SUBARU FORESTER 2004 Service Repair Manual

ME(H4SO)-12
MECHANICAL
General Description
6. CRANKSHAFT AND PISTON
ME-00190
T1
T1
(9)(1)
(16)(17)(16)(17)(6)
(5)(4)(3)
(2) (12) (11) (10)
(7) (9) (9)
(8) (6) (5) (4)
(15)
(18)
(9)
(8) (10) (12)
(11) (7)
(13) (12) (14)
T2
T2

ME(H4SO)-13
MECHANICAL
General Description
(1) Flywheel (MT model) (9) Snap ring (17) Crankshaft bearing #2, #4
(2) Reinforcement (AT model) (10) Connecting rod bolt (18) Crankshaft bearing #5
(3) Drive plate (AT model) (11) Connecting rod
(4) Top ring (12) Connecting rod bearingTightening torque: N
⋅m (kgf-m, ft-lb)
(5) Second ring (13) Connecting rod capT1: 45 (4.6, 33.3)
(6) Oil ring (14) CrankshaftT2: 72 (7.3, 52.8)
(7) Piston (15) Woodruff key
(8) Piston pin (16) Crankshaft bearing #1, #3

ME(H4SO)-14
MECHANICAL
General Description
7. ENGINE MOUNTING
(1) Front cushion rubber (2) Front engine mounting bracketTightening torque: N⋅m (kgf-m, ft-lb)
T1: 35 (3.6, 25.8)
T2: 42 (4.3, 31.0)
T3: 85 (8.7, 63)
ME-00413
T2
T1
T1
T3
T3 (2)(2)
(1)(1)
T2

ME(H4SO)-15
MECHANICAL
General Description
C: CAUTION
 Wear working clothing, including a cap, protec-
tive goggles and protective shoes during operation.
 Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
 Keep the disassembled parts in order and pro-
tect them from dust or dirt.
 Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly and replacement.
 Be careful not to burn yourself, because each
part in the vehicle is hot after running.
 Be sure to tighten bolts and nuts to the specified
torque.
 Place shop jacks or rigid racks at the specified
points.
 Before disconnecting electrical connectors of
sensors or units, be sure to disconnect the ground
cable from battery.
 All parts should be thoroughly cleaned, paying
special attention to the engine oil passages, pis-
tons and bearings. Rotating parts and sliding parts such as piston,
bearing and gear should be coated with oil prior to
assembly.
 Be careful not to let oil, grease or coolant contact
the timing belt, clutch disc and flywheel.
 All removed parts, if to be reused, should be re-
installed in the original positions and directions.
 Bolts, nuts and washers should be replaced with
new ones as required.
 Even if necessary inspections have been made
in advance, proceed with assembly work while
making rechecks.
 Remove or install engine in an area where chain
hoists, lifting devices, etc. are available for ready
use.
 Be sure not to damage coated surfaces of body
panels with tools, or not to stain seats and windows
with coolant or oil. Place a cover over fenders, as
required, for protection.
 Prior to starting work, prepare the following:
Service tools, clean cloth, containers to catch cool-
ant and oil, wire ropes, chain hoist, transmission
jacks, etc.
 Lift-up or lower the vehicle when necessary.
Make sure to support the correct positions.
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
18231AA010 CAM SPROCKET
WRENCH Used for removing and installing cam
sprocket. (LH side)
 Also the CAM SPROCKET WRENCH
(499207100) can be used.
24082AA230
(Newly adopted tool)CARTRIDGE Troubleshooting for electrical systems.
ST18231AA010
ST24082AA230

ME(H4SO)-16
MECHANICAL
General Description
22771AA030 SUBARU SELECT
MONITOR KITTroubleshooting for electrical systems.
 English: 22771AA030 (Without printer)
 German: 22771AA070 (Without printer)
 French: 22771AA080 (Without printer)
 Spanish: 22771AA090 (Without printer)
498267800 CYLINDER HEAD
TABLE Used for replacing valve guides.
 Used for removing and installing valve springs.
498277200 STOPPER SET Used for installing automatic transmission
assembly to engine.
498457000 ENGINE STAND
ADAPTER RHUsed with ENGINE STAND (499817000). ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST22771AA030
ST-498267800
ST-498277200
ST-498457000

ME(H4SO)-17
MECHANICAL
General Description
498457100 ENGINE STAND
ADAPTER LHUsed with ENGINE STAND (499817000).
498497100 CRANKSHAFT
STOPPERUsed for stopping rotation of flywheel when loos-
ening and tightening crank pulley bolt, etc.
498547000 OIL FILTER
WRENCHUsed for removing and installing oil filter.
(Outer diameter : 80 mm (3.15 in))
18332AA000 OIL FILTER
WRENCHUsed for removing and installing oil filter.
(Outer diameter : 68 mm (2.68 in)) ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-498457100
ST-498497100
ST-498547000
ST18332AA000

ME(H4SO)-18
MECHANICAL
General Description
18332AA010 OIL FILTER
WRENCHUsed for removing and installing oil filter.
(Outer diameter : 65 mm (2.56 in))
398744300
(2.0 L model)PISTON GUIDE Used for installing piston in cylinder.
498747300
(2.5 L model)PISTON GUIDE Used for installing piston in cylinder.
498857100 VALVE OIL SEAL
GUIDEUsed for press-fitting of intake and exhaust valve
guide oil seals. ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST18332AA010
ST-398744300
ST-498747300
ST-498857100

ME(H4SO)-19
MECHANICAL
General Description
499017100 PISTON PIN GUIDE Used for installing piston pin, piston and con-
necting rod.
499037100 CONNECTING ROD
BUSHING
REMOVER &
INSTALLERUsed for removing and installing connecting rod
bushing.
499057000 TORX PLUS Used for removing flywheel (Dual mass fly-
wheel).
499587200 CRANKSHAFT OIL
SEAL INSTALLER Used for installing crankshaft oil seal.
 Used with CRANKSHAFT OIL SEAL GUIDE
(499597100). ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-499017100
ST-499037100
ST-499057000
ST-499587200

ME(H4SO)-20
MECHANICAL
General Description
499587500 OIL SEAL
INSTALLERUsed for installing camshaft oil seal.
499587700 CAMSHAFT OIL
SEAL INSTALLERUsed for installing cylinder head plug.
499097700 PISTON PIN
REMOVER ASSYUsed for removing piston pin.
499207400 CAM SPROCKET
WRENCHUsed for removing and installing cam sprocket.
(RH side) ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-499587500
ST-499587700
ST-499097700
ST-499207400

ME(H4SO)-21
MECHANICAL
General Description
499497000 TORX PLUS Used for removing and installing camshaft cap.
499587100 OIL SEAL
INSTALLERUsed for installing oil pump oil seal.
499597000 OIL SEAL GUIDE  Used for installing camshaft oil seal.
 Used with CAMSHAFT OIL SEAL INSTALLER
(499587500).
499597100 CRANKSHAFT OIL
SEAL GUIDE Used for installing crankshaft oil seal.
 Used with CRANKSHAFT OIL SEAL
INSTALLER (499587200). ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-499497000
ST-499587100
ST-499597000
ST-499597100