Control unit SUBARU LEGACY 1995 Service Repair Manual

1. Engine Cooling System
Trouble Possible cause Corrective action
Over-heatinga. Insufficient engine coolantReplenish engine coolant, inspect for leakage, and
repair.
b. Loose timing belt Repair or replace timing belt tensioner.
c. Oil on drive belt Replace.
d. Malfunction of thermostat Replace.
e. Malfunction of engine coolant pump Replace.
f. Clogged engine coolant passage Clean.
g. Improper ignition timingInspect and repair ignition control system.

h. Clogged or leaking radiator Clean or repair, or replace.
i. Improper engine oil in engine coolant Replace engine coolant.
j. Air/fuel mixture ratio too leanInspect and repair fuel injection system.

k. Excessive back pressure in exhaust system Clean or replace.
l. Insufficient clearance between piston and cylinder Adjust or replace.
m. Slipping clutch Repair or replace.
n. Dragging brake Adjust.
o. Improper transmission oil Replace.
p. Defective thermostat Replace.
q. Malfunction of electric fanInspect radiator fan relay, engine coolant temperature
sensor or radiator motor and replace there.
Over-coolinga. Atmospheric temperature extremely low Partly cover radiator front area.
b. Defective thermostat Replace.
Engine coolant
leaks.a. Loosened or damaged connecting units on hoses Repair or replace.
b. Leakage from engine coolant pump Replace.
c. Leakage from engine coolant pipe Repair or replace.
d. Leakage around cylinder head gasket Retighten cylinder head bolts or replace gasket.
e. Damaged or cracked cylinder head and crankcase Repair or replace.
f. Damaged or cracked thermostat case Repair or replace.
g. Leakage from radiator Repair or replace.
Noisea. Defective drive belt Replace.
b. Defective radiator fan Replace.
c. Defective engine coolant pump bearing Replace engine coolant pump.
d. Defective engine coolant pump mechanical seal Replace engine coolant pump.
19
2-5DIAGNOSTICS
1. Engine Cooling System

G3M0291
2. INHIBITOR SWITCH
The inhibitor switch allows the back-up lights to turn on
when the select lever is in the R range and the starter
motor to start when the lever is in the N or P range. It also
monitors the input signal electronically controlled for each
range and turns on the corresponding range light on the
instrument panel.
When light operation, driving condition or starter motor
operation is erroneous, first check the shift linkage for
improper operation. If the shift linkage is functioning
properly, check the inhibitor switch.

(1) Disconnect cable end from select lever.
(2) Disconnect inhibitor switch connector.
(3) Check continuity in inhibitor switch circuits with
select lever moved to each position.
CAUTION:
Also check that continuity in ignition circuit does not
exist when selector lever is in R, D, 3, 2 and 1 ranges.
PinNo. 432187651211109
Lead color
B Y Br YG W BY R GW BY BW BW RW
Position
P





R




N




D


3


2


1


Signal sent to AT control unit Ignition circuitBack-up light
circuit
B3H0016A
28
3-2SERVICE PROCEDURE
2. On-Car Service

G3M0424
(4) Secure the housing with two nuts.
Tightening torque:
41±3 N⋅m (4.2±0.3 kg-m, 30.4±2.2 ft-lb)
G3M0394
3. TORQUE CONVERTER CLUTCH CASE AND
TRANSMISSION CASE
1) Apply proper amount of liquid gasket (THREE BOND
Part No. 1215) to the entire torque converter clutch case
mating surface.
NOTE:
Make sure that the rubber seal and seal pipe are fitted in
position.
G3M0335
2) Install the torque converter clutch case assembly to the
transmission case assembly, and secure with six bolts and
four nuts.
Tightening torque:
41±3 N⋅m (4.2±0.3 kg-m, 30.4±2.2 ft-lb)
CAUTION:
When installing, be careful not to damage the torque
converter clutch case bushing and oil seal.
G3M0425
4. CONTROL VALVE AND OIL PAN
1) Install four accumulators with oil pans facing upward.
CAUTION:
Be careful not to confuse the springs and installation
positions.
Spring specification
Unit: mm (in)
Accumulator spring Outer diameter Free length
1—2 28.5 (1.122) 44.5 (1.752)
2—3 20.5 (0.807) 31.0 (1.220)
3—4 17.3 (0.681) 43.7 (1.720)
N—D 17.8 (0.701) 36.5 (1.437)
74
3-2SERVICE PROCEDURE
4. Overall Transmission

Unit: mm (in)
No. Part name Wire dia. Outer dia. Effective turn Free length
25 Pressure regulator spring 1.6 (0.063) 14.0 (0.551) 5.6 31.5 (1.240)
26 Pressure modifier spring 0.8 (0.031) 6.8 (0.268) 10.0 31.95 (1.2579)
27 Modifier accumulator spring 1.3 (0.051) 9.8 (0.386) 8.8 30.5 (1.201)
28 Pilot spring 1.1 (0.043) 9.1 (0.358) 8.3 25.7 (1.012)
29 Accumulator control spring 0.4 (0.016) 6.6 (0.260) 11.0 27.5 (1.083)
30 Shift B spring 0.65 (0.0256) 7.0 (0.276) 9.5 25.0 (0.984)
31 Shift A spring 0.5 (0.020) 7.0 (0.276) 9.5 25.0 (0.984)
32 Shuttle shift spring 0.65 (0.0256) 5.65 (0.2224) 27.6 51.0 (2.008)
33 Overrunning clutch control spring 0.7 (0.028) 6.0 (0.236) 12.0 26.5 (1.043)
34 4-2 sequence spring 0.55 (0.0217) 6.95 (0.2736) 11.0 29.1 (1.146)
35 4-2 relay spring 0.55 (0.0217) 6.95 (0.2736) 11.0 29.1 (1.146)
36 Servo charger spring 0.7 (0.028) 6.7 (0.264) 9.0 23.0 (0.906)
37 3-2 timing spring 0.75 (0.0295) 6.75 (0.2657) 7.5 20.55 (0.8091)
38 1st reducing spring 0.75 (0.0295) 6.75 (0.2657) 12.5 25.4 (1.000)
39 Overrunning clutch reducing spring 1.05 (0.0413) 7.05 (0.2776) 15.21 34.7 (1.366)
40 Torque converter regulator spring 1.3 (0.051) 9.0 (0.354) 11.7 38.0 (1.496)
41 Lock-up control spring 0.75 (0.0295) 13.0 (0.512) 3.5 18.5 (0.728)
42 Shuttle duty shift spring 0.75 (0.0295) 5.65 (0.2224) 27.6 51.0 (2.008)
86
3-2SERVICE PROCEDURE
6. Control Valve Body

G3M0906
5) Temporarily assemble lower valve body to upper valve
body.
CAUTION:
Be careful not to drop the upper body interior steel
ball, or the lower body interior filter, orifice check
spring, or orifice check valve.
B3M0406A
6) Install the duty solenoid B and the four brackets.
7) Tighten twenty seven bolts & washers and two reamer
bolts.
Tightening torque:
T1: 8±1 N⋅m (0.8±0.1 kg-m, 5.8±0.7 ft-lb)
T2: 11.3±1.5 N⋅m (1.15±0.15 kg-m, 8.3±1.1 ft-lb)
Unit: mm (in)
abcde
Length 70 (2.76) 50 (1.97) 33 (1.30) 27 (1.06) 28 (1.10)
Numbers 2 6 16 1 2
G3M0864
8) Install the shift solenoid and duty solenoid A.
a length : 16 mm (0.63 in)
b length : 27 mm (1.06 in)
Tightening torque:
8±1 N⋅m (0.8±0.1 kg-m, 5.8±0.7 ft-lb)
G3M0445
7. Oil Pump Assembly
A: DISASSEMBLY
1) Remove the oil seal retainer.
Also remove the O-ring and oil seal (air breather).
89
3-2SERVICE PROCEDURE
6. Control Valve Body - 7. Oil Pump Assembly

G3M0906
5) Temporarily assemble lower valve body to upper valve
body.
CAUTION:
Be careful not to drop the upper body interior steel
ball, or the lower body interior filter, orifice check
spring, or orifice check valve.
B3M0406A
6) Install the duty solenoid B and the four brackets.
7) Tighten twenty seven bolts & washers and two reamer
bolts.
Tightening torque:
T1: 8±1 N⋅m (0.8±0.1 kg-m, 5.8±0.7 ft-lb)
T2: 11.3±1.5 N⋅m (1.15±0.15 kg-m, 8.3±1.1 ft-lb)
Unit: mm (in)
abcde
Length 70 (2.76) 50 (1.97) 33 (1.30) 27 (1.06) 28 (1.10)
Numbers 2 6 16 1 2
G3M0864
8) Install the shift solenoid and duty solenoid A.
a length : 16 mm (0.63 in)
b length : 27 mm (1.06 in)
Tightening torque:
8±1 N⋅m (0.8±0.1 kg-m, 5.8±0.7 ft-lb)
G3M0445
7. Oil Pump Assembly
A: DISASSEMBLY
1) Remove the oil seal retainer.
Also remove the O-ring and oil seal (air breather).
89
3-2SERVICE PROCEDURE
6. Control Valve Body - 7. Oil Pump Assembly

G3M0450
2) Selection of oil pump components (rotor, vanes, control
piston and cam ring)
(1) Using a micrometer, measure the height of the
rotor, vanes, control piston and cam ring in at least four
positions. (Measure the height at one place for each of
the nine vanes.)
NOTE:
Remove the control piston seals when measuring.
Remove the friction ring from the cam ring when mea-
suring.
G3M0451
(2) Using a depth gauge, measure the depth of the oil
pump housing from the contact/sliding surface of the
above mentioned component parts in the same manner
as above.
G3M0452
(3) Make sure that the clearances are within the speci-
fied wear limits. If the wear limit is exceeded, select
pump components so that the standard clearance can
be obtained.
Unit: mm (in)
Part name Wear limit Standard value
Rotor, control piston,
vanes0.054
(0.0021)0.030—0.044
(0.0012—0.0017)
Cam ring0.034
(0.0013)0.010—0.024
(0.0004—0.0009)
NOTE:
Select vanes which are the same height as the rotor.
G3M0453
C: ASSEMBLY
1) Coat both the O-ring and friction ring with vaseline and
attach to the cam ring. Then fit them into the oil pump
housing.
91
3-2SERVICE PROCEDURE
7. Oil Pump Assembly

3. Steering Gearbox (Power Steering
System) [LHD model]
NOTE:
For disassembly and assembly of gearbox unit, refer to
section Control Valve (Power Steering Gearbox).
B4M0131A
1Cotter pin

2Castle nut

3Dust cover

4Clip

5Tie-rod end

6Clip

7Boot

8Clip

9Spacer

10Tie-rod

11Lock washer

12Circlip

13Rack stopper

14Oil seal

15Rack bushing
16O-ring

17Rack

18Back-up washer

19Rack housing

20Adapter

21Clamp

22Lock nut

23Adjusting screw

24Spring

25Sleeve

26C-ring

27Ball bearing

28Valve

29Seal ring

30Packing
31Valve housing

32Dust seal

33Universal joint

34Spring washer
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 13±3 (1.3±0.3, 9.4±2.2)
T2: 24±3 (2.4±0.3, 17.4±2.2)
T3: 25±5 (2.5±0.5, 18.1±3.6)
T4: 27.0±2.5
(2.75±0.25, 19.9±1.8)
T5: 39±10 (4.0±1.0, 29±7)
T6: 59±12 (6.0±1.2, 43±9)
T7: 78±10 (8.0±1.0, 58±7)
T8: 83±5 (8.5±0.5, 61.5±3.6)
15
4-3SERVICE PROCEDURE
3. Steering Gearbox (Power Steering System) [LHD model]

4. Steering Gearbox (Power Steering
System) [RHD model]
NOTE:
For disassembly and assembly of gearbox unit, refer to
section Control Valve (Power Steering Gearbox).
B4M0666A
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 20±4 (2.0±0.4, 14.5±2.9)
T2: 25±5 (2.5±0.5, 18.1±3.6)
T3: 39±10 (4.0±1.0, 29±7)
T4: 64±10 (6.5±1.0, 47±7)
T5: 78±10 (8.0±1.0, 58±7)
T6: 83±5 (8.5±0.5, 61.5±3.6)
28
4-3SERVICE PROCEDURE
4. Steering Gearbox (Power Steering System) [RHD model]

2. OIL LEAK CHECK PROCEDURE AND
REPLACEMENT PARTS
NOTE:
Parts requiring replacement are described in the smallest
unit of spare parts including damaged parts and spare
parts damaged. In actual disassembly work, accidental
damage as well as inevitable damage to some related
parts must be taken into account, and spare parts for them
must also be prepared. However, it is essential to pinpoint
the cause of trouble, and limit the number of replacement
parts as much as possible.
1) Leakage from“a”
The oil seal is damaged. Replace valve assembly with a
new one.
2) Leakage from“b”
The torsion bar O-ring is damaged. Replace valve assem-
bly with a new one.
3) Leakage from“c”
The oil seal is damaged. Replace valve assembly with a
new one.
4) Leakage from“d”
The pipe is damaged. Replace the faulty pipe or O-ring.
5) If leak is other than a, b, c, or d, and if oil is leaking from
the gearbox, move the right and left boots toward tie-rod
end side, respectively, with the gearbox mounted to the
vehicle, and remove oil from the surrounding portions.
Then, turn the steering wheel from lock to lock 30 to 40
times with the engine running, then make comparison of
the leaked portion immediately after and several hours
after this operation.
6) Leakage from“e”
The cylinder seal is damaged. Replace rack bush with a
new one.
7) Leakage from“f”
There are two possible causes. Take following step first.
Remove the pipe assembly B from the valve housing, and
close the circuit with ST.
ST 926420000 PLUG
Turn the steering wheel from lock to lock 30 to 40 times
with the engine running, then make comparison of the
leaked portion between immediately after and several
hours after this operation.
CAUTION:

If leakage from“f”is noted again:
The oil seal of pinion and valve assembly is damaged.
Replace pinion and valve assembly with a new one. Or
replace the oil seal and the parts that are damaged
during disassembly with new ones.

If oil stops leaking from“f”:
The oil seal of rack housing is damaged.
Replace the oil seal and the parts that are damaged
during disassembly with new ones.
41
4-3SERVICE PROCEDURE
5. Control Valve (Power Steering Gearbox) [LHD model]