Engine Mechanical (H4SO): Overhaul Subaru Outback BP

DISASSEMBLY

1. Remove bolts which secure rocker shaft.
2. Extract rocker shaft. Remove valve rocker arms, springs, plates and shaft supports from rocker shaft. NOTE: Arrange all removed parts in order so that they can be installed in their original positions.
3. Remove nut and adjuster screw from valve rocker.

ASSEMBLY

1. Install adjuster screw and nut to valve rocker.
2. Arrange valve rocker arms, springs and shaft supports in assembly order and insert 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 parts with same markings are properly assembled.
3. Install valve rocker shaft securing bolts.

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1. Measure inside diameter of valve rocker arm and outside diameter of valve rocker shaft, and determine the difference between the two (= oil clearance). Clearance between arm and shaft: Standard: 0.020 - 0.054 mm (0.0008 - 0.0021 in) Limit: 0.10 mm (0.0039 in)
2. If oil clearance exceeds the limit, replace 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 cam or valve contact surface of valve rocker arm is worn or dented excessively, replace valve rocker arm.
4. Check that valve rocker arm roller rotates smoothly. If not, replace valve rocker arm.

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1. Remove V-belt. Refer to «REMOVAL»(ref-208360-S13242530772005120700000) , V-BELT.
2. Remove crankshaft pulley. Refer to «REMOVAL»(ref-208360-S21251795552005120700000) , CRANKSHAFT PULLEY.
3. Remove belt cover. Refer to «REMOVAL»(ref-208360-S35879128732005120700000) , BELT COVER.
4. Remove timing belt assembly. Refer to «REMOVAL»(ref-208360-S07939121822005120700000) , TIMING BELT ASSEMBLY.
5. Remove camshaft sprocket. Refer to «REMOVAL»(ref-208360-S34341168092005120700000) , CAMSHAFT SPROCKET.
6. Remove crankshaft sprocket. Refer to «REMOVAL»(ref-208360-S15507875572005120700000) , CRANKSHAFT SPROCKET.
7. Remove belt cover No. 2 (LH).
8. Remove belt cover No. 2 (RH). NOTE: Do not damage or lose the seal rubber when removing belt covers.
9. Remove tensioner bracket.
10. Remove camshaft position sensor support. (LH side only)
11. Remove oil level gauge guide. (LH side only)
12. Remove valve rocker assembly. Refer to «REMOVAL»(ref-208360-S23225660322005120700000) , VALVE ROCKER ASSEMBLY.
13. Remove camshaft cap. Remove bolts (a) through (b) in alphabetical sequence. Equally loosen bolts (c) through (j) all the way in alphabetical sequence. Remove bolts (k) through (p) in alphabetical sequence using ST. ST 499497000 TORX PLUS Remove camshaft cap.
14. Remove camshaft.
15. Remove oil seal.
16. Remove plug from rear side of camshaft. NOTE: Do not remove oil seal unless necessary. Do not scratch journal surface when removing oil seal.

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1. Apply a coat of engine oil to camshaft journals and install camshaft.
2. Install camshaft cap. Apply liquid gasket on the around of camshaft cap. Liquid gasket: THREE BOND 1280B P/N K0877YA018 NOTE: Thinly apply a 3 mm (0.12 in) diameter (A) continuous strip of liquid gasket along edge (B) of camshaft cap (C) mating surface. Temporarily tighten bolts (g) through (j) in alphabetical sequence. Install valve rocker assembly. Tighten bolts (a) through (h) in alphabetical sequence. Tightening torque: 25 N.m (2.5 kgf-m, 18.1 ft-lb) tighten TORX bolts (i) through (n) in alphabetical sequence using ST. ST 499497000 TORX PLUS Tightening torque: 18 N.m (1.8 kgf-m, 13.0 ft-lb) Tighten bolts (o) through (v) in alphabetical sequence. Tightening torque: 10 N.m (1.0 kgf-m, 7.2 ft-lb) Tighten bolts (w) through (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 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 plug using ST. ST 499587700 OIL SEAL INSTALLER
5. Adjust the valve clearance. Refer to «ADJUSTMENT»(ref-208360-S22126397542005120700000) , Valve Clearance.
6. Install rocker cover and connect PCV hose.
7. Install oil level gauge guide. (LH side only)
8. Install camshaft position sensor support. (LH side only)
9. Install tensioner bracket. Tightening torque: 25 N.m (2.5 kgf-m, 18.1 ft-lb)
10. Install belt cover No. 2 (RH). Tightening torque: 5 N.m (0.5 kgf-m, 3.6 ft-lb)
11. Install belt cover No. 2 (LH). Tightening torque: 5 N.m (0.5 kgf-m, 3.6 ft-lb)
12. Install crankshaft sprocket. Refer to «INSTALLATION»(ref-208360-S37321035592005120700000) , CRANKSHAFT SPROCKET.
13. Install camshaft sprocket. Refer to «INSTALLATION»(ref-208360-S23395148232005120700000) , CAMSHAFT SPROCKET.
14. Install timing belt assembly. Refer to «INSTALLATION»(ref-208360-S12148340212005120700000) , Timing Belt Assembly.
15. Install belt cover. Refer to «INSTALLATION»(ref-208360-S18673814782005120700000) , BELT COVER.
16. Install crankshaft pulley. Refer to «INSTALLATION»(ref-208360-S09900277832005120700000) , CRANKSHAFT PULLEY.
17. Install V-belt. Refer to «INSTALLATION»(ref-208360-S17941312302005120700000) , V-BELT.

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1. Measure the bend, and repair or replace if necessary. Limit: 0.025 mm (0.0010 in)
2. Check journal for damage and wear. Replace if faulty.
3. Measure outside diameter of camshaft journal and inside diameter of cylinder head journal, and determine the difference between the two (= oil clearance). If oil clearance exceeds specifications, replace camshaft or cylinder head as necessary.
4. Check cam face condition; remove minor faults by grinding with oil stone. Measure the cam height H; replace if the limit has been exceeded. Cam height: H Cam base circle diameter A: IN: 34.00 mm (1.3386 in) EX: 34.00 mm (1.3386 in)