Cylinder Block: Installation

WARNING: This page is about a different car, the 2003 Subaru Outback, 2003 Subaru Legacy, and 2003 Subaru Baja. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Installing Cylinder Blocks

Courtesy of SUBARU OF AMERICA, INC.

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

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.
Fluid packing:

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: Applying Fluid Packing To Mating Surface Of Cylinder Block
Courtesy of SUBARU OF AMERICA, INC.
Tighten 10 mm cylinder block connecting bolts in alphabetical sequence shown in figure. (LH side)
1. Tightening torque: 15 N.m (1.5 kgf-m, 11 ft-lb)
Fig 3: Tightening Cylinder Block Connecting Bolts (LH)
Courtesy of SUBARU OF AMERICA, INC.
Tighten 10 mm cylinder block connecting bolts in alphabetical sequence shown in figure. (RH side)
1. Tightening torque: 15 N.m (1.5 kgf-m, 11 ft-lb)
Fig 4: Tightening Cylinder Block Connecting Bolts (RH)
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 On Left Side Of Cylinder Block (A To D)
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 On Right Side Of Cylinder Block (E To J)
Courtesy of SUBARU OF AMERICA, INC.
Tighten 8 mm and 6 mm cylinder block connecting bolts in alphabetical sequence shown in figure.
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 (8mm & 6mm)
Courtesy of SUBARU OF AMERICA, INC.
Install rear oil seal using ST1 and ST2.
1. ST1 499597100 OIL SEAL GUIDE
2. 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 the figure.
Position the second ring gap at 180° on the reverse side for the top ring gap.

Fig 9: Positioning Second Ring Gap On Reverse Side
Courtesy of SUBARU OF AMERICA, INC.
Position the expander gap at (C) in the figure.

Fig 10: Positioning Expander Gap
Courtesy of SUBARU OF AMERICA, INC.
Position the lower rail gap at (D) in the figure.

Fig 11: Positioning Lower Rail Gap
Courtesy of SUBARU OF AMERICA, INC.

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

Fig 12: Aligning Lower Rail Spin Stopper With Piston Side Surface Hole
Courtesy of SUBARU OF AMERICA, INC.
Position the upper rail gap at (G) in the figure.

Fig 13: Positioning Upper Rail Gap
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 14: Installing Snap Rings In Piston Holes
Courtesy of SUBARU OF AMERICA, INC.

NOTE: Piston front marks faces towards the front of the engine.

Fig 15: Making Sure Piston Front Mark Faces Towards Front Of Engine
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.
  1. ST1 499987500 CRANKSHAFT SOCKET
  Fig 16: Turning Crankshaft Using ST1
  Courtesy of SUBARU OF AMERICA, INC.
3. Apply a coat of engine oil to pistons and cylinders and insert pistons in their cylinders using ST2.
  1. ST2 498747300 PISTON GUIDE
Fig 17: Applying Coat Of Engine Oil To Piston & Cylinders
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.
  1. ST3 499017100 PISTON PIN GUIDE
  Fig 18: Inserting ST3 Into Service Hole
  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 19: Installing Snap Ring
  Courtesy of SUBARU OF AMERICA, INC.
5. Apply fluid packing around the service hole plug.
  Fluid packing:
  
  Part number 004403007
  1. THREE BOND 1215 or equivalent
  Fig 20: 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 21: Installing Service Hole Plug & Gasket
  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.
  
  Fig 22: Installing Pistons & Piston Pins With Torque Specifications
  Courtesy of SUBARU OF AMERICA, INC.
Install water pipe.

Fig 23: Installing Water Pipe
Courtesy of SUBARU OF AMERICA, INC.
Install baffle plate.
1. Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7ft-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.
Fluid packing:

Part number 004403007
1. THREE BOND 1215 or equivalent
Fig 24: Applying Fluid Packing To Matching Surfaces Of Oil Pan
Courtesy of SUBARU OF AMERICA, INC.
Apply fluid packing to matching surfaces and install oil separator cover.
Fluid packing:

Part number 004403007
1. THREE BOND 1215 or equivalent
Fig 25: Applying Fluid Packing To Matching Surfaces Of Oil Separator Cover
Courtesy of SUBARU OF AMERICA, INC.
Install flywheel or drive plate.
To lock crankshaft, use ST.
1. ST 498497100 CRANKSHAFT STOPPER
1. Tightening torque: 72 N.m (7.3 kgf-m, 52.8 ft-lb)
Fig 26: Installing Flywheel
Courtesy of SUBARU OF AMERICA, INC.

Fig 27: Installing Drive Plate
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.
  1. ST 499587100 OIL SEAL INSTALLER
  Fig 28: Replacing Front Oil Seal Using ST
  Courtesy of SUBARU OF AMERICA, INC.
2. Apply fluid packing to matching surface of oil pump.
  Fluid packing:
  
  Part number 004403007
  1. THREE BOND 1215 or equivalent
  Fig 29: 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 30: 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.
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 figure.
Fig 31: Installing Water Pump & Gasket
Courtesy of SUBARU OF AMERICA, INC.
Install water by-pass pipe for heater.
Install oil filter using ST.
1. ST 498547000 OIL FILTER WRENCH
Fig 32: Installing Oil Filter Using ST
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 180s.
  
  Fig 33: Tightening Cylinder Head Bolts In Sequence
  Courtesy of SUBARU OF AMERICA, INC.
Install oil level gauge guide and tighten attaching bolt (left side only).
Install rocker cover.Tightening torque: 5 N.m (0.5 kgf-m, 3.6 ft-lb).
Install crankshaft sprocket. See INSTALLATION , Crankshaft Sprockets.
Install camshaft sprocket. See INSTALLATION , Camshaft Sprockets.
Install timing belt assembly. See INSTALLATION , Timing Belt Assembly.
Install belt cover. See INSTALLATION , Belt Cover.
Install crankshaft pulley. See INSTALLATION , Crankshaft Pulley.
Install generator and A/C compressor brackets on cylinder head.
Install V-belt. See INSTALLATION , V-belt.
Install intake manifold. See INSTALLATION , Intake Manifold.