engine SUBARU LEGACY 1996 Service Repair Manual

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

E: INSTALLATION
1. CYLINDER HEAD
B2M0771A
1) Install cylinder head and gaskets on cylinder block.
CAUTION:
Use new cylinder head gaskets.
G2M0771
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
numerical sequence.
Then tighten all bolts to 69 N⋅m (7.0 kg-m, 51 ft-lb) in
numerical sequence.
(3) Back off all bolts by 180°first; back them off by 180°
again.
(4) Tighten bolts

1and
2to 34 N⋅m (3.5 kg-m, 25 ft-
lb).
(5) Tighten bolts

3,
4,
5and
6to 15 N⋅m (1.5 kg-m,
11 ft-lb).
(6) Tighten all bolts by 80 to 90°in numerical
sequence.
CAUTION:
Do not tighten bolts more than 90°.
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2-3bSERVICE PROCEDURE
4. Cylinder Head

2) Install camshaft sprockets, timing belt and related parts.

B2M0702
B2M0703
3) Install engine coolant pipe.
CAUTION:
Use new gaskets.
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2-3bSERVICE PROCEDURE
4. Cylinder Head

2. OIL PUMP AND ENGINE COOLANT PUMP
B2M0705A
1) Remove housing cover.
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2-3bSERVICE PROCEDURE
5. Cylinder Block

B2M0706A
2) Remove drive plate.
To lock crankshaft use ST.
ST 498497100 CRANKSHAFT STOPPER
3) Remove oil separator cover.
4) Remove engine coolant pipe.
5) Remove engine coolant pump.
G2M0162
6) Remove oil pump from cylinder block.
Use a flat-bladed screwdriver as shown in Figure when
removing oil pump.
CAUTION:
Be careful not to scratch the mating surface of cylin-
der block and oil pump.
G2M0163
7) Removal of oil pan
(1) Turn cylinder block with #2 and #4 piston sides
facing upward.
(2) Remove bolts which secure oil pan to cylinder
block.
(3) Insert a oil pan cutter blade between cylinder block-
to-oil pan clearance and remove oil pan.
CAUTION:
Do not use a screwdriver or similar tool in place of oil-
pan cutter.
8) Remove oil strainer stay.
9) Remove oil strainer.
10) Remove baffle plate.
11) Remove oil filter.
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2-3bSERVICE PROCEDURE
5. Cylinder Block

B2M0087A
2. CYLINDER BLOCK
1) Install ST to cylinder block, then install crankshaft bear-
ings.
ST 499817000 ENGINE STAND
CAUTION:
Remove oil the mating surface of bearing and cylinder
block before installation. Also apply a coat of engine
oil to crankshaft pins.
2) Position crankshaft on the #2 and #4 cylinder block.
Tightening torque:
T1: 25±2 N⋅m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
T2: 47±3 N⋅m (4.8±0.3 kg-m, 34.7±2.2 ft-lb)
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2-3bSERVICE PROCEDURE
5. Cylinder Block

3. PISTON AND PISTON PIN (#1 AND #2)
B2M0128A
Tightening torque: N⋅m (kg-m, ft-lb)
T: 69±7 (7.0±0.7, 50.6±5.1)
G2M0188
1) Installing piston
(1) Turn cylinder block so that #1 and #2 cylinders face
upward.
(2) Using ST1, turn crankshaft so that #1 and #2 con-
necting rods are set at bottom dead center.
ST1 499987500 CRANKSHAFT SOCKET
(3) Apply a coat of engine oil to pistons and cylinders
and insert pistons in their cylinders by using ST2.
ST2 498747300 PISTON GUIDE
G2M0189
2) Installing piston pin
(1) Insert ST3 into service hole to align piston pin hole
with connecting rod small end.
CAUTION:
Apply a coat of engine oil to ST3 before insertion.
ST3 499017100 PISTON PIN GUIDE
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2-3bSERVICE PROCEDURE
5. Cylinder Block

(2) Apply a coat of engine oil to piston pin and insert
piston pin into piston and connecting rod through ser-
vice hole.
G2M0190
(3) Install circlip.
CAUTION:
Use new circlips.
(4) Install service hole plug and gasket.
CAUTION:
Use a new gasket and apply a coat of fluid packing to
it before installation.
Fluid packing:
THREE BOND 1215 or equivalent
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2-3bSERVICE PROCEDURE
5. Cylinder Block

E: INSTALLATION
1. OIL PUMP AND ENGINE COOLANT PUMP
B2M0705B
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: 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)
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2-3bSERVICE PROCEDURE
5. Cylinder Block