meter SUBARU FORESTER 2004 Service Repair Manual

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)-28
MECHANICAL
General Description
499977400 CRANK PULLEY
WRENCHUsed for stopping rotation of crank pulley when
loosening and tightening crank pulley bolts. (2.0
L model)
499977100 CRANK PULLEY
WRENCHUsed for stopping rotation of crank pulley when
loosening and tightening crank pulley bolts. (2.5
L model)
499987500 CRANKSHAFT
SOCKETUsed for rotating crankshaft.
18332AA000 OIL FILTER
WRENCHUsed for removing and installing the oil filter.
(Outer diameter: 68 mm (2.68 in)) ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-499977400
ST-499977100
ST-499987500
ST18332AA000

ME(H4DOTC)-29
MECHANICAL
General Description
18332AA010 OIL FILTER
WRENCHUsed for removing and installing the oil filter.
(Outer diameter: 65 mm (2.56 in))
499587100 OIL SEAL
INSTALLERUsed for installing oil pump oil seal.
499587600 OIL SEAL
INSTALLERUsed for installing camshaft oil seal for DOHC
engine.
499597200 OIL SEAL GUIDE  Used for installing camshaft oil seal for DOHC
engine.
 Used with OIL SEAL GUIDE (499587600). ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST18332AA010
ST-499587100
ST-499587600
ST-499597200

ME(H4DOTC)-39
MECHANICAL
Valve Clearance
(3) Set the arrow mark on camshaft sprocket to
position shown in the figure, and then measure
the #1 cylinder exhaust valve and #4 cylinder in-
take valve clearances.
15) After inspection, install the related parts in the
reverse order of removal.
Tightening torque:
33 N
⋅m (3.4 kgf-m, 25 ft-lb)
B: ADJUSTMENT
CAUTION:
Adjustment of the valve clearance should be
performed while engine is cold.
1) Measure all valve clearances. ME(H4DOTC)-37, INSPECTION, Valve Clear-
ance.>
NOTE:
Record each valve clearance after it has been
measured.
2) Remove the camshaft. 69, REMOVAL, Camshaft.>
3) Remove the valve lifter.4) Measure the thickness of valve lifter with a mi-
crometer.
5) Select a shim of suitable thickness using mea-
sured valve clearance and valve lifter thickness, by
referring to the following table.
ME-00736
ME-00023
ME-00024
Unit: mm
Intake valve: S = (V+T) –0.20
Exhaust valve: S = (V+T) –0.35
S: Required thickness of valve lifter
V: Measured valve clearance
T: Used valve lifter thickness
Part No. Thickness mm (in)
13228 AB101 4.68 (0.1843)
13228 AB111 4.69 (0.1846)
13228 AB121 4.70 (0.1850)
13228 AB131 4.71 (0.1854)
13228 AB141 4.72 (0.1858)
13228 AB151 4.73 (0.1862)
13228 AB161 4.74 (0.1866)
13228 AB171 4.75 (0.1870)
13228 AB181 4.76 (0.1874)
13228 AB191 4.77 (0.1878)
13228 AB201 4.78 (0.1882)
13228 AB211 4.79 (0.1886)
13228 AB221 4.80 (0.1890)
13228 AB231 4.81 (0.1894)
13228 AB241 4.82 (0.1898)
13228 AB251 4.83 (0.1902)
13228 AB261 4.84 (0.1906)
13228 AB271 4.85 (0.1909)
13228 AB281 4.86 (0.1913)
13228 AB291 4.87 (0.1917)
13228 AB301 4.88 (0.1921)
13228 AB311 4.89 (0.1925)
13228 AB321 4.90 (0.1929)
13228 AB331 4.91 (0.1933)
13228 AB341 4.92 (0.1937)
13228 AB351 4.93 (0.1941)
13228 AB361 4.94 (0.1945)
13228 AB371 4.95 (0.1949)
13228 AB381 4.96 (0.1953)
ME-00025

ME(H4DOTC)-73
MECHANICAL
Camshaft
C: INSPECTION
1) Measure the bend, and repair or replace if nec-
essary.
Limit:
0.020 mm (0.0008 in)
2) Check the journal for damage and wear. Re-
place if faulty.
3) Measure the outside diameter of camshaft jour-
nal. If the journal diameter is not as specified,
check the oil clearance.
4) Measurement of the camshaft journal oil clear-
ance:
(1) Clean the bearing caps and camshaft jour-
nals.
(2) Place the camshafts on cylinder head.
(Without installing the valve rocker.)
(3) Place a plastigage across each of the cam-
shaft journals.
(4) Gradually tighten the cap in at least two
stages in alphabetical sequence shown in the
figure, and then tighten to specified torque.
Do not turn the camshaft.
Tightening torque:
T1: 10 N
⋅m (1.0 kgf-m, 7.2 ft-lb)
T2: 20 N
⋅m (2.0 kgf-m, 14.5 ft-lb)
 2.0 L MODEL 2.5 L MODEL
(5) Remove the bearing caps.
(6) Measure the widest point of plastigage on
each journal. If the oil clearance exceeds the
limit, replace the camshaft. If necessary, replace
the camshaft caps and cylinder head as a set.
Standard:
0.037 — 0.072 mm (0.0015 — 0.0028 in)
Limit:
0.10 mm (0.0039 in)
(7) Completely remove the plastigage.
5) Check the cam face condition; remove the minor
faults by grinding with oil stone. Measure the cam
height H, replace if the limit has been exceeded.
Cam height: H
Standard:
2.0 L MODEL
Intake:
44.75 — 44.85 mm (1.762 — 1.766 in)
Exhaust:
44.75 — 44.85 mm (1.762 — 1.766 in)
2.5 L MODEL
Intake:
46.55 — 46.65 mm (1.833 — 1.837 in)
Exhaust:
46.75 — 46.85 mm (1.841 — 1.844 in)
Camshaft journal
Front Center, rear
Standard37.946 — 37.963 mm
(1.4939 — 1.4946 in)29.946 — 29.963 mm
(1.1790 — 1.1796 in)
ME-00118
ME-00371
(F) (D)(C)
T1
T2(A)(E)
(B)
ME-00774
(A)(E)
(F)(B)(D)
(C)T2
T1
ME-00119

ME(H4DOTC)-74
MECHANICAL
Camshaft
Limit:
2.0 L MODEL
Intake:
44.65 mm (1.758 in)
Exhaust:
44.65 mm (1.758 in)
2.5 L MODEL
Intake:
46.45 mm (1.829 in)
Exhaust:
46.65 mm (1.837 in)
Cam base circle diameter A:
37.0 mm (1.457 in)
6) Measure the thrust clearance of camshaft with
dial gauge. If the clearance exceeds the limit, re-
place the caps and cylinder head as a set. If neces-
sary, replace the camshaft.
Standard:
0.068 — 0.116 mm (0.0027 — 0.0046 in)
Limit:
0.14 mm (0.0055 in)
ME-00120
H
A
ME-00121

ME(H4DOTC)-79
MECHANICAL
Cylinder Head Assembly
3. VALVE GUIDE
1) Check the clearance between valve guide and
stem. The clearance can be checked by measuring
the outside diameter of valve stem and the inside
diameter of valve guide with outside and inside mi-
crometers respectively.
Clearance between the valve guide and valve
stem:
Standard
Intake
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)
2) If the clearance between valve guide and stem
exceeds the limit, replace the valve guide or valve
itself whichever shows greater amount of wear.
See the following procedure for valve guide re-
placement.
Valve guide inner diameter:
6.000 — 6.012 mm (0.2362 — 0.2367 in)
Valve stem outer diameters:
Intake
5.955 — 5.970 mm (0.2344 — 0.2350 in)
Exhaust
5.945 — 5.960 mm (0.2341 — 0.2346 in)
(1) Place the cylinder head on ST1 with the
combustion chamber upward so that valve
guides enter the holes in ST1.
(2) Insert the ST2 into valve guide and press it
down to remove the valve guide.
ST1 498267600 CYLINDER HEAD TABLE
ST2 499767200 VALVE GUIDE REMOVER
(3) Turn the cylinder head upside down and
place ST as shown in the figure.ST 18251AA020 VALVE GUIDE ADJUSTER
(4) Before installing a new valve guide, make
sure that neither scratches nor damages exist
on the inside surface of the valve guide holes in
cylinder head.
(5) Put a new valve guide, coated with sufficient
oil, in cylinder head, and insert ST1 into valve
guide. Press in until the valve guide upper end is
flush with the upper surface of ST2.
ST1 499767200 VALVE GUIDE REMOVER
ST2 18251AA020 VALVE GUIDE ADJUSTER
(6) Check the valve guide protrusion.
Valve guide protrusion: L
15.8 — 16.2 mm (0.622 — 0.638 in)
(7) Ream the inside of valve guide with ST.
Gently rotate the reamer clockwise while press-
ing it lightly into the valve guide, and return it
also rotating clockwise.
(8) After reaming, clean the valve guide to re-
move chips.
ST 499767400 VALVE GUIDE REAMER
CAUTION:
Apply engine oil to ST when reaming.
NOTE:
 If the inner surface of the valve guide is torn, the
edge of the reamer should be slightly ground with
an oil stone.
 If the inner surface of the valve guide becomes
lustrous and the reamer does not chip, use a new
reamer or remedy the reamer.
ME-00128
ST1
ST2ME-00757
ST
L
ME-00130
ST1
ST2