2004 SUBARU FORESTER engine

IN(H4DOTC)-5
INTAKE (INDUCTION)
General Description
4. TURBOCHARGER
(1) Oil inlet pipe (7) GasketTightening torque: N⋅m (kgf-m, ft-lb)
(2) Metal gasket (8) Oil outlet pipeT1: 4.4 (0.45, 3.3)
(3) Turbocharger (9) ClipT2: 4.9 (0.50, 3.6)
(4) Water pipe (10) Oil outlet hoseT3: 29 (3.0, 21.7)
(5) Clamp (11) Turbocharger bracket RHT4: 33 (3.4, 24.6)
(6) Engine coolant hose (12) Turbocharger bracket LHT5: 16 (1.6, 11.6)
IN-00249
T5
T1(3)
(8)
(4) (5) (9)
(9)(6)
(12) (1)
(2)
(2)
(2)
(2)
(2)
(7)
(2)
(11)(10)
T4
T2
T3
T4
(2)

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

IN(H4DOTC)-12
INTAKE (INDUCTION)
Turbocharger
6. Turbocharger
A: REMOVAL
1) Set the vehicle on a lift.
2) Disconnect the ground cable from battery.
3) Remove the center exhaust pipe. EX(H4DOTC)-9, REMOVAL, Center Exhaust
Pipe.>
4) Lower the vehicle.
5) Separate the turbocharger joint pipe from turbo-
charger.
6) Disconnect the engine coolant hose which is
connected to coolant filler tank.7) Loosen the clamp which secures turbocharger to
intake duct.
8) Remove the bolt which secures bracket of oil
pipe to turbocharger.
9) Remove the oil pipe from turbocharger.
10) Remove the turbocharger bracket.
11) Disconnect the oil outlet hose from pipe.
12) Take out the turbocharger from engine com-
partment.
FU-00009
IN-00019
IN-00020IN-00074
IN-00022
IN-00023
IN-00024

IN(H4DOTC)-13
INTAKE (INDUCTION)
Turbocharger
B: INSTALLATION
1) Connect the oil outlet hose to outlet pipe.
2) Install the turbocharger to intake duct.
Tightening torque:
3 N
⋅m (0.3 kgf-m, 2.2 ft-lb)
3) Install the oil pipe to turbocharger.
Tightening torque:
16 N
⋅m (1.6 kgf-m, 11.6 ft-lb)
4) Install the joint pipe to turbocharger.
NOTE:
Replace the gasket with a new one.Tightening torque:
35 N
⋅m (3.6 kgf-m, 26.0 ft-lb)
5) Install the turbocharger bracket.
Tightening torque:
33 N
⋅m (3.4 kgf-m, 24.6 ft-lb)
6) Connect the engine coolant hose which is con-
nected to coolant filler tank.
7) Lift-up the vehicle.
8) Install the center exhaust pipe. EX(H4DOTC)-10, INSTALLATION, Center Ex-
haust Pipe.>
IN-00024
IN-00074
IN-00022
IN-00019
IN-00023
IN-00020

IN(H4DOTC)-15
INTAKE (INDUCTION)
Resonator Chamber
8. Resonator Chamber
A: REMOVAL
1) Set the vehicle on a lift.
2) Remove the air intake duct. IN(H4DOTC)-8, REMOVAL, Air Intake Duct.>
3) Remove the air cleaner lower case. IN(H4DOTC)-7, REMOVAL, Air Cleaner.>
4) Remove the resonator chamber mounting bolt
on the right of engine compartment.
5) Remove the front right tire, and lift the vehicle.
6) Remove the front mudguard RH.
7) Remove the resonator chamber from the inside
front fender.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
7.5 N
⋅m (0.76 kgf-m, 5.5 ft-lb)
C: INSPECTION
Inspect for cracks and loose connections. Check
that no foreign objects are mixed in the resonator
chamber.
IN-00025
IN-00026
IN-00026
IN-00025

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 information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.
All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.FUEL INJECTION (FUEL SYSTEM) FU(H4DOTC)
EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICE)EC(H4DOTC)
INTAKE (INDUCTION) IN(H4DOTC)
MECHANICAL ME(H4DOTC)
EXHAUST EX(H4DOTC)
COOLING CO(H4DOTC)
LUBRICATION LU(H4DOTC)
SPEED CONTROL SYSTEM SP(H4DOTC)
IGNITION IG(H4DOTC)
STARTING/CHARGING SYSTEM SC(H4DOTC)
ENGINE (DIAGNOSTIC) EN(H4DOTC)

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)-2
MECHANICAL
General Description
1. General Description
A: SPECIFICATION
1. 2.0 L MODEL
NOTE:
STD: Standard I.D.: Inner Diameter O.D.: Outer Diameter OS: Oversize US: Undersize
EngineTy p eHorizontally opposed, liquid cooled, 4-cylinder, 4-stroke
gasoline engine
Valve arrangement Belt driven, double overhead camshaft, 4-valve/cylinder
Bore×Stroke mm (in) 92×75 (3.62×2.95)
Piston displacement
cm
3 (cu in)1,994 (121.67)
Compression ratio 8.0
Compression pres-
sure (at 200 — 300
rpm)kPa (kgf/cm
2, psi)981 — 1,177 (10 — 12, 142 — 171)
Number of piston rings Pressure ring: 2, Oil ring: 1
Intake valve timingOpeningMax. retard BTDC 3°
Min. advance BTDC 33°
ClosingMax. retard ABDC 33°
Min. advance ABDC 3°
Exhaust valve timingOpening BBDC 33°
Closing ATDC 3°
Valve clearanceIntake mm (in) 0.20±0.02 (0.0079±0.0008)
Exhaust mm (in) 0.35±0.02 (0.0138±0.0008)
Idling speed
[At neutral position on MT, or “P” or
“N” range on AT]
rpmNo loadMT: 700±100
AT : 7 0 0±100
A/C ONA/C Refrigerant pressure
(LOW)MT: 725±100
AT : 7 5 0±100
A/C Refrigerant pressure
(HIGH)MT: 800±100
AT : 8 2 5±100
Firing order 1 → 3 → 2 → 4
Ignition timing BTDC/rpm 12°±10°/700
Belt ten-
sion
adjusterProtrusion of adjuster rod 5.7 — 6.7 mm (0.224 — 0.264 in)
Belt ten-
sionerSpacer O.D. 17.955 — 17.975 mm (0.7069 — 0.7077 in)
Tensioner bush I.D. 18.0 — 18.08 mm (0.7087 — 0.7118 in)
Clearance between spacer and bushSTD 0.025 — 0.125 mm (0.0010 — 0.0049 in)
Limit 0.175 mm (0.0069 in)
Side clearance of spacerSTD 0.2 — 0.55 mm (0.0079 — 0.0217 in)
Limit 0.81 mm (0.0319 in)