Subaru Legacy (2005 year). Service manual — part 265

ME(H4DOTC)-3

MECHANICAL

General Description

Belt ten-
sion
adjuster

Protrusion of adjuster rod

mm (in)

5.2 — 6.2 (0.205 — 0.244)

Belt ten-
sioner

Spacer O.D.

mm (in)

17.955 — 17.975 (0.7069 — 0.7077)

Tensioner bushing I.D.

mm (in)

18.0 — 18.08 (0.7087 — 0.7118)

Clearance between spacer and
bushing

mm (in) Standard

0.025 — 0.125 (0.0010 — 0.0049)

Side clearance of spacer

mm (in) Standard

0.2 — 0.55 (0.0079 — 0.0217)

Camshaft

Bend limit

mm (in)

0.020 (0.0008) or less

Thrust clearance

mm (in) Standard

0.068 — 0.116 (0.0027 — 0.0046)

Cam lobe height

mm (in)

Intake

Standard

45.85 — 45.95 (1.805 — 1.809)

Exhaust

Standard

45.75 — 45.85 (1.801 — 1.805)

Journal O.D.

mm (in) Standard

Front

37.946 — 37.963 (1.4939 — 1.4946)

Center rear

29.946 — 29.963 (1.1790 — 1.1797)

Clearance at journal

mm (in) Standard

0.037 — 0.072 (0.0015 — 0.0028)

Cylinder
head

Surface warpage limit

mm (in)

0.035 (0.0014)

Grinding limit

mm (in)

0.3 (0.012)

Standard height

mm (in)

127.5 (5.02)

Valve seat

Refacing angle

90

°

Contacting width

mm (in)

Intake

Standard

0.6 — 1.4 (0.024 — 0.055)

Exhaust

Standard

1.2 — 1.8 (0.047 — 0.071)

Valve guide

Inside diameter

mm (in)

6.000 — 6.012 (0.2362 — 0.2367)

Protrusion above head

mm (in)

15.8 — 16.2 (0.622 — 0.638)

Valve

Head edge thick-
ness

mm (in)

Intake

Standard

1.0 — 1.4 (0.039 — 0.055)

Exhaust

Standard

1.3 — 1.7 (0.051 — 0.067)

Stem outer diame-
ter

mm (in)

Intake

5.955 — 5.970 (0.2344 — 0.2350)

Exhaust

5.945 — 5.960 (0.2341 — 0.2346)

Valve stem gap

mm (in) Standard

Intake

0.030 — 0.057 (0.0012 — 0.0022)

Exhaust

0.040 — 0.067 (0.0016 — 0.0026)

Overall length

mm (in)

Intake

104.4 (4.110)

Exhaust

104.65 (4.1201)

Valve spring

Free length

mm (in)

44.67 (1.759)

Squareness

2.5

°, 2.0 mm (0.079 in)

Tension/spring
height

N (kgf, lbf)/mm (in)

Set

206 — 236 (21.0 — 24.1, 46.3 — 53.1)/

36.00 (1.417)

Lift

485 — 537 (49.5 — 54.8, 109 — 121)/

26.60 (1.047)

Cylinder
block

Surface warpage limit
(mating with cylinder head)

mm (in)

0.025 (0.00098)

Grinding limit

mm (in)

0.1 (0.004)

Cylinder inner
diameter

mm (in) Standard

A

92.005 — 92.015 (3.6222 — 3.6226)

B

91.995 — 92.005 (3.6219 — 3.6222)

Cyrindricality

mm (in) Standard

0.015 (0.0006)

Out-of-roundness

mm (in) Standard

0.010 (0.0004)

Piston clearance

mm (in) Standard

−0.010 — 0.010 (−0.00039 — 0.00039)

Boring limit

mm (in)

0.5 (0.020)

Piston

Outer diameter

mm (in)

Standard

A

92.005 — 92.015 (3.6222 — 3.6226)

B

91.995 — 92.005 (3.6219 — 3.6222)

0.25 (0.0098) OS

92.245 — 92.265 (3.6317 — 3.6325)

0.50 (0.0197) OS

92.495 — 92.515 (3.6415 — 3.6423)

ME(H4DOTC)-4

MECHANICAL

General Description

Piston pin

Standard clearance between pis-
ton and piston pin

mm (in) Standard

0.004 — 0.008 (0.0002 — 0.0003)

Degree of fit

Piston pin must be fitted into position with

thumb at 20

°C (68°F).

Piston ring

Ring closed gap

mm (in)

Top ring

Standard

Outer circle side: 0.20 — 0.25 (0.0079 —

0.0098)

Inner circle side: 0.20 — 0.30 (0.0079 —

0.012)

Second ring

Standard

0.40 — 0.50 (0.016 — 0.020)

Oil ring

Standard

0.20 — 0.50 (0.0079 — 0.0197)

Ring groove gap

mm (in)

Top ring

Standard

0.040 — 0.080 (0.0016 — 0.0031)

Second ring

Standard

0.030 — 0.070 (0.0012 — 0.0028)

Connecting
rod

Bend or twist per 100 mm (3.94
in) in length

mm (in) Limit

0.10 (0.0039)

Thrust clearance of large end

mm (in) Standard

0.070 — 0.330 (0.0028 — 0.0130)

Bearing of
large end

Oil clearance

mm (in) Standard

0.026 — 0.052 (0.0010 — 0.0020)

Bearing size
(Thickness at cen-
ter)

mm (in)

Standard

1.486 — 1.498 (0.0585 — 0.0590)

0.03 (0.0012) US

1.504 — 1.512 (0.0592 — 0.0595)

0.05 (0.0020) US

1.514 — 1.522 (0.0596 — 0.0599)

0.25 (0.0098) US

1.614 — 1.622 (0.0635 — 0.0639)

Bushing of
small end

Clearance between piston pin
and bushing

mm (in) Standard

0 — 0.022 (0 — 0.0009)

Crankshaft

Bend limit

mm (in)

0.035 (0.0014)

Crank pin and crank
journal

Out-of-roundness

mm (in)

0.005 (0.0002) or less

Grinding limit (dia.)

mm (in)

Crank pin: To 51.750 (2.0374)

Crank journal: To 59.750 (2.3524)

Crank pin outer
diameter

mm (in)

Standard

51.984 — 52.000 (2.0466 — 2.0472)

0.03 (0.0012) US

51.954 — 51.970 (2.0454 — 2.0461)

0.05 (0.0020) US

51.934 — 51.950 (2.0447 — 2.0453)

0.25 (0.0098) US

51.734 — 51.750 (2.0368 — 2.0374)

Crank journal outer
diameter

mm (in)

Standard

59.992 — 60.008 (2.3619 — 2.3625)

0.03 (0.0012) US

59.962 — 59.978 (2.3607 — 2.3613)

0.05 (0.0020) US

59.942 — 59.958 (2.3599 — 2.3606)

0.25 (0.0098) US

59.742 — 59.758 (2.3521 — 2.3527)

Thrust clearance

mm (in) Standard

0.030 — 0.115 (0.0012 — 0.0045)

Oil clearance

mm (in) Standard

0.010 — 0.030 (0.00039 — 0.0012)

Main bear-
ing

Bearing size (Thick-
ness at center)

#1, #3

Standard

1.998 — 2.011 (0.0787 — 0.0792)

0.03 (0.0012) US

2.017 — 2.020 (0.0794 — 0.0795)

0.05 (0.0020) US

2.027 — 2.030 (0.0798 — 0.0799)

0.25 (0.0098) US

2.127 — 2.130 (0.0837 — 0.0839)

mm (in)

#2, #4, #5

Standard

2.000 — 2.013 (0.0787 — 0.0793)

0.03 (0.0012) US

2.019 — 2.022 (0.0795 — 0.0796)

0.05 (0.0020) US

2.029 — 2.032 (0.0799 — 0.0800)

0.25 (0.0098) US

2.129 — 2.132 (0.0838 — 0.0839)

ME(H4DOTC)-5

MECHANICAL

General Description

B: COMPONENT

1. TIMING BELT

(1)

Timing belt cover No. 2 (RH)

(11)

Exhaust cam sprocket (LH)

Tightening torque: N

⋅

m (kgf-m, ft-lb)

(2)

Timing belt guide (MT model)

(12)

Timing belt

T1: 5 (0.5, 3.7)

(3)

Crank sprocket

(13)

Belt idler No. 2

T2: 9.75 (1.0, 7.2)

(4)

Timing belt cover No. 2 (LH)

(14)

Belt idler

T3: 24.5 (2.5, 18.1)

(5)

Tensioner bracket

(15)

Timing belt cover (LH)

T4: 39 (4.0, 28.8)

(6)

Automatic belt tension adjuster
ASSY

(16)

Front belt cover

T5: <Ref. to ME(H4DOTC)-54,

INSTALLATION, Cam
Sprocket.>

(17)

Timing belt cover (RH)

(7)

Belt idler

(18)

Crank pulley (MT model)

(8)

Exhaust cam sprocket (RH)

(19)

Crank pulley (AT model)

T6: <Ref. to ME(H4DOTC)-43,

INSTALLATION, Crank Pulley.>

(9)

Intake cam sprocket (RH)

(20)

O-ring

(10)

Intake cam sprocket (LH)

T7: 6.4 (0.65, 4.7)

T8: 3.4 (0.3, 2.5)

T9: 25 (2.5, 18.4)

ME-02555

T1

T6

(7)

(6)

(10)

(18)

(5)

(14)

(2)

(3)

T2

(4)

(1)

(2)

(2)

T7

T4

T3

T9

T4

T8

T5

T4

T1

T7

(11)

(15)

(17)

(2)

(9)

(13)

(14)

(12)

(16)

T1

T1

T7

T1

T1

T5

T8

(19)

(8)

T8

(20)

(20)

(20)

(20)

ME(H4DOTC)-6

MECHANICAL

General Description

2. CYLINDER HEAD AND CAMSHAFT

T4

(1)

ME-02557

T3

T3

T5

T5

T5

T5

T4

T1

(3)

(7)

(6)

(9)

(8)

(10)

(12)

(29)

(13)

(26)

(23)

(24)

(21)

(20)

(6)

(16)

(17)

(18)

(9)

(25)

(8)

(19)

(15)

(14)

(30)

(11)

(5)

(4)

(22)

T4

T4

(14)

(30)

(32)

(31)

(12)

(28)

(28)

(27)

(28)

T2

T2

T2

T6

T1

(11)

(2)

(32)

(31)

T6

T6

T2

T2

T6

T3

T7