Cylinder Block: Installation

Liquid gasket: 

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

Fig 2: Applying Liquid Gasket To Cylinder Block

Courtesy of SUBARU OF AMERICA, INC.

Tightening torque: 

10 N.m (1.0 kgf-m, 7.4 ft-lb) 

Fig 3: Identifying Cylinder Block Connecting Bolts On LH Side (A - D)

Courtesy of SUBARU OF AMERICA, INC.

Tightening torque: 

10 N.m (1.0 kgf-m, 7.4 ft-lb) 

Fig 4: Identifying Cylinder Block Connecting Bolts On RH Side (E - J)

Courtesy of SUBARU OF AMERICA, INC.

Tightening torque: 

18 N.m (1.8 kgf-m, 13.3 ft-lb) 

Fig 5: Identifying Cylinder Block Connecting Bolts On LH Side (A - D)

Courtesy of SUBARU OF AMERICA, INC.

Tightening torque: 

18 N.m (1.8 kgf-m, 13.3 ft-lb) 

Fig 6: Identifying Cylinder Block Connecting Bolts On RH Side (E - J)

Courtesy of SUBARU OF AMERICA, INC.

• (A), (C): Angle tightening

  Tightening angle: 90° 

• (B), (D): Torque tightening

Tightening torque: 

40 N.m (4.1 kgf-m, 29.5 ft-lb) 

Fig 7: Identifying Cylinder Block Connecting Bolts On LH Side (A - D)

Courtesy of SUBARU OF AMERICA, INC.

Tightening angle: 90° 

Fig 8: Identifying Cylinder Block Connecting Bolts On RH Side (E - J)

Courtesy of SUBARU OF AMERICA, INC.

Tightening torque: 

(A) - (G): 25 N.m (2.5 kgf-m, 18.4 ft-lb) 

(H): 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 

Fig 9: Identifying Cylinder Block Bolts Tightening Sequence

Courtesy of SUBARU OF AMERICA, INC.

ST1 499597100 CRANKSHAFT OIL SEAL GUIDE

ST2 499587200 CRANKSHAFT OIL SEAL INSTALLER

Fig 10: Installing Real Oil Seal Using Crankshaft Oil Seal And Crankshaft Oil Seal Installer

Courtesy of SUBARU OF AMERICA, INC.

Before positioning the piston on the cylinder block, attach the snap ring in the service hole of the cylinder block, and the piston pin hole on the opposite side.

Fig 16: Identifying Snap Ring Installation Sequence

Courtesy of SUBARU OF AMERICA, INC.

Fig 17: Identifying Piston, Gasket, Piston Pin, Service Hole Plug And Snap Ring

Courtesy of SUBARU OF AMERICA, INC.

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

T: 70 (7.1, 51.6) 

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

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

   Courtesy of SUBARU OF AMERICA, INC.
   NOTE: Face the piston front mark towards the front of the engine.
   Fig 19: Identifying Piston Front Mark

   Courtesy of SUBARU OF AMERICA, INC.

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: Installing Piston Pin

   Courtesy 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: Identifying Snap Ring

   Courtesy 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 Fluid Packing Around Service Hole Plug

   Courtesy of SUBARU OF AMERICA, INC.
6. Install the service hole plug and gasket.
   NOTE: Use a new gasket.

   Tightening torque: 

   70 N.m (7.1 kgf-m, 51.6 ft-lb) 

   Fig 23: Installing Service Hole Plug And Gasket

   Courtesy of SUBARU OF AMERICA, INC.
   Fig 24: Identifying Cylinder Block And Related Components With Lubrication Points

   Courtesy of SUBARU OF AMERICA, INC.

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

   T1: 6.4 (0.7, 4.7) 

   T2: 70 (7.1, 51.6) 

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.

   Tightening torque: 

   6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 

Tightening torque: 

6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 

Fig 25: Identifying Water Pipe

Courtesy of SUBARU OF AMERICA, INC.

Tightening torque: 

6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 

Liquid gasket: 

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

Fig 27: Identifying Lower Cylinder Block Liquid Gasket Applying Area

Courtesy of SUBARU OF AMERICA, INC.

Tightening torque: 

T1: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 

T2: 16 N.m (1.6 kgf-m, 11.8 ft-lb) 

Liquid gasket: 

• Mating surface 

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

Fig 28: Cylinder Block Bolts With Torque Specification

Courtesy of SUBARU OF AMERICA, INC.

Liquid gasket: 

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

Fig 29: Identifying Oil Pan Sealing Area

Courtesy of SUBARU OF AMERICA, INC.

Tightening torque: 

5 N.m (0.5 kgf-m, 3.7 ft-lb) 

Fig 30: Locating Oil Separator Cover Bolts

Courtesy of SUBARU OF AMERICA, INC.

• (A) bolt thread (when reusing bolts) 

THREE BOND 1324 (Part No. 004403042) or equivalent 

Tightening torque: 

6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 

Fig 32: Identifying Oil Separator Cover Sealing Area

Courtesy of SUBARU OF AMERICA, INC.

1. Using the ST, install the front oil seal.

   ST 499587100 OIL SEAL INSTALLER

   NOTE: Use a new front oil seal.
   Fig 33: Identifying Oil Seal

   Courtesy of SUBARU OF AMERICA, INC.
2. Apply liquid gasket to the mating surfaces of oil pump.
   NOTE: Install within 5 min. after applying liquid gasket.

   Liquid gasket: 

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

   Fig 34: Identifying Oil Pump Mating Surface Liquid Gasket Applying Area

   Courtesy of SUBARU OF AMERICA, INC.
3. Apply a coat of engine oil to the inside of oil seal.
   Fig 35: Applying Coat Of Engine Oil To Inside Of Oil Seal

   Courtesy of SUBARU OF AMERICA, INC.
4. Install the oil pump to cylinder block.
   CAUTION:

   • Be careful not to damage the front oil seal during installation.
   • Make sure the front oil seal lip is not folded.
   NOTE:

   • Align the flat surface of oil pump's inner rotor with that of crankshaft before installation.
   • Use new O-rings.
   • 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: 

   6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 

   Fig 36: Identifying Liquid Gasket Application Points On Bolts

   Courtesy of SUBARU OF AMERICA, INC.

Tightening torque: 

First: 12 N.m (1.2 kgf-m, 8.9 ft-lb) 

Second: 12 N.m (1.2 kgf-m, 8.9 ft-lb) 

Fig 37: Identifying Water Pump Bolts

Courtesy of SUBARU OF AMERICA, INC.

Tightening torque: 

6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 

Tightening torque: 

36 N.m (3.7 kgf-m, 26.6 ft-lb) 

1. Install the rocker cover gasket to the rocker cover.
   NOTE: Use a new rocker cover gasket.
2. Temporarily tighten the rocker cover bolts in alphabetical order shown in the figure, and then tighten to specified torque in alphabetical order in two steps.

   Tightening torque: 

   1st 

   6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 

   Second (only (a) and (b) are tightened) 

   6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 

   RH side

   Fig 38: Identifying Rocker Cover Bolts - RH Side

   Courtesy of SUBARU OF AMERICA, INC.

   LH side

   Fig 39: Identifying Rocker Cover Bolts - LH Side

   Courtesy of SUBARU OF AMERICA, INC.