engine SUBARU LEGACY 1999 Service Manual PDF

E: INSTALLATION
Installation is in the reverse order of removal.
Observe the following:
1) Apply fluid packing to matching surfaces of oil
pump.
Fluid packing:
THREE BOND 1215 or equivalent
H2M2424A
2) Replace O-ring with a new one.
3) Apply a coat of engine oil to the inside of the oil
seal.
S2M0118A
4) Be careful not to scratch oil seal when installing
oil pump on cylinder block.
5) Position the oil pump, aligning the notched area
with the crankshaft, and push the oil pump straight.
CAUTION:
Make sure the oil seal lip is not folded.
6) Install oil pump.
Tightening torque:
6.4 N´m (0.65 kg-m, 4.7 ft-lb)
S2M0120A
2. Oil Pan and Oil Strainer
A: REMOVAL
1) Disconnect battery ground cable.
G6M0095
2) Remove front wheels.
3) Remove air intake duct and air cleaner assem-
bly. (2200 cc California spec. vehicles)
B2M2771
4) Remove air intake duct and air intake chamber.
(Except 2200 cc California spec. vehicles)
B2M2772
10
2-4[W1E0]SERVICE PROCEDURE
2. Oil Pan and Oil Strainer

E: INSTALLATION
Installation is in the reverse order of removal.
Observe the following:
1) Apply fluid packing to matching surfaces of oil
pump.
Fluid packing:
THREE BOND 1215 or equivalent
H2M2424A
2) Replace O-ring with a new one.
3) Apply a coat of engine oil to the inside of the oil
seal.
S2M0118A
4) Be careful not to scratch oil seal when installing
oil pump on cylinder block.
5) Position the oil pump, aligning the notched area
with the crankshaft, and push the oil pump straight.
CAUTION:
Make sure the oil seal lip is not folded.
6) Install oil pump.
Tightening torque:
6.4 N´m (0.65 kg-m, 4.7 ft-lb)
S2M0120A
2. Oil Pan and Oil Strainer
A: REMOVAL
1) Disconnect battery ground cable.
G6M0095
2) Remove front wheels.
3) Remove air intake duct and air cleaner assem-
bly. (2200 cc California spec. vehicles)
B2M2771
4) Remove air intake duct and air intake chamber.
(Except 2200 cc California spec. vehicles)
B2M2772
10
2-4[W1E0]SERVICE PROCEDURE
2. Oil Pan and Oil Strainer

5) Disconnect front oxygen sensor connector.
B2M1979A
S2M0127A
6) Disconnect rear oxygen sensor connector.
(2500 cc California spec. vehicles)
S2M0128
7) Remove pitching stopper.
G2M0295
8) Remove radiator upper bracket.
B2M0320
9) Support engine with a lifting device and wire
ropes.
B2M0053
10) Lift-up the vehicle.
CAUTION:
At this time, raise up wire ropes.
11) Remove under cover.
B2M0014
11
[W2A0]2-4SERVICE PROCEDURE
2. Oil Pan and Oil Strainer

12) Drain engine oil.
Set container under the vehicle, and remove drain
plug from oil pan.
G2M0066
13) Disconnect connector from rear oxygen sen-
sor. (Except 2500 cc California spec. vehicles)
B2M0312
14) Remove front exhaust pipe.
(1) Separate front catalytic converter from cen-
ter exhaust pipe.
B2M0421
(2) Remove front exhaust pipe from engine.
S2M0236
(3) Remove bolt which installs front exhaust
pipe on bracket.
15) Remove nuts which install front cushion rub-
ber onto front crossmember.
G2M0293
16) Remove bolts which install oil pan on cylinder
block while raising up engine.
B2M2687A
S2M0131A
17) Insert oil pan cutter blade between cylinder
block-to-oil pan clearance.
CAUTION:
Do not use a screwdriver or similar tool in
place of oil pan cutter.
12
2-4[W2A0]SERVICE PROCEDURE
2. Oil Pan and Oil Strainer

18) Remove oil strainer.
S2M0238
19) Remove baffle plate.
S2M0309
B: INSPECTION
By visual check make sure oil pan, oil strainer and
baffle plate are not damaged.
C: INSTALLATION
CAUTION:
Before installing oil pan, clean sealant from oil
pan and engine block.
1) Install baffle plate.
Tightening torque:
6.4 N´m (0.65 kg-m, 4.7 ft-lb)
S2M0309
2) Install oil strainer onto baffle plate.
CAUTION:
Replace O-ring with a new one.
Tightening torque:
10 N´m (1.0 kg-m, 7 ft-lb)
S2M0238
3) Apply fluid packing to mating surfaces and
install oil pan.
Fluid packing:
THREE BOND 1215 or equivalent
G2M0084
13
[W2C0]2-4SERVICE PROCEDURE
2. Oil Pan and Oil Strainer

4) Tighten bolts which install oil pan onto engine
block.
Tightening torque:
5 N´m (0.5 kg-m, 3.6 ft-lb)
B2M2687A
S2M0131A
5) Lower engine onto front crossmember.
6) Tighten nuts which install front cushion rubber
onto front crossmember.
Tightening torque:
69
±15 N´m (7.0±1.5 kg-m, 51±11 ft-lb)
G2M0293
7) Install front exhaust pipe.
CAUTION:
Always use the new gaskets.
(1) Place front exhaust pipe on bracket.
(2) Tighten nuts which install front exhaust pipe
on engine.
Tightening torque:
30
±5 N´m (3.1±0.5 kg-m, 22.4±3.6 ft-lb)
S2M0236
(3) Tighten nuts which install front catalytic con-
verter to center exhaust pipe.
Tightening torque:
35
±5 N´m (3.6±0.5 kg-m, 26.0±3.6 ft-lb)
B2M0421
(4) Tighten bolt which installs front exhaust
pipe on bracket.
Tightening torque:
24
±3 N´m (2.4±0.3 kg-m, 17.4±2.2 ft-lb)
B2M0313
14
2-4[W2C0]SERVICE PROCEDURE
2. Oil Pan and Oil Strainer

15) Install radiator upper brackets.
Tightening torque:
18
±5 N´m (1.8±0.5 kg-m, 13±4 ft-lb)
B2M0320
16) Install air intake duct and air cleaner assem-
bly. (2200 cc California spec. vehicles)
B2M2771
17) Install air intake duct and air intake chamber.
(Except 2200 cc California spec. vehicles)
B2M2772
18) Fill engine oil through filler pipe up to upper
point of level gauge.
Engine oil capacity:
2200 cc ; Upper level
4.0
(4.2 US qt, 3.5 Imp qt)
2200 cc ; Lower level
3.0
(3.2 US qt, 2.6 Imp qt)
2500 cc ; Upper level
4.5
(4.8 US qt, 4.0 Imp qt)
2500 cc ; Lower level
3.5
(3.7 US qt, 3.1 Imp qt)
3. Oil Pressure Switch
A: REMOVAL
1) Remove alternator from bracket.
(1) Disconnect connector and terminal from
generator.
H6M0402
(2) Remove V-belt cover.
B2M0017
(3) Loosen lock bolt and slider bolt, and remove
front side V-belt.
(4) Remove bolts which install generator on
bracket.
H2M1499
16
2-4[W3A0]SERVICE PROCEDURE
3. Oil Pressure Switch

15) Install radiator upper brackets.
Tightening torque:
18
±5 N´m (1.8±0.5 kg-m, 13±4 ft-lb)
B2M0320
16) Install air intake duct and air cleaner assem-
bly. (2200 cc California spec. vehicles)
B2M2771
17) Install air intake duct and air intake chamber.
(Except 2200 cc California spec. vehicles)
B2M2772
18) Fill engine oil through filler pipe up to upper
point of level gauge.
Engine oil capacity:
2200 cc ; Upper level
4.0
(4.2 US qt, 3.5 Imp qt)
2200 cc ; Lower level
3.0
(3.2 US qt, 2.6 Imp qt)
2500 cc ; Upper level
4.5
(4.8 US qt, 4.0 Imp qt)
2500 cc ; Lower level
3.5
(3.7 US qt, 3.1 Imp qt)
3. Oil Pressure Switch
A: REMOVAL
1) Remove alternator from bracket.
(1) Disconnect connector and terminal from
generator.
H6M0402
(2) Remove V-belt cover.
B2M0017
(3) Loosen lock bolt and slider bolt, and remove
front side V-belt.
(4) Remove bolts which install generator on
bracket.
H2M1499
16
2-4[W3A0]SERVICE PROCEDURE
3. Oil Pressure Switch

2) Disconnect terminal from oil pressure switch.
G2M0091
3) Remove oil pressure switch.
S2M0119
B: INSTALLATION
1) Apply fluid packing to oil pressure switch
threads before installation.
Fluid packing:
THREE BOND 1215 or equivalent
S2M0124A
2) Install oil pressure switch onto engine block.
Tightening torque:
25
±3 N´m (2.5±0.3 kg-m, 18.1±2.2 ft-lb)
S2M0119
3) Connect terminal of oil pressure switch.
G2M0091
4) Install generator on bracket and temporarily
tighten installing bolts.
H2M1499
5) Install front side V-belt and adjust it. 1-5 [G2A0].>
6) Install V-belt cover.
B2M0017
17
[W3B0]2-4SERVICE PROCEDURE
3. Oil Pressure Switch

1. Engine Lubrication System
Trouble in General
Before troubleshooting, make sure that the engine
oil level is correct and no oil leakage exists.
Trouble Possible cause Corrective action
1. Warning light remains
on.1) Oil pressure switch
failureCracked diaphragm or oil leakage within switch Replace.
Broken spring or seized contacts Replace.
2) Low oil pressureClogged oil filter Replace.
Malfunction of oil by-pass valve of oil filter Clean or replace.
Malfunction of oil relief valve of oil pump Clean or replace.
Clogged oil passage Clean.
Excessive tip clearance and side clearance of oil
pump rotor and gearReplace.
Clogged oil strainer or broken pipe Clean or replace.
3) No oil pressureInsufficient engine oil Replenish.
Broken pipe of oil strainer Replace.
Stuck oil pump rotor Replace.
2. Warning light does
not go on.1) Burn-out bulb Replace.
2) Poor contact of switch contact points Replace.
3) Disconnection of wiring Repair.
3. Warning light flickers
momentarily.1) Poor contact at terminals Repair.
2) Defective wiring harness Repair.
3) Low oil pressureCheck for the same
possible causes as
listed in 1.Ð2)
19
[K100]2-4DIAGNOSTICS
1. Engine Lubrication System Trouble in General