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Home >> Subaru >> 2017 >> Forester 2.0XT Touring >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical (H4DOTC) >> 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 To Chain Cover Using ST
    G11266822Courtesy 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 O-Rings To Cylinder Head
    G11266820Courtesy 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: Cylinder Head And Cylinder Block Liquid Gasket Applying Gaps Area
    G11266824Courtesy 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: Liquid Gasket Applying Dimension To Chain Cover Mating Surface And Center Boss
    G11266825Courtesy 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: Cam Sprocket Sensor Plate Contact Protrusion
    G11266818Courtesy 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: Chain Cover Bolts Tightening Sequence
    G11266827Courtesy 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 Cover And Protrusion
      G11266828Courtesy 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: Locating O-Ring To Oil Level Gauge Guide With Torque Specifications
    G11266829Courtesy 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: Checking Oil Pressure Switch Terminal Angle
    G11266830Courtesy of SUBARU OF AMERICA, INC.

    Tightening torque: 

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

    Fig 10: Connecting Terminal To Oil Pressure Switch
    G10266746Courtesy of SUBARU OF AMERICA, INC.
  8. Attach the rubber cap to the oil pressure switch.
    Fig 11: Locating Rubber Cap To Oil Pressure Switch
    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 Engine Harness Stay Bolt
    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: Removing Engine Harness Clips
    G11266812Courtesy of SUBARU OF AMERICA, INC.
  11. Install the vacuum pipe assembly to the chain cover, and connect the vacuum control hose (C) and vacuum hose (D) to the vacuum pipe assembly.

    Tightening torque: 

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

  12. Install the connector (A) and connector (B) to the vacuum pipe assembly.
    Fig 14: Locating Vacuum Pipe Assembly Bracket Bolts
    G11266811Courtesy of SUBARU OF AMERICA, INC.
  13. Install the blow-by diagnosis connector harness to the PCV hose assembly No. 1, and connect the connector (A) to the engine wiring harness.
    Fig 15: Locating Connector To Engine Wiring Harness
    G11266810Courtesy of SUBARU OF AMERICA, INC.
  14. Install the PCV pipe to the clip (A).
    Fig 16: Installing PCV Pipe To Clip
    G11266837Courtesy of SUBARU OF AMERICA, INC.
  15. Fix the PCV pipe to the intake manifold using the clip.
    Fig 17: Locating PCV Pipe To Intake Manifold Clip
    G11266808Courtesy of SUBARU OF AMERICA, INC.
  16. Install the front engine oil cooler pipe assembly. Ref. to LUBRICATION(H4DO)>Engine Oil Cooler Pipe>INSTALLATION>FRONT ENGINE OIL COOLER PIPE .
  17. Attach the engine oil cooler. Ref. to LUBRICATION(H4DO)>Engine Oil Cooler>INSTALLATION .
  18. Install the crank pulley. Ref. to MECHANICAL (H4DOTC)>Crank Pulley>INSTALLATION .
  19. Install the water pump pulley. Ref. to COOLING(H4DOTC)>Water Pump>INSTALLATION>WATER PUMP .
  20. Install the generator. Ref. to STARTING/CHARGING SYSTEMS(H4DO)>Generator>INSTALLATION .
  21. Install the V-belts. Ref. to MECHANICAL (H4DOTC)>V-belt> INSTALLATION>V-BELT .
  22. Fill engine oil. Ref. to LUBRICATION(H4DO)>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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