SUBARU LEGACY 1997 Service Repair Manual

B: INSPECTION
1. BATTERY
1) External parts
Check for the existence of dirt or cracks on the battery
case, top cover, vent plugs, and terminal posts. If
necessary, clean with water and wipe with a dry cloth.
Apply a thin coat of grease on the terminal posts to prevent
corrosion.
2) Electrolyte level
Check the electrolyte level in each cell. If the level is below
MIN LEVEL, bring the level to MAX LEVEL by pouring dis-
tilled water into the battery cell. Do not fill beyond MAX
LEVEL.
WARNING:

Electrolyte has toxicity; be careful handling the
fluid.

Avoid contact with skin, eyes or clothing. Especially
at contact with eyes, blush with water for 15 minutes
and get prompt medical attention.

Batteries produce explosive gasses. Keep sparks,
flame, cigarettes away.

Ventilate when charging or using in enclosed space.

For safety, in case an explosion does occur, wear
eye protection or shield your eyes when working near
any battery. Never lean over a battery.

Do not let battery fluid contact eyes, skin, fabrics, or
paint-work because battery fluid is corrosive acid.

To lessen the risk of sparks, remove rings, metal
watch-bands, and other metal jewelry. Never allow
metal tools to contact the positive battery terminal and
anything connected to it while you are at the same time
in contact with any other metallic portion of the vehicle
because a short circuit will be caused.
5
6-2SERVICE PROCEDURE
2. Battery

G6M0103
3) Specific gravity of electrolyte
Measure specific gravity of electrolyte using a hydrometer
and a thermometer.
Specific gravity varies with temperature of electrolyte so
that it must be corrected at 20°C (68°F) using the follow-
ing equation:
S
20= St + 0.0007 x (t 20)
S
20:Specific gravity corrected at electrolyte tempera-
ture of 20°C (68°F)
St :Measured specific gravity
t :Measured temperature °C
Determine whether or not battery must be charged,
according to corrected specific gravity.
Standard specific gravity: 1.220 — 1.290 [at 20°C
(68°F)]
Measuring the specific gravity of the electrolyte in the bat-
tery will disclose the state of charge of the battery. The
relation between the specific gravity and the state of
charge is as shown in figure.
C: CHARGING
WARNING:

Do not bring an open flame close to the battery at
this time.
CAUTION:

Prior to charging, corroded terminals should be
cleaned with a brush and common baking soda solu-
tion.

Be careful since battery electrolyte overflows while
charging the battery.

Observe instructions when handling battery
charger.

Before charging the battery on vehicle, disconnect
battery ground terminal. Failure to follow this rule may
damage generator’s diodes or other electrical units.
1. NORMAL CHARGING
Charge the battery at current value specified by manufac-
turer or at approximately 1/10 of battery’s ampere hour
rating.
2. QUICK CHARGING
Quick charging is a method in which the battery is charged
in a short period of time with a relatively large current by
using a quick charger.
Since a large current flow raises electrolyte temperature,
the battery is subject to damage if the large current is used
for prolonged time. For this reason, the quick charging
must be carried out within a current range that will not
increase the electrolyte temperature above 40°C (104°F).
It should be also remembered that the quick charging is a
temporary means to bring battery voltage up to a fair value
and, as a rule, a battery should be charged slowly with a
low current.
6
6-2SERVICE PROCEDURE
2. Battery

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
B6M0824A
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
B6M0824A
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.
B6M0825A
3) Look at the beam angle gauge (horizontal movement).
The indicator should not deviate from the center of the
gauge by more than two segments on either side of the
gauge.
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.
9
6-2SERVICE PROCEDURE
4. Headlight

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.
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
10
6-2SERVICE PROCEDURE
4. Headlight

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.
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.
11
6-2SERVICE PROCEDURE
4. Headlight

D: INSPECTION
1. COMBINATION SWITCH (ON-CAR)
1) Remove instrument panel lower cover.
2) Remove lower column cover.
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
12
6-2SERVICE PROCEDURE
4. Headlight