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Engine Disassembly & Reassembly: Disassembly

  1. Separate engine from transmission if necessary. Ensure that converter remains attached to automatic transmission (if equipped). Drain oil and coolant. Make sure that liquid does not run over clutch cover. On manual transmission models, remove clutch cover and disc.
  2. Disconnect ignition wiring from engine. Remove distributor and distributor plate. Remove bolts securing alternator to alternator bracket and remove alternator. Remove EGR pipe and cover. Disconnect wiring harness leads for oil pressure gauge or switch. Remove clamp securing air suction manifold. Remove connecting hoses from valve covers. Unclamp heater hoses. Disconnect 2 water by-pass hoses from intake manifold. Remove intake manifold assembly. Remove alternator brackets and air suction system.
  3. Remove oil filter duct. 4WD models have a bracket. Use a puller and remove crankshaft pulley. Remove oil pump and filter as an assembly. Remove water pump with hoses and tubes attached.
  4. Turn engine over on stand and remove oil pan, crankcase, gasket and transmission cover (if necessary). Remove oil strainer and brackets. Remove either flywheel or converter drive plate. Take off flywheel housing.
  5. Remove spark plugs and valve cover. Remove rocker assembly and push rods. Remove cylinder head bolts in sequence See  Fig 1 .  Remove cylinder head and gasket. Use Allen wrench and remove crankcase plug.
  6. Position pistons at bottom dead center and remove circlip with long nosed pliers. Access to No. 1 and No. 2 pins is through front crankcase plug holes. Access to No. 3 and No. 4 pins is through rear service holes. Remove pins and pistons, marking for reassembly.
  7. Work through hole in camshaft gear and straighten lock washer, then remove nut. Remove nuts and washers and separate cases. Use valve lifter clips (899804100 or equivalent), to prevent upper crankcase lifters from falling off.
    Fig 1: Cylinder Head Nut Loosening Sequence
    G09359930Courtesy of SUBARU OF AMERICA, INC.
    NOTE: Pull camshaft to rear for crankcase clearance.
  8. Remove oil seal. Lift out crankshaft, distributor gear, and connecting rods. Keep crankshaft bearings in order for reassembly. Remove camshaft and gear. Remove oil pressure switch and valve lifters.
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