engine SUBARU LEGACY 1997 Service Repair Manual

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.
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4-3SERVICE PROCEDURE
5. Control Valve (Power Steering Gearbox) [LHD model]

2. OIL LEAK CHECK PROCEDURE AND
REPLACEMENT PARTS
NOTE:
Parts requiring replacement are described in the smallest
unit of spare parts including damaged parts and spare
parts damaged. In actual disassembly work, accidental
damage as well as inevitable damage to some related
parts must be taken into account, and spare parts for them
must also be prepared. However, it is essential to pinpoint
the cause of trouble, and limit the number of replacement
parts as much as possible.
1) Leakage from“a”
The oil seal is damaged. Replace valve assembly with a
new one.
2) Leakage from“b”
The torsion bar O-ring is damaged. Replace valve assem-
bly with a new one.
3) Leakage from“c”
The oil seal is damaged. Replace valve assembly with a
new one.
4) Leakage from“d”
The pipe is damaged. Replace the faulty pipe or O-ring.
5) If leak is other than a, b, c, or d, and if oil is leaking from
the gearbox, move the right and left boots toward tie-rod
end side, respectively, with the gearbox mounted to the
vehicle, and remove oil from the surrounding portions.
Then, turn the steering wheel from lock to lock 30 to 40
times with the engine running, then make comparison of
the leaked portion immediately after and several hours
after this operation.
6) Leakage from“e”
The cylinder seal is damaged. Replace rack bush with a
new one.
7) Leakage from“f”
There are two possible causes. Take following step first.
Remove the pipe assembly B from the valve housing, and
close the circuit with ST.
ST 926420000 PLUG
Turn the steering wheel from lock to lock 30 to 40 times
with the engine running, then make comparison of the
leaked portion between immediately after and several
hours after this operation.
CAUTION:

If leakage from“f”is noted again:
The oil seal of pinion and valve assembly is damaged.
Replace pinion and valve assembly with a new one. Or
replace the oil seal and the parts that are damaged
during disassembly with new ones.

If oil stops leaking from“f”:
The oil seal of rack housing is damaged.
Replace the oil seal and the parts that are damaged
during disassembly with new ones.
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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.
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4-3SERVICE PROCEDURE
6. Control Valve (Power Steering Gearbox) [RHD model]

2. OIL LEAK CHECK PROCEDURE AND
REPLACEMENT PARTS
NOTE:
Parts requiring replacement are described in the smallest
unit of spare parts including damaged parts and spare
parts damaged. In actual disassembly work, accidental
damage as well as inevitable damage to some related
parts must be taken into account, and spare parts for them
must also be prepared. However, it is essential to pinpoint
the cause of trouble, and limit the number of replacement
parts as much as possible.
1) Leakage from“a”
The oil seal is damaged. Replace valve assembly with a
new one.
2) Leakage from“b”
The torsion bar O-ring is damaged. Replace valve assem-
bly with a new one.
3) Leakage from“c”
The oil seal is damaged. Replace valve assembly with a
new one.
4) Leakage from“d”
The pipe is damaged. Replace the faulty pipe or O-ring.
5) If leak is other than a, b, c, or d, and if oil is leaking from
the gearbox, move the right and left boots toward tie-rod
end side, respectively, with the gearbox mounted to the
vehicle, and remove oil from the surrounding portions.
Then, turn the steering wheel from lock to lock 30 to 40
times with the engine running, then make comparison of
the leaked portion immediately after and several hours
after this operation.
6) Leakage from“e”
There are two possible causes. Take following step first.
Remove the pipe assembly B from the valve housing, and
close the circuit with ST.
ST 926420000 PLUG
Turn the steering wheel from lock to lock 30 to 40 times
with the engine running, then make comparison of the
leaked portion between immediately after and several
hours after this operation.
CAUTION:

If leakage from“e”is noted again:
The oil seal of pinion and valve assembly is damaged.
Replace pinion and valve assembly with a new one. Or
replace the oil seal and the parts that are damaged
during disassembly with new ones.

If oil stops leaking from“e”:
The oil seal of rack housing is damaged.
Replace the oil seal and the parts that are damaged
during disassembly with new ones.
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4-3SERVICE PROCEDURE
6. Control Valve (Power Steering Gearbox) [RHD model]

B4M0557A
6) Temporarily install clamp E on pipes C and D.
CAUTION:
Ensure that the letter“8”on each clamp side are
diagonally opposite each other as shown in the figure.
7) Tighten clamp E firmly.
Tightening torque:
7.4±2.0 N⋅m (0.75±0.20 kg-m, 5.4±1.4 ft-lb)
8) Tighten joint nut.
Tightening torque:
15±5 N⋅m (1.5±0.5 kg-m, 10.8±3.6 ft-lb)
G4M0099
9) Connect pipes A and B to four pipe joints of gearbox.
Connect upper pipe B first, and lower pipe A second.
Tightening torque:
13±3 N⋅m (1.3±0.3 kg-m, 9.4±2.2 ft-lb)
10) Install jack-up plate.
11) Connect battery minus terminal.
12) Feed the specified fluid and discharge air.
NOTE:
Never start the engine before feeding the fluid; otherwise
vane pump might be seized up.
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4-3SERVICE PROCEDURE
7. Pipe Assembly (Power Steering System)

10) Install jack-up plate.
11) Connect battery negative terminal.
12) Feed the specified fluid and discharge air.
NOTE:
Never start the engine before feeding the fluid; otherwise
vane pump might be seized up.
B4M0674A
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4-3SERVICE PROCEDURE
7. Pipe Assembly (Power Steering System)

B4M1160
8. Oil Pump (Power Steering System)
A: REMOVAL
1) Remove ground cable from battery.
2) Drain the working fluid about 0.35
(0.4 US qt, 0.3 Imp
qt) from oil tank.
3) Remove pulley belt cover bracket.
B4M1161A
4) Loosen oil pump pulley nut, then remove bolts which
secure alternator.
5) Loosen pulley belt(s).
6) Remove the nut and detach oil pump pulley.
B4M1159A
7) Remove bolt A. Disconnect pipe C from oil pump. Dis-
connect pipe D from oil tank.
CAUTION:

Do not allow fluid from the hose end to come into
contact with pulley belt.

To prevent foreign matter from entering the hose
and pipe, cover the open ends of them with a clean
cloth.

Except when only oil tank needs to be inspected,
detach oil tank and oil pump as a unit. Then separate
one from the other on a work bench to prevent oil from
spilling on any part of the engine.
B4M0560
8) Remove three bolts from the front side of oil pump and
detach the pump.
9) Remove three bolts from the lower side of bracket and
detach the bracket.
CAUTION:
The bracket does not need to be removed unless it is
damaged.
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4-3SERVICE PROCEDURE
8. Oil Pump (Power Steering System)

6) Check
(1) When reassembly procedures have been
completed, turn shaft by hand to ensure it turns
smoothly. If it binds or other unusual conditions are
evident, disassemble again and check for foreign mat-
ter trapped on sliding surfaces and improper installa-
tion. Eliminate the cause of trouble.
(2) Check followings by referring to“CHECK”article.

Excessive play in pulley shaft

Ditch deflection of pulley

Resistance to rotation of pulley

Measurement of generated oil pressure
F: INSTALLATION
1) Install bracket on engine.
Tightening torque:
22±2 N⋅m (2.2±0.2 kg-m, 15.9±1.4 ft-lb)
2) Install oil pump on oil tank as follows outside the
vehicle:
NOTE:
Prior to installation, make sure that all oil is removed from
oil pump, oil tank and pipe.
B4M0562A
3) Place oil pump in vise.
CAUTION:
Do not place oil pump directly in vise; use soft pads
and hold oil pump lightly to protect it.
4) Install O-ring on oil pump.
CAUTION:
Discard old O-ring and replace with a new one.
5) Install oil tank on oil pump.
Tightening torque:
Bolt C: 15.7±2.4 N⋅m
(1.60±0.24 kg-m, 11.58±1.77 ft-lb)
Bolt D: 18.1±2.5 N⋅m
(1.85±0.25 kg-m, 13.35±1.84 ft-lb)
CAUTION:
Discard old seal washer and replace with a new one.
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4-3SERVICE PROCEDURE
8. Oil Pump (Power Steering System)

B4M1163A
6) Install stay to oil pump. (2500 cc model only)
Tightening torque:
15.7±2.5 N⋅m (1.6±0.25 kg-m, 11.6±1.8 ft-lb)
B4M0560
7) Install oil pump, previously assembled to oil tank, on
bracket.
Tightening torque:
20.1±2.5 N⋅m (2.05±0.25 kg-m, 14.8±1.8 ft-lb)
8) Place oil pump pulley and tighten pulley nut temporarily.
B4M1159A
9) Interconnect pipes C and D.
Tightening torque:
Joint nut
15±5 N⋅m (1.5±0.5 kg-m, 10.8±3.6 ft-lb)
CAUTION:
If a hose is twisted at this step, the hose may come into
contact with some other parts.
10) Connect pipe D from oil tank.
11) Connect pipe C from oil pump.
CAUTION:
Use a new gasket.
Tightening torque:
34±5 N⋅m (3.5±0.5 kg-m, 25.3±3.6 ft-lb)
12) Tighten bolt A.
Tightening torque:
13±3 N⋅m (1.3±0.3 kg-m, 9.4±2.2 ft-lb)
13) Install pulley belt to oil pump.
14) Tighten oil pump pulley nut to the specified torque.
Tightening torque:
61±7 N⋅m (6.2±0.7 kg-m, 44.8±5.1 ft-lb)
15) Adjust pulley belt tension.
16) Tighten bolt belt tension.
Tightening torque:
8±2 N⋅m (0.8±0.2 kg-m, 5.8±1.4 ft-lb)
17) Install pulley belt cover bracket.
18) Connect minus terminal of battery.
19) Feed the specified fluid and discharge air.
NOTE:
Never start the engine before feeding the fluid; otherwise
vane pump might be seized up.
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4-3SERVICE PROCEDURE
8. Oil Pump (Power Steering System)

9. Power Steering Fluid
A: RECOMMENDED AIR BLEEDING AND
POWER STEERING FLUID
Recommended power steering fluid Manufacturer
ATF DEXRON II or ATF DEXRON IIEB.P.
CALTEX
CASTROL
MOBIL
SHELL
TEXACO
1) Feed the specified fluid with its level being about 5 cm
(2.0 in) lower than the mouth of tank.
2) Continue to turn steering wheel slowly from lock to lock
until bubbles stop appearing in the tank while keeping the
fluid at that level.
3) In case air is absorbed to deliver bubbles into piping
because the fluid level is lower, leave it about half an hour
and then do the step 2) all over again.
4) Start, and idle the engine.
5) Continue to turn steering wheel slowly from lock to lock
again until bubbles stop appearing in the tank while keep-
ing the fluid at that level.
It is normal that bubbles stop appearing after three times
turning of steering wheel.
6) In case bubbles do not stop appearing in the tank, leave
it about half an hour and then do the step 5) all over again.
7) Stop the engine, and take out safety stands after jack-
ing up vehicle again.
Then lower the vehicle, and idle the engine.
8) Continue to turn steering wheel from lock to lock until
bubbles stop appearing and change of the fluid level is
within 3 mm (0.12 in).
9) In case the following happens, leave it about half an
hour and then do step 8) again.
(1) The fluid level changes over 3 mm (0.12 in).
(2) Bubbles remain on the upper surface of the fluid.
(3) Grinding noise is generated from oil pump.
10) Check the fluid leakage at flare nuts after turning
steering wheel from lock to lock with engine running.
CAUTION:

Before checking, wipe off any fluid on flare nuts and
piping.

In case the fluid leaks from flare nut, it is caused by
dust (or the like) and/or damage between flare and
tapered seat in piping.

So remove the flare nut, tighten again it to the speci-
fied torque after cleaning flare and tapered seat. If flare
or tapered seat is damaged, replace it with a new one.
11) Inspect fluid level on flat and level surface with engine
“OFF”by indicator of filler cap.
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4-3SERVICE PROCEDURE
9. Power Steering Fluid