engine SUBARU LEGACY 1999 Service User Guide

S2M0242
Oil pressure:
98 kPa (1.0 kg/cm2,14 psi) or more at 800
rpm
294 kPa (3.0 kg/cm
2, 43 psi) or more at
5,000 rpm
CAUTION:
IIf oil pressure is out of specification, check
oil pump, oil filter and lubrication line. 2-4 [K100].>
IIf oil pressure warning light is turned ON and
oil pressure is in specification, replace oil pres-
sure switch.
NOTE:
The specified data is based on an engine oil tem-
perature of 80ÉC (176ÉF).
8) After measuring oil pressure, install oil pressure
switch.
Tightening torque:
25
±3 N´m (2.5±0.3 kg-m, 18.1±2.2 ft-lb)
9) Install generator and V-belt in the reverse order
of removal, and adjust the V-belt deflection.
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.
B2M1723
3) Remove engine coolant reservoir tank. 2-5 [W9A0].>
S2M0028
4) Remove timing belt cover (LH).
B2M2031
5) Remove rocker cover.
IWhen inspecting #1 and #3 cylinders:
ILow emission vehicle:
7
[W7A1]2-2SERVICE PROCEDURE
7. Valve Clearance

7) Measure #1 cylinder valve clearance by using
thickness gauge.
CAUTION:
IInsert the thickness gauge in at as horizon-
tal a direction as a possible with respect to the
valve stem end face.
IMeasure exhaust valve clearances while lift-
ing-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)
B2M2028A
8) If necessary, adjust the valve clearance. to 2-2 [W7B1].>
9) Similar to measurement procedures used for #1
cylinder, measure #2, #3 and #4 cylinder valve
clearances.
NOTE:
IBe sure to set cylinder pistons to their respective
top dead centers on the compression stroke before
measuring valve clearances.
ITo set #3, #2 and #4 cylinder pistons to their top
dead centers on the compression stroke, turn
crankshaft pulley clockwise 90É at a time starting
with arrow mark on left- hand camshaft sprocket
facing up.
B2M2029A
10) 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 (Taiwan spec. vehicles only).
4) Remove two bolts on the upper side which
secure timing belt cover (RH).
5) Lift-up the vehicle.
6) Remove under cover (RH).
7) Remove canister bracket (Taiwan spec.
vehicles only).
8) Loosen remaining bolt on under side which
secures timing belt cover (RH), then remove belt
cover.
9) Lower the vehicle.
10) Remove rocker cover.
IWhen inspecting #1 and #3 cylinders;
(1) Disconnect connector from mass air flow
sensor.
B2M1225A
(2) Loosen clamp which connects air intake
duct to air intake chamber.
B2M1226A
(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.
11
[W7A2]2-2SERVICE PROCEDURE
7. Valve Clearance

(1) Set arrow mark on camshaft sprocket to
position shown in figure, and measure #2 cylin-
der exhaust valve and #3 cylinder intake valve
clearances.
B2M1235A
(2) Set arrow mark on camshaft sprocket to
position shown in figure, and measure #2 cylin-
der intake valve and #4 cylinder exhaust valve
clearances.
B2M1236A
(3) Set arrow mark on camshaft sprocket to
position shown in figure, and measure #1 cylin-
der exhaust valve and #4 cylinder intake valve
clearances.
B2M1237A
15) After inspection, install the related parts in the
reverse order of removal.
B: ADJUSTMENT
1. 2200 cc MODEL
CAUTION:
Adjustment of valve clearance should be per-
formed while engine is cold.
1) Set #1 cylinder piston to top dead center of
compression stroke by rotating crankshaft pulley
clockwise.
NOTE:
When arrow mark on camshaft sprocket (LH)
comes exactly to the top, #1 cylinder piston is
brought to the top dead center of the compression
stroke.
B2M2027A
13
[W7B1]2-2SERVICE PROCEDURE
7. Valve Clearance

2) Adjust the #1 cylinder valve clearance.
(1) Loosen the valve rocker nut and screw.
(2) Place suitable thickness gauge.
(3) While noting valve clearance, tighten valve
rocker adjust screw.
(4) When specified valve clearance is obtained,
tighten valve rocker nut.
Tightening torque:
10
±1 N´m (1.0±0.1 kg-m, 7.2±0.7 ft-lb)
CAUTION:
IInsert the thickness gauge in at as horizon-
tal a direction as possible with respect to the
valve stem end face.
IAdjust exhaust valve clearances while lift-
ing-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)
B2M2030A
(a) Thickness gauge
(b) Valve rocker nut
(c) Valve rocker screw
3) Ensure that valve clearances are within speci-
fications.
4) Turn crankshaft two complete rotations until #1
cylinder piston is again set to top dead center on
compression stroke.
5) Ensure that valve clearances are within speci-
fications. If necessary, re-adjust valve clearances.6) Similar to adjustment procedures used for #1
cylinder, adjust #2, #3 and #4 cylinder valve clear-
ances.
NOTE:
IBe sure to set cylinder pistons to their respective
top dead centers on the compression stroke before
adjusting valve clearances.
ITo set #3, #2 and #4 cylinder pistons to their top
dead centers on the compression stroke, turn
crankshaft pulley clockwise 90É at a time starting
with arrow mark on left-hand camshaft sprocket
facing up.
B2M2029A
2. 2500 cc MODEL
CAUTION:
Adjustment of valve clearance should be per-
formed while engine is cold.
1) Measure all valve clearances. [W7A2].>
NOTE:
Record each valve clearance after it has been
measured.
B2M1234A
14
2-2[W7B2]SERVICE PROCEDURE
7. Valve Clearance

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´Stroke mm (in) 96.9´75.0 (3.815´2.953)
Displacement cm
3(cu in) 2,212 (135.0)
Compression ratio 9.7
Compression pressure
(at 200 Ð 300 rpm)kPa (kg/cm
2, psi) 1,079 Ð 1,275 (11.0 Ð 13.0, 156 Ð 185)
Number of piston rings Pressure ring: 2, Oil ring: 1
Intake valve timingOpening 4É BTDC
Closing 52É ABDC
Exhaust valve timingOpening 48É BBDC
Closing 12É 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 ªPº or
ªNº position on AT]rpm700±100 (No load)
850±50 (A/C switch ON)
Firing order 1®3®2®4
Ignition timing BTDC/rpm 14ɱ8É/700 (MT), 20ɱ8É/700 (AT)
B: SERVICE DATA
NOTE:
STD: Standard, I.D.: Inner Diameter, O.D.: Outer Diameter, OS: Oversize, US: Undersize
Belt ten-
sioner
adjusterProtrusion of adjuster rod 5.2 Ð 6.2 mm (0.205 Ð 0.244 in)
Belt ten-
sionerSpacer O.D. 17.955 Ð 17.975 mm (0.7069 Ð 0.7077 in)
Tensioner bush I.D. 18.00 Ð 18.08 mm (0.7087 Ð 0.7118 in)
Clearance between spacer and bushSTD 0.025 Ð 0.125 mm (0.0010 Ð 0.0049 in)
Limit 0.175 mm (0.0069 in)
Side clearance of spacerSTD 0.2 Ð 0.55 mm (0.0079 Ð 0.0217 in)
Limit 0.81 mm (0.0319 in)
Valve
rocker
armClearance between shaft and armSTD 0.020 Ð 0.054 mm (0.0008 Ð 0.0021 in)
Limit 0.10 mm (0.0039 in)
Cam-
shaftBend limit 0.020 mm (0.0008 in)
Thrust clearanceSTD 0.030 Ð 0.090 mm (0.0012 Ð 0.0035 in)
Limit 0.11 mm (0.0043 in)
Cam lobe heightIntakeSTD 34.00 Ð 38.782 mm (1.3386 Ð 1.5268 in)
Limit 33.84 mm (1.3323 in)
ExhaustSTD 34.00 Ð 39.307 mm (1.3386 Ð 1.5475 in)
Limit 33.84 mm (1.3323 in)
Camshaft journal O.D. 31.928 Ð 31.945 mm (1.2570 Ð 1.2577 in)
Camshaft journal hole I.D. 32.000 Ð 32.018 mm (1.2598Ð 1.2605 in)
Oil clearanceSTD 0.055 Ð 0.090 mm (0.0022 Ð 0.0035 in)
Limit 0.118 mm (0.0046 in)
2
2-3a[S1A0]SPECIFICATIONS AND SERVICE DATA
1. Engine

Cylinder
headSurface warpage limit 0.05 mm (0.0020 in)
Surface grinding limit 0.3 mm (0.012 in)
Standard height 97.5 mm (3.839 in)
Valve
setRefacing angle 90É
Contacting widthIntakeSTD 1.0 mm (0.039 in)
Limit 1.7 mm (0.067 in)
ExhaustSTD 1.4 mm (0.055 in)
Limit 2.1 mm (0.083 in)
Valve
guideInner diameter 6.000 Ð 6.012 mm (0.2362 Ð 0.2367 in)
Protrusion above headIntake 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)
ValveHead edge thicknessIntakeSTD 1.0 mm (0.039 in)
Limit 0.6 mm (0.024 in)
ExhaustSTD 1.2 mm (0.047 in)
Limit 0.6 mm (0.024 in)
Stem diameterIntake 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)
Stem oil clearanceSTDIntake 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 Ð 0.15 mm (0.0059 in)
Overall lengthIntake 120.6 mm (4.75 in)
Exhaust 121.7 mm (4.79 in)
Valve
springFree 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)
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 Ð 96.915 mm (3.8151 Ð 3.8155 in)
B 96.895 Ð 96.905 mm (3.8148 Ð 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 Ð 0.030 mm (0.0004 Ð 0.0012 in)
Limit 0.050 mm (0.0020 in)
Enlarging (boring) limit 0.5 mm (0.020 in)
Piston Outer diameterSTDA 96.885 Ð 96.895 mm (3.8144 Ð 3.8148 in)
B 96.875 Ð 96.885 mm (3.8140 Ð 3.8144 in)
0.25 mm (0.0098
in) OS97.125 Ð 97.135 mm (3.8238 Ð 3.8242 in)
0.50 mm (0.0197
in) OS97.375 Ð 97.385 mm (3.8337 Ð 3.8340 in)
Piston
pinStandard clearance between piston
pin and hole in pistonSTD 0.004 Ð 0.008 mm (0.0002 Ð 0.0003 in)
Limit 0.020 mm (0.0008 in)
Degree of fitPiston pin must be fitted into position with thumb at 20ÉC
(68ÉF).
3
[S1B0]2-3aSPECIFICATIONS AND SERVICE DATA
1. Engine

Piston
ringPiston ring gapTop ringSTD 0.20 Ð 0.35 mm (0.0079 Ð 0.0138 in)
Limit 1.0 mm (0.039 in)
Second ringSTD 0.37 Ð 0.52 mm (0.0146 Ð 0.0205 in)
Limit 1.0 mm (0.039 in)
Oil ringSTD 0.20 Ð 0.50 mm (0.0079 Ð 0.0197 in)
Limit 1.0 mm (0.039 in)
Clearance between
piston ring and pis-
ton ring grooveTop ringSTD 0.040 Ð 0.080 mm (0.0016 Ð 0.0031 in)
Limit 0.15 mm (0.0059 in)
Second ringSTD 0.030 Ð 0.070 mm (0.0012 Ð 0.0028 in)
Limit 0.15 mm (0.0059 in)
Con-
necting
rodBend twist per 100 mm (3.94 in) in
lengthLimit 0.10 mm (0.0039 in)
Side clearanceSTD 0.070 Ð 0.330 mm (0.0028 Ð 0.0130 in)
Limit 0.4 mm (0.016 in)
Con-
necting
rod
bearingOil clearanceSTD 0.010 Ð 0.038 mm (0.0004 Ð 0.0015 in)
Limit 0.05 mm (0.0020 in)
Thickness at center portionSTD 1.492 Ð 1.501 mm (0.0587 Ð 0.0591 in)
0.03 mm (0.0012
in) US1.510 Ð 1.513 mm (0.0594 Ð 0.0596 in)
0.05 mm (0.0020
in) US1.520 Ð 1.523 mm (0.0598 Ð 0.0600 in)
0.25 mm (0.0098
in) US1.620 Ð 1.623 mm (0.0638 Ð 0.0639 in)
Con-
necting
rod
bushingClearance between piston pin and
bushingSTD 0 Ð 0.022 mm (0 Ð 0.0009 in)
Limit 0.030 mm (0.0012 in)
4
2-3a[S1B0]SPECIFICATIONS AND SERVICE DATA
1. Engine

Crank-
shaftBend limit 0.035 mm (0.0014 in)
Crankpin and crank journalOut-of-roundness 0.030 mm (0.0012 in) or less
Grinding limit 0.250 mm (0.0098 in)
Crankpin outer diameterSTD 51.984 Ð 52.000 mm (2.0466 Ð 2.0472 in)
0.03 mm (0.0012
in) US51.954 Ð 51.970 mm (2.0454 Ð 2.0461 in)
0.05 mm (0.0020
in) US51.934 Ð 51.950 mm (2.0446 Ð 2.0453 in)
0.25 mm (0.0098
in) US51.734 Ð 51.750 mm (2.0368 Ð 2.0374 in)
Crank journal outer diam-
eter#1,
#5STD 59.992 Ð 60.008 mm (2.3619 Ð 2.3625 in)
0.03 mm (0.0012
in) US59.962 Ð 59.978 mm (2.3607 Ð 2.3613 in)
0.05 mm (0.0020
in) US59.942 Ð 59.958 mm (2.3599 Ð 2.3605 in)
0.25 mm (0.0098
in) US59.742 Ð 59.758 mm (2.3520 Ð 2.3527 in)
#2,
#3,
#4STD 59.992 Ð 60.008 mm (2.3619 Ð 2.3625 in)
0.03 mm (0.0012
in) US59.962 Ð 59.978 mm (2.3607 Ð 2.3613 in)
0.05 mm (0.0020
in) US59.942 Ð 59.958 mm (2.3599 Ð 2.3605 in)
0.25 mm (0.0098
in) US59.742 Ð 59.758 mm (2.3520 Ð 2.3527 in)
Thrust clearanceSTD 0.030 Ð 0.115 mm (0.0012 Ð 0.0045 in)
Limit 0.25 mm (0.0098 in)
Oil clearance#1,
#5STD 0.003 Ð 0.030 mm (0.0001 Ð 0.0012 in)
#2,
#3,
#4STD 0.010 Ð 0.033 mm (0.0004 Ð 0.0013 in)
#1,
#3,
#5Limit 0.040 mm (0.0016 in)
#2,
#4Limit 0.045 mm (0.0018 in)
Crank-
shaft
bearingCrankshaft bearing thick-
ness#1,
#5STD 1.998 Ð 2.011 mm (0.0787 Ð 0.0792 in)
0.03 mm (0.0012
in) US2.017 Ð 2.020 mm (0.0794 Ð 0.0795 in)
0.05 mm (0.0020
in) US2.027 Ð 2.030 mm (0.0798 Ð 0.0799 in)
0.25 mm (0.0098
in) US2.127 Ð 2.130 mm (0.0837 Ð 0.0839 in)
#2,
#3,
#4STD 2.000 Ð 2.013 mm (0.0787 Ð 0.0793 in)
0.03 mm (0.0012
in) US2.019 Ð 2.022 mm (0.0795 Ð 0.0796 in)
0.05 mm (0.0020
in) US2.029 Ð 2.032 mm (0.0799 Ð 0.0800 in)
0.25 mm (0.0098
in) US2.129 Ð 2.132 mm (0.0838 Ð 0.0839 in)
5
[S1B0]2-3aSPECIFICATIONS AND SERVICE DATA
1. Engine

1. General Precautions
A: 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
B2M2582A
2) All parts should be thoroughly cleaned, paying
special attention to the engine oil passages, pis-
tons 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 con-
tact 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) All removed parts, if to be reused, should be
reinstalled in the original positions and directions.
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.
12
2-3a[W1A0]SERVICE PROCEDURE
1. General Precautions

4. CRANKSHAFT PULLEY AND BELT COVER
B2M2583B
(1) Front belt cover
(2) Belt cover (LH)
(3) Crankshaft pulley
(4) Crankshaft pulley bolt(5) Rear side V-belt (With A/C
model)
(6) Front side V-beltTightening torque: N´m (kg-m, ft-lb)
T1:
5±1 (0.5±0.1, 3.6±0.7)
T2:127+10/þ5(13.0+1.0/þ0.5,
94+7.2/þ3.6)
1) Install front belt cover.
2) Install belt cover (LH).
B2M2587A
3) Install crankshaft pulley.
4) Install pulley bolt.
To lock crankshaft, use ST.
ST 499977000 CRANKSHAFT PULLEY
WRENCH
(1) Clean the crankshaft pulley thread using an
air gun.
(2) Apply engine oil to the crankshaft pulley bolt
seat and thread.
(3) Tighten the bolts temporarily with tightening
torque of 44 N´m (4.5 kg-m, 33 ft-lb).
(4) Tighten the crankshaft pulley bolts.
Tightening torque:
127
±5 N´m (13.0±0.5 kg-m, 94.0±3.6 ft-lb)
B2M2586A
5) Confirm that the tightening angle of the crank-
shaft pulley bolt is 45 degrees or more. If not, con-
duct the following procedures (1) through (4).
25
[W2C4]2-3aSERVICE PROCEDURE
2. Timing Belt