Subaru LEGACY Service Manual
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Subaru LEGACY Service Manual

Subaru LEGACY Service Manual

2003
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See also: Service Manual , Owner's Manual
2003 LEGACY SERVICE MANUAL
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.
FUJI HEAVY INDUSTRIES LTD.
QUICK REFERENCE INDEX
FRONT SUSPENSION
REAR SUSPENSION
WHEEL AND TIRE SYSTEM
DIFFERENTIALS
TRANSFER CASE
DRIVE SHAFT SYSTEM
ABS
ABS (DIAGNOSTICS)
VDC
VDC (DIAGNOSTICS)
BRAKE
PARKING BRAKE
POWER ASSISTED SYSTEM
(POWER STEERING)
FS
RS
WT
DI
TC
DS
ABS
ABS
VDC
VDC
BR
PB
PS
G2300GE6

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  • Page 1 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX CHASSIS SECTION FRONT SUSPENSION REAR SUSPENSION WHEEL AND TIRE SYSTEM DIFFERENTIALS This service manual has been prepared to provide SUBARU service personnel TRANSFER CASE with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.

  • Page 3: Table Of Contents

    BRAKE Page General Description ..................2 Front Brake Pad ..................20 Front Disc Rotor ..................22 Front Disc Brake Assembly...............23 Rear Brake Pad..................26 Rear Disc Rotor..................27 Rear Disc Brake Assembly ...............29 Master Cylinder ..................32 Brake Booster ...................34 Proportioning Valve...................39 Brake Fluid ....................40 Air Bleeding....................42 Brake Hose ....................44 Brake Pipe....................46 Hill Holder....................47...

  • Page 4: General Description

    GENERAL DESCRIPTION BRAKE 1. General Description A: SPECIFICATIONS 16 inch type Size 15 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) 24 × 277 mm (0.94 × Front disc Disc thickness ×...
  • Page 5 GENERAL DESCRIPTION BRAKE ITEM STANDARD SERVICE LIMIT Pad thickness 17 mm (0.67 in) 7.5 mm (0.295 in) (including back metal) Front brake Disc thickness 24 mm (0.94 in) 22 mm (0.87 in) Disc runout — 0.075 mm (0.0030 in) Pad thickness 14 mm (0.55 in) 6.5 mm (0.256 in) (including back metal)

  • Page 6: Front Disc Brake

    GENERAL DESCRIPTION BRAKE B: COMPONENT 1. FRONT DISC BRAKE ( 2 ) ( 1 ) ( 3 ) ( 4 ) ( 5 ) ( 6 ) ( 7 ) ( 8 ) ( 9 ) ( 4 ) (1 8 ) (10) (17) (19)

  • Page 7: Rear Disc Brake

    GENERAL DESCRIPTION BRAKE 2. REAR DISC BRAKE ( 2 ) ( 3 ) ( 4 ) ( 1 ) (10) ( 5 ) ( 6 ) ( 7 ) ( 8 ) (14) (12) ( 9 ) (11) ( 3 3) (4 ) (14) (17)
  • Page 8 GENERAL DESCRIPTION BRAKE 3. MASTER CYLINDER • LHD models without VDC (10) BR-00153 (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...
  • Page 9 GENERAL DESCRIPTION BRAKE • LHD model with VDC ( 1 ) ( 2 ) ( 3 ) (10) ( 9 ) ( 8 ) ( 4 ) ( 5 ) ( 6 ) ( 7 ) BR-00206 (1) Cap (6) Secondary piston Tightening torque: N·m (kgf-m, ft-lb) (2) Filter (7) Cylinder body...
  • Page 10 GENERAL DESCRIPTION BRAKE • RHD model ( 1 ) ( 2 ) (11) ( 3 ) ( 4 ) (10) ( 9 ) ( 5 ) ( 6 ) ( 7 ) ( 8 ) BR-00207 (1) Cap (6) Primary piston (11) Pin (2) Filter (7) Secondary piston...
  • Page 11 GENERAL DESCRIPTION BRAKE 4. HILL HOLDER ( 6 ) ( 1 ) ( 1 ) ( 3 ) ( 2 ) ( 4 ) ( 5 ) BR-00121 (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)
  • Page 12 GENERAL DESCRIPTION BRAKE 5. BRAKE PIPES AND HOSE • LHD model ( 2 ) AT MODEL MT MODEL ( 2 ) ( 1 ) ( 1 ) ( 3 ) (14) ( 3 ) ( 4 ) ( 4 ) (13) (12) (11)
  • Page 13 GENERAL DESCRIPTION BRAKE Front brake pipe assembly (8) Rear brake hose LH Tightening torque: N·m (kgf-m, ft-lb) Proportioning valve (9) Rear brake pipe LH T1: 15 (1.5, 10.8) Front brake hose RH (10) Rear brake hose rear LH T2: 18 (1.8, 13.0) Front brake hose LH (11) Rear brake hose RH Center brake pipe assembly...
  • Page 14 GENERAL DESCRIPTION BRAKE • RHD model AT MODEL MT MODEL ( 2 ) ( 1 ) ( 1 ) ( 2 ) (14) ( 3 ) ( 4 ) ( 4 ) ( 3 ) (13) (12) (11) ( 7 ) (10) ( 6 ) ( 9 )
  • Page 15 GENERAL DESCRIPTION BRAKE (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...
  • Page 16 GENERAL DESCRIPTION BRAKE 6. BRAKE BOOSTER (11) (10) ( 8 ) (12) ( 7 ) ( 1 ) ( 2 ) ( 4 ) ( 5 ) ( 3 ) ( 6 ) ( 9 ) BR-00008 (1) Push rod (5) Filter (9) Valve body (2) Return spring...
  • Page 17 GENERAL DESCRIPTION BRAKE 7. BRAKE PEDAL FOR MT MODEL • LHD model ( 7 ) ( 3 ) (26) (11) ( 4 ) (25) ( 2 ) (24) (23) (11) (22) (20) (21) ( 2 ) ( 1 ) ( 1 ) (19) (18) (14)
  • Page 18 GENERAL DESCRIPTION BRAKE • RHD model ( 2 ) ( 1 ) ( 3 ) ( 4 ) ( 5 ) ( 6 ) ( 8 ) ( 4 ) ( 7 ) ( 9 ) (10) BR-00212 Stop light switch Stopper Tightening torque: N·m (kgf-m, ft-lb) Pedal bracket...
  • Page 19 GENERAL DESCRIPTION BRAKE 8. BRAKE PEDAL FOR AT MODEL • LHD model ( 3 ) ( 4 ) ( 5 ) ( 2 ) (10) ( 2 ) ( 1 ) ( 6 ) ( 9 ) ( 7 ) ( 8 ) BR-00162 (1) Stopper...
  • Page 20 GENERAL DESCRIPTION BRAKE • RHD model ( 1 ) ( 2 ) ( 3 ) ( 4 ) ( 5 ) ( 6 ) ( 4 ) (10) ( 9 ) ( 7 ) ( 8 ) BR-00214 Pedal bracket Brake pedal pad Tightening torque: N·m (kgf-m, ft-lb) Stop light switch...
  • Page 21 • Be careful not to burn your hands, because each part in the vehicle is hot after running. • Use SUBARU genuine grease etc. or the equiv- alent. Do not mix grease etc. with that of another grade or from other manufacturers.

  • Page 22: Front Brake Pad

    FRONT BRAKE PAD BRAKE 2. Front Brake Pad (4) Place a rod of less than 12 mm (0.47 in) dia. on the shaded area of brake pad, and strike the A: REMOVAL rod with a hammer to drive brake pad out of place.
  • Page 23 FRONT BRAKE PAD BRAKE C: INSPECTION Check pad thickness A. BR-00264 Pad thickness Standard value 17 mm (0.67 in) (including back Wear limit 7.5 mm (0.295 in) metal) CAUTION: • Always replace the pads for both the left and right wheels at the same time. Also replace pad clips if they are twisted or worn.

  • Page 24: Front Disc Rotor

    FRONT DISC ROTOR BRAKE 3. Front Disc Rotor C: INSPECTION 1) Secure disc rotor by tightening the five wheel A: REMOVAL nuts. 1) Loosen wheel nuts, jack-up vehicle, support it 2) Set a dial gauge on the disc rotor. Turn disc rotor with safety stands, and remove wheel.

  • Page 25: Front Disc Brake Assembly

    FRONT DISC BRAKE ASSEMBLY BRAKE 4. Front Disc Brake Assembly 6) Remove disc rotor from hub. NOTE: A: REMOVAL If disc rotor seizes up within hub, drive disc rotor out 1) Loosen wheel nuts, jack-up vehicle, support it by installing an 8-mm bolt in holes B on the rotor. with safety stands, and remove wheel.
  • Page 26 FRONT DISC BRAKE ASSEMBLY BRAKE C: DISASSEMBLY 5) Remove the piston seal from caliper body cylin- der. 1) Clean mud and foreign particles from the caliper body assembly and support. CAUTION: Be careful not to scratch the inner surface of CAUTION: cylinder and piston seal groove.
  • Page 27 FRONT DISC BRAKE ASSEMBLY BRAKE 5) Apply a coat of specified grease to boot and fit in groove on ends of cylinder and piston. Grease: NIGLUBE RX-2 (Part No. 003606000) To facilitate installation, fit boot starting with piston end. ( 1 ) ( 4 ) ( 2 ) ( 3 )

  • Page 28: Rear Brake Pad

    REAR BRAKE PAD BRAKE 5. Rear Brake Pad 6) Check that brake fluid level is at max. line. C: INSPECTION A: REMOVAL Check pad thickness (including back metal). 1) Loosen wheel nuts, jack-up vehicle, support it with safety stands, and remove wheel. Pad thickness: A 2) Remove bottom bolt.

  • Page 29: Rear Disc Rotor

    REAR DISC ROTOR BRAKE 6. Rear Disc Rotor (2) If disc rotor seizes up within hub, drive disc rotor out by installing an 8-mm bolt in holes B on A: REMOVAL the rotor. 1) Lift-up vehicle and remove wheels. 2) Remove the two mounting bolts and remove the disc brake assembly.
  • Page 30 REAR DISC ROTOR BRAKE 3) Measure disc rotor thickness. BR-00036 NOTE: Make sure that micrometer is set 5 mm (0.20 in) in- ward of rotor outer perimeter. Disc rotor thickness: A Standard value 10 mm (0.39 in) Service limit 8.5 mm (0.335 in) BR-28...

  • Page 31: Rear Disc Brake Assembly

    REAR DISC BRAKE ASSEMBLY BRAKE 7. Rear Disc Brake Assembly B: INSTALLATION 1) Install disc rotor on hub. A: REMOVAL 2) Install support on back plate. 1) Lift-up vehicle and remove wheels. Tightening torque: 2) Disconnect brake hose from caliper body as- 78 N·m (8.0 kgf-m, 58 ft-lb) sembly.
  • Page 32 REAR DISC BRAKE ASSEMBLY BRAKE C: DISASSEMBLY 4) Remove piston seal from caliper body cylinder. 1) Remove the boot ring. ( 1 ) BR-00043 BR-00040 5) Remove lock pin sleeve and boot from caliper body. (1) Boot ring 6) Remove guide pin boot. D: ASSEMBLY 2) Remove the piston boot.
  • Page 33 REAR DISC BRAKE ASSEMBLY BRAKE 7) Apply a coat of specified grease to guide pin, outer surface, sleeve outer surface, cylinder inner surface, and boot grooves. Grease: NIGLUBE RX-2 (Part No. 003606000) ( 3 ) ( 1 ) ( 2 ) BR-00030 (1) Pin boot (2) Lock pin or guide pin...

  • Page 34: Master Cylinder

    MASTER CYLINDER BRAKE 8. Master Cylinder 3) Pry up the pawl and remove the piston retainer. (Without VDC) A: REMOVAL NOTE: 1) Thoroughly drain brake fluid from reservoir tank. Piston may jump out from master cylinder. 2) Disconnect fluid level indicator harness connec- tor.
  • Page 35 MASTER CYLINDER BRAKE 2) Install cylinder pin while pushing in primary pis- 5) Install seal to reservoir tank. ton. ( 1 ) ( 1 ) BR-00072 BR-00069 (1) Seal (1) Cylinder pin 6) Install pin with drift pins which secures reservoir 3) Press the pawl and install the piston retainer into tank to master cylinder.

  • Page 36: Brake Booster

    BRAKE BOOSTER BRAKE 9. Brake Booster Standard: Without VDC A: REMOVAL L = 10 mm (0.39 in) With VDC CAUTION: L = 1.8 mm (0.071 in) If external force is applied from above when brake booster is placed in this position, the res- in portion as indicated by “P”, may be dam- aged.
  • Page 37 BRAKE BOOSTER BRAKE 3) Connect vacuum hose to brake booster. 9) Apply grease to operating rod connecting pin to prevent it from wearing. 10) Bleed air from brake system. Tightening torque (Air bleeder screw): 8 N·m (0.8 kgf-m, 5.8 ft-lb) 11) Conduct road tests to ensure brakes do not drag.
  • Page 38 BRAKE BOOSTER BRAKE • Operation check 2. OPERATION CHECK (WITH GAUGES) 1) With engine off, depress brake pedal several CAUTION: times applying the same pedal force and make When checking operation, be sure to securely sure that the pedal height does not vary with each apply the hand brake.
  • Page 39 BRAKE BOOSTER BRAKE • Damaged diaphragm • Leak from valve body seal and bearing portion • Leak from plate and seal assembly portion • Leak from poppet valve assembly portion • Loaded air tightness check 1) Start engine and depress brake pedal with pedal force of 196 N (20 kgf, 44 lb).
  • Page 40 BRAKE BOOSTER BRAKE • Lack of boosting action check Turn off engine, and depress the brake pedal until the vacuum gauge reading indicates “0”. Then, check the fluid pressure when brake pedal is depressed. The pressure must be greater than the standard value listed. OUTBACK Model Except OUTBACK...

  • Page 41: Proportioning Valve

    PROPORTIONING VALVE BRAKE 10.Proportioning Valve C: INSPECTION 1) Install oil pressure gauges to measure the mas- A: REMOVAL ter cylinder fluid pressure (front wheel brake fluid pressure) and rear wheel cylinder fluid pressure. 2) Bleed air from oil pressure gauges. 3) Check the master cylinder fluid pressure and rear wheel cylinder fluid pressure.

  • Page 42: Brake Fluid

    BRAKE FLUID BRAKE 11.Brake Fluid 5) Install one end of a vinyl tube onto the air bleeder and insert the other end into a container to collect A: INSPECTION the brake fluid. 1) Check that brake fluid level remains between “MIN”...
  • Page 43 BRAKE FLUID BRAKE 11) Depress brake pedal with a force of approxi- mately 294 N (30 kgf, 66 lb) and hold it there for ap- proximately 20 seconds. At this time check pedal to see if it shows any unusual movement. Visually inspect bleeder screws and brake pipe joints to make sure that there is no fluid leakage.

  • Page 44: Air Bleeding

    AIR BLEEDING BRAKE 12.Air Bleeding 5) Close outlet plug with your finger, and release brake pedal. A: PROCEDURE CAUTION: • The FMVSS No. 116, fresh DOT3 or 4 brake fluid must be used. • Cover bleeder with waste cloth when loosen- ing it to prevent brake fluid from being splashed over surrounding parts.
  • Page 45 AIR BLEEDING BRAKE 6) Check the pedal stroke. CAUTION: While the engine is idling, depress the brake pedal Brake fluid replacement sequence; (A) Front right → → → → (B) Rear left → → → → (C) Front left → → → → (D) Rear with a 490 N (50 kgf, 110 lb) load and measure the distance between the brake pedal and steering right...

  • Page 46: Brake Hose

    BRAKE HOSE BRAKE 13.Brake Hose 2. REAR BRAKE HOSE 1) Separate brake pipe from brake hose. A: REMOVAL NOTE: 1. FRONT BRAKE HOSE Always use flare nut wrench and be careful not to deform flare nut. 1) Separate brake pipe from brake hose. NOTE: Always use flare nut wrench and be careful not to deform flare nut.
  • Page 47 BRAKE HOSE BRAKE B: INSTALLATION 2. REAR BRAKE HOSE 1) Pass brake hose through the hole of bracket, 1. FRONT BRAKE HOSE and lightly tighten flare nut to connect brake pipe. 1) Route end of brake hose (on caliper side) 2) Insert clamp upward to fix brake hose.

  • Page 48: Brake Pipe

    BRAKE PIPE BRAKE 14.Brake Pipe A: REMOVAL NOTE: Airbag system wiring harness is routed near the center brake pipe. CAUTION: • All airbag system wiring harness and con- nectors are colored yellow. Do not use electri- cal test equipment on these circuits. •...

  • Page 49: Hill Holder

    HILL HOLDER BRAKE 15.Hill Holder 5) Detach PHV along with support from side frame. CAUTION: A: REMOVAL Exercise utmost care to prevent foreign matter from entering into PHV when removing it. 1. PHV (PRESSURE HOLD VALVE) 1) Drain brake fluid from reservoir of master cylin- der.
  • Page 50 HILL HOLDER BRAKE 4) Remove PHV cable. B: INSTALLATION 1. PHV (PRESSURE HOLD VALVE) 1) Install PHV onto side frame. ( 2 ) Tightening torque: ( 1 ) 18 N·m (1.8 kgf-m, 13.0 ft-lb) 2) Connect brake pipes to PHV. Tightening torque: 15 N·m (1.5 kgf-m, 10.8 ft-lb) CAUTION:...
  • Page 51 HILL HOLDER BRAKE C: INSPECTION D: ADJUSTMENT Check up removed parts as follows, and replace Confirm stopping and starting performances by ac- defective ones. tivating hill holder on an uphill road of 3° or higher inclination. 1) Check if boots of PHV cable are damaged or de- graded, and if inner cable is damaged or corroded.

  • Page 52: Brake Pedal

    BRAKE PEDAL BRAKE 16.Brake Pedal 8) Remove cable clamp, and disconnect PHV ca- ble from PHV. A: REMOVAL CAUTION: Carefully protect boot and inner cable from 1. MT MODEL damage when disconnecting PHV cable. • LHD model 1) Pull up parking brake lever and block tires. 2) Disconnect battery ground cable.
  • Page 53 BRAKE PEDAL BRAKE • RHD model 2. AT MODEL 1) Pull up parking brake lever and block tires. • LHD model 2) Disconnect ground cable from battery. 1) Pull up parking brake lever. 3) Remove instrument panel lower cover from in- 2) Disconnect ground cable from battery.
  • Page 54 BRAKE PEDAL BRAKE C: DISASSEMBLY 2. AT MODEL 1) Remove the brake switch. 1. MT MODEL 2) Unbolt, and then remove the brake pedal. • LHD model 1) Remove the brake switch. <Ref. to BR-55, REMOVAL, Stop Light Switch.> 2) Remove the clutch pedal. <Ref.
  • Page 55 BRAKE PEDAL BRAKE D: ASSEMBLY E: INSPECTION 1) Attach stop light switch, etc. to pedal bracket 1) Move brake and clutch pedal pads in the lateral temporarily. direction with a force of approximately 10 N (1 kgf, 2 lb) to ensure pedal deflection is in specified 2) Clean inside of bores of clutch pedal and brake range.
  • Page 56 BRAKE PEDAL BRAKE 2) Check position of pedal pad. Pedal height: L AT: 158 mm (6.22 in) MT: 153 mm (6.02 in) Brake pedal free play: A 1 — 3 mm (0.04 — 0.12 in) [Depress brake pedal pad with a force of less than 10 N (1 kgf, 2 lb).] ( 1 ) ( 3 )

  • Page 57: Stop Light Switch

    STOP LIGHT SWITCH BRAKE 17.Stop Light Switch C: INSPECTION 1) If stop light switch does not operate properly (or A: REMOVAL if it does not stop at the specified position), replace 1) Disconnect battery ground cable. with a new one. 2) Disconnect stop light switch connector.
  • Page 58 STOP LIGHT SWITCH BRAKE D: ADJUSTMENT Loosen the lock nut, and adjust stop light switch po- sition until the clearance (A) between threaded end of the stop light switch and the stopper becomes 0.3 mm (0.012 in). Then, tighten the lock nut. ( 1 ) ( 2 ) ( 3 )

  • Page 59: General Diagnostics

    GENERAL DIAGNOSTICS BRAKE 18.General Diagnostics A: INSPECTION 1. BRAKE SYSTEM Trouble and possible cause Corrective action 1. Insufficient braking (1) Fluid leakage from the hydraulic mechanism Repair or replace (cup, piston seal, piston boot, master cylinder piston kit, pipe or hose). (2) Entry of air into the hydraulic mechanism Bleed the air.
  • Page 60 GENERAL DIAGNOSTICS BRAKE 2. HILL HOLDER CAUTION: • Description in parentheses is a characteristic of hill holder and does not indicate abnormality. Depressing force required for clutch pedal equipped to hill holder specifications is 20 to 29 N (2 to 3 kgf, 4 to 7 lb) larger than the conventional specifications, which does not constitute abnormality.

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