99 Lego Engine Teardown

I'm starting a new thread with this instead of using my existing one. I'm going to post all my tear down and engine pull pictures for my 99 SUS Legacy, mostly for my own use later when I'm putting the damn thing back together I'm going to replace most of the seals and gaskets, timing belt, reconditioning the heads at the machine shop and replacing the headgaskets. Through all that I'm going to try and obsessively document it for you kid's consumption.

 

I'll post all parts and instructions as I put them in.

 

Starting pictures

 

These are all the pictures with everything together

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-sZMMk9G/0/L/IMG_5704-L.jpg

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-dDFCBdj/0/L/IMG_5705-L.jpg

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-SpwcKgs/0/L/IMG_5706-L.jpg

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-MxQ4GvB/0/L/IMG_5707-L.jpg

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-wmMrVmV/0/L/IMG_5708-L.jpg

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-wwRQPSL/0/L/IMG_5709-L.jpg

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-ZPGdKpx/0/L/IMG_5710-L.jpg

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-tmBTHPv/0/L/IMG_5711-L.jpg

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-xXdhmB8/0/L/IMG_5712-L.jpg

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-VXVSHDn/0/L/IMG_5713-L.jpg

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-rfvGGBG/0/L/IMG_5714-L.jpg

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-7CHQ2RN/0/L/IMG_5725-L.jpg

 

Engine Pull

 

First things first, disconnect the fuel pump, and start the engine for a bit to release fuel pressure.

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-f7F5hBh/0/L/IMG_5717-L.jpg

 

Next, use this radiator fluid drain plug to drain out the radiator fluid.

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-9wMrNMF/0/L/IMG_5719-L.jpg

 

Then I disconnected the upper return line for the radiator. This along with opening the radiator fill cap, allowed air to get into the top and allows the fluid to flow out more quickly.

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-ptK8c2G/0/L/IMG_5721-L.jpg

 

Next loosen the intake assembly, there's a few clamps to get rid of then two bolts on the larger assembly. Take those off and slide the whole thing out, there's a few vacuum hoses on the underside, I've circled them here.

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-HZFR4Gb/0/L/IMG_5726-L.jpg

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-jDLbrxS/0/L/IMG_5727-L.jpg

 

Now there should most of the fluid should drained out of the radiator, take off the large hose on the bottom drivers side, and then the two transmission fluid lines. Take the whole assembly out.

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-dfJ4rdd/0/L/IMG_5728-L.jpg

 

Next I didn't want to disconnect the A/C lines and be forced to deal with refrigerant and the like. So I plan on just taking the whole compressor unit off and stowing it to the side. There's 5 bolts holding the whole thing on, one was pretty tricky to get to and required a u-joint on my wrench. Just lift the thing up and set it to the side.

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-dfJ4rdd/0/L/IMG_5728-L.jpg

Next up is a few fuel lines, I've marked them with tape and my ever trust worthy tally marks to tell which fuel line goes to where

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-3LKtHrQ/0/L/IMG_5735-L.jpg

 

After this I took off the throttle and cruise control wires. They just pop off and I should have marked which was which, but I didn't so lets hope that doesn't cause a problem putting it back together

 

Now on to the engine mount studs. I just removed the two bolts at the bottom, figure I'll leave the mounts on when I remove the engine and then take them off the engine when they're easier to get to.

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-p7G4QcG/0/L/IMG_5738-L.jpg

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-z6vkCWP/0/L/IMG_5739-Edit-L.jpg

 

Now there's two heat exchange hoses that go to the heater core from the back of the engine to the firewall. Take those clips off and remove those. Should be careful to have buckets under the engine as you'll probably get some more radiator fluid coming out.

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-JcG2frT/0/L/IMG_5741-L.jpg

 

Now to take off the starter connections. There's a ground line on the front and the hot line more towards the back.

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-vBDBwmX/0/L/IMG_5742-L.jpg

 

Now on to the majority of the electrical harness. There's two that look very similar so I marked the two with tape and tally marks.

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-KPBxXfc/0/L/IMG_5746-L.jpg

 

So the next step is to disconnect the torque converter, in order to do this I'd heard you need to disconnect the alternator, which in my case isn't true. However I removed the alternator anyhow.

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-ZLGLVPN/0/L/IMG_5748-L.jpg

 

There's a plastic cover for an access port on the rear of the engine right in front of the bell housing. Take that off.

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-C6T9KRC/0/L/IMG_5750-L.jpg

 

Then rotate the engine until a bolt comes around to the access port. Undo the bolt, there ends up being 4 to takeout.

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-JPtGwCw/0/L/IMG_5751-L.jpg

 

Now there's 3 bolts on each side of the bell housing, and 2 nuts on the lower end to take off. I unfortunately didn't get a picture of them as they're pretty hard to photograph but fairly easy to find.

 

Also I took off the transmission bolts on the underside. This allows you to move the whole drive train up and slip the engine off the torque converter.

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-rFp4xfV/0/L/IMG_5754-Edit-L.jpg

 

And out it comes!

 

Engine Teardown

 

Here's the engine set up on the stand. Most of the teardown is pretty straight forward so I'm just going to post pictures of what it looks like while being taken apart.

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-hf9p3t3/0/L/IMG_5755-L.jpg

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-cn2Jj44/0/L/IMG_5756-L.jpg

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-4JCG5wZ/0/L/IMG_5757-L.jpg[/url

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-fqgRNKB/0/L/IMG_5758-L.jpg

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-LCsw7sW/0/L/IMG_5759-L.jpg

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-XSVpXBV/0/L/IMG_5760-L.jpg

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-98RGc3x/0/L/IMG_5761-L.jpg

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-kV3D2Nr/0/L/IMG_5762-L.jpg

 

Removed the power steering pump and ignition coil/wires.

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-MkWTfSj/0/L/IMG_5763-L.jpg

 

Removed the intake headers

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-fG9bJfs/0/L/IMG_5765-L.jpg

 

Removed the cover for the timing belt and the harmonic balancer. In order to get the balancer off I placed a screwdriver on the back fly wheel to stop the engine from turning then used a breaker bar to get the bolt off.

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-r5CgvSn/0/L/IMG_5766-L.jpg

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-vBks5sx/0/L/IMG_5767-L.jpg

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-hc9VT89/0/L/IMG_5768-L.jpg

 

Now I aligned the engine for top dead center. There really isn't much point because the heads are coming off anyhow and I'm going to ruin that timing but it'll be good to know the pistons are aligned right. Match the double marks so they're pointing together, and match the single marks so they align with the marks on the cover. The arrows should be pointing up and to the right.

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-6XD7kdk/0/L/IMG_5769-L.jpg

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-9KpS2jh/0/L/IMG_5771-L.jpg

 

The crankshaft marking had me confused because the service manual had it pointing up. However when I aligned all my cams it ended up pointing more towards the right. So gonna have to double check this I guess. \

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-rQ2jcxr/0/L/IMG_5770-L.jpg

 

Now to take the covers off the heads.

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-tgjsCK2/0/L/IMG_5772-L.jpg

 

I need to take the head bolts off. I took the cams off. I know it's possible to not do that but I didn't want to risk banging up anything in there. So take off the bearings and the pulleys on the end.

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-tgjsCK2/0/L/IMG_5772-L.jpg

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-tnGGw9q/0/L/IMG_5773-L.jpg

 

Now I have free access to the head bolts. So just take these off, there's 6

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-KGwL4VJ/0/L/IMG_5774-L.jpg

Once the head bolts are off the cylinder head should just come off.

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-BFZPztM/0/L/IMG_5776-L.jpg

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-mpBh3QN/0/L/IMG_5777-L.jpg

 

And now I seal off the cylinders so no crap gets in there and the heads go off to the machine shop.

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-mJStBGd/0/L/IMG_5778-L.jpg

reserved #3

reserved #4

reserved #5

Next up is a few vacuum lines, I've marked them with tape and my ever trust worthy tally marks to tell which vacuum line goes to where

 

http://photos.jonathancummins.com/Cars/SubaruEngineTeardown/i-3LKtHrQ/0/L/IMG_5735-L.jpg

 

Those are your fuel supply, return and vent lines.

 

Looks like you are having fun lol!

This thread has the makings of permanent 'sticky' material. The photo quality is great, good luck with the teardown.

Those are your fuel supply, return and vent lines.

 

Looks like you are having fun lol!

 

haha, ya i found that out today Pulled the top line and some fuel came squirting out, I'll update the thread

This thread has the makings of permanent 'sticky' material. The photo quality is great, good luck with the teardown.

 

thanks, I'm using a camera that has no business in the garage, but it's proving to be great for documentation

So I'm going to update the pictures here in a second, but I got down to the engine/tranny tonight. I'd like to pull just the engine if I can, however this is the first automatic tranny I've ever disconnected. All my jeeps are all manual like the good lord intended. I'm assuming i can just loosen the bolts connecting the engines to the bellhousing and pull the engine forward. Are there any tricks I should know?

Is this an AT? if so something about undoing a bolt somewhere else you'll never be able to get the flywheel back on or something...

haha, glad I asked then. It's definitely an AT

ya, you have to take out the torque converter bolts before you split it.

 

Yes there is. There is an access on top of the engine. Some can get the bolts with a long extension after removing the alternator, others remove the intake to get to it. The access is on the passenger side rear of the engine on top of it. Can't remember if there is a cover, but you should be able to tell once you dive in.

 

Steve

 

from another thread.

Gonna update this thread in a bit, as I've pretty much got the entire engine tore down. I've noticed a lot of the valve cover seals and other seals are using sealant as well as a gasket. Is this a particular sealant from the factory or do you think this was applied later?

Also so I need to get a oil pan gasket? The only ones online that I can find are cork and I'd like to go OEM if possible, I haven't taken the oil pan off yet and don't want to until I have to, has anyone replaced this?

Ok added all my new pictures. Enjoy!

The sealant is Fujibond, equivalent sealant is gray permatex.

 

Great pics man hope you get it running soon. I would have liked to have docd this like you did but I write manuals for a living so I'm tired of that shit lol.

The rubber seals form the timing cover are also starting to go out. I can't seem to find a replacement for those anywhere, does anyone know a good place or am I gonna have to order them from the stealership?

Subarupartsforyou.com is where I got all mine

Got it all back together now, rebuild was pretty much reversal of teardown so I didn't take too many pictures. However it runs really rough and shoots out white smoke out the back. So I checked the oil and sure enough trace amounts of water, so I guess I'm gonna have to pull the engine again and put new head gaskets on it.

 

Does anyone have any experience with the head bolt procedure? Here's the procedure I used from the FSM and I was pretty careful in applying it...

 

2) Tighten cylinder head bolts.

 

(1) Apply a coat of engine oil to washers and

 

bolt threads.

 

(2) Tighten all bolts to 29 N·m (3.0 kg-m, 22

 

ft-lb) in alphabetical sequence.

 

Then tighten all bolts to 69 N·m (7.0 kg-m, 51

 

ft-lb) in alphabetical sequence.

 

(3) Back off all bolts by 180° first; back them off

 

by 180° again.

 

(5) Tighten bolts ©, (D), (E) and (F) to 15 N·m

 

(1.5 kg-m, 11 ft-lb).

 

(6) Tighten all bolts by 80 to 90° in alphabetical

 

sequence.

 

CAUTION:

 

Do not tighten bolts more than 90°.

 

(7) Further tighten all bolts by 80 to 90° in

 

alphabetical sequence.

 

i used it with no problems.

 

what brand of head gaskets did you use?

 

did you send the heads to the machine shop?

ya the heads were cleaned and checked at the machine shop. I used OEM headgaskets from this guy

 

http://www.ebay.com/sch/barnfindbernie/m.html?_nkw=&_armrs=1&_ipg=&_from=

so I used 11044AA610 as the headgasket. There's so many posts from so many people all over the internet. Has anyone has any luck with this particular head gasket on the 992.5 EJ25D?

 

It's the MLS OEM gasket so I was under the impression it would work out.