camshaft SUBARU FORESTER 2004 Service Owner's Manual

ME(H4SO)-61
MECHANICAL
Camshaft
C: INSPECTION
1. CAMSHAFT
1) Measure the bend, and repair or replace if nec-
essary.
Limit:
0.025 mm (0.0010 in)
2) Check the journal for damage and wear. Re-
place if faulty.
3) Measure the outside diameter of camshaft jour-
nal and inside diameter of cylinder head journal,
and determine the difference between two (= oil
clearance). If the oil clearance exceeds specifica-
tions, replace the camshaft or cylinder head as
necessary.
4) 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: HCam base circle diameter A:
IN: 34.00 mm (1.3386 in)
EX: 34.00 mm (1.3386 in)
2. CAMSHAFT SUPPORT
Measure the thrust clearance of camshaft with dial
gauge. If the clearance exceeds the limit, replace
the camshaft support.
Standard:
0.030 — 0.090 mm (0.0012 — 0.0035 in)
Limit:
0.10 mm (0.0039 in)
Unit: mm (in)
Clear-
ance at
journalStandard 0.055 — 0.090 (0.0022 — 0.0035)
Limit 0.10 (0.0039)
Camshaft journal O.D.31.928 — 31.945 (1.2570 —
1.2577)
Journal hole I.D.32.000 — 32.018 (1.2598 —
1.2605)
Model Item Unit: mm (in)
2.0 LIntakeSTD38.732 — 38.832
(1.5249 — 1.528885)
Limit 38.632 (1.5209)
ExhaustSTD39.259 — 39.359
(1.5456 — 1.5496)
Limit 39.157 (1.5416)
2.5 LIntakeSTD39.485 — 39.585
(1.5545 — 1.5585)
Limit 39.385 (1.5506)
ExhaustSTD39.259 — 39.359
(1.5456 — 1.5496)
Limit 39.157 (1.5416)
ME-00275
ME-00276
H
A
ME-00277

ME(H4SO)-62
MECHANICAL
Cylinder Head
20.Cylinder Head
A: REMOVAL
1) Remove the V-belt. MOVAL, V-belt.>
2) Remove the crank pulley. 45, REMOVAL, Crank Pulley.>
3) Remove the timing belt cover. ME(H4SO)-47, REMOVAL, Timing Belt Cover.>
4) Remove the timing belt. REMOVAL, Timing Belt.>
5) Remove the cam sprocket. 53, REMOVAL, Cam Sprocket.>
6) Remove the intake manifold. 14, REMOVAL, Intake Manifold.>
7) Remove the bolt which installs A/C compressor
bracket on cylinder head.
8) Remove the valve rocker assembly. ME(H4SO)-56, REMOVAL, Valve Rocker Assem-
bly.>
9) Remove the camshaft. REMOVAL, Camshaft.>
10) Remove the cylinder head bolts in alphabetical
sequence shown in the figure.
NOTE:
Leave the bolts (a) and (c) engaged by three or four
threads to prevent cylinder head from falling.
11) While tapping the cylinder head with a plastic
hammer, separate it from cylinder block.
12) Remove the bolts (a) and (c) to remove cylinder
head.
13) Remove the cylinder head gasket.CAUTION:
Do not scratch the mating surface of cylinder
head and cylinder block.
14) Similarly, remove the right side cylinder head.
B: INSTALLATION
1) Install the cylinder head and gaskets on cylinder
block.
CAUTION:
 Use new cylinder head gaskets.
 Be careful not to scratch the mating surface
of cylinder block and cylinder head.
2) Tighten the cylinder head bolts.
(1) Apply a coat of engine oil to washers and
bolt threads.
(2) Tighten all bolts to 29 N⋅m (3.0 kgf-m, 22 ft-
lb) in alphabetical sequence.
Then tighten all bolts to 69 N⋅m (7.0 kgf-m, 51 ft-
lb) in alphabetical sequence.
(3) Back off all bolts by 180° in reverse order of
installation, and back them off again by 180°.
(4) Tighten all bolts to 42 N⋅m (3.9 kgf-m, 31 ft-
lb) in alphabetical sequence.
(5) Tighten all bolts by 80° — 90° in alphabeti-
cal sequence.
(6) Tighten all bolts by 40° — 45° in alphabeti-
cal sequence.
NOTE:
Do not tighten the bolts more than 45°.
(7) Further tighten bolts (a) and (b) by 40° —
45°.
NOTE:
Ensure the total “re-tightening angle” in the [former
two steps], do not exceed 90°.
3) Install the camshaft. STALLATION, Camshaft.>
4) Install the valve rocker assembly. ME(H4SO)-56, INSTALLATION, Valve Rocker As-
sembly.>
5) Install the A/C compressor bracket on cylinder
head.
6) Install the intake manifold. 16, INSTALLATION, Intake Manifold.>
ME-00278
(c)
(b)
(f)
(d) (a)(e)
ME-00278
(c)
(b)
(f)
(d) (a)(e)
ME-00279
(c)
(b)(f)
(d) (a)
(e)

ME(H4SO)-64
MECHANICAL
Cylinder Head
D: ASSEMBLY
1) Installation of valve spring and valve
(1) Place the cylinder head on ST.
ST 498267800 CYLINDER HEAD TABLE
(2) Coat the stem of each valve with engine oil
and insert valve into valve guide.
NOTE:
When inserting the valve into valve guide, use spe-
cial care not to damage the oil seal lip.
(3) Install the valve spring and retainer.
NOTE:
Be sure to install the valve springs with their close-
coiled end facing the seat on the cylinder head.(4) Set the ST on valve spring.
ST 499718000 VALVE SPRING REMOVER
(1) Valve (6) Retainer (11) Plug
(2) Valve guide (7) Retainer key (12) Camshaft cap
(3) Valve spring seat (8) Spark plug gasket (13) Valve rocker ASSY
(4) Oil seal (9) Camshaft
(5) Valve spring (10) Oil seal
ME-00281 (10)(9)(6) (1)
(2)(3)
(4)(5)
(7)(8)
(11)
(13) (12)
ME-00280
ST

ME(H4SO)-91
MECHANICAL
Engine Trouble in General
22.Engine Trouble in General
A: INSPECTION
NOTE:
“RANK” shown in the chart refer to the possibility of reason for the trouble in order (“Very often” to “Rarely”)
A — Very often
B — Sometimes
C — Rarely
TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK
1. Engine will not start.
1) Starter does not turn. Starter Defective battery-to-starter harness B
Defective starter switch C
Defective inhibitor switch or neutral switch C
Defective starter B
Battery Poor terminal connection A
Run-down battery A
Defective charging system B
Friction Seizure of crankshaft and connecting rod bearing C
Seized camshaft C
Seized or stuck piston and cylinder C
2) Initial combustion does
not occur. Starter Defective starter C
Engine control system A
Fuel line Defective fuel pump and relay A
Lack of or insufficient fuel B
Belt Defective B
Defective timing B
Compression Incorrect valve clearance C
Loosened spark plugs or defective gasket C
Loosened cylinder head bolts or defective gasket C
Improper valve seating C
Defective valve stem C
Worn or broken valve spring B
Worn or stuck piston rings, cylinder and piston C
Incorrect valve timing B
Improper engine oil (low viscosity) B
3) Initial combustion occurs. Engine control system A
Intake system Defective intake manifold gasket B
Defective throttle body gasket B
Fuel line Defective fuel pump and relay C
Clogged fuel line C
Lack of or insufficient fuel B
Belt Defective B
Defective timing B
Compression Incorrect valve clearance C
Loosened spark plugs or defective gasket C
Loosened cylinder head bolts or defective gasket C
Improper valve seating C
Defective valve stem C
Worn or broken valve spring B
Worn or stuck piston rings, cylinder and piston C
Incorrect valve timing B
Improper engine oil (low viscosity) B

ME(H4SO)-96
MECHANICAL
Engine Noise
23.Engine Noise
A: INSPECTION
NOTE*:
When disconnecting fuel injector connector, the malfunction indicator light illuminates and DTC is stored in ECM memory.
Therefore, carry out the clear memory mode and inspection mode
after connecting fuel injector connector.Type of sound Condition Possible cause
Regular clicking soundSound increases as engine
speed increases. Valve mechanism is defective.
 Incorrect valve clearance
 Worn valve rocker
 Worn camshaft
 Broken valve spring
Heavy and dull clankOil pressure is low. Worn crankshaft main bearing
 Worn connecting rod bearing (big end)
Oil pressure is normal. Loose flywheel mounting bolts
 Damaged engine mounting
High-pitched clank (Spark
knock)Sound is noticeable when
accelerating with an overload. Ignition timing advanced
 Accumulation of carbon inside combustion chamber
 Wrong spark plug
 Improper gasoline
Clank when engine speed is
medium (1,000 to 2,000 rpm).Sound is reduced when fuel
injector connector of noisy cyl-
inder is disconnected.
(NOTE*) Worn crankshaft main bearing
 Worn bearing at crankshaft end of connecting rod
Knocking sound when engine
is operating under idling speed
and engine is warmSound is reduced when fuel
injector connector of noisy cyl-
inder is disconnected.
(NOTE*) Worn cylinder liner and piston ring
 Broken or stuck piston ring
 Worn piston pin and hole at piston end of connecting rod
Sound is not reduced if each
fuel injector connector is dis-
connected in turn. (NOTE*) Unusually worn valve lifter
 Worn cam gear
 Worn camshaft journal bore in crankcase
Squeaky sound — Insufficient generator lubrication
Rubbing sound — Defective generator brush and rotor contact
Gear scream when starting
engine— Defective ignition starter switch
 Worn gear and starter pinion
Sound like polishing glass with
a dry cloth— Loose drive belt
 Defective water pump shaft
Hissing sound — Loss of compression
 Air leakage in air intake system, hoses, connections or mani-
folds
Timing belt noise — Loose timing belt
 Belt contacting case/adjacent part
Valve tappet noise — Incorrect valve clearance

CO(H4SO)-21
COOLING
Water Pump
4. Water Pump
A: REMOVAL
1. NON-TURBO MODEL
1) Remove the radiator. REMOVAL, Radiator.>
2) Remove the V-belts.

3) Remove the timing belt.
AL, Timing Belt.>
4) Remove the automatic belt tension adjuster.
5) Remove the belt idler No. 2.
6) Remove the camshaft sprocket (LH) by using
ST.
ST 18231AA010 CAM SPROCKET WRENCH
NOTE:
Also the CAM SPROCKET WRENCH (499207100)
can be used.7) Remove the belt cover No. 2 (LH).
8) Remove the tensioner bracket.
9) Disconnect the hose from water pump.
10) Remove the water pump.
CO-00016
CO-00017
CO-00018
ST
CO-00019
CO-00020
CO-00021

CO(H4SO)-22
COOLING
Water Pump
2. TURBO MODEL
1) Remove the radiator. REMOVAL, Radiator.>
2) Remove the V-belts. REMOVAL, V-belt.>
3) Remove the timing belt. 58, REMOVAL, Timing Belt Assembly.>
4) Remove the automatic belt tension adjuster (A).
5) Remove the belt idler (B).
6) Remove the belt idler No. 2 (C).
7) Remove the camshaft position sensor. (2.0 L mod-
el) shaft Position Sensor.>
8) Remove the cam sprockets (LH) by using ST.
ST 499977500 CAM SPROCKET WRENCH
(Intake)
ST 499207400 CAM SPROCKET WRENCH
(Exhaust)9) Remove the belt cover No. 2 (LH).
10) Remove the tensioner bracket.
11) Disconnect the hose from water pump.
12) Remove the water pump.
CO-00023
(A)
(B)
(C)
ME-00710
ME-00709
CO-00024
CO-00025
CO-00021

CO(H4SO)-23
COOLING
Water Pump
B: INSTALLATION
1. NON-TURBO MODEL
1) Install water pump onto cylinder block (LH).
NOTE:
 Replace the gasket with a new one.
 When installing the water pump, tighten bolts in
two stages in alphabetical sequence as shown in
the figure.
Tightening torque:
First:
12 N
⋅m (1.2 kgf-m, 8.7 ft-lb)
Second:
12 N
⋅m (1.2 kgf-m, 8.7 ft-lb)
 Model without ATF warmer
 Model with ATF warmer
2) Connect the hose to water pump.
3) Install the tensioner bracket.
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)4) Install the belt cover No. 2 (LH).
Tightening torque:
5 N
⋅m (0.5 kgf-m, 3.6 ft-lb)
5) Install the camshaft sprockets (LH) by using ST.
ST 18231AA010 CAM SPROCKET WRENCH
NOTE:
Also the CAM SPROCKET WRENCH (499207100)
can be used.
Tightening torque:
78 N
⋅m (8.0 kgf-m, 57.9 ft-lb)
6) Install the belt idler No. 2.
Tightening torque:
39 N
⋅m (4.0 kgf-m, 28.9 ft-lb)
7) Install the automatic belt tension adjuster which
tension rod is holded with pin. 49, AUTOMATIC BELT TENSION ADJUSTER AS-
SEMBLY AND BELT IDLER, INSTALLATION,
Timing Belt.>
8) Install the timing belt. TIMING BELT, INSTALLATION, Timing Belt.>
CO-00026
(E)
(D)
(B)
(C)(A) (F)
CO-02008
(B) (C) (D)(E)(F)
(A)
CO-00020
CO-00019
CO-00018
ST
CO-00017

CO(H4SO)-24
COOLING
Water Pump
9) Install the V-belts. STALLATION, V-belt.>
10) Install the radiator. STALLATION, Radiator.>
2. TURBO MODEL
1) Install the water pump onto cylinder block (LH).
NOTE:
 Replace the gasket with a new one.
 When installing the water pump, tighten bolts in
two stages in alphabetical sequence as shown in
the figure.
Tightening torque:
First:
12 N
⋅m (1.2 kgf-m, 8.7 ft-lb)
Second:
12 N
⋅m (1.2 kgf-m, 8.7 ft-lb)
2) Connect the hose to water pump.
3) Install the tensioner bracket.
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)4) Install the belt cover No. 2 (LH).
Tightening torque:
5 N
⋅m (0.5 kgf-m, 3.6 ft-lb)
5) Install the cam sprockets (LH) by using ST.
ST 499977500 CAM SPROCKET WRENCH
(Intake)
Tightening torque:
2.0 L model
98 N
⋅m (10.0 kgf-m, 72.4 ft-lb)
2.5 L model
29.5 N
⋅m (3.0 kgf-m, 21.8 ft-lb), and then
tighten 45
° furthermove
ST 499207400 CAM SPROCKET WRENCH
(Exhaust)
Tightening torque:
98 N
⋅m (10.0 kgf-m, 72.4 ft-lb)
6) Install the camshaft position sensor. (2.0 L mod-
el) Camshaft Position Sensor.>
7) Install the belt idler No. 2 (C).
8) Install the belt idler (B).
CO-00027
(B) (C) (D)(E)(F)
(A)
CO-00025
CO-00024
ME-00710
ME-00709

EN(H4SO)-11
ENGINE (DIAGNOSTIC)
Electrical Component Location
 SENSOR
EN-02379
(1)(2)
(3)(4)
(5)
(6) (7)(8)
(1) Intake air temperature sensor (4) Throttle position sensor (8) Engine coolant temperature sen-
sor (with AT warmer)
(2) Manifold absolute pressure sensor (5) Knock sensor
(3) Engine coolant temperature sen-
sor (without AT warmer)(6) Camshaft position sensor
(7) Crankshaft position sensor