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Home >> Subaru >> 2016 >> Outback 2.5i >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical (H4DO) >> Engine Assembly >> Removal

Engine Assembly: Removal

  1. Fully open the front hood. < Ref. to FRONT HOOD DAMPER STAY , NOTE, Repair Contents. >
  2. Remove the V-belt covers.
    Fig 1: Locating V-Belt Covers Bolts
    G10262379Courtesy of SUBARU OF AMERICA, INC.
  3. Collect the refrigerant. < Ref. to REFRIGERANT RECOVERY PROCEDURE . >
  4. Release the fuel pressure. < Ref. to RELEASING OF FUEL PRESSURE , PROCEDURE, Fuel. >
  5. 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.
  6. Disconnect the ground terminal from battery sensor. < Ref. to BATTERY , NOTE, Repair Contents. >
  7. Remove the air intake duct. < Ref. to REMOVAL , Air Intake Duct. >
  8. Remove the air intake boot. < Ref. to REMOVAL , Air Intake Boot. >
  9. Remove the radiator. < Ref. to REMOVAL , Radiator. >
  10. Disconnect the connector (A) from the mass air flow and intake air temperature sensor, and remove the clip (B) securing the bulkhead wiring harness.
  11. Remove the clip (C), and the air cleaner case (rear) together with the air cleaner element.
    Fig 2: Identifying Air Cleaner Case (Rear) Clip And Connector
    G10262184Courtesy of SUBARU OF AMERICA, INC.
  12. Disconnect the connector (A), connector (B), connector (C) and terminal (D).
  13. Remove the clip (E) and clip (F) securing the generator cord.
    Fig 3: Identifying Generator Cord, Connector, Terminal And Clip
    G10262516Courtesy of SUBARU OF AMERICA, INC.
  14. Remove the bolt (A) securing the generator cord stay to the chain cover, and move the generator cord to the left side wheel apron.
  15. Remove the bolt (B) securing the A/C pressure hose to A/C compressor, and disconnect the A/C pressure hoses from A/C compressor. < Ref. to REMOVAL , Hose and Pipe. >
    Fig 4: Identifying A/C Pressure Hose And Bolt
    G10262517Courtesy of SUBARU OF AMERICA, INC.
  16. Disconnect the engine harness connector (A) from the main fuse box, and remove the engine harness from the claw (B) of the main fuse box.
  17. Remove the engine harness from the clip (C) and move the engine harness to the engine side.
    Fig 5: Removing Engine Harness From Clip
    G10262518Courtesy of SUBARU OF AMERICA, INC.
  18. Disconnect the brake booster vacuum hose (A), heater inlet hose (B) and heater outlet hose (C).
    Fig 6: Disconnecting Brake Booster Vacuum Hose
    G10262519Courtesy of SUBARU OF AMERICA, INC.
  19. While pressing the area (A) shown in the figure, move the lock lever (B) in the direction of the arrow to disconnect the engine harness connector from ECM.
    Fig 7: Moving Lock Lever
    G10262520Courtesy of SUBARU OF AMERICA, INC.
  20. Disconnect the engine coolant hose from the CVTF cooler (with warmer feature) and EGR cooler. (CVT model)
    Fig 8: Locating Engine Coolant Hose Clamp
    G10262521Courtesy of SUBARU OF AMERICA, INC.
  21. Lift up the vehicle.
  22. Remove the front exhaust pipe. < Ref. to REMOVAL , Front Exhaust Pipe. >
  23. Disconnect the ground cable on the engine side.
    Fig 9: Locating Ground Cable On Engine Side
    G10262522Courtesy of SUBARU OF AMERICA, INC.
  24. Remove the bolts and nuts which hold the lower side of transmission to the engine.
    • CVT model
      Fig 10: Locating Transmission Bolts And Nuts (CVT Model)
      G08316839Courtesy of SUBARU OF AMERICA, INC.
    • MT model
      Fig 11: Locating Engine Transmission Lower Side Nuts And Bolts (MT Model)
      G08316840Courtesy of SUBARU OF AMERICA, INC.
  25. Lower the vehicle.
  26. Remove the starter. < Ref. to REMOVAL , Starter. >
  27. Separate the torque converter clutch from the drive plate. (CVT model)
    1. Remove the service hole plug.
    2. Insert the wrench into the crank pulley bolt, and rotate the crank pulley to remove the four bolts securing the torque converter clutch to the drive plate.
      Fig 12: Locating Service Hole Plug
      G10262525Courtesy of SUBARU OF AMERICA, INC.
    3. Attach the ST to the torque converter clutch case.

      ST 498277200 STOPPER SET

      Fig 13: Attaching ST To Torque Converter Clutch Case
      G10262526Courtesy of SUBARU OF AMERICA, INC.
  28. 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. Remove the clip (A) securing the fuel delivery tube to the fuel pipe assembly.
    2. Attach ST to the fuel pipe assembly and push ST in the direction of arrow mark to disconnect the quick connector of the fuel delivery tube (B).

      ST 42099AE000 QUICK CONNECTOR RELEASE

    3. Disconnect the evaporation hose (C).
      Fig 14: Disconnecting Evaporation Hose From Fuel Pipe Assembly
      G10262126Courtesy of SUBARU OF AMERICA, INC.
  29. Using the ST1, install the ST2 to the engine unit.

    ST1 18363AA050 BOLT

    ST2 18360AA040 HANGER

    Tightening torque: 

    43 N.m (4.4 kgf-m, 31.7 ft-lb) 

    Fig 15: Installing ST2 To Engine Unit
    G10262528Courtesy of SUBARU OF AMERICA, INC.
  30. Support the engine with a lifting device and wire ropes.
    Fig 16: Supporting Engine Using Lifting Device And Wire Ropes
    G08316851Courtesy of SUBARU OF AMERICA, INC.
  31. Remove the bolt and nut securing the front mounting bracket to the cradle, and remove the front mounting bracket and front cushion rubber together from the engine mounting bracket.
    Fig 17: Locating Front Mounting Bracket Bolts And Nuts
    G10262530Courtesy of SUBARU OF AMERICA, INC.
  32. Remove the engine mounting bracket from the engine.
    Fig 18: Locating Engine Mounting Bracket Bolts
    G10262531Courtesy of SUBARU OF AMERICA, INC.
  33. Remove the bolt securing the upper side of the transmission to the engine, and separate the transmission and the engine.
    CAUTION: Before removing the engine away from transmission, check to be sure no work has been overlooked.
    • CVT model
      Fig 19: Locating Transmission Bolts (CVT Model)
      G08316854Courtesy of SUBARU OF AMERICA, INC.
    • MT model
      Fig 20: Locating Engine Transmission Upper Side Bolts (MT Model)
      G08316855Courtesy of SUBARU OF AMERICA, INC.
  34. Remove the engine from the vehicle.
    NOTE: Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc.
    1. Move the engine horizontally until engine is withdrawn from transmission. (CVT model)
    2. Move the engine horizontally until main shaft is withdrawn from clutch cover. (MT model)
    3. Slowly move the engine away from engine compartment.
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