lock SUBARU FORESTER 2004 Service Repair Manual
[x] Cancel search | Manufacturer: SUBARU, Model Year: 2004, Model line: FORESTER, Model: SUBARU FORESTER 2004Pages: 2870, PDF Size: 38.67 MB
Page 870 of 2870
MECHANICAL
ME(H4SO)
Page
1. General Description ....................................................................................2
2. Compression .............................................................................................25
3. Idle Speed .................................................................................................26
4. Ignition Timing ...........................................................................................27
5. Intake Manifold Vacuum............................................................................28
6. Engine Oil Pressure ..................................................................................29
7. Fuel Pressure ............................................................................................30
8. Valve Clearance ........................................................................................31
9. Engine Assembly ......................................................................................34
10. Engine Mounting .......................................................................................41
11. Preparation for Overhaul ...........................................................................42
12. V-belt .........................................................................................................43
13. Crank Pulley ..............................................................................................45
14. Timing Belt Cover......................................................................................47
15. Timing Belt ................................................................................................48
16. Cam Sprocket ...........................................................................................53
17. Crank Sprocket .........................................................................................55
18. Valve Rocker Assembly ............................................................................56
19. Camshaft ...................................................................................................58
20. Cylinder Head ...........................................................................................62
21. Cylinder Block ...........................................................................................69
22. Engine Trouble in General ........................................................................91
23. Engine Noise .............................................................................................96
Page 872 of 2870
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)
Page 879 of 2870
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:
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)
Page 880 of 2870
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:
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
Page 898 of 2870
ME(H4SO)-29
MECHANICAL
Engine Oil Pressure
6. Engine Oil Pressure
A: INSPECTION
1) Disconnect the ground cable from battery.
2) Remove the generator from bracket.
3) Disconnect the connector from oil pressure
switch.
4) Remove the oil pressure switch from cylinder
block.
5) Connect the oil pressure gauge hose to cylinder
block.
6) Connect the battery ground cable to battery.
7) Start the engine, and then measure the oil pres-
sure.
Oil pressure:
Standard:
88 kPa (0.9 kg/cm
2, 13 psi) or more at 800 rpm
294 kPa (3.0 kg/cm2, 43 psi) or more at 5,000
rpmCAUTION:
If the oil pressure is out of specification,
check the oil pump, oil filter and lubrication
line.
If the oil pressure warning light is turned ON
and oil pressure is in specification, replace the
oil pressure switch.
in General.>
NOTE:
The specified data is based on an engine oil tem-
perature of 80°C (176°F).
8) After measuring the oil pressure, install the oil
pressure switch.
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
9) Install the generator and V-belt in the reverse or-
der of removal, and then adjust the V-belt deflec-
tion.
FU-00009
FU-00009
ME-00196
Page 900 of 2870
ME(H4SO)-31
MECHANICAL
Valve Clearance
8. Valve Clearance
A: INSPECTION
NOTE:
Inspection and adjustment of the valve clearance
should be performed while engine is cold.
1) Set the vehicle on a lift.
2) Lift-up the vehicle.
3) Remove the under cover.
4) Lower the vehicle.
5) Disconnect the ground cable from battery.
6) Remove the belt cover (LH).
7) When inspecting the #1 and #3 cylinders:
(1) Disconnect the spark plug cords from spark
plugs RH side.
(2) Disconnect the PCV hose from rocker cover
(RH).
(3) Remove the bolts, and then remove the
rocker cover (RH).
8) When inspecting the #2 and #4 cylinders:
(1) Disconnect the spark plug cords from spark
plugs (LH Side)
(2) Disconnect the PCV hose from rocker cover
(LH).
(3) Remove the bolts, and then remove the
rocker cover (LH).
9) Set the #1 cylinder piston to top dead center of
compression stroke by rotating crank pulley clock-
wise using a socket wrench.NOTE:
When arrow mark (A) on the cam sprocket (LH)
comes exactly to the top, #1 cylinder piston is
brought to the top dead center of compression
stroke.
10) Measure the #1 cylinder valve clearance by us-
ing thickness gauge.
CAUTION:
Insert the thickness gauge (A) in as horizon-
tal a direction as possible with respect to the
valve stem end face.
Measure the exhaust valve clearances while
lifting-up the vehicle.
Valve clearance (Standard):
Intake;
0.20
±0.04 mm (0.0079±0.0016 in)
Exhaust;
0.25
±0.04 mm (0.0098±0.0016 in)
11) If necessary, adjust the valve clearance.
ance.>
12) Similar to measurement procedures used for
#1 cylinder, measure the #2, #3 and #4 cylinder
valve clearances.
NOTE:
Be sure to set the cylinder pistons to their re-
spective top dead centers on compression stroke
before measuring valve clearances.
FU-00009
ME-00199
ME-00200
(A)
ME-00201
(A)
Page 901 of 2870
ME(H4SO)-32
MECHANICAL
Valve Clearance
To set the #3, #2 and #4 cylinder pistons to their
top dead centers on compression stroke, turn the
crank pulley clockwise 90° at a time starting with ar-
row mark on cam sprocket (LH) facing up.
13) After inspection, install the related parts in the
reverse order of removal.
Tightening torque:
Resonator chamber;
33 N
⋅m (3.4 kgf-m, 25 ft-lb)
B: ADJUSTMENT
NOTE:
Adjustment of the valve clearance should be per-
formed while engine is cold.
1) Set the #1 cylinder piston to top dead center of
compression stroke by rotating crank pulley clock-
wise using socket wrench.
NOTE:
When arrow mark (A) on the cam sprocket (LH)
comes exactly to the top, #1 cylinder piston is
brought to the top dead center of compression
stroke.2) Adjust the #1 cylinder valve clearance.
(1) Loosen the valve rocker nut and screw.
(2) Place suitable thickness gauge.
(3) While noting the valve clearance, tighten the
valve rocker adjusting screw.
(4) When specified valve clearance is obtained,
tighten the valve rocker nut.
Tightening torque:
10 N
⋅m (1.0 kgf-m, 7.2 ft-lb)
CAUTION:
Insert the thickness gauge in as horizontally
as possible with respect to the valve stem end
face.
Adjust the exhaust valve clearances while
lifting up the vehicle.
Valve clearance:
Intake:
0.20
±0.04 mm (0.0079±0.0016 in)
Exhaust:
0.25
±0.04 mm (0.0098±0.0016 in)
3) Ensure the valve clearances are within specifi-
cations.
4) Turn the crankshaft two complete rotations until
#1 cylinder piston is again set to the top dead cen-
ter of compression stroke.
5) Ensure the valve clearances are within specifi-
cations. If necessary, readjust the valve clearanc-
es.
6) Similar to adjustment procedures used for #1
cylinder, adjust the #2, #3 and #4 cylinder valve
clearances.
ME-00202
#1
#2#3 #4
IN-00044
ME-00200
(A)
ME-00203
Page 902 of 2870
ME(H4SO)-33
MECHANICAL
Valve Clearance
NOTE:
Be sure to set the cylinder pistons to their re-
spective top dead centers on compression stroke
before adjusting valve clearances.
To set the #3, #2 and #4 cylinder pistons to their
top dead centers of compression stroke, turn the
crank pulley clockwise 90° at a time starting with ar-
row mark on cam sprocket (LH) facing up.
ME-00202
#1
#2#3 #4
Page 905 of 2870
ME(H4SO)-36
MECHANICAL
Engine Assembly
(2) Loosen the lock bolt and slider bolt, and
then remove the front side V-belt.
AL, V-belt.>
(3) Remove the pipe with bracket.
(4) Remove the bolts which install power steer-
ing pump bracket.
(5) Remove the reservoir tank from bracket by
pulling it upward.
(6) Place the power steering pump on right side
wheel apron.14) Remove the front and center exhaust pipe.
15) Remove the nuts which hold lower side of
transmission to engine.
16) Remove the nuts which install front cushion
rubber onto front crossmember.
17) Separate the torque converter clutch from drive
plate. (AT model)
(1) Lower the vehicle.
(2) Remove the service hole plug.
(3) Remove the bolts which hold torque con-
verter clutch to drive plate.
(4) Remove other bolts while rotating the en-
gine using socket wrench.
ME-00331
FU-00139
FU-00020
FU-00140ME-00210
ME-00211
ME-00212
Page 912 of 2870
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
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.
ME-00222
ME-00223
(B)
(C)
(A)
ME-00224
(A) (B)
ME-00225
ME-00223
(B)
(C)
(A)