Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Subaru Legacy 1995-1999 Approved Subaru Legacy 1999 1999 Service Manual ENGINE SECTION ENGINE (DOHC) MSA5TCD99L55

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2-3b [W5A1] SERVICE PROCEDURE
5. Cylinder Block

5. Cylinder Block
A: REMOVAL
1. RELATED PARTS
1) Remove timing belt, camshaft sprockets and related parts.

S2M0303

48
SERVICE PROCEDURE [W5A1] 2-3b
5. Cylinder Block

2) Remove rocker cover, camshafts and related parts.

S2M0298
3) Remove cylinder heads.

S2M0421

49
2-3b [W5A1] SERVICE PROCEDURE
5. Cylinder Block

4) Remove water pipe.

S2M0299A

(1) Water pipe (2) O-ring

50
SERVICE PROCEDURE [W5A2] 2-3b
5. Cylinder Block

2. OIL PUMP AND WATER PUMP

B2M1767A

(1) Clutch housing cover (MT (4) Oil separator cover (8) Oil pan
vehicles only) (5) Water by-pass pipe (9) Oil strainer
(2) Flywheel (MT vehicles only) (6) Water pump (10) Baffle plate
(3) Drive plate (AT vehicles only) (7) Oil pump (11) Oil filter

51
2-3b [W5A2] SERVICE PROCEDURE
5. Cylinder Block

1) Remove clutch housing cover (MT vehicles 7) Removal of oil pan
only). (1) Turn cylinder block with #2 and #4 piston
2) Remove flywheel (MT vehicles only) or drive sides facing upward.
plate (AT vehicles only). (2) Remove bolts which secure oil pan to cylin-
Using ST, lock crankshaft. der block.
ST 498497100 CRANKSHAFT STOPPER (3) Insert a oil pan cutter blade between cylin-
der block-to-oil pan clearance and remove oil
pan.
CAUTION:
Do not use a screwdriver or similar tool in
place of oil pan cutter.

G2M0776

G2M0163

8) Remove oil strainer stay.
9) Remove oil strainer.
10) Remove baffle plate.
11) Remove oil filter.
B2M0706A

3) Remove oil separator cover.
4) Remove water by-pass pipe for heater.
5) Remove water 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
cylinder block and oil pump.

S2M0722A

52
SERVICE PROCEDURE [W5B1] 2-3b
5. Cylinder Block

B: DISASSEMBLY
1. PISTON PIN AND CYLINDER BLOCK CONNECTING BOLT

B2M1180A

(1) Service hole plug (3) Circlip (5) Service hole cover
(2) Gasket (4) Piston pin

1) Remove service hole cover and service hole 3) Draw out piston pin from #1 and #2 pistons by
plugs using hexagon wrench (14 mm). using ST.
2) Rotate crankshaft to bring #1 and #2 pistons to ST 499097700 PISTON PIN REMOVER
bottom dead center position, then remove piston CAUTION:
circlip through service hole of #1 and #2 cylinders. Be careful not to confuse original combination
of piston, piston pin and cylinder.

G2M0165

G2M0166

4) Similarly remove piston pins from #3 and #4
pistons.
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
2-3b [W5B2] SERVICE PROCEDURE
5. Cylinder Block

2. CYLINDER BLOCK

B2M2408A

(1) Cylinder block (3) Crankshaft (5) Piston
(2) Rear oil seal (4) Crankshaft bearing

1) Set up cylinder block so that #1 and #3 cylin- 5) Remove crankshaft bearings from cylinder
ders are on the upper side, then remove cylinder block using hammer handle.
block connecting bolts.
CAUTION:
2) Separate left-hand and right-hand cylinder
blocks. Do not confuse combination of crankshaft
bearings. Press bearing at the end opposite to
CAUTION: locking lip.
When separating cylinder block, do not allow
the connecting rod to fall and damage the cyl- 6) Draw out each piston from cylinder block using
inder block. wooden bar or hammer handle.
3) Remove rear oil seal. CAUTION:
4) Remove crankshaft together with connecting Do not confuse combination of piston and cyl-
rod. inder.

54
SERVICE PROCEDURE [W5C1] 2-3b
5. Cylinder Block

3. CRANKSHAFT AND PISTON

B2M1320I

(1) Connecting rod cap (3) Top ring (5) Oil ring
(2) Connecting rod bearing (4) Second ring (6) Circlip

1) Remove connecting rod cap.
2) Remove connecting rod bearing.
CAUTION:
Arrange removed connecting rod, connecting
rod cap and bearing in order to prevent confu-
sion.
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.

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 cyl-
inder 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)

55
2-3b [W5C2] SERVICE PROCEDURE
5. Cylinder Block

2. CYLINDER AND PISTON 2) How to measure the inner diameter of each
cylinder
1) The cylinder bore size is stamped on the cylin-
Measure the inner diameter of each cylinder in
der block's front upper surface.
both the thrust and piston pin directions at the
NOTE: heights shown in figure, using a cylinder bore
Standard sized pistons are classified into two gauge.
grades, "A" and "B". These grades should be used
CAUTION:
as a guide line in selecting a standard piston.
Measurement should be performed at a tem-
Standard diameter: perature 20

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