A/t & M/t Control Systems: Removal & Installation Subaru Outback BR

INSTALLATION

Install in the reverse order of removal.

Note. Insert the solenoid unit terminals to the harness connector.

Scheme 26

REMOVAL

Scheme 27

Scheme 28

Scheme 29

Scheme 30

Scheme 31

Scheme 32

Scheme 33

Scheme 34

Scheme 35

Scheme 36

Scheme 37

Scheme 38

Scheme 39

Scheme 40

Scheme 41

Scheme 42

Scheme 43

1. Set the vehicle on a lift.
2. Disconnect the ground cable from battery.
3. Remove the air intake duct. Non-turbo model Ref. to «REMOVAL»(ref-371894-S28286124812010091900000) , Air Intake Duct. Turbo model Ref. to «REMOVAL»(ref-371895-S27294329222010091900000) , Air Intake Duct.
4. Remove the intercooler and the intercooler stay, (turbo model) Ref. to «REMOVAL»(ref-371895-S26814185912010091900000) , Intercooler.
5. Remove the air intake boot assembly, (non-turbo model) Ref. to «REMOVAL»(ref-371894-S06764648272010091900000) , Air Intake Boot.
6. Remove the throttle body, (non-turbo model) Ref. to «REMOVAL»(ref-371892-S36593103462010091900000) , Throttle Body.
7. Remove the bolt and remove the engine harness connector, (non-turbo model)
8. Remove the engine harness connector from the engine hanger rear, (non-turbo model)
9. Remove the engine hanger rear, (non-turbo model)
10. Install the engine hanger rear for turbo model, (non-turbo model) Part No. 10004AA180 Engine hanger rear Tightening torque: 16 N.m (1.6 kgf-m, 11.8 ft-lb)
11. Lift up the vehicle.
12. Remove the center exhaust pipe and rear exhaust pipe, (non-turbo model) Ref. to «REMOVAL»(ref-371916-S36161192712010091900000) , Center Exhaust Pipe. Ref. to «REMOVAL»(ref-371916-S24336289852010091900000) , Rear Exhaust Pipe.
13. Remove the center exhaust pipe (rear) and rear exhaust pipe, (turbo model) Ref. to «REMOVAL»(ref-371921-S11272465202010091900000) , Center Exhaust Pipe. Ref. to «REMOVAL»(ref-371921-S14593980742010091900000) , Rear Exhaust Pipe.
14. Remove the heat shield cover.
15. Lower the vehicle.
16. Remove the nuts from left and right transmission mounting brackets.
17. Set an engine crane to the vehicle. CAUTION: When lifting the engine, make sure that the lift chain does not contact sensors.
18. Remove the stopper rod.
19. Lift the engine slightly and remove the bolts of engine front mounting.
20. Remove the bolt and nuts of engine front mounting and remove the engine mounting.
21. Temporarily install the ST by using two bolts. ST 41099AJ000 FRONT MOUNTING H4
22. Lift the engine even higher, and attach the bolts and nuts to the vehicle. CAUTION: Do not lift up higher than enough level to install the ST to avoid damage to the hoses and pipes inside the engine room. NOTE: If it is difficult to pull out the stud bolt from transmission mounting bracket, shake the engine unit slightly while lifting up.
23. Tighten the mounting bolts on the engine side. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)
24. Put aside the engine crane.
25. Lift up the vehicle.
26. Set the transmission jack to the transmission.
27. Remove the clamp cable and take out the MT gear select cable from the clamp.
28. Remove the mounting bolts from the front crossmember and rear crossmember, and lower the transmission. CAUTION: When lowering the transmission, make sure that the transmission jack does not come off from the transmission.
29. Insert a spanner between the selector lever COMPL and the MT gear select cable and remove the MT gear select cable by raising the handle. NOTE: Use a spanner with 11 to 13 in size. The thickness of the spanner must not exceed 6 mm (0.2 in).
30. Remove the MT gear select cable and select bracket as an assembly from the transmission body.
31. Remove the plate cable assembly.
32. Disconnect the MT gear select cable. CAUTION: Be careful not to deform the cable inner. NOTE: To remove the MT gear select cable, push it in the direction of arrow.
33. Remove the clamp which holds the MT gear select cable.
34. Pull out the MT gear select cable from the cover cable assembly. CAUTION: Do not bend the MT gear select cable sharply.

Scheme 44

Scheme 45

Scheme 46

Scheme 47

Scheme 48

Scheme 49

Scheme 50

Scheme 51

Scheme 52

Scheme 53

Scheme 54

Scheme 55

1. Remove the MT gear select cable from the select bracket. CAUTION: Check for assembling position before removing the MT gear select cable from the select bracket.
2. Set to the new MT gear select cable to the select bracket and secure it with the clamp. CAUTION: Be careful not to mistake the MT gear select cable installing direction.
3. Install the MT gear select cable and select bracket as a single unit to the transmission body. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb)
4. Install the MT gear select cable to the select lever COMPL.
5. Measure the exposed length (a) of MT gear select cable. If out of specification, adjust the MT gear select cable. Ref. to «ADJUSTMENT»(ref-371931-S17274144462010091900000) , MT Gear Select Cable. Exposed length (a) of MT gear select cable: Specification: 11 mm (0.4 in)
6. Connect the MT gear select cable.
7. Install the plate cable assembly. Tightening torque: 7.5 N.m (0.8 kgf-m, 5.5 ft-lb)
8. Insert the MT gear select cable into clamp cable, and install to the transmission. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb)
9. Raise the transmission jack, install the front crossmember and rear crossmember. Tightening torque: T1: 75 N.m (7.6 kgf-m, 55.3 ft-lb) T2: 140 N.m (14.3 kgf-m, 103.3 ft-lb)
10. Take out the transmission jack.
11. Install the heat shield cover. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb)
12. Install the center exhaust pipe and rear exhaust pipe, (non-turbo model) Ref. to «INSTALLATION»(ref-371916-S02981401052010091900000) , Center Exhaust Pipe. Ref. to «INSTALLATION»(ref-371916-S31662490962010091900000) , Rear Exhaust Pipe.
13. Install the center exhaust pipe (rear) and rear exhaust pipe, (turbo model) Ref. to «INSTALLATION»(ref-371921-S21684767632010091900000) , Center Exhaust Pipe. Ref. to «INSTALLATION»(ref-371921-S14454219392010091900000) , Rear Exhaust Pipe.
14. Lower the vehicle.
15. Lift the engine slightly and remove the bolts from the ST (FRONT MOUNTING H4).
16. Remove the bolts and nuts, and remove the ST (FRONT MOUNTING H4).
17. Place and temporarily attach the front engine mounting with bolts.
18. Tighten the bolts and nuts of front engine mounting. NOTE: Always start tightening from the bolts on the engine side. Tightening torque: T1: 25 N.m (2.5 kgf-m, 18.4 ft-lb) T2: 45 N.m (4.6 kgf-m, 33.2 ft-lb)
19. Install the stopper rod. Tightening torque: 36 N.m (3.7 kgf-m, 26.6 ft-lb)
20. Attach the nuts to the left and right transmission mounting brackets. Tightening torque: 45 N.m (4.6 kgf-m, 33.2 ft-lb)
21. Remove the engine hanger rear for turbo model and install the engine hanger rear for non-turbo model. (non-turbo model) Tightening torque: T1: 16 N.m (1.6 kgf-m, 11.8 ft-lb) T2: 19 N.m (1.9 kgf-m, 14.0 ft-lb)
22. Install the throttle body, (non-turbo model) Ref. to «INSTALLATION»(ref-371892-S39969274732010091900000) , Throttle Body.
23. Install the engine harness connectors to the engine hanger rear, (non-turbo model)
24. Connect the engine harness connectors, and install harness bracket to the engine hanger rear, (non-turbo model) Tightening torque: 7.5 N.m (0.8 kgf-m, 5.5 ft-lb)
25. Install the air intake boot assembly, (non-turbo model) Ref. to «INSTALLATION»(ref-371894-S23105748052010091900000) , Air Intake Boot.
26. Install the intercooler stay and the intercooler. (turbo model) Ref. to «INSTALLATION»(ref-371895-S01655365462010091900000) , Intercooler.
27. Install the air intake duct. Non-turbo model Ref. to «INSTALLATION»(ref-371894-S07613473472010091900000) , Air Intake Duct. Turbo model Ref. to «INSTALLATION»(ref-371895-S33355550542010091900000) , Air Intake Duct.
28. Make sure the gears can be shifted accurately into each gear.