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Cylinder Block: Installation

WARNING: This page is about a different car, the 2008 Subaru Impreza. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Cylinder Block Components

G05659847

Courtesy of SUBARU OF AMERICA, INC.

Remove oil on the mating surface of cylinder block before installation. Apply a coat of engine oil to the bearing and crankshaft journal.
Position the crankshaft and O-ring on cylinder block RH.
Apply liquid gasket to the mating surfaces of cylinder block RH, and position cylinder block LH.
NOTE:
- Install within 5 min. 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

Fig 2: Identifying Liquid Gasket Applying Area
Courtesy of SUBARU OF AMERICA, INC.
Apply a coat of engine oil to the washer and bolt thread.
NOTE: Use a new seal washer.
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, 7.2 ft-lb)

Fig 3: Identifying Cylinder Block Connecting Bolts Torque Sequence - LH
Courtesy of SUBARU OF AMERICA, INC.
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, 7.2 ft-lb)

Fig 4: Identifying Cylinder Block Connecting Bolts Torque Sequence - RH
Courtesy of SUBARU OF AMERICA, INC.
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 Cylinder Block Connecting Bolts Torque Sequence - LH
Courtesy of SUBARU OF AMERICA, INC.
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 Cylinder Block Connecting Bolts Torque Sequence - RH
Courtesy of SUBARU OF AMERICA, INC.
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, 29.6 ft-lb)

Fig 7: Identifying Cylinder Block Connecting Bolts Torque Sequence - LH
Courtesy of SUBARU OF AMERICA, INC.
Tighten the RH side cylinder block connecting bolts (E - J) in alphabetical order.
Tightening angle:

90°

Fig 8: Identifying Cylinder Block Connecting Bolts Torque Sequence - RH
Courtesy of SUBARU OF AMERICA, INC.
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 (0.65 kgf-m, 4.7 ft-lb)

Fig 9: Identifying Cylinder Block Connecting Bolts Torque Sequence - LH Side
Courtesy of SUBARU OF AMERICA, INC.
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
Courtesy of SUBARU OF AMERICA, INC.
Position the top ring gap at (A) or (B) in the figure.
Position the second ring gap at 180° on the reverse side the top ring gap.

Fig 11: Positioning Top Ring Gap
Courtesy of SUBARU OF AMERICA, INC.
Position the upper rail gap at (C) in the figure.

Fig 12: Positioning Upper Rail Gap
Courtesy of SUBARU OF AMERICA, INC.
Align the upper rail spin stopper (E) to the side hole (D) on the piston.

Fig 13: Aligning Upper Rail Spin Stopper
Courtesy of SUBARU OF AMERICA, INC.
Position the expander gap at (F) in the figure.

Fig 14: Positioning Expander Gap
Courtesy of SUBARU OF AMERICA, INC.
Position the lower rail gap at (G) in the figure.

Fig 15: Positioning Lower Rail Gap
Courtesy 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.
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
Courtesy of SUBARU OF AMERICA, INC.

Fig 17: Identifying Piston Components With Torque Specifications
Courtesy of SUBARU OF AMERICA, INC.
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: Installing Piston
  Courtesy of SUBARU OF AMERICA, INC.
  
  NOTE: Face the piston front mark towards the front of the engine.
  
  Fig 19: Aligning Piston Front Mark
  Courtesy of SUBARU OF AMERICA, INC.
Install 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: Installing Piston Pin
  Courtesy 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
  Courtesy 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
  Courtesy of SUBARU OF AMERICA, INC.
6. Install the water pump and gasket.
  NOTE: Use a new gasket.
  
  Fig 23: Installing Water Pump And Gasket
  Courtesy of SUBARU OF AMERICA, INC.
  
  Fig 24: Identifying Piston Components
  Courtesy 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.
Install the water pipe.
NOTE: Use new O-rings.

Tightening torque:

6.4 N.m (0.65 kgf-m, 4.7 ft-lb)

Fig 25: Installing Water Pipe
Courtesy of SUBARU OF AMERICA, INC.
Install the baffle plate.
Tightening torque:

6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
Install the oil strainer.
NOTE: Use new O-rings.

Tightening torque:

10 N.m (1.0 kgf-m, 7.4 ft-lb)
Tighten the oil strainer stay together with the baffle plate.
Tightening torque:

6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
Apply liquid gasket to the mating surfaces of the oil pan, and install the oil pan.
NOTE: Install within 5 min. 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: Identifying Liquid Gasket Apply Area
Courtesy of SUBARU OF AMERICA, INC.
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 min. after applying liquid gasket.
- Use a new separator cover.
Liquid gasket:
- Mating surface
THREE BOND 1217G (Part No. K0877Y0100) or equivalent
- Bolt thread area (A) (when reusing the bolt)
THREE BOND 1324 (Part No. 004403042) or equivalent

Tightening torque:

6.4 N.m (0.65 kgf-m, 4.7 ft-lb)

Fig 27: Identifying Liquid Gasket Apply Area
Courtesy of SUBARU OF AMERICA, INC.
Install the flywheel. (MT model)
<Ref. to INSTALLATION , Flywheel . >
Install the clutch disc and cover. (MT model) <Ref. to INSTALLATION , Clutch Disc and Cover . >
Install the drive plate. (AT model) To lock the crankshaft, use the ST.
ST 498497100 CRANKSHAFT STOPPER

Tightening torque:

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

Fig 28: Identifying Special Tool
Courtesy of SUBARU OF AMERICA, INC.
Install the oil pump.
1. Using the ST, install the front oil seal.
  ST 499587100 OIL SEAL INSTALLER
  
  NOTE: Use a new front oil seal.
  
  Fig 29: Installing Front Oil Seal
  Courtesy of SUBARU OF AMERICA, INC.
2. Apply liquid gasket to the matching surface of oil pump.
  NOTE: Install within 5 min. after applying liquid gasket.
  
  Liquid gasket:
  
  THREE BOND 1217G (Part No. K0877Y0100) or equivalent
  
  Fig 30: Identifying Liquid Gasket Applying Area
  Courtesy of SUBARU OF AMERICA, INC.
3. Apply a coat of engine oil to the inside of oil seal.
  
  Fig 31: Identifying Engine Oil Applying Area
  Courtesy 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 (0.65 kgf-m, 4.7 ft-lb)

Fig 32: Identifying Liquid Gasket Applying Area
Courtesy of SUBARU OF AMERICA, INC.
Install the service hole plug 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, 8.7 ft-lb)

Second: 12 N.m (1.2 kgf-m, 8.7 ft-lb)

Fig 33: Identifying Service Hole Plug And Gasket
Courtesy of SUBARU OF AMERICA, INC.
Install the water by-pass pipe for heater.
Tightening torque:

6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
Install the oil filter. <Ref. to INSTALLATION , Engine Oil Filter . >
Install the cylinder head. <Ref. to INSTALLATION , Cylinder Head. >
Install the camshaft. <Ref. to INSTALLATION , Camshaft. >
Install the valve rocker assembly. <Ref. to INSTALLATION , Valve Rocker Assembly. >
Install the generator and A/C compressor with their brackets.
Tightening torque:

36 N.m (3.7 kgf-m, 26.6 ft-lb)
Install the crank sprocket. <Ref. to INSTALLATION , Crank Sprocket. >
Install the cam sprocket. <Ref. to INSTALLATION , Cam Sprocket. >
Install the timing belt. <Ref. to INSTALLATION , Timing Belt. >
Adjust the valve clearance. <Ref. to ADJUSTMENT , Valve Clearance. >
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 sequence as shown in figure, then tighten the bolt in 2 steps.
Tightening torque:

1st

6.4 N.m (0.65 kgf-m, 4.7 ft-lb)

2nd (only (a) and (b) are tightened)

6.4 N.m (0.65 kgf-m, 4.7 ft-lb)

RH side

Fig 34: Identifying Rocker Cover Gasket Bolts Torque Sequence - RH Side
Courtesy of SUBARU OF AMERICA, INC.

LH side

Fig 35: Identifying Rocker Cover Gasket Bolts Torque Sequence - LH Side
Courtesy of SUBARU OF AMERICA, INC.
Install the timing belt cover. <Ref. to INSTALLATION , Timing Belt Cover. >
Install the crank pulley. <Ref. to INSTALLATION , Crank Pulley. >
Install the intake manifold. <Ref. to INSTALLATION , Intake Manifold . >
Install the V-belts. <Ref. to INSTALLATION , V-belt. >