2004 SUBARU FORESTER Service Repair Manual

service reset turn signal wiper blades lumbar support air condition technical specifications

Page 1569 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4DOTC)-109
MECHANICAL
Cylinder Block
2) Squarely place the piston ring and oil ring in cyl-
inder, and then measure the piston ring gap with a
thickness gauge.
2.0 L MODEL
2.5 L MODEL
3) Measu

Page 1570 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4DOTC)-110
MECHANICAL
Cylinder Block
3) Install the connecting rod fitted with bearing to
crankshaft, and then measure the side clearance
(thrust clearance). Replace the connecting rod if
the side

ME(H4DOTC)-110
MECHANICAL
Cylinder Block
3) Install the connecting rod fitted with bearing to
crankshaft, and then measure the side clearance
(thrust clearance). Replace the connecting rod if
the side clearance exceeds the specified limit.
Connecting rod side clearance:
Standard
0.070 — 0.330 mm (0.0028 — 0.0130 in)
Limit
0.40 mm (0.016 in)
4) Inspect the connecting rod bearing for scar,
peeling, seizure, melting, wear, etc.
5) Measure the oil clearance on individual connect-
ing rod bearings by means of plastigage. If any oil
clearance is not within specification, replace the
defective bearing with a new one of standard size
or undersize as necessary (See the table).
2.0 L MODEL
Connecting rod oil clearance:
Standard
0.020 — 0.046 mm (0.0008 — 0.0018 in)
Limit
0.050 mm (0.0020 in)2.5 L MODEL
Connecting rod oil clearance:
Standard
0.017 — 0.045 mm (0.0007 — 0.0018 in)
Limit
0.05 mm (0.0020 in)
6) Inspect the bushing at connecting rod small end,
and replace if worn or damaged. Also measure the
piston pin clearance at connecting rod small end.
Clearance between piston pin and bushing:
Standard
0 — 0.022 mm (0 — 0.0009 in)
Limit
0.030 mm (0.0012 in)
Unit: mm (in)
BearingBearing size
(Thickness at cen-
ter)Outer diameter of
crank pin
Standard1.486 — 1.498
(0.0585 — 0.0590)51.984 — 52.000
(2.0466 — 2.0472)
0.03
(0.0012)
undersize1.504 — 1.512
(0.0592 — 0.0595)51.954 — 51.970
(2.0454 — 2.0461)
0.05
(0.0020)
undersize1.514 — 1.522
(0.0596 — 0.0599)51.934 — 51.950
(2.0447 — 2.0453)
0.25
(0.0098)
undersize1.614 — 1.622
(0.0635 — 0.0639)51.734 — 51.750
(2.0368 — 2.0374)
ME-00180
Unit: mm (in)
BearingBearing size
(Thickness at cen-
ter)Outer diameter of
crank pin
Standard1.490 — 1.502
(0.0587 — 0.0591)51.984 — 52.000
(2.0466 — 2.0472)
0.03
(0.0012)
undersize1.504 — 1.512
(0.0592 — 0.0595)51.954 — 51.970
(2.0454 — 2.0461)
0.05
(0.0020)
undersize1.514 — 1.522
(0.0596 — 0.0599)51.934 — 51.950
(2.0447 — 2.0453)
0.25
(0.0098)
undersize1.614 — 1.622
(0.0635 — 0.0639)51.734 — 51.750
(2.0368 — 2.0374)
ME-00181
ME-00174

Page 1571 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4DOTC)-111
MECHANICAL
Cylinder Block
7) Replacement procedure is as follows:
(1) Remove the bushing from connecting rod
with ST and press.
(2) Press the bushing with ST after applying oil
on the p

Page 1572 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4DOTC)-112
MECHANICAL
Cylinder Block
2.0 L MODEL
O.D.: Outer Diameter
2.5 L MODEL
O.D.: Outer DiameterUnit: mm (in)
Crank journal diameter
Crank pin diameter
#1, #3, #5 #2, #4
StandardJournal

ME(H4DOTC)-112
MECHANICAL
Cylinder Block
2.0 L MODEL
O.D.: Outer Diameter
2.5 L MODEL
O.D.: Outer DiameterUnit: mm (in)
Crank journal diameter
Crank pin diameter
#1, #3, #5 #2, #4
StandardJournal O.D.59.992 — 60.008
(2.3619 — 2.3625)59.992 — 60.008
(2.3619 — 2.3625)51.984 — 52.000
(2.0466 — 2.0472)
Bearing size
(Thickness at cen-
ter)1.998 — 2.011
(0.0787 — 0.0792)2.000 — 2.013
(0.0787 — 0.0793)1.486 — 1.498
(0.0585 — 0.0590)
0.03 (0.0012)
undersizeJournal O.D.59.962 — 59.978
(2.3607 — 2.3613)59.962 — 59.978
(2.3607 — 2.3613)51.954 — 51.970
(2.0454 — 2.0461)
Bearing size
(Thickness at cen-
ter)2.017 — 2.020
(0.0794 — 0.0795)2.019 — 2.022
(0.0795 — 0.0796)1.504 — 1.512
(0.0592 — 0.0595)
0.05 (0.0020)
undersizeJournal O.D.59.942 — 59.958
(2.3599 — 2.3605)59.942 — 59.958
(2.3599 — 2.3605)51.934 — 51.950
(2.0447 — 2.0453)
Bearing size
(Thickness at cen-
ter)2.027 — 2.030
(0.0798 — 0.0799)2.029 — 2.032
(0.0799 — 0.0800)1.514 — 1.522
(0.0596 — 0.0599)
0.25 (0.0098)
undersizeJournal O.D.59.742 — 59.758
(2.3520 — 2.3527)59.742 — 59.758
(2.3520 — 2.3527)51.734 — 51.750
(2.0368 — 2.0374)
Bearing size
(Thickness at cen-
ter)2.127 — 2.130
(0.0837 — 0.0839)2.129 — 2.132
(0.0838 — 0.0839)1.614 — 1.622
(0.0635 — 0.0639)
Unit: mm (in)
Crank journal diameter
Crank pin outer diameter
#1, #3, #5 #2, #4
StandardJournal O.D.59.992 — 60.008
(2.3619 — 2.3625)59.992 — 60.008
(2.3619 — 2.3625)51.984 — 52.000
(2.0466 — 2.0472)
Bearing size
(Thickness at cen-
ter)1.998 — 2.011
(0.0787 — 0.0792)2.000 — 2.013
(0.0787 — 0.0793)1.490 — 1.502
(0.0587 — 0.0591)
0.03 (0.0012)
undersizeJournal O.D.59.962 — 59.978
(2.3607 — 2.3613)59.962 — 59.978
(2.3607 — 2.3613)51.954 — 51.970
(2.0454 — 2.0461)
Bearing size
(Thickness at cen-
ter)2.017 — 2.020
(0.0794 — 0.0795)2.019 — 2.022
(0.0795 — 0.0796)1.504 — 1.512
(0.0592 — 0.0595)
0.05 (0.0020)
undersizeJournal O.D.59.942 — 59.958
(2.3599 — 2.3605)59.942 — 59.958
(2.3599 — 2.3605)51.934 — 51.950
(2.0447 — 2.0453)
Bearing size
(Thickness at cen-
ter)2.027 — 2.030
(0.0798 — 0.0799)2.029 — 2.032
(0.0799 — 0.0800)1.514 — 1.522
(0.0596 — 0.0599)
0.25 (0.0098)
undersizeJournal O.D.59.742 — 59.758
(2.3520 — 2.3527)59.742 — 59.758
(2.3520 — 2.3527)51.734 — 51.750
(2.0368 — 2.0374)
Bearing size
(Thickness at cen-
ter)2.127 — 2.130
(0.0837 — 0.0839)2.129 — 2.132
(0.0838 — 0.0839)1.614 — 1.622
(0.0635 — 0.0639)

Page 1573 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4DOTC)-113
MECHANICAL
Cylinder Block
4) Measure the thrust clearance of crankshaft at
center bearing. If the clearance exceeds the limit,
replace the bearing.
Crankshaft thrust clearance:
Standard

Page 1574 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4DOTC)-114
MECHANICAL
Intake and Exhaust Valve
21.Intake and Exhaust Valve
A: REMOVAL AND INSTALLATION
For operations related to intake and exhaust valve,
refer to “19. Cylinder Head.” <Ref. t

Page 1575 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4DOTC)-115
MECHANICAL
Piston
22.Piston
A: REMOVAL AND INSTALLATION
For operations related to piston, refer to “20. Cylin-
der Block.” <Ref. to ME(H4DOTC)-84, REMOVAL,
Cylinder Block.> <Ref. to

Page 1576 of 2870

SUBARU FORESTER 2004 Service Repair Manual ME(H4DOTC)-116
MECHANICAL
Connecting Rod
23.Connecting Rod
A: REMOVAL AND INSTALLATION
For operations related to connecting rod, refer to
“20. Cylinder Block.” <Ref. to ME(H4DOTC)-84,
REMOVAL, Cyl

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