fuel type SUBARU LEGACY 1997 Service Repair Manual

4. Engine Compression
A: MEASUREMENT
1. 2200 cc MODEL
1) After warming-up the engine, turn ignition switch to
OFF.
2) Make sure that the battery is fully charged.
3) Remove all the spark plugs.
4) Disconnect connectors from fuel injectors.
5) Fully open throttle valve.
6) Check the starter motor for satisfactory performance
and operation.
G2M0098
7) Hold the compression gauge tight against the spark
plug hole.
CAUTION:
When using a screw-in type compression gauge, the
screw (put into cylinder head spark plug hole) should
be less than 18 mm (0.71 in) long.
8) Crank the engine by means of the starter motor, and
read the maximum value on the gauge when the pointer is
steady.
9) Perform at least two measurements per cylinder, and
make sure that the values are correct.
Compression (200—300 rpm and fully open throttle):
Standard
1,079—1,275 kPa
(11.0—13.0 kg/cm
2, 156—185 psi)
Limit
883 kPa (9.0 kg/cm
2, 128 psi)
Difference between cylinders
196 kPa (2.0 kg/cm
2, 28 psi)
2. 2500 cc MODEL
CAUTION:
After warming-up, engine becomes very hot. Be care-
ful not to burn yourself during measurement.
1) After warming-up the engine, turn ignition switch to
OFF.
2) Make sure that the battery is fully charged.
3) Remove all the spark plugs. [W3E0].>
4) Disconnect connectors from fuel injectors.
4
2-2
4. Engine Compression

2. Engine Noise
Type of sound Condition Possible cause
Regular clicking soundSound increases as engine
speed increases.Valve mechanism is defective.
Incorrect valve clearance
Worn valve rocker
Worn camshaft
Broken valve spring
Heavy and dull clankOil pressure is low.Worn crankshaft main bearing
Worn connecting rod bearing (big end)
Oil pressure is normal.Loose flywheel mounting bolts
Damaged engine mounting
High-pitched clank
(Spark knock)Sound is noticeable when
accelerating with an overload.Ignition timing advanced
Accumulation of carbon inside combustion chamber
Wrong spark plug
Improper gasoline
Clank when engine speed is
medium (1,000 to 2,000 rpm).Sound is reduced when fuel
injector connector of noisy
cylinder is disconnected.
(NOTE*)Worn crankshaft main bearing
Worn bearing at crankshaft end of connecting rod
Knocking sound when engine
is operating under idling speed
and engine is warm.Sound is reduced when fuel
injector connector of noisy
cylinder is disconnected.
(NOTE*)Worn cylinder liner and piston ring
Broken or stuck piston ring
Worn piston pin and hole at piston end of connecting rod
Sound is not reduced if each
fuel injector connector is
disconnected in turn. (NOTE*)Worn camshaft journal bore in crankcase
Squeaky sound—Insufficient generator lubrication
Rubbing sound—Defective generator brush and rotor contact
Gear scream when starting
engine—Defective ignition starter switch
Worn gear and starter pinion
Sound like polishing glass with
a dry cloth—Loose drive belt
Defective engine coolant pump shaft
Hissing sound—Loss of compression
Air leakage in air intake system, hoses, connections or
manifolds
Timing belt noise—Loose timing belt
Belt contacting case/adjacent part
Valve tappet noise—Incorrect valve clearance
NOTE*:
When disconnecting fuel injector connector, Malfunction Indicator Light (CHECK ENGINE light) illuminates and trouble code is stored in
ECM memory.
Therefore, carry out the CLEAR MEMORY MODE and INSPECTION MODE after connecting fuel injector connector. (Ref. to 2-7 On-Board
Diagnostics II System.)
78
2-3DIAGNOSTICS
2. Engine Noise

2. Engine Noise
Type of sound Condition Possible cause
Regular clicking soundSound increases as engine
speed increases.Valve mechanism is defective.
Incorrect valve clearance
Worn camshaft
Broken valve spring
Heavy and dull clankOil pressure is low.Worn crankshaft main bearing
Worn connecting rod bearing (big end)
Oil pressure is normal.Loose flywheel mounting bolts
Damaged engine mounting
High-pitched clank
(Spark knock)Sound is noticeable when
accelerating with an overload.Ignition timing advanced
Accumulation of carbon inside combustion chamber
Wrong spark plug
Improper gasoline
Clank when engine speed is
medium (1,000 to 2,000 rpm).Sound is reduced when fuel
injector connector of noisy
cylinder is disconnected.
(NOTE*)Worn crankshaft main bearing
Worn bearing at crankshaft end of connecting rod
Knocking sound when engine
is operating under idling speed
and engine is warm.Sound is reduced when fuel
injector connector of noisy
cylinder is disconnected.
(NOTE*)Worn cylinder liner and piston ring
Broken or stuck piston ring
Worn piston pin and hole at piston end of connecting rod
Sound is not reduced if each
fuel injector connector is
disconnected in turn. (NOTE*)Unusually worn valve lifter
Worn camshaft journal bore in crankcase
Squeaky sound—Insufficient generator lubrication
Rubbing sound—Defective generator brush and rotor contact
Gear scream when starting
engine—Defective ignition starter switch
Worn gear and starter pinion
Sound like polishing glass with
a dry cloth—Loose drive belt
Defective engine coolant pump shaft
Hissing sound—Loss of compression
Air leakage in air intake system, hoses, connections or
manifolds
Timing belt noise—Loose timing belt
Belt contacting case/adjacent part
Valve tappet noise—Incorrect valve clearance
NOTE*:
When disconnecting fuel injector connector, Malfunction Indicator Light (CHECK ENGINE light) illuminates and trouble code is stored in
ECM memory.
Therefore, carry out the CLEAR MEMORY MODE and INSPECTION MODE after connecting fuel injector connector. (Ref. to 2-7 On-Board
Diagnostics II System.)
80
2-3bDIAGNOSTICS
2. Engine Noise

1. Fuel System
A: SPECIFICATIONS
Fuel tankCapacity 60
(15.9 US gal, 13.2 Imp gal)
Location Under rear seat
Fuel pumpType Impeller
Discharge pressure 250.1 kPa (2.55 kg/cm
2, 36.3 psi)
Discharge flowAWD: More than 80
(21.1 US gal, 17.6 Imp gal)/h
FWD: More than 65
(17.2 US gal, 14.3 Imp gal)/h
[12 V at 300 kPa (3.06 kg/cm
2, 43.5 psi)]
Fuel filterCartridge type
2
2-8SPECIFICATIONS AND SERVICE DATA
1. Fuel System

G2M0357
3) Install hose and hold down clips at positions indicated
in Figure.
Tightening torque:
1.0
+0.5
0N⋅m (0.1+0.05
0kg-m, 0.7+0.4
0ft-lb)
Type A: When fitting length is specified.
Type B: When fitting length is not specified.


1Fitting


2Clamp


3Hose

: 1.0 — 4.0 mm (0.039 — 0.157 in)
L: 20 — 25 mm (0.79 — 0.98 in)
G2M0358

1Hose


2Clip


3Pipe
Fuel return hose:
L = 20 — 25 mm (0.79 — 0.98 in)
Evaporation hose:
L = 15 — 20 mm (0.59 — 0.79 in)
G2M0356
4) Tighten band mounting bolts.
Tightening torque:
33±10 N⋅m (3.4±1.0 kg-m, 25±7 ft-lb)
G4M0545
5) Install rear crossmember.
15
2-8SERVICE PROCEDURE
3. Fuel Tank

G2M0357
B: INSTALLATION
Installation is in the reverse order of removal.
1) Connect fuel delivery hose to pipe with an overlap of 20
to 25 mm (0.79 to 0.98 in).
Type A: When fitting length is specified.
Type B: When fitting length is not specified.


1Fitting


2Clamp


3Hose

: 1.0—4.0 mm (0.039—0.157 in)
L: 20—25 mm (0.79—0.98 in)
G2M0358
2) Connect evaporation hose to pipe by approx. 15 mm
(0.59 in) from hose end.


1Hose


2Clip


3Pipe
L=15—20 mm (0.59—0.79 in)
CAUTION:
Be sure to inspect hoses and their connections for any
leakage of fuel.
24
2-8SERVICE PROCEDURE
8. Fuel Delivery, Return and Evaporation Lines

G6M0088
2) Carbon fouled
Dry fluffy carbon deposits on insulator and electrode are
mostly caused by slow speed driving in city, weak ignition,
too rich fuel mixture, dirty air cleaner, etc.
It is advisable to replace with plugs having hotter heat
range.
G6M0089
3) Oil fouled
Wet black deposits show excessive oil entrance into com-
bustion chamber through worn rings and pistons or exces-
sive clearance between valve guides and stems. If same
condition remains after repair, use a hotter plug.
G6M0090
4) Overheating
White or light gray insulator with black or gray brown spots
and bluish burnt electrodes indicate engine overheating.
Moreover, the appearance results from incorrect ignition
timing, loose spark plugs, wrong selection of fuel, hotter
range plug, etc. It is advisable to replace with plugs having
colder heat range.
G6M0091
C: CLEANING AND REGAPPING
Clean spark plugs in a sand blast type cleaner.
Avoid excessive blasting. Clean and remove carbon or
oxide deposits, but do not wear away porcelain.
If deposits are too stubborn, discard plugs.
After cleaning spark plugs, recondition firing surface of
electrodes with file. Then correct the spark plug gap using
a gap gauge.
Spark plug gap: L
1.0—1.1 mm (0.039—0.043 in)
D: REMOVAL AND INSTALLATION (2500 cc
EXCEPT OUTBACK MODEL)
CAUTION:
All spark plugs installed on an engine, must be of the
same heat range.
Spark plug:
NGK: PFR5B-11
24
6-1SERVICE PROCEDURE
3. Spark Plug

1. Body Electrical
A: SPECIFICATIONS
BatteryReserve capacity 82 minutes (MT), 100 minutes (AT)
Cold cranking ampere 430 amperes (MT), 490 amperes (AT)
Fuse10 A, 15 A, 20 A
Combination
meterSpeedometer Electric pulse type
Tachometer Electric impulse type
Water temperature gauge Thermistor cross coil type
Fuel gauge Resistance cross coil type
Charge indicator light 12 V—1.4 W
Brake fluid level warning/parking brake indicator light 12 V—1.4 W
AT oil temperature warning light (AWD only) 12 V—1.4 W
ABS warning light 12 V—1.4 W
CHECK ENGINE warning light
(Malfunction indicator lamp)12 V—1.4 W
Oil pressure warning light 12 V—1.4 W
AIRBAG system warning light 12 V—1.4 W
Low fuel warning light 12 V—3W
FWD indicator light 12 V—1.4 W
TCS warning light 12 V—1.4 W
TCS indicator light 12 V—1.4 W
Turn signal indicator light 12 V—1.4 W (2 pieces)
Seat belt warning light 12 V—1.4 W
Door open warning light 12 V—1.4 W (5 pieces)
Headlight beam indicator light 12 V—1.4 W
Meter illumination light12 V—3 W (2 pieces)
12 V—3.4 W (4 pieces)
Headlight 12 V—60/55 W (Halogen)
Front clearance light 12 V—5W
Turn signal lightFront 12 V—21 W
Rear 12 V—21 W
Tail/Stop light 12 V—5/21 W
Back-up light 12 V—21 W
High-mount stop light12 V—18 W (SEDAN), 12 V—13 W
(WAGON)
License plate light 12 V—5W
Room light 12 V—8W
Trunk room light (SEDAN) 12 V—5W
Luggage room light (WAGON) 12 V—5W
Spot light 12 V—8 W (2 pieces)
Glove box light 12 V—3.4 W
Ash tray illumination light 12 V—1.7 W
Selector lever illumination light (AT model) 12 V—1.7 W
2
6-2SPECIFICATIONS
1. Body Electrical

B2M0648A
7) Use engine grounding terminal or engine proper as the
grounding point to the body when measuring voltage and
resistance in the engine compartment.
OBD0040B
8) Use TCM mounting stud bolts at the body head ground-
ing point when measuring voltage and resistance inside the
passenger compartment.
9) Every MFI-related part is a precision part. Do not drop
them.
10) Observe the following cautions when installing a radio
in MFI equipped models.
CAUTION:

The antenna must be kept as far apart as possible
from the control unit.
(The ECM is located under the steering column, inside
of the instrument panel lower trim panel.)

The antenna feeder must be placed as far apart as
possible from the ECM and MFI harness.

Carefully adjust the antenna for correct matching.

When mounting a large power type radio, pay spe-
cial attention to the three items above mentioned.

Incorrect installation of the radio may affect the
operation of the ECM.
11) Before disconnecting the fuel hose, disconnect the fuel
pump connector and crank the engine for more than five
seconds to release pressure in the fuel system. If engine
starts during this operation, run it until it stops.
12) Problems in the electronic-controlled automatic trans-
mission may be caused by failure of the engine, the elec-
tronic control system, the transmission proper, or by a com-
bination of these. These three causes must be distin-
guished clearly when performing diagnostics.
13) Diagnostics should be conducted by rotating with
simple, easy operations and proceeding to complicated,
difficult operations. The most important thing in diagnostics
is to understand the customer’s complaint, and distinguish
between the three causes.
77
2-7ON-BOARD DIAGNOSTICS II SYSTEM
4. Cautions

G6M0205
11) Each connector number shown in the wiring diagram
corresponds to that in the wiring harness. The location of
each connector in the actual vehicle is determined by read-
ing the first character of the connector (for example, a“F”
for F8,“i”for i16, etc.) and the type of wiring harness.
The first character of each connector number refers to the
area or system of the vehicle, as indicated in table below.
Symbol Wiring harness and Cord
F Front wiring harness
B Bulkhead wiring harness
E Engine wiring harness
T Transmission cord
D Door cord LH & RH, Rear gate cord
I Instrument panel wiring harness
RRear wiring harness, Rear defogger cord
Room light cord,
Fuel tank cord,
Sunroof cord,
Trunk lid cord
P Floor wiring harness
7
6-3WIRING DIAGRAM
1. General Description