Connecting Rod

WARNING: This page is about a different car, the 2004 Subaru Baja. 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 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 For Bend Or Twist Using Connecting Rod Aligner
Courtesy of SUBARU OF AMERICA, INC.
Install the connecting rod fitted with bearing to crankshaft, and then 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)

Limit

0.40 mm (0.016 in)

Fig 2: Measuring Side Clearance (Thrust Clearance)
Courtesy of SUBARU OF AMERICA, INC.
Inspect the connecting rod bearing for scar, peeling, seizure, melting, wear, etc.
Measure the oil clearance on individual connecting rod bearings by means of plastigauge. 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.)
Connecting rod oil clearance:

Standard

0.017 - 0.045 mm (0.0007 - 0.0018 in)

Limit

0.050 mm (0.0020 in)

Fig 3: Connecting Rod Oil Clearance Specification
Courtesy of SUBARU OF AMERICA, INC.
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)

Limit

0.030 mm (0.0012 in)

Fig 4: Inspecting Bushing At Connecting Rod Small End
Courtesy of SUBARU OF AMERICA, INC.

Fig 5: Inspecting 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 AND INSTALLER
  
  Fig 6: Pressing Bushing With ST
  Courtesy of SUBARU OF AMERICA, INC.
3. Make two 3 mm (0.12 in) holes in bushing. Ream the inside of bushing.
4. After the completion of reaming, clean the bushing to remove chips.