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Cylinder Block: Removal

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: Before conducting this procedure, drain engine oil completely.
  1. Remove intake manifold. Refer to REMOVAL , Intake Manifold.
  2. Remove V-belt. Refer to REMOVAL , V-BELT.
  3. Remove crankshaft Pulley.
  4. Remove belt cover. Refer to REMOVAL , BELT COVER.
  5. Remove timing belt assembly. Refer to REMOVAL , TIMING BELT ASSEMBLY.
  6. Remove camshaft sprocket. Refer to REMOVAL , CAMSHAFT SPROCKET.
  7. Remove crankshaft sprocket. Refer to 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 Fig 1 .
    NOTE: Leave bolts (a) and (b) engaged by three or four threads to prevent cylinder head from falling.
    Fig 1: Removing Cylinder Head Bolts In Alphabetical Sequence
    G00900904Courtesy 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 Bolts (a Through c) To Removing Cylinder Head
    G00900905Courtesy 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.

    ST 498497100 CRANKSHAFT STOPPER

    Fig 3: Removing Flywheel (MT Vehicles)
    G00900906Courtesy of SUBARU OF AMERICA, INC.
    Fig 4: Removing Drive Plate (AT Vehicles)
    G00900907Courtesy 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 Fig 5 and remove water pump.
    Fig 5: Removing Bolts In Alphabetical Sequence & Removing Water Pump
    G00900908Courtesy of SUBARU OF AMERICA, INC.
  20. Remove oil pump from cylinder block.

    Use a flat-bladed screwdriver as shown in Fig 6 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 Using Screwdriver
    G00900909Courtesy 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 Using Oil Pan Cutter
    G00900910Courtesy of SUBARU OF AMERICA, INC.
  22. Remove oil strainer stay.
  23. Remove oil strainer.
  24. Remove baffle plate.
  25. Remove oil filter using ST.

    ST 498547000 OIL FILTER WRENCH [outer diameter 80 mm (3.15 in) for oil filter]

    ST 18332AA000 OIL FILTER WRENCH [outer diameter 68 mm (2.68 in) for oil filter]

    ST 18332AA010 OIL FILTER WRENCH [outer diameter 65 mm (2.56 in) for oil filter]

    Fig 8: Removing Oil Filter Using ST
    G00900911Courtesy of SUBARU OF AMERICA, INC.
  26. Remove water pipe.
    Fig 9: Removing Water Pipe
    G00900912Courtesy of SUBARU OF AMERICA, INC.
    Fig 10: Removing Cylinder Block Bolts
    G00900913Courtesy 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 & Service Hole Plugs Using Hexagon Wrench
    G00900914Courtesy 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 Through Service Hole
    G00900915Courtesy of SUBARU OF AMERICA, INC.
  29. Draw out piston pin from #1 and #2 pistons using ST.

    ST 499097700 PISTON PIN REMOVER

    NOTE: Be careful not to confuse original combination of piston, piston pin and cylinder.
    Fig 13: Drawing Out Piston Pin From #1 & #2 Pistons Using ST
    G00900916Courtesy of SUBARU OF AMERICA, INC.
  30. Similarly remove piston pins from #3 and #4 pistons.
  31. Remove bolts which connect cylinder block of 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: Identifying Parts Of Cylinder Block & Crankcase
    G00900917Courtesy 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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