SUBARU LEGACY 1996 Service Repair Manual

B2M0764A
1) Camshaft installation
Apply engine oil to cylinder head at camshaft bearing loca-
tion before installing camshaft. Install camshaft so that
rocker arm is close to or in contact with“base circle”of cam
lobe.
CAUTION:
When camshafts are positioned as shown in figure,
camshafts need to be rotated at a minimum to align
with timing belt during installation.
Right-hand camshaft need not be rotated when set
at position shown in figure.
Left-hand intake camshaft: Rotate 80°clockwise.
Left-hand exhaust camshaft: Rotate 45°counter-clock-
wise.
G2M0752
2) Camshaft cap installation
(1) Apply fluid packing sparingly to cap mating surface.
CAUTION:
Do not apply fluid packing excessively. Failure to do so
may cause excess packing to come out and flow
toward oil seal, resulting in oil leaks.
Fluid packing:
THREE BOND 1215 or equivalent
G2M0753
(2) Apply engine oil to cap bearing surface and install
cap on camshaft as shown by identification mark.
(3) Gradually tighten cap in at least two stages in the
numerical order shown in figure, and then tighten to
specified torque.
(4) Similarly, tighten cap on exhaust side.
After tightening cap, ensure camshaft rotates only
slightly while holding it at“base”circle.
G2M0754
3) Camshaft oil seal installation
Apply grease to new oil seal lips and press onto front end
of camshaft by using ST1 and ST2.
CAUTION:
Use a new oil seal.
ST1 499587100 OIL SEAL INSTALLER
ST2 499597000 OIL SEAL GUIDE
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2-3bSERVICE PROCEDURE
3. Camshaft

G2M0755
4) Rocker cover installation
(1) Install gasket on rocker cover.
Install peripheral gasket and ignition coil gasket.
(2) Apply fluid packing to four front open edges of
peripheral gasket.
Fluid packing:
THREE BOND 1215 or equivalent
(3) Install rocker cover on cylinder head. Ensure gas-
ket is properly positioned during installation.
5) Install ignition coil.
6) Install cam angle sensor.
7) Similarly, install parts on right-hand side.
2. RELATED PARTS
Install timing belt, camshaft sprockets and related parts.
<Ref. to 2-3b [W2C0].>
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2-3bSERVICE PROCEDURE
3. Camshaft

4. Cylinder Head
A: REMOVAL
1. INTAKE MANIFOLD
1) Remove V-belt.
2) Remove generator, air conditioner compressor and
brackets.
3) Remove hoses and tubes from cylinder block.
4) Disconnect each connector and/or remove connector
bracket.
5) Remove coolant filler tank.
6) Remove intake manifold assembly and gasket.
7) Remove water pipe.
8) Remove crank angle sensor, cam angle sensor and
knock sensor.
9) Remove timing belt, camshaft sprockets and related
parts.
<Ref. to 2-3b [W2A0].>
10) Remove rocker cover, camshafts and related parts.
<Ref. to 2-3b [W3A0].>
2. CYLINDER HEAD
B2M0770A
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2-3bSERVICE PROCEDURE
4. Cylinder Head

G2M0757
1) Remove oil level gauge guide attaching bolt (left-hand
only).
2) Remove cylinder head bolts in numerical sequence
shown in figure.
CAUTION:
Leave bolts

1and
4engaged by three or four threads
to prevent cylinder head from falling.
3) While tapping cylinder head with a plastic hammer,
separate it from cylinder block.
Remove bolts

1and
4to remove cylinder head.
4) Remove cylinder head gasket.
5) Similarly, remove right-hand cylinder head.
B: DISASSEMBLY
G2M0758
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2-3bSERVICE PROCEDURE
4. Cylinder Head

G2M0759
1) Remove hydraulic lash adjusters.
2) Compress the valve spring and remove the valve spring
retainer key. Remove each valve and valve spring.
ST1 498267600 CYLINDER HEAD TABLE
ST2 499718000 VALVE SPRING REMOVER
CAUTION:
Mark each valve to prevent confusion.
Use extreme care not to damage the lips of the
intake valve oil seals and exhaust valve oil seals.
G2M0760
C: INSPECTION
1. CYLINDER HEAD
1) Make sure that no crack or other damage exists. In
addition to visual inspection, inspect important areas by
means of red check.
2) Measure the warping of the cylinder head surface that
mates with crankcase by using a straight edge and thick-
ness gauge.
If the warping exceeds 0.05 mm (0.0020 in), regrind the
surface with a surface grinder.
Warping limit:
0.05 mm (0.0020 in)
Grinding limit:
0.3 mm (0.012 in)
Standard height of cylinder head:
127.5 mm (5.02 in)
CAUTION:
Uneven torque for the cylinder head nuts can cause
warping. When reassembling, pay special attention to
the torque so as to tighten evenly.
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2-3bSERVICE PROCEDURE
4. Cylinder Head

G2M0761
2. VALVE SEAT
Inspect intake and exhaust valve seats, and correct the
contact surfaces with valve seat cutter if they are defective
or when valve guides are replaced.
Valve seat width: W
Intake
Standard
1.0 mm (0.039 in)
Limit
1.7 mm (0.067 in)
Exhaust
Standard
1.5 mm (0.059 in)
Limit
2.2 mm (0.087 in)
3. VALVE GUIDE
1) Check the clearance between valve guide and stem.
The clearance can be checked by measuring the outside
diameter of valve stem and the inside diameter of valve
guide with outside and inside micrometers respectively.
Clearance between the valve guide and valve stem:
Standard
Intake
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)
Valve guide inner diameter:
6.000—6.015 mm (0.2362—0.2368 in)
Valve stem outer diameter:
Intake
5.950—5.965 mm (0.2343—0.2348 in)
Exhaust
5.950—5.965 mm (0.2343—0.2348 in)
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2-3bSERVICE PROCEDURE
4. Cylinder Head

G2M0762
2) If the clearance between valve guide and stem exceeds
the specification, replace guide as follows:
(1) Place cylinder head on ST1 with the combustion
chamber upward so that valve guides enter the holes
in ST1.
(2) Insert ST2 into valve guide and press it down to
remove valve guide.
ST1 498267600 CYLINDER HEAD TABLE
ST2 499767200 VALVE GUIDE REMOVER
G2M0763
(3) Turn cylinder head upside down and place ST as
shown in the figure.
ST 498267700 VALVE GUIDE ADJUSTER
G2M0764
(4) Before installing new valve guide, make sure that
neither scratches nor damages exist on the inside sur-
face of the valve guide holes in cylinder head.
(5) Put new valve guide, coated with sufficient oil, in
cylinder, and insert ST1 into valve guide. Press in until
the valve guide upper end is flush with the upper sur-
face of ST2.
ST1 499767200 VALVE GUIDE REMOVER
ST2 498267700 VALVE GUIDE ADJUSTER
(6) Check the valve guide protrusion.
Valve guide protrusion: L
12.0—12.4 mm (0.472—0.488 in)
(7) Ream the inside of valve guide with ST. Gently
rotate the reamer clockwise while pressing it lightly into
valve guide, and return it also rotating clockwise. After
reaming, clean valve guide to remove chips.
ST 499767400 VALVE GUIDE REAMER
CAUTION:
Apply engine oil to the reamer when reaming.
If the inner surface of the valve guide is torn, the
edge of the reamer should be slightly ground with an
oil stone.
If the inner surface of the valve guide becomes lus-
trous and the reamer does not chips, use a new reamer
or remedy the reamer.
(8) Recheck the contact condition between valve and
valve seat after replacing valve guide.
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2-3bSERVICE PROCEDURE
4. Cylinder Head

G2M0153
4. INTAKE AND EXHAUST VALVE
1) Inspect the flange and stem of valve, and replace if
damaged, worn, or deformed, or if“H”is less than the
specified limit.
H:
Intake
Standard
1.2 mm (0.047 in)
Limit
0.8 mm (0.031 in)
Exhaust
Standard
1.5 mm (0.059 in)
Limit
0.8 mm (0.031 in)
Valve overall length:
Intake 93.3 mm (3.673 in)
Exhaust 93.6 mm (3.685 in)
2) Put a small amount of grinding compound on the seat
surface and lap the valve and seat surface. Install a new
intake valve oil seal after lapping.
G2M0154
5. VALVE SPRINGS
1) Check valve springs for damage, free length, and ten-
sion. Replace valve spring if it is not to the specifications
presented below.
2) To measure the squareness of the valve spring, stand
the spring on a surface plate and measure its deflection at
the top using a try square.
Valve spring
Free length 39.8 mm (1.567 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)
Squareness 2.5°, 1.7 mm (0.067 in)
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2-3bSERVICE PROCEDURE
4. Cylinder Head

G2M0765
6. INTAKE AND EXHAUST VALVE OIL SEAL
Replace oil seal with new one, if lip is damaged or spring
out of place, or when the surfaces of intake valve and valve
seat are reconditioned or intake valve guide is replaced.
1) Place cylinder head on ST1.
2) Press in oil seal to the specified dimension indicated in
the figure by using ST2.
ST1 498267600 CYLINDER HEAD TABLE
ST2 498857100 VALVE OIL SEAL GUIDE
CAUTION:
Apply engine oil to oil seal before force-fitting.
Differentiate between intake valve oil seal and
exhaust valve oil seal by noting their difference in
color.
Color of rubber part:
Intake [Black]
Exhaust [Brown]
Color of spring part:
Intake [Black]
Exhaust [Black]
G2M0766
7. VALVE LASH ADJUSTER
1) Check valve lash adjuster visually.
2) Measure outer diameter of valve lash adjuster.
Outer diameter:
29.959—29.975 mm (1.1795—1.1801 in)
G2M0767
3) Measure inner diameter of bush on cylinder head.
Inner diameter:
29.994—30.016 mm (1.1809—1.1817 in)
CAUTION:
If difference between outer diameter of valve lash
adjuster and inner diameter of bush is over the limit,
replace cylinder head.
Standard:
0.019—0.057 mm (0.0007—0.0022 in)
Limit:
0.100 mm (0.0039 in)
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2-3bSERVICE PROCEDURE
4. Cylinder Head

D: ASSEMBLY
G2M0768
G2M0759
1) Installation of valve spring and valve
(1) Coat stem of each valve with engine oil and insert
valve into valve guide.
CAUTION:
When inserting valve into valve guide, use special care
not to damage the oil seal lip.
(2) Set cylinder head on ST1.
(3) Install valve spring and retainer using ST2.
ST1 498267600 CYLINDER HEAD TABLE
ST2 499718000 VALVE SPRING REMOVER
CAUTION:
Be sure to install the valve springs with their close-
coiled end facing the seat on the cylinder head.
(4) Compress valve spring and fit valve spring retainer
key.
(5) After installing, tap valve spring retainers lightly
with wooden hammer for better seating.
2) Install hydraulic lash adjuster.
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2-3bSERVICE PROCEDURE
4. Cylinder Head