Cylinder Block: Installation

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Fig 1: Installing Cylinder Block & Crankshaft

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 No. 2 and 4 cylinder block.
Apply fluid packing to the mating surface of No. 1 and 3 cylinder block, and position it on No. 2 and 4 cylinder block.
Fluid packing:

Part number 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
Courtesy of SUBARU OF AMERICA, INC.
Coat the washers and threaded parts of the bolts with engine oil.
Tighten 10 mm cylinder block connecting bolts in alphabetical sequence shown (LH side).
Tightening torque: 10 N.m (1.0 kgf-m, 7.4 ft-lb)

Fig 3: Tightening Cylinder Block Connecting Bolts (LH Side) In Alphabetical Sequence
Courtesy of SUBARU OF AMERICA, INC.
Tighten 10 mm cylinder block connecting bolts in alphabetical sequence shown (RH side).
Tightening torque: 10 N.m (1.0 kgf-m, 7.4 ft-lb)

Fig 4: Tightening Cylinder Block Connecting Bolts (RH Side) In Alphabetical Sequence
Courtesy of SUBARU OF AMERICA, INC.
Tighten bolts (A to D) on left side of cylinder block more in alphabetical sequence.
Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb)

Fig 5: Tightening Bolts (A To D) On Left Side Of Cylinder Block In Alphabetical Sequence
Courtesy of SUBARU OF AMERICA, INC.
Tighten bolts (E to J) on right side of cylinder block more in alphabetical sequence.
Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb)

Fig 6: Tightening Bolts (E To J) On Right Side Of Cylinder Block In Alphabetical Sequence
Courtesy of SUBARU OF AMERICA, INC.
Tighten bolts (A and C) on left side of cylinder block 90° more in alphabetical order. & tighten bolts (B and D) more in alphabetical sequence.
Tightening torque: 40 N.m (4.1 kgf-m, 29.5 ft-lb

Fig 7: Tightening Bolts (A & C) On Left Side Of Cylinder Block 90° In Alphabetical Sequence
Courtesy of SUBARU OF AMERICA, INC.
Tighten bolts (E to J) on right side of cylinder block 90° more in alphabetical sequence.

Fig 8: Tightening Bolts (E To J) On Right Side Of Cylinder Block 90° In Alphabetical Sequence
Courtesy of SUBARU OF AMERICA, INC.
Tighten 8 mm and 6 mm cylinder block connecting bolts in alphabetical sequence shown.
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 In Alphabetical Sequence
Courtesy of SUBARU OF AMERICA, INC.
Install rear oil seal using ST1 and ST2.
ST1 499597100 OIL SEAL GUIDE

ST2 499587200 OIL SEAL INSTALLER

Fig 10: Installing Rear Oil Seal (Using ST 499587200)
Courtesy of SUBARU OF AMERICA, INC.
Position the top ring gap at (A) or (B) as shown.
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 For Top Ring Gap
Courtesy of SUBARU OF AMERICA, INC.
Position the expander gap at (C) as shown.

Fig 12: Positioning Expander Gap At (C)
Courtesy of SUBARU OF AMERICA, INC.
Position the lower rail gap at (D) as shown.

Fig 13: Positioning Lower Rail Gap At (D)
Courtesy of SUBARU OF AMERICA, INC.

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

Fig 14: Aligning Lower Rail Spin Stopper With Piston Side Surface Hole
Courtesy of SUBARU OF AMERICA, INC.
Position the upper rail gap at (G) as shown.

Fig 15: Positioning Upper Rail Gap At (G)
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.

CAUTION: Use new snap rings.

Fig 16: Installing Snap Ring
Courtesy of SUBARU OF AMERICA, INC.

CAUTION: Piston front marks (A) faces towards the front of the engine.

Fig 17: Identifying Piston Front Mark
Courtesy of SUBARU OF AMERICA, INC.

Fig 18: Locating Grease Applying Point & Torque Specification
Courtesy of SUBARU OF AMERICA, INC.
Installing piston
1. Turn cylinder block so that No. 1 and 2 cylinders face upward.
2. Using ST1, turn crankshaft so that No. 1 and 2 connecting rods are set at bottom dead center.
  ST1 499987500 CRANKSHAFT SOCKET
3. Apply a coat of engine oil to pistons and cylinders and insert pistons in their cylinders using ST2.
  ST2 498747300 PISTON GUIDE
  
  Fig 19: Installing Piston
  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.
  ST3 499017100 PISTON PIN GUIDE
  
  Fig 20: Installing Piston Pin (Using ST 499017100)
  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.
  CAUTION: Use new snap rings.
  
  Fig 21: Installing Piston Pin Snap Ring
  Courtesy of SUBARU OF AMERICA, INC.
5. Apply fluid packing around the service hole plug.
  Fluid packing:
  
  Part number 004403007
  
  THREE BOND 1215 or equivalent
  
  Fig 22: Applying Fluid Packing Around Service Hole Plug
  Courtesy of SUBARU OF AMERICA, INC.
6. Install service hole plug and gasket.
  CAUTION: Use a new gasket.
  
  Fig 23: Installing Service Hole Plug & Gasket
  Courtesy of SUBARU OF AMERICA, INC.
  
  Fig 24: Locating Grease Applying Point & Torque Specifications
  Courtesy of SUBARU OF AMERICA, INC.
7. Turn cylinder block so that No. 3 and 4 cylinders face upward. Using the same procedures as used for No. 1 and 2 cylinders, install pistons and piston pins.
Install water pipe.

Fig 25: Installing Water Pipe
Courtesy of SUBARU OF AMERICA, INC.
Install baffle plate.
Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
Install oil strainer and O-ring
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 No. 004403012

THREE BOND 1207C or equivalent

Fig 26: Applying Fluid Packing To Oil Pan Flange
Courtesy of SUBARU OF AMERICA, INC.
Apply fluid packing to matching surfaces and install oil separator cover.
Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)

Fluid packing:

Part number 004403012

THREE BOND 1207C or equivalent

Fig 27: Applying Fluid Packing To Oil Separator Cover
Courtesy of SUBARU OF AMERICA, INC.
Install flywheel or drive plate.
To lock crankshaft, use ST.

ST 498497100 CRANKSHAFT STOPPER

Tightening torque: 72 N.m (7.3 kgf-m, 52.8 ft-lb)

Fig 28: Installing Flywheel (Using ST 498497100)
Courtesy of SUBARU OF AMERICA, INC.

Fig 29: Installing Drive Plate (Using ST 498497100)
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.
  ST 499587100 OIL SEAL INSTALLER
  
  Fig 30: Installing Oil Seal (Using ST 499587100)
  Courtesy of SUBARU OF AMERICA, INC.
2. Apply fluid packing to matching surface of oil pump.
  Fluid packing:
  
  Part number 004403007
  
  THREE BOND 1215 or equivalent
  
  Fig 31: Applying Fluid Packing To Oil Pump
  Courtesy of SUBARU OF AMERICA, INC.
3. Apply a coat of engine oil to the inside of the oil seal.
  
  Fig 32: 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.
  Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb
CAUTION:
- 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:

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

Second: 12 N.m (1.2 kgf-m, 8.7 ft-lb)
CAUTION:
- Be sure to use a new gasket.
- When installing water pump, tighten bolts in two stages in alphabetical sequence as shown.
  
  Fig 33: Tightening Water Pump Bolt In Alphabetical Sequence
  Courtesy of SUBARU OF AMERICA, INC.
Install water by-pass pipe for heater.
Prepare oil filter and apply a thin coat of engine oil to the seal rubber.
Using the ST, install the oil filter.
ST 498547000 OIL FILTER WRENCH [for oil filter with 80 mm (3.15 in) outer diameter]

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

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

Install oil filter by turning it by hand, being careful not to damage seal rubber.
- Further tighten (approximately 2/3 to 3/4 turn) with ST the oil filter with outer diameter of 80 mm (3.15 in) or 65 mm (2.56 in) after the seal rubber contacts the cylinder block.
- Further tighten (approximately 1 turn) with ST the oil filter with outer diameter of 68 mm (2.68 in) after the seal rubber contacts the cylinder block.
CAUTION: Do not tighten excessively, or oil may leak.

Fig 34: Installing Oil Filter
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: tighten them 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 180°.

Fig 35: Identifying Cylinder Head Bolts
Courtesy of SUBARU OF AMERICA, INC.
Install oil level gauge guide and tighten attaching bolt (left side only).
Install rocker cover.
Install crankshaft sprocket. Refer to INSTALLATION , Crankshaft Sprocket.
Install camshaft sprocket. Refer to INSTALLATION , Camshaft Sprocket.
Install timing belt. Refer to INSTALLATION , Timing Belt.
Install timing belt cover. Refer to INSTALLATION , Timing Belt Cover.
Install crankshaft pulley. Refer to INSTALLATION , Crankshaft Pulley.
Install generator and A/C compressor brackets on cylinder head.
Install V-belt. Refer to INSTALLATION , V-belt.
Install intake manifold. Refer to INSTALLATION , Intake Manifold.