Subaru 2003 Legacy Manuel utilisateur

FUJI HEAVY INDUSTRIES LTD. G2300GE6

2003 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

VDC VDC

VDC (DIAGNOSTICS) VDC

BRAKE BR

PARKING BRAKE PB

POWER ASSISTED SYSTEM

(POWER STEERING) PS

VDC VDC

Page

1. General Description ....................................................................................2

2. VDC Control Module (VDCCM)...................................................................8

3. Hydraulic Control Unit (H/U)......................................................................10

4. ABS Sequence Control.............................................................................16

5. VDC Sequence Control.............................................................................19

6. Yaw Rate and Lateral G Sensor ...............................................................22

7. Steering Angle Sensor..............................................................................26

8. Front ABS Sensor.....................................................................................27

9. Rear ABS Sensor......................................................................................28

10. Front Tone Wheel .....................................................................................29

11. Rear Tone Wheel......................................................................................30

12. VDC Off Switch.........................................................................................31

VDC-2

VDC GENERAL DESCRIPTION

1. General Description

A: SPECIFICATIONS

Item Standard or remarks

ABS sensor

ABS sensor gap Front 0.3 —0.8 mm (0.012 —0.031 in)

Rear 0.44 —0.94 mm (0.0173 —0.0370 in)

ABS sensor resistance 1.25±0.25 kΩ

Marks

of the

harness

Front LH Except OUTBACK Yellow

OUTBACK Brown

Front

RH Except OUTBACK White

OUTBACK Light blue

Rear LH Except OUTBACK Yellow

OUTBACK Yellow

Rear RH Except OUTBACK White

OUTBACK White

Yaw rate and

lateral G sensor Lateral G sensor voltage 2.5±0.2 V

VDC hydraulic control unit marks D2

VDC control

module marks

Except Australia

spec.

Except OUTBACK K

OUTBACK Except 3.0 L model M

3.0 L model N

Australia spec. Except OUTBACK J

OUTBACK Y

VDC-3

VDC

GENERAL DESCRIPTION

B: COMPONENT

1. ABS SENSOR

(1) Clip (5) Housing Tightening torque: N·m (kgf-m, ft-lb)

(2) Rear ABS sensor (6) Front ABS sensor T: 33 (3.3, 24)

(3) ABS spacer (7) Tone wheel (Front)

(4) Tone wheel (Rear)

VDC00069

( 7 ) ( 6 ) ( 3 )

( 5 )

( 4 )

( 3 )

( 2 )

( 1 )

VDC-4

VDC GENERAL DESCRIPTION

2. YAW RATE AND LATERAL G SENSOR

3. STEERING ANGLE SENSOR

(1) Yaw rate and lateral G sensor Tightening torque: N·m (kgf-m, ft-lb)

T: 7.5 (0.76, 5.5)

VDC00070

( 1 )

(1) Steering angle sensor (2) Roll connector (3) Combination base switch

( 1 )

( 2 )

( 3 )

VDC00189

VDC-5

VDC

GENERAL DESCRIPTION

4. VDC CONTROL MODULE (VDCCM)

•LHD model

•RHD model

(1) VDC control module Tightening torque: N·m (kgf-m, ft-lb)

T: 7.5 (0.76, 5.5)

(1) VDC control module Tightening torque: N·m (kgf-m, ft-lb)

T: 7.5 (0.76, 5.5)

VDC00072

( 1 )

VDC00158

( 1 )

VDC-6

VDC GENERAL DESCRIPTION

5. HYDRAULIC CONTROL UNIT (H/U)

(1) Relay box (9) Pressure sensor Tightening torque: N·m (kgf-m, ft-lb)

(2) Motor relay (10) Ground terminal T1: 13 (1.3, 9.4)

(3) Valve relay (11) Front-LH outlet T2: 18 (1.8, 13.0)

(4) Cap (12) Secondary inlet T3: 33 (3.3, 24)

(5) Bracket (13) Front-RH outlet T4: 38 (3.9, 28)

(6) Hydraulic control unit (14) Primary inlet

(7) Damper (15) Rear-LH outlet

(8) Stud bolt (16) Rear-RH outlet

( 4 )

VDC00073

( 3 )

( 2 )

( 1 )

( 5 )

( 6 ) ( 7 ) ( 8 )

( 9 )

( 8 )

( 7 )

(11) (12) (13) (14)

(15)

(16)

(10)

VDC-7

VDC

GENERAL DESCRIPTION

C: CAUTION

•Wear working clothing, including, a cap, protec-

tive goggles, and protective shoes during opera-

tion.

•Remove contamination including dirt and corro-

sion before removal, installation or disassembly.

•Keep the disassembled parts in order and pro-

tect them from dust or dirt.

•Before removal, installation or disassembly, be

sure to clarify the failure. Avoid unnecessary re-

moval, installation, disassembly, and replacement.

•Be careful not to burn your hands, because each

part on the vehicle is hot after running.

•Be sure to tighten fasteners including bolts and

nuts to the specified torque.

•Place shopjacks or safetystands at thespecified

points.

•Before disconnecting electrical connectors of

sensors or units, be sure to disconnect ground ca-

ble from battery.

D: PREPARATION TOOL

1. SPECIAL TOOLS

2. GENERAL PURPOSE TOOLS

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

24082AA210 CARTRIDGE Troubleshooting for electrical systems.

22771AA030 SELECT MONI-

TOR KIT Troubleshooting for electrical systems.

•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.

ST24082AA210

ST22771AA030

VDC-8

VDC VDC CONTROL MODULE (VDCCM)

2. VDC Control Module (VDC-

CM)

A: REMOVAL

1) Disconnect battery ground cable.

2) Remove lower cover of instrument panel and

disconnect connectors on the back side of the cov-

er.

3) Remove three bolts which secure the fuse box

onto body side, then move the fuse box aside.

LHD model

RHD model

4) Remove two bolts which install VDCCM onto

body side bracket.

LHD model

RHD model

5) Disconnect connector from VDCCM by pulling

up the securing holder.

6) Remove VDCCM.

FU-00009

VDC00074

VDC00075

VDC00159

VDC00076

VDC00160

VDC00077

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