2004 SUBARU FORESTER belt

ME(H4DOTC)-103
MECHANICAL
Cylinder Block
NOTE:
 Be sure to use a new gasket.
 When installing the water pump, tighten the bolts
in two stages in alphabetical sequence as shown in
the figure.
33) Install the water by-pass pipe for heater.
34) Install the oil cooler.
Tightening torque:
T1: 45 N
⋅m (4.6 kgf-m, 33 ft-lb)
T2: 6.4 N
⋅m (0.65 kgf-m, 4.7 ft-lb)
T3: 54 N
⋅m (5.3 kgf-m, 39 ft-lb)
35) Install the oil filter using ST. LU(H4SO)-23, INSTALLATION, Engine Oil Filter.>
ST 498547000 OIL FILTER WRENCH36) Install the water by-pass pipe between oil cool-
er and water pump.
37) Install the water pipe.
CAUTION:
Always use a new O-ring.
38) Install the cylinder head assembly. ME(H4DOTC)-76, INSTALLATION, Cylinder Head
Assembly.>
39) Install the oil level gauge guide and tighten the
attaching bolt (LH side).
40) Install the rocker cover.
41) Install the crank sprocket. ME(H4DOTC)-68, INSTALLATION, Crank Sprock-
et.>
42) Install the cam sprocket. ME(H4DOTC)-67, INSTALLATION, Cam Sprock-
et.>
43) Install the timing belt assembly. ME(H4DOTC)-60, INSTALLATION, Timing Belt
Assembly.>
44) Install the timing belt cover. ME(H4DOTC)-57, INSTALLATION, Timing Belt
Cover.>
45) Install the crank pulley. 55, INSTALLATION, Crank Pulley.>
46) Install the generator and A/C compressor
brackets on cylinder head.
47) Install the V-belt. INSTALLATION, V-belt.>
48) Install the intake manifold. FU(H4DOTC 2.5)-17, INSTALLATION, Intake
Manifold.>
(A) Adapter (1)
(B) Adapter connector
(C) Adapter (2)
(D) Oil cooler
(E) Oil cooler connector
ME-00167
(B) (C) (D)(E)(F)
(A)
LU-00044
(A)
(B)
(C)
(D)
(E)
T1
T2
T3

ME(H4DOTC)-118
MECHANICAL
Engine Trouble in General
25.Engine Trouble in General
A: INSPECTION
NOTE:
“RANK” shown in the chart refers to the possibility of reason for the trouble in order (“Very often” to “Rarely”)
A — Very often
B — Sometimes
C — Rarely
TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK
1. Engine will not start.
1) Starter does not turn. Starter Defective battery-to-starter harness B
Defective starter switch C
Defective inhibitor switch or neutral switch C
Defective starter B
Battery Poor terminal connection A
Run-down battery A
Defective charging system B
Friction Seizure of crankshaft and connecting rod bearing C
Seized camshaft C
Seized or stuck piston and cylinder C
2) Initial combustion does
not occur. Starter Defective starter C
Engine control system A
Fuel line Defective fuel pump and relay A
Lack of or insufficient fuel B
Belt Defective (deterioration, etc.) B
Defective timing B
Compression Incorrect valve clearance C
Loosened spark plugs or defective gasket C
Loosened cylinder head bolts or defective gasket C
Improper valve seating C
Defective valve stem C
Worn or broken valve spring B
Worn or stuck piston rings, cylinder and piston C
Incorrect valve timing B
Improper engine oil (low viscosity) B
3) Initial combustion occurs. Engine control system A
Intake system Defective intake manifold gasket B
Defective throttle body gasket B
Fuel line Defective fuel pump and relay C
Clogged fuel line C
Lack of or insufficient fuel B
Belt Defective (deterioration, etc.) B
Defective timing B
Compression Incorrect valve clearance C
Loosened spark plugs or defective gasket C
Loosened cylinder head bolts or defective gasket C
Improper valve seating C
Defective valve stem C
Worn or broken valve spring B
Worn or stuck piston rings, cylinder and piston C
Incorrect valve timing B
Improper engine oil (low viscosity) B

ME(H4DOTC)-119
MECHANICAL
Engine Trouble in General
4) Engine stalls after initial
combustion. Engine control system A
Intake system Loosened or cracked intake duct B
Loosened or cracked PCV hose C
Loosened or cracked vacuum hose C
Defective intake manifold gasket B
Defective throttle body gasket B
Dirty air cleaner element C
Fuel line Clogged fuel line C
Lack of or insufficient fuel B
Belt Defective (deterioration, etc.) B
Defective timing B
Compression Incorrect valve clearance C
Loosened spark plugs or defective gasket C
Loosened cylinder head bolts or defective gasket C
Improper valve seating C
Defective valve stem C
Worn or broken valve spring B
Worn or stuck piston rings, cylinder and piston C
Incorrect valve timing B
Improper engine oil (low viscosity) B
2. Rough idle and engine
stallEngine control system A
Intake system Loosened or cracked intake duct A
Loosened or cracked PCV hose A
Loosened or cracked vacuum hose A
Defective intake manifold gasket B
Defective throttle body gasket B
Defective PCV valve C
Loosened oil filler cap B
Dirty air cleaner element C
Fuel line Defective fuel pump and relay C
Clogged fuel line C
Lack of or insufficient fuel B
Belt Defective timing C
Compression Incorrect valve clearance B
Loosened spark plugs or defective gasket B
Loosened cylinder head bolts or defective gasket B
Improper valve seating B
Defective valve stem C
Worn or broken valve spring B
Worn or stuck piston rings, cylinder and piston B
Incorrect valve timing A
Improper engine oil (low viscosity) B
Lubrication system Incorrect oil pressure B
Defective rocker cover gasket C
Cooling system Overheating C
Others Malfunction of evaporative emission control system A
Stuck or damaged throttle valve B
Accelerator cable out of adjustment C TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK

ME(H4DOTC)-120
MECHANICAL
Engine Trouble in General
3. Low output, hesitation and
poor accelerationEngine control system A
Intake system Loosened or cracked intake duct A
Loosened or cracked PCV hose A
Loosened or cracked vacuum hose B
Defective intake manifold gasket B
Defective throttle body gasket B
Defective PCV valve B
Loosened oil filler cap B
Dirty air cleaner element A
Fuel line Defective fuel pump and relay B
Clogged fuel line B
Lack of or insufficient fuel C
Belt Defective timing B
Compression Incorrect valve clearance B
Loosened spark plugs or defective gasket B
Loosened cylinder head bolts or defective gasket B
Improper valve seating B
Defective valve stem C
Worn or broken valve spring B
Worn or stuck piston rings, cylinder and piston C
Incorrect valve timing A
Improper engine oil (low viscosity) B
Lubrication system Incorrect oil pressure B
Cooling system Overheating C
Over cooling C
Others Malfunction of evaporative emission control system A
4. Surging Engine control system A
Intake system Loosened or cracked intake duct A
Loosened or cracked PCV hose A
Loosened or cracked vacuum hose A
Defective intake manifold gasket B
Defective throttle body gasket B
Defective PCV valve B
Loosened oil filler cap B
Dirty air cleaner element B
Fuel line Defective fuel pump and relay B
Clogged fuel line B
Lack of or insufficient fuel C
Belt Defective timing B
Compression Incorrect valve clearance B
Loosened spark plugs or defective gasket C
Loosened cylinder head bolts or defective gasket C
Improper valve seating C
Defective valve stem C
Worn or broken valve spring C
Worn or stuck piston rings, cylinder and piston C
Incorrect valve timing A
Improper engine oil (low viscosity) B
Cooling system Overheating B
Others Malfunction of evaporative emission control system C TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK

ME(H4DOTC)-121
MECHANICAL
Engine Trouble in General
5. Engine does not return to
idle.Engine control system A
Intake system Loosened or cracked vacuum hose A
Others Stuck or damaged throttle valve A
Accelerator cable out of adjustment (2.0 L model) B
6. Dieseling (Run-on) Engine control system A
Cooling system Overheating B
Others Malfunction of evaporative emission control system B
7. Afterburning in exhaust
systemEngine control system A
Intake system Loosened or cracked intake duct C
Loosened or cracked PCV hose C
Loosened or cracked vacuum hose B
Defective PCV valve B
Loosened oil filler cap C
Belt Defective timing B
Compression Incorrect valve clearance B
Loosened spark plugs or defective gasket C
Loosened cylinder head bolts or defective gasket C
Improper valve seating B
Defective valve stem C
Worn or broken valve spring C
Worn or stuck piston rings, cylinder and piston C
Incorrect valve timing A
Lubrication system Incorrect oil pressure C
Cooling system Over cooling C
Others Malfunction of evaporative emission control system C
8. Knocking Engine control system A
Intake system Loosened oil filler cap B
Belt Defective timing B
Compression Incorrect valve clearance C
Incorrect valve timing B
Cooling system Overheating A
9. Excessive engine oil con-
sumptionIntake system Loosened or cracked PCV hose A
Defective PCV valve B
Loosened oil filler cap C
Compression Defective valve stem A
Worn or stuck piston rings, cylinder and piston A
Lubrication system Loosened oil pump attaching bolts and defective gas-
ketB
Defective oil filter o-ring B
Defective crankshaft oil seal B
Defective rocker cover gasket B
Loosened oil drain plug or defective gasket B
Loosened oil pan fitting bolts or defective oil pan B TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK

ME(H4DOTC)-122
MECHANICAL
Engine Trouble in General
10. Excessive fuel consump-
tionEngine control system A
Intake system Dirty air cleaner element A
Belt Defective timing B
Compression Incorrect valve clearance B
Loosened spark plugs or defective gasket C
Loosened cylinder head bolts or defective gasket C
Improper valve seating B
Defective valve stem C
Worn or broken valve spring C
Worn or stuck piston rings, cylinder and piston B
Incorrect valve timing B
Lubrication system Incorrect oil pressure C
Cooling system Over cooling C
Others Accelerator cable out of adjustment (2.0 L model) B TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK

ME(H4DOTC)-123
MECHANICAL
Engine Noise
26.Engine Noise
A: INSPECTION
NOTE*:
When disconnecting the fuel injector connector, Malfunction Indicator Light illuminates and DTC is stored in
ECM memory.
Therefore, carry out the CLEAR MEMORY MODE Mode.> and INSPECTION MODE after con-
necting the fuel injector connector.
Type of sound Condition Possible cause
Regular clicking soundSound increases as engine
speed increases. Valve mechanism is defective.
 Incorrect valve clearance
 Worn valve rocker
 Worn camshaft
 Broken valve spring
Heavy and dull clankOil pressure is low. Worn crankshaft main bearing
 Worn connecting rod bearing (big end)
Oil pressure is normal. Loose flywheel mounting bolts
 Damaged engine mounting
High-pitched clank (Spark
knock)Sound is noticeable when
accelerating with an overload. Ignition timing advanced
 Accumulation of carbon inside combustion chamber
 Wrong heat range of spark plug
 Improper octane number of gasoline
Clank when engine speed is
medium (1,000 to 2,000 rpm).Sound is reduced when fuel
injector connector of noisy cyl-
inder is disconnected.
(NOTE*) Worn crankshaft main bearing
 Worn bearing at crankshaft end of connecting rod
Knocking sound when engine
is operating under idling speed
and engine is warmSound is reduced when fuel
injector connector of noisy cyl-
inder is disconnected.
(NOTE*) Worn cylinder liner and piston ring
 Broken or stuck piston ring
 Worn piston pin and hole at piston end of connecting rod
Sound is not reduced if each
fuel injector connector is dis-
connected in turn. (NOTE*) Unusually worn valve lifter
 Worn cam gear
 Worn camshaft journal bore in crankcase
Squeaky sound —  Insufficient generator lubrication
Rubbing sound —  Defective generator brush and rotor contact
Gear scream when starting
engine— Defective ignition starter switch
 Worn gear and starter pinion
Sound like polishing glass with
a dry cloth— Loose drive belt
 Defective water pump shaft
Hissing sound — Loss of compression
 Air leakage in air intake system, hoses, connections or mani-
folds
Timing belt noise — Loose timing belt
 Belt contacting case/adjacent part
Valve tappet noise —  Incorrect valve clearance

EN(H4DOTC)-80
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
19.Diagnostic Procedure with Diagnostic Trouble Code (DTC)
A: DTC P0011 “A” CAMSHAFT POSITION - TIMING OVER - ADVANCED OR
SYSTEM PERFORMANCE (BANK 1)
DTC DETECTING CONDITION:
Detect as soon as the malfunction occurs.
TROUBLE SYMPTOM:
 Engine stalls.
 Erroneous idling
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode ERATION, Clear Memory Mode.> and Inspection Mode .
Step Check Yes No
1 CHECK DTC ON DISPLAY.Is any other DTC displayed? Inspect the rele-
vant DTC using
“List of Diagnostic
Trouble Code
(DTC)”. EN(H4DOTC)-74,
List of Diagnostic
Trouble Code
(DTC).>Go to step 2.
2 CHECK CURRENT DATA.
1) Start the engine and idle it.
2) Check the AVCS system operating angle
and oil flow control solenoid valve duty output
using Subaru Select Monitor or OBD-II general
scan tool.
N
OTE:
 Subaru Select Monitor
For detailed operation procedure, refer to
“READ CURRENT DATA SHOWN ON DIS-
PLAY FOR ENGINE”. 33, Subaru Select Monitor.>
 OBD-II general scan tool
For detailed operation procedures, refer to the
OBD-II General Scan Tool Operation Manual.Is the AVCS system operating
angle approx. 0 degree and oil
flow control solenoid valve duty
output approx. 10%?A temporary poor
malfunction. Per-
for m the following
to clean oil routing.
Replace the
engine oil, and
then idle the
engine for 5 min-
utes and replace
the oil filter and
engine oil.Check the follow-
ing and repair or
replace it if neces-
sary.
 Oil pipe (clog-
ging)
 Oil flow con-
trol solenoid
valve (clogging
or dirt of oil
routing, spring
setting, clog-
ging of valve)
 Intake cam-
shaft (dirt, dam-
age of
camshaft)
 Timing belt
(alignment of
timing mark)