SUBARU FORESTER 2004 Service Repair Manual

IN(H4DOTC)-12
INTAKE (INDUCTION)
Turbocharger
6. Turbocharger
A: REMOVAL
1) Set the vehicle on a lift.
2) Disconnect the ground cable from battery.
3) Remove the center exhaust pipe. EX(H4DOTC)-9, REMOVAL, Center Exhaust
Pipe.>
4) Lower the vehicle.
5) Separate the turbocharger joint pipe from turbo-
charger.
6) Disconnect the engine coolant hose which is
connected to coolant filler tank.7) Loosen the clamp which secures turbocharger to
intake duct.
8) Remove the bolt which secures bracket of oil
pipe to turbocharger.
9) Remove the oil pipe from turbocharger.
10) Remove the turbocharger bracket.
11) Disconnect the oil outlet hose from pipe.
12) Take out the turbocharger from engine com-
partment.
FU-00009
IN-00019
IN-00020IN-00074
IN-00022
IN-00023
IN-00024

IN(H4DOTC)-13
INTAKE (INDUCTION)
Turbocharger
B: INSTALLATION
1) Connect the oil outlet hose to outlet pipe.
2) Install the turbocharger to intake duct.
Tightening torque:
3 N
⋅m (0.3 kgf-m, 2.2 ft-lb)
3) Install the oil pipe to turbocharger.
Tightening torque:
16 N
⋅m (1.6 kgf-m, 11.6 ft-lb)
4) Install the joint pipe to turbocharger.
NOTE:
Replace the gasket with a new one.Tightening torque:
35 N
⋅m (3.6 kgf-m, 26.0 ft-lb)
5) Install the turbocharger bracket.
Tightening torque:
33 N
⋅m (3.4 kgf-m, 24.6 ft-lb)
6) Connect the engine coolant hose which is con-
nected to coolant filler tank.
7) Lift-up the vehicle.
8) Install the center exhaust pipe. EX(H4DOTC)-10, INSTALLATION, Center Ex-
haust Pipe.>
IN-00024
IN-00074
IN-00022
IN-00019
IN-00023
IN-00020

IN(H4DOTC)-14
INTAKE (INDUCTION)
Air By-pass Valve
7. Air By-pass Valve
A: REMOVAL
1) Disconnect the air by-pass hoses from air by-
pass valve.
2) Remove the air by-pass valve from intercooler.
B: INSTALLATION
Install in the reverse order of removal.
NOTE:
Install the O-ring in proper position.
Tightening torque:
16 N
⋅m (1.6 kgf-m, 11.6 ft-lb)
IN-00013
IN-00017
IN-00017

IN(H4DOTC)-15
INTAKE (INDUCTION)
Resonator Chamber
8. Resonator Chamber
A: REMOVAL
1) Set the vehicle on a lift.
2) Remove the air intake duct. IN(H4DOTC)-8, REMOVAL, Air Intake Duct.>
3) Remove the air cleaner lower case. IN(H4DOTC)-7, REMOVAL, Air Cleaner.>
4) Remove the resonator chamber mounting bolt
on the right of engine compartment.
5) Remove the front right tire, and lift the vehicle.
6) Remove the front mudguard RH.
7) Remove the resonator chamber from the inside
front fender.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
7.5 N
⋅m (0.76 kgf-m, 5.5 ft-lb)
C: INSPECTION
Inspect for cracks and loose connections. Check
that no foreign objects are mixed in the resonator
chamber.
IN-00025
IN-00026
IN-00026
IN-00025

IN(H4DOTC)-16
INTAKE (INDUCTION)
Resonator Chamber

FUJI HEAVY INDUSTRIES LTD. G8080GE3
2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
ENGINE SECTION 2
This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.
All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.FUEL INJECTION (FUEL SYSTEM) FU(H4DOTC)
EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICE)EC(H4DOTC)
INTAKE (INDUCTION) IN(H4DOTC)
MECHANICAL ME(H4DOTC)
EXHAUST EX(H4DOTC)
COOLING CO(H4DOTC)
LUBRICATION LU(H4DOTC)
SPEED CONTROL SYSTEM SP(H4DOTC)
IGNITION IG(H4DOTC)
STARTING/CHARGING SYSTEM SC(H4DOTC)
ENGINE (DIAGNOSTIC) EN(H4DOTC)

MECHANICAL
ME(H4DOTC)
Page
1. General Description ....................................................................................2
2. Compression .............................................................................................31
3. Idle Speed .................................................................................................32
4. Ignition Timing ...........................................................................................33
5. Intake Manifold Vacuum............................................................................34
6. Engine Oil Pressure ..................................................................................35
7. Fuel Pressure ............................................................................................36
8. Valve Clearance ........................................................................................37
9. Engine Assembly ......................................................................................41
10. Engine Mounting .......................................................................................50
11. Preparation for Overhaul ...........................................................................51
12. V-belt .........................................................................................................52
13. Crank Pulley ..............................................................................................55
14. Timing Belt Cover......................................................................................57
15. Timing Belt Assembly................................................................................58
16. Cam Sprocket ...........................................................................................67
17. Crank Sprocket .........................................................................................68
18. Camshaft ...................................................................................................69
19. Cylinder Head Assembly ...........................................................................76
20. Cylinder Block ...........................................................................................84
21. Intake and Exhaust Valve .......................................................................115
22. Piston ......................................................................................................116
23. Connecting Rod ......................................................................................117
24. Crankshaft ...............................................................................................118
25. Engine Trouble in General ......................................................................119
26. Engine Noise ...........................................................................................124

ME(H4DOTC)-2
MECHANICAL
General Description
1. General Description
A: SPECIFICATION
1. 2.0 L MODEL
NOTE:
STD: Standard I.D.: Inner Diameter O.D.: Outer Diameter OS: Oversize US: Undersize
EngineTy 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) 92×75 (3.62×2.95)
Piston displacement
cm
3 (cu in)1,994 (121.67)
Compression ratio 8.0
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 BTDC 3°
Min. advance BTDC 33°
ClosingMax. retard ABDC 33°
Min. advance ABDC 3°
Exhaust valve timingOpening BBDC 33°
Closing ATDC 3°
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/rpm 12°±10°/700
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 (0.0069 in)
Side clearance of spacerSTD 0.2 — 0.55 mm (0.0079 — 0.0217 in)
Limit 0.81 mm (0.0319 in)

ME(H4DOTC)-3
MECHANICAL
General Description
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 44.75 — 44.85 mm (1.762 — 1.766 in)
Limit 44.65 mm (1.758 in)
ExhaustSTD 44.75 — 44.85 mm (1.762 — 1.766 in)
Limit 44.65 mm (1.758 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 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 44.67 mm (1.759 in)
Squareness 2.5°, 2.0 mm (0.079 in)
Tension/spring heightSet206 — 236 N (21.0 — 24.1 kgf, 46.3 — 53.1 lb)/
36.0 mm (1.417 in)
Lift485 — 537 N (49.5 — 54.8 kgf, 109 — 121 lb)/
26.6 mm (1.047 in)
Cylinder
blockSurface warpage limit (mating with cylinder head) 0.05 mm (0.0020 in)
Surface grinding limit 0.1 mm (0.004 in)
Cylinder bore STDA 92.005 — 92.015 mm (3.6222 — 3.6226 in)
B 91.995 — 92.005 mm (3.6218 — 3.6222 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 — 0.030 mm (0.0004 — 0.0012 in)
Limit 0.050 mm (0.0020 in)
Enlarging (boring) limit 0.5 mm (0.020 in)

ME(H4DOTC)-4
MECHANICAL
General Description
Piston Outer diameterSTDA 91.985 — 91.995 mm (3.6214 — 3.6218 in)
B 91.975 — 91.985 mm (3.6211 — 3.6214 in)
0.25 mm (0.0098 in)
OS92.225 — 92.235 mm (3.6309 — 3.6313 in)
0.50 mm (0.0197 in)
OS92.475 — 92.485 mm (3.6407 — 3.6411 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 0.40 — 0.50 mm (0.016 — 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 0.010 — 0.038 mm (0.0004 — 0.0015 in)
Limit 0.05 mm (0.0020 in)
Thickness at center portionSTD 1.486 — 1.498 mm (0.0585 — 0.0590 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)