1999 SUBARU LEGACY specifications

C: INSPECTION
1. VALVE ROCKER ARM
1) Measure inside diameter of valve rocker arm
and outside diameter of valve rocker shaft, and
determine the difference between the two (= oil
clearance).
Clearance between arm and shaft:
Standard
0.020 Ð 0.054 mm (0.0008 Ð 0.0021 in)
Limit
0.10 mm (0.0039 in)
IIf oil clearance exceeds specifications, replace
valve rocker arm or shaft.
NOTE:
Replace valve rocker arm or shaft, whichever
shows greater amount of wear.
Rocker arm inside diameter:
22.020 Ð 22.041 mm (0.8669 Ð 0.8678 in)
Rocker shaft diameter:
21.987 Ð 22.000 mm (0.8656 Ð 0.8661 in)
B2M0072
B2M0073
2) Measure inside diameter of rocker shaft sup-
port and outside diameter of valve rocker shaft,
and determine the difference between the two (=
oil clearance).
Clearance between support and shaft:
Standard
0.005 Ð 0.039 mm (0.0002 Ð 0.0015 in)
Limit
0.05 mm (0.0020 in)
IIf oil clearance exceeds specifications, replace
rocker shaft support or shaft.
NOTE:
Replace rocker shaft support or shaft, whichever
shows greater amount of wear.
Rocker shaft support inside diameter:
22.005 Ð 22.026 mm (0.8663 Ð 0.8672 in)
Rocker shaft diameter:
21.987 Ð 22.000 mm (0.8656 Ð 0.8661 in)
3) If cam or valve contact surface of valve rocker
arm is worn or dented excessively, replace valve
rocker arm.
4) Check that valve rocker arm roller rotates
smoothly. If not, replace valve rocker arm.
2. INTAKE AND EXHAUST VALVE
ROCKER SHAFT
Visually check oil relief valve of shaft end for any
of the following abnormalities.
IBreaks in check ball body
IForeign particles caught in valve spring
IOil leakage at check ball
CAUTION:
Repair or replace valve rocker shaft as neces-
sary.
29
[W3C2]2-3aSERVICE PROCEDURE
3. Valve Rocker Assembly

3) Measure outside diameter of camshaft journal
and inside diameter of cylinder head journal, and
determine the difference between the two (= oilclearance). If oil clearance exceeds specifications,
replace camshaft or cylinder head as necessary.
Unit: mm (in)
Clearance at journalStandard 0.055 Ð 0.090 (0.0022 Ð 0.0035)
Limit 0.118 (0.0046)
Camshaft journal O.D. 31.928 Ð 31.945 (1.2570 Ð 1.2577)
Journal hole I.D. 32.000 Ð 32.018 (1.2598 Ð 1.2605)
4) Check cam face condition; remove minor faults
by grinding with oil stone. Measure the cam height
H; replace if the limit has been exceeded.
Cam height: H
Unit: mm (in)
Item Standard Limit
Intake34.00 Ð 38.782
(1.3386 Ð 1.5268)33.84 (1.3323)
Exhaust34.00 Ð 39.307
(1.3386 Ð 1.5475)33.84 (1.3323)
Cam base circle diameter A:
IN: 27.5 mm (1.083 in)
EX: 27.0 mm (1.063 in)
B2M1209A
2. CAMSHAFT SUPPORT
Measure the thrust clearance of camshaft with dial
gauge. If the clearance exceeds the limit, replace
camshaft support.
Standard:
0.030 Ð 0.090 mm (0.0012 Ð 0.0035 in)
Limit:
0.11 mm (0.0043 in)
B2M2618A
35
[W4B2]2-3aSERVICE PROCEDURE
4. Camshaft

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
46
2-3a[W5C4]SERVICE PROCEDURE
5. Cylinder Head

7) Replacement procedure is as follows.
(1) Remove bushing from connecting rod with
ST and press.
(2) Press bushing with ST after applying oil on
the periphery of bushing.
ST 499037100 CONNECTING ROD BUSH-
ING REMOVER AND
INSTALLER
G2M0177
(3) Make two 3 mm (0.12 in) holes in bushing.
Ream the inside of bushing.
(4) After completion of reaming, clean bushing
to remove chips.
6. CRANKSHAFT AND CRANKSHAFT
BEARING
1) Clean crankshaft completely and check for
cracks by means of red lead check etc., and
replace if defective.
2) Measure the crankshaft bend, and correct or
replace if it exceeds the limit.
CAUTION:
If a suitable V-block is not available, install #1
and #5 crankshaft bearing on cylinder block,
position crankshaft on these bearings and
measure crankshaft bend using a dial gauge.
Crankshaft bend limit:
0.035 mm (0.0014 in)
G2M0178
3) Inspect the crank journal and crank pin for
wear. If not to specifications, replace bearing with
an undersize one, and replace or recondition
crankshaft as necessary. When grinding crank
journal or crank pin, finish them to the specified
dimensions according to the undersize bearing to
be used.
Crank pin and crank journal:
Out-of-roundness
0.030 mm (0.0012 in) or less
Taper limit
0.07 mm (0.0028 in)
Grinding limit
0.250 mm (0.0098 in)
G2M0179
61
[W6C6]2-3aSERVICE PROCEDURE
6. Cylinder Block

1. Engine
A: SPECIFICATIONS
EngineTypeHorizontally opposed, liquid cooled, 4-cylinder,
4-stroke gasoline engine
Valve arrangementBelt driven, double over-head camshaft, 4-valve/
cylinder
Bore´Stroke mm (in) 99.5´79.0 (3.917´3.110)
Displacement cm
3(cu in) 2,457 (149.93)
Compression ratio 9.5
Compression pressure
(at 200 Ð 300 rpm)Standard kPa (kg/cm
2, psi) þ rpm 1,216 (12.4, 176) þ 350
Limit kPa (kg/cm2, psi) þ rpm 941 (9.6, 137) þ 350
Number of piston rings Pressure ring: 2, Oil ring: 1
Intake valve timingOpening 6É BTDC
Closing 50É ABDC
Exhaust valve timingOpeningFront: 54É BBDC, Rear: 30É BBDC (Position in
degrees)
ClosingFront: 10É ATDC, Rear: 10É ATDC (Position in
degrees)
Valve clearanceIntake mm (in) 0.20±0.02 (0.0079±0.0008)
Exhaust mm (in) 0.25±0.02 (0.0098±0.0008)
Idling speed
[At neutral position on MT, or ªPº
or ªNº position on AT]rpm700±100 (No load)
850±50 (A/C switch ON)
Firing order 1®3®2®4
Ignition timing BTDC/rpm 15ɱ8É/700 rpm
2
2-3b[S1A0]SPECIFICATIONS AND SERVICE DATA
1. Engine

B: SERVICE DATA
NOTE:
STD: Standard, I.D.: Inner Diameter, O.D.: Outer Diameter, OS: Oversize, US: Undersize
Belt ten-
sion
adjusterProtrusion of adjuster rod 5.2 Ð 6.2 mm (0.205 Ð 0.244 in)
Belt ten-
sionerSpacer O.D. 17.955 Ð 17.975 mm (0.7069 Ð 0.7077 in)
Tensioner bush I.D. 18.00 Ð 18.08 mm (0.7087 Ð 0.7118 in)
Clearance between spacer and
bushSTD 0.025 Ð 0.125 mm (0.0010 Ð 0.0049 in)
Limit 0.175 mm (0.0069 in)
Side clearance of spacerSTD 0.2 Ð 0.55 mm (0.0079 Ð 0.0217 in)
Limit 0.81 mm (0.0319 in)
CamshaftBend limit 0.020 mm (0.0008 in)
Thrust clearanceSTD 0.040 Ð 0.080 mm (0.0016 Ð 0.0031 in)
Limit 0.10 mm (0.0039 in)
Cam lobe heightIntakeSTD 42.20 Ð 42.30 mm (1.6614 Ð 1.6654 in)
Limit 42.04 mm (1.6551 in)
ExhaustSTDFront: 42.50 Ð 42.60 mm
Rear: 41.40 Ð 41.50 mm(1.6732 Ð 1.6772 in) (1.6299
Ð 1.6339 in)
LimitFront: 42.34 mm Rear: 41.24
mm(1.6669 in) (1.6236 in)
Camshaft journal O.D.Front 31.946 Ð 31.963 mm (1.2577 Ð 1.2584 in)
Center 27.946 Ð 27.963 mm (1.1002 Ð 1.1009 in)
Rear 27.946 Ð 27.963 mm (1.1002 Ð 1.1009 in)
Camshaft journal hole I.D.Front 32.000 Ð 32.018 mm (1.2598 Ð 1.2605 in)
Center 28.000 Ð 28.018 mm (1.1024 Ð 1.1031 in)
Rear 28.000 Ð 28.018 mm (1.1024 Ð 1.1031 in)
Oil clearanceSTD 0.037 Ð 0.072 mm (0.0015 Ð 0.0028 in)
Limit 0.10 mm (0.0039 in)
Cylinder
headSurface warpage limit 0.05 mm (0.0020 in)
Surface grinding limit 0.3 mm (0.012 in)
Standard height 127.5 mm (5.02 in)
Valve seatRefacing angle 90É
Contacting widthIntakeSTD 1.0 mm (0.039 in)
Limit 1.7 mm (0.067 in)
ExhaustSTD 1.5 mm (0.059 in)
Limit 2.2 mm (0.087 in)
Valve guideInner diameter 6.000 Ð 6.015 mm (0.2362 Ð 0.2368 in)
Protrusion above head 12.0 Ð 12.4 mm (0.472 Ð 0.488 in)
ValveHead edge thicknessIntakeSTD 1.2 mm (0.047 in)
Limit 0.8 mm (0.031 in)
ExhaustSTD 1.5 mm (0.059 in)
Limit 0.8 mm (0.031 in)
Stem diameterIntake 5.950 Ð 5.965 mm (0.2343 Ð 0.2348 in)
Exhaust 5.950 Ð 5.965 mm (0.2343 Ð 0.2348 in)
Stem oil clearanceSTDIntake 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 Ð 0.15 mm (0.0059 in)
Overall lengthIntake 105.9 mm (4.169 in)
Exhaust 106.2 mm (4.181 in)
3
[S1B0]2-3bSPECIFICATIONS AND SERVICE DATA
1. Engine

Valve
springFree length 48.04 mm (1.8913 in)
Squareness 2.5É, 2.1 mm (0.083 in)
Tension/spring height146.1 Ð 167.7 N (14.9 Ð 17.1 kg, 32.9 Ð 37.7 lb)/42.0 mm
(1.654 in) 455.0 Ð 523.7 N (46.4 Ð 53.4 kg, 102.3 Ð 117.7
lb)/33.4 mm (1.315 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 Ð 99.515 mm (3.9175 Ð 3.9179 in)
B 99.495 Ð 99.505 mm (3.9171 Ð 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 Ð 0.030 mm (0.0004 Ð 0.0012 in)
Limit 0.050 mm (0.0020 in)
Enlarging (boring) limit 0.5 mm (0.020 in)
Piston Outer diameterSTDA 99.485 Ð 99.495 mm (3.9167 Ð 3.9171 in)
B 99.475 Ð 99.485 mm (3.9163 Ð 3.9167 in)
0.25 mm (0.0098 in) OS 99.725 Ð 99.735 mm (3.9262 Ð 3.9266 in)
0.50 mm (0.0197 in) OS 99.975 Ð 99.985 mm (3.9360 Ð 3.9364 in)
Piston pinStandard clearance between piston
pin and hole in pistonSTD 0.004 Ð 0.010 mm (0.0002 Ð 0.0004 in)
Limit 0.020 mm (0.0008 in)
Degree of fitPiston pin must be fitted into position with thumb at 20ÉC
(68ÉF).
Piston ringPiston ring gapTop ringSTD 0.20 Ð 0.35 mm (0.0079 Ð 0.0138 in)
Limit 1.0 mm (0.039 in)
Second
ringSTD 0.37 Ð 0.52 mm (0.0146 Ð 0.0205 in)
Limit 1.0 mm (0.039 in)
Oil ringSTD 0.20 Ð 0.60 mm (0.0079 Ð 0.0236 in)
Limit 1.5 mm (0.059 in)
Clearance between
piston ring and piston
ring grooveTop ringSTD 0.040 Ð 0.080 mm (0.0016 Ð 0.0031 in)
Limit 0.15 mm (0.0059 in)
Second
ringSTD 0.030 Ð 0.070 mm (0.0012 Ð 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 Ð 0.330 mm (0.0028 Ð 0.0130 in)
Limit 0.4 mm (0.016 in)
Connecting
rod bearingOil clearanceSTD 0.010 Ð 0.038 mm (0.0004 Ð 0.0015 in)
Limit 0.05 mm (0.0020 in)
Thickness at center portionSTD 1.492 Ð 1.501 mm (0.0587 Ð 0.0591 in)
0.03 mm
(0.0012 in)
US1.510 Ð 1.513 mm (0.0594 Ð 0.0596 in)
0.05 mm
(0.0020 in)
US1.520 Ð 1.523 mm (0.0598 Ð 0.0600 in)
0.25 mm
(0.0098 in)
US1.620 Ð 1.623 mm (0.0638 Ð 0.0639 in)
Connecting
rod bush-
ingClearance between piston pin and
bushingSTD 0 Ð 0.022 mm (0 Ð 0.0009 in)
Limit 0.030 mm (0.0012 in)
4
2-3b[S1B0]SPECIFICATIONS AND SERVICE DATA
1. Engine

CrankshaftBend limit 0.035 mm (0.0014 in)
Crank pin and crank
journalOut-of-roundness 0.020 mm (0.0008 in) or less
Grinding limit 0.25 mm (0.0098 in)
Crank pin outer diameterSTD 51.984 Ð 52.000 mm (2.0466 Ð 2.0472 in)
0.03 mm
(0.0012 in)
US51.954 Ð 51.970 mm (2.0454 Ð 2.0461 in)
0.05 mm
(0.0020 in)
US51.934 Ð 51.950 mm (2.0446 Ð 2.0453 in)
0.25 mm
(0.0098 in)
US51.734 Ð 51.750 mm (2.0368 Ð 2.0374 in)
Crank journal outer
diameter#1, #5STD 59.992 Ð 60.008 mm (2.3619 Ð 2.3625 in)
0.03 mm
(0.0012 in)
US59.962 Ð 59.978 mm (2.3607 Ð 2.3613 in)
0.05 mm
(0.0020 in)
US59.942 Ð 59.958 mm (2.3599 Ð 2.3605 in)
0.25 mm
(0.0098 in)
US59.742 Ð 59.758 mm (2.3520 Ð 2.3527 in)
#2, #3, #4STD 59.992 Ð 60.008 mm (2.3619 Ð 2.3625 in)
0.03 mm
(0.0012 in)
US59.962 Ð 59.978 mm (2.3607 Ð 2.3613 in)
0.05 mm
(0.0020 in)
US59.942 Ð 59.958 mm (2.3599 Ð 2.3605 in)
0.25 mm
(0.0098 in)
US59.742 Ð 59.758 mm (2.3520 Ð 2.3527 in)
Thrust clearanceSTD 0.030 Ð 0.115 mm (0.0012 Ð 0.0045 in)
Limit 0.25 mm (0.0098 in)
Oil clearance#1, #5 STD 0.003 Ð 0.030 mm (0.0001 Ð 0.0012 in)
#2, #3, #4 STD 0.010 Ð 0.033 mm (0.0004 Ð 0.0013 in)
#1, #3, #5 Limit 0.040 mm (0.0016 in)
#2, #4 Limit 0.045 mm (0.0018 in)
5
[S1B0]2-3bSPECIFICATIONS AND SERVICE DATA
1. Engine