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Subaru Legacy III (2000-2003 year). Manual - part 269

ME(H6DO)-64

MECHANICAL

CYLINDER BLOCK

ST2

18254AA000 PISTON GUIDE

10) Installing piston pin.

(1) Apply a coat of engine oil to ST3.

ST3

18253AA000 PISTON PIN GUIDE

(2) Insert ST3 into service hole to align piston
pin hole with connecting rod small end.

(3) Apply a coat of engine oil to piston pin and
insert piston pin into piston and connecting rod
small end through service hole.
(4) Using ST4, install circlip.

ST4

18233AA000 PISTON PIN CIRCLIP PLIER

NOTE:
Use a new circlip.

11) Repeat the same steps for pistons #1 and #2,
#5 and #6.
12) Install service hole plug and cover.
13) Apply fluid gasket to mating surface of upper oil
pan.
14) Install O-ring.

Fluid gasket:

THREE BOND 1280B
Part No.: K0877YA018

15) Temporarily tighten the upper oil pan.

NOTE:
Do not confuse the mounting positions of the bolts.

Bolt dimension:

16) Tighten the upper oil pan mounting bolts in the
numerical sequence shown in the figure.

Tightening torque:

18 N·m (1.8 kgf-m, 13.0 ft-lb)

ME-00576

ST2

ME-00577

ST3

ME-00564

ST4

(A) O-ring

(A) 8

(B) 8

(D) 8

130

(E) 8

ME-00578

( A )

ME-00579

( A )

( B )

( B ) ( B )

( B )

( C )

( D )

( E ) ( E )

ME-00580

( 1 )

( 2 )

( 3 )

( 4 )

( 5 )

( 6 )

( 7 )

( 8 )

( 9 )

(10)

(11)

(12)

(13)

(14)

(15)

(16)

(17)

(18)

(19)

(20)

(21)

(22)

(23)

(25)

(24)

(27)

(28)

(26)

ME(H6DO)-65

MECHANICAL

CYLINDER BLOCK

17) Install oil strainer.

NOTE:
Use a new O-ring.

18) Apply fluid gasket to mating surface of lower oil
pan.

Fluid gasket:

THREE BOND 1280B
Part No.: K0877YA018

Fluid gasket application diameter:

5.0

±±±±

1.0 mm (0.097

±±±±

0.039 in)

19) Tighten the lower oil pan mounting bolts in the
numerical sequence shown in the figure.

Tightening torque:

6.4 N·m (0.65 kgf-m, 4.7 ft-lb)

20) Install crankshaft position sensor bracket.

Tightening torque:

6.4 N·m (0.65 kgf-m, 4.7 ft-lb)

21) Install crankshaft position sensor plate.

22) Install drive plate.
Using ST, lock crankshaft.
ST

498497100

CRANKSHAFT STOPPER

Tightening torque:

81 N·m (8.3 kgf-m, 60 ft-lb)

23) Install cylinder head assembly. <Ref. to
ME(H6DO)-54, INSTALLATION, Cylinder Head
Assembly.>
24) Install camshafts. <Ref. to ME(H6DO)-50, IN-
STALLATION, Camshaft.>
25) Install rear chain cover. <Ref. to ME(H6DO)-
48, INSTALLATION, Rear Chain Cover.>
26) Install crankshaft sprocket. <Ref. to
ME(H6DO)-47, INSTALLATION, Crankshaft
Sprocket.>
27) Install camshaft sprockets. <Ref. to
ME(H6DO)-46, INSTALLATION, Camshaft
Sprocket.>

ME-00561

ME-00581

ME-00582

( 1 )

( 2 )

( 3 )

( 4 )

( 5 )

( 6 )

( 7 )

( 8 )

( 9 )

(10)

(11)

(12)

(13)

(14)

(15)

ME-00559

ME-00558

ME-00557

ME(H6DO)-66

MECHANICAL

CYLINDER BLOCK

28) Install timing chain assembly. <Ref. to
ME(H6DO)-42, INSTALLATION, Timing Chain As-
sembly.>

29) Install front chain cover. <Ref. to ME(H6DO)-
39, INSTALLATION, Front Chain Cover.>
30) Install crankshaft pulley. <Ref. to ME(H6DO)-
38, INSTALLATION, Crankshaft Pulley.>

C: DISASSEMBLY

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

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

NOTE:
Arrange the removed piston rings in good order to
prevent confusion.
5) Remove circlip.

(1) Connecting rod cap

(3) Top ring

(5) Oil ring

(2) Connecting rod bearing

(4) Second ring

(6) Circlip

ME-00583

( 1 )

( 2 )

( 3 )

( 4 )

( 5 )

( 6 )

ME(H6DO)-67

MECHANICAL

CYLINDER BLOCK

D: ASSEMBLY

1) Install connecting rod bearings on connecting
rods and connecting rod caps.

CAUTION:
Apply oil to the surfaces of the connecting rod
bearings.
2) Install connecting rod on crankshaft.

CAUTION:
Position each connecting rod with the side
marked facing forward.
3) Install connecting rod cap with connecting rod
nut.
Ensure the arrow on connecting rod cap faces the
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) Installation of piston rings and oil ring

E: INSPECTION

1. CYLINDER BLOCK

1) Visually check for cracks and damage. Especial-
ly, inspect important parts by means of red lead
check.
2) Check the oil passages for clogging.
3) Inspect crankcase surface that mates with cylin-
der head for warping by using a straight edge, and
correct by grinding if necessary.

Warping limit:

0.05 mm (0.0020 in)

Grinding limit:

0.1 mm (0.004 in)

Standard height of cylinder block:

202 mm (7.95 in)

(1) Connecting rod cap

(5) Oil ring

Tightening torque: N·m (kgf-m, ft-lb)

(2) Connecting rod bearing

(6) Circlip

T: 53 (5.4, 39)

(3) Top ring

(7) Connecting rod

(4) Second ring

ME-00584

( 1 )

( 2 )

( 7 )

( 3 )

( 4 )

( 5 )

( 7 )

( 3 )

( 4 )

( 5 )

( 6 )

Content .. 267 268 269 270 ..