Subaru 2004 FORESTER Service Manual
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Subaru 2004 FORESTER Service Manual

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See also: Service Manual , Owner's Manual
2004 FORESTER SERVICE MANUAL

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.
FUJI HEAVY INDUSTRIES LTD.
QUICK REFERENCE INDEX
FUEL INJECTION (FUEL SYSTEM)
EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICE)
INTAKE (INDUCTION)
MECHANICAL
EXHAUST
COOLING
LUBRICATION
SPEED CONTROL SYSTEM
IGNITION
STARTING/CHARGING SYSTEM
ENGINE (DIAGNOSTIC)
FU(H4DOTC)
EC(H4DOTC)
IN(H4DOTC)
ME(H4DOTC)
EX(H4DOTC)
CO(H4DOTC)
LU(H4DOTC)
SP(H4DOTC)
IG(H4DOTC)
SC(H4DOTC)
EN(H4DOTC)
G8080GE3

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  • Page 1: Engine Section

    2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 2 FUEL INJECTION (FUEL SYSTEM) FU(H4DOTC) EMISSION CONTROL EC(H4DOTC) (AUX. EMISSION CONTROL DEVICE) INTAKE (INDUCTION) IN(H4DOTC) MECHANICAL ME(H4DOTC) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4DOTC)
  • Page 2 MECHANICAL ME(H4DOTC) Page General Description ..................2 Compression .....................31 Idle Speed ....................32 Ignition Timing...................33 Intake Manifold Vacuum................34 Engine Oil Pressure ..................35 Fuel Pressure....................36 Valve Clearance..................37 Engine Assembly ..................41 Engine Mounting ..................50 Preparation for Overhaul................51 V-belt......................52 Crank Pulley....................55 Timing Belt Cover..................57 Timing Belt Assembly................58 Cam Sprocket ...................67 Crank Sprocket ..................68 Camshaft....................69...

  • Page 3: Cylinder Block

    Cylinder Block MECHANICAL 20.Cylinder Block 16) Remove the oil cooler. A: REMOVAL NOTE: Before conducting this procedure, drain the engine oil completely if applicable. 1) Remove intake manifold. <Ref. to FU(H4DOTC)-14, REMOVAL, Intake Manifold.> or <Ref. to FU(H4DOTC 2.5)-14, REMOVAL, Intake Manifold.>...
  • Page 4 Cylinder Block MECHANICAL NOTE: Be careful not to scratch the mating surface of cyl- inder block and oil pump. ME-00138 ME-00139 Service hole plug Circlip Service hole cover Gasket Piston pin O-ring ME(H4DOTC)-84...
  • Page 5 Cylinder Block MECHANICAL 24) Remove the service hole cover and service 29) Back off the bolts which connect the cylinder hole plugs using hexagon wrench [14 mm (0.55 block on the side of #1 and #3 cylinders two or in)]. three turns.
  • Page 6 Cylinder Block MECHANICAL NOTE: When separating the cylinder block, do not allow the connecting rod to fall and damage the cylinder block. ME-00143 Cylinder block Crankshaft Piston Rear oil seal Crankshaft bearing 32) Remove the rear oil seal. 33) Remove the crankshaft together with connect- ing rod.
  • Page 7 Cylinder Block MECHANICAL B: INSTALLATION 1. 2.0 L MODEL ( 1 ) ( 4 ) ( 1 ) ( 3 ) ( 2 ) ( 3 ) ME-00144 Crankshaft bearing Cylinder block Rear oil seal Crankshaft 1) Remove oil in the mating surface of bearing and NOTE: cylinder block before installation.
  • Page 8 Cylinder Block MECHANICAL 5) Tighten the 10 mm cylinder block connecting 8) Further tighten the RH side bolts (E — J) to 90° bolts in alphabetical sequence shown in the figure. in alphabetical sequence. (LH side) Tightening torque: ⋅ 15 N m (1.5 kgf-m, 10.8 ft-lb) ME-00399 9) Tighten the 8 mm and 6 mm cylinder block con-...
  • Page 9 Cylinder Block MECHANICAL 16) Position the upper rail gap at (G) in the figure. 0 20 ME-00718 ME-00721 13) Position the expander gap at (C) in the figure. NOTE: • Ensure ring gaps do not face the same direction. • Ensure ring gaps are not within the piston skirt area.
  • Page 10 Cylinder Block MECHANICAL NOTE: Use new circlips. ME-00154 (A) Front side ME-00155 ⋅ Piston Gasket Tightening torque: N m (kgf-m, ft-lb) Piston pin Service hole plug T: 70 (7.1, 51.4) Circlip 18) Installing the piston: ST2 398744300 PISTON GUIDE (1) Turn the cylinder block so that #1 and #2 cyl- inders face upward.
  • Page 11 Cylinder Block MECHANICAL Liquid gasket: Part No. 004403007 THREE BOND 1215 or equivalent ME-00722 (A) Front mark 19) Installing piston pin: ME-00160 (1) Apply a coat of engine oil to ST3. (6) Install the service hole plug and gasket. (2) Insert the ST3 into service hole to align pis- ton pin hole with connecting rod small end.
  • Page 12 Cylinder Block MECHANICAL NOTE: Use a new gasket. ME-00140 ME-00161 ⋅ Piston Service hole plug Tightening torque: N m (kgf-m, ft-lb) Piston pin Service hole cover T1: 6.4 (0.65, 4.7) Circlip O-ring T2: 70 (7.1, 51.4) Gasket (7) Turn the cylinder block so that #3 and #4 cyl- Tightening torque: ⋅...
  • Page 13 Cylinder Block MECHANICAL Liquid gasket: 29) Installation of oil pump: Part No. 004403007 (1) Discard the front oil seal after removal. Re- THREE BOND 1215 or equivalent place with a new one using the ST. ST 499587100 OIL SEAL INSTALLER ME-00162 ME-00164 25) Apply liquid gasket to the matching surfaces,...
  • Page 14 Cylinder Block MECHANICAL Liquid gasket: 30) Install the water pump and gasket. Part No. 004403007 Tightening torque: THREE BOND 1215 or equivalent ⋅ 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: •...
  • Page 15 Cylinder Block MECHANICAL 33) Install the oil filter using ST. <Ref. to 40) Install sprocket. <Ref. LU(H4SO)-23, INSTALLATION, Engine Oil Filter.> ME(H4DOTC)-67, INSTALLATION, Cam Sprock- et.> 34) Install the water by-pass pipe between oil cool- er and water pump. 41) Install the timing belt assembly. <Ref. to ME(H4DOTC)-60, INSTALLATION, Timing Belt 35) Install the water pipe.
  • Page 16 Cylinder Block MECHANICAL 1) Remove oil in the mating surface of bearing and 6) Tighten the 10 mm cylinder block connecting cylinder block before installation. Apply a coat of bolts in alphabetical sequence shown in the figure. engine oil to crankshaft pins. (RH side) 2) Install crankshaft bearings on the cylinder block, Tightening torque:...
  • Page 17 Cylinder Block MECHANICAL Tightening torque: 11) Tighten the 8 mm and 6 mm cylinder block con- ⋅ necting bolts in alphabetical sequence shown in the (E), (F), (G), (I): 20 N m (2.0 kgf-m, 14.8 ft-lb) ⋅ figure. (H), (J): 18 N m (1.8 kgf-m, 13.3 ft-lb) Tightening torque: ⋅...
  • Page 18 Cylinder Block MECHANICAL 15) Position the upper rail gap at (C) in the figure. ME-00782 16) Align upper rail spin stopper (D) with piston side surface hole (E). ME-00783 17) Position the expander gap at (F) in the figure. ME-00784 18) Position the lower rail gap at (G) in the figure.
  • Page 19 Cylinder Block MECHANICAL 19) Install the circlip. NOTE: Install the circlips in piston holes located opposite Use new circlips. of service holes in cylinder block, when positioning all pistons in the corresponding cylinders. ME-00154 (A) Front side ME-00155 ⋅ Piston Gasket Tightening torque: N m (kgf-m, ft-lb)
  • Page 20 Cylinder Block MECHANICAL (5) Apply liquid gasket around the service hole NOTE: plug. Piston front mark faces towards the front of the en- gine. Liquid gasket: Part No. 004403007 THREE BOND 1215 or equivalent ME-00786 (A) Front mark ME-00160 21) Installing piston pin: (6) Install the service hole plug and gasket.
  • Page 21 Cylinder Block MECHANICAL ME-00161 ⋅ Piston Service hole plug Tightening torque: N m (kgf-m, ft-lb) Piston pin Service hole cover T1: 6.4 (0.65, 4.7) Circlip O-ring T2: 70 (7.1, 51.4) Gasket (7) Turn the cylinder block so that #3 and #4 cyl- Tightening torque: ⋅...
  • Page 22 Cylinder Block MECHANICAL 27) Apply liquid gasket to the matching surfaces, (2) Apply liquid gasket to the matching surface and then install the oil separator cover. of oil pump. Liquid gasket: Liquid gasket: Part No. 004403007 Part No. 004403007 THREE BOND 1215 or equivalent THREE BOND 1215 or equivalent Tightening torque: ⋅...
  • Page 23 Cylinder Block MECHANICAL 36) Install the water by-pass pipe between oil cool- NOTE: er and water pump. • Be sure to use a new gasket. 37) Install the water pipe. • When installing the water pump, tighten the bolts in two stages in alphabetical sequence as shown in CAUTION: the figure.
  • Page 24 Cylinder Block MECHANICAL C: DISASSEMBLY ME-00168 Connecting rod cap Top ring Oil ring Connecting rod bearing Second ring Circlip 1) Remove the connecting rod cap. 2) Remove the connecting rod bearing. NOTE: Arrange the removed connecting rod, connecting rod cap and bearing in order to prevent confusion. 3) Remove the piston rings using the piston ring ex- pander.

  • Page 25: Cylinder And Piston

    Cylinder Block MECHANICAL D: ASSEMBLY ME-00169 ⋅ Connecting rod bearing Second ring Tightening torque: N m (kgf-m, ft-lb) Connecting rod Top ring T: 45 (4.6, 33) Connecting rod cap Circlip Oil ring Side mark 1) Apply oil to the surfaces of the connecting rod E: INSPECTION bearings.
  • Page 26 Cylinder Block MECHANICAL 2.0 L MODEL Out-of-roundness: Standard Standard diameter: 0.010 mm (0.0004 in) A: 92.005 — 92.015 mm (3.6222 — 3.6226 in) Limit B: 91.995 — 92.005 mm (3.6218 — 3.6222 in) 0.050 mm (0.0020 in) 2.5 L MODEL Standard diameter: A: 99.505 —...

  • Page 27: Piston And Piston Pin

    Cylinder Block MECHANICAL 2.0 L MODEL 2.5 L MODEL Standard Piston grade point H: − − 0.010 — 0.010 mm ( 0.0004 — 0.0004 in) 40.0 mm (1.57 in) Limit Piston outer diameter: 0.030 mm (0.0012 in) Standard 6) Boring and honing: A: 91.985 —...

  • Page 28: Piston Ring

    Cylinder Block MECHANICAL 4) Make sure that the piston pin can be inserted 4. PISTON RING into the piston pin hole with a thumb at 20°C (68°F). 1) If the piston ring is broken, damaged, or worn, or Replace if defective. if its tension is insufficient, or when the piston is re- Standard clearance between piston pin and placed, replace the piston ring with a new one of...

  • Page 29: Connecting Rod

    Cylinder Block MECHANICAL 2) Squarely place the piston ring and oil ring in cyl- inder, and then measure the piston ring gap with a thickness gauge. • 2.0 L MODEL Unit: mm (in) Standard Limit 0.20 — 0.25 Top ring 1.0 (0.039) (0.0079 —...
  • Page 30 Cylinder Block MECHANICAL 3) Install the connecting rod fitted with bearing to 2.5 L MODEL crankshaft, and then measure the side clearance Connecting rod oil clearance: (thrust clearance). Replace the connecting rod if Standard the side clearance exceeds the specified limit. 0.017 —...
  • Page 31 Cylinder Block MECHANICAL 7) Replacement procedure is as follows: them to specified dimensions according to the un- dersize bearing to be used. (1) Remove the bushing from connecting rod with ST and press. Crank pin and crank journal: (2) Press the bushing with ST after applying oil Out-of-roundness on the periphery of bushing.
  • Page 32 Cylinder Block MECHANICAL • 2.0 L MODEL Unit: mm (in) Crank journal diameter Crank pin diameter #1, #3, #5 #2, #4 59.992 — 60.008 59.992 — 60.008 51.984 — 52.000 Journal O.D. (2.3619 — 2.3625) (2.3619 — 2.3625) (2.0466 — 2.0472) Standard Bearing size 1.998 —...
  • Page 33 Cylinder Block MECHANICAL 4) Measure the thrust clearance of crankshaft at 6) Measure the oil clearance on each crankshaft center bearing. If the clearance exceeds the limit, bearing by means of plastigage. If the measure- replace the bearing. ment is not within the specification, replace the de- fective bearing with an undersize one, and replace Crankshaft thrust clearance: or recondition the crankshaft as necessary.

  • Page 34: Intake And Exhaust Valve

    Intake and Exhaust Valve MECHANICAL 21.Intake and Exhaust Valve A: REMOVAL AND INSTALLATION For operations related to intake and exhaust valve, refer “19. Cylinder Head.” <Ref. ME(H4DOTC)-76, REMOVAL, Cylinder Head As- sembly.> <Ref. to ME(H4DOTC)-76, INSTALLA- TION, Cylinder Head Assembly.> ME(H4DOTC)-114...
  • Page 35 Piston MECHANICAL 22.Piston A: REMOVAL AND INSTALLATION For operations related to piston, refer to “20. Cylin- der Block.” <Ref. to ME(H4DOTC)-84, REMOVAL, Cylinder Block.> <Ref. to ME(H4DOTC)-88, IN- STALLATION, Cylinder Block.> ME(H4DOTC)-115...
  • Page 36 Connecting Rod MECHANICAL 23.Connecting Rod A: REMOVAL AND INSTALLATION For operations related to connecting rod, refer to “20. Cylinder Block.” <Ref. to ME(H4DOTC)-84, REMOVAL, Cylinder Block.> <Ref. ME(H4DOTC)-88, INSTALLATION, Cylinder Block.> ME(H4DOTC)-116...
  • Page 37 Crankshaft MECHANICAL 24.Crankshaft A: REMOVAL AND INSTALLATION For operations related to crankshaft, refer to “20. Cylinder Block.” <Ref. to ME(H4DOTC)-84, RE- MOVAL, Cylinder Block.> <Ref. to ME(H4DOTC)- 88, INSTALLATION, Cylinder Block.> ME(H4DOTC)-117...

  • Page 38: Engine Trouble In General

    Engine Trouble in General MECHANICAL 25.Engine Trouble in General A: INSPECTION NOTE: “RANK” shown in the chart refers to the possibility of reason for the trouble in order (“Very often” to “Rarely”) A — Very often B — Sometimes C — Rarely TROUBLE PROBLEM PARTS, ETC.
  • Page 39 Engine Trouble in General MECHANICAL TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK 4) Engine stalls after initial Engine control system <Ref. to EN(H4DOTC)-2, Basic Diagnostics Procedure.> combustion. Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective intake manifold gasket Defective throttle body gasket Dirty air cleaner element...
  • Page 40 Engine Trouble in General MECHANICAL TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK 3. Low output, hesitation and Engine control system <Ref. to EN(H4DOTC)-2, Basic Diagnostics Procedure.> poor acceleration Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective intake manifold gasket Defective throttle body gasket...
  • Page 41 Engine Trouble in General MECHANICAL TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK 5. Engine does not return to Engine control system <Ref. to EN(H4DOTC)-2, Basic Diagnostics Procedure.> idle. Intake system Loosened or cracked vacuum hose Others Stuck or damaged throttle valve Accelerator cable out of adjustment (2.0 L model) 6.
  • Page 42 Engine Trouble in General MECHANICAL TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK 10. Excessive fuel consump- Engine control system <Ref. to EN(H4DOTC)-2, Basic Diagnostics Procedure.> tion Intake system Dirty air cleaner element Belt Defective timing Compression Incorrect valve clearance Loosened spark plugs or defective gasket Loosened cylinder head bolts or defective gasket Improper valve seating Defective valve stem...

  • Page 43: Engine Noise

    Engine Noise MECHANICAL 26.Engine Noise A: INSPECTION Type of sound Condition Possible cause • Valve mechanism is defective. • Incorrect valve clearance Sound increases as engine Regular clicking sound • Worn valve rocker speed increases. • Worn camshaft • Broken valve spring •...
  • Page 44 Engine Noise MECHANICAL ME(H4DOTC)-124...

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