SUBARU LEGACY 1996 Service Repair Manual

G2M0294
15) Separate torque converter from drive plate. (AT model)
(1) Lower the vehicle.
(2) Remove service hole plug.
(3) Remove bolts which hold torque converter to drive
plate.
(4) Remove other bolts while rotating the engine using
ST.
ST 499977000 CRANK PULLEY WRENCH
G2M0295
16) Remove pitching stopper.
B2M0336
17) Disconnect fuel delivery hose, return hose and evapo-
ration hose.
CAUTION:
Disconnect hose with its end wrapped with cloth to
prevent fuel from splashing.
Catch fuel from hose into container.
G2M0297
18) Support engine with a lifting device and wire ropes.
G2M0298
19) Support transmission with a garage jack.
CAUTION:
Before moving engine away from transmission, check
to be sure no work has been overlooked. Doing this is
very important in order to facilitate re-installation and
because transmission lowers under its own weight.
18
2-11SERVICE PROCEDURE
2. Engine

G2M0299
20) Remove bolts which hold upper side of transmission to
engine.
G2M0300
21) Remove engine from vehicle.
(1) Slightly raise engine.
(2) Raise transmission with garage jack.
(3) Move engine horizontally until mainshaft is with-
drawn from clutch cover.
(4) Slowly move engine away from engine compart-
ment.
CAUTION:
Be careful not to damage adjacent parts or body pan-
els with crank pulley, oil pressure gauge, etc.
19
2-11SERVICE PROCEDURE
2. Engine

B: INSTALLATION
1. Install engine to transmission.
2. Tighten bolts which hold upper side of transmission to engine.
3. Remove lifting device and wire rope.
4. Remove garage jack.
5. Install pitching stopper.
AT model
6. Install torque converter onto drive plate.
7. Install canister and bracket.
8. Install power steering pump on bracket.
9. Tighten nuts which hold lower side of transmission to engine.
10. Tighten nuts which install front cushion rubber onto cross-
member.
11. Install front exhaust pipe and center exhaust pipe.
12. Connect hoses, connectors and cables.
13. Install air intake system.
Air intake duct
Air cleaner element and upper cover.
With A/C
14. Install A/C pressure hoses.
15. Install cooling system.
16. Install battery onto the vehicle, and connect cables.
17. Fill coolant.
18. Check ATF level, and connect if necessary. [AT]
19. Correct power steering oil, and bleed air.
20. Remove front hood stay, and close front hood.
21. Take off the vehicle from lift arms.












20
2-11SERVICE PROCEDURE
2. Engine

G2M0301
1) Install engine onto transmission.
(1) Position engine in engine compartment and align it
with transmission.
CAUTION:
Be careful not to damage adjacent parts or body pan-
els with crank pulley, oil pressure gauge, etc.
(2) Apply a small amount of grease to spline of main-
shaft.
G2M0299
2) Tighten bolts which hold upper side of transmission to
engine.
Tightening torque:
50±4 N⋅m (5.1±0.4 kg-m, 36.9±2.9 ft-lb)
G2M0297
3) Remove lifting device and wire ropes.
4) Remove garage jack.
21
2-11SERVICE PROCEDURE
2. Engine

G2M0302
5) Install pitching stopper.
Tightening torque:
T1: 49±5 N⋅m (5.0±0.5 kg-m, 36.2±3.6 ft-lb)
T2: 57±10 N⋅m (5.8±1.0 kg-m, 42±7 ft-lb)
G2M0294
6) Install torque converter onto drive plate. (AT model)
(1) Tighten bolts which hold torque converter to drive
plate.
(2) Tighten other bolts while rotating the engine by
using ST.
ST 499977000 CRANK PULLEY WRENCH
CAUTION:
Be careful not to drop bolts into torque converter
housing.
Tightening torque:
25±2 N⋅m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
(3) Clog plug onto service hole.
G2M0272
7) Install canister and bracket.
B2M0334
8) Install power steering pump on bracket.
(1) Install power steering pump on bracket, and tighten
bolts.
Tightening torque:
39±10 N⋅m (4.0±1.0 kg-m, 29±7 ft-lb)
22
2-11SERVICE PROCEDURE
2. Engine

B2M0340
(2) Install power steering pipe bracket on right side
intake manifold, and install spark plug codes.
G2M0286
(3) Install front side V-belt, and adjust it.

G2M0292
9) Tighten nuts which hold lower side of transmission to
engine.
Tightening torque:
50±4 N⋅m (5.1±0.4 kg-m, 36.9±2.9 ft-lb)
G2M0303
10) Tighten nuts which install front cushion rubber onto
crossmember.
Tightening torque:
69±15 N⋅m (7.0±1.5 kg-m, 51±11 ft-lb)
CAUTION:
Be sure to tighten front cushion rubber mounting bolts
in the innermost elliptical hole in the front crossmem-
ber.
23
2-11SERVICE PROCEDURE
2. Engine

11) Install front exhaust pipe and center exhaust pipe.
12) Connect hoses, connectors and cables.
(1) Connect the following hoses.
Fuel delivery hose, return hose and evaporation
hose
Heater inlet and outlet hoses
Brake booster vacuum hose
(2) Connect the following connectors.
Engine ground terminal
Engine harness connectors
Front oxygen sensor connector
Rear oxygen sensor connector
Alternator connector and terminal
A/C compressor connectors (With A/C)
(3) Connect the following cables.
Accelerator cable
Cruise control cables (With cruise control)
Clutch cable
Clutch release spring
CAUTION:
After connecting each cable, adjust them.
G2M0271
13) Install air intake system.
(1) Install air cleaner element.
(2) Install air intake duct with air cleaner upper cover.
B2M0030
(3) Connect connector to mass air flow sensor.
24
2-11SERVICE PROCEDURE
2. Engine

G2M0270
14) Install A/C pressure hoses. (With A/C)

CAUTION:
Use new O-rings.
Tightening torque:
25±7 N⋅m (2.5±0.7 kg-m, 18.1±5.1 ft-lb)
B2M0307A
15) Install cooling system.
(1) Attach radiator mounting cushions to body.
G2M0220
(2) Install radiator while fitting radiator pins to cush-
ions.
B2M0320
(3) Install radiator brackets and tighten bolts.
Tightening torque:
13.7±1.5 N⋅m (1.4±0.15 kg-m, 10.1±1.1 ft-lb)
G2M0263
(4) Connect radiator fan motor connector.
25
2-11SERVICE PROCEDURE
2. Engine

G2M0267
(5) Connect radiator inlet hose.
B2M0016A
(6) Connect radiator outlet hose.
(7) Connect ATF cooler hoses. (AT model)
B2M0017
(8) Install V-belt cover.
16) Install battery in the vehicle, and connect cables.
17) Fill coolant.

18) Check ATF level and correct if necessary. (AT model)

19) Charge A/C system with refrigerant.

20) Remove front hood stay, and close front hood.
21) Take off the vehicle from lift arms.
26
2-11SERVICE PROCEDURE
2. Engine

3. Transmission
A: REMOVAL
1. Open front hood fully, and support it with stay.
2. Disconnect battery ground terminal.
3. Remove air intake duct.
4. Disconnect connectors and cables.
5. Remove starter.
6. Remove pitching stopper.
AT model
7. Separate torque converter from drive plate.
8. Remove ATF level gauge.
9. Remove transmission connector bracket.
10. Set special tools.
11. Remove bolt which holds right upper side of transmission to
engine.
12. Remove exhaust system.
Front exhaust pipe
Center exhaust pipe
Rear exhaust pipe [AWD]
AT model
13. Drain ATF to remove ATF drain plug.
14. Disconnect ATF cooler hose from pipe on transmission side,
and remove ATF level gauge guide.
AWD model
15. Remove propeller shaft.

A












27
2-11SERVICE PROCEDURE
3. Transmission