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Home >> Subaru >> 2005 >> Outback R VDC Limited >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 4 (Engine Mechanical (H4SO)) >> Cylinder Block >> Removal

Cylinder Block: Removal

WARNING: This page is about a different variant/trim than selected.
NOTE: Before conducting this procedure, drain the 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 Pulley. >
  8. Remove the generator and A/C compressor with their brackets.
  9. Remove the rocker cover.
  10. Remove the cylinder head bolts in alphabetical sequence as shown in Fig 1 .
    NOTE: Leave bolts (a) and (c) engaged by three or four threads to prevent the cylinder head from falling.
    Fig 1: Removing Bolts In Sequence
    G03828047Courtesy of SUBARU OF AMERICA, INC.
  11. While tapping the cylinder head with a plastic hammer, separate it from cylinder block.
  12. Remove the bolts (a) and (c) to remove the cylinder head.
    Fig 2: Removing Bolts In Sequence
    G03828048Courtesy of SUBARU OF AMERICA, INC.
  13. Remove the cylinder head gasket.
    NOTE: Do not scratch the mating surface of cylinder head and cylinder block.
  14. Similarly, remove the right side cylinder head.
  15. Remove the clutch housing cover. (MT model)
  16. Remove the flywheel (MT model) or drive plate (AT model).

    Lock the crankshaft using ST.

    ST 498497100 CRANKSHAFT STOPPER

    • MT model
      Fig 3: Locking Crankshaft Using Special Tool - MT Model
      G03828049Courtesy of SUBARU OF AMERICA, INC.
    • AT model
    Fig 4: Locking Crankshaft Using Special Tool - AT Model
    G03828050Courtesy of SUBARU OF AMERICA, INC.
  17. Remove the oil separator cover.
  18. Remove the water by-pass pipe for heater.
  19. Remove the water pump.
  20. Remove the bolts which secure oil pump to cylinder block.
  21. Remove the oil pump from cylinder block. Use a flat tip screwdriver as shown in Fig 5 when removing the oil pump.
    CAUTION: Be careful not to scratch the mating surface of cylinder block and oil pump.
    Fig 5: Removing Oil Pump From Cylinder Block Using Flat Tip Screwdriver
    G03828051Courtesy of SUBARU OF AMERICA, INC.
  22. Remove the oil pan.
    1. Place the cylinder block to face the #2 and #4 piston 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.
  23. Remove the oil strainer stay.
  24. Remove the oil strainer.
  25. Remove the baffle plate.
  26. Remove the oil filter.
    Fig 6: Removing Oil Filter
    G03828052Courtesy of SUBARU OF AMERICA, INC.
  27. Remove the water pipe.
    Fig 7: Removing Water Pipe
    G03828053Courtesy of SUBARU OF AMERICA, INC.
    Fig 8: Identifying Components Cylinder Head
    G03828054Courtesy of SUBARU OF AMERICA, INC.
  28. Remove the service hole cover and service hole plugs using a hexagon wrench [14 mm (0.55 in)].
    Fig 9: Removing Service Hole Cover And Service Hole Plugs Using Hexagon Wrench
    G03828055Courtesy of SUBARU OF AMERICA, INC.
  29. 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.
    NOTE: Be careful not to confuse the original combination of piston, piston pin and cylinder.
    Fig 10: Removing Piston Snap Ring
    G03828056Courtesy of SUBARU OF AMERICA, INC.
  30. Draw out the piston pin from #1 and #2 pistons using ST.

    ST 499097700 PISTON PIN REMOVER

    Fig 11: Removing Piston Pin Using ST 499097700 Piston Pin Remover
    G03828057Courtesy of SUBARU OF AMERICA, INC.
  31. Similarly remove the piston pins from #3 and #4 pistons.
  32. Remove the bolts which connect cylinder block on the side of #2 and #4 cylinders.
  33. Back off the bolts which connect cylinder block on the side of #1 and #3 cylinders two or three turns.
  34. Set up the cylinder block so that #1 and #3 cylinders are on the upper side, then remove the cylinder block connecting bolts.
  35. Separate the cylinder block (RH) and (LH).
    NOTE: When separating the cylinder block, do not allow the connecting rod to fall or damage the cylinder block.
    Fig 12: Removing Components Cylinder Block
    G03828058Courtesy of SUBARU OF AMERICA, INC.
  36. Remove the rear oil seal.
  37. Remove the crankshaft together with connecting rod.
  38. Remove the crankshaft bearings from cylinder block using a hammer handle.
    NOTE: Be careful not to confuse the crankshaft bearing combination. Press the bearing at the end opposite to locking lip.
  39. 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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