come on •...
  • Page 328 Check List for Interview VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) 4. CONDITIONS UNDER WHICH TROUBLE OCCURS ❏ Fine Environment a) Weather ❏ Cloudy ❏ Rainy ❏ Snowy ❏ Others: °C (°F) b) Ambient temperature ❏ Inner city c) Road ❏ Suburbs ❏...
  • Page 329 Check List for Interview VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Condition a) Brakes Deceleration: ❏ continuous / ❏ intermittent b) Accelerator Acceleration: ❏ continuous / ❏ intermittent c) Vehicle speed km/h ❏ Advancing ❏ When accelerating ❏ When decelerating ❏ At low speed ❏...

  • Page 330: General Description

    General Description VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) 3. General Description 6. TIRE Check the tire specifications, tire wear and air pres- A: CAUTION sure. <Ref. to WT-2, SPECIFICATION, General 1. SUPPLEMENTAL RESTRAINT SYSTEM Description.> “AIRBAG” Airbag system wiring harness is routed near the ABS wheel speed sensor and VDCCM&H/U.
  • Page 331 TOOL NUMBER DESCRIPTION REMARKS 24082AA230 CARTRIDGE Troubleshooting for electrical system. ST24082AA230 22771AA030 SUBARU SELECT Troubleshooting for electrical system. MONITOR KIT • English: 22771AA030 (Without printer) • German: 22771AA070 (Without printer) • French: 22771AA080 (Without printer) • Spanish: 22771AA090 (Without printer) ST22771AA030 2.

  • Page 332: Electrical Component Location

    Electrical Component Location VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) 4. Electrical Component Location A: LOCATION (4) (5) (6) (15) (12) (11) (10) (13) (14) (16) (10) (11) VDC00241 VDC control module and hydraulic ABS warning light (11) ABS wheel speed sensor control unit (VDCCM&H/U) VDC indicator light (12)
  • Page 333 Electrical Component Location VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) VDC00231 VDC00251 (11) (10) (10) VDC00235 VDC00234 (12) (13) VDC00250 VDC00242 (14) VDC00230 VDC(diag)-11...

  • Page 334: Control Module I/O Signal

    Control Module I/O Signal VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) 5. Control Module I/O Signal A: ELECTRICAL SPECIFICATION B310 17 18 22 23 24 25 26 33 34 38 39 40 41 42 VDC00211 NOTE: • Terminal numbers in VDCCM&H/U connector are as shown in the figure. •...
  • Page 335 10 — 15 V when the stop light is ON. Diagnosis connector When the ignition switch is ON, 10 — 15 V. 0 ←→ 12 V pulse (in communication) Subaru Select Monitor 26 — 6 0 ←→ 5 V pulse Vehicle speed output signal Ground —...
  • Page 336 Control Module I/O Signal VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) B: WIRING DIAGRAM (20) (21) (22) (23) (24) (25) (26) (27) (30) (28) (29) (31) (32) (33) (34) (35) (10) (11) (36) (12) (13) (37) (14) (15) (38) (16) (39) (17) (40) (18) (41)

  • Page 337: Terminal No

    Control Module I/O Signal VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) C: MEASUREMENT Measure input and output signal voltage. 1. WAVEFORM 28 – 16 2.1 – 2.9 V 5.0 V 2 – 16 20 ms VDC00212 Yaw rate sensor Terminal No. Vehicle is at a standstill. VDC(diag)-15...

  • Page 338: Subaru Select Monitor

    Do not connect the scan tools except for Suba- (DTC) ru Select Monitor. 1) Prepare the Subaru Select Monitor kit. <Ref. to 5) Turn the ignition switch to ON (engine OFF) and VDC(diag)-9, SPECIAL TOOL, PREPARATION turn the Subaru Select Monitor switch to ON.
  • Page 339 Select Monitor display. which is suffixed with a question mark “?” appears Indicate the latest DTC in previous trou- on the Subaru Select Monitor display. This shows it ble on the Subaru Select Monitor display. may be an unreliable reading.
  • Page 340 5) When “Done” and “Turn ignition switch OFF” are Wheel speed detected by rear ABS RL Wheel shown on the display screen, turn the Subaru Se- wheel speed sensor LH is displayed in Speed lect Monitor and ignition switch to OFF.
  • Page 341 Subaru Select Monitor VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) B: INSPECTION 1. COMMUNICATION FOR INITIALIZING IMPOSSIBLE DETECTING CONDITION: Defective harness connector TROUBLE SYMPTOM: Communication is impossible between VDC and Subaru Select Monitor. WIRING DIAGRAM: BATTERY DATA LINK CONNECTOR IGNITION SWITCH B310 VDCCM &...
  • Page 342 MUNICATION. model year displayed on Sub- 1) Turn the ignition switch to ON. aru Select Monitor? 2) Using the Subaru Select Monitor, check whether communication to other system can be executed normally. CHECK SUBARU SELECT MONITOR COM- Are the system name and Replace the Go to step 6.
  • Page 343 Subaru Select Monitor VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Step Check CHECK POWER SUPPLY CIRCUIT. Is the voltage 10 — 15 V? Go to step 11. Repair the open 1) Turn the ignition switch to ON. (engine circuit in harness OFF)

  • Page 344: Read Diagnostic Trouble Code (Dtc)

    Read Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) 7. Read Diagnostic Trouble Code (DTC) A: OPERATION For details concerning DTC reading procedure, re- fer to “Subaru Select Monitor”. <Ref. to VDC(diag)- 16, Subaru Select Monitor.> VDC(diag)-22...

  • Page 345: Inspection Mode

    Inspection Mode VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) 8. Inspection Mode A: PROCEDURE Reproduce the malfunction occurrence condition as possible. Drive the vehicle at least ten minutes. NOTE: Make sure the vehicle is not dragged to one side under usual driving condition. VDC(diag)-23...

  • Page 346: Clear Memory Mode

    Clear Memory Mode VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) 9. Clear Memory Mode A: OPERATION For details concerning DTC clear operation, refer to “Subaru Select Monitor”. <Ref. to VDC(diag)-16, Subaru Select Monitor.> VDC(diag)-24...

  • Page 347: Warning Light Illumination Pattern

    Warning Light Illumination Pattern VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) 10.Warning Light Illumination Pattern A: INSPECTION (10) (11) (12) (13) (14) VDC00214 Ignition switch Light ON (11) Several seconds (depending on engine coolant temperature) 1.5 sec. VDC indicator light (12) Brake warning light (EBD warning light) Engine start (10)
  • Page 348 Go to step 3. Replace the When the engine does not start, display the set to “ON”? VDCCM. current data of VDCCM using Subaru Select Monitor. CHECK LAN SYSTEM. Is there any fault in LAN sys- Perform the diag- Go to step 4.
  • Page 349 Warning Light Illumination Pattern VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) C: ABS WARNING LIGHT DOES NOT COME ON DETECTING CONDITION: • Defective combination meter • Defective harness TROUBLE SYMPTOM: When the ignition switch is turned to ON (engine OFF), ABS warning light does not come on. WIRING DIAGRAM: •...
  • Page 350 Warning Light Illumination Pattern VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) • RHD model BATTERY SBF-1 IGNITION SWITCH NO.5 BRAKE FLUID LEVEL SWITCH B310 VDCCM & H/U B229 PARKING BRAKE SWITCH B310 1 2 3 4 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26...
  • Page 351 Warning Light Illumination Pattern VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Step Check CHECK OTHER LIGHTS TURN ON. Do other warning lights illumi- Go to step 2. Check the combi- Turn the ignition switch to ON. (engine OFF) nate? nation meter. READ DTC. Is DTC displayed? Perform the diag- Go to step 3.
  • Page 352 Warning Light Illumination Pattern VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) D: ABS WARNING LIGHT DOES NOT GO OFF DETECTING CONDITION: • Defective combination meter • Open in harness TROUBLE SYMPTOM: When starting the engine, the ABS warning light is kept ON. WIRING DIAGRAM: •...
  • Page 353 Warning Light Illumination Pattern VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) • RHD model BATTERY SBF-1 IGNITION SWITCH NO.5 BRAKE FLUID LEVEL SWITCH B310 VDCCM & H/U B229 PARKING BRAKE SWITCH B310 1 2 3 4 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26...
  • Page 354 Warning Light Illumination Pattern VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Step Check READ DTC. Is DTC displayed? Perform the diag- Go to step 2. Read the DTC. <Ref. to VDC(diag)-22, Read nosis according to Diagnostic Trouble Code (DTC).> DTC. CHECK WIRING HARNESS. Is the resistance less than 0.5 Go to step 3.
  • Page 355 Warning Light Illumination Pattern VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) F: VDC WARNING LIGHT AND VDC OFF INDICATOR LIGHT DO NOT GO OFF DETECTING CONDITION: • Defective combination meter • Defective CAN communication • Defective engine • VDC OFF switch is shorted. TROUBLE SYMPTOM: When starting the engine, VDC OFF indicator light is kept ON.
  • Page 356 Warning Light Illumination Pattern VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) G: BRAKE WARNING LIGHT DOES NOT GO OFF DETECTING CONDITION: • Brake warning light circuit is shorted. • Defective sensor/connector TROUBLE SYMPTOM: After starting the engine, the brake warning light is kept on though the parking lever is released. WIRING DIAGRAM: •...
  • Page 357 Warning Light Illumination Pattern VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) • RHD model BATTERY SBF-1 IGNITION SWITCH NO.5 BRAKE FLUID LEVEL SWITCH B310 VDCCM & H/U B229 PARKING BRAKE SWITCH B310 1 2 3 4 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26...
  • Page 358 Warning Light Illumination Pattern VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Step Check CHECK INSTALLATION OF VDCCM&H/U Is the connector firmly Go to step 2. Insert the CONNECTOR. inserted? VDCCM&H/U con- 1) Turn the ignition switch to OFF. nector until it is 2) Check that VDCCM&H/U connector is locked by clamp.

  • Page 359: List Of Diagnostic Trouble Code (Dtc)

    List of Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) 11.List of Diagnostic Trouble Code (DTC) A: LIST Detailed Display Content of diagnosis Reference target code <Ref. to VDC(diag)-43, DTC C0021 FRONT ABS Abnormal power sup- FR sensor power supply WHEEL SPEED SENSOR RH POWER SUPPLY 698XH ply of front ABS wheel...
  • Page 360 List of Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Detailed Display Content of diagnosis Reference target code 608XH 648XH 688XH 6C8XH 704XH 606XH 646XH <Ref. to VDC(diag)-57, DTC C0029 ABS WHEEL 686XH ABS wheel speed sen- Any One of Four ABS SPEED SENSOR SIGNAL MALFUNCTION IN C0029 6C6XH...

  • Page 361: Power

    List of Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Detailed Display Content of diagnosis Reference target code <Ref. to VDC(diag)-62, DTC C0063 SECOND- Secondary suction Normal closing valve 1 ARY SUCTION VALVE MALFUNCTION IN C0063 520XH valve malfunction in malfunction VDCCM&H/U, Diagnostic Procedure with Diag- VDCCM&H/U...
  • Page 362 List of Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Detailed Display Content of diagnosis Reference target code <Ref. to VDC(diag)-75, DTC C0051 VALVE Valve relay OFF mal- 048XH Valve relay OFF failure RELAY OFF MALFUNCTION, Diagnostic Proce- function dure with Diagnostic Trouble Code (DTC).>...
  • Page 363 List of Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Detailed Display Content of diagnosis Reference target code <Ref. to VDC(diag)-94, DTC C0071 EXCESSIVE Excessive steering Steering angle sensor STEERING ANGLE SENSOR OUTPUT OFFSET, 148XH angle sensor output off- offset is too big Diagnostic Procedure with Diagnostic Trouble Code (DTC).>...
  • Page 364 List of Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Detailed Display Content of diagnosis Reference target code <Ref. to VDC(diag)-117, DTC C0073 EXCES- Excessive amount of 1C8XH Lateral G sensor offset SIVE AMOUNT OF LATERAL G SENSOR OUT- lateral G sensor output 1CAXH is too big...

  • Page 365: Diagnostic Procedure With Diagnostic Trouble Code (Dtc)

    Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) 12.Diagnostic Procedure with Diagnostic Trouble Code (DTC) A: DTC C0021 FRONT ABS WHEEL SPEED SENSOR RH POWER SUPPLY MALFUNCTION NOTE: For the diagnostic procedure, refer to DTC C0027 “REAR ABS WHEEL SPEED SENSOR LH POWER SUP- PLY MALFUNCTION”.
  • Page 366 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) D: DTC C0027 REAR ABS WHEEL SPEED SENSOR LH POWER SUPPLY MAL- FUNCTION DTC DETECTING CONDITION: Defective ABS wheel speed sensor TROUBLE SYMPTOM: • ABS does not operate. •...
  • Page 367 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Step Check CHECK POOR CONTACT IN CONNECTOR. Is there poor contact? Repair the con- Go to step 2. Check if there is poor contact in VDCCM&H/U nector. power supply circuit. CHECK VDCCM&H/U POWER SUPPLY CIR- Is the voltage 10 —...
  • Page 368 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) E: DTC C0021 OPEN/HIGH INPUT OF FRONT ABS WHEEL SPEED SENSOR RH NOTE: For the diagnostic procedure, refer to DTC C0027 “OPEN/HIGH INPUT OF REAR ABS WHEEL SPEED SENSOR LH”.
  • Page 369 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) H: DTC C0027 OPEN/HIGH INPUT OF REAR ABS WHEEL SPEED SENSOR LH DTC DETECTING CONDITION: • Defective ABS wheel speed sensor (broken wire, input voltage too high) • Defective harness connector TROUBLE SYMPTOM: •...
  • Page 370 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) • RHD model B310 VDCCM & H/U FRONT ABS FRONT ABS REAR ABS REAR ABS WHEEL SPEED WHEEL SPEED WHEEL SPEED WHEEL SPEED SENSOR LH SENSOR RH SENSOR LH SENSOR RH B310 1 2 3 4...
  • Page 371 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Step Check CHECK POOR CONTACT IN CONNECTOR. Is there poor contact? Repair the con- Go to step 2. Check if there is poor contact between nector. VDCCM&H/U and ABS wheel speed sensor. CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 0.5 Go to step 3.
  • Page 372 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Step Check CHECK VDCCM&H/U POWER SUPPLY CIR- Is the voltage 10 — 15 V? Go to step 7. Check the genera- CUIT. tor, battery and 1) Turn the ignition switch to OFF. VDCCM&H/U 2) Disconnect the VDCCM&H/U connector.
  • Page 373 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) I: DTC C0022 FRONT ABS WHEEL SPEED SENSOR RH SIGNAL MALFUNC- TION NOTE: For the diagnostic procedure, refer to DTC C0028 “REAR ABS WHEEL SPEED SENSOR LH SIGNAL MAL- FUNCTION”.
  • Page 374 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) L: DTC C0028 REAR ABS WHEEL SPEED SENSOR LH SIGNAL MALFUNC- TION DTC DETECTING CONDITION: • Defective ABS wheel speed sensor signal (noise, irregular signal, etc.) • Defective harness connector TROUBLE SYMPTOM: •...
  • Page 375 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) WIRING DIAGRAM: • LHD model B310 VDCCM & H/U FRONT ABS FRONT ABS REAR ABS REAR ABS WHEEL SPEED WHEEL SPEED WHEEL SPEED WHEEL SPEED SENSOR LH SENSOR RH SENSOR LH SENSOR RH B310...
  • Page 376 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) • RHD model B310 VDCCM & H/U FRONT ABS FRONT ABS REAR ABS REAR ABS WHEEL SPEED WHEEL SPEED WHEEL SPEED WHEEL SPEED SENSOR LH SENSOR RH SENSOR LH SENSOR RH B310 1 2 3 4...
  • Page 377 2) Read the ABS wheel speed sensor output in the straight-ahead position? corresponding to the faulty wheel in Subaru Select Monitor data display mode. CHECK POOR CONTACT IN CONNECTOR. Is there poor contact in con- Repair the con- Go to step 3.
  • Page 378 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Step Check CHECK VDCCM&H/U. Is the same DTC displayed? Replace the Go to step 13. 1) Connect all the connectors. VDCCM&H/U. 2) Erase the memory. <Ref. to VDC-7, 3) Perform the inspection mode.
  • Page 379 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) M: DTC C0029 ABS WHEEL SPEED SENSOR SIGNAL MALFUNCTION IN ONE OF FOUR WHEELS DTC DETECTING CONDITION: • Defective ABS wheel speed sensor signal (noise, irregular signal, etc.) •...
  • Page 380 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) WIRING DIAGRAM: • LHD model B310 VDCCM & H/U FRONT ABS FRONT ABS REAR ABS REAR ABS WHEEL SPEED WHEEL SPEED WHEEL SPEED WHEEL SPEED SENSOR LH SENSOR RH SENSOR LH SENSOR RH B310...
  • Page 381 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) • RHD model B310 VDCCM & H/U FRONT ABS FRONT ABS REAR ABS REAR ABS WHEEL SPEED WHEEL SPEED WHEEL SPEED WHEEL SPEED SENSOR LH SENSOR RH SENSOR LH SENSOR RH B310 1 2 3 4...
  • Page 382 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Step Check WHETHER A WHEEL TURNED FREELY OR Did the wheels turn freely? VDC is normal. Go to step 2. NOT. Erase the memory. Check if the wheels have been turned freely for NOTE: more than one minute, such as when the vehi- When the wheels...
  • Page 383 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Step Check CHECK OTHER DTC DETECTION. Is any other DTC displayed? Perform the diag- It results from a nosis according to temporary noise DTC. interference. NOTE: Though the ABS warning light re- mains on at this time, it is normal.
  • Page 384 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) S: DTC C0036 REAR OUTLET SOLENOID VALVE RH MALFUNCTION IN VDC- CM&H/U NOTE: For the diagnostic procedure, refer to DTC C0064 “PRIMARY SUCTION VALVE MALFUNCTION IN VDC- CM&H/U”. <Ref. to VDC(diag)-63, DTC C0064 PRIMARY SUCTION VALVE MALFUNCTION IN VDC- CM&H/U, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>...
  • Page 385 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Y: DTC C0064 PRIMARY SUCTION VALVE MALFUNCTION IN VDCCM&H/U DTC DETECTING CONDITION: • Defective harness connector • Defective VDCH/U solenoid valve TROUBLE SYMPTOM: • ABS does not operate. •...
  • Page 386 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Step Check CHECK INPUT VOLTAGE FOR VDCCM&H/ Is the voltage 10 — 15 V? Go to step 2. Repair the power supply circuit. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from VDCCM&H/ 3) Run the engine at idle.
  • Page 387 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Z: DTC C0041 VDC CONTROL MODULE MALFUNCTION DTC DETECTING CONDITION: Defective VDCCM&H/U TROUBLE SYMPTOM: • ABS does not operate. • EBD does not operate. • VDC does not operate. WIRING DIAGRAM: B310 VDCCM &...
  • Page 388 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Step Check CHECK GROUND CIRCUIT FOR VDCCM&H/ Is the resistance less than 0.5 Go to step 2. Repair the Ω? VDCCM&H/U 1) Turn the ignition switch to OFF. ground harness.
  • Page 389 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) AA:DTC C0042 POWER VOLTAGE MALFUNCTION DTC DETECTING CONDITION: Defective VDCCM&H/U power voltage TROUBLE SYMPTOM: • ABS does not operate. • EBD may not operate. • VDC does not operate. NOTE: Warning lights go off if voltage returns.
  • Page 390 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) WIRING DIAGRAM: BATTERY GENERATOR IGNITION SWITCH B310 VDCCM & H/U B310 1 2 3 4 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38...
  • Page 391 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Step Check CHECK GENERATOR. Is the voltage 10 — 15 V? Go to step 2. Repair the genera- 1) Start the engine. tor. <Ref. to 2) Run the engine at idle after warming up. SC(H4SO 2.0)-14, 3) Measure the voltage between generator B Generator.>...
  • Page 392 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) AB:DTC C0042 ABS WHEEL SPEED SENSOR POWER MALFUNCTION NOTE: For the diagnostic procedure, refer to DTC C0042 “POWER VOLTAGE MALFUNCTION”. <Ref. to VDC(di- ag)-67, DTC C0042 POWER VOLTAGE MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>...
  • Page 393 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) AD:DTC C0045 DIFFERENT VDC CONTROL MODULE SPECIFICATION DTC DETECTING CONDITION: Different control module specification TROUBLE SYMPTOM: • ABS does not operate. • VDC does not operate. Step Check CHECK VDCCM&H/U SPECIFICATION.
  • Page 394 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) AE:DTC C0045 AT CONTROL MODULE MALFUNCTION DTC DETECTING CONDITION: Defective TCM TROUBLE SYMPTOM: • ABS does not operate. • VDC does not operate. Step Check CHECK AT SYSTEM. Is DTC of AT system dis- Repair the AT sys- Go to step 2.
  • Page 395 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) AF:DTC C0047 IMPROPER CAN COMMUNICATION DTC DETECTING CONDITION: CAN communication line circuit is open or shorted. TROUBLE SYMPTOM: • ABS does not operate. • VDC does not operate. WIRING DIAGRAM: B310 VDCCM &...
  • Page 396 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Step Check CHECK LAN SYSTEM. Is there any fault in LAN sys- Perform the diag- Go to step 2. Perform the diagnosis for LAN system. <Ref. to tem? nosis according to LAN(diag)-24, OPERATION, Read Diagnostic DTC for LAN sys-...
  • Page 397 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) AG:DTC C0051 VALVE RELAY OFF MALFUNCTION DTC DETECTING CONDITION: Defective valve relay TROUBLE SYMPTOM: • ABS does not operate. • EBD does not operate. • VDC does not operate. WIRING DIAGRAM: BATTERY SBF-1...
  • Page 398 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Step Check CHECK INPUT VOLTAGE FOR VDCCM&H/ Is the voltage 10 — 15 V? Go to step 2. Repair the har- ness connector 1) Turn the ignition switch to OFF. between battery 2) Disconnect the connector from VDCCM&H/ and VDCCM&H/U.
  • Page 399 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) AH:DTC C0051 VALVE RELAY MALFUNCTION DTC DETECTING CONDITION: Defective valve relay TROUBLE SYMPTOM: • ABS does not operate. • EBD does not operate. • VDC does not operate. WIRING DIAGRAM: BATTERY SBF-1...
  • Page 400 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Step Check CHECK INPUT VOLTAGE FOR VDCCM&H/ Is the voltage 10 — 15 V? Go to step 2. Repair the power supply circuit. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from VDCCM&H/ 3) Run the engine at idle.
  • Page 401 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) AI: DTC C0051 VALVE RELAY TEST MALFUNCTION DTC DETECTING CONDITION: Defective valve relay TROUBLE SYMPTOM: • ABS does not operate. • EBD does not operate. • VDC does not operate. WIRING DIAGRAM: BATTERY SBF-1...
  • Page 402 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Step Check CHECK INPUT VOLTAGE FOR VDCCM&H/ Is the voltage 10 — 15 V? Go to step 2. Repair the power supply circuit in 1) Turn the ignition switch to OFF. VDCCM&H/U.
  • Page 403 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) AJ:DTC C0051 VALVE RELAY ON MALFUNCTION DTC DETECTING CONDITION: Defective valve relay TROUBLE SYMPTOM: • ABS does not operate. • VDC does not operate. • EBD may not operate. WIRING DIAGRAM: BATTERY SBF-1...
  • Page 404 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Step Check CHECK VALVE RELAY FOR VDCCM&H/U. Is the resistance more than 1 Go to step 2. Replace the 1) Disconnect the connector from VDCCM&H/ MΩ? VDCCM&H/U. <Ref. to VDC-7, 2) Measure the resistance between VDC Control Mod- VDCCM&H/U connector terminals.
  • Page 405 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) AK:DTC C0052 MOTOR/MOTOR RELAY MALFUNCTION DTC DETECTING CONDITION: • Defective motor and motor relay • Defective harness connector TROUBLE SYMPTOM: • ABS does not operate. • VDC does not operate. •...
  • Page 406 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Step Check CHECK INPUT VOLTAGE FOR VDCCM&H/ Is the voltage 10 — 15 V? Go to step 2. Repair the power supply circuit in 1) Turn the ignition switch to OFF. VDCCM&H/U.
  • Page 407 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) AL:DTC C0052 MOTOR/MOTOR RELAY OFF MALFUNCTION DTC DETECTING CONDITION: • Defective motor relay • Defective harness connector TROUBLE SYMPTOM: • ABS does not operate. • VDC does not operate. •...
  • Page 408 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) AM:DTC C0052 MOTOR/MOTOR RELAY ON MALFUNCTION DTC DETECTING CONDITION: • Defective motor relay • Defective harness connector TROUBLE SYMPTOM: • ABS does not operate. • VDC does not operate. •...
  • Page 409 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Step Check CHECK MOTOR RELAY FOR VDCCM&H/U. Is the resistance more than 1 Go to step 2. Replace the 1) Disconnect the connector from VDCCM&H/ MΩ? VDCCM&H/U. <Ref. to VDC-7, 2) Measure the resistance between VDC Control Mod- VDCCM&H/U connector terminals.
  • Page 410 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) AN:DTC C0052 MOTOR DTC DETECTING CONDITION: • Defective motor • Defective motor relay • Defective harness connector TROUBLE SYMPTOM: • ABS does not operate. • VDC does not operate. •...
  • Page 411 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) AO:DTC C0054 BLS OPEN CIRCUIT DTC DETECTING CONDITION: Defective stop light switch TROUBLE SYMPTOM: • ABS does not operate. • VDC does not operate. WIRING DIAGRAM: BATTERY STOP LIGHT SWITCH WC : WITH CRUISE CONTROL OC WC...
  • Page 412 1) Select {Current Data Display & Save} in Subaru Select Monitor. 2) Release the brake pedal. 3) Read the stop light switch output in Subaru Select Monitor. CHECK OUTPUT OF STOP LIGHT SWITCH Is ON displayed on the dis- Go to step 5.
  • Page 413 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) AP:DTC C0054 BLS ON MALFUNCTION DTC DETECTING CONDITION: Defective stop light switch TROUBLE SYMPTOM: • ABS does not operate. • VDC does not operate. WIRING DIAGRAM: BATTERY STOP LIGHT SWITCH WC : WITH CRUISE CONTROL OC WC...
  • Page 414 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Step Check CHECK STOP LIGHT SWITCH. Is the resistance more than 1 Go to step 2. Replace the stop 1) Turn the ignition switch to OFF. MΩ when switch is OFF (when light switch.
  • Page 415 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) AQ:DTC C0057 EGI COMMUNICATION DTC DETECTING CONDITION: No CAN signal from ECM. TROUBLE SYMPTOM: • ABS does not operate. • VDC does not operate. Step Check CHECK LAN SYSTEM. Is there any fault in LAN sys- Perform the diag- Go to step 2.
  • Page 416 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) AR:DTC C0071 EXCESSIVE STEERING ANGLE SENSOR OUTPUT OFFSET DTC DETECTING CONDITION: Defective steering angle sensor TROUBLE SYMPTOM: VDC does not operate. WIRING DIAGRAM: B310 VDCCM & H/U B231 STEERING ANGLE SENSOR B231...
  • Page 417 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Step Check CHECK STEERING WHEEL. Is the deviation from the center Go to step 2. Perform the cen- 1) Drive the vehicle on a flat road. of steering wheel less than 5°? tering adjustment 2) Park the vehicle straight.
  • Page 418 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) AS:DTC C0071 EXCESSIVE VARIATION AMOUNT OF STEERING ANGLE SEN- SOR OUTPUT DTC DETECTING CONDITION: Defective steering angle sensor TROUBLE SYMPTOM: VDC does not operate. WIRING DIAGRAM: B310 VDCCM & H/U B231 STEERING ANGLE SENSOR...
  • Page 419 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Step Check CHECK VDCCM&H/U. Is the same DTC displayed? Replace the Go to step 2. 1) Turn the ignition switch to OFF. VDCCM&H/U. 2) Connect all the connectors. <Ref.
  • Page 420 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) AT:DTC C0071 STEERING ANGLE SENSOR OUTPUT DTC DETECTING CONDITION: Defective steering angle sensor TROUBLE SYMPTOM: VDC does not operate. WIRING DIAGRAM: B310 VDCCM & H/U B231 STEERING ANGLE SENSOR B231 B310 1 2 3 4...
  • Page 421 CHECK OUTPUT OF STEERING ANGLE Does the steering angle sensor Go to step 4. Replace the steer- SENSOR WITH SUBARU SELECT MONI- output value on the display ing angle sensor. TOR. vary in accordance with steer- 1) Select {Current Data Display &...

  • Page 422: Signal

    Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) AU:DTC C0071 STEERING ANGLE SENSOR COMMUNICATION DTC DETECTING CONDITION: Signal does not come from the steering angle sensor. TROUBLE SYMPTOM: VDC does not operate. WIRING DIAGRAM: B310 VDCCM & H/U B231 STEERING ANGLE SENSOR...
  • Page 423 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Step Check CHECK POWER SUPPLY FOR STEERING Is the voltage 10 — 15 V? Go to step 4. Go to step 2. ANGLE SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from steering angle sensor.
  • Page 424 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Step Check CHECK STEERING ANGLE SENSOR. Is the same DTC displayed? Replace the Go to step 10. 1) Turn the ignition switch to OFF. VDCCM&H/U. 2) Connect all the connectors. <Ref.
  • Page 425 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) AV:DTC C0071 STEERING ANGLE SENSOR POWER SUPPLY MALFUNCTION DTC DETECTING CONDITION: Defective steering angle sensor TROUBLE SYMPTOM: • ABS does not operate. • VDC does not operate. NOTE: •...
  • Page 426 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) WIRING DIAGRAM: B310 VDCCM & H/U B231 STEERING ANGLE SENSOR B310 B231 1 2 3 4 1 2 3 4 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30...
  • Page 427 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Step Check CHECK POWER SUPPLY FOR STEERING Is the voltage 10 — 15 V? Go to step 4. Go to step 2. ANGLE SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from steering angle sensor.
  • Page 428 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) AW:DTC C0072 YAW RATE SENSOR OUTPUT DTC DETECTING CONDITION: Defective yaw rate sensor TROUBLE SYMPTOM: VDC does not operate. WIRING DIAGRAM: B310 VDCCM & H/U B312 B347 B230 YAW RATE &...
  • Page 429 CHECK OUTPUT OF YAW RATE & LATER- Is the reading indicated on Go to step 4. Replace the yaw monitor display −4 — 4 deg/s? AL G SENSOR WITH SUBARU SELECT rate & lateral G MONITOR. sensor. 1) Drive the vehicle on a flat road.
  • Page 430 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) AX:DTC C0072 YAW RATE SENSOR POWER/OUTPUT DTC DETECTING CONDITION: Defective yaw rate sensor TROUBLE SYMPTOM: VDC does not operate. WIRING DIAGRAM: B310 VDCCM & H/U B312 B347 B230 YAW RATE &...
  • Page 431 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Step Check CHECK YAW RATE & LATERAL G SENSOR Is the voltage 10 — 15 V? Go to step 4. Go to step 2. POWER SUPPLY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from the yaw rate &...
  • Page 432 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Step Check CHECK YAW RATE & LATERAL G SENSOR. Is the same DTC displayed? Replace the Go to step 11. 1) Turn the ignition switch to OFF. VDCCM&H/U. 2) Connect all the connectors.
  • Page 433 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) AY:DTC C0072 YAW RATE SENSOR REFERENCE DTC DETECTING CONDITION: Defective yaw rate sensor TROUBLE SYMPTOM: VDC does not operate. WIRING DIAGRAM: B310 VDCCM & H/U B312 B347 B230 YAW RATE &...
  • Page 434 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Step Check CHECK POWER SUPPLY FOR YAW RATE & Is the voltage 10 — 15 V? Go to step 3. Go to step 2. LATERAL G SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from yaw rate &...
  • Page 435 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Step Check CHECK VDCCM&H/U. Is the same DTC displayed? Replace the Go to step 10. 1) Turn the ignition switch to OFF. VDCCM&H/U. 2) Connect all the connectors. <Ref.
  • Page 436 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) AZ:DTC C0072 EXCESSIVE VARIATION AMOUNT OF YAW RATE SENSOR OUTPUT DTC DETECTING CONDITION: Defective yaw rate sensor TROUBLE SYMPTOM: VDC does not operate. WIRING DIAGRAM: B310 VDCCM & H/U B312 B347 B230...

  • Page 437: Power Supply

    Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Step Check CHECK DRIVING PLACE. Did the vehicle run the road VDCCM&H/U may Go to step 2. Check if the vehicle ran the road with banks or with banks or sandy surface record DTC when sandy surface (which does not mean a dirt (which does not mean a dirt...

  • Page 438: Signal

    Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Step Check CHECK YAW RATE & LATERAL G SENSOR. Is the voltage 2.1 — 2.9 V? Go to step 11. Replace the yaw 1) Turn the ignition switch to OFF. rate &...
  • Page 439 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) BA:DTC C0073 EXCESSIVE AMOUNT OF LATERAL G SENSOR OUTPUT OFF- NOTE: For the diagnostic procedure, refer to DTC C0073. <Ref. to VDC(diag)-118, DTC C0073 EXCESSIVE LAT- ERAL G SENSOR OUTPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> BB:DTC C0073 LATERAL G SENSOR OUTPUT NOTE: For the diagnostic procedure, refer to DTC C0073.
  • Page 440 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) BD:DTC C0073 EXCESSIVE LATERAL G SENSOR OUTPUT DTC DETECTING CONDITION: Defective lateral G sensor TROUBLE SYMPTOM: VDC does not operate. WIRING DIAGRAM: B310 VDCCM & H/U B312 B347 B230 YAW RATE &...
  • Page 441 6.8 sensor. from vehicle. — 12.8 m/s 3) Turn the ignition switch to ON, and select {Current Data Display & Save} in Subaru Select Monitor. 4) Read the lateral G sensor output displayed on display. CHECK LATERAL G SENSOR.
  • Page 442 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) BE:DTC C0073 LATERAL G SENSOR POWER/OUTPUT DTC DETECTING CONDITION: Defective lateral G sensor DTC DETECTING CONDITION: VDC does not operate. WIRING DIAGRAM: B310 VDCCM & H/U B312 B347 B230 YAW RATE &...
  • Page 443 Go to step 3. monitor display −1.5 — 1.5 1) Park the vehicle on a level surface. 2) Select {Current Data Display & Save} in Subaru Select Monitor. 3) Read the lateral G sensor output displayed on display. CHECK POOR CONTACT IN CONNECTORS.
  • Page 444 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Step Check CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in con- Repair the con- Go to step 10. nector between VDCCM&H/U nector. and yaw rate & lateral G sen- sor? CHECK VDCCM&H/U.
  • Page 445 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) BF:DTC C0074 PRESSURE SENSOR TEST MALFUNCTION DTC DETECTING CONDITION: Defective pressure sensor TROUBLE SYMPTOM: • ABS does not operate. • VDC does not operate. WIRING DIAGRAM: B310 VDCCM & H/U B348 PRESSURE SENSOR B310...
  • Page 446 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Step Check CHECK PRESSURE SENSOR POWER SUP- Is the voltage 4.75 — 5.25 V? Go to step 4. Go to step 2. PLY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from pressure sensor.
  • Page 447 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) BG:DTC C0074 EXCESSIVE PRESSURE SENSOR OUTPUT OFFSET DTC DETECTING CONDITION: Defective pressure sensor TROUBLE SYMPTOM: • ABS does not operate. • VDC does not operate. WIRING DIAGRAM: B310 VDCCM &...
  • Page 448 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Step Check CHECK STOP LIGHT SWITCH CIRCUIT. Is the stop light switch circuit Go to step 2. Repair the stop Check stop light switch open circuit. light switch circuit. CHECK VDCCM&H/U.
  • Page 449 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) BI: DTC C0074 PRESSURE SENSOR OUTPUT DTC DETECTING CONDITION: Defective pressure sensor TROUBLE SYMPTOM: • ABS does not operate. • VDC does not operate. WIRING DIAGRAM: B310 VDCCM & H/U B348 PRESSURE SENSOR B310...
  • Page 450 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Step Check CHECK STOP LIGHT SWITCH CIRCUIT. Is the stop light switch circuit Go to step 2. If there is malfunc- Check stop light switch open circuit. tion in the stop light switch circuit, DTC may be recorded in the...
  • Page 451 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Step Check CHECK OTHER DTC DETECTION. Is any other DTC displayed? Perform the diag- Temporary poor nosis according to contact occurs. DTC. VDC(diag)-129...
  • Page 452 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) BJ:DTC C0074 PRESSURE SENSOR POWER MALFUNCTION DTC DETECTING CONDITION: Defective pressure sensor TROUBLE SYMPTOM: • ABS does not operate. • VDC does not operate. WIRING DIAGRAM: BATTERY GENERATOR IGNITION SWITCH B310...
  • Page 453 Diagnostic Procedure with Diagnostic Trouble Code (DTC) VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Step Check CHECK POOR CONTACT IN CONNECTORS. Is there poor contact? Repair the con- Go to step 2. Check if there is poor contact in VDCCM&H/U nector. power supply circuit. CHECK VDCCM&H/U POWER SUPPLY CIR- Is the voltage 10 —...
  • Page 454 General Diagnostic Table VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) 13.General Diagnostic Table A: INSPECTION Symptom Main probable cause Other probable cause Poor brake per- Long braking/ • VDCCM&H/U • Defective ABS wheel speed sensor or sensor formance stopping dis- • Brake pad tance •...
  • Page 455 General Diagnostic Table VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Symptom Main probable cause Other probable cause Vibration or Excessive • Road surface (uneven) • VDCCM&H/U noise brake pedal • Incorrect wiring or piping connections • Brake booster • When brak- vibration •...
  • Page 456 General Diagnostic Table VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Symptom Main probable cause Other probable cause Poor change- Deviation to • VDCCM&H/U • Disc rotor direction-opera- right or left • Defective ABS wheel speed sensor or • Brake pipe tion stability of direction sensor gap •...
  • Page 457 General Diagnostic Table VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) Symptom Main probable cause Other probable cause VDC OFF indicator light does not • Harness come on when the VDC OFF • Indicator light bulb switch is depressed. • VDC OFF switch NOTE: When pressing VDC OFF switch for more than 10 seconds, VDC...
  • Page 458 General Diagnostic Table VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) VDC(diag)-136...

  • Page 459: Power

    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 460 BRAKE Page General Description ..................2 Front Brake Pad ..................16 Front Disc Rotor ..................19 Front Disc Brake Assembly...............20 Rear Brake Pad..................25 Rear Disc Rotor..................26 Rear Disc Brake Assembly ...............28 Master Cylinder ..................30 Brake Booster ...................32 Brake Fluid ....................36 Air Bleeding....................38 Brake Hose ....................40 Brake Pipe....................42 Brake Pedal....................43 Stop Light Switch ..................45...

  • Page 461: General Description

    • When brake fluid is supplemented, be careful not to allow any dust into the reser- voir. • Use fresh SUBARU genuine brake fluid when replacing or refilling the fluid. NOTE: Refer to “PB” section for parking brake specifications. <Ref. to PB-2, SPECIFICATION, General Descrip- tion.>...
  • Page 462 General Description BRAKE Item Standard value Limit Except 17-inch 11 (0.43) 1.5 (0.059) Pad thickness type mm (in) 17-inch type 11 (0.43) 1.5 (0.059) Front brake Except 17-inch 24 (0.94) 22 (0.87) Disc thickness type mm (in) 17-inch type 30 (1.18) 28 (1.10) Disc runout mm (in)
  • Page 463 General Description BRAKE B: COMPONENT 1. FRONT DISK BRAKE • Except for EC, EK, OUTBACK model ( 3) (4 ) (1 ) (7 ) (A ) (17 ) (10 ) ( 11 ) ( 12 ) (B ) ( 14 ) (13) (12) (1 1)
  • Page 464 General Description BRAKE • EC, EK, OUTBACK model ( 2) (5 ) (7 ) ( 8) (17) ( 10) (4 ) ( 11 ) ( 12 ) ( 14) (13) (11 ) ( 16) ( 15) BR-00373 Caliper body Support (17) Bushing Air bleeder screw...
  • Page 465 General Description BRAKE 2. REAR DISC BRAKE (34 ) (3 ) ( 4) ( 35 ) ( 14) (1 4) ( 12) (1 0) (4 ) (1 1) (1 4) ( 17) (1 6) (1 1) (13 ) (1 8) (1 9) ( 20) ( 21)
  • Page 466 General Description BRAKE 3. MASTER CYLINDER • LHD model (10) (11) BR-00371 Secondary piston (11) O-ring Filter Cylinder body ⋅ Reservoir tank Cylinder pin Tightening torque: N m (kgf-m, ft-lb) C-ring Seal T: 13 (1.3, 9.6) Primary piston (10) BR-7...
  • Page 467 General Description BRAKE • RHD model (10) (11) BR-00334 Secondary piston (11) O-ring Filter Cylinder body ⋅ Reservoir tank Cylinder pin Tightening torque: N m (kgf-m, ft-lb) C-ring Seal T: 13 (1.3, 9.6) Primary piston (10) BR-8...
  • Page 468 General Description BRAKE 4. FRONT BRAKE PIPES AND HOSE • LHD model (10) BR-00372 ⋅ Model with ABS Clamp Tightening torque: N m (kgf-m, ft-lb) Model with Vehicle dynamics con- Gasket T1: 15 (1.5, 10.8) trol (VDC) ABS control module and hydraulic T2: 18 (1.8, 13.0) control unit (ABSCM&H/U) T3: 19 (1.9, 14.0)
  • Page 469 General Description BRAKE • RHD model (10) BR-00336 ⋅ Model with ABS Gasket Tightening torque: N m (kgf-m, ft-lb) Model with VDC ABS control module and hydraulic T1: 15 (1.5, 10.8) control unit (ABSCM&H/U) T2: 18 (1.8, 13.0) Front brake pipe ASSY Bracket T3: 19 (1.9, 14.0) Two-way connector...
  • Page 470 General Description BRAKE 5. CENTER AND REAR BRAKE PIPES AND HOSE (11) (11) (10) (10) (12) (10) (11) (10) (11) (10) (10) BR-00337 ⋅ Center brake pipe ASSY Rear brake pipe LH Tightening torque: N m (kgf-m, ft-lb) Two-way connector Rear brake hose rear RH T1: 15 (1.5, 10.8) Rear brake pipe ASSY...
  • Page 471 General Description BRAKE 6. BRAKE BOOSTER BR-00335 Brake booster BR-12...
  • Page 472 General Description BRAKE 7. BRAKE PEDAL • LHD MT model BR-00375 ⋅ Brake pedal ASSY Clutch pedal Tightening torque: N m (kgf-m, ft-lb) Stop light switch Clutch pedal pad T1: 8 (0.8, 5.8) Brake pedal pad Clutch switch T2: 18 (1.8, 13.0) BR-13...
  • Page 473 General Description BRAKE • LHD AT model, RHD model BR-00338 ⋅ Brake pedal ASSY Brake pedal pad Tightening torque: N m (kgf-m, ft-lb) Stop light switch T1: 8 (0.8, 5.8) T2: 18 (1.8, 13.0) BR-14...
  • Page 474 • Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary re- moval, installation, disassembly and replacement. • Use SUBARU genuine grease etc. or equivalent. Do not mix grease, etc. with that of another grade or from other manufacturers.

  • Page 475: Front Brake Pad

    Front Brake Pad BRAKE 2. Front Brake Pad (4) Attach a rod of less than 12 mm (0.47 in) di- ameter to the shaded area of the brake pad, and A: REMOVAL strike the rod with a hammer to drive brake pad out of place.
  • Page 476 Front Brake Pad BRAKE 3) Apply a thin coat of Molykote AS880N (Part No. 3) Apply a thin coat of Molykote AS880N (Part No. K0779YA010) to the three frictional portions be- K0779YA010) to the three frictional portions be- tween inner shim and outer shim of outer pads. tween inner shim and outer shim of outer pads.
  • Page 477 Front Brake Pad BRAKE • When the pad return spring is deformed or 3. 17-INCH TYPE damaged, replace the brake pad with new one. Check the pad thickness A. BR-00343 BR-00360 (1) Pad return spring Standard 11 (0.43) Pad thickness (2) Supporting surface of pad clip value mm (in)

  • Page 478: Front Disc Rotor

    Front Disc Rotor BRAKE 3. Front Disc Rotor C: INSPECTION 1) Check front wheel bearing play and axial hub A: REMOVAL runout before disc rotor runout limit inspection. <Ref. to DS-15, INSPECTION, Front Axle.> 1. 15-INCH TYPE 2) Secure the disc rotor by tightening five wheel 1) Lift-up the vehicle, and remove the front wheels.

  • Page 479: Front Disc Brake Assembly

    Front Disc Brake Assembly BRAKE 4. Front Disc Brake Assembly 6) Clean mud and foreign particles from the caliper body assembly and the support. A: REMOVAL 2. 16-INCH TYPE 1. 15-INCH TYPE Refer to 15-inch type. <Ref. to BR-20, 15-INCH TYPE, REMOVAL, Front Disc Brake Assembly.>...
  • Page 480 Front Disc Brake Assembly BRAKE 4) Apply a thin coat of Molykote AS880N (Part No. 3) Apply a thin coat of Molykote AS880N (Part No. K0777YA010) to the three frictional portions be- K0777YA010) to the frictional portion between pad tween inner shim and outer shim of outer pads. and inner shim.
  • Page 481 Front Disc Brake Assembly BRAKE 5) Install the pad on support. 7) Using new brake hose gaskets, connect the brake hose. NOTE: Install the pad indicator in proper direction. Tightening torque: ⋅ 18 N m (1.8 kgf-m, 13.0 ft-lb) 8) Bleed air from brake system. C: DISASSEMBLY 1.
  • Page 482 Front Disc Brake Assembly BRAKE CAUTION: CAUTION: Do not damage the cylinder and piston seal Do not force the piston into cylinder. groove. BR-00242 BR-00027 (1) Piston (1) Piston seal (2) Piston boot 6) Remove the guide pin and boot from caliper 6) Position the boot in the grooves on cylinder and body.
  • Page 483 Front Disc Brake Assembly BRAKE 2. 16-INCH TYPE Refer to 15-inch type. <Ref. to BR-23, 15-INCH TYPE, ASSEMBLY, Front Disc Brake Assembly.> 3. 17-INCH TYPE Refer to 15-inch type. <Ref. to BR-23, 15-INCH TYPE, ASSEMBLY, Front Disc Brake Assembly.> E: INSPECTION 1) Repair or replace the faulty parts.

  • Page 484: Rear Brake Pad

    Rear Brake Pad BRAKE 5. Rear Brake Pad 4) Install the caliper body on support. Tightening torque: A: REMOVAL Solid disc brake model 1) Lift-up the vehicle, and then remove the rear ⋅ 27 N m (2.8 kgf-m, 19.9 ft-lb) wheels.

  • Page 485: Rear Disc Rotor

    Rear Disc Rotor BRAKE 6. Rear Disc Rotor (2) If the disc rotor seizes up within hub, drive the disc rotor out by pushing with an 8 mm bolt in A: REMOVAL holes B on the rotor. 1) Lift-up the vehicle, and then remove the rear wheels.
  • Page 486 Rear Disc Rotor BRAKE 4) Set a micrometer 10 mm (0.39 in) inward of the rotor outer perimeter, and then measure the disc rotor thickness. If the thickness of disc rotor is out- side the service limit, replace with a new disc rotor. BR-00036 Standard value Limit...

  • Page 487: Rear Disc Brake Assembly

    Rear Disc Brake Assembly BRAKE 7. Rear Disc Brake Assembly B: INSTALLATION 1) Install the support on housing. A: REMOVAL Tightening torque: CAUTION: ⋅ 53 N m (5.4 kgf-m, 39.1 ft-lb) Do not allow brake fluid to come in contact with 2) Apply a thin coat of Molykote M7439 to the pad vehicle body;...
  • Page 488 Rear Disc Brake Assembly BRAKE 3) Gradually supply compressed air via installation 6) Position the boot in grooves on cylinder and pis- hole of brake hose to force the piston out. ton. BR-00042 BR-00243 (1) Place a 30 mm (1.18 in) wide wooden block (1) Piston here.

  • Page 489: Master Cylinder

    Master Cylinder BRAKE 8. Master Cylinder NOTE: To avoid damaging master cylinder, use aluminum A: REMOVAL plate while holding with vise. CAUTION: 3) Remove the pin which secures the reservoir tank Do not allow brake fluid to come in contact with to master cylinder, and then remove the reservoir vehicle body;...
  • Page 490 Master Cylinder BRAKE 9) Ensure that the inner wall of master cylinder, and D: INSPECTION piston assembly are free of dirt when assembling. Inspect for oil leakage from the master cylinder. Install the primary piston assembly and secondary NOTE: piston assembly, while taking care not to damage After replacing piston kit;...

  • Page 491: Brake Booster

    Brake Booster BRAKE 9. Brake Booster • Use care when placing the brake booster on the floor. A: REMOVAL • Do not change the push rod length. 1) Remove or disconnect the following parts at en- CAUTION: gine compartment. • Do not disassemble the brake booster. (1) Disconnect the connector for brake fluid lev- •...
  • Page 492 Brake Booster BRAKE 3) Connect the operating rod to brake pedal with 8) Measure the clearance between the threaded clevis pin and snap pin. end of stop light switch and stopper. If it is not within specified value, adjust it by adjust- ing the position of stop light switch.
  • Page 493 Brake Booster BRAKE • AIR TIGHTNESS CHECK 3) As engine starts, the brake pedal should move slowly toward the floor. If no change occurs in the Start the engine, and idle it for 1 to 2 minutes, then pedal height, the brake booster is faulty. turn it OFF.
  • Page 494 Brake Booster BRAKE • AIR TIGHTNESS CHECK 2) Stop the engine and watch vacuum gauge. If the vacuum drop range is less than 3.3 kPa (25 1) Start the engine and keep it running until a vac- mmHg, 0.98 inHg) within 15 seconds after stopping uum of 66.7 kPa (500 mmHg, 19.69 inHg) = point A the engine, brake booster is functioning properly.

  • Page 495: Brake Fluid

    RH → (B) Rear LH → (C) Front LH → (D) Rear RH • Fresh Subaru genuine fluid must be used. • Cover the bleeder with cloth, when loosening it, to prevent brake fluid from being splashed over surrounding parts.
  • Page 496 Brake Fluid BRAKE 11) Depress the brake pedal with a force of approx- imately 294 N (30 kgf, 66 lb) and hold it there for ap- proximately 20 seconds to check for no entry of air and if pedal height remain same. Visually inspect the bleeder screws and brake pipe joints to make sure that there is no fluid leakage.

  • Page 497: Air Bleeding

    A: PROCEDURE 7) Remove the plastic bag. 8) Install the brake pipes to master cylinder. CAUTION: • Fresh Subaru genuine fluid must be used. Tightening torque: ⋅ • Cover the bleeder with cloth, when loosening 15 N m (1.5 kgf-m, 10.8 ft-lb)
  • Page 498 Air Bleeding BRAKE 3) Slowly depress the brake pedal and keep it de- 7) If the distance is more than specified, there is a pressed. Then, open the air bleeder to discharge possibility that air is in the brake line. Bleed the air together with the fluid.

  • Page 499: Brake Hose

    Brake Hose BRAKE 12.Brake Hose 3) Remove the clamp and remove the brake hose. A: REMOVAL 1. FRONT BRAKE HOSE 1) Separate the brake pipe from brake hose using a flare nut wrench. 2) Remove the clamp, bolt at strut mount, and union bolt.
  • Page 500 Brake Hose BRAKE 3) Install the brake hose to rear brake caliper using CAUTION: a new gasket. Be sure the brake hose is not twisted. 4) Temporarily tighten the flare nut to connect the Tightening torque (Union bolt): ⋅ brake pipe and hose. 18 N m (1.8 kgf-m, 13.0 ft-lb) 5) Fix the brake hose with clamp at wheel apron...

  • Page 501: Brake Pipe

    Brake Pipe BRAKE 13.Brake Pipe A: REMOVAL NOTE: Airbag system wiring harness is routed near the center brake pipe. CAUTION: • All airbag system wiring harness and con- nectors are colored yellow. Do not use the elec- trical test equipment on these circuits. •...

  • Page 502: Brake Pedal

    Brake Pedal BRAKE 14.Brake Pedal 4) Remove the bolts and nuts which secure pedal bracket. A: REMOVAL 1. LHD MT MODEL 1) Remove the steering shaft. 2) Disconnect the connectors (stop light switch) from pedal bracket. 3) Remove the clevis pin which secures lever to push rod.
  • Page 503 Brake Pedal BRAKE CAUTION: If excessive deflection is noted, replace the bushing with a new one. Deflection of brake pedal: Limit 5.0 mm (0.197 in) or less BR-00105 (1) Brake pedal 2) Check the position of pedal pad. Pedal height L: LHD: 150 —...

  • Page 504: Stop Light Switch

    Stop Light Switch BRAKE 15.Stop Light Switch Specified position L: 2 mm (0.079 in) A: REMOVAL 1) Disconnect the ground cable from battery. 2) Disconnect the stop light switch connector. 3) Loosen the nuts, and unscrew the stop light switch to remove. BR-00109 2) Measure the clearance between the threaded end of stop light switch and stopper.
  • Page 505 Stop Light Switch BRAKE Tightening torque: ⋅ m (0.8 kgf-m, 5.8 ft-lb) BR-00111 (1) Stop light switch (2) Lock nut A (3) Lock nut B (4) Stopper (5) Brake pedal NOTE: Tighten the lock nut B until the clearance between the threaded end of stop light switch and stopper becomes 0 mm (0 inch).

  • Page 506: Diagnosis

    Diagnosis BRAKE 16.Diagnosis A: INSPECTION Trouble and possible cause Corrective action 1. Insufficient braking (1) Fluid leakage from the hydraulic mechanism Correct or replace. (cup, piston seal, piston boot, master cylinder piston kit, pipe or hose) (2) Entry of air into the hydraulic mechanism Bleed air.
  • Page 507 Diagnosis BRAKE BR-48...

  • Page 508: Power

    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 509 PARKING BRAKE Page General Description ..................2 Parking Brake Lever..................5 Parking Brake Cable ...................6 Parking Brake Assembly (Rear Disc Brake) ..........7 General Diagnostic Table................10...

  • Page 510: General Description

    General Description PARKING BRAKE 1. General Description A: SPECIFICATION Type Mechanical on rear brakes, drum in disc Effective drum mm (in) 170 (6.69) diameter Lining dimensions 163.1 × 30.0 × 3.2 (length × width × mm (in) (6.421 × 1.181 × 0.126) thickness) Clearance adjustment Manual adjustment...
  • Page 511 General Description PARKING BRAKE B: COMPONENT 1. PARKING BRAKE (REAR DISC BRAKE) (17) (11) (13) (10) (12) (15) (14) (16) PB-00048 Back plate Strut spring (13) Adjuster Retainer Strut (14) Shoe hold-down cup Spring washer Shoe guide plate (15) Shoe hold-down spring Lever (10) Primary return spring...
  • Page 512 • Be careful not to burn your hands, because each part on the vehicle is hot after running. • Use SUBARU genuine grease etc. or the equiv- alent. Do not mix grease etc. with that of another grade or from other manufacturers.

  • Page 513: Parking Brake Lever

    Parking Brake Lever PARKING BRAKE 2. Parking Brake Lever A: REMOVAL 1) Set the wheel stoppers to tires. 2) Remove the console box. 3) Disconnect the parking brake switch connector. 4) Remove the parking cable adjusting nut (self- locking nut). 5) Remove the parking brake lever.

  • Page 514: Parking Brake Cable

    Parking Brake Cable PARKING BRAKE 3. Parking Brake Cable 12) Remove the cable assembly. B: INSTALLATION A: REMOVAL 1) Install in the reverse order of removal. 1) Remove the rear seat cushion. NOTE: 2) Remove the console box. Be sure to pass the cable through the cable guide 3) Remove the parking cable adjusting nut (self- inside tunnel.

  • Page 515: Parking Brake Assembly (Rear Disc Brake)

    Parking Brake Assembly (Rear Disc Brake) PARKING BRAKE 4. Parking Brake Assembly (2) If the disc rotor seizes up within hub, drive out the disc rotor by pushing two 8 mm bolts in (Rear Disc Brake) holes B on rotor. A: REMOVAL 1) Release the parking brake.
  • Page 516 Parking Brake Assembly (Rear Disc Brake) PARKING BRAKE B: INSTALLATION • Install the adjuster assembly with screw on left side. CAUTION: Be sure the lining surface is free from oil and grease contamination. 1) Apply brake grease to the following places. Brake grease: Brake Grease (Part No.

  • Page 517: Standard (Yaw Rate Sensor)

    Parking Brake Assembly (Rear Disc Brake) PARKING BRAKE C: INSPECTION 2. LEVER STROKE 1) Measure the brake disc rotor inside diameter. If 1) Adjust the shoe clearance before lever stroke the disc is scored or worn, replace the brake disc adjustment.

  • Page 518: General Diagnostic Table

    General Diagnostic Table PARKING BRAKE 5. General Diagnostic Table A: INSPECTION Symptom Possible cause Remedy Parking brake lever is maladjusted. Adjustment. Parking brake cable does not move. Repair or replace. Brake drag Parking brake shoe clearance is maladjusted. Adjustment. Return spring is faulty. Replace.

  • Page 519: Vdc(Diag)-13

    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 520 POWER ASSISTED SYSTEM (POWER STEERING) Page General Description ..................2 Steering Wheel..................20 Universal Joint...................21 Tilt Steering Column..................23 Steering Gearbox [LHD Model] ..............25 Steering Gearbox [RHD Model] ..............46 Pipe Assembly [LHD Model] ..............65 Pipe Assembly [RHD Model]..............71 Oil Pump ....................77 Reservoir Tank..................83 Power Steering Fluid.................84 General Diagnostic Table................85...
  • Page 521 General Description POWER ASSISTED SYSTEM (POWER STEERING) 1. General Description A: SPECIFICATION Non-turbo Model Turbo 3.0 R (Except for 3.0 R) Minimum turning radius m (ft) 5.4 (17.8) 2.0 i, 2.5 i: 37.3° — 33.0°, 2.0 GT, 3.0 R: 37.2° — 32.9°, Steering angle (Inside —...
  • Page 522 General Description POWER ASSISTED SYSTEM (POWER STEERING) Steering Free play mm (in) 17 (0.67) wheel 2.0 i, 2.5 i: 37.3°±1.5°, 2.0 GT, 3.0 R: 37.2°±1.5°, Inner wheel OUTBACK: 37.8°±1.5° Steering angle 2.0 i, 2.5 i: 33.0°±1.5°, 2.0 GT, 3.0 R: 32.9°±1.5°, Outer wheel OUTBACK: 33.5°±1.5°...
  • Page 523 General Description POWER ASSISTED SYSTEM (POWER STEERING) B: COMPONENT 1. STEERING WHEEL AND COLUMN PS-00501 ⋅ Bushing Steering wheel Tightening torque: N m (kgf-m, ft-lb) Steering shaft Airbag module T1: 1.2 (0.12, 0.9) Steering roll connector Steering wheel lower cover T2: 25 (2.5, 18.1) Column cover Insulator...

  • Page 524: General Description

    General Description POWER ASSISTED SYSTEM (POWER STEERING) 2. POWER ASSISTED SYSTEM • Hose and tank (16) (19) (19) (17) (15) (18) (19) (19) (20) (12) (13) (11) (10) (14) PS-00479 Eye bolt (10) Oil pump (19) Clip Hose (11) Suction hose (Non-turbo model) (20) Clip Eye bolt gasket...
  • Page 525 General Description POWER ASSISTED SYSTEM (POWER STEERING) • Gearbox (LHD model) (39) (20) (21) (17) (16) (18) (19) (22) (34) (41) (23) (33) (14) (24) (12) (25) (13) (10) (15) (26) (39) (11) (31) (42) (32) (22) (27) (23) (27) (30) (40) (28)
  • Page 526 General Description POWER ASSISTED SYSTEM (POWER STEERING) • Gearbox (RHD model) (35) (19) (34) (33) (28) (32) (31) (27) (26) (30) (25) (29) (24) (23) (22) (36) (21) (20) (12) (37) (11) (19) (10) (13) (18) (14) (17) (16) (15) PS-00505 Universal joint (17)

  • Page 527: Oil Pump

    General Description POWER ASSISTED SYSTEM (POWER STEERING) 3. OIL PUMP PS-00480 ⋅ Oil pump Tightening torque: N m (kgf-m, ft-lb) Pulley T1: 8 (0.8, 5.8) Bracket T2: 15.7 (1.6, 11.6) Belt tension nut T3: 22 (2.2, 15.9) T4: 25 (2.5, 18.1) T5: 37.3 (3.8, 27.5) PS-8...
  • Page 528 • Be careful not to burn yourself, because each part on the vehicle is hot after running. • Use SUBARU genuine power steering fluid, grease etc. or the equivalent. Do not mix fluid, grease etc. with that of another grade or from other manufacturers.
  • Page 529 General Description POWER ASSISTED SYSTEM (POWER STEERING) D: PREPARATION TOOL 1. SPECIAL TOOL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 925711000 PRESSURE Used for measuring oil pump pressure. GAUGE ST-925711000 926200000 STAND • Used when inspecting characteristic of gear- box assembly and disassembling it. •...
  • Page 530 General Description POWER ASSISTED SYSTEM (POWER STEERING) ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 926230000 SPANNER For the lock nut when adjusting backlash of gear- box. ST-926230000 34099PA100 SPANNER Used when measuring the rotating resistance of gearbox assembly. ST34099PA100 926420000 PLUG When fluid leaks from pinion side of gearbox assembly, remove pipe B from valve housing, attach this tool and check fluid leaking points.
  • Page 531 General Description POWER ASSISTED SYSTEM (POWER STEERING) ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 34099FA060 PUNCH HOLDER Used for caulking. ST34099FA060 34099FA080 PUNCH • Used for removing caulking. • For RHD model. ST34099FA080 34199AE090 PLUG WRENCH • Used for removing plug. • For RHD model. ST34199AE090 34199AE100 OIL SEAL PLUG...
  • Page 532 General Description POWER ASSISTED SYSTEM (POWER STEERING) ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 34199AE110 OIL SEAL PLUG • Used for installing oil seal plug. INSTALLER • For RHD model. ST34199AE110 34199AE120 GEARBOX OIL • Used for removing gearbox oil seal. SEAL REMOVER •...
  • Page 533 General Description POWER ASSISTED SYSTEM (POWER STEERING) ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 927490000 INSTALLER A, B, C • Used for installing oil seal to rack assembly. • Except for turbo and 3.0 R model. ST-927490000 34199FE010 REMOVER • Used for removing backup ring and oil seal. •...
  • Page 534 General Description POWER ASSISTED SYSTEM (POWER STEERING) ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 34199AE000 GUIDE • Used for installing rack and seal into housing assembly. • Except for turbo and 3.0 R model. ST34199AE000 34199FE000 INSTALLER & • Used for removing and installing rack oil seal REMOVER (outer &...
  • Page 535 General Description POWER ASSISTED SYSTEM (POWER STEERING) ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 34199AE010 INSTALLER • Used for installing rack oil seal (outer). • Except for turbo and 3.0 R model. • For RHD model. ST34199AE010 34199FE020 BASE • Used for support housing assembly. •...
  • Page 536 General Description POWER ASSISTED SYSTEM (POWER STEERING) ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 34199AG040 GUIDE • Used for installing sealing of rack. • For 3.0 R model. • For LHD model. ST34199AG040 34199AG030 GUIDE • Used for installing seal ring of rack. •...
  • Page 537 General Description POWER ASSISTED SYSTEM (POWER STEERING) ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 34199AG060 GUIDE G (26) • Used for forming seal ring of rack. • For 3.0 R model. • For LHD model. • Used with FORMER PISTON (34199AG080). ST34199AG060 34199AG050 GUIDE G (24) •...
  • Page 538 General Description POWER ASSISTED SYSTEM (POWER STEERING) ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 34199AG090 INSTALLER & • Used for installing oil seal of valve housing. REMOVER • Used with SEAL INSTALLER (34099FA130). • Used for installing ball bearing of valve hous- ing.

  • Page 539: Steering Wheel

    Steering Wheel POWER ASSISTED SYSTEM (POWER STEERING) 2. Steering Wheel 2) Check the splines on the steering wheel for dam- age. If the damage is excessive, replace the steer- A: REMOVAL ing wheel. 1) Disconnect the ground cable from battery. 2) Set the tire to the straight-ahead position.

  • Page 540: Universal Joint

    Universal Joint POWER ASSISTED SYSTEM (POWER STEERING) 3. Universal Joint Tightening torque: ⋅ 24 N m (2.4 kgf-m, 17.4 ft-lb) A: REMOVAL CAUTION: 1) Remove the steering wheel. <Ref. to PS-20, RE- Excessively large tightening torque of univer- MOVAL, Steering Wheel.> sal joint bolts may lead to heavy steering wheel 2) Place alignment marks on universal joint.
  • Page 541 Universal Joint POWER ASSISTED SYSTEM (POWER STEERING) Service limit: Maximum load: 3.8 N (0.39 kgf, 0.86 lb) or less PS-00035 (1) Yoke (Gearbox side) Service limit: Maximum load: 7.3 N (0.74 kgf, 1.64 lb) or less PS-00036 (1) Yoke (Steering column side) Service limit: Maximum load: 7.3 N (0.74 kgf, 1.64 lb) or less PS-00037...

  • Page 542: Tilt Steering Column

    Tilt Steering Column POWER ASSISTED SYSTEM (POWER STEERING) 4. Tilt Steering Column A: REMOVAL PS-00466 Tilt steering column Universal joint 1) Remove the steering wheel. <Ref. to PS-20, RE- CAUTION: MOVAL, Steering Wheel.> • Be sure to remove the universal joint before 2) Remove the universal joint.
  • Page 543 Tilt Steering Column POWER ASSISTED SYSTEM (POWER STEERING) B: INSTALLATION D: ASSEMBLY 1) Install the grommet to toe board. Insert the combination switch to the upper column shaft, and install the upper column cover. Then route the ignition key harness and combination switch harness between column cover mounting bosses.

  • Page 544: Steering Gearbox [Lhd Model]

    Steering Gearbox [LHD Model] POWER ASSISTED SYSTEM (POWER STEERING) 5. Steering Gearbox [LHD Mod- 9) Remove the one pipe joint at the center of gear- box, and connect the vinyl hose to the pipe and the joint. Discharge the fluid by turning steering wheel fully clockwise and counterclockwise.
  • Page 545 Steering Gearbox [LHD Model] POWER ASSISTED SYSTEM (POWER STEERING) 12) Remove the clamp bolts securing gearbox to 3) Tighten the gearbox to the crossmember bracket crossmember, and remove the clamp. via clamp with bolt temporarily. PS-00554 PS-00554 (1) Clamp (1) Clamp 13) Remove the bolts which secure gearbox brack- 4) Tighten the bolts which temporary tightening the et, and remove the bracket and gearbox.
  • Page 546 Steering Gearbox [LHD Model] POWER ASSISTED SYSTEM (POWER STEERING) Castle nut tightening torque: NOTE: ⋅ 27 N m (2.75 kgf-m, 19.9 ft-lb) When adjusting toe-in, hold the boot as shown to prevent it from being rotated or twisted. If twisted, CAUTION: straighten it.
  • Page 547 Steering Gearbox [LHD Model] POWER ASSISTED SYSTEM (POWER STEERING) 4) Remove the small clip from the boot using pliers, 7) Tighten the adjusting screw until it no longer and then move the boot to tie-rod end side. tightens. PS-00508 PS-00495 (1) Clip (1) Adjusting screw 5) Using a flat-tip screwdriver, remove the band...
  • Page 548 Steering Gearbox [LHD Model] POWER ASSISTED SYSTEM (POWER STEERING) 11) Carefully draw out the input shaft, and then re- 16) Insert the ST from pinion housing side, and move the valve assembly. then remove the oil seal using a press. ST 34099PA010 OIL SEAL REMOVER (3.0 R model) ST 34199AE050 OIL SEAL REMOVER (Except...
  • Page 549 Steering Gearbox [LHD Model] POWER ASSISTED SYSTEM (POWER STEERING) 6) Remove the two bolts securing valve assembly. CAUTION: Secure the gearbox in a vise using ST as shown. Do not attempt to secure it without this PS-00116 7) Carefully draw out the input shaft, and then re- move the valve assembly.
  • Page 550 Steering Gearbox [LHD Model] POWER ASSISTED SYSTEM (POWER STEERING) 9) Using a press remove the pinion & valve assem- CAUTION: bly from valve housing. Be careful not to scratch the pinion & valve as- sembly. PS-00149 PS-00518 (1) Pinion & valve ASSY (2) Valve housing (1) Snap ring (3) Cloth...
  • Page 551 Steering Gearbox [LHD Model] POWER ASSISTED SYSTEM (POWER STEERING) 3) Install the seal ring to piston portion of rack. (3) Insert the ST-A with oil seal assembled from the gear side of rack. Remove the oil seal from (1) Using the ST, form the seal ring properly ST-A near piston, and then remove the ST-A ST1 34199AG080 FORMER PISTON from rack.
  • Page 552 Steering Gearbox [LHD Model] POWER ASSISTED SYSTEM (POWER STEERING) 11) Using a press, press-fit until the groove of ST NOTE: reaches the end of holder. Do not use this ST for turbo model. PS-00522 PS-00078 (1) Groove (1) Rack piston inner ring (2) Holder (2) Outer side oil seal (3) Rack...
  • Page 553 Steering Gearbox [LHD Model] POWER ASSISTED SYSTEM (POWER STEERING) ST 34099FA060 PUNCH HOLDER 17) Install a new gasket on valve assembly. Insert the valve assembly into place while facing the rack teeth toward pinion. PS-00523 (1) 2 mm (0.08 in) PS-00117 (2) Diameter: 2 —...
  • Page 554 Steering Gearbox [LHD Model] POWER ASSISTED SYSTEM (POWER STEERING) 24) Verify that play is within specified value. <Ref. Tightening torque: ⋅ to PS-43, SERVICE LIMIT, INSPECTION, Steer- 78 N m (8.0 kgf-m, 57.9 ft-lb) ing Gearbox [LHD Model].> 25) Loosen the adjusting screw, and then apply liq- uid gasket to at least 1/3 of the entire perimeter of adjusting screw thread.
  • Page 555 Steering Gearbox [LHD Model] POWER ASSISTED SYSTEM (POWER STEERING) 33) Install a new boot band. Using band clamp pli- CAUTION: ers, caulk the boot band until caulking part clear- Right side boot has groove for identification. ance is 2 mm (0.079 in) or less. Be sure to install the boots after identifying left and right boots.
  • Page 556 Steering Gearbox [LHD Model] POWER ASSISTED SYSTEM (POWER STEERING) Installed tie-rod length L: (2) Connect the pipe C and D to gearbox. 31 mm (1.22 in) Tightening torque: ⋅ Pipe C: 15 N m (1.5 kgf-m, 10.8 ft-lb) ⋅ Pipe D: 25 N m (2.5 kgf-m, 18.1 ft-lb) PS-00097 37) Inspect the gearbox as follows:...
  • Page 557 Steering Gearbox [LHD Model] POWER ASSISTED SYSTEM (POWER STEERING) 5) Press the oil seal into place using a press. 8) Install the backup ring and oil seal to pinion, and then remove the vinyl tape. ST 34199AG090 INSTALLER & REMOVER PS-00528 (1) Oil seal (2) Vinyl tape...
  • Page 558 Steering Gearbox [LHD Model] POWER ASSISTED SYSTEM (POWER STEERING) 12) Install the valve to pinion, and install the snap 16) Install the dust cover on valve assembly. ring. CAUTION: Be sure to install the dust cover to groove on shaft properly. PS-00531 (1) Snap ring PS-00534...
  • Page 559 Steering Gearbox [LHD Model] POWER ASSISTED SYSTEM (POWER STEERING) 19) Insert the valve assembly into place while fac- Liquid gasket: ing rack teeth toward pinion. THREE BOND 1141 PS-00143 PS-00092 20) Tighten the bolts alternately to secure valve as- (1) Apply liquid gasket to at least 1/3 of entire sembly.
  • Page 560 Steering Gearbox [LHD Model] POWER ASSISTED SYSTEM (POWER STEERING) (2) Connect the pipe C and D to gearbox. Tightening torque: ⋅ Pipe C: 15 N m (1.5 kgf-m, 10.8 ft-lb) ⋅ Pipe D: 25 N m (2.5 kgf-m, 18.1 ft-lb) PS-00525 (1) Pipe C (2) Pipe D...

  • Page 561: Basic Inspection

    Steering Gearbox [LHD Model] POWER ASSISTED SYSTEM (POWER STEERING) E: INSPECTION 1. BASIC INSPECTION 1) Clean all disassembled parts, and check for wear, damage or any other faults, then repair or replace as necessary. 2) When disassembling, check the inside of gearbox for water. If any water is found, carefully check the boot for damage, input shaft dust seal, adjusting screw and boot clips for poor sealing.
  • Page 562 Steering Gearbox [LHD Model] POWER ASSISTED SYSTEM (POWER STEERING) 2. SERVICE LIMIT On condition L: 5 mm (0.20 in) Make a measurement as follows. If it exceeds the P: 122.6 N (12.5 kgf, 27.6 lb) specified service limit, adjust or replace. NOTE: When making a measurement, vise the gearbox using ST.
  • Page 563 Steering Gearbox [LHD Model] POWER ASSISTED SYSTEM (POWER STEERING) On condition 5. TURNING RESISTANCE OF GEARBOX P: 20 — 49 N (2 — 5 kgf, 4 — 11 lb) Using the ST, measure the gearbox turning resis- tance. ST 34099PA100 SPANNER Service limit: Maximum allowable resistance: 10.5 N (1.1 kgf, 2.4 lb) or less...
  • Page 564 Steering Gearbox [LHD Model] POWER ASSISTED SYSTEM (POWER STEERING) 1) Lift up the vehicle. F: ADJUSTMENT 2) Even if the location of leak can be easily found 1) Adjust the front toe. <Ref. to FS-12, FRONT by observing the leaking condition, it is necessary WHEEL TOE-IN, INSPECTION, Wheel Align- to thoroughly remove the fluid from the suspected ment.>...
  • Page 565 Steering Gearbox [RHD Model] POWER ASSISTED SYSTEM (POWER STEERING) 6. Steering Gearbox [RHD Mod- • Small type A: REMOVAL 1) Set the vehicle on a lift. 2) Disconnect the ground cable from battery. 3) Loosen the front wheel nuts. 4) Lift-up the vehicle and remove the front wheels. 5) Remove the under cover.
  • Page 566 Steering Gearbox [RHD Model] POWER ASSISTED SYSTEM (POWER STEERING) 11) Disconnect the return hose and pressure hose 13) Remove the bolts which secure the gearbox from gearbox. bracket, and remove the bracket and gearbox. PS-00449 (1) Bracket B: INSTALLATION 1) Insert the gearbox into the crossmember, being careful not to damage gearbox boot.
  • Page 567 Steering Gearbox [RHD Model] POWER ASSISTED SYSTEM (POWER STEERING) 5) Connect the return hose and pressure hose to 8) After tightening the castle nut to specified tight- gearbox. ening torque, tighten it further within 60° until cotter pin hole is aligned with slot in the nut. Fit the cotter Tightening torque: pin into nut, and then bend the pin to lock.
  • Page 568 Steering Gearbox [RHD Model] POWER ASSISTED SYSTEM (POWER STEERING) 3) Remove the tie-rod end and lock nut from gear- NOTE: box. When adjusting toe-in, hold the boot as shown to 4) Remove the clip from outside boot using pliers, prevent it from being rotated or twisted. If twisted, and then move the boot to tie-rod end side.
  • Page 569 Steering Gearbox [RHD Model] POWER ASSISTED SYSTEM (POWER STEERING) 7) Tighten the adjusting screw until it no longer ST 34199AE090 PLUG WRENCH tightens. PS-00495 (1) Adjusting screw 8) Using a 32 mm spanner or adjustable wrench with cinching boot, remove the tie-rod. PS-00061 (1) Plug 12) Remove the valve assembly paying attention...
  • Page 570 Steering Gearbox [RHD Model] POWER ASSISTED SYSTEM (POWER STEERING) 13) Remove the holder using a 36 mm spanner or 15) Insert the ST from the valve side and press the adjustable wrench. back-up ring and oil seal out. ST 34199FE010 REMOVER (Turbo and 3.0 R model) ST 927580000...
  • Page 571 Steering Gearbox [RHD Model] POWER ASSISTED SYSTEM (POWER STEERING) 16) Using ST1 and ST2, repair the caulking portion NOTE: of cylinder. Do not apply force on the plug edge surface. ST1 34099FA080 PUNCH ST2 34199FE020 BASE (Turbo and 3.0 R mod- ST2 34099FA070 BASE (Except for turbo and 3.0 R model) PS-00068...
  • Page 572 Steering Gearbox [RHD Model] POWER ASSISTED SYSTEM (POWER STEERING) 20) Set the stopper to gearbox, and then insert the 22) While fixing the 2-surface width, pull out the oil tip of ST to gearbox. seal by rotating nut. CAUTION: Take care not to scratch the gearbox inner sur- face.
  • Page 573 Steering Gearbox [RHD Model] POWER ASSISTED SYSTEM (POWER STEERING) 3) Attach the steering body to ST as shown in the 5) Insert the ST-A with oil seal assembled from the figure. Apply a coat of grease to needle bearing. gear side of rack. Remove the oil seal from ST-A near piston, and then remove the ST-A from rack.
  • Page 574 Steering Gearbox [RHD Model] POWER ASSISTED SYSTEM (POWER STEERING) ST2 34199FE060 INSTALLER (Turbo and 3.0 R NOTE: model) Do not use this ST for turbo model. 34199AE010 INSTALLER (Except for turbo and 3.0 R model) PS-00078 PS-00431 (1) Rack piston inner ring (2) Outer side oil seal (1) Outer side oil seal (3) Rack...
  • Page 575 Steering Gearbox [RHD Model] POWER ASSISTED SYSTEM (POWER STEERING) ST 34099FA060 PUNCH HOLDER 13) Apply a coat of grease on the gear teeth of valve assembly, and then attach the valve assem- bly taking care not to scratch oil seal and seal ring. PS-00084 (A) Holder PS-00086...
  • Page 576 Steering Gearbox [RHD Model] POWER ASSISTED SYSTEM (POWER STEERING) 15) Using the ST, install plug. Charge the adjusting screw with grease, and then insert the spring into adjusting screw and install on ST 34199AE090 PLUG WRENCH steering body. Tightening torque: ⋅...
  • Page 577 Steering Gearbox [RHD Model] POWER ASSISTED SYSTEM (POWER STEERING) 25) Install the lock nut. While holding adjusting NOTE: screw with a wrench, tighten the lock nut using ST. Use a new boot band. ST 926230000 SPANNER Tightening torque (Lock nut): ⋅...
  • Page 578 Steering Gearbox [RHD Model] POWER ASSISTED SYSTEM (POWER STEERING) Installed tie-rod length L: 31 mm (1.22 in) PS-00097 32) Inspect the gearbox as follows: “A” Holding tie-rod end, repeat lock to lock two or three times as quickly as possible. “B”...
  • Page 579 Steering Gearbox [RHD Model] POWER ASSISTED SYSTEM (POWER STEERING) E: INSPECTION 1. BASIC INSPECTION 1) Clean all disassembled parts, and check for wear, damage or any other faults, then repair or replace as necessary. 2) When disassembling, check inside of gearbox for water. If any water is found, carefully check boot for damage, input shaft dust seal, adjusting screw and boot clips for poor sealing.
  • Page 580 Steering Gearbox [RHD Model] POWER ASSISTED SYSTEM (POWER STEERING) 2. LIMIT On condition L: 5 mm (0.20 in) Make a measurement as follows. If it exceeds the P: 98 N (10 kgf, 22 lb) specified service limit, adjust or replace. NOTE: When making a measurement, vise the gearbox using ST.
  • Page 581 Steering Gearbox [RHD Model] POWER ASSISTED SYSTEM (POWER STEERING) On condition P: 98 N (10 kgf, 22 lb) PS-00328 In axial direction: Service limit 0.27 mm (0.0106 in) or less On condition P: 20 — 49 N (2 — 5 kgf, 4 — 11 lb) PS-00329 5.
  • Page 582 Steering Gearbox [RHD Model] POWER ASSISTED SYSTEM (POWER STEERING) 6. OIL LEAKING PS-00331 Power cylinder Rack piston Input shaft Cylinder Rack axle Valve housing F: ADJUSTMENT 1) Lift-up the vehicle. 2) Even if the location of leak can be easily found 1) Adjust the front toe.
  • Page 583 Steering Gearbox [RHD Model] POWER ASSISTED SYSTEM (POWER STEERING) 3) If the steering wheel spokes are not horizontal when wheels are set in the straight ahead position, or error is more than 5° on the periphery of steering wheel, correctly re-install the steering wheel. PS-00513 (1) Within 5°...

  • Page 584: Pipe Assembly [Lhd Model]

    Pipe Assembly [LHD Model] POWER ASSISTED SYSTEM (POWER STEERING) 7. Pipe Assembly [LHD Model] 5) Disconnect the return hose and pipe D, pressure hose and pipe C. A: REMOVAL 1) Disconnect the ground cable from battery. 2) Lift-up the vehicle, and then remove the front crossmember support plate and jack-up plate.
  • Page 585 Pipe Assembly [LHD Model] POWER ASSISTED SYSTEM (POWER STEERING) 8) Disconnect the suction hose and return hose CAUTION: from reservoir tank. Remove the oil cooler from oil Align the installation position of the resin clip cooler bracket. with the protector edge of suction hose. PS-00482 PS-00455 (1) Reservoir tank...
  • Page 586 Pipe Assembly [LHD Model] POWER ASSISTED SYSTEM (POWER STEERING) Tightening torque: NOTE: ⋅ 39 N m (4.0 kgf-m, 28.9 ft-lb) Ensure that the letter “8” on each clamp are diago- nally opposite each other as shown in the figure. PS-00460 PS-00540 (1) Suction hose (2) Pressure hose...
  • Page 587 Pipe Assembly [LHD Model] POWER ASSISTED SYSTEM (POWER STEERING) Tightening torque: ⋅ 13 N m (1.3 kgf-m, 9.4 ft-lb) PS-00451 (1) Hose ASSY (2) Hose bracket 12) Install the air intake duct. <Ref. to IN(H4DOTC)-9, INSTALLATION, Air In- take Duct.> <Ref. to IN(H4SO 2.0)-9, INSTALLA- TION, Air Intake Duct.>...
  • Page 588 Pipe Assembly [LHD Model] POWER ASSISTED SYSTEM (POWER STEERING) C: INSPECTION Check all disassembled parts for wear, damage or other abnormalities. Repair or replace defective parts as necessary. Parts Maintenance Parts Corrective action • O-ring fitting surface for damage Pipe •...
  • Page 589 Pipe Assembly [LHD Model] POWER ASSISTED SYSTEM (POWER STEERING) NOTE: It is likely that although one judges fluid leakage, there is actually no leakage. This is because the fluid spilt during the last maintenance was not completely wiped off. Be sure to wipe off spilt fluid thoroughly after main- tenance.

  • Page 590: Pipe Assembly [Rhd Model]

    Pipe Assembly [RHD Model] POWER ASSISTED SYSTEM (POWER STEERING) 8. Pipe Assembly [RHD Model] 4) Remove the clamp E from the return hose and pressure hose. A: REMOVAL 1) Disconnect the ground cable from battery. 2) Lift-up the vehicle, and then remove the front crossmember support plate and jack-up plate.
  • Page 591 Pipe Assembly [RHD Model] POWER ASSISTED SYSTEM (POWER STEERING) 6) Remove intake duct. <Ref. 9) Remove the hose bracket and take out the hose IN(H4DOTC)-9, REMOVAL, Air Intake Duct.> assembly from vehicle. <Ref. to IN(H4SO 2.0)-9, REMOVAL, Air Intake Duct.> 7) Disconnect the suction hose and pressure hose from the oil pump.
  • Page 592 Pipe Assembly [RHD Model] POWER ASSISTED SYSTEM (POWER STEERING) • Turbo model • Non-turbo model PS-00456 PS-00460 (1) Resin clip (1) Suction hose (2) Protector (2) Pressure hose (3) Suction hose • Turbo model (4) Pressure hose 3) Connect the suction hose and return hose to res- ervoir tank.
  • Page 593 Pipe Assembly [RHD Model] POWER ASSISTED SYSTEM (POWER STEERING) 5) Temporarily connect the return hose and pres- 7) Tighten the joint nut. sure hose to gearbox. Place the clamp E in the po- Tightening torque: sition shown in the figure, and tighten the bolt ⋅...
  • Page 594 Pipe Assembly [RHD Model] POWER ASSISTED SYSTEM (POWER STEERING) 15) Finally, check clearance between pipes or hos- es as shown in the figure indicated in “General Di- agnostic Table”. <Ref. to PS-89, INSPECTION OF CLEARANCE, INSPECTION, General Diagnostic Table.> C: INSPECTION Check all disassembled parts for wear, damage or other abnormalities.
  • Page 595 Pipe Assembly [RHD Model] POWER ASSISTED SYSTEM (POWER STEERING) NOTE: It is likely that although one judges fluid leakage, there is actually no leakage. This is because the fluid spilt during the last maintenance was not completely wiped off. Be sure to wipe off spilt fluid thoroughly after main- tenance.

  • Page 596: Oil Pump

    Oil Pump POWER ASSISTED SYSTEM (POWER STEERING) 9. Oil Pump • Turbo model A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove intake duct. <Ref. IN(H4DOTC)-9, REMOVAL, Air Intake Duct.> <Ref. to IN(H4SO 2.0)-9, REMOVAL, Air Intake Duct.> 3) Remove the pulley belt cover.
  • Page 597 Oil Pump POWER ASSISTED SYSTEM (POWER STEERING) 10) Disassemble the oil pump and bracket by in- Tightening torque: ⋅ serting a flat tip screwdriver as shown in the figure. 37.3 N m (3.8 kgf-m, 27.5 ft-lb) PS-00137 PS-00129 B: INSTALLATION 2) Tighten the bolts which hold the power steering pump bracket.
  • Page 598 Oil Pump POWER ASSISTED SYSTEM (POWER STEERING) • Turbo model PS-00459 (1) Suction hose (2) Pressure hose 4) Connect the connector to power steering pump switch. 5) Install the V-belts to oil pump. 6) Check the tension of V-belt. <Ref. to ME(H4SO 2.0)-39, INSPECTION, V-belt.> 7) Tighten the belt tension bolt.
  • Page 599 Oil Pump POWER ASSISTED SYSTEM (POWER STEERING) C: INSPECTION 1. BASIC INSPECTION Perform the following inspection procedures and replace defective parts. Parts INSPECTION Corrective action (1) Crack, damage or oil leakage Replace the oil pump with a new one. Measure the radial play and axial play. Oil pump (Exterior) (2) Play of pulley shaft If any of these exceeds the service limit, replace the...
  • Page 600 Oil Pump POWER ASSISTED SYSTEM (POWER STEERING) 2) Ditch deflection of pulley • Put cloth at a place where fluid drops before pressure gauge is installed. Wipe off spilt fluid thor- Service limit: oughly after the measurement. 1.0 mm (0.039 in) or less 1) Regular pressure measurement NOTE: (1) Connect ST1, ST2 and ST3.
  • Page 601 Oil Pump POWER ASSISTED SYSTEM (POWER STEERING) (8) Measure the regular pressure. 3) Measure working pressure. ST1 925711000 PRESSURE GAUGE (1) Using the STs, measure the working pres- sure. ST2 34099AC020 ADAPTER HOSE B ST3 34099AC010 ADAPTER HOSE A (2) Open the valve. (3) Measure the working pressure of control valve by turning steering wheel from stop to stop.

  • Page 602: Reservoir Tank

    Reservoir Tank POWER ASSISTED SYSTEM (POWER STEERING) 10.Reservoir Tank C: INSPECTION Check the reservoir tank for cracks, breakage and A: REMOVAL damage. If a failure is found, replace the reservoir 1) Drain fluid from the reservoir tank. tank. 2) Disconnect the hose from reservoir tank. CAUTION: To prevent foreign matter from entering the hose and pipe, cover the open ends of them...

  • Page 603: Power Steering Fluid

    Power Steering Fluid POWER ASSISTED SYSTEM (POWER STEERING) 11.Power Steering Fluid 6) If turning the steering wheel in low fluid level condition, air will be sucked in pipe. In this case, A: SPECIFICATION leave it about half an hour and then do the step 5) again.

  • Page 604: General Diagnostic Table

    General Diagnostic Table POWER ASSISTED SYSTEM (POWER STEERING) 12.General Diagnostic Table A: INSPECTION Trouble Possible cause Corrective action • Heavy steering effort in all 1. Pulley belt ranges • Unequal length of pulley belts • Heavy steering effort at • Adhesion of oil and grease stand still •...

  • Page 605: Noise And Vibration

    General Diagnostic Table POWER ASSISTED SYSTEM (POWER STEERING) *3 In cold weather or with insufficient warm-up of engine, steering effort may be heavy due to excessive drop of idling when turn- ing steering wheel. In this case, it is recommended to start the vehicle with increasing engine speed than usual. Then if steering effort reduces normally, there is no abnormal thing.
  • Page 606 General Diagnostic Table POWER ASSISTED SYSTEM (POWER STEERING) Trouble Possible cause Corrective action Maladjustment of pulley belt Adjust or replace. Damaged or charged pulley belt Squeal, squeak (intermittent or (Replace two belts as a set.) Unequal length of pulley belts continuous) While engine is running.
  • Page 607 General Diagnostic Table POWER ASSISTED SYSTEM (POWER STEERING) 2. MEASUREMENT OF STEERING EFFORT Step Check CHECK STEERING EFFORT. Is the steering effort less than Go to step 2. Adjust the back- 1) Stop the vehicle on a concrete road. 29.4 N (3.0 kgf, 6.6 lb)? lash.
  • Page 608 General Diagnostic Table POWER ASSISTED SYSTEM (POWER STEERING) 3. INSPECTION OF CLEARANCE This table lists various clearances that must be correctly adjusted to ensure the normal vehicle driving with- out interfering noise, or any other faults. LOCATION Minimum allowance mm (in) (1) Crossmember-to-Hose ASSY 3 (0.12) (2) Front exhaust pipe-to-Hose ASSY (Turbo model)
  • Page 609 General Diagnostic Table POWER ASSISTED SYSTEM (POWER STEERING) • LHD model (19) (12) (18) (17) (8),(9) (10),(11),(16) (27) (24) (26) (21) (20) (32) (13),(14) (22) (15) (25) (23) (33) (28),(31) (30) (29) PS-00515 • RHD model (12) (19) (18) (17) (8),(9) (10),(11),(16) (24)

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