engine SUBARU FORESTER 2004 Service Repair Manual

ME(H4DOTC)-23
MECHANICAL
General Description
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
498267600 CYLINDER HEAD
TABLE Used for replacing valve guides.
 Used for removing and installing valve springs.
498457000 ENGINE STAND
ADAPTER RHUsed with ENGINE STAND (499817000).
498457100 ENGINE STAND
ADAPTER LHUsed with ENGINE STAND (499817000).
498497100 CRANKSHAFT
STOPPERUsed for stopping rotation of flywheel when loos-
ening and tightening crankshaft pulley bolt, etc.
ST-498267600
ST-498457000
ST-498457100
ST-498497100

ME(H4DOTC)-24
MECHANICAL
General Description
398744300 PISTON GUIDE Used for installing piston in cylinder for 2.0 L
engine.
498747300 PISTON GUIDE Used for installing piston in cylinder for 2.5 L
engine.
498857100 VALVE OIL SEAL
GUIDEUsed for press-fitting of intake and exhaust valve
guide oil seals.
499017100 PISTON PIN GUIDE Used for installing piston pin, piston and con-
necting rod. ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-398744300
ST-498747300
ST-498857100
ST-499017100

ME(H4DOTC)-27
MECHANICAL
General Description
18251AA020 VALVE GUIDE
ADJUSTERUsed for installing intake and exhaust valve
guides.
499767200 VALVE GUIDE
REMOVERUsed for removing valve guides.
499767400 VALVE GUIDE
REAMERUsed for reaming valve guides.
499817000 ENGINE STAND  Stand used for engine disassembly and
assembly.
 Used with ENGINE STAND ADAPTER RH
(498457000) & LH (498457100). ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST18251AA020
ST-499767200
ST-499767400
ST-499817000

ME(H4DOTC)-29
MECHANICAL
General Description
18332AA010 OIL FILTER
WRENCHUsed for removing and installing the oil filter.
(Outer diameter: 65 mm (2.56 in))
499587100 OIL SEAL
INSTALLERUsed for installing oil pump oil seal.
499587600 OIL SEAL
INSTALLERUsed for installing camshaft oil seal for DOHC
engine.
499597200 OIL SEAL GUIDE  Used for installing camshaft oil seal for DOHC
engine.
 Used with OIL SEAL GUIDE (499587600). ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST18332AA010
ST-499587100
ST-499587600
ST-499597200

ME(H4DOTC)-30
MECHANICAL
General Description
2. GENERAL TOOL
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
 Camshaft
 Cylinder Head
498277200 STOPPER SET Used for installing automatic transmission
assembly to engine.
24082AA230
(Newly adopted tool)CARTRIDGE Troubleshooting for electrical systems.
22771AA030 SUBARU SELECT
MONITOR KITTroubleshooting for electrical systems.
 English: 22771AA030 (Without printer)
 German: 22771AA070 (Without printer)
 French: 22771AA080 (Without printer)
 Spanish: 22771AA090 (Without printer)
TOOL NAME REMARKS
Compression gauge Used for measuring compression.ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-498277200
ST24082AA230
ST22771AA030

ME(H4DOTC)-31
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. FU(H4DOTC)-54, RELEASING OF FUEL PRES-
SURE, OPERATION, Fuel.>
4) Remove all the spark plugs. IG(H4DOTC)-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
981 — 1,177 kPa (10 — 12 kgf/cm
2, 142 —
171 psi)
Limit
882 kPa (9.0 kgf/cm
2, 128 psi)
Difference between cylinders
Less than 49 kPa (0.5 kgf/cm
2, 7 psi)
ME-00007

ME(H4DOTC)-32
MECHANICAL
Idle Speed
3. Idle Speed
A: INSPECTION
1. USING SUBARU SELECT MONITOR
1) Before checking the idle speed, check the fol-
lowing:
(1) Ensure the air cleaner element is free from
clogging, ignition timing is correct, spark plugs
are in good condition, and that the hoses are
connected 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) Insert the cartridge to Subaru Select Monitor.
5) Connect the Subaru Select Monitor to data link
connector.
6) Turn the ignition switch to ON, and Subaru Se-
lect Monitor switch to ON.
7) Select the {2. Each System Check} in Main
Menu.
8) Select the {Engine Control System} in Selection
Menu.
9) Select the {1. Current Data Display & Save} in
Engine Control System Diagnosis.
10) Select the {1.12 Data Display} in Data Display
Menu.
11) Start the engine, and then read the engine idle
speed.
12) 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 neutral]:
700
±100 rpm
13) Check the idle speed when loaded. (Turn the
air conditioning switch to “ON” and operate the
compressor for at least 1 minute before measure-
ment.)
Idle speed [A/C “ON”, no load and gears in neu-
tral]:
A/C Refrigerant pressure (LOW)
MT: 725
±100 rpm
AT: 750
±100 rpm
A/C Refrigerant pressure (HIGH)
MT: 800
±100 rpm
AT: 825
±100 rpm
NOTE:
As idle speed is controlled by the automatic adjust-
ment type, it can not be adjusted manually. If the
idle speed is out of specifications, refer to General
On-board Diagnosis Table under “Engine Control
System”. tics Procedure.>

ME(H4DOTC)-33
MECHANICAL
Ignition Timing
4. Ignition Timing
A: INSPECTION
1. USING SUBARU SELECT MONITOR
1) Before checking the ignition timing speed, check
the following:
(1) Ensure the air cleaner element is free from
clogging, spark plugs are in good condition, and
that hoses are connected 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) Insert the cartridge to Subaru Select Monitor.
5) Connect the Subaru Select Monitor to data link
connector.
6) Turn the ignition switch to ON, and Subaru Se-
lect Monitor switch to ON.
7) Select the {2. Each System Check} in Main
Menu.
8) Select the {Engine Control System} in Selection
Menu.
9) Select the {1. Current Data Display & Save} in
Engine Control System Diagnosis.
10) Select the {1.12 Data Display} in Data Display
Menu.
11) Start the engine and check the ignition timing at
idle speed.
Ignition timing [BTDC/rpm]:
2.0 L model
12
°±10°/700
2.5 L model
17
°±10°/700
If the timing is not correct, check the ignition control
system. Refer to Engine Control System. EN(H4DOTC)-2, Basic Diagnostics Procedure.>

ME(H4DOTC)-34
MECHANICAL
Intake Manifold Vacuum
5. Intake Manifold Vacuum
A: INSPECTION
1) Warm-up the engine.
2) Disconnect the brake vacuum hose, and then in-
stall the vacuum gauge to hose fitting on manifold.
3) Keep the engine at the 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 inHg)
ME-00008
Diagnosis of engine condition by measurement of 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.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.Back 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 or throttle chamber idle adjustment

ME(H4DOTC)-35
MECHANICAL
Engine Oil Pressure
6. Engine Oil Pressure
A: INSPECTION
1) Remove the oil pressure switch from engine cyl-
inder block. Pressure Switch.>
2) Connect the oil pressure gauge hose to cylinder
block.
3) Connect the battery ground cable to battery.
4) Start the engine, and then measure the oil pres-
sure.
Oil pressure:
98 kPa (1.0 kg/cm
2, 14 psi) or more at 800 rpm
294 kPa (3.0 kg/cm2, 43 psi) or more at 5,000
rpm
 If the oil pressure is out of specification, check oil
pump, oil filter and lubrication line. LU(H4SO)-24, INSPECTION, Engine Lubrication
System Trouble in General.>
 If the oil pressure warning light is turned ON and
oil pressure is in specification, replace the oil pres-
sure switch. Engine Lubrication System Trouble in General.>
NOTE:
The specified data is based on an engine oil tem-
perature of 80°C (176°F).
5) After measuring the oil pressure, install the oil
pressure switch. LATION, Oil Pressure Switch.>
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
FU-00009
ME-00009