SUBARU FORESTER 2004 Service Repair Manual

ME(H4SO)-22
MECHANICAL
General Description
499718000 VALVE SPRING
REMOVERUsed for removing and installing valve spring.
499767200 VALVE GUIDE
REMOVERUsed for removing valve guides.
499767400 VALVE GUIDE
REAMERUsed for reaming valve guides.
499767700
(Intake side)
499767800
(Exhaust side)VALVE GUIDE
ADJUSTERUsed for installing valve guides. ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-499718000
ST-499767200
ST-499767400
ST-499767700

ME(H4SO)-23
MECHANICAL
General Description
2. GENERAL TOOL
499817100 ENGINE STAND  Stand used for engine disassembly and
assembly.
 Used with ENGINE STAND ADAPTER RH
(498457000) & LH (498457100).
499977100 CRANK PULLEY
WRENCHUsed for stopping rotation of crank pulley when
loosening and tightening crank pulley bolts. (2.5
L model)
499977400 CRANK PULLEY
WRENCHUsed for stopping rotation of crank pulley when
loosening and tightening crank pulley bolts. (2.0
L model)
499987500 CRANKSHAFT
SOCKETUsed for rotating crankshaft.
TOOL NAME REMARKS
Compression gauge Used for measuring compression.
Tachometer (secondary pick-up type) Used for measuring idle speed.
Timing light Used for measuring ignition timing.ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-499817100
ST-499977100
ST-499977400
ST-499987500

ME(H4SO)-24
MECHANICAL
General Description
E: PROCEDURE
It is possible to conduct the following service proce-
dures with engine on the vehicle, however, the pro-
cedures described in this section are based on the
condition that the engine is removed from the vehi-
cle.
V-belt
 Timing Belt
 Valve Rocker Assembly
 Camshaft
 Cylinder Head

ME(H4SO)-25
MECHANICAL
Compression
2. Compression
A: INSPECTION
CAUTION:
After warming-up, engine becomes very hot. Be
careful not to burn yourself during measure-
ment.
1) After warming-up the engine, turn the ignition
switch to OFF.
2) Make sure that the battery is fully charged.
3) Release the fuel pressure. <Ref. to FU(H4SO)-
47, RELEASING OF FUEL PRESSURE, OPERA-
TION, Fuel.>
4) Remove all the spark plugs. <Ref. to IG(H4SO)-
5, REMOVAL, Spark Plug.>
5) Fully open the throttle valve.
6) Check the starter motor for satisfactory perfor-
mance and operation.
7) Hold the compression gauge tight against spark
plug hole.
NOTE:
When using a screw-in type compression gauge,
the screw (put into cylinder head spark plug hole)
should be less than 18 mm (0.71 in) long.
8) Crank the engine by means of starter motor, and
then read the maximum value on the gauge when
the pointer is steady.
9) Perform at least two measurements per cylinder,
and make sure that the values are correct.
Compression (350 rpm and fully open throttle):
Standard;
1,275 kPa (13.0 kgf/cm
2, 185 psi)
Limit;
1,020 kPa (10.4 kgf/cm
2, 148 psi)
Difference between cylinders;
49 kPa (0.5 kgf/cm
2, 7 psi), or less
ME-00192

ME(H4SO)-26
MECHANICAL
Idle Speed
3. Idle Speed
A: INSPECTION
1) Before checking idle speed, check the following:
(1) Ensure the air cleaner element is free from
clogging, ignition timing is correct, spark plugs
are in good condition, and the hoses are con-
nected properly.
(2) Ensure the malfunction indicator light does
not illuminate.
2) Warm-up the engine.
3) Stop the engine, and then turn the ignition switch
to OFF.
4) When using the Subaru Select Monitor, refer to
the following. <Ref. to ME(H4SO)-15, SPECIAL
TOOL, PREPARATION TOOL, General Descrip-
tion.>
(1) Insert the cartridge to Subaru Select Moni-
tor.
(2) Connect the Subaru Select Monitor to data
link connector.
(3) Turn the ignition switch to ON, and Subaru
Select Monitor switch to ON.
(4) Select the {Each System Check} in Main
Menu.
(5) Select the {Engine Control System} in Se-
lection Menu.
(6) Select the {Current Data Display & Save} in
Engine Control System Diagnosis.
(7) Select the {Data Display} in Data Display
Menu.
(8) Start the engine, and then read the engine
idle speed.
5) When using the tachometer (Secondary pick-up
type).
(1) Attach the pick-up clip to No. 1 cylinder
spark plug cord.(2) Start the engine, and then read the engine
idle speed.
NOTE:
 When using the OBD-II general scan tool, care-
fully read its operation manual.
 This ignition system provides simultaneous igni-
tion for #1 and #2 plugs. It must be noted that some
tachometers may register twice that of actual en-
gine speed.
6) Check the idle speed when unloaded. (With
headlights, heater fan, rear defroster, radiator fan,
air conditioning, etc. OFF)
Idle speed [No load and gears in “N” or “P”
range]:
650
±100 rpm
7) Check the idle speed when loaded. (Turn the air
conditioning switch to “ON” and operate the com-
pressor for at least 1 minute before measurement.)
Idle speed [A/C “ON”, no load and gears in “N”
or “P” range]:
850
±100 rpm
NOTE:
Idle speed can not be adjusted manually, because
the idle speed is automatically adjusted.
If the specified idle speed can not be maintained,
refer to General On-board Diagnosis Table under
“Engine Control System”. <Ref. to EN(H4SO)-2,
Basic Diagnostics Procedure.>
ME-00325
ME-00193

ME(H4SO)-27
MECHANICAL
Ignition Timing
4. Ignition Timing
A: INSPECTION
CAUTION:
After warming-up, engine becomes very hot. Be
careful not to burn yourself during measure-
ment.
1) Warm-up the engine.
2) To check the ignition timing, connect a timing
light to #1 cylinder spark plug cord, and illuminate
the timing mark with timing light.
3) Start the engine at idle speed and check the ig-
nition timing.
Ignition timing [BTDC/rpm]:
10
°±10°/650
If the timing is not correct, check the ignition control
system. <Ref. to EN(H4SO)-2, Basic Diagnostics
Procedure.>
ME-00194

ME(H4SO)-28
MECHANICAL
Intake Manifold Vacuum
5. Intake Manifold Vacuum
A: INSPECTION
1) Warm-up the engine.
2) Disconnect the brake vacuum hose from intake
manifold, and then install the vacuum gauge.
3) Keep the engine at idle speed, and then read the
vacuum gauge indication.By observing the gauge needle movement, the in-
ternal condition of engine can be diagnosed as de-
scribed below.
Vacuum pressure (at idling, A/C “OFF”):
Less than
−60.0 kPa (−450 mmHg, −17.72 in-
Hg)
ME-00195
Diagnosis of engine condition by measurement of intake manifold vacuum
Vacuum gauge indication Possible engine condition
1. Needle is steady but lower than normal position. This ten-
dency becomes more evident as engine temperature rises.Air leakage around intake manifold gasket or disconnection or
damaged vacuum hose
2. When engine speed is reduced slowly from higher speed,
needle stops temporarily when it is lowering or becomes steady
above normal position.Exhaust pressure too high, or exhaust system clogged
3. Needle intermittently drops to position lower than normal
position.Leakage around cylinder
4. Needle drops suddenly and intermittently from normal posi-
tion.Sticky valves
5. When engine speed is gradually increased, needle begins to
vibrate rapidly at certain speed, and then vibration increases as
engine speed increases.Weak or broken valve springs
6. Needle vibrates above and below normal position in narrow
range.Defective ignition system

ME(H4SO)-29
MECHANICAL
Engine Oil Pressure
6. Engine Oil Pressure
A: INSPECTION
1) Disconnect the ground cable from battery.
2) Remove the generator from bracket. <Ref. to
SC(H4SO)-15, REMOVAL, Generator.>
3) Disconnect the connector from oil pressure
switch.
4) Remove the oil pressure switch from cylinder
block. <Ref. to LU(H4SO)-20, REMOVAL, Oil Pres-
sure Switch.>
5) Connect the oil pressure gauge hose to cylinder
block.
6) Connect the battery ground cable to battery.
7) Start the engine, and then measure the oil pres-
sure.
Oil pressure:
Standard:
88 kPa (0.9 kg/cm
2, 13 psi) or more at 800 rpm
294 kPa (3.0 kg/cm2, 43 psi) or more at 5,000
rpmCAUTION:
 If the oil pressure is out of specification,
check the oil pump, oil filter and lubrication
line. <Ref. to LU(H4SO)-24, INSPECTION, En-
gine Lubrication System Trouble in General.>
 If the oil pressure warning light is turned ON
and oil pressure is in specification, replace the
oil pressure switch. <Ref. to LU(H4SO)-24, IN-
SPECTION, Engine Lubrication System Trouble
in General.>
NOTE:
The specified data is based on an engine oil tem-
perature of 80°C (176°F).
8) After measuring the oil pressure, install the oil
pressure switch. <Ref. to LU(H4SO)-20, INSTAL-
LATION, Oil Pressure Switch.>
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
9) Install the generator and V-belt in the reverse or-
der of removal, and then adjust the V-belt deflec-
tion. <Ref. to ME(H4SO)-43, INSTALLATION, V-
belt.>
FU-00009
FU-00009
ME-00196

ME(H4SO)-30
MECHANICAL
Fuel Pressure
7. Fuel Pressure
A: INSPECTION
WARNING:
Before removing the fuel pressure gauge, re-
lease the fuel pressure.
NOTE:
If out of specification, check or replace the pressure
regulator and pressure regulator vacuum hose.
1) Release the fuel pressure. <Ref. to FU(H4SO)-
47, RELEASING OF FUEL PRESSURE, OPERA-
TION, Fuel.>
2) Open the fuel flap lid, and then remove the fuel
filler cap.
3) Disconnect the fuel delivery hoses from fuel
damper, and then connect the fuel pressure gauge.
4) Connect the connector of fuel pump relay.
5) Start the engine.
6) Measure the fuel pressure while disconnecting
the pressure regulator vacuum hose from intake
manifold.Fuel pressure:
Standard:
284 — 314 kPa (2.9 — 3.2 kg/cm
2, 41 — 46 psi)
7) After connecting the pressure regulator vacuum
hose, measure the fuel pressure.
Fuel pressure:
Standard:
206 — 235 kPa (2.1 — 2.4 kg/cm
2, 30 — 34 psi)
NOTE:
The fuel pressure gauge registers 10 to 20 kPa (0.1
to 0.2 kg/cm
2, 1 to 3 psi) higher than standard val-
ues during high-altitude operations.
FU-00208
FU-00262
ME-00198
ME-00198

ME(H4SO)-31
MECHANICAL
Valve Clearance
8. Valve Clearance
A: INSPECTION
NOTE:
Inspection and adjustment of the valve clearance
should be performed while engine is cold.
1) Set the vehicle on a lift.
2) Lift-up the vehicle.
3) Remove the under cover.
4) Lower the vehicle.
5) Disconnect the ground cable from battery.
6) Remove the belt cover (LH).
7) When inspecting the #1 and #3 cylinders:
(1) Disconnect the spark plug cords from spark
plugs RH side. <Ref. to IG(H4SO)-5, RH SIDE,
REMOVAL, Spark Plug.>
(2) Disconnect the PCV hose from rocker cover
(RH).
(3) Remove the bolts, and then remove the
rocker cover (RH).
8) When inspecting the #2 and #4 cylinders:
(1) Disconnect the spark plug cords from spark
plugs (LH Side) <Ref. to IG(H4SO)-5, LH SIDE,
REMOVAL, Spark Plug.>
(2) Disconnect the PCV hose from rocker cover
(LH).
(3) Remove the bolts, and then remove the
rocker cover (LH).
9) Set the #1 cylinder piston to top dead center of
compression stroke by rotating crank pulley clock-
wise using a socket wrench.NOTE:
When arrow mark (A) on the cam sprocket (LH)
comes exactly to the top, #1 cylinder piston is
brought to the top dead center of compression
stroke.
10) Measure the #1 cylinder valve clearance by us-
ing thickness gauge.
CAUTION:
 Insert the thickness gauge (A) in as horizon-
tal a direction as possible with respect to the
valve stem end face.
 Measure the exhaust valve clearances while
lifting-up the vehicle.
Valve clearance (Standard):
Intake;
0.20
±0.04 mm (0.0079±0.0016 in)
Exhaust;
0.25
±0.04 mm (0.0098±0.0016 in)
11) If necessary, adjust the valve clearance. <Ref.
to ME(H4SO)-32, ADJUSTMENT, Valve Clear-
ance.>
12) Similar to measurement procedures used for
#1 cylinder, measure the #2, #3 and #4 cylinder
valve clearances.
NOTE:
 Be sure to set the cylinder pistons to their re-
spective top dead centers on compression stroke
before measuring valve clearances.
FU-00009
ME-00199
ME-00200
(A)
ME-00201
(A)