Subaru Legacy (2005 year). Service manual — part 390

ME(H6DO)-35

MECHANICAL

Engine Assembly

15) Place the power steering pump onto right side
wheel apron.

16) Lift-up the vehicle.
17) Remove the under cover.
18) Remove the front exhaust pipe.
<Ref. to EX(H6DO)-4, REMOVAL, Front Exhaust
Pipe.>

NOTE:
Be careful not to let the front exhaust pipe interfere
with water pipes on engine side.
19) Remove the ground cable.

20) Remove the bolts and nuts which hold lower
side of transmission to engine.

21) Remove the nuts which install front cushion
rubber onto front crossmember.

22) Lower the vehicle.
23) Separate the clutch release fork from the re-
lease bearing. (MT model)

(1) Remove the clutch operating cylinder from
the transmission.
(2) Remove the plug using 10 mm hexagon
wrench.

(A) Cloth

(A)

ME-00483

ME-02027

ME-00484

ME-00485

ME-00042

ME(H6DO)-36

MECHANICAL

Engine Assembly

(3) Screw the 6 mm dia. bolt into release fork
shaft, and remove it.

(4) Raise the release fork, and then unfasten
the release bearing tabs to remove release fork.

NOTE:
Step (4) is required to prevent interference with en-
gine when removing the engine from transmission.
24) Separate the torque converter clutch from drive
plate. (AT model)

(1) Lower the vehicle.
(2) Remove the service hole plug (A).
(3) Remove the bolts which hold torque con-
verter clutch to drive plate.

(4) Remove other bolts while rotating the en-
gine using socket wrench.

25) Remove the pitching stopper.

26) Disconnect the fuel delivery hose and evapora-
tion hose.

CAUTION:
• Collect fuel from the hose into container.
• Disconnect the hose with its end wrapped
with cloth to prevent fuel from splashing.

27) Support the engine with a lifting device and
wire ropes.

(A) Release fork shaft

(B) Bolt

ME-00043

(B)

(A)

(A)

ME-02445

ME-02446

FU-02116

ME(H6DO)-37

MECHANICAL

Engine Assembly

28) Support the transmission with a garage jack.

CAUTION:
Doing this is very important because the trans-
mission lowers for its own weight. This work is
also of great importance for facilitating reinstal-
lation.

CAUTION:
Before removing the engine away from trans-
mission, check to be sure no work has been
overlooked.
29) Separation of engine and transmission:

(1) Remove the starter. <Ref. to SC(H4SO 2.0)-
6, REMOVAL, Starter.>
(2) Remove the bolts which hold upper side of
transmission to engine.

NOTE:
Tighten the bolt (A) as shown in the figure together
with starter. (MT model)

30) Install the ST to converter case. (AT model)
ST

498277200

STOPPER SET

31) Remove the engine from vehicle.

(1) Slightly raise the engine.
(2) Raise the transmission with garage jack.
(3) Move the engine horizontally until main
shaft is withdrawn from clutch cover.
(4) Slowly move the engine away from engine
compartment.

NOTE:
Be careful not to damage adjacent parts or body
panels with crank pulley, oil level gauge, etc.
32) Remove the front cushion rubbers.

B: INSTALLATION

1) Install the clutch release fork and bearing onto
the transmission. (MT model)

(1) Remove the release bearing from clutch
cover with a flat tip screwdriver.

(2) Install the release bearing onto transmis-
sion.

(A) Transmission

(B) Garage jack

(A)

(B)

ME-00490

ME-02627

(A)

ST

ME-00492

ME-00051

ME(H6DO)-38

MECHANICAL

Engine Assembly

(3) Install the release fork into release bearing
tab.

(4) Apply grease to the specified points.
• Spline: FX2200
• Shaft: SUNLIGHT 2 (Part No. 003602010)

(5) Insert the release fork shaft into release
fork.

CAUTION:
Make sure the cutout portion of release fork
shaft contacts spring pin.

(6) Tighten the plug.

Tightening torque:

44 N

⋅

m (4.5 kgf-m, 32.5 ft-lb)

2) Install the front cushion rubbers to engine.

Tightening torque:

35 N

⋅

m (3.6 kgf-m, 25.8 ft-lb)

3) Install the engine to transmission.

(1) 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 pressure gauge, etc.

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

(A) Release fork

(B) Release bearing

(A) Spline (FX2200)

(B) Shaft (SUNLIGHT 2)

ME-02591

(A)

(B)

CL-00304

(A)

(B)

(A) Release fork

(B) Release fork shaft

(C) Spring pin

ME-00054

(A)

(B)

(C)

ME-02592