SUBARU LEGACY 1999 Service Repair Manual

6) Inspect bushing at connecting rod small end,
and replace if worn or damaged. Also measure the
piston pin clearance at the connecting rod small
end.
Clearance between piston pin and bushing:
Standard
0 Ð 0.022 mm (0 Ð 0.0009 in)
Limit
0.030 mm (0.0012 in)
B2M0085
B2M0084A
7) Replacement procedure is as follows.
(1) Remove bushing from connecting rod with
ST and press.
(2) Press bushing with ST after applying oil on
the periphery of bushing.
ST 499037100 CONNECTING ROD BUSH-
ING REMOVER AND
INSTALLER
G2M0177
(3) Make two 3 mm (0.12 in) holes in bushing.
Ream the inside of bushing.
(4) After completion of reaming, clean bushing
to remove chips.
6. CRANKSHAFT AND CRANKSHAFT
BEARING
1) Clean crankshaft completely and check for
cracks by means of red lead check etc., and
replace if defective.
2) Measure the crankshaft bend, and correct or
replace if it exceeds the limit.
CAUTION:
If a suitable V-block is not available, install #1
and #5 crankshaft bearing on cylinder block,
position crankshaft on these bearings and
measure crankshaft bend using a dial gauge.
Crankshaft bend limit:
0.035 mm (0.0014 in)
G2M0178
3) Inspect the crank journal and crank pin for
wear. If not to specifications, replace bearing with
an undersize one, and replace or recondition
crankshaft as necessary. When grinding crank
journal or crank pin, finish them to the specified
dimensions according to the undersize bearing to
be used.
Crank pin and crank journal:
Out-of-roundness
0.020 mm (0.0008 in) or less
Taper limit
0.07 mm (0.0028 in)
Grinding limit
0.25 mm (0.0098 in)
G2M0179
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2-3b[W5C6]SERVICE PROCEDURE
5. Cylinder Block

Unit: mm (in)
Crank journal diameter
Crank pin diameter
#1, #5 #2, #3, #4
StandardJournal O.D.59.992 Ð 60.008
(2.3619 Ð 2.3625)59.992 Ð 60.008
(2.3619 Ð 2.3625)51.984 Ð 52.000
(2.0466 Ð 2.0472)
Bearing size
(Thickness at
center)1.998 Ð 2.011
(0.0787 Ð 0.0792)2.000 Ð 2.013
(0.0787 Ð 0.0793)1.492 Ð 1.501
(0.0587 Ð 0.0591)
0.03 (0.0012)
undersizeJournal O.D.59.962 Ð 59.978
(2.3607 Ð 2.3613)59.962 Ð 59.978
(2.3607 Ð 2.3613)51.954 Ð 51.970
(2.0454 Ð 2.0461)
Bearing size
(Thickness at
center)2.017 Ð 2.020
(0.0794 Ð 0.0795)2.019 Ð 2.022
(0.0795 Ð 0.0796)1.510 Ð 1.513
(0.0594 Ð 0.0596)
0.05 (0.0020)
undersizeJournal O.D.59.942Ð 59.958
(2.3599 Ð 2.3605)59.942 Ð 59.958
(2.3599 Ð 2.3605)51.934 Ð 51.950
(2.0446 Ð 2.0453)
Bearing size
(Thickness at
center)2.027 Ð 2.030
(0.0798 Ð 0.0799)2.029 Ð 2.032
(0.0799 Ð 0.0800)1.520 Ð 1.523
(0.0598 Ð 0.0600)
0.25 (0.0098)
undersizeJournal O.D.59.742 Ð 59.758
(2.3520 Ð 2.3527)59.742 Ð 59.758
(2.3520 Ð 2.3527)51.734 Ð 51.750
(2.0368 Ð 2.0374)
Bearing size
(Thickness at
center)2.127 Ð 2.130
(0.0837 Ð 0.0839)2.129 Ð 2.132
(0.0838 Ð 0.0839)1.620 Ð 1.623
(0.0638 Ð 0.0639)
O.D. ... Outer Diameter
4) Measure the thrust clearance of crankshaft at
center bearing. If the clearance exceeds the limit,
replace bearing.
Crankshaft thrust clearance:
Standard
0.030 Ð 0.115 mm (0.0012 Ð 0.0045 in)
Limit
0.25 mm (0.0098 in)
G2M0180
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 measure-
ment is not within the specification, replace defec-
tive bearing with an undersize one, and replace or
recondition crankshaft as necessary.
Unit: mm (in)
Crankshaft oil clearance
Standard#1, #50.003 Ð 0.030
(0.0001 Ð
0.0012)
#2, #3, #40.010 Ð 0.033
(0.0004 Ð
0.0013)
Limit#1, #3, #5 0.040 (0.0016)
#2, #4 0.045 (0.0018)
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[W5C6]2-3bSERVICE PROCEDURE
5. Cylinder Block

D: ASSEMBLY
1. CRANKSHAFT AND PISTON
B2M1320J
(1) Connecting rod bearing
(2) Connecting rod
(3) Connecting rod cap
(4) Oil ring(5) Second ring
(6) Top ring
(7) CirclipTightening torque: N´m (kg-m, ft-lb)
T:
44±2 (4.5±0.2, 32.5±1.4)
1) Install connecting rod bearings on connecting
rods and connecting rod caps.
CAUTION:
Apply oil to the surfaces of the connecting rod
bearings.
2) Install connecting rod on crankshaft.
CAUTION:
Position each connecting rod with the side
marked facing forward.
3) Install connecting rod cap with connecting rod
nut.
Ensure the arrow on connecting rod cap faces the
front during installation.
CAUTION:
IEach connecting rod has its own mating cap.
Make sure that they are assembled correctly by
checking their matching number.
IWhen tightening the connecting rod nuts,
apply oil on the threads.
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.
B2M1223B
(3) Position the second ring gap at 180É on the
reverse side for the top ring gap.
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2-3b[W5D1]SERVICE PROCEDURE
5. Cylinder Block

(4) Position the upper rail gap at (C) or (D) in
the figure.
B2M1224B
(5) Position the expander gap at 180É of the
reverse side for the upper rail gap.
(6) Position the lower rail gap at (E) or (F) in the
figure.
CAUTION:
IEnsure ring gaps do not face the same direc-
tion.
IEnsure ring gaps are not within the piston
skirt area.
B2M1224B
5) Install circlip.
Install circlips in piston holes located opposite ser-
vice holes in cylinder block, when positioning all
pistons in the corresponding cylinders.
CAUTION:
Use new circlips.
B2M1403A
63
[W5D1]2-3bSERVICE PROCEDURE
5. Cylinder Block

2. CYLINDER BLOCK
B2M2407A
(1) Crankshaft bearing
(2) Crankshaft
(3) Cylinder block(4) Rear oil sealTightening torque: N´m (kg-m, ft-lb)
T1:
25±2 (2.5±0.2, 18.1±1.4)
T2:47±3 (4.8±0.3, 34.7±2.2)
1) Install ST to cylinder block, then install crank-
shaft bearings.
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.3) Apply fluid packing to the mating surface of #1
and #3 cylinder block, and position it on #2 and #4
cylinder block.
Fluid packing:
THREE BOND 1215 or equivalent
CAUTION:
Do not allow fluid packing to jut into O-ring
grooves, oil passages, bearing grooves, etc.
G2M0185
64
2-3b[W5D2]SERVICE PROCEDURE
5. Cylinder Block

4) Temporarily tighten 10 mm cylinder block con-
necting bolts in alphabetical sequence shown in
figure.
B2M0088D
5) Tighten 10 mm cylinder block connecting bolts
in alphabetical sequence.
Tightening torque:
47
±3 N´m (4.8±0.3 kg-m, 34.7±2.2 ft-lb)
B2M0088D
6) Tighten 8 mm and 6 mm cylinder block connect-
ing bolts in alphabetical sequence shown in figure.
Tightening torque:
(A) Ð (G): 25
±2 N´m (2.5±0.2 kg-m,
18.1
±1.4 ft-lb)
(H): 6.4 N´m (0.65 kg-m, 4.7 ft-lb)
B2M0089F
7) Install rear oil seal by using ST1 and ST2.
ST1 499597100 OIL SEAL GUIDE
ST2 499587200 OIL SEAL INSTALLER
G2M0186
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[W5D2]2-3bSERVICE PROCEDURE
5. Cylinder Block

3. PISTON AND PISTON PIN (#1 AND #2)
B2M1322E
(1) Piston
(2) Piston pin
(3) Circlip(4) Gasket
(5) Service hole plugTightening torque: N´m (kg-m, ft-lb)
T:
69±7 (7.0±0.7, 50.6±5.1)
1) Installing piston
(1) Turn cylinder block so that #1 and #2 cylin-
ders face upward.
(2) Using ST1, turn crankshaft so that #1 and
#2 connecting rods are set at bottom dead cen-
ter.
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 498747300 PISTON GUIDE
S2M0306A
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 inser-
tion.
ST3 499017100 PISTON PIN GUIDE
G2M0189
(2) Apply a coat of engine oil to piston pin and
insert piston pin into piston and connecting rod
through service hole.
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2-3b[W5D3]SERVICE PROCEDURE
5. Cylinder Block

(3) Install circlip.
CAUTION:
Use new circlips.
G2M0190
(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
4. PISTON AND PISTON PIN (#3 AND #4)
B2M1323E
(1) Piston
(2) Piston pin
(3) Circlip
(4) Gasket(5) Service hole plug
(6) Service hole coverTightening torque: N´m (kg-m, ft-lb)
T1:
6.4 (0.65, 4.7)
T2:69±7 (7.0±0.7, 50.6±5.1)
Turn cylinder block so that #3 and #4 cylinders face
upward. Using the same procedures as used for #1
and #2 cylinders, install pistons and piston pins.
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[W5D4]2-3bSERVICE PROCEDURE
5. Cylinder Block

E: INSTALLATION
1. OIL PUMP AND WATER PUMP
B2M1767C
(1) Baffle plate
(2) Oil strainer
(3) Oil pan
(4) Oil separator cover
(5) Drive plate (AT vehicles only)
(6) Flywheel (MT vehicles only)
(7) Clutch housing cover (MT
vehicles only)(8) Oil pump
(9) Water pump
(10) Water by-pass pipe
(11) Oil filterTightening 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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2-3b[W5E1]SERVICE PROCEDURE
5. Cylinder Block

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 1215 or equivalent
G2M0084
5) Apply fluid packing to matching surfaces and
install oil separator cover.
Fluid packing:
THREE BOND 1215 or equivalent
G2M0194
6) Install flywheel (MT vehicles only) or drive plate
(AT vehicles only).
To lock crankshaft, use ST.
ST 498497100 CRANKSHAFT STOPPER
G2M0776
B2M0706A
7) Install clutch housing cover. (MT vehicles only)
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
S2M0235
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[W5E1]2-3bSERVICE PROCEDURE
5. Cylinder Block