Subaru Legacy III (2000-2003 year). Manual - part 66

ME(H4SO)-76

MECHANICAL

CYLINDER BLOCK

15) Installing piston

(1) Turn the cylinder block to face the #1 and #2
piston side upward.
(2) Using the ST1, turn the crankshaft so that
#1 and #2 connecting rods are set at bottom
dead center.

ST1

499987500

CRANKSHAFT SOCKET

(3) Apply a coat of engine oil to pistons and cyl-
inders, and then insert the pistons in their cylin-
ders using ST2.

ST2

398744300

PISTON GUIDE (2000 cc 
model)

ST2

498747300

PISTON GUIDE (2500 cc 
model)

16) Installing piston pin

(1) Apply a coat of engine oil to the ST3 before
insertion.
(2) Insert the ST3 into service hole to align pis-
ton pin hole with connecting rod small end.

ST3

499017100

PISTON PIN GUIDE

(3) Apply a coat of engine oil to the piston pin,
and then insert the piston pin into piston and
connecting rod through service hole.
(4) Install the circlip.

NOTE:
Use new circlips.
ST3

499897200

PISTON SNAPRING PLIER

(1) Piston

(4) Gasket

Tightening torque: N·m (kgf-m, ft-lb)

(2) Piston pin

(5) Service hole plug

T: 70 (7.0, 50.6)

(3) Circlip

( 1 )

( 2 )

( 3 )

( 4 )

( 5 )

( 2 )

( 3 )

( 4 )

( 5 )

T

( 1 )

ME-00155

ME-00157

ST1

ST2

ME-00158

ST1

ST3

ME-00159

ME(H4SO)-77

MECHANICAL

CYLINDER BLOCK

(5) Apply fluid packing around the service hole
plug.

Fluid packing:

Part No. 004403007

THREE BOND 1215 or equivalent

(6) Install the service hole plug and gasket.

NOTE:
Use a new gasket.

(7) Turn the cylinder block to face the #3 and #4
piston side upward. Using the same procedures
as used for #1 and #2 cylinders, install the pis-
tons and piston pins.

ME-00160

ME-00140

(1) Piston

(5) Service hole plug

Tightening torque: N·m (kgf-m, ft-lb)

(2) Piston pin

(6) Service hole cover

T1: 6.4 (0.65, 4.7)

(3) Circlip

(7) O-ring

T2: 70 (7.1, 51.4)

(4) Gasket

( 1 )

( 1 )

ME-00161

( 3 )

( 2 )

( 5 )

( 4 )

( 6 )

( 7 )

( 2 )

( 3 )

T2

T1

ME(H4SO)-78

MECHANICAL

CYLINDER BLOCK

17) Install the water pipe.

18) Install the baffle plate.

Tightening torque:

6.4 N·m (0.65 kgf-m, 4.7 ft-lb)

19) Install the oil strainer and O-ring.

Tightening torque:

10 N·m (1.0 kgf-m, 7 ft-lb)

20) Install the oil strainer stay.
21) Apply fluid packing to the matching surfaces,
and then install the oil pan.

Fluid packing:

Part No. 004403007

THREE BOND 1215 or equivalent

22) Apply fluid packing to the matching surfaces,
and then install the oil separator cover.

Fluid packing:

Part No. 004403007

THREE BOND 1215 or equivalent

23) Install the flywheel or drive plate.
To lock the crankshaft, use ST.
ST

498497100

CRANKSHAFT STOPPER

Tightening torque:

72 N·m (7.3 kgf-m, 52.8 ft-lb)

• MT VEHICLES

• AT VEHICLES

NOTE:
Using STs, remove the flywheel. (2500 cc MT mod-
el)
ST1

498497100

CRANKSHAFT STOPPER

ST2

499057000

TORX PLUS

24) Install the housing cover.

ME-00300

ME-00162

ME-00163

(A) Flywheel

ME-00297

ST

ME-00298

ST

ME-00382

ST1

ST2

( A )

ME(H4SO)-79

MECHANICAL

CYLINDER BLOCK

25) Installation of oil pump

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

ST

499587100

OIL SEAL INSTALLER

(2) Apply fluid packing to the matching surface
of oil pump.

Fluid packing:

Part No. 004403007

THREE BOND 1215 or equivalent

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

(4) Install the oil pump on 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)

NOTE:
• Do not forget to install the O-ring and seal when
installing oil pump.
• Align flat surface of oil pump's inner rotor with
crankshaft before installation.
26) 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)

NOTE:
• 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.

27) Install the water by-pass pipe for heater.
28) Install the oil filter using ST.
ST

498547000

OIL FILTER WRENCH

29) Tighten the cylinder head bolts.

(1) Apply a coat of engine oil to the 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 alphabetical sequence.
(3) Back off all bolts by 180

°

 first; back them off

by 180

°

 again.

(4) Tighten the bolts (a) and (b) to 34 N·m (3.5
kgf-m, 25 ft-lb).
(5) Tighten the bolts (c), (d), (e) and (f) to 15
N·m (1.5 kgf-m, 11 ft-lb).
(6) Tighten all bolts by 80 to 90

°

 in alphabetical

sequence.

NOTE:
Do not tighten bolts more than 90

°

.

(7) Further tighten all bolts by 80 to 90

°

 in al-

phabetical sequence.

(A) O-ring

ME-00164

( A )

ME-00165

ME-00312

ME-00333

( A )

( B )

( C )

( D )

( E )

( F )