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Cylinder Block: Installation

  1. Install the cylinder block LH to the engine stand.
  2. Apply engine oil to the crankshaft bearing, and install the crankshaft bearing to the cylinder block.
    CAUTION: When performing the operation of the cylinder block RH, be careful of the following.
    1. Place a wood board wrapped with a waste cloth to prevent the knock pin damage and to stabilize the cylinder block before work.
    2. Be careful not to scratch the mating surface of cylinder block during work.
    Fig 1: Setting Crankshaft Bearing To Cylinder Block
    G09480561Courtesy of SUBARU OF AMERICA, INC.
  3. Install O-rings to the cylinder block LH.
    NOTE: Use new O-rings.
    Fig 2: Locating Cylinder Block LH O-Ring
    G09480561Courtesy of SUBARU OF AMERICA, INC.
  4. Apply engine oil to the crankshaft journal, and set the crankshaft to cylinder block LH.
    Fig 3: Locating Cylinder Block LH Crankshaft Journal
    G09480563Courtesy of SUBARU OF AMERICA, INC.
  5. Apply liquid gasket to the mating surface of cylinder block RH as shown in the figure.
    CAUTION:
    • Place a wood board wrapped with a waste cloth to prevent the knock pin damage and to stabilize the cylinder block before work.
    • Be careful not to scratch the mating surface of cylinder block during work.
    • Do not let the liquid gasket overflow to the oil passage and crankshaft bearing portions, because the engine seizure may result.
    NOTE:
    • Before applying liquid gasket, degrease the old liquid gasket seal surface of the cylinder block RH and cylinder block LH.
    • Install within 5 min. after applying liquid gasket.

    Liquid gasket: 

    THREE BOND 1217G (Part No. K0877Y0100), THREE BOND 1217H or equivalent 

    Liquid gasket applying diameter: 

    Mating surfaces other than ranges A, B and C 

    1±0.5 mm (0.0394±0.0197 in) 

    Mating surfaces of ranges A and C 

    4±0.5 mm (0.1575±0.0197 in) 

    Mating surfaces of range B 

    3.2±0.5 mm (0.1260±0.0197 in) 

    Fig 4: Identifying Liquid Gasket Applying Area On Cylinder Block
    G10292055Courtesy of SUBARU OF AMERICA, INC.
  6. Install the cylinder block RH to the cylinder block LH.
  7. Join the cylinder blocks.
    1. Apply a coat of engine oil to the washers and cylinder block mounting bolt threads.
      NOTE: To prevent mixture of engine oil into the water jacket, do not apply a large amount.
    2. Tighten all mounting bolts with a torque of 35 N.m (3.6 kgf-m, 25.8 ft-lb) in numerical order as shown in the figure.
      CAUTION: When tightening the mounting bolts with specified torque, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block.
      Fig 5: Cylinder Block LH Mounting Bolts Tightening Sequence
      G09480565Courtesy of SUBARU OF AMERICA, INC.
    3. Loosen all mounting bolts by 180° in numerical order as shown in the figure.
      CAUTION: When loosening the mounting bolts, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block.
      Fig 6: Cylinder Block LH Mounting Bolts Loosening Sequence
      G09480558Courtesy of SUBARU OF AMERICA, INC.
    4. Tighten all mounting bolts with a torque of 35 N.m (3.6 kgf-m, 25.8 ft-lb) in numerical order as shown in the figure.
      CAUTION: When tightening the mounting bolts with specified torque, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block.
      Fig 7: Cylinder Block LH Mounting Bolts Tightening Sequence
      G09480565Courtesy of SUBARU OF AMERICA, INC.
    5. Loosen the mounting bolts (4 places) by 180° in numerical order as shown in the figure.
      CAUTION: When loosening the mounting bolts, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block.
      Fig 8: Cylinder Block LH Mounting Bolts Loosening Sequence (4 Places)
      G09480568Courtesy of SUBARU OF AMERICA, INC.
    6. Tighten the mounting bolts (4 places) with a torque of 17 N.m (1.7 kgf-m, 12.5 ft-lb) in numerical order as shown in the figure.
      CAUTION: When tightening the mounting bolts with specified torque, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block.
      Fig 9: Cylinder Block LH Mounting Bolts Tightening Sequence (4 Places)
      G09480569Courtesy of SUBARU OF AMERICA, INC.
    7. Using angle gauge, tighten the mounting bolts (4 places) with specified angle in numerical order as shown in the figure.
      CAUTION: When tightening the mounting bolts with specified angle, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block.

      Tightening angle: 

      60°±2° 

      Fig 10: Tightening Cylinder Block Mounting Bolts Using Angle Gauge
      G09480570Courtesy of SUBARU OF AMERICA, INC.
    8. Loosen the mounting bolts (6 places) by 180° in numerical order as shown in the figure.
      CAUTION: When loosening the mounting bolts, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block.
      Fig 11: Cylinder Block Mounting Bolts Loosening Sequence
      G09480571Courtesy of SUBARU OF AMERICA, INC.
    9. Tighten the mounting bolts (6 places) with a torque of 17 N.m (1.7 kgf-m, 12.5 ft-lb) in numerical order as shown in the figure.
      CAUTION: When tightening the mounting bolts with specified torque, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block.
      Fig 12: Cylinder Block Mounting Bolts Tightening Sequence
      G09480572Courtesy of SUBARU OF AMERICA, INC.
    10. Using angle gauge, tighten the mounting bolts (6 places) with specified angle in numerical order as shown in the figure.
      CAUTION: When tightening the mounting bolts with specified angle, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block.

      Tightening angle: 

      60°±2° 

      Fig 13: Tightening Mounting Bolts Using Angle Gauge
      G09480573Courtesy of SUBARU OF AMERICA, INC.
    11. Install the bolt shown in the figure.
      NOTE: After tightening, if the liquid gasket is squeezed out in the seal surface area of the chain cover and oil pan upper, completely remove any liquid gasket that is squeezed out. Any liquid gasket on the chamfer area, however, should not be removed.

      Tightening torque: 

      25 N.m (2.5 kgf-m, 18.4 ft-lb) 

      Fig 14: Locating Cylinder Block Bolts
      G09480557Courtesy of SUBARU OF AMERICA, INC.
  8. Set the part so that the installation surface of the oil pan upper is on the upper side.
  9. Check that the piston ring gap for each piston is positioned correctly. < Ref. to PISTON AND CONNECTING ROD , ASSEMBLY, Cylinder Block. >
  10. Install the piston and connecting rod to the cylinder block.
    1. Apply engine oil to the outer circumference of each piston, crankshaft pin, and in the cylinder block.
    2. Turn the crankshaft so that the #1 pin (A) of crankshaft is positioned at TDC using ST.

      ST 18252AA000 CRANKSHAFT SOCKET

      Fig 15: Turning Crankshaft At TDC Using Crankshaft Socket (ST 18252AA000)
      G09480575Courtesy of SUBARU OF AMERICA, INC.
    3. Compress the piston ring using piston ring compressor, and insert the #1 connecting rod with #1 piston into cylinder block.
      CAUTION:
      • Be careful not to damage the cylinder liner and #1 pin of crankshaft by the #1 connecting rod large end.
      • Be careful not to apply strong impact when inserting to prevent connecting rod bearing from falling off.
      NOTE:
      • Face the piston front mark (round mark) towards the front of the engine.
        Fig 16: Identifying Piston Front Mark (Round Mark)
        G10292067Courtesy of SUBARU OF AMERICA, INC.
      • Insert while lightly tapping the crown of the piston with the handle of a plastic hammer.
      Fig 17: Inserting Piston Crown Using Plastic Hammer Handle
      G09480577Courtesy of SUBARU OF AMERICA, INC.
    4. Turn the crankshaft counterclockwise so that the #1 pin of crankshaft and the large end (A) of #1 connecting rod are positioned as shown in the figure using ST, while pressing the #1 piston crown, and then set the #1 connecting rod cap and #1 connecting rod cap bolt.
      NOTE:
      • Each connecting rod has its own mating cap. Make sure that they are assembled correctly by checking their matching symbol.
      • Use a new connecting rod cap bolt.
      • Apply a coat of engine oil to the #1 connecting rod cap seat and the connecting rod cap bolt threads.

      ST 18252AA000 CRANKSHAFT SOCKET

      Fig 18: Turning Crankshaft Using Crankshaft Socket (ST 18252AA000)
      G09480578Courtesy of SUBARU OF AMERICA, INC.
    5. Using ST, tighten the #1 connecting rod cap bolts to 10 N.m (1.0 kgf-m, 7.4 ft-lb) in numerical order as shown in the figure, then retighten the bolts to 25 N.m (2.5 kgf-m, 18.4 ft-lb) in numerical order as shown in the figure.

      ST 18270AA020 SOCKET

      Fig 19: Tightening Connecting Rod Cap Bolts Using Socket (ST 18270AA020)
      G09480579Courtesy of SUBARU OF AMERICA, INC.
    6. Turn the crankshaft clockwise so that the #2 pin (A) of crankshaft is positioned at TDC using ST.

      ST 18252AA000 CRANKSHAFT SOCKET

      Fig 20: Turning Crankshaft Using Crankshaft Socket (ST 18252AA000)
      G09480580Courtesy of SUBARU OF AMERICA, INC.
    7. Compress the piston ring using piston ring compressor, and insert the #2 connecting rod with #2 piston into cylinder block.
      CAUTION:
      • Be careful not to damage the cylinder liner and #2 pin of crankshaft by the #2 connecting rod large end.
      • Be careful not to apply strong impact when inserting to prevent connecting rod bearing from falling off.
      NOTE:
      • Face the piston front mark (round mark) towards the front of the engine.
        Fig 21: Identifying Piston Front Mark (Round Mark)
        G10292072Courtesy of SUBARU OF AMERICA, INC.
      • Insert while lightly tapping the crown of the piston with the handle of a plastic hammer.
      Fig 22: Inserting Piston Crown Using Plastic Hammer Handle
      G09480582Courtesy of SUBARU OF AMERICA, INC.
    8. Turn the crankshaft clockwise so that the #2 pin of crankshaft and the large end (A) of #2 connecting rod are positioned as shown in the figure using ST, while pressing the #2 piston crown, and then set the #2 connecting rod cap and #2 connecting rod cap bolt.
      NOTE:
      • Each connecting rod has its own mating cap. Make sure that they are assembled correctly by checking their matching symbol.
      • Use a new connecting rod cap bolt.
      • Apply a coat of engine oil to the #2 connecting rod cap seat and the connecting rod cap bolt threads.

      ST 18252AA000 CRANKSHAFT SOCKET

      Fig 23: Turning Crankshaft Using Crankshaft Socket (ST 18252AA000)
      G09480583Courtesy of SUBARU OF AMERICA, INC.
    9. Using ST, tighten the #2 connecting rod cap bolts to 10 N.m (1.0 kgf-m, 7.4 ft-lb) in numerical order as shown in the figure, then retighten the bolts to 25 N.m (2.5 kgf-m, 18.4 ft-lb) in numerical order as shown in the figure.

      ST 18270AA020 SOCKET

      Fig 24: Tightening Connecting Rod Cap Bolts Using Socket (ST 18270AA020)
      G09480584Courtesy of SUBARU OF AMERICA, INC.
    10. Install #3 and #4 pistons and connecting rod caps in the same installation procedure as #1 and #2 pistons and connecting rod caps.
    11. Using ST and angle gauge, tighten the #1 connecting rod cap bolts and #4 connecting rod cap bolts with specified angle in numerical order as shown in the figure.

      ST 18270AA020 SOCKET

      Tightening angle: 

      90°+5° -0° 

      Fig 25: Tightening Connecting Rod Cap Bolts Using Socket (ST 18270AA020)
      G09480585Courtesy of SUBARU OF AMERICA, INC.
    12. Turn the crankshaft so that the #2 connecting rod cap (A) and #3 connecting rod cap (B) is located at the position shown in the figure using ST.

      ST 18252AA000 CRANKSHAFT SOCKET

      Fig 26: Turning Crankshaft Using Crankshaft Socket (ST 18252AA000)
      G09480586Courtesy of SUBARU OF AMERICA, INC.
    13. Using ST and angle gauge, tighten the #2 connecting rod cap bolts and #3 connecting rod cap bolts with specified angle in numerical order as shown in the figure.

      ST 18270AA020 SOCKET

      Tightening angle: 

      90°+5° -0° 

      Fig 27: Tightening Connecting Rod Cap Bolts Using Socket (ST 18270AA020)
      G09480587Courtesy of SUBARU OF AMERICA, INC.
  11. Install the oil pan upper with oil pan to the cylinder block.
    1. Apply liquid gasket to the mating surface of oil pan upper as shown in the figure.
      NOTE:
      • Before applying liquid gasket, degrease the old liquid gasket seal surface of the cylinder block and the oil pan upper.
      • Install within 5 min. after applying liquid gasket.
      • Apply liquid gasket 1.5 mm (0.0591 in) outside from the chamfer surface. However, application of liquid gasket on the chamfer surface around the bolt hole is allowed.

      Liquid gasket: 

      THREE BOND 1217G (Part No. K0877Y0100), THREE BOND 1217H or equivalent 

      Liquid gasket applying diameter: 

      5±1 mm (0.1969±0.0394 in) 

      Fig 28: Identifying Cylinder Block Liquid Gasket Application Dimensions
      G10292079Courtesy of SUBARU OF AMERICA, INC.
    2. Install the O-ring to the cylinder block.
      NOTE: Use new O-rings.
      Fig 29: Locating Cylinder Block O-Ring
      G09480547Courtesy of SUBARU OF AMERICA, INC.
    3. Set the oil pan with oil pan upper to the cylinder block, and tighten the bolts in numerical order as shown in the figure.
      NOTE: After tightening, if the liquid gasket is squeezed out onto the seal surface of the chain cover, completely remove any squeezed-out liquid gasket.

      Tightening torque: 

      18 N.m (1.8 kgf-m, 13.3 ft-lb) 

      Fig 30: Cylinder Block Bolts Tightening Sequence
      G10292081Courtesy of SUBARU OF AMERICA, INC.
  12. Set the part so that the installation surface of the intake manifold is on the upper side.
  13. Install the crankshaft position sensor with crankshaft position sensor holder to the cylinder block LH.

    Tightening torque: 

    6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 

    Fig 31: Locating Crankshaft Position Sensor Holder Bolts
    G09480544Courtesy of SUBARU OF AMERICA, INC.
  14. Install the PCV valve onto the cylinder block RH.
    NOTE: Apply liquid gasket to the bolt threads of PCV valve.

    Liquid gasket: 

    THREE BOND 1324 (Part No. 004403042) or equivalent 

    Tightening torque: 

    23 N.m (2.3 kgf-m, 17.0 ft-lb) 

    Fig 32: Locating PCV Valve Bolt Threads
    G09480543Courtesy of SUBARU OF AMERICA, INC.
  15. Install the knock sensor to the cylinder block LH.
    NOTE: Knock sensor must be positioned toward engine front so that the connector center position is within the range of shaded area shown in the figure.

    Tightening torque: 

    24 N.m (2.4 kgf-m, 17.7 ft-lb) 

    Fig 33: Identifying Knock Sensor Installation Position To Cylinder Block LH
    G10292084Courtesy of SUBARU OF AMERICA, INC.
  16. Install the O-ring to the cylinder block and PCV connector.
    NOTE: Use new O-rings.
    Fig 34: Locating Cylinder Block And PCV Connector O-Rings
    G09480541Courtesy of SUBARU OF AMERICA, INC.
  17. Install the water pipe assembly and PCV connector to the cylinder block.

    Tightening torque: 

    6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 

    Fig 35: Locating Water Pipe Assembly And PCV Connector Bolts
    G09480540Courtesy of SUBARU OF AMERICA, INC.
  18. Install the engine rear hanger to the cylinder block RH.

    Tightening torque: 

    21 N.m (2.1 kgf-m, 15.5 ft-lb) 

    Fig 36: Locating Cylinder Block RH Engine Rear Hanger Bolts
    G09480539Courtesy of SUBARU OF AMERICA, INC.
  19. Install the crank sprocket. < Ref. to INSTALLATION , Crank Sprocket. >
  20. Install the cylinder head. < Ref. to INSTALLATION , Cylinder Head. >
  21. Install the cam carrier. < Ref. to INSTALLATION , Cam Carrier. >
  22. Install the rocker cover. < Ref. to INSTALLATION , Rocker Cover. >
  23. Install the chain cover. < Ref. to INSTALLATION , Chain Cover. >
  24. Install the engine wiring harness. < Ref. to INSTALLATION , Engine Wiring Harness. >
  25. Install the air intake adapter. < Ref. to INSTALLATION , Tumble Generator Valve Assembly. >
  26. Install the intake manifold. < Ref. to INSTALLATION , Intake Manifold. >
  27. Apply a coat of engine oil to the oil seal inner periphery and outer periphery, and install the rear oil seal using ST1 and ST2.
    NOTE: Use a new rear oil seal.

    ST1 18671AA020 OIL SEAL GUIDE

    ST2 18657AA030 OIL SEAL INSTALLER

    Fig 37: Installing Rear Oil Seal Using Oil Seal Guide (ST1 18671AA020)
    G10292088Courtesy of SUBARU OF AMERICA, INC.
  28. Install the crankshaft position sensor plate with drive plate. (CVT model) < Ref. to INSTALLATION , Drive Plate. >
  29. Install the crankshaft position sensor plate with flywheel. (MT model) < Ref. to INSTALLATION , Flywheel. >
  30. Install the clutch disc and cover. (MT model) < Ref. to INSTALLATION , Clutch Disc and Cover. >
  31. Install the engine to the vehicle. < Ref. to INSTALLATION , Engine Assembly. >
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