SUBARU LEGACY 1999 Service Repair Manual

4) Tighten bolts which install oil pan onto engine
block.
Tightening torque:
5 N´m (0.5 kg-m, 3.6 ft-lb)
B2M2687A
S2M0131A
5) Lower engine onto front crossmember.
6) Tighten nuts which install front cushion rubber
onto front crossmember.
Tightening torque:
69
±15 N´m (7.0±1.5 kg-m, 51±11 ft-lb)
G2M0293
7) Install front exhaust pipe.
CAUTION:
Always use the new gaskets.
(1) Place front exhaust pipe on bracket.
(2) Tighten nuts which install front exhaust pipe
on engine.
Tightening torque:
30
±5 N´m (3.1±0.5 kg-m, 22.4±3.6 ft-lb)
S2M0236
(3) Tighten nuts which install front catalytic con-
verter to center exhaust pipe.
Tightening torque:
35
±5 N´m (3.6±0.5 kg-m, 26.0±3.6 ft-lb)
B2M0421
(4) Tighten bolt which installs front exhaust
pipe on bracket.
Tightening torque:
24
±3 N´m (2.4±0.3 kg-m, 17.4±2.2 ft-lb)
B2M0313
14
2-4[W2C0]SERVICE PROCEDURE
2. Oil Pan and Oil Strainer

8) Connect connector to rear oxygen sensor.
(Except 2500 cc California spec. vehicles)
B2M0312
9) Install under cover.
B2M0014
10) Lower the vehicle.
CAUTION:
At this time, lower lifting device and release
steel cables.
11) Remove lifting device and steel cables.
B2M0053
12) Connect connector to front oxygen sensor.
B2M1979A
S2M0127A
13) Connect connector to rear oxygen sensor.
(2500 cc California spec. vehicles)
S2M0128
14) Install pitching stopper.
Tightening torque:
T1: 49
±5 N´m (5.0±0.5 kg-m, 36.2±3.6 ft-lb)
T2: 57
±10 N´m (5.8±1.0 kg-m, 42±7 ft-lb)
G2M0302
15
[W2C0]2-4SERVICE PROCEDURE
2. Oil Pan and Oil Strainer

15) Install radiator upper brackets.
Tightening torque:
18
±5 N´m (1.8±0.5 kg-m, 13±4 ft-lb)
B2M0320
16) Install air intake duct and air cleaner assem-
bly. (2200 cc California spec. vehicles)
B2M2771
17) Install air intake duct and air intake chamber.
(Except 2200 cc California spec. vehicles)
B2M2772
18) Fill engine oil through filler pipe up to upper
point of level gauge. <Ref. to 1-5 [G4A0].>
Engine oil capacity:
2200 cc ; Upper level
4.0
(4.2 US qt, 3.5 Imp qt)
2200 cc ; Lower level
3.0
(3.2 US qt, 2.6 Imp qt)
2500 cc ; Upper level
4.5
(4.8 US qt, 4.0 Imp qt)
2500 cc ; Lower level
3.5
(3.7 US qt, 3.1 Imp qt)
3. Oil Pressure Switch
A: REMOVAL
1) Remove alternator from bracket.
(1) Disconnect connector and terminal from
generator.
H6M0402
(2) Remove V-belt cover.
B2M0017
(3) Loosen lock bolt and slider bolt, and remove
front side V-belt.
(4) Remove bolts which install generator on
bracket.
H2M1499
16
2-4[W3A0]SERVICE PROCEDURE
3. Oil Pressure Switch

15) Install radiator upper brackets.
Tightening torque:
18
±5 N´m (1.8±0.5 kg-m, 13±4 ft-lb)
B2M0320
16) Install air intake duct and air cleaner assem-
bly. (2200 cc California spec. vehicles)
B2M2771
17) Install air intake duct and air intake chamber.
(Except 2200 cc California spec. vehicles)
B2M2772
18) Fill engine oil through filler pipe up to upper
point of level gauge. <Ref. to 1-5 [G4A0].>
Engine oil capacity:
2200 cc ; Upper level
4.0
(4.2 US qt, 3.5 Imp qt)
2200 cc ; Lower level
3.0
(3.2 US qt, 2.6 Imp qt)
2500 cc ; Upper level
4.5
(4.8 US qt, 4.0 Imp qt)
2500 cc ; Lower level
3.5
(3.7 US qt, 3.1 Imp qt)
3. Oil Pressure Switch
A: REMOVAL
1) Remove alternator from bracket.
(1) Disconnect connector and terminal from
generator.
H6M0402
(2) Remove V-belt cover.
B2M0017
(3) Loosen lock bolt and slider bolt, and remove
front side V-belt.
(4) Remove bolts which install generator on
bracket.
H2M1499
16
2-4[W3A0]SERVICE PROCEDURE
3. Oil Pressure Switch

2) Disconnect terminal from oil pressure switch.
G2M0091
3) Remove oil pressure switch.
S2M0119
B: INSTALLATION
1) Apply fluid packing to oil pressure switch
threads before installation.
Fluid packing:
THREE BOND 1215 or equivalent
S2M0124A
2) Install oil pressure switch onto engine block.
Tightening torque:
25
±3 N´m (2.5±0.3 kg-m, 18.1±2.2 ft-lb)
S2M0119
3) Connect terminal of oil pressure switch.
G2M0091
4) Install generator on bracket and temporarily
tighten installing bolts.
H2M1499
5) Install front side V-belt and adjust it. <Ref. to
1-5 [G2A0].>
6) Install V-belt cover.
B2M0017
17
[W3B0]2-4SERVICE PROCEDURE
3. Oil Pressure Switch

7) Connect connector and terminal to generator.
H6M0402
18
2-4[W3B0]SERVICE PROCEDURE
3. Oil Pressure Switch

1. Engine Lubrication System
Trouble in General
Before troubleshooting, make sure that the engine
oil level is correct and no oil leakage exists.
Trouble Possible cause Corrective action
1. Warning light remains
on.1) Oil pressure switch
failureCracked diaphragm or oil leakage within switch Replace.
Broken spring or seized contacts Replace.
2) Low oil pressureClogged oil filter Replace.
Malfunction of oil by-pass valve of oil filter Clean or replace.
Malfunction of oil relief valve of oil pump Clean or replace.
Clogged oil passage Clean.
Excessive tip clearance and side clearance of oil
pump rotor and gearReplace.
Clogged oil strainer or broken pipe Clean or replace.
3) No oil pressureInsufficient engine oil Replenish.
Broken pipe of oil strainer Replace.
Stuck oil pump rotor Replace.
2. Warning light does
not go on.1) Burn-out bulb Replace.
2) Poor contact of switch contact points Replace.
3) Disconnection of wiring Repair.
3. Warning light flickers
momentarily.1) Poor contact at terminals Repair.
2) Defective wiring harness Repair.
3) Low oil pressureCheck for the same
possible causes as
listed in 1.Ð2)
19
[K100]2-4DIAGNOSTICS
1. Engine Lubrication System Trouble in General

MEMO:
20
2-4DIAGNOSTICS

1. Specifications
A: 2200 cc MODEL
Cooling systemElectric fan + Forced engine coolant circula-
tion system
Total engine coolant capacity(US qt, Imp qt) Approx. 6.1 (6.4, 5.4)
Water pumpType Centrifugal impeller type
Discharge performance IDischarge 20(5.3 US gal, 4.4 Imp gal)/min.
Pump speedÐtotal engine
coolant head760 rpm Ð 0.3 mAq (1.0 ftAq)
Engine coolant temperature 85ÉC (185ÉF)
Discharge performance IIDischarge 100(26.4 US gal, 22.0 Imp gal)/min.
Pump speedÐtotal engine
coolant head3,000 rpm Ð 5.0 mAq (16.4 ftAq)
Engine coolant temperature 85ÉC (185ÉF)
Discharge performance IIIDischarge 200(52.8 US gal, 44.0 Imp gal)/min.
Pump speedÐtotal engine
coolant head6,000 rpm Ð 23.0 mAq (75.5 ftAq)
Engine coolant temperature 85ÉC (185ÉF)
Impeller diameter 76 mm (2.99 in)
Number of impeller vanes 8
Pump pulley diameter 60 mm (2.36 in)
ThermostatTypeWax pellet type
Starts to open 76 Ð 80ÉC (169 Ð 176ÉF)
Fully opened 91ÉC (196ÉF)
Valve lift 9.0 mm (0.354 in) or more
Valve bore 35 mm (1.38 in)
Radiator fanMotor120 W
Fan diameter´Blade 320 mm (12.60 in)´5
RadiatorType Cross flow, pressure type
Core dimensions670´361´16 mm
(26.38´14.21´0.63 in)
Pressure range in which cap valve is openAbove: 88±10 kPa
(0.9±0.1 kg/cm
2, 12.8±1.4 psi)
Below: þ4.9 to þ9.8 kPa
(þ0.05 to þ0.1 kg/cm
2, þ0.7 to þ1.4 psi)
FinsCorrugated fin type
Reservoir
tankCapacity 0.5(0.5 US qt, 0.4 Imp qt)
2
2-5[S1A0]SPECIFICATIONS AND SERVICE DATA
1. Specifications

B: 2500 cc MODEL
Cooling systemElectric fan + Forced engine coolant circula-
tion system
Total engine coolant capacity(US qt, Imp qt) Approx. 6.1 (6.4, 5.4)
Water pumpType Centrifugal impeller type
Discharge performance IDischarge 20(5.3 US gal, 4.4 Imp gal)/min.
Pump speedÐtotal engine
coolant head760 rpm Ð 0.3 mAq (1.0 ftAq)
Engine coolant temperature 85ÉC (185ÉF)
Discharge performance IIDischarge 100(26.4 US gal, 22.0 Imp gal)/min.
Pump speedÐtotal engine
coolant head3,000 rpm Ð 5.0 mAq (16.4 ftAq)
Engine coolant temperature 85ÉC (185ÉF)
Discharge performance IIIDischarge 200(52.8 US gal, 44.0 Imp gal)/min.
Pump speedÐtotal engine
coolant head6,000 rpm Ð 23.0 mAq (75.5 ftAq)
Engine coolant temperature 85ÉC (185ÉF)
Impeller diameter 76 mm (2.99 in)
Number of impeller vanes 8
Pump pulley diameter 60 mm (2.36 in)
ThermostatTypeWax pellet type
Starts to open 76 Ð 80ÉC (169 Ð 176ÉF)
Fully opened 91ÉC (196ÉF)
Valve lift 9.0 mm (0.354 in) or more
Valve bore 35 mm (1.38 in)
Radiator fanMotor120 W (main fan)
140 W (sub fan)
Fan diameter´Blade340 mm (13.39 in)´5 (main fan)
280 mm (11.02 in)´4 (sub fan)
RadiatorType Cross flow, pressure type
Core dimensions670´361´16 mm
(26.38´14.21´0.63 in)
Pressure range in which cap valve is openAbove: 88±10 kPa
(0.9±0.1 kg/cm
2, 12.8±1.4 psi)
Below: þ4.9 to þ9.8 kPa
(þ0.05 to þ0.1 kg/cm
2, þ0.7 to þ1.4 psi)
FinsCorrugated fin type
Reservoir
tankCapacity 0.5(0.5 US qt, 0.4 Imp qt)
2. Service Data
Water pump
Clearance between impeller and caseStandard0.5 Ð 0.7 mm (0.020 Ð 0.028
in)
Limit 1.0 mm (0.039 in)
ªThrustº runout of impeller end 0.5 mm (0.020 in)
3
[S200]2-5SPECIFICATIONS AND SERVICE DATA
2. Service Data