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Cylinder Block: Installation

WARNING: This page is about a different variant/trim than selected.
  1. 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.
  2. Mount the crankshaft in cylinder block (LH).
  3. 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), THREE BOND 1217H or equivalent

    Liquid gasket applying diameter: 

    1.0±0.2 mm (0.0394±0.0079 in)

    G12405629Courtesy of SUBARU OF AMERICA, INC.
  4. Attach cylinder block (RH) to cylinder block (LH).
  5. Apply a coat of engine oil to the washer and bolt thread.
  6. 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 1: Cylinder Block Bolts (Tightening Sequence)
    G05667901Courtesy of SUBARU OF AMERICA, INC.
  7. 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 2: Cylinder Block Bolts (Tightening Sequence)
    G05667901Courtesy of SUBARU OF AMERICA, INC.
  8. Tighten all bolts by 90° in numerical order as shown in the figure.
    Fig 3: Cylinder Block Bolts (Tightening Sequence)
    G05667901Courtesy of SUBARU OF AMERICA, INC.
  9. 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.
    G05667904Courtesy of SUBARU OF AMERICA, INC.
  10. 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 

    G13248313Courtesy of SUBARU OF AMERICA, INC.
  11. Face the front of the engine up, standing the engine on one end.
    G05667889Courtesy of SUBARU OF AMERICA, INC.
  12. 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).
      G05018790Courtesy 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.
      G05018791Courtesy 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.
  13. 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.
      G06342208Courtesy 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 

      G13248318Courtesy 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.
      1. 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 29 N.m (3.0 kgf-m, 21.4 ft-lb) in numerical order as shown in the figure.
      2. Using an angle gauge, tighten the connecting rod cap bolts to the specified angle in numerical order as shown in the figure.

        Tightening angle: 

        90°- 95°

        Fig 4: Connecting Rod Cap Bolts Tightening Sequence
        G13248319Courtesy of SUBARU OF AMERICA, INC.
  14. 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.
  15. Install the O-ring to the underside of the cylinder block.
    NOTE: Use new O-rings.
    G05667890Courtesy of SUBARU OF AMERICA, INC.
  16. 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), THREE BOND 1217H or equivalent

    Liquid gasket applying diameter: 

    5.0±1.0 mm (0.1969±0.0394 in)

    G12405642Courtesy of SUBARU OF AMERICA, INC.
  17. Temporarily tighten the oil pan upper.
  18. 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 5: Oil Pan Upper Bolts Tightening Sequence
    G05667914Courtesy of SUBARU OF AMERICA, INC.
  19. Install the thermostat and thermostat cover.

    Tightening torque: 

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

    G13248323Courtesy of SUBARU OF AMERICA, INC.
  20. Install the oil level switch. Ref. to LUBRICATION (H6DO)>OIL LEVEL SWITCH>INSTALLATION .
  21. Install the oil pump. Ref. to LUBRICATION (H6DO)>OIL PUMP>INSTALLATION .
  22. 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.
    G13248324Courtesy of SUBARU OF AMERICA, INC.
  23. 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), THREE BOND 1217H or equivalent

    Liquid gasket applying diameter: 

    5.0±1.0 mm (0.1969±0.0394 in)

    G12405646Courtesy of SUBARU OF AMERICA, INC.
  24. 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 6: Oil Pan Lower Bolts Tightening Sequence
    G05667918Courtesy of SUBARU OF AMERICA, INC.
  25. Install the crankshaft position sensor plate.
    G05018775Courtesy of SUBARU OF AMERICA, INC.
  26. Install the crankshaft position sensor.

    Tightening torque: 

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

    G05667883Courtesy of SUBARU OF AMERICA, INC.
  27. Install the drive plate. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>DRIVE PLATE>INSTALLATION .
  28. Install the knock sensor. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H6DO)>KNOCK SENSOR>INSTALLATION .
  29. Install the generator. Ref. to STARTING/CHARGING SYSTEMS (H6DO)>GENERATOR>INSTALLATION .
  30. Install the crank sprocket. Ref. to MECHANICAL (H6DO)>Crank Sprocket>INSTALLATION .
  31. Install the cylinder head. Ref. to MECHANICAL (H6DO)>Cylinder Head>INSTALLATION .
  32. Install the engine to the vehicle. Ref. to MECHANICAL (H6DO)>Engine Assembly>INSTALLATION .
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