1999 SUBARU LEGACY Service Repair Manual

9) Connect pipes A and B to four pipe joints of
gearbox. Connect upper pipe B first, and lower
pipe A second.
Tightening torque:
13
±3 N´m (1.3±0.3 kg-m, 9.4±2.2 ft-lb)
G4M0099
10) Install jack-up plate.
11) Connect battery minus terminal.
12) Feed the specified fluid and discharge air.
NOTE:
Never start the engine before feeding the fluid; oth-
erwise vane pump might be seized up.
B4M1137A
13) Finally check clearance between pipes and/or
hoses, as shown above.
If clearance between cruise control pump and
power steering hose is less than 10 mm (0.39 in),
proceed as follows:
(1) Move clamped section (A) (refer to figure
above.) down to a point where pipe is close to
crossmember.
Pipe-to-crossmember clearance:
10 mm (0.39 in), min.
(2) Check that clearance between cruise con-
trol pump and power steering hose is at least 10
mm (0.39 in). If it is not, bend section (B) down
until a clearance of at least 10 mm (0.39 in) is
obtained.
56
4-3[W7C1]SERVICE PROCEDURE
7. Pipe Assembly (Power Steering System)

2. RHD MODEL
1) Interconnect pipes C and D.
Tightening torque:
Joint nut
15
±5 N´m (1.5±0.5 kg-m, 10.8±3.6 ft-lb)
CAUTION:
Visually check that hose between tank and pipe
D is free from bending or twisting.
B4M1159A
2) Connect pipe D from oil tank.
3) Connect pipe C from oil pump.
CAUTION:
Use a new gasket.
Tightening torque:
34
±5 N´m (3.5±0.5 kg-m, 25.3±3.6 ft-lb)
4) Tighten bolt A.
Tightening torque:
13
±3 N´m (1.3±0.3 kg-m, 9.4±2.2 ft-lb)
5) Temporarily connect pipes C and D to control
valve of gearbox.
B4M0673A
6) Temporarily install clamp E on pipes C and D.
CAUTION:
Ensure that the letter ª8º side of clamp E is on
the pipe C side as shown in the figure.
B4M0667A
7) Tighten clamp E firmly.
Tightening torque:
7.4
±2.0 N´m (0.75±0.20 kg-m, 5.4±1.4 ft-lb)
8) Tighten joint nut.
Tightening torque:
15
±5 N´m (1.5±0.5 kg-m, 10.8±3.6 ft-lb)
9) Connect pipes A and B to four pipe joints of
gearbox. Connect upper pipe A first, and lower pipe
B second.
Tightening torque:
13
±3 N´m (1.3±0.3 kg-m, 9.4±2.2 ft-lb)
B4M0671A
10) Install jack-up plate.
11) Connect battery negative terminal.
57
[W7C2]4-3SERVICE PROCEDURE
7. Pipe Assembly (Power Steering System)

12) Feed the specified fluid and discharge air.
NOTE:
Never start the engine before feeding the fluid; otherwise vane pump might be seized up.
B4M0674A
58
4-3[W7C2]SERVICE PROCEDURE
7. Pipe Assembly (Power Steering System)

8. Oil Pump (Power Steering
System)
A: REMOVAL
1) Remove ground cable from battery.
2) Drain the working fluid about 0.35(0.4 US qt,
0.3 Imp qt) from oil tank.
B4M1160
3) Remove pulley belt cover bracket.
4) Loosen oil pump pulley nut, then remove bolts
which secure alternator.
B4M1161A
5) Loosen pulley belt(s).
6) Remove the nut and detach oil pump pulley.7) Remove bolt A. Disconnect pipe C from oil
pump. Disconnect pipe D from oil tank.
CAUTION:
IDo not allow fluid from the hose end to come
into contact with pulley belt.
ITo prevent foreign matter from entering the
hose and pipe, cover the open ends of them
with a clean cloth.
IExcept when only oil tank needs to be
inspected, detach oil tank and oil pump as a
unit. Then separate one from the other on a
work bench to prevent oil from spilling on any
part of the engine.
B4M1159A
8) Remove three bolts from the front side of oil
pump and detach the pump.
B4M0560
9) Remove three bolts from the lower side of
bracket and detach the bracket.
CAUTION:
The bracket does not need to be removed
unless it is damaged.
59
[W8A0]4-3SERVICE PROCEDURE
8. Oil Pump (Power Steering System)

10) Place oil pump in a vise, remove two bolts
from oil tank and detach oil tank.
CAUTION:
Do not place oil pump directly in the vise; use
soft pads and hold oil pump lightly to protect
the pump.
B4M0561A
11) Remove O-ring from oil pump.
12) Remove stay from oil pump. (2500 cc model
only)
B: CHECK
In accordance with the following table, check all
removed parts for wear and damage, and make
repair or replacement if necessary.
No. Parts Inspection Corrective action
1 Oil pump (Exterior)(1)Crack, damage or oil leakage Replace oil pump with a new one.
(2)Play of pulley shaftMeasure radial play and axial play.
If any of these exceeds the service limit,
replace oil pump with a new one. 4-3 [W8B1].>
2 Pulley(1)Damage Replace it with a new one.
(2)BendMeasure V ditch deflection.
If it exceeds the service limit, replace pul-
ley with a new one.
3 Cap Crack or damage Replace it with a new one.
4 Strainer(1)Clogging with dirt Wash it.
(2)Breakage Replace it with a new one.
5 Oil pump (Interior)(1)Defect or burning of vane pumpCheck resistance to rotation of pulley.
If it is past the service limit, replace oil
pump with a new one. [W8B1].>
(2)Bend in the shaft or damage to bearingOil pump emits a noise that is markedly
different in tone and loudness from a
sound of a new oil pump when turning with
a string put around its pulley, replace oil
pump with a new one.
6 O-ring Crack or deterioration Replace it with a new one.
7 Oil tank Crack, damage or oil leakage Replace it with a new one.
8 Bracket Crack or damage Replace it with a new one.
1. SERVICE LIMIT
Make a measurement as follows. If it exceeds the
specified service limit, replace the parts with new
ones.
CAUTION:
IFix oil pump on a vise to make a measure-
ment. At this time, hold oil pump with the least
possible force between two wood pieces.
IDo not set outside of flow control valve or
pulley on a vise; otherwise outside or pulleymight be deformed. Select properly sized wood
pieces.
Play of pulley shaft
On condition:
P: 9.8 N (1.0 kg, 2.2 lb)
Service limit:
Radial play
0.4 mm (0.016 in) or less
60
4-3[W8B0]SERVICE PROCEDURE
8. Oil Pump (Power Steering System)

G4M0172
Axial play
0.9 mm (0.035 in) or less
G4M0173
Ditch deflection of pulley
Service limit:
1.0 mm (0.039 in) or less
NOTE:
Read the value for one surface of V ditch, and then
the value for another off the dial.
G4M0174
Resistance to rotation of pulley
Service limit:
Maximum load; 9.22 N (0.94 kg, 2.07 lb)
or less
NOTE:
IA rather higher value may be indicated when
pulley starts turning.
IMeasure the load during rotation and make a
judgment.
G4M0175
61
[W8B1]4-3SERVICE PROCEDURE
8. Oil Pump (Power Steering System)

C: DISASSEMBLY
B4M0142B
(1) Pulley
(2) Snap ring
(3) Bearing
(4) Oil seal
(5) Shaft
(6) Connector
(7) O-ring
(8) Spool valve(9) Spring
(10) Front casing
(11) Rear cover
(12) Knock pin
(13) Seal washer
(14) Cam ring
(15) Vane
(16) Rotor(17) Side plate
Tightening torque: N´m (kg-m, ft-lb)
T1:
16±2 (1.6±0.2, 11.6±1.4)
T2:61±7 (6.2±0.7, 45.0±5.2)
T3:74±5 (7.5±0.5, 54.2±3.6)
1) Oil pump body
(1) Place oil pump in a vise, and remove two
bolts which secure tank.
CAUTION:
Do not place oil pump directly in vise; use soft
pads and hold oil pump lightly to protect it.
B4M0561A
(2) Remove four bolts which secure rear cover.
G4M0178
62
4-3[W8C0]SERVICE PROCEDURE
8. Oil Pump (Power Steering System)

(3) Remove the following parts from front cas-
ing.
CAUTION:
Discard old seal washer; replace with a new
one.
B4M1138A
(1) Seal washer
(2) Knock pin.....2 ea.
(3) Cam ring
(4) Rotor
(5) Vane.....10 ea.
(6) Side plate
(7) O-ring.....2 ea.
2) Control valve
Slightly loosen outlet connector, and remove con-
nector. Remove the following parts for pump cas-
ing.
ISpool valve assembly
IFlow control spring
IConnector
IO-ring
G4M0180
3) Shaft
(1) Remove snap ring from front casing.
G4M0181
(2) Remove shaft using a hand press.
CAUTION:
IDiscard old drive shaft assembly; replace
with a new one.
IBe careful not to scratch or dent casing's
surface which serves as a seal.
G4M0182
(3) Pry oil seal off using a screwdriver.
CAUTION:
Be careful not to scratch inner surface of cas-
ing.
G4M0183
4) Remove pressure switch.
D: INSPECTION
Perform the following inspection procedures and
repair or replace defective parts.
63
[W8D0]4-3SERVICE PROCEDURE
8. Oil Pump (Power Steering System)