1996 SUBARU LEGACY height

Valve springFree length 39.8 mm (1.567 in)
Squareness 2.5°, 1.7 mm (0.067 in)
Tension/spring height228.5—261.8 N
(23.3—26.7 kg, 51.4—58.9 lb)/31.0 mm (1.220 in)
462.9—531.5 N
(47.2—54.2 kg, 104.1—119.5 lb)/23.2 mm (0.913 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 99.505—99.515 mm (3.9175—3.9179 in)
B 99.495—99.505 mm (3.9171—3.9175 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—0.030 mm (0.0004—0.0012 in)
Limit 0.050 mm (0.0020 in)
Enlarging (boring) limit 0.5 mm (0.020 in)
Piston Outer diameterSTDA 99.485—99.495 mm (3.9167—3.9171 in)
B 99.475—99.485 mm (3.9163—3.9167 in)
0.25 mm (0.0098 in)
OS99.725—99.735 mm (3.9262—3.9266 in)
0.50 mm (0.0197 in)
OS99.975—99.985 mm (3.9360—3.9364 in)
Piston pinStandard clearance between piston
pin and hole in pistonSTD 0.004—0.010 mm (0.0002—0.0004 in)
Limit 0.020 mm (0.0008 in)
Degree of fitPiston pin must be fitted into position with thumb at 20°C
(68°F).
Piston ringPiston ring gapTop ringSTD 0.20—0.35 mm (0.0079—0.0138 in)
Limit 1.0 mm (0.039 in)
Second
ringSTD 0.37—0.52 mm (0.0146—0.0205 in)
Limit 1.0 mm (0.039 in)
Oil ringSTD 0.20—0.60 mm (0.0079—0.0236 in)
Limit 1.5 mm (0.059 in)
Clearance between piston
ring and piston ring grooveTop ringSTD 0.040—0.080mm (0.0016—0.0031 in)
Limit 0.15 mm (0.0059 in)
Second
ringSTD 0.030—0.070 mm (0.0012—0.0028 in)
Limit 0.15 mm (0.0059 in)
Connecting
rodBend twist per 100 mm (3.94 in) in
lengthLimit 0.10 mm (0.0039 in)
Side clearanceSTD 0.070—0.330 mm (0.0028—0.0130 in)
Limit 0.4 mm (0.016 in)
Connecting
rod bearingOil clearanceSTD 0.010—0.038 mm (0.0004—0.0015 in)
Limit 0.05 mm (0.0020 in)
Thickness at center portionSTD 1.492—1.501 mm (0.0587—0.0591 in)
0.03 mm
(0.0012 in)
US1.510—1.513 mm (0.0594—0.0596 in)
0.05 mm
(0.0020 in)
US1.520—1.523 mm (0.0598—0.0600 in)
0.25 mm
(0.0098 in)
US1.620—1.623 mm (0.0638—0.0639 in)
Connecting
rod bushingClearance between piston pin and
bushingSTD 0—0.022 mm (0—0.0009 in)
Limit 0.030 mm (0.0012 in)
STD: Standard OS: Oversize US: Undersize
4
2-3bSPECIFICATIONS AND SERVICE DATA
1. Engine

G2M0138
5) Check cam face condition; remove minor faults by
grinding with oil stone. Measure the cam height H; replace
if the limit has been exceeded.
Standard:
Intake 41.68—41.78 mm (1.6409—1.6449 in)
Exhaust 41.98—42.08 mm (1.6528—1.6567 in)
Limit:
Intake 41.52 mm (1.6346 in)
Exhaust 41.82 mm (1.6465 in)
G2M0748
6) Measure the thrust clearance of camshaft with dial
gauge. If the clearance exceeds the limit, replace caps and
cylinder head as a set. If necessary replace camshaft.
Standard:
0.040—0.080 mm (0.0016—0.0031 in)
Limit:
0.1 mm (0.004 in)
C: INSTALLATION
1. CAMSHAFT
G2M0750
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 10±0.7 (1.0±0.07, 7.2±0.5)
T2: 20±2 (2.0±0.2, 14.5±1.4)
32
2-3bSERVICE PROCEDURE
3. Camshaft

G2M0759
1) Remove hydraulic lash adjusters.
2) Compress the valve spring and remove the valve spring
retainer key. Remove each valve and valve spring.
ST1 498267600 CYLINDER HEAD TABLE
ST2 499718000 VALVE SPRING REMOVER
CAUTION:
Mark each valve to prevent confusion.
Use extreme care not to damage the lips of the
intake valve oil seals and exhaust valve oil seals.
G2M0760
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 check.
2) 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:
0.3 mm (0.012 in)
Standard height of cylinder head:
127.5 mm (5.02 in)
CAUTION:
Uneven torque for the cylinder head nuts can cause
warping. When reassembling, pay special attention to
the torque so as to tighten evenly.
37
2-3bSERVICE PROCEDURE
4. Cylinder Head

G2M0153
4. INTAKE AND EXHAUST VALVE
1) Inspect the flange and stem of valve, and replace if
damaged, worn, or deformed, or if“H”is less than the
specified limit.
H:
Intake
Standard
1.2 mm (0.047 in)
Limit
0.8 mm (0.031 in)
Exhaust
Standard
1.5 mm (0.059 in)
Limit
0.8 mm (0.031 in)
Valve overall length:
Intake 93.3 mm (3.673 in)
Exhaust 93.6 mm (3.685 in)
2) Put a small amount of grinding compound on the seat
surface and lap the valve and seat surface. Install a new
intake valve oil seal after lapping.
G2M0154
5. VALVE SPRINGS
1) Check valve springs for damage, free length, and ten-
sion. Replace valve spring if it is not to the specifications
presented below.
2) To measure the squareness of the valve spring, stand
the spring on a surface plate and measure its deflection at
the top using a try square.
Valve spring
Free length 39.8 mm (1.567 in)
Tension/spring height228.5—261.8 N
(23.3—26.7 kg, 51.4—58.9 lb)/31.0 mm
(1.220 in)
462.9—531.5 N
(47.2—54.2 kg, 104.1—119.5 lb)/23.2 mm
(0.913 in)
Squareness 2.5°, 1.7 mm (0.067 in)
40
2-3bSERVICE PROCEDURE
4. Cylinder Head

C: INSPECTION
1. CYLINDER BLOCK
1) Check for cracks and damage visually. Especially,
inspect important parts by means of red lead check.
2) Check the oil passages for clogging.
3) Inspect crankcase surface that mates with cylinder
head for warping by using a straight edge, and correct by
grinding if necessary.
Warping limit:
0.05 mm (0.0020 in)
Grinding limit:
0.1 mm (0.004 in)
Standard height of cylinder block:
201.0 mm (7.91 in)
B2M0082A
2. CYLINDER AND PISTON
1) The cylinder bore size is stamped on the cylinder
block’s front upper surface.
NOTE:
Standard sized pistons are classified into two grades,“A”
and“B”. These grades should be used as a guide line in
selecting a standard piston.
Standard diameter:
A: 99.505—99.515 mm (3.9175—3.9179 in)
B: 99.495—99.505 mm (3.9171—3.9175 in)
56
2-3bSERVICE PROCEDURE
5. Cylinder Block

G2M0170
2) How to measure the inner diameter of each cylinder
Measure the inner diameter of each cylinder in both the
thrust and piston pin directions at the heights shown in the
Figure, using a cylinder bore gauge.
CAUTION:
Measurement should be performed at a temperature
20°C (68°F).
Taper:
Standard
0.015 mm (0.0006 in)
Limit
0.050 mm (0.0020 in)
Out-of-roundness:
Standard
0.010 mm (0.0004 in)
Limit
0.050 mm (0.0020 in)
3) When piston is to be replaced due to general or cylin-
der wear, determine a suitable sized piston by measuring
the piston clearance.
B2M0419B
4) How to measure the outer diameter of each piston
Measure the outer diameter of each piston at the height
shown in the Figure. (Thrust direction)
CAUTION:
Measurement should be performed at a temperature of
20°C (68°F).
Piston outer diameter:
Standard
A: 99.485—99.495 mm (3.9167—3.9171 in)
B: 99.475—99.485 mm (3.9163—3.9167 in)
0.25 mm (0.0098 in) oversize
99.725—99.735 mm (3.9262—3.9266 in)
0.50 mm (0.0197 in) oversize
99.975—99.985 mm (3.9360—3.9364 in)
5) Calculate the clearance between cylinder and piston.
CAUTION:
Measurement should be performed at a temperature of
20°C (68°F).
Cylinder to piston clearance at 20°C (68°F):
Standard
0.010—0.030 mm (0.0004—0.0012 in)
Limit
0.050 mm (0.0020 in)
57
2-3bSERVICE PROCEDURE
5. Cylinder Block

B3M0042A
2) Installation of shifter arm
1and selector arm
8
Install shifter arm into the partition from the front while
inserting selector arm into the opening in reverse check
sleeve. Pass shaft through hole in selector arm until its end
comes out of the rear of transfer case.
NOTE:
Apply a coat of gear oil to shifter arm. Also make sure oil
seal is positioned properly.
Tightening torque:
T1: 6.4±0.5 N⋅m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)
T2: 10±1 N⋅m (1.0±0.1 kg-m, 7.2±0.7 ft-lb)
T3: 19.6±1.5 N⋅m (2.00±0.15 kg-m, 14.5±1.1 ft-lb)
T4: 25±2 N⋅m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
B3M0049A
3. COMBINATION OF TRANSFER CASE AND
EXTENSION ASSEMBLY
1) Install center differential

1and transfer driven gear
2
into transfer case.
Tightening torque:
T: 37±3 N⋅m (3.8±0.3 kg-m, 27.5±2.2 ft-lb)
B3M0050A
2) Selection of thrust washer (52 x 61 x t)
(1) Measure height“W”between transfer case and ball
bearing on the transfer driven gear

3.
26
3-1SERVICE PROCEDURE
2. Transfer Case and Extension (AWD Model)

No. Part Name Part Number Dimension mm (in) Application
1 Control piston2500 cc 31235AA000—030
13.5
0.030
0.037(0.53150.0012
0.0015), 13.50.023
0.030(0.53150.0009
0.0012),
13.50.016
0.023(0.53150.0006
0.0009), 13.50.009
0.016(0.53150.0004
0.0006)Adjusting side clear-
ance of oil pump
2200 cc 31235AA040 — 070
2 Cam ring 31241AA001 — 03117
0.010
0.017(0.66930.0004
0.0007), 170.003
0.010(0.66930.0001
0.0004),
17+0.004
0.003(0.6693+0.0002
0.0001), 17+0.011
+0.004(0.6693+0.0004
+0.0002)Adjusting side clear-
ance of oil pump
3 Vane (Oil pump) 31243AA000 — 03017
0.030
0.037(0.66930.0012
0.0015), 170.023
0.030(0.66930.0009
0.0012),
170.016
0.023(0.66930.0006
0.0009), 17+0.009
+0.016(0.6693+0.0004
+0.0006)Adjusting side clear-
ance of oil pump
4 Rotor (Oil pump) 31240AA000 — 03017
0.030
0.037(0.66930.0012
0.0015), 170.023
0.030(0.66930.0009
0.0012),
170.016
0.023(0.66930.0006
0.0009), 17+0.009
+0.016(0.6693+0.0004
+0.0006)Adjusting side clear-
ance of oil pump
5Thrust washer
(Reverse clutch)31299AA000 — 0600.7, 0.9, 1.1, 1.3, 1.5, 1.7, 1.9
(0.028, 0.035, 0.043, 0.051, 0.059, 0.067, 0.075)Adjusting end play of
reverse clutch drum
6 Bearing race 803031021 — 0270.8, 1.0, 1.2, 1.4, 1.6, 1.8, 2.0
(0.031, 0.039, 0.047, 0.055, 0.063, 0.071, 0.079)Adjusting total end
play
7 Retaining plate 31567AA350 — 4004.6, 4.8, 5.0, 5.2, 5.4, 5.6 (0.181, 0.189, 0.197, 0.205,
0.213, 0.220)Adjusting clearance
of reverse clutch
8 Retaining plate31567AA340,
31567AA190 — 2603.4, 3.6, 3.8, 4.0, 4.2, 4.4, 4.6, 4.8, 5.0
(0.134, 0.142, 0.150, 0.157, 0.165, 0.173, 0.181, 0.189,
0.197)Adjusting clearance
of high clutch
9 Retaining plate31567AA010,
31567AA060 — 1104.0, 4.2, 4.4, 4.6, 4.8, 5.0, 5.2
(0.157, 0.165, 0.173, 0.181, 0.189, 0.197, 0.205)Adjusting clearance
of forward clutch
10 Retaining plate 31567AA410 — 4708.0, 8.2, 8.4, 8.6, 8.8, 9.0, 9.2
(0.315, 0.323, 0.331, 0.339, 0.346, 0.354, 0.362)Adjusting clearance
of overrunning clutch
11Retaining plate
No. 231667AA180 — 2506.5, 6.8, 7.1, 7.4, 7.7, 8.0, 8.2, 8.4
(0.256, 0.268, 0.280, 0.291, 0.303, 0.315, 0.323, 0.331)Adjusting clearance
of low and reverse
brake
12Pressure plate
(Front)31593AA151 — 1813.3, 3.7, 4.1, 4.5
(0.130, 0.146, 0.161, 0.177)Adjusting clearance
of transfer clutch
13Thrust bearing
(35x53xT)806536020,
806535030 — 070,
0903.8, 4.0, 4.2, 4.4, 4.6, 4.8, 5.0
(0.150, 0.157, 0.165, 0.173, 0.181, 0.189, 0.197)Adjusting end play of
transfer clutch
14Washer
(38.1 x 50 x T)803038021 — 0230.95, 1.00, 1.05
(0.0374, 0.0394, 0.0413)Adjusting backlash
of differential bevel
gear
15 Drive pinion shim 31451AA050 — 1000.150, 0.175, 0.200, 0.225, 0.250, 0.275
(0.0059, 0.0069, 0.0079, 0.0089, 0.0098, 0.0108)Adjusting drive pin-
ion height
5
3-2SPECIFICATIONS AND SERVICE DATA
1. Automatic Transmission and Differential