Engine Mechanical (H4SO): Diagnosis Subaru Forester SG рестайлинг

INSPECTION

Scheme 102

1. After warming-up the engine, turn the ignition switch to OFF.
2. Make sure that the battery is fully charged.
3. Release the fuel pressure. RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel. >
4. Remove all the spark plugs. REMOVAL, Spark Plug. >
5. Fully open the throttle valve.
6. Check the starter motor for satisfactory performance and operation.
7. Hold the compression gauge tightly against the spark plug hole. NOTE: When using a screw-in type compression gauge, the screw (put into cylinder head spark plug hole) should be less than 18 mm (0.71 in) long.
8. Crank the engine by means of the starter motor, and read the maximum value on the gauge when the pointer is steady. see scheme 8: Checking Compression
9. Perform at least two measurements per cylinder, and make sure that the values are correct. Compression (350 rpm and fully open throttle): Standard: 1,275 kPa (13.0 kgf/cm 2, 185 psi) Service limit: 1,020 kPa (10.4 kgf/cm 2, 148 psi) Difference between cylinders: 49 kPa (0.5 kgf/cm 2, 7 psi), or less

Scheme 103

1. Before checking the idle speed, check the following item: Check the air cleaner element is free from clogging, ignition timing is correct, spark plugs are in good condition, and hoses are connected properly. Check the malfunction indicator light does not illuminate.
2. Warm-up the engine.
3. Stop the engine, and turn the ignition switch to OFF.
4. Insert the cartridge to Subaru Select Monitor.
5. Connect the Subaru Select Monitor to data link connector. see scheme 9: Locating Data Link Connector
6. Turn the ignition switch to ON and Subaru Select Monitor switch to ON.
7. Select {Each System Check} in Main Menu.
8. Select {Engine Control System} in Selection Menu.
9. Select {Current Data Display & Save} in Engine Control System Diagnosis.
10. Select {Data Display} in Data Display Menu.
11. Start the engine, and read the engine idle speed. NOTE: The ignition system ignites #1 and #2 plugs simultaneously. The value of the actual engine speed x2 is recorded in the tacometer. Be careful.
12. Check the idle speed when no-loaded. (Headlight, heater fan, rear defroster, radiator fan, A/C and etc. are OFF) Idle speed [No load and gears in "N" or "P" range]: 650±100 rpm (MT model) 700±100 rpm (AT model)
13. Check the idle speed when loaded. (Turn the A/C switch to "ON" and operate the compressor for at least one minute before measurement.) Idle speed [A/C "ON" and gears in "N" or "P" range]: 850±100 rpm NOTE: Idle speed cannot be adjusted manually, because the idle speed is automatically adjusted. If the prescribed idle speed cannot be maintained, refer to General On-board Diagnosis Table under "Engine Control System". BASIC DIAGNOSTIC PROCEDURE. >

1. Before checking the ignition timing, check the following item: Check the air cleaner element is free from clogging, spark plugs are in good condition, and hoses are connected properly. Check the malfunction indicator light does not illuminate.
2. Warm-up the engine.
3. Stop the engine, and turn the ignition switch to OFF.
4. Insert the cartridge to Subaru Select Monitor.
5. Connect the Subaru Select Monitor to data link connector.
6. Turn the ignition switch to ON and Subaru Select Monitor to ON.
7. Select {Each System Check} in Main Menu.
8. Select {Engine Control System} in Selection Menu.
9. Select {Current Data Display & Save} in Engine Control System Diagnosis.
10. Select {Data Display} in Data Display Menu.
11. Start the engine and check the ignition timing at idle speed. Ignition timing [BTDC/rpm]: 10°±8°/650 (MT model) 15°±8°/700 (AT model) If the timing is not correct, check the ignition control system. Refer to "Engine Control System". BASIC DIAGNOSTIC PROCEDURE . >

1. Warm-up the engine.
2. Disconnect the brake vacuum hose from intake manifold, and then install the vacuum gauge.
3. Keep the engine at idle speed and read the vacuum gauge indication. By observing the gauge needle movement, internal condition of the engine can be diagnosed as described below.

Scheme 104

Vacuum pressure (at idling, A/C "OFF")

Less than -60.0 kPa (-450 mmHg, -17.72 inHg)

DIAGNOSIS OF ENGINE CONDITION BY MEASUREMENT OF INTAKE MANIFOLD VACUUM

Scheme 105

Scheme 106

1. Remove the oil pressure switch. REMOVAL, Oil Pressure Switch. >
2. Connect the oil pressure gauge to cylinder block.
3. Connect the ground cable to battery. see scheme 11: Connecting Battery Ground Cable
4. Start the engine, and measure the oil pressure. see scheme 12: Checking Engine Oil Pressure Oil pressure: Standard: 98 kPa (1.0 kg/cm 2, 14 psi) or more at 600 rpm 294 kPa (3.0 kg/cm 2, 43 psi) or more at 5,000 rpm CAUTION: If the oil pressure is out of standard values, check oil pump, oil filter and lubrication line. INSPECTION, Engine Lubrication System Trouble in General. > If the oil pressure warning light is turned ON and oil pressure is in specified range, replace the oil pressure switch. INSPECTION, Engine Lubrication System Trouble in General. > NOTE: Standard value is based on an engine oil temperature of 80°C (176°F).
5. After measuring the oil pressure, install the oil pressure switch. INSTALLATION, Oil Pressure Switch. > Tightening torque: 25 N.m (2.5 kgf-m, 18.1 ft-lb)

Scheme 107

Scheme 108

1. Release the fuel pressure. RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel. >
2. Disconnect the fuel delivery hose from fuel damper, and connect fuel pressure gauge. see scheme 13: Checking Fuel Pressure
3. Connect the connector of fuel pump relay. see scheme 14: Identifying Fuel Pump Relay Connector
4. Start the engine.
5. Measure the fuel pressure after warming up the engine. Fuel pressure: Standard: 339.5 - 360.5 kPa (3.5 - 3.7 kg/cm 2, 49 - 52 psi) NOTE: The fuel pressure gauge registers 10 to 20 kPa (0.1 to 0.2 kg/cm 2, 1 to 3 psi) higher than standard values during high-altitude operations.

Scheme 109

Scheme 110

Scheme 111

1. Set the vehicle on a lift.
2. Lift-up the vehicle.
3. Remove the under cover.
4. Lower the vehicle.
5. Disconnect the ground cable from battery. see scheme 15: Disconnecting Battery Ground Cable
6. Remove the timing belt cover (LH). see scheme 16: Identifying Timing Belt Cover (LH)
7. Remove the fuel injector. REMOVAL, Fuel Injector. >
8. When inspecting #1 and #3 cylinders: Disconnect the spark plug cords from spark plugs RH side. RH SIDE, REMOVAL, Spark Plug. > Disconnect the PCV hose from rocker cover (RH). Remove the bolts, then remove the rocker cover (RH).
9. When inspecting #2 and #4 cylinders: Disconnect the spark plug cords from spark plugs (LH side). LH SIDE, REMOVAL, Spark Plug. > Disconnect the PCV hose from rocker cover (LH). Remove the bolts, then remove the rocker cover (LH).
10. Set #1 cylinder piston to top dead center of compression stroke by rotating the crank pulley clockwise using the socket wrench. NOTE: When the arrow mark (A) on cam sprocket (LH) comes exactly to the top, #1 cylinder piston is brought to the top dead center of compression stroke. see scheme 17: Identifying Arrow Mark On Cam Sprocket
11. Measure #1 cylinder valve clearance by using thickness gauge. CAUTION: Insert the thickness gauge (A) in as horizontally as possible with respect to the valve stem end face. Measure the exhaust valve clearance while lifting-up the vehicle. Valve clearance (standard): Intake 0.20±0.04 mm (0.0079 ± 0.0016 in) Exhaust 0.25±0.04 mm (0.0098 ± 0.0016 in) see scheme 18: Measuring Exhaust Valve Clearance
12. If necessary, adjust the valve clearance. ADJUSTMENT, VALVE CLEARANCE. >
13. Measure the valve clearance in #3, #2 and #4 cylinder in the same measurement procedure as #1 cylinder. NOTE: Be sure to set the cylinder pistons to their respective top dead centers on compression stroke before measuring valve clearances. By rotating the crank pulley clockwise every 180° from the state that #1 cylinder piston is on the top dead center of compression stroke, #3, #2 and #4 cylinder pistons come to the top dead center of compression stroke in this order.
14. After inspection, install the related parts in the reverse order of removal.

1. Check that pipes, hoses, connectors and clamps are installed firmly.
2. Check the engine coolant and ATF are at specified levels.
3. Start the engine and check for exhaust gas, engine coolant, leaks of fuel, etc. Also check for noise and vibrations.

Make sure that no crack or other damages do not exist.

Scheme 112

1. After removing the engine from body, secure it to ST in the following procedure. ST1 498457000 ENGINE STAND ADAPTER RH ST2 498457100 ENGINE STAND ADAPTER LH ST3 499817100 ENGINE STAND see scheme 53: Identifying Engine Stand Adapters
2. In this article the procedures described under each index are all connected and stated in order. The procedure for overhauling of the engine will be completed when you go through all steps in the process. Therefore, in this article, to conduct the particular procedure within the flow of a information, you need to go back and conduct the procedure described previously in order to do that particular procedure.

1. Make sure the V-belt is not worn or otherwise damaged.
2. Check the tension of the belt. INSPECTION, V-BELT. >

Scheme 113

1. Remove the V-belts. REMOVAL, V-BELT. >
2. Remove the crank pulley. REMOVAL, CRANK PULLEY. >
3. Remove the timing belt cover (LH).
4. Remove the front timing belt cover. see scheme 65: Identifying Timing Belt Cover And Front Timing Belt Cover

Scheme 114

1. Install the front timing belt cover. Tightening torque: 5 N.m (0.5 kgf-m, 3.6 ft-lb)
2. Install the timing belt cover (LH). Tightening torque: 5 N.m (0.5 kgf-m, 3.6 ft-lb) see scheme 66: Identifying Timing Belt Cover And Front Timing Belt Cover
3. Install the crank pulley. INSTALLATION, CRANK PULLEY. >
4. Install the V-belts. INSTALLATION, V-BELT. >

Check the cover for damage.

Scheme 115

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Scheme 119

Scheme 120

Scheme 121

1. Remove the V-belts. REMOVAL, V-BELT. >
2. Remove the crank pulley. REMOVAL, CRANK PULLEY. >
3. Remove the timing belt cover. REMOVAL, TIMING BELT COVER. >
4. Remove the timing belt guide. (MT model) see scheme 67: Locating Timing Belt Guide Bolts (MT Model)
5. If the alignment mark or arrow mark (which indicates rotation direction) on timing belt fade away, put new marks before removing the timing belt as shown in procedures below. Use the ST to turn crankshaft. Align the mark (a) of sprocket to the cylinder block notch (b), and then ensure the right side cam sprocket mark (c), cam cap and cylinder head matching surface (d) or left side cam sprocket mark (e), timing belt cover notch (f) are properly adjusted. ST 499987500 CRANKSHAFT SOCKET see scheme 68: Turning Crankshaft Using Crankshaft Socket ST499987500 see scheme 69: Identifying Aligning Mark Of Sprocket Using white paint, put an alignment mark or an arrow mark on timing belts in relation to the crank sprocket and cam sprockets. see scheme 70: Putting Alignment Marks On Timing Belt Specified data: Z 1: Length of 46.8-teeth Z 2: Length of 43.7-teeth see scheme 71: Identifying Drive Belt Length
6. Remove the belt idler (No. 2).
7. Remove the belt idler No. 2. see scheme 72: Locating Belt Idler
8. Remove the timing belt. see scheme 73: Identifying Timing Belt

Scheme 122

Scheme 123

1. Remove the belt idler (No. 1). see scheme 74: Identifying Belt Idler
2. Remove the automatic belt tension adjuster assembly. see scheme 75: Locating Automatic Belt Tension Adjuster Assembly

Scheme 124

Scheme 125

Scheme 126

1. Preparation for installation of automatic belt tension adjuster assembly. CAUTION: Always use a vertical type pressing tool to move the adjuster rod down. Do not use a lateral type vise. Push the adjuster rod vertically. Press-in the push adjuster rod gradually taking more than three minutes. Do not allow press pressure to exceed 9,807 N (1,000 kgf, 2,205 lb). Press the adjuster rod as far as the end surface of the cylinder. Do not press the adjuster rod into cylinder. Doing so may damage the cylinder. Do not release the press pressure until stopper pin is completely inserted. Attach the automatic belt tension adjuster assembly to vertical pressing tool. Slowly move the adjuster rod down with a pressure of more than 294 N (30 kgf, 66 lb) until the adjuster rod is aligned with the stopper pin hole in the cylinder. see scheme 76: Moving Adjuster Rod Down With a 2 mm (0.08 in) dia. stopper pin or a 2 mm (0.08 in) (nominal) dia. hex wrench inserted into the stopper pin hole in cylinder, secure the adjuster rod. see scheme 77: Inserting Hex Wrench Into Stopper Pin Hole In Cylinder
2. Install the automatic belt tension adjuster assembly. Tightening torque: 39 N.m (4.0 kgf-m, 28.9 ft-lb) (Scheme 112): Identifying Automatic Belt Tension Adjuster Assembly
3. Install the belt idler (No. 1). Tightening torque: 39 N.m (4.0 kgf-m, 28.9 ft-lb) see scheme 79: Identifying Belt Idler

Scheme 127

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Scheme 129

Scheme 130

Scheme 131

Scheme 132

1. Prepare for installation of automatic belt tension adjuster assembly. AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER, INSTALLATION, TIMING BELT. >
2. Installation of timing belt: Turn the camshaft sprocket No. 2 using ST1, and turn the camshaft sprocket No. 1 using ST2 so that their alignment marks (A) come to top positions. ST1 18231AA010 CAM SPROCKET WRENCH NOTE: CAM SPROCKET WRENCH (499207100) can also be used. ST2 499207400 CAM SPROCKET WRENCH see scheme 80: Identifying Alignment Marks On Cam Sprocket While aligning the alignment mark (B) on timing belt with the mark (A) on sprockets, position the timing belt properly. see scheme 81: Identifying Aligning Alignment Marks On Timing Belt
3. Install the belt idler (No. 2). Tightening torque: 39 N.m (4.0 kgf-m, 28.9 ft-lb)
4. After ensuring the marks on timing belt and camshaft sprockets are aligned, remove the stopper pin from belt tension adjuster. see scheme 82: Removing Stopper Pin From Belt Tension Adjuster
5. Install the timing belt guide. (MT model) Temporarily tighten the bolts mounting the timing belt guide. see scheme 83: Locating Timing Belt Guide Mounting Bolts Check and adjust the clearance between timing belt and timing belt guide by using thickness gauge. Clearance: 1.0±0.5 mm (0.039 ± 0.020 in) see scheme 84: Identifying Clearance Between Timing Belt And Timing Belt Guide Tighten the bolts mounting the timing belt guide. Tightening torque: 9.75 N.m (1.0 kgf-m, 7.2 ft-lb) see scheme 85: Tightening Timing Belt Guide Mounting Bolts
6. Install the timing belt cover. INSTALLATION, TIMING BELT COVER. >
7. Install the crank pulley. INSTALLATION, CRANK PULLEY. >
8. Install the V-belts. INSTALLATION, V-BELT. >

Scheme 133

1. Check the timing belt teeth for breaks, cracks or wear. If any fault is found, replace the belt.
2. Check the condition of the backside of belt. If cracks are found, replace the belt. CAUTION: Be careful not to let oil, grease or coolant contact the belt. Remove quickly and thoroughly if this happens. Do not bend the timing belt sharply. In radial diameter h: 60 mm (2.36 in) or more see scheme 86: Identifying Timing Belt Radial Diameter

Scheme 134

1. Visually check the oil seals for leaks, and rod ends for abnormal wear and scratches. If necessary, replace the automatic belt tension adjuster assembly. NOTE: Slight traces of oil at rod's oil seal does not indicate a problem.
2. Check that the adjuster rod does not move when a pressure of 294 N (30 kgf, 66 lb) is applied to it. This is to check adjuster rod stiffness.
3. If the adjuster rod is not stiff and moves freely when applying 294 N (30 kgf, 66 lb), check it using the following procedures: Slowly press the adjuster rod down to the end surface of cylinder. Repeat this operation two to three times. With the adjuster rod moved all the way up, apply a pressure of 294 N (30 kgf, 66 lb) to it. Check the adjuster rod stiffness. If the adjuster rod is not stiff and moves down, replace the automatic belt tension adjuster assembly with a new one. CAUTION: Always use a vertical type pressing tool to move the adjuster rod down. Do not use a lateral type vise. Push the adjuster rod vertically. Press the adjuster rod gradually taking more than three minutes. Do not allow press pressure to exceed 9,807 N (1,000 kgf, 2,205 1b). Press the adjuster rod as far as the end surface of the cylinder. Do not press the adjuster rod into cylinder. Doing so may damage the cylinder.
4. Measure the amount of rod protrusion beyond the body. If it is not within specified range, replace with new one. Amount of rod protrusion H: 5.2 - 6.2 mm (0.204 - 0.244 in) see scheme 87: Identifying Rod Protrusion

1. Check the cam sprocket teeth for abnormal wear and scratches.
2. Make sure there is no free play between cam sprocket and key.
3. Check the cam sprocket protrusion used for sensor for damage and contamination of foreign matter.

Scheme 135

1. Remove the V-belts. REMOVAL, V-BELT. >
2. Remove the crank pulley. REMOVAL, CRANK PULLEY. >
3. Remove the timing belt cover. REMOVAL, TIMING BELT COVER. >
4. Remove the timing belt. REMOVAL, TIMING BELT. >
5. Remove the crank sprocket. (Scheme 115): Identifying Crank Sprocket

1. Check the crank sprocket teeth for abnormal wear and scratches.
2. Make sure there is no free play between crank sprocket and key.
3. Check the crank sprocket protrusion used for sensor for damage and contamination of foreign matter.

Scheme 136

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Scheme 139

1. Remove the V-belts. REMOVAL, V-BELT. >
2. Remove the crank pulley. REMOVAL, CRANK PULLEY. >
3. Remove the timing belt cover. REMOVAL, TIMING BELT COVER. >
4. Remove the timing belt. REMOVAL, TIMING BELT. >
5. Remove the cam sprocket. REMOVAL, CAM SPROCKET. >
6. Disconnect the PCV hose and remove the rocker cover.
7. Remove the valve rocker assembly. Use the ST to rotate the spring stopper in the direction of the arrow to remove it from adjuster pin. ST 18258AA000 SPRING INSTALLER (Scheme 117): Identifying Spring Installer ST 18258AA000 (Scheme 118): Rotating Spring Stopper Remove the bolts (a) through (j) in alphabetical sequence. NOTE: Leave two or three threads of bolts (i) and (j) engaged in order to retain the valve rocker assembly. (Scheme 119): Identifying Removal Sequence Of Valve Rocker Assembly Bolts Remove the valve rocker assembly. NOTE: Set the ST in the position shown in the drawing to remove the intake valve rocker assembly. ST 18354AA000 VALVE ROCKER HOLDER (Scheme 120): Identifying Valve Rocker Holder ST 18354AA000

Scheme 140

Scheme 141

Scheme 142

Scheme 143

1. Install the valve rocker assembly. Temporarily tighten the bolts equally in alphabetical order as shown in the figure. NOTE: Do not temporarily tighten the bolts (i) and (j). Set the ST in the position shown in the drawing to mount the intake valve rocker assembly. ST 18354AA000 VALVE ROCKER HOLDER (Scheme 121): Identifying Valve Rocker Holder ST 18354AA000 Tighten the bolts (a) through (h) to specified torque. Tightening torque: 25 N.m (2.5 kgf-m, 18.1 ft-lb) Tighten the bolts (i) through (j) to specified torque. Tightening torque: 8 N.m (0.8 kgf-m, 5.9 ft-lb) (Scheme 122): Identifying Tightening Sequence Of Valve Rocker Assembly Bolts Use the ST to rotate the spring stopper in the direction of the arrow to fasten the adjuster pin. ST 18258AA000 SPRING INSTALLER (Scheme 123): Identifying Spring Installer ST 18258AA000 (Scheme 124): Rotating Spring Stopper
2. Adjust the valve clearance. ADJUSTMENT, VALVE CLEARANCE. >
3. Install the rocker cover and rocker cover gasket, and then connect PCV hose. NOTE: Use a new rocker cover gasket. Tighten the bolts in two stages in alphabetical sequence as shown in figure. Tightening torque: First time 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) Second time 6.4 N.m (0.65 kgf-m, 4.7 ft-lb) RH side (Scheme 125): Identifying Tightening Sequence Rocker Cover Of Bolts - RH Side LH side (Scheme 126): Identifying Tightening Sequence Of Rocker Cover Bolts - LH Side
4. Install the cam sprocket. INSTALLATION, CAM SPROCKET. >
5. Install the timing belt. INSTALLATION, TIMING BELT. >
6. Install the timing belt cover. INSTALLATION, TIMING BELT COVER. >
7. Install the crank pulley. INSTALLATION, CRANK PULLEY. >
8. Install the V-belts. INSTALLATION, V-BELT. >

Note. "RANK" shown in the chart refers to the possibility of the cause of trouble in order "Very often" to "Rarely"

A - Very often

B - Sometimes

C - Rarely

PROBLEM SYMPTOMS CHART

PROBLEM SYMPTOMS CHART - ENGINE NOISE