1999 SUBARU LEGACY engine

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
47
[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

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).
50
2-3a[W5E2]SERVICE PROCEDURE
5. Cylinder Head

(4) Position the upper rail gap at (C) or (D) in
the figure.
B2M2636A
(5) Position the expander gap at 180É of the
reverse side for the upper rail gap.
(6) Position the lower rail gap at (E) or (F) in the
figure.
CAUTION:
IEnsure ring gaps do not face the same direc-
tion.
IEnsure ring gaps are not within the piston
skirt area.
B2M2636A
5) Install circlip.
Install circlips in piston holes located opposite ser-
vice holes in cylinder block, when positioning all
pistons in the corresponding cylinders.
CAUTION:
Use new circlips.
B2M1403A
CAUTION:
Piston front mark faces towards the front of the
engine.
B2M2800A
64
2-3a[W6D1]SERVICE PROCEDURE
6. Cylinder Block

2. CYLINDER BLOCK
B2M2407A
(1) Crankshaft bearing
(2) Crankshaft
(3) Cylinder block(4) Rear oil sealTightening torque: N´m (kg-m, ft-lb)
T1:
25±2 (2.5±0.2, 18.1±1.4)
T2:47±3 (4.8±0.3, 34.7±2.2)
1) Install ST to cylinder block, then install crank-
shaft bearings.
ST 499817000 ENGINE STAND
CAUTION:
Remove oil in the mating surface of bearing
and cylinder block before installation. Also
apply a coat of engine oil to crankshaft pins.
2) Position crankshaft on the #2 and #4 cylinder
block.3) Apply fluid packing to the mating surface of #1
and #3 cylinder block, and position it on #2 and #4
cylinder block.
Fluid packing:
THREE BOND 1215 or equivalent
CAUTION:
Do not allow fluid packing to jut into O-ring
grooves, oil passages, bearing grooves, etc.
G2M0185
65
[W6D2]2-3aSERVICE PROCEDURE
6. Cylinder Block

3. PISTON AND PISTON PIN (#1 AND #2)
B2M1322E
(1) Piston
(2) Piston pin
(3) Circlip(4) Gasket
(5) Service hole plugTightening torque: N´m (kg-m, ft-lb)
T:
69±7 (7.0±0.7, 50.6±5.1)
1) Installing piston
(1) Turn cylinder block so that #1 and #2 cylin-
ders face upward.
(2) Using ST1, turn crankshaft so that #1 and
#2 connecting rods are set at bottom dead cen-
ter.
ST1 499987500 CRANKSHAFT SOCKET
(3) Apply a coat of engine oil to pistons and
cylinders and insert pistons in their cylinders
using ST2.
ST2 498747100 PISTON GUIDE
S2M0306A
2) Installing piston pin
(1) Insert ST3 into service hole to align piston
pin hole with connecting rod small end.
CAUTION:
Apply a coat of engine oil to ST3 before inser-
tion.
ST3 499017100 PISTON PIN GUIDE
G2M0189
(2) Apply a coat of engine oil to piston pin and
insert piston pin into piston and connecting rod
through service hole.
67
[W6D3]2-3aSERVICE PROCEDURE
6. Cylinder Block

(2) Apply fluid packing to matching surface of
oil pump.
Fluid packing:
THREE BOND 1215 or equivalent
S2M0739A
(3) Apply a coat of engine oil to the inside of the
oil seal.
S2M0118A
(4) Install oil pump on cylinder block. Be care-
ful not to damage oil seal during installation.
CAUTION:
IDo not forget to install O-ring and seal when
installing oil pump.
IAlign flat surface of oil pump's inner rotor
with crankshaft before installation.
9) Install water pump and gasket.
CAUTION:
IBe sure to use a new gasket.
IWhen installing water pump, tighten bolts in
two stages in alphabetical sequence as shown
in figure.
H2M1568B
10) Install water by-pass pipe for heater.
11) Install oil filter using ST.
ST 498187300 OIL FILTER WRENCH
B2M2611A
2. RELATED PARTS
1) Install cylinder head, valve rocker assembly
and rocker cover.

2) Install timing belt and camshaft sprocket.

3) Install water pipe.
4) Install intake manifold.
72
2-3a[W6E2]SERVICE PROCEDURE
6. Cylinder Block

1. Engine Trouble in General
NOTE:
ªRANKº shown in the chart refer to the possibility of reason for the trouble in order (ªVery oftenº to ªRarelyº)
A Ð Very often
B Ð Sometimes
C Ð Rarely
TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK
1. Engine will not start.
1) Starter does not turn.IStarterIDefective battery-to-starter harness B
IDefective starter switch C
IDefective inhibitor switch or neutral switch C
IDefective starter B
IBatteryIPoor terminal connecton A
IRun-down battrey A
IDefective charging system B
IFrictionISeizure of crankshaft and connecting rod bearing C
ISeized camshaft C
ISeized or stuck piston and cylinder C
2) Initial combustion does
not occur.IStarterIDefective starter C
IFuel injection system A
IFuel lineIDefective fuel pump and relay A
ILack of or insufficient fuel B
IBeltIDefective B
IDefective timing B
ICompressionIIncorrect valve clearance C
ILoosened spark plugs or defective gasket C
ILoosened cylinder head bolts or defective gasket C
IImproper valve seating C
IDefective valve stem C
IWorn or broken valve spring B
IWorn or stuck piston rings, cylinder and piston C
IIncorrect valve timing B
IImproper engine oil (low viscosity) B
3) Initial combustion occur.IFuel injection system A
IIntake systemIDefective intake manifold gasket B
IDefective throttle body gasket B
IFuel lineIDefective fuel pump and relay C
IClogged fuel line C
ILack of or insufficient fuel B
IBeltIDefective B
IDefective timing B
ICompressionIIncorrect valve clearance C
ILoosened spark plugs or defective gasket C
ILoosened cylinder head bolts or defective gasket C
IImproper valve seating C
IDefective valve stem C
IWorn or broken valve spring B
IWorn or stuck piston rings, cylinder and piston C
IIncorrect valve timing B
IImproper engine oil (low viscosity) B
73
[K100]2-3aDIAGNOSTICS
1. Engine Trouble in General