SUBARU LEGACY 1999 Service Repair Manual

B: 2500 cc MODEL
Cooling systemElectric fan + Forced engine coolant circula-
tion system
Total engine coolant capacity(US qt, Imp qt) Approx. 6.1 (6.4, 5.4)
Water pumpType Centrifugal impeller type
Discharge performance IDischarge 20(5.3 US gal, 4.4 Imp gal)/min.
Pump speedÐtotal engine
coolant head760 rpm Ð 0.3 mAq (1.0 ftAq)
Engine coolant temperature 85ÉC (185ÉF)
Discharge performance IIDischarge 100(26.4 US gal, 22.0 Imp gal)/min.
Pump speedÐtotal engine
coolant head3,000 rpm Ð 5.0 mAq (16.4 ftAq)
Engine coolant temperature 85ÉC (185ÉF)
Discharge performance IIIDischarge 200(52.8 US gal, 44.0 Imp gal)/min.
Pump speedÐtotal engine
coolant head6,000 rpm Ð 23.0 mAq (75.5 ftAq)
Engine coolant temperature 85ÉC (185ÉF)
Impeller diameter 76 mm (2.99 in)
Number of impeller vanes 8
Pump pulley diameter 60 mm (2.36 in)
ThermostatTypeWax pellet type
Starts to open 76 Ð 80ÉC (169 Ð 176ÉF)
Fully opened 91ÉC (196ÉF)
Valve lift 9.0 mm (0.354 in) or more
Valve bore 35 mm (1.38 in)
Radiator fanMotor120 W (main fan)
140 W (sub fan)
Fan diameter´Blade340 mm (13.39 in)´5 (main fan)
280 mm (11.02 in)´4 (sub fan)
RadiatorType Cross flow, pressure type
Core dimensions670´361´16 mm
(26.38´14.21´0.63 in)
Pressure range in which cap valve is openAbove: 88±10 kPa
(0.9±0.1 kg/cm
2, 12.8±1.4 psi)
Below: þ4.9 to þ9.8 kPa
(þ0.05 to þ0.1 kg/cm
2, þ0.7 to þ1.4 psi)
FinsCorrugated fin type
Reservoir
tankCapacity 0.5(0.5 US qt, 0.4 Imp qt)
2. Service Data
Water pump
Clearance between impeller and caseStandard0.5 Ð 0.7 mm (0.020 Ð 0.028
in)
Limit 1.0 mm (0.039 in)
ªThrustº runout of impeller end 0.5 mm (0.020 in)
3
[S200]2-5SPECIFICATIONS AND SERVICE DATA
2. Service Data

1. Water Pump
B2M1188A
(1) Water pump ASSY
(2) Gasket
(3) Heater hose
(4) Thermostat
(5) Gasket(6) Thermostat caseTightening torque: N´m (kg-m, ft-lb)
T1:
First 10+4/þ0
(1.0+0.4/þ0, 7.2+2.9/þ0)
Second 10+4/þ0
(1.0+0.4/þ0, 7.2+2.9/þ0)
T2:6.4±0.5 (0.65±0.05, 4.7±0.4)
4
2-5[C100]COMPONENT PARTS
1. Water Pump

2. Radiator and Radiator Fan
B2M2034A
(1) Radiator lower cushion
(2) Radiator
(3) O-ring
(4) Air vent plug
(5) Radiator upper cushion
(6) Radiator upper bracket
(7) Clamp
(8) Radiator inlet hose
(9) Support
(10) Radiator sub fan ASSY
(11) Sub fan shroud
(12) Radiator main fan ASSY
(13) Main fan shroud(14) Engine coolant reservoir tank
cap
(15) Over flow hose
(16) Engine coolant reservoir tank
(17) ATF hose clamp (AT vehicles
only)
(18) ATF inlet hose A (AT vehicles
only)
(19) ATF outlet hose A (AT vehicles
only)
(20) ATF pipe (AT vehicles only)
(21) ATF inlet hose B (AT vehicles
only)(22) ATF outlet hose B (AT vehicles
only)
(23) Radiator outlet hose
(24) Radiator drain pipe
(25) Gasket
(26) Radiator drain plug
Tightening torque: N´m (kg-m, ft-lb)
T1:
7.4±2.0 (0.75±0.20, 5.4±1.4)
T2:12±3 (1.2±0.3, 8.7±2.2)
T3:18±5 (1.8±0.5, 13.0±3.6)
5
[C200]2-5COMPONENT PARTS
2. Radiator and Radiator Fan

3. Water Pipe
B2M1189A
(1) Engine coolant temperature sen-
sor
(2) Engine coolant temperature
gauge(3) Water pipe
(4) O-ring
(5) By-pass hoseTightening torque: N´m (kg-m, ft-lb)
T:
6.4±0.5 (0.65±0.05, 4.7±0.4)
6
2-5[C300]COMPONENT PARTS
3. Water Pipe

1. On-car Service
A: DRAINING OF ENGINE
COOLANT
1) Lift-up the vehicle.
2) Fit vinyl tube to drain pipe.
B2M0133A
3) Loosen drain cock to drain engine coolant into
container.
NOTE:
Remove radiator cap so that engine coolant will
drain faster.
B2M0015A
B: FILLING OF ENGINE COOLANT
1) Remove air vent plug from radiator.
B2M0301
2) Fill engine coolant into radiator up to filler neck
position.
B2M0135
3) Fill engine coolant into reservoir tank up to
upper level.
B2M0140
4) Attach radiator cap and reservoir tank cap prop-
erly.
5) Install air vent plug.
6) Warm-up engine completely for more than five
minutes at 2,000 to 3,000 rpm.
7) Stop engine and wait until temperature drops to
a safe level.
8) If engine coolant level drops in radiator, add
engine coolant to filler neck position.
9) If engine coolant level drops from upper level of
reservoir tank, add engine coolant to upper level.
10) Attach radiator cap and reservoir tank cap
properly.
7
[W1B0]2-5SERVICE PROCEDURE
1. On-car Service

C: CHECKING OF COOLING
SYSTEM
1) Remove radiator cap, top off radiator, and
attach tester to radiator in place of cap.
B2M0136
2) Apply a pressure of 157 kPa (1.6 kg/cm2,23
psi) to radiator to check if:
(1) Engine coolant leaks at/around radiator.
(2) Engine coolant leaks at/around hoses or
connections.
CAUTION:
IEngine should be off.
IWipe engine coolant from check points in
advance.
IBe careful to prevent engine coolant from
spurting out when removing tester.
IBe careful also not to deform filler neck of
radiator when installing or removing tester.
2. Water Pump
A: REMOVAL AND INSTALLATION
1. 2200 cc MODEL
1) Disconnect ground cable from battery.
B2M1723
2) Lift-up the vehicle.
3) Remove under cover.
B2M0014
4) Drain engine coolant completely. [W1A0].>
B2M0015A
8
2-5[W1C0]SERVICE PROCEDURE
2. Water Pump

C: CHECKING OF COOLING
SYSTEM
1) Remove radiator cap, top off radiator, and
attach tester to radiator in place of cap.
B2M0136
2) Apply a pressure of 157 kPa (1.6 kg/cm2,23
psi) to radiator to check if:
(1) Engine coolant leaks at/around radiator.
(2) Engine coolant leaks at/around hoses or
connections.
CAUTION:
IEngine should be off.
IWipe engine coolant from check points in
advance.
IBe careful to prevent engine coolant from
spurting out when removing tester.
IBe careful also not to deform filler neck of
radiator when installing or removing tester.
2. Water Pump
A: REMOVAL AND INSTALLATION
1. 2200 cc MODEL
1) Disconnect ground cable from battery.
B2M1723
2) Lift-up the vehicle.
3) Remove under cover.
B2M0014
4) Drain engine coolant completely. [W1A0].>
B2M0015A
8
2-5[W1C0]SERVICE PROCEDURE
2. Water Pump

5) Disconnect radiator outlet hose (A) and heater
by-pass hose (B) from water pump.
H2M2515A
6) Disconnect connectors from radiator main fan
(A) and sub fan (B) motors.
B2M2035A
7) Lower the vehicles.
8) Remove radiator main fan [W6A0].> and sub fan motor assembly [W7A0].>.
B2M2036
9) Remove V-belts.

B2M2308
10) Remove timing belt.

B2M2037
11) Remove automatic belt tension adjuster.
H2M2375
12) Remove belt idler No. 2.
H2M2518
13) Remove camshaft position sensor.

B2M2038
9
[W2A1]2-5SERVICE PROCEDURE
2. Water Pump

14) Remove left-hand camshaft sprocket by using
ST.
ST 499207100 CAMSHAFT SPROCKET
WRENCH
B2M2039A
15) Remove left-hand belt cover No. 2.
B2M2040
16) Remove tensioner bracket.
H2M2380
17) Remove tensioner bracket.
18) Disconnect heater hose from water pump.
19) Remove water pump.
G2M0210
20) Installation is in the reverse order of removal.
CAUTION:
IReplace gasket with a new one.
IWhen installing water pump, tighten bolts in
two stages in alphabetical sequence as shown
in figure.
Tightening torque:
10+4/þ0N´m (1.0+0.4/þ0kg-m, 7.2+2.9/þ0ft-lb)
S2M0760A
2. 2500 cc MODEL
1) Disconnect ground cable from the battery.
B2M1723
2) Lift-up the vehicle.
3) Remove under cover.
B2M0014
10
2-5[W2A2]SERVICE PROCEDURE
2. Water Pump

4) Drain engine coolant completely.

B2M0015A
5) Disconnect connectors from radiator main fan
(A) and sub fan (B) motors.
B2M2035A
6) Loosen bolts which hold lower side of radiator
main fan and sub fan shrouds.
B2M2041
7) Disconnect radiator outlet hose (A) and heater
by-pass hose (B) from water pump.
H2M2515A
8) Lower the vehicle.
9) Remove radiator main fan [W6A0].> and sub fan assemblies [W7A0].>.
B2M2036
10) Remove V-belts.

B2M2308
11) Remove timing belt.

S2M0017
12) Remove automatic belt tension adjuster.
H2M2403
11
[W2A2]2-5SERVICE PROCEDURE
2. Water Pump