1999 SUBARU LEGACY height

1. Engine
A: SPECIFICATIONS
EngineModel2200 cc
TypeHorizontally opposed, liquid cooled, 4-cylinder, 4-stroke
gasoline engine
Valve arrangement Belt driven, single over-head camshaft, 4-valve/cylinder
Bore´Stroke mm (in) 96.9´75.0 (3.815´2.953)
Displacement cm
3(cu in) 2,212 (135.0)
Compression ratio 9.7
Compression pressure
(at 200 Ð 300 rpm)kPa (kg/cm
2, psi) 1,079 Ð 1,275 (11.0 Ð 13.0, 156 Ð 185)
Number of piston rings Pressure ring: 2, Oil ring: 1
Intake valve timingOpening 4É BTDC
Closing 52É ABDC
Exhaust valve timingOpening 48É BBDC
Closing 12É ATDC
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 14ɱ8É/700 (MT), 20ɱ8É/700 (AT)
B: SERVICE DATA
NOTE:
STD: Standard, I.D.: Inner Diameter, O.D.: Outer Diameter, OS: Oversize, US: Undersize
Belt ten-
sioner
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)
Valve
rocker
armClearance between shaft and armSTD 0.020 Ð 0.054 mm (0.0008 Ð 0.0021 in)
Limit 0.10 mm (0.0039 in)
Cam-
shaftBend limit 0.020 mm (0.0008 in)
Thrust clearanceSTD 0.030 Ð 0.090 mm (0.0012 Ð 0.0035 in)
Limit 0.11 mm (0.0043 in)
Cam lobe heightIntakeSTD 34.00 Ð 38.782 mm (1.3386 Ð 1.5268 in)
Limit 33.84 mm (1.3323 in)
ExhaustSTD 34.00 Ð 39.307 mm (1.3386 Ð 1.5475 in)
Limit 33.84 mm (1.3323 in)
Camshaft journal O.D. 31.928 Ð 31.945 mm (1.2570 Ð 1.2577 in)
Camshaft journal hole I.D. 32.000 Ð 32.018 mm (1.2598Ð 1.2605 in)
Oil clearanceSTD 0.055 Ð 0.090 mm (0.0022 Ð 0.0035 in)
Limit 0.118 mm (0.0046 in)
2
2-3a[S1A0]SPECIFICATIONS AND SERVICE DATA
1. Engine

Cylinder
headSurface warpage limit 0.05 mm (0.0020 in)
Surface grinding limit 0.3 mm (0.012 in)
Standard height 97.5 mm (3.839 in)
Valve
setRefacing angle 90É
Contacting widthIntakeSTD 1.0 mm (0.039 in)
Limit 1.7 mm (0.067 in)
ExhaustSTD 1.4 mm (0.055 in)
Limit 2.1 mm (0.083 in)
Valve
guideInner diameter 6.000 Ð 6.012 mm (0.2362 Ð 0.2367 in)
Protrusion above headIntake 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)
ValveHead edge thicknessIntakeSTD 1.0 mm (0.039 in)
Limit 0.6 mm (0.024 in)
ExhaustSTD 1.2 mm (0.047 in)
Limit 0.6 mm (0.024 in)
Stem diameterIntake 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)
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 120.6 mm (4.75 in)
Exhaust 121.7 mm (4.79 in)
Valve
springFree 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)
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 96.905 Ð 96.915 mm (3.8151 Ð 3.8155 in)
B 96.895 Ð 96.905 mm (3.8148 Ð 3.8151 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 96.885 Ð 96.895 mm (3.8144 Ð 3.8148 in)
B 96.875 Ð 96.885 mm (3.8140 Ð 3.8144 in)
0.25 mm (0.0098
in) OS97.125 Ð 97.135 mm (3.8238 Ð 3.8242 in)
0.50 mm (0.0197
in) OS97.375 Ð 97.385 mm (3.8337 Ð 3.8340 in)
Piston
pinStandard clearance between piston
pin and hole in pistonSTD 0.004 Ð 0.008 mm (0.0002 Ð 0.0003 in)
Limit 0.020 mm (0.0008 in)
Degree of fitPiston pin must be fitted into position with thumb at 20ÉC
(68ÉF).
3
[S1B0]2-3aSPECIFICATIONS AND SERVICE DATA
1. Engine

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

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
43
[W5C2]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
46
2-3a[W5C4]SERVICE PROCEDURE
5. Cylinder Head

4) Remove crankshaft together with connecting
rod.
5) Remove crankshaft bearings from cylinder
block using hammer handle.
CAUTION:
Do not confuse combination of crankshaft
bearings. Press bearing at the end opposite to
locking lip.6) Draw out each piston from cylinder block using
wooden bar or hammer handle.
CAUTION:
Do not confuse combination of piston and cyl-
inder.
3. CRANKSHAFT AND PISTON
B2M1320I
(1) Connecting rod cap
(2) Connecting rod bearing(3) Top ring
(4) Second ring(5) Oil ring
(6) Circlip
1) Remove connecting rod cap.
2) Remove connecting rod bearing.
CAUTION:
Arrange removed connecting rod, connecting
rod cap and bearing in order to prevent confu-
sion.
3) Remove piston rings using the piston ring
expander.
4) Remove the oil ring by hand.
CAUTION:
Arrange the removed piston rings in good
order to prevent confusion.
5) Remove circlip.
C: INSPECTION
1. CYLINDER BLOCK
1) Visually check for cracks and damage.
Especially, inspect important parts by means of red
lead check.
2) Check the oil passages for clogging.3) Inspect crankcase surface that mates with cyl-
inder head for warping by using a straight edge,
and correct by grinding if necessary.
Warping limit:
0.05 mm (0.0020 in)
Grinding limit:
0.1 mm (0.004 in)
Standard height of cylinder block:
201.0 mm (7.91 in)
56
2-3a[W6B3]SERVICE PROCEDURE
6. Cylinder Block

2. CYLINDER AND PISTON
1) The cylinder bore size is stamped on the cylin-
der block's front upper surface.
CAUTION:
Measurement should be performed at a tem-
perature 20ÉC (68ÉF).
NOTE:
Standard sized pistons are classified into two
grades, ªAº and ªBº. These grades should be used
as a guide line in selecting a standard piston.
Standard diameter:
A: 96.905 Ð 96.915 mm (3.8151 Ð 3.8155
in)
B: 96.895 Ð 96.905 mm (3.8148 Ð 3.8151
in)
H2M1732A
2) How to measure the inner diameter of each
cylinder
Measure the inner diameter of each cylinder in
both the thrust and piston pin directions at the
heights shown in the figure, using a cylinder bore
gauge.
CAUTION:
Measurement should be performed at a tem-
perature 20ÉC (68ÉF).
Taper:
Standard
0.015 mm (0.0006 in)
Limit
0.050 mm (0.0020 in)
Out-of-roundness:
Standard
0.010 mm (0.0004 in)
Limit
0.050 mm (0.0020 in)
G2M0170
3) When piston is to be replaced due to general or
cylinder wear, determine a suitable sized piston by
measuring the piston clearance.
57
[W6C2]2-3aSERVICE PROCEDURE
6. Cylinder Block

4) How to measure the outer diameter of each
piston
Measure the outer diameter of each piston at the
height shown in the figure. (Thrust direction)
CAUTION:
Measurement should be performed at a tem-
perature of 20ÉC (68ÉF).
Piston grade point H:
40.0 mm (1.575 in)
Piston outer diameter:
Standard
A: 96.885 Ð 96.895 mm (3.8144 Ð 3.8148
in)
B: 96.875 Ð 96.885 mm (3.8140 Ð 3.8144
in)
0.25 mm (0.0098 in) oversize
97.125 Ð 97.135 mm (3.8238 Ð 3.8242 in)
0.50 mm (0.0197 in) oversize
97.375 Ð 97.385 mm (3.8337 Ð 3.8340 in)
B2M1305A
5) Calculate the clearance between cylinder and
piston.
CAUTION:
Measurement should be performed at a tem-
perature of 20ÉC (68ÉF).
Cylinder to piston clearance at 20ÉC (68ÉF):
Standard
0.010 Ð 0.030 mm (0.0004 Ð 0.0012 in)
Limit
0.050 mm (0.0020 in)
6) Boring and honing
(1) If the value of taper, out-of-roundness, or
cylinder- to-piston clearance measured exceeds
the specified limit or if there is any damage on
the cylinder wall, rebore it to use an oversize
piston.
CAUTION:
When any of the cylinders needs reboring, all
other cylinders must be bored at the same
time, and use oversize pistons. Do not perform
boring on one cylinder only, nor use an over-
size piston for one cylinder only.(2) If the cylinder inner diameter exceeds the
limit after boring and honing, replace the crank-
case.
CAUTION:
Immediately after reboring, the cylinder diam-
eter may differ from its real diameter due to
temperature rise. Thus, pay attention to this
when measuring the cylinder diameter.
Limit of cylinder enlarging (boring):
0.5 mm (0.020 in)
3. PISTON AND PISTON PIN
1) Check pistons and piston pins for damage,
cracks, and wear and the piston ring grooves for
wear and damage. Replace if defective.
2) Measure the piston-to-cylinder clearance at
each cylinder. If any of the
clearances is not to specification, replace the pis-
ton or bore the cylinder to use an oversize piston.
3) Make sure that piston pin can be inserted into
the piston pin hole with a thumb at 20ÉC (68ÉF).
Replace if defective.
Standard clearance between piston pin and
hole in piston:
Standard
0.004 Ð 0.008 mm (0.0002 Ð 0.0003 in)
Limit
0.020 mm (0.0008 in)
B2M1401
B2M0084A
58
2-3a[W6C3]SERVICE PROCEDURE
6. Cylinder Block