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

AUTI

•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 )

( 5 )

( 6 ) ( 7 ) ( 8 )

(10)

(11)

(12)

(19)

(12)

(19)

(13)

(14)

(15)

(16)

(17)

(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)

(12)

(13)

(14)

(15)

(16)

(17)

(18)(19)

(20) (21)

(24)

(23)

(25)

(26)

(27)

(29)

(30)

(31)

(28)

(22)

(32)

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

(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)

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)

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