SUBARU FORESTER 2004 Service Repair Manual

ME(H4DOTC)-53
MECHANICAL
V-belt
2. REAR SIDE BELT
1) Install the belt, and tighten the slider bolt (B) so
as to obtain the specified belt tension. ME(H4DOTC)-53, INSPECTION, V-belt.>
2) Tighten the lock nut (A).
Tightening torque:
Lock nut (A);
22.6 N
⋅m (2.3 kgf-m, 16.6 ft-lb)
C: INSPECTION
1) Replace the belts, if cracks, fraying or wear is
found.
2) Check the drive belt tension and adjust it if nec-
essary by changing generator installing position
and/or idler pulley installing position.
Belt tension (With using belt tension gauge)
(A)
Replaced: 640 — 780 N (65 — 80 kgf, 144 —
175 lb)
Reused: 490 — 640 N (50 — 65 kgf, 110 — 144
lb)
(B)*
Replaced: 740 — 880 N (76 — 89 kgf, 167 —
197 lb)
Reused: 350 — 450 N (36 — 46 kgf, 78 — 101
lb)
*: With air conditioner
(A)
(B)
ME-00060
(A) Front side belt
(B) Rear side belt
C/P Crank pulley
GEN Generator
P/S Power steering oil pump pulley
A/C A/C compressor pulley
I/P Idler pulley
C/P P/SA/C
GEN
(A)
(B)
I/P
PM-00154

ME(H4DOTC)-54
MECHANICAL
V-belt
Belt tension (Without using belt tension gauge)
(A)
Replaced: 7 — 9 mm (0.276 — 0.354 in)
Reused: 9 — 11 mm (0.354 — 0.433 in)
(B)*
Replaced: 7.5 — 8.5 mm (0.295 — 0.335 in)
Reused: 9.0 — 10.0 mm (0.354 — 0.394 in)
*: With air conditioner
(A) Front side belt
(B) Rear side belt
C/P Crank pulley
GEN Generator
P/S Power steering oil pump pulley
A/C Air conditioning compressor pulley
I/P Idler pulley
ME-00062
P/S
C/PGEN
I/P A/C 98 N (10 kgf, 22 lb)
(A)(B)

ME(H4DOTC)-55
MECHANICAL
Crank Pulley
13.Crank Pulley
A: REMOVAL
1) Remove the V-belt. REMOVAL, V-belt.>
2) Remove the crank pulley bolt. To lock the crank-
shaft, use ST.
ST 499977400 CRANK PULLEY WRENCH
(2.0 L model)
ST 499977100 CRANK PULLEY WRENCH
(2.5 L model)
3) Remove the crank pulley.
B: INSTALLATION
1. 2.0 L MODEL
1) Install the crank pulley.
2) Install the pulley bolt.
To lock the crankshaft, use ST.
ST 499977400 CRANK PULLEY WRENCH
(1) Clean the crank pulley thread using an air
gun.
(2) Apply engine oil to the crank pulley bolt seat
and thread.
(3) Tighten the bolts temporarily with tightening
torque of 44 N⋅m (4.5 kgf-m, 33 ft-lb).
(4) Tighten the crank pulley bolts.
Tightening torque:
127 N
⋅m (13 kgf-m, 94.0 ft-lb)
3) Confirm that the tightening angle of crank pulley
bolt is 45 degrees or more. If the tightening angle of
crank pulley bolt is less than 45 degrees, conduct
the following procedures.CAUTION:
If the tightening angle of crankshaft pulley bolt
is less than 45 degrees, the bolt should be dam-
aged. In this case, the bolt must be replaced.
(1) Replace the crankshaft pulley bolts and
clean them.
Crankshaft pulley bolt:
12369AA011
(2) Clean the crankshaft thread using an air
gun.
(3) Tighten the bolts temporarily with tightening
torque of 44 N⋅m (4.5 kgf-m, 33 ft-lb).
(4) Tighten the crankshaft pulley bolts keeping
them in an angle between 45 degrees and 60
degrees.
NOTE:
Conduct the tightening procedures by confirming
the turning angle of crankshaft pulley bolt referring
to the gauge indicated on timing belt cover.
4) Install the A/C belt tensioner.
5) Install the V-belt. STALLATION, V-belt.>
2. 2.5 L MODEL
1) Install the crank pulley.
2) Install the pulley bolt.
To lock the crankshaft, use ST.
ST 499977100 CRANK PULLEY WRENCH
(1) Clean the crank pulley thread using an air
gun.
(2) Apply engine oil to the crank pulley bolt seat
and thread.
(3) Tighten the bolts temporarily with tightening
torque of 44 N⋅m (4.5 kgf-m, 33 ft-lb).
(4) Tighten the crank pulley bolts.
ME-00227
STST
ME-00227
STST
ME-00061

ME(H4DOTC)-56
MECHANICAL
Crank Pulley
Tightening torque:
180 N
⋅m (18.3 kgf-m, 132.7 ft-lb)
3) Confirm that the tightening angle of crank pulley
bolt is 65 degrees or more. If the tightening angle of
crank pulley bolt is less than 65 degrees, conduct
the following procedures.
CAUTION:
If the tightening angle of crank pulley bolt is
less than 65 degrees, the bolt should be dam-
aged. In this case, the bolt must be replaced.
(1) Replace the crank pulley bolts and clean
them.
Crank pulley bolt:
12369AA011
(2) Clean the crankshaft thread using an air
gun.
(3) Apply engine oil to the crank pulley bolt seat
and thread.
(4) Tighten the bolts temporarily with tightening
torque of 44 N⋅m (4.5 kgf-m, 33 ft-lb).
(5) Tighten the crank pulley bolts keeping them
in an angle between 65 degrees and 75 de-
grees.
NOTE:
Conduct the tightening procedures by confirming
the turning angle of crank pulley bolt referring to the
gauge indicated on timing belt cover.
4) Install the A/C belt tensioner.
5) Install the V-belt. STALLATION, V-belt.>
C: INSPECTION
1) Make sure the V-belt is not worn or otherwise
damaged.
2) Check the tension of the belt. ME(H4DOTC)-53, INSPECTION, V-belt.>
ME-00063ST
ME-00061

ME(H4DOTC)-57
MECHANICAL
Timing Belt Cover
14.Timing Belt Cover
A: REMOVAL
1) Remove the V-belt. REMOVAL, V-belt.>
2) Remove the crank pulley. 55, REMOVAL, Crank Pulley.>
3) Remove the timing belt cover (LH) (A).
4) Remove the timing belt cover (RH) (B).
5) Remove the front timing belt cover (C).
B: INSTALLATION
1) Install the front timing belt cover (C).
Tightening torque:
5 N
⋅m (0.5 kgf-m, 3.6 ft-lb)
2) Install the timing belt cover (RH) (B).
Tightening torque:
5 N
⋅m (0.5 kgf-m, 3.6 ft-lb)
3) Install the timing belt cover (LH) (A).
Tightening torque:
5 N
⋅m (0.5 kgf-m, 3.6 ft-lb)
4) Install the crank pulley. 55, INSTALLATION, Crank Pulley.>
5) Install the V-belt. STALLATION, V-belt.>
C: INSPECTION
Make sure the cover is not damaged.
ME-00064
(A)
(C) (B)
ME-00064
(A)
(C) (B)

ME(H4DOTC)-58
MECHANICAL
Timing Belt Assembly
15.Timing Belt Assembly
A: REMOVAL
1. TIMING BELT
1) Remove the V-belt. REMOVAL, V-belt.>
2) Remove the crank pulley. ME(H4DOTC)-55, REMOVAL, Crank Pulley.>
3) Remove the timing belt cover. ME(H4DOTC)-57, REMOVAL, Timing Belt Cover.>
4) Remove the timing belt guides. (MT model)5) If the alignment mark and/or arrow mark (which
indicates rotation direction) on timing belt fade
away, put new marks before removing the timing
belt as follows:
(1) Turn the crankshaft using ST, and align the
alignment marks on crankshaft sprocket, intake
camshaft sprocket (LH), exhaust camshaft
sprocket (LH), intake camshaft sprocket (RH)
and exhaust camshaft sprocket (RH) with notch-
es of timing belt cover and cylinder block.
ST 499987500 CRANKSHAFT SOCKET
(2) Using white paint, put alignment and/or ar-
row marks on the timing belts in relation to the
sprockets.
ME-00065
ME-00727
ME-00728
ME-00729
ME-00069ST
ME-00070
ME-00071

ME(H4DOTC)-59
MECHANICAL
Timing Belt Assembly
Z1: 54.5 tooth length
Z
2: 51 tooth length
Z
3: 28 tooth length
6) Remove the belt idler (A).
7) Remove the timing belt.
CAUTION:
After the timing belt has been removed, never
rotate the intake and exhaust, camshaft sprock-
et. If the camshaft sprocket is rotated, the in-
take and exhaust valve heads strike together
and valve stems are bent.
2. BELT IDLER AND AUTOMATIC BELT
TENSION ADJUSTER ASSEMBLY
1) Remove the belt idler (B) and (C).2) Remove the belt idler No. 2.
3) Remove the automatic belt tension adjuster as-
sembly.
B: INSTALLATION
1. AUTOMATIC BELT TENSION ADJUST-
ER ASSEMBLY AND BELT IDLER
1) Preparation for installation of automatic belt ten-
sion adjuster assembly:
NOTE:
 Always use a vertical type pressing tool to move
the adjuster rod down.
 Do not use a lateral type vise.
 Push the adjuster rod vertically.
 Be sure to slowly move the adjuster rod down ap-
plying a pressure of 294 N (30 kgf, 66 lb).
 Press-in the push adjuster rod gradually taking
more than 3 minutes.
 Do not allow press pressure to exceed 9,807 N
(1,000 kgf, 2,205 lb).
 Press the adjuster rod as far as the end surface
of cylinder. Do not press the adjuster rod into the
cylinder. Doing so may damage the cylinder.
ME-00072
Z3Z1Z2Z3
ME-00073
(A)(B)
(C)
ME-00074
(A)(B)
(C)
ME-00075
ME-00076

ME(H4DOTC)-60
MECHANICAL
Timing Belt Assembly
 Do not release the press pressure until stopper
pin is completely inserted.
(1) Attach the automatic belt tension adjuster
assembly to the vertical pressing tool.
(2) Slowly move the adjuster rod down with a
pressure of 294 N (30 kgf, 66 lb) until the adjust-
er rod is aligned with the stopper pin hole in the
cylinder.
(3) With a 2 mm (0.08 in) dia. stopper pin or a 2
mm (0.08 in) (nominal) dia. hex bar wrench in-
serted into the stopper pin hole in the cylinder,
secure the adjuster rod.
2) Install the automatic belt tension adjuster as-
sembly.
Tightening torque:
39 N
⋅m (4.0 kgf-m, 28.9 ft-lb)3) Install the belt idler No. 2.
Tightening torque:
39 N
⋅m (4.0 kgf-m, 28.9 ft-lb)
4) Install the belt idler.
Tightening torque:
39 N
⋅m (4.0 kgf-m, 28.9 ft-lb)
2. TIMING BELT
1) Preparation for installation of automatic belt ten-
sion adjuster assembly. AUTOMATIC BELT TENSION ADJUSTER AS-
SEMBLY AND BELT IDLER, INSTALLATION,
Timing Belt Assembly.>
2) Crankshaft and camshaft sprocket alignment.
(1) Align mark (A) on the crankshaft sprocket
with mark on the oil pump cover at cylinder
block.
ME-00077
ME-00078
ME-00079
ME-00075
ME-00080
(A)
ME-00081

ME(H4DOTC)-61
MECHANICAL
Timing Belt Assembly
(2) Align single line mark (A) on the exhaust
camshaft sprocket (RH) with notch (B) on timing
belt cover.
(3) Align single line mark (A) on the intake cam-
shaft sprocket (RH) with notch (B) on timing belt
cover.
(Make sure double lines (C) on intake camshaft
and exhaust camshaft sprockets are aligned.)
(4) Align single line mark (A) on exhaust cam-
shaft sprocket (LH) with notch (B) on timing belt
cover by turning the sprocket counterclockwise
(as viewed from front of engine).
(5) Align the single line mark (A) on intake cam-
shaft sprocket (LH) with notch (B) on timing beltcover by turning the sprocket clockwise (as
viewed from front of engine).
Ensure the double lines (C) on intake and ex-
haust camshaft sprockets are aligned.
(6) Ensure the camshaft and crankshaft sprock-
ets are positioned properly.
CAUTION:
 Intake and exhaust camshafts for this DOHC
engine can be independently rotated with the
timing belts removed. As can be seen from the
figure, if the intake and exhaust valves are lifted
simultaneously, their heads will interfere with
each other, resulting in bent valves.
ME-00082
(A)
(B)
ME-00083
(B)
(C)
(A)
ME-00084
(B)
(A)
(A) Intake camshaft
(B) Exhaust camshaft
ME-00085
(A) (B)
(C)
ME-00086
(A)
(B)

ME(H4DOTC)-62
MECHANICAL
Timing Belt Assembly
 When the timing belts are not installed, four
camshafts are held at the “zero-lift” position,
where all cams on camshafts do not push the
intake and exhaust valves down. (Under this
condition, all valves remain unlifted.)
 When the camshafts are rotated to install the
timing belts, #2 intake and #4 exhaust cam of
camshafts (LH) are held to push their corre-
sponding valves down. (Under this condition,
these valves are held lifted.) Camshafts (RH)
are held so that their cams do not push valves
down.
 Camshafts (LH) must be rotated from the “ze-
ro-lift” position to the position where the timing
belt is to be installed at as small an angle as
possible, in order to prevent mutual interfer-
ence of intake and exhaust valve heads.
 Do not allow the camshafts to rotate in the di-
rection shown in the figure as this causes both
intake and exhaust valves to lift simultaneous-
ly, resulting in interference with their heads.
3) Installation of timing belt:
(A) Rotating direction
(B) Timing belt installation position
(C) Bad example
(D) Good example
(A) (A) (A) (A)
(D) (C)
(B)(B)
ME-00314
ME-00088