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Home >> Subaru >> 2013 >> Forester F4-2.5L DOHC >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Cylinder Block Assembly >> Service and Repair >> Part 1

Part 1

Cylinder Block

REMOVAL

1) Remove the engine from the vehicle.
2) Remove the intake manifold.
3) Remove the tumble generator valve assembly.
4) Remove the chain cover.
5) Remove the rocker cover.
6) Remove the cam carrier.
7) Remove the cylinder head.
8) Remove the crank sprocket.
9) Remove the engine rear hanger from cylinder block RH.





10) 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.





11) Remove the O-ring from the cylinder block and PCV connector.





12) Remove the knock sensor from cylinder block LH.





13) Remove the PCV hose assembly (A) and the vacuum hose (B) from cylinder block and PCV valve.

NOTE:
Pinch the clamp of the PCV hose assembly (A) by fitting the cut out in the ST with the protrusion on the clamp as shown in the figure, and unlock the clamp.

ST 18353AA000 CLAMP PLIERS





14) Remove the PCV valve from the cylinder block RH.





15) Remove the crankshaft position sensor plate with drive plate. (AT model)
16) Remove the clutch disc and cover. (MT model)
17) Remove the crankshaft position sensor plate with flywheel. (MT model)
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.





19) Set the cylinder block so that the oil pan is on the upper side, remove the ST1, ST2, ST3 and ST4 from cylinder block and oil pan upper.
ST1 498457000 ENGINE STAND ADAPTER RH
ST2 498457100 ENGINE STAND ADAPTER LH
ST3 18362AA020 ADAPTER
ST4 499817100 ENGINE STAND





20) Remove the thermostat cover from oil pan upper, and then remove the thermostat.





21) Remove the oil pan upper with oil pan from cylinder block.





22) Remove the O-ring from the cylinder block.





23) Install the A/C compressor bracket bolts and the power steering pump bracket bolts at the locations shown in the figure.

NOTE:
^ This procedure is required to prevent the knock pin damage when the cylinder block is raised in the next step.
^ Use the same length bolt for the four bolts.





24) Raise the cylinder block so that the rear oil seal is on the lower side.
25) Add a front mark on the piston using a marker as shown in the figure.





26) Remove the #1 and #4 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) and #4 connecting rod cap (B) is located at the position shown in the figure using ST.
ST 18252AA000 CRANKSHAFT SOCKET





(2) Using ST, loosen the #1 connecting rod cap bolt, and remove the #1 connecting rod cap bolt and #1 connecting rod cap.
ST 18270AA010 SOCKET





(3) Using ST, loosen the #4 connecting rod cap bolt, and remove the #4 connecting rod cap bolt and #4 connecting rod cap.
ST 18270AA010 SOCKET





(4) Using the ST, turn the crankshaft clockwise and separate the positions of the #1 crank pin (A) and the large end of the #1 connecting rod (B).
ST 18252AA000 CRANKSHAFT SOCKET





(5) Push the #1 connecting rod in the direction of the arrow, and remove the #1 piston with #1 connecting rod from the cylinder block.





(6) Using the ST, turn the crankshaft counterclockwise and separate the positions of the #4 crank pin (A) and the large end of the #4 connecting rod (B).
ST 18252AA000 CRANKSHAFT SOCKET





(7) Push the #4 connecting rod in the direction of the arrow, and remove the #4 piston with #4 connecting rod from the cylinder block.





27) Remove the #2 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 #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





(2) Using ST, loosen the #2 connecting rod cap bolt, and remove the #2 connecting rod cap bolt and #2 connecting rod cap.
ST 18270AA010 SOCKET





(3) Using ST, loosen the #3 connecting rod cap bolt, and remove the #3 connecting rod cap bolt and #3 connecting rod cap.
ST 18270AA010 SOCKET





(4) Using the ST, turn the crankshaft counterclockwise and separate the positions of the #2 crank pin (A) and the large end of the #2 connecting rod (B).
ST 18252AA000 CRANKSHAFT SOCKET





(5) Push the #2 connecting rod in the direction of the arrow, and remove the #2 piston with #2 connecting rod from the cylinder block.





(6) Using the ST, turn the crankshaft clockwise and separate the positions of the #3 crank pin (A) and the large end of the #3 connecting rod (B).
ST 18252AA000 CRANKSHAFT SOCKET





(7) Push the #3 connecting rod in the direction of the arrow, and remove the #3 piston with #3 connecting rod from the cylinder block.





28) Set the cylinder block so that the oil pan side is on the upper side, and remove the A/C compressor bracket bolts and the power steering pump bracket bolts attached at the locations shown in the figure.





29) Set the part so that the cylinder block RH is on the upper side, and separate the cylinder block.

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.

(1) Remove the bolt shown in the figure.





(2) Loosen the cylinder block mounting bolts in numerical order as shown in the figure, and separate the cylinder block RH and LH.

NOTE:
Lift the cylinder block RH slightly, 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.





30) Remove the crankshaft from cylinder block LH, and remove the rear oil seal.
31) Remove the O-ring from the cylinder block LH.





32) 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).





33) Remove the liquid gasket from cylinder block.

INSTALLATION

1) Apply engine oil to the crankshaft bearing, and install the crankshaft bearing to the cylinder block.

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.





2) Install O-rings to the cylinder block LH.

NOTE:
Use new O-rings.





3) Apply engine oil to the crankshaft journal, and set the crankshaft to the cylinder block LH.





4) Apply liquid gasket to the mating surface of cylinder block RH as shown in the figure.

CAUTION:
Do not let the liquid gasket overflow to the oil passage, journal groove, 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) or equivalent

Liquid gasket applying diameter:
Mating surfaces other than ranges A and B
1±0.5 mm (0.0394±0.0197 in)
Mating surfaces of ranges A and B
4±0.5 mm (0.1575±0.0197 in)





5) Install the cylinder block RH to the cylinder block LH.
6) 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) Install the cylinder head bolt at the locations shown in the figure.

NOTE:
This procedure is required to tighten the cylinder block mounting bolts with specified angle using ST.





(3) Tighten all mounting bolts with a torque of 35 Nm (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.





(4) 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.





(5) Tighten all mounting bolts with a torque of 35 Nm (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.





(6) 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.





(7) Tighten the mounting bolts (4 places) with a torque of 17 Nm (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.





(8) Using ST, 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.

NOTE:
Attach the magnet used for securing the ST (ANGLE GAUGE) to the cylinder head bolt attached in step (2).

ST 18854AA000 ANGLE GAUGE

Tightening angle:
60°±2°





(9) 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.





(10) Tighten the mounting bolts (6 places) with a torque of 17 Nm (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.





(11) Using ST, 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.

NOTE:
Attach the magnet used for securing the ST (ANGLE GAUGE) to the cylinder head bolt attached in step (2).

ST 18854AA000 ANGLE GAUGE

Tightening angle:
60°±2°





(12) Remove the cylinder head bolt attached at the locations shown in the figure.





(13) 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 Nm (2.5 kgf-m, 18.4 ft-lb)





7) Set the part so that the oil pan side of cylinder block is on the upper side.
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