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Engine Assembly: Installation

WARNING: This page is about a different car, the 2005 Subaru Baja. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install front cushion rubbers.

    Tightening torque:  35 N.m (3.6 kgf-m, 26.0 ft-lb)

  2. Install engine onto transmission.
    1. Position engine in engine room 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 Onto Transmission
      G03748371Courtesy 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: Locating Bolts Holding Transmission Upper Side To Engine
    G03748372Courtesy of SUBARU OF AMERICA, INC.
  4. Remove lifting device and wire ropes.
    Fig 3: Removing Lifting Device & Wire Ropes
    G03748373Courtesy of SUBARU OF AMERICA, INC.
  5. Remove garage jack.
  6. Install pitching stopper.

    Tightening torque: 

    T1:  50 N.m (5.1 kgf-m, 36.9 ft-lb)

    T2:  58 N.m (5.9 kgf-m, 43 ft-lb)

    Fig 4: Tightening Pitching Stopper Bolt
    G03748374Courtesy 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 , 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 crankshaft pulley 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: Installing Torque Converter Clutch Onto Drive Plate
      G03748375Courtesy of SUBARU OF AMERICA, INC.
    3. Clog plug onto service hole.
  10. Install power steering pump on bracket.
    1. Install power steering tank on bracket.
      Fig 6: Installing Power Steering Fluid Tank On Bracket
      G03748376Courtesy of SUBARU OF AMERICA, INC.
    2. Install power steering pump on bracket, and tighten bolts.

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

      Fig 7: Tightening Power Steering Pump Bolts
      G03748377Courtesy of SUBARU OF AMERICA, INC.
    3. Tighten bolt which installs power steering pump bracket, and install spark plug codes.
      Fig 8: Tightening Bolts Holding Power Steering Pump Bracket
      G03748378Courtesy of SUBARU OF AMERICA, INC.
    4. Connect power steering switch connector.
      Fig 9: Connecting Power Steering Switch Connector
      G03748379Courtesy of SUBARU OF AMERICA, INC.
    5. Front side V-belt

      Install and adjust it. Refer to V-BELT .

    6. Install resonator chamber.

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

      Fig 10: Installing Resonator Chamber
      G03748380Courtesy 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 11: Tightening Nuts Holding Transmission Lower Side To Engine
    G03748381Courtesy of SUBARU OF AMERICA, INC.
  12. Tighten nuts which install front cushion rubber onto crossmember.

    Tightening torque:  75 N.m (7.7 kgf-m, 55.4 ft-lb)

    CAUTION: Make sure the front cushion rubber mounting bolts (A) and locator (B) are securely installed.
    Fig 12: Locating Nuts Holding Front Cushion Rubber Onto Crossmember
    G03748382Courtesy of SUBARU OF AMERICA, INC.
  13. Install front and center exhaust pipe.

    Refer to INSTALLATION , Front Exhaust Pipe, also see INSTALLATION , Center Exhaust Pipe.

  14. Connect the following hoses.
    1. Fuel delivery hose, return hose and evaporation hose. Refer to INSTALLATION , Fuel Delivery, Return and Evaporation Lines.
    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. Alternator connector and terminal
    4. A/C compressor connectors
    5. Power steering pressure switch
  16. Connect the following cables.
    1. Accelerator cable
    2. Cruise control cables (With cruise control)
  17. After connecting each cable, adjust them.
  18. Install air cleaner case stay.

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

  19. Install A/C pressure hoses.

    Refer to INSTALLATION , Flexible Hose.

  20. Install radiator to vehicle. Refer to INSTALLATION , Radiator.
  21. Install ATF cooler pipe to body. Refer to INSTALLATION , ATF Cooler Pipe and Hose.
  22. Install air intake duct and cleaner case.

    Refer to INSTALLATION , Air Intake Duct, also see INSTALLATION , Air Cleaner Case.

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

    Refer to FILLING OF ENGINE COOLANT , REPLACEMENT, Engine Coolant.

  26. Check ATF level and correct if necessary (AT model).

    Refer to AUTOMATIC TRANSMISSION FLUID .

  27. Charge A/C system with refrigerant.

    Refer to REFRIGERANT CHARGING PROCEDURE , Refrigerant Charging Procedure.

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