1999 SUBARU LEGACY engine

1) Installation of valve spring and valve
(1) 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.
(2) Set cylinder head on ST1.
(3) Install valve spring and retainer using ST2.
ST1 498267600 CYLINDER HEAD TABLE
ST2 499718000 VALVE SPRING REMOVER
CAUTION:
Be sure to install the valve springs with their
close-coiled end facing the seat on the cylinder
head.
B2M1221A
(4) Compress valve spring and fit valve spring
retainer key.
(5) After installing, tap valve spring retainers
lightly with wooden hammer for better seating.
2) Install valve lifter and valve shim.
43
[W4D0]2-3bSERVICE PROCEDURE
4. Cylinder Head

E: INSTALLATION
1. CYLINDER HEAD
S2M0421B
(1) Bolt
(2) Cylinder head bolt(3) Cylinder head
(4) Cylinder head gasket
1) Install cylinder head and gaskets on cylinder
block.
CAUTION:
Use new cylinder head gaskets.
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).
B2M1397D
44
2-3b[W4E1]SERVICE PROCEDURE
4. Cylinder Head

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 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
64
2-3b[W5D2]SERVICE PROCEDURE
5. 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 by
using ST2.
ST2 498747300 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.
66
2-3b[W5D3]SERVICE PROCEDURE
5. Cylinder Block

1. Engine Trouble in General
NOTE:
A, B and C shown in the RANK of table refer to the
possibility of reason for the trouble in order (ªVery
oftenº to ªRarelyº).A : Very often
B : Sometimes
C : 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 connection A
IRun-down battery 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
occurs.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
71
[K100]2-3bDIAGNOSTICS
1. Engine Trouble in General

TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK
4) Engine stalls after initial
combustion.IFuel injection system A
IIntake systemILoosened or cracked intake duct B
ILoosened or cracked PCV hose C
ILoosened or cracked vacuum hose C
IDefective intake manifold gasket B
IDefective throttle body gasket B
IDirty air cleaner element C
IFuel lineIClogged 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
2. Rough idle and engine
stallIFuel injection system A
IIntake systemILoosened or cracked intake duct A
ILoosened or cracked PCV hose A
ILoosened or cracked vacuum hose A
IDefective intake manifold gasket B
IDefective throttle body gasket B
IDefective PCV valve C
ILoosened oil filler cap B
IDirty air cleaner element C
IFuel lineIDefective fuel pump and relay C
IClogged fuel line C
ILack of/or insufficient fuel B
IBeltIDefective timing C
ICompressionIIncorrect valve clearance B
ILoosened spark plugs or defective gasket B
ILoosened cylinder head bolts or defective gasket B
IImproper valve seating B
IDefective valve stem C
IWorn or broken valve spring B
IWorn or stuck piston rings, cylinder and piston B
IIncorrect valve timing A
IImproper engine oil (low viscosity) B
ILubrication systemIIncorrect oil pressure B
IDefective rocker cover gasket C
ICooling systemIOverheating C
IOthersIMalfunction of evaporative emission control system A
IStuck or damaged throttle valve B
IAccelerator cable out of adjustment C
72
2-3b[K100]DIAGNOSTICS
1. Engine Trouble in General

TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK
3. Low output, hesitation
and poor accelerationIFuel injection system A
IIntake systemILoosened or cracked intake duct A
ILoosened or cracked PCV hose A
ILoosened or cracked vacuum hose B
IDefective intake manifold gasket B
IDefective throttle body gasket B
IDefective PCV valve B
ILoosened oil filler cap B
IDirty air cleaner element A
IFuel lineIDefective fuel pump and relay B
IClogged fuel line B
ILack of/or insufficient fuel C
IBeltIDefective timing B
ICompressionIIncorrect valve clearance B
ILoosened spark plugs or defective gasket B
ILoosened cylinder head bolts or defective gasket B
IImproper valve seating B
IDefective valve stem C
IWorn or broken valve spring B
IWorn or stuck piston rings, cylinder and piston C
IIncorrect valve timing A
IImproper engine oil (low viscosity) B
ILubrication systemIIncorrect oil pressure B
ICooling systemIOverheating C
IOver cooling C
IOthersIMalfunction of evaporative emission control system A
4. SurgingIFuel injection system A
IIntake systemILoosened or cracked intake duct A
ILoosened or cracked PCV hose A
ILoosened or cracked vacuum hose A
IDefective intake manifold gasket B
IDefective throttle body gasket B
IDefective PCV valve B
ILoosened oil filler cap B
IDirty air cleaner element B
IFuel lineIDefective fuel pump and relay B
IClogged fuel line B
ILack of/or insufficient fuel C
IBeltIDefective timing B
ICompressionIIncorrect valve clearance B
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 C
IWorn or stuck piston rings, cylinder and piston C
IIncorrect valve timing A
IImproper engine oil (low viscosity) B
ICooling systemIOverheating B
IOthersIMalfunction of evaporative emission control system C
73
[K100]2-3bDIAGNOSTICS
1. Engine Trouble in General

TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK
5. Engine does not return
to idle.IFuel injection system A
IIntake systemILoosened or cracked vacuum hose A
IOthersIStuck or damaged throttle valve A
IAccelerator cable out of adjustment B
6. Dieseling (Run-on)IFuel injection system A
ICooling systemIOverheating B
IOthersIAccelerator cable out of adjustment B
7. After burning in exhaust
systemIFuel injection system A
IIntake systemILoosened or cracked intake duct C
ILoosened or cracked PCV hose C
ILoosened or cracked vacuum hose B
IDefective PCV valve B
ILoosened oil filler cap C
IBeltIDefective timing B
ICompressionIIncorrect valve clearance B
ILoosened spark plugs or defective gasket C
ILoosened cylinder head bolts or defective gasket C
IImproper valve seating B
IDefective valve stem C
IWorn or broken valve spring C
IWorn or stuck piston rings, cylinder and piston C
IIncorrect valve timing A
ILubrication systemIIncorrect oil pressure C
ICooling systemIOver cooling C
IOthersIMalfunction of evaporative emission control system C
8. KnockingIFuel injection system A
IIntake systemILoosened oil filler cap B
IBeltIDefective timing B
ICompressionIIncorrect valve clearance C
IIncorrect valve timing B
ICooling systemIOverheating A
9. Excessive engine oil
consumptionIIntake systemILoosened or cracked PCV hose A
IDefective PCV valve B
ILoosened oil filler cap C
ICompressionIDefective valve stem A
IWorn or stuck piston rings, cylinder and piston A
ILubrication systemILoosened oil pump attaching bolts and defective gasket B
IDefective oil filter seal B
IDefective crankshaft oil seal B
IDefective rocker cover gasket B
ILoosened oil drain plug or defective gasket B
ILoosened oil pan fitting bolts or defective oil pan B
74
2-3b[K100]DIAGNOSTICS
1. Engine Trouble in General