Piston Installation
The pistons are directional and must be returned to the original cylinder
locations. Use piston guide 498747100 to install the pistons. The pistons are
marked with an “L” for the left side and an “R” for the right side. The arrow on
the head of each piston must point to the front of the engine.
Rotate the crankshaft to position the connecting rod with the piston. Use piston
pin guide 499017100 to align the piston and connecting rod. Then install the piston
pin. Install the circlip. Note the proper direction of the circlip on early production
models. The tang must be tilted out. Repeat for the remaining pistons. Slowly
rotate the crankshaft two revolutions. This confirms the proper installation of
the pins. Install the front piston pin access plugs. Use new aluminum sealing
rings and sealer.
Install the left side access cover and new o-ring, PCV baffle plate, and piston
pin plug using a new sealing ring and sealer.
Install the oil pan baffle plate and oil pick-up tube. Be sure to install a new
o-ring to the oil pick-up tube.
Install a new oil seal on the oil return tube. Apply liquid gasket sealer FUJI
Bond 1207C or equivalent to the oil pan mating surface. Install the oil pan and oil
pan retaining bolts. Diagonally torque the oil pan bolts on one pass to 0.5 Kg-m
(3.6 ft lbs).
Install the dipstick tube. Be sure to use two (2) new o-ring seals.
Install the rear main oil seal using seal installer (499587200), oil seal guide (499597100)
and a plastic hammer. Lubricate the seal with engine oil prior to installation.
Install the oil pump. Refer to service manual section 2-4([W1D0) for proper
location of the sealer and o-ring. Apply FUJI Bond 1215 sealer or equivalent to the
mating surface of the oil pump. Align the flats two on the oil pump with the two
flats on the crankshaft and the mounting holes in the oil pump flange with the two
dowel pins. Install the mounting bolts and torque to specifications.
Cylinder Head Torque Sequence
Install a new cylinder head gasket (dry) and the
cylinder head. Follow the bolt torque sequence and
procedures listed in the appropriate MY Legacy
Service Manual, Section 2-3 (W5E1).
Compressing the Tensioner
Slowly compress the cam belt tensioner in a
vise, using aluminum or brass jaws, until the hole
in the piston aligns with the hole in the tensioner
case. Install a tensioner plunger retaining pin. You
may use a small allen wrench as a retaining pin.
Install tensioner assembly to the crankcase, do not
tighten the mounting bolts.
Note: Do not remove plunger retaining pin until
cam belt is completely installed.
A revised cam belt tensioner design was intro-
duced on later 2.2 liter engines. The revised tension-
er requires a special service procedure to retract the
tension piston. Compressing the piston in a vise
will damage the tensioner piston and it will not
extend properly when it is reinstalled on the
engine. Refer to the appropriate section in the
Subaru service manual for tensioner handling
procedures.
Installing Pistons
Piston Pin Guide
Installing Rear Main Seal
Installing Oil Pump
Torquing Cylinder Head Bolts
Compressing Belt Tensioner Piston
Revised Belt Tensioner Procedure
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