boot SUBARU LEGACY 1999 Service Manual PDF

7) While holding hexagonal part of brake hose fit-
ting with a wrench, tighten flare nut to the specified
torque.
Tightening torque (Brake pipe flare nut):
15+3/þ2N´m (1.5+0.3/þ0.2kg-m, 10.8+2.2/þ1.4ft-lb)
8) Bleed air from the brake system.
2. REAR BRAKE HOSE
1) Pass brake hose through the hole of bracket,
and lightly tighten flare nut to connect brake pipe.
2) Insert clamp upward to fix brake hose.
3) While holding hexagonal part of brake hose fit-
ting with a wrench, tighten flare nut to the specified
torque.
Tightening torque (Brake pipe flare nut):
15+3/þ2N´m (1.5+0.3/þ0.2kg-m, 10.8+2.2/þ1.4ft-lb)
4) Bleed air from the brake system.
8. Hill Holder
A: REMOVAL
1) Drain brake fluid from reservoir of master cylin-
der.
2) Remove adjusting nut and cable clamp, and
disconnect PHV cable from cable bracket on
engine.
G4M0428
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:
IPay attention not to drop brake fluid onto
body painting since it may dissolve paint.
IPay 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 cor-
roded.
2) Check if return spring is worn out, damaged or
corroded.
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.
C: INSTALLATION
1) Install PHV onto side frame.
44
4-4[W7B2]SERVICE PROCEDURE
8. Hill Holder

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 cylin-
der 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 cylin-
der piston kit, pipe or hose).
(4) Improperly adjusted shoe clearance Adjust.
(5) Improper lining contact or worn lining Correct or replace.
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
springReplace 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 rotorClean 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)
64
4-4[K100]DIAGNOSTICS
1. Entire Brake System

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 bush-
ing and clip with new ones.
G4M0333
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)
G4M0327
D: ASSEMBLY
1. BRAKE AND CLUTCH PEDAL
1) Attach stop light switch, etc. to pedal bracket
temporarily.
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)
G4M0329
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 accelerator pedal. Install accelerator pedal onto
pedal bracket.
E: INSTALLATION
1) Installation is in the reverse order of removal
procedures.
CAUTION:
IBe careful not to bend clutch cable too
much.
INever fail to cover outer cable end with boot.
IBe careful not to kink accelerator cable.
10
4-5[W1C2]SERVICE PROCEDURE
1. Pedal

2. Console Box
B5M0021B
(1) Shift boot
(2) Front cover (MT)
(3) Front cover (AT)
(4) Console cover
(5) Strip(6) Lock
(7) Lid
(8) Hinge
(9) Arm
(10) Ash tray ASSY(11) Console pocket
(12) Console BRKT
(13) Console box
3
[C200]5-4COMPONENT PARTS
2. Console Box

(3) Remove air intake duct (A) and (B) as a
unit.
B2M2012
(4) Remove resonator chamber.
B2M2306
3) Remove air cleaner upper case and air cleaner
element. (Except California SPEC. vehicle)
(1) Disconnect mass air flow sensor connector.
B2M2018
(2) Remove two clips securing air cleaner
upper cover.
(3) Loosen the clamp screw and separate air
cleaner upper cover from air intake duct.
(4) Remove air cleaner element.
B2M2290
4) Remove #1 spark plug cord by pulling boot, not
cord itself.
B6M0922A
5) Remove spark plug with the spark plug socket.
B6M0923
6) Installation is in the reverse order of removal.
Tightening torque (Spark plug):
20.6
±2.9 N´m (2.10±0.30 kg-m, 15.19±2.14
ft-lb)
21
[W3A1]6-1SERVICE PROCEDURE
3. Spark Plug

2. #2 SPARK PLUG
1) Disconnect battery ground cable.
G6M0095
2) Remove #2 spark plug cord by pulling boot, not
cord itself.
B6M0927A
3) Remove spark plug with the spark plug socket.
B6M0924
4) Installation is in the reverse order of removal.
Tightening torque (Spark plug):
20.6
±2.9 N´m (2.10±0.30 kg-m, 15.19±2.14
ft-lb)
3. #3 SPARK PLUG
1) Disconnect battery ground cable.
G6M0095
2) Remove air intake duct and air chamber. (Cali-
fornia SPEC. vehicle)
(1) Remove bolt which installs air intake duct
(A) on the front side of body.
B2M2283
(2) Remove bolt which installs air intake duct
(B) on body.
B2M2284
22
6-1[W3A2]SERVICE PROCEDURE
3. Spark Plug

(3) Remove air intake duct (A) and (B) as a
unit.
B2M2012
(4) Remove resonator chamber.
B2M2306
3) Remove air cleaner upper case and air cleaner
element. (Except California SPEC. vehicle)
(1) Disconnect mass air flow sensor connector.
B2M2018
(2) Remove two clips securing air cleaner
upper cover.
(3) Loosen the clamp screw and separate air
cleaner upper cover from air intake duct.
(4) Remove air cleaner element.
B2M2290
4) Remove #3 spark plug cord by pulling boot, not
cord itself.
B6M0928A
5) Remove spark plug with the spark plug socket.
B6M0925
6) Installation is in the reverse order of removal.
Tightening torque (Spark plug):
20.6
±2.9 N´m (2.10±0.30 kg-m, 15.19±2.14
ft-lb)
23
[W3A3]6-1SERVICE PROCEDURE
3. Spark Plug

4. #4 SPARK PLUG
1) Disconnect battery ground cable.
G6M0095
2) Disconnect washer motor connector.
S2M0546
3) Disconnect rear window glass washer hose
from washer motor, then plug connection with a
suitable cap.
4) Remove the two bolts which hold the washer
tank, then take the tank away from the working
area.
B2M2023
5) Remove #4 spark plug cord by pulling boot, not
cord itself.
B6M0929A
6) Remove spark plug with the spark plug socket.
B6M0926
7) Installation is in the reverse order of removal.
Tightening torque (Spark plug):
20.6
±2.9 N´m (2.10±0.30 kg-m, 15.19±2.14
ft-lb)
CAUTION:
The above torque should be only applied to
new spark plugs without oil on their threads.
In case their threads are lubricated, the torque
should be reduced by approximately 1/3 of the
specified torque in order to avoid over-stress-
ing.
24
6-1[W3A4]SERVICE PROCEDURE
3. Spark Plug

B: REMOVAL AND INSTALLATION
(2500 cc EXCEPT OUTBACK
MODEL)
CAUTION:
All spark plugs installed on an engine, must be
of the same heat range.
Spark plug:
NGK: PFR5B-11
1. #1 SPARK PLUG
1) Disconnect battery ground cable.
G6M0095
2) Remove #1 spark plug cord by pulling boot, not
cord itself.
B6M0552A
3) Remove spark plug with the spark plug socket.
B6M0553
4) Installation is in the reverse order of removal.
Tightening torque (Spark plug):
20.6
±2.9 N´m (2.10±0.30 kg-m, 15.19±2.14
ft-lb)
2. #2 SPARK PLUG
1) Disconnect battery ground cable.
G6M0095
2) Remove battery.
B6M0554
3) Remove #2 spark plug cord by pulling boot, not
cord itself.
B6M0555A
4) Remove spark plug with the spark plug socket.
B6M0556
5) Installation is in the reverse order of removal.
25
[W3B2]6-1SERVICE PROCEDURE
3. Spark Plug

Tightening torque (Spark plug):
20.6
±2.9 N´m (2.10±0.30 kg-m, 15.19±2.14
ft-lb)
3. #3 SPARK PLUG
1) Disconnect battery ground cable.
G6M0095
2) Disconnect mass air flow sensor connector.
B6M0557A
3) Remove four clips securing air cleaner upper
cover.
4) Loosen the clamp screw and separate air
cleaner upper cover from air intake duct.
B6M0558
5) Remove air cleaner element.6) Remove #3 spark plug cord by pulling boot, not
cord itself.
B6M0559A
7) Remove spark plug with the spark plug socket.
B6M0560
8) Installation is in the reverse order of removal.
Tightening torque (Spark plug):
20.6
±2.9 N´m (2.10±0.30 kg-m, 15.19±2.14
ft-lb)
4. #4 SPARK PLUG
1) Disconnect battery ground cable.
G6M0095
26
6-1[W3B3]SERVICE PROCEDURE
3. Spark Plug