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Home >> Subaru >> 2002 >> Forester Base >> Repair and Diagnosis >> Engine Mechanical >> Timing Belt >> Engine Mechanical 2.5L SOHC >> Cylinder Block >> Removal

Cylinder Block: Removal

NOTE: Before conducting this procedure, drain engine oil completely if applicable.
  1. Remove intake manifold. Refer to REMOVAL under INTAKE MANIFOLD .
  2. Remove V-belt. Refer to REMOVAL under V-BELT .
  3. Remove crankshaft pulley. Refer to REMOVAL under CRANKSHAFT PULLEY .
  4. Remove belt cover. Refer to REMOVAL under BELT COVER .
  5. Remove timing belt assembly. Refer to REMOVAL under TIMING BELT ASSEMBLY .
  6. Remove camshaft sprocket. Refer to REMOVAL under CAMSHAFT SPROCKET .
  7. Remove crankshaft sprocket. Refer to REMOVAL under 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.
    CAUTION: Leave bolts (a) and (b) engaged by three or four threads to prevent cylinder head from falling.
    Fig 1: Removing Cylinder Head Bolts In Sequence
    G02862298Courtesy of SUBARU OF AMERICA, INC.
  11. While tapping cylinder head with a plastic hammer, separate it from cylinder block.
  12. Remove bolts (a) and (b) to remove cylinder head.
    Fig 2: Removing Cylinder Head
    G02862299Courtesy of SUBARU OF AMERICA, INC.
  13. Remove cylinder head gasket.
    CAUTION: 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

    • MT MODEL
      Fig 3: Locking Crankshaft (MT Model)
      G02862300Courtesy of SUBARU OF AMERICA, INC.
    • AT MODEL
    Fig 4: Locking Crankshaft (AT Model)
    G02862301Courtesy of SUBARU OF AMERICA, INC.
  17. Remove oil separator cover.
  18. Remove water by-pass pipe for heater.
  19. Remove water by-pass pipe between oil cooler and water pump (AT vehicles only).
    Fig 5: Removing Water By-Pass Pipe Between Oil Cooler And Water Pump
    G02862302Courtesy of SUBARU OF AMERICA, INC.
  20. Remove oil filter using ST.

    ST 498187300:  OIL FILTER WRENCH

  21. Remove oil cooler. (AT vehicles only)
    Fig 6: Removing Oil Cooler
    G02862303Courtesy of SUBARU OF AMERICA, INC.
  22. 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.
    CAUTION: Do not use a screwdriver or similar tool in place of oil pan cutter.
    Fig 7: Removing Oil Pan
    G02862304Courtesy of SUBARU OF AMERICA, INC.
  23. Remove oil strainer stay.
  24. Remove oil strainer.
  25. Remove baffle plate.
  26. Remove water pips.
  27. Remove water pump.
  28. Remove oil pump from cylinder block.

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

    CAUTION: Be careful not to scratch the mating surface of cylinder block and oil pump.
    Fig 8: Removing Oil Pump From Cylinder Block
    G02862305Courtesy of SUBARU OF AMERICA, INC.
    Fig 9: Exploded View Of Cylinder Block And Bolts
    G02862306Courtesy of SUBARU OF AMERICA, INC.
  29. Remove service hole cover and service hole plugs using hexagon wrench [14 mm (0.55 in)].
    Fig 10: Removing Service Hole Cover
    G02862307Courtesy of SUBARU OF AMERICA, INC.
  30. Rotate crankshaft to bring #1 and #2 pistons to bottom dead center position, then remove piston circlip through service hole of #1 and #2 cylinders.
    Fig 11: Removing Piston Circlip
    G02862308Courtesy of SUBARU OF AMERICA, INC.
  31. Draw out piston pin from #1 and #2 pistons using ST.

    ST 499097700:  PISTON PIN REMOVER

    CAUTION: Be careful not to confuse original combination of piston, piston pin and cylinder.
    Fig 12: Removing Piston Pin
    G02862309Courtesy of SUBARU OF AMERICA, INC.
  32. Similarly remove piston pins from #3 and #4 pistons.
  33. Remove bolts which connect cylinder block on the side of #2 and #4 cylinders.
  34. Back off bolts which connect cylinder block on the side of #1 and #3 cylinders two or three turns.
  35. Set up cylinder block so that #1 and #3 cylinders are on the upper side, then remove cylinder block connecting bolts.
  36. Separate left-hand and right-hand cylinder blocks.
    CAUTION: When separating cylinder block, do not allow the connecting rod to fall and damage the cylinder block.
    Fig 13: Separating Cylinder Block
    G02862310Courtesy of SUBARU OF AMERICA, INC.
  37. Remove rear oil seal.
  38. Remove crankshaft together with connecting rod.
  39. Remove crankshaft bearings from cylinder block using hammer handle.
    CAUTION: Do not confuse combination of crankshaft bearings. Press bearing at the end opposite to locking lip.
  40. Draw out each piston from cylinder block using wooden bar or hammer handle.
    CAUTION: Do not confuse combination of piston and cylinder.
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