SUBARU LEGACY 1999 Service Repair Manual

larly continuous work of relief valve over 5 sec-
onds causes to reduce service lives of the
hoses, the oil pump, the fluid, etc. due to over
heat.So, avoid to keep this kind of condition when
servicing as well as driving.
Trouble Possible cause Corrective action
Pressure hose burst Excessive holding time of relief status Instruct customers.
Malfunction of relief valve Replace oil pump.
Poor cold characteristic of fluid Replace fluid.
Forced out return hose Poor connection Correct.
Poor holding of clip Retighten.
Poor cold characteristic of fluid Replace fluid.
Fluid bleeding out of hose
slightlyWrong layout, tensioned Replace hose.
Excessive play of engine due to deterioration of engine
mounting rubberReplace defective parts.
Improper stop position of pitching stopper Replace defective parts.
Crack on hose Excessive holding time of relief status Replace.
Instruct customer.
Excessive tightening torque for return hose clip Replace.
Power steering fluid, brake fluid, engine oil, electrolyte
adhere on the hose surfaceReplace.
Pay attention on service work.
Too many times use in extremely cold weather Replace.
Instruct customers.
77
[K1G0]4-3DIAGNOSTICS
1. Power Steering

MEMO:
78
4-3DIAGNOSTICS

1. Brakes
A: SPECIFICATIONS
1. MODELS WITH ABS
Model Sedan Wagon
Engine (cc) 2200 2200
Driving system AWD AWD
LLSLLS
Front brakeType Disc (Floating type, ventilated)
Effective disc diameter mm (in) 210 (8.27)
Disc thickness´Outer diameter
mm (in)24´260 (0.94´10.24)
Effective cylinder diameter mm (in) 57.2 (2.252)
Pad dimensions
(length´width´thickness) mm (in)112.4´44.3´11.0 (4.43´1.744´0.433)
Clearance adjustment Automatic adjustment
Rear brakeType Disc (Floating type)
Effective disc diameter mm (in) 230 (9.06)
Disc thickness´Outer diameter
mm (in)10´266 (0.39´10.47)
Effective cylinder diameter mm (in) 34.9 (1.374) 38.1 (1.500)
Pad dimensions
(length´width´thickness) mm (in)92.4´33.7´10.0 (3.638´1.327´0.394)
Clearance adjustment Automatic adjustment
Model 4 Door Sedan Wagon
Engine (cc) 2200 2200
Driving system AWD AWD
LLSLLS
Hill holderHÐHÐ
Parking brakeType Mechanical on rear brakes, drum in disc
Effective drum diameter mm (in) 170 (6.69)
Lining dimensions
(length´width´thickness) mm (in)162.6´30.0´3.2 (6.40´1.181´0.126)
Clearance adjustment Manual adjustment
Master cylin-
derType 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)
Proportioning
valveSplit point kPa (kg/cm
2, psi) 2,942 (30.0, 427)
Reducing ratio 0.3
Brake lineDual circuit system
ABS OP STD OP STD
H: Equipped on manual transmission vehicle.
2
4-4[S1A1]SPECIFICATIONS AND SERVICE DATA
1. Brakes

2. MODELS WITHOUT ABS
Model Sedan Wagon
Engine (cc) 2200
Driving system AWD AWD
L POST BRIGHTON L
Front brakeType Disc (Floating type, ventilated)
Effective disc diameter mm (in) 210 (8.27)
Disc thickness´Outer diameter
mm (in)24´260 (0.94´10.24)
Effective cylinder diameter mm (in) 57.2 (2.252)
Pad dimensions
(length´width´thickness) mm (in)112.4´44.3´11.0 (4.43´1.744´0.433)
Clearance adjustment Automatic adjustment
Rear brakeType Drum (Leading-Trailing type)
Effective drum diameter mm (in) 228.6 (9)
Effective cylinder diameter mm (in) 17.4 (0.685) 19.0 (0.748)
Lining dimensions
(length´width´thickness) mm (in)218.8´35.0´4.1 (8.61´1.378´0.161)
Clearance adjustment Automatic adjustment
Model Sedan Wagon
Engine (cc) 2200
Driving system AWD AWD
L POST BRIGHTON L
Hill holderHÐÐH
Parking brakeType Mechanical on rear brakes, drum in disc
Effective drum diameter mm (in) 228.6 (9)
Lining dimensions
(length´width´thickness) mm (in)218.8´35.0´4.1 (8.61´1.378´0.161)
Clearance adjustment Automatic adjustment
Master cylin-
derType Tandem
Effective diameter mm (in) 23.81 (15/16)
Reservoir type Sealed type
Brake fluid reservoir capacity
cm
3(cu in)190 (11.59)
Brake boosterType Vacuum suspended
Effective diameter mm (in) 230 (9.06)
Proportioning
valveSplit point kPa (kg/cm
2, psi) 3,678 (37.5, 533)
Reducing ratio 0.3
Brake lineDual circuit system
H: Equipped on manual transmission vehicle.
3
[S1A2]4-4SPECIFICATIONS AND SERVICE DATA
1. Brakes

3. 2500 cc MODEL
Model Sedan Wagon
Engine (cc) 2500
Driving system AWD
GT LSi GT LSi OUTBACK
Front brakeType Disc (Floating type, ventilated)
Effective disc diameter mm (in) 228 (8.98)
Disc thickness´Outer diameter
mm (in)24´277 (0.94´10.91)
Effective cylinder diameter mm (in) 42.8 (1.687)´2
Pad dimensions
(length´width´thickness) mm (in)112.3´50.0´11.0 (4.42´1.969´0.433)
Clearance adjustment Automatic adjustment
Rear brakeType Disc (Floating type)
Effective disc diameter mm (in) 230 (9.06)
Disc thickness´Outer diameter mm
(in)10´266 (0.39´10.47)
Effective cylinder diameter mm (in) 38.1 (1.500)
Pad dimensions
(length´width´thickness) mm (in)92.4´33.7´10.0 (3.638´1.327´0.394)
Clearance adjustment Automatic adjustment
Model Sedan Wagon
Engine (cc) 2500
Driving system AWD
GT LSi GT LSi OUTBACK
Hill holderÐÐÐÐÐ
Parking
brakeType Mechanical on rear brakes, drum in disc
Effective drum diameter mm (in) 170 (6.69)
Lining dimensions
(length´width´thickness) mm (in)162.6´30.0´3.2 (6.40´1.181´0.126)
Clearance adjustment Manual adjustment
Master cylin-
derType 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)
Proportion-
ing valveSplit point kPa (kg/cm
2, psi) 3,678 (37.5, 533)
Reducing ratio 0.3
Brake lineDual circuit system
ABSSTD
4
4-4[S1A3]SPECIFICATIONS 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 Ð 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 Ð 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 park-
ing)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 With ABS
Brake boosterBrake pedal force Fluid pressure
Brake fluid pressure
without engine running147N (15 kg, 33 lb)785 kPa (8 kg/cm
2,114
psi)588 kPa (6 kg/cm2,85
psi)
294N (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)147N (15 kg, 33 lb)5,492 kPa (56 kg/cm
2,
796 psi)5,394 kPa (55 kg/cm2,
782 psi)
294N (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:
IAvoid mixing brake fluid of different brands
to prevent the fluid performance from degrad-
ing.
IWhen brake fluid is supplemented, be care-
ful not to allow any dust into the reservoir.
IUse fresh DOT3 or 4 brake fluid when replac-
ing 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
205 cm
3(12.51 cu in)
5
[S1D0]4-4SPECIFICATIONS AND SERVICE DATA
1. Brakes

1. Front Disc Brake
A: EXCEPT 2500 cc MODEL
B4M1152C
(1) Caliper body
(2) Air bleeder screw
(3) Guide pin (Green)
(4) Pin boot
(5) Piston seal
(6) Piston
(7) Piston boot
(8) Lock pin (Yellow)(9) Support
(10) Pad clip
(11) Outer shim
(12) Inner shim
(13) Pad (Outside)
(14) Pad (Inside)
(15) Disc rotor
(16) Disc coverTightening torque: N´m (kg-m, ft-lb)
T1:
8±1 (0.8±0.1, 5.8±0.7)
T2:18±5 (1.8±0.5, 13.0±3.6)
T3:37±5 (3.8±0.5, 27.5±3.6)
T4:78±10 (8.0±1.0, 58±7)
6
4-4[C1A0]COMPONENT PARTS
1. Front Disc Brake

B: 2500 cc MODEL
B4M1151C
(1) Caliper body
(2) Air bleeder screw
(3) Guide pin (Green)
(4) Pin boot
(5) Piston seal
(6) Piston
(7) Piston boot
(8) Boot ring(9) Lock pin (Yellow)
(10) Support
(11) Pad clip
(12) Outer shim
(13) Inner shim
(14) Pad (Outside)
(15) Pad (Inside)
(16) Disc rotor(17) Disc cover
Tightening torque: N´m (kg-m, ft-lb)
T1:
8±1 (0.8±0.1, 5.8±0.7)
T2:18±5 (1.8±0.5, 13.0±3.6)
T3:37±5 (3.8±0.5, 27.5±3.6)
T4:78±10 (8.0±1.0, 58±7)
7
[C1B0]4-4COMPONENT PARTS
1. Front Disc Brake

2. Rear Disc Brake
B4M0066B
(1) Lock pin
(2) Lock pin sleeve
(3) Lock pin boot
(4) Air bleeder screw
(5) Caliper body
(6) Guide pin
(7) Guide pin boot
(8) Piston seal
(9) Piston
(10) Piston boot
(11) Boot ring
(12) Support
(13) Shim
(14) Inner shim
(15) Inner pad(16) Pad clip
(17) Outer pad
(18) Outer shim
(19) Shoe hold-down pin
(20) Cover
(21) Back plate
(22) Retainer
(23) Spring washer
(24) Parking brake lever
(25) Parking brake shoe (Secondary)
(26) Parking brake shoe (Primary)
(27) Adjusting spring
(28) Strut
(29) Strut shoe spring
(30) Shoe guide plate(31) Secondary shoe return spring
(32) Primary shoe return spring
(33) Adjuster
(34) Shoe hold-down cup
(35) Shoe hold-down spring
(36) Disc rotor
Tightening torque: N´m (kg-m, ft-lb)
T1:
8±1 (0.8±0.1, 5.8±0.7)
T2:20±4 (2.0±0.4, 14.5±2.9)
T3:26±5 (2.7±0.5, 19.5±3.6)
T4:52±6 (5.3±0.6, 38.3±4.3)
8
4-4[C200]COMPONENT PARTS
2. Rear Disc Brake

3. Rear Drum Brake
B4M1120A
(1) Air bleeder cap
(2) Air bleeder screw
(3) Boot
(4) Piston
(5) Cup
(6) Spring
(7) Wheel cylinder body
(8) Pin
(9) Plug
(10) Back plate(11) Upper shoe return spring
(12) Retainer
(13) Washer
(14) Parking brake lever
(15) Brake shoe (Trailing)
(16) Brake shoe (Leading)
(17) Shoe hold-down spring
(18) Cup
(19) Adjusting lever
(20) Adjuster(21) Lower shoe return spring
(22) Adjusting spring
(23) Drum
(24) Plug
Tightening torque: N´m (kg-m, ft-lb)
T1:
8±1 (0.8±0.1, 5.8±0.7)
T2:10±2 (1.0±0.2, 7.2±1.4)
T3:52±6 (5.3±0.6, 38.3±4.3)
9
[C300]4-4COMPONENT PARTS
3. Rear Drum Brake