Subaru Legacy (2005 year). Manual - part 400

ME(H6DO)-75

MECHANICAL

Cylinder Block

4. PISTON RING

1) If the piston ring is broken, damaged or worn, or
if its tension is insufficient, or when the piston is re-
placed, replace the piston ring with a new one of
the same size as the piston.

CAUTION:
• Marks are displayed on the end of top and
second rings. When installing the rings to the
piston, face those marks upward.
• Oil ring consists of the upper rail, expander
and lower rail. When installing on piston, be
careful of each rail’s direction.

2) Squarely place the piston ring and oil ring in cyl-
inder, and measure the piston ring gap with a thick-
ness gauge.

3) Measure the clearance between piston ring and
piston ring groove using thickness gauge.

NOTE:
Before measuring the clearance, clean the piston
ring groove and piston ring.

(A) Top ring

(B) Second ring

(a) Upper rail

(b) Expander

Standard

mm (in)

Piston ring gap

Top ring

0.20 — 0.35

(0.0079 — 0.0138)

Second ring

0.35 — 0.50

(0.0138 — 0.0197)

Oil ring

0.20 — 0.60

(0.0079 — 0.0236)

(a)

(c)

(b)

(A)

(B)

(C)

ME-00591

ME-00592

Standard

mm (in)

Clearance
between piston
ring and piston
ring groove

Top ring

0.040 — 0.080

(0.0016 — 0.0031)

Second ring

0.030 — 0.070

(0.0012 — 0.0028)

Clearance between oil ring and oil
ring groove

0.045 — 0.125

(0.0018 — 0.0049)

ME-00178

ME(H6DO)-76

MECHANICAL

Cylinder Block

5. CONNECTING ROD

1) Replace the connecting rod, if the large or small
end thrust surface is damaged.
2) Check for bend or twist using a connecting rod
aligner. Replace the connecting rod if it has the
bend or twist.

3) Install the connecting rod fitted with bearing to
crankshaft and measure the thrust clearance. If the
thrust clearance exceeds the standard or offset
wearing is emitted, replace the connecting rod.

Connecting rod thrust clearance:

Standard

0.070 — 0.330 mm (0.0028 — 0.0130 in)

4) Inspect the connecting rod bearing for scar,
peeling, seizure, melting, wear, etc.

5) Measure the oil clearance on individual connect-
ing rod bearings by means of plastigauge. If the oil
clearance is not within the standard, replace the
defective bearing with a new one of standard size
or undersize as necessary. (See the table below.)

Connecting rod oil clearance:

Standard

0.016 — 0.043 mm (0.0006 — 0.0017 in)

6) Inspect the 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 — 0.022 mm (0 — 0.0009 in)

(A) Thickness gauge

(B) Connecting rod

( A )

( B )

ME-00179

ME-00180

Unit: mm (in)

Bearing

Bearing size

(Thickness at cen-

ter)

Outer diameter of

crank pin

Standard

1.490 — 1.506

(0.0587 — 0.0593)

51.984 — 52.000

(2.0466 — 2.0472)

0.03

(0.0012)

undersize

1.509 — 1.513

(0.0594 — 0.0596)

51.954 — 51.970

(2.0454 — 2.0461)

0.05

(0.0020)

undersize

1.519 — 1.523

(0.0598 — 0.0600)

51.934 — 51.950

(2.0446 — 2.0453)

0.25

(0.0098)

undersize

1.619 — 1.623

(0.0637 — 0.0639)

51.734 — 51.750

(2.0368 — 2.0374)

ME-00181

ME-00174

ME(H6DO)-77

MECHANICAL

Cylinder Block

7) Replacement procedure is as follows.

(1) Remove the bushing from connecting rod
with ST and press.
(2) Press the bushing with ST after applying oil
on the periphery of bushing.

18350AA000

CONNECTING ROD BUSH-
ING REMOVER AND IN-
STALLER

(3) Make two 3 mm (0.12 in) holes in bushing.
Ream the inside of bushing.
(4) After completion of reaming, clean the bush-
ing to remove chips.

6. CRANKSHAFT AND CRANKSHAFT
BEARING

1) Clean the crankshaft completely, and check it for
cracks using liquid penetrant tester. Replace if de-
fective.
2) Check the crankshaft for bend, and repair or re-
place if needed. Repair or replace if bended.

NOTE:
If a suitable V-block is not available, install #1 and
#5 crankshaft bearing on cylinder block, position
the crankshaft on these bearings, and then mea-
sure the crankshaft bend using a dial gauge.

3) Inspect the crank journal and crank pin for wear.
If they are not within the specifications, replace the
bearing with a suitable (undersize) one, and re-
place or recondition crankshaft as necessary.
When grinding the 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

0.005 mm (0.0002 in)

Cylindricality

0.006 mm (0.0002 in)

ME-00597

ME-00598

ME-00184

ME(H6DO)-78

MECHANICAL

Cylinder Block

4) Measure the thrust clearance of crankshaft at
center bearing. If thrust clearance exceeds the
standard, replace the bearing.

Crankshaft thrust clearance:

Standard

0.030 — 0.115 mm (0.0012 — 0.0045 in)

5) Inspect individual crankshaft bearings for signs
of flaking, seizure, melting, and wear.
6) Measure the oil clearance on each crankshaft
bearing using plastigauge. If the oil clearance is not
within the standard, replace the defective bearing
with an undersize one, and replace or recondition
the crankshaft as necessary.

Crankshaft oil clearance:

Standard

0.010 — 0.030 mm (0.0004 — 0.0012 in)

Unit: mm (in)

Crank journal diameter

Crank pin outer diameter

#1, #3, #5, #7

#2, #4, #6

Standard

Journal O.D.

63.992 — 64.008

(2.5194 — 2.5200)

51.984 — 52.000

(2.0466 — 2.0472)

Bearing size
(Thickness at cen-
ter)

1.992 — 2.005

(0.0784 — 0.0789)

1.996 — 2.009

(0.0786 — 0.0791)

1.490 — 1.506

(0.0587 — 0.0593)

0.03 (0.0012)
undersize

Journal O.D.

63.962 — 63.978

(2.5182 — 2.5188)

51.954 — 51.970

(2.0454 — 2.0461)

Bearing size
(Thickness at cen-
ter)

2.011 — 2.014

(0.0792 — 0.0793)

2.015 — 2.018

(0.0793 — 0.0794)

1.509 — 1.513

(0.0594 — 0.0596)

0.05 (0.0020)
undersize

Journal O.D.

63.942 — 63.958

(2.5174 — 2.5180)

51.934 — 51.950

(2.0446 — 2.0453)

Bearing size
(Thickness at cen-
ter)

2.021 — 2.024

(0.0796 — 0.0797)

2.025 — 2.028

(0.0797 — 0.0798)

1.519 — 1.523

(0.0598 — 0.0600)

0.25 (0.0098)
undersize

Journal O.D.

63.742 — 63.758

(2.5095 — 2.5102)

51.734 — 51.750

(2.0368 — 2.0374)

Bearing size
(Thickness at cen-
ter)

2.121 — 2.124

(0.0835 — 0.0836)

2.125 — 2.128

(0.0837 — 0.0838)

1.619 — 1.623

(0.0637 — 0.0639)

ME-00600

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