Chain Cover: Installation

WARNING: This page is about a different car, the 2015 Subaru XV Crosstrek and 2015 Subaru Impreza. However, it is still accessible from the selected car via links, so may be relevant.

Apply a light coat of engine oil to the front oil seal inner periphery and outer periphery, and install the front oil seal using ST. (HEV model)
NOTE: Use a new front oil seal.

ST 398437700 OIL SEAL INSTALLER

Front oil seal press-fit position:

1 ⁺⁰ _-1 mm (0.0039 ⁺⁰ _-0.0039 in) position from chain cover end face

Fig 1: Installing Front Oil Seal Using Tool
Courtesy of SUBARU OF AMERICA, INC.
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 2: Locating Cylinder Head And Block O-Ring
Courtesy of SUBARU OF AMERICA, INC.
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) or equivalent

Fig 3: Identifying Liquid Gasket Applying Area On Chain Cover
Courtesy of SUBARU OF AMERICA, INC.
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) or equivalent

Liquid gasket applying diameter:

4±0.5 mm (0.1575±0.0197 in)

Fig 4: Identifying Liquid Gasket Applying Dimension On Chain Cover
Courtesy of SUBARU OF AMERICA, INC.
Set the chain cover, and tighten the bolts in numerical order as shown in the figure.
CAUTION: For gasoline engine models, 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 5: Identifying Chain Cover Mounting Bolts Tightening Sequence
Courtesy 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 6: Identifying Chain Cover Mounting Bolts Tightening Sequence
Courtesy of SUBARU OF AMERICA, INC.
Install the idler pulley (D), crank pulley boss (C) and oil level gauge guide (B), and insert the oil level gauge (A). (Gasoline engine model)
NOTE:
- When installing the idler pulley, be careful of the idler pulley cover direction.
  
  Fig 7: Identifying Idler Pulley Cover And Protrusion
  Courtesy 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)
- Gasoline engine model
  
  Fig 8: Identifying Gasoline Engine Model
  Courtesy of SUBARU OF AMERICA, INC.
- HEV model
  
  Fig 9: Identifying HEV Model
  Courtesy of SUBARU OF AMERICA, INC.
Connect the terminal (A) to the oil pressure switch, connector (B) to the engine oil temperature sensor, connector (C) to the intake oil control solenoid LH, connector (D) to the exhaust oil control solenoid LH, connector (E) to the intake camshaft position sensor LH, and connector (F) to the exhaust camshaft position sensor LH, and secure the engine harness with the clips (G) and (H).
NOTE: The oil pressure switch harness must be positioned toward the left lower side of the vehicle within the range of 90°.

Fig 10: Identifying Oil Pressure Switch Installation Position
Courtesy of SUBARU OF AMERICA, INC.

Tightening torque:

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

Fig 11: Identifying Oil Pressure Switch Connectors
Courtesy of SUBARU OF AMERICA, INC.
Attach the rubber cap to the oil pressure switch.

Fig 12: Locating Oil Pressure Switch Rubber Cap
Courtesy of SUBARU OF AMERICA, INC.
Secure the oil level switch harness with clips (A), and connect the connectors to the oil level switch.

Fig 13: Locating Oil Level Switch And Clips
Courtesy of SUBARU OF AMERICA, INC.
Connect the connector (A) to the intake oil control solenoid RH, connector (B) to the exhaust oil control solenoid RH, and connector (C) to the intake camshaft position sensor RH, and then secure the engine harness with the clips (D) (gasoline engine model) and the clips (E).

Fig 14: Identifying Intake Oil Control Solenoid Connector
Courtesy of SUBARU OF AMERICA, INC.
Connect the connector (A) to the exhaust camshaft position sensor RH, and install the engine harness stay to the chain cover.
Tightening torque:

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

Fig 15: Locating Engine Harness Stay To Chain Cover Mounting Bolt
Courtesy of SUBARU OF AMERICA, INC.
Install the crank pulley. < Ref. to INSTALLATION , Crank Pulley.>
Install the water pump pulley. < Ref. to WATER PUMP , INSTALLATION, Water Pump.>
Fill engine oil. < Ref. to REPLACEMENT , Engine Oil.>
Install the generator. (Gasoline engine model) INSTALLATION , Generator.>
Install the ISG. (HEV model) < Ref. to INSTALLATION , Integrated Starter Generator (ISG).>
When working on the vehicle
NOTE:
When working on the vehicle, perform the following steps also.
1. Install the radiator. < Ref. to INSTALLATION , Radiator.>
2. Install the front exhaust pipe. < Ref. to INSTALLATION , Front Exhaust Pipe.>
3. Install the generator cord stay to the chain cover. (Gasoline engine model)
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 16: Locating Generator Cord Stay
Courtesy of SUBARU OF AMERICA, INC.