Cylinder Block: Installation

WARNING: This page is about a different variant/trim than selected.

Fig 1: Installing Cylinder Block

G03829683

Courtesy of SUBARU OF AMERICA, INC.

Remove oil on the mating surface of bearing and cylinder block before installation. Apply a coat of engine oil to crankshaft pins.
Position the crankshaft on the #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.
Liquid gasket:

THREE BOND 1215 (Part No. 004403007) or equivalent

NOTE: Do not allow liquid gasket to run over to O-ring grooves, oil passages, bearing grooves, etc.

Fig 2: Applying Liquid Gasket To Mating Surface
Courtesy of SUBARU OF AMERICA, INC.
Apply a coat of engine oil to washers and bolt threads.
Tighten the 10 mm cylinder block connecting bolts on LH side (A - D) in alphabetical sequence as shown in Fig 3.
Tightening torque:

10 N.m (1.0 kgf-m, 7.2 ft-lb)

Fig 3: Tightening Cylinder Block Connecting Bolts
Courtesy of SUBARU OF AMERICA, INC.
Tighten the 10 mm cylinder block connecting bolts on RH side (E - J) in alphabetical sequence as shown in Fig 4.
Tightening torque:

10 N.m (1.0 kgf-m, 7.2 ft-lb)

Fig 4: Identifying Cylinder Block Connecting Bolts
Courtesy of SUBARU OF AMERICA, INC.
Further tighten the LH side bolts (A - D) in alphabetical sequence as shown in Fig 5.
Tightening torque:

18 N.m (1.8 kgf-m, 13.0 ft-lb)

Fig 5: Tightening LH Side Bolts
Courtesy of SUBARU OF AMERICA, INC.
Further tighten the RH side bolts (E - J) in alphabetical sequence as shown in Fig 6.
Tightening torque:

18 N.m (1.8 kgf-m, 13.0 ft-lb)

Fig 6: Tightening RH Side Bolts
Courtesy of SUBARU OF AMERICA, INC.
Further tighten the LH side bolts (A - D) in alphabetical sequence as shown in Fig 7.
(A), (C): 90°

(B), (D): 40 N.m (4.1 kgf-m, 29.5 ft-lb)

Fig 7: Tightening LH Side Bolts
Courtesy of SUBARU OF AMERICA, INC.
Further tighten the RH side bolts (E - J) to 90° in alphabetical sequence as shown in Fig 8.

Fig 8: Tightening RH Side Bolts
Courtesy of SUBARU OF AMERICA, INC.
Tighten the 8 mm and 6 mm cylinder block connecting bolts on LH side (A - H) in alphabetical sequence as shown in Fig 9.
Tightening torque:

(A) - (G): 25 N.m (2.5 kgf-m, 18.1 ft-lb)

(H): 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)

Fig 9: Tightening Cylinder Block Connecting Bolts On LH Side
Courtesy of SUBARU OF AMERICA, INC.
Install the rear oil seal using ST1 and ST2.
ST1 499597100 CRANKSHAFT OIL SEAL GUIDE

ST2 499587200 CRANKSHAFT OIL SEAL INSTALLER

Fig 10: Installing Crankshaft Oil Seal Installer ST2 499587200
Courtesy of SUBARU OF AMERICA, INC.
Position the top ring gap at (A) or (B) shown in Fig 11 .
Position the second ring gap at 180° on the reverse side of the top ring gap.

Fig 11: Positioning Top Ring Gap
Courtesy of SUBARU OF AMERICA, INC.
Position the upper rail gap at (C) shown in Fig 12 .

Fig 12: Positioning Upper Rail Gap
Courtesy of SUBARU OF AMERICA, INC.
Align the upper rail spin stopper (D) to the side hole (E) on the piston.

Fig 13: Aligning Upper Rail Spin Stopper
Courtesy of SUBARU OF AMERICA, INC.
Position the expander gap at 180° on the reverse side of (C) that shown (F) in Fig 14 .

Fig 14: Positioning Expander Gap 180° On Reverse Side
Courtesy of SUBARU OF AMERICA, INC.
Position the lower rail gap at (G) shown in Fig 15 .

Fig 15: Positioning Lower Rail Gap
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 snap ring.
Install snap rings in the piston holes located opposite to the service holes in cylinder block, when positioning all pistons in the corresponding cylinders.

NOTE: Use new snap rings.

Fig 16: Installing Snap Ring
Courtesy of SUBARU OF AMERICA, INC.

Fig 17: Identifying Piston And Gasket
Courtesy of SUBARU OF AMERICA, INC.
Installation of piston:
1. Place the cylinder block to face the #1 and #2 cylinder side upward.
2. Using the ST1, turn the crankshaft so that #1 and #2 connecting rods are set at bottom dead center.
  ST1 499987500 CRANKSHAFT SOCKET
3. Apply a coat of engine oil to the pistons and cylinders and insert pistons in their cylinders using ST2.
ST2 498747300 PISTON GUIDE

Fig 18: Installing Piston Guide ST2 498747300
Courtesy of SUBARU OF AMERICA, INC.

NOTE: Piston front mark faces towards the front of engine.

Fig 19: Identifying Piston Front Mark Faces
Courtesy of SUBARU OF AMERICA, INC.
Installation of piston pin:
1. Apply a coat of engine oil to ST3 before insertion, and then insert it into the service hole to align piston pin hole with connecting rod small end.
  ST3 499017100 PISTON PIN GUIDE
  
  Fig 20: Installing Piston Pin Guide ST3 499017100
  Courtesy of SUBARU OF AMERICA, INC.
2. Apply a coat of engine oil to piston pin, and insert the piston pin into piston and connecting rod through service hole.
3. Install the snap ring.
  NOTE: Use new snap rings.
  
  Fig 21: Installing Snap Ring
  Courtesy of SUBARU OF AMERICA, INC.
4. Apply liquid gasket around the service hole plug.
  Liquid gasket:
  
  THREE BOND 1215 (Part No. 004403007) 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: Identifying Cylinder Block
  Courtesy of SUBARU OF AMERICA, INC.
6. Place the cylinder block to face the #3 and #4 cylinder side upward. Following the same procedures as used for #1 and #2 cylinders, install the pistons and piston pins.
Install the water pipe.
Install the baffle plate.
Tightening torque:

6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
Install the oil strainer and O-ring.
Tightening torque:

10 N.m (1.0 kgf-m, 7.2 ft-lb)
Install the oil strainer stay.
Apply liquid gasket to mating surfaces and install the oil pan.
Liquid gasket:

THREE BOND 1207C (Part No. 004403012) or equivalent

Tightening torque:

5 N.m (0.5 kgf-m, 3.6 ft-lb)

Fig 25: Applying Liquid Gasket To Mating Surfaces
Courtesy of SUBARU OF AMERICA, INC.
Apply liquid gasket to the mating surfaces and threaded portion of bolt (A) as shown in Fig 26 , and install the oil separator cover.
NOTE: Install them within 20 min. from applying liquid gasket.

Liquid gasket:

THREE BOND 1207C (Part No. 004403012) or equivalent

Tightening torque:

6.4 N.m (0.65 kgf-m, 4.7 ft-lb)

Fig 26: Applying Liquid Gasket
Courtesy of SUBARU OF AMERICA, INC.
Install the flywheel. (MT model) < Ref. to INSTALLATION , Flywheel. >
Install the clutch disc and cover. (MT model) < Ref. to INSTALLATION , Clutch Disc and Cover. >
Install the drive plate. (AT model) To lock the crankshaft, use ST.
ST 498497100 CRANKSHAFT STOPPER

Tightening torque:

72 N.m (7.3 kgf-m, 52.8 ft-lb)

Fig 27: Installing Drive Plate Using Special Tool
Courtesy of SUBARU OF AMERICA, INC.
Installation of oil pump:
1. Install the front oil seal by using ST.
  ST 499587100 OIL SEAL INSTALLER
  
  NOTE: Use a new front oil seal.
  
  Fig 28: Installing Front Oil Seal Using Special Tool
  Courtesy of SUBARU OF AMERICA, INC.
2. Apply liquid gasket to the matching surface of oil pump.
  Liquid gasket:
  
  THREE BOND 1215 (Part No. 004403007) or equivalent
  
  Fig 29: 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 oil seal.
  
  Fig 30: 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.
5. Apply liquid gasket to the threaded portion of three bolts.
  Fluid packing:
  
  THREE BOND 1215 (Part No. 004403007) or equivalent
  
  Tightening torque:
  
  6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
  
  Fig 31: Applying Liquid Gasket To Threaded Portion Of Bolts
  Courtesy of SUBARU OF AMERICA, INC.
CAUTION:
- 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:

First: 12 N.m (1.2 kgf-m, 8.9 ft-lb)

Second: 12 N.m (1.2 kgf-m, 8.9 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 Fig 32 .
Fig 32: Tightening Bolts
Courtesy of SUBARU OF AMERICA, INC.
Install the water by-pass pipe for heater.
Install the oil cooler.
Tightening torque:

T1: 54 N.m (5.5 kgf-m, 40 ft-lb)

T2: 70 N.m (7.1 kgf-m, 50.6 ft-lb)

Fig 33: Installing Oil Cooler
Courtesy of SUBARU OF AMERICA, INC.
Install the oil filter. < Ref. to INSTALLATION , Engine Oil Filter. >
Install the water by-pass pipe between oil cooler and water pump.
Install the water pipe.
NOTE: Always use new O-rings.
Install the cylinder head.
< Ref. to , INSTALLATION , Cylinder Head. >
Install the oil level gauge guide. (LH side)
Install the rocker cover and rocker cover gasket.
NOTE: Use a new rocker cover gasket.
Install the crank sprocket.
< Ref. to , INSTALLATION , Crank Sprocket. >
Install the cam sprocket.
< Ref. to , INSTALLATION , Cam Sprocket. >
Install the timing belt.
< Ref. to , INSTALLATION , Timing Belt. >
Install the timing belt cover.
< Ref. to , INSTALLATION , Timing Belt Cover. >
Install the crank pulley.
< Ref. to , INSTALLATION , Crank Pulley. >
Install the generator and A/C compressor brackets on cylinder head.
Install the V-belts. < Ref. to , INSTALLATION , V-belt. >
Install the intake manifold.
< Ref. to INSTALLATION , Intake Manifold. >