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Connecting Rod

WARNING: This page is about a different car, the 2004 Subaru Outback, 2004 Subaru Legacy, and 2004 Subaru Baja. However, it is still accessible from the selected car via links, so may be relevant.
  1. Replace connecting rod, if the large or small end thrust surface is damaged.
  2. Check for bend or twist using a connecting rod aligner. Replace connecting rod if the bend or twist exceeds the limit.
    1. Limit of bend or twist per 100 mm (3.94 in) in length:  0.10 mm (0.0039 in)
    Fig 1: Checking Connecting Rod For Bend Or Twist
    G00900968Courtesy of SUBARU OF AMERICA, INC.
  3. Install connecting rod fitted with bearing to crankshaft and measure the side clearance (thrust clearance). Replace connecting rod if the side clearance exceeds the specified limit.
    1. Connecting rod side clearance: 
      1. Standard:  0.070 - 0.330 mm (0.0028 - 0.0130 in)
      2. Limit:  0.4 mm (0.016 in)
    Fig 2: Installing Connecting Rod
    G00900969Courtesy of SUBARU OF AMERICA, INC.
  4. Inspect connecting rod bearing for scar, peeling, seizure, melting, wear, etc.
  5. Measure the oil clearance on individual connecting rod bearings by means of plastigage. If any oil clearance is not within specification, replace the defective bearing with a new one of standard size or undersize as necessary. (See the table below.)
    1. Connecting rod oil clearance: 
      1. Standard:  0.016 - 0.044 mm (0.0006 - 0.0017 in)
      2. Limit:  0.050 mm (0.0020 in)
    Fig 3: Connecting Rod Side Clearance Specification Chart
    G00900970Courtesy of SUBARU OF AMERICA, INC.
  6. Inspect bushing at connecting rod small end, and replace if worn or damaged. Also measure the piston pin clearance at the connecting rod small end.
    1. Clearance between piston pin and bushing: 
      1. Standard:  0 - 0.022 mm (0 - 0.0009 in)
      2. Limit:  0.030 mm (0.0012 in)
    Fig 4: Measuring Clearance Between Piston Pin & Bushing (1 Of 2)
    G00900971Courtesy of SUBARU OF AMERICA, INC.
    Fig 5: Measuring Clearance Between Piston Pin & Bushing (2 Of 2)
    G00900972Courtesy of SUBARU OF AMERICA, INC.
  7. Replacement procedure is as follows.
    1. Remove bushing from connecting rod with ST and press.
    2. Press bushing with ST and press after applying oil on the periphery of bushing.

      ST 499037100 CONNECTING ROD BUSHING REMOVER AND INSTALLER

      Fig 6: Removing Piston Pin Bush, Using SST
      G00900973Courtesy 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 bushing to remove chips.
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