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HOMESERVICE MANUALSSUBARU2005OUTBACK I, STANDARDREPAIR AND DIAGNOSISENGINE MECHANICALTIMING BELTENGINE MECHANICAL (H4SO)CYLINDER BLOCKINSPECTIONCONNECTING ROD
2005 Subaru Outback i, Standard

Connecting Rod

2005 Subaru Outback i, StandardSECTION Connecting Rod
  1. Replace the connecting rod, if the large or small end thrust surface is damaged.
  2. 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 Aligner
    G03828111Courtesy of SUBARU OF AMERICA, INC.
  3. Install the connecting rod fitted with bearing to crankshaft and measure the side clearance (thrust clearance). If side clearance exceeds the limit, replace the connecting rod.

    Connecting rod side clearance: 

    Standard 

    0.070 - 0.330 mm (0.0028 - 0.0130 in) 

    Fig 2: Measuring Side Clearance (Thrust Clearance)
    G03828112Courtesy of SUBARU OF AMERICA, INC.
  4. Inspect the connecting rod bearing for scar, peeling, seizure, melting, wear, etc.
  5. Measure the oil clearance on individual connecting rod bearings by means of plastigauge. If any oil clearance is not within the 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 

    0.016 - 0.044 mm (0.00063 - 0.0017 in) 

    OIL CLEARANCE REFERENCE

    Unit: mm (in)
    Bearings 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)
  6. Inspect the bushing at connecting rod small end, and replace if worn or damaged. Also measure the piston pin clearance at the connecting rod small end.

    Clearance between piston pin and bushing: 

    Standard 

    0 - 0.022 mm (0 - 0.0009 in) 

    Fig 3: Measuring Piston Pin Clearance Connecting Rod Small End
    G03828113Courtesy of SUBARU OF AMERICA, INC.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.