oil type SUBARU LEGACY 1997 Service Repair Manual

BRAKES
IM13-21
4-4
13
.
Anti-lock
Brake
System
(ABS)
[5
.3i
Type]

2
.
FUNCTIONS
OF
SENSORS
AND
ACTUATORS

Name
Function

ABS
control
moduleand
hydraulic
ABSCM-
e
Calculates
and
determine
the
conditionsof
the
wheels
and
body
from
control
unit
(ABSCM&H/U)
section
the
wheel
speedsand
makes
a
proper
decision
suitable
for
the
current
situation
to
control
the
hydraulic
unit
.

In
the
ABS
operation
mode,
the
module
outputs
a
cooperative
control
signal
to
the
AT
control
module
.
(AT
vehicles
only)

Whenever
the
ignition
switch
is
placed
at
ON,
the
module
makes
a
self
diagnosis
.
When
anything
wrong
is
detected,
the
module
cuts
off
the
system
.

Communicates
with
the
Subaru
select
monitor
.

H/U-section
In
the
ABS
operation
mode,
the
H/U
changes
fluid
passages
to
control

the
fluid
pressure
of
the
wheel
cylinders
in
response
to
an
instruction
from
the
ABSCM
.

The
H/U
also
constitutes
thebrake
fluid
passage
from
the
master
cylin-
der
to
the
wheel
cylinders
together
with
pipings
.

Valve
relay-
Serves
asa
power
switch
for
the
solenoid
valve
and
motor
relay
coil
in
section
response
to
an
instruction
from
the
ABSCM
.

Motor
relay-
Serves
as
a
power
switch
for
the
pump
motor
in
response
to
an
instruc-
section
tion
from
the
ABSCM
.

Wheel
speed
sensor
(ABS
sensor)
Detects
the
wheel
speed
in
terms
of
a
change
in
the
magnetic
flux
den-
sity
passingthrough
the
sensor,
converts
it
into
an
electrical
signal,
and
outputs
the
electrical
signal
to
the
ABSCM
.

Tone
wheel
Gives
a
change
in
the
magnetic
flux
density
by
the
teeth
around
the
tone
wheel
to
let
the
ABS
sensor
generate
an
electrical
signal
.

G
sensor
(AWD
vehicle
only)
Detects
a
change
in
G
in
the
longitudinal
direction
of
the
vehicle
and
outputs
it
to
the
ABSCM
in
terms
of
a
change
in
voltage
.

Stop
light
switch
Transmits
the
information
on
whether
the
brakepedal
is
depressed
or
not
to
the
ABSCM
for
use
as
a
condition
in
determining
ABS
operation
.

ABS
warning
light
Alerts
the
driver
to
an
ABS
fault
.
When
the
diagnosis
connector
and
diagnosis
terminal
are
connected,
the
light
flashes
to
indicate
a
trouble
codes
in
response
to
an
instruction
from
the
ABSCM
.

AT
control
module
(TCM)
(AT
vehicles
only)
Provides
shift
controls
(fixing
the
speed
at
3rd
or
changing
front
and
rear
wheel
transmission
characteristics
on
4WD
vehicle)
in
response
to
an
instruction
fromthe
ABSCM
.

BRAKES
[ABS
5
.31
TYPE]
IT8N3I4-4d

8
.
DiagnosticsChart
with
Trouble
Code
by
ABS
Warning
Light

819
11
Oil
111
21131141

4

161171181191212112
9
23
24
25
26
1
2
81
2
1301
31
1

F=_1

V
B4
M
1234A

F49

1
1
2
1
3
1
4
1
5
1
6
1
7
1
8
1
9
101112131415
11
16
1
17
1
18
1
19
1
2
01
212
23
24
25
26
L-~
7
1
28
1
2001
11

]L
COO
B4M
1243A

$N1
I
CHECK
INPUT
VOLTAGE
OF
ABSCM&H/U
.

1)
Disconnect
connector
from
ABSCM&H/U
.

2)
Run
theengine
at
idle
.

3)
Measure
voltage
between
ABSCM&H/U
connector
and

chassis
ground
.

Connector
&
terminal

(F49)
No
.
1
(+)
-
Chassis
ground
(-)
:

CHECK
;
Is
the
voltage
between
10
V
and
15
V?

,rES
:
Go
tostep
8N2
.

No
:
Repair
harness
connector
between
battery,
igni-

tion
switch
and
ABSCM&H/U
.

$N2
I
CHECK
GROUND
CIRCUIT
OF
ABSCM&H/U
.

1)
Turn
ignition
switch
to
OFF
.

2)
Measure
resistance
between
ABSCM&H/U
connector

and
chassis
ground
.

Connector
&
terminal

(F49)
No
.
23
-
Chassis
ground
:

CHECK
:
Is
the
resistance
less
than
0
.5
S2?

Go
to
step
8N3
.

No
:
Repair
ABSCM&H/U
ground
harness
.

$N3
I
CHECKPOOR
CONTACT
IN
CONNECTORS
.

Is
there
poor
contact
in
connectors
between

generator,
battery
and
ABSCM&HlU?
<
Ref
.

to
FOREWORD
[T3C1]
.*10
>

YES
:
Repair
connector
.

No
:
Go
to
step
8N4
.

55

1. Engine
A: SPECIFICATIONS
EngineModel2200 cc
TypeHorizontally opposed, liquid cooled, 4-cylinder, 4-stroke
gasoline engine
Valve arrangement Belt driven, single over-head camshaft, 4-valve/cylinder
Bore x Stroke mm (in) 96.9 x 75.0 (3.815 x 2.953)
Displacement cm
3(cu in) 2,212 (135.0)
Compression ratio9.7
Compression pressure
(at 200 — 300 rpm) kPa (kg/cm
2, psi)1,079 — 1,275
(11.0 — 13.0, 156 — 185)
Number of piston rings Pressure ring: 2, Oil ring: 1
Intake valve timingOpening 4° BTDC
Closing 52° ABDC
Exhaust valve timingOpening 48° BBDC
Closing 12° ATDC
Valve clearanceIntake mm (in) 0.20±0.02 (0.0079±0.0008)
Exhaust mm (in) 0.25±0.02 (0.0098±0.0008)
Idling speed
[At neutral position on MT, or
“P” or “N” position on AT] rpm700±100 (No load)
850±50 (A/C switch ON)
Firing order1,3,2,4
Ignition timing BTDC/rpm 14°±8°/700 (MT), 20°±8°/700 (AT)
2
2-3SPECIFICATIONS AND SERVICE DATA
1. Engine

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

1. Engine
A: SPECIFICATIONS
EngineModel2500 cc
TypeHorizontally opposed, liquid cooled, 4-cylinder, 4-stroke
gasoline engine
Valve arrangement Belt driven, double over-head camshaft, 4-valve/cylinder
Bore x Stroke mm (in) 99.5 x 79.0 (3.917 x 3.110)
Displacement cm
3(cu in) 2,457 (149.93)
Compression ratio9.5
Compression pressure
(at 200 — 300 rpm)
kPa (kg/cm
2, psi) rpmStandard 1,216 (12.4, 176) 350
Limit 941 (9.6, 137) 350
Number of piston rings Pressure ring: 2, Oil ring: 1
Intake valve timingOpening 6° BTDC
Closing 50° ABDC
Exhaust valve timingOpening Front: 54° BBDC, Rear: 30° BBDC (Position in degrees)
Closing Front: 10° ATDC, Rear: 10° ATDC (Position in degrees)
Valve clearanceIntake mm (in) 0.20±0.02 (0.0079±0.0008)
Exhaust mm (in) 0.25±0.02 (0.0098±0.0008)
Idling speed
[At neutral position on MT, or
“P” or “N” position on AT] rpm700±100 (No load)
850±50 (A/C switch ON)
Firing order1,3,2,4
Ignition timing BTDC/rpm 15°±8°/700 rpm
2
2-3bSPECIFICATIONS AND SERVICE DATA
1. Engine

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. Lubrication System
A: SPECIFICATIONS
1. 2200 cc MODEL
Lubrication methodForced lubrication
Oil pumpPump typeTrochoid type
Number of teethInner rotor 9
Outer rotor 10
Outer rotor diameter x thickness 78x9mm(3.07 x 0.35 in)
Tip clearance between inner and outer rotorSTANDARD 0.04 — 0.14 mm (0.0016 — 0.0055 in)
LIMIT 0.18 mm (0.0071 in)
Side clearance between inner rotor and pump
caseSTANDARD 0.02 — 0.07 mm (0.0008 — 0.0028 in)
LIMIT 0.15 mm (0.0059 in)
Case clearance between outer rotor and pump
caseSTANDARD 0.10 — 0.175 mm (0.0039 — 0.0069 in)
LIMIT 0.20 mm (0.0079 in)
Capacity at
80°C (176°F)700 rpm Discharge- pressure 98 kPa (1.0 kg/cm
2, 14 psi) or more
- quantity 4.2
(4.4 US qt, 3.7 Imp qt)/min.
5,000 rpm Discharge- pressure 294 kPa (3.0 kg/cm
2, 43 psi) or more
- quantity 42.0
(11.10 US gal, 9.24 Imp gal)/min.
Relief valve operation pressure 490 kPa (5.0 kg/cm
2, 71 psi)
Oil filterTypeFull-flow filter type
Filtration area 1,000 cm
2(155 sq in)
By-pass valve opening pressure 157 kPa (1.6 kg/cm
2, 23 psi)
Outer diameter x width 80 x 70 mm (3.15 x 2.76 in)
Oil filter to engine thread size M 20 x 1.5
Relief valve (on rocker shaft) operation pressure 69 kPa (0.7kg/cm
2, 10 psi)
Oil pressure
switchTypeImmersed contact point type
Working voltage — wattage 12 V — 3.4 W or less
Warning light activation pressure 14.7 kPa (0.15 kg/cm
2, 2.1 psi)
Proof pressure More than 981 kPa (10 kg/cm
2, 142 psi)
Oil pan capacity4.0
(4.2 US qt, 3.5 Imp qt)
2
2-4SPECIFICATIONS AND SERVICE DATA
1. Lubrication System

2. 2500 cc MODEL
Lubrication methodForced lubrication
Oil pumpPump typeTrochoid type
Number of teethInner rotor 9
Outer rotor 10
Outer rotor diameter x thickness 78 x 10 mm (3.07 x 0.39 in)
Tip clearance between inner and outer rotorSTANDARD 0.04—0.14 mm (0.0016—0.0055 in)
LIMIT 0.18 mm (0.0071 in)
Side clearance between inner rotor and pump
caseSTANDARD 0.02—0.07 mm (0.0008—0.0028 in)
LIMIT 0.15 mm (0.0059 in)
Case clearance between outer rotor and pump
caseSTANDARD 0.10—0.175 mm (0.0039—0.0069 in)
LIMIT 0.20 mm (0.0079 in)
Capacity at
80°C (176°F)600 rpm Discharge- pressure 98 kPa (1.0 kg/cm
2, 14 psi) or more
- quantity 4.6
(4.9 US qt, 4.0 Imp qt)/min.
5,000 rpm Discharge- pressure 294 kPa (3.0 kg/cm
2, 43 psi) or more
- quantity 47.0
(12.4 US gal, 10.3 Imp gal)/min.
Relief valve operation pressure 588 kPa (6.0 kg/cm
2, 85 psi)
Oil filterTypeFull-flow filter type
Filtration area 1,000 cm
2(155 sq in)
By-pass valve opening pressure 157 kPa (1.6 kg/cm
2, 23 psi)
Outer diameter x width 80 x 70 mm (3.15 x 2.76 in)
Oil filter to engine thread size M 20 x 1.5
Oil pressure
switchTypeImmersed contact point type
Working voltage—wattage 12 V—3.4 W or less
Warning light activation pressure 14.7 kPa (0.15 kg/cm
2, 2.1 psi)
Proof pressure More than 981 kPa (10 kg/cm
2, 142 psi)
Oil pan capacity4.5
(4.8 US qt, 4.0 Imp qt)
3
2-4SPECIFICATIONS AND SERVICE DATA
1. Lubrication System

G2M0235
3) Upon completion of adjustment, securely lock spherical
nut with lock nut.
Install return spring on lever (Models without hill holder
only).
NOTE:
Hook the long hook side of the return spring with the lever
(Models without hill holder only).
G2M0236
4) Depress clutch pedal to assure there is no abnormality
in the clutch system.
G2M0970
2. HYDRAULIC APPLICATION TYPE
Bleed air from oil line with the help of a co-worker.
1) Fit one end of a vinyl tube into the air bleeder of clutch
damper and put the other end into a clutch fluid container.
G2M0971
2) Slowly depress the clutch pedal and keep it depressed.
Then open the air bleeder to discharge air together with the
fluid.
Release the air bleeder for 1 or 2 seconds. Next, with the
bleeder closed, slowly release the clutch pedal.
3) Repeat these steps until there are no more air bubbles
in the vinyl tube.
CAUTION:
Cover bleeder with waste cloth when loosening it, to
prevent clutch fluid from being splashed over sur-
rounding parts.
7
2-10SERVICE PROCEDURE
2. On-Car Service

1. Manual Transmission and
Differential
A: SPECIFICATIONS
ItemModel
2200 cc 2500 cc OUTBACK
Type 5-forward speeds with synchromesh and 1-reverse
Transmission gear ratio1st 3.545
2nd 2.111
3rd 1.448
4th 1.088
5th 0.780 0.871
Reverse 3.416
Front
reduction
gearFinalType of gear Hypoid
Gear ratio 3.900 4.111
Rear
reduction
gearTransferType of gear Helical
Gear ratio 1.000
FinalType of gear Hypoid
Gear ratio 3.900 4.111
Front
differentialType and number of gear Straight bevel gear (Bevel pinion: 2, Bevel gear: 2)
Center
differentialType and number of gear Straight bevel gear (Bevel pinion: 2, Bevel gear: 2 and viscous coupling)
Transmission gear oil GL-5
Transmission oil capacity 3.5
(3.7 US qt, 3.1 Imp qt)
2
3-1SPECIFICATIONS AND SERVICE DATA
1. Manual Transmission and Differential