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 (SOHC) MSA5TCD99L41
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SERVICE PROCEDURE [W6A1] 2-3a
6. Cylinder Block
6. Cylinder Block
A: REMOVAL
1. RELATED PARTS
1) Remove timing belt, camshaft sprockets and
related parts.
2) Remove cylinder heads.
3) Remove water pipe.
B2M2638
51
2-3a [W6A2] SERVICE PROCEDURE
6. 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
52
SERVICE PROCEDURE [W6A2] 2-3a
6. 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 using ST.
B2M0706A ST 498187300 OIL FILTER WRENCH
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.
B2M2611A
G2M0162
53
2-3a [W6B1] SERVICE PROCEDURE
6. 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 2) Rotate crankshaft to bring #1 and #2 pistons to
plugs using hexagon wrench [14 mm (0.55 in)]. bottom dead center position, then remove piston
circlip through service hole of #1 and #2 cylinders.
B2M2620
G2M0165
54
SERVICE PROCEDURE [W6B2] 2-3a
6. Cylinder Block
3) Draw out piston pin from #1 and #2 pistons 4) Similarly remove piston pins from #3 and #4
using ST. pistons.
ST 499097700 PISTON PIN REMOVER 5) Remove bolts which connect cylinder block on
CAUTION: the side of #2 and #4 cylinders.
Be careful not to confuse original combination 6) Back off bolts which connect cylinder block on
of piston, piston pin and cylinder. the side of #1 and #3 cylinders two or three turns.
G2M0166
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- CAUTION:
ders are on the upper side, then remove cylinder When separating cylinder block, do not allow
block connecting bolts. the connecting rod to fall and damage the cyl-
2) Separate left-hand and right-hand cylinder inder block.
blocks. 3) Remove rear oil seal.
55
2-3a [W6B3] SERVICE PROCEDURE
6. Cylinder Block
4) Remove crankshaft together with connecting 6) Draw out each piston from cylinder block using
rod. wooden bar or hammer handle.
5) Remove crankshaft bearings from cylinder
CAUTION:
block using hammer handle.
Do not confuse combination of piston and cyl-
CAUTION: inder.
Do not confuse combination of crankshaft
bearings. Press bearing at the end opposite to
locking lip.
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. 3) Inspect crankcase surface that mates with cyl-
2) Remove connecting rod bearing. inder head for warping by using a straight edge,
CAUTION: and correct by grinding if necessary.
Arrange removed connecting rod, connecting Warping limit:
rod cap and bearing in order to prevent confu- 0.05 mm (0.0020 in)
sion. Grinding limit:
3) Remove piston rings using the piston ring 0.1 mm (0.004 in)
expander. Standard height of cylinder block:
4) Remove the oil ring by hand. 201.0 mm (7.91 in)
CAUTION:
Arrange the removed piston rings in good
order to prevent confusion.
5) Remove circlip.
C: INSPECTION
1. CYLINDER BLOCK
1) Visually check for cracks and damage.
Especially, inspect important parts by means of red
lead check.
2) Check the oil passages for clogging.
56
SERVICE PROCEDURE [W6C2] 2-3a
6. 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
CAUTION: heights shown in the figure, using a cylinder bore
Measurement should be performed at a tem- gauge.
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