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Chain Cover: Installation

WARNING: This page is about a different car, the 2016 Subaru Outback and 2016 Subaru Legacy. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the O-rings to cylinder head RH, cylinder head LH, cylinder block LH and oil pan upper.
    NOTE:
    • Use new O-rings.
    • Apply a coat of engine oil to the O-rings.
    Fig 1: Locating Cylinder Head RH O-Rings
    G10308318Courtesy of SUBARU OF AMERICA, INC.
  2. Apply liquid gasket if there are gaps between front camshaft cap and cam carrier (A), cam carrier and cylinder head (B), and cylinder head and cylinder block (C) as shown in the figure.

    Liquid gasket: 

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

    Fig 2: Identifying Front Camshaft Cap, Cam Carrier, Cylinder Block And Cylinder Head
    G10308320Courtesy of SUBARU OF AMERICA, INC.
  3. 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) 

    Fig 3: Identifying Liquid Gasket Applying Area On Chain Cover Mating Surface
    G10308321Courtesy of SUBARU OF AMERICA, INC.
  4. 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.
    Fig 4: Identifying Cam Sprocket Sensor Plate Protrusion
    G10308316Courtesy 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 5: Identifying Chain Cover Mounting Bolts
    G10308323Courtesy of SUBARU OF AMERICA, INC.
  5. Install the idler pulley (C) and oil level gauge guide (B), and insert the oil level gauge (A).
    NOTE:
    • When installing the idler pulley, be careful of the idler pulley cover direction.
      Fig 6: Identifying Idler Pulley Cover And Protrusion
      G10308324Courtesy of SUBARU OF AMERICA, INC.
    • 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: 

    T1: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 

    T2: 36 N.m (3.7 kgf-m, 26.6 ft-lb) 

    Fig 7: Installing Idler Pulley And Oil Level Gauge Guide
    G10262599Courtesy of SUBARU OF AMERICA, INC.
  6. Connect the terminal (C), connector (D), connector (E) and connector (F), and secure the engine harness with the clip (G) and clip (H).
  7. Secure the oil level switch harness with clip (B), and connect the connector (A).
    Fig 8: Identifying Oil Level Switch Harness Connector And Clip
    G10262588Courtesy of SUBARU OF AMERICA, INC.
  8. Connect the connector (A) and connector (B) and secure the engine harness with the clip (C) and clip (D).
  9. Install the bolt securing the engine harness stay.

    Tightening torque: 

    6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 

    Fig 9: Identifying Engine Harness Connectors And Clip
    G10262587Courtesy of SUBARU OF AMERICA, INC.
  10. Install the crank pulley. < Ref. to INSTALLATION , Crank Pulley. >
  11. Install the water pump pulley. < Ref. to WATER PUMP , INSTALLATION, Water Pump. >
  12. Install the generator. < Ref. to INSTALLATION , Generator. >
  13. Install the V-belts. < Ref. to V-BELT , INSTALLATION, V-belt. >
  14. Fill engine oil. < Ref. to REPLACEMENT , Engine Oil. >
  15. When working on the vehicle
    NOTE: When working on the vehicle, perform the following steps also.
    1. Install the generator cord stay to the chain cover.
      NOTE: Install the generator cord stay so that the folded end (a) touches the chain cover boss.

      Tightening torque: 

      6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 

      Fig 10: Locating Generator Cord Stay Bolt
      G10262602Courtesy of SUBARU OF AMERICA, INC.
    2. Install the engine mount. < Ref. to INSTALLATION , Engine Mounting. >
    3. Install the front exhaust pipe. < Ref. to INSTALLATION , Front Exhaust Pipe. >
    4. Install the radiator. < Ref. to INSTALLATION , Radiator. >
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