1996 SUBARU LEGACY wheel torque

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) 4-4 [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.
63
4-4SERVICE PROCEDURE
11. Air Bleeding (Without TCS model)

G4M0434
G4M0438
G4M0435
5) Install one end of a vinyl tube onto the air bleeder of and
insert the other end of the tube into a container to collect
the brake fluid.
6) Instruct your co-worker to depress the brake pedal
slowly two or three times and then hold it depressed.
7) Loosen bleeder screw approximately 1/4 turn until a
small amount of brake fluid drains into container, and then
quickly tighten screw.
8) Repeat steps 6) and 7) above until there are no air
bubbles in drained brake fluid and new fluid flows through
vinyl tube.
CAUTION:
Add brake fluid as necessary while performing the air
bleed operation, in order to prevent the tank from run-
ning short of brake fluid.
9) After completing the bleeding operation, hold brake
pedal depressed and tighten screw and install bleeder cap.
Tightening torque (Bleeder screw):
8±1 N⋅m (0.8±0.1 kg-m, 5.8±0.7 ft-lb)
10) Bleed air from each wheel cylinder using the same
procedures as described in steps 6) through 7) above.
11) Depress brake pedal with a force of approximately 294
N (30 kg, 66 lb) and hold it there for approximately 20 sec-
onds. At this time check pedal to see if it shows any
unusual movement.
Visually inspect bleeder screws and brake pipe joints to
make sure that there is no fluid leakage.
12) Install wheels, and drive vehicle for a short distance
between 2 to 3 km (1 to 2 miles) to make sure that brakes
are operating properly.
65
4-4SERVICE PROCEDURE
12. Brake Fluid Replacement

G4M0440
13. Proportioning Valve
G4M0668
G4M0915
A: INSPECTION
1) Install the oil pressure gauges to measure the master
cylinder fluid pressure (front wheel brake fluid pressure)
and rear wheel cylinder fluid pressure.
2) Bleed air from the oil pressure gauges.
3) Check the master cylinder fluid pressure and rear wheel
cylinder fluid pressure.
The standard values are shown in Figure.
4) For the oil pressure in case of split point, refer to A:
SPECIFICATIONS 4-4 [S0A0].
B: REMOVAL
1) Remove brake pipe from proportioning valve at four
places.
2) Remove proportioning valve from its bracket.
CAUTION:
Do not disassemble or adjust the proportioning valve.
(The proportioning valve must be replaced as an
assembly.)
C: INSTALLATION
1) Install proportioning valve to bracket.
2) Connect brake pipes correctly to proportioning valve.
3) Bleed air, then check each joint of brake pipe for oil
leaks.
Tightening torque:
Proportioning valve to brake pipe flare nut:
15
+3
2N⋅m (1.5+0.3
0.2kg-m, 10.8+2.2
1.4ft-lb)
Proportioning valve to bracket:
18±5 N⋅m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)
66
4-4SERVICE PROCEDURE
13. Proportioning Valve

G4M0451
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)
5) Place a thickness gauge between ABS sensor’s pole
piece and tone wheel’s tooth face. After standard clearance
is obtained over the entire perimeter, tighten ABS sensor
on housing to specified torque.
ABS sensor standard clearance:
0.9—1.4 mm (0.035—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: yellow)
NOTE:
If the clearance is outside specifications, readjust.
2. REAR ABS SENSOR
1) Install rear tone wheel on hub, then rear housing on
hub.
G4M0445
2) Temporarily install rear ABS sensor on back plate.
CAUTION:
Be careful not to strike ABS sensor’s pole piece and
tone wheel’s teeth against adjacent metal parts during
installation.
71
4-4SERVICE PROCEDURE
14. ABS Sensor

3) Install rear drive shaft to rear housing and rear differen-
tial spindle.
G4M0453
4) Install rear sensor harness on rear trailing link.
Tightening torque:
32±10 N⋅m (3.3±1.0 kg-m, 24±7 ft-lb)
5) Place a thickness gauge between ABS sensor’s pole
piece and tone wheel’s tooth face. After standard clearance
is obtained over the entire perimeter, tighten ABS sensor
on back plate to specified torque.
ABS sensor standard clearance:
0.7—1.2 mm (0.028—0.047 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: yellow)
NOTE:
If the clearance is outside specifications, readjust.
72
4-4SERVICE PROCEDURE
14. ABS Sensor

B: INSPECTION
Check that connector is connected correctly and that con-
nector terminal sliding resistance is correct.
G4M0469
C: INSTALLATION
1) Connect connector to ABS control module.
2) Install ABS control module on the body.
G4M0470
17. G Sensor for ABS System (Except
ABS 5.3 Type)
A: REMOVAL AND INSTALLATION
The G sensor is located on the right front wheel apron.
G4M0471
B: INSPECTION
1) Check to ensure that G sensor is securely installed on
front wheel apron, and that connector is properly installed.
2) Disconnect connector from G sensor and measure con-
tact resistance between terminals.
Condition of G sensor Standard
On flat surface 610±60Ω
* When slanting about
14°—21.3°(θ)610±60Ω,
More than 100 kΩ
NOTE:

Tilt G sensor forward as shown in Figure. If it is tilted
backward, it will not operate.

Hysteresis occurs during ON-OFF operation of sensor.
Sensor should turn OFF from ON (610Ω,More than 100
kΩ) when it is tilted in a range from 14°to 21.3°.
Tightening torque:
7.4±2.0 N⋅m (0.75±0.2 kg-m, 5.4±1.4 ft-lb)
81
4-4SERVICE PROCEDURE
16. ABS Control Module (Except ABS 5.3 Type)- 17. G Sensor for ABS System (Except ABS 5.3 Type)

B: INSPECTION
Check that connector is connected correctly and that con-
nector terminal sliding resistance is correct.
G4M0469
C: INSTALLATION
1) Connect connector to ABS control module.
2) Install ABS control module on the body.
G4M0470
17. G Sensor for ABS System (Except
ABS 5.3 Type)
A: REMOVAL AND INSTALLATION
The G sensor is located on the right front wheel apron.
G4M0471
B: INSPECTION
1) Check to ensure that G sensor is securely installed on
front wheel apron, and that connector is properly installed.
2) Disconnect connector from G sensor and measure con-
tact resistance between terminals.
Condition of G sensor Standard
On flat surface 610±60Ω
* When slanting about
14°—21.3°(θ)610±60Ω,
More than 100 kΩ
NOTE:

Tilt G sensor forward as shown in Figure. If it is tilted
backward, it will not operate.

Hysteresis occurs during ON-OFF operation of sensor.
Sensor should turn OFF from ON (610Ω,More than 100
kΩ) when it is tilted in a range from 14°to 21.3°.
Tightening torque:
7.4±2.0 N⋅m (0.75±0.2 kg-m, 5.4±1.4 ft-lb)
81
4-4SERVICE PROCEDURE
16. ABS Control Module (Except ABS 5.3 Type)- 17. G Sensor for ABS System (Except ABS 5.3 Type)

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 cylinder
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 cylinder
piston kit, pipe or hose).
(4) Improperly adjusted shoe clearance Adjust.
(5) Improper lining contact or worn lining Correct or replace.
124
4-4DIAGNOSTICS
1. Entire Brake System