Cylinder Block: Removal

WARNING: This page is about a different variant/trim than selected.

NOTE: Before conducting this procedure, drain the engine oil completely.

Remove the engine from vehicle. Refer to , REMOVAL , Engine Assembly.
Remove the crank pulley. Refer to , REMOVAL , Crank Pulley.
Remove the chain cover. Refer to , REMOVAL , Chain Cover.
Remove the timing chain assembly. Refer to , REMOVAL , Timing Chain Assembly.
Remove the cam sprocket. Refer to , REMOVAL , Cam Sprocket.
Remove the crank sprocket. Refer to , REMOVAL , Crank Sprocket.
Remove the camshaft. Refer to , REMOVAL , Camshaft.
Remove the cylinder head. Refer to , REMOVAL , Cylinder Head.
Use the ST to lock the crankshaft, and remove the drive plate.
ST 498497100 CRANKSHAFT STOPPER

Fig 1: Removing Drive Plate Using Crankshaft Stopper
Courtesy of SUBARU OF AMERICA, INC.
Remove the crankshaft position sensor.

Fig 2: Removing Crankshaft Position Sensor
Courtesy of SUBARU OF AMERICA, INC.
Remove the crankshaft position sensor plate.

Fig 3: Removing Crankshaft Position Sensor Plate
Courtesy of SUBARU OF AMERICA, INC.
Rotate the engine to set oil pan upper.
Remove the bolts which secure oil pan lower to oil pan upper.

Fig 4: Identifying Oil Pan Mounting Bolts
Courtesy of SUBARU OF AMERICA, INC.
Insert an oil pan cutter blade into the gap between oil pan upper and oil pan lower, and remove the oil pan lower.
CAUTION: Do not use a screwdriver or similar tools in place of oil pan cutter.
Remove the oil cooler connector and remove the oil cooler.

Fig 5: Identifying Oil Cooler Connector, Oil Cooler, O-Ring And Upper Oil Pan
Courtesy of SUBARU OF AMERICA, INC.
Remove the oil pump. Refer to OIL PUMP .
Remove the oil level switch. Refer to OIL LEVEL SWITCH .
Remove the thermostat cover, and then remove the thermostat.

Fig 6: Identifying Upper Oil Pan, Thermostat And Thermostat Cover
Courtesy of SUBARU OF AMERICA, INC.
Remove the oil pump cover.

Fig 7: Locating Oil Pump Cover Mounting Pins
Courtesy of SUBARU OF AMERICA, INC.
Face the front of the engine up, standing the engine on one end.

Fig 8: Identifying Engine On Stand
Courtesy of SUBARU OF AMERICA, INC.
Remove ten O-rings from the underside of the cylinder block.

Fig 9: Identifying Cylinder Block O-Rings
Courtesy of SUBARU OF AMERICA, INC.
Mark the direction of front and the number of connecting rod caps.
Remove the #1 and #4 connecting rod caps and pistons from the cylinder block.
NOTE:
- Use 3/8 inch (9.5sq.) for the extension and TORX® socket (E12).
- After removing the two connecting rod connection bolts, turning the crankshaft (ST) counterclockwise will remove the connecting rod cap.
- Mark each connecting rod cap and piston with connecting rod cap number and piston number.
- The removal of all connecting rod caps and pistons are performed in three separate steps. First, remove the #1 and #4 connecting rod caps and pistons are simultaneously, then the #2 and #5 connecting rod caps and pistons simultaneously, and then the #3 and #6 connecting rod caps and pistons simultaneously.
1. Using the ST, turn the crankshaft and set the #1 piston at the mid point between TDC and BDC.
  ST 18252AA000 CRANKSHAFT SOCKET
2. Remove the two #1 connecting rod cap connection bolts, and remove the connecting rod cap.
  
  Fig 10: Removing Connecting Rod Cap
  Courtesy of SUBARU OF AMERICA, INC.
3. Remove the two #4 connecting rod cap connection bolts, and remove the connecting rod cap.
  
  Fig 11: Removing Connecting Rod Cap Connection Bolts
  Courtesy of SUBARU OF AMERICA, INC.
4. Using the ST, turn the crankshaft and separate the positions of the crank pin and the large end of the #1 connecting rod.
  ST 18252AA000 CRANKSHAFT SOCKET
  
  Fig 12: Identifying #1 Connecting Rod And Crank Pin
  Courtesy of SUBARU OF AMERICA, INC.
5. Push the #1 connecting rod in the direction of the arrow, and remove the #1 piston and connecting rod from the cylinder block.
  
  Fig 13: Identifying #1 Connecting Rod Removal Direction
  Courtesy of SUBARU OF AMERICA, INC.
6. Using the ST, turn the crankshaft and separate the positions of the crank pin and the large end of the #4 connecting rod.
  ST 18252AA000 CRANKSHAFT SOCKET
  
  Fig 14: Identifying #4 Connecting Rod And Crank Pin
  Courtesy of SUBARU OF AMERICA, INC.
7. Push the #4 connecting rod in the direction of the arrow, and remove the #4 piston and connecting rod from the cylinder block.
  
  Fig 15: Identifying #4 Connecting Rod Removal Direction
  Courtesy of SUBARU OF AMERICA, INC.
Remove the #2 and #5 connecting rods and pistons from the cylinder block in the same manner.
ST 18252AA000 CRANKSHAFT SOCKET
Remove the #3 and #6 connecting rods and pistons from the cylinder block in the same manner.
ST 18252AA000 CRANKSHAFT SOCKET
Face the cylinder block (RH) up.

Fig 16: Identifying Cylinder Block
Courtesy of SUBARU OF AMERICA, INC.
Remove the upper bolt.

Fig 17: Locating Cylinder Block Mounting Bolts
Courtesy of SUBARU OF AMERICA, INC.
Loosen the cylinder block bolts in the order indicated in the figure, and separate cylinder block (RH) and (LH).
NOTE: 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 18: Identifying Cylinder Block Bolts Loosening Sequence
Courtesy of SUBARU OF AMERICA, INC.
Remove the rear oil seal.
Remove the crankshaft from cylinder block (LH).
Remove the crankshaft bearings from cylinder block using a hammer handle.
NOTE:
- Do not confuse the combination of crankshaft bearings.
- Press the bearing at the end opposite to locking lip.