1999 SUBARU LEGACY engine

TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK
10. Excessive fuel con-
sumptionIFuel injection system A
IIntake systemIDirty air cleaner element A
IBeltIDefective timing B
ICompressionIIncorrect valve clearance B
ILoosened spark plugs or defective gasket C
ILoosened cylinder head bolts or defective gasket C
IImproper valve seating B
IDefective valve stem C
IWorn or broken spring C
IWorn or stuck piston rings, cylinder and piston B
IIncorrect valve timing B
ILubrication systemIIncorrect oil pressure C
ICooling systemIOver cooling C
IOthersIAccelerator cable out of adjustment B
75
[K100]2-3bDIAGNOSTICS
1. Engine Trouble in General

2. Engine Noise
If noise still exists, conduct diagnostics procedures
in accordance with the following table.CAUTION:
Do not disconnect spark plug cord while
engine is running.
Type of sound Condition Possible cause
Regular clicking soundSound increases as engine
speed increases.Valve mechanism is defective.
IIncorrect valve clearance
IWorn camshaft
IBroken valve spring
Heavy and dull clankOil pressure is low.IWorn crankshaft main bearing
IWorn connecting rod bearing (big end)
Oil pressure is normal.ILoose flywheel mounting bolts
IDamaged engine mounting
High-pitched clank
(Spark knock)Sound is noticeable when
accelerating with an overload.IIgnition timing advanced
IAccumulation of carbon inside combustion chamber
IWrong spark plug
IImproper gasoline
Clank when engine speed is
medium (1,000 to 2,000 rpm).Sound is reduced when fuel
injector connector of noisy cyl-
inder is disconnected.
(NOTE*)IWorn crankshaft main bearing
IWorn 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 cyl-
inder is disconnected.
(NOTE*)IWorn cylinder liner and piston ring
IBroken or stuck piston ring
IWorn piston pin and hole at piston end of connecting rod
Sound is not reduced if each
fuel injector connector is dis-
connected in turn.
(NOTE*)IUnusually worn valve lifter
IWorn camshaft journal bore in crankcase
Squeaky sound ÐIInsufficient generator lubrication
Rubbing sound ÐIDefective generator brush and rotor contact
Gear scream when starting
engineÐIDefective ignition starter switch
IWorn gear and starter pinion
Sound like polishing glass with
a dry clothÐILoose drive belt
IDefective engine coolant pump shaft
Hissing sound ÐILoss of compression
IAir leakage in air intake system, hoses, connections or
manifolds
Timing belt noise ÐILoose timing belt
IBelt contacting case/adjacent part
Valve tappet noise ÐIIncorrect 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. [T6A0].>
76
2-3b[K200]DIAGNOSTICS
2. Engine Noise

1. Specifications
A: 2200 cc MODEL
Lubrication methodForced lubrication
Oil pumpPump type Trochoid type
Number of teethInner rotor 9
Outer rotor 10
Outer rotor diameter´thickness 78´9 mm (3.07´0.35 in)
Tip clearance between inner and outer rotorSTANDARD 0.04 Ð 0.14 mm (0.0016 Ð 0.0055 in)
LIMIT 0.18 mm (0.0071 in)
Side clearance between inner rotor and
pump caseSTANDARD 0.02 Ð 0.07 mm (0.0008 Ð 0.0028 in)
LIMIT 0.15 mm (0.0059 in)
Case clearance between outer rotor and
pump caseSTANDARD 0.10 Ð 0.175 mm (0.0039 Ð 0.0069 in)
LIMIT 0.20 mm (0.0079 in)
Capacity at
80ÉC (176ÉF)700 rpm Discharge- pressure 98 kPa (1.0 kg/cm
2, 14 psi) or more
- quantity 4.2(4.4 US qt, 3.7 Imp qt)/min.
5,000 rpm Discharge- pressure 294 kPa (3.0 kg/cm
2, 43 psi) or more
- quantity 42.0(11.10 US gal, 9.24 Imp gal)/min.
Relief valve operation pressure 490 kPa (5.0 kg/cm
2, 71 psi)
Oil filterTypeFull-flow filter type
Filtration area 1,000 cm
2(155 sq in)
By-pass valve opening pressure 157 kPa (1.6 kg/cm2, 23 psi)
Outer diameter´width 80´70 mm (3.15´2.76 in)
Oil filter to engine thread size M 20´1.5
Relief valve (on rocker shaft) operation pressure 69 kPa (0.7 kg/cm
2, 10 psi)
Oil pressure
switchType Immersed contact point type
Working voltage Ð wattage 12 V Ð 3.4 W or less
Warning light activation pressure 14.7 kPa (0.15 kg/cm
2, 2.1 psi)
Proof pressure More than 981 kPa (10 kg/cm2, 142 psi)
Oil pan capacity4.0(4.2 US qt, 3.5 Imp qt)
2
2-4[S1A0]SPECIFICATIONS AND SERVICE DATA
1. Specifications

B: 2500 cc MODEL
Lubrication methodForced lubrication
Oil pumpPump type Trochoid type
Number of teethInner rotor 9
Outer rotor 10
Outer rotor diameter´thickness 78´10 mm (3.07´0.39 in)
Tip clearance between inner and outer rotorSTANDARD 0.04 Ð 0.14 mm (0.0016 Ð 0.0055 in)
LIMIT 0.18 mm (0.0071 in)
Side clearance between inner rotor and pump
caseSTANDARD 0.02 Ð 0.07 mm (0.0008 Ð 0.0028 in)
LIMIT 0.15 mm (0.0059 in)
Case clearance between outer rotor and
pump caseSTANDARD 0.10 Ð 0.175 mm (0.0039 Ð 0.0069 in)
LIMIT 0.20 mm (0.0079 in)
Capacity at
80ÉC (176ÉF)600 rpm Discharge- pressure 98 kPa (1.0 kg/cm
2, 14 psi) or more
- quantity 4.6(4.9 US qt, 4.0 Imp qt)/min.
5,000 rpm Discharge- pressure 294 kPa (3.0 kg/cm
2, 43 psi) or more
- quantity 47.0(12.4 US gal, 10.3 Imp gal)/min.
Relief valve operation pressure 588 kPa (6.0 kg/cm
2, 85 psi)
Oil filterTypeFull-flow filter type
Filtration area 1,000 cm
2(155 sq in)
By-pass valve opening pressure 157 kPa (1.6 kg/cm2, 23 psi)
Outer diameter´width 80´70 mm (3.15´2.76 in)
Oil filter to engine thread size M 20´1.5
Oil pressure
switchType Immersed contact point type
Working voltage Ð wattage 12 V Ð 3.4 W or less
Warning light activation pressure 14.7 kPa (0.15 kg/cm
2, 2.1 psi)
Proof pressure More than 981 kPa (10 kg/cm2, 142 psi)
Oil pan capacity4.5(4.8 US qt, 4.0 Imp qt)
3
[S1B0]2-4SPECIFICATIONS AND SERVICE DATA
1. Specifications

E: INSTALLATION
Installation is in the reverse order of removal.
Observe the following:
1) Apply fluid packing to matching surfaces of oil
pump.
Fluid packing:
THREE BOND 1215 or equivalent
H2M2424A
2) Replace O-ring with a new one.
3) Apply a coat of engine oil to the inside of the oil
seal.
S2M0118A
4) Be careful not to scratch oil seal when installing
oil pump on cylinder block.
5) Position the oil pump, aligning the notched area
with the crankshaft, and push the oil pump straight.
CAUTION:
Make sure the oil seal lip is not folded.
6) Install oil pump.
Tightening torque:
6.4 N´m (0.65 kg-m, 4.7 ft-lb)
S2M0120A
2. Oil Pan and Oil Strainer
A: REMOVAL
1) Disconnect battery ground cable.
G6M0095
2) Remove front wheels.
3) Remove air intake duct and air cleaner assem-
bly. (2200 cc California spec. vehicles)
B2M2771
4) Remove air intake duct and air intake chamber.
(Except 2200 cc California spec. vehicles)
B2M2772
10
2-4[W1E0]SERVICE PROCEDURE
2. Oil Pan and Oil Strainer

E: INSTALLATION
Installation is in the reverse order of removal.
Observe the following:
1) Apply fluid packing to matching surfaces of oil
pump.
Fluid packing:
THREE BOND 1215 or equivalent
H2M2424A
2) Replace O-ring with a new one.
3) Apply a coat of engine oil to the inside of the oil
seal.
S2M0118A
4) Be careful not to scratch oil seal when installing
oil pump on cylinder block.
5) Position the oil pump, aligning the notched area
with the crankshaft, and push the oil pump straight.
CAUTION:
Make sure the oil seal lip is not folded.
6) Install oil pump.
Tightening torque:
6.4 N´m (0.65 kg-m, 4.7 ft-lb)
S2M0120A
2. Oil Pan and Oil Strainer
A: REMOVAL
1) Disconnect battery ground cable.
G6M0095
2) Remove front wheels.
3) Remove air intake duct and air cleaner assem-
bly. (2200 cc California spec. vehicles)
B2M2771
4) Remove air intake duct and air intake chamber.
(Except 2200 cc California spec. vehicles)
B2M2772
10
2-4[W1E0]SERVICE PROCEDURE
2. Oil Pan and Oil Strainer

5) Disconnect front oxygen sensor connector.
B2M1979A
S2M0127A
6) Disconnect rear oxygen sensor connector.
(2500 cc California spec. vehicles)
S2M0128
7) Remove pitching stopper.
G2M0295
8) Remove radiator upper bracket.
B2M0320
9) Support engine with a lifting device and wire
ropes.
B2M0053
10) Lift-up the vehicle.
CAUTION:
At this time, raise up wire ropes.
11) Remove under cover.
B2M0014
11
[W2A0]2-4SERVICE PROCEDURE
2. Oil Pan and Oil Strainer

12) Drain engine oil.
Set container under the vehicle, and remove drain
plug from oil pan.
G2M0066
13) Disconnect connector from rear oxygen sen-
sor. (Except 2500 cc California spec. vehicles)
B2M0312
14) Remove front exhaust pipe.
(1) Separate front catalytic converter from cen-
ter exhaust pipe.
B2M0421
(2) Remove front exhaust pipe from engine.
S2M0236
(3) Remove bolt which installs front exhaust
pipe on bracket.
15) Remove nuts which install front cushion rub-
ber onto front crossmember.
G2M0293
16) Remove bolts which install oil pan on cylinder
block while raising up engine.
B2M2687A
S2M0131A
17) Insert oil pan cutter blade between cylinder
block-to-oil pan clearance.
CAUTION:
Do not use a screwdriver or similar tool in
place of oil pan cutter.
12
2-4[W2A0]SERVICE PROCEDURE
2. Oil Pan and Oil Strainer