1999 SUBARU LEGACY all wheel drive

E: INSTALLATION
1. OIL PUMP AND WATER PUMP
B2M1767B
(1) Baffle plate
(2) Oil strainer
(3) Oil pan
(4) Oil separater cover
(5) Drive plate (AT vehicles only)
(6) Flywheel (MT vehicles only)
(7) Clutch housing cover (MT
vehicles only)(8) Oil pump
(9) Water pump
(10) Water by-pass pipe
(11) Oil filterTightening torque: N´m (kg-m, ft-lb)
T1:
5 (0.5, 3.6)
T2:6.4 (0.65, 4.7)
T3:10 (1.0, 7)
T4:72±3 (7.3±0.3, 52.8±2.2)
T5:First 12±2 (1.2±0.2, 8.7±1.4)
Second 12
±2 (1.2±0.2,
8.7
±1.4)
70
2-3a[W6E1]SERVICE PROCEDURE
6. Cylinder Block

1) Install baffle plate.
2) Install oil strainer and O-ring
3) Install oil strainer stay.
4) Apply fluid packing to matching surfaces and
install oil pan.
Fluid packing:
THREE BOND 1215 or equivalent
G2M0084
5) Apply fluid packing to matching surfaces and
install oil separator cover.
Fluid packing:
THREE BOND 1215 or equivalent
G2M0194
6) Install flywheel or drive plate.
To lock crankshaft, use ST.
ST 498497100 CRANKSHAFT STOPPER
G2M0161
7) Install housing cover.
8) Installation of oil pump
(1) Discard front oil seal after removal. Replace
with a new one using ST.
ST 499587100 OIL SEAL INSTALLER
S2M0235
71
[W6E1]2-3aSERVICE PROCEDURE
6. Cylinder Block

2. Engine Noise
Type of sound Condition Possible cause
Regular clicking soundSound increases as engine
speed increases.IValve mechanism is defective.
IIncorrect valve clearance
IWorn valve rocker
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 warmSound 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 cam gear
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 con-
necting fuel injector connector.
78
2-3a[K200]DIAGNOSTICS
2. Engine Noise

E: INSTALLATION
1. OIL PUMP AND WATER PUMP
B2M1767C
(1) Baffle plate
(2) Oil strainer
(3) Oil pan
(4) Oil separator cover
(5) Drive plate (AT vehicles only)
(6) Flywheel (MT vehicles only)
(7) Clutch housing cover (MT
vehicles only)(8) Oil pump
(9) Water pump
(10) Water by-pass pipe
(11) Oil filterTightening torque: N´m (kg-m, ft-lb)
T1:
5 (0.5, 3.6)
T2:6.4 (0.65, 4.7)
T3:10 (1.0, 7)
T4:72±3 (7.3±0.3, 52.8±2.2)
T5:First 12±2 (1.2±0.2, 8.7±1.4)
Second 12
±2 (1.2±0.2,
8.7
±1.4)
68
2-3b[W5E1]SERVICE PROCEDURE
5. Cylinder Block

1) Install baffle plate.
2) Install oil strainer and O-ring.
3) Install oil strainer stay.
4) Apply fluid packing to matching surfaces and
install oil pan.
Fluid packing:
THREE BOND 1215 or equivalent
G2M0084
5) Apply fluid packing to matching surfaces and
install oil separator cover.
Fluid packing:
THREE BOND 1215 or equivalent
G2M0194
6) Install flywheel (MT vehicles only) or drive plate
(AT vehicles only).
To lock crankshaft, use ST.
ST 498497100 CRANKSHAFT STOPPER
G2M0776
B2M0706A
7) Install clutch housing cover. (MT vehicles only)
8) Installation of oil pump
(1) Discard front oil seal after removal. Replace
with a new one by using ST.
ST 499587100 OIL SEAL INSTALLER
S2M0235
69
[W5E1]2-3bSERVICE PROCEDURE
5. Cylinder Block

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

(3) Loosen lock bolt and slider bolt, and remove
power steering pump drive V-belt.
B2M2308
(4) Remove bolts which secure power steering
pipe brackets to intake manifold.
NOTE:
Do not disconnect power steering hose.
B2M2309
(5) Remove bolts which install power steering
pump to bracket.
B2M2310
(6) Remove bolt which holds power steering
fluid tank bracket onto cylinder block.
B2M2325
(7) Place power steering pump on the right side
wheel apron.
B2M2311
14) Remove fuel pipe protector LH. (LHD model
only)
B2M2754
15) Remove fuel pipe protector RH. (RHD model
only)
B2M2755
27
[W4A1]2-7SERVICE PROCEDURE
4. Intake Manifold

3) Damaged or worn disc contact surface of pres-
sure plate.
4) Loose strap plate setting bolt.
5) Worn diaphragm sliding surface.
G2M0249
3. FLYWHEEL
CAUTION:
Since this bearing is grease sealed and is of a
nonlubrication type, do not wash with gasoline
or any solvent.
1) Damage of facing and ring gear
If defective, replace flywheel.
G2M0250
2) Smoothness of rotation
Rotate ball bearing applying pressure in thrust
direction.3) If noise or excessive play is noted, replace ball
bearing as follows:
(1) Drive out ball bearing from flywheel.
(2) Press bearing into flywheel until bearing
end surface is flush with clutch disc contact sur-
face of flywheel. Do not press inner race.
ST 899754112 SNAP RING PRESS
H2M1563A
C: INSTALLATION
1) Install flywheel and ST.
ST 498497100 CRANKSHAFT STOPPER
B2M0332A
2) Tighten the flywheel attaching bolts to the
specified torque.
NOTE:
Tighten flywheel installing bolts gradually. Each
bolt should be tightened to the specified torque in
a crisscross fashion.
Tightening torque:
72
±3 N´m (7.3±0.3 kg-m, 52.8±2.2 ft-lb)
B2M0331B
13
[W4C0]2-10SERVICE PROCEDURE
4. Clutch Disc and Cover