Subaru Forester 1998-05

Cylinder Head

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Removal & Installation



DOHC Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:
  6.  
  7. Disconnect the negative battery cable.
  8.  
  9. Remove the drive belts.
  10.  
  11. Remove the crankshaft pulley.
  12.  
  13. Remove the timing belt cover, timing belt assembly and camshaft sprockets.
  14.  
  15. Remove the intake manifold.
  16.  
  17. Remove the bolt attaching the A/C compressor bracket to the head.
  18.  
  19. Remove the camshaft.
  20.  
  21. Remove the bolts in the sequence illustrated. Leave boltsAD
  22.  
  23. Separate the cylinder head from the block. Use a plastic-faced hammer, if needed.
  24.  
  25. Remove bolts A and D. Remove the cylinder head and gasket.
  26.  
  27. Clean all gasket material from both mating surfaces.
  28.  


    Click image to see an enlarged view

    Fig. Cylinder head bolt loosening sequence-DOHC engines


To install:

  1. Inspect the cylinder head for warpage. Warpage should not exceed 0.0020 in. (0.05mm).
  2.  
  3. Install the cylinder head(s) on the block using new gaskets. Secure in place with the mounting bolts. Coat each bolts with clean engine oil, and hand-tighten.
  4.  
  5. Tighten the cylinder head bolts as follows:
    1. Step 1: Torque all the bolts in sequence to 22 ft. lbs. (29 Nm).
    2.  
    3. Step 2: Torque all the bolts in sequence to 51 ft. lbs. (69 Nm).
    4.  
    5. Step 3: Loosen all bolts in sequence by 180 degrees, then loosen an additional 180 degrees.
    6.  
    7. Step 4: Tighten all bolts in sequence to 36 ft. lbs. (49 Nm).
    8.  
    9. Step 5: Tighten all bolts in sequence an additional 80-90 degrees
    10.  
    11. Step 6: All bolts: turn an additional 40-45 degrees.
    12.  
    13. Step 7: BoltsAB
    14.  

  6.  


    Click image to see an enlarged view

    Fig. Cylinder head torque sequence-2.5L engine



WARNING
Do not exceed 90 degrees total tightening in the previous two steps.

  1. Install the remaining components in the reverse order of removal.
  2.  
  3. Start the engine and allow it to reach operating temperature.
  4.  
  5. Check for leaks.
  6.  

Non-Turbo Engine


Click image to see an enlarged view

Fig. Exploded view of the cylinder head mounting-Non-Turbo engine

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Oxygen (O 2 S) sensor. If equipped with California emissions, disconnect the rear O 2 S sensor.
     
    Engine undercover
     
    Exhaust Y-pipe and lower it just enough to clear the studs in the heads. Do not allow the Y-pipe to hang without support.
     
    Accessory drive belts
     
    Engine accessories and brackets from the side of the engine the cylinder head is being removed
     
    Connector bracket attaching bolt, if necessary
     

  6.  
  7. On the left cylinder head, remove the CMP sensor.
  8.  
  9. Remove or disconnect the following:

    Fuel pipes
     
    Intake manifold and gasket
     
    Timing belt, camshaft sprockets, and related components
     
    Valve covers, camshafts and related components
     
    Oil dipstick tube attaching bolt on the left cylinder head
     
    Bolt attaching the A/C compressor to the head
     
    Cylinder head bolts in the proper sequence. Leave bolts C and F installed loosely to prevent the cylinder head from falling.
     

  10.  
  11. Separate the cylinder head from the block. Use a plastic-faced hammer, if needed.
  12.  
  13. Remove bolts C and F. Remove the cylinder head and gasket.
  14.  
  15. Clean all gasket material from both mating surfaces.

    Click image to see an enlarged view

    Fig. Cylinder head bolt loosening sequence-Non-Turbo engine

  16.  

To install:

  1. Inspect the cylinder head for warpage. Warpage should not exceed 0.0020 in. (0.05mm).
  2.  
  3. Install the cylinder head(s) on the block using new gaskets. Secure in place with the mounting bolts. Coat each bolts with clean engine oil, and hand-tighten.

    Click image to see an enlarged view

    Fig. Cylinder head torque sequence-Non-Turbo engine

  4.  
  5. Tighten the cylinder head bolts as follows:


    1. Step 1: Torque all the bolts in sequence to 22 ft. lbs. (29 Nm).
    2.  
    3. Step 2: Torque all the bolts in sequence to 51 ft. lbs. (69 Nm).
    4.  
    5. Step 3: Loosen all bolts in sequence by 180 degrees, then loosen an additional 180 degrees.
    6.  
    7. Step 4: Tighten all bolts in sequence: 40-45 degrees.
      CAUTION
      Do not tighten the bolts more that 45 degrees in step 4.

    8.  
    9. Step 5: Tighten bolts A and B in sequence: 40-45 degrees.
      WARNING
      Do not exceed 90 degrees total tightening.

    10.  

  6.  
  7. Install or connect the following:

    Oil dipstick tube attaching bolt on the left cylinder head
     
    Valve covers, camshafts and related components
     
    Camshaft sprocket, timing belt, and related components
     
    Intake manifold
     
    Fuel delivery pipes
     

  8.  
  9. On the left cylinder head, install the CMP sensor.
  10.  
  11. Install or connect the following:

    Connector bracket attaching bolt
     
    Spark plug wires
     
    Engine accessories and brackets
     
    Accessory drive belts
     
    Exhaust Y-pipe. Torque the fasteners to 19-26 ft. lbs. (25-35 Nm).
     
    Engine undercover
     
    Front O 2 S and rear O 2 S, if removed.
     
    Negative battery cable
     

  12.  
  13. Start the engine and allow it to reach operating temperature.
  14.  
  15. Check for leaks.
  16.  

SOHC Engines


Click image to see an enlarged view

Fig. Exploded view of the cylinder head mounting-SOHC engine

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Oxygen (O2S) sensor. If equipped with California emissions, disconnect the rear O2S sensor.
     
    Engine undercover
     
    Exhaust Y-pipe and lower it just enough to clear the studs in the heads. Do not allow the Y-pipe to hang without support.
     
    Accessory drive belts
     
    Engine accessories and brackets from the side of the engine the cylinder head is being removed
     
    Connector bracket attaching bolt, if necessary
     

  6.  
  7. On the left cylinder head, remove the CMP sensor.
  8.  
  9. Remove or disconnect the following:

    Fuel pipes
     
    Intake manifold and gasket
     
    Timing belt, camshaft sprockets, and related components
     
    Valve covers, camshafts and related components
     
    Oil dipstick tube attaching bolt on the left cylinder head
     
    Bolt attaching the A/C compressor to the head
     
    Cylinder head bolts in the proper sequence. Leave bolts C and F installed loosely to prevent the cylinder head from falling.
     

  10.  
  11. Separate the cylinder head from the block. Use a plastic-faced hammer, if needed.
  12.  
  13. Remove bolts C and F. Remove the cylinder head and gasket.
  14.  
  15. Clean all gasket material from both mating surfaces.
  16.  


    Click image to see an enlarged view

    Fig. Cylinder head bolt loosening sequence-SOHC engine


To install:

  1. Inspect the cylinder head for warpage. Warpage should not exceed 0.0020 in. (0.05mm).
  2.  
  3. Install the cylinder head(s) on the block using new gaskets. Secure in place with the mounting bolts. Coat each bolts with clean engine oil, and hand-tighten.
  4.  
  5. Tighten the cylinder head bolts as follows:
    1. Step 1: Torque all the bolts in sequence to 22 ft. lbs. (29 Nm).
    2.  
    3. Step 2: Torque all the bolts in sequence to 51 ft. lbs. (69 Nm).
    4.  
    5. Step 3: Loosen all bolts in sequence by 180 degrees, then loosen an additional 180 degrees.
    6.  
    7. Step 4: Tighten all bolts in sequence: 40-45 degrees.
    8.  

  6.  


    Click image to see an enlarged view

    Fig. Cylinder head torque sequence-SOHC engine



CAUTION
Do not tighten the bolts more that 45 degrees in step 4.

  1. Step 5: Tighten bolts A and B in sequence: 40-45 degrees.
  2.  


WARNING
Do not exceed 90 degrees total tightening.

  1. Install or connect the following:

    Oil dipstick tube attaching bolt on the left cylinder head
     
    Valve covers, camshafts and related components
     
    Camshaft sprocket, timing belt, and related components
     
    Intake manifold
     
    Fuel delivery pipes
     

  2.  
  3. On the left cylinder head, install the CMP sensor.
  4.  
  5. Install or connect the following:

    Connector bracket attaching bolt
     
    Spark plug wires
     
    Engine accessories and brackets
     
    Accessory drive belts
     
    Exhaust Y-pipe. Torque the fasteners to 19-26 ft. lbs. (25-35 Nm).
     
    Engine undercover
     
    Front O2S and rear O2S, if removed.
     
    Negative battery cable
     

  6.  
  7. Start the engine and allow it to reach operating temperature.
  8.  
  9. Check for leaks.
  10.  

Turbo Engines
  1. Properly relieve the fuel system pressure.
  2.  
  3. Remove or disconnect the following:
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the drive belts.
  8.  
  9. Remove the crankshaft pulley.
  10.  
  11. Remove the timing belt cover, timing belt assembly and camshaft sprockets.
  12.  
  13. Remove the intake manifold.
  14.  
  15. Remove the bolt attaching the A/C compressor bracket to the head.
  16.  
  17. Remove the camshaft.
  18.  
  19. Remove the bolts in the sequence illustrated. Leave bolts A and D installed loosely to prevent the cylinder head from falling.
  20.  
  21. Separate the cylinder head from the block. Use a plastic-faced hammer, if needed.
  22.  
  23. Remove bolts A and D. Remove the cylinder head and gasket.
  24.  
  25. Clean all gasket material from both mating surfaces.

    Click image to see an enlarged view

    Fig. Cylinder head bolt loosening sequence-Turbo engines

  26.  

To install:

  1. Inspect the cylinder head for warpage. Warpage should not exceed 0.0020 in. (0.05mm).
  2.  
  3. Install the cylinder head(s) on the block using new gaskets. Secure in place with the mounting bolts. Coat each bolts with clean engine oil, and hand-tighten.

    Click image to see an enlarged view

    Fig. Cylinder head torque sequence-Turbo engines

  4.  
  5. Tighten the cylinder head bolts as follows:


    1. Step 1: Torque all the bolts in sequence to 22 ft. lbs. (29 Nm).
    2.  
    3. Step 2: Torque all the bolts in sequence to 51 ft. lbs. (69 Nm).
    4.  
    5. Step 3: Loosen all bolts in sequence by 180 degrees, then loosen an additional 180 degrees.
    6.  
    7. Step 4: Tighten all bolts in sequence to 36 ft. lbs. (49 Nm).
    8.  
    9. Step 5: Tighten all bolts in sequence an additional 80-90 degrees
    10.  
    11. Step 6: All bolts: turn an additional 40-45 degrees.
    12.  
    13. Step 7: Bolts A and B an additional 40-45 degrees.
      WARNING
      Do not exceed 90 degrees total tightening in the previous two steps.

    14.  

  6.  
  7. Install the remaining components in the reverse order of removal.
  8.  
  9. Start the engine and allow it to reach operating temperature.
  10.  
  11. Check for leaks.
  12.  

 
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