Subaru Crosstrek Service Manual: Removal

1. Remove the engine from the vehicle. Engine Assembly > REMOVAL">

2. Remove the intake manifold. Intake Manifold > REMOVAL">

3. Remove the engine wiring harness. Engine Wiring Harness > REMOVAL">

4. Remove the tumble generator valve assembly. Tumble Generator Valve Assembly > REMOVAL">

5. Remove the chain cover. Chain Cover > REMOVAL">

6. Remove the rocker cover. Rocker Cover > REMOVAL">

7. Remove the cam carrier. Cam Carrier > REMOVAL">

8. Remove the cylinder head. Cylinder Head > REMOVAL">

9. Remove the crank sprocket. Crank Sprocket > REMOVAL">

10. Remove the engine rear hanger from cylinder block RH.

11. 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.

• CVT model

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

13. Remove the knock sensor. Knock Sensor > REMOVAL">

14. Remove the PCV valve. PCV Valve > REMOVAL">

15. Remove the crankshaft position sensor plate with drive plate. (CVT model) Drive Plate > REMOVAL">

16. Remove the clutch disc and cover. (MT model) Clutch Disc and Cover > REMOVAL">

17. Remove the crankshaft position sensor plate with flywheel. (MT model) Flywheel > REMOVAL">

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. Remove the water jacket spacer from the cylinder block RH and cylinder block LH.

20. 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.

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

22. Remove the oil pan upper. Oil Pan > REMOVAL">

23. Install a bolt of suitable length (M10 ? P1.25) 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 of bolt for the four bolts.

24. Raise the cylinder block so that the rear oil seal is on the lower side.

25. 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.

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

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

(4) 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.

(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 clockwise and separate the positions of the #4 pin (A) of crankshaft and the large end (B) of #4 connecting rod.

(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.

26. 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.

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

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

(4) Using the ST, turn the crankshaft clockwise and separate the positions of the #2 pin (A) of crankshaft and the large end (B) of #2 connecting rod.

(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 counterclockwise and separate the positions of the #3 pin (A) of crankshaft and the large end (B) of #3 connecting rod.

(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.

27. Set the cylinder block so that the oil pan side faces upward, and remove the mounting bolts attached to the locations shown in the figure.

28. 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.

29. Remove the crankshaft from cylinder block LH, and remove the rear oil seal.

30. Remove the O-ring from the cylinder block LH.

31. 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).

32. Remove the liquid gasket from cylinder block.

Disassembly

Inspection

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