thrust SUBARU LEGACY 1995 Service Repair Manual

B: SERVICE DATA
Belt
tension
adjusterProtrusion of adjuster rod 15.4—16.4 mm (0.606—0.646 in)
Belt ten-
sionerSpacer O.D. 16 mm (0.63 in)
Tensioner bush I.D. 16.16 mm (0.6362 in)
Clearance between spacer and bushSTD 0.117—0.180 mm (0.0046—0.0071 in)
Limit 0.230 mm (0.0091 in)
Side clearance of spacerSTD 0.37—0.54 mm (0.0146—0.0213 in)
Limit 0.8 mm (0.031 in)
Valve
rocker armClearance between shaft and armSTD 0.020—0.054 mm (0.0008—0.0021 in)
Limit 0.10 mm (0.0039 in)
CamshaftBend limit 0.025 mm (0.0010 in)
Thrust clearanceSTD 0.030—0.260 mm (0.0012—0.0102 in)
Limit 0.35 mm (0.0138 in)
Cam lobe heightIntakeSTD 31.994—32.094 mm (1.2596—1.2635 in)
Limit 31.844 mm (1.2537 in)
ExhaustSTD 32.624—32.724 mm (1.2844—1.2883 in)
Limit 32.474 mm (1.2785 in)
Camshaft journal O.D. RHFront
LHRear 31.935—31.950 mm (1.2573—1.2579 in)
Center Center 37.435—37.450 mm (1.4738—1.4744 in)
Rear Front 37.935—37.950 mm (1.4935—1.4941 in)
Camshaft journal hole
I.D.RHFront
LHRear 32.005—32.025 mm (1.2600—1.2608 in)
Center Center 37.505—37.525 mm (1.4766—1.4774 in)
Rear Front 38.005—38.025 mm (1.4963—1.4970 in)
Oil clearanceSTD 0.055—0.090 mm (0.0022—0.0035 in)
Limit 0.10 mm (0.0039 in)
Cylinder
headSurface warpage limit 0.05 mm (0.0020 in)
Surface grinding limit 0.1 mm (0.004 in)
Standard height 98.3 mm (3.870 in)
Valve setRefacing angle 90°
Contacting widthIntakeSTD 0.7 mm (0.028 in)
Limit 1.4 mm (0.055 in)
ExhaustSTD 1.4 mm (0.055 in)
Limit 1.8 mm (0.071 in)
Valve
guideInner diameter 6.000—6.012 mm (0.2362—0.2367 in)
Protrusion above head 17.5—18.0 mm (0.689—0.709 in)
ValveHead edge thicknessIntakeSTD 1.0 mm (0.039 in)
Limit 0.8 mm (0.031 in)
ExhaustSTD 1.2 mm (0.047 in)
Limit 0.8 mm (0.031 in)
Stem diameterIntake 5.950—5.965 mm (0.2343—0.2348 in)
Exhaust 5.945—5.960 mm (0.2341—0.2346 in)
Stem oil clearanceSTDIntake 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 lengthIntake 101.0 mm (3.976 in)
Exhaust 101.2 mm (3.984 in)
STD: Standard I.D.: Inner Diameter O.D.: Outer Diameter
3
2-3SPECIFICATIONS AND SERVICE DATA
1. Engine

CrankshaftBend limit 0.035 mm (0.0014 in)
Crank pin and crank journalOut-of-roundness 0.030 mm (0.0012 in) or less
Grinding limit 0.25 mm (0.0098 in)
Crank pin outer diameterSTD 51.984—52.000 mm (2.0466—2.0472 in)
0.03 mm
(0.0012 in)
US51.954—51.970 mm (2.0454—2.0461 in)
0.05 mm
(0.0020 in)
US51.934—51.950 mm (2.0446—2.0453 in)
0.25 mm
(0.0098 in)
US51.734—51.750 mm (2.0368—2.0374 in)
Crank journal outer diameter#1, #5STD 59.992—60.008 mm (2.3619—2.3625 in)
0.03 mm
(0.0012 in)
US59.962—59.978 mm (2.3607—2.3613 in)
0.05 mm
(0.0020 in)
US59.934—59.950 mm (2.3596—2.3602 in)
0.25 mm
(0.0098 in)
US59.742—59.758 mm (2.3520—2.3527 in)
#2, #3, #4STD 59.992—60.008 mm (2.3619—2.3625 in)
0.03 mm
(0.0012 in)
US59.954—59.970 mm (2.3604—2.3610 in)
0.05 mm
(0.0020 in)
US59.934—59.950 mm (2.3596—2.3602 in)
0.25 mm
(0.0098 in)
US59.734—59.750 mm (2.3517—2.3524 in)
Thrust clearanceSTD 0.030—0.115 mm (0.0012—0.0045 in)
Limit 0.25 mm (0.0098 in)
Oil clearance#1, #5 STD 0.003—0.030 mm (0.0001—0.0012 in)
#2, #3, #4 STD 0.010—0.033 mm (0.0004—0.0013 in)
#1, #3, #5 Limit 0.040 mm (0.0016 in)
#2, #4 Limit 0.035 mm (0.0014 in)
Crankshaft
bearingCrankshaft bearing thickness#1, #5STD 1.998—2.011 mm (0.0787—0.0792 in)
0.03 mm
(0.0012 in)
US2.017—2.020 mm (0.0794—0.0795 in)
0.05 mm
(0.0020 in)
US2.027—2.030 mm (0.0798—0.0799 in)
0.25 mm
(0.0098 in)
US2.127—2.130 mm (0.0837—0.0839 in)
#2, #3, #4STD 2.000—2.013 mm (0.0787—0.0793 in)
0.03 mm
(0.0012 in)
US2.019—2.022 mm (0.0795—0.0796 in)
0.05 mm
(0.0020 in)
US2.029—2.032 mm (0.0799—0.0800 in)
0.25 mm
(0.0098 in)
US2.129—2.132 mm (0.0838—0.0839 in)
STD: Standard US: Undersize
5
2-3SPECIFICATIONS AND SERVICE DATA
1. Engine

3) Measure outside diameter of camshaft journal and
inside diameter of cylinder head journal, and determine the
difference between the two (= oil clearance). If oil clear-
ance exceeds specifications, replace camshaft or cylinder
head as necessary.
Unit: mm (in)
ItemRight-hand camshaft Front Center Rear
Left-hand camshaft Rear Center Front
Clearance at journalStandard 0.055—0.090 (0.0022—0.0035 )
Limit 0.10 (0.0039 )
Camshaft journal O.D.31.935—31.950
(1.2573—1.2579 )37.435—37.450
(1.4738—1.4744 )37.935—37.950
(1.4935—1.4941 )
Journal hole I.D.32.005—32.025
(1.2600—1.2608 )37.505—37.525
(1.4766—1.4774 )38.005—38.025
(1.4963—1.4970 )
G2M0138
4) Check cam face condition; remove minor faults by
grinding with oil stone. Measure the cam height H; replace
if the limit has been exceeded.
Cam height: H
Standard
IN: 31.994—32.094 mm (1.2596—1.2635 in)
EX: 32.624—32.724 mm (1.2844—1.2883 in)
Limit
IN: 31.844 mm (1.2537 in)
EX: 32.474 mm (1.2785 in)
G2M0139
2. CAMSHAFT SUPPORT
Measure the thrust clearance of camshaft with dial gauge.
If the clearance exceeds the limit, replace camshaft sup-
port.
Standard:
0.030—0.260 mm (0.0012—0.0102 in)
Limit:
0.35 mm (0.0138 in)
35
2-3SERVICE PROCEDURE
5. Camshaft

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)
57
2-3SERVICE PROCEDURE
7. Cylinder Block

G2M0175
3) Measure the clearance between piston ring and piston
ring groove with a thickness gauge.
CAUTION:
Before measuring the clearance, clean the piston ring
groove and piston ring.
Unit: mm (in)
Standard Limit
Clearance
between piston
ring and piston
ring grooveTop ring0.040—0.080
(0.0016—
0.0031)0.15 (0.0059)
Second ring0.030—0.070
(0.0012—
0.0028)0.15 (0.0059)
5. CONNECTING ROD
1) Replace connecting rod, if the large or small end thrust
surface is damaged.
G2M0196
2) Check for bend or twist using a connecting rod aligner.
Replace connecting rod if the bend or twist exceeds the
limit.
Limit of bend or twist per 100 mm (3.94 in) in length:
0.10 mm (0.0039 in)


1Thickness gauge


2Connecting rod
60
2-3SERVICE PROCEDURE
7. Cylinder Block

G2M0176
3) Install connecting rod fitted with bearing to crankshaft
and measure the side clearance (thrust clearance).
Replace connecting rod if the side clearance exceeds the
specified limit.
Connecting rod side clearance:
Standard
0.070—0.330 mm (0.0028—0.0130 in)
Limit
0.4 mm (0.016 in)
4) Inspect connecting rod bearing for scar, peeling,
seizure, melting, wear, etc.
5) Measure the oil clearance on individual connecting rod
bearings by means of plastigauge. If any oil clearance is
not within specification, replace the defective bearing with
a new one of standard size or undersize as necessary.
(See the table below.)
Connecting rod oil clearance:
Standard
0.015—0.045 mm (0.0006—0.0018 in)
Limit
0.05 mm (0.0020 in)
Unit: mm (in)
BearingBearing size
(Thickness at center)Outer diameter of
crank pin
Standard1.492—1.501
(0.0587—0.0591)51.984—52.000
(2.0466—2.0472)
0.03 (0.0012)
undersize1.510—1.513
(0.0594—0.0596)51.954—51.970
(2.0454—2.0461)
0.05 (0.0020)
undersize1.520—1.523
(0.0598—0.0600)51.934—51.950
(2.0446—2.0453)
0.25 (0.0098)
undersize1.620—1.623
(0.0638—0.0639)51.734—51.750
(2.0368—2.0374)
61
2-3SERVICE PROCEDURE
7. Cylinder Block

G2M0180
4) Measure the thrust clearance of crankshaft at center
bearing. If the clearance exceeds the limit, replace bearing.
Crankshaft thrust clearance:
Standard
0.030—0.115 mm (0.0012—0.0045 in)
Limit
0.25 mm (0.0098 in)
5) Inspect individual crankshaft bearings for signs of
flaking, seizure, melting, and wear.
6) Measure the oil clearance on each crankshaft bearing
by means of plastigauge. If the measurement is not within
the specification, replace defective bearing with an under-
size one, and replace or recondition crankshaft as neces-
sary.
Unit: mm (in)
Crankshaft oil clearance
Standard#1, #50.003—0.030
(0.0001—0.0012)
#2, #3, #40.010—0.033
(0.0004—0.0013)
Limit#1, #3, #5 0.040 (0.0016)
#2, #4 0.035 (0.0014)
64
2-3SERVICE PROCEDURE
7. Cylinder Block

1. Engine Cooling System
A: SPECIFICATIONS
Cooling systemElectric fan + Forced engine coolant circulation
system
Total engine coolant capacity
(US qt, Imp qt) Approx. 6.1 (6.4, 5.4)
Engine
coolant
pumpTypeCentrifugal impeller type
Discharge performance IDischarge 20
(5.3 US gal, 4.4 Imp gal)/min.
Pump speed—total engine cool-
ant head760 rpm — 0.3 mAq (1.0 ftAq)
Engine coolant temperature 85°C (185°F)
Discharge performance IIDischarge 100
(26.4 US gal, 22.0 Imp gal)/min.
Pump speed—total engine cool-
ant head3,000 rpm — 5.0 mAq (16.4 ftAq)
Engine coolant temperature 85°C (185°F)
Discharge performance IIIDischarge 200
(52.8 US gal, 44.0 Imp gal)/min.
Pump speed—total engine cool-
ant head6,000 rpm — 23.0 mAq (75.5 ftAq)
Engine coolant temperature 85°C (185°F)
Impeller diameter 76 mm (2.99 in)
Number of impeller vanes 8
Pump pulley diameter 60 mm (2.36 in)
ThermostatTypeWax pellet type
Starts to open 76 — 80°C (169 — 176°F)
Fully opened91°C (196°F)
Valve lift9.0 mm (0.354 in) or more
Valve bore35 mm (1.38 in)
Radiator fanMotor120 W
Fan diameter x Blade 320 mm (12.60 in) x 5
RadiatorTypeCross flow, pressure type
Core dimensions670x361x16mm
(26.38 x 14.21 x 0.63 in)
Pressure range in which cap valve is openAbove: 88±10 kPa
(0.9±0.1 kg/cm
2, 12.8±1.4 psi)
Below: 4.9 to 9.8 kPa
(0.05 to 0.1 kg/cm
2, 0.7 to 1.4 psi)
FinsCorrugated fin type
Reservoir
tankCapacity 0.5
(0.5 US qt, 0.4 Imp qt)
B: SERVICE DATA
Engine
coolant
pumpClearance between impeller and caseStandard
Limit0.5 — 0.7 mm (0.020 — 0.028 in)
1.0 mm (0.039 in)
“Thrust” runout of impeller end 0.5 mm (0.020 in)
2
2-5SPECIFICATIONS AND SERVICE DATA
1. Engine Cooling System

G2M0210
12) Remove tensioner bracket.
13) Disconnect heater hose from engine coolant pump.
14) Remove engine coolant pump.
B: INSPECTION
1) Check engine coolant pump bearing for smooth rota-
tion.
2) Check engine coolant pump pulley for abnormalities.
G2M0211
3) Using a dial gauge, measure impeller runout in thrust
direction while rotating the pulley.
“Thrust”runout limit:
0.5 mm (0.020 in)
G2M0212
4) Check clearance between impeller and pump case.
Clearance between impeller and pump case:
Standard
0.5—0.7 mm (0.020—0.028 in)
Limit
1.0 mm (0.039 in)
5) After engine coolant pump installation, check pulley
shaft for engine coolant leaks. If leaks are noted, replace
engine coolant pump assembly.
10
2-5SERVICE PROCEDURE
2. Engine Coolant Pump

B2M0173A
B: INSPECTION
1. RELEASE BEARING
CAUTION:
Since this bearing is grease sealed and is of a nonlu-
brication type, do not wash with gasoline or any sol-
vent when servicing the clutch.
1) Check the bearing for smooth movement by applying
force in the radial direction.
Radial direction stroke:
FWD; Approx.
1.0 mm (0.039 in)
AWD; Approx.
1.4 mm (0.055 in)
G2M0240
2) Check the bearing for smooth rotation by applying pres-
sure in the thrust direction.
3) Check wear and damage of bearing case surface con-
tacting with lever.
G2M0241
2. RELEASE LEVER
Check lever pivot portion and the point of contact with
release bearing case for wear.
C: INSTALLATION
CAUTION:
Before or during assembling, lubricate the following
points with a light coat of grease.
Inner groove of release bearing
Contact surface of lever and pivot
Contact surface of lever and bearing
Transmission main shaft spline (Use grease contain-
ing molybdenum disulphide.)
6
2-10SERVICE PROCEDURE
3. Release Bearing and Lever