engine oil SUBARU LEGACY 1999 Service Repair Manual

Diagnosis of engine condition by measurement of manifold vacuum
Vacuum gauge indication Possible engine condition
1. Needle is steady but lower than normal position. This ten-
dency becomes more evident as engine temperature rises.Leakage around intake manifold gasket or disconnection or
damaged vacuum hose
2. When engine speed is reduced slowly from higher speed,
needle stops temporarily when it is lowering or becomes
steady above normal position.Back pressure too high, or exhaust system clogged
3. Needle intermittently drops to position lower than normal
position.Leakage around cylinder
4. Needle drops suddenly and intermittently from normal posi-
tion.Sticky valves
5. When engine speed is gradually increased, needle begins
to vibrate rapidly at certain speed, and then vibration
increases as engine speed increases.Weak or broken valve springs
6. Needle vibrates above and below normal position in narrow
range.Defective ignition system or throttle chamber idle adjustment
6. Engine Oil Pressure
A: MEASUREMENT
1) Disconnect battery ground cable.
2) Remove generator from bracket.
(1) Disconnect connector and terminal from
generator.
G2M0088
(2) Remove V-belt cover
G2M0089
(3) Loosen lock bolt and slider bolt, and remove
V-belt for generator.
(4) Remove generator lock bolt.
(5) Remove bolt which install generator on
bracket.
G2M0090
3) Disconnect connector from oil pressure switch.
4) Remove oil pressure switch from engine cylin-
der block.
G2M0091
5) Connect oil pressure gauge hose to cylinder
block.
6) Connect battery ground cable.
7) Start the engine, and measure oil pressure.
6
2-2[W6A0]SERVICE PROCEDURE
6. Engine Oil Pressure

Diagnosis of engine condition by measurement of manifold vacuum
Vacuum gauge indication Possible engine condition
1. Needle is steady but lower than normal position. This ten-
dency becomes more evident as engine temperature rises.Leakage around intake manifold gasket or disconnection or
damaged vacuum hose
2. When engine speed is reduced slowly from higher speed,
needle stops temporarily when it is lowering or becomes
steady above normal position.Back pressure too high, or exhaust system clogged
3. Needle intermittently drops to position lower than normal
position.Leakage around cylinder
4. Needle drops suddenly and intermittently from normal posi-
tion.Sticky valves
5. When engine speed is gradually increased, needle begins
to vibrate rapidly at certain speed, and then vibration
increases as engine speed increases.Weak or broken valve springs
6. Needle vibrates above and below normal position in narrow
range.Defective ignition system or throttle chamber idle adjustment
6. Engine Oil Pressure
A: MEASUREMENT
1) Disconnect battery ground cable.
2) Remove generator from bracket.
(1) Disconnect connector and terminal from
generator.
G2M0088
(2) Remove V-belt cover
G2M0089
(3) Loosen lock bolt and slider bolt, and remove
V-belt for generator.
(4) Remove generator lock bolt.
(5) Remove bolt which install generator on
bracket.
G2M0090
3) Disconnect connector from oil pressure switch.
4) Remove oil pressure switch from engine cylin-
der block.
G2M0091
5) Connect oil pressure gauge hose to cylinder
block.
6) Connect battery ground cable.
7) Start the engine, and measure oil pressure.
6
2-2[W6A0]SERVICE PROCEDURE
6. Engine Oil Pressure

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

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

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