Subaru Legacy/Outback

1999-2003 of release

Repair and operation of the car



Subaru of Legasi, Autbek
+ Cars Subaru Legacy, Outback
+ Operation manual
- Routine maintenance
   Schedule of routine maintenance of Subaru Legacy and Outback cars
   Specifications
   General information about settings and adjustments
   Check of levels of liquids (according to the Schedule of routine maintenance)
   Replacement of motive oil and oil filter
   Check of a state and replacement of the hoses located in a motive compartment
   Rotation of wheels
   Greasing of components of the chassis
   Check of a condition of components of system of production of the fulfilled gases
   Check of a condition of seat belts
   Check of a condition of components of a suspension bracket
   Check of a condition of components of the steering drive
   Check and adjustment of composition of mix of idling, - a stern of the models equipped with the catalytic converter
   Check of a condition of protective covers of hinges of power shafts
   Check of a state, adjustment of effort of a tension of belts of the drive of auxiliary units
   Check and adjustment of the antiretractable device
   Check of serviceability of functioning and adjustment of components of coupling
   Checks and adjustments of brake system
   Check of a condition of components of the cooling system
   Check of a state and replacement of cooling liquid of the engine
   Replacement of the filtering air cleaner element
   Check of a condition of components of a power supply system
   Replacement of brake liquid / pumping of a hydraulic path
   Replacement of ATF of automatic transmission
   Replacement of the RKPP transmission oil
   Replacement of greasings of back and forward differential
   Check of a state and replacement of a gas-distributing belt - l models 2.0 and 2.5
   Check and replacement of the fuel filter
   Check of a state and replacement of spark plugs and VV of an electrical wiring
   Check of wheel bearings
   Check of valvate gaps
   Replacement of belts of the drive of auxiliary units and replacement
+ Engine
+ Cooling systems, heating
+ Power supply system and release
+ Electric equipment of the engine
+ Manual box and differential
+ Automatic transmission
+ Coupling
+ Brake system
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment









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Checks and adjustments of brake system

Scheme of an arrangement of components of the drum brake mechanism

1 — the Direction of rotation of the drum (forward)
2 — the Wheel cylinder
3 — the Top coupling spring
4 — the regulator Lever

5 — the Back boot
6 — the Lower coupling spring
7 — the Forward boot


Measurement of a free wheeling of a pedal of a brake

1 — the Lock-nut
2 — the Rod of a pusher of assembly of the servo-driver of vacuum strengthening of brakes
3 — the Side play of landing of a pin of a cutting finger
4 — the Sensor switch of stoplights
5 — Adjusting nuts

6 — 0.3 mm
7 — the Emphasis
8 — the Pin of fastening of a cutting finger
9 — the Cutting finger of fastening of a rod to the pedal lever
10 — the Free wheeling of a pedal (1-3 mm)


 PERFORMANCE ORDER

 Remember that the dust developed when functioning brake mechanisms may contain extremely unhealthy the person asbestos. Do not blow off dust compressed air at all and do not inhale it, at service of mechanisms put on a protective mask or a respirator. Do not use for rubbing of components of brake system gasoline or solvents on an oil basis at all - apply only firm cleaners or methyl alcohol! Try to use when replacing blocks only the components which are not containing asbestos.


 More detailed illustrative material is given in the Head Brake system.

1. The condition of components of brake system, besides the regular, stipulated Schedule of routine maintenance, checks, has to be estimated every time at removal of wheels or at emergence of signs of violation of functioning of system. Blocks of disk brake mechanisms are usually equipped with the special indicators notifying on excessive wear of frictional slips characteristic squeal when braking. The listed below symptoms can be a sign of malfunction of components of brake mechanisms:

a) When braking the car loses course stability (there is a withdrawal in one of the parties);
b) During braking brake mechanisms publish squeal or a scratch;
c) Excessively the course of a pedal of a foot brake increases;
d) When squeezing a brake pedal pulsations are felt;
e) Traces of leak of brake fluid take place (usually on an internal surface of disks of wheels and tires).
2. Weaken nuts of fastening of wheels.
3. The car also establish to Poddomkratta it on props.
4. Remove wheels.


Check of a condition of brake lines (each 50 000 km [30 000 miles] of run or time in 24 months)

 PERFORMANCE ORDER

1. Examine all brake lines on existence of signs of damages, wear, destruction as a result of aging of material, traces of leaks, bends, twisting and other deformations, the person paying attention to places of connection of flexible hoses to supports / to wheel cylinders of brake mechanisms. Check reliability of fastening of hoses collars.

 In case of need use a mirror.

2. Make sure that any of brake hoses do not adjoin to acute angles of the components of a body, system of production of the fulfilled gases located in the neighbourhood or suspension brackets (at any provisions of a steering wheel). In case of need make the corresponding repair or correct a route of laying of lines. Replace defective components (see the Head Brake system).
3. Study on existence of signs of development of leaks/corrosion and mechanical damages of a surface of GTTs, wheel cylinders and the valve of management of pressure. Replace defective components.


Disk brake mechanisms of lobbies and back wheels (each 25 000 km [15 000 miles] of run or time in 12 months)

 PERFORMANCE ORDER

1. The support of each of brake mechanisms is equipped with two blocks, - internal and external. End faces of blocks are well looked through through special observation ports in the support case after removal of a wheel.

2. The assessment of residual thickness of blocks is made visually through the observation ports mentioned above. If frictional slips are worn-out over an admissible limit, it is necessary to make complex replacement of brake shoes.

 Remember that frictional overlays of a priklepana or are pasted to a metal substrate. Its thickness is included into the size specified in Specifications.

3. If visually to estimate the residual thickness of blocks it appears difficult, or there is a need for more detailed survey of blocks, remove a support(s) and take blocks for more detailed studying (see the Head Brake system).

4. After blocks are taken from a support, clear them by means of special means and measure the residual thickness of slips by means of a ruler or a caliper with a vernier scale.

5. Measure by a micrometer thickness of brake disks, then determine the size of their lateral beating in the point located not further 5 mm from the outer edge. Compare results of measurements to standard requirements (see Specifications). If thickness or size of a lateral beating any of disks leaves abroad admissible range, replace it (see the Head Brake system). If disk thickness in norm, check its general state. Pay attention to such defects as deep scratches, furrows, teases, overheat traces, etc., in case of need remove a disk and send him to a pro-point (see the Head Brake system). The worn-out or deformed spring clamps of blocks are also subject to replacement.

 Replacement of brake shoes should be made in a set for both wheels of one axis of the car!


Drum brake mechanisms (only models of 2001) (each 50 000 km [30 000 miles] of run or time in 24 months)

 PERFORMANCE ORDER

1. The scheme of an arrangement of components of the drum brake mechanism are presented on an illustration.
2. Remove brake drums (see the Head Brake system).

3. Make careful cleaning of brake mechanisms with application of the special cleaning structure.

 Do not blow off brake dust from a surface of components compressed air at all and do not inhale it - dust may contain asbestos, harmful to your health!

Estimate the residual thickness of frictional overlays of brake boots (forward and back), check components for existence of traces of pollution by brake fluid and oil. If the frictional slip acts over heads of rivets less than on 1.6 mm, boots are subject to replacement in a set for brake mechanisms of both wheels (see the Head Brake system). Boots should be replaced also in case of identification of cracks, zapolirovanny to gloss of sites of slips, or traces of hit of brake fluid.

4. Make sure of correctness of connection and serviceability of a condition of all springs of assembly of the brake mechanism (see the Head Brake system). The neglect replacement of the deformed or weakened springs is fraught with premature wear of boots as a result of "prikhvatyvaniye" of brakes.

5. Check assembly components for existence of traces of leak of brake fluid. Having carefully hooked a finger or a small screw-driver, remove rubber boots from the wheel cylinder located holding apart the top ends of boots. Identification of any signs of leaks in these parts demands carrying out immediate recovery repair of assembly of the cylinder (see the Head Brake system). Also check all brake hoses and their nipple connections for existence of traces of leaks.

6. Carefully wipe internal surfaces of a drum the pure rags impregnated with methyl alcohol. Try not to inhale the brake dust containing asbestos. Examine a working surface of a drum on existence of cracks, zadir, traces of an overheat and other damages. If defects cannot be removed by processing of a surface with a fine-grained emery paper, the drum should be given for a pro-point to a workshop of car service, or to replace (see the Head Brake system). Measure the internal diameter of a drum.

7. Repeat procedure for components of the opposite brake mechanism. Install into place reels, fix wheels and lower the car on the earth. Tighten wheel nuts with the demanded effort.

 Adjustment of the main drum brake mechanisms is made automatically.


Adjustments of a pedal of a foot brake (each 50 000 km [30 000 miles] of run or time in 24 months)

 PERFORMANCE ORDER

1. Measure the size of a free wheeling of a pedal of a foot brake when pressing it with effort slightly less than 1 kgf. Compare result of measurement to requirements of Specifications, in case of need make the corresponding adjustment (see further).
2. Kill the engine and, having several times squeezed out a pedal of a foot brake, completely dump residual depression in the servo-driver of the vacuum amplifier.
3. The cutting finger of a pusher of the vacuum amplifier of brakes has to have a connection side play to the pedal lever.
4. Press a hand on a block of a pedal of a foot brake.
5. In the absence of a side play of a cutting finger make correction of landing of the sensor switch of stoplights, having provided between an adjusting nut and a persistent washer a gap about 0.3 mm.

6. Measure the size of the reserve course of a pedal of a foot brake for what start the engine, press a pedal with effort about 50 kgfs and measure distance from a pedal block to bottom edge of a rim of a steering wheel. Then release a pedal and repeat measurement. The size of the reserve course of a pedal is defined by subtraction result of the second measurement from result of the first measurement and should not exceed value in 95 mm. The excessive size of the reserve course of a pedal of a foot brake usually is a consequence of hit to the hydraulic highway of air. If this size more, perhaps, is in the hydraulic module air, - pump over brake system (see the Section Replacement of Brake Liquid / Pumping of a Hydraulic Path).

And = l1 – l2 the Size of the reserve course of a pedal of a foot brake

7. During a short trip check serviceability of functioning of brake system, - when braking on an equal horizontal covering the vehicle has to keep course stability.


The vacuum amplifier (each 50 000 km [30 000 miles] of run or time in 24 months)

 PERFORMANCE ORDER

1. Check of serviceability of functioning of the vacuum amplifier of brakes is made from a driver's place.
2. At the switched-off engine several times squeeze out a pedal of a foot brake with identical effort and make sure that the size of its course ceased to change (residual depression is dumped).
3. At completely squeezed out pedal of a foot brake start the engine, - the pedal has to fail a little more.
4. At the working engine several times squeeze out a pedal of a foot brake, - the size of the course of a pedal has to remain invariable.
5. Squeeze out a pedal, kill the engine and continue to hold a pedal pressed within about 30 more seconds during which it should not neither fail below, nor rise.
6. Again start the engine, let's it work for about a minute, then again muffle. Again several times firmly squeeze out a pedal, - the size of the course has to be reduced with each muscleman.
7. Check serviceability of functioning of the amplifier of the control valve who is built in a vacuum hose. Disconnect a hose and blow in it from assembly of the servo-driver, - the valve has to pass freely air towards the engine. Blow in a hose since the opposite end, - the valve has to block the section through passage. In case of need replace a hose assembled with the valve.

 At installation of a hose pay attention to its marking: the party of assembly turned to the engine is marked with an inscription of "ENGINE".

8. Send an air stream to the end of a vacuum hose from the amplifier of brakes. Air has to leaves the end of a hose from the engine. Then send an air stream to the end of a vacuum hose from the engine. Air should not leaves the end of a hose from the amplifier of brakes. If it does not occur, replace the vacuum valve together with a hose. The end of a shlag from the engine has marking of "ENGINE".

9. Check a hose for existence of cracks and other damages, track density of its landing on unions. Attention: At installation of a vacuum hose do not moisten unions with any greasing or soap water!


The parking brake (back disk brake) (each 25 000 km [15 000 miles] of run or time in the 12th month)

Check

 PERFORMANCE ORDER

1. Check frictional overlays of boots and drums of both parking brake mechanisms at the same time.

2. Examine brake boots on existence of deformations and mechanical damages. Measure thickness of brake slips.

3. Examine a working surface of a drum on existence of cracks, zadir, traces of an overheat and other damages. If defects cannot be removed by processing of a surface with a fine-grained emery paper, the drum should be given for a pro-point to a workshop of car service, or to replace (see the Head Brake system). Measure the internal diameter of brake drums.

4. If the tension of a coupling spring weakened, replace it, - do not mix the lower and top springs.


Adjustment

 PERFORMANCE ORDER

1. For adjustment of the parking brake pump over a brake path and remove the back rubber cap established from the back party of a brake board.

2. By means of a screw-driver with a flat sting develop a wheel of the regulator flat up to an emphasis, then return it back on 3-4 teeth and establish into place a rubber cap.