1996 SUBARU LEGACY intake

Condition Possible cause and testing Corrective action
4. Noisy
clutchExamine whether the noise is generated when the clutch is disengaged, engaged, or partially engaged.
(a) Broken, worn or unlubricated release bearing Replace release bearing.
(b) Insufficient lubrication of pilot bearing Apply grease.
(c) Loose clutch disc hub Replace clutch disc.
(d) Loose torsion spring retainer Replace clutch disc.
(e) Deteriorated or broken torsion spring Replace clutch disc.
5. Clutch
grabs.When starting the vehicle with the clutch partially engaged, the clutch engages suddenly and the vehicle jumps
instead of making a smooth start.
(a) Grease or oil on facing Replace clutch disc.
(b) Deteriorated cushioning spring Replace clutch disc.
(c) Worn or rusted spline of clutch disc or mainTake off rust, apply grease or replace clutch shaft disc or
mainshaft.
(d) Deteriorated or broken torsion spring Replace clutch disc.
(e) Loose engine mounting Retighten or replace mounting.
(f ) Deteriorated diaphragm spring Replace.
12
2-10DIAGNOSTICS
1. Clutch System

2. Engine
A: REMOVAL
1. Set the vehicle on lift arms.
2. Open front hood and support with a stay.
3. Release fuel pressure.
4. Disconnect battery cable and remove battery from vehicle.
5. Drain coolant.
6. Remove cooling system.
With A/C
7. Collect refrigerant, and remove pressure hoses.
8. Remove air intake system.
9. Remove canister and bracket.
10. Disconnect connectors, cables and hoses.
11. Remove power steering pump from bracket.
12. Remove front exhaust pipe and center exhaust pipe.
13. Remove nuts which hold lower side of transmission to
engine.
14. Remove nuts which install front cushion rubber onto front
crossmember.
AT model
15. Separate torque converter from drive plate.
16. Remove pitching stopper.
17. Disconnect fuel delivery hose, return hose and evaporation
hoses.
18. Support engine with a lifting device and wire ropes.
19. Support transmission with a garage jack.
20. Remove bolts which hold upper side of transmission to
engine.
21. Remove engine from vehicle.















8
2-11SERVICE PROCEDURE
2. Engine

G2M0270
(3) Disconnect A/C pressure hoses from A/C compres-
sor.
G2M0271
8) Remove air intake system.
(1) Disconnect connector from mass air flow sensor.
(2) Remove air intake duct with air cleaner upper
cover, and remove air cleaner element.
G2M0272
9) Remove canister and bracket.
11
2-11SERVICE PROCEDURE
2. Engine

G2M0286
11) Remove power steering pump from bracket.
(1) Loosen lock bolt and slider bolt, and remove front
side V-belt.
B2M0340
(2) Remove pipe with bracket from intake manifold.
B2M0334
(3) Remove bolts which install power steering pump
from bracket.
B2M0029
(4) Place power steering pump on the right side wheel
apron.
G2M0290
12) Remove front exhaust pipe and center exhaust pipe.
(1) Lift-up the vehicle.
(2) Remove nuts which install front exhaust pipe onto
engine.
16
2-11SERVICE PROCEDURE
2. Engine

B: INSTALLATION
1. Install engine to transmission.
2. Tighten bolts which hold upper side of transmission to engine.
3. Remove lifting device and wire rope.
4. Remove garage jack.
5. Install pitching stopper.
AT model
6. Install torque converter onto drive plate.
7. Install canister and bracket.
8. Install power steering pump on bracket.
9. Tighten nuts which hold lower side of transmission to engine.
10. Tighten nuts which install front cushion rubber onto cross-
member.
11. Install front exhaust pipe and center exhaust pipe.
12. Connect hoses, connectors and cables.
13. Install air intake system.
Air intake duct
Air cleaner element and upper cover.
With A/C
14. Install A/C pressure hoses.
15. Install cooling system.
16. Install battery onto the vehicle, and connect cables.
17. Fill coolant.
18. Check ATF level, and connect if necessary. [AT]
19. Correct power steering oil, and bleed air.
20. Remove front hood stay, and close front hood.
21. Take off the vehicle from lift arms.












20
2-11SERVICE PROCEDURE
2. Engine

B2M0340
(2) Install power steering pipe bracket on right side
intake manifold, and install spark plug codes.
G2M0286
(3) Install front side V-belt, and adjust it.

G2M0292
9) Tighten nuts which hold lower side of transmission to
engine.
Tightening torque:
50±4 N⋅m (5.1±0.4 kg-m, 36.9±2.9 ft-lb)
G2M0303
10) Tighten nuts which install front cushion rubber onto
crossmember.
Tightening torque:
69±15 N⋅m (7.0±1.5 kg-m, 51±11 ft-lb)
CAUTION:
Be sure to tighten front cushion rubber mounting bolts
in the innermost elliptical hole in the front crossmem-
ber.
23
2-11SERVICE PROCEDURE
2. Engine

11) Install front exhaust pipe and center exhaust pipe.
12) Connect hoses, connectors and cables.
(1) Connect the following hoses.
Fuel delivery hose, return hose and evaporation
hose
Heater inlet and outlet hoses
Brake booster vacuum hose
(2) Connect the following connectors.
Engine ground terminal
Engine harness connectors
Front oxygen sensor connector
Rear oxygen sensor connector
Alternator connector and terminal
A/C compressor connectors (With A/C)
(3) Connect the following cables.
Accelerator cable
Cruise control cables (With cruise control)
Clutch cable
Clutch release spring
CAUTION:
After connecting each cable, adjust them.
G2M0271
13) Install air intake system.
(1) Install air cleaner element.
(2) Install air intake duct with air cleaner upper cover.
B2M0030
(3) Connect connector to mass air flow sensor.
24
2-11SERVICE PROCEDURE
2. Engine

3. Transmission
A: REMOVAL
1. Open front hood fully, and support it with stay.
2. Disconnect battery ground terminal.
3. Remove air intake duct.
4. Disconnect connectors and cables.
5. Remove starter.
6. Remove pitching stopper.
AT model
7. Separate torque converter from drive plate.
8. Remove ATF level gauge.
9. Remove transmission connector bracket.
10. Set special tools.
11. Remove bolt which holds right upper side of transmission to
engine.
12. Remove exhaust system.
Front exhaust pipe
Center exhaust pipe
Rear exhaust pipe [AWD]
AT model
13. Drain ATF to remove ATF drain plug.
14. Disconnect ATF cooler hose from pipe on transmission side,
and remove ATF level gauge guide.
AWD model
15. Remove propeller shaft.

A












27
2-11SERVICE PROCEDURE
3. Transmission