Subaru Forester 1998-05

Valve Lash (Clearance) Adjustment

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DOHC Engines




NOTE
The valve adjustment should be performed while the engine is cold.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the air intake duct.
  6.  
  7. Remove the right hand timing belt cover.
  8.  
  9. When inspecting Nos. 1 and 3 cylinders remove the following:
    1. Pull out the engine harness connector with the bracket from the air cleaner upper cover.
    2.  
    3. Remove the air cleaner case and the ignition coil.
    4.  

  10.  
  11. Disconnect the Positive Crankcase ventilation (PCV) hose from the valve cover.
    1. Remove the right hand rocker cover.
    2.  

  12.  
  13. When inspecting Nos. 2 and 4 cylinders remove the following:
    1. Remove the battery and battery tray.
    2.  
    3. Remove the bolt that attaches the engine harness bracket to the body.
    4.  
    5. Disconnect the window washer motor connectors.
    6.  
    7. Remove the washer tank mounting bolts and secure out of the way.
    8.  
    9. Remove the ignition coil.
    10.  

  14.  
  15. Disconnect the Positive Crankcase ventilation (PCV) hose from the valve cover.
    1. Remove the left hand rocker cover.
    2.  

  16.  
  17. To inspect the Nos. 1 intake and 3 exhaust, turn the crankshaft pulley clockwise until the arrow mark on the camshaft sprocket is set as shown in the accompanying illustration.
  18.  
  19. To inspect the Nos. 2 exhaust and 3 intake, turn the crankshaft pulley clockwise until the arrow mark on the camshaft sprocket is set as shown in the accompanying illustration.
  20.  
  21. To inspect the Nos. 2 intake and 4 exhaust, turn the crankshaft pulley clockwise until the arrow mark on the camshaft sprocket is set as shown in the accompanying illustration.
  22.  
  23. To inspect the Nos. 1 exhaust and 4 intake, turn the crankshaft pulley clockwise until the arrow mark on the camshaft sprocket is set as shown in the accompanying illustration.
  24.  
  25. Check the valve clearance:

    Intake valve: 0.0063-0.0095 in. (0.14-0.24mm).
     
    Exhaust valve: 0.0118-0.0158 in. (0.30-0.40mm).
     

  26.  
  27. If any valve needs adjustment, perform the following:
    1. Remove the camshaft.
    2.  
    3. Remove the valve lifter and measure the thickness of the lifter using a micrometer.
    4.  
    5. Select a suitable replacement valve lifter after referring to the formula table and thickness tables illustrated.
    6.  


      Click image to see an enlarged view

      Fig. Select a suitable replacement valve lifter after referring to this formula table-DOHC engines



      Click image to see an enlarged view

      Fig. Valve lifter thickness table-DOHC engines (1 of 3)



      Click image to see an enlarged view

      Fig. Valve lifter thickness table-DOHC engines (2 of 3)



      Click image to see an enlarged view

      Fig. Valve lifter thickness table-DOHC engines (3 of 3)

    7. Re-inspect valve clearances again and adjust if necessary.
    8.  

  28.  
  29. Once valve adjustment has been performed and rechecked, install the removed components in the reverse order of removal. Refer to camshaft removal and installation procedure in this section for camshaft and valve cover installation procedures.
  30.  


    Click image to see an enlarged view

    Fig. To inspect the Nos. 1 intake and 3 exhaust, turn the crankshaft pulley clockwise until the arrow mark on the camshaft sprocket is set as shown-DOHC engine



    Click image to see an enlarged view

    Fig. To inspect the Nos. 2 exhaust and 3 intake, turn the crankshaft pulley clockwise until the arrow mark on the camshaft sprocket is set as shown-DOHC engine



    Click image to see an enlarged view

    Fig. To inspect the Nos. 2 intake and 4 exhaust, turn the crankshaft pulley clockwise until the arrow mark on the camshaft sprocket is set as shown-DOHC engine



    Click image to see an enlarged view

    Fig. To inspect the Nos. 1 exhaust and 4 intake, turn the crankshaft pulley clockwise until the arrow mark on the camshaft sprocket is set as shown-DOHC engine




Click image to see an enlarged view

Fig. Exploded view of the shim replace kit

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Battery cables and tray
     
    Upper and center timing belt cover mounting bolts
     
    Engine undercover
     
    Timing belt cover lower mounting bolts, then the covers
     
    Mass Air Flow (MAF) sensor, and the air intake duct with the air cleaner assembly
     
    Blow-by hose
     
    Spark plug wires
     
    Washer tank, motor and connectors
     
    Valve cover
     

  4.  
  5. Turn the crankshaft pulley clockwise until the arrow mark on the camshaft is set to the position as shown.
    NOTE
    The checking or adjusting the exhaust valve is performed from under the vehicle.

  6.  
  7. Check the valve clearance:

    Intake valve: 0.0071-0.0087 in. (0.18-0.22mm).
     
    Exhaust valve: 0.0090-0.0106 in. (0.23-0.27mm).
     

  8.  
  9. If any valve needs adjustment, perform the following, while referring to the accompanying illustrations:

    Click image to see an enlarged view

    Fig. Position the lifter notch as shown, to remove the shim



    Click image to see an enlarged view

    Fig. First install part -A- of the tool to the camshaft...



    Click image to see an enlarged view

    Fig. ...then part -B- under part -A- as shown



    Click image to see an enlarged view

    Fig. Turn part -C- until the adjusting shim can be removed

    1. Rotate the notch of the lifter outward by 45 degrees.
    2.  
    3. Install part -A- of the Replacer onto the camshaft.
    4.  
    5. Install part -B- of the Replacer as shown.
    6.  
    7. Install part -C- and turn until part -B- pushes the lifter away.
    8.  
    9. Insert tweezers into the notch of the valve lifter, and take out the shim.
    10.  
    11. Measure the thickness of the shim, then using the chart select and install a new shim and recheck the clearance.
    12.  

  10.  
  11. Remove the adjusting tools.
  12.  
  13. Install or connect the following:

    Valve covers
     
    Spark plug wires
     
    Blow-by hose
     
    MAF sensor
     
    Engine undercover
     
    Upper and center timing belt cover
     
    Washer tank
     
    Battery and tray
     

  14.  
  15. Check the engine oil level.

    Click image to see an enlarged view

    Fig. Position the camshaft as shown to adjust No. 1 intake valve and No. 3 exhaust valve



    Click image to see an enlarged view

    Fig. Position the camshaft as shown to adjust No. 3 intake valve and No. 2 exhaust valve



    Click image to see an enlarged view

    Fig. Position the camshaft as shown to adjust No. 2 intake valve and No. 4 exhaust valve



    Click image to see an enlarged view

    Fig. Position the camshaft as shown to adjust No. 4 intake valve and No. 1 exhaust valve



    Click image to see an enlarged view

    Fig. Valve adjusting shim chart

  16.  


NOTE
The valve adjustment should be performed while the engine is cold.

  1. Raise and support the vehicle safely.
  2.  
  3. Remove the under cover.
  4.  
  5. Lower the vehicle.
  6.  
  7. Remove the collector cover.
  8.  
  9. Disconnect the negative battery cable.
  10.  
  11. Remove the air intake duct.
  12.  
  13. Remove the bolt that retains the right side timing belt cover. Remove the remaining bolts and remove the right side timing belt cover.
  14.  
  15. Disconnect the ignition coil electrical connector. Remove the ignition coil.
  16.  
  17. Position a suitable container under the vehicle.
  18.  
  19. Disconnect the PCV hose from the rocker cover. Remove the rocker cover retaining bolts. Remove the rocker cover from the vehicle.
  20.  
  21. Position the number one piston at TDC of the compression stroke.
  22.  
  23. Using a feeler gauge, measure and record the clearance of the number one cylinder intake and the number three cylinder exhaust valves.
    NOTE
    Insert the feeler gauge in a horizontally as possible with respect to the valve lifter. Measure and record the exhaust valve clearance while lifting up the vehicle.

  24.  
  25. Rotate the crankshaft pulley clockwise until the arrow mark on the camshaft is positioned as shown to measure and record the clearance on the number two exhaust and number three intake valves.
  26.  
  27. Rotate the crankshaft pulley clockwise until the arrow mark on the camshaft is positioned as shown to measure and record the number two intake and number four exhaust valves.
  28.  
  29. Rotate the crankshaft pulley clockwise until the arrow mark on the camshaft is positioned as shown to measure and record the number one exhaust and number four intake valves.

    Click image to see an enlarged view

    Fig. Turn the crankshaft pulley clockwise until the arrow mark on the camshaft is positioned as shown to measure the No. 1 intake and No. 3 exhaust valves-DOHC engine



    Click image to see an enlarged view

    Fig. Use a feeler gauge to inspect the valve clearance-DOHC engine



    Click image to see an enlarged view

    Fig. Turn the crankshaft pulley clockwise until the arrow mark on the camshaft is positioned as shown to measure the No. 2 exhaust and No. 3 intake valves-DOHC engine



    Click image to see an enlarged view

    Fig. Turn the crankshaft pulley clockwise until the arrow mark on the camshaft is positioned as shown to measure the No. 2 intake and No. 4 exhaust valves-DOHC engine



    Click image to see an enlarged view

    Fig. Turn the crankshaft pulley clockwise until the arrow mark on the camshaft is positioned as shown to measure the No. 1 exhaust and No. 4 intake valves-DOHC engine

  30.  
  31. If adjustment is required, remove the camshafts.
  32.  
  33. Remove and measure the thickness of the valve lifter. Select a suitable shim, using the shim selection chart.
  34.  
  35. Install the replacement shim to the lifter.
  36.  
  37. After all shims have been adjusted, inspect the valve clearances again.
  38.  
  39. After completion, install all removed components.

    Click image to see an enlarged view

    Fig. Use this table to help you select a suitable shim-DOHC engine



    Click image to see an enlarged view

    Fig. Valve adjusting shim chart-DOHC engine

  40.  

SOHC Engines




NOTE
The valve adjustment should be performed while the engine is cold. A Shim Replace Kit 498187100 will be needed to perform the valve adjustment.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Adjustment should be performed when engine is cold.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Engine coolant reservoir tank
     
    Timing belt cover on the left hand side
     

  6.  
  7. When inspecting Nos. 1 and 3 cylinders remove the following:

    Air intake duct as a unit
     
    Resonator chamber
     
    Spark plug wires from Nos. 1 and 3 cylinders
     
    Blow-by house from valve cover
     
    Engine undercover
     
    Timing belt cover on the right hand side
     
    Valve cover on the right hand side
     

  8.  
  9. When inspecting Nos. 2 and 4 cylinders remove the following:

    Battery and battery tray
     
    Window washer motor connectors front and rear
     
    Rear gate glass washer hose from the washer motor
     
    Washer tank mounting bolts and secure out of the way
     
    Spark plug wires from Nos. 2 and 4 cylinders
     
    Blow by hose from valve cover
     
    Timing belt cover on the right hand side
     
    Valve cover on the left hand side
     

  10.  
  11. Set No. 1 cylinder to Top Dead Center (TDC).
  12.  


NOTE
When arrow mark on the left hand side comes exactly to the top, No. 1 cylinder piston is brought to TDC of the compression stroke.

  1. Check the valve clearance:

    Intake valve: 0.0071-0.0087 in. (0.18-0.22mm).
     
    Exhaust valve: 0.0090-0.0106 in. (0.23-0.27mm).
     

  2.  
  3. If any valve needs adjustment, perform the following:
    1. Loosen the valve rocker nut and screw.
    2.  
    3. Place a thickness gage in at as horizontal a direction as possible with respect to the vale stem and face.
    4.  
    5. Adjust the screw until proper clearance is obtained.
    6.  
    7. Tighten the rocker nut after adjusted to 7 ft. lbs. (10 Nm).
    8.  

  4.  
  5. Install or connect the following:

    Valve covers left and right
     
    Timing belt covers
     
    Blow-by hoses to valve covers
     
    Spark plug wires
     
    Washer tank
     
    Rear gate glass washer hose to the washer motor
     
    Washer motor connectors
     
    Battery and battery tray
     
    Engine undercover
     
    Resonator chamber
     
    Air intake duct unit
     
    Engine coolant reservoir tank
     

  6.  


    Click image to see an enlarged view

    Fig. Position the camshaft for adjustment to valves



NOTE
The valve adjustment should be performed while the engine is cold. A Shim Replace Kit 498187100 will be needed to perform the valve adjustment.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Adjustment should be performed when engine is cold.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Engine coolant reservoir tank
     
    Timing belt cover on the left hand side
     

  6.  
  7. When inspecting the No. 1 and 3 cylinders remove the following:

    Air intake duct as a unit
     
    Resonator chamber
     
    Spark plug wires from the No. 1 and 3 cylinders
     
    Blow-by house from valve cover
     
    Engine undercover
     
    Timing belt cover on the right hand side
     
    Valve cover on the right hand side
     

  8.  
  9. When inspecting the No. 2 and 4 cylinders remove the following:

    Battery and battery tray
     
    Window washer motor connectors front and rear
     
    Rear gate glass washer hose from the washer motor
     
    Washer tank mounting bolts and secure out of the way
     
    Spark plug wires from the No. 2 and 4 cylinders
     
    Blow by house from valve cover
     
    Timing belt cover on the right hand side
     
    Valve cover on the left hand side
     

  10.  
  11. Set No. 1 cylinder to Top Dead Center (TDC).
    NOTE
    When arrow mark on the left hand side comes exactly to the top, No. 1 cylinder piston is brought to TDC of the compression stroke.

  12.  
  13. Check the valve clearance:
  14.  
  15. If any valve needs adjustment, perform the following:
    1. Loosen the valve rocker nut and screw.
    2.  
    3. Place a thickness gauge in at as horizontal a direction as possible with respect to the valve stem and face.
    4.  
    5. Adjust the screw until proper clearance is obtained.
    6.  
    7. Tighten the rocker nut after adjusted.
    8.  

  16.  
  17. Install or connect the following:

    Valve covers left and right
     
    Timing belt covers
     
    Blow-by houses to valve covers
     
    Spark plug wires
     
    Washer tank
     
    Rear gate glass washer hose to the washer motor
     
    Washer motor connectors
     
    Battery and battery tray
     
    Engine undercover
     
    Resonator chamber
     
    Air intake duct unit
     
    Engine coolant reservoir tank
     

  18.  


NOTE
The valve adjustment should be performed while the engine is cold.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Remove the under cover.
  6.  
  7. Lower the vehicle.
  8.  
  9. Disconnect the negative battery cable.
  10.  
  11. To remove the front side V belt, remove the belt covers. Loosen the lock bolt. Loosen the slider bolt. Remove the front side belt.
  12.  
  13. To remove the rear side V belt, remove the belt covers. Loosen the lock bolt. Loosen the slider bolt. Remove the rear side belt. Remove the belt tensioner.
  14.  
  15. Remove the crankshaft pulley bolt.
  16.  
  17. Lock the crankshaft in place using tool ST499977100, or equivalent.
  18.  
  19. Remove the crankshaft pulley.
  20.  
  21. Remove the left side timing belt cover.
  22.  
  23. Remove the fuel injector.
  24.  
  25. Remove the rocker cover.
  26.  
  27. Position the number one piston at TDC of the compression stroke.
    NOTE
    When the arrow (see illustration) on the camshaft sprocket (left side) comes exactly to the top, number one cylinder piston is at TDC of the compression stroke.



    Click image to see an enlarged view

    Fig. TDC alignment-2005 SOHC engine

  28.  
  29. Measure the valve clearance, using a feeler gauge.
  30.  
  31. If adjustment is needed, loosen the valve rocker nut and screw. Position the feeler gauge.
    NOTE
    Insert the feeler gauge in a horizontally as possible with respect to the valve stem end face. Adjust the exhaust valve clearance while lifting up the vehicle.

  32.  
  33. While noting the valve clearance, tighten the rocker adjusting screw.
  34.  
  35. When the proper valve clearance is obtained, tighten the valve rocker nut to 7.2 ft. lbs.
  36.  
  37. Adjust the valve clearance on the remaining cylinders, following the above procedure.
    NOTE
    Be sure to position the pistons to their respective TDC positions on the compression stroke, before checking and adjusting the valves. By rotating the crankshaft pulley clockwise every 180 degrees from the state that number one piston is on TDC of the compression stroke, the remaining pistons come to TDC of the compression stroke in the following order, No. 3, No. 2, and No. 4.

  38.  
  39. After adjustment, replace any removed components.
  40.  
  41. Be sure to use new gaskets and seals, as required.
  42.  

 
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