Subaru Legacy III (2000-2003 year). Manual - part 267

ME(H6DO)-56

MECHANICAL

CYLINDER HEAD ASSEMBLY

E: INSPECTION

1. 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.

2. INTAKE AND EXHAUST VALVE STEM 
SEAL

Replace oil seal with new one, if lip is damaged or
spring out of place, or when the surfaces of intake
valve and valve seat are reconditioned or intake
valve guide is replaced. Use pliers to pinch and re-
move oil seal from valve.
1) Place cylinder head on ST1.
2) Press-fit oil seal to the specified dimension indi-
cated in the figure using ST2.

NOTE:
• Apply engine oil to stem seal before press-fitting.
• When press-fitting stem seal, do not use hammer
or strike in.
ST1

18250AA000 CYLINDER HEAD TABLE

ST2

498857100

VALVE OIL SEAL GUIDE

3. VALVE LIFTER

1) Check valve lifter visually.
2) Measure outer diameter of valve lifter.

Outer diameter:

33.959 — 33.975 mm (1.3370 — 1.3376 in)

3) Measure inner diameter of valve lifter mating
part on cylinder head.

Inner diameter:

34.006 — 34.016 mm (1.3388 — 1.3392 in)

NOTE:
If difference between outer diameter of valve lifter
and inner diameter of valve lifter mating part is over
the limit, replace cylinder head.

Standard:

0.019 — 0.057 mm (0.0007 — 0.0022 in)

Limit:

0.100 mm (0.0039 in)

Free length

46.79 mm (1.8421 in)

Squareness

2.5

°

, 2.0 mm (0.079 in)

ME-00547

ME-00548

ME-00549

ME-00550

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MECHANICAL

CYLINDER HEAD ASSEMBLY

F: ADJUSTMENT

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

18250AA000

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), re-
grind the surface with a surface grinder.

Warping limit:

0.05 mm (0.0020 in)

Grinding limit:

0.1 mm (0.004 in)

Standard height of cylinder head:

124 mm (4.88 in)

NOTE:
Uneven torque for the cylinder head bolts can
cause warping. When reassembling, pay special
attention to the torque so as to tighten evenly.

2. VALVE SEAT

Inspect intake and exhaust valve seats, and correct
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

1.5 mm (0.059 in)

Limit

2.2 mm (0.087 in)

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

0.030 — 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)

(A) Straight edge

(B) Thickness gauge

ME-00551

( A )

( B )

ME-00552

w

90

˚

150

˚

ME(H6DO)-58

MECHANICAL

CYLINDER HEAD ASSEMBLY

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

Valve guide inner diameter:

5.500 — 5.512 mm (0.2165 — 0.2170 in)

Valve stem outer diameter:

Intake

5.455 — 5.470 mm (0.2148 — 0.2154 in)

Exhaust

5.455 — 5.460 mm (0.2148 — 0.2150 in)

(1) Place cylinder head on ST1 with the com-
bustion chamber upward so that valve guides
enter the holes in ST1.
(2) Insert ST2 into valve guide and press it
down to remove valve guide.

ST1

18250AA000 CYLINDER HEAD TABLE

ST2

499765700

VALVE GUIDE REMOVER

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

ST

18251AA000

VALVE GUIDE ADJUSTER

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

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

ST1

499765700

VALVE GUIDE REMOVER

ST2

18251AA000 VALVE GUIDE ADJUSTER

(6) Check the valve guide protrusion.

Valve guide protrusion: L

12.3 — 12.7 mm (0.484 — 0.500 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 valve
guide to remove chips.

ST

499765900

VALVE GUIDE REAMER

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.

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

ME-00553

ME-00554

ST

ST1

ST2

ME-00555

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MECHANICAL

CYLINDER HEAD ASSEMBLY

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

0.8 mm (0.031 in)

Exhaust

Standard

1.2 mm (0.047 in)

Limit

0.8 mm (0.031 in)

Valve overall length:

Intake

103.5 mm (4.075 in)

Exhaust

103.2 mm (4.063 in)

2) Put a small amount of grinding compound on the
seat surface and lap the valve and seat surface. In-
stall a new intake valve oil seal after lapping.

ME-00556

90˚

+1

-0

H

H

45˚

90˚

+1

-0

45˚