Cylinder Block: Installation

WARNING: This page is about a different car, the 2006 Subaru Outback. However, it is still accessible from the selected car via links, so may be relevant.

After setting the cylinder block to ST, install the crankshaft bearing.
ST 18232AA000 ENGINE STAND

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 and connecting rod on #2, #4 and #6 cylinder block.
Apply liquid gasket to the mating surface of the #1, #3 and #5 cylinder blocks, and position it on #2, #4 and #6 cylinder blocks.
Liquid gasket:

Three bond 1215B (Part No. 004403007)

NOTE: Do not allow liquid gasket to run over to O-ring grooves, oil passages, bearing grooves, etc.

Applying liquid gasket diameter:

1.0±0.2 mm (0.039±0.008 in)

Fig 1: Applying Liquid Gasket Diameter
Apply a coat of engine oil to the washer and bolt thread.
Tighten all bolts in the numerical order as shown in the figure.
Tightening torque:

(1) - (11), (13):25 N.m (2.5 kgf-m, 18 ft-lb) (12), (14):20 N.m (2.0 kgf-m, 14 ft-lb)

Fig 2: Tightening Sequence Of Bolts
Retighten all bolts in the numerical order as shown in the figure.
Tightening torque:

(1) - (11), (13):25 N.m (2.5 kgf-m, 18.4 ft-lb) (12), (14):20 N.m (2.0 kgf-m, 14 ft-lb)

Fig 3: Tightening Sequence Of Bolts
Tighten all bolts 90° - 110° in the numerical order as shown in the figure.

Fig 4: Tightening Sequence Of Bolts
Install the upper bolt to cylinder block.
Tightening torque:

25 N.m (2.5 kgf-m, 18 ft-lb)

NOTE: Remove the liquid gasket which is running over to sealing surface between cylinder block and rear chain cover, cylinder block and oil pan upper, after tightening the bolts which combine the cylinder block.

Fig 5: Identifying Cylinder Block Bolts
Install the rear oil seal using ST1 and ST2.
ST1 499597100 CRANKSHAFT OIL SEAL GUIDE

ST2 499587200 CRANKSHAFT OIL SEAL INSTALLER

NOTE: Apply engine oil to the pressing-in portion.

Fig 6: Applying Engine Oil To Pressing-In Portion
Position the top ring gap at (A) in the figure.
Position the second ring gap at (B).

Fig 7: Identifying Second Ring
Position the upper rail gap at (C) in the figure.
Position the expander gap at (D) in the figure.
Position the lower rail gap at (E) in the figure.

Fig 8: Identifying Lower Rail
CAUTION:
- Make sure ring gaps do not face the same direction.
- Make sure ring gaps are not within the piston skirt area.
- Assemble it so that R mark faces to top side of piston.
Install the snap ring.
Install the snap rings in the piston holes located opposite to the service holes in cylinder block when positioning all pistons in corresponding cylinders.

NOTE: Use new snap rings.

Fig 9: Locating Snap Rings
Installing piston:
1. Using the ST1, turn the crankshaft so that #3 and #4 connecting rod small ends are set on the service hole (A).
  ST1 18252AA000 CRANKSHAFT SOCKET
  
  Fig 10: Identifying Service Hole
2. Apply a thin coat of engine oil to piston and cylinder.
3. Using the ST2, press-fit the piston into cylinder.
  ST2 18254AA000 PISTON GUIDE
  
  Fig 11: Pressing Piston Into Cylinder
  
  NOTE: Let the piston front mark (A) face towards the front of engine.
  
  Fig 12: Identifying Piston Front Mark
Installing piston pin:
1. Apply a thin coat of engine oil to ST3 before insertion, and then insert it into the service hole to align piston pin hole with connecting rod small end.
  ST3 18253AA000 PISTON GUIDE
  
  Fig 13: Identifying ST3 18253Aa000 Piston Guide
2. Apply a thin coat of engine oil to piston pin, and insert the piston pin into piston and connecting rod through service hole.
3. Using the ST4, install the snap ring.
  ST4 18233AA000 PISTON PIN SNAP RING PLIERS
  
  NOTE: Use new snap rings.
  
  Fig 14: Identifying Snap Rings
4. Similarly install the #1, #2, #5 and #6 pistons.
Install the service hole plug and O-ring.
NOTE: Use new O-rings.
Apply liquid gasket to the mating surface of oil pan upper.
Liquid gasket:

THREE BOND 1280B (Part No. K0877YA018)

Applying liquid gasket diameter:

Full line part

3.0±1.0 mm (0.12±0.04 in)

Broken line part

1.0 mm (0.04 in)

Fig 15: Applying Liquid Gasket To Mating Surface Of Oil Pan Upper

NOTE: Use new O-rings.
Temporarily tighten the oil pan upper.
NOTE: Do not install the bolts in wrong place.

Fig 16: Locating Oil Pan Upper Bolts
Tighten the oil pan upper installing bolts in the numerical order as shown in the figure.
Tightening torque:

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

Fig 17: Locating Oil Pan Upper Bolts
Install the oil strainer.
Tightening torque:

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

NOTE: Use new O-rings.

Fig 18: Identifying O-Rings
Apply liquid gasket to the matching surface of oil pan lower.
Liquid gasket:

THREE BOND 1280B (Part No. K0877YA018)

Applying liquid gasket diameter:

5.0±1.0 mm (0.20±0.04 in)

Fig 19: Applying Liquid Gasket To Matching Surface Of Oil Pan Lower
Tighten the oil pan lower installing bolts in the numerical order as shown in the figure.
Tightening torque:

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

Fig 20: Locating Oil Pan Lower Bolts
Install the crankshaft sensor bracket.
Tightening torque:

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

Fig 21: Identifying Crankshaft Sensor Bracket
Install the crankshaft sensor plate.

Fig 22: Locating Crankshaft Sensor Plate
Install the drive plate.
To lock the crankshaft, use ST.

ST 498497100 CRANKSHAFT STOPPER

Tightening torque:

81 N.m (8.3 kgf-m, 60 ft-lb)

Fig 23: Identifying Drive Plate
Install the cylinder head. < Ref. to INSTALLATION , Cylinder Head. >
Install the camshaft. < Ref. to INSTALLATION , Camshaft. >
Install the rear chain cover. < Ref. to INSTALLATION , Rear Chain Cover. >
Install the crank sprocket.
< Ref. to INSTALLATION , Crank Sprocket. >
Install the cam sprocket. < Ref. to INSTALLATION , Cam Sprocket. >
Install the timing chain assembly.
< Ref. to INSTALLATION , Timing Chain Assembly. >
Install the front chain cover.
< Ref. to INSTALLATION , Front Chain Cover. >
Install the crank pulley.
< Ref. to INSTALLATION , Crank Pulley. >