Cylinder Block: Installation

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

Fig 1: Identifying Cylinder Block Components

Courtesy of SUBARU OF AMERICA, INC.

NOTE: Remove oil in the mating surface of bearing and cylinder block before installation. Also apply a coat of engine oil to crankshaft pins.

Position crankshaft on the #2 and #4 cylinder block.
Apply fluid packing to the mating surface of #1 and #3 cylinder block, and position it on #2 and #4 cylinder block.
Fluid packing:

Part number 004403007

THREE BOND 1215 or equivalent
CAUTION:
- Do not allow fluid packing to jut into O-ring grooves, oil passages, bearing grooves, etc.
- Use a new O-ring.
  
  Fig 2: Applying Liquid Gasket To Cylinder Block
  Courtesy of SUBARU OF AMERICA, INC.
Coat the washers and threaded parts of the bolts with engine oil.
Tighten 10 mm cylinder block connecting bolts in alphabetical sequence shown in Fig 3. (LH side)
Tightening torque:

10 N.m (1.0 kgf-m, 7.4 ft-lb)

Fig 3: Identifying Cylinder Block Connecting Bolt In Alphabetical Sequence
Courtesy of SUBARU OF AMERICA, INC.
Tighten 10 mm cylinder block connecting bolts in alphabetical sequence shown in figure. (RH side)
Tightening torque:

10 N.m (1.0 kgf-m, 7.4 ft-lb)

Fig 4: Identifying Cylinder Block Connecting Bolts Tightening Sequence In Alphabetical Order
Courtesy of SUBARU OF AMERICA, INC.
Tighten bolts (A to D) on left side of cylinder block more in alphabetical sequence.
Tightening torque:

18 N.m (1.8 kgf-m, 13.3 ft-lb)

Fig 5: Identifying Cylinder Block Connecting Bolt Alphabetical Sequence
Courtesy of SUBARU OF AMERICA, INC.
Tighten bolts (E to J) on right side of cylinder block more in alphabetical sequence.
Tightening torque:

18 N.m (1.8 kgf-m, 13.3 ft-lb)

Fig 6: Identifying RH Cylinder Block Connecting Bolts In Alphabetical Sequence (E to J)
Courtesy of SUBARU OF AMERICA, INC.
Further tighten the LH side bolts (A to D) in alphabetical sequence. Further tighten the bolts (A and C) by 90°. Further tighten the bolts (B and D) to 40 N.m (4.1 kgf-m, 29.5 ft-lb).

Fig 7: Identifying LH Cylinder Block Connecting Bolts In Alphabetical Sequence (A to D)
Courtesy of SUBARU OF AMERICA, INC.
Tighten bolts (E to J) on right side of cylinder block 90° more in alphabetical sequence.

Fig 8: Identifying RH Cylinder Block Connecting Bolts In Alphabetical Sequence (E to J)
Courtesy of SUBARU OF AMERICA, INC.
Tighten 8 mm and 6 mm cylinder block connecting bolts in alphabetical sequence shown in figure.
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: Identifying Cylinder Block Connecting Bolts In Alphabetical Sequence
Courtesy of SUBARU OF AMERICA, INC.
Install rear oil seal using ST1 and ST2.
ST1 499597100 OIL SEAL GUIDE

ST2 499587200 OIL SEAL INSTALLER

Fig 10: Identifying Rear Oil Seal
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 for the top ring gap.

Fig 11: Identifying Top Ring Gap Direction
Courtesy of SUBARU OF AMERICA, INC.
Position the expander gap at (C) in the figure.

Fig 12: Identifying Expander Gap Direction
Courtesy of SUBARU OF AMERICA, INC.
Position the lower rail gap at (D) in the figure.

Fig 13: Identifying Lower Rail Gap Direction
Courtesy of SUBARU OF AMERICA, INC.

NOTE: Align lower rail spin stopper (F) with piston side surface hole (E).

Fig 14: Aligning Lower Rail Spin Stopper
Courtesy of SUBARU OF AMERICA, INC.
Position the upper rail gap at (G) in the figure.

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

CAUTION: Use new snap rings.

Fig 16: Identifying Snap Ring And Piston
Courtesy of SUBARU OF AMERICA, INC.

CAUTION: Piston front mark (A) faces towards the front of the engine.

Fig 17: Identifying Piston Front Mark
Courtesy of SUBARU OF AMERICA, INC.

Fig 18: Cylinder Block Replacement Components With Torque Specifications
Courtesy of SUBARU OF AMERICA, INC.
Installing piston
1. Turn cylinder block so that #1 and #2 cylinders face upward.
2. Using ST1, turn 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 pistons and cylinders and insert pistons in their cylinders using ST2.
  ST2 498747300 PISTON GUIDE
  
  Fig 19: Inserting Pistons In Cylinders Using Piston Guide ST2 498747300
  Courtesy of SUBARU OF AMERICA, INC.
Installing piston pin
1. Apply a coat of engine oil to ST3.
2. Insert ST3 into service hole to align piston pin hole with connecting rod small end.
  ST3 499017100 PISTON PIN GUIDE
  
  Fig 20: Inserting ST3 Into Service Hole To Align Piston Pin Hole With Connecting Rod Small End
  Courtesy of SUBARU OF AMERICA, INC.
3. Apply a coat of engine oil to piston pin and insert piston pin into piston and connecting rod through service hole.
4. Install snap ring.
  CAUTION: Use new snap rings.
  
  Fig 21: Identifying Snap Ring
  Courtesy of SUBARU OF AMERICA, INC.
5. Apply fluid packing around the service hole plug.
  Fluid packing:
  
  Part number 004403007
  
  THREE BOND 1215 or equivalent
  
  Fig 22: Applying Fluid Packing Around Service Hole Plug
  Courtesy of SUBARU OF AMERICA, INC.
6. Install service hole plug and gasket.
  CAUTION: Use a new gasket.
  
  Fig 23: Identifying Service Hole Plug
  Courtesy of SUBARU OF AMERICA, INC.
  
  Fig 24: Cylinder Block Replacement Components With Torque Specifications
  Courtesy of SUBARU OF AMERICA, INC.
7. Turn cylinder block so that #3 and #4 cylinders face upward. Using the same procedures as used for #1 and #2 cylinders, install pistons and piston pins.
Install water pipe.
Tightening torque:

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

Fig 25: Identifying Water Pipe
Courtesy of SUBARU OF AMERICA, INC.
Install baffle plate.
Tightening torque:

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

10 N.m (1.0 kgf-m, 7 ft-lb)
Install oil strainer stay.
Apply fluid packing to matching surfaces and install oil pan.
Fluid packing:

Part number 004403012

THREE BOND 1207C or equivalent

Fig 26: Applying Liquid Gasket To Mating Surfaces Of Oil Pan
Courtesy of SUBARU OF AMERICA, INC.
Apply fluid packing to matching surfaces and the bolt thread (A) as shown in the figure, and install oil separator cover.
Tightening torque:

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

Fluid packing (Contact surface):

Part number 004403012

THREE BOND 1207C or equivalent

Fluid packing (Thread):

Part number 004403042

THREE BOND 1324 or equivalent

Fig 27: Applying Liquid Gasket To Mating Surfaces And Threaded Portion Of Bolt (A)
Courtesy of SUBARU OF AMERICA, INC.
Install flywheel or drive plate.
To lock crankshaft, use ST.

ST 498497100 CRANKSHAFT STOPPER

Tightening torque:

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

Fig 28: Locking Crankshaft Using Crankshaft Stopper ST (498497100) - MT Model
Courtesy of SUBARU OF AMERICA, INC.

Fig 29: Locking Crankshaft Using Crankshaft Stopper ST (498497100) - AT Model
Courtesy of SUBARU OF AMERICA, INC.
Install housing cover.
Installation of oil pump
1. Discard front oil seal after removal. Replace with a new one using ST.
  ST 499587100 OIL SEAL INSTALLER
  
  Fig 30: Installing Front Oil Seal Using Oil Seal Installer ST 499587100
  Courtesy of SUBARU OF AMERICA, INC.
2. Apply fluid packing to matching surface of oil pump.
  CAUTION: Use a new O-ring.
  
  Fluid packing:
  
  Part number 004403007
  
  THREE BOND 1215 or equivalent
  
  Fig 31: Applying Fluid Packing To Matching Surface Of Oil Pump
  Courtesy of SUBARU OF AMERICA, INC.
3. Apply a coat of engine oil to the inside of the oil seal.
  
  Fig 32: Applying Coat Of Engine Oil To Inside Of Oil Seal
  Courtesy of SUBARU OF AMERICA, INC.
4. Install oil pump on cylinder block. Be careful not to damage oil seal during installation.
5. Position oil pump, and align the cutout surface with crankshaft, push oil pump straight.
  CAUTION:
  - Do not fold the oil seal lip.
  - Never fail to install O-ring and seal when installing oil pump.
6. Install oil pump.
7. Apply fluid packing to the threads of three bolts.
  Fluid packing:
  
  Part number 004403042
  
  THREE BOND 1324 or equivalent
  
  Tightening torque:
  
  6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
  
  Fig 33: Applying Liquid Gasket To Oil Pump Bolts
  Courtesy of SUBARU OF AMERICA, INC.
Install water pump and gasket.
Tightening torque:

First; 12 N.m (1.2 kgf-m, 8.7 ft-lb)

Second; 12 N.m (1.2 kgf-m, 8.7 ft-lb)
CAUTION:
- Be sure to use a new gasket.
- When installing water pump, tighten bolts in two stages in alphabetical sequence as shown in figure.
  
  Fig 34: Identifying Water Pump Bolts
  Courtesy of SUBARU OF AMERICA, INC.
Install water by-pass pipe for heater.
Prepare oil filter and apply a thin coat of engine oil to the seal rubber.
Using the ST, install the oil filter.
ST 498547000 OIL FILTER WRENCH [for oil filter with 80 mm (3.15 in) outer diameter]

ST 18332AA000 OIL FILTER WRENCH [for oil filter with 68 mm (2.68 in) outer diameter]

ST 18332AA010 OIL FILTER WRENCH [for oil filter with 65 mm (2.56 in) outer diameter]

Install oil filter by turning it by hand, being careful not to damage seal rubber.
- Further tighten (approximately 2/3 to 3/4 turn) with ST the oil filter with outer diameter of 80 mm (3.15 in) or 65 mm (2.56 in) after the seal rubber contacts the cylinder block.
- Further tighten (approximately 1 turn) with ST the oil filter with outer diameter of 68 mm (2.68 in) after the seal rubber contacts the cylinder block.
CAUTION: Do not tighten excessively, or oil may leak.

Fig 35: Tightening Oil Filter
Courtesy of SUBARU OF AMERICA, INC.
Tighten cylinder head bolts.
1. Apply a thin 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° with reversing order of assembly and after that back them off by 180° again.
4. Tighten all bolts to 42 N.m (4.3 kgf-m, 31 ft-lb).
5. Tighten all bolts by 80 to 90° in alphabetical sequence.
6. Tighten all bolts by 40 to 45° in alphabetical sequence.
  CAUTION: Make sure that the tightening angle of bolt does not exceed 45°.
7. Further tighten bolts (a) and (b) by 40 to 45°.
  CAUTION: Ensure that the total "re-tightening angle" [in the steps 6 and 7], do not exceed 90°.
  
  Fig 36: Identifying Cylinder Head Bolts
  Courtesy of SUBARU OF AMERICA, INC.
Install oil level gauge guide and tighten attaching bolt (left side only).
Install rocker cover.
Install crankshaft sprocket. < Ref. to INSTALLATION , CRANKSHAFT SPROCKET. >
Install camshaft sprocket. < Ref. to INSTALLATION , CAMSHAFT SPROCKET. >
Install timing belt. < Ref. to INSTALLATION , Timing Belt. >
Install timing belt cover. < Ref. to INSTALLATION , TIMING BELT COVER. >
Install crankshaft pulley. < Ref. to INSTALLATION , CRANKSHAFT PULLEY. >
Install generator and A/C compressor brackets on cylinder head.
Install V-belt. < Ref. to INSTALLATION , V-BELT. >
Install intake manifold. < Ref. to INSTALLATION , INTAKE MANIFOLD. >