Subaru Car 1998-05

Camshaft, Bearings & Lifters 3

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Removal & Installation



3.0L Engine
  1. Rear chain cover gasket and clean the mating surfaces.
  2.  
  3. Apply liquid gasket maker to the mating surfaces of the cover. Refer to the illustration for gasket maker application and diameter.
  4.  


    Click image to see an enlarged view

    Fig. Apply liquid gasket maker to the mating surfaces of the cover as shown-3.0L engine



    Click image to see an enlarged view

    Fig. Rear cover O-ring sizes and locations-3.0L engine

  5. Install new O-rings. Refer to the illustration for O-ring location and size
  6.  
  7. Install the rear chain cover and temporarily tighten the bolts, refer to the illustration for size and locations.
  8.  
  9. Replace mounting boltsG
  10.  
  11. Tighten the cover bolts in the sequence illustrated to the specifications shown in the illustration.
  12.  



Click image to see an enlarged view

Fig. Rear cover bolt tightening sequence and torque specifications-3.0L engine

  1. Install or connect the following:

    Water pump
     
    Oil pump relief valve and tighten the bolts to 4.7 ft. lbs. (6.4 Nm) in the sequence illustrated.
     


    Click image to see an enlarged view

    Fig. Oil pump relief valve bolt tightening sequence and bolt specifications-3.0L engine

    Oil pump
     
    Crankshaft sprocket. Refer to the procedure in this section.
     
    Camshaft sprocket. Refer to the procedure in this section.
     
    Timing chain. Refer to the procedure in this section.
     
    Crankshaft pulley, apply clean oil to the bolt threads and tighten the bolt to 131 ft. lbs. (178 Nm)
     
    Camshaft pulley cover and tighten the bolts to 5 ft. lbs. (7 Nm)
     
    Negative battery cable
     

  2.  
  3. Start the engine and allow it to reach operating temperature. Check for leaks.
  4.  

  1. Remove or disconnect the following:

    Negative battery cable
     
    Crankshaft pulley cover
     
    Crankshaft pulley bolt using tool 499977100 to hold the crankshaft
     
    Crankshaft pulley
     
    Timing chain cover and the chain. Refer to the procedure in this section.
     
    Camshaft and crankshaft sprockets. Refer to the procedure in this section.
     
    Oil pump. Refer to the procedure in this section.
     
    Oil pump relief valve
     
    Water pump. Refer to the procedure in this section.
     
    Rear chain cover
     
    Right hand valve cover
     
    Front camshaft cap bolts equally in small increments in the sequence illustrated on the right hand side

    Click image to see an enlarged view

    Fig. Remove the front camshaft cap bolts equally in small increments in the sequence shown-2001-2004 3.0L engine



    Click image to see an enlarged view

    Fig. Remove the camshaft cap bolts equally in small increments in the sequence shown-2001-2004 3.0L engine

     

  2.  
  3. Install or connect the following:
    NOTE
    Mark the camshaft caps so that they can be reinstalled in their original positions.



    Camshaft cap and intake camshaft on the right hand side
     
    Camshaft cap bolts equally in small increments in the sequence illustrated
     
    Camshaft cap and exhaust camshaft of the right hand side
     



    Plug from the left hand side
     
    Left hand camshaft components in the same manner as the right hand components
     

  4.  

To install:

  1. Apply a coat of engine oil to the journals on the camshafts and place the camshafts into position.
  2.  
  3. When installing the camshaft, adjust the camshaft front flange knock pin (A) at the 12 O-clock position on the left hand side and the 10 O-clock position on the right hand side. Refer to the illustration for more detail.

    Click image to see an enlarged view

    Fig. Install the camshafts so the flange knock pin (A) is positioned as shown-2001-2004 3.0L engine

  4.  
  5. Apply 0.059-0.099 inch (1.5-2.5mm) of fluid packing sparingly to the front and back of the camshaft cap as illustrated. Subaru recommends Three Bond 1280B for this purpose.
    CAUTION
    Do not apply too much gasket maker. This may cause excess fluid gasket maker to come out and flow towards the camshaft journal resulting in engine damage.



    Click image to see an enlarged view

    Fig. Apply 0.059-0.099 inch (1.5-2.5mm) of fluid gasket sparingly to the front and back of the camshaft cap where indicated-2001-2004 3.0L engine



    Click image to see an enlarged view

    Fig. Tighten the camshaft cap bolts in the sequence shown to the proper specification-2001-2004 3.0L engine



    Click image to see an enlarged view

    Fig. Tighten the front camshaft cap bolts in the sequence shown-2001-2004 3.0L engine

  6.  
  7. Apply oil to the cap bearing surface.
  8.  
  9. Install or connect the following:

    Camshaft cap in the their original location
     
    Camshaft cap bolts and tighten to 11.6 ft. lbs. (16 Nm) in the sequence illustrated
     
    Front camshaft cap bolts and tighten to 7 ft. lbs. (10 Nm) in the sequence illustrated
     

  10.  
  11. Apply fluid gasket maker of the of the cylinder heads and valve covers as illustrated. Subaru recommends Three Bond 1280B for this purpose.
    CAUTION
    Do not apply too much gasket maker. This may cause excess fluid gasket maker to come out and flow towards the camshaft journal resulting in engine damage.

  12.  
  13. Install or connect the following:

    Valve cover bolts and tighten to 5 ft. lbs. (7 Nm) in the sequence illustrated.
     

  14.  
  15. Install the rear chain cover as follows:
    NOTE
    There are several size bolts used, refer to the illustration for size and locations.



    Click image to see an enlarged view

    Fig. Rear timing chain bolt sizes and locations-2001-2004 3.0L engine

    1. Rear chain cover gasket and clean the mating surfaces.
    2.  
    3. Apply liquid gasket maker to the mating surfaces of the cover. Refer to the illustration for gasket maker application and diameter.

      Click image to see an enlarged view

      Fig. Rear cover O-ring sizes and locations-2001-2004 3.0L engine

    4.  
    5. Install new O-rings. Refer to the illustration for O-ring location and size
    6.  
    7. Install the rear chain cover and temporarily tighten the bolts, refer to the illustration for size and locations.
    8.  
    9. Replace mounting bolts G with new bolts, refer to the illustration for location.
    10.  
    11. Tighten the cover bolts in the sequence illustrated to the specifications shown in the illustration.

      Click image to see an enlarged view

      Fig. Rear cover bolt tightening sequence and torque specifications-2001-2004 3.0L engine

    12.  

  16.  
  17. Install or connect the following:

    Water pump
     
    Oil pump relief valve and tighten the bolts to 4.7 ft. lbs. (6.4 Nm) in the sequence illustrated.

    Click image to see an enlarged view

    Fig. Oil pump relief valve bolt tightening sequence and bolt specifications-2001-2004 3.0L engine

     
    Oil pump
     
    Crankshaft sprocket. Refer to the procedure in this section.
     
    Camshaft sprocket. Refer to the procedure in this section.
     
    Timing chain. Refer to the procedure in this section.
     
    Crankshaft pulley, apply clean oil to the bolt threads and tighten the bolt to 131 ft. lbs. (178 Nm)
     
    Camshaft pulley cover and tighten the bolts to 5 ft. lbs. (7 Nm)
     
    Negative battery cable
     

  18.  
  19. Start the engine and allow it to reach operating temperature. Check for leaks.
  20.  

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the crankshaft pulley cover.
  4.  
  5. Remove the crankshaft pulley bolt.
  6.  
  7. Lock the crankshaft in place using tool ST499977100, or equivalent.
  8.  
  9. Remove the crankshaft pulley.
  10.  
  11. Remove the front timing chain cover.
    NOTE
    Bolts are three different sizes. Be careful to install the correct bolt in the correct hole.

  12.  
  13. Remove the timing chain.
  14.  
  15. Remove the camshaft sprocket.
    NOTE
    Be sure to lock the camshaft in place using tool ST499977500, or equivalent.

  16.  
  17. Remove the crankshaft sprocket.
  18.  
  19. Remove the oil pump.
  20.  
  21. Remove the water pump.
  22.  
  23. Remove the rear timing chain cover retaining bolts. Remove the rear timing chain cover.
    NOTE
    There are seven different size bolts. Be sure not to confuse them on installation.

  24.  
  25. Disconnect the oil pipe.
  26.  
  27. Remove the rocker cover retaining bolts. Remove the rocker cover. Discard the gasket.
  28.  
  29. Remove the plugs, see illustration for location.
  30.  
  31. Loosen the camshaft cap bolts in the proper sequence. Remove the camshaft caps and remove the camshaft.

    Click image to see an enlarged view

    Fig. Camshaft plug bolt location-2005 3.0L engine



    Click image to see an enlarged view

    Fig. Camshaft bolt loosening sequence-2005 3.0L engine

  32.  

To install:

  1. Apply a coat of engine oil to the journals on the camshafts and place the camshafts into position.
  2.  
  3. To install the camshaft cap, apply a small amount of liquid gasket to the mating surface of the cap. Do not apply an excessive amount of sealant, as it will squish out and flow toward the cam journal resulting in engine seizure.

    Click image to see an enlarged view

    Fig. Camshaft cap liquid gasket application points-2005 3.0L engine

  4.  
  5. Apply a thin coat of engine oil to the cap bearing surface and install the cap. Tighten cap bolts 1 through 12 to 12 ft. lbs. and bolts 13 through 16 to 7.2 ft. lbs. in the proper sequence. Install the plugs and torque to 44 ft. lbs.

    Click image to see an enlarged view

    Fig. Camshaft bolt tightening sequence-2005 3.0L engine

  6.  
  7. Apply fluid gasket maker of the of the cylinder heads and valve covers.
    CAUTION
    Do not apply too much gasket maker. This may cause excess fluid gasket maker to come out and flow towards the camshaft journal resulting in engine damage.



    Click image to see an enlarged view

    Fig. Apply fluid gasket maker on the cylinder heads and valve covers as shown-3.0L engine



    Click image to see an enlarged view

    Fig. Tighten the valve cover bolts in this sequence-3.0L engine

  8.  
  9. Tighten the valve cover bolts to 4.7 ft. lbs. and in the proper sequence.
  10.  
  11. Install the rear chain cover as follows:
    NOTE
    There are several size bolts used, refer to the illustration for size and locations.



    Click image to see an enlarged view

    Fig. Rear timing chain bolt sizes and locations-2005 3.0L engine

    1. Rear chain cover gasket and clean the mating surfaces.
    2.  
    3. Apply liquid gasket maker to the mating surfaces of the cover. Refer to the illustration for gasket maker application and diameter.

      Click image to see an enlarged view

      Fig. Apply liquid gasket maker to the mating surfaces of the cover as shown-3.0L engine



      Click image to see an enlarged view

      Fig. Rear cover O-ring sizes and locations-2005 3.0L engine

    4.  
    5. Install new O-rings. Refer to the illustration for O-ring location and size
    6.  
    7. Install the rear chain cover and temporarily tighten the bolts, refer to the illustration for size and locations.
    8.  
    9. Tighten the cover bolts in the sequence illustrated to the specifications shown in the illustration.

      Click image to see an enlarged view

      Fig. Rear cover bolt tightening sequence and torque specifications-2005 3.0L engine

    10.  

  12.  
  13. Continue the installation in the reverse order of the removal procedure.
  14.  

3.3L Engine


Click image to see an enlarged view

Fig. Camshaft cap bolt removal sequence-3.3L engine



Click image to see an enlarged view

Fig. Camshaft cap bolt tightening sequence-3.3L engine



Click image to see an enlarged view

Fig. Align the notches on the front of the camshafts-3.3L engine



Click image to see an enlarged view

Fig. There are also alignment marks on the rear of the camshaft gears-3.3L engine


CAUTION
Fuel injection systems remain under pressure after the engine has been turned OFF. Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the timing belt followed by the camshaft sprockets.
  6.  
  7. Detach the cam angle sensor connector and remove the bracket.
  8.  
  9. Disconnect the ignition coil harness and remove the individual ignition coils.
  10.  
  11. Disconnect the blow-by hose and remove the cylinder head cover and gasket.
  12.  
  13. Remove the front camshaft cap.
  14.  
  15. Remove the camshaft oil seal and plug.
    WARNING
    Since the camshaft thrust clearance is small, the camshaft must be removed by holing it parallel to the cylinder head. If the camshaft is not parallel to the cylinder head, the cylinder head thrust bearing journal may be damaged.

  16.  
  17. Rotate the intake (upper) and exhaust (lower) camshafts until the notch at the front of the camshafts face the 6 o'clock position on the left cylinder head, and the 12 o'clock position on the right cylinder head.
  18.  
  19. Inspect the rear of the camshaft and check that the matchmarks on the rear gears are aligned.
  20.  
  21. Install a service bolt to the sub-gear mounting bolt hole of the intake camshaft gear to lock the sub-gear and driven gear.
  22.  
  23. Loosen the intake camshaft bolt caps in sequence. Make sure that, as the bolts are turned, the clearance between the camshaft journal and the cylinder head journal bearing increase evenly. If not, tighten the bolts and repeat the loosening procedure.
  24.  
  25. Remove the camshaft caps while securing the intake camshaft with one hand. When the caps are removed, then lift out the intake camshaft.
  26.  
  27. Arrange the camshaft caps in the order they were removed. They must be installed to their original positions.
  28.  
  29. If you are removing the exhaust camshaft, rotate the camshaft clockwise for additional access.
  30.  
  31. Loosen the exhaust camshaft bolt caps in sequence. Make sure that, as the bolts are turned, the clearance between the camshaft journal and the cylinder head journal bearing increase evenly. If not, tighten the bolts and repeat the loosening procedure.
  32.  
  33. Remove the camshaft caps while securing the exhaust camshaft with one hand. When the caps are removed, then lift out the intake camshaft.
  34.  
  35. Arrange the camshaft caps in the order they were removed. They must be installed to their original positions.
  36.  
  37. Remove the hydraulic lash adjusters. Keep the lash adjusters in the order they were removed. They must be installed into their original positions.
  38.  

To install:

  1. Measure the thrust clearance of the camshaft with the hydraulic lash adjusters not installed. If thrust clearance exceeds 0.0051 inch (0.13mm) for the intake and 0.0047 inch (0.12mm) for the exhaust, replace the camshaft caps and the cylinder head as an assembly. If necessary replace the camshaft.
  2.  
  3. Measure the camshaft journal oil clearance with the lash adjusters not installed. If clearance exceeds 0.0039 inch (0.10mm), replace the camshaft.
  4.  
  5. Measure the camshaft gear backlash with the intake sub-gear not installed. If backlash exceeds 0.0118 inch (0.30mm), replace the camshafts as a set.
  6.  
  7. Lubricate and install the hydraulic lash adjusters.
  8.  
  9. Lubricate and install the camshafts with the notch on the front facing the 6 o'clock position for the left cylinder head camshafts and the 12 o'clock position for the right cylinder head camshafts. Ensure that the marks for both camshafts are facing the same position.
  10.  
  11. Install the camshaft caps and bolts and hand-tight.
  12.  
  13. Tighten the camshaft bolts on the caps equally, in small increments, in the correct sequence. Make sure that, as the bolts are turned, the clearance between the camshaft journal and the cylinder head journal bearing decreases evenly. If not, loosen the bolts and repeat the tightening procedure.
  14.  
  15. Tighten the camshaft cap bolts to a final tighten of 7 ft. lbs. (10 Nm).
  16.  
  17. Ensure that the matchmarks on the rear side of the camshaft gears are aligned.
  18.  
  19. Remove the sub-gear securing bolt from the camshaft.
  20.  
  21. Install the front camshaft cover using new gaskets.
  22.  
  23. Lubricate and install new oil seals.
  24.  
  25. Install the camshaft plug.
  26.  
  27. Install the camshaft cover and connect the blow-by hose.
  28.  
  29. Connect the ignition coil harnesses and coils.
  30.  
  31. Connect the cam angle sensor and bracket.
  32.  
  33. Install the timing belt and camshaft sprockets.
  34.  
  35. Connect the negative battery cable.
  36.  

 
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