SUBARU LEGACY 1996 Service Repair Manual

B4M1005
7) Remove bolt cover and bolt.
B4M1006
8) Remove ABSCM upper mounting bolt.
B4M1045A
9) Pull the lower part of the instrument panel rearward 5
cm (1.97 in).
CAUTION:
When pulled more than 6 cm (2.4 in), the instrument
panel may be deformed.
NOTE:
At this time, instrument panel securing clips can be
removed.
B4M1008
10) Remove two ABSCM lower mounting bolts from the
lower part of the instrument panel.
B4M1009A
11) While holding the lower part of instrument panel rear-
ward 5 cm (1.97 in) remove the ABSCM.
CAUTION:
When pulled more than 6 cm (2.4 in), the instrument
panel may be deformed.
12) Disconnect connector from ABSCM.
CAUTION:
Do not drop or bump ABSCM.
120
4-4SERVICE PROCEDURE
23. ABS Control Module (ABS 5.3 Type)

B: INSPECTION
Check that connector is connected correctly and that con-
nector terminal sliding resistance is correct.
C: INSTALLATION
To install, reverse the removal procedure.
121
4-4SERVICE PROCEDURE
23. ABS Control Module (ABS 5.3 Type)

24. G Sensor for ABS System (ABS 5.3
Type)
A: REMOVAL AND INSTALLATION
1) Turn ignition switch to OFF.
2) Remove console box.
3) Disconnect connector from G sensor.
B4M1011
4) Remove G sensor from body.
5) To install, reverse the removal procedure.
CAUTION:
Do not drop or bump G sensor.
B4M0915
B: INSPECTION
1. USING CIRCUIT TESTER
1) Turn ignition switch to OFF.
2) Remove G sensor from vehicle.
3) Connect connector to G sensor.
4) Turn ignition switch to ON.
5) Measure voltage between G sensor connector termi-
nals.
: Connector & terminal
(P9) No. 2 (+)—No.1()
Is voltage 2.3±0.2 V when G sensor is hori-
zontal?
: Go to next.
: Replace G sensor.
B4M0917A
: Connector & terminal
(P9) No. 2 (+)—No.1()
Is voltage 3.9±0.2 V when G sensor is
inclined forwards to 90°?
: Go to next.
: Replace G sensor.
122
4-4SERVICE PROCEDURE
24. G Sensor for ABS System (ABS 5.3 Type)

B4M0918A
: Connector & terminal
(P9) No. 2 (+)—No.1()
Is voltage 0.7±0.2 V when G sensor is
inclined backwards to 90°?
: G sensor is normal.
: Replace G sensor.
2. USING SELECT MONITOR
1) Turn ignition switch to OFF.
2) Connect select monitor connector to data link connec-
tor.
3) Turn select monitor into ABS mode.
B4M0927
4) Press F,1and 0on the select monitor.
5) Read the select monitor display.
: Is the indicated reading 2.3±0.2 V when the
vehicle is in horizontal position?
: Go to next step 6).
: Replace G sensor.
6) Remove console box.
7) Remove G sensor from vehicle. (Do not disconnect
connector.)
B4M0917A
8) Read the select monitor display.
: Is the indicated reading 3.9±0.2 V when G
sensor is inclined forwards to 90°?
: Go to next.
: Replace G sensor.
B4M0918A
: Is the indicated reading 0.7±0.2 V when G
sensor is inclined backwards to 90°?
: G sensor is normal.
: Replace G sensor.
123
4-4SERVICE PROCEDURE
24. G Sensor for ABS System (ABS 5.3 Type)

1. Entire Brake System
Trouble and possible cause Corrective action
1. Insufficient braking
(1) Fluid leakage from the hydraulic mechanismRepair or replace (cup, piston seal, piston boot, master cylinder
piston kit, pipe or hose).
(2) Entry of air into the hydraulic mechanism Bleed the air.
(3) Excessively wide shoe clearance Adjust the clearance.
(4) Wear, deteriorated surface material, adhering water or fluid
on the liningReplace, grind or clean.
(5) Improper operation of master cylinder, disc caliper, brake
booster or check valveCorrect or replace.
2. Unstable or uneven braking
(1) Fluid on the lining, drum or rotor Eliminate cause of fluid leakage, clean, or replace.
(2) Drum or rotor eccentricity Correct or replace the drum or rotor.
(3) Worn brake drum, or damage to the drum caused by sand Correct by grinding, or replace.
(4) Improper lining contact, deteriorated surface material,
improper inferior material, or wearCorrect by grinding, or replace.
(5) Deformed back plate Correct or replace.
(6) Improper tire inflation Inflate to correct pressure.
(7) Disordered wheel alignment Adjust alignment.
(8) Loosened back plate or the support installing bolts Retighten.
(9) Loosened wheel bearing Retighten to normal tightening torque or replace.
(10) Trouble in the hydraulic system Replace the cylinder, brake pipe or hose.
(11) Uneven effect of the parking brake Check, adjust, or replace the rear brake and cable system.
3. Excessive pedal stroke
(1) Entry of air into the hydraulic mechanism Bleed the air.
(2) Excessive play in the master cylinder push rod Adjust.
(3) Fluid leakage from the hydraulic mechanismRepair or replace (cup, piston seal, piston boot, master cylinder
piston kit, pipe or hose).
(4) Improperly adjusted shoe clearance Adjust.
(5) Improper lining contact or worn lining Correct or replace.
124
4-4DIAGNOSTICS
1. Entire Brake System

Trouble and possible cause Corrective action
4. Brake dragging or improper brake return
(1) Insufficient pedal play Adjust play.
(2) Improper master cylinder return Clean or replace the cylinder.
(3) Clogged hydraulic system Replace.
(4) Improper return or adjustment of parking brake Correct or adjust.
(5) Weakened spring tension or breakage of shoe return spring Replace the spring.
(6) Excessively narrow shoe clearance Adjust the clearance.
(7) Improper disc caliper operation Correct or replace.
(8) Improper adjusted wheel bearing Adjust or replace.
5. Brake noise (1) (creak sound)
(1) Hardened or deteriorated lining Replace the shoe assembly or pad.
(2) Worn lining Replace the shoe assembly or pad.
(3) Loosened back plate or the support installing bolts Retighten.
(4) Loose wheel bearing Retighten to normal tightening torque.
(5) Dirty drum or rotor Clean the drum or rotor, or clean and replace the brake assembly.
6. Brake noise (2) (hissing sound)
(1) Worn lining Replace the shoe assembly or pad.
(2) Improper installed shoe or pad Correct or replace the shoe assembly or pad.
(3) Loose or bent drum or rotor Retighten or replace.
7. Brake noise (3) (click sound)
In the case of the disc brake:
(1) Excessively worn pad or the support Replace the pad or the support.
In the case of the drum brake:
(1) Excessively worn shoe ridge Replace the back plate.
(2) Lack of oil on the shoe ridge surface and anchor Add more grease.
125
4-4DIAGNOSTICS
1. Entire Brake System

2. Hill Holder
Trouble and possible cause Corrective action
1. Counterforce of clutch pedal is too strong.
(1) PHV cable is damaged or does not operate properly. Repair or replace.
(2) Lever of PHV is defective. Replace entire PHV assembly.
(3) Clutch system is anomalous. Refer to“Clutch and pedal cable system”.
2. Vehicle does not stop on uphill road of 3°or higher inclination.
(1) Front side of vehicle is lowered. Refer to“Suspension”.
(2) PHV cable is broken. Replace.
(3) Play of clutch is excessive. Adjust.
(4) PHV cable is elongated. Adjust.
(5) Sealing of PHV is poor. Replace entire PHV assembly.
3. Shock is felt when starting.
(1) Poor adjustment of starting performance: Adjust.
(2) When depressing the brake pedal strongly:(The stronger brake pedal depressing force, the later hill holder
releases.)
(3) When starting on flat road after stopping reverse movement: (Because hill holder is activated.)
4. Vehicle slips down when starting.
(1) PHV cable is elongated. Adjust.
(2) Clutch facing is worn out. Adjust or replace.
(3) Bracket (cable) or stay (PHV) is deformed. Repair or replace.
5. Vehicle cannot start after stoppage.
(1) Return spring is fatigued or broken. Replace.
(2) PHV lever won’t return. Replace entire PHV assembly.
(3) When intentionally depressing brake pedal strongly:[When the brake pedal is depressed by a force of 1,177 N (120
kg, 265 lb) or more.]
6. Abnormal sound is generated upon releasing brake pedal when stopping.
(1) Rotor and pad matched with each other due to inadequate
depressing force to brake pedal.(Abnormal sound is not generated when depressing brake pedal a
little stronger.)
7. Abnormal sound is generated when operating clutch pedal.
(1) Grease is inadequate for the hook of return spring and slid-
ing portion of PHV cable end.Apply grease.
(2) When releasing after maintaining high fluid pressure: (Flowing sound of fluid when releasing high fluid pressure.)
(3) Clutch system is anomalous. Refer to“Clutch and pedal cable system”.
CAUTION:

Description in parentheses is a characteristic of hill holder and does not indicate abnormality.
Depressing force required for clutch pedal equipped to hill holder specifications is 20 to 29 N (2 to 3 kg, 4 to 7 lb) larger than
the conventional specifications, which does not constitute abnormality.

When vehicle cannot travel (brake cannot be released) because return spring is broken, remove adjusting nut, disconnect
clutch and PHV, and then return PHV lever to release the brake. (Be sure to apply the parking brake before starting this opera-
tion.)

The hill holder may not be activated on a slope of an extremely small inclination.
126
4-4DIAGNOSTICS
2. Hill Holder

1. Pedal System
A: SERVICE DATA
Brake pedal Free play1—3mm(0.04 — 0.12 in)
[Depress brake pedal pad with a force of less than
10 N (1 kg, 2 lb).]
Clutch pedalFree play At clutch pedal pad 10 — 20 mm (0.39 — 0.79 in)
Full stroke At clutch pedal pad 140 — 145 mm (5.51 — 5.71 in)
Accelerator pedalFree play At pedal pad1—4mm(0.04 — 0.16 in)
Stroke At pedal pad 50 — 55 mm (1.97 — 2.17 in)
2
4-5SPECIFICATIONS AND SERVICE DATA
1. Pedal 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)