Engine Assembly: Removal

WARNING: This page is about a different car, the 2004 Subaru Baja. However, it is still accessible from the selected car via links, so may be relevant.

Set the vehicle on a lift.
Open the front hood fully, and then support with the hood stay.
Collect the refrigerant from A/C system. Refer to REFRIGERANT RECOVERY PROCEDURE .
Release the fuel pressure.
1. Disconnect the fuel pump relay connector.
  
  Fig 1: Disconnecting Fuel Pump Relay Connector
  Courtesy of SUBARU OF AMERICA, INC.
2. Start the engine, and run until stalls.
3. After the engine stalls, crank it for 5 seconds more.
4. Turn the ignition switch to OFF.
Remove the filler cap.
Disconnect the ground cable from battery.

Fig 2: Disconnecting Ground Cable From Battery
Courtesy of SUBARU OF AMERICA, INC.
Remove the radiator from vehicle. Refer to REMOVAL , Radiator.
Remove the coolant filler tank. Refer to REMOVAL , Coolant Filler Tank.
Disconnect the A/C pressure hoses from A/C compressor.

Fig 3: Disconnecting A/C Pressure Hoses From A/C Compressor
Courtesy of SUBARU OF AMERICA, INC.
Remove the intercooler. Refer to REMOVAL , Intercooler.
Disconnect the following connectors and cable
1. Engine harness connector
  
  Fig 4: Locating Engine Harness Connector
  Courtesy of SUBARU OF AMERICA, INC.
2. Engine ground terminal
  
  Fig 5: Locating Engine Ground Terminal
  Courtesy of SUBARU OF AMERICA, INC.
3. Disconnect engine ground cables on the left and right sides.
  
  Fig 6: Disconnecting Engine Ground Cables On Left
  Courtesy of SUBARU OF AMERICA, INC.
  
  Fig 7: Disconnecting Engine Ground Cables On Right Sides
  Courtesy of SUBARU OF AMERICA, INC.
4. Engine harness connector
  
  Fig 8: Identifying Engine Harness Connector
  Courtesy of SUBARU OF AMERICA, INC.
5. Generator connector, terminal and A/C compressor connectors
  
  Fig 9: Locating Generator Connector, Terminal & A/C Compressor Connectors
  Courtesy of SUBARU OF AMERICA, INC.
6. Clutch release spring (MT model)
  
  Fig 10: Identifying Clutch Release Spring (MT Model)
  Courtesy of SUBARU OF AMERICA, INC.
Disconnect the following hoses.
1. Brake booster vacuum hose
  
  Fig 11: Disconnecting Brake Booster Vacuum Hose
  Courtesy of SUBARU OF AMERICA, INC.
2. Heater inlet outlet hose
  
  Fig 12: Disconnecting Heater Inlet Outlet Hose
  Courtesy of SUBARU OF AMERICA, INC.
Remove the power steering pump from bracket.
1. Loosen the lock bolt and slider bolt, and then remove the front side V-belt. Refer to V-BELT .
2. Disconnect the power steering switch connector.
  
  Fig 13: Disconnecting Power Steering Switch Connector
  Courtesy of SUBARU OF AMERICA, INC.
3. Remove the pipe with bracket from intake manifold.
  
  Fig 14: Removing Pipe With Bracket From Intake Manifold
  Courtesy of SUBARU OF AMERICA, INC.
4. Remove the power steering pump from engine.
  
  Fig 15: Removing Power Steering Pump From Engine
  Courtesy of SUBARU OF AMERICA, INC.
5. Remove the power steering tank from bracket by pulling it upward.
  
  Fig 16: Removing Power Steering Tank From Bracket
  Courtesy of SUBARU OF AMERICA, INC.
6. Place the power steering pump on right side wheel apron.
  
  Fig 17: Placing Power Steering Pump On Right Side Wheel Apron
  Courtesy of SUBARU OF AMERICA, INC.
Lift-up the vehicle.
Remove ATF cooler pipe from frame. (AT model)
Remove the center exhaust pipe. Refer to REMOVAL , Center Exhaust Pipe.
Remove the nuts which hold the lower side of transmission to engine.

Fig 18: Removing Nuts Which Hold Lower Side Of Transmission To Engine
Courtesy of SUBARU OF AMERICA, INC.
Remove the nuts which install the front cushion rubber onto front crossmember.

Fig 19: Removing Nuts Which Install Front Cushion Rubber Onto Front Crossmember
Courtesy of SUBARU OF AMERICA, INC.
Lower the vehicle.
Separate the clutch release fork from release bearing. (MT model)
1. Remove the clutch operating cylinder from transmission.
2. Remove the plug using a 10 mm hexagon wrench.
  
  Fig 20: Removing Plug Using 10 Mm Hexagon Wrench
  Courtesy of SUBARU OF AMERICA, INC.
3. Screw the 6 mm dia. bolt into release fork shaft, and remove it.
  
  Fig 21: Screwing Bolt Into Release Fork Shaft
  Courtesy of SUBARU OF AMERICA, INC.
4. Raise the release fork, and then unfasten the release bearing tabs to free release fork.
NOTE: Step (4) is required to prevent interference with engine when removing the engine from transmission.
Separate torque converter clutch from drive plate. (AT model)
1. Lower the vehicle.
2. Remove service hole plug.
3. Remove bolts which hold torque converter clutch to drive plate.
4. Remove other bolts while rotating the engine using socket wrench.
  
  Fig 22: Removing Other Bolts While Rotating Engine Using Socket Wrench
  Courtesy of SUBARU OF AMERICA, INC.
Remove the pitching stopper.

Fig 23: Removing Pitching Stopper
Courtesy of SUBARU OF AMERICA, INC.
Disconnect the fuel delivery hose, return hose and evaporation hose.
NOTE:
- Catch fuel from the hose into container.
- Disconnect the hose with its end wrapped with cloth to prevent fuel from splashing.
Fig 24: Disconnecting Hose
Courtesy of SUBARU OF AMERICA, INC.
Remove fuel filter and bracket.

Fig 25: Removing Fuel Filter & Bracket
Courtesy of SUBARU OF AMERICA, INC.
Support the engine with a lifting device and wire ropes.

Fig 26: Supporting Engine With Lifting Device & Wire Ropes
Courtesy of SUBARU OF AMERICA, INC.
Support the transmission with a garage jack.
NOTE: Before moving the engine away from transmission, check to be sure no work has been overlooked. Doing this is very important in order to facilitate re-installation and because transmission lowers under its own weight.

Fig 27: Supporting Transmission With Floor Jack
Courtesy of SUBARU OF AMERICA, INC.
Separation of the engine and transmission.
1. Remove the starter. Refer to REMOVAL , Starter.
2. Install special tool to torque converter clutch case. (AT model)
  ST 498277200 STOPPER SET
  
  Fig 28: Installing Special Tool To Torque Converter Clutch Case
  Courtesy of SUBARU OF AMERICA, INC.
3. Remove the bolts which hold the right upper side of transmission to engine.
  
  Fig 29: Removing Bolts Which Hold Right Upper Side Of Transmission To Engine
  Courtesy of SUBARU OF AMERICA, INC.
Remove the engine from vehicle.
1. Slightly raise the engine.
2. Raise the transmission with garage jack.
3. Move the engine horizontally until the mainshaft is withdrawn from clutch cover.
4. Slowly move the engine away from engine compartment.
NOTE: Be careful not to damage adjacent parts or body panels with crank pulley, oil pressure gauge, etc.
Remove the front cushion rubbers.