1996 SUBARU LEGACY gas type

1-1
[s2o2]
SPECIFICATIONS

2
.
Station
Wagon

2
.
Station
Wagon

2
.
ENGINE

Engine
type
Horizontally
opposed,
liquid
cooled,
4-cylinder,
4-stroke
gasoline
engine
Valve
arrangement
Overhead
camshaft
type

Bore
x
Stroke
mm
(in)
96
.9
x75
.0(3
.815
x2
.953)

Displacement
cm3
(cu
in)
2,212
(135
.0)

Compression
ratio
9
.7

Firing
order
1-3-2-4

Idle
speed
at
Park/Neutral
position
rpm700

Maximum
output
kW
(HP)/rpm
101
(135)/5,400

Maximum
torque
N
.m
(kg-m,
ft-Ib)/rpm
190
(19
.4,140)/4,400

3
.
ELECTRICAL

Ignition
timing
atidling
speed
BTDC/rpm
20°/700
Spark
plug
Type
and
manufacturer
CHAMPION
:
RC10YC4
(Standard)
NGK
:
BKR6E-11
NIPPONDENSO
:
K20PR-U11

Generator
12V
-
85A

Battery
Reserve
capacity
min100

Cold
cranking
amperes
amp
.I
490

SUPPLEMENTAL
RESTRAINT
SYSTEM
(ELECTRIC
SENSOR
TYPE)
[Ml-2I
5-5b
1
.
SRS
Airbag
System

2
.
FUNCTION

The
SRS
airbag
is
provided
asan
auxiliary
driver
and
passenger
front
seat
restraint
system
to
be

used
in
combination
with
the
seat
belt
.
When
an
impact
greater
than
a
set
level
is
applied
to
the

front
of
the
vehicle,
the
sensor
senses
it
and
generates
an
electrical
pulse
to
inflate
the
bag
in
the
airbag
module,
thuspreventing
the
upper
bodies
of
the
driver
and
passenger
in
the
front
seat
from

impacting
the
steering
wheel,instrument
panel
and
windshield
.

Driver
side

Safety
sensor
and
electric
sensor,

Passenger
side

Collision

Safety
sensorand
electric
sensor
detect
a
set
strength
of
collision
.
Operation
of
inflator
Nitrogen
gas
is
generated
.
The
Airbag
inflation
completes
.
Discharge
of
gas

Completion

1-151-10656A

3

5-5b
IMZ-10I
SUPPLEMENTAL
RESTRAINT
SYSTEM
(ELECTRIC
SENSOR
TYPE)
2
.
Const
r
uc
ti
on

10
.
WARNING
AND
CAUTION
LABELS

B5H0433A

O

SRS
AIRBAG
CONTROL
UNIT
CAUTION

"
READ
SERVICE
MANUAL
"
NO
SERVICEABLE
INSIDE
~
DO
NOT
DISASSEMBLE
OR
TAMPER
"
DO
NOT
DROP
;
KEEP
DRY
"
STORE
IN
CLEAN
DRYAREA

Precaution

*
lisez
le
manuel
d'entretien
.
aucune
piece
interne
nepeut
titre
remplacee
ou
r6paree
*ne
d6montez
ou
alterez
pas
cetteunite
de
controle
.n'echappez
pas
"
emmagasinez
dans
un
endroit
sec

'~`J~~'«*~-~~~=

Jtd~ahl~~4~LZF~~~o
"eMt,t~,-'7
9
"
ML
Lt--
LJASI
.t
IALtdI
.)T-Fc~Oo

CAUTION
:
ALWAYS
USE
SEATBELTS
OR
CHILDSEAT

"
This
car
is
equipped
with
driver
and
front
seat
passenger
SRS
AIRBAG
.
It
is
designed
to
SUPPLEMENT
THE
SEAT-
BELT
"
If
your
"AIRBAG"
indicator
in
the
instrument
panel
lights
while
driving,
see
your
nearest
SUBARU
dealer
.
"
See
your
owner's
manual
for
more
information
.

ATTENTION
:
ATfACHEZ
VOTRE
CEINTURE
DE
SECURITE
ET
UTILISEZ
UN
SIEGE
POUR
ENFANT

"
Cette
voiture
est
pourvue
d'un
coussin
d'air
SRS
pour
le
conducteur
etle
passagerdu
siegeavant
.
Ce
coussin
a
ete
Q
conqu
comme
COMPLEMENT
A
LA
CEINTURE
DE
SECURITE
.'
""
'
'
"
Si
(
indication
AIRBAG
(coussin
d
air)
s
allume
sur
le
tableau
debord
pendant
la
conduite,
consultez
votre
revendeur
SUBARU
le
plus
proche
.
"
Consultez
votre
manuel
du
proprietaire
.

VORSICHT
Vervvenden
Sie
stets
den
Sicherheitsgurt
oder
den
Kindersitz
.

"
Dieses
Fahrzeug
ist
mit
einer
Fahrer=und
Beifahrer-SRS-Luftsackanlage
ausgerustet
.
Es
wurde
vorgesehen,
um
den
Sicherheitsgurt
zu
erganzen
.
"
Wenn
wahrend
der
Fahrt
die

AIRBAG"-Anzeige
am
Instrumentenbrett
leuchtet,
setzen
Sie
sich
mit
Ihrem
ortlichen
SUBARU-Handler
in
Verbindung
.
"
Nahere
Angaben
dazu
sind
aus
der
Bedienungsanleitung
zu
entnehmen
.

SUPPLEMENTAL
RESTRAINT
SYSTEM
(ELECTRIC
SENSOR
TYPE)
[M2-10]
5-5b
2
.
Construction

U

Ullv''

H5H0660

CAUTION
[BEFORE
INSTALLING]

1.
POINT
FRONT
WHEELS
STRAIGHT
AHEAD
.

2
.
ROTATE
2
.65
TURNS
FROM
RIGHT
END
STOP
.

3
.
ALIGN
MATCH-MARKS
(CENTER
MARKS
Y
)
.

4
.
READ
SERVICE
MANUAL
.

(~~J~1f~~~1~,)

2
.
~OO~~t~~J~~~J2
.65O0~OO~o
3
.
(CENTER
MARK
:
;
)
~o~tr~o
4
.

AIR
BAG
MODULE

98
00-4
.
FRU&t,~
-3F4
~

WARNING
To
prevent
personal
injury
.
Do
not
dismantle,

repair
or
install
in
another
vehicle
.
Service
or
dispose
as
directed
in
the
service
manual
.

r
8
ATTENTION
Pour
eviter
tout
risque
de
blessures
corporel-
les
:
Ne
pas
demonter,
reparer,
installer
dans
un
autre
vehi-

~~
cule
.
L'entretenir
ou
le
remplacer
comme
indique
dans
le
manual
d'entretien
.

ACHTUNG
Zur
Vermeidung
von
Verletzungen
.
Nicht
zer-
I
legen,reparieren
oder
in
einem
anderen
Fahrzeug
instal-
lieren
.
Wartung
and
Ausbau
wie
im
Reparaturhandbuch
beschrieben
.
G5H0287

AIRBAG
GAS
GENERATOR
HERG,
:94/94
UTM
TG-6
BAM
.
PTA
.0369

THIS
GAS
GENERATOR
SHOULD
ONLY
BE
INSTALLED
IN
VEHICLES
EQUIPPEDWITH
AIRBAG
SYSTEMS
AND
IS
TO
BE
INSTALLED
AND/OR
DISASSEMBLED
ONLY
BYTRAINED
PERSONNEL
.
CONTENTS
AREPOISONOUS
AND
EXTREMELY
FLAMMABLE
.
DO
NOT
DISMANTLE,
INCINERATE,
OR
BRING
INTO
CON-TACTWITH
ELECTRICITY,
OR
STORE
AT
TEMPERATURES
EXCEEDING
200°F
.
FIRST
AID
:
IF
CONTENTS
ARE
SWALLOWED,
INDUCE
VOM-
ITING
:
FOR
EYE
CONTACT,
FLUSH
EYES
WITH
WATER
FOR
15
MIN
.
IN
EVERY
CASE
GET
PROMPT
MEDICAL
ATTENTION
.

OO
s
UMGANG
NUR
DURCH
GESCHULTES
PERSONAL
ERLAUBT
~
VERWENDUNG
NUR
ALSINSASSEN-RUCKHALTE
SYSTEM
MIT
LUFTSACK
FUR
KRAFTFAHRZEUGE
ERLAUBT
BEI
AUS-
C
LOSUNG
KANN
DIE
NICHT
MONTIERTE
AIRBAG-EIN-HEIT
1
~
ZUM
GEFAHRLICHEN
WURFSTUCK
WERDEN
.

SUBARU
DEUTSCHLAND
GmbH
DUSSELDORF
MORTON
INTERNATIONAL,
INC
.
OGDEM,USA

DANGER
ACHTUNG
ATTENTION

G5H0288

5-5b
[M2-10]
SUPPLEMENTAL
RESTRAINT
SYSTEM
(ELECTRIC
SENSOR
TYPE)
2
.
Co
n
struction

0

DANGER
:
POISONOUSFLAMMABLE
MATERIAL

ACHTUNG
:
GIFTIGES
LEICHT
ENTZUNDLICHES
MATE-
RIAL

ATTENTION
:
MATERIAU
TOXIQUE
ET
INFLAMMABLE

"
DO
NOT
USE
ELECTRIC
TESTING
EQUIPMENTS
AND
OTHER
ELECTRIC
RELATED
PRODUCTS
.
"
DO
NOT
OVERHAUL
THE
SYSTEM
AND
AVOID
STRONG
IMPACT
.
"
MAXIMUM
SAFE
TEMPERATURE
FORTHE
AIR
BAG
SYSTEM
IS
200°F
(93°C)
.
"
STORE
THE
SYSTEM
WITH
TOP
SIDE
UP
.
"
REFER
TO
SERVICE
MANUAL
FOR
HANDLING
STORAGEAND
DISPOSAL
PROCEDURES
.

"
KEINE
ELEKTRISCHEN
PRUFGERATE
ODER
AHNLI-
CHE
INSTRUMENTE
VERWENDEN
.
"
NICHT
VERSUCHEN,
ZU
ZERLEGEN
ODER
ZU
RE-
PARIEREN
.
VOR
STOSSEN
SCHUTZEN
.
"
LAGERTEMPERATUR
DARF
93°C
(200°F)
NICHT
UBERSCHREITEN
.
"
MIT
DEM
DECKELNACH
OBEN
LAGERN
.
"
ZU
BEDIENUNG,
LAGERUNG
UND
BESEITIGUNG
SIEHE
WARTUNGSHANDBUCH
.

"
NE
PAS
UTILISER
LE
TESTEUR
ELECTRIQUE
.
"
CE
MODULE
NE
PEUTETRE
NI
DEMONTE
NI
REPA-RE
.
EVITER
LES
CHOCS
.
"
NE
JAMAIS
ENTREPOSER
SOUS
UNE
TEMPERATU-
RE
SUPERIEURE
A
93°C
(200°F)
.
"
LE
MODULE
DOIT
TOUJOURS
ETRE
POSE
AVEC
LE
COUVERCLE
VERS
LE
HAUT
"
CONCERNANT
LE
MODE
D'EMPLOI,
DE
CONSERVA-
TION
ETDE
REJET,
VEUILLEZ
VOUS
REFERER
A
LA
NOTICE
D'UTILISATION
.

AIRBAG
GAS
GENERATOR
UT12016
MORTON
INTERNATIONAL
.
INC
.
OGDEN
.
UT
.
USA
.

BAM-PTi
-0437

EINFUHRER
:
SUBARU
TELEFON
(06031)
6060
DEUTSCHLAND
GmbH,
FRIEDBURG
HERG,
:94/95
BC
.

UMGANG
NUR
DURCH
GESCHULTES
PERSONAL
ER-
LAUBT
VERWENDUNG
NUR
ALS
INSASSEN-RUCK-
HALTESYSTEM
MIT
LUFTSACK
FUR
KRAFTFAHRZEU-
GE
ERLAUBT
BEI
AUSLOSUNG
KANN
DIE
NICHT
MONTIERTE
AIR-
BAG-EINHEIT
ZUM
GEFAHRLICHEN
WURFSTUCK
WERDEN
.

0
42
(93`CC
.t±)
z~1~'~m1~o
"
I)
v
G5H0586
"
$QlJ&1,)
.

1. Engine
A: SPECIFICATIONS
EngineModel2200 cc
TypeHorizontally opposed, liquid cooled, 4-cylinder, 4-stroke
gasoline engine
Valve arrangement Belt driven, single over-head camshaft, 4-valve/cylinder
Bore x Stroke mm (in) 96.9 x 75.0 (3.815 x 2.953)
Displacement cm
3(cu in) 2,212 (135.0)
Compression ratio9.7
Compression pressure
(at 200 — 300 rpm)kPa (kg/cm
2, psi)1,079 — 1,275
(11.0 — 13.0, 156 — 185)
Number of piston rings Pressure ring: 2, Oil ring: 1
Intake valve timingOpening 1° BTDC
Closing 55° ABDC
Exhaust valve timingOpening 48° BBDC
Closing 12° ATDC
Idling speed
[At neutral position on MT, or
“P” or “N” position on AT] rpm700±100 (No load)
850±50 (A/C switch ON)
Firing order1,3,2,4
Ignition timing BTDC/rpm 14°±8°/700 (MT), 20°±8°/700 (AT)
2
2-3SPECIFICATIONS AND SERVICE DATA
1. Engine

2. Engine Noise
Valve lash adjusters may make clicking noise once engine
starts. It is normal if clicking noise ceases after a few min-
utes.
If clicking noise continues after a few minutes, check
engine oil level and add oil if necessary.
Then, do as follows to cease clicking noise.
1) Warm-up engine for five minutes.
2) Turn ignition switch OFF.
3) Connect test mode connector.
4) Start the engine and run it at approximately 2,000 rpm
for twenty minutes.
5) Turn ignition switch OFF.
6) Disconnect test mode connector.
7) Start the engine and check that clicking noise is ceased.
If noise still exists, conduct troubleshooting procedures in
accordance with the following table.
CAUTION:
Do not disconnect spark plug cord while engine is run-
ning.
Type of sound Condition Possible cause
Regular clicking soundSound increases as engine
speed increases.Valve mechanism is defective.
Broken lash adjuster
Worn valve rocker
Worn camshaft
Broken valve spring
Worn valve lifter hole
Heavy and dull clankOil pressure is low.Worn crankshaft main bearing
Worn connecting rod bearing (big end)
Oil pressure is normal.Loose flywheel mounting bolts
Damaged engine mounting
High-pitched clank
(Spark knock)Sound is noticeable when
accelerating with an overload.Ignition timing advanced
Accumulation of carbon inside combustion chamber
Wrong spark plug
Improper gasoline
Clank when engine speed is
medium (1,000 to 2,000 rpm).Sound is reduced when fuel
injector connector of noisy
cylinder is disconnected.
(NOTE*)Worn crankshaft main bearing
Worn bearing at crankshaft end of connecting rod
Knocking sound when engine
is operating under idling speed
and engine is warm.Sound is reduced when fuel
injector connector of noisy
cylinder is disconnected.
(NOTE*)Worn cylinder liner and piston ring
Broken or stuck piston ring
Worn piston pin and hole at piston end of connecting rod
Sound is not reduced if each
fuel injector connector is
disconnected in turn. (NOTE*)Unusually worn valve lifter
Worn cam gear
Worn camshaft journal bore in crankcase
Squeaky sound—Insufficient generator lubrication
Rubbing sound—Defective generator brush and rotor contact
Gear scream when starting
engine—Defective ignition starter switch
Worn gear and starter pinion
Sound like polishing glass with
a dry cloth—Loose drive belt
Defective engine coolant pump shaft
78
2-3DIAGNOSTICS
2. Engine Noise

1. Engine
A: SPECIFICATIONS
EngineModel2500 cc
TypeHorizontally opposed, liquid cooled, 4-cylinder, 4-stroke
gasoline engine
Valve arrangement Belt driven, double over-head camshaft, 4-valve/cylinder
Bore x Stroke mm (in) 99.5 x 79.0 (3.917 x 3.110)
Displacement cm
3(cu in) 2,457 (149.93)
Compression ratio9.5
Compression pressure
(at 200 — 300 rpm)
kPa (kg/cm
2, psi) rpmStandard 1,216 (12.4, 176) 350
Limit 941 (9.6, 137) 350
Number of piston rings Pressure ring: 2, Oil ring: 1
Intake valve timingOpening 6° BTDC
Closing 50° ABDC
Exhaust valve timingOpening 62° BBDC
Closing 10° ATDC
Idling speed
[At neutral position on MT, or
“P” or “N” position on AT] rpm700±100 (No load)
850±50 (A/C switch ON)
Firing order1,3,2,4
Ignition timing BTDC/rpm 15°±8°/700 rpm
2
2-3bSPECIFICATIONS AND SERVICE DATA
1. Engine