1999 SUBARU LEGACY Brake check valve

2. 2500 cc MODEL
CAUTION:
After warming-up, engine becomes very hot.
Be careful not to burn yourself during mea-
surement.
1) After warming-up the engine, turn ignition
switch to OFF.
2) Make sure that the battery is fully charged.
3) Remove all the spark plugs. [W3B0].>
4) Disconnect connectors from fuel injectors.
5) Fully open throttle valve.
6) Check the starter motor for satisfactory perfor-
mance and operation.
7) Hold the compression gauge tight against the
spark plug hole.
CAUTION:
When using a screw-in type compression
gauge, the screw (put into cylinder head spark
plug hole) should be less than 18 mm (0.71 in)
long.
8) Crank the engine by means of the starter motor,
and read the maximum value on the gauge when
the pointer is steady.
B2M0752A
9) Perform at least two measurements per
cylinder, and make sure that the values are correct.
Compression (350 rpm and fully open
throttle):
Standard;
1,216 kPa (12.4 kg/cm
2, 176 psi)
Limit;
941 kPa (9.6 kg/cm
2, 137 psi)
Difference between cylinders;
49 kPa (0.5 kg/cm
2, 7 psi), or less
5. Intake Manifold Vacuum
A: MEASUREMENT
1) Warm-up the engine.
2) Disconnect the brake vacuum hose and install
the vacuum gauge to the hose fitting on the mani-
fold.
3) Keep the engine at the idle speed and read the
vacuum gauge indication.
By observing the gauge needle movement, the
internal condition of the engine can be diagnosed
as described below.
H2M1601
Vacuum pressure (at idling, A/C ªOFFº):
Less than þ60.0 kPa (þ450 mmHg, þ17.72
inHg)
5
[W5A0]2-2SERVICE PROCEDURE
5. Intake Manifold Vacuum

2. 2500 cc MODEL
CAUTION:
After warming-up, engine becomes very hot.
Be careful not to burn yourself during mea-
surement.
1) After warming-up the engine, turn ignition
switch to OFF.
2) Make sure that the battery is fully charged.
3) Remove all the spark plugs. [W3B0].>
4) Disconnect connectors from fuel injectors.
5) Fully open throttle valve.
6) Check the starter motor for satisfactory perfor-
mance and operation.
7) Hold the compression gauge tight against the
spark plug hole.
CAUTION:
When using a screw-in type compression
gauge, the screw (put into cylinder head spark
plug hole) should be less than 18 mm (0.71 in)
long.
8) Crank the engine by means of the starter motor,
and read the maximum value on the gauge when
the pointer is steady.
B2M0752A
9) Perform at least two measurements per
cylinder, and make sure that the values are correct.
Compression (350 rpm and fully open
throttle):
Standard;
1,216 kPa (12.4 kg/cm
2, 176 psi)
Limit;
941 kPa (9.6 kg/cm
2, 137 psi)
Difference between cylinders;
49 kPa (0.5 kg/cm
2, 7 psi), or less
5. Intake Manifold Vacuum
A: MEASUREMENT
1) Warm-up the engine.
2) Disconnect the brake vacuum hose and install
the vacuum gauge to the hose fitting on the mani-
fold.
3) Keep the engine at the idle speed and read the
vacuum gauge indication.
By observing the gauge needle movement, the
internal condition of the engine can be diagnosed
as described below.
H2M1601
Vacuum pressure (at idling, A/C ªOFFº):
Less than þ60.0 kPa (þ450 mmHg, þ17.72
inHg)
5
[W5A0]2-2SERVICE PROCEDURE
5. Intake Manifold Vacuum

3) Install valve body to transmission case.
CAUTION:
When installing control valve body, be careful
not to interfere with transfer duty solenoid wir-
ing (brown).
NOTE:
Align manual valve connections.
Tightening torque:
8
±1 N´m (0.8±0.1 kg-m, 5.8±0.7 ft-lb)
B3M1037A
(A) Short bolts
(B) Long bolts
4) Connect harness connectors at 8 places.
Connect connectors of same color, and secure
connectors to valve body using clips.
B2M2263C
(A) Lock-up duty solenoid (Blue)
(B) Low clutch timing solenoid (Gray)
(C) Line pressure duty solenoid (Red)
(D) Shift solenoid 2 (Yellow)
(E) Shift solenoid 1 (Green)
(F) 2-4 brake timing solenoid (Black)
(G) 2-4 brake duty solenoid (Red)
(H) ATF temperature sensor
5) Apply proper amount of liquid gasket (THREE
BOND Part No. 1217B) to the entire oil pan mat-
ing surface.
B3M1040A
6) Install oil pan.
Tightening torque:
4.9
±0.5 N´m (0.50±0.05 kg-m, 3.6±0.4 ft-lb)
B3M1036A
7) Add ATF and check level.
B3M1020A
36
3-2[W4B0]SERVICE PROCEDURE
4. Shift Solenoid, Duty Solenoid and Valve

G3M0322
3. ENGINE BRAKE OPERATION
Engine brake operation:
D range
®4th gear
3 range
®3rd gear
2 range
®2nd gear
1 range
®1st gear
4. AWD FUNCTION
If ªtight-corner brakingº occurs when the steering
wheel is fully turned at low speed:
1) Determine the applicable trouble code and
check the corresponding duty solenoid C (transfer)
for improper operation.
2) If the solenoid is operating properly, check
transfer clutch pressure.
3) If oil pressure is normal but ªtight-corner brak-
ingº occurs:
Check the transfer control valve for sticking, and
the transfer clutch facing for wear. [W20B0].> and
7. Stall Test
A: MEASUREMENT
1. GENERAL INFORMATION
The stall test is of extreme importance in diagnos-
ing the condition of the automatic transmission and
the engine. It should be conducted to measure the
engine stall speeds in R and 2 ranges.
Purposes of the stall test:
1) To check the operation of the automatic trans-
mission clutch.
2) To check the operation of the torque converter
clutch.
3) To check engine performance.
2. TEST METHODS
1) Preparations before test:
(1) Check that throttle valve opens fully.
(2) Check that engine oil level is correct.
(3) Check that coolant level is correct.
(4) Check that ATF level is correct.
(5) Check that differential gear oil level is cor-
rect.
(6) Increase ATF temperature to 50 to 80ÉC
(122 to 176ÉF) by idling the engine for approxi-
mately 30 minutes (with select lever set to ªNº
or ªPº).
2) Install an engine tachometer at a location vis-
ible from the driver's compartment and mark the
41
[W7A2]3-2SERVICE PROCEDURE
7. Stall Test

G3M0322
3. ENGINE BRAKE OPERATION
Engine brake operation:
D range
®4th gear
3 range
®3rd gear
2 range
®2nd gear
1 range
®1st gear
4. AWD FUNCTION
If ªtight-corner brakingº occurs when the steering
wheel is fully turned at low speed:
1) Determine the applicable trouble code and
check the corresponding duty solenoid C (transfer)
for improper operation.
2) If the solenoid is operating properly, check
transfer clutch pressure.
3) If oil pressure is normal but ªtight-corner brak-
ingº occurs:
Check the transfer control valve for sticking, and
the transfer clutch facing for wear. [W20B0].> and
7. Stall Test
A: MEASUREMENT
1. GENERAL INFORMATION
The stall test is of extreme importance in diagnos-
ing the condition of the automatic transmission and
the engine. It should be conducted to measure the
engine stall speeds in R and 2 ranges.
Purposes of the stall test:
1) To check the operation of the automatic trans-
mission clutch.
2) To check the operation of the torque converter
clutch.
3) To check engine performance.
2. TEST METHODS
1) Preparations before test:
(1) Check that throttle valve opens fully.
(2) Check that engine oil level is correct.
(3) Check that coolant level is correct.
(4) Check that ATF level is correct.
(5) Check that differential gear oil level is cor-
rect.
(6) Increase ATF temperature to 50 to 80ÉC
(122 to 176ÉF) by idling the engine for approxi-
mately 30 minutes (with select lever set to ªNº
or ªPº).
2) Install an engine tachometer at a location vis-
ible from the driver's compartment and mark the
41
[W7A2]3-2SERVICE PROCEDURE
7. Stall Test

8. Time Lag Test
A: INSPECTION
1. GENERAL INFORMATION
If the shift lever is shifted while the engine is idling,
there will be a certain time elapse or lag before the
shock can be felt. This is used for checking the
condition of the low clutch, reverse clutch, low &
reverse brake and one-way clutch.
CAUTION:
IPerform the test at normal operation fluid
temperature 60 to 80ÉC (140 to 176ÉF).
IBe sure to allow a one minute interval
between tests.
IMake three measurements and take the aver-
age value.
2. TEST METHODS
1) Fully apply the parking brake.
2) Start the engine.
Check idling speed (A/C OFF).
ªNº range: 800±100 rpm
3) Shift the shift lever from ªNº to ªDº range.
Using a stop watch, measure the time it takes from
shifting the lever until the shock is felt.
Time lag: Less than 1.2 seconds
4) In same manner, measure the time lag for ªNº
®ªRº.
Time lag: Less than 1.5 seconds
3. EVALUATION
1) If ªNº®ªDº time lag is longer than specified:
ILine pressure too low
ILow clutch worn
IOne-way clutch not operating properly
2) If ªNº®ªRº time lag is longer than specified:
ILine pressure too low
IReverse clutch worn
ILow & reverse brake worn
9. Line Pressure Test
A: MEASUREMENT
1. GENERAL INFORMATION
If the clutch or the brake shows a sign of slippage
or shifting sensation is not correct, the line pres-
sure should be checked.
IExcessive shocks during upshifting or shifting
takes place at a higher point than under normal
circumstances, may be due to the line pressure
being too high.
ISlippage or inability to operate the vehicle may,
in most cases, be due to loss of oil pressure for the
operation of the clutch, brake or control valve.
1) Line pressure measurement (under no load)
CAUTION:
IBefore measuring line pressure, jack-up all
wheels.
IMaintain temperature of ATF at approxi-
mately 50ÉC (122ÉF) during measurement.
(ATF will reach the above temperature after
idling the engine for approximately 30 minutes
with select lever in ªNº or ªPº.)
2) Line pressure measurement (under heavy load)
CAUTION:
IBefore measuring line pressure, apply both
foot and parking brakes with all wheels
chocked (Same as for ªstallº test conditions).
IMeasure line pressure when select lever is in
ªRº, ª2º with engine under stall conditions.
IMeasure line pressure within 5 seconds after
shifting the select lever to each position. (If line
pressure needs to be measured again, allow
the engine to idle and then stop. Wait for at
least one minute before measurement.)
IMaintain the temperature of ATF at approxi-
mately 50ÉC (122ÉF) during measurement. (ATF
will reach the above temperature after idling
the engine for approximately 30 minutes with
the select lever in ªNº or ªPº.)
43
[W9A1]3-2SERVICE PROCEDURE
9. Line Pressure Test

8. Time Lag Test
A: INSPECTION
1. GENERAL INFORMATION
If the shift lever is shifted while the engine is idling,
there will be a certain time elapse or lag before the
shock can be felt. This is used for checking the
condition of the low clutch, reverse clutch, low &
reverse brake and one-way clutch.
CAUTION:
IPerform the test at normal operation fluid
temperature 60 to 80ÉC (140 to 176ÉF).
IBe sure to allow a one minute interval
between tests.
IMake three measurements and take the aver-
age value.
2. TEST METHODS
1) Fully apply the parking brake.
2) Start the engine.
Check idling speed (A/C OFF).
ªNº range: 800±100 rpm
3) Shift the shift lever from ªNº to ªDº range.
Using a stop watch, measure the time it takes from
shifting the lever until the shock is felt.
Time lag: Less than 1.2 seconds
4) In same manner, measure the time lag for ªNº
®ªRº.
Time lag: Less than 1.5 seconds
3. EVALUATION
1) If ªNº®ªDº time lag is longer than specified:
ILine pressure too low
ILow clutch worn
IOne-way clutch not operating properly
2) If ªNº®ªRº time lag is longer than specified:
ILine pressure too low
IReverse clutch worn
ILow & reverse brake worn
9. Line Pressure Test
A: MEASUREMENT
1. GENERAL INFORMATION
If the clutch or the brake shows a sign of slippage
or shifting sensation is not correct, the line pres-
sure should be checked.
IExcessive shocks during upshifting or shifting
takes place at a higher point than under normal
circumstances, may be due to the line pressure
being too high.
ISlippage or inability to operate the vehicle may,
in most cases, be due to loss of oil pressure for the
operation of the clutch, brake or control valve.
1) Line pressure measurement (under no load)
CAUTION:
IBefore measuring line pressure, jack-up all
wheels.
IMaintain temperature of ATF at approxi-
mately 50ÉC (122ÉF) during measurement.
(ATF will reach the above temperature after
idling the engine for approximately 30 minutes
with select lever in ªNº or ªPº.)
2) Line pressure measurement (under heavy load)
CAUTION:
IBefore measuring line pressure, apply both
foot and parking brakes with all wheels
chocked (Same as for ªstallº test conditions).
IMeasure line pressure when select lever is in
ªRº, ª2º with engine under stall conditions.
IMeasure line pressure within 5 seconds after
shifting the select lever to each position. (If line
pressure needs to be measured again, allow
the engine to idle and then stop. Wait for at
least one minute before measurement.)
IMaintain the temperature of ATF at approxi-
mately 50ÉC (122ÉF) during measurement. (ATF
will reach the above temperature after idling
the engine for approximately 30 minutes with
the select lever in ªNº or ªPº.)
43
[W9A1]3-2SERVICE PROCEDURE
9. Line Pressure Test

2. TEST METHODS
1) Temporarily attach the ST to a suitable place in
the driver's compartment, remove the blind plug
located in front of the toe board and pass the hose
of the ST to the engine compartment.
ST 498575400 OIL PRESSURE GAUGE
ASSY
B3M0568C
(A) Pressure gauge hose
(B) Hole in toe board (blank cap hole)
(C) Brake pedal
2) Remove the test plug and install ST instead.
ST 498897200 OIL PRESSURE GAUGE
ADAPTER
B3M1046A
3) Connect ST1 with ST2.
ST1 498897200 OIL PRESSURE GAUGE
ADAPTER
ST2 498575400 OIL PRESSURE GAUGE
ASSY4) Check for duty ratio changes by opening and
closing throttle valve using Subaru Select Monitor.
(1) Insert the cartridge to Subaru Select Moni-
tor.
ST 24082AA090 CARTRIDGE
S2M0286A
(2) Connect Subaru Select Monitor to data link
connector.
5) Check line pressure in accordance with the fol-
lowing chart.
3. EVALUATION
NOTE:
IUnder no load: ªDº
IUnder full load: ªRº, ª2º
(With engine running at stall speed)
Standard line pressure
Range
positionLine pressure
duty ratio (%)Line pressure
kPa (kg/cm
2, psi)
251,128 Ð 1,304
(11.5 Ð 13.3, 164 Ð 189)
R51,520 Ð 1,716
(15.5 Ð 17.5, 220 Ð 249)
D95304 Ð 412
(3.1 Ð 4.2, 44 Ð 60)
44
3-2[W9A2]SERVICE PROCEDURE
9. Line Pressure Test