SUBARU LEGACY 1996 Service Repair Manual

B: SERVICE DATA
Belt
tension
adjusterProtrusion of adjuster rod 15.4—16.4 mm (0.606—0.646 in)
Belt ten-
sionerSpacer O.D. 16 mm (0.63 in)
Tensioner bush I.D. 16.16 mm (0.6362 in)
Clearance between spacer and bushSTD 0.117—0.180 mm (0.0046—0.0071 in)
Limit 0.230 mm (0.0091 in)
Side clearance of spacerSTD 0.37—0.54 mm (0.0146—0.0213 in)
Limit 0.8 mm (0.031 in)
CamshaftBend limit 0.020 mm (0.0008 in)
Thrust clearanceSTD 0.040—0.080 mm (0.0016—0.0031 in)
Limit 0.10 mm (0.0039 in)
Cam lobe heightIntakeSTD 41.68—41.78 mm (1.6409—1.6449 in)
Limit 41.52 mm (1.6346 in)
ExhaustSTD 41.98—42.08 mm (1.6528—1.6567 in)
Limit 41.82 mm (1.6465 in)
Camshaft journal O.D.Front 31.946—31.963 mm (1.2577—1.2584 in)
Center 27.946—27.963 mm (1.1002—1.1009 in)
Rear 27.946—27.963 mm (1.1002—1.1009 in)
Camshaft journal hole I.D.Front 32.000—32.018 mm (1.2598—1.2605 in)
Center 28.000—28.018 mm (1.1024—1.1031 in)
Rear 28.000—28.018 mm (1.1024—1.1031 in)
Oil clearanceSTD 0.037—0.072 mm (0.0015—0.0028 in)
Limit 0.10 mm (0.0039 in)
Cylinder
headSurface warpage limit 0.05 mm (0.0020 in)
Surface grinding limit 0.3 mm (0.012 in)
Standard height 127.5 mm (5.02 in)
Valve seatRefacing angle 90°
Contacting widthIntakeSTD 1.0 mm (0.039 in)
Limit 1.7 mm (0.067 in)
ExhaustSTD 1.5 mm (0.059 in)
Limit 2.2 mm (0.087 in)
Valve
guideInner diameter 6.000—6.015 mm (0.2362—0.2368 in)
Protrusion above head 12.0—12.4 mm (0.472—0.488 in)
ValveHead edge thicknessIntakeSTD 1.2 mm (0.047 in)
Limit 0.8 mm (0.031 in)
ExhaustSTD 1.5 mm (0.059 in)
Limit 0.8 mm (0.031 in)
Stem diameterIntake 5.950—5.965 mm (0.2343—0.2348 in)
Exhaust 5.950—5.965 mm (0.2343—0.2348 in)
Stem oil clearanceSTDIntake 0.035—0.062 mm (0.0014—0.0024 in)
Exhaust 0.040—0.067 mm (0.0016—0.0026 in)
Limit—0.15 mm (0.0059 in)
Overall lengthIntake 93.3 mm (3.673 in)
Exhaust 93.6 mm (3.685 in)
STD: Standard I.D.: Inner Diameter O.D.: Outer Diameter
3
2-3bSPECIFICATIONS AND SERVICE DATA
1. Engine

Valve springFree length 39.8 mm (1.567 in)
Squareness 2.5°, 1.7 mm (0.067 in)
Tension/spring height228.5—261.8 N
(23.3—26.7 kg, 51.4—58.9 lb)/31.0 mm (1.220 in)
462.9—531.5 N
(47.2—54.2 kg, 104.1—119.5 lb)/23.2 mm (0.913 in)
Cylinder
blockSurface warpage limit (mating with cylinder head) 0.05 mm (0.0020 in)
Surface grinding limit 0.1 mm (0.004 in)
Cylinder bore STDA 99.505—99.515 mm (3.9175—3.9179 in)
B 99.495—99.505 mm (3.9171—3.9175 in)
TaperSTD 0.015 mm (0.0006 in)
Limit 0.050 mm (0.0020 in)
Out-of-roundnessSTD 0.010 mm (0.0004 in)
Limit 0.050 mm (0.0020 in)
Piston clearanceSTD 0.010—0.030 mm (0.0004—0.0012 in)
Limit 0.050 mm (0.0020 in)
Enlarging (boring) limit 0.5 mm (0.020 in)
Piston Outer diameterSTDA 99.485—99.495 mm (3.9167—3.9171 in)
B 99.475—99.485 mm (3.9163—3.9167 in)
0.25 mm (0.0098 in)
OS99.725—99.735 mm (3.9262—3.9266 in)
0.50 mm (0.0197 in)
OS99.975—99.985 mm (3.9360—3.9364 in)
Piston pinStandard clearance between piston
pin and hole in pistonSTD 0.004—0.010 mm (0.0002—0.0004 in)
Limit 0.020 mm (0.0008 in)
Degree of fitPiston pin must be fitted into position with thumb at 20°C
(68°F).
Piston ringPiston ring gapTop ringSTD 0.20—0.35 mm (0.0079—0.0138 in)
Limit 1.0 mm (0.039 in)
Second
ringSTD 0.37—0.52 mm (0.0146—0.0205 in)
Limit 1.0 mm (0.039 in)
Oil ringSTD 0.20—0.60 mm (0.0079—0.0236 in)
Limit 1.5 mm (0.059 in)
Clearance between piston
ring and piston ring grooveTop ringSTD 0.040—0.080mm (0.0016—0.0031 in)
Limit 0.15 mm (0.0059 in)
Second
ringSTD 0.030—0.070 mm (0.0012—0.0028 in)
Limit 0.15 mm (0.0059 in)
Connecting
rodBend twist per 100 mm (3.94 in) in
lengthLimit 0.10 mm (0.0039 in)
Side clearanceSTD 0.070—0.330 mm (0.0028—0.0130 in)
Limit 0.4 mm (0.016 in)
Connecting
rod bearingOil clearanceSTD 0.010—0.038 mm (0.0004—0.0015 in)
Limit 0.05 mm (0.0020 in)
Thickness at center portionSTD 1.492—1.501 mm (0.0587—0.0591 in)
0.03 mm
(0.0012 in)
US1.510—1.513 mm (0.0594—0.0596 in)
0.05 mm
(0.0020 in)
US1.520—1.523 mm (0.0598—0.0600 in)
0.25 mm
(0.0098 in)
US1.620—1.623 mm (0.0638—0.0639 in)
Connecting
rod bushingClearance between piston pin and
bushingSTD 0—0.022 mm (0—0.0009 in)
Limit 0.030 mm (0.0012 in)
STD: Standard OS: Oversize US: Undersize
4
2-3bSPECIFICATIONS AND SERVICE DATA
1. Engine

CrankshaftBend limit 0.035 mm (0.0014 in)
Crank pin and crank journalOut-of-roundness 0.020 mm (0.0008 in) or less
Grinding limit 0.25 mm (0.0098 in)
Crank pin outer diameterSTD 47.984—48.000 mm (1.8891—1.8898 in)
0.03 mm
(0.0012 in)
US47.954—47.970 mm (1.8879—1.8886 in)
0.05 mm
(0.0020 in)
US47.934—47.950 mm (1.8872—1.8878 in)
0.25 mm
(0.0098 in)
US47.734—47.750 mm (1.8793—1.8799 in)
Crank journal outer diameter#1, #5STD 59.992—60.008 mm (2.3619—2.3625 in)
0.03 mm
(0.0012 in)
US59.962—59.978 mm (2.3607—2.3613 in)
0.05 mm
(0.0020 in)
US59.942—59.958 mm (2.3599—2.3605 in)
0.25 mm
(0.0098 in)
US59.742—59.758 mm (2.3520—2.3527 in)
#2, #3, #4STD 59.992—60.008 mm (2.3619—2.3625 in)
0.03 mm
(0.0012 in)
US59.962—59.978 mm (2.3607—2.3613 in)
0.05 mm
(0.0020 in)
US59.942—59.958 mm (2.3599—2.3605 in)
0.25 mm
(0.0098 in)
US59.742—59.758 mm (2.3520—2.3527 in)
Thrust clearanceSTD 0.030—0.115 mm (0.0012—0.0045 in)
Limit 0.25 mm (0.0098 in)
Oil clearance#1, #5 STD 0.003—0.030 mm (0.0001—0.0012 in)
#2, #3, #4 STD 0.010—0.033 mm (0.0004—0.0013 in)
#1, #3, #5 Limit 0.040 mm (0.0016 in)
#2, #4 Limit 0.045 mm (0.0018 in)
Crankshaft
bearingCrankshaft bearing thickness#1, #5STD 1.998—2.011 mm (0.0787—0.0792 in)
0.03 mm
(0.0012 in)
US2.017—2.020 mm (0.0794—0.0795 in)
0.05 mm
(0.0020 in)
US2.027—2.030 mm (0.0798—0.0799 in)
0.25 mm
(0.0098 in)
US2.127—2.130 mm (0.0837—0.0839 in)
#2, #3, #4STD 2.000—2.013 mm (0.0787—0.0793 in)
0.03 mm
(0.0012 in)
US2.019—2.022 mm (0.0795—0.0796 in)
0.05 mm
(0.0020 in)
US2.029—2.032 mm (0.0799—0.0800 in)
0.25 mm
(0.0098 in)
US2.129—2.132 mm (0.0838—0.0839 in)
STD: Standard US: Undersize
5
2-3bSPECIFICATIONS AND SERVICE DATA
1. Engine

1. Timing Belt
B2M0726A

1Right-hand belt cover No. 2


2Crankshaft sprocket


3Left-hand belt cover No. 2


4Tensioner bracket


5Tensioner adjuster


6Belt tensioner


7Belt idler


8Right-hand exhaust camshaft sprocket


9Right-hand intake camshaft sprocket


10Left-hand intake camshaft sprocket


11Left-hand exhaust camshaft sprocket


12Timing belt


13Belt idler No. 2

14Belt idler


15Left-hand belt cover


16Front belt cover


17Right-hand belt cover


18Crankshaft pulley
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 4.9±0.5 (0.5±0.05, 3.6±0.4)
T2: 25±2 (2.5±0.2, 18.1±1.4)
T3: 39±4 (4.0±0.4, 28.9±2.9)
T4: 78±5 (8.0±0.5, 57.9±3.6)
T5: 127±5 (13.0±0.5, 94.0±3.6)
6
2-3bCOMPONENT PARTS
1. Timing Belt

2. Cylinder Head and Camshaft
B2M0681A

1Rocker cover (RH)


2Rocker cover gasket (RH)


3Oil separator cover


4Gasket


5Intake camshaft cap (Front RH)


6Intake camshaft cap (Center RH)


7Intake camshaft cap (Rear RH)


8Intake camshaft (RH)


9Exhaust camshaft cap (Front RH)


10Exhaust camshaft cap (Center RH)


11Exhaust camshaft cap (Rear RH)


12Exhaust camshaft (RH)


13Intake valve guide

14Exhaust valve guide


15Cylinder head bolt


16Oil seal


17Cylinder head (RH)


18Cylinder head gasket (RH)


19Cylinder head gasket (LH)


20Cylinder head (LH)


21Intake camshaft (LH)


22Exhaust camshaft (LH)


23Intake camshaft cap (Front LH)


24Intake camshaft cap (Center LH)


25Intake camshaft cap (Rear LH)


26Exhaust camshaft (Front LH)

27Exhaust camshaft cap (Center LH)


28Exhaust camshaft cap (Rear LH)


29Rocker cover gasket (LH)


30Rocker cover (LH)


31Oil filler cap


32Gasket


33Oil filler duct


34Gasket
Tightening torque: N⋅m (kg-m, ft-lb)
T1: Refer to 2-3b [W4E1].
T2: 5 (0.5, 3.6)
T3: 10 (1.0, 7)
7
2-3bCOMPONENT PARTS
2. Cylinder Head and Camshaft

3. Cylinder Head and Valve Assembly
G2M0706

1Exhaust valve


2Intake valve


3Cylinder head


4Valve spring seat


5Intake valve oil seal


6Valve spring


7Retainer


8Retainer key

9Hydraulic lash adjuster


10Exhaust valve oil seal
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 5 (0.5, 3.6)
T2: 12 (1.2, 9)
8
2-3bCOMPONENT PARTS
3. Cylinder Head and Valve Assembly

4. Cylinder Block
B2M0381A

1Oil pressure switch


2Cylinder block (RH)


3Service hole plug


4Gasket


5Oil separator cover


6Water pipe


7Oil pump


8Front oil seal


9Rear oil seal


10O-ring


11Service hole cover


12Cylinder block (LH)


13Engine coolant pump


14Baffle plate


15Oil strainer stay


16Oil strainer

17Gasket


18Oil pan


19Oil drain plug


20Gasket


21Oil filler pipe
Tightening 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: 25±2 (2.5±0.2, 18.1±1.4)
T5: 47±3 (4.8±0.3, 34.7±2.2)
T6: 69±7 (7.0±0.7, 50.6±5.1)
T7: First 12±2 (1.2±0.2, 8.7±1.4)
Second 12±2 (1.2±0.2, 8.7±1.4)
9
2-3bCOMPONENT PARTS
4. Cylinder Block

5. Crankshaft and Piston
B2M0683A

1Drive plate


2Reinforcement


3Top ring


4Second ring


5Oil ring


6Piston


7Piston pin


8Circlip


9Connecting rod bolt


10Connecting rod


11Connecting rod bearing

12Connecting rod cap


13Crankshaft


14Woodruff key


15Crankshaft bearing #1, #5


16Crankshaft bearing #2, #4


17Crankshaft bearing #3
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 44±2 (4.5±0.2, 32.5±1.4)
T2: 72±3 (7.3±0.3, 52.8±2.2)
10
2-3bCOMPONENT PARTS
5. Crankshaft and Piston

G2M0709
1. General Precautions
1) Before disassembling engine, place it on ST3.
ST1 498457000 ENGINE STAND ADAPTER RH
ST2 498457100 ENGINE STAND ADAPTER LH
ST3 499817000 ENGINE STAND
2) All parts should be thoroughly cleaned, paying special
attention to the engine oil passages, pistons and bearings.
3) Rotating parts and sliding parts such as piston, bearing
and gear should be coated with oil prior to assembly.
4) Be careful not to let oil, grease or coolant contact the
timing belt, clutch disc and flywheel.
5) All removed parts, if to be reused, should be reinstalled
in the original positions and directions.
6) Gaskets and lock washers must be replaced with new
ones. Liquid gasket should be used where specified to
prevent leakage.
7) Bolts, nuts and washers should be replaced with new
ones as required.
8) Even if necessary inspections have been made in
advance, proceed with assembly work while making
rechecks.
11
2-3bSERVICE PROCEDURE
1. General Precautions

2. Timing Belt
A: REMOVAL
1. CRANKSHAFT PULLEY AND BELT COVER
B2M0684A
G2M0711
1) Remove V-belt cover, V-belt and air conditioning com-
pressor drive belt tensioner. <Ref. to 1-5 [01A0].>
2) Remove pulley bolt. To lock crankshaft, use ST.
ST 499977000 CRANKSHAFT PULLEY WRENCH
3) Remove crankshaft pulley.
B2M0729
4) Remove left-hand belt cover.
12
2-3bSERVICE PROCEDURE
2. Timing Belt