transmission oil 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

ON-BOARD
DIAGNOSTICS
II
SYSTEM
[Tsn2i
2-7

6
.
Wiring
Diagram
and
Wiring
Harness

FWD
switch
(AWD)

B9
ffl

Droppig
Cruise
resistor
cont
rol
modu
le

OBD-II
Data
link
serviceCheck
connectorconnectorconnector

B78
ERB40
0
B79
m
B4
E
K
E
)

w
7
OEs
o
-
-
-
------------------
-
------
-
-
L
a
....

c
H
0
U
It

C
Y
0
.N
;W
Rr
06
N

BI1
T41
Ref
.
to
/Engine
electrical
system
.

a
:
B54

b
:
B55

c
:
856

She
ild
joint
connector
884

~

WK
LZIM
WL

B53
Engine
control
B9(B
I
ac
k)
module
1
2

854
(B
I
ac
k)
B79
(Grey)

1
23456
1
23
45
67
7
1
8
1
9101112
8
910
1112
1
13
1
14
r,

Bll
(Grey)
(B
I
ac
k)
B56894
(B
I
aCk)

34

S

78

D

q
Oil
2
9
Pl
.
12131415,91617
la19
110
I
5
16
1
3
14
1111121131141151161171161191201

AT
contro
I
------------
a
,,
Vehicle
speed
i(Transmission)
___
_____
__
__
sensor
1

ATF
temperature
sensor
Line
pressuresolenoid

Lock-up
solenoid

AWD
solenoid

Shift
solenoid
1

Shift
solenoid
2

Shift
solenoid
3

R3
Throttle
~-Cz'1
R~l
position
sensor

B2l
E2
El3

O
(Gray)
E13
(Brown)
853
B78
(Y
e
II
ow)

12
123
1234
56789

B55
(B
I
ack)
(
ED
(Grey)

12345678
12345678
9~011t213141St6
91111213141516

864
(L
i
ght
b
I
ue)

12
345678
9l0
lll21314
1516
I7l8l9
20
2122
23
24
2627282930
3132
3334
35
3637383940
4142
43
44
454647
1
48
1
49
~
0
1
51
2
15
3
15
4
~
5
1
56
15
7
8596061626364656667686970
7172
73
1
74
1
75
1
76
1
77
78
1
79
1
60
1
81
B
1
132
1
83d
8485
86
87888990
9192
93
94
9596

BUR41-02B

55

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

3-2
[TSAO1
AUTOMATIC
TRANSMISSION
AND
DIFFERENTIAL

6
.
Diagnostic
Chart
for
On-board
Diagnostics
System

6
.
Diagnostic
Chart
for
On-board

Diagnostics
System

A
:
BASICDIAGNOSTIC
PROCEDURE

TROUBLE
OCCURS
.

INTERVIEW

1
.
Oil
level
check
<
Ref
.
to
3-2

[W2A1],
[W2A2]
.*1
>

2
.
Oil
leak
check
<
Ref
.
to
3-2

[W2A3]
.x`r1
>

3
.
Brake
band
adjustment
<
Ref
.

to
3-2
[W2B1]
.t`r1
>

4
.
Stall
test
<
Ref
.
to
3-2

[W3A0]
.*1
>

5
.
Line
pressure
test
<
Ref
.
to
3-2
[W3C0]
.*1
>

6
.
Transfer
clutch
pressure
test
<
Ref
.
to
3-2
[W3D0]
.*1
>

7
.
Time
lag
test
<
Ref
.
to
3-2

[W3B0]
.*1
>

8
.
Road
test

<
Ref
.
to
3-2
[W3E0]
.*1
>

BASIC
CHECKS

TROUBLE
INDICATION
(AT
OIL
TEMP
INDICATOR)

Not
indicated
.

Indicated
.

ON-BOARD

DIAGNOSTICS

Inspection
using
General

Diagnostic
Table
[T900]*I
.

I

Inspection
using
Diagnostic

Chart
with
Select
Monitor

[T800]*1,
*2
.

Not
OK

No
trouble
code

Trouble
code

Repair
.

CLEAR
MEMORY

Confirmation
test
Trouble
code
(ON-BOARD
DIAGNOSTICS)

No
trouble
code

End

Check
in

accordance

trouble
code

[T700]*1,
*2
.

2

3-2
R7101
AUTOMATIC
TRANSMISSION
AND
DIFFERENTIAL

7
.
Diagnostic
Chart
with
Trouble
Code

I
:
TROUBLE
CODE
23

-
ENGINE
SPEED
SIGNAL
-

DIAGNOSIS
:

Engine
speed
input
signal
circuit
is
open
or
shorted
.

TROUBLE
SYMPTOM
:

"
No
lock-up
(after
engine
warm-up)

"
AT
OIL
TEMP
indicator
remains
on
when
vehicle
speed

is

0

.

1
.
Check
harness
and
connector
between
TCM
Not
OK

and
ECM
.

Repair
or
replace
harnessconnectors
.

OK

2
.
Check
inputsignal
for
TCM
.
OK

Not
OK

"
Repair
TCM
connector
terminal
poor
contact
.

"
Replace
TCM
.

Conduct
diagnostics
for
ECM's
ignition
system
.

B54884

ECM
TC
M

U
B54
B84

9
10
11
12
13141516

1
1
1
2
1
3
1
4
1
5
1
6
3132
3334
35
3637383940
4142
4344
1
58
1
59
1
60
1
61
1
6263
1
7
8
9
1011
12889
84
85
8687
88
8990
9192
9394
95
96

B2M0585

6

1. Engine Cooling System
Trouble Possible cause Corrective action
Over-heatinga. Insufficient engine coolantReplenish engine coolant, inspect for leakage, and
repair.
b. Loose timing belt Repair or replace timing belt tensioner.
c. Oil on drive belt Replace.
d. Malfunction of thermostat Replace.
e. Malfunction of engine coolant pump Replace.
f. Clogged engine coolant passage Clean.
g. Improper ignition timingInspect and repair ignition control system.

h. Clogged or leaking radiator Clean or repair, or replace.
i. Improper engine oil in engine coolant Replace engine coolant.
j. Air/fuel mixture ratio too leanInspect and repair fuel injection system.

k. Excessive back pressure in exhaust system Clean or replace.
l. Insufficient clearance between piston and cylinder Adjust or replace.
m. Slipping clutch Repair or replace.
n. Dragging brake Adjust.
o. Improper transmission oil Replace.
p. Defective thermostat Replace.
q. Malfunction of electric fanInspect radiator fan relay, engine coolant temperature
sensor or radiator motor and replace there.
Over-coolinga. Atmospheric temperature extremely low Partly cover radiator front area.
b. Defective thermostat Replace.
Engine coolant
leaks.a. Loosened or damaged connecting units on hoses Repair or replace.
b. Leakage from engine coolant pump Replace.
c. Leakage from engine coolant pipe Repair or replace.
d. Leakage around cylinder head gasket Retighten cylinder head bolts or replace gasket.
e. Damaged or cracked cylinder head and crankcase Repair or replace.
f. Damaged or cracked thermostat case Repair or replace.
g. Leakage from radiator Repair or replace.
Noisea. Defective drive belt Replace.
b. Defective radiator fan Replace.
c. Defective engine coolant pump bearing Replace engine coolant pump.
d. Defective engine coolant pump mechanical seal Replace engine coolant pump.
20
2-5DIAGNOSTICS
1. Engine Cooling System

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

1. Engine Cooling System
Trouble Possible cause Corrective action
Over-heatinga. Insufficient engine coolantReplenish engine coolant, inspect for leakage, and
repair.
b. Loose timing belt Repair or replace timing belt tensioner.
c. Oil on drive belt Replace.
d. Malfunction of thermostat Replace.
e. Malfunction of engine coolant pump Replace.
f. Clogged engine coolant passage Clean.
g. Improper ignition timingInspect and repair ignition control system.

h. Clogged or leaking radiator Clean or repair, or replace.
i. Improper engine oil in engine coolant Replace engine coolant.
j. Air/fuel mixture ratio too leanInspect and repair fuel injection system.

k. Excessive back pressure in exhaust system Clean or replace.
l. Insufficient clearance between piston and cylinder Adjust or replace.
m. Slipping clutch Repair or replace.
n. Dragging brake Adjust.
o. Improper transmission oil Replace.
p. Defective thermostat Replace.
q. Malfunction of electric fanInspect radiator fan relay, engine coolant temperature
sensor or radiator motor and replace there.
Over-coolinga. Atmospheric temperature extremely low Partly cover radiator front area.
b. Defective thermostat Replace.
Engine coolant
leaks.a. Loosened or damaged connecting units on hoses Repair or replace.
b. Leakage from engine coolant pump Replace.
c. Leakage from engine coolant pipe Repair or replace.
d. Leakage around cylinder head gasket Retighten cylinder head bolts or replace gasket.
e. Damaged or cracked cylinder head and crankcase Repair or replace.
f. Damaged or cracked thermostat case Repair or replace.
g. Leakage from radiator Repair or replace.
Noisea. Defective drive belt Replace.
b. Defective radiator fan Replace.
c. Defective engine coolant pump bearing Replace engine coolant pump.
d. Defective engine coolant pump mechanical seal Replace engine coolant pump.
20
2-5DIAGNOSTICS
1. Engine Cooling System

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