2004 SUBARU FORESTER Service Repair Manual

check oil ESP inoperative jacking points brake sensor steering bonnet

Page 1497 of 2870

SUBARU FORESTER 2004 Service Repair Manual FUJI HEAVY INDUSTRIES LTD. G8080GE3
2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
ENGINE SECTION 2
This service manual has been prepared
to provide SUBARU service personnel
with the necessary inf

Page 1498 of 2870

SUBARU FORESTER 2004 Service Repair Manual MECHANICAL
ME(H4DOTC)
Page
1. General Description ....................................................................................2
2. Compression .................................................

MECHANICAL
ME(H4DOTC)
Page
1. General Description ....................................................................................2
2. Compression .............................................................................................31
3. Idle Speed .................................................................................................32
4. Ignition Timing ...........................................................................................33
5. Intake Manifold Vacuum............................................................................34
6. Engine Oil Pressure ..................................................................................35
7. Fuel Pressure ............................................................................................36
8. Valve Clearance ........................................................................................37
9. Engine Assembly ......................................................................................41
10. Engine Mounting .......................................................................................50
11. Preparation for Overhaul ...........................................................................51
12. V-belt .........................................................................................................52
13. Crank Pulley ..............................................................................................55
14. Timing Belt Cover......................................................................................57
15. Timing Belt Assembly................................................................................58
16. Cam Sprocket ...........................................................................................67
17. Crank Sprocket .........................................................................................68
18. Camshaft ...................................................................................................69
19. Cylinder Head Assembly ...........................................................................76
20. Cylinder Block ...........................................................................................84
21. Intake and Exhaust Valve .......................................................................115
22. Piston ......................................................................................................116
23. Connecting Rod ......................................................................................117
24. Crankshaft ...............................................................................................118
25. Engine Trouble in General ......................................................................119
26. Engine Noise ...........................................................................................124

Page 1499 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4DOTC)-41
MECHANICAL
Engine Assembly
9. Engine Assembly
A: REMOVAL
1) Set the vehicle on a lift.
2) Open the front hood fully, and then support with
the hood stay.
3) Collect the refrigerant from

Page 1500 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4DOTC)-42
MECHANICAL
Engine Assembly
(4) Engine harness connector
(5) Generator connector, terminal and A/C
compressor connectors
(6) Accelerator cable (2.0 L model)
(7) Clutch release spring (MT

Page 1501 of 2870

SUBARU FORESTER 2004 Service Repair Manual 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

Page 1502 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4DOTC)-44
MECHANICAL
Engine Assembly
(3) Screw the 6 mm dia. bolt into release fork
shaft, and remove it.
(4) Raise the release fork, and then unfasten
the release bearing tabs to free release for

Page 1503 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4DOTC)-45
MECHANICAL
Engine Assembly
26) Support the transmission with a garage jack.
NOTE:
Before moving the engine away from transmission,
check to be sure no work has been overlooked. Do-
ing t

Page 1504 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4DOTC)-46
MECHANICAL
Engine Assembly
(4) Apply grease to the specified points.
Spline FX2200
Shaft SUNLIGHT 2
(5) Insert the release fork shaft into release fork.
CAUTION:
Make sure the cutout

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