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Chain Cover: Installation

  1. 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.
    G13198749Courtesy of SUBARU OF AMERICA, INC.
  2. Apply liquid gasket if there is a dent at the positions as shown in the figure.

    Liquid gasket: 

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

    G14610663Courtesy 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)

    G16384668Courtesy 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) 34 mm (1.3386 in)
    (J) 13 mm (0.5118 in)
    (K) 129.2 mm (5.0866 in)
    (L) Range C
    (M) Liquid gasket applying position of mating surfaces of range A
    (N) Liquid gasket applying position of center boss (5 places)
    (O) Liquid gasket applying position of mating surfaces of range B
    (P) Liquid gasket applying position of mating surfaces of range C
    (Q) Liquid gasket applying position of mating surfaces other than range A, range B and range C
    (R) ø4±0.5 mm (0.1575±0.0197 in)
    (S) 2.3 mm (0.0906 in)
    (T) ø12 mm (0.4724 in)
    (U) 2.8 mm (0.1102 in)
    (V) 1.2 mm (0.0472 in)
    (W) 1 mm (0.0394 in)
  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.
    G13198747Courtesy 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 With Torque Specification
    G16384670Courtesy of SUBARU OF AMERICA, INC.
    (A) M6 x 20
    (B) M6 x 50
    (C) M8 x 25
    (D) M8 x 60
  5. Install the 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)

    G13198745Courtesy of SUBARU OF AMERICA, INC.
  6. Place the engine wiring harness and secure the engine wiring harness with the clip (C).
  7. Connect the connector (B) and connector (A).
    G16439083Courtesy of SUBARU OF AMERICA, INC.
  8. Place the engine wiring harness and secure the engine wiring harness with the clip (E) and clip (D).
  9. Connect the connector (C) and connector (B).
  10. Place the vacuum hose (A) together with the vacuum hose stay, and install the bolt securing the vacuum hose stay.

    Tightening torque: 

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

    G16439084Courtesy of SUBARU OF AMERICA, INC.
  11. Place the PCV pipe assembly, and install the PCV pipe assembly to the intake manifold assembly.
  12. Install the blow-by diagnosis connector harness to the hook (B), and connect the connector (A).
    G16439085Courtesy of SUBARU OF AMERICA, INC.
  13. Install the front engine oil cooler pipe. Ref. to LUBRICATION (H4DOTC)>ENGINE OIL COOLER>INSTALLATION>FRONT ENGINE OIL COOLER PIPE .
  14. Attach the engine oil cooler. Ref. to LUBRICATION (H4DOTC)>ENGINE OIL COOLER>INSTALLATION .
  15. Install the oil pipe. Ref. to LUBRICATION (H4DOTC)>OIL PIPE>INSTALLATION .
  16. Install the crank pulley. Ref. to MECHANICAL (H4DOTC)>CRANK PULLEY>INSTALLATION .
  17. Install the water pump pulley. Ref. to COOLING (H4DOTC)>WATER PUMP>INSTALLATION>WATER PUMP PULLEY .
  18. Install the A/C compressor. Ref. to AIR CONDITIONER>COMPRESSOR>INSTALLATION .
  19. Install the generator. Ref. to STARTING/CHARGING SYSTEMS (H4DOTC)>GENERATOR>INSTALLATION .
  20. Install the V-belt tensioner assembly. Ref. to MECHANICAL (H4DOTC)>V-BELT>INSTALLATION>V-BELT TENSIONER ASSEMBLY .
  21. Install the V-belts. Ref. to MECHANICAL (H4DOTC)>V-BELT>INSTALLATION>V-BELT .
  22. Fill engine oil. Ref. to LUBRICATION (H4DOTC)>ENGINE OIL>REPLACEMENT .
  23. When working on the vehicle
    NOTE: When working on the vehicle, perform the following steps also.
    1. Install the front exhaust pipe. Ref. to EXHAUST (H4DOTC)>FRONT EXHAUST PIPE>INSTALLATION .
    2. Install the intake duct No. 1 and intake duct No. 2. Ref. to INTAKE (INDUCTION) (H4DOTC)>INTAKE DUCT>INSTALLATION>INTAKE DUCT NO. 1 . Ref. to INTAKE (INDUCTION) (H4DOTC)>INTAKE DUCT>INSTALLATION>INTAKE DUCT NO. 2 .
    3. Install the radiator. Ref. to COOLING (H4DOTC)>RADIATOR>INSTALLATION .
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