1996 SUBARU LEGACY length

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

G2M0175
3) Measure the clearance between piston ring and piston
ring groove with a thickness gauge.
CAUTION:
Before measuring the clearance, clean the piston ring
groove and piston ring.
Unit: mm (in)
Standard Limit
Clearance
between piston
ring and piston
ring grooveTop ring0.040—0.080
(0.0016—
0.0031)0.15 (0.0059)
Second ring0.030—0.070
(0.0012—
0.0028)0.15 (0.0059)
5. CONNECTING ROD
1) Replace connecting rod, if the large or small end thrust
surface is damaged.
G2M0196
2) Check for bend or twist using a connecting rod aligner.
Replace connecting rod if the bend or twist exceeds the
limit.
Limit of bend or twist per 100 mm (3.94 in) in length:
0.10 mm (0.0039 in)


1Thickness gauge


2Connecting rod
60
2-3bSERVICE PROCEDURE
5. Cylinder Block

B2M0318
3. SIDE CLEARANCE
Measure clearance between oil pump inner rotor and pump
cover. If the clearance exceeds the limit, replace rotor or
pump body.
Side clearance:
Standard
0.02—0.07 mm (0.0008—0.0028 in)
Limit
0.15 mm (0.0059 in)
4. OIL RELIEF VALVE
Check the valve for fitting condition and damage, and the
relief valve spring for damage and deterioration. Replace
the parts if defective.
Relief valve spring:
Free length; 71.8 mm (2.827 in)
Installed length; 54.7 mm (2.154 in)
Load when installed; 77.08 N (7.86 kg, 17.33 lb)
5. OIL PUMP CASE
Check the oil pump case for worn shaft hole, clogged oil
passage, worn rotor chamber, cracks, and other faults.
6. OIL SEAL
Check the oil seal lips for deformation, hardening, wear,
etc. and replace if defective.
G2M0076
D: ASSEMBLY
1) Install front oil seal by using ST.
ST 499587100 OIL SEAL INSTALLER
CAUTION:
Use a new oil seal.
7
2-4SERVICE PROCEDURE
1. Oil Pump

G2M0357
3) Install hose and hold down clips at positions indicated
in Figure.
Tightening torque:
1.0
+0.5
0N⋅m (0.1+0.05
0kg-m, 0.7+0.4
0ft-lb)
Type A: When fitting length is specified.
Type B: When fitting length is not specified.


1Fitting


2Clamp


3Hose

: 1.0 — 4.0 mm (0.039 — 0.157 in)
L: 20 — 25 mm (0.79 — 0.98 in)
G2M0358

1Hose


2Clip


3Pipe
Fuel return hose:
L = 20 — 25 mm (0.79 — 0.98 in)
Evaporation hose:
L = 15 — 20 mm (0.59 — 0.79 in)
G2M0356
4) Tighten band mounting bolts.
Tightening torque:
33±10 N⋅m (3.4±1.0 kg-m, 25±7 ft-lb)
G4M0545
5) Install rear crossmember.
15
2-8SERVICE PROCEDURE
3. Fuel Tank

G2M0357
B: INSTALLATION
Installation is in the reverse order of removal.
1) Connect fuel delivery hose to pipe with an overlap of 20
to 25 mm (0.79 to 0.98 in).
Type A: When fitting length is specified.
Type B: When fitting length is not specified.


1Fitting


2Clamp


3Hose

: 1.0—4.0 mm (0.039—0.157 in)
L: 20—25 mm (0.79—0.98 in)
G2M0358
2) Connect evaporation hose to pipe by approx. 15 mm
(0.59 in) from hose end.


1Hose


2Clip


3Pipe
L=15—20 mm (0.59—0.79 in)
CAUTION:
Be sure to inspect hoses and their connections for any
leakage of fuel.
24
2-8SERVICE PROCEDURE
8. Fuel Delivery, Return and Evaporation Lines

G2M0357
3) Install hose and hold down clips at positions indicated
in Figure.
Tightening torque:
1.0
+0.5
0N⋅m (0.1+0.05
0kg-m, 0.7+0.4
0ft-lb)
Type A: When fitting length is specified.
Type B: When fitting length is not specified.


1Fitting


2Clamp


3Hose

: 1.0 — 4.0 mm (0.039 — 0.157 in)
L: 20 — 25 mm (0.79 — 0.98 in)
G2M0358

1Hose


2Clip


3Pipe
Fuel return hose:
L = 20 — 25 mm (0.79 — 0.98 in)
Evaporation hose:
L = 15 — 20 mm (0.59 — 0.79 in)
G2M0356
4) Tighten band mounting bolts.
Tightening torque:
33±10 N⋅m (3.4±1.0 kg-m, 25±7 ft-lb)
G4M0545
5) Install rear crossmember.
15
2-8SERVICE PROCEDURE
3. Fuel Tank

G2M0357
B: INSTALLATION
Installation is in the reverse order of removal.
1) Connect fuel delivery hose to pipe with an overlap of 20
to 25 mm (0.79 to 0.98 in).
Type A: When fitting length is specified.
Type B: When fitting length is not specified.


1Fitting


2Clamp


3Hose

: 1.0—4.0 mm (0.039—0.157 in)
L: 20—25 mm (0.79—0.98 in)
G2M0358
2) Connect evaporation hose to pipe by approx. 15 mm
(0.59 in) from hose end.


1Hose


2Clip


3Pipe
L=15—20 mm (0.59—0.79 in)
CAUTION:
Be sure to inspect hoses and their connections for any
leakage of fuel.
24
2-8SERVICE PROCEDURE
8. Fuel Delivery, Return and Evaporation Lines

G3M0863
(6) Remove control valve body and two brackets.
Remove 6 long bolts (Black) and 11 short bolts (Yellow).
NOTE:
Be careful because oil flows from valve body.
Be careful not to damage accumulator spring at rear of
control valve.
G3M0864
(7) Remove shift solenoids 1, 2, and 3, and duty sole-
noid A.
a length : 16 mm (0.63 in)
b length : 27 mm (1.06 in)
(8) Remove duty solenoid B.
G3M0302
2) Installation
(1) Install duty solenoid B (lock-up).
Tightening torque:
11.3±1.5 N⋅m (1.15±0.15 kg-m, 8.3±1.1 ft-lb)
G3M0864
(2) Install solenoid valves.
Shift solenoids, 1, 2 and 3, and duty solenoid A (line
pressure).
Tightening torque:
8±1 N⋅m (0.8±0.1 kg-m, 5.8±0.7 ft-lb)
32
3-2SERVICE PROCEDURE
2. On-Car Services