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Engine Assembly: Removal

WARNING: Place "NO OPEN FLAMES" signs near the working area.
CAUTION: Do not start the engine after the refrigerant is collected. If the engine is started, replace the compressor assembly.
  1. Remove the striker assembly front hood. Ref. to EXTERIOR BODY PANELS>FRONT HOOD>DISASSEMBLY .
    NOTE: This procedure is necessary to prevent the lifting device and the striker assembly front hood from contacting with each other and causing damage. However, the procedure may be omitted if it is assured that the lifting device to be used will not make a contact.
  2. Fully open the hood COMPL front. Ref. to REPAIR CONTENTS>NOTE>STAY ASSEMBLY FRONT HOOD .
  3. Prepare for collection of refrigerant.
    1. Perform compressor oil return operation. Ref. to AIR CONDITIONER>COMPRESSOR OIL>OPERATION .
    2. Turn the A/C switch to OFF.
  4. Release the fuel pressure. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>FUEL>PROCEDURE>RELEASING OF FUEL PRESSURE .
  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 the battery sensor, and disconnect the positive terminal of the battery. Ref. to REPAIR CONTENTS>NOTE>BATTERY .
  7. Collect the refrigerant. Ref. to AIR CONDITIONER>REFRIGERANT RECOVERY PROCEDURE>PROCEDURE .
  8. Remove the air intake boot. Ref. to INTAKE (INDUCTION) (H4DO)>AIR INTAKE BOOT>REMOVAL .
  9. Remove the air cleaner case (rear). Ref. to INTAKE (INDUCTION) (H4DO)>AIR CLEANER CASE>REMOVAL .
  10. Remove the radiator. Ref. to COOLING (H4DO)>RADIATOR>REMOVAL .
  11. Disconnect the connector (A), connector (B) and terminal (C).
  12. Remove the clip (D) and clip (E) that secure the battery cable assembly.
  13. Disconnect the hose pressure suction and the hose pressure discharge from the A/C compressor. Ref. to AIR CONDITIONER>HOSE AND PIPE>REMOVAL .
    G16761022Courtesy of SUBARU OF AMERICA, INC.
  14. Disconnect the connector (A), and remove the clip (B) securing the engine wiring harness.
  15. Remove the clip (C) securing battery cable assembly and release the claw (D).
    G16761023Courtesy of SUBARU OF AMERICA, INC.
  16. Disconnect connector (A) from ECM.
    CAUTION: In order to prevent damaging the connector (A), check that the lock is released completely when moving the lever.
    NOTE: To disconnect the connector (A), press the portion (a) shown in the figure to release the lock and move the lever in the direction of arrow.
    G16523377Courtesy of SUBARU OF AMERICA, INC.
  17. Disconnect the connector (B) from the main fuse box, and remove the engine wiring harness from the clip (C).
    NOTE: When disconnecting the connector (B), pry the portion (a) shown in the figure to release the lock using a flat tip screwdriver or similar tool wrapped with protective tape, and move the lever in the direction of arrow.
    G16760392Courtesy of SUBARU OF AMERICA, INC.
    G16761026Courtesy of SUBARU OF AMERICA, INC.
  18. Release the claw (A) securing the battery cable assembly to the bracket.
  19. Release the claw (B) securing the engine wiring harness to the bracket, and place it aside so that it does not interfere with work.
    G16761027Courtesy of SUBARU OF AMERICA, INC.
  20. Disconnect the heater inlet hose (A) and the heater outlet hose (B).
    G16761028Courtesy of SUBARU OF AMERICA, INC.
  21. Disconnect the transmission harness connector from the engine wiring harness.
    G16761029Courtesy of SUBARU OF AMERICA, INC.
  22. Remove the TCM. (Impreza model) Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR580)>TRANSMISSION CONTROL MODULE (TCM)>REMOVAL .
  23. Remove the pitching stopper. (Crosstrek model) Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR580)>TRANSMISSION MOUNTING SYSTEM>REMOVAL>PITCHING STOPPER .
  24. Disconnect the water hose (A) and water hose (B) from the CVTF cooler (with warmer feature) and the EGR cooler.
    G16761030Courtesy of SUBARU OF AMERICA, INC.
  25. Lift up the vehicle.
  26. Disconnect the ground cord on the engine side.
    G16761031Courtesy of SUBARU OF AMERICA, INC.
  27. Remove the nuts which secure the engine mounting to the crossmember COMPL front.
    G16761032Courtesy of SUBARU OF AMERICA, INC.
  28. Remove the crossmember support rear RH. Ref. to FRONT SUSPENSION>CROSSMEMBER SUPPORT>REMOVAL .
  29. Remove the bolts and nuts which hold the lower side of transmission to the engine.
    G16761033Courtesy of SUBARU OF AMERICA, INC.
  30. Lower the vehicle.
  31. Remove the starter. Ref. to STARTING/CHARGING SYSTEMS (H4DO)>STARTER>REMOVAL .
  32. Separate the torque converter from drive plate. (2.0 L model)
    1. Remove the PCV hose No. 1. Ref. to EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) (H4DO)>PCV HOSE>REMOVAL>PCV HOSE NO. 1 .
    2. Disconnect the connector (A) and connector (B), and remove the clip (C) from the bracket.
    3. Remove the plug (D) from the service hole.
      G16761034Courtesy of SUBARU OF AMERICA, INC.
    4. Insert the wrench into the crank pulley bolt, and rotate the crank pulley to remove the bolts (6 places) securing the torque converter to the drive plate.
      G16761035Courtesy of SUBARU OF AMERICA, INC.
    5. Attach the ST to the converter case.

      Preparation tool  :

      ST: STOPPER SET (498277200) 

      G14403719Courtesy of SUBARU OF AMERICA, INC.
  33. Separate the torque converter from drive plate. (2.5 L model)
    1. Remove the PCV hose No. 1. Ref. to EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) (H4DO)>PCV HOSE>REMOVAL>PCV HOSE NO. 1 .
    2. Disconnect the connector (A), and remove the plug (B) from the service hole.
      G16761037Courtesy of SUBARU OF AMERICA, INC.
    3. Insert the wrench into the crank pulley bolt, and rotate the crank pulley to remove the bolts (4 places) securing the torque converter to the drive plate.
      G16761038Courtesy of SUBARU OF AMERICA, INC.
    4. Attach the ST to the converter case.

      Preparation tool  :

      ST: STOPPER SET (498277200) 

      G14403719Courtesy of SUBARU OF AMERICA, INC.
  34. 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. Disconnect the evaporation hose (A) from the purge control solenoid valve, and remove the evaporation hose (A) from the clip (B).
    2. Remove the clip (B) from the intake manifold assembly, and disconnect the quick connector of the fuel delivery tube (C) from the fuel pipe.
      NOTE: Disconnect the quick connector as shown in the figure.
      G16761003Courtesy of SUBARU OF AMERICA, INC.
      (a)  Slider 
      G16761041Courtesy of SUBARU OF AMERICA, INC.
  35. Separate the engine and transmission.
    CAUTION: Before removing the engine away from transmission, check to be sure no work has been overlooked.
    1. Using the ST1, install the ST2 to the engine unit.

      Preparation tool  :

      ST1: BOLT (18363AA050)

      ST2: HANGER (18360AA040)

      Tightening torque  :

      43 N.m (4.4 kgf-m, 31.7 ft-lb)

      G16761042Courtesy of SUBARU OF AMERICA, INC.
    2. Support the engine with a lifting device and wire ropes.
      G16523762Courtesy of SUBARU OF AMERICA, INC.
      (A)  To engine rear hanger 
      (B)  To ST (HANGER) 
    3. Support the front differential of the transmission with a garage jack.
      CAUTION:
      • Be sure to perform this procedure to prevent the transmission from lowering by its own weight  .
      • Do not support the oil pan of the transmission to prevent possible transmission damage and CVTF leakage  .
      G16523764Courtesy of SUBARU OF AMERICA, INC.
      (A)  Front differential of transmission 
      (B)  Garage jack 
    4. Remove the bolts which hold the upper side of the transmission to the engine.
      G16761045Courtesy of SUBARU OF AMERICA, INC.
  36. Remove the engine unit from the vehicle.
    NOTE: Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc.
    1. With a lifting device and a garage jack, lift the engine unit together with the transmission.
      CAUTION: When lifting up the engine unit, pay attention to the clearance of each part and be careful not to lift the engine too much, in order to prevent damaging the vehicle.
      NOTE: Lift it high enough until the stud bolt of the engine mounting is completely drawn out of the crossmember COMPL front.
    2. Move the engine unit forward until the engine unit is withdrawn from the transmission.
      NOTE: If it is hard to pull out the stud bolt from the transmission body, precisely adjust the height of the transmission body with garage jack so that no load is applied to the stud bolt.
    3. Slowly move the engine unit away from engine compartment.
  37. Remove the engine mounting from the engine unit.
  38. Set the engine unit on the engine stand, etc. and remove the lifting device and wire ropes. Ref. to MECHANICAL (H4DO)>PREPARATION FOR OVERHAUL>PROCEDURE .
  39. Remove the ST1 and ST2 from the engine unit.
    G16761042Courtesy of SUBARU OF AMERICA, INC.