key SUBARU FORESTER 2004 Service Workshop Manual

ME(H4SO)-63
MECHANICAL
Cylinder Head
7) Install the cam sprocket. INSTALLATION, Cam Sprocket.>
8) Install the timing belt assembly. ME(H4SO)-49, INSTALLATION, Timing Belt.>
9) Install the timing belt cover. 47, INSTALLATION, Timing Belt Cover.>
10) Install the crank pulley. INSTALLATION, Crank Pulley.>
11) Install the V-belt. STALLATION, V-belt.>C: DISASSEMBLY
1) Place the cylinder head on ST.
ST 498267800 CYLINDER HEAD TABLE
2) Set the ST on valve spring. Compress the valve
spring, and then remove the valve spring retainer
key. Remove each valve and valve spring.
ST 499718000 VALVE SPRING REMOVER
CAUTION:
 Mark each valve to prevent confusion.
 Use extreme care not to damage the lips of in-
take valve oil seals and exhaust valve oil seals.
ME-00280
ST

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)-65
MECHANICAL
Cylinder Head
(5) Compress the valve spring, and then fit the
valve spring retainer key.
(6) After installing, tap the valve spring retainers
lightly with plastic hammer for better seating.
E: INSPECTION
1. VALVE SPRING
1) Check the valve springs for damage, free length,
and tension. Replace the valve spring if it is not
within the standard value 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. INTAKE AND EXHAUST VALVE OIL
SEAL
In the following case, pinch and remove the oil seal
from valve using pliers, and then replace it with a
new one.
 When the lip is damaged.
 When the spring is out of the specified position. When readjusting the surfaces of intake valve
and valve sheet.
 When replacing the intake valve guide.
1) Place the cylinder head on ST1.
2) Using ST2, press-fit the oil seal.
CAUTION:
 Apply engine oil to oil seal before press-fit-
ting.
 When press-fitting oil seal, do not use ham-
mer or strike in.
 Differentiate between intake valve oil seal
and exhaust valve oil seal by noting their differ-
ence in color.
ST1 498267800 CYLINDER HEAD TABLE
ST2 498857100 VALVE OIL SEAL GUIDE
Color of rubber part:
Intake [Black]
Exhaust [Brown]
Color of spring part:
Intake [Silver]
Exhaust [Silver]
F: ADJUSTMENT
1. CYLINDER HEAD
1) Make sure that no crack or other damage exists.
In addition to visual inspection, inspect important
areas by means of red lead check.
Also make sure that gasket installing surface
shows no trace of gas and water leaks.
2) Place the cylinder head on ST.
ST 498267800 CYLINDER HEAD TABLE
3) Measure the warping of the cylinder head sur-
face that mates with crankcase using a straight
edge and thickness gauge.
If the warping exceeds the limit, regrind the surface
with a surface grinder.
Warping limit:
0.05 mm (0.0020 in)
Grinding limit:
0.1 mm (0.004 in)
Standard height of cylinder head:
97.5 mm (3.839 in)
(A) Retainer
(B) Valve spring
Free length 54.30 mm (2.1378 in)
Squareness 2.5°, 2.4 mm (0.094 in)
Tension/spring
height215 — 246 N
(21.9 — 25.1 kgf, 48.2 — 55.3 lb)/
45.0 mm (1.772 in)
527 — 582 N
(53.7 — 59.3 kgf, 118.1 — 130.8 lb)/
34.7 mm (1.366 in)
ME-00282
(B)(B)
(A)
ME-00283
ME-00284
ST1
ST2

EN(H4SO)-30
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» display screen, select the {Current Data Display/Save}, and then press the
[YES] key.
5) On the «Data Display Menu» display screen, select the {Data Display} and press the [YES] key.
6) Using the scroll key, scroll the display screen up or down until the desired data is shown.
 A list of the support data is shown in the following table.
Description Display Unit of measure
Battery voltage Battery Voltage V
Vehicle speed signal Meter vehicle speed km/h or MPH
Engine speed signal Engine speed rpm
Engine coolant temperature signal Engine coolant temperature°C or (°F)
Ignition timing signal Ignition timing deg
Throttle position signal Amount of intake air %
Throttle position signal Throttle Sensor Voltage V
Injection pulse width Fuel injection pulse width ms
Idle air control signal ISC Steps STEP
Engine load data Engine load %
Front oxygen (A/F) sensor resistance A/F sensor resistance value 1 ohm
Front oxygen (A/F) sensor output signal A/F sensor current value 1 —
Rear oxygen sensor output signalRear oxygen sensor voltage
valueV
Short term fuel trim A/F Compensation 1 %
Knock sensor signal Knock Correction deg
Atmospheric absolute pressure signal Atmospheric pressure mmHg, kPa, inHg or psi
Intake manifold relative pressure signal Mani. Relative Pressure mmHg, kPa, inHg or psi
Intake manifold absolute pressure signalIntake manifold absolute pres-
suremmHg, kPa, inHg or psi
A/F correction (short term fuel trim) by rear oxygen sensor A/F Compensation 3 %
Long term whole fuel trim A/F learning 1 %
Front oxygen (A/F) sensor heater current Front O2 heater current value A
Rear oxygen sensor heater current Rear O2 heater current value A
Canister purge control solenoid valve duty ratio CPC Valve Duty Ratio %
Fuel level signal Fuel level voltage V
Intake air temperature signal Intake air temperature°C or (°F)
Learned ignition timing Ignition learning value deg
EGR signal EGR Steps STEP
Ignition switch signal Ignition SW ON or OFF
Test mode connector signal Test mode signal ON or OFF
Neutral position switch signal Neutral SW ON or OFF
Air conditioning switch signal A/C SW ON or OFF
Air conditioning compressor signal A/C Compressor Signal ON or OFF
Radiator main fan relay signal Radiator fan relay 1 ON or OFF
Fuel pump relay signal Fuel pump relay ON or OFF
Knocking signal Knock signal ON or OFF
Radiator sub fan relay signal Radiator fan relay 2 ON or OFF
Power steering switch signal Power steering SW input signal ON or OFF
Engine torque control signal #1 AT coordinate request signal 1 ON or OFF
Engine torque control signal #2 AT coordinate request signal 2 ON or OFF

EN(H4SO)-32
ENGINE (DIAGNOSTIC)
Subaru Select Monitor
5. READ CURRENT DATA FOR ENGINE (OBD 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» display screen, select the {OBD system} and press the [YES] key.
5) On the «OBD Menu» display screen, select the {Current Data Display & Save}, and press the [YES] key.
6) On the «Data Display Menu» display screen, select the {Data Display} and press the [YES] key.
7) Using the scroll key, scroll the display screen up or down until the desired data is shown.
 A list of the support data is shown in the following table.
NOTE:
For detailed operation procedure, refer to the “SUBARU SELECT MONITOR OPERATION MANUAL”.
Description Display Unit of measure
Number of DTC Number of diagnosis code —
Condition of malfunction indicator light MI (MIL) ON or OFF
Monitoring test of misfire Misfire Monitoring Complete or incomplete
Monitoring test of fuel system Fuel System Diagnosis Complete or incomplete
Monitoring test of comprehensive component Component Diagnosis Complete or incomplete
Test of catalyst Catalyst diagnosis Complete or incomplete
Test of heating-type catalyst Heated catalyst diagnosis No support
Test of evaporative emission purge control system Evap. purge diagnosis Complete or incomplete
Test of secondary air system Secondary air diagnosis No support
Test of air conditioning system refrigerant A/C refrigerant diagnosis No support
Test of oxygen sensor O2 sensor diagnosis Complete or incomplete
Test of oxygen sensor heater O2 heater diagnosis Complete or incomplete
Test of EGR system EGR diagnosis —
Air fuel ratio control system for bank 1 Fuel System for bank 1 —
Engine load data Engine load %
Engine coolant temperature signal Engine coolant temperature°C or (°F)
Short term fuel trim by front oxygen (A/F) sensor Short term fuel trim B1 %
Long term fuel trim by front oxygen (A/F) sensor Long term fuel trim B1 %
Intake manifold absolute pressure signalIntake manifold absolute pres-
suremmHg, kPa, inHg or psi
Engine speed signal Engine speed rpm
Vehicle speed signal Meter vehicle speed km/h or MPH
Ignition timing advance for #1 cylinder Ignition timing adv. #1°
Intake air temperature signal Intake air temperature°C or (°F)
Amount of intake air Amount of intake air g/s
Throttle position signal Throttle valve angle %
Rear oxygen sensor output signal O2 sensor #12 V
Air fuel ratio correction by rear oxygen sensor Short term fuel trim #12 %
On-board diagnostic system OBD system —
Oxygen sensor #11 O2 sensor #11 With support
Oxygen sensor #12 O2 sensor #12 With support
A/F sensor #11 A/F sensor #11 —

EN(H4SO)-33
ENGINE (DIAGNOSTIC)
Subaru Select Monitor
6. READ FREEZE FRAME DATA FOR ENGINE. (OBD 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» display screen, select the {OBD System} and press the [YES] key.
5) On the «OBD Menu» display screen, select the {Freeze Frame Data} and press the [YES] key.
 A list of the support data is shown in the following table.
NOTE:
For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.
Description Display Unit of measure
DTC of freeze frame data Freeze frame data DTC
Air fuel ratio control system for bank 1 Fuel system for Bank 1 ON or OFF
Engine load data Engine load %
Engine coolant temperature signal Engine coolant temperature°C or (°F)
Short term fuel trim by front oxygen (A/F) sensor Short term fuel trim B1 %
Long term fuel trim by front oxygen (A/F) sensor Long term fuel trim B1 %
Intake manifold absolute pressure signalIntake manifold absolute pres-
suremmHg, kPa, inHg or psi
Engine speed signal Engine speed rpm
Vehicle speed signal Meter vehicle speed km/h or MPH

EN(H4SO)-34
ENGINE (DIAGNOSTIC)
Subaru Select Monitor
7. LED OPERATION MODE FOR ENGINE
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» display screen, select the {Current Data Display/Save}, and then press the
[YES] key.
5) On the «Data Display Menu» display screen, select the {Data & LED Display} and press the [YES] key.
6) Using the scroll key, scroll the display screen up or down until the desired data is shown.
 A list of the support data is shown in the following table.
NOTE:
For detailed operation procedure, refer to the “SUBARU SELECT MONITOR OPERATION MANUAL”.
Description Display Message LED “ON” requirements
Ignition switch signal Ignition SW ON or OFF When ignition switch is ON
Test mode connector signal Test mode signal ON or OFF When test mode connector is connected.
Neutral position switch signal Neutral SW ON or OFF When neutral position signal is entered.
Air conditioning switch signal A/C SW ON or OFF When air conditioning switch is ON
Air conditioning relay signal A/C Compressor Relay ON or OFF When air conditioning relay is in function.
Radiator main fan relay signal Radiator fan relay 1 ON or OFF When radiator main fan relay is in function.
Fuel pump relay signal Fuel pump relay ON or OFF When fuel pump relay is in function.
Knocking signal Knock signal ON or OFF When knocking signal is input.
Radiator sub fan relay signal Radiator fan relay 2 ON or OFF When radiator sub fan relay is in function.
Engine torque control signal #1 AT coordinate request signal 1 ON or OFFWhen engine torque control signal 1 is
entered
Engine torque control signal #2 AT coordinate request signal 2 ON or OFFWhen engine torque control signal 2 is
entered
Engine torque control permission
signalAT coordinate permission sig-
nalON or OFFWhen engine torque control permission sig-
nal is entered.
Front oxygen (A/F) sensor rich sig-
nalFront O2 Rich Signal #1 ON or OFFWhen front oxygen (A/F) sensor mixture ratio
is rich.
Rear oxygen sensor rich signal RrO2 monitor ON or OFFWhen rear oxygen sensor mixture ratio is
rich.
Starter switch signal Starter SW ON or OFF When starter switch signal is entered.
Idle switch signal Idle Switch Signal ON or OFF When idle switch signal is entered.
Crankshaft position sensor signal Crankshaft position signal ON or OFFWhen crankshaft position sensor signal is
input.
Camshaft position sensor signal Camshaft position signal ON or OFFWhen camshaft position sensor signal is
entered.

EN(H4SO)-35
ENGINE (DIAGNOSTIC)
Subaru Select Monitor
8. READ CURRENT DATA FOR AT
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 {Transmission} and press the [YES] key.
3) Press the [YES] key after the information of transmission type is displayed.
4) On the «Transmission Diagnosis» display screen, select the {Current Data Display & Save} and press the
[YES] key.
5) On the «Transmission Diagnosis» display screen, select the {Data Display} and press the [YES] key.
6) Using the scroll key, scroll the display screen up or down until the desired data is shown.
 A list of the support data is shown in the following table.
Description Display Unit of measure
Battery voltage Battery Voltage V
Rear vehicle speed sensor signal Rear Wheel Speed km/h or MPH
Front vehicle speed sensor signal Front Wheel Speed km/h or MPH
Engine speed signal Engine speed rpm
ATF temperature signal ATF Temp.°C or °F
Throttle position sensor Throttle Sensor Voltage V
Gear Position Gear position —
Line pressure control duty ratio Line pressure duty %
Lock up clutch control duty ratio L/U Duty %
Transfer clutch control duty ratio AWD duty %
Throttle position sensor power supply Throttle sensor power supply V
Turbine revolution signal Turbine Revolution Speed rpm
2-4 Brake timing pressure control duty ratio 2-4 B Pressure Duty %
Intake manifold pressure sensor voltage Mani. Relative Voltage V
FWD switch signal FWD SW ON or OFF
Kick down switch signal Kick Down Switch ON or OFF
Stop light switch signal Stop Light SW ON or OFF
Anti lock brake system signal ABS signal ON or OFF
Cruise control system signal Cruise Control Signal ON or OFF
Neutral/Parking range signal N/P range ON or OFF
Reverse range signal R Range ON or OFF
Drive range signal D Range ON or OFF
3rd range signal 3rd Range Signal ON or OFF
2nd range signal 2nd Range Signal ON or OFF
1st range signal 1st Range Signal ON or OFF
Shift control solenoid A Shift Solenoid #1 ON or OFF
Shift control solenoid B Shift Solenoid #2 ON or OFF
Torque control output signal #1 Torque control output signal 1 ON or OFF
Torque control output signal #2 Torque control output signal 2 ON or OFF
Torque control cut signal Torque Control Cut Sig ON or OFF
2-4 brake timing control solenoid valve 2-4B Timing Solenoid ON or OFF
Low clutch timing control solenoid valve L/C timing solenoid ON or OFF
Automatic transmission diagnosis light output signal Diagnosis Lamp ON or OFF

EN(H4SO)-36
ENGINE (DIAGNOSTIC)
Read Diagnostic Trouble Code (DTC)
11.Read Diagnostic Trouble
Code (DTC)
A: OPERATION
1. SUBARU SELECT MONITOR (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 en-
gine type was displayed.
4) On the «Engine Diagnosis» screen, select the
{DTC Display}, and then press the [YES] key.
5) On the «Diagnostic Code(s) Display» screen,
select the {Current Diagnostic Code(s)} or {History
Diagnostic Code(s)}, and then press the [YES] key.
NOTE:
 For detailed operation procedure, refer to the “SUB-
ARU SELECT MONITOR OPERATION MANUAL”.
 For details concerning DTC, refer to the List of Di-
agnostic Trouble Code (DTC). 72, List of Diagnostic Trouble Code (DTC).>
2. SUBARU SELECT MONITOR (OBD
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 en-
gine type was displayed.
4) On the «Engine Diagnosis» display screen, se-
lect the {OBD System} and press the [YES] key.
5) On the «OBD Menu» display screen, select the
{DTC Display} and press the [YES] key.
6) Make sure DTC is shown on the screen.
NOTE:
 For detailed operation procedure, refer to the
“SUBARU SELECT MONITOR OPERATION
MANUAL”.
 For details concerning DTC, refer to the List of Di-
agnostic Trouble Code (DTC). 72, List of Diagnostic Trouble Code (DTC).>
3. OBD-II GENERAL SCAN TOOL
Refers to data denoting emission-related power-
train DTC.
For details concerning DTC, refer to the List of Di-
agnostic Trouble Code (DTC). 72, List of Diagnostic Trouble Code (DTC).>NOTE:
Refer to OBD-II general scan tool manufacturer’s
instruction manual to access powertrain DTC
(MODE $03).

EN(H4SO)-37
ENGINE (DIAGNOSTIC)
Inspection Mode
12.Inspection Mode
A: OPERATION
Perform the diagnosis on the “Diagnosis Trouble Codes (DTC) List” below.
Refer to the item of drive cycle when perform the diagnosis not on the “Diagnosis Trouble Codes (DTC) List”
below.
DTC Item
P0030 HO2S Heater Control Circuit (Bank 1 Sensor 1)
P0031 HO2S Heater Control Circuit Low (Bank 1 Sensor 1)
P0032 HO2S Heater Control Circuit High (Bank 1 Sensor 1)
P0037 HO2S Heater Control Circuit Low (Bank 1 Sensor 2)
P0038 HO2S Heater Control Circuit High (Bank 1 Sensor 2)
P0068 Manifold Pressure Sensor Range/Performance
P0107 Manifold Absolute Pressure/Barometric Pressure Circuit Low Input
P0108 Manifold Absolute Pressure/Barometric Pressure Circuit High Input
P0112 Intake Air Temperature Circuit Low Input
P0113 Intake Air Temperature Circuit High Input
P0117 Engine Coolant Temperature Circuit Low Input
P0118 Engine Coolant Temperature Circuit High Input
P0122 Throttle/Pedal Position Sensor/Switch “A” Circuit Low Input
P0123 Throttle/Pedal Position Sensor/Switch “A” Circuit High Input
P0129 Barometric Pressure Too Low
P0131 O
2 Sensor Circuit Low Voltage (Bank 1 Sensor 1)
P0132 O
2 Sensor Circuit High Voltage (Bank 1 Sensor 1)
P0134 O
2 Sensor Circuit No Activity Detected (Bank 1 Sensor 1)
P0137 O
2 Sensor Circuit Low Voltage (Bank 1 Sensor 2)
P0138 O
2 Sensor Circuit High Voltage (Bank 1 Sensor 2)
P0327 Knock Sensor 1 Circuit Low Input (Bank 1 or Single Sensor)
P0328 Knock Sensor 1 Circuit High Input (Bank 1 or Single Sensor)
P0335 Crankshaft Position Sensor “A” Circuit
P0336 Crankshaft Position Sensor “A” Circuit Range/Performance
P0340 Camshaft Position Sensor “A” Circuit (Bank 1 or Single Sensor)
P0341 Camshaft Position Sensor “A” Circuit Range/Performance (Bank 1 or Single Sensor)
P0458 Evaporative Emission Control System Purge Control Valve Circuit Low
P0462 Fuel Level Sensor Circuit Low Input
P0463 Fuel Level Sensor Circuit High Input
P0502 Vehicle Speed Sensor Circuit Low Input
P0503 Vehicle Speed Sensor Intermittent/Erratic/High
P0512 Starter Request Circuit
P0513 Incorrect Immobilizer Key
P0519 Idle Control System Malfunction (Fail-Safe)
P0565 Cruise Control On Signal
P0604 Internal Control Module Random Access Memory (RAM) Error
P0703 Torque Converter/Brake Switch “B” Circuit
P0705 Transmission Range Sensor Circuit (PRNDL Input)
P0710 Transmission Fluid Temperature Sensor Circuit
P0716 Torque converter turbine speed sensor
P0720 AT Vehicle Speed Sensor Circuit Malfunction
P0726 Engine Speed Input Circuit Malfunction
P0731 Gear 1 Incorrect Ratio
P0732 Gear 2 Incorrect Ratio
P0733 Gear 3 Incorrect Ratio