engine SUBARU LEGACY 1997 Service Repair Manual

B2M0323
5) Remove radiator fan motor assembly.
6) Remove fan motor from shroud.
B: INSTALLATION
Installation is in the reverse order of removal procedures.
Do the following:
1) Before installing radiator fan motor, apply a coat of seal-
ant to threads and tighten nuts.
2) Make sure radiator fan does not come into contact with
shroud when installed.
3) After installation, make sure there is no unusual noise
or vibration when fan is rotated.
G6M0095
7. Engine Coolant Pipe
A: REMOVAL
1) Release fuel pressure.

2) Disconnect ground cable from the battery.
B2M0015A
3) Drain engine coolant completely.

B2M0160
4) Remove intake manifold.

17
2-5SERVICE PROCEDURE
6. Radiator Fan and Fan Motor - 7. Engine Coolant Pipe

B2M0138
5) Disconnect heater inlet hose.
B2M0139
6) Disconnect radiator inlet hose from engine coolant pipe.
B2M0141
7) Remove bolts which install engine coolant pipe on cyl-
inder block.
B2M0141
B: INSTALLATION
1) Install engine coolant pipe on cylinder block.
Tightening torque:
6.4±0.5 N⋅m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)
CAUTION:
Use a new O-ring.
B2M0139
2) Connect radiator inlet hose.
18
2-5SERVICE PROCEDURE
7. Engine Coolant Pipe

B2M0138
3) Connect heater inlet hose.
B2M0160
4) Install intake manifold.

G6M0095
5) Connect ground cable to battery terminal.
19
2-5SERVICE PROCEDURE
7. Engine Coolant Pipe

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

A: OPERATION (WITHOUT A/C MODEL)
CONDITION:
Engine coolant temperature is above 95°C (203°F).
TROUBLE SYMPTOM:
Radiator main fan does not operate under the above
condition.
1. Check fuse and power supply.
OK
Not OK
Melted fuse,repair the shorted part of the circuit
,replace fuse.
2. Check harness connector between fuse and
relay box, and A/C relay holder.
OK
Not OK
Repair or replace wiring harness.
3. Check A/C relay holder.
OK
Not OK
Repair or replace A/C relay holder.
4. Check harness connector between A/C relay
holder and main fan motor.
OK
Not OK
Repair or replace wiring harness.
5. Check ground circuit of main fan motor.
OK
Not OK
Repair or replace wiring harness.
6. Check main fan motor.
OK
Not OK
Replace main fan motor.
Refer to 2-7 On-Board Diagnostics II System.
B2M0427A
1. CHECK FUSE AND POWER SUPPLY.
1) Check fuse No. 13.
2) Turn ignition switch to ACC.
3) Measure voltage between fuse and relay box, and body.
Connector & terminal / Specified voltage:
(F40) No. 3—Body / 10 V, or more






22
2-5DIAGNOSTICS
2. Radiator Main Fan

B: LO MODE OPERATION (WITH A/C MODEL)
CONDITION:
Condition (1) :
Engine coolant temperature is below 89°C (192°F).
A/C switch is turned ON.
Vehicle speed is below 10 km/h (6 MPH).
Condition (2) :
Engine coolant temperature is above 95°C (203°F).
A/C switch is turned OFF.
Vehicle speed is below 10 km/h (6 MPH).
TROUBLE SYMPTOM:
Radiator main fan does not rotate at LO speed under
conditions (1) and (2) above.
1. Check power supply to main fan relay-1.
OK
Not OK
Melted fuse (in A/C relay holder),repair the
shorted part of the circuit,replace fuse.
2. Check main fan relay-1.
OK
Not OK
Replace main fan relay-1.
3. Check harness connector between main fan
relay-1 and main fan motor.
OK
Not OK
Repair or replace wiring harness.
4. Check ground circuit of main fan motor.
OK
Not OK
Repair or replace wiring harness.
5. Check main fan motor.
OK
Not OK
Replace main fan motor.
Refer to 2-7 On-Board Diagnostics II System.





24
2-5DIAGNOSTICS
2. Radiator Main Fan

C: HI MODE OPERATION (WITH A/C MODEL)
CONDITION:
Condition (1) :
Engine coolant temperature is below 89°C (192°F).
A/C switch is turned ON.
Vehicle speed is over 20 km/h (12 MPH).
Condition (2) :
Engine coolant temperature is above 95°C (203°F).
A/C switch is turned OFF.
Vehicle speed is over 20 km/h (12 MPH).
Condition (3) :
Engine coolant temperature is above 95°C (203°F).
A/C switch is turned ON.
TROUBLE SYMPTOM:
Radiator main fan does not rotate at HI speed under
conditions (1), (2) and (3) above.
1. Check operation of main fan motor LO mode.
OK
Not OK
Check LO mode operation.
2. Check power supply to main fan relay-2.
OK
Not OK
Melted fuse (in A/C relay holder),repair the
shorted part of the circuit,replace fuse.
3. Check main fan relay-2.
OK
Not OK
Replace main fan relay-2.
4. Check harness connector between main fan
relay-2 and main fan motor.
OK
Not OK
Repair or replace wiring harness.
5. Check ground circuit of main fan motor.
OK
Not OK
Repair or replace wiring harness.
6. Check main fan motor.
OK
Not OK
Replace main fan motor.
Refer to 2-7 On-Board Diagnostics II System.






27
2-5DIAGNOSTICS
2. Radiator Main Fan

1Intake manifold gasket LH


2Intake manifold gasket RH


3Fuel injector pipe insulator


4Fuel injector pipe


5O-ring A


6O-ring B


7Fuel injector


8Insulator


9Fuel injector cap


10Plate


11Sealing


12Gasket


13Engine coolant hose B


14Air by-pass hose


15Idle air control solenoid valve


16Engine coolant hose A


17Nipple (AT model)


18Plug


19PCV valve


20Purge control solenoid valve


21Nipple


22BPT (Except 2200 cc MT model)


23BPT holder bracket (Except 2200 cc MT model)


24Back pressure hose (Except 2200 cc MT model)


25EGR vacuum hose A (Except 2200 cc MT model)

26EGR vacuum hose B (Except 2200 cc MT model)


27EGR valve (Except 2200 cc MT model)


28Gasket (Except 2200 cc MT model)


29EGR solenoid valve (Except 2200 cc MT model)


30EGR pipe (Except 2200 cc MT model)


31Pressure sensor


32Pressure sources switching solenoid valve


33Vacuum hose A


34Vacuum hose B


35Vacuum hose C


36Bracket (Except Canada spec. vehicles)


37Bracket (For Canada spec. vehicles)


38Intake manifold
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 3.4±0.5 (0.35±0.05, 2.5±0.4)
T2: 4.9±0.5 (0.5±0.05, 3.6±0.4)
T3: 6.4±0.5 (0.65±0.05, 4.7±0.4)
T4: 16±1.5 (1.6±0.15, 11.6±1.1)
T5: 19±1.5 (1.9±0.15, 13.7±1.1)
T6: 19±2 (1.9±0.2, 13.7±1.4)
T7: 23±3 (2.3±0.3, 16.6±2.2)
T8: 25±2 (2.5±0.2, 18.1±1.4)
T9: 34±2 (3.5±0.2, 25.3±1.4)
3
2-7COMPONENT PARTS
1. Intake Manifold

2. 2500 cc MODEL
B2M1198A

1Intake manifold gasket LH


2Intake manifold gasket RH


3Fuel injector pipe insulator


4Fuel injector pipe


5O-ring A


6O-ring B


7Fuel injector


8Insulator


9Fuel injector cap


10Plate


11Sealing


12Gasket


13Engine coolant hose B


14Air by-pass hose


15Idle air control solenoid valve


16Engine coolant hose A


17Nipple (AT model)


18Plug


19PCV valve

20Purge control solenoid valve


21Nipple


22BPT


23BPT holder bracket


24Back pressure hose


25EGR vacuum hose A


26EGR vacuum pipe


27EGR vacuum hose C


28EGR valve


29Gasket


30EGR vacuum hose B


31EGR solenoid valve


32EGR pipe


33Pressure sensor


34Pressure sources switching solenoid
valve


35Vacuum hose A


36Vacuum hose B


37Vacuum hose C

38Bracket
(Except Canada spec. vehicles)


39Bracket
(For Canada spec. vehicles)


40Collar


41Intake manifold
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 3.4±0.5 (0.35±0.05, 2.5±0.4)
T2: 4.9±0.5 (0.5±0.05, 3.6±0.4)
T3: 6.4±0.5 (0.65±0.05, 4.7±0.4)
T4: 16±1.5 (1.6±0.15, 11.6±1.1)
T5: 19±1.5 (1.9±0.15, 13.7±1.1)
T6: 19±2 (1.9±0.2, 13.7±1.4)
T7: 23±3 (2.3±0.3, 16.6±2.2)
T8: 25±2 (2.5±0.2, 18.1±1.4)
T9: 34±2 (3.5±0.2, 25.3±1.4)
4
2-7COMPONENT PARTS
1. Intake Manifold

B2M1214A
3. Throttle Body
A: REMOVAL AND INSTALLATION
1) Loosen clamps which connect air intake duct to air
intake chamber and mass air flow sensor.
2) Disconnect blow-by hose from air intake duct.
3) Remove air intake duct.
B2M1218
4) Loosen clamp which connects air intake chamber to
throttle body.
5) Disconnect air hoses, and remove air intake chamber.
G2M0280
6) Disconnect accelerator cable
1.
7) Disconnect cruise control cable

2. (With cruise control
model)
B2M1247
8) Disconnect connector from throttle position sensor.
B2M1248
9) Disconnect engine coolant hoses from throttle body.
9
2-7SERVICE PROCEDURE
3. Throttle Body