Subaru LEGACY User manual

FUJI HEAVY INDUSTRIES LTD. G2320GE6

2004 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX

CHASSIS SECTION

This service manual has been prepared

to provide SUBARU service personnel

with the necessary information and data

for the correct maintenance and repair

of SUBARU vehicles.

This manual includes the procedures

for maintenance, disassembling, reas-

sembling, inspection and adjustment of

components and diagnostics for guid-

ance of experienced mechanics.

Please peruse and utilize this manual

fully to ensure complete repair work for

satisfying our customers by keeping

their vehicle in optimum condition.

When replacement of parts during

repair work is needed, be sure to use

SUBARU genuine parts.

All information, illustration and specifi-

cations contained in this manual are

based on the latest product information

available at the time of publication

approval.

FRONT SUSPENSION FS

REAR SUSPENSION RS

WHEEL AND TIRE SYSTEM WT

DIFFERENTIALS DI

TRANSFER CASE TC

DRIVE SHAFT SYSTEM DS

ABS ABS

ABS (DIAGNOSTICS) ABS(diag)

VEHICLE DYNAMICS CONTROL (VDC) VDC

VEHICLE DYNAMICS CONTROL (VDC)

(DIAGNOSTICS) VDC(diag)

BRAKE BR

PARKING BRAKE PB

POWER ASSISTED SYSTEM

(POWER STEERING) PS

ABS (DIAGNOSTICS)ABS(diag)

Page

1. Basic Diagnostic Procedure........................................................................2

2. Check List for Interview...............................................................................4

3. General Description ....................................................................................8

4. Electrical Component Location .................................................................10

5. Control Module I/O Signal.........................................................................12

6. Subaru Select Monitor...............................................................................15

7. Read Diagnostic Trouble Code (DTC)......................................................25

8. Inspection Mode........................................................................................26

9. Clear Memory Mode..................................................................................27

10. ABS Warning Light / Brake Warning Light Illumination Pattern ................28

11. List of Diagnostic Trouble Code (DTC).....................................................39

12. Diagnostic Procedure with Diagnostic Trouble Code (DTC).....................42

13. General Diagnostic Table..........................................................................82

ABS(diag)-2

ABS (DIAGNOSTICS) Basic Diagnostic Procedure

1. Basic Diagnostic Procedure

A: PROCEDURE

CAUTION:

Remove foreign matters (dust, water, oil, etc.) from the ABSCM&H/U connector during removal and

installation.

NOTE:

• To check harness for broken wires or short circuits, shake trouble spot or connector.

• Refer to “Check List for Interview”. <Ref. to ABS(diag)-4, Check List for Interview.>

Step Check Yes No

1 CHECK PRE-INSPECTION.

1) Ask the customer when and how the trou-

ble occurred using interview checklist. <Ref. to

ABS(diag)-4, Check List for Interview.>

2) Before performing diagnostics, check the

component which might affect ABS problems.

<Ref. to ABS(diag)-8, INSPECTION, General

Description.>

Is the component that might

influence the ABS problem

normal?

Go to step 2. Repair or replace

each unit.

2 CHECK INDICATION OF DTC ON SCREEN.

1) Turn the ignition switch to OFF.

2) Connect the Subaru Select Monitor to data

link connector.

3) Turn the ignition switch to ON and Subaru

Select Monitor to ON.

NOTE:

If the communication function of the Subaru Se-

lect Monitor cannot be executed normally,

check the communication circuit. <Ref. to

ABS(diag)-18, COMMUNICATION FOR INI-

TIALIZING IMPOSSIBLE, INSPECTION, Sub-

aru Select Monitor.>

4) Read the DTC. <Ref. to ABS(diag)-25,

OPERATION, Read Diagnostic Trouble Code

(DTC).>

5) Record all DTCs and Freeze Frame Data.

Is DTC displayed? Go to step 4. Go to step 3.

3 PERFORM THE GENERAL DIAGNOSTICS.

1) Inspect using “General Diagnostic Table”.

<Ref. to ABS(diag)-82, General Diagnostic

Table.>

2) Perform clear memory mode. <Ref. to

ABS(diag)-17, CLEAR MEMORY MODE,

OPERATION, Subaru Select Monitor.>

3) Perform the inspection mode. <Ref. to

ABS(diag)-26, Inspection Mode.>

4) Read the DTC. <Ref. to ABS(diag)-15,

READ DIAGNOSTIC TROUBLE CODE (DTC),

OPERATION, Subaru Select Monitor.>

Check the DTC does not displayed.

Does the ABS warning light go

off after turning the ignition

switch to ON?

Finish the diagno-

sis. Check in accor-

dance with “Diag-

nostic Procedure

for ABS”. <Ref. to

ABS(diag)-21,

WITHOUT DTC,

INSPECTION,

Subaru Select

Monitor.>

ABS(diag)-3

ABS (DIAGNOSTICS)

Basic Diagnostic Procedure

4 PERFORM THE DIAGNOSIS.

1) Refer to the “List of Diagnostic Trouble

Code (DTC)”. <Ref. to ABS(diag)-39,LIST, List

of Diagnostic Trouble Code (DTC).>

2) Fix the wrong part.

3) Perform clear memory mode. <Ref. to

ABS(diag)-17, CLEAR MEMORY MODE,

OPERATION, Subaru Select Monitor.>

4) Perform the inspection mode. <Ref. to

ABS(diag)-26, Inspection Mode.>

5) Read the DTC. <Ref. to ABS(diag)-15,

READ DIAGNOSTIC TROUBLE CODE (DTC),

OPERATION, Subaru Select Monitor.>

Is DTC displayed? Repeat step 1 to 4

until DTC is not

shown.

Finish the diagno-

sis.

Step Check Yes No

ABS(diag)-4

ABS (DIAGNOSTICS) Check List for Interview

2. Check List for Interview

A: CHECK

Check the following items about the vehicle’s state.

1. STATE OF ABS WARNING LIGHT

2. STATE OF BRAKE WARNING LIGHT

ABS warning light

comes on. ❏Always

❏Sometimes

❏Only once

❏Not come on

•When / how long does it come on?

Ignition key position ❏LOCK

❏ACC

❏ON (before starting engine)

❏START

❏ON (after Engine starting, engine is running)

❏ON (after Engine starting, engine is at a standstill)

Timing ❏Immediately after turning the ignition to ON

❏Immediately after turning the ignition to START

❏When accelerating — km/h

—MPH

❏When driving at a constant speed km/h MPH

❏When decelerating — km/h

—MPH

❏When turning to the right Steering angle: deg

Steering time: Sec.

❏When turning to the left Steering angle: deg

Steering time: Sec.

❏When operating other electrical parts

•Parts name:

•Operating condition:

Brake warning light

comes on. ❏Always

❏Sometimes

❏Only once

❏Not come on

❏When pulling the parking brake lever up.

❏When releasing the parking brake lever down.

•When / how long does it come on?

Ignition key position ❏LOCK

❏ACC

❏ON (before starting engine)

❏START

❏ON (after Engine starting, engine is running)

❏ON (after Engine starting, engine is at a standstill)

ABS(diag)-5

ABS (DIAGNOSTICS)

Check List for Interview

3. SYMPTOMS

Timing ❏Immediately after turning the ignition to ON

❏Immediately after turning the ignition to START

❏When accelerating — km/h

—MPH

❏When driving at a constant speed km/h MPH

❏When decelerating — km/h

—MPH

❏When turning to the right Steering angle: deg

Steering time: Sec.

❏When turning to the left Steering angle: deg

Steering time: Sec.

❏When operating other electrical parts

•Parts name:

•Operating condition:

ABS operating condi-

tion ❏Does not move.

❏Operates only when applying an abrupt brake. Vehicle speed: km/h

MPH

•How to step on brake pedal:

a) Operating time: Sec.

b) Operating noise: ❏Occurs. / ❏Does not occur.

•What kind of noise? ❏Knocking

❏Gong gong

❏Bong

❏Buzz

❏Gong gong buzz

❏Others:

c) Reaction force of brake pedal

❏Stick

❏Weak pedal resistance

❏Strong pedal resistance

❏Others:

ABS(diag)-6

ABS (DIAGNOSTICS) Check List for Interview

4. CONDITIONS UNDER WHICH TROUBLE OCCURS

Behavior of vehicle a) Directional stability cannot be obtained or the steering refuses to work when applying brakes:

❏Yes / ❏No

•When: ❏When turning to the right

❏When turning to the left

❏When spinning

❏Others:

a) Directional stability cannot be obtained or the steering refuses to work when accelerating:

❏Yes / ❏No

•When: ❏When turning to the right

❏When turning to the left

❏When spinning

❏Others:

c) Poor brake performance: ❏Yes / ❏No

•What kind: ❏Long braking/stopping distance

❏Brakes lock or drag

❏Long pedal stroke

❏Pedal sticks.

❏Others:

d) Poor acceleration: ❏Yes / ❏No

•What kind: ❏Not accelerate

❏Engine stalls.

❏Others:

e) Occurrence of vibration: ❏Yes / ❏No

•Where

•What kind:

f) Occurrence of noise: ❏Yes / ❏No

•Where

•What kind:

g) Other troubles occurred: ❏Yes / ❏No

•What kind:

Environment a) Weather ❏Fine

❏Cloudy

❏Rainy

❏Snowy

❏Others:

b) Ambient temperature °C (°F)

c) Road ❏Inner city

❏Suburbs

❏Highway

❏Local street

❏Uphill

❏Downhill

❏Paved road

❏Gravel road

❏Muddy road

❏Sandy place

❏Others:

d) Road surface ❏Dried

❏Wet

❏Covered with fresh snow

❏Covered with hardened snow

❏Frozen slope

❏Others:

ABS(diag)-7

ABS (DIAGNOSTICS)

Check List for Interview

Condition a) Brakes Deceleration: G

❏Intermittent / ❏Temporary

b) Accelerator Acceleration: G

❏Intermittent / ❏Temporary

c) Vehicle speed km/h MPH

❏Advancing

❏When accelerating

❏When decelerating

❏At low speed

❏When turning

❏Others:

d) Tire inflation pressure Front RH tire: kPa

Front LH tire: kPa

Rear RH tire: kPa

Rear LH tire: kPa

e) Degree of wear Front RH tire:

Front LH tire:

Rear RH tire:

Rear LH tire:

f) Genuine parts are used.: ❏Yes / ❏No

g) Tire chain is attached.: ❏Yes / ❏No

h) T-type tire is used.: ❏Yes / ❏No

i) Condition of suspension alignment:

j) Loading state:

k) Repair parts are used.: ❏Yes / ❏No

•Contents:

l) Others:

ABS(diag)-8

ABS (DIAGNOSTICS) General Description

3. General Description

A: CAUTION

1. SUPPLEMENTAL RESTRAINT SYSTEM

“AIRBAG”

Airbag system wiring harness is routed near the

ABS wheel speed sensor and ABSCM&H/U.

CAUTION:

• All airbag system wiring harness and con-

nectors are colored yellow. Do not use the elec-

trical test equipment on these circuits.

• Be careful not to damage the airbag system

wiring harness when servicing the ABS wheel

speed sensor and ABSCM&H/U.

B: INSPECTION

Before performing diagnosis, check the following

items which might affect ABS problems.

1. BATTERY

Measure battery voltage and check electrolyte.

Standard voltage: 12 V or more

Specific gravity: More than 1.260

2. BRAKE FLUID

1) Check the brake fluid level.

2) Check the brake fluid for leaks.

3. HYDRAULIC UNIT

Check the hydraulic unit.

• With brake tester <Ref. to ABS-8, CHECKING

THE HYDRAULIC UNIT ABS OPERATION WITH

BRAKE TESTER, INSPECTION, ABS Control

Module and Hydraulic Control Unit (ABSCM&H/

U).>

• Without brake tester <Ref. to ABS-7, CHECK-

ING THE HYDRAULIC UNIT ABS OPERATION

BY PRESSURE GAUGE, INSPECTION, ABS

Control Module and Hydraulic Control Unit (AB-

SCM&H/U).>

4. BRAKE DRAG

Check for brake drag.

5. BRAKE PAD AND ROTOR

Check the brake pad and rotor.

• FRONT <Ref. to BR-18, INSPECTION, Front

Brake Pad.> <Ref. to BR-19, INSPECTION, Front

Disc Rotor.>

• REAR <Ref. to BR-25, INSPECTION, Rear

Brake Pad.> <Ref. to BR-26, INSPECTION, Rear

Disc Rotor.>

6. TIRE

Check the tire specifications, tire wear and air pres-

sure. <Ref. to WT-2, SPECIFICATION, General

Description.>

ABS(diag)-9

ABS (DIAGNOSTICS)

General Description

C: PREPARATION TOOL

1. SPECIAL TOOL

2. GENERAL TOOL

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

24082AA230 CARTRIDGE Troubleshooting for electrical system.

22771AA030 SUBARU SELECT

MONITOR KIT Troubleshooting for electrical system.

• English: 22771AA030 (Without printer)

• German: 22771AA070 (Without printer)

• French: 22771AA080 (Without printer)

• Spanish: 22771AA090 (Without printer)

TOOL NAME REMARKS

Circuit tester Used for measuring resistance, voltage and ampere.

Oscilloscope Used for measuring sensor.

ST24082AA23

ST22771AA03

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