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Cylinder Block: Installation

WARNING: This page is about a different car, the 2004 Subaru Baja. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Installing Bolts Which Connect Cylinder Block
G00923843Courtesy of SUBARU OF AMERICA, INC.
  1. Remove oil in the mating surface of bearing and cylinder block before installation. Also apply a coat of engine oil to crankshaft pins.
  2. Position the crankshaft on #2 and #4 cylinder block.
  3. 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 No. 004403007 

    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 #1 & #3 Cylinder Block
    G00923844Courtesy of SUBARU OF AMERICA, INC.
  4. Apply engine oil to washers and thread of bolts.
  5. Tighten the 10 mm cylinder block connecting bolts in alphabetical sequence shown in the figure. (LH side)

    Tightening torque: 

    10 N.m (1.0 kgf-m, 7.4 ft-lb) 

    Fig 3: Tightening Cylinder Block Connecting Bolts
    G00923845Courtesy of SUBARU OF AMERICA, INC.
  6. Tighten the 10 mm cylinder block connecting bolts in alphabetical sequence shown in the figure. (RH side)

    Tightening torque: 

    10 N.m (1.0 kgf-m, 7.4 ft-lb) 

    Fig 4: Tightening Cylinder Block Connecting Bolts
    G00923846Courtesy of SUBARU OF AMERICA, INC.
  7. Further tighten the LH side bolts (A - D) in alphabetical sequence.

    Tightening torque: 

    (A), (C): 20 N.m (2.0 kgf-m, 14.8 ft-lb) 

    (B), (D): 15 N.m (1.5 kgf-m, 10.8 ft-lb) 

    Fig 5: Tightening LH Side Bolts
    G00923847Courtesy of SUBARU OF AMERICA, INC.
  8. Further tighten the RH side bolts (E - J) in alphabetical sequence.

    Tightening torque: 

    (E), (F), (G), (I): 20 N.m (2.0 kgf-m, 14.8 ft-lb) 

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

    Fig 6: Tightening RH Side Bolts
    G00923848Courtesy of SUBARU OF AMERICA, INC.
  9. Further tighten the LH side bolts (A - D) by 90° in alphabetical sequence.
    Fig 7: Tightening LH Side Bolts
    G00923849Courtesy of SUBARU OF AMERICA, INC.
  10. Further tighten the RH side bolts (E - J) by 90° in alphabetical sequence.
    Fig 8: Tightening RH Side Bolts (E - J)
    G00923850Courtesy of SUBARU OF AMERICA, INC.
  11. Tighten the 8 mm and 6 mm cylinder block connecting bolts in alphabetical sequence shown in the figure.

    Tightening torque: 

    (A) - (G): 25 N.m (2.5 kgf-m, 18.1 ft-lb) 

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

    Fig 9: Tightening Cylinder Block Connecting Bolts
    G00923851Courtesy of SUBARU OF AMERICA, INC.
  12. Install the rear oil seal using ST1 and ST2.

    ST1 499597100 CRANKSHAFT OIL SEAL GUIDE

    ST2 499587200 CRANKSHAFT OIL SEAL INSTALLER

    Fig 10: Installing Rear Oil Seal Using ST1 & ST2
    G00923852Courtesy of SUBARU OF AMERICA, INC.
  13. Position the top ring gap at (A) or (B) in the figure.
  14. Position the second ring gap at 180° on the reverse side for the top ring gap.
    Fig 11: Positioning Second Ring Gap At 180° On Reverse Side
    G00923853Courtesy of SUBARU OF AMERICA, INC.
  15. Position the upper rail gap at (C) in the figure.
    Fig 12: Positioning Upper Rail Gap
    G00923854Courtesy of SUBARU OF AMERICA, INC.
  16. Align upper rail spin stopper (D) with piston side surface hole (E).
    Fig 13: Aligning Upper Rail Spin Stopper With Piston Side Surface Hole
    G00923855Courtesy of SUBARU OF AMERICA, INC.
  17. Position the expander gap at (F) in the figure.
    Fig 14: Positioning Expander Gap
    G00923856Courtesy of SUBARU OF AMERICA, INC.
  18. Position the lower rail gap at (G) in the figure.
    Fig 15: Positioning Lower Rail Gap
    G00923857Courtesy of SUBARU OF AMERICA, INC.
    NOTE:
    • Ensure ring gaps do not face the same direction.
    • Ensure ring gaps are not within the piston skirt area.
  19. Install the circlip.

    Install the circlips in piston holes located opposite of service holes in cylinder block, when positioning all pistons in the corresponding cylinders.

    NOTE: Use new circlips.
    Fig 16: Installing Circlip
    G00923858Courtesy of SUBARU OF AMERICA, INC.
    Fig 17: Installing Circlip
    G00923859Courtesy of SUBARU OF AMERICA, INC.
  20. Installing the piston:
    1. Turn the cylinder block so that #1 and #2 cylinders face upward.
    2. Using the ST1, turn the 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 the pistons and cylinders and insert pistons in their cylinders using ST2.

      ST2 498747300 PISTON GUIDE

      Fig 18: Inserting Pistons In Their Cylinders Using ST2
      G00923860Courtesy of SUBARU OF AMERICA, INC.
    NOTE: Piston front mark faces towards the front of the engine.
    Fig 19: Identifying Piston Front Mark
    G00923861Courtesy of SUBARU OF AMERICA, INC.
  21. Installing piston pin:
    1. Apply a coat of engine oil to ST3, and then insert the ST3 into service hole to align piston pin hole with connecting rod small end.

      ST3 499017100 PISTON PIN GUIDE

      Fig 20: Installing Piston Pin
      G00923862Courtesy of SUBARU OF AMERICA, INC.
    2. Apply a coat of engine oil to the piston pin and insert piston pin into piston and connecting rod through service hole.
    3. Using the ST, install the circlip.
      NOTE: Use new circlips.
      Fig 21: Installing Circlip
      G00923863Courtesy of SUBARU OF AMERICA, INC.
    4. Apply fluid packing around the service hole plug.

      Fluid packing: 

      Part No. 004403007 

      THREE BOND 1215 or equivalent 

      Fig 22: Applying Fluid Packing Around Service Hole Plug
      G00923864Courtesy of SUBARU OF AMERICA, INC.
    5. Install the service hole plug and gasket.
      NOTE: Use a new gasket.
      Fig 23: Installing Service Hole Plug & Gasket
      G00923865Courtesy of SUBARU OF AMERICA, INC.
      Fig 24: Identifying Piston
      G00923866Courtesy of SUBARU OF AMERICA, INC.
    6. Turn the cylinder block so that #3 and #4 cylinders face upward. Using the same procedures as used for #1 and #2 cylinders, install the pistons and piston pins.
  22. Install the water pipe.
  23. Install the baffle plate.

    Tightening torque: 

    6.4 N.m (0.65 kgf-m, 4.7 ft-lb) 

  24. Install the oil strainer and O-ring

    Tightening torque: 

    10 N.m (1.0 kgf-m, 7 ft-lb) 

  25. Install the oil strainer stay.
  26. Apply fluid packing to the matching surfaces, and then install the oil pan.

    Fluid packing: 

    Part No. 004403012 

    THREE BOND 1207C or equivalent 

    Tightening torque: 

    5 N.m (0.5 kgf-m, 3.6 ft-lb) 

    Fig 25: Applying Fluid Packing To Matching Surfaces
    G00923867Courtesy of SUBARU OF AMERICA, INC.
  27. Apply fluid packing to the matching surfaces, and then install the oil separator cover.

    Fluid packing: 

    Part No. 004403007 

    THREE BOND 1215 or equivalent 

    Tightening torque: 

    6.4 N.m (0.65 kgf-m, 4.7 ft-lb) 

    Fig 26: Applying Fluid Packing To Matching Surfaces
    G00923868Courtesy of SUBARU OF AMERICA, INC.
  28. Install the flywheel. Refer to INSTALLATION , Clutch Disc and Cover.
  29. Install the clutch disc and cover. Refer to REMOVAL , Clutch Disc and Cover.
  30. Installation of oil pump:
    1. Discard the front oil seal after removal. Replace with a new one using the ST.

      ST 499587100 OIL SEAL INSTALLER

      Fig 27: Replacing Oil Seal Using ST
      G00923869Courtesy of SUBARU OF AMERICA, INC.
    2. Apply fluid packing to the matching surface of oil pump.

      Fluid packing: 

      Part No. 004403007 

      THREE BOND 1215 or equivalent 

      Fig 28: Applying Fluid Packing To Matching Surface Of Oil Pump
      G00923870Courtesy of SUBARU OF AMERICA, INC.
    3. Apply a coat of engine oil to the inside of the oil seal.
      Fig 29: Applying Coat Of Engine Oil To Inside Of Oil Seal
      G00923871Courtesy of SUBARU OF AMERICA, INC.
    4. Install the oil pump on cylinder block. Be careful not to damage the oil seal during installation.

    Tightening torque: 

    6.4 N.m (0.65 kgf-m, 4.7 ft-lb) 

    NOTE:
    • Do not forget to install the O-ring and seal when installing the oil pump.
    • Align the flat surface of oil pump's inner rotor with crankshaft before installation.
  31. Install the water pump and gasket.

    Tightening torque: 

    First; 12 N.m (1.2 kgf-m, 8.7 ft-lb) 

    Second; 12 N.m (1.2 kgf-m, 8.7 ft-lb) 

    NOTE:
    • Be sure to use a new gasket.
    • When installing the water pump, tighten the bolts in two stages in alphabetical sequence as shown in the figure.
    Fig 30: Installing Water Pump & Gasket
    G00923872Courtesy of SUBARU OF AMERICA, INC.
  32. Install the water by-pass pipe for heater.
  33. Install the oil cooler.

    Tightening torque: 

    T1: 45 N.m (4.6 kgf-m, 33 ft-lb) 

    T2: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) 

    T3: 54 N.m (5.3 kgf-m, 39 ft-lb) 

    Fig 31: Installing Oil Cooler
    G00923873Courtesy of SUBARU OF AMERICA, INC.
  34. Install the oil filter using ST.

    ST 18332AA000 OIL FILTER WRENCH (Outer diameter: 68 mm)

    ST 18332AA010 OIL FILTER WRENCH (Outer diameter: 65 mm)

  35. Install the water by-pass pipe between oil cooler and water pump.
  36. Install the water pipe.
    NOTE: Always use a new O-ring.
  37. Install the cylinder head assembly. Refer to  CYLINDER HEAD ASSEMBLY  . 
  38. Install the oil level gauge guide and tighten the attaching bolt (LH side).
  39. Install the rocker cover.
  40. Install the crankshaft sprocket. Refer to  CRANKSHAFT SPROCKET  . 
  41. Install the camshaft sprocket. Refer to CAMSHAFT SPROCKET .
  42. Install the timing belt assembly. Refer to INSTALLATION , Timing Belt Assembly.
  43. Install the timing belt cover. Refer to TIMING BELT COVER .
  44. Install the crankshaft pulley. Refer to  CRANKSHAFT PULLEY  . 
  45. Install the generator and A/C compressor brackets on cylinder head.
  46. Install the V-belt. Refer to V-BELT .
  47. Install the intake manifold. Refer to INSTALLATION , Intake Manifold.
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