1996 SUBARU LEGACY relay

20. Hydraulic Unit for ABS/TCS System
B4M0707A
1ABS/TCS hydraulic
control unit

2Rear-RH outlet

3Front-LH outlet

4Front-RH outlet

5Rear-LH outlet

6Secondary inlet

7Primary inlet
8Secondary suction line

9Primary suction line

10Bumper

11Bracket

12Pressure switch

13Valve relay

14Motor relay
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 7.4±2.0 (0.75±0.2, 5.4±1.4)
T2: 29±7 (3.0±0.7, 21.7±5.1)
T3: 32±10 (3.3±1.0, 24±7)
T4: 38±10 (3.8±1.0, 27±7)
T5: 3.1±1 (0.32±0.1, 2.3±0.7)
A: REMOVAL
1) Disconnect ground cable from battery.
2) Remove canister, air intake and air cleaner case duct
from engine compartment to facilitate removal of hydraulic
unit.
3) Disconnect brake pipes from hydraulic unit.
CAUTION:
Wrap brake pipes with vinyl bag to avoid spilling brake
fluid on vehicle body.
4) Disconnect connector from hydraulic unit.
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4-4SERVICE PROCEDURE
20. Hydraulic Unit for ABS/TCS System

B4M0628
5) Remove bolts which secure hydraulic unit bracket, 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.

Be careful to prevent foreign particles from getting
into hydraulic unit.

Do not pull harness disconnecting harness connec-
tor.
B: INSPECTION
1) Check connected and fixed condition of connector.
2) Check for discontinuity or short circuits.
Condition Terminal number Standard Diagram Terminal location
Valve relayTurning off
electricity.A—B90Ω
B4M0629A
B4M0630
C—F0Ω
C—E
Turning on
electricity between
A and B.
(DC 12 V)C—F
C—E0Ω
Motor relayTurning off
electricity.a—b* 57Ω
B4M0631AB4M0632
c—d
Turning on
electricity between
a and b.
(DC 12 V)c—d0Ω
*: Attach circuit tester positive probe to terminal“a”and its negative probe to terminal“b”and measure the circuit resistance.
94
4-4SERVICE PROCEDURE
20. Hydraulic Unit for ABS/TCS System

B4M0628
G: INSTALLATION
1) Install hydraulic unit and bracket.
Tightening torque:
32±7 N⋅m (3.3±0.7 kg-m, 23.9±5.1 ft-lb)
2) Connect brake pipes to their correct hydraulic unit con-
nections.
3) Connect connector to hydraulic unit.
4) Install canister.
5) Install air cleaner case.
6) Install air intake duct.
7) Connect ground cable to battery.
CAUTION:
Cover relay securely with rubber boot.
21. ABS/TCS Control Module
A: REMOVAL
1) Disconnect ground cable from battery.
2) Remove floor mat located under lower right side of front
seat.
B4M0643A
3) Remove screw which secure ABS/TCS control module
from the body.
4) Disconnect connector from ABS/TCS control module.
B: INSPECTION
Check that connector is connected correctly and that con-
nector terminal sliding resistance is correct.
107
4-4SERVICE PROCEDURE
20. Hydraulic Unit for ABS/TCS System - 21. ABS/TCS Control Module

B4M0628
G: INSTALLATION
1) Install hydraulic unit and bracket.
Tightening torque:
32±7 N⋅m (3.3±0.7 kg-m, 23.9±5.1 ft-lb)
2) Connect brake pipes to their correct hydraulic unit con-
nections.
3) Connect connector to hydraulic unit.
4) Install canister.
5) Install air cleaner case.
6) Install air intake duct.
7) Connect ground cable to battery.
CAUTION:
Cover relay securely with rubber boot.
21. ABS/TCS Control Module
A: REMOVAL
1) Disconnect ground cable from battery.
2) Remove floor mat located under lower right side of front
seat.
B4M0643A
3) Remove screw which secure ABS/TCS control module
from the body.
4) Disconnect connector from ABS/TCS control module.
B: INSPECTION
Check that connector is connected correctly and that con-
nector terminal sliding resistance is correct.
107
4-4SERVICE PROCEDURE
20. Hydraulic Unit for ABS/TCS System - 21. ABS/TCS Control Module

22. Hydraulic Unit for ABS System
(ABS 5.3 Type)
B4M0994A
1Hydraulic control unit

2Damper

3Stud bolt

4Rear-RH outlet

5Rear-LH outlet

6Secondary inlet

7Primary inlet

8Front-LH outlet
9Front-RH outlet

10Cable clip

11Bracket

12Relay box

13Motor relay

14Valve relay

15Cap

16Connector bracket
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 18±5 (1.8±0.5, 13.0±3.6)
T2: 29±7 (3.0±0.7, 21.7±5.1)
T3: 32±10 (3.3±1.0, 24±7)
A: REMOVAL
1. HYDRAULIC UNIT
1) Disconnect ground cable from battery.
2) Remove air intake duct and canister from engine com-
partment to facilitate removal of hydraulic unit.
3) Disconnect connector from hydraulic unit.
4) Unlock cable clip.
5) Disconnect brake pipes from hydraulic unit.
CAUTION:
Wrap brake pipes with vinyl bag to avoid spilling brake
fluid on vehicle body.
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4-4SERVICE PROCEDURE
22. Hydraulic Unit for ABS System (ABS 5.3 Type)

B4M0996
6) Remove nuts and bolt which secure hydraulic unit
bracket, and remove hydraulic unit from engine compart-
ment.
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.

Be careful to prevent foreign particles from getting
into hydraulic unit.

When a new hydraulic unit is installed, apply a coat
of rust-preventive wax (Nippeco LT or GB) to bracket
attaching bolt after tightening.

Do not pull harness disconnecting harness connec-
tor.
2. RELAY BOX
1) Disconnect ground cable from battery.
2) Remove air intake duct and canister from engine com-
partment to facilitate removal of relay box.
B4M1029
3) Disconnect connector from relay box.
4) Unlock cable clip.
5) Remove nuts which secure relay box, and remove relay
box and connector bracket.
CAUTION:
Do not drop or bump relay box.
11 0
4-4SERVICE PROCEDURE
22. Hydraulic Unit for ABS System (ABS 5.3 Type)

B: INSPECTION
1) Check connected and fixed condition of connector.
2) Check valve relay and motor relay for discontinuity or
short circuits.
Condition Terminal number Standard Diagram Terminal location
Valve relayTurning off
electricity.85—86 103±10Ω
G4M0456G4M0457
30—87a less than 0.5Ω
30—87 more than 1 MΩ
Turning on
electricity between
85 and 86.
(DC 12 V)30—87a more than 1 MΩ
30—87 less than 0.5Ω
Motor relayTurning off
electricity.85—86 80±8Ω
G4M0458G4M0459
30—87 more than 1 MΩ
Turning on
electricity between
85 and 86.
(DC 12 V)30—87 less than 0.5Ω
C: CHECKING THE HYDRAULIC UNIT ABS
OPERATION
1. CHECKING THE HYDRAULIC UNIT ABS
OPERATION BY PRESSURE GAUGE
1) Lift-up vehicle and remove wheels.
2) Disconnect the air bleeder screws from the FL and FR
caliper bodies.
B4M0633A
3) Connect two pressure gauges to the FL and FR caliper
bodies.
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.
NOTE:
Wrap sealing tape around the pressure gauge.
111
4-4SERVICE PROCEDURE
22. Hydraulic Unit for ABS System (ABS 5.3 Type)

B4M0996
E: INSTALLATION
1. HYDRAULIC UNIT
1) Install hydraulic unit.
Tightening torque:
18±5 N⋅m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)
2) Connect hydraulic unit ground cable to body.
Tightening torque:
32±10 N⋅m (3.3±1.0 kg-m, 24±7 ft-lb)
3) Connect brake pipes to their correct hydraulic unit con-
nections.
B4M1031A
4) Secure hydraulic unit connector to connector bracket.
CAUTION:
Align connector with mating receptacle.
5) Using cable clip, secure hydraulic unit harness to relay
box harness.
CAUTION:
Make sure hydraulic unit harness band is secured
beneath cable clip.
6) Connect connector to hydraulic unit.
7) Install canister.
8) Install air intake duct.
9) Connect ground cable to battery.
10) Bleed air from the brake system.
B4M1029
2. RELAY BOX
1) Install relay box and connector bracket.
Tightening torque:
18±5 N⋅m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)
11 8
4-4SERVICE PROCEDURE
22. Hydraulic Unit for ABS System (ABS 5.3 Type)