Subaru Legacy III (2000-2003 year). Service manual — part 409
IN(H4DOSTC)-24
INTAKE (INDUCTION)
DIFFERENTIAL PRESSURE SENSOR
MEMO:
MECHANICAL
ME(H4DOSTC)
Page
General Description . . . . . . . . . . . . . . . . . . . . . 2
Compression . . . . . . . . . . . . . . . . . . . . . . . .21
Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . .22
Ignition Timing. . . . . . . . . . . . . . . . . . . . . . ...23
Intake Manifold Vacuum. . . . . . . . . . . . . . . . . . . 24
Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . ..25
Fuel Pressure. . . . . . . . . . . . . . . . . . . . . . . 26
Valve Clearance. . . . . . . . . . . . . . . . . . . . . . 27
Engine Assembly . . . . . . . . . . . . . . . . . . . . . ..31
Engine Mounting . . . . . . . . . . . . . . . . . . . . . ...40
Preparation for Overhaul. . . . . . . . . . . . . . . . . . ...41
V-belt. . . . . . . . . . . . . . . . . . . . . . . . . . .42
Crankshaft Pulley . . . . . . . . . . . . . . . . . . . . . ..44
Belt Cover . . . . . . . . . . . . . . . . . . . . . . . . .46
Timing Belt Assembly. . . . . . . . . . . . . . . . . . . . 47
Camshaft Sprocket. . . . . . . . . . . . . . . . . . . . . 55
Crankshaft Sprocket. . . . . . . . . . . . . . . . . . . . ..56
Camshaft. . . . . . . . . . . . . . . . . . . . . . . . ...57
Cylinder Head Assembly . . . . . . . . . . . . . . . . . . ...62
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . ...70
Engine Trouble in General . . . . . . . . . . . . . . . . . . 90
Engine Noise. . . . . . . . . . . . . . . . . . . . . . . .95
ME(H4DOSTC)-2
MECHANICAL
GENERAL DESCRIPTION
1. General Description
A: SPECIFICATIONS
NOTE:
STD: Standard I.D.: Inner Diameter O.D.: Outer Diameter OS: Oversize US: Undersize
Engine
Type
Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gaso-
line engine
Valve arrangement
Belt driven, single over-head camshaft, 4-valve/cylinder
Bore x Stroke
mm (in)
92 x 75 (3.62 x 2.95)
Piston displacement
cm
3
(cu in)
1,994 (121.67)
Compression ratio
9.0
Compression pres-
sure (at 200 — 300
rpm)
kPa (kg/cm
2
, psi)
1,079 — 1,275 (11 — 13, 155 — 183)
Number of piston rings
Pressure ring: 2, Oil ring: 1
Intake valve timing
Opening
9
°
BTDC
Closing
51
°
ABDC
Exhaust valve timing
Opening
53
°
BBDC
Closing
7
°
ATDC
Valve clearance
Intake
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]
rpm
MT
700
±
100 (No load)
800
±
150 (A/C switch ON)
AT
650
±
100 (No load)
850
±
150 (A/C switch ON)
Firing order
1
→
3
→
2
→
4
Ignition timing
BTDC/rpm
MT
14
°±
10
°
/700 rpm
AT
14
°±
10
°
/650 rpm
Belt ten-
sion
adjuster
Protrusion of adjuster rod
5.2 — 6.2 mm (0.205 — 0.244 in)
Belt ten-
sioner
Spacer O.D.
17.955 — 17.975 mm (0.7069 — 0.7077 in)
Tensioner bus I.D.
18.0 — 18.08 mm (0.7087 — 0.7118 in)
Clearance between spacer and bush
STD
0.025 — 0.125 mm (0.0010 — 0.0049 in)
Limit
0.175 mm (0.0069 in)
Side clearance of spacer
STD
0.2 — 0.55 mm (0.0079 — 0.0217 in)
Limit
0.81 mm (0.0319 in)
Camshaft
Bend limit
0.020 mm (0.0079 in)
Thrust clearance
STD
0.015 — 0.070 mm (0.0006 — 0.0028 in)
Limit
0.10 mm (0.0039 in)
Cam lobe height
Intake
STD
46.25 — 46.35 mm (1.821 — 1.825 in)
Limit
46.15 mm (1.817 in)
Exhaust
STD
46.15 — 46.25 mm (1.817 — 1.821 in)
Limit
46.65 mm (1.813 in)
Jounal O.D.
STD
Front
37.946 — 37.963 mm (1.4939 — 1.4946 in)
Center
rear
29.946 — 29.963 mm (1.1790 — 1.1796 in)
Oil clearance
STD
0.037 — 0.072 mm (0.0015 — 0.0028 in)
Limit
0.10 mm (0.0039 in)
Cylinder
head
Surface warpage limit
0.05 mm (0.0020 in)
Surface grinding limit
0.3 mm (0.012 in)
Standard height
127.5 mm (5.02 in)
ME(H4DOSTC)-3
MECHANICAL
GENERAL DESCRIPTION
Valve seat
Refacing angle
90
°
Contacting width
Intake
STD
1.0 mm (0.039 in)
Limit
1.7 mm (0.067 in)
Exhaust
STD
1.5 mm (0.059 in)
Limit
2.2 mm (0.087 in)
Valve guide
Inner diameter
6.000 — 6.012 mm (0.2362 — 0.2367 in)
Protrusion above head
15.8 — 16.2 mm (0.622 — 0.638 in)
Valve
Head edge thickness
Intake
STD
1.2 mm (0.047 in)
Limit
0.8 mm (0.031 in)
Exhaust
STD
1.5 mm (0.059 in)
Limit
0.8 mm (0.031 in)
Stem diameter
Intake
5.955 — 5.970 mm (0.2344 — 0.2350 in)
Exhaust
5.945 — 5.960 mm (0.2341 — 0.2346 in)
Stem oil clearance
STD
Intake
0.030 — 0.057 mm (0.0012 — 0.0022 in)
Exhaust
0.040 — 0.067 mm (0.0016 — 0.0026 in)
Limit
—
0.15 mm (0.0059 in)
Overall length
Intake
104.4 mm (4.110 in)
Exhaust
104.7 mm (4.122 in)
Valve
spring
Free length
44.67 mm (1.7587 in)
Squareness
2.5
°
, 2.0 mm (0.079 in)
Tension/spring height
206 — 236 N (21.0 — 24.1 kgf, 46.2 — 53.0 lb)/
36.0 mm (1.417 in)
485 — 537 N (49.5 — 54.8 kgf, 109.2 — 120.6 lb)/
26.6 mm (1.047 in)
Cylinder
block
Surface warpage limit (mating with cylinder head)
0.05 mm (0.0020 in)
Surface grinding limit
0.1 mm (0.004 in)
Cylinder bore
STD
A
92.005 — 92.015 mm (3.6222 — 3.6226 in)
B
91.995 — 92.005 mm (3.6218 — 3.6222 in)
Taper
STD
0.015 mm (0.0006 in)
Limit
0.050 mm (0.0020 in)
Out-of-roundness
STD
0.010 mm (0.0004 in)
Limit
0.050 mm (0.0020 in)
Piston clearance
STD
0.010 — 0.030 mm (0.0004 — 0.0012 in)
Limit
0.050 mm (0.0020 in)
Enlarging (boring) limit
0.5 mm (0.020 in)
Piston
Outer diameter
STD
A
91.985 — 91.995 mm (3.6214 — 3.6218 in)
B
91.975 — 91.985 mm (3.6211 — 3.6214 in)
0.25 mm (0.0098 in) OS
92.225 — 92.235 mm (3.6309 — 3.6313 in)
0.50 mm (0.0197 in) OS
92.475 — 92.485 mm (3.6407 — 3.6411 in)
Piston pin
Standard clearance between piston pin and
hole in piston
STD
0.004 — 0.008 mm (0.0002 — 0.0003 in)
Limit
0.020 mm (0.0008 in)
Degree of fit
Piston pin must be fitted into position with thumb at
20
°
C (68
°
F).
Piston ring
Piston ring gap
Top ring
STD
0.20 — 0.25 mm (0.0079 — 0.0098 in)
Limit
1.0 mm (0.039 in)
Second
ring
STD
0.35 — 0.50 mm (0.0138 — 0.0197 in)
Limit
1.0 mm (0.039 in)
Oil ring
STD
0.20 — 0.50 mm (0.0079 — 0.0197 in)
Limit
1.5 mm (0.059 in)
Clearance
between piston
ring and piston
ring groove
Top ring
STD
0.055 — 0.090 mm (0.0022 — 0.0035 in)
Limit
0.15 mm (0.0059 in)
Second
ring
STD
0.030 — 0.070 mm (0.0012 — 0.0028 in)
Limit
0.15 mm (0.0059 in)
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