2004 SUBARU FORESTER Service Repair Manual

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Page 1529 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4DOTC)-71
MECHANICAL
Camshaft
3) Camshaft oil seal installation: Apply grease to
new oil seal lips and press onto front end of cam-
shaft by using ST1 and ST2.
NOTE:
Use a new oil seal.
ST1 499587

Page 1530 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4DOTC)-72
MECHANICAL
Camshaft
5) Install the oil pipe.
Tightening torque:
30 N
⋅m (3.1 kgf-m, 22.1 ft-lb)
6) Connect the oil flow control solenoid valve con-
nector.
7) Install the spark plug co

Page 1531 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4DOTC)-73
MECHANICAL
Camshaft
C: INSPECTION
1) Measure the bend, and repair or replace if nec-
essary.
Limit:
0.020 mm (0.0008 in)
2) Check the journal for damage and wear. Re-
place if faulty.
3)

Page 1532 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4DOTC)-74
MECHANICAL
Camshaft
Limit:
2.0 L MODEL
Intake:
44.65 mm (1.758 in)
Exhaust:
44.65 mm (1.758 in)
2.5 L MODEL
Intake:
46.45 mm (1.829 in)
Exhaust:
46.65 mm (1.837 in)
Cam base circle diame

Page 1533 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4DOTC)-75
MECHANICAL
Cylinder Head Assembly
19.Cylinder Head Assembly
A: REMOVAL
1) Remove the V-belt. <Ref. to ME(H4DOTC)-52,
REMOVAL, V-belt.>
2) Remove the crank pulley. <Ref. to
ME(H4DOTC)-55,

ME(H4DOTC)-75
MECHANICAL
Cylinder Head Assembly
19.Cylinder Head Assembly
A: REMOVAL
1) Remove the V-belt. REMOVAL, V-belt.>
2) Remove the crank pulley. ME(H4DOTC)-55, REMOVAL, Crank Pulley.>
3) Remove the timing belt cover. ME(H4DOTC)-57, REMOVAL, Timing Belt Cover.>
4) Remove the timing belt assembly. ME(H4DOTC)-58, REMOVAL, Timing Belt Assem-
bly.>
5) Remove the cam sprocket. ME(H4DOTC)-67, REMOVAL, Cam Sprocket.>
6) Remove the intake manifold. FU(H4DOTC)-14, REMOVAL, Intake Manifold.>
7) Remove the bolt which installs the A/C compres-
sor bracket on cylinder head.
8) Remove the camshaft. 69, REMOVAL, Camshaft.>
9) Remove the cylinder head bolts in alphabetical
sequence shown in the figure.
Leave bolts (A) and (D) engaged by three or four
threads to prevent the cylinder head from falling.
10) While tapping the cylinder head with a plastic
hammer, separate it from cylinder block. Remove
the bolts (A) and (D) to remove cylinder head.11) Remove the cylinder head gasket.
NOTE:
Do not scratch the mating surface of cylinder head
and cylinder block.
12) Similarly, remove the cylinder head (RH).
B: INSTALLATION
1) Install the cylinder head and gaskets on cylinder
block.
NOTE:
Use new cylinder head gaskets.
Be careful not to scratch the mating surface of
cylinder head and cylinder block.
2) Tighten the cylinder head bolts.
(1) Apply a coat of engine oil to the washers and
bolt threads.
(2) Tighten all bolts to 29 N⋅m (3.0 kgf-m, 22 ft-
lb) in alphabetical sequence.
(3) Tighten all bolts to 69 N⋅m (7.0 kgf-m, 51 ft-
lb) in alphabetical sequence again.
(4) Back off all bolts by 180° first; back them off
by 180° again in reverse order of installation.
(5) Tighten all bolts to 49 N⋅m (5.0 kgf-m, 36 ft-
lb) in alphabetical sequence.
(6) Tighten all bolts 80 to 90° in alphabetical se-
quence.
(7) Tighten all bolts by 40 to 45° in alphabetical
sequence again.
NOTE:
Do not tighten the bolts by more than 45°.
(8) Further tighten all bolts (A) and (B) by 40 to
45°.
NOTE:
Ensure that the total “re-tightening angle” in the
previous two steps do not exceed 90°.
3) Install the camshaft. INSTALLATION, Camshaft.>
4) Install the A/C compressor bracket on cylinder
head.
5) Install the intake manifold. 17, INSTALLATION, Intake Manifold.>
6) Install the cam sprocket. 67, INSTALLATION, Cam Sprocket.>
ME-00122
(B)(C)
(D)
(E)
(F)(A)
ME-00122
(B)(C)
(D)
(E)
(F)(A)
ME-00123
(B)
(C)
(D)(E)
(F)(A)

Page 1534 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4DOTC)-76
MECHANICAL
Cylinder Head Assembly
7) Install the timing belt assembly. <Ref. to
ME(H4DOTC)-60, INSTALLATION, Timing Belt
Assembly.>
8) Install the timing belt cover. <Ref. to
ME(H4DOTC)-

Page 1535 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4DOTC)-77
MECHANICAL
Cylinder Head Assembly
D: ASSEMBLY
(1) Exhaust valve (5) Intake valve oil seal (9) Valve lifter
(2) Intake valve (6) Valve spring (10) Exhaust valve oil seal
(3) Cylinder head

Page 1536 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4DOTC)-78
MECHANICAL
Cylinder Head Assembly
1) Installation of valve spring and valve.
(1) Coat the stem of each valve with engine oil
and insert the valve into valve guide.
NOTE:
When inserting t

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