Cylinder Block: Installation

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Fig 1: Identifying Cylinder Block, Crankshaft Bearing, Rear Oil Seal And Related Components

G08563564

Courtesy of SUBARU OF AMERICA, INC.

Remove oil on the mating surface of cylinder block before installation. Apply a coat of engine oil to the bearing and crankshaft journal.
Position the crankshaft and O-ring on cylinder block RH.
NOTE: Use new O-rings.
Apply liquid gasket to the mating surfaces of cylinder block RH, and position cylinder block LH.
NOTE:
- Install within 5 min. after applying liquid gasket.
- Do not allow liquid gasket to jut into O-ring grooves, oil passages, bearing grooves, etc.
Liquid gasket:

THREE BOND 1217G (Part No. K0877Y0100) or equivalent

Fig 2: Applying Liquid Gasket To Cylinder Block
Courtesy of SUBARU OF AMERICA, INC.
Apply a coat of engine oil to the washer and bolt thread.
NOTE: Use a new seal washer.
Tighten the 10 mm cylinder block connecting bolts on the LH side (A - D) in alphabetical order.
Tightening torque:

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

Fig 3: Identifying Cylinder Block Bolts Tightening Sequence (LH Side)
Courtesy of SUBARU OF AMERICA, INC.
Tighten the 10 mm cylinder block connecting bolts on the RH side (E - J) in alphabetical order.
Tightening torque:

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

Fig 4: Identifying Cylinder Block Bolts Tightening Sequence (RH Side)
Courtesy of SUBARU OF AMERICA, INC.
Tighten the LH side cylinder block connecting bolts (A - D) further in alphabetical order.
Tightening torque:

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

Fig 5: Identifying Cylinder Block Bolts Tightening Sequence (LH Side)
Courtesy of SUBARU OF AMERICA, INC.
Tighten the RH side cylinder block connecting bolts (E - J) further in alphabetical order.
Tightening torque:

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

Fig 6: Identifying Cylinder Block Bolts Tightening Sequence (RH Side)
Courtesy of SUBARU OF AMERICA, INC.
Tighten the LH side cylinder block connecting bolts (A - D) further in alphabetical order.
- (A), (C): Angle tightening
  Tightening angle:
  
  90°
- (B), (D): Torque tightening
  Tightening torque:
  
  40 N.m (4.1 kgf-m, 29.5 ft-lb)
  
  Fig 7: Identifying Cylinder Block Bolts Tightening Sequence (LH Side)
  Courtesy of SUBARU OF AMERICA, INC.
Tighten the RH side cylinder block connecting bolts (E - J) further in alphabetical order.
Tightening angle:

90°

Fig 8: Identifying Cylinder Block Bolts Tightening Sequence (RH Side)
Courtesy of SUBARU OF AMERICA, INC.
Tighten the 8 mm and 6 mm cylinder block connecting bolts on the LH side (A - H) in alphabetical order.
Tightening torque:

(A) - (G): 25 N.m (2.5 kgf-m, 18.4 ft-lb)

(H): 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)

Fig 9: Identifying Cylinder Block Bolts Tightening Sequence (LH Side)
Courtesy of SUBARU OF AMERICA, INC.
Apply a coat of engine oil to the oil seal inner periphery and outer periphery, and install the rear oil seal using ST1 and ST2.
NOTE: Use a new rear oil seal.

ST1 499597100 CRANKSHAFT OIL SEAL GUIDE

ST2 499587200 CRANKSHAFT OIL SEAL INSTALLER

Fig 10: Installing Rear Oil Seal Using ST1 And ST2
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 the top ring gap.

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

Fig 12: Identifying Upper Rail Gap Position
Courtesy of SUBARU OF AMERICA, INC.
Align the upper rail spin stopper (E) to the side hole (D) on the piston.

Fig 13: Aligning Upper Rail Spin Stopper With Piston Side Surface Hole
Courtesy of SUBARU OF AMERICA, INC.
Position the expander gap at (F) in the figure on the 180° opposite direction of (C).

Fig 14: Identifying Expander Gap Position
Courtesy of SUBARU OF AMERICA, INC.
Set the lower rail gap at position (G), located 120° clockwise from (C) in the figure.

Fig 15: Identifying Lower Rail Gap Position
Courtesy of SUBARU OF AMERICA, INC.
NOTE:
- Make sure ring gaps do not face the same direction.
- Make sure ring gaps are not within the piston skirt area.
Install the snap ring.
Before positioning the piston on the cylinder block, attach the snap ring in the service hole of the cylinder block, and the piston hole on the opposite side.

NOTE: Use new snap rings.

Fig 16: Identifying Snap Ring Installing Positions
Courtesy of SUBARU OF AMERICA, INC.

Fig 17: Identifying Piston, Gasket, Piston Pin, Service Hole Plug And Snap Ring
Courtesy of SUBARU OF AMERICA, INC.

Tightening torque: N.m (kgf-m, ft-lb)

T: 70 (7.1, 51.6)
Install the piston.
1. Set the parts so that the #1 and #2 cylinders are on the upper side.
2. Using the ST1, turn the 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 the pistons and cylinders and insert pistons in their cylinders using ST2.
  ST2 498747300 PISTON GUIDE
  
  Fig 18: Inserting Piston In Cylinder Using Piston Guide
  Courtesy of SUBARU OF AMERICA, INC.
  
  NOTE: Face the piston front mark towards the front of the engine.
  
  Fig 19: Identifying Piston Front Mark
  Courtesy of SUBARU OF AMERICA, INC.
Install the piston pin.
1. Apply a coat of engine oil to ST3.
2. Insert ST3 into the service hole to align the piston pin hole and the connecting rod small end.
  ST3 499017100 PISTON PIN GUIDE
  
  Fig 20: Installing Piston Pin
  Courtesy of SUBARU OF AMERICA, INC.
3. Apply a thin coat of engine oil to piston pin, and insert the piston pin into piston and connecting rod through service hole.
4. Install the snap ring.
  NOTE: Use new snap rings.
  
  Fig 21: Installing Snap Ring
  Courtesy of SUBARU OF AMERICA, INC.
5. Apply liquid gasket to the threaded portion of the service hole plug.
  Liquid gasket:
  
  THREE BOND 1105 (Part No. 004403010) or equivalent
  
  Fig 22: Applying Liquid Gasket To Threaded Portion Of Service Hole Plug
  Courtesy of SUBARU OF AMERICA, INC.
6. Install the service hole plug and gasket.
  NOTE: Use a new gasket.
  
  Tightening torque:
  
  70 N.m (7.1 kgf-m, 51.6 ft-lb)
  
  Fig 23: Removing/Installing Service Hole Plug Using Hexagon Wrench
  Courtesy of SUBARU OF AMERICA, INC.
  
  Fig 24: Identifying Piston, Pin, Snap Ring, Gasket And Related Components
  Courtesy of SUBARU OF AMERICA, INC.
  
  Tightening torque: N.m (kgf-m, ft-lb)
  
  T1: 6.4 (0.7, 4.7)
  
  T2: 70 (7.1, 51.6)
7. Set the parts so that the #3 and #4 cylinders are on the upper side. Following the same procedures as used for #1 and #2 cylinders, install the pistons and piston pins.
8. Install the service hole cover.
NOTE: Use new O-rings.

Tightening torque:

6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
Install the water tank pipe assembly onto the cylinder block RH.
NOTE: Use a new clamp for the water tank pipe assembly clamp, fit the cut out in the ST with the protrusion on the clamp as shown in the figure, and lock the clamp.

ST 18353AA000 CLAMP PLIERS

Fig 25: Removing/Installing Hose Clamp Using ST
Courtesy of SUBARU OF AMERICA, INC.
Install the baffle plate.
Tightening torque:

6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
Install the oil strainer.
NOTE: Use new O-rings.

Tightening torque:

10 N.m (1.0 kgf-m, 7.4 ft-lb)
Tighten the oil strainer stay together with the baffle plate.
Tightening torque:

6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
Apply liquid gasket to the mating surfaces of oil pan, and install the oil pan.
NOTE: Install within 5 min. after applying liquid gasket.

Liquid gasket:

THREE BOND 1217G (Part No. K0877Y0100) or equivalent

Tightening torque:

5 N.m (0.5 kgf-m, 3.7 ft-lb)

Fig 26: Identifying Liquid Gasket Applying Area On Mating Surfaces Of Oil Pan
Courtesy of SUBARU OF AMERICA, INC.
Apply liquid gasket to the mating surface of oil separator cover and the threaded portion of bolt (A) shown in the figure (when reusing the bolt), and then install the oil separator cover.
NOTE:
- Install within 5 min. after applying liquid gasket.
- Use new oil separator cover.
Liquid gasket:

Mating surface

THREE BOND 1217G (Part No.

K0877Y0100) or equivalent

Bolt thread (A) (when reusing the bolt)

THREE BOND 1324 (Part No. 004403042) or equivalent

Tightening torque:

6.4 N.m (0.7 kgf-m, 4.7 ft-lb)

Fig 27: Identifying Liquid Gasket Applying Area On Mating Surface Of Oil Separator Cover
Courtesy of SUBARU OF AMERICA, INC.
Install the drive plate. < Refer to INSTALLATION , Drive Plate. >
Install the oil pump.
1. Using the ST, install the front oil seal.
  ST 499587100 OIL SEAL INSTALLER
  
  NOTE: Use a new front oil seal.
  
  Fig 28: Installing Front Oil Seal Using Oil Seal Installer
  Courtesy of SUBARU OF AMERICA, INC.
2. Apply liquid gasket to the mating surfaces of oil pump.
  NOTE: Install within 5 min. after applying liquid gasket.
  
  Liquid gasket:
  
  THREE BOND 1217G (Part No. K0877Y0100) or equivalent
  
  Fig 29: Identifying Liquid Gasket Applying Area On Mating Surfaces Of Oil Pump
  Courtesy of SUBARU OF AMERICA, INC.
3. Apply a thin coat of engine oil to the inside of front oil seal.
  
  Fig 30: Identifying Engine Oil Thin Coat Applying Area Inside Front Oil Seal
  Courtesy of SUBARU OF AMERICA, INC.
4. Install the oil pump to cylinder block.
  CAUTION:
  - Be careful not to damage the front oil seal during installation.
  - Make sure the front oil seal lip is not folded.
  NOTE:
  - Align the flat surface of oil pump's inner rotor with that of crankshaft before installation.
  - Use new O-rings.
  - Do not forget to assemble O-rings.
5. Apply liquid gasket to the three bolts thread shown in figure. (when reusing bolts)
  Liquid gasket:
  
  THREE BOND 1324 (Part No. 004403042) or equivalent
  
  Tightening torque:
  
  6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
  
  Fig 31: Identifying Liquid Gasket Applying Area On Bolts Threaded End
  Courtesy of SUBARU OF AMERICA, INC.
Install the water pump and gasket.
NOTE:
- When installing the water pump, tighten bolts in two stages in alphabetical order as shown in the figure.
- Use a new gasket.
Tightening torque:

First:

12 N.m (1.2 kgf-m, 8.9 ft-lb)

Second:

12 N.m (1.2 kgf-m, 8.9 ft-lb)

Fig 32: Identifying Tightening Sequence Of Water Pump Mounting Bolts
Courtesy of SUBARU OF AMERICA, INC.
Install the water by-pass pipe for heater.
Tightening torque:

6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
Install the oil filter. < Refer to INSTALLATION , Engine Oil Filter. >
Install the cylinder head. < Refer to INSTALLATION , Cylinder Head. >
Install the camshaft. < Refer to INSTALLATION , Camshaft. >
Install the generator and A/C compressor with their brackets.
Tightening torque:

36 N.m (3.7 kgf-m, 26.6 ft-lb)
Install the crank sprocket. < Refer to INSTALLATION , Crank Sprocket. >
Install the cam sprocket. < Refer to INSTALLATION , Cam Sprocket. >
Install the timing belt. < Refer to INSTALLATION , Timing Belt. >
Adjust the valve clearance. < Refer to ADJUSTMENT , Valve Clearance. >
Install the rocker cover.
1. Install the rocker cover gasket to the rocker cover. (outer section and ignition coil section)
  NOTE: Use a new rocker cover gasket.
2. Apply liquid gasket to the specified point of the cylinder head.
  NOTE: Install within 5 min. after applying liquid gasket.
  
  Liquid gasket:
  
  THREE BOND 1217G (Part No. K0877Y0100) or equivalent
  
  Fig 33: Identifying Liquid Gasket Applying Area On Cylinder Head
  Courtesy of SUBARU OF AMERICA, INC.
3. Install the rocker cover onto cylinder heads. Ensure the gasket is properly positioned during installation.
4. Temporarily tighten the rocker cover bolts in alphabetical order shown in the figure, and then tighten to specified torque in alphabetical order.
  Tightening torque:
  
  6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
  
  Fig 34: Identifying Tightening Sequence Of Rocker Cover Bolts
  Courtesy of SUBARU OF AMERICA, INC.
Connect the PCV hose (A) and PCV hose assembly (B) to the rocker cover.
NOTE: Use a new clamp for the PCV hose (A), fit the cut out in the ST with the protrusion on the clamp as shown in the figure, and lock the clamp.

ST 18353AA000 CLAMP PLIERS

Fig 35: Removing/Installing PCV Hose Clamp Using ST
Courtesy of SUBARU OF AMERICA, INC.

Fig 36: Identifying PCV Hose And Assembly
Courtesy of SUBARU OF AMERICA, INC.
Install the timing belt cover. < Refer to INSTALLATION , Timing Belt Cover. >
Install the crank pulley. < Refer to INSTALLATION , Crank Pulley. >
Install the intake manifold. < Refer to INSTALLATION , Intake Manifold. >
Install the rear side belt. < Refer to REAR SIDE BELT , INSTALLATION, V-belt. >
Install the engine to the vehicle. < Refer to INSTALLATION , Engine Assembly. >