SUBARU LEGACY 1996 Service Repair Manual

CAUTION:

Observe the items in 1. NORMAL CHARGING 6-2
[W2C1].

Never use more than 10 amperes when charging the
battery because that will shorten battery life.
3. JUDGMENT OF BATTERY IN CHARGED
CONDITION
1) Specific gravity of electrolyte is held at a specific value
in a range from 1.250 to 1.290 for more than one hour.
2) Voltage per battery cell is held at a specific value in a
range from 2.5 to 2.8 volts for more than one hour.
4. CHECK HYDROMETER FOR STATE OF CHARGE
Hydrometer indicator State of charge Required action
Green dot Above 65% Load test
Dark dot Below 65% Charge battery
Clear dot Low electrolyteReplace battery.* (If
cranking complaint)
*: Check electrical system before replacement.
B6M0236
3. Ignition Switch
A: REMOVAL AND INSTALLATION
1. IGNITION SWITCH
1) Remove screws, separate upper column cover and
lower column cover.
2) Remove instrument panel lower cover.
B6M0333
3) Disconnect ignition switch connector from body har-
ness.
4) Using a drift and hammer, hit the torn bolt head to
loosen and remove the ignition switch.
B6M0334A
5) When installing, tighten the connecting bolt until its
head twists off.
7
6-2SERVICE PROCEDURE
2. Battery - 3. Ignition Switch

CAUTION:

Observe the items in 1. NORMAL CHARGING 6-2
[W2C1].

Never use more than 10 amperes when charging the
battery because that will shorten battery life.
3. JUDGMENT OF BATTERY IN CHARGED
CONDITION
1) Specific gravity of electrolyte is held at a specific value
in a range from 1.250 to 1.290 for more than one hour.
2) Voltage per battery cell is held at a specific value in a
range from 2.5 to 2.8 volts for more than one hour.
4. CHECK HYDROMETER FOR STATE OF CHARGE
Hydrometer indicator State of charge Required action
Green dot Above 65% Load test
Dark dot Below 65% Charge battery
Clear dot Low electrolyteReplace battery.* (If
cranking complaint)
*: Check electrical system before replacement.
B6M0236
3. Ignition Switch
A: REMOVAL AND INSTALLATION
1. IGNITION SWITCH
1) Remove screws, separate upper column cover and
lower column cover.
2) Remove instrument panel lower cover.
B6M0333
3) Disconnect ignition switch connector from body har-
ness.
4) Using a drift and hammer, hit the torn bolt head to
loosen and remove the ignition switch.
B6M0334A
5) When installing, tighten the connecting bolt until its
head twists off.
7
6-2SERVICE PROCEDURE
2. Battery - 3. Ignition Switch

B6M0048
B: INSPECTION
1. IGNITION SWITCH (ON-CAR)
1) Remove instrument panel lower cover.
2) Remove lower column cover.
3) Unfasten holddown clip which secures harness, and
disconnect connector of ignition switch from body harness.
4) Turn ignition key to each position and check continuity
between terminals of ignition switch connector.
Terminal
Positiona-1 a-2 a-5 a-4
LOCK
ACC
ON
START
B6M0335A
4. Headlight
A: ADJUSTMENT
1. HEADLIGHT AIMING
1) Adjust the headlight aiming by turning the adjusting
screws.
CAUTION:
Before checking the headlight aiming, be sure of the
following:

Turn off the light before adjusting headlight aiming.
If the light is necessary to check aiming, do not turn on
for more than two minutes.

The area around the headlight has not sustained any
accident, damage or other type of deformation.

Vehicle is parked on level ground.

The inflation pressure of tires is correct.

Vehicle’s gas tank is fully charged.

Bounce the vehicle several times to normalize the
suspension.

Make certain that someone is seated in the driver’s
seat.
NOTE:
Adjust vertical aim first, then horizontal aim.
8
6-2SERVICE PROCEDURE
3. Ignition Switch - 4. Headlight

B6M0048
B: INSPECTION
1. IGNITION SWITCH (ON-CAR)
1) Remove instrument panel lower cover.
2) Remove lower column cover.
3) Unfasten holddown clip which secures harness, and
disconnect connector of ignition switch from body harness.
4) Turn ignition key to each position and check continuity
between terminals of ignition switch connector.
Terminal
Positiona-1 a-2 a-5 a-4
LOCK
ACC
ON
START
B6M0335A
4. Headlight
A: ADJUSTMENT
1. HEADLIGHT AIMING
1) Adjust the headlight aiming by turning the adjusting
screws.
CAUTION:
Before checking the headlight aiming, be sure of the
following:

Turn off the light before adjusting headlight aiming.
If the light is necessary to check aiming, do not turn on
for more than two minutes.

The area around the headlight has not sustained any
accident, damage or other type of deformation.

Vehicle is parked on level ground.

The inflation pressure of tires is correct.

Vehicle’s gas tank is fully charged.

Bounce the vehicle several times to normalize the
suspension.

Make certain that someone is seated in the driver’s
seat.
NOTE:
Adjust vertical aim first, then horizontal aim.
8
6-2SERVICE PROCEDURE
3. Ignition Switch - 4. Headlight

B6M0336A
2) Look at the beam angle gauge (vertical movement).
The bubble on the gauge should not deviate from the cen-
ter of the gauge.
B6M0337A
3) Look at the beam angle gauge (horizontal movement).
The center mark (the red line on the inner scale) should not
deviate from the black line on the outer case.
B: REMOVAL AND INSTALLATION
1. HEADLIGHT BULB
1) Disconnect the connector from inside of the engine
compartment.
2) Remove rubber cap.
3) Remove the light bulb retaining spring to remove the
bulb.
4) Replace the bulb with a new one and hook the spring.
5) Attach the rubber cap and connect the connector.
M6A0139
CAUTION:

Since the tungsten halogen bulb operates at high
temperature, dirt and oil on the bulb surface decreases
the bulb’s useful life. When replacing the bulb, hold the
flange portion and do not touch the glass portion.
M6A0140

Attach the rubber cap with letters TOP on the top so
that the drain hole will be on the lower side.

To keep water out, correctly engage the groove por-
tion of the rubber cap.
9
6-2SERVICE PROCEDURE
4. Headlight

2. HEADLIGHT
1) Remove front grille and disconnect connectors from
headlight.
B6M0338
2) Remove bolts which secure headlight and remove
headlight.
Tightening torque:
6.4±0.5 N⋅m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)
NOTE:
When installing the headlight, securely fit clip into locating.
B6M0339
B6M0236
3. COMBINATION SWITCH (WITHOUT AIRBAG
MODEL)
Refer to 5-5 [W7A0] as for removal of combination
switch on airbag equipped model.
1) Remove steering wheel.
2) Remove screws which secure upper column cover to
lower column cover.
3) Remove screws which secure knee protector and
remove knee protector.
CAUTION:
When installing knee protector, ensure that harness is
not caught by adjacent parts.
4) Disconnect connector from body harness and undo
holddown band.
10
6-2SERVICE PROCEDURE
4. Headlight

G6M0107
5) Remove screws which secure switch and remove
switch.
CAUTION:
During installation (with key interlock)

When routing combination switch harness around
steering system, do not place it over key interlock
release knob.

After installing lower column cover, ensure that key
interlock release knob is accessible.
B6M0237
C: DISASSEMBLY AND ASSEMBLY
1. COMBINATION SWITCH
1) Remove screws which secure slip ring to combination
switch, and remove slip ring.
G6M0109
2) Remove screws which secure lighting switch, wiper and
washer switch. Remove both switches.
Assembly is in the reverse order of disassembly.
D: INSPECTION
1. COMBINATION SWITCH (ON-CAR)
1) Remove instrument panel lower cover.
2) Remove lower column cover.
11
6-2SERVICE PROCEDURE
4. Headlight

B6M0238
3) Unfasten holddown clip which secures harness, and
disconnect connectors from body harness.
4) Move combination switch to respective positions and
check continuity between terminals as indicated in the fol-
lowing tables:
Lighting switch
Terminal
Switch positionc-1 c-2 c-3
OFF
Tail
*
Head
Parking switch
Terminal
Switch positionc-10 c-11 c-9
OFF
*XX
ON
Dimmer and passing switch
Terminal
Switch positiona-3 a-2 a-1 a-4
Flash

*
Low beam
*
HI-beam
G6M0111
2. HEADLIGHT RELAY
Check continuity between terminals as indicated in table
below, when connecting the battery to terminal No. 1 and
No. 3.
When current flows.Between terminals
No. 2 and No. 4Continuity exists.
When current does not flow.Between terminals
No. 2 and No. 4Continuity does not
exist.
Between terminals
No. 1 and No. 3Continuity exists.
12
6-2SERVICE PROCEDURE
4. Headlight

G6M0113
3. DAYTIME RUNNING LIGHT RELAY
Check continuity between terminals (indicated in table
below) when terminal No. 1 is connected to battery and
terminal No. 2 is grounded.
When current flows.Between terminals
No. 3 and No. 4Continuity exists.
When current does not flow.Between terminals
No. 3 and No. 4Continuity does not
exist.
Between terminals
No. 1 and No. 2Continuity exists.
G6M0114
Check continuity between terminals (indicated in table
below) when terminal No. 1 is connected to battery and
terminal No. 2 is grounded.
When current flows.Between terminals
No. 3 and No. 5Continuity does not
exist.
Between terminals
No. 3 and No. 4Continuity exists.
When current does not flow.Between terminals
No. 3 and No. 5Continuity exists.
Between terminals
No. 3 and No. 4Continuity does not
exist.
Between terminals
No. 1 and No. 2Continuity exists.
13
6-2SERVICE PROCEDURE
4. Headlight

B6M0055A
B6M0056A
5. Stop and Tail Light
A: REMOVAL AND INSTALLATION
1. REAR COMBINATION LIGHT
1) Remove rear trim.
2) Disconnect connector from rear combination light.
3) Remove nuts which secure rear combination light.
Tightening torque:
2.5±0.5 N⋅m (0.25±0.05 kg-m, 1.8±0.4 ft-lb)
4) Attach adhesive cloth tape to body area around rear
combination light.
5) Using a standard screwdriver, carefully pry rear combi-
nation light off and away from the vehicle.
CAUTION:

Do not pry rear combination light forcefully as this
may scratch vehicle body.

Remove all traces of adhesive tape from body before
installation.

Attach butyl rubber tape to back of rear combination
light before installing rear combination light on body
for sealing purposes.
B6M0057A
B6M0058A
2. REAR FINISHER
1) Remove trunk lid trim (SEDAN) or rear gate trim
(WAGON).
2) Disconnect connectors from rear finisher.
3) Remove rear wiper motor (WAGON).
4) Remove nuts which secure rear finisher.
Tightening torque:
2.5±0.5 N⋅m (0.25±0.05 kg-m, 1.8±0.4 ft-lb)
5) Attach adhesive cloth tape to body area around rear
finisher.
6) Using a standard screwdriver, carefully pry rear finisher
off and away from the vehicle.
CAUTION:
Do not pry rear finisher forcefully as this may scratch
vehicle body.
14
6-2SERVICE PROCEDURE
5. Stop and Tail Light