FixVault

Engine Assembly: Installation

  1. Install the engine mounting onto the engine.

    Tightening torque: 

    35 N.m (3.6 kgf-m, 25.8 ft-lb) 

  2. Apply a small amount of grease to splines of main shaft. (MT model)

    Grease: 

    NICHIMOLY N-130 or equivalent 

  3. 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.
  4. Install the bolts which hold upper side of transmission to engine.

    Tightening torque: 

    50 N.m (5.1 kgf-m, 36.9 ft-lb) 

    • CVT model
      Fig 1: Locating Engine Transmission Bolts - CVT Model
      G09480221Courtesy of SUBARU OF AMERICA, INC.
    • MT model
      Fig 2: Locating Engine Transmission Bolts - MT Model
      G08316855Courtesy of SUBARU OF AMERICA, INC.
  5. Remove the lifting device and wire ropes.
    Fig 3: Supporting Engine Using Lifting Device And Wire Ropes
    G08316851Courtesy of SUBARU OF AMERICA, INC.
  6. Remove the garage jack.
  7. Install the clip (B) to the pitching stopper bracket, and then install the air breather hose to the clip (B). (CVT model)
  8. Install the bolt (A) which secures the transmission harness stay to the CVT. (CVT model)

    Tightening torque: 

    15 N.m (1.6 kgf-m, 11.8 ft-lb) 

    Fig 4: Identifying Air Breather Hose And Pitching Stopper Bracket Clips
    G10266681Courtesy of SUBARU OF AMERICA, INC.
  9. Install the CVTF cooler (with warmer feature) to the CVT. (CVT model)
    1. Temporarily tighten the upper bolt which secures the CVTF cooler (with warmer feature) to the CVT.
    2. Using clip (A), fix the bulkhead harness to the CVTF cooler (with warmer feature).
      Fig 5: Locating CVTF Cooler Upper Bolt
      G09480214Courtesy of SUBARU OF AMERICA, INC.
    3. Lift up the vehicle.
    4. Install the lower bolt which secures CVTF cooler (with warmer feature) to the CVT.

      Tightening torque: 

      23 N.m (2.3 kgf-m, 17.0 ft-lb) 

      Fig 6: Locating CVTF Cooler Lower Bolt
      G09480207Courtesy of SUBARU OF AMERICA, INC.
    5. Lower the vehicle.
    6. Tighten the upper bolt which secures the CVTF cooler (with warmer feature) to the CVT.

      Tightening torque: 

      23 N.m (2.3 kgf-m, 17.0 ft-lb) 

      Fig 7: Locating CVTF Cooler Upper Bolt
      G09480227Courtesy of SUBARU OF AMERICA, INC.
  10. Install the torque converter clutch to drive plate. (CVT model)
    1. Remove the ST from torque converter clutch case.
      NOTE: Be careful not to drop the ST into the torque converter clutch case when removing the ST.

      ST 498277200 STOPPER SET

      Fig 8: Installing Torque Converter Clutch To Drive Plate (CVT Model)
      G09480213Courtesy of SUBARU OF AMERICA, INC.
    2. Insert the wrench into the crank pulley bolt and rotate the crank pulley to install the bolts which hold torque converter clutch to drive plate.
      NOTE: Be careful not to drop bolts into the torque converter clutch case.

      Tightening torque: 

      25 N.m (2.5 kgf-m, 18.4 ft-lb) 

      Fig 9: Inserting Wrench Into Crank Pulley Bolt
      G10266697Courtesy of SUBARU OF AMERICA, INC.
    3. Fit the plug to service hole.
      Fig 10: Locating Service Hole Plug
      G09480211Courtesy of SUBARU OF AMERICA, INC.
  11. Install the starter. < Ref. to INSTALLATION , Starter. >
  12. Lift up the vehicle.
  13. Install 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) 

    • CVT model
      Fig 11: Locating Engine Transmission Bolts And Nut
      G09480208Courtesy of SUBARU OF AMERICA, INC.
    • MT model
      Fig 12: Locating Engine Transmission Bolts And Nut - MT Model
      G08316840Courtesy of SUBARU OF AMERICA, INC.
  14. Install the nuts which hold the engine mounting to the crossmember.
    NOTE:
    • Make sure that locators (a) of the engine mounting are securely inserted.
    • Use a new nut.

    Tightening torque: 

    60 N.m (6.1 kgf-m, 44.3 ft-lb) 

    Fig 13: Locating Crossmember Engine Mounting Nuts
    G10266701Courtesy of SUBARU OF AMERICA, INC.
  15. Connect the ground cable to the oil pipe assembly.

    Tightening torque: 

    7 N.m (0.7 kgf-m, 5.2 ft-lb) 

    Fig 14: Locating Oil Pipe Assembly Ground Cable
    G09480206Courtesy of SUBARU OF AMERICA, INC.
  16. Set the transmission jack to the transmission. (CVT model)
    NOTE: Be careful that the support plate of transmission jack does not touch the transmission oil pan.
  17. Remove the ST and install the rear crossmember. (CVT model)

    ST 41099YC001 ST REAR MOUNT

    Tightening torque: 

    T1: 18 N.m (1.8 kgf-m, 13.3 ft-lb) 

    T2: 35 N.m (3.6 kgf-m, 25.8 ft-lb) 

    T3: 70 N.m (7.1 kgf-m, 51.6 ft-lb) 

    Fig 15: Locating Rear Crossmember Bolts
    G10266703Courtesy of SUBARU OF AMERICA, INC.
  18. Remove the transmission jack. (CVT model)
  19. Install the front exhaust pipe. < Ref. to INSTALLATION , Front Exhaust Pipe. >
  20. Lift up the vehicle.
  21. Install the oil catch tank. < Ref. to INSTALLATION , Oil Catch Tank. >
  22. Install 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 16: Identifying Oil Catch Tank Pitching Stopper
    G10266704Courtesy of SUBARU OF AMERICA, INC.
  23. Connect the fuel delivery tube and evaporation hose.
    1. Connect the evaporation hose to fuel pipe assembly.
      Fig 17: Locating Evaporation Hose
      G09480218Courtesy of SUBARU OF AMERICA, INC.
    2. Connect the quick connector on the fuel delivery tube to the fuel pipe assembly, and fix the fuel delivery tube using clip (A).
      CAUTION:
      • Check that there is no damage or dust on the quick connector. If necessary, clean the seal surface of the pipe.
      • When connecting the quick connector, make sure to insert it all the way in before locking the slider.
      • When it is difficult to lock the slider, check that the connector is fully inserted.
      • After locking the slider, check that the quick connector is securely connected.
      NOTE: Connect the quick connector as shown in the figure.
      Fig 18: Connecting Quick Connector
      G10291745Courtesy of SUBARU OF AMERICA, INC.
      Fig 19: Locating Fuel Delivery Tube Quick Connector
      G10266683Courtesy of SUBARU OF AMERICA, INC.
  24. Connect the engine coolant inlet hose and engine coolant outlet hose to the CVTF cooler (with warmer feature) and EGR cooler. (CVT model)
    Fig 20: Locating Engine Coolant Inlet And Outlet Hose Clamps
    G10266669Courtesy of SUBARU OF AMERICA, INC.
  25. Connect the heater inlet hose (A) to the water pipe assembly, and connect the heater outlet hose (B) to the water pipe LH.
    NOTE: Be careful not to mix up the heater inlet hose and the heater outlet hose when connecting them.
    Fig 21: Connecting Water Pipe Assembly Heater Inlet Hose
    G10291748Courtesy of SUBARU OF AMERICA, INC.
    Fig 22: Identifying Water Pipe LH Heater Outlet Hose
    G10266668Courtesy of SUBARU OF AMERICA, INC.
  26. Connect the hose - pressure suction and the hose - pressure discharge to the A/C compressor. < Ref. to INSTALLATION , Hose and Pipe. >
  27. Set the generator cord, and fix the generator cord to the fuel pipe protector using clip (C).
  28. Install the generator cord to clip (B), and connect the connector (A) to A/C compressor.
    Fig 23: Identifying Generator Cord Clip And Generator Connector
    G10266711Courtesy of SUBARU OF AMERICA, INC.
  29. Using clip (D), fix the generator cord to the generator cord stay, and connect the connector (B) and the terminal (C) to the generator.

    Tightening torque: 

    15 N.m (1.5 kgf-m, 11.1 ft-lb) 

  30. Connect the connector (A) to the brake vacuum pump.
    Fig 24: Identifying Brake Vacuum Pump Connector
    G10266666Courtesy of SUBARU OF AMERICA, INC.
  31. Connect the bulkhead harness connector to the engine harness connector.
    Fig 25: Locating Bulkhead Harness Connectors
    G10266665Courtesy of SUBARU OF AMERICA, INC.
  32. Install the brake booster vacuum hose to the clip (D).
    NOTE: If the clip is removed from the intake manifold, install the clip to the position of alignment mark of intake manifold.
  33. Connect sections (A) and (B) of the brake booster vacuum hose to the brake vacuum pump and intake manifold, and install the brake booster vacuum hose to the clip (C).
    Fig 26: Identifying Booster Vacuum Hose Clip
    G10266664Courtesy of SUBARU OF AMERICA, INC.
  34. Install the radiator. < Ref. to INSTALLATION , Radiator. >
  35. Install the intake duct No. 1 and intake duct No. 2. < Ref. to INTAKE DUCT NO. 1 , INSTALLATION, Intake Duct. > < Ref. to INTAKE DUCT NO. 2 , INSTALLATION, Intake Duct. >
  36. Install the ECM. < Ref. to INSTALLATION , Engine Control Module (ECM). >
  37. Install the intercooler. < Ref. to INSTALLATION , Intercooler. >
  38. Install the air intake duct. < Ref. to INSTALLATION , Air Intake Duct. >
  39. Connect the ground terminal to battery sensor. < Ref. to BATTERY , NOTE, Note. >
  40. Charge the A/C system with refrigerant. < Ref. to PROCEDURE , Refrigerant Charging Procedure. >
  41. Fill engine coolant. < Ref. to FILLING OF ENGINE COOLANT , REPLACEMENT, Engine Coolant. >
  42. Install the collector cover. < Ref. to INSTALLATION , Collector Cover. >
  43. Set the front hood to the normal position. < Ref. to FRONT HOOD DAMPER STAY , NOTE, Note. >
  44. Install the striker - front hood. < Ref. to ASSEMBLY , Front Hood. >
  45. Close the front hood.