Subaru 2003 Legacy Bedienungsanleitung

FUJI HEAVY INDUSTRIES LTD. G2300GE5

2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX

TRANSMISSION 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.

CONTROL SYSTEMS CS

AUTOMATIC TRANSMISSION AT

AUTOMATIC TRANSMISSION

(DIAGNOSTICS) AT

MANUAL TRANSMISSION AND

DIFFERENTIAL MT

CLUTCH SYSTEM CL

AUTOMATIC TRANSMISSION (DIAGNOS-

TICS) AT

Page

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

2. Check List for Interview...............................................................................5

3. General Description ....................................................................................6

4. Electrical Components Location..................................................................9

5. Transmission Control Module (TCM) I/O Signal .......................................14

6. Subaru Select Monitor...............................................................................21

7. Read Diagnostic Trouble Code (DTC)......................................................24

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

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

10. POWER Indicator Light Display ................................................................28

11. List of Diagnostic Trouble Code (DTC).....................................................29

12. Diagnostic Procedure for POWER Indicator Light ....................................30

13. Diagnostic Procedure for Select Monitor Communication.........................38

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

15. Diagnostic Procedure for No-diagnostic Trouble Code (DTC)................121

16. Symptom Related Diagnostic..................................................................160

AT-2

AUTOMATIC TRANSMISSION (DIAGNOSTICS)

BASIC DIAGNOSTIC PROCEDURE

1. Basic Diagnostic Procedure

A: PROCEDURE

Step Value Yes No

1 CHECK PRE-INSPECTION.

1) Ask the customer when and how the trou-

ble occurred using interview checklist.

<Ref. to AT-5, Check List for Interview.>

2) Before performing diagnosis, inspect the

following items which might influence the

AT problems.

•General inspection <Ref. to AT-6, INSPEC-

TION, General Description.>

•Oil leak

•Stall speed test <Ref. to AT-33, Stall Test.>

•Line pressure test <Ref. to AT-36, Line Pres-

sure Test.>

•Transfer clutch pressure test <Ref. to AT-38,

Transfer Clutch Pressure Test.>

•Time lag test <Ref. to AT-35, Time Lag Test.>

•Road test <Ref. to AT-32, Road Test.>

•Inhibitor switch <Ref. to AT-47, INSTALLA-

TION, Transmission Mounting System.>

Is unit that might influence the AT problem

normal?

Unit is normal. Go to step 2. Repair or replace

each item.

2 CHECK POWER INDICATOR LIGHT.

Turn ignition switch to ON.

Does not the POWER indicator light light up?

Indicator light flashes. Go to step 4. Go to step 3.

3 CHECK POWER INDICATOR LIGHT.

1) Turn ignition switch to OFF.

2) Repair POWER indicator light circuit or

power supply and ground line circuit.

<Ref. to AT-30, Diagnostic Procedure for

POWER Indicator Light.>

3) Turn ignition switch to ON.

Is the POWER indicator light flashing?

Indicator light flashes. Go to step 4. Go to step 5.

4 CHECK INDICATION OF DTC.

Calling up the DTC.

Without Subaru Select Monitor

<Ref. to AT-24, WITHOUT SUBARU SELECT

MONITOR, OPERATION, Read Diagnostic

Trouble Code (DTC).>

With Subaru Select Monitor

<Ref. to AT-25, WITH SUBARU SELECT

MONITOR, OPERATION, Read Diagnostic

Trouble Code (DTC).>

TE:

If the communication function of the select

monitor cannot be executed normally, check

the communication circuit. <Ref. to AT-38,

COMMUNICATION FOR INITIALIZING IM-

POSSIBLE, Diagnostic Procedure for Select

Monitor Communication.>

Is the DTC displayed?

DTC is displayed. Go to step 6.

TE:

Record all DTCs.

Go to step 5.

AT-3

AUTOMATIC TRANSMISSION (DIAGNOSTICS)

BASIC DIAGNOSTIC PROCEDURE

5 PERFORM THE GENERAL DIAGNOSTICS.

1) Inspect using “Diagnostic Procedure for

No-diagnostic Trouble Code (DTC)”. <Ref.

to AT-121, Diagnostic Procedure for No-

diagnostic Trouble Code (DTC).>

2) Inspect using “Symptom Related Diagnos-

tic”. <Ref. to AT-160, Symptom Related

Diagnostic.>

3) Perform the clear memory mode.

With Subaru Select Monitor

<Ref. to AT-27, WITH SUBARU SELECT

MONITOR, OPERATION, Clear Memory

Mode.>

Without Subaru Select Monitor

<Ref. to AT-27, WITHOUT SUBARU

SELECT MONITOR, OPERATION, Clear

Memory Mode.>

4) Perform the inspection mode. <Ref. to AT-

26, Inspection Mode.>

Calling up the diagnostic trouble code

(DTC).

Without Subaru Select Monitor

<Ref. to AT-24, WITHOUT SUBARU

SELECT MONITOR, OPERATION, Read

Diagnostic Trouble Code (DTC).>

With Subaru Select Monitor

<Ref. to AT-25, WITH SUBARU SELECT

MONITOR, OPERATION, Read Diagnos-

tic Trouble Code (DTC).>

Is the DTC displayed?

DTC is displayed Go to step 6. Complete the

diagnosis.

Step Value Yes No

AT-4

AUTOMATIC TRANSMISSION (DIAGNOSTICS)

BASIC DIAGNOSTIC PROCEDURE

6 PERFORM THE DIAGNOSIS.

1) Inspect using “Diagnostics Chart with Diag-

nostic Trouble Code”. <Ref. to AT-42, Diag-

nostic Procedure with Diagnostic Trouble

Code (DTC).>

TE:

For trouble code table, refer to “List of Diagnos-

tic Trouble Code (DTC)”. <Ref. to AT-29, List of

Diagnostic Trouble Code (DTC).>

2) Repair trouble cause.

3) Perform the clear memory mode.

With Subaru Select Monitor

<Ref. to AT-27, WITH SUBARU SELECT

MONITOR, OPERATION, Clear Memory

Mode.>

Without Subaru Select Monitor

<Ref. to AT-27, WITHOUT SUBARU

SELECT MONITOR, OPERATION, Clear

Memory Mode.>

4) Perform the inspection mode. <Ref. to AT-

26, Inspection Mode.>

5) Calling up the diagnostic trouble code

(DTC).

Without Subaru Select Monitor

<Ref. to AT-24, WITHOUT SUBARU

SELECT MONITOR, OPERATION, Read

Diagnostic Trouble Code (DTC).>

With Subaru Select Monitor

<Ref. to AT-25, WITH SUBARU SELECT

MONITOR, OPERATION, Read Diagnos-

tic Trouble Code (DTC).>

Is the DTC displayed?

DTC is displayed Inspect using

“Diagnostics Chart

with Diagnostic

Connector”. <Ref.

to AT-42, Diagnos-

tic Procedure with

Diagnostic Trou-

ble Code (DTC).>

Complete the

diagnosis.

Step Value Yes No

AT-5

AUTOMATIC TRANSMISSION (DIAGNOSTICS)

CHECK LIST FOR INTERVIEW

2. Check List for Interview

A: CHECK

Check the following items when problem has occurred.

NOTE:

Use copies of this page for interviewing customers.

Customer's name

Data vehicle brought in

Data of repair

Trans. model TRANSMISSION VIN

Odometer reading km/h or mile

Frequency ❏Continuous ❏Intermittent ( times a day)

Weather ❏Fine ❏Cloudy ❏Rainy ❏Snowy

❏Various/Others

( )

Place ❏Highway ❏Suburbs ❏Inner city ❏Uphill ❏Rough road

❏Others

()

Outdoor temperature ❏Hot ❏Warm ❏Cool ❏Cold

Vehicle speed km/h (MPH)

Malfunction indicator lamp (MIL) ❏Continuously lit ❏Not lit

Select lever position ❏P ❏R ❏N ❏D ❏3 ❏2 ❏1

Driving condition ❏Not affected

❏At racing

❏While decelerating

❏At starting

❏While accelerating

❏While turning (❏RH/❏

LH)

❏While idling

❏While cruising

POWER switch ❏ON ❏OFF

HOLD switch ❏ON ❏OFF

Symptoms ❏No up-shift

❏No down-shift

❏No kick down

❏Vehicle does not move (❏Any position ❏Particular position)

❏Lock-up malfunction

❏Noise or vibration

❏Shift shock or slip

❏Select lever does not move

❏Others

( )

AT-6

AUTOMATIC TRANSMISSION (DIAGNOSTICS)

GENERAL DESCRIPTION

3. General Description

A: CAUTION

•Supplemental Restraint System “Airbag”

Airbag system wiring harness is routed near the

transmission control module (TCM).

CAUTION:

•All airbag system wiring harness and con-

nectors are colored yellow. Do not use electri-

cal test equipment on these circuit.

•Be careful not to damage airbag system wir-

ing harness when performing diagnostics and

servicing the TCM.

•Measurement

When measuring voltage and resistance of the

ECM, TCM or each sensor, use a tapered pin with

a diameter of less than 0.64 mm (0.025 in) in order

to avoid poor contact. Do not insert the pin more

than 0.65 mm (0.0256 in).

B: INSPECTION

1. BATTERY

Measure battery voltage and specific gravity of

electrolyte.

Standard voltage: 12 V or more

Specific gravity: Above 1.260

2. TRANSMISSION GROUND

Make sure that the ground terminalbolt is tightened

securely.

•Chassis side

Tightening torque:

13 N·m (1.3 kgf-m, 9.4 ft-lb)

3. ATF LEVEL

Make sure that ATF level is in the specification.

<Ref. to AT-30, Automatic Transmission Fluid.>

4. FRONT DIFFERENTIAL OIL LEVEL

Make sure that front differential oil level is in the

specification.

AT-00621

(A) Level gauge

(B) Inspection position at ”HOT”

(D) Lower level

(E) Inspection position at ”COLD”

(A) Upper level

(B) Lower level

PI-00105

COLD

LF HOT

( A )

( C )

( D )

( C )

( D )

( E )

( B )

AT-00317

( B )

( A )

AT-7

AUTOMATIC TRANSMISSION (DIAGNOSTICS)

GENERAL DESCRIPTION

5. OPERATION OF SHIFT SELECT LEVER

Make sure there is no abnormal noise, dragging or

contact pattern in each select lever range.

WARNING:

Stop the engine while checking operation of se-

lect lever.

•Without SPORT shift

•With SPORT shift

6. POWER SWITCH

Make sure that POWER indicator light in combina-

tion meter comes ON, when turning power switch

to ON.

7. HOLD SWITCH

Make sure that HOLD indicator light in combination

meter comes ON, when turning hold switch to ON.

AT-00413

AT-00761

AT-00793

AT-00794

AT-8

AUTOMATIC TRANSMISSION (DIAGNOSTICS)

GENERAL DESCRIPTION

C: PREPARATION TOOL

1. SPECIAL TOOLS

2. GENERAL PURPOSE TOOLS

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

24082AA210

(Newly adopted tool) CARTRIDGE Troubleshooting for electrical systems.

22771AA030 SELECT MONITOR

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.

Oscilloscope Used for measuring sensor.

ST24082AA210

ST22771AA030

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