engine SUBARU LEGACY 1997 Service Repair Manual

B2M1241
16) Disconnect engine coolant hose from throttle body.
H2M1259A
17) Disconnect engine coolant hose
1from idle air con-
trol solenoid valve.
18) Disconnect air by-pass hose

2from idle air control
solenoid valve.
B2M0342
19) Disconnect brake booster hose.
B2M1242
20) Remove EGR pipe.
G2M0370
21) Disconnect canister hoses from pipes. (2500 cc, 2200
cc FWD and Taiwan spec. vehicles)
13
2-7SERVICE PROCEDURE
4. Intake Manifold

B2M0019
22) Disconnect engine harness connectors from bulkhead
harness connectors, and remove engine harness connec-
tors from bracket.
B2M0345A
23) Disconnect connectors from engine coolant tempera-
ture sensor

1and thermometer
2.
B2M1243A
24) Disconnect knock sensor connector.
B2M1251A
25) Disconnect connector from camshaft position sensor.
B2M1252A
26) Disconnect connector from crankshaft position sensor.
14
2-7SERVICE PROCEDURE
4. Intake Manifold

B2M1253A
27) Disconnect connector from oil pressure switch.
G2M0296
28) Disconnect fuel hoses from fuel pipes.
WARNING:
Catch fuel from hoses in a container.
B2M0159
29) Remove bolts which hold intake manifold onto cylinder
heads.
B2M0160
30) Remove intake manifold.
B2M0757A
B: DISASSEMBLY
1) Disconnect engine ground terminal from intake mani-
fold.
15
2-7SERVICE PROCEDURE
4. Intake Manifold

B2M0347A
2) Disconnect connectors from throttle position sensor,
ignition coil, fuel injectors, idle air control solenoid valve,
purge control solenoid valve and EGR solenoid valve.
3) Remove engine harness from intake manifold.


1EGR solenoid valve


2Throttle position sensor


3Idle air control solenoid valve


4Purge control solenoid valve


5Harness band
H2M1247
4) Remove idle air control solenoid valve from intake
manifold.
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
16
2-7SERVICE PROCEDURE
4. Intake Manifold

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)
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)
17
2-7SERVICE PROCEDURE
4. Intake Manifold

B2M0345A
7) Connect connectors to engine coolant temperature sen-
sor

1and thermometer
2.
B2M0019
8) Install engine harness connectors to bracket, and con-
nect engine harness connectors to bulkhead connectors.
G2M0370
9) Connect canister hoses. (2500 cc, 2200 cc FWD and
Taiwan spec. vehicles)
B2M1242
10) Install EGR pipe.
Tightening torque:
34±2 N⋅m (3.5±0.2 kg-m, 25.3±1.4 ft-lb)
B2M0342
11) Connect brake booster hose.
19
2-7SERVICE PROCEDURE
4. Intake Manifold

H2M1259A
12) Connect engine coolant hose
1to idle air control sole-
noid valve.
13) Connect air by-pass hose

2to idle air control solenoid
valve.
B2M1241
14) Connect engine coolant hose to throttle body.
B2M1239
15) Connect PCV hose to intake manifold.
B6M0772
16) Connect spark plug cords to ignition coil.
B2M0334
17) 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)
20
2-7SERVICE PROCEDURE
4. Intake Manifold

B2M1218
21) Install air intake chamber and connect air hoses.
Tightening torque:
4.9±0.5 N⋅m (0.5±0.05 kg-m, 3.6±0.4 ft-lb)
B2M1213
22) Install air cleaner element.
23) Install air cleaner upper cover and air intake duct as a
unit.
CAUTION:
Before installing air cleaner upper cover, align holes
with protruding portions of air cleaner lower case, then
secure upper cover to lower case.
B2M1225A
24) 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.
22
2-7SERVICE PROCEDURE
4. Intake Manifold - 5. Engine Coolant Temperature Sensor

B2M1218
21) Install air intake chamber and connect air hoses.
Tightening torque:
4.9±0.5 N⋅m (0.5±0.05 kg-m, 3.6±0.4 ft-lb)
B2M1213
22) Install air cleaner element.
23) Install air cleaner upper cover and air intake duct as a
unit.
CAUTION:
Before installing air cleaner upper cover, align holes
with protruding portions of air cleaner lower case, then
secure upper cover to lower case.
B2M1225A
24) 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.
22
2-7SERVICE PROCEDURE
4. Intake Manifold - 5. 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.
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.
23
2-7SERVICE PROCEDURE
5. Engine Coolant Temperature Sensor - 7. Front Oxygen Sensor