SUBARU FORESTER 2004 Service Repair Manual

ME(H4SO)-42
MECHANICAL
Preparation for Overhaul
11.Preparation for Overhaul
A: PROCEDURE
1) After removing the engine from body, secure it in
the ST shown below.
ST1 498457000 ENGINE STAND ADAPTER
RH
ST2 498457100 ENGINE STAND ADAPTER
LH
ST3 499817100 ENGINE STAND
2) In this section the procedures described under
each index are all connected and stated in order. It
will be the complete procedure for overhauling of
the engine itself when you go through all steps in
the process.
Therefore, in this section, to conduct the particular
procedure within the flow of a section, you need to
go back and conduct the procedure described pre-
viously in order to do that particular procedure.
ME-00221ST2ST1ST3

ME(H4SO)-43
MECHANICAL
V-belt
12.V-belt
A: REMOVAL
1. FRONT SIDE BELT
NOTE:
Perform the following procedures 1) to 4) with the
engine installed to body.
1) Remove the V-belt cover.
2) Loosen the lock bolt (A).
3) Loosen the slider bolt (B).
4) Remove the front side belt (C).
2. REAR SIDE BELT
1) Loosen the lock nut (A).
2) Loosen the slider bolt (B).
3) Remove the A/C belt.4) Remove the A/C belt tensioner.
B: INSTALLATION
1. FRONT SIDE BELT
1) Wipe off any oil or water on the belt and pulley.
2) Install the V-belt (C), and tighten the slider bolt
so as to obtain the specified belt tension <Ref. to
ME(H4SO)-44, INSPECTION, V-belt.>
3) Tighten the lock bolt (A).
4) Tighten the slider bolt (B).
Tightening torque:
Lock bolt through bolt:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
Slider bolt:
8 N
⋅m (0.8 kgf-m, 5.5 ft-lb)
2. REAR SIDE BELT
1) Install the V-belt, and tighten the slider bolt (B)
so as to obtain the specified belt tension. <Ref. to
ME(H4SO)-44, INSPECTION, V-belt.>
ME-00222
ME-00223
(B)
(C)
(A)
ME-00224
(A) (B)
ME-00225
ME-00223
(B)
(C)
(A)

ME(H4SO)-44
MECHANICAL
V-belt
2) Tighten the lock nut (A).
Tightening torque:
Lock nut (A)
22.6 N
⋅m (2.3 kgf-m, 16.6 ft-lb)
C: INSPECTION
1) Replace the belts, if cracks, fraying or wear is
found.
2) Check the drive belt tension and adjust it if nec-
essary by changing the generator installing position
or idler pulley installing position.
Belt tension
(A)
replaced: 7 — 9 mm (0.276 — 0.354 in)
reused: 9 — 11 mm (0.354 — 0.433 in)
(B)
replaced: 7.5 — 8.5 mm (0.295 — 0.335 in)
reused: 9.0 — 10.0 mm (0.354 — 0.394 in)
C/P Crank pulley
GEN Generator
P/S Power steering oil pump pulley
A/C Air conditioning compressor pulley
I/P Idler pulley
ME-00224
(A) (B)
ME-00226
(A) (B)(C)GEN
C/P
I/P A/C
P/S

ME(H4SO)-45
MECHANICAL
Crank Pulley
13.Crank Pulley
A: REMOVAL
1) Remove the V-belt. <Ref. to ME(H4SO)-43, RE-
MOVAL, V-belt.>
2) Remove the crank pulley bolt. Use ST to lock the
crankshaft.
ST 499977400 CRANK PULLEY WRENCH
(2.0 L model)
ST 499977100 CRANK PULLEY WRENCH
(2.5 L model)
3) Remove the crank pulley.
B: INSTALLATION
1. 2.0 L MODEL
1) Install the crank pulley.
2) Install the pulley bolt.
Use ST to lock the crankshaft.
ST 499977400 CRANK PULLEY WRENCH
(1) Clean the crank pulley thread using an air
gun.
(2) Apply engine oil to the crank pulley bolt seat
and thread.
(3) Tighten the bolts temporarily with tightening
torque of 44 N⋅m (4.5 kgf-m, 33 ft-lb).
(4) Tighten the crank pulley bolts.
Tightening torque:
127 N
⋅m (13.0 kgf-m, 94.0 ft-lb)
3) Confirm that the tightening angle of crank pulley
bolt is 45° or more. If the tightening angle of crank
pulley bolt is less than 45°, conduct the following
procedures.(1) Replace the crank pulley bolts and clean
them.
Crank pulley bolt:
12369AA011
(2) Clean the crankshaft thread using an air
gun.
(3) Apply engine oil to the crank pulley bolt seat
and thread.
(4) Tighten the bolts temporarily with tightening
torque of 44 N⋅m (4.5 kgf-m, 33 ft-lb).
(5) Tighten the crank pulley bolts keeping them
in an angle between 45° and 60°.
NOTE:
Conduct the tightening procedures by confirming
the turning angle of crank pulley bolt referring to the
gauge indicated on belt cover.
4) Install the A/C belt tensioner.
5) Install the A/C belt.
2. 2.5 L MODEL
1) Install the crank pulley.
2) Install the pulley bolt.
Use ST to lock the crankshaft.
ST 499977100 CRANK PULLEY WRENCH
(1) Clean the crank pulley thread using an air
gun.
(2) Apply engine oil to the crank pulley bolt seat
and thread.
(3) Tighten the bolts temporarily with tightening
torque of 44 N⋅m (4.5 kgf-m, 33 ft-lb).
ME-00227
STST
ME-00227
STST
ME-00225
ME-00228

ME(H4SO)-46
MECHANICAL
Crank Pulley
(4) Tighten the crank pulley bolts.
Tightening torque:
177 N
⋅m (18.0 kgf-m, 130.2 ft-lb)
3) Confirm that the tightening angle of crank pulley
bolt is 65° or more. If the tightening angle of crank
pulley bolt is less than 65°, conduct the following
procedures.
(1) Replace the crank pulley bolts and clean
them.
Crank pulley bolt:
12369AA011
(2) Clean the crankshaft thread using an air
gun.
(3) Apply engine oil to the crank pulley bolt seat
and thread.
(4) Tighten the bolts temporarily with tightening
torque of 44 N⋅m (4.5 kgf-m, 33 ft-lb).
(5) Tighten the crank pulley bolts keeping them
in an angle between 65° and 75°.
NOTE:
Conduct the tightening procedures by confirming
the turning angle of crank pulley bolt referring to the
gauge indicated on belt cover.
4) Install the A/C belt tensioner.5) Install the A/C belt.
C: INSPECTION
1) Make sure the V-belt is not worn or otherwise
damaged.
2) Check the tension of the belt. <Ref. to
ME(H4SO)-44, INSPECTION, V-belt.>ME-00227
STST
ME-00225
ME-00228

ME(H4SO)-47
MECHANICAL
Timing Belt Cover
14.Timing Belt Cover
A: REMOVAL
1) Remove the V-belt. <Ref. to ME(H4SO)-43, RE-
MOVAL, V-belt.>
2) Remove the crank pulley. <Ref. to ME(H4SO)-
45, REMOVAL, Crank Pulley.>
3) Remove the belt cover (LH).
4) Remove the front belt cover.
B: INSTALLATION
1) Install the front belt cover.
Tightening torque:
5 N
⋅m (0.5 kgf-m, 3.6 ft-lb)
2) Install the belt cover (LH).
Tightening torque:
5 N
⋅m (0.5 kgf-m, 3.6 ft-lb)
3) Install the crank pulley. <Ref. to ME(H4SO)-45,
INSTALLATION, Crank Pulley.>
4) Install the V-belt. <Ref. to ME(H4SO)-43, IN-
STALLATION, V-belt.>
C: INSPECTION
Make sure the cover is not damaged.
(A) Timing belt cover (LH)
(B) Front timing belt cover
(A) Timing belt cover (LH)
(B) Front timing belt cover
ME-00229
(A)
(B)
ME-00229
(A)
(B)

ME(H4SO)-48
MECHANICAL
Timing Belt
15.Timing Belt
A: REMOVAL
1. TIMING BELT
1) Remove the V-belt. <Ref. to ME(H4SO)-43, RE-
MOVAL, V-belt.>
2) Remove the crank pulley. <Ref. to ME(H4SO)-
45, REMOVAL, Crank Pulley.>
3) Remove the belt cover. <Ref. to ME(H4SO)-47,
REMOVAL, Timing Belt Cover.>
4) Remove the timing belt guide. (MT model)
5) If the alignment mark (a) or arrow mark (which
indicates rotation direction) on timing belt fade
away, put new marks before removing the timing
belt as shown in procedures below.
(1) Turn the crankshaft using ST. Align the
mark (a) of sprocket to cylinder block notch (b)
and ensure the right side cam sprocket mark (c),
cam cap and cylinder head matching surface (d)
or left side cam sprocket mark (e) and belt cover
notch (f) are properly adjusted.
ST 499987500 CRANKSHAFT SOCKET(2) Using white paint, put alignment or arrow
marks on the timing belts in relation to crank
sprocket and cam sprockets.
Specified data:
Z
1: 46.8 tooth length
Z
2: 43.7 tooth length
6) Remove the belt idler (No. 2).
ME-00230
ME-00231ST
ME-00232
(a) (b) (d)
(c)
(f)
(e)
ME-00233
ME-000234
Z1Z2

ME(H4SO)-49
MECHANICAL
Timing Belt
7) Remove the belt idler No. 2.
8) Remove the timing belt.
2. BELT IDLER AND AUTOMATIC BELT
TENSION ADJUSTER ASSEMBLY
1) Remove the belt idler (No. 1).
2) Remove the automatic belt tension adjuster as-
sembly.
B: INSTALLATION
1. AUTOMATIC BELT TENSION ADJUST-
ER ASSEMBLY AND BELT IDLER
1) Preparation for installation of automatic belt ten-
sion adjuster assembly
CAUTION:
 Always use a vertical type pressing tool to
move the adjuster rod down.
 Do not use a lateral type vise.
 Push the adjuster rod vertically.
 Press-in the push adjuster rod gradually tak-
ing more than 3 minutes.
 Do not allow press pressure to exceed 9,807
N (1,000 kgf, 2,205 lb).
 Press the adjuster rod as far as the end sur-
face of cylinder. Do not press the adjuster rod
into the cylinder. Doing so may damage the cyl-
inder.
 Do not release the press pressure until stop-
per pin is completely inserted.
(1) Attach the automatic belt tension adjuster
assembly to the vertical pressing tool.
(2) Slowly move the adjuster rod down with a
pressure of 294 N (30 kgf, 66 lb) until the adjust-
er rod is aligned with the stopper pin hole in the
cylinder.
(3) With a 2 mm (0.08 in) dia. stopper pin or a 2
mm (0.08 in) (nominal) dia. hex wrench inserted
into the stopper pin hole in the cylinder, secure
the adjuster rod.
ME-00235
ME-00236
ME-00237
ME-00238
ME-00239
ME-00350

ME(H4SO)-50
MECHANICAL
Timing Belt
2) Install the automatic belt tension adjuster as-
sembly.
Tightening torque:
39 N
⋅m (4.0 kgf-m, 28.9 ft-lb)
3) Install the belt idler (No. 1).
Tightening torque:
39 N
⋅m (4.0 kgf-m, 28.9 ft-lb)
2. TIMING BELT
1) Preparation for the installation of automatic belt
tension adjuster assembly <Ref. to ME(H4SO)-49,
AUTOMATIC BELT TENSION ADJUSTER AS-
SEMBLY AND BELT IDLER, INSTALLATION,
Timing Belt.>
2) Installation of timing belt
(1) Turn the cam sprocket No. 2 using ST1, and
then turn the cam sprocket No. 1 using ST2 so
that their alignment marks (A) come to top posi-
tions.
ST1 18231AA010 CAM SPROCKET WRENCH
NOTE:
Also the CAM SPROCKET WRENCH (499207100)
can be used.ST2 499207400 CAM SPROCKET WRENCH
(2) While aligning alignment marks (B) on the
timing belt with marks (A) on sprockets, position
the timing belt properly.
3) Install the belt idler No. 2.
Tightening torque:
39 N
⋅m (4.0 kgf-m, 28.9 ft-lb)
4) Install the belt idler (No. 2).
Tightening torque:
39 N
⋅m (4.0 kgf-m, 28.9 ft-lb)
ME-00241
ME-00242
ME-00243
(A)
ME-00244
ME-00235

ME(H4SO)-51
MECHANICAL
Timing Belt
5) After ensuring that the marks on timing belt and
cam sprockets are aligned, remove the stopper pin
from belt tension adjuster.
6) Install the timing belt guide. (MT model)
(1) Temporarily tighten the remaining bolts.
(2) Check and adjust the clearance between
timing belt and timing belt guide by using thick-
ness gauge.
Clearance:
1.0
±0.5 mm (0.039±0.020 in)(3) Tighten the remaining bolts.
Tightening torque:
10 N
⋅m (1.0 kgf-m, 7.2 ft-lb)
7) Install the belt cover. <Ref. to ME(H4SO)-47, IN-
STALLATION, Timing Belt Cover.>
8) Install the crank pulley. <Ref. to ME(H4SO)-45,
INSTALLATION, Crank Pulley.>
9) Install the V-belt. <Ref. to ME(H4SO)-43, IN-
STALLATION, V-belt.>
C: INSPECTION
1. TIMING BELT
1) Check the timing belt teeth for breaks, cracks,
and wear. If any fault is found, replace the belt.
2) Check the condition of back side of belt; if any
crack is found, replace the belt.
CAUTION:
 Be careful not to let oil, grease or coolant
contact the belt. Remove quickly and thorough-
ly if this happens.
 Do not bend the timing belt sharply.
In radial diameter: h
60 mm (2.36 in) or more
ME-00245
ME-00230
ME-00246
ME-00247
ME-00248
h