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Home >> Subaru >> 2005 >> Outback R VDC Limited >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 17 (Engine Mechanical (H4DOTC)) >> Cylinder Block >> Removal

Cylinder Block: Removal

WARNING: This page is about a different variant/trim than selected.
NOTE: Before conducting this procedure, drain engine oil completely.
  1. Remove the intake manifold.

    < Ref. to REMOVAL , Intake Manifold. >

  2. Remove the V-belts. < Ref. to , REMOVAL , V-belt. >
  3. Remove the crank pulley.

    < Ref. to , REMOVAL , Crank Pulley. >

  4. Remove the timing belt cover.

    < Ref. to , REMOVAL , Timing Belt Cover. >

  5. Remove the timing belt.

    < Ref. to , REMOVAL , Timing Belt. >

  6. Remove the cam sprocket.

    < Ref. to , REMOVAL , Cam Sprocket. >

  7. Remove the crank sprocket.

    < Ref. to , REMOVAL , Crank Sprocket. >

  8. Remove the generator and A/C compressor with their brackets.
  9. Remove the cylinder head.

    < Ref. to , REMOVAL , Cylinder Head. >

  10. Remove the clutch disc and cover. < Ref. to REMOVAL , Clutch Disc and Cover. >
  11. Remove the flywheel. (MT model) < Ref. to REMOVAL , Flywheel. >

    ST 498497100 CRANKSHAFT STOPPER

    Fig 1: Removing Flywheel Using Special Tool
    G03829674Courtesy of SUBARU OF AMERICA, INC.
  12. Remove the drive plate. (AT model) To lock crankshaft, use ST.

    ST 498497100 CRANKSHAFT STOPPER

    Fig 2: Removing Drive Plate Using Special Tool
    G03829675Courtesy of SUBARU OF AMERICA, INC.
  13. Remove the oil separator cover.
  14. Remove the water by-pass pipe for heater.
  15. Remove the water pump.
  16. Remove the oil filter. < Ref. to REMOVAL , Engine Oil Filter. >
  17. Remove the oil cooler.
    Fig 3: Removing Oil Cooler
    G03829676Courtesy of SUBARU OF AMERICA, INC.
  18. Remove the bolts which secure oil pump to cylinder block.
  19. Remove the oil pump by using flat tip screwdriver.
    CAUTION: Be careful not to scratch the mating surface of cylinder block and oil pump.
    Fig 4: Removing Oil Pump By Using Flat Tip Screwdriver
    G03829677Courtesy of SUBARU OF AMERICA, INC.
    Fig 5: Identifying Service Hole Plug And Piston Pin
    G03829678Courtesy of SUBARU OF AMERICA, INC.
  20. Removal of oil pan:
    1. Place the cylinder block to face the #2 and #4 cylinder side upward.
    2. Remove the bolts which secure oil pan to cylinder block.
    3. Insert a oil pan cutter blade between cylinder block-to-oil pan clearance and remove the oil pan. Do not use a screwdriver or similar tools in place of oil pan cutter.
  21. Remove the oil strainer stay.
  22. Remove the oil strainer.
  23. Remove the baffle plate.
  24. Remove the water pipe.
  25. Remove the service hole cover and service hole plugs using a hexagon wrench [14 mm].
    Fig 6: Removing Service Hole Cover And Service Hole Plugs Using Hexagon Wrench [14 MM]
    G03829679Courtesy of SUBARU OF AMERICA, INC.
  26. Rotate the crankshaft to bring #1 and #2 pistons to bottom dead center position, then remove the piston snap ring through service hole of #1 and #2 cylinders.
    Fig 7: Removing Piston Snap Ring
    G03829680Courtesy of SUBARU OF AMERICA, INC.
  27. Draw out the piston pins from #1 and #2 pistons using ST.

    ST 499097700 PISTON PIN REMOVER

    NOTE: Be careful not to confuse the original combination of piston, piston pin and cylinder.
    Fig 8: Identifying Piston Pin Remover ST 499097700
    G03829681Courtesy of SUBARU OF AMERICA, INC.
  28. Similarly remove the piston pins from #3 and #4 pistons.
  29. Remove the bolts which connect cylinder block on the side of #2 and #4 cylinders.
  30. Back off the bolts which connect cylinder block on the side of #1 and #3 cylinders two or three turns.
  31. Place the cylinder block to face the #1 and #3 cylinder side upward, and remove cylinder block connecting bolts.
  32. Separate the cylinder block (LH) and (RH).
    NOTE: When separating the cylinder block, do not allow the connecting rod to fall and damage the cylinder block.
    Fig 9: Identifying Cylinder Block And Crankshaft
    G03829682Courtesy of SUBARU OF AMERICA, INC.
  33. Remove the rear oil seal.
  34. Remove the crankshaft together with connecting rod.
  35. Remove the crankshaft bearings from cylinder block using a hammer handle.
    NOTE: Do not confuse the combination of crankshaft bearings. Press the bearing at the end opposite to locking lip.
  36. Draw out each piston from cylinder block using a wooden bar or hammer handle.
NOTE: Be careful not to confuse the original combination of piston and cylinder.
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