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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

    G13876092Courtesy 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.
    G13600741Courtesy 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

    G13600745Courtesy 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)

    G13876095Courtesy 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 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.
    G13876096Courtesy 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 (With Torque Specification)
    G13876097Courtesy of SUBARU OF AMERICA, INC.
  6. Install the crank pulley boss (C) and oil level gauge guide (B), and insert the oil level gauge (A).
    NOTE:
    • Use a new O-ring to the oil level gauge guide.
    • 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)

    G11253233Courtesy of SUBARU OF AMERICA, INC.
  7. Place the engine wiring harness and secure the engine wiring harness with the clip (H) and clip (G). (Impreza model)
  8. Connect the connector (F), connector (EX), connector (D) and terminal (C). (Impreza model)
  9. Secure the oil level switch harness with clip (B), and connect the connector (A). (Impreza model)
    G13230146Courtesy of SUBARU OF AMERICA, INC.
  10. Place the engine wiring harness and secure the engine wiring harness with the clip (I) and clip (H). (Crosstrek 2.0 L model)
  11. Connect the connector (G), connector (F), connector (EX), and the terminal (D). (Crosstrek 2.0 L model)
    NOTE: The oil pressure switch harness must be positioned toward the left lower side of the vehicle within the range of 90°.
    G13876100Courtesy of SUBARU OF AMERICA, INC.

    Tightening torque: 

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

  12. Attach the rubber cap (C) to the oil pressure switch. (Crosstrek 2.0 L model)
  13. Secure the oil level switch harness with clip (B), and connect the connector (A). (Crosstrek 2.0 L model)
    G13230147Courtesy of SUBARU OF AMERICA, INC.
  14. Place the engine wiring harness and secure the engine wiring harness with the clip (L) and clip (K). (2.5 L model)
  15. Connect the connector (J), connector (I), connector (H) and terminal (G). (2.5 L model)
    NOTE: The oil pressure switch harness must be positioned toward the left lower side of the vehicle within the range of 90°.
    G13876102Courtesy of SUBARU OF AMERICA, INC.

    Tightening torque: 

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

  16. Attach the rubber cap (F) to the oil pressure switch. (2.5 L model)
  17. Secure the oil level switch harness with clip (EX), and connect the connector (D). (2.5 L model)
  18. Install the bracket (C) to the water pump. (2.5 L model)

    Tightening torque: 

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

  19. Install the connector (B) to the chain cover and connect the connector (A). (2.5 L model)
    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.
  20. Place the engine wiring harness and secure the engine wiring harness with the clip (D) (2.0 L gasoline engine model) and the clip (C).
  21. Connect the connector (B) and connector (A).
    G13230145Courtesy of SUBARU OF AMERICA, INC.
  22. Install the bolt which holds the engine wiring harness to the chain cover. (2.5 L model)

    Tightening torque: 

    19 N.m (1.9 kgf-m, 14.0 ft-lb)

    G13876081Courtesy of SUBARU OF AMERICA, INC.
  23. Install the crank pulley. Ref. to MECHANICAL (H4DO (EXCEPT FOR HEV))>CRANK PULLEY>INSTALLATION .
  24. Install the water pump pulley.

    Gasoline engine model: 

    Ref. to COOLING (H4DO (EXCEPT FOR HEV))>WATER PUMP>INSTALLATION>WATER PUMP PULLEY .

    Hybrid model: 

    Ref. to COOLING (H4DO(HEV))>WATER PUMP>INSTALLATION>WATER PUMP PULLEY .

  25. Install the idler pulley. (2.5 L model and hybrid model)

    2.5 L model: 

    Ref. to MECHANICAL (H4DO (EXCEPT FOR HEV))>V-BELT>INSTALLATION>GASOLINE ENGINE MODEL>IDLER PULLEY .

    Hybrid model: 

    Ref. to MECHANICAL (H4DO (EXCEPT FOR HEV))>V-BELT>INSTALLATION>HYBRID MODEL>IDLER PULLEY .

  26. Install the compressor assembly.

    Gasoline engine model: 

    Ref. to AIR CONDITIONER (EXCEPT FOR HEV)>COMPRESSOR>INSTALLATION .

    Hybrid model: 

    Ref. to AIR CONDITIONER (HEV)>COMPRESSOR>INSTALLATION .

  27. Install the generator. (Gasoline engine model) Ref. to STARTING/CHARGING SYSTEMS (H4DO (EXCEPT FOR HEV))>GENERATOR>INSTALLATION .
  28. Install the V-belt tensioner assembly. (Gasoline engine model) Ref. to MECHANICAL (H4DO (EXCEPT FOR HEV))>V-BELT>INSTALLATION>GASOLINE ENGINE MODEL>V-BELT TENSIONER ASSEMBLY .
  29. Install the EGR cooler. (Hybrid model) Ref. to EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) (H4DO(HEV))>EGR COOLER>INSTALLATION .
  30. Fill engine oil. Ref. to LUBRICATION (H4DO (EXCEPT FOR HEV))>ENGINE OIL>REPLACEMENT .
  31. When working on the vehicle
    NOTE: When working on the vehicle, perform the following steps also.
    1. Install the inverter front water pipe. (Hybrid model) Ref. to COOLING (H4DO(HEV))>INVERTER WATER PIPE>INSTALLATION>INVERTER FRONT WATER PIPE .
    2. Install the radiator and the condenser as an assembly.

      Gasoline engine model: 

      Ref. to COOLING (H4DO (EXCEPT FOR HEV))>RADIATOR>INSTALLATION .

      Hybrid model: 

      Ref. to COOLING (H4DO(HEV))>RADIATOR>INSTALLATION .

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