Subaru Coupes/Sedans/Wagons 1985-1996 Repair Guide

Hydraulic Actuator

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REMOVAL & INSTALLATION



See Figures 1, 2 and 3

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Fig. Fig. 1: ABS hydraulic assembly and mounting bolts in engine compartment



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Fig. Fig. 2: Nippon hydraulic assembly and components



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Fig. Fig. 3: Bosch hydraulic assembly and components

  1. Disconnect the harness connectors at the hydraulic unit.
  2.  
  3. Remove the emission canister from the engine compartment to allow access.
  4.  
  5. Disconnect the inlet and outlet lines from the top of the actuator. Label the lines before removal; exact reinstallation is required.
  6.  
  7. Immediately plug the lines and ports to prevent entry of dirt and debris into the system.
  8.  
  9. Remove the screw holding the ABS relay cover and remove the cover.
  10.  
  11. Remove the bolts holding the hydraulic unit bracket to the body. Note that one of these bolts has the pump motor ground lug attached.
  12.  
  13. Lift the actuator and bracket clear of the vehicle. Keep the unit upright at all times; do not drop or bump it.
  14.  
  15. The brackets and relays may be removed for transfer to a replacement unit.
  16.  
  17. Except for the 2 relays, the hydraulic unit contains no replaceable components. Never attempt to disassemble the unit or repair it.
  18.  

To install:
  1. Install or transfer the relays and brackets. The nuts on the bushing bolts holding the hydraulic unit to the brackets should be tightened to 6 ft. lbs. (8 Nm).
  2.  
  3. Install the hydraulic unit and brackets into the engine compartment. The nuts and bolts holding the brackets to the body should be tightened to 25 ft. lbs. (34 Nm). Make certain the pump motor ground lug in engaged beneath the proper bolt.
  4.  
  5. Check that the relays are firmly seated in place. Install the relay cover box and tighten the screw just snug. Do not over tighten.
  6.  
  7. Connect the brake lines to the correct positions. Tighten each line to 11 ft. lbs. (15 Nm).
  8.  
  9. Install the canister in the engine compartment.
  10.  
  11. Bleed all 4 wheels, then bleed the hydraulic actuator. Both the primary and secondary circuits must be bled.
  12.  

 
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