2004 SUBARU FORESTER belt
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ME(H4SO)-51
MECHANICAL
Timing Belt
5) After ensuring that the marks on timing belt and
cam sprockets are aligned, remove the stopper pin
from belt tension adjuster.
6) Install the timing belt guide. (MT model)
(1) Temporarily tighten the remaining bolts.
(2) Check and adjust the clearance between
timing belt and timing belt guide by using thick-
ness gauge.
Clearance:
1.0
±0.5 mm (0.039±0.020 in)(3) Tighten the remaining bolts.
Tightening torque:
10 N
⋅m (1.0 kgf-m, 7.2 ft-lb)
7) Install the belt cover.
8) Install the crank pulley.
9) Install the V-belt.
C: INSPECTION
1. TIMING BELT
1) Check the timing belt teeth for breaks, cracks,
and wear. If any fault is found, replace the belt.
2) Check the condition of back side of belt; if any
crack is found, replace the belt.
CAUTION:
Be careful not to let oil, grease or coolant
contact the belt. Remove quickly and thorough-
ly if this happens.
Do not bend the timing belt sharply.
In radial diameter: h
60 mm (2.36 in) or more
ME-00245
ME-00230
ME-00246
ME-00247
ME-00248
h
Page 921 of 2870
ME(H4SO)-52
MECHANICAL
Timing Belt
2. AUTOMATIC BELT TENSION ADJUST-
ER
1) Visually check oil seals for leaks, and rod ends
for abnormal wear or scratches. If necessary, re-
place faulty parts.
2) Check that the adjuster rod does not move when
a pressure of 294 N (30 kgf, 66 lb) is applied to it.
This is to check adjuster rod stiffness.
3) If the adjuster rod is not stiff and moves freely
when applying 294 N (30 kgf, 66 lb), check it using
the following procedures:
(1) Slowly press the adjuster rod down to the
end surface of the cylinder. Repeat this motion 2
or 3 times.
(2) With the adjuster rod moved all the way up,
apply a pressure of 294 N (30 kgf, 66 lb) to it.
Check adjuster rod stiffness.
(3) If the adjuster rod is not stiff and moves
down, replace the automatic belt tension adjust-
er assembly with a new one.
CAUTION:
Always use a vertical type pressing tool to
move the adjuster rod down.
Do not use a lateral type vise.
Push the adjuster rod vertically.
Press-in the adjuster rod gradually taking
more than 3 minutes.
Do not allow press pressure to exceed 9,807
N (1,000 kgf, 2,205 lb).
Press the adjuster rod as far as the end sur-
face of the cylinder. Do not press the adjuster
rod into the cylinder. Doing so may damage the
cylinder.
4) Measure the extension of rod beyond the body.
If it is not within specifications, replace with a new
one.
Rod extension: H
5.7
±0.5 mm (0.224±0.020 in)
3. BELT TENSION PULLEY
1) Check the mating surfaces of timing belt and
contact point of adjuster rod for abnormal wear or
scratches. Replace the automatic belt tension ad-
juster assembly if faulty.2) Check the tension pulley for smooth rotation.
Replace if noise or excessive play is noted.
3) Check the tension pulley for grease leakage.
4. BELT IDLER
1) Check the belt idler for smooth rotation. Replace
if noise or excessive play is noted.
2) Check the belt outer contacting surfaces of idler
pulley for abnormal wear and scratches.
3) Check the belt idler for grease leakage.
ME-00249
H
Page 923 of 2870
MECHANICAL
ME(H4SO)
Page
1. General Description ....................................................................................2
2. Compression .............................................................................................25
3. Idle Speed .................................................................................................26
4. Ignition Timing ...........................................................................................27
5. Intake Manifold Vacuum............................................................................28
6. Engine Oil Pressure ..................................................................................29
7. Fuel Pressure ............................................................................................30
8. Valve Clearance ........................................................................................31
9. Engine Assembly ......................................................................................34
10. Engine Mounting .......................................................................................41
11. Preparation for Overhaul ...........................................................................42
12. V-belt .........................................................................................................43
13. Crank Pulley ..............................................................................................45
14. Timing Belt Cover......................................................................................47
15. Timing Belt ................................................................................................48
16. Cam Sprocket ...........................................................................................53
17. Crank Sprocket .........................................................................................55
18. Valve Rocker Assembly ............................................................................56
19. Camshaft ...................................................................................................58
20. Cylinder Head ...........................................................................................62
21. Cylinder Block ...........................................................................................69
22. Engine Trouble in General ........................................................................91
23. Engine Noise .............................................................................................96
Page 924 of 2870
ME(H4SO)-53
MECHANICAL
Cam Sprocket
16.Cam Sprocket
A: REMOVAL
1. REMOVAL
1) Remove the V-belt.
2) Remove the crank pulley.
3) Remove the belt cover.
4) Remove the timing belt assembly.
5) Remove the camshaft position sensor.
Sensor.>
6) Remove the cam sprocket No. 2. To lock the
camshaft, use ST.
ST 18231AA010 CAM SPROCKET WRENCH
NOTE:
Also the CAM SPROCKET WRENCH (499207100)
can be used.
7) Remove the cam sprocket No. 1. Use ST to lock
the camshaft.
ST 499207400 CAM SPROCKET WRENCH
B: INSTALLATION
1) Install the cam sprocket No. 1. To lock the cam-
shaft, use ST.
ST 499207400 CAM SPROCKET WRENCH
Tightening torque:
78 N
⋅m (8.0 kgf-m, 57.9 ft-lb)
NOTE:
Do not confuse the right and left side cam sprock-
ets during installation. The cam sprocket No. 2 is
identified by a projection used to monitor camshaft
position sensor.
2) Install the cam sprocket No. 2. Use ST to lock
camshaft.
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)
3) Install the camshaft position sensor.
Sensor.>
4) Install the timing belt assembly.
5) Install the belt cover.
6) Install the crank pulley.
7) Install the V-belt.
ME-00250
ST
ME-00251
ST
ME-00251
ST
ME-00250
ST
Page 926 of 2870
ME(H4SO)-55
MECHANICAL
Crank Sprocket
17.Crank Sprocket
A: REMOVAL
1) Remove the V-belt.
2) Remove the crank pulley.
3) Remove the belt cover.
4) Remove the timing belt assembly.
5) Remove the cam sprocket.
6) Remove the crank sprocket.
B: INSTALLATION
1) Install the crank sprocket.
2) Install the cam sprocket.
3) Install the timing belt assembly.
4) Install the belt cover.
5) Install the crank pulley.
6) Install the V-belt.
C: INSPECTION
1) Check the crank sprocket teeth for abnormal
wear and scratches.
2) Make sure there is no free play between crank
sprocket and key.
3) Check the crank sprocket notch for sensor for
damage and contamination of foreign matter.
ME-00252
ME-00252
Page 927 of 2870
ME(H4SO)-56
MECHANICAL
Valve Rocker Assembly
18.Valve Rocker Assembly
A: REMOVAL
1) Remove the V-belt.
2) Remove the crank pulley.
3) Remove the belt cover.
4) Remove the timing belt assembly.
5) Remove the cam sprocket.
6) Disconnect the PCV hose and remove rocker
cover.
7) Removal of valve rocker assembly
(1) Remove the bolts (a) through (h) in alpha-
betical sequence.
NOTE:
Leave two or three threads of bolts (g and h) en-
gaged to retain the valve rocker assembly.
(2) Remove the valve rocker assembly.
B: INSTALLATION
1) Installation of valve rocker assembly
(1) Temporarily tighten the bolts (a) through (d)
equally as shown in the figure.
NOTE:
Do not allow the valve rocker assembly to gouge
knock pins.
(2) Tighten the bolts (e) through (h) to specified
torque.
(3) Tighten the bolts (a) through (d) to specified
torque.Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
2) Adjust the valve clearances.
3) Install the rocker cover and connect PCV hose.
4) Install the cam sprocket.
5) Install the timing belt assembly.
6) Install the belt cover.
7) Install the crank pulley.
8) Install the V-belt.
C: DISASSEMBLY
1) Remove the bolts which secure rocker shaft.
2) Extract the rocker shaft. Remove the valve rock-
er arms, springs and shaft supports from rocker
shaft.
NOTE:
Arrange all removed parts in order so that they can
be installed in their original positions.
3) Remove the nut and adjusting screw from valve
rocker.
ME-00253(a) (b)
(c)(d)
(e)(f)
(g) (h)
ME-00254
ME-00255
(a)
(b)(c)
(d)(e)
(f)(g)
(h)
Page 929 of 2870
ME(H4SO)-58
MECHANICAL
Camshaft
19.Camshaft
A: REMOVAL
1) Remove the V-belt.
2) Remove the crank pulley.
3) Remove the belt cover.
4) Remove the timing belt assembly.
5) Remove the cam sprocket.
6) Remove the crank sprocket.
7) Remove the belt cover No. 2 (LH).
8) Remove the belt cover No. 2 (RH).
NOTE:
Do not damage or lose the seal rubber when re-
moving belt covers.
9) Remove the tensioner bracket.
10) Remove the camshaft position sensor support.
(LH side only)
11) Remove the oil level gauge guide. (LH side only)
12) Remove the valve rocker assembly.
bly.>
13) Remove the camshaft cap.(1) Remove the bolts (a) through (b) in alpha-
betical sequence.
(2) Equally loosen the bolts (c) through (j) all the
way in alphabetical sequence.
(3) Remove the bolts (k) through (p) in alpha-
betical sequence using ST.
ST 499497000 TORX PLUS
(4) Remove the camshaft cap.
14) Remove the camshaft.
15) Remove the oil seal.
ME-00258
ME-00259
ME-00260
(b)(a)
ME-00261
(c)(e)
(g)
(h)
(d) (f) (j)(i)
ME-00262
(k)
(o)
(n) (l) (p) (m)
ME-00263
Page 931 of 2870
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-
ical sequence.
Tightening torque:
10 N
⋅m (1.0 kgf-m, 7.2 ft-lb)
3) Apply a coat of grease to oil seal lips, and then
install the oil seal (A) on camshaft using ST1 and
ST2.
NOTE:
Use a new oil seal.
ST1 499597000 OIL SEAL GUIDE
ST2 499587500 OIL SEAL INSTALLER
4) Install the plug using ST.
ST 499587700 CAMSHAFT OIL SEAL IN-
STALLER
5) Adjust the valve clearance.
6) Install the rocker cover and connect PCV hose.7) Install the oil level gauge guide. (LH side only)
8) Install the camshaft position sensor support. (LH
side only)
9) Install the tensioner bracket.
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
10) Install the belt cover No. 2 (RH).
Tightening torque:
5 N
⋅m (0.5 kgf-m, 3.6 ft-lb)
11) Install the belt cover No. 2 (LH).
Tightening torque:
5 N
⋅m (0.5 kgf-m, 3.6 ft-lb)
12) Install the crank sprocket.
13) Install the cam sprocket.
14) Install the timing belt assembly.
15) Install the belt cover.
16) Install the crank pulley.
17) Install the V-belt.
ME-00270
(o)
(r)(q)
(v)(u)
(p)(s)
(t)
ME-00271
(x) (w)
ME-00272(A)
ST2
ST1
ME-00273
ME-00274