Engine Mechanical (SOHC): Adjustments Subaru Forester SG

ADJUSTMENT

Note. Adjustment of the valve clearance should be performed while engine is cold.

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1. Set the #1 cylinder piston to top dead center of compression stroke by rotating crankshaft pulley clockwise using ST. ST 499977100 CRANK PULLEY WRENCH NOTE: When arrow mark (A) on the camshaft sprocket (LH) comes exactly to the top, #1 cylinder piston is brought to the top dead center of compression stroke.
2. Adjust the #1 cylinder valve clearance. Loosen the valve rocker nut and screw. Place suitable thickness gauge. While noting the valve clearance, tighten the valve rocker adjust screw. When specified valve clearance is obtained, tighten the valve rocker nut. Tightening torque: 10 N.m (1.0 kgf-m, 7.2 ft-lb) CAUTION: Insert the thickness gauge in as horizontal a direction as possible with respect to the valve stem end face. Adjust the exhaust valve clearances while lifting up the vehicle. Valve clearance: Intake; 0.20+/-0.02 mm (0.0079+/-0.0008 in) Exhaust; 0.25+/-0.02 mm (0.0098+/-0.0008 in)
3. Ensure the valve clearances are within specifications.
4. Turn the crankshaft two complete rotations until #1 cylinder piston is again set to the top dead center on compression stroke.
5. Ensure the valve clearances are within specifications. If necessary, readjust the valve clearances.
6. Similar to adjustment procedures used for #1 cylinder, adjust the #2, #3 and #4 cylinder valve clearances. NOTE: Be sure to set the cylinder pistons to their respective top dead centers on compression stroke before adjusting valve clearances. To set the #3, #2 and #4 cylinder pistons to their top dead centers on compression stroke, turn the crankshaft pulley clockwise 90° at a time starting with arrow mark on camshaft sprocket (LH) facing up.

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1. Set the vehicle on lift arms.
2. Open the front hood fully, and then support with the hood stay.
3. Lower the fuel pressure. Refer to «OPERATION»(ref-200785-S18118591322005102300000) , Fuel.
4. Collect the refrigerant, and then remove the pressure hoses. Place and connect the attachment hose to refrigerant recycle system. Collect the refrigerant from A/C system. Disconnect the A/C pressure hoses from A/C compressor.
5. Remove the fuel filler cap.
6. Disconnect the ground cable from battery.
7. Remove the air intake duct and air cleaner case. Refer to «REMOVAL»(ref-200787-S34281602712005102300000) , Air Intake Duct and «REMOVAL»(ref-200787-S24445141242005102300000) , Air Cleaner Case.
8. Remove the under cover.
9. Remove the radiator from vehicle. Refer to «REMOVAL»(ref-200790-S09062525022005102300000) , Radiator.
10. Remove the air cleaner case stay. MT VEHICLES AT VEHICLES
11. Disconnect the following connectors and cables. Front oxygen (A/F) sensor connector Rear oxygen sensor connector Engine ground cable Engine harness connectors Generator connector, terminal and A/C compressor connector Accelerator cable (A) and cruise control cable (B) Pressure switch
12. Disconnect the following hoses. Brake booster vacuum hose Heater inlet outlet hose
13. Remove the power steering pump from bracket. Remove the resonator chamber. Loosen the lock bolt and slider bolt, and then remove the front side V-belt. Refer to «REMOVAL»(ref-200788-S33926247212005102300000) , V-belt. Remove the pipe with bracket. Remove the bolts which install power steering pump bracket. Remove the power steering tank from bracket by pulling it upward. Place the power steering pump on right side wheel apron.
14. Remove the front and center exhaust pipe. Refer to «REMOVAL»(ref-200789-S02976811952005102300000) , Front Exhaust Pipe.
15. Remove the nuts which hold lower side of transmission to engine.
16. Remove the nuts which install front cushion rubber onto front crossmember.
17. Separate the torque converter clutch from drive plate. (AT vehicles) Lower the vehicle. Remove the service hole plug. Remove the bolts which hold torque converter clutch to drive plate. Remove other bolts while rotating the engine using ST. ST 499977100 CRANK PULLEY WRENCH
18. Remove the pitching stopper.
19. Disconnect the fuel delivery hose (A), return hose (B) and evaporation hose (C). CAUTION: Disconnect the hose with its end wrapped with cloth to prevent fuel from splashing. Catch fuel from the hose into container.
20. Support the engine with a lifting device and wire ropes.
21. Support the transmission with a garage jack. CAUTION: Before moving the engine away from transmission, check to be sure no work has been overlooked. Doing this is very important in order to facilitate re-installation and because the transmission lowers under its own weight.
22. Separation of the engine and transmission. Remove the starter. Refer to «REMOVAL»(ref-167769-S39205696652004102100000) , Starter. Remove the bolts which hold upper side of transmission to engine.
23. Install the ST to torque converter clutch case. (AT vehicles) ST 498277200 STOPPER SET
24. Remove the engine from vehicle. Slightly raise the engine. Raise the transmission with garage jack. Move the engine horizontally until main shaft is withdrawn from clutch cover. Slowly move the engine away from engine compartment. NOTE: Be careful not to damage the adjacent parts or body panels with crank pulley, oil level gauge, etc.
25. Remove the front cushion rubbers.

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1. Install the front cushion rubbers. Tightening torque: 34 N.m (3.5 kgf-m, 25.3 ft-lb)
2. Install the engine onto transmission. Position the engine in engine compartment and align it with transmission. NOTE: Be careful not to damage the adjacent parts or body panels with crank pulley, oil level gauge, etc. Apply a small amount of grease to the spline of main shaft. (MT vehicles)
3. Tighten the bolts which hold upper side of transmission to engine. Tightening torque: 50 N.m (5.1 kgf-m, 36.9 ft-lb)
4. Remove the lifting device and wire ropes.
5. Remove the garage jack.
6. Install the pitching stopper. Tightening torque: T1: 50 N.m (5.1 kgf-m, 37 ft-lb) T2: 58 N.m (5.9 kgf-m, 43 ft-lb)
7. Remove the ST from torque converter clutch case. (AT vehicles) NOTE: Be careful not to drop the ST into torque converter clutch case when removing ST. ST 498277200 STOPPER SET
8. Install the starter. Refer to «INSTALLATION»(ref-167769-S00031971462004102100000) , Starter.
9. Install the torque converter clutch onto drive plate. (AT vehicles) Tighten the bolts which hold torque converter clutch to drive plate. Tighten other bolts while rotating the engine by using ST. NOTE: Be careful not to drop the bolts into torque converter clutch housing. ST 499977100 CRANK PULLEY WRENCH Tightening torque: 25 N.m (2.5 kgf-m, 18.1 ft-lb) Clog the plug onto service hole.
10. Install the power steering pump on bracket. Install the power steering tank on bracket. Install the power steering pump on bracket, and then tighten the bolts. Tightening torque: 20.1 N.m (2.05 kgf-m, 14.8 ft-lb) Tighten the bolts which install power steering pump bracket, and then install the spark plug cords. Connect the power steering switch connector. Install the front side V-belt, and adjust it. Refer to «INSTALLATION»(ref-200788-S14994437452005102300000) , V-belt. Install the resonator chamber. Tightening torque: 33 N.m (3.4 kgf-m, 24.6 ft-lb)
11. Tighten the nuts which hold lower side of transmission to engine. Tightening torque: 50 N.m (5.1 kgf-m, 36.9 ft-lb)
12. Tighten the nuts which install front cushion rubber onto crossmember. Tightening torque: 85 N.m (8.7 kgf-m, 63 ft-lb) NOTE: Make sure the front cushion rubber mounting bolts (A) and locator (B) are securely installed.
13. Install the front and center exhaust pipe. Refer to «INSTALLATION»(ref-200789-S17193731862005102300000) , Front Exhaust Pipe.
14. Connect the following hoses. Fuel delivery hose, return hose and evaporation hose Heater inlet and outlet hoses Brake booster vacuum hose
15. Connect the following connectors. Engine ground cables Tightening torque: 14 N.m (1.4 kgf-m, 10.1 ft-lb) Engine harness connectors Generator connector and terminal A/C compressor connectors Power steering pressure switch
16. Connect the following cables. Accelerator cable Cruise control cable (With cruise control)
17. Adjust each connected cable.
18. Install the air cleaner case stay. Tightening torque: 16 N.m (1.6 kgf-m, 11.6 ft-lb)
19. Install the A/C pressure hoses. Refer to «REMOVAL»(ref-200802-S16416673272005102300000) , Hose and Tube. NOTE: Use new O-rings. Tightening torque: 25 N.m (2.5 kgf-m, 18.1 ft-lb)
20. Install the radiator to vehicle. Refer to «INSTALLATION»(ref-200790-S41643596842005102300000) , Radiator.
21. Install the air intake duct and air cleaner case. Refer to «INSTALLATION»(ref-200787-S29216310462005102300000) , Air Intake Duct and «INSTALLATION»(ref-200787-S32054192432005102300000) , Air Cleaner Case.
22. Install the under cover.
23. Install battery in the vehicle, and then connect the cables.
24. Fill engine coolant. Refer to «REPLACEMENT»(ref-200790-S26176006012005102300000) , Engine Coolant.
25. Check the ATF level and correct if necessary. (AT vehicles) Refer to «INSPECTION»(ref-200793-S13406383872005102300000) , Automatic Transmission Fluid.
26. Charge the A/C system with refrigerant. Refer to «OPERATION»(ref-200802-S28881992342005102300000) , Refrigerant Charging Procedure.
27. Remove the front hood stay, and then close the front hood.
28. Take off the vehicle from lift arms.