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Cylinder Block: Removal

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.
NOTE: Before conducting this procedure, drain engine oil completely.
  1. Remove intake manifold. See REMOVAL , Intake Manifold.
  2. Remove V-belt. See REMOVAL , V-belt.
  3. Remove crankshaft pulley. See REMOVAL , Crankshaft Pulley.
  4. Remove belt cover. See REMOVAL , Belt Cover.
  5. Remove timing belt assembly. See REMOVAL , Timing Belt Assembly.
  6. Remove camshaft sprocket. See REMOVAL , Camshaft Sprocket.
  7. Remove crankshaft sprocket. See REMOVAL , Crankshaft Pulley.
  8. Remove generator and A/C compressor with their brackets.
  9. Remove rocker cover.
  10. Remove cylinder head bolts in alphabetical sequence shown in figure.
    NOTE: Leave bolts (a) and (b) engaged by three or four threads to prevent cylinder head from falling.
    Fig 1: Removing Cylinder Head Bolt In Sequence
    G02875375Courtesy of SUBARU OF AMERICA, INC.
  11. While tapping cylinder head with a plastic hammer, separate it from cylinder block.
  12. Remove bolts (a) through (c) to remove cylinder head.
    Fig 2: Removing Cylinder Head
    G02875376Courtesy of SUBARU OF AMERICA, INC.
  13. Remove cylinder head gasket.
    NOTE: Do not scratch the mating surface of cylinder head and cylinder block.
  14. Similarly, remove right side cylinder head.
  15. Remove clutch housing cover (MT vehicles only).
  16. Remove flywheel (MT vehicles only) or drive plate (AT vehicles only).

    Using ST, lock crankshaft.

    1. ST 498497100 CRANKSHAFT STOPPER
    Fig 3: Removing Flywheel (MT) Using ST
    G02875377Courtesy of SUBARU OF AMERICA, INC.
    Fig 4: Removing Drive Plate (AT) Using ST
    G02875378Courtesy of SUBARU OF AMERICA, INC.
  17. Remove oil separator cover.
  18. Remove water by-pass pipe for heater.
  19. Loosen bolts in alphabetical sequence as shown in figure and remove water pump.
    Fig 5: Removing Water Pump In Sequence
    G02875379Courtesy of SUBARU OF AMERICA, INC.
  20. Remove oil pump from cylinder block.

    Use a flat-bladed screwdriver as shown in figure when removing oil pump.

    NOTE: Be careful not to scratch the mating surface of cylinder block and oil pump.
    Fig 6: Removing Oil Pump From Cylinder Block
    G02875380Courtesy of SUBARU OF AMERICA, INC.
  21. Removal of oil pan
    1. Turn cylinder block with #2 and #4 piston sides facing upward.
    2. Remove bolts which secure oil pan to cylinder block.
    3. Insert a oil pan cutter blade between cylinder block-to-oil pan clearance and remove oil pan.
    NOTE: Do not use a screwdriver or similar tool in place of oil pan cutter.
    Fig 7: Removing Oil Pan
    G02875381Courtesy of SUBARU OF AMERICA, INC.
  22. Remove oil strainer stay.
  23. Remove oil strainer.
  24. Remove baffle plate.
  25. Remove oil filter using ST.
    1. ST 498547000 OIL FILTER WRENCH
    Fig 8: Removing Oil Filter Using ST
    G02875382Courtesy of SUBARU OF AMERICA, INC.
  26. Remove water pipe.
    Fig 9: Removing Water Pipe
    G02875383Courtesy of SUBARU OF AMERICA, INC.
    Fig 10: Exploded View Of Cylinder Block Components
    G02875384Courtesy of SUBARU OF AMERICA, INC.
  27. Remove service hole cover and service hole plugs using hexagon wrench [14 mm (0.55 in)].
    Fig 11: Removing Service Hole Cover & Plugs Using Hexagon Wrench
    G02875385Courtesy of SUBARU OF AMERICA, INC.
  28. Rotate crankshaft to bring #1 and #2 pistons to bottom dead center position, then remove piston snap ring through service hole of #1 and #2 cylinders.
    Fig 12: Removing Piston Snap Ring
    G02875386Courtesy of SUBARU OF AMERICA, INC.
  29. Draw out piston pin from #1 and #2 pistons using ST.
    1. ST 499097700 PISTON PIN REMOVER
    NOTE: Be careful not to confuse original combination of piston, piston pin and cylinder.
    Fig 13: Removing Piston Pin From Pistons Using ST
    G02875387Courtesy of SUBARU OF AMERICA, INC.
  30. Similarly remove piston pins from #3 and #4 pistons.
  31. Remove bolts which connect cylinder block on the side of #2 and #4 cylinders.
  32. Loosen bolts which connect cylinder block on the side of #1 and #3 cylinders two or three turns.
  33. Set up cylinder block so that #1 and #3 cylinders are on the upper side, then remove cylinder block connecting bolts.
  34. Separate left-hand and right-hand cylinder blocks.
    NOTE: When separating cylinder block, do not allow the connecting rod to fall and damage the cylinder block.
    Fig 14: Separating Left-Hand & Right-Hand Cylinder Blocks
    G02875388Courtesy of SUBARU OF AMERICA, INC.
  35. Remove rear oil seal.
  36. Remove crankshaft together with connecting rod.
  37. Remove crankshaft bearings from cylinder block using hammer handle.
    NOTE: Do not confuse combination of crankshaft bearings. Press bearing at the end opposite to locking lip.
  38. Remove pistons from cylinder block using hammer handle.
    NOTE: Do not confuse combination of pistons and cylinders.
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