SUBARU LEGACY 1999 Service Repair Manual

4) Install front ABS sensor on strut and wheel
apron bracket.
Tightening torque:
32
±10 N´m (3.3±1.0 kg-m, 24±7 ft-lb)
B4M1442A
5) Place a thickness gauge between ABS sensor's
pole piece and tone wheel's tooth face. After stan-
dard clearance is obtained over the entire
perimeter, tighten ABS sensor on housing to speci-
fied torque.
ABS sensor standard clearance:
0.9 Ð 1.4 mm (0.035 Ð 0.055 in)
Tightening torque:
32
±10 N´m (3.3±1.0 kg-m, 24±7 ft-lb)
CAUTION:
Check the marks on the harness to make sure
that no distortion exists. (RH: white, LH: yel-
low)
NOTE:
If the clearance is outside specifications, readjust.
17. Brake Pipe
A: SUPPLEMENTAL RESTRAINT
SYSTEM ªAIRBAGº
Airbag system wiring harness is routed near the
center brake pipe.
CAUTION:
IAll Airbag system wiring harness and con-
nectors are colored yellow. Do not use electri-
cal test equipment on these circuit.
IBe careful not to damage Airbag system wir-
ing harness when servicing the center brake
pipe.
B: REMOVAL AND INSTALLATION
CAUTION:
IWhen removing and installing the brake
pipe, make sure that it is not bent.
IAfter installing the brake pipe and hose,
bleed the air.
IAfter installing the brake hose, make sure
that it does not touch the tire or suspension
assembly, etc.
Brake pipe tightening torque:
15+3/þ2N´m (1.5+0.3/þ0.2kg-m, 10.8+2.2/þ1.4ft-lb)
63
[W17B0]4-4SERVICE PROCEDURE
17. Brake Pipe

4) Install front ABS sensor on strut and wheel
apron bracket.
Tightening torque:
32
±10 N´m (3.3±1.0 kg-m, 24±7 ft-lb)
B4M1442A
5) Place a thickness gauge between ABS sensor's
pole piece and tone wheel's tooth face. After stan-
dard clearance is obtained over the entire
perimeter, tighten ABS sensor on housing to speci-
fied torque.
ABS sensor standard clearance:
0.9 Ð 1.4 mm (0.035 Ð 0.055 in)
Tightening torque:
32
±10 N´m (3.3±1.0 kg-m, 24±7 ft-lb)
CAUTION:
Check the marks on the harness to make sure
that no distortion exists. (RH: white, LH: yel-
low)
NOTE:
If the clearance is outside specifications, readjust.
17. Brake Pipe
A: SUPPLEMENTAL RESTRAINT
SYSTEM ªAIRBAGº
Airbag system wiring harness is routed near the
center brake pipe.
CAUTION:
IAll Airbag system wiring harness and con-
nectors are colored yellow. Do not use electri-
cal test equipment on these circuit.
IBe careful not to damage Airbag system wir-
ing harness when servicing the center brake
pipe.
B: REMOVAL AND INSTALLATION
CAUTION:
IWhen removing and installing the brake
pipe, make sure that it is not bent.
IAfter installing the brake pipe and hose,
bleed the air.
IAfter installing the brake hose, make sure
that it does not touch the tire or suspension
assembly, etc.
Brake pipe tightening torque:
15+3/þ2N´m (1.5+0.3/þ0.2kg-m, 10.8+2.2/þ1.4ft-lb)
63
[W17B0]4-4SERVICE PROCEDURE
17. Brake Pipe

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

Trouble and possible cause Corrective action
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.
2. Hill Holder
CAUTION:
IDescription in parentheses is a characteris-
tic of hill holder and does not indicate abnor-
mality.
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 con-
ventional specifications, which does not con-
stitute abnormality.IWhen 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 operation.)
IThe hill holder may not be activated on a
slope of an extremely small inclination.
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 ªClutch and pedal cable systemº.
2. Vehicle does not stop on uphill road of 3É or higher inclination.
(1) Front side of vehicle is lowered. Refer to ªSuspensionº.
(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 move-
ment:(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
sliding 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 ªClutch and pedal cable systemº.
65
[K200]4-4DIAGNOSTICS
2. Hill Holder

Trouble and possible cause Corrective action
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.
2. Hill Holder
CAUTION:
IDescription in parentheses is a characteris-
tic of hill holder and does not indicate abnor-
mality.
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 con-
ventional specifications, which does not con-
stitute abnormality.IWhen 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 operation.)
IThe hill holder may not be activated on a
slope of an extremely small inclination.
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 ªClutch and pedal cable systemº.
2. Vehicle does not stop on uphill road of 3É or higher inclination.
(1) Front side of vehicle is lowered. Refer to ªSuspensionº.
(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 move-
ment:(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
sliding 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 ªClutch and pedal cable systemº.
65
[K200]4-4DIAGNOSTICS
2. Hill Holder

MEMO:
66
4-4DIAGNOSTICS

1. Pedal System
Brake pedal Free play1Ð3mm(0.04 Ð 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 padExcept 2500 cc model: 10 Ð 20 mm (0.39 Ð 0.79 in)
2500 cc model:4Ð13mm(0.16 Ð 0.51 in)
Full stroke At clutch pedal padExcept 2500 cc model: 140 Ð 145 mm (5.51 Ð 5.71 in)
2500 cc model: 130 Ð 135 mm (5.12 Ð 5.31 in)
Accelerator pedalFree play At pedal pad1Ð4mm(0.04 Ð 0.16 in)
Stroke At pedal pad 50 Ð 55 mm (1.97 Ð 2.17 in)
2
4-5[S100]SPECIFICATIONS AND SERVICE DATA
1. Pedal System

1. Pedal
A: MT MODEL
1. EXCEPT 2500 cc MODEL
B4M0737B
(1) Accelerator pedal
(2) Bushing
(3) Holder
(4) Accelerator bracket
(5) Stopper
(6) Clip
(7) Accelerator spring
(8) Accelerator pedal spring
(9) Spring pin
(10) Accelerator pedal pad
(11) Accelerator stopper
(12) Clip
(13) Accelerator plate(14) Pedal bracket
(15) Stop light switch
(16) Brake pedal
(17) Spacer
(18) Snap pin
(19) Brake pedal pad
(20) Clevis pin
(21) Brake pedal spring
(22) Washer
(23) Clutch pedal pad
(24) Clutch pedal
(25) Bushing assist
(26) Spring assist(27) Clutch cable clamp
(28) Clutch cable
(29) Mass damper
(30) Clutch switch (Starter interlock)
(31) Clutch switch (With cruise con-
trol)
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
[C1A1]4-5COMPONENT PARTS
1. Pedal

2. 2500 cc MODEL
S4M0134A
(1) Holder
(2) Accelerator bracket
(3) Stopper
(4) Bushing
(5) Clip
(6) Accelerator spring
(7) Accelerator pedal spring
(8) Accelerator pedal
(9) Spring pin
(10) Accelerator pedal pad
(11) Accelerator stopper
(12) Snap pin
(13) Brake pedal pad
(14) Brake pedal
(15) Clevis pin(16) Brake pedal spring
(17) Clutch pedal pad
(18) Clutch pedal
(19) Bushing C
(20) Clutch clevis pin
(21) Assist rod A
(22) Clip
(23) Assist spring
(24) Assist bushing
(25) Assist rod B
(26) Rod S
(27) Spring S
(28) Bushing S
(29) O-ring
(30) Clip(31) Clutch switch (Starter interlock)
(32) Clutch switch (With cruise con-
trol)
(33) Stop light switch
(34) Pedal bracket
(35) Clutch master cylinder bracket
(36) Lever
(37) Lock wire
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)
4
4-5[C1A2]COMPONENT PARTS
1. Pedal

B: AT MODEL
B4M0738B
(1) Accelerator pedal
(2) Bushing
(3) Holder
(4) Accelerator bracket
(5) Stopper
(6) Clip
(7) Accelerator spring
(8) Accelerator pedal spring
(9) Spring pin
(10) Accelerator pedal pad(11) Accelerator stopper
(12) Clip
(13) Accelerator plate
(14) Plug
(15) Pedal bracket
(16) Stop light switch
(17) Spacer
(18) Stopper
(19) Snap pin
(20) Brake pedal pad(21) Brake pedal
(22) Clevis pin
(23) Brake 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
[C1B0]4-5COMPONENT PARTS
1. Pedal