transmission SUBARU LEGACY 1999 Service Repair Manual

1. Engine Cooling System Trouble in General
TroubleCorrective action
Over-heatinga. Insufficient engine coolantReplenish engine coolant, inspect for leakage, and
repair.
b. Loose timing belt Repair or replace timing belt tensioner.
c. Oil on drive belt Replace.
d. Malfunction of thermostat Replace.
e. Malfunction of water pump Replace.
f. Clogged engine coolant passage Clean.
g. Improper ignition timingInspect and repair ignition control system.
On-Board Diagnostics II System
h. Clogged or leaking radiator Clean or repair, or replace.
i. Improper engine oil in engine coolant Replace engine coolant.
j. Air/fuel mixture ratio too leanInspect and repair fuel injection system.
On-Board Diagnostics II System
k. Excessive back pressure in exhaust system Clean or replace.
l. Insufficient clearance between piston and cylinder Adjust or replace.
m. Slipping clutch Repair or replace.
n. Dragging brake Adjust.
o. Improper transmission oil Replace.
p. Defective thermostat Replace.
q. Malfunction of electric fanInspect radiator fan relay, engine coolant temperature
sensor or radiator motor and replace there.
Over-coolinga. Atmospheric temperature extremely low Partly cover radiator front area.
b. Defective thermostat Replace.
Engine coolant
leaks.a. Loosened or damaged connecting units on
hosesRepair or replace.
b. Leakage from water pump Replace.
c. Leakage from water pipe Repair or replace.
d. Leakage around cylinder head gasket Retighten cylinder head bolts or replace gasket.
e. Damaged or cracked cylinder head and crank-
caseRepair or replace.
f. Damaged or cracked thermostat case Repair or replace.
g. Leakage from radiator Repair or replace.
Noisea. Defective drive belt Replace.
b. Defective radiator fan Replace.
c. Defective water pump bearing Replace water pump.
d. Defective water pump mechanical seal Replace water pump.
26
2-5[K100]DIAGNOSTICS
1. Engine Cooling System Trouble in General

18) Disconnect PCV hose (A) and pressure regu-
lator vacuum hose (B) from intake manifold.
19) Disconnect vacuum hose (C) to cruise control
diaphragm. (With cruise control models)
S2M0089A
20) Disconnect engine coolant hose from throttle
body.
B2M2304
21) Disconnect brake booster hose.
B2M2314
22) Remove air intake chamber stay RH, engine
harness bracket from transmission housing, and
disconnect engine harness connectors from bulk-
head harness connectors.
B2M2315
23) Disconnect connectors from engine coolant
temperature sensor (A) and thermometer (B).
B2M0345B
24) Disconnect knock sensor connector.
B2M2327A
25) Disconnect connector from camshaft position
sensor.
B2M2317B
32
2-7[W4A2]SERVICE PROCEDURE
4. Intake Manifold

9) Take out ECM.
B2M0679A
10) Installation is in the reverse order of removal.
16. Main Relay
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
G6M0095
2) Remove lower cover and then disconnect con-
nectors.
B5M0024A
3) Lower transmission control module.
4) Remove the front pillar lower trim.

5) Remove fuse box mounting nuts.
6) Lower fuse box.
7) Remove fuse box mounting bracket.
8) Remove screw which retains bracket of main
relay and fuel pump relay.
B2M1191
87
[W16A0]2-7SERVICE PROCEDURE
16. Main Relay

9) Take out ECM.
B2M0679A
10) Installation is in the reverse order of removal.
16. Main Relay
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
G6M0095
2) Remove lower cover and then disconnect con-
nectors.
B5M0024A
3) Lower transmission control module.
4) Remove the front pillar lower trim.

5) Remove fuse box mounting nuts.
6) Lower fuse box.
7) Remove fuse box mounting bracket.
8) Remove screw which retains bracket of main
relay and fuel pump relay.
B2M1191
87
[W16A0]2-7SERVICE PROCEDURE
16. Main Relay

17. Fuel Pump Relay
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
G6M0095
2) Remove lower cover and then disconnect con-
nectors.
B5M0024A
3) Lower transmission control module.
4) Remove the front pillar lower trim.

5) Remove fuse box mounting nuts.
6) Lower fuse box.
7) Remove fuse box mounting bracket.
8) Remove fuel pump relay (A) from main relay
and fuel pump relay mounting bracket.
B2M1192D
(A) Fuel pump relay
(B) Main relay
9) Disconnect connector from fuel pump relay.
B2M1192D
(A) Fuel pump relay
(B) Main relay
10) Installation is in the reverse order of removal.
88
2-7[W17A0]SERVICE PROCEDURE
17. Fuel Pump Relay

13) Loosen clamp, and disconnect evaporation
hose from canister.
B2M2381A
14) Loosen clamp, disconnect hose from joint
pipe.
B2M2382A
15) Disconnect connector from pressure control
solenoid valve.
B2M1742
16) Disconnect connector from drain valve.
B2M1743
17) Disconnect hoses from roll over valve.
S2M0167
18) Remove bolts which hold parking brake cable
holding bracket.
S2M0191
19) Remove rear differential assembly.
(1) Remove rear axle shafts from rear differen-
tial assembly.
(2) Remove rear differential front cover.
(3) Remove propeller shaft.
(4) Remove lower differential bracket.
(5) Set transmission jack under rear differential.
(6) Remove bolts which install rear differential
onto rear crossmember.

G3M0059
11
[W2A0]2-8SERVICE PROCEDURE
2. Fuel Tank

3. Release Bearing and Lever
A: REMOVAL
1. MECHANICAL APPLICATION TYPE
1) Remove transmission assembly from vehicle
body.

2) Remove release lever return spring (Models
without hill holder only).
3) Remove the two clips from clutch release lever
and remove release bearing.
CAUTION:
Be careful not to deform clips.
4) Remove release lever seal.
B2M0633D
(A) Release lever return spring
(B) Clip
(C) Release lever
(D) Release lever seal
(E) Retainer spring
(F) Clutch release lever
5) Remove release lever retainer spring from
release lever pivot with a screwdriver by accessing
it through clutch housing release lever hole. Then
remove release lever.
B2M0174A
2. HYDRAULIC APPLICATION TYPE
1) Remove transmission assembly from vehicle
body.

2) Remove operating cylinder.

3) Remove the two clips from clutch release lever
and remove release bearing.
CAUTION:
Be careful not to deform clips.
4) Remove release lever seal.
B2M1257G
(A) Operating cylinder
(B) Clip
(C) Clutch release lever
(D) Release bearing
(E) Release lever seal
8
2-10[W3A1]SERVICE PROCEDURE
3. Release Bearing and Lever

5) Remove release lever retainer spring from
release lever pivot with a screwdriver by accessing
it through clutch housing release lever hole. Then
remove release lever.
B2M1258A
B: INSPECTION
1. RELEASE BEARING
CAUTION:
Since this bearing is grease sealed and is of a
nonlubrication type, do not wash with gasoline
or any solvent when servicing the clutch.
1) Check the bearing for smooth movement by
applying force in the radial direction.
Radial direction stroke:
FWD; Approx.
1.0 mm (0.039 in)
AWD; Approx.
1.4 mm (0.055 in)
B2M0173A
2) Check the bearing for smooth rotation by apply-
ing pressure in the thrust direction.
G2M0240
3) Check wear and damage of bearing case sur-
face contacting with lever.
2. RELEASE LEVER
1) Check lever pivot portion and the point of con-
tact with release bearing case for wear.
G2M0241
C: INSTALLATION
CAUTION:
Before or during assembling, lubricate the fol-
lowing points with a light coat of grease.
IInner groove of release bearing
IContact surface of lever and pivot
IContact surface of lever and bearing
ITransmission main shaft spline (Use grease
containing molybdenum disulphide.)
9
[W3C0]2-10SERVICE PROCEDURE
3. Release Bearing and Lever

1. MECHANICAL APPLICATION TYPE
1) While pushing release lever to pivot and twist-
ing it to both sides, fit retainer spring onto the con-
stricted portion of pivot.
NOTE:
Confirm that retainer spring is securely fitted by
observing it through the main case hole.
2) Install release bearing and fasten it with two
clips.
3) Install release lever seal.
B2M0633E
(A) Release lever return spring
(B) Clip
(C) Release lever
(D) Release lever seal
(E) Retainer spring
(F) Release lever bearing
4) After remounting engine and transmission on
body, make adjustment of the clutch release lever
end play.
CAUTION:
Take care not to twist the cable during adjust-
ment.
G2M0235
5) Install release lever return spring (Models with-
out hill holder only).
NOTE:
Hook up the return spring to right side hole of the
release lever.
10
2-10[W3C1]SERVICE PROCEDURE
3. Release Bearing and Lever

2. HYDRAULIC APPLICATION TYPE
1) While pushing release lever to pivot and twist-
ing it to both sides, fit retainer spring onto the con-
stricted portion of pivot.
NOTE:
IApply grease (SUNLIGHT 2: P/N 003602010) to
contact point of release lever and operating cylin-
der.
IConfirm that retainer spring is securely fitted by
observing it through the main case hole.
2) Install release bearing and fasten it with two
clips.
3) Install release lever seal.
4) Install operating cylinder.
Tightening torque:
T: 3 7
±3 N´m (3.8±0.3 kg-m, 27.5±2.2 ft-lb)
B2M1257F
(A) Release lever
(B) Retainer spring
(C) Release bearing
(D) Clip
(E) Release lever seal
(F) Operating cylinder
5) After remounting engine and transmission on
body.

6) Bleed air from oil line with the help of a co-
worker.

4. Clutch Disc and Cover
A: REMOVAL
1) Install ST on flywheel.
ST 498497100C RANKSHAFT STOPPER
G2M0242
2) Remove clutch cover and clutch disc.
CAUTION:
ITake care not to allow oil on the clutch disc
facing.
IDo not disassemble either clutch cover or
clutch disc.
3) Remove flywheel.
G2M0243
11
[W4A0]2-10SERVICE PROCEDURE
4. Clutch Disc and Cover