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Cylinder Block: Removal

WARNING: This page is about a different variant/trim than selected.
NOTE: Before conducting this procedure, drain the engine oil completely.
  1. Remove the engine from vehicle. Refer to REMOVAL .
  2. Remove the crank pulley. Refer to REMOVAL .
  3. Remove the chain cover. Refer to REMOVAL .
  4. Remove the timing chain assembly. Refer to REMOVAL .
  5. Remove the cam sprocket. Refer to REMOVAL .
  6. Remove the crank sprocket. Refer to REMOVAL .
  7. Remove the camshaft. Refer to REMOVAL .
  8. Remove the cylinder head. Refer to REMOVAL .
  9. Remove the drive plate. Refer to REMOVAL .
  10. Remove the crankshaft position sensor.
    Fig 1: Identifying Crankshaft Position Sensor
    G05667883Courtesy of SUBARU OF AMERICA, INC.
  11. Remove the crankshaft position sensor plate.
    Fig 2: Removing/Installing Crankshaft Position Sensor Plate
    G05018775Courtesy of SUBARU OF AMERICA, INC.
  12. Rotate the engine to set oil pan upper.
  13. Remove the bolts which secure oil pan lower to oil pan upper.
    Fig 3: Identifying Oil Pan Lower To Upper Securing Bolts
    G05667885Courtesy of SUBARU OF AMERICA, INC.
  14. Insert an oil pan cutter blade into the gap between oil pan upper and oil pan lower, and remove the oil pan lower.
    CAUTION: Do not use a screwdriver or similar tools in place of oil pan cutter.
  15. Remove the oil cooler connector and remove the oil cooler.
    Fig 4: Identifying Oil Cooler And Connector, O-Ring And Oil Pan Upper
    G08581405Courtesy of SUBARU OF AMERICA, INC.
  16. Remove the oil pump. Refer to REMOVAL .
  17. Remove the oil level switch. Refer to REMOVAL .
  18. Remove the thermostat cover, and then remove the thermostat.
    Fig 5: Identifying Oil Pan Upper, Thermostat And Cover
    G08581406Courtesy of SUBARU OF AMERICA, INC.
  19. Remove the oil pan upper.
    Fig 6: Locating Oil Pan Upper Mounting Bolts
    G05667888Courtesy of SUBARU OF AMERICA, INC.
  20. Face the front of the engine up, standing the engine on one end.
    Fig 7: Identifying Engine Supported On Stand
    G05667889Courtesy of SUBARU OF AMERICA, INC.
  21. Remove ten O-rings from the underside of the cylinder block.
    Fig 8: Locating O-Rings On Underside Of Cylinder Block
    G05667890Courtesy of SUBARU OF AMERICA, INC.
  22. Mark the direction of front and the number of connecting rod caps.
  23. Remove the #1 and #4 connecting rod caps and pistons from the cylinder block.
    NOTE:
    • Use 3/8 inch (9.5 sq.) for the extension and TORX® socket (E12).
    • After removing the two connecting rod connection bolts, turning the crankshaft (ST) counterclockwise will remove the connecting rod cap.
    • Mark each connecting rod cap and piston with connecting rod cap number and piston number.
    • The removal of all connecting rod caps and pistons are performed in three separate steps. First, remove the #1 and #4 connecting rod caps and pistons are simultaneously, then the #2 and #5 connecting rod caps and pistons simultaneously, and then the #3 and #6 connecting rod caps and pistons simultaneously.
    1. Using the ST, turn the crankshaft and set the #1 piston at the mid point between TDC and BDC.

      ST 18252AA000 CRANKSHAFT SOCKET

    2. Remove the two #1 connecting rod cap connection bolts, and remove the connecting rod cap.
      Fig 9: Removing Two No. 1 Connecting Rod Cap Connection Bolts
      G08581410Courtesy of SUBARU OF AMERICA, INC.
    3. Remove the two #4 connecting rod cap connection bolts, and remove the connecting rod cap.
      Fig 10: Removing Two No. 4 Connecting Rod Cap Connection Bolts
      G08581411Courtesy of SUBARU OF AMERICA, INC.
    4. Using the ST, turn the crankshaft and separate the positions of the crank pin and the large end of the #1 connecting rod.

      ST 18252AA000 CRANKSHAFT SOCKET

      Fig 11: Turning Crankshaft
      G08581412Courtesy of SUBARU OF AMERICA, INC.
    5. Push the #1 connecting rod in the direction of the arrow, and remove the #1 piston and connecting rod from the cylinder block.
      Fig 12: Pushing No. 1 Connecting Rod
      G08581413Courtesy of SUBARU OF AMERICA, INC.
    6. Using the ST, turn the crankshaft and separate the positions of the crank pin and the large end of the #4 connecting rod.

      ST 18252AA000 CRANKSHAFT SOCKET

      Fig 13: Identifying No. 4 Connecting Rod And Crank Pin
      G08581414Courtesy of SUBARU OF AMERICA, INC.
    7. Push the #4 connecting rod in the direction of the arrow, and remove the #4 piston and connecting rod from the cylinder block.
      Fig 14: Pushing No. 4 Connecting Rod
      G08581415Courtesy of SUBARU OF AMERICA, INC.
  24. Remove the #2 and #5 connecting rods and pistons from the cylinder block in the same manner.

    ST 18252AA000 CRANKSHAFT SOCKET

  25. Remove the #3 and #6 connecting rods and pistons from the cylinder block in the same manner.

    ST 18252AA000 CRANKSHAFT SOCKET

  26. Face the cylinder block (RH) up.
    Fig 15: Facing Cylinder Block (RH) Up
    G08581416Courtesy of SUBARU OF AMERICA, INC.
  27. Remove the upper bolt.
    Fig 16: Locating Cylinder Block Upper Mounting Bolts
    G05667904Courtesy of SUBARU OF AMERICA, INC.
  28. Loosen the cylinder block bolts in the order indicated in the figure, and separate cylinder block (RH) and (LH).
    NOTE: Confirm that the crankshaft is remaining in the cylinder block (LH).
    If the cylinder block (RH) is lifted carelessly when separating, the crankshaft may stick to cylinder block (RH), then fall off.
    Fig 17: Identifying Cylinder Block Bolts Loosening Sequence
    G05667899Courtesy of SUBARU OF AMERICA, INC.
  29. Remove the rear oil seal.
  30. Remove the crankshaft from cylinder block (LH).
  31. 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.
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