Subaru Legacy III (2000-2003 year). Manual - part 63

ME(H4SO)-64

MECHANICAL

CYLINDER HEAD ASSEMBLY

3. VALVE GUIDE

1) Check the clearance between valve guide and
stem. The clearance can be checked by measuring
the outside diameter of valve stem and the inside
diameter of valve guide with outside and inside mi-
crometers respectively.

Clearance between the valve guide and valve 
stem:

Standard

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)

2) If the clearance between valve guide and stem
exceeds the limit, replace the valve guide or valve
itself whichever shows greater amount of wear.
See the following procedure for valve guide re-
placement.

Valve guide inner diameter:

6.000 — 6.012 mm (0.2362 — 0.2367 in)

Valve stem outer diameters:

Intake

5.950 — 5.965 mm (0.2343 — 0.2348 in)

Exhaust

5.945 — 5.960 mm (0.2341 — 0.2346 in)

(1) Place the cylinder head on ST1 with the
combustion chamber upward so that valve
guides enter the holes in ST1.

(2) Insert the ST2 into valve guide and press it
down to remove valve guide.

ST1

498267800

CYLINDER HEAD TABLE

ST2

499767200

VALVE GUIDE REMOVER

(3) Turn the cylinder head upside down and
place ST as shown in the figure.

Intake side:
ST

499767700

VALVE GUIDE ADJUSTER

Exhaust side:
ST

499767800

VALVE GUIDE ADJUSTER

(4) Before installing new oversize valve guide,
make sure that neither scratches nor damages
exist on the inside surface of valve guide holes
in cylinder head.

Valve guide

ME-00288

Y

X

ME-00289

(A) Valve guide

ME-00290

ST1

ST2

ST

( A )

ME-00291

ME(H4SO)-65

MECHANICAL

CYLINDER HEAD ASSEMBLY

(5) Put new valve guide, coated with sufficient
oil, in the cylinder, and then insert the ST1 into
valve guide. Press in until the valve guide upper
end is flush with the upper surface of ST2.

ST1

499767200

VALVE GUIDE REMOVER

Intake side:
ST2

499767700

VALVE GUIDE ADJUSTER

Exhaust side:
ST2

499767800

VALVE GUIDE ADJUSTER

(6) Check the valve guide protrusion.

Valve guide protrusion: L

Intake

20.0 — 20.5 mm (0.787 — 0.807 in)

Exhaust

16.5 — 17.0 mm (0.650 — 0.669 in)

(7) Ream the inside of valve guide with ST.
Gently rotate the reamer clockwise while press-
ing it lightly into valve guide, and return it also ro-
tating clockwise. After reaming, clean the valve
guide to remove chips.

NOTE:
• Apply engine oil to the reamer when reaming.
• If the inner surface of the valve guide is torn, the
edge of the reamer should be slightly ground with
an oil stone.
• If the inner surface of the valve guide becomes
lustrous and the reamer does not chips, use a new
reamer or remedy the reamer. 

ST

499767400

VALVE GUIDE REAMER

(8) Recheck the contact condition between
valve and valve seat after replacing valve guide.

4. INTAKE AND EXHAUST VALVE

1) Inspect the flange and stem of valve, and re-
place if damaged, worn, or deformed, or if “H” 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)

(A) Valve guide

ME-00292

ST2

ST1

L

( A )

ME-00293

ME-00294

ME-00295

90˚

+1

-0

H

H

45˚

90˚

+1

-0

45˚

ME(H4SO)-66

MECHANICAL

CYLINDER HEAD ASSEMBLY

2) Put a small amount of grinding compound on the
seat surface and lap the valve and seat surface.
<Ref. to ME(H4SO)-63, VALVE SEAT, ADJUST-
MENT, Cylinder Head Assembly.>  Install a new in-
take valve oil seal after lapping.

ME(H4SO)-67

MECHANICAL

CYLINDER BLOCK

21.Cylinder Block

A: REMOVAL

NOTE:
Before conducting this procedure, drain the engine
oil completely if applicable.
1) Remove the intake manifold.  <Ref. to
FU(H4SO)-15, REMOVAL, Intake Manifold.>
2) Remove the V-belt. <Ref. to ME(H4SO)-41, RE-
MOVAL, V-belt.>
3) Remove the crankshaft pulley. <Ref. to
ME(H4SO)-43, REMOVAL, Crankshaft Pulley.>
4) Remove the belt cover. <Ref. to ME(H4SO)-45,
REMOVAL, Belt Cover.>
5) Remove the timing belt assembly. <Ref. to
ME(H4SO)-46, REMOVAL, Timing Belt Assem-
bly.>
6) Remove the camshaft sprocket. <Ref. to
ME(H4SO)-51, REMOVAL, Camshaft Sprocket.>
7) Remove the crankshaft sprocket. <Ref. to
ME(H4SO)-43, REMOVAL, Crankshaft Pulley.>
8) Remove the generator and A/C compressor with
their brackets.
9) Remove the rocker cover.
10) Remove the cylinder head bolts in alphabetical
sequence shown in the figure.

NOTE:
Leave bolts (a) and (c) engaged by three or four
threads to prevent cylinder head from falling.

11) While tapping the cylinder head with a plastic
hammer, separate it from cylinder block.

12) Remove the bolts (a) and (c) to remove cylinder
head.

13) Remove the cylinder head gasket.

NOTE:
Do not scratch the mating surface of cylinder head
and cylinder block.
14) Similarly, remove the right side cylinder head.
15) Remove the clutch housing cover (MT vehi-
cles).
16) Remove the flywheel (MT vehicles) or drive
plate (AT vehicles).
Using the ST, lock the crankshaft.
ST

498497100

CRANKSHAFT STOPPER

• MT VEHICLES

• AT VEHICLES

NOTE:
Using STs, remove the flywheel. (2500 cc MT mod-
el)

(A) Front 

ME-00296

( a )

( A )

( b )

( c )

( d )

( e )

( f )

(A) Front 

ME-00296

( a )

( A )

( b )

( c )

( d )

( e )

( f )

ME-00297

ST

ME-00298

ST