meter SUBARU FORESTER 2004 Service Manual PDF

FU(H4SO)-29
FUEL INJECTION (FUEL SYSTEM)
Throttle Position Sensor
8. Throttle Position Sensor
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Disconnect the connector from the throttle posi-
tion sensor.
3) Remove the throttle position sensor holding
screws, and remove it.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
1.6 N
⋅m (0.16 kgf-m, 1.2 ft-lb)
CAUTION:
When installing throttle position sensor, adjust
to the specified data.
C: ADJUSTMENT
1) Turn the ignition switch to OFF.
2) Loosen the throttle position sensor holding
screws.
3) When using voltage meter;
(1) Take out the ECM.
(2) Turn the ignition switch to ON.
(3) Adjust the throttle position sensor to the
proper position to allow the voltage signal to the
ECM to be in specification.
Connector & terminal / Specified voltage
(B135) No. 13 (+) — (B135) No. 19 (
−) / 0.45 —
0.55 V
[Fully closed.]
FU-00009
FU-00289
FU-00290
FU-00290
FU-00291
FU-00520
4
1 526
18 1516
7
891011
17
19
20121314
B135
3
2122232425262728

FU(H4SO)-66
FUEL INJECTION (FUEL SYSTEM)
Fuel System Trouble in General
29.Fuel System Trouble in General
A: INSPECTION
NOTE:
 When the vehicle is left unattended for an ex-
tended period of time, water may accumulate in the
fuel tank.
To prevent water condensation.
(1) Top off the fuel tank or drain the fuel com-
pletely.
(2) Drain the water condensation from the fuel
filter.
 Refilling the fuel tank.
Refill the fuel tank while there is still some fuel left in
the tank.
 Protecting the fuel system against freezing and
water condensation.
(3) Cold areas :
In snow-covered areas, mountainous areas, ski-
ing areas, etc. where ambient temperatures
drop below 0°C (32°F) throughout the winter
season, use an anti-freeze solution in the fuel
tank. Refueling will also complement the effect
of anti-freeze solution each time the fuel leveldrops to about one-half. After the winter season,
drain the water which may have accumulated in
the fuel filter and fuel tank in the manner same
as that described under “Affected areas” below.
(4) Affected areas :
When the water condensation is notched in the
fuel filter, drain the water from both the fuel filter
and fuel tank or use a water removing agent (or
anti-freeze solution) in the fuel tank.
 Observe the instructions, notes, etc., indicated
on the label affixed to the anti-freeze solution (wa-
ter removing agent) container before use.
Trouble and possible cause Corrective action
1. Insufficient fuel supply to the injector
1) Fuel pump will not operate.
❍Defective terminal contact.Inspect connections, especially ground, and tighten
securely.
❍Trouble in electromagnetic or electronic circuit parts. Replace fuel pump.
2) Lowering of fuel pump function. Replace fuel pump.
3) Clogged dust or water in the fuel filter. Replace fuel filter, clean or replace fuel tank.
4) Clogged or bent fuel pipe or hose. Clean, correct or replace fuel pipe or hose.
5) Air is mixed in the fuel system. Inspect or retighten each connection part.
6) Clogged or bent breather tube or pipe. Clean, correct or replace air breather tube or pipe.
7) Damaged diaphragm of pressure regulator. Replace.
2. Leakage or blow out fuel
1) Loosened joints of the fuel pipe. Retightening.
2) Cracked fuel pipe, hose and fuel tank. Replace.
3) Defective welding part on the fuel tank. Replace.
4) Defective drain packing of the fuel tank. Replace.
5) Clogged or bent air breather tube or air vent tube.Clean, correct or replace air breather tube or air vent
tube.
3. Gasoline smell inside of compartment
1)Loose joints at air breather tube, air vent tube and fuel filler
pipe.Retightening.
2) Defective packing air tightness on the fuel saucer. Correct or replace packing.
3) Cracked fuel separator. Replace separator.
4) Inoperative fuel pump modulator or circuit. Replace.
4. Defective fuel meter indicator
1) Defective operation of fuel level sensor. Replace.
2) Defective operation of fuel meter. Replace.
5. Noise
1) Large operation noise or vibration of fuel pump. Replace.

ME(H4SO)-2
MECHANICAL
General Description
1. General Description
A: SPECIFICATION
NOTE:
STD: Standard I.D.: Inner Diameter O.D.: Outer Diameter US: Undersize OS: Oversize
EngineModel 2.0 L 2.5 L
Ty p eHorizontally opposed, liquid cooled, 4-cylinder, 4-stroke gaso-
line engine
Valve arrangement Belt driven, single over-head camshaft, 4-valve/cylinder
Bore×Stroke mm (in) 92×75 (3.62×2.95)99.5×79.0
(3.917×3.110)
Displacement
cm
3 (cu in)1,994 (121.67) 2,457 (150)
Compression ratio 10.0
Compression pressure
(at 200 — 300 rpm)kPa (kg/cm
2, psi)1,079 — 1,275 (11.0 — 13.0, 156 — 185)
Number of piston rings Pressure ring: 2, Oil ring: 1
Intake valve timingOpen 4° BTDC 1° BTDC
Close 48° ABDC 51° ABDC
Exhaust valve timingOpen 48° BBDC 50° BBDC
Close 4° AT D C 6° AT D C
Valve clearance Intake mm (in) 0.20±0.04 (0.0079±0.0016)
Exhaust mm (in) 0.25±0.04 (0.0098±0.0016)
Idling speed [at neutral position on
MT, or “P” or “N” range on AT]rpm650±100 (No load)
850±100 (A/C switch ON)
Firing order 1 → 3 → 2 → 4
Ignition timing BTDC/rpm 10°±10°/650
Belt
tensioner
adjusterProtrusion of adjuster rod mm (in) 5.7 — 6.7 (0.224 — 0.263)
Belt
tensionerSpacer O.D. mm (in) 17.955 — 17.975 (0.7069 — 0.7077)
Tensioner bush I.D. mm (in) 18.00 — 18.08 (0.7087 — 0.7118)
Clearance between spacer and bush mm (in)STD 0.025 — 0.125 (0.0010 — 0.0049)
Limit 0.175 (0.0069)
Side clearance of spacer mm (in)STD 0.20 — 0.55 (0.0079 — 0.0217)
Limit 0.81 (0.0319)
Valve rocker
armClearance between shaft and arm mm (in)STD 0.020 — 0.054 (0.0008 — 0.0021)
Limit 0.10 (0.0039)
CamshaftBend limit mm (in) 0.025 (0.0010)
Thrust clearance mm (in)STD 0.030 — 0.090 (0.0012 — 0.0035)
Limit 0.10 (0.0039)
Cam lobe height mm (in)2.0 LIntakeSTD 38.732 — 38.832 (1.5249 — 1.5288)
Limit 38.632 (1.5209)
ExhaustSTD 39.259 — 39.359 (1.5456 — 1.5496)
Limit 39.157 (1.5417)
2.5 LIntakeSTD 39.485 — 39.585 (1.5545 — 1.5585)
Limit 39.385 (1.5506)
ExhaustSTD 39.259 — 39.359 (1.5456 — 1.5496)
Limit 39.159 (1.5417)
Camshaft journal O.D. mm (in) 31.928 — 31.945 (1.2570 — 1.2577)
Camshaft journal hole I.D. (Cylinder head) mm (in) 32.000 — 32.018 (1.2598 — 1.2605)
Oil clearance mm (in)STD 0.055 — 0.090 (0.0022 — 0.0035)
Limit 0.10 (0.0039)

ME(H4SO)-3
MECHANICAL
General Description
Cylinder
headSurface warpage limit (mating with cylinder block) mm (in) 0.05 (0.0020)
Grinding limit mm (in) 0.1 (0.004)
Standard height mm (in) 97.5 (3.84)
Va l ve s e a tRefacing angle90°
Contacting width mm (in)IntakeSTD 1.1 (0.043)
Limit 1.8 (0.070)
ExhaustSTD 1.5 (0.059)
Limit 2.2 (0.087)
Valve guideInner diameter mm (in) 6.000 — 6.012 (0.2362 — 0.2367)
Protrusion above head mm (in)Intake 20.0 — 20.5 (0.787 — 0.807)
Exhaust 16.5 — 17.0 (0.650 — 0.669)
Va l veHead edge thickness mm (in)IntakeSTD 1.0 (0.039)
Limit 0.6 (0.024)
ExhaustSTD 1.2 (0.047)
Limit 0.6 (0.024)
Stem outer diameter mm (in)Intake 5.950 — 5.965 (0.2343 — 0.2348)
Exhaust 5.945 — 5.960(0.2341 — 0.2346)
Stem oil clearance mm (in)STDIntake 0.035 — 0.062 (0.0014 — 0.0024)
Exhaust 0.040 — 0.067 (0.0016 — 0.0026)
Limit — 0.15 (0.0059)
Overall length mm (in)Intake 120.6 (4.75)
Exhaust 121.7 (4.79)
Valve springFree length mm (in) 54.30 (2.1378)
Squareness mm (in) 2.5°, 2.4 (0.094)
Tension/spring height N (kgf, lb)/mm (in)Set214 — 246 (22 — 25, 48 — 55)/
45.0 (1.772)
Lift526 — 582 (54 — 59, 119 — 130)/
34.7 (1.366)
Cylinder
blockSurface warpage limit (mating with cylinder head) mm (in) 0.05 (0.0020)
Grinding limit mm (in) 0.1 (0.004)
Cylinder inner
diametermm (in)2.0 L STDA 92.005 — 92.015 (3.6222 — 3.6226)
B 91.995 — 92.005 (3.6218 — 3.6222)
2.5 L STDA 99.505 — 99.515 (3.9175 — 3.9179)
B 99.495 — 99.505 (3.9171 — 3.9175)
Ta p e r m m ( i n )STD 0.015 (0.0006)
Limit 0.050 (0.0020)
Out-of-roundness mm (in)STD 0.010 (0.0004)
Limit 0.050 (0.0020)
Piston clearance mm (in)STD 0.010 — 0.030 (0.0004 — 0.0012)
Limit 0.050 (0.0020)
Boring mm (in) 0.5 (0.020)
PistonOuter diameter mm (in)2.0 LSTDA 91.985 — 91.995 (3.6214 — 3.6218)
B 91.975 — 91.985 (3.6211 — 3.6214)
0.25 (0.0098) OS 92.225 — 92.235 (3.6309 — 3.6313)
0.50 (0.0197) OS 92.475 — 92.485 (3.6407 — 3.6411)
2.5 LSTDA 99.485 — 99.495 (3.9167 — 3.9171)
B 99.475 — 99.485 (3.9163 — 3.9167)
0.25 (0.0098) OS 99.725 — 99.735 (3.9262 — 3.9266)
0.50 (0.0197) OS 99.975 — 99.985 (3.9360 — 3.9364)
Piston pin standard diameter mm (in) 23.000 — 23.006 (0.9055 — 0.9057)

ME(H4SO)-4
MECHANICAL
General Description
Piston pinOuter diameter mm (in) 22.994 — 23.000 (0.9053 — 0.9055)
Standard clearance between piston and piston pin mm (in) 0.004 — 0.008 (0.0002 — 0.0003)
Degree of fitPiston pin must be fitted into position with
thumb at 20°C (68°F).
Piston ringRing closed gap mm (in)Top ringSTD 0.20 — 0.35 (0.0079 — 0.0138)
Limit 1.0 (0.039)
Second
ring2.0 LSTD 0.35 — 0.50 (0.0138 — 0.0197)
Limit 1.0 (0.039)
2.5 LSTD 0.37 — 0.52 (0.0146 — 0.0204)
Limit 1.0 (0.039)
Oil ringSTD 0.20 — 0.50 (0.0079 — 0.0197)
Limit 1.5 (0.059)
Ring groove gap mm (in)Top ringSTD 0.040 — 0.080 (0.0016 — 0.0031)
Limit 0.15 (0.0059)
Second
ringSTD 0.030 — 0.070 (0.0012 — 0.0028)
Limit 0.15 (0.0059)
Connecting
rodBend or twist per 100 mm
(3.94 in) in lengthmm (in) Limit 0.10 (0.0039)
Side clearance at large end mm (in)STD 0.070 — 0.330 (0.0028 — 0.0130)
Limit 0.4 (0.016)
Connecting
rod bearingOil clearance mm (in)STD 0.0158 — 0.0438 (0.0006 — 0.0017)
Limit 0.05 (0.0020)
Thickness at cen-
ter portionmm (in)2.0 LSTD 1.492 — 1.501 (0.0587 — 0.0591)
0.03 (0.0012) US 1.510 — 1.513 (0.0594 — 0.0596)
0.05 (0.0020) US 1.520 — 1.523 (0.0598 — 0.0600)
0.25 (0.0098) US 1.620 — 1.623 (0.0638 — 0.0639)
2.5 LSTD 1.492 — 1.503 (0.0587 — 0.0591)
0.03 (0.0012) US 1.510 — 1.513 (0.0594 — 0.0596)
0.05 (0.0020) US 1.520 — 1.523 (0.0598 — 0.0600)
0.25 (0.0098) US 1.620 — 1.623 (0.0638 — 0.0639)
Connecting
rod bushingClearance between piston pin
and bushingmm (in)STD 0 — 0.022 (0 — 0.0009)
Limit 0.030 (0.0012)

ME(H4SO)-5
MECHANICAL
General Description
CrankshaftBend limit mm (in) 0.035 (0.0014)
Crank pin and
crank journalmm (in)Out-of-roundness 0.020 (0.0008) or less
Grinding limit 0.250 (0.0098)
Crank pin outer diameter mm (in)STD 51.984 — 52.000 (2.0466 — 2.0472)
0.03 (0.0012) US 51.954 — 51.970 (2.0454 — 2.0461)
0.05 (0.0020) US 51.934 — 51.950 (2.0446 — 2.0453)
0.25 (0.0098) US 51.734 — 51.750 (2.0368 — 2.0374)
Crank journal
outer diametermm (in)#1, #3STD 59.992 — 60.008 (2.3619 — 2.3625)
0.03 (0.0012) US 59.962 — 59.978 (2.3607 — 2.3613)
0.05 (0.0020) US 59.942 — 59.958 (2.3599 — 2.3605)
0.25 (0.0098) US 59.742 — 59.758 (2.3520 — 2.3527)
#2, #4, #5STD 59.992 — 60.008 (2.3619 — 2.3625)
0.03 (0.0012) US 59.962 — 59.978 (2.3607 — 2.3613)
0.05 (0.0020) US 59.942 — 59.958 (2.3599 — 2.3605)
0.25 (0.0098) US 59.742 — 59.758 (2.3520 — 2.3527)
Side clearance mm (in)STD 0.030 — 0.115 (0.0012 — 0.0045)
Limit 0.25 (0.0098)
Oil clearance mm (in)#1STD 0.010 — 0.030 (0.0004 — 0.0012)
Limit 0.040 (0.0016)
#2STD 0.010 — 0.030 (0.0004 — 0.0012)
Limit 0.045 (0.0018)
#3STD 0.010 — 0.030 (0.0004 — 0.0012)
Limit 0.040 (0.0016)
#4STD 0.010 — 0.030 (0.0004 — 0.0012)
Limit 0.045 (0.0018)
#5STD 0.010 — 0.030 (0.0004 — 0.0012)
Limit 0.040 (0.0016)
Crankshaft
bearingCrankshaft bear-
ing thicknessmm (in)#1, #3STD 1.998 — 2.011 (0.0787 — 0.0792)
0.03 (0.0012) US 2.017 — 2.020 (0.0794 — 0.0795)
0.05 (0.0020) US 2.027 — 2.030 (0.0798 — 0.0799)
0.25 (0.0098) US 2.127 — 2.130 (0.0837 — 0.0839)
#2, #4, #5STD 2.000 — 2.013 (0.0787 — 0.0793)
0.03 (0.0012) US 2.019 — 2.022 (0.0795 — 0.0796)
0.05 (0.0020) US 2.029 — 2.032 (0.0799 — 0.0800)
0.25 (0.0098) US 2.129 — 2.132 (0.0838 — 0.0839)

ME(H4SO)-17
MECHANICAL
General Description
498457100 ENGINE STAND
ADAPTER LHUsed with ENGINE STAND (499817000).
498497100 CRANKSHAFT
STOPPERUsed for stopping rotation of flywheel when loos-
ening and tightening crank pulley bolt, etc.
498547000 OIL FILTER
WRENCHUsed for removing and installing oil filter.
(Outer diameter : 80 mm (3.15 in))
18332AA000 OIL FILTER
WRENCHUsed for removing and installing oil filter.
(Outer diameter : 68 mm (2.68 in)) ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-498457100
ST-498497100
ST-498547000
ST18332AA000

ME(H4SO)-18
MECHANICAL
General Description
18332AA010 OIL FILTER
WRENCHUsed for removing and installing oil filter.
(Outer diameter : 65 mm (2.56 in))
398744300
(2.0 L model)PISTON GUIDE Used for installing piston in cylinder.
498747300
(2.5 L model)PISTON GUIDE Used for installing piston in cylinder.
498857100 VALVE OIL SEAL
GUIDEUsed for press-fitting of intake and exhaust valve
guide oil seals. ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST18332AA010
ST-398744300
ST-498747300
ST-498857100

ME(H4SO)-23
MECHANICAL
General Description
2. GENERAL TOOL
499817100 ENGINE STAND  Stand used for engine disassembly and
assembly.
 Used with ENGINE STAND ADAPTER RH
(498457000) & LH (498457100).
499977100 CRANK PULLEY
WRENCHUsed for stopping rotation of crank pulley when
loosening and tightening crank pulley bolts. (2.5
L model)
499977400 CRANK PULLEY
WRENCHUsed for stopping rotation of crank pulley when
loosening and tightening crank pulley bolts. (2.0
L model)
499987500 CRANKSHAFT
SOCKETUsed for rotating crankshaft.
TOOL NAME REMARKS
Compression gauge Used for measuring compression.
Tachometer (secondary pick-up type) Used for measuring idle speed.
Timing light Used for measuring ignition timing.ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-499817100
ST-499977100
ST-499977400
ST-499987500

ME(H4SO)-26
MECHANICAL
Idle Speed
3. Idle Speed
A: INSPECTION
1) Before checking idle speed, check the following:
(1) Ensure the air cleaner element is free from
clogging, ignition timing is correct, spark plugs
are in good condition, and the hoses are con-
nected 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) When using the Subaru Select Monitor, refer to
the following. TOOL, PREPARATION TOOL, General Descrip-
tion.>
(1) Insert the cartridge to Subaru Select Moni-
tor.
(2) Connect the Subaru Select Monitor to data
link connector.
(3) Turn the ignition switch to ON, and Subaru
Select Monitor switch to ON.
(4) Select the {Each System Check} in Main
Menu.
(5) Select the {Engine Control System} in Se-
lection Menu.
(6) Select the {Current Data Display & Save} in
Engine Control System Diagnosis.
(7) Select the {Data Display} in Data Display
Menu.
(8) Start the engine, and then read the engine
idle speed.
5) When using the tachometer (Secondary pick-up
type).
(1) Attach the pick-up clip to No. 1 cylinder
spark plug cord.(2) Start the engine, and then read the engine
idle speed.
NOTE:
 When using the OBD-II general scan tool, care-
fully read its operation manual.
 This ignition system provides simultaneous igni-
tion for #1 and #2 plugs. It must be noted that some
tachometers may register twice that of actual en-
gine speed.
6) 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 “N” or “P”
range]:
650
±100 rpm
7) Check the idle speed when loaded. (Turn the air
conditioning switch to “ON” and operate the com-
pressor for at least 1 minute before measurement.)
Idle speed [A/C “ON”, no load and gears in “N”
or “P” range]:
850
±100 rpm
NOTE:
Idle speed can not be adjusted manually, because
the idle speed is automatically adjusted.
If the specified idle speed can not be maintained,
refer to General On-board Diagnosis Table under
“Engine Control System”. Basic Diagnostics Procedure.>
ME-00325
ME-00193