SUBARU LEGACY 1999 Service Repair Manual

1. Pedal
A: ON-CAR SERVICE
1. BRAKE PEDAL
1) Check position of pedal pad.
Pedal height: L
148 mm (5.83 in)
B4M0366B
(1) Stop light switch
(2) Mat
(3) Toe board
(4) Brake booster operating rod
2) If it is not in specified value, adjust it by adjust-
ing brake booster operating rod length.
3) 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
1Ð3mm(0.04 Ð 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)
4) Apply grease to operating rod connecting pin to
prevent it from wearing.
2. CLUTCH PEDAL (EXCEPT 2500 cc
MODEL)
1) Check clutch pedal free play by operating pedal
by hand.
Free play: L (At clutch pedal pad)
10 Ð 20 mm (0.39 Ð 0.79 in)
G4M0318
Pedal height: Y
158 nn (6.22 in)
Pedal stroke: A
140 Ð 145 mm (5.51 Ð 5.71 in)
B4M0367B
(1) Toe board
(2) Mat
6
4-5[W1A1]SERVICE PROCEDURE
1. Pedal

2) If it is not in specified value, adjust it by turning
adjusting nut on engine side end of clutch cable.
Free play: L
3Ð4mm(0.12 Ð 0.16 in)
Full stroke: A
25.5 Ð 27 mm (1.004 Ð 1.063 in)
B4M1115A
(1) Lock nut
(2) Adjusting nut
(3) Release fork
3) Apply grease to connecting portion of clutch
pedal and clutch cable.
Lock nut tightening torque:
5.9
±1.5 N´m (0.60±0.15 kg-m, 4.3±1.1 ft-lb)
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 turn-
ing nut connecting accelerator cable to throttle
body.
Free play at pedal pad: L
1Ð4mm(0.04 Ð 0.16 in)
Stroke at pedal pad: A
50 Ð 55 mm (1.97 Ð 2.17 in)
B4M1116A
(1) Accelerator pedal
(2) Toe board
(3) Accelerator cable
Accelerator cable lock nut tightening torque:
14
±4 N´m (1.4±0.4 kg-m, 10.1±2.9 ft-lb)
4. CLUTCH PEDAL (2500 cc MODEL)
1) Push release fork until operating cylinder push
rod retracts. Check that clutch fluid level in reser-
voir tank increases.
B4M1191A
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.
4) Check the fluid level on the outside of the clutch
master cylinder tank. If the level is below ªMINº,
add clutch fluid to bring it up to ªMAXº.
Recommended clutch fluid:
FMVSS No. 116, fresh DOT 3 or DOT 4
brake fluid
7
[W1A4]4-5SERVICE PROCEDURE
1. Pedal

B: REMOVAL
1. ACCELERATOR PEDAL
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.
4) Disconnect accelerator cable from accelerator
pedal lever.
G4M0322
5) Working inside engine compartment, remove
casing cap out of the toe board by turning it clock-
wise.
G4M0335
6) Pull out the cable from the toe board hole.
7) Remove accelerator pedal connecting bolt from
accelerator pedal bracket.
G4M0321
2. BRAKE AND CLUTCH PEDAL (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.
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.
B4M0154A
7) Depress clutch pedal, disconnect clutch cable
from clutch pedal.
3. BRAKE PEDAL
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.
8
4-5[W1B1]SERVICE PROCEDURE
1. Pedal

4) Remove two bolts and four nuts which secure
brake pedal to pedal.
G4M0324
4. BRAKE AND CLUTCH PEDAL (2500 cc
MODEL)
1) Remove steering bolts.
2) Raise vehicle on hoist and remove the two bolts
which secure steering unit to underside of body.
3) Lower vehicle to floor.
4) Remove instrument panel lower cover from
instrument panel.
5) Disconnect the following parts from pedal
bracket.
IOperating rod of brake booster
IElectrical connectors (for stop light switch, etc.)
6) Remove clevis pin which secures lever to push
rod.
7) Remove nut which secures clutch master cylin-
der.
8) Remove steering assembly.
9) Remove bolts and nuts which secure brake and
clutch pedals, and remove pedal assembly.
C: INSPECTION
1. BRAKE AND CLUTCH PEDALS
Move brake and clutch pedal pads in the lateral
direction with a force of approximately 10 N (1 kg,
2 lb) to ensure pedal deflection is in specified
range.
Deflection of brake and clutch pedal:
Service limit
5.0 mm (0.197 in) or less
CAUTION:
If excessive deflection is noted, replace bush-
ings with new ones.
S4M0135A
G4M0326
9
[W1C1]4-5SERVICE PROCEDURE
1. Pedal

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

IMake sure that holder and casing cap are
securely connected.
B4M0159B
(1) Casing cap
(2) Accelerator cable
(3) Toe board
(4) Accelerator pedal bracket
(5) Holder
2) Adjust clutch pedal (2500 cc model) 4-5 [W1F1].>
3) Adjustment after pedal installation [W1A0].>
F: ADJUSTMENT
1. CLUTCH PEDAL (2500 cc MODEL)
1) Turn cruise control clutch switch lock nuts until
clutch pedal full stroke length is within specifica-
tions.
CAUTION:
Do not attempt to turn clutch switch to adjust
clutch pedal full stroke length.
NOTE:
If lock nuts cannot adjust clutch pedal full stroke
length to specifications, turn master cylinder push
rod to adjust it.
Specified clutch pedal full stroke: A
130 Ð 135 mm (5.12 Ð 5.31 in)
Tightening torque (Clutch switch lock nut):
8
±2 N´m (0.8±0.2 kg-m, 5.8±1.4 ft-lb)
B4M1190A
2) Turn master cylinder push rod so that clevis pin
moves to the left and then to the right. Clevis pin
must move without resistance while it is rattling.
Tightening torque (Push rod lock nut):
8
±2 N´m (0.8±0.2 kg-m, 5.8±1.4 ft-lb)
B4M1189A
3) Depress and release clutch pedal 2 to 3 times
to ensure that clutch pedal and release fork oper-
ate smoothly. If clutch pedal and release fork do
not operate smoothly, bleed air from clutch hydrau-
lic system.
4) Measure clutch pedal full stroke length again to
ensure that it is within specifications. If it is not,
repeat adjustment procedures again from the
beginning.
Specified clutch pedal full stroke:
130 Ð 135 mm (5.12 Ð 5.31 in)
5) Move clevis pin to the left and then to the right.
It should move without resistance while it is rattling.
If resistance is felt, repeat adjustment procedures
again from the beginning.
6) Push release lever until operating cylinder push
rod retracts. Ensure that clutch fluid level in reser-
voir tank increases. If clutch fluid level increases,
hydraulic clutch is properly adjusted; if fluid level
does not increase or push rod does not retract,
replace master cylinder with new one. 2-10 [W600].>
B4M1191A
11
[W1F1]4-5SERVICE PROCEDURE
1. Pedal

2. Clutch Cable
A: REMOVAL
1) Disconnect clutch cable from release lever.
2) Depress clutch pedal to the floor.
3) Remove clutch cable clamp from pedal bracket.
B4M0160A
4) Disconnect clutch cable from pedal bracket and
pedal end.
5) Remove clutch cable from body.
CAUTION:
Before removing clutch cable from toe board,
remove grommet. Slowly remove clutch cable,
being careful not to scratch it.
B: INSTALLATION
1) Clean clutch pedal fitting hole, and apply
grease. Connect clutch cable to clutch pedal.
G4M0332
2) Fit clutch pedal to pedal bolt, and connect
clutch cable to bracket with clamp.
3) Connect clutch cable end to pedal end.
4) Connect clutch cable from release lever.
5) Install grommet to toe board.
6) Adjust after cable installation. [W1A3].>
12
4-5[W2A0]SERVICE PROCEDURE
2. Clutch Cable

3. Accelerator Cable
A: REMOVAL
B4M0768B
B4M1451A
13
[W3A0]4-5SERVICE PROCEDURE
3. Accelerator Cable

1) Disconnect accelerator cable from connector
inside engine compartment first.
2) Remove lock nut from accelerator cable
bracket.
3) Separate accelerator cable (1) from bracket,
then unlock inner cable.
B4M1185A
4) Remove cable end from throttle cam using your
fingertips.
CAUTION:
Be careful not to bend inner cable.
5) Disconnect cable end from accelerator cable
bracket inside driver compartment.
6) Remove clip inside engine compartment.
7) Working inside engine compartment, remove
the casing cap out of the toe board by turning it
clockwise.
G4M0335
8) Pull out the cable from the toe board hole.
B: INSTALLATION
1) Installation is in the reverse order of removal
procedures.
CAUTION:
IBe careful not to kink accelerator cable.
IMake sure that holder and casing cap are
securely connected.
B4M0159B
(1) Casing cap
(2) Accelerator cable
(3) Toe board
(4) Accelerator pedal bracket
(5) Holder
2) Adjustment after cable installation [W1A3].>
14
4-5[W3B0]SERVICE PROCEDURE
3. Accelerator Cable

1. Pedal System and Control Cables
Trouble Corrective action
Excessively worn brake pedal pad Replace.
Failure of clutch and/or accelerator pedals to operate Connect cables correctly.
Stop light switch does not light up. Adjust position of stop light switch.
Stop light switch is not smooth and/or stroke is not correct. Replace.
Insufficient pedal play Adjust pedal play.
Clutch and/or brake pedal free play insufficient Adjust pedal free play.
Maladjustment of brake pedal or booster push rod Inspect and adjust.
Excessively worn and damaged pedal shaft and/or bushing Replace bushing and/or shaft with new one.
15
[K100]4-5DIAGNOSTICS
1. Pedal System and Control Cables