light SUBARU LEGACY 1995 Service Manual PDF

F: TCS SEQUENCE CONTROL
1) Under the TCS sequence control, after the hydraulic
unit solenoid valve is driven, the operation of the hydraulic
unit can be checked by means of the brake tester or pres-
sure gauge.
2) TCS sequence control can be started by diagnosis con-
nector or select monitor.
B4M0082C
1. OPERATIONAL GUIDELINES OF THE TCS
SEQUENCE CONTROL WITH DIAGNOSIS
CONNECTOR
1) Connect diagnosis terminals to terminal No. 4 of the
diagnosis connector beside driver seat heater unit.
2) Ignition switch is turned to ON.
3) Make sure only the start code (code 11) is shown in
normal condition.
NOTE:
When trouble codes are stored in memory, repair the faulty
parts.
4) Set the speed of all wheels at 10 km/h (6 MPH) or less.
5) Turn ignition switch OFF.
6) Start engine, and within 0.5 seconds after the ABS
warning light and TCS warning light go out, press TCS OFF
switch. Within 1.0 second thereafter, release and press the
switch again. Then, keep the switch pressed.
NOTE:

When the TCS sequence control is set to on, the brake
pedal must not be depressed.

Engine must operate.

When TCS OFF switch is not depressed within 0.5 sec-
onds after ABS and TCS warning lights turn off, the trouble
code mode comes on.
7) After completion of TCS sequence control, turn ignition
switch OFF.
95
4-4SERVICE PROCEDURE
20. Hydraulic Unit for ABS/TCS System

3. CONDITIONS FOR COMPLETION OF TCS
SEQUENCE CONTROL
When the following conditions develop, the TCS sequence
control stops and ABS and TCS warning lights come on
while the ABS and TCS function will then stop. The brake
system functions as a conventional brake system.
1) When the speed of at least one wheel reaches 10 km/h
(6 MPH).
2) When terminal No. 4 is separated from ground. (When
select monitor is not used.)
3) When the brake pedal is depressed during sequence
control and the braking lamp switch is set to ON.
4) When TCS OFF switch is released. (When select moni-
tor is not used.)
5) After completion of the TCS sequence control.
6) When output signal to break TCS control is emitted from
ECM.
7) When malfunction is detected.
NOTE:
When malfunction has been detected and the TCS
sequence control operation has stopped, the trouble codes
are stored in memory.
97
4-4SERVICE PROCEDURE
20. Hydraulic Unit for ABS/TCS System

1. Pedal (MT Model)
B4M0737A

1Accelerator pedal


2Bushing


3Holder


4Accelerator bracket


5Stopper


6Clip


7Accelerator spring


8Accelerator pedal spring


9Spring pin


10Accelerator pedal pad


11Accelerator stopper


12Clip


13Accelerator plate

14Pedal bracket


15Stop light switch (Without T.C.S.) /
stroke sensor (With T.C.S.)


16Brake pedal


17Spacer


18Snap pin


19Brake pedal pad


20Clevis pin


21Brake pedal spring


22Washer


23Clutch pedal pad


24Clutch pedal


25Bushing assist

26Spring assist


27Clutch cable clamp


28Clutch cable


29Mass damper


30Clutch switch (Starter interlock)


31Clutch switch (With cruise control)
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 5.9±1.5 (0.60±0.15, 4.3±1.1)
T2: 8±2 (0.8±0.2, 5.8±1.4)
T3: 18±5 (1.8±0.5, 13.0±3.6)
T4: 29±7 (3.0±0.7, 21.7±5.1)
3
4-5COMPONENT PARTS
1. Pedal (MT Model)

2. Pedal (AT Model)
1. LHD MODEL
B4M0738A

1Accelerator pedal


2Bushing


3Holder


4Accelerator bracket


5Stopper


6Clip


7Accelerator spring


8Accelerator pedal spring


9Spring pin


10Accelerator pedal pad

11Accelerator stopper


12Clip


13Accelerator plate


14Plug


15Pedal bracket


16Stop light switch (Without T.C.S.) /
stroke sensor (With T.C.S.)


17Spacer


18Stopper


19Snap pin

20Brake pedal pad


21Brake pedal


22Clevis pin


23Brake pedal spring
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 8±2 (0.8±0.2, 5.8±1.4)
T2: 18±5 (1.8±0.5, 13.0±3.6)
T3: 29±7 (3.0±0.7, 21.7±5.1)
4
4-5COMPONENT PARTS
2. Pedal (AT Model)

2. RHD MODEL
B4M0677A

1Accelerator pedal


2Accelerator pedal spring


3Spring pin


4Accelerator pedal pad


5Stopper


6Bushing


7Holder


8Pedal bracket

9Clip


10Stop light switch


11Accelerator spring


12Brake pedal spring


13Brake pedal


14Spacer


15Clevis pin


16Brake pedal pad

17Snap pin


18Bushing
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 8±2 (0.8±0.2, 5.8±1.4)
T2: 18±5 (1.8±0.5, 13.0±3.6)
T3: 29±7 (3.0±0.7, 21.7±5.1)
5
4-5COMPONENT PARTS
2. Pedal (AT Model)

B4M0366A
1. Pedal
A: ON-CAR SERVICE
1. BRAKE PEDAL
1) Check position of pedal pad.


1Stop light switch


2Mat


3Toe board


4Brake booster operating rod
Pedal height: L
148 mm (5.83 in)
If it is not in specified value, adjust it by adjusting brake
booster operating rod length.
2) Check free play by operating pedal by hand.
If it is not in specified value, adjust it by adjusting position
of stop light switch.
CAUTION:
Be careful not to rotate stop light switch.
Brake pedal free play: A
1 — 3 mm (0.04 — 0.12 in)
[Depress brake pedal pad with a force of less than
10 N (1 kg, 2 lb).]
Stop light switch lock nut tightening torque:
8±2 N⋅m (0.8±0.2 kg-m, 5.8±1.4 ft-lb)
3) Apply grease to operating rod connecting pin to prevent
it from wearing.
G4M0318
2. CLUTCH PEDAL
1) Check clutch pedal free play by operating pedal by
hand.
Free play: L (At clutch pedal pad)
10 — 20 mm (0.39 — 0.79 in)
B4M0367A
Pedal height: Y
158 mm (6.22 in)
Pedal stroke: A
140 — 145 mm (5.51 — 5.71 in)


1Toe board


2Mat
6
4-5SERVICE PROCEDURE
1. Pedal

2. BRAKE AND CLUTCH PEDAL (LHD MODEL)
1) Disconnect ground cable from battery.
2) Disconnect clutch cable from release lever.
3) Remove instrument panel lower cover from instrument
panel.
4) Disconnect the following parts from pedal bracket.
(1) Operating rod of brake booster
(2) Electrical connectors (for stop light switch, etc.)
5) Remove clevis pin which secures pedal to push rod.
B4M0154A
6) Remove bolts and nuts which secure brake and clutch
pedals, and remove pedal bracket and clutch cable as a
unit.
CAUTION:
Before removing clutch cable from toe board, remove
grommet. Slowly remove clutch cable, being careful
not to scratch it.
7) Depress clutch pedal, disconnect clutch cable from
clutch pedal.
G4M0324
3. BRAKE PEDAL (LHD MODEL)
1) Disconnect ground cable from battery.
2) Remove instrument panel lower cover from instrument
panel.
3) Remove clevis pin which secures brake pedal to brake
booster operating rod. Also disconnect stop light switch
connector.
4) Remove two bolts and four nuts which secure brake
pedal to pedal.
9
4-5SERVICE PROCEDURE
1. Pedal

4. ACCELERATOR AND BRAKE PEDAL (RHD
MODEL)
1) Disconnect negative cable from battery.
2) Disconnect accelerator cable from throttle body.
CAUTION:
Be careful not to kink accelerator cable.
3) Remove instrument panel lower cover from instrument
panel.
4) Remove clevis pin which secures brake pedal to brake
booster operating rod. Also disconnect electrical connec-
tors (for stop light switch, etc.).
G4M0322
5) Disconnect accelerator cable from accelerator pedal
lever.
B4M0156A
6) Remove the casing cap out of the toe board by turning
it clockwise.
7) Pull out the cable from the toe board hole.
10
4-5SERVICE PROCEDURE
1. Pedal

G4M0325
G4M0326
C: INSPECTION
1. BRAKE AND CLUTCH PEDALS
Move brake and clutch pedal pads in the lateral direction
with a force of approximately 10 N (1 kg, 2 lb) to ensure
pedal deflection is in specified range.
Deflection of brake and clutch pedal:
Service limit
5.0 mm (0.197 in) or less
CAUTION:
If excessive deflection is noted, replace bushings with
new ones.
G4M0333
2. ACCELERATOR PEDAL
Lightly move pedal pad in lateral the direction to ensure
pedal deflection is in specified range.
Deflection of accelerator pedal:
Service limit
5.0 mm (0.197 in) or less
CAUTION:
If excessive deflection is noted, replace bushing and
clip with new ones.
G4M0327
3. STOP LIGHT SWITCH
If stop light switch does not operate properly (or if it does
not stop at the specified position), replace with a new one.
Specified position: L
2.8
+1.5
0mm (0.110+0.059
0in)
12
4-5SERVICE PROCEDURE
1. Pedal

G4M0329
D: ASSEMBLY
1. BRAKE AND CLUTCH PEDAL
1) Attach stop light switch, etc. to pedal bracket tempo-
rarily.
2) Clean inside of bores of clutch pedal and brake pedal,
apply grease, and set bushings into bores.
3) Align bores of pedal bracket, clutch pedal and brake
pedal, attach brake pedal return spring and clutch pedal
effort reducing spring (vehicle with hill holder), and then
install pedal bolt.
Tightening torque:
T2: 29±7 N⋅m (3.0±0.7 kg-m, 21.7±5.1 ft-lb)
NOTE:
Clean up inside of bushings and apply grease before
installing spacer.
4) Set brake pedal position by adjusting position of stop
light switch.
Pedal position: L
125.9 mm (4.96 in)
Tightening torque:
T1: 8±2 N⋅m (0.8±0.2 kg-m, 5.8±1.4 ft-lb)
2. ACCELERATOR PEDAL
Clean and apply grease to spacer and inside bore of accel-
erator pedal. Install accelerator pedal onto pedal bracket.
13
4-5SERVICE PROCEDURE
1. Pedal