engine SUBARU LEGACY 1996 Service Repair Manual

B2M0362
3) Remove pressure sources switching solenoid valve
from bracket.
4) Installation is in the reverse order of removal.
Tightening torque:
6.4±0.5 N⋅m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)
G2M0398
14. Fuel Injector
A: REMOVAL AND INSTALLATION
1) Release fuel pressure.

2) Disconnect connector from fuel injector.
G2M0431
3) Remove fuel injector from fuel pipe assembly.
B2M0169A
4) Installation is in the reverse order of removal.
CAUTION:
Replace O-rings and insulator.
Tightening torque:
T: 3.4±0.5 N⋅m (0.35±0.05 kg-m, 2.5±0.4 ft-lb)


1O-ring B


2O-ring A


3Fuel injector


4Insulator


5Fuel injector cup
G6M0095
15. Engine Control Module
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
28
2-7SERVICE PROCEDURE
13. Pressure Sources Switching Solenoid Valve (AT model) - 15. Engine Control Module

G2M0434
2) Detach floor mat of front passenger seat.
3) Remove protect cover.
B2M0363
4) Release the lock of ECM connector and disconnect it.
5) Remove nuts which install ECM onto body.
6) Take out ECM.
B2M0364
7) Connect ECM connector and lock it.
8) Installation is in the reverse order of removal.
29
2-7SERVICE PROCEDURE
15. Engine Control Module

1. Precautions
WARNING:
Place “No fire” signs near the working area.
Disconnect ground terminal from battery.
Be careful not to spill fuel on the floor.
G2M0340
A: RELEASING OF FUEL PRESSURE
1) Take off floor mat.
2) Remove access hole lid.
B2M0047
3) Disconnect connector from fuel pump.
4) Start the engine, and run it until it stalls.
5) After the engine stalls, crank it for five more seconds.
6) Turn ignition switch OFF.
G2M0340
B: DRAINING OF FUEL
1) Remove rear seat and seat back.
2) Remove access hole lid.
B2M0047
3) Disconnect connector from fuel pump.
4) Release fuel pressure.
10
2-8SERVICE PROCEDURE
1. Precautions

B2M0049
11) On AWD model, after removing fuel sub meter unit,
drain fuel from there.
WARNING:
Do not use a motor pump when draining fuel.
2. On-Car Services
A: MEASUREMENT OF FUEL PRESSURE
1) Release fuel pressure.
2) Connect connector to fuel pump.
G2M0347
3) Disconnect fuel delivery hoses from fuel filter, and con-
nect fuel pressure gauge.
G2M0348
4) Start the engine.
5) Measure fuel pressure while disconnecting pressure
regulator vacuum hose from collector chamber.
Fuel pressure:
235 — 265 kPa (2.4 — 2.7 kg/cm
2, 34 — 38 psi)
6) After connecting pressure regulator vacuum hose, mea-
sure fuel pressure.
Fuel pressure:
177 — 206 kPa (1.8 — 2.1 kg/cm
2, 26 — 30 psi)
WARNING:
Before removing fuel pressure gauge, release fuel
pressure.
NOTE:
If out of specification as measured at step 6), check or
replace pressure regulator and pressure regulator vacuum
hose.
12
2-8SERVICE PROCEDURE
1. Precautions - 2. On-Car Services

B2M0973A
G2M0296
4) In engine compartment, detach fuel delivery hose,
return hose and evaporation hose.
G2M0370
5) In engine compartment, detach canister hoses from
canister. (Except 2200 cc AWD model)
23
2-8SERVICE PROCEDURE
8. Fuel Delivery, Return and Evaporation Lines

B2M0633A
1. MECHANICAL APPLICATION TYPE
1) While pushing release lever

3to pivot and twisting it to
both sides, fit retainer spring

5onto the constricted portion
of pivot.
NOTE:
Confirm that retainer spring is securely fitted by observing
it through the main case hole.
2) Install release bearing

6and fasten it with two clips
2.
3) Install release lever seal

4.
G2M0235
4) After remounting engine and transmission on body,
make adjustment of the clutch release lever end play.
CAUTION:
Take care not to twist the cable during adjustment.
5) Install release lever return spring (Models without hill
holder only).
NOTE:
Hook up the return spring to right side hole of the release
lever.
G2M0242
4. Clutch Disc and Cover
A: REMOVAL
1) Install ST on flywheel.
ST 498497100 CRANKSHAFT STOPPER
2) Remove clutch cover and clutch disc.
CAUTION:
Take care not to allow oil on the clutch disc facing.
Do not disassemble either clutch cover or clutch
disc.
G2M0243
3) Remove flywheel.
7
2-10SERVICE PROCEDURE
3. Release Bearing and Lever - 4. Clutch Disc and Cover

B2M0328
B: INSPECTION
1. CLUTCH DISC
1) Facing wear
Measure the depth of rivet head from the surface of facing.
Replace if facings are worn locally or worn down to less
than the specified value.
Depth of rivet head:
Standard value
1.3—1.9 mm (0.051—0.075 in)
Limit of sinking
0.3 mm (0.012 in)
CAUTION:
Do not wash clutch disc with any cleaning fluid.
B2M0329A
2) Hardened facing
Correct by using emery paper or replace.
3) Oil soakage on facing
Replace clutch disc and inspect transmission front oil seal,
transmission case mating surface, engine rear oil seal and
other points for oil leakage.
B2M0330A
4) Deflection on facing
If deflection exceeds the specified value at the outer cir-
cumference of facing, repair or replace.
Limit for deflection:
1.0 mm (0.039 in) at R = 107 mm (4.21 in)
B2M0333A
5) Worn spline, loose rivets and torsion spring failure
Replace defective parts.
8
2-10SERVICE PROCEDURE
4. Clutch Disc and Cover

G2M0213
C: INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
Replace gasket with a new one.
When installing engine coolant pump, tighten bolts
in two stages in numerical sequence as shown in fig-
ure.
Tightening torque:
10
+4
0N⋅m (1.0+0.4
0kg-m, 7.2+2.9
0ft-lb)
G2M0214
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.
G2M0227
4) Install the thermostat in the intake manifold, and install
the thermostat cover together with a gasket.
CAUTION:
When reinstalling the thermostat, use a new gasket.
The thermostat must be installed with the jiggle pin
upward.
In this time, set the jiggle pin of thermostat for front
side.
G2M0215
B: INSPECTION
Replace the thermostat if the valve does not close com-
pletely at an ambient temperature or if the following 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—80.0°C (169—176°F)
Fully opens:
91°C (196°F)
12
2-5SERVICE PROCEDURE
2. Engine Coolant Pump - 3. Thermostat

B2M0015A
4. Radiator
A: REMOVAL
1) Disconnect battery cables and remove battery from
body.
2) Drain engine coolant.
Set container under the vehicle, and remove drain cock
from radiator.
B2M0304
3) Disconnect radiator outlet hose from thermostat cover.
4) Disconnect ATF cooler hoses from radiator. (AT model)
B2M0017
5) Remove V-belt cover.
B2M0305
6) Disconnect inlet hose from radiator.
G2M0263
7) Disconnect connectors of radiator main fan and sub fan
motor.
13
2-5SERVICE PROCEDURE
4. Radiator

B2M0323
5) Remove radiator fan motor assembly.
6) Remove fan motor from shroud.
B: INSTALLATION
Installation is in the reverse order of removal procedures.
Do the following:
1) Before installing radiator fan motor, apply a coat of seal-
ant to threads and tighten nuts.
2) Make sure radiator fan does not come into contact with
shroud when installed.
3) After installation, make sure there is no unusual noise
or vibration when fan is rotated.
G6M0095
7. Engine Coolant Pipe
A: REMOVAL
1) Release fuel pressure.

2) Disconnect ground cable from the battery.
B2M0015A
3) Drain engine coolant completely.

B2M0160
4) Remove intake manifold.

17
2-5SERVICE PROCEDURE
6. Radiator Fan and Fan Motor - 7. Engine Coolant Pipe