SUBARU LEGACY 1999 Service Repair Manual

13) Remove belt idler No. 2.
H2M2518
14) Remove camshaft position sensor.
<Ref. to 2-7 [W10A0].>
S2M0184
15) Remove left-hand camshaft sprockets by
using ST.
ST 499207300 CAMSHAFT SPROCKET
WRENCH
S2M0019A
16) Remove tensioner bracket.
S2M0020
17) Remove left-hand belt cover No. 2.
S2M0021
18) Remove water pump.
H2M2516
19) Installation is in the reverse order of removal.
CAUTION:
IReplace gasket with a new one.
IWhen installing water pump, tighten bolts in
two stages in alphabetical sequence as shown
in figure.
Tightening torque:
10+4/þ0N´m (1.0+0.4/þ0kg-m, 7.2+2.9/þ0ft-lb)
S2M0760A
B: INSPECTION
1) Check water pump bearing for smooth rotation.
2) Check water pump pulley for abnormalities.
12
2-5[W2B0]SERVICE PROCEDURE
2. Water Pump

3) Using a dial gauge, measure impeller runout in
thrust direction while rotating the pulley.
ªThrustº runout limit:
0.5 mm (0.020 in)
G2M0211
4) Check clearance between impeller and pump
case.
Clearance between impeller and pump case:
Standard
0.5 Ð 0.7 mm (0.020 Ð 0.028 in)
Limit
1.0 mm (0.039 in)
G2M0212
5) After water pump installation, check pulley shaft
for engine coolant leaks. If leaks are noted, replace
water pump assembly.
3. Thermostat
A: REMOVAL AND INSTALLATION
1) Drain engine coolant.
Set container under the vehicle, and remove drain
cock from radiator.
2) Disconnect radiator outlet hose from thermostat
cover.
3) Remove thermostat cover and gasket, and pull
out the thermostat.
G2M0214
4) Install the thermostat in the intake manifold,
and install the thermostat cover together with a
gasket.
CAUTION:
IWhen reinstalling the thermostat, use a new
gasket.
IThe thermostat must be installed with the
jiggle pin upward.
IIn this time, set the jiggle pin of thermostat
for front side.
G2M0227
13
[W3A0]2-5SERVICE PROCEDURE
3. Thermostat

3) Using a dial gauge, measure impeller runout in
thrust direction while rotating the pulley.
ªThrustº runout limit:
0.5 mm (0.020 in)
G2M0211
4) Check clearance between impeller and pump
case.
Clearance between impeller and pump case:
Standard
0.5 Ð 0.7 mm (0.020 Ð 0.028 in)
Limit
1.0 mm (0.039 in)
G2M0212
5) After water pump installation, check pulley shaft
for engine coolant leaks. If leaks are noted, replace
water pump assembly.
3. Thermostat
A: REMOVAL AND INSTALLATION
1) Drain engine coolant.
Set container under the vehicle, and remove drain
cock from radiator.
2) Disconnect radiator outlet hose from thermostat
cover.
3) Remove thermostat cover and gasket, and pull
out the thermostat.
G2M0214
4) Install the thermostat in the intake manifold,
and install the thermostat cover together with a
gasket.
CAUTION:
IWhen reinstalling the thermostat, use a new
gasket.
IThe thermostat must be installed with the
jiggle pin upward.
IIn this time, set the jiggle pin of thermostat
for front side.
G2M0227
13
[W3A0]2-5SERVICE PROCEDURE
3. Thermostat

B: INSPECTION
Replace the thermostat if the valve does not close
completely at an ambient temperature or if the fol-
lowing test shows unsatisfactory results.
Immerse the thermostat and a thermometer in
water. Raise water temperature gradually, and
measure the temperature and valve lift when the
valve begins to open and when the valve is fully
opened. During the test, agitate the water for even
temperature distribution. The measurement should
be to the specification.
Starts to open:
76.0 Ð 80.0ÉC (169 Ð 176ÉF)
Fully opens:
91ÉC (196ÉF)
H2M2357A
(A) Thermometer
(B) Thermostat
4. Radiator
A: REMOVAL
1) Disconnect battery ground cable.
B2M1723
2) Lift-up the vehicle.
3) Remove under cover.
B2M0014
4) Drain engine coolant completely. <Ref. to 2-5
[W1A0].>
B2M0015A
14
2-5[W3B0]SERVICE PROCEDURE
4. Radiator

B: INSPECTION
Replace the thermostat if the valve does not close
completely at an ambient temperature or if the fol-
lowing test shows unsatisfactory results.
Immerse the thermostat and a thermometer in
water. Raise water temperature gradually, and
measure the temperature and valve lift when the
valve begins to open and when the valve is fully
opened. During the test, agitate the water for even
temperature distribution. The measurement should
be to the specification.
Starts to open:
76.0 Ð 80.0ÉC (169 Ð 176ÉF)
Fully opens:
91ÉC (196ÉF)
H2M2357A
(A) Thermometer
(B) Thermostat
4. Radiator
A: REMOVAL
1) Disconnect battery ground cable.
B2M1723
2) Lift-up the vehicle.
3) Remove under cover.
B2M0014
4) Drain engine coolant completely. <Ref. to 2-5
[W1A0].>
B2M0015A
14
2-5[W3B0]SERVICE PROCEDURE
4. Radiator

5) Disconnect connectors of radiator main fan (A)
and sub fan (B) motors.
B2M2035A
6) Disconnect radiator outlet hose from thermostat
cover.
H2M2515
7) Lower the vehicle.
8) Remove reservoir tank.
S2M0028
9) Disconnect ATF cooler hoses from radiator. (AT
vehicles only)
S2M0029
10) Remove V-belt covers.
B2M2307
11) Disconnect radiator inlet hose from radiator.
S2M0031
12) Remove radiator upper brackets.
B2M0320
13) While slightly lifting radiator, slide it to left.
14) Lift radiator up and away from vehicle.
B2M2323
15
[W4A0]2-5SERVICE PROCEDURE
4. Radiator

B: INSTALLATION
1) Attach radiator mounting cushions to pins on
the lower side of radiator.
S2M0034
2) Install radiator while fitting radiator pins to cush-
ions.
NOTE:
Fit cushion on lower side of radiator into holes on
body side.
B2M2323
3) Install radiator brackets and tighten bolts.
Tightening torque:
18
±5 N´m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)
B2M0320
4) Connect ATF cooler hoses. (AT vehicles only)
S2M0029
5) Connect radiator inlet hose.
S2M0031
6) Install reservoir tank.
Tightening torque:
7.4
±2.0 N´m (0.75±0.20 kg-m, 5.4±1.4 ft-lb)
B2M2042
7) Lift-up the vehicle.
8) Connect connectors to radiator main fan (A)
and sub fan (B) motors.
B2M2035A
16
2-5[W4B0]SERVICE PROCEDURE
4. Radiator

9) Connect radiator outlet hose.
H2M2515
10) Install under cover.
B2M0014
11) Lower the vehicle.
12) Install V-belt covers.
B2M2307
13) Connect battery ground cable.
B2M1723
14) Fill coolant. <Ref. to 2-5 [W1B0].>
B2M0135
17
[W4B0]2-5SERVICE PROCEDURE
4. Radiator

5. Radiator Cap
A: INSPECTION
1) Attach radiator cap to tester.
G2M0223
2) Increase pressure until tester gauge pointer
stops. Radiator cap is functioning properly if it
holds the service limit pressure for five to six sec-
onds.
Standard pressure:
78 Ð 98 kPa (0.8 Ð 1.0 kg/cm2,11Ð14
psi)
Service limit pressure:
69 kPa (0.7 kg/cm
2, 10 psi)
CAUTION:
Be sure to remove foreign matter and rust from
the cap in advance; otherwise, results of pres-
sure test will be incorrect.
6. Radiator Main Fan and Fan
Motor
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
B2M1723
2) Lift-up the vehicle.
3) Remove under cover.
B2M0014
4) Disconnect connector of main fan motor.
B2M2043
18
2-5[W5A0]SERVICE PROCEDURE
5. Radiator Cap

5. Radiator Cap
A: INSPECTION
1) Attach radiator cap to tester.
G2M0223
2) Increase pressure until tester gauge pointer
stops. Radiator cap is functioning properly if it
holds the service limit pressure for five to six sec-
onds.
Standard pressure:
78 Ð 98 kPa (0.8 Ð 1.0 kg/cm2,11Ð14
psi)
Service limit pressure:
69 kPa (0.7 kg/cm
2, 10 psi)
CAUTION:
Be sure to remove foreign matter and rust from
the cap in advance; otherwise, results of pres-
sure test will be incorrect.
6. Radiator Main Fan and Fan
Motor
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
B2M1723
2) Lift-up the vehicle.
3) Remove under cover.
B2M0014
4) Disconnect connector of main fan motor.
B2M2043
18
2-5[W5A0]SERVICE PROCEDURE
5. Radiator Cap