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Cylinder Block: Installation

  1. Install the cylinder block LH to the engine stand.
  2. Apply engine oil to the crankshaft bearing, and install the crankshaft bearing to the cylinder block.
    CAUTION: When performing the operation of the cylinder block RH, be careful of the following.
    1. Place a wood board wrapped with a waste cloth to prevent the knock pin damage and to stabilize the cylinder block before work.
    2. Be careful not to scratch the mating surface of cylinder block during work.
    G11253455Courtesy of SUBARU OF AMERICA, INC.
  3. Install new O-rings to the cylinder block LH.
    G11253453Courtesy of SUBARU OF AMERICA, INC.
  4. Apply engine oil to the crankshaft journal, and set the crankshaft to cylinder block LH.
    G11253457Courtesy of SUBARU OF AMERICA, INC.
  5. Apply liquid gasket to the mating surface of cylinder block RH as shown in the figure.
    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.
    • 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)

    G13230408Courtesy of SUBARU OF AMERICA, INC.
  6. Install the cylinder block RH to the cylinder block LH.
  7. Join the cylinder blocks.
    CAUTION: When tightening the mounting bolts, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block.
    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. 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.
    3. Loosen all mounting bolts by 180° in the reverse order of tightening in step (2).
    4. 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.
    5. Loosen the mounting bolts (4 places) by 180° in the order of (6) → (5) → (4) → (3) as shown in the figure.
    6. Tighten the mounting bolts (4 places) with a torque of 17 N.m (1.7 kgf-m, 12.5 ft-lb) in the order of (3) → (4) → (5) → (6) as shown in the figure.
    7. Using an angle gauge, tighten the mounting bolts (4 places) with torque of 58°- 62° in the order of (3) → (4) → (5) → (6) as shown in the figure.
    8. Loosen the mounting bolts (6 places) by 180° in the order of (8) → (7) → (10) → (9) → (2) → (1) as shown in the figure.
    9. Tighten the mounting bolts (6 places) with a torque of 17 N.m (1.7 kgf-m, 12.5 ft-lb) in the order of (1) → (2) → (9) → (10) → (7) → (8) as shown in the figure.
    10. Using an angle gauge, tighten the mounting bolts (3 places) with torque of 58°- 62° in the order of (1) → (2) → (9) as shown in the figure.
    11. Using an angle gauge, tighten the mounting bolt (10) (1 place) shown in the figure to the angle of 78°- 82°.
    12. Using an angle gauge, tighten the mounting bolt (7) (1 place) shown in the figure to the angle of 58°- 62°.
    13. Using an angle gauge, tighten the mounting bolt (8) (1 place) shown in the figure to the angle of 78°- 82°.
      Fig 1: Cylinder Block Mounting Bolts (Tightening Sequence)
      G11253459Courtesy of SUBARU OF AMERICA, INC.
    14. Install the bolt shown in the figure.
      NOTE: After tightening, if the liquid gasket is squeezed out onto the seal surfaces of the chain cover and oil pan upper, remove any squeezed-out liquid gasket. Any liquid gasket on the chamfer area, however, should not be removed.

    Tightening torque: 

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

    G11253451Courtesy of SUBARU OF AMERICA, INC.
  8. Set the part so that the installation surface of the oil pan upper is on the upper side.
  9. Check that the piston ring gap for each piston is positioned correctly. Refer to MECHANICAL (H4DO (EXCEPT FOR HEV))>CYLINDER BLOCK>ASSEMBLY>PISTON AND CONNECTING ROD .
  10. 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. Using the ST, turn the crankshaft so that the #1 pin (A) of crankshaft is positioned at TDC.

      Preparation tool: 

      ST: CRANKSHAFT SOCKET (18252AA000)

      G11253461Courtesy 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 towards the front of the engine.
        G13230412Courtesy of SUBARU OF AMERICA, INC.
      • Insert while lightly tapping the crown of the piston with the handle of a plastic hammer.
      G11253463Courtesy of SUBARU OF AMERICA, INC.
    4. Using the ST, 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, 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.

      Preparation tool: 

      ST: CRANKSHAFT SOCKET (18252AA000)

      G11253464Courtesy of SUBARU OF AMERICA, INC.
    5. Using the ST, follow the numerical order shown in the figure to tighten the #1 connecting rod cap bolt to a torque of 10 N.m (1.0 kgf-m, 7.4 ft-lb) and then, in the numerical order, tighten them to a torque of 22 N.m (2.2 kgf-m, 16.2 ft-lb) (except for hybrid model), 25 N.m (2.5 kgf-m, 18.4 ft-lb) (for hybrid model).

      Preparation tool: 

      ST: SOCKET (18270AA020)

      G11253465Courtesy of SUBARU OF AMERICA, INC.
    6. Using the ST, turn the crankshaft clockwise so that the #2 pin (A) of crankshaft is positioned at TDC.

      Preparation tool: 

      ST: CRANKSHAFT SOCKET (18252AA000)

      G11253466Courtesy 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 (round mark) towards the front of the engine.
        G13230417Courtesy of SUBARU OF AMERICA, INC.
      • Insert while lightly tapping the crown of the piston with the handle of a plastic hammer.
      G11253468Courtesy of SUBARU OF AMERICA, INC.
    8. Using the ST, 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, 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.

      Preparation tool: 

      ST: CRANKSHAFT SOCKET (18252AA000)

      G11253469Courtesy of SUBARU OF AMERICA, INC.
    9. Using the ST, follow the numerical order shown in the figure to tighten the #2 connecting rod cap bolt to a torque of 10 N.m (1.0 kgf-m, 7.4 ft-lb) and then, in the numerical order, tighten them to a torque of 22 N.m (2.2 kgf-m, 16.2 ft-lb) (except for hybrid model), 25 N.m (2.5 kgf-m, 18.4 ft-lb) (for hybrid model).

      Preparation tool: 

      ST: SOCKET (18270AA020)

      G11253470Courtesy of SUBARU OF AMERICA, INC.
    10. Install #3 and #4 pistons and connecting rod caps in the same installation procedure as #1 and #2 pistons and connecting rod caps.
    11. Using the ST and angle gauge, tighten the #1 connecting rod cap bolts and #4 connecting rod cap bolts with a torque of 135°- 140° in numerical order as shown in the figure.

      Preparation tool: 

      ST: SOCKET (18270AA020)

      G11253471Courtesy of SUBARU OF AMERICA, INC.
    12. Using the ST, 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.

      Preparation tool: 

      ST: CRANKSHAFT SOCKET (18252AA000)

      G11253472Courtesy of SUBARU OF AMERICA, INC.
    13. Using the ST and angle gauge, tighten the #2 connecting rod cap bolts and #3 connecting rod cap bolts with a torque of 135°- 140° in numerical order as shown in the figure.

    Preparation tool: 

    ST: SOCKET (18270AA020)

    G11253473Courtesy of SUBARU OF AMERICA, INC.
  11. Set the part so that the installation surface of the intake manifold is on the upper side.
  12. 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)

    G11253441Courtesy of SUBARU OF AMERICA, INC.
  13. Install the engine rear hanger to the cylinder block RH.

    Tightening torque: 

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

    G11253440Courtesy of SUBARU OF AMERICA, INC.
  14. Install the PCV valve.

    Except for hybrid model: 

    Refer to EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) (H4DO (EXCEPT FOR HEV))>PCV VALVE>INSTALLATION .

    Hybrid model: 

    Refer to EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) (H4DO (HEV))>PCV VALVE>INSTALLATION .

  15. Install the knock sensor.

    Except for hybrid model: 

    Refer to FUEL INJECTION (FUEL SYSTEMS) (H4DO (EXCEPT FOR HEV))>KNOCK SENSOR>INSTALLATION .

    Hybrid model: 

    Refer to FUEL INJECTION (FUEL SYSTEMS) (H4DO (HEV))>KNOCK SENSOR>INSTALLATION .

  16. Install the PCV connector.

    Except for hybrid model: 

    Refer to EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) (H4DO (EXCEPT FOR HEV))>PCV CONNECTOR>INSTALLATION .

    Hybrid model: 

    Refer to EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) (H4DO (HEV))>PCV CONNECTOR>INSTALLATION .

  17. Install the water tank pipe assembly. Refer to COOLING (H4DO (EXCEPT FOR HEV))>WATER PIPE>INSTALLATION>WATER TANK PIPE ASSEMBLY .

    Except for hybrid model: 

    Refer to COOLING (H4DO (EXCEPT FOR HEV))>WATER PIPE>INSTALLATION>WATER TANK PIPE ASSEMBLY .

    Hybrid model: 

    Refer to COOLING (H4DO (HEV))>WATER PIPE>INSTALLATION>WATER TANK PIPE ASSEMBLY .

  18. Install the crank sprocket. Refer to MECHANICAL (H4DO (EXCEPT FOR HEV))>CRANK SPROCKET>INSTALLATION .
  19. Install the oil pan upper. Refer to LUBRICATION (H4DO (EXCEPT FOR HEV))>OIL PAN>INSTALLATION>OIL PAN UPPER .
  20. Install the cylinder head. Refer to MECHANICAL (H4DO (EXCEPT FOR HEV))>CYLINDER HEAD>INSTALLATION .
  21. Apply a coat of engine oil to the oil seal inner periphery and outer periphery, and install new rear oil seal using ST1 and ST2.

    Preparation tool: 

    ST1: OIL SEAL GUIDE (18671AA020)

    ST2: OIL SEAL INSTALLER (18657AA030)

    G13230426Courtesy of SUBARU OF AMERICA, INC.
  22. Install the crankshaft position sensor plate with drive plate. (Except for hybrid model (CVT model)) Refer to CONTINUOUSLY VARIABLE TRANSMISSION (TR580)>DRIVE PLATE>INSTALLATION .
  23. Install the crankshaft position sensor plate with flywheel. (MT model and hybrid model)

    MT model: 

    Refer to CLUTCH SYSTEM>FLYWHEEL>INSTALLATION .

    Hybrid model: 

    Refer to CONTINUOUSLY VARIABLE TRANSMISSION (TH2A)>FLYWHEEL>INSTALLATION .

  24. Install the engine to the vehicle.

    Except for hybrid model: 

    Refer to MECHANICAL (H4DO (EXCEPT FOR HEV))>ENGINE ASSEMBLY>INSTALLATION>EXCEPT FOR HYBRID MODEL .

    Hybrid model: 

    Refer to MECHANICAL (H4DO (EXCEPT FOR HEV))>ENGINE ASSEMBLY>INSTALLATION>HYBRID MODEL .

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