2004 SUBARU FORESTER engine

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)-83
MECHANICAL
Cylinder Block
20.Cylinder Block
A: REMOVAL
NOTE:
Before conducting this procedure, drain the engine
oil completely if applicable.
1) Remove the intake manifold. FU(H4DOTC)-14, REMOVAL, Intake Manifold.> or
Manifold.>
2) Remove the V-belt. REMOVAL, V-belt.>
3) Remove the crank pulley. ME(H4DOTC)-55, REMOVAL, Crank Pulley.>
4) Remove the timing belt cover. ME(H4DOTC)-57, REMOVAL, Timing Belt Cover.>
5) Remove the timing belt assembly. ME(H4DOTC)-58, REMOVAL, Timing Belt Assem-
bly.>
6) Remove the cam sprocket. ME(H4DOTC)-67, REMOVAL, Cam Sprocket.>
7) Remove the crank sprocket. ME(H4DOTC)-68, REMOVAL, Crank Sprocket.>
8) Remove the generator and A/C compressor with
their brackets.
9) Remove the cylinder head assembly. ME(H4DOTC)-76, REMOVAL, Cylinder Head As-
sembly.>
10) Remove the clutch disc and cover. (MT model)
er.>
11) Remove the flywheel. (MT model) 19, REMOVAL, Flywheel.>
12) Remove the drive plate. (AT model)
Using the ST, lock crankshaft.
ST 498497100 CRANKSHAFT STOPPER
13) Remove the oil separator cover.
14) Remove the water by-pass pipe for heater.
15) Remove the oil filter using ST.
ter.>16) Remove the oil cooler.
17) Removal of oil pan:
(1) Turn the cylinder block with #2 and #4 piston
sides facing upward.
(2) Remove the bolts which secure oil pan to
cylinder block.
(3) Insert an oil pan cutter blade between cylin-
der block-to-oil pan clearance, and then remove
the oil pan.
Do not use a screwdriver or similar tool in place
of oil pan cutter.
18) Remove the oil strainer stay.
19) Remove the oil strainer.
20) Remove the baffle plate.
21) Remove the water pipes.
22) Remove the water pump.
23) Remove the oil pump from cylinder block.
Use a flat-bladed screwdriver as shown in the fig-
ure when removing the oil pump.
ME-00136
ST
(A) Adapter (1)
(B) Adapter connector
(C) Adapter (2)
(D) Oil cooler
(E) Oil cooler connector
LU-00041
(A)
(B)
(C)
(D)
(E)

ME(H4DOTC)-87
MECHANICAL
Cylinder Block
B: INSTALLATION
1. 2.0 L MODEL
1) Remove oil in the mating surface of bearing and
cylinder block before installation. Also apply a coat
of engine oil to crankshaft pins.
2) Position the crankshaft on #2 and #4 cylinder
block.
3) Apply liquid gasket to the mating surface of #1
and #3 cylinder block, and position it on #2 and #4
cylinder block.
Liquid gasket:
Part No. 004403007
THREE BOND 1215 or equivalentNOTE:
Do not allow liquid gasket to jut into O-ring grooves,
oil passages, bearing grooves, etc.
4) Apply a coat of engine oil to washers and bolt
threads.
(1) Crankshaft bearing (3) Cylinder block (4) Rear oil seal
(2) Crankshaft
ME-00144
( 1 )
( 1 )
( 2 )
( 3 )
( 3 )
( 4 )
ME-00145

ME(H4DOTC)-90
MECHANICAL
Cylinder Block
NOTE:
Use new circlips.
18) Installing the piston:
(1) Turn the cylinder block so that #1 and #2 cyl-
inders face upward.
(2) Using the ST1, turn the crankshaft so that
#1 and #2 connecting rods are set at bottom
dead center.
ST1 499987500 CRANKSHAFT SOCKET
(3) Apply a coat of engine oil to the pistons and
cylinders and insert pistons in their cylinders us-
ing ST2.ST2 398744300 PISTON GUIDE
NOTE:
Piston front mark faces towards the front of the en-
gine.
(A) Front side
ME-00154
#4 #3
#2 #1
(A)
(1) Piston (4) GasketTightening torque: N⋅m (kgf-m, ft-lb)
(2) Piston pin (5) Service hole plugT: 70 (7.1, 51.4)
(3) Circlip
ME-00155
(1) (1)
(2)
(2) (3)
(3) (4)
(4) (5)
(5)
T
ME-00157
ST2
ST1

ME(H4DOTC)-91
MECHANICAL
Cylinder Block
19) Installing piston pin:
(1) Apply a coat of engine oil to ST3.
(2) Insert the ST3 into service hole to align pis-
ton pin hole with connecting rod small end.
ST3 499017100 PISTON PIN GUIDE
(3) Apply a coat of engine oil to the piston pin
and insert piston pin into piston and connecting
rod through service hole.
(4) Using the needle nose plier, install the cir-
clip.
NOTE:
Use new circlips.
(5) Apply liquid gasket around the service hole
plug.Liquid gasket:
Part No. 004403007
THREE BOND 1215 or equivalent
(6) Install the service hole plug and gasket.
(A) Front mark
ME-00722
(A)
ME-00158
ST1ST3
ME-00159
ME-00160

ME(H4DOTC)-94
MECHANICAL
Cylinder Block
Liquid gasket:
Part No. 004403007
THREE BOND 1215 or equivalent
(3) Apply a coat of engine oil to the inside of the
oil seal.
(4) Install the oil pump on cylinder block. Be
careful not to damage the oil seal during instal-
lation.
Tightening torque:
6.4 N
⋅m (0.65 kgf-m, 4.7 ft-lb)
NOTE:
 Do not forget to install the O-ring and seal when
installing the oil pump.
 Align the flat surface of oil pump’s inner rotor with
crankshaft before installation.30) Install the water pump and gasket.
Tightening torque:
First; 12 N
⋅m (1.2 kgf-m, 8.7 ft-lb)
Second; 12 N
⋅m (1.2 kgf-m, 8.7 ft-lb)
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.
31) Install the water by-pass pipe for heater.
32) Install the oil cooler.
Tightening torque:
T1: 45 N
⋅m (4.6 kgf-m, 33 ft-lb)
T2: 6.4 N
⋅m (0.65 kgf-m, 4.7 ft-lb)
T3: 54 N
⋅m (5.3 kgf-m, 39 ft-lb)
(A) O-ring
ME-00165
(A)
ME-00312
(A) Adapter (1)
(B) Adapter connector
(C) Adapter (2)
(D) Oil cooler
(E) Oil cooler connector
ME-00167
(B) (C) (D)(E)(F)
(A)
LU-00044
(A)
(B)
(C)
(D)
(E)
T1
T2
T3

ME(H4DOTC)-95
MECHANICAL
Cylinder Block
33) Install the oil filter using ST. LU(H4SO)-23, INSTALLATION, Engine Oil Filter.>
34) Install the water by-pass pipe between oil cool-
er and water pump.
35) Install the water pipe.
NOTE:
Always use a new O-ring.
36) Install the cylinder head assembly. ME(H4DOTC)-76, INSTALLATION, Cylinder Head
Assembly.>
37) Install the oil level gauge guide and tighten the
attaching bolt (LH side).
38) Install the rocker cover.
39) Install the crank sprocket. ME(H4DOTC)-68, INSTALLATION, Crank Sprock-
et.>40) Install the cam sprocket. ME(H4DOTC)-67, INSTALLATION, Cam Sprock-
et.>
41) Install the timing belt assembly. ME(H4DOTC)-60, INSTALLATION, Timing Belt
Assembly.>
42) Install the timing belt cover. ME(H4DOTC)-57, INSTALLATION, Timing Belt
Cover.>
43) Install the crank pulley. 55, INSTALLATION, Crank Pulley.>
44) Install the generator and A/C compressor
brackets on cylinder head.
45) Install the V-belt. INSTALLATION, V-belt.>
46) Install the intake manifold. FU(H4DOTC)-17, INSTALLATION, Intake Mani-
fold.>
2. 2.5 L MODEL
(1) Crankshaft bearing (3) Cylinder block (4) Rear oil seal
(2) Crankshaft
ME-00144
( 1 )
( 1 )
( 2 )
( 3 )
( 3 )
( 4 )

ME(H4DOTC)-96
MECHANICAL
Cylinder Block
1) Remove oil in the mating surface of bearing and
cylinder block before installation. Apply a coat of
engine oil to crankshaft pins.
2) Install crankshaft bearings on the cylinder block,
apply a coat of engine oil to crankshaft bearings,
and position the crankshaft on #2 and #4 cylinder
block.
3) Apply liquid gasket to the mating surface of #1
and #3 cylinder block, and position it on #2 and #4
cylinder block.
Liquid gasket:
Part No. 004403007
THREE BOND 1215 or equivalent
NOTE:
Do not allow liquid gasket to jut into O-ring grooves,
oil passages, bearing grooves, etc.
4) Apply engine oil to washers and thread of bolts.
5) Tighten the 10 mm cylinder block connecting
bolts in alphabetical sequence shown in the figure.
(LH side)
Tightening torque:
10 N
⋅m (1.0 kgf-m, 7.2 ft-lb)6) Tighten the 10 mm cylinder block connecting
bolts in alphabetical sequence shown in the figure.
(RH side)
Tightening torque:
10 N
⋅m (1.0 kgf-m, 7.2 ft-lb)
7) Further tighten the LH side bolts (A — D) in al-
phabetical sequence.
Tightening torque:
(A), (C): 20 N
⋅m (2.0 kgf-m, 14.8 ft-lb)
(B), (D): 15 N
⋅m (1.5 kgf-m, 10.8 ft-lb)
8) Further tighten the RH side bolts (E — J) in al-
phabetical sequence.
ME-00145
ME-00779
(A)
(B)
(D)
(C)
ME-00780
(J)
(H)
(G)
(E)
(F)(I)
ME-00779
(A)
(B)
(D)
(C)