Subaru 2001 LEGACY User manual

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.
2001 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX
SUPPLEMENT FOR 6 CYLINDER
ENGINE MODEL
G2281GE

2001 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX
SUPPLEMENT FOR 6 CYLINDER
ENGINE MODEL
G2281GE

REAR SUSPENSION
RS
Page
1. General Description.....................................................................................2
2. Wheel Alignment .........................................................................................8
3. Rear Stabilizer...........................................................................................14
4. Rear Arm ...................................................................................................15
5. Link Upper .................................................................................................19
6. Rear Shock Absorber ................................................................................21
7. Link Front ..................................................................................................25
8. Link Rear ...................................................................................................26
9. Rear Sub Frame........................................................................................28
10. Helper........................................................................................................29
11. General Diagnostic Table ..........................................................................30

1. General Description S201001
A: SPECIFICATIONS S201001E49
Item Sedan Wagon OUTBACK
Camber (tolerance: ±0°45′)−0°30′−0°20′−0°10′
Toe-in 0±3mm(0±0.12 in)
Each toe-in angle: ±0°15′
Wheel arch height
[tolerance:
+12
/
−24
mm (
+0.47
/
−0.94
in)]
371 mm
(14.61 in)
381 mm
(15.00 in)
421 mm
(16.57 in)
Thrust angle 0°±30′
Diameter of stabilizer 2.0 L Wagon model 15 mm (0.59 in)
Except 2.0 L Wagon model 14 mm (0.55 in)
NOTE:
쐌Front and rear toe-ins and front camber can be
adjusted. If toe-in or camber tolerance exceeds
specifications, adjust toe-in and camber to the
middle value of specification.
쐌The other items indicated in the specification
table cannot be adjusted. If the other items
exceeds specifications, check suspension parts
and connections for deformities; replace with new
ones as required.
B4M2250C
(1) Front
A−B = Positive: Toe-in, Negative: Toe-out
α1, α2: Each toe-in angle
RS-2
GENERAL DESCRIPTION
Rear Suspension

B: COMPONENT S201001A05
1. REAR SUSPENSION S201001A0501
B4M1782B
(1) Shock absorber
(2) Self-locking nut
(3) Stabilizer
(4) Stabilizer bushing
(5) Clamp
(6) Stabilizer link
(7) Link rear
(8) Adjusting bolt
(9) Link rear bushing
(10) Adjusting washer
(11) Rear arm
(12) Rear arm rear bushing
(13) Rear arm front bushing
(14) Rear arm bracket
(15) Hub bearing unit
(16) Helper
(17) Link upper
(18) Link upper bushing (Inside)
(19) Link upper bushing (Outside)
(20) Link front
(21) Rear sub frame
(22) Support sub frame (RH)
(23) Support sub frame (LH)
(24) Stopper upper (Except OUT-
BACK model)
(25) Stopper upper (OUTBACK
MODEL)
(26) Stopper lower
Tightening torque: N·m (kgf-m, ft-lb)
T1: 30 (3.1, 22.4)
T2: 40 (4.1, 30)
T3: 44 (4.5, 32.5)
T4: 65 (6.6, 48)
T5: 110 (11.2, 81)
T6: 120 (12.2, 88)
T7: 150 (15.3, 111)
T8: 160 (16.3, 118)
T9: 175 (17.8, 129)
RS-3
GENERAL DESCRIPTION Rear Suspension

2. SHOCK ABSORBER S201001A0502
B4M1860A
(1) Mount
(2) Rubber seat upper
(3) Dust cover
(4) Coil spring
(5) Shock absorber
(6) Self-locking nut Tightening torque: N·m (kgf-m, ft-lb)
T1: 30 (3.1, 22.4)
T2: 35 (3.6, 26)
T3: 160 (16.3, 118)
RS-4
GENERAL DESCRIPTION
Rear Suspension

C: CAUTION S201001A03
쐌Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
쐌Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
쐌Keep the disassembled parts in order and pro-
tect them from dust or dirt.
쐌Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary
removal, installation, disassembly, and replace-
ment.
쐌Use SUBARU genuine grease etc. or the
equivalent. Do not mix grease etc. with that of
another grade or from other manufacturers.
쐌Be sure to tighten fasteners including bolts and
nuts to the specified torque.
쐌Place shop jacks or safety stands at the speci-
fied points.
쐌Apply grease onto sliding or revolution surfaces
before installation.
쐌Before installing O-rings or snap rings, apply
sufficient amount of grease to avoid damage and
deformation.
쐌Before securing a part on a vise, place cushion-
ing material such as wood blocks, aluminum plate,
or shop cloth between the part and the vise.
쐌Before disposing shock absorbers, be sure to
bleed gas completely. Also, do not throw away in
fire.
RS-5
GENERAL DESCRIPTION Rear Suspension

D: PREPARATION TOOL S201001A17
1. SPECIAL TOOLS S201001A1701
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
B4M2378A
927380002 ADAPTER Used as an adapter for camber & caster gauge
when measuring camber and caster.
(1) 28199AC000 PLATE
(2) 28199AC010 BOLT
B4M2379
20099AE000 INSTALLER &
REMOVER
Used for replacing link rear bushing.
B4M2380
20099AE010 INSTALLER &
REMOVER
Used for replacing link upper bushing.
B4M2381
20099AE020 INSTALLER &
REMOVER
Used for replacing rear arm front bushing.
RS-6
GENERAL DESCRIPTION
Rear Suspension

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
B4M2382
20099AE040 INSTALLER &
REMOVER
Used for replacing rear arm rear bushing.
B4M2383
20099AE030 HELPER SOCKET
WRENCH
Used for replacing helper.
B4M2384
927760000 STRUT MOUNT
SOCKET
Used for disassembling and assembling strut
and shock mount.
2. GENERAL PURPOSE TOOLS S201001A1702
TOOL NAME REMARKS
Alignment Gauge Used for wheel alignment measurement.
Turning Radius Gauge Used for wheel alignment measurement.
Toe-in Gauge Used for toe-in measurement.
Transmission Jack Used for suspension assembly/disassembly.
Bearing Puller Used for removing bushings.
RS-7
GENERAL DESCRIPTION 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
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”in figure below) to determine a point directly above center
of spindle.
5) Measure distance between measuring point “A”and center of spindle.
B4M1783A
Model Specified wheel arch height
Sedan 371
+12
/
−24
mm (14.61
+0.47
/
−0.94
in)
Wagon 381
+12
/
−24
mm (15.00
+0.47
/
−0.94
in)
OUTBACK 421
+12
/
−24
mm (16.57
+0.47
/
−0.94
in)
RS-9
WHEEL ALIGNMENT Rear Suspension

2. CAMBER S201116A1002
쐌Inspection
1) Place front wheel on turning radius gauge.
Make sure ground contacting surfaces of front and
rear wheels are set at the same height.
2) Set ST into the center of the wheel, and then
install the wheel alignment gauge.
ST 927380002 ADAPTER
B4M0567B
(1) Alignment gauge
(2) Turning radius gauge
NOTE:
Refer to the “SPECIFICATIONS”for the camber
values.
<Ref. to RS-2 SPECIFICATIONS, General
Description.>
쐌Front Camber Adjustment
Refer to “FS”section for front camber adjustment.
<Ref. to FS-6 INSPECTION, Wheel Alignment.>
3. WHEEL TOE-IN S201116A1003
쐌Inspection
1) Using a toe-in gauge, measure rear wheel toe-
in.
Toe-in:
0±3mm(0±0.12 in)
2) Mark rear sides of left and right tires at height
corresponding to center of spindles and measure
distance “A”between marks.
3) Move vehicle forward so that marks line up with
front sides at height corresponding to center of
spindles.
4) Measure distance “B”between left and right
marks. Toe-in can then be obtained by the follow-
ing equation:
A−B = Toe-in
H4M1279B
쐌Adjustment
1) Loosen self-locking nut on inner side of link
rear.
CAUTION:
쐌When loosening or tightening adjusting bolt,
hold bolt head and turn self-locking nut.
쐌Discard loosened self-locking nut and
replace with a new one.
B4M1785B
(1) Adjusting bolt
(2) Link rear
2) Turn adjusting bolt head until toe-in is at the
specification.
RS-10
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
Toe-in is increased.
B4M1786
Rotate clockwise.
B4M1787
Rotate counterclock-
wise.
Toe-in is decreased.
B4M1787
Rotate counterclock-
wise.
B4M1786
Rotate clockwise.
3) Tighten self-locking nut.
Tightening torque:
120 N·m (12.2 kgf-m, 88 ft-lb)
RS-11
WHEEL ALIGNMENT Rear Suspension

4. THRUST ANGLE S201116A1004
쐌Inspection
1) Position vehicle on a level surface.
2) Move vehicle 3 to 4 meters directly forward.
3) Determine locus of both front and rear axles.
4) Measure distance “L”between center line of
loci of the axles.
Thrust angle:
Less than 30 ′when “L”is equal to or
less than 23 mm (0.91 in).
S4M0350B
(1) Center line of loci (front axle)
(2) Center line of loci (rear axle)
쐌Adjustment
1) Make thrust angle adjustments by turning toe-in
adjusting bolts of rear suspension equally in the
same direction.
2) When one rear wheel is adjusted in a toe-in
direction, adjust the other rear wheel equally in
toe-out direction, in order to make thrust angle
adjustment.
3) When left and right adjusting bolts are turned
incrementally by one graduation in the same
direction, the thrust angle will change approxi-
mately 10′[“L”is almost equal to 7.5 mm (0.295
in)].
Thrust angle:
0°±30 ′
S4M0350B
(1) Center line of loci (front axle)
(2) Center line of loci (rear axle)
NOTE:
Thrust angle refers to a mean value of left and right
rear wheel toe angles in relation to vehicle body
center line. Vehicle is driven straight in the thrust
angle direction while swinging in the oblique direc-
tion depending on the degree of the mean thrust
angle.
B4M0193B
(1) Front
(2) Thrust angle
(3) Body center line
RS-12
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 αand βin the equation.
B4M0194B
(1) Front
(2) Body center line
RS-13
WHEEL ALIGNMENT 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.
B4M1851
B: INSTALLATION S201118A11
Install in the reverse order of removal.
Tightening torque:
Stabilizer link to rear arm
44 N·m (4.5 kgf-m, 32.5 ft-lb)
Clamp to sub frame
40 N·m (4.1 kgf-m, 30 ft-lb)
C: INSPECTION S201118A10
1) Check bushing for cracks, fatigue or damage.
2) Check stabilizer links for deformities, cracks, or
damage, and bushing for protrusions from the hole
of stabilizer link.
RS-14
REAR STABILIZER
Rear Suspension

4. Rear Arm 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.
B4M1790
4) Remove bolt securing brake hose to rear arm.
B4M1791
5) Remove bolt securing ABS sensor to rear arm.
B4M1792
6) Using a flare nut wrench, disconnect brake pipe
from wheel cylinder. (Drum brake model only)
CAUTION:
Cover open end of wheel cylinder and pipe to
prevent entry of foreign particles.
7) Suspend the back plate from sub frame.
B4M1793
8) Remove nut securing stabilizer link to rear arm.
B4M1871
9) Remove bolt securing shock absorber to rear
arm.
B4M1794
10) Use transmission jack to support rear arm
horizontally.
B4M1795
RS-15
REAR ARM Rear Suspension

11) Remove bolt securing rear arm to body.
B4M1796
12) Loosen nut securing front rink to rear arm.
B4M1797
13) Loosen nut securing rear link to rear arm.
B4M1798
14) Loosen nut securing upper link to rear arm.
B4M1799
15) Remove bolts securing rear arm to links and
remove rear arm.
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. to DS-24 INSTALLATION, Hub Unit Bear-
ing.>
4) Install bolt securing ABS sensor to rear arm.
5) Install bolt securing brake hose to rear arm.
6) Install bolt securing parking brake cable clamp
to rear arm.
7) Place jack (furnished with vehicle) upside down
and position it between link rear and sub frame.
Adjust jack position so rear shock absorber is
aligned with rear arm at their corresponding holes.
Install lower shock absorber bolts.
CAUTION:
Put a cloth between jack and its mating area to
protect link rear and sub frame from scratches.
B4M1805
8) Using transmission jack, support rear arm hori-
zontally and tighten nuts and bolts securing rear
arm, link front, link rear, link upper and shock
absorber.
B4M1806B
(1) Rear arm
(2) Transmission jack
NOTE:
Check wheel alignment and adjust if necessary.
RS-16
REAR ARM
Rear Suspension

C: DISASSEMBLY S201105A06
1. FRONT BUSHING S201105A0601
1) Using ST-A, B, press front bushing out of place.
ST-A, B 20099AE020 INSTALLER &
REMOVER SET
(1) Set ST-A in position with larger inside diam-
eter side facing up.
(2) Set rear arm with protruded bushing side
facing down.
(3) Place ST-B on upper side of bushing, then
press bushing out of position.
B4M1800A
2. REAR BUSHING S201105A0602
Using ST-C and bearing puller, press rear bushing
out of place.
ST-C 20099AE040 INSTALLER & REMOVER
SET
B4M1801B
(1) Bearing puller
D: ASSEMBLY S201105A02
1. FRONT BUSHING S201105A0201
1) Using ST-A, B, press bushing into trailing link.
ST-A, B 20099AE020 INSTALLER &
REMOVER SET
(1) Set ST-A in position with smaller inside
diameter side facing up.
(2) Set rear arm in position with outer side of
vehicle body facing down.
(3) Place bushing on upper side of rear arm.
(4) Place ST-B on upper side of bushing, then
press bushing into position.
CAUTION:
쐌Install bushing with painted side facing up.
쐌Install front bushing in the proper direction,
as shown in figure.
B4M1803A
B4M1802B
(1) Bushing
RS-17
REAR ARM Rear Suspension

2. REAR BUSHING S201105A0202
1) Using ST-C, D and bearing puller, press bush-
ing into trailing link.
ST-C, D 20099AE040 INSTALLER &
REMOVER SET
(1) Insert bushing into bore in ST-D.
(2) Set ST-C, ST-D and bearing puller in
position, as shown in the figure, and press
bushing into position.
B4M1804B
E: INSPECTION S201105A10
Check trailing links for bends, corrosion or dam-
age.
RS-18
REAR ARM
Rear Suspension