Subaru Legacy (2005 year). Manual - part 284

 

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Subaru Legacy (2005 year). Manual - part 284

 

 

ME(H4DOTC)-79

MECHANICAL

Cylinder Block

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

NOTE:
Install them within 20 min. from applying liquid gas-
ket.

Liquid gasket:

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

Tightening torque:

6.4 N

⋅

m (0.65 kgf-m, 4.7 ft-lb)

28) 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, 53.1 ft-lb)

29) Install the flywheel. (MT model) <Ref. to CL-21,
INSTALLATION, Flywheel.>
30) Install the clutch disk and cover. (MT model)
<Ref. to CL-16, INSTALLATION, Clutch Disc and
Cover.>

31) Installation of oil pump

(1) Install the front oil seal using ST.

ST

499587100

OIL SEAL INSTALLER

NOTE:
Use a new front oil seal.

(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.

ME-02452

(A)

ME-00136

ST

(A) O-ring

ME-00164

ME-00165

(A)

ME-00312

ME(H4DOTC)-80

MECHANICAL

Cylinder Block

(4) Install the oil pump to cylinder block. Be
careful not to damage the oil seal during instal-
lation.

Tightening torque:

6.4 N

⋅

m (0.65 kgf-m, 4.7 ft-lb)

CAUTION:
• Do not forget to install the O-ring and seal
when installing oil pump.
• Align the flat surface of oil pump’s inner rotor
with crankshaft before installation.
32) Install the water pump and gasket.

Tightening torque:

First: 12 N

⋅

m (1.2 kgf-m, 8.9 ft-lb)

Second: 12 N

⋅

m (1.2 kgf-m, 8.9 ft-lb)

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

33) Install the water by-pass pipe for heater.

34) Install the oil cooler. (MT model)

Tightening torque:

T1: 54 N

⋅

m (5.5 kgf-m, 39.8 ft-lb)

T2: 69 N

⋅

m (7.0 kgf-m, 50.9 ft-lb)

35) Install the oil filter.
36) Install the water by-pass pipe between oil cool-
er and water pump.
37) Install the water pipe.

NOTE:
Always use new O-rings.
38) Install the cylinder head.
<Ref. to ME(H4DOTC)-62, INSTALLATION, Cylin-
der Head.>
39) Install the oil level gauge guide. (LH side)
40) Install the rocker cover.
41) Install the crank sprocket. <Ref. to
ME(H4DOTC)-55, INSTALLATION, Crank Sprock-
et.>
42) Install the cam sprocket.
<Ref. to ME(H4DOTC)-54, INSTALLATION, Cam
Sprocket.>
43) Install the timing belt.
<Ref. to ME(H4DOTC)-48, INSTALLATION, Tim-
ing Belt.>
44) Install the timing belt cover.
<Ref. to ME(H4DOTC)-45, INSTALLATION, Tim-
ing Belt Cover.>

ME-02463

(F)

(E)

(D)

(C)

(B)

(A)

(A) O-ring

(B) Oil cooler

(C) Oil cooler connector

ME-00723

T2

(C)

(B)

(A)

T1

ME(H4DOTC)-81

MECHANICAL

Cylinder Block

45) Install the crank pulley.
<Ref. to ME(H4DOTC)-43, INSTALLATION, Crank
Pulley.>
46) Install the generator and A/C compressor
brackets on cylinder head.

47) Install the V-belts. <Ref. to ME(H4DOTC)-40,
INSTALLATION, V-belt.>
48) Install the intake manifold.
<Ref. to FU(H4DOTC)-14, INSTALLATION, Intake
Manifold.>

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.

(1)

Connecting rod cap

(3)

Top ring

(5)

Oil ring

(2)

Connecting rod bearing

(4)

Second ring

(6)

Snap ring

ME-00168

(2)

(2)

(6)

(5)

(4)

(3)

(1)

ME(H4DOTC)-82

MECHANICAL

Cylinder Block

D: ASSEMBLY

1) Apply oil to the surfaces of the connecting rod
bearings. Install the connecting rod bearings on
connecting rods and connecting rod caps.
2) Install the connecting rod on crankshaft.

NOTE:
Position each connecting rod with the side marked
facing forward.
3) Install the connecting rod cap.
Ensure the arrow mark on connecting rod cap fac-
ing 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.
4) Install the oil ring spacer, upper rail and lower rail
in this order by hand. Then install the second ring
and top ring with a 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 crankcase 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)

(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-00169

(2)

(4)

(5)

(6)

(1)

(1)

(7)

(8)

(3)

T

 

 

 

 

 

 

 

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