2004 SUBARU FORESTER Service Repair Manual

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Page 945 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4SO)-74
MECHANICAL
Cylinder Block
4) Tighten the 10 mm cylinder block connecting
bolts on LH side (A — D) in alphabetical sequence.
Tightening torque:
15 N
⋅m (1.5 kgf-m, 10.8 ft-lb)
5) Tighte

Page 946 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4SO)-75
MECHANICAL
Cylinder Block
2.5 L model
12) Position the expander gap at (C) in the figure.
2.0 L model
2.5 L model13) Position the lower rail gap at (D) in the figure.
2.0 L model

Page 947 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4SO)-76
MECHANICAL
Cylinder Block
2.5 L model
CAUTION:
Ensure ring gaps do not face the same direc-
tion.
Ensure ring gaps are not within the piston
skirt area.
15) Install snap ring.
Instal

Page 948 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4SO)-77
MECHANICAL
Cylinder Block
16) Installing piston
(1) Turn the cylinder block to face the #1 and #2
piston side upward.
(2) Using the ST1, turn the crankshaft so that
#1 and #2 connecting ro

Page 949 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4SO)-78
MECHANICAL
Cylinder Block
(5) Apply liquid gasket around the service hole
plug.
Liquid gasket:
THREE BOND 1215 (Part No. 004403007) or
equivalent(6) Install the service hole plug and gask

Page 950 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4SO)-79
MECHANICAL
Cylinder Block
18) Install the water pipe.
19) Install the baffle plate.
Tightening torque:
6.4 N
⋅m (0.65 kgf-m, 4.7 ft-lb)
20) Install the oil strainer and O-ring.
Tightenin

Page 951 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4SO)-80
MECHANICAL
Cylinder Block
ST2 499057000 TORX PLUS
25) Install the housing cover.
26) Installation of oil pump
(1) Discard the front oil seal after removal. Re-
place with a new one using t

Page 952 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4SO)-81
MECHANICAL
Cylinder Block
Model with ATF warmer
28) Install the water by-pass pipe for heater.
29) Get a engine oil filter and apply a thin coat of
engine oil to the seal rubber.
30) Ins

ME(H4SO)-81
MECHANICAL
Cylinder Block
Model with ATF warmer
28) Install the water by-pass pipe for heater.
29) Get a engine oil filter and apply a thin coat of
engine oil to the seal rubber.
30) Install the oil filter by turning it by hand, being
careful not to damage the seal rubber.
Tighten the oil filter 80 mm (3.15 in) or 65 mm
(2.56 in) in diameter by approx. 2/3 — 3/4 rotation
more after the seal rubber of oil filter comes in con-
tact with cylinder block or oil cooler.
Tighten the oil filter 68 mm (2.68 in) in diameter
by approx. 1 rotation more after the seal rubber of
oil filter comes in contact with cylinder block or oil
cooler.
CAUTION:
Do not tighten excessively, or oil may leak.
31) Tighten the cylinder head bolts.
(1) Apply a coat of engine oil to washers and
bolt threads.
(2) Tighten all bolts to 29 N⋅m (3.0 kgf-m, 22 ft-
lb) in alphabetical sequence.
Then tighten all bolts to 69 N⋅m (7.0 kgf-m, 51 ft-
lb) in alphabetical sequence.
(3) Back off all bolts by 180° in reverse order of
installation, and back them off again by 180°.
(4) Tighten all bolts to 42 N⋅m (3.9 kgf-m, 31 ft-
lb) in alphabetical sequence.
(5) Tighten all bolts by 80° — 90° in alphabeti-
cal sequence.
(6) Tighten all bolts by 40° — 45° in alphabeti-
cal sequence.
NOTE:
Do not tighten the bolts more than 45°.
(7) Further tighten bolts (a) and (b) by 40° —
45°.NOTE:
Ensure the total “re-tightening angle” in the [former
two steps], do not exceed 90°.
32) Install the oil level gauge guide and tighten the
attaching bolt (left side only).
33) Install the rocker cover.
34) Install the crank sprocket. 55, INSTALLATION, Crank Sprocket.>
35) Install the cam sprocket. 53, INSTALLATION, Cam Sprocket.>
36) Install the timing belt assembly. ME(H4SO)-49, INSTALLATION, Timing Belt.>
37) Install the belt cover. INSTALLATION, Timing Belt Cover.>
38) Install the crank pulley. INSTALLATION, Crank Pulley.>
39) Install the generator and A/C compressor
brackets on cylinder head.
40) Install the V-belt. STALLATION, V-belt.>
41) Install the intake manifold. 16, INSTALLATION, Intake Manifold.>
ME-02017
(B) (C) (D)(E)(F)
(A)
ME-00279
(c)
(b)(f)
(d) (a)
(e)

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