Engine Mechanical (H4DOTC): Adjustments Subaru Forester SH

ADJUSTMENT

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

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1. Measure all the valve clearances. Refer to «INSPECTION»(ref-325302-S09629648042009071800000) , Valve Clearance . NOTE: Record each valve clearance after measurement.
2. Remove the camshaft. Refer to «REMOVAL»(ref-325302-S00849469062009071800000) , Camshaft .
3. Remove the valve lifter.
4. Measure the thickness of valve lifter using micrometer.
5. Select and install a valve lifter of suitable thickness from the following table, based on the measured valve clearance and valve lifter thickness. NOTE: Use new valve lifters. VALVE LIFTERS REFERENCE Unit: (mm) Intake valve: S = (V + T) - 0.19 Exhaust valve: S = (V + T) - 0.35 S: Valve lifter thickness required V: Measured valve clearance T: Valve lifter thickness to be used PART THICKNESS CHART Part No. Thickness mm (in) 13228 AB102 4.68 (0.1843) 13228 AB112 4.69 (0.1846) 13228 AB122 4.70 (0.1850) 13228 AB132 4.71 (0.1854) 13228 AB142 4.72 (0.1858) 13228 AB152 4.73 (0.1862) 13228 AB162 4.74 (0.1866) 13228 AB172 4.75 (0.1870) 13228 AB182 4.76 (0.1874) 13228 AB192 4.77 (0.1878) 13228 AB202 4.78 (0.1882) 13228 AB212 4.79 (0.1886) 13228 AB222 4.80 (0.1890) 13228 AB232 4.81 (0.1894) 13228 AB242 4.82 (0.1898) 13228 AB252 4.83 (0.1902) 13228 AB262 4.84 (0.1906) 13228 AB272 4.85 (0.1909) 13228 AB282 4.86 (0.1913) 13228 AB292 4.87 (0.1917) 13228 AB302 4.88 (0.1921) 13228 AB312 4.89 (0.1925) 13228 AB322 4.90 (0.1929) 13228 AB332 4.91 (0.1933) 13228 AB342 4.92 (0.1937) 13228 AB352 4.93 (0.1941) 13228 AB362 4.94 (0.1945) 13228 AB372 4.95 (0.1949) 13228 AB382 4.96 (0.1953) 13228 AB392 4.97 (0.1957) 13228 AB402 4.98 (0.1961) 13228 AB412 4.99 (0.1965) 13228 AB422 5.00 (0.1969) 13228 AB432 5.01 (0.1972) 13228 AB442 5.02 (0.1976) 13228 AB452 5.03 (0.1980) 13228 AB462 5.04 (0.1984) 13228 AB472 5.05 (0.1988) 13228 AB482 5.06 (0.1992) 13228 AB492 5.07 (0.1996) 13228 AB502 5.08 (0.2000) 13228 AB512 5.09 (0.2004) 13228 AB522 5.10 (0.2008) 13228 AB532 5.11 (0.2012) 13228 AB542 5.12 (0.2016) 13228 AB552 5.13 (0.2020) 13228 AB562 5.14 (0.2024) 13228 AB572 5.15 (0.2028) 13228 AB582 5.16 (0.2031) 13228 AB592 5.17 (0.2035) 13228 AB602 5.18 (0.2039) 13228 AB612 5.19 (0.2043) 13228 AB622 5.20 (0.2047) 13228 AB632 5.21 (0.2051) 13228 AB642 5.22 (0.2055) 13228 AB652 5.23 (0.2059) 13228 AB662 5.24 (0.2063) 13228 AB672 5.25 (0.2067) 13228 AB682 5.26 (0.2071) 13228 AB692 5.27 (0.2075) 13228 AB702 4.38 (0.1724) 13228 AB712 4.40 (0.1732) 13228 AB722 4.42 (0.1740) 13228 AB732 4.44 (0.1748) 13228 AB742 4.46 (0.1756) 13228 AB752 4.48 (0.1764) 13228 AB762 4.50 (0.1771) 13228 AB772 4.52 (0.1780) 13228 AB782 4.54 (0.1787) 13228 AB792 4.56 (0.1795) 13228 AB802 4.58 (0.1803) 13228 AB812 4.60 (0.1811) 13228 AB822 4.62 (0.1819) 13228 AB832 4.64 (0.1827) 13228 AB842 4.66 (0.1835) 13228 AB852 5.29 (0.2083) 13228 AB862 5.31 (0.2091) 13228 AB872 5.33 (0.2098) 13228 AB882 5.35 (0.2106) 13228 AB892 5.37 (0.2114) 13228 AB902 5.39 (0.2122) 13228 AB912 5.41 (0.2123) 13228 AB922 5.43 (0.2138) 13228 AB932 5.45 (0.2146) 13228 AB942 5.47 (0.2154) 13228 AB952 5.49 (0.2161) 13228 AB962 5.51 (0.2169) 13228 AB972 5.53 (0.2177) 13228 AB982 5.55 (0.2185) 13228 AB992 5.57 (0.2193) 13228 AC002 5.59 (0.2201) 13228 AC012 5.61 (0.2209) 13228 AC022 5.63 (0.2217) 13228 AC032 5.65 (0.2224)
6. Install the camshaft. Refer to «INSTALLATION»(ref-325302-S19247684902009071800000) , Camshaft .
7. Install the cam sprocket. Refer to «INSTALLATION»(ref-325302-S41439610452009071800000) , Cam Sprocket .
8. Install the timing belt. Refer to «TIMING BELT»(ref-325302-S05081370952009071800000) , INSTALLATION, Timing Belt .
9. Measure all valves for valve clearance again at this time. If the valve clearance is not within the adjustment value, repeat the procedure over again from the first step. Valve clearance (adjustment value): Intake 0.20 +0.01 -0.03 mm (0.0079 +0.0004 -0.0012 in) Exhaust 0.35±0.02 mm (0.0138±0.0008 in)
10. After measuring, install the related parts in the reverse order of removal.

Note. Use a new rocker cover gasket.

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1. Set the vehicle on a lift.
2. Change the bolt mounting position from (A) to (B), and completely open the front hood. Tightening torque: 7.5 N.m (0.8 kgf-m, 5.5 ft-lb)
3. Remove the collector cover.
4. Collect the refrigerant from the A/C system. Refer to «REFRIGERANT RECOVERY PROCEDURE»(ref-325325-S22610905782009071800000) .
5. Release the fuel pressure. Refer to «RELEASING OF FUEL PRESSURE»(ref-325306-S29431132992009071800000) , PROCEDURE, Fuel .
6. Disconnect the battery cable, and remove the battery from the vehicle.
7. Open the fuel filler lid, and remove the fuel filler cap.
8. Remove the air intake duct and air cleaner case. Refer to «REMOVAL»(ref-325300-S04200539772009071800000) , Air Intake Duct . Refer to «REMOVAL»(ref-325300-S05802953992009071800000) , Air Cleaner Case .
9. Remove the intercooler. Refer to «REMOVAL»(ref-325300-S41039960822009071800000) , Intercooler .
10. Remove the radiator from the vehicle. Refer to «REMOVAL»(ref-325304-S02558817302009071800000) , Radiator .
11. Remove the coolant filler tank. Refer to «REMOVAL»(ref-325304-S31724839482009071800000) , Coolant Filler Tank .
12. Disconnect the A/C pressure hoses from the A/C compressor. Refer to «REMOVAL»(ref-325325-S42385480992009071800000) , Hose and Pipe .
13. Disconnect the following connectors and cables. Engine harness connectors Generator connector and terminal A/C compressor connector Secondary air pump connector
14. Disconnect the following hoses. Brake booster vacuum hose Heater inlet and outlet hoses
15. Remove the power steering pump. Remove the front side belts. Refer to «FRONT SIDE BELT»(ref-325302-S29866740192009071800000) , REMOVAL, V-belt . Disconnect the power steering pump switch connector. Remove the power steering pump from the engine. Place the power steering pump on the right side wheel apron.
16. Remove the center exhaust pipe. Refer to «REMOVAL»(ref-325336-S28652404252009071800000) , Center Exhaust Pipe .
17. Remove the turbocharger. Refer to «REMOVAL»(ref-325300-S34759768802009071800000) , Turbocharger .
18. Remove the joint pipe and front exhaust pipe. Refer to «REMOVAL»(ref-325336-S34120480642009071800000) , Joint Pipe . Refer to «REMOVAL»(ref-325336-S42130722872009071800000) , Front Exhaust Pipe .
19. Lift up the vehicle.
20. Disconnect the ground cable on the engine side.
21. Remove the bolts and nuts which hold the lower side of transmission to the engine.
22. Remove the nuts which hold the engine mount to the front crossmember.
23. Separate the torque converter clutch from drive plate. 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 crankshaft using socket wrench.
24. Remove the pitching stopper.
25. Attach ST to the fuel delivery pipe and push ST in the direction of arrow mark to disconnect the fuel delivery hose. ST 42099AE000 QUICK CONNECTOR RELEASE CAUTION: Be careful not to spill fuel. Catch the fuel from hoses using a container or cloth.
26. Disconnect the fuel return hose using the ST. ST 18371AA000 CONNECTOR REMOVER CAUTION: Be careful not to spill fuel. Catch the fuel from hoses using a container or cloth. Attach the ST to the fuel return pipe as shown in the figure. Insert the front side of ST into the quick connector. Insert the back side of ST into the quick connector and push ST in the direction of arrow mark to disconnect the fuel return hose.
27. Remove the clip and disconnect the evaporation hose from the fuel pipe.
28. Support the engine with a lifting device and wire ropes.
29. Support the transmission with a garage jack. CAUTION: Doing this is very important to prevent the transmission from lowering due to its own weight.
30. Separation of engine and transmission. CAUTION: Before removing the engine away from transmission, check to be sure no work has been overlooked. Remove the starter. Refer to «REMOVAL»(ref-325316-S07256448182009071800000) , Starter . Set the ST to torque converter clutch case. ST 498277200 STOPPER SET Remove the bolts which hold the upper side of the transmission to the engine.
31. Remove the engine from vehicle. Slightly raise the engine. Raise the transmission with garage jack. Slowly move the engine away from engine compartment. NOTE: Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc.
32. Remove the engine mount from the engine.

Scheme 323

Scheme 324

1. Install the engine mount onto the engine. Tightening torque: 35 N.m (3.6 kgf-m, 25.8 ft-lb)
2. Position the engine in engine compartment and align it with transmission. NOTE: Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc.
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, 36.9 ft-lb) T2: 58 N.m (5.9 kgf-m, 42.8 ft-lb)
7. Remove the ST from the torque converter clutch case. NOTE: Be careful not to drop the ST into the torque converter clutch case when removing the ST. ST 498277200 STOPPER SET
8. Install the starter. Refer to «INSTALLATION»(ref-325316-S02097978352009071800000) , Starter .
9. Install the torque converter clutch to drive plate. Tighten the bolts which hold torque converter clutch to drive plate. Tighten other bolts while rotating the crankshaft using socket wrench. NOTE: Be careful not to drop bolts into the torque converter clutch housing. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb) Fit the plug to service hole.
10. Install the power steering pump. Install the power steering pump. Tightening torque: Refer to "COMPONENT" of "Power Steering" for the tightening torque . Refer to «COMPONENT»(ref-325326-S32161679162009071800000) , General Description . Connect the power steering pump switch connector. Install and adjust the front side belt. Refer to «FRONT SIDE BELT»(ref-325302-S29866740192009071800000) , INSTALLATION, V-belt .
11. Lift up the vehicle.
12. Tighten the bolts and nuts which hold lower side of the transmission to engine. Tightening torque: 50 N.m (5.1 kgf-m, 36.9 ft-lb)
13. Tighten the nuts which hold the engine mount to the crossmember. NOTE: Make sure that the engine mount nuts (A) and locator (B) are securely installed. Tightening torque: 85 N.m (8.7 kgf-m, 62.7 ft-lb)
14. Install the joint pipe and front exhaust pipe. Refer to «INSTALLATION»(ref-325336-S16849661982009071800000) , Front Exhaust Pipe. Refer to «INSTALLATION»(ref-325336-S37925656412009071800000) , Joint Pipe .
15. Attach the turbo charger. Refer to «INSTALLATION»(ref-325300-S05639877632009071800000) , Turbocharger .
16. Install the center exhaust pipe. Refer to «INSTALLATION»(ref-325336-S00612259482009071800000) , Center Exhaust Pipe .
17. Connect the ground cable. Tightening torque: 7.5 N.m (0.8 kgf-m, 5.5 ft-lb)
18. Lower the vehicle.
19. Connect the following hoses. Fuel delivery hose, fuel return hose and evaporation hose Heater inlet and outlet hoses Brake booster vacuum hose
20. Connect the following connectors and terminals. Engine harness connectors Generator connector and terminal Tightening torque: 15 N.m (1.5 kgf-m, 11.1 ft-lb) A/C compressor connector Secondary air pump connector Install the intercooler. Refer to «INSTALLATION»(ref-325300-S37233999532009071800000) , Intercooler .
21. Install the A/C pressure hoses. Refer to «INSTALLATION»(ref-325325-S11602039362009071800000) , Hose and Pipe .
22. Install the radiator. Refer to «INSTALLATION»(ref-325304-S24193942152009071800000) , Radiator .
23. Install the coolant filler tank. Refer to «INSTALLATION»(ref-325304-S10123057082009071800000) , Coolant Filler Tank .
24. Install the air cleaner case and air intake duct. Refer to «INSTALLATION»(ref-325300-S13529159962009071800000) , Air Cleaner Case . Refer to «INSTALLATION»(ref-325300-S02354694642009071800000) , Air Intake Duct .
25. Install the battery to the vehicle, and connect the battery cables.
26. Fill engine coolant. Refer to «FILLING OF ENGINE COOLANT»(ref-325304-S22895877052009071800000) , REPLACEMENT, Engine Coolant .
27. Charge the A/C system with refrigerant. Refer to «PROCEDURE»(ref-325325-S06059658022009071800000) , Refrigerant Charging Procedure .
28. Check the ATF level and replenish it if necessary. Refer to «INSPECTION»(ref-325309-S11821766972009071800000) , Automatic Transmission Fluid .
29. Install the collector cover.
30. Change the bolt mounting position from (B) to (A), and close the front hood. Tightening torque: 7.5 N.m (0.8 kgf-m, 5.5 ft-lb)
31. Lower the vehicle from the lift.