dimensions SUBARU LEGACY 1996 Service Repair Manual

G2M0178
2) Measure the crankshaft bend, and correct or replace if
it exceeds the limit.
CAUTION:
If a suitable V-block is not available, install #1 and #5
crankshaft bearing on cylinder block, position crank-
shaft on these bearings and measure crankshaft bend
using a dial gauge.
Crankshaft bend limit:
0.035 mm (0.0014 in)
G2M0179
3) Inspect the crank journal and crank pin for wear. If not
to specifications, replace bearing with an undersize one,
and replace or recondition crankshaft as necessary. When
grinding crank journal or crank pin, finish them to the speci-
fied dimensions according to the undersize bearing to be
used.
Crank pin and crank journal:
Out-of-roundness
0.030 mm (0.0012 in) or less
Taper limit
0.07 mm (0.0028 in)
Grinding limit
0.25 mm (0.0098 in)
Unit: mm (in)
Crank journal diameter
Crank pin diameter
#1, #5 #2, #3, #4
StandardJournal O.D.59.992—60.008
(2.3619—2.3625)59.992—60.008
(2.3619—2.3625)51.984—52.000
(2.0466—2.0472)
Bearing size
(Thickness at
center)1.998—2.011
(0.0787—0.0792)2.000—2.013
(0.0787—0.0793)1.492—1.501
(0.0587—0.0591)
0.03 (0.0012)
undersizeJournal O.D.59.962—59.978
(2.3607—2.3613)59.954—59.970
(2.3604—2.3610)51.954—51.970
(2.0454—2.0461)
Bearing size
(Thickness at
center)2.017—2.020
(0.0794—0.0795)2.019—2.022
(0.0795—0.0796)1.510—1.513
(0.0594—0.0596)
0.05 (0.0020)
undersizeJournal O.D.59.934—59.950
(2.3596—2.3602)59.934—59.950
(2.3596—2.3602)51.934—51.950
(2.0446—2.0453)
Bearing size
(Thickness at
center)2.027—2.030
(0.0798—0.0799)2.029—2.032
(0.0799—0.0800)1.520—1.523
(0.0598—0.0600)
0.25 (0.0098)
undersizeJournal O.D.59.742—59.758
(2.3520—2.3527)59.734—59.750
(2.3517—2.3524)51.734—51.750
(2.0368—2.0374)
Bearing size
(Thickness at
center)2.127—2.130
(0.0837—0.0839)2.129—2.132
(0.0838—0.0839)1.620—1.623
(0.0638—0.0639)
O.D. ... Outer Diameter
63
2-3SERVICE PROCEDURE
7. Cylinder Block

G2M0178
2) Measure the crankshaft bend, and correct or replace if
it exceeds the limit.
CAUTION:
If a suitable V-block is not available, install #1 and #5
crankshaft bearing on cylinder block, position crank-
shaft on these bearings and measure crankshaft bend
using a dial gauge.
Crankshaft bend limit:
0.035 mm (0.0014 in)
G2M0179
3) Inspect the crank journal and crank pin for wear. If not
to specifications, replace bearing with an undersize one,
and replace or recondition crankshaft as necessary. When
grinding crank journal or crank pin, finish them to the speci-
fied dimensions according to the undersize bearing to be
used.
Crank pin and crank journal:
Out-of-roundness
0.020 mm (0.0008 in) or less
Taper limit
0.07 mm (0.0028 in)
Grinding limit
0.25 mm (0.0098 in)
Unit: mm (in)
Crank journal diameter
Crank pin diameter
#1, #5 #2, #3, #4
StandardJournal O.D.59.992—60.008
(2.3619—2.3625)59.992—60.008
(2.3619—2.3625)47.984—48.000
(1.8891—1.8898)
Bearing size
(Thickness at
center)1.998—2.011
(0.0787—0.0792)2.000—2.013
(0.0787—0.0793)1.492—1.501
(0.0587—0.0591)
0.03 (0.0012)
undersizeJournal O.D.59.962—59.978
(2.3607—2.3613)59.962—59.978
(2.3607—2.3613)47.954—47.970
(1.8879—1.8886)
Bearing size
(Thickness at
center)2.017—2.020
(0.0794—0.0795)2.019—2.022
(0.0795—0.0796)1.510—1.513
(0.0594—0.0596)
0.05 (0.0020)
undersizeJournal O.D.59.942—59.958
(2.3599—2.3605)59.942—59.958
(2.3599—2.3605)47.934—47.950
(1.8872—1.8878)
Bearing size
(Thickness at
center)2.027—2.030
(0.0798—0.0799)2.029—2.032
(0.0799—0.0800)1.520—1.523
(0.0598—0.0600)
0.25 (0.0098)
undersizeJournal O.D.59.742—59.758
(2.3520—2.3527)59.742—59.758
(2.3520—2.3527)47.734—47.750
(1.8793—1.8799)
Bearing size
(Thickness at
center)2.127—2.130
(0.0837—0.0839)2.129—2.132
(0.0838—0.0839)1.620—1.623
(0.0638—0.0639)
O.D. ... Outer Diameter
63
2-3bSERVICE PROCEDURE
5. Cylinder Block

1. Engine Cooling System
A: SPECIFICATIONS
1. 2200 cc MODEL
Cooling systemElectric fan + Forced engine coolant circulation
system
Total engine coolant capacity
(US qt, Imp qt) Approx. 6.1 (6.4, 5.4)
Engine
coolant
pumpTypeCentrifugal impeller type
Discharge performance IDischarge 20
(5.3 US gal, 4.4 Imp gal)/min.
Pump speed—total engine cool-
ant head760 rpm — 0.3 mAq (1.0 ftAq)
Engine coolant temperature 85°C (185°F)
Discharge performance IIDischarge 100
(26.4 US gal, 22.0 Imp gal)/min.
Pump speed—total engine cool-
ant head3,000 rpm — 5.0 mAq (16.4 ftAq)
Engine coolant temperature 85°C (185°F)
Discharge performance IIIDischarge 200
(52.8 US gal, 44.0 Imp gal)/min.
Pump speed—total engine cool-
ant head6,000 rpm — 23.0 mAq (75.5 ftAq)
Engine coolant temperature 85°C (185°F)
Impeller diameter 76 mm (2.99 in)
Number of impeller vanes 8
Pump pulley diameter 60 mm (2.36 in)
ThermostatTypeWax pellet type
Starts to open 76 — 80°C (169 — 176°F)
Fully opened91°C (196°F)
Valve lift9.0 mm (0.354 in) or more
Valve bore35 mm (1.38 in)
Radiator fanMotor120 W
Fan diameter x Blade 320 mm (12.60 in) x 5
RadiatorTypeCross flow, pressure type
Core dimensions670x361x16mm
(26.38 x 14.21 x 0.63 in)
Pressure range in which cap valve is openAbove: 88±10 kPa
(0.9±0.1 kg/cm
2, 12.8±1.4 psi)
Below: 4.9 to 9.8 kPa
(0.05 to 0.1 kg/cm
2, 0.7 to 1.4 psi)
FinsCorrugated fin type
Reservoir
tankCapacity 0.5
(0.5 US qt, 0.4 Imp qt)
2
2-5SPECIFICATIONS AND SERVICE DATA
1. Engine Cooling System

2. 2500 cc MODEL
Cooling systemElectric fan + Forced engine coolant circulation
system
Total engine coolant capacity
(US qt, Imp qt) Approx. 6.1 (6.4, 5.4)
Engine
coolant
pumpTypeCentrifugal impeller type
Discharge performance IDischarge 20
(5.3 US gal, 4.4 Imp gal)/min.
Pump speed—total engine cool-
ant head760 rpm—0.3 mAq (1.0 ftAq)
Engine coolant temperature 85°C (185°F)
Discharge performance IIDischarge 100
(26.4 US gal, 22.0 Imp gal)/min.
Pump speed—total engine cool-
ant head3,000 rpm—5.0 mAq (16.4 ftAq)
Engine coolant temperature 85°C (185°F)
Discharge performance IIIDischarge 200
(52.8 US gal, 44.0 Imp gal)/min.
Pump speed—total engine cool-
ant head6,000 rpm—23.0 mAq (75.5 ftAq)
Engine coolant temperature 85°C (185°F)
Impeller diameter 76 mm (2.99 in)
Number of impeller vanes 8
Pump pulley diameter 60 mm (2.36 in)
ThermostatTypeWax pellet type
Starts to open 76—80°C (169—176°F)
Fully opened91°C (196°F)
Valve lift9.0 mm (0.354 in) or more
Valve bore35 mm (1.38 in)
Radiator fanMotor120 W (main fan)
140 W (sub fan)
Fan diameter x Blade340 mm (13.39 in) x 5 (main fan)
280 mm (11.02 in) x 4 (sub fan)
RadiatorTypeCross flow, pressure type
Core dimensions670x361x25mm
(26.38 x 14.21 x 0.98 in)
Pressure range in which cap valve is openAbove: 88±10 kPa
(0.9±0.1 kg/cm
2, 12.8±1.4 psi)
Below:4.9 to9.8 kPa
(0.05 to0.1 kg/cm
2,0.7 to1.4 psi)
FinsCorrugated fin type
Reservoir
tankCapacity 0.5
(0.5 US qt, 0.4 Imp qt)
B: SERVICE DATA
Engine
coolant
pumpClearance between impeller and caseStandard
Limit0.5—0.7 mm (0.020—0.028 in)
1.0 mm (0.039 in)
“Thrust”runout of impeller end 0.5 mm (0.020 in)
3
2-5SPECIFICATIONS AND SERVICE DATA
1. Engine Cooling System

1. Brakes
A: SPECIFICATIONS
1. MODELS WITH ABS OR ABS/TCS
Model Sedan Wagon
Engine (cc) 2200 2200
Driving system FWD AWD FWD AWD
L+ L+ LS L+ L+ OUTBACK LS
Front
brakeType Disc (Floating type, ventilated)
Effective disc diameter
mm (in)210 (8.27)
Disc thickness x Outer
diameter
mm (in)24 x 260 (0.94 x 10.24)
Effective cylinder
diameter
mm (in)57.2 (2.252)
Pad dimensions
(length x width x
thickness)
mm (in)112.4 x 44.3 x 11.0 (4.43 x 1.744 x 0.433)
Clearance adjustment Automatic adjustment
Rear
brakeType Disc (Floating type)
Effective disc diameter
mm (in)230 (9.06)
Disc thickness x Outer
diameter
mm (in)10 x 266 (0.39 x 10.47)
Effective cylinder
diameter
mm (in)34.9 (1.374) 38.1 (1.500)
Pad dimensions
(length x width x
thickness)
mm (in)92.4 x 33.7 x 10.0 (3.638 x 1.327 x 0.394)
Clearance adjustment Automatic adjustment
2
4-4SPECIFICATIONS AND SERVICE DATA
1. Brakes

Model 4 Door Sedan Wagon
Engine (cc) 2200 2200
Driving system FWD AWD FWD AWD
L+ L+ LS L+ L+ OUTBACK LS
Hill holder

——

—
Parking
brakeType Mechanical on rear brakes, drum in disc
Effective drum diameter
mm (in)170 (6.69)
Lining dimensions
(length x width x
thickness)
mm (in)162.6 x 30.0 x 3.2 (6.40 x 1.181 x 0.126)
Clearance adjustment Manual adjustment
Master
cylinderType Tandem
Effective diameter
mm (in)26.99 (1-1/16)
Reservoir type Sealed type
Brake fluid reservoir
capacity
cm
3(cu in)190 (11.59)
Brake
boosterType Vacuum suspended
Effective diameter
mm (in)205 + 230 (8.07 + 9.06)
Proportioning
valveSplit point
kPa (kg/cm
2, psi)2,942 (30.0, 427)
Reducing ratio 0.3
Brake line Dual circuit system
ABS—OP STD—OP OP STD
ABS/TCS OP—OP—

: Equipped on manual transmission vehicle. (Except TCS model)
3
4-4SPECIFICATIONS AND SERVICE DATA
1. Brakes

2. MODELS WITHOUT ABS OR ABS/TCS
Model Sedan Wagon
Engine (cc) 2200
Driving system FWD AWD FWD AWD
L, L+ L, L+ L, L+ POST BRIGHTON L, L+ OUTBACK
Front
brakeType Disc (Floating type, ventilated)
Effective disc diameter
mm (in)210 (8.27)
Disc thickness x Outer
diameter
mm (in)24 x 260 (0.94 x 10.24)
Effective cylinder
diameter
mm (in)57.2 (2.252)
Pad dimensions
(length x width x
thickness)
mm (in)112.4 x 44.3 x 11.0 (4.43 x 1.744 x 0.433)
Clearance adjustment Automatic adjustment
Rear
brakeType Drum (Leading-Trailing type)
Effective drum diameter
mm (in)228.6 (9)
Effective cylinder
diameter
mm (in)17.4 (0.685) 19.0 (0.748)
Lining dimensions
(length x width x
thickness)
mm (in)218.8 x 35.0 x 4.1 (8.61 x 1.378 x 0.161)
Clearance adjustment Automatic adjustment
4
4-4SPECIFICATIONS AND SERVICE DATA
1. Brakes

Model Sedan Wagon
Engine (cc) 2200
Driving system FWD AWD FWD AWD
L+ L+ L+ POST BRIGHTON L+ OUTBACK
Hill holder

—— —
—
Parking
brakeType Mechanical on rear brakes, drum in disc
Effective drum diameter
mm (in)228.6 (9)
Lining dimensions
(length x width x
thickness
mm (in)218.8 x 35.0 x 4.1 (8.61 x 1.378 x 0.161)
Clearance adjustment Automatic adjustment
Master
cylinderType Tandem
Effective diameter
mm (in)23.81 (15/16)
Reservoir type Sealed type
Brake fluid reservoir
capacity
cm
3(cu in)190 (11.59)
Brake
boosterType Vacuum suspended
Effective diameter
mm (in)230 (9.06)
Proportioning
valveSplit point
kPa (kg/cm
2, psi)3,678 (37.5, 533)
Reducing ratio 0.3
Brake line Dual circuit system

: Equipped on manual transmission vehicle.
5
4-4SPECIFICATIONS AND SERVICE DATA
1. Brakes

3. 2500 cc AND OUTBACK (STEP ROOF) MODEL
Model Sedan Wagon
Engine (cc) 2500 2200 2500
Driving system AWD
GT LSi GT LSi OUTBACK* OUTBACK*
Front
brakeType Disc (Floating type, ventilated)
Effective disc diameter
mm (in)228 (8.98)
Disc thickness x Outer
diameter
mm (in)24 x 277 (0.94 x 10.91)
Effective cylinder
diameter
mm (in)42.8 (1.687) x 2
Pad dimensions
(length x width x
thickness)
mm (in)112.3 x 50.0 x 11.0 (4.42 x 1.969 x 0.433)
Clearance adjustment Automatic adjustment
Rear
brakeType Disc (Floating type)
Effective disc diameter
mm (in)230 (9.06)
Disc thickness x Outer
diameter
mm (in)10 x 266 (0.39 x 10.47)
Effective cylinder
diameter
mm (in)38.1 (1.500)
Pad dimensions
(length x width x
thickness)
mm (in)92.4 x 33.7 x 10.0 (3.638 x 1.327 x 0.394)
Clearance adjustment Automatic adjustment
*: Step roof model
6
4-4SPECIFICATIONS AND SERVICE DATA
1. Brakes

Model Sedan Wagon
Engine (cc) 2500 2200 2500
Driving system AWD
GT LSi GT LSi OUTBACK* OUTBACK*
Hill holder————STD—
Parking
brakeType Mechanical on rear brakes, drum in disc
Effective drum diameter
mm (in)170 (6.69)
Lining dimensions
(length x width x
thickness)
mm (in)162.6 x 30.0 x 3.2 (6.40 x 1.181 x 0.126)
Clearance adjustment Manual adjustment
Master
cylinderType Tandem
Effective diameter
mm (in)26.99 (1-1/16)
Reservoir type Sealed type
Brake fluid reservoir
capacity
cm
3(cu in)190 (11.59)
Brake
boosterType Vacuum suspended
Effective diameter
mm (in)205 + 230 (8.07 + 9.06)
Propor-
tioning
valveSplit point
kPa (kg/cm
2, psi)3,678 (37.5, 533)
Reducing ratio 0.3
Brake line Dual circuit system
ABSSTD
*: Step roof model
7
4-4SPECIFICATIONS AND SERVICE DATA
1. Brakes