When removing the intake manifold, as shown in the photos below, leave the TGV
assemblies attached to the upper intake, remove the 2 nuts holding the EGR tube to the water
pipe then remove the complete assembly from the cylinder heads as a unit.

•

There is no need to remove the oil dipstick tube or the original oil filter from the front chain
cover. While the cover is removed, store it face (front side) down to minimize the chances of
damaging the machined sealing surface on the block / head side. Also, don’t use it as a tray
to store other removed parts.

•

IMPORTANT: After all 32 bolts securing the chain cover are removed, be EXTREMELY
careful where you pry and what you pry on to break the silicone sealant’s bond. The photos
below show an example of where NOT to pry. In this case, the cam cap became cracked
requiring a complete cam carrier replacement. Patience is the key!

Reference View

Rear View
Chain Cover

Prying on “Unsupported” Corner of Cam Cap

Continued...
Bulletin Number: 02-157-14; Revised: 09/29/14

Page 8

•

Refer to the instructions found in the Technician Reference Booklet (TRB) for Technical
Training Module 105: “Chain Driven Valve Train Boxer Engines” when removing and
reassembling the timing chain components. The photos and instructions found in the TRB
and provided below have shown to be preferable to those provided in the Service Manual.

•

The timing chains driving the camshafts are identical and are provided with colored
identification links used to align with component timing marks. Chain guides are also
identical for the left and right banks. It is recommended to mark the parts as they are
removed. Return them to their original positions during reassembly to maintain established
wear patterns. Colors used for the identification links will vary.

•

Begin timing chain removal by positioning the crankshaft keyway at the 6:00 position. The
RIGHT bank intake camshaft timing mark (Δ) must be at 6:00 with right bank exhaust timing
mark at 12:00 (camshafts will be unloaded).
6:00

6:00

Identification Link

12:00

•

Compress the chain tensioner by hand, insert a pin through the lever into the access hole
to lock the plunger in place then remove the 2 bolts, tensioner, guides and right side timing
chain.

•

After turning the crankshaft CLOCKWISE, repeat the procedure for the LEFT side with the
timing marks (Δ) positioned as shown below. Align the crank sprocket keyway with RH
chain dowel pin (shown in red below).
8:00

Dowel Pin

1:00

Continued...
Bulletin Number: 02-157-14; Revised: 09/29/14

Page 9

•

Compress the chain tensioner by hand, insert a pin through the lever into the access hole to
lock the plunger in place then remove the 2 bolts, tensioner, guides and the left side timing
chain.

•

After the left chain is removed, turn the crankshaft in a COUNTER CLOCKWISE direction
until the timing mark on the crankshaft sprocket (NOT the keyway) is back to the 6:00
position as shown below. This positions all the pistons away from TDC and prevents
accidental contact between the pistons and valves.

Timing Mark

Crankcase Seam

•

Before proceeding, it is best to rotate the engine on the stand 90 degrees so it is vertical with
one cylinder head facing up (head gasket surface horizontal).

•

Remove the rocker cover then the cam carrier from the head that is “up”. Do not disturb the
small camshaft end cap covers. Remove the cam carrier with the camshafts as an assembly.
At this point, the rest of the valve train is sitting loose on the cylinder head. It is imperative
all the rockers, selective lash caps and rocker pivots are returned to their original
positions on the cylinder head during reassembly. TIP: An egg carton for each head
makes a perfect organizer tray. Make sure to mark it as necessary (front, intake, exhaust) to
eliminate any mixing of parts.

•

Loosen the cylinder head bolts in proper order, remove the head, then flip the engine over and
repeat the same steps for the opposite side.

•

It is very important to take the time necessary to thoroughly clean the old silicone sealer from
all the removed components before reassembly. It is a good idea to clean the surrounding
areas then use tape to block off any oil passages in the front cover and cam carriers so any
small bits of removed silicone debris are kept from entering the oil passages and possibly
causing problems after reassembly. Once all the old sealer has been removed, remove any
block-off tape, rinse out any oil passages thoroughly with brake cleaner and shop air.
Continued...

Bulletin Number: 02-157-14; Revised: 09/29/14

Page 10

•

Don’t forget to clean (without removing) the filter screens in the cam carriers (one filter in
each carrier). In addition, always be sure to do a thorough inspection and cleaning of the oil
pan, pick-up tube and screen as shown in the photos below before reassembly.

Cam Carrier Filter Screen

Oil Pick Up Tube/Filter Screen Assembly

REASSEMBLY
Begin by putting the new short block onto your engine stand using the same mounting points as
before.
Important Reminders:
•

Install the new one-time use PCV adapter. NOTE: Never try to reuse the original.

•

Swap over the PCV assembly and the PCV baffle plate onto the front of the block.
NOTE: No sealer is used between the baffle plate and the block.

Continued...
Bulletin Number: 02-157-14; Revised: 09/29/14

Page 11

•

If equipped, swap over the lower water jacket coolant baffles into the new block.

•

Head gaskets are marked “L” and “R”. Always make sure they are properly installed while
paying close attention to the sealer application areas as outlined in the Service Manual.

•

Always make sure to clean the head bolt threads and apply engine oil to the threads and head
bolt washers before starting the torque sequence. Always follow the torque sequence closely.

•

IMPORTANT: If by chance the AVCS filter screens in the cam carriers have come loose
or fallen out during disassembly, they are directional and MUST be reinstalled in their
original position. There is an oil passage in the cam case which MUST align with a hole on
the outside diameter of the filter screen tube otherwise, oil flow to the AVCS will be restricted
or blocked resulting in engine damage.

•

Before installing the upper and lower oil pans, always thoroughly clean and inspect the
pick-up tube and screen. Always use new o-rings on the pick-up tube and both oil pans
during reassembly.

•

Once the basic “long block” has been reassembled (valve cover to valve cover), proceed with
installation of the timing components as outlined below.
Continued...

Bulletin Number: 02-157-14; Revised: 09/29/14

Page 12

IMPORTANT REMINDER: To eliminate possible confusion, it is strongly recommended
to follow the timing chain reinstallation procedure outlined in this TSB and / or the Technician
Reference Booklet (TRB) for Module 105: “Chain Driven Valve Train Boxer Engines” instead of
the Service Manual procedure.
•

To begin timing chain re-installation, turn the crankshaft COUNTER-CLOCKWISE until
the crankshaft sprocket keyway is back to the 6:00 position. This positions the pistons away
from TDC and prevents accidental contact with the valves. NOTE: The keyway is NOT a
timing mark. The oblong / oval-shaped timing mark must face front and be to the RIGHT of
the keyway as shown below. Do not confuse this mark with a mark which may be found on
the back side of the sprocket.

Keyway
Oblong / Oval-Shaped
Timing Mark to the
RIGHT of the keyway

•

Arrange the timing marks as shown below, turning the crankshaft CLOCKWISE into
position. Align the indicator link with the timing mark on the crankshaft sprocket, keyway
with the dowel pin.

8:00

Keyway

1:00

Continued...
Bulletin Number: 02-157-14; Revised: 09/29/14

Page 13

•

Align the indicator links to the timing marks found on the outside of the sprocket assemblies
as shown in the photos below (Exhaust sprocket face images vary with / without exhaust
VVT).
Timing Marks Aligned With
Indicator Links

Intake and Exhaust VVT Sprocket

No VVT Exhaust Sprocket

•

Install the chain guides and tensioner. Once proper positioning has been confirmed, pull the pin
to release the tensioner. With your hand, grab and squeeze the upper and lower chain / guides
together as shown in the reference photo below to allow the plunger in the tensioner to fully
extend and click into its furthest notch.

•

If you have 3 notches showing, you want to get one more “click” so that 4 notches are visible
as shown in the photos below. If you have 4 showing, you want to end up with 5. Whether
you start with 3 or 4 will depend on the amount of wear present on the chains and guides.
The number of clicks listed here is simply a guide. The point is to ensure proper initial chain
tension is applied to avoid creating a brief rattle sound at engine start.

Continued...
Bulletin Number: 02-157-14; Revised: 09/29/14

Page 14

•

If necessary, insert a plastic screwdriver handle between the lip of the block and the left side
(B2) guide. Then, VERY CAREFULLY push down on the guide just enough to get the extra
tensioner notch / “click”. When using this method, always make sure you are using plastic on
plastic and NOT metal on plastic to avoid damaging the chain guides.

Plastic screw driver handle inserted between front
lip of the block and the B2 upper chain guide
VERY CAREFULLY pushing downward on the upper guide.

•

Rotate the crankshaft COUNTER-CLOCKWISE until the crankshaft sprocket timing mark
is at the 6:00 position. Position the cam sprocket timing marks as shown below; intake 6:00,
exhaust 12:00.

6:00

•

12:00

Align the indicator link with the timing mark on the crankshaft sprocket as shown below.

Continued...
Bulletin Number: 02-157-14; Revised: 09/29/14

Page 15

•

Same as the left side, align the indicator links to the timing marks found on the cam sprocket
assemblies. Install the chain guides and tensioner. Once proper positioning has been
confirmed, pull the pin to release the tensioner. With your hand, grab and squeeze the upper
and lower left side chain / guides together to allow the plunger in the tensioner to extend fully
and click into its furthest notch as shown in the previous (right side) photo. If necessary,
insert a rubber-coated plier handle between the ledge area on the front of the block and the
right side (B1) lower chain guide. Then, VERY CAREFULLY lift up on the guide just
enough to get the extra “click” on the tensioner as shown in the photo below.

Rubber-coated plier handle inserted between a ledge area
on the front of the block and the B1 lower chain guide
VERY CAREFULLY lifting upward on the lower guide.

•

IMPORTANT: When re-installing the front cover assembly, be very careful to not allow it
to contact any of the timing sprockets. If contact does occur, it will most likely be with the
exhaust sprockets and it is almost a guarantee the silicone sealer you have put on the front
cover will be disturbed. If not properly addressed, that area will most likely be the source of
an oil leak after reassembly. Don’t hesitate to use a helper for the installation to prevent this.

•

REMINDER: When replacing the short block, in addition to transferring the crankshaft
position sensor, be sure to index the reluctor properly onto the crankshaft as shown in the
photos below. The reluctor is indexed by a dowel pin in the rear crankshaft flange which
aligns with a corresponding hole in the reluctor. It is possible to install the reluctor without
indexing it correctly. Failure to index the reluctor correctly will result in a no-start condition
due to an out of time crank position signal to the ECM.

Continued...
Bulletin Number: 02-157-14; Revised: 09/29/14

Page 16

•

Once the engine is back in the car and filled with fluids, remove the fuel pump fuse and
crank the engine over (for no more than 10 seconds at a time) to prime the oiling system until
the oil pressure warning light goes out. Re-install the fuel pump fuse then run the engine
initially with the original oil filter left on the front cover for approximately 5 minutes to catch
any other remaining debris. Check for any fluid leaks then install a new oil filter. Start the
engine again and run it for another few minutes. Shut off the engine and allow it cool down
for at least five minutes. Re-check and top off the engine oil to the full mark on the dipstick
before releasing the vehicle.

•

Be advised, some higher than expected oil consumption may occur initially following
the shortblock replacement until the new piston rings become seated. While higher than
expected normally, this oil consumption rate should not be as severe as verified prior to
the repair. This will generally improve within 1000 miles of driving until the expected oil
consumption rate is achieved.

•

Complete the following procedure (where applicable) to conclude the repair procedure, even
if no complaint of this condition has been indicated by the customer.

SERVICE PROCEDURE TO REDUCE FALSE ILLUMINATION OF LOW OIL LEVEL
WARNING LAMP (ON MODELS SO EQUIPPED)
•

Any repairs performed as part of this bulletin must include installation of the applicable
reprogramming file for this condition where applicable. (See Applicable Vehicle Model and
MY in the Warranty/ Claim Information section of this Service Bulletin.)

•

If a vehicle is presented where no repairs for actual oil consumption are required but an
oil consumption test was completed, this reprogramming must also be completed. (See
Applicable Vehicle Model and MY in the Warranty/ Claim Information section of this
Service Bulletin.)

NOTES:
SOA now highly recommends connecting the Midtronics GR8 Diagnostic Battery Charger to the
vehicle and utilizing the Power Supply Mode feature anytime a vehicle control module is being
reprogrammed. Once the GR8 is connected to the vehicle, as long as the battery is fully charged, it
takes less than 3 minutes to boot-up the charger, select the Power Supply Mode, and have the battery
voltage stabilized and ready for reprogramming.
VERY IMPORTANT: This information is applicable to the Midtronics GR8 Diagnostic Battery
Charger ONLY. It does not apply to any other brand / type of “generic” battery charger whatsoever.
ONLY the GR8 and its Power Supply Mode feature has been tested and approved by Subaru of
America, Inc. (SOA).
If the GR8 indicates the vehicle’s battery must be charged, charge the battery using the GR8 before
proceeding to reprogram the vehicle while using the Power Supply Mode.
•

Control module failures as a result of battery discharge during reprogramming are not a
matter for warranty. Should any DTCs reset after the reprogramming update is performed,
diagnose per the procedure outlined in the applicable Service Manual.

Continued...
Bulletin Number: 02-157-14; Revised: 09/29/14

Page 17

WARRANTY / CLAIM INFORMATION
For vehicles within the Basic New Car Limited and / or Powertrain Warranty period, this repair may
be claimed using the following information:
LABOR DESCRIPTION

VEHICLE MODEL

Oil Consumption
Test Including: Oil
and Filter Change, Oil
Leak and PCV System
Inspection

ALL

LABOR
TRANSMISSION
OPERATION #
TYPE

A295-308

2011-2013MY Forester
2014MY Forester
Shortblock
Replacement

2013-2014MY Legacy
& Outback

A295-341

2012-2013MY Impreza
2.0L & 2013MY XV
Crosstrek 2.0L

LABOR
TIME

FAIL
CODE

ALL

0.5

AFU-86

5MT

11.4

4AT
6MT
CVT
6MT
CVT
6MT

11.9
11.5
11.9
11.4
11.9
10.7

CVT

11.0

AFT-48

Oil Consumption Test
Completed, No Repair
Required*

ALL

B295-303*

ALL

0.2

AFY-86

ECM Reprogramming
for False Warning
Lamp Illumination

2013-2014 Legacy
& Outback

C295-305

ALL

0.3

AFZ-86

Adjustment of Oil
Level While Waiting for
Repair Parts*

ALL

A245-232*

ALL

0.2

BAW-88

* 1 quart of motor oil (SOA635045) may be claimed with this labor operation.

Bulletin Number: 02-157-14; Revised: 09/29/14

Page 18