engine SUBARU LEGACY 1995 Service Owner's Guide

7. Cylinder Block
A: REMOVAL
1. RELATED PARTS
1) Remove timing belt, camshaft sprocket and related
parts.

2) Remove intake manifold and cylinder head.

2. OIL PUMP AND ENGINE COOLANT PUMP
B2M0124A
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2-3SERVICE PROCEDURE
7. Cylinder Block

1) Remove housing cover.
G2M0161
2) Remove flywheel or drive plate.
To lock crankshaft use ST.
ST 498497100 CRANKSHAFT STOPPER
3) Remove oil separator cover.
4) Remove engine coolant pipe.
5) Remove engine coolant pump.
G2M0162
6) Remove oil pump from cylinder block.
Use a flat-bladed screwdriver as shown in Figure when
removing oil pump.
CAUTION:
Be careful not to scratch the mating surface of cylin-
der block and oil pump.
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2-3SERVICE PROCEDURE
7. Cylinder Block

H2M1707B
4) Installation of piston rings and oil ring
(1) Install oil ring spacer, upper rail and lower rail in this
order by hand. Then install second ring and top ring
with a piston ring expander.
(2) Position the top ring gap at A or B in the Figure.
(3) Position the second ring gap at 180°on the reverse
side for the top ring gap.
H2M1708B
(4) Position the upper rail gap at C or D in the Figure.
(5) Position the expander gap at 180°of the reverse
side for the upper rail gap.
(6) Position the lower rail gap at E or F in the Figure.
CAUTION:
Ensure ring gaps do not face the same direction.
Ensure ring gaps are not within the piston skirt area.
B2M1403A
5) Install circlip.
Install circlips in piston holes located opposite service
holes in cylinder block, when positioning all pistons in the
corresponding cylinders.
CAUTION:
Use new circlips.
NOTE:
Piston front mark“
”facer toward front of engine.
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2-3SERVICE PROCEDURE
7. Cylinder Block

B2M0087A
2. CYLINDER BLOCK
1) Install ST to cylinder block, then install crankshaft bear-
ings.
ST 499817000 ENGINE STAND
CAUTION:
Remove oil the mating surface of bearing and cylinder
block before installation. Also apply a coat of engine
oil to crankshaft pins.
2) Position crankshaft on the #2 and #4 cylinder block.
Tightening torque:
T1: 25±2 N⋅m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
T2: 47±3 N⋅m (4.8±0.3 kg-m, 34.7±2.2 ft-lb)
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7. Cylinder Block

3. PISTON AND PISTON PIN (#1 AND #2)
B2M0128A
Tightening torque: N⋅m (kg-m, ft-lb)
T: 69±7 (7.0±0.7, 50.6±5.1)
G2M0188
1) Installing piston
(1) Turn cylinder block so that #1 and #2 cylinders face
upward.
(2) Using ST1, turn crankshaft so that #1 and #2 con-
necting rods are set at bottom dead center.
ST1 499987500 CRANKSHAFT SOCKET
(3) Apply a coat of engine oil to pistons and cylinders
and insert pistons in their cylinders by using ST2.
ST2 498747100 PISTON GUIDE
G2M0189
2) Installing piston pin
(1) Insert ST3 into service hole to align piston pin hole
with connecting rod small end.
CAUTION:
Apply a coat of engine oil to ST3 before insertion.
ST3 499017100 PISTON PIN GUIDE
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2-3SERVICE PROCEDURE
7. Cylinder Block

(2) Apply a coat of engine oil to piston pin and insert
piston pin into piston and connecting rod through ser-
vice hole.
G2M0190
(3) Install circlip.
CAUTION:
Use new circlips.
(4) Install service hole plug and gasket.
CAUTION:
Use a new gasket and apply a coat of fluid packing to
it before installation.
Fluid packing:
THREE BOND 1215 or equivalent
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2-3SERVICE PROCEDURE
7. Cylinder Block

E: INSTALLATION
1. OIL PUMP AND ENGINE COOLANT PUMP
B2M0124B
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 5 (0.5, 3.6)
T2: 6.4 (0.65, 4.7)
T3: 10 (1.0, 7)
T4: 72±3 (7.3±0.3, 52.8±2.2)
T5: First 12±2 (1.2±0.2, 8.7±1.4)
Second 12±2 (1.2±0.2, 8.7±1.4)
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2-3SERVICE PROCEDURE
7. Cylinder Block

B2M0390A
(2) Apply fluid packing to matching surface of oil pump.
Fluid packing:
THREE BOND 1215 or equivalent
(3) Install oil pump on cylinder block. Be careful not to
damage oil seal during installation.
CAUTION:
Do not forget to install O-ring and seal when install-
ing oil pump.
Align flat surface of oil pump’s inner rotor with
crankshaft before installation.
G2M0628
9) Install engine coolant pump and gasket.
CAUTION:
Be sure to use a new gasket.
When installing engine coolant pump, tighten bolts
in two stages in numerical sequence as shown in Fig-
ure.
10) Install engine coolant pipe.
11) Install oil filter.
2. RELATED PARTS
1) Install cylinder head and intake manifold.

2) Install timing belt, camshaft sprocket and related parts.

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7. Cylinder Block

1. Engine Trouble in General
Numbers shown in the chart refer to the possibility of reason for the
trouble in order (“Very often”to“Rarely”)
1—Very often
2—Sometimes
3—Rarely
TROUBLE
Engine will not start.
Rough idle and engine stall
Low output, hesitation and poor acceleration
Surging
Engine does not return to idle.
Dieseling (Run-on)
After burning in exhaust system
Knocking
Excessive engine oil consumption
Excessive fuel consumption Starter does not turn.
Initial combustion does not occur.
Initial combustion occurs.
Engine stalls after initial combustion.
POSSIBLE CAUSE
STARTER
2Defective battery-to-starter harness
3Defective starter switch
3Defective inhibitor switch
23Defective starter
BATTERY
1Poor terminal connection
1Run-down battery
2Defective charging system
1111111111 1Fuel injection system Diagnostics II System.>
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2-3DIAGNOSTICS
1. Engine Trouble in General

TROUBLE
Engine will not start.
Rough idle and engine stall
Low output, hesitation and poor acceleration
Surging
Engine does not return to idle.
Dieseling (Run-on)
After burning in exhaust system
Knocking
Excessive engine oil consumption
Excessive fuel consumption Starter does not turn.
Initial combustion does not occur.
Initial combustion occurs.
Engine stalls after initial combustion.
INTAKE SYSTEM
2111 3Loosened or cracked intake air pipe
3111 3 1Loosened or cracked blow-by hose
31211 2Loosened or cracked vacuum hose
22222Defective intake manifold gasket
22222Defective throttle body gasket
322 2 2Defective PCV valve
222 323Loosened oil filler cap
3312 1Dirty air cleaner element
FUEL LINE
13 322Defective fuel pump and relay
33322Clogged fuel line
222233Lack of or insufficient fuel
BELT
222Defective
222322 22 2Defective timing
FRICTION
3Seizure of crankshaft and connecting rod bearing
3Seized camshaft
3Seized or stuck piston and cylinder
COMPRESSION
333222 23 2Defective hydraulic lash adjuster
333223 3 3Loosened spark plugs or defective gasket
333223 3 3Loosened cylinder head bolts or defective gasket
333223 2 2Improper valve seating
333333 3 13Defective valve stem
222223 3 3Worn or broken valve spring
333233 3 12Worn or stuck piston rings, cylinder and piston
222111 12 2Incorrect valve timing
222222Improper engine oil (low viscosity)
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2-3DIAGNOSTICS
1. Engine Trouble in General