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Home >> Subaru >> 2019 >> BRZ Limited, Automatic Trans >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical System >> Partial Engine ASSY (FA20) >> Removal

Partial Engine ASSY (FA20): Removal

  1. Hood SUB-ASSY set
    G12586613Courtesy of SUBARU OF AMERICA, INC.
    1. Change the hood stay position from A to B in order to support the hood SUB-ASSY at the position B.
  2. Refrigerant draining (Refer to ADJUSTMENT )
  3. Fuel spill prevention procedure (Refer to FUEL SYSTEM (FA20) )
  4. Disconnection of the battery ground terminal (Refer to WORKING PRECAUTIONS AND NOTES )
  5. Front strut tower bar LH removal (Refer to REMOVAL )
  6. Removal of flexible V-shaped bar LH (tS model) (Refer to REMOVAL )
  7. Front strut tower bar RH removal (Refer to REMOVAL )
  8. Removal of flexible V-shaped bar RH (tS model) (Refer to REMOVAL )
  9. Air cleaner case SUB-ASSY removal
    1. Disconnect the hose from the chamber ASSY.
      G12586614Courtesy of SUBARU OF AMERICA, INC.
    2. Remove the two bolts and remove the chamber ASSY.
      G12586615Courtesy of SUBARU OF AMERICA, INC.
    3. Move the hose clip and disconnect the ventilation hose NO. 2.
      G12586616Courtesy of SUBARU OF AMERICA, INC.
    4. Release the clamp and disconnect the wiring harness from the air cleaner cap.
    5. Disconnect the connector from the intake air flow meter SUB-ASSY.
      G12586617Courtesy of SUBARU OF AMERICA, INC.
    6. Loosen the hose clamp.
      G12586618Courtesy of SUBARU OF AMERICA, INC.
    7. Remove the three bolts and remove the air cleaner case SUB-ASSY.
      G12586619Courtesy of SUBARU OF AMERICA, INC.
    8. Remove the bolt and remove the stay.
      G12586620Courtesy of SUBARU OF AMERICA, INC.
  10. Engine oil draining
    1. Remove the oil filler cap.
    2. Remove the oil pan drain plug and gasket.
    3. After draining the oil, install the oil pan drain plug with a new gasket.

      Standard value: T=41. 7N. m {425kgf. cm} {30. 8ft. lbf}

  11. Draining of coolant (SUBARU Super Coolant) (Refer to COOLANT (FA20) )
  12. Removal of radiator reservoir tank ASSY (Refer to INSTALLATION )
  13. Removal of water filler SUB-ASSY
    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.
    G12586621Courtesy of SUBARU OF AMERICA, INC.
  14. Removal of injector driver (Refer to INJECTOR DRIVER (FA20) )
  15. DISCONNECT ENGINE WIRE
    NOTE: Fix the disconnected harness components with tape to keep them out of the way.
    1. Remove the 2 bolts and wire harness clamp bracket from the No. 2 engine hanger.
      G11258579Courtesy of SUBARU OF AMERICA, INC.
    2. Release the lock of connector (A) and disconnect the connector.
    3. Disconnect the connector (B).
      G12586623Courtesy of SUBARU OF AMERICA, INC.
    4. Disconnect the connector.
      G11258581Courtesy of SUBARU OF AMERICA, INC.
    5. Remove the connector from the engine hanger No. 2.
      G11258582Courtesy of SUBARU OF AMERICA, INC.
    6. Disconnect the 2 wire harness clamps.
      G12586626Courtesy of SUBARU OF AMERICA, INC.
    7. for Automatic Transmission.
      1. Release the lock of connector (A) and disconnect the connector.
      2. Disconnect the connector (B).
        G12586627Courtesy of SUBARU OF AMERICA, INC.
      3. Slide the connector in the direction shown in the illustration, and disconnect the wire harness.
        G11258585Courtesy of SUBARU OF AMERICA, INC.
      4. Disconnect the 4 wire harness clamps.
      5. Remove the bolt and wire harness clamp bracket.
    8. Disconnect the terminal cap.
      G11258586Courtesy of SUBARU OF AMERICA, INC.
    9. Remove the nut and disconnect the wire harness from terminal B.
    10. Disconnect the generator connector and disengage the clamp.
  16. Removal of alternator cover (Refer to REMOVAL )
  17. Removal of A/C cover (Refer to REMOVAL )
  18. Removal of V-belt (Refer to REMOVAL )
  19. Removal of engine cover SUB-ASSY No. 1 (transmission A/T) (Refer to DISASSEMBLY )
  20. Removal of flywheel housing under cover (transmission A/T)
    1. Remove the flywheel housing under cover.
    G12586630Courtesy of SUBARU OF AMERICA, INC.
    G10213249Courtesy of SUBARU OF AMERICA, INC.
  21. Removal of drive plate and torque converter setting bolt (transmission A/T)
    1. Use the SST to secure the crankshaft pulley.

      SST 18355AA000, 18334AA000

      G12586632Courtesy of SUBARU OF AMERICA, INC.
      G12586633Courtesy of SUBARU OF AMERICA, INC.
    2. Remove the six drive plate & torque converter setting bolts through the service hole.
    G12586634Courtesy of SUBARU OF AMERICA, INC.
  22. Vacuum tube connector hose disconnection (transmission A/T)
    1. Move the clamp and disconnect the vacuum tube connector hose from the vacuum pump ASSY.
      G12586635Courtesy of SUBARU OF AMERICA, INC.
    2. Remove the 2 bolts and disconnect the vacuum tube connector hose.
    3. Loosen the hose clamp and remove the vacuum tube connector hose.
    G11258373Courtesy of SUBARU OF AMERICA, INC.
  23. 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.
  24. Removal of exhaust manifold (Refer to REMOVAL )
  25. Exhaust pipe SUB-ASSY FR fixation (transmission M/T)
    1. Tie the exhaust pipe SUB-ASSY FR to the front suspension cross-member SUB-ASSY with the rope.
      NOTE: This operation is required to avoid dropping the exhaust pipe SUB-ASSY FR.
    G12586637Courtesy of SUBARU OF AMERICA, INC.
  26. Heater water hose disconnection
    1. Move the two hose clamps and disconnect the two heater water hoses.
    G12586638Courtesy of SUBARU OF AMERICA, INC.
    G12586639Courtesy of SUBARU OF AMERICA, INC.
  27. Transmission oil cooler hose NO. 3 disconnection (transmission A/T)
    1. Move the hose clamp and disconnect the transmission oil cooler hose NO. 3.
    G12586640Courtesy of SUBARU OF AMERICA, INC.
  28. Transmission oil cooler hose NO. 1 disconnection (transmission A/T)
    1. Move the hose clamp and disconnect the transmission oil cooler hose NO. 1.
    G12586641Courtesy of SUBARU OF AMERICA, INC.
  29. Radiator outlet hose disconnection
    1. Move the hose clamp and disconnect the radiator outlet hose.
    G12586642Courtesy of SUBARU OF AMERICA, INC.
  30. 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.
      G11258600Courtesy of SUBARU OF AMERICA, INC.
    3. Remove bolts and turn the hook type connector in the direction of the arrow 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 the disconnected suction hose SUB-ASSY and the unit to prevent entry of dirt or moisture.
  31. Cooler refrigerant discharge hose NO. 1 disconnection (Refer to REMOVAL )
  32. Removal of starter ASSY (Refer to REMOVAL )
    G08554235Courtesy of SUBARU OF AMERICA, INC.
  33. SST installation (transmission A/T)
    1. Attach the SST to the starter hole of torque converter clutch case.

      SST 18750AA010

    G12586645Courtesy of SUBARU OF AMERICA, INC.
  34. Ground cable disconnection
    1. Remove the two bolts and remove the two ground cables.
    G12586646Courtesy of SUBARU OF AMERICA, INC.
  35. Under cover rear LH (with under cover rear LH)
    1. Remove 3 bolts and 8 clips to remove the under cover rear LH.
  36. Removal of stabilizer bar FR (transmission A/T) (Refer to REMOVAL )
    G12586647Courtesy of SUBARU OF AMERICA, INC.
  37. Exhaust pipe SUB-ASSY FR fixation (transmission A/T)
    1. Tie the exhaust pipe SUB-ASSY FR to the front suspension cross-member SUB-ASSY with the rope.
      NOTE: This operation is required to avoid dropping the exhaust pipe SUB-ASSY FR.
    G12586648Courtesy of SUBARU OF AMERICA, INC.
  38. Automatic transmission ASSY disconnection (transmission A/T)
    1. Remove the three bolts A and two nuts.
    G12586649Courtesy of SUBARU OF AMERICA, INC.
    CAUTION: Do not remove the bolt B to prevent the ASSY from falling off.
  39. Manual transmission ASSY removal (transmission M/T)
    1. Remove the three bolts A and two nuts.
    CAUTION: Do not remove the bolt B to prevent the ASSY from falling off.
  40. Disconnection of front crossmember SUB-ASSY
    1. Remove the two nuts of front crossmember SUB-ASSY.
    G12586650Courtesy of SUBARU OF AMERICA, INC.
    G12586651Courtesy of SUBARU OF AMERICA, INC.
  41. SEPARATE FUEL HOSE
    1. Put alignment marks on the fuel hoses No. 1 and No. 2.
    2. Using SST, disconnect the fuel hose NO. 1 and fuel hose NO. 2 from the fuel pipe (See FUEL SYSTEM (FA20) ).

      SST 42099AE000

      G08552525Courtesy of SUBARU OF AMERICA, INC.
    3. Remove the clamp and disconnect the purge hose from the fuel pipe.
  42. Engine hanger installation
    1. Install the engine hanger NO. 1 to the position as shown in the figure.

      SST 12281-38150, 90119-14120

      Standard value: T=43N. m {439kgf. cm} {31. 7ft. lbf}

    2. Support the engine with an engine sling device and lifter.
    G12586653Courtesy of SUBARU OF AMERICA, INC.
    G08554246Courtesy of SUBARU OF AMERICA, INC.
  43. 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.
      G12586655Courtesy of SUBARU OF AMERICA, INC.
      CAUTION: Support the transmission ASSY until the installation of partial engine ASSY is completed.
    G12586656Courtesy of SUBARU OF AMERICA, INC.
  44. 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.
  45. Engine ASSY removal
    1. Remove the connecting bolt of transmission ASSY.
      G12586657Courtesy of SUBARU OF AMERICA, INC.
    2. Suspend the partial engine ASSY with an engine sling device and mini-crane.
  46. Removal of drive plate & ring gear SUB-ASSY (transmission A/T) (Refer to REMOVAL )
  47. Clutch cover ASSY removal (transmission M/T) (Refer to REMOVAL )
  48. Clutch disc ASSY removal (transmission M/T) (Refer to REMOVAL )
  49. Flywheel SUB-ASSY removal (transmission M/T) (Refer to REMOVAL )
  50. Crank angle sensor plate removal (Refer to REMOVAL )
  51. Engine stand installation
    G11258615Courtesy of SUBARU OF AMERICA, INC.
    1. Use the sections shown in the figure to 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.
      • To prevent damage to the engine, make sure to secure at four positions.
    G12586659Courtesy of SUBARU OF AMERICA, INC.
  52. Engine mounting insulator FR removal
    1. Remove the four bolts and remove the two engine mounting insulators FR.
  53. Engine hanger removal
    1. Remove the bolt and remove the engine hanger.
  54. Removal of alternator ASSY (Refer to REMOVAL )
  55. Idler pulley SUB-ASSY NO. 2 removal (Refer to DISASSEMBLY )
  56. Oil level gauge guide removal (Refer to DISASSEMBLY )
  57. V-ribbed belt tensioner ASSY removal (Refer to DISASSEMBLY )
  58. Removal of compressor ASSY (with magnet clutch) (Refer to REMOVAL )
  59. Removal of intake manifold (Refer to REMOVAL )
  60. Fuel delivery pipe NO. 2 removal (Refer to REMOVAL )
  61. Fuel delivery pipe removal (Refer to REMOVAL )
  62. Removal of fuel delivery pipe (bank 2 side) (Refer to REMOVAL )
  63. Removal of fuel delivery pipe (bank 1 side) (Refer to REMOVAL )
  64. Fuel injector ASSY removal (Refer to REMOVAL )
  65. Fuel injector seal removal (Refer to REMOVAL )
  66. Removal of fuel pump ASSY (Refer to REMOVAL )
  67. Fuel pump lifter removal (Refer to REMOVAL )
  68. Pump drive case ASSY removal (Refer to REMOVAL )
    G12586660Courtesy of SUBARU OF AMERICA, INC.
  69. Engine wiring removal
    1. Remove the two bolts and disconnect the engine wiring.
    2. Disconnect each connector and clamp to remove the engine wiring.
    G12586661Courtesy of SUBARU OF AMERICA, INC.
  70. Ventilation hose NO. 2 removal
    1. Move the hose clamp and remove the ventilation hose NO. 2.
    G08554266Courtesy of SUBARU OF AMERICA, INC.
  71. PCV hose connector removal
    1. Remove the three bolts and remove the PCV hose connector.
    2. Move the hose clamp and disconnect the water by-pass hose NO. 1 from the water pipe ASSY.
    3. Move the hose clamp and remove the water by-pass hose NO. 1 from the PCV hose connector.
      G12586663Courtesy of SUBARU OF AMERICA, INC.
    4. Remove the two O-rings from the PCV hose connector.
    G12586664Courtesy of SUBARU OF AMERICA, INC.
  72. Water by-pass hose NO. 2 removal
    1. Move the hose clamp and remove the water by-pass hose NO. 2.
  73. Transmission oil cooler hose NO. 3 removal (transmission A/T)
    1. Move the hose clamp and remove the transmission oil cooler hose NO. 3.
  74. Water pipe ASSY removal
    1. Move the hose clamp and remove the water by-pass hose NO. 3.
    2. Remove the four bolts, and remove the water pipe ASSY.
      G12586665Courtesy of SUBARU OF AMERICA, INC.
      G12586666Courtesy of SUBARU OF AMERICA, INC.
    3. Remove the two O-rings from the cylinder block (bank 1 side and bank 2 side).
    G12586667Courtesy of SUBARU OF AMERICA, INC.
  75. Water by-pass pipe NO. 1 removal (transmission M/T)
    1. Move the hose clamp and disconnect the water by-pass hose NO. 4.
    2. Remove the two bolts and remove the water by-pass pipe NO. 1.
    G08554272Courtesy of SUBARU OF AMERICA, INC.
  76. Water by-pass pipe NO. 1 removal (transmission A/T)
    1. Move the two hose clamps and disconnect the two water by-pass hoses.
    2. Remove the two bolts and remove the water by-pass pipe NO. 1.
  77. Vacuum pump ASSY removal (transmission A/T) (Refer to REMOVAL )
  78. Cylinder head plate RR removal (transmission M/T)
    1. Remove the three bolts and remove the cylinder head plate RR from the cam carrier RH.
    G12586669Courtesy of SUBARU OF AMERICA, INC.
  79. Removal of knock control sensor (Refer to REMOVAL )
  80. Removal of crankshaft position sensor (Refer to REMOVAL )
  81. PCV valve removal (Refer to PCV VALVE (FA20) )
  82. Idler pulley SUB-ASSY NO. 1 removal (Refer to DISASSEMBLY )
  83. Water pump pulley removal (Refer to REMOVAL )
  84. Engine water pump ASSY removal (Refer to REMOVAL )
  85. Thermostat cover removal (Refer to REMOVAL )
  86. Thermostat removal (Refer to REMOVAL )
  87. Crankshaft pulley removal (Refer to REMOVAL )
  88. Chain cover oil seal removal (Refer to REMOVAL )
  89. Chain cover removal (Refer to DISASSEMBLY )
  90. Removal of timing chain (bank 1 side) (Refer to REMOVAL )
  91. Removal of timing chain (bank 2 side) (Refer to REMOVAL )
  92. Piston and valve damage prevention procedure (Refer to REMOVAL )
  93. Crankshaft sprocket removal
    1. Remove the crankshaft sprocket.
    G12586670Courtesy of SUBARU OF AMERICA, INC.
  94. Removal of ignition coil ASSY (bank 2 side)
    G10213054Courtesy of SUBARU OF AMERICA, INC.
    1. Disconnect 2 connectors for the ignition coil ASSY.
      NOTE: Slide the connectors in the direction of the arrow using a tool such as a clip remover while pressing the spring (a) shown in the figure.
    2. Remove 2 bolts, and remove 2 ignition coil ASSYs.
    G12586672Courtesy of SUBARU OF AMERICA, INC.
  95. Removal of ignition coil ASSY (bank 1 side)
    G10213057Courtesy of SUBARU OF AMERICA, INC.
    1. Disconnect 2 connectors for the ignition coil ASSY.
      NOTE: Slide the connectors in the direction of the arrow using a tool such as a clip remover while pressing the spring (a) shown in the figure.
      G12586674Courtesy of SUBARU OF AMERICA, INC.
    2. Remove 2 bolts, and remove 2 ignition coil ASSYs.
  96. Injector driver bracket removal
    1. Remove the two bolts and remove the injector driver bracket.
    G12586675Courtesy of SUBARU OF AMERICA, INC.
  97. Removal of rocker cover RH
    1. Operate the engine stand, and make the bank 1 side face upward.
    2. Remove the 8 bolts.
      G12586676Courtesy of SUBARU OF AMERICA, INC.
    3. Remove the rocker cover RH using a flat tip screwdriver wrapped with protective tape.
      CAUTION: Do not damage the cam carrier, cam cap and rocker cover.
    4. Remove the rocker cover gasket.
      G12586677Courtesy of SUBARU OF AMERICA, INC.
    5. Remove the two spark plug pipe gaskets.
      CAUTION: When removing the seal gasket using scraper etc., be careful not to damage the cam lobe of camshaft.
  98. Cam carrier RH removal
    CAUTION: Do not remove the intake and exhaust camshafts before removing the cam carrier. Doing so will result in distortion of cam carrier.
    Fig 1: Cam Carrier RH Bolts (Loosening Sequence)
    G12586678Courtesy of SUBARU OF AMERICA, INC.
    1. Loosen the nine bolts equally in the order as shown in the figure and remove them.
    2. Remove the cam carrier RH using a flat tip screwdriver wrapped with protective tape.
      CAUTION: Do not damage the cylinder head and cam carrier.
      G12586679Courtesy of SUBARU OF AMERICA, INC.
    3. Remove the two O-rings and eight roller rocker arm from the cylinder head RH.
      NOTE: The removed parts must be organized by installation location.
      G12586680Courtesy of SUBARU OF AMERICA, INC.
    4. Remove the eight valve shims and eight roller rocker arm pivots from the cylinder head RH.
      NOTE: The removed parts must be organized by installation location.
  99. Cylinder head RH removal (Refer to REMOVAL )
  100. Cylinder head gasket removal (Refer to REMOVAL )
  101. Rocker cover LH removal
    1. Operate the engine stand, and make the bank 2 side face upward.
    2. Remove the 8 bolts.
      G12586681Courtesy of SUBARU OF AMERICA, INC.
    3. Remove the rocker cover LH using a flat tip screwdriver wrapped with protective tape.
      CAUTION: Do not damage the cam carrier, cam cap and rocker cover.
    4. Remove the rocker cover gasket NO. 2.
    5. Remove the two spark plug pipe gaskets.
      CAUTION: When removing the seal gasket using scraper etc., be careful not to damage the cam lobe of camshaft.
    Fig 2: Cam Carrier LH Bolts (Loosening Sequence)
    G12586682Courtesy of SUBARU OF AMERICA, INC.
  102. Cam carrier LH removal
    CAUTION: Do not remove the intake and exhaust camshafts before removing the cam carrier. Doing so will result in distortion of cam carrier.
    1. Loosen the nine bolts equally in the order as shown in the figure and remove them.
      G12586683Courtesy of SUBARU OF AMERICA, INC.
    2. Remove the cam carrier using a flat tip screwdriver wrapped with protective tape.
      CAUTION: Do not damage the cylinder head and cam carrier.
      G12586684Courtesy of SUBARU OF AMERICA, INC.
    3. Remove the two O-rings and eight roller rocker arms from the cylinder head LH.
      NOTE: The removed parts must be organized by installation location.
      G12586685Courtesy of SUBARU OF AMERICA, INC.
    4. Remove the eight valve shims and eight roller rocker arm pivots from the cylinder head LH.
      NOTE: The removed parts must be organized by installation location.
  103. Cylinder head LH removal (Refer to REMOVAL )
  104. Cylinder head gasket NO. 2 removal (Refer to REMOVAL )
  105. Engine hanger NO. 2 removal
    1. Remove the two bolts and remove the engine hanger NO. 2 from the cylinder block (bank 1 side).
    G12586686Courtesy of SUBARU OF AMERICA, INC.
  106. Removal of housing cover
    1. Remove the two bolts and remove the housing cover from the oil pan upper.
    G12586687Courtesy of SUBARU OF AMERICA, INC.
    G12586688Courtesy of SUBARU OF AMERICA, INC.
  107. Oil pan removal
    1. Remove the 11 bolts.
      G12586689Courtesy of SUBARU OF AMERICA, INC.
    2. Remove the oil pan with a oil pan seal cutter.
      CAUTION: Do not damage the installation surface of oil pan upper and the flange portion of oil pan.
      G12586690Courtesy of SUBARU OF AMERICA, INC.
    3. Remove the two seal rings from the oil pan.
    G12586691Courtesy of SUBARU OF AMERICA, INC.
  108. Oil strainer removal
    1. Remove the two bolts and remove the oil strainer.
    2. Remove the O-ring.
    G12586692Courtesy of SUBARU OF AMERICA, INC.
  109. Oil pan upper removal
    1. Remove the 13 bolts.
    2. Remove the oil pan upper using a flat tip screwdriver wrapped with protective tape.
      CAUTION: Do not damage the installation surfaces of cylinder block and oil pan upper.
      G12586693Courtesy of SUBARU OF AMERICA, INC.
    3. Remove the three O-rings from the cylinder block.
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