Subaru LEGACY User manual

FUJI HEAVY INDUSTRIES LTD. G2300GE6
2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX
CHASSIS SECTION
This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.
All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.
FRONT SUSPENSION FS
REAR SUSPENSION RS
WHEEL AND TIRE SYSTEM WT
DIFFERENTIALS DI
TRANSFER CASE TC
DRIVE SHAFT SYSTEM DS
ABS ABS
ABS (DIAGNOSTICS) ABS
VDC VDC
VDC (DIAGNOSTICS) VDC
BRAKE BR
PARKING BRAKE PB
POWER ASSISTED SYSTEM
(POWER STEERING) PS

BRAKE BR
Page
1. General Description ....................................................................................2
2. Front Brake Pad........................................................................................20
3. Front Disc Rotor........................................................................................22
4. Front Disc Brake Assembly.......................................................................23
5. Rear Brake Pad.........................................................................................26
6. Rear Disc Rotor.........................................................................................27
7. Rear Disc Brake Assembly .......................................................................29
8. Master Cylinder.........................................................................................32
9. Brake Booster ...........................................................................................34
10. Proportioning Valve...................................................................................39
11. Brake Fluid................................................................................................40
12. Air Bleeding...............................................................................................42
13. Brake Hose ...............................................................................................44
14. Brake Pipe.................................................................................................46
15. Hill Holder..................................................................................................47
16. Brake Pedal...............................................................................................50
17. Stop Light Switch ......................................................................................55
18. General Diagnostics..................................................................................57

BR-2
BRAKE GENERAL DESCRIPTION
1. General Description
A: SPECIFICATIONS
NOTE:
Refer to “PB”section for parking brake SPECIFICATIONS.
Front disc
brake
Size 15 inch type 16 inch type 16 inch type
(Turbo model)
Type Disc (Floating type, ventilated)
Effective disc diameter 228 mm (8.98 in) 248 mm (9.76 in)
Disc thickness ×Outer diameter 24 ×277 mm (0.94 ×
10.91 in) 24 ×294 mm (0.94 ×11.57 in)
Effective cylinder diameter 42.8 mm (1.685 in) ×2
Pad dimensions
(length ×width ×thickness) 112.3 ×50.0 ×11.0 mm (4.421 ×1.969 ×0.433 in)
Clearance adjustment Automatic adjustment
Rear disc
brake
Type Disc (Floating type)
Effective disc diameter 254 mm (10.0 in)
Disc thickness ×Outer diameter 10 ×290 mm (0.39 ×11.42 in) 18 ×290 mm (0.71 ×
11.42 in)
Effective cylinder diameter 38.1 mm (1.500 in)
Pad dimensions
(length ×width ×thickness) 82.4 ×33.7 ×9.0 mm (3.244 ×1.327 ×0.354 in)
Clearance adjustment Automatic adjustment
Master cyl-
inder
Type Tandem
Effective diameter 26.99 mm (1-1/16 in)
RHD without VDC: 25.4
mm (1 in)
LHD and RHD with
VDC: 26.99 mm (1-1/16
in)
26.99 mm (1-1/16 in)
Reservoir type Sealed type
Brake fluid reservoir capacity 205 cm3(12.51 cu in)
Brake
booster Type Vacuum suspended
Effective diameter 205 + 230 mm (8.07 + 9.06 in)
Propor-
tioning
valve
Split point 2,942 kPa
(30 kg/cm2, 427 psi)
With VDC: 3,678 kPa
(37.5 kg/cm2, 533 psi)
Without VDC: 2,942
kPa
(30 kg/cm2, 427 psi)
2,942 kPa
(30 kg/cm2, 427 psi)
Reducing ratio 0.3
Brake line Dual circuit system
Brake fluid
C
AUTI
O
N:
•Avoid mixing brake fluid of different brands
to prevent the fluid performance from degrad-
ing.
•When brake fluid is supplemented, be care-
ful not to allow any dust into the reservoir.
•Use fresh DOT3 or 4 brake fluid when
replacing or refilling the fluid.
FMVSS No. 116, DOT3 or DOT4

BR-3
BRAKE
GENERAL DESCRIPTION
ITEM STANDARD SERVICE LIMIT
Front brake
Pad thickness
(including back metal) 17 mm (0.67 in) 7.5 mm (0.295 in)
Disc thickness 24 mm (0.94 in) 22 mm (0.87 in)
Disc runout —0.075 mm (0.0030 in)
Rear brake
Pad thickness
(including back metal) 14 mm (0.55 in) 6.5 mm (0.256 in)
Disc thickness Turbo model: 18 mm (0.71 in) Non-turbo model: 10 mm
(0.39 in)
Turbo model: 16 mm (0.63 in)
Non-turbo model: 8.5 mm
(0.335 in)
Disc runout —0.070 mm (0.0028 in)
Parking brake Inside diameter 170 mm (6.69 in) 171 mm (6.73 in) Lining thickness 3.2 mm (0.126 in) 1.5 mm (0.059 in)
Lever stroke 7 to 8 notches/196 N (20 kgf, 44 lb)
Model OUTBACK Except OUTBACK
RHD without VDC RHD with VDC, LHD Non-turbo model Turbo model
Brake pedal
force Fluid pressure Fluid pressure
Brake fluid pres-
sure without
engine running
147 N
(15 kgf, 33 lb) 686 kPa
(7 kg/cm2, 100 psi) 588 kPa
(6 kg/cm2, 85 psi) 588 kPa (6 kg/cm2, 85 psi) 686 kPa (7 kg/cm2, 100 psi)
294 N
(30 kgf, 66 lb) 1,863 kPa
(19 kg/cm2, 270 psi) 1,667 kPa
(17 kg/cm2, 242 psi) 1,667 kPa (17 kg/cm2, 242 psi) 1,765 kPa (18 kg/cm2, 256 psi)
Brake fluid pres-
sure with engine
running and vac-
uum at 66.7 kPa
(500 mmHg,
19.69 inHg)
147 N
(15 kgf, 33 lb) 5,884 kPa
(60 kg/cm2, 853 psi) 5,688 kPa
(58 kg/cm2, 825 psi) 5,688 kPa (58 kg/cm2, 825 psi) 6,082 kPa (62 kg/cm2, 882 psi)
294 N
(30 kgf, 66 lb)
10,886 kPa
(111 kg/cm2, 1,578
psi)
9,703 kPa
(99 kg/cm2, 1,408
psi)
9,702 kPa
(99 kg/cm2, 1,407
psi)
11,674 kPa
(119 kg/cm2, 1,693
psi)
Brake pedal Free play 1 —3 mm (0.04 —0.12 in)
[Depress brake pedal pad with a force of less than 10 N (1 kgf, 2 lb).]

BR-4
BRAKE GENERAL DESCRIPTION
B: COMPONENT
1. FRONT DISC BRAKE
*: Refer to ID section for the option code. <Ref. to ID-4, MODEL NUMBER PLATE, IDENTIFICATION, Identification.>
BR-00259
( 1 )
( 2 )
( 3 )
( 4 )
( 4 )
( 5 )
( 6 ) ( 7 ) ( 8 )
(10)
(11)
(12)
(19)
(12)
(19)
(13)
(13)
(14)
(15)
(16)
(17)
T2
T4
T3
T1
(18)
( 9 )
(1) Caliper body (11) Pad clip (19) Adhesive shim
[Option code*: EC, EK, KA (B4
MT)]
(2) Air bleeder screw (12) Outer shim [Option code*: KO, K1,
K4, KA (Except B4 MT), KS]
(3) Guide pin (Green)
(4) Pin boot (13) Inner shim [Option code*: KO, K1,
K4, KA (Except B4 MT), KS]
(5) Piston seal Tightening torque: N·m (kgf-m, ft-lb)
(6) Piston (14) Pad (Outside) T1: 8 (0.8, 5.8)
(7) Piston boot (15) Pad (Inside) T2: 18 (1.8, 13.0)
(8) Boot ring (16) Disc rotor T3: 39 (4.0, 28.9)
(9) Lock pin (Yellow) (17) Disc cover T4: 78 (8.0, 58)
(10) Support (18) Bushing

BR-5
BRAKE
GENERAL DESCRIPTION
2. REAR DISC BRAKE
(1) Caliper body (14) Shim (27) Primary shoe return spring
(2) Air bleeder screw (15) Shoe hold-down pin (28) Adjusting spring
(3) Guide pin (Green) (16) Cover (29) Adjuster
(4) Pin boot (17) Back plate (30) Shoe hold-down cup
(5) Piston seal (18) Retainer (31) Shoe hold-down spring
(6) Piston (19) Spring washer (32) Disc rotor
(7) Piston boot (20) Parking brake lever (33) Bushing
(8) Boot ring (21) Parking brake shoe (Secondary)
(9) Lock pin (Yellow) (22) Parking brake shoe (Primary) Tightening torque: N·m (kgf-m, ft-lb)
(10) Support (23) Strut T1: 8 (0.8, 5.8)
(11) Pad clip (24) Strut shoe spring T2: 39 (4.0, 28.9)
(12) Pad (Inner) (25) Shoe guide plate T3: 52 (5.3, 38.3)
(13) Pad (Outer) (26) Secondary shoe return spring
BR-00260
( 1 )
( 2 )
( 3 ) ( 4 )
( 5 ) ( 6 ) ( 7 )
( 8 )
(10)
(11)
(11)
(12)
(13)
(14)
(14)
(15)
(16)
(17)
(18)(19)
(20) (21)
(24)
(23)
(25)
(26)
(27)
(29)
(30)
(31)
(28)
(22)
(32)
T3
T2 T1
(4)
(33)
(9)

BR-6
BRAKE GENERAL DESCRIPTION
3. MASTER CYLINDER
•LHD models without VDC
(1) Cap (6) Secondary piston Tightening torque: N·m (kgf-m, ft-lb)
(2) Filter (7) Cylinder body T: 14 (1.4, 10.1)
(3) Reservoir tank (8) Cylinder pin (With ABS)
(4) Piston retainer (9) Seal
(5) Primary piston (10) Pin
BR-00153
T
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)

BR-7
BRAKE
GENERAL DESCRIPTION
•LHD model with VDC
(1) Cap (6) Secondary piston Tightening torque: N·m (kgf-m, ft-lb)
(2) Filter (7) Cylinder body T: 14 (1.4, 10.1)
(3) Reservoir tank (8) Cylinder pin
(4) C-ring (9) Seal
(5) Primary piston (10) Pin
BR-00206
( 1 )
( 2 )
( 3 )
( 4 )
( 5 )
( 6 )
( 7 )
( 8 )
( 9 )
(10)
T

BR-8
BRAKE GENERAL DESCRIPTION
•RHD model
(1) Cap (6) Primary piston (11) Pin
(2) Filter (7) Secondary piston
(3) Reservoir tank (8) Cylinder body Tightening torque: N·m (kgf-m, ft-lb)
(4) Bracket (9) Cylinder pin (With ABS) T: 14 (1.4, 10.1)
(5) Piston retainer (10) Seal
BR-00207
( 1 )
( 2 )
( 3 )
( 4 )
( 5 )
( 6 )
( 7 )
( 8 )
( 9 )
(10)
(11)
T

BR-9
BRAKE
GENERAL DESCRIPTION
4. HILL HOLDER
(1) Clamp (4) Adjusting nut Tightening torque: N·m (kgf-m, ft-lb)
(2) PHV cable (5) Lock nut T1: 3.5 (0.35, 2.5)
(3) PHV (Pressure hold valve) (6) To clutch pedal T2: 18 (1.8, 13.0)
BR-00121
( 1 )
( 1 )
( 2 )
( 3 )
( 4 )
( 5 )
T1
T2
( 6 )

BR-10
BRAKE GENERAL DESCRIPTION
5. BRAKE PIPES AND HOSE
•LHD model
BR-00209
AT MODEL MT MODEL
( 1 ) ( 1 )
( 2 ) ( 2 )
( 3 ) ( 3 )
( 4 )
( 4 )
( 5 )
( 6 )
( 7 )
( 8 )
( 9 )
(10)
(11)
(12)
(13)
(14)
T2
T1
T1
T2
T1
T1
T1
T1
T1
T1
T2
T1
T1 T1
T1
T1
T2
T1
T1
T1
T1
T1 T2
T2
T1
T1
T1
T1 T1
T1
T1
T1
T1
T1

BR-11
BRAKE
GENERAL DESCRIPTION
(1) Front brake pipe assembly (8) Rear brake hose LH Tightening torque: N·m (kgf-m, ft-lb)
(2) Proportioning valve (9) Rear brake pipe LH T1: 15 (1.5, 10.8)
(3) Front brake hose RH (10) Rear brake hose rear LH T2: 18 (1.8, 13.0)
(4) Front brake hose LH (11) Rear brake hose RH
(5) Center brake pipe assembly (12) Rear brake pipe RH
(6) Two-way connector (13) Rear brake hose rear RH
(7) Rear brake pipe assembly (14) Adapter pipe

BR-12
BRAKE GENERAL DESCRIPTION
•RHD model
BR-00210
AT MODEL MT MODEL
( 1 ) ( 1 )
( 2 )
( 2 )
( 3 )
( 3 )
( 4 )
( 4 )
( 5 )
( 6 )
( 7 )
( 8 )
( 9 )
(10)
(11)
(12)
(13)
(14)
T1 T1
T1
T1
T1
T1
T1
T1
T1
T1
T1
T1
T1
T1
T1
T1
T1 T1
T1
T1
T1
T1
T1
T1
T1
T1
T2
T2
T2
T2
T2
T2
T2 T2

BR-13
BRAKE
GENERAL DESCRIPTION
(1) Front brake pipe assembly (8) Rear brake hose LH Tightening torque: N·m (kgf-m, ft-lb)
(2) Proportioning valve (9) Rear brake pipe LH T1: 15 (1.5, 10.8)
(3) Front brake hose RH (10) Rear brake hose rear LH T2: 18 (1.8, 13.0)
(4) Front brake hose LH (11) Rear brake hose RH
(5) Center brake pipe assembly (12) Rear brake pipe RH
(6) Two-way connector (13) Rear brake hose rear RH
(7) Rear brake pipe assembly (14) Adapter pipe (With VDC)

BR-14
BRAKE GENERAL DESCRIPTION
6. BRAKE BOOSTER
(1) Push rod (5) Filter (9) Valve body
(2) Return spring (6) Silencer (10) Plunger valve
(3) Reaction disc (7) Operating rod (11) Diaphragm plate
(4) Key (8) Poppet valve (12) Valve return spring
( 8 )
( 7 )
( 9 )
( 6 )
( 5 )( 4 )
( 3 )
( 2 )
( 1 )
(11)
(10)
(12)
BR-00008

BR-15
BRAKE
GENERAL DESCRIPTION
7. BRAKE PEDAL FOR MT MODEL
•LHD model
(1) Stopper (12) Clutch clevis pin (23) Stop light switch
(2) Bushing (13) Assist rod A (24) Pedal bracket
(3) Spring pin (14) Clip (25) Clutch master cylinder bracket
(4) Snap pin (15) Assist spring (26) Lever
(5) Brake pedal pad (16) Assist bushing
(6) Brake pedal (17) Assist rod B Tightening torque: N·m (kgf-m, ft-lb)
(7) Clevis pin (18) Spring S T1: 8 (0.8, 5.8)
(8) Brake pedal spring (19) Rod S T2: 18 (1.8, 13.0)
(9) Clutch pedal pad (20) Bushing S
(10) Clutch pedal (21) Clip
(11) Bushing C (22) Clutch switch (With cruise control)
BR-00211
( 2 )
( 3 )
( 7 )
( 4 )
( 6 )
( 5 )
( 9 )
( 4 )
( 1 )
( 2 )
( 8 )
( 2 )
( 2 )
( 7 )
( 1 )
( 1 )
(25)
(26)
(11)
(10)
(11)
(24) (23)
(22)
(21)
(20)
(11)
(12)
(15)
(16)
(17)
(12)
(14)
(13)
(14)
(18)
(19) T1
T1
T2
T2
T2
T1

BR-16
BRAKE GENERAL DESCRIPTION
•RHD model
(1) Stop light switch (6) Stopper Tightening torque: N·m (kgf-m, ft-lb)
(2) Pedal bracket (7) Snap pin T1: 8 (0.8, 5.8)
(3) Spacer (8) Brake pedal spring T2: 18 (1.8, 13.0)
(4) Bushing (9) Brake pedal pad T3: 29 (3.0, 21.7)
(5) Clevis pin (10) Brake pedal
( 2 )
( 1 )
( 4 )
( 8 )
( 7 )
( 9 )
( 6 )
( 5 )
( 4 )
( 3 )
(10)
T2
T1
T2
T1
T3
BR-00212

BR-17
BRAKE
GENERAL DESCRIPTION
8. BRAKE PEDAL FOR AT MODEL
•LHD model
(1) Stopper (7) Brake pedal pad Tightening torque: N·m (kgf-m, ft-lb)
(2) Bushing (8) Brake pedal T1: 8 (0.8, 5.8)
(3) Pedal bracket (9) Clevis pin T2: 18 (1.8, 13.0)
(4) Stop light switch (10) Brake pedal spring T3: 30 (3.1, 22.4)
(5) Spacer
(6) Snap pin
BR-00162
T2
T2
T3
T1
T1
( 1 )
( 2 )
( 2 )
( 3 )
( 4 )
( 5 )
( 6 )
( 7 )
( 8 )
( 9 )
(10)

BR-18
BRAKE GENERAL DESCRIPTION
•RHD model
(1) Pedal bracket (7) Brake pedal pad Tightening torque: N·m (kgf-m, ft-lb)
(2) Stop light switch (8) Brake pedal T1: 8 (0.8, 5.8)
(3) Spacer (9) Snap pin T2: 18 (1.8, 13.0)
(4) Bushing (10) Brake pedal spring T3: 30 (3.1, 22.4)
(5) Clevis pin
(6) Stopper
BR-00214
( 1 )
( 2 )
( 4 ) ( 9 )
( 6 )
( 8 )
( 7 )
( 5 )
( 4 )
( 3 )
(10)
T2
T1
T2
T1
T3