clock SUBARU FORESTER 2004 Service User Guide

ME(H4SO)-32
MECHANICAL
Valve Clearance
 To set the #3, #2 and #4 cylinder pistons to their
top dead centers on compression stroke, turn the
crank pulley clockwise 90° at a time starting with ar-
row mark on cam sprocket (LH) facing up.
13) After inspection, install the related parts in the
reverse order of removal.
Tightening torque:
Resonator chamber;
33 N
⋅m (3.4 kgf-m, 25 ft-lb)
B: ADJUSTMENT
NOTE:
Adjustment of the valve clearance should be per-
formed while engine is cold.
1) Set the #1 cylinder piston to top dead center of
compression stroke by rotating crank pulley clock-
wise using 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.2) Adjust the #1 cylinder valve clearance.
(1) Loosen the valve rocker nut and screw.
(2) Place suitable thickness gauge.
(3) While noting the valve clearance, tighten the
valve rocker adjusting screw.
(4) When specified valve clearance is obtained,
tighten the valve rocker nut.
Tightening torque:
10 N
⋅m (1.0 kgf-m, 7.2 ft-lb)
CAUTION:
 Insert the thickness gauge in as horizontally
as possible with respect to the valve stem end
face.
 Adjust the exhaust valve clearances while
lifting up the vehicle.
Valve clearance:
Intake:
0.20
±0.04 mm (0.0079±0.0016 in)
Exhaust:
0.25
±0.04 mm (0.0098±0.0016 in)
3) Ensure the valve clearances are within specifi-
cations.
4) Turn the crankshaft two complete rotations until
#1 cylinder piston is again set to the top dead cen-
ter of compression stroke.
5) Ensure the valve clearances are within specifi-
cations. If necessary, readjust the valve clearanc-
es.
6) Similar to adjustment procedures used for #1
cylinder, adjust the #2, #3 and #4 cylinder valve
clearances.
ME-00202
#1
#2#3 #4
IN-00044
ME-00200
(A)
ME-00203

ME(H4SO)-33
MECHANICAL
Valve Clearance
NOTE:
 Be sure to set the cylinder pistons to their re-
spective top dead centers on compression stroke
before adjusting valve clearances.
 To set the #3, #2 and #4 cylinder pistons to their
top dead centers of compression stroke, turn the
crank pulley clockwise 90° at a time starting with ar-
row mark on cam sprocket (LH) facing up.
ME-00202
#1
#2#3 #4

ME(H4SO)-67
MECHANICAL
Cylinder Head
(2) Insert the ST2 into valve guide and press it
down to remove valve guide.
ST1 498267800 CYLINDER HEAD TABLE
ST2 499767200 VALVE GUIDE REMOVER
(3) Turn the cylinder head upside down and
place ST as shown in the figure.
Intake side:
ST 499767700 VALVE GUIDE ADJUSTER
Exhaust side:
ST 499767800 VALVE GUIDE ADJUSTER
(4) Before installing new oversize valve guide,
make sure that neither scratches nor damages
exist on the inside surface of valve guide holes
in cylinder head.
(5) Put new valve guide, coated with sufficient
oil, in the cylinder, and then insert the 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
Intake side:
ST2 499767700 VALVE GUIDE ADJUSTER
Exhaust side:
ST2 499767800 VALVE GUIDE ADJUSTER
(6) Check the valve guide protrusion.
Valve guide protrusion: L
Intake
20.0 — 20.5 mm (0.787 — 0.807 in)
Exhaust
16.5 — 17.0 mm (0.650 — 0.669 in)
(7) Ream the inside of valve guide with ST.
Gently rotate the reamer clockwise while press-
ing it lightly into valve guide, and return it also ro-
tating clockwise. After reaming, clean the valve
guide to remove chips.
CAUTION:
 Apply engine oil to the reamer when reaming.
 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 be-
comes lustrous and the reamer does not chips,
use a new reamer or remedy the reamer.
(A) Valve guide
ME-00290
ST2
ST1
(A)
ME-00291
ST
(A) Valve guide
ST2
ME-00292
ST1
ME-00293(A)L

LU(H4SO)-10
LUBRICATION
Engine Oil
3. Engine Oil
A: INSPECTION
1) Park the vehicle on a level surface.
2) Remove the oil level gauge and wipe it clean.
3) Reinsert the level gauge all the way. Be sure that
the level gauge is correctly inserted and in the
proper orientation.
4) Remove it again and note the reading. If the en-
gine oil level is below the “L” line, add oil to bring
the level up to “F” line.
5) After turning off the engine, wait a few minutes
for the oil to drain back into the oil pan before
checking the level.
6) Just after driving or while the engine is warm, en-
gine oil level may show in the range between the
“F” line and notch mark. This is caused by thermal
expansion of the engine oil.
NOTE:
To prevent overfilling the engine oil, do not add oil
above the “F” line when the engine is cold.
B: REPLACEMENT
1) Open the engine oil filler cap for quick draining of
the engine oil.
2) Remove six clips.
3) Turn the service hole cover counterclockwise.
4) Drain the engine oil by loosening the engine oil
drain plug.
5) Replace the drain plug gasket.
(A) Oil level gauge
(B) Engine oil filler cap
(C) Upper level
(D) Lower level
(E) Approx. 1.02 (1.1 US qt, 0.9 Imp qt)
LU-00138
(A)(B)
(C)
(D) (E)
(A) Drain plug
(B) Oil filter
LU-00103
LU-00104
LU-00089
(B)
(A)

LU(H4SO)-23
LUBRICATION
Engine Oil Filter
8. Engine Oil Filter
A: REMOVAL
1) Remove six clips on the under cover.
2) Turn the service hole cover counterclockwise.
3) Remove the oil filter with ST.
ST 498547000 OIL FILTER WRENCH (Outer
diameter: 80 mm (3.15 in))
ST 18332AA000 OIL FILTER WRENCH (Outer
diameter: 68 mm (2.68 in))
ST 18332AA010 OIL FILTER WRENCH (Outer
diameter: 65 mm (2.56 in))
B: INSTALLATION
1) Wipe and clean the oil filter matching surface on
cylinder block and oil cooler.
2) Get a new oil filter and apply a thin coat of engine
oil to the seal rubber.
CAUTION:
Be careful not to use the oil filter 80 mm (3.15 in)
in diameter to turbo model.
3) Install the oil filter by turning it by hand, being
careful not to damage seal rubber.
 Tighten the oil filter 80 mm (3.15 in) or 65 mm
(2.56 in) in diameter by approx. 2/3 — 3/4 rotation
more after the seal rubber of oil filter comes in con-
tact with cylinder block or oil cooler.
 Tighten the oil filter 68 mm (2.68 in) in diameter
by approx. 1 rotation more after the seal rubber of
oil filter comes in contact with cylinder block or oil
cooler.
CAUTION:
Do not tighten excessively, or oil may leak.
C: INSPECTION
1) After installing the oil filter, run the engine and
make sure that no oil is leaking around seal rubber.
NOTE:
The filter element and filter case are permanently
jointed; therefore, interior cleaning is not neces-
sary.
2) Check the engine oil level. 10, INSPECTION, Engine Oil.>
(A) Oil filter
LU-00103
LU-00104
LU-00091
(A)

SC(H4SO)-2
STARTING/CHARGING SYSTEM
General Description
1. General Description
A: SPECIFICATION
Item Designation
StarterType Reduction type
Vehicle type MT model AT model
Model M000T30471 M000T20171
Manufacturer Mitsubishi Electric
Voltage and output 12 V — 1.0 kW 12 V — 1.4 kW
Direction of rotation Counterclockwise (viewed from pinion gear side)
Number of pinion teeth 8 9
No-load charac-
teristicsVo l t a g e 1 1 V
Current 95 A or less 90 A or less
Rotating speed 2,500 rpm or more 2,000 rpm or more
Load character-
isticsVoltage 7.5 V 7.7 V
Current 300 A 400 A
Torque 8.84 N (0.90 kgf, 1.99 lb) or more 16.7 N (1.70 kgf, 3.75 lb) or more
Rotating speed 870 rpm or more 710 rpm or more
Lock character-
isticsVo l t a g e 4 V 3 . 5 V
Current 680 A or less 960 A or less
Torque 17 N (1.73 kgf, 12.5 lb) or more 31 N (3.16 kgf, 22.9 lb) or more
GeneratorTy p eRotating-field three-phase type, Voltage regulator built-in type, with load
response control system
ModelEC, EK model: A002TG0391
Other model: A002TB6991
Manufacturer Mitsubishi Electric
Voltage and output 12 V — 90 A
Polarity on ground side Negative
Rotating direction Clockwise (viewed from pulley side)
Armature connection 3-phase Y-type
Output currentEC, EK model1,500 rpm — 40 A or more
2,500 rpm — 74 A or more
5,000 rpm — 84 A or more
Other model1,500 rpm — 36 A or more
2,500 rpm — 65 A or more
5,000 rpm — 86 A or more
Regulated voltage 14.1 — 14.8 V [20°C (68°F)]

SC(H4SO)-12
STARTING/CHARGING SYSTEM
Starter
2. YOKE
Make sure the pole is set in position.
3. OVERRUNNING CLUTCH
Inspect the teeth of pinion for wear and damage.
Replace if it is damaged. Rotate the pinion in direc-
tion of rotation (counterclockwise). It should rotate
smoothly. But in opposite direction, it should be
locked.
CAUTION:
Do not clean the overrunning clutch with oil to
prevent grease from flowing out.
4. BRUSH AND BRUSH HOLDER
1) Brush length
Measure the brush length, and then replace if it ex-
ceeds the service limit.
Replace if abnormal wear or cracks are noticed.
Brush length:
Standard
12.3 mm (0.484 in)
Service limit
7.0 mm (0.276 in)
2) Brush movement
Be sure the brush moves smoothly inside brush
holder.
3) Brush spring force
Measure the brush spring force with a spring scale.
If it is less than the service limit, replace the brush
holder.
Brush spring force:
Standard
15.9 — 19.5 N (1.62 — 1.99 kgf, 3.57 — 4.38
lb) (when new)
Service limit
2.5 N (0.25 kgf, 0.56 lb)
5. SWITCH ASSEMBLY
Be sure there is continuity between the terminals S
and M, and between terminal S and ground. Use a
circuit tester (set in “ohm”).
Also check to be sure there is no continuity be-
tween terminal M and B.
Terminal / Specified resistance:
S — M / Less than 1
Ω
S — Ground / Less than 1 Ω
M — B / More than 1 MΩ
6. SWITCH ASSEMBLY OPERATION
1) Connect the terminal S of switch assembly to
positive terminal of battery with a lead wire, and
starter body to ground terminal of battery. The pin-
ion should be forced endwise on shaft.
CAUTION:
With the pinion forced endwise on shaft, starter
motor can sometimes rotate because current
flows, through pull-in coil, to motor. This is not
a problem.
2) Disconnect the connector from terminal M, and
then connect the positive terminal of battery and
terminal M using a lead wire and ground terminal to
starter body.
In this test set up, the pinion should return to its
original position even when it is pulled out with a
screwdriver.
(A) Service limit line
(B) Brush
SC-00102
(A)
(B)
(A) Terminal S
(B) Terminal M
SC-00075
B
M
S
SC-00076
(B) (A)

ME(H4DOTC)-38
MECHANICAL
Valve Clearance
(5) Move the washer tank upward.
(6) Disconnect the ignition coil connector.
(7) Remove the ignition coil.
(8) Place a suitable container under the vehicle.
(9) Disconnect the PCV hose from rocker cover
(LH).
(10)Remove the bolts, and then remove the
rocker cover (LH).
11) Turn the crankshaft pulley clockwise until arrow
mark on the camshaft sprocket is set to position
shown in the figure.
NOTE:
Turn the crankshaft using socket wrench.
12) Measure the #1 cylinder intake valve and #3
cylinder exhaust valve clearance by using thick-
ness gauge (A).
NOTE:
 Insert the thickness gauge in as horizontal a di-
rection as possible with respect to the shim.
 Measure the exhaust valve clearances while lift-
ing-up the vehicle.
Valve clearance:
Intake: 0.20
±0.02 mm (0.0079±0.0008 in)
Exhaust: 0.35
±0.02 mm (0.0138±0.0008 in)NOTE:
If the measured value is not within specification,
take notes of the value in order to adjust the valve
clearance later on.
13) If necessary, adjust the valve clearance. to ME(H4DOTC)-39, ADJUSTMENT, Valve Clear-
ance.>
14) Further turn the crankshaft pulley clockwise.
Using the same procedures described previously,
and then measure the valve clearances again.
(1) Set the arrow mark on camshaft sprocket to
position shown in the figure, and then measure
the #2 cylinder exhaust valve and #3 cylinder in-
take valve clearances.
(2) Set the arrow mark on camshaft sprocket to
position shown in the figure, and then measure
the #2 cylinder intake valve and #4 cylinder ex-
haust valve clearances.
ME-00017
ME-00733
ME-00019
(A)
ME-00734
ME-00735

ME(H4DOTC)-61
MECHANICAL
Timing Belt Assembly
(2) Align single line mark (A) on the exhaust
camshaft sprocket (RH) with notch (B) on timing
belt cover.
(3) Align single line mark (A) on the intake cam-
shaft sprocket (RH) with notch (B) on timing belt
cover.
(Make sure double lines (C) on intake camshaft
and exhaust camshaft sprockets are aligned.)
(4) Align single line mark (A) on exhaust cam-
shaft sprocket (LH) with notch (B) on timing belt
cover by turning the sprocket counterclockwise
(as viewed from front of engine).
(5) Align the single line mark (A) on intake cam-
shaft sprocket (LH) with notch (B) on timing beltcover by turning the sprocket clockwise (as
viewed from front of engine).
Ensure the double lines (C) on intake and ex-
haust camshaft sprockets are aligned.
(6) Ensure the camshaft and crankshaft sprock-
ets are positioned properly.
CAUTION:
 Intake and exhaust camshafts for this DOHC
engine can be independently rotated with the
timing belts removed. As can be seen from the
figure, if the intake and exhaust valves are lifted
simultaneously, their heads will interfere with
each other, resulting in bent valves.
ME-00082
(A)
(B)
ME-00083
(B)
(C)
(A)
ME-00084
(B)
(A)
(A) Intake camshaft
(B) Exhaust camshaft
ME-00085
(A) (B)
(C)
ME-00086
(A)
(B)

ME(H4DOTC)-69
MECHANICAL
Camshaft
16) Remove the oil flow control solenoid valve as-
sembly, intake camshaft cap, and camshaft.
17) Loosen the exhaust camshaft cap bolts equal-
ly, a little at a time in alphabetical sequence shown
in the figure.
 2.0 L MODEL
 2.5 L MODEL
18) Remove the exhaust camshaft cap and cam-
shaft.
NOTE:
Arrange the camshaft caps in order so that they
can be installed in their original positions.
19) Similarly, remove the camshafts (RH) and re-
lated parts.B: INSTALLATION
1) Camshaft installation: Apply engine oil to cylin-
der head at camshaft bearing location before in-
stalling the camshaft. Install the camshaft so that
each valve is close to or in contact with “base circle”
of cam lobe.
NOTE:
 When the camshafts are positioned as shown in
the figure, camshafts need to be rotated at a mini-
mum to align with the timing belt during installation.
 Camshaft (RH) need not be rotated when set at
position shown in the figure. Intake camshaft (LH):
Rotate 80° clockwise. Exhaust camshaft (LH): Ro-
tate 45° counterclockwise.
2) Camshaft cap and oil flow control solenoid valve
assembly installation:
(1) Apply liquid gasket sparingly to cap mating
surface.
NOTE:
Do not apply liquid gasket excessively. Failure to
do so may cause excess packing to come out and
flow toward the oil seal, resulting in oil leaks.
ME-00714(B)
(A)
(E)
(F) (D)(C)
ME-00772
(A)(E)
(F)(B)(D)
(C)
A Cylinder head (LH)
B Cylinder head (RH)
(a) Intake camshaft
(b) Exhaust camshaft
ME-00111
1111
77.5 77.5
(a)
(b)
(a)(b)
A
B