Subaru Legacy III (2000-2003 year). Manual - part 62

ME(H4SO)-60

MECHANICAL

CYLINDER HEAD ASSEMBLY

20.Cylinder Head Assembly

A: REMOVAL

1) Remove the V-belt. <Ref. to ME(H4SO)-41, RE-
MOVAL, V-belt.>
2) Remove the crankshaft pulley. <Ref. to
ME(H4SO)-43, REMOVAL, Crankshaft Pulley.>
3) Remove the belt cover. <Ref. to ME(H4SO)-45,
REMOVAL, Belt Cover.>
4) Remove the timing belt assembly. <Ref. to
ME(H4SO)-46, REMOVAL, Timing Belt Assem-
bly.>
5) Remove the camshaft sprocket. <Ref. to
ME(H4SO)-51, REMOVAL, Camshaft Sprocket.>
6) Remove the intake manifold.  <Ref. to
FU(H4SO)-28, REMOVAL, Camshaft Position
Sensor.>
7) Remove the bolt which installs A/C compressor
bracket on cylinder head.
8) Remove the valve rocker assembly. <Ref. to
ME(H4SO)-54, REMOVAL, Valve Rocker Assem-
bly.>
9) Remove the camshaft. <Ref. to ME(H4SO)-56,
REMOVAL, Camshaft.>
10) Remove the cylinder head bolts in alphabetical
sequence shown in figure.

NOTE:
Leave the bolts (a) and (c) engaged by three or four
threads to prevent cylinder head from falling.

11) While tapping the cylinder head with a plastic
hammer, separate it from cylinder block.
12) Remove the bolts (a) and (c) to remove cylinder
head.

13) Remove the cylinder head gasket.

NOTE:
Do not scratch the mating surface of cylinder head
and cylinder block.
14) Similarly, remove the right side cylinder head.

B: INSTALLATION

1. CYLINDER HEAD

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

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

(1) Apply a coat of engine oil to the washers and
bolt threads.
(2) Tighten all bolts to 29 N·m (3.0 kgf-m, 22 ft-
lb) in alphabetical sequence.
Then tighten all bolts to 69 N·m (7.0 kgf-m, 51 ft-
lb) in alphabetical sequence.
(3) Back off all bolts by 180

°

 first; back them off

by 180

°

 again in reverse order of installation.

(4) Tighten the bolts (a) and (b) to 34 N·m (3.5
kgf-m, 25 ft-lb) in reverse order of installation.
(5) Tighten the bolts (c), (d), (e) and (f) to 15
N·m (1.5 kgf-m, 11 ft-lb).
(6) Tighten all bolts by 80 to 90

°

 in alphabetical

sequence.

NOTE:
Do not tighten bolts more than 90

°

.

(7) Further tighten all bolts by 80 to 90

°

 in al-

phabetical sequence shown in figure below.

NOTE:
Ensure that the total “re-tightening angle” [in the
former two steps], do not exceed 180

°

.

3) Install the camshaft. <Ref. to ME(H4SO)-57, IN-
STALLATION, Camshaft.>
4) Install the valve rocker assembly. <Ref. to
ME(H4SO)-54, INSTALLATION, Valve Rocker As-
sembly.>

ME-00278

( a )

( b )

( c )

( d )

( e )

( f )

ME-00278

( a )

( b )

( c )

( d )

( e )

( f )

ME-00279

( c )

( d )

( f )

( e )

( a )

( b )

ME(H4SO)-61

MECHANICAL

CYLINDER HEAD ASSEMBLY

5) Install the A/C compressor bracket on cylinder
head.
6) Install the intake manifold.  <Ref. to FU(H4SO)-
17, INSTALLATION, Intake Manifold.>
7) Install the camshaft sprocket. <Ref. to
ME(H4SO)-51, INSTALLATION, Camshaft
Sprocket.>
8) Install the timing belt assembly. <Ref. to
ME(H4SO)-47, INSTALLATION, Timing Belt As-
sembly.>
9) Install the belt cover. <Ref. to ME(H4SO)-45, IN-
STALLATION, Belt Cover.>
10) Install the crankshaft pulley. <Ref. to
ME(H4SO)-43, INSTALLATION, CRANKSHAFT
PULLEY.>
11) Install the V-belt. <Ref. to ME(H4SO)-42, IN-
STALLATION, V-belt.>

C: DISASSEMBLY

1) Place the cylinder head on ST.

ST

498267800

CYLINDER HEAD TABLE

2) Set the ST on valve spring. Compress the valve
spring, and then remove the valve spring retainer
key. Remove each valve and valve spring.
ST

499718000

VALVE SPRING REMOVER

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

D: ASSEMBLY

ME-00280

ST

(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-00281

( 1 )

( 2 )

( 3 )

( 4 )

( 5 )

( 6 )

( 7 )

( 8 )

( 9 )

(10)

(11)

(12)

(13)

ME(H4SO)-62

MECHANICAL

CYLINDER HEAD ASSEMBLY

1) Installation of valve spring and valve

(1) Place cylinder head on ST.

ST

498267800

CYLINDER HEAD TABLE

(2) Coat the stem of each valve with engine oil
and insert 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 springs with their close-
coiled end facing the seat on the cylinder head.

(4) Set the ST on valve spring.

ST

499718000

VALVE SPRING REMOVER

(5) Compress the valve spring, and then fit the
valve spring retainer key.

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

E: INSPECTION

1. VALVE SPRING

1) Check the valve springs for damage, free length,
and tension. Replace the valve spring if it is not to
the specifications presented below.
2) To measure the squareness of valve spring,
stand the spring on a surface plate and measure its
deflection at the top using a try square.

2. INTAKE AND EXHAUST VALVE OIL 
SEAL

Replace the oil seal with new one, if lip is damaged
or spring out of place, or when the surfaces of valve
and valve seat are reconditioned or valve guide is
replaced. Use pliers to pinch and remove oil seal
from valve.
1) Place the cylinder head on ST1.
2) Press-fit oil seal as shown in the figure using
ST2.

NOTE:
• Apply engine oil to oil seal before press-fitting.
• When press-fitting oil seal, do not use hammer or
strike in.
• Differentiate between intake valve oil seal and
exhaust valve oil seal by noting their difference in
color.
ST1

498267800

CYLINDER HEAD TABLE

ST2

498857100

VALVE OIL SEAL GUIDE

Color of rubber part:

Intake [Black]
Exhaust [Brown]

(A) Retainer 

(B) Painted face

ME-00280

ST

ME-00282

( A )

( B )

( B )

Free length

54.30 mm (2.1378 in)

Squareness

2.5

°

, 2.4 mm (0.094 in)

Tension/spring height

215 — 246 N
(21.9 — 25.1 kgf, 48.2 — 55.3 lb)/
45.0 mm (1.772 in)

527 — 582 N
(53.7 — 59.3 kgf, 118.1 — 130.8 
lb)/34.7 mm (1.366 in)

ME-00283

ME(H4SO)-63

MECHANICAL

CYLINDER HEAD ASSEMBLY

Color of spring part:

Intake [Silver]
Exhaust [Silver]

F: ADJUSTMENT

1. CYLINDER HEAD

1) Make sure that no crack or other damage exists.
In addition to visual inspection, inspect important
areas by means of red lead check.
Also make sure that gasket installing surface
shows no trace of gasoline and water leaks.
2) Place the cylinder head on 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 0.05 mm (0.0020 in), re-
grind the surface with a surface grinder.

Warping limit:

0.05 mm (0.0020 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
then correct the contact surfaces with valve seat
cutter if they are defective or when valve guides are
replaced.

Valve seat width: W

Intake (A)

Standard 1.1 mm (0.043 in)
Limit 1.8 mm (0.071 in)

Exhaust (B)

Standard 1.5 mm (0.059 in)
Limit 2.2 mm (0.087 in)

(A) Straightedge

(B) Thickness gauge

ME-00284

ST2 

ST1

ME-00285

( A )

( B )

ST

ME-00397

90˚

150˚

W

W

60˚

150

˚

40˚

90˚

( A )

( B )

ME-00287