Subaru Legacy 1997 GT Wagon 2.5L DOHC, Legacy 1997 GT Wagon AWD 2.5L DOHC Workshop Manual

subaru :: Subaru Legacy GT Wagon AWD F4-2.5L
DOHC (1997)

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation

Alarm Module: Description and Operation

SECURITY CONTROL MODULE

All signals from switches (door, engine hood, .. etc.) are input to the security control module. Based on the signals from these individual switches, the control module recognizes the emergency condition and controls all of the security system functions.
The security control module is installed inside the right side of instrument panel.

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation > Page 7

Control Module I/O Signal

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation > Page 8

Alarm Module: Service and Repair

Security Control Module

Removal and Installation

1) Remove instrument panel.2) Remove bolt which secures security control module (A).3) Remove security control module while disconnecting connector.4) Installation is in the reverse order of removal.

Tightening torque:

7.4 2.0 Nm (5.4 1.4 ft.lb.)

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antitheft Relay > Component Information > Description and Operation

Antitheft Relay: Description and Operation
STARTER INTERRUPT RELAY/HEADLIGHT ALARM RELAY

The starter interrupt relay, activates by a signal from the security control module, interrupts the starter circuit keeping the starter from operation.
In armed state, the system will not activate the starter interrupt relay and starter circuit functions normally.
The system activates the starter interrupt relay when the system is in alarm state, and keep this condition until the system is turned to disarmed state.
The headlight alarm relay is adopted in headlight circuit, and this relay activates when the security system is in alarm state.
In alarm state, the security control module switches the output signal ON-OFF alternately to flash the headlight via a headlight alarm relay.
The starter interrupt and headlight alarm relays employ the same parts and are interchangeable.
The starter interrupt relay and headlight alarm relay are installed behind the lower cover located under the steering column.

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antitheft Relay > Component Information > Description and Operation > Page 12

Antitheft Relay: Service and Repair
Security System

REMOVAL AND INSTALLATION

1. STARTER INTERRUPT RELAY

NOTE:

The starter interrupt relay and headlight alarm relay use the same parts and are mounted parallel to each other.Therefore, before removal and installation identify the starter interrupt relay by the color of its wiring connection.

1. Remove instrument panel lower cover.2. Disconnect connector of starter interrupt relay.3. Remove starter interrupt relay.4. Installation is in the reverse order of removal.

2. HEADLIGHT ALARM RELAY

NOTE:

The headlight alarm relay and starter interrupt relay use the same parts and are mounted parallel to each other.Therefore, before removal and installation, identify the headlight alarm relay by the color of its wiring connection.

1. Remove instrument panel lower cover.2. Disconnect connector of headlight alarm relay.3. Remove headlight alarm relay.4. Installation is in the reverse order of removal.

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > RKE Installation

Keyless Entry Module: Service and RepairRKE Installation
A. Pre-Installation Notes

Connector Orientation

1. Connector Orientation2. Vehicle Preparation
a. Roll down the driver's side window to avoid locking the keys in the vehicle during installation.b. Remove the left lower dash trim to access the underdash wiring:

- Remove two (2) phillips screws at the bottom of the knee blocker panel.

- Remove one plastic clip on the side ot the dash closest to the driver's door.

c. Remove the negative battery cable.

3. System Preparation
a. Remove the 10-amp fuses from the module WHITE/BLACK and PINK wires. Plug the wiring harnesses into the remote keyless entry module.

The supplied wiring harness is pre-cut to proper length.Note:

B. Connecting the Keyless Entry Harness

1. Locate the keyless entry connector:

a. The connector is taped to a vehicle harness that crosses behind the metal knee protector under the driver's dash.b. The connector is a white 10-pin plug with a mating connector attached. The mating connector has a single wire loop.c. To locate the connector, reach behind the knee protector at a point just to the right of the fuse block. Pull the con nector down for access.

2. Remove the mating connector and discard. Replace with the 10-pin connector from the keyless entry harness.

C. Programming Button

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > RKE

Installation > Page 17

Legacy GT Wagon AWD F4-2.5L DOHC (1997)

1. On the keyless entry harness, locate the programming button. The button is taped and tie-wrapped to the harness near the 18-pin connector.

2. Carefully cut the tie wrap. Unravel the button wiring and pull button away from harness.

3. Remove the button housing by turning it counter-clockwise.

4. Using a drill with a 5/16" bit, carefully drill a hole in the left lower dash trim, below the diagnostic connector (white arrow). Hold the diagnostic
connector harness clear of the drill bit. Drill the hole from the inside of the panel to prevent burrs or scratches.

5. Clear away any burrs or plastic debris from both sides of the hole.6. Insert the button into the hole from behind. Secure the button from the front by re-attaching the button housing. Turn clockwise to tighten.

D. System Power-Up and Programming

1. The system will not operate until the following steps are completed.

a. Re-connect the negative battery cable.b. Turn the ignition key to the "ON" position (do not start the engine).c. Insert the 10-amp fuses into the module WHITE/BLACK and PINK wires.d. Open the driver's door before proceeding any further.e. Press and hold the programming button.

­In fifteen (15) seconds the door locks will cycle three (3) times to indicate that the system is in the transmitter programming mode. DONOT release the programming button.

f.

Press the LOCK button two (2) times on one of the transmitters.-

The door locks will cycle each time a button is pressed to confirm programming.

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > RKE

Installation > Page 18

Legacy GT Wagon AWD F4-2.5L DOHC (1997)

g. Repeat step 6 for the second transmitter.h. Release the programming button and turn the ignition key to the "OFF" position.

E. Installation Testing

If an incorrect response to test procedure is observed, refer to the corresponding installation step and verify installation.Note:

1. Close all vehicle doors (with dome switch set to "doors" - middle position).2. Press the LOCK button on one of the remote transmitters.
a. All vehicle doors will lock.b. The parking lights will flash once.

3. Press the UNLOCK button on one of the remote transmitters.
a. The driver's door will unlock.

b. The vehicle courtesy light and DOOR AJAR indicator will turn on.c. The parking lights will flash once.

4. Press and hold UNLOCK on the same transmitter.
a. All doors will unlock.

5. Repeat steps 3 and 4 with the second remote transmitter.

F. Warning Label Installation

1. Open the hood and clean any dirt or oil from the radiator support in the area located directly in front of the battery.2. Adhere the label to the radiator support (label has large lettering).3. Clean any dirt and oil from the black/yellow (ground) battery cable in an area located approximately 3" from the battery terminal.4. Adhere the battery cable label to the clean area (label has small lettering).

G. Mounting the Module

1. Mount the keyless entry module to the bracket using the supplied screws and nuts as shown.2. The hole at the top of the module bracket will fit onto a threaded bolt behind the fuse block. To find the bolt, reach behind the fuse block. There
are two bolts extending downward, mounted approximately 3 inches apart. The module bracket will mount to the bolt closest to the passenger sideof the vehicle.

3. Fit the bracket onto the bolt, with the module SUBARU label facing the front of the vehicle. Use the supplied 1O mm nut to secure the bracket and
module. Tighten to 45-60 inch lbs.

H. Notes on System Operation

1. Parking lights will flash when the vehicle battery is disconnected and reconnected. To stop lights from flashing, either:
a. Press remote transmitter Unlock button once.b. Turn ignition to the "ON" position and press programming button for one second (mounted on trim beneath diagnostic connector).

2. The vehicle courtesy light and DOOR AJAR indicator will stay on tor 60 seconds upon exiting the vehicle unless the door is locked with the
remote transmitter.

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > RKE

Installation > Page 19

Legacy GT Wagon AWD F4-2.5L DOHC (1997)

3. The instrument panel lights will tlash when the parking lights flash.

IMPORTANT!!

If installing the Security Upgrade system at the same time as the Keyless Entry system, review now the Security Upgradeinstructions to continue the installation procedure.

Finishing the Installation

1. Route the WHITE/BLACK antenna wire (8" wire extending from the side of the module) away from the module and surrounding harnesses. Keep
the antenna as straight as possible. Make sure the end of the antenna does not make contact with metal.

The antenna is cut to the appropriate length to ensure optimum performance. Do not cut or add wire to the antenna.Note:

2. Using the supplied short tie wraps, secure the system wiring harness to existing wiring harnesses so that they are concealed and clear of any

moving vehicle components.

3. Replace the left lower dash trim panel.4. Place the Owner's Manual in glovebox.

INSTALLATION IS NOW COMPLETE.

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > RKE Installation > Page 20

Keyless Entry Module: Service and RepairRKE Programming
SYSTEM OPERATION

1. Parking lights will flash when the vehicle battery is disconnected and reconnected. To stop lights from flashing, either:

- Press remote transmitter UNLOCK button once.

- Turn ignition to the "ON" or "RUN" position and press programming button for one second (see location below).

2. The vehicle courtesy light and DOOR AJAR indicator will illuminate for 60 seconds when the ignition is turned off, or until the doors are locked
with the remote transmitter.

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > RKE

Installation > Page 21

Legacy GT Wagon AWD F4-2.5L DOHC (1997)

3. The instrument panel lights will flash when the parking lights flash.4. Your SUBARU keyless Entry System is equipped with two remote transmitters.

Programming Buttons Location

The Programming Button is located under the driver's side dash beneath the diagnostic connector (to the right and below the fuse block accesscover).

Adding or Deleting Remote Transmitters

Up to four (4) transmitters can be programmed to your keyless entry system.

NOTE:

Make sure no one is operating another keyless entry or security system within range of your vehicle when you are programming remotetransmitters. Another transmitter code could be inadvertently "learned" by your system, allowing someone unauthorized access to your vehicle.

To program an additional transmitter:

1. Open the driver's door.2. Turn the vehicle ignition to the ON position.3. Press and hold the Programming button* in.

-.

After approximately 15 seconds, the door locks will cycle 3 times. This indicates that the system is in the Transmitter Programming Mode. Donot release the Programming button.

4. Press the LOCK button on the new transmitter. The door locks will cycle once.5. Repeat step 4 for any additional transmitters.6. Exit the Transmitter Programming Mode by releasing the Programming button and turning the vehicle ignition off. Test all remote transmitters to
ensure that they work properly.

To delete a lost or stolen transmitter:

1. Follow steps 1-3 as described above.2. Re-program the remaining transmitters as described in step 4.

- If there is only one remaining transmitter, perform step 4 four times.

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > RKE

Installation > Page 22

Legacy GT Wagon AWD F4-2.5L DOHC (1997)

- If there are two remaining transmitters, perform step 4 twice for each transmitter.

Your keyless entry system does not require any specific maintenance except for occasionally changing the transmitter battery. The 12-volt batteryin the remote transmitter should last approximately one year, depending on usage. When the battery begins to weaken, you will notice a decreasein range, or the distance from your vehicle that the remote transmitter will operate.(Battery not covered under SUBARU warranty.)

To Change the Remote Transmitter Battery:

1. Remove the phillips screw on the back of the remote transmitter case. Use a small coin to separate the case halves and expose the battery.2. Remove the old battery and replace with type GP-23A or equivalent.3. Close the transmitter case and replace the screw.

About Transmitter Range:

The receiver inside your vehicle security system and the remote control transmitters are designed together to have an average operating range of25-50 feet during ideal conditions. Although at times you may experience range greater than that, there may be occasions when range is less than

normal. Atmospheric conditions or interference from other RF-emitting devices can effectively reduce transmitter range.

This device complies with FCC rules part 15. Operation is subject to the following two conditions: (1) this device may not cause harmfulinterference and (2) this device must accept any interference that may cause undesired operation.

> Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > RKE Installation

Keyless Entry Module: Service and RepairRKE Installation
A. Pre-Installation Notes

Connector Orientation

1. Connector Orientation2. Vehicle Preparation
a. Roll down the driver's side window to avoid locking the keys in the vehicle during installation.b. Remove the left lower dash trim to access the underdash wiring:

- Remove two (2) phillips screws at the bottom of the knee blocker panel.

- Remove one plastic clip on the side ot the dash closest to the driver's door.

c. Remove the negative battery cable.

3. System Preparation
a. Remove the 10-amp fuses from the module WHITE/BLACK and PINK wires. Plug the wiring harnesses into the remote keyless entry module.

The supplied wiring harness is pre-cut to proper length.Note:

B. Connecting the Keyless Entry Harness

1. Locate the keyless entry connector:

a. The connector is taped to a vehicle harness that crosses behind the metal knee protector under the driver's dash.b. The connector is a white 10-pin plug with a mating connector attached. The mating connector has a single wire loop.c. To locate the connector, reach behind the knee protector at a point just to the right of the fuse block. Pull the con nector down for access.

2. Remove the mating connector and discard. Replace with the 10-pin connector from the keyless entry harness.

C. Programming Button

> Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > RKE Installation > Page 28

Legacy GT Wagon AWD F4-2.5L DOHC (1997)

1. On the keyless entry harness, locate the programming button. The button is taped and tie-wrapped to the harness near the 18-pin connector.

2. Carefully cut the tie wrap. Unravel the button wiring and pull button away from harness.

3. Remove the button housing by turning it counter-clockwise.

4. Using a drill with a 5/16" bit, carefully drill a hole in the left lower dash trim, below the diagnostic connector (white arrow). Hold the diagnostic
connector harness clear of the drill bit. Drill the hole from the inside of the panel to prevent burrs or scratches.

5. Clear away any burrs or plastic debris from both sides of the hole.6. Insert the button into the hole from behind. Secure the button from the front by re-attaching the button housing. Turn clockwise to tighten.

D. System Power-Up and Programming

1. The system will not operate until the following steps are completed.

a. Re-connect the negative battery cable.b. Turn the ignition key to the "ON" position (do not start the engine).c. Insert the 10-amp fuses into the module WHITE/BLACK and PINK wires.d. Open the driver's door before proceeding any further.e. Press and hold the programming button.

­In fifteen (15) seconds the door locks will cycle three (3) times to indicate that the system is in the transmitter programming mode. DONOT release the programming button.

f.

Press the LOCK button two (2) times on one of the transmitters.-

The door locks will cycle each time a button is pressed to confirm programming.

> Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > RKE Installation > Page 29

Legacy GT Wagon AWD F4-2.5L DOHC (1997)

g. Repeat step 6 for the second transmitter.h. Release the programming button and turn the ignition key to the "OFF" position.

E. Installation Testing

If an incorrect response to test procedure is observed, refer to the corresponding installation step and verify installation.Note:

1. Close all vehicle doors (with dome switch set to "doors" - middle position).2. Press the LOCK button on one of the remote transmitters.
a. All vehicle doors will lock.b. The parking lights will flash once.

3. Press the UNLOCK button on one of the remote transmitters.
a. The driver's door will unlock.

b. The vehicle courtesy light and DOOR AJAR indicator will turn on.c. The parking lights will flash once.

4. Press and hold UNLOCK on the same transmitter.
a. All doors will unlock.

5. Repeat steps 3 and 4 with the second remote transmitter.

F. Warning Label Installation

1. Open the hood and clean any dirt or oil from the radiator support in the area located directly in front of the battery.2. Adhere the label to the radiator support (label has large lettering).3. Clean any dirt and oil from the black/yellow (ground) battery cable in an area located approximately 3" from the battery terminal.4. Adhere the battery cable label to the clean area (label has small lettering).

G. Mounting the Module

1. Mount the keyless entry module to the bracket using the supplied screws and nuts as shown.2. The hole at the top of the module bracket will fit onto a threaded bolt behind the fuse block. To find the bolt, reach behind the fuse block. There
are two bolts extending downward, mounted approximately 3 inches apart. The module bracket will mount to the bolt closest to the passenger sideof the vehicle.

3. Fit the bracket onto the bolt, with the module SUBARU label facing the front of the vehicle. Use the supplied 1O mm nut to secure the bracket and
module. Tighten to 45-60 inch lbs.

H. Notes on System Operation

1. Parking lights will flash when the vehicle battery is disconnected and reconnected. To stop lights from flashing, either:
a. Press remote transmitter Unlock button once.b. Turn ignition to the "ON" position and press programming button for one second (mounted on trim beneath diagnostic connector).

2. The vehicle courtesy light and DOOR AJAR indicator will stay on tor 60 seconds upon exiting the vehicle unless the door is locked with the
remote transmitter.

> Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > RKE Installation > Page 30

Legacy GT Wagon AWD F4-2.5L DOHC (1997)

3. The instrument panel lights will tlash when the parking lights flash.

IMPORTANT!!

If installing the Security Upgrade system at the same time as the Keyless Entry system, review now the Security Upgradeinstructions to continue the installation procedure.

Finishing the Installation

1. Route the WHITE/BLACK antenna wire (8" wire extending from the side of the module) away from the module and surrounding harnesses. Keep
the antenna as straight as possible. Make sure the end of the antenna does not make contact with metal.

The antenna is cut to the appropriate length to ensure optimum performance. Do not cut or add wire to the antenna.Note:

2. Using the supplied short tie wraps, secure the system wiring harness to existing wiring harnesses so that they are concealed and clear of any

moving vehicle components.

3. Replace the left lower dash trim panel.4. Place the Owner's Manual in glovebox.

INSTALLATION IS NOW COMPLETE.

> Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > RKE Installation > Page 31

Keyless Entry Module: Service and RepairRKE Programming
SYSTEM OPERATION

1. Parking lights will flash when the vehicle battery is disconnected and reconnected. To stop lights from flashing, either:

- Press remote transmitter UNLOCK button once.

- Turn ignition to the "ON" or "RUN" position and press programming button for one second (see location below).

2. The vehicle courtesy light and DOOR AJAR indicator will illuminate for 60 seconds when the ignition is turned off, or until the doors are locked
with the remote transmitter.

> Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > RKE Installation > Page 32

Legacy GT Wagon AWD F4-2.5L DOHC (1997)

3. The instrument panel lights will flash when the parking lights flash.4. Your SUBARU keyless Entry System is equipped with two remote transmitters.

Programming Buttons Location

The Programming Button is located under the driver's side dash beneath the diagnostic connector (to the right and below the fuse block accesscover).

Adding or Deleting Remote Transmitters

Up to four (4) transmitters can be programmed to your keyless entry system.

NOTE:

Make sure no one is operating another keyless entry or security system within range of your vehicle when you are programming remotetransmitters. Another transmitter code could be inadvertently "learned" by your system, allowing someone unauthorized access to your vehicle.

To program an additional transmitter:

1. Open the driver's door.2. Turn the vehicle ignition to the ON position.3. Press and hold the Programming button* in.

-.

After approximately 15 seconds, the door locks will cycle 3 times. This indicates that the system is in the Transmitter Programming Mode. Donot release the Programming button.

4. Press the LOCK button on the new transmitter. The door locks will cycle once.5. Repeat step 4 for any additional transmitters.6. Exit the Transmitter Programming Mode by releasing the Programming button and turning the vehicle ignition off. Test all remote transmitters to
ensure that they work properly.

To delete a lost or stolen transmitter:

1. Follow steps 1-3 as described above.2. Re-program the remaining transmitters as described in step 4.

- If there is only one remaining transmitter, perform step 4 four times.

> Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > RKE Installation > Page 33

Legacy GT Wagon AWD F4-2.5L DOHC (1997)

- If there are two remaining transmitters, perform step 4 twice for each transmitter.

Your keyless entry system does not require any specific maintenance except for occasionally changing the transmitter battery. The 12-volt batteryin the remote transmitter should last approximately one year, depending on usage. When the battery begins to weaken, you will notice a decreasein range, or the distance from your vehicle that the remote transmitter will operate.(Battery not covered under SUBARU warranty.)

To Change the Remote Transmitter Battery:

1. Remove the phillips screw on the back of the remote transmitter case. Use a small coin to separate the case halves and expose the battery.2. Remove the old battery and replace with type GP-23A or equivalent.3. Close the transmitter case and replace the screw.

About Transmitter Range:

The receiver inside your vehicle security system and the remote control transmitters are designed together to have an average operating range of25-50 feet during ideal conditions. Although at times you may experience range greater than that, there may be occasions when range is less than

normal. Atmospheric conditions or interference from other RF-emitting devices can effectively reduce transmitter range.

This device complies with FCC rules part 15. Operation is subject to the following two conditions: (1) this device may not cause harmfulinterference and (2) this device must accept any interference that may cause undesired operation.

> Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Relay > Component Information > Locations

Sunroof / Moonroof Relay: Locations

Behind LH side of I/P, under steering column

> Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Specifications

ABS Main Relay: Specifications
TIGHTENING SPECIFICATIONS

Mounting Hardware ........................................................................................................................................................... 18 5 Nm (13.0 3.6 ft. lbs.)

> Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Specifications > Page 41

ABS Main Relay: Service and Repair
REMOVAL

1) Disconnect ground cable from battery.2) Remove air intake duct and canister from engine compartment to facilitate removal of relay box.3) Disconnect connector from relay box.4) Unlock cable clip.

5) Remove nuts which secure relay box, and remove relay box and connector bracket.

Do not drop or bump relay box.CAUTION:

INSTALLATION

1) Install relay box and connector bracket.

Tightening torque: 18 5 Nm (1.8 0.5 kg-m, 13.0 3.6 ft. lbs.)

2) Secure relay box connector to connector bracket.

Align connector with mating receptacle.CAUTION:

3) Using cable clip, secure hydraulic unit harness to relay box harness.

Make sure hydraulic unit harness band is secured beneath cable clip.CAUTION:

4) Connect connector to relay box.5) Install canister.6) Install air intake duct.7) Connect ground cable to battery.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Brake Fluid Pump Relay > Component Information > Technical Service Bulletins > Customer Interest for Brake Fluid Pump Relay: > 06-28-96 > Jun

> 96 > ABS Relay - Sticking

Brake Fluid Pump Relay: Customer InterestABS Relay - Sticking

NUMBER: 06-28-96DATE: 06-11-96
APPLICABILITY: LEGACY, IMPREZA AND SVX EQUIPPED WITH ABS BRAKES

SUBJECT: ABS RELAY STICKING

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Brake Fluid Pump Relay > Component Information > Technical Service Bulletins > Customer

Interest for Brake Fluid Pump Relay: > 06-28-96 > Jun > 96 > ABS Relay - Sticking > Page 50

Legacy GT Wagon AWD F4-2.5L DOHC (1997)

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Brake Fluid Pump Relay > Component Information > Technical Service Bulletins > Customer

Interest for Brake Fluid Pump Relay: > 06-28-96 > Jun > 96 > ABS Relay - Sticking > Page 51

Legacy GT Wagon AWD F4-2.5L DOHC (1997)

Should you encounter the following condition(s) please follow the trouble shooting chart as shown.
^ The ABS Hydraulic Unit Motor continues to run and/or buzz when the ignition key is turned to the off position.
^ The ABS warning light comes on and a trouble code "52" for a faulty hydraulic motor and/or motor relay is stored in memory.

Note:

It is possible for this condition to occur intermittently. Under these conditions the symptoms may not always be duplicated.

Troubleshooting Steps:

1. Check if the ABS Hydraulic Unit Motor is running or if you can duplicate the condition.

2. If the Hydraulic Unit Motor is running, does it continue to run with the key in the off position?

3. Confirm the trouble code, if any, and trouble shoot according to the Diagnostic Chart in the corresponding Service Manual.

4.
Replace the ABS Hydraulic Unit Motor Relay with a modified one. The new part number is 26735AA012. The new relay can be identified by awhite line under the word Japan on the relay case.

Note:

Always check the part number supersession for any changes.

5. If the wiring harness is at fault repair and/or replace as necessary.

The new ABS Motor Relay has been changed in production begining with the following VIN's.

Legacy (SIA built):

Sedan: T*206647S/W: T*308128O/B: T*374098
SVX: T*100004

Impreza: Sedan: T*510065S/W: T*810189Coupe: T*410116

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Brake Fluid Pump Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Fluid Pump Relay: >

06-28-96 > Jun > 96 > ABS Relay - Sticking

Brake Fluid Pump Relay: All Technical Service BulletinsABS Relay - Sticking

NUMBER: 06-28-96DATE: 06-11-96
APPLICABILITY: LEGACY, IMPREZA AND SVX EQUIPPED WITH ABS BRAKES

SUBJECT: ABS RELAY STICKING

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Brake Fluid Pump Relay > Component Information > Technical Service Bulletins > All

Technical Service Bulletins for Brake Fluid Pump Relay: > 06-28-96 > Jun > 96 > ABS Relay - Sticking > Page 57

Legacy GT Wagon AWD F4-2.5L DOHC (1997)

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Brake Fluid Pump Relay > Component Information > Technical Service Bulletins > All

Technical Service Bulletins for Brake Fluid Pump Relay: > 06-28-96 > Jun > 96 > ABS Relay - Sticking > Page 58

Legacy GT Wagon AWD F4-2.5L DOHC (1997)

Should you encounter the following condition(s) please follow the trouble shooting chart as shown.
^ The ABS Hydraulic Unit Motor continues to run and/or buzz when the ignition key is turned to the off position.
^ The ABS warning light comes on and a trouble code "52" for a faulty hydraulic motor and/or motor relay is stored in memory.

Note:

It is possible for this condition to occur intermittently. Under these conditions the symptoms may not always be duplicated.

Troubleshooting Steps:

1. Check if the ABS Hydraulic Unit Motor is running or if you can duplicate the condition.

2. If the Hydraulic Unit Motor is running, does it continue to run with the key in the off position?

3. Confirm the trouble code, if any, and trouble shoot according to the Diagnostic Chart in the corresponding Service Manual.

4.
Replace the ABS Hydraulic Unit Motor Relay with a modified one. The new part number is 26735AA012. The new relay can be identified by awhite line under the word Japan on the relay case.

Note:

Always check the part number supersession for any changes.

5. If the wiring harness is at fault repair and/or replace as necessary.

The new ABS Motor Relay has been changed in production begining with the following VIN's.

Legacy (SIA built):

Sedan: T*206647S/W: T*308128O/B: T*374098
SVX: T*100004

Impreza: Sedan: T*510065S/W: T*810189Coupe: T*410116

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Brakes - ABS ECU Replacement

Electronic Brake Control Module: Technical Service BulletinsBrakes - ABS ECU Replacement

NUMBER: 06-31-03R DATE: 12/08/04

APPLICABILITY: 1997~04MY Legacy, Outback & Baja (Excluding VDC Equipped Vehicles); 1998~04MY Impreza and Forester

SUBJECT:Replacement of ECU for ABS Repair
INTRODUCTION

In order to improve serviceability of ABS system, the ECU was subdivided and has been newly established as a spare part. This service bulletin detailsthe part numbers and replacement procedures of the ECU as a spare part.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins >

Brakes - ABS ECU Replacement > Page 63

Legacy GT Wagon AWD F4-2.5L DOHC (1997)

PARTS NUMBERS AND APPLICABLE MODELS
REPAIR PROCEDURE

1) Turn off the ignition switch.

2) Disconnect the negative terminal from the battery.

3) Disconnect the air intake duct from the Air Box.

4) Remove the air cleaner case from the inner fender.

Removal of ECU

:NOTE

When removing the ECU, the brake pipes remain connected.

1) Disconnect all electrical connections from the ECU (top and bottom).

2) Remove the two installation bolts (M8) from the bracket of the hydraulic unit and the ECU assembly

3) Lift the hydraulic unit and the ECU assembly from the bracket by about 5 cm (0.2 inches) and support it with a small piece of wood.

: CAUTION

Be careful not to deform the brake pipe during this procedure.

4) Unlock the connector for the motor power source and disconnect the connector as shown in figure 2.

5) Remove the 6 torx head screws (T20) which join the hydraulic unit and the ECU.

: NOTE

Do not reuse the torx head screws once removed.

6) Remove the ECU from the hydraulic unit by pulling it gently.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins >

Brakes - ABS ECU Replacement > Page 64

Legacy GT Wagon AWD F4-2.5L DOHC (1997)

:NOTE

A) Do not insert anything into the gap between the ECU and the hydraulic unit
B) Do not pry the ECU, but pull it straight from the hydraulic unit
C) Do not reuse the seal from the ECU.

Installation of new ECU

1) Confirm that the sealing surface of the hydraulic unit is clean.

:NOTE

A) Do not machine the sealing surface.
B) If the sealing surface is damaged, replace not only ECU but also the hydraulic unit and the ECU assembly with new one.
C) Clean dust or foreign material from the sealing surface with a clean cloth and alcohol.
D) Do not blow compressed air onto the ECU surface or the hydraulic unit

2) In order to prevent damage on the valves protruded from the hydraulic unit, do not tilt the ECU against the hydraulic unit when assembling.

3) Install the new ECU.

4) Temporarily tighten 6 screws by hand.

: NOTE

Do not reuse the screws that were previously removed from the ECU.

5)
Tighten the 6 screws in the exact order shown in Figure 4.4; use the specified tightening torque of 2.65 +/- 0.30Nm(1.95 +/- 0.22ft-lbs) (26.4inch-lbs).

6) Check if the screws are securely tightened by confirming no clearance between ECU and hydraulic unit visually.

7) Connect the motor power source connector to ECU.

: NOTE

Confirm that you hear a clicking sound when locking the connector lock.

8)

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins >

Brakes - ABS ECU Replacement > Page 65

Legacy GT Wagon AWD F4-2.5L DOHC (1997)

Install the hydraulic unit and the ECU assembly onto the bracket and tighten the two nuts with a tightening torque of 18 +/- 5Nm (13.28 +/- 3.69ft-lbs) (44.28 inch-lbs).

: NOTE

Attach the damper under the hydraulic unit with the hydraulic unit and the bracket securely.

9) Reconnect the ECU harness connector with the ECU.

Restoration of surrounding parts

1) Install the air cleaner case.

2) Install the air intake duct.

3) Connect the negative terminal to the battery.

Testing after replacement

1) Confirm that the ABS warning lamp light comes on on normally and then turns off when the ignition switch is turned on.

2) Connect the select monitor and confirm in the first dislay that the model year, driving system and transmission system are correct.

3) Confirm that the ABS warning lamp does not light when starting the engine and driving up to more than 12.5 m/h (20 km/h).

: NOTE

If something abnormal was found in above three testing procedures, follow the repair instructions described in the diagnostic procedures of thevehicle's Service Manual.

CLAIM REIMBURSEMENT/WARRANTY INFORMATION

For vehicles within the warranty period, this repair can be claimed using the warranty information shown.

Disclaimer

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions

Electronic Brake Control Module: Diagram Information and Instructions

The following color codes are used to indicate the colors of the wires used.

..................................................................................................................................................................................................................Color Code Color

L ...................................................................................................................................................................................................................................... BlueB ................................................................................................................................................................................................................................... BlackY ................................................................................................................................................................................................................................. YellowG ................................................................................................................................................................................................................................... GreenR ...................................................................................................................................................................................................................................... RedW .................................................................................................................................................................................................................................. WhiteBr ................................................................................................................................................................................................................................. BrownLg ......................................................................................................................................................................................................................... Light greenGr ................................................................................................................................................................................................................................... GrayP ...................................................................................................................................................................................................................................... PinkOr ................................................................................................................................................................................................................................ OrangeLb .......................................................................................................................................................................................................................... Light BlueV ................................................................................................................................................................................................................................... VioletSA .................................................................................................................................................................................................................... Sealed (Inner)SB ................................................................................................................................................................................................................... Sealed (Outer)

The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) byits first letter and the stripe marking by its second letter.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 68

Electronic Brake Control Module: Connector Views

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information

and Instructions > Page 69

Legacy GT Wagon AWD F4-2.5L DOHC (1997)

NOTE:

^ The terminal numbers in the ABS control module and hydraulic control unit connector are as shown in the figure.
^ When the connector is removed from the ABSCM&H/U, the connector switch closes the circuit between terminal No. 21 and No. 23. The ABS

warning light illuminates.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 70

Electronic Brake Control Module: Electrical Diagrams

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information

and Instructions > Page 71

Legacy GT Wagon AWD F4-2.5L DOHC (1997)

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information

and Instructions > Page 72

Legacy GT Wagon AWD F4-2.5L DOHC (1997)

(Part 1 Of 2)

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information

and Instructions > Page 73

Legacy GT Wagon AWD F4-2.5L DOHC (1997)

(Part 2 Of 2)

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Diagram Information

and Instructions > Page 74

Legacy GT Wagon AWD F4-2.5L DOHC (1997)

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > ABS Only

Electronic Brake Control Module: Description and OperationABS Only
DESCRIPTION

(ABSCM) (MCMs)

The ABS Control Module is a digital control type electronic control module accommodating two Microcontrol Modules ;master and slave. Both MCMs process the same program and monitor the respective outputs, and when a mismatch occurs, cut off the system toactivate the fail-safe function.A maximum of 3 trouble codes are stored in the EEP ROM and if 3 or more areas fail, then only the 3 most recent failures are stored. The troublecodes remain stored until they are erased.This ABSCM induces a sequence control pattern and facilitates the checking of the hydraulic unit.

ABS Control

Based on the four wheel speed signals, the ABSCM calculates a simulated body speed or body deceleration rate, while referencing the G sensoroutput as an auxiliary means, and compares them with the wheel speeds and wheel deceleration rates. If it determines that the wheels are about tolock, it controls the solenoid valve or motor pump of the H/U to adjust the brake fluid pressures that act on the wheel cylinders, thereby preventingthe wheels from locking. The ABSCM controls the right and left front wheel fluid pressures independently and controls the rear wheel fluid pressures on the basis of thewheel which is more likely to lock (Select-low control).

Select Monitor Associated Functions

The Subaru select monitor may be used to perform the following operations.^

To read out analog data.
^ To read out ON/OFF data.
^ To read out or erase trouble code.
^ To read out status information in the event of trouble (Freeze frame data).
^ To initiate ABS sequence control pattern.

Indication Functions

The ABS warning light can be made to indicate the following three states.^

ABS trouble.
^ Flashes to indicate trouble codes in diagnosis mode.
^ Valve ON/OFF when sequence control pattern is in effect.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > ABS Only > Page 77

Electronic Brake Control Module: Description and OperationABS With Traction Control

^ The Control Module of this system is a digitally controlled electronic control module equipped with two 8-bit CPUs of main and sub ones. The(C/M)

(TCS)

C/M not only logically processes wheel speed signals for the ABS control and Traction Control System control (brake control) functions buthas the self-diagnosis function, fail-safe function, and Subaru select monitor communication function. The C/M is installed under the front right seat.

^ The trouble codes of all the failures that occurred in the past are stored in the EEPROM. (When the same failure occurs twice or more, the trouble

code of the most recent failure is stored only once.) The trouble codes remain stored until they are erased. The trouble codes can be determined by theflashing of the TCS warning light located in the combination meter. This ABS/TCS control module induces a sequence control pattern (ABS, TCS)and facilitates the checking of the hydraulic unit.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Page 78

Electronic Brake Control Module: Testing and Inspection
INSPECTION

Check that connector is connected correctly and that connector terminal sliding resistance is correct.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > ABS Control Module

Electronic Brake Control Module: Service and RepairABS Control Module

Removal

REMOVAL

1) Remove floor mat located under lower right side of front seat.

2) Remove screw which secure ABS control module from the body.

3) Disconnect connector from ABS control module.

Inspection

INSPECTION

Check that connector is connected correctly and that connector terminal sliding resistance is correct.

Installation

INSTALLATION

1) Connect connector to ABS control module.2) Install ABS control module on the body.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > ABS Control Module > Page 81

Electronic Brake Control Module: Service and RepairABS/TCS Control Module

Removal

REMOVAL

1) Disconnect ground cable from battery.2) Remove floor mat located under lower right side of front seat.3) Remove screw which secure ABS/TCS control module from the body.4) Disconnect connector from ABS/TCS control module.

Inspection

INSPECTION

Check that connector is connected correctly and that connector terminal sliding resistance is correct.

Installation

INSTALLATION

1) Connect connector to ABS/TCS control module.2) Install ABS/TCS control module on the body.

CAUTION:

-

When installing seat rail, be careful no to have the harness caught in the rail.

- Cover the connector completely with rubber boot.

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations

Radiator Cooling Fan Motor Relay: Locations
Relay and Fuse

LOCATION

Relays used with A/C system are located as shown in figure.

1. A/C relay2. Main fan (radiator fan) relay3. Sub fan (condenser fan) relay4. Sub fan (condenser fan) water temperature relay5. Fuses ( and )10 A 20 A

> Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Testing and Inspection

Cruise Control Module: Testing and Inspection

Control Unit Pin Voltage Test

Refer to , for pin voltage test.Fig. 25

> Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations

Blower Motor Relay: Locations

LH side of I/P, near fuse Panel

> Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 94

Blower Motor Relay: Description and Operation
Hi Relay

The Hi relay is located on the heater unit. It receives a signal from the auto amplifier to operate the blower motor at high speed.

> Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations

Compressor Clutch Relay: Locations

LH side of Engine compartment in main fuse/relay box