SUBARU LEGACY 1999 Service Repair Manual

(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 surface of ST2.
ST1 499767200 VALVE GUIDE REMOVER
ST2 498267700 VALVE GUIDE ADJUSTER
B2M1398A
(6) Check the valve guide protrusion.
Valve guide protrusion: L
12.0 Ð 12.4 mm (0.472 Ð 0.488 in)
(7) Ream the inside of valve guide with ST.
Gently rotate the reamer clockwise while press-
ing 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:
IApply engine oil to the reamer when ream-
ing.
IIf the inner surface of the valve guide is torn,
the edge of the reamer should be slightly
ground with an oil stone.
IIf the inner surface of the valve guide
becomes lustrous 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.
4. INTAKE AND EXHAUST VALVE
1) Inspect the flange and stem of valve, and
replace if damaged, worn, or deformed, or if ªHº 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
105.9 mm (4.169 in)
Exhaust
106.2 mm (4.181 in)
G2M0153
2) Put a small amount of grinding compound on
the seat surface and lap the valve and seat sur-
face. Install a new intake valve oil seal after lap-
ping.
40
2-3b[W4C4]SERVICE PROCEDURE
4. Cylinder Head

5. VALVE SPRINGS
1) Check valve springs for damage, free length,
and tension. Replace valve spring if it is not to the
specifications presented in the table.
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 Ð 261.8 N
(23.3 Ð 26.7 kg, 51.4 Ð 58.9
lb)/31.0 mm (1.220 in)
462.9 Ð 531.5 N
(47.2 Ð 54.2 kg, 104.1 Ð 119.5
lb)/23.2 mm (0.913 in)
Squareness 2.5É, 1.7 mm (0.067 in)
G2M0154
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 indi-
cated in the figure by using ST2.
ST1 498267600 CYLINDER HEAD TABLE
ST2 498857100 VALVE OIL SEAL GUIDE
CAUTION:
IApply engine oil to oil seal before force-fit-
ting.
IDifferentiate between intake valve oil seal
and exhaust valve oil seal by noting their dif-
ference in color.
Color of rubber part:
Intake [Black]
Exhaust [Brown]
Color of spring part:
Intake [Silver]
Exhaust [Silver]
B2M1399A
7. VALVE LIFTER
1) Check valve lifter visually.
2) Measure outer diameter of valve lifter.
Outer diameter:
32.959 Ð 32.975 mm (1.2976 Ð 1.2982 in)
B2M1222
41
[W4C7]2-3bSERVICE PROCEDURE
4. Cylinder Head

3) Measure inner diameter of valve lifter mating
part on cylinder head.
Inner diameter:
32.994 Ð 33.016 mm (1.2990 Ð 1.2998 in)
B2M1400
CAUTION:
If difference between outer diameter of valve
lifter and inner diameter of valve lifter mating
part is over the limit, replace cylinder head.
Standard:
0.019 Ð 0.057 mm (0.0007 Ð 0.0022 in)
Limit:
0.100 mm (0.0039 in)
D: ASSEMBLY
S2M0420A
(1) Valve shim
(2) Valve lifter
(3) Valve retainer key(4) Valve retainer
(5) Valve spring
(6) Valve oil seal(7) Valve spring seat
(8) Intake valve
(9) Exhaust valve
42
2-3b[W4D0]SERVICE PROCEDURE
4. Cylinder Head

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 spe-
cial 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.
B2M1221A
(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 valve lifter and valve shim.
43
[W4D0]2-3bSERVICE PROCEDURE
4. Cylinder Head

E: INSTALLATION
1. CYLINDER HEAD
S2M0421B
(1) Bolt
(2) Cylinder head bolt(3) Cylinder head
(4) Cylinder head gasket
1) Install cylinder head and gaskets on cylinder
block.
CAUTION:
Use new cylinder head gaskets.
2) Tighten cylinder head bolts.
(1) Apply a coat of engine oil to washers and
bolt threads.
(2) Tighten all bolts to 29 N´m (3.0 kg-m, 22
ft-lb) in alphabetical sequence.
Then tighten all bolts to 69 N´m (7.0 kg-m, 51
ft-lb) in alphabetical sequence.
(3) Back off all bolts by 180É first; back them off
by 180É again.(4) Tighten bolts (A) and (B) to 34 N´m (3.5
kg-m, 25 ft-lb).
B2M1397D
44
2-3b[W4E1]SERVICE PROCEDURE
4. Cylinder Head

(5) Tighten bolts (C), (D), (E) and (F) to 15 N´m
(1.5 kg-m, 11 ft-lb).
B2M1397D
(6) Tighten all bolts by 80 to 90É in alphabetical
sequence.
CAUTION:
Do not tighten bolts more than 90É.
(7) Further tighten all bolts by 80 to 90É in
alphabetical sequence.
CAUTION:
Ensure that the total ªre-tightening angleº [in
the two previous steps] do not exceed 180É.
3) Install oil level gauge guide attaching bolt (LH
side only).
45
[W4E1]2-3bSERVICE PROCEDURE
4. Cylinder Head

2. RELATED PARTS
1) Install camshafts, rocker cover and related parts.
<Ref. to 2-3b [W3C1].>
S2M0298C
(1) Intake camshaft (LH)
(2) Exhaust camshaft (LH)
(3) Intake camshaft cap (LH)
(4) Exhasut camshaft cap (LH)
(5) Rocker cover gasket (LH)(6) Rocker cover (LH)
(7) Spark plug cordTightening torque: N´m (kg-m, ft-lb)
T1:
4.9±0.5 (0.5±0.05, 3.6±0.4)
T2:10±0.7 (1.0±0.07, 7.2±0.5)
T3:20±2 (2.0±0.2, 14.5±1.4)
2) Similarly, install parts on right-hand side.
46
2-3b[W4E2]SERVICE PROCEDURE
4. Cylinder Head

3) Install camshaft sprockets, timing belt and related parts.
<Ref. to 2-3b [W2C1].>
S2M0303
4) Install intake manifold.
CAUTION:
Use new gaskets.
G2M0774
5) Install camshaft position sensor. Use dry com-
pressed air to remove foreign particles before
installing sensor.
6) Connect each connector and/or install connec-
tor bracket.
7) Connect hoses and tubes to cylinder block.
8) Install brackets, generator and air conditioner
compressor.
9) Install V-belt.
47
[W4E2]2-3bSERVICE PROCEDURE
4. Cylinder Head

5. Cylinder Block
A: REMOVAL
1. RELATED PARTS
1) Remove timing belt, camshaft sprockets and related parts.
<Ref. to 2-3b [W2A0].>
S2M0303
48
2-3b[W5A1]SERVICE PROCEDURE
5. Cylinder Block

2) Remove rocker cover, camshafts and related parts. <Ref. to 2-3b [W3A0].>
S2M0298
3) Remove cylinder heads. <Ref. to 2-3b [W4A0].>
S2M0421
49
[W5A1]2-3bSERVICE PROCEDURE
5. Cylinder Block