Connecting Rod

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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 the bend or twist exceeds the limit.
Limit of bend or twist per 100 mm (3.94 in) in length:

0.10 mm (0.0039 in)

Fig 1: Checking Bend Or Twist Using Connecting Rod
Courtesy of SUBARU OF AMERICA, INC.
Install the connecting rod fitted with bearing to crankshaft and measure the side clearance (thrust clearance). Replace the connecting rod if the side clearance exceeds the specified limit.
Connecting rod side clearance:

Standard:

0.070 - 0.330 mm (0.0028 - 0.0130 in)

Fig 2: Checking Connecting Rod Side Clearance
Courtesy of SUBARU OF AMERICA, INC.
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 under-size as necessary. (See the STANDARD BEARING SIZE (THICKNESS AT CENTER) SPECIFICATION below.)

Connecting rod oil clearance:

Standard:

0.016 - 0.044 mm (0.00063 - 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	1.492 - 1.501 (0.0587 - 0.0591)	51.984 - 52.000 (2.0466 - 2.0472)
0.03 (0.0012) Undersize	1.510-1.513 (0.0594 - 0.0596)	51.954 - 51.970 (2.0454 - 2.0461)
0.05 (0.0020) Undersize	1.520 - 1.523 (0.0598 - 0.0600)	51.934 - 51.950 (2.0446 - 2.0453)
0.25 (0.0098) Undersize	1.620 - 1.623 (0.0638 - 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 Inside Diameter Of Connecting Rod Small End
Courtesy of SUBARU OF AMERICA, INC.

Fig 4: Checking Outer Diameter Of Piston Pin
Courtesy of SUBARU OF AMERICA, INC.
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 499037100 CONNECTING ROD BUSHING REMOVER & INSTALLER
  
  Fig 5: Pressing Bushing With ST (499037100)
  Courtesy of SUBARU OF AMERICA, INC.
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.