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Cylinder Block: Removal

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.
NOTE: Before conducting this procedure, drain the engine oil completely.
  1. Remove the crank pulley. < Ref. to REMOVAL , Crank Pulley. >
  2. Remove the front chain cover. < Ref. to REMOVAL , Front Chain Cover. >
  3. Remove the timing chain assembly.

    < Ref. to REMOVAL , Timing Chain Assembly. >

  4. Remove the cam sprocket.

    < Ref. to REMOVAL , Cam Sprocket. >

  5. Remove the crank sprocket.

    < Ref. to REMOVAL , Crank Sprocket. >

  6. Remove the rear chain cover.

    < Ref. to REMOVAL , Rear Chain Cover. >

  7. Remove the camshaft. < Ref. to REMOVAL , Camshaft. >
  8. Remove the cylinder head. < Ref. to REMOVAL , Cylinder Head. >
  9. Remove the drive plate.

    Using the ST, lock the crankshaft.

    ST 498497100 CRANKSHAFT STOPPER

    Fig 1: Identifying ST 498497100 Crankshaft Stopper
    G05018774
  10. Remove the crankshaft position sensor plate.
    Fig 2: Identifying Crankshaft Position Sensor Plate
    G05018775
  11. Remove the crankshaft position sensor bracket.
    Fig 3: Identifying Crankshaft Position Sensor Bracket
    G05018776
  12. Rotate the engine to set oil pan upper.
  13. Remove the bolts which secure oil pan lower to oil pan upper.
    Fig 4: Identifying Oil Pan
    G05018777
  14. Insert an oil pan cutter blade between cylinder block-to-oil pan clearance and remove the oil pan.
    CAUTION: Do not use a screwdriver or similar tools in place of oil pan cutter.
  15. Remove the oil strainer.
    Fig 5: Identifying Oil Strainer
    G05018936
  16. Remove the bolts which install oil pan upper onto cylinder block.
    NOTE: Installation bolt has five different sizes. To prevent the confusion in installation, keep these bolts on container individually.
    Fig 6: Identifying Oil Pan Bolts
    G05018779
  17. Remove the service hole cover and service hole plugs using a hexagon wrench.
    Fig 7: Locating Service Hole Cover And Service Hole Plugs
    G05018780
  18. Rotate the crankshaft to bring #1 and #2 pistons to bottom dead center position, then, using the ST, remove the piston snap ring through service hole of #1 and #2 cylinders.

    ST 18233AA000 PISTON PIN SNAP RING PLIERS

    Fig 8: Removing Piston Snap Ring Through Service Hole
    G05018781
  19. Draw out the piston pin from #1 and #2 pistons using ST.

    ST 499097500 PISTON PIN REMOVER

    NOTE: Be careful not to confuse the original combination of piston, piston pin and cylinder.
    Fig 9: Drawing Out Piston Pin From Pistons Using ST
    G05018782
  20. Similarly remove the piston pins from #3, #4, #5, and #6 pistons.
  21. Remove the bolts which secure cylinder block.
    Fig 10: Identifying Cylinder Block Bolts
    G05018783
  22. Separate the cylinder block (LH) and (RH).
    NOTE: When separating the cylinder block, do not allow the connecting rod to fall and damage the cylinder block.
  23. Remove the rear oil seal.
  24. Remove the crankshaft together with connecting rod.
  25. Remove the crankshaft bearings from cylinder block using a hammer handle.
    NOTE:
    • Do not confuse the combination of crankshaft bearings.
    • Press the bearing at the end opposite to locking lip.
  26. Draw out each piston from cylinder block using wooden bar or hammer handle.
    NOTE: Be careful not to confuse the original combination of piston and cylinder.
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