remove SUBARU LEGACY 1997 Service Service Manual

7. Valve Clearance
A: INSPECTION
1. 2200 cc MODEL
CAUTION:
Inspection and adjustment of valve clearance should
be performed while engine is cold.
1) Set the vehicle onto the lift.
2) Disconnect battery ground cable.
3) Remove timing belt cover (RH).
B2M1225A
4) Remove rocker cover.

When inspecting #1 and #3 cylinders;
(1) Disconnect connector from mass air flow sensor.
B2M1226A
(2) Loosen clamp which connects air intake duct to air
intake chamber.
(3) Remove the two clips from air cleaner upper cover.
CAUTION:
Before installing air cleaner upper cover, align hole(s)
with protruding portions of air cleaner lower case, then
secure upper cover.
(4) Disconnect blow-by hose from air intake duct.
B2M1227
(5) Remove air intake duct and air cleaner upper cover
as a unit.
(6) Remove air cleaner element.
(7) Disconnect spark plug cords from spark plugs (#1
and #3 cylinders).
(8) Remove under cover (RH).
(9) Place suitable container under the vehicle.
(10) Disconnect PCV hose from rocker cover (RH).
(11) Remove bolts, then remove rocker cover (RH).
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7. Valve Clearance

When inspecting #2 and #4 cylinders;
(1) Disconnect battery cables, and then remove bat-
tery and battery carrier.
(2) Disconnect washer motor connectors.
(3) Disconnect rear window glass washer hose from
washer motor, then plug connection with a suitable cap.
(4) Remove the two bolts which holds washer tank,
then secure the tank away from working area.
(5) Disconnect spark plug cords from spark plugs (#2
and #4 cylinders).
(6) Remove under cover (LH).
(7) Place suitable container under the vehicle.
(8) Disconnect PCV hose from rocker cover (LH).
(9) Remove bolts, then remove rocker cover (LH).
B2M1228A
5) Set #1 cylinder piston to top dead center of compres-
sion stroke by rotating crankshaft pulley clockwise.
NOTE:
When arrow mark on camshaft sprocket (RH) comes
exactly to the top, #1 cylinder piston is brought to the top
dead center of compression stroke.
B2M1229A
6) Measure #1 cylinder valve clearance by using thickness
gauge.
CAUTION:

Insert the thickness gauge in as horizontal a direc-
tion as possible with respect to the valve stem end
face.

Measure exhaust valve clearances while lifting-up
the vehicle.
Valve clearance:
Intake: 0.20±0.02 mm (0.0079±0.0008 in)
Exhaust: 0.25±0.02 mm (0.0098±0.0008 in)
7) If necessary, adjust the valve clearance. [07B1].>
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7. Valve Clearance

B2M1230A
8) Similar to measurement procedures used for #1
cylinder, measure #2, #3 and #4 cylinder valve clearances.
NOTE:

Be sure to set cylinder pistons to their respective top
dead centers on compression stroke before measuring
valve clearances.

To set #3, #2 and #4 cylinder pistons to their top dead
centers on compression stroke, turn crankshaft pulley
clockwise 90°at a time starting with arrow mark on right-
hand camshaft sprocket facing up.
9) After inspection, install the related parts in the reverse
order of removal.
2. 2500 cc MODEL
CAUTION:
Inspection and adjustment of valve clearance should
be performed while engine is cold.
1) Set the vehicle onto the lift.
2) Disconnect battery ground cable.
3) Remove canister.
4) Remove one bolt which secures timing belt cover (RH).
5) Lift-up the vehicle.
6) Remove under cover (RH).
7) Remove canister bracket.
8) Loosen remaining bolts which secure timing belt cover
(RH), then remove belt cover.
9) Lower the vehicle.
B2M1225A
10) Remove rocker cover.

When inspecting #1 and #3 cylinders;
(1) Disconnect connector from mass air flow sensor.
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7. Valve Clearance

B2M1226A
(2) Loosen clamp which connects air intake duct to air
intake chamber.
(3) Remove the two clips from air cleaner upper cover.
CAUTION:
Before installing air cleaner upper cover, align hole(s)
with protruding portions of air cleaner lower case, then
secure upper cover.
(4) Disconnect blow-by hose from air intake duct.
B2M1227
(5) Remove air intake duct and air cleaner upper cover
as a unit.
(6) Remove air cleaner element.
B2M1232A
(7) Remove air cleaner lower case.
(8) Disconnect spark plug cords from spark plugs (#1
and #3 cylinders).
(9) Place suitable container under the vehicle.
(10) Disconnect PCV hose from rocker cover (RH).
(11) Remove bolts, then remove rocker cover (RH).

When inspecting # 2 and #4 cylinders;
(1) Disconnect battery cables, and then remove bat-
tery and battery carrier.
(2) Disconnect washer motor connectors.
(3) Disconnect washer hoses from washer motors,
then plug connections with suitable caps.
(4) Remove washer tank.
(5) Disconnect spark plug cords from spark plugs (#2
and #4 cylinders).
(6) Remove under cover (LH).
(7) Place suitable container under the vehicle.
(8) Disconnect PCV hose from rocker cover (LH).
(9) Remove bolts, then remove rocker cover (LH).
12
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7. Valve Clearance

B2M1230A
6) Similar to adjustment procedures used for #1 cylinder,
adjust #2, #3 and #4 cylinder valve clearances.
NOTE:

Be sure to set cylinder pistons to their respective top
dead centers on compression stroke before adjusting valve
clearances.

To set #3, #2 and #4 cylinder pistons to their top dead
centers on compression stroke, turn crankshaft pulley
clockwise 90°at a time starting with arrow mark on right-
hand camshaft sprocket facing up.
B2M1234A
2. 2500 cc MODEL
CAUTION:
Adjustment of valve clearance should be performed
while engine is cold.
1) Measure all valve clearances.
NOTE:
Record each valve clearance after it has been measured.
2) Remove timing belt, camshaft sprockets, and related
parts.
3) Remove camshaft.
B2M1240A
4) Remove shim from valve lifter.
5) Measure thickness of shim with micrometer.
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7. Valve Clearance

G2M0106
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.
2. Hydraulic Lash Adjuster
A: INSPECTION
1) Disconnect blow-by hose from rocker cover.
2) Remove spark plug cap.
B2M0413A
3) Remove left and right rocker covers.
CAUTION:
Before removing left rocker cover, disconnect battery
cables and generator cable.
11
2-3SERVICE PROCEDURE
1. General Precautions - 2. Hydraulic Lash Adjuster

G2M0106
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.
2. Hydraulic Lash Adjuster
A: INSPECTION
1) Disconnect blow-by hose from rocker cover.
2) Remove spark plug cap.
B2M0413A
3) Remove left and right rocker covers.
CAUTION:
Before removing left rocker cover, disconnect battery
cables and generator cable.
11
2-3SERVICE PROCEDURE
1. General Precautions - 2. Hydraulic Lash Adjuster

G2M0198
4) Manually push valve rocker (at lash adjuster location) to
check that there is no air in it.
NOTE:
When air is in lash adjuster, valve rocker moves when
pushed with fingers.
G2M0199
5) If air is in lash adjuster, remove valve rocker assembly
from engine and bleed air completely.
B2M0382A
B: AIR BLEEDING
1) Remove valve rocker assembly.
(1) Remove bolts

1through
4in numerical
sequence.
CAUTION:
Leave two or three threads of bolt

1engaged to retain
valve rocker assembly.
(2) Equally loosen bolts

5through
8all the way,
being careful that knock pin is not gouged.
2) Manually remove lash adjusters where air is trapped.
CAUTION:
If lash adjuster is difficult to remove manually, use pli-
ers. Be careful not to scratch lash adjuster.
12
2-3SERVICE PROCEDURE
2. Hydraulic Lash Adjuster

G2M0131
3) Bleed air from hydraulic lash adjuster as described
below:
(1) While dipping hydraulic lash adjuster in engine oil,
as shown in Figure, push check ball in usinga2mm
(0.08 in) diameter round bar.
(2) With check ball pushed in, manually move plunger
up and down at one second intervals until air bubbles
disappear.
(3) After air bubbles disappear, remove round bar and
quickly push plunger in to ensure it is locked. If plunger
does not lock properly, replace hydraulic lash adjuster.
CAUTION:
Leave hydraulic lash adjuster (after air is bled) in
engine oil until it is ready for installation.
G2M0200
4) Using ST;
(1) Insert lash adjuster into ST, and fill ST with engine
oil. Usinga2mm(0.08 in) diameter rod, push check
ball in.
ST 499597000 OIL SEAL GUIDE
(2) With check ball pushed in, push plunger at an inter-
val of one second.
(3) Move plunger up and down until air bubbles are no
longer emitted from lash adjuster.
NOTE:
Hold hydraulic lash adjusters vertically during air bleeding.
5) Remove the rod. Push plunger to ensure that air is
completely bled out.
CAUTION:
If plunger does not properly lock (when pushed),
replace lash adjuster with a new one.
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2-3SERVICE PROCEDURE
2. Hydraulic Lash Adjuster

3. Timing Belt
A: REMOVAL
1. CRANKSHAFT PULLEY AND BELT COVER
G2M0107
G2M0108
1) Remove V-belt and A/C belt tensioner.
2) Remove pulley bolt. To lock crankshaft use ST.
ST 499977000 CRANKSHAFT PULLEY WRENCH
3) Remove crankshaft pulley.
4) Remove left side belt cover.
5) Remove right side belt cover.
6) Remove front belt cover.
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2-3SERVICE PROCEDURE
3. Timing Belt