SUBARU LEGACY 1997 Service Repair Manual

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

1. Clutch System
A: SPECIFICATIONS
2200 cc 2500 cc
Clutch cover Diaphragm set load kg (lb) 450 (992) 550 (1,213)
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 1.6
Release bearing Grease-packed self-aligning
B: SERVICE DATA
2200 cc 2500 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
1. MECHANICAL APPLICATION TYPE
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

2. HYDRAULIC APPLICATION TYPE
B2M1009B

1Snap pin


2Clevis pin


3Master cylinder ASSY


4Bracket


5Clutch hose B


6Clutch damper


7Damper bracket


8Clutch hose A


9Operating cylinder

10Clutch release lever sealing


11Retainer spring


12Pivot


13Release lever


14Clip


15Release bearing


16Clutch cover


17Clutch disc


18Flywheel

19Spacer
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 15.7±1.5
(1.6±0.15, 11.6±1.1)
T2: 18±3 (1.8±0.3, 13.0±2.2)
T3: 25±7 (2.5±0.7, 18.1±5.1)
T4: 37±3 (3.8±0.3, 27.5±2.2)
4
2-10COMPONENT PARTS
1. Clutch System

2. Master Cylinder and Reservoir Tank
G2M0976

1Reservoir cap


2Reservoir tank


3Reservoir band


4Seat

5Master cylinder


6Piston


7Push rod


8Piston stop ring
5
2-10COMPONENT PARTS
2. Master Cylinder and Reservoir Tank

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.
B2M1177A
2. HYDRAULIC APPLICATION TYPE
1) Check fluid level using a scale on outside of reservoir
tank. If the level is below“MIN”, add clutch fluid to bring it
up to“MAX”.
Recommended clutch fluid:
FMVSS No. 116, fresh DOT3 or DOT4 brake fluid
CAUTION:
Avoid mixing different brakes of brake fluid to pre-
vent degradation of the fluid.
Be careful not to allow dirt or dust to get into the
reservoir tank.
Use fresh DOT3 or DOT4 brake fluid when refilling
fluid.
2) Make sure that clutch fluid does not leak from master
cylinder, operating cylinder and piping.
3) Apply grease sufficiently to the release lever pinion.
4) Check for proper clutch disengagement and clutch
pedal return ability.
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)
6
2-10SERVICE PROCEDURE
1. General - 2. On-Car Service

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.
B2M1177A
2. HYDRAULIC APPLICATION TYPE
1) Check fluid level using a scale on outside of reservoir
tank. If the level is below“MIN”, add clutch fluid to bring it
up to“MAX”.
Recommended clutch fluid:
FMVSS No. 116, fresh DOT3 or DOT4 brake fluid
CAUTION:
Avoid mixing different brakes of brake fluid to pre-
vent degradation of the fluid.
Be careful not to allow dirt or dust to get into the
reservoir tank.
Use fresh DOT3 or DOT4 brake fluid when refilling
fluid.
2) Make sure that clutch fluid does not leak from master
cylinder, operating cylinder and piping.
3) Apply grease sufficiently to the release lever pinion.
4) Check for proper clutch disengagement and clutch
pedal return ability.
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)
6
2-10SERVICE PROCEDURE
1. General - 2. On-Car Service

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).
G2M0236
4) Depress clutch pedal to assure there is no abnormality
in the clutch system.
G2M0970
2. HYDRAULIC APPLICATION TYPE
Bleed air from oil line with the help of a co-worker.
1) Fit one end of a vinyl tube into the air bleeder of clutch
damper and put the other end into a clutch fluid container.
G2M0971
2) Slowly depress the clutch pedal and keep it depressed.
Then open the air bleeder to discharge air together with the
fluid.
Release the air bleeder for 1 or 2 seconds. Next, with the
bleeder closed, slowly release the clutch pedal.
3) Repeat these steps until there are no more air bubbles
in the vinyl tube.
CAUTION:
Cover bleeder with waste cloth when loosening it, to
prevent clutch fluid from being splashed over sur-
rounding parts.
7
2-10SERVICE PROCEDURE
2. On-Car Service

G2M0972
4) Tighten air bleeder.
Tightening torque:
T: 18±3 N⋅m (1.8±0.3 kg-m, 13.0±2.2 ft-lb)
B2M1178A
5) Remove air chamber.

6) Repeat steps 1) through 3) using air bleeder on oper-
ating cylinder.
B2M1179A
7) Tighten air bleeder.
Tightening torque:
T: 18±3 N⋅m (1.8±0.3 kg-m, 13.0±2.2 ft-lb)
8) After depressing the clutch pedal, make sure that there
are no leaks evident in the entire system.
9) After bleeding air from system, ensure that clutch oper-
ates properly.
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.
8
2-10SERVICE PROCEDURE
2. On-Car Service - 3. Release Bearing and Lever