1999 SUBARU LEGACY light

1. Foreword
A: GENERAL
This chapter describes major inspection and ser-
vice procedures for the engine mounted on the
body. For procedures not found in this chapter,
refer to the service procedure section in the appli-
cable chapter.
2. Ignition Timing
A: MEASUREMENT
CAUTION:
After warming-up, engine becomes very hot.
Be careful not to burn yourself during mea-
surement.
1) Warm-up the engine.
2) To check the ignition timing, connect a timing
light to #1 cylinder spark plug cord, and illuminate
the timing mark with the timing light.
3) Start the engine at idle speed and check the
ignition timing.
Ignition timing [BTDC/rpm]:
2200 cc California spec. vehicles
15É
±8É/700
2200 cc except California spec. vehicles
10É
±8É/700 (MT model)
15É
±8É/700 (AT model)
2500 cc model
15É
±8É/700
B2M2010
If the timing is not correct, check the ignition con-
trol system.

2
2-2[W1A0]SERVICE PROCEDURE
1. Foreword

1. Foreword
A: GENERAL
This chapter describes major inspection and ser-
vice procedures for the engine mounted on the
body. For procedures not found in this chapter,
refer to the service procedure section in the appli-
cable chapter.
2. Ignition Timing
A: MEASUREMENT
CAUTION:
After warming-up, engine becomes very hot.
Be careful not to burn yourself during mea-
surement.
1) Warm-up the engine.
2) To check the ignition timing, connect a timing
light to #1 cylinder spark plug cord, and illuminate
the timing mark with the timing light.
3) Start the engine at idle speed and check the
ignition timing.
Ignition timing [BTDC/rpm]:
2200 cc California spec. vehicles
15É
±8É/700
2200 cc except California spec. vehicles
10É
±8É/700 (MT model)
15É
±8É/700 (AT model)
2500 cc model
15É
±8É/700
B2M2010
If the timing is not correct, check the ignition con-
trol system.

2
2-2[W1A0]SERVICE PROCEDURE
1. Foreword

3. Engine Idle Speed
A: MEASUREMENT
1) Before checking idle speed, check the follow-
ing:
(1) Ensure that air cleaner element is free from
clogging, ignition timing is correct, spark plugs
are in good condition, and that hoses are con-
nected properly.
(2) Ensure that malfunction indicator light
(CHECK ENGINE light) does not illuminate.
2) Warm-up the engine.
3) Stop the engine, and turn ignition switch to
OFF.
4) When using SUBARU SELECT MONITOR;
NOTE:
For detailed operation procedures, refer to the
SUBARU SELECT MONITOR OPERATION
MANUAL.
(1) Insert the cartridge to SUBARU SELECT
MONITOR.
ST 24082AA090 CARTRIDGE
S2M0286A
(2) Connect SUBARU SELECT MONITOR to
the data link connector.
(3) Turn ignition switch to ON, and SUBARU
SELECT MONITOR switch to ON.
(4) Select {2. Each System Check} in Main
Menu.
(5) Select {EGI/EMPI} in Selection Menu.
(6) Select {1. Current Data Display & Save} in
EGI/EMPI Diagnosis.
(7) Select {1.12 Data Display} in Data Display
Menu.(8) Start the engine, and read engine idle
speed.
S2M0098
5) When using tachometer (Secondary pick-up
type).
(1) Attach the pick-up clip to No. 1 cylinder
spark plug cord.
(2) Start the engine, and read engine idle
speed.
B2M2011
NOTE:
IWhen using the OBD-II general scan tool, care-
fully read its operation manual.
IThis ignition system provides simultaneous igni-
tion for #1 and #2 plugs. It must be noted that
some tachometers may register twice that of actual
engine speed.
6) Check idle speed when unloaded. (With
headlights, heater fan, rear defroster, radiator fan,
air conditioning, etc. OFF)
Idle speed (No load and gears in neutral (MT),
or N or P (AT) position):
700
±100 rpm
7) Check idle speed when loaded. (Turn air con-
ditioning switch to |P¢rdquo;ON|P'ldquo; and oper-
ate compressor for at least one minute before
measurement.)
Idle speed [A/C ªONº, no load and gears in
neutral (MT) or N or P (AT) position]:
850
±50 rpm
3
[W3A0]2-2SERVICE PROCEDURE
3. Engine Idle Speed

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

3) Remove crankshaft sprocket.
B2M2600A
S2M0414A
4) Remove belt cover No. 2 (LH).
5) Remove belt cover No. 2 (RH).
CAUTION:
Do not damage or lose the seal rubber when
removing belt covers.
B2M2601
6) Remove tensioner bracket.
H2M2380
B: INSPECTION
1. TIMING BELT
1) Check timing belt teeth for breaks, cracks, and
wear. If any fault is found, replace belt.
2) Check the condition of back side of belt; if any
crack is found, replace belt.
CAUTION:
IBe careful not to let oil, grease or coolant
contact the belt. Remove quickly and thor-
oughly if this happens.
IDo not bend the belt sharply.
Bending radius: h
60 mm (2.36 in) or more
G2M0115
2. AUTOMATIC BELT TENSION
ADJUSTER
1) Visually check oil seals for leaks, and rod ends
for abnormal wear or scratches. If necessary,
replace faulty parts.
CAUTION:
Slight traces of oil at rod's oil seal does not
indicate a problem.
2) Check that the adjuster rod does not move
when a pressure of 294 N (30 kg, 66 lb) is applied
to it. This is to check adjuster rod stiffness.
3) If the adjuster rod is not stiff and moves freely
when applying 294 N (30 kg, 66 lb), check it using
the following procedures:
(1) Slowly press the adjuster rod down to the
end surface of the cylinder. Repeat this motion
2 or 3 times.
(2) With the adjuster rod moved all the way up,
apply a pressure of 294 N (30 kg, 66 lb) to it.
Check adjuster rod stiffness.
(3) If the adjuster rod is not stiff and moves
down, replace the automatic belt tension
adjuster assembly with a new one.
CAUTION:
IAlways use a vertical type pressing tool to
move the adjuster rod down.
IDo not use a lateral type vise.
IPush adjuster rod vertically.
18
2-3a[W2B1]SERVICE PROCEDURE
2. Timing Belt

(5) Put new valve guide, coated with sufficient
oil, in cylinder, and insert ST1 into valve guide.
Press in until the valve guide upper end is flush
with the upper surface of ST2.
ST1 499767400 VALVE GUIDE REMOVER
Intake side:
ST2 499767700 VALVE GUIDE ADJUSTER
Exhaust side:
ST2 499767800 VALVE GUIDE ADJUSTER
B2M2632A
(6) Check the valve guide protrusion.
Valve guide protrusion: L
Intake
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)
B2M0077A
(7) Ream the inside of valve guide with ST.
Gently rotate the reamer clockwise while press-
ing it lightly into valve guide, and return it also
rotating clockwise. After reaming, clean valve
guide to remove chips.
CAUTION:
IApply engine oil to the reamer when ream-
ing.
IIf the inner surface of the valve guide is torn,
the edge of the reamer should be slightly
ground with an oil stone.
IIf the inner surface of the valve guide
becomes lustrous and the reamer does not
chips, use a new reamer or remedy the reamer.
ST 499767400 VALVE GUIDE REAMER
B2M0078
(8) Recheck the contact condition between
valve and valve seat after replacing valve guide.
45
[W5C3]2-3aSERVICE PROCEDURE
5. Cylinder Head

(5) Compress valve spring and fit valve spring
retainer key.
B2M2634A
(6) After installing, tap valve spring retainers
lightly with wooden hammer for better seating.
2) Install plug.
3) Install camshaft, camshaft cap and valve rocker
assembly.

4) Install plug using ST.
ST 499587100 OIL SEAL INSTALLER
5) Install oil seal using ST.
ST 499587500 OIL SEAL INSTALLER
E: INSTALLATION
1. CYLINDER HEAD
B2M2627B
(1) Cylinder head gasket
(2) Cylinder head(3) Cylinder head bolt
(4) Rocker cover
1) Install cylinder head and gaskets on cylinder
block.
CAUTION:
Use new cylinder head gaskets.
49
[W5E1]2-3aSERVICE PROCEDURE
5. Cylinder Head