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Home >> Subaru >> 2006 >> Baja Turbo, Automatic >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 7 (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 engine oil completely.
  1. Remove intake manifold. < Ref. to REMOVAL , INTAKE MANIFOLD. >
  2. Remove V-belt. < Ref. to REMOVAL , V-BELT. >
  3. Remove crankshaft pulley. < Ref. to REMOVAL , CRANKSHAFT PULLEY. >
  4. Remove timing belt cover. < Ref. to REMOVAL , TIMING BELT COVER. >
  5. Remove timing belt. < Ref. to REMOVAL , TIMING BELT. >
  6. Remove camshaft sprocket. < Ref. to REMOVAL , CAMSHAFT SPROCKET. >
  7. Remove crankshaft sprocket. < Ref. to REMOVAL , CRANKSHAFT PULLEY. >
  8. Remove generator and A/C compressor with their brackets.
  9. Remove rocker cover.
  10. Remove cylinder head bolts in alphabetical sequence shown in figure.
    NOTE: Leave bolts (a) and (b) engaged by three or four threads to prevent cylinder head from falling.
    Fig 1: Identifying Cylinder Head Bolts
    G04988358Courtesy of SUBARU OF AMERICA, INC.
  11. While tapping cylinder head with a plastic hammer, separate it from cylinder block.
  12. Remove bolts (a) and (c) to remove cylinder head.
    Fig 2: Identifying Cylinder Head Bolts
    G04988359Courtesy of SUBARU OF AMERICA, INC.
  13. Remove cylinder head gasket.
    NOTE: Do not scratch the mating surface of cylinder head and cylinder block.
  14. Similarly, remove right side cylinder head.
  15. Remove clutch housing cover (MT vehicles only).
  16. Remove flywheel (MT vehicles only) or drive plate (AT vehicles only).

    Using ST, lock crankshaft.

    ST 498497100 CRANKSHAFT STOPPER

    • MT model
      Fig 3: Locking Crankshaft Using Crankshaft Stopper ST (498497100) - MT Model
      G04997722Courtesy of SUBARU OF AMERICA, INC.
    • AT model
      Fig 4: Locking Crankshaft Using Crankshaft Stopper ST (498497100) - AT Model
      G04988361Courtesy of SUBARU OF AMERICA, INC.
  17. Remove oil separator cover.
  18. Remove water by-pass pipe for heater.
  19. Loosen bolts in alphabetical sequence as shown in figure and remove water pump.
    Fig 5: Identifying Water By-Pass Pipe Bolts
    G04988362Courtesy of SUBARU OF AMERICA, INC.
  20. Remove oil pump from cylinder block.

    Use a flat-bladed screwdriver as shown in figure when removing oil pump.

    NOTE: Be careful not to scratch the mating surface of cylinder block and oil pump.
    Fig 6: Identifying Oil Pump From Cylinder Block
    G04997726Courtesy of SUBARU OF AMERICA, INC.
  21. Removal of oil pan
    1. Turn cylinder block with #2 and #4 piston sides facing upward.
    2. Remove bolts which secure oil pan to cylinder block.
    3. Insert a oil pan cutter blade between cylinder block-to-oil pan clearance and remove oil pan.
      NOTE: Do not use a screwdriver or similar tool in place of oil pan cutter.
      Fig 7: Inserting Oil Pan Cutter Blade Between Cylinder Block-To-Oil Pan
      G04988364Courtesy of SUBARU OF AMERICA, INC.
  22. Remove oil strainer stay.
  23. Remove oil strainer.
  24. Remove baffle plate.
  25. Remove oil filter using ST.

    ST 498547000 OIL FILTER WRENCH [outer diameter 80 mm (3.15 in) for oil filter]

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

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

    Fig 8: Removing Oil Filter
    G04988365Courtesy of SUBARU OF AMERICA, INC.
  26. Remove water pipe.
    Fig 9: Identifying Water Pipe
    G04997728Courtesy of SUBARU OF AMERICA, INC.
    Fig 10: Identifying Cylinder Block Components
    G04988367Courtesy of SUBARU OF AMERICA, INC.
  27. Remove service hole cover and service hole plugs using hexagon wrench [14 mm (0.55 in)].
    Fig 11: Identifying Service Hole Cover And Plugs
    G04997730Courtesy of SUBARU OF AMERICA, INC.
  28. Rotate crankshaft to bring #1 and #2 pistons to bottom dead center position, then remove piston snap ring through service hole of #1 and #2 cylinders.
    Fig 12: Identifying Piston Snap Ring
    G04997731Courtesy of SUBARU OF AMERICA, INC.
  29. Draw out piston pin from #1 and #2 pistons using ST.

    ST 499097700 PISTON PIN REMOVER

    NOTE: Be careful not to confuse original combination of piston, piston pin and cylinder.
    Fig 13: Drawing Out Piston Pin From Pistons
    G04997732Courtesy of SUBARU OF AMERICA, INC.
  30. Similarly remove piston pins from #3 and #4 pistons.
  31. Remove bolts which connect cylinder block on the side of #2 and #4 cylinders.
  32. Loosen bolts which connect cylinder block on the side of #1 and #3 cylinders two or three turns.
  33. Set up cylinder block so that #1 and #3 cylinders are on the upper side, then remove cylinder block connecting bolts.
  34. Separate left-hand and right-hand cylinder blocks.
    CAUTION: When separating cylinder block, do not allow the connecting rod to fall and damage the cylinder block.
    Fig 14: Identifying Cylinder Block Components
    G04988371Courtesy of SUBARU OF AMERICA, INC.
  35. Remove rear oil seal.
  36. Remove crankshaft together with connecting rod.
  37. Remove crankshaft bearings from cylinder block using hammer handle.
    NOTE: Do not confuse combination of crankshaft bearings. Press bearing at the end opposite to locking lip.
  38. Remove pistons from cylinder block using hammer handle.
    NOTE: Do not confuse combination of pistons and cylinders.
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