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Cylinder Block: Removal

WARNING: This page is about a different car, the 2012 Subaru Forester. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Before conducting this procedure, drain the engine oil completely.
  1. Remove the engine from the vehicle. < Ref. to REMOVAL , Engine Assembly. >
  2. Remove the rear side belt. < Ref. to REAR SIDE BELT , REMOVAL, V-belt. >
  3. Remove the intake manifold. < Ref. to REMOVAL , Intake Manifold. >
  4. Remove the crank pulley. < Ref. to REMOVAL , Crank Pulley. >
  5. Remove the timing belt cover. < Ref. to REMOVAL , Timing Belt Cover. >
  6. Remove the timing belt. < Ref. to REMOVAL , Timing Belt. >
  7. Remove the cam sprocket. < Ref. to REMOVAL , Cam Sprocket. >
  8. Remove the crank sprocket. < Ref. to REMOVAL , Crank Sprocket. >
  9. Remove the generator and A/C compressor with their brackets.
  10. Remove the camshaft. < Ref. to REMOVAL , Camshaft. >
  11. Remove the cylinder head. < Ref. to REMOVAL , Cylinder Head. >
  12. Remove the drive plate. < Ref. to REMOVAL , Drive Plate. >
  13. Remove the oil separator cover.
  14. Remove the water by-pass pipe for heater.
  15. Remove the oil filter. < Ref. to REMOVAL , Engine Oil Filter. >
  16. Remove the water pump. < Ref. to REMOVAL , Water Pump. >
  17. Remove the bolts which secure oil pump to cylinder block.
    NOTE: When disassembling and checking the oil pump, loosen the relief valve plug before removing the oil pump.
    Fig 1: Checking Oil Pump
    G07670851Courtesy of SUBARU OF AMERICA, INC.
  18. Remove the oil pump from cylinder block using a flat tip screwdriver.
    CAUTION: Be careful not to scratch the mating surface of the cylinder block and oil pump.
    Fig 2: Removing Oil Pump From Cylinder Block Using Flat Tip Screwdriver
    G07670852Courtesy of SUBARU OF AMERICA, INC.
  19. Remove the front oil seal from the oil pump.
  20. Remove the oil pan.
    1. Set the part so that the cylinder block LH is on the upper side.
    2. Remove the bolts which secure oil pan to cylinder block.
    3. Insert an oil pan cutter blade between cylinder block-to-oil pan clearance and remove the oil pan.
    CAUTION: Do not use a screwdriver or similar tools in place of oil pan cutter.
  21. Remove the oil strainer.
  22. Remove the baffle plate.
  23. Remove the water tank pipe assembly from the cylinder block RH.
    NOTE: Pinch the clamp of the water tank pipe assembly by fitting the cut out in the ST with the protrusion on the clamp as shown in the illustration, and unlock the clamp.

    ST 18353AA000 CLAMP PLIERS

    Fig 3: Pinching Clamp Of Water Hose Using Special Tool
    G07670853Courtesy of SUBARU OF AMERICA, INC.
    Fig 4: Service Hole Plug, Piston Pin, Seal Washer, Gasket, Service Hole Cover, Washer And Snap Ring
    G07670854Courtesy of SUBARU OF AMERICA, INC.
  24. Remove the service hole plugs using a hexagon wrench [14 mm].
    Fig 5: Removing Service Hole Plugs Using Hexagon Wrench
    G07670855Courtesy of SUBARU OF AMERICA, INC.
  25. Remove the service hole cover.
  26. Rotate the crankshaft to bring #1 and #2 pistons to bottom dead center position, then remove the piston snap ring through service hole of #1 and #2 cylinders.
    Fig 6: Removing Piston Snap Ring Through Service Hole
    G07670856Courtesy of SUBARU OF AMERICA, INC.
  27. Draw out the piston pin from #1 and #2 pistons using ST.

    ST 499097700 PISTON PIN REMOVER ASSY

    NOTE: Be careful not to confuse the original combination of piston, piston pin and cylinder.
    Fig 7: Drawing Out Piston Pin From #1 And #2 Pistons Using ST
    G07670857Courtesy of SUBARU OF AMERICA, INC.
  28. Similarly draw out the piston pins from #3 and #4 pistons.
  29. Remove the cylinder block connecting bolt on the RH side.
  30. Loosen the cylinder block connecting bolt on the LH side by 2 to 3 turns.
  31. Set the part so that the cylinder block LH is on the upper side, and remove the cylinder block connecting bolt.
  32. Separate the cylinder block LH and RH.
    NOTE: When separating the cylinder block, do not allow the connecting rod to fall or damage the cylinder block.
    Fig 8: Identifying Cylinder Block, Crankshaft Bearing, Seal Washer, Rear Oil Seal, Piston And Crankshaft
    G07670858Courtesy of SUBARU OF AMERICA, INC.
  33. Remove the rear oil seal.
  34. Remove the crankshaft together with connecting rod.
  35. Remove the crankshaft bearings from cylinder block using a hammer handle.
    NOTE:
    • Press the crankshaft bearing at the end opposite to locking lip to remove.
    • Be careful not to confuse the crankshaft bearing combination.
  36. Remove each piston from the cylinder block using a wooden bar or hammer handle.
    NOTE: Be careful not to confuse the original combination of piston and cylinder.
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