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Home >> Subaru >> 2009 >> Outback Limited >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical (H4SO) >> Cylinder Block >> Installation

Cylinder Block: Installation

Fig 1: Exploded View Of Cylinder Block
G06334407Courtesy of SUBARU OF AMERICA, INC.
  1. Remove oil on the mating surface of cylinder block before installation. Apply a coat of engine oil to the bearing and crankshaft journal.
  2. Position the crankshaft and O-ring on the cylinder block RH.
    NOTE: Use new O-rings.
  3. Apply liquid gasket to the mating surfaces of cylinder block RH, and position the cylinder block LH.
    Fig 2: Applying Liquid Gasket To Mating Surfaces Of Cylinder Block
    G04997735Courtesy of SUBARU OF AMERICA, INC.
    NOTE:
    • Install within 5 minutes after applying liquid gasket.
    • Do not allow liquid gasket to jut into O-ring grooves, oil passages, bearing grooves, etc.

    Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent 

  4. Apply a coat of engine oil to the washer and bolt thread.
    NOTE: Use a new seal washer.
  5. Tighten the 10 mm cylinder block connecting bolts on the LH side (A - D) in alphabetical order.

    Tightening torque: 10 N.m (1.0 kgf-m, 7.4 ft-lb) 

    Fig 3: Identifying 10 mm Cylinder Block Connecting Bolts Tightening Alphabetical Order
    G05659849Courtesy of SUBARU OF AMERICA, INC.
  6. Tighten the 10 mm cylinder block connecting bolts on the RH side (E - J) in alphabetical order.

    Tightening torque: 10 N.m (1.0 kgf-m, 7.4 ft-lb) 

    Fig 4: Identifying 10 mm Cylinder Block Connecting Bolts Tightening Alphabetical Order
    G05659850Courtesy of SUBARU OF AMERICA, INC.
  7. Tighten the LH side cylinder block connecting bolts (A - D) further in alphabetical order.

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

    Fig 5: Identifying LH Side Cylinder Block Connecting Bolts Tightening Alphabetical Order
    G05659849Courtesy of SUBARU OF AMERICA, INC.
  8. Tighten the RH side cylinder block connecting bolts (E - J) further in alphabetical order.

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

    Fig 6: Identifying RH Side Cylinder Block Connecting Bolts Tightening Alphabetical Order
    G05659850Courtesy of SUBARU OF AMERICA, INC.
  9. Tighten the LH side cylinder block connecting bolts (A - D) further in alphabetical order.
    • (A), (C): Angle tightening

      Tightening angle: 90° 

    • (B), (D): Torque tightening

      Tightening torque: 40 N.m (4.1 kgf-m, 29.5 ft-lb) 

      Fig 7: Identifying LH Side Cylinder Block Connecting Bolts Tightening Alphabetical Order
      G05659849Courtesy of SUBARU OF AMERICA, INC.
  10. Tighten the RH side cylinder block connecting bolts (E - J) further in alphabetical order.

    Tightening angle: 90° 

    Fig 8: Identifying RH Side Cylinder Block Connecting Bolts Tightening Alphabetical Order
    G05659850Courtesy of SUBARU OF AMERICA, INC.
  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, 18.4 ft-lb) 

    (H): 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 

    Fig 9: Identifying 8 mm And 6 mm Cylinder Block Connecting Bolts Tightening Alphabetical Sequence
    G04997742Courtesy of SUBARU OF AMERICA, INC.
  12. Apply a coat of engine oil to the oil seal periphery, then install the rear oil seal using ST1 and ST2.
    NOTE: Use new rear oil seal.

    ST1 499597100 CRANKSHAFT OIL SEAL GUIDE

    ST2 499587200 CRANKSHAFT OIL SEAL INSTALLER

    Fig 10: Installing Rear Oil Seal Using ST1 And ST2
    G06334416Courtesy of SUBARU OF AMERICA, INC.
  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: Positioning Second Ring Gap At 180° On Reverse Side Top Ring Gap
    G04997744Courtesy of SUBARU OF AMERICA, INC.
  15. Position the upper rail gap at (C) in the figure.
    Fig 12: Positioning Upper Rail Gap At (C)
    G04997745Courtesy of SUBARU OF AMERICA, INC.
  16. Align the upper rail spin stopper (E) to the side hole (D) on the piston.
    Fig 13: Aligning Upper Rail Spin Stopper To Side Hole On Piston
    G04998766Courtesy of SUBARU OF AMERICA, INC.
  17. Position the expander gap at (F) on the 180° opposite direction of (C) in the figure.
    Fig 14: Positioning Expander Gap At (F) On 180° Opposite Direction Of (C)
    G04997747Courtesy of SUBARU OF AMERICA, INC.
  18. Set the lower rail gap at position (G), located 120° clockwise from (C).
    Fig 15: Setting Lower Rail Gap At Position (G)
    G04992634Courtesy of SUBARU OF AMERICA, INC.
    NOTE:
    • Make sure ring gaps do not face the same direction.
    • Make sure ring gaps are not within the piston skirt area.
  19. Install the snap ring.

    Before positioning the piston on the cylinder block, attach the snap ring in the service hole of the cylinder block, and the piston hole on the opposite side.

    NOTE: Use new snap rings.
    Fig 16: Identifying Snap Ring
    G06334422Courtesy of SUBARU OF AMERICA, INC.
    Fig 17: Identifying Snap Ring And Service Hole Plug
    G06334423Courtesy of SUBARU OF AMERICA, INC.
  20. Install the piston.
    1. Set the parts so that the #1 and #2 cylinders are on the upper side.
    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 Their Cylinders Using ST2
      G04997752Courtesy of SUBARU OF AMERICA, INC.
      NOTE: Face the piston front mark towards the front of the engine.
      Fig 19: Facing Piston Front Mark Towards Front Of Engine
      G06334425Courtesy of SUBARU OF AMERICA, INC.
  21. 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: Aligning 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: Installing Snap Ring
      G04997754Courtesy of SUBARU OF AMERICA, INC.
    5. Apply liquid gasket to the threaded portion of the service hole plug.

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

      Fig 22: Applying Liquid Gasket To Threaded Portion Of Service Hole Plug
      G04997755Courtesy of SUBARU OF AMERICA, INC.
    6. Install the service hole plug and gasket.
      NOTE: Use a new gasket.

      Tightening torque: 70 N.m (7.1 kgf-m, 51.6 ft-lb) 

      Fig 23: Installing Service Hole Plug And Gasket
      G04997730Courtesy of SUBARU OF AMERICA, INC.
      Fig 24: Identifying Service Hole Plug And Gasket
      G06334430Courtesy of SUBARU OF AMERICA, INC.
    7. Set the parts so that the #3 and #4 cylinders are on the upper side. Following the same procedures as used for #1 and #2 cylinders, install the pistons and piston pins.
    8. Install the service hole cover.
      NOTE: Use new O-rings.

      Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 

  22. Install the water pipe assembly.
    NOTE: Use new O-rings.

    Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 

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

    Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 

  24. Install the oil strainer.
    NOTE: Use new O-rings.

    Tightening torque: 10 N.m (1.0 kgf-m, 7.4 ft-lb) 

  25. Tighten the oil strainer stay together with the baffle plate.

    Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 

  26. Apply liquid gasket to the mating surfaces of oil pan, and install the oil pan.
    NOTE: Install within 5 minutes after applying liquid gasket.

    Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent 

    Tightening torque: 5 N.m (0.5 kgf-m, 3.7 ft-lb) 

    Fig 26: Applying Liquid Gasket To Mating Surfaces Of Oil Pan
    G06334432Courtesy of SUBARU OF AMERICA, INC.
  27. Apply liquid gasket to the mating surfaces of the oil separator cover and the threaded portion of bolt (A) shown in the figure (when reusing the bolt), and then install the oil separator cover.
    NOTE:
    • Install within 5 minutes after applying liquid gasket.
    • Use a new separator cover.

    Liquid gasket: 

    • Mating surface THREE BOND 1217G (Part No. K0877Y0100) or equivalent 
    • (A) bolt thread (when reusing bolts THREE BOND 1324 (Part No. 004403042) or equivalent 

    Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 

    Fig 27: Applying Liquid Gasket To Mating Surfaces Of Oil Separator Cover And Threaded Portion Of Bolt
    G05657387Courtesy of SUBARU OF AMERICA, INC.
  28. Install the flywheel. (MT model) Refer to INSTALLATION , Flywheel.
  29. Install the clutch disc and cover. (MT model) Refer to INSTALLATION , Clutch Disc and Cover.
  30. Use the ST to lock the crankshaft, and install the drive plate. (AT model)

    ST 498497100 CRANKSHAFT STOPPER

    Tightening torque: 72 N.m (7.3 kgf-m, 53.1 ft-lb) 

    Fig 28: Locking Crankshaft Using ST
    G04997723Courtesy of SUBARU OF AMERICA, INC.
  31. Install the oil pump.
    1. Install the front oil seal using the ST.

      ST 499587100 OIL SEAL INSTALLER

      NOTE: Use a new front oil seal.
      Fig 29: Installing Oil Pump
      G04997893Courtesy of SUBARU OF AMERICA, INC.
    2. Apply liquid gasket to the matching surface of oil pump.
      NOTE: Install within 5 minutes after applying liquid gasket.

      Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent 

      Fig 30: Applying Liquid Gasket To Matching Surface Of Oil Pump
      G06334436Courtesy of SUBARU OF AMERICA, INC.
    3. Apply a coat of engine oil to the inside of oil seal.
      Fig 31: 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.
      NOTE:
      • Make sure the oil seal lip is not folded.
      • Align the flat surface of oil pump's inner rotor with crankshaft before installation.
      • Use new O-rings and oil seals.
      • Do not forget to assemble O-rings.
    5. Apply liquid gasket to the three bolts thread shown in figure, (when reusing bolts)

      Liquid gasket: THREE BOND 1324 (Part No. 004403042) or equivalent 

      Tightening torque: T: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 

      Fig 32: Applying Liquid Gasket To Three Bolts Thread
      G04997766Courtesy of SUBARU OF AMERICA, INC.
  32. Install the water pump and gasket.
    NOTE:
    • When installing the water pump, tighten bolts in two stages in alphabetical order as shown in the figure.
    • Use a new 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) 

    Fig 33: Identifying Water Pump Bolts Tightening Alphabetical Order
    G04997724Courtesy of SUBARU OF AMERICA, INC.
  33. Install the water bypass pipe for heater.

    Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 

  34. Install the oil filter. Refer to INSTALLATION , Engine Oil Filter.
  35. Install the cylinder head. Refer to INSTALLATION , Cylinder Head.
  36. Install the generator and A/C compressor with their brackets.

    Tightening torque: 36 N.m (3.7 kgf-m, 26.6 ft-lb) 

  37. Install the crank sprocket. Refer to INSTALLATION , Crank Sprocket.
  38. Install the timing belt. Refer to INSTALLATION , Timing Belt.
  39. Adjust the valve clearance. Refer to ADJUSTMENT , Valve Clearance.
  40. Install the rocker cover.
    1. Install the rocker cover gasket to the rocker cover.
      NOTE: Use a new rocker cover gasket.
    2. Temporarily tighten the bolts in alphabetical order shown in the figure, tighten them in two stages.

      Tightening torque: 

      1st 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 

      2nd (only (a) and (b) are tightened) 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 

      RH side

      Fig 34: Identifying Rocker Cover Bolts Tightening Sequence - RH Side
      G04997677Courtesy of SUBARU OF AMERICA, INC.

      LH side

      Fig 35: Identifying Rocker Cover Bolts Tightening Sequence - LH Side
      G04997678Courtesy of SUBARU OF AMERICA, INC.
  41. Install the timing belt cover. Refer to INSTALLATION , Timing Belt Cover.
  42. Install the crank pulley. Refer to INSTALLATION , Crank Pulley.
  43. Install the intake manifold. Refer to INSTALLATION , Intake Manifold.
  44. Install the V-belts. Refer to INSTALLATION , V-belt.
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