2004 SUBARU FORESTER Service Repair Manual

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Page 1561 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4DOTC)-101
MECHANICAL
Cylinder Block
(7) Turn the cylinder block so that #3 and #4 cyl-
inders face upward. Using the same procedures
as used for #1 and #2 cylinders, install the pis-
tons and pis

Page 1562 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4DOTC)-102
MECHANICAL
Cylinder Block
27) Apply liquid gasket to the matching surfaces,
and then install the oil separator cover.
Liquid gasket:
Part No. 004403007
THREE BOND 1215 or equivalent
Tig

Page 1563 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4DOTC)-103
MECHANICAL
Cylinder Block
NOTE:
Be sure to use a new gasket.
When installing the water pump, tighten the bolts
in two stages in alphabetical sequence as shown in
the figure.
33) Ins

Page 1564 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4DOTC)-104
MECHANICAL
Cylinder Block
C: DISASSEMBLY
1) Remove the connecting rod cap.
2) Remove the connecting rod bearing.
NOTE:
Arrange the removed connecting rod, connecting
rod cap and bearing

Page 1565 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4DOTC)-105
MECHANICAL
Cylinder Block
D: ASSEMBLY
1) Apply oil to the surfaces of the connecting rod
bearings. Install the connecting rod bearings on
connecting rods and connecting rod caps.
2) Ins

Page 1566 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4DOTC)-106
MECHANICAL
Cylinder Block
2.0 L MODEL
Standard diameter:
A: 92.005 — 92.015 mm (3.6222 — 3.6226 in)
B: 91.995 — 92.005 mm (3.6218 — 3.6222 in)
2.5 L MODEL
Standard diameter:
A:

Page 1567 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4DOTC)-107
MECHANICAL
Cylinder Block
2.0 L MODEL
Piston grade point H:
40.0 mm (1.57 in)
Piston outer diameter:
Standard
A: 91.985 — 91.995 mm
(3.6214 — 3.6218 in)
B: 91.975 — 91.985 mm
(3.6

ME(H4DOTC)-107
MECHANICAL
Cylinder Block
2.0 L MODEL
Piston grade point H:
40.0 mm (1.57 in)
Piston outer diameter:
Standard
A: 91.985 — 91.995 mm
(3.6214 — 3.6218 in)
B: 91.975 — 91.985 mm
(3.6211 — 3.6214 in)
0.25 mm (0.0098 in) oversize
92.225 — 92.235 mm
(3.6309 — 3.6313 in)
0.50 mm (0.0197 in) oversize
92.475 — 92.485 mm
(3.6407 — 3.6411 in)
2.5 L MODEL
Piston grade point H:
38.2 mm (1.50 in)
Piston outer diameter:
Standard
A: 99.505 — 99.515 mm
(3.9175 — 3.9179 in)
B: 99.495 — 99.505 mm
(3.9171 — 3.9175 in)
0.25 mm (0.0098 in) oversize
99.745 — 99.765 mm
(3.9270 — 3.9278 in)
0.50 mm (0.0197 in) oversize
99.995 — 100.015 mm
(3.9368 — 3.9376 in)
5) Calculate the clearance between cylinder and
piston.
NOTE:
Measurement should be performed at a tempera-
ture of 20°C (68°F).
Cylinder to piston clearance at 20
°C (68°F):
2.0 L MODEL
Standard
0.010 — 0.030 mm (0.0004 — 0.0012 in)
Limit
0.050 mm (0.0020 in)2.5 L MODEL
Standard
−0.010 — 0.010 mm (−0.0004 — 0.0004 in)
Limit
0.030 mm (0.0012 in)
6) Boring and honing:
(1) If the value of taper, out-of-roundness, or
cylinder-to-piston clearance measured exceeds
the specified limit or if there is any damage on
the cylinder wall, reboring it to use an oversize
piston.
CAUTION:
When any of the cylinders needs reboring, all
other cylinders must be bored at the same time,
and use oversize pistons. Do not perform bor-
ing on one cylinder only, nor use an oversize
piston for one cylinder only.
(2) If the cylinder inner diameter exceeds the
limit after boring and honing, replace the crank-
case.
NOTE:
Immediately after reboring, the cylinder diameter
may differ from its real diameter due to temperature
rise. Thus, pay attention to this when measuring
the cylinder diameter.
Limit of cylinder enlarging (boring):
0.5 mm (0.020 in)
3. PISTON AND PISTON PIN
1) Check the pistons and piston pins for damage,
cracks and wear, Replace if defective.
2) Check the piston ring grooves for wear and dam-
age, Replace if defective.
3) Measure the piston-to-cylinder clearance at
each cylinder. DER AND PISTON, INSPECTION, Cylinder
Block.> If any of the clearances is not within speci-
fication, replace the piston or bore the cylinder to
use an oversize piston.
ME-00172
H

Page 1568 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4DOTC)-108
MECHANICAL
Cylinder Block
4) Make sure that the piston pin can be inserted
into the piston pin hole with a thumb at 20°C (68°F).
Replace if defective.
Standard clearance between pisto

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