SUBARU LEGACY 1996 Service Repair Manual

B2M0157
5) Remove throttle body from intake manifold.
B2M0161B
6) Remove fuel pipes, etc. from intake manifold.


1Pressure regulator


2Fuel pipe ASSY
7) Remove EGR solenoid valve and purge control sole-
noid valve.
B2M0161B
C: ASSEMBLY
1) Install EGR solenoid valve and purge control solenoid
valve.
2) Assemble fuel pipes, etc. to intake manifold.


1Pressure regulator


2Fuel pipe ASSY
B2M0157
3) Assemble throttle body to intake manifold.
CAUTION:
Replace gasket with a new one.
Tightening torque:
22±2 N⋅m (2.2±0.2 kg-m, 15.9±1.4 ft-lb)
H2M1247
4) Install idle air control solenoid valve to intake manifold.
CAUTION:
Replace gasket with a new one.
Tightening torque:
6.4±0.5 N⋅m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)
13
2-7SERVICE PROCEDURE
4. Intake Manifold

B2M0347A
5) Install engine harness onto intake manifold.
6) Connect connectors to throttle position sensor, ignition
coil, fuel injectors, idle air control solenoid valve, purge
control solenoid valve and EGR solenoid valve.


1EGR solenoid valve


2Throttle position sensor


3Idle air control solenoid valve


4Purge control solenoid valve


5Harness band
B2M0757A
7) Connect engine ground terminal to intake manifold.
B2M0159
D: INSTALLATION
1) Install intake manifold onto cylinder heads.
CAUTION:
Always use new gaskets.
Tightening torque:
25±2 N⋅m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
G2M0296
2) Connect fuel hoses.
G2M0091
3) Connect connector to oil pressure switch.
14
2-7SERVICE PROCEDURE
4. Intake Manifold

G2M0408
4) Connect connector to crankshaft position sensor.
G2M0416
5) Connect connector to camshaft position sensor.
B2M0346
6) Connect connector to knock sensor.
B2M0345A
7) Connect connectors to engine coolant temperature sen-
sor

1and thermometer
2.
B2M0019
8) Connect engine harness connector to bulkhead har-
ness connectors.
15
2-7SERVICE PROCEDURE
4. Intake Manifold

G2M0370
9) Connect canister hoses.
B2M0342
10) Connect brake booster vacuum hose.
H2M1259A
11) Connect engine coolant hose
1to idle air control sole-
noid valve.
12) Connect air by-pass hose

2to idle air control solenoid
valve.
H2M1246
13) Connect engine coolant hoses to throttle body.
B6M0160
14) Connect spark plug cords to ignition coil.
16
2-7SERVICE PROCEDURE
4. Intake Manifold

B2M0334
15) Install power steering pump on bracket.
(1) Install power steering pump on bracket, and tighten
bolts.
Tightening torque:
20.1±2.5 N⋅m (2.05±0.25 kg-m, 14.8±1.8 ft-lb)
B2M0340
(2) Install power steering pipe bracket on right side
intake manifold.
G2M0286
(3) Install front side V-belt, and adjust it.

B2M0017
(4) Install V-belt cover.
G2M0280
16) Connect accelerator cable
1.
17) Connect cruise control cable

2. (With cruise control
model)
17
2-7SERVICE PROCEDURE
4. Intake Manifold

B2M0154
18) Install air cleaner element, air cleaner upper cover and
air intake duct.
19) Connect connector to mass air flow sensor.
B2M0154
5. Engine Coolant Temperature Sensor
A: REMOVAL AND INSTALLATION
1) Remove air intake duct.
G2M0407
2) Disconnect connector from engine coolant temperature
sensor.
3) Remove engine coolant temperature sensor.
G2M0407
4) Installation is in the reverse order of removal.
Tightening torque:
25±3 N⋅m (2.5±0.3 kg-m, 18.1±2.2 ft-lb)
G2M0408
6. Crankshaft Position Sensor
A: REMOVAL AND INSTALLATION
1) Remove bolt which install crankshaft position sensor to
cylinder block.
18
2-7SERVICE PROCEDURE
4. Intake Manifold - 6. Crankshaft Position Sensor

G2M0409
2) Remove crankshaft position sensor, and disconnect
connector from it.
G2M0408
3) 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)
B2M0154
7. Front Oxygen Sensor
A: REMOVAL
1) Remove air intake duct.
G2M0544
2) Disconnect connector from front oxygen sensor.
3) Lift-up the vehicle.
4) Apply SUBARU CRC or its equivalent to threaded por-
tion of front oxygen sensor, and leave it for one minute or
more.
SUBARU CRC (Part No. 004301003)
19
2-7SERVICE PROCEDURE
6. Crankshaft Position Sensor - 7. Front Oxygen Sensor

G2M0411
5) Remove front oxygen sensor.
CAUTION:
When removing oxygen sensor, do not force oxygen
sensor especially when exhaust pipe is cold, other-
wise it will damage exhaust pipe.
G2M0412
B: INSTALLATION
1) Before installing front oxygen sensor, apply anti-seize
compound only to threaded portion of front oxygen sensor
to make the next removal easier.
Anti-seize compound:
SS-30 by JET LUBE
CAUTION:
Never apply anti-seize compound to protector of front
oxygen sensor.
G2M0411
2) Install front oxygen sensor.
Tightening torque:
21±3 N⋅m (2.1±0.3 kg-m, 15.2±2.2 ft-lb)
3) Lower the vehicle.
4) Connect connector of front oxygen sensor.
5) Install air intake duct.
20
2-7SERVICE PROCEDURE
7. Front Oxygen Sensor

B2M0335
8. Rear Oxygen Sensor
A: REMOVAL
1. EXCEPT CALIFORNIA 2200 cc MODEL
1) Lift-up the vehicle.
2) Disconnect connector from rear oxygen sensor.
3) Apply SUBARU CRC or its equivalent to threaded por-
tion of rear oxygen sensor, and leave it for one minute or
more.
SUBARU CRC (Part No. 004301003)
B2M0351
4) Remove rear oxygen sensor.
CAUTION:
When removing rear oxygen sensor, do not force rear
oxygen sensor especially when exhaust pipe is cold,
otherwise it will damage exhaust pipe.
B2M0740
2. CALIFORNIA 2200 cc MODEL
1) Disconnect connector from rear oxygen sensor.
2) Lift-up the vehicle.
3) Apply SUBARU CRC or its equivalent to threaded por-
tion of rear oxygen sensor, and leave it for one minute or
more.
SUBARU CRC (Part No. 004301003)
21
2-7SERVICE PROCEDURE
8. Rear Oxygen Sensor

B2M0741
4) Remove rear oxygen sensor.
CAUTION:
When removing rear oxygen sensor, do not force rear
oxygen sensor especially when exhaust pipe is cold,
otherwise it will damage exhaust pipe.
B2M0352A
B: INSTALLATION
1. EXCEPT CALIFORNIA 2200 cc MODEL
1) Before installing rear oxygen sensor, apply anti-seize
compound only to threaded portion of rear oxygen sensor
to make the next removal easier.
Anti-seize compound:
SS-30 by JET LUBE
CAUTION:
Never apply anti-seize compound to protector of rear
oxygen sensor.
B2M0351
2) Install rear oxygen sensor.
Tightening torque:
21±3 N⋅m (2.1±0.3 kg-m, 15.2±2.2 ft-lb)
3) Connect connector of rear oxygen sensor.
4) Lower the vehicle.
B2M0742A
2. CALIFORNIA 2200 cc MODEL
1) Before installing rear oxygen sensor, apply anti-seize
compound only to threaded portion of rear oxygen sensor
to make the next removal easier.
Anti-seize compound:
SS-30 by JET LUBE
CAUTION:
Never apply anti-seize compound to protector of rear
oxygen sensor.
22
2-7SERVICE PROCEDURE
8. Rear Oxygen Sensor