Subaru Car 1998-05

Cylinder Head 2

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Removal & Installation



3.0L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. 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
     
    Camshafts. Refer to the procedure in this section.
     
    Cylinder head bolts in the sequence illustrated. Leave bolts 2 and 4 connected by a few threads to prevent the head from falling. Tap the head with a plastic mallet to separate it from the block.
     
    Bolts 2 and 4, the cylinder head and gasket
     

  4.  
  5. Clean all gasket material from both mating surfaces.
  6.  


    Click image to see an enlarged view

    Fig. Cylinder head bolt loosening sequence-3.0L engines


To install:



Click image to see an enlarged view

Fig. Cylinder head bolt tightening sequence-3.0L engines

  1. Inspect the cylinder head for warpage. Warpage should not exceed 0.0020 in. (0.05mm).
  2.  
  3. Make sure not to scratch or damage the mating surfaces of the cylinder head, block and oil pump.
  4.  
  5. Install a new head gasket and the cylinder head.
  6.  
  7. Secure the head in place with the mounting bolts. Coat each bolts with clean engine oil, and hand-tighten. Tighten the cylinder head bolts to the following specifications:
    1. Step 1: all bolts to 14 ft. lbs. (20 Nm).
    2.  
    3. Step 2: all bolts to 37 ft. lbs. (50 Nm).
    4.  
    5. Step 3: loosen all bolts by 180 degrees, then loosen an additional 180 degrees.
    6.  
    7. Step 4: all bolts to 18 ft. lbs. (25 Nm).
    8.  
    9. Step 5: all bolts to 18 ft. lbs. (25 Nm).
    10.  
    11. Step 6: all bolts plus 90 degrees.
    12.  
    13. Step 7: bolts 1, 2, 3 and 4 plus 80-90 degrees.
    14.  
    15. Step 8: bolts 5, 6, 7 and 8 plus 45 degrees.
    16.  

  8.  


NOTE
Do not exceed 180 degrees total tightening.

  1. Install or connect the following:

    Camshafts. Refer to the procedure in this section.
     

  2.  
  3. Install the rear chain cover as follows:
  4.  


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-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
     
    Camshafts. Refer to the procedure in this section.
     
    Cylinder head bolts in the sequence illustrated. Leave bolts 2 and 4 connected by a few threads to prevent the head from falling. Tap the head with a plastic mallet to separate it from the block.
     
    Bolts 2 and 4, the cylinder head and gasket
     

  2.  
  3. Clean all gasket material from both mating surfaces.

    Click image to see an enlarged view

    Fig. Cylinder head bolt loosening sequence-2002-2004 3.0L engine

  4.  

To install:

Click image to see an enlarged view

Fig. Cylinder head bolt tightening sequence-2002-2004 3.0L engine

  1. Inspect the cylinder head for warpage. Warpage should not exceed 0.0020 in. (0.05mm).
  2.  
  3. Make sure not to scratch or damage the mating surfaces of the cylinder head, block and oil pump.
  4.  
  5. Install a new head gasket and the cylinder head.
  6.  
  7. Secure the head in place with the mounting bolts. Coat each bolts with clean engine oil, and hand-tighten. Tighten the cylinder head bolts to specification.
  8.  
  9. Install or connect the following:

    Camshafts. Refer to the procedure in this section.
     

  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-2002-2004 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. 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-2002-2004 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. On 2002-2004 engine, 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-2002-2004 3.0L engine

    12.  

  12.  
  13. 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-2002-2004 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
     

  14.  
  15. Start the engine and allow it to reach operating temperature. Check for leaks.
  16.  

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

  10.  
  11. Remove the timing chain.
  12.  
  13. Remove the camshaft sprocket.
    NOTE
    Be sure to lock the camshaft in place using tool ST499977500, or equivalent.

  14.  
  15. Remove the crankshaft sprocket.
  16.  
  17. Remove the oil pump.
  18.  
  19. Remove the water pump.
  20.  
  21. 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.

  22.  
  23. Remove the camshafts.
  24.  
  25. Remove the cylinder head bolts in the proper sequence. Leave bolts 2 and 4 connected by a few threads to prevent the head from falling. Tap the head with a plastic mallet to separate it from the block.
  26.  
  27. Remove bolts 2 and 4 from the cylinder head. Remove the cylinder head from the engine. Discard the gasket.
  28.  
  29. Clean all gasket material from both mating surfaces.

    Click image to see an enlarged view

    Fig. Cylinder head bolt loosening sequence-2005 3.0L engine



    Click image to see an enlarged view

    Fig. Cylinder head bolt tightening sequence-2005 3.0L engine

  30.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Apply a thin coat of clean engine oil to the washers and cylinder head bolts.
  4.  
  5. Tighten the cylinder head retaining bolts to specification and in the proper sequence.
  6.  
  7. Install the rear chain cover as follows:
    NOTE
    There are several size bolts used, refer to the illustration for size and locations.

    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.  
    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.
    10.  

  8.  
  9. Start the engine and allow it to reach operating temperature.
  10.  
  11. Check for leaks, correct as required.

    Click image to see an enlarged view

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



    Click image to see an enlarged view

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



    Click image to see an enlarged view

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

  12.  

3.3L Engines


Click image to see an enlarged view

Fig. Cylinder head assembly-3.3L engine



Click image to see an enlarged view

Fig. Cylinder head bolt loosening sequence-3.3L engine



Click image to see an enlarged view

Fig. Cylinder head bolt tightening sequence-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 intake and exhaust manifolds from the cylinder head.
  6.  
  7. Remove the timing belt and sprockets.
  8.  
  9. Remove both the camshafts.
  10.  
  11. Remove the oil dipstick and tube.
  12.  
  13. Remove the heater pipe.
  14.  
  15. Remove the cylinder head bolts in the proper sequence. DO NOT fully remove bolt number 5 or 8. One of these bolts should remain three of four threads into the block to prevent the cylinder head from falling.
  16.  
  17. Free the cylinder head from the block then remove the bolt left loosely in place. If the cylinder head will not come free easily, then tap the side of the head with a plastic-faced hammer.
  18.  
  19. Remove the cylinder head and gasket.
  20.  
  21. Clean all gasket material from both mating surfaces.
  22.  

To install:

  1. Install the cylinder head using a new gasket. Loosely install the cylinder head mounting bolts, coating each with clean engine oil.
  2.  
  3. Tighten the mounting bolts as follows:
    1. Tighten the bolts in sequence to 22 ft. lbs. (29 Nm).
    2.  
    3. Tighten the bolts in sequence to 51 ft. lbs. (69 Nm).
    4.  
    5. Back off all the bolts 180°.
    6.  
    7. Back off all bolts an additional 180°.
    8.  
    9. Tighten the bolts in sequence to 20 ft. lbs. (27 Nm).
    10.  
    11. Tighten bolts 1, 2, 3 and 4 an additional 90°.
    12.  
    13. Tighten bolts 5, 6, 7, and 8 to 33 ft. lbs. (44 Nm).
    14.  
    15. Tighten all bolts in sequence an additional 90°.
    16.  

  4.  
  5. Install the camshafts.
  6.  
  7. Install the heater pipe.
  8.  
  9. Install the oil dipstick and tube.
  10.  
  11. Connect the intake and exhaust manifolds to the cylinder head.
  12.  
  13. Install the timing belt and sprockets.
  14.  
  15. Connect the negative battery cable.
  16.  

 
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