1997 SUBARU LEGACY ESP

C: INSPECTION
1. CYLINDER BLOCK
1) Check for cracks and damage visually. Especially,
inspect important parts by means of red lead check.
2) Check the oil passages for clogging.
3) Inspect crankcase surface that mates with cylinder
head for warping by using a straight edge, and correct by
grinding if necessary.
Warping limit:
0.05 mm (0.0020 in)
Grinding limit:
0.1 mm (0.004 in)
Standard height of cylinder block:
201.0 mm (7.91 in)
B2M0082A
2. CYLINDER AND PISTON
1) The cylinder bore size is stamped on the cylinder
block’s front upper surface.
NOTE:
Standard sized pistons are classified into two grades,“A”
and“B”. These grades should be used as a guide line in
selecting a standard piston.
Standard diameter:
A: 99.505—99.515 mm (3.9175—3.9179 in)
B: 99.495—99.505 mm (3.9171—3.9175 in)
58
2-3bSERVICE PROCEDURE
5. Cylinder Block

B2M1223A
4) Installation of piston rings and oil ring
(1) Install oil ring spacer, upper rail and lower rail in this
order by hand. Then install second ring and top ring
with a piston ring expander.
(2) Position the top ring gap at A or B in the Figure.
(3) Position the second ring gap at 180°on the reverse
side for the top ring gap.
B2M1224A
(4) Position the upper rail gap at C or D in the Figure.
(5) Position the expander gap the at 180°of the
reverse side for the upper rail gap.
(6) Position the lower rail gap at E or F in the Figure.
CAUTION:
Ensure ring gaps do not face the same direction.
Ensure ring gaps are not within the piston skirt area.
G2M0183
5) Install circlip.
Install circlips in piston holes located opposite service
holes in cylinder block, when positioning all pistons in the
corresponding cylinders.
CAUTION:
Use new circlips.
NOTE:
Piston front mark“
”faces toward front of engine.
68
2-3bSERVICE PROCEDURE
5. Cylinder Block

G2M0544
2) Disconnect connector from front oxygen sensor.
3) Lift-up the vehicle.
4) Apply SUBARU CRC or its equivalent to threaded por-
tion of front oxygen sensor, and leave it for one minute or
more.
SUBARU CRC (Part No. 004301003)
G2M0411
5) Remove front oxygen sensor.
CAUTION:
When removing oxygen sensor, do not force oxygen
sensor especially when exhaust pipe is cold, other-
wise it will damage exhaust pipe.
G2M0412
B: INSTALLATION
1) Before installing front oxygen sensor, apply anti-seize
compound only to threaded portion of front oxygen sensor
to make the next removal easier.
Anti-seize compound:
SS-30 by JET LUBE
CAUTION:
Never apply anti-seize compound to protector of front
oxygen sensor.
G2M0411
2) Install front oxygen sensor.
Tightening torque:
21±3 N⋅m (2.1±0.3 kg-m, 15.2±2.2 ft-lb)
3) Lower the vehicle.
4) Connect connector of front oxygen sensor.
5) Install air intake duct.
24
2-7SERVICE PROCEDURE
7. Front Oxygen Sensor

B2M0335
8. Rear Oxygen Sensor
A: REMOVAL
1. EXCEPT CALIFORNIA 2200 cc MODEL
1) Lift-up the vehicle.
2) Disconnect connector from rear oxygen sensor.
3) Apply SUBARU CRC or its equivalent to threaded por-
tion of rear oxygen sensor, and leave it for one minute or
more.
SUBARU CRC (Part No. 004301003)
B2M0351
4) Remove rear oxygen sensor.
CAUTION:
When removing rear oxygen sensor, do not force rear
oxygen sensor especially when exhaust pipe is cold,
otherwise it will damage exhaust pipe.
B2M0740
2. CALIFORNIA 2200 cc MODEL
1) Disconnect connector from rear oxygen sensor.
2) Lift-up the vehicle.
3) Apply SUBARU CRC or its equivalent to threaded por-
tion of rear oxygen sensor, and leave it for one minute or
more.
SUBARU CRC (Part No. 004301003)
25
2-7SERVICE PROCEDURE
8. Rear Oxygen Sensor

B2M0741
4) Remove rear oxygen sensor.
CAUTION:
When removing rear oxygen sensor, do not force rear
oxygen sensor especially when exhaust pipe is cold,
otherwise it will damage exhaust pipe.
B2M0352A
B: INSTALLATION
1. EXCEPT CALIFORNIA 2200 cc MODEL
1) Before installing rear oxygen sensor, apply anti-seize
compound only to threaded portion of rear oxygen sensor
to make the next removal easier.
Anti-seize compound:
SS-30 by JET LUBE
CAUTION:
Never apply anti-seize compound to protector of rear
oxygen sensor.
B2M0351
2) Install rear oxygen sensor.
Tightening torque:
21±3 N⋅m (2.1±0.3 kg-m, 15.2±2.2 ft-lb)
3) Connect connector of rear oxygen sensor.
4) Lower the vehicle.
B2M0742A
2. CALIFORNIA 2200 cc MODEL
1) Before installing rear oxygen sensor, apply anti-seize
compound only to threaded portion of rear oxygen sensor
to make the next removal easier.
Anti-seize compound:
SS-30 by JET LUBE
CAUTION:
Never apply anti-seize compound to protector of rear
oxygen sensor.
26
2-7SERVICE PROCEDURE
8. Rear Oxygen Sensor

1. Fuel System
Trouble and possible cause Corrective action
1. Insufficient fuel supply to the injector
1) Fuel pump will not operate.

Defective terminal contact.Inspect connections, especially ground, and tighten
securely.

Trouble in electromagnetic or electronic circuit parts. Replace fuel pump.
2) Lowering of fuel pump function. Replace fuel pump.
3) Clogged dust or water in the fuel filter. Replace fuel filter, clean or replace fuel tank.
4) Clogged or bent fuel pipe or hose. Clean, correct or replace fuel pipe or hose.
5) Air is mixed in the fuel system. Inspect or retighten each connection part.
6) Clogged or bent breather tube or pipe. Clean, correct or replace air breather tube or pipe.
7) Damaged diaphragm of pressure regulator. Replace.
2. Leakage or blow out fuel
1) Loosened joints of the fuel pipe. Retightening.
2) Cracked fuel pipe, hose and fuel tank. Replace.
3) Defective welding part on the fuel tank. Replace.
4) Defective drain packing of the fuel tank. Replace.
5) Clogged or bent air breather tube or air vent tube. Clean, correct or replace air breather tube or air vent tube.
3. Gasoline smell inside of compartment
1)Loose joints at air breather tube, air vent tube and fuel filler
pipe.Retightening.
2) Defective packing air tightness on the fuel saucer. Correct or replace packing.
3) Cracked fuel separator. Replace separator.
4. Defective fuel meter indicator
1) Defective operation of fuel meter unit. Replace.
2) Defective operation of fuel meter. Replace.
5. Noise
1) Large operation noise or vibration of fuel pump. Replace.
NOTE:
When the vehicle is left unattended for an extended period of time, water may accumulate in the fuel
tank.
To prevent water condensation:
1) Top off the fuel tank or drain the fuel completely.
2) Drain water condensation from the fuel filter.
Refilling the fuel tank:
Refill the fuel tank while there is still some fuel left in the tank.
Protecting the fuel system against freezing and water condensation:
1) Cold areas
In snow-covered areas, mountainous areas, skiing areas, etc. where ambient temperatures drop
below 0°C (32°F) throughout the winter season, use an anti-freeze solution in the cooling system.
Refueling will also complement the effect of anti-freeze solution each time the fuel level drops to about
one-half. After the winter season, drain water which may have accumulated in the fuel filter and fuel
tank in the manner same as that described under affected areas as below.
2) Affected areas
When water condensation is notched in the fuel filter, drain water from both the fuel filter and fuel tank
or use a water removing agent (or anti-freeze solution) in the fuel tank.
Observe the instructions, notes, etc., indicated on the label affixed to the anti-freeze solution (water
removing agent) container before use.
27
2-8DIAGNOSTICS
1. Fuel System

1. Clutch System
Condition Possible cause and testing Corrective action
1. Clutch slip-
pageIt is hard to perceive clutch slippage in the early stage, but pay attention to the following symptoms.
(a) Engine revs up when shifting.
(b) High speed driving is impossible; especially rapid acceleration impossible and vehicle speed does not increase in
proportion to an increase in engine speed.
(c) Power falls, particularly when ascending a slope, and there is a smell of burning of the clutch facing.
Method of testing: Put the vehicle in stationary condition with parking brake fully applied. Disengage the clutch and
shift the transmission gear into the first. Gradually allow the clutch to engage while gradually increasing the engine
speed. The clutch function is satisfactory if the engine stalls. However, the clutch is slipping if the vehicle does not
start off and the engine does not stall.
(a) No clutch pedal play Readjust.
(b) No release lever end play Readjust.
(c) Clutch facing smeared by oil Replace.
(d) Worn clutch facing Replace.
(e) Deteriorated diaphragm spring Replace.
(f ) Distorted pressure plate or flywheel Correct or replace.
(g) Defective release bearing holder Correct or replace.
(h) Defective pedal and cable system Correct or replace.
2. Clutch
drags.As a symptom of this trouble, a harsh scratching noise develops and control becomes quite difficult when shifting
gears. The symptom becomes more apparent when shifting into the first gear. However, because much trouble of the
this sort is due to defective synchronization mechanism, carry out the test as described after.
Method of testing: Refer to DIAGNOSTIC DIAGRAM on page after.
It may be judged as insufficient disengagement of clutch if any noise occurs during this test.
(a) Excessive clutch pedal play Readjust.
(b) Excessive clutch release lever play Readjust.
(c) Worn or rusty clutch disc hub spline Replace clutch disc.
(d) Excessive deflection of clutch disc facing Correct or replace.
(e) Seized crankshaft pilot needle bearing Replace.
(f ) Malfunction of pedal and cable system Correct or replace.
(g) Cracked clutch disc facing Replace.
(h) Sticked clutch disc (smeared by oil or water) Replace.
3. Clutch chat-
ters.Clutch chattering is an unpleasant vibration to the whole body when the vehicle is just started with clutch partially
engaged.
(a) Improper clutch cable routing Correct.
(b) Adhesion of oil on the facing Replace clutch disc.
(c) Weak or broken torsion spring Replace clutch disc.
(d) Defective facing contact or excessive disc Replace clutch disc defection.
(e) Warped pressure plate or flywheel Correct or replace.
(f ) Loose disc rivets Replace clutch disc.
(g) Loose engine mounting Retighten or replace mounting.
(h) Improper adjustment of pitching stopper Adjustment.
19
2-10DIAGNOSTICS
1. Clutch System

1. Manual Transmission and
Differential
Symptom and possible cause Remedy
1. Gears are difficult to intermesh.
The cause for difficulty in shifting gears can be classified into two kinds: one is malfunction of the gear shift system and the
other is malfunction of the transmission. However, if the operation is heavy and engagement of the gears is difficult, defective
clutch disengagement may also be responsible. Check whether the clutch is correctly functioning, before checking the gear
shift system and transmission.
(a) Worn, damaged or burred chamfer of internal spline of
sleeve and reverse driven gearReplace.
(b) Worn, damaged or burred chamfer of spline of gears Replace.
(c) Worn or scratched bushings Replace.
(d) Incorrect contact between synchronizer ring and gear
cone or wearCorrect or replace.
2. Gear slips out.
(1) Gear slips out when coasting on rough road.
(2) Gear slips out during acceleration.
(a) Defective pitching stopper adjustment Adjust.
(b) Loose engine mounting bolts Tighten or replace.
(c) Worn fork shifter, broken shifter fork rail spring Replace.
(d) Worn or damaged ball bearing Replace.
(e) Excessive clearance between splines of synchronizer hub
and synchronizer sleeveReplace.
(f) Worn tooth step of synchronizer hub (responsible for slip-
out of 3rd gear)Replace.
(g) Worn 1st driven gear, needle bearing and race Replace.
(h) Worn 2nd driven gear, needle bearing and race Replace.
(i) Worn 3rd drive gear and bushing Replace.
(j) Worn 4th drive gear and bushing Replace.
(k) Worn reverse idler gear and bushing Replace.
3. Unusual noise comes from transmission.
If an unusual noise is heard when the vehicle is parked with its engine idling and if the noise ceases when the clutch is
disengaged, it may be considered that the noise comes from the transmission.
(a) Insufficient or improper lubrication Lubricate or replace with specified oil.
(b) Worn or damaged gears and bearings Replace.
NOTE: If the trouble is only wear of the tooth surfaces, merely
a high roaring noise will occur at high speeds, but if any part
is broken, rhythmical knocking sound will be heard even at
low speeds.
72
3-1DIAGNOSTICS
1. Manual Transmission and Differential