check engine light SUBARU LEGACY 1996 Service User Guide

1. Foreword
This chapter describes major inspection and service pro-
cedures for the engine mounted on the body. For proce-
dures not found in this chapter, refer to the service proce-
dure section in the applicable chapter.
2. Ignition Timing
A: MEASUREMENT
1. 2200 cc MODEL
1) Warm-up the engine.
G2M0094
2) To check the ignition timing, connect a timing light to #1
cylinder spark plug cord, and illuminate the timing mark
with the timing light.
3) Start the engine at idle speed and check the ignition
timing.
If the timing is not correct, check the ignition control sys-
tem.
Ignition timing [BTDC/rpm]:
14°±8°/700 (MT)
20°±8°/700 (AT)
2. 2500 cc MODEL
CAUTION:
After warming-up, engine becomes very hot. Be care-
ful not to burn yourself during measurement.
1) Warm-up the engine.
B2M0750A
2) To check the ignition timing, connect a timing light to #1
cylinder spark plug cord, and illuminate the timing mark
with the timing light.
3) Start the engine at idle speed and check the ignition
timing.
If the timing is not correct, check the ignition control sys-
tem.
Ignition timing [BTDC/rpm]:
15°±8°/700
2
2-2
1. Foreword - 2. Ignition Timing

1. Foreword
This chapter describes major inspection and service pro-
cedures for the engine mounted on the body. For proce-
dures not found in this chapter, refer to the service proce-
dure section in the applicable chapter.
2. Ignition Timing
A: MEASUREMENT
1. 2200 cc MODEL
1) Warm-up the engine.
G2M0094
2) To check the ignition timing, connect a timing light to #1
cylinder spark plug cord, and illuminate the timing mark
with the timing light.
3) Start the engine at idle speed and check the ignition
timing.
If the timing is not correct, check the ignition control sys-
tem.
Ignition timing [BTDC/rpm]:
14°±8°/700 (MT)
20°±8°/700 (AT)
2. 2500 cc MODEL
CAUTION:
After warming-up, engine becomes very hot. Be care-
ful not to burn yourself during measurement.
1) Warm-up the engine.
B2M0750A
2) To check the ignition timing, connect a timing light to #1
cylinder spark plug cord, and illuminate the timing mark
with the timing light.
3) Start the engine at idle speed and check the ignition
timing.
If the timing is not correct, check the ignition control sys-
tem.
Ignition timing [BTDC/rpm]:
15°±8°/700
2
2-2
1. Foreword - 2. Ignition Timing

3. Engine Idle Speed
A: MEASUREMENT
1) Before checking idle speed, check the following:
(1) Ensure that air cleaner element is free from
clogging, ignition timing is correct, spark plugs are in
good condition, and that hoses are connected properly.
(2) Ensure that malfunction indicator light (CHECK
ENGINE light) does not illuminate.
2) Warm-up the engine.
G2M0096
3) Connect Subaru Select Monitor or the OBD-II general
scan tool to data link connector.
CAUTION:
When connecting Subaru Select Monitor, turn ignition
switch to OFF.
4) Start the engine and measure engine speed.
NOTE:
Engine speed is indicated on Subaru Select Monitor by
selecting “MODE F04”.
G2M0097
NOTE:

When using the OBD-II general scan tool, carefully read
its operation manual.

When Subaru Select Monitor is not used, attach the
pickup sensor on tachometer (Secondary pickup type) to
#1 cylinder spark plug cord.

This ignition system provides simultaneous ignition for
#1 and #2 plugs. It must be noted that some tachometers
may register twice that of actual engine speed.
5) Check idle speed when unloaded. (With headlights,
heater fan, rear defroster, radiator fan, air conditioning, etc.
OFF)
Idle speed (No load and gears in neutral (MT) or N or
P (AT) position):
700±100 rpm
6) Check idle speed when loaded. (Turn air conditioning
switch to “ON” and operate compressor for at least one
minute before measurement.)
Idle speed [A/C“ON”, no load and gears in neutral
(MT) or N or P (AT) position]:
850±50 rpm
CAUTION:
Never rotate idle adjusting screw. If idle speed is out
of specifications, refer to General On-board Diagnosis
Table under “2-7 On-Board Diagnostics II System”.
3
2-2
3. Engine Idle Speed

G2M0093
4) Connect oil pressure gauge hose to cylinder block.
5) Start the engine, and measure oil pressure.
Oil pressure:
98 kPa (1.0 kg/cm
2,14 psi) or more at 800 rpm
294 kPa (3.0 kg/cm2, 43 psi) or more at 5,000 rpm
CAUTION:

If oil pressure is out of specification, check oil
pump, oil filter and lubrication line.


If oil pressure warning light is turned ON and oil
pressure is in specification, replace oil pressure
switch.

NOTE:
The specified data is based on an engine oil temperature
of 80°C (176°F).
6) After measuring oil pressure, install oil pressure switch.
Tightening torque:
25±3 N⋅m (2.5±0.3 kg-m, 18.1±2.2 ft-lb)
7) Install generator and V-belt in the reverse order of
removal, and adjust the V-belt deflection.
8
2-2
6. Engine Oil Pressure

B2M0077A
(6) Check the valve guide protrusion.
Valve guide protrusion: L
17.5—18.0 mm (0.689—0.709 in)
B2M0078
(7) Ream the inside of valve guide with ST. Gently
rotate the reamer clockwise while pressing it lightly into
valve guide, and return it also rotating clockwise. After
reaming, clean valve guide to remove chips.
ST 499767400 VALVE GUIDE REAMER
CAUTION:
Apply engine oil to the reamer when reaming.
If the inner surface of the valve guide is torn, the
edge of the reamer should be slightly ground with an
oil stone.
If the inner surface of the valve guide becomes lus-
trous and the reamer does not chips, use a new reamer
or remedy the reamer.
(8) Recheck the contact condition between valve and
valve seat after replacing valve guide.
43
2-3SERVICE PROCEDURE
6. Cylinder Head

Type of sound Condition Possible cause
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
2-3DIAGNOSTICS
2. Engine Noise

G2M0762
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 498267600 CYLINDER HEAD TABLE
ST2 499767200 VALVE GUIDE REMOVER
G2M0763
(3) Turn cylinder head upside down and place ST as
shown in the figure.
ST 498267700 VALVE GUIDE ADJUSTER
G2M0764
(4) Before installing new valve guide, make sure that
neither scratches nor damages exist on the inside sur-
face 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 498267700 VALVE GUIDE ADJUSTER
(6) Check the valve guide protrusion.
Valve guide protrusion: L
12.0—12.4 mm (0.472—0.488 in)
(7) Ream the inside of valve guide with ST. Gently
rotate the reamer clockwise while pressing it lightly into
valve guide, and return it also rotating clockwise. After
reaming, clean valve guide to remove chips.
ST 499767400 VALVE GUIDE REAMER
CAUTION:
Apply engine oil to the reamer when reaming.
If the inner surface of the valve guide is torn, the
edge of the reamer should be slightly ground with an
oil stone.
If the inner surface of the valve guide becomes lus-
trous and the reamer does not chips, use a new reamer
or remedy the reamer.
(8) Recheck the contact condition between valve and
valve seat after replacing valve guide.
39
2-3bSERVICE PROCEDURE
4. Cylinder Head

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. Engine Lubrication System
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 pos-
sible causes as listed in
1.—2)
17
2-4DIAGNOSTICS
1. Engine Lubrication System

B3M0417A
8) Insert the thread portion of the other inner cable end
into the connector hole of the selector lever, and fix the
other outer cable end to the bracket.
9) Adjust the inner cable length.
(1) Put connector into contact with nut

2.
(2) Tighten nut

1.
Tightening torque:
7.4±2.0 N⋅m (0.75±0.2 kg-m, 5.4±1.4 ft-lb)
10) After completion of fitting, make sure that the selector
lever operates smoothly all across the operating range.
11) Connect the harnesses and check the following items.
(1) The engine starts operating when selector lever is
in position“P”, but not in other positions.
(2) The back-up light is lit when the selector lever is in
position“R”, but not in other positions.
B3M0348A
12) Check selector lever operation.
WARNING:
Stop the engine while checking operation of selector
lever.
(1) Check that selector lever does not move from“N”
to“R”without pushing the button.
(2) Check that selector lever does not move from“R”
to“P”without pushing the button.
(3) Check that selector lever does not move from“P”
to“R”without pushing the button and the brake pedal
depressed. [With ignition key set at“ON”.]
(4) Check that selector lever does not move from“3”to
“2”without pushing the button.
13) Check shift-lock system.
(1) Ensure ignition switch rotates from“ACC”to
“LOCK”when the selector lever is set at“P”. Also check
that ignition key can be removed from the“LOCK”posi-
tion only.
(2) Ensure selector lever moves from“P”to any other
position when the brake pedal is depressed with igni-
tion key set at“ON”or“START”.
16
3-3SERVICE PROCEDURE
2. Automatic Transmission