2004 SUBARU FORESTER belt

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)-6
MECHANICAL
General Description
B: COMPONENT
1. TIMING BELT
(1) Timing belt cover No. 2 (RH) (9) Automatic belt tension adjuster
ASSYTightening torque: N⋅m (kgf-m, ft-lb)
(2) Timing belt guide (MT model)T1: 5 (0.5, 3.6)
(3) Crank sprocket (10) Belt idler No. 2T2: 10 (1.0, 7.2)
(4) Timing belt cover No. 2 (LH) (11) Cam sprocket No. 2T3: 25 (2.5, 18.1)
(5) Cam sprocket No. 1 (12) Timing beltT4: 39 (4.0, 28.9)
(6) Belt idler (No. 1) (13) Front timing belt coverT5: 78 (8.0, 57.9)
(7) Tensioner bracket (14) Timing belt cover (LH)T6: INSTALLATION, Crank Pulley.>
(8) Belt idler (No. 2) (15) Crank pulley (2.0 L model)
(16) Crank pulley (2.5 L model)
ME-00376
T5
T4
T1
T1
T6
T5 (5)
(6)
(8)
(9)
(11) (10)
(14) (15)
(16)(12)
(13)(7)(4) (1)
(2)
(3)
T1
T2
T1
T3
T4
T6
T4

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)-24
MECHANICAL
General Description
E: PROCEDURE
It is possible to conduct the following service proce-
dures with engine on the vehicle, however, the pro-
cedures described in this section are based on the
condition that the engine is removed from the vehi-
cle.
V-belt
 Timing Belt
 Valve Rocker Assembly
 Camshaft
 Cylinder Head

ME(H4SO)-29
MECHANICAL
Engine Oil Pressure
6. Engine Oil Pressure
A: INSPECTION
1) Disconnect the ground cable from battery.
2) Remove the generator from bracket. SC(H4SO)-15, REMOVAL, Generator.>
3) Disconnect the connector from oil pressure
switch.
4) Remove the oil pressure switch from cylinder
block. sure Switch.>
5) Connect the oil pressure gauge hose to cylinder
block.
6) Connect the battery ground cable to battery.
7) Start the engine, and then measure the oil pres-
sure.
Oil pressure:
Standard:
88 kPa (0.9 kg/cm
2, 13 psi) or more at 800 rpm
294 kPa (3.0 kg/cm2, 43 psi) or more at 5,000
rpmCAUTION:
 If the oil pressure is out of specification,
check the oil pump, oil filter and lubrication
line. gine Lubrication System Trouble in General.>
 If the oil pressure warning light is turned ON
and oil pressure is in specification, replace the
oil pressure switch. SPECTION, Engine Lubrication System Trouble
in General.>
NOTE:
The specified data is based on an engine oil tem-
perature of 80°C (176°F).
8) After measuring the oil pressure, install the oil
pressure switch. LATION, Oil Pressure Switch.>
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
9) Install the generator and V-belt in the reverse or-
der of removal, and then adjust the V-belt deflec-
tion. belt.>
FU-00009
FU-00009
ME-00196

ME(H4SO)-31
MECHANICAL
Valve Clearance
8. Valve Clearance
A: INSPECTION
NOTE:
Inspection and adjustment of the valve clearance
should be performed while engine is cold.
1) Set the vehicle on a lift.
2) Lift-up the vehicle.
3) Remove the under cover.
4) Lower the vehicle.
5) Disconnect the ground cable from battery.
6) Remove the belt cover (LH).
7) When inspecting the #1 and #3 cylinders:
(1) Disconnect the spark plug cords from spark
plugs RH side. REMOVAL, Spark Plug.>
(2) Disconnect the PCV hose from rocker cover
(RH).
(3) Remove the bolts, and then remove the
rocker cover (RH).
8) When inspecting the #2 and #4 cylinders:
(1) Disconnect the spark plug cords from spark
plugs (LH Side) REMOVAL, Spark Plug.>
(2) Disconnect the PCV hose from rocker cover
(LH).
(3) Remove the bolts, and then remove the
rocker cover (LH).
9) Set the #1 cylinder piston to top dead center of
compression stroke by rotating crank pulley clock-
wise using a socket wrench.NOTE:
When arrow mark (A) on the cam sprocket (LH)
comes exactly to the top, #1 cylinder piston is
brought to the top dead center of compression
stroke.
10) Measure the #1 cylinder valve clearance by us-
ing thickness gauge.
CAUTION:
 Insert the thickness gauge (A) in as horizon-
tal a direction as possible with respect to the
valve stem end face.
 Measure the exhaust valve clearances while
lifting-up the vehicle.
Valve clearance (Standard):
Intake;
0.20
±0.04 mm (0.0079±0.0016 in)
Exhaust;
0.25
±0.04 mm (0.0098±0.0016 in)
11) If necessary, adjust the valve clearance. to ME(H4SO)-32, ADJUSTMENT, Valve Clear-
ance.>
12) Similar to measurement procedures used for
#1 cylinder, measure the #2, #3 and #4 cylinder
valve clearances.
NOTE:
 Be sure to set the cylinder pistons to their re-
spective top dead centers on compression stroke
before measuring valve clearances.
FU-00009
ME-00199
ME-00200
(A)
ME-00201
(A)

ME(H4SO)-36
MECHANICAL
Engine Assembly
(2) Loosen the lock bolt and slider bolt, and
then remove the front side V-belt. ME(H4SO)-43, FRONT SIDE BELT, REMOV-
AL, V-belt.>
(3) Remove the pipe with bracket.
(4) Remove the bolts which install power steer-
ing pump bracket.
(5) Remove the reservoir tank from bracket by
pulling it upward.
(6) Place the power steering pump on right side
wheel apron.14) Remove the front and center exhaust pipe.
Pipe.>
15) Remove the nuts which hold lower side of
transmission to engine.
16) Remove the nuts which install front cushion
rubber onto front crossmember.
17) Separate the torque converter clutch from drive
plate. (AT model)
(1) Lower the vehicle.
(2) Remove the service hole plug.
(3) Remove the bolts which hold torque con-
verter clutch to drive plate.
(4) Remove other bolts while rotating the en-
gine using socket wrench.
ME-00331
FU-00139
FU-00020
FU-00140ME-00210
ME-00211
ME-00212

ME(H4SO)-39
MECHANICAL
Engine Assembly
(1) Tighten the bolts which hold torque convert-
er clutch to drive plate.
(2) Tighten other bolts while rotating the engine
by using a socket wrench.
NOTE:
Be careful not to drop the bolts into torque convert-
er clutch housing.
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
(3) Plug up the service hole and prevent foreign
matters from getting in.
10) Install the power steering pump on bracket.
(1) Install the reservoir tank on bracket.
(2) Install the power steering pump on bracket,
and then tighten the bolts.
Tightening torque:
20.1 N
⋅m (2.05 kgf-m, 14.8 ft-lb)(3) Tighten the bolts which install power steer-
ing pump bracket, and then install the spark plug
cords.
(4) Connect the power steering switch connec-
tor.
(5) Install the front side V-belt, and adjust it.
STALLATION, V-belt.>
(6) Install the resonator chamber.
Tightening torque:
33 N
⋅m (3.4 kgf-m, 24.6 ft-lb)
ME-00212
FU-00020
FU-00139
ME-00331
FU-00017
IN-00044