Cylinder Block: Installation

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

Fig 1: Installing Components Cylinder Block

G03828059

Courtesy of SUBARU OF AMERICA, INC.

NOTE: 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 flow into O-ring grooves, oil passages, bearing grooves, etc.

Fig 2: Applying Liquid Gasket
Courtesy of SUBARU OF AMERICA, INC.
Tighten the 10 mm cylinder block connecting bolts on LH side (A - D) in alphabetical sequence.
Tightening torque:

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

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

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

Fig 4: Tightening Bolts In Sequence
Courtesy of SUBARU OF AMERICA, INC.
Further tighten the LH side bolts (A - D) in alphabetical sequence.
Tightening torque:

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

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

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

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

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

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

Fig 8: Tightening Bolts In Sequence
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.
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 Bolts In Sequence
Courtesy of SUBARU OF AMERICA, INC.
Install the rear oil seal using ST1 and ST2.
ST1 499597100 OIL SEAL GUIDE

ST2 499587200 OIL SEAL INSTALLER

Fig 10: Installing Rear Oil Seal Using ST1 499597100 Oil Seal Guide And ST2 499587200 Oil Seal Installer
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 of the top ring gap.
- U5 model
  
  Fig 11: Positioning Second Ring Gap - U5 Model
  Courtesy of SUBARU OF AMERICA, INC.
- Except for U5 model
Fig 12: Positioning Second Ring Gap - Except U5 Model
Courtesy of SUBARU OF AMERICA, INC.
Set the oil ring. (U5 model)
1. Position the expander gap at (C) shown in Fig 13 .
  
  Fig 13: Positioning Expander Gap
  Courtesy of SUBARU OF AMERICA, INC.
2. Position the upper rail gap at (D) shown in Fig 14 .
  
  Fig 14: Positioning Upper Rail Gap
  Courtesy of SUBARU OF AMERICA, INC.
  
  NOTE: Align upper rail spin stopper (F) with piston side surface hole (E) shown in Fig 15.
  
  Fig 15: Aligning Upper Rail Spin Stopper
  Courtesy of SUBARU OF AMERICA, INC.
3. Position the lower rail gap at (G) shown in Fig 16 .
Fig 16: 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.
Set the oil ring. (Except for U5 model)
1. Position the upper rail gap at (C) in the figure.
  
  Fig 17: Positioning Upper Rail Gap
  Courtesy of SUBARU OF AMERICA, INC.
2. Align the upper rail spin stopper (E) to the side hole (D) on the piston.
  
  Fig 18: Aligning Upper Rail Spin Stopper
  Courtesy of SUBARU OF AMERICA, INC.
3. Position the expander gap at 180° on the reverse side of (C) that shown (F) in Fig 19 .
  
  Fig 19: Positioning Expander Gap
  Courtesy of SUBARU OF AMERICA, INC.
4. Position the lower rail gap at 120° on counterclockwise of (C) that shown (G) in Fig 20 .
Fig 20: 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 21: Installing Snap Rings
Courtesy of SUBARU OF AMERICA, INC.

CAUTION: Piston front mark faces towards the front of engine.
- U5 model
  
  Fig 22: Locating Piston Mark - U5 Model
  Courtesy of SUBARU OF AMERICA, INC.
- Except for U5 model
Fig 23: Locating Piston Mark - Except U5 Model
Courtesy of SUBARU OF AMERICA, INC.

Fig 24: Identifying Components Piston
Courtesy of SUBARU OF AMERICA, INC.
Install the piston.
1. Place the cylinder block to face the #1 and #2 cylinder side upward.
2. Using 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 25: Inserting Pistons In Cylinders Using Special Tool
Courtesy of SUBARU OF AMERICA, INC.
Install the piston pin.
1. Apply a coat of engine oil to ST3.
2. Insert ST3 into the service hole to align piston pin hole with connecting rod small end.
  ST3 499017100 PISTON PIN GUIDE
  
  Fig 26: Inserting ST3 499017100 PISTON PIN GUIDE
  Courtesy of SUBARU OF AMERICA, INC.
3. Apply a coat of engine oil to piston pin, and insert the piston pin into piston and connecting rod through service hole.
4. Install the snap ring.
  NOTE: Use new snap rings.
  
  Fig 27: Installing Snap Ring
  Courtesy of SUBARU OF AMERICA, INC.
5. Apply liquid gasket around the service hole plug.
  Liquid gasket:
  
  THREE BOND 1215 (Part No. 004403007) or equivalent
  
  Fig 28: Applying Liquid Gasket
  Courtesy of SUBARU OF AMERICA, INC.
6. Install the service hole plug and gasket.
  NOTE: Use a new gasket.
  
  Fig 29: Installing Service Hole Plug
  Courtesy of SUBARU OF AMERICA, INC.
  
  Fig 30: Installing Components Piston
  Courtesy of SUBARU OF AMERICA, INC.
7. 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.

Fig 31: Installing Water Pipe
Courtesy of SUBARU OF AMERICA, INC.
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 32: Applying Liquid Gasket
Courtesy of SUBARU OF AMERICA, INC.
Apply liquid gasket to the mating surfaces and the threaded portion of a bolt (A) shown in Fig 33 , and then install the oil separator cover.
Liquid gasket:

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

Tightening torque:

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

Fig 33: Applying Liquid Gasket
Courtesy of SUBARU OF AMERICA, INC.
Install the flywheel. (MT model)
< Ref. to INSTALLATION , Flywheel.> To lock the crankshaft, use the ST.

ST 498497100 CRANKSHAFT STOPPER

Tightening torque:

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

Fig 34: Locking Crankshaft Using Special Tool
Courtesy of SUBARU OF AMERICA, INC.
Install the drive plate. (AT model) To lock the crankshaft, use the ST.
ST 498497100 CRANKSHAFT STOPPER

Tightening torque:

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

Fig 35: Locking Crankshaft Using Special Tool
Courtesy of SUBARU OF AMERICA, INC.
Install the housing cover.
Installation of oil pump:
1. Discard the front oil seal after removal. Replace with a new one using ST.
  ST 499587100 OIL SEAL INSTALLER
  
  Fig 36: Installing Oil Pump 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 37: Applying Liquid Gasket
  Courtesy of SUBARU OF AMERICA, INC.
3. Apply a coat of engine oil to the inside of oil seal.
  
  Fig 38: 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 a coat of liquid gasket to the threaded portion of 3 bolts.
Liquid gasket:

THREE BOND 1215 (Part No. 004403007) or equivalent

Tightening torque:

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

Fig 39: Applying Liquid Gasket To 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 bolts in two stages in alphabetical sequence as shown in Fig 40 .
Fig 40: Installing Bolts In Sequence
Courtesy of SUBARU OF AMERICA, INC.
Install the water by-pass pipe for heater.
Install the oil filter.
Tighten the cylinder head bolts.
1. Apply a coat of engine oil to washers and bolt threads.
2. Tighten all bolts to 29 N.m (3.0 kgf-m, 22 ft-lb) in alphabetical sequence. Then tighten all bolts to 69 N.m (7.0 kgf-m, 51 ft-lb) in alphabetical sequence.
3. Back off all bolts by 180° first; and back them off again by 180°.
4. Tighten the bolts (a) and (b) to 34 N.m (3.5 kgf-m, 25 ft-lb).
5. Tighten the bolts (c), (d), (e) and (f) to 15 N.m (1.5 kgf-m, 11 ft-lb).
6. Tighten all bolts by 80°- 90° in alphabetical sequence.
  CAUTION: Do not tighten the bolts more than 90°.
7. Further tighten all bolts by 80° - 90° in alphabetical sequence.
CAUTION: Ensure the total "re-tightening angle" of the step (6) and (7) does not exceed 180°.

Fig 41: Tightening Bolts
Courtesy of SUBARU OF AMERICA, INC.
Install the oil level gauge guide and tighten the bolt (LH side only).
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. >