Engine Disassembly

With engine and transmission removed from vehicle as an assembly proceed as follows:

1. Remove two nuts and bolts securing transmission to engine and separate. Mount engine on suitable stand and drain oil and coolant.
2. Remove clutch cover and pressure plate from flywheel. Disconnect breather hose from valve cover and remove air cleaner. Remove engine breather pipe and dipstick.
3. On EA62 & 63, remove air cleaner bracket. On EA63S, remove spark plug wire stay.
4. Remove distributor and spark plug wires as a unit, leaving distributor vacuum line attached to distributor. Remove generator drive belts and generator along with both mounting brackets.
5. On EA61, remove left and right intake manifold, thermostat case and carburetor as a unit. Six bolts and one socket bolt secure intake manifold assembly.
6. On 1971 EA62, remove intake manifold and carburetor as an assembly.
7. On 1971 EA61 & 62, remove water pipe elbow, hose and pipe as a unit.
8. Remove water by-pass hose from carburetor and water bypass hose from connector. Then remove intake manifold and carburetor as an assembly, which includes thermostat case cover, water by-pass connector (EA63A & S), control valve and air damper (EA62).
9. Remove crankshaft pulley using a suitable puller (899524100). Remove four attaching bolts and withdraw oil pump and filter as a unit. Remove attaching bolts and water pump, pipes, and hoses as a unit.
10. Invert engine and remove oil pan. Unscrew socket bolt and remove oil strainer.
    NOTE: Do not remove strainer unless necessary.

    Remove flywheel and flywheel housing.

11. Rotate camshaft gear hole to expose two bolts behind gear. Bend back lock tab and remove bolts. Remove spark plugs and rocker covers.
12. Remove four bolts attaching rocker shaft assembly. Pull out push rods and retain them in order.
13. Remove cylinder heads and gaskets by unscrewing nuts (EA61) and bolts (EA62 & 63) in proper sequence (see Fig 1).
    Fig 1: Cylinder Head Loosening Sequence

    Courtesy of SUBARU OF AMERICA, INC.
14. Remove crankcase Allen plugs using suitable Allen wrench (899974101). Remove cylinder liner using suitable puller (899704100).
    NOTE: Mark edge of cylinder liner flange and cylinder block so exact positioning may be accomplished on reassembly. Keep liners and liner gaskets in matched sets.
15. Reaching through crankcase plug hole, remove piston pin circlips. Remove piston pins and pistons.
16. On 1971 EA61 & 62, split crankcase halves by removing one bolt and 10 nuts, on 1972 EA62 remove 10 bolts and on EA63 engines remove one bolt and 11 nuts.
17. Remove oil seal. Lift out crankshaft and connecting rods. Retain crankshaft bearings in proper order for reassembly. Remove camshaft and camshaft gear. Remove oil pressure switch and valve lifters.

This completes major engine disassembly. Repair or replacement of individual components will be covered under separate titles. In the following section Engine Reassembly it will be assumed all components are properly fitted and in good condition.