SUBARU LEGACY 1999 Service Manual Online

1) Disconnect PCV hose and remove rocker
cover.
2) Removal of valve rocker assembly
(1) Remove bolts (a) through (b) in alphabetical
sequence.
CAUTION:
Leave two or three threads of bolt (a) engaged
to retain valve rocker assembly.
B2M2605A
(2) Equally loosen bolts (e) through (h) all the
way, being careful that knock pin is not gouged.
B2M2605A
(3) Remove valve rocker assembly.
B2M2606
27
[W3A0]2-3aSERVICE PROCEDURE
3. Valve Rocker Assembly

B: DISASSEMBLY
B2M2607A
(1) Bolt
(2) Intake valve rocker shaft
(3) Rocker shaft support(4) Intake valve rocker arm
(5) Spring
(6) Exhaust valve rocker shaft(7) Exhaust valve rocker arm
(8) Valve rocker nut
(9) Valve rocker adjust screw
1) Remove bolts which secure rocker shaft.
2) Extract rocker shaft. Remove valve rocker
arms, springs, plates and shaft supports from
rocker shaft.
CAUTION:
Arrange all removed parts in order so that they
can be installed in their original positions.
3) Remove nut and adjuster screw from valve
rocker.
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2-3a[W3B0]SERVICE PROCEDURE
3. Valve Rocker Assembly

C: INSPECTION
1. VALVE ROCKER ARM
1) Measure inside diameter of valve rocker arm
and outside diameter of valve rocker shaft, and
determine the difference between the two (= oil
clearance).
Clearance between arm and shaft:
Standard
0.020 Ð 0.054 mm (0.0008 Ð 0.0021 in)
Limit
0.10 mm (0.0039 in)
IIf 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 Ð 22.041 mm (0.8669 Ð 0.8678 in)
Rocker shaft diameter:
21.987 Ð 22.000 mm (0.8656 Ð 0.8661 in)
B2M0072
B2M0073
2) Measure inside diameter of rocker shaft sup-
port and outside diameter of valve rocker shaft,
and determine the difference between the two (=
oil clearance).
Clearance between support and shaft:
Standard
0.005 Ð 0.039 mm (0.0002 Ð 0.0015 in)
Limit
0.05 mm (0.0020 in)
IIf 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 Ð 22.026 mm (0.8663 Ð 0.8672 in)
Rocker shaft diameter:
21.987 Ð 22.000 mm (0.8656 Ð 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.
2. INTAKE AND EXHAUST VALVE
ROCKER SHAFT
Visually check oil relief valve of shaft end for any
of the following abnormalities.
IBreaks in check ball body
IForeign particles caught in valve spring
IOil leakage at check ball
CAUTION:
Repair or replace valve rocker shaft as neces-
sary.
29
[W3C2]2-3aSERVICE PROCEDURE
3. Valve Rocker Assembly

D: ASSEMBLY
B2M2607B
(1) Valve rocker adjust screw
(2) Valve rocker nut
(3) Intake valve rocker arm
(4) Spring(5) Rocker shaft support
(6) Intake valve rocker shaft
(7) Exhaust valve rocker arm
(8) Exhaust valve rocker shaftTightening torque: N´m (kg-m, ft-lb)
T:
5±1 (0.5±0.1, 3.6±0.7)
1) Install adjuster screw and nut to valve rocker.
2) Arrange valve rocker arms, springs and shaft
supports in assembly order and insert valve rocker
shaft.
CAUTION:
Valve rocker arms, rocker shaft and shaft sup-
ports have identification marks. Ensure parts
with same markings are properly assembled.
3) Install valve rocker shaft securing bolts.
30
2-3a[W3D0]SERVICE PROCEDURE
3. Valve Rocker Assembly

E: INSTALLATION
B2M2604B
(1) Spark plug pipe gasket
(2) Intake valve rocker ASSY
(3) Exhaust valve rocker ASSY(4) Rocker coverTightening torque: N´m (kg-m, ft-lb)
T1:
5±1 (0.5±0.1, 3.6±0.7)
T2:25±2 (2.5±0.2, 18.1±1.4)
1) Installation of valve rocker assembly
(1) Temporarily tighten bolts (a) through (d)
equally as shown in figure.
CAUTION:
Do not allow valve rocker assembly to gouge
knock pins.
(2) Tighten bolts (e) through (h) to specified
torque.
(3) Tighten bolts (a) through (d) to specified
torque.
Tightening torque:
25
±2 N´m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
B2M2605A
2) Adjust the valve clearances. [W7B1].>
3) Install rocker cover and connect PCV hose.
31
[W3E0]2-3aSERVICE PROCEDURE
3. Valve Rocker Assembly

4. Camshaft
A: REMOVAL
1. RELATED PARTS
Remove timing belt, camshaft sprockets and
related parts.
2. CAMSHAFT (LH)
B2M2610A
(1) Bolt
(2) Oil level gauge guide(3) Camshaft cap
(4) Camshaft (LH)(5) Oil seal
(6) Plug
1) Remove camshaft position sensor.
CAUTION:
Do not damage the camshaft position sensor.
2) Remove oil level gauge guide attaching bolt.
3) Remove oil level gauge guide.
4) Remove camshaft position sensor support.
5) Remove camshaft cap.
(1) Remove valve rocker assembly.

B2M2606
(2) Remove bolts (a) through (b) in alphabetical
sequence.
B2M2612A
32
2-3a[W4A1]SERVICE PROCEDURE
4. Camshaft

(3) Equally loosen bolts (c) through (j) all the
way in alphabetical sequence.
B2M2612A
(4) Remove bolts (k) through (p) in alphabetical
sequence using ST.
ST 499497000 TORX PLUS
B2M2612A
(5) Remove camshaft cap.
B2M2613
6) Remove camshaft (LH).
7) Remove oil seal.
8) Remove plug from rear side of camshaft (LH).
CAUTION:
IDo not remove oil seal unless necessary.
IDo not scratch journal surface when remov-
ing oil seal.
3. CAMSHAFT (RH)
B2M2614A
(1) Camshaft (RH)
(2) Camshaft cap(3) Valve rocker ASSY
(4) Oil seal(5) Plug
1) Remove camshaft cap.
33
[W4A3]2-3aSERVICE PROCEDURE
4. Camshaft

(1) Remove valve rocker assembly RH.

B2M2615
(2) Remove bolts (a) through (b) in alphabetical
sequence.
B2M2612A
(3) Equally loosen bolts (c) through (j) all the
way in alphabetical sequence.
B2M2612A
(4) Remove bolts (k) through (p) in alphabetical
sequence using ST.
ST 499497000 TORX PLUS
B2M2612A
(5) Remove camshaft cap.
B2M2613
2) Remove camshaft (RH).
3) Remove oil seal.
4) Remove plug from rear side of camshaft (RH).
CAUTION:
IDo not remove oil seal unless necessary.
IDo not scratch journal surface when remov-
ing oil seal.
B: INSPECTION
1. CAMSHAFT
1) Measure the bend, and repair or replace if nec-
essary.
Limit:
0.020 mm (0.0008 in)
B2M2617
2) Check journal for damage and wear. Replace if
faulty.
34
2-3a[W4B1]SERVICE PROCEDURE
4. Camshaft

3) Measure outside diameter of camshaft journal
and inside diameter of cylinder head journal, and
determine the difference between the two (= oilclearance). If oil clearance exceeds specifications,
replace camshaft or cylinder head as necessary.
Unit: mm (in)
Clearance at journalStandard 0.055 Ð 0.090 (0.0022 Ð 0.0035)
Limit 0.118 (0.0046)
Camshaft journal O.D. 31.928 Ð 31.945 (1.2570 Ð 1.2577)
Journal hole I.D. 32.000 Ð 32.018 (1.2598 Ð 1.2605)
4) Check cam face condition; remove minor faults
by grinding with oil stone. Measure the cam height
H; replace if the limit has been exceeded.
Cam height: H
Unit: mm (in)
Item Standard Limit
Intake34.00 Ð 38.782
(1.3386 Ð 1.5268)33.84 (1.3323)
Exhaust34.00 Ð 39.307
(1.3386 Ð 1.5475)33.84 (1.3323)
Cam base circle diameter A:
IN: 27.5 mm (1.083 in)
EX: 27.0 mm (1.063 in)
B2M1209A
2. CAMSHAFT SUPPORT
Measure the thrust clearance of camshaft with dial
gauge. If the clearance exceeds the limit, replace
camshaft support.
Standard:
0.030 Ð 0.090 mm (0.0012 Ð 0.0035 in)
Limit:
0.11 mm (0.0043 in)
B2M2618A
35
[W4B2]2-3aSERVICE PROCEDURE
4. Camshaft

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