Subaru Legacy III (2000-2003 year). Manual - part 821

BR-42

BRAKE

AIR BLEEDING

12.Air Bleeding

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.
• Avoid mixing different brands of brake fluid
to prevent degrading the quality of the fluid.
• Be careful not to allow dirt or dust to get into
the reservoir tank.
• Be extremely careful not to spill brake fluid.
Brake fluid spilt on the vehicle body will harm
the painted surface; wash it off quickly if spilt.

NOTE:
• Start with the brakes (wheels) connected to the
secondary chamber of the master cylinder.
• The time interval between two brake pedal oper-
ations (from the time when the pedal is released to
the time when it is depressed another time) should
be approximately 3 seconds.
• The air bleeder on each brake should be re-
leased for 1 to 2 seconds.

1. MASTER CYLINDER

NOTE:
• If master cylinder is disassembled or reservoir
tank is empty, bleed master cylinder. 
• During bleeding operation, keep the brake reser-
voir tank filled with brake fluid to eliminate entry of
air.
• Brake pedal operation must be very slow.
• For convenience and safety, two people should
do the work.
1) Loosen wheel nuts, jack-up vehicle, support it
with safety stands, and remove wheel.
2) Disconnect brake line at primary and secondary
sides.
3) Put plastic bag cover on the master cylinder.
4) Carefully depress and hold brake pedal.

5) Close outlet plug with your finger, and release
brake pedal.

6) Repeat above steps 4) and 5) until master cylin-
der is completely bled.
7) Install brake pipes to master cylinder.

Tightening torque:

8 N·m (0.8 kgf-m, 5.8 ft-lb)

8) Cleanly wash away brake fluid spilt on master
cylinder etc.
9) Bleed air from brake system. <Ref. to BR-42,
BRAKE LINE, PROCEDURE, Air Bleeding.>

2. BRAKE LINE

NOTE:
• During bleeding operation, keep the brake reser-
voir tank filled with brake fluid to eliminate entry of
air.
• Brake pedal operation must be very slow.
• For convenience and safety, two people should
do the work.
1) Make sure that there is no leak from joints and
connections of the brake system.
2) Fit one end of vinyl tube into the air bleeder and
put the other end into a brake fluid container.

BR-00090

BR-00091

BR-00087

BR-43

BRAKE

AIR BLEEDING

CAUTION:
Brake fluid replacement sequence; (A) Front 
right 

→

→

→

→

 (B) Rear left 

→

→

→

→

 (C) Front left 

→

→

→

→

 (D) Rear 

right

3) Slowly depress the brake pedal and keep it de-
pressed. Then, open the air bleeder to discharge
air together with the fluid.
Release air bleeder for 1 to 2 seconds.
Next, with the bleeder closed, slowly release the
brake pedal.
Repeat these steps until there are no more air bub-
bles in the vinyl tube.
Allow 3 to 4 seconds between two brake pedal op-
erations.

CAUTION:
Cover bleeder with waste cloth, when loosen-
ing it, to prevent brake fluid from being 
splashed over surrounding parts.

NOTE:
Brake pedal operating must be very slow.
4) Tighten air bleeder securely when no air bubbles
are visible.

Air bleeder tightening torque:

8 N·m (0.8 kgf-m, 5.8 ft-lb)

5) Perform these steps for the brakes connecting to
the secondary chamber of master cylinder, first,
and then for the ones connecting to primary cham-
ber. With all procedures completed, fully depress
the brake pedal and keep it in that position for ap-
proximately 20 seconds to make sure that there is
no leak evident in the entire system.

6) Check the pedal stroke.
While the engine is idling, depress the brake pedal
with a 490 N (50 kgf, 110 lb) load and measure the
distance between the brake pedal and steering
wheel. With the brake pedal released, measure the
distance between the pedal and steering wheel
again. The difference between the two measure-
ments must be more than specified.

Specified pedal stroke:

95 mm (3.74 in)
When depressing brake pedal with a 490 N 
(50 kgf, 110 lb) load.

7) If the distance is more than specifications, there
is a possibility that air is in the brake line. Bleed
brake line until pedal stroke meets the specifica-
tion. 
8) Operate hydraulic control unit in the sequence
control mode.
With ABS: <Ref. to ABS-9, ABS Sequence Con-
trol.>
With VDC: <Ref. to VDC-19, VDC Sequence Con-
trol.> 
9) Recheck the brake stroke.
10) If the distance is more than specifications,
there is a possibility air is in the inside of the hy-
draulic unit. Repeat above steps 2) to 9) above until
pedal stroke meets the specification.
11) Add brake fluid to the required level (MAX. lev-
el) of reservoir tank.
12) As a final step, test run the vehicle at low speed
and apply brakes relatively hard 2 to 3 times to en-
sure that brakes provide normal braking action on
all four wheels without dragging and uneven brak-
ing.

(1) Master cylinder

(2) Hydraulic unit

(3) Proportioning valve

BR-00089

( 3 )

( 1 )

( 2 )

( A )

( B )

( C )

( D )

(1) Pressure gauge

(2) Vacuum gauge

(3) Adapter hose

(4) Vacuum hose

(5) Pedal force gauge

BR-00082

( 3 ) ( 4 )

( 5 )

( 1 )

( 2 )

BR-44

BRAKE

BRAKE HOSE

13.Brake Hose

A: REMOVAL

1. FRONT BRAKE HOSE

1) Separate brake pipe from brake hose.

NOTE:
Always use flare nut wrench and be careful not to
deform flare nut.

2) Pull out clamp to remove brake hose.
3) Remove bolt at strut and union bolt.

2. REAR BRAKE HOSE

1) Separate brake pipe from brake hose.

NOTE:
Always use flare nut wrench and be careful not to
deform flare nut.

2) Pull out clamp to remove brake hose.

(1) Brake hose

(2) Brake pipe

BR-00095

( 1 )

( 2 )

(1) Brake pipe

(2) Brake hose

(1) Brake pipe

( 1 )

( 2 )

BR-00172

( 1 )

BR-00173

BR-45

BRAKE

BRAKE HOSE

B: INSTALLATION

1. FRONT BRAKE HOSE

1) Route end of brake hose (on caliper side)
through hole in brake hose bracket at strut location.
2) Tighten end of brake hose at caliper using a
union bolt.

Tightening torque (Union bolt):

18 N·m (1.8 kgf-m, 13.0 ft-lb)

3) Secure middle fitting of brake hose to bracket at
strut location using a clamp.
4) Position disc in straight-forward direction and
route brake hose through hole in bracket on wheel
apron side.

CAUTION:
Be sure brake hose is not twisted.
5) Temporarily tighten flare nut to connect brake
pipe and hose.
6) Fix brake hose with clamp at wheel apron brack-
et.
7) While holding hexagonal part of brake hose fit-
ting with a wrench, tighten flare nut to the specified
torque.

Tightening torque (Brake pipe flare nut):

15 N·m (1.5 kgf-m, 10.8 ft-lb)

8) Bleed air from the brake system.

2. REAR BRAKE HOSE

1) Pass brake hose through the hole of bracket,
and lightly tighten flare nut to connect brake pipe.
2) Insert clamp upward to fix brake hose.
3) While holding hexagonal part of brake hose fit-
ting with a wrench, tighten flare nut to the specified
torque.

Tightening torque (Brake pipe flare nut):

15 N·m (1.5 kgf-m, 10.8 ft-lb)

4) Bleed air from the brake system.

C: INSPECTION

Ensure there are no cracks, breakage, or damage
on hoses. Check joints for fluid leakage. If any
cracks, breakage, damage or leakage is found, re-
pair or replace hose.

BR-00021

(1) Brake pipe

(2) Brake hose

(1) Brake pipe

( 1 )

( 2 )

BR-00172

( 1 )

BR-00173