specifications SUBARU LEGACY 1997 Service Repair Manual

BRAKES
44

Page

S
SPECIFICATIONS
AND
SERVICE
DATA

1
.
Brakes

C
COMPONENT
PARTS
...........
.
.
.
.....................
.
.
......
..
.
.
.
..........................

1
.
FrontDisc
Brake

2
.
Rear
Disc
Brake

3
.
Rear
Drum
Brake

4
.
Master
Cylinder

5
.
Brake
Booster

6
.
ABS
System
7
.
Hill
Holder

8
.
Parking
(Hand)
Brake
9
.
ABS/TCS
System

10
.
ABS
System(ABS
5
.3i
Type)
...
....
.
...
..........................
.
.
...
.
.............

W
SERVICE
PROCEDURE
...............
.
.
......
.
.
...
.
....................
.
.
.
.
.
.
...
.
...
.
.......

1
.
Front
Disc
Brake
2
.
Rear
Disc
Brake

3
.
Rear
Drum
Brake
4
.
Parking
Brake
(Rear
Disc
Brake)
5
.
Master
Cylinder

6
.
Brake
Booster

7
.
Brake
Hose
8
.
Hill
Holder

9
.
Parking
Brake
Lever

10
.
Parking
Brake
Cable

11
.
Air
Bleeding
(Without
TCS
model)

12
.
Brake
Fluid
Replacement

13
.
Proportioning
Valve

14
.
ABS
Sensor

15
.
Hydraulic
Unit
for
ABS
System

16
.
ABS
Control
Module

17
.
G
Sensor
for
ABS
System

18
.
Brake
Hose
and
Pipe
am
.
.
.....
.
.................................
.
.
...
.
.....
..

19
.
Air
Bleeding
(With
TCS
model)

20
.
Hydraulic
Unit
for
ABS/TCS
System

21
.
ABS/TCS
Control
Module

22
.
Hydraulic
Unit
for
ABS
System
(ABS
5
.3
Type)

23
.
ABS
Control
Module
(ABS
5
.3
Type)

24
.
G
Sensor
for
ABS
System
(ABS
5
.3
Type)

25
.
ABS
Control
Module
and
Hydraulic
Control
Unit
(ABSCM&H/U)
[ABS
5
.3i
Type]
.
.
.
.
.
.
.
...
.
.
.
.
.
..
.
.
...................................
.
...
.
.
.........
..........
26
.
ABS
Sensor
(ABS
5
.3i
Type)
....
...........................................
.
.
....
.
...
.
27
G
Sensor
(ABS
5
3i
T
e)

2

....
.2

....
.4

........
.
.
..
.4

....
..
.15

....
..
.15
yp
....
.
.
......
...
.
...................................
.
.
.
.
.......
.
.
.....

K
DIAGNOSTICS

1
.
Entire
BrakeSystem

2
.
Hill
Holder

PRECAUTION
FORSUPPLEMENTAL
RESTRAINT
SYSTEM
"AIRBAG"
The
Supplemental
Restraint
System
"Airbag"
helps
to
reduce
the
risk
or
severity
of
injury
to
the
driver
in
a
frontal
collision
.
The
Supplemental
Restraint
System
consists
of
an
airbag
module
(located
in
the
center
of
the
steer-
ing
wheel),sensors,
a
control
module,warning
light,
wiring
harness
and
roll
connector
.
Information
necessary
to
servicethe
safety
is
included
in
the"5-5
.
SUPPLEMENTAL
RESTRAINT
SYSTEM"
ofthis
Service
Manual
.
WARNING
:
"
To
avoid
rendering
the
Airbag
system
inoperative,
which
could
lead
to
personal
injury
or
death
in
the
event
of
a
severe
frontal
collision,
all
maintenance
must
be
performed
byan
authorized
SUBARU
dealer
.
"
Improper
maintenance,
including
incorrect
removal
and
installation
of
the
Airbag
system,
can
lead
to
personal
injury
caused
by
unintentional
activation
of
the
Airbag
system
.
"
All
Airbag
system
electrical
wiring
harnesses
and
connectors
are
covered
with
yellow
outer
insu-
lation
.
Do
not
use
electrical
test
equipment
on
any
circuit
relatedtothe
Supplemental
Restraint
System
"Airbag"
.

4-4
[w2sBO]
SERVICE
PROCEDURE

25
.
ABS
Control
Module
and
Hydraulic
Control
Unit
(ABSCM&H/U)
[ABS
5
.3i
Type]

B
:
INSPECTION

i
Mark

>
ABSCM&H/U
B4M
1248A

/Pressure
ga
u
ge
\
'
/\

B4M0633A

1)
Check
connected
and
fixed
condition
of
connector
.

2)
Check
specifications
of
the
mark
with
ABSCM&H/U
.

Mark
Model

C3
AWD
AT

C4
AWD
MT

C
:
CHECKING
THE
HYDRAULIC
UNIT
ABS

OPERATION

1
.
CHECKINGTHE
HYDRAULIC
UNIT
ABS
OPERATION

BY
PRESSURE
GAUGE

1)
Lift-up
vehicle
and
remove
wheels
.

2)
Disconnect
the
air
bleeder
screwsfrom
the
FL
andFR

caliper
bodies
.

3)
Connect
two
pressure
gauges
to
the
FL
andFR
cali-

perbodies
.

CAUTION
:

Pressure
gauges
used
exclusively
for
brake
fluid

must
be
used
.

e
Do
not
employ
pressure
gauge
previously
used
for

transmission
since
the
piston
seal
is
expanded
which

may
lead
to
malfunction
of
the
brake
.

NOTE
:

Wrap
sealing
tape
around
the
pressure
gauge
.

8

SERVICE
PROCEDURE
Iwz7oo1
4-4

25
.
ABS
Control
Module
and
Hydraulic
Control
Unit
(ABSCM&H/U)
[ABS
5
.3i
Type]
-
27
.
G
Sensor
(ABS
5
.3i
Type)

E
:
INSTALLATION

1)
Install
ABSCM&H/U
.

CAUTION
:

Confirm
that
the
specifications
of
the
ABSCM&H/U
con-

forms
to
the
vehicle
specifications
.

Tightening
torque
:

18
f
5
N~m
(1
.8
±
0
.5
kg-m,
13
.0
±
3
.6ft-Ib)
2)
Connect
brake
pipes
to
their
correct
ABSCM&H/U
con-

nections
.
<
Ref
.
to
[W18A4]
.*10
>

3)
Using
cable
clip,
secure
ABSCM&H/U
harness
to

bracket
.

4)
Connect
connector
to
ABSCM&H/U
.

CAUTION
:

9
Be
sure
to
remove
all
foreign
matter
from
inside
the

connector
before
connecting
.

9
Ensure
that
the
ABSCM&H/U
connetor
is
securely

locked
.

5)
Install
air
intake
duct
.

6)
Connect
ground
cable
to
battery
.

7)
Bleed
air
from
the
brake
system
.

26
.
ABS
Sensor
(ABS
5
.3i
Type)

<
Ref
.
to
4-4
[W1400]
.*1
>

27
.
G
Sensor
(ABS
5
.3i
Type)

Ref
.
to
4-4
[W2400]
.*5
>

15

4-4d
[T1oo]
BRAKES
[ABS
5
.31
TYPE]

1
.
Supplemental
Restraint
System
"Airbag"
-
2
.
Pre-inspection

1
.
Supplemental
Restraint
System

"Airbag"

Airbagsystem
wiring
harness
is
routed
near
the
ABS

sensor,
ABS
control
module
and
hydraulic
control
unit
.

CAUTION
:

All
Airbag
system
wiring
harness
and
connectors
are

colored
yellow
.
Do
not
use
electrical
test
equipment
on

these
circuit
.

e
Be
careful
not
to
damage
Airbag
system
wiring
har-

ness
when
servicing
the
ABS
sensor,
ABS
control
mod-

ule
and
hydraulic
control
unit
.

2
.
Pre-inspection
Before
performing
diagnostics,
check
the
following
items

which
might
affect
ABS
problems
:

A
:
MECHANICAL
INSPECTION

1
.
POWER
SUPPLY

1)
Measure
battery
voltage
and
specific
gravity
of
electro-

lyte
.

Standard
voltage
:
12
V,
or
more

Specific
gravity
:
Above
1
.260

2)
Check
the
condition
of
the
main
and
other
fuses,
and

harnesses
and
connectors
.
Also
check
for
proper
ground-

ing
.

2
.
BRAKE
FLUID

1)
Check
brake
fluidlevel
.

2)
Check
brake
fluid
leakage
.

3
.
BRAKEDRAG

Check
brake
drag
.
<
Ref
.
to
4-4
[K100].*1
>

4
.
BRAKE
PADAND
ROTOR

Check
brake
padand
rotor
.
<
Ref
.
to
4-4
[K100].*1
>

5
.
TIRE
SPECIFICATIONS,
TIRE
WEARAND
AIR

PRESSURE

Check
tire
specifications,
tire
wear
and
air
pressure
.
<
Ref
.

to
4-2
[S1
A1
],
[S1
A2]
.*1
>

2

4-4d
[T1oo]
BRAKES
[ABS
5
.31
TYPE]

1
.
Supplemental
Restraint
System
"Airbag"
-
2
.
Pre-inspection

1
.
Supplemental
Restraint
System

"Airbag"

Airbagsystem
wiring
harness
is
routed
near
the
ABS

sensor,
ABS
control
module
and
hydraulic
control
unit
.

CAUTION
:

All
Airbag
system
wiring
harness
and
connectors
are

colored
yellow
.
Do
not
use
electrical
test
equipment
on

these
circuit
.

e
Be
careful
not
to
damage
Airbag
system
wiring
har-

ness
when
servicing
the
ABS
sensor,
ABS
control
mod-

ule
and
hydraulic
control
unit
.

2
.
Pre-inspection
Before
performing
diagnostics,
check
the
following
items

which
might
affect
ABS
problems
:

A
:
MECHANICAL
INSPECTION

1
.
POWER
SUPPLY

1)
Measure
battery
voltage
and
specific
gravity
of
electro-

lyte
.

Standard
voltage
:
12
V,
or
more

Specific
gravity
:
Above
1
.260

2)
Check
the
condition
of
the
main
and
other
fuses,
and

harnesses
and
connectors
.
Also
check
for
proper
ground-

ing
.

2
.
BRAKE
FLUID

1)
Check
brake
fluidlevel
.

2)
Check
brake
fluid
leakage
.

3
.
BRAKEDRAG

Check
brake
drag
.
<
Ref
.
to
4-4
[K100].*1
>

4
.
BRAKE
PADAND
ROTOR

Check
brake
padand
rotor
.
<
Ref
.
to
4-4
[K100].*1
>

5
.
TIRE
SPECIFICATIONS,
TIRE
WEARAND
AIR

PRESSURE

Check
tire
specifications,
tire
wear
and
air
pressure
.
<
Ref
.

to
4-2
[S1
A1
],
[S1
A2]
.*1
>

2

4-4d
[TSES1
BRAKES
[ABS
5
.31
TYPE]

8
.
Diagnostics
Chart
with
Trouble
Code
by
ABS
Warning
Light

G4M0700
I

Rear
Sensor
gap

G4M0701

8E8
I
CHECK
INSTALLATION
OFTONE
WHEEL
.

Tightening
torque
:

13
f
3
N~m
(1.3
f
0
.3
kg-m,
9
f
2
.2
ft-Ib)

CHECK
:
Are
thetone
wheel
installation
bolts
tight-

ened
securely?

,rES
:
Go
to
step
8E9
.

No
:
Tightentone
wheel
installation
bolts
securely
.

8E9
I
CHECK
ABS
SENSOR
GAP
.

Measure
tone
wheel-to-pole
piece
gap
over
entire
perim-

eter
of
the
wheel
.

CHECK
;
Is
the
gap
within
the
specifications
shown
in

the
following
table?

Front
wheel
Rear
wheel

Specifications0
.9
-
1
.4
mm

(0
.035
-
0
.055
in)
0
.7
-
1
.2
mm

(0
.028
-
0
.047
in)

ves
:
Go
to
step
8E10
.

No
:
Adjust
the
gap
.

NOTE
:

Adjust
the
gap
using
spacers
(Part
No
.
26755AA000)
.
If

spacers
cannot
correct
the
gap,
replace
worn
sensor
or

worn
tone
wheel
.

8E10
CHECK
HUB
RUNOUT
.

Measure
hub
runout
.

CHECK
:
Is
the
runouf
less
than
0
.05
mm
(0
.0020
in)?

vES
:
Go
to
step
8E11
.

No
:
Repair
hub
.

36
Sensorgap

BRAKES
[ABS
5
.31
TYPE]
[T814]
4-4d

8
.
DiagnosticsChart
with
Trouble
Code
by
ABS
Warning
Light

G4M0700

G4M0701

811
1
CHECK
INSTALLATION
OF
ABS
SENSOR
.

Tightening
torque
:

32
f
10
N~m
(3
.3
+
1
.0
kg-m,
24
f
7
ft-Ib)

CHECK
:
Are
the
ABS
sensor
installation
bolts
tight-

ened
securely?

vES
:
Go
to
step
812
.

No
:
Tighten
ABS
sensor
installation
bolts
securely
.

812
1
CHECK
INSTALLATION
OF
TONEWHEEL
.l

Tightening
torque
:

13
f
3
N
&#34;
m
(1.3
f
0
.3
kg-m,
9
f
2
.2
ft-Ib)

CHECK
:
Are
the
tone
wheel
installation
bolts
tight-

ened
securely?

vES
:
Go
to
step
813
.

No
:
Tightentone
wheel
installation
bolts
securely
.

$13
I
CHECK
ABS
SENSOR
GAP
.

Measure
tone
wheel
to
pole
piece
gap
over
entire
perim-

eterof
the
wheel
.

CHECK
:
Is
the
gap
within
the
specifications
shown
in

the
following
table?

Front
wheel
Rear
wheel

Specifications
0
.9
-
1
.4
mm

(0
.035
-
0
.055
in)
0
.7
-
1.2
mm

(0
.028
-
0
.047
in)

0
:
Go
to
step
814
.

No
:
Adjust
the
gap
.

NOTE
:

Adjustthe
gap
using
spacer
(Part
No
.
26755AA000)
.
If

spacers
cannot
correct
the
gap,
replace
worn
sensor
or

worn
tone
wheel
.

1814
1
CHECK
OSCILLOSCOPE
.

Is
an
oscilloscopeavailable?

,res
:
Go
to
step
815
.

No
:
Go
to
step
816
.

41

Sensor
gap

Sensor
gap

BRAKES
[ABS
5
.31
TYPE]
[T8J5]
4-4d

8
.
Diagnostics
Chart
with
Trouble
Code
by
ABS
Warning
Light

811
CHECK

FREELY'FOR
ALONG
TIME
.

TURNED

Check
if
the
wheels
havebeen
turned
freely

for
more
than
one
minute,
such
as
when
the

vehicle
is
jacked-up,
under
full-lock
corner-
ing
or
when
fire
is
not
in
contact
with
road

surface
.

The
ABS
is
normal
.
Erase
the
trouble
code
.

NOTE
:

When
the
wheels
turn
freely
for
along
time,
such
as
when

the
vehicle
is
towed
or
jacked-up,
or
when
steering
wheel

is
continuouslyturned
all
the
way,
this
trouble
code
may

sometimes
occur
.

No
:
Go
to
step
8,12
.

18J2
I
CHECK
TIRE
SPECIFICATIONS
.

CHECK
:
Are
the
fire
specifications
correct?

,res
:
Go
tostep8
.113
.

No
:
Replace
tire
.

18,13
1
CHECK
WEAR
OF
TIRE
.

CHECK
:
Is
the
fire
worn
excessively?

,res
:
Replace
tire
.

No
:
Go
tostep
8,14
.

18J4
I
CHECK
TIRE
PRESSURE
.

CHECK
:
Is
the
fire
pressure
correct?

,rES
:
Go
to
step
8J5
.

No
:
Adjust
tire
pressure
.

18,15
1
CHECK
INSTALLATION
OF
ABS
SENSOR
.

Tighteningtorque
:

32
f
10
N~m
(3
.3
f
1
.0
kg-m,
24
±
7
ft-Ib)

CHECK
:
Are
the
ABS
sensor
installation
bolts
tight-

ened
securely?

,res
:
Go
to
step
8J6
.

No
:
Tighten
ABS
sensor
installation
bolts
securely
.

49

4-4d
[TSJs1
BRAKES
[ABS
5
.31
TYPE]

8
.
Diagnostics
Chart
with
Trouble
Code
by
ABS
Warning
Light

G4M0700
I

G4M0701

CHECK
INSTALLATION
OF
TONE
WHEEL
.

Tightening
torque
:

13
f
3
N~m
(1.3
f
0
.3
kg-m,
9
f
2
.2
ft-Ib)

CHECK
:
Are
the
tone
wheel
installation
bolts
tight-

ened
securely?

,res
:
Go
to
step
8J7
.

No
:
Tightentone
wheel
installation
bolts
securely
.

8J7
I
CHECK
ABS
SENSOR
GAP
.

Measure
tone
wheel
to
pole
piece
gap
over
entire
perim-

eter
of
the
wheel
.

CHECK
:
Is
the
gap
within
thespecifications
shown
in

the
following
table?

Front
wheel
Rear
wheel

Specifications
0
.9
-
1.4
mm

(0
.035
-
0
.055
in)
0
.7
-
1.2
mm

(0
.028
-
0
.047
in)

,
.ES
:
Go
tostep
8J8
.

No
:
Adjust
the
gap
.

NOTE
:

Adjustthe
gap
using
spacer
(Part
No
.
26755AA000)
.
If

spacers
cannot
correct
the
gap,
replace
worn
sensor
or

worn
tone
wheel
.

18,18
1
CHECK
OSCILLOSCOPE
.

Is
an
oscilloscopeavailable?

YES
:
Go
to
step
8J9
.

No
:
Go
to
step
8,1110
.

8J9
I
CHECK
ABS
SENSOR
SIGNAL
.

1)
Raise
all
four
wheels
of
ground
.

2)
Turn
ignition
switch
OFF
.

3)
Connect
theoscilloscope
to
the
connector
(F1)
or
con-

nector(B100)
.

4)
Turn
ignition
switch
ON
.

50

t
Sensor
gap

Sensor
gap

BRAKES
[ABS
5
.31
TYPE]
[TM]
4-4d

8
.
Diagnostics
Chart
with
Trouble
Code
by
ABS
Warning
Light

`L/

Tn
Mark
1
h
.I
t,~
\
;d

ABSCM&HlU
B4M
1248A

181
.11
I
CHECK
SPECIFICATIONS
OF
THE
ABSCM
.

Check
specifications
of
the
mark
to
the
ABSCM&H/U
.

Mark
Model

C3
AWD
AT

C4
AWD
MT

CHECK
:
Is
an
ABSCM&H/U
for
AT
model
installed
on

a
MT
model?

,res
:
Replace
ABSCM&H/U
.

No
:
Go
to
step
81
.12
.

$U2
CHECK
GROUND
SHORT
OF
HARNESS
.

1)
Turn
ignition
switch
to
OFF
.

2)
Disconnect
two
connectors
from
TCM
.

3)
Disconnect
connector
from
ABSCM&H/U
.

4)
Measure
resistance
between
ABSCM&H/U
connector

and
chassis
ground
.

Connector
&
terminal

(F49)
No
.
3
-
Chassis
ground
:

CHECK
:
Is
theresistance
more
than1
MS2?

ves
:
Go
to
step
8U3
.

No
:
Repair
harness
between
TCM
and
ABSCM&H/U
.

181
.13
CHECK
BATTERY
SHORT
OF
HARNESS
.

Measure
voltage
between
ABSCM&H/U
connector
and

chassis
ground
.

Connector
&
terminal

(F49)
No
.
3
(+)
-
Chassis
ground
(
)
:

CHECK
;
Is
thevoltage
less
than
1
V?

YES
:
Go
to
step
8U4
.

No
:
Repair
harness
between
TCM
and
ABSCM&H/U
.

71