SUBARU FORESTER 2004 Service Repair Manual

ME(H4DOTC)-73
MECHANICAL
Camshaft
C: INSPECTION
1) Measure the bend, and repair or replace if nec-
essary.
Limit:
0.020 mm (0.0008 in)
2) Check the journal for damage and wear. Re-
place if faulty.
3) Measure the outside diameter of camshaft jour-
nal. If the journal diameter is not as specified,
check the oil clearance.
4) Measurement of the camshaft journal oil clear-
ance:
(1) Clean the bearing caps and camshaft jour-
nals.
(2) Place the camshafts on cylinder head.
(Without installing the valve rocker.)
(3) Place a plastigage across each of the cam-
shaft journals.
(4) Gradually tighten the cap in at least two
stages in alphabetical sequence shown in the
figure, and then tighten to specified torque.
Do not turn the camshaft.
Tightening torque:
T1: 10 N
⋅m (1.0 kgf-m, 7.2 ft-lb)
T2: 20 N
⋅m (2.0 kgf-m, 14.5 ft-lb)
 2.0 L MODEL 2.5 L MODEL
(5) Remove the bearing caps.
(6) Measure the widest point of plastigage on
each journal. If the oil clearance exceeds the
limit, replace the camshaft. If necessary, replace
the camshaft caps and cylinder head as a set.
Standard:
0.037 — 0.072 mm (0.0015 — 0.0028 in)
Limit:
0.10 mm (0.0039 in)
(7) Completely remove the plastigage.
5) Check the cam face condition; remove the minor
faults by grinding with oil stone. Measure the cam
height H, replace if the limit has been exceeded.
Cam height: H
Standard:
2.0 L MODEL
Intake:
44.75 — 44.85 mm (1.762 — 1.766 in)
Exhaust:
44.75 — 44.85 mm (1.762 — 1.766 in)
2.5 L MODEL
Intake:
46.55 — 46.65 mm (1.833 — 1.837 in)
Exhaust:
46.75 — 46.85 mm (1.841 — 1.844 in)
Camshaft journal
Front Center, rear
Standard37.946 — 37.963 mm
(1.4939 — 1.4946 in)29.946 — 29.963 mm
(1.1790 — 1.1796 in)
ME-00118
ME-00371
(F) (D)(C)
T1
T2(A)(E)
(B)
ME-00774
(A)(E)
(F)(B)(D)
(C)T2
T1
ME-00119

ME(H4DOTC)-74
MECHANICAL
Camshaft
Limit:
2.0 L MODEL
Intake:
44.65 mm (1.758 in)
Exhaust:
44.65 mm (1.758 in)
2.5 L MODEL
Intake:
46.45 mm (1.829 in)
Exhaust:
46.65 mm (1.837 in)
Cam base circle diameter A:
37.0 mm (1.457 in)
6) Measure the thrust clearance of camshaft with
dial gauge. If the clearance exceeds the limit, re-
place the caps and cylinder head as a set. If neces-
sary, replace the camshaft.
Standard:
0.068 — 0.116 mm (0.0027 — 0.0046 in)
Limit:
0.14 mm (0.0055 in)
ME-00120
H
A
ME-00121

ME(H4DOTC)-75
MECHANICAL
Cylinder Head Assembly
19.Cylinder Head Assembly
A: REMOVAL
1) Remove the V-belt. REMOVAL, V-belt.>
2) Remove the crank pulley. ME(H4DOTC)-55, REMOVAL, Crank Pulley.>
3) Remove the timing belt cover. ME(H4DOTC)-57, REMOVAL, Timing Belt Cover.>
4) Remove the timing belt assembly. ME(H4DOTC)-58, REMOVAL, Timing Belt Assem-
bly.>
5) Remove the cam sprocket. ME(H4DOTC)-67, REMOVAL, Cam Sprocket.>
6) Remove the intake manifold. FU(H4DOTC)-14, REMOVAL, Intake Manifold.>
7) Remove the bolt which installs the A/C compres-
sor bracket on cylinder head.
8) Remove the camshaft. 69, REMOVAL, Camshaft.>
9) Remove the cylinder head bolts in alphabetical
sequence shown in the figure.
Leave bolts (A) and (D) engaged by three or four
threads to prevent the cylinder head from falling.
10) While tapping the cylinder head with a plastic
hammer, separate it from cylinder block. Remove
the bolts (A) and (D) to remove cylinder head.11) Remove the cylinder head gasket.
NOTE:
Do not scratch the mating surface of cylinder head
and cylinder block.
12) Similarly, remove the cylinder head (RH).
B: INSTALLATION
1) Install the cylinder head and gaskets on cylinder
block.
NOTE:
 Use new cylinder head gaskets.
 Be careful not to scratch the mating surface of
cylinder head and cylinder block.
2) Tighten the cylinder head bolts.
(1) Apply a coat of engine oil to the washers and
bolt threads.
(2) Tighten all bolts to 29 N⋅m (3.0 kgf-m, 22 ft-
lb) in alphabetical sequence.
(3) Tighten all bolts to 69 N⋅m (7.0 kgf-m, 51 ft-
lb) in alphabetical sequence again.
(4) Back off all bolts by 180° first; back them off
by 180° again in reverse order of installation.
(5) Tighten all bolts to 49 N⋅m (5.0 kgf-m, 36 ft-
lb) in alphabetical sequence.
(6) Tighten all bolts 80 to 90° in alphabetical se-
quence.
(7) Tighten all bolts by 40 to 45° in alphabetical
sequence again.
NOTE:
Do not tighten the bolts by more than 45°.
(8) Further tighten all bolts (A) and (B) by 40 to
45°.
NOTE:
Ensure that the total “re-tightening angle” in the
previous two steps do not exceed 90°.
3) Install the camshaft. INSTALLATION, Camshaft.>
4) Install the A/C compressor bracket on cylinder
head.
5) Install the intake manifold. 17, INSTALLATION, Intake Manifold.>
6) Install the cam sprocket. 67, INSTALLATION, Cam Sprocket.>
ME-00122
(B)(C)
(D)
(E)
(F)(A)
ME-00122
(B)(C)
(D)
(E)
(F)(A)
ME-00123
(B)
(C)
(D)(E)
(F)(A)

ME(H4DOTC)-76
MECHANICAL
Cylinder Head Assembly
7) Install the timing belt assembly. ME(H4DOTC)-60, INSTALLATION, Timing Belt
Assembly.>
8) Install the timing belt cover. ME(H4DOTC)-57, INSTALLATION, Timing Belt
Cover.>
9) Install the crank pulley. 55, INSTALLATION, Crank Pulley.>
10) Install the V-belt. INSTALLATION, V-belt.>
C: DISASSEMBLY
1) Remove the valve lifters.
2) Compress the valve spring and remove the
valve spring retainer key. Remove each valve and
valve spring.
ST1 498267600 CYLINDER HEAD TABLE
ST2 499718000 VALVE SPRING REMOVER
NOTE:
 Keep the removed parts in order for re-installing
in their original positions.
 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.
ME-00124
ST1
ST2

ME(H4DOTC)-77
MECHANICAL
Cylinder Head Assembly
D: ASSEMBLY
(1) Exhaust valve (5) Intake valve oil seal (9) Valve lifter
(2) Intake valve (6) Valve spring (10) Exhaust valve oil seal
(3) Cylinder head (7) Retainer (11) Intake valve guide
(4) Valve spring seat (8) Retainer key (12) Exhaust valve guide
ME-00003
(3) (1)
(2)(11) (4) (5) (6) (7) (8) (9)
(11)
(12)
(12)(10)(4)
(4)(5) (6)
(6)(7)
(7)(8)
(8)(9)
(9)
(10) (4)
(6)
(7)
(8)
(9)

ME(H4DOTC)-78
MECHANICAL
Cylinder Head Assembly
1) Installation of valve spring and valve.
(1) Coat the stem of each valve with engine oil
and insert the valve into valve guide.
NOTE:
When inserting the valve into valve guide, use spe-
cial care not to damage the oil seal lip.
(2) Set the cylinder head on ST1.
(3) Install the valve spring and retainer using
ST2.
ST1 498267600 CYLINDER HEAD TABLE
ST2 499718000 VALVE SPRING REMOVER
NOTE:
Be sure to install the valve springs with their close-
coiled end facing the seat on cylinder head.
(4) Compress the valve spring, and then fit the
valve spring retainer key.
(5) After installing, tap the valve spring retainers
lightly with wooden hammer for better seating.
2) Apply oil to the surface of the valve lifter.
3) Install the valve lifter.
E: INSPECTION
1. CYLINDER HEAD
1) Make sure that no crack or other damage exists.
In addition to visual inspection, inspect the impor-
tant areas by means of red check.
2) Measure the warping of the cylinder head sur-
face that mates with crankcase by using a straight
edge (A) and thickness gauge (B).
If the warping exceeds 0.05 mm (0.0020 in), re-
grind the surface with a surface grinder.
Warping limit:
0.05 mm (0.0020 in)
Grinding limit:
0.3 mm (0.012 in)
Standard height of cylinder head:
127.5 mm (5.02 in)NOTE:
Uneven torque for the cylinder head nuts can
cause warping. When reassembling, pay special
attention to the torque so as to tighten evenly.
2. VALVE SEAT
Inspect the intake and exhaust valve seats, and
then correct the contact surfaces with valve seat
cutter if they are defective or when valve guides are
replaced.
Valve seat width: W
Intake
Standard
1.0 mm (0.039 in)
Limit
1.7 mm (0.067 in)
Exhaust
Standard
1.5 mm (0.059 in)
Limit
2.2 mm (0.087 in)
ME-00124
ST1
ST2
ME-00126
(A)
(B)
ME-00127
W

ME(H4DOTC)-79
MECHANICAL
Cylinder Head Assembly
3. VALVE GUIDE
1) Check the clearance between valve guide and
stem. The clearance can be checked by measuring
the outside diameter of valve stem and the inside
diameter of valve guide with outside and inside mi-
crometers respectively.
Clearance between the valve guide and valve
stem:
Standard
Intake
0.030 — 0.057 mm (0.0012 — 0.0022 in)
Exhaust
0.040 — 0.067 mm (0.0016 — 0.0026 in)
Limit
0.15 mm (0.0059 in)
2) If the clearance between valve guide and stem
exceeds the limit, replace the valve guide or valve
itself whichever shows greater amount of wear.
See the following procedure for valve guide re-
placement.
Valve guide inner diameter:
6.000 — 6.012 mm (0.2362 — 0.2367 in)
Valve stem outer diameters:
Intake
5.955 — 5.970 mm (0.2344 — 0.2350 in)
Exhaust
5.945 — 5.960 mm (0.2341 — 0.2346 in)
(1) Place the cylinder head on ST1 with the
combustion chamber upward so that valve
guides enter the holes in ST1.
(2) Insert the ST2 into valve guide and press it
down to remove the valve guide.
ST1 498267600 CYLINDER HEAD TABLE
ST2 499767200 VALVE GUIDE REMOVER
(3) Turn the cylinder head upside down and
place ST as shown in the figure.ST 18251AA020 VALVE GUIDE ADJUSTER
(4) Before installing a new valve guide, make
sure that neither scratches nor damages exist
on the inside surface of the valve guide holes in
cylinder head.
(5) Put a new valve guide, coated with sufficient
oil, in cylinder head, and insert ST1 into valve
guide. Press in until the valve guide upper end is
flush with the upper surface of ST2.
ST1 499767200 VALVE GUIDE REMOVER
ST2 18251AA020 VALVE GUIDE ADJUSTER
(6) Check the valve guide protrusion.
Valve guide protrusion: L
15.8 — 16.2 mm (0.622 — 0.638 in)
(7) Ream the inside of valve guide with ST.
Gently rotate the reamer clockwise while press-
ing it lightly into the valve guide, and return it
also rotating clockwise.
(8) After reaming, clean the valve guide to re-
move chips.
ST 499767400 VALVE GUIDE REAMER
CAUTION:
Apply engine oil to ST when reaming.
NOTE:
 If the inner surface of the valve guide is torn, the
edge of the reamer should be slightly ground with
an oil stone.
 If the inner surface of the valve guide becomes
lustrous and the reamer does not chip, use a new
reamer or remedy the reamer.
ME-00128
ST1
ST2ME-00757
ST
L
ME-00130
ST1
ST2

ME(H4DOTC)-80
MECHANICAL
Cylinder Head Assembly
(9) Recheck the contact condition between
valve and valve seat after replacing the valve
guide.
4. INTAKE AND EXHAUST VALVE
1) Inspect the flange and stem of valve, and re-
place if damaged, worn, or deformed, or if “H” is
less than the specified limit.
H:
Intake (A)
Standard
1.2 mm (0.047 in)
Limit
0.8 mm (0.031 in)
Exhaust (B)
Standard
1.5 mm (0.059 in)
Limit
0.8 mm (0.031 in)
Valve overall length:
Intake (A)
104.4 mm (4.110 in)
Exhaust (B)
104.65 mm (4.120 in)2) Put a small amount of grinding compound on the
seat surface and lap the valve and seat surface. In-
stall a new valve oil seal after lapping.
NOTE:
 Replace intake valve oil seal with a new one if the
valve and seat are lapped.
 Differentiate intake valve and exhaust valve by
overall length.
5. VALVE SPRINGS
1) Check the valve springs for damage, free length,
and tension. Replace the valve spring if it is not
within specifications presented in the table.
2) To measure the squareness of valve spring,
stand the spring on a surface plate and measure its
deflection at the top using a try square.
 2.0 L model
 2.5 L model
ME-00758
H
H
(B) (A)
Valve spring
Free length 44.67 mm (1.759 in)
Tension/spring
heightSet206 — 236 N
(21.0 — 24.1 kgf, 46.3 — 53.1 lb)
/36.0 mm (1.417 in)
Lift485 — 537 N (49.5 — 54.8 kgf, 109
— 121 lb) /26.6 mm (1.041 in)
Squareness 2.5°, 2.0 mm (0.079 in)
Valve spring
Free length 47.32 mm (1.863 in)
Tension/spring
heightSet205 — 235 N
(20.9 — 24.0 kgf, 46.1 — 52.8 lb)
/36.0 mm (1.417 in)
Lift426 — 490 N (43.4 — 50.0 kgf, 95.8
— 110 lb) /26.5 mm (1.04 in)
Squareness 2.5°, 2.1 mm (0.083 in)
ME-00132

ME(H4DOTC)-81
MECHANICAL
Cylinder Head Assembly
6. INTAKE AND EXHAUST VALVE OIL
SEAL
1) Replace the oil seal with a new one in the follow-
ing condition, Refer to procedure 2) for replace-
ment procedure.
 Lip portion is damaged.
 Spring is out of place.
 Valve and valve seat are reconditioned.
 Valve guide is replaced.
2) Place the cylinder head on ST1.
3) Press-fit oil seal to the specified dimension indi-
cated in the figure by using ST2.
ST1 498267600 CYLINDER HEAD TABLE
ST2 499718000 VALVE SPRING REMOVER
CAUTION:
 Apply engine oil to oil seal before press-fit.
 When press-fitting oil seal, do not use ham-
mer or strike in.
 Differentiate between the intake valve oil seal
and exhaust valve oil seal by noting their differ-
ence in color.
Color of rubber part:
Intake [Black]
Exhaust [Brown]
Color of spring part:
2.0 L model
Intake [Yellow]
Exhaust [Yellow]
2.5 L model
Intake [White]
Exhaust [White]
7. VALVE LIFTER
1) Visually check the valve lifter.
2) Measure the outer diameter of valve lifter.
Outer diameter:
34.959 — 34.975 mm (1.3763 — 1.3770 in)
3) Measure the inner diameter of valve lifter mating
part on cylinder head.
Inner diameter:
34.994 — 35.016 mm (1.3777 — 1.3786 in)
NOTE:
If difference between outer diameter of valve lifter
and inner diameter of valve lifter mating part is over
the limit, replace the cylinder head.
Standard:
0.019 — 0.057 mm (0.0007 — 0.0022 in)
Limit:
0.100 mm (0.0039 in)
ME-00133
ST2
ME-00134
ME-00135

ME(H4DOTC)-82
MECHANICAL
Cylinder Head Assembly
F: DISPOSAL
CAUTION:
 Metallic sodium is enclosed in the exhaust
valve. Metallic sodium is extremely alkaline and
may produce severe chemical reactions. Full
consideration must therefore be given to the
following points when handling or disposing of
the valve.
 Since metallic sodium may cause blindness if
contacted with the eyes, burns if contacted with
the skin, and fire, do not deliberately take the
valve apart.
If the valve is damaged, remove the valve and neu-
tralize it by immersing it in water, and dispose of it
in the same way that general steel materials are
disposed of. The disposal method is described in
the following.
1) Wearing rubber gloves, remove the damaged
valve from the cylinder head.
2) Prepare a large receptacle (bucket or other con-
tainer) in a well ventilated location, and fill the re-
ceptacle with water (at least 102 (10 US qt, 9 Imp
qt)).
3) Immerse the damaged valve in the receptacle.
CAUTION:
A severe reaction may occur, so stand at least 2
— 3 m from the receptacle. Because the reac-
tion will produce hydrogen gas, moreover, keep
the receptacle away from sparks or flames.
4) Once the reaction is completed (about 4 — 5
hours have elapsed), carefully remove the valve
using large pincers so that the reaction liquid does
not contact your skin, and dispose of it with other
parts that are being disposed of.
5) The reaction liquid is a strong alkaline solution,
so it must be disposed of in accordance with local
regulations.
CAUTION:
Make sure the reaction liquid does not contact
your skin. If contact with skin occurs, immedi-
ately wash the affected area with large quanti-
ties of water.
ME-00755