1999 SUBARU LEGACY wheel

5. Crankshaft and Piston
B2M1958A
(1) Flywheel (MT)
(2) Bell bearing (MT)
(3) Reinforcement (AT)
(4) Drive plate (AT)
(5) Top ring
(6) Second ring
(7) Oil ring
(8) Piston(9) Piston pin
(10) Circlip
(11) Connecting rod bolt
(12) Connecting rod
(13) Connecting rod bearing
(14) Connecting rod cap
(15) Crankshaft
(16) Woodruff key(17) Crankshaft bearing #1, #3
(18) Crankshaft bearing #2, #4
(19) Crankshaft bearing #5
Tightening torque: N´m (kg-m, ft-lb)
T1:
44±2 (4.5±0.2, 32.5±1.4)
T2:72±3 (7.3±0.3, 52.8±2.2)
10
2-3a[C500]COMPONENT PARTS
5. Crankshaft and Piston

1. General Precautions
A: GENERAL PRECAUTIONS
1) Before disassembling engine, place it on ST3.
ST1 498457000 ENGINE STAND ADAPTER
RH
ST2 498457100 ENGINE STAND ADAPTER
LH
ST3 499817000 ENGINE STAND
B2M2582A
2) All parts should be thoroughly cleaned, paying
special attention to the engine oil passages, pis-
tons and bearings.
3) Rotating parts and sliding parts such as piston,
bearing and gear should be coated with oil prior to
assembly.
4) Be careful not to let oil, grease or coolant con-
tact the timing belt, clutch disc and flywheel.
5) All removed parts, if to be reused, should be
reinstalled in the original positions and directions.
6) All removed parts, if to be reused, should be
reinstalled in the original positions and directions.
7) Bolts, nuts and washers should be replaced
with new ones as required.
8) Even if necessary inspections have been made
in advance, proceed with assembly work while
making rechecks.
12
2-3a[W1A0]SERVICE PROCEDURE
1. General Precautions

2. OIL PUMP AND WATER PUMP
B2M1767A
(1) Clutch housing cover (MT
vehicles only)
(2) Flywheel (MT vehicles only)
(3) Drive plate (AT vehicles only)(4) Oil separator cover
(5) Water by-pass pipe
(6) Water pump
(7) Oil pump(8) Oil pan
(9) Oil strainer
(10) Baffle plate
(11) Oil filter
52
2-3a[W6A2]SERVICE PROCEDURE
6. Cylinder Block

1) Remove clutch housing cover (MT vehicles
only).
2) Remove flywheel (MT vehicles only) or drive
plate (AT vehicles only).
Using ST, lock crankshaft.
ST 498497100 CRANKSHAFT STOPPER
G2M0776
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.
G2M0162
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 cylin-
der block.
(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.
G2M0163
8) Remove oil strainer stay.
9) Remove oil strainer.
10) Remove baffle plate.
11) Remove oil filter using ST.
ST 498187300 OIL FILTER WRENCH
B2M2611A
53
[W6A2]2-3aSERVICE PROCEDURE
6. Cylinder Block

E: INSTALLATION
1. OIL PUMP AND WATER PUMP
B2M1767B
(1) Baffle plate
(2) Oil strainer
(3) Oil pan
(4) Oil separater cover
(5) Drive plate (AT vehicles only)
(6) Flywheel (MT vehicles only)
(7) Clutch housing cover (MT
vehicles only)(8) Oil pump
(9) Water pump
(10) Water by-pass pipe
(11) Oil filterTightening torque: N´m (kg-m, ft-lb)
T1:
5 (0.5, 3.6)
T2:6.4 (0.65, 4.7)
T3:10 (1.0, 7)
T4:72±3 (7.3±0.3, 52.8±2.2)
T5:First 12±2 (1.2±0.2, 8.7±1.4)
Second 12
±2 (1.2±0.2,
8.7
±1.4)
70
2-3a[W6E1]SERVICE PROCEDURE
6. Cylinder Block

1) Install baffle plate.
2) Install oil strainer and O-ring
3) Install oil strainer stay.
4) Apply fluid packing to matching surfaces and
install oil pan.
Fluid packing:
THREE BOND 1215 or equivalent
G2M0084
5) Apply fluid packing to matching surfaces and
install oil separator cover.
Fluid packing:
THREE BOND 1215 or equivalent
G2M0194
6) Install flywheel or drive plate.
To lock crankshaft, use ST.
ST 498497100 CRANKSHAFT STOPPER
G2M0161
7) Install housing cover.
8) Installation of oil pump
(1) Discard front oil seal after removal. Replace
with a new one using ST.
ST 499587100 OIL SEAL INSTALLER
S2M0235
71
[W6E1]2-3aSERVICE PROCEDURE
6. Cylinder Block

2. Engine Noise
Type of sound Condition Possible cause
Regular clicking soundSound increases as engine
speed increases.IValve mechanism is defective.
IIncorrect valve clearance
IWorn valve rocker
IWorn camshaft
IBroken valve spring
Heavy and dull clankOil pressure is low.IWorn crankshaft main bearing
IWorn connecting rod bearing (big end)
Oil pressure is normal.ILoose flywheel mounting bolts
IDamaged engine mounting
High-pitched clank
(Spark knock)Sound is noticeable when
accelerating with an overload.IIgnition timing advanced
IAccumulation of carbon inside combustion chamber
IWrong spark plug
IImproper gasoline
Clank when engine speed is
medium (1,000 to 2,000 rpm)Sound is reduced when fuel
injector connector of noisy cyl-
inder is disconnected.
(NOTE*)IWorn crankshaft main bearing
IWorn bearing at crankshaft end of connecting rod
Knocking sound when engine
is operating under idling speed
and engine is warmSound is reduced when fuel
injector connector of noisy cyl-
inder is disconnected.
(NOTE*)IWorn cylinder liner and piston ring
IBroken or stuck piston ring
IWorn piston pin and hole at piston end of connecting rod
Sound is not reduced if each
fuel injector connector is dis-
connected in turn. (NOTE*)IUnusually worn valve lifter
IWorn cam gear
IWorn camshaft journal bore in crankcase
Squeaky sound ÐIInsufficient generator lubrication
Rubbing sound ÐIDefective generator brush and rotor contact
Gear scream when starting
engineÐIDefective ignition starter switch
IWorn gear and starter pinion
Sound like polishing glass with
a dry clothÐILoose drive belt
IDefective engine coolant pump shaft
Hissing sound ÐILoss of compression
IAir leakage in air intake system, hoses, connections or
manifolds
Timing belt noise ÐILoose timing belt
IBelt contacting case/adjacent part
Valve tappet noise ÐIIncorrect valve clearance
NOTE*:
When disconnecting fuel injector connector, Malfunction Indicator Light (CHECK ENGINE light) illuminates and trouble code is
stored in ECM memory.
Therefore, carry out the CLEAR MEMORY MODE and INSPECTION MODE after con-
necting fuel injector connector.
78
2-3a[K200]DIAGNOSTICS
2. Engine Noise

5. Crankshaft and Piston
B2M1958A
(1) Flywheel (MT vehicles only)
(2) Bell bearing (MT vehicles only)
(3) Reinforcement (AT vehicles only)
(4) Drive plate (AT vehicles only)
(5) Top ring
(6) Second ring
(7) Oil ring
(8) Piston(9) Piston pin
(10) Circlip
(11) Connecting rod bolt
(12) Connecting rod
(13) Connecting rod bearing
(14) Connecting rod cap
(15) Crankshaft
(16) Woodruff key(17) Crankshaft bearing #1, #3
(18) Crankshaft bearing #2, #4
(19) Crankshaft bearing #5
Tightening torque: N´m (kg-m, ft-lb)
T1:
44±2 (4.5±0.2, 32.5±1.4)
T2:72±3 (7.3±0.3, 52.8±2.2)
12
2-3b[C500]COMPONENT PARTS
5. Crankshaft and Piston