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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

1
2
3
...
»

Summary of Contents for 2004 LEGACY

Page 1: ...s 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...

Page 2: ... FS Page 1 General Description 2 2 Wheel Alignment 8 3 Front Crossmember Support Plate 15 4 Front Stabilizer 16 5 Front Ball Joint 17 6 Front Arm 19 7 Front Strut 22 8 Front Crossmember 26 9 General Diagnostic Table 27 ...

Page 3: ...45 5 05 Steering angle Toler ance 1 5 Inner wheel 37 3 37 8 Outer wheel 33 0 33 5 Toe in mm in 0 3 0 0 12 Toe angle sum of both wheels 0 0 15 Kingpin angle 13 50 13 45 13 50 12 25 Diameter of stabilizer mm in 20 0 79 21 0 83 20 0 79 21 0 83 Rear Wheel arch height mm in 360 14 2 375 14 8 430 16 9 Tolerance 12 24 mm 0 47 in 0 94 in Camber Tolerance 0 45 Differences between RH and LH 45 or less 0 45 ...

Page 4: ...amber 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 replace with new ones as required 1 Front A B Positive Toe in Negative Toe out α Each toe angle FS 00001 B A 1 ...

Page 5: ...pper spring seat T5 50 5 1 36 9 7 Front bushing 19 Dust cover T6 55 5 6 41 8 Stud bolt 20 Helper T7 60 6 1 44 3 9 Stabilizer link 21 Coil spring T8 95 9 7 70 1 10 Bracket 22 Damper strut T9 110 11 2 81 1 11 Bushing 23 Adjusting bolt T10 150 15 3 110 6 12 Stabilizer 24 Castle nut T11 175 17 8 129 13 Crossmember support plate Large type 25 Self locking nut 26 Cotter pin FS 00131 T1 T11 T6 T8 T8 T5 T...

Page 6: ...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 Before securing a part on a vice place cushion ing material such as wood blocks aluminum plate or cloth between the part and the vice Be sure to tighten fasteners including bolts and nuts to the specified torque Place shop jacks ...

Page 7: ...r and caster 1 28199AC000 PLATE 2 28199AC010 BOLT 927680000 INSTALLER REMOVER SET Used for replacing the front arm front bushing 20299AG000 Newly adopted tool REMOVER Used for replacing the front arm rear bushing Used with BASE 20999AG010 20299AG010 Newly adopted tool BASE Used for replacing the front arm rear bushing Used with REMOVER 20999AG000 1 2 ST 927380002 ST 927680000 ST20299AG000 ST20299A...

Page 8: ...TRUT MOUNT SOCKET Used for disassembling and assembling the strut mount 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 Dial gauge Used for damper strut measurement Coil spring compressor Used for strut assembly disassembly ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS ST20299AG...

Page 9: ...rmation and excessive play in suspension parts Check adjust and measure the wheel alignment in accordance with the procedures indicated in the figure Wheel arch height front and rear wheels Ref to FS 9 WHEEL ARCH HEIGHT INSPECTION Wheel Alignment Camber front and rear wheels Ref to FS 10 CAMBER INSPECTION Wheel Alignment Caster front wheel Ref to FS 11 CASTER INSPECTION Wheel Alignment Steering an...

Page 10: ...hread from wheel arch point A in the figure below to determine the point directly above the center of wheel 5 Measure the distance between the point A and the center of wheel 1 Wheel arch height 4 Front wheel arch height 7 Point of measurement 2 Front fender 5 Rear wheel arch height 8 Tip end of spindle 3 Rear quarter 6 Flange bend line Wheel arch height standard value mm in Tolerance 12 mm Model ...

Page 11: ...When the adjusting bolt needs to be loosened or tightened hold its head with a wrench and turn the self locking nut 3 Turn the camber adjusting bolt so that the cam ber is set at specification NOTE Moving the adjusting bolt by one scale changes the camber by approx 0 15 1 Alignment gauge 2 Turning radius gauge Model Camber Differences between RH and LH 45 or less Sedan 0 20 0 45 Wagon 2 0 i 2 5 i ...

Page 12: ...ERING ANGLE INSPECTION 1 Place the vehicle on turning radius gauge 2 While depressing the brake pedal turn the steer ing wheel fully to the left and right With the steering wheel held at each fully turned position measure both the inner and outer wheel steering angle To increase camber Rotate the left side counterclockwise Rotate the right side clockwise To decrease camber Rotate the left side clo...

Page 13: ...e in adjust it to the following value Toe in 0 2 mm 0 0 08 in 1 Check that the left and right wheel steering angle is within specifications 2 Loosen the left and right side steering tie rod lock nuts 3 Turn the left and right tie rods equal amounts un til the toe in is at the specification Both the left and right tie rods are right hand threaded To increase toe in turn both tie rods clockwise by e...

Page 14: ... left and right wheels are adjusted for toe in at the same time the movement of one scale graduation changes toe in by approx 0 6 mm 0 02 in 3 Tighten a new self locking nut Tightening torque 120 N m 12 2 kgf m 88 5 ft lb 1 Adjusting bolt 2 Rear link FS 00103 1 2 To increase toe in Rotate the left side clockwise Rotate the right side counterclockwise To decrease toe in Rotate the left side counter...

Page 15: ...on adjust the other rear wheel equally in toe out direction in order to make the thrust angle ad justment 3 When the left and right adjusting bolts are turned by one graduation the thrust angle will change ap prox 17 L is approx 13 mm 0 51 in NOTE Thrust angle refers to a mean value of left and right rear wheel toe angles in relation to the vehicle body center line Vehicle is driven straight in th...

Page 16: ...the reverse order of removal NOTE Tighten the small type crossmember support plate together with stabilizer bracket After installing the stabilizer bracket to crossmem ber tighten the crossmember support plate togeth er Tightening torque Crossmember support plate 60 N m 6 1 kgf m 44 3 ft lb Crossmember support plate Joint tightening portion of stabilizer bracket 25 N m 2 5 kgf m 18 1 ft lb Jack up...

Page 17: ...removal NOTE Use a new self locking nut Ensure that the stabilizer bushing and stabilizer have the same identification colors Install the stabilizer bushing front crossmember side while aligning it with the paint mark on stabi lizer Stabilizer bracket has an orientation so install it with the arrow mark faced to the front side of vehi cle Tightening torque Stabilizer link 45 N m 4 6 kgf m 33 2 ft ...

Page 18: ...ighten the castle nut further within 60 until the hole in ball stud is aligned with a slot in castle nut Then insert a new cotter pin and bend it around castle nut 4 Install the stabilizer bracket NOTE Stabilizer bracket has an orientation so install it with the arrow mark faced to the front side of vehi cle Tightening torque 25 N m 2 5 kgf m 18 1 ft lb 5 Install the front wheels C INSPECTION 1 Me...

Page 19: ...INT 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 3 Remove the ball joint and cover check them for wear damage or cracks and then replace them if any defective part is found 4 If the dust cover is damaged replace with a new ball joint ...

Page 20: ...tall the stud bolt ST 20299AG020 STUD BOLT SOCKET Tightening torque 110 N m 11 2 kgf m 81 1 ft lb 2 Using new bolts and self locking nuts temporari ly tighten the front arm to crossmember 3 Secure the front arm to body and then install the support plate with new bolts and self locking nuts Tightening torque Support plate to Front arm 110 N m 11 2 kgf m 81 1 ft lb Support plate to Body 150 N m 15 3...

Page 21: ... aligning the position on bushing installation 2 Using the ST and a press remove the rear bush ing ST1 20299AG000 REMOVER ST2 20299AG010 BASE D ASSEMBLY 1 FRONT BUSHING Assemble in the reverse order of disassembly CAUTION Install the front bushing in proper direction as shown in the figure 1 Put an alignment mark 2 Recess portion ST FS 00110 FS 00136 2 1 1 1 Press 2 Front arm 3 Rear bushing 1 Face...

Page 22: ...gning mark on the front arm 3 Using the ST and a press install the rear bush ing ST1 20299AG000 REMOVER ST2 20299AG010 BASE E INSPECTION 1 Check the front arm for wear damage or cracks and correct or replace if defective 2 Check the bushing for crack fatigue or damage 1 Front arm 2 Bushing inner cylinder 3 Longer 4 Shorter 5 Protrusion portion 1 Alignment mark 2 Recess portion FS 00113 2 1 3 4 5 F...

Page 23: ...e strut mount at the upper side of strut to body and tighten it with new self locking nuts Tightening torque 20 N m 2 0 kgf m 14 5 ft lb 2 Align alignment marks on the camber adjusting bolt and strut Using new self locking nuts install the strut to housing NOTE While holding the head of adjusting bolt tighten the self locking nut Tightening torque 175 N m 17 8 kgf m 129 ft lb 3 Secure the ABS whee...

Page 24: ... at least 10 mm 0 39 in in the former step purge air from the strut 3 Air purging procedure 1 Place the strut vertically with the piston rod facing up 2 Fully extend the piston rod 3 With the piston rod fully extended place the piston rod side down The strut must stand ver tically 4 Fully contract the piston rod 5 Repeat 3 to 4 times from the step 1 NOTE After completely purging air from the strut...

Page 25: ...hat it operates smoothly without any hitch 3 Piston rod play Measure the play as follows Fix the outer shell and fully extend the rod Set a dial gauge at the end of rod L 10 mm 0 39 in and then read the dial gauge indication P1 while apply ing a force of W 20 N 2 kgf 4 lb to threaded por tion Apply a force of 20 N 2 kgf 4 lb in the opposite direction of W and then read the dial gauge indication P2...

Page 26: ... 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 1 Place the strut on a level surface with the piston rod fully expanded 2 Using a 2 to 3 mm 0 08 to 0 12 in dia drill make holes in areas shown in the figure 1 40 mm 1 57 in FS 00047 1 ...

Page 27: ...rder of removal NOTE Use a new bolt and self locking nut For the parts which are not reusable refer to COMPONENT Ref to FS 4 COMPONENT General Descrip tion Always tighten the bushing in the state that wheels are in full contact with the ground and the vehicle is curb weight Tightening torque Crossmember to body 95 N m 9 7 kgf m 70 1 ft lb Engine mounting to crossmember 85 N m 8 7 kgf m 62 7 ft lb ...

Page 28: ... height Adjust or replace the coil springs with new ones 4 Fault in operation of damper strut or shock absorber Replace 5 Damage or deformation of strut mount or shock absorber mount Replace 6 Unsuitability of maximum or minimum length of damper strut or shock absorber Replace with proper parts 7 Deformation or loss of bushing Replace 8 Deformation or damage of helper in strut assembly or shock ab...

Page 29: ...FS 28 FRONT SUSPENSION General Diagnostic Table ...

Page 30: ...s 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...

Page 31: ... 2 Wheel Alignment 8 3 Rear Stabilizer 9 4 Rear Arm 10 5 Upper Link 14 6 Rear Shock Absorber 16 7 Front Link 18 8 Rear Link 19 9 Sub Frame Support Arm 21 10 Sub Frame Support Plate 22 11 Rear Sub Frame 23 12 Helper 24 13 General Diagnostic Table 25 ...

Page 32: ...ons for deformation and replace with new ones as re quired Model Sedan Wagon 2 0 i 2 5 i 2 0 GT 3 0 R 2 0 i 2 5 i OUTBACK 2 5 i OUTBACK 3 0 R Wheel arch height Tolerance 12 mm 24 mm 0 47 in 0 94 in mm in 360 14 2 375 14 8 430 16 9 Camber Tolerance 0 45 Differences between RH and LH 45 or less 0 45 0 30 0 00 Toe in mm in 0 3 0 0 12 Toe angle sum of both wheels 0 0 15 Thrust angle tolerance 0 30 0 D...

Page 33: ...32 5 6 Stabilizer link 19 Upper link bushing outer side T5 57 5 8 42 7 Rear link 20 Front link T6 62 6 3 48 8 Adjusting bolt 21 Rear sub frame T7 65 6 6 48 9 Rear link bushing 22 Sub frame support arm T8 80 8 2 59 10 Adjusting washer 23 Sub frame support plate T9 120 12 2 89 11 Rear arm T10 125 12 7 92 12 Rear arm rear bushing T11 150 15 3 111 13 Rear arm front bushing T12 175 17 8 129 RS 00137 1 ...

Page 34: ...ment Use SUBARU genuine grease etc or the equiv alent Do not mix grease etc with that of another grade or from other manufacturers Before securing a part on a vice place cushion ing material such as wood blocks aluminum plate or cloth between the part and the vice Be sure to tighten fasteners including bolts and nuts to specified torque Place shop jacks or rigid racks at the specified points 1 Mou...

Page 35: ...ber caster gauge when measuring the camber and caster 1 28199AC000 PLATE 2 28199AC010 BOLT 20099AE000 INSTALLER REMOVER Used for replacing the rear link bushing 20099AE010 INSTALLER REMOVER Used for replacing the upper link bushing 20099AE020 INSTALLER REMOVER SET Used for replacing the rear arm front bushing 1 2 ST 927380002 ST20099AE000 ST20099AE010 ST20099AE020 ...

Page 36: ...WRENCH Used for replacing the helper 20399AG000 New adopted tool STRUT MOUNT SOCKET Used for removing and installing the shock mount 28099PA090 OIL SEAL PROTEC TOR Used for installing the rear drive shaft to rear differential For oil seal protection ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS ST20099AE040 ST20099AE030 ST20399AG000 ST28099PA090 ...

Page 37: ...nment measurement Turning radius gauge Used for wheel alignment measurement Toe in gauge Used for toe in measurement Transmission jack Used for removing and installing suspension Bearing puller Used for removing bushings Coil spring compressor Used for disassembling and assembling shock absorber ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS ST28099PA100 ...

Page 38: ...eel Alignment 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 ...

Page 39: ...er bushing align the paint mark end of stabilizer to the end of stabilizer bush ing Stabilizer bracket has an orientation so install it with the arrow mark faced to the upper side of ve hicle 2 Always tighten the stabilizer bushing in the state that wheels are in full contact with the ground and the vehicle is curb weight Tightening torque Stabilizer link 44 N m 4 5 kgf m 32 5 ft lb Stabilizer bra...

Page 40: ... which secure the parking brake cable clamp to rear arm bracket 6 Remove the bolt which hold the brake hose bracket and ABS wheel speed sensor bracket to rear arm 7 Remove the bolts which secure the brake hose bracket to rear arm Remove the bolts which se cure the ABS wheel speed sensor to rear arm 8 Remove the stabilizer link from rear arm 9 Remove the shock absorber from rear arm 10 Support the ...

Page 41: ...rm and temporarily tighten the bolts which hold the rear arm to the link 3 Install the bearing unit Ref to DS 20 INSTALLATION Rear Hub Unit Bearing 4 Install the bolts which secure the ABS wheel speed sensor to rear arm 5 Install the bolts which secure the brake hose to rear arm 6 Install the bolts which secure the parking brake cable clamp to rear arm bracket 7 Set the jack which is originally eq...

Page 42: ...on C DISASSEMBLY 1 FRONT BUSHING 1 Set the ST A with the larger side of its inner di ameter turned upward 2 Set the rear arm with the protruding side of bush ing turned upward 3 Place the ST B on bushing and push the bush ing out ST A 20099AE020 INSTALLER REMOVER SET ST B 20099AE020 INSTALLER REMOVER SET 2 REAR BUSHING Using the ST C and bearing puller press the rear bushing out of place ST C 2009...

Page 43: ...side of ST D 2 Set the ST C ST D and bearing puller in the specified position as shown in the figure and then press fit the bush until the outer end of bush and rear end of rear arm in flat ST C 20099AE040 INSTALLER REMOVER SET ST D 20099AE040 INSTALLER REMOVER SET E INSPECTION Check the rear arm for bend corrosion or damage 1 0 5 2 Identification paint Assemble with the identification paint side ...

Page 44: ...support the rear arm horizontally 2 Using new self locking nuts install the upper link NOTE Inspect the wheel alignment and adjust it if neces sary Tightening torque Upper link to Sub frame 57 N m 5 8 kgf m 42 ft lb Upper link to Rear arm 65 N m 6 6 kgf m 48 ft lb C DISASSEMBLY Using the ST press the bushing out of place ST 20099AE010 INSTALLER REMOVER D ASSEMBLY Using the ST press the bushing int...

Page 45: ...tation Assem ble it with the longer protrusion faced to the rear side of vehicle E INSPECTION 1 Visually check the upper link for damage and de formation 2 Visually check the bush for crack damage and fatigue 1 Rear arm 2 Rear sub frame 3 Rear side of vehicle RS 00121 3 1 2 ...

Page 46: ...position of rear shock absorber and rear arm by adjusting the jack position Using new self locking nuts temporary tighten the bolt CAUTION Protect the rear link and sub frame from scratch in the way of putting a shop cloth between the jack and the mating portion 4 Using the transmission jack support the rear arm horizontally 5 Using new self locking nuts tighten the bolt and nut which secure the s...

Page 47: ...not disassemble the shock absorber or place it into a fire Drill a hole into shock absorbers in case of discarding shock absorbers filled with gas 1 Place the shock absorber on a level surface with the piston rod fully expanded 2 Make a hole into the specified position 30 mm 1 18 in deep using a drill with 2 to 3 mm 0 08 to 0 12 in diameter 1 40 mm 1 57 in RS 00135 1 ...

Page 48: ...B INSTALLATION 1 Using the transmission jack support the rear arm horizontally 2 Using new self locking nuts install the front link CAUTION Install the front link with the protrusion side faced to the front side of vehicle NOTE Inspect the wheel alignment and adjust it if neces sary Tightening torque 57 N m 5 8 kgf m 42 ft lb C INSPECTION Visually check the front link for damage and defor mation 1...

Page 49: ...red when loosening the adjusting bolt B INSTALLATION 1 Using the transmission jack support the rear arm horizontally 2 Using new self locking nuts install the rear link NOTE Tighten the self locking nut with the bolt head se cured when installing the adjusting bolt Inspect the wheel alignment and adjust it if nec essary Tightening torque Rear link to Sub frame 120 N m 12 2 kgf m 89 ft lb Rear link...

Page 50: ...Rear Link D ASSEMBLY Using the ST A and ST B press fit the bushing ST A 20099AE000 INSTALLER REMOVER ST B 20099AE000 INSTALLER REMOVER E INSPECTION Visually check the rear link for damage and defor mation RS 00083 ST A ST B ...

Page 51: ...t stand 2 Remove the sub frame support arm B INSTALLATION Install in the reverse order of removal Tightening torque Sub frame support arm to Rear arm bracket 80 N m 8 2 kgf m 59 ft lb Sub frame support arm to Rear sub frame 175 N m 17 8 kgf m 129 ft lb C INSPECTION Visually check the sub frame support arm for dam age and deformation RS 00088 ...

Page 52: ... the rear sub frame with support stand 2 Remove the sub frame support plate B INSTALLATION Install in the reverse order of removal Tightening torque Support plate to Sub frame 175 N m 17 8 kgf m 129 ft lb Support plate to Body 65 N m 6 6 kgf m 48 ft lb C INSPECTION Visually check the support plate for damage FU 01134 ...

Page 53: ...e the upper link from sub frame Ref to RS 14 REMOVAL Upper Link 10 Remove the sub frame support arm 11 After removing the bolt remove the sub frame and sub frame support plate from vehicle B INSTALLATION 1 Install in the reverse order of removal 2 Follow the procedure below for the rear differen tial installation and tightening torque T type Ref to DI 30 INSTALLATION Rear Differential T type VA ty...

Page 54: ...cle and then remove the rear wheels 2 Remove the helper using ST ST 20099AE030 HELPER SOCKET WRENCH B INSTALLATION Install in the reverse order of removal Tightening torque 32 N m 3 3 kgf m 24 ft lb C INSPECTION Check the helper for crack fatigue and damage RS 00087 ST ...

Page 55: ...eight Adjust or replace the coil springs with new ones 4 Fault in operation of damper strut or shock absorber Replace 5 Damage or deformation of strut mount or shock absorber mount Replace 6 Unsuitability of maximum or minimum length of damper strut or shock absorber Replace with proper parts 7 Deformation or loss of bushing Replace 8 Deformation or damage of helper in strut assembly or shock abso...

Page 56: ...RS 26 REAR SUSPENSION General Diagnostic Table ...

Page 57: ...s 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...

Page 58: ...WHEEL AND TIRE SYSTEM WT Page 1 General Description 2 2 Tire 4 3 Steel Wheel 5 4 Aluminum Wheel 6 5 Wheel Balancing 7 6 T type Tire 9 7 General Diagnostic Table 10 ...

Page 59: ...45R17 87W 17 7JJ 230 2 3 33 220 2 2 32 2 5 i KA model 215 45R17 87W 17 7JJ 230 2 3 33 220 2 2 32 3 0 R 215 45R17 87W 17 7JJ 230 2 3 33 220 2 2 32 2 0 GT 215 45R17 87W 17 7JJ 230 2 3 33 220 2 2 32 Wagon 2 0 i 2 5 i 205 55R16 89V 16 61 2JJ 220 2 2 32 220 2 2 32 2 5 i OP 215 45R17 87W 17 7JJ 230 2 3 33 210 2 1 31 2 5 i KA model 215 45R17 87W 17 7JJ 230 2 3 33 210 2 1 31 3 0 R 215 45R17 87W 17 7JJ 230...

Page 60: ...r Adhesive type weight for alumi num wheel Weight 28101AG000 5 g 0 18 oz 28101AG010 7 5 g 0 26 oz 28101AG020 10 g 0 35 oz 28101AG030 12 5 g 0 44 oz 28101AG040 15 g 0 53 oz 28101AG050 17 5 g 0 62 oz 28101AG060 20 g 0 71 oz 28101AG070 22 5 g 0 79 oz 28101AG080 25 g 0 88 oz 28101AG090 27 5 g 0 97 oz 28101AG100 30 g 1 06 oz 28101AG110 32 5 g 1 15 oz 28101AG120 35 g 1 23 oz 28101AG130 37 5 g 1 32 oz 28...

Page 61: ...e as originally installed 1 When large crack on side wall damage or crack on tread is found 2 When the tread wear indicator appears as a solid band across the tread 3 When a crack on tire valve is found replace the tire valve 1 TIRE ROTATION Rotate tires periodically 5 000 km 3 100 miles as shown in the figure in order to prevent them from uneven wear and to prolong their life 1 Tread wear indicat...

Page 62: ...ection to the specified torque Use a wheel nut wrench Wheel nut tightening torque 90 N m 9 1 kgf m 65 7 ft lb CAUTION Tighten the wheel nuts in two or three steps by gradually increasing the torque and working diagonally until they reach the specified torque Do not depress the wrench with foot Always use both hands when tightening Make sure the bolt nut and the nut seating surface of the wheel are...

Page 63: ...eir appearance and safety do the followings 1 Do not damage the aluminum wheels during re moval installation wheel balancing etc After re moving the aluminum wheels place them on a rubber mat etc 2 While driving the vehicle be careful not to ride over sharp obstacles or allow aluminum wheels to contact the shoulder of the road 3 When installing a tire chain be sure to install it properly not to ha...

Page 64: ...41590 60 g 2 12 oz Balance weight part number Knock on type weight for alumi num wheel Weight 28101SA000 5 g 0 18 oz 28101SA010 10 g 0 35 oz 28101SA020 15 g 0 53 oz 28101SA030 20 g 0 71 oz 28101SA040 25 g 0 88 oz 23141GA512 30 g 1 06 oz 23141GA522 35 g 1 23 oz 23141GA532 40 g 1 41 oz 23141GA542 45 g 1 59 oz 23141GA552 50 g 1 76 oz 55 g 1 94 oz 23141GA572 60 g 2 12 oz Balance weight part number Adh...

Page 65: ...ights of knock on type weight for alu minum wheel are available for use with any of 15 to 17 inch aluminum wheels Service limit A Knock on type weight for steel wheel 5 25 g 0 18 0 88 oz 2 0 mm 0 08 in 30 g 1 06 oz or more 1 8 mm 0 07 in Knock on type weight for aluminum wheel 5 25 g 0 18 0 88 oz 5 0 mm 0 20 in 30 g 1 06 oz or more 4 5 mm 0 177 in 1 Knock on type weight for aluminum wheel 2 Knock ...

Page 66: ...an 100 km h 62 MPH Drive as slowly as possible and avoid pass ing over bumps B REPLACEMENT Refer to Steel Wheel for installation procedure of T type tire Ref to WT 5 REMOVAL Steel Wheel CAUTION Replace with a conventional tire as soon as possible since the T type tire is only for tem porary use C INSPECTION 1 Check the tire air pressure Specifications 420 kPa 4 2 kg cm2 60 psi 2 Take the stones gl...

Page 67: ...bearing Ref to DS 21 INSPECTION Rear Hub Unit Bearing Vehicle is abnormally out of balance 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 Front stabilizer Check the front stabilizer Ref to FS 16 INSPECTION Front Stabi lizer Front wheel alignment Check the front wheel alignments ...

Page 68: ...ure Improper wheel balancing Check the wheel balance Ref to WT 7 ADJUSTMENT Wheel Bal ancing Front wheel alignment Check the front wheel alignments Ref to FS 8 INSPECTION Wheel Alignment Rear wheel alignment Check the rear wheel alignments Ref to RS 8 INSPECTION Wheel Alignment Symptom Possible cause Corrective action ...

Page 69: ...WT 12 WHEEL AND TIRE SYSTEM General Diagnostic Table ...

Page 70: ...s 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...

Page 71: ...rential Gear Oil 26 3 Front Differential Assembly 28 4 Rear Differential T type 29 5 Rear Differential VA type 46 6 Rear Differential Front Oil Seal 72 7 Rear Differential Side Oil Seal 74 8 Rear Differential Front Member 75 9 General Diagnostic Table 76 ...

Page 72: ... 0 L Turbo AT MT AT MT AT KA KS 1 EC EK K4 1 Rear differential type VA1 type T type VA2 type Classification XJ T2 VB XT XU LSD type Viscous coupling Type of gear Hypoid gear Gear ratio Number of gear teeth 4 111 37 9 3 700 37 10 3 083 37 12 3 272 36 11 Oil capacity 0 82 0 8 US qt 0 7 Imp qt Rear differential gear oil GL 5 Model OUTBACK 2 5 L 3 0 L AT MT AT EC EK K4 1 KS KA 1 Rear differential type...

Page 73: ... Rear differential gear oil 3 API classification 4 SAE viscosity No and applicable temperature DI 00397 1 MT 00001 1 4 GL 5 3 2 C F 30 26 15 15 90 85W 80W 75W 90 25 30 5 0 22 15 23 32 86 59 77 5 Drive pinion bearing preload at companion flange bolt hole N kgf lb T type 18 1 38 8 1 8 4 0 4 1 8 7 VA type 12 7 32 4 1 3 3 3 2 9 7 3 Side gear backlash mm in T type 0 10 0 20 0 0039 0 0079 VA1 type only ...

Page 74: ...0 0972 383775200 2 45 0 0965 383785200 2 43 0 0957 383795200 2 41 0 0949 383805200 2 39 0 0941 383815200 2 37 0 0933 383825200 2 35 0 0925 383835200 2 33 0 0917 383845200 2 31 0 0909 Pinion height adjusting washer Part No Thickness mm in 383495200 3 09 0 1217 383505200 3 12 0 1228 383515200 3 15 0 1240 383525200 3 18 0 1252 383535200 3 21 0 1264 383545200 3 24 0 1276 383555200 3 27 0 1287 38356520...

Page 75: ...445203 0 85 0 90 0 0335 0 0354 Side bearing standard width mm in 20 00 0 7874 Side bearing retainer shim Part No Thickness mm in 383475201 0 20 0 0079 383475202 0 25 0 0098 383475203 0 30 0 0118 383475204 0 40 0 0157 383475205 0 50 0 0197 Hypoid driven gear to drive pinion backlash Limit mm in 0 10 0 20 0 0039 0 0079 Hypoid driven gear runout on its back sur face 0 05 0 0020 ...

Page 76: ...160 1 613 0 0635 38336AA050 1 625 0 0640 38336AA170 1 638 0 0645 38336AA060 1 650 0 0650 38336AA180 1 663 0 0655 38336AA070 1 675 0 0659 38336AA190 1 688 0 0665 38336AA080 1 700 0 0669 38336AA200 1 713 0 0674 38336AA090 1 725 0 0679 38336AA210 1 738 0 0684 38336AA100 1 750 0 0689 38336AA220 1 763 0 0694 38336AA110 1 775 0 0699 Pinion height adjusting washer Part No Thickness mm in 32295AA200 0 150...

Page 77: ...606 38336AA470 1 550 0 0610 38336AA480 1 563 0 0615 38336AA490 1 575 0 0620 38336AA500 1 588 0 0625 38336AA510 1 600 0 0630 38336AA520 1 613 0 0635 38336AA530 1 625 0 0640 38336AA540 1 638 0 0645 38336AA550 1 650 0 0650 38336AA560 1 663 0 0655 38336AA570 1 675 0 0659 38336AA580 1 688 0 0665 38336AA590 1 700 0 0669 38336AA600 1 713 0 0674 38336AA610 1 725 0 0679 38336AA620 1 738 0 0684 38336AA630 1...

Page 78: ...ase 5 Bearing preload adjusting washer 18 Side gear thrust washer 31 Gasket 6 Differential carrier 19 Side gear 7 Front bearing 20 Pinion mate gear Tightening torque N m kgf m ft lb 8 Collar 21 Pinion mate gear washer T1 10 3 1 05 7 6 9 Pilot bearing 22 Pinion shaft lock pin T2 29 3 0 21 7 10 Front oil seal 23 Snap ring T3 49 5 0 36 2 11 Companion flange 24 Pinion mate shaft T4 105 10 7 77 4 12 Se...

Page 79: ... adjusting collar 15 Side bearing retainer shim Tightening torque N m kgf m ft lb 5 Bearing preload adjusting washer 16 Side bearing retainer T1 10 3 1 05 7 6 6 Differential carrier 17 Side oil seal T2 29 3 0 21 7 7 Front bearing 18 Gasket T3 49 5 0 36 2 8 Collar 19 Differential case ASSY T4 105 10 7 77 4 9 Pilot bearing 20 Rear cover T5 181 18 5 134 10 Front oil seal 21 Air breather cap DI 00002 ...

Page 80: ... 5 Bearing preload adjusting washer 18 Side gear thrust washer 6 Differential carrier 19 Side gear Tightening torque N m kgf m ft lb 7 Front bearing 20 Pinion mate gear T1 25 2 5 18 1 8 Collar 21 Pinion shaft lock pin T2 34 3 5 25 3 9 Pilot bearing 22 Differential case T3 62 6 3 45 6 10 Front oil seal 23 Pinion mate shaft T4 191 19 5 141 11 Companion flange 24 Air breather cap 12 Self locking nut ...

Page 81: ...t 4 Bearing preload adjusting collar 15 O ring 5 Bearing preload adjusting washer 16 Axle shaft holder Tightening torque N m kgf m ft lb 6 Differential carrier 17 Side oil seal T1 25 2 5 18 1 7 Front bearing 18 Differential case ASSY T2 29 3 0 21 4 8 Collar 19 Air breather cap T3 34 3 5 25 3 9 Pilot bearing 20 Stud bolt T4 62 6 3 45 6 10 Front oil seal 21 Gasket T5 191 19 5 141 DI 00349 T4 T3 14 5...

Page 82: ...ERENTIAL MOUNTING SYSTEM 1 Rear differential front member 4 Sub frame Tightening torque N m kgf m ft lb 2 Rear differential member plate 5 Self locking nut T1 52 5 3 38 3 Rear differential ASSY T2 70 7 1 51 T3 110 11 2 81 DI 00350 4 T2 T3 T1 3 2 1 5 5 5 ...

Page 83: ...cturers Be sure to tighten fasteners including bolts and nuts to the specified torque Place shop jacks or rigid racks at the specified points Apply gear oil onto sliding or revolution surfaces before installation Before installing O rings or snap rings apply suf ficient amount of gear oil to avoid damage and de formation Before securing a part on a vice place cushion ing material such as wood bloc...

Page 84: ...ompanion flange when removing and tightening self locking nut 398467700 DRIFT Used for removing pinion pilot bearing and front bearing cone For T type and VA1 type 399780104 WEIGHT Used for installing front bearing cone and pilot bearing companion flange ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS ST 498447120 ST 498427200 ST 398467700 ST 399780104 ...

Page 85: ...rential pinion shaft lock pin 498247001 MAGNET BASE Used for measuring backlash between side gear and pinion and hypoid gear Used with DIAL GAUGE 498247100 498247100 DIAL GAUGE Used for measuring backlash between side gear and pinion and hypoid gear Used with MAGNET BASE 498247001 ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS ST 899580100 ST 899904100 ST 498247001 ST 498247100 ...

Page 86: ...ER Used for installing rear bearing cone For T type and VA2 type 398457700 ATTACHMENT Used for removal of side bearing retainer For T type 398477703 DRIFT 2 Used for press fitting bearing race rear of dif ferential carrier For T type and VA2 type ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS ST 398507704 ST 398177700 ST 398457700 ST 398477703 ...

Page 87: ...2 DUMMY SHAFT Used for adjusting pinion height and preload For T type 398507703 DUMMY COLLAR Used for adjusting pinion height and preload For T type 398517700 REPLACER Used for removing rear bearing cone For T type and VA2 type ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS ST 398437700 ST 398507702 ST 398507703 ST 398517700 ...

Page 88: ...FFERENTIAL CARRIER GAUGE Used for adjusting pinion height For T type 398527700 PULLER ASSY Used for removing front oil seal Used for removing side bearing cup T type 398227700 DRIFT Used for installing side bearing For T type and VA2 type ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS ST 398487700 ST 398507701 ST 398527700 ST 398227700 ...

Page 89: ...or oil seal protection 398237700 DRIFT Used for installing side bearing For T type 28099PA100 DRIVE SHAFT REMOVER Used for removing rear drive shaft from rear differential For T type 399703600 PULLER ASSY Used for removing companion flange ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS ST28099PA090 ST 398237700 ST28099PA100 ST 399703600 ...

Page 90: ... REMOVER Used for removing side bearing cone from dif ferential For VA2 type 899864100 REMOVER Used for removing differential side bearing 499277200 INSTALLER Used for installing front bearing cone For VA2 type ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS ST 899874100 ST 498077000 ST 899864100 ST 499277200 ...

Page 91: ... removing differential from side bear ing cone For T type 18678AA000 Newly adopted tool DUMMY SHAFT Used for adjusting pinion height and preload For VA2 type 18831AA010 Newly adopted tool DIFFERENTIAL CARRIER GAUGE Used for adjusting pinion height For VA2 type ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS ST18758AA000 ST18759AA000 ST18678AA000 ST18831AA010 ...

Page 92: ...NOTE Also available for VA1 type 498175500 INSTALLER Used for installing rear bearing cone For VA1 type 499785500 WRENCH ASSY Used for removing and installing side oil seal holder For VA1 type 498447100 INSTALLER Used for installing oil seal For VA1 type ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS ST18630AA010 ST 498175500 ST 499785500 ST 498447100 ...

Page 93: ...5400 DRIFT Used for installing side bearing cone For VA1 type 498505501 DIFFERENTIAL CARRIER GAUGE Used for adjusting pinion height For VA1 type 498447110 DRIFT Used for press fitting the bearing race front of differential carrier For VA1 type ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS ST 399520105 ST 498485400 ST 498505501 ST 498447110 ...

Page 94: ...REPLACER Used for removing rear bearing cone For VA1 type 32285AA000 DUMMY COLLAR Used for adjusting pinion height and preload For VA1 type 499705404 SEAT Used for removing side bearing race Used with PULLER ASSY 499705401 For VA1 type ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS ST 498447150 ST 498515500 ST32285AA000 ST 499705404 ...

Page 95: ...OL NAME REMARKS Transmission jack Used for assembly disassembly of rear differential Puller Used for removal of side bearing retainer Thickness gauge Used for measuring clearance Hexagon wrench Used for installing and removing filler and drain plug Tire lever Used for removal of rear drive shaft VA type ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS ST 499705401 ...

Page 96: ...hands because gear oil becomes extremely hot after running Except for VA2 type VA2 type 3 Tighten the oil drain plug NOTE Apply liquid gasket to the drain plug threads for T type Liquid gasket THREE BOND 1105 Part No 004403010 or equivalent Use a new aluminum gasket for VA1 type Use a new metal gasket for VA2 type Tightening torque T type 49 N m 5 0 kgf m 36 2 ft lb VA1 type 34 N m 3 5 kgf m 25 3 ...

Page 97: ...NOTE Apply liquid gasket to the filler plug threads for T type Liquid gasket THREE BOND 1105 Part No 004403010 or equivalent Use a new aluminum gasket for VA1 type Use a new metal gasket for VA2 type Tightening torque T type 49 N m 5 0 kgf m 36 2 ft lb VA1 type 34 N m 3 5 kgf m 25 3 ft lb VA2 type 29 N m 3 0 kgf m 21 4 ft lb A Filler plug B Drain plug A Filler plug B Drain plug DI 00391 A B B DI 0...

Page 98: ...nt 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 Ref to 5AT 94 Front Differential 2 MT MODEL For front differential of manual transmission refer to 5MT section Ref to 5MT 85 Front Differen tial Assembly ...

Page 99: ...Ref to EX H4DOTC 11 Rear Exhaust Pipe 8 Remove the propeller shaft Ref to DS 10 REMOVAL Propeller Shaft 9 Prepare the transmission jack and band 10 Loosen the self locking nuts which hold the rear differential to rear crossmember 11 Remove the DOJ of rear drive shaft from rear differential using ST ST 28099PA100 DRIVE SHAFT REMOVER 12 Remove the rear differential front member 13 Support the rear d...

Page 100: ... If it is difficult to remove the axle shaft from rear dif ferential remove it using ST ST 28099PA100 DRIVE SHAFT REMOVER 19 Lower the transmission jack 20 Secure the rear drive shaft to lateral link using wire 21 Remove the rear differential member plate from rear differential B INSTALLATION 1 Install the rear differential member plate to rear differential 2 Set the rear differential to transmiss...

Page 101: ...tial stud bolt into rear cross member bushing properly 8 After inserting the rear differential stud bolt into rear crossmember bushing lift up the transmission jack and align the rear differential with its own posi tion 9 Tighten the rear crossmember self locking nut temporarily 10 Remove the band from rear differential Lift up the rear differential until the rear differential is sep arated from t...

Page 102: ...lug Liquid gasket THREE BOND 1105 Part No 004403010 or equivalent Tightening torque 49 0 N m 5 0 kgf m 36 2 ft lb C DISASSEMBLY To detect the real cause of trouble inspect the fol lowing items before disassembling Tooth contact of hypoid driven gear and drive pinion and backlash Hypoid driven gear runout on its back surface Total preload of drive pinion 1 Set the ST on vise and install the differe...

Page 103: ...ul not to hit the teeth against the case 7 When replacing the side bearing remove the bearing cup from side bearing retainer using ST ST 398527700 PULLER ASSY 8 Extract the bearing cone with ST NOTE Do not attempt to disassemble the parts unless necessary Set the puller so that its claws catch the edge of the bearing cone Never mix up the bearing races RH and LH and cones ST 18759AA000 PULLER ASSY...

Page 104: ...ANGE WRENCH 13 Extract the companion flange with a puller 14 Press the end of drive pinion shaft and extract it together with rear bearing cone pinion height ad just washer and washer NOTE Hold the drive pinion so as not to drop it ST 398467700 DRIFT 15 Remove the rear bearing cone from drive pin ion by supporting the cone with ST NOTE Place the replacer so that its center recessed side faces the ...

Page 105: ...es RH and LH Use new O rings and gasket Replace the oil seals with new ones at every dis assembly Apply grease to the lips when installing the oil seals Be careful not to mix up the differential oil seal RH and LH 1 Adjusting preload for front and rear bearings Adjust the bearing preload with collar and washer between front and rear bearings Pinion height ad justing washer are not affected by this...

Page 106: ...ied preload is obtained when nut is tight ened to the specified torque NOTE Use a new self locking nut Be careful not to give excessive preload When tightening the self locking nut lock ST1 with ST2 as shown in the figure Measure the preload in direction of tangent to flange ST1 398507702 DUMMY SHAFT ST2 398507704 BLOCK Tightening torque 181 N m 18 5 kgf m 134 ft lb A Pinion height adjusting washe...

Page 107: ...2 Result Thickness 3 42 mm Therefore use the pinion height adjusting wash er of part number 383605200 Preload adjusting collar Part No Length mm in 383695201 56 2 2 213 383695202 56 4 2 220 383695203 56 6 2 228 383695204 56 8 2 236 383695205 57 0 2 244 383695206 57 2 2 252 A Pinion height adjusting washer RH LH N A ST2 ST3 ST1 DI 00083 ST2 ST1 DI 00084 T Thickness of pinion height adjusting washer...

Page 108: ...100 INSTALLER 6 Insert the collar then press fit the pilot bearing with ST1 and ST2 ST1 399780104 WEIGHT ST2 899580100 INSTALLER 7 Fit a new oil seal with ST NOTE Press fit until end of oil seal is 1 mm 0 04 in in ward from end of carrier Apply grease to the oil seal lips ST 498447120 INSTALLER 8 Press fit the companion flange with ST1 and ST2 NOTE Be careful not to damage the bearing ST1 89987410...

Page 109: ...ar backlash 0 10 0 20 mm 0 0039 0 0079 in 2 Adjust the side gear backlash as specified by selecting side gear thrust washer 3 Check the condition of rotation after apply ing oil to the gear tooth surfaces and thrust sur faces 4 After inserting the pinion shaft lock pin into differential case stake the both sides of the hole to prevent pin from falling off 11 Install the hypoid driven gear to diffe...

Page 110: ...ter race is not dam aged by bearing roller 5 Tighten the side bearing retainer bolts Tightening torque 10 3 N m 1 05 kgf m 7 6 ft lb 6 Measure the hypoid driven gear to drive pin ion backlash Set the magnet base on differen tial carrier Align the contact point of dial gauge with tooth face of hypoid driven gear and move hypoid driven gear while holding drive pinion still Read the value indicated o...

Page 111: ...e exceed the specification verify that there is any for eign material between hypoid driven gear and dif ferential case and they are not deformed Hypoid driven gear runout on its back surface 0 05 mm 0 0020 in 17 Checking and adjusting the tooth contact of hy poid driven gear 1 Apply an even coat of red lead on both sides of three or four teeth on the hypoid driven gear Check the contact pattern a...

Page 112: ...washer in order to bring drive pin ion away from hypoid driven gear Toe contact inside end contact Checking item Contact areas is small Contact pattern Corrective action Reduce thickness of drive pinion height adjusting washer in order to bring drive pin ion away from hypoid driven gear Heel contact outside end contact Checking item Contact areas is small Contact pattern Corrective action Increase...

Page 113: ...d driven gear and drive pinion If abnormal tooth contact is evident find out the cause and adjust to give correct tooth contact Re place the gear if excessively worn or incapable of adjustment If crack score or seizure is evident replace as a set Slight damage of tooth can be corrected by oil stone or the like 2 Side gear and pinion mate gear Replace if crack score or other defects are evi dent on...

Page 114: ...0 05 mm 0 0020 in If the hypoid driven gear runout exceeds 0 05 mm 0 0020 in replace the hypoid driven gear 4 TOOTH CONTACT BETWEEN HYPOID DRIVEN GEAR AND DRIVE PINION Inspect the tooth contact between hypoid driven gear and drive pinion Ref to DI 35 ASSEMBLY Rear Differential T type 5 TOTAL PRELOAD Using a spring balance check the total preload Total preload 20 7 54 4 N 2 1 5 5 kgf 4 7 12 2 lb If...

Page 115: ...t exceeds the limit after replacing the companion flange the drive pinion may be assem bled incorrectly or bearing is faulty F ADJUSTMENT 1 SIDE GEAR BACKLASH Adjust the side gear backlash Ref to DI 35 ASSEMBLY Rear Differential T type 2 HYPOID DRIVEN GEAR BACKLASH Adjust hypoid driven gear backlash Ref to DI 35 ASSEMBLY Rear Differential T type 3 TOOTH CONTACT BETWEEN HYPOID DRIVEN GEAR AND DRIVE...

Page 116: ...ller shaft Ref to DS 10 REMOVAL Propeller Shaft 10 Prepare the transmission jack and band 11 Loosen the self locking nuts which hold the rear differential to rear crossmember 12 Remove the DOJ of rear drive shaft from rear differential 13 Remove the nuts which hold the rear differen tial front member 14 Support the rear differential with transmission jack 15 Remove the rear differential front memb...

Page 117: ...ll out the axle shaft from rear differential NOTE If it is difficult to remove the axle shaft from rear dif ferential remove it using tire lever 21 Lower the transmission jack 22 Secure the rear drive shaft to lateral link using wire 23 Remove the rear differential member plate from rear differential B INSTALLATION 1 Insert the rear differential member plate into rear differential 2 Set the rear d...

Page 118: ... stud bolt into rear cross member bushing properly 8 After inserting the rear differential stud bolt into rear crossmember bushing lift up the transmission jack and align the rear differential to the height of rear differential 9 Tighten a new self locking nut temporarily to rear crossmember 10 Remove the band from rear differential Lift up the rear differential until the rear differential is left...

Page 119: ...bling Tooth contact and backlash between hypoid driv en gear and drive pinion Hypoid driven gear runout on its back surface Total preload of drive pinion 1 Set the ST on vise and install the differential as sembly to ST ST 398217700 ATTACHMENT 2 Drain the gear oil by removing plug 3 Remove the rear cover by loosening retaining bolts 4 Remove the air breather cap NOTE Do not attempt to remove the a...

Page 120: ...nging oil seal 10 Extract the bearing cone with ST1 and ST2 NOTE Do not attempt to disassemble the parts unless necessary Set the puller so that its claws catch the edge of the bearing cone Never mix up the bearing races RH and LH and cones ST1 899524100 PULLER SET ST2 399520105 SEAT 11 Remove the hypoid driven gear by loosening hypoid driven gear bolts 12 Drive out the pinion shaft lock pin from ...

Page 121: ...he companion flange with a puller 16 Press the end of drive pinion shaft and extract it together with rear bearing cone pinion height ad just washer and washer NOTE Hold the drive pinion so as not to drop it ST 398467700 DRIFT 17 Remove the rear bearing cone from drive pin ion by supporting the cone with ST NOTE Place the replacer so that its center recessed side faces the pinion gear ST 498515500...

Page 122: ...items before disassembling Tooth contact and backlash between hypoid driv en gear and drive pinion Hypoid driven gear runout on its back surface Total preload of drive pinion 1 Set the ST on vise and install the differential as sembly to ST ST 398217700 ATTACHMENT 2 Drain the gear oil by removing plug 3 Remove the rear cover by loosening retaining bolts 4 Remove the lock plate RH and LH A Differen...

Page 123: ...ST 18758AA000 PULLER NOTE Make sure the bolt of puller turn manually Set the puller so that its claws catch the groove of holder 8 Remove the oil seal from holder RH and LH us ing screwdriver NOTE Perform this operation only when changing oil seal 9 Extract the bearing cone with ST1 ST2 and ST3 NOTE Do not attempt to disassemble the parts unless necessary Never mix up the bearing races RH and LH a...

Page 124: ...e with ST NOTE Place the replacer so that its center recessed side faces the pinion gear ST 398517700 REPLACER 15 Remove the front oil seal from differential carri er using screwdriver 16 Remove the pilot bearing front bearing cone and collar 17 When replacing the bearings hit out the front bearing cup and rear bearing cup in this order out of case by using a brass bar A Companion flange B Puller ...

Page 125: ...398477701 HANDLE ST2 398477702 DRIFT 2 Install the front bearing race to differential carrier using ST1 and ST2 ST1 398477701 HANDLE ST2 498447110 DRIFT 3 Insert the front bearing cone NOTE Use new front bearing cone 4 Measure and record the thickness of pinion height adjust washer NOTE If tooth contact drive pinion hypoid driven gear is normal in the inspection before disassembling ver ify that t...

Page 126: ...bearing preload For new bearing 12 7 32 2 N 1 3 3 3 kgf 2 9 7 3 lb Measure at companion flange bolt hole Preload adjusting washer Part No Thickness mm in 38336AA000 1 500 0 0591 38336AA120 1 513 0 0596 38336AA010 1 525 0 0600 38336AA130 1 538 0 0606 38336AA020 1 550 0 0610 38336AA140 1 563 0 0615 38336AA030 1 575 0 0620 38336AA150 1 588 0 0625 38336AA040 1 600 0 0630 38336AA160 1 613 0 0635 38336A...

Page 127: ...he front bearing cone into carrier with ST1 ST2 and ST3 ST1 32285AA000 DUMMY COLLAR ST2 399780104 WEIGHT ST3 899580100 INSTALLER 6 Insert the collar then press fit the pilot bearing with ST1 and ST2 ST1 399780104 WEIGHT ST2 899580100 INSTALLER 7 Fit a new oil seal with ST NOTE Press fit until end of oil seal is 1 mm 0 04 in in ward from end of carrier Apply grease to the oil seal lips T Thickness ...

Page 128: ...aft before installing Insert the pinion mate shaft into the differential case by aligning the lock pin holes 1 Measure the side gear backlash Side gear backlash 0 05 0 15 mm 0 0020 0 0059 in 2 Adjust the side gear backlash as specified by selecting side gear thrust washer 3 Check the condition of rotation after apply ing oil to the gear tooth surfaces and thrust sur faces 4 After inserting the pin...

Page 129: ...0 INSTALLER 2 Install the bearing race into holder RH and LH ST 398477702 DRIFT CAUTION Make sure that the oil seal bearing outer race and cone are properly assembled 3 Install the differential assembly into differen tial carrier in the reverse order of disassembly 4 Temporally tighten the side holder RH and LH in differential carrier to install 14 Perform the backlash adjustment between the hypoi...

Page 130: ...ial carrier Align the contact point of dial gauge with tooth face of hypoid driven gear and move hypoid driven gear while holding drive pin ion still Read the value indicated on dial gauge NOTE If measured backlash is not within specified range repeat the procedures for pinion driven gear set backlash adjustment and differential side bearing preload adjustment Backlash 0 10 0 15 mm 0 0039 0 0059 i...

Page 131: ...E Be sure to wipe off red lead completely after adjust ment is completed Correct tooth contact Checking item Tooth contact pattern is slightly shifted toward to toe side under no load rotation When loaded contact pattern moves toward heel Face contact Checking item Backlash is too large Contact pattern Corrective action Increase thickness of drive pin ion height adjusting washer in order to bring ...

Page 132: ...ned and the hypoid gear backlash 20 Install the new gasket and rear cover to differ ential carrier and tighten the bolts to specified torque Tightening torque 25 N m 2 5 kgf m 18 1 ft lb 2 VA2 TYPE NOTE Assemble in the reverse order of disassembly Check and adjust each part during assembly Use a new gasket Keep the shims and washers in order so that they are not improperly installed Thoroughly cle...

Page 133: ...e use the used washer 5 Insert the ST1 into carrier with pinion height adjusting washer and rear bearing cone fitted onto it NOTE Use new rear bearing cone 6 Install the preload adjusting collar and washer front bearing cone collar companion flange and washer and self locking nut ST1 18678AA000 DUMMY SHAFT 7 Turn the ST1 with hand to make it seated and tighten the self locking nut while measuring ...

Page 134: ...oad adjusting washer Part No Thickness mm in 38336AA430 1 500 0 0591 38336AA440 1 513 0 0596 38336AA450 1 525 0 0600 38336AA460 1 538 0 0606 38336AA470 1 550 0 0610 38336AA480 1 563 0 0615 38336AA490 1 575 0 0620 38336AA500 1 588 0 0625 38336AA510 1 600 0 0630 38336AA520 1 613 0 0635 38336AA530 1 625 0 0640 38336AA540 1 638 0 0645 38336AA550 1 650 0 0650 38336AA560 1 663 0 0655 38336AA570 1 675 0 ...

Page 135: ...tall the previously selected bearing preload adjust ing collar and washer 5 Set ST and differential carrier to the press and install the front bearing cone ST 399780104 WEIGHT NOTE Set the carrier to the press until the companion flange is installed 6 Insert the collar then install the pilot bearing T Thickness of pinion height adjusting washer mm in To Thickness of washer temporally inserted mm i...

Page 136: ...T 498427200 FLANGE WRENCH Tightening torque 191 N m 19 1 kgf m 141 ft lb 10 Install the hypoid driven gear on differential case NOTE Tighten diagonally while tapping the bolt heads Set a cushioning such as wooden block alumi num plate or shop cloth between vise and differen tial case if the side gear comes into contact with vise Tightening torque 62 N m 6 3 kgf m 45 6 ft lb 11 Press the side beari...

Page 137: ...ith ST ST 18630AA010 WRENCH 3 Back off the side hypoid driven gear side holder approx 1 1 2 teeth of holder and tighten the other side holder by approx 2 teeth approx 1 1 2 1 2 teeth Back off amount of side hy poid driven gear side holder 1 2 tooth This 1 2 tooth gives preload 4 Temporarily tighten the lock plate NOTE Turn over the lock plate to displace the holder 1 2 tooth 5 Measure the hypoid d...

Page 138: ...ing the tooth contact of hy poid driven gear 1 Apply an even coat of red lead on both sides of three or four teeth on the hypoid driven gear Check the contact pattern after rotating the hy poid driven gear several revolutions back and forth until a definite contact pattern appears on the hypoid driven gear 2 When the contact pattern is incorrect read just NOTE Be sure to wipe off red lead complete...

Page 139: ... washer in order to bring drive pin ion away from hypoid driven gear Toe contact inside end contact Checking item Contact areas is small Contact pattern Corrective action Reduce thickness of drive pinion height adjusting washer in order to bring drive pin ion away from hypoid driven gear Heel contact outside end contact Checking item Contact areas is small Contact pattern Corrective action Increas...

Page 140: ... evident 4 Thrust washers of side gear and pinion mate gear Replace if seizure flaw abnormal wear or other defect is evident 5 Oil seal Replace if deformed or damaged and at every dis assembling 6 Differential carrier Replace if the bearing bores are worn or damaged 7 Differential case Replace if its sliding surfaces are worn or cracked 8 Companion flange Replace if the oil seal lip contacting sur...

Page 141: ...panion flange and recheck the runout 6 If the runout exceeds the limit after replacing the companion flange the drive pinion may be assem bled incorrectly or bearing is faulty F ADJUSTMENT 1 SIDE GEAR BACKLASH Adjust the side gear backlash VA1 type Ref to DI 55 ASSEMBLY Rear Differential VA type 2 HYPOID DRIVEN GEAR BACKLASH Adjust hypoid driven gear backlash Ref to DI 55 ASSEMBLY Rear Differentia...

Page 142: ...t for VA1 type Use a new metal gasket for VA2 type Liquid gasket THREE BOND 1105 Part No 004403010 or equivalent Tightening torque T type 49 N m 5 0 kgf m 36 2 ft lb VA1 type 34 N m 3 5 kgf m 25 3 ft lb For VA2 type 29 N m 3 0 kgf m 21 4 ft lb 6 Jack up the rear wheel and support the body with rigid racks 7 Remove the rear exhaust pipe and muffler 8 Remove the propeller shaft Ref to DS 10 RE MOVAL...

Page 143: ...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 ST 498427200 FLANGE WRENCH NOTE Use a new self locking nut Tightening torque T type 181 N m 18 5 kgf m 134 ft lb VA type 191 N m 19 5 kgf m 141 ft lb 15 Hereafter reassemble in the reverse order of disassembly DI 00292 ST DI 0...

Page 144: ...tial T type Ref to DI 46 REMOVAL Rear Differential VA type 2 Remove the rear differential side oil seal using a screwdriver wrapped with vinyl tape to prevent the side retainer from scratches 3 Using the ST install the oil seal to the side re tainer T type and VA2 type ST 398437700 DRIFT VA1 type ST 498447100 INSTALLER 4 Install the rear differential Ref to DI 30 IN STALLATION Rear Differential T ...

Page 145: ...ront member with a new self locking nut Tightening torque T1 52 N m 5 3 kgf m 38 ft lb T2 110 N m 11 2 kgf m 81 ft lb C INSPECTION 1 Check the rear differential front member for damage bend and corrosion If damage bend or corrosion is excessive replace the rear differential front member 2 Check the bushings of rear differential member for cracking hardening and damage If cracking hardening or dama...

Page 146: ... replace 3 Insufficient or improper oil used Replace seized part and fill with specified oil to specified level 3 Damage NOTE Damaged parts should be replaced and also other parts should be thoroughly checked for any defect and should be re paired or replaced as required 1 Improper backlash for hypoid gear Replace 2 Insufficient or excessive preload for side rear or front bearing Readjust or repla...

Page 147: ...ouble When listening to noises shift gears into four wheel drive and fourth speed position try ing to pick up only differential noise 1 Improper tooth contact of hypoid gear Readjust or replace hypoid gear set 2 Improper backlash for hypoid gear Readjust 3 Scored or chipped teeth of hypoid gear Replace hypoid gear set 4 Seized hypoid gear Replace hypoid gear set 5 Improper preload for front or rea...

Page 148: ...DI 78 DIFFERENTIALS General Diagnostic Table ...

Page 149: ...s 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...

Page 150: ... 3 Transfer Clutch 4 4 Extension Case 5 5 Extension Case and Intermediate Case 6 6 Oil Seal 7 7 Transfer Drive Gear 8 8 Transfer Driven Gear 9 9 Reduction Drive Gear 10 10 Center Differential Carrier 11 11 Reduction Driven Gear 12 12 Center Differential 13 13 Transfer Clutch Pressure Test 14 ...

Page 151: ...l Description 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 ...

Page 152: ... CASE Transfer Case and Extension Case Assembly 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 ...

Page 153: ...4 TRANSFER CASE Transfer Clutch 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 ...

Page 154: ...TC 5 TRANSFER CASE Extension Case 4 Extension Case A NOTE For removal installation and inspection refer to 4AT section Ref to 4AT 82 Extension Case ...

Page 155: ... TRANSFER CASE Extension Case and Intermediate 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 ...

Page 156: ... 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 5MT model Ref to 5MT 39 Oil Seal Ref to 5MT 40 Dif ferential Side Retainer Oil Seal ...

Page 157: ...TC 8 TRANSFER CASE Transfer Drive Gear 7 Transfer Drive Gear A NOTE For removal installation and inspection refer to 5MT section Ref to 5MT 48 Transfer Drive Gear ...

Page 158: ...TC 9 TRANSFER CASE Transfer Driven Gear 8 Transfer Driven Gear A NOTE For removal installation and inspection refer to 5MT section Ref to 5MT 50 Transfer Driven Gear ...

Page 159: ...TC 10 TRANSFER CASE Reduction Drive Gear 9 Reduction Drive Gear A NOTE For removal installation and inspection refer to 4AT section Ref to 4AT 96 Reduction Drive Gear ...

Page 160: ...ifferential Carrier 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 ...

Page 161: ...ASE Reduction Driven Gear 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 ...

Page 162: ...TC 13 TRANSFER CASE Center Differential 12 Center Differential A NOTE For removal installation and inspection refer to 5MT section Ref to 5MT 52 Center Differen tial ...

Page 163: ... Transfer Clutch Pressure Test 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 ...

Page 164: ...s 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...

Page 165: ...AFT SYSTEM DS Page 1 General Description 2 2 Propeller Shaft 10 3 Front Axle 13 4 Front Hub Unit Bearing 17 5 Rear Hub Unit Bearing 19 6 Front Drive Shaft 22 7 Rear Drive Shaft 26 8 General Diagnostic Table 30 ...

Page 166: ...T 5AT Propeller shaft type EDJ Propeller shaft length L mm in 1490 58 66 1430 56 30 1317 51 85 Front propeller shaft Joint to joint length L1 mm in 735 28 9 675 26 6 562 22 1 Rear propeller shaft Joint to Joint length L2 mm in 755 29 7 Outer diameter of tube mm in D1 63 5 2 50 D2 57 5 2 26 DS 00226 D1 D2 L L1 L2 ...

Page 167: ...m 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 A Axle diameter B Axle length Model Type of drive shaft Axle diameter φ D mm in Axle length L mm in 2 0 L Non turbo AT BJ75 DOJ75 22 0 87 366 5 14 43 Except 2 0 L Non turbo AT EBJ82 DOJ79 22 0 87 375 1 14 77 A Axle diameter B Axle length DS 00227 B A DS 00228 A B ...

Page 168: ...on B COMPONENT 1 PROPELLER SHAFT 1 Propeller shaft 4 Rear differential T type Tightening torque N m kgf m ft lb 2 Bushing 5 Rear differential VA2 type T1 31 3 2 23 1 3 Rear differential VA1 type T2 52 5 3 38 3 DS 00229 2 2 T2 1 3 T1 T1 4 5 T1 ...

Page 169: ...nd 13 Front hub unit bearing 2 Baffle plate 8 Boot PTJ 14 Axle nut 3 Outer race PTJ 9 Boot EBJ 4 Snap ring 10 EBJ shaft ASSY Tightening torque N m kgf m ft lb 5 Trunnion 11 Housing T1 220 22 4 162 6 Circlip 12 Hub bolt T2 65 6 6 47 9 3 2 1 13 4 5 14 9 10 12 7 6 11 T2 T1 8 DS 00232 ...

Page 170: ...ace DOJ 9 Boot DOJ 13 Hub bolt 3 Snap ring 10 Boot BJ 14 Axle nut olive color 4 Inner race 11 BJ shaft ASSY 2 0 L Non turbo AT model 5 Ball Tightening torque N m kgf m ft lb 6 Cage EBJ shaft ASSY Except 2 0 L Non turbo AT model T1 65 6 6 47 9 7 Snap ring T2 190 19 4 140 DS 00233 13 12 T1 5 4 6 3 2 1 11 10 9 8 8 8 7 14 T2 ...

Page 171: ... or from other manufacturers Be sure to tighten fasteners including bolts and nuts to the specified torque Place shop jacks or rigid racks at the specified points Apply grease onto sliding or revolution surfaces before installation Before installing snap rings apply sufficient amount of grease to avoid damage and deforma tion Before securing a part on a vise place cushion ing material such as wood...

Page 172: ...80000 HUB STAND Used for assembling hub bolt in hub 927140000 AXLE SHAFT PULLER PLATE Same as plate 2 included in AXLE SHAFT PULLER 926470000 28099PA090 OIL SEAL PROTEC TOR Used for installing rear drive shaft into rear dif ferential For protecting oil seal ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS ST18675AA000 ST 927080000 ST 927140000 ST28099PA090 ...

Page 173: ...oil seal 28399AG000 New adopted tool HUB STAND Used for extracting hub bolt DESCRIPTION REMARKS Puller Used for removing ball joint from knuckle arm Dial gauge Used for inspecting propeller shaft run out Extension cap Used for preventing leak of gear oil or ATF Bar Used for extracting drive shaft ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS ST28399SA010 ST28399AG000 ...

Page 174: ...enter exhaust pipe 6 Remove the rear exhaust pipe and muffler 7 Remove the heat shield cover 8 Make matching marks on the flange yoke and rear differential before removal 9 Remove the three bolts which hold propeller shaft to rear differential 10 Remove the remaining bolt 11 Remove the two bolts which hold center bear ing to vehicle body 12 Remove the propeller shaft from transmission CAUTION Be c...

Page 175: ...ree play noise or non smooth operation Oil seals for abnormal wear or damage Center bearing for breakage Check the following points with propeller shaft in stalled in vehicle 1 JOINTS AND CONNECTIONS 1 Remove the center exhaust pipe 2 Remove the heat shield cover 3 Check for any looseness of the yoke flange mounting bolts which connect to rear differential and center bearing bracket mounting bolts...

Page 176: ...1 Remove the front and center exhaust pipe 2 Remove the rear exhaust pipe and muffler 3 Remove the heat shield cover 4 Move the propeller shaft near center bearing up and down and left and right with your hand to check for any abnormal bearing free play A Propeller shaft B Dial gauge DS 00036 B A DS 00037 ...

Page 177: ...ove the disc brake caliper from housing and suspend it from strut using a wire 7 Remove the disc rotor from hub NOTE If the disc rotor seizes up within hub drive disc rotor out by installing an 8 mm bolt in screw hole on ro tor 8 Remove the cotter pin and castle nut which se cure tie rod end to housing knuckle arm 9 Using a puller remove the tie rod ball joint from knuckle arm 10 Remove the ABS wh...

Page 178: ...BS wheel speed sensor on housing Tightening torque 32 N m 3 3 kgf m 23 9 ft lb 6 Install the disc rotor on hub 7 Install the disc brake caliper on housing Tightening torque 78 N m 8 0 kgf m 57 9 ft lb 8 Install the stabilizer link 9 Connect the tie rod end ball joint to the knuckle arm with a castle nut Tightening torque 27 0 N m 2 75 kgf m 19 9 ft lb CAUTION When connecting do not hit the cap at ...

Page 179: ...ASSEMBLY Front Hub Unit Bearing 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 Tightening torque 65 N m 6 6 kgf m 47 9 ft lb CAUTION Do not get closer the tool which charged magnetism to magnetic encorder Be careful not to damage the magnetic en coder E INSPECTION 1 M...

Page 180: ...DS 16 DRIVE SHAFT SYSTEM Front Axle 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 ...

Page 181: ...om hub NOTE If the disc rotor seizes up within hub drive disc rotor out by installing an 8 mm bolt in screw hole on ro tor 7 Remove four bolts from housing CAUTION Do not get closer the tool which charged magnetism to magnetic encorder Be careful not to damage the magnetic en coder 8 Remove the front hub unit bearing If it is hard to remove use STs ST1 926470000 AXLE SHAFT PULLER ST2 927140000 AXL...

Page 182: ...the axle nut lock it securely 8 Install the wheel and tighten the wheel nuts to specified torque Tightening torque 90 N m 9 2 kgf m 66 ft lb C DISASSEMBLY Using the ST and a hydraulic press drive hub bolts out ST 28399AG000 HUB STAND CAUTION Be careful not to hammer the hub bolts This may deform the hub Do not reuse the hub bolt NOTE Since the hub unit bearing can not be disassem bled only hub bol...

Page 183: ...ensor 7 Remove the disc brake caliper from back plate and suspend it from stabilizer using wire 8 Remove the disc rotor from hub NOTE Mark the mating surface of hub and disc rotor be fore removing the disc rotor to avoid confusing when installing If the disc rotor seizes up within hub drive the disc rotor out by installing an 8 mm bolt in screw hole on rotor 9 Remove the four bolts from rear arm 1...

Page 184: ...r 2 Tighten the four bolts to the back plate Tightening torque 65 N m 6 6 kgf m 47 9 ft lb 3 Remove the axle nut 4 Draw the rear drive shaft into specified position 5 Tighten the new axle nut temporarily CAUTION Use a new axle nut olive color 6 Install the disc rotor on hub 7 Install the disc brake caliper on back plate Tightening torque 52 N m 5 3 kgf m 38 3 ft lb 8 Install the rear ABS wheel spe...

Page 185: ...hydraulic press drive hub bolts out ST 28399AG000 HUB STAND CAUTION Be careful not to hammer the hub bolts This may deform the hub Do not reuse the hub bolt NOTE Since the hub unit bearing can not be disassem bled only hub bolts can be removed D ASSEMBLY 1 Attach the hub to ST securely ST 927080000 HUB STAND 2 Using a press press the new hub bolts until their seating surfaces contact the hub NOTE ...

Page 186: ... ST 18675AA000 DIFFERENTIAL SIDE OIL SEAL INSTALLER NOTE After pulling out the drive shaft be sure to replace with a new oil seal 2 Insert the EBJ into hub splines 3 Draw the drive shaft into specified position CAUTION Do not hammer drive shaft when installing it 4 Tighten the axle nut temporarily 5 Using the ST install the front drive shaft to trans mission ST 28399SA010 OIL SEAL PROTECTOR 6 Conn...

Page 187: ...assem bly 5 Wipe off grease CAUTION The grease is a special grease Do not confuse with other greases 6 Place alignment marks on the roller kit and trun nion 7 Remove the roller kit from trunnion CAUTION Be careful with the roller kit position 8 Place alignment marks on the trunnion and shaft 9 Remove the snap ring and trunnion CAUTION Be sure to wrap shaft splines with vinyl tape to prevent boot f...

Page 188: ...outer race 8 Install the snap ring in the groove on PTJ outer race CAUTION Pull the shaft lightly and assure that the snap ring is completely fitted in the groove 9 Apply an even coat of the specified grease 30 to 40 g 1 06 to 1 41 oz to the entire inner surface of boot 10 Install the PTJ boot taking care not to twist it CAUTION The large end of PTJ boot and the boot groove shall be cleaned comple...

Page 189: ...e end of the band is in close contact with clip 16 Extend and retract the PTJ to provide equal grease coating E INSPECTION Check the removed parts for damage wear corro sion etc If faulty repair or replace PTJ pillow tripod joint Check for seizure corrosion damage wear and excessive play EBJ high efficiency compact ball fixed joint Check for seizure corrosion damage and exces sive play Shaft Check...

Page 190: ... INSTALLATION 1 Insert the BJ or EBJ into rear hub splines CAUTION Be careful not to damage the magnetic en coder Do not get closer the tool which charged magnetism to magnetic encorder 2 Draw the rear drive shaft into specified position CAUTION Do not hammer drive shaft when installing it 3 Tighten the axle nut temporarily 4 Install the rear differential assembly T type Ref to DI 30 INSTALLATION ...

Page 191: ...eases NOTE Disassemble exercising care not to lose balls 6 pcs 8 To remove the cage from inner race turn the cage by a half pitch to the track groove of inner race and shift the cage 9 Remove the snap ring which fixes inner race to shaft using pliers 10 Take out the DOJ inner race 11 Take off the DOJ cage from shaft and remove DOJ boot CAUTION Be sure to wrap shaft splines with vinyl tape to preve...

Page 192: ... with the track on the inner race and then turn by a half pitch 6 Fill 80 to 90 g 2 82 to 3 17 oz of specified grease into the interior of DOJ outer race 7 Apply a coat of specified grease to the cage pocket and six balls 8 Insert six balls into the cage pocket 9 Align the outer race track and ball positions and place the shaft inner race cage and balls in the original positions and then fit outer...

Page 193: ... band until it cannot be moved by hand 16 Tap on the clip with the punch provided at the end of ST ST 925091000 BAND TIGHTENING TOOL NOTE Tap to an extent that the boot underneath is not damaged 17 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 NOTE Be careful so that the end of the band is in close contact with clip 18 Install t...

Page 194: ... 8 INSPECTION Wheel Alignment Rear wheel alignment Check the rear wheel alignment Ref to RS 8 INSPECTION Wheel Alignment Front strut Check the front strut Ref to FS 24 INSPEC TION Front Strut Rear shock absorber Check the rear shock absorber Ref to RS 16 INSPECTION Rear Shock Absorber Front drive shaft Check the front drive shaft Ref to DS 25 INSPECTION Front Drive Shaft Rear drive shaft Check the...

Page 195: ...s 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...

Page 196: ...iption 2 2 ABS Control Module and Hydraulic Control Unit ABSCM H U 6 3 ABS Sequence Control 10 4 Front ABS Wheel Speed Sensor 13 5 Rear ABS Wheel Speed Sensor 15 6 Front Magnetic Encoder 16 7 Rear Magnetic Encoder 17 8 G Sensor 18 ...

Page 197: ...wheel speed sensor gap for refer ence Front 0 77 1 43 mm 0 030 0 056 in Rear 0 64 1 56 mm 0 025 0 061 in Marks of harness Marks Color Front RH K1 White LH K2 Yellow Rear RH K5 White LH K6 Yellow G sensor G sensor voltage 2 3 0 2 V ABSCM H U identifica tion AT Except for OUTBACK J1 MT Except for OUTBACK J2 AT OUTBACK J3 MT OUTBACK J4 ...

Page 198: ...HEEL SPEED SENSOR 1 G sensor 4 Rear ABS wheel speed sensor LH Tightening torque N m kgf m ft lb 2 Front ABS wheel speed sensor LH 5 Hub unit bearing T1 7 5 0 76 5 5 3 Front housing 6 Magnetic encoder T2 33 3 3 24 T1 ABS00380 T2 T1 1 5 4 3 2 T2 T1 6 T2 ...

Page 199: ...necessary re moval installation disassembly and replacement Be careful not to burn yourself because each part on the vehicle is hot after running Be sure to tighten fasteners including bolts and nuts to the specified torque Place shop jacks or rigid racks at the specified points 1 ABS control module and hydraulic control unit ABSCM H U 6 Primary inlet 11 Bracket 7 Secondary inlet 2 Front outlet RH...

Page 200: ...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 Pressure gauge Used for measuring oil pressure Oscilloscope Used for measuring sensor ST24082AA230 ST22771AA030 ...

Page 201: ...CM H U upside down or place it sideways for storage Be careful that no foreign objects are mixed in ABSCM H U Be careful that no water enters inside the connectors 8 Remove the ABSCM H U bracket B INSTALLATION 1 Install the ABSCM H U bracket Tightening torque 33 N m 3 3 kgf m 24 ft lb 2 Install the ABSCM H U aligning the groove of damper on ABSCM H U side with the pawl of bracket NOTE Check the id...

Page 202: ...k back is normal and tightness is nor mal 8 Remove the pressure gauges from the FL and FR caliper bodies 9 Connect the air bleeder screws of the FL and FR caliper bodies 10 Remove the air bleeder screws from the RL and RR caliper bodies 11 Connect two pressure gauges to the RL and RR caliper bodies 12 Bleed air from the brake system 13 Bleed air from the pressure gauges and the RL and RR caliper b...

Page 203: ...sion meets the standard values 9 After the inspection depress the brake pedal and check that it is not abnormally hard and tight ness is normal D REPLACEMENT CAUTION Because the seal of ABSCM cannot be re placed do not pull or peel it with lifting up Because the screw part of H U deteriorates in every replacement procedure do not perform the replacement more than five times on it When the malfunct...

Page 204: ...er To remove the sealing use resin scraper Do not use the chemical materials thinner and etc 7 Position the coil of new ABSCM to align H U valve 8 To prevent deforming of ABSCM housing cover hold the corner of ABSCM and install it to the H U without tilting 9 Using TORX bit T20 tighten the screws step wise in the order of 1 through 4 CAUTION Always use new screws Tightening torque 1 5 N m 0 15 kgf...

Page 205: ... lease it again and then press it NOTE Engine must not start 5 After completion of ABS sequence control turn the ignition switch to OFF 2 ABS SEQUENCE CONTROL WITH SUB ARU SELECT MONITOR 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...

Page 206: ...CE CONTROL ABS00385 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 28 31 30 32 29 V max 4 km h 2 5 MPH 16 OFF 19 20 OFF ON OFF ON OFF ON 25 22 OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON ON 18 23 22 23 V max 10 km h 6 MPH 17 19 20 20 19 19 25 22 26 27 24 22 21 ...

Page 207: ... light goes out Without Subaru Select Monitor 5 When the ignition key is turned to ON but the brake pedal is not depressed within 3 seconds after ABS warning light goes OFF Without Subaru Se lect Monitor 6 After completion of ABS sequence control 7 When malfunction is detected 1 All wheel speed 13 RL decompression valve 21 Within 3 seconds 2 DL terminal 14 RL compression valve 22 1 0 second 3 Igni...

Page 208: ...5 5 ft lb Bracket 33 N m 3 3 kgf m 24 ft lb CAUTION Be careful not to damage the sensor portion NOTE Check the identification mark on the harness to make sure that no warp exists RH K1 White LH K2 Yellow Check if the harness is not pulled and does not come in contact with the suspension or body during steering wheel effort C INSPECTION 1 INSPECTION WITH SUBARU SELECT MONITOR 1 Connect the Subaru S...

Page 209: ...ll the resistance to No 1 terminal Rotate the wheel about 2 75 km h 2 MPH or equivalent measure the voltage using oscilloscope Standard value of output voltage 0 7 1 4 V NOTE Check the ABS wheel speed sensor cable for dis continuity If necessary replace with a new one 1 Oscilloscope 2 ABS wheel speed sensor ABS00388 2 1 100 1 4 V 0 7 V 12 V 2 1 1 2 ...

Page 210: ...ensor portion Do not apply excessive force to the sensor harness B INSTALLATION Install in the reverse order of removal CAUTION Be careful not to damage the sensor portion Tightening torque Sensor 7 5 N m 0 76 kgf m 5 5 ft lb Bracket 33 N m 3 3 kgf m 24 ft lb NOTE Check the identification mark on the harness to make sure that no warp exists RH K5 White LH K6 Yellow C INSPECTION 1 ABS WHEEL SPEED S...

Page 211: ...to Front Hub Bearing for installation be cause the front magnetic encoder is integrated with front hub bearing Ref to DS 17 INSTALLATION Front Hub Unit Bearing C INSPECTION Visually check the magnetic encoder for any dam age If necessary replace with a new hub unit bear ing NOTE Replace the hub unit bearing with a new one if there is any defect found on the magnetic encoder since the magnetic enco...

Page 212: ...to Rear Hub Unit Bearing for installation because the rear magnetic encoder is integrated with rear hub unit bearing Ref to DS 20 INSTALLATION Rear Hub Unit Bearing C INSPECTION Visually check the magnetic encoder for any dam age If necessary replace with a new hub unit bear ing NOTE Replace the hub unit bearing with a new one if there is any defect found on the magnetic encoder since the magnetic...

Page 213: ...e Box 3 Disconnect the connector from G sensor 4 Remove the G sensor from body CAUTION Do not drop or bump the G sensor Since G sensor is a unit with the bracket do not disassemble them B INSTALLATION Install in the reverse order of removal CAUTION Do not drop or bump the G sensor Tightening torque 7 5 N m 0 76 kgf m 5 5 ft lb ABS00463 ...

Page 214: ...ar ness connector between G sensor and ABSCM H U Or replace G sen sor 2 CHECK G SENSOR 1 Remove the console box 2 Remove the G sensor from vehicle Do not disconnect connector 3 Read the Subaru Select Monitor display Is the value 8 1 11 2 m s2 when G sensor is inclined for ward to 90 Go to step 3 Repair the har ness connector between G sensor and ABSCM H U Or replace G sen sor 3 CHECK G SENSOR Read...

Page 215: ...ABS 20 ABS G Sensor ...

Page 216: ...s 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...

Page 217: ...ion 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 ...

Page 218: ...ink 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 F...

Page 219: ... 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 ...

Page 220: ...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 O...

Page 221: ... 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 gon...

Page 222: ...hen 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...

Page 223: ...g 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 Cont...

Page 224: ...pecific 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 G...

Page 225: ...or 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 ST24082AA230 ST22771AA030 ...

Page 226: ...link connector For Subaru Select Monitor 9 Caliper body 10 G sensor 2 Two way connector 6 Transmission control module TCM AT model 11 Stop light switch 3 Diagnosis connector Used for ABS sequence control 12 Master cylinder 7 Magnetic encoder seal 13 Brake and EBD warning light 4 ABS warning light 8 ABS wheel speed sensor ABS00458 1 12 2 6 4 13 11 8 7 9 3 10 5 8 7 9 ...

Page 227: ...ABS diag 11 ABS DIAGNOSTICS Electrical Component Location ABS00405 1 ABS00106 3 ABS00438 13 4 ABS00464 5 ABS00408 8 7 7 FRONT 8 7 7 ABS00407 REAR 10 ABS00406 ...

Page 228: ...ION NOTE Terminal numbers in ABSCM H U connector are as shown in the figure ABS warning light is illuminates when the connector is removed from ABSCM H U 1 ABS control module and hydraulic control unit ABSCM H U con nector ABS00409 B301 7 8 9 10 11 6 5 4 1 15 14 13 12 2 3 22 23 24 25 26 21 20 19 16 17 18 1 ...

Page 229: ...e signal Valve relay power supply 1 14 15 10 15 V Motor relay power supply 1 13 15 10 15 V G sensor Power supply 24 10 4 75 5 25 V Ground 10 Output 21 10 2 1 2 5 V when the vehicle is on a level surface Stop light switch 1 20 15 Less than 1 5 V when the stop light is OFF otherwise 10 15 V when the stop light is ON ABS warning light 22 15 After turning the ignition switch to ON 10 15 V during 1 5 s...

Page 230: ... ABS control module 16 Body integrated unit 27 Rear ABS wheel speed sensor RH 5 Valve relay 17 Diagnosis connector 6 Motor relay 18 Data link connector 28 Parking brake switch 7 Motor 19 ABS warning light 29 Brake fluid level switch 8 Front inlet solenoid valve LH 20 Brake warning light 30 Engine control module ECM 9 Front outlet solenoid valve LH 21 Stop light switch 31 Transmission control modul...

Page 231: ...ess the YES key 7 On the System Selection Menu display screen select the Brake Control and press the YES key 8 Press the YES key after the ABS is displayed 9 On the ABS Diagnosis display screen select the DTC Display and press the YES key NOTE For details concerning operation procedure re fer to the SUBARU SELECT MONITOR OPERA TION MANUAL For details concerning DTCs refer to the List of Diagnostic...

Page 232: ...itor display Older Indicate the latest DTC in second previ ous trouble on the Subaru Select Monitor display Before 3 Indicate the latest DTC in third previous trouble on the Subaru Select Monitor dis play Display Contents to be monitored Unit of measure FR Wheel Speed Wheel speed detected by front ABS wheel speed sensor RH is dis played km h or MPH FL Wheel Speed Wheel speed detected by front ABS ...

Page 233: ...ars on the Subaru Select Monitor display This shows it may be an unreliable reading Display Contents to be monitored Clear memory Function of clearing DTC Display Contents to be monitored Index No ABS sequence control Operate the valve and pump motor continuously to perform the ABS sequence control Ref to ABS 10 ABS Sequence Con trol Display Contents to be monitored FR Wheel Wheel speed detected b...

Page 234: ...ness connector TROUBLE SYMPTOM Communication is impossible between ABS and Subaru Select Monitor WIRING DIAGRAM ABS00411 B301 B40 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 SBF 1 SBF 7 No 33 B40 B301 E E 1 10 7 15 18 ABSCM H U 1 2 3 4 5 6 7 8 9 10 11 16 17 18 19 20 21 22 23 24 25 26 13 12 15 14 IGNITION SWITCH BATTERY DATA LINK CONNECTOR No 13 ...

Page 235: ...he ignition switch to OFF 2 Disconnect ABSCM H U ECM and TCM 3 Measure the resistance between data link connector and chassis ground Connector terminal B40 No 10 Chassis ground Is the resistance more than 1 MΩ Go to step 7 Repair the har ness and connec tor between each control module and data link con nector 7 CHECK OUTPUT SIGNAL FOR ABSCM H U 1 Turn the ignition switch to ON 2 Measure the voltag...

Page 236: ...erminal B301 No 15 Chassis ground Is the resistance less than 0 5 Ω Go to step 12 Repair the open circuit in harness between ABSCM H U and inhibitor side con nector and poor contact in cou pling connector 12 CHECK POOR CONTACT IN CONNECTOR Is there poor contact in control module power supply ground circuit and data link connector Repair the con nector Replace the ABSCM only Ref to ABS 8 REPLACEMEN...

Page 237: ...efective combination meter Open in harness TROUBLE SYMPTOM 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 ...

Page 238: ... No 33 A i10 COMBINATION METER E E E B301 4 8 5 18 25 15 22 B82 GROUND TERMINAL B81 ABSCM H U 7 8 ABS WARNING LIGHT BRAKE WARNING LIGHT i3 B38 3 1 2 3 4 5 6 7 8 9 10 11 16 17 18 19 20 21 22 23 24 25 26 13 12 15 14 i10 2 1 3 4 6 7 8 9 10 22 21 20 19 18 17 16 15 14 13 12 11 5 A B301 20 9 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 B38 ...

Page 239: ...NATION METER E E E B301 4 8 5 18 25 15 22 B82 GROUND TERMINAL B81 ABSCM H U 7 8 ABS WARNING LIGHT BRAKE WARNING LIGHT i1 B36 3 1 2 3 4 5 6 7 8 9 10 11 16 17 18 19 20 21 22 23 24 25 26 13 12 15 14 1 2 3 4 5 6 7 8 9 10 16 11 15 14 13 12 17 19 18 23 25 24 20 22 21 26 28 27 i10 2 1 3 4 6 7 8 9 10 22 21 20 19 18 17 16 15 14 13 12 11 5 A B301 i1 4 3 ...

Page 240: ...ule and Hydraulic Control Unit ABSCM H U Go to step 2 2 CHECK WIRING HARNESS Measure the resistance between ABSCM con nector and combination meter connector Connector terminal i10 No 5 B301 No 22 Is the resistance less than 0 5 Ω Go to step 3 Repair the har ness and connec tor between ABSCM H U and combination meter connector 3 CHECK POOR CONTACT IN CONNECTOR Is there poor contact in ABSCM connect...

Page 241: ...ag 25 ABS DIAGNOSTICS Read Diagnostic Trouble Code DTC 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 ...

Page 242: ...diag 26 ABS DIAGNOSTICS Inspection Mode 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 ...

Page 243: ...ABS diag 27 ABS DIAGNOSTICS Clear Memory Mode 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 ...

Page 244: ...ern 10 ABS Warning Light Brake Warning Light Illumination Pattern A INSPECTION 1 Ignition switch 5 ABS warning light 9 Brake warning light EBD warning light 2 OFF 6 Light OFF 3 ON 7 Light ON 10 Parking brake 4 Start 8 1 5 seconds 11 Released ABS00442 2 1 3 3 4 6 5 6 7 8 9 10 6 6 11 7 ...

Page 245: ...o off check the combination meter circuit Ref to ABS diag 33 ABS WARNING LIGHT DOES NOT GO OFF ABS Warning Light Brake Warning Light Illumination Pattern 4 When brake warning light does not go off check the brake warning light circuit combination meter circuit Ref to ABS diag 36 BRAKE WARNING LIGHT DOES NOT GO OFF ABS Warning Light Brake Warning Light Illumination Pattern NOTE Even though the ABS ...

Page 246: ... warning light does not come on WIRING DIAGRAM LHD model ABS00459 B82 1 2 3 4 5 6 BATTERY IGNITION SWITCH SBF 1 SBF 7 No 5 No 33 A i10 COMBINATION METER E E E B301 4 8 5 18 25 15 22 B82 GROUND TERMINAL B81 ABSCM H U 7 8 ABS WARNING LIGHT BRAKE WARNING LIGHT i3 B38 3 1 2 3 4 5 6 7 8 9 10 11 16 17 18 19 20 21 22 23 24 25 26 13 12 15 14 i10 2 1 3 4 6 7 8 9 10 22 21 20 19 18 17 16 15 14 13 12 11 5 A B...

Page 247: ... No 33 A i10 COMBINATION METER E E E B301 4 8 5 18 25 15 22 B82 GROUND TERMINAL B81 ABSCM H U 7 8 ABS WARNING LIGHT BRAKE WARNING LIGHT i1 B36 3 1 2 3 4 5 6 7 8 9 10 11 16 17 18 19 20 21 22 23 24 25 26 13 12 15 14 1 2 3 4 5 6 7 8 9 10 16 11 15 14 13 12 17 19 18 23 25 24 20 22 21 26 28 27 i10 2 1 3 4 6 7 8 9 10 22 21 20 19 18 17 16 15 14 13 12 11 5 A B301 i1 4 3 ...

Page 248: ...nnector i10 from the combination meter 4 Measure the resistance between ABSCM connector and chassis ground Connector terminal B301 No 22 Chassis ground Is the resistance more than 1 MΩ Go to step 4 Repair the har ness and connec tor between ABSCM H U and combination meter connector 4 CHECK ABSCM 1 Connect the connector B301 to the ABSCM H U 2 Turn the ignition to ON 3 Immediately after turning ign...

Page 249: ...ight is kept on WIRING DIAGRAM LHD model ABS00459 B82 1 2 3 4 5 6 BATTERY IGNITION SWITCH SBF 1 SBF 7 No 5 No 33 A i10 COMBINATION METER E E E B301 4 8 5 18 25 15 22 B82 GROUND TERMINAL B81 ABSCM H U 7 8 ABS WARNING LIGHT BRAKE WARNING LIGHT i3 B38 3 1 2 3 4 5 6 7 8 9 10 11 16 17 18 19 20 21 22 23 24 25 26 13 12 15 14 i10 2 1 3 4 6 7 8 9 10 22 21 20 19 18 17 16 15 14 13 12 11 5 A B301 20 9 1 2 3 4...

Page 250: ... No 33 A i10 COMBINATION METER E E E B301 4 8 5 18 25 15 22 B82 GROUND TERMINAL B81 ABSCM H U 7 8 ABS WARNING LIGHT BRAKE WARNING LIGHT i1 B36 3 1 2 3 4 5 6 7 8 9 10 11 16 17 18 19 20 21 22 23 24 25 26 13 12 15 14 1 2 3 4 5 6 7 8 9 10 16 11 15 14 13 12 17 19 18 23 25 24 20 22 21 26 28 27 i10 2 1 3 4 6 7 8 9 10 22 21 20 19 18 17 16 15 14 13 12 11 5 A B301 i1 4 3 ...

Page 251: ...ector Connector terminal B301 No 22 i10 No 5 Is the resistance less than 0 5 Ω Go to step 3 Repair the har ness and connec tor between ABSCM H U and combination meter connector 3 CHECK POOR CONTACT IN CONNECTOR Check poor contact in all connectors Is there poor contact Repair the con nector Go to step 4 4 CHECK ABSCM 1 Connect the connector B301 to the ABSCM H U 2 Turn the ignition switch to ON 3 ...

Page 252: ...HD model B301 i1 B16 1 2 B38 E SBF 1 SBF 7 E No 5 8 B301 B38 B16 i3 B97 R1 R4 i10 A ABSCM H U A3 A4 4 1 2 1 2 B229 1 2 3 4 5 6 7 8 9 10 16 11 15 14 13 12 17 19 18 23 25 24 20 22 21 26 28 27 1 2 3 4 5 6 7 8 9 10 11 16 17 18 19 20 21 22 23 24 25 26 13 12 15 14 2 1 3 4 6 7 8 9 10 22 21 20 19 18 17 16 15 14 13 12 11 5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 B229 1 2 i10 A BATTERY IGNITION S...

Page 253: ...U A3 A4 5 A8 A7 16 4 1 2 1 2 B229 1 2 3 4 5 6 7 8 9 10 16 11 15 14 13 12 17 19 18 23 25 24 20 22 21 26 28 27 1 2 3 4 5 6 7 8 9 10 11 16 17 18 19 20 21 22 23 24 25 26 13 12 15 14 i10 2 1 3 4 6 7 8 9 10 22 21 20 19 18 17 16 15 14 13 12 11 5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 B229 1 2 A BATTERY IGNITION SWITCH BRAKE FLUID LEVEL SWITCH BRAKE WARNING LIGHT PARKING BRAKE SWITCH ...

Page 254: ...ce between parking brake switch terminal and chassis ground Is the resistance more than 1 MΩ Go to step 6 Replace the park ing brake switch 6 CHECK GROUND SHORT OF HARNESS 1 Disconnect the connector i10 from combi nation meter 2 Measure the resistance between combina tion meter connector and chassis ground Connector terminal i10 No 8 Chassis ground Is the resistance more than 1 MΩ Go to step 7 Rep...

Page 255: ...sor Signal Ref to ABS diag 46 DTC C0105 ABS WHEEL SPEED SENSOR RR MALFUNC TION ABS WHEEL SPEED SENSOR ABNORMAL SIGNAL Diagnostic Proce dure with Diagnostic Trouble Code DTC C0106 Abnormal signal of rear ABS wheel speed sensor LH Rear Left ABS Sensor Signal Ref to ABS diag 46 DTC C0106 ABS WHEEL SPEED SENSOR RL MALFUNC TION ABS WHEEL SPEED SENSOR ABNORMAL SIGNAL Diagnostic Proce dure with Diagnosti...

Page 256: ...S CONTROL MODULE AND HYDRAULIC CONTROL UNIT ABSCM H U Diagnostic Procedure with Diagnostic Trouble Code DTC C0122 Inlet valve malfunction in hydraulic unit Front inlet valve RH FR Hold Valve mal function Ref to ABS diag 55 DTC C0122 FRONT INLET SOLENOID VALVE RH MALFUNC TION IN ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT ABSCM H U Diagnostic Procedure with Diagnostic Trouble Code DTC C0123 Outle...

Page 257: ... DTC C0127 REAR OUTLET SOLENOID VALVE RH MAL FUNCTION IN ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT ABSCM H U Diagnostic Procedure with Diagnostic Trouble Code DTC C0140 CAN communication malfunction Improper CAN com munication Ref to ABS diag 68 DTC C0140 CAN COMMUNICATION MALFUNCTION Diag nostic Procedure with Diagnostic Trouble Code DTC DTC Content of diagnosis Display Reference target ...

Page 258: ...nostic Trouble Code DTC B DTC C0102 ABS WHEEL SPEED SENSOR RL 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 C DTC C0103 ABS WHEEL SPEED SENSOR FR MALFUNCTION BROKEN WIRE INPUT VOLTAGE TOO HI...

Page 259: ...onnector TROUBLE SYMPTOM ABS does not operate WIRING DIAGRAM LHD model ABS00461 4 3 1 16 17 2 15 B98 R72 R2 E 1 2 15 14 6 5 R73 1 2 B6 B15 2 1 6 5 B301 1 2 FRONT ABS WHEEL SPEED SENSOR LH TWISTED WIRE FRONT ABS WHEEL SPEED SENSOR RH REAR ABS WHEEL SPEED SENSOR LH REAR ABS WHEEL SPEED SENSOR RH TWISTED WIRE TWISTED WIRE TWISTED WIRE ABSCM H U 1 2 R73 R72 B15 B6 B301 1 2 3 4 5 6 7 8 9 10 11 16 17 18...

Page 260: ... B15 R73 R72 2 1 1 2 6 5 B301 1 2 B15 B6 B301 B97 1 2 3 4 5 6 7 8 9 10 11 16 17 18 19 20 21 22 23 24 25 26 13 12 15 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 FRONT ABS WHEEL SPEED SENSOR LH TWISTED WIRE FRONT ABS WHEEL SPEED SENSOR RH REAR ABS WHEEL SPEED SENSOR LH REAR ABS WHEEL SPEED SENSOR RH TWISTED WIRE TWISTED WIRE TWISTED WIRE ABSCM H U ...

Page 261: ...o 1 B15 No 2 Is the resistance less than 0 5 Ω Go to step 3 Repair the har ness connector between ABSCM H U and ABS wheel speed sensor 3 CHECK GROUND SHORT OF HARNESS Measure the resistance between ABSCM H U connector and chassis ground Connector terminal DTC C0101 B301 No 4 Chassis ground DTC C0102 B301 No 17 Chassis ground DTC C0103 B301 No 6 Chassis ground DTC C0104 B301 No 1 Chassis ground Is ...

Page 262: ...Diagnostic Trouble Code DTC 5 CHECK ABSCM H U POWER SUPPLY CIR CUIT 1 Turn the ignition switch to OFF 2 Disconnect the ABSCM H U connector 3 Turn the ignition switch to ON 4 Measure the voltage between ABSCM H U connector and chassis ground Connector terminal B301 No 18 B301 No 15 Is the voltage 10 15 V Go to step 7 Check the genera tor battery ABSCM H U power circuit 6 CHECK ABS WHEEL SPEED SENSO...

Page 263: ...connector TROUBLE SYMPTOM ABS does not operate WIRING DIAGRAM LHD model ABS00461 4 3 1 16 17 2 15 B98 R72 R2 E 1 2 15 14 6 5 R73 1 2 B6 B15 2 1 6 5 B301 1 2 FRONT ABS WHEEL SPEED SENSOR LH TWISTED WIRE FRONT ABS WHEEL SPEED SENSOR RH REAR ABS WHEEL SPEED SENSOR LH REAR ABS WHEEL SPEED SENSOR RH TWISTED WIRE TWISTED WIRE TWISTED WIRE ABSCM H U 1 2 R73 R72 B15 B6 B301 1 2 3 4 5 6 7 8 9 10 11 16 17 1...

Page 264: ... B15 R73 R72 2 1 1 2 6 5 B301 1 2 B15 B6 B301 B97 1 2 3 4 5 6 7 8 9 10 11 16 17 18 19 20 21 22 23 24 25 26 13 12 15 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 FRONT ABS WHEEL SPEED SENSOR LH TWISTED WIRE FRONT ABS WHEEL SPEED SENSOR RH REAR ABS WHEEL SPEED SENSOR LH REAR ABS WHEEL SPEED SENSOR RH TWISTED WIRE TWISTED WIRE TWISTED WIRE ABSCM H U ...

Page 265: ... Read the DTC Is the same DTC displayed Replace the ABSCM only Ref to ABS 8 REPLACEMENT ABS Control Mod ule and Hydraulic Control Unit ABSCM H U Go to step 6 6 CHECK ANY OTHER DTC ON DISPLAY Is any other DTC displayed Perform the diag nosis according to DTC It results from a temporary noise interference 7 CHECK INSTALLATION OF ABS WHEEL SPEED SENSOR Is the ABS wheel speed sen sor installation bolt...

Page 266: ... 17 CLEAR MEMORY MODE OPERATION Subaru Select Monitor 4 Read the DTC Is the same DTC displayed Replace the ABSCM only Ref to ABS 8 REPLACEMENT ABS Control Mod ule and Hydraulic Control Unit ABSCM H U Go to step 13 13 CHECK ANY OTHER DTC ON DISPLAY Is any other DTC displayed Perform the diag nosis according to DTC It results from a temporary noise interference NOTE Though ABS warn ing light remains...

Page 267: ...NAL MALFUNCTION IN ONE OF FOUR WHEELS DTC DETECTING CONDITION Defective ABS wheel speed sensor signal noise abnormal signal etc Defective magnetic encoder When a wheel is turned freely for a long time TROUBLE SYMPTOM ABS does not operate EBD does not operate NOTE Brake warning light comes on as well as ABS warning light ...

Page 268: ... 5 R73 1 2 B6 B15 2 1 6 5 B301 1 2 FRONT ABS WHEEL SPEED SENSOR LH TWISTED WIRE FRONT ABS WHEEL SPEED SENSOR RH REAR ABS WHEEL SPEED SENSOR LH REAR ABS WHEEL SPEED SENSOR RH TWISTED WIRE TWISTED WIRE TWISTED WIRE ABSCM H U 1 2 R73 R72 B15 B6 B301 1 2 3 4 5 6 7 8 9 10 11 16 17 18 19 20 21 22 23 24 25 26 13 12 15 14 B98 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 ...

Page 269: ... B15 R73 R72 2 1 1 2 6 5 B301 1 2 B15 B6 B301 B97 1 2 3 4 5 6 7 8 9 10 11 16 17 18 19 20 21 22 23 24 25 26 13 12 15 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 FRONT ABS WHEEL SPEED SENSOR LH TWISTED WIRE FRONT ABS WHEEL SPEED SENSOR RH REAR ABS WHEEL SPEED SENSOR LH REAR ABS WHEEL SPEED SENSOR RH TWISTED WIRE TWISTED WIRE TWISTED WIRE ABSCM H U ...

Page 270: ...gf m 5 5 ft lb four of them Go to step 6 Tighten the ABS wheel speed sen sor installation bolts 6 CHECK ABS WHEEL SPEED SENSOR SIG NAL 1 Install the ABS wheel speed sensor 2 Prepare an oscilloscope 3 Check ABS wheel speed sensor Ref to ABS 13 ABS WHEEL SPEED SENSOR INSPECTION Front ABS Wheel Speed Sen sor Does the oscilloscope indicate the waveform pattern like shown in the figure when the tire is...

Page 271: ...CTION IN ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT AB SCM H U Diagnostic Procedure with Diagnostic Trouble Code DTC L DTC C0124 REAR INLET SOLENOID VALVE LH MALFUNCTION IN ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT ABSCM H U NOTE For the diagnostic procedure refer to DTC C0126 Ref to ABS diag 56 DTC C0126 REAR INLET SOLE NOID VALVE RH MALFUNCTION IN ABS CONTROL MODULE AND HYDRAULIC CONTROL ...

Page 272: ... 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 ABS does not operate EBD does not operate NOTE Brake warning light comes on as well as ABS warning light ...

Page 273: ... Diagnostic Procedure with Diagnostic Trouble Code DTC WIRING DIAGRAM ABS00414 SBF 1 SBF 7 No 33 B301 E E 15 18 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 13 12 15 14 BATTERY IGNITION SWITCH GENERATOR ...

Page 274: ...ctor and chassis ground Connector terminal B301 No 15 Chassis ground Is the resistance less than 0 5 Ω Go to step 3 Repair the ABSCM H U ground harness 3 CHECK POOR CONTACT IN CONNECTOR Is there poor contact in con nector between generator bat tery and ABSCM H U Repair the con nector Go to step 4 4 CHECK ABSCM H U 1 Connect all the connectors 2 Erase the memory 3 Perform the inspection mode 4 Read...

Page 275: ... VALVE RH 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 P DTC C0125 REAR OUTLET SOLENOID VALVE LH MALFUNCTION IN ABS CONTROL MODULE AND H...

Page 276: ... 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 ABS does not operate EBD does not operate NOTE Brake warning light comes on as well as ABS warning light ...

Page 277: ... Diagnostic Procedure with Diagnostic Trouble Code DTC WIRING DIAGRAM ABS00414 SBF 1 SBF 7 No 33 B301 E E 15 18 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 13 12 15 14 BATTERY IGNITION SWITCH GENERATOR ...

Page 278: ...ctor and chassis ground Connector terminal B301 No 15 Chassis ground Is the resistance less than 0 5 Ω Go to step 3 Repair the ABSCM H U ground harness 3 CHECK POOR CONTACT IN CONNECTOR Is there poor contact in con nector between generator bat tery and ABSCM H U Repair the con nector Go to step 4 4 CHECK ABSCM H U 1 Connect all the connectors 2 Erase the memory 3 Perform the inspection mode 4 Read...

Page 279: ...OL 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 ABS00415 E ABSCM H U B301 15 B301 1 2 3 4 5 6 7 8 9 10 11 16 17 18 19 20 21 22 23 24 25 26 13 12 15 14 ...

Page 280: ...SIGNAL NOISE Is the car telephone or the radio properly installed Go to step 4 Properly install the car telephone or the wireless trans mitter 4 CHECK SOURCES OF SIGNAL NOISE Are noise sources such as an antenna installed near the sensor harness Install the noise sources apart from the sensor har ness Go to step 5 5 CHECK ABSCM H U 1 Connect all the connectors 2 Erase the memory 3 Perform the insp...

Page 281: ... 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 Both warning lights go off if voltage returns ...

Page 282: ... Diagnostic Procedure with Diagnostic Trouble Code DTC WIRING DIAGRAM ABS00414 SBF 1 SBF 7 No 33 B301 E E 15 18 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 13 12 15 14 BATTERY IGNITION SWITCH GENERATOR ...

Page 283: ...onnector terminal B301 No 18 Chassis ground Is the voltage 10 15 V Go to step 4 Repair the ABSCM H U power circuit 4 CHECK GROUND CIRCUIT OF ABSCM H U 1 Turn the ignition switch to OFF 2 Measure the resistance between ABSCM H U connector and chassis ground Connector terminal B301 No 15 Chassis ground Is the resistance less than 0 5 Ω Go to step 5 Repair the ABSCM H U ground harness 5 CHECK POOR CO...

Page 284: ...ROUBLE SYMPTOM Possibly the vehicle speed cannot output on CAN Step Check Yes No 1 CHECK LAN SYSTEM Perform the diagnosis for LAN system Ref to LAN diag 24 OPERATION Read Diagnostic Trouble Code DTC Is there any fault in LAN sys tem Repair it according to DTC of LAN system Replace the ABSCM only Ref to ABS 8 REPLACEMENT ABS Control Mod ule and Hydraulic Control Unit ABSCM H U ...

Page 285: ...depending on the trouble contents NOTE Brake warning light comes on as well as ABS warning light when EBD does not operate WIRING DIAGRAM B301 ABS00416 B301 E 14 15 ABSCM H U 18 M SBF 1 SBF 7 No 1 No 33 E 7 8 9 10 11 6 5 4 1 15 14 13 12 2 3 22 23 24 25 26 21 20 19 16 17 18 BATTERY IGNITION SWITCH MOTOR RELAY VALVE RELAY SOLENOID VALVE PUMP MOTOR FL INLET RL INLET FR INLET RR INLET FL OUTLET RL OUT...

Page 286: ...ep 3 Repair the ABSCM H U ground harness 3 CHECK VALVE RELAY IN ABSCM H U Measure the resistance between ABSCM H U terminals Terminals No 14 No 15 Is the resistance more than 1 MΩ Go to step 4 Replace the ABSCM only Ref to ABS 8 REPLACEMENT ABS Control Mod ule and Hydraulic Control Unit ABSCM H U 4 CHECK POOR CONTACT IN CONNECTOR Is there poor contact in con nector between generator bat tery and A...

Page 287: ...r relay Defective harness connector TROUBLE SYMPTOM ABS does not operate WIRING DIAGRAM ABS00417 B301 E E 13 15 12 ABSCM H U 18 M SBF 1 SBF 7 No 33 E SBF 2 B301 7 8 9 10 11 6 5 4 1 15 14 13 12 2 3 22 23 24 25 26 21 20 19 16 17 18 BATTERY IGNITION SWITCH MOTOR RELAY VALVE RELAY SOLENOID VALVE PUMP MOTOR FL INLET RL INLET FR INLET RR INLET FL OUTLET RL OUTLET FR OUTLET RR OUTLET ...

Page 288: ...to step 4 Repair the har ness connector between battery ignition switch and ABSCM H U 4 CHECK GROUND CIRCUIT OF ABSCM H U 1 Turn the ignition switch to OFF 2 Measure the resistance between ABSCM H U connector and chassis ground Connector terminal B301 No 15 Chassis ground Is the resistance less than 0 5 Ω Go to step 5 Repair the ABSCM H U ground harness 5 CHECK MOTOR OPERATION Operate the ABS sequ...

Page 289: ...t of Diag nostic Trouble Code DTC Ref to ABS diag 39 List of Diagnostic Trou ble Code DTC Temporary poor contact occurs NOTE Though ABS warn ing light remains to illuminate at this time it is normal Drive the vehicle at more than 12 km h 7 MPH in order to make ABS warning light go off Be sure to drive the vehicle and check the warning light goes off Step Check Yes No ...

Page 290: ...ING CONDITION Defective stop light switch WIRING DIAGRAM ABS00462 SBF 1 SBF 3 No 8 B301 2 3 E 20 ABSCM H U B64 OC WC 1 2 OC B65 WC 9 5 WC OC WITH CRUISE CONTROL WITHOUT CRUISE CONTROL B159 STOP LIGHT SWITCH BATTERY B64 1 2 3 4 5 6 7 8 9 10 11 16 17 18 19 20 21 22 23 24 25 26 13 12 15 14 9 4 7 6 2 1 5 3 8 1 2 B159 B301 B65 1 3 4 2 ...

Page 291: ...N HARNESS 1 Turn the ignition switch to OFF 2 Disconnect the connector from ABSCM H U 3 Depress the brake pedal 4 Measure the voltage between ABSCM H U connector and chassis ground Connector terminal B301 No 20 Chassis ground Is the voltage 10 15 V Go to step 5 Repair harness between stop light switch and ABSCM H U con nector 5 CHECK POOR CONTACT IN CONNECTOR Is there poor contact in con nector be...

Page 292: ...TC C0118 G SENSOR OUTPUT VOLTAGE MALFUNCTION DTC DETECTING CONDITION Defective G sensor TROUBLE SYMPTOM ABS does not operate WIRING DIAGRAM ABS00419 ABSCM H U B301 B301 10 24 21 15 B292 ABS G SENSOR E 3 2 1 B292 1 2 3 1 2 3 4 5 6 7 8 9 10 11 16 17 18 19 20 21 22 23 24 25 26 13 12 15 14 ...

Page 293: ...3 Remove the G sensor from vehicle Do not disconnect connector 4 Turn the ignition switch to ON 5 Measure the voltage between G sensor connector terminals Connector terminal B292 No 1 No 3 Is the voltage 4 75 5 25 V Go to step 6 Repair the har ness connector between G sensor and ABSCM H U 6 CHECK OPEN CIRCUIT IN G SENSOR OUT PUT HARNESS AND GROUND HARNESS 1 Turn the ignition switch to OFF 2 Discon...

Page 294: ...tep 11 Replace G sen sor Ref to ABS 18 G Sensor 11 CHECK POOR CONTACT IN CONNECTOR Turn the ignition switch to OFF Is there poor contact in con nector between ABSCM H U and G sensor Repair the con nector Go to step 12 12 CHECK ABSCM H U 1 Connect all the connectors 2 Erase the memory 3 Perform the inspection mode 4 Read the DTC Is the same DTC displayed Replace the ABSCM only Ref to ABS 8 REPLACEM...

Page 295: ...9 G SENSOR OUTPUT VOLTAGE MALFUNCTION DTC DETECTING CONDITION Defective G sensor output signal TROUBLE SYMPTOM ABS does not operate WIRING DIAGRAM ABS00419 ABSCM H U B301 B301 10 24 21 15 B292 ABS G SENSOR E 3 2 1 B292 1 2 3 1 2 3 4 5 6 7 8 9 10 11 16 17 18 19 20 21 22 23 24 25 26 13 12 15 14 ...

Page 296: ...2 m s when G sensor is inclined backward to 90 Go to step 5 Replace G sen sor Ref to ABS 18 G Sensor 5 CHECK POOR CONTACT IN CONNECTOR Turn the ignition switch to OFF Is there poor contact in con nector between ABSCM H U and G sensor Repair the con nector Go to step 6 6 CHECK ABSCM H U 1 Connect all the connectors 2 Erase the memory 3 Perform the inspection mode 4 Read the DTC Is the same DTC disp...

Page 297: ...clined for wards to 90 Go to step 12 Replace G sen sor Ref to ABS 18 G Sensor 12 CHECK G SENSOR Measure the voltage between G sensor con nector terminals Connector terminal B292 No 2 No 3 Is the voltage 0 5 1 0 V when G sensor is inclined backward to 90 Go to step 13 Replace G sen sor Ref to ABS 18 G Sensor 13 CHECK ABSCM H U 1 Turn the ignition switch to OFF 2 Connect all the connectors 3 Erase t...

Page 298: ...M H U solenoid valve ABS wheel speed sensor Master cylinder Brake caliper and piston Parking Brake Axle and wheels Brake pedal play Long brake pedal stroke Air in brake line Brake pedal play Vehicle vertical pitching Suspension play or fatigue reduced damping Incorrect wiring or piping connections Road surface uneven Unstable or uneven braking ABSCM H U solenoid valve ABS wheel speed sensor Brake ...

Page 299: ...s 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...

Page 300: ...draulic Control Unit VDCCM H U 7 3 ABS Sequence Control 10 4 VDC Sequence Control 11 5 Yaw Rate Lateral G Sensor 14 6 Steering Angle Sensor 16 7 Front ABS Wheel Speed Sensor 18 8 Rear ABS Wheel Speed Sensor 19 9 Front Magnetic Encoder 20 10 Rear Magnetic Encoder 21 11 VDC OFF Switch 22 ...

Page 301: ... ABS wheel speed sensor gap for reference Front 0 77 1 43 mm 0 030 0 056 in Rear 0 64 1 56 mm 0 025 0 061 in Marks of harness Marks Color Front RH K1 White LH K2 Yellow Rear RH K5 White LH K6 Yellow Yaw rate lateral G sensor Lateral G sensor voltage 2 5 0 2 V Marks of VDCCM H U Wagon 2 5 i G3 Sedan 2 5 i G9 Wagon 3 0 R G4 Sedan 3 0 R GA OUTBACK 3 0 R G2 ...

Page 302: ...ion B COMPONENT 1 ABS WHEEL SPEED SENSOR 1 Front ABS wheel speed sensor 4 Hub unit bearing Tightening torque N m kgf m ft lb 2 Front housing 5 Magnetic encoder T1 7 5 0 76 5 5 3 Rear ABS wheel speed sensor T2 33 3 4 24 VDC00194 T1 T2 T1 3 2 1 T2 4 5 T2 ...

Page 303: ... CONTROL VDC General Description 2 YAW RATE LATERAL G SENSOR 3 STEERING ANGLE SENSOR 1 Yaw rate lateral G sensor 2 Bracket Tightening torque N m kgf m ft lb T 7 5 0 76 5 5 VDC00195 1 T T 2 1 Steering angle sensor VDC00196 1 ...

Page 304: ...CCM H U 1 VDC control module and hydraulic control unit VDCCM H U 5 Rear LH outlet 10 Pressure sensor 6 Secondary inlet 11 Damper 2 Clip 7 Primary inlet 3 Bracket 8 Front LH outlet Tightening torque N m kgf m ft lb 4 Rear RH outlet 9 Front RH outlet T 33 3 4 24 VDC00197 T T 9 8 7 6 5 4 10 1 2 3 T 11 T ...

Page 305: ...t Be careful not to burn yourself because each part on the vehicle is hot after running Be sure to tighten fasteners including bolts and nuts to the specified torque Place shop jacks or rigid racks at the specified points D PREPARATION TOOL 1 SPECIAL TOOL 2 GENERAL TOOL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 24082AA230 CARTRIDGE Troubleshooting for electrical system 22771AA030 SUBARU SELECT ...

Page 306: ...e pipe using a vinyl bag not to spill the brake fluid on the vehicle body CAUTION When the brake fluid is attached to vehicle body wash it off with water and wipe the water 7 Remove the clips and then remove the VDC CM H U CAUTION VDCCM H U cannot be disassembled Do not attempt to loosen the bolts and nuts Do not drop or bump the VDCCM H U Do not turn VDCCM H U upside down or place it sideways for...

Page 307: ...two pressure gauges to the FL and FR caliper bodies CAUTION Pressure gauges used exclusively for brake fluid must be used Do not use the pressure gauge for the mea surement of transmission oil pressure since the piston seal may be expanded and de formed NOTE Wrap a sealing tape around the pressure gauge 4 Bleed air from the pressure gauges 5 Perform VDC sequence control Ref to VDC 11 VDC Sequence ...

Page 308: ...etween de compression and compression meets the standard values 8 After the inspection depress the brake pedal and check that it is not abnormally hard and tight ness is normal D ADJUSTMENT When the following replacement removal and in stallation is performed be sure to perform the cen tering setting of steering angle sensor and zero point setting of yaw rate lateral G sensor VDCCM H U Steering an...

Page 309: ... 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 B SPECIFICATION 1 CONDITIONS FOR COMPLETION OF ABS SEQUENCE CONTROL Ref to ABS 12 CONDITIONS FOR COMPLE TION OF ...

Page 310: ...N and start the en gine immediately without pressing the brake pedal 4 After VDC warning light goes out and starting the engine perform the brake pedal operation as fol lows depress it within 3 seconds release it depress it again release it again 5 After completion of VDC sequence control turn the ignition switch to OFF 2 VDC SEQUENCE CONTROL WITH SUB ARU SELECT MONITOR NOTE In the event of any tr...

Page 311: ... SEQUENCE CONTROL 22 ON ON ON 26 26 26 5 6 20 36 4 3 2 1 21 25 25 25 25 35 V max 4 km h 2 5 MPH V max 10 km h 6 MPH OFF OFF OFF OFF OFF ON VDC 23 24 30 31 28 29 27 32 33 34 28 27 9 8 10 11 OFF 12 OFF 13 OFF 15 OFF 16 OFF 17 OFF 14 OFF 19 OFF 18 7 37 39 38 40 VDC00203 32 33 34 28 ...

Page 312: ... and when 3 seconds or more have elapsed after the VDC warning light goes OFF 6 After completion of VDC sequence control 7 When malfunction is detected 1 All wheel speed 16 RR decompression valve 30 Point A 2 DL terminal 17 RR compression valve 31 Reset 3 Ignition key 18 RL decompression valve 32 0 8 sec 4 ABS warning light 19 RL compression valve 33 1 2 sec 5 VDC warning light 20 Pump motor 34 0 ...

Page 313: ... NOTE Install the yaw rate lateral G sensor to body with directing the arrow mark on sensors to vehicle front Tightening torque 7 5 N m 0 76 kgf m 5 5 ft lb CAUTION After completion of installation set the follow ing two positions Positioning to the center of steering angle sensor Positioning of the yaw rate lateral G sensor to zero The above procedure is required VDCCM H U to identify the vehicle...

Page 314: ... 1 Remove the console box 2 Remove the yaw rate lateral G sensor from vehicle Do not disconnect the connec tor 3 Read the display of Subaru Select Monitor NOTE When the yaw rate lateral G sensor is moved with its power supply on DTC of yaw rate lat eral G sensor may be recorded Is the value 6 8 12 8 m s when the yaw rate lateral G sensor are inclined rightward to 90 Go to step 3 Repair the har nes...

Page 315: ...ing wheel Ref to PS 20 REMOVAL Steering Wheel 5 Remove the screws and detach the steering col umn lower cover 6 Remove the two screws securing the steering column upper cover 7 Unlock the harness band and disconnect the connector of steering angle sensor 8 Remove the screws which secure the roll con nector to steering column 9 Remove the steering angle sensor from roll con nector 10 Turn the protr...

Page 316: ...module to steering wheel Ref to AB 14 INSTALLATION Driver s Airbag Module WARNING Always refer to Airbag System before per forming the service operation Ref to AB 4 CAUTION General Description 17 Connect the battery ground cable to battery CAUTION After completion of installation adjust the fol lowing two positions Positioning to the center of steering angle sensor Positioning of the yaw rate late...

Page 317: ...ront ABS Wheel Speed Sen sor 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 Ref to ABS 13 Front ABS Wheel Speed Sen sor ...

Page 318: ...Rear ABS Wheel Speed Sen sor 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 Ref to ABS 15 Rear ABS Wheel Speed Sen sor ...

Page 319: ...der 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 to ABS 16 Front Magnetic Encoder ...

Page 320: ...der 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 to ABS 17 Rear Magnetic Encoder ...

Page 321: ...INSTALLATION Install in the reverse order of removal C INSPECTION Measure the resistance between VDC OFF switch terminals RHD model LHD model If NG replace the VDC OFF switch Switch position Terminal No Standard OFF 2 3 More than 1 MΩ ON 2 3 Less than 1 Ω Switch position Terminal No Standard OFF 2 15 More than 1 MΩ ON 2 15 Less than 1 Ω VDC00210 4 3 2 1 VDC00240 7 6 5 4 3 2 1 15 14 13 12 11 10 9 8...

Page 322: ...s 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...

Page 323: ...ectrical Component Location 10 5 Control Module I O Signal 12 6 Subaru Select Monitor 16 7 Read Diagnostic Trouble Code DTC 22 8 Inspection Mode 23 9 Clear Memory Mode 24 10 Warning Light Illumination Pattern 25 11 List of Diagnostic Trouble Code DTC 37 12 Diagnostic Procedure with Diagnostic Trouble Code DTC 43 13 General Diagnostic Table 132 ...

Page 324: ...roblem normal Go to step 2 Repair or replace each component 2 CHECK INDICATION OF DTC 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 the Sub aru Select Monitor switch to ON 4 Read the DTC Ref to VDC diag 22 OPERATION Read Diagnostic Trouble Code DTC NOTE If the communication function of the Subaru Se lect Monitor ca...

Page 325: ... DTC Ref to VDC diag 37 LIST List of Diagnostic Trouble Code DTC 2 Fix the wrong part 3 Perform the clear memory mode Ref to VDC diag 24 OPERATION Clear Memory Mode 4 Perform the inspection mode Ref to VDC diag 23 PROCEDURE Inspection Mode 5 Read the DTC Ref to VDC diag 22 OPERATION Read Diagnostic Trouble Code DTC Is DTC displayed Repeat step 4 until DTC is not shown Finish the diagno sis Step Ch...

Page 326: ...efore 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 switch to ON Immediately after turning the ignition switch 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 ...

Page 327: ...en 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 Part name Operating condition VDC operation indi cator 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 ru...

Page 328: ...e 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 Straight road Sharp curve Gentle curve S curve Road with a slope on both sides Others d Road surface Dried Wet Covered with fresh snow Covered with hardened snow Frozen slope Others ...

Page 329: ...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 Steering wheel Sharp turning Gentle turning Straight forward motion Gentle return Sharp return g Tire Wheel size Specified size Except specification h Tire variation Summer tire Studless tire Brand i Tire chains are fitted Yes No j T type tire is u...

Page 330: ...ge 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 VDC 8 CHECKING THE HYDRAULIC UNIT ABS OPERATION WITH BRAKE TESTER INSPECTION VDC Control Module Hydraulic Control Unit VDCCM H U Without brake tester Ref to VDC 8 CHECK ING THE HYDRAULIC UNIT ABS OPERATION ...

Page 331: ...leshooting 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 current Oscilloscope Used for measuring sensor ST24082AA230 ST22771AA030 ...

Page 332: ...6 VDC indicator light 12 Yaw rate lateral G sensor 2 Pressure sensor 7 VDC warning light and VDC OFF indicator light 13 Data link connector 3 Transmission control module TCM 14 Diagnosis connector Used for ABS sequence control 8 Steering angle sensor 4 Brake warning light EBD warning light 9 VDC OFF switch 15 Engine control module ECM 10 Magnetic encoder 16 Stop light switch VDC00241 4 5 6 7 8 1 2...

Page 333: ...VDC diag 11 VEHICLE DYNAMICS CONTROL VDC DIAGNOSTICS Electrical Component Location 1 2 VDC00231 VDC00251 6 7 5 4 8 VDC00235 VDC00234 11 10 10 12 VDC00250 VDC00242 13 VDC00230 14 ...

Page 334: ...L SPECIFICATION NOTE Terminal numbers in VDCCM H U connector are as shown in the figure When the connector is removed from VDCCM H U the ABS warning light and VDC warning light illumi nate VDC00211 B310 22 23 24 25 26 21 20 19 16 15 14 13 12 11 4 5 6 7 8 9 10 3 2 1 17 18 38 39 40 41 42 37 36 35 32 31 30 29 28 27 33 34 ...

Page 335: ...est 2 16 5 1 V cycle for 40 ms pulse signal Ref to VDC diag 15 WAVEFORM MEASURE MENT Control Module I O Signal Ground 16 CAN communication line 13 2 5 1 5 V pulse signal CAN communication line 29 3 5 2 5 V pulse signal Valve relay power supply 5 6 When the ignition switch is ON 10 15 V Motor relay power supply 9 10 When the ignition switch is ON 10 15 V Pressure sensor Power supply 27 12 When the ...

Page 336: ...sor 7 Motor 23 Combination meter 36 Yaw rate lateral G sensor 8 Front inlet solenoid valve LH 24 VDC indicator light 37 Pressure sensor 9 Front outlet solenoid valve LH 25 VDC warning light and VDC OFF indicator light 38 Front ABS wheel speed sensor LH 10 Front inlet solenoid valve RH 39 Front ABS wheel speed sensor RH 11 Front outlet solenoid valve RH 26 ABS warning light 12 Rear inlet solenoid v...

Page 337: ...L VDC DIAGNOSTICS Control Module I O Signal C MEASUREMENT Measure input and output signal voltage 1 WAVEFORM 1 Yaw rate sensor 2 Terminal No 3 Vehicle is at a standstill VDC00212 28 16 20 ms V 3 2 1 0 5 0 V 2 1 2 9 V 0 5 10 1 2 2 16 2 3 ...

Page 338: ... SPECIAL TOOL PREPA RATION TOOL General Description 4 Connect the Subaru Select Monitor to data link connector 1 Data link connector is located in the lower portion of instrument panel on the driver s side 2 Connect the diagnosis cable to data link connector CAUTION Do not connect the scan tools except for Suba ru Select Monitor 5 Turn the ignition switch to ON engine OFF and turn the Subaru Selec...

Page 339: ...is dis played km h or MPH FL Wheel Speed Wheel speed detected by front ABS wheel speed sensor LH is dis played km h or MPH RR Wheel Speed Wheel speed detected by rear ABS wheel speed sensor RH is dis played km h or MPH RL Wheel Speed Wheel speed detected by rear ABS wheel speed sensor LH is dis played km h or MPH Steering Angle Sensor Steering angle detected by steering angle sensor is displayed d...

Page 340: ...played Yaw rate sensor Vehicle angular speed detected by yaw rate sensor is displayed Lateral G sensor Vehicle lateral acceleration detected by lateral G sensor is displayed Pressure sensor Brake fluid pressure detected by pres sure sensor is displayed Vehicle Speed Vehicle speed calculated by VDC control module is displayed FR Wheel Speed Wheel speed detected by front ABS wheel speed sensor RH is...

Page 341: ...nector TROUBLE SYMPTOM Communication is impossible between VDC and Subaru Select Monitor WIRING DIAGRAM VDC00244 SBF 1 SBF 7 No 33 B310 E E 26 6 14 VDCCM H U B310 B40 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 11 12 13 14 27 28 29 30 15 16 17 18 31 32 33 34 19 20 21 22 35 36 37 38 23 24 25 26 39 40 41 42 5 6 7 8 9 10 BATTERY IGNITION SWITCH DATA LINK CONNECTOR B40 10 1 ...

Page 342: ... to VDC 7 VDC Control Mod ule Hydraulic Control Unit VDCCM H U Go to step 6 6 CHECK HARNESS CONNECTOR BETWEEN EACH CONTROL MODULE AND DATA LINK CONNECTOR 1 Turn the ignition switch to OFF 2 Disconnect the VDCCM H U ECM and TCM 3 Measure the resistance between data link connector and chassis ground Connector terminal B40 No 10 Chassis ground Is the resistance more than 1 MΩ Go to step 7 Repair the ...

Page 343: ...D CHASSIS GROUND 1 Turn the ignition switch to OFF 2 Disconnect the connector from VDCCM H U 3 Measure the resistance of harness between VDCCM H U and chassis ground Connector terminal B310 No 6 Chassis ground Is the resistance less than 0 5 Ω Go to step 12 Repair the open circuit in harness between VDCCM H U and inhibitor side con nector and poor contact in cou pling connector 12 CHECK POOR CONTA...

Page 344: ...MICS CONTROL VDC DIAGNOSTICS Read Diagnostic Trouble Code DTC 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 ...

Page 345: ...C DIAGNOSTICS Inspection Mode 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 ...

Page 346: ... 24 VEHICLE DYNAMICS CONTROL VDC DIAGNOSTICS Clear Memory Mode 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 ...

Page 347: ...eter circuit or CAN communication circuit Ref to VDC diag 32 VDC INDICATOR LIGHT DOES NOT GO OFF Warning Light Illumination Pattern NOTE Even though the ABS warning light does not go off after 1 5 seconds from ABS warning light illumination the ABS system operates normally when the warning light goes off while driving at approximately 12 km h 7 MPH However the ABS system does not work while the AB...

Page 348: ... When pressing VDC OFF switch for more than 10 seconds VDC OFF indicator light goes off and cannot op erate any more When turning the ignition switch from OFF to ON the OFF operation enabled status is re stored Step Check Yes No 1 CHECK OTHER INDICATOR LIGHT Turn the ignition switch to ON Does other indicator light illu minate soon after ON Go to step 2 Perform the self diagnosis of com bination m...

Page 349: ... NO 5 B16 B97 R1 R4 A3 A4 4 1 2 1 2 B229 1 2 3 4 5 6 7 8 9 10 16 11 15 14 13 12 17 19 18 23 25 24 20 22 21 26 28 27 i10 2 1 3 4 6 7 8 9 10 22 21 20 19 18 17 16 15 14 13 12 11 5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 B229 1 2 A BATTERY IGNITION SWITCH BRAKE FLUID LEVEL SWITCH PARKING BRAKE SWITCH BRAKE WARNING LIGHT ABS WARNING LIGHT 20 35 B310 B38 i3 i10 A VDCCM H U A7 1 2 3 4 11 12 13...

Page 350: ... 19 18 23 25 24 20 22 21 26 28 27 i10 2 1 3 4 6 7 8 9 10 22 21 20 19 18 17 16 15 14 13 12 11 5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 B229 1 2 A BATTERY IGNITION SWITCH BRAKE FLUID LEVEL SWITCH PARKING BRAKE SWITCH BRAKE WARNING LIGHT ABS WARNING LIGHT 20 35 B310 B36 i1 i10 A VDCCM H U A8 A5 16 3 A7 4 1 2 3 4 11 12 13 14 27 28 29 30 15 16 17 18 31 32 33 34 19 20 21 22 35 36 37 38 23 24...

Page 351: ...ct the connector B310 from VDCCM H U 3 Disconnect the connector i10 from combi nation meter 4 Measure the resistance between VDCCM H U connector and chassis ground Connector terminal B310 No 35 Chassis ground Is the resistance more than 1 MΩ Go to step 4 Repair the har ness connector between VDCCM H U and combination meter 4 CHECK VDCCM 1 Connect the connector B310 to VDCCM H U 2 Turn the ignition...

Page 352: ... R4 A3 A4 4 1 2 1 2 B229 1 2 3 4 5 6 7 8 9 10 16 11 15 14 13 12 17 19 18 23 25 24 20 22 21 26 28 27 i10 2 1 3 4 6 7 8 9 10 22 21 20 19 18 17 16 15 14 13 12 11 5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 B229 1 2 A BATTERY IGNITION SWITCH BRAKE FLUID LEVEL SWITCH PARKING BRAKE SWITCH BRAKE WARNING LIGHT ABS WARNING LIGHT 20 35 B310 B38 i3 i10 A VDCCM H U A7 1 2 3 4 11 12 13 14 27 28 29 30 ...

Page 353: ... 19 18 23 25 24 20 22 21 26 28 27 i10 2 1 3 4 6 7 8 9 10 22 21 20 19 18 17 16 15 14 13 12 11 5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 B229 1 2 A BATTERY IGNITION SWITCH BRAKE FLUID LEVEL SWITCH PARKING BRAKE SWITCH BRAKE WARNING LIGHT ABS WARNING LIGHT 20 35 B310 B36 i1 i10 A VDCCM H U A8 A5 16 3 A7 4 1 2 3 4 11 12 13 14 27 28 29 30 15 16 17 18 31 32 33 34 19 20 21 22 35 36 37 38 23 24...

Page 354: ...connector between VDCCM H U and combination meter 3 CHECK POOR CONTACT IN CONNECTOR Check poor contact in all connectors Is there poor contact Repair the con nector Go to step 4 4 CHECK VDCCM 1 Connect the connector to VDCCM H U B310 2 Turn the ignition switch to ON 3 Measure the resistance between combina tion meter connector and chassis ground Connector terminal i10 No A5 Chassis ground Is the r...

Page 355: ...ing to DTC Go to step 2 2 CHECK ENGINE Does the malfunction indicator light illuminate Repair the engine Go to step 3 3 CHECK ENGINE COOLANT Warm up the engine and check if VDC warning light and VDC OFF indicator light illumination condition changes When the engine coolant tem perature is too low VDC warn ing light and VDC OFF indicator light illuminate Does the lights go off when the engine is wa...

Page 356: ... E SBF 1 SBF 7 E NO 5 B16 B97 R1 R4 A3 A4 4 1 2 1 2 B229 1 2 3 4 5 6 7 8 9 10 16 11 15 14 13 12 17 19 18 23 25 24 20 22 21 26 28 27 i10 2 1 3 4 6 7 8 9 10 22 21 20 19 18 17 16 15 14 13 12 11 5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 B229 1 2 A BATTERY IGNITION SWITCH BRAKE FLUID LEVEL SWITCH PARKING BRAKE SWITCH BRAKE WARNING LIGHT ABS WARNING LIGHT 20 35 B310 B38 i3 i10 A VDCCM H U A7 ...

Page 357: ... 19 18 23 25 24 20 22 21 26 28 27 i10 2 1 3 4 6 7 8 9 10 22 21 20 19 18 17 16 15 14 13 12 11 5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 B229 1 2 A BATTERY IGNITION SWITCH BRAKE FLUID LEVEL SWITCH PARKING BRAKE SWITCH BRAKE WARNING LIGHT ABS WARNING LIGHT 20 35 B310 B36 i1 i10 A VDCCM H U A8 A5 16 3 A7 4 1 2 3 4 11 12 13 14 27 28 29 30 15 16 17 18 31 32 33 34 19 20 21 22 35 36 37 38 23 24...

Page 358: ...g brake 3 Measure the resistance between parking brake switch terminal and chassis ground Is the resistance more than 1 MΩ Go to step 6 Replace the park ing brake switch 6 CHECK GROUND SHORT OF HARNESS 1 Disconnect the connector i10 from combi nation meter 2 Measure the resistance between combina tion meter connector and chassis ground Connector terminal i10 No A7 Chassis ground Is the resistance ...

Page 359: ...eft ABS Sensor Signal Front ABS wheel speed sensor LH signal mal function Ref to VDC diag 51 DTC C0024 FRONT ABS WHEEL SPEED SENSOR LH SIGNAL MAL FUNCTION Diagnostic Procedure with Diagnos tic Trouble Code DTC C0025 658XH RR sensor power sup ply failure Rear ABS wheel speed sensor RH power sup ply malfunction Ref to VDC diag 43 DTC C0025 REAR ABS WHEEL SPEED SENSOR RH POWER SUPPLY MALFUNCTION Diag...

Page 360: ...UNCTION IN VDCCM H U Diagnostic Procedure with Diag nostic Trouble Code DTC C0035 2A0XH RR hold valve malfunc tion Rear inlet solenoid valve RH malfunction in VDCCM H U Ref to VDC diag 61 DTC C0035 REAR INLET SOLENOID VALVE RH MALFUNCTION IN VDCCM H U Diagnostic Procedure with Diag nostic Trouble Code DTC C0036 2E0XH RR pressure reducing valve malfunction Rear outlet solenoid valve RH malfunction ...

Page 361: ...C C0042 POWER VOLTAGE MALFUNCTION Diagnostic Proce dure with Diagnostic Trouble Code DTC 7CCXH Speed sen power sup ply failure ABS wheel speed sen sor power malfunction Ref to VDC diag 70 DTC C0042 ABS WHEEL SPEED SENSOR POWER MALFUNCTION Diagnostic Procedure with Diagnostic Trouble Code DTC C0044 9A0XH TCM communication circuit CAN communication malfunction of transmis sion control module Ref to ...

Page 362: ...edure with Diagnostic Trouble Code DTC 5A0XH Motor and motor relay OFF failure Motor motor relay OFF malfunction Ref to VDC diag 85 DTC C0052 MOTOR MOTOR RELAY OFF MALFUNCTION Diagnos tic Procedure with Diagnostic Trouble Code DTC 58EXH Motor and motor relay ON failure Motor motor relay ON malfunction Ref to VDC diag 86 DTC C0052 MOTOR MOTOR RELAY ON MALFUNCTION Diagnostic Procedure with Diagnosti...

Page 363: ...SENSOR POWER SUPPLY MALFUNC TION Diagnostic Procedure with Diagnostic Trou ble Code DTC C0072 184XH 188XH 18EXH Abnormal yaw rate sen sor output Yaw rate sensor output Ref to VDC diag 106 DTC C0072 YAW RATE SENSOR OUTPUT Diagnostic Procedure with Diagnostic Trouble Code DTC 180XH 182XH 186XH 190XH 194XH 196XH 198XH 19AXH Abnormal yaw rate sen sor output Yaw rate sensor output Ref to VDC diag 106 D...

Page 364: ...120 DTC C0073 LATERAL G SENSOR POWER OUTPUT Diagnostic Proce dure with Diagnostic Trouble Code DTC C0074 118XH Pressure sensor test failure Pressure sensor test malfunction Ref to VDC diag 123 DTC C0074 PRESSURE SENSOR TEST MALFUNCTION Diagnostic Pro cedure with Diagnostic Trouble Code DTC 110XH Pressure sensor offset is too big Excessive pressure sensor output offset Ref to VDC diag 125 DTC C0074...

Page 365: ...nostic Trouble Code DTC B DTC C0023 FRONT ABS WHEEL SPEED SENSOR LH POWER SUPPLY MALFUNCTION NOTE For the diagnostic procedure refer to DTC C0027 REAR ABS WHEEL SPEED SENSOR LH POWER SUP PLY MALFUNCTION Ref to VDC diag 44 DTC C0027 REAR ABS WHEEL SPEED SENSOR LH POW ER SUPPLY MALFUNCTION Diagnostic Procedure with Diagnostic Trouble Code DTC C DTC C0025 REAR ABS WHEEL SPEED SENSOR RH POWER SUPPLY M...

Page 366: ... SUPPLY MAL FUNCTION DTC DETECTING CONDITION Defective ABS wheel speed sensor TROUBLE SYMPTOM ABS does not operate VDC does not operate WIRING DIAGRAM VDC00216 SBF 1 SBF 7 No 33 B310 B310 E E 6 14 VDCCM H U 1 2 3 4 11 12 13 14 27 28 29 30 15 16 17 18 31 32 33 34 19 20 21 22 35 36 37 38 23 24 25 26 39 40 41 42 5 6 7 8 9 10 BATTERY GENERATOR IGNITION SWITCH ...

Page 367: ...ect the VDCCM H U connector 3 Turn the ignition switch to ON 4 Measure the voltage between VDCCM H U connector terminals Terminals B310 No 14 B310 No 6 Is the voltage 10 15 V Go to step 3 Check the genera tor battery and VDCCM H U power supply cir cuit 3 CHECK VDCCM H U 1 Connect all the connectors 2 Erase the memory 3 Perform the inspection mode 4 Read the DTC Is the same DTC displayed Replace th...

Page 368: ...e DTC F DTC C0023 OPEN HIGH INPUT OF FRONT ABS WHEEL SPEED SENSOR LH NOTE For the diagnostic procedure refer to DTC C0027 OPEN HIGH INPUT OF REAR ABS WHEEL SPEED SENSOR LH Ref to VDC diag 47 DTC C0027 OPEN HIGH INPUT OF REAR ABS WHEEL SPEED SENSOR LH Diagnostic Procedure with Diagnostic Trouble Code DTC G DTC C0025 OPEN HIGH INPUT OF REAR ABS WHEEL SPEED SENSOR RH NOTE For the diagnostic procedure...

Page 369: ...t operate VDC does not operate WIRING DIAGRAM LHD model B15 B6 R73 R72 1 2 B310 B98 1 2 3 4 11 12 13 14 27 28 29 30 15 16 17 18 31 32 33 34 19 20 21 22 35 36 37 38 23 24 25 26 39 40 41 42 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 VDC00246 38 23 25 41 40 24 6 B98 R72 R2 E 1 2 15 14 6 5 R73 1 2 1 2 1 2 B6 B15 21 22 B310 VDCCM H U TWISTED WIRE FRONT ABS WHEEL SPEED SENSOR LH TWISTED WIRE TW...

Page 370: ...5 B15 B6 R73 R72 1 2 B310 21 22 B310 B97 VDCCM H U TWISTED WIRE FRONT ABS WHEEL SPEED SENSOR LH 1 2 3 4 11 12 13 14 27 28 29 30 15 16 17 18 31 32 33 34 19 20 21 22 35 36 37 38 23 24 25 26 39 40 41 42 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 TWISTED WIRE TWISTED WIRE TWISTED WIRE FRONT ABS WHEEL SPEED SENSOR RH REAR ABS WHEEL SPEED SENSOR LH REAR ABS WHEEL SPEED SENSOR RH ...

Page 371: ...4 R73 No 1 B310 No 40 R73 No 2 Is the resistance less than 0 5 Ω Go to step 3 Repair the har ness connector between VDCCM H U and ABS wheel speed sensor 3 CHECK GROUND SHORT OF HARNESS Measure the resistance between VDCCM H U connector and chassis ground Connector terminal DTC C0021 B310 No 21 Chassis ground DTC C0023 B310 No 25 Chassis ground DTC C0025 B310 No 38 Chassis ground DTC C0027 B310 No ...

Page 372: ...he ABS wheel speed sensor 2 Prepare an oscilloscope 3 Check the ABS wheel speed sensor Ref to ABS 15 ABS WHEEL SPEED SENSOR INSPECTION Rear ABS Wheel Speed Sen sor Is waveform pattern same as shown in the figure Go to step 7 Replace the ABS wheel speed sen sor 7 CHECK VDCCM H U 1 Connect all the connectors 2 Erase the memory 3 Perform the inspection mode Ref to VDC diag 23 PROCEDURE Inspection Mod...

Page 373: ...DTC J DTC C0024 FRONT ABS WHEEL SPEED SENSOR LH SIGNAL MALFUNC TION NOTE For the diagnostic procedure refer to DTC C0028 REAR ABS WHEEL SPEED SENSOR LH SIGNAL MAL FUNCTION Ref to VDC diag 52 DTC C0028 REAR ABS WHEEL SPEED SENSOR LH SIGNAL MAL FUNCTION Diagnostic Procedure with Diagnostic Trouble Code DTC K DTC C0026 REAR ABS WHEEL SPEED SENSOR RH SIGNAL MALFUNC TION NOTE For the diagnostic procedu...

Page 374: ...e with Diagnostic Trouble Code DTC 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 ABS does not operate VDC does not operate ...

Page 375: ...6 17 18 31 32 33 34 19 20 21 22 35 36 37 38 23 24 25 26 39 40 41 42 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 VDC00246 38 23 25 41 40 24 6 B98 R72 R2 E 1 2 15 14 6 5 R73 1 2 1 2 1 2 B6 B15 21 22 B310 VDCCM H U TWISTED WIRE FRONT ABS WHEEL SPEED SENSOR LH TWISTED WIRE TWISTED WIRE TWISTED WIRE FRONT ABS WHEEL SPEED SENSOR RH REAR ABS WHEEL SPEED SENSOR LH REAR ABS WHEEL SPEED SENSOR RH ...

Page 376: ...5 B15 B6 R73 R72 1 2 B310 21 22 B310 B97 VDCCM H U TWISTED WIRE FRONT ABS WHEEL SPEED SENSOR LH 1 2 3 4 11 12 13 14 27 28 29 30 15 16 17 18 31 32 33 34 19 20 21 22 35 36 37 38 23 24 25 26 39 40 41 42 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 TWISTED WIRE TWISTED WIRE TWISTED WIRE FRONT ABS WHEEL SPEED SENSOR RH REAR ABS WHEEL SPEED SENSOR LH REAR ABS WHEEL SPEED SENSOR RH ...

Page 377: ...ule Hydraulic Control Unit VDCCM H U Go to step 6 6 CHECK OTHER DTC DETECTION Is any other DTC displayed Perform the diag nosis according to DTC It results from a temporary noise interference 7 CHECK INSTALLATION OF ABS WHEEL SPEED SENSOR Is the ABS wheel speed sen sor installation bolt tightened 7 5 N m 0 76 kgf m 5 5 ft lb Go to step 8 Tighten the ABS wheel speed sen sor installation bolts 8 CHE...

Page 378: ...yed Replace the VDCCM H U Ref to VDC 7 VDC Control Mod ule Hydraulic Control Unit VDCCM H U Go to step 13 13 CHECK OTHER DTC DETECTION Is any other DTC displayed Perform the diag nosis according to DTC It results from a temporary noise interference NOTE Though the ABS warning light re mains on at this time it is normal Drive the vehicle at more than 12 km h 7 MPH in order to turn ABS warning light...

Page 379: ...TION IN ONE OF FOUR WHEELS DTC DETECTING CONDITION Defective ABS wheel speed sensor signal noise irregular signal etc Defective magnetic encoder When a wheel is turned freely for a long time TROUBLE SYMPTOM ABS does not operate VDC does not operate EBD may not operate NOTE Brake warning light comes on as well as ABS warning light when EBD does not operate ...

Page 380: ...6 17 18 31 32 33 34 19 20 21 22 35 36 37 38 23 24 25 26 39 40 41 42 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 VDC00246 38 23 25 41 40 24 6 B98 R72 R2 E 1 2 15 14 6 5 R73 1 2 1 2 1 2 B6 B15 21 22 B310 VDCCM H U TWISTED WIRE FRONT ABS WHEEL SPEED SENSOR LH TWISTED WIRE TWISTED WIRE TWISTED WIRE FRONT ABS WHEEL SPEED SENSOR RH REAR ABS WHEEL SPEED SENSOR LH REAR ABS WHEEL SPEED SENSOR RH ...

Page 381: ...5 B15 B6 R73 R72 1 2 B310 21 22 B310 B97 VDCCM H U TWISTED WIRE FRONT ABS WHEEL SPEED SENSOR LH 1 2 3 4 11 12 13 14 27 28 29 30 15 16 17 18 31 32 33 34 19 20 21 22 35 36 37 38 23 24 25 26 39 40 41 42 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 TWISTED WIRE TWISTED WIRE TWISTED WIRE FRONT ABS WHEEL SPEED SENSOR RH REAR ABS WHEEL SPEED SENSOR LH REAR ABS WHEEL SPEED SENSOR RH ...

Page 382: ...lation bolts tightened to 7 5 N m 0 76 kgf m 5 5 ft lb For four wheels Go to step 6 Tighten the ABS wheel speed sen sor installation bolts 6 CHECK ABS WHEEL SPEED SENSOR SIG NAL 1 Install the ABS wheel speed sensor 2 Prepare an oscilloscope 3 Check the ABS wheel speed sensor Ref to ABS 13 ABS WHEEL SPEED SENSOR INSPECTION Front ABS Wheel Speed Sen sor Is the oscilloscope pattern the same waveform ...

Page 383: ...DTC C0064 PRIMARY SUCTION VALVE MALFUNCTION IN VDC CM H U Diagnostic Procedure with Diagnostic Trouble Code DTC Q DTC C0034 FRONT OUTLET SOLENOID VALVE LH 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 Trou...

Page 384: ...UCTION 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 V DTC C0061 SECONDARY CUT VALVE MALFUNCTION IN VDCCM 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...

Page 385: ...CTING CONDITION Defective harness connector Defective VDCH U solenoid valve TROUBLE SYMPTOM ABS does not operate EBD does not operate VDC does not operate WIRING DIAGRAM VDC00216 SBF 1 SBF 7 No 33 B310 B310 E E 6 14 VDCCM H U 1 2 3 4 11 12 13 14 27 28 29 30 15 16 17 18 31 32 33 34 19 20 21 22 35 36 37 38 23 24 25 26 39 40 41 42 5 6 7 8 9 10 BATTERY GENERATOR IGNITION SWITCH ...

Page 386: ...OFF 2 Measure the resistance between VDCCM H U connector and chassis ground Connector terminal B310 No 6 Chassis ground Is the resistance less than 0 5 Ω Go to step 3 Repair the VDCCM H U ground harness 3 CHECK POOR CONTACT IN CONNECTORS Is there poor contact in con nector between generator bat tery and VDCCM H U Repair the con nector Go to step 4 4 CHECK VDCCM H U 1 Connect all the connectors 2 E...

Page 387: ... 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 VDC00217 VDCCM H U 6 B310 B310 E 1 2 3 4 11 12 13 14 27 28 29 30 15 16 17 18 31 32 33 34 19 20 21 22 35 36 37 38 23 24 25 26 39 40 41 42 5 6 7 8 9 10 ...

Page 388: ...r the con nector Go to step 3 3 CHECK SOURCES OF SIGNAL NOISE Is the car phone or radio prop erly installed Go to step 4 Install the car phone or radio properly 4 CHECK SOURCES OF SIGNAL NOISE Are noise sources such as an antenna installed near the sensor harness Install the noise sources apart from the sensor har ness Go to step 5 5 CHECK VDCCM H U 1 Connect all the connectors 2 Erase the memory ...

Page 389: ... Procedure with Diagnostic Trouble Code DTC 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: ... Procedure with Diagnostic Trouble Code DTC WIRING DIAGRAM VDC00216 SBF 1 SBF 7 No 33 B310 B310 E E 6 14 VDCCM H U 1 2 3 4 11 12 13 14 27 28 29 30 15 16 17 18 31 32 33 34 19 20 21 22 35 36 37 38 23 24 25 26 39 40 41 42 5 6 7 8 9 10 BATTERY GENERATOR IGNITION SWITCH ...

Page 391: ...ge between VDCCM H U connector and chassis ground Connector terminal B310 No 14 Chassis ground Is the voltage 10 15 V Go to step 4 Repair the power supply circuit 4 CHECK GROUND CIRCUIT FOR VDCCM H U 1 Turn the ignition switch to OFF 2 Measure the resistance between VDCCM H U connector and chassis ground Connector terminal B310 No 6 Chassis ground Is the resistance less than 0 5 Ω Go to step 5 Rep...

Page 392: ...AN system Ref to LAN diag 24 OPERATION Read Diagnostic Trouble Code DTC Is there any fault in LAN sys tem Perform the diag nosis according to DTC for LAN sys tem Go to step 2 2 CHECK POOR CONTACT IN CONNECTORS Is there poor contact in TCM connector Repair the con nector Go to step 3 3 CHECK TCM Is the TCM normal Go to step 4 Replace the TCM Ref to 4AT 65 Transmission Con trol Module TCM Ref to 5AT...

Page 393: ...TCM specification Is the specification of TCM same as vehicle specification Go to step 3 Replace the TCM Ref to 4AT 65 Transmission Con trol Module TCM Ref to 5AT 61 Transmis sion Control Mod ule TCM 3 CHECK AT SYSTEM 1 Start the engine 2 Check the DTC in AT system Is DTC of AT system dis played Repair the AT sys tem Go to step 4 4 CHECK ECM SPECIFICATION Check the ECM specification Is the specifi...

Page 394: ...ck Yes No 1 CHECK AT SYSTEM 1 Start the engine 2 Check the DTC in AT system Is DTC of AT system dis played Repair the AT sys tem Go to step 2 2 CHECK VDCCM H U 1 Connect all the connectors 2 Erase the memory 3 Perform the inspection mode 4 Read the DTC Is the same DTC displayed Replace the VDCCM H U Go to step 3 3 CHECK OTHER DTC DETECTION Is any other DTC displayed Perform the diag nosis accordin...

Page 395: ...CTING CONDITION CAN communication line circuit is open or shorted TROUBLE SYMPTOM ABS does not operate VDC does not operate WIRING DIAGRAM VDC00247 30 29 13 B231 E 2 4 1 3 B310 B310 VDCCM H U 1 2 3 4 11 12 13 14 27 28 29 30 15 16 17 18 31 32 33 34 19 20 21 22 35 36 37 38 23 24 25 26 39 40 41 42 5 6 7 8 9 10 1 2 3 4 B231 TWISTED WIRE STEERING ANGLE SENSOR ...

Page 396: ...ault in LAN sys tem Perform the diag nosis according to DTC for LAN sys tem Go to step 2 2 CHECK POOR CONTACT IN CONNECTORS Is there poor contact in VDCCM H U connector Repair the con nector Go to step 3 3 CHECK VDCCM H U 1 Connect all the connectors 2 Erase the memory 3 Perform the inspection mode 4 Read the DTC Is the same DTC displayed Replace the VDCCM H U Ref to VDC 7 VDC Control Mod ule Hydr...

Page 397: ... not operate VDC does not operate WIRING DIAGRAM VDC00219 B310 B310 E 5 6 VDCCM H U 14 M SBF 1 SBF 7 No 21 No 33 E 22 23 24 25 26 21 20 19 16 15 14 13 12 11 4 5 6 7 8 9 10 3 2 1 17 18 38 39 40 41 42 37 36 35 32 31 30 29 28 27 33 34 BATTERY IGNITION SWITCH VALVE RELAY SOLENOID VALVE PUMP MOTOR FL INLET RL INLET FR INLET RR INLET FL OUTLET RL OUTLET FR OUTLET RR OUTLET MOTOR RELAY PRIMARY SUCTION SE...

Page 398: ...ion switch to OFF 2 Measure the resistance between VDCCM H U connector and chassis ground Connector terminal B310 No 6 Chassis ground Is the resistance less than 0 5 Ω Go to step 3 Repair the VDCCM H U ground harness 3 CHECK POOR CONTACT IN CONNECTORS Is there poor contact in con nector between generator bat tery and VDCCM H U Repair the con nector Go to step 4 4 CHECK VDCCM H U 1 Connect all the ...

Page 399: ...ot operate VDC does not operate WIRING DIAGRAM VDC00219 B310 B310 E 5 6 VDCCM H U 14 M SBF 1 SBF 7 No 21 No 33 E 22 23 24 25 26 21 20 19 16 15 14 13 12 11 4 5 6 7 8 9 10 3 2 1 17 18 38 39 40 41 42 37 36 35 32 31 30 29 28 27 33 34 BATTERY IGNITION SWITCH VALVE RELAY SOLENOID VALVE PUMP MOTOR FL INLET RL INLET FR INLET RR INLET FL OUTLET RL OUTLET FR OUTLET RR OUTLET MOTOR RELAY PRIMARY SUCTION SECO...

Page 400: ...H U 1 Turn the ignition switch to OFF 2 Measure the resistance between VDCCM H U connector and chassis ground Connector terminal B310 No 6 Chassis ground Is the resistance less than 0 5 Ω Go to step 4 Repair the VDCCM H U ground harness 4 CHECK VALVE RELAY FOR VDCCM H U Measure the resistance between VDCCM H U connector terminals Connector terminal B310 No 5 B310 No 6 Is the resistance more than 1...

Page 401: ... not operate VDC does not operate WIRING DIAGRAM VDC00219 B310 B310 E 5 6 VDCCM H U 14 M SBF 1 SBF 7 No 21 No 33 E 22 23 24 25 26 21 20 19 16 15 14 13 12 11 4 5 6 7 8 9 10 3 2 1 17 18 38 39 40 41 42 37 36 35 32 31 30 29 28 27 33 34 BATTERY IGNITION SWITCH VALVE RELAY SOLENOID VALVE PUMP MOTOR FL INLET RL INLET FR INLET RR INLET FL OUTLET RL OUTLET FR OUTLET RR OUTLET MOTOR RELAY PRIMARY SUCTION SE...

Page 402: ...l B310 No 6 Chassis ground Is the resistance less than 0 5 Ω Go to step 3 Repair the ground circuit in VDCCM H U 3 CHECK VALVE RELAY FOR VDCCM H U Measure the resistance between VDCCM H U connector terminals Connector terminal B310 No 5 B310 No 6 Is the resistance more than 1 MΩ Go to step 4 Replace the H U 4 CHECK POOR CONTACT IN CONNECTORS Is there poor contact in con nector between generator ba...

Page 403: ... not operate EBD may not operate WIRING DIAGRAM VDC00219 B310 B310 E 5 6 VDCCM H U 14 M SBF 1 SBF 7 No 21 No 33 E 22 23 24 25 26 21 20 19 16 15 14 13 12 11 4 5 6 7 8 9 10 3 2 1 17 18 38 39 40 41 42 37 36 35 32 31 30 29 28 27 33 34 BATTERY IGNITION SWITCH VALVE RELAY SOLENOID VALVE PUMP MOTOR FL INLET RL INLET FR INLET RR INLET FL OUTLET RL OUTLET FR OUTLET RR OUTLET MOTOR RELAY PRIMARY SUCTION SEC...

Page 404: ...lic Control Unit VDCCM H U 2 CHECK POOR CONTACT IN CONNECTORS Is there poor contact in con nector between generator bat tery and VDCCM H U Repair the con nector Go to step 3 3 CHECK VDCCM H U 1 Connect all the connectors 2 Erase the memory 3 Perform the inspection mode 4 Read the DTC Is the same DTC displayed Replace the VDCCM H U Ref to VDC 7 VDC Control Mod ule Hydraulic Control Unit VDCCM H U G...

Page 405: ...t operate VDC does not operate EBD may not operate WIRING DIAGRAM VDC00220 B310 E 9 6 VDCCM H U 14 M SBF 1 SBF 7 No 33 E SBF 2 B310 22 23 24 25 26 21 20 19 16 15 14 13 12 11 4 5 6 7 8 9 10 3 2 1 17 18 38 39 40 41 42 37 36 35 32 31 30 29 28 27 33 34 E 10 BATTERY IGNITION SWITCH VALVE RELAY SOLENOID VALVE PUMP MOTOR FL INLET RL INLET FR INLET RR INLET FL OUTLET RL OUTLET FR OUTLET RR OUTLET MOTOR RE...

Page 406: ...sistance more than 1 MΩ Go to step 4 Replace the VDCCM H U 4 CHECK MOTOR OPERATION Operate the sequence control Is the motor revolution noise buzz heard when carrying out the sequence control Go to step 5 Replace the VDCCM H U Ref to VDC 7 VDC Control Mod ule Hydraulic Control Unit VDCCM H U 5 CHECK POOR CONTACT IN CONNECTORS Turn the ignition switch to OFF Is there poor contact in con nector betw...

Page 407: ...ION DTC DETECTING CONDITION Defective motor relay Defective harness connector TROUBLE SYMPTOM ABS does not operate VDC does not operate EBD may not operate NOTE For the diagnostic procedure refer to DTC C0052 MOTOR MOTOR RELAY MALFUNCTION Ref to VDC diag 83 DTC C0052 MOTOR MOTOR RELAY MALFUNCTION Diagnostic Procedure with Diagnos tic Trouble Code DTC ...

Page 408: ...erate VDC does not operate EBD may not operate WIRING DIAGRAM VDC00220 B310 E 9 6 VDCCM H U 14 M SBF 1 SBF 7 No 33 E SBF 2 B310 22 23 24 25 26 21 20 19 16 15 14 13 12 11 4 5 6 7 8 9 10 3 2 1 17 18 38 39 40 41 42 37 36 35 32 31 30 29 28 27 33 34 E 10 BATTERY IGNITION SWITCH VALVE RELAY SOLENOID VALVE PUMP MOTOR FL INLET RL INLET FR INLET RR INLET FL OUTLET RL OUTLET FR OUTLET RR OUTLET MOTOR RELAY ...

Page 409: ...CCM H U 1 Connect all the connectors 2 Erase the memory 3 Perform the inspection mode 4 Read the DTC Is the same DTC displayed Replace the VDCCM H U Ref to VDC 7 VDC Control Mod ule Hydraulic Control Unit VDCCM H U Go to step 3 3 CHECK OTHER DTC DETECTION Is any other DTC displayed Perform the diag nosis according to DTC Ref to VDC diag 37 List of Diagnostic Trou ble Code DTC Temporary poor contac...

Page 410: ...ITION Defective motor Defective motor relay Defective harness connector TROUBLE SYMPTOM ABS does not operate VDC does not operate EBD may not operate NOTE For the diagnostic procedure refer to DTC C0052 MOTOR MOTOR RELAY MALFUNCTION Ref to VDC diag 83 DTC C0052 MOTOR MOTOR RELAY MALFUNCTION Diagnostic Procedure with Diagnos tic Trouble Code DTC ...

Page 411: ...OUBLE SYMPTOM ABS does not operate VDC does not operate WIRING DIAGRAM VDC00221 SBF 1 SBF 3 No 8 B310 B159 E 37 VDCCM H U B64 OC B65 B65 B310 B159 1 2 3 4 B64 1 2 5 9 2 3 2 1 OC WC 9 4 7 6 2 1 5 3 8 1 2 3 4 11 12 13 14 27 28 29 30 15 16 17 18 31 32 33 34 19 20 21 22 35 36 37 38 23 24 25 26 39 40 41 42 5 6 7 8 9 10 WC WC OC BATTERY STOP LIGHT SWITCH WITH CRUISE CONTROL WITHOUT CRUISE CONTROL ...

Page 412: ...p 4 Repair the stop lights circuit 4 CHECK OPEN CIRCUIT OF HARNESS 1 Turn the ignition switch to OFF 2 Disconnect the connector from VDCCM H U 3 Depress the brake pedal 4 Measure the voltage between VDCCM H U connector and chassis ground Connector terminal B310 No 37 Chassis ground Is the voltage 10 15 V Go to step 5 Repair the har ness between stop light switch and VDCCM H U con nector 5 CHECK PO...

Page 413: ...ROUBLE SYMPTOM ABS does not operate VDC does not operate WIRING DIAGRAM VDC00221 SBF 1 SBF 3 No 8 B310 B159 E 37 VDCCM H U B64 OC B65 B65 B310 B159 1 2 3 4 B64 1 2 5 9 2 3 2 1 OC WC 9 4 7 6 2 1 5 3 8 1 2 3 4 11 12 13 14 27 28 29 30 15 16 17 18 31 32 33 34 19 20 21 22 35 36 37 38 23 24 25 26 39 40 41 42 5 6 7 8 9 10 WC WC OC BATTERY STOP LIGHT SWITCH WITH CRUISE CONTROL WITHOUT CRUISE CONTROL ...

Page 414: ...tor pedal and brake pedal were depressed simultaneously with depressing brake pedal with left foot Were the acceleration pedal and brake pedal depressed simultaneously during driving System is in good order DTC may be recorded while brake is applied during driving Go to step 3 3 CHECK VDCCM H U 1 Connect all the connectors 2 Erase the memory 3 Perform the inspection mode 4 Read the DTC Is the same...

Page 415: ...m the diag nosis according to DTC for LAN sys tem Go to step 2 2 CHECK POOR CONTACT IN CONNECTORS Is the poor contact in ECM connector Repair the con nector Go to step 3 3 CHECK ECM Is ECM normal Go to step 4 Replace the ECM 4 CHECK VDCCM H U 1 Connect all the connectors 2 Erase the memory 3 Perform the inspection mode 4 Read the DTC Is the same DTC displayed Replace the VDCCM H U Ref to VDC 7 VDC...

Page 416: ...SENSOR OUTPUT OFFSET DTC DETECTING CONDITION Defective steering angle sensor TROUBLE SYMPTOM VDC does not operate WIRING DIAGRAM VDC00247 30 29 13 B231 E 2 4 1 3 B310 B310 VDCCM H U 1 2 3 4 11 12 13 14 27 28 29 30 15 16 17 18 31 32 33 34 19 20 21 22 35 36 37 38 23 24 25 26 39 40 41 42 5 6 7 8 9 10 1 2 3 4 B231 TWISTED WIRE STEERING ANGLE SENSOR ...

Page 417: ...han 5 Go to step 2 Perform the cen tering adjustment of steering wheel 2 CHECK VDCCM H U 1 Turn the ignition switch to OFF 2 Connect all the connectors 3 Erase the memory 4 Perform the inspection mode 5 Read the DTC Is the same DTC displayed Replace the VDCCM H U Ref to VDC 7 VDC Control Mod ule Hydraulic Control Unit VDCCM H U Go to step 3 3 CHECK OTHER DTC DETECTION Is any other DTC displayed Pe...

Page 418: ...EERING ANGLE SEN SOR OUTPUT DTC DETECTING CONDITION Defective steering angle sensor TROUBLE SYMPTOM VDC does not operate WIRING DIAGRAM VDC00247 30 29 13 B231 E 2 4 1 3 B310 B310 VDCCM H U 1 2 3 4 11 12 13 14 27 28 29 30 15 16 17 18 31 32 33 34 19 20 21 22 35 36 37 38 23 24 25 26 39 40 41 42 5 6 7 8 9 10 1 2 3 4 B231 TWISTED WIRE STEERING ANGLE SENSOR ...

Page 419: ...ll the connectors 3 Erase the memory 4 Perform the inspection mode 5 Read the DTC Is the same DTC displayed Replace the VDCCM H U Ref to VDC 7 VDC Control Mod ule Hydraulic Control Unit VDCCM H U Go to step 2 2 CHECK OTHER DTC DETECTION Is any other DTC displayed Perform the diag nosis according to DTC Ref to VDC diag 37 List of Diagnostic Trou ble Code DTC Temporary poor contact occurs ...

Page 420: ...ENSOR OUTPUT DTC DETECTING CONDITION Defective steering angle sensor TROUBLE SYMPTOM VDC does not operate WIRING DIAGRAM VDC00247 30 29 13 B231 E 2 4 1 3 B310 B310 VDCCM H U 1 2 3 4 11 12 13 14 27 28 29 30 15 16 17 18 31 32 33 34 19 20 21 22 35 36 37 38 23 24 25 26 39 40 41 42 5 6 7 8 9 10 1 2 3 4 B231 TWISTED WIRE STEERING ANGLE SENSOR ...

Page 421: ...banks or sandy surface which does not mean a dirt road Go to step 3 3 CHECK OUTPUT OF STEERING ANGLE SENSOR WITH SUBARU SELECT MONI TOR 1 Select Current Data Display Save in Subaru Select Monitor 2 Read the steering angle sensor output dis played on display Does the steering angle sensor output value on the display vary in accordance with steer ing operation when turning the steering wheel to the ...

Page 422: ...CATION DTC DETECTING CONDITION Signal does not come from the steering angle sensor TROUBLE SYMPTOM VDC does not operate WIRING DIAGRAM VDC00247 30 29 13 B231 E 2 4 1 3 B310 B310 VDCCM H U 1 2 3 4 11 12 13 14 27 28 29 30 15 16 17 18 31 32 33 34 19 20 21 22 35 36 37 38 23 24 25 26 39 40 41 42 5 6 7 8 9 10 1 2 3 4 B231 TWISTED WIRE STEERING ANGLE SENSOR ...

Page 423: ...tance 0 5 Ω Go to step 5 Repair ground cir cuit in the steering angle sensor 5 CHECK STEERING ANGLE SENSOR HAR NESS 1 Disconnect the connector from VDCCM H U 2 Measure the resistance between VDCCM H U and steering angle sensor Connector terminal B231 No 1 B310 No 29 B231 No 2 B310 No 13 Is the resistance 0 5 Ω Go to step 6 Repair the har ness between steering angle sensor and VDCCM H U 6 CHECK GRO...

Page 424: ...pection mode 5 Read the DTC Is the same DTC displayed Replace the VDCCM H U Ref to VDC 7 VDC Control Mod ule Hydraulic Control Unit VDCCM H U Go to step 10 10 CHECK OTHER DTC DETECTION Is any other DTC displayed Perform the diag nosis according to DTC Temporary poor contact occurs 11 CHECK OTHER DTC DETECTION Is any other DTC displayed Perform the diag nosis according to DTC Original steering angl...

Page 425: ...Code DTC 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 Warning light does not illuminate though problem is detected The ABS and VDC operate normally if voltage returns ...

Page 426: ...edure with Diagnostic Trouble Code DTC WIRING DIAGRAM VDC00247 30 29 13 B231 E 2 4 1 3 B310 B310 VDCCM H U 1 2 3 4 11 12 13 14 27 28 29 30 15 16 17 18 31 32 33 34 19 20 21 22 35 36 37 38 23 24 25 26 39 40 41 42 5 6 7 8 9 10 1 2 3 4 B231 TWISTED WIRE STEERING ANGLE SENSOR ...

Page 427: ...al B231 No 3 Chassis ground Is the resistance 0 5 Ω Go to step 5 Repair ground cir cuit in the steering angle sensor 5 CHECK STEERING ANGLE SENSOR 1 Turn the ignition switch to OFF 2 Connect all the connectors 3 Erase the memory 4 Perform the inspection mode 5 Read the DTC Is the same DTC displayed Go to step 6 Go to step 8 6 CHECK VDCCM H U 1 Turn the ignition switch to OFF 2 Replace the steering...

Page 428: ...TC DETECTING CONDITION Defective yaw rate sensor TROUBLE SYMPTOM VDC does not operate WIRING DIAGRAM VDC00222 28 2 1 30 3 16 6 B312 B347 4 2 1 3 5 6 B230 1 B230 B310 VDCCM H U 1 3 4 5 6 2 B312 1 2 B310 E 1 2 3 4 11 12 13 14 27 28 29 30 15 16 17 18 31 32 33 34 19 20 21 22 35 36 37 38 23 24 25 26 39 40 41 42 5 6 7 8 9 10 YAW RATE LATERAL G SENSOR ...

Page 429: ...4 Replace the yaw rate lateral G sensor 4 CHECK OUTPUT OF STEERING ANGLE SENSOR WITH SUBARU SELECT MONI TOR 1 Drive the vehicle on a flat road 2 Park the vehicle straight 3 Select Current Data Display Save in Subaru Select Monitor 4 Read the steering angle sensor output dis played on display Is the reading indicated on monitor display 5 5 Go to step 5 Perform the cen tering adjustment of steering ...

Page 430: ...T DTC DETECTING CONDITION Defective yaw rate sensor TROUBLE SYMPTOM VDC does not operate WIRING DIAGRAM VDC00222 28 2 1 30 3 16 6 B312 B347 4 2 1 3 5 6 B230 1 B230 B310 VDCCM H U 1 3 4 5 6 2 B312 1 2 B310 E 1 2 3 4 11 12 13 14 27 28 29 30 15 16 17 18 31 32 33 34 19 20 21 22 35 36 37 38 23 24 25 26 39 40 41 42 5 6 7 8 9 10 YAW RATE LATERAL G SENSOR ...

Page 431: ...esistance between VDCCM H U and chassis ground Connector terminal B310 No 16 Chassis ground Is the resistance less than 0 5 Ω Repair the har ness between yaw rate lateral G sensor and VDCCM H U Go to step 6 6 CHECK POOR CONTACT IN CONNECTORS Is there poor contact in con nector Correct or replace the connector Go to step 10 7 CHECK YAW RATE LATERAL G SENSOR HARNESS 1 Disconnect the connector from V...

Page 432: ...to OFF 2 Connect all the connectors 3 Erase the memory 4 Perform the inspection mode 5 Read the DTC Is the same DTC displayed Replace the VDCCM H U Ref to VDC 7 VDC Control Mod ule Hydraulic Control Unit VDCCM H U Go to step 11 11 CHECK OTHER DTC DETECTION Is any other DTC displayed Perform the diag nosis according to DTC Temporary poor contact occurs Step Check Yes No ...

Page 433: ... DTC DETECTING CONDITION Defective yaw rate sensor TROUBLE SYMPTOM VDC does not operate WIRING DIAGRAM VDC00222 28 2 1 30 3 16 6 B312 B347 4 2 1 3 5 6 B230 1 B230 B310 VDCCM H U 1 3 4 5 6 2 B312 1 2 B310 E 1 2 3 4 11 12 13 14 27 28 29 30 15 16 17 18 31 32 33 34 19 20 21 22 35 36 37 38 23 24 25 26 39 40 41 42 5 6 7 8 9 10 YAW RATE LATERAL G SENSOR ...

Page 434: ... B310 No 16 Chassis ground Is the resistance less than 0 5 Ω Repair the har ness between yaw rate lateral G sensor and VDCCM H U Go to step 5 5 CHECK POOR CONTACT IN CONNECTORS Is there poor contact in con nector Correct or replace the connector Go to step 9 6 CHECK HARNESS OF YAW RATE LATER AL G SENSOR 1 Turn the ignition switch to OFF 2 Disconnect the connector from VDCCM H U 3 Measure the resis...

Page 435: ... Connect all the connectors 3 Erase the memory 4 Perform the inspection mode 5 Read the DTC Is the same DTC displayed Replace the VDCCM H U Ref to VDC 7 VDC Control Mod ule Hydraulic Control Unit VDCCM H U Go to step 10 10 CHECK OTHER DTC DETECTION Is any other DTC displayed Perform the diag nosis according to DTC Temporary poor contact occurs Step Check Yes No ...

Page 436: ...SENSOR OUTPUT DTC DETECTING CONDITION Defective yaw rate sensor TROUBLE SYMPTOM VDC does not operate WIRING DIAGRAM VDC00222 28 2 1 30 3 16 6 B312 B347 4 2 1 3 5 6 B230 1 B230 B310 VDCCM H U 1 3 4 5 6 2 B312 1 2 B310 E 1 2 3 4 11 12 13 14 27 28 29 30 15 16 17 18 31 32 33 34 19 20 21 22 35 36 37 38 23 24 25 26 39 40 41 42 5 6 7 8 9 10 YAW RATE LATERAL G SENSOR ...

Page 437: ...5 V Repair the har ness between yaw rate lateral G sensor and VDCCM H U Go to step 7 5 CHECK GROUND CIRCUIT OF YAW RATE LATERAL G SENSOR Measure the resistance between yaw rate lateral G sensor and chassis ground Connector terminal B230 No 6 Chassis ground Is the resistance less than 0 5 Ω Go to step 8 Go to step 6 6 CHECK GROUND CIRCUIT FOR VDCCM H U Measure the resistance between VDCCM H U and c...

Page 438: ...e ignition switch to OFF 2 Connect all the connectors 3 Erase the memory 4 Perform the inspection mode 5 Read the DTC Is the same DTC displayed Go to step 13 Go to step 15 13 CHECK VDCCM H U 1 Turn the ignition switch to OFF 2 Replace the yaw rate lateral G sensor 3 Erase the memory 4 Perform the inspection mode 5 Read the DTC Is the same DTC displayed Replace the VDCCM H U Ref to VDC 7 VDC Contro...

Page 439: ...nostic Procedure with Diagnostic Trouble Code DTC BB DTC C0073 LATERAL G SENSOR OUTPUT 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 BC DTC C0073 EXCESSIVE VARIATION AMOUNT OF LATERAL G SENSOR OUTPUT NOTE For the diagnostic procedure refer to DTC C0073 Ref to VDC diag 118 D...

Page 440: ...PUT DTC DETECTING CONDITION Defective lateral G sensor TROUBLE SYMPTOM VDC does not operate WIRING DIAGRAM VDC00222 28 2 1 30 3 16 6 B312 B347 4 2 1 3 5 6 B230 1 B230 B310 VDCCM H U 1 3 4 5 6 2 B312 1 2 B310 E 1 2 3 4 11 12 13 14 27 28 29 30 15 16 17 18 31 32 33 34 19 20 21 22 35 36 37 38 23 24 25 26 39 40 41 42 5 6 7 8 9 10 YAW RATE LATERAL G SENSOR ...

Page 441: ...y Save in Subaru Select Monitor 4 Read the lateral G sensor output displayed on display When the yaw rate lateral G sensor is inclined 90 to the right is the indicated value 6 8 12 8 m s2 Go to step 4 Replace the yaw rate lateral G sensor 4 CHECK LATERAL G SENSOR Read the lateral G sensor output displayed on screen When the yaw rate lateral G sensor is inclined 90 to the left is the indicated valu...

Page 442: ...C DETECTING CONDITION Defective lateral G sensor DTC DETECTING CONDITION VDC does not operate WIRING DIAGRAM VDC00222 28 2 1 30 3 16 6 B312 B347 4 2 1 3 5 6 B230 1 B230 B310 VDCCM H U 1 3 4 5 6 2 B312 1 2 B310 E 1 2 3 4 11 12 13 14 27 28 29 30 15 16 17 18 31 32 33 34 19 20 21 22 35 36 37 38 23 24 25 26 39 40 41 42 5 6 7 8 9 10 YAW RATE LATERAL G SENSOR ...

Page 443: ...teral G sensor and VDCCM H U Go to step 5 5 CHECK POOR CONTACT IN CONNECTORS Is there poor contact in con nector Correct or replace the connector Go to step 10 6 CHECK OPEN CIRCUIT IN LATERAL G SEN SOR OUTPUT HARNESS 1 Disconnect the connector from yaw rate lateral G sensor 2 Disconnect the connector from VDCCM H U 3 Measure the resistance between VDCCM H U and yaw rate lateral G sensor Connector ...

Page 444: ... sor Repair the con nector Go to step 10 10 CHECK VDCCM H U 1 Connect all the connectors 2 Erase the memory 3 Perform the inspection mode 4 Read the DTC Is the same DTC displayed Replace the VDCCM H U Ref to VDC 7 VDC Control Mod ule Hydraulic Control Unit VDCCM H U Go to step 11 11 CHECK OTHER DTC DETECTION Is any other DTC displayed Perform the diag nosis according to DTC Temporary poor contact ...

Page 445: ...OR TEST MALFUNCTION DTC DETECTING CONDITION Defective pressure sensor TROUBLE SYMPTOM ABS does not operate VDC does not operate WIRING DIAGRAM VDC00223 27 11 12 B348 B348 1 2 3 B310 VDCCM H U B310 1 2 3 4 11 12 13 14 27 28 29 30 15 16 17 18 31 32 33 34 19 20 21 22 35 36 37 38 23 24 25 26 39 40 41 42 5 6 7 8 9 10 1 2 3 PRESSURE SENSOR ...

Page 446: ...the resistance between VDCCM H U and chassis ground Connector terminal B310 No 12 Chassis ground Is the resistance less than 0 5 Ω Repair the har ness between pressure sensor and VDCCM H U Go to step 6 6 CHECK POOR CONTACT IN CONNECTORS Is there poor contact in con nector Correct or replace the connector Go to step 9 7 CHECK PRESSURE SENSOR HARNESS 1 Turn the ignition switch to OFF 2 Disconnect th...

Page 447: ...RE SENSOR OUTPUT OFFSET DTC DETECTING CONDITION Defective pressure sensor TROUBLE SYMPTOM ABS does not operate VDC does not operate WIRING DIAGRAM VDC00223 27 11 12 B348 B348 1 2 3 B310 VDCCM H U B310 1 2 3 4 11 12 13 14 27 28 29 30 15 16 17 18 31 32 33 34 19 20 21 22 35 36 37 38 23 24 25 26 39 40 41 42 5 6 7 8 9 10 1 2 3 PRESSURE SENSOR ...

Page 448: ... with Di agnostic Trouble Code DTC Step Check Yes No 1 CHECK STOP LIGHT SWITCH CIRCUIT Check stop light switch open circuit Is the stop light switch circuit OK Go to step 2 Repair the stop light switch circuit 2 CHECK VDCCM H U 1 Connect all the connectors 2 Erase the memory 3 Perform the inspection mode 4 Read the DTC Is the same DTC displayed Replace the VDCCM H U Ref to VDC 7 VDC Control Mod ul...

Page 449: ... SENSOR OUTPUT DTC DETECTING CONDITION Defective pressure sensor TROUBLE SYMPTOM ABS does not operate VDC does not operate WIRING DIAGRAM VDC00223 27 11 12 B348 B348 1 2 3 B310 VDCCM H U B310 1 2 3 4 11 12 13 14 27 28 29 30 15 16 17 18 31 32 33 34 19 20 21 22 35 36 37 38 23 24 25 26 39 40 41 42 5 6 7 8 9 10 1 2 3 PRESSURE SENSOR ...

Page 450: ... and chassis ground Connector terminal B348 No 1 Chassis ground Is the resistance less than 0 5 Ω Go to step 8 Go to step 6 6 CHECK GROUND CIRCUIT OF VDCCM H U Measure the resistance between VDCCM H U and chassis ground Connector terminal B310 No 12 Chassis ground Is the resistance less than 0 5 Ω Repair the har ness between pressure sensor and VDCCM H U Go to step 7 7 CHECK POOR CONTACT IN CONNEC...

Page 451: ...MICS CONTROL VDC DIAGNOSTICS Diagnostic Procedure with Diagnostic Trouble Code DTC 11 CHECK OTHER DTC DETECTION Is any other DTC displayed Perform the diag nosis according to DTC Temporary poor contact occurs Step Check Yes No ...

Page 452: ...R MALFUNCTION DTC DETECTING CONDITION Defective pressure sensor TROUBLE SYMPTOM ABS does not operate VDC does not operate WIRING DIAGRAM VDC00216 SBF 1 SBF 7 No 33 B310 B310 E E 6 14 VDCCM H U 1 2 3 4 11 12 13 14 27 28 29 30 15 16 17 18 31 32 33 34 19 20 21 22 35 36 37 38 23 24 25 26 39 40 41 42 5 6 7 8 9 10 BATTERY GENERATOR IGNITION SWITCH ...

Page 453: ...he voltage 10 15 V Go to step 3 Check the power supply circuit in VDCCM H U 3 CHECK VDCCM H U 1 Connect all the connectors 2 Erase the memory 3 Perform the inspection mode 4 Read the DTC Is the same DTC displayed Replace the VDCCM H U Ref to VDC 7 VDC Control Mod ule Hydraulic Control Unit VDCCM H U Go to step 4 4 CHECK OTHER DTC DETECTION Is any other DTC displayed Perform the diag nosis accordin...

Page 454: ...ake Axle and wheels Brake pedal play Defective steering angle sensor or improper neutral position Defective yaw rate lateral G sensor or improper installation Brake pad Brake pipe Long brake pedal stroke Aeration to brake line Brake pedal play VDCCM H U Master cylinder Brake caliper Brake pad Brake pipe Brake booster Vehicle vertical pitching VDCCM H U Road surface uneven Suspension play or fatigu...

Page 455: ...ke booster Suspension play or fatigue poor damp ing Axle and wheels Tire specifications tire wear and air pressures Noise inside passenger seat VDCCM H U Defective steering angle sensor or improper neutral position Defective yaw rate lateral G sensor or improper installation Noise from the rear side of vehicle Defective ABS wheel speed sensor or sensor gap Brake caliper Brake pad Disc rotor Parkin...

Page 456: ... wear and air pressures Incorrect wiring or piping connections Brake caliper Brake pipe Steering wheel drag while driving VDCCM H U Defective ABS wheel speed sensor or sensor gap Defective steering angle sensor or improper neutral position Defective yaw rate lateral G sensor or improper installation Incorrect wiring or piping connections Power steering system Brake caliper Brake pad Disc rotor Whe...

Page 457: ... the VDC OFF switch is depressed NOTE When pressing VDC OFF switch for more than 10 seconds VDC OFF indicator light goes off and cannot operate any more When turning the ignition switch from OFF to ON the previous status is restored Harness Indicator light bulb VDC OFF switch Symptom Main probable cause Other probable cause ...

Page 458: ...VDC diag 136 VEHICLE DYNAMICS CONTROL VDC DIAGNOSTICS General Diagnostic Table ...

Page 459: ...s 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...

Page 460: ...or 19 4 Front Disc Brake Assembly 20 5 Rear Brake Pad 25 6 Rear Disc Rotor 26 7 Rear Disc Brake Assembly 28 8 Master Cylinder 30 9 Brake Booster 32 10 Brake Fluid 36 11 Air Bleeding 38 12 Brake Hose 40 13 Brake Pipe 42 14 Brake Pedal 43 15 Stop Light Switch 45 16 Diagnosis 47 ...

Page 461: ... Disc Floating type solid Disc Floating type ven tilated Effective disc diameter mm in 238 9 37 254 10 0 Disc thickness Outer diameter mm in 10 274 0 39 10 79 18 290 0 71 11 42 Effective cylinder diameter mm in 38 1 1 500 Pad dimensions length width thick ness mm in 92 0 33 0 9 0 3 622 1 299 0 354 82 4 33 7 9 0 3 244 1 327 0 354 Clearance adjustment Automatic adjustment Master cylinder Type Tandem...

Page 462: ...out mm in 0 05 0 0020 Parking brake Inside diameter mm in 170 6 69 171 6 73 Lining thickness mm in 3 2 0 126 1 5 0 059 Lever stroke 5 6 notches 200 N 20 kgf 45 lb Brake pedal force N kgf lb Fluid pressure kPa kg cm2 psi 15 inch type 16 inch type 17 inch type Brake Booster Brake fluid pressure without engine running 147 15 33 545 6 79 294 30 66 1 564 16 227 Brake fluid pressure with engine running ...

Page 463: ... Yellow 17 Bushing 9 Support 1 Caliper body 10 Pad clip Tightening torque N m kgf m ft lb 2 Air bleeder screw 11 Outer shim T1 8 0 8 5 8 3 Guide pin Green 12 Inner shim T2 27 2 8 19 9 4 Pin boot 13 Pad Outside T3 80 8 2 59 5 Piston seal 14 Pad Inside 6 Piston 15 Disc rotor BR 00332 1 2 3 4 4 17 10 11 11 12 12 16 A B 13 14 15 5 6 7 9 8 T2 T3 11 11 12 12 13 14 13 T1 ...

Page 464: ... clip 3 Guide pin Green 11 Outer shim Tightening torque N m kgf m ft lb 4 Pin boot 12 Inner shim T1 8 0 8 5 8 5 Piston seal 13 Pad Outside T2 27 2 8 19 9 6 Piston 14 Pad Inside T3 80 8 2 59 7 Piston boot 15 Disc rotor 8 Lock pin Yellow 16 Disc cover BR 00373 1 2 3 4 4 17 10 11 11 12 16 13 14 15 5 6 7 9 8 T2 T3 T1 ...

Page 465: ...olid disc brake 7 Piston boot 21 Parking brake shoe Secondary 35 Bolt For ventilated disc brake 8 Support 22 Parking brake shoe Primary 9 Lock pin Yellow 23 Strut Tightening torque N m kgf m ft lb 10 Bushing 24 Strut shoe spring T1 8 0 8 5 8 11 Pad clip 25 Shoe guide plate T2 27 2 8 19 9 12 Inner pad 26 Secondary shoe return spring T3 37 3 8 27 5 13 Outer pad 27 Primary shoe return spring T4 53 5 ...

Page 466: ...STER CYLINDER LHD model 1 Cap 6 Secondary piston 11 O ring 2 Filter 7 Cylinder body 3 Reservoir tank 8 Cylinder pin Tightening torque N m kgf m ft lb 4 C ring 9 Seal T 13 1 3 9 6 5 Primary piston 10 Pin BR 00371 T 1 2 3 7 8 9 10 4 11 5 6 ...

Page 467: ...tion RHD model 1 Cap 6 Secondary piston 11 O ring 2 Filter 7 Cylinder body 3 Reservoir tank 8 Cylinder pin Tightening torque N m kgf m ft lb 4 C ring 9 Seal T 13 1 3 9 6 5 Primary piston 10 Pin BR 00334 T 1 2 3 7 8 9 10 4 11 5 6 ...

Page 468: ...BS control module and hydraulic control unit ABSCM H U T2 18 1 8 13 0 T3 19 1 9 14 0 1 Front brake pipe ASSY 8 Bracket T4 33 3 4 24 3 2 Two way connector 9 Master cylinder 3 Front brake hose RH 10 VDC control module hydraulic control unit VDCCM H U 4 Front brake hose LH BR 00372 T1 T2 T4 T2 T2 T2 T4 T1 T1 8 2 3 5 6 4 7 6 5 T1 T2 T4 T2 T2 T2 T4 T3 T3 8 2 3 5 6 4 10 6 5 A B T1 T1 T1 1 9 T3 T1 T3 1 9...

Page 469: ... H U T1 15 1 5 10 8 T2 18 1 8 13 0 1 Front brake pipe ASSY 8 Bracket T3 19 1 9 14 0 2 Two way connector 9 Master cylinder T4 33 3 4 24 3 3 Front brake hose RH 10 VDC control module hydraulic control unit VDCCM H U 4 Front brake hose LH 5 Clamp BR 00336 T1 T1 T1 T1 T2 T4 T2 T2 T2 T4 T1 T1 1 8 2 9 3 5 6 4 7 6 5 T1 T3 T3 T1 T2 T4 T2 T2 T2 T4 T3 T3 1 8 2 9 3 5 6 4 10 6 5 A B ...

Page 470: ...m ft lb 2 Two way connector 8 Rear brake hose rear RH T1 15 1 5 10 8 3 Rear brake pipe ASSY 9 Rear brake hose rear LH T2 18 1 8 13 0 4 Rear brake hose RH 10 Clamp T3 33 3 4 24 3 5 Rear brake hose LH 11 Gasket 6 Rear brake pipe RH 12 Bracket BR 00337 1 T1 T1 T2 T1 T2 T3 T1 T3 T3 T3 T1 T2 T2 T1 2 3 5 7 9 4 6 8 10 10 10 10 10 11 11 11 11 10 T1 12 ...

Page 471: ...BR 12 BRAKE General Description 6 BRAKE BOOSTER 1 Brake booster BR 00335 1 ...

Page 472: ...7 BRAKE PEDAL LHD MT model 1 Brake pedal ASSY 4 Clutch pedal Tightening torque N m kgf m ft lb 2 Stop light switch 5 Clutch pedal pad T1 8 0 8 5 8 3 Brake pedal pad 6 Clutch switch T2 18 1 8 13 0 BR 00375 T2 5 4 3 2 6 1 T2 T2 T1 T1 T2 ...

Page 473: ...BR 14 BRAKE General Description LHD AT model RHD model 1 Brake pedal ASSY 3 Brake pedal pad Tightening torque N m kgf m ft lb 2 Stop light switch T1 8 0 8 5 8 T2 18 1 8 13 0 BR 00338 T2 T1 T2 T1 1 2 3 ...

Page 474: ...uine grease etc or equivalent Do not mix grease etc with that of another grade or from other manufacturers Before securing a part on a vice place cushion ing material such as wood blocks aluminum plate or shop cloth between the part and the vice Be sure to tighten fasteners including bolts and nuts to the specified torque Place shop jacks or rigid racks at the specified points D PREPARATION TOOL 1...

Page 475: ... wooden blocks 4 Attach a rod of less than 12 mm 0 47 in di ameter to the shaded area of the brake pad and strike the rod with a hammer to drive brake pad out of place 2 16 INCH TYPE Refer to 15 inch type Ref to BR 16 15 INCH TYPE REMOVAL Front Brake Pad 3 17 INCH TYPE Refer to 15 inch type Ref to BR 16 15 INCH TYPE REMOVAL Front Brake Pad B INSTALLATION 1 15 INCH TYPE 1 Apply a thin coat of Molyk...

Page 476: ...of Molykote M7439 to the pad clip 2 Apply a thin coat of Molykote AS880N Part No K0779YA010 to the frictional portion between pad and pad inner shim 3 Apply a thin coat of Molykote AS880N Part No K0779YA010 to the three frictional portions be tween inner shim and outer shim of outer pads 4 Install the pad on support NOTE Install the pad indicator in proper direction CAUTION Correctly install the p...

Page 477: ...lips if they are twisted or worn Replace the pad if there is oil or grease on it 2 16 INCH TYPE Refer to 15 inch type Ref to BR 18 15 INCH AND 16 INCH TYPE INSPECTION Front Brake Pad 3 17 INCH TYPE Check the pad thickness A NOTE Always replace the pads for both right and left wheels at the same time Replace the pad if there is oil or grease on it 1 Pad return spring 2 Supporting surface of pad cli...

Page 478: ...ous ing Tightening torque 80 N m 8 2 kgf m 59 ft lb 3 Install the front wheels C INSPECTION 1 Check front wheel bearing play and axial hub runout before disc rotor runout limit inspection Ref to DS 15 INSPECTION Front Axle 2 Secure the disc rotor by tightening five wheel nuts 3 Set a dial gauge 10 mm 0 39 in inward of rotor outer perimeter Turn the disc rotor to check runout If the disc rotor runo...

Page 479: ...using NOTE Remove the support only when replacing itself or rotor It need not be removed when servicing the caliper body assembly 6 Clean mud and foreign particles from the caliper body assembly and the support 2 16 INCH TYPE Refer to 15 inch type Ref to BR 20 15 INCH TYPE REMOVAL Front Disc Brake Assembly 3 17 INCH TYPE Refer to 15 inch type Ref to BR 20 15 INCH TYPE REMOVAL Front Disc Brake Asse...

Page 480: ... m 13 0 ft lb 8 Bleed air from brake system 2 16 INCH TYPE Refer to 15 inch type Ref to BR 20 15 INCH TYPE INSTALLATION Front Disc Brake Assem bly 3 17 INCH TYPE 1 Install the support on housing Tightening torque 80 N m 8 2 kgf m 59 ft lb 2 Apply a thin coat of Molykote M7439 to the pad clip 3 Apply a thin coat of Molykote AS880N Part No K0777YA010 to the frictional portion between pad and inner s...

Page 481: ...CH TYPE 1 Clean mud and foreign particles from the caliper body assembly and the support CAUTION Be careful not to allow foreign particles to enter inlet at brake hose connector 2 Place a wooden block in caliper body as shown in the figure to prevent piston from jumping out and avoid being damaged 3 Gradually supply compressed air via installation hole of brake hose to force the piston out 4 Remov...

Page 482: ...fluid to the entire inner sur face of cylinder and outer surface of piston 4 Apply a coat of specified grease to the boot and fit in to the groove on ends of cylinder Grease NIGLUBE RX 2 Part No K0779GA102 5 Insert the piston into cylinder CAUTION Do not force the piston into cylinder 6 Position the boot in the grooves on cylinder and piston 7 Apply a coat of specified grease to the lock pin and g...

Page 483: ...SSEMBLY 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 2 Check the caliper body and piston for uneven wear damage or rust 3 Check the rubber parts for damage and deterio ration ...

Page 484: ...pport 4 Install the caliper body on support Tightening torque Solid disc brake model 27 N m 2 8 kgf m 19 9 ft lb Ventilated disc brake model 37 N m 3 7 kgf m 27 2 ft lb C INSPECTION Check the pad thickness A NOTE Always replace the pads for both right and left wheels at the same time Also replace pad clips if they are twisted or worn A wear indicator is provided on the inner disc brake pad If the ...

Page 485: ...rotor out by pushing with an 8 mm bolt in holes B on the rotor B INSTALLATION 1 Install in the reverse order of removal 2 Adjust the parking brake Ref to PB 9 AD JUSTMENT Parking Brake Assembly Rear Disc Brake C INSPECTION 1 Check rear wheel bearing play and axial hub runout before disc rotor runout limit inspection Ref to DS 21 INSPECTION Rear Hub Unit Bearing 2 Secure the disc rotor by tightenin...

Page 486: ...ter 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 A B BR 00036 Standard value Limit Disc outer dia Disc rotor thickness A mm in Solid disc 10 0 39 8 5 0 335 274 10 79 Ventilated disc 18 0 71 16 0 63 290 11 42 ...

Page 487: ...CAUTION Be careful not to allow foreign particles to enter inlet at brake hose connector B INSTALLATION 1 Install the support on housing Tightening torque 53 N m 5 4 kgf m 39 1 ft lb 2 Apply a thin coat of Molykote M7439 to the pad clip 3 Apply a thin coat of Molykote AS880N Part No K0777YA010 to the frictional portion between pad and shim 4 Install the pad on support 5 Install the caliper body on...

Page 488: ...ds of cylinder Grease NIGLUBE RX 2 Part No K0779GA102 5 Insert the piston into cylinder CAUTION Do not force the piston into cylinder 6 Position the boot in grooves on cylinder and pis ton 7 Apply a coat of specified grease to the guide pin outer surface sleeve outer surface cylinder inner surface and boot grooves Grease NIGLUBE RX 2 Part No K0779GA102 8 Install the guide pin boot on support 9 Ins...

Page 489: ...Air Bleeding C REPLACEMENT 1 Remove mud and dirt from the surface of brake master cylinder 2 Secure the master cylinder on a vise NOTE To avoid damaging master cylinder use aluminum plate while holding with vise 3 Remove the pin which secures the reservoir tank to master cylinder and then remove the reservoir tank and seal 4 With pushing in the primary piston remove the C ring using pliers 5 With ...

Page 490: ... CAUTION Ensure the secure installation 12 Install the seal to reservoir tank 13 Install the reservoir tank to master cylinder and secure with pin 14 Replace the O ring for the master cylinder with a new one D INSPECTION Inspect for oil leakage from the master cylinder NOTE After replacing piston kit when the oil leakage is found without damaging or scratching the inside of cylinder wear of master...

Page 491: ...n dropped Use special care when handling the operating rod If excessive force is applied to operating rod sufficient to cause a change in the angle in excess of 3 it may result in damage to the power piston cylinder Use care when placing the brake booster on the floor Do not change the push rod length CAUTION Do not disassemble the brake booster If external force is applied from above when brake b...

Page 492: ...witch CAUTION Be careful not to rotate the stop light switch Stop light switch clearance A 0 3 mm 0 012 in 9 Apply grease to operating rod connecting pin to prevent it from wearing 10 Bleed air from brake system Tightening torque Air bleeder screw 8 N m 0 8 kgf m 5 8 ft lb 11 Conduct road tests to ensure brakes do not drag C INSPECTION 1 OPERATION CHECK WITHOUT GAUG ES CAUTION When checking operat...

Page 493: ...pedal 2 With the brake pedal depressed start the en gine 3 As engine starts the brake pedal should move slowly toward the floor If no change occurs in the pedal height the brake booster is faulty NOTE If faulty check precisely with gauges LOADED AIR TIGHTNESS CHECK Depress the brake pedal while engine is running and turn OFF the engine while the pedal is still de pressed Keep the pedal depressed f...

Page 494: ...watch vacuum gauge If the vacuum drop range is less than 3 3 kPa 25 mmHg 0 98 inHg within 15 seconds after stopping the engine brake booster is functioning properly If defective refer to AIR TIGHTNESS CHECK Ref to BR 33 INSPECTION Brake Booster 3 If any fault is found on brake booster replace the brake booster with a new one LACK OF BOOSTING ACTION CHECK Turn OFF the engine and set the vacuum gaug...

Page 495: ...tely 500 m2 16 9 US fl oz 17 6 Imp fl oz for to tal brake system 1 Either lift up the vehicle to place a rigid rack un der it or lift up the vehicle 2 Remove both the front and rear wheels 3 Draw out the brake fluid from master cylinder 4 Refill the reservoir tank with recommended brake fluid Recommended brake fluid Refer to the specification Ref to BR 2 SPECIFICATION General Description 5 Install...

Page 496: ... 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 12 Install the wheels and drive vehicle for a short distance between 2 to 3 km 1 to 2 miles to make sure that brakes are operating properly ...

Page 497: ... wheels 2 Disconnect the brake line at primary and sec ondary sides 3 Put a plastic bag cover on master cylinder 4 Carefully depress and hold the brake pedal 5 Close the outlet plug with your finger and then release the brake pedal 6 Repeat the step4 and 5 until brake fluid is com pletely drained from outlet plug 7 Remove the plastic bag 8 Install the brake pipes to master cylinder Tightening torq...

Page 498: ... the entire system 6 Check the pedal stroke While the engine is idling after warming up de press the brake pedal with a 500 N 51 kgf 112 lb load and measure the distance between brake ped al and steering wheel With the brake pedal re leased measure the distance between pedal and steering wheel again The difference between the two measurements must not be more than speci fied value Specified pedal ...

Page 499: ...ve the brake hose B INSTALLATION 1 FRONT BRAKE HOSE 1 Secure the brake hose to strut mount Tightening torque 33 N m 3 4 kgf m 24 3 ft lb 2 Install the brake hose to caliper using a new gas ket Tightening torque Union bolt 18 N m 1 8 kgf m 13 0 ft lb 3 Position the disc in straight forward direction and route the brake hose through the hole in bracket on wheel apron side 1 Brake hose 2 Brake pipe 1...

Page 500: ... connect brake pipe 2 Insert the clamp upward to fix brake hose 3 Install the brake hose to rear brake caliper using a new gasket Tightening torque Union bolt 18 N m 1 8 kgf m 13 0 ft lb 4 Tighten the flare nut to specified torque Tightening torque Brake pipe flare nut 15 N m 1 5 kgf m 10 8 ft lb 5 Bleed air from the brake system C INSPECTION Ensure there are no cracks breakage or damage on hoses ...

Page 501: ...ring 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 center brake pipe When installing the brake pipe make sure that it is not bent After installing the brake pipe and hose bleed air After installing the brake hose make sure that it does not touch the tire or suspensi...

Page 502: ...itch from pedal bracket 3 Remove the clevis pin which secures lever to push rod 4 Remove the bolts and nuts which secure pedal bracket 3 RHD MODEL Refer to LHD AT model Ref to BR 43 LHD AT MODEL REMOVAL Brake Pedal B INSTALLATION 1 Install in the reverse order of removal CAUTION Always use new clevis pins 2 Inspect the brake pedal after installation Ref to BR 43 INSPECTION Brake Pedal C INSPECTION...

Page 503: ...ht L LHD 150 160 mm 5 91 6 30 in RHD 162 172 mm 6 38 6 77 in Brake pedal free play A 0 5 2 mm 0 02 0 08 in When the brake pedal is pulled upward with force of less than 10 N 1 kgf 2 lb 3 If it is not within the specified value adjust it by adjusting the brake booster operating rod length 1 Brake pedal 1 Stop light switch 2 Mat 3 Toe board 4 Brake booster operating rod 1 BR 00105 1 3 4 2 A BR 00106...

Page 504: ...x at the specified position re place with a new one Specified position L 2 mm 0 079 in 2 Measure the clearance between the threaded end of stop light switch and stopper CAUTION Be careful not to rotate the stop light switch Stop light switch clearance A 0 3 mm 0 012 in 3 If it is not within the specified value adjust it by adjusting the position of stop light switch CAUTION Be careful not to rotat...

Page 505: ...the clearance between the threaded end of stop light switch and stopper becomes 0 mm 0 inch Hold the stop light switch to prevent turning and then loosen the lock nut B approx 60 The clearance A becomes 0 3 mm 0 012 in 1 Stop light switch 2 Lock nut A 3 Lock nut B 4 Stopper 5 Brake pedal 5 4 1 A 2 3 BR 00111 ...

Page 506: ...k adjust or replace the rear brake and cable system 3 Excessive pedal stroke 1 Entry of air into the hydraulic mechanism Bleed air 2 Excessive play in the master cylinder push rod Adjust 3 Fluid leakage from the hydraulic mechanism Correct or replace cup piston seal piston boot master cylinder piston kit pipe or hose 4 Improper lining contact or worn lining Correct or replace 4 Brake dragging or i...

Page 507: ...BR 48 BRAKE Diagnosis ...

Page 508: ...s 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...

Page 509: ...PARKING BRAKE PB Page 1 General Description 2 2 Parking Brake Lever 5 3 Parking Brake Cable 6 4 Parking Brake Assembly Rear Disc Brake 7 5 General Diagnostic Table 10 ...

Page 510: ...SPECIFICATION Type Mechanical on rear brakes drum in disc Effective drum diameter mm in 170 6 69 Lining dimensions length width thickness mm in 163 1 30 0 3 2 6 421 1 181 0 126 Clearance adjustment Manual adjustment Lever stroke notches N kgf lb 5 to 6 200 20 4 45 ...

Page 511: ...iner 8 Strut 14 Shoe hold down cup 3 Spring washer 9 Shoe guide plate 15 Shoe hold down spring 4 Lever 10 Primary return spring 16 Shoe hold down pin 5 Parking brake shoe Primary 11 Secondary return spring 17 Adjusting hole cover 6 Parking brake shoe Secondary 12 Adjusting spring PB 00048 16 10 13 11 9 6 2 1 17 3 4 7 8 14 15 12 5 ...

Page 512: ...tc with that of another grade or from other manufacturers Be sure to tighten fasteners including bolts and nuts to the specified torque Place shop jacks or rigid racks at the specified points Before securing a part on a vice place cushion ing material such as wood blocks aluminum plate or shop cloth between the part and the vice Keep grease etc away from parking brake shoes 1 Parking brake lever 6...

Page 513: ...tall a new adjusting nut self locking nut 3 Adjust the lever stroke Ref to PB 5 ADJUST MENT Parking Brake Lever C INSPECTION 1 Operate the parking brake lever 3 to 4 times and return the lever fully 2 While pulling the parking brake lever upward count the notches Lever stroke 5 to 6 notches when pulled with a force of 200 N 20 4 kgf 45 lb If it is not within the specified value adjust the park ing...

Page 514: ...embly Rear Disc Brake 9 Remove the clamp from rear brake 10 Remove the cable clamp from rear arm brack et 11 Remove the cable clamp from rear floor 12 Remove the cable assembly B INSTALLATION 1 Install in the reverse order of removal NOTE Be sure to pass the cable through the cable guide inside tunnel 2 Adjust the lever stroke Ref to PB 5 ADJUST MENT Parking Brake Lever C INSPECTION Check and repl...

Page 515: ... the disc rotor seizes up within hub drive out the disc rotor by pushing two 8 mm bolts in holes B on rotor 5 Remove the shoe return spring from parking brake assembly 6 Remove the front shoe hold down spring and pin 7 Remove the strut and strut spring 8 Remove the adjuster assembly from parking brake assembly 9 Remove the brake shoe 10 Remove the rear shoe hold down spring and pin with pliers 11 ...

Page 516: ...se cure the secondary side brake shoe with shoe hold down pin and cup NOTE Install the strut spring of both right and left wheel facing vehicle front Install the adjuster assembly with screw on left side 7 Install the secondary return spring and adjusting spring 8 Adjust the parking brake Ref to PB 9 AD JUSTMENT Parking Brake Assembly Rear Disc Brake 9 Drive the vehicle for parking brake lining br...

Page 517: ...ose contact with disc rotor 4 Turn back downward the adjusting screw 3 to 4 notches CAUTION Check there is no brake drag 5 Install the adjusting hole cover to back plate 6 Adjust the parking lever stroke Ref to PB 9 LEVER STROKE ADJUSTMENT Parking Brake Assembly Rear Disc Brake 2 LEVER STROKE 1 Adjust the shoe clearance before lever stroke adjustment Ref to PB 9 SHOE CLEARANCE ADJUSTMENT Parking B...

Page 518: ...le cause Remedy Brake drag Parking brake lever is maladjusted Adjustment Parking brake cable does not move Repair or replace Parking brake shoe clearance is maladjusted Adjustment Return spring is faulty Replace Noise from brake Return spring is faulty Replace Shoe hold down spring is faulty Replace ...

Page 519: ...s 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...

Page 520: ...ering Wheel 20 3 Universal Joint 21 4 Tilt Steering Column 23 5 Steering Gearbox LHD Model 25 6 Steering Gearbox RHD Model 46 7 Pipe Assembly LHD Model 65 8 Pipe Assembly RHD Model 71 9 Oil Pump 77 10 Reservoir Tank 83 11 Power Steering Fluid 84 12 General Diagnostic Table 85 ...

Page 521: ...mp Power steering system Type Vane pump Oil tank Installed on body Specific output cm3 cu in rev 7 2 0 439 8 5 0 519 9 6 0 586 Relief pressure kPa kg cm2 psi 6 767 7 453 69 76 981 1 081 7 350 8 036 75 82 1 067 1 165 8 300 9 000 85 92 1 204 1 305 Hydraulic fluid control Dropping in response to increased engine revolutions Hydraulic fluid 2 US qt Imp qt 1 000 rpm 6 5 6 9 5 7 3 000 rpm 5 5 3 4 4 1 00...

Page 522: ...r less Vertical movement 0 4 0 016 or less RHD 0 3 0 16 or less Input shaft play In radial direction mm in 0 18 0 0071 or less In axial direction mm in 0 27 0 0106 or less Resistance to rotation N kgf lb Maximum allowable value 13 1 3 2 9 or less Difference between right and left sliding resistance Less than 20 Oil pump Power steering system Pulley shaft Radial play mm in 0 4 0 016 or less Axial p...

Page 523: ...EERING WHEEL AND COLUMN 1 Bushing 5 Steering wheel Tightening torque N m kgf m ft lb 2 Steering shaft 6 Airbag module T1 1 2 0 12 0 9 3 Steering roll connector 7 Steering wheel lower cover T2 25 2 5 18 1 4 Column cover 8 Insulator T3 45 4 6 33 2 PS 00501 T2 T1 T3 6 5 8 1 2 3 4 7 ...

Page 524: ...n hose Turbo model 4 Clip 13 Suction hose Turbo model Tightening torque N m kgf m ft lb 5 Clamp E 14 Suction hose Turbo model T1 7 4 0 75 5 4 6 O ring 15 Return hose T2 17 6 1 79 13 0 7 Cap 16 Oil cooler T3 12 7 1 30 9 4 8 Reservoir tank 17 Return hose T4 15 1 5 10 8 9 Pulley 18 Hose bracket T5 39 2 4 0 28 9 PS 00479 T3 T3 T2 T1 T3 T5 11 1 12 4 13 4 4 8 7 19 15 19 20 2 19 19 17 18 5 6 10 9 4 3 16 ...

Page 525: ... 6 62 2 10 Seal ring 29 Band T4 13 1 3 9 4 11 Pinion valve ASSY 30 Tie rod T5 15 1 5 10 8 12 Oil seal 31 Pipe B T6 24 2 4 17 4 13 Back up washer 32 Pipe A T7 25 2 5 18 1 14 Ball bearing 33 Steering body T8 27 2 75 19 9 15 Snap ring 34 Oil seal T9 60 6 1 44 1 16 Lock nut 35 Piston ring T10 39 4 0 28 9 17 Adjusting screw 36 Rack T11 78 8 0 57 9 18 Spring 37 Rack bushing 19 Sleeve 38 Holder T9 T8 T5 ...

Page 526: ...seal 8 Oil seal 24 O ring Tightening torque N m kgf m ft lb 9 Adapter 25 Rack T1 27 2 75 19 9 10 Clamp 26 Oil seal T2 85 8 6 62 2 11 Castle nut 27 Back up washer T3 20 2 0 14 5 12 Cotter pin 28 Steering body T4 24 2 4 17 4 13 Dust seal 29 Pipe A T5 64 6 5 47 0 14 Clip 30 Pipe B T6 90 9 0 65 1 15 Tie rod end 31 Lock nut T7 60 6 1 44 1 16 Clip 32 Adjusting screw T8 39 4 0 28 9 1 2 3 4 5 7 6 9 10 11 ...

Page 527: ...TEERING General Description 3 OIL PUMP 1 Oil pump Tightening torque N m kgf m ft lb 2 Pulley T1 8 0 8 5 8 3 Bracket T2 15 7 1 6 11 6 4 Belt tension nut T3 22 2 2 15 9 T4 25 2 5 18 1 T5 37 3 3 8 27 5 PS 00480 T4 T3 T3 T5 T1 T2 T3 3 2 1 4 ...

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 Be sure to tighten fasteners including bolts and nuts to the specified torque Place shop jacks or rigid racks at the specified points Before securing a part on a ...

Page 529: ...00 PRESSURE GAUGE Used for measuring oil pump pressure 926200000 STAND Used when inspecting characteristic of gear box assembly and disassembling it Used with BOSS D 34199AG000 34099AC010 ADAPTER HOSE A Used with PRESSURE GAUGE 925711000 34099AC020 ADAPTER HOSE B Used with PRESSURE GAUGE 925711000 ST 925711000 ST 926200000 ST34099AC010 ST34099AC020 ...

Page 530: ...ing resistance of gearbox assembly 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 926250000 GUIDE Used for installing holder assembly into rack housing Except for turbo and 3 0 R model ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS ST 926230000 ST34099PA100 ST 926420000 ST 926250000 ...

Page 531: ...ulking 34099FA080 PUNCH Used for removing caulking For RHD model 34199AE090 PLUG WRENCH Used for removing plug For RHD model 34199AE100 OIL SEAL PLUG REMOVER Used for removing oil seal plug For RHD model ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS ST34099FA060 ST34099FA080 ST34199AE090 ST34199AE100 ...

Page 532: ...GEARBOX OIL SEAL REMOVER Used for removing gearbox oil seal For RHD model 34199AE130 GEARBOX OIL SEAL INSTALLER Used for installing gearbox oil seal For RHD model 34199FE040 INSTALLER A B C Used for installing oil seal to rack assembly For turbo and 3 0 R model ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS ST34199AE110 ST34199AE120 ST34199AE130 ST34199FE040 ...

Page 533: ...9FE010 REMOVER Used for removing backup ring and oil seal For turbo and 3 0 R model 927580000 REMOVER Used for removing backup ring and oil seal Except for turbo and 3 0 R model 34199FE050 GUIDE Used for installing rack and seal into housing assembly For turbo and 3 0 R model ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS ST 927490000 ST34199FE010 ST 927580000 ST34199FE050 ...

Page 534: ...ed for removing and installing rack oil seal outer inner For turbo and 3 0 R model 34199FA030 INSTALLER REMOVER Used for removing and installing rack oil seal outer inner Except for turbo and 3 0 R model 34199FE060 INSTALLER Used for installing rack oil seal outer For turbo and 3 0 R model For RHD model ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS ST34199AE000 ST34199FE000 ST34199FA030 ST34199FE06...

Page 535: ... Used for support housing assembly For turbo and 3 0 R model For RHD model 34099FA070 BASE Used for support housing assembly Except for turbo and 3 0 R model For RHD model 34199AG000 BOSS D Used for inspecting characteristic of gearbox assembly and disassembling it Used with STAND 926200000 ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS ST34199AE010 ST34199FE020 ST34099FA070 ST34199AG000 ...

Page 536: ...LHD model 34199AG030 GUIDE Used for installing seal ring of rack Except for 3 0 R model For LHD model 34199AG070 FORMER Used for forming seal ring of pinion For LHD model 34199AG020 GUIDE Used for installing seal ring of pinion For LHD model ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS ST34199AG040 ST34199AG030 ST34199AG070 ST34199AG020 ...

Page 537: ...50 GUIDE G 24 Used for forming seal ring of rack Except for 3 0 R model For LHD model Used with FORMER PISTON 34199AG080 34199AE050 OIL SEAL REMOVER Used for removing oil seal Except for 3 0 R model For LHD model 34099PA010 OIL SEAL REMOVER Used for removing oil seal For 3 0 R model For LHD model ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS ST34199AG060 ST34199AG050 ST34199AE050 ST34099PA010 ...

Page 538: ...ll bearing of valve hous ing Used for removing oil seal and ball bearing from valve housing For LHD model 34199AG080 FORMER PISTON Used for forming seal of rack For LHD model Used with GUIDE G 26 34199AG060 or GUIDE G 24 34199AG050 34199AG010 INSTALLER Used for press fit oil seal of gearbox cylinder For LHD model ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS ST34199AG090 ST34199AG080 ST34199AG010 ...

Page 539: ...fer to Airbag System before per forming airbag module service Ref to AB 4 CAUTION General Description 1 Align the center of roll connector Ref to AB 23 ADJUSTMENT Roll Connector 2 Install in the reverse order of removal NOTE Align the alignment marks on the steering wheel and steering shaft Tightening torque 45 N m 4 6 kgf m 33 2 ft lb Column cover to steering wheel clearance 2 4 mm 0 08 0 16 in C...

Page 540: ...AUTION Excessively large tightening torque of univer sal joint bolts may lead to heavy steering wheel operation Clearance between coupling of universal joint to turbo cover 15 mm 0 59 in or more 4 Align the center of roll connector Ref to AB 23 ADJUSTMENT Roll Connector 5 Install the steering wheel Ref to PS 20 IN STALLATION Steering Wheel C INSPECTION Check for wear damage or any other faults If ...

Page 541: ...limit Maximum load 3 8 N 0 39 kgf 0 86 lb or less Service limit Maximum load 7 3 N 0 74 kgf 1 64 lb or less Service limit Maximum load 7 3 N 0 74 kgf 1 64 lb or less 1 Yoke Gearbox side 1 Yoke Steering column side 1 Yoke Steering column side PS 00035 PS 00036 PS 00037 ...

Page 542: ...r 5 Remove all connectors from the steering col umn 6 Remove the two bolts under instrument panel securing steering column 7 Pull out the steering shaft assembly from the hole on toe board CAUTION Be sure to remove the universal joint before removing steering shaft assembly installing bolts when removing steering shaft assembly or when lowering it for servicing of other parts Do not loosen the til...

Page 543: ...teering Wheel CAUTION Insert roll connector guide pin into guide hole on lower end of steering wheel surface to pre vent damage C DISASSEMBLY Remove the two screws securing upper steering column covers and the two screws securing com bination switch and then remove the related parts D ASSEMBLY Insert the combination switch to the upper column shaft and install the upper column cover Then route the...

Page 544: ... after pulling off cotter pin and remov ing castle nut 8 Remove the front crossmember support plate jack up plate and front stabilizer Ref to FS 16 REMOVAL Front Stabilizer 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 Discharge the fluid similarly from ot...

Page 545: ... the crossmember bracket via clamp with bolt temporarily 4 Tighten the bolts which temporary tightening the clamp and bracket of gearbox to specified torque Tightening torque 60 N m 6 1 kgf m 44 1 ft lb 5 Connect the pipe D to return hose first and the pipe C to pressure hose second Tightening torque 15 N m 1 5 kgf m 10 8 ft lb 6 Install the universal joint Ref to PS 21 IN STALLATION Universal Joi...

Page 546: ...to PS 20 REMOVAL Steering Wheel 17 Align the center of roll connector Ref to AB 23 ADJUSTMENT Roll Connector 18 Install the steering wheel Ref to PS 20 IN STALLATION Steering Wheel 19 Connect the battery ground cable to battery 20 Pour fluid into the oil tank and bleed air Ref to PS 84 Power Steering Fluid 21 Check for fluid leaks 22 Check the fluid level in oil tank 23 After adjusting toe in and ...

Page 547: ...ion 6 Using the ST loosen the lock nut ST 926230000 SPANNER 7 Tighten the adjusting screw until it no longer tightens 8 Hold the rack with a wrench 22 mm width across flats and then remove the tie rod using a wrench 32 mm width across flats or adjustable wrench 9 Loosen the adjusting screw and then remove the spring and sleeve 10 Remove the two bolts securing valve assem bly 1 Clip 1 Band 1 Lock n...

Page 548: ... rack bushing and rack stopper from rack assembly 15 Remove the oil seal from rack 16 Insert the ST from pinion housing side and then remove the oil seal using a press ST 34099PA010 OIL SEAL REMOVER 3 0 R model ST 34199AE050 OIL SEAL REMOVER Except for 3 0 R model 17 Using a press remove the bushing at gearbox installation portion 2 CONTROL VALVE 1 Disconnect the pipes A and B from gearbox 2 Secur...

Page 549: ...4 Tighten the adjusting screw until it no longer tightens 5 Loosen the adjusting screw and then remove the spring and sleeve 6 Remove the two bolts securing valve assembly 7 Carefully draw out the input shaft and then re move the valve assembly 8 Wrap the tape to spline part and slide the dust cover out 1 Clamp 1 Lock nut 1 Adjusting screw PS 00492 1 ST1 ST2 PS 00494 ST 1 PS 00495 1 1 Dust cover P...

Page 550: ...11 Using a snap ring pliers remove the snap ring valve oil seal and backup washer CAUTION Be careful not to scratch the pinion valve as sembly D ASSEMBLY 1 RACK HOUSING ASSEMBLY 1 Using a press install the bushing to the gearbox installation portion 2 Insert the ST into rack ST 34199AG040 GUIDE 3 0 R model ST 34199AG030 GUIDE Except for 3 0 R mod el 1 Pinion valve ASSY 2 Valve housing 3 Cloth 1 Oi...

Page 551: ...the oil seal in the direction as shown in the fig ure 3 Insert the ST A with oil seal assembled from the gear side of rack Remove the oil seal from ST A near piston and then remove the ST A from rack 4 Install the backup washer from gear side of rack 5 Install the ST on rack and equally apply a thin coat of grease to the rack and ST then install the oil seal ST 926250000 GUIDE CAUTION Be careful n...

Page 552: ...arbox cylin der 10 Set the ST to the end of rack ST 34199FE000 INSTALLER REMOVER 3 0 R model ST 34099FA030 INSTALLER REMOVER Except for 3 0 R model 11 Using a press press fit until the groove of ST reaches the end of holder 12 Secure the gearbox in a vice using ST ST1 926200000 STAND ST2 34199AG000 BOSS D 13 Tighten the holder Tightening torque 3 0 R model 90 N m 9 18 kgf m 66 4 ft lb Except for 3...

Page 553: ... from lock to lock two or three times to make it fit in Remove the grease blocking air vent hole CAUTION If operating the rack from lock to lock without installing tie rod it may damage the oil seal Al ways install the tie rods LH and RH 20 Apply a coat of grease to the sliding surface of sleeve and seating surface of spring and then in sert sleeve into steering body Charge the adjusting screw wit...

Page 554: ... lock nut While holding the adjusting screw with a wrench tighten lock nut using ST ST 926230000 SPANNER Tightening torque Lock nut 39 N m 4 0 kgf m 28 9 ft lb NOTE Hold the adjusting screw with a wrench to prevent it from turning while tightening lock nut 29 Extend the rack approx 40 mm 1 57 in be yond side of steering body 30 Install the tie rod and a new lock washer into rack Tightening torque ...

Page 555: ...p pli ers caulk the boot band until caulking part clear ance is 2 mm 0 079 in or less 34 Fix the boot end with clip small 35 After installing check the boot end is posi tioned into groove on tie rod 36 If the tie rod end has been removed screw in the lock nut and tie rod end to screwed portion of tie rod and then tighten the lock nut temporarily in a position as shown in the figure 1 Right side bo...

Page 556: ...e A and B to four pipe joints of gearbox Tightening torque 13 N m 1 3 kgf m 9 4 ft lb 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 2 CONTROL VALVE ASSEMBLY Specified steering grease VALIANT GREASE M2 Part No 003608001 1 Clean all parts and tools before reassembling 2 Apply a coat of specified power steering fluid to t...

Page 557: ...l tape to the groove portion of pinion 8 Install the backup ring and oil seal to pinion and then remove the vinyl tape 9 Set the ST to pinion and install the seal ring ST 34199AG020 GUIDE 10 Remove the ST GUIDE and form the seal ring properly using ST FORMER ST 34199AG070 FORMER 11 Put vinyl tape around the pinion shaft splines to protect oil seal from damage 1 Special bearing 2 Oil seal PS 00526 ...

Page 558: ...race 15 Apply the specified grease to dust cover 16 Install the dust cover on valve assembly CAUTION Be sure to install the dust cover to groove on shaft properly 17 Apply genuine grease to the pinion gear and bearing of valve assembly 18 Install a new O ring on valve assembly 1 Snap ring 2 Valve 1 Valve housing 2 Pinion valve ASSY 1 Pinion valve ASSY 2 Bearing 3 Housing PS 00531 2 1 PS 00532 1 2 ...

Page 559: ...PS 43 SERVICE LIMIT INSPECTION Steer 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 Liquid gasket THREE BOND 1141 26 Tighten the adjusting screw to specified torque Tightening torque 7 4 N m 0 75 kgf m 5 4 ft lb 27 After tightening to the specified tightening torque loosen it by 25 28 Install the l...

Page 560: ...ASSISTED SYSTEM POWER STEERING Steering Gearbox LHD Model 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 1 Pipe C 2 Pipe D PS 00525 1 2 ...

Page 561: ... pinion engage uni formly and smoothly with each other Refer to Service limit 2 Keeping the rack pulled out all the way so that all teeth emerge check teeth for damage Even if abnormality is found in either 1 or 2 replace the entire gearbox 4 Gearbox unit 1 Bend of rack shaft 2 Bend of cylinder portion 3 Crack or damage on cast iron portion Replace the gearbox with a new one 4 Wear or damage on ra...

Page 562: ...istance of rack shaft Service limit 400 N 41 kgf 90 lb or less 3 RACK SHAFT PLAY IN RADIAL DIREC TION Right turn steering Service limit 0 19 mm 0 0075 in or less On condition L 5 mm 0 20 in P 122 6 N 12 5 kgf 27 6 lb Left turn steering Service limit Direction 0 3 mm 0 012 in or less Direction 0 15 mm 0 0059 in or less 4 INPUT SHAFT PLAY In radial direction Service limit 0 18 mm 0 0071 in or less O...

Page 563: ...sure the gearbox turning resis tance ST 34099PA100 SPANNER Service limit Maximum allowable resistance 10 5 N 1 1 kgf 2 4 lb or less Difference between right and left turning re sistance 20 or less 6 OIL LEAKING PS 00104 P PS 00105 1 Power cylinder 3 Rack piston 5 Input shaft 2 Cylinder 4 Rack axle 6 Valve housing PS 00272 4 3 2 5 6 c d d a b 1 d e d f g d g ...

Page 564: ...s operation 1 Leakage from e The cylinder seal is damaged Replace the rack bush with a new one 2 Leakage from f There are two possible causes Take the follow ing step first Remove the pipe assembly B from the valve housing and close the circuit with ST ST 926420000 PLUG Turn the steering wheel from lock to lock thirty to forty times with the engine running then make comparison of the leaked portio...

Page 565: ...e the tie rod end from the knuckle arm after pulling off cotter pin and remov ing castle nut 8 Remove the front crossmember support plate jack up plate and front stabilizer Ref to FS 16 REMOVAL Front Stabilizer Large type Small type 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 clockwis...

Page 566: ...TALLATION 1 Insert the gearbox into the crossmember being careful not to damage gearbox boot 2 Install the gearbox and bracket Tighten the bolt temporarily 3 Tighten the gearbox to the crossmember bracket via clamp with bolt temporarily 4 Tighten the bolts which temporary tightening the clamp and bracket of gearbox to specified torque Tightening torque 60 N m 6 1 kgf m 44 1 ft lb 1 Return hose 2 P...

Page 567: ...late and jack up plate 11 Install the front exhaust pipe assembly Non turbo model Ref to EX H4SO 2 0 8 INSTALLA TION Front Exhaust Pipe 12 Install the under cover Ref to EI 26 INSTAL LATION Front Under Cover 13 Install the front wheels 14 Tighten the wheel nuts to specified torque Tightening torque 90 N m 9 1 kgf m 65 8 ft lb 15 Lower the vehicle 16 Remove the steering wheel Ref to PS 20 REMOVAL S...

Page 568: ...G000 BOSS D CAUTION Secure the gearbox assembly in a vice using the ST as shown Do not secure the gearbox without this ST 3 Remove the tie rod end and lock nut from gear box 4 Remove the clip from outside boot using pliers and then move the boot to tie rod end side 5 Using a flat tip screwdriver remove the band from boot NOTE Replace the boot if there is damage cracks or de terioration 6 Using the...

Page 569: ...attention not to scratch the housing or input shaft and not to allow foreign matter to enter the gear box interior CAUTION Wrap the tape to the spline part of input shaft to avoid damaging dust cover 11 Align the ST pin with the plug hole to install Ro tate the ST counterclockwise to remove the plug ST 34199AE090 PLUG WRENCH 12 Remove the valve assembly paying attention not to scratch seal ring or...

Page 570: ...y inner surface ST 34199FE010 INSTALLER REMOVER Turbo and 3 0 R model ST 34199FA030 INSTALLER REMOVER Except for turbo and 3 0 R model NOTE Block the pipe connection of steering body to pre vent fluid from flowing out 15 Insert the ST from the valve side and press the back up ring and oil seal out ST 34199FE010 REMOVER Turbo and 3 0 R model ST 927580000 REMOVER Except for turbo and 3 0 R model 1 R...

Page 571: ...t for turbo and 3 0 R model 17 If the cylinder edge is deformed in a convex shape repair using an oil stone 18 Remove the oil seal using ST and press from plug ST 34199AE100 OIL SEAL PLUG REMOVER NOTE Do not apply force on the plug edge surface 19 Set the ST in the dimension as shown in the fig ure ST 34199AE120 GEARBOX OIL SEAL RE MOVER 1 Cylinder PS 00066 PS 00067 1 Oil seal 2 O ring 1 70 mm 2 7...

Page 572: ...eal by rotating nut CAUTION Take care not to scratch the gearbox inner sur face D ASSEMBLY 1 Apply a coat of grease to the inside and outside of new oil seal Steering grease VALIANT GREASE M2 Part No 003608001 2 Verify the oil seal direction and installation posi tion Using the ST and press press fit the oil seal to gearbox ST 34199AE130 GEARBOX OIL SEAL IN STALLER 1 Stopper 2 Oil seal 1 Rod 2 2 s...

Page 573: ...for turbo and 3 0 R model NOTE Face the oil seal in the direction as shown in the fig ure 5 Insert the ST A with oil seal assembled from the gear side of rack Remove the oil seal from ST A near piston and then remove the ST A from rack 6 Install the back up washer from gear side of rack 7 Install the ST on rack and equally apply a thin coat of grease to the rack and ST then install the oil seal ST...

Page 574: ...th ST2 and the edge surface of rack is aligned with that of ST2 ST1 34199FE050 GUIDE Turbo and 3 0 R mod el 34199AE000 GUIDE Except for turbo and 3 0 R model ST2 34199FE060 INSTALLER Turbo and 3 0 R model 34199AE010 INSTALLER Except for turbo and 3 0 R model 10 Install a new holder to the cylinder side of steer ing body Tightening torque Turbo and 3 0 R model 90 N m 9 18 kgf m 66 4 ft lb Except fo...

Page 575: ...en attach the valve assem bly taking care not to scratch oil seal and seal ring 14 Apply grease on the oil seal circumference and then press it into the plug using ST and press Re place the O rings of plug circumference with new ones ST 34199AE110 OIL SEAL PLUG INSTALLER CAUTION Install the oil seal paying attention to its direc tion A Holder B 3 mm 0 12 in 1 Vinyl tape PS 00084 A B ST ST PS 00085...

Page 576: ...d then insert the spring into adjusting screw and install on steering body 19 Tighten the adjusting screw to specified torque Tightening torque 9 8 N m 1 0 kgf m 7 2 ft lb 20 After tightening the adjusting screw with the specified tightening torque loosen it Tightening torque 4 9 N m 0 50 kgf m 3 6 ft lb 21 After tightening the adjusting screw with the specified tightening torque loosen 37 it Tigh...

Page 577: ...gn material dirt and etc 27 Apply a coat of grease to the tie rod groove and then install the boot to housing NOTE Make sure that the boot is installed without unusual inflation or deflation 28 Caulk the boot so the space inside boot band caulking portion becomes 2 mm 0 08 in or less NOTE Use a new boot band 29 Fix the boot end with clip small 30 After installing check that the boot end is posi ti...

Page 578: ...nd turn it slowly at a radius one or two times as large as possible After all make sure that the boot is installed in the specified position without deflation 33 Take off the gearbox from ST ST1 926200000 STAND ST2 34199AG000 BOSS D 34 Install the pipe A and B to steering body and control valve housing Tightening torque T1 20 N m 2 0 kgf m 14 5 ft lb T2 24 N m 2 4 kgf m 17 4 ft lb 1 Pipe A 2 Pipe ...

Page 579: ... pinion engage uniformly and smoothly with each other Refer to Service limit 2 Keeping rack pulled out all the way so that all teeth emerge check teeth for damage Even if abnormality is found in either 1 or 2 replace the entire gearbox 4 Gearbox unit 1 Bend of rack shaft 2 Bend of cylinder portion 3 Crack or damage on cast iron portion Replace the gearbox with a new one 4 Wear or damage on rack bu...

Page 580: ...ss Difference between right and left sliding resis tance 20 or less 3 RACK SHAFT PLAY IN RADIAL DIREC TION Right turn steering Limit Direction 0 4 mm 0 016 in or less Direction 0 6 mm 0 024 in or less On condition L 5 mm 0 20 in P 98 N 10 kgf 22 lb Left turn steering Limit Direction 0 4 mm 0 016 in or less 4 INPUT SHAFT PLAY In radial direction Limit 0 18 mm 0 0071 in or less 1 Right turn steering...

Page 581: ...27 mm 0 0106 in or less On condition P 20 49 N 2 5 kgf 4 11 lb 5 TURNING RESISTANCE OF GEARBOX Using the ST measure the gearbox turning resis tance ST 34099PA100 SPANNER Service limit Maximum allowable resistance 13 N 1 3 kgf 9 6 lb or less Difference between right and left turning re sistance 20 or less PS 00328 P PS 00329 P PS 00330 ST ...

Page 582: ... oil leakage from b The torsion bar O ring is damaged Replace the valve assembly with a new one 5 Cause and measure for oil leakage from c The oil seal is damaged Replace the oil seal with a new one 6 Cause and measure for oil leakage from d The pipe is damaged Replace the faulty pipe or O ring F ADJUSTMENT 1 Adjust the front toe Ref to FS 12 FRONT WHEEL TOE IN INSPEC TION Wheel Alignment Standard...

Page 583: ...head position or error is more than 5 on the periphery of steering wheel correctly re install the steering wheel 4 If the steering wheel spokes are not horizontal with vehicle set in the straight ahead position after this adjustment correct it by turning the right and left tie rods in the opposite direction each other by the same angle 1 Within 5 PS 00513 1 ...

Page 584: ...ockwise Discharge the flu id similarly from other pipes 4 Remove the clamp E from return hose and pres sure hose 5 Disconnect the return hose and pipe D pressure hose and pipe C 6 Remove the air intake duct Ref to IN H4DOTC 9 REMOVAL Air Intake Duct Ref to IN H4SO 2 0 9 REMOVAL Air Intake Duct 7 Disconnect the suction hose and pressure hose from oil pump 1 Front crossmember support plate 2 Jack up...

Page 585: ...tor edge of suction hose 3 Connect the suction hose and return hose to res ervoir tank Install the oil cooler to oil cooler brack et CAUTION Firmly insert the resin clip of return hose to the bracket 4 Connect the suction hose and pressure hose to the oil pump Tighten the eye bolt of pressure hose 1 Reservoir tank 2 Suction hose 3 Return hose 4 Oil cooler 5 Oil cooler bracket 1 Hose ASSY 2 Hose br...

Page 586: ...e 7 4 N m 0 75 kgf m 5 4 ft lb 7 Tighten the pressure hose and pipe C the return hose and pipe D Tightening torque 15 N m 1 5 kgf m 10 8 ft lb 8 Connect the pipe A and B to the four pipe joints of gearbox Tightening torque 13 N m 1 3 kgf m 9 4 ft lb 9 Install the front crossmember support plate and jack up plate 10 Lower the vehicle 11 Tighten the bolts which hold the hose bracket 1 Suction hose 2...

Page 587: ...LLA TION Air Intake Duct 13 Connect the battery ground cable to battery 14 Feed the specified fluid CAUTION Never start the engine before feeding the fluid otherwise vane pump might be seized up 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 1 Hose ASSY 2 Hose ...

Page 588: ...pump the fluid etc due to over heat Parts Maintenance Parts Corrective action Pipe O ring fitting surface for damage Nut for damage Pipe for damage Replace with a new one Clamp Clamps for weak clamping force Replace with a new one Hose Flare surface for damage Flare nut for damage Outer surface for cracks Outer surface for wear Clip for damage End coupling or adapter for deformation Replace with a...

Page 589: ...x also Leakage from hose 9 through 13 in figure Crack or damage in hose Replace with a new one Crack or damage in hose hardware Replace with a new one Leakage from surrounding of cast iron portion of oil pump 14 and 15 in figure Damaged O ring Replace the oil pump Damaged gasket Replace the oil pump Leakage from oil tank 16 and 17 in figure Crack in oil tank Replace the oil tank Leakage from fille...

Page 590: ...vinyl hose to the pipe and the joint Discharge the fluid by turning steering wheel fully clockwise and counterclockwise Discharge the flu id similarly from other pipes 4 Remove the clamp E from the return hose and pressure hose 5 Disconnect the return hose and pressure hose from gearbox 1 Front crossmember support plate 1 Front crossmember support plate 2 Jack up plate 1 Pipe A 2 Pipe B PS 00445 1...

Page 591: ...hose bracket and take out the hose assembly from vehicle B INSTALLATION 1 Temporarily tighten the bolt of hose bracket 2 Install the resin clip to the pressure hose and suction hose CAUTION Align the installation position of the resin clip with the protector edge of suction hose Non turbo model 1 Suction hose 2 Pressure hose 1 Reservoir tank 2 Suction hose 3 Return hose 4 Oil cooler 5 Oil cooler b...

Page 592: ...the bracket 4 Connect the suction hose and pressure hose to the oil pump Tighten the eye bolt of pressure hose Tightening torque 39 N m 4 0 kgf m 28 9 ft lb Non turbo model Turbo model 1 Resin clip 2 Protector 3 Suction hose 4 Pressure hose 1 Reservoir tank 2 Suction hose 3 Return hose 4 Oil cooler 5 Oil cooler bracket PS 00456 1 2 3 4 PS 00482 1 3 2 5 4 1 Suction hose 2 Pressure hose 1 Suction ho...

Page 593: ...ox Tightening torque 13 N m 1 3 kgf m 9 4 ft lb 9 Install the front crossmember support plate and jack up plate 10 Lower the vehicle 11 Tighten the bolts which hold the hose bracket Tightening torque 13 N m 1 3 kgf m 9 4 ft lb 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 13 Connect the battery ground cable to bat...

Page 594: ...ous work of relief valve over 5 seconds causes to reduce service lives of the hos es the oil pump the fluid etc due to over heat Parts Maintenance Parts Corrective action Pipe O ring fitting surface for damage Nut for damage Pipe for damage Replace with a new one Clamp Clamps for weak clamping force Replace with a new one Hose Flare surface for damage Flare nut for damage Outer surface for cracks ...

Page 595: ...x also Leakage from hose 11 12 and 13 in figure Crack or damage in hose Replace with a new one Crack or damage in hose hardware Replace with a new one Leakage from surrounding of cast iron portion of oil pump 14 and 15 in figure Damaged O ring Replace the oil pump Damaged gasket Replace the oil pump Leakage from oil tank 16 and 17 in figure Crack in oil tank Replace the oil tank Leakage from fille...

Page 596: ...d suction hose from oil pump CAUTION Do not allow fluid to come into contact with pulley belt To prevent foreign matter from entering the hose and pipe cover the open ends with a clean cloth Non turbo model Turbo model 7 Remove the bolts which hold the power steering pump bracket 8 Place the oil pump bracket in a vise and remove the two bolts from the front side of oil pump CAUTION When securing t...

Page 597: ...bracket with the least possi ble force between two wood pieces 2 Tighten the bolt which holds the oil pump to bracket Tightening torque 15 7 N m 1 6 kgf m 11 6 ft lb Tightening torque 37 3 N m 3 8 kgf m 27 5 ft lb 2 Tighten the bolts which hold the power steering pump bracket 3 Interconnect the pressure hose and suction hose Tightening torque Eye bolt 39 N m 4 0 kgf m 28 9 ft lb CAUTION If a hose ...

Page 598: ...ing torque 25 N m 2 5 kgf m 18 1 ft lb 8 Install the pulley belt cover 9 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 10 Connect the battery ground cable to battery 11 Feed the specified power steering fluid Ref to PS 84 Power Steering Fluid CAUTION Never start the engine before feeding the fluid otherwise vane pump...

Page 599: ...ctive action 1 Oil pump Exterior 1 Crack damage or oil leakage Replace the oil pump with a new one 2 Play of pulley shaft Measure the radial play and axial play If any of these exceeds the service limit replace the oil pump with a new one 2 Pulley 1 Damage Replace with a new one 2 Bend Measure the V ditch deflection If it exceeds the service limit replace the pulley with a new one 3 Oil pump Inter...

Page 600: ...eering wheel at stop end for 5 seconds or more in any case as the oil pump may be dam aged due to long keep of these conditions Put cloth at a place where fluid drops before pressure gauge is installed Wipe off spilt fluid thor oughly after the measurement 1 Regular pressure measurement 1 Connect ST1 ST2 and ST3 ST1 925711000 PRESSURE GAUGE ST2 34099AC020 ADAPTER HOSE B ST3 34099AC010 ADAPTER HOSE...

Page 601: ... 7 453 kPa 69 76 kg cm2 981 1 081 psi Turbo model 7 350 8 036 kPa 75 82 kg cm2 1 067 1 165 psi 3 0 R model 8 300 9 000 kPa 85 92 kg cm2 1 204 1 305 psi 4 If it is not within the specified value replace the oil pump 3 Measure working pressure 1 Using the STs measure the working pres sure 2 Open the valve 3 Measure the working pressure of control valve by turning steering wheel from stop to stop ST1...

Page 602: ...LATION 1 Install the reservoir tank to body Tightening torque 13 N m 1 3 kgf m 9 4 ft lb 2 Connect the hose to reservoir tank 3 Feed the power steering fluid to specified level Ref to PS 84 Power Steering Fluid C INSPECTION Check the reservoir tank for cracks breakage and damage If a failure is found replace the reservoir tank 1 Reservoir tank 2 Suction hose 3 Return hose 4 Oil cooler 5 Oil cooler...

Page 603: ...y from lock to lock until the bubbles stop appearing on oil surface while keeping the fluid at the level in the Step 4 6 If turning the steering wheel in low fluid level condition air will be sucked in pipe In this case leave it about half an hour and then do the step 5 again 7 Start the engine and let it idle 8 Continue to turn the steering wheel slowly from lock to lock again until the bubbles s...

Page 604: ...ce 2 Tire and wheel Improper tires out of specification 1 Improper wheel out of specification 1 Tires not properly inflated Replace or reinflate 3 Fluid Low fluid level Aeration Dust mix Deterioration of fluid Poor warming up of fluid 2 Refill bleed air replace or instruct customer 4 Idle speed Lower idle speed Excessive drop of idle speed at start or at turning steering wheel 3 Adjust or instruct...

Page 605: ...speed and turning speed of steering wheel fluid temperature and braking condition These phenomena do not indicate there are some abnormal functions in the system Confirm the vibration by turning the steering wheel repeatedly at various speeds from slow to rapid step by step with parking brake applied on concrete road and in D range for AT model Trouble Possible cause Corrective action Hiss noise c...

Page 606: ...nt or continuous While engine is running with without steering turned Loosened installation of oil pump oil pump bracket Retighten Abnormal inside of oil pump hose Replace the oil pump or hose if the noise can be heard when running as well as stand still Torque converter growl air conditioner compression growl Remove the power steering pul ley belt and confirm Grinding noise continuous While engin...

Page 607: ...e of the joint yoke of steering column side Ref to PS 21 INSPECTION Universal Joint Is the folding torque less than 7 3 N 0 74 kgf 1 64 lb Go to step 6 Replace with a new one 6 CHECK UNIVERSAL JOINT Measure the folding torque of the joint yoke of gearbox side Ref to PS 21 INSPECTION Universal Joint Is the folding torque less than 3 8 N 0 39 kgf 0 86 lb Go to step 7 Replace with a new one 7 CHECK F...

Page 608: ...n hose Model with ABS 10 0 39 14 Front suspension bracket to Return hose 5 0 20 15 Front wheel apron to Return hose 5 0 20 16 VDC H U bracket to Suction hose Model with vehicle dynamics control VDC 5 0 20 17 Air cleaner case to Suction hose 5 0 20 18 Air intake duct to Suction hose Turbo model 10 0 39 19 Air duct to Suction hose Turbo model 10 0 39 20 Front wheel apron to Reservoir tank 5 0 20 21 ...

Page 609: ...ERING General Diagnostic Table LHD model RHD model PS 00515 4 1 6 15 20 21 22 23 29 30 32 33 24 25 26 27 5 8 9 13 14 28 31 10 11 16 3 12 19 18 17 7 2 PS 00514 4 2 10 11 16 1 8 9 12 19 18 17 20 15 6 5 3 7 13 14 21 27 24 26 25 23 22 28 29 33 ...

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