engine SUBARU LEGACY 1999 Service Owner's Manual

C: INSTALLATION
1. CAMSHAFT (LH)
B2M2610B
(1) Camshaft (LH)
(2) Camshaft cap(3) Plug
(4) Oil seal(5) Oil level gauge guide
(6) Bolt
1) Apply a coat of engine oil to camshaft journals
and install camshaft (LH).
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.

B2M2606
36
2-3a[W4C1]SERVICE 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

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

(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

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-fit oil seal to the specified dimension indi-
cated in the figure using ST2.
CAUTION:
IApply engine oil to oil seal before press-fit-
ting.
IWhen press-fitting oil seal, do not use ham-
mer or strike in.
IDifferentiate between intake valve oil seal
and exhaust valve oil seal by noting their dif-
ference in color.
ST1 498267800 CYLINDER HEAD TABLE
ST2 498857100 VALVE OIL SEAL GUIDE
Color of rubber part:
Intake [Black]
Exhaust [Brown]
Color of spring part:
Intake [Silver]
Exhaust [Silver]
B2M2633A
47
[W5C6]2-3aSERVICE PROCEDURE
5. Cylinder Head

D: ASSEMBLY
B2M2629B
(1) Valve
(2) Valve guide
(3) Valve spirng seat
(4) Oil seal
(5) Valve spring(6) Retainer
(7) Retainer key
(8) Spark plug gasket
(9) Camshaft
(10) Oil seal(11) Plug
(12) Camshaft cap
(13) Valve rocker ASSY
1) Installation of valve spring and valve
(1) Place cylinder head on ST.
ST 498267400 CYLINDER HEAD TABLE
(2) Coat stem of each valve with engine oil and
insert valve into valve guide.
CAUTION:
When inserting valve into valve guide, use spe-
cial care not to damage the oil seal lip.
(3) Install valve spring and retainer.
CAUTION:
Be sure to install the valve springs with their
close-coiled end facing the seat on the cylinder
head.(4) Set ST on valve spring.
ST 499718000 VALVE SPRING REMOVER
B2M2630A
48
2-3a[W5D0]SERVICE PROCEDURE
5. Cylinder Head

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 alphabetical sequence.
Then tighten all bolts to 69 N´m (7.0 kg-m, 51
ft-lb) in alphabetical sequence.
(3) Back off all bolts by 180É first; back them off
by 180É again.
(4) Tighten bolts (a) and (b) to 34 N´m (3.5
kg-m, 25 ft-lb).
(5) Tighten bolts (c), (d), (e) and (f) to 15 N´m
(1.5 kg-m, 11 ft-lb).
(6) Tighten all bolts by 80 to 90É in alphabetical
sequence.
CAUTION:
Do not tighten bolts more than 90É.
(7) Further tighten all bolts by 80 to 90É in
alphabetical sequence.
CAUTION:
Ensure that the total ªre-tightening angleº [in
the former two steps], do not exceed 180É.
B2M2628B
3) Install oil level gauge guide and tighten attach-
ing bolt (left side only).
4) Install timing belt, camshaft sprocket and
related parts.

2. RELATED PARTS
CAUTION:
Be careful not to scratch the mating surface of
cylinder block and oil pump.
1) Install engine coolant pipe.
2) Install intake manifold.
3) Connect blow-by hose.
4) Connect oil pressure switch connector.
5) Install camshaft position sensor and camshaft
position sensor support.
6) Install connector bracket attaching bolt.
7) Connect spark plug cords.
8) Install generator and bracket.
9) Install A/C compressor and bracket. (With A/C
model)
10) Install V-belt(s).
11) Remove ENGINE STAND (ST).
50
2-3a[W5E2]SERVICE PROCEDURE
5. Cylinder Head

(4) Position the upper rail gap at (C) or (D) in
the figure.
B2M2636A
(5) Position the expander gap at 180É of the
reverse side for the upper rail gap.
(6) Position the lower rail gap at (E) or (F) in the
figure.
CAUTION:
IEnsure ring gaps do not face the same direc-
tion.
IEnsure ring gaps are not within the piston
skirt area.
B2M2636A
5) Install circlip.
Install circlips in piston holes located opposite ser-
vice holes in cylinder block, when positioning all
pistons in the corresponding cylinders.
CAUTION:
Use new circlips.
B2M1403A
CAUTION:
Piston front mark faces towards the front of the
engine.
B2M2800A
64
2-3a[W6D1]SERVICE PROCEDURE
6. Cylinder Block

2. CYLINDER BLOCK
B2M2407A
(1) Crankshaft bearing
(2) Crankshaft
(3) Cylinder block(4) Rear oil sealTightening torque: N´m (kg-m, ft-lb)
T1:
25±2 (2.5±0.2, 18.1±1.4)
T2:47±3 (4.8±0.3, 34.7±2.2)
1) Install ST to cylinder block, then install crank-
shaft bearings.
ST 499817000 ENGINE STAND
CAUTION:
Remove oil in 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.3) Apply fluid packing to the mating surface of #1
and #3 cylinder block, and position it on #2 and #4
cylinder block.
Fluid packing:
THREE BOND 1215 or equivalent
CAUTION:
Do not allow fluid packing to jut into O-ring
grooves, oil passages, bearing grooves, etc.
G2M0185
65
[W6D2]2-3aSERVICE PROCEDURE
6. Cylinder Block

3. PISTON AND PISTON PIN (#1 AND #2)
B2M1322E
(1) Piston
(2) Piston pin
(3) Circlip(4) Gasket
(5) Service hole plugTightening torque: N´m (kg-m, ft-lb)
T:
69±7 (7.0±0.7, 50.6±5.1)
1) Installing piston
(1) Turn cylinder block so that #1 and #2 cylin-
ders face upward.
(2) Using ST1, turn crankshaft so that #1 and
#2 connecting rods are set at bottom dead cen-
ter.
ST1 499987500 CRANKSHAFT SOCKET
(3) Apply a coat of engine oil to pistons and
cylinders and insert pistons in their cylinders
using ST2.
ST2 498747100 PISTON GUIDE
S2M0306A
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 inser-
tion.
ST3 499017100 PISTON PIN GUIDE
G2M0189
(2) Apply a coat of engine oil to piston pin and
insert piston pin into piston and connecting rod
through service hole.
67
[W6D3]2-3aSERVICE PROCEDURE
6. Cylinder Block