SUBARU FORESTER 2004 Service Repair Manual

ME(H4DOTC)-5
MECHANICAL
General Description
CrankshaftBend limit 0.035 mm (0.0014 in)
Crank pin and crank jour-
nalOut-of-roundness 0.005 mm (0.0002 in) or less
Grinding limit 0.25 mm (0.0098 in)
Crank pin outer diameter STD 51.984 — 52.000 mm (2.0466 — 2.0472 in)
0.03 mm
(0.0012
in) US51.954 — 51.970 mm (2.0454 — 2.0461 in)
0.05 mm
(0.0020
in) US51.934 — 51.950 mm (2.0447 — 2.0453 in)
0.25 mm
(0.0098
in) US51.734 — 51.750 mm (2.0368 — 2.0374 in)
Crank journal outer diam-
eter#1, #3, #5STD 59.992 — 60.008 mm (2.3619 — 2.3625 in)
0.03 mm
(0.0012
in) US59.962 — 59.978 mm (2.3607 — 2.3613 in)
0.05 mm
(0.0020
in) US59.942 — 59.958 mm (2.3599 — 2.3605 in)
0.25 mm
(0.0098
in) US59.742 — 59.758 mm (2.3520 — 2.3527 in)
#2, #4STD 59.992 — 60.008 mm (2.3619 — 2.3625 in)
0.03 mm
(0.0012
in) US59.962 — 59.978 mm (2.3607 — 2.3613 in)
0.05 mm
(0.0020
in) US59.942 — 59.958 mm (2.3599 — 2.3605 in)
0.25 mm
(0.0098
in) US59.742 — 59.758 mm (2.3520 — 2.3527 in)
Thrust clearanceSTD 0.030 — 0.115 mm (0.0012 — 0.0045 in)
Limit 0.25 mm (0.0098 in)
Oil clearanceSTD 0.010 — 0.030 mm (0.0004 — 0.0012 in)
Limit 0.040 mm (0.0016 in)
Crankshaft
bearingCrankshaft bearing thick-
ness#1, #3STD 1.998 — 2.011 mm (0.0787 — 0.0792 in)
0.03 mm
(0.0012
in) US2.017 — 2.020 mm (0.0794 — 0.0795 in)
0.05 mm
(0.0020
in) US2.027 — 2.030 mm (0.0798 — 0.0799 in)
0.25 mm
(0.0098
in) US2.127 — 2.130 mm (0.0837 — 0.0839 in)
#2, #4, #5STD 2.000 — 2.013 mm (0.0787 — 0.0793 in)
0.03 mm
(0.0012
in) US2.019 — 2.022 mm (0.0795 — 0.0796 in)
0.05 mm
(0.0020
in) US2.029 — 2.032 mm (0.0799 — 0.0800 in)
0.25 mm
(0.0098
in) US2.129 — 2.132 mm (0.0838 — 0.0839 in)

ME(H4DOTC)-6
MECHANICAL
General Description
2. 2.5 L MODEL
NOTE:
STD: Standard I.D.: Inner Diameter O.D.: Outer Diameter OS: Oversize US: Undersize
EngineModel2.5 L
Ty 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) 99.5×79.0 (3.92×3.11)
Piston displacement
cm
3 (cu in)2,457 (149.94)
Compression ratio 8.2
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 ATDC 5°
Min. advance BTDC 15°
ClosingMax. retard ABDC 65°
Min. advance ABDC 45°
Exhaust valve timingOpening BBDC 55°
Closing ATDC 5°
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/rpmMT model 17°±10°/700
AT model 17°±10°/700

ME(H4DOTC)-7
MECHANICAL
General Description
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 (0.069 in)
Side clearance of spacerSTD 0.2 — 0.55 mm (0.0079 — 0.0217 in)
Limit 0.81 mm (0.0319 in)
CamshaftBend limit 0.020 mm (0.0079 in)
Thrust clearanceSTD 0.068 — 0.116 mm (0.0027 — 0.0046 in)
Limit 0.14 mm (0.0055 in)
Cam lobe heightIntakeSTD 46.55 — 46.65 mm (1.833 — 1.837 in)
Limit 46.45 mm (1.829 in)
ExhaustSTD 46.75 — 46.85 mm (1.841 — 1.844 in)
Limit 46.65 mm (1.837 in)
Journal O.D. STDFront 37.946 — 37.963 mm (1.4939 — 1.4946 in)
Center
rear29.946 — 29.963 mm (1.1790 — 1.1796 in)
Oil clearanceSTD 0.037 — 0.072 mm (0.0015 — 0.0028 in)
Limit 0.10 mm (0.0039 in)
Cylinder
headSurface warpage limit (mating with cylinder head) 0.05 mm (0.0020 in)
Surface grinding limit 0.3 mm (0.012 in)
Standard height 127.5 mm (5.02 in)
Va l ve s e a tRefacing angle 90°
Contacting widthIntakeSTD 1.0 mm (0.039 in)
Limit 1.7 mm (0.067 in)
ExhaustSTD 1.5 mm (0.059 in)
Limit 2.2 mm (0.087 in)
Valve guideInner diameter 6.000 — 6.012 mm (0.2362 — 0.2367 in)
Protrusion above head 15.8 — 16.2 mm (0.622 — 0.638 in)
Va l veHead edge thicknessIntakeSTD 1.2 mm (0.047 in)
Limit 0.8 mm (0.031 in)
ExhaustSTD 1.5 mm (0.059 in)
Limit 0.8 mm (0.031 in)
Stem diameterIntake 5.955 — 5.970 mm (0.2344 — 0.2350 in)
Exhaust 5.945 — 5.960 mm (0.2341 — 0.2346 in)
Stem oil clearanceSTDIntake 0.030 — 0.057 mm (0.0012 — 0.0022 in)
Exhaust 0.040 — 0.067 mm (0.0016 — 0.0026 in)
Limit — 0.15 mm (0.0059 in)
Overall lengthIntake 104.4 mm (4.110 in)
Exhaust 104.65 mm (4.120 in)
Va l ve
springFree length 47.32 mm (1.863 in)
Squareness 2.5°, 2.1 mm (0.083 in)
Tension/spring heightSet205 — 235 N (20.9 — 24.0 kgf, 46.1 — 52.8 lb)/
36.0 mm (1.417 in)
Lift426 — 490 N (43.4 — 50.0 kgf, 95.8 — 110 lb)/
26.50 mm (1.043 in)

ME(H4DOTC)-8
MECHANICAL
General Description
Cylinder
blockSurface warpage limit (mating with cylinder head) 0.05 mm (0.0020 in)
Surface grinding limit 0.1 mm (0.004 in)
Standard height 201.0 mm (7.91 in)
Cylinder bore STDA 99.505 — 99.515 mm (3.9175 — 3.9179 in)
B 99.495 — 99.505 mm (3.9171 — 3.9175 in)
TaperSTD 0.015 mm (0.0006 in)
Limit 0.050 mm (0.0020 in)
Out-of-roundnessSTD 0.010 mm (0.0004 in)
Limit 0.050 mm (0.0020 in)
Piston clearanceSTD−0.010 — 0.010 mm (−0.0004 — 0.0004 in)
Limit 0.030 mm (0.0012 in)
Enlarging (boring) limit 0.5 mm (0.020 in)
Piston Outer diameterSTDA 99.505 — 99.515 mm (3.9175 — 3.9179 in)
B 99.495 — 99.505 mm (3.9171 — 3.9175 in)
0.25 mm (0.0098 in)
OS99.745 — 99.765 mm (3.9270 — 3.9278 in)
0.50 mm (0.0197 in)
OS99.995 — 100.015 mm (3.9368 — 3.9376 in)
Piston pinStandard clearance between piston
pin and hole in pistonSTD 0.004 — 0.008 mm (0.0002 — 0.0003 in)
Limit 0.020 mm (0.0008 in)
Degree of fitPiston pin must be fitted into position with thumb at 20°C
(68°F).
Piston ringPiston ring gapTop ringSTD 0.20 — 0.25 mm (0.0079 — 0.0098 in)
Limit 1.0 mm (0.039 in)
Second
ringSTD 0.37 — 0.52 mm (0.015 — 0.020 in)
Limit 1.0 mm (0.039 in)
Oil ringSTD 0.20 — 0.50 mm (0.0079 — 0.020 in)
Limit 1.5 mm (0.059 in)
Clearance between piston
ring and piston ring
grooveTop ringSTD 0.040 — 0.080 mm (0.0016 — 0.0031 in)
Limit 0.15 mm (0.0059 in)
Second
ringSTD 0.030 — 0.070 mm (0.0012 — 0.0028 in)
Limit 0.15 mm (0.0059 in)
Connecting
rodBend twist per 100 mm (3.94 in) in
lengthLimit 0.10 mm (0.0039 in)
Side clearanceSTD 0.070 — 0.330 mm (0.0028 — 0.0130 in)
Limit 0.4 mm (0.016 in)
Connecting
rod bearingOil clearanceSTD 0.017 — 0.045 mm (0.0007 — 0.0018 in)
Limit 0.05 mm (0.0020 in)
Thickness at center portionSTD 1.490 — 1.502 mm (0.0587 — 0.0591 in)
0.03 mm
(0.0012
in) US1.504 — 1.512 mm (0.0592 — 0.0595 in)
0.05 mm
(0.0020
in) US1.514 — 1.522 mm (0.0596 — 0.0599 in)
0.25 mm
(0.0098
in) US1.614 — 1.622 mm (0.0635 — 0.0639 in)
Connecting
rod bushingClearance between piston pin and
bushingSTD 0 — 0.022 mm (0 — 0.0009 in)
Limit 0.030 mm (0.0012 in)

ME(H4DOTC)-9
MECHANICAL
General Description
CrankshaftBend limit 0.035 mm (0.0014 in)
Crank pin and crank jour-
nalOut-of-roundness 0.005 mm (0.0002 in) or less
Grinding limit 0.25 mm (0.0098 in)
Crank pin outer diameterSTD 51.984 — 52.000 mm (2.0466 — 2.0472 in)
0.03 mm
(0.0012
in) US51.954 — 51.970 mm (2.0454 — 2.0461 in)
0.05 mm
(0.0020
in) US51.934 — 51.950 mm (2.0447 — 2.0453 in)
0.25 mm
(0.0098
in) US51.734 — 51.750 mm (2.0368 — 2.0374 in)
Crank journal outer diam-
eter#1, #3, #5STD 59.992 — 60.008 mm (2.3619 — 2.3625 in)
0.03 mm
(0.0012
in) US59.962 — 59.978 mm (2.3607 — 2.3613 in)
0.05 mm
(0.0020
in) US59.942 — 59.958 mm (2.3599 — 2.3605 in)
0.25 mm
(0.0098
in) US59.742 — 59.758 mm (2.3520 — 2.3527 in)
#2, #4STD 59.992 — 60.008 mm (2.3619 — 2.3625 in)
0.03 mm
(0.0012
in) US59.962 — 59.978 mm (2.3607 — 2.3613 in)
0.05 mm
(0.0020
in) US59.942 — 59.958 mm (2.3599 — 2.3605 in)
0.25 mm
(0.0098
in) US59.742 — 59.758 mm (2.3520 — 2.3527 in)
Thrust clearanceSTD 0.030 — 0.115 mm (0.0012 — 0.0045 in)
Limit 0.25 mm (0.0098 in)
Oil clearanceSTD 0.010 — 0.030 mm (0.0004 — 0.0012 in)
Limit 0.040 mm (0.0016 in)
Crankshaft
bearingCrankshaft bearing thick-
ness#1, #3STD 1.998 — 2.011 mm (0.0787 — 0.0792 in)
0.03 mm
(0.0012
in) US2.017 — 2.020 mm (0.0794 — 0.0795 in)
0.05 mm
(0.0020
in) US2.027 — 2.030 mm (0.0798 — 0.0799 in)
0.25 mm
(0.0098
in) US2.127 — 2.130 mm (0.0837 — 0.0839 in)
#2, #4, #5STD 2.000 — 2.013 mm (0.0787 — 0.0793 in)
0.03 mm
(0.0012
in) US2.019 — 2.022 mm (0.0795 — 0.0796 in)
0.05 mm
(0.0020
in) US2.029 — 2.032 mm (0.0799 — 0.0800 in)
0.25 mm
(0.0098
in) US2.129 — 2.132 mm (0.0838 — 0.0839 in)

ME(H4DOTC)-10
MECHANICAL
General Description
B: COMPONENT
1. TIMING BELT
(1) Timing belt cover No. 2 (RH) (11) Exhaust cam sprocket (LH)Tightening torque: N⋅m (kgf-m, ft-lb)
(2) Timing belt guide (12) Timing beltT1: 5 (0.5, 3.6)
(3) Crank sprocket (13) Belt idler No. 2T2: 10 (1.0, 7)
(4) Timing belt cover No. 2 (LH) (14) Belt idlerT3: 25 (2.5, 18.1)
(5) Tensioner bracket (15) Timing belt cover (LH)T4: 39 (4.0, 28.9)
(6) Automatic belt tension adjuster
ASSY(16) Front belt coverT5: <Ref. to ME(H4DOTC)-67,
INSTALLATION, Cam
Sprocket.> (17) Timing belt cover (RH)
(7) Belt idler (18) Crank pulley (2.0 L model)
(8) Exhaust cam sprocket (RH) (19) Crank pulley (2.5 L model)T6: <Ref. to ME(H4DOTC)-55,
INSTALLATION, Crank Pulley.>
(9) Intake cam sprocket (RH)
(10) Intake cam sprocket (LH)T7: 6.4 (0.65, 4.7)
ME-02008
T5
T1T6(7)(6)
(10)
(19)(5)
(14)(2)
(3)
T2
(4)
(1)(2)
(2)
T7
T4
T3
T3
T4
T5
T4
T5T1
T7(11)
(15)
(17)
(2)
(9)
(8)
(13) (14) (12)
T1
T1
T7
T1
T1
T5
(16)
T6(18)

ME(H4DOTC)-11
MECHANICAL
General Description
2. CYLINDER HEAD AND CAMSHAFT
 2.0 L MODEL
ME-02013
T4
T5
T2
T2 T1
(3)
(7)
(6)
(9)(10)
(12)
(13)
(28)
(24)
(25)
(26)
(23) (19)(20) (28)
(15)
(16) (11)
(17)
(22) (27)
(21) (18) (10) (14) (13)
(11) (5) (4)
T4 T4 T3
T4T6
T6
T6
T6 (29)
T6
(29) T5 T3
(31)
(30)
T3 (8)
T2
(1)(2)
T3
(30)
(31)

ME(H4DOTC)-12
MECHANICAL
General Description
(1) Rocker cover (RH) (15) Intake camshaft (LH) (29) Oil flow control solenoid valve
(2) Rocker cover gasket (RH) (16) Exhaust camshaft (LH) (30) Gasket
(3) Intake camshaft cap (Front RH) (17) Intake camshaft cap (Front LH) (31) Oil return cover
(4) Intake camshaft cap (Rear RH) (18) Intake camshaft cap (Rear LH)
(5) Intake camshaft (RH) (19) Exhaust camshaft cap (Front LH)Tightening torque: N
⋅m (kgf-m, ft-lb)
(6) Exhaust camshaft cap (Front RH) (20) Exhaust camshaft cap (Center
LH)T1: <Ref. to ME(H4DOTC)-76,
INSTALLATION, Cylinder Head
Assembly.> (7) Exhaust camshaft cap (Center
RH) (21) Exhaust camshaft cap (Rear LH)
(8) Exhaust camshaft cap (Rear RH) (22) Rocker cover gasket (LH)T2: 5 (0.5, 3.6)
(9) Exhaust camshaft (RH) (23) Rocker cover (LH)T3: 8 (0.8, 5.9)
(10) Cylinder head bolt (24) Oil filler capT4: 10 (1.0, 7)
(11) Oil seal (25) GasketT5: 6.4 (0.65, 4.7)
(12) Cylinder head (RH) (26) Oil filler ductT6: 20 (2.0, 14.5)
(13) Cylinder head gasket (27) O-ring
(14) Cylinder head (LH) (28) Stud bolt

ME(H4DOTC)-13
MECHANICAL
General Description
 2.5 L MODEL
T4(1)
ME-00765
T3
T3
T5
T5
T5
T5
T4
T1
(3)(7)(6)
(9) (8)
(10)
(12)(29)
(13)
(26) (23)
(24)
(21)
(20)(6) (16)
(17)
(18) (9)
(25) (8)
(19) (15)(14)
(30)
(11)(5) (4)
(22)T4T4
(14)
(30)
(12)
(28)
(28) (27)
T1(11)
(2)
T2
T6
T6
T2
T2
T2
T6
T6
T2

ME(H4DOTC)-14
MECHANICAL
General Description
(1) Rocker cover (RH) (15) Cylinder head (LH) (29) Oil pipe (RH)
(2) Rocker cover gasket (RH) (16) Intake camshaft (LH) (30) Stud bolt
(3) Camshaft cap (Front RH) (17) Exhaust camshaft (LH)
(4) Intake camshaft cap (Rear RH) (18) Camshaft cap (Front LH)Tightening torque: N
⋅m (kgf-m, ft-lb)
(5) Intake camshaft (RH) (19) Intake camshaft cap (Rear LH)T1: <Ref. to ME(H4DOTC)-76,
INSTALLATION, CYLINDER
HEAD ASSEMBLY.> (6) Oil flow control solenoid valve (20) Exhaust camshaft cap (Rear LH)
(7) Exhaust camshaft cap (Rear RH) (21) Rocker cover gasket (LH)
(8) Gasket (22) Rocker cover (LH)T2: 8 (0.8, 5.9)
(9) Oil return cover (23) Oil filler capT3: 10 (1.0, 7.2)
(10) Exhaust camshaft (RH) (24) GasketT4: 6.4 (0.65, 4.7)
(11) Cylinder head bolt (25) Oil filler ductT5: 20 (2.0, 14.5)
(12) Oil seal (26) O-ringT6: 29 (3.0, 21.4)
(13) Cylinder head (RH) (27) Oil pipe (LH)
(14) Cylinder head gasket (28) Gasket