Cylinder Block: Installation

Fig 1: Installing Cylinder Block

G00967065

Courtesy of SUBARU OF AMERICA, INC.

CAUTION:

Remove oil in the mating surface of bearing and cylinder block before installation.
Apply a coat of engine oil to crankshaft pins.

Install crankshaft bearings on the cylinder block, apply a coat of engine oil to crankshaft bearings, and position the crankshaft on #2 and #4 cylinder block.
Apply liquid gasket to the mating surface of #1 and #3 cylinder block, and position it on #2 and #4 cylinder block.
1. Liquid gasket:
2. Part No. 004403007
3. THREE BOND 1215 or equivalent
CAUTION: Do not allow liquid gasket to jut into O-ring grooves, oil passages, bearing grooves, etc.

Fig 2: Applying Liquid Gasket To Mating Surface Of No 1 And No 3 Cylinder Block
Courtesy of SUBARU OF AMERICA, INC.
Apply engine oil to washers and thread of bolts.
Tighten the 10 mm cylinder block connecting bolts in alphabetical sequences shown in the figure. (LH side)
1. Tightening torque: 10 N.m (1.0 kgf-m, 7.2 ft-lb)
Fig 3: Tightening Cylinder Block Connecting Bolts (LH Side)
Courtesy of SUBARU OF AMERICA, INC.
Tighten the 10 mm cylinder block connecting bolts in alphabetical sequence shown in the figure. (RH side)
1. Tightening torque: 10 N.m (1.0 kgf-m, 7.2 ft-lb)
Fig 4: Tightening Cylinder Block Connecting Bolts (RH Side)
Courtesy of SUBARU OF AMERICA, INC.
Further tighten the LH side bolts (A - D) in alphabetical sequence.
Tightening torque:
1. (A), (C): 20 N.m (2.0 kgf-m, 14.8 ft-lb)
2. (B), (D): 15 N.m (1.5 kgf-m, 10.8 ft-lb)
Fig 5: Tightening Cylinder Block Connecting Bolts (LH Side)
Courtesy of SUBARU OF AMERICA, INC.
Further tighten the RH side bolts (E - J) in alphabetical sequence.
Tightening torque:
1. (E), (F), (G), (I): 20 N.m (2.0 kgf-m, 14.8 ft-lb)
2. (H), (J): 18 N.m (1.8 kgf-m, 13.3 ft-lb)
Fig 6: Tightening Cylinder Block Connecting Bolts (RH Side)
Courtesy of SUBARU OF AMERICA, INC.
Further tighten the LH side bolts (A - D) by 90° in alphabetical sequence.

Fig 7: Tightening Cylinder Block Connecting Bolts (LH Side)
Courtesy of SUBARU OF AMERICA, INC.
Further tighten the RH side bolts (E - J) by 90° in alphabetical sequence.

Fig 8: Tightening Cylinder Block Connecting Bolts (RH Side)
Courtesy of SUBARU OF AMERICA, INC.
Tighten the 8 mm and 6 mm cylinder block connecting bolts in alphabetical sequence shown in the figure.
Tightening torque:
1. (A) - (G): 25 N.m (2.5 kgf-m, 18.1 ft-lb)
2. (H): 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
Fig 9: Tightening Cylinder Block Connecting Bolts
Courtesy of SUBARU OF AMERICA, INC.
Install the rear oil seal using ST1 and ST2.
1. ST1 499597100 CRANKSHAFT OIL SEAL GUIDE
2. ST2 499587200 CRANKSHAFT OIL SEAL INSTALLER
Fig 10: Installing Engine Rear Oil Seal
Courtesy of SUBARU OF AMERICA, INC.
Position the top ring gap at (A) or (B) in the figure.
Position the second ring gap at 180° on the reverse side for the top ring gap.

Fig 11: Identifying Second Ring Gap At 180° On Reverse Side For Top Ring Gap
Courtesy of SUBARU OF AMERICA, INC.
Position the upper rail gap at (C) in the figure.

Fig 12: Identifying Upper Rail Gap Angle
Courtesy of SUBARU OF AMERICA, INC.
Align upper rail spin stopper (D) with piston side surface hole (E).

Fig 13: Aligning Upper Rail Spin Stopper With Piston Side Surface Hole
Courtesy of SUBARU OF AMERICA, INC.
Position the expander gap at (F) in the figure.

Fig 14: Identifying Expander Gap Angle
Courtesy of SUBARU OF AMERICA, INC.
Position the lower rail gap at (G) in the figure.

Fig 15: Identifying Lower Rail Gap Angle
Courtesy of SUBARU OF AMERICA, INC.
CAUTION:
- Ensure ring gaps do not face the same direction.
- Ensure ring gaps are not within the piston skirt area.
Install the circlip.
Install the circlips in piston holes located opposite of service holes in cylinder block, when positioning all pistons in the corresponding cylinders.

NOTE: Use new circlips.

Fig 16: Installing Piston Circlip
Courtesy of SUBARU OF AMERICA, INC.

Fig 17: Applying Coat Of Engine Oil To Pistons And Cylinders
Courtesy of SUBARU OF AMERICA, INC.
Installing the piston:
1. Turn the cylinder block so that #1 and #2 cylinders face upward.
2. Using the ST1, turn the crankshaft so that #1 and #2 connecting rods are set at bottom dead center.
  1. ST1 499987500 CRANKSHAFT SOCKET
3. Apply a coat of engine oil to the pistons and cylinders and insert pistons in their cylinders using ST2.
  1. ST2 498747300 PISTON GUIDE
  Fig 18: Turning Crankshaft For Positioning No 1 And No 2 Connecting Rods At Bottom Dead Center
  Courtesy of SUBARU OF AMERICA, INC.
CAUTION: Piston front mark faces towards the front of the engine.

Fig 19: Identifying Piston Front Mark
Courtesy of SUBARU OF AMERICA, INC.
Installing piston pin:
1. Apply a coat of engine oil to ST3, and then insert the ST3 into service hole to align piston pin hole with connecting rod small end.
  1. ST3 499017100 PISTON PIN GUIDE
  Fig 20: Installing Piston Pin
  Courtesy of SUBARU OF AMERICA, INC.
2. Apply a coat of engine oil to the piston pin and insert piston pin into piston and connecting rod through service hole.
3. Using the needle nose plier, install the circlip.
  NOTE: Use new circlips.
  
  Fig 21: Installing Piston Circlips
  Courtesy of SUBARU OF AMERICA, INC.
4. Apply liquid gasket around the service hole plug.
  1. Liquid gasket:
  2. Part No. 004403007
  3. THREE BOND 1215 or equivalent
  Fig 22: Applying Liquid Gasket Around Service Hole Plug
  Courtesy of SUBARU OF AMERICA, INC.
5. Install the service hole plug and gasket.
  NOTE: Use a new gasket.
  
  Fig 23: Installing Service Hole Plug And Gasket
  Courtesy of SUBARU OF AMERICA, INC.
  
  Fig 24: Applying Coat Of Engine Oil To Piston And Piston Pin
  Courtesy of SUBARU OF AMERICA, INC.
6. Turn the cylinder block so that #3 and #4 cylinders face upward. Using the same procedures as used for #1 and #2 cylinders, install the pistons and piston pins.
Install the water pipe.
Install the baffle plate.
1. Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
Install the oil strainer and O-ring
1. Tightening torque: 10 N.m (1.0 kgf-m, 7 ft-lb)
Install the oil strainer stay.
Apply liquid gasket to the matching surfaces, and then install the oil pan.
1. Liquid gasket:
2. Part No. 004403007
3. THREE BOND 1215 or equivalent
1. Tightening torque: 5 N.m (0.5 kgf-m, 3.6 ft-lb)
Fig 25: Applying Liquid Gasket (1 Of 2)
Courtesy of SUBARU OF AMERICA, INC.
Apply liquid gasket to the matching surfaces, and then install the oil separator cover.
1. Liquid gasket:
2. Part No. 004403007
3. THREE BOND 1215 or equivalent
1. Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
Fig 26: Applying Liquid Gasket (2 Of 2)
Courtesy of SUBARU OF AMERICA, INC.
Install the flywheel. < Ref. to INSTALLATION , Flywheel . >
Install the clutch disc and cover. < Ref. to INSTALLATION , Clutch Disc and Cover . >
Installation of oil pump:
1. Discard the front oil seal after removal. Replace with a new one using the ST.
  1. ST 499587100 OIL SEAL INSTALLER
  Fig 27: Installing Front Oil Seal
  Courtesy of SUBARU OF AMERICA, INC.
2. Apply liquid gasket to the matching surface of oil pump.
  1. Liquid gasket:
  2. Part No. 004403007
  3. THREE BOND 1215 or equivalent
  Fig 28: Applying Liquid Gasket To Matching Surface Of Oil Pump
  Courtesy of SUBARU OF AMERICA, INC.
3. Apply a coat of engine oil to the inside of the oil seal.
  
  Fig 29: Applying Coat Of Engine Oil To Inside Of Oil Seal
  Courtesy of SUBARU OF AMERICA, INC.
4. Install the oil pump on cylinder block. Be careful not to damage the oil seal during installation.
1. Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
NOTE:
- Do not forget to install the O-ring and seal when installing the oil pump.
- Align the flat surface of oil pump's inner rotor with crankshaft before installation.
Install the water pump and gasket.
Tightening torque:
1. First; 12 N.m (1.2 kgf-m, 8.7 ft-lb)
2. Second; 12 N.m (1.2 kgf-m, 8.7 ft-lb)
CAUTION:
- Be sure to use a new gasket.
- When installing the water pump, tighten the bolts in two stages in alphabetical sequence as shown in the figure.
Fig 30: Tightening Water Pump Bolts
Courtesy of SUBARU OF AMERICA, INC.
Install the water by-pass pipe for heater.
Install the oil cooler.
Tightening torque:
1. T1: 45 N.m (4.6 kgf-m, 33 ft-lb)
2. T2: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
3. T3: 54 N.m (5.3 kgf-m, 39 ft-lb)
Fig 31: Installing Oil Cooler
Courtesy of SUBARU OF AMERICA, INC.
Get an engine oil filter and apply a thin coat of engine oil to the seal rubber.
Install the oil filter by turning it by hand, being careful not to damage the seal rubber.
1. Tighten the oil filter 68 mm (2.68 in) or 65 mm (2.56 in) in diameter by approx. 1 rotation more after the seal rubber of oil filter comes in contact with cylinder block or oil cooler.
CAUTION:
- Do not tighten excessively or oil may leak.
- Be careful not to use the oil filter 80 mm (3.15 in) in diameter to turbo model.
Install the water by-pass pipe between oil cooler and water pump.
Install the water pipe.
CAUTION: Always use a new O-ring.
Install the cylinder head assembly. < Ref. to INSTALLATION . >
Install the oil level gauge guide and tighten the attaching bolt (LH side).
Install the rocker cover.
Install the crank sprocket. < Ref. to INSTALLATION . >
Install the cam sprocket. < Ref. to INSTALLATION . >
Install the timing belt assembly. < Ref. to INSTALLATION . >
Install the timing belt cover. < Ref. to INSTALLATION . >
Install the crank pulley. < Ref. to INSTALLATION . >
Install the generator and A/C compressor brackets on cylinder head.
Install the V-belt. < Ref. to INSTALLATION . >
Install the intake manifold. < Ref. to REMOVAL , Intake Manifold . >