SUBARU LEGACY 1997 Service Repair Manual

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

2. Air Intake System
B2M1166A

1Gasket


2Throttle position sensor


3Throttle body


4Clamp


5Air intake duct


6By-pass hose


7Air intake chamber

8Stay A


9Stay B (AT model)


10Stay C (MT model)


11Stay D (MT model)


12Spacer


13Bush
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 2.2±0.2 (0.22±0.02, 1.6±0.1)
T2: 4.9±0.5 (0.5±0.05, 3.6±0.4)
T3: 22±2 (2.2±0.2, 15.9±1.4)
5
2-7COMPONENT PARTS
2. Air Intake System

3. Air Cleaner
B2M1245A

1Mass air flow sensor bracket


2Mass air flow sensor ASSY


3Air cleaner upper cover


4Air cleaner element


5Spacer


6Bush

7Clip


8Air cleaner case


9Cushion rubber


10Air intake duct


11Resonator chamber ASSY


12Clip
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 7.4±2.0 (0.75±0.2, 5.4±1.4)
T2: 33±10 (3.4±1.0, 25±7)
6
2-7COMPONENT PARTS
3. Air Cleaner

B2M1225A
1. Air Cleaner and Air Intake Duct
A: REMOVAL AND INSTALLATION
1) Disconnect connector from mass air flow sensor.
B2M1226A
2) Loosen clamp which connects air intake duct to air
intake chamber.
3) Remove two clips of air cleaner upper cover.
4) Disconnect blow-by hose from air intake duct.
B2M1227
5) Remove air intake duct and air cleaner upper cover as
a unit.
6) Remove air cleaner element.
B2M1232A
7) Remove air cleaner lower case.
B2M1213
8) Installation is in the reverse order of removal.
CAUTION:
Before installing air cleaner upper cover, align holes
with protruding portions of air cleaner lower case, then
secure upper cover to lower case.
7
2-7SERVICE PROCEDURE
1. Air Cleaner and Air Intake Duct

B2M1214A
2. Mass Air Flow Sensor
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.
B2M1246A
4) Disconnect connector from mass air flow sensor.
G2M0390
5) Remove two clips, then remove air cleaner upper cover.
G2M0393
6) Remove mass air flow sensor from air cleaner upper
cover.
7) Installation is in the reverse order of removal.
Tightening torque:
7.4±2.0 N⋅m (0.75±0.2 kg-m, 5.4±1.4 ft-lb)
CAUTION:
Before installing air cleaner upper cover, align holes
with protruding portions of air cleaner lower case, then
secure upper cover to lower case.
8
2-7SERVICE PROCEDURE
2. Mass Air Flow Sensor

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

B2M1249
10) Remove bolts which install throttle body to intake
manifold.
11) Installation is in the reverse order of removal.
CAUTION:
Always use a new gasket.
Before installing air cleaner upper cover, align holes
with protruding portions of air cleaner lower case, then
secure upper cover to lower case.
Tightening torque:
Throttle body:
22±2 N⋅m (2.2±0.2 kg-m, 15.9±1.4 ft-lb)
Air intake chamber:
4.9±0.5 N⋅m (0.5±0.05 kg-m, 3.6±0.4 ft-lb)
B2M1225A
4. Intake Manifold
A: REMOVAL
1) Release fuel pressure.
2) Disconnect connector from mass air flow sensor.
B2M1226A
3) Loosen clamp which connects air intake duct to air
intake chamber.
4) Remove two clips of air cleaner upper cover.
5) Disconnect blow-by hose from air intake duct.
B2M1227
6) Remove air intake duct and air cleaner upper cover as
a unit.
7) Remove air cleaner element.
10
2-7SERVICE PROCEDURE
3. Throttle Body - 4. Intake Manifold

B2M1249
10) Remove bolts which install throttle body to intake
manifold.
11) Installation is in the reverse order of removal.
CAUTION:
Always use a new gasket.
Before installing air cleaner upper cover, align holes
with protruding portions of air cleaner lower case, then
secure upper cover to lower case.
Tightening torque:
Throttle body:
22±2 N⋅m (2.2±0.2 kg-m, 15.9±1.4 ft-lb)
Air intake chamber:
4.9±0.5 N⋅m (0.5±0.05 kg-m, 3.6±0.4 ft-lb)
B2M1225A
4. Intake Manifold
A: REMOVAL
1) Release fuel pressure.
2) Disconnect connector from mass air flow sensor.
B2M1226A
3) Loosen clamp which connects air intake duct to air
intake chamber.
4) Remove two clips of air cleaner upper cover.
5) Disconnect blow-by hose from air intake duct.
B2M1227
6) Remove air intake duct and air cleaner upper cover as
a unit.
7) Remove air cleaner element.
10
2-7SERVICE PROCEDURE
3. Throttle Body - 4. Intake Manifold

B2M1218
8) Loosen clamp which connects air intake chamber to
throttle body.
9) Disconnect air hoses, and remove air intake chamber.
G2M0280
10) Disconnect accelerator cable
1.
11) Disconnect cruise control cable

2. (With cruise control
model)
B2M1231A
12) Disconnect vacuum hoses from pressure sources
switching solenoid valve.
B2M0017
13) Remove power steering pump from bracket.
(1) Remove V-belt cover.
G2M0286
(2) Loosen lock bolt and slider bolt, and remove power
steering pump drive V-belt.
11
2-7SERVICE PROCEDURE
4. Intake Manifold