SUBARU LEGACY 1999 Service Repair Manual

(4) Clutch return spring (Models without hill
holder only)
CAUTION:
After connecting each cable, adjust them.
14) Install chamber stay.
15) Install air intake system.
(1) Install air cleaner element.
(2) Install air intake chamber and air intake duct
with air cleaner upper cover. (Except 2200 cc
California spec. vehicles)
(3) Connect connector to mass air flow sensor.
B2M2018
(4) Install air intake duct with air cleaner case.
(2200 cc California spec. vehicles) [W1A0].> and
16) Install A/C flexible 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)
B2M2774
17) Install cooling system.(1) Attach radiator mounting cushions to body.
B2M0307A
(2) Install radiator while fitting radiator pins to
cushions.
B2M2323
(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)
B2M0320
(4) Connect radiator fan motor connector.
H2M2515
19
[W1C0]2-11SERVICE PROCEDURE
1. Engine

(5) Connect radiator inlet hose.
S2M0031
(6) Connect radiator outlet hose.
(7) Connect ATF cooler hoses. (AT vehicles)
B2M0016A
(8) Install reservoir tank.
(9) Install V-belt cover.
B2M2307
18) Install under cover.
B2M0014
19) Install battery in the vehicle, and connect
cables.
20) Fill coolant.

Engine coolant capacity;
5.8
(6.1 US qt, 5.1 lmp qt)
21) Charge A/C system with refrigerant.

22) Remove front hood stay, and close front hood.
23) Take off the vehicle from lift arms.
20
2-11[W1C0]SERVICE PROCEDURE
1. Engine

2. Transmission
A: GENERAL PRECAUTION
(1) Remove or install transmission in an area
where chain hoists, lifting devices, etc. are avail-
able for ready use.
(2) Be sure not to damage coated surfaces of
body panels with tools or stain seats and windows
with coolant or oil. Place a cover over fenders, as
required, for protection.
(3) Prior to starting work, prepare the following:
Service tools, clean cloth, containers to catch cool-
ant and oil, wire ropes, chain hoist, transmission
jacks, etc.
(4) Lift-up or lower the vehicle when necessary.
Make sure to support the correct positions. to 1-3 [G700].>
B: REMOVAL
1) Open front hood fully, and support with stay.
2) Disconnect battery ground terminal.
3) Remove air intake duct and chamber. (Except
2200 cc California spec. vehicles) [W1A0].>
4) Install air intake duct with air cleaner case.
(2200 cc California spec. vehicles) [W1A0].> and
5) Remove chamber stay.
IMT vehicles
S2M0210
IAT vehicles
S6M0023
6) Disconnect the following connectors.
(1) Oxygen sensor connector
S2M0200A
(1) Front oxygen sensor connector
(2) Rear oxygen sensor connector (California spec.
vehicles)
(2) Transmission harness connector (AT
vehicles)
S2M0212A
(3) Transmission ground terminal
(4) Neutral position switch connector (MT
vehicles)
(5) Back-up light switch connector (MT
vehicles)
B2M0337
21
[W2B0]2-11SERVICE PROCEDURE
2. Transmission

7) Disconnect the following cables.
(1) Clutch return spring (Without hill holder
vehicles)
(2) Clutch cable (2200 cc MT vehicles)
G2M0545
8) Remove starter.
(1) Disconnect connectors and terminal from
starter.
(2) Remove bolt which installs upper side of
starter.
(3) Remove nut which installs lower side of
starter, and remove starter from transmission.
G2M0309
9) Remove pitching stopper.
G2M0295
10) Separate torque converter from drive plate.
(AT vehicles)
(1) Remove service hole plug.(2) Remove bolts which hold torque converter
to drive plate.
S2M0207
(3) While rotating the engine, remove other
bolts using ST.
CAUTION:
Be careful not to drop bolts into torque con-
verter housing.
2200 cc vehicles:
ST 499977300 CRANK PULLEY WRENCH
2500 cc vehicles:
ST 499977100 CRANK PULLEY WRENCH
11) Remove ATF level gauge. (AT vehicles)
CAUTION:
Plug opening to prevent entry of foreign par-
ticles into transmission fluid.
S2M0214
12) Remove operating cylinder. (2500 cc MT
vehicles)
B2M1179B
22
2-11[W2B0]SERVICE PROCEDURE
2. Transmission

13) Set ST.
ST 41099AA020 ENGINE SUPPORT ASSY
NOTE:
Also is available Part No. 927670000.
G2M0313
14) Remove bolt which holds right upper side of
transmission to engine.
B2M2791
15) Remove exhaust system.
(1) Lift-up the vehicle.
(2) Remove under cover.
(3) Disconnect connector from rear oxygen
sensor. (Except California spec. vehicles)
B2M0335
(4) Remove nuts which install front exhaust
pipe onto engine.
G2M0290
(5) Separate rear exhaust pipe from center
exhaust pipe.
B2M0055
(6) Remove bolt which installs center exhaust
pipe to hanger bracket.
S2M0206
(7) Take off front and center exhaust pipes.
23
[W2B0]2-11SERVICE PROCEDURE
2. Transmission

(8) Remove rear exhaust pipe.
CAUTION:
When removing exhaust pipes, be careful each
exhaust pipe does not drop out.
S2M0158
(9) Remove heat shield cover of rear exhaust
pipe.
G2M0830
(10) Remove hanger bracket from right side of
transmission.
B2M0032
16) Drain ATF to remove ATF drain plug. (AT
vehicles)
B3M1036A
17) Disconnect ATF cooler hoses from pipes of
transmission side, and remove ATF level gauge
guide. (AT vehicles)
G2M0317
18) Remove propeller shaft.
(1) Remove front cover of rear differential
mount.
(2) Separate propeller shaft from rear differen-
tial.
G3M0023
24
2-11[W2B0]SERVICE PROCEDURE
2. Transmission

(3) Remove bolts which hold center bearing
onto body.
CAUTION:
Be careful not to drop propeller shaft.
S2M0219
(4) Remove propeller shaft from transmission.
CAUTION:
IBe sure to use an empty container to catch
oil flowing out when removing propeller shaft.
IBe sure not to damage oil seals and the fric-
tional surface of sleeve yoke.
IBe sure to plug the opening in transmission
after removal of propeller shaft.
S2M0220
19) Remove gear shift rod and stay from transmis-
sion. (MT vehicles)
(1) Remove spring.
(2) Disconnect stay from transmission.
(3) Disconnect rod from transmission.
G3M0697
20) Remove shift selector cable. (AT vehicles)
(1) Disconnect shift selector cable from selec-
tor lever.
(2) Remove cable bracket from body.
S3M0013A
21) Remove bolts which install stabilizer clamps
onto crossmember.
G2M0323
22) Remove front drive shafts from transmission.
(1) Remove transverse link from housing.
G2M0324
(2) Lower transverse link.
25
[W2B0]2-11SERVICE PROCEDURE
2. Transmission

(3) Remove spring pins and separate front
drive shafts from each side of the transmission.
CAUTION:
Discard removing spring pin. Replace with a
new one.
G2M0325
23) Remove nuts which hold lower side of trans-
mission to engine.
B2M2790
24) Place transmission jack under transmission.
CAUTION:
IAlways support transmission case with a
transmission jack.
IOn AT vehicles, make sure that the support
plates of transmission jack don't touch the oil
pan.
G2M0326
25) Remove transmission rear crossmember.
IMT vehicles
G2M0831
IAT vehicles
S2M0221
26) Remove transmission.
CAUTION:
IMove transmission jack toward rear until
mainshaft is withdrawn from clutch cover. (MT
vehicles)
IMove transmission and torque converter as
a unit away from engine. (AT vehicles)
B2M0035
26
2-11[W2B0]SERVICE PROCEDURE
2. Transmission

C: INSTALLATION
1) Install ST to torque converter clutch case. (AT
vehicles)
ST 498277200 STOPPER SET
H2M1961A
2) Install transmission to engine.
(1) Gradually raise transmission with transmis-
sion jack.
B2M0035
(2) Engage them at splines.
CAUTION:
Be careful not to strike mainshaft against
clutch cover. (MT vehicles)
3) Install transmission rear crossmember.
IMT vehicles
Tightening torque:
T1: 69
±15 N´m (7.0±1.5 kg-m, 51±11 ft-lb)
T2: 137
±20 N´m (14±2 kg-m, 101±14 ft-lb)
G2M0832
IAT vehicles
Tightening torque:
T1: 37
±10 N´m (3.8±1.0 kg-m, 27±7 ft-lb)
T2: 69
±15 N´m (7.0±1.5 kg-m, 51±11 ft-lb)
S2M0221A
4) Take off transmission jack.
5) Tighten nuts which hold lower side of transmis-
sion to engine.
Tightening torque:
50
±4 N´m (5.1±0.4 kg-m, 36.9±2.9 ft-lb)
B2M2790
6) Tighten bolt which holds upper side of transmis-
sion to engine.
Tightening torque:
50
±4 N´m (5.1±0.4 kg-m, 36.9±2.9 ft-lb)
B2M2791
7) Install torque converter to drive plate. (AT
vehicles)
27
[W2C0]2-11SERVICE PROCEDURE
2. Transmission

(1) Tighten bolts which hold torque converter to
drive plate.
S2M0207
(2) Tighten other bolts while rotating the engine
by using ST.
2200 cc vehicles:
ST 499977300 CRANK PULLEY WRENCH
2500 cc vehicles:
ST 499977100 CRANK PULLEY WRENCH
CAUTION:
Be careful not to drop bolts into torque con-
verter 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.
(4) Remove ST.
ST 498277200 STOPPER SET
8) Install operating cylinder. (2500 cc MT vehicles)
Tightening torque:
37
±3 N´m (3.8±0.3 kg-m, 27.5±2.2 ft-lb)
B2M1179B
9) Remove special tools.
G2M0313
10) Install pitching stopper.
Tightening torque:
T1: 57
±10 N´m (5.8±1.0 kg-m, 42±7 ft-lb)
T2: 49
±5 N´m (5.0±0.5 kg-m, 36.2±3.6 ft-lb)
G2M0302
11) Install front drive shafts into transmission.
(1) Lift-up the vehicle.
(2) Install front drive shaft into transmission.
(3) Drive spring pin into chamfered hole of drive
shaft.
CAUTION:
Always use a new spring pin.
G2M0325
(4) Install ball joints of lower arm into knuckle
arm of housing, and tighten installing bolts.
Tightening torque:
49
±10 N´m (5.0±1.0 kg-m, 36±7 ft-lb)
G2M0324
28
2-11[W2C0]SERVICE PROCEDURE
2. Transmission