1999 SUBARU LEGACY engine

1. Steering System
A: SPECIFICATIONS
Except OUTBACK model OUTBACK model
Whole systemMinimum turning radius m (ft) 5.3 (17.4) 5.6 (18.4)
Steering angle (Inside-Outside) 37.6É Ð 32.6É 34.4É Ð 30.2É
Steering wheel diameter mm (in) 385 (15.16)
Overall gear ratio (Turns, lock to lock) 16.5 (3.2) 19 (3.4)
GearboxType Rack and pinion, Integral
Backlash 0 (Automatically adjustable)
Valve (Power steering system) Rotary valve
Pump
(Power steering sys-
tem)Type Vane pump
Oil tank Installed on pump
Output cm
3(cu in)/rev. 7.2 (0.439)
Relief pressure kPa (kg/cm2, psi) 7,355 (75, 1,067)
Hydraulic fluid control Dropping in response to increased engine revolutions
Hydraulic fluid(US qt, Imp qt)1,000 rpm: 7 (7.4, 6.2)
3,000 rpm: 5 (5.3, 4.4)
Range of revolution rpm 500 Ð 7,500
Revolving direction Clockwise
Working fluid
(Power steering sys-
tem)Name ATF DEXRON II, IIE or III
CapacityOil tank(US qt, Imp qt) 0.35 (0.4, 0.3)
Total 0.7 (0.7, 0.6)
B: SERVICE DATA
Except OUTBACK model OUTBACK model
Steering wheel Free play mm (in) 17 (0.67)
Turning angleInner tire & wheel 37.6É 34.4É
Outer tire & wheel 32.6É 30.2É
Steering shaftClearance between steering wheel and
column cover mm (in)3.0 (0.118)
Steering gearbox
(Power steering sys-
tem)Sliding resistance N (kg, lb) 240.3 (24.5, 54.0) or less
Rack shaft play in
radial direc-
tion mm (in)0.15 (0.0059) or less
Right-turn steering Horizontal movement: 0.3 (0.012) or less
Left-turn steering Vertical movement: 0.15 (0.0059) or less
Input shaft
play mm (in)In radial direction 0.18 (0.0071) or less
In axial direction 0.1 (0.004) or less
Turning resistance N (kg, lb)Within 30 mm (1.18 in) from rack center in straight ahead
position: Less than 11.18 (1.14, 2.51)
Maximum allowable value: 12.7 (1.3, 2.9)
Oil pump
(Power steering sys-
tem)Pulley shaft mm
(in)Radial play 0.4 (0.016) or less
Axial play 0.9 (0.035) or less
PulleyDitch deflec-
tion mm (in)1.0 (0.039) or less
Resistance to rota-
tion N (kg, lb)9.22 (0.94, 2.07) or less
Regular pressure kPa (kg/cm
2, psi) 981 (10, 142) or less
Relief pressure kPa (kg/cm2, psi) 7,355 (75, 1,067)
Steering wheel effort
(Power steering sys-
tem)At standstill with engine idling on a con-
crete road N (kg, lb)31.4 (3.2, 7.1) or less
At standstill with engine stalled on a
concrete road N (kg, lb)147 (15, 33) or less
2
4-3[S1A0]SPECIFICATIONS AND SERVICE DATA
1. Steering System

5. Control Valve (Power Steering Gearbox) [LHD model]
A: CHECKING OIL LEAKING POINTS
B4M1132A
(1) Power cylinder
(2) Cylinder
(3) Rack piston
(4) Rack axle
(5) Input shaft(6) Torsion bar
(7) Valve housing
(8) Valve body
(9) Control valve
(10) Pipe B(11) Pipe A
(12) Pinion
(13) Pinion axle
1. OIL LEAKING POINTS
1) If leak point is other than a, b, c, or d, perform
check step 5) in ªOIL LEAK CHECK PROCEDURE
AND REPLACEMENT PARTSº before dismounting
gearbox from vehicle. If
gearbox is dismounted without confirming where
the leak is, it must be mounted again to locate the
leak point.
2) Even if the location of the leak can be easily
found by observing the leaking condition, it is nec-
essary to thoroughly remove the oil from the sus-
pected portion and turn the steering wheel from
lock to lock about 30 to 40 times with engine
running, then make comparison of the suspected
portion between immediately after and several
hours after this operation.
3) Before starting oil leak repair work, be sure to
clean the gearbox, hoses, pipes, and surrounding
parts. After completing repair work, clean these
areas again.
2. OIL LEAK CHECK PROCEDURE AND
REPLACEMENT PARTS
NOTE:
Parts requiring replacement are described in the
smallest unit of spare parts including damaged
parts and spare parts damaged. In actual disas-sembly work, accidental damage as well as inevi-
table damage to some related parts must be taken
into account, and spare parts for them must also
be prepared. However, it is essential to pinpoint the
cause of trouble, and limit the number of replace-
ment parts as much as possible.
1) Leakage from ªaº
The oil seal is damaged. Replace valve assembly
with a new one.
2) Leakage from ªbº
The torsion bar O-ring is damaged. Replace valve
assembly with a new one.
3) Leakage from ªcº
The oil seal is damaged. Replace valve assembly
with a new one.
4) Leakage from ªdº
The pipe is damaged. Replace the faulty pipe or
O-ring.
5) If leak is other than a, b, c, or d, and if oil is
leaking from the gearbox, move the right and left
boots toward tie-rod end side, respectively, with the
gearbox mounted to the vehicle, and remove oil
from the surrounding portions. Then, turn the steer-
ing wheel from lock to lock 30 to 40 times with the
engine running, then make comparison of the
leaked portion immediately after and several hours
after this operation.
35
[W5A2]4-3SERVICE PROCEDURE
5. Control Valve (Power Steering Gearbox) [LHD model]

6) Leakage from ªeº
The cylinder seal is damaged. Replace rack bush
with a new one.
7) Leakage from ªfº
There are two possible causes. Take following step
first. Remove the pipe assembly B from the valve
housing, and close the circuit with ST.
ST 926420000 PLUG
Turn the steering wheel from lock to lock 30 to 40
times with the engine running, then make compari-
son of the leaked portion between immediately
after and several hours after this operation.
CAUTION:
IIf leakage from ªfº is noted again:
The oil seal of pinion and valve assembly is
damaged. Replace pinion and valve assembly
with a new one. Or replace the oil seal and the
parts that are damaged during disassembly
with new ones.
IIf oil stops leaking from ªfº:
The oil seal of rack housing is damaged.
Replace the oil seal and the parts that are dam-
aged during disassembly with new ones.
B: DISASSEMBLY
NOTE:
This section focuses on the disassembly and reas-
sembly of control valve. For the inspection and
adjustment and the service procedures for associ-
ated parts, refer to ªSteering Gearbox (Power
Steering System) [LHD model]º.

1. VALVE ASSEMBLY
1) Loosen two bolts securing valve assembly.
G4M0137
2) Carefully draw out input shaft and remove valve
assembly.
G4M0138
3) Draw out pinion and valve assembly from valve
housing, as necessary, using pipe of I.D. 44 to 46
mm (1.73 to 1.81 in) and a press.
G4M0139
2. RACK ASSEMBLY
1) Slide mounting rubber to expose slit.
G4M0140
36
4-3[W5B0]SERVICE PROCEDURE
5. Control Valve (Power Steering Gearbox) [LHD model]

6. Control Valve (Power Steering Gearbox) [RHD model]
A: CHECKING OIL LEAKING POINTS
B4M0668A
1. OIL LEAKING POINTS
1) If leak point is other than a, b, c, or d, perform
check step 5) in ªOIL LEAK CHECK PROCEDURE
AND REPLACEMENT PARTSº before dismounting
gearbox from vehicle. If
gearbox is dismounted without confirming where
the leak is, it must be mounted again to locate the
leak point.
2) Even if the location of the leak can be easily
found by observing the leaking condition, it is nec-
essary to thoroughly remove the oil from the sus-
pected portion and turn the steering wheel from
lock to lock about 30 to 40 times with engine
running, then make comparison of the suspected
portion between immediately after and several
hours after this operation.
3) Before starting oil leak repair work, be sure to
clean the gearbox, hoses, pipes, and surrounding
parts. After completing repair work, clean these
areas again.
2. OIL LEAK CHECK PROCEDURE AND
REPLACEMENT PARTS
NOTE:
Parts requiring replacement are described in the
smallest unit of spare parts including damaged
parts and spare parts damaged. In actual disas-
sembly work, accidental damage as well as inevi-
table damage to some related parts must be taken
into account, and spare parts for them must also
be prepared. However, it is essential to pinpoint the
cause of trouble, and limit the number of replace-
ment parts as much as possible.
1) Leakage from ªaº
The oil seal is damaged. Replace valve assembly
with a new one.
2) Leakage from ªbº
The torsion bar O-ring is damaged. Replace valve
assembly with a new one.
3) Leakage from ªcº
The oil seal is damaged. Replace valve assembly
with a new one.
4) Leakage from ªdº
The pipe is damaged. Replace the faulty pipe or
O-ring.
5) If leak is other than a, b, c, or d, and if oil is
leaking from the gearbox, move the right and left
42
4-3[W6A0]SERVICE PROCEDURE
6. Control Valve (Power Steering Gearbox) [RHD model]

boots toward tie-rod end side, respectively, with the
gearbox mounted to the vehicle, and remove oil
from the surrounding portions. Then, turn the steer-
ing wheel from lock to lock 30 to 40 times with the
engine running, then make comparison of the
leaked portion immediately after and several hours
after this operation.
6) Leakage from ªeº
There are two possible causes. Take following step
first. Remove the pipe assembly B from the valve
housing, and close the circuit with ST.
ST 926420000 PLUG
Turn the steering wheel from lock to lock 30 to 40
times with the engine running, then make compari-
son of the leaked portion between immediately
after and several hours after this operation.
CAUTION:
IIf leakage from ªeº is noted again:
The oil seal of pinion and valve assembly is
damaged. Replace pinion and valve assembly
with a new one. Or replace the oil seal and the
parts that are damaged during disassembly
with new ones.
IIf oil stops leaking from ªeº:
The oil seal of rack housing is damaged.
Replace the oil seal and the parts that are dam-
aged during disassembly with new ones.
B: DISASSEMBLY
NOTE:
This section focuses on the disassembly and reas-
sembly of control valve. For the inspection and
adjustment and the service procedures for associ-
ated parts, refer to ªSteering Gearbox (Power
Steering System) [RHD model]º. [W400].>
1. VALVE ASSEMBLY
1) Slide dust cover out.
CAUTION:
IBe careful not to scratch housing or input
shaft during dust cover removal. Also do not
allow foreign matter to enter housing interior.
IReplace dust cover with a new one if its
inside bore or lips are worn or damaged.
G4M0817
2) Remove the two bolts securing valve housing.
G4M0818
3) Remove valve housing, pinion and valve as a
unit.
G4M0819
2. RACK ASSEMBLY
1) Remove holder using a 32 mm (1.26 in) wrench
or adjustable wrench.
CAUTION:
Discard old holder and replace with new one.
G4M0820
43
[W6B2]4-3SERVICE PROCEDURE
6. Control Valve (Power Steering Gearbox) [RHD model]

9) Connect pipes A and B to four pipe joints of
gearbox. Connect upper pipe B first, and lower
pipe A second.
Tightening torque:
13
±3 N´m (1.3±0.3 kg-m, 9.4±2.2 ft-lb)
G4M0099
10) Install jack-up plate.
11) Connect battery minus terminal.
12) Feed the specified fluid and discharge air.
NOTE:
Never start the engine before feeding the fluid; oth-
erwise vane pump might be seized up.
B4M1137A
13) Finally check clearance between pipes and/or
hoses, as shown above.
If clearance between cruise control pump and
power steering hose is less than 10 mm (0.39 in),
proceed as follows:
(1) Move clamped section (A) (refer to figure
above.) down to a point where pipe is close to
crossmember.
Pipe-to-crossmember clearance:
10 mm (0.39 in), min.
(2) Check that clearance between cruise con-
trol pump and power steering hose is at least 10
mm (0.39 in). If it is not, bend section (B) down
until a clearance of at least 10 mm (0.39 in) is
obtained.
56
4-3[W7C1]SERVICE PROCEDURE
7. Pipe Assembly (Power Steering System)

12) Feed the specified fluid and discharge air.
NOTE:
Never start the engine before feeding the fluid; otherwise vane pump might be seized up.
B4M0674A
58
4-3[W7C2]SERVICE PROCEDURE
7. Pipe Assembly (Power Steering System)

8. Oil Pump (Power Steering
System)
A: REMOVAL
1) Remove ground cable from battery.
2) Drain the working fluid about 0.35(0.4 US qt,
0.3 Imp qt) from oil tank.
B4M1160
3) Remove pulley belt cover bracket.
4) Loosen oil pump pulley nut, then remove bolts
which secure alternator.
B4M1161A
5) Loosen pulley belt(s).
6) Remove the nut and detach oil pump pulley.7) Remove bolt A. Disconnect pipe C from oil
pump. Disconnect pipe D from oil tank.
CAUTION:
IDo not allow fluid from the hose end to come
into contact with pulley belt.
ITo prevent foreign matter from entering the
hose and pipe, cover the open ends of them
with a clean cloth.
IExcept when only oil tank needs to be
inspected, detach oil tank and oil pump as a
unit. Then separate one from the other on a
work bench to prevent oil from spilling on any
part of the engine.
B4M1159A
8) Remove three bolts from the front side of oil
pump and detach the pump.
B4M0560
9) Remove three bolts from the lower side of
bracket and detach the bracket.
CAUTION:
The bracket does not need to be removed
unless it is damaged.
59
[W8A0]4-3SERVICE PROCEDURE
8. Oil Pump (Power Steering System)