Subaru Legacy III (2000-2003 year). Service manual — part 47
IN(H4SO)-8
INTAKE (INDUCTION)
RESONATOR CHAMBER
5. Resonator Chamber
A: REMOVAL
1) Remove air intake duct. <Ref. to IN(H4SO)-7,
REMOVAL, Air Intake Duct.>
2) Remove resonator chamber.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
33 N·m (3.4 kgf-m, 24.6 ft-lb)
C: INSPECTION
Inspect for cracks and loose connections.
IN-00062
IN-00062
MECHANICAL
ME(H4SO)
Page
General Description . . . . . . . . . . . . . . . . . . . . . 2
Compression . . . . . . . . . . . . . . . . . . . . . . . .23
Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . .24
Ignition Timing. . . . . . . . . . . . . . . . . . . . . . ...25
Intake Manifold Vacuum. . . . . . . . . . . . . . . . . . . 26
Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . ..27
Fuel Pressure. . . . . . . . . . . . . . . . . . . . . . . 28
Valve Clearance. . . . . . . . . . . . . . . . . . . . . . 29
Engine Assembly . . . . . . . . . . . . . . . . . . . . . ..32
Engine Mounting . . . . . . . . . . . . . . . . . . . . . ...39
Preparation for Overhaul. . . . . . . . . . . . . . . . . . ...40
V-belt. . . . . . . . . . . . . . . . . . . . . . . . . . .41
Crankshaft Pulley . . . . . . . . . . . . . . . . . . . . . ..43
Belt Cover . . . . . . . . . . . . . . . . . . . . . . . . .45
Timing Belt Assembly. . . . . . . . . . . . . . . . . . . . 46
Camshaft Sprocket. . . . . . . . . . . . . . . . . . . . . 51
Crankshaft Sprocket. . . . . . . . . . . . . . . . . . . . ..53
Valve Rocker Assembly . . . . . . . . . . . . . . . . . . . 54
Camshaft. . . . . . . . . . . . . . . . . . . . . . . . ...56
Cylinder Head Assembly . . . . . . . . . . . . . . . . . . ...60
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . ...67
Engine Trouble in General . . . . . . . . . . . . . . . . . . 89
Engine Noise. . . . . . . . . . . . . . . . . . . . . . . .94
ME(H4SO)-2
MECHANICAL
GENERAL DESCRIPTION
1. General Description
A: SPECIFICATIONS
NOTE:
STD: Standard
I.D.: Inner Diameter
O.D.: Outer Diameter
US: Undersize
OS: Oversize
Engine
Model
2000 cc
2500 cc
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)
99.5 x 79.0 (3.917 x 3.110)
Displacement
cm
3
(cu in)
1,994 (121.67)
2,457 (150)
Compression ratio
10.0
Compression pres-
sure (at 200 — 300
rpm)
kPa (kg/cm
2
, psi)
1,079 — 1,275 (11.0 — 13.0, 156 — 185)
Number of piston rings
Pressure ring: 2, Oil ring: 1
Intake valve timing
Opening
4
°
BTDC
1
°
BTDC
Closing
48
°
ABDC
51
°
ABDC
Exhaust valve timing
Opening
48
°
BBDC
50
°
BBDC
Closing
4
°
ATDC
6
°
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
on MT, or “P” or “N” position on
AT]
rpm
650
±
100 (No load)
850
±
100 (A/C switch ON)
Firing order
1
→
3
→
2
→
4
Ignition timing
BTDC/rpm
10
°±10°
/700
10
°±
10
°
/700 (MT)
15
°±10°
/700 (AT)
ME(H4SO)-3
MECHANICAL
GENERAL DESCRIPTION
Belt ten-
sioner
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 bushing I.D.
18.00 — 18.08 mm (0.7087 — 0.7118 in)
Clearance between spacer and bushing
STD
0.025 — 0.125 mm (0.0010 — 0.0049 in)
Limit
0.175 mm (0.0069 in)
Side clearance of spacer
STD
0.20 — 0.55 mm (0.0079 — 0.0217 in)
Limit
0.81 mm (0.0319 in)
Valve
rocker arm
Clearance between shaft and arm
STD
0.020 — 0.054 mm (0.0008 — 0.0021 in)
Limit
0.10 mm (0.0039 in)
Camshaft
Bend limit
0.025 mm (0.0010 in)
Thrust clearance
STD
0.030 — 0.090 mm (0.0012 — 0.0035 in)
Limit
0.10 mm (0.0039 in)
Cam lobe height
2000 cc
Intake
STD
38.732 — 38.832 mm (1.5249 — 1.5288 in)
Limit
38.632 mm (1.5209 in)
Exhaust
STD
39.257 — 39.357 mm (1.5455 — 1.5495 in)
Limit
39.157 mm (1.5416 in)
2500 cc
Intake
STD
39.485 — 39.585 mm (1.5545 — 1.5585 in)
Limit
39.385 mm (1.5506 in)
Exhaust
STD
39.257 — 39.357 mm (1.5455 — 1.5495 in)
Limit
39.157 mm (1.5416 in)
Camshaft journal O.D.
31.928 — 31.945 mm (1.2570 — 1.2577 in)
Camshaft journal hole I.D. (Cylinder head)
32.000 — 32.018 mm (1.2598 — 1.2605 in)
Journal clearance
STD
0.055 — 0.090 mm (0.0022 — 0.0035 in)
Limit
0.10 mm (0.0039 in)
Cylinder
head
Surface warpage limit (mating with cylinder block)
0.05 mm (0.0020 in)
Surface grinding limit
0.1 mm (0.004 in)
Standard height
97.5 mm (3.84 in)
Valve set
Refacing angle
90
°
Contacting width
Intake
STD
1.1 mm (0.043 in)
Limit
1.8 mm (0.070 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
Intake
20.0 — 20.5 mm (0.787 — 0.807 in)
Exhaust
16.5 — 17.0 mm (0.650 — 0.669 in)
Valve
Head edge thickness
Intake
STD
1.0 mm (0.039 in)
Limit
0.6 mm (0.024 in)
Exhaust
STD
1.2 mm (0.047 in)
Limit
0.6 mm (0.024 in)
Stem diameter
Intake
5.950 — 5.965 mm (0.2343 — 0.2348 in)
Exhaust
5.945 — 5.960 mm (0.2341 — 0.2346 in)
Stem oil clearance
STD
Intake
0.035 — 0.062 mm (0.0014 — 0.0024 in)
Exhaust
0.040 — 0.067 mm (0.0016 — 0.0026 in)
Limit
—
0.15 mm (0.0059 in)
Overall length
Intake
120.6 mm (4.75 in)
Exhaust
121.7 mm (4.79 in)
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