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Cylinder Block: Removal

  1. Remove the engine from the vehicle. Ref. to MECHANICAL (H4DO)>Engine Assembly>REMOVAL .
  2. Remove the crankshaft position sensor plate with drive plate. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR580)>DRIVE PLATE>REMOVAL .
  3. Remove the cylinder head. Ref. to MECHANICAL (H4DO)>Cylinder Head>REMOVAL .
  4. Remove the oil pan upper. Ref. to LUBRICATION (H4DO)>OIL PAN>REMOVAL>OIL PAN UPPER .
  5. Remove the crank sprocket. Ref. to MECHANICAL (H4DO)>Crank Sprocket>REMOVAL .
  6. Remove the water tank pipe assembly. Ref. to COOLING (H4DO)>WATER PIPE>REMOVAL>WATER TANK PIPE ASSEMBLY .
  7. Remove the PVC connector. Ref. to EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) (H4DO)>PCV CONNECTOR>REMOVAL .
  8. Remove the knock sensor. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>KNOCK SENSOR>REMOVAL .
  9. Remove the PCV valve. Ref. to EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) (H4DO)>PCV VALVE>REMOVAL .
  10. Remove the engine rear hanger from cylinder block RH.
    G11253440Courtesy of SUBARU OF AMERICA, INC.
  11. 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.
    G13224547Courtesy of SUBARU OF AMERICA, INC.
  12. Set the part so that the cylinder block RH is on the upper side.
  13. 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. Using the ST, turn the crankshaft so that the #1 connecting rod cap (A) is located at the position shown in the figure.

      Preparation tool: 

      ST: CRANKSHAFT SOCKET (18252AA000)

      G13224548Courtesy of SUBARU OF AMERICA, INC.
    2. Using the ST, loosen the #1 connecting rod cap bolt, and remove the #1 connecting rod cap bolt and #1 connecting rod cap.

      Preparation tool: 

      ST: SOCKET (18270AA020)

      G13224549Courtesy 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.

      Preparation tool: 

      ST: CRANKSHAFT SOCKET (18252AA000)

      G13224550Courtesy 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.
      G13224551Courtesy of SUBARU OF AMERICA, INC.
    5. Using the ST, turn the crankshaft so that the #3 connecting rod cap (A) is located at the position shown in the figure.

      Preparation tool: 

      ST: CRANKSHAFT SOCKET (18252AA000)

      G13224552Courtesy of SUBARU OF AMERICA, INC.
    6. Using the ST, loosen the #3 connecting rod cap bolt, and remove the #3 connecting rod cap bolt and #3 connecting rod cap.

      Preparation tool: 

      ST: SOCKET (18270AA020)

      G13224553Courtesy 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.

      Preparation tool: 

      ST: CRANKSHAFT SOCKET (18252AA000)

      G13224554Courtesy 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.
    G13224555Courtesy of SUBARU OF AMERICA, INC.
  14. Set the part so that the cylinder block LH is on the upper side.
  15. Remove #2 and #4 connecting rod caps and pistons in the same removal procedure as #1 and #3 connecting rod caps and pistons.
  16. 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.
      G13224556Courtesy of SUBARU OF AMERICA, INC.
    2. Remove the bolt shown in the figure.
      G13224557Courtesy of SUBARU OF AMERICA, INC.
    3. Loosen the cylinder block mounting bolts in numerical order as shown in the figure, and then remove the bolts.
      Fig 1: Cylinder Block Mounting Bolts Loosening Sequence
      G13224558Courtesy 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. Lifting the cylinder block RH carelessly may cause the crankshaft to fall off.
  17. Remove the crankshaft from cylinder block LH, and remove the rear oil seal.
  18. Remove the O-ring from the cylinder block LH.
    G13224559Courtesy of SUBARU OF AMERICA, INC.
  19. 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).
    G13224560Courtesy of SUBARU OF AMERICA, INC.
  20. Remove the liquid gasket from cylinder block.
  21. Remove the cylinder block LH from the engine stand.
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