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Cylinder Block: Installation

  1. Apply engine oil to the crankshaft bearing, and install the crankshaft bearing to 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.
    G10262807Courtesy of SUBARU OF AMERICA, INC.
  2. Install O-rings to the cylinder block LH.
    NOTE: Use new O-rings.
    G08548053Courtesy of SUBARU OF AMERICA, INC.
  3. Apply engine oil to the crankshaft journal, and set the crankshaft to cylinder block LH.
    G08317169Courtesy of SUBARU OF AMERICA, INC.
  4. Apply liquid gasket to the mating surface of cylinder block RH as shown in the figure.
    CAUTION: Do not let the liquid gasket overflow to the oil passage and crankshaft bearing portions, because the engine seizure may result.
    NOTE:
    • Before applying liquid gasket, degrease the old liquid gasket seal surface of the cylinder block RH and cylinder block LH.
    • Install within 5 min. after applying liquid gasket.

    Liquid gasket:

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

    Liquid gasket applying diameter:

    Mating surfaces other than ranges A, B and C

    1±0.5 mm (0.0394±0.0197 in)

    Mating surfaces of ranges A and C

    4±0.5 mm (0.1575±0.0197 in)

    Mating surfaces of range B

    3.2±0.5 mm (0.1260±0.0197 in)

    G12406430Courtesy of SUBARU OF AMERICA, INC.
  5. Install the cylinder block RH to the cylinder block LH.
  6. Join the cylinder blocks.
    1. Apply a coat of engine oil to the washers and cylinder block mounting bolt threads.
      NOTE: To prevent mixture of engine oil into the water jacket, do not apply a large amount.
    2. Install the cylinder head bolt at the locations shown in the figure.
      NOTE: This procedure is required to tighten the cylinder block mounting bolts with specified angle using angle gauge.
      G08317171Courtesy of SUBARU OF AMERICA, INC.
    3. Tighten all mounting bolts with a torque of 35 N.m (3.6 kgf-m, 25.8 ft-lb) in numerical order as shown in the figure.
      CAUTION: When tightening the mounting bolts with specified torque, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block.
      Fig 1: Cylinder Block LH Mounting Bolts (Tightening Sequence)
      G10262812Courtesy of SUBARU OF AMERICA, INC.
    4. Loosen all mounting bolts by 180° in numerical order as shown in the figure.
      CAUTION: When loosening the mounting bolts, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block.
      Fig 2: Cylinder Block LH Mounting Bolts (Loosening Sequence)
      G10262813Courtesy of SUBARU OF AMERICA, INC.
    5. Tighten all mounting bolts with a torque of 35 N.m (3.6 kgf-m, 25.8 ft-lb) in numerical order as shown in the figure.
      CAUTION: When tightening the mounting bolts with specified torque, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block.
      Fig 3: Cylinder Block RH Mounting Bolts (Tightening Sequence)
      G10262812Courtesy of SUBARU OF AMERICA, INC.
    6. Loosen the mounting bolts (4 places) by 180° in numerical order as shown in the figure.
      CAUTION: When loosening the mounting bolts, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block.
      Fig 4: Cylinder Block LH Mounting Bolts (Loosening Sequence)
      G10262815Courtesy of SUBARU OF AMERICA, INC.
    7. Tighten the mounting bolts (4 places) with a torque of 17 N.m (1.7 kgf-m, 12.5 ft-lb) in numerical order as shown in the figure.
      CAUTION: When tightening the mounting bolts with specified torque, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block.
      Fig 5: Cylinder Block RH Mounting Bolts (Tightening Sequence)
      G10262816Courtesy of SUBARU OF AMERICA, INC.
    8. Using angle gauge, tighten the mounting bolts (4 places) with specified angle in numerical order as shown in the figure.
      CAUTION: When tightening the mounting bolts with specified angle, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block.

      Tightening angle:

      60°±2°

      Fig 6: Cylinder Block RH Mounting Bolts (Tightening Sequence)
      G10262817Courtesy of SUBARU OF AMERICA, INC.
    9. Loosen the mounting bolts (6 places) by 180° in numerical order as shown in the figure.
      CAUTION: When loosening the mounting bolts, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block.
      Fig 7: Cylinder Block RH Mounting Bolts (Loosening Sequence)
      G10262818Courtesy of SUBARU OF AMERICA, INC.
    10. Tighten the mounting bolts (6 places) with a torque of 17 N.m (1.7 kgf-m, 12.5 ft-lb) in numerical order as shown in the figure.
      CAUTION: When tightening the mounting bolts with specified torque, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block.
      Fig 8: Cylinder Block RH Mounting Bolts (Tightening Sequence)
      G10262819Courtesy of SUBARU OF AMERICA, INC.
    11. Using angle gauge, tighten the mounting bolts (6 places) with specified angle in numerical order as shown in the figure.
      CAUTION: When tightening the mounting bolts with specified angle, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block.

      Tightening angle:

      60°±2°

      Fig 9: Cylinder Block LH Bolts (Tightening Sequence)
      G10262820Courtesy of SUBARU OF AMERICA, INC.
    12. Remove the cylinder head bolt attached at the locations shown in the figure.
      G08317171Courtesy of SUBARU OF AMERICA, INC.
    13. Install the bolt shown in the figure.
      NOTE: After tightening, if the liquid gasket is squeezed out in the seal surface area of the chain cover and oil pan upper, completely remove any liquid gasket that is squeezed out. Any liquid gasket on the chamfer area, however, should not be removed.

      Tightening torque: 

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

      G08317163Courtesy of SUBARU OF AMERICA, INC.
  7. Set the part so that the oil pan side of cylinder block is on the upper side.
  8. 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 18671AA020 OIL SEAL GUIDE 

    ST2 18657AA030 OIL SEAL INSTALLER 

    G12406443Courtesy of SUBARU OF AMERICA, INC.
  9. Install a bolt of suitable length (M10 x P1.25) 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 of bolt for the four bolts.
    G09476212Courtesy of SUBARU OF AMERICA, INC.
  10. Raise the cylinder block so that the rear oil seal is on the lower side.
  11. Adjust the positions of piston ring gap for each piston.
    NOTE: Check that the piston ring mark of compression ring faces the top side of the piston.
    1. Set the ring gap of the top ring to the position (A) in the figure.
      G10262825Courtesy of SUBARU OF AMERICA, INC.
    2. Position the ring gap of second ring at (B) in the figure on the 180° opposite direction of (A).
      G10262826Courtesy of SUBARU OF AMERICA, INC.
    3. Set the ring gap of the upper rail to the position (C) in the figure.
      G10262827Courtesy of SUBARU OF AMERICA, INC.
    4. Align the upper rail spin stopper (E) to the side hole (D) on the piston.
      G10262828Courtesy of SUBARU OF AMERICA, INC.
    5. Position the ring gap of expander at (F) in the figure on the 180° opposite direction of (C).
      G10262829Courtesy of SUBARU OF AMERICA, INC.
    6. Set the ring gap of lower rail at position (G), located 120° clockwise from (C) in the figure.
      G10262830Courtesy of SUBARU OF AMERICA, INC.
    7. Check that the positions of piston ring gap are properly adjusted.
      NOTE: When checking the positions of piston ring gap, also check that the piston ring gaps are not positioned within the range of piston skirt extended line.
  12. Install the piston and connecting rod to the cylinder block.
    1. Apply engine oil to the outer circumference of each piston, crankshaft pin, and in the cylinder block.
    2. Turn the crankshaft so that the #1 pin (A) of crankshaft is positioned at TDC using ST.

      ST 18252AA000 CRANKSHAFT SOCKET 

      G10262831Courtesy of SUBARU OF AMERICA, INC.
    3. Compress the piston ring using piston ring compressor, and insert the #1 connecting rod with #1 piston into cylinder block.
      CAUTION:
      • Be careful not to damage the cylinder liner and #1 pin of crankshaft by the #1 connecting rod large end.
      • Be careful not to apply strong impact when inserting to prevent connecting rod bearing from falling off.
      NOTE:
      • Face the piston front mark (arrow) towards the front of the engine.
        G12406452Courtesy of SUBARU OF AMERICA, INC.
      • Insert while lightly tapping the crown of the piston with the handle of a plastic hammer.
      G08317193Courtesy of SUBARU OF AMERICA, INC.
    4. Turn the crankshaft counterclockwise so that the #1 pin of crankshaft and the large end (A) of #1 connecting rod are positioned as shown in the figure using ST, while pressing the #1 piston crown, and then set the #1 connecting rod cap and #1 connecting rod cap bolt.
      NOTE:
      • Each connecting rod has its own mating cap. Make sure that they are assembled correctly by checking their matching symbol.
      • Use a new connecting rod cap bolt.
      • Apply a coat of engine oil to the #1 connecting rod cap seat and the connecting rod cap bolt threads.

      ST 18252AA000 CRANKSHAFT SOCKET 

      G10262834Courtesy of SUBARU OF AMERICA, INC.
    5. Using ST, tighten the #1 connecting rod cap bolts to 10 N.m (1.0 kgf-m, 7.4 ft-lb) in numerical order as shown in the figure, then retighten the bolts to 22 N.m (2.2 kgf-m, 16.2 ft-lb) in numerical order as shown in the figure.

      ST 18270AA020 SOCKET 

      G12406455Courtesy of SUBARU OF AMERICA, INC.
    6. Turn the crankshaft clockwise so that the #2 pin (A) of crankshaft is positioned at TDC using ST.

      ST 18252AA000 CRANKSHAFT SOCKET 

      G10262836Courtesy of SUBARU OF AMERICA, INC.
    7. Compress the piston ring using piston ring compressor, and insert the #2 connecting rod with #2 piston into cylinder block.
      CAUTION:
      • Be careful not to damage the cylinder liner and #2 pin of crankshaft by the #2 connecting rod large end.
      • Be careful not to apply strong impact when inserting to prevent connecting rod bearing from falling off.
      NOTE:
      • Face the piston front mark (arrow) towards the front of the engine.
        G12406457Courtesy of SUBARU OF AMERICA, INC.
      • Insert while lightly tapping the crown of the piston with the handle of a plastic hammer.
      G08317198Courtesy of SUBARU OF AMERICA, INC.
    8. Turn the crankshaft clockwise so that the #2 pin of crankshaft and the large end (A) of #2 connecting rod are positioned as shown in the figure using ST, while pressing the #2 piston crown, and then set the #2 connecting rod cap and #2 connecting rod cap bolt.
      NOTE:
      • Each connecting rod has its own mating cap. Make sure that they are assembled correctly by checking their matching symbol.
      • Use a new connecting rod cap bolt.
      • Apply a coat of engine oil to the #2 connecting rod cap seat and the connecting rod cap bolt threads.

      ST 18252AA000 CRANKSHAFT SOCKET 

      G10262839Courtesy of SUBARU OF AMERICA, INC.
    9. Using ST, tighten the #2 connecting rod cap bolts to 10 N.m (1.0 kgf-m, 7.4 ft-lb) in numerical order as shown in the figure, then retighten the bolts to 22 N.m (2.2 kgf-m, 16.2 ft-lb) in numerical order as shown in the figure.

      ST 18270AA020 SOCKET 

      G12406460Courtesy of SUBARU OF AMERICA, INC.
    10. Turn the crankshaft clockwise so that the #3 pin (A) of crankshaft is positioned at TDC using ST.

      ST 18252AA000 CRANKSHAFT SOCKET 

      G10262841Courtesy of SUBARU OF AMERICA, INC.
    11. Compress the piston ring using piston ring compressor, and insert the #3 connecting rod with #3 piston into cylinder block.
      CAUTION:
      • Be careful not to damage the cylinder liner and #3 pin of crankshaft by the #3 connecting rod large end.
      • Be careful not to apply strong impact when inserting to prevent connecting rod bearing from falling off.
      NOTE:
      • Face the piston front mark (arrow) towards the front of the engine.
        G12406462Courtesy of SUBARU OF AMERICA, INC.
      • Insert while lightly tapping the crown of the piston with the handle of a plastic hammer.
      G08317203Courtesy of SUBARU OF AMERICA, INC.
    12. Turn the crankshaft counterclockwise so that the #3 pin of crankshaft and the large end (A) of #3 connecting rod are positioned as shown in the figure using ST, while pressing the #3 piston crown, and then set the #3 connecting rod cap and #3 connecting rod cap bolt.
      NOTE:
      • Each connecting rod has its own mating cap. Make sure that they are assembled correctly by checking their matching symbol.
      • Use a new connecting rod cap bolt.
      • Apply a coat of engine oil to the #3 connecting rod cap seat and the connecting rod cap bolt threads.

      ST 18252AA000 CRANKSHAFT SOCKET 

      G10262844Courtesy of SUBARU OF AMERICA, INC.
    13. Using ST, tighten the #3 connecting rod cap bolts to 10 N.m (1.0 kgf-m, 7.4 ft-lb) in numerical order as shown in the figure, then retighten the bolts to 22 N.m (2.2 kgf-m, 16.2 ft-lb) in numerical order as shown in the figure.

      ST 18270AA020 SOCKET 

      G12406465Courtesy of SUBARU OF AMERICA, INC.
    14. Turn the crankshaft clockwise so that the #4 pin (A) of crankshaft is positioned at TDC using ST.

      ST 18252AA000 CRANKSHAFT SOCKET 

      G10262846Courtesy of SUBARU OF AMERICA, INC.
    15. Compress the piston ring using piston ring compressor, and insert the #4 connecting rod with #4 piston into cylinder block.
      CAUTION:
      • Be careful not to damage the cylinder liner and #4 pin of crankshaft by the #4 connecting rod large end.
      • Be careful not to apply strong impact when inserting to prevent connecting rod bearing from falling off.
      NOTE:
      • Face the piston front mark (arrow) towards the front of the engine.
        G12406467Courtesy of SUBARU OF AMERICA, INC.
      • Insert while lightly tapping the crown of the piston with the handle of a plastic hammer.
      G08317208Courtesy of SUBARU OF AMERICA, INC.
    16. Turn the crankshaft clockwise so that the #4 pin of crankshaft and the large end (A) of #4 connecting rod are positioned as shown in the figure using ST, while pressing the #4 piston crown, and then set the #4 connecting rod cap and #4 connecting rod cap bolt.
      NOTE:
      • Each connecting rod has its own mating cap. Make sure that they are assembled correctly by checking their matching symbol.
      • Use a new connecting rod cap bolt.
      • Apply a coat of engine oil to the #4 connecting rod cap seat and the connecting rod cap bolt threads.

      ST 18252AA000 CRANKSHAFT SOCKET 

      G10262849Courtesy of SUBARU OF AMERICA, INC.
    17. Using ST, tighten the #4 connecting rod cap bolts to 10 N.m (1.0 kgf-m, 7.4 ft-lb) in numerical order as shown in the figure, then retighten the bolts to 22 N.m (2.2 kgf-m, 16.2 ft-lb) in numerical order as shown in the figure.

      ST 18270AA020 SOCKET 

      G12406470Courtesy of SUBARU OF AMERICA, INC.
    18. Install the cam carrier mounting bolts at the locations shown in the figure.
      NOTE: This procedure is required to tighten the connecting rod cap bolts with specified angle using angle gauge.
      G08317211Courtesy of SUBARU OF AMERICA, INC.
    19. 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 

      G10262852Courtesy of SUBARU OF AMERICA, INC.
    20. Using ST and angle gauge, tighten the #1 connecting rod cap bolts and #4 connecting rod cap bolts with specified angle in numerical order as shown in the figure.

      ST 18270AA020 SOCKET 

      Tightening angle:

      137°+3°-2°

      G12406473Courtesy of SUBARU OF AMERICA, INC.
    21. 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 

      G10262854Courtesy of SUBARU OF AMERICA, INC.
    22. Using ST and angle gauge, tighten the #2 connecting rod cap bolts and #3 connecting rod cap bolts with specified angle in numerical order as shown in the figure.

      ST 18270AA020 SOCKET 

      Tightening angle:

      137°+3°-2°

      G12406475Courtesy of SUBARU OF AMERICA, INC.
    23. Remove the cam carrier mounting bolts attached at the locations shown in the figure.
      G08317211Courtesy of SUBARU OF AMERICA, INC.
  13. Set the cylinder block so that the oil pan side of the block faces upward, and remove the mounting bolts attached to the locations shown in the figure.
    G09476212Courtesy of SUBARU OF AMERICA, INC.
  14. Install the oil pan upper. Ref. to LUBRICATION(H4DO)>Oil Pan>INSTALLATION>OIL PAN UPPER
  15. Install the ST1, ST2, ST3 and ST4 to the 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 

    Tightening torque: 

    35 N.m (3.6 kgf-m, 25.8 ft-lb)

    G10262782Courtesy of SUBARU OF AMERICA, INC.
  16. Install the water jacket spacer to the cylinder block RH and cylinder block LH.
    G09486474Courtesy of SUBARU OF AMERICA, INC.
  17. Install the crankshaft position sensor with crankshaft position sensor holder to the cylinder block LH.

    Tightening torque: 

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

    G12406404Courtesy of SUBARU OF AMERICA, INC.
  18. Install the crankshaft position sensor plate with drive plate. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Drive Plate>INSTALLATION
  19. Install the PCV valve. Ref. to EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) (H4DO)>PCV Valve>INSTALLATION
  20. Install the knock sensor. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>Knock Sensor>INSTALLATION
  21. Install the O-ring to the cylinder block and PCV connector.
    NOTE: Use new O-rings.
    G10262779Courtesy of SUBARU OF AMERICA, INC.
  22. Set the water pipe assembly and PCV connector to the cylinder block, and install the bolts which secure the water pipe assembly and PCV connector to the cylinder block.

    Tightening torque: 

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

    G12406402Courtesy of SUBARU OF AMERICA, INC.
  23. Install the engine rear hanger to the cylinder block RH.

    Tightening torque: 

    36 N.m (3.7 kgf-m, 26.6 ft-lb)

    G10262776Courtesy of SUBARU OF AMERICA, INC.
  24. Install the crank sprocket. Ref. to MECHANICAL(H4DO)>Crank Sprocket>INSTALLATION 
  25. Install the cylinder head. Ref. to MECHANICAL(H4DO)>Cylinder Head>INSTALLATION 
  26. Install the engine to the vehicle. Ref. to MECHANICAL(H4DO)>Engine Assembly>INSTALLATION 
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