1995 SUBARU LEGACY engine

8. LACK OF BOOSTING ACTION CHECK
Turn off engine, and set the vacuum gauge reading at“0”.
Then, check the fluid pressure when brake pedal is
depressed. The pressure must be greater than the stan-
dard value listed below.
Brake pedal force 147N (15 kg, 33 lb) 294N (30kg, 66 lb)
Models without ABS and
TCS785 kPa
(8 kg/cm
2, 114 psi)2,158 kPa
(22 kg/cm2, 313 psi)
Models with ABS and
TCS588 kPa
(6 kg/cm
2, 85 psi)1,667 kPa
(17 kg/cm2, 242 psi)
9. BOOSTING ACTION CHECK
Set the vacuum gauge reading at 66.7 kPa (500 mmHg,
19.69 inHg) by running engine. Then, check the fluid pres-
sure when brake pedal is depressed. The pressure must
be greater than the standard value listed below.
Brake pedal force 147N (15 kg, 33 lb) 294N (30kg, 66 lb)
Models without ABS and
TCS5,492 kPa
(56 kg/cm
2, 796 psi)8,434 kPa
(86 kg/cm2, 1,223 psi)
Models with ABS and
TCS5,394 kPa
(55 kg/cm
2,782 psi)10,003 kPa
(102 kg/cm2, 1,450
psi)
D: HANDLING PRECAUTIONS
1) Be careful not to drop brake booster. Brake booster
should be discarded if it has been dropped.
2) Use special care when handling operating rod.
If excessive force is applied to operating rod, sufficient to
cause a change in the angle in excess of ±3°, it may result
in damage to the power piston cylinder.
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4-4SERVICE PROCEDURE
6. Brake Booster

G4M0428
8. Hill Holder
A: REMOVAL
1) Drain brake fluid from reservoir of master cylinder.
2) Remove adjusting nut and cable clamp, and disconnect
PHV cable from cable bracket on engine.
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:

Pay attention not to drop brake fluid onto body
painting since it may dissolve paint.

Pay 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 corroded.
2) Check if return spring is worn out, damaged or cor-
roded.
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.
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4-4SERVICE PROCEDURE
8. Hill Holder

C: INSTALLATION
1) Install PHV onto side frame.
Tightening torque:
18±5 N⋅m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)
2) Connect brake pipes to PHV.
Tightening torque:
15
+3
2N⋅m (1.5+0.3
0.2kg-m, 10.8+2.2
1.4ft-lb)
CAUTION:
Confirm that brake pipes are not deformed and/or dam-
aged. Replace them with new ones if necessary.
3) Install PHV cable to PHV stay.
CAUTION:
If cable clamp (and clips) is damaged, replace it with a
new one.
4) Connect PHV cable with clips.
NOTE:
Avoid sharp bending of PHV cable as it may cause break-
age.
5) Install PHV cable onto cable bracket on engine.
6) Apply grease to the following points.

Hook portion of return spring

Cable end portion of lever
Grease:
SUNLIGHT 2 (Part No. 003602010)
7) Be sure to bleed air from the system.
CAUTION:
After replacing PHV cable or clutch cable with new
one, operate clutch pedal about 30 times as a run-
ning-in operation prior to adjustment.
D: ADJUSTMENTS
Confirm stopping and starting performances by activating
hill holder on an uphill road of 3°or higher inclination.
(1) If vehicle does not stop;
Tighten adjusting nut of PHV cable.
(2) If vehicle does not start properly;

Case A—When hill holder is released later than
engagement of clutch pedal (Engine tends to stall.):
Loosen adjusting nut gradually until smooth starting
is enabled.

Case B—When hill holder is released earlier than
engagement of clutch pedal (Vehicle slips down
slightly.):
Tighten adjusting nut so that hill holder is released
later than engagement of clutch pedal (status in Case
A). Then make adjustment the same as in Case A.
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4-4SERVICE PROCEDURE
8. Hill Holder

Air bleeder tightening torque:
8±1 N⋅m (0.8±0.1 kg-m, 5.8±0.7 ft-lb)
5) Perform these steps for the brakes connecting to the
secondary chamber of master cylinder, first, and then for
the ones connecting to primary chamber. With all proce-
dures completed, fully depress the brake pedal and keep
it in that position for approximately 20 seconds to make
sure that there is no leak evident in the entire system.
G4M0436
6) Perform sequence control. (With ABS model) [W15C1].>
7) Check the pedal stroke.
While the engine is idling, depress the brake pedal with a
490 N (50 kg, 110 lb) load and measure the distance
between the brake pedal and steering wheel. With the
brake pedal released, measure the distance between the
pedal and steering wheel again. The difference between
the two measurements must be more than specified.
Specified pedal stroke:
Without ABS
90 mm (3.54 in)
With ABS
95 mm (3.74 in)
When depressing brake pedal with a 490 N (50 kg,
110 lb) load.
(1) Models without ABS
If the distance is more than specifications, there is a
possibility that air is in the brake line. Bleed air from the
brake line.
(2) Models with ABS
If the distance is more than specifications, there is a
possibility air is in the inside of the hydraulic unit.
Therefore, air must be bled from the inside of the
hydraulic unit to the brake pipes in accordance with the
bleeding sequence control.
8) Add brake fluid to the required level (MAX. level) of
reserve tank.
9) As a final step, test run the vehicle at low speed and
apply brakes relatively hard 2 to 3 times to ensure that
brakes provide normal braking action on all four wheels
without dragging and uneven braking.
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4-4SERVICE PROCEDURE
11. Air Bleeding (Without TCS model)

14. ABS Sensor
A: REMOVAL
1. FRONT ABS SENSOR
1) Disconnect front ABS sensor connector located in
engine compartment.
B4M0079A
2) Remove bolts which secure sensor harness to strut.
G4M0451
3) Remove bolts which secure sensor harness to body.
G4M0443
4) Remove bolts which secure front ABS sensor to
housing, and remove front ABS sensor.
CAUTION:

Be careful not to damage pole piece located at tip of
the sensor and teeth faces during removal.

Do not pull sensor harness during removal.
5) Remove front disc brake caliper and disc rotor from
housing after removing front tire.
6) Remove front drive shaft and housing and hub assem-
bly.
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4-4SERVICE PROCEDURE
14. ABS Sensor

15. Hydraulic Unit for ABS System
B4M0069A
1Connector

2Cap

3Motor relay

4Valve relay

5Hydraulic control unit

6Front-RH outlet

7Rear-LH outlet
8Rear-RH outlet

9Front-LH outlet

10Primary inlet

11Secondary inlet

12Bracket
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 1.2±0.2
(0.125±0.025, 0.9±0.2)
T2: 18±5 (1.8±0.5, 13.0±3.6)
T3: 29±7 (3.0±0.7, 21.7±5.1)
T4: 32±10 (3.3±1.0, 24±7)
A: REMOVAL
1) Remove air intake duct.
2) Remove canister from engine compartment to facilitate
removal of hydraulic unit.
3) Disconnect brake pipes from hydraulic unit and plug
open joints to prevent entry of foreign particles.
G4M0455
4) Remove nuts and bolts which secure hydraulic unit, and
remove hydraulic unit from engine compartment.
CAUTION:

Hydraulic unit cannot be disassembled. Do not
attempt to loosen bolts and nuts.

Do not drop or bump hydraulic unit.

Do not turn the hydraulic unit upside down or place
it on its side.
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4-4SERVICE PROCEDURE
15. Hydraulic Unit for ABS System

2. CHECKING THE HYDRAULIC UNIT OPERATION BY
PRESSURE GAUGE
1) Remove the FL and FR pipes from the hydraulic unit.
G4M0460
2) Connect two pressure gauges to the hydraulic unit.
CAUTION:

Pressure gauges used exclusively for brake fluid
must be used.

Do not employ pressure gauge previously used for
transmission since the piston seal is expanded which
may lead to malfunction of the brake.
3) Bleed air from the pressure gauges.
4) Perform sequence control.
B4M0082A
(1) Connect diagnosis terminals to 3 terminals (K) and
6 terminals (L) of the diagnosis connector beside driver
seat heater unit.
(2) Turn ignition switch ON.
(3) The ABS warning light comes on.
(4) Depress the brake pedal within 0.5 seconds after
the warning light goes out so that the pressure gauge
registers a pressure equal to the initial value.
CAUTION:
Do not depress the clutch pedal.
NOTE:
The engine must not be operating.
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4-4SERVICE PROCEDURE
15. Hydraulic Unit for ABS System

G4M0462
3. CHECKING THE HYDRAULIC UNIT WITH BRAKE
TESTER
1) In the case of AWD vehicles, install a spare fuse with
the FWD connector in the engine compartment to simulate
FWD vehicles.
B4M0082A
2) Connect diagnosis terminals to 3 terminals (K) and 6
terminals (L) of the diagnosis connector beside driver seat
heater unit.
G4M0464
3) Set the front wheels or rear wheels on the brake tester
and set the select lever’s position at“neutral”.
4) Operate the brake tester.
5) Perform sequence control.
(1) Turn ignition switch ON.
(2) The ABS warning light comes on.
(3) Depress the brake pedal within 0.5 seconds after
the warning light goes out so that the brake tester reg-
isters a pressure equal to the initial value.
CAUTION:
Do not depress the clutch pedal.
NOTE:
The engine must not be operating.
6) Hydraulic unit begins to work; and check the following
working sequence.
(1) The left front wheel performs decompression,
holding, and compression in sequence, and subse-
quently the right front wheel repeats the cycle.
(2) Simultaneously both right and left rear wheel per-
form decompression, holding, and compression in
sequence.
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4-4SERVICE PROCEDURE
15. Hydraulic Unit for ABS System