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Home › Subaru › 2012 › Outback Base, Automatic CVT Trans › Repair and Diagnosis › Engine Mechanical › Timing Belt › Mechanical (H4SO) › Cylinder Block › Removal

Cylinder Block: Removal

NOTE: Before conducting this procedure, drain the engine oil completely.
  1. Remove the engine from the vehicle. < Refer to , REMOVAL , Engine Assembly.>
  2. Remove the intake manifold. Refer to REMOVAL
  3. Remove the crank pulley. < Refer to , REMOVAL , Crank Pulley.>
  4. Remove the timing belt cover. < Refer to , REMOVAL , Timing Belt Cover.>
  5. Remove the timing belt. < Refer to , REMOVAL , Timing Belt.>
  6. Remove the crank sprocket. < Refer to , REMOVAL , Crank Sprocket.>
  7. Remove the generator and A/C compressor with their brackets.
  8. Remove the cylinder head. < Refer to , REMOVAL , Cylinder Head.>
  9. Remove the drive plate. (CVT model). Refer to REMOVAL
  10. Remove the clutch disc and cover. (MT model). Refer to REMOVAL
  11. Remove the flywheel. (MT model). Refer to REMOVAL
  12. Remove the oil separator cover.
  13. Remove the water by-pass pipe for heater.
  14. Remove the water pump. Refer to REMOVAL
  15. Remove the bolts which secure oil pump to cylinder block.
    NOTE: When disassembling and checking the oil pump, loosen the relief valve plug before removing the oil pump.
    Fig 1: Removing Oil Pump Bolts
    G04997725Courtesy of SUBARU OF AMERICA, INC.
  16. Remove the oil pump from cylinder block using a flat tip screwdriver.
    CAUTION: Be careful not to scratch the mating surface of cylinder block and oil pump.
    Fig 2: Removing Oil Pump From Cylinder Block
    G04997726Courtesy of SUBARU OF AMERICA, INC.
  17. Remove the front oil seal from the oil pump.
  18. Remove the clip holding the oil level switch harness from cylinder block.
    Fig 3: Identifying Oil Level Switch Harness Clip
    G00525696Courtesy of SUBARU OF AMERICA, INC.
  19. Remove the oil pan and cylinder block lower.
    1. Set the part so that the cylinder block LH is on the upper side.
    2. Remove the bolts which secure the oil pan to the cylinder block lower.
    3. Insert an oil pan cutter blade into the gap between cylinder block lower and oil pan, and remove the oil pan.
      CAUTION: Do not use a screwdriver or similar tools in place of oil pan cutter.
    4. Remove the bolts which secure the cylinder block lower to the cylinder block, and remove the cylinder block lower by using flat tip screwdriver.
      CAUTION: Insert the flat tip screwdriver to the position shown in the figure, and be careful not to damage the mating surface of the cylinder block and cylinder block lower.
      Fig 4: Locating Cylinder Block Lower
      G06650797Courtesy of SUBARU OF AMERICA, INC.
  20. Remove the oil strainer.
  21. Remove the baffle plate.
  22. Remove the oil filter. Refer to REMOVAL
  23. Remove the water pipe assembly.
    Fig 5: Identifying Water Pipe Assembly
    G04997728Courtesy of SUBARU OF AMERICA, INC.
    Fig 6: Identifying Service Plug Hole, Piston Pin, Seal Washer, Gasket, Service Hole Cover And Washer
    G07911624Courtesy of SUBARU OF AMERICA, INC.
  24. Remove the service hole plugs using a hexagon wrench [14 mm].
    Fig 7: Identifying Service Hole Plug
    G04997730Courtesy of SUBARU OF AMERICA, INC.
  25. Remove the service hole cover.
  26. Rotate the crankshaft to bring #1 and #2 pistons to bottom dead center position, then remove the piston snap ring through service hole of #1 and #2 cylinders.
    Fig 8: Removing Piston Snap Ring
    G04997731Courtesy of SUBARU OF AMERICA, INC.
  27. Draw out the piston pin from #1 and #2 pistons using ST.

    ST 18320AA010 PISTON PIN REMOVER ASSY

    NOTE:
    • PISTON PIN REMOVER ASSY (499097700) can also be used.
    • Be careful not to confuse the original combination of piston, piston pin and cylinder.
      Fig 9: Removing Piston Pin Using Piston Pin Remover
      G05659845Courtesy of SUBARU OF AMERICA, INC.
  28. Similarly draw out the piston pins from #3 and #4 pistons.
  29. Remove the cylinder block connecting bolt on the RH side.
  30. Loosen the cylinder block connecting bolt on the LH side by 2 to 3 turns.
  31. Set the part so that the cylinder block LH is on the upper side, and remove the cylinder block connecting bolt.
  32. Separate the cylinder block LH and RH.
    NOTE: When separating the cylinder block, do not allow the connecting rod to fall or damage the cylinder block.
    Fig 10: Exploded View Of Cylinder Block
    G07911628Courtesy of SUBARU OF AMERICA, INC.
  33. Remove the rear oil seal.
  34. Remove the crankshaft along with the connecting rods.
  35. Remove the crankshaft bearings from cylinder block using a hammer handle.
    NOTE:
    • Press the crankshaft bearing at the end opposite to locking lip to remove.
    • Be careful not to confuse the crankshaft bearing combination.
  36. Remove each piston from the cylinder block using a wooden bar or hammer handle.
    NOTE: Be careful not to confuse the original combination of piston and cylinder.
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