2004 SUBARU FORESTER check engine

ME(H4DOTC)-45
MECHANICAL
Engine Assembly
26) Support the transmission with a garage jack.
NOTE:
Before moving the engine away from transmission,
check to be sure no work has been overlooked. Do-
ing this is very important in order to facilitate re-in-
stallation and because transmission lowers under
its own weight.
27) Separation of the engine and transmission.
(1) Remove the starter. REMOVAL, Starter.>
(2) Install the ST to torque converter clutch
case. (AT model)
ST 498277200 STOPPER SET
(3) Remove the bolts which hold the right upper
side of transmission to engine.
28) Remove the engine from vehicle.
(1) Slightly raise the engine.
(2) Raise the transmission with garage jack.
(3) Move the engine horizontally until the main-
shaft is withdrawn from clutch cover.
(4) Slowly move the engine away from engine
compartment.NOTE:
Be careful not to damage adjacent parts or body
panels with crank pulley, oil pressure gauge, etc.
29) Remove the front cushion rubbers.
B: INSTALLATION
1) Install the clutch release fork and bearing onto
transmission. (MT model)
(1) Remove the release bearing from clutch
cover with flat type screw driver.
(2) Install the release bearing on transmission.
(3) Install the release fork into release bearing
tab.
ME-00048
ST
ME-00049
ME-00050
(A) Release fork
(B) Release bearing
ME-00051
ME-00052
(A)
(B)

ME(H4DOTC)-56
MECHANICAL
Crank Pulley
Tightening torque:
180 N
⋅m (18.3 kgf-m, 132.7 ft-lb)
3) Confirm that the tightening angle of crank pulley
bolt is 65 degrees or more. If the tightening angle of
crank pulley bolt is less than 65 degrees, conduct
the following procedures.
CAUTION:
If the tightening angle of crank pulley bolt is
less than 65 degrees, the bolt should be dam-
aged. In this case, the bolt must be replaced.
(1) Replace the crank pulley bolts and clean
them.
Crank pulley bolt:
12369AA011
(2) Clean the crankshaft thread using an air
gun.
(3) Apply engine oil to the crank pulley bolt seat
and thread.
(4) Tighten the bolts temporarily with tightening
torque of 44 N⋅m (4.5 kgf-m, 33 ft-lb).
(5) Tighten the crank pulley bolts keeping them
in an angle between 65 degrees and 75 de-
grees.
NOTE:
Conduct the tightening procedures by confirming
the turning angle of crank pulley bolt referring to the
gauge indicated on timing belt cover.
4) Install the A/C belt tensioner.
5) Install the V-belt. STALLATION, V-belt.>
C: INSPECTION
1) Make sure the V-belt is not worn or otherwise
damaged.
2) Check the tension of the belt. ME(H4DOTC)-53, INSPECTION, V-belt.>
ME-00063ST
ME-00061

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 the valve into valve guide, use spe-
cial care not to damage the oil seal lip.
(2) Set the cylinder head on ST1.
(3) Install the valve spring and retainer using
ST2.
ST1 498267600 CYLINDER HEAD TABLE
ST2 499718000 VALVE SPRING REMOVER
NOTE:
Be sure to install the valve springs with their close-
coiled end facing the seat on cylinder head.
(4) Compress the valve spring, and then fit the
valve spring retainer key.
(5) After installing, tap the valve spring retainers
lightly with wooden hammer for better seating.
2) Apply oil to the surface of the valve lifter.
3) Install the valve lifter.
E: INSPECTION
1. CYLINDER HEAD
1) Make sure that no crack or other damage exists.
In addition to visual inspection, inspect the impor-
tant areas by means of red check.
2) Measure the warping of the cylinder head sur-
face that mates with crankcase by using a straight
edge (A) and thickness gauge (B).
If the warping exceeds 0.05 mm (0.0020 in), re-
grind the surface with a surface grinder.
Warping limit:
0.05 mm (0.0020 in)
Grinding limit:
0.3 mm (0.012 in)
Standard height of cylinder head:
127.5 mm (5.02 in)NOTE:
Uneven torque for the cylinder head nuts can
cause warping. When reassembling, pay special
attention to the torque so as to tighten evenly.
2. VALVE SEAT
Inspect the intake and exhaust valve seats, and
then correct the contact surfaces with valve seat
cutter if they are defective or when valve guides are
replaced.
Valve seat width: W
Intake
Standard
1.0 mm (0.039 in)
Limit
1.7 mm (0.067 in)
Exhaust
Standard
1.5 mm (0.059 in)
Limit
2.2 mm (0.087 in)
ME-00124
ST1
ST2
ME-00126
(A)
(B)
ME-00127
W

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

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 procedure.
 Lip portion is damaged.
 Spring is out of place.
 Valve and valve seat are reconditioned.
 Valve guide is replaced.
2) Place the cylinder head on ST1.
3) Press-fit oil seal to the specified dimension indi-
cated in the figure by using ST2.
ST1 498267600 CYLINDER HEAD TABLE
ST2 499718000 VALVE SPRING REMOVER
CAUTION:
 Apply engine oil to oil seal before press-fit.
 When press-fitting oil seal, do not use ham-
mer or strike in.
 Differentiate between the intake valve oil seal
and exhaust valve oil seal by noting their differ-
ence in color.
Color of rubber part:
Intake [Black]
Exhaust [Brown]
Color of spring part:
2.0 L model
Intake [Yellow]
Exhaust [Yellow]
2.5 L model
Intake [White]
Exhaust [White]
7. VALVE LIFTER
1) Visually check the valve lifter.
2) Measure the outer diameter of valve lifter.
Outer diameter:
34.959 — 34.975 mm (1.3763 — 1.3770 in)
3) Measure the inner diameter of valve lifter mating
part on cylinder head.
Inner diameter:
34.994 — 35.016 mm (1.3777 — 1.3786 in)
NOTE:
If difference between outer diameter of valve lifter
and inner diameter of valve lifter mating part is over
the limit, replace the cylinder head.
Standard:
0.019 — 0.057 mm (0.0007 — 0.0022 in)
Limit:
0.100 mm (0.0039 in)
ME-00133
ST2
ME-00134
ME-00135

ENGINE (DIAGNOSTIC)
EN(H4DOTC)
Page
1. Basic Diagnostics Procedure ......................................................................2
2. Check List for Interview ...............................................................................4
3. General Description ....................................................................................6
4. Electrical Component Location ...................................................................9
5. Engine Control Module (ECM) I/O Signal .................................................23
6. Engine Condition Data ..............................................................................27
7. Transmission Control Module (TCM) I/O Signal .......................................28
8. Data Link Connector .................................................................................29
9. OBD-II General Scan Tool ........................................................................30
10. Subaru Select Monitor...............................................................................33
11. Read Diagnostic Trouble Code (DTC) ......................................................39
12. Inspection Mode ........................................................................................40
13. Drive Cycle ................................................................................................45
14. Clear Memory Mode..................................................................................47
15. Compulsory Valve Operation Check Mode ...............................................48
16. Malfunction Indicator Light ........................................................................50
17. Diagnostics for Engine Starting Failure .....................................................59
18. List of Diagnostic Trouble Code (DTC) .....................................................74
19. Diagnostic Procedure with Diagnostic Trouble Code (DTC) .....................80
20. General Diagnostic Table........................................................................295

EN(H4DOTC)-2
ENGINE (DIAGNOSTIC)
Basic Diagnostics Procedure
1. Basic Diagnostics Procedure
A: PROCEDURE
1. ENGINE
Step Check Yes No
1 CHECK ENGINE START FAILURE.
1) Ask the customer when and how the trou-
ble occurred using the interview check list.
Check List for Interview.>
2) Start the engine.Does the engine start? Go to step 2.Inspection using
“Diagnostics for
Engine Start Fail-
ure”. EN(H4DOTC)-59,
Diagnostics for
Engine Starting
Fai lu r e.>
2 CHECK ILLUMINATION OF MALFUNCTION
INDICATOR LIGHT.Does malfunction indicator
light illuminate?Go to step 3.Inspection using
“General Diagnos-
tic Table”. EN(H4DOTC)-
295, General Diag-
nostic Table.>
3 CHECK INDICATION OF DTC ON DISPLAY.
1) Turn the ignition switch to OFF.
2) Connect the Subaru Select Monitor or the
OBD-II general scan tool to data link connec-
tor.
3) Turn the ignition switch to ON and the Sub-
aru Select Monitor or OBD-II general scan tool
switch to ON.
4) Read the DTC on the Subaru Select Moni-
tor or OBD-II general scan tool.Does the Subaru Select Moni-
tor or OBD-II general scan tool
indicate DTC?Record the
DTC.Repair the
trouble cause.
EN(H4DOTC)-74,
List of Diagnostic
Trouble Code
(DTC).> Go to
step 4.Repair the related
parts.
N
OTE:
If DTC is not shown
on display although
the malfunction in-
dicator light illumi-
nates, perform the
diagnostics for mal-
function indicator
light circuit or com-
bination meter.
EN(H4DOTC)-50,
Malfunction Indica-
tor Light.>
4 PERFORM THE DIAGNOSIS.
1) Perform clear memory mode. EN(H4DOTC)-47, Clear Memory Mode.>
2) Perform the “INSPECTION MODE”. to EN(H4DOTC)-40, Inspection Mode.>Does the Subaru Select Moni-
tor or OBD-II general scan tool
indicate DTC?Check on “Diag-
nostic Chart with
Diagnostic Trou-
ble Code (DTC)”
EN(H4DOTC)-80,
Diagnostic Proce-
dure with Diagnos-
tic Trouble Code
(DTC).>Finish the diagno-
sis.

EN(H4DOTC)-3
ENGINE (DIAGNOSTIC)
Basic Diagnostics Procedure
2. AUTOMATIC TRANSMISSION
When the DTC about automatic transmission is
shown on display, carry out the following basic
check.After that, carry out the replacement or re-
pair work.
1) ATF level check Transmission Fluid.>
2) Differential gear oil level check Differential Gear Oil.>
3) ATF leak check Transmission Fluid.>
4) Differential gear oil leak check Differential Gear Oil.>
5) Stall Test
6) Line Pressure Test sure Test.>
7) Transfer Clutch Pressure Test Transfer Clutch Pressure Test.>
8) Time Lag Test
9) Road Test
10) Shift characteristics Clutch Pressure Test.>