02-157-14R

ATTENTION:
CLAIMS PERSONNEL q
IMPORTANT - All
Service Personnel
Should Read and
Initial in the boxes
provided, right.
SERVICE MANAGER
© 2015 Subaru of America, Inc. All rights reserved.
GENERAL MANAGER q
PARTS MANAGER
q
q
SERVICE BULLETIN
APPLICABILITY:  2
 013-14MY Legacy and Outback Models
with 2.5L FB Engines
2011-14MY Forester Models with 2.5L FB Engines
2015 MY Forester (Manual Transmissions Only)
with 2.5L FB Engines
2012-13 MY Impreza and XV Crosstrek Models
with 2.0 FB Engines
2014-15 MY Impreza and XV Crosstrek Models
(Manual Transmissions Only) with 2.0 FB Engines
NUMBER: 02-157-14R
DATE: 08/28/14
REVISED: 11/19/15
SUBJECT:	
Surface Treatment Change To Oil Control
Piston Rings
INTRODUCTION
This bulletin announces information regarding a major change to the repair procedures previously
outlined in Service Bulletins 02-143-13R, 02-144-13R and 02-145-13R. These bulletins provided
a repair procedure for the replacement of the piston rings to address verified concerns of unusual
engine oil consumption. Vehicles confirmed as having this condition which are within the supplied
VIN ranges will no longer be repaired with piston ring replacement. The revised repair procedure
to address verified unusual oil consumption concerns on these specific vehicles will consist of
replacing the engine short block assembly.
It is critical to understand the nature of the concern as reported by the customer and to confirm the
actual condition prior to attempting repairs. Some oil consumption can and should be expected
as a by-product of engine operation even where no concern exists. Failure to recognize this along
with incorrectly diagnosing the condition presented can result in unnecessary repairs. For example:
a vehicle which is presented with a report of a low engine oil level (as read on engine dipstick/
gauge or indicated by illumination of the low engine oil level warning lamp), which is at or near
the time / mileage of the next service interval (based upon the date / mileage of the most recent oil
change), is not representative of unusual oil consumption. The information supplied in this bulletin
is only applicable to vehicles within the specific production ranges of this publication exhibiting
the condition(s) previously described. Additional production enhancements have been incorporated
to the piston rings used in engines mated with manual transmissions. In a limited number of
cases, it has been found that certain driving styles specific to manual transmission operation such
as: extended higher engine rpm operation and / or extensive use of engine braking may create
conditions under which higher than expected oil consumption may occur. These additional
production enhancements are designed to compensate for the engine conditions created under this
type of usage.
IMPORTANT: Read and understand this bulletin COMPLETELY before starting an oil
consumption test or initiating any repairs.
Continued...
CAUTION: VEHICLE SERVICING PERFORMED BY UNTRAINED PERSONS COULD
RESULT IN SERIOUS INJURY TO THOSE PERSONS OR TO OTHERS.
Subaru Service Bulletins are intended for use by professional technicians ONLY. They
are written to inform those technicians of conditions that may occur in some vehicles,
or to provide information that could assist in the proper servicing of the vehicle. Properly
trained technicians have the equipment, tools, safety instructions, and know-how to
do the job correctly and safely. If a condition is described, DO NOT assume that this
Service Bulletin applies to your vehicle, or that your vehicle will have that condition.
Bulletin Number: 02-157-14R; Revised: 11/19/15
SUBARU OF AMERICA, INC. IS
ISO 14001 COMPLIANT
ISO 14001 is the international standard for
excellence in Environmental Management
Systems. Please recycle or dispose of
automotive products in a manner that is friendly
to our environment and in accordance with all
local, state and federal laws and regulations.
Page 1
Concerns related to a possible oil consumption condition are generally initiated when the customer
believes the engine oil level on the dipstick has dropped since the last time it was checked or when
the low oil lamp illuminates. These types of complaints by themselves do not directly indicate
a concern with the vehicle exists. It is important to understand all the factors involved in order
to make a sound decision regarding whether or not a repair is required or if an oil consumption
test should even be started. When speaking with customers about a reported or suspected oil
consumption concern, always keep the following in mind:
Some engine oil will always be consumed as part of normal engine operation. How much and
when it is consumed varies according to manufacturing tolerances, wear, and vehicle usage patterns.
With the extended service intervals commonly used for today’s engines combined with one or more
of the conditions listed below, typical engine oil consumption may require adding engine oil in
between scheduled maintenance intervals:
• When the engine is new and within the break-in period (during the first 1000 miles of
operation)
• When the engine oil being used is of lower quality (other than “Energy or Resource
Conserving” API Classification SM or SN or ILSAC, look for the starburst design with GF-4
or GF-5)
• When the incorrect oil viscosity is used (viscosity other than 0W-20 in the
case of these specific vehicles)
• When engine braking is employed (use of the transmission’s gear ranges
to decelerate while using the engine to apply resistance)
• When the engine is operated at high engine speeds (continually or under
frequent, hard acceleration)
• When the engine is operated under heavy loads (frequent carrying of heavy
cargo, passengers or trailer towing)
• When the engine idles for long periods of time (may be related to frequent
use of a remote engine start system)
• When the vehicle is operated in stop and go and/or heavy traffic situations
• When the vehicle is used under severe temperature conditions (cold or hot)
• When the vehicle accelerates and decelerates frequently
Under these or similar operating conditions, the oil level should be checked more frequently. The
engine oil and filter may also need to be changed more often. As per the Owner’s Manual, engine oil
consumption under these conditions may be as high as 1 quart per 1200 miles.
As related information, the low oil level warning light (on models so equipped) is designed to
illuminate when the engine oil level in the sump drops below approximately 4 quarts with the engine
not running (engine is 1.1 quarts low on oil) and 2.4 quarts when the engine is running. While this
may seem very low, keep in mind that oil remains suspended in the engine while running and will
not fully drain back until the engine has been shut off for at least 5 minutes. In some rare cases, this
light may illuminate with more oil present when the engine is running due to specific road or driving
conditions such as repeated hard acceleration/ deceleration, tight turning, driving on undulating
roads. In these cases, the light will generally reset on its own once the actual level is determined to
be above the illumination threshold. However, this may take some time as certain driving parameters
must be met for the system to self-correct. As long as the oil level has been checked and adjusted (if
necessary), the immediate concern has been addressed. If the lamp does not extinguish on its own
after some time and the oil level remains full, an inspection of the circuit and components should
be performed. See Section 3 of the Owner’s Manual for more information on the oil level warning
system. See Service Procedure to reduce false illumination of low oil level warning lamp (on models
so equipped) later in this bulletin for instructions on how to address customer concerns where the low
engine oil level warning lamp illuminates when the engine oil level is either full or nearly full.
Continued...
Bulletin Number: 02-157-14R; Revised: 11/19/15
Page 2
PRODUCTION CHANGE INFORMATION
The updated piston rings were incorporated into production as per the table below. Vehicles with
VINs / engine numbers PRIOR to those listed below should be repaired following the procedures
outlined in this TSB and the applicable Service Manual.
MODEL
MODEL YEAR
STARTING VIN
ENGINE NUMBER
All
All
Below F*543650
Below 527514
All
All
Below E*529004
Below 132164
All
All
2015
Below F*270253
Below 627010
2012
All
All
2013
Below D*033336
Below 930025 (FA1 Line*)
or 652640 (FB2 Line*)
2012
All
All
Below D*886714
Below 930025 (FA1 Line*)
or 652640 (FB2 Line*)
2011-14
2015
Forester
2011-13
2014
Impreza 4- &
5-Door
Impreza
4-Door
Impreza
5-Door
2012-14
TRANSMISSION
MT
4AT or CVT
MT
CVT
CVT
2013
2013-14
MT
All
All
2013
CVT
Below D*048086
Below 151602
2013-14
MT
All
All
2013
CVT
Below D*321435
Below 151602
All
All
Below F*270284
Below 627010
Below D*856139
Below 930025 (FA1 Line*)
or 652640 (FB2 Line*)
Legacy
Outback
2013-14
MT
XV Crosstrek
2015
2013
CVT
* NOTE: When determining the engine number, use the LAST 8
characters of the number stamped into the boss on top of the block
adjacent to the starter and shown in the illustration. The engine number
range for the FA1 assembly line is 800000 to 930025 and the FB2 range
is 000000 to 652640.
PART INFORMATION
The chart below provides a required part list for the short block
replacement procedure. This list is provided as a reference only and
may not be totally complete depending on the needs of your specific
repair. Always verify with your Parts Department that all needed
parts with the most up-to-date part numbers are ordered.
Bulletin Number: 02-157-14R; Revised: 11/19/15
Engine
Number
Location
Continued...
Page 3
PART NUMBER
DESCRIPTION
QTY. /REPAIR
APPLICABILITY
10103AC590
2014MY Forester
10103AC600
2013-2014MY Legacy & Outback
10103AC390*
2013MY XV Crosstrek 2.0L CVT
10103AC700*
Short Block Assy.
1
2013MY XV Crosstrek 2.0L MT
10103AC420*
2012-2013MY Impreza 2.0L CVT
10103AC690*
2012-2013MY Impreza 2.0L MT
10103AC610
2011-2013MY Forester
11821AA660
PCV Adaptor
1
44011AC030
Exhaust Gasket
2
44616AA200
Center Pipe Gasket
1
14035AA580
Intake Gasket
2
14852AA040
14738AA150
806912190
806924120
806915100
806916080
10966AA040
EGR Pipe Gasket
O-Ring, Chain Cover
O-Ring, Tensioner
Seal, Spark Plug Tube
13270AA240
13272AA170
13270AA27A*
1
3
1
1
Up to 1/2012
1
2/2012 and Later
4
1
Rocker Gasket*
13272AA21A*
806915170
1
1
1
1
O-Ring, Cam Carrier
1
10944AA080
1
Head Gasket*
10944AA070*
1
1
11122AA350
Sealing-Oil Pan
2
806949060
O-Ring, Pick-Up Tube
1
806932030
O-Ring, Upper Oil Pan
3
21236AA050
Thermostat Gasket
1
806939060
O-Ring, Crank Extension
1
806750080
Oil Seal, Front Crankshaft
1
Bulletin Number: 02-157-14R; Revised: 11/19/15
*Legacy & Outback
4
11044AA790
11044AA780*
Impreza, Forester and
XV Crosstrek
Legacy, Outback and Forester
*Impreza and XV Crosstrek
w/ 2.0L
Page 4
PART NUMBER
DESCRIPTION
16608KA000
Injector O-Rings
16698AA110
QTY. /REPAIR
4
4
15208AA15A
Oil Filter
1
803916010
Gasket, Drain Plug
1
806933010
O-Ring, Coolant Cross-Over
2
11136AA140
11136AA160
Oil Level Switch
APPLICABILITY
1
All EXCEPT 2012MY Impreza
1
2012MY Impreza w/ 5MT ONLY
* IMPORTANT NOTES:
•
When the Short Block Assembly for your vehicle application is a 10103AC390, that
number is for CVT models only. For M/T models, when a 10103AC390 is specified, use
10103AC700.
•
When the Short Block Assembly for your vehicle application is a 10103AC420, that
number is for CVT models only. For M/T models, when a 10103AC420 is specified, use
10103AC690.
MISCELLANEOUS MATERIALS
SOA (ORDERABLE)
PART NUMBER
SOA868V9610
SOA868V9270
SOA427V1310
WARRANTY
PART NUMBER
SOA635305
SOA635041
SOA635045
DESCRIPTION
QUANTITY
ThreeBond 1217H
Super Coolant, (qt.)
Engine Oil (qt.) 0W-20
1
8
6
SERVICE PROCEDURE / INFORMATION
Before starting any repairs, the first step is to always confirm the customer’s complaint. It is critical
to get as much information from the customer as possible to help you make the most accurate diagnosis.
•
Review all the available service and repair history along with any other records the customer can
provide to establish whether or not the vehicle has been properly maintained.
•
Perform a thorough visual inspection to make sure there are no external oil leaks that could
be contributing to the condition.
•
It is also very important to not overlook the engine’s PCV system and to confirm it is
operating properly. Check the air filter assembly and throttle body / intake manifold for any
excessive oil residue which could be an indicator of a sticking or failed PCV valve.
NOTES:
•
An oil consumption test will need to be completed to determine the proper course of action.
There is a specific procedure and Oil Consumption Test form which must be completed. See
Subarunet \ Service \ Forms for the latest test form. Always print the latest form anytime a
new test is started.
Continued...
Bulletin Number: 02-157-14R; Revised: 11/19/15
Page 5
•
Where applicable, available reprogramming to reduce the possibility of false low engine oil
level warning lamp illumination must be installed.
•
See Service Procedure to reduce false illumination of low oil level warning lamp (on
models so equipped) later in this bulletin for further instructions. This must be completed at
either the start or end of the consumption testing regardless of the final outcome.
•
IMPORTANT: At the start of the Oil Consumption Test Form, specific information
regarding what prompted (reason for) the testing must be collected. Once this questionnaire
section of the form is completed, it must be faxed to 856-488-3199. Upon completion of the
actual consumption test, the remainder of the form must be completed and faxed AGAIN to
856-488-3199. This information is being collected for quality assurance purposes only. You
will not receive any response from these submissions. This is NOT an authorization process.
Proceed with any necessary testing or repairs as indicated by the information provided in
this service bulletin, the Oil Consumption Test form results, Subaru’s Claims Policies and
Procedures, and your evaluation of the actual condition presented based upon your review
of all three areas. Keep in mind, these repairs should only be completed when unusual oil
consumption has been confirmed.
Before initiating the consumption test, all basic checks must be completed. These include (but are not
limited to): confirming the actual oil level, noting if any oil has been added prior to this visit and how
much, checking for any external leaks, confirming PCV operation, and verifying that a consumption
test has not already been started or completed previously. Always use the latest Oil Consumption
Test form form found on Subarunet in the Service Forms area. Follow the instructions outlined on the
form.
NOTE: The oil and filter change is only necessary if no prior consumption test has been completed
or is already in process. There is no need for duplicate or repeat testing. One-time documented results
are all that is required to move forward with these repairs. Always close the repair order on the day
the oil change has been completed and submit the claim for the oil consumption test using the coding
provided at the end of this bulletin. Indicate “Oil Consumption Test” in the comments field / box
when entering your claim. DO NOT hold the repair order open until the vehicle returns. Have the
customer drive the vehicle then return for inspection when any of the following have occurred:
•
At least 1200 miles have elapsed
•
When the low engine oil level warning lamp illuminates (when equipped)
•
When the oil level reaches the lower hole in the dipstick/ gauge (as determined by the
customer).
The customer should be advised to not add oil unless there will be a significant delay before they can
return for inspection once a low oil condition occurs. A one-time check of the oil consumption by the
retailer is all that is needed to establish if the condition outlined in this bulletin applies.
SPECIFIC SERVICE PROCEDURES
The following information is provided to underscore service procedures specific to the repairs
outlined in this bulletin. The procedures provided here are specific to certain steps in the
overall process. They are not meant to represent the entire repair process from start to finish.
In some cases, they will differ greatly from the Service Manual instructions and should be
followed in place of the Service Manual for these specific areas only. For the balance of the
repair procedure, refer to the Service Manual. It is highly recommended to review all of the
Service Manual procedures for short block replacement then review these specific procedures to
become familiar with the differences.
Continued...
Bulletin Number: 02-157-14R; Revised: 11/19/15
Page 6
•
•
•
When draining the engine oil, do not remove the engine oil filter. Leave the existing oil filter
in place through engine disassembly, reassembly, installation and initial startup after engine
reassembly.
When removing the engine, there is no need to remove the transmission case cover (CVT
only) or to disconnect / disturb any of the transmission harness connectors. While raising
the transmission with the service jack placed under the front differential as shown in the
illustration below, only raise it enough to access and remove the engine mounting
hardware. Raising it too high can push the transmission up into the bulkhead / transmission
tunnel and possibly cause damage.
When removing the CVT fluid cooler (if equipped), leave it attached to its mounting bracket
and remove as an assembly (3 bolts) from the transmission. Disconnect just the engine
coolant hoses from it and do not disturb the 2 short CVT fluid lines. Hook one of the cooler’s
mounting bracket “ears” behind the bulkhead harness as shown in the photo below to keep
the cooler assembly out of your way. Use a shop cloth between the “ear” and the bulkhead
harness to prevent any chafing.
Continued...
Bulletin Number: 02-157-14R; Revised: 11/19/15
Page 7
•
To make separating the transmission (CVT) from the engine easier, there is a pry relief
shown below in the machined mounting surface of the transmission case near the engine
number. Use caution when applying any prying pressure and avoid twisting the tool to
prevent case damage.
•
Once the engine is removed, if you are using a generic engine stand (preferable since engine
rotation is necessary), use the four mounting holes on the engine block shown below to
mount it. NOTE: Do not use the mounting studs in the upper oil pan.
Continued...
Bulletin Number: 02-157-14R; Revised: 11/19/15
Page 8
•
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: 02-157-14R; Revised: 11/19/15
Page 9
•
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: 02-157-14R; Revised: 11/19/15
Page 10
•
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 be returned to their original
positions and orientation on the cylinder heads during reassembly. This eliminates the
need to check and / or adjust the valve lash / cam clearances. 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: 02-157-14R; Revised: 11/19/15
Page 11
•
Don’t forget to thoroughly clean (without removing) the filter screens in the cam carriers. 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: 02-157-14R; Revised: 11/19/15
Page 12
•
•
If equipped, swap over the water jacket coolant spacers / 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,
fallen out or become lost during disassembly, they are available separately (p.n. 14451AA050).
NOTE: The filter screens are directional and MUST be reinstalled in their original
position, flush with the machined surface of the cam carrier. There is an oil passage in the
cam case which MUST align with the ”screen” area on the outside surface of the filter (see
insets below) otherwise, oil flow to the AVCS can become restricted or blocked resulting in
engine damage. Engines with AVCS on both intake and exhaust will have 2 filters in each
carrier (blue arrows) as opposed to just one (intake only AVCS) as shown in the photo below.
•
Filter Screen
Installed
NO Filter Screen
Installed
Orifice
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.
• After cleaning the upper oil pan assembly,
replace the oil level switch assembly as
shown in the illustration on the right.
Torque the 2 retaining bolts to 6.4 Nm
(56 inch-pounds).
NOTE: DO NOT use any sealer in conjunction
with the new o-ring included with the new oil
level switch.
•
Bulletin Number: 02-157-14R; Revised: 11/19/15
Continued...
Page 13
•
•
•
Once the basic “long block” has been reassembled (valve cover to valve cover), proceed with
installation of the timing components as outlined below.
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: 02-157-14R; Revised: 11/19/15
Page 14
•
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: 02-157-14R; Revised: 11/19/15
Page 15
•
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: 02-157-14R; Revised: 11/19/15
Page 16
•
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 fresh silicone sealer beads applied to the
cover will be disturbed. To minimize the possibility of this happening, alignment pins as
shown in the photos below have been developed to “guide” the cover into its proper position
without disturbing the fresh sealer. The Subaru Special Tool number for the alignment pin kit
is J-51972. Each kit includes 2 pins.
•
If alignment pins are not used and the sealer gets disturbed during the cover installation,
unless properly addressed, the affected area(s) will most likely be the source of an oil leak
after reassembly. Don’t hesitate to use a helper for the cover installation to prevent this from
happening.
Continued...
Bulletin Number: 02-157-14R; Revised: 11/19/15
Page 17
•
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.
•
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 THE LOW OIL LEVEL
WARNING LAMP (ON MODELS SO EQUIPPED)
Any repairs performed as part of this bulletin MUST include installation of the applicable ECM
reprogramming file for Oil Level Detection and replacement of the oil level switch. Refer to the
applicable TSBs as listed below:
•
11-145-14R for 2013-2014MY Legacy and Outback models
•
11-148-14R for 2014-15MY Forester models
•
11-149-14R for 2013-14MY Impreza 2.0L and XV Crosstrek models
•
11-150-14R for 2012MY 2.0L Impreza models
VERY IMPORTANT: If a vehicle is presented where no repairs for actual oil consumption are
required but an oil consumption test was completed, BOTH the applicable ECM reprogramming file
for Oil Level Detection AND the updated oil level switch MUST be installed before releasing the
vehicle to the customer.
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).
Continued...
Bulletin Number: 02-157-14R; Revised: 11/19/15
Page 18
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.
WARRANTY / CLAIM INFORMATION
For vehicles within the Basic New Car Limited and / or Powertrain Warranty period or covered by an
active Subaru Added Security Powertrain, Classic or Gold plan, this repair may be submitted using
the following claim information:
LABOR DESCRIPTION
VEHICLE MODEL
Oil Consumption Test
Including: Oil and Filter
Change, Oil Leak and
PCV System Inspection
ALL
LABOR
TRANSMISSION
OPERATION #
TYPE
B295-308
2011-2013MY Forester
2014MY Forester
Shortblock
Replacement includes Oil
Level Switch Replacement
2015MY Forester
(MT ONLY)
2013-2014MY Legacy
& Outback
B295-341
2012-2013MY Impreza
2.0L & 2013MY XV
Crosstrek 2.0L
2014-2015MY Impreza
2.0L & XV Crosstrek 2.0L
(MT ONLY)
Oil Consumption Test
Completed, No Repair
Required*
Adjustment of Oil
Level While Waiting for
Repair Parts*
ECM Reprogramming to
prevent False Warning
Lamp Illumination
LABOR
TIME
FAIL
CODE
ALL
0.5
AFU-86
5MT
11.5
4AT
CVT
6MT
12.0
12.0
11.6
6MT
11.6
6MT
CVT
11.5
12.0
CVT
11.1
5MT
10.8
5MT
10.8
AFT-48
ALL
B295-303*
ALL
0.2
AFY-86
ALL
B245-232*
ALL
0.2
BAW-88
ALL
C295-305**
ALL
0.3
AFZ-86
* 1 quart of motor oil (SOA635045) may be claimed with this labor operation.
**	This labor operation may only be claimed ONE TIME in combination with ONE of the “B”
operations listed above.
IMPORTANT REMINDERS:
• SOA strongly discourages the printing and/or local storage of service information as
previously released information and electronic publications may be updated at any time.
• Always check for any open recalls or campaigns anytime a vehicle is in for servicing.
• Always refer to STIS for the latest service information before performing any repairs.
Bulletin Number: 02-157-14R; Revised: 11/19/15
Page 19