LEMON Manuals: Even more car manuals for everyone
Home >> Audi >> 2010 >> S4 Automatic DCT >> Repair and Diagnosis >> External Pages >> Different car >> Section 195 (Engine Mechanical (H4DO)) >> Engine Assembly >> Installation

Engine Assembly: Installation

WARNING: This page is about a different car, the 2012 Subaru Forester. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the engine mounting onto the engine.

    Tightening torque: 35 N.m (3.6 kgf-m, 25.8 ft-lb) 

  2. Apply a small amount of grease to splines of main shaft. (MT model)

    Grease: NICHIMOLY N-130 or equivalent 

  3. Position the engine in engine compartment and align it with transmission.
    NOTE: Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc.
  4. Tighten the bolts which hold upper side of transmission to engine.

    Tightening torque: 50 N.m (5.1 kgf-m, 36.9 ft-lb) 

    • AT model
      Fig 1: Locating Upper Side Of Transmission Gasket Bolts (AT Model)
      G07669282Courtesy of SUBARU OF AMERICA, INC.
    • MT model
      Fig 2: Locating Upper Side Of Transmission Gasket Bolts (MT Model)
      G07669283Courtesy of SUBARU OF AMERICA, INC.
  5. Remove the lifting device and wire ropes.
    Fig 3: Removing Lifting Device And Wire Ropes
    G07669284Courtesy of SUBARU OF AMERICA, INC.
  6. Remove the garage jack.
  7. Install the pitching stopper.

    Tightening torque: 

    T1: 50 N.m (5.1 kgf-m, 36.9 ft-lb) 

    T2: 58 N.m (5.9 kgf-m, 42.8 ft-lb) 

    Fig 4: Identifying Pitching Stopper Bolt And Nut
    G07669285Courtesy of SUBARU OF AMERICA, INC.
  8. Remove the ST from torque converter clutch case. (AT model)
    NOTE: Be careful not to drop the ST into the torque converter clutch case when removing the ST.

    ST 498277200 STOPPER SET

    Fig 5: Removing ST From Torque Converter Clutch Case (AT Model)
    G07669286Courtesy of SUBARU OF AMERICA, INC.
  9. Install the starter. < refer to INSTALLATION , Starter >
  10. Install the torque converter clutch to drive plate. (AT model)
    1. Insert the wrench into the crank pulley bolt and rotate the crank pulley to install the bolts which hold torque converter clutch to drive plate.
      NOTE: Be careful not to drop bolts into the torque converter clutch case.

      Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb) 

      Fig 6: Installing Torque Converter Clutch From Drive Plate (AT Model)
      G07669287Courtesy of SUBARU OF AMERICA, INC.
    2. Fit the plug to service hole.
  11. Install the power steering pump.
    1. Install the power steering pump onto the engine.

      Tightening torque: 

      Refer to "COMPONENT" of "Power Steering" for the tightening torque.  < refer to COMPONENT , General Description >

      Fig 7: Locating Engine Power Steering Pump Bolts
      G07669288Courtesy of SUBARU OF AMERICA, INC.
    2. Connect the connector to the power steering pump switch.
      Fig 8: Locating Power Steering Pump Switch Connector
      G07669289Courtesy of SUBARU OF AMERICA, INC.
    3. Install the generator. < refer to INSTALLATION , Generator >
    4. Install the V-belts. < refer to INSTALLATION , V-belt >
  12. Lift up the vehicle.
  13. Install the bolts and nuts which hold lower side of the transmission to engine.

    Tightening torque: 50 N.m (5.1 kgf-m, 36.9 ft-lb) 

    • AT model
      Fig 9: Locating Lower Side Of Transmission Gasket Bolts And Nuts (AT Model)
      G07669290Courtesy of SUBARU OF AMERICA, INC.
    • MT model
      Fig 10: Locating Lower Side Of Transmission Gasket Bolts And Nuts (MT Model)
      G07669291Courtesy of SUBARU OF AMERICA, INC.
  14. Install the nuts which hold the engine mounting to the crossmember.

    Tightening torque: 85 N.m (8.7 kgf-m, 62.7 ft-lb) 

    Fig 11: Locating Front Crossmember Engine Mounting Nuts
    G07669292Courtesy of SUBARU OF AMERICA, INC.
  15. Connect the ground cable.

    Tightening torque: 7.5 N.m (0.8 kgf-m, 5.5 ft-lb) 

    Fig 12: Locating Ground Cable Bolts
    G07669293Courtesy of SUBARU OF AMERICA, INC.
  16. Install the front exhaust pipe. < refer to INSTALLATION , Front Exhaust Pipe >
  17. Lower the vehicle.
  18. Connect the following hoses.
    1. Fuel delivery hose and evaporation hose
    2. Heater inlet hose and heater outlet hose
    3. Brake booster vacuum hose
    4. A/C pressure hose < refer to INSTALLATION , Hose and Pipe >
  19. Place the generator code and install the generator cord to the clip (D).
  20. Connect connector (A) and terminal (B) to the generator, and connect connector (C) to A/C compressor.

    Tightening torque: 15 N.m (1.5 kgf-m, 11.1 ft-lb) 

    Fig 13: Identifying Clip, A/C Compressor Connector, Generator Connector And Terminal
    G07669294Courtesy of SUBARU OF AMERICA, INC.
  21. Install the generator cord stay to the chain cover.
    NOTE: Install the generator cord stay so that the folded end (A) touches at the chain cover boss.

    Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 

    Fig 14: Locating Generator Cord Stay Bolt
    G07669295Courtesy of SUBARU OF AMERICA, INC.
  22. Connect the engine harness connector.
    1. Connect the bulkhead harness connector to the engine harness connector (black) and engine harness connector (brown).
      Fig 15: Locating Bulkhead Harness Connector And Engine Harness Connector
      G07669296Courtesy of SUBARU OF AMERICA, INC.
    2. Install the bolt which secures the bulkhead harness connector bracket.

      Tightening torque: 7.5 N.m (0.8 kgf-m, 5.5 ft-lb) 

      Fig 16: Locating Bulkhead Harness Connector Bracket Bolt
      G07669297Courtesy of SUBARU OF AMERICA, INC.
  23. Install the radiator. < refer to INSTALLATION , Radiator >
  24. Install the air intake case (rear).
    Fig 17: Locating Air Cleaner Case Clamps (Rear)
    G07669298Courtesy of SUBARU OF AMERICA, INC.
  25. Install the clip (B) which secures the mass air flow and intake air temperature sensor harness, and connect the connector (A) to the mass air flow and intake air temperature sensor.
  26. Install the suction hose (C) to the air cleaner case (rear).
    Fig 18: Identifying Air Cleaner Case Suction Hose, Clip, Mass Air Flow And Intake Air Temperature Sensor Connector
    G07669299Courtesy of SUBARU OF AMERICA, INC.
  27. Install the air intake boot. < refer to INSTALLATION , Air Intake Boot >
  28. Install the air intake duct (rear). < refer to INSTALLATION , Air Intake Duct >
  29. Install the battery. < refer to INSTALLATION , Battery >
  30. Fill engine coolant. < refer to FILLING OF ENGINE COOLANT , REPLACEMENT, Engine Coolant >
  31. Check the ATF level and replenish it if necessary. (AT model) < refer to INSPECTION , Automatic Transmission Fluid >
  32. Charge the A/C system with refrigerant. < refer to PROCEDURE , Refrigerant Charging Procedure >
  33. Install the V-belt cover.

    Tightening torque: 13 N.m (1.3 kgf-m, 9.6 ft-lb) 

    Fig 19: Locating V-Belt Cover Bolt
    G07669300Courtesy of SUBARU OF AMERICA, INC.
  34. Change the bolt installation position from (B) to (A), then close the front hood.

    Tightening torque: 7.5 N.m (0.8 kgf-m, 5.5 ft-lb) 

    Fig 20: Identifying Front Hood Bolts Installation Position
    G07669301Courtesy of SUBARU OF AMERICA, INC.
scientia non olet · About LEMON Manuals