Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Subaru Legacy 1995-1999 Approved Subaru Legacy 1996 1996 Tech Service Bulletin 18-23-9534436
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SU6ARUa NUMBER 18-23-95
SUBJECT SERVICE MANUAL SUPPLEMENT (MSA5T9602A) CORRECTION PAGES
Please replace the attached correction pages in the 1996 Legacy Service Manaul Supplement. These
pages are indicated by a revision date of 9/95 at the bottom.
CAUTION
VEHICLE SERVICING PERFORMED BY UNTRAINED PERSONS COULD RESULT IN SERIOUS INJURY TO THOSE PERSONS OR TO OTHERS.
Subaru Service Bulletins are intended for use by professional technicians ONLY. They are written to inform those technicians of conditions that may occur in some vehicles, or
to provide information that could assist in the proper servicing of the vehicle. Properly trained technicians have the equipment, tools, safety instructions, and know-how to do the
job correctly and safely. If a condition is described, DO NOT assume that this Service Bulletin applies to your vehicle, or that your vehicle will have that condition.
SPECIFICATIONS AND SERVICE DATA [SlBO] 2-3b
1. Enaine
Bend limit 10.035 mm (0.0014 in)
Out-of-roundness 0.020 mm (0.0008 in) or less
Crank pin and crank journal
Grinding Ii lit 0.25 mm (0.0098 in)
STD 47.984 - 48.000 mm (1.8891 - 1.8898 in)
0.03 mm
(1.8879 - 1.8886 in)
Crank pin outer diameter
(1.8872 - 1.8878 in)
~
0.25 mm
(0.0098 in) 47.734 - 47.750 mm (1.8793 - 1.8799 in)
us
STD 59.992 - 60.008 mm
~ ~~
(2.3619 - 2.3625 in)
0.03 mm
(0.0012 in) 59.962 - 59.978 mm (2.3607 - 2.3613 in)
us
0.05 mm
(0.0020 in)
us
59.942 - 59.958 mm (2.3599 - 2.3605 in)
>rankshaft
0.25 mm
(0.0098 in)
us
59.742 - 59.758 mm (2.3520 - 2.3527 in)
Crank journal outer diameter
STD 59.992 - 60.008 mm (2.3619 - 2.3625 in)
0.03 mm
(0.0012 in)
us
59.962 - 59.978 mm (2.3607 - 2.3613 in)
0.05 mm
(0.0020 in) 59.942 - 59.958 mm (2.3599 - 2.3605 in)
us
0.25 mm
(0.0098 in) 59.742 - 59.758 mm (2.3520 - 2.3527 in)
us
Thrust clearance
STD 0.030 - 0.115 mm (0.0012 - 0.0045 in)
Limit 10.25 mm (0.0098 in)
#I,
#5 STD 0.003 - 0.030 mm (0.0001 - 0.0012 in)
#2, #3, #4 STD 0.010 - 0.033 mm (0.0004 - 0.0013 in)
Oil clearance
# l , #3, #5 Limit 0.040 mm (0.0016 in)
#2, #4 Limit 10.045 mm (0.0018 in)
STD 1.998 - 2.01 1 mm (0.0787 - 0.0792 in)
0.03 mm
(0.0012 in) 2.017 - 2.020 mm (0.0794 - 0.0795 in)
us
0.05 mm
#5
#I,
(0.0020 in)
us
2.027 - 2.030 mm (0.0798 - 0.0799 in)
0.25 mm
(0.0098 in) 2.127 - 2.130 mm (0.0837 - 0.0839 in)
:rankshaft us
Crankshaft bearing thickness
iearing STD 2.000 - 2.013 mm (0.0787 - 0.0793 in)
0.03 mm
(0.0012 in) 2.019 - 2.022 mm (0.0795 - 0.0796 in)
us
#4 0.05 mm
#2, #3,
(0.0020 in) 2.029 - 2.032 mm (0.0799 - 0.0800 in)
us
0.25 mm
(0.0098 in) 2.129 - 2.132 mm (0.0838 - 0.0839 in)
us
TD Standarc US: Underrlre
2-3b [CIOOI COMPONENT PARTS
1. Timina Belt
1. Timing Belt
P
El
B2M0726A
@)Right-hand belt cover No. 2 @ Belt idler
@ Crankshaft sprocket @ Left-hand belt cover
@ Left-hand belt cover No. 2 @ Front belt cover
@ Tensioner bracket @ Right-hand belt cover
@ Tensioner adjuster 0 Crankshaft pulley
@ tensioner'
Belt
I
@ Belt idler T/ghtenlng torque: N.m (kg-m, R-lb)
T1: 4.9 f 0.5 (0.5 f 0.05, 3.6 f 0.4)
@ I
Right-hand exhaust camshaft sprocket
T2: 25 f 2 (2.5 f 0.2, 78.7 f 7.4)
@ Right-hand intake camshaft sprocket
I
T3: 39 f 4 (4.0 f 0.4, 28.9 f 2.9)
@ Left-hand intake camshaft sprocket T4: 78 f 5 (8.0 f 0.5, 57.9 f 3.6)
@ Left-hand exhaust camshaft sprocket T5: 127 f 5 (13.0 f 0.5, 94.0 f 3.6)
@ Timing belt
@ Belt idler No. 2
I
Revised 9/95
84
1a-7d-Oq ,q
SERVICE PROCEDURE w3B1] 2-3b
3. Camshaft
6) Loosen exhaust camshaft cap bolts equally, a little at
rn a time in the numerical sequence shown in figure.
7) Remove camshaft caps and exhaust camshaft.
CAUTION:
Arrange camshaft caps in order so that they can be
installed in their original positions.
8) Similarly, remove right-hand camshafts and related
parts.
G2M0745
B: INSPECTION
1. CAMSHAFT
1) Measure the bend, and repair or replace if necessary.
Limit:
0.020 rnm (0.0008 in)
2) Check journal for damage and wear. Replace if faulty.
3) Measure outside diameter of camshaft journal. If the
journal diameter is not as specified, check the oil clear-
G2M0746 ance.
I Camshaft journal I
I Front ICenter, rear I
- 27.963 rnm
I
Standard
31.946 - 31.963 rnrn
(1.2577 - 1.2584 in)
27.946
(1.1002- 1.1009 in) I
4) Measurement of the camshaft journal oil clearance
(1) Clean the bearing caps and camshaft journals.
(2) Place the camshafts on the cylinder head. (With-
out installing valve rocker.)
(3) Place plastigauge across each of the camshaft
journals.
(4) Install the bearing caps.
G2M074i
CAUTION:
Do not turn the camshaft.
( 5 ) Remove the bearing caps.
(6) Measure the widest point of the plastigauge on
each journal.
If the oil clearance exceeds the limit, replace the cam-
shaft. If necessary, replace the camshaft caps and
cylinder head as a set.
Standard oil clearance:
0.037
Limit:
- 0.072 mm (0.0015 -
0.0028 in)
0.10 mm (0.0039 in)
(7) Completely remove the plastigauge.
85
2-3b W C 1 1 SERVICE PROCEDURE
3. Camshaft
1 5) Check cam face condition; remove minor faults by
grinding with oil stone. Measure the cam height H; replace
...-... if the limit has been exceeded.
Standard:
lntake 47.68 -
41.78 mm (1.6409 1.6449 in) -
Exhaust 41.98 -42.08 mm (1.6528 1.6567 in) -
Limit:
28 mm (1.10 In) lnfake 41.52 mm (1.6346 in)
G2M0138 I
Exhaust 41.82 mm (1.6465 in)
6) Measure the thrust clearance of camshaft with dial
gauge. If the clearance exceeds the limit, replace caps
and cylinder head as a set. If necessary replace camshaft.
Standard:
0.040 - 0.080 mm (0.0016 -
0.0031 in)
Limit:
0.1 mm (0.004 in)
C: INSTALLATION
1. CAMSHAFT
Tightening torque: Nvn (kg-m, R-lb)
T I : 5 f 0.5 (0.5 f O.OS, 3.6 f 0.4)
T2: 10 f 0.7 (1.0 f 0.07, 7.2 f 0.5)
86
SERVICE PROCEDURE [W4E1] 2-3b
4. Cvlinder Head
E: INSTALLATION
1. CYLINDER HEAD
P
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
numerical sequence.
Then tighten all bolts to 69 Nkm (7.0 kg-m, 51 ft-lb) in
numerical sequence.
(3) Back off all bolts by 180" first; back them off by
180" again.
G2M0771
(4) Tighten bolts @ and @ to 34 N.m (3.5 kg-m, 25
ft-l b).
( 5 ) Tighten bolts @ ,, and @ to 15 N-m (1.5
@I @
kg-m, 11 ft-lb).
(6) Tighten all bolts by 80 to 90" in numerical
sequence.
CAUTION:
Do not tighten bolts more than 90".
87
2-3b [W4E2] SERVICE PROCEDURE
4. Cylinder Head
(7) Further tighten all bolts by 80 to 90"in numerical
sequence.
CAUTION:
Ensure that the total "re-tightening angle" [steps (6) and
(7) above] do not exceed 180".
3) Install oil level gauge guide attaching bolt (left side
only).
2. INTAKE MANIFOLD
1) Install camshafts, rocker cover and related parts.
< Ref. to 2-3b [W3CO].62 >
G2M0750
lighlenlng torgue: N:m (kg-m, R-lb)
T1: 5 f 0.5 (0.5 f O.OS, 36 2 0.4)
.
T2: 10 f 0.7 (1.0 f 0.07, 7.2 2 0.5)
Revised 9/95
88
ra,77.-a..\- `I
;
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