window SUBARU LEGACY 1999 Service Repair Manual

(3) Remove clips of air cleaner upper cover.
(4) Remove air intake duct and air cleaner
upper cover as a unit.
B2M2020
(5) Remove air cleaner element.
(6) Remive air cleaner lower case.
S2M0179
(7) Disconnect spark plug cords from spark
plugs (#1 and #3 cylinders).
B2M2014
(8) Disconnect blow-by hose from rocker
cover (RH).
B2M2015
(9) Lift-up the vehicle.(10) Remove under cover (RH).
(11) Place suitable container under the
vehicle.
(12) Lower the vehicle.
(13) Remove the timing belt cover (RH) bolt.
B2M2016
(14) Remove rocker cover bolts, then
remove rocker cover (RH).
B2M2017
IWhen inspecting #2 and #4 cylinders:
(1) Disconnect battery cables, and then
remove battery and battery carrier.
(2) Disconnect front window washer motor
connector.
(3) Disconnect rear gate glass washer motor
connector. (Wagon only)
S2M0546
9
[W7A1]2-2SERVICE PROCEDURE
7. Valve Clearance

13) Installation is in the reverse order of removal.
CAUTION:
Replace O-rings with new ones.
Tightening torque:
3.4
±0.5 N´m (0.35±0.05 kg-m, 2.5±0.4 ft-lb)
B2M2366
2. LH SIDE OF 2200 cc MODEL
1) Release fuel pressure.
2) Open fuel flap lid, and remove fuel filler cap.
B2M1746
3) Disconnect battery ground cable.
B2M1723
4) Disconnect connector from front window
washer motor.
5) Disconnect connector from rear gate glass
washer motor. (Wagon only)
S2M0546
6) Disconnect rear window glass washer hose
from washer motor, then plug connection with a
suitable cap.
7) Remove two bolts which install washer tank on
body.
B2M2764
8) Move washer tank, and secure it away from
working area.
B2M2023
82
2-7[W14A2]SERVICE PROCEDURE
14. Fuel Injector

1. Engine
A: GENERAL PRECAUTION
(1) Remove or install engine in an area where
chain hoists, lifting devices, etc. are available 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) Set the vehicle on lift arms.
2) Open front hood and support with a stay.
3) Release fuel pressure.
(1) Disconnect fuel tank connector.
G2M0341
(2) Start the engine, and run until it stalls.
(3) After the engine stalls, crank it for five sec-
onds more.
(4) Turn ignition switch to ªOFFº.
4) Disconnect battery cables and remove battery
from vehicle.
G6M0095
5) Remove under cover
B2M0014
6) Drain coolant
Set container under the vehicle, and remove drain
cock from radiator.

B2M0015A
7) Remove cooling system.
(1) Disconnect radiator fan motor connector.
B2M2035A
(A) Main fan motor connector
(B) Sub fan motor connector
7
[W1B0]2-11SERVICE 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

4) Measurement of backlash (Selection of washer)
Measure the gear backlash with ST1 and ST2, and
insert ST2 through the access window of the case.
ST1 498247001 MAGNET BASE
ST2 498247100 DIAL GAUGE
NOTE:
Measure the backlash by applying a pinion tooth
between two bevel gear teeth.
Standard value:
0.13 Ð 0.18 mm (0.0051 Ð 0.0071 in)
G3M0491
5) Using ST, install taper roller bearing.
ST 398487700 DRIFT
G3M0492
20. Transfer Clutch
A: DISASSEMBLY
1) Remove the seal ring.
CAUTION:
Be careful not to damage the seal ring.
G3M0493
2) Using a press and ST, remove the ball bearing.
CAUTION:
Do not reuse the bearing.
ST 498077600 REMOVER
G3M0494
3) Remove the snap ring, and take out the pres-
sure plate, drive plates, and driven plates.
G3M0495
99
[W20A0]3-2SERVICE PROCEDURE
20. Transfer Clutch

4) Measurement of backlash (Selection of washer)
Measure the gear backlash with ST1 and ST2, and
insert ST2 through the access window of the case.
ST1 498247001 MAGNET BASE
ST2 498247100 DIAL GAUGE
NOTE:
Measure the backlash by applying a pinion tooth
between two bevel gear teeth.
Standard value:
0.13 Ð 0.18 mm (0.0051 Ð 0.0071 in)
G3M0491
5) Using ST, install taper roller bearing.
ST 398487700 DRIFT
G3M0492
20. Transfer Clutch
A: DISASSEMBLY
1) Remove the seal ring.
CAUTION:
Be careful not to damage the seal ring.
G3M0493
2) Using a press and ST, remove the ball bearing.
CAUTION:
Do not reuse the bearing.
ST 498077600 REMOVER
G3M0494
3) Remove the snap ring, and take out the pres-
sure plate, drive plates, and driven plates.
G3M0495
99
[W20A0]3-2SERVICE PROCEDURE
20. Transfer Clutch

C: PURGE THE CENTER HOSE
CAUTION:
Be certain that goggles and gloves are worn.
1) Verify that all three hose connections are tight
at the manifold gauge set.
G4M0603
2) Open the valve on the HFC-134a source.
3) Loosen the center hose connection at the mani-
fold and allow the HFC-134a to escape for no more
than two or three seconds, then quickly retighten
the hose fitting at the manifold.
D: INITIAL CHARGING THROUGH
THE HIGH SIDE
1) Connect a tachometer to the engine.
2) With the engine off, start charging by slowly
opening the high-pressure manifold valve.
NOTE:
The initial charge rate can be increased by
immersing the can in lukewarm [Below 38ÉC
(100ÉF)] water for a short time.
G4M0604
E: CHECK THE GAUGE READINGS
When both the high- and low-pressure gauge read-
ings are about equal, or the HFC-134a source is
empty, or the system has been filled to
specifications, close the high- pressure manifold
valve.
G4M0605
F: ADD ADDITIONAL CANS
If the HFC-134a source is exhausted, first close
the high- pressure manifold valve, second, close
the can tap valve, then slowly purge the refrigerant
from the service hose by loosening the fitting at the
can tap.
G: COMPLETE CHARGING
THROUGH THE LOW SIDE
1) Verify that the high-pressure manifold valve is
closed (should have already been closed).
2) Verify that the low-pressure manifold valve is
closed (should have already been closed).
G4M0606
3) With the A/C switch off and the windows rolled
down, start the engine and run at idle rpm.
4) Set the A/C controls on maximum cool and set
the blower speed on the highest setting.
17
[W7G0]4-7SERVICE PROCEDURE
7. Evacuating and Charging

10. Performance Test
A: INSPECTION
1. VEHICLE SET UP
In order to obtain meaningful test results, the
vehicle must be set up to meet the following con-
ditions.
IVehicle in shade
INo wind
IAll vehicle doors closed
IFront windows opened
IHood opened
IEngine speed set at 1,500 rpm.
IA/C ON
ITemperature control lever Ð Maximum cold
IAir source Ð Recirculation
IBlower speed Ð 4th position (High)
IOperate A/C for 10 minutes (Minimum) before
taking measurement.
2. MEASUREMENTS
After 10 minutes (Minimum) of A/C operation and
using accurate test equipment, take the following
measurements (in order).
1) Evaporator intake air temperature at recircula-
tion door.
2) Evaporator discharge air temperature at center
grill.
3) Condenser (Ambient) intake air temperature
measured 0.9 m (3 ft) in front and in line with the
center of the condenser.
4) Suction (Low) side pressure
5) Discharge (High) side pressure
NOTE:
If only one thermometer is available; 1)take the
ambient measurement first; then 2)the intake air;
and 3)discharge air temperature.
22
4-7[W10A1]SERVICE PROCEDURE
10. Performance Test

C: FRONT WINDSHIELD AND REAR WINDOW
B5M0254B
Point to point Dimension Point to point Dimension
(0) to (39) 934 (36.77) (40) RH to (41) RH 700 (27.56)
(0) to (40) RH 1,133 (44.61) (40) LH to (41) LH 700 (27.56)
(0) to (40) LH 1,133 (44.61) (41) RH to (41) LH 1,396 (54.96)
(39) to (41) RH 940 (37.01) (42) to (44) RH 871 (34.29)
(39) to (41) LH 940 (37.01) (42) to (44) LH 871 (34.29)
(40) RH to (40) LH 1,076 (42.36) (42) to (45) 760 (29.92)
(40) RH to (41) LH 1,411 (55.55) (43) RH to (43) LH 986 (38.82)
(41) RH to (40) LH 1,411 (55.55) (44) RH to (44) LH 1,216 (47.87)
Unit: mm (in)
20
5-1[S3C0]SPECIFICATIONS AND SERVICE DATA
3. Datum Dimensions

3. Fixed Glass
B5M0502A
(1) Windshield glass
(2) Dam rubber
(3) Molding(4) Locate pin
(5) Fastener
(6) Garnish(7) Rear window glass
(8) Rear quarter glass
5
[C300]5-2COMPONENT PARTS
3. Fixed Glass