SUBARU LEGACY 1999 Service Owners Manual

(4) Tighten bolts (a) through (h) in alphabetical
sequence.
Tightening torque:
25
±2 N´m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
B2M2621B
(5) Tighten TORX bolts (i) through (n) in alpha-
betical sequence using ST.
ST 499497000 TORX PLUS
Tightening torque:
18
±2 N´m (1.8±0.2 kg-m, 13.0±1.4 ft-lb)
B2M2621C
(6) Tighten bolts (o) through (v) in alphabetical
sequence.
Tightening torque:
10
±2 N´m (1.0±0.2 kg-m, 7.2±1.4 ft-lb)
B2M2621D
(7) Tighten bolts (w) through (x) in alphabetical
sequence.
Tightening torque:
10
±2 N´m (1.0±0.2 kg-m, 7.2±1.4 ft-lb)
B2M2621E
3) Apply a coat of grease to oil seal lips and install
oil seal (A) on camshaft using ST1 and ST2.
CAUTION:
Use a new oil seal.
ST1 499597000 OIL SEAL GUIDE
ST2 499587500 OIL SEAL INSTALLER
B2M2622A
4) Install plug using ST.
ST 499587100 OIL SEAL INSTALLER
5) Install oil level gauge guide.
6) Install camshaft position sensor support.
37
[W4C1]2-3aSERVICE PROCEDURE
4. Camshaft

2. CAMSHAFT (RH)
B2M2614A
(1) Camshaft support (RH)
(2) O-ring(3) Camshaft (RH)
(4) Oil seal(5) Plug
1) Apply a coat of engine oil to camshaft journals
and install camshaft (RH).
2) Install camshaft cap.
(1) Apply liquid gasket on the around of cam-
shaft cap.
Liquid gasket:
THREE BOND 1280B (Part No.
0029431130)
B2M2619
(2) Temporarily tighten bolts (g) through (j) in
alphabetical sequence.
B2M2612A
(3) Install valve rocker assembly.

B2M2615
38
2-3a[W4C2]SERVICE PROCEDURE
4. Camshaft

(4) Tighten bolts (a) through (h) in alphabetical
sequence.
Tightening torque:
25
±2 N´m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
B2M2621B
(5) Tighten TORX bolts (i) through (n) in alpha-
betical sequence using ST.
ST 499427000 TORX PLUS
Tightening torque:
18
±2 N´m (1.8±0.2 kg-m, 13.0±1.4 ft-lb)
B2M2621C
(6) Tighten bolts (o) through (v) in alphabetical
sequence.
Tightening torque:
10
±2 N´m (1.0±0.2 kg-m, 7.2±1.4 ft-lb)
B2M2621D
(7) Tighten bolts (o) through (p) in alphabetical
sequence.
Tightening torque:
10
±2 N´m (1.0±0.2 kg-m, 7.2±1.4 ft-lb)
B2M2621E
3) Apply a coat of grease to oil seal lips and install
oil seal (A) on camshaft using ST1 and ST2.
CAUTION:
Use a new oil seal.
ST1 499597000 OIL SEAL GUIDE
ST2 499587500 OIL SEAL INSTALLER
B2M2623A
4) Install plug using ST.
ST 499587100 OIL SEAL INSTALLER
3. RELATED PARTS
Install timing belt, camshaft sprockets and related
parts.

39
[W4C3]2-3aSERVICE PROCEDURE
4. Camshaft

5. Cylinder Head
A: REMOVAL
1. RELATED PARTS
1) Release fuel pressure.
2) Drain engine coolant.
3) Remove V-belt(s).
4) Remove generator and bracket.
5) Remove A/C compressor and bracket. (With
A/C model)6) Disconnect spark plug cords.
7) Remove connector bracket attaching bolt.
8) Remove camshaft position sensor and cam-
shaft position sensor support.
9) Disconnect oil pressure switch connector.
10) Disconnect blow-by hose.
11) Remove intake manifold. [W4A0].>
2. CYLINDER HEAD
B2M2627A
(1) Rocker cover
(2) Cylinder head bolt(3) Cylinder head
(4) Cylinder head gasket
1) Remove timing belt, camshaft sprocket and
related parts.

2) Remove oil level gauge guide attaching bolt
(left hand only) and oil level gauge guide.
3) Remove rocker cover.
40
2-3a[W5A1]SERVICE PROCEDURE
5. Cylinder Head

4) Remove cylinder head bolts in alphabetical
sequence shown in figure.
CAUTION:
Leave bolts (a) and (c) engaged by three or four
threads to prevent cylinder head from falling.
B2M2628A
5) While tapping cylinder head with a plastic
hammer, separate it from cylinder block.
6) Remove bolts (a) and (b) to remove cylinder
head.
B2M2628A
7) Remove cylinder head gasket.
CAUTION:
Do not scratch the mating surface of cylinder
head and cylinder block.
8) Similarly, remove right side cylinder head.
41
[W5A2]2-3aSERVICE PROCEDURE
5. Cylinder Head

B: DISASSEMBLY
B2M2629A
(1) Valve rocker ASSY
(2) Camshaft cap
(3) Camshaft
(4) Oil seal
(5) Plug(6) Spark plug pipe gasket
(7) Retainer key
(8) Retainer
(9) Valve spring
(10) Oil seal(11) Valve spring seat
(12) Valve guide
(13) Valve
1) Remove valve rocker assembly, camshaft cap
and camshaft.
2) Remove oil seal.
3) Remove plug.
4) Place cylinder head on ST.
ST 498267800 CYLINDER HEAD TABLE5) Set ST on valve spring. Compress valve spring
and remove the valve spring retainer key. Remove
each valve and valve spring.
ST 499718000 VALVE SPRING REMOVER
CAUTION:
IMark each valve to prevent confusion.
IUse extreme care not to damage the lips of
the intake valve oil seals and exhaust valve oil
seals.
B2M2630A
42
2-3a[W5B0]SERVICE PROCEDURE
5. Cylinder Head

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 lead check.
Also make sure that gasket installing surface
shows no trace of gas and water leaks.
2) Place cylinder head on ST.
ST 498267800 CYLINDER HEAD TABLE
3) Measure the warping of the cylinder head sur-
face that mates with crankcase using a straight
edge and thickness 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:
97.5 mm (3.839 in)
CAUTION:
Uneven torque for the cylinder head bolts can
cause warping. When reassembling, pay spe-
cial attention to the torque so as to tighten
evenly.
G2M0148
2. VALVE SEAT
Inspect intake and exhaust valve seats, and cor-
rect 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 1.4 mm (0.055 in)
Limit 2.1 mm (0.083 in)
G2M0149
B2M0074
43
[W5C2]2-3aSERVICE PROCEDURE
5. Cylinder Head

3. VALVE GUIDE
1) Check the clearance between valve guide and
stem. The clearance can be checked by measur-
ing 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 Ð 0.062 mm (0.0014 Ð
0.0024 in)
Exhaust 0.040 Ð 0.067 mm (0.0016 Ð
0.0026 in)
Limit
0.15 mm (0.0059 in)
Valve guide inner diameter:
6.000 Ð 6.012 mm (0.2362 Ð 0.2367 in)
B2M0387A
Valve stem outer diameters:
Intake
5.945 Ð 5.960 mm (0.2341 Ð 0.2346 in)
Exhaust
5.950 Ð 5.965 mm (0.2343 Ð 0.2348 in)
B2M0076A
2) If the clearance between valve guide and stem
exceeds the specification, replace guide as fol-
lows:
(1) Place cylinder head on ST1 with the com-
bustion 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 498267800 CYLINDER HEAD TABLE
ST2 499767400 VALVE GUIDE REMOVER
G2M0150
(3) Turn cylinder head upside down and place
ST as shown in the figure.
Intake side:
ST 499767700 VALVE GUIDE ADJUSTER
Exhaust side:
ST 499767800 VALVE GUIDE ADJUSTER
B2M0077B
(4) Before installing new oversize valve guide,
make sure that neither scratches nor damages
exist on the inside surface of the valve guide
holes in cylinder head.
44
2-3a[W5C3]SERVICE PROCEDURE
5. 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 surface of ST2.
ST1 499767400 VALVE GUIDE REMOVER
Intake side:
ST2 499767700 VALVE GUIDE ADJUSTER
Exhaust side:
ST2 499767800 VALVE GUIDE ADJUSTER
B2M2632A
(6) Check the valve guide protrusion.
Valve guide protrusion: L
Intake
20.0 Ð 20.5 mm (0.787 Ð 0.807 in)
Exhaust
16.5 Ð 17.0 mm (0.650 Ð 0.669 in)
B2M0077A
(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.
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.
ST 499767400 VALVE GUIDE REAMER
B2M0078
(8) Recheck the contact condition between
valve and valve seat after replacing valve guide.
45
[W5C3]2-3aSERVICE PROCEDURE
5. Cylinder Head

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 1.0 mm (0.039 in)
Limit 0.6 mm (0.024 in)
Exhaust
Standard 1.2 mm (0.047 in)
Limit 0.6 mm (0.024 in)
Valve overall length:
Intake
120.6 mm (4.75 in)
Exhaust
121.7 mm (4.79 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 lapping.
5. VALVE SPRING
1) Check valve springs for damage, free length,
and tension. 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 54.30 mm (2.1378 in)
Squareness 2.5É, 2.4 mm (0.094 in)
Tension/spring
height214.8 Ð 246.2 N
(21.9 Ð 25.1 kg, 48.3 Ð 55.3 lb)
/ 45.0 mm (1.772 in)
526.6 Ð 581.6 N
(53.7 Ð 59.3 kg, 118.4 Ð 130.8 lb)
/ 34.7 mm (1.366 in)
G2M0154
46
2-3a[W5C4]SERVICE PROCEDURE
5. Cylinder Head