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Cylinder Block: Removal

WARNING: This page is about a different variant/trim than selected.
  1. Remove the engine from the vehicle. < Ref. to REMOVAL , Engine Assembly. >
  2. Remove the crankshaft position sensor plate with drive plate. (CVT model) < Ref. to REMOVAL , Drive Plate. >
  3. Remove the clutch disc and cover. (MT model) < Ref. to REMOVAL , Clutch Disc and Cover. >
  4. Remove the crankshaft position sensor plate with flywheel. (MT model) < Ref. to REMOVAL , Flywheel. >
  5. Remove the intake manifold. < Ref. to REMOVAL , Intake Manifold. >
  6. Remove the air intake adapter. < Ref. to REMOVAL , Tumble Generator Valve Assembly. >
  7. Remove the engine wiring harness. < Ref. to REMOVAL , Engine Wiring Harness. >
  8. Remove the chain cover. < Ref. to REMOVAL , Chain Cover. >
  9. Remove the rocker cover. < Ref. to REMOVAL , Rocker Cover. >
  10. Remove the cam carrier. < Ref. to REMOVAL , Cam Carrier. >
  11. Remove the cylinder head. < Ref. to REMOVAL , Cylinder Head. >
  12. Remove the crank sprocket. < Ref. to REMOVAL , Crank Sprocket. >
  13. Remove the engine rear hanger from cylinder block RH.
    Fig 1: Locating Cylinder Block RH Engine Rear Hanger Bolts
    G09480539Courtesy of SUBARU OF AMERICA, INC.
  14. Remove the bolts securing the water pipe assembly and PCV connector to the cylinder block, and remove the water pipe assembly and PCV connector as a set from cylinder block.
    Fig 2: Locating Water Pipe Assembly And PCV Connector Bolts
    G09480540Courtesy of SUBARU OF AMERICA, INC.
  15. Remove the O-ring from the cylinder block and PCV connector.
    Fig 3: Locating Cylinder Block And PCV Connector O-Rings
    G09480541Courtesy of SUBARU OF AMERICA, INC.
  16. Remove the knock sensor from cylinder block LH.
    Fig 4: Locating Cylinder Block LH Knock Sensors
    G09480542Courtesy of SUBARU OF AMERICA, INC.
  17. Remove the PCV valve from the cylinder block RH.
    Fig 5: Locating PCV Valve Bolt Threads
    G09480543Courtesy of SUBARU OF AMERICA, INC.
  18. Remove the bolts securing the crankshaft position sensor holder from the cylinder block LH, and remove the crankshaft position sensor with crankshaft position sensor holder.
    Fig 6: Locating Crankshaft Position Sensor Holder Bolts
    G09480544Courtesy of SUBARU OF AMERICA, INC.
  19. Set the part so that the oil pan is on the upper side.
  20. Remove the oil pan upper with oil pan from cylinder block.
    NOTE: Pry the points shown in the figure with a crowbar wrapped by protective tape, and then remove the oil pan upper.
    Fig 7: Locating Oil Pan Upper Tape Applying Area
    G10292036Courtesy of SUBARU OF AMERICA, INC.
    Fig 8: Locating Cylinder Block Bolts
    G09480546Courtesy of SUBARU OF AMERICA, INC.
  21. Remove the O-ring from the cylinder block.
    Fig 9: Locating Cylinder Block O-Ring
    G09480547Courtesy of SUBARU OF AMERICA, INC.
  22. Set the part so that the cylinder block RH is on the upper side.
  23. Remove the #1 and #3 connecting rod caps and pistons from the cylinder block.
    NOTE: Mark each connecting rod cap and piston with a cylinder number.
    1. Turn the crankshaft so that the #1 connecting rod cap (A) is located at the position shown in the figure using ST.

      ST 18252AA000 CRANKSHAFT SOCKET

      Fig 10: Turning Crankshaft Using Crankshaft Socket (ST 18252AA000)
      G09480548Courtesy of SUBARU OF AMERICA, INC.
    2. Using ST, loosen the #1 connecting rod cap bolt, and remove the #1 connecting rod cap bolt and #1 connecting rod cap.

      ST 18270AA020 SOCKET

      Fig 11: Loosening Connecting Rod Cap Bolt Using Socket (ST 18270AA020)
      G09480549Courtesy of SUBARU OF AMERICA, INC.
    3. Using the ST, turn the crankshaft counterclockwise and separate the positions of the #1 pin (A) of crankshaft and the large end (B) of #1 connecting rod.

      ST 18252AA000 CRANKSHAFT SOCKET

      Fig 12: Turning Crankshaft Using Crankshaft Socket (ST 18252AA000)
      G09480550Courtesy of SUBARU OF AMERICA, INC.
    4. Push the #1 connecting rod in the direction of the arrow, and remove the #1 piston with #1 connecting rod from the cylinder block.
      Fig 13: Pushing Connecting Rod
      G09480551Courtesy of SUBARU OF AMERICA, INC.
    5. Turn the crankshaft so that the #3 connecting rod cap (A) is located at the position shown in the figure using ST.

      ST 18252AA000 CRANKSHAFT SOCKET

      Fig 14: Turning Crankshaft Using Crankshaft Socket (ST 18252AA000)
      G09480552Courtesy of SUBARU OF AMERICA, INC.
    6. Using ST, loosen the #3 connecting rod cap bolt, and remove the #3 connecting rod cap bolt and #3 connecting rod cap.

      ST 18270AA020 SOCKET

      Fig 15: Loosening Connecting Rod Cap Bolt Using Socket (ST 18270AA020)
      G09480553Courtesy of SUBARU OF AMERICA, INC.
    7. Using the ST, turn the crankshaft counterclockwise and separate the positions of the #3 pin (A) of crankshaft and the large end (B) of #3 connecting rod.

      ST 18252AA000 CRANKSHAFT SOCKET

      Fig 16: Turning Crankshaft Using Crankshaft Socket (ST 18252AA000)
      G09480554Courtesy of SUBARU OF AMERICA, INC.
    8. Push the #3 connecting rod in the direction of the arrow, and remove the #3 piston with #3 connecting rod from the cylinder block.
      Fig 17: Pushing Connecting Rod
      G09480555Courtesy of SUBARU OF AMERICA, INC.
  24. Set the part so that the cylinder block LH is on the upper side.
  25. Remove #2 and #4 connecting rod caps and pistons in the same removal procedure as #1 and 3# connecting rod caps and pistons.
  26. Set the part so that the cylinder block RH is on the upper side, and separate the cylinder block.
    1. Remove the engine stand from the cylinder block RH.
      Fig 18: Locating Cylinder Block RH Engine Stand
      G09480556Courtesy of SUBARU OF AMERICA, INC.
    2. Remove the bolt shown in the figure.
      Fig 19: Locating Cylinder Block Bolts
      G09480557Courtesy of SUBARU OF AMERICA, INC.
    3. Loosen the cylinder block mounting bolts in numerical order as shown in the figure.
      Fig 20: Cylinder Block LH Mounting Bolts Loosening Sequence
      G09480558Courtesy of SUBARU OF AMERICA, INC.
    4. While tapping the cylinder block RH with a plastic hammer, separate the cylinder block RH from the cylinder block LH.
      NOTE: Lift the cylinder block RH gradually, and confirm that the crankshaft is remaining in the cylinder block LH. If the cylinder block RH is lifted carelessly when separating, the crankshaft may stick to cylinder block RH, then fall off.
  27. Remove the crankshaft from cylinder block LH, and remove the rear oil seal.
  28. Remove the O-ring from the cylinder block LH.
    Fig 21: Locating Cylinder Block LH O-Ring
    G09480559Courtesy of SUBARU OF AMERICA, INC.
  29. Remove the crankshaft bearings from the cylinder block.
    NOTE:
    • Be careful not to confuse the crankshaft bearing combination.
    • Press the bearing at the end opposite to locking lip (A).
    Fig 22: Removing Crankshaft Bearings From Cylinder Block
    G09480560Courtesy of SUBARU OF AMERICA, INC.
  30. Remove the liquid gasket from cylinder block.
  31. Remove the cylinder block LH from the engine stand.
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