1995 SUBARU LEGACY width

B: SERVICE DATA
Belt
tension
adjusterProtrusion of adjuster rod 15.4—16.4 mm (0.606—0.646 in)
Belt ten-
sionerSpacer O.D. 16 mm (0.63 in)
Tensioner bush I.D. 16.16 mm (0.6362 in)
Clearance between spacer and bushSTD 0.117—0.180 mm (0.0046—0.0071 in)
Limit 0.230 mm (0.0091 in)
Side clearance of spacerSTD 0.37—0.54 mm (0.0146—0.0213 in)
Limit 0.8 mm (0.031 in)
Valve
rocker armClearance between shaft and armSTD 0.020—0.054 mm (0.0008—0.0021 in)
Limit 0.10 mm (0.0039 in)
CamshaftBend limit 0.025 mm (0.0010 in)
Thrust clearanceSTD 0.030—0.260 mm (0.0012—0.0102 in)
Limit 0.35 mm (0.0138 in)
Cam lobe heightIntakeSTD 31.994—32.094 mm (1.2596—1.2635 in)
Limit 31.844 mm (1.2537 in)
ExhaustSTD 32.624—32.724 mm (1.2844—1.2883 in)
Limit 32.474 mm (1.2785 in)
Camshaft journal O.D. RHFront
LHRear 31.935—31.950 mm (1.2573—1.2579 in)
Center Center 37.435—37.450 mm (1.4738—1.4744 in)
Rear Front 37.935—37.950 mm (1.4935—1.4941 in)
Camshaft journal hole
I.D.RHFront
LHRear 32.005—32.025 mm (1.2600—1.2608 in)
Center Center 37.505—37.525 mm (1.4766—1.4774 in)
Rear Front 38.005—38.025 mm (1.4963—1.4970 in)
Oil clearanceSTD 0.055—0.090 mm (0.0022—0.0035 in)
Limit 0.10 mm (0.0039 in)
Cylinder
headSurface warpage limit 0.05 mm (0.0020 in)
Surface grinding limit 0.1 mm (0.004 in)
Standard height 98.3 mm (3.870 in)
Valve setRefacing angle 90°
Contacting widthIntakeSTD 0.7 mm (0.028 in)
Limit 1.4 mm (0.055 in)
ExhaustSTD 1.4 mm (0.055 in)
Limit 1.8 mm (0.071 in)
Valve
guideInner diameter 6.000—6.012 mm (0.2362—0.2367 in)
Protrusion above head 17.5—18.0 mm (0.689—0.709 in)
ValveHead edge thicknessIntakeSTD 1.0 mm (0.039 in)
Limit 0.8 mm (0.031 in)
ExhaustSTD 1.2 mm (0.047 in)
Limit 0.8 mm (0.031 in)
Stem diameterIntake 5.950—5.965 mm (0.2343—0.2348 in)
Exhaust 5.945—5.960 mm (0.2341—0.2346 in)
Stem oil clearanceSTDIntake 0.035—0.062 mm (0.0014—0.0024 in)
Exhaust 0.040—0.067 mm (0.0016—0.0026 in)
Limit—0.15 mm (0.0059 in)
Overall lengthIntake 101.0 mm (3.976 in)
Exhaust 101.2 mm (3.984 in)
STD: Standard I.D.: Inner Diameter O.D.: Outer Diameter
3
2-3SPECIFICATIONS AND SERVICE DATA
1. Engine

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 498267200 CYLINDER HEAD TABLE
G2M0148
3) Measure the warping of the cylinder head surface that
mates with crankcase by using a straight edge and thick-
ness 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:
0.1 mm (0.004 in)
Standard height of cylinder head:
98.3 mm (3.870 in)
CAUTION:
Uneven torque for the cylinder head bolts can cause
warping. When reassembling, pay special attention to
the torque so as to tighten evenly.
G2M0149
B2M0074
2. VALVE SEAT
Inspect intake and exhaust valve seats, and correct the
contact surfaces with valve seat cutter if they are defective
or when valve guides are replaced.
Valve seat width: W
Intake
Standard
0.7 mm (0.028 in)
Limit
1.4 mm (0.055 in)
Exhaust
Standard
1.4 mm (0.055 in)
Limit
1.8 mm (0.071 in)
41
2-3SERVICE PROCEDURE
6. Cylinder Head

1. Lubrication System
A: SPECIFICATIONS
Lubrication methodForced lubrication
Oil pumpPump typeTrochoid type
Number of teethInner rotor 9
Outer rotor 10
Outer rotor diameter x thickness 78x9mm(3.07 x 0.35 in)
Tip clearance between inner and outer rotorSTANDARD 0.04 — 0.14 mm (0.0016 — 0.0055 in)
LIMIT 0.18 mm (0.0071 in)
Side clearance between inner rotor and pump
caseSTANDARD 0.02 — 0.07 mm (0.0008 — 0.0028 in)
LIMIT 0.15 mm (0.0059 in)
Case clearance between outer rotor and pump
caseSTANDARD 0.10 — 0.175 mm (0.0039 — 0.0069 in)
LIMIT 0.20 mm (0.0079 in)
Capacity at
80°C (176°F)700 rpm Discharge- pressure 98 kPa (1.0 kg/cm
2, 14 psi) or more
- quantity 4.2
(4.4 US qt, 3.7 Imp qt)/min.
5,000 rpm Discharge- pressure 294 kPa (3.0 kg/cm
2, 43 psi) or more
- quantity 42.0
(11.10 US gal, 9.24 Imp gal)/min.
Relief valve operation pressure 490 kPa (5.0 kg/cm
2, 71 psi)
Oil filterTypeFull-flow filter type
Filtration area 1,000 cm
2(155 sq in)
By-pass valve opening pressure 157 kPa (1.6 kg/cm
2, 23 psi)
Outer diameter x width 80 x 70 mm (3.15 x 2.76 in)
Oil filter to engine thread size M 20 x 1.5
Relief valve (on rocker shaft) operation pressure 69 kPa (0.7kg/cm
2, 10 psi)
Oil pressure
switchTypeImmersed contact point type
Working voltage — wattage 12 V — 3.4 W or less
Warning light activation pressure 14.7 kPa (0.15 kg/cm
2, 2.1 psi)
Proof pressure More than 981 kPa (10 kg/cm
2, 142 psi)
Oil pan capacity4.0
(4.2 US qt, 3.5 Imp qt)
2
2-4SPECIFICATIONS AND SERVICE DATA
1. Lubrication System

Pinion height adjusting shim thicknessPart No. Thickness
383495200 3.09 mm (0.1217 in)
383505200 3.12 mm (0.1228 in)
383515200 3.15 mm (0.1240 in)
383525200 3.18 mm (0.1252 in)
383535200 3.21 mm (0.1264 in)
383545200 3.24 mm (0.1276 in)
383555200 3.27 mm (0.1287 in)
383565200 3.30 mm (0.1299 in)
383575200 3.33 mm (0.1311 in)
383585200 3.36 mm (0.1323 in)
383595200 3.39 mm (0.1335 in)
383605200 3.42 mm (0.1346 in)
383615200 3.45 mm (0.1358 in)
383625200 3.48 mm (0.1370 in)
383635200 3.51 mm (0.1382 in)
383645200 3.54 mm (0.1394 in)
383655200 3.57 mm (0.1406 in)
383665200 3.60 mm (0.1417 in)
383675200 3.63 mm (0.1429 in)
383685200 3.66 mm (0.1441 in)
Side bearing standard width—20.00 mm (0.7874 in)
Side bearing retainer shim thicknessPart No. Thickness
383475201 0.20 mm (0.0079 in)
383475202 0.25 mm (0.0098 in)
383475203 0.30 mm (0.0118 in)
383475204 0.40 mm (0.0157 in)
383475205 0.50 mm (0.0197 in)
Crown gear to drive pinion backlash
Limit0.10—0.20 mm (0.0039—0.0079 in)
Crown gear runout on its back surface 0.05 mm (0.0020 in)
Oil capacity0.8
(0.8 US qt, 0.7 Imp qt)
5
3-4SPECIFICATIONS AND SERVICE DATA
1. AWD System

G3M0720
9) Press-fit companion flange with ST1 and ST2.
CAUTION:
Be careful not to damage bearing.
ST1 899874100 INSTALLER
ST2 399780104 WEIGHT
G3M1052
10) Install self-locking nut. Then tighten it with ST.
ST 498427200 FLANGE WRENCH
Tightening torque:
181±15 N⋅m (18.5±1.5 kg-m, 134±11 ft-lb)
G3M0069
11) Install crown gear on differential case.
Tightening Torque:
103±10 N⋅m (10.5±1.0 kg-m, 76±7 ft-lb)
NOTE:
Tighten diagonally while tapping the bolt heads.
G3M1041
12) Before installing side bearing, measure the bearing
width by using a dial gauge, ST1 and ST2.
Standard bearing width:
20.00 mm (0.7874 in)
NOTE:
Set the dial gauge needle to zero, using a standard bear-
ing or block of specified height in advance.
ST1 398227700 WEIGHT
ST2 398237700 GAUGE
G3M0091
13) Press side bearing cone onto differential case with
ST1.
ST1 398487700 DRIFT
31
3-4SERVICE PROCEDURE
2. Rear Differential

G3M1043
B3M0134A
14) Adjusting side bearing retainer shims
(1) The drive gear backlash and side bearing preload
can be determined by the side bearing retainer shim
thickness.
(2) When replacing differential case, differential carrier,
side bearing and side bearing retainer, obtain the right
and left retainer shim thickness from the following for-
mulas.
T
1(Left) = (A + C + G1D) x 0.01 + 0.76E (mm)
T
2(Right) = (B+D+G2) x 0.01 + 0.76F (mm)
T
1&T2: Thickness of left and right side bearing
retainer shim (mm)
A & B : Number marked on differential carrier
C & D : Number marked on differential case
E & F : Difference of width of left and right side
bearing from standard width 20.0 mm,
expressed in a unit of 0.01 mm. For
example, if the bearing measured width
is 19.89 mm, value of E or F is as follows.
20.0019.89 = 0.11 (E or F)
G
1&G2: Number marked on side bearing retainer
If a number is not marked, regard it as zero.
NOTE:
Use several shims to obtain the calculated thickness.
Side bearing retainer shim thicknessPart No. Thickness mm (in)
383475201 0.20 (0.0079)
383475202 0.25 (0.0098)
383475203 0.30 (0.0118)
383475204 0.40 (0.0157)
383475205 0.50 (0.0197)
32
3-4SERVICE PROCEDURE
2. Rear Differential

G4M0792
6) Using ST, loosen lock nut.
ST 926230000 SPANNER
G4M0793
7) Tighten adjusting screw until it no longer tightens.
G4M0794
8) Using a wrench [32 mm (1.26 in) width across flats] or
adjustable wrench, remove tie-rod.
CAUTION:

Check ball joint for free play, and tie-rod for bends.
Replace if necessary.

Check dust seals used with tie-rod end ball joint for
damage or deterioration. Replace if necessary.
9) Loosen adjusting screw and remove spring and sleeve.
CAUTION:
Replace spring and/or sleeve if damaged.
G4M0795
10) Disconnect pipes A and B from steering body and con-
trol valve housing.
CAUTION:
Replace pipes and/or flare nuts if damaged.
32
4-3SERVICE PROCEDURE
4. Steering Gearbox (Power Steering System) [RHD model]

3. MEASUREMENT OF STEERING EFFORT
*4
Measure steering efforts in stand still with engine idling on
concrete road.
Result: 29.4 N (3.0 kg, 6.6 lb) or less in both directions
GOOD
NOT GOOD
Adjust backlash.
Measure steering efforts in stand still with engine stalled on
concrete road.
Result: 294.2 N (30.0 kg, 66.2 lb) or less in both directions
NOT GOOD GOOD*4 When turning steering more
quickly than necessary from
a direction to the other direc-
tion at an engine speed over
2,000 rpm, steering effort
may be heavy. This is caused
by flow characteristic of oil
pump and is not a problem.
Adjust backlash.
Remove universal joint.
Measure steering wheel effort.
Result: Maximum force is 2.26 N (0.23 kg, 0.51 lb) or less in
both directions.
Fluctuation width is 1.08 N (0.11 kg, 0.24 lb) or less.
GOOD
NOT GOOD
Check, readjust, replace if
necessary.
Measure folding torque of the joint.
Result: 5.49 N (0.56 kg, 1.23 lb) or less for long yoke
8.43 N (0.86 kg, 1.90 lb) or less for short yoke
GOOD
NOT GOOD
Replace with a new one.
Check front wheels for unsteady revolution or rattling and brake
for dragging.
GOOD
NOT GOOD
Inspect, readjust, replace if
necessary.
Remove tie-rod ends.
(To be continued.)








87
4-3DIAGNOSTICS
1. Power Steering