1999 SUBARU LEGACY Service Repair Manual

C: INSTALLATION
1) Install engine onto transmission.
(1) Position engine in engine compartment and
align it with transmission.
CAUTION:
Be careful not to damage adjacent parts or
body panels with crank pulley, oil pressure
gauge, etc.
G2M0300
(2) Apply a small amount of grease to spline of
mainshaft.
2) Tighten bolts which hold upper side of transmis-
sion to engine.
Tightening torque:
50
±4 N´m (5.1±0.4 kg-m, 36.9±2.9 ft-lb)
B2M2794
3) Remove lifting device and wire ropes.
G2M0297
4) Remove garage jack.5) Install pitching stopper.
Tightening torque:
T1: 57
±10 N´m (5.8±1.0 kg-m, 42±7 ft-lb)
T2: 49
±5 N´m (5.0±0.5 kg-m, 36.2±3.6 ft-lb)
G2M0302
6) Install torque converter onto drive plate. (AT
vehicles)
(1) Tighten bolts which hold torque converter to
drive plate.
(2) Tighten other bolts while rotating the engine
by using ST.
2200cc vehicles:
ST 499977300 CRANK PULLEY WRENCH
2500cc vehicles:
ST 499977100 CRANK PULLEY WRENCH
CAUTION:
Be careful not to drop bolts into torque con-
verter housing.
Tightening torque:
25
±2 N´m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
S2M0207
(3) Clog plug onto service hole.
17
[W1C0]2-11SERVICE PROCEDURE
1. Engine

7) Install canister and bracket.
(1) Install power stering pump on bracket, and
tighten bolts.
Tightening torque:
39
±10 N´m (4.0±1.0 kg-m, 29±7 ft-lb)
S2M0086
(2) Install power steering pipe bracket on right
side intake manifold, and install spark plug
codes.
B2M2309
(3) Install front side V-belt, and adjust it.

G2M0286
8) Tighten nuts which hold lower side of transmis-
sion to engine.
Tightening torque:
50
±4 N´m (5.1±0.4 kg-m, 36.9±2.9 ft-lb)
B2M2790
9) 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 mount-
ing bolts in the innermost elliptical hole in the
front crossmember.
G2M0303
10) Install front exhaust pipe and center exhaust
pipe.
11) Connect the following hoses.
(1) Fuel delivery hose, return hose and evapo-
ration hose
(2) Heater inlet and outlet hoses
(3) Brake booster vacuum hose
12) Connect the following connectors.
(1) Engine ground terminal
(2) Engine harness connectors
(3) Front oxygen sensor connector
(4) Rear oxygen sensor connector (California
spec. vehicles)
(5) Alternator connector and terminal
(6) A/C compressor connectors (With A/C)
13) Connect the following cables.
(1) Accelerator cable
(2) Cruise control cables (With cruise control)
(3) Clutch cable (2200 cc MT vehicles)
18
2-11[W1C0]SERVICE PROCEDURE
1. Engine

(4) Clutch return spring (Models without hill
holder only)
CAUTION:
After connecting each cable, adjust them.
14) Install chamber stay.
15) Install air intake system.
(1) Install air cleaner element.
(2) Install air intake chamber and air intake duct
with air cleaner upper cover. (Except 2200 cc
California spec. vehicles)
(3) Connect connector to mass air flow sensor.
B2M2018
(4) Install air intake duct with air cleaner case.
(2200 cc California spec. vehicles) [W1A0].> and
16) Install A/C flexible hoses. (With A/C)

CAUTION:
Use new O-rings.
Tightening torque:
25
±7 N´m (2.5±0.7 kg-m, 18.1±5.1 ft-lb)
B2M2774
17) Install cooling system.(1) Attach radiator mounting cushions to body.
B2M0307A
(2) Install radiator while fitting radiator pins to
cushions.
B2M2323
(3) Install radiator brackets and tighten bolts.
Tightening torque:
13.7
±1.5 N´m (1.4±0.15 kg-m, 10.1±1.1
ft-lb)
B2M0320
(4) Connect radiator fan motor connector.
H2M2515
19
[W1C0]2-11SERVICE PROCEDURE
1. Engine

(5) Connect radiator inlet hose.
S2M0031
(6) Connect radiator outlet hose.
(7) Connect ATF cooler hoses. (AT vehicles)
B2M0016A
(8) Install reservoir tank.
(9) Install V-belt cover.
B2M2307
18) Install under cover.
B2M0014
19) Install battery in the vehicle, and connect
cables.
20) Fill coolant.

Engine coolant capacity;
5.8
(6.1 US qt, 5.1 lmp qt)
21) Charge A/C system with refrigerant.

22) Remove front hood stay, and close front hood.
23) Take off the vehicle from lift arms.
20
2-11[W1C0]SERVICE 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

7) Disconnect the following cables.
(1) Clutch return spring (Without hill holder
vehicles)
(2) Clutch cable (2200 cc MT vehicles)
G2M0545
8) Remove starter.
(1) Disconnect connectors and terminal from
starter.
(2) Remove bolt which installs upper side of
starter.
(3) Remove nut which installs lower side of
starter, and remove starter from transmission.
G2M0309
9) Remove pitching stopper.
G2M0295
10) Separate torque converter from drive plate.
(AT vehicles)
(1) Remove service hole plug.(2) Remove bolts which hold torque converter
to drive plate.
S2M0207
(3) While rotating the engine, remove other
bolts using ST.
CAUTION:
Be careful not to drop bolts into torque con-
verter housing.
2200 cc vehicles:
ST 499977300 CRANK PULLEY WRENCH
2500 cc vehicles:
ST 499977100 CRANK PULLEY WRENCH
11) Remove ATF level gauge. (AT vehicles)
CAUTION:
Plug opening to prevent entry of foreign par-
ticles into transmission fluid.
S2M0214
12) Remove operating cylinder. (2500 cc MT
vehicles)
B2M1179B
22
2-11[W2B0]SERVICE PROCEDURE
2. Transmission

13) Set ST.
ST 41099AA020 ENGINE SUPPORT ASSY
NOTE:
Also is available Part No. 927670000.
G2M0313
14) Remove bolt which holds right upper side of
transmission to engine.
B2M2791
15) Remove exhaust system.
(1) Lift-up the vehicle.
(2) Remove under cover.
(3) Disconnect connector from rear oxygen
sensor. (Except California spec. vehicles)
B2M0335
(4) Remove nuts which install front exhaust
pipe onto engine.
G2M0290
(5) Separate rear exhaust pipe from center
exhaust pipe.
B2M0055
(6) Remove bolt which installs center exhaust
pipe to hanger bracket.
S2M0206
(7) Take off front and center exhaust pipes.
23
[W2B0]2-11SERVICE PROCEDURE
2. Transmission

(8) Remove rear exhaust pipe.
CAUTION:
When removing exhaust pipes, be careful each
exhaust pipe does not drop out.
S2M0158
(9) Remove heat shield cover of rear exhaust
pipe.
G2M0830
(10) Remove hanger bracket from right side of
transmission.
B2M0032
16) Drain ATF to remove ATF drain plug. (AT
vehicles)
B3M1036A
17) Disconnect ATF cooler hoses from pipes of
transmission side, and remove ATF level gauge
guide. (AT vehicles)
G2M0317
18) Remove propeller shaft.
(1) Remove front cover of rear differential
mount.
(2) Separate propeller shaft from rear differen-
tial.
G3M0023
24
2-11[W2B0]SERVICE PROCEDURE
2. Transmission