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Home >> Subaru >> 2016 >> WRX Base >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical (WRX) >> Chain Cover >> Installation

Chain Cover: Installation

  1. Degrease the press-fit section for the chain cover front oil seal, and install the front oil seal to the chain cover 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.
    NOTE: Use a new front oil seal.

    ST 41399FG020 SPECIAL TOOL B

    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 Press-Fit Position
    G10291792Courtesy of SUBARU OF AMERICA, INC.
  2. 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 Oil Pan Upper O-Rings (RH And LH)
    G10266751Courtesy of SUBARU OF AMERICA, INC.
  3. 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 3: Identifying Front Camshaft Cap, Cam Carrier And Cylinder Head
    G10266755Courtesy 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) 

    Fig 4: Identifying Chain Cover Liquid Gasket Application Dimensions
    G10291795Courtesy 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.
    Fig 5: Identifying Cam Sprocket Sensor Plate Protrusions
    G10266749Courtesy 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
    G10291797Courtesy of SUBARU OF AMERICA, INC.
  6. Install the idler pulley (D), crank pulley boss (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 7: Identifying Idler Pulley And Oil Level Gauge Guide Bolts With Torque Specifications
      G10291798Courtesy 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 8: Identifying Idler Pulley And Oil Level Gauge Guide Bolts With Torque Specifications
    G09480291Courtesy of SUBARU OF AMERICA, INC.
  7. 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, and the connector (E) to the intake camshaft position sensor LH, and fix the engine harness using the clip (F).
    NOTE: The oil pressure switch harness must be positioned toward the left lower side of the vehicle within the range of 90°.
    Fig 9: Positioning Oil Pressure Switch Harness To Vehicle Left Lower Side
    G10291800Courtesy of SUBARU OF AMERICA, INC.

    Tightening torque: 

    1.5 N.m (0.2 kgf-m, 1.1 ft-lb) 

    Fig 10: Identifying Oil Pressure Switch And Engine Oil Temperature Sensor Connectors
    G10266746Courtesy of SUBARU OF AMERICA, INC.
  8. Attach the rubber cap to the oil pressure switch.
    Fig 11: Locating Oil Pressure Switch Rubber Cap
    G10266745Courtesy of SUBARU OF AMERICA, INC.
  9. Connect the connector (A) to the exhaust camshaft position sensor LH and the connector (B) to the oil level switch, 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 12: Locating Exhaust Camshaft Position Sensor LH And Oil Level Switch Connectors
    G09480278Courtesy of SUBARU OF AMERICA, INC.
  10. Connect the connector (A) to the intake oil control solenoid RH, connector (B) to the exhaust oil control solenoid RH, connector (C) to the intake camshaft position sensor RH, and the connector (D) to the exhaust camshaft position sensor RH, and then fix the engine harness using the clips (E) and (F).
    Fig 13: Identifying Intake And Exhaust Oil Control Solenoid Connectors
    G10266743Courtesy of SUBARU OF AMERICA, INC.
  11. Install the vacuum pipe assembly to the chain cover, and connect the vacuum control hose (A) and vacuum hose (B) to the vacuum pipe assembly.

    Tightening torque: 

    6.4 N.m (0.7 kgf-m, 4.7 ft-lb) 

    Fig 14: Locating Vacuum Pipe Assembly Bolts
    G10266742Courtesy of SUBARU OF AMERICA, INC.
  12. Install the PCV pipe together with the intake duct No. 1 (when working on the vehicle) to the clip (A).
    Fig 15: Identifying PCV Pipe Clip
    G10266766Courtesy of SUBARU OF AMERICA, INC.
  13. Fix the PCV pipe to the intake manifold using the clip.
    Fig 16: Locating Intake Manifold PCV Pipe Clips
    G09480274Courtesy of SUBARU OF AMERICA, INC.
  14. When worked on the engine unit only
    NOTE: When work was done on the engine unit only, also perform the following steps.
    1. Install the PCV hose assembly to the chain cover.
      NOTE: Use a new clamp. To connect the PCV hose assembly, fit the cut outs of the ST with the protrusions on the clamp as shown in the figure, squeeze the ST's handles together and lock the clamp.

      ST 18353AA000 CLAMP PLIERS

      Fig 17: Fitting Clamp Pliers (ST 18353AA000) Cut Outs With Protrusions On Clamp
      G10266768Courtesy of SUBARU OF AMERICA, INC.
  15. Install the front engine oil cooler pipe assembly. < Ref. to FRONT ENGINE OIL COOLER PIPE , INSTALLATION, Engine Oil Cooler Pipe. >
  16. Attach the engine oil cooler. < Ref. to INSTALLATION , Engine Oil Cooler. >
  17. Install the crank pulley. < Ref. to INSTALLATION , Crank Pulley. >
  18. Install the water pump pulley. < Ref. to WATER PUMP , INSTALLATION, Water Pump. >
  19. Install the generator. < Ref. to INSTALLATION , Generator. >
  20. Install the V-belts. < Ref. to V-BELT , INSTALLATION, V-belt. >
  21. Fill engine oil. < Ref. to REPLACEMENT , Engine Oil. >
  22. When working on the vehicle
    NOTE: When working on the vehicle, perform the following steps also.
    1. Install the air intake boot to the intake duct No. 1, then connect the connector (A) to the wastegate control solenoid valve.
      Fig 18: Identifying Wastegate Control Solenoid Valve Connector
      G10266738Courtesy of SUBARU OF AMERICA, INC.
    2. Install the front exhaust pipe. < Ref. to INSTALLATION , Front Exhaust Pipe. >
    3. Install the intake duct No. 2. < Ref. to INTAKE DUCT NO. 2 , INSTALLATION, Intake Duct. >
    4. Install the radiator. < Ref. to INSTALLATION , Radiator. >
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