2004 SUBARU FORESTER engine

IN(H4SO)-3
INTAKE (INDUCTION)
General Description
(1) Spacer (10) Clip (19) Spacer
(2) Bushing (11) Air cleaner element (20) Clip
(3) Resonator chamber (12) Air cleaner case B
(4) Cushion (13) Stay LH (MT model)Tightening torque: N
⋅m (kgf-m, ft-lb)
(5) Air intake duct A (14) Stay LH (AT model)T1: 33 (3.4, 24.6)
(6) Air intake duct B (15) Stay RHT2: 6.5 (0.66, 4.8)
(7) Bushing (16) Engine harness bracketT3: 7.5 (0.76, 5.5)
(8) Intake air temperature sensor (17) ClampT4: 16 (1.6, 11.6)
(9) Air cleaner case A (18) BushingT5: 3 (0.3, 2.2)

FUJI HEAVY INDUSTRIES LTD. G8080GE2
2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
ENGINE SECTION 1
This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.
All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.FUEL INJECTION (FUEL SYSTEM) FU(H4SO)
EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICE)EC(H4SO)
INTAKE (INDUCTION) IN(H4SO)
MECHANICAL ME(H4SO)
EXHAUST EX(H4SO)
COOLING CO(H4SO)
LUBRICATION LU(H4SO)
SPEED CONTROL SYSTEM SP(H4SO)
IGNITION IG(H4SO)
STARTING/CHARGING SYSTEM SC(H4SO)
ENGINE (DIAGNOSTIC) EN(H4SO)

MECHANICAL
ME(H4SO)
Page
1. General Description ....................................................................................2
2. Compression .............................................................................................25
3. Idle Speed .................................................................................................26
4. Ignition Timing ...........................................................................................27
5. Intake Manifold Vacuum............................................................................28
6. Engine Oil Pressure ..................................................................................29
7. Fuel Pressure ............................................................................................30
8. Valve Clearance ........................................................................................31
9. Engine Assembly ......................................................................................34
10. Engine Mounting .......................................................................................41
11. Preparation for Overhaul ...........................................................................42
12. V-belt .........................................................................................................43
13. Crank Pulley ..............................................................................................45
14. Timing Belt Cover......................................................................................47
15. Timing Belt ................................................................................................48
16. Cam Sprocket ...........................................................................................53
17. Crank Sprocket .........................................................................................55
18. Valve Rocker Assembly ............................................................................56
19. Camshaft ...................................................................................................58
20. Cylinder Head ...........................................................................................62
21. Cylinder Block ...........................................................................................69
22. Engine Trouble in General ........................................................................91
23. Engine Noise .............................................................................................96

ME(H4SO)-2
MECHANICAL
General Description
1. General Description
A: SPECIFICATION
NOTE:
STD: Standard I.D.: Inner Diameter O.D.: Outer Diameter US: Undersize OS: Oversize
EngineModel 2.0 L 2.5 L
Ty p eHorizontally opposed, liquid cooled, 4-cylinder, 4-stroke gaso-
line engine
Valve arrangement Belt driven, single over-head camshaft, 4-valve/cylinder
Bore×Stroke mm (in) 92×75 (3.62×2.95)99.5×79.0
(3.917×3.110)
Displacement
cm
3 (cu in)1,994 (121.67) 2,457 (150)
Compression ratio 10.0
Compression pressure
(at 200 — 300 rpm)kPa (kg/cm
2, psi)1,079 — 1,275 (11.0 — 13.0, 156 — 185)
Number of piston rings Pressure ring: 2, Oil ring: 1
Intake valve timingOpen 4° BTDC 1° BTDC
Close 48° ABDC 51° ABDC
Exhaust valve timingOpen 48° BBDC 50° BBDC
Close 4° AT D C 6° AT D C
Valve clearance Intake mm (in) 0.20±0.04 (0.0079±0.0016)
Exhaust mm (in) 0.25±0.04 (0.0098±0.0016)
Idling speed [at neutral position on
MT, or “P” or “N” range on AT]rpm650±100 (No load)
850±100 (A/C switch ON)
Firing order 1 → 3 → 2 → 4
Ignition timing BTDC/rpm 10°±10°/650
Belt
tensioner
adjusterProtrusion of adjuster rod mm (in) 5.7 — 6.7 (0.224 — 0.263)
Belt
tensionerSpacer O.D. mm (in) 17.955 — 17.975 (0.7069 — 0.7077)
Tensioner bush I.D. mm (in) 18.00 — 18.08 (0.7087 — 0.7118)
Clearance between spacer and bush mm (in)STD 0.025 — 0.125 (0.0010 — 0.0049)
Limit 0.175 (0.0069)
Side clearance of spacer mm (in)STD 0.20 — 0.55 (0.0079 — 0.0217)
Limit 0.81 (0.0319)
Valve rocker
armClearance between shaft and arm mm (in)STD 0.020 — 0.054 (0.0008 — 0.0021)
Limit 0.10 (0.0039)
CamshaftBend limit mm (in) 0.025 (0.0010)
Thrust clearance mm (in)STD 0.030 — 0.090 (0.0012 — 0.0035)
Limit 0.10 (0.0039)
Cam lobe height mm (in)2.0 LIntakeSTD 38.732 — 38.832 (1.5249 — 1.5288)
Limit 38.632 (1.5209)
ExhaustSTD 39.259 — 39.359 (1.5456 — 1.5496)
Limit 39.157 (1.5417)
2.5 LIntakeSTD 39.485 — 39.585 (1.5545 — 1.5585)
Limit 39.385 (1.5506)
ExhaustSTD 39.259 — 39.359 (1.5456 — 1.5496)
Limit 39.159 (1.5417)
Camshaft journal O.D. mm (in) 31.928 — 31.945 (1.2570 — 1.2577)
Camshaft journal hole I.D. (Cylinder head) mm (in) 32.000 — 32.018 (1.2598 — 1.2605)
Oil clearance mm (in)STD 0.055 — 0.090 (0.0022 — 0.0035)
Limit 0.10 (0.0039)

ME(H4SO)-14
MECHANICAL
General Description
7. ENGINE MOUNTING
(1) Front cushion rubber (2) Front engine mounting bracketTightening torque: N⋅m (kgf-m, ft-lb)
T1: 35 (3.6, 25.8)
T2: 42 (4.3, 31.0)
T3: 85 (8.7, 63)
ME-00413
T2
T1
T1
T3
T3 (2)(2)
(1)(1)
T2

ME(H4SO)-15
MECHANICAL
General Description
C: CAUTION
 Wear working clothing, including a cap, protec-
tive goggles and protective shoes during operation.
 Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
 Keep the disassembled parts in order and pro-
tect them from dust or dirt.
 Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly and replacement.
 Be careful not to burn yourself, because each
part in the vehicle is hot after running.
 Be sure to tighten bolts and nuts to the specified
torque.
 Place shop jacks or rigid racks at the specified
points.
 Before disconnecting electrical connectors of
sensors or units, be sure to disconnect the ground
cable from battery.
 All parts should be thoroughly cleaned, paying
special attention to the engine oil passages, pis-
tons and bearings. Rotating parts and sliding parts such as piston,
bearing and gear should be coated with oil prior to
assembly.
 Be careful not to let oil, grease or coolant contact
the timing belt, clutch disc and flywheel.
 All removed parts, if to be reused, should be re-
installed in the original positions and directions.
 Bolts, nuts and washers should be replaced with
new ones as required.
 Even if necessary inspections have been made
in advance, proceed with assembly work while
making rechecks.
 Remove or install engine in an area where chain
hoists, lifting devices, etc. are available for ready
use.
 Be sure not to damage coated surfaces of body
panels with tools, or not to stain seats and windows
with coolant or oil. Place a cover over fenders, as
required, for protection.
 Prior to starting work, prepare the following:
Service tools, clean cloth, containers to catch cool-
ant and oil, wire ropes, chain hoist, transmission
jacks, etc.
 Lift-up or lower the vehicle when necessary.
Make sure to support the correct positions.
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
18231AA010 CAM SPROCKET
WRENCH Used for removing and installing cam
sprocket. (LH side)
 Also the CAM SPROCKET WRENCH
(499207100) can be used.
24082AA230
(Newly adopted tool)CARTRIDGE Troubleshooting for electrical systems.
ST18231AA010
ST24082AA230

ME(H4SO)-16
MECHANICAL
General Description
22771AA030 SUBARU SELECT
MONITOR KITTroubleshooting for electrical systems.
 English: 22771AA030 (Without printer)
 German: 22771AA070 (Without printer)
 French: 22771AA080 (Without printer)
 Spanish: 22771AA090 (Without printer)
498267800 CYLINDER HEAD
TABLE Used for replacing valve guides.
 Used for removing and installing valve springs.
498277200 STOPPER SET Used for installing automatic transmission
assembly to engine.
498457000 ENGINE STAND
ADAPTER RHUsed with ENGINE STAND (499817000). ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST22771AA030
ST-498267800
ST-498277200
ST-498457000

ME(H4SO)-17
MECHANICAL
General Description
498457100 ENGINE STAND
ADAPTER LHUsed with ENGINE STAND (499817000).
498497100 CRANKSHAFT
STOPPERUsed for stopping rotation of flywheel when loos-
ening and tightening crank pulley bolt, etc.
498547000 OIL FILTER
WRENCHUsed for removing and installing oil filter.
(Outer diameter : 80 mm (3.15 in))
18332AA000 OIL FILTER
WRENCHUsed for removing and installing oil filter.
(Outer diameter : 68 mm (2.68 in)) ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-498457100
ST-498497100
ST-498547000
ST18332AA000