2004 SUBARU FORESTER Service Repair Manual

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Page 929 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4SO)-58
MECHANICAL
Camshaft
19.Camshaft
A: REMOVAL
1) Remove the V-belt. <Ref. to ME(H4SO)-43, IN-
STALLATION, V-belt.>
2) Remove the crank pulley. <Ref. to ME(H4SO)-
45, REMOVAL, Crank Pulley.>
3

Page 930 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4SO)-59
MECHANICAL
Camshaft
16) Remove the plug from rear side of camshaft.
CAUTION:
Do not remove the oil seal unless necessary.
Do not scratch the journal surface when re-
moving oil seal.
B

Page 931 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4SO)-60
MECHANICAL
Camshaft
(6) Tighten the bolts (o) through (v) in alphabet-
ical sequence.
Tightening torque:
10 N
⋅m (1.0 kgf-m, 7.2 ft-lb)
(7) Tighten the bolts (w) through (x) in alphabet-

Page 932 of 2870

SUBARU FORESTER 2004 Service Repair 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

Page 933 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4SO)-62
MECHANICAL
Cylinder Head
20.Cylinder Head
A: REMOVAL
1) Remove the V-belt. <Ref. to ME(H4SO)-43, RE-
MOVAL, V-belt.>
2) Remove the crank pulley. <Ref. to ME(H4SO)-
45, REMOVAL, Crank Pulle

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)

Page 934 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4SO)-63
MECHANICAL
Cylinder Head
7) Install the cam sprocket. <Ref. to ME(H4SO)-53,
INSTALLATION, Cam Sprocket.>
8) Install the timing belt assembly. <Ref. to
ME(H4SO)-49, INSTALLATION, Timing Bel

Page 935 of 2870

SUBARU FORESTER 2004 Service Repair Manual 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 engi

Page 936 of 2870

SUBARU FORESTER 2004 Service Repair Manual 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 bet

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

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