wheel SUBARU LEGACY 1995 Service Repair Manual

5. Crankshaft and Piston
G2M0105

1Drive plate (AT)


2Reinforcement (AT)


3Flywheel (MT)


4Bell bearing (MT)


5Top ring


6Second ring


7Oil ring


8Piston


9Piston pin


10Circlip


11Connecting rod bolt


12Connecting rod

13Connecting rod bearing


14Connecting rod cap


15Crankshaft


16Woodruff key


17Crankshaft bearing #1, #5


18Crankshaft bearing #2, #4


19Crankshaft bearing #3
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 44±2 (4.5±0.2, 32.5±1.4)
T2: 72±3 (7.3±0.3, 52.8±2.2)
10
2-3COMPONENT PARTS
5. Crankshaft and Piston

G2M0106
1. General Precautions
1) Before disassembling engine, place it on ST3.
ST1 498457000 ENGINE STAND ADAPTER RH
ST2 498457100 ENGINE STAND ADAPTER LH
ST3 499817000 ENGINE STAND
2) All parts should be thoroughly cleaned, paying special
attention to the engine oil passages, pistons and bearings.
3) Rotating parts and sliding parts such as piston, bearing
and gear should be coated with oil prior to assembly.
4) Be careful not to let oil, grease or coolant contact the
timing belt, clutch disc and flywheel.
5) All removed parts, if to be reused, should be reinstalled
in the original positions and directions.
6) Gaskets and lock washers must be replaced with new
ones. Liquid gasket should be used where specified to
prevent leakage.
7) Bolts, nuts and washers should be replaced with new
ones as required.
8) Even if necessary inspections have been made in
advance, proceed with assembly work while making
rechecks.
2. Hydraulic Lash Adjuster
A: INSPECTION
1) Disconnect blow-by hose from rocker cover.
2) Remove spark plug cap.
B2M0413A
3) Remove left and right rocker covers.
CAUTION:
Before removing left rocker cover, disconnect battery
cables and generator cable.
11
2-3SERVICE PROCEDURE
1. General Precautions - 2. Hydraulic Lash Adjuster

G2M0106
1. General Precautions
1) Before disassembling engine, place it on ST3.
ST1 498457000 ENGINE STAND ADAPTER RH
ST2 498457100 ENGINE STAND ADAPTER LH
ST3 499817000 ENGINE STAND
2) All parts should be thoroughly cleaned, paying special
attention to the engine oil passages, pistons and bearings.
3) Rotating parts and sliding parts such as piston, bearing
and gear should be coated with oil prior to assembly.
4) Be careful not to let oil, grease or coolant contact the
timing belt, clutch disc and flywheel.
5) All removed parts, if to be reused, should be reinstalled
in the original positions and directions.
6) Gaskets and lock washers must be replaced with new
ones. Liquid gasket should be used where specified to
prevent leakage.
7) Bolts, nuts and washers should be replaced with new
ones as required.
8) Even if necessary inspections have been made in
advance, proceed with assembly work while making
rechecks.
2. Hydraulic Lash Adjuster
A: INSPECTION
1) Disconnect blow-by hose from rocker cover.
2) Remove spark plug cap.
B2M0413A
3) Remove left and right rocker covers.
CAUTION:
Before removing left rocker cover, disconnect battery
cables and generator cable.
11
2-3SERVICE PROCEDURE
1. General Precautions - 2. Hydraulic Lash Adjuster

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.
51
2-3SERVICE PROCEDURE
7. Cylinder Block

G2M0084
1) Install baffle plate.
2) Install oil strainer and O-ring
3) Install oil strainer stay.
4) Apply fluid packing to matching surfaces and install oil
pan.
Fluid packing:
THREE BOND 1207C or equivalent
G2M0194
5) Apply fluid packing to matching surfaces and install oil
separator cover.
Fluid packing:
THREE BOND 1215 or equivalent
G2M0161
6) Install flywheel or drive plate.
To lock crankshaft, use ST.
ST 498497100 CRANKSHAFT STOPPER
7) Install housing cover.
G2M0076
8) Installation of oil pump
(1) Discard front oil seal after removal. Replace with a
new one by using ST.
ST 499587100 OIL SEAL INSTALLER
73
2-3SERVICE PROCEDURE
7. Cylinder Block

2. Engine Noise
Valve lash adjusters may make clicking noise once engine
starts. It is normal if clicking noise ceases after a few min-
utes.
If clicking noise continues after a few minutes, check
engine oil level and add oil if necessary.
Then, do as follows to cease clicking noise.
1) Warm-up engine for five minutes.
2) Turn ignition switch OFF.
3) Connect test mode connector.
4) Start the engine and run it at approximately 2,000 rpm
for twenty minutes.
5) Turn ignition switch OFF.
6) Disconnect test mode connector.
7) Start the engine and check that clicking noise is ceased.
If noise still exists, conduct troubleshooting procedures in
accordance with the following table.
CAUTION:
Do not disconnect spark plug cord while engine is run-
ning.
Type of sound Condition Possible cause
Regular clicking soundSound increases as engine
speed increases.Valve mechanism is defective.
Broken lash adjuster
Worn valve rocker
Worn camshaft
Broken valve spring
Worn valve lifter hole
Heavy and dull clankOil pressure is low.Worn crankshaft main bearing
Worn connecting rod bearing (big end)
Oil pressure is normal.Loose flywheel mounting bolts
Damaged engine mounting
High-pitched clank
(Spark knock)Sound is noticeable when
accelerating with an overload.Ignition timing advanced
Accumulation of carbon inside combustion chamber
Wrong spark plug
Improper gasoline
Clank when engine speed is
medium (1,000 to 2,000 rpm).Sound is reduced when fuel
injector connector of noisy
cylinder is disconnected.
(NOTE*)Worn crankshaft main bearing
Worn bearing at crankshaft end of connecting rod
Knocking sound when engine
is operating under idling speed
and engine is warm.Sound is reduced when fuel
injector connector of noisy
cylinder is disconnected.
(NOTE*)Worn cylinder liner and piston ring
Broken or stuck piston ring
Worn piston pin and hole at piston end of connecting rod
Sound is not reduced if each
fuel injector connector is
disconnected in turn. (NOTE*)Unusually worn valve lifter
Worn cam gear
Worn camshaft journal bore in crankcase
Squeaky sound—Insufficient generator lubrication
Rubbing sound—Defective generator brush and rotor contact
Gear scream when starting
engine—Defective ignition starter switch
Worn gear and starter pinion
Sound like polishing glass with
a dry cloth—Loose drive belt
Defective engine coolant pump shaft
78
2-3DIAGNOSTICS
2. Engine Noise

G2M0544
2. Oil Pan and Oil Strainer
A: REMOVAL
1) Remove front wheels.
2) Remove air intake duct.
3) Disconnect connector from front oxygen sensor.
G2M0295
4) Remove pitching stopper.
B2M0320
5) Remove radiator upper brackets.
B2M0053
6) Support engine with a lifting device and wire ropes.
7) Lift-up the vehicle.
CAUTION:
At this time, raise up wire ropes.
G2M0066
8) Drain engine oil.
Set container under the vehicle, and remove drain plug
from oil pan.
8
2-4SERVICE PROCEDURE
2. Oil Pan and Oil Strainer

B2M0334
(3) Remove bolts which install power steering pump
from bracket.
B2M0029
(4) Place power steering pump on the right side wheel
apron.
B6M0160
8) Disconnect spark plug cords from ignition coil.
H2M1246
9) Disconnect engine coolant hoses from throttle body.
H2M1259A
10) Disconnect engine coolant hose
1from idle air con-
trol solenoid valve.
11) Disconnect air by-pass hose

2from idle air control
solenoid valve.
9
2-7SERVICE PROCEDURE
4. Intake Manifold

G2M0360
3) Remove right rear wheel.
4) Open fuel filler flap and remove filler cap.
5) Remove screws holding packing in place.
G2M0361
6) Lift-up the vehicle.
7) Remove fuel filler pipe protector.
G2M0353
8) Remove clip, and separate air vent hose from pipe.
9) Loosen clamp, and separate fuel filler hose from pipe.


1Fuel filler hose


2Air vent hose
10) Remove fuel filler pipe to under side of the vehicle.
G2M0364
B: INSTALLATION
1) Hold fuel filler flap open.
2) Set fuel saucer

1with rubber packing
3, and insert fuel
filler pipe into hole from the inner side of apron.
3) Align holes in fuel filler pipe neck and set cup

2, and
tighten screws.
NOTE:
If edges of rubber packing are folded toward the inside,
straighten it with a screwdriver.
G2M0353
4) Insert fuel filler hose approximately 25 to 30 mm (0.98
to 1.18 in) over the lower end of fuel filler pipe and tighten
clamp.


1Fuel filler hose


2Air vent hose
CAUTION:
Do not allow clips to touch air vent hose and rear sus-
pension crossmember.
13
2-8SERVICE PROCEDURE
4. Fuel Filler Pipe

G2M0358
5) Insert air vent hose approximately 25 to 30 mm (0.98 to
1.18 in) into the lower end of air vent pipe and hold clip.


1Hose


2Clip


3Pipe
L=25—30 mm (0.98—1.18 in)
G2M0361
6) Install fuel filler pipe protector.
7) Install right rear wheel.
5. Fuel Filter
A: REMOVAL
1) Release fuel pressure.
G2M0347
2) Disconnect fuel delivery hoses from fuel filter.
3) Remove filter from holder.
B: INSPECTION
1) Check the inside of fuel filter for dirt and water sedi-
ment.
2) If it is clogged, or if replacement interval has been
reached, replace it.
3) If water is found in it, shake and expel the water from
inlet port.
14
2-8SERVICE PROCEDURE
4. Fuel Filler Pipe - 5. Fuel Filter