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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
G05018183
  1. Remove oil on the mating surface of bearing and cylinder block before installation. Apply a coat of engine oil to crankshaft pins.
  2. Position the crankshaft on the #2 and #4 cylinder block.
  3. Apply liquid gasket to the mating surface of #1 and #3 cylinder blocks, and position it on cylinder block #2 and #4.

    Liquid gasket: THREE BOND 1215 (Part No. 004403007) or equivalent 

    NOTE: Do not allow liquid gasket to run over to O-ring grooves, oil passages, bearing grooves, etc.
    Fig 2: Applying Liquid Gasket To Cylinder Block
    G04997735
  4. Apply a coat of engine oil to the washer and bolt thread.
  5. Tighten the 10 mm cylinder block connecting bolts on LH side (A - D) in alphabetical sequence.

    Tightening torque: 10 N.m (1.0 kgf-m, 7.2 ft-lb) 

    Fig 3: Identifying Cylinder Block Bolts Tightening Sequence (LH Side)
    G04998756
  6. Tighten the 10 mm cylinder block connecting bolts on RH side (E - J) in alphabetical sequence.

    Tightening torque: 10 N.m (1.0 kgf-m, 7.2 ft-lb) 

    Fig 4: Identifying Cylinder Block Bolts Tightening Sequence (RH Side)
    G04998757
  7. Further tighten the LH side bolts (A - D) in alphabetical sequence.

    Tightening torque: 18 N.m (1.8 kgf-m, 13.0 ft-lb) 

    Fig 5: Identifying Cylinder Block Bolts Tightening Sequence (LH Side)
    G04998756
  8. Further tighten the RH side bolts (E - J) in alphabetical sequence.

    Tightening torque: 18 N.m (1.8 kgf-m, 13.0 ft-lb) 

    Fig 6: Identifying Cylinder Block Bolts Tightening Sequence (RH Side)
    G04998757
  9. Further tighten the LH side bolts (A - D) in alphabetical sequence.

    (A), (C): 90° 

    (B), (D): 40 N.m (4.1 kgf-m, 29.5 ft-lb) 

    Fig 7: Identifying Cylinder Block Bolts Tightening Sequence (LH Side)
    G04998756
  10. Tighten the RH side bolts (E - J) 90° further in alphabetical sequence.
    Fig 8: Identifying Cylinder Block Bolts Tightening Sequence (RH Side)
    G04998757
  11. 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: Identifying Cylinder Block Bolts Tightening Sequence (LH Side)
    G04997742
  12. Install the rear oil seal using ST1 and ST2.
    NOTE: Use a new rear oil seal.

    ST1 499597100 CRANKSHAFT OIL SEAL GUIDE 

    ST2 499587200 CRANKSHAFT OIL SEAL INSTALLER 

    Fig 10: Installing Rear Oil Seal Using ST1 499597100 And ST2 499587200
    G05018192
  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 the top ring gap.
    Fig 11: Identifying Second Ring Gap
    G05018193
  15. Position the upper rail gap at (C) in the figure.
    Fig 12: Identifying Upper Rail Gap
    G05018194
  16. Align the upper rail spin stopper (D) to the side hole (E) on the piston.
    Fig 13: Aligning Upper Rail Spin Stopper To Side Hole On Piston
    G05018195
  17. Position the expander gap at (F) in the figure on the 180° opposite direction of (C).
    Fig 14: Identifying Expander Gap
    G04998767
  18. Position the lower rail gap at (G) in the figure.
    Fig 15: Identifying Lower Rail Gap
    G04998768
  19. 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: View Of Snap Ring
    G05018198
    Fig 17: Piston Replacement Components With Torque Specifications
    G05018199
  20. Installing piston:
    1. 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 18: Inserting Pistons In Cylinders Using Piston Guide ST2 498747300
      G04997752
    NOTE: Face the piston front mark towards the front of the engine.
    Fig 19: Identifying Piston Front Mark
    G05018201
  21. 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 499017100 PISTON PIN GUIDE 

      Fig 20: Inserting Piston Pin Guide ST3 499017100 Into Service Hole
      G04997753
    2. Apply a coat of engine oil to piston pin, and insert the piston pin into piston and connecting rod through service hole.
    3. Install the snap ring.
      NOTE: Use new snap rings.
      Fig 21: Installing Snap Ring
      G04997754
    4. Apply liquid gasket around the service hole plug.

      Liquid gasket: THREE BOND 1105 (Part No. 004403010) or equivalent 

      Fig 22: Applying Liquid Gasket On Service Hole Plug
      G04997755
    5. Install the service hole plug and gasket.
      NOTE: Use a new gasket.
      Fig 23: Identifying Service Hole Plug
      G04997730
      Fig 24: Piston Replacement Components With Torque Specifications
      G05018206
    6. 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.
  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, 7.2 ft-lb) 

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

    Liquid gasket: THREE BOND 1207C (Part No.004403012) or equivalent 

    Tightening torque: 5 N.m (0.5 kgf-m, 3.6 ft-lb) 

    Fig 25: Applying Liquid Gasket To Mating Surfaces Of Oil Pan
    G04997759
  27. 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.
    NOTE: Install within 20 min. after applying liquid gasket.

    Liquid gasket: 

    Mating surface THREE BOND 1207C (Part No.004403012) or equivalent 

    Bolt thread (A) THREE BOND 1324 (Part No.004403042) or equivalent 

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

    Fig 26: Applying Liquid Gasket To Oil Separator Cover Mating Surfaces
    G04997760
  28. Install the flywheel. (MT model)< Ref. to INSTALLATION , Flywheel. >
  29. Install the clutch disc and cover. (MT model)< Ref. to INSTALLATION , Clutch Disc and Cover. >
  30. Install the drive plate. (AT model). Refer to the appropriate Service Information.
  31. Installation of oil pump:
    1. Using the ST, install the front oil seal.

      ST 499587100 OIL SEAL INSTALLER 

      NOTE: Use a new front oil seal.
      Fig 27: Installing Front Oil Seal Using Oil Seal Installer ST 499587100
      G04997763
    2. Apply liquid gasket to the matching surface of oil pump.

      Liquid gasket: THREE BOND 1215 (Part No. 004403007) or equivalent 

      Fig 28: Applying Liquid Gasket To Matching Surface Of Oil Pump
      G05018211
    3. Apply a coat of engine oil to the inside of oil seal.
      Fig 29: Applying Coat Of Engine Oil To Inside Of Oil Seal
      G04997765
    4. Install the oil pump to cylinder block. Be careful not to damage the oil seal during installation.
    5. Apply liquid gasket to the three bolts thread.

      Liquid gasket: THREE BOND 1215 (Part No. 004403007) or equivalent 

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

      Fig 30: Applying Liquid Gasket To Oil Pump Bolts
      G04997766
      CAUTION:
      • 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.
  32. Install the water pump and gasket.

    Tightening torque: 

    First: 12 N.m (1.2 kgf-m, 8.9 ft-lb) 

    Second: 12 N.m (1.2 kgf-m, 8.9 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 31: Identifying Water Pump Bolts Tightening Sequence
      G04997724
  33. Install the water bypass pipe for heater.
  34. Install the oil cooler.

    Tightening torque: 

    T1: 54 N.m (5.5 kgf-m, 40 ft-lb) 

    T2: 70 N.m (7.1 kgf-m, 50.6 ft-lb) 

    Fig 32: Identifying Oil Cooler Components
    G05018215
  35. Install the oil filter. < Ref. to INSTALLATION , Engine Oil Filter. >
  36. Install the water bypass pipe between oil cooler and water pump.
  37. Install the water pipe.
    NOTE: Always use new O-rings.
  38. Install the cylinder head.

    < Ref. to INSTALLATION , Cylinder Head. >

  39. Install the oil level gauge guide. (LH side)
  40. Install the rocker cover and rocker cover gasket.
    NOTE: Use a new rocker cover gasket.
  41. Install the crank sprocket. < Ref. to INSTALLATION , Crank Sprocket. >
  42. Install the cam sprocket.

    < Ref. to INSTALLATION , Cam Sprocket. >

  43. Install the timing belt.

    < Ref. to INSTALLATION , Timing Belt. >

  44. Install the timing belt cover.

    < Ref. to INSTALLATION , Timing Belt Cover. >

  45. Install the crank pulley.

    < Ref. to INSTALLATION , Crank Pulley. >

  46. Install the generator and A/C compressor brackets on cylinder head.
  47. Install the V-belts. < Ref. to INSTALLATION , V-belt. >
  48. Install the intake manifold.

    < Ref. to INSTALLATION , Intake Manifold. >

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