Chain Cover: Installation

WARNING: This page is about a different variant/trim than selected.

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 1: Locating O-Rings
Courtesy of SUBARU OF AMERICA, INC.
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 2: Applying Liquid Gasket Gaps Between Front Camshaft Cap And Cam Carrier
Courtesy of SUBARU OF AMERICA, INC.
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 3: Applying Liquid Gasket To Chain Cover Mating Surface And Center Boss
Courtesy of SUBARU OF AMERICA, INC.
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 4: Identifying Cam Sprocket Sensor Plate Protrusion
Courtesy 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 5: Chain Cover Bolts Tightening Sequence
Courtesy of SUBARU OF AMERICA, INC.
Install the idler pulley (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 6: Identifying Idler Pulley Cover Protrusion
  Courtesy 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 7: Installing Oil Level Gauge Guide With Torque Specifications
Courtesy of SUBARU OF AMERICA, INC.
Connect the terminal (A), connector (B), connector (C) and connector (D), and secure the engine harness using the clip (E) and 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 8: Checking Oil Pressure Switch Harness Terminal Angle
Courtesy of SUBARU OF AMERICA, INC.

Tightening torque:

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

Fig 9: Securing Engine Harness Using Clips
Courtesy of SUBARU OF AMERICA, INC.
Attach the rubber cap to the oil pressure switch.

Fig 10: Locating Rubber Cap To Oil Pressure Switch
Courtesy of SUBARU OF AMERICA, INC.
Secure the oil level switch harness with clips (A), and connect the connectors to the oil level switch.

Fig 11: Locating Connectors To Oil Level Switch
Courtesy of SUBARU OF AMERICA, INC.
Connect the connector (A) and connector (B) and secure the engine harness with the clip (C) and clip (D).

Fig 12: Securing Engine Harness With Clips
Courtesy of SUBARU OF AMERICA, INC.
Install the engine harness stay to the chain cover.
Tightening torque:

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

Fig 13: Locating Engine Harness Stay Bolts
Courtesy of SUBARU OF AMERICA, INC.
Install the crank pulley. Ref. to MECHANICAL(H4DO)>Crank Pulley>INSTALLATION .
Install the water pump pulley. Ref. to COOLING(H4DO)>Water Pump>INSTALLATION>WATER PUMP .
Install the generator. Ref. to STARTING/CHARGING SYSTEMS(H4DO)>Generator>INSTALLATION .
Fill engine oil. Ref. to LUBRICATION(H4DO)>Engine Oil>REPLACEMENT .
When working on the vehicle

NOTE: When working on the vehicle, perform the following steps also.

Install the generator cord stay to the chain cover.
NOTE: Install the generator cord stay so that the folded end (a) touches the chain cover boss.

Tightening torque:

8 N.m (0.8 kgf-m, 5.9 ft-lb)

Fig 14: Locating Generator Cord Stay Bolt
Courtesy of SUBARU OF AMERICA, INC.
Install the front exhaust pipe. Ref. to EXHAUST(H4DO)>Front Exhaust Pipe>INSTALLATION .
Install the radiator. Ref. to COOLING(H4DO)>Radiator>INSTALLATION .