2004 SUBARU FORESTER Service Repair Manual

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Page 1521 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4DOTC)-63
MECHANICAL
Timing Belt Assembly
Align the alignment mark on timing belt with marks on sprockets in alphabetical order shown in the figure.
While aligning marks, position the timing belt

Page 1522 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4DOTC)-64
MECHANICAL
Timing Belt Assembly
6) Install the timing belt guide. (MT model)
(1) Temporarily tighten the bolts.
(2) Check and adjust the clearance between
timing belt and timing belt gui

Page 1523 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4DOTC)-65
MECHANICAL
Timing Belt Assembly
7) Install the timing belt cover. <Ref. to
ME(H4DOTC)-57, INSTALLATION, Timing Belt
Cover.>
8) Install the crank pulley. <Ref. to ME(H4DOTC)-
55, INSTALL

ME(H4DOTC)-65
MECHANICAL
Timing Belt Assembly
7) Install the timing belt cover. ME(H4DOTC)-57, INSTALLATION, Timing Belt
Cover.>
8) Install the crank pulley. 55, INSTALLATION, Crank Pulley.>
9) Install the V-belt. STALLATION, V-belt.>
C: INSPECTION
1. TIMING BELT
1) Check the timing belt teeth for breaks, cracks,
and wear. If any fault is found, replace the belt.
2) Check the condition of back side of belt; if any
crack is found, replace the belt.
NOTE:
Be careful not to let oil, grease or coolant contact
the belt. Remove quickly and thoroughly if this hap-
pens.
Do not bend the belt sharply.
Bending radius: h
60 mm (2.36 in) or more
2. AUTOMATIC BELT TENSION ADJUST-
ER
1) Visually check the oil seals for leaks, and rod
ends for abnormal wear or scratches. If necessary,
replace the automatic belt tension adjuster assem-
bly.
NOTE:
Slight traces of oil at rod’s oil seal does not indicate
a problem.
2) Check that the adjuster rod does not move when
a pressure of 294 N (30 kgf, 66 lb) is applied to it.
This is to check adjuster rod stiffness.
3) If the adjuster rod is not stiff and moves freely
when applying 294 N (30 kgf, 66 lb), check it using
the following procedures:
(1) Slowly press the adjuster rod down to the
end surface of the cylinder. Repeat this motion 2
or 3 times.
(2) With the adjuster rod moved all the way up,
apply a pressure of 294 N (30 kgf, 66 lb) to it.
Check the adjuster rod stiffness.(3) If the adjuster rod is not stiff and moves
down, replace the automatic belt tension adjust-
er assembly with a new one.
NOTE:
Always use a vertical type pressing tool to move
the adjuster rod down.
Do not use a lateral type vise.
Push the adjuster rod vertically.
Press-in the push adjuster rod gradually taking
more than 3 minutes.
Do not allow press pressure to exceed 9,807 N
(1,000 kgf, 2,205 lb).
Press the adjuster rod as far as the end surface
of the cylinder. Do not press the adjuster rod into
the cylinder. Doing so may damage the cylinder.
4) Measure the extension of rod beyond the body.
If it is not within specifications, replace with a new
one.
Rod extension: H
6.2
±0.5 mm (0.244±0.020 in)
3. BELT TENSION PULLEY
1) Check the mating surfaces of timing belt and
contact point of adjuster rod for abnormal wear or
scratches. Replace the belt tension pulley if faulty.
2) Check the belt tension pulley for smooth rota-
tion. Replace if noise or excessive play is noted.
3) Check the belt tension pulley for grease leakage.
4. BELT IDLER
1) Check the belt idler for smooth rotation. Replace
if noise or excessive play is noted.
2) Check the outer contacting surfaces of idler pul-
ley for abnormal wear and scratches.
3) Check the belt idler for grease leakage.
ME-00099
h
ME-00100
H

Page 1524 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4DOTC)-66
MECHANICAL
Cam Sprocket
16.Cam Sprocket
A: REMOVAL
1) Remove the V-belt. <Ref. to ME(H4DOTC)-52,
REMOVAL, V-belt.>
2) Remove the crank pulley. <Ref. to
ME(H4DOTC)-55, REMOVAL, Crank Pull

Page 1525 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4DOTC)-67
MECHANICAL
Crank Sprocket
17.Crank Sprocket
A: REMOVAL
1) Remove the V-belt. <Ref. to ME(H4DOTC)-52,
REMOVAL, V-belt.>
2) Remove the crank pulley. <Ref. to ME(H4DOTC)-
55, REMOVAL, Crank

Page 1526 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4DOTC)-68
MECHANICAL
Camshaft
18.Camshaft
A: REMOVAL
1) Remove the V-belt. <Ref. to ME(H4DOTC)-52,
INSTALLATION, V-belt.>
2) Remove the crank pulley. <Ref. to ME(H4DOTC)-
55, REMOVAL, Crank Pulley

Page 1527 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4DOTC)-69
MECHANICAL
Camshaft
16) Remove the oil flow control solenoid valve as-
sembly, intake camshaft cap, and camshaft.
17) Loosen the exhaust camshaft cap bolts equal-
ly, a little at a time

Page 1528 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4DOTC)-70
MECHANICAL
Camshaft
Liquid gasket:
Part No. 004403007
THREE BOND 1215 or equivalent
2.0 L MODEL
2.5 L MODEL
(2) Apply engine oil to cap bearing surface and
install the cap on camshaf

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