Engine Mechanical (H4DO): Overhaul Subaru Forester SJ

WHEN TIMING CHAIN ASSEMBLY IS NOT REMOVED

Note. Inspection of cam clearance should be performed while engine is cold. If the engine is removed from vehicle, performing the step 1) is not necessary.

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1. Disconnect the ground cable from battery.
2. Remove the V-belts. < Ref. to «V-BELT»(ref-662116-S26119621172014101300000) , REMOVAL, V-belt. >
3. When inspecting #1 and #3 cylinders Remove the rocker cover RH. < Ref. to «ROCKER COVER RH»(ref-662116-S15311492072014101300000) , REMOVAL, Rocker Cover. > NOTE: When working on the vehicle, place a suitable container under the vehicle. Set #1 cylinder piston to top dead center of compression stroke by rotating the crank pulley clockwise using the socket wrench. NOTE: When the timing mark (A) on crank pulley is aligned to the 0° in timing gauge (B) on chain cover as shown in the figure, the #1 cylinder piston is located at TDC of compression stroke if the intake camshaft and exhaust camshaft does not depress the #1 cylinder intake side roller rocker arm (intake valve) and exhaust side roller rocker arm (exhaust valve). If roller rocker arm (valve) is depressed, turn the crank pulley by 360° in order to make #1 cylinder piston at TDC of compression stroke. Check the cam clearance for #1 cylinder intake, #1 cylinder exhaust and #3 cylinder exhaust. NOTE: Measure the roller surface of cam base circle and roller rocker arm using thickness gauge (A). If the measured value is out of standard, take notes of the value in order to adjust the cam clearance later on. Cam clearance: Intake Standard 0.13 +0.02 -0.03 mm (0.0051 +0.0008 -0.0012 in) Exhaust Standard 0.22±0.02 mm (0.0087±0.0008 in) Turn the crank pulley by 360°. Check the clearance of #3 cylinder intake. NOTE: Measure the roller surface of cam base circle and roller rocker arm using thickness gauge (A). If the measured value is out of standard, take notes of the value in order to adjust the cam clearance later on. Cam clearance: Standard 0.13 +0.02 -0.03 mm (0.0051 +0.0008 -0.0012 in)
4. When inspecting #2 and #4 cylinders Remove the rocker cover LH. < Ref. to «ROCKER COVER LH»(ref-662116-S21067973512014101300000) , REMOVAL, Rocker Cover. > NOTE: When working on the vehicle, place a suitable container under the vehicle. Set #2 cylinder piston to top dead center of compression stroke by rotating the crank pulley clockwise using the socket wrench. NOTE: When the timing mark (A) on crank pulley is aligned to the 0° in timing gauge (B) on chain cover as shown in the figure, the #2 cylinder piston is located at TDC of compression stroke if the intake camshaft and exhaust camshaft does not depress the #2 cylinder intake side roller rocker arm (intake valve) and exhaust side roller rocker arm (exhaust valve). If roller rocker arm (valve) is depressed, turn the crank pulley by 360° in order to make #2 cylinder piston at TDC of compression stroke. Check the cam clearance for #2 cylinder intake, #2 cylinder exhaust and #4 cylinder exhaust. NOTE: Measure the roller surface of cam base circle and roller rocker arm using thickness gauge (A). If the measured value is out of standard, take notes of the value in order to adjust the cam clearance later on. Cam clearance: Intake Standard 0.13 +0.02 -0.03 mm (0.0051 +0.0008 -0.0012 in) Exhaust Standard 0.22±0.02 mm (0.0087±0.0008 in) Turn the crank pulley by 360°. Check the clearance of #4 cylinder intake. NOTE: Measure the roller surface of cam base circle and roller rocker arm using thickness gauge (A). If the measured value is out of standard, take notes of the value in order to adjust the cam clearance later on. Cam clearance: Standard 0.13 +0.02 -0.03 mm (0.0051 +0.0008 -0.0012 in)
5. If necessary, adjust the cam clearance. < Ref. to «ADJUSTMENT»(ref-662116-S00000248562014101300000) , Cam Clearance. >
6. After inspection, install the related parts in the reverse order of removal.

WHEN TIMING CHAIN ASSEMBLY IS REMOVED

Note. Inspection of cam clearance should be performed while engine is cold.

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1. When inspecting #1 and #3 cylinders Remove the rocker cover RH. < Ref. to «ROCKER COVER RH»(ref-662116-S15311492072014101300000) , REMOVAL, Rocker Cover. > NOTE: When working on the vehicle, place a suitable container under the vehicle. Check the #1 and #3 cylinder cam clearance. CAUTION: Intake and exhaust camshafts can be independently rotated with the timing chain removed. When the intake valve and exhaust valve lift at the same time, the valve heads contact each other and valve stem may bend. Do not turn it to the outside of range of zero lift (cam base circle position) (in range where it can be turned lightly by hand). NOTE: For cam clearance inspection, adjust the cam base circle position so that the thickness gauge (A) can be inserted easily by hand turning the camshaft (cam sprocket) to be measured. Measure the roller surface of cam base circle and roller rocker arm using thickness gauge (A). If the measured value is out of standard, take notes of the value in order to adjust the cam clearance later on. Cam clearance: Intake Standard 0.13 +0.02 -0.03 mm (0.0051 +0.0008 -0.0012 in) Exhaust Standard 0.22±0.02 mm (0.0087±0.0008 in)
2. When inspecting #2 and #4 cylinders Remove the rocker cover LH. < Ref. to «ROCKER COVER LH»(ref-662116-S21067973512014101300000) , REMOVAL, Rocker Cover. > NOTE: When working on the vehicle, place a suitable container under the vehicle. Check the #2 and #4 cylinder cam clearance. CAUTION: Intake and exhaust camshafts can be independently rotated with the timing chain removed. When the intake valve and exhaust valve lift at the same time, the valve heads contact each other and valve stem may bend. Do not turn it to the outside of range of zero lift (cam base circle position) (in range where it can be turned lightly by hand). NOTE: For cam clearance inspection, adjust the cam base circle position so that the thickness gauge (A) can be inserted easily by hand turning the camshaft (cam sprocket) to be measured. Measure the roller surface of cam base circle and roller rocker arm using thickness gauge (A). If the measured value is out of standard, take notes of the value in order to adjust the cam clearance later on. Cam clearance: Intake Standard 0.13 +0.02 -0.03 mm (0.0051 +0.0008 -0.0012 in) Exhaust Standard 0.22±0.02 mm (0.0087±0.0008 in)
3. If necessary, adjust the cam clearance. < Ref. to «ADJUSTMENT»(ref-662116-S00000248562014101300000) , Cam Clearance. >
4. After inspection, install the related parts in the reverse order of removal.

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1. Remove the engine from the vehicle. < Ref. to «REMOVAL»(ref-662116-S04219794502014101300000) , Engine Assembly. >
2. Remove the chain cover. < Ref. to «REMOVAL»(ref-662116-S23929380932014101300000) , Chain Cover. >
3. When adjusting #1 and #3 cylinders Remove the timing chain RH. < Ref. to «TIMING CHAIN RH»(ref-662116-S15387790442014101300000) , REMOVAL, Timing Chain Assembly. > Remove the cam carrier RH. < Ref. to «CAM CARRIER RH»(ref-662116-S41659734192014101300000) , REMOVAL, Cam Carrier. > Measure the thickness of valve shim using micrometer. NOTE: Measurement should be performed at a temperature of 20°C (68°F). Select a valve shim of suitable thickness using the measured cam clearance and valve shim thickness. NOTE: Use a new valve shim. Engine type FB25#####A Intake side: S = T + 1.54 x (V - 0.13 mm (0.0051 in)) Exhaust side: S = T + 1.69 x (V - 0.22 mm (0.0087 in)) S: Valve shim thickness required V: Measured cam clearance T: Current valve shim thickness Engine type FB25#####F Intake side: S = T + 1.69 x (V - 0.13 mm (0.0051 in)) Exhaust side: S = T + 1.87 x (V - 0.22 mm (0.0087 in)) S: Valve shim thickness required V: Measured cam clearance T: Current valve shim thickness Install the cam carrier RH. < Ref. to «CAM CARRIER RH»(ref-662116-S29314056722014101300000) , INSTALLATION, Cam Carrier. > Check all the cam clearance of RH side at this time. If the cam clearance is not within the standard value, repeat the procedure over again from step 2 ). NOTE: When the removing/installing of cam carrier RH has been performed, cam clearance may be outside the standard value. Checking of all cam clearance of RH side is necessary. Refer to INSPECTION of " «CAM CLEARANCE»(ref-662116-S24266792922014101300000) " for the cam clearance inspection. < Ref. to «WHEN TIMING CHAIN ASSEMBLY IS REMOVED»(ref-662116-S33306910282014101300000) , INSPECTION, Cam Clearance. > Cam clearance: Intake Standard 0.13 +0.02 -0.03 mm (0.0051 +0.0008 -0.0012 in) Exhaust Standard 0.22±0.02 mm (0.0087±0.0008 in)
4. When adjusting #2 and #4 cylinders Remove the timing chain LH. < Ref. to «TIMING CHAIN LH»(ref-662116-S10496934012014101300000) , REMOVAL, Timing Chain Assembly. > Remove the cam carrier LH. < Ref. to «CAM CARRIER LH»(ref-662116-S41519828502014101300000) , REMOVAL, Cam Carrier. > Measure the thickness of valve shim using micrometer. NOTE: Measurement should be performed at a temperature of 20°C (68°F). Select a valve shim of suitable thickness using the measured cam clearance and valve shim thickness. NOTE: Use a new valve shim. Engine type FB25#####A Intake side: S = T + 1.54 x (V - 0.13 mm (0.0051 in)) Exhaust side: S = T + 1.69 x (V - 0.22 mm (0.0087 in)) S: Valve shim thickness required V: Measured cam clearance T: Current valve shim thickness Engine type FB25#####F Intake side: S = T + 1.69 x (V - 0.13 mm (0.0051 in)) Exhaust side: S = T + 1.87 x (V - 0.22 mm (0.0087 in)) S: Valve shim thickness required V: Measured cam clearance T: Current valve shim thickness Install the cam carrier LH. < Ref. to «CAM CARRIER LH»(ref-662116-S07014270672014101300000) , INSTALLATION, Cam Carrier. > Check all the cam clearance of LH side at this time. If the cam clearance is not within the standard value, repeat the procedure over again from step 2 ). NOTE: When the removing/installing of cam carrier LH has been performed, cam clearance may be outside the standard value. Checking of all cam clearance of LH side is necessary. Refer to INSPECTION of " «CAM CLEARANCE»(ref-662116-S24266792922014101300000) " for the cam clearance inspection. < Ref. to «WHEN TIMING CHAIN ASSEMBLY IS REMOVED»(ref-662116-S33306910282014101300000) , INSPECTION, Cam Clearance. > Cam clearance: Intake Standard 0.13 +0.02 -0.03 mm (0.0051 +0.0008 -0.0012 in) Exhaust Standard 0.22±0.02 mm (0.0087±0.0008 in)
5. After adjustment, install the related parts in the reverse order of removal.

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1. Open the front hood, and remove the upper grille bracket from the front hood.
2. Using a marker pen, make alignment marks (A) on both the front hood and the front hood striker.
3. Remove the front hood striker from the front hood.
4. Remove the front center grille assembly from the front hood.
5. Change the front hood damper mounting position from (A) to (B), and completely open the front hood. Tightening torque: 20 N.m (2.0 kgf-m, 14.8 ft-lb)
6. Remove the V-belt covers.
7. Collect the refrigerant from A/C system. < Ref. to «REFRIGERANT RECOVERY PROCEDURE»(ref-662134-S41814187102014101300000) . >
8. Release the fuel pressure. < Ref. to «RELEASING OF FUEL PRESSURE»(ref-662118-S15085292042014101300000) , PROCEDURE, Fuel. >
9. Disconnect the ground cable from battery.
10. Remove the air intake duct. < Ref. to «REMOVAL»(ref-662120-S42382818082014101300000) , Air Intake Duct. >
11. Remove the air intake boot. < Ref. to «REMOVAL»(ref-662120-S21870412022014101300000) , Air Intake Boot. >
12. Disconnect the connector (A) from the mass air flow and intake air temperature sensor, and remove the clip (B) which holds the mass air flow and intake air temperature sensor harness.
13. Remove the air cleaner case (rear).
14. Remove the radiator. < Ref. to «REMOVAL»(ref-662122-S05365879092014101300000) , Radiator. >
15. Disconnect the brake booster vacuum hose from the intake manifold.
16. Disconnect the engine harness connector. Remove the bolt securing the bulkhead harness connector bracket. Disconnect the bulkhead harness connector from the engine harness connector (black) and engine harness connector (brown).
17. Remove the bolt which secures the generator cord stay A to the chain cover.
18. Disconnect connector (A) and terminal (B) from the generator, and disconnect connector (C) from A/C compressor.
19. Remove the bolt (E) securing the generator cord stay B to the generator bracket.
20. Remove the generator cord from the clip (D) and move the generator cord to the left side wheel apron.
21. Disconnect the following hoses. A/C pressure hose < Ref. to «REMOVAL»(ref-662134-S35863784852014101300000) , Hose and Pipe. > Heater inlet hose and heater outlet hose
22. Disconnect the water hose from CVTF cooler (with warmer feature). (CVT model)
23. Remove the bolt which secures the CVTF cooler (with warmer feature) to the transmission, and move the CVTF cooler (with warmer feature) to the right side of the transmission. (CVT model)
24. Lift up the vehicle.
25. Remove the front exhaust pipe. < Ref. to «REMOVAL»(ref-662139-S23483353282014101300000) , Front Exhaust Pipe. >
26. Remove the under cover front - transmission.
27. Disconnect the ground cable on the engine side.
28. Remove the bolts and nuts which hold the lower side of transmission to the engine. CVT model MT model
29. Remove the nuts which secure the engine mounting to the front crossmember. (Hydraulic engine mounting model)
30. Remove the nuts which secure the engine mounting to the front crossmember. (Solid engine mounting model)
31. Lower the vehicle.
32. Separate the torque converter clutch from the drive plate. (CVT model) Remove the service hole plug. Insert the wrench into the crank pulley bolt and rotate the crank pulley to remove the bolts which hold torque converter clutch to drive plate.
33. Disconnect the bulkhead harness connector from the transmission harness connector (A) and the inhibitor harness connector (B), and disconnect the transmission radio ground terminal (C) from the vehicle body. (CVT model)
34. Remove the pitching stopper.
35. Remove the transmission case cover. (CVT model)
36. Remove the transmission harness stay and move to the engine side. (CVT model)
37. Remove the bolt which holds the transmission harness to the control valve body, and turn the transmission harness clockwise till the bolt hole can be seen as shown in the figure, and tighten the bolt to temporary lock the harness. (CVT model) NOTE: This procedure is required to prevent the transmission harness from touching the vehicle body during engine removal/installation.
38. Disconnect the fuel delivery tube and evaporation hose. CAUTION: Be careful not to spill fuel. Catch the fuel from the tubes using a container or cloth. Disconnect the quick connector on the fuel delivery tube from the fuel pipe assembly, and remove the clip (A) securing the fuel delivery tube. NOTE: Disconnect the quick connector as shown in the figure. Disconnect the evaporation hose from the fuel pipe assembly.
39. Support the engine with a lifting device and wire ropes.
40. Support the transmission with a garage jack. CAUTION: Be sure to perform this procedure to prevent the transmission from lowering by its own weight.
41. Separate the engine and transmission. CAUTION: Before removing the engine away from transmission, check to be sure no work has been overlooked. Remove the starter. < Ref. to «REMOVAL»(ref-662144-S29498763952014101300000) , Starter. > Attach the ST to the torque converter clutch case. (CVT model) ST 498277200 STOPPER SET Remove the bolts which hold the upper side of the transmission to the engine. CVT model MT model
42. Remove the engine from the vehicle. NOTE: Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc. Slightly raise the engine. Raise the transmission with garage jack. Move the engine horizontally until main shaft is withdrawn from clutch cover. (MT model) Slowly move the engine away from engine compartment.
43. Remove the engine mounting from the engine.

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1. Install the engine mounting onto the engine. Tightening torque: 35 N.m (3.6 kgf-m, 25.8 ft-lb)
2. Apply a small amount of grease to splines of main shaft. (MT model) Grease: NICHIMOLY N-130 or equivalent
3. 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.
4. Install the bolts which hold upper side of transmission to engine. Tightening torque: 50 N.m (5.1 kgf-m, 36.9 ft-lb) CVT model MT model
5. Remove the lifting device and wire ropes.
6. Remove the garage jack.
7. Remove the bolt and turn the transmission harness counterclockwise to install the transmission harness to the control valve body. (CVT model) Tightening torque: 7 N.m (0.7 kgf-m, 5.2 ft-lb)
8. Install the transmission harness stay. (CVT model) Tightening torque: 7 N.m (0.7 kgf-m, 5.2 ft-lb)
9. Install the transmission case cover. (CVT model) Tightening torque: 8 N.m (0.8 kgf-m, 5.9 ft-lb)
10. 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)
11. Connect the transmission radio ground terminal (C) to the vehicle body, and connect the bulkhead harness connector to the transmission harness connector (A) and the inhibitor harness connector (B). (CVT model) Tightening torque: 13 N.m (1.3 kgf-m, 9.6 ft-lb)
12. Remove the ST from torque converter clutch case. (CVT model) NOTE: Be careful not to drop the ST into the torque converter clutch case when removing the ST. ST 498277200 STOPPER SET
13. Install the starter. < Ref. to «INSTALLATION»(ref-662144-S10832284602014101300000) , Starter. >
14. Install the torque converter clutch to drive plate. (CVT model) Insert the wrench into the crank pulley bolt and rotate the crank pulley to install the bolts which hold torque converter clutch to drive plate. NOTE: Be careful not to drop bolts into the torque converter clutch case. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb) Fit the plug to service hole.
15. Lift up the vehicle.
16. Install 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) CVT model MT model
17. Install the nuts which hold the engine mounting to the crossmember. (Hydraulic engine mounting model) NOTE: Make sure that locators (A) of the engine mounting are securely inserted. Tightening torque: 45 N.m (4.6 kgf-m, 33.2 ft-lb)
18. Install the nuts which hold the engine mounting to the crossmember. (Solid engine mounting model) Tightening torque: 45 N.m (4.6 kgf-m, 33.2 ft-lb)
19. Connect the ground cable. Tightening torque: 7.5 N.m (0.8 kgf-m, 5.5 ft-lb)
20. Install the under cover front - transmission. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb)
21. Install the front exhaust pipe. < Ref. to «INSTALLATION»(ref-662139-S42712300302014101300000) , Front Exhaust Pipe. >
22. Lower the vehicle.
23. Install the CVTF cooler (with warmer feature) to the transmission. (CVT model) Tightening torque: 23 N.m (2.3 kgf-m, 17.0 ft-lb)
24. Connect the water hose to the CVTF cooler (with warmer feature). (CVT model)
25. Connect the fuel delivery tube and evaporation hose. Connect the evaporation hose to fuel pipe assembly. Connect the quick connector on the fuel delivery tube to the fuel pipe assembly, and fix the fuel delivery tube using clip (A). CAUTION: Check that there is no damage or dust on the quick connector. If necessary, clean the seal surface of the pipe. When connecting the quick connector, make sure to insert the pipe all the way in before locking the slider. When it is difficult to lock the slider, check that the pipe is fully inserted. Make sure that the quick connector is securely connected. NOTE: Connect the quick connector as shown in the figure.
26. Connect the following hoses. Heater inlet hose and heater outlet hose NOTE: Be careful not to mix up the heater inlet hose and the heater outlet hose when connecting them. Brake booster vacuum hose A/C pressure hose < Ref. to «INSTALLATION»(ref-662134-S07956159822014101300000) , Hose and Pipe. >
27. Place the generator code and install the generator cord to the clip (D).
28. Install the bolt (E) which secures the generator cord stay B to the generator bracket.
29. Connect connector (A) and terminal (B) to the generator, and connect connector (C) to A/C compressor. Tightening torque: Generator cord stay B (E) 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) Terminal (B) 15 N.m (1.5 kgf-m, 11.1 ft-lb)
30. Install the generator cord stay A to the chain cover. NOTE: Install the generator cord stay so that the folded end (A) touches at the chain cover boss. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
31. Connect the engine harness connector. Connect the bulkhead harness connector to the engine harness connector (black) and engine harness connector (brown). Install the bolt which secures the bulkhead harness connector bracket. Tightening torque: 7.5 N.m (0.8 kgf-m, 5.5 ft-lb)
32. Install the radiator. < Ref. to «INSTALLATION»(ref-662122-S21112920992014101300000) , Radiator. >
33. Install the air intake case (rear).
34. Install the clip (B) which secures the air flow and intake air temperature sensor harness, and connect the connector (A) to the air flow and intake air temperature sensor.
35. Install the air intake boot. < Ref. to «INSTALLATION»(ref-662120-S17609314842014101300000) , Air Intake Boot. >
36. Install the air intake duct. < Ref. to «INSTALLATION»(ref-662120-S29587944542014101300000) , Air Intake Duct. >
37. Connect the battery ground terminal.
38. Fill engine coolant. < Ref. to «FILLING OF ENGINE COOLANT»(ref-662122-S34703936652014101300000) , REPLACEMENT, Engine Coolant. >
39. Check the CVTF level and replenish it if necessary. (CVT model) < Ref. to «ADJUSTMENT»(ref-662125-S03981071882014101300000) , CVTF. >
40. Charge the A/C system with refrigerant. < Ref. to «PROCEDURE»(ref-662134-S39973495562014101300000) , Refrigerant Charging Procedure. >
41. Install the V-belt cover. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
42. Change the installation position of the front hood damper from (B) to (A). Tightening torque: 20 N.m (2.0 kgf-m, 14.8 ft-lb)
43. Install the front center grille assembly to the front hood. Tightening torque: 4.5 N.m (0.5 kgf-m, 3.3 ft-lb)
44. Align the alignment marks (A), and install the front hood striker to the front hood. Tightening torque: 33 N.m (3.4 kgf-m, 24.3 ft-lb)
45. Install the upper grille bracket to the front hood, and close the front hood. Tightening torque: 4.5 N.m (0.5 kgf-m, 3.3 ft-lb)

ASSEMBLY

1. Install the sensor cover to the chain cover. NOTE: Use new O-rings. Apply a coat of engine oil to the O-rings. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
2. Install the actuator cover to chain cover. NOTE: Use new O-rings. Apply a coat of engine oil to the O-rings. Tightening torque: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb)
3. Install the camshaft position sensor. < Ref. to «INSTALLATION»(ref-662118-S06348689452014101300000) , Camshaft Position Sensor. >
4. Install the oil control solenoid. < Ref. to «INSTALLATION»(ref-662118-S14979618262014101300000) , Oil Control Solenoid. >
5. Install the engine oil temperature sensor. < Ref. to «INSTALLATION»(ref-662118-S04048190302014101300000) , Engine Oil Temperature Sensor. >
6. Install the oil pressure switch. < Ref. to «INSTALLATION»(ref-662113-S36092070782014101300000) , Oil Pressure Switch. >
7. Install the engine oil filter and the oil pump union. < Ref. to «INSTALLATION»(ref-662113-S31225671492014101300000) , Engine Oil Filter. >
8. Install the oil filler cap.