1999 SUBARU LEGACY Service Repair Manual

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

MEMO:
66
4-4DIAGNOSTICS

1. Pedal System
Brake pedal Free play1Ð3mm(0.04 Ð 0.12 in) [Depress brake pedal pad
with a force of less than 10 N (1 kg, 2 lb).]
Clutch pedalFree play At clutch pedal padExcept 2500 cc model: 10 Ð 20 mm (0.39 Ð 0.79 in)
2500 cc model:4Ð13mm(0.16 Ð 0.51 in)
Full stroke At clutch pedal padExcept 2500 cc model: 140 Ð 145 mm (5.51 Ð 5.71 in)
2500 cc model: 130 Ð 135 mm (5.12 Ð 5.31 in)
Accelerator pedalFree play At pedal pad1Ð4mm(0.04 Ð 0.16 in)
Stroke At pedal pad 50 Ð 55 mm (1.97 Ð 2.17 in)
2
4-5[S100]SPECIFICATIONS AND SERVICE DATA
1. Pedal System

1. Pedal
A: MT MODEL
1. EXCEPT 2500 cc MODEL
B4M0737B
(1) Accelerator pedal
(2) Bushing
(3) Holder
(4) Accelerator bracket
(5) Stopper
(6) Clip
(7) Accelerator spring
(8) Accelerator pedal spring
(9) Spring pin
(10) Accelerator pedal pad
(11) Accelerator stopper
(12) Clip
(13) Accelerator plate(14) Pedal bracket
(15) Stop light switch
(16) Brake pedal
(17) Spacer
(18) Snap pin
(19) Brake pedal pad
(20) Clevis pin
(21) Brake pedal spring
(22) Washer
(23) Clutch pedal pad
(24) Clutch pedal
(25) Bushing assist
(26) Spring assist(27) Clutch cable clamp
(28) Clutch cable
(29) Mass damper
(30) Clutch switch (Starter interlock)
(31) Clutch switch (With cruise con-
trol)
Tightening torque: N´m (kg-m, ft-lb)
T1:
5.9±1.5 (0.60±0.15, 4.3±1.1)
T2:8±2 (0.8±0.2, 5.8±1.4)
T3:18±5 (1.8±0.5, 13.0±3.6)
T4:29±7 (3.0±0.7, 21.7±5.1)
3
[C1A1]4-5COMPONENT PARTS
1. Pedal

2. 2500 cc MODEL
S4M0134A
(1) Holder
(2) Accelerator bracket
(3) Stopper
(4) Bushing
(5) Clip
(6) Accelerator spring
(7) Accelerator pedal spring
(8) Accelerator pedal
(9) Spring pin
(10) Accelerator pedal pad
(11) Accelerator stopper
(12) Snap pin
(13) Brake pedal pad
(14) Brake pedal
(15) Clevis pin(16) Brake pedal spring
(17) Clutch pedal pad
(18) Clutch pedal
(19) Bushing C
(20) Clutch clevis pin
(21) Assist rod A
(22) Clip
(23) Assist spring
(24) Assist bushing
(25) Assist rod B
(26) Rod S
(27) Spring S
(28) Bushing S
(29) O-ring
(30) Clip(31) Clutch switch (Starter interlock)
(32) Clutch switch (With cruise con-
trol)
(33) Stop light switch
(34) Pedal bracket
(35) Clutch master cylinder bracket
(36) Lever
(37) Lock wire
Tightening torque: N´m (kg-m, ft-lb)
T1:
8±2 (0.8±0.2, 5.8±1.4)
T2:18±5 (1.8±0.5, 13.0±3.6)
4
4-5[C1A2]COMPONENT PARTS
1. Pedal

B: AT MODEL
B4M0738B
(1) Accelerator pedal
(2) Bushing
(3) Holder
(4) Accelerator bracket
(5) Stopper
(6) Clip
(7) Accelerator spring
(8) Accelerator pedal spring
(9) Spring pin
(10) Accelerator pedal pad(11) Accelerator stopper
(12) Clip
(13) Accelerator plate
(14) Plug
(15) Pedal bracket
(16) Stop light switch
(17) Spacer
(18) Stopper
(19) Snap pin
(20) Brake pedal pad(21) Brake pedal
(22) Clevis pin
(23) Brake pedal spring
Tightening torque: N´m (kg-m, ft-lb)
T1:
8±2 (0.8±0.2, 5.8±1.4)
T2:18±5 (1.8±0.5, 13.0±3.6)
T3:29±7 (3.0±0.7, 21.7±5.1)
5
[C1B0]4-5COMPONENT PARTS
1. Pedal

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