engine SUBARU LEGACY 1996 Service Repair Manual

Model Sedan Wagon
Engine (cc) 2500 2200 2500
Driving system AWD
GT LSi GT LSi OUTBACK* OUTBACK*
Hill holder————STD—
Parking
brakeType Mechanical on rear brakes, drum in disc
Effective drum diameter
mm (in)170 (6.69)
Lining dimensions
(length x width x
thickness)
mm (in)162.6 x 30.0 x 3.2 (6.40 x 1.181 x 0.126)
Clearance adjustment Manual adjustment
Master
cylinderType Tandem
Effective diameter
mm (in)26.99 (1-1/16)
Reservoir type Sealed type
Brake fluid reservoir
capacity
cm
3(cu in)190 (11.59)
Brake
boosterType Vacuum suspended
Effective diameter
mm (in)205 + 230 (8.07 + 9.06)
Propor-
tioning
valveSplit point
kPa (kg/cm
2, psi)3,678 (37.5, 533)
Reducing ratio 0.3
Brake line Dual circuit system
ABSSTD
*: Step roof model
7
4-4SPECIFICATIONS AND SERVICE DATA
1. Brakes

B: SERVICE DATA
ITEM STANDARD SERVICE LIMIT
Front brakePad thickness
(including back metal)17 mm (0.67 in) 7.5 mm (0.295 in)
Disc thickness 24 mm (0.94 in) 22 mm (0.87 in)
Disc runout—0.075 mm (0.0030 in)
Rear brake (Disc type)Pad thickness
(including back metal)15 mm (0.59 in) 6.5 mm (0.256 in)
Disc thickness 10 mm (0.39 in) 8.5 mm (0.335 in)
Disc runout—0.10 mm (0.0039 in)
Rear brake (Drum type)Inside diameter 228.6 mm (9 in) 230.6 mm (9.08 in)
Lining thickness 4.1 mm (0.161 in) 1.5 mm (0.059 in)
Rear brake (Disc type
parking)Inside diameter 170 mm (6.69 in) 171 mm (6.73 in)
Lining thickness 3.2 mm (0.126 in) 1.5 mm (0.059 in)
Parking brake Lever stroke 7 to 8 notches/196N (20 kg, 44 lb)
Without ABS and TCS With ABS and TCS
Brake boosterBrake pedal force Fluid pressure
Brake fluid pressure
without engine running147 N
(15 kg, 33 lb)785 kPa
(8 kg/cm
2, 114 psi)588 kPa
(6 kg/cm2, 85 psi)
294 N
(30kg, 66 lb)2,158 kPa
(22 kg/cm
2, 313 psi)1,667 kPa
(17 kg/cm2, 242 psi)
Brake fluid pressure with
engine running and
vacuum at 66.7 kPa (500
mmHg, 19.69 inHg)147 N
(15 kg, 33 lb)5,492 kPa
(56 kg/cm
2, 796 psi)5,394 kPa
(55 kg/cm2, 782 psi)
294 N
(30kg, 66 lb)8,434 kPa
(86 kg/cm
2, 1,223 psi)10,003 kPa
(102 kg/cm2, 1,450 psi)
C: RECOMMENDED BRAKE FLUID
FMVSS No. 116, fresh DOT3 or 4 brake fluid
CAUTION:

Avoid mixing brake fluid of different brands to pre-
vent the fluid performance from degrading.

When brake fluid is supplemented, be careful not to
allow any dust into the reservoir.

Use fresh DOT3 or 4 brake fluid when replacing or
refilling the fluid.
D: BRAKE FLUID LEVEL INDICATOR
Reserve tank with level indicator:
Residual fluid quantity at light ON
Approx. 80 cm
3(4.88 cu in)
Tank capacity
190 cm
3(11.59 cu in)
8
4-4SPECIFICATIONS AND SERVICE DATA
1. Brakes

6. Brake Booster
A: REMOVAL
1) Remove or disconnect the following parts at engine
compartment.
(1) Disconnect connector for brake fluid level indicator.
(2) Remove brake pipes from master cylinder.
(3) Remove master cylinder installing nuts.
(4) Disconnect vacuum hose from brake booster.
2) Remove the following parts from the pedal bracket.
(1) Snap pin and clevis pin
(2) Four brake booster installing nuts
3) Remove brake booster while shunning brake pipes.
B4M0117A
B: INSTALLATION
1) Mount brake booster in position.
2) Connect operating rod to brake pedal with clevis pin
and snap pin.

1Clevis pin

2Snap pin

3Operating rod
G4M0420
3) Connect vacuum hose to brake booster.
4) Mount master cylinder onto brake booster.
5) Connect brake pipes to master cylinder.
6) Connect electric connector for brake fluid level indica-
tor.
50
4-4SERVICE PROCEDURE
6. Brake Booster

G4M0744
2. AIR TIGHTNESS CHECK
Start engine, and run it for 1 to 2 minutes, then turn it off.
Depress brake pedal several times applying the same
pedal force as that used in ordinary braking operations.
The pedal stroke should be greatest on the 1st depression,
and it should become smaller with each successive
depression. If no change occurs in the pedal height while
in a depressed state, brake booster is faulty.
NOTE:

In the event of defective operation, inspect the condition
of the check valve and vacuum hose.

Replace them if faulty and conduct the test again.

If no improvement is observed, check precisely with
gauges.
G4M0914
3. OPERATION CHECK
1) With engine off, depress brake pedal several times
applying the same pedal force and make sure that the
pedal height does not vary with each depression of the
pedal.
2) With brake pedal depressed, start engine.
3) As engine starts, brake pedal should move slightly
toward the floor. If no change occurs in the pedal height,
brake booster is faulty.
NOTE:
If faulty, check precisely with gauges.
4. LOADED AIR TIGHTNESS CHECK
Depress brake pedal while engine is running, and turn off
engine while the pedal is still depressed. Keep the pedal
depressed for 30 seconds; if no change occurs in the pedal
height, brake booster is functioning normally; if the pedal
height increases, it is faulty.
NOTE:
If faulty, check precisely with gauges.
52
4-4SERVICE PROCEDURE
6. Brake Booster

G4M0423
5. CHECKING WITH GAUGES
Connect gauges as shown in Figure. After bleeding air from
pressure gauges, proceed to each check.
G4M0746
6. AIR TIGHTNESS CHECK
1) Start engine and keep it running until a vacuum of 66.7
kPa (500 mmHg, 19.69 inHg) = point A is indicated on
vacuum gauge. Do not depress brake pedal.
2) Stop engine and watch the gauge. If the vacuum drop
range is less than 3.3 kPa (25 mmHg, 0.98 inHg) within 15
seconds after stopping engine, brake booster is functioning
properly.
If defective, the cause may be one of those listed below.

Check valve malfunction

Leak from vacuum hose

Leak from the shell jointed portion or stud bolt welded
portion

Damaged diaphragm

Leak from valve body seal and bearing portion

Leak from plate and seal assembly portion

Leak from poppet valve assembly portion
G4M0747
7. LOADED AIR TIGHTNESS CHECK
1) Start engine and depress brake pedal with pedal force
of 196 N (20 kg, 44 lb). Keep engine running until a vacuum
of 66.7 kPa (500 mmHg, 19.69 inHg) = point B is indicated
on vacuum gauge while the pedal is still depressed.
2) Stop engine and watch vacuum gauge.
If the vacuum drop range is less than 3.3 kPa (25 mmHg,
0.98 inHg) within 15 seconds after stopping engine, brake
booster is functioning properly.
If defective, refer to“AIR TIGHTNESS CHECK”described
above.
53
4-4SERVICE PROCEDURE
6. Brake Booster

8. LACK OF BOOSTING ACTION CHECK
Turn off engine, and set the vacuum gauge reading at“0”.
Then, check the fluid pressure when brake pedal is
depressed. The pressure must be greater than the stan-
dard value listed below.
Brake pedal force 147N (15 kg, 33 lb) 294N (30kg, 66 lb)
Models without ABS and
TCS785 kPa
(8 kg/cm
2, 114 psi)2,158 kPa
(22 kg/cm2, 313 psi)
Models with ABS and
TCS588 kPa
(6 kg/cm
2, 85 psi)1,667 kPa
(17 kg/cm2, 242 psi)
9. BOOSTING ACTION CHECK
Set the vacuum gauge reading at 66.7 kPa (500 mmHg,
19.69 inHg) by running engine. Then, check the fluid pres-
sure when brake pedal is depressed. The pressure must
be greater than the standard value listed below.
Brake pedal force 147N (15 kg, 33 lb) 294N (30kg, 66 lb)
Models without ABS and
TCS5,492 kPa
(56 kg/cm
2, 796 psi)8,434 kPa
(86 kg/cm2, 1,223 psi)
Models with ABS and
TCS5,394 kPa
(55 kg/cm
2,782 psi)10,003 kPa
(102 kg/cm2, 1,450
psi)
D: HANDLING PRECAUTIONS
1) Be careful not to drop brake booster. Brake booster
should be discarded if it has been dropped.
2) Use special care when handling operating rod.
If excessive force is applied to operating rod, sufficient to
cause a change in the angle in excess of ±3°, it may result
in damage to the power piston cylinder.
54
4-4SERVICE PROCEDURE
6. Brake Booster

G4M0428
8. Hill Holder
A: REMOVAL
1) Drain brake fluid from reservoir of master cylinder.
2) Remove adjusting nut and cable clamp, and disconnect
PHV cable from cable bracket on engine.
3) Detach PHV cable from clips.
4) Remove cable clamp, and disconnect PHV cable from
PHV stay.
CAUTION:
Carefully protect boots and inner cable from damage
when disconnecting PHV cable.
5) Disconnect brake pipes from PHV.
CAUTION:

Pay attention not to drop brake fluid onto body
painting since it may dissolve paint.

Pay attention not to damage hexagonal head of flare
nut by using pipe wrench without fail.
6) Detach PHV along with support from side frame.
CAUTION:
Exercise utmost care to prevent foreign matter from
entering into PHV when removing it.
B: INSPECTION
Check up removed parts as follows, and replace defective
ones.
1) Check if boots of PHV cable are damaged or degraded,
and if inner cable is damaged or corroded.
2) Check if return spring is worn out, damaged or cor-
roded.
3) Confirm that rolling sound of ball is heard with PHV
inclined and lever rotates smoothly.
CAUTION:
Never disassemble PHV. Replace entire PHV assembly
if necessary.
57
4-4SERVICE PROCEDURE
8. Hill Holder

C: INSTALLATION
1) Install PHV onto side frame.
Tightening torque:
18±5 N⋅m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)
2) Connect brake pipes to PHV.
Tightening torque:
15
+3
2N⋅m (1.5+0.3
0.2kg-m, 10.8+2.2
1.4ft-lb)
CAUTION:
Confirm that brake pipes are not deformed and/or dam-
aged. Replace them with new ones if necessary.
3) Install PHV cable to PHV stay.
CAUTION:
If cable clamp (and clips) is damaged, replace it with a
new one.
4) Connect PHV cable with clips.
NOTE:
Avoid sharp bending of PHV cable as it may cause break-
age.
5) Install PHV cable onto cable bracket on engine.
6) Apply grease to the following points.

Hook portion of return spring

Cable end portion of lever
Grease:
SUNLIGHT 2 (Part No. 003602010)
7) Be sure to bleed air from the system.
CAUTION:
After replacing PHV cable or clutch cable with new
one, operate clutch pedal about 30 times as a run-
ning-in operation prior to adjustment.
D: ADJUSTMENTS
Confirm stopping and starting performances by activating
hill holder on an uphill road of 3°or higher inclination.
(1) If vehicle does not stop;
Tighten adjusting nut of PHV cable.
(2) If vehicle does not start properly;

Case A—When hill holder is released later than
engagement of clutch pedal (Engine tends to stall.):
Loosen adjusting nut gradually until smooth starting
is enabled.

Case B—When hill holder is released earlier than
engagement of clutch pedal (Vehicle slips down
slightly.):
Tighten adjusting nut so that hill holder is released
later than engagement of clutch pedal (status in Case
A). Then make adjustment the same as in Case A.
58
4-4SERVICE PROCEDURE
8. Hill Holder

Air bleeder tightening torque:
8±1 N⋅m (0.8±0.1 kg-m, 5.8±0.7 ft-lb)
5) Perform these steps for the brakes connecting to the
secondary chamber of master cylinder, first, and then for
the ones connecting to primary chamber. With all proce-
dures completed, fully depress the brake pedal and keep
it in that position for approximately 20 seconds to make
sure that there is no leak evident in the entire system.
G4M0436
6) Perform sequence control. (With ABS model) 4-4 [W15C1].>
7) Check the pedal stroke.
While the engine is idling, depress the brake pedal with a
490 N (50 kg, 110 lb) load and measure the distance
between the brake pedal and steering wheel. With the
brake pedal released, measure the distance between the
pedal and steering wheel again. The difference between
the two measurements must be more than specified.
Specified pedal stroke:
Without ABS
90 mm (3.54 in)
With ABS
95 mm (3.74 in)
When depressing brake pedal with a 490 N (50 kg,
110 lb) load.
(1) Models without ABS
If the distance is more than specifications, there is a
possibility that air is in the brake line. Bleed air from the
brake line.
(2) Models with ABS
If the distance is more than specifications, there is a
possibility air is in the inside of the hydraulic unit.
Therefore, air must be bled from the inside of the
hydraulic unit to the brake pipes in accordance with the
bleeding sequence control.
8) Add brake fluid to the required level (MAX. level) of
reserve tank.
9) As a final step, test run the vehicle at low speed and
apply brakes relatively hard 2 to 3 times to ensure that
brakes provide normal braking action on all four wheels
without dragging and uneven braking.
63
4-4SERVICE PROCEDURE
11. Air Bleeding (Without TCS model)

14. ABS Sensor
A: REMOVAL
1. FRONT ABS SENSOR
1) Disconnect front ABS sensor connector located in
engine compartment.
B4M0079A
2) Remove bolts which secure sensor harness to strut.
G4M0451
3) Remove bolts which secure sensor harness to body.
G4M0443
4) Remove bolts which secure front ABS sensor to
housing, and remove front ABS sensor.
CAUTION:

Be careful not to damage pole piece located at tip of
the sensor and teeth faces during removal.

Do not pull sensor harness during removal.
5) Remove front disc brake caliper and disc rotor from
housing after removing front tire.
6) Remove front drive shaft and housing and hub assem-
bly.
67
4-4SERVICE PROCEDURE
14. ABS Sensor