ESP SUBARU LEGACY 1996 Service User Guide

3-2
[r7La]
AUTOMATIC
TRANSMISSION
AND
DIFFERENTIAL

7
.
Diagnostic
Chart
with
Trouble
Code

THV
(F09)

4
.6V

83M0383

E13

B3M0238A
I

Data
link
connector
(for
Subaru
select
monitor
and
OBD-II
general
scan
tool)

~l
i
a
I
nk
connector
Dat
(for
Subaru
select
monitor
only)

OBD0145A
I

THVCC
(F14)

S
.ZV

OBD0506

(5)
Designate
mode
using
function
key
.

(6)
Read
data
onSubaru
select
monitor
.

Function
mode
:
F09

SPECIFIED
DATA
:

0
.5
f
0
.2
V
(Throttle
fully
closed
.)

4
.6
f
0
.3
V
(Throttle
fully
open
.)

[Must
be
changed
correspondingly
with
accelera-

tor
pedal
operation
(from
"released"
to

"depressed"
position)
.]

4
.
CHECKPOWER
SUPPLY
TO
THROTTLE
POSITION

SENSOR
.

1)
Turn
ignition
switch
to
OFF
.

2)
Disconnect
connector
from
throttle
position
sensor
.

3)
Turn
ignition
switch
to
ON
.

4)
Measure
power
supply
voltage
to
throttle
position
sen-

sor
.

Connector
&
terminal
l
Specified
voltage
:

(E13)
No
.
1
-
Body
l
5
.12
±
0
.1
V

9
Using
Subaru
select
monitor
:

(1)
Turn
ignition
switch
to
OFF
.

(2)
Connect
the
Subaru
select

connector
.

(3)
Turn
ignition
switch
to
ON

monitor
switch
to
ON
.

monitor
to
data
link

and
Subaru
select

(4)
Designate
mode
using
function
key
.

(5)
Read
data
onSubaru
select
monitor
.

Function
mode
:
F14

SPECIFIED
DATA
:

5
.12
f
0
.1
V

12

2_7
[T10A0]
ON-BOARD
DIAGNOSTICS
11
SYSTEM
10
.
Diagnostics
Chart
with
Trouble
Code

10
.
Diagnostics
Chart
with
Trouble
Code

A
:
DIAGNOSTIC
TROUBLE
CODE
(DTC)
LIST

DTC

No
.

Abbreviation

(Subaru
select
monitor)Item
Page

P0100
QA
Mass
air
flow
sensor
circuit
malfunction
'1

P0101
QA
-
R
Mass
air
flow
sensor
circuit
range/performance
problem
`1

P0105
P
-
S
Pressure
sensor
circuit
malfunction
*1

P0106
PS
-
R
Pressure
sensor
circuit
range/performance
problem
*1

P0115
TW
Engine
coolant
temperature
sensor
circuit
malfunction
'1

P0120
THV
Throttle
position
sensor
circuit
malfunction
'1

P0121
TH
-
R
Throttle
position
sensor
circuit
range/performance
problem
'1

P0125
TW
-
CL
Insufficient
coolant
temperature
for
closed
loop
fuel
control
'1

P0130
F02
-
V
Front
oxygen
sensor
circuit
malfunction
*1

P0133
F02
-
R
Front
oxygen
sensor
circuit
slowresponse
'1

P0135
F02H
Front
oxygen
sensor
heater
circuit
malfunction
*1

P0136
R02
-
V
Rear
oxygen
sensor
circuit
malfunction
'1

P0139
R02
-
R
Rear
oxygen
sensor
circuit
slowresponse
*1

P0141
R02H
Rear
oxygen
sensor
heater
circuit
malfunction
*1

P0170
FUEL
Fuel
trim
malfunction
'1

P0180
TNKT
Fuel
temperature
sensor
A
circuit
malfunction
10

P0181
TNKT-
FFuel
temperature
sensor
A
circuit
range/performance
problem
16

P0201
INJ1
Fuel
injector
circuit
malfunction
-
#1

P0202
INJ2Fuel
injector
circuit
malfunction
-
#2
"
1
P0203
INJ3Fuel
injector
circuit
malfunction
-
#3

P0204
INJ4Fuel
injector
circuit
malfunction
-
#4

P0301
MIS
-
1
Cylinder
1
misfire
detected

P0302
MIS
-
2Cylinder2
misfire
detected

P0303
MIS
-
3
Cylinder
3
misfire
detected

P0304
MIS
-
4
Cylinder
4
misfire
detected

P0325
KNOCK
Knock
sensor
circuit
malfunction
'1

P0335
CRANK
Crankshaft
position
sensor
circuit
malfunction
'1

P0340
CAM
Camshaft
position
sensor
circuit
malfunction
'1

P0400
EGR
Exhaust
gas
recirculation
flow
malfunction
`1

P0403
EGRSOL
Exhaust
gas
recirculation
circuit
malfunction
'1

P0420
CAT
Catalyst
system
efficiency
below
threshold
'1

P0440
EVAP
Evaporative
emission
control
system
malfunction
18

P0441
CPC
-
F
Evaporative
emission
control
system
incorrect
purge
flow
'1

P0443
CPC
Evaporative
emission
control
system
purge
control
valve
circuit
malfunction
'1

P0446
VCMSOL
Evaporative
emission
control
system
vent
control
malfunction
22

P0450
TNKP
Evaporative
emission
control
system
pressure
sensor
malfunction
28

P0451
TNKP
-
F
Evaporative
emission
control
system
pressure
sensor
range/performance

problem
36

'1
:
.
to
2-7
[T11A0]
.*4>

B2M0387A
B2M0076A
3. VALVE GUIDE
1) Check the clearance between valve guide and stem.
The clearance can be checked by measuring the outside
diameter of valve stem and the inside diameter of valve
guide with outside and inside micrometers respectively.
Clearance between the valve guide and valve stem:
Standard
Intake
0.035—0.062 mm (0.0014—0.0024 in)
Exhaust
0.040—0.067 mm (0.0016—0.0026 in)
Limit
0.15 mm (0.0059 in)
Valve guide inner diameter:
6.000—6.012 mm (0.2362—0.2367 in)
Valve stem outer diameters:
Intake
5.950—5.965 mm (0.2343—0.2348 in)
Exhaust
5.945—5.960 mm (0.2341—0.2346 in)
G2M0150
2) If the clearance between valve guide and stem exceeds
the specification, replace guide as follows:
(1) Place cylinder head on ST1 with the combustion
chamber upward so that valve guides enter the holes
in ST1.
(2) Insert ST2 into valve guide and press it down to
remove valve guide.
ST1 498267200 CYLINDER HEAD TABLE
ST2 499767200 VALVE GUIDE REMOVER
G2M0151
(3) Turn cylinder head upside down and place ST as
shown in the Figure.
ST 499767000 VALVE GUIDE ADJUSTER
B2M0388A
(4) Before installing new oversize valve guide, make
sure that neither scratches nor damages exist on the
inside surface of the valve guide holes in cylinder head.
(5) Put new valve guide, coated with sufficient oil, in
cylinder, and insert ST1 into valve guide. Press in until
the valve guide upper end is flush with the upper sur-
face of ST2.
ST1 499767200 VALVE GUIDE REMOVER
ST2 499767000 VALVE GUIDE ADJUSTER
42
2-3SERVICE PROCEDURE
6. Cylinder Head

C: INSPECTION
1. CYLINDER BLOCK
1) Check for cracks and damage visually. Especially,
inspect important parts by means of red lead check.
2) Check the oil passages for clogging.
3) Inspect crankcase surface that mates with cylinder
head for warping by using a straight edge, and correct by
grinding if necessary.
Warping limit:
0.05 mm (0.0020 in)
Grinding limit:
0.1 mm (0.004 in)
Standard height of cylinder block:
201.0 mm (7.91 in)
B2M0082A
2. CYLINDER AND PISTON
1) The cylinder bore size is stamped on the cylinder
block’s front upper surface.
NOTE:
Standard sized pistons are classified into two grades,“A”
and“B”. These grades should be used as a guide line in
selecting a standard piston.
Standard diameter:
A: 96.905—96.915 mm (3.8151—3.8155 in)
B: 96.895—96.905 mm (3.8148—3.8151 in)
56
2-3SERVICE PROCEDURE
7. Cylinder Block

H2M1707B
4) Installation of piston rings and oil ring
(1) Install oil ring spacer, upper rail and lower rail in this
order by hand. Then install second ring and top ring
with a piston ring expander.
(2) Position the top ring gap at A or B in the Figure.
(3) Position the second ring gap at 180°on the reverse
side for the top ring gap.
H2M1708B
(4) Position the upper rail gap at C or D in the Figure.
(5) Position the expander gap at 180°of the reverse
side for the upper rail gap.
(6) Position the lower rail gap at E or F in the Figure.
CAUTION:
Ensure ring gaps do not face the same direction.
Ensure ring gaps are not within the piston skirt area.
B2M1403A
5) Install circlip.
Install circlips in piston holes located opposite service
holes in cylinder block, when positioning all pistons in the
corresponding cylinders.
CAUTION:
Use new circlips.
NOTE:
Piston front mark“
”facer toward front of engine.
66
2-3SERVICE PROCEDURE
7. Cylinder Block

B2M0698A
When timing belts are not installed, four camshafts
are held at the“zero-lift”position, where all cams on
camshafts do not push intake and exhaust valves
down. (Under this condition, all valves remain
unlifted.)
When camshafts are rotated to install timing belts,
#2 intake and #4 exhaust cam of left-hand camshafts
are held to push their corresponding valves down.
(Under this condition, these valves are held lifted.)
Right-side camshafts are held so that their cams do
not push valves down.
Left-hand camshafts must be rotated from the“zero-
lift”position to the position where timing belt is to be
installed at as small an angle as possible, in order to
prevent mutual interference of intake and exhaust
valve heads.
Do not allow camshafts to rotate in the direction
shown in the upper of figure as this causes both intake
and exhaust valves to lift simultaneously, resulting in
interference with their heads.
B2M0699
2) Installation of timing belt
Align alignment mark on timing belt with marks on sprock-
ets in the numerical order shown in figure. While aligning
marks, position timing belt properly.
CAUTION:
Ensure belt’s rotating direction is correct.
G2M0738
26
2-3bSERVICE PROCEDURE
2. Timing Belt

G2M0761
2. VALVE SEAT
Inspect intake and exhaust valve seats, and correct the
contact surfaces with valve seat cutter if they are defective
or when valve guides are replaced.
Valve seat width: W
Intake
Standard
1.0 mm (0.039 in)
Limit
1.7 mm (0.067 in)
Exhaust
Standard
1.5 mm (0.059 in)
Limit
2.2 mm (0.087 in)
3. VALVE GUIDE
1) Check the clearance between valve guide and stem.
The clearance can be checked by measuring the outside
diameter of valve stem and the inside diameter of valve
guide with outside and inside micrometers respectively.
Clearance between the valve guide and valve stem:
Standard
Intake
0.035—0.062 mm (0.0014—0.0024 in)
Exhaust
0.040—0.067 mm (0.0016—0.0026 in)
Limit
0.15 mm (0.0059 in)
Valve guide inner diameter:
6.000—6.015 mm (0.2362—0.2368 in)
Valve stem outer diameter:
Intake
5.950—5.965 mm (0.2343—0.2348 in)
Exhaust
5.950—5.965 mm (0.2343—0.2348 in)
38
2-3bSERVICE PROCEDURE
4. Cylinder Head

C: INSPECTION
1. CYLINDER BLOCK
1) Check for cracks and damage visually. Especially,
inspect important parts by means of red lead check.
2) Check the oil passages for clogging.
3) Inspect crankcase surface that mates with cylinder
head for warping by using a straight edge, and correct by
grinding if necessary.
Warping limit:
0.05 mm (0.0020 in)
Grinding limit:
0.1 mm (0.004 in)
Standard height of cylinder block:
201.0 mm (7.91 in)
B2M0082A
2. CYLINDER AND PISTON
1) The cylinder bore size is stamped on the cylinder
block’s front upper surface.
NOTE:
Standard sized pistons are classified into two grades,“A”
and“B”. These grades should be used as a guide line in
selecting a standard piston.
Standard diameter:
A: 99.505—99.515 mm (3.9175—3.9179 in)
B: 99.495—99.505 mm (3.9171—3.9175 in)
56
2-3bSERVICE PROCEDURE
5. Cylinder Block

B2M0707A
4) Installation of piston rings and oil ring
(1) Install oil ring spacer, upper rail and lower rail in this
order by hand. Then install second ring and top ring
with a piston ring expander.
(2) Position the top ring gap at A or B in the Figure.
(3) Position the second ring gap at 180°on the reverse
side for the top ring gap.
B2M0708A
(4) Position the upper rail gap at C or D in the Figure.
(5) Position the expander gap the at 180°of the
reverse side for the upper rail gap.
(6) Position the lower rail gap at E or F in the Figure.
CAUTION:
Ensure ring gaps do not face the same direction.
Ensure ring gaps are not within the piston skirt area.
G2M0183
5) Install circlip.
Install circlips in piston holes located opposite service
holes in cylinder block, when positioning all pistons in the
corresponding cylinders.
CAUTION:
Use new circlips.
66
2-3bSERVICE PROCEDURE
5. Cylinder Block

G2M0411
5) Remove front oxygen sensor.
CAUTION:
When removing oxygen sensor, do not force oxygen
sensor especially when exhaust pipe is cold, other-
wise it will damage exhaust pipe.
G2M0412
B: INSTALLATION
1) Before installing front oxygen sensor, apply anti-seize
compound only to threaded portion of front oxygen sensor
to make the next removal easier.
Anti-seize compound:
SS-30 by JET LUBE
CAUTION:
Never apply anti-seize compound to protector of front
oxygen sensor.
G2M0411
2) Install front oxygen sensor.
Tightening torque:
21±3 N⋅m (2.1±0.3 kg-m, 15.2±2.2 ft-lb)
3) Lower the vehicle.
4) Connect connector of front oxygen sensor.
5) Install air intake duct.
20
2-7SERVICE PROCEDURE
7. Front Oxygen Sensor