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Cylinder Block: Installation

WARNING: This page is about a different car, the 2006 Subaru Outback and 2006 Subaru Legacy. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Identifying Cylinder Block Components
G05017158Courtesy of SUBARU OF AMERICA, INC.
NOTE: Remove oil on the mating surface of bearing and cylinder block before installation. Apply a coat of engine oil to crankshaft pins.
  1. Position the crankshaft on the #2 and #4 cylinder block.
  2. Apply liquid gasket to the mating surface of #1 and #3 cylinder block, and position it on #2 and #4 cylinder block.

    Liquid gasket: 

    Three bond 1215 (Part No. 004403007) or equivalent 

    NOTE: Do not allow liquid gasket to jut into O-ring grooves, oil passages, bearing grooves, etc.
    Fig 2: Applying Liquid Gasket To Cylinder Block
    G04997735Courtesy of SUBARU OF AMERICA, INC.
  3. Apply a coat of engine oil to the washer and bolt thread.
  4. Tighten the 10 mm cylinder block connecting bolts on LH side (A - D) in alphabetical sequence.

    Tightening torque: 

    9.75 N.m (1.0 kgf-m, 7.2 ft-lb) 

    Fig 3: Tightening Sequence Of Cylinder Block Connecting Bolt - LH Side
    G04997736Courtesy of SUBARU OF AMERICA, INC.
  5. Tighten the 10 mm cylinder block connecting bolts on RH side (E - J) in alphabetical sequence.

    Tightening torque: 

    9.75 N.m (1.0 kgf-m, 7.2 ft-lb) 

    Fig 4: Tightening Sequence Of Cylinder Block Connecting Bolt - RH Side
    G04997737Courtesy of SUBARU OF AMERICA, INC.
  6. Further tighten the LH side bolts (A - D) in alphabetical sequence.

    Tightening torque: 

    18 N.m (1.8 kgf-m, 13 ft-lb) 

    Fig 5: Tightening Sequence Of Cylinder Block Connecting Bolt - LH Side
    G04997736Courtesy of SUBARU OF AMERICA, INC.
  7. Further tighten the RH side bolts (E - J) in alphabetical sequence.

    Tightening torque: 

    18 N.m (1.8 kgf-m, 13 ft-lb) 

    Fig 6: Tightening Sequence Of Cylinder Block Connecting Bolt - RH Side
    G04997737Courtesy of SUBARU OF AMERICA, INC.
  8. Further tighten the LH side bolts (A - D) in alphabetical sequence.
    • (A), (C): Angle tightening

      Tightening angle: 

      90° 

    • (B), (D): Torque tightening

      Tightening torque: 

      40 N.m (4.1 kgf-m, 29.6 ft-lb) 

      Fig 7: Tightening Sequence Of Cylinder Block Connecting Bolt - LH Side
      G04997736Courtesy of SUBARU OF AMERICA, INC.
  9. Tighten the RH side bolts (E - J) 90° further in alphabetical sequence.
    Fig 8: Tightening Sequence Of Cylinder Block Connecting Bolt - RH Side
    G04997737Courtesy of SUBARU OF AMERICA, INC.
  10. Tighten the 8 mm and 6 mm cylinder block connecting bolts on LH side (A - H) in alphabetical sequence.

    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 Sequence Of Cylinder Block Connecting Bolt - LH Side
    G04997742Courtesy of SUBARU OF AMERICA, INC.
  11. Install the rear oil seal using ST1 and ST2.

    ST1 499597100 OIL SEAL GUIDE

    ST2 499587200 OIL SEAL INSTALLER

    Fig 10: Installing Rear Oil Seal Using ST1 And ST2
    G05017167Courtesy of SUBARU OF AMERICA, INC.
    NOTE: Use a new rear oil seal.
  12. Position the top ring gap at (A) or (B) in the figure.
    NOTE: Assemble so that the piston ring mark "R" faces the upper side of the piston.
  13. Position the second ring gap at 180° on the reverse side the top ring gap.
    NOTE: Assemble so that the piston ring mark "R" faces the upper side of the piston.
    Fig 11: Identifying Ring Gap Position
    G04997744Courtesy of SUBARU OF AMERICA, INC.
  14. Position the upper rail gap at (C) in the figure.
    Fig 12: Positioning Upper Rail Gap
    G04997745Courtesy of SUBARU OF AMERICA, INC.
  15. Align the upper rail spin stopper (E) to the side hole (D) on the piston.
    Fig 13: Aligning Upper Rail Spin Stopper With Piston Side Surface Hole
    G04998766Courtesy of SUBARU OF AMERICA, INC.
  16. Position the expander gap at (F) in the figure.
    Fig 14: Identifying Upper Rail Gap Position
    G04997747Courtesy of SUBARU OF AMERICA, INC.
  17. Position the lower rail gap at (G) in the figure.
    Fig 15: Identifying Lower Rail Gap
    G04992634Courtesy of SUBARU OF AMERICA, INC.
    CAUTION:
    • Make sure ring gaps do not face the same direction.
    • Make sure ring gaps are not within the piston skirt area.
  18. Install the snap ring.

    Install the snap rings in the piston holes located opposite to the service holes in cylinder block when positioning all pistons in corresponding cylinders.

    NOTE: Use new snap rings.
    Fig 16: Identifying Snap Rings And Piston
    G05017173Courtesy of SUBARU OF AMERICA, INC.
    CAUTION: Piston front mark faces towards the front of engine.
    Fig 17: Identifying Piston Front Mark
    G05017174Courtesy of SUBARU OF AMERICA, INC.
    Fig 18: Piston Replacement Components With Torque Specifications
    G05017175Courtesy of SUBARU OF AMERICA, INC.

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

    T: 70(7.1, 50.6) 

  19. Install the piston.
    1. Place the cylinder block to face the #1 and #2 cylinder side 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 19: Inserting Pistons In Cylinders Using Piston Guide ST2 498747300
      G04997752Courtesy of SUBARU OF AMERICA, INC.
  20. Install the piston pin.
    1. Apply a coat of engine oil to ST3.
    2. Insert ST3 into the service hole to align piston pin hole with connecting rod small end.

      ST3 499017100 PISTON PIN GUIDE

      Fig 20: Inserting ST3 Into Service Hole To Align Piston Pin Hole With Connecting Rod Small End
      G04997753Courtesy of SUBARU OF AMERICA, INC.
    3. Apply a coat of engine oil to piston pin, and insert the piston pin into piston and connecting rod through service hole.
    4. Install the snap ring.
      NOTE: Use new snap rings.
      Fig 21: Identifying Snap Ring
      G04997754Courtesy of SUBARU OF AMERICA, INC.
    5. Apply liquid gasket around the service hole plug.

      Liquid gasket: 

      Three bond 1105 (Part No. 004403010) or equivalent 

      Fig 22: Applying Fluid Packing Around Service Hole Plug
      G04997755Courtesy of SUBARU OF AMERICA, INC.
    6. Install the service hole plug and gasket.
      NOTE: Use a new gasket.
      Fig 23: Identifying Service Hole Plug
      G04997730Courtesy of SUBARU OF AMERICA, INC.
      Fig 24: Piston Replacement Components With Torque Specifications
      G05017181Courtesy of SUBARU OF AMERICA, INC.
    7. Place the cylinder block to face the #3 and #4 cylinder side upward. Following the same procedures as used for #1 and #2 cylinders, install the pistons and piston pins.
  21. Install the water pipe.

    Tightening torque: 

    6.4 N.m (0.65 kgf-m, 4.7 ft-lb) 

    Fig 25: Identifying Water Pipe
    G04997728Courtesy of SUBARU OF AMERICA, INC.
  22. Install the baffle plate.

    Tightening torque: 

    6.4 N.m (0.65 kgf-m, 4.7 ft-lb) 

  23. Install the oil strainer and O-ring.

    Tightening torque: 

    9.75 N.m(1.0 kgf-m, 7.2 ft-lb) 

  24. Install the oil strainer stay.
  25. Apply liquid gasket to the mating surfaces, and install the oil pan.

    Liquid gasket: 

    Three bond 1207C (Part No.004403012) or equivalent 

    Fig 26: Applying Liquid Gasket To Mating Surfaces Of Oil Pan
    G04997759Courtesy of SUBARU OF AMERICA, INC.
  26. Apply liquid gasket to the mating surfaces and the threaded portion of bolt (A) shown in the figure, and then install the oil separator cover.

    Liquid gasket: 

    • Mating surface 

      Three bond 1207C (Part No.004403012) or equivalent 

    • (A) bolt threads 

      Three bond 1324 (Part No.004403042) or equivalent 

    Tightening torque: 

    6.4 N.m (0.65 kgf-m, 4.7 ft-lb) 

    Fig 27: Applying Liquid Gasket To Mating Surfaces
    G04997760Courtesy of SUBARU OF AMERICA, INC.
  27. Install the flywheel. (MT model)

    < Ref. to INSTALLATION , Flywheel. >

    To lock the crankshaft, use the ST.

    ST 498497100 CRANKSHAFT STOPPER

    Tightening torque: 

    72 N.m (7.3 kgf-m, 52.8 ft-lb) 

    Fig 28: Locking Crankshaft Using Crankshaft Stopper ST (498497100)- MT Model
    G04997722Courtesy of SUBARU OF AMERICA, INC.
  28. Install the drive plate.

    To lock the crankshaft, use the ST.

    ST 498497100 CRANKSHAFT STOPPER

    Tightening torque: 

    72 N.m (7.3 kgf-m, 52.8 ft-lb) 

    Fig 29: Locking Crankshaft Using Crankshaft Stopper ST (498497100)- AT Model
    G04997723Courtesy of SUBARU OF AMERICA, INC.
  29. Install the housing cover.
  30. Installation of oil pump:
    1. Discard the front oil seal after removal. Replace with a new part using ST.

      ST 499587100 OIL SEAL INSTALLER

      Fig 30: Installing Front Oil Seal Using Oil Seal Installer ST 499587100
      G04997763Courtesy of SUBARU OF AMERICA, INC.
    2. Apply liquid gasket to the matching surface of oil pump.

      Liquid gasket: 

      Three bond 1215 (Part No. 004403007) or equivalent 

      Fig 31: Applying Liquid Gasket To Matching Surface Of Oil Pump
      G05017188Courtesy of SUBARU OF AMERICA, INC.
    3. Apply a coat of engine oil to the inside of oil seal.
      Fig 32: Applying Coat Of Engine Oil To Inside Of Oil Seal
      G04997765Courtesy of SUBARU OF AMERICA, INC.
    4. Install the oil pump to cylinder block. Be careful not to damage the oil seal during installation.
      CAUTION:
      • Make sure the oil seal lip is not folded.
      • Do not forget to install the O-ring and seal when installing oil pump.
    5. Apply liquid gasket to the three bolts thread shown in figure.

      Liquid gasket: 

      Three bond 1324 (Part No.004403042) or equivalent 

      Tightening torque: 

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

      Fig 33: Applying Fluid Packing To Threads Of Bolts
      G04997766Courtesy of SUBARU OF AMERICA, INC.
  31. Install the service hole plug 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 the water pump, tighten bolts in two stages in alphabetical sequence as shown in the figure.
      Fig 34: Tightening Sequence Of Water Pump Bolts
      G04997724Courtesy of SUBARU OF AMERICA, INC.
  32. Install the water bypass pipe for heater.
  33. Install the oil filter.

    < Ref. to INSTALLATION , Engine Oil Filter. >

  34. Tighten the cylinder head bolts. < Ref. to INSTALLATION , Cylinder Head. >
  35. Install the oil level gauge guide and tighten the bolts. (LH side only)
  36. Install the rocker cover and rocker cover gasket.
    NOTE: Use a new rocker cover gasket.
  37. Install the crank sprocket.

    < Ref. to INSTALLATION , Crank Sprocket. >

  38. Install the cam sprocket. < Ref. to INSTALLATION , Cam Sprocket. >
  39. Install the timing belt. < Ref. to INSTALLATION , Timing Belt. >
  40. Install the timing belt cover.

    < Ref. to INSTALLATION , Timing Belt Cover. >

  41. Install the crank pulley. < Ref. to INSTALLATION , Crank Pulley. >
  42. Install the generator and A/C compressor brackets on cylinder head.
  43. Install the V-belts. < Ref. to INSTALLATION , V-belt. >
  44. Install the intake manifold.

    < Ref. to INSTALLATION , Intake Manifold. >

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