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Engine Assembly: Installation

WARNING: This page is about a different car, the 2006 Subaru Outback and 2006 Subaru Legacy. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the front cushion rubbers to engine.

    Tightening torque: 

    35 N.m (3.6 kgf-m, 25.8 ft-lb) 

  2. Position the engine in engine compartment and align it with transmission.
    NOTE: Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc.
    Fig 1: Supporting Engine With Lifting Device And Wire Ropes
    G04997613Courtesy of SUBARU OF AMERICA, INC.
  3. Apply a small amount of grease to splines of mainshaft. (MT model)
  4. Tighten the bolts which hold upper side of transmission to engine.

    Tightening torque: 

    50 N.m (5.1 kgf-m, 36.9 ft-lb) 

    Fig 2: Locating Transmission Bolts Location
    G04997615Courtesy of SUBARU OF AMERICA, INC.
  5. Remove the lifting device and wire ropes.
  6. Remove the garage jack.
  7. Attach the pitching stopper.

    Tightening torque: 

    T1: 50 N.m (5.1 kgf-m, 36.9 ft-lb) 

    T2: 58 N.m (5.9 kgf-m, 42.8 ft-lb) 

    Fig 3: Identifying Pitching Stopper
    G04997619Courtesy of SUBARU OF AMERICA, INC.
  8. Remove the ST from converter case. (AT model)
    NOTE: Be careful not to drop the ST into the converter case when removing the ST.

    ST 498277200 STOPPER SET

  9. Install the starter. < Ref. to INSTALLATION , Starter. >
  10. Install the torque converter clutch to drive plate. (AT model)
    1. Tighten the bolts which hold torque converter clutch to drive plate.
    2. Tighten other bolts while rotating the crankshaft using socket wrench.
      CAUTION: Be careful not to drop bolts into the torque converter clutch housing.

      Tightening torque: 

      25 N.m (2.5 kgf-m, 18.1 ft-lb) 

      Fig 4: Removing Torque Converter Clutch Bolts
      G04997610Courtesy of SUBARU OF AMERICA, INC.
    3. Attach the service hole plug to prevent entry of foreign objects.
  11. Install the power steering pump.
    1. Install the power steering pump to the bracket, and tighten the bolts.

      Tightening torque: 

      22 N.m (2.2 kgf-m, 16 ft-lb) 

      Fig 5: Locating Power Steering Pump Bracket Bolts
      G04997328Courtesy of SUBARU OF AMERICA, INC.
    2. Connect the power steering switch connector.
      Fig 6: Locating Power Steering Switch Connector
      G04997602Courtesy of SUBARU OF AMERICA, INC.
    3. Install and adjust the front side belt. < Ref. to FRONT SIDE BELT , INSTALLATION, V-belt. >
  12. Lift-up the vehicle.
  13. Tighten the bolts and nuts which hold lower side of the transmission to engine.

    Tightening torque: 

    50 N.m (5.1 kgf-m, 36.9 ft-lb) 

    Fig 7: Locating Transmission Nuts Location
    G04997625Courtesy of SUBARU OF AMERICA, INC.
  14. Tighten the nuts which install the front cushion rubber onto crossmember.

    Tightening torque: 

    75 N.m (7.6 kgf-m, 55.3 ft-lb) 

    NOTE: Make sure the front cushion rubber mounting bolts (A) and locator (B) are securely installed.
    Fig 8: Locating Crossmember Bolts
    G04997626Courtesy of SUBARU OF AMERICA, INC.
  15. Connect the ground cable.
  16. Install the front and center exhaust pipe.

    < Ref. to INSTALLATION , Front Exhaust Pipe. >

  17. Lower the vehicle.
  18. Connect the following hoses.
    1. Fuel delivery hose and evaporation hose
    2. Heater inlet and outlet hoses
    3. Brake booster vacuum hose
  19. Connect the following connectors.
    1. Front oxygen (A/F) sensor connector
    2. Rear oxygen sensor connector
    3. Engine harness connectors
    4. Generator connector and terminal
    5. A/C compressor connector
  20. Install the air intake chamber stay.

    Tightening torque: 

    16 N.m (1.6 kgf-m, 11.6 ft-lb) 

  21. Tighten the engine ground cable.

    Tightening torque: 

    14 N.m (1.4 kgf-m, 10.1 ft-lb) 

  22. Install the A/C pressure hoses.

    < Ref. to INSTALLATION , Hose and Tube. >

  23. Install the radiator to vehicle. < Ref. to INSTALLATION , Radiator. >
  24. Install the air intake duct, air cleaner case and air intake chamber. < Ref. to INSTALLATION , Air Intake Duct. > < Ref. to INSTALLATION , Air Cleaner Case. > < Ref. to INSTALLATION , Air Intake Chamber. >
  25. Install the under cover.
  26. Install the battery in the vehicle, and connect cables.
  27. Fill engine coolant.

    < Ref. to FILLING OF ENGINE COOLANT , REPLACEMENT, Engine Coolant. >

  28. Check the ATF level and replenish it if necessary.

    < Ref. to INSPECTION , Automatic Transmission Fluid. >

  29. Charge the A/C system with refrigerant. < Ref. to PROCEDURE , Refrigerant Charging Procedure. >
  30. Remove the front hood stay, and close the front hood.
  31. Lower the vehicle from the lift.
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