SUBARU LEGACY 1995 Service Manual PDF

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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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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7. Cylinder Block

G2M0163
7) Removal of oil pan
(1) Turn cylinder block with #2 and #4 piston sides
facing upward.
(2) Remove bolts which secure oil pan to cylinder
block.
(3) Insert a oil pan cutter blade between cylinder block-
to-oil pan clearance and remove oil pan.
CAUTION:
Do not use a screwdriver or similar tool in place of oil-
pan cutter.
8) Remove oil strainer stay.
9) Remove oil strainer.
10) Remove baffle plate.
11) Remove oil filter.
B: DISASSEMBLY
1. PISTON PIN AND CYLINDER BLOCK
CONNECTING BOLT
G2M0164
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7. Cylinder Block

1) Remove service hole cover and service hole plugs
using hexagon wrench (14 mm).
G2M0165
2) Rotate crankshaft to bring #1 and #2 pistons to bottom
dead center position, then remove piston circlip through
service hole of #1 and #2 cylinders.
G2M0166
3) Draw out piston pin from #1 and #2 pistons by using ST.
ST 499097500 PISTON PIN REMOVER
CAUTION:
Be careful not to confuse original combination of
piston, piston pin and cylinder.
4) Similarly remove piston pins from #3 and #4 pistons by
using ST.
5) Remove bolts which connect cylinder block on the side
of #2 and #4 cylinders.
6) Back off bolts which connect cylinder block on the side
of #1 and #3 cylinders two or three turns.
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7. Cylinder Block

G2M0167
2. CYLINDER BLOCK
1) Set up cylinder block so that #1 and #3 cylinders are on
the upper side, then remove cylinder block connecting
bolts.
2) Separate left-hand and right-hand cylinder blocks.
CAUTION:
When separating cylinder block, do not allow the con-
necting rod to fall and damage the cylinder block.
3) Remove rear oil seal.
4) Remove crankshaft together with connecting rod.
5) Remove crankshaft bearings from cylinder block using
hammer handle.
CAUTION:
Do not confuse combination of crankshaft bearings.
Press bearing at the end opposite to locking lip.
6) Draw out each piston from cylinder block using wooden
bar or hammer handle.
CAUTION:
Do not confuse combination of piston and cylinder.
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7. Cylinder Block

3. CRANKSHAFT AND PISTON
G2M0168
1) Remove connecting rod cap.
2) Remove connecting rod bearing.
CAUTION:
Arrange removed connecting rod, connecting rod cap
and bearing in order to prevent confusion.
3) Remove piston rings using the piston ring expander.
4) Remove the oil ring by hand.
CAUTION:
Arrange the removed piston rings in good order to
prevent confusion.
5) Remove circlip.
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7. Cylinder Block

C: INSPECTION
1. CYLINDER BLOCK
1) Check for cracks and damage visually. Especially,
inspect important parts by means of red lead check.
2) Check the oil passages for clogging.
3) Inspect crankcase surface that mates with cylinder
head for warping by using a straight edge, and correct by
grinding if necessary.
Warping limit:
0.05 mm (0.0020 in)
Grinding limit:
0.1 mm (0.004 in)
Standard height of cylinder block:
201.0 mm (7.91 in)
B2M0082A
2. CYLINDER AND PISTON
1) The cylinder bore size is stamped on the cylinder
block’s front upper surface.
NOTE:
Standard sized pistons are classified into two grades,“A”
and“B”. These grades should be used as a guide line in
selecting a standard piston.
Standard diameter:
A: 96.905—96.915 mm (3.8151—3.8155 in)
B: 96.895—96.905 mm (3.8148—3.8151 in)
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7. Cylinder Block

G2M0170
2) How to measure the inner diameter of each cylinder
Measure the inner diameter of each cylinder in both the
thrust and piston pin directions at the heights shown in the
Figure, using a cylinder bore gauge.
CAUTION:
Measurement should be performed at a temperature
20°C (68°F).
Taper:
Standard
0.015 mm (0.0006 in)
Limit
0.050 mm (0.0020 in)
Out-of-roundness:
Standard
0.010 mm (0.0004 in)
Limit
0.050 mm (0.0020 in)
3) When piston is to be replaced due to general or cylin-
der wear, determine a suitable sized piston by measuring
the piston clearance.
B2M0419A
4) How to measure the outer diameter of each piston
Measure the outer diameter of each piston at the height
shown in the Figure. (Thrust direction)
CAUTION:
Measurement should be performed at a temperature of
20°C (68°F).
Piston outer diameter:
Standard
A: 96.885—96.895 mm (3.8144—3.8148 in)
B: 96.875—96.885 mm (3.8140—3.8144 in)
0.25 mm (0.0098 in) oversize
97.115—97.145 mm (3.8234—3.8246 in)
0.50 mm (0.0197 in) oversize
97.365—97.395 mm (3.8333—3.8344 in)
5) Calculate the clearance between cylinder and piston.
CAUTION:
Measurement should be performed at a temperature of
20°C (68°F).
Cylinder to piston clearance at 20°C (68°F):
Standard
0.010—0.030 mm (0.0004—0.0012 in)
Limit
0.050 mm (0.0020 in)
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7. Cylinder Block

6) Boring and honing
(1) If the value of taper, out-of-roundness, or cylinder-
to-piston clearance measured exceeds the specified
limit or if there is any damage on the cylinder wall,
rebore it to use an oversize piston.
CAUTION:
When any of the cylinders needs reboring, all other
cylinders must be bored at the same time, and use
oversize pistons. Do not perform boring on one cylin-
der only, nor use an oversize piston for one cylinder
only.
(2) If the cylinder inner diameter exceeds the limit after
boring and honing, replace the crankcase.
CAUTION:
Immediately after reboring, the cylinder diameter may
differ from its real diameter due to temperature rise.
Thus, pay attention to this when measuring the cylin-
der diameter.
Limit of cylinder enlarging (boring):
0.5 mm (0.020 in)
3. PISTON AND PISTON PIN
1) Check pistons and piston pins for damage, cracks, and
wear and the piston ring grooves for wear and damage.
Replace if defective.
2) Measure the piston-to-cylinder clearance at each cylin-
der as instructed in 2. CYLINDER AND PISTON [W7C2].
If any of the clearances is not to specification, replace the
piston or bore the cylinder to use an oversize piston.
B2M0083
3) Make sure that piston pin can be inserted into the pis-
ton pin hole with a thumb at 20°C (68°F). Replace if defec-
tive.
Standard clearance between piston pin and hole in
piston:
Standard
0.004—0.010 mm (0.0002—0.0004 in)
Limit
0.020 mm (0.0008 in)
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7. Cylinder Block

B2M0084A
B2M0420A
4) Check circlip installation groove on the piston for burr.
If necessary, remove burr from the groove so that piston
pin can lightly move.
5) Check piston pin circlip for distortion, cracks and wear.
G2M0623
4. PISTON RING
1) If piston ring is broken, damaged, or worn, or if its ten-
sion is insufficient, or when the piston is replaced, replace
piston ring with a new one of the same size as the piston.
CAUTION:
“R”is marked on the end of the top and second
rings. When installing the rings to the piston, face this
mark upward.
G2M0624
The oil ring is a combined ring consisting of two
rails and a spacer in between. When installing, be care-
ful to assemble correctly.
G2M0174
2) Squarely place piston ring and oil ring in cylinder, and
measure the piston ring gap with a thickness gauge.
Unit: mm (in)
Standard Limit
Piston
ring gapTop ring0.20—0.35
(0.0079—0.0138)1.0 (0.039)
Second ring0.20—0.50
(0.0079—0.0197)1.0 (0.039)
Oil ring rail0.20—0.70
(0.0079—0.0276)1.5 (0.059)
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7. Cylinder Block