1999 SUBARU LEGACY Service Repair Manual

E: INSTALLATION
1) Install ABSCM&H/U.
CAUTION:
Confirm that the specifications of the
ABSCM&H/U conforms to the vehicle specifica-
tions.
Tightening torque:
18
±5 N´m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)
B4M1222
2) Connect brake pipes to their correct
ABSCM&H/U connections.
Brake pipe tightening torque:
15+3/þ2N´m (1.5+0.3/þ0.2kg-m, 10.8+2.2/þ1.4ft-lb)
3) Using cable clip, secure ABSCM&H/U harness
to bracket.
4) Connect connector to ABSCM&H/U.
CAUTION:
IBe sure to remove all foreign matter from
inside the connector before connecting.
IEnsure that the ABSCM&H/U connetor is
securely locked.
5) Install air intake duct.
6) Connect ground cable to battery.
7) Bleed air from the brake system.
16. G Sensor
A: REMOVAL
1. FRONT ABS SENSOR
1) Disconnect front ABS sensor connector located
in engine compartment.
2) Remove bolts which secure sensor harness to
strut.
B4M1442A
3) Remove bolts which secure sensor harness to
body.
B4M1181A
4) Remove bolts which secure front ABS sensor to
housing, and remove front ABS sensor.
CAUTION:
IBe careful not to damage pole piece located
at tip of the sensor and teeth faces during
removal.
IDo not pull sensor harness during removal.
B4M1183A
5) Remove front disc brake caliper and disc rotor
from housing after removing front tire.
60
4-4[W15E0]SERVICE PROCEDURE
16. G Sensor

E: INSTALLATION
1) Install ABSCM&H/U.
CAUTION:
Confirm that the specifications of the
ABSCM&H/U conforms to the vehicle specifica-
tions.
Tightening torque:
18
±5 N´m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)
B4M1222
2) Connect brake pipes to their correct
ABSCM&H/U connections.
Brake pipe tightening torque:
15+3/þ2N´m (1.5+0.3/þ0.2kg-m, 10.8+2.2/þ1.4ft-lb)
3) Using cable clip, secure ABSCM&H/U harness
to bracket.
4) Connect connector to ABSCM&H/U.
CAUTION:
IBe sure to remove all foreign matter from
inside the connector before connecting.
IEnsure that the ABSCM&H/U connetor is
securely locked.
5) Install air intake duct.
6) Connect ground cable to battery.
7) Bleed air from the brake system.
16. G Sensor
A: REMOVAL
1. FRONT ABS SENSOR
1) Disconnect front ABS sensor connector located
in engine compartment.
2) Remove bolts which secure sensor harness to
strut.
B4M1442A
3) Remove bolts which secure sensor harness to
body.
B4M1181A
4) Remove bolts which secure front ABS sensor to
housing, and remove front ABS sensor.
CAUTION:
IBe careful not to damage pole piece located
at tip of the sensor and teeth faces during
removal.
IDo not pull sensor harness during removal.
B4M1183A
5) Remove front disc brake caliper and disc rotor
from housing after removing front tire.
60
4-4[W15E0]SERVICE PROCEDURE
16. G Sensor

6) Remove front drive shaft and housing and hub
assembly.
7) Remove tone wheel while removing hub from
housing and hub assembly.
CAUTION:
Be careful not to damage teeth faces of tone
wheel during removal.
G4M0444
B: INSPECTION WITH CIRCUIT
TESTER
16B1 : CHECK G SENSOR.
1) Turn ignition switch to OFF.
2) Remove G sensor from vehicle.
3) Connect connector to G sensor.
4) Turn ignition switch to ON.
5) Measure voltage between G sensor connector
terminals.
Connector & terminal
(P11) No. 2 (+) Ð No. 3 (þ)
B4M0915
:Is the voltage 2.3±0.2 V when G sen-
sor is horizontal?
: Go to step16B2.
: Replace G sensor.16B2 : CHECK G SENSOR.
Measure voltage between G sensor connector ter-
minals.
Connector & terminal
(P11) No. 2 (+) Ð No. 3 (þ)
B4M0917A
:Is the voltage 3.9±0.2 V when G sen-
sor is inclined forwards to 90É?
: Go to step16B3.
: Replace G sensor.
16B3 : CHECK G SENSOR.
Measure voltage between G sensor connector ter-
minals.
Connector & terminal
(P11) No. 2 (+) Ð No. 3 (þ)
B4M0918A
:Is the voltage 0.7±0.2 V when G sen-
sor is inclined backwards to 90É?
: G sensor is normal.
: Replace G sensor.
61
[W16B3]4-4SERVICE PROCEDURE
16. G Sensor

C: INSPECTION WITH SELECT
MONITOR
16C1 : CHECK G SENSOR.
1) Turn ignition switch to OFF.
2) Connect select monitor connector to data link
connector.
3) Turn select monitor into {ABS/TCS} mode.
4) Set the display in the {Current Data Display &
Save} mode.
5) Read the G sensor output voltage.
:Is the indicated reading 2.3±0.2 V
when the vehicle is in horizontal
position?
: Go to step16C2.
: Replace G sensor.
16C2 : CHECK G SENSOR.
1) Remove console box.
2) Remove G sensor from vehicle. (Do not discon-
nect connector.)
3) Read the select monitor display.
B4M0917A
:Is the indicated reading 3.9±0.2 V
when G sensor is inclined forwards
to 90É?
: Go to step16C3.
: Replace G sensor.16C3 : CHECK G SENSOR.
Read the select monitor display.
B4M0918A
:Is the indicated reading 0.7±0.2 V
when G sensor is inclined backwards
to 90É?
: G sensor is normal.
: Replace G sensor.
D: INSTALLATION
1. FRONT ABS SENSOR
1) Install tone wheel on hub, then install housing
on hub assembly.
2) Temporarily install front ABS sensor on hous-
ing.
CAUTION:
Be careful not to strike ABS sensor's pole
piece and tone wheel's teeth against adjacent
metal parts during installation.
B4M1183A
3) Install front drive shaft to hub spline. 4-2 [W1E0].>
62
4-4[W16C1]SERVICE PROCEDURE
16. G Sensor

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