1999 SUBARU LEGACY air suspension

1. Power Steering
A: STEERING CONDITION
Trouble Possible cause Corrective action
IHeavy steering effort in all
ranges
IHeavy steering effort at stand
still
ISteering wheel surges when
turning.1. Pulley belt
IUnequal length of pulley belts
IAdhesion of oil and grease
ILoose or damage of pulley belt
IPoor uniformity of pulley belt cross section
IPulley belt touches to pulley bottom
IPoor revolution of pulleys except oil pump pulley
IPoor revolution of oil pump pulleyAdjust or replace.
2. Tire and rim
IImproper tires out of specification
IImproper rims out of specification
ITires not properly inflated*1Replace or reinflate.
3. Fluid
ILow fluid level
IAeration
IDust mix
IDeterioration of fluid
IPoor warming-up of fluid *2Refill, bleed air, replace
or instruct customer.
4. Idling speed
ILower idling speed
IExcessive drop of idling speed at start or at turning steering
wheel *3Adjust or instruct cus-
tomer.
5. Measure hydraulic pressure. Replace problem parts.
6. Measure steering effort. Adjust or replace.
IVehicle leads to one side or the
other.
IPoor return of steering wheel to
center
ISteering wheel surges when
turning.1. Fluid line
IFolded hose
IFlattened pipeReform or replace.
2. Tire and rim
IFlat tire
IMix use of different tires
IMix use of different rims
IAbnormal wear of tire
IUnbalance of remained grooves
IUnbalance of tire pressureFix or replace.
3. Front alignment
IImproper or unbalance caster
IImproper or unbalance toe-in
ILoose connection of suspensionAdjust or retighten.
4. Others
IDamaged joint assembly
IUnbalanced height
IOne-sided weightReplace, adjust or
instruct customer.
5. Measure steering effort. Adjust or replace.
*1 If tires and/or rims are wider, the load to power steering system is the more. Accordingly, in a condition, for example
before fluid warms-up, relief valve may work before maximum turning angle. In this case, steering effort may be heavy.
When measured hydraulic pressure is normal, there is no abnormal thing.
*2 In cold weather, steering effort may be heavy due to increased flow resistance of cold fluid. After warming up engine,
turn steering wheel from stop to stop several times to warm up fluid. Then if steering effort reduces normally, there is no
abnormal thing.
*3 In cold weather or with insufficient warm-up of engine, steering effort may be heavy due to excessive drop of idling
when turning steering wheel. In this case, it is recommended to start the vehicle with increasing engine speed than usual.
Then if steering effort reduces normally, there is no abnormal thing.
69
[K1A0]4-3DIAGNOSTICS
1. Power Steering

Trouble Possible cause Corrective action
Rattling noise (intermittent)
While engine is running.Interference with adjacent parts Check clearance.
Correct if necessary.

Loosened installation of oil pump, oil tank, pump bracket, gear-
box or crossmemberRetighten.
Loosened installation of oil pump pulley or other pulley(s) Retighten.
Loosened linkage or play of steering or suspension
Loosened tightening of joint or steering columnRetighten or replace.
Sound generates from the inside of gearbox or oil pump. Replace the gearbox or oil
pump.
Knocking
When turning steering wheel
in both direction with small
angle repeatedly at engine
ON or OFF.Excessive backlash
Loosened lock nut for adjusting backlashAdjust and retighten.
Loosened tightening or play of tie-rod, tie-rod end Retighten or replace.
Grinding noise (continuous)
While engine is running.Vane pump aeration Inspect and retighten fluid line
connection.
Refill fluid and vent air.
Vane pump seizing Replace oil pump.
Pulley bearing seizing of oil pump Replace oil pump.
Folded hose, flat pipe Replace.
Squeal, squeak (intermittent
or continuous)
While engine is running.Maladjustment of pulley belt
Damaged or charged pulley belt
Unequal length of pulley beltsAdjust or replace.
(Replace two belts as a set.)
Run out or soilage of V-groove surface of oil pump pulley Clean or replace.
Sizzling noise (continuous)
While engine is running.Fluid aeration Fix wrong part causing aera-
tion.
Replace fluid and vent air.
Damaged pipe of gearbox Replace pipe.
Abnormal inside of hose or pipe
Flat hose or pipeRectify or replace.
Abnormal inside of oil tank Replace.
Removed oil tank cap Install cap.
Whistle (continuous)
While engine is running.Abnormal pipe of gearbox or abnormal inside of hose Replace bad parts of gearbox
or hose.
Whine or growl (continuous or
intermittent)
While engine is running with/
without steering turned.Loosened installation of oil pump, oil pump bracket Retighten.
Abnormal inside of oil pump, hose Replace oil pump, hose, if the
noise can be heard when run-
ning as well as stand still.
Torque converter growl air conditioner compression growl Remove power steering pul-
ley belt and confirm.
Creaking noise (intermittent)
While engine is running with
steering turned.Abnormal inside of gearbox Replace bad parts of gear-
box.
Abnormal bearing for steering shaft Apply grease or replace.
Generates when turning steering wheel with brake (service or
parking) applied.If the noise goes off when
brake is released, it is normal.
Vibration
While engine is running with/
without steering turned.Too low engine speed at start Adjust and instruct custom-
ers.
Vane pump aeration Fix wrong part.
Vent air.
Damaged valve in oil pump, gearbox Replace oil pump, bad parts
of gearbox.
Looseness of play of steering, suspension parts Retighten.
75
[K1E0]4-3DIAGNOSTICS
1. Power Steering

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

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

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