Content .. 67 68 69 70 ..

Subaru Legacy (2005 year). Manual - part 69

ME(H4SO 2.0)-59

MECHANICAL

Cylinder Head

D: ASSEMBLY

1) Installation of valve spring and valve

(1) Place the cylinder head on the ST.

498267800

CYLINDER HEAD TABLE

(2) Coat the stem of each valve with engine oil
and insert the valve into valve guide.

CAUTION:
Use extreme care not to damage the oil seal lips
when inserting the valve into valve guide.

(3) Install the valve spring and retainer.

NOTE:
Be sure to install the valve spring with its close-
coiled end facing the seat on cylinder head.

(4) Set the ST on valve spring.

499718000

VALVE SPRING REMOVER

(1)

Valve

(6)

Retainer

(11)

Plug

(2)

Valve guide

(7)

Retainer key

(12)

Camshaft cap

(3)

Valve spring seat

(8)

Spark plug gasket

(13)

Valve rocker ASSY

(4)

Oil seal

(9)

Camshaft

(5)

Valve spring

(10)

Oil seal

ME-02528

(10)

(9)

(6)

(1)

(2)

(3)

(4)

(5)

(7)

(8)

(11)

(13)

(12)

ME-00280

ME(H4SO 2.0)-60

MECHANICAL

Cylinder Head

(5) Compress the valve spring and install the
valve spring retainer key.

(6) After installing, tap the valve spring retainers
lightly with a plastic hammer for better seating.

E: INSPECTION

1. CYLINDER HEAD

1) Make sure that no crack or other damage do not
exist. In addition to visual inspection, inspect impor-
tant areas using liquid penetrant tester.
Also make sure the gasket installing surface shows
no trace of gas and water leaks.
2) Place the cylinder head on the ST.
ST

498267800

CYLINDER HEAD TABLE

3) Measure the warping of the cylinder head sur-
face that mates with crankcase using a straight
edge and thickness gauge.
If the warping exceeds the limit, regrind the surface
with a surface grinder.

Warping limit:

0.03 mm (0.0012 in)

Grinding limit:

0.1 mm (0.004 in)

Standard height of cylinder head:

97.5 mm (3.839 in)

NOTE:
Uneven torque for the cylinder head bolts can
cause warping. When reassembling, pay special
attention to the torque so as to tighten evenly.

2. VALVE SEAT

Inspect the intake and exhaust valve seats, and
correct the contact surfaces with a valve seat cutter
if they are defective or when valve guides are re-
placed.

Valve seat width W:

Intake (A)

Standard 0.8 — 1.4 mm (0.03 — 0.055 in)

Exhaust (B)

Standard 1.2 — 1.8 mm (0.047 — 0.071 in)

(A) Retainer key

(B) Valve spring

ME-00282

(B)

(A)

(A) Straight edge

(B) Thickness gauge

(A)

(B)

ME-00285

(A)

(B)

ME-00397

ME-00287

ME(H4SO 2.0)-61

MECHANICAL

Cylinder Head

3. VALVE GUIDE

1) Check the clearance between valve guide and
stem. The clearance can be checked by measuring
respectively the outer diameter of valve stem and
inner diameter of valve guide.

Clearance between the valve guide and valve
stem:

Intake

Standard 0.035 — 0.062 mm (0.0014 —
0.0024 in)

Exhaust

Standard 0.040 — 0.067 mm (0.0016 —
0.0026 in)

2) If the clearance between valve guide and stem
exceeds the standard, replace the valve guide or
valve itself whichever shows greater amount of
wear. See the following procedure for valve guide
replacement.

Valve guide inner diameter:

6,000 — 6.012 mm (0.2362 — 0.2367 in)

Valve stem outer diameter:

Intake

5.950 — 5.965 mm (0.2343 — 0.2348 in)

Exhaust

5.945 — 5.960 mm (0.2341 — 0.2346 in)

(1) Place the cylinder head on ST1 with the
combustion chamber upward so that valve
guides fit the holes in ST1.
(2) Insert the ST2 into valve guide and press it
down to remove the valve guide.

ST1

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CYLINDER HEAD TABLE

ST2

499767200

VALVE GUIDE REMOVER

(3) Turn the cylinder head upside down and
place the ST as shown in the figure.

Intake side:
ST

499767700

VALVE GUIDE ADJUSTER

Exhaust side:
ST

499767800

VALVE GUIDE ADJUSTER

(4) Before installing a new valve guide, make
sure that neither scratches nor damages exist
on the inside surface of the valve guide holes in
cylinder head.
(5) Put a new valve guide, coated with sufficient
oil, in cylinder, and insert the ST1 into valve
guide. Press in until the valve guide upper end is
flush with the upper surface of ST2.

ST1

499767200

VALVE GUIDE REMOVER

Intake side:
ST2

499767700

VALVE GUIDE ADJUSTER

Exhaust side:
ST2

499767800

VALVE GUIDE ADJUSTER

(A) Valve guide

ME-00763

(A)

ME-00289

(A) Valve guide

ME-00290

ST2

ST1

(A)

ME-00291

ST2

ME-00292

ST1

ME(H4SO 2.0)-62

MECHANICAL

Cylinder Head

(6) Check the valve guide protrusion.

Valve guide protrusion L:

Intake

20.0 — 21.0 mm (0.787 — 0.827 in)

Exhaust

16.5 — 17.5 mm (0.650 — 0.689 in)

(7) Ream the inside of valve guide using ST.
Put the reamer in valve guide, and rotate the
reamer slowly clockwise while pushing it lightly.
Bring the reamer back while rotating it clock-
wise. After reaming, clean the valve guide to re-
move chips.

CAUTION:
• Apply engine oil to the reamer when reaming.
• If the inner surface of the valve guide is torn,
the edge of the reamer should be slightly
ground with an oil stone.
• If the inner surface of the valve guide be-
comes lustrous and the reamer does not chip,
use a new reamer or remedy the reamer.
ST

499767400

VALVE GUIDE REAMER

(8) Recheck the contact condition between
valve and valve seat after replacing the valve
guide.

4. INTAKE AND EXHAUST VALVE

1) Inspect the flange and stem of valve, and re-
place if damaged, worn or deformed, or if “H” ex-
ceeds the standard.

Intake

Standard 0.8 — 1.2 mm (0.03 — 0.047 in)

Exhaust

Standard 1.0 — 1.4 mm (0.039 — 0.055 in)

Valve overall length:

Intake

120.6 mm (4.75 in)

Exhaust

121.7 mm (4.79 in)

2) Put a small amount of grinding compound on the
seat surface, and lap the valve and seat surface.
<Ref. to ME(H4SO 2.0)-60, VALVE SEAT, IN-
SPECTION, Cylinder Head.> Install a new intake
valve oil seal after lapping.

(A) Valve guide

ME-00293

(A)

ME-00294

ME-00295

Content .. 67 68 69 70 ..