Subaru LEGACY 2001 Service Manual
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Subaru LEGACY 2001 Service Manual

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2001 LEGACY SERVICE MANUAL
SUPPLEMENT FOR 6 CYLINDER
ENGINE MODEL
This service manual has been prepared to provide
SUBARU service personnel with the necessary infor-
mation and data for the correct maintenance and
repair of SUBARU vehicles.
This manual includes the procedures for maintenance,
disassembling, reassembling, inspection and adjust-
ment of components and diagnostics for guidance of
experienced mechanics.
Please peruse and utilize this manual fully to ensure
complete repair work for satisfying our customers by
keeping their vehicle in optimum condition. When
replacement of parts during repair work is needed, be
sure to use SUBARU genuine parts.
All information, illustration and specifications con-
tained in this manual are based on the latest product
information available at the time of publication
approval.
FUJI HEAVY INDUSTRIES LTD.
QUICK REFERENCE INDEX
G2281GE

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  • Page 1 SUPPLEMENT FOR 6 CYLINDER ENGINE MODEL This service manual has been prepared to provide SUBARU service personnel with the necessary infor- mation and data for the correct maintenance and repair of SUBARU vehicles. This manual includes the procedures for maintenance,...
  • Page 2 2001 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX SUPPLEMENT FOR 6 CYLINDER ENGINE MODEL G2281GE...

  • Page 3: Table Of Contents

    REAR SUSPENSION Page General Description..................2 Wheel Alignment ..................8 Rear Stabilizer...................14 Rear Arm ....................15 Link Upper ....................19 Rear Shock Absorber ................21 Link Front ....................25 Link Rear ....................26 Rear Sub Frame..................28 Helper ......................29 General Diagnostic Table ................30...

  • Page 4: General Description

    GENERAL DESCRIPTION Rear Suspension 1. General Description S201001 A: SPECIFICATIONS S201001E49 Item Sedan Wagon OUTBACK Camber (tolerance: ±0°45′) −0°30′ −0°20′ −0°10′ 0±3 mm (0±0.12 in) Toe-in Each toe-in angle: ±0°15′ Wheel arch height 371 mm 381 mm 421 mm +0.47 [tolerance: mm ( in)]...
  • Page 5 GENERAL DESCRIPTION Rear Suspension B: COMPONENT S201001A05 1. REAR SUSPENSION S201001A0501 B4M1782B (1) Shock absorber (15) Hub bearing unit Tightening torque: N·m (kgf-m, ft-lb) (2) Self-locking nut (16) Helper 30 (3.1, 22.4) (3) Stabilizer (17) Link upper 40 (4.1, 30) (4) Stabilizer bushing (18) Link upper bushing (Inside) 44 (4.5, 32.5)
  • Page 6 GENERAL DESCRIPTION Rear Suspension 2. SHOCK ABSORBER S201001A0502 B4M1860A (1) Mount (5) Shock absorber Tightening torque: N·m (kgf-m, ft-lb) (2) Rubber seat upper (6) Self-locking nut 30 (3.1, 22.4) (3) Dust cover 35 (3.6, 26) (4) Coil spring 160 (16.3, 118) RS-4...
  • Page 7 Avoid unnecessary removal, installation, disassembly, and replace- ment. ¼ Use SUBARU genuine grease etc. or the equivalent. Do not mix grease etc. with that of another grade or from other manufacturers. ¼ Be sure to tighten fasteners including bolts and nuts to the specified torque.

  • Page 8: Special Tools

    GENERAL DESCRIPTION Rear Suspension D: PREPARATION TOOL S201001A17 1. SPECIAL TOOLS S201001A1701 ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 927380002 ADAPTER Used as an adapter for camber & caster gauge when measuring camber and caster. (1) 28199AC000 PLATE (2) 28199AC010 BOLT B4M2378A 20099AE000 INSTALLER &...
  • Page 9 GENERAL DESCRIPTION Rear Suspension ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 20099AE040 INSTALLER & Used for replacing rear arm rear bushing. REMOVER B4M2382 20099AE030 HELPER SOCKET Used for replacing helper. WRENCH B4M2383 927760000 STRUT MOUNT Used for disassembling and assembling strut SOCKET and shock mount.

  • Page 10: Wheel Alignment

    WHEEL ALIGNMENT Rear Suspension 2. Wheel Alignment S201116 A: INSPECTION S201116A10 Check, adjust and/or measure wheel alignment in accordance with procedures indicated in figure: B4M1088A RS-8...
  • Page 11 WHEEL ALIGNMENT Rear Suspension 1. WHEEL ARCH HEIGHT S201116A1001 1) Adjust tire pressure to specifications. 2) Set vehicle under “curb weight” conditions. (Empty luggage compartment, install spare tire, jack, ser- vice tools, and top up fuel tank.) 3) Set steering wheel in a wheel-forward position. 4) Suspend thread from wheel arch (point “A”...
  • Page 12 WHEEL ALIGNMENT Rear Suspension 2. CAMBER 3. WHEEL TOE-IN S201116A1002 S201116A1003 ¼ Inspection ¼ Inspection 1) Using a toe-in gauge, measure rear wheel toe- 1) Place front wheel on turning radius gauge. Make sure ground contacting surfaces of front and rear wheels are set at the same height.
  • Page 13 WHEEL ALIGNMENT Rear Suspension NOTE: When left and right wheels are adjusted for toe-in at the same time, the movement of one scale gradua- tion changes toe-in by approximately 3 mm (0.12 in). Left side Right side Rotate counterclock- Toe-in is increased. Rotate clockwise.
  • Page 14 WHEEL ALIGNMENT Rear Suspension 4. THRUST ANGLE 3) When left and right adjusting bolts are turned S201116A1004 incrementally by one graduation in the same ¼ Inspection direction, the thrust angle will change approxi- mately 10′ [“L” is almost equal to 7.5 mm (0.295 1) Position vehicle on a level surface.
  • Page 15 WHEEL ALIGNMENT Rear Suspension Thrust angle: r = (α − β)/2 α: Right rear wheel toe-in angle β: Left rear wheel toe-in angle NOTE: Here, use only positive toe-in values from each wheel to substitute for α and β in the equation. B4M0194B Front Body center line...

  • Page 16: Rear Stabilizer

    REAR STABILIZER Rear Suspension 3. Rear Stabilizer S201118 A: REMOVAL S201118A18 1) Jack-up the rear part of the vehicle, support it with safety stands (rigid racks). 2) Remove bolts which secure stabilizer link to rear arm. B4M1874 3) Remove bolts which secure stabilizer to sub frame.

  • Page 17: Rear Arm

    REAR ARM Rear Suspension 4. Rear Arm 7) Suspend the back plate from sub frame. S201105 A: REMOVAL S201105A18 1) Lift-up the vehicle and remove rear wheel. 2) Remove bearing unit. <Ref. to DS-22 REMOVAL, Hub Unit Bearing.> 3) Remove bolt securing parking brake cable clamp to rear arm.
  • Page 18 REAR ARM Rear Suspension 11) Remove bolt securing rear arm to body. B: INSTALLATION S201105A11 1) Use a transmission jack to support the rear arm. 2) Install rear arm and temporarily tighten bolts securing rear arm to links. 3) Install bearing unit. <Ref.
  • Page 19 REAR ARM Rear Suspension C: DISASSEMBLY D: ASSEMBLY S201105A06 S201105A02 1. FRONT BUSHING 1. FRONT BUSHING S201105A0601 S201105A0201 1) Using ST-A, B, press front bushing out of place. 1) Using ST-A, B, press bushing into trailing link. ST-A, B 20099AE020 INSTALLER & ST-A, B 20099AE020 INSTALLER &...
  • Page 20 REAR ARM Rear Suspension 2. REAR BUSHING E: INSPECTION S201105A0202 S201105A10 1) Using ST-C, D and bearing puller, press bush- Check trailing links for bends, corrosion or dam- ing into trailing link. age. ST-C, D 20099AE040 INSTALLER & REMOVER SET (1) Insert bushing into bore in ST-D.

  • Page 21: Link Upper

    LINK UPPER Rear Suspension 5. Link Upper B: INSTALLATION S201103A11 S201103 Install in the reverse order of removal, observing A: REMOVAL S201103A18 the following instructions. 1) Loosen wheel nuts. Lift-up vehicle and remove CAUTION: wheel. ¼ Using transmission jack, support rear arm 2) Use transmission jack to support rear arm hori- horizontally, install link upper and tighten nuts zontally.
  • Page 22 LINK UPPER Rear Suspension C: DISASSEMBLY D: ASSEMBLY S201103A06 S201103A02 Using ST, press bushing out of place. 1) Using ST, press bushing into place. ST 20099AE010 INSTALLER & REMOVER ST 20099AE010 INSTALLER & REMOVER CAUTION: Outer bushing has a “directional” design. Be sure to install bushing with longer inner hous- ing side facing vehicle rear.

  • Page 23: Rear Shock Absorber

    REAR SHOCK ABSORBER Rear Suspension 6. Rear Shock Absorber 7) Remove nuts securing shock absorber mount S201104 to body. ¼ Wagon A: REMOVAL S201104A18 1) Lift-up vehicle and remove rear wheels. 2) Remove clip and detach floor mat. (Wagon model) B4M1863 ¼...
  • Page 24 REAR SHOCK ABSORBER Rear Suspension B: INSTALLATION C: DISASSEMBLY S201104A11 S201104A06 1) Use a jack to support the shock absorber. For disassembly of shock absorber, refer to proce- dures outlined under front strut as a guide. 2) Tighten self-locking nut used to secure shock <Ref.
  • Page 25 REAR SHOCK ABSORBER Rear Suspension E: INSPECTION S201104A10 1) Refer to Front Strut as a guide for inspection procedures. <Ref. to FS-18 INSPECTION, Front Strut.> 2) If vehicle equipped with self-leveling suspension, check the following. Step Check CHECK WHEEL ARCH HEIGHT. Is B between 411 mm Go to step 2.
  • Page 26 REAR SHOCK ABSORBER Rear Suspension F: DISPOSAL S201104A07 CAUTION: ¼ Completely discharge the gas from the shock absorber before disposal. Follow the disposal procedure outlined below. ¼ Do not disassemble shock absorber or place into a fire. ¼ Drill holes before disposing of shock absorber.

  • Page 27: Link Front

    LINK FRONT Rear Suspension 7. Link Front B: INSTALLATION S201106A11 S201106 Install in the reverse order of removal, observing A: REMOVAL S201106A18 the following instructions. 1) Loosen wheel nuts. Lift-up vehicle and remove CAUTION: wheel. ¼ Using transmission jack, support rear arm 2) Use transmission jack to support rear arm hori- horizontally, install link front and tighten nuts zontally.

  • Page 28: Link Rear

    LINK REAR Rear Suspension 8. Link Rear 5) Use transmission jack to support rear arm hori- S201102 zontally. A: REMOVAL S201102A18 1) Loosen wheel nuts. Lift-up vehicle and remove wheel. 2) Remove bolt securing stabilizer clamps to sub frame. B4M1806B Rear arm Transmission jack 6) Remove bolt securing link rear to rear arm.
  • Page 29 LINK REAR Rear Suspension B: INSTALLATION D: ASSEMBLY S201102A11 S201102A02 Install in the reverse order of removal, observing Using ST, press bushing into place. ST-A, B 20099AE000 INSTALLER & the following instructions. REMOVER CAUTION: ¼ Using transmission jack, support rear arm horizontally, install link rear and tighten nuts to specified torque.

  • Page 30: Rear Sub Frame

    REAR SUB FRAME Rear Suspension 9. Rear Sub Frame B: INSTALLATION S201111A11 S201111 1) Install in reverse order of removal. A: REMOVAL S201111A18 2) For installation and tightening torque of rear dif- 1) Separate front exhaust pipe and rear exhaust ferential.

  • Page 31: Helper

    HELPER Rear Suspension 10. Helper S201539 A: REMOVAL S201539A18 1) Jack-up the rear part of the vehicle, support it with safety stands (rigid racks). 2) Using ST, remove helper. ST 20099AE030 HELPER B4M1867A B: INSTALLATION S201539A11 Install in the reverse order of removal. Tightening torque: 30 N·m (3.1 kgf-m, 22 ft-lb) C: INSPECTION...

  • Page 32: General Diagnostic Table

    GENERAL DIAGNOSTIC TABLE Rear Suspension 11. General Diagnostic Table S201257 A: INSPECTION S201257A10 1. IMPROPER VEHICLE POSTURE OR IMPROPER WHEEL ARCH HEIGHT S201257A1001 Possible causes Countermeasures (1) Permanent distortion or breakage of coil spring Replace. (2) Unsmooth operation of damper strut and/or shock absorber Replace.

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