Part 2
Installation (Continued)
30. Cylinder head plate RR installation (transmission M/T)
(1) Apply THREE BOND 1217G to the camshaft housing SUB-ASSY RH as shown in the figure.
Captions in illustration
CAUTION:
^ Clean and degrease the installation surface.
^ Install within 5 min. after applying liquid gasket.
(2) Install the cylinder head plate with the three bolts.
Standard value:T=16Nm {163kgf-cm} {11.8ft-lbf}
31. Vacuum pump ASSY installation (transmission A/T)
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:T=6.4Nm {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:T=6.4Nm {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:T=6.4Nm {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:T=6.4Nm {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
(1) Confirm the connection of each connector and clamp as shown in the figure.
Captions in illustration
40. Pump drive case ASSY installation
41. Valve lifter installation
42. Fuel pump ASSY installation
(1) Install the fuel pump ASSY with a TORX PLUS socket wrench 40IP and the two bolts.
Standard value:T=21Nm {214kgf-cm} {15.5ft-lbf}
43. Fuel injector seal installation
44. Fuel injector ASSY installation
45. Fuel delivery pipe (bank 1 side) installation
46. Fuel delivery pipe (bank 2 side) installation
47. Fuel delivery pipe installation
48. Fuel delivery pipe NO. 2 installation
49. Intake manifold installation
(1) Install two new gaskets to the intake manifold.
(2) Install the intake manifold with the six bolts.
Standard value:T=25Nm {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 of vacuum switching valve ASSY.
(6) Connect the connector of 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
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:T=6.4Nm {65kgf-cm} {4.7ft-lbf}
(3) Connect the fuel delivery pipe SUB-ASSY with a new gasket and the union bolt.
Standard value:T=31Nm {316kgf-cm} {22.9ft-lbf}
52. Intake manifold protector (bank 2 side) installation
(1) Install the intake manifold protector (bank 2 side) with the two bolts.
Standard value:T=19Nm {194kgf-cm} {14.0ft-lbf}
53. Intake manifold protector (bank 1 side) installation
(1) Install the intake manifold protector (bank 1 side) with the two bolts.
Standard value:T=19Nm {194kgf-cm} {14.0ft-lbf}
54. Compressor ASSY (with magnet clutch) installation
(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:T=36Nm {367kgf-cm} {26.6ft-lbf}
55. V-ribbed belt tensioner ASSY installation
56. Oil level gauge guide installation
57. Idler pulley SUB-ASSY NO. 2 installation
58. Generator ASSY installation
(1) Install the generator ASSY with the two bolts.
Standard value:T=25Nm {255kgf-cm} {18.4ft-lbf}
59. Engine mounting insulator FR installation
(1) Install the two engine mounting insulators FR with the four bolts.
Standard value:T=35Nm {357kgf-cm} {25.8ft-lbf}
60. Engine hanger installation
61. 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.
62. Crank angle sensor plate NO. 1 installation
63. Flywheel SUB-ASSY installation (transmission M/T)
64. Clutch disc ASSY installation (transmission M/T)
65. Clutch cover ASSY installation (transmission M/T)
66. Drive plate & ring gear SUB-ASSY installation (transmission A/T)
67. Engine ASSY installation
(1) Make sure that the two knock pins are installed at the two 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.
68. Transmission ASSY installation
(1) Install the connecting bolt of transmission ASSY.
Captions in illustration
Standard value:T=50Nm {510kgf-cm} {36.9ft-lbf}
(2) Remove the SST. (Transmission A/T)
69. Engine hanger removal
70. 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 fuel hose NO. 1 and fuel hose NO. 2.
71. Drive plate & torque converter setting bolt installation (transmission A/T)
72. Flywheel housing under cover installation
73. Front crossmember SUB-ASSY installation
(1) Install the two nuts of front crossmember SUB-ASSY.
Standard value:T=45Nm {459kgf-cm} {33.2ft-lbf}
74. Manual transmission ASSY installation (transmission M/T)
(1) Install the manual transmission ASSY with the three bolts A and two nuts.
Standard value:T=50Nm {510kgf-cm} {36.9ft-lbf}
Captions in illustration
75. Automatic transmission ASSY installation (transmission A/T)
(1) Install the automatic transmission ASSY with the three bolts A and two nuts.
Standard value:T=50Nm {510kgf-cm} {36.9ft-lbf}
Captions in illustration
76. Stabilizer bar FR installation (transmission A/T)
77. Engine under cover RR LH installation (with rear spoiler)
(1) Install the engine under cover RR LH with the three bolts and eight clips.
Standard value:T=7.5Nm {77kgf-cm} {5.5ft-lbf}
78. Ground cable installation
(1) Install the ground cable with the two bolts.
Standard value:T=7.5Nm {77kgf-cm} {5.5ft-lbf}
79. Radiator outlet hose connection
(1) Connect the radiator outlet hose with the hose clamp.
80. Transmission oil cooler hose NO. 3 connection (transmission A/T)
(1) Connect the transmission oil cooler hose NO. 3 with the hose clamp.
81. SST removal (transmission A/T)
(1) Remove the SST from the starter hole of torque converter clutch case.
82. Starter ASSY installation
83. Cooler refrigerant discharge hose NO. 1 connection
84. Suction hose SUB-ASSY installation
(1) Remove the vinyl tape wrapped on the connection of suction hose SUB-ASSY.
(2) Apply sufficient compressor oil (ND-OIL8) 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:T=10Nm {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 (ND-OIL8) 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 pipe joint into the sealing hole until its center fits in securely.
(9) Turn the hook-shaped connector to its clamped position and secure it with the bolt.
Standard value:T=7.5Nm {77kgf-cm} {5.5ft-lbf}
(10) Install the suction hose SUB-ASSY with the nut.
Standard value:T=10Nm {102kgf-cm} {7.4ft-lbf}
85. Transmission oil cooler hose NO. 1 connection (transmission A/T)
(1) Connect the transmission oil cooler hose NO. 1 with the hose clamp.
86. Heater water hose connection
(1) Install the heater water hoses with the two hose clamps.
87. Exhaust manifold installation
88. Vacuum tube connector hose connection (transmission M/T)
(1) Install the vacuum tube connector hose with the bolt.
Standard value:T=18Nm {184kgf-cm} {13.3ft-lbf}
(2) Connect the vacuum tube connector hose with the hose clamp.
89. Vacuum tube connector hose connection (transmission A/T)
(1) Connect the vacuum tube connector hose with the hose clamp.
90. Drive plate & torque converter setting bolt installation
(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:T=25Nm {255kgf-cm} {18.4ft-lbf}
91. Flywheel housing under cover installation
(1) Install the flywheel housing under cover.
92. Engine cover SUB-ASSY NO. 1 installation
93. Fan & generator V-belt installation
94. Belt generator cover installation
95. Generator cover installation
96. Engine wiring harness connection
(1) Connect the connector and clamp to connect the wiring harness.
(2) Connect the wiring harness to the terminal B with the nut.
Standard value:T=16Nm {163kgf-cm} {11.8ft-lbf}
(3) Install the terminal cap.
(4) Engage the clamp and connect the wiring harness.
(5) Engage the five clamps and connect the wiring harness.
(6) Install the two wiring harness clamp brackets with the two clamps and two bolts.
Standard value:T=11Nm {112kgf-cm} {8.1ft-lbf}
(7) Connect the connector B.
(8) Turn down the lock of connector A to securely lock the connector.
(9) Install the wiring harness clamp bracket with the bolt.
Standard value:T=10Nm {102kgf-cm} {7.4ft-lbf}
(10) Transmission A/T:
(a) Slide the connector in the direction as shown in the figure and connect the wiring harness.
(b) Engage the two clamps and connect the wiring harness.
(c) Connect the connector B.
(d) Turn down the lock of connector A to securely lock the connector.
97. Injector driver installation
98. 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:T=7.5Nm {77kgf-cm} {5.5ft-lbf}
99. Radiator reservoir tank ASSY installation
100. Air cleaner case SUB-ASSY installation
(1) Install the stay with the bolt.
Standard value:T=35Nm {357kgf-cm} {25.8ft-lbf}
(2) Install the air cleaner case SUB-ASSY with the three bolts.
Standard value:T=6.0Nm {61kgf-cm} {4.4ft-lbf}
(3) Tighten the hose clamp.
Standard value:T=2.0Nm {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:T=6.0Nm {61kgf-cm} {4.4ft-lbf}
(8) Connect the hose to the chamber ASSY.
101. Front upper suspension to cowl brace SUB-ASSY LH installation
102. Front upper suspension to cowl brace SUB-ASSY RH installation
103. Engine oil refill
104. Battery negative terminal connection
Standard value:T=6.0Nm {61kgf-cm} {4.4ft-lbf}
105. Coolant (SUBARU Super Coolant) refill
106. Shift lever position check (transmission A/T) )
107. Refrigerant HFC-134a (R134a) refill
108. Coolant (SUBARU Super Coolant) leakage check Testing and Inspection
109. Engine oil leakage check
110. Fuel leakage check)
111. Exhaust gas leakage check
112. Engine oil leakage check
113. Throttle body function check
114. Ignition timing check Testing and Inspection
115. Idle speed check Testing and Inspection
116. CO, HC concentration check
117. Coolant (SUBARU Super Coolant) level check Testing and Inspection
118. Engine oil level check Testing and Inspection
119. Hood SUB-ASSY set
(1) Change the front hood stay position from B to A and store it in the position A.
