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Engine Assembly: Removal

  1. Fully open the panel COMPL front hood. Ref. to REPAIR CONTENTS>NOTE>STAY ASSEMBLY FRONT HOOD .
  2. Release the fuel pressure. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>FUEL>PROCEDURE>RELEASING OF FUEL PRESSURE .
  3. Open the fuel filler lid and remove the fuel filler cap.
    NOTE: This operation is required to release the inner pressure of the fuel tank.
  4. Disconnect the ground terminal of battery sensor. Ref. to REPAIR CONTENTS>NOTE>BATTERY
  5. Collect the refrigerant. Ref. to AIR CONDITIONER>REFRIGERANT RECOVERY PROCEDURE>PROCEDURE .
  6. Drain engine coolant. Ref. to COOLING (H4DO)>ENGINE COOLANT>REPLACEMENT>DRAINING OF ENGINE COOLANT
  7. Remove the air cleaner case. Ref. to INTAKE (INDUCTION) (H4DO)>AIR CLEANER CASE>REMOVAL .
    NOTE: When removing/installing the engine unit, the chain cover may come in contact with the air cleaner case bracket. Therefore, the air cleaner case bracket must also be removed.
  8. Remove the air intake boot. Ref. to INTAKE (INDUCTION) (H4DO)>AIR INTAKE BOOT>REMOVAL .
  9. Remove the radiator inlet hose. Ref. to COOLING (H4DO)>RADIATOR HOSE>REMOVAL>RADIATOR INLET HOSE .
  10. Remove the ECM. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>ENGINE CONTROL MODULE (ECM)>REMOVAL .
  11. Remove the collector cover. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>COLLECTOR COVER>REMOVAL .
  12. Remove the strut tower bar. Ref. to FRONT SUSPENSION>STRUT TOWER BAR>REMOVAL .
  13. Remove the brake vacuum hose & pipe. Ref. to BRAKE>BRAKE VACUUM PUMP>REMOVAL>BRAKE VACUUM HOSE & PIPE .
  14. Disconnect the connector (A) and terminal (B) from the generator.
  15. Remove the clip (C) securing the generator cord to the fuel pipe protector RH No. 1, and place it aside so that it does not interfere with the work.
    G16523742Courtesy of SUBARU OF AMERICA, INC.
  16. Remove the hose pressure suction. Ref. to AIR CONDITIONER>HOSE AND PIPE>REMOVAL .
  17. Disconnect the hose pressure discharge from the A/C compressor. Ref. to AIR CONDITIONER>HOSE AND PIPE>REMOVAL .
    G16523743Courtesy of SUBARU OF AMERICA, INC.
  18. Disconnect the heater inlet hose (A) and the heater outlet hose (B) from the water tank pipe assembly and the water pipe.
    G16523744Courtesy of SUBARU OF AMERICA, INC.
  19. Disconnect the water hose (A) and the water hose (B) from the oil cooler pipe and the water pipe. (AT model)
    G16523745Courtesy of SUBARU OF AMERICA, INC.
  20. Remove the front exhaust pipe. Ref. to EXHAUST (H4DO)>FRONT EXHAUST PIPE>REMOVAL .
  21. Remove the sub frame front LWR C COMPL LH. Ref. to FRONT SUSPENSION>SUB FRAME>REMOVAL .
  22. Disconnect the radiator outlet hose from the engine unit.
    G16523746Courtesy of SUBARU OF AMERICA, INC.
  23. Remove the ground cord RH (A) together with the rear oxygen sensor bracket from the engine unit and disconnect the ground cord LH (B) on the engine unit side.
    G16523747Courtesy of SUBARU OF AMERICA, INC.
  24. Remove the nuts which secure the engine mounting to the crossmember COMPL front.
    G16523748Courtesy of SUBARU OF AMERICA, INC.
  25. Remove the bolts (3 locations) and nuts (2 locations) which hold the transmission body to the engine unit as shown in the figure.
    NOTE: For the MT model, remove the cover plate (a) together with the bolts.
    • AT model
      G16523749Courtesy of SUBARU OF AMERICA, INC.
    • MT model
    G16523750Courtesy of SUBARU OF AMERICA, INC.
  26. Attach the ST to the transmission body. (AT model)

    Preparation tool: 

    ST: STAND ASSY (18632AA010)

    1. Remove the stabilizer front and the sub frame COMPL. Ref. to FRONT SUSPENSION>STABILIZER>REMOVAL .
    2. Remove the cover from the converter case.
      CAUTION: Be sure to perform this procedure to prevent the cover from being damaged by the ST.
      G16523751Courtesy of SUBARU OF AMERICA, INC.
    3. Attach the rubber sheet to the ST with double sided tape, etc. at the location shown in the figure.
      CAUTION: Be sure to perform this procedure to prevent the transmission body from being damaged by the ST.
      G16523752Courtesy of SUBARU OF AMERICA, INC.
      (A) Approx. 45 mm (Approx. 1.77 in)
      (B) Approx. 5 mm (Approx. 0.20 in)
    4. Attach the ST to the transmission body with a rope, etc.
    G16523753Courtesy of SUBARU OF AMERICA, INC.
  27. Remove the starter. Ref. to STARTING/CHARGING SYSTEMS (H4DO)>STARTER>REMOVAL .
  28. Remove the connector (A) from the engine rear hanger and remove the clip (B) securing the battery cable assembly to the intake manifold assembly.
  29. Remove the clip (C) securing the battery cable assembly to the engine rear hanger, and place it aside so that it does not interfere with work.
    G16523754Courtesy of SUBARU OF AMERICA, INC.
  30. Remove the clip securing the engine wiring harness to the vehicle.
    G16523755Courtesy of SUBARU OF AMERICA, INC.
  31. Separate the torque converter from drive plate. (AT model)
    1. Remove the PCV hose No. 1. Ref. to EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) (H4DO)>PCV HOSE>REMOVAL>PCV HOSE NO. 1 .
    2. Remove the plug from the service hole.
      G16523756Courtesy of SUBARU OF AMERICA, INC.
    3. Insert the wrench into the crank pulley bolt, and rotate the crank pulley to remove the bolts (6 places) securing the torque converter to the drive plate.
      G16523757Courtesy of SUBARU OF AMERICA, INC.
    4. Attach the ST to the converter case.

      Preparation tool: 

      ST: STOPPER SET (18750AA010)

    G16523758Courtesy of SUBARU OF AMERICA, INC.
  32. Disconnect the fuel delivery tube and evaporation hose.
    CAUTION:
    • Be careful not to spill fuel.
    • Catch the fuel from the tubes using a container or cloth.
    1. Disconnect the evaporation hose (A) from the vacuum pipe.
    2. Open the claw (B) on the fuel delivery tube clamp.
    3. Disconnect the quick connector on the fuel delivery tube (cylinder direct injection side) (C) from the fuel delivery pipe assembly, and disconnect the quick connector on the fuel delivery tube (port injection side) (D) from the fuel pipe LH.
      NOTE: Disconnect the quick connector as shown in the figure.
    G16523716Courtesy of SUBARU OF AMERICA, INC.
    (a) Slider
    G16523760Courtesy of SUBARU OF AMERICA, INC.
  33. Separate the engine unit and transmission.
    CAUTION: Before removing the engine unit away from transmission, check to be sure no work has been overlooked.
    1. Using the ST1, install the ST2 to the engine unit.

      Preparation tool: 

      ST1: BOLT (90119-14120)

      ST2: ENGINE HANGER NO. 1 (12281-38150)

      Tightening torque: 

      43 N.m (4.4 kgf-m, 31.7 ft-lb)

      G16523761Courtesy of SUBARU OF AMERICA, INC.
    2. Support the engine unit with a lifting device and wire ropes.
      G16523762Courtesy of SUBARU OF AMERICA, INC.
      (A) To engine rear hanger
      (B) To ST (ENGINE HANGER NO. 1)
    3. Support the transmission with a garage jack.
      CAUTION:
      • Be sure to perform this procedure to prevent the transmission from lowering by its own weight.
      • For the AT model, support the (a) part of ST with a garage jack.
        G16523763Courtesy of SUBARU OF AMERICA, INC.
      • For the MT model, be careful not to let the garage jack come in contact with the front stabilizer.
      G16523764Courtesy of SUBARU OF AMERICA, INC.
      (A) Transmission
      (B) Garage jack
    4. Remove the bolt (1 location) which holds the transmission body to the engine unit as shown in the figure.
      • AT model
        G16523765Courtesy of SUBARU OF AMERICA, INC.
      • MT model
    G16523766Courtesy of SUBARU OF AMERICA, INC.
  34. Remove the engine unit from the vehicle.
    NOTE: Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc.
    1. With a lifting device and a garage jack, lift the engine unit together with the transmission body.
      CAUTION: When lifting up the engine unit, pay attention to the clearance of each part and be careful not to lift the engine too much, in order to prevent damaging the vehicle.
      NOTE: Lift it high enough until the stud bolt of the engine mounting is completely drawn out of the crossmember COMPL front.
    2. Move the engine unit horizontally until the engine unit is withdrawn from transmission body. (AT model)
      NOTE: If it is hard to pull out the stud bolt from the transmission body, precisely adjust the height of the transmission body with garage jack so that no load is applied to the stud bolt.
    3. Move the engine unit horizontally until the clutch disc is pulled out from the main shaft and the engine unit is withdrawn from transmission body. (MT model)
      NOTE: If it is hard to pull out the stud bolt from the transmission body, precisely adjust the height of the transmission body with garage jack so that no load is applied to the stud bolt.
    4. Slowly move the engine unit away from engine compartment.
  35. Remove the engine mounting from the engine unit.
  36. Set the engine unit on the engine stand, etc. and remove the lifting device and wire ropes. Ref. to MECHANICAL (H4DO)>PREPARATION FOR OVERHAUL>PROCEDURE .
  37. Remove the ST1 and ST2 from the engine unit.
G16523761Courtesy of SUBARU OF AMERICA, INC.
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