2004 SUBARU FORESTER Service Repair Manual

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Page 1537 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4DOTC)-79
MECHANICAL
Cylinder Head Assembly
3. VALVE GUIDE
1) Check the clearance between valve guide and
stem. The clearance can be checked by measuring
the outside diameter of valve stem and the

ME(H4DOTC)-79
MECHANICAL
Cylinder Head Assembly
3. VALVE GUIDE
1) Check the clearance between valve guide and
stem. The clearance can be checked by measuring
the outside diameter of valve stem and the inside
diameter of valve guide with outside and inside mi-
crometers respectively.
Clearance between the valve guide and valve
stem:
Standard
Intake
0.030 — 0.057 mm (0.0012 — 0.0022 in)
Exhaust
0.040 — 0.067 mm (0.0016 — 0.0026 in)
Limit
0.15 mm (0.0059 in)
2) If the clearance between valve guide and stem
exceeds the limit, replace the valve guide or valve
itself whichever shows greater amount of wear.
See the following procedure for valve guide re-
placement.
Valve guide inner diameter:
6.000 — 6.012 mm (0.2362 — 0.2367 in)
Valve stem outer diameters:
Intake
5.955 — 5.970 mm (0.2344 — 0.2350 in)
Exhaust
5.945 — 5.960 mm (0.2341 — 0.2346 in)
(1) Place the cylinder head on ST1 with the
combustion chamber upward so that valve
guides enter the holes in ST1.
(2) Insert the ST2 into valve guide and press it
down to remove the valve guide.
ST1 498267600 CYLINDER HEAD TABLE
ST2 499767200 VALVE GUIDE REMOVER
(3) Turn the cylinder head upside down and
place ST as shown in the figure.ST 18251AA020 VALVE GUIDE ADJUSTER
(4) Before installing a new valve guide, make
sure that neither scratches nor damages exist
on the inside surface of the valve guide holes in
cylinder head.
(5) Put a new valve guide, coated with sufficient
oil, in cylinder head, and insert ST1 into valve
guide. Press in until the valve guide upper end is
flush with the upper surface of ST2.
ST1 499767200 VALVE GUIDE REMOVER
ST2 18251AA020 VALVE GUIDE ADJUSTER
(6) Check the valve guide protrusion.
Valve guide protrusion: L
15.8 — 16.2 mm (0.622 — 0.638 in)
(7) Ream the inside of valve guide with ST.
Gently rotate the reamer clockwise while press-
ing it lightly into the valve guide, and return it
also rotating clockwise.
(8) After reaming, clean the valve guide to re-
move chips.
ST 499767400 VALVE GUIDE REAMER
CAUTION:
Apply engine oil to ST when reaming.
NOTE:
If the inner surface of the valve guide is torn, the
edge of the reamer should be slightly ground with
an oil stone.
If the inner surface of the valve guide becomes
lustrous and the reamer does not chip, use a new
reamer or remedy the reamer.
ME-00128
ST1
ST2ME-00757
ST
L
ME-00130
ST1
ST2

Page 1538 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4DOTC)-80
MECHANICAL
Cylinder Head Assembly
(9) Recheck the contact condition between
valve and valve seat after replacing the valve
guide.
4. INTAKE AND EXHAUST VALVE
1) Inspect the flange and st

Page 1539 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4DOTC)-81
MECHANICAL
Cylinder Head Assembly
6. INTAKE AND EXHAUST VALVE OIL
SEAL
1) Replace the oil seal with a new one in the follow-
ing condition, Refer to procedure 2) for replace-
ment proce

Page 1540 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4DOTC)-82
MECHANICAL
Cylinder Head Assembly
F: DISPOSAL
CAUTION:
Metallic sodium is enclosed in the exhaust
valve. Metallic sodium is extremely alkaline and
may produce severe chemical reactions

Page 1541 of 2870

SUBARU FORESTER 2004 Service Repair Manual FUJI HEAVY INDUSTRIES LTD. G8080GE3
2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
ENGINE SECTION 2
This service manual has been prepared
to provide SUBARU service personnel
with the necessary inf

Page 1542 of 2870

SUBARU FORESTER 2004 Service Repair Manual MECHANICAL
ME(H4DOTC)
Page
1. General Description ....................................................................................2
2. Compression .................................................

MECHANICAL
ME(H4DOTC)
Page
1. General Description ....................................................................................2
2. Compression .............................................................................................31
3. Idle Speed .................................................................................................32
4. Ignition Timing ...........................................................................................33
5. Intake Manifold Vacuum............................................................................34
6. Engine Oil Pressure ..................................................................................35
7. Fuel Pressure ............................................................................................36
8. Valve Clearance ........................................................................................37
9. Engine Assembly ......................................................................................41
10. Engine Mounting .......................................................................................50
11. Preparation for Overhaul ...........................................................................51
12. V-belt .........................................................................................................52
13. Crank Pulley ..............................................................................................55
14. Timing Belt Cover......................................................................................57
15. Timing Belt Assembly................................................................................58
16. Cam Sprocket ...........................................................................................67
17. Crank Sprocket .........................................................................................68
18. Camshaft ...................................................................................................69
19. Cylinder Head Assembly ...........................................................................76
20. Cylinder Block ...........................................................................................84
21. Intake and Exhaust Valve .......................................................................115
22. Piston ......................................................................................................116
23. Connecting Rod ......................................................................................117
24. Crankshaft ...............................................................................................118
25. Engine Trouble in General ......................................................................119
26. Engine Noise ...........................................................................................124

Page 1543 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4DOTC)-83
MECHANICAL
Cylinder Block
20.Cylinder Block
A: REMOVAL
NOTE:
Before conducting this procedure, drain the engine
oil completely if applicable.
1) Remove the intake manifold. <Ref. to
FU(H

Page 1544 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4DOTC)-84
MECHANICAL
Cylinder Block
NOTE:
Be careful not to scratch the mating surface of cyl-
inder block and oil pump.
ME-00138
(1) Service hole plug (3) Circlip (5) Service hole cover
(2) Gaske

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