engine section SUBARU LEGACY 1997 Service Repair Manual

TABLE
OFCONTENTS

2-1
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2-2
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2-3b
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ENGINE
SECTION
2-6
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2-7
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2-8
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2-9
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2-10
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2-11
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3-1
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TRANSMISSION
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SECTION
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3-4
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4-1
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4-2
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4-3
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MECHANICAL
COMPONENTS
4-4
Brakes
SECTION

4-5
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4-6
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4-7
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5-1
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5-2
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5-3
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BODY
SECTION
5-4
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5-5
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6-1
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ELECTRICAL
SECTION
6-2
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All
right
reserved
.
This
book
may
not
bereproduced

or
copied,
in
whole
or
in
part,
withoutthe
written

permission
of
FUJI
HEAVY
INDUSTRIES
LTD
.,

TOKYO
JAPAN
.

SUBARU,
++
and
O
are
trademarks
of

FUJI
HEAVY
INDUSTRIES
LTD
.

@
Copyright
1996
FUJI
HEAVY
INDUSTRIES
LTD
.

2

1. Foreword
This chapter describes major inspection and service pro-
cedures for the engine mounted on the body. For proce-
dures not found in this chapter, refer to the service proce-
dure section in the applicable chapter.
2. Ignition Timing
A: MEASUREMENT
1. 2200 cc MODEL
1) Warm-up the engine.
G2M0094
2) To check the ignition timing, connect a timing light to #1
cylinder spark plug cord, and illuminate the timing mark
with the timing light.
3) Start the engine at idle speed and check the ignition
timing.
If the timing is not correct, check the ignition control sys-
tem.
Ignition timing [BTDC/rpm]:
14°±8°/700 (MT)
20°±8°/700 (AT)
2. 2500 cc MODEL
CAUTION:
After warming-up, engine becomes very hot. Be care-
ful not to burn yourself during measurement.
1) Warm-up the engine.
B2M0750A
2) To check the ignition timing, connect a timing light to #1
cylinder spark plug cord, and illuminate the timing mark
with the timing light.
3) Start the engine at idle speed and check the ignition
timing.
If the timing is not correct, check the ignition control sys-
tem.
Ignition timing [BTDC/rpm]:
15°±8°/700
2
2-2
1. Foreword - 2. Ignition Timing

1. Foreword
This chapter describes major inspection and service pro-
cedures for the engine mounted on the body. For proce-
dures not found in this chapter, refer to the service proce-
dure section in the applicable chapter.
2. Ignition Timing
A: MEASUREMENT
1. 2200 cc MODEL
1) Warm-up the engine.
G2M0094
2) To check the ignition timing, connect a timing light to #1
cylinder spark plug cord, and illuminate the timing mark
with the timing light.
3) Start the engine at idle speed and check the ignition
timing.
If the timing is not correct, check the ignition control sys-
tem.
Ignition timing [BTDC/rpm]:
14°±8°/700 (MT)
20°±8°/700 (AT)
2. 2500 cc MODEL
CAUTION:
After warming-up, engine becomes very hot. Be care-
ful not to burn yourself during measurement.
1) Warm-up the engine.
B2M0750A
2) To check the ignition timing, connect a timing light to #1
cylinder spark plug cord, and illuminate the timing mark
with the timing light.
3) Start the engine at idle speed and check the ignition
timing.
If the timing is not correct, check the ignition control sys-
tem.
Ignition timing [BTDC/rpm]:
15°±8°/700
2
2-2
1. Foreword - 2. Ignition Timing

5. Control Valve (Power Steering
Gearbox) [LHD model]
NOTE:
This section focuses on the disassembly and reassembly
of control valve. For the inspection and adjustment and the
service procedures for associated parts, refer to“Steering
Gearbox”.
G4M0136
1Power cylinder

2Cylinder

3Rack piston

4Rack axle

5Input shaft
6Torsion bar

7Valve housing

8Valve body

9Control valve
10Pipe B

11Pipe A

12Pinion

13Pinion axle
A: CHECKING OIL LEAKING POINTS
1. OIL LEAKING POINTS
1) If leak point is other than a, b, c, or d, perform check
step 5) in 4-3 [W5A2] before dismounting gearbox from
vehicle. If gearbox is dismounted without confirming where
the leak is, it must be mounted again to locate the leak
point.
2) Even if the location of the leak can be easily found by
observing the leaking condition, it is necessary to thor-
oughly remove the oil from the suspected portion and turn
the steering wheel from lock to lock about 30 to 40 times
with engine running, then make comparison of the sus-
pected portion between immediately after and several
hours after this operation.
3) Before starting oil leak repair work, be sure to clean the
gearbox, hoses, pipes, and surrounding parts. After com-
pleting repair work, clean these areas again.
40
4-3SERVICE PROCEDURE
5. Control Valve (Power Steering Gearbox) [LHD model]

6. Control Valve (Power Steering
Gearbox) [RHD model]
NOTE:
This section focuses on the disassembly and reassembly
of control valve. For the inspection and adjustment and the
service procedures for associated parts, refer to“Steering
Gearbox”.
B4M0668A
A: CHECKING OIL LEAKING POINTS
1. OIL LEAKING POINTS
1) If leak point is other than a, b, c, or d, perform check
step 5) in 4-3 [W6A2] before dismounting gearbox from
vehicle. If gearbox is dismounted without confirming where
the leak is, it must be mounted again to locate the leak
point.
2) Even if the location of the leak can be easily found by
observing the leaking condition, it is necessary to thor-
oughly remove the oil from the suspected portion and turn
the steering wheel from lock to lock about 30 to 40 times
with engine running, then make comparison of the sus-
pected portion between immediately after and several
hours after this operation.
3) Before starting oil leak repair work, be sure to clean the
gearbox, hoses, pipes, and surrounding parts. After com-
pleting repair work, clean these areas again.
49
4-3SERVICE PROCEDURE
6. Control Valve (Power Steering Gearbox) [RHD model]

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.








82
4-3DIAGNOSTICS
1. Power Steering

G4M0596
7. Evacuating and Charging
The following points should be kept in mind when evacu-
ating and charging with a manifold gauge set.
1) Be certain that goggles and gloves are worn.
2) If bulk refrigerant [13.6 kg (30 lb) canister] is used, be
certain to weigh the charge amount carefully, using the
correct equipment, to avoid overcharging the system.
3) The charging procedure described in this section
begins by chargingliquidrefrigerant into the high- pres-
sure side of the systemwith the engine off.The proce-
dure is completed by charging refrigerantvaporinto the
low-pressure side of the system with the engine running.
CAUTION:
Never open the high-pressure manifold valve when the
engine is running.
G4M0597
1. CONNECT THE GAUGE SET
1) Close the high- and low-pressure manifold valves.
2) Attach the low-pressure manifold hose to the low- pres-
sure service port on the vehicle. Check the low- pressure
gauge. If more than 68.6 kPa (0.70 kg/cm
2, 10 psi) is
indicated, discharge the system prior to charging.
3) Attach the high-pressure manifold hose to the high-
pressure service port on the vehicle.
4) Connect the center hose from the manifold to the
vacuum pump.
5) Turn on the vacuum pump.
6) Slowly open the low-pressure manifold valve.
7) When the low-pressure gauge reaches approximately
66.43 kPa (498.3 mmHg, 19.62 inHg), slowly open the
high-pressure manifold valve.
G4M0598
8) Maintain a minimum vacuum level of 100.56 kPa (754.4
mmHg, 29.70 inHg) for a minimum of 15 minutes on a new
system or 30 minutes for an in-service system.
NOTE:
The gauge will read 4 kPa (25 mmHg, 1 inHg) less for
every 304.8 m (1,000 ft) above sea level.
19
4-7SERVICE PROCEDURE
7. Evacuating and Charging

8. Leak Testing
The following points should be kept in mind when conduct-
ing a refrigerant leak test.
1) The A/C system to be tested must have an adequate
refrigerant charge to begin with.
2) The area where the leak test is conducted must be free
of wind and drafts, with still air being the ideal condition.
3) The atmosphere where the leak test is conducted must
be free of refrigerant contamination.
4) Operate the A/C system for approx. 10 minutes, then
turn the engine off an begin the leak test.
5) Refrigerant gas is heavier than air, therefore always
hold the probe below the connection being tested.
6) When checking for a leak along a length of hose or
tube, the leak detector probe must be moved slowly,
approx. 25 mm (1 in) per second making sure probe does
not come in contact with the component being tested.
7) When checking for a leak at a certain point, the leak
detector probe must be held at that point for at least 5
seconds.
G4M0609
1. CHECK THE SYSTEM PRESSURE
With gauges connected to the A/C system, operate the A/C
and confirm that the high side pressure is above 690 kPa
(7.03 kg/cm
2, 100 psi). If not, evacuate and charge the
system before leak checking (refer to evacuation and
charging sections).
2. CLEAN CONNECTIONS BEFORE TESTING
Before testing, use a clean shop towel to wipe off refriger-
ant oil, dirt, or foreign material from all of the connections
and components to be tested.
NOTE:
Since refrigerant oil absorbs refrigerant, excess oil on or
near a connection may falsely signal a leak.
B4M0089
3. CALIBRATE LEAK DETECTOR
Refer to the manufacturer’s instructions for the particular
type of detector used and calibrate the instrument.
CAUTION:
Always make sure that the probe tip filter is clean and
free of contamination.
23
4-7SERVICE PROCEDURE
8. Leak Testing

G4M0612
4. LEAK TEST — HIGH-PRESSURE SIDE
Operate the A/C system for approx. 10 minutes, then turn
the engine off and begin the leak test.
1) Begin at the connection of the high-pressure tube to the
evaporator, and work your way along the high- pressure
side of the system to the compressor. There are three
places to check on each tube connection.
2) Check the area.
(1) Check the area where the fitting joins the tube.
G4M0613
(2) Check the area where the two parts of the fitting
join each other.
G4M0614
(3) Check the area where the nut joins the tube.
3) Check the area of the sight glass and pressure switch
(dual switch), and also check the seams of the receiver
drier.
4) Check the connections of the tubes to the condenser,
and also check any welded joints on the condenser.
CAUTION:
An oily area on the fins of the condenser may indicate
a leak.
5) Check the area where the hoses attach to the compres-
sor.
6) Check around the machined portions of the compressor
(where the compressor sections join each other).
7) If equipped, check the thermal limiter on the compres-
sor housing.
8) Check the compressor shaft seal by probing near the
center of the compressor clutch pulley.
NOTE:
Some shaft seals have a very slight amount of normal
leakage [approximately 28 g (1.0 oz) per year].
24
4-7SERVICE PROCEDURE
8. Leak Testing

B5M0275
9) Remove bolts (engine compartment side) from bumper
stays.
B5M0276
10) Remove front bumper assembly.
NOTE:
Front bumper surface is accessible for removal after
removing the following parts:
Two bolts (on the lower center of bumper), mud guard,
bolts (on the side of bumper), front grille, headlight, clips
(on both sides of front bumper), clips (on the upper section
of bumper), and clips (on the lower section of bumper).
G6M0095
2. OUTBACK WITH STEP ROOF
1) Disconnect the ground cable from the battery.
B5M0273
2) Remove two bolts from lower center of bumper.
3) Remove mud guard.
NOTE:
It is not necessary to remove the entire mud guard.
Remove clips from the front section of mud guard, if nec-
essary.
4) Remove the canister.
B5M0274
5) Remove two bolts from side of bumper.
6) Remove front grill.
7) Remove headlight.
39
5-1SERVICE PROCEDURE
4. Front Bumper