Cylinder Block: Installation

WARNING: This page is about a different car, the 2004 Subaru Outback, 2004 Subaru Legacy, and 2004 Subaru Baja. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Remove oil in the mating surface of bearing and cylinder block before installation. Also apply a coat of engine oil to crankshaft pins.

Fig 1: Applying Coat Of Engine Oil To Crankshaft Pins

Courtesy of SUBARU OF AMERICA, INC.

Position crankshaft on the #2 and #4 cylinder block.
Apply fluid packing to the mating surface of #1 and #3 cylinder block, and position it on #2 and #4 cylinder block.
1. Fluid packing:
  1. Part number 004403007
    1. THREE BOND 1215 or equivalent
NOTE: Do not allow fluid packing to jut into O-ring grooves, oil passages, bearing grooves, etc.

Fig 2: Identifying Fluid Packing
Courtesy of SUBARU OF AMERICA, INC.
Tighten 10 mm cylinder block connecting bolts in alphabetical sequence shown in Fig 3 . (LH side)
1. Tightening torque: 15 N.m (1.5 kgf-m, 11 ft-lb)
Fig 3: Tightening Cylinder Block Connecting Bolts In Alphabetical Sequence
Courtesy of SUBARU OF AMERICA, INC.
Tighten 10 mm cylinder block connecting bolts in alphabetical sequence shown in Fig 4 . (RH side)
1. Tightening torque: 15 N.m (1.5 kgf-m, 11 ft-lb)
Fig 4: Tightening Cylinder Block Connecting Bolts In Alphabetical Sequence
Courtesy of SUBARU OF AMERICA, INC.
Tighten bolts (A to D) on left side of cylinder block more 90° in alphabetical sequence.

Fig 5: Tightening Bolts (A To D) Additional 90° (Left Of Cylinder Block)
Courtesy of SUBARU OF AMERICA, INC.
Tighten bolts (E to J) on right side of cylinder block more 90° in alphabetical sequence.

Fig 6: Tightening Bolts (E To J) Additional 90° (Right Of Cylinder Block)
Courtesy of SUBARU OF AMERICA, INC.
Tighten 8 mm and 6 mm cylinder block connecting bolts in alphabetical sequence shown in Fig 7 .
1. Tightening torque:
  1. (A) - (G): 25 N.m (2.5 kgf-m, 18.1 ft-lb)
  2. (H): 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
Fig 7: Tightening Cylinder Block Connecting Bolts In Alphabetical Sequence
Courtesy of SUBARU OF AMERICA, INC.
Install rear oil seal using ST1 and ST2.
ST1 499597100 OIL SEAL GUIDE

ST2 499587200 OIL SEAL INSTALLER

Fig 8: Installing Rear Oil Seal Using ST1 & ST2
Courtesy of SUBARU OF AMERICA, INC.
Position the top ring gap at (A) or (B) in Fig 9 .
Position the second ring gap at 180° on the reverse side for the top ring gap.

Fig 9: Positioning Top Ring Gap
Courtesy of SUBARU OF AMERICA, INC.
Position the expander gap at (C) in Fig 10 or Fig 11 .

Fig 10: Positioning Expander Gap (Except U5)
Courtesy of SUBARU OF AMERICA, INC.

Fig 11: Positioning Expander Gap (U5)
Courtesy of SUBARU OF AMERICA, INC.
Position the lower rail gap at (D) in Fig 12 or Fig 13 .

Fig 12: Positioning Lower Rail Gap (Except U5)
Courtesy of SUBARU OF AMERICA, INC.

Fig 13: Positioning Lower Rail Gap (U5)
Courtesy of SUBARU OF AMERICA, INC.

NOTE: Align lower rail spin stopper (F) with piston side surface hole (E).

Fig 14: Aligning Lower Rail Spin Stopper With Piston Side Surface Hole
Courtesy of SUBARU OF AMERICA, INC.
Position the upper rail gap at (G) in Fig 15 or Fig 16 .

Fig 15: Positioning Upper Rail Gap (Except U5)
Courtesy of SUBARU OF AMERICA, INC.

Fig 16: Positioning Upper Rail Gap (Except U5)
Courtesy of SUBARU OF AMERICA, INC.
CAUTION:
- Ensure ring gaps do not face the same direction.
- Ensure ring gaps are not within the piston skirt area.
Install snap ring.
Install snap rings in piston holes located opposite service holes in cylinder block, when positioning all pistons in the corresponding cylinders.

NOTE: Use new snap rings.

Fig 17: Installing Snap Ring
Courtesy of SUBARU OF AMERICA, INC.

NOTE: Piston front mark (A) faces towards the front of the engine.

Fig 18: Facing Front Mark (A) Towards Front Of Engine (Except U5)
Courtesy of SUBARU OF AMERICA, INC.

Fig 19: Facing Front Mark (A) Towards Front Of Engine (U5)
Courtesy of SUBARU OF AMERICA, INC.

Fig 20: Applying Coat Of Engine Oil To Pistons
Courtesy of SUBARU OF AMERICA, INC.
Installing piston
1. Turn cylinder block so that #1 and #2 cylinders face upward.
2. Using ST1, turn crankshaft so that #1 and #2 connecting rods are set at bottom dead center.
  ST1 499987500 CRANKSHAFT SOCKET
3. Apply a coat of engine oil to pistons and cylinders and insert pistons in their cylinders using ST2.
  ST2 498747300 PISTON GUIDE
  
  Fig 21: Installing Piston
  Courtesy of SUBARU OF AMERICA, INC.
Installing piston pin
1. Apply a coat of engine oil to ST3.
2. Insert ST3 into service hole to align piston pin hole with connecting rod small end.
  ST3 499017100 PISTON PIN GUIDE
  
  Fig 22: Installing Piston Pin Using Piston Pin Guide
  Courtesy of SUBARU OF AMERICA, INC.
3. Apply a coat of engine oil to piston pin and insert piston pin into piston and connecting rod through service hole.
4. Install snap ring.
  NOTE: Use new snap rings.
  
  Fig 23: Installing Snap Ring
  Courtesy of SUBARU OF AMERICA, INC.
5. Apply fluid packing around the service hole plug.
  1. Fluid packing:
    1. Part number 004403007
      1. THREE BOND 1215 or equivalent
  Fig 24: Applying Fluid Packing Around Service Hole Plug
  Courtesy of SUBARU OF AMERICA, INC.
6. Install service hole plug and gasket.
  NOTE: Use a new gasket.
  
  Fig 25: Installing Service Hole Plug & Gasket
  Courtesy of SUBARU OF AMERICA, INC.
  
  Fig 26: Lubricating Pistons
  Courtesy of SUBARU OF AMERICA, INC.
7. Turn cylinder block so that #3 and #4 cylinders face upward. Using the same procedures as used for #1 and #2 cylinders, install pistons and piston pins.
Install water pipe.

Fig 27: Installing Water Pipe
Courtesy of SUBARU OF AMERICA, INC.
Install baffle plate.
1. Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb
Install oil strainer and O-ring.
1. Tightening torque: 10 N.m (1.0 kgf-m, 7 ft-lb
Install oil strainer stay.
Apply fluid packing to matching surfaces and install oil pan.
1. Fluid packing:
  1. Part number 004403007
    1. THREE BOND 1215 or equivalent
Fig 28: Applying Fluid Packing To Matching Surfaces
Courtesy of SUBARU OF AMERICA, INC.
Apply fluid packing to matching surfaces and install oil separator cover.
1. Fluid packing:
  1. Part number 004403007
    1. THREE BOND 1215 or equivalent
Fig 29: Applying Fluid Packing To Matching Surfaces
Courtesy of SUBARU OF AMERICA, INC.
Install flywheel or drive plate.
To lock crankshaft, use ST.

ST 498497100 CRANKSHAFT STOPPER
1. Tightening torque: 72 N.m (7.3 kgf-m, 52.8 ft-lb)
Fig 30: Installing Flywheel Using ST To Lock Crankshaft
Courtesy of SUBARU OF AMERICA, INC.

Fig 31: Installing Drive Plate Using ST To Lock Crankshaft
Courtesy of SUBARU OF AMERICA, INC.
Install housing cover.
Installation of oil pump
1. Discard front oil seal after removal. Replace with a new one using ST.
  ST 499587100 OIL SEAL INSTALLER
  
  Fig 32: Installing Oil Pump
  Courtesy of SUBARU OF AMERICA, INC.
2. Apply fluid packing to matching surface of oil pump.
  1. Fluid packing:
    1. Part number 004403007
      1. THREE BOND 1215 or equivalent
  Fig 33: Applying Fluid Packing To Matching Surface Of Oil Pump
  Courtesy of SUBARU OF AMERICA, INC.
3. Apply a coat of engine oil to the inside of the oil seal.
  
  Fig 34: Applying Coat Of Engine Oil To Inside Of Oil Seal
  Courtesy of SUBARU OF AMERICA, INC.
4. Install oil pump on cylinder block. Be careful not to damage oil seal during installation.
  1. Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
  NOTE:
  - Do not forget to install O-ring and seal when installing oil pump.
  - Align flat surface of oil pump's inner rotor with crankshaft before installation.
Install water pump and gasket.
1. Tightening torque:
  1. First: 12 N.m (1.2 kgf-m, 8.7 ft-lb)
  2. Second: 12 N.m (1.2 kgf-m, 8.7 ft-lb)
NOTE:
- Be sure to use a new gasket.
- When installing water pump, tighten bolts in two stages in alphabetical sequence as shown in Fig 35 .
Fig 35: Installing Water Pump & Tightening Bolts In Alphabetical Sequence
Courtesy of SUBARU OF AMERICA, INC.
Install water by-pass pipe for heater.
Install oil filter by turning it by hand, being careful not to damage seal rubber.
- Further tighten (approximately 2/3 to 3/4 turn) the oil filter with outer diameter of 80 mm (3.15 in) after the seal rubber contacts the cylinder block or the oil cooler.
- Further tighten (approximately 1 turn) the oil filter with outer diameter of 68 mm (2.68 in) or 65 mm (2.56 in) after the seal rubber contacts the cylinder block.
CAUTION:
- Oil filter with outer diameter of 80 mm (3.15 in) is not available for turbo model.
- Do not tighten excessively, or oil may leak.
Fig 36: Installing Oil Fuel Filter
Courtesy of SUBARU OF AMERICA, INC.
Tighten cylinder head bolts.
1. Apply a coat of engine oil to washers and bolt threads.
2. Tighten all bolts to 29 N.m (3.0 kgf-m, 22 ft-lb) in alphabetical sequence.
  Then tighten all bolts to 69 N.m (7.0 kgf-m, 51 ft-lb) in alphabetical sequence.
3. Back off all bolts by 180° first; back them off by 180° again.
4. Tighten bolts (a) and (b) to 34 N.m (3.5 kgf-m, 25 ft-lb).
5. Tighten bolts (c), (d), (e) and (f) to 15 N.m (1.5 kgf-m, 11 ft-lb).
6. Tighten all bolts by 80 to 90° in alphabetical sequence.
  CAUTION: Do not tighten bolts more than 90°.
7. Further tighten all bolts by 80 to 90° in alphabetical sequence.
  CAUTION: Ensure that the total "re-tightening angle" [in the former two steps], do not exceed 180°.
  
  Fig 37: Tightening Bolts Additional 80° To 90°
  Courtesy of SUBARU OF AMERICA, INC.
Install oil level gauge guide and tighten attaching bolt (left side only).
Install rocker cover.
Install crankshaft sprocket. Refer to INSTALLATION , CRANKSHAFT SPROCKET.
Install camshaft sprocket. Refer to INSTALLATION , CAMSHAFT SPROCKET.
Install timing belt assembly. Refer to INSTALLATION , Timing Belt Assembly.
Install belt cover. Refer to INSTALLATION , BELT COVER.
Install crankshaft pulley. Refer to INSTALLATION , CRANKSHAFT PULLEY.
Install generator and A/C compressor brackets on cylinder head.
Install V-belt. Refer to INSTALLATION , V-BELT.
Install intake manifold. Refer to INSTALLATION , Intake Manifold.