LEMON Manuals: Even more car manuals for everyone
Home >> Subaru >> 2023 >> Outback Base >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical System (2.5L) >> Chain Cover >> Installation

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

    G16383360Courtesy of SUBARU OF AMERICA, INC.
    (A) Chain cover
    (B) Oil seal
    (C) Front oil seal press-fit position (1+0-1 mm (0.0394+0-0.0394 in) position from chain cover end face)
  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.
    G13618905Courtesy of SUBARU OF AMERICA, INC.
  3. Apply liquid gasket if there is a dent at the positions as shown in the figure.

    Preparation items: 

    Liquid gasket: THREE BOND 1217G (part No. K0877Y0100), THREE BOND 1217H or equivalent

    G16383362Courtesy 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.

    Preparation items: 

    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)

    G16335256Courtesy of SUBARU OF AMERICA, INC.
    (A) 14.5 mm (0.5709 in)
    (B) 17.5 mm (0.6890 in)
    (C) Range A
    (D) 316.2 mm (12.4488 in)
    (E) 24.5 mm (0.9646 in)
    (F) 18.5 mm (0.7283 in)
    (G) 127 mm (5.0000 in)
    (H) Range B
    (I) Liquid gasket applying position of mating surfaces of range A
    (J) Liquid gasket applying position of center boss (5 places)
    (K) Liquid gasket applying position of mating surfaces of range B
    (L) Liquid gasket applying position of mating surfaces other than range A and range B
    (M) ø4±0.5 mm (0.1575±0.0197 in)
    (N) 2.3 mm (0.0906 in)
    (O) ø12 mm (0.4724 in)
    (P) 2.8 mm (0.1102 in)
    (Q) 1 mm (0.0394 in)
  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.
    G13618903Courtesy 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
    G16383365Courtesy of SUBARU OF AMERICA, INC.
    (A) M6 x 20
    (B) M6 x 50
    (C) M8 x 25
    (D) M8 x 60
  6. Install the crank pulley boss (C) and oil level gauge guide (B) using a new O-ring, and insert the oil level gauge (A).
    NOTE: 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)

    G13618901Courtesy of SUBARU OF AMERICA, INC.
  7. Place the engine wiring harness and secure the engine wiring harness with the clip (K) and clip (J).
  8. Connect the connector (I), connector (H), connector (G) and the terminal (F).
  9. Secure the oil level switch harness with clip (E), and connect the connector (D).
  10. Install the bracket (C) to the water pump.

    Tightening torque: 

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

  11. Install the connector (B) to the chain cover and connect the connector (A).
    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.
    G13590270Courtesy of SUBARU OF AMERICA, INC.
    G13618900Courtesy of SUBARU OF AMERICA, INC.
  12. Place the engine wiring harness and secure the engine wiring harness with the clip (C).
  13. Connect the connector (B) and connector (A).
    G13224334Courtesy of SUBARU OF AMERICA, INC.
  14. Install the crank pulley. Ref. to MECHANICAL (H4DO)>CRANK PULLEY>INSTALLATION .
  15. Install the water pump pulley. Ref. to COOLING (H4DO)>WATER PUMP>INSTALLATION>WATER PUMP PULLEY .
  16. Install the idler pulley. Ref. to MECHANICAL (H4DO)>V-BELT>INSTALLATION>IDLER PULLEY .
  17. Install the A/C compressor. Ref. to AIR CONDITIONER>COMPRESSOR>INSTALLATION .
  18. Install the generator. Ref. to STARTING/CHARGING SYSTEMS (H4DO)>GENERATOR>INSTALLATION .
  19. Install the V-belt tensioner assembly. Ref. to MECHANICAL (H4DO)>V-BELT>INSTALLATION>V-BELT TENSIONER ASSEMBLY .
  20. Fill engine oil. Ref. to LUBRICATION (H4DO)>ENGINE OIL>REPLACEMENT .
  21. When working on the vehicle
    NOTE: When working on the vehicle, perform the following steps also.
    1. Install the radiator. Ref. to COOLING (H4DO)>RADIATOR>INSTALLATION .
scientia non olet · About LEMON Manuals