Subaru Legacy III (2000-2003 year). Manual - part 822

BR-46

BRAKE

BRAKE PIPE

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.
• Be careful not to damage airbag system wir-
ing harness when servicing the center brake
pipe.
• When removing the brake pipe, make sure
that it is not bent.

B: INSTALLATION

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.
• Be careful not to damage airbag system wir-
ing harness when servicing the center brake
pipe.
• When installing the brake pipe, make sure
that it is not bent.
• After installing the brake pipe and hose,
bleed the air.
• After installing the brake hose, make sure
that it does not touch the tire or suspension as-
sembly, etc.

Brake pipe tightening torque:

15 N·m (1.5 kgf-m, 10.8 ft-lb)

C: INSPECTION

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

NOTE:
Use a mirror when inspecting low-visible part or
back side.

BR-47

BRAKE

HILL HOLDER

15.Hill Holder

A: REMOVAL

1. PHV (PRESSURE HOLD VALVE)

1) Drain brake fluid from reservoir of master cylin-
der.
2) Remove adjusting nut and lock nut.

3) Remove cable clamp, and disconnect PHV ca-
ble from PHV.

CAUTION:
Carefully protect boots and inner cable from 
damage when disconnecting PHV cable.

4) Disconnect brake pipes from PHV.

CAUTION:
• Pay attention not to drop brake fluid onto
body painting since it may dissolve paint.
• Pay attention not to damage hexagonal head
of flare nut by using pipe wrench without fail.

5) Detach PHV along with support from side frame.

CAUTION:
Exercise utmost care to prevent foreign matter 
from entering into PHV when removing it.

2. PHV CABLE

1) Remove adjusting nut and lock nut.

2) Remove cable clamp, and disconnect PHV ca-
ble from PHV.

CAUTION:
Carefully protect boot and inner cable from 
damage when disconnecting PHV cable.

3) Remove clutch pedal. <Ref. to CL-33, REMOV-
AL, Clutch Pedal.>

(1) Adjusting nut

(2) Lock nut

(3) PHV

(1) PHV cable

(2) Clamp

BR-00131

( 1 )

( 2 )

( 3 )

BR-00132

( 1 )

( 2 )

(1) Adjusting nut

(2) Lock nut

(3) PHV

(1) PHV cable

(2) Clamp

BR-00133

BR-00131

( 1 )

( 2 )

( 3 )

BR-00132

( 1 )

( 2 )

BR-48

BRAKE

HILL HOLDER

4) Remove PHV cable.

B: INSTALLATION

1. PHV (PRESSURE HOLD VALVE)

1) Install PHV onto side frame.

Tightening torque:

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:
Confirm that brake pipes are not deformed and/
or damaged. Replace them with new ones if 
necessary.
3) Install PHV cable to PHV.

CAUTION:
If cable clamp (and clips) is damaged, replace it 
with a new one.
4) Connect PHV cable with clips.

NOTE:
Avoid sharp bending of PHV cable as it may cause
breakage.
5) Apply grease to the following points.
• Hook portion of return spring
• Cable end portion of lever

Grease:

SUNLIGHT 2 (Part No. 003602010)

6) Be sure to bleed air from the brake system.
7) Adjust PHV cable. <Ref. to BR-49, Adjustment.>

CAUTION:
After replacing PHV cable with new one, oper-
ate clutch pedal about 30 times as a running-in 
operation prior to adjustment.

2. PHV CABLE

1) Install PHV cable in the reverse order of remov-
al.

CAUTION:
• If cable clamp is damaged, replace it with a
new one.
• Avoid sharp bending of PHV cable as it may
cause breakage.
2) Apply grease to the following points.
• Hook portion of return spring
• Cable end portion of lever

Grease:

SUNLIGHT 2 (Part No. 003602010)

3) Adjust PHV cable. <Ref. to BR-49, Adjustment.>

CAUTION:
After replacing PHV cable with new one, oper-
ate clutch pedal about 30 times as a running-in 
operation prior to adjustment.

(1) Snap ring

(2) Clutch pedal

(3) Clamp

(4) PHV cable

BR-00222

( 1 )

( 2 )

( 3 )

( 4 )

BR-49

BRAKE

HILL HOLDER

C: INSPECTION

Check up removed parts as follows, and replace
defective ones.
1) Check if boots of PHV cable are damaged or de-
graded, and if inner cable is damaged or corroded.
2) Check if return spring is worn out, damaged or
corroded.
3) Confirm that rolling sound of ball is heard with
PHV inclined and lever rotates smoothly.

CAUTION:
Never disassemble PHV. Replace entire PHV 
assembly if necessary.

D: ADJUSTMENT

Confirm stopping and starting performances by ac-
tivating hill holder on an uphill road of 3

°

 or higher

inclination.
1) If vehicle does not stop;
Tighten adjusting nut of PHV cable.
2) If vehicle does not start properly;
• Case A — When hill holder is released later than
engagement of clutch pedal (Engine tends to stall.):
Loosen adjusting nut gradually until smooth start-
ing is enabled.
• Case B — When hill holder is released earlier
than engagement of clutch pedal (Vehicle slips
down slightly.):
Tighten adjusting nut so that hill holder is released
later than engagement of clutch pedal (status in
Case A). Then make adjustment the same as in
Case A.

CAUTION:
Whenever turning adjusting nut, prevent PHV 
cable from revolving.

3) Tighten lock nut.

Tightening torque:

3.4 N·m (0.35 kgf-m, 2.5 ft-lb)

(1) Adjusting nut

(2) Lock nut

(3) PHV

BR-00131

( 1 )

( 2 )

( 3 )