Cylinder Block: Installation

WARNING: This page is about a different variant/trim than selected.

After setting the cylinder block to ST, install the crankshaft bearing.
ST 18232AA000 ENGINE STAND

NOTE: Remove oil on the mating surface of bearing and cylinder block before installation. Apply a coat of engine oil to crankshaft pins.
Position the crankshaft and connecting rod on the #2, #4 and #6 cylinder block.
Apply liquid gasket to the mating surface of #1, #3 and #5 cylinder block, and position it on #2, #4 and #6 cylinder block.
Liquid gasket:

THREE BOND 1215B (Part No. 004403007)

NOTE: Do not allow liquid gasket to jut into O-ring grooves, oil passages, bearing grooves, etc.

Applying liquid gasket diameter:

1.0+/-0.2 mm (0.039+/-0.008 in)

Fig 1: Identifying Liquid Gasket Applying Areas
Courtesy of SUBARU OF AMERICA, INC.
Apply a coat of engine oil to washers and bolt threads.
Tighten all bolts in the numerical order as shown in Fig 2 .
Tightening torque:

(1) - (11), (13): 25 N.m (2.5 kgf-m, 18 ft-lb)

(12), (14): 20 N.m (2.0 kgf-m, 14 ft-lb)

Fig 2: Identifying Bolts Tightening Sequence
Courtesy of SUBARU OF AMERICA, INC.
Retighten all bolts in the numerical order as shown in Fig 3 .
Tightening torque:

(1) - (11), (13): 25 N.m (2.5 kgf-m, 18 ft-lb)

(12), (14): 20 N.m (2.0 kgf-m, 14 ft-lb)

Fig 3: Identifying Bolts Retightening Sequence
Courtesy of SUBARU OF AMERICA, INC.
Tighten all bolts 90° in the numerical order as shown in Fig 4 .

Fig 4: Identifying Bolts Tightening Sequence
Courtesy of SUBARU OF AMERICA, INC.
Install the upper bolt to cylinder block.
Tightening torque:

25 N.m (2.5 kgf-m, 18 ft-lb)

NOTE: Remove the liquid gasket which is running over to sealing surface between cylinder block and rear chain cover, cylinder block and oil pan upper, after tightening the bolts which combine the cylinder block.

Fig 5: Installing Upper Bolt To Cylinder Block
Courtesy of SUBARU OF AMERICA, INC.
Install the rear oil seal using ST1 and ST2.
ST1 499597100 CRANKSHAFT OIL SEAL GUIDE

ST2 499587200 CRANKSHAFT OIL SEAL INSTALLER

NOTE: Apply engine oil to the pressing-in portion.

Fig 6: Installing Rear Oil Seal Using Crankshaft Oil Seal Guide ST1 499597100 And Crankshaft Oil Seal Installer ST2 499587200
Courtesy of SUBARU OF AMERICA, INC.
Position the top ring gap at (A) shown in Fig 7 .
Position the second ring gap at (B) shown in Fig 7.

Fig 7: Positioning Top Ring And Second Ring Gap
Courtesy of SUBARU OF AMERICA, INC.
Position the upper rail gap at (C) shown in Fig 8 .
Position the expander gap at (D) shown in Fig 8 .
Position the lower rail gap at (E) shown in Fig 8 .

Fig 8: Positioning Upper, Lower And Expander Gap
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.
- Ensure R mark faces to top side of piston.
Install the snap ring.
Install snap rings in the piston holes located opposite to the service holes in cylinder block, when positioning all pistons in the corresponding cylinders.

NOTE: Use new snap rings.

Fig 9: Installing Snap Rings In Piston Holes
Courtesy of SUBARU OF AMERICA, INC.
Installing the piston:
1. Using ST1, turn the crankshaft so that #3 and #4 connecting rods small end are set on the service hole (A).
  ST1 18252AA000 CRANKSHAFT SOCKET
  
  Fig 10: Turning Crankshaft Using Crankshaft Socket ST1 18252AA000
  Courtesy of SUBARU OF AMERICA, INC.
2. Apply a thin coat of engine oil to piston and cylinder.
3. Using ST2, press-fit the piston into cylinder.
ST2 18254AA000 PISTON GUIDE

Fig 11: Press-Fiting Piston Into Cylinder Using Piston Guide ST2 18254AA000
Courtesy of SUBARU OF AMERICA, INC.

NOTE: Piston front mark (A) faces towards the front of engine.

Fig 12: Identifying Piston Front Mark
Courtesy of SUBARU OF AMERICA, INC.
Installing piston pin:
1. Apply a coat of engine oil to ST3 before insertion, and then insert it into the service hole to align piston pin hole with connecting rod small end.
  ST3 18253AA000 PISTON GUIDE
  
  Fig 13: Installing Piston Pin Using Piston Guide ST3 18253AA000
  Courtesy of SUBARU OF AMERICA, INC.
2. Apply a coat of engine oil to piston pin, and insert the piston pin into piston and connecting rod through service hole.
3. Using the ST4, install the snap ring.
  ST4 18233AA000 PISTON PIN SNAP RING PRIERS
  
  NOTE: Use new snap rings.
  
  Fig 14: Installing Snap Ring Using Piston Pin Snap Ring Priers ST4 18233AA000
  Courtesy of SUBARU OF AMERICA, INC.
4. Similarly install the #1, #2, #5 and #6 pistons.
Install the service hole plug and O-ring.
NOTE: Use a new O-ring.
Apply liquid gasket to the matching surface of oil pan upper.
Liquid gasket:

THREE BOND 1280B (Part No. K0877YA018)

Applying liquid gasket diameter:

Full line part

3.0+/-1.0 mm (0.12+/-0.04 in)

Broken line part

1.0 mm (0.04 in)

Fig 15: Identifying O-Ring
Courtesy of SUBARU OF AMERICA, INC.

NOTE: Use new O-rings.
Temporarily tighten the oil pan upper.
NOTE: Do not install the bolts in wrong place.

Fig 16: Identifying Oil Pan Upper Bolts
Courtesy of SUBARU OF AMERICA, INC.
Tighten the oil pan upper installing bolts in the numerical order as shown in Fig 17 .
Tightening torque:

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

Fig 17: Identifying Oil Pan Upper Bolts Tightening Sequence
Courtesy of SUBARU OF AMERICA, INC.
Install the oil strainer.
Tightening torque:

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

NOTE: Use new O-rings.

Fig 18: Installing Oil Strainer
Courtesy of SUBARU OF AMERICA, INC.
Apply liquid gasket to the matching surface of oil pan lower.
Liquid gasket:

THREE BOND 1280B (Part No. K0877YA018)

Applying liquid gasket diameter:

5.0+/-1.0 mm (0.20+/-0.04 in)

Fig 19: Identifying Liquid Gasket Applying Areas
Courtesy of SUBARU OF AMERICA, INC.
Tighten the oil pan lower installing bolts in the numerical order as shown in Fig 20 .
Tightening torque:

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

Fig 20: Identifying Oil Pan Lower Installing Bolts Tightening Sequence
Courtesy of SUBARU OF AMERICA, INC.
Install the crankshaft sensor bracket.
Tightening torque:

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

Fig 21: Installing Crankshaft Sensor Bracket
Courtesy of SUBARU OF AMERICA, INC.
Install the crankshaft sensor plate.

Fig 22: Installing Crankshaft Sensor Plate
Courtesy of SUBARU OF AMERICA, INC.
Install the drive plate.
To lock the crankshaft, use ST.

ST 498497100 CRANKSHAFT STOPPER

Tightening torque:

81 N.m (8.3 kgf-m, 60 ft-lb)

Fig 23: Locking Crankshaft Using Crankshaft Stopper ST 498497100
Courtesy of SUBARU OF AMERICA, INC.
Install the cylinder head. < Ref. to , INSTALLATION , Cylinder Head. >
Install the camshaft. < Ref. to , INSTALLATION , Camshaft. >
Install the rear chain cover. < Ref. to , INSTALLATION , Rear Chain Cover. >
Install the crank sprocket. < Ref. to , INSTALLATION , Crank Sprocket. >
Install the cam sprocket. < Ref. to , INSTALLATION , Cam Sprocket. >
Install the timing chain assembly. < Ref. to , INSTALLATION , Timing Chain Assembly. >
Install the front chain cover. < Ref. to , INSTALLATION , Front Chain Cover. >
Install the crank pulley. < Ref. to , INSTALLATION , Crank Pulley. >