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Connecting Rod

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  1. Check that the large or small end thrust surface is not damaged.
  2. Install the connecting rod to the crankshaft, and check the thrust clearance using a thickness gauge. If it is not within the standard, replace the connecting rod.
    NOTE:
    • Do not forget to install the connecting rod bearing and the connecting rod cap bearing, when installing the connecting rod to the crankshaft.
    • Measurement should be performed at a temperature of 20°C (68°F).
    • Measure the thrust clearance of each connecting rod at several points, and replace the connecting rod if there is uneven wear.

    Connecting rod thrust clearance: 

    Standard 

    0.070 - 0.330 mm (0.0028 - 0.0130 in) 

    Fig 1: Measuring Connecting Rod Thrust Clearance Using Thickness Gauge
    G08317256Courtesy of SUBARU OF AMERICA, INC.
  3. Check for bend or twist using a connecting rod aligner. If it exceeds the limit, replace the connecting rod.

    Limit of bend or twist per 100 mm (3.94 in) in length: 

    0.10 mm (0.0039 in) 

    Fig 2: Checking Bend Or Twist Using Connecting Rod Aligner
    G08563273Courtesy of SUBARU OF AMERICA, INC.
  4. Inspect the connecting rod bearing for scar, peeling, seizure, melting or wear, etc.
  5. Check the oil clearance on each connecting rod bearing using plastigauge. If it is not within the standard, replace the connecting rod bearing.
    NOTE:
    • Measurement should be performed at a temperature of 20°C (68°F).
    • Measure the outer diameter of crank pin using micrometer, and select the suitable size connecting rod bearing when replacing the connecting rod bearing.
    Unit: mm (in)
    Bearing Bearing size (Thickness at center) Outer diameter of crank pin
    Standard 1.492 - 1.508 (0.0587 - 0.0594) 47.976 - 48.000 (1.8888 - 1.8898)
    0.03 (0.0012) Undersize 1.511 - 1.515 (0.0595 - 0.0596) 47.946 - 47.970 (1.8876 - 1.8886)
    0.05 (0.0020) Undersize 1.521 - 1.525 (0.0599 - 0.0600) 47.926 - 47.950 (1.8868 - 1.8878)
    0.25 (0.0098) Undersize 1.621 - 1.625 (0.0638 - 0.0640) 47.726 - 47.750 (1.8790 - 1.8799)

    Connecting rod oil clearance: 

    Standard 

    0.017 - 0.047 mm (0.0007 - 0.0019 in) 

  6. Check that the connecting rod bushing is not damaged.
  7. Check the clearance between piston pin and connecting rod bushing. Check the clearance between piston pin and connecting rod bushing by measuring the outer diameter of piston pin and the inner diameter of connecting rod bushing respectively.
    1. Measure the outer diameter of piston pin with a micrometer.
      NOTE:
      • Measurement should be performed at a temperature of 20°C (68°F).
      • Record the measured value.
      Fig 3: Measuring Outer Diameter Of Piston Pin Using Micrometer
      G08563274Courtesy of SUBARU OF AMERICA, INC.
    2. Using a caliper gauge, measure the inner diameter of connecting rod bushing.
      NOTE:
      • Measurement should be performed at a temperature of 20°C (68°F).
      • Record the measured value.
      Fig 4: Measuring Inner Diameter Of Connecting Rod Bushing Using Caliper Gauge
      G08563275Courtesy of SUBARU OF AMERICA, INC.
    3. Calculate the clearance between piston pin and connecting rod bushing.

      Clearance between piston pin and connecting rod bushing: 

      Standard 

      0.004 - 0.026 mm (0.0002 - 0.0010 in) 

  8. If the clearance between piston pin and connecting rod bushing is not within the standard, replace the connecting rod bushing and piston pin as a set. For replacement procedure of connecting rod bushing, refer to the following.
    1. Using the ST and a press, pull out the connecting rod bushing from the small end of the connecting rod.
      NOTE: The direction of ST for pulling out and for press fitting is different. Therefore, attention must be paid to the direction of usage for ST.

      ST 18350AA000 CONNECTING ROD BUSHING REMOVER AND INSTALLER

      Fig 5: Removing Connecting Rod Bushing From Connecting Rod Small End Using ST And Press
      G08317263Courtesy of SUBARU OF AMERICA, INC.
    2. Press the connecting rod bushing with ST and the press, after applying engine oil on the periphery of connecting rod bushing.
      NOTE:
      • Clinch area of the connecting rod bushing is as shown in the figure.
        Fig 6: Identifying Connecting Rod Bushing Clinch Area
        G08563277Courtesy of SUBARU OF AMERICA, INC.
      • The direction of ST for pulling out and for press fitting is different. Therefore, attention must be paid to the direction of usage for ST.

      ST 18350AA000 CONNECTING ROD BUSHING REMOVER AND INSTALLER

      Fig 7: Removing Connecting Rod Bushing From Connecting Rod Small End Using Tool
      G08317265Courtesy of SUBARU OF AMERICA, INC.
    3. Make two 3 mm (0.12 in) holes in the pressed connecting rod bushing by aligning with the pre-manufactured holes provided on the small end of the connecting rod.
    4. Using a reamer, ream the inside surface of the connecting rod bushing. Insert the reamer in the connecting rod bushing, and turn slowly clockwise while pushing lightly. Bring the reamer back while rotating it clockwise.
      NOTE:
      • Use a reamer with a diameter of ø22.
      • Apply engine oil to the reamer.
      • If the inner surface of valve guide is damaged, the edge of reamer should be slightly ground with oil stone.
      • If the inner surface of connecting rod bushing becomes lustrous and the reamer does not chip, use a new reamer or remedy the reamer.
    5. After completion of reaming, clean the connecting rod bushing to remove chips.
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