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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

    G13230154Courtesy 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.
    G11253237Courtesy 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

    G11253241Courtesy 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)

    G13230157Courtesy 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.
    G11253235Courtesy 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
    G13230159Courtesy 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 (E), 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 model)
  11. Connect the connector (G), connector (F), connector (E), and the terminal (D). (Crosstrek model)
    NOTE: The oil pressure switch harness must be positioned toward the left lower side of the vehicle within the range of 90°.
    G13230162Courtesy 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 model)
  13. Secure the oil level switch harness with clip (B), and connect the connector (A). (Crosstrek model)
    G13230147Courtesy of SUBARU OF AMERICA, INC.
  14. Place the engine wiring harness and secure the engine wiring harness with the clip (D) (except for hybrid model) and the clip (C).
  15. Connect the connector (B) and connector (A).
    G13230145Courtesy of SUBARU OF AMERICA, INC.
  16. Install the crank pulley. Refer to MECHANICAL (H4DO (EXCEPT FOR HEV))>CRANK PULLEY>INSTALLATION .
  17. Install the water pump pulley.

    Except for hybrid model: 

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

    Hybrid model: 

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

  18. Install the idler pulley. (Hybrid model) Refer to MECHANICAL (H4DO (EXCEPT FOR HEV))>V-BELT>INSTALLATION>HYBRID MODEL>IDLER PULLEY .
  19. Install the electric compressor assembly.

    Except for hybrid model: 

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

    Hybrid model: 

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

  20. Install the generator. (Except for hybrid model) Refer to STARTING/CHARGING SYSTEMS (H4DO (EXCEPT FOR HEV))>GENERATOR>INSTALLATION .
  21. Install the V-belt tensioner assembly. (Except for hybrid model) Refer to MECHANICAL (H4DO (EXCEPT FOR HEV))>V-BELT>INSTALLATION>EXCEPT FOR HYBRID MODEL>V-BELT TENSIONER ASSEMBLY .
  22. Install the EGR cooler. (Hybrid model) Refer to EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) (H4DO (HEV))>EGR COOLER>INSTALLATION .
  23. Fill engine oil. Refer to LUBRICATION (H4DO (EXCEPT FOR HEV))>ENGINE OIL>REPLACEMENT .
  24. 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) Refer to COOLING (H4DO (HEV))>INVERTER WATER PIPE>INSTALLATION>INVERTER FRONT WATER PIPE .
    2. Install the radiator and the condenser as an assembly.

      Except for hybrid model: 

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

      Hybrid model: 

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

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