Cylinder Block: Installation

WARNING: This page is about a different variant/trim than selected.

Apply engine oil to the crankshaft bearing, and install the crankshaft bearing to the cylinder block.
CAUTION:
- Place a wood board wrapped with a waste cloth to prevent the knock pin damage and to stabilize the cylinder block before work.
- Be careful not to scratch the mating surface of cylinder block during work.
Fig 1: Locating Crankshaft Bearing To Cylinder Block
Courtesy of SUBARU OF AMERICA, INC.
Install O-rings to the cylinder block LH.
NOTE: Use new O-rings.

Fig 2: Locating O-Ring To Cylinder Block LH
Courtesy of SUBARU OF AMERICA, INC.
Apply engine oil to the crankshaft journal, and set the crankshaft to cylinder block LH.

Fig 3: Locating Engine Oil Applying Area To Crankshaft Journal
Courtesy of SUBARU OF AMERICA, INC.
Apply liquid gasket to the mating surface of cylinder block RH as shown in the figure.
CAUTION: Do not let the liquid gasket overflow to the oil passage and crankshaft bearing portions, because the engine seizure may result.
NOTE:
- Before applying liquid gasket, degrease the old liquid gasket seal surface of the cylinder block RH and cylinder block LH.
- Install within 5 min. after applying liquid gasket.
Liquid gasket:

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

Liquid gasket applying diameter:

Mating surfaces other than ranges A, B and C

1±0.5 mm (0.0394±0.0197 in)

Mating surfaces of ranges A and C

4±0.5 mm (0.1575±0.0197 in)

Mating surfaces of range B

3.2±0.5 mm (0.1260±0.0197 in)

Fig 4: Identifying Cylinder Block RH Mating Surface Liquid Gasket Applying Dimension
Courtesy of SUBARU OF AMERICA, INC.
Install the cylinder block RH to the cylinder block LH.
Join the cylinder blocks.
1. Apply a coat of engine oil to the washers and cylinder block mounting bolt threads.
  NOTE: To prevent mixture of engine oil into the water jacket, do not apply a large amount.
2. Install the cylinder head bolt at the locations shown in the figure.
  NOTE: This procedure is required to tighten the cylinder block mounting bolts with specified angle using angle gauge.
  
  Fig 5: Installing Cylinder Head Bolt
  Courtesy of SUBARU OF AMERICA, INC.
3. Tighten all mounting bolts with a torque of 35 N.m (3.6 kgf-m, 25.8 ft-lb) in numerical order as shown in the figure.
  CAUTION: When tightening the mounting bolts with specified torque, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block.
  
  Fig 6: Cylinder Block Mounting Bolts
  Courtesy of SUBARU OF AMERICA, INC.
4. Loosen all mounting bolts by 180° in numerical order as shown in the figure.
  CAUTION: When loosening the mounting bolts, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block.
  
  Fig 7: Cylinder Block Mounting Bolts
  Courtesy of SUBARU OF AMERICA, INC.
5. Tighten all mounting bolts with a torque of 35 N.m (3.6 kgf-m, 25.8 ft-lb) in numerical order as shown in the figure.
  CAUTION: When tightening the mounting bolts with specified torque, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block.
  
  Fig 8: Cylinder Block Mounting Bolts
  Courtesy of SUBARU OF AMERICA, INC.
6. Loosen the mounting bolts (4 places) by 180° in numerical order as shown in the figure.
  CAUTION: When loosening the mounting bolts, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block.
  
  Fig 9: Cylinder Block Mounting Bolts
  Courtesy of SUBARU OF AMERICA, INC.
7. Tighten the mounting bolts (4 places) with a torque of 17 N.m (1.7 kgf-m, 12.5 ft-lb) in numerical order as shown in the figure.
  CAUTION: When tightening the mounting bolts with specified torque, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block.
  
  Fig 10: Cylinder Block Mounting Bolts
  Courtesy of SUBARU OF AMERICA, INC.
8. Using angle gauge, tighten the mounting bolts (4 places) with specified angle in numerical order as shown in the figure.
  CAUTION: When tightening the mounting bolts with specified angle, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block.
  
  Tightening angle:
  
  60°±2°
  
  Fig 11: Using Angle Gauge
  Courtesy of SUBARU OF AMERICA, INC.
9. Loosen the mounting bolts (6 places) by 180° in numerical order as shown in the figure.
  CAUTION: When loosening the mounting bolts, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block.
  
  Fig 12: Cylinder Block Mounting Bolts
  Courtesy of SUBARU OF AMERICA, INC.
10. Tighten the mounting bolts (6 places) with a torque of 17 N.m (1.7 kgf-m, 12.5 ft-lb) in numerical order as shown in the figure.
  CAUTION: When tightening the mounting bolts with specified torque, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block.
  
  Fig 13: Cylinder Block Mounting Bolts
  Courtesy of SUBARU OF AMERICA, INC.
11. Using angle gauge, tighten the mounting bolts (6 places) with specified angle in numerical order as shown in the figure.
  CAUTION: When tightening the mounting bolts with specified angle, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block.
  
  Tightening angle:
  
  60°±2°
  
  Fig 14: Using Angle Gauge
  Courtesy of SUBARU OF AMERICA, INC.
12. Remove the cylinder head bolt attached at the locations shown in the figure.
  
  Fig 15: Removing Cylinder Head Bolt
  Courtesy of SUBARU OF AMERICA, INC.
13. Install the bolt shown in the figure.
  NOTE: After tightening, if the liquid gasket is squeezed out in the seal surface area of the chain cover and oil pan upper, completely remove any liquid gasket that is squeezed out. Any liquid gasket on the chamfer area, however, should not be removed.
  
  Tightening torque:
  
  25 N.m (2.5 kgf-m, 18.4 ft-lb)
  
  Fig 16: Locating Cylinder Block Bolts
  Courtesy of SUBARU OF AMERICA, INC.
Set the part so that the oil pan side of cylinder block is on the upper side.
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 18671AA020 OIL SEAL GUIDE

ST2 18657AA030 OIL SEAL INSTALLER

Fig 17: Tapping Rear Oil Seal Using ST1 And ST2
Courtesy of SUBARU OF AMERICA, INC.
Install a bolt of suitable length (M10 x P1.25) at the locations shown in the figure.
NOTE:
- This procedure is required to prevent the knock pin damage when the cylinder block is raised in the next step.
- Use the same length of bolt for the four bolts.
Fig 18: Locating Cylinder Block Oil Pan Side Mounting Bolts
Courtesy of SUBARU OF AMERICA, INC.
Raise the cylinder block so that the rear oil seal is on the lower side.
Adjust the positions of piston ring gap for each piston.
NOTE: Check that the piston ring mark of compression ring faces the top side of the piston.
1. Set the ring gap of the top ring to the position (A) in the figure.
  
  Fig 19: Identifying Ring Gap Of Top Ring Position
  Courtesy of SUBARU OF AMERICA, INC.
2. Position the ring gap of second ring at (B) in the figure on the 180° opposite direction of (A).
  
  Fig 20: Identifying Ring Gap Of Second Ring Position
  Courtesy of SUBARU OF AMERICA, INC.
3. Set the ring gap of the upper rail to the position (C) in the figure.
  
  Fig 21: Identifying Ring Gap Of Upper Rail Position
  Courtesy of SUBARU OF AMERICA, INC.
4. Align the upper rail spin stopper (E) to the side hole (D) on the piston.
  
  Fig 22: Aligning Upper Rail Spin Stopper To Side Hole On Piston
  Courtesy of SUBARU OF AMERICA, INC.
5. Position the ring gap of expander at (F) in the figure on the 180° opposite direction of (C).
  
  Fig 23: Identifying Ring Gap Of Expander Position
  Courtesy of SUBARU OF AMERICA, INC.
6. Set the ring gap of lower rail at position (G), located 120° clockwise from (C) in the figure.
  
  Fig 24: Identifying Ring Gap Of Lower Rail Position
  Courtesy of SUBARU OF AMERICA, INC.
7. Check that the positions of piston ring gap are properly adjusted.
  NOTE: When checking the positions of piston ring gap, also check that the piston ring gaps are not positioned within the range of piston skirt extended line.
Install the piston and connecting rod to the cylinder block.
1. Apply engine oil to the outer circumference of each piston, crankshaft pin, and in the cylinder block.
2. Turn the crankshaft so that the #1 pin (A) of crankshaft is positioned at TDC using ST.
  ST 18252AA000 CRANKSHAFT SOCKET
  
  Fig 25: Turning Crankshaft 1 Pin Of Crankshaft Position At TDC Using ST
  Courtesy of SUBARU OF AMERICA, INC.
3. Compress the piston ring using piston ring compressor, and insert the #1 connecting rod with #1 piston into cylinder block.
  CAUTION:
  - Be careful not to damage the cylinder liner and #1 pin of crankshaft by the #1 connecting rod large end.
  - Be careful not to apply strong impact when inserting to prevent connecting rod bearing from falling off.
  NOTE:
  - Face the piston front mark (arrow) towards the front of the engine.
    
    Fig 26: Identifying Face Piston Front Mark Arrow Towards Front Of Engine
    Courtesy of SUBARU OF AMERICA, INC.
  - Insert while lightly tapping the crown of the piston with the handle of a plastic hammer.
  Fig 27: Inserting Crown Of Piston With Handle Of Plastic Hammer
  Courtesy of SUBARU OF AMERICA, INC.
4. Turn the crankshaft counterclockwise so that the #1 pin of crankshaft and the large end (A) of #1 connecting rod are positioned as shown in the figure using ST, while pressing the #1 piston crown, and then set the #1 connecting rod cap and #1 connecting rod cap bolt.
  NOTE:
  - Each connecting rod has its own mating cap. Make sure that they are assembled correctly by checking their matching symbol.
  - Use a new connecting rod cap bolt.
  - Apply a coat of engine oil to the #1 connecting rod cap seat and the connecting rod cap bolt threads.
  ST 18252AA000 CRANKSHAFT SOCKET
  
  Fig 28: Turning Crankshaft Counterclockwise
  Courtesy of SUBARU OF AMERICA, INC.
5. Using ST, tighten the #1 connecting rod cap bolts to 10 N.m (1.0 kgf-m, 7.4 ft-lb) in numerical order as shown in the figure, then retighten the bolts to 22 N.m (2.2 kgf-m, 16.2 ft-lb) in numerical order as shown in the figure.
  ST 18270AA020 SOCKET
  
  Fig 29: Tightening 1 Connecting Rod Cap Bolts
  Courtesy of SUBARU OF AMERICA, INC.
6. Turn the crankshaft clockwise so that the #2 pin (A) of crankshaft is positioned at TDC using ST.
  ST 18252AA000 CRANKSHAFT SOCKET
  
  Fig 30: Turning Crankshaft Clockwise
  Courtesy of SUBARU OF AMERICA, INC.
7. Compress the piston ring using piston ring compressor, and insert the #2 connecting rod with #2 piston into cylinder block.
  CAUTION:
  - Be careful not to damage the cylinder liner and #2 pin of crankshaft by the #2 connecting rod large end.
  - Be careful not to apply strong impact when inserting to prevent connecting rod bearing from falling off.
  NOTE:
  - Face the piston front mark (arrow) towards the front of the engine.
    
    Fig 31: Identifying Face Piston Front Mark Arrow Towards Front Of Engine
    Courtesy of SUBARU OF AMERICA, INC.
  - Insert while lightly tapping the crown of the piston with the handle of a plastic hammer.
  Fig 32: Inserting Crown Of Piston With Handle Of Plastic Hammer
  Courtesy of SUBARU OF AMERICA, INC.
8. Turn the crankshaft clockwise so that the #2 pin of crankshaft and the large end (A) of #2 connecting rod are positioned as shown in the figure using ST, while pressing the #2 piston crown, and then set the #2 connecting rod cap and #2 connecting rod cap bolt.
  NOTE:
  - Each connecting rod has its own mating cap. Make sure that they are assembled correctly by checking their matching symbol.
  - Use a new connecting rod cap bolt.
  - Apply a coat of engine oil to the #2 connecting rod cap seat and the connecting rod cap bolt threads.
  ST 18252AA000 CRANKSHAFT SOCKET
  
  Fig 33: Turning Crankshaft Clockwise
  Courtesy of SUBARU OF AMERICA, INC.
9. Using ST, tighten the #2 connecting rod cap bolts to 10 N.m (1.0 kgf-m, 7.4 ft-lb) in numerical order as shown in the figure, then retighten the bolts to 22 N.m (2.2 kgf-m, 16.2 ft-lb) in numerical order as shown in the figure.
  ST 18270AA020 SOCKET
  
  Fig 34: Tightening Sequence of #2 Connecting Rod Cap Bolts
  Courtesy of SUBARU OF AMERICA, INC.
10. Turn the crankshaft clockwise so that the #3 pin (A) of crankshaft is positioned at TDC using ST.
  ST 18252AA000 CRANKSHAFT SOCKET
  
  Fig 35: Turning Crankshaft Clockwise
  Courtesy of SUBARU OF AMERICA, INC.
11. Compress the piston ring using piston ring compressor, and insert the #3 connecting rod with #3 piston into cylinder block.
  CAUTION:
  - Be careful not to damage the cylinder liner and #3 pin of crankshaft by the #3 connecting rod large end.
  - Be careful not to apply strong impact when inserting to prevent connecting rod bearing from falling off.
  NOTE:
  - Face the piston front mark (arrow) towards the front of the engine.
    
    Fig 36: Identifying Face Piston Front Mark Arrow Towards Front Of Engine
    Courtesy of SUBARU OF AMERICA, INC.
  - Insert while lightly tapping the crown of the piston with the handle of a plastic hammer.
  Fig 37: Inserting Crown Of Piston With Handle Of Plastic Hammer
  Courtesy of SUBARU OF AMERICA, INC.
12. Turn the crankshaft counterclockwise so that the #3 pin of crankshaft and the large end (A) of #3 connecting rod are positioned as shown in the figure using ST, while pressing the #3 piston crown, and then set the #3 connecting rod cap and #3 connecting rod cap bolt.
  NOTE:
  - Each connecting rod has its own mating cap. Make sure that they are assembled correctly by checking their matching symbol.
  - Use a new connecting rod cap bolt.
  - Apply a coat of engine oil to the #3 connecting rod cap seat and the connecting rod cap bolt threads.
  ST 18252AA000 CRANKSHAFT SOCKET
  
  Fig 38: Turning Crankshaft Counterclockwise
  Courtesy of SUBARU OF AMERICA, INC.
13. Using ST, tighten the #3 connecting rod cap bolts to 10 N.m (1.0 kgf-m, 7.4 ft-lb) in numerical order as shown in the figure, then retighten the bolts to 22 N.m (2.2 kgf-m, 16.2 ft-lb) in numerical order as shown in the figure.
  ST 18270AA020 SOCKET
  
  Fig 39: Tightening Sequence of #3 Connecting Rod Cap Bolts
  Courtesy of SUBARU OF AMERICA, INC.
14. Turn the crankshaft clockwise so that the #4 pin (A) of crankshaft is positioned at TDC using ST.
  ST 18252AA000 CRANKSHAFT SOCKET
  
  Fig 40: Turning Crankshaft Clockwise
  Courtesy of SUBARU OF AMERICA, INC.
15. Compress the piston ring using piston ring compressor, and insert the #4 connecting rod with #4 piston into cylinder block.
  CAUTION:
  - Be careful not to damage the cylinder liner and #4 pin of crankshaft by the #4 connecting rod large end.
  - Be careful not to apply strong impact when inserting to prevent connecting rod bearing from falling off.
  NOTE:
  - Face the piston front mark (arrow) towards the front of the engine.
    
    Fig 41: Identifying Face Piston Front Mark (Arrow) Towards Front Of Engine
    Courtesy of SUBARU OF AMERICA, INC.
  - Insert while lightly tapping the crown of the piston with the handle of a plastic hammer.
  Fig 42: Inserting Crown Of Piston With Handle Of Plastic Hammer
  Courtesy of SUBARU OF AMERICA, INC.
16. Turn the crankshaft clockwise so that the #4 pin of crankshaft and the large end (A) of #4 connecting rod are positioned as shown in the figure using ST, while pressing the #4 piston crown, and then set the #4 connecting rod cap and #4 connecting rod cap bolt.
  NOTE:
  - Each connecting rod has its own mating cap. Make sure that they are assembled correctly by checking their matching symbol.
  - Use a new connecting rod cap bolt.
  - Apply a coat of engine oil to the #4 connecting rod cap seat and the connecting rod cap bolt threads.
  ST 18252AA000 CRANKSHAFT SOCKET
  
  Fig 43: Turning Crankshaft Clockwise
  Courtesy of SUBARU OF AMERICA, INC.
17. Using ST, tighten the #4 connecting rod cap bolts to 10 N.m (1.0 kgf-m, 7.4 ft-lb) in numerical order as shown in the figure, then retighten the bolts to 22 N.m (2.2 kgf-m, 16.2 ft-lb) in numerical order as shown in the figure.
  ST 18270AA020 SOCKET
  
  Fig 44: Tightening 4 Connecting Rod Cap Bolts
  Courtesy of SUBARU OF AMERICA, INC.
18. Install the cam carrier mounting bolts at the locations shown in the figure.
  NOTE: This procedure is required to tighten the connecting rod cap bolts with specified angle using angle gauge.
  
  Fig 45: Locating Cam Carrier Mounting Bolts
  Courtesy of SUBARU OF AMERICA, INC.
19. Turn the crankshaft so that the #1 connecting rod cap (A) and #4 connecting rod cap (B) is located at the position shown in the figure using ST.
  ST 18252AA000 CRANKSHAFT SOCKET
  
  Fig 46: Turning Crankshaft 1 Connecting Rod Cap And 4 Connecting Rod Cap
  Courtesy of SUBARU OF AMERICA, INC.
20. Using ST and angle gauge, tighten the #1 connecting rod cap bolts and #4 connecting rod cap bolts with specified angle in numerical order as shown in the figure.
  ST 18270AA020 SOCKET
  
  Tightening angle:
  
  137°^+3°_-2°
  
  Fig 47: Tightening Sequence of #1 Connecting Rod Cap Bolts And #4 Connecting Rod Cap Bolts
  Courtesy of SUBARU OF AMERICA, INC.
21. Turn the crankshaft so that the #2 connecting rod cap (A) and #3 connecting rod cap (B) is located at the position shown in the figure using ST.
  ST 18252AA000 CRANKSHAFT SOCKET
  
  Fig 48: Turning Crankshaft 2 Connecting Rod Cap And 3 Connecting Rod Cap
  Courtesy of SUBARU OF AMERICA, INC.
22. Using ST and angle gauge, tighten the #2 connecting rod cap bolts and #3 connecting rod cap bolts with specified angle in numerical order as shown in the figure.
  ST 18270AA020 SOCKET
  
  Tightening angle:
  
  137°^+3°_-2°
  
  Fig 49: Tightening Sequence of 2 Connecting Rod Cap Bolts And 3 Connecting Rod Cap Bolts
  Courtesy of SUBARU OF AMERICA, INC.
23. Remove the cam carrier mounting bolts attached at the locations shown in the figure.
  
  Fig 50: Locating Cam Carrier Mounting Bolts
  Courtesy of SUBARU OF AMERICA, INC.
Set the cylinder block so that the oil pan side of the block faces upward, and remove the mounting bolts attached to the locations shown in the figure.

Fig 51: Locating Cylinder Block Oil Pan Side Mounting Bolts
Courtesy of SUBARU OF AMERICA, INC.
Install the oil pan upper. Ref. to LUBRICATION(H4DO)>Oil Pan>INSTALLATION>OIL PAN UPPER .
Install the ST1, ST2, ST3 and ST4 to the cylinder block and oil pan upper.
ST1 498457000 ENGINE STAND ADAPTER RH

ST2 498457100 ENGINE STAND ADAPTER LH

ST3 18362AA020 ADAPTER

ST4 499817100 ENGINE STAND

Tightening torque:

35 N.m (3.6 kgf-m, 25.8 ft-lb)

Fig 52: Installing ST1, ST2, ST3 And ST4 To Cylinder Block And Oil Pan Upper
Courtesy of SUBARU OF AMERICA, INC.
Install the water jacket spacer to the cylinder block RH and cylinder block LH.

Fig 53: Installing Water Jacket Spacer To Cylinder Block RH And Cylinder Block LH
Courtesy of SUBARU OF AMERICA, INC.
Install the crankshaft position sensor with crankshaft position sensor holder to the cylinder block LH.
Tightening torque:

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

Fig 54: Locating Crankshaft Position Sensor Bolts
Courtesy of SUBARU OF AMERICA, INC.
Install the crankshaft position sensor plate with drive plate. (CVT model) Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Drive Plate>INSTALLATION .
Install the crankshaft position sensor plate with flywheel. (MT model) Ref. to CLUTCH SYSTEM>Flywheel>INSTALLATION .
Install the clutch disc and cover. (MT model) Ref. to CLUTCH SYSTEM>Clutch Disc and Cover>INSTALLATION .
Install the PCV valve. Ref. to EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) (H4DO)>PCV Valve>INSTALLATION .
Install the knock sensor. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>Knock Sensor>INSTALLATION .
Install the O-ring to the cylinder block and PCV connector.
NOTE: Use new O-rings.

Fig 55: Locating O-Ring To Cylinder Block And PCV Connector
Courtesy of SUBARU OF AMERICA, INC.
Set the water pipe assembly and PCV connector to the cylinder block, and install the bolts which secure the water pipe assembly and PCV connector to the cylinder block.
Tightening torque:

6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
- CVT model
  
  Fig 56: Locating Water Pipe Assembly Bolts (CVT Model)
  Courtesy of SUBARU OF AMERICA, INC.
- MT model
Fig 57: Locating Water Pipe Assembly Bolts (MT Model)
Courtesy of SUBARU OF AMERICA, INC.
Install the engine rear hanger to the cylinder block RH.
Tightening torque:

21 N.m (2.1 kgf-m, 15.5 ft-lb)

Fig 58: Locating Engine Rear Hanger To Cylinder Block RH Bolts
Courtesy of SUBARU OF AMERICA, INC.
Install the crank sprocket. Ref. to MECHANICAL(H4DO)>Crank Sprocket>INSTALLATION .
Install the cylinder head. Ref. to MECHANICAL(H4DO)>Cylinder Head>INSTALLATION .
Install the cam carrier. Ref. to MECHANICAL(H4DO)>Cam Carrier>INSTALLATION .
Install the rocker cover. Ref. to MECHANICAL(H4DO)>Rocker Cover>INSTALLATION .
Install the chain cover. Ref. to MECHANICAL(H4DO)>Chain Cover>INSTALLATION .
Install the engine wiring harness. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>Engine Wiring Harness>INSTALLATION .
Install the intake manifold assembly. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>Intake Manifold Assembly>INSTALLATION .
Install the engine to the vehicle. Ref. to MECHANICAL(H4DO)>Engine Assembly>INSTALLATION .