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DIY 2001 Subaru Cylinder Head Gasket Replacement

143938 Views 116 Replies 27 Participants Last post by  greengoblin68
Hi everyone,
Yes, I'm new to posting on this forum, but trust me, I have poured over the threads and used this site on several occasions to fix my 2001 Subaru Outback, standard transmission, 2.5L SOHC 4 cylinder engine. Finally, at over 160K, my subie has developed the famous external head gasket leak. Yes, drivers side, rear. I have oil weeping from the seam, coolant in the back. Yes, I have strange odor. The coolant in my reservoir is still green but seems to be leaking more than the oil in my engine (which is not milky). I know what I need to do, the question is whether or not I can do it myself. I'm strongly inclined to try, but this would be the biggest automotive repair project I've ever tried. I've been studying these forums and reading and rereading my Haynes guide. My Haynes is going to be the step-by-step for my actions, specifically Chapter 2, Section 12 (Cylinder heads - removal and installation). Most of the instructions on this refer you to other manual sections, which I've spent the last two weekends just reading, looking and planning, and I think now is a good time to ask a couple of questions.

1) TDC vs. camshaft sprockets. Haynes instructs me to find Top Dead Center of the #1 cylinder by adjusting the camshaft pulley with a breaker bar while a compression gauge is in the sparkplug hole. I have a pretty good idea where this is already (the marks are still on the pulley from an earlier timing belt change), but I will run through the procedure anyways. I'm not really sure what to look for on the compression gauge though. Are there any play-by-plays out there for what to do exactly? Next I take off my drivebelts, then after a few other removals, Haynes recommends using a chain wrench to hold the pulley while loosening the crankshaft pulley bolt. I'm not sure about using a chain wrench here. Does anyone have any comments or alternatives? I feel like I'm going to have to wrench the heck out of the crankshaft pulley bolt. Correct me if I'm wrong, but if I get even ONE tick off of TDC I'm screwed here correct? Last question on this point, and I feel like I have a big knowledge gap here, but after removing the pulley and the covers and the timing belt guide, the next step is to "Turn the crankshaft and align the marks on the crankshaft sprocket, the left camshaft sprocket and the right camshaft sprocket with etc., " Won't this throw off my TDC? I'm hugely concerned about this, if you respond to nothing else, please advise on this.

2) Camshaft removal - after removing sprockets, valve covers, CMP, rocker arm assembly, tb tensioner/bracket, and dipstick Haynes says to remove the "camshaft end cap assembly" then "remove the camshaft carefully from the cylinder head so that the lobes do not nick the journal bores. Remove the camshaft oil seal and the end plug from the camshaft end cap assembly." Is this it? There are no diagrams, no photos. I'm just really vague on what to expect when I get in there, what it will look like.

3) Unforeseen difficulties - I'm planning on being methodical. In fact, I will be photographing EVERYTHING, labeling EVERYTHING with tags and I writing EVERYTHING down. When I'm done, it will be posted. Promise. I'm planning on having to buy some tools. Of course I'll need a torque wrench, spark plug remover, compressor gauge, chain wrench, and pin wrench. I have a wrench set, socket set, hammer (just kidding). I also plan on replacing the left/right valve cover gaskets, spark plugs and, of course, cylinder gaskets. I guess I'll need new cam seals too. I have some money for unforeseen expenses, I have a little time, a place to work. Is there anything else that I'll need that you can think of? Has anyone who has followed the Haynes (or Chilton. . .it's about the same) done this before and found out that something just wasn't covered properly? I want to get everything I need, then do this all at once. I want to keep this car running a while longer, I also want to learn about what is under my hood. Thanks for all your help.
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Hi everyone,
Yes, I'm new to posting on this forum, but trust me, I have poured over the threads and used this site on several occasions to fix my 2001 Subaru Outback, standard transmission, 2.5L SOHC 4 cylinder engine. Finally, at over 160K, my subie has developed the famous external head gasket leak. Yes, drivers side, rear. I have oil weeping from the seam, coolant in the back. Yes, I have strange odor. The coolant in my reservoir is still green but seems to be leaking more than the oil in my engine (which is not milky). I know what I need to do, the question is whether or not I can do it myself. I'm strongly inclined to try, but this would be the biggest automotive repair project I've ever tried. I've been studying these forums and reading and rereading my Haynes guide. My Haynes is going to be the step-by-step for my actions, specifically Chapter 2, Section 12 (Cylinder heads - removal and installation). Most of the instructions on this refer you to other manual sections, which I've spent the last two weekends just reading, looking and planning, and I think now is a good time to ask a couple of questions.

1) TDC vs. camshaft sprockets. Haynes instructs me to find Top Dead Center of the #1 cylinder by adjusting the camshaft pulley with a breaker bar while a compression gauge is in the sparkplug hole. I have a pretty good idea where this is already (the marks are still on the pulley from an earlier timing belt change), but I will run through the procedure anyways. I'm not really sure what to look for on the compression gauge though. Are there any play-by-plays out there for what to do exactly? Next I take off my drivebelts, then after a few other removals, Haynes recommends using a chain wrench to hold the pulley while loosening the crankshaft pulley bolt. I'm not sure about using a chain wrench here. Does anyone have any comments or alternatives? I feel like I'm going to have to wrench the heck out of the crankshaft pulley bolt. Correct me if I'm wrong, but if I get even ONE tick off of TDC I'm screwed here correct? Last question on this point, and I feel like I have a big knowledge gap here, but after removing the pulley and the covers and the timing belt guide, the next step is to "Turn the crankshaft and align the marks on the crankshaft sprocket, the left camshaft sprocket and the right camshaft sprocket with etc., " Won't this throw off my TDC? I'm hugely concerned about this, if you respond to nothing else, please advise on this.

2) Camshaft removal - after removing sprockets, valve covers, CMP, rocker arm assembly, tb tensioner/bracket, and dipstick Haynes says to remove the "camshaft end cap assembly" then "remove the camshaft carefully from the cylinder head so that the lobes do not nick the journal bores. Remove the camshaft oil seal and the end plug from the camshaft end cap assembly." Is this it? There are no diagrams, no photos. I'm just really vague on what to expect when I get in there, what it will look like.

3) Unforeseen difficulties - I'm planning on being methodical. In fact, I will be photographing EVERYTHING, labeling EVERYTHING with tags and I writing EVERYTHING down. When I'm done, it will be posted. Promise. I'm planning on having to buy some tools. Of course I'll need a torque wrench, spark plug remover, compressor gauge, chain wrench, and pin wrench. I have a wrench set, socket set, hammer (just kidding). I also plan on replacing the left/right valve cover gaskets, spark plugs and, of course, cylinder gaskets. I guess I'll need new cam seals too. I have some money for unforeseen expenses, I have a little time, a place to work. Is there anything else that I'll need that you can think of? Has anyone who has followed the Haynes (or Chilton. . .it's about the same) done this before and found out that something just wasn't covered properly? I want to get everything I need, then do this all at once. I want to keep this car running a while longer, I also want to learn about what is under my hood. Thanks for all your help.
This is likely something you can do yourself if you have worked on engines before. Be very careful of the Haines book. Some of their instructions are just plain WRONG. I assume your 2001 is a non-turbo SOHC. If that is the case, you do not remove the camshafts to get the head off. The bolts are readily accessible. Forget about that TDC instruction. If you set the #1 piston to TDC, you could bend a couple of valves. You will be setting the crankshaft mark to the vertical position and aligning both cam marks as if you were setting it up for a timing belt replacement job. That sets all 4 pistons half way down in the cylinders. At that location, with the timing belt off, you can safely move the camshaft sprockets without fear of piston/valve collision.

The big problem with this job is the tight clearances. You can remove the nuts for the engine mounts and remove the dog bone mount under the airbox (top center at firewall area), and with a block of wood protecting your oil pan, raise the engine and move it left or right about 1-2 inches. That gets you some badly needed clearance to R&R the heads. The head bolts will have to stay in the head as you remove it since there is not enough clearance to get all of them to fully slide out. The same goes for re-installing them and you may need a 2nd person to help lift and guid the head back up into place. Doing it by yourself may cause you to scrape the heagasket with a bolt. It is not real straightforward. Spend a lot of time cleaning up the block and head mating surfaces using a very fine wire wheel and 400 grit paper. It might be worth having a machine shop check the heads and smoothing the surface.

It is also not necessary to completely remove the intake manifold. Once the intake manifold bolts are off, each side can be lifted high enough, either by a helper or a couple of heavy black rubber bungy cords. There are locating pins on the head that stick up (to locate the intake manifold gaskets), so you must lift to clear those when re-installing the heads.

Be sure to have a 14 mm 12 point 1/2" socket with 1/2" breaker bar for removal, and a 3/8" 14 mm 12 point socket along with various adapters and a torque wrench. The Haines loosening/tightning sequence is correct, but if you are doing valve lash adjustment, Haines is wrong (use your underhood label).

I just completed one on a 2001 that required a lot more work (i.e. bent valves), so if I am online, I'll try to answer your question. There are also many other knowledgeable folks here to give you good advice.
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The head gasket purchase comes up in discussion quite often. If Subaru does not provide an updated MLS gasket for your 2001 (and it sounds like they don't), buy the Six Star gaskets which are supposedly better than any of the OEM gaskets. Do a search on how to get these. For my 01, I went with an MLS gasket I got off of E-Bay that is advertised for a certain Saab model that uses the Subaru 2.5 engine. So far, I think I'm the first here on the board that has tried that one. It is holding fine, but only time will tell. I would not suggest buying any of the composite gaskets I see advertised. Also, I hear that headbolts can be re-used 1 time if they are not distorted. Be sure to wire brush the threads and oil the threads and washer prior to lifting the heads in-place and torquing them down.
Since you have a fairly new belt on there, go ahead and line up all the timing marks as explained. Then use some nail polish or white out to mark the edge of the belt and the cam sprocket. Then you will a 2nd reference and won't have to worry about the marks when it appears that one is about half way off. The half way off view occurs before you release the tensioner pin and the first couple of times I did it the job, I ended being off 1 tooth after making the 2 revolutions.

Unless you are planning on changing the cam seals, it is not necessary to remove the camshaft sprockets, but it does help a little when R&Ring the head with the engine in the vehicle. You will need to make or purchase a holding tool to get the camshaft to sprocket bolts off. They can be a little stubborn.
Hi everyone! Thanks for all the fast responses and great links. I've poured over them and put together the following plan. If anyone has time I'd love to hear if there is anything you see that I am missing (or overdoing!) Thanks again for everyones help.

2001 Subaru Outback
2.5L, SOHC, 4 cylinders, standard transmission

Each step will be photographed before and after completion. All parts will be tagged and labeled. All bolts will be placed into labeled zip-lock bags. Each component will be stored in a separate box.

Procedure for replacing cylinder head gaskets
1.Check camshaft pulley bolt first. Either use “starter bump” method or impact wrench if the bolt is stuck.
2.Drive onto ramps.
3.Relieve fuel pressure by removing fuel pump fuse.
4.Remove washer fluid reservoir from engine compartment.
5.Remove battery from vehicle.
6.Drain coolant from radiator and from engine block. I might need to remove the radiator and fans for space, but I’m not sure yet. Inspect hoses while I am doing this. I might need a lower radiator hose and/or clamp.
7.Remove air intake components (housing, resonator and ducts).
8.Remove spark plugs.
9.Remove drive belts. Remove a/c tensioner adjuster and main drivebelt tensioner.
10.Remove timing belt covers. Remove crankshaft bolt completely. Remove crankshaft pulley. Remove timing belt guide. Turn crankshaft sprocket and align the marks on the crankshaft sprocket, the left camshaft sprocket and the right camshaft sprocket with the notches on the oil pump, the inner timing belt cover and the cylinder head seam. Clearly mark these areas and mark where the timing belt connects these areas. Mark the direction of the timing belt rotation. Remove idler pulley number 1 to release timing belt tension. Remove idler sprocket number 2 to make clearances for timing belt. Remove timing belt. After this point I can no longer adjust the crankshaft or camshaft sprockets or the valve heads may contact piston crowns. Remove crankshaft pulley sprocket from crankshaft. Remove bolt and timing belt tensioner. Without moving the camshaft sprockets from their alignments, remove sprocket bolts and sprockets and mark them as left and right. Remove inner timing belt covers.
11.Remove bolts from valve covers. Remove oil filler pipe on left side. Remove the bracket that holds the dipstick (i.e. brace). Separate the covers from the cylinder heads. When replacing, replace valve gaskets
12.Remove camshaft position sensor. Remove the camshaft sensor bracket and small bolt before sending heads to machine shop.
13.Disconnect exhaust manifolds from underneath the cylinder heads. Remove one supporting bolt for the exhaust pipe near the rear area of the transmission. Support the exhaust system on a stand or block. This allows the exhaust headers to be moved away (left or right) so that the heads can easily be dropped out the bottom.
13(a). Remove the 2 nuts for the engine cradle mounts. Remove the through bolt on the dog bone mount under the airbox (center, near firewall on top of engine). using a floor jack, raise the engine a couple of inches. Jack at the oil pan with a block of 2X4 protecting the oil pan. At this point the engine can be moved an inch or more left or right, as needed for more clearance.
14. (comment - this step is not necessary if you are dropping the heads out the bottom. See my text below) Remove intake manifold. Detach spark plug wires from ignition coil on top. Clamp off and disconnect coolant hoses from throttle body (if I haven’t removed the radiator already). Disconnect fuel injectors, CKP, CMP, ECT, knock sensors, oxygen sensors. Remove power steering pump and position off to the side without disconnecting power steering fluid lines. Remove alternator. Remove a/c compressor and mounting bracket. Do not disconnect refrigerant lines. Disconnect PCV hose from intake manifold. Label and remove all vacuum hoses. Disconnect fuel delivery and return hoses from fuel rail. Remove the fuel rails from each cylinder head and keep injectors attached to the fuel rail. Disconnect accelerator cable and cruise control cable if equipped from the throttle body. Remove air assist injector solenoid valve and bracket. Disconnect and remove the air filter housing brace. Disconnect the vacuum hose, the vent hose and the purge hose from the evaporation pipe. Remove intake manifold mounting bolts and carefully lift the manifold off the engine with the throttle body attached.
15.Loosen cylinder head bolts in the reverse of the tightening sequence. Remove heads and old gaskets. Clean gasket mating surfaces of the cylinder heads and crankcase using a plastic scraper and light acetone or thinner. Have heads inspected by machinist at subarupair, inc. Replace both gaskets. Replace bolts. Carefully torque. Reverse order of operations.
I know I am responding too late to help the original poster, but for anyone else doing this job, step 14 is totally not necessary. You only need to remove the 4 bolts on each side of the intake manifold that attach to the heads. The manifold will raise up enough to R&R the heads. I mentioned this in an early post, but apparently it was missed. A huge amount of time is saved by not unbolting the power steering pump, alternator, AC compressor, fuel rail/injectors, vacuum lines, electrical connectors, etc.
I believe this is one of the incorrect steps mentioned in the Haynes manual.

I added in a bit more information in red that will really simplify the job. Be sure to adjust the valve lash using the information on the underhood label (not the numbers shown in the Haynes manual). The go no-go feeler gauges work good for this application but some gauge sets are a bit long and cumbersome.

As a suggestion, when re-starting the engine for the first time after major work like this, temporarily remove the fuel pump fuse and leave the spark plugs out. Make sure the timing belt is properly installed and checked. Then crank the engine a few 5-10 second cycles to get the oil pressure up. You should be able to get the oil light to go out. With no sparkplugs in, the engine will crank pretty fast. This step is even more important if you have removed and re-installed the oil pump for re-sealing.
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I made some edits to the last post in this thread to help those who are DIYer's and are replacing the headgaskets on their SOHC 2.5. I suspect a lot of folks already do it this way, but for those who are working their first job, I hope this helps.
Arron,
When I did this on the 2001 with the intake manifold left on (but lifted slightly), I removed and replaced the heads from under the car, so the intake manifold was not an issue. We had rubber bands stretched between each adjacent bolt (horizontally) to keep the bolts from sliding while manuevering the head in-place. The bands were right under the top of the bolt and allowed us to move them a bit, but they would not slide around or slide out of the head as we moved the head into position.

For your torque wrench: Use a 3/8" click type torque wrench. Get a 3/8" to 1/2" socket adapter, and use a 1/2" socket. I found that combination gets the wrench out far enough from the rockers but gives you clearance inside the body side rails. It should work perfect. After you complete all the steps but the final 2, get a sharpie and draw a vertical line on each head bolt. Then complete the 80 to 90 degree turn. Rub off the mark and remark a new vertical stripe. Then do your final 80 to 90 degree turn. For the last 2 steps, just use a breaker bar. If you have cleaned the mating surfaces well and have the head surfaced (my shop just polished them up to a mirror finish), you should have no problems with your HG from here on out.
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I can't answer the theory behind the torque sequence, but I'm sure that a lot of study and experience went into the technique. The thing that will really suprise you is that when you back the bolts out after torquing them, they are practically only finger tight. I thought that was weird, but I guess the first 2 steps "crush" or "set" the gasket to match any very slight imperfections. Definitely follow all the steps and be patient. The Haynes book is correct for this procedure. Be sure to lightly oil the headbolt threads and the washers before putting them in the heads.
Glad it helped, but remember the manifold will need to be lifted about 3/8" so that the pins for the intake manifold on the head (gasket locating pins) clear the intake manifold flange.
I never knew there was a special socket for the HG's. I used a Craftsman-Sears 1/2 inch.

What you will find out is that on the final 80-90 degree turn for the last step in the torquing sequence is that these bolts are not really that tight. I guess the removal is so tight because of the thousands of heat up and cool down cycles that tend to bond the threads in the block. Thank God you did not snap a headbolt!!
I can't see that making any difference providing the gasket stayed in the dowel pins as the heads were put on. I assume both left and right look like this. I don't think there is any way to get these reversed and I would have to assume that you looked at all the passageways to check that the gasket wasn't blocking any of the openings for coolant and oil.

After your belt is on and properly lined up and double checked via rotation, pull the fuel pump fuse and leave the spark plugs out. Make sure the oil level is up to par and crank the engine a few times to get the oil circulating.
Congrats on your HG replacement job. For having no prior experience, you did well. :)
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