Subaru 2004 Forester User manual

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)-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. <Ref. to
FU(H4DOTC)-14, REMOVAL, Intake Manifold.> or
<Ref. to FU(H4DOTC 2.5)-14, REMOVAL, Intake
Manifold.>
2) Remove the V-belt. <Ref. to ME(H4DOTC)-52,
REMOVAL, V-belt.>
3) Remove the crank pulley. <Ref. to
ME(H4DOTC)-55, REMOVAL, Crank Pulley.>
4) Remove the timing belt cover. <Ref. to
ME(H4DOTC)-57, REMOVAL, Timing Belt Cover.>
5) Remove the timing belt assembly. <Ref. to
ME(H4DOTC)-58, REMOVAL, Timing Belt Assem-
bly.>
6) Remove the cam sprocket. <Ref. to
ME(H4DOTC)-67, REMOVAL, Cam Sprocket.>
7) Remove the crank sprocket. <Ref. to
ME(H4DOTC)-68, REMOVAL, Crank Sprocket.>
8) Remove the generator and A/C compressor with
their brackets.
9) Remove the cylinder head assembly. <Ref. to
ME(H4DOTC)-76, REMOVAL, Cylinder Head As-
sembly.>
10) Remove the clutch disc and cover. (MT model)
<Ref. to CL-16, REMOVAL, Clutch Disc and Cov-
er.>
11) Remove the flywheel. (MT model) <Ref. to CL-
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.
<Ref. to LU(H4SO)-23, REMOVAL, Engine Oil Fil-
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)-84
MECHANICAL
Cylinder Block
NOTE:
Be careful not to scratch the mating surface of cyl-
inder block and oil pump.
ME-00138
(1) Service hole plug (3) Circlip (5) Service hole cover
(2) Gasket (4) Piston pin (6) O-ring
ME-00139
(3)
(4)
(2) (1)
(3)
(4)
(5)
(6)
(2)
(3)
(2)
(1)
(3)
(4)
(4)
(1)

ME(H4DOTC)-85
MECHANICAL
Cylinder Block
24) Remove the service hole cover and service
hole plugs using hexagon wrench [14 mm (0.55
in)].
25) Rotate the crankshaft to bring #1 and #2 pis-
tons to bottom dead center position, and then re-
move the piston circlip through service hole of #1
and #2 cylinders.
26) Draw out the piston pin from #1 and #2 pistons
using ST.
ST 499097600 PISTON PIN REMOVER (2.0
L model)
ST 499097700 PISTON PIN REMOVER (2.5
L model)
NOTE:
Be careful not to confuse the original combination
of piston, piston pin and cylinder.
27) Similarly remove the piston pins from #3 and #4
pistons.
28) Remove the bolts which connect the cylinder
block on the side of #2 and #4 cylinders.
29) Back off the bolts which connect the cylinder
block on the side of #1 and #3 cylinders two or
three turns.
30) Set up the cylinder block so that #1 and #3 cyl-
inders are on the upper side, then remove the cyl-
inder block connecting bolts.
31) Separate the cylinder blocks (LH) and (RH).
ME-00140
ME-00141
ME-00142
ST

ME(H4DOTC)-86
MECHANICAL
Cylinder Block
NOTE:
When separating the cylinder block, do not allow
the connecting rod to fall and damage the cylinder
block.
32) Remove the rear oil seal.
33) Remove the crankshaft together with connect-
ing rod.
34) Remove the crankshaft bearings from cylinder
block using a hammer handle.
NOTE:
Do not confuse the combination of crankshaft bear-
ings. Press the bearing at the end opposite to lock-
ing lip.
35) Draw out each piston from cylinder block using
a wooden bar or hammer handle.
NOTE:
Do not confuse the combination of piston and cylin-
der.
(1) Cylinder block (3) Crankshaft (5) Piston
(2) Rear oil seal (4) Crankshaft bearing
ME-00143
(2)
(3)
(4)
(4)
(5)
(5)
(1)
(1)

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 equivalent
NOTE:
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)-88
MECHANICAL
Cylinder Block
5) Tighten the 10 mm cylinder block connecting
bolts in alphabetical sequence shown in the figure.
(LH side)
Tightening torque:
15 N
⋅ m (1.5 kgf-m, 10.8 ft-lb)
6) Tighten the 10 mm cylinder block connecting
bolts in alphabetical sequence shown in the figure.
(RH side)
Tightening torque:
15 N
⋅ m (1.5 kgf-m, 10.8 ft-lb)
7) Further tighten the LH side bolts (A — D) to 90°
in alphabetical sequence.
8) Further tighten the RH side bolts (E — J) to 90°
in alphabetical sequence.
9) Tighten the 8 mm and 6 mm cylinder block con-
necting bolts in alphabetical sequence shown in the
figure.
Tightening torque:
(A) — (G): 25 N
⋅ m (2.5 kgf-m, 18.1 ft-lb)
(H): 6.4 N
⋅ m (0.65 kgf-m, 4.7 ft-lb)
10) Install the rear oil seal using ST1 and ST2.
ST1 499597100 CRANKSHAFT OIL SEAL
GUIDE
ST2 499587200 CRANKSHAFT OIL SEAL IN-
STALLER
11) Position the top ring gap at (A) or (B) in the fig-
ure.
12) Position the second ring gap at 180°on the re-
verse side for the top ring gap.
ME-00398
(A)
(B)
(C)
(D)
ME-00399
(E)(G)
(F)
(I)
(J)
(H)
ME-00398
(A)
(B)
(C)
(D)
(A) Rear oil seal
(B) Flywheel attaching bolt
ME-00399
(E)(G)
(F)
(I)
(J)
(H)
ME-00147
(B)
(C)
(D)
(E)
(F)
(G)
(H)
(A)
ME-00148
ST1
ST2
(B) (A)

ME(H4DOTC)-89
MECHANICAL
Cylinder Block
13) Position the expander gap at (C) in the figure.
14) Position the lower rail gap at (D) in the figure.
15) Align lower rail spin stopper (F) with piston side
surface hole (E).
16) Position the upper rail gap at (G) in the figure.
NOTE:
• Ensure ring gaps do not face the same direction.
• Ensure ring gaps are not within the piston skirt
area.
17) Install the circlip.
Install the circlips in piston holes located opposite
of service holes in cylinder block, when positioning
all pistons in the corresponding cylinders.
ME-00718
(A) (B)
180
ME-00719
(C)
ME-00720
(D)
25
ME-00152
ME-00721
(G)
0 20

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) Gasket Tightening torque: N ⋅ m (kgf-m, ft-lb)
(2) Piston pin (5) Service hole plug T: 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
ST1 ST3
ME-00159
ME-00160

ME(H4DOTC)-92
MECHANICAL
Cylinder Block
NOTE:
Use a new gasket.
(7) Turn the cylinder block so that #3 and #4 cyl-
inders face upward. Using the same procedures
as used for #1 and #2 cylinders, install the pis-
tons and piston pins.
20) Install the water pipe.
21) Install the baffle plate.
Tightening torque:
6.4 N
⋅ m (0.65 kgf-m, 4.7 ft-lb)
22) Install the oil strainer and O-ring.
Tightening torque:
10 N
⋅ m (1.0 kgf-m, 7 ft-lb)
23) Install the oil strainer stay.
24) Apply liquid gasket to the matching surfaces,
and then install the oil pan.
ME-00140
(1) Piston (5) Service hole plug Tightening torque: N ⋅ m (kgf-m, ft-lb)
(2) Piston pin (6) Service hole cover T1: 6.4 (0.65, 4.7)
(3) Circlip (7) O-ring T2: 70 (7.1, 51.4)
(4) Gasket
(1)
(2)
(3)
(1)
(2)
(6)
(3)
(7)
(4)
(5)
ME-00161
T2 T1

ME(H4DOTC)-93
MECHANICAL
Cylinder Block
Liquid gasket:
Part No. 004403007
THREE BOND 1215 or equivalent
25) Apply liquid gasket to the matching surfaces,
and then install the oil separator cover.
Liquid gasket:
Part No. 004403007
THREE BOND 1215 or equivalent
Tightening torque:
6.4 N
⋅ m (0.65 kgf-m, 4.7 ft-lb)
26) Install the drive plate. (AT model)
To lock the crankshaft, use ST.
ST 498497100 CRANKSHAFT STOPPER
Tightening torque:
72 N
⋅ m (7.3 kgf-m, 52.8 ft-lb)
27) Install the flywheel. (MT model) <Ref. to CL-19,
INSTALLATION, Flywheel.>
28) Install the clutch disc and cover. (MT model)
<Ref. to CL-16, INSTALLATION, Clutch Disc and
Cover.>
29) Installation of oil pump:
(1) Discard the front oil seal after removal. Re-
place with a new one using the ST.
ST 499587100 OIL SEAL INSTALLER
(2) Apply liquid gasket to the matching surface of oil pump.
ME-00162
ME-00163
ME-00136
ST
ME-00164

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. <Ref. to
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. <Ref. to
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. <Ref. to
ME(H4DOTC)-68, INSTALLATION, Crank Sprock-
et.>
40) Install the cam sprocket. <Ref. to
ME(H4DOTC)-67, INSTALLATION, Cam Sprock-
et.>
41) Install the timing belt assembly. <Ref. to
ME(H4DOTC)-60, INSTALLATION, Timing Belt
Assembly.>
42) Install the timing belt cover. <Ref. to
ME(H4DOTC)-57, INSTALLATION, Timing Belt
Cover.>
43) Install the crank pulley. <Ref. to ME(H4DOTC)-
55, INSTALLATION, Crank Pulley.>
44) Install the generator and A/C compressor
brackets on cylinder head.
45) Install the V-belt. <Ref. to ME(H4DOTC)-52,
INSTALLATION, V-belt.>
46) Install the intake manifold. <Ref. to
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)

ME(H4DOTC)-97
MECHANICAL
Cylinder Block
Tightening torque:
(E), (F), (G), (I): 20 N
⋅ m (2.0 kgf-m, 14.8 ft-lb)
(H), (J): 18 N
⋅ m (1.8 kgf-m, 13.3 ft-lb)
9) Further tighten the LH side bolts (A — D) by 90°
in alphabetical sequence.
10) Further tighten the RH side bolts (E — J) by 90°
in alphabetical sequence.
11) Tighten the 8 mm and 6 mm cylinder block con-
necting bolts in alphabetical sequence shown in the
figure.
Tightening torque:
(A) — (G): 25 N
⋅ m (2.5 kgf-m, 18.1 ft-lb)
(H): 6.4 N
⋅ m (0.65 kgf-m, 4.7 ft-lb)
12) Install the rear oil seal using ST1 and ST2.
ST1 499597100 CRANKSHAFT OIL SEAL
GUIDE
ST2 499587200 CRANKSHAFT OIL SEAL IN-
STALLER
13) Position the top ring gap at (A) or (B) in the fig-
ure.
14) Position the second ring gap at 180°on the re-
verse side for the top ring gap.
ME-00780
(J)
(H)
(G)
(E)
(F)
(I)
ME-00779
(A)
(B)
(D)
(C)
ME-00780
(J)
(H)
(G)
(E)
(F)
(I)
(A) Rear oil seal
(B) Flywheel attaching bolt
ME-00147
(B)
(C)
(D)
(E)
(F)
(G)
(H)
(A)
ME-00148
ST1
ST2
(B) (A)
ME-00781
(A) (B)
180

ME(H4DOTC)-98
MECHANICAL
Cylinder Block
15) Position the upper rail gap at (C) in the figure.
16) Align upper rail spin stopper (D) with piston
side surface hole (E).
17) Position the expander gap at (F) in the figure.
18) Position the lower rail gap at (G) in the figure.
NOTE:
• Ensure ring gaps do not face the same direction.
• Ensure ring gaps are not within the piston skirt
area.
ME-00782
(D)
(C)
25
ME-00783
(E) (D)
ME-00784
(F)
25
ME-00785
35
(G)

ME(H4DOTC)-99
MECHANICAL
Cylinder Block
19) Install the circlip.
Install the circlips in piston holes located opposite
of service holes in cylinder block, when positioning
all pistons in the corresponding cylinders.
NOTE:
Use new circlips.
20) 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 498747300 PISTON GUIDE
(A) Front side
ME-00154
#4
#3
#2
#1
(A)
(1) Piston (4) Gasket Tightening torque: N ⋅ m (kgf-m, ft-lb)
(2) Piston pin (5) Service hole plug T: 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)-100
MECHANICAL
Cylinder Block
NOTE:
Piston front mark faces towards the front of the en-
gine.
21) 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.
NOTE:
Use a new gasket.
(A) Front mark
ME-00786
(A)
ME-00158
ST1 ST3
ME-00159
ME-00160
ME-00140