Subaru Legacy III (2000-2003 year). Manual - part 418

ME(H4DOSTC)-36

MECHANICAL

ENGINE ASSEMBLY

(4) Apply grease to the specified points.

• Spline FX2200
• Shaft SUNLIGHT 2

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

NOTE:
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:

34 N·m (3.5 kgf-m, 25.3 ft-lb)

3) Install the engine onto transmission.

(1) Position the engine in engine compartment,
and then align it with the transmission.

NOTE:
Be careful not to damage the adjacent parts or
body panels with crank pulley, oil pressure gauge,
etc.

(2) Apply a small amount of grease to the
splines of mainshaft. (MT vehicles)

4) Tighten the bolts which hold right upper side of
transmission to engine.

Tightening torque:

50 N·m (5.1 kgf-m, 36.9 ft-lb)

5) Remove the lifting device and wire ropes.

(A) Spline (FX2200)

(B) Shaft (SUNLIGHT 2)

(A) Release fork

(B) Release shaft

(C) Spring pin

( A )

( B )

ME-00053

( A )

( B )

( C )

ME-00054

ME-00055

ME-00050

ME(H4DOSTC)-37

MECHANICAL

ENGINE ASSEMBLY

6) Remove the garage jack.

7) Install the pitching stopper.

Tightening torque:

T1: 50 N·m (5.1 kgf-m, 37 ft-lb)
T2: 58 N·m (5.9 kgf-m, 43 ft-lb)

8) Remove the ST from torque converter clutch
case. (AT vehicles)

NOTE:
Be careful not to drop the ST into torque converter
clutch case when removing ST.
ST

498277200

STOPPER SET

9) Install the starter. 

<Ref. to SC(H4DOSTC)-6, 

IN-

STALLATION, Starter.>
10) Install the torque converter clutch onto drive
plate. (AT vehicles)

(1) Tighten the bolts which hold torque convert-
er clutch to drive plate.
(2) Tighten other bolts while rotating the engine
by using ST.

NOTE:
Be careful not to drop bolts into the torque convert-
er clutch housing.
ST

499977300

CRANK PULLEY WRENCH

Tightening torque:

25 N·m (2.5 kgf-m, 18.1 ft-lb)

(3) Clog the service hole with plug.

11) Install the fuel filter and bracket.

12) Install the power steering pump on bracket.

(1) Install the power steering tank on bracket.

(2) Install the power steering pump.

Tightening torque:

20.1 N·m (2.05 kgf-m, 14.8 ft-lb)

ME-00047

T1

T2

MT-00085

ME-00044

ME-00046

ME-00038

ME-00037

ME(H4DOSTC)-38

MECHANICAL

ENGINE ASSEMBLY

(3) Install the power steering pipe bracket on
right side intake manifold.

(4) Connect the power steering switch connec-
tor.

(5) Install the front side V-belt, and adjust it.
<Ref. to ME(H4DOSTC)-42, INSTALLATION,
V-belt.>

13) Lift-up the vehicle.
14) Tighten the nuts which hold lower side of trans-
mission to engine.

Tightening torque:

50 N·m (5.1 kgf-m, 36.9 ft-lb)

15) Tighten the nuts which install front cushion rub-
ber onto crossmember.

Tightening torque:

83 N·m (8.5 kgf-m, 61 ft-lb)

NOTE:
Make sure the front cushion rubber mounting bolts
(A) and locator (B) are securely installed.

16) Install the ATF cooler pipe to frame. (AT vehi-
cles)
17) Install the center exhaust pipe.

<Ref. to EX(H4DOSTC)-8, 

INSTALLATION, Center

Exhaust Pipe.>
18) Lower the vehicle.
19) Connect the following hoses:

(1) Fuel delivery hose, return hose and evapo-
ration hose
(2) Heater inlet and outlet hoses
(3) Brake booster vacuum hose

20) Connect the following connectors and termi-
nals:

(1) Engine ground terminal
(2) Engine harness connectors
(3) Generator connector and terminal
(4) A/C compressor connectors

21) Connect the following cables:

(1) Accelerator cable
(2) Clutch release spring

22) After connecting each cable, adjust them.
23) Install the air intake system.

(1) Install the intercooler. 

<Ref. to

IN(H4DOSTC)-14, 

INSTALLATION, Intercool-

er.>
(2) Install the air cleaner element and air clean-
er upper cover.
(3) Install the engine harness connector brack-
et.
(4) Install the filler hose to air cleaner case.

ME-00631

ME-00035

ME-00040

ME-00056

( A )

( B )

( A )

( B )

ME(H4DOSTC)-39

MECHANICAL

ENGINE ASSEMBLY

24) Install the A/C pressure hoses.

NOTE:
Use new O-rings.

Tightening torque:

25 N·m (2.5 kgf-m, 18.1 ft-lb)

25) Install the radiator. <Ref. to CO(H4DOSTC)-
24, INSTALLATION, Radiator.>
26) Install the coolant filler tank. <Ref. to
CO(H4DOSTC)-33, INSTALLATION, Coolant Filler
Tank.>
27) Install the window washer tank.
28) Install the battery in the vehicle, and connect
cables.
29) Fill coolant. <Ref. to CO(H4DOSTC)-15, FILL-
ING OF ENGINE COOLANT, REPLACEMENT,
Engine Coolant.>
30) Charge the A/C system with refrigerant. <Ref.
to AC-24, OPERATION, Refrigerant Charging Pro-
cedure.>
31) Remove the front hood stay, and close the front
hood.
32) Take off the vehicle from lift arms.

ME-00625