Subaru Legacy III (2000-2003 year). Service manual — part 48
ME(H4SO)-4
MECHANICAL
GENERAL DESCRIPTION
Valve
spring
Free length
54.30 mm (2.1378 in)
Squareness
2.5
°
, 2.4 mm (0.094 in)
Tension/spring height
Set
214 — 246 N (22 — 25 kgf, 48 — 55 lb)/
45.0 mm (1.772 in)
Lift
526 — 582 N (54 — 59 kgf, 119 — 130 lb)/
34.7 mm (1.366 in)
Cylinder
block
Surface warpage limit (mating with cylinder head)
0.05 mm (0.0020 in)
Surface grinding limit
0.1 mm (0.004 in)
Cylinder bore
2000 cc
STD
A
92.005 — 92.015 mm (3.6222 — 3.6226 in)
B
91.995 — 92.005 mm (3.6218 — 3.6222 in)
2500 cc
STD
A
99.505 — 99.515 mm (3.9175 — 3.9179 in)
B
99.495 — 99.505 mm (3.9171 — 3.9175 in)
Taper
STD
0.015 mm (0.0006 in)
Limit
0.050 mm (0.0020 in)
Out-of-roundness
STD
0.010 mm (0.0004 in)
Limit
0.050 mm (0.0020 in)
Piston clearance
STD
0.010 — 0.030 mm (0.0004 — 0.0012 in)
Limit
0.050 mm (0.0020 in)
Enlarging (boring) limit
0.5 mm (0.020 in)
Piston
Outer diameter
2000 cc
STD
A
91.985 — 91.995 mm (3.6214 — 3.6218 in)
B
91.975 — 91.985 mm (3.6211 — 3.6214 in)
0.25 mm (0.0098 in) OS
92.225 — 92.235 mm (3.6309 — 3.6313 in)
0.50 mm (0.0197 in) OS
92.475 — 92.485 mm (3.6407 — 3.6411 in)
2500 cc
STD
A
99.485 — 99.495 mm (3.9167 — 3.9171 in)
B
99.475 — 99.485 mm (3.9163 — 3.9167 in)
0.25 mm (0.0098 in) OS
99.725 — 99.735 mm (3.9262 — 3.9266 in)
0.50 mm (0.0197 in) OS
99.975 — 99.985 mm (3.9360 — 3.9364 in)
Standard inner diameter of piston pin hole
23.000 — 23.006 mm (0.9055 — 0.9057 in)
Piston pin
Outer diameter
22.994 — 23.000 mm (0.9053 — 0.9055 in)
Standard clearance between piston pin and piston
0.004 — 0.008 mm (0.0002 — 0.0003 in)
Degree of fit
Piston pin must be fitted into position with thumb at
20
°
C (68
°
F).
Piston ring
Piston ring gap
Top ring
STD
0.20 — 0.35 mm (0.0079 — 0.0138 in)
Limit
1.0 mm (0.039 in)
Second
ring
2000 cc
STD
0.35 — 0.50 mm (0.0138 — 0.0197 in)
Limit
1.0 mm (0.039 in)
2500 cc
STD
0.37 — 0.52 mm (0.0146 — 0.0204 in)
Limit
1.0 mm (0.039 in)
Oil ring
STD
0.20 — 0.50 mm (0.0079 — 0.0197 in)
Limit
1.5 mm (0.059 in)
Clearance
between piston
ring and piston
ring groove
Top ring
STD
0.040 — 0.080 mm (0.0016 — 0.0031 in)
Limit
0.15 mm (0.0059 in)
Second
ring
STD
0.030 — 0.070 mm (0.0012 — 0.0028 in)
Limit
0.15 mm (0.0059 in)
Connecting
rod
Bend twist per 100 mm (3.94
in) in length
Limit
0.10 mm (0.0039 in)
Side clearance
STD
0.070 — 0.330 mm (0.0028 — 0.0130 in)
Limit
0.4 mm (0.016 in)
ME(H4SO)-5
MECHANICAL
GENERAL DESCRIPTION
Connecting
rod bearing
Oil clearance
2000 cc
STD
0.010 — 0.038 mm (0.0004 — 0.0015 in)
Limit
0.05 mm (0.0020 in)
2500 cc
STD
0.012 — 0.038 mm (0.0005 — 0.0015 in)
Limit
0.05 mm (0.0020 in)
Thickness at cen-
ter portion
2000 cc
STD
1.492 — 1.501 mm (0.0587 — 0.0591 in)
0.03 mm (0.0012 in) US
1.510 — 1.513 mm (0.0594 — 0.0596 in)
0.05 mm (0.0020 in) US
1.520 — 1.523 mm (0.0598 — 0.0600 in)
0.25 mm (0.0098 in) US
1.620 — 1.623 mm (0.0638 — 0.0639 in)
2500 cc
STD
1.490 — 1.502 mm (0.0587 — 0.0591 in)
0.03 mm (0.0012 in) US
1.504 — 1.512 mm (0.0592 — 0.0595 in)
0.05 mm (0.0020 in) US
1.514 — 1.522 mm (0.0596 — 0.0599 in)
0.25 mm (0.0098 in) US
1.614 — 1.622 mm (0.0635 — 0.0639 in)
Connecting
rod bushing
Clearance between piston pin
and bushing
STD
0 — 0.022 mm (0 — 0.0009 in)
Limit
0.030 mm (0.0012 in)
Crankshaft
Bend limit
0.035 mm (0.0014 in)
Crank pin and
crank journal
Out-of-roundness
0.020 mm (0.0008 in) or less
Grinding limit
0.250 mm (0.0098 in)
Crank pin outer diameter
STD
51.984 — 52.000 mm (2.0466 — 2.0472 in)
0.03 mm (0.0012 in) US
51.954 — 51.970 mm (2.0454 — 2.0461 in)
0.05 mm (0.0020 in) US
51.934 — 51.950 mm (2.0446 — 2.0453 in)
0.25 mm (0.0098 in) US
51.734 — 51.750 mm (2.0368 — 2.0374 in)
Crank journal
outer diameter
#1, #3
STD
59.992 — 60.008 mm (2.3619 — 2.3625 in)
0.03 mm (0.0012 in) US
59.962 — 59.978 mm (2.3607 — 2.3613 in)
0.05 mm (0.0020 in) US
59.942 — 59.958 mm (2.3599 — 2.3605 in)
0.25 mm (0.0098 in) US
59.742 — 59.758 mm (2.3520 — 2.3527 in)
#2, #4, #5
STD
59.992 — 60.008 mm (2.3619 — 2.3625 in)
0.03 mm (0.0012 in) US
59.962 — 59.978 mm (2.3607 — 2.3613 in)
0.05 mm (0.0020 in) US
59.942 — 59.958 mm (2.3599 — 2.3605 in)
0.25 mm (0.0098 in) US
59.742 — 59.758 mm (2.3520 — 2.3527 in)
Thrust clearance
STD
0.030 — 0.115 mm (0.0012 — 0.0045 in)
Limit
0.25 mm (0.0098 in)
Oil clearance
#1
STD
0.003 — 0.030 mm (0.0001 — 0.0012 in)
Limit
0.040 mm (0.0016 in)
#2
STD
0.012 — 0.033 mm (0.0005 — 0.0013 in)
Limit
0.045 mm (0.0018 in)
#3
STD
0.003 — 0.030 mm (0.0001 — 0.0012)
Limit
0.040 mm (0.0016 in)
#4
STD
0.012 — 0.033 mm (0.0005 — 0.0013 in)
Limit
0.045 mm (0.0018 in)
#5
STD
0.010 — 0.031 mm (0.0004 — 0.0012 in)
Limit
0.040 mm (0.0016 in)
Crankshaft
bearing
Crankshaft bear-
ing thickness
#1, #3
STD
1.998 — 2.011 mm (0.0787 — 0.0792 in)
0.03 mm (0.0012 in) US
2.017 — 2.020 mm (0.0794 — 0.0795 in)
0.05 mm (0.0020 in) US
2.027 — 2.030 mm (0.0798 — 0.0799 in)
0.25 mm (0.0098 in) US
2.127 — 2.130 mm (0.0837 — 0.0839 in)
#2, #4, #5
STD
2.000 — 2.013 mm (0.0787 — 0.0793 in)
0.03 mm (0.0012 in) US
2.019 — 2.022 mm (0.0795 — 0.0796 in)
0.05 mm (0.0020 in) US
2.029 — 2.032 mm (0.0799 — 0.0800 in)
0.25 mm (0.0098 in) US
2.129 — 2.132 mm (0.0838 — 0.0839 in)
ME(H4SO)-6
MECHANICAL
GENERAL DESCRIPTION
B: COMPONENT
1. TIMING BELT
(1) Belt cover No. 2 (RH)
(9) Automatic belt tension adjuster
ASSY
Tightening torque: N·m (kgf-m, ft-lb)
(2) Timing belt guide (MT vehicles
only)
T1: 5 (0.5, 3.6)
(10) Belt idler No. 2
T2: 10 (1.0, 7.2)
(3) Crankshaft sprocket
(11) Camshaft sprocket No. 2
T3: 25 (2.5, 18.1)
(4) Belt cover No. 2 (LH)
(12) Timing belt
T4: 39 (4.0, 28.9)
(5) Camshaft sprocket No. 1
(13) Front belt cover
T5: 78 (8.0, 57.9)
(6) Belt idler (No. 1)
(14) Belt cover (LH)
T6: <Ref. to ME(H4SO)-43, INSTAL-
(7) Tensioner bracket
(15) Crankshaft pulley (2000 cc model)
(8) Belt idler (No. 2)
(16) Crankshaft pulley (2500 cc model)
ME-00376
T5
T4
T1
T1
T6
T5
(5)
(6)
(8)
(9)
(11)
(10)
(14)
(15)
(16)
(12)
(13)
(7)
(4)
(1)
(2)
(3)
T1
T2
T1
T3
T4
T6
T4
ME(H4SO)-7
MECHANICAL
GENERAL DESCRIPTION
2. CYLINDER HEAD AND CAMSHAFT
(1) Rocker cover (RH)
(11) Cylinder head (LH)
Tightening torque: N·m (kgf-m, ft-lb)
(2) Intake valve rocker ASSY
(12) Camshaft (LH)
T1: <Ref. to ME(H4SO)-60, CYLIN-
DER HEAD, INSTALLATION,
CYLINDER HEAD ASSEMBLY.>
(3) Exhaust valve rocker ASSY
(13) Camshaft cap (LH)
(4) Camshaft cap (RH)
(14) Oil filler cap
(5) Oil seal
(15) Gasket
T2: 5 (0.5, 3.6)
(6) Camshaft (RH)
(16) Oil filler duct
T3: 10 (1.0, 7.2)
(7) Plug
(17) O-ring
T4: 18 (1.8, 13.0)
(8) Spark plug pipe gasket
(18) Rocker cover (LH)
T5: 25 (2.5, 18.1)
(9) Cylinder head (RH)
(19) Stud bolt
T6: 6.4 (0.65, 4.7)
(10) Cylinder head gasket
( 1 )
( 2 )
( 3 )
( 2 )
( 3 )
( 4 )
( 5 )
( 5 )
( 6 )
( 7 )
( 7 )
( 8 )
( 8 )
( 9 )
(10)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(19)
T2
T2
T2
T2
T1
T1
T3
T3
T3
T3
T4
T4
T4
T5
T5
T5
T6
( 8 )
ME-00186
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