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Home >> Subaru >> 2002 >> Forester Base >> Repair and Diagnosis >> Engine Mechanical >> Timing Belt >> Engine Mechanical 2.5L SOHC >> Engine Assembly >> Installation

Engine Assembly: Installation

  1. Install front cushion rubbers.

    Tightening torque:  34 N.m (3.5 kgf-m, 25.3 ft-lb)

  2. Install engine onto transmission.
    1. Position engine in engine compartment and align it with transmission.
      CAUTION: Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc.
      Fig 1: Installing Engine Into Engine Compartment
      G02862196Courtesy of SUBARU OF AMERICA, INC.
    2. Apply a small amount of grease to spline of main shaft. (MT model)
  3. Tighten bolts which hold upper side of transmission to engine.

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

    Fig 2: Tightening Bolts
    G02862197Courtesy of SUBARU OF AMERICA, INC.
  4. Remove lifting device and wire ropes.
    Fig 3: Removing Lifting Device And Wire Ropes
    G02862198Courtesy of SUBARU OF AMERICA, INC.
  5. Remove garage jack.
  6. Install pitching stopper.

    Tightening torque: 

    1. T1;  50 N.m (5.1 kgf-m, 36.9 ft-lb)
    2. T2;  58 N.m (5.9 kgf-m, 43 ft-lb)
    Fig 4: Installing Pitching Stopper
    G02862199Courtesy of SUBARU OF AMERICA, INC.
  7. Remove ST from torque converter clutch case. (AT model)
    NOTE: Be careful not to drop the ST into the torque converter clutch case when removing ST.

    ST 498277200:  STOPPER SET

  8. Install starter. Refer to INSTALLATION under STARTER .
  9. Install torque converter clutch onto drive plate. (AT model)
    1. Tighten bolts which hold torque converter clutch to drive plate.
    2. Tighten other bolts while rotating the engine by using ST.
      CAUTION: Be careful not to drop bolts into torque converter clutch housing.

      ST 499977100:  CRANK PULLEY WRENCH

      Tightening torque:  25 N.m (2.5 kgf-m, 18.1 ft-lb)

      Fig 5: Tightening Bolts Which Hold Torque Converter Clutch To Drive Plate
      G02862200Courtesy of SUBARU OF AMERICA, INC.
    3. Clog plug onto service hole.
  10. Install power steering pump on bracket.
    1. Install power steering pump on bracket, and tighten bolts.

      Tightening torque:  20.1 N.m (2.05 kgf-m, 14.8 ft-lb)

      Fig 6: Installing Power Steering Pump
      G02862201Courtesy of SUBARU OF AMERICA, INC.
    2. Tighten bolt which installs power steering pump bracket, and install spark plug cords.
      Fig 7: Installing Power Steering Pump Bracket Bolts
      G02862202Courtesy of SUBARU OF AMERICA, INC.
    3. Connect power steering switch connector.
      Fig 8: Connecting Power Steering Switch Connector
      G02862203Courtesy of SUBARU OF AMERICA, INC.
    4. Install front side V-belt, and adjust it. Refer to INSTALLATION under FRONT SIDE BELT under V-BELT 
    5. Install resonator chamber.

    Tightening torque:  33 N.m (3.4 kgf-m, 24.6 ft-lb)

    Fig 9: Installing Resonator Chamber
    G02862204Courtesy of SUBARU OF AMERICA, INC.
  11. Tighten nuts which hold lower side of transmission to engine.

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

    Fig 10: Tightening Transmission Nuts
    G02862205Courtesy of SUBARU OF AMERICA, INC.
  12. Tighten nuts which install front cushion rubber onto crossmember.

    Tightening torque:  85 N.m (8.7 kgf-m, 63 ft-lb)

    CAUTION: Make sure the front cushion rubber mounting bolts (A) and locator (B) are securely installed.
    Fig 11: Installing Front Cushion Rubber Onto Crossmember
    G02862206Courtesy of SUBARU OF AMERICA, INC.
  13. Install front and center exhaust pipe. Refer to INSTALLATION under FRONT EXHAUST PIPE .
  14. Connect the following hoses.
    1. Fuel delivery hose, return hose and evaporation hose
    2. Heater inlet and outlet hoses
    3. Brake booster vacuum hose
  15. Connect the following connectors.
    1. Engine ground terminals

      Tightening torque:  14 N.m (1.4 kgf-m, 10.1 ft-lb)

    2. Engine harness connectors
    3. Generator connector and terminal
    4. A/C compressor connectors
  16. Connect the following cables.
    1. Accelerator cable
    2. Cruise control cables (With cruise control)
    CAUTION: After connecting each cable, adjust them.
  17. Install air cleaner case stay.

    Tightening torque:  16 N.m (1.6 kgf-m, 11.6 ft-lb)

  18. Install A/C pressure hoses. Refer to INSTALLATION under FLEXIBLE HOSE .
    CAUTION: Use new O-rings.

    Tightening torque:  25 N.m (2.5 kgf-m, 18.1 ft-lb)

    Fig 12: Installing A/C Pressure Hoses
    G02862207Courtesy of SUBARU OF AMERICA, INC.
  19. Install radiator to vehicle. Refer to INSTALLATION under RADIATOR .
  20. Install ATF cooler pipe to cylinder head. Refer to INSTALLATION under ATF COOLER PIPE AND HOSE .
  21. Install under cover.
  22. Install battery in the vehicle, and connect cables.
  23. Fill coolant. Refer to FILLING OF ENGINE COOLANT .
  24. Check ATF level and correct if necessary (AT model). Refer to INSPECTION under AUTOMATIC TRANSMISSION FLUID .
  25. Charge A/C system with refrigerant. Refer to OPERATION under REFRIGERANT CHARGING PROCEDURE, .
  26. Install air intake duct and air cleaner case. Refer to INSTALLATION under AIR INTAKE DUCT and AIR CLEANER CASE .
  27. Remove front hood stay, and close front hood.
  28. Take off the vehicle from lift arms.
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