engine SUBARU LEGACY 1996 Service Repair Manual

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”
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“e”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“e”:
The oil seal of rack housing is damaged.
Replace the oil seal and the parts that are damaged
during disassembly with new ones.
50
4-3SERVICE PROCEDURE
6. Control Valve (Power Steering Gearbox) [RHD model]

B4M0557A
4) Temporarily install clamp E on pipes C and D.
CAUTION:
Ensure that the letter“8”on each clamp side are
diagonally opposite each other as shown in the figure.
5) Tighten clamp E firmly.
Tightening torque:
7.4±2.0 N⋅m (0.75±0.20 kg-m, 5.4±1.4 ft-lb)
6) Tighten joint nut.
Tightening torque:
15±5 N⋅m (1.5±0.5 kg-m, 10.8±3.6 ft-lb)
G4M0099
7) Connect pipes A and B to four pipe joints of gearbox.
Connect upper pipe B first, and lower pipe A second.
Tightening torque:
13±3 N⋅m (1.3±0.3 kg-m, 9.4±2.2 ft-lb)
8) Install jack-up plate.
9) Connect battery minus terminal.
10) Feed the specified fluid and discharge air.
NOTE:
Never start the engine before feeding the fluid; otherwise
vane pump might be seized up.
65
4-3SERVICE PROCEDURE
7. Pipe Assembly (Power Steering System) [LHD model]

B4M0671A
7) Connect pipes A and B to four pipe joints of gearbox.
Connect upper pipe A first, and lower pipe B second.
Tightening torque:
13±3 N⋅m (1.3±0.3 kg-m, 9.4±2.2 ft-lb)
8) Install jack-up plate.
9) Connect battery negative terminal.
10) Feed the specified fluid and discharge air.
NOTE:
Never start the engine before feeding the fluid; otherwise
vane pump might be seized up.
B4M0674A
70
4-3SERVICE PROCEDURE
8. Pipe Assembly (Power Steering System) [RHD model]

B4M0558
9. Oil Pump (Power Steering System)
A: REMOVAL
1) Remove ground cable from battery.
2) Drain the working fluid about 0.35
(0.4 US qt, 0.3 Imp
qt) from oil tank.
3) Remove pulley belt cover bracket.
B4M0559A
4) Loosen oil pump pulley nut, then remove bolts which
secure alternator.
5) Loosen pulley belt(s).
6) Remove the nut and detach oil pump pulley.
B4M0556A
7) Remove bolt A. Disconnect pipe C from oil pump. Dis-
connect pipe D from oil tank.
CAUTION:

Do not allow fluid from the hose end to come into
contact with pulley belt.

To prevent foreign matter from entering the hose
and pipe, cover the open ends of them with a clean
cloth.

Except when only oil tank needs to be inspected,
detach oil tank and oil pump as a unit. Then separate
one from the other on a work bench to prevent oil from
spilling on any part of the engine.
B4M0560
8) Remove three bolts from the front side of oil pump and
detach the pump.
9) Remove three bolts from the lower side of bracket and
detach the bracket.
CAUTION:
The bracket does not need to be removed unless it is
damaged.
71
4-3SERVICE PROCEDURE
9. Oil Pump (Power Steering System)

6) Check
(1) When reassembly procedures have been
completed, turn shaft by hand to ensure it turns
smoothly. If it binds or other unusual conditions are
evident, disassemble again and check for foreign mat-
ter trapped on sliding surfaces and improper installa-
tion. Eliminate the cause of trouble.
(2) Check followings by referring to“CHECK”article.

Excessive play in pulley shaft

Ditch deflection of pulley

Resistance to rotation of pulley

Measurement of generated oil pressure
F: INSTALLATION
1) Install bracket on engine.
Tightening torque:
22±2 N⋅m (2.2±0.2 kg-m, 15.9±1.4 ft-lb)
2) Install oil pump on oil tank as follows outside the
vehicle:
NOTE:
Prior to installation, make sure that all oil is removed from
oil pump, oil tank and pipe.
B4M0562A
3) Place oil pump in vise.
CAUTION:
Do not place oil pump directly in vise; use soft pads
and hold oil pump lightly to protect it.
4) Install oil tank on oil pump.
Tightening torque:
Bolt C: 15.7±2.4 N⋅m
(1.60±0.24 kg-m, 11.58±1.77 ft-lb)
Bolt D: 18.1±2.5 N⋅m
(1.85±0.25 kg-m, 13.35±1.84 ft-lb)
CAUTION:
Discard old seal washer and replace with a new one.
79
4-3SERVICE PROCEDURE
9. Oil Pump (Power Steering System)

B4M0560
5) Install oil pump, previously assembled to oil tank, on
bracket.
Tightening torque:
20.1±2.5 N⋅m (2.05±0.25 kg-m, 14.8±1.8 ft-lb)
6) Place oil pump pulley and tighten pulley nut temporarily.
B4M0556A
7) Interconnect pipes C and D.
Tightening torque:
Joint nut
15±5 N⋅m (1.5±0.5 kg-m, 10.8±3.6 ft-lb)
CAUTION:
If a hose is twisted at this step, the hose may come into
contact with some other parts.
8) Install pulley belt to oil pump.
9) Tighten oil pump pulley nut to the specified torque.
Tightening torque:
61±7 N⋅m (6.2±0.7 kg-m, 44.8±5.1 ft-lb)
10) Adjust pulley belt tension.
11) Tighten bolt belt tension.
Tightening torque:
8±2 N⋅m (0.8±0.2 kg-m, 5.8±1.4 ft-lb)
12) Install pulley belt cover bracket.
13) Connect minus terminal of battery.
14) Feed the specified fluid and discharge air.
NOTE:
Never start the engine before feeding the fluid; otherwise
vane pump might be seized up.
80
4-3SERVICE PROCEDURE
9. Oil Pump (Power Steering System)

10. Power Steering Fluid
A: RECOMMENDED AIR BLEEDING AND
POWER STEERING FLUID
Recommended power steering fluid Manufacturer
ATF DEXRON II or ATF DEXRON IIEB.P.
CALTEX
CASTROL
MOBIL
SHELL
TEXACO
1) Feed the specified fluid with its level being about 5 cm
(2.0 in) lower than the mouth of tank.
2) Continue to turn steering wheel slowly from lock to lock
until bubbles stop appearing in the tank while keeping the
fluid at that level.
3) In case air is absorbed to deliver bubbles into piping
because the fluid level is lower, leave it about half an hour
and then do the step 2) all over again.
4) Start, and idle the engine.
5) Continue to turn steering wheel slowly from lock to lock
again until bubbles stop appearing in the tank while keep-
ing the fluid at that level.
It is normal that bubbles stop appearing after three times
turning of steering wheel.
6) In case bubbles do not stop appearing in the tank, leave
it about half an hour and then do the step 5) all over again.
7) Stop the engine, and take out safety stands after jack-
ing up vehicle again.
Then lower the vehicle, and idle the engine.
8) Continue to turn steering wheel from lock to lock until
bubbles stop appearing and change of the fluid level is
within 3 mm (0.12 in).
9) In case the following happens, leave it about half an
hour and then do step 8) again.
(1) The fluid level changes over 3 mm (0.12 in).
(2) Bubbles remain on the upper surface of the fluid.
(3) Grinding noise is generated from oil pump.
81
4-3SERVICE PROCEDURE
10. Power Steering Fluid

10) Check the fluid leakage at flare nuts after turning
steering wheel from lock to lock with engine running.
CAUTION:

Before checking, wipe off any fluid on flare nuts and
piping.

In case the fluid leaks from flare nut, it is caused by
dust (or the like) and/or damage between flare and
tapered seat in piping.

So remove the flare nut, tighten again it to the speci-
fied torque after cleaning flare and tapered seat. If flare
or tapered seat is damaged, replace it with a new one.
11) Inspect fluid level on flat and level surface with engine
“OFF”by indicator of filler cap.
If the level is at lower point or below, add fluid to keep the
level in the specified range of the indicator. If at upper point
or above, drain fluid by using a syringe or the like.
Fluid capacity:
0.7
(0.7 US qt, 0.6 Imp qt)
B4M0563
(1) Check at temperature 21°C (70°F) on reservoir sur-
face of oil pump.
(2) Check at temperature 60°C (140°F) on reservoir
surface of oil pump.
82
4-3SERVICE PROCEDURE
10. Power Steering Fluid

1. Power Steering
1. STEERING CONDITION
Heavy steering
effort in all rangeHeavy steering
effort at stand stillSteering wheel
surges when turn-
ing.Vehicle leads to
one side or the
other.Poor return of
steering wheel to
center
Pulley belt
1. Unequal length of pulley
belts
2. Adhesion of oil and
grease
3. Loose or damage of pul-
ley belt
4. Poor uniformity of pulley
belt cross section
5. Pulley belt touches to
pulley bottom
6. Poor revolution of pulleys
except oil pump pulley
7. Poor revolution of oil
pump pulley
GOOD
NOT GOOD
Adjust or replace.Fluid line
1. Folded hose
2. Flattened pipe
GOOD
NOT
GOODReform or
replace.
Tire and rim
1. Flat tire
2. Mix use of different tires
3. Mix use of different rims
4. Abnormal wear of tire
5. Unbalance of remained
grooves
6. Unbalance of tire pres-
sure
GOOD
NOT
GOODFix or replace.
Tire and rim
1. Improper tires out of
specification
2. Improper rims out of
specification
3. Tires not properly
inflated*1
GOOD
NOT GOOD
Replace or reinflate.Front alignment
1. Improper or unbalance
caster
2. Improper or unbalance
toe-in
3. Loose connection of sus-
pension
GOOD
NOT
GOODAdjust or
retighten.
Fluid
1. Low fluid level
2. Aeration
3. Dust mix
4. Deterioration of fluid
5. Poor warming-up of fluid
*2
GOOD
NOT GOOD
Refill, bleed air, replace or
instruct customer.Others
1. Damaged joint assembly
2. Unbalanced height
3. One-sided weight
GOOD
Measure steering effort.
NOT
GOODReplace, adjust or
instruct customer.
Idling speed
1. Lower idling speed
2. Excessive drop of
idling speed at start
or at turning steering
wheel *3
GOOD
NOT GOOD
Adjust or instruct customer.
*1 If tires and/or rims are wider, the load to power steering system is the more. Accordingly, in a
condition, for example before fluid warms-up, relief valve may work before maximum turning angle.
In this case, steering effort may be heavy. When measured hydraulic pressure is normal, there is
no abnormal thing.
*2 In cold weather, steering effort may be heavy due to increased flow resistance of cold fluid. After
warming up engine, turn steering wheel from stop to stop several times to warm up fluid. Then if
steering effort reduces normally, there is no abnormal thing.
*3 In cold weather or with insufficient warm-up of engine, steering effort may be heavy due to exces-
sive drop of idling when turning steering wheel. In this case, it is recommended to start the vehicle
with increasing engine speed than usual. Then if steering effort reduces normally, there is no
abnormal thing. Measure hydraulic pressure.
GOOD
Measure steering effort.








83
4-3DIAGNOSTICS
1. Power Steering

2. MEASUREMENT OF HYDRAULIC PRESSURE
CAUTION:
Be sure to complete all items aforementioned in
“STEERING CONDITION”4-3 [K101], prior to measur-
ing hydraulic pressure. Otherwise, pressure can not be
measured correctly.
Measure regular pressure at
idling with valve opened.
GOOD
NOT GOOD
Flattened pipes or hosesReplace bad parts.
NOT GOOD
Leakage of fluid lineReplace.
NOT GOOD
Obstacle in fluid lineReplace fluid or component of
fluid line.
Measure relief pressure at
idling with valve closed.
GOOD
NOT GOOD
Poor work of relief valveReplace oil pump.
NOT GOOD
Fluid leakage inside oil pump
NOT GOOD
Excessive wear of vane pump
mechanism
Measure working pressure of
control valve at idling with
valve opened, turning steering
wheel from stop to stop.NOT GOOD
Poor work of control valveReplace valve assembly or
pinion and valve assembly.
CAUTION:

Do not leave the valve of pressure gauge closed or
hold the steering wheel at stop end for 5 seconds or
more in any case, as the oil pump may be damaged
due to long keep of these conditions.

Put cotton cloth waste at a place where fluid drops
before pressure gauge is installed. Wipe off split fluid
thoroughly after the measurement.
NOTE:
Keep engine idling during the measurement.


84
4-3DIAGNOSTICS
1. Power Steering