torque SUBARU FORESTER 2004 Service Repair Manual

IN(H4SO)-8
INTAKE (INDUCTION)
Resonator Chamber
5. Resonator Chamber
A: REMOVAL
1) Remove the air intake duct. 7, REMOVAL, Air Intake Duct.>
2) Remove the resonator chamber.
B: INSTALLATION
Install in the reverse order of removal.
NOTE:
Refer to “COMPONENT” for tightening torque.
scription.>
C: INSPECTION
Inspect for cracks and loose connections.
IN-00044

ME(H4SO)-6
MECHANICAL
General Description
B: COMPONENT
1. TIMING BELT
(1) Timing belt cover No. 2 (RH) (9) Automatic belt tension adjuster
ASSYTightening torque: N⋅m (kgf-m, ft-lb)
(2) Timing belt guide (MT model)T1: 5 (0.5, 3.6)
(3) Crank sprocket (10) Belt idler No. 2T2: 10 (1.0, 7.2)
(4) Timing belt cover No. 2 (LH) (11) Cam sprocket No. 2T3: 25 (2.5, 18.1)
(5) Cam sprocket No. 1 (12) Timing beltT4: 39 (4.0, 28.9)
(6) Belt idler (No. 1) (13) Front timing belt coverT5: 78 (8.0, 57.9)
(7) Tensioner bracket (14) Timing belt cover (LH)T6: INSTALLATION, Crank Pulley.>
(8) Belt idler (No. 2) (15) Crank pulley (2.0 L model)
(16) Crank pulley (2.5 L model)
ME-00376
T5
T4
T1
T1
T6
T5 (5)
(6)
(8)
(9)
(11) (10)
(14) (15)
(16)(12)
(13)(7)(4) (1)
(2)
(3)
T1
T2
T1
T3
T4
T6
T4

ME(H4SO)-7
MECHANICAL
General Description
2. CYLINDER HEAD AND CAMSHAFT
(1) Rocker cover (RH) (11) Cylinder head (LH)Tightening torque: N⋅m (kgf-m, ft-lb)
(2) Intake valve rocker ASSY (12) Camshaft (LH)T1: INSTALLATION, Cylinder
Head.> (3) Exhaust valve rocker ASSY (13) Camshaft cap (LH)
(4) Camshaft cap (RH) (14) Oil filler cap
(5) Oil seal (15) GasketT2: 5 (0.5, 3.6)
(6) Camshaft (RH) (16) Oil filler ductT3: 10 (1.0, 7.2)
(7) Plug (17) O-ringT4: 18 (1.8, 13.0)
(8) Spark plug pipe gasket (18) Rocker cover (LH)T5: 25 (2.5, 18.1)
(9) Cylinder head (RH) (19) Stud boltT6: 6.4 (0.65, 4.7)
(10) Cylinder head gasket
ME-00186
(17)
(10)
(11)
(19)
(12)(13)(14)
(15)
(16)
(18) (2)
(3) (8)
(5) (1)
(2)
(3) (4)
(8) (6)
(7)
(8)
(7) (9)
(10)
(19)
T2
T5
(5)
T4
T5
T6
T1
T1
T3
T5
T2T3
T3
T4
T3
T4

ME(H4SO)-8
MECHANICAL
General Description
3. VALVE ROCKER ASSEMBLY
(1) Intake valve rocker arm (5) Rocker shaft spacerTightening torque: N⋅m (kgf-m, ft-lb)
(2) Valve rocker nut (6) Intake rocker shaftT1: 5 (0.5, 3.6)
(3) Valve rocker adjust screw (7) Exhaust rocker shaftT2: 10 (1.0, 7.2)
(4) Spring (8) Exhaust valve rocker armT3: 25 (2.5, 18.1)
ME-00187 (2)
(2)(2)
(3)(3) (3)(3) (4)(5)(4)(1)
(2)(6)
(8)
(7) (1)(2)(2)
(3)(3)
(4)(4)(1)
(5)
(1)
T2T1
T3
T1
T2
T3T2
T2

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: INSTALLATION, Cylinder
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)

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: INSTALLATION, Cylinder
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

ME(H4SO)-13
MECHANICAL
General Description
(1) Flywheel (MT model) (9) Snap ring (17) Crankshaft bearing #2, #4
(2) Reinforcement (AT model) (10) Connecting rod bolt (18) Crankshaft bearing #5
(3) Drive plate (AT model) (11) Connecting rod
(4) Top ring (12) Connecting rod bearingTightening torque: N
⋅m (kgf-m, ft-lb)
(5) Second ring (13) Connecting rod capT1: 45 (4.6, 33.3)
(6) Oil ring (14) CrankshaftT2: 72 (7.3, 52.8)
(7) Piston (15) Woodruff key
(8) Piston pin (16) Crankshaft bearing #1, #3

ME(H4SO)-14
MECHANICAL
General Description
7. ENGINE MOUNTING
(1) Front cushion rubber (2) Front engine mounting bracketTightening torque: N⋅m (kgf-m, ft-lb)
T1: 35 (3.6, 25.8)
T2: 42 (4.3, 31.0)
T3: 85 (8.7, 63)
ME-00413
T2
T1
T1
T3
T3 (2)(2)
(1)(1)
T2

ME(H4SO)-15
MECHANICAL
General Description
C: CAUTION
 Wear working clothing, including a cap, protec-
tive goggles and protective shoes during operation.
 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 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 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 not to stain seats and windows
with coolant or oil. Place a cover over fenders, as
required, 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.
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
18231AA010 CAM SPROCKET
WRENCH Used for removing and installing cam
sprocket. (LH side)
 Also the CAM SPROCKET WRENCH
(499207100) can be used.
24082AA230
(Newly adopted tool)CARTRIDGE Troubleshooting for electrical systems.
ST18231AA010
ST24082AA230

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. SC(H4SO)-15, REMOVAL, Generator.>
3) Disconnect the connector from oil pressure
switch.
4) Remove the oil pressure switch from cylinder
block. sure Switch.>
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. gine Lubrication System Trouble in General.>
 If the oil pressure warning light is turned ON
and oil pressure is in specification, replace the
oil pressure switch. SPECTION, Engine Lubrication System Trouble
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. LATION, 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. belt.>
FU-00009
FU-00009
ME-00196