1996 SUBARU LEGACY maintenance

IMPORTANT
SAFETY
NOTICE

Providing
appropriate
service
and
repair
is
a
matter
of
great
importance
in
the
serviceman's
safety

maintenance
and
safe
operation,
function
and
performance
which
the
SUBARU
vehicle
possesses
.

In
case
the
replacement
of
partsor
replenishment
of
consumables
is
required,
genuine
SUBARU
parts

whose
parts
numbers
are
designated
or
their
equivalents
must
be
utilized
.

It
must
be
made
well
known
that
the
safety
of
the
serviceman
and
the
safe
operation
of
thevehicle
would

be
jeopardized
if
heused
any
service
parts,
consumables,
special
tools
and
work
procedure
manuals
which

are
not
approved
or
designated
by
SUBARU
.

How
to
use
this
manual

Service
Manual
is
divided
into
six
volumes
bysection
.
Refer
to
the
Table
of
Contents,
select
anduse
the
nec-

essary
section
.

This
supplement
includes
corrective
and/or
additional
information
in
relationto
the
above
six
service
manual

volumes
.
Please
place
it
in
a
handy
place
for
ready
reference
.

For
informationnot
covered
in
this
supplement,
refer
to
1992
SERVICE
MANUALS
(Pub
.
No
.
G205BE
and
G206BE)

and
1993
SERVICE
MANUAL
(Pub
.
No
.
G210BE)
.

Each
chapter
in
the
manual
is
basically
made
of
the
following
five
types
of
areas
.

M
:
Mechanism
and
function

C
:
Component
parts

W
:
Service
procedure

(X
:
Service
procedure)

(Y
:
Service
procedure)

T
:
Troubleshooting

~
The
description
of
each
area
is
provided
withfour
types
of
titles
different
in
size
as
shown
below
.
The
Title
No
.

or
Symbol
prefixes
each
title
in
order
that
the
construction
ofthe
article
and
theflow
of
explanation
can
be
easily

understood
.

[Example
of
each
title]

"
Area
title
:
W
.
Service
procedure
(one
of
the
five
types
of
areas)

"
Large
title
(Heading)
:
1
.
Oil
Pump
(to
denotethe
main
item
of
explanation)

"
Medium
title
(Section)
:
A
.
REMOVAL
(to
denote
thetype
of
work
in
principle)

"
Small
title
(Sub-section)
:
1
.
INNER
ROTATOR
(to
denote
a
derivative
item
of
explanation)

2

4. FLUID LEAKAGE (LHD MODEL)
CAUTION:
It is likely that although one judges fluid leakage, there
is actually no leakage. This is because the fluid spilt
during the last maintenance was not completely wiped
off. Be sure to wipe off spilt fluid thoroughly after
maintenance.
Leakage from connecting portions of
pipes and hoses, numbered with1thru9in figure
Insufficient tightening of flare nut,
catching dirt or the like, damage to
flare or flare nutLoosen and retighten, if ineffective,
replace.
Poor insertion of hose, poor clamp-
ingRetighten or replace clamp.
Damaged O-ringReplace O-ring pipe or hose with
new one, if ineffective, replace gear-
box also.
Leakage from hose10and11in
figureCrack or damage in hoseReplace with a new one.
Crack or damage in hose hardware
Leakage from surrounding of cast
iron portion of oil pump12and13in
figureDamaged oil sealReplace oil seal.
Damaged oil seal
Leakage from oil tank,14and15in figureCrack in oil tank,14Replace oil tank.
Damaged O-ring,15Replace O-ring.
Leakage from filler neck16Damaged cap packingReplace cap.
Crack in root of filler neckReplace oil tank.
High fluid level *5Adjust fluid level.
Leakage from surrounding of power
cylinder of gearbox,17in figureDamaged oil sealReplace bad parts.
Leakage from control valve of
gearbox,18and19in figureDamaged packing or oil seal
Damage in control valve
*5 Fluid level is specified at optimum position (range) for ordinary use. Accordingly, if the vehicle is used often under hard con-
ditions such as on very rough roads or in mountainous areas, fluid may bleed out from cap air vent hole. This is not a prob-
lem. If a customer complains strongly and is not likely to be satisfied with the leakage, lower the fluid level to the extent that
fluid will not bleed out under the conditions described, and have the customer check the fluid level and its quality more fre-
quency than usual.
90
4-3DIAGNOSTICS
1. Power Steering

5. FLUID LEAKAGE (RHD MODEL)
CAUTION:
It is likely that although one judges fluid leakage, there
is actually no leakage. This is because the fluid spilt
during the last maintenance was not completely wiped
off. Be sure to wipe off spilt fluid thoroughly after
maintenance.
Leakage from connecting portions of
pipes and hoses, numbered with1thru9in figure
Insufficient tightening of flare nut,
catching dirt or the like, damage to
flare or flare nutLoosen and retighten, if ineffective,
replace.
Poor insertion of hose, poor clamp-
ingRetighten or replace clamp.
Damaged O-ringReplace O-ring pipe or hose with
new one, if ineffective, replace gear-
box also.
Leakage from hose10and11in
figureCrack or damage in hoseReplace with a new one.
Crack or damage in hose hardware
Leakage from surrounding of cast
iron portion of oil pump12and13in
figureDamaged oil sealReplace oil seal.
Damaged oil seal
Leakage from oil tank,14and15in figureCrack in oil tank,14Replace oil tank.
Damaged O-ring,15Replace O-ring.
Leakage from filler neck16Damaged cap packingReplace cap.
Crack in root of filler neckReplace oil tank.
High fluid level *5Adjust fluid level.
Leakage from surrounding of power
cylinder of gearbox,17in figureDamaged oil sealReplace bad parts.
Leakage from control valve of
gearbox,18and19in figureDamaged packing or oil seal
Damage in control valve
*5 Fluid level is specified at optimum position (range) for ordinary use. Accordingly, if the vehicle is used often under hard con-
ditions such as on very rough roads or in mountainous areas, fluid may bleed out from cap air vent hole. This is not a prob-
lem. If a customer complains strongly and is not likely to be satisfied with the leakage, lower the fluid level to the extent that
fluid will not bleed out under the conditions described, and have the customer check the fluid level and its quality more fre-
quency than usual.
92
4-3DIAGNOSTICS
1. Power Steering

12. Brake Fluid Replacement
NOTE:
To always maintain the brake fluid characteristics, replace
the brake fluid according to maintenance schedule or ear-
lier than that when used in severe condition.
A: REPLACEMENT
CAUTION:

The FMVSS No. 116, fresh DOT3 or 4 brake fluid
must be used.

Cover bleeder with waste cloth, when loosening it,
to prevent brake fluid from being splashed over sur-
rounding parts.

Avoid mixing different brands of brake fluid to pre-
vent degrading the quality of the fluid.

Be careful not to allow dirt or dust to get into the
reservoir tank.
NOTE:

During bleeding operation, keep the brake reserve tank
filled with brake fluid to eliminate entry of air.

Brake pedal operating must be very slow.

For convenience and safety, it is advisable to have two
man working.

The amount of brake fluid required is approximately 500
m
(16.9 US fl oz, 17.6 Imp fl oz) for total brake system.
1) Either jack-up vehicle and place a safety stand under it,
or lift-up vehicle.
2) Remove both front and rear wheels.
3) Draw out the brake fluid from reserve tank with syringe.
4) Refill reservoir tank with recommended brake fluid.
Recommended brake fluid:
FMVSS No. 116, fresh DOT3 or 4 brake fluid
64
4-4SERVICE PROCEDURE
12. Brake Fluid Replacement

1. Safety Precautions
1. HFC-134a AIR CONDITIONING SYSTEM
Component parts of the cooling system, refrigerant, com-
pressor oil, and other parts are not the same for the HFC-
134a system and the older CFC-12 system. Do not inter-
change parts or liquid.
Vehicles with HFC-134a air conditioning systems, use only
HFC-134a parts that are indicated on a label attached to
the vehicle. Before performing any maintenance, verify the
type of air conditioning system installed in the vehicle.
B4M0780
2. COMPRESSOR OIL
Do not use any compressor oil that is not specifically des-
ignated for the HFC-134a air conditioning system; only use
ZXL200PG. Also, do not use HFC-134a compressor oil in
the CFC-12 air conditioning system. If compression oils are
mixed, poor lubrication will result and the compressor itself
may be damaged.
Because HFC-134a compressor oil is very hygroscopic
(easily absorbs moisture), when parts of the air condition-
ing system are being removed, quickly install a blind plug
to prevent contact with the outside air. Also, always make
sure that the service container for compressor oil is tightly
closed except when in use. Store compressor oil in a tightly
closed steel container.
9
4-7SERVICE PROCEDURE
1. Safety Precautions

Important safety notice

Providing appropriate service and repair is a matter of great importance in the serviceman’s safety maintenance
and safe operation, function and performance which the SUBARU vehicle possesses.

In case the replacement of parts or replenishment of consumables is required, genuine SUBARU parts whose
parts numbers are designated or their equivalents must be utilized.

It must be made well known that the safety of the serviceman and the safe operation of the vehicle would be
jeopardized if the used any service parts, consumables, special tools and work procedure manuals which are
not approved or designated by SUBARU.
All right reserved. This book may not be reproduced
or copied, in whole or in part, without the written
permission of FUJI HEAVY INDUSTRIES LTD.,
TOKYO JAPAN.
SUBARU,
andare trademarks of
FUJI HEAVY INDUSTRIES LTD.
© Copyright 1995 FUJI HEAVY INDUSTRIES LTD.
2

In this manual, the following symbols are used.
*: Selective part

: Replacement part
: Should be lubricated with oil.
: Should be lubricated with grease.
: Sealing point
: Tightening torque

WARNING, CAUTION, NOTE

WARNING: Indicates the item which must be observed precisely during performance of maintenance ser-
vices in order to avoid injury to the mechanics and other persons.

CAUTION: Indicates the item which must be followed precisely during performance of maintenance ser-
vices so as to avoid damage and breakage to the vehicle and its parts and components.

NOTE: Indicates the hints, knacks, etc. which make the maintenance job easier.

SPECIAL TOOLS
When any special tool is required to perform the job, it is identified by“ST”in the applicable illustration and its
part number is shown in the manual.
M1H0120
1. Procedures for adjusting backlash
1) Set steering wheel to the straight-ahead position.
2) Remove the exhaust pipe
3) Loosen the lock nut with ST.

{ST1 921650000 STEERING GEARBOX WRENCH
ST2 921550000 STEERING GEARBOX WRENCH
Description
(of job method)
Shows the part name
Shows the part number
Tells that two kinds of special tools are required.
When two or more kinds of special tools are required to do
a job, they are identified by ST1, ST2,......respectively.


5

Important safety notice

Providing appropriate service and repair is a matter of great importance in the serviceman’s safety maintenance
and safe operation, function and performance which the SUBARU vehicle possesses.

In case the replacement of parts or replenishment of consumables is required, genuine SUBARU parts whose
parts numbers are designated or their equivalents must be utilized.

It must be made well known that the safety of the serviceman and the safe operation of the vehicle would be
jeopardized if the used any service parts, consumables, special tools and work procedure manuals which are
not approved or designated by SUBARU.
All right reserved. This book may not be reproduced
or copied, in whole or in part, without the written
permission of FUJI HEAVY INDUSTRIES LTD.,
TOKYO JAPAN.
SUBARU,
andare trademarks of
FUJI HEAVY INDUSTRIES LTD.
© Copyright 1995 FUJI HEAVY INDUSTRIES LTD.
2