Engine Assembly: Installation

WARNING: This page is about a different variant/trim than selected.

Install the clutch release fork and bearing to the transmission.
1. Using a flat tip screwdriver, remove the release bearing from the clutch cover.
  
  Fig 1: Removing Release Bearing From Clutch Cover Using Flat Tip Screwdriver
  Courtesy of SUBARU OF AMERICA, INC.
2. Attach the release bearing to the transmission.
3. Install the release fork into the release bearing tab.
  
  Fig 2: Locating Release Fork And Release Bearing Tab
  Courtesy of SUBARU OF AMERICA, INC.
4. Apply grease to the specified areas.
  Grease:
  
  Spline part
  
  NICHIMOLY N-130 or equivalent
  
  Shaft part
  
  KOPR-KOTE or equivalent
  
  Fig 3: Locating Grease Application Area Of Spline And Shaft
  Courtesy of SUBARU OF AMERICA, INC.
5. Insert the release shaft to release fork.
  NOTE: Allow the cutout portion of release shaft to come into contact with the spring pin.
  
  Fig 4: Inserting Release Shaft To Release Fork
  Courtesy of SUBARU OF AMERICA, INC.
6. Install the service hole plug.
  Tightening torque:
  
  44 N.m (4.5 kgf-m, 32.5 ft-lb)
  
  Fig 5: Service Hole Plug Location
  Courtesy of SUBARU OF AMERICA, INC.
Install the engine mounting onto the engine.
Tightening torque:

35 N.m (3.6 kgf-m, 25.8 ft-lb)
Apply a small amount of grease to splines of main shaft.
Grease:

NICHIMOLY N-130 or equivalent
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.
Install the bolts which hold upper side of transmission to engine.
Tightening torque:

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

Fig 6: Locating Transmission Upper Side Bolts
Courtesy of SUBARU OF AMERICA, INC.
Remove the lifting device and wire ropes.

Fig 7: Supporting Engine With Lifting Device And Wire Ropes
Courtesy of SUBARU OF AMERICA, INC.
Remove the garage jack.
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 8: Locating Pitching Stopper Bolts
Courtesy of SUBARU OF AMERICA, INC.
Install the return spring.

Fig 9: Locating Return Spring Of Release Fork
Courtesy of SUBARU OF AMERICA, INC.
Install the operating cylinder.
NOTE: Check that the clutch hose is routed properly.

Tightening torque:

41 N.m (4.2 kgf-m, 30.2 ft-lb)

Fig 10: Locating Operating Cylinder Bolts
Courtesy of SUBARU OF AMERICA, INC.
Install the starter. <Ref. to INSTALLATION , Starter.>
Install the power steering pump.
1. Install the power steering pump onto the engine.
  Tightening torque:
  
  Refer to "COMPONENT" of "Power Steering" for the tightening torque. <Ref. to COMPONENT , General Description.>
  
  Fig 11: Locating Power Steering Pump Bolts
  Courtesy of SUBARU OF AMERICA, INC.
2. Install the purge control solenoid valve 1 to the intake manifold.
  Tightening torque:
  
  19 N.m (1.9 kgf-m, 14.0 ft-lb)
  
  Fig 12: Locating Purge Control Solenoid Valve Bolt
  Courtesy of SUBARU OF AMERICA, INC.
3. Connect the connector to the power steering pump switch.
  
  Fig 13: Locating Power Steering Pump Switch Connector
  Courtesy of SUBARU OF AMERICA, INC.
4. Install the front side belt. <Ref. to FRONT SIDE BELT , INSTALLATION, V-belt.>
Remove the intercooler stay RH No. 2.

Fig 14: Locating Intercooler Stay Bolts
Courtesy of SUBARU OF AMERICA, INC.
Lift up the vehicle.
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)

Fig 15: Locating Transmission Lower Side Bolts
Courtesy of SUBARU OF AMERICA, INC.
Install the nuts which hold the engine mounting to the crossmember.
NOTE: Use a new nut.

Tightening torque:

60 N.m (6.1 kgf-m, 44.3 ft-lb)

Fig 16: Locating Engine Mounting Bolts
Courtesy of SUBARU OF AMERICA, INC.
Connect the ground cable.
Tightening torque:

7.5 N.m (0.8 kgf-m, 5.5 ft-lb)

Fig 17: Locating Engine Side Ground Cable Bolt
Courtesy of SUBARU OF AMERICA, INC.
Install the joint pipe and front exhaust pipe. <Ref. to INSTALLATION , Front Exhaust Pipe.> <Ref. to INSTALLATION , Joint Pipe.>
Install the turbocharger. <Ref. to INSTALLATION , Turbocharger.>
Install the center exhaust pipe. <Ref. to INSTALLATION , Center Exhaust Pipe.>
Connect the following hoses.
1. Fuel delivery hose, fuel return hose and evaporation hose
2. Heater inlet hose and heater outlet hose
3. Brake booster vacuum hose and pressure regulator vacuum hose
4. A/C pressure hose <Ref. to INSTALLATION , Hose and Pipe.>
Secure the generator cord using the clip (B) and connect the connector (A) to A/C compressor.

Fig 18: Locating Generator Cord Clip
Courtesy of SUBARU OF AMERICA, INC.
Connect the following connectors and terminals.
1. Generator connector and terminal
  Tightening torque:
  
  15 N.m (1.5 kgf-m, 11.1 ft-lb)
2. Secondary air pump connector
Install the engine harness connector to engine harness bracket, then connect the bulkhead harness connector to the engine harness connector.

Fig 19: Installing Engine Harness Connector To Engine Harness Bracket
Courtesy of SUBARU OF AMERICA, INC.
Install the intercooler. <Ref. to INSTALLATION , Intercooler.>
Install the radiator. <Ref. to INSTALLATION , Radiator.>
Install the coolant filler tank. <Ref. to INSTALLATION , Coolant Filler Tank.>
Install the air cleaner case and air intake duct. <Ref. to INSTALLATION , Air Cleaner Case.> <Ref. to INSTALLATION , Air Intake Duct.>
Install the battery. <Ref. to INSTALLATION , Battery.>
Fill engine coolant. <Ref. to FILLING OF ENGINE COOLANT , REPLACEMENT, Engine Coolant.>
Charge the A/C system with refrigerant. <Ref. to REFRIGERANT CHARGING PROCEDURE , Refrigerant Charging Procedure.>
Install the V-belt cover.
Tightening torque:

13 N.m (1.3 kgf-m, 9.6 ft-lb)

Fig 20: Locating V-Belt Covers Clip
Courtesy of SUBARU OF AMERICA, INC.
Set the front hood to the normal position. <Ref. to FRONT HOOD DAMPER STAY , NOTE, Note.>
Install the striker - front hood. <Ref. to ASSEMBLY , Front Hood.>
Close the front hood.