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Cylinder Block: Installation

Fig 1: Identifying Cylinder Block, Crankshaft, Rear Oil Seal And Seal Washer
G05339505Courtesy of SUBARU OF AMERICA, INC.
  1. Remove oil on the mating surface of cylinder block before installation. Apply a coat of engine oil to the bearing and crankshaft journal.
  2. Position the crankshaft and O-ring on the cylinder block (RH).
  3. Apply liquid gasket to the mating surfaces of cylinder block (RH), and position the 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 1215 (Part No. 004403007) or equivalent 

    Fig 2: Applying Liquid Gasket To Cylinder Block
    G04997735Courtesy of SUBARU OF AMERICA, INC.
  4. Apply a coat of engine oil to the washer and bolt thread.
    NOTE: Use a new seal washer.
  5. 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, 7.2 ft-lb) 

    Fig 3: Tightening Sequence Of Cylinder Block Connecting Bolts - LH Side
    G05333086Courtesy of SUBARU OF AMERICA, INC.
  6. 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, 7.2 ft-lb) 

    Fig 4: Tightening Sequence Of Cylinder Block Connecting Bolts - RH Side
    G05333087Courtesy of SUBARU OF AMERICA, INC.
  7. Tighten the LH side cylinder block connecting bolts (A - D) further in alphabetical order.

    Tightening torque: 18 N.m (1.8 kgf-m, 13 ft-lb) 

    Fig 5: Tightening Sequence Of Cylinder Block Connecting Bolts - LH Side
    G05333086Courtesy of SUBARU OF AMERICA, INC.
  8. Tighten the RH side cylinder block connecting bolts (E - J) further in alphabetical order.

    Tightening torque: 18 N.m (1.8 kgf-m, 13 ft-lb) 

    Fig 6: Tightening Sequence Of Cylinder Block Connecting Bolts - RH Side
    G05333087Courtesy of SUBARU OF AMERICA, INC.
  9. 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, 29.6 ft-lb) 

      Fig 7: Tightening Sequence Of Cylinder Block Connecting Bolts - LH Side
      G05333086Courtesy of SUBARU OF AMERICA, INC.
  10. Tighten the RH side cylinder block connecting bolts (E - J) in alphabetical order.

    Tightening angle: 90° 

    Fig 8: Tightening Sequence Of Cylinder Block Connecting Bolts - RH Side
    G05333087Courtesy of SUBARU OF AMERICA, INC.
  11. Tighten the 8 mm and 6 mm cylinder block connecting bolts on LH side (A - H) in alphabetical sequence.

    Tightening torque: (A) - (G): 25 N.m (2.5 kgf-m, 18.1 ft-lb) 

    (H): 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) 

    Fig 9: Tightening Sequence Of Cylinder Block Connecting Bolts - LH Side
    G04997742Courtesy of SUBARU OF AMERICA, INC.
  12. Apply a coat of engine oil to the oil seal periphery, then install the rear oil seal using ST1 and ST2.
    NOTE: Use 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
    G05339514Courtesy of SUBARU OF AMERICA, INC.
  13. Position the top ring gap at (A) or (B) in the figure.
  14. Position the second ring gap at 180° on the reverse side the top ring gap.
    Fig 11: Identifying Second Ring Gap Position
    G04997744Courtesy of SUBARU OF AMERICA, INC.
  15. Position the upper rail gap at (C) in the figure.
    Fig 12: Identifying Upper Rail Gap Position
    G04997745Courtesy of SUBARU OF AMERICA, INC.
  16. Align the upper rail spin stopper (E) to the side hole (D) on the piston.
    Fig 13: Aligning Upper Rail Spin Stopper To Side Hole On Piston
    G04998766Courtesy of SUBARU OF AMERICA, INC.
  17. Position the expander gap at (F) in the figure.
    Fig 14: Identifying Expander Gap Position
    G04997747Courtesy of SUBARU OF AMERICA, INC.
  18. Position the lower rail gap at (G) in the figure.
    Fig 15: Identifying Lower Rail Gap Position
    G04992634Courtesy 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.
  19. Install the snap ring.

    Before installing the piston to the cylinder block, install the snap rings to the piston holes on the opposite side of the service holes on the cylinder block.

    NOTE: Use new snap rings.
    Fig 16: Identifying Piston And Snap Rings Position
    G05339520Courtesy of SUBARU OF AMERICA, INC.
    Fig 17: Piston, Piston Pin, Service Hole Plug, Gasket And Snap Ring With Torque Specifications
    G05339521Courtesy of SUBARU OF AMERICA, INC.
  20. 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 

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

      T: 70 (7.1, 50.6) 

    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 Pistons In Cylinders Using Piston Guide ST2 498747300
      G04997752Courtesy of SUBARU OF AMERICA, INC.
      NOTE: Face the piston front mark towards the front of the engine.
      Fig 19: Identifying Piston Front Mark Position
      G05339523Courtesy of SUBARU OF AMERICA, INC.
  21. Install the piston pin.
    1. Apply a coat of engine oil to ST3.
    2. Insert ST3 into the service hole to align piston pin hole with connecting rod small end.

      ST3 499017100 PISTON PIN GUIDE 

      Fig 20: Aligning Piston Pin Hole With Connecting Rod Small End
      G04997753Courtesy of SUBARU OF AMERICA, INC.
    3. Apply a 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
      G04997754Courtesy 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
      G04997755Courtesy of SUBARU OF AMERICA, INC.
    6. Install the service hole plug and gasket.
      NOTE: Use a new gasket.
      Fig 23: Installing Service Hole Plug And Gasket
      G04997730Courtesy of SUBARU OF AMERICA, INC.
      Fig 24: Piston, Piston Pin, Service Hole Plug And Cover, Gasket And Snap Ring With Torque Specifications
      G05339528Courtesy of SUBARU OF AMERICA, INC.
    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.
  22. Install the water pipe.
    NOTE: Use new O-rings.

    Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) 

    Fig 25: Identifying Water Pipe
    G04997728Courtesy of SUBARU OF AMERICA, INC.
  23. Install the baffle plate.

    Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) 

  24. Install the oil strainer.
    NOTE: Use new O-rings.

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

  25. Install the oil strainer stay.
    NOTE: Tighten the oil strainer stay together with baffle plate.

    Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) 

  26. Apply liquid gasket to the mating surfaces, and install the oil pan.
    NOTE: Install within 5 min. after applying liquid gasket.

    Liquid gasket: THREE BOND 1207C (Part No. 004403012) or equivalent 

    Tightening torque: 5 N.m (0.5 kgf-m, 3.6 ft-lb) 

    Fig 26: Applying Liquid Gasket To Mating Surfaces Of Oil Pan
    G04997759Courtesy of SUBARU OF AMERICA, INC.
  27. Apply liquid gasket to the mating surfaces 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 a new separator cover.

    Liquid gasket: 

    • Mating surface 

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

    • (A) bolt threads (when reusing bolts) 

      THREE BOND 1324 (Part No. 004403042) or equivalent 

      Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) 

      Fig 27: Identifying Oil Separator Cover Mating Surface Liquid Gasket Applying Area
      G07682215Courtesy of SUBARU OF AMERICA, INC.
  28. Install the flywheel. (MT model) <Ref. to B: INSTALLATION , Flywheel .>
  29. Install the clutch disc and cover. (MT model) <Ref. to INSTALLATION .>
  30. Install the drive plate. (AT model)

    To lock the crankshaft, use the ST.

    ST 498497100 CRANKSHAFT STOPPER 

    Tightening torque: 72 N.m (7.3 kgf-m, 52.8 ft-lb) 

    Fig 28: Locking Crankshaft Using Crankshaft Stopper ST (498497100)- AT Model
    G04997723Courtesy of SUBARU OF AMERICA, INC.
  31. Installation of oil pump:
    1. Using the ST, install the front oil seal.

      ST 499587100 OIL SEAL INSTALLER 

      NOTE: Use a new front oil seal.
      Fig 29: Installing Front Oil Seal Using Oil Seal Installer ST 499587100
      G04997763Courtesy of SUBARU OF AMERICA, INC.
    2. Apply liquid gasket to the matching surface of oil pump.
      NOTE: Install within 5 min. after applying liquid gasket.

      Liquid gasket: THREE BOND 1215 (Part No. 004403007) or equivalent 

      Fig 30: Applying Liquid Gasket To Matching Surface Of Oil Pump
      G05339535Courtesy of SUBARU OF AMERICA, INC.
    3. Apply a coat of engine oil to the inside of oil seal.
      Fig 31: Applying Coat Of Engine Oil To Inside Of Oil Seal
      G04997765Courtesy of SUBARU OF AMERICA, INC.
    4. Install the oil pump to cylinder block. Be careful not to damage the oil seal during installation.
      NOTE:
      • Make sure the oil seal lip is not folded.
      • Align the flat surface of oil pump's inner rotor with crankshaft before installation.
      • Use new O-rings and oil seals.
      • 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: T: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) 

      Fig 32: Applying Fluid Packing To Threads Of Bolts
      G04997766Courtesy of SUBARU OF AMERICA, INC.
  32. 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, 8.7 ft-lb) 

    Second: 12 N.m (1.2 kgf-m, 8.7 ft-lb) 

    Fig 33: Tightening Sequence Of Water Pump Bolts
    G04997724Courtesy of SUBARU OF AMERICA, INC.
  33. Install the water by-pass pipe for heater.

    Tightening torque: 

    6.4 N.m (0.65 kgf-m, 4.7 ft-lb) 

  34. Install the oil filter. <Ref. to INSTALLATION , Engine Oil Filter .>
  35. Install the cylinder head. <Ref. to INSTALLATION , Cylinder Head .>
  36. Install the camshaft. <Ref. to INSTALLATION .>
  37. Install the valve rocker assembly. <Ref. to INSTALLATION .>
  38. Install the crank sprocket. <Ref. to INSTALLATION , Crank Sprocket .>
  39. Install the cam sprocket. <Ref. to INSTALLATION , Cam Sprocket .>
  40. Install the timing belt. <Ref. to INSTALLATION , Timing Belt .>
  41. Adjust the valve clearance. <Ref. to ADJUSTMENT , Valve Clearance .>
  42. Install the rocker cover.
    1. Install the rocker cover gasket to the rocker cover.
      NOTE: Use a new rocker cover gasket.
    2. Tighten the bolts in two stages in alphabetical sequence as shown in figure.

      Tightening torque: 

      1st 

      6.4 N.m (0.65 kgf-m, 4.7 ft-lb) 

      2nd (only (a) and (b) are tightened) 

      6.4 N.m (0.65 kgf-m, 4.7 ft-lb) 

      RH side 

      Fig 34: Identifying Rocker Cover Bolts - RH Side
      G07656874Courtesy of SUBARU OF AMERICA, INC.

      LH side 

      Fig 35: Identifying Rocker Cover Bolts - LH Side
      G07656875Courtesy of SUBARU OF AMERICA, INC.
  43. Connect the PCV hose.
  44. Install the timing belt cover. <Ref. to INSTALLATION , Timing Belt Cover .>
  45. Install the crank pulley. <Ref. to INSTALLATION , Crank Pulley .>
  46. Install the intake manifold. <Ref. to INSTALLATION , Intake Manifold .>
  47. Install the generator and A/C compressor brackets on cylinder head.
  48. Install the V-belts. <Ref. to INSTALLATION , V-belt .>
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