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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.
    G13198955Courtesy of SUBARU OF AMERICA, INC.
  3. Install new O-rings to the cylinder block LH.
    G13198953Courtesy of SUBARU OF AMERICA, INC.
  4. Apply engine oil to the crankshaft journal, and set the crankshaft to cylinder block LH.
    G13198957Courtesy 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)

    G13862755Courtesy of SUBARU OF AMERICA, INC.
  6. Install the cylinder block RH to the cylinder block LH.
  7. Join the cylinder blocks.
    CAUTION: When tightening the mounting bolts, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block.
    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.
    3. Loosen all mounting bolts by 180° in the reverse order of tightening in step (2).
    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.
    5. Loosen the mounting bolts (4 places) by 180° in the order of (6) → (5) → (4) → (3) as shown in the figure.
    6. Tighten the mounting bolts (4 places) with a torque of 17 N.m (1.7 kgf-m, 12.5 ft-lb) in the order of (3) → (4) → (5) → (6) as shown in the figure.
    7. Using an angle gauge, tighten the mounting bolts (4 places) with torque of 58° - 62° in the order of (3) → (4) → (5) → (6) as shown in the figure.
    8. Loosen the mounting bolts (6 places) by 180° in the order of (8) → (7) → (10) → (9) → (2) → (1) as shown in the figure.
    9. Tighten the mounting bolts (6 places) with a torque of 17 N.m (1.7 kgf-m, 12.5 ft-lb) in the order of (1) → (2) → (9) → (10) → (7) → (8) as shown in the figure.
    10. Using an angle gauge, tighten the mounting bolts (3 places) with torque of 58° - 62° in the order of (1) → (2) → (9) as shown in the figure.
    11. Using an angle gauge, tighten the mounting bolt (10) (1 place) shown in the figure to the angle of 78° - 82°.
    12. Using an angle gauge, tighten the mounting bolt (7) (1 place) shown in the figure to the angle of 58° - 62°.
    13. Using an angle gauge, tighten the mounting bolt (8) (1 place) shown in the figure to the angle of 78° - 82°.
      Fig 1: Cylinder Block Mounting Bolts (Tightening Sequence)
      G13198959Courtesy of SUBARU OF AMERICA, INC.
    14. Install the bolt shown in the figure.
      NOTE: After tightening, if the liquid gasket is squeezed out onto the seal surfaces of the chain cover and oil pan upper, remove any squeezed-out liquid gasket. 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)

    G13198951Courtesy 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 MECHANICAL (H4DOTC)>Cylinder Block>ASSEMBLY>PISTON AND CONNECTING ROD .
  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. Using the ST, turn the crankshaft so that the #1 pin (A) of crankshaft is positioned at TDC.

      Preparation tool: 

      ST: CRANKSHAFT SOCKET (18252AA000)

      G13198961Courtesy 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.
        G13862759Courtesy of SUBARU OF AMERICA, INC.
      • Insert while lightly tapping the crown of the piston with the handle of a plastic hammer.
      G13198963Courtesy of SUBARU OF AMERICA, INC.
    4. Using the ST, 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, 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.

      Preparation tool: 

      ST: CRANKSHAFT SOCKET (18252AA000)

      G13198964Courtesy 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.

      Preparation tool: 

      ST: SOCKET (18270AA020)

      G13198965Courtesy of SUBARU OF AMERICA, INC.
    6. Using the ST, turn the crankshaft clockwise so that the #2 pin (A) of crankshaft is positioned at TDC.

      Preparation tool: 

      ST: CRANKSHAFT SOCKET (18252AA000)

      G13198966Courtesy 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.
        G13862764Courtesy of SUBARU OF AMERICA, INC.
      • Insert while lightly tapping the crown of the piston with the handle of a plastic hammer.
      G13198968Courtesy of SUBARU OF AMERICA, INC.
    8. Using the ST, 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, 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.

      Preparation tool: 

      ST: CRANKSHAFT SOCKET (18252AA000)

      G13198969Courtesy 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.

      Preparation tool: 

      ST: SOCKET (18270AA020)

      G13198970Courtesy 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 the ST and angle gauge, tighten the #1 connecting rod cap bolts and #4 connecting rod cap bolts with a torque of 90° - 95° in numerical order as shown in the figure.

      Preparation tool: 

      ST: SOCKET (18270AA020)

      G13198971Courtesy of SUBARU OF AMERICA, INC.
    12. Using the ST, 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.

      Preparation tool: 

      ST: CRANKSHAFT SOCKET (18252AA000)

      G13198972Courtesy of SUBARU OF AMERICA, INC.
    13. Using the ST and angle gauge, tighten the #2 connecting rod cap bolts and #3 connecting rod cap bolts with a torque of 90° - 95° in numerical order as shown in the figure.

      Preparation tool: 

      ST: SOCKET (18270AA020)

      G13198973Courtesy of SUBARU OF AMERICA, INC.
  11. Set the part so that the installation surface of the intake manifold is on the upper side.
  12. 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)

    G13198941Courtesy of SUBARU OF AMERICA, INC.
  13. Install the engine rear hanger to the cylinder block RH.

    Tightening torque: 

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

    G13198940Courtesy of SUBARU OF AMERICA, INC.
  14. Install the PCV valve. Ref. to EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) (H4DOTC)>PCV Valve>INSTALLATION .
  15. Install the knock sensor. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DOTC)>Knock Sensor>INSTALLATION .
  16. Install the PCV pipe assembly. Ref. to EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) (H4DOTC)>PCV Pipe>INSTALLATION .
  17. Install the water tank pipe assembly. Ref. to COOLING (H4DOTC)>Water Pipe>INSTALLATION>WATER TANK PIPE ASSEMBLY .
  18. Install the scavenge pump. Ref. to LUBRICATION (H4DOTC)>Scavenge Pump>INSTALLATION .
  19. Install the oil pan upper. Ref. to LUBRICATION (H4DOTC)>Oil Pan>INSTALLATION>OIL PAN UPPER .
  20. Install the cylinder head. Ref. to MECHANICAL (H4DOTC)>Cylinder Head>INSTALLATION .
  21. Apply a coat of engine oil to the oil seal inner periphery and outer periphery, and install new rear oil seal using ST1 and ST2.

    Preparation tool: 

    ST1: OIL SEAL GUIDE (18671AA020)

    ST2: OIL SEAL INSTALLER (18657AA030)

    G13862773Courtesy of SUBARU OF AMERICA, INC.
  22. Install the crankshaft position sensor plate with drive plate. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>Drive Plate>INSTALLATION .
  23. Install the engine to the vehicle. Ref. to MECHANICAL (H4DOTC)>Engine Assembly>INSTALLATION .
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