Subaru Legacy (2005 year). Manual - part 280

ME(H4DOTC)-63

MECHANICAL

Cylinder Head

6) Install the cam sprocket.
<Ref. to ME(H4DOTC)-54, INSTALLATION, Cam
Sprocket.>
7) Install the timing belt.
<Ref. to ME(H4DOTC)-48, INSTALLATION, Tim-
ing Belt.>
8) Install the timing belt cover.
<Ref. to ME(H4DOTC)-45, INSTALLATION, Tim-
ing Belt Cover.>
9) Install the crank pulley.
<Ref. to ME(H4DOTC)-43, INSTALLATION, Crank
Pulley.>
10) Install the V-belts. <Ref. to ME(H4DOTC)-40,
INSTALLATION, V-belt.>

C: DISASSEMBLY

1) Remove the valve lifter.
2) Compress the valve spring and remove the
valve spring retainer key. Remove each valve and
valve spring.
ST1

498267600

CYLINDER HEAD TABLE

ST2

499718000

VALVE SPRING REMOVER

NOTE:
Keep all the removed parts in order for re-installing
in their original positions.

CAUTION:
• Mark each valve to prevent confusion.
• Use extreme care not to damage the lips of
the intake valve oil seals and exhaust valve oil
seals.

ME-00124

ST1

ST2

ME(H4DOTC)-64

MECHANICAL

Cylinder Head

D: ASSEMBLY

(1)

Exhaust valve

(5)

Intake valve oil seal

(9)

Valve lifter

(2)

Intake valve

(6)

Valve spring

(10)

Exhaust valve oil seal

(3)

Cylinder head

(7)

Retainer

(11)

Intake valve guide

(4)

Valve spring seat

(8)

Retainer key

(12)

Exhaust valve guide

ME-00795

(3)

(1)

(2)

(11)

(4)

(5)

(6)

(7)

(8)

(9)

(11)

(12)

(12)

(10)

(4)

(4)

(5)

(6)

(6)

(7)

(7)

(8)

(8)

(9)

(9)

(10)

(4)

(6)

(7)

(8)

(9)

ME(H4DOTC)-65

MECHANICAL

Cylinder Head

1) Installation of valve spring and valve

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

NOTE:
When inserting the valve into valve guide, use spe-
cial care not to damage the oil seal lip.

(2) Set the cylinder head on ST1.
(3) Install the valve spring and retainer using
ST2.

ST1

498267600

CYLINDER HEAD TABLE

ST2

499718000

VALVE SPRING REMOVER

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

(4) Compress the valve spring and install the
valve spring retainer key.
(5) After installing, tap the valve spring retainers
lightly with a wooden hammer for better seating.

2) Apply oil to the surfaces of the valve lifter.
3) Install the valve lifter.

E: INSPECTION

1. CYLINDER HEAD

1) Make sure that crack or other damages do not
exist. In addition to visual inspection, inspect impor-
tant areas using liquid penetrant tester.
2) Measure the warping of the cylinder head sur-
face that mates with crankcase using a straight
edge (A) and thickness gauge (B).
If the warping exceeds the limit, regrind the surface
with a surface grinder.

Warping limit:

0.035 mm (0.0014 in)

Grinding limit:

0.3 mm (0.012 in)

Standard height of cylinder head:

127.5 mm (5.02 in)

NOTE:
Uneven torque for the cylinder head nuts can
cause warping. When reinstalling, pay special at-
tention 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

Standard

0.6 — 1.4 mm (0.024 — 0.055 in)

Exhaust

Standard

1.2 — 1.8 mm (0.047 — 0.071 in)

3. VALVE GUIDE 

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

Clearance between the valve guide and valve 
stem:

Standard
Intake

0.030 — 0.057 mm (0.0012 — 0.0022 in)

Exhaust

0.040 — 0.067 mm (0.0016 — 0.0026 in)

ME-00124

ST1

ST2

ME-00126

(A)

(B)

ME-00127

W

ME(H4DOTC)-66

MECHANICAL

Cylinder Head

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 or damage, etc. 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

5.955 — 5.970 mm (0.2344 — 0.2350 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

498267600

CYLINDER HEAD TABLE

ST2

499767200

VALVE GUIDE REMOVER

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

ST

18251AA020

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

ST2

18251AA020 VALVE GUIDE ADJUSTER

(6) Check the valve guide protrusion.

Valve guide protrusion L:

15.8 — 16.2 mm (0.622 — 0.638 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.

ST

499767400

VALVE GUIDE REAMER

NOTE:
• 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 becomes
lustrous and the reamer does not chip, use a new
reamer or remedy the reamer.

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

ME-00128

ST1

ST2

ME-00757

ST

L

ME-00130

ST1

ST2