Subaru Legacy III (2000-2003 year). Manual - part 271

 

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Subaru Legacy III (2000-2003 year). Manual - part 271

 

 

ME(H6DO)-72

MECHANICAL

CYLINDER BLOCK

6) Inspect 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)

Limit

0.030 mm (0.0012 in)

7) Replacement procedure is as follows.

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

ST

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 bushing
to remove chips.

6. CRANKSHAFT AND CRANKSHAFT 
BEARING

1) Clean crankshaft completely and check for
cracks by means of red lead check etc., and re-
place if defective.
2) Measure the crankshaft bend, and correct or re-
place if it exceeds the limit.

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

Crankshaft bend limit:

0.035 mm (0.0014 in)

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

0.020 mm (0.0008 in) or less

Grinding limit

0.250 mm (0.0098 in)

ME-00596

ME-00589

ME-00597

ST

ME-00598

ME-00599

ME(H6DO)-73

MECHANICAL

CYLINDER BLOCK

O.D. ... Outer Diameter

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

Crankshaft thrust clearance:

Standard

0.030 — 0.115 mm (0.0012 — 0.0045 in)

Limit

0.25 mm (0.0098 in)

5) Inspect individual crankshaft bearings for signs
of flaking, seizure, melting, and wear.

6) Measure the oil clearance on each crankshaft
bearing by means of plastigauge. If the measure-
ment is not within the specification, replace defec-
tive bearing with an undersize one, and replace or
recondition crankshaft as necessary.

Unit: mm (in)

Crank journal diameter

Crank pin 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 — 2.000

(0.0786 — 0.0787)

1.490 — 1.502

(0.0587 — 0.0591)

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)

2.017 — 2.020

(0.0794 — 0.0795)

2.019 — 2.020

(0.0795 — 0.0795)

1.510 — 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)

2.027 — 2.030

(0.0798 — 0.0799)

2.029 — 2.032

(0.0799 — 0.0800)

1.520 — 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)

2.127 — 2.130

(0.0837 — 0.0839)

2.129 — 2.132

(0.0838 — 0.0839)

1.620 — 1.623

(0.0638 — 0.0639)

ME-00600

Unit: mm (in)

Crankshaft oil clearance

Standard

0.010 — 0.030 (0.0004 — 

0.0012)

Limit

0.050 (0.0020)

ME(H6DO)-74

MECHANICAL

ENGINE TROUBLE IN GENERAL

19.Engine Trouble in General

A: INSPECTION

NOTE:
“RANK” shown in the chart refer to the possibility of reason for the trouble in order (“Very often” to “Rarely”)
A — Very often
B — Sometimes
C — Rarely

TROUBLE

PROBLEM PARTS, ETC.

POSSIBLE CAUSE

RANK

1. Engine will not start.

 1) Starter does not turn.

• Starter

• Defective battery-to-starter harness

B

• Defective starter switch

C

• Defective inhibitor switch or neutral switch

C

• Defective starter

B

• Battery

• Poor terminal connection

A

• Run-down battery

A

• Defective charging system

B

• Friction

• Seizure of crankshaft and connecting rod bearing

C

• Seized camshaft

C

• Seized or stuck piston and cylinder

C

  2) Initial combustion does 
not occur. 

• Starter

• Defective starter

C

• Engine control system <Ref. to EN(H6DO)-2, Basic Diagnostic Procedure.>

A

• Fuel line

• Defective fuel pump and relay

A

• Lack of or insufficient fuel

B

• Chain

• Defective

B

• Defective timing

B

• Compression

• Incorrect valve clearance

C

• Loosened spark plugs or defective gasket

C

• Loosened cylinder head bolts or defective gasket

C

• Improper valve seating

C

• Defective valve stem

C

• Worn or broken valve spring

B

• Worn or stuck piston rings, cylinder and piston

C

• Incorrect valve timing

B

• Improper engine oil (low viscosity)

B

 3) Initial combustion occur.

• Engine control system <Ref. to EN(H6DO)-2, Basic Diagnostic Procedure.>

A

• Intake system

• Defective intake manifold gasket

B

• Defective throttle body gasket

B

• Fuel line

• Defective fuel pump and relay

C

• Clogged fuel line

C

• Lack of or insufficient fuel

B

• Chain

• Defective

B

• Defective timing

B

• Compression

• Incorrect valve clearance

C

• Loosened spark plugs or defective gasket

C

• Loosened cylinder head bolts or defective gasket

C

• Improper valve seating

C

• Defective valve stem

C

• Worn or broken valve spring

B

• Worn or stuck piston rings, cylinder and piston

C

• Incorrect valve timing

B

• Improper engine oil (low viscosity)

B

ME(H6DO)-75

MECHANICAL

ENGINE TROUBLE IN GENERAL

  4) Engine stalls after initial 
combustion. 

• Engine control system <Ref. to EN(H6DO)-2, Basic Diagnostic Procedure.>

A

• Intake system

• Loosened or cracked intake duct

B

• Loosened or cracked PCV hose

C

• Loosened or cracked vacuum hose

C

• Defective intake manifold gasket

B

• Defective throttle body gasket

B

• Dirty air cleaner element

C

• Fuel line

• Clogged fuel line

C

• Lack of or insufficient fuel

B

• Chain

• Defective

B

• Defective timing

B

• Compression

• Incorrect valve clearance

C

• Loosened spark plugs or defective gasket

C

• Loosened cylinder head bolts or defective gasket

C

• Improper valve seating

C

• Defective valve stem

C

• Worn or broken valve spring

B

• Worn or stuck piston rings, cylinder and piston

C

• Incorrect valve timing

B

• Improper engine oil (low viscosity)

B

2. Rough idle and engine 
stall

• Engine control system <Ref. to EN(H6DO)-2, Basic Diagnostic Procedure.>

A

• Intake system

• Loosened or cracked intake duct

A

• Loosened or cracked PCV hose

A

• Loosened or cracked vacuum hose

A

• Defective intake manifold gasket

B

• Defective throttle body gasket

B

• Defective PCV valve

C

• Loosened oil filter cap

B

• Dirty air cleaner element

C

• Fuel line

• Defective fuel pump and relay

C

• Clogged fuel line

C

• Lack of or insufficient fuel

B

• Chain

• Defective timing

C

• Compression

• Incorrect valve clearance

B

• Loosened spark plugs or defective gasket

B

• Loosened cylinder head bolts or defective gasket

B

• Improper valve seating

B

• Defective valve stem

C

• Worn or broken valve spring

B

• Worn or stuck piston rings, cylinder and piston

B

• Incorrect valve timing

A

• Improper engine oil (low viscosity)

B

• Lubrication system

• Incorrect oil pressure

B

• Defective rocker cover gasket

C

• Cooling system

• Overheating

C

• Others

• Malfunction of evaporative emission control system

A

• Stuck or damaged throttle valve

B

• Accelerator cable out of adjustment

C

TROUBLE

PROBLEM PARTS, ETC.

POSSIBLE CAUSE

RANK

 

 

 

 

 

 

 

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