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Chain Cover: Installation

  1. Degrease the press-fit section for the chain cover front oil seal, and install new front oil seal using ST.
    CAUTION: Do not apply fluid such as engine oil to the front oil seal and the chain cover; otherwise engine oil leakage may occur.

    Preparation tool: 

    ST: SPECIAL TOOL B (41399FG020)

    Front oil seal press-fit position: 

    1+0-1 mm (0.0394+0-0.0394 in) position from chain cover end face

    G13867904Courtesy of SUBARU OF AMERICA, INC.
  2. Install new O-rings to cylinder head RH, cylinder head LH, cylinder block LH and oil strainer.
    NOTE: Apply a coat of engine oil to the O-rings.
    G13224340Courtesy of SUBARU OF AMERICA, INC.
  3. If there are gaps between head gasket and the chain cover seal surface between the cylinder head and cylinder block (A), apply liquid gasket into the gaps.

    Liquid gasket: 

    THREE BOND 1217G (Part No. K0877Y0100), THREE BOND 1217H or equivalent

    G13224344Courtesy of SUBARU OF AMERICA, INC.
  4. Apply liquid gasket to the chain cover mating surface and center boss (5 places) as shown in the figure.
    NOTE:
    • Before applying liquid gasket, degrease the old liquid gasket seal surface of the engine and chain cover.
    • Install within 5 min. after applying liquid gasket.

    Liquid gasket: 

    THREE BOND 1217G (Part No. K0877Y0100), THREE BOND 1217H or equivalent

    Liquid gasket applying diameter: 

    4±0.5 mm (0.1575±0.0197 in)

    G13867907Courtesy of SUBARU OF AMERICA, INC.
  5. Set the chain cover, and tighten the bolts in numerical order as shown in the figure.
    CAUTION: The chain cover may contact the protrusion (a) of cam sprocket sensor plate and cause damage. When setting the chain cover, move the chain cover horizontally and set it while taking care not to contact with the cam sprocket.
    G13224338Courtesy of SUBARU OF AMERICA, INC.

    Tightening torque: 

    T1: 10 N.m (1.0 kgf-m, 7.4 ft-lb)

    T2: 25 N.m (2.5 kgf-m, 18.4 ft-lb)

    Fig 1: Chain Cover Bolts Tightening Sequence
    G13867909Courtesy of SUBARU OF AMERICA, INC.
  6. Install the crank pulley boss (C) and oil level gauge guide (B) using a new O-ring, and insert the oil level gauge (A).
    NOTE: Apply a light coat of engine oil to the O-rings of the oil level gauge guide and the oil level gauge.

    Tightening torque: 

    6.4 N.m (0.7 kgf-m, 4.7 ft-lb)

    G13224336Courtesy of SUBARU OF AMERICA, INC.
  7. Place the engine wiring harness and secure the engine wiring harness with the clip (L) and clip (K).
  8. Connect the connector (J), connector (I), connector (H) and terminal (G).
    NOTE: The oil pressure switch harness must be positioned toward the left lower side of the vehicle within the range of 90°.
    G13867911Courtesy of SUBARU OF AMERICA, INC.

    Tightening torque: 

    1.5 N.m (0.2 kgf-m, 1.1 ft-lb)

  9. Attach the rubber cap (F) to the oil pressure switch.
  10. Secure the oil level switch harness with clip (E), and connect the connector (D).
  11. Install the bracket (C) to the water pump.

    Tightening torque: 

    8.5 N.m (0.9 kgf-m, 6.3 ft-lb)

  12. Install the connector (B) to the chain cover and connect the connector (A).
    CAUTION:
    • If the clip (a) of the connector (B) is damaged, replace it with a new clip.
    • If the installation part for the clip (a) of the connector (B) is damaged, replace it with a new inlet engine coolant temperature sensor.
    • If the clip (a) has been replaced, put a marking (b) to ensure that the replacement of clips can be identified.
    G13223942Courtesy of SUBARU OF AMERICA, INC.
    G13224335Courtesy of SUBARU OF AMERICA, INC.
  13. Place the engine wiring harness and secure the engine wiring harness with the clip (C).
  14. Connect the connector (B) and connector (A).
    G13224334Courtesy of SUBARU OF AMERICA, INC.
  15. Install the crank pulley. Ref. to MECHANICAL (H4DO)>Crank Pulley>INSTALLATION .
  16. Install the water pump pulley. Ref. to WATER PUMP .
  17. Install the idler pulley. Ref. to MECHANICAL (H4DO)>V-belt>INSTALLATION>IDLER PULLEY .
  18. Install the A/C compressor. Ref. to AIR CONDITIONER>COMPRESSOR>INSTALLATION .
  19. Install the generator. Ref. to STARTING/CHARGING SYSTEM (H4DO)>GENERATOR>INSTALLATION .
  20. Install the V-belt tensioner assembly. Ref. to MECHANICAL (H4DO)>V-belt>INSTALLATION>V-BELT TENSIONER ASSY .
  21. Fill engine oil. Ref. to LUBRICATION (H4DO)>ENGINE OIL>REPLACEMENT .
  22. When working on the vehicle
    NOTE: When working on the vehicle, perform the following steps also.
    1. Install the radiator. Ref. to COOLING (H4DO)>RADIATOR>INSTALLATION .
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