Cylinder head SUBARU LEGACY 1997 Service Workshop Manual

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.

76
2-3bSERVICE PROCEDURE
5. Cylinder Block

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

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

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

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

G4M0803
4) Apply a coat of grease to sliding surface of sleeve and
seating surface of spring, and insert sleeve into steering
body. Charge adjusting screw with grease, insert spring
into adjusting screw and install on steering body.

1Sleeve

2Seat

3Spring

4Adjusting screw

5Lock nut
G4M0804
5) Installation of tie-rod
(1) Tighten adjusting screw until it will no longer
tighten.
(2) Install lock washers and tighten left and right tie-
rods into rack ends.
On condition
L: Approximately 40 mm (1.57 in)
Tightening torque:
78±10 N⋅m (8.0±1.0 kg-m, 58±7 ft-lb)
G4M0805
(3) The left and right tie-rod differ as indicated in the
table below.
Right tie-rod
(pinion side)No air vent hole provided.Grooved.
(for identification)
Left tie-rod
(cylinder side)Air vent hole provided.Not grooved.
(for identification)
G4M0806
6) Using a chisel and hammer, bend lock washers (at two
places).
CAUTION:
Be careful not to scratch rack.
G4M0807
7) Rack and pinion backlash adjustment
(1) Loosen adjusting screw three to four turns.
(2) Rotate input shaft so that rack is in the straight
ahead direction. [Ensure that distance between rack
end and stopper is 70.8 mm (2.787 in).]
(3) Tighten adjusting screw by two threads.
36
4-3SERVICE PROCEDURE
4. Steering Gearbox (Power Steering System) [RHD model]

G4M0428
8. Hill Holder
A: REMOVAL
1) Drain brake fluid from reservoir of master cylinder.
2) Remove adjusting nut and cable clamp, and disconnect
PHV cable from cable bracket on engine.
3) Detach PHV cable from clips.
4) Remove cable clamp, and disconnect PHV cable from
PHV stay.
CAUTION:
Carefully protect boots and inner cable from damage
when disconnecting PHV cable.
5) Disconnect brake pipes from PHV.
CAUTION:

Pay attention not to drop brake fluid onto body
painting since it may dissolve paint.

Pay attention not to damage hexagonal head of flare
nut by using pipe wrench without fail.
6) Detach PHV along with support from side frame.
CAUTION:
Exercise utmost care to prevent foreign matter from
entering into PHV when removing it.
B: INSPECTION
Check up removed parts as follows, and replace defective
ones.
1) Check if boots of PHV cable are damaged or degraded,
and if inner cable is damaged or corroded.
2) Check if return spring is worn out, damaged or cor-
roded.
3) Confirm that rolling sound of ball is heard with PHV
inclined and lever rotates smoothly.
CAUTION:
Never disassemble PHV. Replace entire PHV assembly
if necessary.
62
4-4SERVICE PROCEDURE
8. Hill Holder

3. Spark Plug
A: REMOVAL AND INSTALLATION
CAUTION:
All spark plugs installed on an engine, must be of the
same heat range.
Spark plug:
CHAMPION: RC10YC4
(Alternate)
NGK: BKR6E-11
NIPPONDENSO: K20PR-U11
1) Remove spark plug cords by pulling boot, not cord itself.
2) Remove spark plugs.
3) When installing spark plugs on cylinder head, use spark
plug wrench.
Tightening torque (Spark plug):
20.6±2.9 N⋅m (2.10±0.30 kg-m, 15.19±2.14 ft-lb)
CAUTION:
The above torque should be only applied to new spark
plugs without oil on their threads.
In case their threads are lubricated, the torque should
be reduced by approximately 1/3 of the specified
torque in order to avoid their over-stressing.
4) Connect spark plug cords.
G6M0086
B: INSPECTION
Check electrodes and inner and outer porcelain of plugs,
noting the type of deposits and the degree of electrode
erosion.
G6M0087
1) Normal
Brown to grayish-tan deposits and slight electrode wear
indicate correct spark plug heat range.
23
6-1SERVICE PROCEDURE
3. Spark Plug

B6M0557A
2) Disconnect mass air flow sensor connector.
3) Remove four clips securing air cleaner upper cover.
B6M0558
4) Loosen the clamp screw and separate air cleaner upper
cover from air intake duct.
B6M0565A
5) Remove air cleaner element and air cleaner case.
B6M0566A
6) Remove #1 spark plug cord by pulling boot, not cord
itself.
B6M0567A
7) After connecting
1spark plug socket,
2extension and


3Universal Joint to each other, securely set them over the
spark plug in cylinder head.
8) Cover ABS pipes with rag to prevent damage.


1Spark plug socket 16 mm (5/8 in)


2Extension


3Universal Joint


4Extension


5Ratchet
30
6-1SERVICE PROCEDURE
3. Spark Plug

B6M0575A
5) Move washer tank upward.
B6M0563A
6) Remove #4 spark plug cord by pulling boot, not cord
itself.
7) For subsequent procedures, refer to the procedure for
#1 spark plug.
CAUTION:
When removing spark plug, cover the ATF cooling
pipes with a rag to prevent damage.
B6M0572A
NOTE:
For easier removal of spark plug, diagonally insert the tools
from the direction of battery stand into plug hole as shown
in figure.
B6M0573
F: INSTALLATION (2500 cc OUTBACK
MODEL)
1. #1 SPARK PLUG
1) After setting spark plug in spark plug socket, connect
the spark plug socket, extension and Universal Joint to
each other.
2) Screw spark plug into cylinder head using the con-
nected tools above mentioned. At this point, it is necessary
to support the rear end of the tools with fingertips.
3) When spark plug is screwed in two or three turns, tem-
porarily disconnect the tools connected in step 1) above.
4) Confirm that spark plug is screwed into the cylinder
head properly by touching it with finger. If it is difficult to
reach it by hand, confirm its condition by using mirror and
suchlike.
5) Cover ABS pipes with rag to prevent damage.
34
6-1SERVICE PROCEDURE
3. Spark Plug