SG Valve Cover Gasket Replacement
All thanks goes to snoozerxt for this excellent DIY.
DIY Valve Cover Gasket Replacement - Toronto Subaru Club
2004-2005 WRX STi 2.5L & Forester XT
2006-2007 WRX 2.5
2.0 WRX and NA Applications are as well relative with the exception of the part #'s
This DIY will demonstrate what is involved when changing the passenger side (USA) valve cover gasket. Driver's side in Australia!
If you are familiar with your engine and are confident in tight spaces while turning a wrench, changing your spark plugs and exposing your cams as well lots of patience; this is something you can complete yourself.
Tools:
Small Ratchet with extension
Flathead Screwdriver
10mm, 12mm
10mm Gear Wrench
Gasket Sealer – “The Right Stuff” Made by Permatex
Wire Brush
Engine Degreaser/Brake Cleaner
Wash Bucket
Paper Towel
3/8” or 1/2” Drive Torque Wrench; 0-50 lb. –ft.
Trouble Light
Tarpaulin/Cardboard (Ground Cover)
Pen/Magic Marker – Large piece of paper for valve cover bolt identification
Parts:
Subaru Part Numbers Specific to 04-07 STi & 06-07 WRX
13272AA140 - Left side large valve cover gasket x1
13270aa190 - Right Side Large valve cover gasket x1
13293AA051 – Spark Plug Seals x4
STEPS IN CHRONOLOGICAL ORDER
PREP
Create a clean and safe work environment. Lay out all of your needed tools; assemble your trouble lights and extension cords so that everything is accessible and conveniently available. Underneath the car, place a tarpaulin/large piece of cardboard; or something that will catch the drips.
Remove the air box assembly or intake if you have one. Be careful with your MAF (Mass Air Flow Sensor). They are very delicate and expensive to replace.
Located at the top of the valve cover are two rubber hoses that connect to the valve cover. One will be attached with spring band clamp the other will be an oeticker clamp.
The oeticker and spring clamp can be very finicky when removing
Remove both coil packs. You will need a 10mm socket. There are harness clips which attach to the coil pack; so when removing from the engine bay area, it sometimes can be easier to disconnect the harness prior to removal.
Here is an image of what the coil pack and harness look like.
REMOVING THE VALVE COVER
Once your coil packs have been removed, you are now ready to remove the VC.
Before you dive in and start removing the 8 bolts, a few things need to be said.
1) Bolt location – relative to the valve cover. Each Bolt is a different length. It is imperative you make a diagram indicating where you removed each bolt from.
Photo of a Subaru valve cover bolt. Flange head with a pre determined thread length; relative to its location on the valve cover.
Remove each VC bolt. There are 8 in total. Organize the bolts relative to their location. This is how I arranged my VC bolts once removed.
Wiggle the VC loose from the block. Depending on how much Fuji bond was used when it was installed at the factory will determine how easy it comes off.
I used a flat head screwdriver to successfully detach mine. This is a great shot of the gasket and the VC partially detached.
VC removed with gasket still partially attached
Valve cover removed. Note the burnt oil and residue from where the oil was seeping. STINKY!
Original OEM cracked VC gasket. The culprit.
Cam Photo 1
Cam Photo 2
Clean the VC’s exterior and interior; ensuring that the remains of any old Fuji-bond are no longer evident. This also goes for the engine block. You can pick away by hand to remove any remaining debris.
Remaining Fuji-Bond from the engine block.
Be sure to remove any particles in the VC gasket channel. (Perimeter of VC)
Once the VC and Block are clear of old gasket & gasket maker and the VC are clean, dry and rid of any contaminants. IE degreaser/brake clean. It is time to assemble the new Gaskets.
Continued...