Subaru Car 1998-05

Camshaft, Bearings & Lifters 1

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On some models, it may be necessary to remove the engine from the vehicle to perform this service.

Description



On some models, it may be necessary to remove the engine from the vehicle to perform this service.

Inspection



  1. Remove the camshaft from the engine.
  2.  
  3. Check the camshaft bearing journals for damage and binding.
  4.  
  5. If the journals are binding, check the cylinder head for damage.
  6.  
  7. Check the cylinder head for clogged oil holes.
  8.  
  9. Check the camshaft surface for abnormal wear and damage. Replace the camshaft, as required.
  10.  
  11. Measure the camshaft lobe surface and replace the camshaft if not within specification.
  12.  
  13. Measure the camshaft journal diameter and replace the camshaft if not within specification.
  14.  
  15. Measure the camshaft run out and replace the camshaft if not within specification.
  16.  

Removal & Installation



On some vehicles, it may be necessary to remove the engine from the vehicle to perform this service.

1.8L Engine


Click image to see an enlarged view

Fig. Camshaft assembly-1.8L engine

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Tag and disconnect the spark plug wires from the distributor cap. Matchmark the distributor to the engine and remove the distributor.
  6.  
  7. Remove the timing belts covers and timing belts. Refer to the procedures in the section.
  8.  
  9. Drain the cooling system.
    CAUTION
    When draining the coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze, and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  10.  
  11. Remove the water pipe.
  12.  
  13. Remove the oil fill pipe.
  14.  
  15. Disconnect the PCV hoses from the valve covers.
  16.  
  17. Remove the EGR pipe cover, clamps and EGR pipe, if equipped.
  18.  
  19. Remove the rocker arm covers.
    NOTE
    When removing the camshaft carrier the rocker arms may fall off the lash adjusters. Place a suitable container beneath the cylinder head to catch the rocker arms.

  20.  
  21. Remove the camshaft case mounting bolts.
  22.  
  23. Remove the camshaft case and place on a clean surface.
  24.  
  25. Remove the camshaft retainer from the front of the camshaft carrier.
  26.  
  27. Slide the camshaft out from the carrier.
  28.  

To install:

  1. Slide the camshaft into the carrier and install the camshaft retainer and bolts. Tighten the retainer bolts to 5 ft. lbs. (7 Nm).
  2.  
  3. Apply grease to the spherical and sliding surface of each valve rocker, then secure the rockers to the valve lash adjusters and valves.
    NOTE
    Failure to apply grease to the rocker arms will result in the rocker arms falling off.

  4.  
  5. Apply sealer to the groove of the camshaft carrier.
  6.  
  7. Install the carrier assembly using the mounting bolts. Tighten the bolts to 14 ft. lbs. (19 Nm).
  8.  
  9. Coat the camshaft with clean engine oil.
  10.  
  11. Install the rocker arm covers using new gaskets. Install the mounting bolts and tighten to 4 ft. lbs. (5 Nm). Install all remaining components. Start the vehicle, adjust the ignition timing if needed and check for fluid leaks.
  12.  

2.0L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Drive belt
     

  4.  
  5. Secure the crankshaft pulley with tool No. 499977300.
  6.  
  7. Remove or disconnect the following:

    Crankshaft pulley bolt and pulley
     
    Belt covers
     
    Timing belt
     
    Camshaft Position (CMP) sensor
     
    Camshaft sprockets using locking tool 499207400 to lock them in place while loosening the bolt
     
    Crankshaft sprocket
     
    Right hand belt cover No. 2
     
    Dipstick tube
     
    Spark plug cord
     
    Rocker cover and gasket
     
    Intake camshaft bolts as illustrated a little at a time
     
    Camshaft caps and the camshaft
     
    Exhaust camshaft bolts as illustrated a little at a time
     
    Camshaft caps and the camshaft
     
    Camshafts
     

  8.  


    Click image to see an enlarged view

    Fig. Loosen the intake camshaft caps as shown-2.0L engines



    Click image to see an enlarged view

    Fig. Loosen the exhaust camshaft caps as shown-2.0L engines


To install:

  1. Apply clean engine oil to the bearings on the head.
  2.  
  3. Install the camshaft so that the valves are closed or in contact with the -base circle- of the cam lobe.
  4.  
  5. If the camshafts are positioned as shown in the accompanying illustration, the camshafts need to be rotated at a minimum to align the with the timing belt during installation.
  6.  
  7. The right hand camshaft need not be rotated when set at the position illustrated, the left hand camshaft should be rotated 80 degrees clockwise. The left hand camshaft should be rotated 45 degrees counterclockwise.
  8.  
  9. Apply fluid packing (three bond 1215) sparingly to the cap mating surface.
  10.  


    Click image to see an enlarged view

    Fig. The right hand camshaft need not be rotated when set at the position illustrated, the left hand camshaft should be rotated 80 degrees clockwise. The left hand camshaft should be rotated 45 degrees counterclockwise-2.0L engines



WARNING
Do not apply fluid packing excessively. Failure to do so may cause excess packing to come out and flow towards oil seal, resulting in leaks.

  1. Apply engine oil to the cap on the camshaft as shown by mark -A- in the accompanying illustration.
  2.  
  3. Tighten the cap in two stages to 14.5 ft. lbs. (20 Nm) in the sequence illustrated.
  4.  
  5. Apply oil to the lip of the new camshaft seal and using guide tool 499597200 and installer 499587600, install the new seal.
  6.  
  7. Install or connect the following:

    Rocker cover, making sure to apply fluid packing (three bond 1215) to the four front open edges of the gasket
     
    Spark plug cord
     
    Right hand belt cover No. 2 and tighten to 3 ft. lbs. (4 Nm)
     
    Tensioner bracket and tighten to 18 ft. lbs. (25 Nm)
     
    Left hand belt cover No. 2 and tighten to 3 ft. lbs. (4 Nm)
     
    Crankshaft sprocket
     
    Camshaft sprockets using locking tool 499207400 to lock them in place while tightening the bolt to 72 ft. lbs. (98 Nm)
     
    Timing belt
     
    Belt cover(s)
     
    Crankshaft pulley and tighten the bolt to 33 ft. lbs. (44 Nm)
     
    Drive belt
     
    Negative battery cable
     

  8.  


    Click image to see an enlarged view

    Fig. Apply engine oil to the cap on the camshaft as shown by mark -A--2.0L engines



    Click image to see an enlarged view

    Fig. Tighten the cap in two stages in the sequence shown-2.0L engines



    Click image to see an enlarged view

    Fig. Using guide tool 499597200 and installer 499587600, install the new camshaft seal-2.0L engines


2.0L Engine
  1. Remove or disconnect the following:

    Negative battery cable
     
    Drive belt
     

  2.  
  3. Secure the crankshaft pulley with tool No. 499977300.
  4.  
  5. Remove or disconnect the following:

    Crankshaft pulley bolt and pulley
     
    Belt covers
     
    Timing belt
     
    Camshaft Position (CMP) sensor
     
    Camshaft sprockets using locking tool 499207400 to lock them in place while loosening the bolt
     
    Crankshaft sprocket
     
    Right hand belt cover No. 2
     
    Dipstick tube
     
    Spark plug cord
     
    Rocker cover and gasket
     
    Intake camshaft bolts as illustrated a little at a time
     
    Camshaft caps and the camshaft
     
    Exhaust camshaft bolts as illustrated a little at a time
     
    Camshaft caps and the camshaft
     
    Camshafts

    Click image to see an enlarged view

    Fig. Intake camshaft cap bolt loosening sequence-2.0L engine and 2005 2.5L DOHC engine



    Click image to see an enlarged view

    Fig. Exhaust camshaft cap bolt loosening sequence-2.0L engine and 2005 2.5L DOHC engine

     

  6.  

To install:

  1. Apply clean engine oil to the bearings on the head.
  2.  
  3. Install the camshaft so that the valves are closed or in contact with the -base circle- of the cam lobe.
  4.  
  5. If the camshafts are positioned as shown in the accompanying illustration, the camshafts need to be rotated at a minimum to align the timing belt during installation.
  6.  
  7. The right hand camshaft need not be rotated when set at the position illustrated, the left hand camshaft should be rotated 80 degrees clockwise. The left hand camshaft should be rotated 45 degrees counterclockwise.

    Click image to see an enlarged view

    Fig. The right hand camshaft need not be rotated when set at the position as shown in the illustration, the left hand intake camshaft should be rotated 80 degrees clockwise. The left hand exhaust camshaft should be rotated 45 degrees counterclockwise-2.0L engine and 2005 2.5L DOHC engine

  8.  
  9. Apply fluid packing (three bond 1215) sparingly to the cap mating surface.
    WARNING
    Do not apply fluid packing excessively. Failure to do so may cause excess packing to come out and flow towards oil seal, resulting in leaks.

  10.  
  11. Apply engine oil to the cap on the camshaft as shown by mark -A- in the accompanying illustration.

    Click image to see an enlarged view

    Fig. Apply engine oil to the cap on the camshaft as shown by mark -A--2.0L engine

  12.  
  13. Tighten the cap in two stages to 14.5 ft. lbs. (20 Nm) in the sequence illustrated.

    Click image to see an enlarged view

    Fig. Camshaft cap bolt tightening sequence-2.0L engine

  14.  
  15. Apply oil to the lip of the new camshaft seal and using guide tool 499597200 and installer 499587600, install the new seal.

    Click image to see an enlarged view

    Fig. Using guide tool 499597200 and installer 499587600, install the new camshaft seal-2.0L engine and 2005 2.5L DOHC engine

  16.  
  17. Install or connect the following:

    Rocker cover, making sure to apply fluid packing (three bond 1215) to the four front open edges of the gasket
     
    Spark plug cord
     
    Right hand belt cover No. 2 and tighten to 3 ft. lbs. (4 Nm)
     
    Tensioner bracket and tighten to 18 ft. lbs. (25 Nm)
     
    Left hand belt cover No. 2 and tighten to 3 ft. lbs. (4 Nm)
     
    Crankshaft sprocket
     
    Camshaft sprockets using locking tool 499207400 to lock them in place while tightening the bolt to 72 ft. lbs. (98 Nm)
     
    Timing belt
     
    Belt cover(s)
     
    Crankshaft pulley and tighten the bolt to 33 ft. lbs. (44 Nm)
     
    Drive belt
     
    Negative battery cable
     

  18.  

2.2L Engine


Click image to see an enlarged view

Fig. Exploded view of the camshaft assembly-2.2L engine

  1. Remove or disconnect the following:

    Negative battery cable
     
    Timing belt covers, timing belt and camshaft sprockets
     
    Valve rocker covers
     
    Rocker arm assemblies. Refer to the rocker arms/shafts procedure in this section.
     
    Camshaft cap bolts in the proper sequence
     
    Camshaft cap

    Click image to see an enlarged view

    Fig. Camshaft cap bolt loosening sequence-1998-2001 2.2L and 2.5L engines

     

  2.  
  3. To remove the left camshaft, remove or disconnect the following:

    Camshaft Position (CMP) sensor
     
    Oil dipstick tube attaching bolt and the dipstick tube
     
    CMP sensor support
     

  4.  
  5. To remove the right camshaft, remove the camshaft support on the right side.
  6.  
  7. Remove or disconnect the following:

    Camshaft O-ring
     
    Camshaft and rear seal
     
    Oil seal from the camshaft support
     

  8.  

To install:


NOTE
Lubricate the camshaft journals with clean engine oil prior to installation.

  1. Install or connect the following:

    Rear oil seal, then the camshaft into the cylinder head
     

  2.  
  3. Apply a bead of sealant in the camshaft cap. Position the camshaft cap, then tighten the bolts 7-10, in sequence, temporarily
  4.  
  5. Install the rocker arm assemblies. Refer to the rocker arms/shafts procedure in this section.
  6.  
  7. Tighten the remaining camshaft cap bolts, in sequence, as follows:
    1. Step 1: bolts 1-8: 17-20 ft. lbs. (23-27 Nm).
    2.  
    3. Step 2: bolts 9-14: 12-15 ft. lbs. (16-20 Nm).
    4.  
    5. Step 3: bolts 15-22: 6-9 ft. lbs. (8-12 Nm), using SST 499497000.
    6.  
    7. Step 4: bolts 23-24: 6-9 ft. lbs. (8-12 Nm).

      Click image to see an enlarged view

      Fig. Camshaft cap bolt locations 1-8-1998-2001 2.2L and 2.5L engines



      Click image to see an enlarged view

      Fig. Camshaft cap bolt locations 9-14-1998-2001 2.2L and 2.5L engines



      Click image to see an enlarged view

      Fig. Camshaft cap bolt locations 15-22-1998-2001 2.2L and 2.5L engines



      Click image to see an enlarged view

      Fig. Camshaft cap bolt locations 23-24-1998-2001 2.2L and 2.5L engines

    8.  

  8.  
  9. To install the left camshaft, install or connect the following:

    O-ring into the camshaft support and install the support. Tighten the front retainer bolts to 84 inch lbs. (9 Nm), and the rear bolts to 12 ft. lbs. (16 Nm).
     
    Oil seal into the camshaft support
     
    Dipstick tube. Tighten the retaining bolt to 10 ft. lbs. (13 Nm).
     
    CMP sensor
     

  10.  
  11. To install the right camshaft, install or connect the following:

    O-ring into the camshaft support and install the support. Tighten the retainer bolts to 12 ft. lbs. (16 Nm).
     
    New oil seal in the rear of the cylinder head
     

  12.  
  13. Install or connect the following:

    Camshaft sprockets, timing belt, timing belt covers, and related components
     
    Negative battery cable
     

  14.  
  15. Check the fluid levels and start the engine.
  16.  
  17. Allow the engine to reach normal operating temperature and check for leaks.
  18.  

 
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