Partial Engine Assy (FA20): Assembly

1. Install the oil spacer LH with two bolts.

   Standard value: T=6.4N.M {65kgf.cm} {4.7ft.lbf}

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1. Install two new oil control valve filters LH to the cam carrier LH as shown in the figure.

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1. Apply new engine oil to the journal of cam carrier LH.
2. Install the intake camshaft LH and exhaust camshaft LH to the cam carrier LH.

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1. Apply THREE BOND 1217G, THREE BOND 1217H or equivalent to the mating surfaces of the front camshaft cap LH, intake rear camshaft cap LH and exhaust rear camshaft cap LH as shown in the figure.

   Courtesy of SUBARU OF AMERICA, INC.

   CAUTION:

   • Clean and degrease the installation surface.
   • Do not apply liquid gasket excessively to avoid engine seizure.
   • Do not apply liquid gasket to the intake center camshaft cap LH and exhaust center camshaft cap LH.
   • Install within 5 min. after applying liquid gasket.
2. Apply new engine oil to the journals of each camshaft cap and set it to the cam carrier LH.
3. Tighten 13 bolts in order as shown in the figure, install the front camshaft cap LH, intake center camshaft cap LH, intake rear camshaft cap LH, exhaust center camshaft cap LH and exhaust rear camshaft cap LH.

   Standard value: T=18N.M {184kgf.cm} {13.3ft.lbf}

   Fig 1: Camshaft Cap Bolts (Tightening Sequence)

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1. Using a new gasket, install the hole plug to the cam carrier RH. Standard value: T=25N.M {225kgf.cm} {18.4ft.lbf}

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1. Using two new gaskets, temporarily tighten the camshaft oil field pipe SUB-ASSY with the two union bolts and bolt.
2. Tighten the bolt to specified torque.

   Standard value: T=6.4N.M {65kgf.cm} {4.7ft.lbf}

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3. Tighten the two union bolts to specified torque.

   Standard value: T=31N.M {316kgf.cm} {22.9ft.lbf}

1. Install the oil spacer RH with two bolts.

   Standard value: T=6.4N.M {65kgf.cm} {4.7ft.lbf}

   Courtesy of SUBARU OF AMERICA, INC.

1. Install two new oil control valve filters RH to the cam carrier RH as shown in the figure.

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1. Apply new engine oil to the journal of cam carrier RH.
2. Install the intake camshaft RH and exhaust camshaft RH to the cam carrier RH.

   Courtesy of SUBARU OF AMERICA, INC.

1. Apply THREE BOND 1217G, THREE BOND 1217H or equivalent to the mating surfaces of the front camshaft cap RH, intake rear camshaft cap RH and exhaust rear camshaft cap RH as shown in the figure.

   Courtesy of SUBARU OF AMERICA, INC.

   CAUTION:

   • Clean and degrease the installation surface.
   • Do not apply liquid gasket excessively to avoid engine seizure.
   • Do not apply liquid gasket to the intake center camshaft cap RH and exhaust center camshaft cap RH.
   • Install within 5 min. after applying liquid gasket.
2. Apply new engine oil to the journals of each camshaft cap and set it to the cam carrier RH.
3. Tighten the 12 bolts in the order shown in the figure, and install the front camshaft cap RH, intake center camshaft cap RH, intake rear camshaft cap RH, exhaust center camshaft cap RH and exhaust rear camshaft cap RH.

   Standard value: T=18N.M {184kgf.cm} {13.3ft.lbf}

   Fig 2: Camshaft Caps Bolts (Tightening Sequence)

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1. Install the two stud bolts to the oil pan upper.

   Standard value: T=10N.M {102kgf.cm} {7.4ft.lbf}

   Stud bolt height (A): 70.0mm {2.756 in}

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2. Install the baffle plate to the oil pan upper with four bolts.

   Standard value: T=6.4N.M {65kgf.cm} {4.7ft.lbf}

   Courtesy of SUBARU OF AMERICA, INC.

3. Apply THREE BOND 1217G, THREE BOND 1217H or equivalent to the mating surface of oil pan upper as shown in the figure.

   Courtesy of SUBARU OF AMERICA, INC.

   CAUTION:

   • Clean and degrease the installation surface.
   • Install within 5 min. after applying liquid gasket.
   • Apply liquid gasket 1.5 mm {0.0591 in} outside from the groove on the oil pan upper. However, application of liquid gasket on the groove around the bolt hole is allowed.
4. Install three new O-rings to the cylinder block.

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5. Tighten the 13 bolts (A, B and C) in the order shown in the figure to install the oil pan upper to the cylinder block.

   Standard value: T=18N.M {184kgf.cm} {13.3ft.lbf}

   Fig 3: Oil Pan Upper Bolts Tightening Sequence

   Courtesy of SUBARU OF AMERICA, INC.

   Bolt type	Bolt length (except for head)
   Bolt A	25 mm {0.984 in}
   Bolt B	75 mm {2.953 in}
   Bolt C	30 mm {1.181 in}

   <Reference>

   • Tighten bolt C using a TORX^® bit T45.
   • After tightening, if the liquid gasket is squeezed out onto the seal surface of chain cover, completely remove any squeezed-out liquid gasket.

1. Install a new O-ring.
2. Install the oil strainer to the oil pan upper with the two bolts.

   Standard value: T=6.4N.M {65kgf.cm} {4.7ft.lbf}

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1. Install two new oil pan seal rings to the oil pan.

   Courtesy of SUBARU OF AMERICA, INC.

2. Apply THREE BOND 1217G, THREE BOND 1217H or equivalent to the mating surface of the oil pan for the oil pan upper as shown in the figure.

   Courtesy of SUBARU OF AMERICA, INC.

   CAUTION:

   • Clean and degrease the installation surface.
   • Install within 5 min. after applying liquid gasket.
3. Tighten the 11 bolts in the order as shown in the figure to install the oil pan.

   Standard value: T=6.4N.M {65kgf.cm} {4.7ft.lbf}

   Fig 4: Oil Pan Bolts Tightening Sequence

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1. Install the housing cover to the oil pan upper with two bolts.

   Standard value: T=5.0N.M {51kgf.cm} {3.7ft.lbf}

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1. Install the engine hanger No. 2 to the cylinder block (bank 1 side) with two bolts.

   Standard value: T=21 N.M {214kgf.cm} {15.5ft.lbf}

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1. Move the engine stand to orientate bank 2 side upward.
2. Clean the bolt holes in the cylinder block (bank 2 side).
   CAUTION: To avoid erroneous tightening of the bolts, clean out the bolt holes sufficiently by blowing with compressed air to eliminate engine coolant etc.
3. Apply THREE BOND 1217G, THREE BOND 1217H or equivalent to both sides of a new cylinder head gasket No. 2 as shown in the figure.

   Courtesy of SUBARU OF AMERICA, INC.

   CAUTION:

   • Clean and degrease the installation surface.
   • Install within 5 min. after applying liquid gasket.
4. Install the cylinder head gasket No. 2.

1. Clean the cylinder head bolt threads and apply sufficient new engine oil to the washer and cylinder head bolt threads.
2. Set the cylinder head LH to the cylinder block (bank 2 side).
3. Tighten the six cylinder head bolts in the order as shown in the figure.

   Standard value: T=20N.M {204kgf.cm} {14.8ft.lbf}

   Fig 5: Cylinder Head LH Bolts (Tightening Sequence)

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4. Further-tighten the six cylinder head bolts in the same order.

   Standard value: T=100N.M {102kgf.cm} {73.8ft.lbf}

   CAUTION: If the bolt makes a stick-slip sound during tightening, clean the bolt holes and installation surface, dry them completely, and then repeat the steps from the application of seal gasket.

   <Reference>

   If the processes are resumed, the cylinder head gasket can be reused.

5. Loosen the six cylinder head bolts by 360° in the order shown in the figure.
   Fig 6: Cylinder Head LH Bolts (Loosening Sequence)

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6. Tighten the six cylinder head bolts in the order as shown in the figure.

   Standard value: T=20N.M {204kgf.cm} {14.8ft.lbf}

   Fig 7: Cylinder Head LH Bolts (Tightening Sequence)

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7. Further-tighten the six cylinder head bolts in the same order.

   Standard value: T=42N.M {428kgf.cm} {31.0ft.lbf}

8. Further-tighten the six cylinder head bolts by 100° using an angle gauge in the order shown in the figure.
   Fig 8: Cylinder Head LH Bolts (Tightening Sequence)

   Courtesy of SUBARU OF AMERICA, INC.

   <Reference>

   As necessary, attach the temporary bolt to fix the angle gauge.

9. Further-tighten the two cylinder head bolts by 100° using an angle gauge in the order shown in the figure.
   Fig 9: Cylinder Head LH Bolts Tightening Sequence

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10. Further-tighten the four cylinder head bolts by 50° using an angle gauge in the order shown in the figure.
    Fig 10: Cylinder Head LH Bolts (Tightening Sequence)

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1. Apply new engine oil to the valve shim and roller rocker arm pivot, and install them to the cylinder head LH.

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2. Apply new engine oil to the eight roller rocker arms and two new O-rings, and install them to the cylinder head LH.
3. Apply THREE BOND 1217G, THREE BOND 1217H or equivalent to the mating surface of cam carrier LH as shown in the figure.

   Courtesy of SUBARU OF AMERICA, INC.

   Courtesy of SUBARU OF AMERICA, INC.

   CAUTION:

   • Clean and degrease the installation surface.
   • Do not apply liquid gasket excessively.
   • Install within 5 min. after applying liquid gasket.
   • Completely remove any liquid gasket that is squeezed out on the installation surface of chain cover.
4. Tighten the nine bolts in the order shown in the figure to install the cam carrier LH.

   Standard value: T=18N.M {184kgf.cm} {13.3ft.lbf}

   Fig 11: Cam Carrier LH Bolts (Tightening Sequence)

   Courtesy of SUBARU OF AMERICA, INC.

   <Reference>

   Set the intake camshaft LH and the exhaust camshaft LH to the zero-lift position.

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5. Loosen the three bolts by 180° in the order shown in the figure.
   Fig 12: Cam Carrier LH Bolts (Loosening Sequence)

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6. Tighten the three bolts in the order as shown in the figure.

   Standard value: T=18N.M {184kgf.cm} {13.3ft.lbf}

   Fig 13: Cam Carrier LH Bolts (Tightening Sequence)

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7. Loosen the three bolts by 180° in the order shown in the figure.
   Fig 14: Cam Carrier LH Bolts (Loosening Sequence)

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8. Tighten the three bolts in the order as shown in the figure.

   Standard value: T=18N.M {184kgf.cm} {13.3ft.lbf}

   Fig 15: Cam Carrier LH Bolts (Tightening Sequence)

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9. Loosen the three bolts by 180° in the order shown in the figure.
   Fig 16: Cam Carrier LH Bolts (Loosening Sequence)

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10. Tighten the three bolts in the order as shown in the figure.

    Standard value: T=18N.M {184kgf.cm} {13.3ft.lbf}

    <Reference>

    After tightening, if the liquid gasket is squeezed out onto the seal surface of chain cover, completely remove any squeezed-out liquid gasket.

    Fig 17: Cam Carrier LH Bolts (Tightening Sequence)

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1. Measure the roller surface of cam base circle and roller rocker arm using a thickness gauge.

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   Standard value (when engine is cold): 0.10 to 0.15 mm {0.0039 to 0.0059 in} (intake side)

   0.20 to 0.24 mm {0.0079 to 0.0094 in} (exhaust side)

   <Reference>

   • For cam clearance inspection, adjust the cam base circle position so that the thickness gauge can be inserted easily by hand turning the camshaft to be measured.
   • If the measured value is out of standard, take notes of the value in order to adjust the cam clearance later on.

1. Remove the cam carrier LH.
2. Remove the roller rocker arm.
3. Remove the valve shim.
4. Measure the thickness of the removed valve shim using a micrometer.

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5. Calculate the thickness of valve shim so that the cam clearance is within the standard value.

   Standard value:

   Intake side:

   (Selected shim thickness) = (Removed shim thickness) + [(Measured clearance) - 0.13 mm {0.0051 in}] x 1.69

   Exhaust side:

   (Selected shim thickness) = (Removed shim thickness) + [(Measured clearance) - 0.22 mm {0.0087 in}] x 1.87

6. Apply new engine oil to the inner circumference of the selected valve shim and install it to the valve.
   CAUTION: After inserting the valve shim, make sure that it turns smoothly.
7. Install the roller rocker arm.
8. Install the cam carrier LH.

1. Apply a thin coat of new engine oil to two new spark plug pipe gaskets and insert them all the way into the spark plug pipe.

   Courtesy of SUBARU OF AMERICA, INC.

2. Install a new rocker cover gasket No. 2 to the rocker cover LH.
3. Apply THREE BOND 1217G, THREE BOND 1217H or equivalent to the mating surface of rocker cover LH as shown in the figure.

   Application area	Application length
   A	10.0 mm {0.394 in} or more
   B	18.8 mm {0.740 in} or less
   C	63.0 mm {2.480 in} or more

   Courtesy of SUBARU OF AMERICA, INC.

4. Set the rocker cover LH and tighten the eight bolts in the order shown in the figure.

   Standard value: T=6.4N.M {65kgf.cm} {4.7ft.lbf}

   Fig 18: Rocker Cover LH Bolts Tightening Sequence

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1. Move the engine stand to orientate bank 1 side upward.
2. Clean the bolt holes in the cylinder block (bank 1 side).
   CAUTION: To avoid erroneous tightening of the bolts, clean out the bolt holes sufficiently by blowing with compressed air to eliminate engine coolant etc.
3. Apply THREE BOND 1217G, THREE BOND 1217H or equivalent to both sides of a new cylinder head gasket as shown in the figure.

   Courtesy of SUBARU OF AMERICA, INC.

   CAUTION:

   • Clean and degrease the installation surface.
   • Install within 5 min. after applying liquid gasket.
4. Attach the cylinder head gasket.

1. Clean the cylinder head bolt threads and apply sufficient new engine oil to the washer and cylinder head bolt threads.
2. Set the cylinder head on the cylinder block (bank 1 side).
3. Tighten the six cylinder head bolts in the order as shown in the figure.

   Standard value: T=20N.M {204kgf.cm} {14.8ft.lbf}

   Fig 19: Cylinder Head Bolts (Tightening Sequence)

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4. Further-tighten the six cylinder head bolts in the same order.

   Standard value: T=100N.M {102kgf.cm} {73.8ft.lbf}

   CAUTION: If the bolt makes a stick-slip sound during tightening, clean the bolt holes and installation surface, dry them completely, and then repeat the steps from the application of seal gasket.

   <Reference>

   If the processes are resumed, the cylinder head gasket can be reused.

5. Loosen the six cylinder head bolts by 360° in the order shown in the figure.
   Fig 20: Cylinder Head Bolts (Loosening Sequence)

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6. Tighten the six cylinder head bolts in the order as shown in the figure.

   Standard value: T=20N.M {204kgf.cm} {14.8ft.lbf}

   Fig 21: Cylinder Head Bolts (Tightening Sequence)

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7. Further-tighten the six cylinder head bolts in the same order.

   Standard value: T=42N.M {428kgf.cm} {31.0ft.lbf}

8. Further-tighten the six cylinder head bolts by 100° using an angle gauge in the order shown in the figure.
   Fig 22: Cylinder Head Bolts (Tightening Sequence)

   Courtesy of SUBARU OF AMERICA, INC.

   <Reference>

   As necessary, attach the temporary bolt to fix the angle gauge.

9. Further-tighten the two cylinder head bolts by 100° using an angle gauge in the order shown in the figure.
   Fig 23: Cylinder Head Bolts (Tightening Sequence)

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10. Further-tighten the four cylinder head bolts by 50° using an angle gauge in the order shown in the figure.
    Fig 24: Cylinder Head Bolts (Tightening Sequence)

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1. Apply new engine oil to the valve shim and roller rocker arm pivot, and install them to the cylinder head RH.

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2. Apply new engine oil to the eight roller rocker arms and two new O-rings, and install them to the cylinder head RH.
3. Apply THREE BOND 1217G, THREE BOND 1217H or equivalent to the mating surface of cam carrier RH as shown in the figure.

   Courtesy of SUBARU OF AMERICA, INC.

   Courtesy of SUBARU OF AMERICA, INC.

   CAUTION:

   • Clean and degrease the installation surface.
   • Do not apply liquid gasket excessively.
   • Install within 5 min. after applying liquid gasket.
   • Completely remove any liquid gasket that is squeezed out on the installation surface of chain cover.
4. Tighten the nine bolts in the order shown in the figure to install the cam carrier RH.

   Standard value: T=18N.M {184kgf.cm} {13.3ft.lbf}

   Fig 25: Cam Carrier RH Bolts (Tightening Sequence)

   Courtesy of SUBARU OF AMERICA, INC.

   <Reference>

   Set the intake camshaft RH and the exhaust camshaft RH to the zero-lift position.

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5. Loosen the three bolts by 180° in the order shown in the figure.
   Fig 26: Cam Carrier RH Bolts (Loosening Sequence)

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6. Tighten the three bolts in the order as shown in the figure.

   Standard value: T=18N.M {184kgf.cm} {13.3ft.lbf}

   Fig 27: Cam Carrier RH Bolts (Tightening Sequence)

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7. Loosen the three bolts by 180° in the order shown in the figure.
   Fig 28: Cam Carrier RH Bolts (Loosening Sequence)

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8. Tighten the three bolts in the order as shown in the figure.

   Standard value: T=18N.M {184kgf.cm} {13.3ft.lbf}

   Fig 29: Cam Carrier RH Bolts (Tightening Sequence)

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9. Loosen the three bolts by 180° in the order shown in the figure.
   Fig 30: Cam Carrier RH Bolts (Loosening Sequence)

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10. Tighten the three bolts in the order as shown in the figure.

    Standard value: T=18N.M {184kgf.cm} {13.3ft.lbf}

    <Reference>

    After tightening, if the liquid gasket is squeezed out onto the seal surface of chain cover, completely remove any squeezed-out liquid gasket.

    Fig 31: Cam Carrier RH Bolts (Tightening Sequence)

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1. Measure the roller surface of cam base circle and roller rocker arm using a thickness gauge.

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   Standard value (when engine is cold): 0.10 to 0.15 mm {0.0039 to 0.0059 in} (intake side)

   0.20 to 0.24 mm {0.0079 to 0.0094 in} (exhaust side)

   <Reference>

   • For cam clearance inspection, adjust the cam base circle position so that the thickness gauge can be inserted easily by hand turning the camshaft to be measured.
   • If the measured value is out of standard, take notes of the value in order to adjust the cam clearance later on.

1. Remove the cam carrier RH.
2. Remove the roller rocker arm.
3. Remove the valve shim.
4. Measure the thickness of the removed valve shim using a micrometer.

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5. Calculate the thickness of valve shim so that the cam clearance is within the standard value.

   Standard value:

   Intake side:

   (Selected shim thickness) = (Removed shim thickness) + [(Measured clearance) - 0.13 mm {0.0051 in}] x 1.69

   Exhaust side:

   (Selected shim thickness) = (Removed shim thickness) + [(Measured clearance) - 0.22 mm {0.0087 in}] x 1.87

6. Apply new engine oil to the inner circumference of the selected valve shim and install it to the valve.
   CAUTION: After inserting the valve shim, make sure that it turns smoothly.
7. Install the roller rocker arm.
8. Install the cam carrier RH.

1. Apply a thin coat of new engine oil to two new spark plug pipe gaskets and insert them all the way into the spark plug pipe.

   Courtesy of SUBARU OF AMERICA, INC.

2. Install a new rocker cover gasket to the rocker cover RH.
3. Apply THREE BOND 1217G, THREE BOND 1217H or equivalent to the mating surface of rocker cover RH as shown in the figure.

   Application area	Application length
   A	10.0 mm {0.394 in} or more
   B	68.0 mm {2.677 in} or more
   C	70.7 mm {2.784 in} or more

   Courtesy of SUBARU OF AMERICA, INC.

4. Set the rocker cover RH and tighten the eight bolts in the order shown in the figure.

   Standard value: T=6.4N.M {65kgf.cm} {4.7ft.lbf}

   Fig 32: Rocker Cover RH Bolts Tightening Sequence

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5. Install the injector driver bracket using two bolts.

   Standard value: T=6.4N.M {65kgf.cm} {4.7ft.lbf}

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1. Install the four spark plugs.

   Standard value: T=17N.M {173kgf.cm} {12.5ft.lbf}

1. Install the exhaust cam sprocket LH by aligning the knock hole of the exhaust cam sprocket LH and the knock pin of the exhaust camshaft LH.

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2. Use the SST to secure the exhaust cam sprocket LH and tighten the three bolts.

   SST 18355AA000, 18334AA020, 18270KA010

   Standard value: T=18N.M {184kgf.cm} {13.3ft.lbf}

   CAUTION: Take care to prevent the SST from falling off.

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1. Install the intake cam sprocket LH by aligning the knock hole of the intake cam sprocket LH and the knock pin of the intake camshaft LH.

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2. Use the SST to secure the intake cam sprocket LH and tighten the three bolts.

   SST 18355AA000, 18334AA020, 18270KA010

   Standard value: T=18N.M {184kgf.cm} {13.3ft.lbf}

   CAUTION: Take care to prevent the SST from falling off.

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1. Install the exhaust cam sprocket RH by aligning the knock hole of the exhaust cam sprocket RH and the knock pin of the exhaust camshaft RH.

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2. Use the SST to secure the exhaust cam sprocket RH and tighten the three bolts.

   SST 18355AA000, 18334AA020, 18270KA010

   Standard value: T=18N.M {184kgf.cm} {13.3ft.lbf}

   CAUTION: Take care to prevent the SST from falling off.

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1. Install the intake cam sprocket RH by aligning the knock hole of the intake cam sprocket RH and the knock pin of the intake camshaft RH.

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2. Use the SST to secure the intake cam sprocket RH and tighten the three bolts.

   SST 18355AA000, 18334AA020, 18270KA010 Standard value: T=18N.M {184kgf.cm} {13.3ft.lbf}

   CAUTION: Take care to prevent the SST from falling off.

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1. Install the crankshaft sprocket.

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<Reference>

Apply new engine oil to all component parts of the timing chain.

1. Attach the SST to the crankshaft.

   SST 18252AA000

2. Move the link plate in the direction of the arrow and press in the plunger.

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3. Insert a wire (with a diameter of approx. 1.3 mm {0.05 in}) into the stopper pin hole to secure the plunger.

   <Reference>

   If the stopper pin hole on the link plate and the stopper pin hole on the chain tensioner are not aligned, check that the first notch of plunger rack is engaged with the stopper tooth. If not engaged, retract the plunger a little so that the first notch of plunger rack is engaged with the stopper tooth.

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4. Check that the crankshaft sprocket is located at the position shown in the figure. If not aligned, turn the crankshaft to bring the crankshaft sprocket alignment mark to the position shown in the figure.

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   CAUTION: Perform properly to avoid contact of the valve and piston.
5. Using the SST, turn the intake cam sprocket LH to bring the alignment mark to the position shown in the figure.

   SST 18355AA000, 18334AA020

   CAUTION:

   • Take care to prevent the SST from falling off.
   • The intake valve and exhaust valve may contact each other, causing the valve stem to bend. Do not turn the exhaust camshaft LH.

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6. Use the SST to turn the crankshaft approximately 200° counterclockwise and bring the crankshaft sprocket key to the position shown in the figure.

   SST 18252AA000

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   CAUTION: Never turn clockwise because the valve and piston may contact. However, turning clockwise is allowed for fine adjustments after aligning the crankshaft sprocket key to the position shown in the figure.
7. Remove the SST.
8. Turn the exhaust cam sprocket LH to bring the alignment mark to the position shown in the figure.
   CAUTION:

   • Take care to prevent the SST from falling off.
   • To prevent valve damage, turn the exhaust cam sprocket LH only within the range of zero-lift (range where it can be turned lightly by hand).

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9. Align the mark (blue) of timing chain to the alignment mark position of crankshaft sprocket.

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10. Align the mark (pink) of timing chain to the timing mark position of intake cam sprocket LH.
11. Align the mark (pink) of timing chain to the timing mark position of exhaust cam sprocket LH.
12. Apply new engine oil to the sliding surface of chain guide bolt.
13. Install the chain guide with the bolt.

    Standard value: T=6.4N.M {65kgf.cm} {4.7ft.lbf}

14. Install a new O-ring to the cylinder block (bank 2 side).

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15. Install the chain tension lever.

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16. Install the chain tensioner No. 2 with the two bolts.

    Standard value: T=6.4N.M {65kgf.cm} {4.7ft.lbf}

17. Make sure that the timing chain is properly installed.

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    1. The mark (blue) of timing chain is aligned to the alignment mark position of crankshaft sprocket.
    2. The mark (pink) of timing chain is aligned to the timing mark position of intake cam sprocket LH.
    3. The mark (pink) of timing chain is aligned to the timing mark position of exhaust cam sprocket LH.
18. Pull out the wire from the chain tensioner No. 2.

    <Reference>

    Push up the chain tension lever and press in the plunger of chain tensioner No. 2 to pull out the wire.

19. Attach the SST to the crankshaft.

    SST 18252AA000

20. Turn the crankshaft clockwise and make sure that there are no abnormal conditions.
    CAUTION: Always make sure to perform this confirmation.

<Reference>

Apply new engine oil to all component parts of the timing chain.

1. Move the link plate in the direction of the arrow and press in the plunger.

   Courtesy of SUBARU OF AMERICA, INC.

2. Insert a dia. 2.5 mm hex wrench into the stopper pin hole to fix the plunger.

   Courtesy of SUBARU OF AMERICA, INC.

   <Reference>

   If the stopper pin hole on the link plate and the stopper pin hole on the chain tensioner are not aligned, check that the first notch of plunger rack is engaged with the stopper tooth. If not engaged, retract the plunger a little so that the first notch of plunger rack is engaged with the stopper tooth.

3. Turn the crankshaft using the SST to position the alignment marks of the crankshaft sprocket, intake cam sprocket LH and exhaust cam sprocket LH as shown in the figure.

   Courtesy of SUBARU OF AMERICA, INC.

   <Reference>

   If the marks are aligned to the positions shown in the figure, the crankshaft sprocket key faces downward.

4. Position the alignment marks of the intake cam sprocket RH and exhaust cam sprocket RH to the positions as shown in the figure.
   CAUTION: To prevent valve damage, turn the intake cam sprocket RH and exhaust cam sprocket RH only within the range of zero-lift (in range where they can be turned lightly by hand).

   Courtesy of SUBARU OF AMERICA, INC.

5. Align the mark (blue) of timing chain to the alignment mark position of crankshaft sprocket.

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6. Align the mark (pink) of timing chain to the timing mark position of intake cam sprocket RH.
7. Align the mark (pink) of timing chain to the timing mark position of exhaust cam sprocket RH.
8. Apply new engine oil to the sliding surface of chain guide bolt.
9. Install the chain guide with the bolt.

   Standard value: T=6.4N.M {65kgf.cm} {4.7ft.lbf}

10. Install the chain tension lever.

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11. Install the chain tensioner No. 1 with the two bolts.

    Standard value: T=6.4N.M {65kgf.cm} {4.7ft.lbf}

12. Make sure that the timing chain is properly installed.

    Courtesy of SUBARU OF AMERICA, INC.

    1. The mark (blue) of timing chain is aligned to the alignment mark position of crankshaft sprocket.
    2. The mark (pink) of timing chain is aligned to the timing mark position of intake cam sprocket RH.
    3. The mark (pink) of timing chain is aligned to the timing mark position of exhaust cam sprocket RH.
13. Pull out the hexagon wrench from the chain tensioner No. 1.
14. Turn the crankshaft clockwise and make sure that there are no abnormal conditions.
    CAUTION: Always make sure to perform this confirmation.
15. Remove the SST from the crankshaft.

1. Apply a thin coat of new engine oil to four new O-rings and install to the engine.
2. Before applying liquid gasket, completely remove the old sealing material attached to the sealing portion.
3. If there are gaps at the locations as shown in the figure, fill the gaps with THREE BOND 1217G, THREE BOND 1217H or equivalent.

   Courtesy of SUBARU OF AMERICA, INC.

4. Apply THREE BOND 1217G, THREE BOND 1217H or equivalent to the locations of chain cover as shown in the figure.

   Courtesy of SUBARU OF AMERICA, INC.

   CAUTION:

   • Clean and degrease the installation surface.
   • Install within 5 min. after applying liquid gasket.
   • To prevent damage caused by the chain cover coming into contact with cam sprocket sensor plate protrusion a, when setting the chain cover, be sure to carefully slide the chain cover horizontally so that it does not contact the cam sprocket.

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5. Temporarily install the chain cover with the 32 bolts.
6. Tighten the 32 bolts in the order as shown in the figure.
   Fig 33: Chain Cover Bolts Tightening Sequence

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   Standard value: Bolts A, B

   T=10N.M {102kgf.cm} {7.4ft.lbf}

   Bolt C, D

   T=25N.M {255kgf.cm} {18.4ft.bf}

   <Reference>

   Bolt type	Bolt length (except for head)	Bolt type	Bolt length (except for head)
   Bolt A	20 mm {0.787 in}	Bolt B	50 mm {1.969 in}
   Bolt C	25 mm {0.984 in}	Bolt D	60 mm {2.362 in}

1. Degrease the chain cover oil seal press-fit section, and use the SST to install a new chain cover oil seal onto the chain cover.

   SST 41399FG020

   CAUTION: To prevent any leakage of engine oil, ensure that no material such as engine oil is present on the chain cover oil seal and chain cover oil seal press-fit section.
   Chain cover oil seal press-fit position: 0 to 1.0 mm from the chain cover end surface

   Courtesy of SUBARU OF AMERICA, INC.

1. Install the crankshaft pulley boss.
2. Install a new O-ring to the crankshaft pulley boss.
3. Install the crankshaft pulley while aligning its knock hole to the knock pin of crankshaft pulley boss.

   Courtesy of SUBARU OF AMERICA, INC.

4. Apply new engine oil to the washer and bolt threads of the crankshaft pulley set bolt.
5. Use the SST to secure the crankshaft pulley and tighten the crankshaft pulley set bolt.

   SST 18355AA000, 18334AA000

   Standard value: T=20N.M {204kgf.cm} {14.8ft.lbf}

6. Draw a reference line (A) on the crankshaft pulley set bolt and end line (B) on the crankshaft pulley according to the engraved lines on the bolt using a marker as shown in the figure.

   Courtesy of SUBARU OF AMERICA, INC.

   <Reference>

   Lines are marked at a interval of 90° on the crankshaft pulley set bolt head portion.

7. Use the SST to secure the crankshaft pulley and retighten the crankshaft pulley bolt by 90° until the reference line (A) and end line (B) are aligned.

   SST 18355AA000, 18334AA000

   Courtesy of SUBARU OF AMERICA, INC.

1. Install a new gasket to the thermostat.

1. Set the thermostat on the oil pan upper and install the thermostat cover with two bolts.

   Standard value: T=6.4N.M {65kgf.cm} {4.7ft.lbf}

   Courtesy of SUBARU OF AMERICA, INC.

1. Using a new gasket, install the water pump ASSY with five bolts.

   Standard value: T=6.4N.M {65kgf.cm} {4.7ft.lbf}

   Courtesy of SUBARU OF AMERICA, INC.

1. Temporarily- tighten the three bolts to the water pump pulley.
2. Use the SST to secure the water pump pulley.

   SST 18355AA000, 18334AA030

   Courtesy of SUBARU OF AMERICA, INC.

3. Tighten the three bolts.

   Standard value: T=14N.M {143kgf.cm} {10.3fMbf}

1. Apply THREE BOND 1217G, THREE BOND 1217H or equivalent to the pump drive case ASSY as shown in the figure.

   Courtesy of SUBARU OF AMERICA, INC.

   CAUTION:

   • Clean and degrease the installation surface.
   • Install within 5 min. after applying liquid gasket.
2. Tighten the three bolts to install the pump drive case ASSY.

   Standard value: T=19N.M {194kgf.cm} {14.0ft.bf}

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1. Apply THREE BOND 1324 or equivalent to the PCV valve.

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2. Install the PCV valve to the cylinder head block.

   Standard value: T=23N.M {235kgf.cm} {17.0ft.lbf}

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1. Install two new O-rings to the cylinder block.

   Courtesy of SUBARU OF AMERICA, INC.

2. Install the water pipe ASSY with the four bolts.

   Standard value: T=6.4N.M {65kgf.cm} {4.7ft.lbf}

   Courtesy of SUBARU OF AMERICA, INC.

1. Install a new O-ring to the oil level gauge guide.
2. Apply new engine oil to the O-ring and install the oil level gauge guide with a bolt.

   Standard value: T=6.4N.M {65kgf.cm} {4.7ft.lbf}

3. Install the oil level gauge.

1. Apply THREE BOND 1217G, THREE BOND 1217H or equivalent to the cam carrier RH as shown in the figure.

   Courtesy of SUBARU OF AMERICA, INC.

   CAUTION:

   • Clean and degrease the installation surface.
   • Install within 5 min. after applying liquid gasket.
2. Install the cylinder head plate RR with three bolts.

   Standard value: T=16N.M {163kgf.cm} {11.8ft.lbf}

   Courtesy of SUBARU OF AMERICA, INC.

1. Apply THREE BOND 1217G, THREE BOND 1217H or equivalent to the cam carrier RH as shown in the figure.

   Courtesy of SUBARU OF AMERICA, INC.

   CAUTION:

   • Clean and degrease the installation surface.
   • Install within 5 min. after applying liquid gasket.
2. Install a new O-ring.
3. Align the groove on the vacuum pump ASSY and the tab on the intake camshaft RH.

   Courtesy of SUBARU OF AMERICA, INC.

   CAUTION: Be careful not to let the O-ring catch.
4. Tighten the three bolts to install the vacuum pump ASSY.

   Standard value: T=16N.M {163kgf.cm} {11.8ft.lbf}

   Courtesy of SUBARU OF AMERICA, INC.

1. Install two new O-rings to the PCV hose connector.

   Courtesy of SUBARU OF AMERICA, INC.

2. Connect the water by-pass hose No. 1 to the PCV hose connector and water pipe ASSY with the hose clamps.
3. Install the PCV hose connector with the three bolts.

   Standard value: T=6.4N.M {65kgf.cm} {4.7ft.lbf}

   Courtesy of SUBARU OF AMERICA, INC.

1. Degrease the threads of the engine oil pressure switch ASSY.
2. Apply THREE BOND 1324 or equivalent to the threaded portion.
   CAUTION: Do not apply THREE BOND 1324 or equivalent to the oil hole.

   Courtesy of SUBARU OF AMERICA, INC.

3. Install the engine oil pressure switch ASSY.

   Standard value: T=18N.M {184kgf.cm} {13.3ft.lbf}

   CAUTION: Do not start the engine within one hour after assembly.

   Courtesy of SUBARU OF AMERICA, INC.

1. Install a new gasket to the engine oil temperature sensor.
2. Install the engine oil temperature sensor.

   Standard value: T=18N.M {184kgf.cm} {13.3ft.lbf}

   Courtesy of SUBARU OF AMERICA, INC.

1. Install the back-up ring to the camshaft timing oil control valve ASSY (bank 2 exhaust side).

   Courtesy of SUBARU OF AMERICA, INC.

2. Install a new O-ring to the camshaft timing oil control valve ASSY (bank 2 exhaust side).
3. Apply new engine oil to the O-ring.
4. Install the camshaft timing oil control valve ASSY (bank 2 exhaust side) using two bolts.

   Standard value: T=6.4N.M {65kgf.cm} {4.7ft.lbf}

5. Install the back-up ring to the camshaft timing oil control valve ASSY (bank 2 intake side).
6. Install a new O-ring to the camshaft timing oil control valve ASSY (bank 2 intake side).
7. Apply new engine oil to the O-ring.

   Courtesy of SUBARU OF AMERICA, INC.

8. Install the camshaft timing oil control valve ASSY (bank 2 intake side) using two bolts.

   Standard value: T=6.4N.M {65kgf.cm} {4.7ft.lbf}

9. Install the back-up ring to the camshaft timing oil control valve ASSY (bank 1 exhaust side).
10. Install a new O-ring to the camshaft timing oil control valve ASSY (bank 1 exhaust side).
11. Apply new engine oil to the O-ring.

    Courtesy of SUBARU OF AMERICA, INC.

12. Install the camshaft timing oil control valve ASSY (bank 1 exhaust side) using two bolts.

    Standard value: T=6.4N.M {65kgf.cm} {4.7ft.lbf}

13. Install the back-up ring to the camshaft timing oil control valve ASSY (bank 1 intake side).
14. Install a new O-ring to the camshaft timing oil control valve ASSY (bank 1 intake side).
15. Apply new engine oil to the O-ring.

    Courtesy of SUBARU OF AMERICA, INC.

16. Install the camshaft timing oil control valve ASSY (bank 1 intake side) using two bolts.

    Standard value: T=6.4N.M {65kgf.cm} {4.7ft.lbf}

    Courtesy of SUBARU OF AMERICA, INC.

1. Install a new O-ring to the camshaft position sensor (bank 2 exhaust side).
2. Apply new engine oil to the O-ring.
3. Install the camshaft position sensor (bank 2 exhaust side) using a bolt.

   Standard value: T=6.4N.M {65kgf.cm} {4.7ft.lbf}

   Courtesy of SUBARU OF AMERICA, INC.

4. Install a new O-ring to the camshaft position sensor (bank 2 intake side).
5. Apply new engine oil to the O-ring.
6. Install the camshaft position sensor (bank 2 intake side) using a bolt.

   Standard value: T=6.4N.M {65kgf.cm} {4.7ft.lbf}

   Courtesy of SUBARU OF AMERICA, INC.

7. Install a new O-ring to the camshaft position sensor (bank 1 exhaust side).
8. Apply new engine oil to the O-ring.
9. Install the camshaft position sensor (bank 1 exhaust side) using a bolt.

   Standard value: T=6.4N.M {65kgf.cm} {4.7ft.lbf}

   Courtesy of SUBARU OF AMERICA, INC.

10. Install a new O-ring to the camshaft position sensor (bank 1 intake side).
11. Apply new engine oil to the O-ring.
12. Install the camshaft position sensor (bank 1 intake side) using a bolt.

    Standard value: T=6.4N.M {65kgf.cm} {4.7ft.lbf}

    Courtesy of SUBARU OF AMERICA, INC.

1. Install the crank position sensor using a bolt.

   Standard value: T=6.4N.M {65kgf.cm} {4.7ft.lbf}

   Courtesy of SUBARU OF AMERICA, INC.

1. Install the two knock control sensors in the direction shown in the figure using two bolts.

   Standard value: T=24N.M {245kgf.cm} {17.7ft.lbf}

   Courtesy of SUBARU OF AMERICA, INC.

1. Using a new gasket, install the engine water temperature sensor.

   Standard value: T=18N.M {184kgf.cm} {13.3ft.lbf}

   CAUTION:

   • When tightening by combining a torque wrench and union nut wrench to extend the whole length, the actual torque will be excessive if tightened until the reading of the torque wrench reaches the specified tightening torque.
   • This repair information only indicates the specified tightening torque. If using an extension tool, it is necessary to use the following formula to calculate the proper torque wrench reading.
   • Formula: T' = TxL2/(L1 +L2)

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   T'	Torque wrench reading [Nm {kgf.cm}]
   T	18N.m {184kgfcm}{13ft.lbf}
   L1	Extension tool effective length [m {in}]
   L2	Torque wrench effective length [m {in}]

   <Reference>

   • This torque value is valid when the extension tool and torque wrench are oriented in a straight line.
   • Attach the extension tool and torque wrench so that they are properly lined up.

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1. Install the oil filter union.

   Standard value: T=45N.M {459kgf.cm} {33.2ft.lbf}

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1. Apply a thin coat of new engine oil to the seal rubber of a new oil filter.
2. Tighten the oil filter by hand.
   CAUTION: Be careful not to damage the seal rubber of oil filter.
3. Tighten the oil filter using the SST.

   SST 18332AA020

   Standard value: T=14N.M {143kgf.cm} {10.3ft.lbf}

   CAUTION:

   • When extending the overall tool length by combining a torque wrench with the SST during tightening, tightening to the point where the value on the torque wrench reaches the specified tightening torque will cause the actual tightening torque to be excessive.
   • This repair information only indicates the specified tightening torque. If using an SST or extension tool, it is necessary to use the following formula to calculate the proper torque wrench reading.
   • Formula: T' = TxL2/(L1+L2)

   T'	Torque wrench reading [N.m {kgf.cm}]
   T	14Nm {143kgf.cm}{10.3ft.lbf}
   L1	0.080m {3.150 in}
   L2	Torque wrench effective length [m {in}]

   <Reference>

   • This torque value is valid when the SST and torque wrench are aligned on a line.
   • Attach the SST and torque wrench so that they are aligned on a line.

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1. Install the oil filler cap.