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.

Remove the engine from the vehicle. < refer to REMOVAL , Engine Assembly >
Remove the intake manifold. < refer to REMOVAL , Intake Manifold >
Remove the tumble generator valve assembly. < refer to REMOVAL , Tumble Generator Valve Assembly >
Remove the chain cover. < refer to REMOVAL , Chain Cover >
Remove the rocker cover. < refer to REMOVAL , Rocker Cover >
Remove the cam carrier. < refer to REMOVAL , Cam Carrier >
Remove the cylinder head. < refer to REMOVAL , Cylinder Head >
Remove the crank sprocket. < refer to REMOVAL , Crank Sprocket >
Remove the engine hanger from cylinder block RH.

Fig 1: Locating Engine Hanger Bolts Of Cylinder Block RH
Courtesy of SUBARU OF AMERICA, INC.
Remove the bolts securing the water pipe assembly and PCV connector to the cylinder block, and remove the water pipe assembly and PCV connector as a set from cylinder block.

Fig 2: Locating Water Pipe Assembly And PCV Connector Bolts
Courtesy of SUBARU OF AMERICA, INC.
Remove the O-ring from the cylinder block and PCV connector.

Fig 3: Locating Cylinder Block And PCV Connector O-Ring
Courtesy of SUBARU OF AMERICA, INC.
Remove the knock sensor from cylinder block LH.

Fig 4: Locating Knock Sensor Of Cylinder Block LH
Courtesy of SUBARU OF AMERICA, INC.
Remove the PCV hose assembly (A) and the vacuum hose (B) from cylinder block and PCV valve.
NOTE: Pinch the clamp of the PCV hose assembly (A) by fitting the cut out in the ST with the protrusion on the clamp as shown in the figure, and unlock the clamp.

ST 18353AA000 CLAMP PLIERS

Fig 5: Pinching Clamp Of PCV Hose Assembly
Courtesy of SUBARU OF AMERICA, INC.
Remove the PCV valve from the cylinder block RH.

Fig 6: Locating PCV Valve Bolt Of Cylinder Block RH
Courtesy of SUBARU OF AMERICA, INC.
Remove the crankshaft position sensor plate with drive plate. (AT model) < refer to REMOVAL , Drive Plate >
Remove the clutch disc and cover. (MT model) < refer to REMOVAL , Clutch Disc and Cover >
Remove the crankshaft position sensor plate with flywheel. (MT model) < refer to REMOVAL , Flywheel >
Remove the bolts securing the crankshaft position sensor holder from the cylinder block LH, and remove the crankshaft position sensor with crankshaft position sensor holder.

Fig 7: Locating Crankshaft Position Sensor Holder Bolts
Courtesy of SUBARU OF AMERICA, INC.
Set the cylinder block so that the oil pan is on the upper side, remove the ST1, ST2, ST3 and ST4 from cylinder block and oil pan upper.
ST1 498457000 ENGINE STAND ADAPTER RH

ST2 498457100 ENGINE STAND ADAPTER LH

ST3 18362AA020 ADAPTER

ST4 499817100 ENGINE STAND

Fig 8: Removing ST1, ST2, ST3 And ST4 From Cylinder Block And Oil Pan Upper
Courtesy of SUBARU OF AMERICA, INC.
Remove the thermostat cover from oil pan upper, and then remove the thermostat.

Fig 9: Locating Thermostat Cover Bolts Of Oil Pan Upper
Courtesy of SUBARU OF AMERICA, INC.
Remove the oil pan upper with oil pan from cylinder block.

Fig 10: Locating Oil Pan Bolts Of Cylinder Block
Courtesy of SUBARU OF AMERICA, INC.
Remove the O-ring from the cylinder block.

Fig 11: Locating O-Ring Of Cylinder Block
Courtesy of SUBARU OF AMERICA, INC.
Install the A/C compressor bracket bolts and the power steering pump bracket bolts at the locations shown in the figure.
NOTE:
- This procedure is required to prevent the knock pin damage when the cylinder block is raised in the next step.
- Use the same length bolt for the four bolts.
  
  Fig 12: Locating A/C Compressor Bracket And Power Steering Pump Bracket Bolts
  Courtesy of SUBARU OF AMERICA, INC.
Raise the cylinder block so that the rear oil seal is on the lower side.
Add a front mark on the piston using a marker as shown in the figure.

Fig 13: Identifying Front Mark On Piston
Courtesy of SUBARU OF AMERICA, INC.
Remove the #1 and #4 connecting rod caps and pistons from the cylinder block.
NOTE: Mark each connecting rod cap and piston with a cylinder number.
1. Turn the crankshaft so that the #1 connecting rod cap (A) and #4 connecting rod cap (B) is located at the position shown in the figure using ST.
  ST 18252AA000 CRANKSHAFT SOCKET
  
  Fig 14: Turning Crankshaft Using Crankshaft Socket
  Courtesy of SUBARU OF AMERICA, INC.
2. Using TORX® socket E12, loosen the #1 connecting rod cap bolt, and remove the #1 connecting rod cap bolt and #1 connecting rod cap.
  
  Fig 15: Removing #1 Connecting Rod Cap And Bolt
  Courtesy of SUBARU OF AMERICA, INC.
3. Using TORX® socket E12, loosen the #4 connecting rod cap bolt, and remove the #4 connecting rod cap bolt and #4 connecting rod cap.
  
  Fig 16: Removing #4 Connecting Rod Cap And Bolt
  Courtesy of SUBARU OF AMERICA, INC.
4. Using the ST, turn the crankshaft clockwise and separate the positions of the #1 crank pin (A) and the large end of the #1 connecting rod (B).
  ST 18252AA000 CRANKSHAFT SOCKET
  
  Fig 17: Turning Crankshaft Using Crankshaft Socket
  Courtesy of SUBARU OF AMERICA, INC.
5. Push the #1 connecting rod in the direction of the arrow, and remove the #1 piston with #1 connecting rod from the cylinder block.
  
  Fig 18: Removing #1 Piston With #1 Connecting Rod From Cylinder Block
  Courtesy of SUBARU OF AMERICA, INC.
6. Using the ST, turn the crankshaft counterclockwise and separate the positions of the #4 crank pin (A) and the large end of the #4 connecting rod (B).
  ST 18252AA000 CRANKSHAFT SOCKET
  
  Fig 19: Turning Crankshaft Using Crankshaft Socket
  Courtesy of SUBARU OF AMERICA, INC.
7. Push the #4 connecting rod in the direction of the arrow, and remove the #4 piston with #4 connecting rod from the cylinder block.
  
  Fig 20: Removing #4 Piston With #4 Connecting Rod From Cylinder Block
  Courtesy of SUBARU OF AMERICA, INC.
Remove the #2 and #3 connecting rod caps and pistons from the cylinder block.
NOTE: Mark each connecting rod cap and piston with a cylinder number.
1. Turn the crankshaft so that the #2 connecting rod cap (A) and #3 connecting rod cap (B) is located at the position shown in the figure using ST.
  ST 18252AA000 CRANKSHAFT SOCKET
  
  Fig 21: Turning Crankshaft Using Crankshaft Socket
  Courtesy of SUBARU OF AMERICA, INC.
2. Using TORX® socket E12, loosen the #2 connecting rod cap bolt, and remove the #2 connecting rod cap bolt and #2 connecting rod cap.
  
  Fig 22: Removing #2 Connecting Rod Cap And Bolt
  Courtesy of SUBARU OF AMERICA, INC.
3. Using TORX® socket E12, loosen the #3 connecting rod cap bolt, and remove the #3 connecting rod cap bolt and #3 connecting rod cap.
  
  Fig 23: Removing #3 Connecting Rod Cap And Bolt
  Courtesy of SUBARU OF AMERICA, INC.
4. Using the ST, turn the crankshaft counterclockwise and separate the positions of the #2 crank pin (A) and the large end of the #2 connecting rod (B).
  ST 18252AA000 CRANKSHAFT SOCKET
  
  Fig 24: Turning Crankshaft Using Crankshaft Socket
  Courtesy of SUBARU OF AMERICA, INC.
5. Push the #2 connecting rod in the direction of the arrow, and remove the #2 piston with #2 connecting rod from the cylinder block.
  
  Fig 25: Removing #2 Piston With #2 Connecting Rod From Cylinder Block
  Courtesy of SUBARU OF AMERICA, INC.
6. Using the ST, turn the crankshaft clockwise and separate the positions of the #3 crank pin (A) and the large end of the #3 connecting rod (B).
  ST 18252AA000 CRANKSHAFT SOCKET
  
  Fig 26: Turning Crankshaft Using Crankshaft Socket
  Courtesy of SUBARU OF AMERICA, INC.
7. Push the #3 connecting rod in the direction of the arrow, and remove the #3 piston with #3 connecting rod from the cylinder block.
  
  Fig 27: Removing #3 Piston With #3 Connecting Rod From Cylinder Block
  Courtesy of SUBARU OF AMERICA, INC.
Set the cylinder block so that the oil pan side is on the upper side, and remove the A/C compressor bracket bolts and the power steering pump bracket bolts attached at the locations shown in the figure.

Fig 28: Locating A/C Compressor Bracket And Power Steering Pump Bracket Bolts
Courtesy of SUBARU OF AMERICA, INC.
Set the part so that the cylinder block RH is on the upper side, and separate the cylinder block.
CAUTION:
- Place a wood board wrapped with a waste cloth to prevent the knock pin damage and to stabilize the cylinder block before work.
- Be careful not to scratch the mating surface of cylinder block during work.
1. Remove the bolt shown in the figure.
  
  Fig 29: Locating Cylinder Block RH Bolts (Upper Side)
  Courtesy of SUBARU OF AMERICA, INC.
2. Loosen the cylinder block mounting bolts in numerical order as shown in the figure, and separate the cylinder block RH and LH.
  NOTE: Lift the cylinder block RH slightly, and confirm that the crankshaft is remaining in the cylinder block LH. If the cylinder block RH is lifted carelessly when separating, the crankshaft may stick to cylinder block RH, then fall off.
  
  Fig 30: Identifying Cylinder Block Mounting Bolts Loosening Sequence
  Courtesy of SUBARU OF AMERICA, INC.
Remove the crankshaft from cylinder block LH, and remove the rear oil seal.
Remove the O-ring from the cylinder block LH.

Fig 31: Locating O-Ring Of Cylinder Block LH
Courtesy of SUBARU OF AMERICA, INC.
Remove the crankshaft bearings from the cylinder block.
NOTE:
- Be careful not to confuse the crankshaft bearing combination.
- Press the bearing at the end opposite to locking lip (A).
  
  Fig 32: Pressing Bearing At Opposite End Of Locking Lip
  Courtesy of SUBARU OF AMERICA, INC.
Remove the liquid gasket from cylinder block.