Subaru Legacy (2005 year). Manual - part 73

ME(H4SO 2.0)-75

MECHANICAL

Cylinder Block

25) Apply liquid gasket to the mating surfaces and
threaded portion of bolt (A) as shown in the figure,
and then install the oil separator cover.

Liquid gasket:

THREE BOND 1207C (Part No. 004403012) or
equivalent

26) Install the flywheel. (MT model)
<Ref. to CL-21, INSTALLATION, Flywheel.>
To lock the crankshaft, use the ST.
ST

498497100

CRANKSHAFT STOPPER

Tightening torque:

72 N

⋅

m (7.3 kgf-m, 53.1 ft-lb)

27) Install the drive plate. (AT model)
To lock the crankshaft, use the ST.
ST

498497100

CRANKSHAFT STOPPER

Tightening torque:

72 N

⋅

m (7.3 kgf-m, 52.8 ft-lb)

28) Install the housing cover.

29) Installation of oil pump

(1) Discard the front oil seal after removal. Re-
place with a new one using ST.

499587100

OIL SEAL INSTALLER

(2) Apply liquid gasket to the matching surface
of oil pump.

Liquid gasket:

THREE BOND 1215 (Part No. 004403007) or
equivalent

(3) Apply a coat of engine oil to the inside of oil
seal.

(4) Install the oil pump to cylinder block. Be
careful not to damage the oil seal during instal-
lation.
(5) Position the oil pump, aligning the notched
area with the crankshaft, and push the oil pump
straight.

ME-02452

(A)

ME-00297

ME-00298

(A) O-ring

ME-00164

ME-00165

(A)

ME-00312

ME(H4SO 2.0)-76

MECHANICAL

Cylinder Block

CAUTION:
• Make sure the oil seal lip is not folded.
• Do not forget to install the O-ring and seal
when installing oil pump.

(6) Install the oil pump.
(7) Apply liquid gasket to the three bolts thread.

Liquid gasket:

THREE BOND 1215 (Part No. 004403007) or
equivalent

Tightening torque:

6.4 N

⋅

m (0.65 kgf-m, 4.7 ft-lb)

30) Install the water pump and gasket.

Tightening torque:

First: 12 N

⋅

m (1.2 kgf-m, 8.7 ft-lb)

Second: 12 N

⋅

m (1.2 kgf-m, 8.7 ft-lb)

CAUTION:
• Be sure to use a new gasket.
• When installing the water pump, tighten bolts
in two stages in alphabetical sequence as
shown in the figure.

31) Install the water by-pass pipe for heater.
32) Install the oil filter.
33) Tighten the cylinder head bolts.

(1) Apply a coat of engine oil to washers and
bolt threads.
(2) Tighten all bolts to 29 N

⋅m (3.0 kgf-m, 22 ft-

lb) in alphabetical sequence. Then tighten all
bolts to 69 N

⋅m (7.0 kgf-m, 51 ft-lb) in alphabet-

ical sequence.
(3) Back off all bolts by 180

° in reverse order of

installation, and back them off again by 180

°.

(4) Tighten all bolts to 42 N

⋅m (4.3 kgf-m, 31 ft-

lb) in alphabetical sequence.
(5) Tighten all bolts by 80 — 90

° in alphabetical

sequence.
(6) Tighten all bolts by 40 — 45

° in alphabetical

sequence.

CAUTION:
Do not tighten the bolts more than 45

°.

(7) Further tighten the bolts (A) and (B) by 40 —
45

°.

CAUTION:
Ensure the total “re-tightening angle” of the
step (6) and (7) does not exceed 90

°.

34) Install the oil level gauge guide and tighten the
bolt. (LH side only)
35) Install the rocker cover and rocker cover gas-
ket.

NOTE:
Use a new rocker cover gasket.
36) Install the crank sprocket.
<Ref. to ME(H4SO 2.0)-50, INSTALLATION,
Crank Sprocket.>
37) Install the cam sprocket. <Ref. to ME(H4SO
2.0)-48, INSTALLATION, Cam Sprocket.>
38) Install the timing belt. <Ref. to ME(H4SO 2.0)-
44, INSTALLATION, Timing Belt.>
39) Install the timing belt cover.
<Ref. to ME(H4SO 2.0)-42, INSTALLATION, Tim-
ing Belt Cover.>
40) Install the crank pulley. <Ref. to ME(H4SO
2.0)-40, INSTALLATION, Crank Pulley.>
41) Install the generator and A/C compressor
brackets on cylinder head.
42) Install the V-belts. <Ref. to ME(H4SO 2.0)-37,
INSTALLATION, V-belt.>
43) Install the intake manifold.
<Ref. to FU(H4SO 2.0)-12, INSTALLATION, Intake
Manifold.>

LU-02103

ME-02463

(F)

(E)

(D)

(C)

(B)

(A)

(A) Front side

ME-00309

(a)

(b)

(c)

(e)

(f)

(A)

(d)

ME(H4SO 2.0)-77

MECHANICAL

Cylinder Block

C: DISASSEMBLY

1) Remove the connecting rod cap.
2) Remove the connecting rod bearing.

NOTE:
Arrange the removed connecting rod, connecting
rod cap and bearing in order, to prevent confusion.
3) Remove the piston rings using piston ring ex-
pander.

4) Remove the oil ring by hand.

NOTE:
Arrange the removed piston rings in proper order,
to prevent confusion.
5) Remove the snap ring.

D: ASSEMBLY

(1)

Connecting rod cap

(3)

Top ring

(5)

Oil ring

(2)

Connecting rod bearing

(4)

Second ring

(6)

Snap ring

ME-00168

(2)

(6)

(5)

(4)

(3)

(1)

Connecting rod bearing

(5)

Second ring

Tightening torque: N

⋅

m (kgf-m, ft-lb)

(2)

Connecting rod

(6)

Top ring

T: 45 (4.6, 33.3)

(3)

Connecting rod cap

(7)

Snap ring

(4)

Oil ring

(8)

Side mark

ME-00392

(2)

(4)

(5)

(6)

(1)

(7)

(8)

(3)

ME(H4SO 2.0)-78

MECHANICAL

Cylinder Block

1) Apply oil to the surfaces of the connecting rod
bearings.
2) Install the connecting rod bearings on connect-
ing rods and connecting rod caps.
3) Position each connecting rod with the marked
side facing forward, and install it.
4) Install the connecting rod cap with connecting
rod nut.
Ensure the arrow on connecting rod cap faces to-
ward front during installation.

CAUTION:
• Each connecting rod has its own mating cap.
Make sure that they are assembled correctly by
checking their matching number.
• When tightening the connecting rod nuts, ap-
ply oil on the threads.
5) Install the expander, lower rail and upper rail in
this order by hand. Install the second ring and top
ring using piston ring expander.

E: INSPECTION

1. CYLINDER BLOCK

1) Visually check for cracks and damage. Especial-
ly, inspect the important parts using liquid pene-
trant tester.
2) Check the oil passages for clogging.
3) Inspect the cylinder block surface that mates
with cylinder head for warping by using a straight
edge, and correct by grinding if necessary.

Warping limit:

0.025 mm (0.00098 in)

Grinding limit:

0.1 mm (0.004 in)

Standard height of cylinder block:

201.0 mm (7.91 in)

2. CYLINDER AND PISTON

1) The cylinder bore size is stamped on the cylinder
block’s front upper surface.

NOTE:
• Measurement should be performed at a temper-
ature of 20

°C (68°F).

• Standard sized pistons are classified into two
grades, “A” and “B”. These grades should be used
as guide lines in selecting a standard piston.

Standard diameter:

2.0 L model

A: 92.005 — 92.015 mm (3.6222 — 3.6226 in)
B: 91.995 — 92.005 mm (3.6218 — 3.6222 in)

2.5 L model

A: 99.505 — 99.515 mm (3.9175 — 3.9179 in)
B: 99.495 — 99.505 mm (3.9671 — 3.9175 in)

(A) Main journal size mark

(B) Cylinder block (RH) - (LH) combination mark

(D) #2 cylinder bore size mark

(E) #3 cylinder bore size mark

(F) #4 cylinder bore size mark

ME-00170

(A)

(B)

(F)

(D)

(C)

(E)

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