Subaru Forester 1998-05

Camshaft, Bearings & Lifters 2

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Removal & Installation



2.5L SOHC (Non-Turbo) Engines
  1. Remove or disconnect the following:

    Negative battery cable
     
    Timing belt covers
     
    Timing belt
     
    Camshaft sprockets
     
    Spark plug wires
     
    Oil level gauge guide and Camshaft Position (CMP) sensor support
     
    Positive Crankcase Ventilation (PCV) hose
     
    Valve cover
     
    Rocker arm assembly
     

  2.  
  3. Remove the camshaft cap as follows:
    1. Bolts -A- through -B- in alphabetical sequence
    2.  
    3. Loosen bolts -C- through -J- equally all the way in alphabetical sequence
    4.  
    5. Bolts -K- through -P- in alphabetical sequence using tool 499497000
    6.  

  4.  
  5. Remove or disconnect the following:

    Camshaft
     
    Oil seal, if necessary
     
    Plug from the rear side of the camshaft

    Click image to see an enlarged view

    Fig. Camshaft cap removal sequence-1999-2003 SOHC Engines

     

  6.  

To install:


NOTE
Lubricate the camshaft bearings prior to camshaft installation.

  1. Install or connect the following:

    Camshaft
     
    Camshaft cap. Apply liquid gasket on the edge of the cam cap mating surface 0.12 inch (3mm) thick
     

  2.  
  3. Temporarily tighten bolts -G- through -J- in alphabetical sequence
  4.  
  5. Install the valve rocker assembly. Torque the bolts -A- through -H- to 18 ft. lbs. (25 Nm).
  6.  
  7. Torque bolts -I- through -N- to 13 ft. lbs. (25 Nm) in alphabetical sequence using tool 499497000
  8.  
  9. Torque bolts -O- through -X- to 7.2 ft. lbs. (10 Nm) in alphabetical sequence
  10.  
  11. Install or connect the following:

    Oil seal to the camshaft using tool 499597000 oil seal guide and 49958700 oil seal installer
     
    Plug to the rear side of the camshaft using tool 499587700 oil seal installer
     
    Valve cover
     
    Oil level gauge guide and CMP sensor support
     
    PCV house
     
    Spark plug wires
     
    Camshaft sprockets. Torque the bolts to 58 ft. lbs. (78 Nm).
     
    Timing belt
     
    Timing belt covers. Torque the bolts to 3.6 ft. lbs. (5 Nm).
     
    Negative battery cable

    Click image to see an enlarged view

    Fig. Camshaft cap tightening sequence-1999-2003 SOHC Engines

     

  12.  

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the drive belts.
  4.  
  5. Remove the crankshaft pulley.
  6.  
  7. Remove the timing belt covers.
  8.  
  9. Remove the timing belt.
  10.  
  11. Remove the camshaft sprocket.
  12.  
  13. Remove the crankshaft sprocket
  14.  
  15. Remove timing belt cover No.2 from the left and right hand sides.
  16.  
  17. Remove the tensioner bracket.
  18.  
  19. Remove the Camshaft Position (CMP) sensor support from the left hand side.
  20.  
  21. Remove the oil level gauge guide from the left hand side.
  22.  
  23. Remove the spark plug wires.
  24.  
  25. Remove the valve cover and gasket.
  26.  
  27. Remove the valve rocker assembly.
    NOTE
    Before removing the camshaft cap bolts mark and note their location so they may be reinstalled in their original positions.

  28.  
  29. Loosen the camshaft cap bolts using several passes in the sequences illustrated in the following order:
    1. Remove bolts A and B.
    2.  
    3. Loosen bolts C through J in sequence.
    4.  
    5. Using a suitable size torque bit, remove bolts K through P in sequence.

      Click image to see an enlarged view

      Fig. Remove camshaft cap bolts A and B using several passes-2004 SOHC engine



      Click image to see an enlarged view

      Fig. Remove camshaft cap bolts C through J using several passes-2004 SOHC engine



      Click image to see an enlarged view

      Fig. Remove camshaft cap bolts K through P using several passes-2004 SOHC engine

    6.  

  30.  
  31. Remove the camshaft caps, camshaft and oil seal.
  32.  
  33. Remove the plug from the rear right hand side of the camshaft.
    CAUTION
    Do not remove the oil seal unless needed. Be careful not to scratch or damage the journal mating surfaces.

  34.  

To install:


NOTE
Lubricate the camshaft bearings prior to camshaft installation.

  1. Install the camshaft.
  2.  
  3. Apply a bead of liquid gasket around the camshaft cap as illustrated.
  4.  
  5. Install the camshaft cap. Apply liquid gasket on the edge (B) of the cam cap (C) mating surface 0.12 inch (3mm) thick (A).

    Click image to see an enlarged view

    Fig. Apply a bead of liquid gasket around the camshaft cap-2004 SOHC engine



    Click image to see an enlarged view

    Fig. Apply liquid gasket on the edge (B) of the cam cap (C) mating surface 0.12 inch (3mm) thick (A)-2004 SOHC engine



    Click image to see an enlarged view

    Fig. Temporarily tighten bolts -G- through -J- in sequence-2004 SOHC engine



    Click image to see an enlarged view

    Fig. Tighten bolts -A- through -H- in sequence-2004 SOHC engine



    Click image to see an enlarged view

    Fig. Tighten bolts -I- through -N- in sequence-2004 SOHC engine



    Click image to see an enlarged view

    Fig. Tighten bolts -O- through -V- in sequence-2004 SOHC engine



    Click image to see an enlarged view

    Fig. Tighten bolts -W- through -X- in sequence-2004 SOHC engine

  6.  
  7. Temporarily tighten bolts -G- through -J- in alphabetical sequence.
  8.  
  9. Install the valve rocker assembly. Torque the bolts -A- through -H- to 18 ft. lbs. (25 Nm).
  10.  
  11. Torque bolts -I- through -N- to 13 ft. lbs. (25 Nm) in alphabetical sequence using Torx tool 499497000.
  12.  
  13. Torque bolts -O- through -V- to 7.2 ft. lbs. (10 Nm) in alphabetical sequence.
  14.  
  15. Torque bolts -W- through -X- to 7.2 ft. lbs. (10 Nm) in alphabetical sequence.
  16.  
  17. Install the oil seal to the camshaft using tool 499597000 oil seal guide and 499587500 oil seal installer.
  18.  
  19. Install the plug to the rear side of the camshaft using tool 499587700 oil seal installer.
  20.  
  21. Adjust the valve clearance.
  22.  
  23. Install the valve cover.
  24.  
  25. Connect the spark plug wires.
  26.  
  27. Connect the PVC house.
  28.  
  29. Install the oil level gauge guide and CMP sensor support
  30.  
  31. Install the tensioner bracket and tighten to 18 ft. lbs. (25 Nm).
  32.  
  33. Install the right and left hand timing belt cover No.2 and tighten the bolts to 3 ft. lbs. (5 Nm).
  34.  
  35. Install the crankshaft and camshaft sprockets.
  36.  
  37. Install the timing belt and cover.
  38.  
  39. Install the crankshaft pulley and tighten the bolt to 130 ft. lbs. (177 Nm).
  40.  
  41. Install the drive belts.
  42.  
  43. Connect the negative battery cable.
  44.  

  1. Disconnect the negative battery cable.
  2.  
  3. To remove the front side V belt, remove the belt covers. Loosen the lock bolt. Loosen the slider bolt. Remove the front side belt.
  4.  
  5. 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.
  6.  
  7. Remove the crankshaft pulley bolt.
  8.  
  9. Lock the crankshaft in place using tool ST499977100, or equivalent.
  10.  
  11. Remove the crankshaft pulley.
  12.  
  13. Remove the left side timing belt cover.
  14.  
  15. Remove the front timing belt cover.
  16.  
  17. Remove the timing belt.
  18.  
  19. Remove the camshaft position sensor.
  20.  
  21. Remove the camshaft sprockets.
    NOTE
    Be sure to lock the camshaft in place using tool ST18231AA010, or equivalent.

  22.  
  23. Remove the left and right timing belt N02 covers.
    NOTE
    Do not damage or loose the rubber seal when removing the covers.

  24.  
  25. Remove the tensioner bracket. Remove the camshaft position sensor support, on the left side.
  26.  
  27. Remove the oil level gauge guide, on the left side.
  28.  
  29. Remove the valve rocker arm assembly.
  30.  
  31. Remove camshaft cap retaining bolts -A- and -B- in the proper sequence.
  32.  
  33. Loosen camshaft cap bolts -C- through -J- all the way in the proper sequence.
  34.  
  35. Remove camshaft cap bolts -K- through -P- in the proper sequence using a Torx® head bit.
  36.  
  37. Remove the camshaft caps.

    Click image to see an enlarged view

    Fig. Camshaft bolt loosening sequence-2005 SOHC engine



    Click image to see an enlarged view

    Fig. Camshaft bolt loosening sequence-2005 SOHC engine



    Click image to see an enlarged view

    Fig. Camshaft bolt loosening sequence-2005 SOHC engine

  38.  
  39. Remove the camshaft. Remove the oil seal. Remove the plug from the rear side of the camshaft.
    NOTE
    Do not remove the oil seal unless necessary.

  40.  

To install:


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

  1. Install the camshaft into the cylinder head.
  2.  
  3. Apply liquid gasket to the mating surfaces of the camshaft cap.
  4.  
  5. Apply a bead of sealant (0.12 inch in diameter) along the edge of the camshaft cap mating surface. Install with 20 minutes after applying the sealant.

    Click image to see an enlarged view

    Fig. Camshaft cap sealant application-2005 SOHC engine



    Click image to see an enlarged view

    Fig. Camshaft bolt tightening sequence-2005 SOHC engine



    Click image to see an enlarged view

    Fig. Camshaft bolt tightening sequence-2005 SOHC engine



    Click image to see an enlarged view

    Fig. Camshaft bolt tightening sequence-2005 SOHC engine



    Click image to see an enlarged view

    Fig. Camshaft bolt tightening sequence-2005 SOHC engine

  6.  
  7. Temporarily tighten the bolts -A- through -D- in the proper sequence.
  8.  
  9. Install the valve rocker arm assembly. Tighten Torx® head bolts -E- through -J- in the proper sequence to 13 ft. lbs.
  10.  
  11. Tighten bolts -K- through -R- in the proper sequence to 7.2 ft. lbs.
  12.  
  13. Tighten bolts -S- through -T- in the proper sequence to 7.2 ft. lbs.
    NOTE
    Be sure to use a new seal washer.

  14.  
  15. Using tools ST499597000 and ST499587500, install a new seal on the camshaft. Be sure to coat the seal with clean engine oil before installation. Use tool ST499587700 and install the plug.
  16.  
  17. Adjust the valve clearance.
  18.  
  19. Continue the installation in the reverse order of the removal procedure.
  20.  

DOHC Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the drive belts.
  6.  
  7. Remove the crankshaft pulley.
  8.  
  9. Remove the timing belt covers.
  10.  
  11. Remove the timing belt.
  12.  
  13. Remove the camshaft sprockets.
  14.  
  15. Remove the crankshaft sprocket
  16.  
  17. Disconnect the oil flow control solenoid valve connector.
  18.  
  19. Remove the tensioner bracket.
  20.  
  21. Remove timing belt cover No.2 from the left hand side and the timing belt cover from the right hand side.
  22.  
  23. Remove the spark plug wires.
  24.  
  25. Remove the oil level gauge guide from the left hand side.
  26.  
  27. Remove the valve cover and gasket.
  28.  
  29. Remove the oil pipe.
  30.  


NOTE
Before removing the camshaft cap bolts mark and note their location so they may be reinstalled in their original positions.

  1. Loosen the oil flow control solenoid valve assembly and intake camshaft cap bolts using several passes in the sequence illustrated.
  2.  
  3. Remove the oil flow control solenoid valve assembly the camshaft caps and the camshaft.
  4.  
  5. Loosen the exhaust camshaft cap bolts using several passes in the sequence illustrated. Remove the caps and camshaft.
  6.  


    Click image to see an enlarged view

    Fig. Loosen the oil flow control solenoid valve assembly and intake camshaft cap bolts using several passes-DOHC engines



    Click image to see an enlarged view

    Fig. Loosen exhaust camshaft cap bolts using several passes-DOHC engines


To install:

  1. Lubricate the camshaft bearings prior to camshaft installation. Install the camshaft so that each valve is close to or in contact with the base circle of the cam lobe.
  2.  


NOTE
When the camshafts are positioned as shown in the accompanying illustration, the camshafts need to be rotated at a minimum to align with the timing belt during installation. The right hand camshaft will not need to be rotated when set at the position show in the accompanying illustration. The left hand intake camshaft should be rotated 80 degrees clockwise and the left hand exhaust camshaft should be rotated 45 degrees counterclockwise.



Click image to see an enlarged view

Fig. Camshaft alignment-DOHC engines

  1. Install the intake camshaft caps and oil flow control solenoid valve assembly as follows:
    1. Apply liquid gasket sparingly to the cap mating surfaces as illustrated. Do not use an excessive amount of gasket maker as this can cause excess packing to come out and block the oil seal which will cause an oil leak.
    2.  

  2.  
  3. Apply clean engine oil to the cap bearing surface and install the cap on the camshaft indicated by the letterA
    1. Tighten the camshaft cap and oil control valve assembly bolts in two to three passes. Apply clean engine oil to the cap bearing surface and install the cap on the camshaft indicated by the letterA
    2.  



    Click image to see an enlarged view

    Fig. Apply clean engine oil to the cap bearing surface and install the cap on the camshaft indicated by the letter A-DOHC engines

  4.  
  5. Install the exhaust caps and tighten the bolts using two or three passes. Tighten bolts C, D E and F to 7 ft. lbs. (10 Nm) and bolts A and B to 14 ft. lbs. (20 Nm).
  6.  
  7. Install the oil seal to the camshaft using tool 499587600 oil seal guide and 499597200 oil seal installer
  8.  
  9. Install a new gasket on the valve cover, also install the peripheral and ignition coil gaskets.
  10.  
  11. Apply liquid gasket maker to the points shown in the accompanying illustration.
  12.  
  13. Install the valve cover and make sure the gasket are positioned correctly. Tighten the valve cover bolts in the sequence illustrated to 5 ft. lbs. (7 Nm).
  14.  
  15. Install the oil pipe and tighten to 21 ft. lbs. (29 Nm).
  16.  
  17. Connect the oil flow control solenoid valve connector.
  18.  
  19. Connect the spark plug wires.
  20.  
  21. Install the right and left hand timing belt cover No.2 and tighten the bolts to 3 ft. lbs. (5 Nm).
  22.  
  23. Install the tensioner bracket and tighten to 18 ft. lbs. (25 Nm).
  24.  
  25. Install th