oil pump SUBARU LEGACY 1999 Service Repair Manual

S2M0242
Oil pressure:
98 kPa (1.0 kg/cm2,14 psi) or more at 800
rpm
294 kPa (3.0 kg/cm
2, 43 psi) or more at
5,000 rpm
CAUTION:
IIf oil pressure is out of specification, check
oil pump, oil filter and lubrication line. 2-4 [K100].>
IIf oil pressure warning light is turned ON and
oil pressure is in specification, replace oil pres-
sure switch.
NOTE:
The specified data is based on an engine oil tem-
perature of 80ÉC (176ÉF).
8) After measuring oil pressure, install oil pressure
switch.
Tightening torque:
25
±3 N´m (2.5±0.3 kg-m, 18.1±2.2 ft-lb)
9) Install generator and V-belt in the reverse order
of removal, and adjust the V-belt deflection.
7. Valve Clearance
A: INSPECTION
1. 2200 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.
B2M1723
3) Remove engine coolant reservoir tank. 2-5 [W9A0].>
S2M0028
4) Remove timing belt cover (LH).
B2M2031
5) Remove rocker cover.
IWhen inspecting #1 and #3 cylinders:
ILow emission vehicle:
7
[W7A1]2-2SERVICE PROCEDURE
7. Valve Clearance

S2M0242
Oil pressure:
98 kPa (1.0 kg/cm2,14 psi) or more at 800
rpm
294 kPa (3.0 kg/cm
2, 43 psi) or more at
5,000 rpm
CAUTION:
IIf oil pressure is out of specification, check
oil pump, oil filter and lubrication line. 2-4 [K100].>
IIf oil pressure warning light is turned ON and
oil pressure is in specification, replace oil pres-
sure switch.
NOTE:
The specified data is based on an engine oil tem-
perature of 80ÉC (176ÉF).
8) After measuring oil pressure, install oil pressure
switch.
Tightening torque:
25
±3 N´m (2.5±0.3 kg-m, 18.1±2.2 ft-lb)
9) Install generator and V-belt in the reverse order
of removal, and adjust the V-belt deflection.
7. Valve Clearance
A: INSPECTION
1. 2200 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.
B2M1723
3) Remove engine coolant reservoir tank. 2-5 [W9A0].>
S2M0028
4) Remove timing belt cover (LH).
B2M2031
5) Remove rocker cover.
IWhen inspecting #1 and #3 cylinders:
ILow emission vehicle:
7
[W7A1]2-2SERVICE PROCEDURE
7. Valve Clearance

4. Cylinder Block
B2M1957A
(1) Oil pressure switch
(2) Cylinder block (RH)
(3) Service hole plug
(4) Gasket
(5) Oil separator cover
(6) Water by-pass pipe
(7) Oil pump
(8) Front oil sea
(9) Rear oil seal
(10) O-ring
(11) Service hole cover(12) Cylinder block (LH)
(13) Water pump
(14) Baffle plate
(15) Oil filter connector
(16) Oil strainer
(17) Gasket
(18) Oil pan
(19) Drain plug
(20) Metal gasket
(21) Oil level gauge guideTightening torque: N´m (kg-m, ft-lb)
T1:
5 (0.5, 3.6)
T2:6.4 (0.65, 4.7)
T3:10 (1.0, 7)
T4:25±2 (2.5±0.2, 18.1±1.4)
T5:47±3 (4.8±0.3, 34.7±2.2)
T6:69±7 (7.0±0.7, 50.6±5.1)
T7:First 12±2 (1.2±0.2, 8.7±1.4)
Second 12
±2 (1.2±0.2,
8.7
±1.4)
9
[C400]2-3aCOMPONENT PARTS
4. Cylinder Block

2) Tighten cylinder head bolts.
(1) Apply a coat of engine oil to washers and
bolt threads.
(2) Tighten all bolts to 29 N´m (3.0 kg-m, 22
ft-lb) in alphabetical sequence.
Then tighten all bolts to 69 N´m (7.0 kg-m, 51
ft-lb) in alphabetical sequence.
(3) Back off all bolts by 180É first; back them off
by 180É again.
(4) Tighten bolts (a) and (b) to 34 N´m (3.5
kg-m, 25 ft-lb).
(5) Tighten bolts (c), (d), (e) and (f) to 15 N´m
(1.5 kg-m, 11 ft-lb).
(6) Tighten all bolts by 80 to 90É in alphabetical
sequence.
CAUTION:
Do not tighten bolts more than 90É.
(7) Further tighten all bolts by 80 to 90É in
alphabetical sequence.
CAUTION:
Ensure that the total ªre-tightening angleº [in
the former two steps], do not exceed 180É.
B2M2628B
3) Install oil level gauge guide and tighten attach-
ing bolt (left side only).
4) Install timing belt, camshaft sprocket and
related parts.

2. RELATED PARTS
CAUTION:
Be careful not to scratch the mating surface of
cylinder block and oil pump.
1) Install engine coolant pipe.
2) Install intake manifold.
3) Connect blow-by hose.
4) Connect oil pressure switch connector.
5) Install camshaft position sensor and camshaft
position sensor support.
6) Install connector bracket attaching bolt.
7) Connect spark plug cords.
8) Install generator and bracket.
9) Install A/C compressor and bracket. (With A/C
model)
10) Install V-belt(s).
11) Remove ENGINE STAND (ST).
50
2-3a[W5E2]SERVICE PROCEDURE
5. Cylinder Head

2. OIL PUMP AND WATER PUMP
B2M1767A
(1) Clutch housing cover (MT
vehicles only)
(2) Flywheel (MT vehicles only)
(3) Drive plate (AT vehicles only)(4) Oil separator cover
(5) Water by-pass pipe
(6) Water pump
(7) Oil pump(8) Oil pan
(9) Oil strainer
(10) Baffle plate
(11) Oil filter
52
2-3a[W6A2]SERVICE PROCEDURE
6. Cylinder Block

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

E: INSTALLATION
1. OIL PUMP AND WATER PUMP
B2M1767B
(1) Baffle plate
(2) Oil strainer
(3) Oil pan
(4) Oil separater cover
(5) Drive plate (AT vehicles only)
(6) Flywheel (MT vehicles only)
(7) Clutch housing cover (MT
vehicles only)(8) Oil pump
(9) Water pump
(10) Water by-pass pipe
(11) Oil filterTightening torque: N´m (kg-m, ft-lb)
T1:
5 (0.5, 3.6)
T2:6.4 (0.65, 4.7)
T3:10 (1.0, 7)
T4:72±3 (7.3±0.3, 52.8±2.2)
T5:First 12±2 (1.2±0.2, 8.7±1.4)
Second 12
±2 (1.2±0.2,
8.7
±1.4)
70
2-3a[W6E1]SERVICE PROCEDURE
6. Cylinder Block

1) Install baffle plate.
2) Install oil strainer and O-ring
3) Install oil strainer stay.
4) Apply fluid packing to matching surfaces and
install oil pan.
Fluid packing:
THREE BOND 1215 or equivalent
G2M0084
5) Apply fluid packing to matching surfaces and
install oil separator cover.
Fluid packing:
THREE BOND 1215 or equivalent
G2M0194
6) Install flywheel or drive plate.
To lock crankshaft, use ST.
ST 498497100 CRANKSHAFT STOPPER
G2M0161
7) Install housing cover.
8) Installation of oil pump
(1) Discard front oil seal after removal. Replace
with a new one using ST.
ST 499587100 OIL SEAL INSTALLER
S2M0235
71
[W6E1]2-3aSERVICE PROCEDURE
6. Cylinder Block

(2) Apply fluid packing to matching surface of
oil pump.
Fluid packing:
THREE BOND 1215 or equivalent
S2M0739A
(3) Apply a coat of engine oil to the inside of the
oil seal.
S2M0118A
(4) Install oil pump on cylinder block. Be care-
ful not to damage oil seal during installation.
CAUTION:
IDo not forget to install O-ring and seal when
installing oil pump.
IAlign flat surface of oil pump's inner rotor
with crankshaft before installation.
9) Install water pump and gasket.
CAUTION:
IBe sure to use a new gasket.
IWhen installing water pump, tighten bolts in
two stages in alphabetical sequence as shown
in figure.
H2M1568B
10) Install water by-pass pipe for heater.
11) Install oil filter using ST.
ST 498187300 OIL FILTER WRENCH
B2M2611A
2. RELATED PARTS
1) Install cylinder head, valve rocker assembly
and rocker cover.

2) Install timing belt and camshaft sprocket.

3) Install water pipe.
4) Install intake manifold.
72
2-3a[W6E2]SERVICE PROCEDURE
6. Cylinder Block

1. Engine Trouble in General
NOTE:
ªRANKº shown in the chart refer to the possibility of reason for the trouble in order (ªVery oftenº to ªRarelyº)
A Ð Very often
B Ð Sometimes
C Ð Rarely
TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK
1. Engine will not start.
1) Starter does not turn.IStarterIDefective battery-to-starter harness B
IDefective starter switch C
IDefective inhibitor switch or neutral switch C
IDefective starter B
IBatteryIPoor terminal connecton A
IRun-down battrey A
IDefective charging system B
IFrictionISeizure of crankshaft and connecting rod bearing C
ISeized camshaft C
ISeized or stuck piston and cylinder C
2) Initial combustion does
not occur.IStarterIDefective starter C
IFuel injection system A
IFuel lineIDefective fuel pump and relay A
ILack of or insufficient fuel B
IBeltIDefective B
IDefective timing B
ICompressionIIncorrect valve clearance C
ILoosened spark plugs or defective gasket C
ILoosened cylinder head bolts or defective gasket C
IImproper valve seating C
IDefective valve stem C
IWorn or broken valve spring B
IWorn or stuck piston rings, cylinder and piston C
IIncorrect valve timing B
IImproper engine oil (low viscosity) B
3) Initial combustion occur.IFuel injection system A
IIntake systemIDefective intake manifold gasket B
IDefective throttle body gasket B
IFuel lineIDefective fuel pump and relay C
IClogged fuel line C
ILack of or insufficient fuel B
IBeltIDefective B
IDefective timing B
ICompressionIIncorrect valve clearance C
ILoosened spark plugs or defective gasket C
ILoosened cylinder head bolts or defective gasket C
IImproper valve seating C
IDefective valve stem C
IWorn or broken valve spring B
IWorn or stuck piston rings, cylinder and piston C
IIncorrect valve timing B
IImproper engine oil (low viscosity) B
73
[K100]2-3aDIAGNOSTICS
1. Engine Trouble in General