Subaru Legacy (2005 year). Manual - part 396

ME(H6DO)-59

MECHANICAL

Camshaft

4) Measurement of the camshaft journal oil clear-
ance.

(1) Clean the bearing caps and camshaft jour-
nals.
(2) Place the camshafts on the cylinder head.
(Without installing the valve rocker.)
(3) Place a plastigauge across each of the cam-
shaft journals.
(4) Install the bearing cap.

NOTE:
Do not turn the camshaft.

(5) Remove the bearing caps.
(6) Measure the widest point of the plastigauge
on each journal. If oil clearance exceeds the
standard, replace the camshaft. If necessary,
replace the camshaft caps and cylinder head as
a set.

Standard:

0.037 — 0.072 mm (0.0015 — 0.0028 in)

(7) Completely remove the plastigauge.

5) Check the cam face condition, and remove the
minor faults by grinding with oil stone. Measure the
cam height H. If it exceeds the standard or offset
wearing is emitted, replace it.

Cam height H:

Standard

Intake

HIGH: 42.09 — 42.19 mm (1.6571 — 1.6610 
in)

Intake

LOW1: 38.14 — 38.24 mm (1.5016 — 1.5055 
in)

Intake

LOW2: 34.94 — 35.04 mm (1.3756 — 1.3795 
in)

Exhaust

41.65 — 41.75 mm (1.6398 — 1.6437 in)

Cam base circle diameter A:

Intake

HIGH: 32.0 mm (1.2598 in)

Intake

LOW1: 31.84 mm (1.2535 in)

Intake

LOW2: 31.84 mm (1.2535 in)

Exhaust

32.0 mm (1.2598 in)

6) Measure the thrust clearance of camshaft with
dial gauge. If the thrust clearance exceeds the
standard or offset wearing is emitted, replace the
camshaft caps and cylinder head as a set. If neces-
sary, replace the camshaft.

Standard:

Intake

0.075 — 0.135 mm (0.0030 — 0.0053 in)

Exhaust

0.030 — 0.090 mm (0.0012 — 0.0035 in)

ME-00119

ME-00120

H

A

ME(H6DO)-60

MECHANICAL

Cylinder Head

20.Cylinder Head 

A: REMOVAL

1) Remove the crank pulley. <Ref. to ME(H6DO)-
44, REMOVAL, Crank Pulley.>
2) Remove the front chain cover. <Ref. to
ME(H6DO)-45, REMOVAL, Front Chain Cover.>
3) Remove the timing chain assembly.
<Ref. to ME(H6DO)-47, REMOVAL, Timing Chain
Assembly.>
4) Remove the cam sprocket.
<Ref. to ME(H6DO)-52, REMOVAL, Cam Sprock-
et.>
5) Remove the crank sprocket.
<Ref. to ME(H6DO)-53, REMOVAL, Crank Sprock-
et.>
6) Remove the rear chain cover.
<Ref. to ME(H6DO)-54, REMOVAL, Rear Chain
Cover.>
7) Remove the camshaft. <Ref. to ME(H6DO)-56,
REMOVAL, Camshaft.>
8) Remove the cylinder head bolts in the numerical
order as shown in the figure.
Leave bolts (2) and (4) engaged by three or four
threads to prevent the cylinder head from falling.

9) While tapping the cylinder head with a plastic
hammer, separate it from cylinder block.
10) Remove the bolts (2) and (4) to remove the cyl-
inder head.

11) Remove the cylinder head gasket.

CAUTION:
Be careful not to scratch the mating surface of 
cylinder head and cylinder block.

12) Similarly, remove the cylinder head (RH).

B: INSTALLATION

1) Install the cylinder head and gaskets on cylinder
block.

CAUTION:
• Use new cylinder head gaskets.
• Be careful not to scratch the mating surface
of cylinder head and cylinder block.
2) Tighten the cylinder head bolts.

(1) Apply a coat of engine oil to washers and
cylinder head bolt threads.
(2) Install the cylinder head to cylinder block,
and then tighten the bolts with torque of 20 N

⋅m

(2.0 kgf-m, 14 ft-lb) in numerical sequence as
shown in the figure.
(3) Tighten the bolts with torque of 50 N

⋅m (5.1

kgf-m, 37 ft-lb) in numerical sequence as shown
in the figure.
(4) Back off all bolts by 180

° in reverse order of

installation, and back them off again by 180

°.

(5) Tighten the bolts with torque of 20 N

⋅m (2.0

kgf-m, 14 ft-lb) in numerical sequence as shown
in the figure.
(6) Tighten the bolts (1) — (4) with torque of 48
N

⋅m (4.9 kgf-m, 35.4 ft-lb) in numerical se-

quence.
(7) Tighten the bolts (5) — (8) with torque of 44
N

⋅m (4.5 kgf-m, 33 ft-lb) in numerical sequence.

(8) Tighten the bolts 90

° in the numerical order

as shown in the figure.
(9) Tighten the bolt (1) — (4) by 45

° in the nu-

merical order.

3) Install the camshaft. <Ref. to ME(H6DO)-57, IN-
STALLATION, Camshaft.>
4) Install the rear chain cover. <Ref. to ME(H6DO)-
54, INSTALLATION, Rear Chain Cover.>
5) Install the crank sprocket.
<Ref. to ME(H6DO)-53, INSTALLATION, Crank
Sprocket.>
6) Install the cam sprocket.
<Ref. to ME(H6DO)-52, INSTALLATION, Cam
Sprocket.>

(2)

(8)

(6)

(5)

(7)

(4)

(1)

(3)

ME-02063

(2)

(8)

(6)

(5)

(7)

(4)

(1)

(3)

ME-02063

(7)

(1)

(3)

(4)

(2)

(5)

(8)

(6)

ME-02064

ME(H6DO)-61

MECHANICAL

Cylinder Head

7) Install the timing chain assembly.
<Ref. to ME(H6DO)-48, INSTALLATION, Timing
Chain Assembly.>
8) Install the front chain cover.
<Ref. to ME(H6DO)-45, INSTALLATION, Front
Chain Cover.>
9) Install the crank pulley.
<Ref. to ME(H6DO)-44, INSTALLATION, Crank
Pulley.>

C: DISASSEMBLY

1) Set the cylinder head on ST.
ST

18250AA010

CYLINDER HEAD TABLE

2) Remove the valve lifter.
3) Set the ST on valve spring retainer. Compress
the valve spring and remove the valve spring re-
tainer key. Remove each valve and valve spring.
ST

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.

D: ASSEMBLY

1) Installation of valve spring and valve

(1) Set the cylinder head on ST.

ST

18250AA010

CYLINDER HEAD TABLE

(2) 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.

(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.
• For the valve spring on intake side, install two of
them (inner and outer).

• Install the valve spring with the painted side fac-
ing to retainer.

(4) Set the ST on valve spring.

ST

499718000

VALVE SPRING REMOVER

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

2) Apply oil to the surface of the valve lifter and
valve shim.
3) Install the valve lifter and valve shim.

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. Check that
there are no marks of gas leaking or water leaking
on gasket installing surface.
2) Set the cylinder head on ST.
ST

18250AA010

CYLINDER HEAD TABLE

ST

ME-00545

(1) Valve spring seat

(2) Valve spring

(3) Retainer

(4) Painted face

(1)

(2)

(3)

(4)

ME-00546

ST

ME-00545

ME(H6DO)-62

MECHANICAL

Cylinder Head

3) Measure the flatness of the cylinder head sur-
face that mates with crankcase using a straight
edge (A) and thickness gauge (B).

Flatness:

Standard

0.02 mm (0.0008 in)

Standard height of cylinder head:

124

±

0.05 mm (4.88

±

0.0020 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

1.0 mm (0.039 in)

Exhaust

Standard

1.5 mm (0.059 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 with a micrometer.

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)

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 damaged and etc. See the following proce-
dure for valve guide replacement.

Valve guide inner diameter:

5.500 — 5.512 mm (0.2165 — 0.2170 in)

Valve stem outer diameter:

Intake

5.455 — 5.470 mm (0.2148 — 0.2154 in)

Exhaust

5.445 — 5.460 mm (0.2144 — 0.2150 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

18250AA010 CYLINDER HEAD TABLE

ST2

499765700

VALVE GUIDE REMOVER

(A)

(B)

ME-00551

ME-00127

W

ME-02601

ST2