specifications SUBARU LEGACY 1997 Service Owner's Manual

1. Engine
A: SPECIFICATIONS
EngineModel2200 cc
TypeHorizontally opposed, liquid cooled, 4-cylinder, 4-stroke
gasoline engine
Valve arrangement Belt driven, single over-head camshaft, 4-valve/cylinder
Bore x Stroke mm (in) 96.9 x 75.0 (3.815 x 2.953)
Displacement cm
3(cu in) 2,212 (135.0)
Compression ratio9.7
Compression pressure
(at 200 — 300 rpm) kPa (kg/cm
2, psi)1,079 — 1,275
(11.0 — 13.0, 156 — 185)
Number of piston rings Pressure ring: 2, Oil ring: 1
Intake valve timingOpening 4° BTDC
Closing 52° ABDC
Exhaust valve timingOpening 48° BBDC
Closing 12° ATDC
Valve clearanceIntake mm (in) 0.20±0.02 (0.0079±0.0008)
Exhaust mm (in) 0.25±0.02 (0.0098±0.0008)
Idling speed
[At neutral position on MT, or
“P” or “N” position on AT] rpm700±100 (No load)
850±50 (A/C switch ON)
Firing order1,3,2,4
Ignition timing BTDC/rpm 14°±8°/700 (MT), 20°±8°/700 (AT)
2
2-3SPECIFICATIONS AND SERVICE DATA
1. Engine

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)
Valve
rocker armClearance between shaft and armSTD 0.020—0.054 mm (0.0008—0.0021 in)
Limit 0.10 mm (0.0039 in)
CamshaftBend limit 0.025 mm (0.0010 in)
Thrust clearanceSTD 0.030—0.260 mm (0.0012—0.0102 in)
Limit 0.35 mm (0.0138 in)
Cam lobe heightIntakeSTD 32.244—32.344 mm (1.2694—1.2734 in)
Limit 32.094 mm (1.2635 in)
ExhaustSTD 31.964—32.064 mm (1.2584—1.2624 in)
Limit 31.814 mm (1.2525 in)
Camshaft journal O.D. RHFront
LHRear 31.935—31.950 mm (1.2573—1.2579 in)
Center Center 37.435—37.450 mm (1.4738—1.4744 in)
Rear Front 37.935—37.950 mm (1.4935—1.4941 in)
Camshaft journal hole
I.D.RHFront
LHRear 32.005—32.025 mm (1.2600—1.2608 in)
Center Center 37.505—37.525 mm (1.4766—1.4774 in)
Rear Front 38.005—38.025 mm (1.4963—1.4970 in)
Oil clearanceSTD 0.055—0.090 mm (0.0022—0.0035 in)
Limit 0.10 mm (0.0039 in)
Cylinder
headSurface warpage limit 0.05 mm (0.0020 in)
Surface grinding limit 0.1 mm (0.004 in)
Standard height 98.3 mm (3.870 in)
Valve setRefacing angle 90°
Contacting widthIntakeSTD 0.7 mm (0.028 in)
Limit 1.4 mm (0.055 in)
ExhaustSTD 1.4 mm (0.055 in)
Limit 1.8 mm (0.071 in)
Valve
guideInner diameter 6.000—6.012 mm (0.2362—0.2367 in)
Protrusion above head 17.5—18.0 mm (0.689—0.709 in)
ValveHead edge thicknessIntakeSTD 1.0 mm (0.039 in)
Limit 0.8 mm (0.031 in)
ExhaustSTD 1.2 mm (0.047 in)
Limit 0.8 mm (0.031 in)
Stem diameterIntake 5.950—5.965 mm (0.2343—0.2348 in)
Exhaust 5.945—5.960 mm (0.2341—0.2346 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 101.0 mm (3.976 in)
Exhaust 101.2 mm (3.984 in)
STD: Standard I.D.: Inner Diameter O.D.: Outer Diameter
3
2-3SPECIFICATIONS AND SERVICE DATA
1. Engine

Valve springFree length 44.05 mm (1.7342 in)
Squareness 2.5°, 1.9 mm (0.075 in)
Tension/spring height174.6—200.1 N
(17.8—20.4 kg, 39.2—45.0 lb)/36.0 mm (1.417 in)
405.0—458.0 N
(41.3—46.7 kg, 91.1—103.0 lb)/28.2 mm (1.110 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 96.905—96.915 mm (3.8151—3.8155 in)
B 96.895—96.905 mm (3.8148—3.8151 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 96.885—96.895 mm (3.8144—3.8148 in)
B 96.875—96.885 mm (3.8140—3.8144 in)
0.25 mm (0.0098 in)
OS97.115—97.145 mm (3.8234—3.8246 in)
0.50 mm (0.0197 in)
OS97.365—97.395 mm (3.8333—3.8344 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 0.20—0.50 mm (0.0079—0.0197 in)
Limit 1.0 mm (0.039 in)
Oil ringSTD 0.20—0.70 mm (0.0079—0.0276 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 0.015—0.045 mm (0.0006—0.0018 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
2-3SPECIFICATIONS AND SERVICE DATA
1. Engine

CrankshaftBend limit 0.035 mm (0.0014 in)
Crank pin and crank journalOut-of-roundness 0.030 mm (0.0012 in) or less
Grinding limit 0.25 mm (0.0098 in)
Crank pin outer diameterSTD 51.984—52.000 mm (2.0466—2.0472 in)
0.03 mm
(0.0012 in)
US51.954—51.970 mm (2.0454—2.0461 in)
0.05 mm
(0.0020 in)
US51.934—51.950 mm (2.0446—2.0453 in)
0.25 mm
(0.0098 in)
US51.734—51.750 mm (2.0368—2.0374 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)
US59.934—59.950 mm (2.3596—2.3602 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)
US59.954—59.970 mm (2.3604—2.3610 in)
0.05 mm
(0.0020 in)
US59.934—59.950 mm (2.3596—2.3602 in)
0.25 mm
(0.0098 in)
US59.734—59.750 mm (2.3517—2.3524 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 0.035 mm (0.0014 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
2-3SPECIFICATIONS AND SERVICE DATA
1. Engine

B2M0108A
3) Measure the extension of rod beyond the body. If it is
not within specifications, replace with a new one.
Rod extension: H
15.4 — 16.4 mm (0.606 — 0.646 in)
3. BELT TENSIONER
1) Check mating surfaces of timing belt and contact point
of tension adjuster rod for abnormal wear or scratches.
Replace belt tensioner if faulty.
2) Check spacer and tensioner bushing for wear.
3) Check tensioner for smooth rotation. Replace if noise or
excessive play is noted.
4) Check tensioner for grease leakage.
4. BELT IDLER
1) Check idler for smooth rotation. Replace if noise or
excessive play is noted.
2) Check outer contacting surfaces of idler pulley for
abnormal wear and scratches.
3) Check idler for grease leakage.
5. SPROCKET
1) Check sprocket teeth for abnormal wear and scratches.
2) Make sure there is no free play between sprocket and
key.
3) Check crankshaft sprocket notch for sensor for damage
and contamination of foreign matter.
21
2-3SERVICE PROCEDURE
3. Timing Belt

B2M0072
B2M0073
2. VALVE ROCKER ARM
1) Measure inside diameter of valve rocker arm and out-
side diameter of valve rocker shaft, and determine the dif-
ference between the two (= oil clearance).
Clearance between arm and shaft:
Standard
0.020—0.054 mm (0.0008—0.0021 in)
Limit
0.10 mm (0.0039 in)
If oil clearance exceeds specifications, replace valve
rocker arm or shaft.
NOTE:
Replace valve rocker arm or shaft, whichever shows
greater amount of wear.
Rocker arm inside diameter:
22.020—22.041 mm (0.8669—0.8678 in)
Rocker shaft diameter:
21.987—22.000 mm (0.8656—0.8661 in)
2) Measure inside diameter of rocker shaft support and
outside diameter of valve rocker shaft, and determine the
difference between the two (= oil clearance).
Clearance between support and shaft:
Standard
0.005—0.039 mm (0.0002—0.0015 in)
Limit
0.05 mm (0.0020 in)
If oil clearance exceeds specifications, replace rocker shaft
support or shaft.
NOTE:
Replace rocker shaft support or shaft, whichever shows
greater amount of wear.
Rocker shaft support inside diameter:
22.005—22.026 mm (0.8663—0.8672 in)
Rocker shaft diameter:
21.987—22.000 mm (0.8656—0.8661 in)
3) If cam or valve contact surface of valve rocker arm is
worn or dented excessively, replace valve rocker arm.
4) Check that valve rocker arm roller rotates smoothly. If
not, replace valve rocker arm.
3. VALVE ROCKER SHAFT
Visually check oil relief valve of shaft end for any of the
following abnormalities.
Breaks in check ball body
Foreign particles caught in valve spring
Oil leakage at check ball
CAUTION:
Repair or replace valve rocker shaft as necessary.
30
2-3SERVICE PROCEDURE
4. Valve Rocker Assembly

3. CAMSHAFT RH
B2M0385A
1) Remove camshaft support RH.
2) Remove O-ring.
3) Remove camshaft.
4) Remove oil seal.
CAUTION:
Do not remove oil seal unless necessary.
Do not scratch journal surface when removing oil
seal.
G2M0137
B: INSPECTION
1. CAMSHAFT
1) Measure the bend, and repair or replace if necessary.
Limit:
0.025 mm (0.0010 in)
2) Check journal for damage and wear. Replace if faulty.
3) Measure outside diameter of camshaft journal and
inside diameter of cylinder head journal, and determine the
difference between the two (= oil clearance). If oil clear-
ance exceeds specifications, replace camshaft or cylinder
head as necessary.
34
2-3SERVICE PROCEDURE
5. Camshaft

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
1.0 mm (0.039 in)
Limit
0.8 mm (0.031 in)
Exhaust
Standard
1.2 mm (0.047 in)
Limit
0.8 mm (0.031 in)
Valve overall length:
Intake
101.0 mm (3.976 in)
Exhaust
101.2 mm (3.984 in)
2) Put a small amount of grinding compound on the seat
surface and lap the valve and seat surface. Also refer to 2.
VALVE SEAT 2-3 [W6C2] at this time. 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.
Free length 44.05 mm (1.7342 in)
Squareness 2.5°, 1.9 mm (0.075 in)
Tension/spring height174.6—200.1 N
(17.8—20.4 kg, 39.2—45.0 lb)/ 36.0 mm
(1.417 in)
405.0—458.0 N
(41.3—46.7 kg, 91.1—103.0 lb)/
28.2 mm (1.110 in)
44
2-3SERVICE PROCEDURE
6. Cylinder Head

G2M0178
2) Measure the crankshaft bend, and correct or replace if
it exceeds the limit.
CAUTION:
If a suitable V-block is not available, install #1 and #5
crankshaft bearing on cylinder block, position crank-
shaft on these bearings and measure crankshaft bend
using a dial gauge.
Crankshaft bend limit:
0.035 mm (0.0014 in)
G2M0179
3) Inspect the crank journal and crank pin for wear. If not
to specifications, replace bearing with an undersize one,
and replace or recondition crankshaft as necessary. When
grinding crank journal or crank pin, finish them to the speci-
fied dimensions according to the undersize bearing to be
used.
Crank pin and crank journal:
Out-of-roundness
0.030 mm (0.0012 in) or less
Taper limit
0.07 mm (0.0028 in)
Grinding limit
0.25 mm (0.0098 in)
Unit: mm (in)
Crank journal diameter
Crank pin diameter
#1, #5 #2, #3, #4
StandardJournal O.D.59.992—60.008
(2.3619—2.3625)59.992—60.008
(2.3619—2.3625)51.984—52.000
(2.0466—2.0472)
Bearing size
(Thickness at
center)1.998—2.011
(0.0787—0.0792)2.000—2.013
(0.0787—0.0793)1.492—1.501
(0.0587—0.0591)
0.03 (0.0012)
undersizeJournal O.D.59.962—59.978
(2.3607—2.3613)59.954—59.970
(2.3604—2.3610)51.954—51.970
(2.0454—2.0461)
Bearing size
(Thickness at
center)2.017—2.020
(0.0794—0.0795)2.019—2.022
(0.0795—0.0796)1.510—1.513
(0.0594—0.0596)
0.05 (0.0020)
undersizeJournal O.D.59.934—59.950
(2.3596—2.3602)59.934—59.950
(2.3596—2.3602)51.934—51.950
(2.0446—2.0453)
Bearing size
(Thickness at
center)2.027—2.030
(0.0798—0.0799)2.029—2.032
(0.0799—0.0800)1.520—1.523
(0.0598—0.0600)
0.25 (0.0098)
undersizeJournal O.D.59.742—59.758
(2.3520—2.3527)59.734—59.750
(2.3517—2.3524)51.734—51.750
(2.0368—2.0374)
Bearing size
(Thickness at
center)2.127—2.130
(0.0837—0.0839)2.129—2.132
(0.0838—0.0839)1.620—1.623
(0.0638—0.0639)
O.D. ... Outer Diameter
63
2-3SERVICE PROCEDURE
7. Cylinder Block

1. Engine
A: SPECIFICATIONS
EngineModel2500 cc
TypeHorizontally opposed, liquid cooled, 4-cylinder, 4-stroke
gasoline engine
Valve arrangement Belt driven, double over-head camshaft, 4-valve/cylinder
Bore x Stroke mm (in) 99.5 x 79.0 (3.917 x 3.110)
Displacement cm
3(cu in) 2,457 (149.93)
Compression ratio9.5
Compression pressure
(at 200 — 300 rpm)
kPa (kg/cm
2, psi) rpmStandard 1,216 (12.4, 176) 350
Limit 941 (9.6, 137) 350
Number of piston rings Pressure ring: 2, Oil ring: 1
Intake valve timingOpening 6° BTDC
Closing 50° ABDC
Exhaust valve timingOpening Front: 54° BBDC, Rear: 30° BBDC (Position in degrees)
Closing Front: 10° ATDC, Rear: 10° ATDC (Position in degrees)
Valve clearanceIntake mm (in) 0.20±0.02 (0.0079±0.0008)
Exhaust mm (in) 0.25±0.02 (0.0098±0.0008)
Idling speed
[At neutral position on MT, or
“P” or “N” position on AT] rpm700±100 (No load)
850±50 (A/C switch ON)
Firing order1,3,2,4
Ignition timing BTDC/rpm 15°±8°/700 rpm
2
2-3bSPECIFICATIONS AND SERVICE DATA
1. Engine