SUBARU LEGACY 1996 Service Repair Manual

G2M0084
1) Install baffle plate.
2) Install oil strainer and O-ring
3) Install oil strainer stay.
4) Apply fluid packing to matching surfaces and install oil
pan.
Fluid packing:
THREE BOND 1207C or equivalent
G2M0194
5) Apply fluid packing to matching surfaces and install oil
separator cover.
Fluid packing:
THREE BOND 1215 or equivalent
B2M0706A
6) Install drive plate.
To lock crankshaft, use ST.
ST 498497100 CRANKSHAFT STOPPER
7) Install housing cover.
G2M0076
8) Installation of oil pump
(1) Discard front oil seal after removal. Replace with a
new one by using ST.
ST 499587100 OIL SEAL INSTALLER
73
2-3bSERVICE PROCEDURE
5. Cylinder Block

B2M0390A
(2) Apply fluid packing to matching surface of oil pump.
Fluid packing:
THREE BOND 1215 or equivalent
(3) Install oil pump on cylinder block. Be careful not to
damage oil seal during installation.
CAUTION:
Do not forget to install O-ring and seal when install-
ing oil pump.
Align flat surface of oil pump’s inner rotor with
crankshaft before installation.
G2M0628
9) Install engine coolant pump and gasket.
CAUTION:
Be sure to use a new gasket.
When installing engine coolant pump, tighten bolts
in two stages in numerical sequence as shown in Fig-
ure.
10) Install engine coolant pipe.
11) Install oil filter.
2. RELATED PARTS
1) Install cylinder heads.
<Ref. to 2-3b [W4E0].>
2) Install camshafts, rocker cover and related parts.
<Ref. to 2-3b [W3C0].>
3) Install camshaft sprockets, timing belt and related parts.
<Ref. to 2-3b [W2C0].>
74
2-3bSERVICE PROCEDURE
5. Cylinder Block

1. Engine Trouble in General
Numbers shown in the chart refer to the possibility of reason for the
trouble in order (“Very often”to“Rarely”)
1—Very often
2—Sometimes
3—Rarely
TROUBLE
Engine will not start.
Rough idle and engine stall
Low output, hesitation and poor acceleration
Surging
Engine does not return to idle.
Dieseling (Run-on)
After burning in exhaust system
Knocking
Excessive engine oil consumption
Excessive fuel consumption Starter does not turn.
Initial combustion does not occur.
Initial combustion occurs.
Engine stalls after initial combustion.
POSSIBLE CAUSE
STARTER
2Defective battery-to-starter harness
3Defective starter switch
3Defective inhibitor switch
23Defective starter
BATTERY
1Poor terminal connection
1Run-down battery
2Defective charging system
1111111111 1Fuel injection system <Ref. to 2-7 On-Board
Diagnostics II System.>
75
2-3bDIAGNOSTICS
1. Engine Trouble in General

TROUBLE
Engine will not start.
Rough idle and engine stall
Low output, hesitation and poor acceleration
Surging
Engine does not return to idle.
Dieseling (Run-on)
After burning in exhaust system
Knocking
Excessive engine oil consumption
Excessive fuel consumption Starter does not turn.
Initial combustion does not occur.
Initial combustion occurs.
Engine stalls after initial combustion.
INTAKE SYSTEM
2111 3Loosened or cracked intake air pipe
3111 3 1Loosened or cracked blow-by hose
31211 2Loosened or cracked vacuum hose
22222Defective intake manifold gasket
22222Defective throttle body gasket
322 2 2Defective PCV valve
222 323Loosened oil filler cap
3312 1Dirty air cleaner element
FUEL LINE
13 322Defective fuel pump and relay
33322Clogged fuel line
222233Lack of or insufficient fuel
BELT
222Defective
222322 22 2Defective timing
FRICTION
3Seizure of crankshaft and connecting rod bearing
3Seized camshaft
3Seized or stuck piston and cylinder
COMPRESSION
333222 23 2Defective hydraulic lash adjuster
333223 3 3Loosened spark plugs or defective gasket
333223 3 3Loosened cylinder head bolts or defective gasket
333223 2 2Improper valve seating
333333 3 13Defective valve stem
222223 3 3Worn or broken valve spring
333233 3 12Worn or stuck piston rings, cylinder and piston
222111 12 2Incorrect valve timing
222222Improper engine oil (low viscosity)
76
2-3bDIAGNOSTICS
1. Engine Trouble in General

TROUBLE
Engine will not start.
Rough idle and engine stall
Low output, hesitation and poor acceleration
Surging
Engine does not return to idle.
Dieseling (Run-on)
After burning in exhaust system
Knocking
Excessive engine oil consumption
Excessive fuel consumption Starter does not turn.
Initial combustion does not occur.
Initial combustion occurs.
Engine stalls after initial combustion.
LUBRICATION SYSTEM
22 3 3Incorrect oil pressure
2Loosened oil pump attaching bolts and defective
gasket
2Defective oil filter seal
2Defective crankshaft oil seal
32Defective rocker cover gasket
2Loosened oil drain plug or defective gasket
2Loosened oil pan fitting bolts or defective oil pan
COOLING SYSTEM
33221Overheating
333Over cooling
OTHERS
113 3Malfunction of Evaporative Emission Control
System
21Stuck or damaged throttle valve
322 2Accelerator cable out of adjustment
77
2-3bDIAGNOSTICS
1. Engine Trouble in General

2. Engine Noise
Valve lash adjusters may make clicking noise once engine
starts. It is normal if clicking noise ceases after a few min-
utes.
If clicking noise continues for more than a few minutes,
inspect Hydraulic Lash Adjuster (HLA) in accordance with
the following flow chart.
Inspect the engine oil level
(1) Adjust the oil level between“F”and“L”.
(2) Replace the oil when deteriorated.
Load less engine operation to bleed air from
HLA.
(1) Warm-up engine for about five minutes.
(2) If the noise is remaining, keep the engine
running at 2,000 rpm for up to 20 minutes until
the noise fades away.Noise is eliminated.
Keep the engine running at 2,500 rpm for about
five minutes to bleed air completely.
Noise remains or comes
back.END
HLA is rigid and has no valve clearance.
Remove the rocker cover and inspect HLA.
Press HLA while it is facing the base circle of
the cam.
HLA is normal. The noise may come from other
sources.
HLA is not rigid.
There is valve clearance.
Check whether the clearance between HLA and
the bushing of the cylinder head is within
allowance or not.
HLA is seized. Replace HLA.
Out of allowance
Replace the cylinder head related parts or the
HLA, whichever is necessary.
Within allowance
Replace HLA.






78
2-3bDIAGNOSTICS
2. Engine Noise

If noise still exists, conduct diagnostics procedures in
accordance with the following table.
CAUTION:
Do not disconnect spark plug cord while engine is run-
ning.
Type of sound Condition Possible cause
Regular clicking soundSound increases as engine
speed increases.Valve mechanism is defective.
Broken lash adjuster
Worn camshaft
Broken valve spring
Worn valve lifter hole
Heavy and dull clankOil pressure is low.Worn crankshaft main bearing
Worn connecting rod bearing (big end)
Oil pressure is normal.Loose flywheel mounting bolts
Damaged engine mounting
High-pitched clank
(Spark knock)Sound is noticeable when
accelerating with an overload.Ignition timing advanced
Accumulation of carbon inside combustion chamber
Wrong spark plug
Improper gasoline
Clank when engine speed is
medium (1,000 to 2,000 rpm).Sound is reduced when fuel
injector connector of noisy
cylinder is disconnected.
(NOTE*)Worn crankshaft main bearing
Worn bearing at crankshaft end of connecting rod
Knocking sound when engine
is operating under idling speed
and engine is warm.Sound is reduced when fuel
injector connector of noisy
cylinder is disconnected.
(NOTE*)Worn cylinder liner and piston ring
Broken or stuck piston ring
Worn piston pin and hole at piston end of connecting rod
Sound is not reduced if each
fuel injector connector is
disconnected in turn. (NOTE*)Unusually worn valve lifter
Worn cam gear
Worn camshaft journal bore in crankcase
Squeaky sound—Insufficient generator lubrication
Rubbing sound—Defective generator brush and rotor contact
Gear scream when starting
engine—Defective ignition starter switch
Worn gear and starter pinion
Sound like polishing glass with
a dry cloth—Loose drive belt
Defective engine coolant pump shaft
Hissing sound—Loss of compression
Air leakage in air intake system, hoses, connections or
manifolds
Timing belt noise—Loose timing belt
Belt contacting case/adjacent part
NOTE*:
When disconnecting fuel injector connector, Malfunction Indicator Light (CHECK ENGINE light) illuminates and trouble code is stored in
ECM memory.
Therefore, carry out the CLEAR MEMORY MODE and INSPECTION MODE after connecting fuel injector connector. (Ref. to 2-7 On-Board
Diagnostics II System.)
79
2-3bDIAGNOSTICS
2. Engine Noise

1. Lubrication System
A: SPECIFICATIONS
1. 2200 cc MODEL
Lubrication methodForced lubrication
Oil pumpPump typeTrochoid type
Number of teethInner rotor 9
Outer rotor 10
Outer rotor diameter x thickness 78x9mm(3.07 x 0.35 in)
Tip clearance between inner and outer rotorSTANDARD 0.04 — 0.14 mm (0.0016 — 0.0055 in)
LIMIT 0.18 mm (0.0071 in)
Side clearance between inner rotor and pump
caseSTANDARD 0.02 — 0.07 mm (0.0008 — 0.0028 in)
LIMIT 0.15 mm (0.0059 in)
Case clearance between outer rotor and pump
caseSTANDARD 0.10 — 0.175 mm (0.0039 — 0.0069 in)
LIMIT 0.20 mm (0.0079 in)
Capacity at
80°C (176°F)700 rpm Discharge- pressure 98 kPa (1.0 kg/cm
2, 14 psi) or more
- quantity 4.2
(4.4 US qt, 3.7 Imp qt)/min.
5,000 rpm Discharge- pressure 294 kPa (3.0 kg/cm
2, 43 psi) or more
- quantity 42.0
(11.10 US gal, 9.24 Imp gal)/min.
Relief valve operation pressure 490 kPa (5.0 kg/cm
2, 71 psi)
Oil filterTypeFull-flow filter type
Filtration area 1,000 cm
2(155 sq in)
By-pass valve opening pressure 157 kPa (1.6 kg/cm
2, 23 psi)
Outer diameter x width 80 x 70 mm (3.15 x 2.76 in)
Oil filter to engine thread size M 20 x 1.5
Relief valve (on rocker shaft) operation pressure 69 kPa (0.7kg/cm
2, 10 psi)
Oil pressure
switchTypeImmersed contact point type
Working voltage — wattage 12 V — 3.4 W or less
Warning light activation pressure 14.7 kPa (0.15 kg/cm
2, 2.1 psi)
Proof pressure More than 981 kPa (10 kg/cm
2, 142 psi)
Oil pan capacity4.0
(4.2 US qt, 3.5 Imp qt)
2
2-4SPECIFICATIONS AND SERVICE DATA
1. Lubrication System

2. 2500 cc MODEL
Lubrication methodForced lubrication
Oil pumpPump typeTrochoid type
Number of teethInner rotor 9
Outer rotor 10
Outer rotor diameter x thickness 78 x 10 mm (3.07 x 0.39 in)
Tip clearance between inner and outer rotorSTANDARD 0.04—0.14 mm (0.0016—0.0055 in)
LIMIT 0.18 mm (0.0071 in)
Side clearance between inner rotor and pump
caseSTANDARD 0.02—0.07 mm (0.0008—0.0028 in)
LIMIT 0.15 mm (0.0059 in)
Case clearance between outer rotor and pump
caseSTANDARD 0.10—0.175 mm (0.0039—0.0069 in)
LIMIT 0.20 mm (0.0079 in)
Capacity at
80°C (176°F)600 rpm Discharge- pressure 98 kPa (1.0 kg/cm
2, 14 psi) or more
- quantity 4.6
(4.9 US qt, 4.0 Imp qt)/min.
5,000 rpm Discharge- pressure 294 kPa (3.0 kg/cm
2, 43 psi) or more
- quantity 47.0
(12.4 US gal, 10.3 Imp gal)/min.
Relief valve operation pressure 588 kPa (6.0 kg/cm
2, 85 psi)
Oil filterTypeFull-flow filter type
Filtration area 1,000 cm
2(155 sq in)
By-pass valve opening pressure 157 kPa (1.6 kg/cm
2, 23 psi)
Outer diameter x width 80 x 70 mm (3.15 x 2.76 in)
Oil filter to engine thread size M 20 x 1.5
Oil pressure
switchTypeImmersed contact point type
Working voltage—wattage 12 V—3.4 W or less
Warning light activation pressure 14.7 kPa (0.15 kg/cm
2, 2.1 psi)
Proof pressure More than 981 kPa (10 kg/cm
2, 142 psi)
Oil pan capacity4.5
(4.8 US qt, 4.0 Imp qt)
3
2-4SPECIFICATIONS AND SERVICE DATA
1. Lubrication System

1. Lubrication System
B2M0314A

1Plug


2Washer


3Relief valve spring


4Relief valve


5Oil seal


6Oil pump case


7Inner rotor


8Outer rotor


9Oil pump cover


10Oil filter


11O-ring


12Oil pump ASSY


13Oil pressure switch


14Oil filler duct

15Baffle plate


16Oil strainer stay


17O-ring


18Oil strainer


19Oil level gauge guide


20Oil pan


21Oil level gauge


22Washer


23Drain plug
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 5 (0.5, 3.6)
T2: 5
+1
0(0.5+0.1
0, 3.6+0.7
0)
T3: 6.4 (0.65, 4.7)
T4: 9.8 (1.0, 7.0)
T5: 44.1±3.4 (4.5±0.35, 32.5±2.5)
4
2-4COMPONENT PARTS
1. Lubrication System