SUBARU LEGACY 1997 Service Repair Manual

G2M0185
3) Apply fluid packing to the mating surface of #1 and #3
cylinder block, and position it on #2 and #4 cylinder block.
Fluid packing:
THREE BOND 1215 or equivalent
CAUTION:
Do not allow fluid packing to jut into O-ring grooves,
oil passages, bearing grooves, etc.
B2M0088A
4) Temporarily tighten 10 mm cylinder block connecting
bolts in numerical order shown in Figure.
5) Tighten 10 mm cylinder block connecting bolts in
numerical order.
Tightening torque:
47±3 N⋅m (4.8±0.3 kg-m, 34.7±2.2 ft-lb)
B2M0089A
6) Tighten 8 mm and 6 mm cylinder block connecting bolts
in numerical order shown in Figure.
Tightening torque:


1—
7: 25±2 N⋅m
(2.5±0.2 kg-m, 18.1±1.4 ft-lb)


8: 6.4 N⋅m (0.65 kg-m, 4.7 ft-lb)
G2M0186
7) Install rear oil seal by using ST1 and ST2.
ST1 499597100 OIL SEAL GUIDE
ST2 499587200 OIL SEAL INSTALLER
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2-3bSERVICE PROCEDURE
5. Cylinder Block

3. PISTON AND PISTON PIN (#1 AND #2)
B2M0128A
Tightening torque: N⋅m (kg-m, ft-lb)
T: 69±7 (7.0±0.7, 50.6±5.1)
G2M0188
1) Installing piston
(1) Turn cylinder block so that #1 and #2 cylinders face
upward.
(2) Using ST1, turn crankshaft so that #1 and #2 con-
necting rods are set at bottom dead center.
ST1 499987500 CRANKSHAFT SOCKET
(3) Apply a coat of engine oil to pistons and cylinders
and insert pistons in their cylinders by using ST2.
ST2 498747300 PISTON GUIDE
G2M0189
2) Installing piston pin
(1) Insert ST3 into service hole to align piston pin hole
with connecting rod small end.
CAUTION:
Apply a coat of engine oil to ST3 before insertion.
ST3 499017100 PISTON PIN GUIDE
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2-3bSERVICE PROCEDURE
5. Cylinder Block

(2) Apply a coat of engine oil to piston pin and insert
piston pin into piston and connecting rod through ser-
vice hole.
G2M0190
(3) Install circlip.
CAUTION:
Use new circlips.
(4) Install service hole plug and gasket.
CAUTION:
Use a new gasket and apply a coat of fluid packing to
it before installation.
Fluid packing:
THREE BOND 1215 or equivalent
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2-3bSERVICE PROCEDURE
5. Cylinder Block

4. PISTON AND PISTON PIN (#3 AND #4)
B2M0129A
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 6.4 (0.65, 4.7)
T2: 69±7 (7.0±0.7, 50.6±5.1)
Turn cylinder block so that #3 and #4 cylinders face
upward. Using the same procedures as used for #1 and #2
cylinders, install pistons and piston pins.
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2-3bSERVICE PROCEDURE
5. Cylinder Block

E: INSTALLATION
1. OIL PUMP AND ENGINE COOLANT PUMP
B2M0705B
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 5 (0.5, 3.6)
T2: 6.4 (0.65, 4.7)
T3: 10 (1.0, 7)
T4: 72±3 (7.3±0.3, 52.8±2.2)
T5: First 12±2 (1.2±0.2, 8.7±1.4)
Second 12±2 (1.2±0.2, 8.7±1.4)
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2-3bSERVICE PROCEDURE
5. Cylinder Block

G2M0084
1) Install baffle plate.
2) Install oil strainer and O-ring
3) Install oil strainer stay.
4) Apply fluid packing to matching surfaces and install oil
pan.
Fluid packing:
THREE BOND 1207C or equivalent
G2M0194
5) Apply fluid packing to matching surfaces and install oil
separator cover.
Fluid packing:
THREE BOND 1215 or equivalent
B2M0706A
6) Install drive plate.
To lock crankshaft, use ST.
ST 498497100 CRANKSHAFT STOPPER
7) Install housing cover.
G2M0076
8) Installation of oil pump
(1) Discard front oil seal after removal. Replace with a
new one by using ST.
ST 499587100 OIL SEAL INSTALLER
B2M0390A
(2) Apply fluid packing to matching surface of oil pump.
Fluid packing:
THREE BOND 1215 or equivalent
(3) Install oil pump on cylinder block. Be careful not to
damage oil seal during installation.
CAUTION:
Do not forget to install O-ring and seal when install-
ing oil pump.
Align flat surface of oil pump’s inner rotor with
crankshaft before installation.
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5. Cylinder Block

G2M0628
9) Install engine coolant pump and gasket.
CAUTION:
Be sure to use a new gasket.
When installing engine coolant pump, tighten bolts
in two stages in numerical sequence as shown in Fig-
ure.
10) Install engine coolant pipe.
11) Install oil filter.
2. RELATED PARTS
1) Install cylinder heads.

2) Install camshafts, rocker cover and related parts.

3) Install camshaft sprockets, timing belt and related parts.

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5. Cylinder Block

1. Engine Trouble in General
Numbers shown in the chart refer to the possibility of reason for the
trouble in order (“Very often”to“Rarely”)
1—Very often
2—Sometimes
3—Rarely
TROUBLE
Engine will not start.
Rough idle and engine stall
Low output, hesitation and poor acceleration
Surging
Engine does not return to idle.
Dieseling (Run-on)
After burning in exhaust system
Knocking
Excessive engine oil consumption
Excessive fuel consumption Starter does not turn.
Initial combustion does not occur.
Initial combustion occurs.
Engine stalls after initial combustion.
POSSIBLE CAUSE
STARTER
2Defective battery-to-starter harness
3Defective starter switch
3Defective inhibitor switch
23Defective starter
BATTERY
1Poor terminal connection
1Run-down battery
2Defective charging system
1111111111 1Fuel injection system Diagnostics II System.>
77
2-3bDIAGNOSTICS
1. Engine Trouble in General

TROUBLE
Engine will not start.
Rough idle and engine stall
Low output, hesitation and poor acceleration
Surging
Engine does not return to idle.
Dieseling (Run-on)
After burning in exhaust system
Knocking
Excessive engine oil consumption
Excessive fuel consumption Starter does not turn.
Initial combustion does not occur.
Initial combustion occurs.
Engine stalls after initial combustion.
INTAKE SYSTEM
2111 3Loosened or cracked intake air pipe
3111 3 1Loosened or cracked blow-by hose
31211 2Loosened or cracked vacuum hose
22222Defective intake manifold gasket
22222Defective throttle body gasket
322 2 2Defective PCV valve
222 323Loosened oil filler cap
3312 1Dirty air cleaner element
FUEL LINE
13 322Defective fuel pump and relay
33322Clogged fuel line
222233Lack of or insufficient fuel
BELT
222Defective
222322 22 2Defective timing
FRICTION
3Seizure of crankshaft and connecting rod bearing
3Seized camshaft
3Seized or stuck piston and cylinder
COMPRESSION
333222 23 2Incorrect valve clearance
333223 3 3Loosened spark plugs or defective gasket
333223 3 3Loosened cylinder head bolts or defective gasket
333223 2 2Improper valve seating
333333 3 13Defective valve stem
222223 3 3Worn or broken valve spring
333233 3 12Worn or stuck piston rings, cylinder and piston
222111 12 2Incorrect valve timing
222222Improper engine oil (low viscosity)
78
2-3bDIAGNOSTICS
1. Engine Trouble in General

TROUBLE
Engine will not start.
Rough idle and engine stall
Low output, hesitation and poor acceleration
Surging
Engine does not return to idle.
Dieseling (Run-on)
After burning in exhaust system
Knocking
Excessive engine oil consumption
Excessive fuel consumption Starter does not turn.
Initial combustion does not occur.
Initial combustion occurs.
Engine stalls after initial combustion.
LUBRICATION SYSTEM
22 3 3Incorrect oil pressure
2Loosened oil pump attaching bolts and defective
gasket
2Defective oil filter seal
2Defective crankshaft oil seal
32Defective rocker cover gasket
2Loosened oil drain plug or defective gasket
2Loosened oil pan fitting bolts or defective oil pan
COOLING SYSTEM
33221Overheating
333Over cooling
OTHERS
113 3Malfunction of Evaporative Emission Control
System
21Stuck or damaged throttle valve
322 2Accelerator cable out of adjustment
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2-3bDIAGNOSTICS
1. Engine Trouble in General