Subaru Legacy (2005 year). Manual - part 399

ME(H6DO)-71

MECHANICAL

Cylinder Block

27) Install the flywheel. <Ref. to CL-21, INSTALLA-
TION, Flywheel.>
28) Install the clutch disc and cover. <Ref. to CL-
16, INSTALLATION, Clutch Disc and Cover.>
29) Install the drive plate using ST. (AT model)
ST1

498497100

CRANKSHAFT STOPPER

ST2

499057000

TORX PLUS

Tightening torque:

81 N

⋅

m (8.3 kgf-m, 60 ft-lb)

30) Install the cylinder head. <Ref. to ME(H6DO)-
60, INSTALLATION, Cylinder Head.>
31) Install the camshaft. <Ref. to ME(H6DO)-57,
INSTALLATION, Camshaft.>
32) Install the rear chain cover. <Ref. to
ME(H6DO)-54, INSTALLATION, Rear Chain Cov-
er.>
33) Install the crank sprocket.
<Ref. to ME(H6DO)-53, INSTALLATION, Crank
Sprocket.>
34) Install the cam sprocket. <Ref. to ME(H6DO)-
52, INSTALLATION, Cam Sprocket.>
35) Install the timing chain assembly.
<Ref. to ME(H6DO)-48, INSTALLATION, Timing
Chain Assembly.>
36) Install the front chain cover.
<Ref. to ME(H6DO)-45, INSTALLATION, Front
Chain Cover.>
37) Install the crank pulley.
<Ref. to ME(H6DO)-44, INSTALLATION, Crank
Pulley.>

C: DISASSEMBLY

ME-00557

(1)

Connecting rod cap

(3)

Top ring

(5)

Oil ring

(2)

Connecting rod bearing

(4)

Second ring

(6)

Snap ring

(1)

(2)

(3)

(4)

(5)

(6)

ME-02097

ME(H6DO)-72

MECHANICAL

Cylinder Block

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) 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 bolts,
apply oil on the threads and flange end.
4) Install the oil ring spacer, upper rail and lower rail
in this order by hand. Install the second ring and top
ring using piston ring expander.

(1)

Connecting rod cap

(5)

Oil ring

Tightening torque: N

⋅

m (kgf-m, ft-lb)

(2)

Connecting rod bearing

(6)

Snap ring

T: 53 (5.4, 39)

(3)

Top ring

(7)

Connecting rod

(4)

Second ring

(1)

(2)

(7)

(3)

(4)

(5)

(7)

(3)

(4)

(5)

(6)

ME-02459

ME(H6DO)-73

MECHANICAL

Cylinder Block

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.

Standard height of cylinder block:

202 mm (7.95 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:

A: 89.205 — 89.215 mm (3.5120 — 3.5124 in)
B: 89.195 — 89.205 mm (3.5116 — 3.5120 in)

2) How to measure the inner diameter of each cyl-
inder:
Measure the inner diameter of each cylinder in both
the thrust and piston pin directions at the heights as
shown in the figure, using a cylinder bore gauge.

NOTE:
Measurement should be performed at a tempera-
ture of 20

°C (68°F).

Cylindricality:

Standard

0.030 mm (0.0012 in)

Out-of-roundness:

Standard

0.010 mm (0.0004 in)

3) When the piston is to be replaced due to general
or cylinder wear, select a suitable sized piston by
measuring the piston clearance.
4) How to measure the outer diameter of each cyl-
inder.
Measure the outer diameter of each piston at the
height as shown in the figure. (Thrust direction)

NOTE:
Measurement should be performed at a tempera-
ture of 20

°C (68°F).

(A) Main journal size mark

(B) Cylinder bore size mark

− (LH) combination mark

#6
#5
#4
#3
#2
#1

BBB

4
2B

(A)

(B)

(C)

ME-00585

(A) Piston pin direction

(B) Thrust direction

H1: 10 mm (0.39 in)

H2: 45 mm (1.77 in)

H3: 80 mm (3.15 in)

ME-00586

Unit: mm (in)

(B)

(A)

ME(H6DO)-74

MECHANICAL

Cylinder Block

Piston grade point H:

37.3 mm (1.4685 in)

Piston outer diameter:

Standard

(A): 89.205 — 89.215 mm (3.5120 — 3.5124 in)
(B): 89.195 — 89.205 mm (3.5116 — 3.5120 in)

0.25 mm (0.0098 in) oversize

89.445 — 89.465 mm (3.5215 — 3.5222 in)

0.50 mm (0.0197 in) oversize

89.695 — 89.715 mm (3.5313 — 3.5321 in)

5) Calculate the clearance between cylinder and
piston.

NOTE:
Measurement should be performed at a tempera-
ture of 20

°C (68°F).

Cylinder to piston clearance at 20

C (68

F):

Standard

−

0.010 — 0.010 mm (

−

0.0004 — 0.0004 in)

6) Boring and honing

(1) If the value of cylindricality, out-of-round-
ness, or cylinder-to-piston clearance measured
is out of standard or if there is any damage on
the cylinder wall, rebore it to use an oversize pis-
ton.

CAUTION:
When any of the cylinders needs reboring, all
other cylinders must be bored at the same time,
and use oversize pistons. Do not perform bor-
ing on one cylinder only. Nor use an oversize
piston for one cylinder only.

(2) If the cylinder inner diameter exceeds
89.715 mm (3.5321 in) after boring and honing,
replace the crankcase.

NOTE:
Immediately after reboring, the cylinder diameter
may differ from its real diameter due to temperature
rise. Thus, pay attention to this when measuring
the cylinder diameter.

3. PISTON AND PISTON PIN

1) Check the pistons and piston pins for damage,
cracks and wear, and the piston ring grooves for
wear and damage. Replace if defective.
2) Measure the piston-to-cylinder clearance at
each cylinder. <Ref. to ME(H6DO)-73, CYLINDER
AND PISTON, INSPECTION, Cylinder Block.> If
any of the clearances is not within standard, re-
place the piston or bore the cylinder to use an over-
size piston.
3) Make sure that the piston pin can be inserted
into the piston pin hole with a thumb at 20

°C (68°F).

Replace if defective.

Standard clearance between hole in piston and
piston pin:

Standard

0.004 — 0.008 mm (0.0002 — 0.0003 in)

4) Check the snap ring installation groove (A) on
the piston for burr. If necessary, remove burr from
the groove so that the piston pin can lightly move.

5) Check the piston pin snap ring for distortion,
cracks and wear.

ME-00172

ME-00173

ME-00174

ME-00175

(A)

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