2004 SUBARU FORESTER Engine Assembly

FU(H4DOTC)-21
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
C: DISASSEMBLY
1) Remove the fuel pipe protector LH.
NOTE:
Bolt (A) is tightened together with ground cable.
2) Remove the fuel pipe protector RH.
NOTE:
Bolt (A) is tightened together with ground cable.
3) Remove the engine ground cable from intake
manifold.4) Disconnect the connector from the throttle posi-
tion sensor (A), idle air control solenoid valve (B)
and manifold absolute pressure sensor (C).
5) Disconnect the engine harness fixed by clip (D)
from intake manifold.
6) Remove the throttle body from intake manifold.
7) Disconnect the connector from fuel injector.
8) Disconnect the connector from tumble generator
valve actuator.
(A)
FU-00523
FU-00522
(A)
FU-00036
FU-00037
FU-00038
(A)
(B) (C)
(D) (D)
FU-00013
FU-00615
FU-00616

FU(H4DOTC)-23
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
 RH SIDE
16) Remove the fuel injector.
17) Remove the harness bracket which holds the
engine harness onto intake manifold.
18) Remove the engine harness from intake mani-
fold.19) Loosen the clamp which holds the front left side
fuel hose to injector pipe, and remove the pipe from
clamp.
20) Remove the fuel injector pipe LH.
21) Remove the bolts which install the fuel pipe on
intake manifold.
22) Remove the fuel pipe assembly and pressure
regulator from intake manifold.
23) Remove the intake duct from intake manifold.
24) Remove the intake manifold.
FU-00046
FU-00619
FU-00048
FU-00049
FU-00620
FU-00051
IN-00250
FU-00053

FU(H4DOTC)-24
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
D: ASSEMBLY
NOTE:
Replace the gasket with a new one.
1) Install the intake manifold.
Tightening torque:
8.25 N
⋅m (0.84 kgf-m, 6.1 ft-lb)
2) Install the air intake duct to intake manifold.
Tightening torque:
19 N
⋅m (1.9 kgf-m, 14.0 ft-lb)
3) Install the fuel pipe assembly and pressure reg-
ulator to intake manifold.
Tightening torque:
5 N
⋅m (0.5 kgf-m, 3.7 ft-lb)
4) Install the fuel injector pipe LH.5) Connect the left side fuel hose to injector pipe,
and tighten the clamp screw.
6) Install the engine harness to intake manifold.
7) Install the harness bracket which holds the en-
gine harness onto intake manifold.
Tightening torque:
19 N
⋅m (1.9 kgf-m, 14.0 ft-lb)
8) Install the fuel injector.FU-00053
IN-00250
FU-00051
FU-00620
FU-00049
FU-00048

FU(H4DOTC)-44
FUEL INJECTION (FUEL SYSTEM)
Wastegate Control Solenoid Valve Assembly
16.Wastegate Control Solenoid
Valve Assembly
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Disconnect the connector from wastegate con-
trol solenoid valve assembly.
3) Disconnect the engine harness connector from
bracket.
4) Remove the bracket from body.
5) Disconnect the pressure hoses (C) from waste-
gate control solenoid valve assembly.6) Remove the wastegate control solenoid valve
assembly from bracket.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
6.5 N
⋅m (0.66 kgf-m, 4.8 ft-lb)
FU-00009
FU-02087
FU-00367
(C)
FU-00368
FU-00368

IN(H4DOTC)-9
INTAKE (INDUCTION)
Intake Duct
4. Intake Duct
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the intake manifold. FU(H4DOTC)-14, REMOVAL, Intake Manifold.> or
Manifold.>
3) Remove the sensor, engine harness, and fuel
pipe attached to intake manifold. FU(H4DOTC)-21, DISASSEMBLY, Intake Mani-
fold.> or SEMBLY, Intake Manifold.>
4) Remove the intake duct from intake manifold.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
19 N
⋅m (1.9 kgf-m, 13.7 ft-lb)
FU-00009
IN-00250
IN-00250

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

ME(H4DOTC)-22
MECHANICAL
General Description
C: CAUTION
 Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
 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 fasteners including 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 the 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 stain seats and windows with
coolant or oil. Place a cover over fenders, as re-
quired, 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.

ME(H4DOTC)-27
MECHANICAL
General Description
18251AA020 VALVE GUIDE
ADJUSTERUsed for installing intake and exhaust valve
guides.
499767200 VALVE GUIDE
REMOVERUsed for removing valve guides.
499767400 VALVE GUIDE
REAMERUsed for reaming valve guides.
499817000 ENGINE STAND  Stand used for engine disassembly and
assembly.
 Used with ENGINE STAND ADAPTER RH
(498457000) & LH (498457100). ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST18251AA020
ST-499767200
ST-499767400
ST-499817000