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Cylinder Block: Removal

WARNING: This page is about a different variant/trim than selected.
  1. Remove the engine from the vehicle. Ref. to MECHANICAL(H4DO)>Engine Assembly>REMOVAL .
  2. Remove the intake manifold assembly. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>Intake Manifold Assembly>REMOVAL .
  3. Remove the engine wiring harness. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>Engine Wiring Harness>REMOVAL .
  4. Remove the chain cover. Ref. to MECHANICAL(H4DO)>Chain Cover>REMOVAL .
  5. Remove the rocker cover. Ref. to MECHANICAL(H4DO)>Rocker Cover>REMOVAL .
  6. Remove the cam carrier. Ref. to MECHANICAL(H4DO)>Cam Carrier>REMOVAL .
  7. Remove the cylinder head. Ref. to MECHANICAL(H4DO)>Cylinder Head>REMOVAL .
  8. Remove the crank sprocket. Ref. to MECHANICAL(H4DO)>Crank Sprocket>REMOVAL .
  9. Remove the engine rear hanger from cylinder block RH.
    Fig 1: Locating Engine Rear Hanger From Cylinder Block RH Bolts
    G08317136Courtesy of SUBARU OF AMERICA, INC.
  10. Remove the bolts securing the water pipe assembly and PCV connector to the cylinder block, and remove the water pipe assembly and PCV connector as a set from cylinder block.
    • CVT model
    Fig 2: Locating Water Pipe Assembly Bolts (CVT Model)
    G11263976Courtesy of SUBARU OF AMERICA, INC.
    • MT model
    Fig 3: Locating Water Pipe Assembly Bolts (MT Model)
    G11263977Courtesy of SUBARU OF AMERICA, INC.
  11. Remove the O-ring from the cylinder block and PCV connector.
    Fig 4: Locating O-Ring From Cylinder Block And PCV Connector
    G11263978Courtesy of SUBARU OF AMERICA, INC.
  12. Remove the knock sensor. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>Knock Sensor>REMOVAL .
  13. Remove the PCV valve. Ref. to EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) (H4DO)>PCV Valve>REMOVAL .
  14. Remove the crankshaft position sensor plate with drive plate. (CVT model) Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Drive Plate>REMOVAL .
  15. Remove the clutch disc and cover. (MT model) Ref. to CLUTCH SYSTEM>Clutch Disc and Cover>REMOVAL .
  16. Remove the crankshaft position sensor plate with flywheel. (MT model) Ref. to CLUTCH SYSTEM>Flywheel>REMOVAL .
  17. Remove the bolts securing the crankshaft position sensor holder from the cylinder block LH, and remove the crankshaft position sensor with crankshaft position sensor holder.
    Fig 5: Locating Crankshaft Position Sensor Bolts
    G11263979Courtesy of SUBARU OF AMERICA, INC.
  18. Remove the water jacket spacer from the cylinder block RH and cylinder block LH.
    Fig 6: Removing Water Jacket Spacer From Cylinder Block RH And Cylinder Block LH
    G09486474Courtesy of SUBARU OF AMERICA, INC.
  19. Set the cylinder block so that the oil pan is on the upper side, remove the ST1, ST2, ST3 and ST4 from 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 

    Fig 7: Removing ST1, ST2, ST3 And ST4 From Cylinder Block And Oil Pan Upper
    G10262782Courtesy of SUBARU OF AMERICA, INC.
  20. Remove the oil pan upper. Ref. to LUBRICATION(H4DO)>Oil Pan>REMOVAL>OIL PAN UPPER .
  21. 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 8: Locating Cylinder Block Oil Pan Side Mounting Bolts
    G09476212Courtesy of SUBARU OF AMERICA, INC.
  22. Raise the cylinder block so that the rear oil seal is on the lower side.
  23. Remove the #1 and #4 connecting rod caps and pistons from the cylinder block.
    NOTE: Mark each connecting rod cap and piston with a cylinder number.
    1. 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 9: Turning Crankshaft
      G10262788Courtesy of SUBARU OF AMERICA, INC.
    2. Using ST, loosen the #1 connecting rod cap bolt, and remove the #1 connecting rod cap bolt and #1 connecting rod cap.

      ST 18270AA020 SOCKET 

      Fig 10: Removing 1 Connecting Rod Cap Bolt
      G08317149Courtesy of SUBARU OF AMERICA, INC.
    3. Using ST, loosen the #4 connecting rod cap bolt, and remove the #4 connecting rod cap bolt and #4 connecting rod cap.

      ST 18270AA020 SOCKET 

      Fig 11: Removing 4 Connecting Rod Cap Bolt
      G08317150Courtesy of SUBARU OF AMERICA, INC.
    4. Using the ST, turn the crankshaft counterclockwise and separate the positions of the #1 pin (A) of crankshaft and the large end (B) of #1 connecting rod.

      ST 18252AA000 CRANKSHAFT SOCKET 

      Fig 12: Turning Crankshaft Counterclockwise
      G10262791Courtesy of SUBARU OF AMERICA, INC.
    5. Push the #1 connecting rod in the direction of the arrow, and remove the #1 piston with #1 connecting rod from the cylinder block.
      Fig 13: Pushing 1 Connecting Rod
      G08317152Courtesy of SUBARU OF AMERICA, INC.
    6. Using the ST, turn the crankshaft clockwise and separate the positions of the #4 pin (A) of crankshaft and the large end (B) of #4 connecting rod.

      ST 18252AA000 CRANKSHAFT SOCKET 

      Fig 14: Turning Crankshaft Clockwise
      G10262793Courtesy of SUBARU OF AMERICA, INC.
    7. Push the #4 connecting rod in the direction of the arrow, and remove the #4 piston with #4 connecting rod from the cylinder block.
    Fig 15: Pushing 4 Connecting Rod
    G08317154Courtesy of SUBARU OF AMERICA, INC.
  24. Remove the #2 and #3 connecting rod caps and pistons from the cylinder block.
    NOTE: Mark each connecting rod cap and piston with a cylinder number.
    1. 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 16: Turning Crankshaft 2 Connecting Rod Cap And 3 Connecting Rod Cap
      G10262795Courtesy of SUBARU OF AMERICA, INC.
    2. Using ST, loosen the #2 connecting rod cap bolt, and remove the #2 connecting rod cap bolt and #2 connecting rod cap.

      ST 18270AA020 SOCKET 

      Fig 17: Removing 2 Connecting Rod Cap Bolt
      G08317156Courtesy of SUBARU OF AMERICA, INC.
    3. Using ST, loosen the #3 connecting rod cap bolt, and remove the #3 connecting rod cap bolt and #3 connecting rod cap.

      ST 18270AA020 SOCKET 

      Fig 18: Removing 3 Connecting Rod Cap Bolt
      G08317157Courtesy of SUBARU OF AMERICA, INC.
    4. Using the ST, turn the crankshaft clockwise and separate the positions of the #2 pin (A) of crankshaft and the large end (B) of #2 connecting rod.

      ST 18252AA000 CRANKSHAFT SOCKET 

      Fig 19: Turning Crankshaft Clockwise
      G10262798Courtesy of SUBARU OF AMERICA, INC.
    5. Push the #2 connecting rod in the direction of the arrow, and remove the #2 piston with #2 connecting rod from the cylinder block.
      Fig 20: Pushing 2 Connecting Rod
      G08317159Courtesy of SUBARU OF AMERICA, INC.
    6. Using the ST, turn the crankshaft counterclockwise and separate the positions of the #3 pin (A) of crankshaft and the large end (B) of #3 connecting rod.

      ST 18252AA000 CRANKSHAFT SOCKET 

      Fig 21: Turning Crankshaft Counterclockwise
      G10262800Courtesy of SUBARU OF AMERICA, INC.
    7. Push the #3 connecting rod in the direction of the arrow, and remove the #3 piston with #3 connecting rod from the cylinder block.
      Fig 22: Pushing 3 Connecting Rod
      G08317161Courtesy of SUBARU OF AMERICA, INC.
  25. 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 23: Locating Cylinder Block Oil Pan Side Mounting Bolts
    G09476212Courtesy of SUBARU OF AMERICA, INC.
  26. Set the part so that the cylinder block RH is on the upper side, and separate 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.
    1. Remove the bolt shown in the figure.
      Fig 24: Locating Cylinder Block Bolts
      G08317163Courtesy of SUBARU OF AMERICA, INC.
    2. Loosen the cylinder block mounting bolts in numerical order as shown in the figure, and separate the cylinder block RH and LH.
    NOTE: Lift the cylinder block RH slightly, and 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 25: Cylinder Block Mounting Bolts Loosening Sequence
    G10262804Courtesy of SUBARU OF AMERICA, INC.
  27. Remove the crankshaft from cylinder block LH, and remove the rear oil seal.
  28. Remove the O-ring from the cylinder block LH.
    Fig 26: Locating O-Ring From Cylinder Block LH
    G08548053Courtesy of SUBARU OF AMERICA, INC.
  29. Remove the crankshaft bearings from the cylinder block.
    NOTE:
    • Be careful not to confuse the crankshaft bearing combination.
    • Press the bearing at the end opposite to locking lip (A).
    Fig 27: Locating Crankshaft Bearings From Cylinder Block
    G10262806Courtesy of SUBARU OF AMERICA, INC.
  30. Remove the liquid gasket from cylinder block.
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