Cylinder Block: Removal

Remove the engine from the vehicle. Refer to REMOVAL .
Remove the intake manifold. Refer to REMOVAL .
Remove the tumble generator valve assembly. Refer to REMOVAL .
Remove the chain cover. Refer to REMOVAL .
Remove the rocker cover. Refer to REMOVAL .
Remove the cam carrier. Refer to REMOVAL .
Remove the cylinder head. Refer to REMOVAL .
Remove the crank sprocket. Refer to REMOVAL .
Remove the engine rear hanger from cylinder block RH.

Fig 1: Locating Engine Rear Hanger Mounting Bolts
Courtesy of SUBARU OF AMERICA, INC.
Remove the bolts securing the water pipe assembly and PCV connector to the cylinder block, and remove the water pipe assembly and PCV connector as a set from cylinder block.

Fig 2: Locating Water Pipe Assembly And PCV Connector Mounting Bolts
Courtesy of SUBARU OF AMERICA, INC.
Remove the O-ring from the cylinder block and PCV connector.

Fig 3: Locating Cylinder Block And PCV Connector O-Rings
Courtesy of SUBARU OF AMERICA, INC.
Remove the knock sensor from cylinder block LH.

Fig 4: Locating Cylinder Block LH Knock Sensor
Courtesy of SUBARU OF AMERICA, INC.
Remove the vacuum hose from the PCV valve.

Fig 5: Locating PCV Valve Vacuum Hose
Courtesy of SUBARU OF AMERICA, INC.
Remove the PCV valve from the cylinder block RH.

Fig 6: Locating Cylinder Block RH PCV Valve
Courtesy of SUBARU OF AMERICA, INC.
Remove the crankshaft position sensor plate with drive plate. (CVT model) Refer to REMOVAL .
Remove the clutch disc and cover. (MT model) Refer to REMOVAL .
Remove the crankshaft position sensor plate with flywheel. (MT model) Refer to REMOVAL .
Remove the bolts securing the crankshaft position sensor holder from the cylinder block LH, and remove the crankshaft position sensor with crankshaft position sensor holder.

Fig 7: Locating Crankshaft Position Sensor Holder Mounting Bolts
Courtesy of SUBARU OF AMERICA, INC.
Set the cylinder block so that the oil pan is on the upper side, remove the ST1, ST2, ST3 and ST4 from cylinder block and oil pan upper.
ST1 498457000 ENGINE STAND ADAPTER RH

ST2 498457100 ENGINE STAND ADAPTER LH

ST3 18362AA020 ADAPTER

ST4 499817100 ENGINE STAND

Fig 8: Supporting Cylinder Block Using Special Tools
Courtesy of SUBARU OF AMERICA, INC.
Remove the thermostat cover from oil pan upper, and then remove the thermostat.

Fig 9: Locating Thermostat Cover Mounting Bolts
Courtesy of SUBARU OF AMERICA, INC.
Remove the oil pan upper with oil pan from cylinder block.

Fig 10: Locating Cylinder Block Oil Pan Upper Mounting Bolts
Courtesy of SUBARU OF AMERICA, INC.
Remove the O-ring from the cylinder block.

Fig 11: Locating Cylinder Block O-Rings
Courtesy of SUBARU OF AMERICA, INC.
Install the mounting bolts for the A/C compressor and the generator bracket at the locations shown in the figure.
NOTE:
- This procedure is required to prevent the knock pin damage when the cylinder block is raised in the next step.
- Use the same length bolt for the four bolts.
  
  Fig 12: Locating A/C Compressor And Generator Bracket Mounting Bolts
  Courtesy of SUBARU OF AMERICA, INC.
Raise the cylinder block so that the rear oil seal is on the lower side.
Remove the #1 and #4 connecting rod caps and pistons from the cylinder block.
NOTE: Mark each connecting rod cap and piston with a cylinder number.
1. Turn the crankshaft so that the #1 connecting rod cap (A) and #4 connecting rod cap (B) is located at the position shown in the figure using ST.
  ST 18252AA000 CRANKSHAFT SOCKET
  
  Fig 13: Aligning No. 1 And No. 4 Connecting Rod Cap
  Courtesy of SUBARU OF AMERICA, INC.
2. Using ST, loosen the #1 connecting rod cap bolt, and remove the #1 connecting rod cap bolt and #1 connecting rod cap.
  ST 18270AA020 SOCKET
  
  Fig 14: Removing No. 1 Connecting Rod Cap
  Courtesy of SUBARU OF AMERICA, INC.
3. Using ST, loosen the #4 connecting rod cap bolt, and remove the #4 connecting rod cap bolt and #4 connecting rod cap.
  ST 18270AA020 SOCKET
  
  Fig 15: Removing No. 4 Connecting Rod Cap
  Courtesy of SUBARU OF AMERICA, INC.
4. Using the ST, turn the crankshaft clockwise and separate the positions of the #1 pin (A) of crankshaft and the large end (B) of #1 connecting rod.
  ST 18252AA000 CRANKSHAFT SOCKET
  
  Fig 16: Aligning No. 1 Crank Pin And Large End Of No. 1 Connecting Rod
  Courtesy of SUBARU OF AMERICA, INC.
5. Push the #1 connecting rod in the direction of the arrow, and remove the #1 piston with #1 connecting rod from the cylinder block.
  
  Fig 17: Removing No. 1 Piston And No. 1 Connecting Rod From Cylinder Block
  Courtesy of SUBARU OF AMERICA, INC.
6. Using the ST, turn the crankshaft counterclockwise and separate the positions of the #4 pin (A) of crankshaft and the large end (B) of #4 connecting rod.
  ST 18252AA000 CRANKSHAFT SOCKET
  
  Fig 18: Aligning No. 4 Crank Pin And Large End Of No. 4 Connecting Rod
  Courtesy of SUBARU OF AMERICA, INC.
7. Push the #4 connecting rod in the direction of the arrow, and remove the #4 piston with #4 connecting rod from the cylinder block.
  
  Fig 19: Removing No. 4 Piston And No. 4 Connecting Rod From Cylinder Block
  Courtesy of SUBARU OF AMERICA, INC.
Remove the #2 and #3 connecting rod caps and pistons from the cylinder block.
NOTE: Mark each connecting rod cap and piston with a cylinder number.
1. Turn the crankshaft so that the #2 connecting rod cap (A) and #3 connecting rod cap (B) is located at the position shown in the figure using ST.
  ST 18252AA000 CRANKSHAFT SOCKET
  
  Fig 20: Aligning No. 2 And No. 3 Connecting Rod Cap
  Courtesy of SUBARU OF AMERICA, INC.
2. Using ST, loosen the #2 connecting rod cap bolt, and remove the #2 connecting rod cap bolt and #2 connecting rod cap.
  ST 18270AA020 SOCKET
  
  Fig 21: Removing No. 2 Connecting Rod Cap
  Courtesy of SUBARU OF AMERICA, INC.
3. Using ST, loosen the #3 connecting rod cap bolt, and remove the #3 connecting rod cap bolt and #3 connecting rod cap.
  ST 18270AA020 SOCKET
  
  Fig 22: Removing No. 3 Connecting Rod Cap
  Courtesy of SUBARU OF AMERICA, INC.
4. Using the ST, turn the crankshaft counterclockwise and separate the positions of the #2 pin (A) of crankshaft and the large end (B) of #2 connecting rod.
  ST 18252AA000 CRANKSHAFT SOCKET
  
  Fig 23: Aligning No. 2 Crank Pin And Large End Of No. 2 Connecting Rod
  Courtesy of SUBARU OF AMERICA, INC.
5. Push the #2 connecting rod in the direction of the arrow, and remove the #2 piston with #2 connecting rod from the cylinder block.
  
  Fig 24: Removing No. 2 Piston And No. 2 Connecting Rod From Cylinder Block
  Courtesy of SUBARU OF AMERICA, INC.
6. Using the ST, turn the crankshaft clockwise and separate the positions of the #3 pin (A) of crankshaft and the large end (B) of #3 connecting rod.
  ST 18252AA000 CRANKSHAFT SOCKET
  
  Fig 25: Aligning No. 3 Crank Pin And Large End Of No. 3 Connecting Rod
  Courtesy of SUBARU OF AMERICA, INC.
7. Push the #3 connecting rod in the direction of the arrow, and remove the #3 piston with #3 connecting rod from the cylinder block.
  
  Fig 26: Removing No. 3 Piston And No. 3 Connecting Rod From Cylinder Block
  Courtesy of SUBARU OF AMERICA, INC.
Set the cylinder block so that the oil pan side faces upward, and remove the mounting bolts for A/C compressor and the generator bracket attached to the locations shown in the figure.

Fig 27: Locating A/C Compressor And Generator Bracket Mounting Bolts
Courtesy of SUBARU OF AMERICA, INC.
Set the part so that the cylinder block RH is on the upper side, and separate the cylinder block.
CAUTION:
- Place a wood board wrapped with a waste cloth to prevent the knock pin damage and to stabilize the cylinder block before work.
- Be careful not to scratch the mating surface of cylinder block during work.
1. Remove the bolt shown in the figure.
  
  Fig 28: Locating Cylinder Block RH Upper Mounting Bolts
  Courtesy of SUBARU OF AMERICA, INC.
2. Loosen the cylinder block mounting bolts in numerical order as shown in the figure, and separate the cylinder block RH and LH.
  NOTE: Lift the cylinder block RH slightly, and 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 29: Identifying Loosening Sequence Of Cylinder Block Mounting Bolts
  Courtesy of SUBARU OF AMERICA, INC.
Remove the crankshaft from cylinder block LH, and remove the rear oil seal.
Remove the O-ring from the cylinder block LH.

Fig 30: Locating Cylinder Block LH O-Ring
Courtesy of SUBARU OF AMERICA, INC.
Remove the crankshaft bearings from the cylinder block.
NOTE:
- Be careful not to confuse the crankshaft bearing combination.
- Press the bearing at the end opposite to locking lip (A).
  
  Fig 31: Locating Crankshaft Bearings
  Courtesy of SUBARU OF AMERICA, INC.
Remove the liquid gasket from cylinder block.