2004 SUBARU FORESTER wheel

ME(H4DOTC)-43
MECHANICAL
Engine Assembly
(4) Remove the power steering pump from en-
gine.
(5) Remove the reservoir tank from bracket by
pulling it upward.
(6) Place the power steering pump on RH side
wheel apron.
14) Lift-up the vehicle.
15) Remove the ATF cooler pipe from frame. (AT
model)
16) Remove the center exhaust pipe. EX(H4DOTC)-9, REMOVAL, Center Exhaust
Pipe.>17) Remove the nuts which hold the lower side of
transmission to engine.
18) Remove the nuts which install the front cushion
rubber onto front crossmember.
19) Lower the vehicle.
20) Separate the clutch release fork from release
bearing. (MT model)
(1) Remove the clutch operating cylinder from
transmission.
(2) Remove the plug using a 10 mm hexagon
wrench.
ME-00037
ME-00038
ME-00039ME-00040
ME-00041
ME-00042

ME(H4DOTC)-83
MECHANICAL
Cylinder Block
20.Cylinder Block
A: REMOVAL
NOTE:
Before conducting this procedure, drain the engine
oil completely if applicable.
1) Remove the intake manifold. FU(H4DOTC)-14, REMOVAL, Intake Manifold.> or
Manifold.>
2) Remove the V-belt. REMOVAL, V-belt.>
3) Remove the crank pulley. ME(H4DOTC)-55, REMOVAL, Crank Pulley.>
4) Remove the timing belt cover. ME(H4DOTC)-57, REMOVAL, Timing Belt Cover.>
5) Remove the timing belt assembly. ME(H4DOTC)-58, REMOVAL, Timing Belt Assem-
bly.>
6) Remove the cam sprocket. ME(H4DOTC)-67, REMOVAL, Cam Sprocket.>
7) Remove the crank sprocket. ME(H4DOTC)-68, REMOVAL, Crank Sprocket.>
8) Remove the generator and A/C compressor with
their brackets.
9) Remove the cylinder head assembly. ME(H4DOTC)-76, REMOVAL, Cylinder Head As-
sembly.>
10) Remove the clutch disc and cover. (MT model)
er.>
11) Remove the flywheel. (MT model) 19, REMOVAL, Flywheel.>
12) Remove the drive plate. (AT model)
Using the ST, lock crankshaft.
ST 498497100 CRANKSHAFT STOPPER
13) Remove the oil separator cover.
14) Remove the water by-pass pipe for heater.
15) Remove the oil filter using ST.
ter.>16) Remove the oil cooler.
17) Removal of oil pan:
(1) Turn the cylinder block with #2 and #4 piston
sides facing upward.
(2) Remove the bolts which secure oil pan to
cylinder block.
(3) Insert an oil pan cutter blade between cylin-
der block-to-oil pan clearance, and then remove
the oil pan.
Do not use a screwdriver or similar tool in place
of oil pan cutter.
18) Remove the oil strainer stay.
19) Remove the oil strainer.
20) Remove the baffle plate.
21) Remove the water pipes.
22) Remove the water pump.
23) Remove the oil pump from cylinder block.
Use a flat-bladed screwdriver as shown in the fig-
ure when removing the oil pump.
ME-00136
ST
(A) Adapter (1)
(B) Adapter connector
(C) Adapter (2)
(D) Oil cooler
(E) Oil cooler connector
LU-00041
(A)
(B)
(C)
(D)
(E)

ME(H4DOTC)-88
MECHANICAL
Cylinder Block
5) Tighten the 10 mm cylinder block connecting
bolts in alphabetical sequence shown in the figure.
(LH side)
Tightening torque:
15 N
⋅m (1.5 kgf-m, 10.8 ft-lb)
6) Tighten the 10 mm cylinder block connecting
bolts in alphabetical sequence shown in the figure.
(RH side)
Tightening torque:
15 N
⋅m (1.5 kgf-m, 10.8 ft-lb)
7) Further tighten the LH side bolts (A — D) to 90°
in alphabetical sequence.8) Further tighten the RH side bolts (E — J) to 90°
in alphabetical sequence.
9) Tighten the 8 mm and 6 mm cylinder block con-
necting bolts in alphabetical sequence shown in the
figure.
Tightening torque:
(A) — (G): 25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
(H): 6.4 N
⋅m (0.65 kgf-m, 4.7 ft-lb)
10) Install the rear oil seal using ST1 and ST2.
ST1 499597100 CRANKSHAFT OIL SEAL
GUIDE
ST2 499587200 CRANKSHAFT OIL SEAL IN-
STALLER
11) Position the top ring gap at (A) or (B) in the fig-
ure.
12) Position the second ring gap at 180° on the re-
verse side for the top ring gap.
ME-00398
(A)
(B)
(C) (D)
ME-00399
(E)(G)
(F)(I)
(J)
(H)
ME-00398
(A)
(B)
(C) (D)
(A) Rear oil seal
(B) Flywheel attaching bolt
ME-00399
(E)(G)
(F)(I)
(J)
(H)
ME-00147
(B)(C)
(D)
(E)
(F)
(G)
(H)
(A)
ME-00148
ST1
ST2
(B)
(A)

ME(H4DOTC)-93
MECHANICAL
Cylinder Block
Liquid gasket:
Part No. 004403007
THREE BOND 1215 or equivalent
25) Apply liquid gasket to the matching surfaces,
and then install the oil separator cover.
Liquid gasket:
Part No. 004403007
THREE BOND 1215 or equivalent
Tightening torque:
6.4 N
⋅m (0.65 kgf-m, 4.7 ft-lb)
26) Install the drive plate. (AT model)
To lock the crankshaft, use ST.
ST 498497100 CRANKSHAFT STOPPER
Tightening torque:
72 N
⋅m (7.3 kgf-m, 52.8 ft-lb)
27) Install the flywheel. (MT model) INSTALLATION, Flywheel.>
28) Install the clutch disc and cover. (MT model)
Cover.>29) Installation of oil pump:
(1) Discard the front oil seal after removal. Re-
place with a new one using the ST.
ST 499587100 OIL SEAL INSTALLER
(2) Apply liquid gasket to the matching surface of oil pump.
ME-00162
ME-00163
ME-00136
ST
ME-00164

ME(H4DOTC)-97
MECHANICAL
Cylinder Block
Tightening torque:
(E), (F), (G), (I): 20 N
⋅m (2.0 kgf-m, 14.8 ft-lb)
(H), (J): 18 N
⋅m (1.8 kgf-m, 13.3 ft-lb)
9) Further tighten the LH side bolts (A — D) by 90°
in alphabetical sequence.
10) Further tighten the RH side bolts (E — J) by 90°
in alphabetical sequence.11) Tighten the 8 mm and 6 mm cylinder block con-
necting bolts in alphabetical sequence shown in the
figure.
Tightening torque:
(A) — (G): 25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
(H): 6.4 N
⋅m (0.65 kgf-m, 4.7 ft-lb)
12) Install the rear oil seal using ST1 and ST2.
ST1 499597100 CRANKSHAFT OIL SEAL
GUIDE
ST2 499587200 CRANKSHAFT OIL SEAL IN-
STALLER
13) Position the top ring gap at (A) or (B) in the fig-
ure.
14) Position the second ring gap at 180° on the re-
verse side for the top ring gap.
ME-00780
(J)
(H)
(G)
(E)
(F)(I)
ME-00779
(A)
(B)
(D)
(C)
ME-00780
(J)
(H)
(G)
(E)
(F)(I)
(A) Rear oil seal
(B) Flywheel attaching bolt
ME-00147
(B)(C)
(D)
(E)
(F)
(G)
(H)
(A)
ME-00148
ST1
ST2
(B)
(A)
ME-00781
(A)(B) 180

ME(H4DOTC)-102
MECHANICAL
Cylinder Block
27) Apply liquid gasket to the matching surfaces,
and then install the oil separator cover.
Liquid gasket:
Part No. 004403007
THREE BOND 1215 or equivalent
Tightening torque:
6.4 N
⋅m (0.65 kgf-m, 4.7 ft-lb)
28) Install the drive plate. (AT model)
To lock the crankshaft, use ST.
ST 498497100 CRANKSHAFT STOPPER
Tightening torque:
72 N
⋅m (7.3 kgf-m, 52.8 ft-lb)
29) Install the flywheel. TION, Flywheel.>
30) Install the clutch disc and cover. 16, INSTALLATION, Clutch Disc and Cover.>
31) Installation of oil pump:
(1) Discard the front oil seal after removal. Re-
place with a new one using the ST.
ST 499587100 OIL SEAL INSTALLER(2) Apply liquid gasket to the matching surface
of oil pump.
Liquid gasket:
Part No. 004403007
THREE BOND 1215 or equivalent
(3) Apply a coat of engine oil to the inside of the
oil seal.
(4) Install the oil pump on cylinder block. Be
careful not to damage the oil seal during instal-
lation.
Tightening torque:
6.4 N
⋅m (0.65 kgf-m, 4.7 ft-lb)
NOTE:
 Do not forget to install the O-ring and seal when
installing the oil pump.
 Align the flat surface of oil pump’s inner rotor with
crankshaft before installation.
32) Install the water pump and gasket.
Tightening torque:
First; 12 N
⋅m (1.2 kgf-m, 8.7 ft-lb)
Second; 12 N
⋅m (1.2 kgf-m, 8.7 ft-lb)
ME-00163
ME-00136
ST
ME-00164
(A) O-ring
ME-00165
(A)
ME-00312

ME(H4DOTC)-123
MECHANICAL
Engine Noise
26.Engine Noise
A: INSPECTION
NOTE*:
When disconnecting the fuel injector connector, Malfunction Indicator Light illuminates and DTC is stored in
ECM memory.
Therefore, carry out the CLEAR MEMORY MODE Mode.> and INSPECTION MODE after con-
necting the fuel injector connector.
Type of sound Condition Possible cause
Regular clicking soundSound increases as engine
speed increases. Valve mechanism is defective.
 Incorrect valve clearance
 Worn valve rocker
 Worn camshaft
 Broken valve spring
Heavy and dull clankOil pressure is low. Worn crankshaft main bearing
 Worn connecting rod bearing (big end)
Oil pressure is normal. Loose flywheel mounting bolts
 Damaged engine mounting
High-pitched clank (Spark
knock)Sound is noticeable when
accelerating with an overload. Ignition timing advanced
 Accumulation of carbon inside combustion chamber
 Wrong heat range of spark plug
 Improper octane number of gasoline
Clank when engine speed is
medium (1,000 to 2,000 rpm).Sound is reduced when fuel
injector connector of noisy cyl-
inder is disconnected.
(NOTE*) Worn crankshaft main bearing
 Worn bearing at crankshaft end of connecting rod
Knocking sound when engine
is operating under idling speed
and engine is warmSound is reduced when fuel
injector connector of noisy cyl-
inder is disconnected.
(NOTE*) Worn cylinder liner and piston ring
 Broken or stuck piston ring
 Worn piston pin and hole at piston end of connecting rod
Sound is not reduced if each
fuel injector connector is dis-
connected in turn. (NOTE*) Unusually worn valve lifter
 Worn cam gear
 Worn camshaft journal bore in crankcase
Squeaky sound —  Insufficient generator lubrication
Rubbing sound —  Defective generator brush and rotor contact
Gear scream when starting
engine— Defective ignition starter switch
 Worn gear and starter pinion
Sound like polishing glass with
a dry cloth— Loose drive belt
 Defective water pump shaft
Hissing sound — Loss of compression
 Air leakage in air intake system, hoses, connections or mani-
folds
Timing belt noise — Loose timing belt
 Belt contacting case/adjacent part
Valve tappet noise —  Incorrect valve clearance

EX(H4DOTC)-12
EXHAUST
Center Exhaust Pipe
12) Place the turbocharger upper cover, and tight-
en the bolts which install upper side of upper cover.
Tightening torque:
7.4 N·m (0.75 kgf-m, 5.4 ft-lb)
13) Lift-up the vehicle.
14) Tighten the bolts which install under side of tur-
bocharger upper cover.
Tightening torque:
7.4 N·m (0.75 kgf-m, 5.4 ft-lb)
15) Install the universal joint. (RHD model)
(1) Align the bolt hole on long yoke side of uni-
versal joint with the cutout at serrated section of
shaft end, and insert the universal joint.
(2) Align the bolt hole on short yoke side of uni-
versal joint with the cutout at serrated section of
gearbox assembly. Lower the universal joint
completely.
(3) Temporarily tighten the bolt on short yoke
side. Raise the universal joint to make sure the
bolt is properly passing through the cutout at
serrated section.
(4) Tighten the bolt on long yoke side, then that
on the short yoke side.
Tightening torque:
24 N·m (2.4 kgf-m, 17.4 ft-lb)CAUTION:
 Make sure that the universal joint bolts are
tightened through notches in shaft serration.
 Excessively large tightening torque of uni-
versal joint bolts may lead to heavy steering
wheel operation.
Standard clearance between gearbox to DOJ:
Over 15 mm (0.59 in)
16) Install the under cover.
17) Lower the vehicle.
18) Install the intercooler bracket.
19) Install the intercooler.
cooler.>
20) Align the center of roll connector. (RHD model)
TION, Inspection Locations After a Collision.>
EX-00017
EX-00009
EX-00008
EX-00007