Cylinder Block: Installation

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

G13258007

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Remove oil on the mating surface of cylinder block before installation. Apply a coat of engine oil to the bearing and crankshaft journal.
Position the crankshaft and O-ring on cylinder block RH.
NOTE: Use new O-rings.
Apply liquid gasket to the mating surfaces of cylinder block RH, and position cylinder block LH.
NOTE:
- Install within 5 min. after applying liquid gasket.
- Do not allow liquid gasket to jut into O-ring grooves, oil passages, bearing grooves, etc.
Liquid gasket:

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

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Apply a coat of engine oil to the washer and bolt thread.
NOTE: Use a new seal washer.
Tighten the 10 mm cylinder block connecting bolts on the LH side (A - D) in alphabetical order.
Tightening torque:

10 N.m (1.0 kgf-m, 7.4 ft-lb)

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Tighten the 10 mm cylinder block connecting bolts on the RH side (E - J) in alphabetical order.
Tightening torque:

10 N.m (1.0 kgf-m, 7.4 ft-lb)

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Tighten the LH side cylinder block connecting bolts (A - D) further in alphabetical order.
Tightening torque:

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

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Tighten the RH side cylinder block connecting bolts (E - J) further in alphabetical order.
Tightening torque:

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

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Tighten the LH side cylinder block connecting bolts (A - D) further in alphabetical order.
- (A), (C): Angle tightening
  Tightening angle:
  
  90°
- (B), (D): Torque tightening
Tightening torque:

40 N.m (4.1 kgf-m, 29.5 ft-lb)

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Tighten the RH side cylinder block connecting bolts (E - J) further in alphabetical order.
Tightening angle:

90°

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Tighten the 8 mm and 6 mm cylinder block connecting bolts on the LH side (A - H) in alphabetical order.
Tightening torque:

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

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

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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

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Position the top ring gap at (A) or (B) in the figure.
Position the second ring gap at 180° on the reverse side the top ring gap.

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Position the upper rail gap at (C) in the figure.

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Align the upper rail spin stopper (E) to the side hole (D) on the piston.

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Position the expander gap at (F) in the figure on the 180° opposite direction of (C).

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Set the lower rail gap at position (G), located 120° clockwise from (C) in the figure.

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NOTE:
- Make sure ring gaps do not face the same direction.
- Make sure ring gaps are not within the piston skirt area.
Install the snap ring.
Before positioning the piston on the cylinder block, attach the snap ring in the service hole of the cylinder block, and the piston hole on the opposite side.

NOTE: Use new snap rings.

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Install the piston.

Set the parts so that the #1 and #2 cylinders are on the upper side.
Using the ST1, turn the crankshaft so that #1 and #2 connecting rods are set at bottom dead center.
ST1 499987500 CRANKSHAFT SOCKET

Apply a coat of engine oil to the pistons and cylinders and insert pistons in their cylinders using ST2.

ST2 498747300 PISTON GUIDE

G04997752

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NOTE: Face the piston front mark towards the front of the engine.

G13258025

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Install the piston pin.

Apply a coat of engine oil to ST3.

Insert ST3 into the service hole to align the piston pin hole and the connecting rod small end.

ST3 499017100 PISTON PIN GUIDE

G04997753

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Apply a thin coat of engine oil to piston pin, and insert the piston pin into piston and connecting rod through service hole.

Install the snap ring.

NOTE: Use new snap rings.

G04997754

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Apply liquid gasket to the threaded portion of the service hole plug.

Liquid gasket:

THREE BOND 1105 (Part No. 004403010) or equivalent

G04997755

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Install the service hole plug and gasket.

NOTE: Use a new gasket.

Tightening torque:

70 N.m (7.1 kgf-m, 51.6 ft-lb)

G04997730

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G13258030

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Set the parts so that the #3 and #4 cylinders are on the upper side. Following the same procedures as used for #1 and #2 cylinders, install the pistons and piston pins.
Install the service hole cover.

NOTE: Use new O-rings.

Tightening torque:

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

Install the water pipe assembly along with the water tank pipe assembly to the cylinder block RH, and install the clamp using the Clamp pincer (14100134).
NOTE: Use new O-rings and clamps.

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Tightening torque:

6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
Install the baffle plate.
Tightening torque:

6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
Install the oil strainer.
NOTE: Use new O-rings.

Tightening torque:

10 N.m (1.0 kgf-m, 7.4 ft-lb)
Tighten the oil strainer stay together with the baffle plate.
Tightening torque:

6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
Apply liquid gasket to the mating surfaces of oil pan, and install the oil pan.
NOTE: Install within 5 min. after applying liquid gasket.

Liquid gasket:

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

Tightening torque:

5 N.m (0.5 kgf-m, 3.7 ft-lb)

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Apply liquid gasket to the mating surface of oil separator cover and the threaded portion of bolt (A) shown in the figure (when reusing the bolt), and then install the oil separator cover.
NOTE:
- Install within 5 min. after applying liquid gasket.
- Use new oil separator cover.
Liquid gasket:

Mating surface

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

Bolt thread (A) (when reusing the bolt)

THREE BOND 1324 (Part No. 004403042) or equivalent

Tightening torque:

6.4 N.m (0.65 kgf-m, 4.7 ft-lb)

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Install the flywheel. Refer to CLUTCH SYSTEM>FLYWHEEL>INSTALLATION .
Install the clutch disc and cover. Refer to CLUTCH SYSTEM>CLUTCH DISC AND COVER>INSTALLATION .

Install the oil pump.

Using the ST, install the front oil seal.

ST 499587100 OIL SEAL INSTALLER

NOTE: Use a new front oil seal.

G04997893

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Apply liquid gasket to the mating surfaces of oil pump.

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

Liquid gasket:

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

G05333114

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Apply a thin coat of engine oil to the inside of front oil seal.

G04997765

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Install the oil pump to cylinder block.
CAUTION:
- Be careful not to damage the front oil seal during installation.
- Make sure the front oil seal lip is not folded.
NOTE:
- Align the flat surface of oil pump's inner rotor with that of crankshaft before installation.
- Use new O-rings.
- Do not forget to assemble O-rings.
Apply liquid gasket to the three bolts thread shown in figure. (When reusing bolts)

Liquid gasket:

THREE BOND 1324 (Part No. 004403042) or equivalent

Tightening torque:

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

G07909946

Courtesy of SUBARU OF AMERICA, INC.

Install the water pump and gasket.
NOTE:
- When installing the water pump, tighten bolts in two stages in alphabetical order as shown in the figure.
- Use a new gasket.
Tightening torque:

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

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

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Install the water by-pass pipe for heater.
Tightening torque:

6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
Install the oil cooler. Refer to LUBRICATION (STI)>ENGINE OIL COOLER>INSTALLATION .
Install the oil filter. Refer to LUBRICATION (STI)>ENGINE OIL FILTER>INSTALLATION .
Install the crank sprocket. Refer to MECHANICAL (STI)>CRANK SPROCKET>INSTALLATION .
Install the cylinder head. Refer to MECHANICAL (STI)>CYLINDER HEAD>INSTALLATION .
Install the engine to the vehicle. Refer to MECHANICAL (STI)>ENGINE ASSEMBLY>INSTALLATION .