tow SUBARU LEGACY 1997 Service Repair Manual

BRAKES
[M13-5]
4-413
.
Anti-lock
Brake
System
(AB
S)
[
5
.3i
Typ
e]

"
HYDRAULIC
CONTROL
UNIT
SECTION
(H/U)

The
H/U
is
a
fluid
pressure
controller
comprising
a
motor,
solenoid
valve,
housing,
relay,
etc
.
It

constitutes
two
diagonally
independent
brake
fluid
circuits
for
a
cross
piping
vehicle
.

"
The
pump
motor
rotates
an
eccentric
cam
to
let
the
plunger
pump
generatea
hydraulicpres-

sure
.

"
The
housing
accommodates
the
pump
motor,
solenoid
valve,
reservoir,
etc
.,
and
also
consti-
tutes
abrake
fluid
passage
.

"
The
plunger
pump
is
a
hydraulic
pump
which
drains
off
the
brake
fluid
which,
when
the
pressure

is
reduced,
is
discharged
to
the
reservoir,
and
sends
it
toward
the
master
cylinder
.

"
The
solenoid
valve
is
a
2-position
type
solenoidvalve
which
switches
the
brake
fluid
passages

between
the
wheel
and
master
cylinder
and
reservoir
sides
in
response
to
an
instruction
from
the

ABSCM
.

For
each
wheel
cylinder,
a
pairof
normally-closed
and
-opened
solenoid
valves
are
provided
.

*
The
inlet
solenoid
valve
is
duty-controlled
to
reduce
brake
fluid
pulsation
for
IowerABS
operation

noise
.

"
The
reservoir
is
a
fluid
chamber
which
temporarily
storesthe
brake
fluid
to
be
discharged
from

the
wheel
cylinder
when
the
pressure
is
reduced
.

"
The
damper
chamber
suppresses
thepulsation
of
the
brake
fluid
which,
when
the
pressure
is

reduced,
is
discharged
from
the
plunger
pump,
thereby
minimizing
the
kickbacks
to
the
brake

pedal
.

*
The
valve
relay
controls
the
solenoid
valve
and
motor
relay
energizing
power
supply
in
response

to
an
instruction
from
the
ABSCM
.
In
normal
(1G
ON)
condition,
the
relay
is
actuated
to
supply

power
to
the
solenoid
valve
and
motor
relay
.
When
an
error
occurs
in
the
system,
the
valve
relay

is
forced
to
OFF
to
keep
the
fluid
pressure
circuit
in
the
normal
mode
(normal
brake
mode)
and

also
constitute
the
ABS
warning
light
operating
circuit
.

"
The
motor
relay
supplies
power
to
the
pump
motor
to
operate
the
plunger
pump
in
response
to

an
instruction
from
the
ABSCM
in
the
ABS
control
mode
.

TheH/U
has
four
operating
modes
;
normal
mode
(control
OFF
:
normalbrake
mode),
"increase",

"hold"
and
"decrease"
modes
(control
ON
in
all
the
three
modes)
.

7

BRAKES
[ABS
5
.31
TYPE]
[T8J5]
4-4d

8
.
Diagnostics
Chart
with
Trouble
Code
by
ABS
Warning
Light

811
CHECK

FREELY'FOR
ALONG
TIME
.

TURNED

Check
if
the
wheels
havebeen
turned
freely

for
more
than
one
minute,
such
as
when
the

vehicle
is
jacked-up,
under
full-lock
corner-
ing
or
when
fire
is
not
in
contact
with
road

surface
.

The
ABS
is
normal
.
Erase
the
trouble
code
.

NOTE
:

When
the
wheels
turn
freely
for
along
time,
such
as
when

the
vehicle
is
towed
or
jacked-up,
or
when
steering
wheel

is
continuouslyturned
all
the
way,
this
trouble
code
may

sometimes
occur
.

No
:
Go
to
step
8,12
.

18J2
I
CHECK
TIRE
SPECIFICATIONS
.

CHECK
:
Are
the
fire
specifications
correct?

,res
:
Go
tostep8
.113
.

No
:
Replace
tire
.

18,13
1
CHECK
WEAR
OF
TIRE
.

CHECK
:
Is
the
fire
worn
excessively?

,res
:
Replace
tire
.

No
:
Go
tostep
8,14
.

18J4
I
CHECK
TIRE
PRESSURE
.

CHECK
:
Is
the
fire
pressure
correct?

,rES
:
Go
to
step
8J5
.

No
:
Adjust
tire
pressure
.

18,15
1
CHECK
INSTALLATION
OF
ABS
SENSOR
.

Tighteningtorque
:

32
f
10
N~m
(3
.3
f
1
.0
kg-m,
24
±
7
ft-Ib)

CHECK
:
Are
the
ABS
sensor
installation
bolts
tight-

ened
securely?

,res
:
Go
to
step
8J6
.

No
:
Tighten
ABS
sensor
installation
bolts
securely
.

49

BRAKES
[ABS
5
.31
TYPE]
[T10M5]
4-4d

10
.
Diagnostics
Chart
with
Select
Monitor

iomi
CHECK

(FREE
Y'FOR

THE

AILONG
TIMEVE

TURNED

CHECK
:
Check
if
the
wheels
have
been
turned
freely

for
more
than
one
minute,
suchas
when
the

vehicle
is
jacked-up,
under
full-lock
corner-

ing
or
when
fire
is
not
in
contact
with
road

surface
.

,rES
:
The
ABS
is
normal
.
Erase
the
trouble
code
.

NOTE
:

When
the
wheels
turn
freelyfor
a
long
time,
such
as
when

the
vehicle
is
towed
or
jacked-up,
or
when
steering
wheel

is
continuously
turned
all
the
way,
this
trouble
code
may

sometimes
occur
.

No
:
Go
to
step
10M2
.

10M2
CHECK
TIRE
SPECIFICATIONS
.

Turn
ignition
switch
to
OFF
.

CHECK
:
Are
the
fire
specifications
correct?

,rES
:
Go
to
step
10M3
.

No
:
Replace
tire
.
1
10M3
I
CHECK
WEAR
OF
TIRE
.

Is
the
fire
worn
excessively?

vES
:
Replace
tire
.

No
:
Go
to
step
10M4
.
1
10M4
I
CHECK
TIRE
PRESSURE
.

CHECK
:
Is
the
fire
pressure
correct?

Go
to
step
10M5
.

No
:
Adjust
fire
pressure
.

1
10M5
I
CHECK
INSTALLATION
OF
ABS
SENSOR
.

Tightening
torque
:

32
f
10
N~m
(3
.3
f
1
.0
kg-m,
24
f
7
ft-Ib)

CHECK
:
Are
the
ABS
sensor
installation
bolts
tight-

ened
securely?

,rES
:
Go
to
step
10M6
.

No
:
Tighten
ABS
sensor
installation
bolts
securely
.

133

B2M0386A
(3) Install valve spring and retainer.
CAUTION:
Be sure to install the valve springs with their painted
facing towards the valve spring retainer.
(4) Set ST on valve spring.
ST 499718000 VALVE SPRING REMOVER
(5) Compress valve spring and fit valve spring retainer
key.
B2M1210A
(6) After installing, tap valve spring retainers lightly
with wooden hammer for better seating.
3) Install camshaft and support.

4) Install valve rocker assembly.

5) Install rocker cover.
47
2-3SERVICE PROCEDURE
6. Cylinder Head

B2M1211A
4) Installation of piston rings and oil ring
(1) Install oil ring spacer, upper rail and lower rail in this
order by hand. Then install second ring and top ring
with a piston ring expander.
(2) Position the top ring gap at A or B in the Figure.
(3) Position the second ring gap at 180°on the reverse
side for the top ring gap.
B2M1212A
(4) Position the upper rail gap at C or D in the Figure.
(5) Position the expander gap at 180°of the reverse
side for the upper rail gap.
(6) Position the lower rail gap at E or F in the Figure.
CAUTION:
Ensure ring gaps do not face the same direction.
Ensure ring gaps are not within the piston skirt area.
G2M0183
5) Install circlip.
Install circlips in piston holes located opposite service
holes in cylinder block, when positioning all pistons in the
corresponding cylinders.
CAUTION:
Use new circlips.
NOTE:
Piston front mark“
”facer toward front of engine.
66
2-3SERVICE PROCEDURE
7. Cylinder Block

G2M0752
2) Camshaft cap installation
(1) Apply fluid packing sparingly to cap mating surface.
CAUTION:
Do not apply fluid packing excessively. Failure to do so
may cause excess packing to come out and flow
toward oil seal, resulting in oil leaks.
Fluid packing:
THREE BOND 1215 or equivalent
G2M0753
(2) Apply engine oil to cap bearing surface and install
cap on camshaft as shown by identification mark.
(3) Gradually tighten cap in at least two stages in the
numerical order shown in figure, and then tighten to
specified torque.
(4) Similarly, tighten cap on exhaust side.
After tightening cap, ensure camshaft rotates only
slightly while holding it at“base”circle.
B2M1219A
3) Inspect for valve clearance.
Measure valve clearances using thickness gauge. 2-2 [07A2].>
If necessary, adjust valve clearances.
G2M0754
4) Camshaft oil seal installation
Apply grease to new oil seal lips and press onto front end
of camshaft by using ST1 and ST2.
CAUTION:
Use a new oil seal.
ST1 499587100 OIL SEAL INSTALLER
ST2 499597000 OIL SEAL GUIDE
G2M0755
5) Rocker cover installation
(1) Install gaskets on rocker cover.
Install peripheral rocker cover gaskets.
(2) Apply fluid packing to four front open edges of
peripheral gasket.
Fluid packing:
THREE BOND 1215 or equivalent
(3) Install rocker cover on cylinder head. Ensure gas-
ket is properly positioned during installation.
34
2-3bSERVICE PROCEDURE
3. Camshaft

D: ASSEMBLY
B2M1220B
B2M1221A
1) Installation of valve spring and valve
(1) Coat stem of each valve with engine oil and insert
valve into valve guide.
CAUTION:
When inserting valve into valve guide, use special care
not to damage the oil seal lip.
(2) Set cylinder head on ST1.
(3) Install valve spring and retainer using ST2.
ST1 498267600 CYLINDER HEAD TABLE
ST2 499718000 VALVE SPRING REMOVER
CAUTION:
Be sure to install the valve springs with their painted
facing towards the valve spring retainer.
(4) Compress valve spring and fit valve spring retainer
key.
(5) After installing, tap valve spring retainers lightly
with wooden hammer for better seating.
2) Install valve lifter and shim.
44
2-3bSERVICE PROCEDURE
4. Cylinder Head

B2M1223A
4) Installation of piston rings and oil ring
(1) Install oil ring spacer, upper rail and lower rail in this
order by hand. Then install second ring and top ring
with a piston ring expander.
(2) Position the top ring gap at A or B in the Figure.
(3) Position the second ring gap at 180°on the reverse
side for the top ring gap.
B2M1224A
(4) Position the upper rail gap at C or D in the Figure.
(5) Position the expander gap the at 180°of the
reverse side for the upper rail gap.
(6) Position the lower rail gap at E or F in the Figure.
CAUTION:
Ensure ring gaps do not face the same direction.
Ensure ring gaps are not within the piston skirt area.
G2M0183
5) Install circlip.
Install circlips in piston holes located opposite service
holes in cylinder block, when positioning all pistons in the
corresponding cylinders.
CAUTION:
Use new circlips.
NOTE:
Piston front mark“
”faces toward front of engine.
68
2-3bSERVICE PROCEDURE
5. Cylinder Block

G2M0360
3) Remove right rear wheel.
4) Open fuel filler flap and remove filler cap.
5) Remove screws holding packing in place.
G2M0361
6) Lift-up the vehicle.
7) Remove fuel filler pipe protector.
G2M0353
8) Remove clip, and separate air vent hose from pipe.
9) Loosen clamp, and separate fuel filler hose from pipe.


1Fuel filler hose


2Air vent hose
10) Remove fuel filler pipe to under side of the vehicle.
G2M0364
B: INSTALLATION
1) Hold fuel filler flap open.
2) Set fuel saucer

1with rubber packing
3, and insert fuel
filler pipe into hole from the inner side of apron.
3) Align holes in fuel filler pipe neck and set cup

2, and
tighten screws.
NOTE:
If edges of rubber packing are folded toward the inside,
straighten it with a screwdriver.
G2M0353
4) Insert fuel filler hose approximately 25 to 30 mm (0.98
to 1.18 in) over the lower end of fuel filler pipe and tighten
clamp.


1Fuel filler hose


2Air vent hose
CAUTION:
Do not allow clips to touch air vent hose and rear sus-
pension crossmember.
17
2-8SERVICE PROCEDURE
4. Fuel Filler Pipe

B2M1171
AT model
B2M0035
25) Remove transmission.
CAUTION:
Move transmission jack toward rear until mainshaft
is withdrawn from clutch cover. (MT model)
Move transmission and torque converter as a unit
away from engine. (AT model)
36
2-11SERVICE PROCEDURE
3. Transmission