Subaru Car 1998-05

Valve Lash (Clearance) Adjustment 1

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1.8L Engine





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Fig. Valve arrangement-1.8L engine



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Fig. Loosen the adjuster locknut-1.8L engine



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Fig. Use a feeler gauge and wrench to adjust the gap if needed-1.8L engine

The valve lash should be checked and adjusted every 15,000 miles (24,000 km).


NOTE
Before adjusting the valve clearance, check the cylinder head torque.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. With the engine cold, rotate the engine so that the No. 1 piston is at Top Dead Center (TDC) of its compression stroke. The No. 1 piston is at top dead center when the distributor rotor is pointing to the No. 1 terminal (as though the distributor cap were in place) and the 0 mark on the flywheel or front pulley is opposite the pointer on the housing or front cover.
  4.  
  5. Check the clearance of both the intake and exhaust valves of the No. 1 cylinder by inserting a feeler gauge between each valve stem and rocker arm.
  6.  
  7. If the clearance is not within specifications, loosen the locknut with the proper size wrench and turn the adjusting stud either in or out until the valve clearance is correct.
    NOTE
    Proper valve clearance is obtained when the feeler gauge slides between the valve stem and the rocker arm with a minimum amount of resistance.

  8.  
  9. Tighten the locknut and recheck the valve stem-to-rocker clearance.
  10.  
  11. The rest of the valves are adjusted in the same way. Bring each piston to TDC of its compression stroke, then check and adjust the valves for that cylinder. The proper valve adjustment sequence is 1-3-2-4.
  12.  
  13. Rotate the crankshaft at least two revolutions, then recheck the valve clearance.
  14.  
  15. Tighten the rocker arm locknuts to 10-13 ft. lbs. (14-18 Nm) for the 1.6L and 1.8L engines.
  16.  
  17. Install the valve covers using new gaskets. Tighten the retaining nuts to 5-6 ft. lbs. (6-7 Nm) on the 1.2L engine and 2-3 ft. lbs. (3-4 Nm).
  18.  

2.0L Engine




NOTE
Inspection and adjustment of the valve clearance should be performed with the engine cold.

  1. Remove or disconnect the following:

    Negative battery cable
     
    Air intake duct
     
    Bolt that attaches the right hand timing cover
     
    Engine undercover
     
    Remaining bolts attaching the right hand timing belt cover and the cover
     

  2.  
  3. When inspecting the No. 1 and No. 3 cylinders:
    1. Pull out the engine harness connector with the bracket from the air cleaner upper cover.
    2.  
    3. Remove the air cleaner case.
    4.  
    5. Disconnect the spark plug wires from the No. 1 and No. 3 cylinders.
    6.  
    7. Disconnect the Positive Crankcase Ventilation (PCV) hose from the right hand rocker cover.
    8.  
    9. Remove the right hand rocker cover.
    10.  

  4.  
  5. When inspecting the No. 2 and No. 4 cylinders:
    1. Remove the battery and tray.
    2.  
    3. Remove the bolt that attaches the engine harness onto the body.
    4.  
    5. Disconnect the washer motor connectors.
    6.  
    7. Remove the washer tank bolts and lift the tank upwards.
    8.  
    9. Disconnect the spark plug wires from the No. 2 and No. 4 cylinders.
    10.  
    11. Disconnect the PCV hose from the left hand rocker cover.
    12.  
    13. Remove the left hand rocker cover.
    14.  
    15. Turn the crankshaft pulley clockwise until the arrow mark on the camshaft is positioned as shown in the illustration to measure the No. 1 intake and No. 3 exhaust valves.
    16.  

  6.  
  7. Using a suitable feeler gauge, measure the No. 1 and No. 3 cylinder exhaust valve clearance. Insert the gauge in as horizontal a direction with respect to the shim. Make sure to measure the exhaust valve clearances while lifting up the vehicle.
  8.  
  9. The intake valve clearance should be 0.0071-0.0087 inch (0.18-0.22mm). The exhaust valve clearance should be 0.0090-0.0106 inch (0.23-0.27mm).
  10.  
  11. If not within specification, adjust the valve as outlined in the adjustment steps.
  12.  
  13. Turn the crankshaft pulley clockwise to measure the valve clearance for the No. 2 exhaust and No. 3 intake valves as shown in the illustration.
  14.  
  15. Turn the crankshaft pulley clockwise to measure the valve clearance for the No. 2 intake and No. 4 exhaust valves as shown in the illustration.
  16.  
  17. Turn the crankshaft pulley clockwise to measure the valve clearance for the No. 1 exhaust and No. 4 intake valves as shown in the illustration.
  18.  
  19. Adjust the valve clearance as follows:
    1. Measure and record all valve clearances using the procedures outlined in the inspection steps in this section.
    2.  
    3. Prepare shim replacer tool 498187200.
    4.  
    5. Rotate the notch of the valve lifter outwards 45 degrees.
    6.  
    7. Adjust the shim replacer tool notch to the lifter and set it.
      NOTE
      Make sure when setting the tool that the edge does not touch the shim.

    8.  
    9. Tighten bolt -A- and attach it to the cylinder head. Refer to the illustration for bolt locations.
    10.  
    11. Tighten bolt -B- and insert the lifter. Refer to the illustration for bolt locations.
    12.  
    13. Use tweezers and remove the shim from the lifter. A magnet can also be used to remove the shim.
    14.  
    15. Measure the shim thickness using a micrometer.
    16.  
    17. Using the table supplied, select a suitable shim using measured valve clearance and shim thickness.
    18.  
    19. Install the replacement shim to the lifter.
    20.  
    21. After all shims have been adjusted, inspect the valve clearances again.
    22.  
    23. After completion, install all removed components.

      Click image to see an enlarged view

      Fig. Turn the crankshaft pulley clockwise until the arrow mark on the camshaft is positioned as shown to measure the No. 1 intake and No. 3 exhaust valves-2.0L engines



      Click image to see an enlarged view

      Fig. Use a feeler gauge to inspect the valve clearance-2.0L engines



      Click image to see an enlarged view

      Fig. Turn the crankshaft pulley clockwise until the arrow mark on the camshaft is positioned as shown to measure the No. 2 exhaust and No. 3 intake valves-2.0L engines



      Click image to see an enlarged view

      Fig. Turn the crankshaft pulley clockwise until the arrow mark on the camshaft is positioned as shown to measure the No. 2 intake and No. 4 exhaust valves-2.0L engines



      Click image to see an enlarged view

      Fig. Turn the crankshaft pulley clockwise until the arrow mark on the camshaft is positioned as shown to measure the No. 1 exhaust and No. 4 intake valves-2.0L engines



      Click image to see an enlarged view

      Fig. Shim replacer tool 498187200 is required to adjust the valves-2.0L engines



      Click image to see an enlarged view

      Fig. Rotate the notch of the valve lifter outwards 45 degrees-2.0L engines



      Click image to see an enlarged view

      Fig. Adjust the shim replacer tool notch to the lifter and set it-2.0L engines



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      Fig. Location of bolts -A- and -B- on the shim replacer tool-2.0L engines



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      Fig. Remove the shim from the lifter-2.0L engine



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      Fig. Use this table to help you select a suitable shim-2.0L engine



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      Fig. Valve adjusting shim chart-2.0L engine



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      Fig. Position the camshaft for adjustment to valves-2.0L engine

    24.  

  20.  

2.2L Engine



  1. With the engine cold, rotate the engine so that the No. 1 piston is at Top Dead Center (TDC) of its compression stroke.
  2.  
  3. Check the clearance of both the intake and exhaust valves of the No. 1 cylinder by inserting a feeler gauge between each valve stem and rocker arm.
  4.  
  5. If the clearance is not within specifications, loosen the locknut with the proper size wrench and turn the adjusting stud either in or out until the valve clearance is correct.
    NOTE
    Proper valve clearance is obtained when the feeler gauge slides between the valve stem and the rocker arm with a minimum amount of resistance.

  6.  
  7. Tighten the locknut and recheck the valve stem-to-rocker clearance.
  8.  
  9. The rest of the valves are adjusted in the same way. Bring each piston to TDC of its compression stroke, then check and adjust the valves for that cylinder. The proper valve adjustment sequence is 1-3-2-4.
  10.  
  11. Rotate the crankshaft at least 2 revolutions, then recheck the valve clearance.
  12.  
  13. Tighten the rocker arm locknuts to 10-13 ft. lbs. (14-18 Nm).
  14.  
  15. Install the valve covers using new gaskets. Tighten the retaining nuts to 24-36 inch lbs. (3-4 Nm).
  16.  

2.5L Engine




NOTE
The valve adjustment should be performed while the engine is cold. A Shim Replace Kit 498187100 will be needed to perform the valve adjustment.

  1. Adjustment should be performed when engine is cold.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Engine coolant reservoir tank
     
    Timing belt cover on the left hand side
     

  4.  
  5. When inspecting the No. 1 and 3 cylinders remove the following:

    Air intake duct as a unit
     
    Resonator chamber
     
    Spark plug wires from the No. 1 and 3 cylinders
     
    Blow-by house from valve cover
     
    Engine undercover
     
    Timing belt cover on the right hand side
     
    Valve cover on the right hand side
     

  6.  
  7. When inspecting the No. 2 and 4 cylinders remove the following:

    Battery and battery tray
     
    Window washer motor connectors front and rear
     
    Rear gate glass washer hose from the washer motor
     
    Washer tank mounting bolts and secure out of the way
     
    Spark plug wires from the No. 2 and 4 cylinders
     
    Blow by house from valve cover
     
    Timing belt cover on the right hand side
     
    Valve cover on the left hand side
     

  8.  
  9. Set No. 1 cylinder to Top Dead Center (TDC).
    NOTE
    When arrow mark on the left hand side comes exactly to the top, No. 1 cylinder piston is brought to TDC of the compression stroke.

  10.  
  11. Check the valve clearance:

    Intake valve: 0.0071-0.0087 in. (0.18-0.22mm)
     
    Exhaust valve: 0.0090-0.0106 in. (0.23-0.27mm)
     

  12.  
  13. If any valve needs adjustment, perform the following:
    1. Loosen the valve rocker nut and screw.
    2.  
    3. Place a thickness gage in at as horizontal a direction as possible with respect to the valve stem and face.
    4.  
    5. Adjust the screw until proper clearance is obtained.
    6.  
    7. Tighten the rocker nut after adjusted.
    8.  

  14.  
  15. Install or connect the following:

    Valve covers left and right
     
    Timing belt covers
     
    Blow-by houses to valve covers
     
    Spark plug wires
     
    Washer tank
     
    Rear gate glass washer hose to the washer motor
     
    Washer motor connectors
     
    Battery and battery tray
     
    Engine undercover
     
    Resonator chamber
     
    Air intake duct unit
     
    Engine coolant reservoir tank
     

  16.  

DOHC Engine

NOTE
The valve adjustment should be performed while the engine is cold.

  1. Raise and support the vehicle safely.
  2.  
  3. Remove the under cover.
  4.  
  5. Lower the vehicle.
  6.  
  7. Remove the collector cover.
  8.  
  9. Disconnect the negative battery cable.
  10.  
  11. Remove the air intake duct.
  12.  
  13. Remove the bolt that retains the right side timing belt cover. Remove the remaining bolts and remove the right side timing belt cover.
  14.  
  15. Disconnect the ignition coil electrical connector. Remove the ignition coil.
  16.  
  17. Position a suitable container under the vehicle.
  18.  
  19. Disconnect the PCV hose from the rocker cover. Remove the rocker cover retaining bolts. Remove the rocker cover from the vehicle.
  20.  
  21. Position the number one piston at TDC of the compression stroke.
  22.  
  23. Using a feeler gauge, measure and record the clearance of the number one cylinder intake and the number three cylinder exhaust valves.
    NOTE
    Insert the feeler gauge in a horizontally as possible with respect to the valve lifter. Measure and record the exhaust valve clearance while lifting up the vehicle.

  24.  
  25. Rotate the crankshaft pulley clockwise until the arrow mark on the camshaft is positioned as shown to measure and record the clearance on the number two exhaust and number three intake valves.
  26.  
  27. Rotate the crankshaft pulley clockwise until the arrow mark on the camshaft is positioned as shown to measure and record the number two intake and number four exhaust valves.
  28.  
  29. Rotate the crankshaft pulley clockwise until the arrow mark on the camshaft is positioned as shown to measure and record the number one exhaust and number four intake valves.

    Click image to see an enlarged view

    Fig. Turn the crankshaft pulley clockwise until the arrow mark on the camshaft is positioned as shown to measure the No. 1 intake and No. 3 exhaust valves-2.0L engine and 2005 2.5L DOHC engine



    Click image to see an enlarged view

    Fig. Use a feeler gauge to inspect the valve clearance-2.0L engine and 2005 2.5L DOHC engine



    Click image to see an enlarged view

    Fig. Turn the crankshaft pulley clockwise until the arrow mark on the camshaft is positioned as shown to measure the No. 2 exhaust and No. 3 intake valves-2.0L engine and 2005 2.5L DOHC engine



    Click image to see an enlarged view

    Fig. Turn the crankshaft pulley clockwise until the arrow mark on the camshaft is positioned as shown to measure the No. 2 intake and No. 4 exhaust valves-2.0L engine and 2005 2.5L DOHC engine



    Click image to see an enlarged view

    Fig. Turn the crankshaft pulley clockwise until the arrow mark on the camshaft is positioned as shown to measure the No. 1 exhaust and No. 4 intake valves-2.0L engine and 2005 2.5L DOHC engine

  30.  
  31. If adjustment is required, remove the camshafts.
  32.  
  33. Remove and measure the thickness of the valve lifter. Select a suitable shim, using the shim selection chart.
  34.  
  35. Install the replacement shim to the lifter.
  36.  
  37. After all shims have been adjusted, inspect the valve clearances again.
  38.  
  39. After completion, install all removed components.

    Click image to see an enlarged view

    Fig. Use this table to help you select a suitable shim-2005 2.5L DOHC engine



    Click image to see an enlarged view

    Fig. Valve adjusting shim chart-2005 2.5L DOHC engine

  40.  

SOHC Engine

NOTE
The valve adjustment should be performed while the engine is cold.

  1. Raise and support the vehicle safely.
  2.  
  3. Remove the under cover.
  4.  
  5. Lower the vehicle.
  6.  
  7. Disconnect the negative battery cable.
  8.  
  9. To remove the front side V belt, remove the belt covers. Loosen the lock bolt. Loosen the slider bolt. Remove the front side belt.
  10.  
  11. To remove the rear side V belt, remove the belt covers. Loosen the lock bolt. Loosen the slider bolt. Remove the rear side belt. Remove the belt tensioner.
  12.  
  13. Remove the crankshaft pulley bolt.
  14.  
  15. Lock the crankshaft in place using tool ST499977100, or equivalent.
  16.  
  17. Remove the crankshaft pulley.
  18.  
  19. Remove the left side timing belt cover.
  20.  
  21. Remove the fuel injector.
  22.  
  23. Remove the rocker cover.
  24.  
  25. Position the number one piston at TDC of the compression stroke.
    NOTE
    When the arrow (see illustration) on the camshaft sprocket (left side) comes exactly to the top, number one cylinder piston is at TDC of the compression stroke.



    Click image to see an enlarged view

    Fig. TDC alignment-2005 2.5L SOHC engine

  26.  
  27. Measure the valve clearance, using a feeler gauge.
  28.  
  29. If adjustment is needed, loosen the valve rocker nut and screw. Position the feeler gauge.
    NOTE
    Insert the feeler gauge in a horizontally as possible with respect to the valve stem end face. Adjust the exhaust valve clearance while lifting up the vehicle.

  30.  
  31. While noting the valve clearance, tighten the rocker adjusting screw.
  32.  
  33. When the proper valve clearance is obtained, tighten the valve rocker nut to 7.2 ft. lbs.
  34.  
  35. Adjust the valve clearance on the remaining cylinders, following the above procedure.
    NOTE
    Be sure to position the pistons to their respective TDC positions on the compression stroke, before checking and adjusting the valves. By rotating the crankshaft pulley clockwise every 180 degrees from the state that number one piston is on TDC of the compression stroke, the remaining pistons come to TDC of the compression stroke in the following order, #3, #2, and #4.

  36.  
  37. After adjustment, replace any removed components.
  38.  
  39. Be sure to use new gaskets and seals, as required.
  40.  

 
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