Engine Assembly: Removal

WARNING: This page is about a different car, the 2004 Subaru Outback, 2004 Subaru Legacy, and 2004 Subaru Baja. However, it is still accessible from the selected car via links, so may be relevant.

Set the vehicle on lift arms.
Open front hood fully and support with stay.
Raise rear seat, and turn floor mat up.
Release fuel pressure. Refer to RELEASING OF FUEL PRESSURE , OPERATION, Fuel.
Remove filler cap.
Collect refrigerant, and remove pressure hoses. (With A/C) Refer to REMOVAL , Flexible Hose.
Disconnect battery ground cable.

Fig 1: Disconnecting Battery Ground Cable
Courtesy of SUBARU OF AMERICA, INC.
Remove air intake duct and air cleaner case. Refer to REMOVAL , Air Intake Duct and REMOVAL , Air Cleaner Case.
Remove under cover.
Remove radiator from vehicle. Refer to REMOVAL , Radiator.
Remove ATF cooler pipe from body, Refer to REMOVAL , ATF Cooler Pipe and Hose.
Remove air cleaner case stay.
- MT model
  
  Fig 2: Removing Air Cleaner Case Stay (MT Model)
  Courtesy of SUBARU OF AMERICA, INC.
- AT model
  
  Fig 3: Removing Air Cleaner Case Stay (AT Model)
  Courtesy of SUBARU OF AMERICA, INC.
Disconnect the following connectors and cables.
1. Engine ground terminal
  
  Fig 4: Disconnecting Engine Ground Terminal
  Courtesy of SUBARU OF AMERICA, INC.
2. Engine harness connectors
  
  Fig 5: Disconnecting Engine Harness Connector
  Courtesy of SUBARU OF AMERICA, INC.
3. Alternator connector, terminal and A/C compressor connector
  
  Fig 6: Identifying Alternator Connector, Terminal & A/C Compressor Connector
  Courtesy of SUBARU OF AMERICA, INC.
4. Accelerator cable and cruise control cable
  
  Fig 7: Identifying Accelerator Cable & Cruise Control Cable
  Courtesy of SUBARU OF AMERICA, INC.
5. Pressure switch
  
  Fig 8: Identifying Pressure Switch
  Courtesy of SUBARU OF AMERICA, INC.
Disconnect the following hoses.
1. Brake booster vacuum hose
  
  Fig 9: Disconnecting Brake Booster Vacuum Hoses
  Courtesy of SUBARU OF AMERICA, INC.
2. Heater inlet/outlet hose
  
  Fig 10: Disconnecting Heater Inlet/Outlet Hose
  Courtesy of SUBARU OF AMERICA, INC.
Remove power steering pump from bracket.
1. Remove resonator chamber (Except U5).
  
  Fig 11: Removing Resonator Chamber
  Courtesy of SUBARU OF AMERICA, INC.
2. Loosen lock bolt and slider bolt, and remove front side V-belt. Refer to REMOVAL , V-BELT.
3. Remove pipe with bracket.
  
  Fig 12: Removing Pipe With Bracket
  Courtesy of SUBARU OF AMERICA, INC.
4. Remove bolts which install power steering pump bracket.
  
  Fig 13: Removing Power Steering Pump Bracket Bolts
  Courtesy of SUBARU OF AMERICA, INC.
5. Remove power steering tank from the bracket by pulling it upward.
  
  Fig 14: Removing Power Steering Tank From Bracket
  Courtesy of SUBARU OF AMERICA, INC.
6. Place power steering pump on the right side wheel apron.
  
  Fig 15: Placing Power Steering Pump On Right Side Of Wheel Apron
  Courtesy of SUBARU OF AMERICA, INC.
Remove front and center exhaust pipe. Refer to REMOVAL , Front Exhaust Pipe and REMOVAL , Center Exhaust Pipe.
Remove nuts which hold lower side of transmission to engine.

Fig 16: Removing Nuts Holding Lower Side Of Transmission
Courtesy of SUBARU OF AMERICA, INC.
Remove nuts which install front cushion rubber onto front crossmember.

Fig 17: Removing Front Cushion Rubber Nuts
Courtesy of SUBARU OF AMERICA, INC.
Separate torque converter clutch from drive plate. (AT model)
1. Lower the vehicle.
2. Remove service hole plug.
3. Remove bolts which hold torque converter clutch to drive plate.
4. Remove other bolts while rotating the crankshaft pulley using ST.
  ST 499977100 CRANK PULLEY WRENCH
Fig 18: Separating Torque Converter Clutch From Drive Plate (AT Model)
Courtesy of SUBARU OF AMERICA, INC.
Remove pitching stopper.

Fig 19: Removing Pitching Stopper
Courtesy of SUBARU OF AMERICA, INC.
Disconnect fuel delivery hose, return hose and evaporation hose.
CAUTION:
- Disconnect hose with its end wrapped with cloth to prevent fuel from splashing.
- Catch fuel from hose into container.
Fig 20: Disconnecting Fuel Delivery Hose, Return Hose & Evaporation Hose
Courtesy of SUBARU OF AMERICA, INC.
Support engine with a lifting device and wire ropes.

Fig 21: Supporting Engine With Lifting Device & Wire Ropes
Courtesy of SUBARU OF AMERICA, INC.
Support transmission with a garage jack.
CAUTION: Before moving engine away from transmission, check to be sure no work has been overlooked. Doing this is very important in order to facilitate re-installation and because transmission lowers under its own weight.

Fig 22: Supporting Transmission With Garage Jack
Courtesy of SUBARU OF AMERICA, INC.
Separation of engine and transmission.
1. Remove starter. Refer to REMOVAL , Starter.
2. Remove bolts which hold upper side of transmission to engine.
Fig 23: Removing Bolts Holding Upper Side Of Transmission
Courtesy of SUBARU OF AMERICA, INC.
Install ST to torque converter clutch case. (AT model)
ST 498277200 STOPPER SET

Fig 24: Installing ST To Torque Converter Clutch Case (AT Model)
Courtesy of SUBARU OF AMERICA, INC.
Remove engine from vehicle.
1. Slightly raise engine.
2. Raise transmission with garage jack.
3. Move engine horizontally until main shaft is withdrawn from clutch cover.
4. Slowly move engine away from engine room.
CAUTION: Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc.

Fig 25: Removing Engine From Vehicle
Courtesy of SUBARU OF AMERICA, INC.
Remove front cushion rubbers.