SUBARU LEGACY 1997 Service Repair Manual

1Clamp

2Adapter

3Hose bracket

4Pipe C

5Pipe D

6Clamp E

7Cap

8Strainer

9Seal washer

10Tank

11O-ring

12Oil pump

13Pulley

14Bracket

15Bush

16Belt cover

17Universal joint

18Dust cover

19Valve housing

20Y-packing

21Ball bearing

22Spacer

23Pinion

24Shim

25Adapter

26Clamp
27Castle nut

28Cotter pin

29Dust seal

30Clip

31Tie-rod end

32Clip

33Boot

34Wire

35Tie-rod

36Lock washer

37Holder

38Bush

39Y-packing

40Oil seal

41O-ring

42Rack

43Oil seal

44Back-up washer

45Housing ASSY

46Pipe A

47Pipe B

48Lock nut

49Adjusting screw

50Spring

51Sleeve

52Gasket
8
4-3COMPONENT PARTS
2. Power Steering System

3. Power Steering Oil Pump
B4M0123A
1Pulley

2Snap ring

3Bearing

4Oil seal

5Shaft

6Connector

7O-ring

8Spool valve
9Spring

10Front casing

11Rear cover

12Gasket

13Knock pin

14Cam ring

15Vane

16Rotor
17Side plate
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 16±2 (1.6±0.2, 11.6±1.4)
T2: 61±7 (6.2±0.7, 44.8±5.1)
T3: 74±5 (7.5±0.5, 54.2±3.6)
9
4-3COMPONENT PARTS
3. Power Steering Oil Pump

1. Supplemental Restraint System
“Airbag”
Airbag system wiring harness is routed near the steering
wheel, steering shaft and column.
WARNING:

All Airbag system wiring harness and connectors
are colored yellow. Do not use electrical test equip-
ment on these circuit.

Be careful not to damage Airbag system wiring har-
ness when servicing the steering wheel, steering shaft
and column.
2. Tilt Steering Column
B4M0554A
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 24±3 (2.4±0.3, 17.4±2.2)
T2: 25±5 (2.5±0.5, 18.1±3.6)
A: REMOVAL
1) Disconnect battery minus terminal.
2) Lift-up vehicle.
3) Remove airbag module. (with airbag model) 5-5 [W3A1].>
WARNING:
Always refer to“5-5 Supplemental Restraint System”
before performing airbag module service (if so
equipped).
10
4-3SERVICE PROCEDURE
1. Supplemental Restraint System“Airbag”- 2. Tilt Steering Column

1. Supplemental Restraint System
“Airbag”
Airbag system wiring harness is routed near the steering
wheel, steering shaft and column.
WARNING:

All Airbag system wiring harness and connectors
are colored yellow. Do not use electrical test equip-
ment on these circuit.

Be careful not to damage Airbag system wiring har-
ness when servicing the steering wheel, steering shaft
and column.
2. Tilt Steering Column
B4M0554A
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 24±3 (2.4±0.3, 17.4±2.2)
T2: 25±5 (2.5±0.5, 18.1±3.6)
A: REMOVAL
1) Disconnect battery minus terminal.
2) Lift-up vehicle.
3) Remove airbag module. (with airbag model) 5-5 [W3A1].>
WARNING:
Always refer to“5-5 Supplemental Restraint System”
before performing airbag module service (if so
equipped).
10
4-3SERVICE PROCEDURE
1. Supplemental Restraint System“Airbag”- 2. Tilt Steering Column

G5M0332
4) Remove steering wheel nut, then draw out steering
wheel from shaft using steering puller.
G4M0086
5) Remove universal joint bolts and then remove universal
joint.
CAUTION:
Scribe alignment marks on universal joint so that it can
be reassembled at the original serration.
6) Remove trim panel under instrument panel.
7) Disconnect connectors for ignition switch and combina-
tion switch wiring harness under instrument panel.
B4M0127A
8) Remove the two bolts under instrument panel securing
steering shaft.
9) Pull out steering shaft assembly from hole on toe board.
CAUTION:
Be sure to remove universal joint before removing
steering shaft assembly installing bolts when remov-
ing steering shaft assembly or when lowering it for
servicing of other parts.
B4M0555
B: DISASSEMBLY
Remove the four screws securing upper and lower steer-
ing column covers, and the two screws securing combina-
tion switch, then remove related parts.
NOTE:
Steering column assembly can not to be disassembled.
11
4-3SERVICE PROCEDURE
2. Tilt Steering Column

C: INSPECTION
1. BASIC INSPECTION
Clean the disassembled parts with a cloth, and check for
wear, damage, or any other faults. If necessary, repair or
replace faulty parts.
Part name Inspection Corrective action
Universal joint
Free play

Swinging torque

Yawing torque
looseness
G4M0089Standard value of universal joint free play: 0 mm (0 in)
Max. value of universal joint swinging torque:
0.3 N⋅m (0.03 kg-m, 0.2 ft-lb)
Replace if faulty.
Steering column
Overall length of steering column
Measure overall length of steering column.
Standard overall length of steering column:
B4M0129C
Replace steering column
assembly.
12
4-3SERVICE PROCEDURE
2. Tilt Steering Column

B4M0555
D: ASSEMBLY
1) Insert combination switch to upper column shaft, and
install lower column cover with tilt lever held in the lowered
position. Then route ignition key harness and combination
switch harness between column cover mounting bosses.
2) Fit upper column cover to lower column cover, and
tighten combination switch and column cover.
Tightening torque:
1.2±0.2 N⋅m (0.12±0.02 kg-m, 0.9±0.1 ft-lb)
CAUTION:
Don’t overtorque screw.
E: INSTALLATION
1) Insert end of steering shaft into toe board grommet.
2) Tighten steering shaft mounting bolts under instrument
panel.
Tightening torque:
25±5 N⋅m (2.5±0.5 kg-m, 18.1±3.6 ft-lb)
3) Connect ignition and combination switch connectors
under instrument panel.
4) Connect airbag system connector at harness spool.
NOTE:
Make sure to apply double lock.
5) Install universal joint.
(1) Align bolt hole on the long yoke side of universal
joint with the cutout at the serrated section of shaft end,
and insert universal joint.
(2) Align bolt hole on the short yoke side of universal
joint with the cutout at the serrated section of gearbox
assembly. Lower universal joint completely.
(3) Temporarily tighten bolt on the short yoke side.
Raise universal joint to make sure the bolt is properly
passing through the cutout at the serrated section.
(4) Tighten bolt on the long yoke side, then that on the
short yoke side.
Tightening torque:
24±3 N⋅m (2.4±0.3 kg-m, 17.4±2.2 ft-lb)
CAUTION:

Make sure that universal joint bolts is tightened
through notch in shaft serration.

Excessively large tightening torque of universal
joint bolts may lead to heavy steering wheel operation.
Standard clearance between gearbox to DOJ:
Over 15 mm (0.59 in)
13
4-3SERVICE PROCEDURE
2. Tilt Steering Column

G5M0328
6) Align center of roll connector. (with airbag model)

CAUTION:
Ensure that front wheels are set in straight-forward
direction.
7) Set steering wheel to neutral and install it onto steering
shaft.
Tightening torque:
34±5 N⋅m (3.5±0.5 kg-m, 25.3±3.6 ft-lb)
Column cover-to-steering wheel clearance:
2 — 4 mm (0.08 — 0.16 in)
CAUTION:
Insert roll connector guide pin into guide hole on lower
end of surface of steering wheel to prevent damage.
Draw out airbag system connector, horn connector
and cruise control connectors from guide hole of
steering wheel lower end. (with airbag model)
8) Install airbag module to steering wheel. (with airbag
model)
WARNING:
Always refer to 5-5 [W7B1] before performing the ser-
vice operation.
14
4-3SERVICE PROCEDURE
2. Tilt Steering Column

3. Steering Gearbox (Power Steering
System) [LHD model]
NOTE:
For disassembly and assembly of gearbox unit, refer to
section Control Valve (Power Steering Gearbox).
B4M0131A
1Cotter pin

2Castle nut

3Dust cover

4Clip

5Tie-rod end

6Clip

7Boot

8Clip

9Spacer

10Tie-rod

11Lock washer

12Circlip

13Rack stopper

14Oil seal

15Rack bushing
16O-ring

17Rack

18Back-up washer

19Rack housing

20Adapter

21Clamp

22Lock nut

23Adjusting screw

24Spring

25Sleeve

26C-ring

27Ball bearing

28Valve

29Seal ring

30Packing
31Valve housing

32Dust seal

33Universal joint

34Spring washer
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 13±3 (1.3±0.3, 9.4±2.2)
T2: 24±3 (2.4±0.3, 17.4±2.2)
T3: 25±5 (2.5±0.5, 18.1±3.6)
T4: 27.0±2.5
(2.75±0.25, 19.9±1.8)
T5: 39±10 (4.0±1.0, 29±7)
T6: 59±12 (6.0±1.2, 43±9)
T7: 78±10 (8.0±1.0, 58±7)
T8: 83±5 (8.5±0.5, 61.5±3.6)
15
4-3SERVICE PROCEDURE
3. Steering Gearbox (Power Steering System) [LHD model]

A: REMOVAL
1) Disconnect battery minus terminal.
2) Loosen front wheel nut.
3) Lift vehicle and remove front wheels.
4) Remove front exhaust pipe assembly.
WARNING:
Be careful, exhaust pipe is hot.
G4M0097
5) Using a puller, remove tie-rod end from knuckle arm
after pulling off cotter pin and removing castle nut.
G4M0098
6) Remove jack-up plate and front stabilizer.
G4M0099
7) Remove one pipe joint at the center of gearbox, and
connect vinyl hose to pipe and joint. Discharge fluid by
turning steering wheel fully clockwise and counterclock-
wise. Discharge fluid similarly from the other pipe.
G4M0086
8) Remove lower side bolt of universal joint, then remove
upper side bolt and lift the joint upward.
NOTE:
Place a mark on the joint and mating serration so that they
can be re-installed at the original position.
16
4-3SERVICE PROCEDURE
3. Steering Gearbox (Power Steering System) [LHD model]