Cylinder Block: Removal

NOTE: Before conducting this procedure, drain the engine oil completely if applicable.

Remove the intake manifold. < Ref. to REMOVAL , Intake Manifold . >
Remove the V-belt. < Ref. to REMOVAL . >
Remove the crank pulley. < Ref. to REMOVAL . >
Remove the timing belt cover. < Ref. to REMOVAL . >
Remove the timing belt assembly. < Ref. to REMOVAL . >
Remove the cam sprocket. < Ref. to REMOVAL . >
Remove the crank sprocket. < Ref. to REMOVAL . >
Remove the generator and A/C compressor with their brackets.
Remove the cylinder head assembly. < Ref. to REMOVAL . >
Remove the clutch disc and cover. < Ref.to REMOVAL , Clutch Disc and Cover . >
Remove the flywheel. < Ref. to REMOVAL , Flywheel . >
1. ST 498497100 CRANKSHAFT STOPPER
Fig 1: Removing Flywheel
Courtesy of SUBARU OF AMERICA, INC.
Remove the oil separator cover.
Remove the water by-pass pipe for heater.
Remove the oil filter.
1. ST 18332AA000 OIL FILTER WRENCH (Outer diameter: 68 mm (2.68 in))
2. ST 18332AA010 OIL FILTER WRENCH (Outer diameter: 65 mm (2.56 in))
Remove the oil cooler.

Fig 2: Removing Oil Cooler
Courtesy of SUBARU OF AMERICA, INC.
Removal of oil pan:
1. Turn the cylinder block with #2 and #4 piston sides facing upward.
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 then remove the oil pan.
  Do not use a screwdriver or similar tool in place of oil pan cutter.
Remove the oil strainer stay.
Remove the oil strainer.
Remove the baffle plate.
Remove the water pipes.
Remove the water pump.
Remove the oil pump from cylinder block.
1. Use a flat-bladed screwdriver as shown in the figure when removing the oil pump.
CAUTION: Be careful not to scratch the mating surface of cylinder block and oil pump.

Fig 3: Removing Oil Pump
Courtesy of SUBARU OF AMERICA, INC.

Fig 4: Identifying Piston Pin, Service Hole Cover And Plug
Courtesy of SUBARU OF AMERICA, INC.
Remove the service hole cover and service hole plugs using hexagon wrench [14 mm (0.55 in)].

Fig 5: Removing Service Hole Cover And Service Hole Plugs
Courtesy of SUBARU OF AMERICA, INC.
Rotate the crankshaft to bring #1 and #2 pistons to bottom dead center position, and then remove the piston circlip through service hole of #1 and #2 cylinders using needle nose plier.

Fig 6: Removing Piston Circlip Through Service Hole
Courtesy of SUBARU OF AMERICA, INC.
Draw out the piston pin from #1 and #2 pistons using ST.
1. ST 499097700 PISTON PIN REMOVER
CAUTION: Be careful not to confuse the original combination of piston, piston pin and cylinder.

Fig 7: Drawing Out Piston Pin From No 1 And No 2 Pistons Using ST
Courtesy of SUBARU OF AMERICA, INC.
Similarly remove the piston pins from #3 and #4 pistons.
Remove the bolts which connect the cylinder block on the side of #2 and #4 cylinders.
Back off the bolts which connect the cylinder block on the side of #1 and #3 cylinders two or three turns.
Set up the cylinder block so that #1 and #3 cylinders are on the upper side, then remove the cylinder block connecting bolts.
Separate the cylinder blocks (LH) and (RH).
NOTE: When separating the cylinder block, do not allow the connecting rod to fall and damage the cylinder block.

Fig 8: Removing Cylinder Block
Courtesy of SUBARU OF AMERICA, INC.
Remove the rear oil seal.
Remove the crankshaft together with connecting rod.
Remove the crankshaft bearings from cylinder block using a hammer handle.
CAUTION: Do not confuse the combination of crankshaft bearings. Press the bearing at the end opposite to locking lip.
Draw out each piston from cylinder block using a wooden bar or hammer handle.
CAUTION: Do not confuse the combination of piston and cylinder.