oil pump SUBARU LEGACY 1996 Service Repair Manual

ON-BOARD
DIAGNOSTICS
II
SYSTEM
[Tiq2]
2-

1
.
General

1~
Engine
control
module
(ECM)
~
Radiator
fan

~2
Ignition
coil~s
Radiator
fan
relay

~3
Ignitqr
~s
Pressure
sources
switching
solenoid
valve

~4
Crankshaft
position
sensor
~
Knock
sensor

~5
Camshaft
position
sensor
~
Back-pressure
transducer

Throttle
position
sensor
~s
Front
oxygen
sensor

~7
duel
injectors
~o
Rear
oxygen
sensor
(Except
California
model)

~8
Pressure
regulator
~
Pressure
sensor

Engine
coolant
temperature
sensor
~z
A/C
compressor

~o
Mass
air
flow
sensor
~
Inhibitor
switch

Idle
air
control
solenoid
valve
~
CHECK
ENGINE
malfunction
indicator
lamp
(MIL)

~z
Purge
control
solenoid
valve
~
Tachometer

0
Fuel
pump
~s
A/C
relay

0
PCV
valve
~
A/C
control
module

~s
Air
cleaner
~eIgnition
switch

Canister
~
Transmission
control
module
(TCM)

~
Main
relay
~o
Vehicle
speed
sensor
2

~a
Fuel
pump
relay
~
Data
link
connector
(For
Subaru
select
monitor)

~s
Fuel
filter
@
Data
link
connector
(For
Subaru
select
monitor
and

~o
Front
catalytic
converter
OBD-II
general
scan
tool)

Rear
catalytic
converter
@
Two
way
valve

~2
MGR
valve
~a
Rear
oxygen
sensor
(California
model
only)

EGR
control
solenoid
valve
~
Filter

3

s-$
[D601]
WIRING
DIAGRAM

6
.
Wiring
Diagram

No
.
Load

MB-2
Powerwindow
circuit
breaker

Engine
control
module

Fuel
pump
relay
MB-3
Main
relay

OBD-II
service
connector

MB-4A/C
relay
holder

MB-6
Headlight
LH

Diode
(Lighting)

Lighting
switch

Combination
meter
M
B_$

Headlight
RH

Combination
meter

Door
lock
timer

MB-9
Luggage
room
light

Radio

Room
light

MB-10
A/C
relay
holder

ALT-1
Combination
meter

IG
A/C
relay
holder

Cruise
control
module

ST
Engine
control
module

Inhibitor
switch

FB-2
Diode
(A/C)

Sub
fan
motor
FB-3
Sub
fan
relay-2

Engine
control
module

Fuel
pump
relay
FB-4
Ignition
coil

Transmission
control
module

Side
marker
light
LH
FB-6
Side
marker
light
RH

FB-7Door
lock
timer

FB-9Hazard
switch

AT
shift
lock
control
module
FB-10
Key
warning
switch

Power
antenna

FB-11
Radio

FB-12
Cigarette
lighter

FB-13
Remote
control
rearview
mirrorswitch

AT
shift
lock
control
module

Combination
switch
Front
washer
motor
FB-14
Front
wipermotor

Rear
washer
motor

Rear
wipermotor

Rear
wiper
relay

FB-15Transmission
control
module

Na
Load

Rear
defogger

FB-16
Rear
defogger
condenser

Reardefogger
switch

FB-17
Rear
defogger
switch

FB-18
AT
shift
lock
control
module

Inhibitor
switch

FB-19
Hazard
switch

Combination
meter
FB-20
Mode
control
panel
FB-21
Combination
meter
(Airbag)

Blower
motor
relay

Check
connector

FB-22
FRESH/RECIRC
actuator

Mode
actuator

Powerwindow
relay

Seat
belt
timer

FB-23
Airbag
.
control
module

FB-24
Airbag
control
module

FB-25
Lighting
switch

FB-26
Parking
switch

FB-27
Parking
switch

FB-28
Illumination
light

FB-29
Illumination
light

FB-30
Stop
light
switch

Stop
&
brake
switch

FB-31
Horn
relay

FB-32
Blower
motor
relay

FB-33
Parking
switch

License
plate
light
LH

License
plate
light
RH

FB-34
Rear
combination
light
LH

Rear
combination
light
RH

Rear
finisher
light
LH

Rear
finisher
light
RH

FB-35
Cruise
control
main
switch
Cruise
control
module

IMPORTANT
SAFETY
NOTICE

Providing
appropriate
service
and
repair
is
a
matter
of
great
importance
in
the
serviceman's
safety

maintenance
and
safe
operation,
function
and
performance
which
the
SUBARU
vehicle
possesses
.

In
case
the
replacement
of
partsor
replenishment
of
consumables
is
required,
genuine
SUBARU
parts

whose
parts
numbers
are
designated
or
their
equivalents
must
be
utilized
.

It
must
be
made
well
known
that
the
safety
of
the
serviceman
and
the
safe
operation
of
thevehicle
would

be
jeopardized
if
heused
any
service
parts,
consumables,
special
tools
and
work
procedure
manuals
which

are
not
approved
or
designated
by
SUBARU
.

How
to
use
this
manual

Service
Manual
is
divided
into
six
volumes
bysection
.
Refer
to
the
Table
of
Contents,
select
anduse
the
nec-

essary
section
.

This
supplement
includes
corrective
and/or
additional
information
in
relationto
the
above
six
service
manual

volumes
.
Please
place
it
in
a
handy
place
for
ready
reference
.

For
informationnot
covered
in
this
supplement,
refer
to
1992
SERVICE
MANUALS
(Pub
.
No
.
G205BE
and
G206BE)

and
1993
SERVICE
MANUAL
(Pub
.
No
.
G210BE)
.

Each
chapter
in
the
manual
is
basically
made
of
the
following
five
types
of
areas
.

M
:
Mechanism
and
function

C
:
Component
parts

W
:
Service
procedure

(X
:
Service
procedure)

(Y
:
Service
procedure)

T
:
Troubleshooting

~
The
description
of
each
area
is
provided
withfour
types
of
titles
different
in
size
as
shown
below
.
The
Title
No
.

or
Symbol
prefixes
each
title
in
order
that
the
construction
ofthe
article
and
theflow
of
explanation
can
be
easily

understood
.

[Example
of
each
title]

"
Area
title
:
W
.
Service
procedure
(one
of
the
five
types
of
areas)

"
Large
title
(Heading)
:
1
.
Oil
Pump
(to
denotethe
main
item
of
explanation)

"
Medium
title
(Section)
:
A
.
REMOVAL
(to
denote
thetype
of
work
in
principle)

"
Small
title
(Sub-section)
:
1
.
INNER
ROTATOR
(to
denote
a
derivative
item
of
explanation)

2

G2M0093
4) Connect oil pressure gauge hose to cylinder block.
5) Start the engine, and measure oil pressure.
Oil pressure:
98 kPa (1.0 kg/cm
2,14 psi) or more at 800 rpm
294 kPa (3.0 kg/cm2, 43 psi) or more at 5,000 rpm
CAUTION:

If oil pressure is out of specification, check oil
pump, oil filter and lubrication line.


If oil pressure warning light is turned ON and oil
pressure is in specification, replace oil pressure
switch.

NOTE:
The specified data is based on an engine oil temperature
of 80°C (176°F).
6) After measuring oil pressure, install oil pressure switch.
Tightening torque:
25±3 N⋅m (2.5±0.3 kg-m, 18.1±2.2 ft-lb)
7) Install generator and V-belt in the reverse order of
removal, and adjust the V-belt deflection.
8
2-2
6. Engine Oil Pressure

4. Cylinder Block
B2M0381A

1Oil pressure switch


2Cylinder block (RH)


3Service hole plug


4Gasket


5Oil separator cover


6Water pipe


7Oil pump


8Front oil seal


9Rear oil seal


10O-ring


11Service hole cover


12Cylinder block (LH)


13Water pump


14Baffle plate


15Oil strainer stay


16Oil strainer

17Gasket


18Oil pan


19Oil drain plug


20Gasket


21Oil filler pipe
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 5 (0.5, 3.6)
T2: 6.4 (0.65, 4.7)
T3: 10 (1.0, 7)
T4: 25±2 (2.5±0.2, 18.1±1.4)
T5: 47±3 (4.8±0.3, 34.7±2.2)
T6: 69±7 (7.0±0.7, 50.6±5.1)
T7: First 12±2 (1.2±0.2, 8.7±1.4)
Second 12±2 (1.2±0.2, 8.7±1.4)
9
2-3COMPONENT PARTS
4. Cylinder Block

7. Cylinder Block
A: REMOVAL
1. RELATED PARTS
1) Remove timing belt, camshaft sprocket and related
parts.

2) Remove intake manifold and cylinder head.

2. OIL PUMP AND ENGINE COOLANT PUMP
B2M0124A
50
2-3SERVICE PROCEDURE
7. Cylinder Block

1) Remove housing cover.
G2M0161
2) Remove flywheel or drive plate.
To lock crankshaft use ST.
ST 498497100 CRANKSHAFT STOPPER
3) Remove oil separator cover.
4) Remove engine coolant pipe.
5) Remove engine coolant pump.
G2M0162
6) Remove oil pump from cylinder block.
Use a flat-bladed screwdriver as shown in Figure when
removing oil pump.
CAUTION:
Be careful not to scratch the mating surface of cylin-
der block and oil pump.
51
2-3SERVICE PROCEDURE
7. Cylinder Block

E: INSTALLATION
1. OIL PUMP AND ENGINE COOLANT PUMP
B2M0124B
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 5 (0.5, 3.6)
T2: 6.4 (0.65, 4.7)
T3: 10 (1.0, 7)
T4: 72±3 (7.3±0.3, 52.8±2.2)
T5: First 12±2 (1.2±0.2, 8.7±1.4)
Second 12±2 (1.2±0.2, 8.7±1.4)
72
2-3SERVICE PROCEDURE
7. Cylinder Block

G2M0084
1) Install baffle plate.
2) Install oil strainer and O-ring
3) Install oil strainer stay.
4) Apply fluid packing to matching surfaces and install oil
pan.
Fluid packing:
THREE BOND 1207C or equivalent
G2M0194
5) Apply fluid packing to matching surfaces and install oil
separator cover.
Fluid packing:
THREE BOND 1215 or equivalent
G2M0161
6) Install flywheel or drive plate.
To lock crankshaft, use ST.
ST 498497100 CRANKSHAFT STOPPER
7) Install housing cover.
G2M0076
8) Installation of oil pump
(1) Discard front oil seal after removal. Replace with a
new one by using ST.
ST 499587100 OIL SEAL INSTALLER
73
2-3SERVICE PROCEDURE
7. Cylinder Block

B2M0390A
(2) Apply fluid packing to matching surface of oil pump.
Fluid packing:
THREE BOND 1215 or equivalent
(3) Install oil pump on cylinder block. Be careful not to
damage oil seal during installation.
CAUTION:
Do not forget to install O-ring and seal when install-
ing oil pump.
Align flat surface of oil pump’s inner rotor with
crankshaft before installation.
G2M0628
9) Install engine coolant pump and gasket.
CAUTION:
Be sure to use a new gasket.
When installing engine coolant pump, tighten bolts
in two stages in numerical sequence as shown in Fig-
ure.
10) Install engine coolant pipe.
11) Install oil filter.
2. RELATED PARTS
1) Install cylinder head and intake manifold.

2) Install timing belt, camshaft sprocket and related parts.

74
2-3SERVICE PROCEDURE
7. Cylinder Block