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Engine Assembly: Installation

WARNING: This page is about a different car, the 2003 Subaru Forester. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the front cushion rubbers.

    Tightening torque: 

    1. 34 N.m (3.5 kgf-m, 25.3 ft-lb) 
  2. Install the engine onto transmission.
    1. Position the engine in engine compartment and align it with transmission.
      NOTE: Be careful not to damage the adjacent parts or body panels with crank pulley, oil level gauge, etc.
      Fig 1: Installing Engine In Engine Compartment
      G02945550Courtesy of SUBARU OF AMERICA, INC.
    2. Apply a small amount of grease to the spline of main shaft. (MT vehicles)
  3. Tighten the bolts which hold upper side of transmission to engine.

    Tightening torque: 

    1. 50 N.m (5.1 kgf-m, 36.9 ft-lb) 
    Fig 2: Tightening Bolts
    G02945551Courtesy of SUBARU OF AMERICA, INC.
  4. Remove the lifting device and wire ropes.
    Fig 3: Removing Lifting Device & Wire Ropes
    G02945552Courtesy of SUBARU OF AMERICA, INC.
  5. Remove the garage jack.
  6. Install the pitching stopper.

    Tightening torque: 

    1. T1: 50 N.m (5.1 kgf-m, 37 ft-lb) 
    2. T2: 58 N.m (5.9 kgf-m, 43 ft-lb) 
    Fig 4: Installing Pitching Stopper
    G02945553Courtesy of SUBARU OF AMERICA, INC.
  7. Remove the ST from torque converter clutch case. (AT vehicles)
    NOTE: Be careful not to drop the ST into torque converter clutch case when removing ST.

    ST 498277200 STOPPER SET

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

      ST 499977100 CRANK PULLEY WRENCH

      Tightening torque: 

      1. 25 N.m (2.5 kgf-m, 18.1 ft-lb) 
      Fig 5: Tightening Bolts While Rotating Engine By Using SST
      G02945554Courtesy of SUBARU OF AMERICA, INC.
    3. Clog the plug onto service hole.
  10. Install the power steering pump on bracket.
    1. Install the power steering tank on bracket.
      Fig 6: Installing Power Steering Tank
      G02945555Courtesy of SUBARU OF AMERICA, INC.
    2. Install the power steering pump on bracket, and then tighten the bolts.

      Tightening torque: 

      1. 20.1 N.m (2.05 kgf-m, 14.8 ft-lb) 
      Fig 7: Tightening Bracket Bolts
      G02945556Courtesy of SUBARU OF AMERICA, INC.
    3. Tighten the bolts which install power steering pump bracket, and then install the spark plug cords.
      Fig 8: Installing Spark Plug Cords
      G02945557Courtesy of SUBARU OF AMERICA, INC.
    4. Connect the power steering switch connector.
      Fig 9: Connecting Power Steering Switch Connector
      G02945558Courtesy of SUBARU OF AMERICA, INC.
    5. Install the front side V-belt, and adjust it.

      Refer to INSTALLATION , V-belt.

    6. Install the resonator chamber.

    Tightening torque: 

    1. 33 N.m (3.4 kgf-m, 24.6 ft-lb) 
    Fig 10: Installing Resonator Chambers
    G02945559Courtesy of SUBARU OF AMERICA, INC.
  11. Tighten the nuts which hold lower side of transmission to engine.

    Tightening torque: 

    1. 50 N.m (5.1 kgf-m, 36.9 ft-lb) 
    Fig 11: Tightening Nuts From Transmission To Engine
    G02945560Courtesy of SUBARU OF AMERICA, INC.
  12. Tighten the nuts which install front cushion rubber onto crossmember.

    Tightening torque: 

    1. 85 N.m (8.7 kgf-m, 63 ft-lb) 
    NOTE: Make sure the front cushion rubber mounting bolts (A) and locator (B) are securely installed.
    Fig 12: Adjusting Front Cushion Rubber Mounting Bolts
    G02945561Courtesy of SUBARU OF AMERICA, INC.
  13. Install the front and center exhaust pipe.

    Refer to INSTALLATION , 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 cables

      Tightening torque: 

      1. 14 N.m (1.4 kgf-m, 10.1 ft-lb) 
      2. Engine harness connectors
    2. Generator connector and terminal
    3. A/C compressor connectors
    4. Power steering pressure switch
  16. Connect the following cables.
    1. Accelerator cable
    2. Cruise control cable (With cruise control)
  17. Adjust each connected cable.
  18. Install the air cleaner case stay.

    Tightening torque: 

    1. 16 N.m (1.6 kgf-m, 11.6 ft-lb) 
  19. Install the A/C pressure hoses.

    Refer to REMOVAL , Hose and Tube.

    NOTE: Use new O-rings.

    Tightening torque: 

    1. 25 N.m (2.5 kgf-m, 18.1 ft-lb) 
    Fig 13: Installing A/C Pressure Hose
    G02945562Courtesy of SUBARU OF AMERICA, INC.
  20. Install the radiator to vehicle. Refer to INSTALLATION , Radiator.
  21. Install the air intake duct and air cleaner case.

    Refer to INSTALLATION , Air Intake Duct and INSTALLATION , Air Cleaner Case.

  22. Install the under cover.
  23. Install battery in the vehicle, and then connect the cables.
  24. Fill engine coolant.

    Refer to REPLACEMENT , Engine Coolant.

  25. Check the ATF level and correct if necessary. (AT vehicles)

    Refer to INSPECTION , Automatic Transmission Fluid.

  26. Charge the A/C system with refrigerant.

    Refer to OPERATION , Refrigerant Charging Procedure.

  27. Remove the front hood stay, and then close the front hood.
  28. Take off the vehicle from lift arms.
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