2004 SUBARU FORESTER timing belt

PERIODIC MAINTENANCE SERVICE
PM
Page
1. General Description ....................................................................................2
2. Schedule .....................................................................................................3
3. Engine Oil....................................................................................................7
4. Engine Oil Filter...........................................................................................9
5. Spark Plugs ...............................................................................................10
6. V-belt .........................................................................................................11
7. Timing Belt ................................................................................................13
8. Fuel Line ...................................................................................................17
9. Fuel Filter ..................................................................................................18
10. Air Cleaner Element ..................................................................................19
11. Cooling System .........................................................................................20
12. Engine Coolant..........................................................................................21
13. Clutch System ...........................................................................................23
14. Transmission Gear Oil ..............................................................................24
15. Hill-holder System .....................................................................................25
16. ATF ...........................................................................................................26
17. Front & Rear Differential Oil ......................................................................28
18. Brake Line .................................................................................................30
19. Brake Fluid ................................................................................................32
20. Disc Brake Pads and Discs .......................................................................33
21. Brake Linings and Drums ..........................................................................34
22. Suspension ...............................................................................................36
23. Wheel Bearing...........................................................................................38
24. Axle Boots & Joints ...................................................................................39
25. Tire Rotation..............................................................................................40
26. Steering System (Power Steering) ............................................................41

PM-13
PERIODIC MAINTENANCE SERVICE
Timing Belt
7. Timing Belt
A: REPLACEMENT
1. NON-TURBO MODEL
1) Remove the radiator fan and air conditioner fan.
Fan Motor.> Fan and Fan Motor.>
2) Shield the radiator from any damage using card-
board and blanket.
3) Remove the V-belt cover.
4) Remove the V-belts. belt.>
5) Remove the air conditioning compressor V-belt
tensioner.
6) To lock the crankshaft, use ST. Remove the pul-
ley bolt.
ST 499977100 CRANK PULLEY WRENCH
7) Remove the crank pulley.
8) Remove the left side belt cover.
9) Remove the front timing belt cover.
10) Remove the timing belt guide. (MT model)11) Turn the crankshaft and align alignment marks
on crankshaft, and right and left cam sprockets with
notches of belt cover and cylinder block.
ST 499987500 CRANKSHAFT SOCKET
12) Remove the belt idler.
13) Remove the belt idler (No. 2).
14) Remove the timing belt.
15) Remove the automatic belt tension adjuster as-
sembly.
PM-00003
PM-00007
ST
PM-00008
(A) Notch
(B) Alignment mark
PM-00009
(B)
(B)
(B) (A)
PM-00010
PM-00011

PM-14
PERIODIC MAINTENANCE SERVICE
Timing Belt
16) Install in the reverse order of removal. ME(H4SO)-49, INSTALLATION, Timing Belt.>
2. TURBO MODEL
1) Remove the radiator fan and air conditioner fan.
Fan Motor.> Fan and Fan Motor.>
2) Protect the radiator with cardboard and blanket.
3) Remove the V-belts. belt.>
4) Remove the air conditioning compressor drive
belt tensioner.
5) To lock the crankshaft use ST. Remove the pul-
ley bolt.
ST 499977300 CRANK PULLEY WRENCH
6) Remove the crank pulley.
7) Remove the air conditioning compressor drive
belt tensioner.
8) Remove the belt cover (LH).
9) Remove the belt cover (RH).
10) Remove the front belt cover.11) Remove the timing belt guide. (MT model)
12) Turn the crankshaft and align alignment marks
on crankshaft, and right and left cam sprockets with
notches of belt cover and cylinder block. To turn the
crankshaft, use ST.
STPM-00093
PM-00008
ME-00727
ME-00728
ME-00729

PM-15
PERIODIC MAINTENANCE SERVICE
Timing Belt
ST 499987500 CRANKSHAFT SOCKET
13) Remove the belt idler.
14) Remove the timing belt.
15) Remove the automatic belt tension adjuster as-
sembly.16) Install in the reverse order of removal. ME(H4DOTC)-58, Timing Belt Assembly.>
CAUTION:
When installing the timing belt, be sure to align
all alignment marks on the belt with corre-
sponding marks on the sprockets. If incorrectly
installed, interference between pistons and
valves may occur.
B: INSPECTION
1. SOHC MODEL
1) Remove the front timing belt cover and timing
belt cover (LH).
2) While cranking the engine at least four rotations,
check the timing belt back surface for cracks or
damage. Replace the faulty timing belt as needed.
3) Measure the timing belt width W. If it is less than
27 mm (1.06 in), check idlers, tensioner, water
pump pulley and cam sprocket to determine idler
alignment (squareness). Replace the worn timing
belt.
4) Install the front timing belt cover and timing belt
cover (LH).
2. DOHC MODEL
1) Remove the timing belt cover (LH).
2) While cranking the engine at least four rotations,
check the timing belt back surface for cracks or
damage. Replace the faulty timing belt as needed.
3) Measure the timing belt width W. If it is less than
30 mm (1.18 in), check idlers, tensioner, water
pump pulley and cam sprocket to determine idler
alignment (squareness). Replace the worn timing
belt.
(A) Notch
(B) Alignment mark
PM-00094
(A)
(B)
(B)
(B) (A)(B)
(B)
(B)(A)
(B)
PM-00095
PM-00096
w
PM-00016

PM-16
PERIODIC MAINTENANCE SERVICE
Timing Belt
4) Install the timing belt cover (LH).
W
PM-00097

MECHANICAL
ME(H4SO)
Page
1. General Description ....................................................................................2
2. Compression .............................................................................................25
3. Idle Speed .................................................................................................26
4. Ignition Timing ...........................................................................................27
5. Intake Manifold Vacuum............................................................................28
6. Engine Oil Pressure ..................................................................................29
7. Fuel Pressure ............................................................................................30
8. Valve Clearance ........................................................................................31
9. Engine Assembly ......................................................................................34
10. Engine Mounting .......................................................................................41
11. Preparation for Overhaul ...........................................................................42
12. V-belt .........................................................................................................43
13. Crank Pulley ..............................................................................................45
14. Timing Belt Cover......................................................................................47
15. Timing Belt ................................................................................................48
16. Cam Sprocket ...........................................................................................53
17. Crank Sprocket .........................................................................................55
18. Valve Rocker Assembly ............................................................................56
19. Camshaft ...................................................................................................58
20. Cylinder Head ...........................................................................................62
21. Cylinder Block ...........................................................................................69
22. Engine Trouble in General ........................................................................91
23. Engine Noise .............................................................................................96

ME(H4SO)-2
MECHANICAL
General Description
1. General Description
A: SPECIFICATION
NOTE:
STD: Standard I.D.: Inner Diameter O.D.: Outer Diameter US: Undersize OS: Oversize
EngineModel 2.0 L 2.5 L
Ty p eHorizontally opposed, liquid cooled, 4-cylinder, 4-stroke gaso-
line engine
Valve arrangement Belt driven, single over-head camshaft, 4-valve/cylinder
Bore×Stroke mm (in) 92×75 (3.62×2.95)99.5×79.0
(3.917×3.110)
Displacement
cm
3 (cu in)1,994 (121.67) 2,457 (150)
Compression ratio 10.0
Compression pressure
(at 200 — 300 rpm)kPa (kg/cm
2, psi)1,079 — 1,275 (11.0 — 13.0, 156 — 185)
Number of piston rings Pressure ring: 2, Oil ring: 1
Intake valve timingOpen 4° BTDC 1° BTDC
Close 48° ABDC 51° ABDC
Exhaust valve timingOpen 48° BBDC 50° BBDC
Close 4° AT D C 6° AT D C
Valve clearance Intake mm (in) 0.20±0.04 (0.0079±0.0016)
Exhaust mm (in) 0.25±0.04 (0.0098±0.0016)
Idling speed [at neutral position on
MT, or “P” or “N” range on AT]rpm650±100 (No load)
850±100 (A/C switch ON)
Firing order 1 → 3 → 2 → 4
Ignition timing BTDC/rpm 10°±10°/650
Belt
tensioner
adjusterProtrusion of adjuster rod mm (in) 5.7 — 6.7 (0.224 — 0.263)
Belt
tensionerSpacer O.D. mm (in) 17.955 — 17.975 (0.7069 — 0.7077)
Tensioner bush I.D. mm (in) 18.00 — 18.08 (0.7087 — 0.7118)
Clearance between spacer and bush mm (in)STD 0.025 — 0.125 (0.0010 — 0.0049)
Limit 0.175 (0.0069)
Side clearance of spacer mm (in)STD 0.20 — 0.55 (0.0079 — 0.0217)
Limit 0.81 (0.0319)
Valve rocker
armClearance between shaft and arm mm (in)STD 0.020 — 0.054 (0.0008 — 0.0021)
Limit 0.10 (0.0039)
CamshaftBend limit mm (in) 0.025 (0.0010)
Thrust clearance mm (in)STD 0.030 — 0.090 (0.0012 — 0.0035)
Limit 0.10 (0.0039)
Cam lobe height mm (in)2.0 LIntakeSTD 38.732 — 38.832 (1.5249 — 1.5288)
Limit 38.632 (1.5209)
ExhaustSTD 39.259 — 39.359 (1.5456 — 1.5496)
Limit 39.157 (1.5417)
2.5 LIntakeSTD 39.485 — 39.585 (1.5545 — 1.5585)
Limit 39.385 (1.5506)
ExhaustSTD 39.259 — 39.359 (1.5456 — 1.5496)
Limit 39.159 (1.5417)
Camshaft journal O.D. mm (in) 31.928 — 31.945 (1.2570 — 1.2577)
Camshaft journal hole I.D. (Cylinder head) mm (in) 32.000 — 32.018 (1.2598 — 1.2605)
Oil clearance mm (in)STD 0.055 — 0.090 (0.0022 — 0.0035)
Limit 0.10 (0.0039)

ME(H4SO)-6
MECHANICAL
General Description
B: COMPONENT
1. TIMING BELT
(1) Timing belt cover No. 2 (RH) (9) Automatic belt tension adjuster
ASSYTightening torque: N⋅m (kgf-m, ft-lb)
(2) Timing belt guide (MT model)T1: 5 (0.5, 3.6)
(3) Crank sprocket (10) Belt idler No. 2T2: 10 (1.0, 7.2)
(4) Timing belt cover No. 2 (LH) (11) Cam sprocket No. 2T3: 25 (2.5, 18.1)
(5) Cam sprocket No. 1 (12) Timing beltT4: 39 (4.0, 28.9)
(6) Belt idler (No. 1) (13) Front timing belt coverT5: 78 (8.0, 57.9)
(7) Tensioner bracket (14) Timing belt cover (LH)T6: INSTALLATION, Crank Pulley.>
(8) Belt idler (No. 2) (15) Crank pulley (2.0 L model)
(16) Crank pulley (2.5 L model)
ME-00376
T5
T4
T1
T1
T6
T5 (5)
(6)
(8)
(9)
(11) (10)
(14) (15)
(16)(12)
(13)(7)(4) (1)
(2)
(3)
T1
T2
T1
T3
T4
T6
T4