1997 SUBARU LEGACY timing belt

G2M0628
9) Install engine coolant pump and gasket.
CAUTION:
Be sure to use a new gasket.
When installing engine coolant pump, tighten bolts
in two stages in numerical sequence as shown in Fig-
ure.
10) Install engine coolant pipe.
11) Install oil filter.
2. RELATED PARTS
1) Install cylinder heads.

2) Install camshafts, rocker cover and related parts.

3) Install camshaft sprockets, timing belt and related parts.

76
2-3bSERVICE PROCEDURE
5. Cylinder Block

TROUBLE
Engine will not start.
Rough idle and engine stall
Low output, hesitation and poor acceleration
Surging
Engine does not return to idle.
Dieseling (Run-on)
After burning in exhaust system
Knocking
Excessive engine oil consumption
Excessive fuel consumption Starter does not turn.
Initial combustion does not occur.
Initial combustion occurs.
Engine stalls after initial combustion.
INTAKE SYSTEM
2111 3Loosened or cracked intake air pipe
3111 3 1Loosened or cracked blow-by hose
31211 2Loosened or cracked vacuum hose
22222Defective intake manifold gasket
22222Defective throttle body gasket
322 2 2Defective PCV valve
222 323Loosened oil filler cap
3312 1Dirty air cleaner element
FUEL LINE
13 322Defective fuel pump and relay
33322Clogged fuel line
222233Lack of or insufficient fuel
BELT
222Defective
222322 22 2Defective timing
FRICTION
3Seizure of crankshaft and connecting rod bearing
3Seized camshaft
3Seized or stuck piston and cylinder
COMPRESSION
333222 23 2Incorrect valve clearance
333223 3 3Loosened spark plugs or defective gasket
333223 3 3Loosened cylinder head bolts or defective gasket
333223 2 2Improper valve seating
333333 3 13Defective valve stem
222223 3 3Worn or broken valve spring
333233 3 12Worn or stuck piston rings, cylinder and piston
222111 12 2Incorrect valve timing
222222Improper engine oil (low viscosity)
78
2-3bDIAGNOSTICS
1. Engine Trouble in General

2. Engine Noise
Type of sound Condition Possible cause
Regular clicking soundSound increases as engine
speed increases.Valve mechanism is defective.
Incorrect valve clearance
Worn camshaft
Broken valve spring
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 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
Hissing sound—Loss of compression
Air leakage in air intake system, hoses, connections or
manifolds
Timing belt noise—Loose timing belt
Belt contacting case/adjacent part
Valve tappet noise—Incorrect valve clearance
NOTE*:
When disconnecting fuel injector connector, Malfunction Indicator Light (CHECK ENGINE light) illuminates and trouble code is stored in
ECM memory.
Therefore, carry out the CLEAR MEMORY MODE and INSPECTION MODE after connecting fuel injector connector. (Ref. to 2-7 On-Board
Diagnostics II System.)
80
2-3bDIAGNOSTICS
2. Engine Noise

G2M0066
1. Oil Pump
A: REMOVAL
1) Drain engine oil.
Set container under the vehicle, and remove drain plug
from oil pan.
B2M0051A
2) Drain coolant.
Set container under the vehicle, and remove drain cock
from radiator.
B2M0302
3) Remove belt covers, timing belt and related parts.

B2M0303
4) Remove belt tensioner bracket.
G2M0210
5) Remove left cam sprocket and left belt cover No. 2.
6) Remove water pump.
5
2-4SERVICE PROCEDURE
1. Oil Pump

B2M0302
7) Remove timing belt.

B2M0303
8) Remove belt tension adjuster.
G2M0417
9) Remove camshaft position sensor.

G2M0207
10) Remove left side camshaft pulley by using ST.
ST 499207100 CAMSHAFT SPROCKET WRENCH
G2M0208
11) Remove left side rear timing belt cover.
10
2-5SERVICE PROCEDURE
2. Engine Coolant Pump

1. Engine Cooling System
Trouble Possible cause Corrective action
Over-heatinga. Insufficient engine coolantReplenish engine coolant, inspect for leakage, and
repair.
b. Loose timing belt Repair or replace timing belt tensioner.
c. Oil on drive belt Replace.
d. Malfunction of thermostat Replace.
e. Malfunction of engine coolant pump Replace.
f. Clogged engine coolant passage Clean.
g. Improper ignition timingInspect and repair ignition control system.

h. Clogged or leaking radiator Clean or repair, or replace.
i. Improper engine oil in engine coolant Replace engine coolant.
j. Air/fuel mixture ratio too leanInspect and repair fuel injection system.

k. Excessive back pressure in exhaust system Clean or replace.
l. Insufficient clearance between piston and cylinder Adjust or replace.
m. Slipping clutch Repair or replace.
n. Dragging brake Adjust.
o. Improper transmission oil Replace.
p. Defective thermostat Replace.
q. Malfunction of electric fanInspect radiator fan relay, engine coolant temperature
sensor or radiator motor and replace there.
Over-coolinga. Atmospheric temperature extremely low Partly cover radiator front area.
b. Defective thermostat Replace.
Engine coolant
leaks.a. Loosened or damaged connecting units on hoses Repair or replace.
b. Leakage from engine coolant pump Replace.
c. Leakage from engine coolant pipe Repair or replace.
d. Leakage around cylinder head gasket Retighten cylinder head bolts or replace gasket.
e. Damaged or cracked cylinder head and crankcase Repair or replace.
f. Damaged or cracked thermostat case Repair or replace.
g. Leakage from radiator Repair or replace.
Noisea. Defective drive belt Replace.
b. Defective radiator fan Replace.
c. Defective engine coolant pump bearing Replace engine coolant pump.
d. Defective engine coolant pump mechanical seal Replace engine coolant pump.
20
2-5DIAGNOSTICS
1. Engine Cooling System

10AI7
GROUP OF #3 AND #4 CYLINDERS
: Are there faults in #3 and #4 cylinders?
NOTE:

Check the following items.

Spark plugs

Fuel injectors

Ignition coil

If no abnormal is discovered, check for“D: IGNITION
CONTROL SYSTEM”of #3 and #4 cylinders side. 2-7 [T8D0].>
: Repair or replace faulty parts.
: Go to step10AI11.
10AI8
GROUP OF #1 AND #3 CYLINDERS
: Are there faults in #1 and #3 cylinders?
NOTE:
Check the following items.

Spark plugs

Fuel injectors

Skipping timing belt teeth
: Repair or replace faulty parts.
: Go to step10AI11.
217
2-7ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostic Chart with Trouble Code for LHD Vehicles

10AI9
GROUP OF #2 AND #4 CYLINDERS
: Are there faults in #2 and #4 cylinders?
NOTE:
Check the following items.

Spark plugs

Fuel injectors

Skipping timing belt teeth
: Repair or replace faulty parts.
: Go to step10AI11.
10AI10
THE CYLINDER AT RANDOM
: Is the engine idle rough?
: Go to step10AI11.
: Go to DTC P0170. and [T10T5].>
B2M0759
10AI11
CHECK EGR SYSTEM.
: Is the minimum EGR system pressure value
(value of function mode (F42) less than 1
kPa?
NOTE:
Use the value read in step10X2for function mode F42.
: Clean EGR valve.
CAUTION:
Do not use solvent when cleaning EGR valve
assembly, as it can damage diaphragm.
NOTE:

Remove and blow away the exhaust deposits. Make
sure the valve operates smoothly and the valve seat area
is completely cleaned.

Replace EGR valve as required.
: Go to DTC P0170. and [T10T5].>
218
2-7ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostic Chart with Trouble Code for LHD Vehicles