Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Subaru Legacy 1995-1999 Approved Subaru Legacy 1996 1996 Tech Service Bulletin 18-57-0034859
<< Back | HomeMost service manuals and schematics are PDF files, so You will need Adobre Acrobat Reader to view : Acrobat Download Some of the files are DjVu format. Readers and resources available here : DjVu Resources
For the compressed files, most common are zip and rar. Please, extract files with Your favorite compression software ( WinZip, WinRAR ... ) before viewing. If a document has multiple parts, You should download all, before extracting.
Good luck. Repair on Your own risk. Make sure You know what You are doing.
Image preview - the first page of the document
>> Download 18-57-0034859 documenatation <<
Text preview - extract from the document
ATTENTION:
GENERALMANAGER 0 PANSMANAGER 0
CWMSPERSONNEL .Q SERVlCEMANAGER .Q
IMPORTANT-All SeNice Personnel ShouldRead and Initid
APPLICABILITY: 1995-2000 Legacy Service Manual NUMBER: 18-57-00
SUBJECT: Service Manual Corrections DATE: 01/27/00
Replace the following revised pages into the applicable Service Manuals listed below:
YEAR VOL# I
MSA# I S E C ~ T O N PAGES I REFERENCE I
1995 2 MSA5T9407A- 3- 1 53-54 [w5B3] / [W5B4]
1996 5 MSA5T9607A 6-3 19 [D8041
1996 5 MSA5T9607A 6-3 25 m041
1997 6 MSA5T9701A 2-3b 13-14 [w3C1] / [w3C1]
1997 6 MSA5T9701A 6-3 67 [D8041
~~~ -
1997 7 MSA5T97 12A 4-4d 105-106 [TlOC4]/ [T10C5]
1997 7 1 MSA5T97 12A 4-4d 107-108 [TlOC8] / [TlODO]
1998 9 MSA5T9802A 4-4d 81-82 [TlOC6]/[TlOC7]
1998 9 MSA5T9802A 6-3 113 P8D11
1999 11 MSA5T9902A 3- 1 37-38 [WSCl] / [W7A1]
1999 12 MSA5T9903A 6-3 73 WD11
continued on next page
CAUTION
VEHICLE SERVICING PERFORMED BY UNTRAINED PERSONS COULD RESULT IN SERIOUS INJURY TO THOSE PERSONS O R TO OTHERS.
Subaru S~M- Bulletnsare intended lor use by prulessmal technlclans ONLY They ere w m to n moSe technclansof m d l m r mat may w r n some vehicles. or to p r o m
m tm
m l o r m a ~ t h a t c o u M a s u m m e ~ ~ ~ ~ l h e v PrOpBrhltnned~laanshavelheequlpment,tools.
ehcle safehlnstnmons.a n d k n o w h o w t o d o m e p b c t y M s a b t y
If a mndtlmn IS described, Do NOT assume mat I~IS Bulletin appliesto your vehele. or mat your vehlde mll have that cond~t~on
Sme
2000 4 MSA5T0004A 2-7 507 [T11BZ7]
2000 4 MSMT0004A 2-7 508 [T11BY8]
2000 5 MSA5T0005A 3- 1 33 ~ 3 ~ 1 1
2000 6 MSMT0006A 4-4 73 ~ 8 ~ 3 1
SERVICE PROCEDURE [W5B3] 3-1
5. Drive Pinion Assembly (AWD Model)
6) Install lock washer (42 x 53 x 2). Install lock nut (42 x
13) and tighten to the specified torque using ST.
ST 499987300 SOCKET WRENCH (50)
Tightening torque:
245 f 10 EI*m (25 f 1 kg-m, 181 f 7 ft-lb)
NOTE:
0 Stake lock nut at two points.
0 Using spring balancer, check that starting torque of
roller bearing @ is 0.1 to 1.5 N.m (1 to 15 kg-cm, 0.9 to
13.0 in-lb).
B3M0079A
3. DRIVE PINION SHAFT
1) Install roller bearing onto drive pinion. Install washer
@ (33 x 50 x 5) using ST1, ST2 and press.
ST1 499277100 BUSH 1-2 INSTALLER
ST2 499277200 INSTALLER
NOTE:
When installing roller bearing 0 ,note its directions (front
and rear) because knock pin hole @ in outer race is off-
set.
2) Install thrust bearing (33 x 50 x 3) and needle bearing
(30 x 37 x 23). Install driven shaft assembly @ .
I I
53
3-1 [WSB4] SERVICE PROCEDURE
5. Drive Pinion Assembly (AWD Model)
3) Install drive pinion collar @ , needle bearing @ (25 x
30 x 20), adjusting washer No. 2 8 (25 x 36 x 4), thrust
bearing @ (25 x 37.5 x 3), adjusting washer No. 1 @ (25
x 36 x t) and differential bevel gear sleeve @ in that order.
NOTE:
Be careful because spacer must be installed in proper
direction.
@ I
: Driven shaft
@ : pinion shaft
Driven
I
I I 4. ADJUSTMENT OF THRUST BEARING PRELOAD
1) After completing the preceding steps 1) through 3),
select adjusting washer No. 2 so that dimension @ is zero
through visual check. Position washer (18.3 x 30 x 4) and
lock washer (18 x 30 x 2) and install lock nut (18 x 13.5).
I
I 1
I - 2) Using ST1, ST2 and ST3, tighten lock nut to the spec-
ified torque.
ST1 899884100 HOLDER
ST2 498427100 STOPPER
ST3 899988608 SOCKET WRENCH (27)
Tightening torque:
718f8 N*m (72f0.8 k p m , 86.8f5.8 ft-lb)
3) After removing ST2, measure starting torque using
torque driver.
ST1 899884100 HOLDER
ST3 899988608 SOCKET WRENCH (27)
Starting torque:
0.3-0.8 N.m (3-8 kg-cm, 2.6-6.9 in-lb)
Revised 01/00 54 LEGACY 1995 Section 3-1
Connector Connecting to Connector Connecting to
No. Pole Color Arkta No. Name No. Pole Color Area No. Name
830 24 * C-1 D1 Front door cord LH 873 2 Black 8-3 Key lock solenoid (AT)
831 7 Yellow C-1 AB1 SRS (Airbag) harness 874 2 Black 8-3 Key warning switch
832 3 Black C-1 Turn 8 hazard module I
I
I I I
Test mode connector
833 4 Brown 6-1 Diode (TCS) 876 I 2 I Green I C-3 1875
834 I 3 I ~
* I
~-
6-1 I
-
!Diode (Door warning) B77 10 Brown 8-2 Mode actuator
835 2 Black 6-1 Diode (Step light) 878 9 Yellow C-2 Data link connector
836 22 Black C-I il 879 14 Gray C-2 Check connector
837
BM I
22
22 I Brown I C-1 I
I C-1 I '2
i3
Instrument panel wiring
harness
I I I
680
I
4 Blue I I I
6-2 i20 Instrument panel wiring
harness I
I I I I
B81 1x 2 ' C-2 Diagnosis terminal (Ground)
839 I 20 I Blue I C-1 1 i4
882 I 6 Black C-2 Diagnosis connector
840 16 Gray C-2 OBD-ll service connector
883 4 * c-3 Shield joint connector (E/G)
841 2 c-2 Power window circuit breaker
884 96 y!
i 8-3 Engine control module
843 I 6 I Black I C-2 I I Illumination control module I 885 1 2 I Black I 8-3 I I Diode (Lighting) I
B86 4 8-3 Blower motor resistor
844 c-2 Seat belt timer
887 2 6-3 Blower motor
845 B-1 R53 Sunroof cord
846 I 4 I Green I 6-1 I I Fuel pump relay I 688 I 3 I Black I 6-3 I I Evaporator thermoswitch I
-a 67Brown B-1 Main relay
689
690
4
4
Brown 8-3
8-4
Diode (Security)
R5O Room light cord
848 I 4 I Blue 6-1 I Front fog light relay
691 4 ' 8-4 FRESHlREClRC actuator
-
849 6-1 I
I
I Horn relay
I
~ ~~
892 8 6-1 Door lock timer
6-1 Blower relay
-
850
893 16 Black 8-4 Security control module
851 I 11 I Gray
FIB 894 20 Black 8-4 Cruise control module
852 I 12 I Gray
I 895 I 2 I Black I 8-4 I I Diode (Daytime running light) I
853 I I I 8-2 I I Shield joint connector (AT)
T
Jg
4 +
Daytime running light control
854 696 10 8-4
module
855 Transmission control module 897 0 * 8-4 R1
856 698 16 Black 8-4 R2 Rearwiring harness
-
857 Black 8-2 699 24 * 8-4 R3
Headlight alarm relay
(Security) I I I
6100 20 I 1 I
8-4 F2 Front wiring harness (With
ABS model) I
859 5 Black 6-1 Interrupt relay (Security) I 6101 I 24 1 I 8-4 I D11 IFront door cord RH I
* Shield joint connector (With 8102 5 Black 8-4 Daytime running light relay
660 4 8-2 TCS modell
High-beam relay (Daytime
861 8 * 8-2 F44 8103 4 Blue 8-4
running light)
Front wiring harness
862 I
I
20 I
1
* I 6-1 I F45
I I I
IBl041 4 I Pink I 8-4 I I Rear power supply relay I
Floor harness (With TCS 8105 4 Blue 6-1 Starter Interlock relay (MT)
863 40 Gray Bl
- plo
model)
8106 2 * 6-1 Clutch switch (MT)
6 4 I
I
2 I Black I
I I
8-2 I
1
IStop light switch
I
8107 2 Blue 8-1 Clutch switch (Cruise control)
Stop 8 brake switch (With
865 4 Black 8-2 cruise control)
I
I
BlOBl
I
2 I
I
Black I I I
1
B-2
I
F46
I
Front wiring harness
(Outback)
I
8109 4 Black C-1 Fuse holder (Outback)
8112 2 Black 6-1 Diode (Front fog light)
Combination switch ~- Connector - r Connecting to
No. Pole Color Area No. Name
Revised 01/00 19 LEGACY 1996 Section 6-3
a m I 0 0
8. Electrical Wiring Harness and Ground Point
I Connector I Connecting to I Connector I Connecting t o 1
No. Pole Color Area No.
Key lock solenoid (AT)
Yellow C-1 A01 SRS (Airbag) harness Key warning switch
032 Black C-1 Turn 6 hazard module
Test mode connector
033 Brown 0-1 Diode (Brake h i d level)
Diode (Door warning) Mode actuator
~ ~~~
Diode (Step light) Yellow Data link connector
036 Black 879 Check connector
037
038
039
I
22
22
20
I Brown
Blue C-1 i4
Instrument panel wiring
I 080
harness
Diagnosis terminal (Ground)
Diagnosis connector
040 16 Gray C-2 OBDll service connector
083 Shield joint connector (E/G)
041 2 c-2
043
1
6
1
Black
1
C-2
I
Power window and sunroof
Illumination control module
I 084
085 2
blue
Black 0-3
Engine control module
Diode (Lighting)
044 0 c-2 Seat belt timer I I
1
* I I I
045 I 4 I * I 0-1 I R53 ISunroof cord
087 I 2 1 I 0-3 I I Blower motor
046 4 Green 0-1 Fuel pump relay
088 I 3 I Black I 0 3 I I Evaporator thermoswitch I
047 6 Brown 0-1 Main relay
069 I 4 I Brown I 0-3 I I Diode (Security) I
i
w I 4 I Blue I 0-1 I Front fog light relay
I
090
091
4
4
0-4
0-4
RSO Room light cord
FRESHlREClRC actuator
Horn relay
092 8 0-1 Door lock timer
Blower relay
093 I 16 I Black I 0-4 I ISecurity control module I
FIB 094 20 Black 0-4 Cruise control module
052
895 2 Black 0-4 Diode (Daytime running light)
053 Shield joint connector (AT) I
Transmission control module
I
Daytime running light control
module I
097 8 0-4 Rl
098 24 Black 0-4 R2 Rear wiring harness
Biack 8-2 Shift-lock control module 099 24 0-4 R3
Black 0-1
Headlight alarm relay
(Security) BlOOl 20 1 Blue I I I
0-4 F2
Front wiring harness (With
ABS modell I
059 5 Black 0-1 Interrupt relay (Security) 0101 I 24 I * I 0-4 I D l l IFront door cord RH I
060 4 0-2
Shield joint connector (With
TCS model)
0102 I 5 I Black I 0-4 I IDaytime running light relay I
High-beam relay (Daytime
861 8 * 8-2 F44 0103 4 Blue 0-4 running light)
81041 4 Pink I 0-4 IRear power supply relay
063 4o Gray B-l plo
Floor hhrness (With TCS 01051 4 I Blue I 0-1 I 1 Starter interlock relay (MT)
864
I
2
I
Black
I
0-2
I I
Stop light switch
01061 2 I I 0-1 I IClutchswitch (MT) I
I I I 0-1 I IClutch switch (Cruisecontrol) I
Black I I
1
0-2
Stop 6 brake switch (With
cruise controll
, 8107
/B10812)8leck
2 Blue
1 I 6-2
Front wiring harness
F 4 8 1 (Outback) I
Pedal stroke sensor (TCS)
0109 4 Black C-1 Fuse holder (Outback)
Pedal stroke switch (TCS)
0112 2 Black 0-1 Diode (Front fog light)
Black Slip ring
~~ ~
069 I1 Black
070 Combination switch I Connector I Connecting to I
071 8 0-3 I No. I Pole I Color I Area I No. I Name I
6 Black 0-3 Ignition switch S1 3 White D-3 Cruise control sub switch
072
Revised 01100 25 LEGACY 1996 Section 6-3
U I m I 0 I n
5
m
W
0
5
m
c
U m 0 n
SERVICE PROCEDURE W C 1 I 2-3b
3. Camshaft
C: INSTALLATION
1. CAMSHAFT
~~
Tlghlenlng rorque: N-m ( k g m , W b )
T1: 5 f 0.5 (0.5 f 0.05, 3.6 f 0.4)
T2: 10 f 0.7 (1 .O i 0.07, 7.2 f 0.5)
~~~
Left side cylinder head 1) Camshaft installation
Exhaust
Apply engine oil to cylinder head at camshaft bearing
Intake camshaft location before installing camshaft. Install camshaft so
zamshaf 11" that rocker arm is close to or in contact with "base circle"
of cam lobe.
CAUTION:
0 When camshafts are positioned as shown in figure,
camshafts need to be rotated at a minimum to align with
timing belt during installation.
0 Right-hand camshaft need not be rotated when set at
position shown in figure.
Right side cylinder head
Left-hand Intake camshaft: Rotate 80" clockwise.
\ h
77.50
Intake
Left-hand exhaust camshaft Rotate 45" counter-clock-
camshafl wise.
B2M12001
Revised 01/00 13 LEGACY 1997 Section 2-3b
2-3b WSCIJ SERVICE PROCEDURE
3. Camshaft
2) Camshaft cap installation
(1) Apply fluid packing sparingly to cap mating sur-
face.
CAUTION:
Fluid Do not apply fluid packing excessively. Failure to do so
packing
may cause excess packing to come out and flow toward
oil seal, resulting in oil leaks.
Fluid packing:
I U G2M0752 I THREE BOND 1215 or equivalent
(2) Apply engine oil to cap bearing surface and install
cap on camshaft as shown by identification mark.
(3) Gradually tighten cap in at least two stages in the
numerical order shown in figure, and then tighten to
specified torque.
(4) Similarly, tighten cap on exhaust side.
After tightening cap, ensure camshaft rotates only
slightly while holding it at "base" circle.
3) Inspect for valve clearance.
Measure valve clearances using thickness gauge. < Ref.
to 2-2 [07A2].*8>
If necessary, adjust valve clearances.
I 02M1219A
4) Camshaft oil seal installation
Apply grease to new oil seal lips and press onto front end
of camshaft by using ST1 and ST2.
CAUTION:
Use a new oil seal.
ST1 499587100 OIL SEAL INSTALLER
ST2 499597000 OIL SEAL GUIDE
5) Rocker cover installation
(1) Install gaskets on rocker cover.
Install peripheral rocker cover gaskets.
(2) Apply fluid packing to four front open edges of
peripheral gasket.
Fluid packing:
THREE BOND 1215 or equivalent
( 3 ) Install rocker cover on cylinder head. Ensure gas-
ket is properly positioned during installation.
14
Connector I -
Connectina to I
No. Pole Color Area No. Name
374 I 2 I Black I 8-3 I Key warnina switch
375 1 I Green I C-2 I 876 Test mode connector
B76
B77
I
2
2
10
I Green I C-3 I 875
Brown
1
8-2 Mode actuator
1
878 9 Yellow C-2 Data link connector
879 14 Gray G2 Check connector
680 I 1 4 Blue [ 6-2 I i20 1 Instrument panel wiring
harness 1
I
I i
Instrument panel wiring
harness B81 1x 2 C-2 Diagnosis terminal (Ground)
882 6 Black C-2 Diagnosis connector
839 20 Blue C-1 i4
083 4 ' G3 Shield ioint connector (EIG)
840 16 Gray C-2 OBD-ll service connector
841 2 * c-2 Power window circuit breaker 884 I I fir I I I
96 8-3
Engine control module
I I I
042 4 * I I I
C-2
Power window and sunroof
relav I
851 11 Gray 0-1
FIB
852 12 Gray 8-1
853 4 8-2 Shield joint connector (AT)
,
854
855
12
16
Black
Black
8-2
8-2 Transmission control module
I I
2o I I B-4
Rear wiring harness
R2 (IOther modelsl 1
898 Rear wiring harness
856 20 Black 8-2 24 Black 8-4 R2 (2200 cc engine AWD except
857 12 Black 8-2 Shift-lock control module Taiwan model)
I 1 1
r
858 5 Black 0-1
Headlight alarm relay
(Security)
I 099 24 8-4
B-4
R3
F2
Rearwiring harness
Front wiring harness
859 5 Black 0-1 IInterrupt relay (Security) 2o Blue (With ABS model)
Shield joint connector 8101 24 8-4 Dl1 Front door cord RH
8-2 (With TCS model)
8102 5 Black 8-4 Daytime running light relay
061
862
8
20
*
*
8-2
0-1
F44
F45
- Front wiring harness 81031 4 I Blue I 1 I
8-4
High-beam relay
(Daytime running light) 1
Rear power supply relay
863 40 Gray 0-1 P10 Floor harness
(With TCS model)
Starter interlock relay (MT)
864 2 Black 8-2 I IStop light switch I Clutch switch (MT)
Stop d brake switch
065 4 Black 8-2 (With cruise control) 8107 Clutch switch (Cruise control)
8-2 Pedal stroke sensor (TCS)
0-2 Pedal stroke switch (TCS)
0109 4 Black C-1 Fuse holder (Outback)
I 068 I 5 I Black 8-3 Slip ring
8112 2 Black 8-1 Diode (Front log light)
8113 2 C-1 050 Front door cord LH
~
872 Black
I Connector ~~~ I Connecting to 1
No. Pole Color Area No. Name
873 2 Black
S1 3 White D-3 Cruise control sub switch
Revised 01100 67 LEGACY 1997 Section 6-3
a m 0 n
0
a m 0 P
BRAKES [ABS 5.3i TYPE] [ T I O W 4-4d
10. Diaanostics Chart with Select Monitor
1OC1 I CHECK GENERATOR. 1
1) Start the engine.
2) Idle the engine.
3) Measure voltage between generator and chassis
ground.
Termina l
Generator 6 terminal (+) - Chassis ground (1 -:
: IS the voltage between 10 and 15 V?
B4MD430
@ : Go to step 10C2.
: Repair generator.
I
1 1 0 ~ 2 CHECK BATTERY TERMINAL. I
Turn ignition switch to OFF.
@ : Is there poor contact at battery terminal?
@ : Repair battery terminal.
@ : Go to step 10C3.
CHECK COMMUNICATION OF SELECT
MONITOR.
Using the select monitor, check whether communication
to other system (such as engine, AT, etc.) can be executed
normally.
: Are the name and year of the system dis-
played on the select monitor?
@ : Go to step 10C4.
@ : Repair select monitor communication cable and
connector.
CHECK INSTALLATION OF ABSCM&H/U
loC4
CONNECTOR.
105
4 4 [TlOC51 BRAKES [ABS 5.31 TYPE]
10. Diagnostics Chart with Select Monitor
10CS CHECK POWER SUPPLY OF ABSCM&H/U.
1) Disconnect connector from ABSCM&H/U.
2) Start engine.
3) Idle the engine. ,
4) Measure voltage between ABSCM&H/U connector and
chassis ground.
Connector & terminal
(F49) No. I (+) - Chassis ground (-):
@ ; Is the voltage between 10 and 75 V?
@ : Go to step 10C6.
: Repair ABSCM&H/U power supply circuit.
llOC6 ICHECK GROUND CIRCUIT OF ABSCM&H/U. I
1) Turn ignition switch to OFF.
2) Measure resistance between ABSCM&H/U connector
and chassis ground.
Connector & terminal
(F49) No. 23 - Chassis ground:
; /s the resistance less than 0.5 Q?
: Go to step 10C7.
: Repair harness/connector between ABSCM&H/U
and select monitor.
Revised 01/00 106 LEGACY 1997 Section 4-4d
BRAKES [ABS 5.31 TYPE] VlOC81 4-4d
10. Diagnostics Chart with Select Monitor
1 0 ~ 7 CHECK HARNESSICONNECTOR BETWEEN
ABSCM&H/U AND DATA LINK CONNECTOR.
84M1267A
11OC8 ICHECK POOR CONTACT IN CONNECTORS. I
; Is there poor contact in connectors between
ABSCMLHIU and data link connector?
a : Repair connector.
a : Replace ABSCM&H/U.
Revised 01/00 107 LEGACY 1997 Section 4-4d
4-4d [TlODO] BRAKES [ASS 5.31 TYPE]
10. Diagnostics Chart with Select Monitor
D: NOTROUBLE
- ALTHOUGH NO TROUBLE APPEARS ON
THE SELECT MONITOR DISPLAY, THE ABS
DOALL I 1 ( F B 1 ) WARNING LIGHT REMAINS ON -
' DIAGNOSIS:
NO TROUBLE 0 ABS warning light circuit is shorted.
TROUBLE SYMPTOM:
0 ABS warning light remains on.
0 NO TROUBLE displayed on the select monitor.
NOTE:
When the ABS warning light is OFF and "NO TROUBLE"
is displayed on the select monitor, the system is in normal
condition.
WIRING DIAGRAM:
IGN sw SBF-4 FL1.258
Cornb inat ion
meter
ABS
control
module
and
hydraulic
contro I
unit
◦ Jabse Service Manual Search 2026 ◦ Jabse Pravopis ◦ onTap.bg ◦ Other service manual resources online : Fixya ◦ eServiceinfo