Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Subaru Legacy 1995-1999 Approved Subaru Legacy 1996 1996 Service Manual ENGINE SECTION ENGINE MSA5TCD96L5970
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2-3 SERVICE PROCEDURE
7. Cylinder Block
7. Cylinder Block
A: REMOVAL
1. RELATED PARTS
1) Remove timing belt, camshaft sprocket and related
parts.
2) Remove intake manifold and cylinder head.
2. OIL PUMP AND ENGINE COOLANT PUMP
B2M0124A
50
SERVICE PROCEDURE 2-3
7. Cylinder Block
1) Remove housing cover.
2) Remove flywheel or drive plate.
To lock crankshaft use ST.
ST 498497100 CRANKSHAFT STOPPER
G2M0161
3) Remove oil separator cover.
4) Remove engine coolant pipe.
5) Remove engine coolant pump.
6) Remove oil pump from cylinder block.
Use a flat-bladed screwdriver as shown in Figure when
removing oil pump.
CAUTION:
Be careful not to scratch the mating surface of cylin-
der block and oil pump.
G2M0162
51
2-3 SERVICE PROCEDURE
7. Cylinder Block
7) Removal of oil pan
(1) Turn cylinder block with #2 and #4 piston sides
facing upward.
(2) Remove bolts which secure oil pan to cylinder
block.
(3) Insert a oil pan cutter blade between cylinder block-
to-oil pan clearance and remove oil pan.
CAUTION:
Do not use a screwdriver or similar tool in place of oil-
G2M0163
pan cutter.
8) Remove oil strainer stay.
9) Remove oil strainer.
10) Remove baffle plate.
11) Remove oil filter.
B: DISASSEMBLY
1. PISTON PIN AND CYLINDER BLOCK
CONNECTING BOLT
G2M0164
52
SERVICE PROCEDURE 2-3
7. Cylinder Block
1) Remove service hole cover and service hole plugs
using hexagon wrench (14 mm).
2) Rotate crankshaft to bring #1 and #2 pistons to bottom
dead center position, then remove piston circlip through
service hole of #1 and #2 cylinders.
G2M0165
3) Draw out piston pin from #1 and #2 pistons by using ST.
ST 499097500 PISTON PIN REMOVER
CAUTION:
Be careful not to confuse original combination of
piston, piston pin and cylinder.
4) Similarly remove piston pins from #3 and #4 pistons by
using ST.
G2M0166
5) Remove bolts which connect cylinder block on the side
of #2 and #4 cylinders.
6) Back off bolts which connect cylinder block on the side
of #1 and #3 cylinders two or three turns.
53
2-3 SERVICE PROCEDURE
7. Cylinder Block
2. CYLINDER BLOCK
1) Set up cylinder block so that #1 and #3 cylinders are on
the upper side, then remove cylinder block connecting
bolts.
2) Separate left-hand and right-hand cylinder blocks.
CAUTION:
When separating cylinder block, do not allow the con-
necting rod to fall and damage the cylinder block.
3) Remove rear oil seal.
4) Remove crankshaft together with connecting rod.
5) Remove crankshaft bearings from cylinder block using
hammer handle.
CAUTION:
Do not confuse combination of crankshaft bearings.
Press bearing at the end opposite to locking lip.
6) Draw out each piston from cylinder block using wooden
bar or hammer handle.
CAUTION:
Do not confuse combination of piston and cylinder.
G2M0167
54
SERVICE PROCEDURE 2-3
7. Cylinder Block
3. CRANKSHAFT AND PISTON
G2M0168
1) Remove connecting rod cap.
2) Remove connecting rod bearing.
CAUTION:
Arrange removed connecting rod, connecting rod cap
and bearing in order to prevent confusion.
3) Remove piston rings using the piston ring expander.
4) Remove the oil ring by hand.
CAUTION:
Arrange the removed piston rings in good order to
prevent confusion.
5) Remove circlip.
55
2-3 SERVICE PROCEDURE
7. Cylinder Block
C: INSPECTION
1. CYLINDER BLOCK
1) Check for cracks and damage visually. Especially,
inspect important parts by means of red lead check.
2) Check the oil passages for clogging.
3) Inspect crankcase surface that mates with cylinder
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:
201.0 mm (7.91 in)
2. CYLINDER AND PISTON
1) The cylinder bore size is stamped on the cylinder
block's front upper surface.
NOTE:
Standard sized pistons are classified into two grades, "A"
and "B". These grades should be used as a guide line in
selecting a standard piston.
Standard diameter:
A: 96.905 -- 96.915 mm (3.8151 -- 3.8155 in)
B: 96.895 -- 96.905 mm (3.8148 -- 3.8151 in)
B2M0082A
56
SERVICE PROCEDURE 2-3
7. Cylinder Block
2) How to measure the inner diameter of each cylinder
Measure the inner diameter of each cylinder in both the
thrust and piston pin directions at the heights shown in the
Figure, using a cylinder bore gauge.
CAUTION:
Measurement should be performed at a temperature
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