1999 SUBARU LEGACY Service Repair Manual

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 0.50 mm (0.0079 Ð 0.0197 in)
Limit 1.0 mm (0.039 in)
Clearance between
piston ring and pis-
ton 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)
Con-
necting
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)
Con-
necting
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)
Con-
necting
rod
bushingClearance between piston pin and
bushingSTD 0 Ð 0.022 mm (0 Ð 0.0009 in)
Limit 0.030 mm (0.0012 in)
4
2-3a[S1B0]SPECIFICATIONS AND SERVICE DATA
1. Engine

Crank-
shaftBend limit 0.035 mm (0.0014 in)
Crankpin and crank journalOut-of-roundness 0.030 mm (0.0012 in) or less
Grinding limit 0.250 mm (0.0098 in)
Crankpin 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 diam-
eter#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,
#5STD 0.003 Ð 0.030 mm (0.0001 Ð 0.0012 in)
#2,
#3,
#4STD 0.010 Ð 0.033 mm (0.0004 Ð 0.0013 in)
#1,
#3,
#5Limit 0.040 mm (0.0016 in)
#2,
#4Limit 0.045 mm (0.0018 in)
Crank-
shaft
bearingCrankshaft bearing thick-
ness#1,
#5STD 1.998 Ð 2.011 mm (0.0787 Ð 0.0792 in)
0.03 mm (0.0012
in) US2.017 Ð 2.020 mm (0.0794 Ð 0.0795 in)
0.05 mm (0.0020
in) US2.027 Ð 2.030 mm (0.0798 Ð 0.0799 in)
0.25 mm (0.0098
in) US2.127 Ð 2.130 mm (0.0837 Ð 0.0839 in)
#2,
#3,
#4STD 2.000 Ð 2.013 mm (0.0787 Ð 0.0793 in)
0.03 mm (0.0012
in) US2.019 Ð 2.022 mm (0.0795 Ð 0.0796 in)
0.05 mm (0.0020
in) US2.029 Ð 2.032 mm (0.0799 Ð 0.0800 in)
0.25 mm (0.0098
in) US2.129 Ð 2.132 mm (0.0838 Ð 0.0839 in)
5
[S1B0]2-3aSPECIFICATIONS AND SERVICE DATA
1. Engine

1. Timing Belt
B2M1953A
(1) Belt cover No. 2 (RH)
(2) Timing belt guide (MT vehicles
only)
(3) Crankshaft sprocket (Except
California spec. vehicles)
(4) Crankshaft sprocket (California
spec. vehicles)
(5) Belt cover No. 2 (LH)
(6) Camshaft sprocket No. 1
(7) Belt idler (No. 1)(8) Tensioner bracket
(9) Belt idler (No. 2)
(10) Automatic belt tension adjuster
ASSY
(11) Belt idler No. 2
(12) Camshaft sprocket No. 2
(13) Timing belt
(14) Front belt cover
(15) Belt cover (LH)
(16) Crankshaft pulleyTightening torque: N´m (kg-m, ft-lb)
T1:
5±1 (0.5±0.1, 3.6±0.7)
T2:9.8±1.0 (1.0±0.1, 7.2±0.7)
T3:25±3 (2.5±0.3, 18.1±2.2)
T4:39±4 (4.0±0.4, 28.9±2.9)
T5:78±5 (8.0±0.5, 57.9±3.6)
T6:127+10/þ5(13.0+1.0/þ0.5,
94+7.2/þ3.6)
6
2-3a[C100]COMPONENT PARTS
1. Timing Belt

2. Cylinder Head and Camshaft
B2M1954A
(1) Rocker cover (RH)
(2) Intake valve rocker ASSY
(3) Exhaust valve rocker ASSY
(4) Camshaft cap (RH)
(5) Oil seal
(6) Camshaft (RH)
(7) Plug
(8) Spark plug pipe gasket
(9) Cylinder head (RH)(10) Cylinder head gasket
(11) Cylinder head (LH)
(12) Camshaft (LH)
(13) Camshaft cap (LH)
(14) Oil filler cap
(15) Gasket
(16) Oil filler pipe
(17) O-ring
(18) Rocker cover (LH)Tightening torque: N´m (kg-m, ft-lb)
T1:

T2:5±1 (0.5±0.1, 3.6±0.7)
T3:10±2 (1.0±0.2, 7.2±1.4)
T4:18±2 (1.8±0.2, 13.0±1.4)
T5:25±2 (2.5±0.2, 18.1±1.4)
7
[C200]2-3aCOMPONENT PARTS
2. Cylinder Head and Camshaft

3. Cylinder Head and Valve Assembly
B2M1955A
(1) Exhaust valve
(2) Intake valve
(3) Intake valve guide
(4) Intake valve spring seat(5) Intake valve oil seal
(6) Valve spring
(7) Retainer
(8) Retainer key(9) Exhaust valve guide
(10) Exhaust valve spring seat
(11) Exhaust valve oil seal
8
2-3a[C300]COMPONENT PARTS
3. Cylinder Head and Valve Assembly

4. Cylinder Block
B2M1957A
(1) Oil pressure switch
(2) Cylinder block (RH)
(3) Service hole plug
(4) Gasket
(5) Oil separator cover
(6) Water by-pass pipe
(7) Oil pump
(8) Front oil sea
(9) Rear oil seal
(10) O-ring
(11) Service hole cover(12) Cylinder block (LH)
(13) Water pump
(14) Baffle plate
(15) Oil filter connector
(16) Oil strainer
(17) Gasket
(18) Oil pan
(19) Drain plug
(20) Metal gasket
(21) Oil level gauge guideTightening torque: N´m (kg-m, ft-lb)
T1:
5 (0.5, 3.6)
T2:6.4 (0.65, 4.7)
T3:10 (1.0, 7)
T4:25±2 (2.5±0.2, 18.1±1.4)
T5:47±3 (4.8±0.3, 34.7±2.2)
T6:69±7 (7.0±0.7, 50.6±5.1)
T7:First 12±2 (1.2±0.2, 8.7±1.4)
Second 12
±2 (1.2±0.2,
8.7
±1.4)
9
[C400]2-3aCOMPONENT PARTS
4. Cylinder Block

5. Crankshaft and Piston
B2M1958A
(1) Flywheel (MT)
(2) Bell bearing (MT)
(3) Reinforcement (AT)
(4) Drive plate (AT)
(5) Top ring
(6) Second ring
(7) Oil ring
(8) Piston(9) Piston pin
(10) Circlip
(11) Connecting rod bolt
(12) Connecting rod
(13) Connecting rod bearing
(14) Connecting rod cap
(15) Crankshaft
(16) Woodruff key(17) Crankshaft bearing #1, #3
(18) Crankshaft bearing #2, #4
(19) Crankshaft bearing #5
Tightening torque: N´m (kg-m, ft-lb)
T1:
44±2 (4.5±0.2, 32.5±1.4)
T2:72±3 (7.3±0.3, 52.8±2.2)
10
2-3a[C500]COMPONENT PARTS
5. Crankshaft and Piston

6. Valve Rocker Assembly
B2M1956A
(1) Intake valve rocker arm
(2) Valve rocker nut
(3) Valve rocker adjust screw
(4) Spring
(5) Rocker shaft support(6) Intake rocker shaft
(7) Exhaust rocker shaft
(8) Exhaust valve rocker armTightening torque: N´m (kg-m, ft-lb)
T1:
5±1 (0.5±0.1, 3.6±0.7)
T2:10±1 (1.0±0.1, 7.2±0.7)
T3:12±1 (1.2±0.1, 8.7±0.7)
11
[C600]2-3aCOMPONENT PARTS
6. Valve Rocker Assembly