Part 1
Removal1. 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. Refrigerant HFC-134a (R134a) draining
3. Fuel spill prevention procedure
4. Battery negative terminal disconnection
5. Front upper suspension to cowl brace SUB-ASSY RH removal
6. Front upper suspension to cowl brace SUB-ASSY LH removal
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 SUBASSY.
(6) Loosen the hose clamp.
(7) Remove the three bolts and remove the air cleaner case SUBASSY.
(8) Remove the bolt and remove the stay.
8. Engine oil draining
9. Coolant (SUBARU Super Coolant) draining
10. Radiator reservoir tank ASSY removal
11. Water filler SUB-ASSY removal
(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. Injector driver removal
13. Engine wiring harness disconnection
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 two clamps and remove the two bolts to remove the two wiring harness clamp brackets.
(6) Release the five clamps and disconnect the wiring harness.
(7) Release the clamp 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.
14. Generator cover removal
15. Belt generator cover removal
16. Fan & generator V-belt removal
17. Engine cover SUB-ASSY NO. 1 removal
18. Flywheel housing under cover removal
(1) Remove the flywheel housing under cover.
19. Drive plate & torque converter setting bolt removal
(1) Use the SST to secure the crankshaft pulley.
SST 18355AA000, 18334AA000
Captions in illustration
(2) Remove the six drive plate & torque converter setting bolts through the service hole.
20. 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.
21. 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.
22. Exhaust manifold removal
23. 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 rope.
NOTE:
This procedure is required to prevent the exhaust pipe SUB-ASSY FR from falling off.
24. Heater water hose disconnection
(1) Move the two hose clamps and disconnect the two heater water hoses.
25. Transmission oil cooler hose NO. 1 disconnection (transmission A/T)
(1) Move the hose clamp and disconnect the transmission oil cooler hose NO. 1.
26. Suction hose SUB-ASSY removal
(1) Remove the bolt and disconnect the suction hose SUB-ASSY.
(2) Remove the O-ring from the suction hose SUB-ASSY.
CAUTION:
Wrap vinyl tape around the fitting areas of disconnected suction hose SUB-ASSY and compressor ASSY (with magnet clutch) to prevent dust, moisture, etc. from entering into them.
(3) Remove the bolt and turn the hook-shaped connector in the direction of the arrow as shown in the figure.
(4) Remove the nut and disconnect the suction hose SUB-ASSY.
(5) Remove the O-ring from the suction hose SUB-ASSY.
CAUTION:
Wrap vinyl tape around the fitting areas of disconnected suction hose SUB-ASSY and unit side to prevent dust, moisture, etc. from entering into them.
27. Cooler refrigerant discharge hose NO. 1 disconnection
28. Starter ASSY removal
29. SST installation (transmission A/T)
(1) Attach the SST to the starter hole of torque converter clutch case.
SST 18750AA010
30. Transmission oil cooler hose NO. 3 disconnection (transmission A/T)
(1) Move the hose clamp and disconnect the transmission oil cooler hose NO. 3.
31. Radiator outlet hose disconnection
(1) Move the hose clamp and disconnect the radiator outlet hose.
32. Ground cable disconnection
(1) Remove the two bolts and remove the two ground cables.
33. 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 rope.
NOTE:
This procedure is required to prevent the exhaust pipe SUB-ASSY FR from falling off.
34. Stabilizer bar FR removal (transmission A/T)
35. Automatic transmission ASSY disconnection (transmission A/T)
(1) Remove the three bolts A and two nuts.
Captions in illustration
CAUTION:
Do not remove the bolt B to prevent the ASSY from falling off.
36. Manual transmission ASSY removal (transmission M/T)
(1) Remove the three bolts A and two nuts.
Captions in illustration
CAUTION:
Do not remove the bolt B to prevent the ASSY from falling off.
37. Front crossmember SUB-ASSY disconnection
(1) Remove the two nuts of front crossmember SUB-ASSY.
38. Flywheel housing under cover removal
39. Drive plate & torque converter setting bolt removal (transmission A/T)
40. SEPARATE FUEL HOSE
(1) Using SST, disconnect the fuel hose NO.1 and fuel hose NO.2 from the fuel pipe.
SST 42099AE000
(2) Remove the clamp and disconnect the purge hose from the fuel pipe.
41. Engine hanger installation
(1) Install the engine hanger NO. 1 to the position as shown in the figure.
SST 12281-38150, 90119-14120
Captions in illustration
Standard value:T=43Nm {439kgf-cm} {31.7ft-lbf}
(2) Support the engine with an engine sling device and lifter.
42. Transmission ASSY support (transmission A/T)
(1) Tie the SST to the transmission ASSY with rope.
SST 18632AA010
(2) Support the SST with a jack.
Captions in illustration
CAUTION:
Support the transmission ASSY until the installation of partial engine ASSY is completed.
43. 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.
44. Engine ASSY removal
(1) Remove the connecting bolt of transmission ASSY.
Captions in illustration
(2) Suspend the partial engine ASSY with an engine sling device and mini-crane.
45. Drive plate & ring gear SUB-ASSY removal (transmission A/T)
46. Clutch cover ASSY removal (transmission M/T)
47. Clutch disc ASSY removal (transmission M/T)
48. Flywheel SUB-ASSY removal (transmission M/T)
49. Crank angle sensor plate NO. 1 removal
50. 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.
51. Engine mounting insulator FR removal
(1) Remove the four bolts and remove the two engine mounting insulators FR.
52. Engine hanger removal
(1) Remove the bolt and remove the engine hanger.
53. Generator ASSY removal
(1) Remove the two bolts and remove the generator ASSY.
54. Idler pulley SUB-ASSY NO. 2 removal
55. Oil level gauge guide removal
56. V-ribbed belt tensioner ASSY removal