Connecting Rod

WARNING: This page is about a different car, the 2006 Subaru Outback. However, it is still accessible from the selected car via links, so may be relevant.

Replace the connecting rod, if the large or small end thrust surface is damaged.
Check for bend or twist using a connecting rod aligner. Replace the connecting rod if it has the bend or twist.

Fig 1: Checking Connecting Rod Bend Or Twist Using Connecting Rod Aligner
Install the connecting rod fitted with bearing to crankshaft and measure the side clearance (thrust clearance). If the clearance exceeds the standard or uneven wear is found, replace the connecting rod.
Connecting rod side clearance:

Standard

0.070 - 0.330 mm (0.0028 - 0.0130 in)

Fig 2: Checking Connecting Rod Side Clearance
Inspect the connecting rod bearing for scar, peeling, seizure, melting, wear, etc.

Measure the oil clearance on each connecting rod bearing using plastigage. If any oil clearance is not within the standard, replace the defective bearing with a new part of standard size or undersize as necessary. (See the STANDARD BEARING SIZE (THICKNESS AT CENTER) SPECIFICATION below.)

Connecting rod oil clearance:

Standard

0.016 - 0.043 mm (0.0006 - 0.0017 in)

STANDARD BEARING SIZE (THICKNESS AT CENTER) SPECIFICATION

Unit: mm (in)
Bearing	Bearing size (Thickness at center)	Outer diameter of crank pin
Standard	1.490 - 1.506 (0.0587 - 0.0593)	51.984 - 52.000 (2.0466 - 2.0472)
0.03 (0.0012) undersize	1.509 - 1.513 (0.0594 - 0.0596)	51.954 - 51.970 (2.0454 - 2.0461)
0.05 (0.0020) undersize	1.519 - 1.523 (0.0598 - 0.0600)	51.934 - 51.950 (2.0446 - 2.0453)
0.25 (0.0098) undersize	1.619 - 1.623 (0.0637 - 0.0639)	51.734 - 51.750 (2.0368 - 2.0374)

Inspect the bushing at connecting rod small end, and replace if worn or damaged. Also measure the piston pin clearance at connecting rod small end.
Clearance between piston pin and bushing:

Standard

0 - 0.022 mm (0 - 0.0009 in)

Fig 3: Checking Clearance Between Piston Pin And Bushing

Fig 4: Checking Piston Pin
Replacement procedure is as follows.
1. Remove the bushing from connecting rod with ST and press.
2. Press the bushing with ST after applying oil on the periphery of bushing.
  ST 18350AA000 CONNECTING ROD BUSHING REMOVER AND INSTALLER
  
  Fig 5: Identifying ST 18350Aa000 Connecting Rod Bushing Remover And Installer
3. Make two 3 mm (0.12 in) holes in bushing. Ream the inside of bushing.
4. After completion of reaming, clean the bushing to remove chips.