1999 SUBARU LEGACY length

1. Suspension
A: IMPROPER VEHICLE POSTURE OR IMPROPER WHEEL ARCH HEIGHT
Possible causes Countermeasures
(1) Permanent distortion or breakage of coil spring Replace.
(2) Unsmooth operation of damper strut Replace.
(3) Installation of wrong strut Replace with proper parts.
(4) Installation of wrong coil spring Replace with proper parts.
B: POOR RIDE COMFORT
1) Large rebound shock
2) Rocking of vehicle continues too long after running over bump and/or hump.
3) Large shock in bumping
Possible causes Countermeasures
(1) Breakage of coil spring Replace.
(2) Over-inflation pressure of tire Adjust.
(3) Improper wheel arch height Adjust or replace coil springs with new ones.
(4) Fault in operation of damper strut Replace.
(5) Damage or deformation of strut mount Replace.
(6) Unsuitability of maximum and/or minimum length of
damper strutReplace with proper parts.
(7) Deformation or loss of bushing Replace.
(8) Deformation or damage of helper in strut assembly Replace.
(9) Oil leakage of damper strut Replace.
C: NOISE
Possible causes Countermeasures
(1) Wear or damage of damper strut component parts Replace.
(2) Loosening of suspension link installing bolt and/or nut Retighten to the specified torque.
(3) Deformation or loss of bushing Replace.
(4) Unsuitability of maximum and/or minimum length of
damper strutReplace with proper parts.
(5) Breakage of coil spring Replace.
(6) Wear or damage of ball joint Replace.
(7) Deformation of stabilizer clamp Replace.
40
4-1[K1A0]DIAGNOSTICS
1. Suspension

10. Installation of Wheel
Assembly to Vehicle
1) Attach the wheel to the hub by aligning the
wheel bolt hole with the hub bolt.
2) Temporarily attach the wheel nuts to the hub
bolts. (In the case of aluminum wheel, use
SUBARU genuine wheel nut for aluminum wheel.)
3) Manually tighten the nuts making sure the
wheel hub hole is aligned correctly to the guide
portion of hub.
4) Tighten the wheel nuts in a diagonal selection
to the specified torque. Use a wheel nut wrench.
Wheel nut tightening torque:
88
±10 N´m (9±1 kg-m, 65±7 ft-lb)
CAUTION:
ITighten the wheel nuts in two or three steps
by gradually increasing the torque and working
diagonally, until the specified torque is
reached. For drum brake models, excess tight-
ening of wheel nuts may cause wheels to ªjud-
derº.
IDo not depress the wrench with a foot;
Always use both hands when tightening.
IMake sure the bolt, nut and the nut seating
surface of the wheel are free from oils.
5) If a wheel is removed for replacement or for
repair of a puncture, retighten the wheel nuts to the
specified torque after running 1,000 km (600
miles).
11. Tire Rotation
If tires are maintained at the same positions for a
long period of time, uneven wear results.
Therefore, they should be periodically rotated.
This lengthens service life of tires.
CAUTION:
When rotating tires, replace unevenly worn or
damaged tires with new ones.
G4M0301
41
[W1100]4-2SERVICE PROCEDURE
11. Tire Rotation

10. Installation of Wheel
Assembly to Vehicle
1) Attach the wheel to the hub by aligning the
wheel bolt hole with the hub bolt.
2) Temporarily attach the wheel nuts to the hub
bolts. (In the case of aluminum wheel, use
SUBARU genuine wheel nut for aluminum wheel.)
3) Manually tighten the nuts making sure the
wheel hub hole is aligned correctly to the guide
portion of hub.
4) Tighten the wheel nuts in a diagonal selection
to the specified torque. Use a wheel nut wrench.
Wheel nut tightening torque:
88
±10 N´m (9±1 kg-m, 65±7 ft-lb)
CAUTION:
ITighten the wheel nuts in two or three steps
by gradually increasing the torque and working
diagonally, until the specified torque is
reached. For drum brake models, excess tight-
ening of wheel nuts may cause wheels to ªjud-
derº.
IDo not depress the wrench with a foot;
Always use both hands when tightening.
IMake sure the bolt, nut and the nut seating
surface of the wheel are free from oils.
5) If a wheel is removed for replacement or for
repair of a puncture, retighten the wheel nuts to the
specified torque after running 1,000 km (600
miles).
11. Tire Rotation
If tires are maintained at the same positions for a
long period of time, uneven wear results.
Therefore, they should be periodically rotated.
This lengthens service life of tires.
CAUTION:
When rotating tires, replace unevenly worn or
damaged tires with new ones.
G4M0301
41
[W1100]4-2SERVICE PROCEDURE
11. Tire Rotation

Part name Inspection Corrective action
Steering columnIOverall length of steering column
Measure overall length of steering column.
Standard overall length of steering column:
B4M0129C
Replace steering col-
umn assembly.
2. AIRBAG MODEL INSPECTION
WARNING:
For airbag model inspection procedures, refer
to Supplemental Restraint System. [W200].>
D: ASSEMBLY
1) Insert combination switch to upper column
shaft, and install lower column cover with tilt lever
held in the lowered position. Then route ignition
key harness and combination switch harness
between column cover mounting bosses.
B4M0555
2) Fit upper column cover to lower column cover,
and tighten combination switch and column cover.
Tightening torque:
1.2
±0.2 N´m (0.12±0.02 kg-m, 0.9±0.1 ft-lb)
CAUTION:
Don't overtorque screw.
E: INSTALLATION
1) Insert end of steering shaft into toe board grom-
met.
2) Tighten steering shaft mounting bolts under
instrument panel.
Tightening torque:
25
±5 N´m (2.5±0.5 kg-m, 18.1±3.6 ft-lb)
3) Connect ignition and combination switch con-
nectors under instrument panel.
4) Connect airbag system connector at harness
spool.NOTE:
Make sure to apply double lock.
5) Install universal joint.
(1) Align bolt hole on the long yoke side of uni-
versal joint with the cutout at the serrated sec-
tion of shaft end, and insert universal joint.
(2) Align bolt hole on the short yoke side of
universal joint with the cutout at the serrated
section of gearbox assembly. Lower universal
joint completely.
(3) Temporarily tighten bolt on the short yoke
side. Raise universal joint to make sure the bolt
is properly passing through the cutout at the
serrated section.
(4) Tighten bolt on the long yoke side, then that
on the short yoke side.
Tightening torque:
24
±3 N´m (2.4±0.3 kg-m, 17.4±2.2 ft-lb)
CAUTION:
IMake sure that universal joint bolts is tight-
ened through notch in shaft serration.
IExcessively large tightening torque of uni-
versal joint bolts may lead to heavy steering
wheel operation.
Standard clearance between gearbox to DOJ:
Over 15 mm (0.59 in)
6) Align center of roll connector. (with airbag
model)

CAUTION:
Ensure that front wheels are set in straight-for-
ward direction.
7) Set steering wheel to neutral and install it onto
steering shaft.
Tightening torque:
34
±5 N´m (3.5±0.5 kg-m, 25.3±3.6 ft-lb)
Column cover-to-steering wheel clearance:
2Ð4mm(0.08 Ð 0.16 in)
13
[W2E0]4-3SERVICE PROCEDURE
2. Tilt Steering Column

13) Fix boot end with clip (small).
CAUTION:
Use screwdriver with blunted tip to prevent
boot from damage, when installing.
NOTE:
After installing, check boot end is positioned into
groove on tie-rod.
G4M0125
14) If tie-rod end was removed, screw in lock nut
and tie-rod end to screwed portion of tie-rod, and
tighten lock nut temporarily in a position as shown
in figure.
Installed tie-rod length: L
15 mm (0.59 in)
NOTE:
Pay attention to difference between right and left
tie-rod ends.
G4M0126
15) Inspect gearbox as follows:
A) Holding tie-rod end, repeat lock to lock two or
three times as quickly as possible.
B) Holding tie-rod end, turn it slowly at a radius
one or two times as large as possible.
After all, make sure that boot is installed in the
specified position without deflation.
G4M0127
16) Remove gearbox from ST.
ST 926200000 STAND
17) Install four pipes on gearbox.
(1) Connect pipes A and B to four pipe joints of
gearbox. Connect upper pipe B first, and lower
pipe A.
Tightening torque:
13
±3 N´m (1.3±0.3 kg-m, 9.4±2.2 ft-lb)
(2) Connect pipes C and D to gearbox.
Connect lower pipe C first, and upper pipe D
second.
Tightening torque:
15
±5 N´m (1.5±0.5 kg-m, 10.8±3.6 ft-lb)
G4M0101
E: INSTALLATION
1) Insert gearbox into crossmember, being careful
not to damage gearbox boot.
22
4-3[W3E0]SERVICE PROCEDURE
3. Steering Gearbox (Power Steering System) [LHD model]

1. Power Steering
A: STEERING CONDITION
Trouble Possible cause Corrective action
IHeavy steering effort in all
ranges
IHeavy steering effort at stand
still
ISteering wheel surges when
turning.1. Pulley belt
IUnequal length of pulley belts
IAdhesion of oil and grease
ILoose or damage of pulley belt
IPoor uniformity of pulley belt cross section
IPulley belt touches to pulley bottom
IPoor revolution of pulleys except oil pump pulley
IPoor revolution of oil pump pulleyAdjust or replace.
2. Tire and rim
IImproper tires out of specification
IImproper rims out of specification
ITires not properly inflated*1Replace or reinflate.
3. Fluid
ILow fluid level
IAeration
IDust mix
IDeterioration of fluid
IPoor warming-up of fluid *2Refill, bleed air, replace
or instruct customer.
4. Idling speed
ILower idling speed
IExcessive drop of idling speed at start or at turning steering
wheel *3Adjust or instruct cus-
tomer.
5. Measure hydraulic pressure. Replace problem parts.
6. Measure steering effort. Adjust or replace.
IVehicle leads to one side or the
other.
IPoor return of steering wheel to
center
ISteering wheel surges when
turning.1. Fluid line
IFolded hose
IFlattened pipeReform or replace.
2. Tire and rim
IFlat tire
IMix use of different tires
IMix use of different rims
IAbnormal wear of tire
IUnbalance of remained grooves
IUnbalance of tire pressureFix or replace.
3. Front alignment
IImproper or unbalance caster
IImproper or unbalance toe-in
ILoose connection of suspensionAdjust or retighten.
4. Others
IDamaged joint assembly
IUnbalanced height
IOne-sided weightReplace, adjust or
instruct customer.
5. Measure steering effort. Adjust or replace.
*1 If tires and/or rims are wider, the load to power steering system is the more. Accordingly, in a condition, for example
before fluid warms-up, relief valve may work before maximum turning angle. In this case, steering effort may be heavy.
When measured hydraulic pressure is normal, there is no abnormal thing.
*2 In cold weather, steering effort may be heavy due to increased flow resistance of cold fluid. After warming up engine,
turn steering wheel from stop to stop several times to warm up fluid. Then if steering effort reduces normally, there is no
abnormal thing.
*3 In cold weather or with insufficient warm-up of engine, steering effort may be heavy due to excessive drop of idling
when turning steering wheel. In this case, it is recommended to start the vehicle with increasing engine speed than usual.
Then if steering effort reduces normally, there is no abnormal thing.
69
[K1A0]4-3DIAGNOSTICS
1. Power Steering

Trouble Possible cause Corrective action
Rattling noise (intermittent)
While engine is running.Interference with adjacent parts Check clearance.
Correct if necessary.

Loosened installation of oil pump, oil tank, pump bracket, gear-
box or crossmemberRetighten.
Loosened installation of oil pump pulley or other pulley(s) Retighten.
Loosened linkage or play of steering or suspension
Loosened tightening of joint or steering columnRetighten or replace.
Sound generates from the inside of gearbox or oil pump. Replace the gearbox or oil
pump.
Knocking
When turning steering wheel
in both direction with small
angle repeatedly at engine
ON or OFF.Excessive backlash
Loosened lock nut for adjusting backlashAdjust and retighten.
Loosened tightening or play of tie-rod, tie-rod end Retighten or replace.
Grinding noise (continuous)
While engine is running.Vane pump aeration Inspect and retighten fluid line
connection.
Refill fluid and vent air.
Vane pump seizing Replace oil pump.
Pulley bearing seizing of oil pump Replace oil pump.
Folded hose, flat pipe Replace.
Squeal, squeak (intermittent
or continuous)
While engine is running.Maladjustment of pulley belt
Damaged or charged pulley belt
Unequal length of pulley beltsAdjust or replace.
(Replace two belts as a set.)
Run out or soilage of V-groove surface of oil pump pulley Clean or replace.
Sizzling noise (continuous)
While engine is running.Fluid aeration Fix wrong part causing aera-
tion.
Replace fluid and vent air.
Damaged pipe of gearbox Replace pipe.
Abnormal inside of hose or pipe
Flat hose or pipeRectify or replace.
Abnormal inside of oil tank Replace.
Removed oil tank cap Install cap.
Whistle (continuous)
While engine is running.Abnormal pipe of gearbox or abnormal inside of hose Replace bad parts of gearbox
or hose.
Whine or growl (continuous or
intermittent)
While engine is running with/
without steering turned.Loosened installation of oil pump, oil pump bracket Retighten.
Abnormal inside of oil pump, hose Replace oil pump, hose, if the
noise can be heard when run-
ning as well as stand still.
Torque converter growl air conditioner compression growl Remove power steering pul-
ley belt and confirm.
Creaking noise (intermittent)
While engine is running with
steering turned.Abnormal inside of gearbox Replace bad parts of gear-
box.
Abnormal bearing for steering shaft Apply grease or replace.
Generates when turning steering wheel with brake (service or
parking) applied.If the noise goes off when
brake is released, it is normal.
Vibration
While engine is running with/
without steering turned.Too low engine speed at start Adjust and instruct custom-
ers.
Vane pump aeration Fix wrong part.
Vent air.
Damaged valve in oil pump, gearbox Replace oil pump, bad parts
of gearbox.
Looseness of play of steering, suspension parts Retighten.
75
[K1E0]4-3DIAGNOSTICS
1. Power Steering

1. Brakes
A: SPECIFICATIONS
1. MODELS WITH ABS
Model Sedan Wagon
Engine (cc) 2200 2200
Driving system AWD AWD
LLSLLS
Front brakeType Disc (Floating type, ventilated)
Effective disc diameter mm (in) 210 (8.27)
Disc thickness´Outer diameter
mm (in)24´260 (0.94´10.24)
Effective cylinder diameter mm (in) 57.2 (2.252)
Pad dimensions
(length´width´thickness) mm (in)112.4´44.3´11.0 (4.43´1.744´0.433)
Clearance adjustment Automatic adjustment
Rear brakeType Disc (Floating type)
Effective disc diameter mm (in) 230 (9.06)
Disc thickness´Outer diameter
mm (in)10´266 (0.39´10.47)
Effective cylinder diameter mm (in) 34.9 (1.374) 38.1 (1.500)
Pad dimensions
(length´width´thickness) mm (in)92.4´33.7´10.0 (3.638´1.327´0.394)
Clearance adjustment Automatic adjustment
Model 4 Door Sedan Wagon
Engine (cc) 2200 2200
Driving system AWD AWD
LLSLLS
Hill holderHÐHÐ
Parking brakeType Mechanical on rear brakes, drum in disc
Effective drum diameter mm (in) 170 (6.69)
Lining dimensions
(length´width´thickness) mm (in)162.6´30.0´3.2 (6.40´1.181´0.126)
Clearance adjustment Manual adjustment
Master cylin-
derType Tandem
Effective diameter mm (in) 26.99 (1-1/16)
Reservoir type Sealed type
Brake fluid reservoir capacity
cm
3(cu in)190 (11.59)
Brake boosterType Vacuum suspended
Effective diameter mm (in) 205 + 230 (8.07 + 9.06)
Proportioning
valveSplit point kPa (kg/cm
2, psi) 2,942 (30.0, 427)
Reducing ratio 0.3
Brake lineDual circuit system
ABS OP STD OP STD
H: Equipped on manual transmission vehicle.
2
4-4[S1A1]SPECIFICATIONS AND SERVICE DATA
1. Brakes