SUBARU LEGACY 1996 Service Repair Manual

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

G2M0091
B: INSTALLATION
1) Install oil pressure switch onto engine block.
Tightening torque:
25±3 N⋅m (2.5±0.3 kg-m, 18.1±2.2 ft-lb)
2) Connect terminal of oil pressure switch.
G2M0090
3) Install generator on bracket and temporary tighten
installing bolts.
B2M0017
4) Install front side V-belt and adjust it.

5) Install V-belt cover.
G2M0088
6) Connect connector and terminal to generator.
16
2-4SERVICE PROCEDURE
3. Oil Pressure Switch

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

1. Engine Cooling System
A: SPECIFICATIONS
1. 2200 cc MODEL
Cooling systemElectric fan + Forced engine coolant circulation
system
Total engine coolant capacity
(US qt, Imp qt) Approx. 6.1 (6.4, 5.4)
Engine
coolant
pumpTypeCentrifugal impeller type
Discharge performance IDischarge 20
(5.3 US gal, 4.4 Imp gal)/min.
Pump speed—total engine cool-
ant head760 rpm — 0.3 mAq (1.0 ftAq)
Engine coolant temperature 85°C (185°F)
Discharge performance IIDischarge 100
(26.4 US gal, 22.0 Imp gal)/min.
Pump speed—total engine cool-
ant head3,000 rpm — 5.0 mAq (16.4 ftAq)
Engine coolant temperature 85°C (185°F)
Discharge performance IIIDischarge 200
(52.8 US gal, 44.0 Imp gal)/min.
Pump speed—total engine cool-
ant head6,000 rpm — 23.0 mAq (75.5 ftAq)
Engine coolant temperature 85°C (185°F)
Impeller diameter 76 mm (2.99 in)
Number of impeller vanes 8
Pump pulley diameter 60 mm (2.36 in)
ThermostatTypeWax pellet type
Starts to open 76 — 80°C (169 — 176°F)
Fully opened91°C (196°F)
Valve lift9.0 mm (0.354 in) or more
Valve bore35 mm (1.38 in)
Radiator fanMotor120 W
Fan diameter x Blade 320 mm (12.60 in) x 5
RadiatorTypeCross flow, pressure type
Core dimensions670x361x16mm
(26.38 x 14.21 x 0.63 in)
Pressure range in which cap valve is openAbove: 88±10 kPa
(0.9±0.1 kg/cm
2, 12.8±1.4 psi)
Below: 4.9 to 9.8 kPa
(0.05 to 0.1 kg/cm
2, 0.7 to 1.4 psi)
FinsCorrugated fin type
Reservoir
tankCapacity 0.5
(0.5 US qt, 0.4 Imp qt)
2
2-5SPECIFICATIONS AND SERVICE DATA
1. Engine Cooling System

2. 2500 cc MODEL
Cooling systemElectric fan + Forced engine coolant circulation
system
Total engine coolant capacity
(US qt, Imp qt) Approx. 6.1 (6.4, 5.4)
Engine
coolant
pumpTypeCentrifugal impeller type
Discharge performance IDischarge 20
(5.3 US gal, 4.4 Imp gal)/min.
Pump speed—total engine cool-
ant head760 rpm—0.3 mAq (1.0 ftAq)
Engine coolant temperature 85°C (185°F)
Discharge performance IIDischarge 100
(26.4 US gal, 22.0 Imp gal)/min.
Pump speed—total engine cool-
ant head3,000 rpm—5.0 mAq (16.4 ftAq)
Engine coolant temperature 85°C (185°F)
Discharge performance IIIDischarge 200
(52.8 US gal, 44.0 Imp gal)/min.
Pump speed—total engine cool-
ant head6,000 rpm—23.0 mAq (75.5 ftAq)
Engine coolant temperature 85°C (185°F)
Impeller diameter 76 mm (2.99 in)
Number of impeller vanes 8
Pump pulley diameter 60 mm (2.36 in)
ThermostatTypeWax pellet type
Starts to open 76—80°C (169—176°F)
Fully opened91°C (196°F)
Valve lift9.0 mm (0.354 in) or more
Valve bore35 mm (1.38 in)
Radiator fanMotor120 W (main fan)
140 W (sub fan)
Fan diameter x Blade340 mm (13.39 in) x 5 (main fan)
280 mm (11.02 in) x 4 (sub fan)
RadiatorTypeCross flow, pressure type
Core dimensions670x361x25mm
(26.38 x 14.21 x 0.98 in)
Pressure range in which cap valve is openAbove: 88±10 kPa
(0.9±0.1 kg/cm
2, 12.8±1.4 psi)
Below:4.9 to9.8 kPa
(0.05 to0.1 kg/cm
2,0.7 to1.4 psi)
FinsCorrugated fin type
Reservoir
tankCapacity 0.5
(0.5 US qt, 0.4 Imp qt)
B: SERVICE DATA
Engine
coolant
pumpClearance between impeller and caseStandard
Limit0.5—0.7 mm (0.020—0.028 in)
1.0 mm (0.039 in)
“Thrust”runout of impeller end 0.5 mm (0.020 in)
3
2-5SPECIFICATIONS AND SERVICE DATA
1. Engine Cooling System

1. Engine Coolant Pump
G2M0201

1Engine coolant pump ASSY


2Gasket


3Heater hose


4Thermostat


5Gasket


6Thermostat case
Tightening torque: N⋅m (kg-m, ft-lb)
T1: First 10+4
0(1.0+0.4
0, 7.2+2.9
0)
Second 10+4
0(1.0+0.4
0, 7.2+2.9
0)
T2: 6.4±0.5 (0.65±0.05, 4.7±0.4)
4
2-5COMPONENT PARTS
1. Engine Coolant Pump

2. Radiator and Radiator Fan
B2M0300A

1Radiator lower cushion


2Radiator


3O-ring


4Air vent plug


5Radiator upper cushion


6Radiator upper bracket


7Clamp


8Radiator inlet hose


9Engine coolant reservoir tank cap


10Over flow hose


11Engine coolant reservoir tank


12Shroud


13Radiator main fan motor ASSY


14Radiator outlet hose

15Radiator drain pipe


16Gasket


17Radiator drain plug


18ATF hose clamp


19ATF inlet hose A


20ATF outlet hose A


21ATF pipe


22ATF outlet hose B


23ATF inlet hose B
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 6.9±1.5 (0.7±0.15, 5.1±1.1)
T2: 12±3 (1.2±0.3, 8.7±2.2)
5
2-5COMPONENT PARTS
2. Radiator and Radiator Fan

3. Engine Coolant Pipe
G2M0203

1Engine coolant temperature sensor


2Engine coolant temperature gauge


3Engine coolant pipe


4O-ring


5By-pass hose
Tightening torque: N⋅m (kg-m, ft-lb)
T: 6.4±0.5 (0.65±0.05, 4.7±0.4)
6
2-5COMPONENT PARTS
3. Engine Coolant Pipe

1. On-Car Service
A: DRAINING OF ENGINE COOLANT
1) Lift-up the vehicle.
B2M0133A
2) Fit vinyl tube to drain pipe.
B2M0015A
3) Loosen drain cock to drain engine coolant into con-
tainer.
NOTE:
Remove radiator cap so that engine coolant will drain
faster.
B2M0301
B: FILLING OF ENGINE COOLANT
1) Remove air vent plug from radiator.
B2M0135
2) Fill engine coolant into radiator up to filler neck position.
7
2-5SERVICE PROCEDURE
1. On-Car Service