Partial engine ASSY (FA20)
Components Removal / installation
ENGINE MECHANICAL
PARTIAL ENGINE ASSY (FA20)
EXPLODED VIEW
REMOVAL
1. Hood SUB-ASSY set
(1) Change the hood stay position from A to B in order to support the hood SUB-ASSY at the position B.
2. Removal of refrigerant (with air conditioning) (Refer to 
)
)3. Fuel spill prevention procedure (Refer to )
)4. Disconnection of the battery ground terminal (Refer to )
)5. Front strut tower bar RH removal (Refer to )
)6. Front strut tower bar LH removal (Refer to )
)
7. Air cleaner case SUB-ASSY removal
(1) Disconnect the hose from the chamber ASSY.
(2) Remove the two bolts and remove the chamber ASSY.
(3) Move the hose clip and disconnect the ventilation hose NO. 2.
(4) Release the clamp and disconnect the wiring harness from the air cleaner cap.
(5) Disconnect the connector from the intake air flow meter SUB-ASSY.
(6) Loosen the hose clamp.
(7) Remove the three bolts and remove the air cleaner case SUB-ASSY.
(8) Remove the bolt and remove the stay.
8. Engine oil draining
(1) Remove the oil filler cap SUB-ASSY.
(2) Remove the oil pan drain plug and gasket.
(3) After draining the oil, install the oil pan drain plug with a new gasket.
Standard value:
Standard value:
Tightening torque=42N·m
{
428kgf·cm}
{31.0ft·lbf}
9. Draining of coolant (SUBARU Super Coolant) (Refer to )
)10. Removal of radiator reservoir tank ASSY (Refer to )
)
11. Removal of water filler SUB-ASSY
(1) Remove the two bolts and remove the water filler SUB-ASSY.
(2) Move the two hose clamps and remove the radiator hose NO. 1 and water filler SUB-ASSY as a unit.
12. Removal of injector driver (Refer to )
)13. DISCONNECT ENGINE WIRE (for LHD)
NOTE:
Fix the disconnected harness components with tape to keep them out of the way.
(1) Remove the bolts and wire harness clamp bracket from the No. 2 engine hanger.
(2) Release the lock of connector (A) and disconnect the connector.
(3) Disconnect the connector (B).
(4) Disconnect the connector.
(5) Disconnect the wire harness clamp and wire harness from the No. 2 engine hanger.
(6) Disconnect the 3 wire harness clamps.
(7) for Automatic Transmission:
(a) Release the lock of connector (A) and disconnect the connector.
(b) Disconnect the connector (B).
(c) Slide the connector in the direction shown in the illustration, and disconnect the wire harness.
(d) Disconnect the 3 wire harness clamps.
(e) Remove the bolt and wire harness clamp bracket.
(8) Disconnect the terminal cap.
(9) Remove the nut and disconnect the wire harness from terminal B.
(10) Disconnect the generator connector and disengage the clamp.
14. Engine wiring harness disconnection (for RHD)
NOTE:
Secure the disconnected harness etc. with tape.
(1) Transmission A/T:
(a) Release the lock of connector A to disconnect the connector.
(b) Disconnect the connector B.
(c) Release the two clamps and disconnect the wiring harness.
(d) Slide the connector in the direction as shown in the figure and disconnect the wiring harness.
(2) Remove the bolt and disconnect the wiring harness clamp bracket.
(3) Release the lock of connector A to disconnect the connector.
(4) Disconnect the connector B.
(5) Release the clamp and disconnect the wiring harness.
(6) Release the two clamps and remove the two bolts to remove the two wiring harness clamp brackets.
(7) Release the five clamps and disconnect the wiring harness.
(8) Turn over the terminal cap.
(9) Remove the nut and disconnect the wiring harness from the terminal B.
(10) Remove the connector and clamp to disconnect the wiring harness.
15. Generator cover removal (Refer to )
)16. Belt generator cover removal (Refer to )
)17. Fan & generator V-belt removal (Refer to )
)18. Removal of engine cover SUB-ASSY NO.1 (with air conditioning) (Refer to )
)
19. Removal of flywheel housing under cover (transmission A/T)
(1) Remove the flywheel housing under cover.
20. Removal of drive plate and torque converter setting bolt
21. Vacuum tube connector hose disconnection (transmission A/T)
(1) Move the clamp and disconnect the vacuum tube connector hose from the vacuum pump ASSY.
(2) Remove the 2 bolts and disconnect the vacuum tube connector hose.
(3) Loosen the hose clamp and remove the vacuum tube connector hose.
22. Vacuum tube connector hose disconnection (transmission M/T)
(1) Move the hose clamp and disconnect the vacuum tube connector hose from the intake manifold ASSY.
(2) Remove the bolt and disconnect the vacuum tube connector hose.
23. Removal of exhaust manifold
(Refer to )
)
24. Exhaust pipe SUB-ASSY FR fixation (transmission M/T)
(1) Tie the exhaust pipe SUB-ASSY FR to the front suspension crossmember SUB-ASSY with the rope.
NOTE:
This operation is required to avoid dropping the exhaust pipe SUB-ASSY FR.
25. Heater water hose disconnection
(1) Move the two hose clamps and disconnect the two heater water hoses.
26. Transmission oil cooler hose NO. 1 disconnection (transmission A/T)
(1) Move the hose clamp and disconnect the transmission oil cooler hose NO. 1.
27. REMOVE SUCTION HOSE SUB-ASSEMBLY (w/ Air Conditioning System)
(1) Remove the bolt and disconnect the suction hose sub-assembly from the compressor assembly with pulley.
(2) Remove the O-ring from the discharge hose sub-assembly.
CAUTION:
Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.
(3) for LHD:
(a) Remove the bolt and slide the hook connector.
(b) Remove the nut and suction pipe sub-assembly.
(c) Remove the O-ring from the suction pipe sub-assembly.
CAUTION:
Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.
(4) for RHD:
(a) Remove the bolt and slide the hook connector.
(b) Disconnect the suction pipe sub-assembly.
(c) Remove the O-ring from the suction pipe sub-assembly.
CAUTION:
Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.
28. Cooler refrigerant discharge hose NO. 1 disconnection (Refer to )
)29. Removal of starter ASSY
(Refer to )
)
30. SST installation (transmission A/T)
(1) Attach the SST to the starter hole of torque converter clutch case.
SST
18750AA010
31. Transmission oil cooler hose NO. 3 disconnection (transmission A/T)
(1) Move the hose clamp and disconnect the transmission oil cooler hose NO. 3.
32. Radiator outlet hose disconnection
(1) Move the hose clamp and disconnect the radiator outlet hose.
33. Ground cable disconnection
(1) Remove the two bolts and remove the two ground cables.
34. REMOVE REAR ENGINE UNDER COVER LH (w/ Floor Under Cover)
(1) Remove the 3 bolts and 8 clips, then remove the rear engine under cover LH.
35. Exhaust pipe SUB-ASSY FR fixation (transmission A/T)
(1) Tie the exhaust pipe SUB-ASSY FR to the front suspension crossmember SUB-ASSY with the rope.
NOTE:
This operation is required to avoid dropping the exhaust pipe SUB-ASSY FR.
36. Stabilizer bar FR removal (transmission A/T)
(Refer to )
)
37. Automatic transmission ASSY disconnection (transmission A/T)
38. Manual transmission ASSY removal (transmission M/T)
39. Disconnection of front crossmember SUB-ASSY
(1) Remove the two nuts of front crossmember SUB-ASSY.
40. Removal of flywheel housing under cover (Refer to )
)41. Removal of drive plate and torque converter setting bolt (transmission A/T) (Refer to )
)
42. Fuel hose and purge hose disconnection
43. Engine hanger installation
44. Transmission ASSY support (transmission A/T)
45. Transmission ASSY support (transmission M/T)
(1) Support the clutch housing portion of transmission ASSY.
CAUTION:
Support the transmission ASSY until the installation of partial engine ASSY is completed.
46. Engine ASSY removal
47. Drive plate & ring gear SUB-ASSY removal (transmission A/T) (Refer to )
)48. Clutch cover ASSY removal (transmission M/T) (Refer to )
)49. Clutch disc ASSY removal (transmission M/T) (Refer to )
)50. Flywheel SUB-ASSY removal (transmission M/T) (Refer to )
)51. Crank angle sensor plate NO. 1 removal (Refer to )
)52. Engine stand installation
(1) Install the engine ASSY to the engine stand.
CAUTION:
Since the operation with the engine ASSY suspended are danger, never perform it other than when installing the ASSY to the engine stand or removing it from the stand.
53. Engine mounting insulator FR removal
(1) Remove the four bolts and remove the two engine mounting insulators FR.
54. Engine hanger removal
(1) Remove the bolt and remove the engine hanger.
55. Generator ASSY removal
(1) Remove the two bolts and remove the generator ASSY.
56. Idler pulley SUB-ASSY NO. 2 removal (Refer to )
)57. Oil level gauge guide removal (Refer to )
)58. V-ribbed belt tensioner ASSY removal (Refer to )
)
59. Removal of compressor ASSY (with magnet clutch) (when there is air conditioning)
(1) Remove the 3 bolts and remove the compressor ASSY (with magnet clutch).
60. Idler pulley bracket removal (when there is no air conditioning)
(1) Remove the 3 bolts and remove the idler pulley bracket.
61. Intake manifold protector (bank 2 side) removal
(1) Remove the 2 bolts and remove the intake manifold protector (bank 2 side).
62. Intake manifold protector (bank 1 side) removal
(1) Remove the 2 bolts and remove the intake manifold protector (bank 1 side).
63. Fuel delivery pipe SUB-ASSY removal
(1) Remove the bolt and disconnect the fuel delivery pipe SUB-ASSY.
(2) Disconnect the vacuum hose SUB-ASSY.
(3) Remove the union bolt and gasket to disconnect the fuel delivery pipe SUB-ASSY.
64. Disconnection of ventilation hose (Refer to )
)
65. Intake manifold removal
(1) Move the two hose clamps and disconnect the water by-pass hoses NO. 2 and NO. 3 from the throttle body ASSY.
(2) Disconnect the connector for air pressure sensor ASSY.
(3) Disconnect the connector for the purge control solenoid valve.
(4) Release the two clamps and disconnect the four connectors to disconnect the wiring harness.
Captions in illustration
| *a |
Bank 2 side |
| *b |
Bank 1 side |
(5) Disconnect the connectors of fuel pump ASSY.
66. Fuel delivery pipe NO.2 removal (Refer to )
)67. Fuel delivery pipe removal (Refer to )
)68. Fuel delivery pipe (bank 2 side) removal (Refer to )
)69. Removal of fuel delivery pipe (bank 1 side) (Refer to )
)70. Fuel injector ASSY removal (Refer to )
)71. Fuel injector seal removal (Refer to )
)
72. Fuel pump ASSY removal
(1) Remove the two bolts with a TORX PLUS socket wrench 40IP to remove the fuel pump ASSY.
73. Valve lifter removal (Refer to )
)74. Pump drive case ASSY removal (Refer to )
)
75. Engine wiring removal
(1) Remove the two bolts and disconnect the engine wiring.
(2) Disconnect each connector and clamp to remove the engine wiring.
76. Ventilation hose NO. 2 removal
(1) Move the hose clamp and remove the ventilation hose NO. 2.
77. PCV hose connector removal
(1) Remove the three bolts and remove the PCV hose connector.
(2) Move the hose clamp and disconnect the water by-pass hose NO. 1 from the water inlet pipe.
(3) Move the hose clamp and remove the water by-pass hose NO. 1 from the PCV hose connector.
(4) Remove the two O-rings from the PCV hose connector.
78. Water by-pass hose NO. 2 removal
(1) Move the hose clamp and remove the water by-pass hose NO. 2.
79. Transmission oil cooler hose NO. 3 removal (transmission A/T)
(1) Move the hose clamp and remove the transmission oil cooler hose NO. 3.
80. Water inlet pipe removal
(1) Move the hose clamp and remove the water by-pass hose NO. 3.
(2) Remove the four bolts and remove the water inlet pipe.
(3) Remove the two O-rings from the cylinder block (bank 1 side and bank 2 side).
81. Water by-pass pipe NO. 1 removal (transmission M/T)
(1) Move the hose clamp and disconnect the water by-pass hose NO. 4.
(2) Remove the two bolts and remove the water by-pass pipe NO. 1.
82. Water by-pass pipe NO. 1 removal (transmission A/T)
(1) Move the two hose clamps and disconnect the two water by-pass hoses.
(2) Remove the two bolts and remove the water by-pass pipe NO. 1.
83. Vacuum pump ASSY removal (transmission A/T) (Refer to )
)
84. Cylinder head plate RR removal (transmission M/T)
(1) Remove the three bolts and remove the cylinder head plate RR from the camshaft housing SUB-ASSY RH.
85. Removal of knock control sensor
(1) Remove the two bolts and remove the two knock control sensors.
86. Removal of crankshaft position sensor
(1) Remove the bolt and remove the crank position sensor.
87. PCV valve removal (Refer to )
)88. Idler pulley SUB-ASSY NO. 1 removal (Refer to )
)89. Water pump pulley removal (Refer to )
)90. Engine water pump ASSY removal (Refer to )
)91. Water outlet removal (Refer to )
)92. Thermostat removal (Refer to )
)93. Crankshaft pulley removal (Refer to )
)94. Timing chain cover oil seal removal (Refer to )
)95. Timing chain cover SUB-ASSY removal (Refer to )
)96. Chain SUB-ASSY removal (bank 1 side) (Refer to )
)97. Removal of chain SUB-ASSY (bank 2 side) (Refer to )
)98. Piston and valve damage prevention procedure (Refer to )
)
99. Crankshaft timing sprocket removal
(1) Remove the crankshaft timing sprocket.
100. Removal of ignition coil ASSY (bank 2 side)
(1) Remove 2 bolts, and remove 2 ignition coil ASSYs.
101. Removal of ignition coil ASSY (bank 1 side)
(1) Remove 2 bolts, and remove 2 ignition coil ASSYs.
102. Injector driver bracket removal
(1) Remove the two bolts and remove the injector driver bracket.
103. Cylinder head cover SUB-ASSY removal
(1) Operate the engine stand, and make the bank 1 side face upward.
(2) Remove the 8 bolts.
(3) Remove the cylinder head cover SUB-ASSY using a flat tip screwdriver wrapped with protective tape.
CAUTION:
Do not damage the camshaft housing SUB-ASSY, cam cap and cylinder head cover SUB-ASSY.
(4) Remove the cylinder head cover gasket.
(5) Remove the two spark plug tube gaskets.
CAUTION:
When removing the seal gasket using scraper etc., be careful not to damage the cam lobe of camshaft.
104. Camshaft housing SUB-ASSY RH removal
CAUTION:
Do not remove the intake and exhaust camshafts before removing the camshaft housing SUB-ASSY. Doing so will result in distortion of camshaft housing SUB-ASSY.
(1) Loosen the nine bolts equally in the order as shown in the figure and remove them.
(2) Remove the camshaft housing SUB-ASSY RH using a flat tip screwdriver wrapped with protective tape.
CAUTION:
Do not damage the cylinder head and camshaft housing SUB-ASSY.
(3) Remove the two O-rings and eight valve rocker arm SUB-ASSYs NO. 1 from the cylinder head SUB-ASSY.
NOTE:
The removed parts must be organized by installation location.
(4) Remove the eight valve adjusting shims and eight roller rocker arm pivot from the cylinder head SUB-ASSY.
NOTE:
The removed parts must be organized by installation location.
105. Cylinder head SUB-ASSY removal (Refer to )
)106. Cylinder head gasket removal (Refer to )
)107. Cylinder head cover SUB-ASSY LH removal
(1) Operate the engine stand, and make the bank 2 side face upward.
(2) Remove the 8 bolts.
(3) Remove the cylinder head cover SUB-ASSY LH using a flat tip screwdriver wrapped with protective tape.
CAUTION:
Do not damage the camshaft housing SUB-ASSY, cam cap and cylinder head cover SUB-ASSY.
(4) Remove the cylinder head cover gasket NO. 2.
(5) Remove the two spark plug tube gaskets.
CAUTION:
When removing the seal gasket using scraper etc., be careful not to damage the cam lobe of camshaft.
108. Camshaft housing SUB-ASSY LH removal
CAUTION:
Do not remove the intake and exhaust camshafts before removing the camshaft housing SUB-ASSY. Doing so will result in distortion of camshaft housing SUB-ASSY.
(1) Loosen the nine bolts equally in the order as shown in the figure and remove them.
(2) Remove the camshaft housing SUB-ASSY using a flat tip screwdriver wrapped with protective tape.
CAUTION:
Do not damage the cylinder head and camshaft housing SUB-ASSY.
(3) Remove the two O-rings and eight valve rocker arm SUB-ASSYs NO. 1 from the cylinder head LH.
NOTE:
The removed parts must be organized by installation location.
(4) Remove the eight valve adjusting shims and eight roller rocker arm pivot from the cylinder head LH.
NOTE:
The removed parts must be organized by installation location.
109. Cylinder head LH removal (Refer to )
)110. Cylinder head gasket NO. 2 removal (Refer to )
)
111. Engine hanger NO. 2 removal
(1) Remove the two bolts and remove the engine hanger NO. 2 from the cylinder block (bank 1 side).
112. Oil pan SUB-ASSY NO. 2 removal
(1) Remove the 11 bolts.
(2) Remove the oil pan SUB-ASSY NO. 2 with a oil pan seal cutter.
CAUTION:
Do not damage the installation surface of oil pan SUB-ASSY and the flange portion of oil pan SUB-ASSY NO. 2.
(3) Remove the two seal rings from the oil pan SUB-ASSY NO. 2.
113. Oil strainer SUB-ASSY removal
(1) Remove the two bolts and remove the oil strainer SUB-ASSY.
(2) Remove the O-ring.
114. Oil pan SUB-ASSY removal
(1) Remove the 13 bolts.
(2) Remove the oil pan SUB-ASSY using a flat tip screwdriver wrapped with protective tape.
CAUTION:
Do not damage the installation surfaces of cylinder block and oil pan SUB-ASSY.
(3) Remove the three O-rings from the cylinder block.
INSTALLATION
1. Oil pan SUB-ASSY installation
(1) Apply THREE BOND 1217G or equivalent to the mating surface of oil pan SUB-ASSY as shown in the figure.
Captions in illustration
| *a |
THREE BOND 1217G or equivalent |
| *b |
Diameter: 4.0 to 6.0 mm {0.158 to 0.236 in} |
| *c |
Groove end |
CAUTION:
·Clean and degrease the installation surface.
·Install within 5 min. after applying liquid gasket.
·Apply liquid gasket 1.5 mm {0.0591 in} outside from the groove on the oil pan SUB-ASSY. However, application of liquid gasket on the groove around the bolt hole is allowed.
·Install within 5 min. after applying liquid gasket.
·Apply liquid gasket 1.5 mm {0.0591 in} outside from the groove on the oil pan SUB-ASSY. However, application of liquid gasket on the groove around the bolt hole is allowed.
(2) Install three new O-rings to the cylinder block.
(3) Tighten the 13 bolts (A and B) in the order as shown in the figure to install the oil pan SUB-ASSY to the cylinder block.
Standard value:
Standard value:
Tightening torque=18N·m
{
184kgf·cm}
Captions in illustration
 |
Bolt A |
 |
Bolt B |
| Bolt type |
Bolt length (except for head) |
| Bolt A |
25 mm {0.984 in} |
| Bolt B |
75 mm {2.953 in} |
NOTE:
After tightening, if the liquid gasket is squeezed out onto the seal surface of timing chain cover SUB-ASSY, completely remove any squeezed-out liquid gasket.
2. Oil strainer SUB-ASSY installation
(1) Install a new O-ring.
(2) Install the oil strainer SUB-ASSY to the oil pan SUB-ASSY with the two bolts.
Standard value:
Standard value:
Tightening torque=6.4N·m
{
65kgf·cm}
{4.7ft·lbf}
3. Oil pan SUB-ASSY NO. 2 installation
(1) Install two new oil pan seal rings to the oil pan SUB-ASSY NO. 2.
(2) Apply THREE BOND 1217G or equivalent to the mating surface of oil pan SUB-ASSY for the oil pan SUB-ASSY NO. 2 as shown in the figure.
Captions in illustration
| *a |
THREE BOND 1217G or equivalent |
| *b |
Diameter: 4.0 to 6.0 mm {0.158 to 0.236 in} |
CAUTION:
·Clean and degrease the installation surface.
·Install within 5 min. after applying liquid gasket.
·Install within 5 min. after applying liquid gasket.
(3) Tighten the 11 bolts in the order as shown in the figure to install the oil pan SUB-ASSY NO. 2.
Standard value:
Standard value:
Tightening torque=6.4N·m
{
65kgf·cm}
{4.7ft·lbf}
4. Engine hanger NO. 2 installation
(1) Install the engine hanger NO. 2 to the cylinder block (bank 1 side) with the two bolts.
Standard value:
Standard value:
Tightening torque=21N·m
{
214kgf·cm}
{15.5ft·lbf}
5. Cylinder head gasket NO. 2 installation (Refer to )
)6. Cylinder head LH installation (Refer to )
)7. Camshaft housing SUB-ASSY LH installation
(1) Apply engine oil to the valve adjusting shim and roller rocker arm pivot, and install them to the cylinder head LH.
(2) Apply engine oil to the eight valve rocker arm SUB-ASSYs NO. 1 and two new O-rings, and install them to the cylinder head LH.
(3) Apply THREE BOND 1217G or equivalent to the mating surface of camshaft housing SUB-ASSY LH as shown in the figure.
Captions in illustration
| *a |
Groove end |
*b |
Area of B-B |
| *c |
1.0 mm {0.0394 in} or less |
*d |
Diameter: 2.5 to 3.5 mm {0.098 to 0.138 in} |
| *e |
-0.5 to 0.5 mm {-0.0197 to 0.0197 in} |
- |
- |
CAUTION:
·Clean and degrease the installation surface.
·Do not apply liquid gasket excessively.
·Install within 5 min. after applying liquid gasket.
·Completely remove any liquid gasket that is squeezed out on the installation surface of timing chain cover SUB-ASSY.
·Do not apply liquid gasket excessively.
·Install within 5 min. after applying liquid gasket.
·Completely remove any liquid gasket that is squeezed out on the installation surface of timing chain cover SUB-ASSY.
(4) Tighten the 9 bolts in the order as shown in the figure to install the camshaft housing SUB-ASSY LH.
Standard value:
Standard value:
Tightening torque=18N·m
{
184kgf·cm}
{13.3ft·lbf}
NOTE:
Set the intake camshaft LH and exhaust camshaft LH to the zero-lift position.
(5) Loosen the three bolts by 180° in the order as shown in the figure.
(6) Tighten the three bolts in the order as shown in the figure.
Standard value:
Standard value:
Tightening torque=18N·m
{
184kgf·cm}
{13.3ft·lbf}
(7) Loosen the three bolts by 180° in the order as shown in the figure.
(8) Tighten the three bolts in the order as shown in the figure.
Standard value:
Standard value:
Tightening torque=18N·m
{
184kgf·cm}
{13.3ft·lbf}
(9) Loosen the three bolts by 180° in the order as shown in the figure.
(10) Tighten the three bolts in the order as shown in the figure.
Standard value:
Standard value:
Tightening torque=18N·m
{
184kgf·cm}
{13.3ft·lbf}
NOTE:
After tightening, if the liquid gasket is squeezed out of the seal surface of timing chain cover SUB-ASSY, completely remove any squeezed-out liquid gasket.
8. Cylinder head cover SUB-ASSY LH installation
(1) Apply a coat of engine oil to two new spark plug tube gaskets and insert them onto the spark plug tube edge.
Captions in illustration
| *a |
Spark plug tube edge |
(2) Install a new cylinder head cover gasket NO. 2 to the cylinder head cover SUB-ASSY LH.
(3) Apply THREE BOND 1217G or equivalent to the mating surface of cylinder head cover SUB-ASSY LH as shown in the figure.
| Application area |
Application length |
| A |
10.0 mm {0.394 in} or more |
| B |
18.8 mm {0.740 in} or more |
| C |
63.0 mm {2.480 in} or more |
Captions in illustration
| *a |
Arch starting point |
| *b |
Diameter: 2.0 to 4.0 mm {0.079 to 0.158 in} |
(4) Set the cylinder head cover SUB-ASSY LH and tighten the eight bolts in the order as shown in the figure.
Standard value:
Standard value:
Tightening torque=6.4N·m
{
65kgf·cm}
{4.7ft·lbf}
9. Cylinder head gasket installation (Refer to )
)10. Cylinder head SUB-ASSY installation (Refer to )
)11. Camshaft housing SUB-ASSY RH installation
(1) Apply engine oil to the valve adjusting shim and roller rocker arm pivot, and install them to the cylinder head SUB-ASSY.
(2) Apply engine oil to the eight valve rocker arm SUB-ASSYs NO. 1 and two new O-rings, and install them to the cylinder head SUB-ASSY.
(3) Apply THREE BOND 1217G or equivalent to the mating surface of camshaft housing SUB-ASSY RH as shown in the figure.
Captions in illustration
| *a |
Area of B-B |
*b |
0 to 1.0 mm {0 to 0.0394 in} |
| *c |
Diameter: 2.5 to 3.5 mm {0.098 to 0.138 in} |
*d |
-0.5 to 0.5 mm {-0.0197 to 0.0197 in} |
| *e |
Groove edge |
- |
- |
CAUTION:
·Clean and degrease the installation surface.
·Do not apply liquid gasket excessively.
·Install within 5 min. after applying liquid gasket.
·Completely remove any liquid gasket that is squeezed out on the installation surface of timing chain cover SUB-ASSY.
·Do not apply liquid gasket excessively.
·Install within 5 min. after applying liquid gasket.
·Completely remove any liquid gasket that is squeezed out on the installation surface of timing chain cover SUB-ASSY.
(4) Tighten the 9 bolts in the order as shown in the figure to install the camshaft housing SUB-ASSY RH.
Standard value:
Standard value:
Tightening torque=18N·m
{
184kgf·cm}
{13.3ft·lbf}
NOTE:
Set the intake camshaft RH and exhaust camshaft RH to the zero-lift position.
(5) Loosen the three bolts by 180° in the order as shown in the figure.
(6) Tighten the three bolts in the order as shown in the figure.
Standard value:
Standard value:
Tightening torque=18N·m
{
184kgf·cm}
{13.3ft·lbf}
(7) Loosen the three bolts by 180° in the order as shown in the figure.
(8) Tighten the three bolts in the order as shown in the figure.
Standard value:
Standard value:
Tightening torque=18N·m
{
184kgf·cm}
{13.3ft·lbf}
(9) Loosen the three bolts by 180° in the order as shown in the figure.
(10) Tighten the three bolts in the order as shown in the figure.
Standard value:
Standard value:
Tightening torque=18N·m
{
184kgf·cm}
{13.3ft·lbf}
NOTE:
After tightening, if the liquid gasket is squeezed out of the seal surface of timing chain cover SUB-ASSY, completely remove any squeezed-out liquid gasket.
12. Cylinder head cover SUB-ASSY installation
(1) Apply a coat of engine oil to two new spark plug tube gaskets and insert them onto the spark plug tube edge.
Captions in illustration
| *a |
Spark plug tube edge |
(2) Install a new cylinder head cover gasket to the cylinder head cover SUB-ASSY.
(3) Apply THREE BOND 1217G or equivalent to the mating surface of cylinder head cover SUB-ASSY as shown in the figure.
| Application area |
Application length |
| A |
10.0 mm {0.394 in} or more |
| B |
68.0 mm {2.677 in} or more |
| C |
70.7 mm {2.784 in} or more |
Captions in illustration
| *a |
Arch starting point |
| *b |
Diameter: 2.0 to 4.0 mm {0.079 to 0.158 in} |
(4) Set the cylinder head cover SUB-ASSY and tighten the eight bolts in the order as shown in the figure.
Standard value:
Standard value:
Tightening torque=6.4N·m
{
65kgf·cm}
{4.7ft·lbf}
13. Injector driver bracket installation
(1) Install the injector driver bracket with the two bolts.
Standard value:
Standard value:
Tightening torque=6.4N·m
{
65kgf·cm}
{4.7ft·lbf}
14. Installation of ignition coil ASSY (bank 1 side)
(1) Using 2 bolts, install the ignition coil ASSY.
Standard value:
Standard value:
Tightening torque=8.5N·m
{
87kgf·cm}
{6.3ft·lbf}
15. Installation of ignition coil ASSY (bank 2 side)
(1) Using 2 bolts, install the ignition coil ASSY.
Standard value:
Standard value:
Tightening torque=8.5N·m
{
87kgf·cm}
{6.3ft·lbf}
16. Crankshaft timing sprocket installation
(1) Install the crankshaft timing sprocket.
17. Chain SUB-ASSY installation (bank 2 side) (Refer to )
)18. Chain SUB-ASSY installation (bank 1 side) (Refer to )
)19. Timing chain cover SUB-ASSY installation (Refer to )
)20. Timing chain cover oil seal installation (Refer to )
)21. Crankshaft pulley installation (Refer to )
)22. Thermostat installation (Refer to )
)23. Water outlet installation (Refer to )
)24. Engine water pump ASSY installation (Refer to )
)25. Water pump pulley installation (Refer to )
)26. Idler pulley SUB-ASSY NO. 1 installation (Refer to )
)27. PCV valve installation (Refer to )
)28. Installation of crankshaft position sensor
(1) Using bolt, install the crankshaft position sensor.
Standard value:
Standard value:
Tightening torque=6.4N·m
{
65kgf·cm}
{4.7ft·lbf}
29. Installation of knock control sensor
30. Cylinder head plate RR installation (transmission M/T)
(1) Apply THREE BOND 1217G or equivalent to the camshaft housing SUB-ASSY RH as shown in the figure.
Captions in illustration
| *a |
Diameter: 2.0 to 4.0 mm {0.079 to 0.158 in} |
| *b |
1.0 mm {0.0394 in} or less |
| *c |
Groove end |
CAUTION:
·Clean and degrease the installation surface.
·Install within 5 min. after applying liquid gasket.
·Install within 5 min. after applying liquid gasket.
(2) Install the cylinder head plate with the three bolts.
Standard value:
Standard value:
Tightening torque=16N·m
{
163kgf·cm}
{11.8ft·lbf}
31. Vacuum pump ASSY installation (transmission A/T) (Refer to )
)32. Water by-pass pipe NO. 1 installation (transmission M/T)
(1) Install the water by-pass pipe NO. 1 with the two bolts.
Standard value:
Standard value:
Tightening torque=6.4N·m
{
65kgf·cm}
{4.7ft·lbf}
(2) Install the water by-pass hose with the hose clamp.
33. Water by-pass pipe NO. 1 installation (transmission A/T)
(1) Install the water by-pass pipe NO. 1 with the two bolts.
Standard value:
Standard value:
Tightening torque=6.4N·m
{
65kgf·cm}
{4.7ft·lbf}
(2) Install the two water by-pass hoses with the two hose clamps.
34. Water inlet pipe installation
(1) Install two new O-rings to the cylinder block.
(2) Install the water inlet pipe with the four bolts.
Standard value:
Standard value:
Tightening torque=6.4N·m
{
65kgf·cm}
{4.7ft·lbf}
(3) Install the water by-pass hose NO. 3 with the hose clamp.
35. Transmission oil cooler hose NO. 3 installation
(1) Connect the transmission oil cooler hose NO. 3.
36. Water by-pass hose NO. 2 installation
(1) Install the water by-pass hose NO. 2 with the hose clamp.
37. PCV hose connector installation
(1) Install two new O-rings to the PCV hose connector.
(2) Connect the water by-pass hose NO. 1 to the PCV hose connector and water inlet pipe with the hose clamps.
(3) Install the PCV hose connector with the three bolts.
Standard value:
Standard value:
Tightening torque=6.4N·m
{
65kgf·cm}
{4.7ft·lbf}
38. Ventilation hose NO. 2 installation
(1) Connect the ventilation hose NO. 2 with the hose clamp.
39. Engine wiring installation
40. Installation of pump drive case ASSY (Refer to )
)41. Valve lifter installation (Refer to )
)42. Fuel pump ASSY installation
(1) Install the fuel pump ASSY with a TORX PLUS socket wrench 40IP and the two bolts.
Standard value:
Standard value:
Tightening torque=21N·m
{
214kgf·cm}
{15.5ft·lbf}
43. Fuel injector seal installation (Refer to )
)44. Fuel injector ASSY installation (Refer to )
)45. Fuel delivery pipe (bank 1 side) installation (Refer to )
)46. Installation of fuel delivery pipe (bank 2 side) (Refer to )
)47. Fuel delivery pipe installation (Refer to )
)48. Fuel delivery pipe NO. 2 installation (Refer to )
)49. Intake manifold installation
(1) Install two new gaskets to the intake manifold.
(2) Install the intake manifold with the six bolts.
Standard value:
Standard value:
Tightening torque=25N·m
{
255kgf·cm}
{18.4ft·lbf}
(3) Engage the four clamps and connect the engine wiring.
(4) Connect the connector of fuel pump ASSY.
(5) Connect the connector for the purge control solenoid valve.
(6) Connect the connector for air pressure sensor ASSY.
(7) Install the water by-pass hoses NO. 2 and water by-pass hoses NO. 3 to the throttle body ASSY with the two clamps.
(8) Connect the connector of throttle body ASSY.
50. Ventilation hose connection (Refer to )
)
51. Fuel delivery pipe SUB-ASSY installation
(1) Connect the vacuum hose SUB-ASSY.
(2) Install the fuel delivery pipe SUB-ASSY with the bolt.
Standard value:
Standard value:
Tightening torque=6.4N·m
{
65kgf·cm}
{4.7ft·lbf}
(3) Connect the fuel delivery pipe SUB-ASSY with a new gasket and the union bolt.
Standard value:
Standard value:
Tightening torque=31N·m
{
316kgf·cm}
{22.9ft·lbf}
52. Intake manifold protector (bank 2 side) installation
(1) Install the intake manifold protector (bank 2 side) with 2 bolts.
Standard value:
Standard value:
Tightening torque=19N·m
{
194kgf·cm}
{14.0ft·lbf}
53. Intake manifold protector (bank 1 side) installation
(1) Install the intake manifold protector (bank 1 side) with 2 bolts.
Standard value:
Standard value:
Tightening torque=19N·m
{
194kgf·cm}
{14.0ft·lbf}
54. Idler pulley bracket installation (when there is no air conditioning)
(1) Tack on the idler pulley bracket with 3 bolts.
(2) Tighten the three bolts in the order as shown in the figure.
Standard value:
Standard value:
Tightening torque=36N·m
{
367kgf·cm}
55. Installation of compressor ASSY (with magnet clutch) (where there is air conditioning)
(1) Temporarily install the compressor ASSY (with pulley) with the three bolts.
(2) Tighten the three bolts in the order as shown in the figure.
Standard value:
Standard value:
Tightening torque=36N·m
{
367kgf·cm}
{26.6ft·lbf}
56. V-ribbed belt tensioner ASSY installation (Refer to )
)57. Oil level gauge guide installation (Refer to )
)58. Idler pulley SUB-ASSY NO. 2 installation (Refer to )
)59. Install the alternator ASSY
(1) Install the generator ASSY with the two bolts.
Standard value:
Standard value:
Tightening torque=25N·m
{
255kgf·cm}
{18.4ft·lbf}
60. Engine mounting insulator FR installation
(1) Install the two engine mounting insulators FR with the four bolts.
Standard value:
Standard value:
Tightening torque=35N·m
{
357kgf·cm}
{25.8ft·lbf}
61. Installation of engine hanger (Refer to )
)62. Engine stand removal
(1) Support the engine ASSY with an engine sling device and mini-crane.
CAUTION:
Since the operation with the engine ASSY suspended are danger, never perform it other than when installing the ASSY to the engine stand or removing it from the stand.
(2) Remove the engine ASSY from the engine stand.
63. Crank angle sensor plate NO. 1 installation (Refer to )
)64. Flywheel SUB-ASSY installation (transmission M/T) (Refer to )
)65. Clutch disc ASSY installation (transmission M/T) (Refer to )
)66. Clutch cover ASSY installation (transmission M/T) (Refer to )
)67. Drive plate & ring gear SUB-ASSY installation (transmission A/T) (Refer to )
)
68. Engine ASSY installation
(1) Make sure that the knock pins are attached to 2 locations on the engine side.
(2) Align the knock pins to the knock holes by leveling the engine and transmission ASSY using an engine sling device and mini-crane.
69. Transmission ASSY installation
70. Removal of engine hanger (Refer to )
)71. Fuel hose and purge hose connection
(1) Align the alignment marks on purge hose and pipe, and secure them with the hose clump.
(2) Connect the 2 new fuel hoses, match up the alignment marks of the fuel hoses and pipes, and tighten the 2 hose clamps.
Standard value:
Standard value:
Tightening torque=1.3N·m
{
13kgf·cm}
{1.0ft·lbf}
CAUTION:
Check the connection status of each fuel hose, and be sure to prevent wrong connections.
72. Installation of drive plate & torque converter setting bolt (transmission A/T) (Refer to )
)73. Flywheel housing under cover installation (Refer to )
)74. Installation of front crossmember SUB-ASSY
(1) Install the two nuts of front crossmember SUB-ASSY.
Standard value:
Standard value:
Tightening torque=45N·m
{
459kgf·cm}
{33.2ft·lbf}
75. Manual transmission ASSY installation (transmission M/T)
76. Automatic transmission ASSY installation (transmission A/T)
77. Stabilizer bar FR installation (transmission A/T)
(Refer to )
)78. Engine under cover RR LH installation (w/ Floor Under Cover)
(1) Install the engine under cover RR LH with the three bolts and eight clips.
Standard value:
Standard value:
Tightening torque=7.5N·m
{
77kgf·cm}
{5.5ft·lbf}
79. Ground cable installation
(1) Install the ground cable with the two bolts.
Standard value:
Standard value:
Tightening torque=7.5N·m
{
77kgf·cm}
{5.5ft·lbf}
80. Radiator outlet hose connection
(1) Connect the radiator outlet hose with the hose clamp.
81. Transmission oil cooler hose NO. 3 connection (transmission A/T)
(1) Connect the transmission oil cooler hose NO. 3 with the hose clamp.
82. SST removal (transmission A/T)
(1) Remove the SST from the starter hole of torque converter clutch case.
83. Installation of starter ASSY (Refer to )
)84. Connection of cooler refrigerant discharge hose NO. 1 (with air conditioning) (Refer to )
)85. Suction hose SUB-ASSY installation (when there is air conditioning)
(1) Remove the vinyl tape wrapped around the joint of the suction hose SUB-ASSY.
(2) Apply sufficient compressor oil to a new O-ring and the fitting area of compressor ASSY (with pulley).
(3) Install the O-ring to the suction hose SUB-ASSY.
CAUTION:
Do not allow dust etc. to adhere to the O-ring and O-ring sealing portion.
(4) Connect the suction hose SUB-ASSY to the compressor ASSY (with pulley) with the bolt.
Standard value:
Standard value:
Tightening torque=10N·m
{
102kgf·cm}
{7.4ft·lbf}
(5) Remove the vinyl tape wrapped on the connection of suction hose SUB-ASSY and unit.
(6) Apply sufficient compressor oil to a new O-ring and the connection of suction hose SUB-ASSY.
(7) Install the O-ring to the suction hose SUB-ASSY.
CAUTION:
Do not allow dust etc. to adhere to the O-ring and O-ring sealing portion.
(8) Push the shaft of the pipe joint into the seal hole until it is completely engaged.
(9) Turn the hook type connector to the tightening position and tighten it with bolts. (for LHD)
Standard value:
Standard value:
Tightening torque=7.5N·m
{
77kgf·cm}
{5.5ft·lbf}
(10) Turn the hook type connector to the tightening position and tighten it with bolts.
Standard value:
Standard value:
Tightening torque=7.5N·m
{
77kgf·cm}
{5.5ft·lbf}
(11) Install the suction hose SUB-ASSY with the nut.
Standard value:
Standard value:
Tightening torque=10N·m
{
102kgf·cm}
{7.4ft·lbf}
86. Transmission oil cooler hose NO. 1 connection (transmission A/T)
(1) Connect the transmission oil cooler hose NO. 1 with the hose clamp.
87. Heater water hose connection
(1) Install the heater water hoses with the two hose clamps.
88. Exhaust manifold installation
(Refer to )
)89. Vacuum tube connector hose connection (transmission M/T)
(1) Install the vacuum tube connector hose with the bolt.
Standard value:
Standard value:
Tightening torque=18N·m
{
184kgf·cm}
{13.3ft·lbf}
(2) Connect the vacuum tube connector hose with the hose clamp.
90. Vacuum tube connector hose connection (transmission A/T)
(1) Connect the vacuum tube connector hose with the hose clamp.
91. Drive plate & torque converter setting bolt installation (transmission A/T)
(1) Use the SST to secure the crank pulley.
SST
18355AA000
18334AA000
(2) Install the six drive plate & torque converter setting bolts through the service hole.
Standard value:
Standard value:
Tightening torque=25N·m
{
255kgf·cm}
{18.4ft·lbf}
92. Flywheel housing under cover installation (transmission A/T)
(1) Install the flywheel housing under cover.
93. Installation of engine cover SUB-ASSY NO.1 (with air conditioning) (Refer to )
)94. Fan & generator V-belt installation (Refer to )
)95. Belt generator cover installation (Refer to )
)96. Generator cover installation (Refer to )
)97. CONNECT ENGINE WIRE (for LHD)
(1) Connect the generator connector and connect the clamp.
(2) Connect the generator wire with the nut.
Standard value:
Standard value:
Tightening torque=16N·m
{
163kgf·cm}
{11.8ft·lbf}
(3) Install the terminal cap.
(4) Connect the 5 wire harness clamps.
(5) Install the 2 wire harness clamp brackets with the 2 bolts.
Standard value:
Standard value:
Tightening torque=11N·m
{
112kgf·cm}
{8.1ft·lbf}
(6) Connect the 2 wire harness clamps to the 2 wire harness clamp brackets.
(7) Connect the wire harness clamp to the No. 2 engine hanger.
(8) Connect the connector (B).
(9) Connect the wire harness connector (A) and securely lock the connector.
(10) Install the wire harness clamp bracket to the No. 2 engine hanger with the bolt.
Standard value:
Standard value:
Tightening torque=10N·m
{
102kgf·cm}
{7.4ft·lbf}
(11) for Automatic Transmission:
(a) Slide the connector in the direction shown in the diagram, and connect the wire harness.
(b) Connect the 2 wire harness clamps.
(c) Connect the wire harness connector (A) and securely lock the connector.
(d) Connect the connector (B).
98. CONNECT ENGINE WIRE (for RHD)
(1) Connect the generator connector and connect the clamp.
(2) Connect the generator wire with the nut.
Standard value:
Standard value:
Tightening torque=16N·m
{
163kgf·cm}
{11.8ft·lbf}
(3) Install the terminal cap.
(4) Connect the 5 wire harness clamps.
(5) Install the 2 wire harness clamp brackets with the 2 bolts.
Standard value:
Standard value:
Tightening torque=11N·m
{
112kgf·cm}
{8.1ft·lbf}
(6) Connect the 2 wire harness clamps to the 2 wire harness clamp brackets.
(7) Connect the wire harness clamp to the No. 2 engine hanger.
(8) Connect the connector (B).
(9) Connect the wire harness connector (A) and securely lock the connector.
(10) Install the wire harness clamp bracket to the No. 2 engine hanger with the bolt.
Standard value:
Standard value:
Tightening torque=10N·m
{
102kgf·cm}
{7.4ft·lbf}
(11) for Automatic Transmission:
(a) Slide the connector in the direction shown in the diagram, and connect the wire harness.
(b) Connect the 2 wire harness clamps.
(c) Connect the wire harness connector (A) and securely lock the connector.
(d) Connect the connector (B).
99. Installation of injector driver (Refer to )
)100. Water filler SUB-ASSY installation
(1) Install the water filler SUB-ASSY with the two hose clamps.
(2) Install the water filler SUB-ASSY with the two bolts.
Standard value:
Standard value:
Tightening torque=7.5N·m
{
77kgf·cm}
{5.5ft·lbf}
101. Radiator reservoir tank ASSY installation (Refer to )
)102. Air cleaner case SUB-ASSY installation
(1) Install the stay with the bolt.
Standard value:
Standard value:
Tightening torque=35N·m
{
357kgf·cm}
{25.8ft·lbf}
(2) Install the air cleaner case SUB-ASSY with the three bolts.
Standard value:
Standard value:
Tightening torque=6.0N·m
{
61kgf·cm}
{4.4ft·lbf}
(3) Tighten the hose clamp.
Standard value:
Standard value:
Tightening torque=2.0N·m
{
20kgf·cm}
{1.5ft·lbf}
(4) Engage the clamp and install the wiring harness to the air cleaner cap.
(5) Connect the connector to the intake air flow meter SUB-ASSY.
(6) Connect the ventilation hose NO. 2 with the hose clamp.
(7) Install the chamber with the two bolts.
Standard value:
Standard value:
Tightening torque=6.0N·m
{
61kgf·cm}
{4.4ft·lbf}
(8) Connect the hose to the chamber ASSY.
103. Front strut tower bar LH installation (Refer to )
)104. Front strut tower bar RH installation (Refer to )
)105. Engine oil refill (Refer to )
)106. Connection of the battery ground terminal
Standard value:
Standard value:
Tightening torque=6.0N·m
{
61kgf·cm}
{4.4ft·lbf}
107. Replenishing of coolant (SUBARU Super Coolant) (Refer to )
)108. Shift lever position check (transmission A/T) (Refer to )
)109. Refilling of the refrigerant (Refer to )
)110. Leak check of coolant (SUBARU Super Coolant) (Refer to )
)111. Engine oil leakage check (Refer to )
)112. Fuel leakage check (Refer to )
)113. Exhaust gas leakage check (Refer to )
)114. Refrigerant gas leakage check (Refer to )
)115. Throttle body function check (Refer to )
)116. Ignition timing check (Refer to )
)117. Idle speed check (Refer to )
)118. CO, HC concentration check (Refer to )
)119. Coolant (SUBARU Super Coolant) level check (Refer to )
)120. Engine oil level check (Refer to )
)121. Hood SUB-ASSY set
(1) Change the front hood stay position from B to A and store it in the position A.