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

Cylinder Block: Removal

NOTE: Before conducting this procedure, drain the engine oil completely.
  1. Remove the V-belts. Refer to REMOVAL , V-belt.
  2. Remove the intake manifold. Refer to REMOVAL , Intake Manifold.
  3. Remove the crank pulley. Refer to REMOVAL , Crank Pulley.
  4. Remove the timing belt cover. Refer to REMOVAL , Timing Belt Cover.
  5. Remove the timing belt. Refer to REMOVAL , Timing Belt.
  6. Remove the crank sprocket. Refer to REMOVAL , Crank Sprocket.
  7. Remove the generator and A/C compressor with their brackets.
  8. Remove the cylinder head. Refer to REMOVAL , Cylinder Head.
  9. Remove the clutch disc and cover. (MT model) Refer to REMOVAL , Clutch Disc and Cover.
  10. Remove the flywheel. (MT model) Refer to REMOVAL , Flywheel.
  11. Use the ST to lock the crankshaft, and remove the drive plate. (AT model)

    ST 498497100 CRANKSHAFT STOPPER

    Fig 1: Locking Crankshaft Using ST
    G04997723Courtesy of SUBARU OF AMERICA, INC.
  12. Remove the oil separator cover.
  13. Remove the water bypass pipe for heater.
  14. Remove the water pump. Refer to REMOVAL , Water Pump.
  15. Remove the bolts which install oil pump onto cylinder block.
    CAUTION: When disassembling and checking the oil pump, loosen the relief valve plug before removing the oil pump.
    Fig 2: Removing Bolts Which Install Oil Pump Onto Cylinder Block
    G04997725Courtesy of SUBARU OF AMERICA, INC.
  16. Remove the oil pump from cylinder block using a flat tip screwdriver.
    CAUTION: Be careful not to scratch the mating surface of cylinder block and oil pump.
    Fig 3: Removing Oil Pump From Cylinder Block Using Flat Tip Screwdriver
    G04997726Courtesy of SUBARU OF AMERICA, INC.
  17. Remove the front oil seal from the oil pump.
  18. Remove the oil pan.
    1. Set the part so that the cylinder block LH is on the upper side.
    2. Remove the bolts which secure oil pan to cylinder block.
    3. Insert an oil pan cutter blade between cylinder block-to-oil pan clearance and remove the oil pan.
      CAUTION: Do not use a screwdriver or similar tools in place of oil pan cutter.
  19. Remove the oil strainer.
  20. Remove the baffle plate.
  21. Remove the oil filter. Refer to REMOVAL , Engine Oil Filter.
  22. Remove the water pipe assembly.
    Fig 4: Identifying Water Pipe Assembly
    G04997728Courtesy of SUBARU OF AMERICA, INC.
    Fig 5: Identifying Service Hole Plug And Snap Ring
    G06334402Courtesy of SUBARU OF AMERICA, INC.
  23. Remove the service hole plugs using a hexagon wrench [14 mm].
    Fig 6: Removing Service Hole Plugs Using Hexagon Wrench (14 mm)
    G04997730Courtesy of SUBARU OF AMERICA, INC.
  24. Remove the service hole cover.
  25. Rotate the crankshaft to bring #1 and #2 pistons to bottom dead center position, then remove the piston snap ring through service hole of #1 and #2 cylinders.
    Fig 7: Removing Piston Snap Ring Through Service Hole Of #1 And #2 Cylinders
    G04997731Courtesy of SUBARU OF AMERICA, INC.
  26. Draw out the piston pin from #1 and #2 pistons using ST.

    ST 499097700 PISTON PIN REMOVER

    NOTE: Be careful not to confuse the original combination of piston, piston pin and cylinder.
    Fig 8: Drawing Out Piston Pin From #1 And #2 Pistons Using ST
    G05659845Courtesy of SUBARU OF AMERICA, INC.
  27. Similarly draw out the piston pins from #3 and #4 pistons.
  28. Remove the cylinder block connecting bolt on the RH side.
  29. Loosen the cylinder block connecting bolt on the LH side by 2-3 turns.
  30. Set the part so that the cylinder block LH is on the upper side, and remove the cylinder block connecting bolt.
  31. Separate the cylinder block LH and RH.
    NOTE: When separating the cylinder block, do not allow the connecting rod to fall or damage the cylinder block.
    Fig 9: Separating Cylinder Block
    G06334406Courtesy of SUBARU OF AMERICA, INC.
  32. Remove the rear oil seal.
  33. Remove the crankshaft along with the connecting rods.
  34. Remove the crankshaft bearings from cylinder block using a hammer handle.
    NOTE:
    • Press the crankshaft bearing at the end opposite to locking lip to remove.
    • Be careful not to confuse the crankshaft bearing combination.
  35. Remove each piston from the cylinder block using a wooden bar or hammer handle.
    NOTE: Be careful not to confuse the original combination of piston and cylinder.
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