oil level SUBARU LEGACY 1996 Service User Guide

2. Engine Noise
Valve lash adjusters may make clicking noise once engine
starts. It is normal if clicking noise ceases after a few min-
utes.
If clicking noise continues for more than a few minutes,
inspect Hydraulic Lash Adjuster (HLA) in accordance with
the following flow chart.
Inspect the engine oil level
(1) Adjust the oil level between“F”and“L”.
(2) Replace the oil when deteriorated.
Load less engine operation to bleed air from
HLA.
(1) Warm-up engine for about five minutes.
(2) If the noise is remaining, keep the engine
running at 2,000 rpm for up to 20 minutes until
the noise fades away.Noise is eliminated.
Keep the engine running at 2,500 rpm for about
five minutes to bleed air completely.
Noise remains or comes
back.END
HLA is rigid and has no valve clearance.
Remove the rocker cover and inspect HLA.
Press HLA while it is facing the base circle of
the cam.
HLA is normal. The noise may come from other
sources.
HLA is not rigid.
There is valve clearance.
Check whether the clearance between HLA and
the bushing of the cylinder head is within
allowance or not.
HLA is seized. Replace HLA.
Out of allowance
Replace the cylinder head related parts or the
HLA, whichever is necessary.
Within allowance
Replace HLA.






78
2-3bDIAGNOSTICS
2. Engine Noise

1. Lubrication System
B2M0314A

1Plug


2Washer


3Relief valve spring


4Relief valve


5Oil seal


6Oil pump case


7Inner rotor


8Outer rotor


9Oil pump cover


10Oil filter


11O-ring


12Oil pump ASSY


13Oil pressure switch


14Oil filler duct

15Baffle plate


16Oil strainer stay


17O-ring


18Oil strainer


19Oil level gauge guide


20Oil pan


21Oil level gauge


22Washer


23Drain plug
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 5 (0.5, 3.6)
T2: 5
+1
0(0.5+0.1
0, 3.6+0.7
0)
T3: 6.4 (0.65, 4.7)
T4: 9.8 (1.0, 7.0)
T5: 44.1±3.4 (4.5±0.35, 32.5±2.5)
4
2-4COMPONENT PARTS
1. Lubrication System

B2M0724
13) Connect connector to front oxygen sensor.
B2M0725
14) Connect connector to rear oxygen sensor. (California
2200 cc model only)
G2M0302
15) 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)
B2M0320
16) Install radiator upper brackets.
Tightening torque:
12±3 N⋅m (1.2±0.3 kg-m, 8.7±2.2 ft-lb)
B2M0321
17) Install air intake duct.
18) Fill engine oil through filler pipe up to upper point of
level gauge.
Engine oil capacity:
2200 cc ; Upper level
4.0
(4.2 US qt, 3.5 Imp qt)
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)
14
2-4SERVICE PROCEDURE
2. Oil Pan and Oil Strainer

Lower level
3.5
(3.7 US qt, 3.1 Imp qt)
G2M0088
3. Oil Pressure Switch
A: REMOVAL
1) Remove alternator from bracket.
(1) Disconnect connector and terminal from generator.
B2M0017
(2) Remove V-belt cover.
(3) Loosen lock bolt and slider bolt, and remove front
side V-belt.
G2M0090
(4) Remove bolts which install generator on bracket.
G2M0091
2) Disconnect terminal from oil pressure switch.
3) Remove oil pressure switch.
15
2-4SERVICE PROCEDURE
2. Oil Pan and Oil Strainer

Lower level
3.5
(3.7 US qt, 3.1 Imp qt)
G2M0088
3. Oil Pressure Switch
A: REMOVAL
1) Remove alternator from bracket.
(1) Disconnect connector and terminal from generator.
B2M0017
(2) Remove V-belt cover.
(3) Loosen lock bolt and slider bolt, and remove front
side V-belt.
G2M0090
(4) Remove bolts which install generator on bracket.
G2M0091
2) Disconnect terminal from oil pressure switch.
3) Remove oil pressure switch.
15
2-4SERVICE PROCEDURE
2. Oil Pan and Oil Strainer

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

B: INSTALLATION
1. Install engine to transmission.
2. Tighten bolts which hold upper side of transmission to engine.
3. Remove lifting device and wire rope.
4. Remove garage jack.
5. Install pitching stopper.
AT model
6. Install torque converter onto drive plate.
7. Install canister and bracket.
8. Install power steering pump on bracket.
9. Tighten nuts which hold lower side of transmission to engine.
10. Tighten nuts which install front cushion rubber onto cross-
member.
11. Install front exhaust pipe and center exhaust pipe.
12. Connect hoses, connectors and cables.
13. Install air intake system.
Air intake duct
Air cleaner element and upper cover.
With A/C
14. Install A/C pressure hoses.
15. Install cooling system.
16. Install battery onto the vehicle, and connect cables.
17. Fill coolant.
18. Check ATF level, and connect if necessary. [AT]
19. Correct power steering oil, and bleed air.
20. Remove front hood stay, and close front hood.
21. Take off the vehicle from lift arms.












20
2-11SERVICE PROCEDURE
2. Engine

G2M0316
13) Drain ATF to remove ATF drain plug. (AT model)


1Front differential oil drain plug


2ATF drain plug
G2M0317
14) Disconnect ATF cooler hoses from pipes of transmis-
sion side, and remove ATF level gauge guide. (AT model)
G3M0023
15) Remove propeller shaft. (AWD model)
(1) Remove front cover of rear differential mount.
(2) Separate propeller shaft from rear differential.
G3M0024
(3) Remove bolts which hold center bearing onto body.
CAUTION:
Be careful not to drop propeller shaft.
G3M0025
(4) Remove propeller shaft from transmission.
CAUTION:
Be sure to use an empty container to catch oil flow-
ing out when removing propeller shaft.
Be sure not to damage oil seals and the frictional
surface of sleeve yoke.
Be sure to plug the opening in transmission after
removal of propeller shaft.
33
2-11SERVICE PROCEDURE
3. Transmission

3. Transmission Case
B3M0327A

1Transmission case ASSY


2Gasket


3Drain plug


4Snap ring (Outer)


5Speedometer driven gear


6Washer


7Speedometer shaft


8Snap ring (Outer)


9Oil seal


10Oil level gauge


11Pitching stopper bracket


12Clamp


13Clip
Tightening torque: N⋅m (kg-m, ft-lb)
T: 44±3 (4.5±0.3, 32.5±2.2)
Size All models Torque
8 mm bolt

5—
15
25±2 N⋅m
(2.5±0.2 kg-m,
18.1±1.4 ft-lb)
10 mm bolt

1—
4

16—
17
39±2 N⋅m
(4.0±0.2 kg-m,
28.9±1.4 ft-lb)
8
3-1COMPONENT PARTS
3. Transmission Case

B3M0037A
B: PRECAUTIONS
1) The following job should be followed before disassem-
bly:
(1) Clean oil, grease, dirt and dust from transmission.
(2) Remove drain plug

1to drain oil. After draining,
retighten it as before.
CAUTION:
Replace gasket with a new one.
Tightening torque:
44±3 N⋅m (4.5±0.3 kg-m, 32.5±2.2 ft-lb)
G3M0517
(3) Attach transmission to ST.
ST 499937100 TRANSMISSION STAND SET
2) Rotating parts should be coated with oil prior to assem-
bly.
3) All disassembled parts, if to be reused, should be rein-
stalled in the original positions and directions.
4) Gaskets and lock washers must be replaced with new
ones.
5) Liquid gasket should be used where specified to pre-
vent leakage.
6) Fill transmission gear oil through the oil level gauge
hole up to upper point level gauge.
C: INSPECTION
Disassembled parts should be washed clean first and then
inspected carefully.
1) Bearings
Replace bearings in the following cases:
Bearings whose balls, outer races and inner races are
broken or rusty.
Worn bearings
Bearings that fail to turn smoothly or make abnormal
noise when turned after gear oil lubrication.
B3M0038A
The ball bearing
3on the rear side of the drive pinion shaft


2should be checked for smooth rotation before the drive
pinion assembly is disassembled. In this case, because a
preload is working on the bearing, its rotation feels like it is
slightly dragging unlike the other bearings.
Bearings having other defects
16
3-1SERVICE PROCEDURE
1. General