SUBARU FORESTER 2004 Service Repair Manual

ME(H4DOTC)-15
MECHANICAL
General Description
3. CYLINDER HEAD AND VALVE ASSEMBLY
(1) Exhaust valve (5) Intake valve oil seal (9) Valve lifter
(2) Intake valve (6) Valve spring (10) Exhaust valve oil seal
(3) Cylinder head (7) Retainer (11) Intake valve guide
(4) Valve spring seat (8) Retainer key (12) Exhaust valve guide
ME-00003
(3) (1)
(2)(11) (4) (5) (6) (7) (8) (9)
(11)
(12)
(12)(10)(4)
(4)(5) (6)
(6)(7)
(7)(8)
(8)(9)
(9)
(10) (4)
(6)
(7)
(8)
(9)

ME(H4DOTC)-16
MECHANICAL
General Description
4. CYLINDER BLOCK
ME-02014
(14)
T2
T6
T7
T2
T2
T2
T2
T8
T5
T4
T5
T4
T2
T6
T6
T2
T11
T12
T10
T1
T1
T3
T9
T2
T2
T2
(9) (8)(7)(6)
(15)(10)
(10)
(10)(11)
(12)
(13) (18)
(15)
(17)(28)
(22)(21)
(23)(20)
(19)
(26)
(18)
(25) (10)
(27)
(5)
(4)
(4)
(4)(3)
(3)
(3) (2)(1)
(24)
(16)T4

ME(H4DOTC)-17
MECHANICAL
General Description
(1) Oil pressure switch (15) AdapterTightening torque: N⋅m (kgf-m, ft-lb)
(2) Cylinder block (RH) (16) Oil coolerT1: 5 (0.5, 3.6)
(3) Service hole plug (17) Waster by-pass pipe T2: 6.4 (0.65, 4.7)
(4) Gasket (18) ConnectorT3: 10 (1.0, 7.2)
(5) Oil separator cover (19) Oil strainerT4: 25 (2.5, 18.1)
(6) Water by-pass pipe (20) GasketT5: INSTALLATION, CYLINDER
BLOCK.> (7) Oil pump (21) Oil pan
(8) Front oil seal (22) Drain plug
(9) Rear oil seal (23) Metal gasketT6: 70 (7.1, 50.6)
(10) O-ring (24) Oil level gauge guideT7: First 12 (1.2, 8.7)
Second 12 (1.2, 8.7)
(11) Service hole cover (25) Oil filter
(12) Cylinder block (LH) (26) GasketT8: 16 (1.6, 11.6)
(13) Water pump (27) Water pump hoseT9: 44 (4.5, 33)
(14) Baffle plate (28) PlugT10: 25 (2.5, 18.1)
T11: 54 (5.3, 39)
T12: 45 (4.6, 33)

ME(H4DOTC)-18
MECHANICAL
General Description
5. CRANKSHAFT AND PISTON
 2.0 L MODEL
(1) Flywheel (MT model) (9) Piston pin (17) Crankshaft bearing #1, #3
(2) Ball bearing (MT model) (10) Circlip (18) Crankshaft bearing #2, #4
(3) Reinforcement (AT model) (11) Connecting rod bolt (19) Crankshaft bearing #5
(4) Drive plate (AT model) (12) Connecting rod
(5) Top ring (13) Connecting rod bearingTightening torque: N
⋅m (kgf-m, ft-lb)
(6) Second ring (14) Connecting rod capT1: 45 (4.6, 33.3)
(7) Oil ring (15) CrankshaftT2: 72 (7.3, 52.8)
(8) Piston (16) Woodruff key
ME-00005
(10)(1)
(17)
(18)(18)(13) (12) (11)
(8)(10) (10)
(9)
(16)
(19)
(10)
(9) (11) (13)
(12) (8)
(14)
(13)(14) (13) (15)
(7)(6)(5)
(17)
T2
(2)
(4)
(3)
(5)
(6) (7)
T2
T1

ME(H4DOTC)-19
MECHANICAL
General Description
 2.5 L MODEL
(1) Flywheel (MT model) (9) Piston pin (17) Crankshaft bearing #1, #3
(2) Ball bearing (MT model) (10) Circlip (18) Crankshaft bearing #2, #4
(3) Reinforcement (AT model) (11) Connecting rod bolt (19) Crankshaft bearing #5
(4) Drive plate (AT model) (12) Connecting rod
(5) Top ring (13) Connecting rod bearingTightening torque: N
⋅m (kgf-m, ft-lb)
(6) Second ring (14) Connecting rod capT1: 52 (5.3, 38.4)
(7) Oil ring (15) CrankshaftT2: 72 (7.3, 52.8)
(8) Piston (16) Woodruff key
ME-00822
T1
(5)
(6)
(7)
(10)
(8)(10)
(12)
(13)
(13)
(16)(13)
(12)
(19)
(18)
(17)
(17)(18)(10)(10)
(7)
(6)
(5)
(9)(8) (13) (15)
(14)
(11) (14)(9)
T1(11)
(1)
T2
(2)(4)
(3)
T2

ME(H4DOTC)-20
MECHANICAL
General Description
6. ENGINE MOUNTING
 2.0 L MODEL
(1) Front cushion rubberTightening torque: N⋅m (kgf-m, ft-lb)
T1: 34 (3.5, 25.3)
T2: 85 (8.7, 62.7)
ME-00407
T1T1
T2
T2
( 1 )

ME(H4DOTC)-21
MECHANICAL
General Description
 2.5 L MODEL
(1) Heat shield cover (3) Front engine mounting bracketTightening torque: N⋅m (kgf-m, ft-lb)
(2) Front cushion rubber T1: 35 (3.6, 25.8)
T2: 42 (4.3, 30.9)
T3: 85 (8.7, 62.7)
ME-00706
(3)
T3
T1
(2)
(1)
(3)
(2)
T3
T1
T2
T2

ME(H4DOTC)-22
MECHANICAL
General Description
C: CAUTION
 Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
 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 fasteners including 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 the 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 stain seats and windows with
coolant or oil. Place a cover over fenders, as re-
quired, 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.

ME(H4DOTC)-23
MECHANICAL
General Description
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
498267600 CYLINDER HEAD
TABLE Used for replacing valve guides.
 Used for removing and installing valve springs.
498457000 ENGINE STAND
ADAPTER RHUsed with ENGINE STAND (499817000).
498457100 ENGINE STAND
ADAPTER LHUsed with ENGINE STAND (499817000).
498497100 CRANKSHAFT
STOPPERUsed for stopping rotation of flywheel when loos-
ening and tightening crankshaft pulley bolt, etc.
ST-498267600
ST-498457000
ST-498457100
ST-498497100

ME(H4DOTC)-24
MECHANICAL
General Description
398744300 PISTON GUIDE Used for installing piston in cylinder for 2.0 L
engine.
498747300 PISTON GUIDE Used for installing piston in cylinder for 2.5 L
engine.
498857100 VALVE OIL SEAL
GUIDEUsed for press-fitting of intake and exhaust valve
guide oil seals.
499017100 PISTON PIN GUIDE Used for installing piston pin, piston and con-
necting rod. ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-398744300
ST-498747300
ST-498857100
ST-499017100