ECU SUBARU LEGACY 1999 Service Repair Manual

(4) Disconnect rear gate glass washer hose
from washer motor, then plug connection
with a suitable cap. (Wagon only)
(5) Remove the two bolts which hold washer
tank, then secure the tank away from work-
ing area.
B2M2023
(6) Disconnect spark plug cords from spark
plugs (#2 and #4 cylinders).
B2M2024
(7) Disconnect blow-by hose form rocker
cover (LH).
B2M2025
(8) Lift-up the vehicle.
(9) Remove under cover (LH).
(10) Place suitable container under the
vehicle.
(11) Remove rocker cover bolts, then
remove rocker cover (LH).
B2M2026
6) Set #1 cylinder piston to top dead center of
compression stroke by rotating crankshaft pulley
clockwise.
NOTE:
When arrow mark on camshaft sprocket (LH)
comes exactly to the top, #1 cylinder piston is
brought to the top dead center of the compression
stroke.
B2M2027A
10
2-2[W7A1]SERVICE PROCEDURE
7. Valve Clearance

7) Measure #1 cylinder valve clearance by using
thickness gauge.
CAUTION:
IInsert the thickness gauge in at as horizon-
tal a direction as a possible with respect to the
valve stem end face.
IMeasure exhaust valve clearances while lift-
ing-up the vehicle.
Valve clearance:
Intake: 0.20
±0.02 mm (0.0079±0.0008 in)
Exhaust: 0.25
±0.02 mm (0.0098±0.0008 in)
B2M2028A
8) If necessary, adjust the valve clearance. to 2-2 [W7B1].>
9) Similar to measurement procedures used for #1
cylinder, measure #2, #3 and #4 cylinder valve
clearances.
NOTE:
IBe sure to set cylinder pistons to their respective
top dead centers on the compression stroke before
measuring valve clearances.
ITo set #3, #2 and #4 cylinder pistons to their top
dead centers on the compression stroke, turn
crankshaft pulley clockwise 90É at a time starting
with arrow mark on left- hand camshaft sprocket
facing up.
B2M2029A
10) After inspection, install the related parts in the
reverse order of removal.
2. 2500 cc MODEL
CAUTION:
Inspection and adjustment of valve clearance
should be performed while engine is cold.1) Set the vehicle onto the lift.
2) Disconnect battery ground cable.
3) Remove canister (Taiwan spec. vehicles only).
4) Remove two bolts on the upper side which
secure timing belt cover (RH).
5) Lift-up the vehicle.
6) Remove under cover (RH).
7) Remove canister bracket (Taiwan spec.
vehicles only).
8) Loosen remaining bolt on under side which
secures timing belt cover (RH), then remove belt
cover.
9) Lower the vehicle.
10) Remove rocker cover.
IWhen inspecting #1 and #3 cylinders;
(1) Disconnect connector from mass air flow
sensor.
B2M1225A
(2) Loosen clamp which connects air intake
duct to air intake chamber.
B2M1226A
(3) Remove the two clips from air cleaner upper
cover.
CAUTION:
Before installing air cleaner upper cover, align
hole(s) with protruding portions of air cleaner
lower case, then secure upper cover.
(4) Disconnect blow-by hose from air intake
duct.
11
[W7A2]2-2SERVICE PROCEDURE
7. Valve Clearance

(3) Witha2mm(0.08 in) dia. stopper pin or a
2 mm (0.08 in) (nominal) dia. hex bar wrench
inserted into the stopper pin hole in the cylinder,
secure the adjuster rod.
H2M2383A
2) Install automatic belt tension adjuster assem-
bly.
H2M2384
3) Install belt idler (No. 1).
B2M2596
22
2-3a[W2C2]SERVICE PROCEDURE
2. Timing Belt

B: DISASSEMBLY
B2M2607A
(1) Bolt
(2) Intake valve rocker shaft
(3) Rocker shaft support(4) Intake valve rocker arm
(5) Spring
(6) Exhaust valve rocker shaft(7) Exhaust valve rocker arm
(8) Valve rocker nut
(9) Valve rocker adjust screw
1) Remove bolts which secure rocker shaft.
2) Extract rocker shaft. Remove valve rocker
arms, springs, plates and shaft supports from
rocker shaft.
CAUTION:
Arrange all removed parts in order so that they
can be installed in their original positions.
3) Remove nut and adjuster screw from valve
rocker.
28
2-3a[W3B0]SERVICE PROCEDURE
3. Valve Rocker Assembly

D: ASSEMBLY
B2M2607B
(1) Valve rocker adjust screw
(2) Valve rocker nut
(3) Intake valve rocker arm
(4) Spring(5) Rocker shaft support
(6) Intake valve rocker shaft
(7) Exhaust valve rocker arm
(8) Exhaust valve rocker shaftTightening torque: N´m (kg-m, ft-lb)
T:
5±1 (0.5±0.1, 3.6±0.7)
1) Install adjuster screw and nut to valve rocker.
2) Arrange valve rocker arms, springs and shaft
supports in assembly order and insert valve rocker
shaft.
CAUTION:
Valve rocker arms, rocker shaft and shaft sup-
ports have identification marks. Ensure parts
with same markings are properly assembled.
3) Install valve rocker shaft securing bolts.
30
2-3a[W3D0]SERVICE PROCEDURE
3. Valve Rocker Assembly

1) Remove clutch housing cover (MT vehicles
only).
2) Remove flywheel (MT vehicles only) or drive
plate (AT vehicles only).
Using ST, lock crankshaft.
ST 498497100 CRANKSHAFT STOPPER
G2M0776
B2M0706A
3) Remove oil separator cover.
4) Remove water by-pass pipe for heater.
5) Remove water pump.
6) Remove oil pump from cylinder block.
Use a flat-bladed screwdriver as shown in figure
when removing oil pump.
CAUTION:
Be careful not to scratch the mating surface of
cylinder block and oil pump.
G2M0162
7) Removal of oil pan
(1) Turn cylinder block with #2 and #4 piston
sides facing upward.
(2) Remove bolts which secure oil pan to cylin-
der block.
(3) Insert a oil pan cutter blade between cylin-
der block-to-oil pan clearance and remove oil
pan.
CAUTION:
Do not use a screwdriver or similar tool in
place of oil pan cutter.
G2M0163
8) Remove oil strainer stay.
9) Remove oil strainer.
10) Remove baffle plate.
11) Remove oil filter using ST.
ST 498187300 OIL FILTER WRENCH
B2M2611A
53
[W6A2]2-3aSERVICE PROCEDURE
6. Cylinder Block

1) Preparation for installation of automatic belt
tension adjuster assembly:
CAUTION:
IAlways use a vertical type pressing tool to
move the adjuster rod down.
IDo not use a lateral type vise.
IPush adjuster rod vertically.
IBe sure to slowly move the adjuster rod
down applying a pressure of 294 N (30 kg, 66
lb).
IPress-in the push adjuster rod gradually tak-
ing more than three minutes.
IDo not allow press pressure to exceed 9,807
N (1,000 kg, 2,205 lb).
IPress the adjuster rod as far as the end sur-
face of the cylinder. Do not press the adjuster
rod into the cylinder. Doing so may damage the
cylinder.
IDo not release press pressure until stopper
pin is completely inserted.
(1) Attach the automatic belt tension adjuster
assembly to the vertical pressing tool.
(2) Slowly move the adjuster rod down with a
pressure of 294 N (30 kg, 66 lb) until the
adjuster rod is aligned with the stopper pin hole
in the cylinder.
H2M2382
(3) Witha2mm(0.08 in) dia. stopper pin or a
2 mm (0.08 in) (nominal) dia. hex bar wrench
inserted into the stopper pin hole in the cylinder,
secure the adjuster rod.
H2M2383A
2) Install Automatic belt tension adjuster assem-
bly.
S2M0416
3) Install belt idler No. 2.
S2M0411
4) Install belt idler.
S2M0410
23
[W2C2]2-3bSERVICE PROCEDURE
2. Timing Belt

1) Remove clutch housing cover (MT vehicles
only).
2) Remove flywheel (MT vehicles only) or drive
plate (AT vehicles only).
Using ST, lock crankshaft.
ST 498497100 CRANKSHAFT STOPPER
G2M0776
B2M0706A
3) Remove oil separator cover.
4) Remove water by-pass pipe for heater.
5) Remove water pump.
6) Remove oil pump from cylinder block.
Use a flat-bladed screwdriver as shown in figure
when removing oil pump.
CAUTION:
Be careful not to scratch the mating surface of
cylinder block and oil pump.
S2M0722A
7) Removal of oil pan
(1) Turn cylinder block with #2 and #4 piston
sides facing upward.
(2) Remove bolts which secure oil pan to cylin-
der block.
(3) Insert a oil pan cutter blade between cylin-
der block-to-oil pan clearance and remove oil
pan.
CAUTION:
Do not use a screwdriver or similar tool in
place of oil pan cutter.
G2M0163
8) Remove oil strainer stay.
9) Remove oil strainer.
10) Remove baffle plate.
11) Remove oil filter.
52
2-3b[W5A2]SERVICE PROCEDURE
5. Cylinder Block

B: DISASSEMBLY
Remove screws which secure oil pump cover and
disassemble oil pump.
Inscribe alignment marks on inner and outer rotors
so that they can be replaced in their original posi-
tions during reassembly.
CAUTION:
Before removing relief valve, loosen plug when
removing oil pump from cylinder block.
B2M1912A
(A) Oil seal
(B) Pump case
(C) Inner rotor
(D) Outer rotor
(E) Pump cover
(F) Relief valve
(G) Relief spring
(H) Plug
(I) Washer
C: INSPECTION
1. TIP CLEARANCE
Measure the tip clearance of rotors. If the clear-
ance exceeds the limit, replace rotors as a
matched set.
Tip clearance:
Standard
0.04 Ð 0.14 mm (0.0016 Ð 0.0055 in)
Limit
0.18 mm (0.0071 in)
B2M1913A
2. CASE CLEARANCE
Measure the clearance between the outer rotor
and the cylinder block rotor housing. If the clear-
ance exceeds the limit, replace the rotor.
Case clearance:
Standard
0.10 Ð 0.175 mm (0.0039 Ð 0.0069 in)
Limit
0.20 mm (0.0079 in)
B2M1914A
8
2-4[W1B0]SERVICE PROCEDURE
1. Oil Pump

2. 2200 cc EXCEPT CALIFORNIA SPEC.
VEHICLES
1) Disconnect battery ground cable.
B2M1723
2) Disconnect connector from mass air flow sen-
sor.
B2M2018
3) Loosen clamp which connects air intake duct to
air intake chamber.
B2M2019
4) Remove two clips of air cleaner upper cover.
B2M2289
5) Remove air intake duct and air cleaner upper
cover as a unit.
B2M2020
6) Remove air cleaner element.
7) Remove air cleaner lower case.
S2M0179
8) Installation is in the reverse order of removal.
CAUTION:
Before installing air cleaner upper cover, align
holes with protruding portions of air cleaner
lower case, then secure upper cover to lower
case.
S2M0180
17
[W1A2]2-7SERVICE PROCEDURE
1. Air Cleaner and Air Intake Duct