SUBARU LEGACY 1996 Service Repair Manual

B2M0313
7) Remove front exhaust pipe and center exhaust pipe
from hanger bracket.
CAUTION:
Be careful not to pull down front exhaust pipe and
center exhaust pipe.
B2M0060
8) Separate front exhaust pipe from front catalytic con-
verter.
B2M0060
B: INSTALLATION
CAUTION:
Replace gaskets with new ones.
1) Install front catalytic converter to front exhaust pipe.
Tightening torque:
30±5 N⋅m (3.1±0.5 kg-m, 22.4±3.6 ft-lb)
B2M0313
2) Install front exhaust pipe and center exhaust pipe.
And temporarily tighten bolt which installs center exhaust
pipe to hanger bracket.
B2M0054
3) Tighten bolts which hold front exhaust pipe onto cylin-
der heads.
Tightening torque:
30±5 N⋅m (3.1±0.5 kg-m, 22.4±3.6 ft-lb)
5
2-9SERVICE PROCEDURE
1. Front Exhaust Pipe and Center Exhaust Pipe

B2M0055
4) Install center exhaust pipe to rear exhaust pipe.
Tightening torque:
18±5 N⋅m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)
B2M0313
5) Tighten bolt which holds center exhaust pipe to hanger
bracket.
Tightening torque:
35±5 N⋅m (3.6±0.5 kg-m, 26.0±3.6 ft-lb)
B2M0312
6) Connect rear oxygen sensor connector. (Except Califor-
nia 2200 cc model)
B2M0725
7) Lower the vehicle.
8) Connect rear oxygen sensor connector. (California
2200 cc model)
B2M0724
9) Connect front oxygen sensor connector.
6
2-9SERVICE PROCEDURE
1. Front Exhaust Pipe and Center Exhaust Pipe

B2M0055
2. Rear Exhaust Pipe
A: REMOVAL
1) Separate rear exhaust pipe from center exhaust pipe.
B2M0061
2) Separate rear exhaust pipe from muffler.
CAUTION:
Be careful not to pull down rear exhaust pipe.
G2M0315
3) Remove rear exhaust pipe bracket from rubber cushion.
NOTE:
To facilitate removal, apply a coat of SUBARU CRC or
equivalent to pipe bracket in advance.
SUBARU CRC (Part No. 004301003)
G2M0315
B: INSTALLATION
CAUTION:
Replace gaskets with new ones.
1) Install rear exhaust pipe bracket to rubber cushion.
NOTE:
To facilitate installation, apply a coat of SUBARU CRC or
equivalent to mating area of rubber cushion in advance.
SUBARU CRC (Part No. 004301003)
B2M0061
2) Install rear exhaust pipe to muffler.
Tightening torque:
48±5 N⋅m (4.9±0.5 kg-m, 35.4±3.6 ft-lb)
7
2-9SERVICE PROCEDURE
2. Rear Exhaust Pipe

B2M0055
3) Install rear exhaust pipe to center exhaust pipe.
Tightening torque:
18±5 N⋅m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)
8
2-9SERVICE PROCEDURE
2. Rear Exhaust Pipe

B2M0061
3. Muffler
A: REMOVAL AND INSTALLATION
1) Separate muffler from rear exhaust pipe.
B2M0062
2) Remove left and right rubber cushions.
CAUTION:
Be careful not to pull down muffler.
NOTE:
To facilitate removal, apply a coat of SUBARU CRC or
equivalent to mating area of rubber cushions in advance.
SUBARU CRC (Part No. 004301003)
B2M0063
3) Remove front rubber cushion, and detach muffler
assembly.
NOTE:
To facilitate removal, apply a coat of SUBARU CRC or
equivalent to mating area of rubber cushion in advance.
SUBARU CRC (Part No. 004301003)
B2M0061
4) Installation is in the reverse order of removal.
CAUTION:
Replace gasket with a new one.
Tightening torque:
48±5 N⋅m (4.9±0.5 kg-m, 35.4±3.6 ft-lb)
9
2-9SERVICE PROCEDURE
3. Muffler

CLUTCH2-10
Page
S SPECIFICATIONS AND SERVICE DATA....................................................2
1. Clutch System ..........................................................................................2
C COMPONENT PARTS................................................................................3
1. Clutch System ..........................................................................................3
W SERVICE PROCEDURE............................................................................4
1. General ...................................................................................................4
2. On-Car Service .......................................................................................4
3. Release Bearing and Lever ....................................................................5
4. Clutch Disc and Cover ............................................................................7
K DIAGNOSTICS..........................................................................................11
1. Clutch System ........................................................................................11

1. Clutch System
A: SPECIFICATIONS
2200 cc
Clutch cover Diaphragm set load kg (lb) 450 (992)
Clutch discFacing material Woven
O.D. x I.D. x thickness mm (in) 225 x 150 x 3.5 (8.86 x 5.91 x 0.138)
Spline O.D. mm (in)
(No. of teeth)25.2 (0.992)
(24)
Clutch release lever ratio 3.0
Release bearing Grease-packed self-aligning
B: SERVICE DATA
2200 cc
Clutch pedal Full stroke mm (in) 140 — 150 (5.51 — 5.91)
Release
leverStroke mm (in) 24 — 26 (0.94 — 1.02)
Play at release lever center mm (in) 3 — 4 (0.12 — 0.16)
Clutch discDepth of rivet head mm (in)Standard 1.3 — 1.9 (0.051 — 0.075)
Limit of sinking 0.3 (0.012)
Limit for runout mm (in) 1.0 (0.039) at R = 107 (4.21)
2
2-10SPECIFICATIONS AND SERVICE DATA
1. Clutch System

1. Clutch System
B2M0632A

1Clutch cable bracket


2Clutch release lever sealing


3Retainer spring


4Pivot


5Clutch release lever


6Clip


7Clutch release bearing


8Clutch cover

9Clutch disc


10Return spring (Models without hill holder only)


11Clutch return spring bracket
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 15.7±1.5 (1.6±0.15, 11.6±1.1)
3
2-10COMPONENT PARTS
1. Clutch System

1. General
A: PRECAUTION
When servicing clutch system, pay attention to the follow-
ing items.
1. MECHANICAL APPLICATION TYPE
1) Check the routing of clutch cable for smoothness.
2) Excessive tightness or looseness of clutch cable have
a bad influence upon the cable durability.
3) Apply grease sufficiently to the connecting portion of
clutch pedal.
4) Apply grease sufficiently to the release lever portion.
5) Position clutch cable through the center of toe board
hole and route it smoothly. Adjustment is done by moving
the outer cable.
6) Make sure not to let the clutch chatter when starting
forward or rearward. If clutch chattering occurs, readjust so
that the bend of clutch outer cable becomes flatter.
G2M0234
2. On-Car Service
1. MECHANICAL APPLICATION TYPE
1) Remove release lever return spring from lever (Models
without hill holder only).
2) Adjust spherical nut so that the play is within the speci-
fied value at the lever end (center of spherical nut).
CAUTION:
Take care not to twist the cable during adjustment
Play: 3 — 4 mm (0.12 — 0.16 in)
Full stroke: 24 — 26 mm (0.94 — 1.02 in)
G2M0235
3) Upon completion of adjustment, securely lock spherical
nut with lock nut.
Install return spring on lever (Models without hill holder
only).
NOTE:
Hook the long hook side of the return spring with the lever
(Models without hill holder only).
4
2-10SERVICE PROCEDURE
1. General - 2. On-Car Service

G2M0236
4) Depress clutch pedal to assure there is no abnormality
in the clutch system.
B2M0633A
3. Release Bearing and Lever
A: REMOVAL
1. MECHANICAL APPLICATION TYPE
1) Remove release lever return spring

1(Models without
hill holder only).
2) Remove the two clips

2from clutch release lever
3
and remove release bearing
6.
CAUTION:
Be careful not to deform clips.
3) Remove release lever seal

4.
B2M0174A
4) Remove release lever retainer spring from release lever
pivot with a screwdriver by accessing it through clutch
housing release lever hole. Then remove release lever.
5
2-10SERVICE PROCEDURE
2. On-Car Service - 3. Release Bearing and Lever