SUBARU LEGACY 1997 Service Repair Manual

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)
1. 2200 cc 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. 2500 cc MODEL
B4M1158A

1Holder


2Accelerator bracket


3Stopper


4Clip


5Bushing


6Accelerator spring


7Accelerator pedal spring


8Accelerator pedal


9Spring pin


10Accelerator pedal pad


11Accelerator stopper


12Snap pin


13Brake pedal pad


14Brake pedal

15Clevis pin


16Brake pedal spring


17Bracket shaft


18Clutch pedal pad


19Clutch pedal


20Bushing C


21Clip


22Clutch clevis pin


23Assist rod


24Assist plate A


25Assist spring A


26Assist spring B


27Assist bushing


28Assist plate ASSY

29Pedal bracket


30Stop light switch


31Wave washer


32Lever


33Clutch switch (Starter interlock)


34Clutch switch (With cruise control)
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 2.2±0.5 (0.22±0.05, 1.6±0.4)
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)
4
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)
5
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)
6
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 (2200 cc MODEL)
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
7
4-5SERVICE PROCEDURE
1. Pedal

G4M0319
2) If it is not in specified value, adjust it by turning adjust-
ing nut on engine side end of clutch cable.
Free play: L
3—4 mm (0.12—0.16 in)
Full stroke: A
25.5—27 mm (1.004—1.063 in)
3) Apply grease to connecting portion of clutch pedal and
clutch cable.


1Lock nut


2Adjusting nut


3Release fork
Lock nut tightening torque:
5.9±1.5 N⋅m (0.60±0.15 kg-m, 4.3±1.1 ft-lb)
G4M0320
3. ACCELERATOR PEDAL
Check pedal stroke and free play by operating accelerator
pedal by hand.
If it is not within specified value, adjust it by turning nut
connecting accelerator cable to throttle body.
Free play at pedal pad: L
1—4 mm (0.04—0.16 in)
Stroke at pedal pad: A
50—55 mm (1.97—2.17 in)


1Accelerator pedal


2Toe board


3Accelerator cable
Accelerator cable lock nut tightening torque:
14±4 N⋅m (1.4±0.4 kg-m, 10.1±2.9 ft-lb)
8
4-5SERVICE PROCEDURE
1. Pedal

B4M1191A
4. CLUTCH PEDAL (2500 cc MODEL)
1) Push release fork until operating cylinder push rod
retracts. Check that clutch fluid level in reservoir tank
increases.
2) If clutch fluid level increases, hydraulic clutch play is
correct.
3) If clutch fluid level does not increase or push rod does
not retract, clutch pedal must be adjusted. [W1F1].>
4) Check the fluid level on the outside of the clutch mas-
ter cylinder tank. If the level is below“MIN”, add clutch fluid
to bring it up to“MAX”.
Recommended clutch fluid:
FMVSS No. 116, fresh DOT 3 or DOT 4 brake fluid
B: REMOVAL
1. ACCELERATOR PEDAL (LHD MODEL)
1) Disconnect ground 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, and connector.
G4M0322
4) Disconnect accelerator cable from accelerator pedal
lever.
G4M0335
5) Working inside engine compartment, remove casing
cap out of the toe board by turning it clockwise.
6) Pull out the cable from the toe board hole.
9
4-5SERVICE PROCEDURE
1. Pedal

G4M0321
7) Remove accelerator pedal connecting bolt from accel-
erator pedal bracket.
2. BRAKE AND CLUTCH PEDAL (LHD EXCEPT 2500
cc 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.
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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.
11
4-5SERVICE PROCEDURE
1. Pedal