Cylinder Block: Installation

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

After setting the cylinder block to ST, install the crankshaft bearing.
ST 18232AA000 ENGINE STAND

NOTE: Apply a coat of engine oil to the bearing and crankshaft journal.
Mount the crankshaft in cylinder block (LH).
Apply liquid gasket to the mating surfaces of cylinder block (RH).
CAUTION: Do not allow liquid gasket to run over into oil passages, bearing grooves, etc.

NOTE: Install within 5 min. after applying liquid gasket.

Liquid gasket:

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

Liquid gasket applying diameter:

1.0±0.2 mm (0.039±0.008 in)

Fig 1: Identifying Liquid Gasket Applying Diameter
Courtesy of SUBARU OF AMERICA, INC.
Attach cylinder block (RH) to cylinder block (LH).
Apply a coat of engine oil to the washer and bolt thread.
Tighten all bolts in the numerical order as shown in the figure.
Tightening torque:

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

Fig 2: Identifying Cylinder Block Tightening Sequence
Courtesy of SUBARU OF AMERICA, INC.
Retighten all bolts in the numerical order as shown in the figure.
Tightening torque:

18 N.m (1.8 kgf-m, 13.3 ft-lb)

Fig 3: Identifying Cylinder Block Tightening Sequence
Courtesy of SUBARU OF AMERICA, INC.
Tighten all bolts by 90° in numerical order as shown in the figure.

Fig 4: Identifying Cylinder Block Tightening Sequence
Courtesy of SUBARU OF AMERICA, INC.
Install the upper bolt to cylinder block.
Tightening torque:

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

NOTE: Remove any liquid gasket squeezed out onto the seal surface between the chain cover and oil pan upper, after tightening the cylinder block connecting bolts.

Fig 5: Locating Cylinder Block Upper Mounting Bolts
Courtesy of SUBARU OF AMERICA, INC.
Apply a coat of engine oil to the oil seal inner periphery and outer periphery, and install the rear oil seal using ST1 and ST2.
NOTE: Use a new rear oil seal.

ST1 499597100 CRANKSHAFT OIL SEAL GUIDE

ST2 499587200 CRANKSHAFT OIL SEAL INSTALLER

Fig 6: Installing Rear Oil Seal Using Special Tools
Courtesy of SUBARU OF AMERICA, INC.
Face the front of the engine up, standing the engine on one end.

Fig 7: Identifying Engine Placed On Stand
Courtesy of SUBARU OF AMERICA, INC.
Attach the piston ring and oil ring to the piston.
1. Position the top ring gap at (A) in the figure.
2. Position the second ring gap at (B).
  
  Fig 8: Identifying Top And Second Ring Gap
  Courtesy of SUBARU OF AMERICA, INC.
3. Position the upper rail gap at (C) in the figure.
4. Position the expander gap at (D) in the figure.
5. Position the lower rail gap at (E) in the figure.
  
  Fig 9: Identifying Expander, Lower And Upper Rail Gap
  Courtesy of SUBARU OF AMERICA, INC.
CAUTION:
- Make sure ring gaps do not face the same direction.
- Make sure ring gaps are not within the piston skirt area.
- Assemble so that the stamp mark N faces towards the top of the piston.
Install the #1 piston and connecting rod to the cylinder block.
1. Apply engine oil to the outer circumference of the piston and in the cylinder block.
2. Face the front mark of piston (A) towards the front of the engine, and set the piston to the ST.
  
  Fig 10: Identifying Front Mark Of Piston
  Courtesy of SUBARU OF AMERICA, INC.
3. Using ST, press-fit the piston into cylinder block.
  NOTE:
  When inserting the piston into the cylinder block, perform according to the items listed below.
  - Insert while lightly tapping the top of the piston with the handle of a plastic hammer.
  - Insert while making sure that the large end of the connecting rod does not scratch the cylinder liner.
  - Insert while continually making sure that the large end of the connecting rod does not touch the crankshaft.
  ST 398744300 PISTON GUIDE
  
  Fig 11: Identifying No. 1 Connecting Rod And Crank Pin
  Courtesy of SUBARU OF AMERICA, INC.
4. Using the ST, turn the crankshaft and match the positions of the crank pin and the large end of the connecting rod.
  ST 18252AA000 CRANKSHAFT SOCKET
5. Install the connecting rod cap.
Tightening torque:

60 N.m (6.1 kgf-m, 44.3 ft-lb)

Fig 12: Identifying Connecting Rod Cap Mounting Bolts With Tightening Torques
Courtesy of SUBARU OF AMERICA, INC.
In the same procedures as for the #1 piston, install the piston and connecting rods to the cylinder block, in the order of #2, #3, #4, #5 and #6.
Install the O-ring to the underside of the cylinder block.
NOTE: Use new O-rings.

Fig 13: Locating O-Rings On Underside Of Cylinder Block
Courtesy of SUBARU OF AMERICA, INC.
Apply liquid gasket to the mating surface of oil pan upper.
NOTE: Install within 5 min. after applying liquid gasket.

Liquid gasket:

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

Liquid gasket applying diameter:

5.0±1.0 mm (0.20±0.04 in)

Fig 14: Identifying Liquid Gasket Applying Area On Mating Surface Of Oil Pan Upper
Courtesy of SUBARU OF AMERICA, INC.
Temporarily tighten the oil pan upper.
Tighten the oil pan upper installing bolts in the numerical order as shown in the figure.
Tightening torque:

18 N.m (1.8 kgf-m, 13.3 ft-lb)

Fig 15: Identifying Oil Pan Upper Mounting Bolts Tightening Sequence
Courtesy of SUBARU OF AMERICA, INC.
Install the thermostat and thermostat cover.
Tightening torque:

6.4 N.m (0.7 kgf-m, 4.7 ft-lb)

Fig 16: Identifying Oil Pan Upper, Thermostat And Cover
Courtesy of SUBARU OF AMERICA, INC.
Install the oil level switch. Refer to INSTALLATION .
Install the oil pump. Refer to INSTALLATION .
Tighten the oil cooler connector to install the oil cooler to the oil pan upper.
Tightening torque:

54 N.m (5.5 kgf-m, 39.8 ft-lb)

NOTE: Use new O-rings.

Fig 17: Identifying Oil Cooler And Connector, O-Ring And Oil Pan Upper
Courtesy of SUBARU OF AMERICA, INC.
Apply liquid gasket to the matching surface of oil pan lower.
NOTE: Install within 5 min. after applying liquid gasket.

Liquid gasket:

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

Liquid gasket applying diameter:

5.0±1.0 mm (0.20±0.04 in)

Fig 18: Identifying Liquid Gasket Applying Areas On Matching Surface Of Oil Pan Lower
Courtesy of SUBARU OF AMERICA, INC.
Tighten the oil pan lower installing bolts in the numerical order as shown in the figure.
Tightening torque:

6.4 N.m (0.7 kgf-m, 4.7 ft-lb)

Fig 19: Identifying Oil Pan Lower Installing Bolts Tightening Sequence
Courtesy of SUBARU OF AMERICA, INC.
Install the crankshaft position sensor plate.

Fig 20: Removing/Installing Crankshaft Position Sensor Plate
Courtesy of SUBARU OF AMERICA, INC.
Install the crankshaft position sensor.
Tightening torque:

6.4 N.m (0.7 kgf-m, 4.7 ft-lb)

Fig 21: Identifying Crankshaft Position Sensor
Courtesy of SUBARU OF AMERICA, INC.
Install the drive plate. Refer to INSTALLATION .
Install the cylinder head. Refer to INSTALLATION .
Install the camshaft. Refer to INSTALLATION .
Install the crank sprocket. Refer to INSTALLATION .
Install the cam sprocket. Refer to INSTALLATION .
Install the timing chain assembly. Refer to INSTALLATION .
Install the chain cover. Refer to INSTALLATION .
Install the crank pulley. Refer to INSTALLATION .
Install the engine to the vehicle. Refer to INSTALLATION .