1999 SUBARU LEGACY Service Repair Manual

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 498267800 CYLINDER HEAD TABLE
3) Measure the warping of the cylinder head sur-
face that mates with crankcase using a straight
edge and thickness 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:
97.5 mm (3.839 in)
CAUTION:
Uneven torque for the cylinder head bolts can
cause warping. When reassembling, pay spe-
cial attention to the torque so as to tighten
evenly.
G2M0148
2. VALVE SEAT
Inspect intake and exhaust valve seats, and cor-
rect the contact surfaces with valve seat cutter if
they are defective or when valve guides are
replaced.
Valve seat width: W
Intake
Standard 1.0 mm (0.039 in)
Limit 1.7 mm (0.067 in)
Exhaust
Standard 1.4 mm (0.055 in)
Limit 2.1 mm (0.083 in)
G2M0149
B2M0074
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[W5C2]2-3aSERVICE PROCEDURE
5. Cylinder Head

3. VALVE GUIDE
1) Check the clearance between valve guide and
stem. The clearance can be checked by measur-
ing the outside diameter of valve stem and the
inside diameter of valve guide with outside and
inside micrometers respectively.
Clearance between the valve guide and valve
stem:
Standard
Intake 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
0.15 mm (0.0059 in)
Valve guide inner diameter:
6.000 Ð 6.012 mm (0.2362 Ð 0.2367 in)
B2M0387A
Valve stem outer diameters:
Intake
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)
B2M0076A
2) If the clearance between valve guide and stem
exceeds the specification, replace guide as fol-
lows:
(1) Place cylinder head on ST1 with the com-
bustion chamber upward so that valve guides
enter the holes in ST1.
(2) Insert ST2 into valve guide and press it
down to remove valve guide.
ST1 498267800 CYLINDER HEAD TABLE
ST2 499767400 VALVE GUIDE REMOVER
G2M0150
(3) Turn cylinder head upside down and place
ST as shown in the figure.
Intake side:
ST 499767700 VALVE GUIDE ADJUSTER
Exhaust side:
ST 499767800 VALVE GUIDE ADJUSTER
B2M0077B
(4) Before installing new oversize valve guide,
make sure that neither scratches nor damages
exist on the inside surface of the valve guide
holes in cylinder head.
44
2-3a[W5C3]SERVICE PROCEDURE
5. Cylinder Head

(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

4. INTAKE AND EXHAUST VALVE
1) Inspect the flange and stem of valve, and
replace if damaged, worn, or deformed, or if ªHº is
less than the specified limit.
H:
Intake
Standard 1.0 mm (0.039 in)
Limit 0.6 mm (0.024 in)
Exhaust
Standard 1.2 mm (0.047 in)
Limit 0.6 mm (0.024 in)
Valve overall length:
Intake
120.6 mm (4.75 in)
Exhaust
121.7 mm (4.79 in)
G2M0153
2) Put a small amount of grinding compound on
the seat surface and lap the valve and seat sur-
face. Install a new intake
valve oil seal after lapping.
5. VALVE SPRING
1) Check valve springs for damage, free length,
and tension. 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.
Free 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)
G2M0154
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2-3a[W5C4]SERVICE PROCEDURE
5. Cylinder Head

6. INTAKE AND EXHAUST VALVE OIL
SEAL
Replace oil seal with new one, if lip is damaged or
spring out of place, or when the surfaces of intake
valve and valve seat are reconditioned or intake
valve guide is replaced.
1) Place cylinder head on ST1.
2) Press-fit oil seal to the specified dimension indi-
cated in the figure using ST2.
CAUTION:
IApply engine oil to oil seal before press-fit-
ting.
IWhen press-fitting oil seal, do not use ham-
mer or strike in.
IDifferentiate between intake valve oil seal
and exhaust valve oil seal by noting their dif-
ference in color.
ST1 498267800 CYLINDER HEAD TABLE
ST2 498857100 VALVE OIL SEAL GUIDE
Color of rubber part:
Intake [Black]
Exhaust [Brown]
Color of spring part:
Intake [Silver]
Exhaust [Silver]
B2M2633A
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[W5C6]2-3aSERVICE PROCEDURE
5. Cylinder Head

D: ASSEMBLY
B2M2629B
(1) Valve
(2) Valve guide
(3) Valve spirng seat
(4) Oil seal
(5) Valve spring(6) Retainer
(7) Retainer key
(8) Spark plug gasket
(9) Camshaft
(10) Oil seal(11) Plug
(12) Camshaft cap
(13) Valve rocker ASSY
1) Installation of valve spring and valve
(1) Place cylinder head on ST.
ST 498267400 CYLINDER HEAD TABLE
(2) Coat stem of each valve with engine oil and
insert valve into valve guide.
CAUTION:
When inserting valve into valve guide, use spe-
cial care not to damage the oil seal lip.
(3) Install valve spring and retainer.
CAUTION:
Be sure to install the valve springs with their
close-coiled end facing the seat on the cylinder
head.(4) Set ST on valve spring.
ST 499718000 VALVE SPRING REMOVER
B2M2630A
48
2-3a[W5D0]SERVICE 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

2) Tighten cylinder head bolts.
(1) Apply a coat of engine oil to washers and
bolt threads.
(2) Tighten all bolts to 29 N´m (3.0 kg-m, 22
ft-lb) in alphabetical sequence.
Then tighten all bolts to 69 N´m (7.0 kg-m, 51
ft-lb) in alphabetical sequence.
(3) Back off all bolts by 180É first; back them off
by 180É again.
(4) Tighten bolts (a) and (b) to 34 N´m (3.5
kg-m, 25 ft-lb).
(5) Tighten bolts (c), (d), (e) and (f) to 15 N´m
(1.5 kg-m, 11 ft-lb).
(6) Tighten all bolts by 80 to 90É in alphabetical
sequence.
CAUTION:
Do not tighten bolts more than 90É.
(7) Further tighten all bolts by 80 to 90É in
alphabetical sequence.
CAUTION:
Ensure that the total ªre-tightening angleº [in
the former two steps], do not exceed 180É.
B2M2628B
3) Install oil level gauge guide and tighten attach-
ing bolt (left side only).
4) Install timing belt, camshaft sprocket and
related parts.

2. RELATED PARTS
CAUTION:
Be careful not to scratch the mating surface of
cylinder block and oil pump.
1) Install engine coolant pipe.
2) Install intake manifold.
3) Connect blow-by hose.
4) Connect oil pressure switch connector.
5) Install camshaft position sensor and camshaft
position sensor support.
6) Install connector bracket attaching bolt.
7) Connect spark plug cords.
8) Install generator and bracket.
9) Install A/C compressor and bracket. (With A/C
model)
10) Install V-belt(s).
11) Remove ENGINE STAND (ST).
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2-3a[W5E2]SERVICE PROCEDURE
5. Cylinder Head