width SUBARU FORESTER 2004 Service User Guide

ME(H4DOTC)-3
MECHANICAL
General Description
CamshaftBend limit 0.020 mm (0.0079 in)
Thrust clearanceSTD 0.068 — 0.116 mm (0.0027 — 0.0046 in)
Limit 0.14 mm (0.0055 in)
Cam lobe heightIntakeSTD 44.75 — 44.85 mm (1.762 — 1.766 in)
Limit 44.65 mm (1.758 in)
ExhaustSTD 44.75 — 44.85 mm (1.762 — 1.766 in)
Limit 44.65 mm (1.758 in)
Journal O.D.
STDFront 37.946 — 37.963 mm (1.4939 — 1.4946 in)
Center
rear29.946 — 29.963 mm (1.1790 — 1.1796 in)
Oil clearanceSTD 0.037 — 0.072 mm (0.0015 — 0.0028 in)
Limit 0.10 mm (0.0039 in)
Cylinder
headSurface warpage limit 0.05 mm (0.0020 in)
Surface grinding limit 0.3 mm (0.012 in)
Standard height 127.5 mm (5.02 in)
Va l ve s e a tRefacing angle 90°
Contacting widthIntakeSTD 1.0 mm (0.039 in)
Limit 1.7 mm (0.067 in)
ExhaustSTD 1.5 mm (0.059 in)
Limit 2.2 mm (0.087 in)
Valve guideInner diameter 6.000 — 6.012 mm (0.2362 — 0.2367 in)
Protrusion above head 15.8 — 16.2 mm (0.622 — 0.638 in)
Va l veHead edge thicknessIntakeSTD 1.2 mm (0.047 in)
Limit 0.8 mm (0.031 in)
ExhaustSTD 1.5 mm (0.059 in)
Limit 0.8 mm (0.031 in)
Stem diameterIntake 5.955 — 5.970 mm (0.2344 — 0.2350 in)
Exhaust 5.945 — 5.960 mm (0.2341 — 0.2346 in)
Stem oil clearanceSTDIntake 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)
Overall lengthIntake 104.4 mm (4.110 in)
Exhaust 104.65 mm (4.120 in)
Va l ve
springFree length 44.67 mm (1.759 in)
Squareness 2.5°, 2.0 mm (0.079 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 (1.047 in)
Cylinder
blockSurface warpage limit (mating with cylinder head) 0.05 mm (0.0020 in)
Surface grinding limit 0.1 mm (0.004 in)
Cylinder bore STDA 92.005 — 92.015 mm (3.6222 — 3.6226 in)
B 91.995 — 92.005 mm (3.6218 — 3.6222 in)
TaperSTD 0.015 mm (0.0006 in)
Limit 0.050 mm (0.0020 in)
Out-of-roundnessSTD 0.010 mm (0.0004 in)
Limit 0.050 mm (0.0020 in)
Piston clearanceSTD 0.010 — 0.030 mm (0.0004 — 0.0012 in)
Limit 0.050 mm (0.0020 in)
Enlarging (boring) limit 0.5 mm (0.020 in)

ME(H4DOTC)-7
MECHANICAL
General Description
Belt ten-
sion
adjusterProtrusion of adjuster rod 5.7 — 6.7 mm (0.224 — 0.264 in)
Belt ten-
sionerSpacer O.D. 17.955 — 17.975 mm (0.7069 — 0.7077 in)
Tensioner bush I.D. 18.0 — 18.08 mm (0.7087 — 0.7118 in)
Clearance between spacer and bushSTD 0.025 — 0.125 mm (0.0010 — 0.0049 in)
Limit 0.175 mm (0.069 in)
Side clearance of spacerSTD 0.2 — 0.55 mm (0.0079 — 0.0217 in)
Limit 0.81 mm (0.0319 in)
CamshaftBend limit 0.020 mm (0.0079 in)
Thrust clearanceSTD 0.068 — 0.116 mm (0.0027 — 0.0046 in)
Limit 0.14 mm (0.0055 in)
Cam lobe heightIntakeSTD 46.55 — 46.65 mm (1.833 — 1.837 in)
Limit 46.45 mm (1.829 in)
ExhaustSTD 46.75 — 46.85 mm (1.841 — 1.844 in)
Limit 46.65 mm (1.837 in)
Journal O.D. STDFront 37.946 — 37.963 mm (1.4939 — 1.4946 in)
Center
rear29.946 — 29.963 mm (1.1790 — 1.1796 in)
Oil clearanceSTD 0.037 — 0.072 mm (0.0015 — 0.0028 in)
Limit 0.10 mm (0.0039 in)
Cylinder
headSurface warpage limit (mating with cylinder head) 0.05 mm (0.0020 in)
Surface grinding limit 0.3 mm (0.012 in)
Standard height 127.5 mm (5.02 in)
Va l ve s e a tRefacing angle 90°
Contacting widthIntakeSTD 1.0 mm (0.039 in)
Limit 1.7 mm (0.067 in)
ExhaustSTD 1.5 mm (0.059 in)
Limit 2.2 mm (0.087 in)
Valve guideInner diameter 6.000 — 6.012 mm (0.2362 — 0.2367 in)
Protrusion above head 15.8 — 16.2 mm (0.622 — 0.638 in)
Va l veHead edge thicknessIntakeSTD 1.2 mm (0.047 in)
Limit 0.8 mm (0.031 in)
ExhaustSTD 1.5 mm (0.059 in)
Limit 0.8 mm (0.031 in)
Stem diameterIntake 5.955 — 5.970 mm (0.2344 — 0.2350 in)
Exhaust 5.945 — 5.960 mm (0.2341 — 0.2346 in)
Stem oil clearanceSTDIntake 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)
Overall lengthIntake 104.4 mm (4.110 in)
Exhaust 104.65 mm (4.120 in)
Va l ve
springFree length 47.32 mm (1.863 in)
Squareness 2.5°, 2.1 mm (0.083 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)/
26.50 mm (1.043 in)

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

EN(H4DOTC)-34
ENGINE (DIAGNOSTIC)
Subaru Select Monitor
4. READ CURRENT DATA FOR ENGINE. (NORMAL MODE)
1) On the «Main Menu» display screen, select the {Each System Check} and press the [YES] key.
2) On the «System Selection Menu» display screen, select the {Engine} and press the [YES] key.
3) Press the [YES] key after the information of engine type was displayed.
4) On the «Engine Diagnosis» screen, select the {Current Data Display/Save}, and then press the [YES] key.
5) On the «Data Display Menu» screen, select the {Data Display} and press the [YES] key.
6) Using the scroll key, move the display screen up or down until the desired data is shown.
 A list of the support data is shown in the following table.
Remarks Display Unit of measure
Battery voltage Battery Voltage V
Vehicle speed signal Vehicle Speed km/h or MPH
Engine speed signal Engine Speed rpm
Engine coolant temperature signal Coolant Temp.°C or °F
Ignition timing signal Ignition Timing deg
Throttle position signal Throttle Opening Angle %
Throttle position signal Throttle Sensor Voltage V
Injection pulse width Fuel Injection #1 Pulse ms
Idle air control signal ISC Valve Duty Ratio %
generated duty control signal ALT Duty %
Fuel pump duty control signal Fuel Pump Duty %
A/F sensor current A/F Sensor #1 Current mA
A/F sensor resistance A/F Sensor #1 ResistanceΩ
Front oxygen (A/F) sensor output signal A/F Sensor #1 —
Rear oxygen sensor output signalRear O
2 Sensor
V
Short term fuel trim A/F Correction #1 %
Knock sensor correction Knocking Correction deg
Atmospheric pressure signal Atmosphere Pressure mmHg, kPa, inHg or psi
Intake manifold relative pressure signal Mani. Relative Pressure mmHg, kPa, inHg or psi
Intake manifold absolute pressure signal Mani. Absolute Pressure mmHg, kPa, inHg or psi
A/F correction (short term fuel trim) by rear oxygen sensor A/F Correction #3 %
Long term whole fuel trim A/F Learning #1 %
Canister purge control solenoid valve duty ratio CPC Valve Duty Ratio %
Primary supercharged pressure control signal Primary Control %
Tumble generated valve position sensor signal (RH side) TGV Position Sensor R V
Tumble generated valve position sensor signal (LH side) TGV Position Sensor L V
Tumble generated valve drive signal TGV Drive OPEN or CLOSE
Fuel level signal Fuel Level Voltage V
Intake air temperature signal Intake Air Temp.°C or °F
Mass air flow sensor signal Mass Air Flow g/s
Mass air flow sensor signal Air Flow Sensor Voltage V
Valve Timing Signal VVT Adv. Ang. amount R deg
Valve Timing Signal VVT Adv. Ang. amount L deg
Oil flow control solenoid valve signal OCV Duty R %
Oil flow control solenoid valve signal OCV Duty L %
Oil flow control solenoid valve current OCV current R mA
Oil flow control solenoid valve current OCV Current L mA
AT/MT identification signal AT Vehicle ID Signal AT or MT
Test Mode Signal Test Mode Signal ON or OFF
Load switch signal Electric Load Signal ON or OFF
Ignition switch signal Ignition Switch ON or OFF
Neutral position switch signal Neutral Position Switch ON or OFF
Air conditioning switch signal A/C Switch ON or OFF

EN(H4DOTC 2.5)-28
ENGINE (DIAGNOSTIC)
Subaru Select Monitor
4. READ CURRENT DATA FOR ENGINE. (NORMAL MODE)
1) On the «Main Menu» display screen, select the {Each System Check} and press the [YES] key.
2) On the «System Selection Menu» display screen, select the {Engine} and press the [YES] key.
3) Press the [YES] key after the information of engine type was displayed.
4) On the «Engine Diagnosis» screen, select the {Current Data Display/Save}, and then press the [YES] key.
5) On the «Data Display Menu» screen, select the {Data Display} and press the [YES] key.
6) Using the scroll key, move the display screen up or down until the desired data is shown.
 A list of the support data is shown in the following table.
Remarks Display Unit of measure
Battery voltage Battery Voltage V
Vehicle speed signal Vehicle Speed km/h or MPH
Engine speed signal Engine Speed rpm
Engine coolant temperature signal Coolant Temp.°C or °F
Ignition timing signal Ignition Timing deg
Throttle position signal Throttle Opening Angle %
Injection pulse width Fuel Injection #1 Pulse ms
Fuel pump duty control signal Fuel Pump Duty %
A/F sensor current A/F Sensor #1 Current mA
A/F sensor resistance A/F Sensor #1 ResistanceΩ
Front oxygen (A/F) sensor lambda value A/F Sensor #1 —
Rear oxygen sensor output signalRear O
2 Sensor
V
Short term fuel trim A/F Correction #1 %
Knock sensor compensation Knocking Correction deg
Atmospheric pressure signal Atmosphere Pressure mmHg, kPa, inHg or psi
Intake manifold relative pressure signal Mani. Relative Pressure mmHg, kPa, inHg or psi
Intake manifold absolute pressure signal Mani. Absolute Pressure mmHg, kPa, inHg or psi
A/F correction (short term fuel trim) by rear oxygen sensor A/F Correction #3 %
Long term whole fuel trim A/F Learning #1 %
Canister purge control solenoid valve duty ratio CPC Valve Duty Ratio %
Primary supercharged pressure control signal Primary Control %
Tumble generated valve position sensor signal (RH side) TGV Position Sensor R V
Tumble generated valve position sensor signal (LH side) TGV Position Sensor L V
Acceleration opening angle Accel Opening Angle %
VVT advance angle amount (R) VVT Adv. Amount R deg
VVT advance angle amount (L) VVT Adv. amount L deg
OCV duty R OCV Duty R %
OCV duty L OCV Duty L %
OCV current R OCV current R mA
OCV current L OCV Current L mA
Throttle motor duty Throttle Motor Duty %
Throttle power supply voltage Throttle Motor Voltage V
Sub throttle sensor voltage Sub-Throttle Sensor V
Main throttle sensor voltage Main-Throttle Sensor V
Sub acceleration sensor voltage Sub-Accelerator Sensor V
Main acceleration sensor voltage Main-Accelerator Sensor V
Memory vehicle speed Memorized Cruise Speed km/h
Alternate duty ratio ALT Duty %
Exhaust gas temperature signal Exhaust gas temperature°C
Estimated cumulative driving distance Odd Meter Km
Fuel level signal Fuel Level Voltage V
Intake air temperature signal Intake Air Temp.°C or °F
Mass air flow sensor signal Mass Air Flow g/s