Subaru Legacy 2004 Service Manual page 3240

BRAKE
8. Master Cylinder
A: REMOVAL
CAUTION:
Do not allow brake fluid to come in contact with
vehicle body; wash away with water and wipe
off completely if spilled.
1) Thoroughly drain the brake fluid from reservoir
tank.
2) Disconnect the fluid level gauge harness con-
nector.
3) Remove the brake pipes from master cylinder.
4) Remove the master cylinder mounting nuts, and
take out the master cylinder from brake booster.
B: INSTALLATION
1) Replace the O-ring for the master cylinder with a
new one.
CAUTION:
Do not install the O-ring in wrong place.
(1) Primary piston
(2) O-ring
(3) Do not install the O-ring on this groove.
2) Install in the reverse order of removal.
Tightening torque:
Master cylinder mounting nut
"
13 N m (1.3 kgf-m, 9.6 ft-lb)
Piping flare nut
Model with ABS
"
15 N m (1.5 kgf-m, 10.8 ft-lb)
Model with VDC
"
19 N m (1.9 kgf-m, 14.0 ft-lb)
CAUTION:
Be sure to use recommended brake fluid.
3) Bleed air from brake system. <Ref. to BR-38,
PROCEDURE, Air Bleeding.>
C: REPLACEMENT
1) Remove mud and dirt from the surface of brake
master cylinder.
2) Secure the master cylinder on a vise.
Master Cylinder
(3)
(2)
(1)
BR-00363
NOTE:
To avoid damaging master cylinder, use aluminum
plate while holding with vise.
3) Remove the pin which secures the reservoir tank
to master cylinder, and then remove the reservoir
tank and seal.
4) With pushing-in the primary piston, remove the
C-ring using pliers.
5) With pushing-in the primary piston, remove the
straight pin from the port on installation part of res-
ervoir tank using magnet pick-up tool.
(1) Straight pin
6) Extract the primary piston assembly and sec-
ondary piston assembly straight out, while taking
care not to scratch the inner surface of cylinder.
7) Clean the inside of master cylinder with brake
fluid. Check the inside of cylinder for damage, de-
form and wear. Replace the master cylinder as as-
sembly if faulty.
8) Apply recommended brake fluid to the inner wall
of master cylinder, and outer surface of piston as-
sembly.
BR-30
BR-00364
BR-00169
(1)
BR-00069