SUBARU FORESTER 2004 Service Repair Manual

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)-3
MECHANICAL
General Description
Cylinder
headSurface warpage limit (mating with cylinder block) mm (in) 0.05 (0.0020)
Grinding limit mm (in) 0.1 (0.004)
Standard height mm (in) 97.5 (3.84)
Va l ve s e a tRefacing angle90°
Contacting width mm (in)IntakeSTD 1.1 (0.043)
Limit 1.8 (0.070)
ExhaustSTD 1.5 (0.059)
Limit 2.2 (0.087)
Valve guideInner diameter mm (in) 6.000 — 6.012 (0.2362 — 0.2367)
Protrusion above head mm (in)Intake 20.0 — 20.5 (0.787 — 0.807)
Exhaust 16.5 — 17.0 (0.650 — 0.669)
Va l veHead edge thickness mm (in)IntakeSTD 1.0 (0.039)
Limit 0.6 (0.024)
ExhaustSTD 1.2 (0.047)
Limit 0.6 (0.024)
Stem outer diameter mm (in)Intake 5.950 — 5.965 (0.2343 — 0.2348)
Exhaust 5.945 — 5.960(0.2341 — 0.2346)
Stem oil clearance mm (in)STDIntake 0.035 — 0.062 (0.0014 — 0.0024)
Exhaust 0.040 — 0.067 (0.0016 — 0.0026)
Limit — 0.15 (0.0059)
Overall length mm (in)Intake 120.6 (4.75)
Exhaust 121.7 (4.79)
Valve springFree length mm (in) 54.30 (2.1378)
Squareness mm (in) 2.5°, 2.4 (0.094)
Tension/spring height N (kgf, lb)/mm (in)Set214 — 246 (22 — 25, 48 — 55)/
45.0 (1.772)
Lift526 — 582 (54 — 59, 119 — 130)/
34.7 (1.366)
Cylinder
blockSurface warpage limit (mating with cylinder head) mm (in) 0.05 (0.0020)
Grinding limit mm (in) 0.1 (0.004)
Cylinder inner
diametermm (in)2.0 L STDA 92.005 — 92.015 (3.6222 — 3.6226)
B 91.995 — 92.005 (3.6218 — 3.6222)
2.5 L STDA 99.505 — 99.515 (3.9175 — 3.9179)
B 99.495 — 99.505 (3.9171 — 3.9175)
Ta p e r m m ( i n )STD 0.015 (0.0006)
Limit 0.050 (0.0020)
Out-of-roundness mm (in)STD 0.010 (0.0004)
Limit 0.050 (0.0020)
Piston clearance mm (in)STD 0.010 — 0.030 (0.0004 — 0.0012)
Limit 0.050 (0.0020)
Boring mm (in) 0.5 (0.020)
PistonOuter diameter mm (in)2.0 LSTDA 91.985 — 91.995 (3.6214 — 3.6218)
B 91.975 — 91.985 (3.6211 — 3.6214)
0.25 (0.0098) OS 92.225 — 92.235 (3.6309 — 3.6313)
0.50 (0.0197) OS 92.475 — 92.485 (3.6407 — 3.6411)
2.5 LSTDA 99.485 — 99.495 (3.9167 — 3.9171)
B 99.475 — 99.485 (3.9163 — 3.9167)
0.25 (0.0098) OS 99.725 — 99.735 (3.9262 — 3.9266)
0.50 (0.0197) OS 99.975 — 99.985 (3.9360 — 3.9364)
Piston pin standard diameter mm (in) 23.000 — 23.006 (0.9055 — 0.9057)

ME(H4SO)-4
MECHANICAL
General Description
Piston pinOuter diameter mm (in) 22.994 — 23.000 (0.9053 — 0.9055)
Standard clearance between piston and piston pin mm (in) 0.004 — 0.008 (0.0002 — 0.0003)
Degree of fitPiston pin must be fitted into position with
thumb at 20°C (68°F).
Piston ringRing closed gap mm (in)Top ringSTD 0.20 — 0.35 (0.0079 — 0.0138)
Limit 1.0 (0.039)
Second
ring2.0 LSTD 0.35 — 0.50 (0.0138 — 0.0197)
Limit 1.0 (0.039)
2.5 LSTD 0.37 — 0.52 (0.0146 — 0.0204)
Limit 1.0 (0.039)
Oil ringSTD 0.20 — 0.50 (0.0079 — 0.0197)
Limit 1.5 (0.059)
Ring groove gap mm (in)Top ringSTD 0.040 — 0.080 (0.0016 — 0.0031)
Limit 0.15 (0.0059)
Second
ringSTD 0.030 — 0.070 (0.0012 — 0.0028)
Limit 0.15 (0.0059)
Connecting
rodBend or twist per 100 mm
(3.94 in) in lengthmm (in) Limit 0.10 (0.0039)
Side clearance at large end mm (in)STD 0.070 — 0.330 (0.0028 — 0.0130)
Limit 0.4 (0.016)
Connecting
rod bearingOil clearance mm (in)STD 0.0158 — 0.0438 (0.0006 — 0.0017)
Limit 0.05 (0.0020)
Thickness at cen-
ter portionmm (in)2.0 LSTD 1.492 — 1.501 (0.0587 — 0.0591)
0.03 (0.0012) US 1.510 — 1.513 (0.0594 — 0.0596)
0.05 (0.0020) US 1.520 — 1.523 (0.0598 — 0.0600)
0.25 (0.0098) US 1.620 — 1.623 (0.0638 — 0.0639)
2.5 LSTD 1.492 — 1.503 (0.0587 — 0.0591)
0.03 (0.0012) US 1.510 — 1.513 (0.0594 — 0.0596)
0.05 (0.0020) US 1.520 — 1.523 (0.0598 — 0.0600)
0.25 (0.0098) US 1.620 — 1.623 (0.0638 — 0.0639)
Connecting
rod bushingClearance between piston pin
and bushingmm (in)STD 0 — 0.022 (0 — 0.0009)
Limit 0.030 (0.0012)

ME(H4SO)-5
MECHANICAL
General Description
CrankshaftBend limit mm (in) 0.035 (0.0014)
Crank pin and
crank journalmm (in)Out-of-roundness 0.020 (0.0008) or less
Grinding limit 0.250 (0.0098)
Crank pin outer diameter mm (in)STD 51.984 — 52.000 (2.0466 — 2.0472)
0.03 (0.0012) US 51.954 — 51.970 (2.0454 — 2.0461)
0.05 (0.0020) US 51.934 — 51.950 (2.0446 — 2.0453)
0.25 (0.0098) US 51.734 — 51.750 (2.0368 — 2.0374)
Crank journal
outer diametermm (in)#1, #3STD 59.992 — 60.008 (2.3619 — 2.3625)
0.03 (0.0012) US 59.962 — 59.978 (2.3607 — 2.3613)
0.05 (0.0020) US 59.942 — 59.958 (2.3599 — 2.3605)
0.25 (0.0098) US 59.742 — 59.758 (2.3520 — 2.3527)
#2, #4, #5STD 59.992 — 60.008 (2.3619 — 2.3625)
0.03 (0.0012) US 59.962 — 59.978 (2.3607 — 2.3613)
0.05 (0.0020) US 59.942 — 59.958 (2.3599 — 2.3605)
0.25 (0.0098) US 59.742 — 59.758 (2.3520 — 2.3527)
Side clearance mm (in)STD 0.030 — 0.115 (0.0012 — 0.0045)
Limit 0.25 (0.0098)
Oil clearance mm (in)#1STD 0.010 — 0.030 (0.0004 — 0.0012)
Limit 0.040 (0.0016)
#2STD 0.010 — 0.030 (0.0004 — 0.0012)
Limit 0.045 (0.0018)
#3STD 0.010 — 0.030 (0.0004 — 0.0012)
Limit 0.040 (0.0016)
#4STD 0.010 — 0.030 (0.0004 — 0.0012)
Limit 0.045 (0.0018)
#5STD 0.010 — 0.030 (0.0004 — 0.0012)
Limit 0.040 (0.0016)
Crankshaft
bearingCrankshaft bear-
ing thicknessmm (in)#1, #3STD 1.998 — 2.011 (0.0787 — 0.0792)
0.03 (0.0012) US 2.017 — 2.020 (0.0794 — 0.0795)
0.05 (0.0020) US 2.027 — 2.030 (0.0798 — 0.0799)
0.25 (0.0098) US 2.127 — 2.130 (0.0837 — 0.0839)
#2, #4, #5STD 2.000 — 2.013 (0.0787 — 0.0793)
0.03 (0.0012) US 2.019 — 2.022 (0.0795 — 0.0796)
0.05 (0.0020) US 2.029 — 2.032 (0.0799 — 0.0800)
0.25 (0.0098) US 2.129 — 2.132 (0.0838 — 0.0839)

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: <Ref. to ME(H4SO)-45,
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

ME(H4SO)-7
MECHANICAL
General Description
2. CYLINDER HEAD AND CAMSHAFT
(1) Rocker cover (RH) (11) Cylinder head (LH)Tightening torque: N⋅m (kgf-m, ft-lb)
(2) Intake valve rocker ASSY (12) Camshaft (LH)T1: <Ref. to ME(H4SO)-62,
INSTALLATION, Cylinder
Head.> (3) Exhaust valve rocker ASSY (13) Camshaft cap (LH)
(4) Camshaft cap (RH) (14) Oil filler cap
(5) Oil seal (15) GasketT2: 5 (0.5, 3.6)
(6) Camshaft (RH) (16) Oil filler ductT3: 10 (1.0, 7.2)
(7) Plug (17) O-ringT4: 18 (1.8, 13.0)
(8) Spark plug pipe gasket (18) Rocker cover (LH)T5: 25 (2.5, 18.1)
(9) Cylinder head (RH) (19) Stud boltT6: 6.4 (0.65, 4.7)
(10) Cylinder head gasket
ME-00186
(17)
(10)
(11)
(19)
(12)(13)(14)
(15)
(16)
(18) (2)
(3) (8)
(5) (1)
(2)
(3) (4)
(8) (6)
(7)
(8)
(7) (9)
(10)
(19)
T2
T5
(5)
T4
T5
T6
T1
T1
T3
T5
T2T3
T3
T4
T3
T4

ME(H4SO)-8
MECHANICAL
General Description
3. VALVE ROCKER ASSEMBLY
(1) Intake valve rocker arm (5) Rocker shaft spacerTightening torque: N⋅m (kgf-m, ft-lb)
(2) Valve rocker nut (6) Intake rocker shaftT1: 5 (0.5, 3.6)
(3) Valve rocker adjust screw (7) Exhaust rocker shaftT2: 10 (1.0, 7.2)
(4) Spring (8) Exhaust valve rocker armT3: 25 (2.5, 18.1)
ME-00187 (2)
(2)(2)
(3)(3) (3)(3) (4)(5)(4)(1)
(2)(6)
(8)
(7) (1)(2)(2)
(3)(3)
(4)(4)(1)
(5)
(1)
T2T1
T3
T1
T2
T3T2
T2

ME(H4SO)-9
MECHANICAL
General Description
4. CYLINDER HEAD AND VALVE ASSEMBLY
(1) Exhaust valve (4) Valve spring seat (7) Retainer
(2) Intake valve (5) Intake valve oil seal (8) Retainer key
(3) Valve guide (6) Valve spring (9) Exhaust valve oil seal
ME-00188
(2)
(2)(6)
(6)(3)
(3)(4)
(4)(5)
(9)(7)
(8)
(7)
(8)
(1)(1)

ME(H4SO)-10
MECHANICAL
General Description
5. CYLINDER BLOCK
 MODEL WITHOUT ATF WARMER
(1) Oil pressure switch (15) Oil filter connectorTightening torque: N⋅m (kgf-m, ft-lb)
(2) Cylinder block (RH) (16) Oil strainerT1: 5 (0.5, 3.6)
(3) Service hole plug (17) GasketT2: 6.4 (0.65, 4.7)
(4) Gasket (18) Oil panT3: 10 (1.0, 7.2)
(5) Oil separator cover (19) Drain plugT4: 25 (2.5, 18.1)
(6) Water by-pass pipe (20) Metal gasketT5: <Ref. to ME(H4SO)-73,
INSTALLATION, Cylinder
Block.> (7) Oil pump (21) Oil level gauge guide
(8) Front oil seal (22) Water pump sealing
(9) Rear oil seal (23) Oil filterT6: 70 (7.1, 50.6)
(10) O-ring (24) GasketT7: First 12 (1.2, 8.7)
Second 12 (1.2, 8.7)
(11) Service hole cover (25) Water pump hose
(12) Cylinder block (LH) (26) PlugT8: 45 (4.6, 33.3)
(13) Water pump (27) O-ringT9: 44 (4.5, 33)
(14) Baffle plateT10: 25 (2.5, 18.1)
ME-02015
(14)
T6
T7
T2
T2
T4
T8
T4
T5
T2
T6
T6
T10
T1
T2
T8
T1
T3
T9
T2
T2
(9) (8)(7)(6)
(10)
(10)
(10)
(26)
(22)(11)
(12)
(13)
(19)(18)
(20)(17)
(16)
(24) (10)
(25)(5)
(4)
(4)
(4)(3)
(3)
(3) (2) (1)
(21)(15)
(23)
T5
T2
T5
T4
(27)

ME(H4SO)-11
MECHANICAL
General Description
 MODEL WITH ATF WARMER
(1) Oil pressure switch (15) Oil filter connectorTightening torque: N⋅m (kgf-m, ft-lb)
(2) Cylinder block (RH) (16) Oil strainerT1: 5 (0.5, 3.6)
(3) Service hole plug (17) GasketT2: 6.4 (0.65, 4.7)
(4) Gasket (18) Oil panT3: 10 (1.0, 7.2)
(5) Oil separator cover (19) Drain plugT4: 25 (2.5, 18.1)
(6) Water by-pass pipe (20) Metal gasketT5: <Ref. to ME(H4SO)-73,
INSTALLATION, Cylinder
Block.> (7) Oil pump (21) Oil level gauge guide
(8) Front oil seal (22) Water pump sealing
(9) Rear oil seal (23) Oil filterT6: 70 (7.1, 50.6)
(10) O-ring (24) GasketT7: First 12 (1.2, 8.7)
Second 12 (1.2, 8.7)
(11) Service hole cover (25) Water pump hose
(12) Cylinder block (LH) (26) PlugT8: 45 (4.6, 33.3)
(13) Water pump (27) O-ringT9: 44 (4.5, 33)
(14) Baffle plateT10: 25 (2.5, 18.1)
ME-02016
(14)
T6
T2
T2
T4
T8
T5
T2
T6
T6
T10
T1
T2
T8
T1
T3
T9
T2
T2
(9) (8)(7)
(10)
(10)
(10)
(26)
(22)(11)
(12)
(19)(18)
(20)(17)
(16)
(24) (10)
(25)(5)
(4)
(4)
(4)(3)
(3)
(3) (2) (1)
(21)(15)
(23)
T5
T2
T5
T4
(27)
T7
(13)
(6)
T4