Subaru 2004 LEGACY User manual

FUJI HEAVY INDUSTRIES LTD. G2320GE2
2004 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX
ENGINE SECTION 1
This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.
All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.
FUEL INJECTION (FUEL SYSTEMS) FU(H4SO 2.0)
EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICES) EC(H4SO 2.0)
INTAKE (INDUCTION) IN(H4SO 2.0)
MECHANICAL ME(H4SO 2.0)
EXHAUST EX(H4SO 2.0)
COOLING CO(H4SO 2.0)
LUBRICATION LU(H4SO 2.0)
SPEED CONTROL SYSTEMS SP(H4SO 2.0)
IGNITION IG(H4SO 2.0)
STARTING/CHARGING SYSTEMS SC(H4SO 2.0)
ENGINE (DIAGNOSTICS) EN(H4SO 2.0)
(diag)
FUEL INJECTION (FUEL SYSTEMS) FU(H4SO 2.5)
EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICES) EC(H4SO 2.5)
INTAKE (INDUCTION) IN(H4SO 2.5)
MECHANICAL ME(H4SO 2.5)
EXHAUST EX(H4SO 2.5)
COOLING CO(H4SO 2.5)

2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX
ENGINE SECTION 1
G2320GE2
LUBRICATION LU(H4SO 2.5)
SPEED CONTROL SYSTEMS SP(H4SO 2.5)
IGNITION IG(H4SO 2.5)
STARTING/CHARGING SYSTEMS SC(H4SO 2.5)
ENGINE (DIAGNOSTICS) EN(H4SO 2.5)
(diag)

MECHANICAL
ME(H4SO 2.0)
Page
1. General Description ....................................................................................2
2. Compression.............................................................................................22
3. Idle Speed.................................................................................................23
4. Ignition Timing...........................................................................................24
5. Intake Manifold Vacuum............................................................................25
6. Engine Oil Pressure ..................................................................................26
7. Fuel Pressure............................................................................................27
8. Valve Clearance........................................................................................28
9. Engine Assembly ......................................................................................30
10. Engine Mounting.......................................................................................36
11. Preparation for Overhaul...........................................................................37
12. V-belt.........................................................................................................38
13. Crank Pulley..............................................................................................40
14. Timing Belt Cover......................................................................................42
15. Timing Belt................................................................................................43
16. Cam Sprocket ...........................................................................................48
17. Crank Sprocket .........................................................................................50
18. Valve Rocker Assembly ............................................................................51
19. Camshaft...................................................................................................53
20. Cylinder Head ...........................................................................................57
21. Cylinder Block...........................................................................................63
22. Engine Trouble in General........................................................................83
23. Engine Noise.............................................................................................88

ME(H4SO 2.0)-43
MECHANICAL
Timing Belt
15.Timing Belt
A: REMOVAL
1. TIMING BELT
1) Remove the V-belts. <Ref. to ME(H4SO 2.0)-38,
REMOVAL, V-belt.>
2) Remove the crank pulley. <Ref. to ME(H4SO
2.0)-40, REMOVAL, Crank Pulley.>
3) Remove the timing belt cover. <Ref. to
ME(H4SO 2.0)-42, REMOVAL, Timing Belt Cov-
er.>
4) Remove the timing belt guide. (MT model)
5) If the alignment mark (a) or arrow mark (which
indicates rotation direction) on timing belt fade
away, put new marks before removing the timing
belt as shown in procedures below.
(1) To turn crankshaft, use the ST: Align the
mark (a) of sprocket to the cylinder block notch
(b), and then ensure the right side cam sprocket
mark (c), cam cap and cylinder head matching
surface (d) or left side cam sprocket mark (e),
timing belt cover notch (f) are properly adjusted.
ST 499987500 CRANKSHAFT SOCKET
(2) Using white paint, put alignment marks or
arrow marks on the timing belts in relation to the
crank sprocket and cam sprockets.
Specified data:
Z1: Length of 46.8 teeth
Z2: Length of 43.7 teeth
6) Remove the belt idler (No. 2).
ME-0006
5
ME-0023
1
ST
ME-0023
2
(a)
(b)
(d)
(c)
(f)
(e)
ME-0023
3
ME-00023
4
Z1Z2

ME(H4SO 2.0)-44
MECHANICAL Timing Belt
7) Remove the belt idler No. 2.
8) Remove the timing belt.
2. BELT IDLER AND AUTOMATIC BELT
TENSION ADJUSTER ASSEMBLY
1) Remove the belt idler (No. 1).
2) Remove the automatic belt tension adjuster as-
sembly.
B: INSTALLATION
1. AUTOMATIC BELT TENSION ADJUST-
ER ASSEMBLY AND BELT IDLER
1) Preparation for installation of automatic belt ten-
sion adjuster assembly.
CAUTION:
• Always use a vertical type pressing tool to
move the adjuster rod down.
• Do not use a lateral type vise.
• Push the adjuster rod vertically.
• Press-in the push adjuster rod gradually tak-
ing more than three minutes.
• Do not allow press pressure to exceed 9,807
N (1,000 kgf, 2,205 lb).
• Press the adjuster rod as far as the end sur-
face of the cylinder. Do not press the adjuster
rod into cylinder. Doing so may damage the cyl-
inder.
• Do not release the press pressure until stop-
per pin is completely inserted.
(1) Attach the automatic belt tension adjuster
assembly to the vertical pressing tool.
(2) Slowly move the adjuster rod down with a
pressure of 294 N (30 kgf, 66 lb) until the adjust-
er rod is aligned with the stopper pin hole in the
cylinder.
(3) With a 2 mm (0.08 in) dia. stopper pin or a 2
mm (0.08 in) (nominal) dia. hex wrench inserted
into the stopper pin hole in cylinder, secure the
adjuster rod.
ME-0023
5
ME-0023
6
ME-0023
7
ME-0023
8
ME-0023
9
ME-0035
0

ME(H4SO 2.0)-45
MECHANICAL
Timing Belt
2) Install the automatic belt tension adjuster as-
sembly.
Tightening torque:
39 N
⋅ m (4.0 kgf-m, 28.9 ft-lb)
3) Install the belt idler (No. 1).
Tightening torque:
39 N
⋅ m (4.0 kgf-m, 28.9 ft-lb)
2. TIMING BELT
1) Prepare for installation of automatic belt tension
adjuster assembly. <Ref.toME(H4SO 2.0)-44, AU-
TOMATIC BELT TENSION ADJUSTER ASSEM-
BLY AND BELT IDLER, INSTALLATION, Timing
Belt.>
2) Installation of timing belt:
(1) Turn the cam sprocket No. 2 using ST1, and
turn the cam sprocket No. 1 using ST2 so that
their alignment marks (A) come to top positions.
ST1 18231AA010 CAM SPROCKET WRENCH
NOTE:
CAM SPROCKET WRENCH (499207100) can
also be used.
ST2 499207400 CAM SPROCKET WRENCH
(2) While aligning the alignment mark (B) on
timing belt with the mark (A) on sprockets, posi-
tion the timing belt properly.
3) Install the belt idler No. 2.
Tightening torque:
39 N
⋅ m (4.0 kgf-m, 28.9 ft-lb)
4) Install the belt idler (No. 2).
Tightening torque:
39 N
⋅ m (4.0 kgf-m, 28.9 ft-lb)
ME-0024
1
ME-0024
2
ME-0024
3
(A)
ME-0024
4
ME-0023
5

ME(H4SO 2.0)-46
MECHANICAL Timing Belt
5) After ensuring the marks on timing belt and cam
sprockets are aligned, remove the stopper pin from
belt tension adjuster.
6) Install the timing belt guide. (MT model)
(1) Temporarily tighten the timing belt guide
mounting bolts.
(2) Check and adjust the clearance between
timing belt and timing belt guide by using thick-
ness gauge.
Clearance:
1.0
± 0.5 mm (0.039 ± 0.020 in)
(3) Tighten the timing belt guide mounting bolts.
Tightening torque:
10 N
⋅ m (1.0 kgf-m, 7.2 ft-lb)
7) Install the timing belt cover.
<Ref. to ME(H4SO 2.0)-42, INSTALLATION, Tim-
ing Belt Cover.>
8) Install the crank pulley. <Ref. to ME(H4SO 2.0)-
40, INSTALLATION, Crank Pulley.>
9) Install the V-belts. <Ref. to ME(H4SO 2.0)-38,
INSTALLATION, V-belt.>
C: INSPECTION
1. TIMING BELT
1) Check the timing belt teeth for breaks, cracks
and wear. If any fault is found, replace the belt.
2) Check the condition of the backside of belt. If
cracks are found, replace the belt.
CAUTION:
• Be careful not to let oil, grease or coolant
contact the belt. Remove quickly and thorough-
ly if this happens.
• Do not bend the timing belt sharply.
In radial diameter h:
60 mm (2.36 in) or more
ME-0024
5
ME-0023
0
ME-0024
6
ME-0024
7
ME-0024
8
h

ME(H4SO 2.0)-47
MECHANICAL
Timing Belt
2. AUTOMATIC BELT TENSION ADJUST-
ER
1) Visually check the oil seals for leaks, and rod
ends for abnormal wear or scratches. If necessary,
replace the faulty parts.
2) Check that the adjuster rod does not move when
a pressure of 294 N (30 kgf, 66 lb) is applied to it.
This is to check adjuster rod stiffness.
3) If the adjuster rod is not stiff and moves freely
when applying 294 N (30 kgf, 66 lb), check it using
the following procedures:
(1) Slowly press the adjuster rod down to the
end surface of the cylinder. Repeat this opera-
tion two to three times.
(2) With the adjuster rod moved all the way up,
apply a pressure of 294 N (30 kgf, 66 lb) to it.
Check the adjuster rod stiffness.
(3) If the adjuster rod is not stiff and moves
down, replace the automatic belt tension adjust-
er assembly with a new one.
CAUTION:
• Always use a vertical type pressing tool to
move the adjuster rod down.
• Do not use a lateral type vise.
• Push the adjuster rod vertically.
• Press the adjuster rod gradually taking more
than three minutes.
• Do not allow press pressure to exceed 9,807
N (1,000 kgf, 2,205 lb).
• Press the adjuster rod as far as the end sur-
face of cylinder. Do not press the adjuster rod
into cylinder. Doing so may damage the cylin-
der.
4) Measure the amount of rod protrusion beyond
the body. If it is not within specifications, replace
with a new one.
Amount of rod protrusion H:
5.7
± 0.5 mm (0.224 ± 0.020 in)
3. BELT TENSION PULLEY
1) Check the mating surfaces of timing belt and
contact point of adjuster rod for abnormal wear or
scratches. Replace the automatic belt tension ad-
juster assembly if faulty.
2) Check the belt tension pulley for smooth rota-
tion. Replace if noise or excessive play occurs.
3) Check the belttension pulley for greaseleakage.
4. BELT IDLER
1) Check the belt idler for smooth rotation. Replace
if noise or excessive play occurs.
2) Check the outer contacting surfaces of idler pul-
ley for abnormal wear and scratches.
3) Check the belt idler for grease leakage.
ME-0024
9
H

ME(H4SO 2.0)-48
MECHANICAL Cam Sprocket
16.Cam Sprocket
A: REMOVAL
1) Remove the V-belts. <Ref. to ME(H4SO 2.0)-38,
REMOVAL, V-belt.>
2) Remove the crank pulley. <Ref. to ME(H4SO
2.0)-40, REMOVAL, Crank Pulley.>
3) Remove the timing belt cover. <Ref. to
ME(H4SO 2.0)-42, REMOVAL, Timing Belt Cov-
er.>
4) Remove the timing belt. <Ref. to ME(H4SO 2.0)-
43, REMOVAL, Timing Belt.>
5) Remove the camshaft position sensor. <Ref. to
FU(H4SO 2.0)-22, REMOVAL, Camshaft Position
Sensor.>
6) Remove the cam sprocket No. 2. To lock the
camshaft, use ST.
ST 18231AA010 CAM SPROCKET WRENCH
NOTE:
CAM SPROCKET WRENCH (499207100) can
also be used.
7) Remove the cam sprocket No. 1. To lock the
camshaft, use ST.
ST 499207400 CAM SPROCKET WRENCH
B: INSTALLATION
1) Install the cam sprocket No. 1. To lock the cam-
shaft, use ST.
ST 499207400 CAM SPROCKET WRENCH
Tightening torque:
78 N
⋅ m (8.0 kgf-m, 57.9 ft-lb)
NOTE:
Do not confuse left and right side cam sprockets
during installation. Cam sprocket No. 2 is identified
by a protrusion used to monitor the camshaft posi-
tion sensor.
2) Install the cam sprocket No. 2. To lock the cam-
shaft, use ST.
ST 18231AA010 CAM SPROCKET WRENCH
NOTE:
CAM SPROCKET WRENCH (499207100) can
also be used.
Tightening torque:
78 N
⋅ m (8.0 kgf-m, 57.9 ft-lb)
3) Install the camshaft position sensor. <Ref. to
FU(H4SO 2.0)-22, INSTALLATION, Camshaft Po-
sition Sensor.>
4) Install the timing belt. <Ref. to ME(H4SO 2.0)-
44, INSTALLATION, Timing Belt.>
5) Install the timing belt cover.
<Ref. to ME(H4SO 2.0)-42, INSTALLATION, Tim-
ing Belt Cover.>
6) Install the crank pulley. <Ref. to ME(H4SO 2.0)-
40, INSTALLATION, Crank Pulley.>
7) Install the V-belts. <Ref. to ME(H4SO 2.0)-38,
INSTALLATION, V-belt.>
C: INSPECTION
1) Check the cam sprocket teeth for abnormal wear
and scratches.
2) Make sure there is no free play between cam
sprocket and key.
ME-0025
0
ST
ME-0025
1
ST
ME-0025
1
ST
ME-0025
0
ST

ME(H4SO 2.0)-49
MECHANICAL
Cam Sprocket
3) Check the cam sprocketprotrusion used for sen-
sor for damage and contamination of foreign mat-
ter.

ME(H4SO 2.0)-50
MECHANICAL Crank Sprocket
17.Crank Sprocket
A: REMOVAL
1) Remove the V-belts. <Ref. to ME(H4SO 2.0)-38,
REMOVAL, V-belt.>
2) Remove the crank pulley. <Ref. to ME(H4SO
2.0)-40, REMOVAL, Crank Pulley.>
3) Remove the timing belt cover. <Ref. to
ME(H4SO 2.0)-42, REMOVAL, Timing Belt Cov-
er.>
4) Remove the timing belt. <Ref. to ME(H4SO 2.0)-
43, REMOVAL, Timing Belt.>
5) Remove the cam sprocket. <Ref. to ME(H4SO
2.0)-48, REMOVAL, Cam Sprocket.>
6) Remove the crank sprocket.
B: INSTALLATION
1) Install the crank sprocket.
2) Install the cam sprocket. <Ref. to ME(H4SO
2.0)-48, INSTALLATION, Cam Sprocket.>
3) Install the timing belt. <Ref. to ME(H4SO 2.0)-
44, INSTALLATION, Timing Belt.>
4) Install the timing belt cover.
<Ref. to ME(H4SO 2.0)-42, INSTALLATION, Tim-
ing Belt Cover.>
5) Install the crank pulley. <Ref. to ME(H4SO 2.0)-
40, INSTALLATION, Crank Pulley.>
6) Install the V-belts. <Ref. to ME(H4SO 2.0)-38,
INSTALLATION, V-belt.>
C: INSPECTION
1) Check the crank sprocket teeth for abnormal
wear and scratches.
2) Make sure there is no free play between crank
sprocket and key.
3) Check the crank sprocket protrusion used for
sensor for damage and contamination of foreign
matter.
ME-0025
2
ME-0025
2

ME(H4SO 2.0)-51
MECHANICAL
Valve Rocker Assembly
18.Valve Rocker Assembly
A: REMOVAL
1) Remove the V-belts. <Ref. to ME(H4SO 2.0)-38,
REMOVAL, V-belt.>
2) Remove the crank pulley. <Ref. to ME(H4SO
2.0)-40, REMOVAL, Crank Pulley.>
3) Remove the timing belt cover. <Ref. to
ME(H4SO 2.0)-42, REMOVAL, Timing Belt Cov-
er.>
4) Remove the timing belt. <Ref. to ME(H4SO 2.0)-
43, REMOVAL, Timing Belt.>
5) Remove the cam sprocket. <Ref. to ME(H4SO
2.0)-48, REMOVAL, Cam Sprocket.>
6) Disconnect the PCV hose and remove the rock-
er cover.
7) Removal of valve rocker assembly
(1) Remove the bolts (a) through (h) in alpha-
betical sequence.
NOTE:
Leave two or three threads of bolts (g) and (h) en-
gaged in order to retain the valve rocker assembly.
(2) Remove the valve rocker assembly.
B: INSTALLATION
1) Install the valve rocker assembly.
(1) Temporarily tighten the bolts (a) through (d)
equally in order as shown in the figure.
NOTE:
Do not allow the valve rocker assembly to damage
knock pins.
(2) Tighten the bolts (e) through (h) to specified
torque.
(3) Tighten the bolts (a) through (d) to specified
torque.
Tightening torque:
25 N
⋅ m (2.5 kgf-m, 18.1 ft-lb)
2) Adjust the valve clearance. <Ref. to ME(H4SO
2.0)-29, ADJUSTMENT, Valve Clearance.>
3) Install the rocker cover and connect PCV hose.
4) Install the cam sprocket. <Ref. to ME(H4SO
2.0)-48, INSTALLATION, Cam Sprocket.>
5) Install the timing belt. <Ref. to ME(H4SO 2.0)-
44, INSTALLATION, Timing Belt.>
6) Install the timing belt cover.
<Ref. to ME(H4SO 2.0)-42, INSTALLATION, Tim-
ing Belt Cover.>
7) Install the crank pulley. <Ref. to ME(H4SO 2.0)-
40, INSTALLATION, Crank Pulley.>
8) Install the V-belts. <Ref. to ME(H4SO 2.0)-38,
INSTALLATION, V-belt.>
C: DISASSEMBLY
1) Remove the bolts which secure the rocker shaft.
2) Extract the rocker shaft. Remove the valve rock-
er arms, springs and shaft supports from rocker
shaft.
NOTE:
Keep all the removed parts in order for re-installing
in their original positions.
3) Remove the nut and adjusting screw from valve
rocker.
D: ASSEMBLY
1) Install the adjusting screw and nut to valve rock-
er.
2) Arrange the valve rocker arms, springs and shaft
supports in assembly order, and then insert the
valve rocker shaft.
Tightening torque (Shaft supports installing
bolts):
5 N
⋅ m (0.5 kgf-m, 3.6 ft-lb)
NOTE:
Valve rocker arms, rocker shaft and shaft supports
have identification marks. Ensure the parts with
same markings are properly assembled.
3) Install the valve rocker shaft securing bolts.
ME-0025
3
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
ME-0025
4
ME-0025
5
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)

ME(H4SO 2.0)-52
MECHANICAL Valve Rocker Assembly
E: INSPECTION
1. VALVE ROCKER ARM AND ROCKER
SHAFT
1) Measure the inner diameter of valve rocker arm
and outer diameter of valve rocker shaft, and deter-
mine the difference (oil clearance) between the two
values.
Clearance between arm and shaft:
Standard:
0.020 — 0.054 mm (0.0008 — 0.0021 in)
2) If the oil clearance exceeds the standard value,
replace the valve rocker arm or shaft, whichever
shows greater amount of wear.
Rocker arm inside diameter:
22.020 — 22.041 mm (0.8669 — 0.8678 in)
Rocker shaft diameter:
21.987 — 22.000 mm (0.8656 — 0.8661 in)
3) If the cam or valve contact surface of valve rock-
er arm is worn or dented excessively, replace the
valve rocker arm.
4) Check that the valve rocker arm roller rotates
smoothly. If not, replace the valve rocker arm.
ME-0025
6
ME-0025
7

ME(H4SO 2.0)-53
MECHANICAL
Camshaft
19.Camshaft
A: REMOVAL
1) Remove the V-belts. <Ref. to ME(H4SO 2.0)-38,
REMOVAL, V-belt.>
2) Remove the crank pulley. <Ref. to ME(H4SO
2.0)-40, REMOVAL, Crank Pulley.>
3) Remove the timing belt cover. <Ref. to
ME(H4SO 2.0)-42, REMOVAL, Timing Belt Cov-
er.>
4) Remove the timing belt. <Ref. to ME(H4SO 2.0)-
43, REMOVAL, Timing Belt.>
5) Remove the cam sprocket. <Ref. to ME(H4SO
2.0)-48, REMOVAL, Cam Sprocket.>
6) Remove the crank sprocket. <Ref. to ME(H4SO
2.0)-50, REMOVAL, Crank Sprocket.>
7) Remove the timing belt cover No. 2 (LH).
8) Remove the timing belt cover No. 2 (RH).
NOTE:
Do not damage or lose the seal rubber when re-
moving the timing belt covers.
9) Remove the tensioner bracket.
10) Remove the camshaft position sensor support.
(LH side only)
11) Remove the oil level gauge guide. (LH side
only)
12) Remove the valve rocker assembly. <Ref. to
ME(H4SO 2.0)-51, REMOVAL, Valve Rocker As-
sembly.>
13) Remove the camshaft cap.
(1) Remove the bolts (a) and (b) in alphabetical
sequence.
(2) Equallyloosen the bolts (c) through (j) allthe
way in alphabetical sequence.
(3) Remove the bolts (k) through (p) in alpha-
betical sequence using ST.
ST 499497000 TORX®PLUS
(4) Remove the camshaft cap.
14) Remove the camshaft.
15) Remove the oil seal.
16) Remove the plug from the rear side of cam-
shaft.
ME-0025
8
ME-0025
9
ME-0026
0
(b)
(a)
ME-0026
1
(c) (e)
(g)
(h)
(d)(f)
(j)
(i)
ME-0026
2
(k) (o)
(n)
(l)
(p)
(m)
ME-0026
3

ME(H4SO 2.0)-54
MECHANICAL Camshaft
CAUTION:
• Do not remove the oil seal unless necessary.
• Do not scratch the journal surface when re-
moving the oil seal.
B: INSTALLATION
1) Apply a coat of engine oil to camshaft journals
and install the camshaft.
2) Install the camshaft cap.
(1) Apply liquid gasket to the mating surfaces of
camshaft cap.
Liquid gasket:
THREE BOND 1280B (Part No. K0877YA018)
NOTE:
• Apply a coat of liquid gasket of 3 mm (0.12 in) in
diameter (A) along the edge (B) of camshaft cap
(C) mating surface.
• Assemble them within 20 min. after applying liq-
uid gasket.
(2) Temporarily tighten the bolts (g) through (j)
in alphabetical sequence.
(3) Install the valve rocker assembly.
(4) Tighten the bolts (a) through (h) in alphabet-
ical sequence.
Tightening torque:
25 N
⋅ m (2.5 kgf-m, 18.1 ft-lb)
(5) Tighten the TORX®bolts (i) through(n) in al-
phabetical sequence using ST.
ST 499497000 TORX®PLUS
Tightening torque:
18 N
⋅ m (1.8 kgf-m, 13.0 ft-lb)
(6) Tighten the bolts (o) through (v) in alphabet-
ical sequence.
ME-0026
4
ME-0026
5
(A)
(B) (C)
ME-0026
6
(g)
(h)
(j)
(i)
ME-0026
7
ME-0026
8
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
ME-0026
9
(i)
(j)
(m)
(n)
(k)
(l)

ME(H4SO 2.0)-55
MECHANICAL
Camshaft
Tightening torque:
10 N
⋅ m (1.0 kgf-m, 7.2 ft-lb)
(7) Tighten the bolts (w) and (x) in alphabetical
sequence.
Tightening torque:
10 N
⋅ m (1.0 kgf-m, 7.2 ft-lb)
3) Apply a coat of grease to oil seal lips and install
the oil seal (A) on camshaft using ST1 and ST2.
NOTE:
Use a new oil seal.
ST1 499597000 OIL SEAL GUIDE
ST2 499587500 OIL SEAL INSTALLER
4) Install the plug using ST.
ST 499587700 CAMSHAFT OIL SEAL IN-
STALLER
5) Adjust the valve clearance. <Ref. to ME(H4SO
2.0)-29, ADJUSTMENT, Valve Clearance.>
6) Install the rocker cover and connect PCV hose.
7) Install the oil level gauge guide. (LH side only)
8) Install the camshaft position sensor support. (LH
side only)
9) Install the tensioner bracket.
Tightening torque:
25 N
⋅ m (2.5 kgf-m, 18.1 ft-lb)
10) Install the timing belt cover No. 2 (RH).
Tightening torque:
5 N
⋅ m (0.5 kgf-m, 3.6 ft-lb)
11) Install the timing belt cover No. 2 (LH).
Tightening torque:
5 N
⋅ m (0.5 kgf-m, 3.6 ft-lb)
12) Install the crank sprocket.
<Ref. to ME(H4SO 2.0)-50, INSTALLATION,
Crank Sprocket.>
13) Install the cam sprocket. <Ref. to ME(H4SO
2.0)-48, INSTALLATION, Cam Sprocket.>
14) Install the timing belt. <Ref. to ME(H4SO 2.0)-
44, INSTALLATION, Timing Belt.>
15) Install the timing belt cover.
<Ref. to ME(H4SO 2.0)-42, INSTALLATION, Tim-
ing Belt Cover.>
16) Install the crank pulley. <Ref. to ME(H4SO
2.0)-40, INSTALLATION, Crank Pulley.>
17) Install the V-belts. <Ref. to ME(H4SO 2.0)-38,
INSTALLATION, V-belt.>
ME-0027
0
(o)
(r)
(q)
(v)
(u)
(p)
(s)
(t)
ME-0027
1
(x)
(w)
ME-0027
2
(A)
ST2
ST1
ME-0027
3
ME-0027
4

ME(H4SO 2.0)-56
MECHANICAL Camshaft
C: INSPECTION
1. CAMSHAFT
1) Measure the bend, and repair or replace if nec-
essary.
Service limit:
0.020 mm (0.00079 in)
2) Check the journal for damage and wear. Re-
place if faulty.
3) Measure the outer diameter of camshaft journal
and inner diameter of cylinder head journal, and
determine the difference (oil clearance) between
the two values. If the oil clearance exceeds stan-
dard value, replace the camshaft or cylinder head
as necessary.
4) Check the cam face condition, and remove the
minor faults by grinding with oil stone. Measure the
cam height H. If it exceeds the limit, replace it.
Cam height: H:
Cam base circle diameter A:
Intake: 34.00 mm (1.3386 in)
Exhaust: 34.00 mm (1.3386 in)
2. CAMSHAFT SUPPORT
Measure the side clearance of camshaft with set-
ting the dial gauge at end of camshaft. If side clear-
ance exceeds the limit, replace the camshaft
support.
Standard:
0.030 — 0.090 mm (0.0012 — 0.0035 in)
Unit: mm (in)
Clear-
ance at
journal Standard 0.055 — 0.090
(0.0022 — 0.0035)
Camshaft journal O.D. 31.928 — 31.945
(1.2570 — 1.2577)
Journal hole I.D. 32.000 — 32.018
(1.2598 — 1.2605)
Model Parts Unit: mm (in)
2.0 L Intake Stan-
dard 39.646 — 39.746 (1.5609 — 1.5648)
Exhaust Stan-
dard 39.351 — 39.451 (1.5493 — 1.5532)
2.5 L Intake Stan-
dard 39.485 — 39.585 (1.5545 — 1.5585)
Exhaust Stan-
dard 39.904 — 40.004 (1.5710 — 1.5750)
ME-0027
5
ME-0027
6
H
A

ME(H4SO 2.0)-57
MECHANICAL
Cylinder Head
20.Cylinder Head
A: REMOVAL
1) Remove the V-belts. <Ref. to ME(H4SO 2.0)-38,
REMOVAL, V-belt.>
2) Remove the crank pulley. <Ref. to ME(H4SO
2.0)-40, REMOVAL, Crank Pulley.>
3) Remove the timing belt cover. <Ref. to
ME(H4SO 2.0)-42, REMOVAL, Timing Belt Cov-
er.>
4) Remove the timing belt. <Ref. to ME(H4SO 2.0)-
43, REMOVAL, Timing Belt.>
5) Remove the cam sprocket. <Ref. to ME(H4SO
2.0)-48, REMOVAL, Cam Sprocket.>
6) Remove the intake manifold. <Ref. to FU(H4SO
2.0)-11, REMOVAL, Intake Manifold.>
7) Remove the boltwhich installs the A/C compres-
sor bracket on cylinder head.
8) Remove the valve rocker assembly. <Ref. to
ME(H4SO 2.0)-51, REMOVAL, Valve Rocker As-
sembly.>
9) Remove the camshaft. <Ref. to ME(H4SO 2.0)-
53, REMOVAL, Camshaft.>
10) Remove the cylinder head bolts in alphabetical
sequence as shown in the figure.
NOTE:
Leave bolts (a) and (c) engaged by three or four
threads to prevent the cylinder head from falling.
11) While tapping the cylinder head with a plastic
hammer, separate it from cylinder block.
12) Remove the bolts (a) and (c) to remove the cyl-
inder head.
13) Remove the cylinder head gasket.
CAUTION:
Be careful not to scratch the mating surface of
cylinder head and cylinder block.
14) Similarly, remove the right side cylinder head.
B: INSTALLATION
1) Install the cylinder head and gaskets on cylinder
block.
CAUTION:
• Use new cylinder head gaskets.
• Be careful not to scratch the mating surface
of cylinder block and cylinder head.
2) Tighten the cylinder head bolts.
(1) Apply a coat of engine oil to washers and
bolt threads.
(2) Tighten all bolts to 29 N⋅m (3.0 kgf-m, 22 ft-
lb) in alphabetical sequence.
Then tighten all bolts to 69 N⋅m (7.0 kgf-m, 51 ft-
lb) in alphabetical sequence.
(3) Back off all bolts by 180°in reverse order of
installation, and back them off again by 180°.
(4) Tighten all bolts to 42 N⋅m (3.9 kgf-m, 31 ft-
lb) in alphabetical sequence.
(5) Tighten all bolts by 80°— 90°in alphabeti-
cal sequence.
(6) Tighten all bolts by 40°— 45°in alphabeti-
cal sequence.
NOTE:
Do not tighten the bolts more than 45°.
(7) Further tighten bolts (a) and (b) by 40°—
45°.
NOTE:
Ensure the total “re-tightening angle” in the [former
two steps], do not exceed 90°.
3) Install the camshaft. <Ref. to ME(H4SO 2.0)-54,
INSTALLATION, Camshaft.>
4) Install the valve rocker assembly. <Ref. to
ME(H4SO 2.0)-51, INSTALLATION, Valve Rocker
Assembly.>
5) Install the A/C compressor bracket on cylinder
head.
6) Install the intake manifold.
<Ref. to FU(H4SO 2.0)-12, INSTALLATION, Intake
Manifold.>
ME-0027
8
(c)
(b)
(f)
(d)
(a)
(e)
ME-0027
8
(c)
(b)
(f)
(d)
(a)
(e) ME-0027
9
(c)
(b)
(f)
(d)
(a)
(e)

ME(H4SO 2.0)-58
MECHANICAL Cylinder Head
7) Install the cam sprocket. <Ref. to ME(H4SO
2.0)-48, INSTALLATION, Cam Sprocket.>
8) Install the timing belt. <Ref. to ME(H4SO 2.0)-
44, INSTALLATION, Timing Belt.>
9) Install the timing belt cover.
<Ref. to ME(H4SO 2.0)-42, INSTALLATION, Tim-
ing Belt Cover.>
10) Install the crank pulley. <Ref. to ME(H4SO
2.0)-40, INSTALLATION, Crank Pulley.>
11) Install the V-belts. <Ref. to ME(H4SO 2.0)-38,
INSTALLATION, V-belt.>
C: DISASSEMBLY
1) Place the cylinder head on the ST.
ST 498267800 CYLINDER HEAD TABLE
2) Set the ST on valve spring. Compress the valve
spring and remove the valve spring retainer key.
Remove each valve and valve spring.
ST 499718000 VALVE SPRING REMOVER
NOTE:
Keep all the removed parts in order for re-installing
in their original positions.
CAUTION:
• Mark each valve to prevent confusion.
• Use extreme care not to damage the lips of
the intake valve oil seals and exhaust valve oil
seals.
D: ASSEMBLY ME-0028
0
ST
(1) Valve (6) Retainer (11) Plug
(2) Valve guide (7) Retainer key (12) Camshaft cap
(3) Valve spring seat (8) Spark plug gasket (13) Valve rocker ASSY
(4) Oil seal (9) Camshaft
(5) Valve springs (10) Oil seal
ME-00281
(10)
(9)
(6)
(1)
(2)
(3)
(4)
(5) (7)
(8)
(11)
(13)
(12)

ME(H4SO 2.0)-59
MECHANICAL
Cylinder Head
1) Installation of valve spring and valve:
(1) Place the cylinder head on the ST.
ST 498267800 CYLINDER HEAD TABLE
(2) Coat the stem of each valve with engine oil
and insert the valve into valve guide.
CAUTION:
Use extreme care not to damage the oil lips
when inserting the valve into valve guide.
(3) Install the valve spring and retainer.
NOTE:
Be sure to install the valve springs with their close-
coiled end facing the seat on the cylinder head.
(4) Set the ST on valve spring.
ST 499718000 VALVE SPRING REMOVER
(5) Compress the valve spring and fit the valve
spring retainer key.
(6) After installing,tapthe valve spring retainers
lightly with a plastic hammer for better seating.
E: INSPECTION
1. VALVE SPRING
1) Check the valve springsfor damage, free length,
and tension. Replace the valve spring if it is not
within the standard value presented in the table.
2) To measure the squareness of the valve spring,
stand the spring on a surface plate and measure its
deflection at the top of spring using a try square.
2. INTAKE AND EXHAUST VALVE OIL
SEAL
In the following case, pinch and remove the oil seal
from valve using pliers, and then replace it with a
new one.
• When the lip is damaged.
• When the spring is out of the specified position.
• When readjusting the surfaces of intake valve
and valve sheet.
• When replacing the intake valve guide.
1) Place the cylinder head on ST1.
2) Using ST2, press-fit the oil seal.
CAUTION:
• Apply engine oil to oil seal before press-fit-
ting.
• When press-fitting the oil seal, do not use a
hammer or strike in.
• Differentiate between the intake valve oil seal
and exhaust valve oil seal by noting their differ-
ence in color.
ST1 498267800 CYLINDER HEAD TABLE
ST2 498857100 VALVE OIL SEAL GUIDE
Color of rubber part:
Intake [Black]
Exhaust [Brown]
(A) Retainer key
(B) Valve springs
ME-0028
0
ST
ME-0028
2
(B)
(B)
(A)
Free length
mm (in) 54.30 (2.1378)
Tension/spring
height
N (kgf, lb)/mm
(in)
Set 214 — 246
(22 — 25, 48 — 55)/45.0 (1.772)
Lift 526 — 582 (54 — 59, 119 — 130)/34.7
(1.366)
Squareness 2.5°, 2.4 mm (0.094 in)
ME-0028
3