SUBARU FORESTER 2004 Service Repair Manual

ME(H4DOTC)-43
MECHANICAL
Engine Assembly
(4) Remove the power steering pump from en-
gine.
(5) Remove the reservoir tank from bracket by
pulling it upward.
(6) Place the power steering pump on RH side
wheel apron.
14) Lift-up the vehicle.
15) Remove the ATF cooler pipe from frame. (AT
model)
16) Remove the center exhaust pipe. EX(H4DOTC)-9, REMOVAL, Center Exhaust
Pipe.>17) Remove the nuts which hold the lower side of
transmission to engine.
18) Remove the nuts which install the front cushion
rubber onto front crossmember.
19) Lower the vehicle.
20) Separate the clutch release fork from release
bearing. (MT model)
(1) Remove the clutch operating cylinder from
transmission.
(2) Remove the plug using a 10 mm hexagon
wrench.
ME-00037
ME-00038
ME-00039ME-00040
ME-00041
ME-00042

ME(H4DOTC)-44
MECHANICAL
Engine Assembly
(3) Screw the 6 mm dia. bolt into release fork
shaft, and remove it.
(4) Raise the release fork, and then unfasten
the release bearing tabs to free release fork.
NOTE:
Step (4) is required to prevent interference with en-
gine when removing the engine from transmission.
21) 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 the torque
converter clutch to drive plate.
(4) Remove the other bolts while rotating the
engine using socket wrench.22) Remove the pitching stopper.
23) Disconnect the fuel delivery hose, return hose
and evaporation hose.
NOTE:
 Catch fuel from the hose into container.
 Disconnect the hose with its end wrapped with
cloth to prevent fuel from splashing.
24) Remove the fuel filter and bracket.
25) Support the engine with a lifting device and
wire ropes.
(A) Shaft
(B) Bolt
ME-00043 (B)(A)
ME-00044
MT-00069
ME-00045
ME-00046
ME-00047

ME(H4DOTC)-45
MECHANICAL
Engine Assembly
26) Support the transmission with a garage jack.
NOTE:
Before moving the engine away from transmission,
check to be sure no work has been overlooked. Do-
ing this is very important in order to facilitate re-in-
stallation and because transmission lowers under
its own weight.
27) Separation of the engine and transmission.
(1) Remove the starter. REMOVAL, Starter.>
(2) Install the ST to torque converter clutch
case. (AT model)
ST 498277200 STOPPER SET
(3) Remove the bolts which hold the right upper
side of transmission to engine.
28) Remove the engine from vehicle.
(1) Slightly raise the engine.
(2) Raise the transmission with garage jack.
(3) Move the engine horizontally until the main-
shaft is withdrawn from clutch cover.
(4) Slowly move the engine away from engine
compartment.NOTE:
Be careful not to damage adjacent parts or body
panels with crank pulley, oil pressure gauge, etc.
29) Remove the front cushion rubbers.
B: INSTALLATION
1) Install the clutch release fork and bearing onto
transmission. (MT model)
(1) Remove the release bearing from clutch
cover with flat type screw driver.
(2) Install the release bearing on transmission.
(3) Install the release fork into release bearing
tab.
ME-00048
ST
ME-00049
ME-00050
(A) Release fork
(B) Release bearing
ME-00051
ME-00052
(A)
(B)

ME(H4DOTC)-46
MECHANICAL
Engine Assembly
(4) Apply grease to the specified points.
 Spline FX2200
 Shaft SUNLIGHT 2
(5) Insert the release fork shaft into release fork.
CAUTION:
Make sure the cutout portion of release fork
shaft contacts spring pin.(6) Tighten the plug.
Tightening torque:
44 N
⋅m (4.5 kgf-m, 32.5 ft-lb)
2) Install the front cushion rubbers to engine.
Tightening torque:
35 N
⋅m (3.6 kgf-m, 25.8 ft-lb)
3) Install the engine onto transmission.
(1) Position the engine in engine compartment,
and then align it with the transmission.
NOTE:
Be careful not to damage the adjacent parts or
body panels with crank pulley, oil pressure gauge,
etc.
(2) Apply a small amount of grease to the
splines of mainshaft. (MT model)
4) Tighten the bolts which hold the right upper side
of transmission to engine.
Tightening torque:
50 N
⋅m (5.1 kgf-m, 36.9 ft-lb)
5) Remove the lifting device and wire ropes.
(A) Spline (FX2200)
(B) Shaft (SUNLIGHT 2)
(A) Release fork
(B) Release shaft
(C) Spring pin
ME-00053 (A)
(B)
ME-00054
(A)(B)
(C)ME-00055
ME-00050

ME(H4DOTC)-47
MECHANICAL
Engine Assembly
6) Remove the garage jack.
7) Install the pitching stopper.
Tightening torque:
T1: 50 N
⋅m (5.1 kgf-m, 37 ft-lb)
T2: 58 N
⋅m (5.9 kgf-m, 43 ft-lb)
8) Remove the ST from torque converter clutch
case. (AT model)
NOTE:
Be careful not to drop the ST into torque converter
clutch case when removing ST.
ST 498277200 STOPPER SET
9) Install the starter. STALLATION, Starter.>
10) Install the torque converter clutch onto drive
plate. (AT model)
(1) Tighten the bolts which hold the torque con-
verter clutch to drive plate.
(2) Tighten other bolts while rotating the engine
by using ST.
CAUTION:
Be careful not to drop bolts into the torque con-
verter clutch housing.
ST 499977300 CRANK PULLEY WRENCHTightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
(3) Clog the service hole with plug.
11) Install the fuel filter and bracket.
12) Install the power steering pump on bracket.
(1) Install the reservoir tank on bracket.
(2) Install the power steering pump.
Tightening torque:
20.1 N
⋅m (2.05 kgf-m, 14.8 ft-lb)
ME-00047
T1
T2
MT-00085ME-00044
ME-00046
ME-00038
ME-00037

ME(H4DOTC)-48
MECHANICAL
Engine Assembly
(3) Install the power steering pipe bracket on in-
take manifold RH.
(4) Connect the power steering switch connec-
tor.
(5) Install the front side V-belt, and adjust it.
INSTALLATION, V-belt.>
13) Lift-up the vehicle.
14) Tighten the nuts which hold the lower side of
transmission to engine.
Tightening torque:
50 N
⋅m (5.1 kgf-m, 36.9 ft-lb)
15) Tighten the nuts which install the front cushion
rubber onto crossmember.
Tightening torque:
85 N
⋅m (8.7 kgf-m, 62.7 ft-lb)NOTE:
Make sure the front cushion rubber mounting bolts
(A) and locator (B) are securely installed.
16) Install the ATF cooler pipe to frame. (AT model)
17) Install the center exhaust pipe.
Exhaust Pipe.>
18) Lower the vehicle.
19) Connect the following hoses:
(1) Fuel delivery hose, return hose and evapo-
ration hose
(2) Heater inlet and outlet hoses
(3) Brake booster vacuum hose
20) Connect the following connectors and termi-
nals:
(1) Engine ground terminal
(2) Engine harness connectors
(3) Generator connector and terminal
(4) A/C compressor connectors
21) Connect the following cables:
(1) Accelerator cable
(2) Clutch release spring
22) After connecting each cable, adjust them.
23) Install the air intake system.
(1) Install the intercooler. 11, INSTALLATION, Intercooler.>
(2) Install the air cleaner element and air clean-
er upper cover.
(3) Install the engine harness connector brack-
et.
(4) Install the filler hose to air cleaner case.
ME-00036
ME-00035
ME-00040
ME-00056
(A)
(A)(B)
(B)

ME(H4DOTC)-49
MECHANICAL
Engine Assembly
24) Install the A/C pressure hoses.
NOTE:
Use new O-rings.
Tightening torque:
15 N
⋅m (1.5 kgf-m, 10.8 ft-lb)
25) Install the radiator. STALLATION, Radiator.>
26) Install the coolant filler tank. CO(H4SO)-42, INSTALLATION, Coolant Filler
Tank.>
27) Install the window washer tank.
28) Install the battery in the vehicle, and then con-
nect the cables.
29) Fill coolant.
COOLANT, REPLACEMENT, Engine Coolant.>
30) Charge the A/C system with refrigerant.
ing Procedure.>
31) Remove the front hood stay, and close the front
hood.
32) Take off the vehicle from lift arms.
ME-00026

ME(H4DOTC)-50
MECHANICAL
Engine Mounting
10.Engine Mounting
A: REMOVAL
1) Remove the engine assembly. ME(H4DOTC)-41, REMOVAL, Engine Assembly.>
2) Remove the engine mounting from engine as-
sembly.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
ENGINE MOUNTING;
35 N
⋅m (3.6 kgf-m, 25.8 ft-lb)
C: INSPECTION
Make sure there are no cracks or other damage.

ME(H4DOTC)-51
MECHANICAL
Preparation for Overhaul
11.Preparation for Overhaul
A: PROCEDURE
1) After removing the engine from body, secure it in
the ST shown below.
ST1 498457000 ENGINE STAND ADAPTER
RH
ST2 498457100 ENGINE STAND ADAPTER
LH
ST3 499817000 ENGINE STAND
2) In this section the procedures described under
each index are all connected and stated in order. It
will be the complete procedure for overhauling of
the engine itself when you go through all steps in
the process.
Therefore, in this section, to conduct the particular
procedure within the flow of a section, you need to
go back and conduct the procedure described pre-
viously in order to do that particular procedure.
ME-00057ST3
ST2
ST1

ME(H4DOTC)-52
MECHANICAL
V-belt
12.V-belt
A: REMOVAL
1. FRONT SIDE BELT
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
CAUTION:
Wipe off any oil or water on the belt and pulley.
1) Install the belt (C), and tighten the slider bolt so
as to obtain the specified belt tension ME(H4DOTC)-53, INSPECTION, V-belt.>
2) Tighten the lock bolt (A).
3) 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)
SC-00096
(A)
(C) (B)
ME-00059
(A)
(B)
ME-00060
ME-00061
(A)
(C) (B)
ME-00059