engine SUBARU FORESTER 2004 Service Repair Manual

ME(H4SO)-73
MECHANICAL
Cylinder Block
B: INSTALLATION
NOTE:
Remove oil in the mating surface of bearing and
cylinder block before installation. Also apply a coat
of engine oil to crankshaft pins.
1) Position the crankshaft on #2 and #4 cylinder
block.
2) Apply liquid gasket to the mating surface of #1
and #3 cylinder block, and position it on #2 and #4
cylinder block.
Liquid gasket:
THREE BOND 1215 (Part No. 004403007) or
equivalentNOTE:
Do not allow liquid gasket to jut into O-ring grooves,
oil passages, bearing grooves, etc.
3) Apply engine oil to washers and bolt threads.
(1) Crankshaft bearing (3) Cylinder block (4) Rear oil seal
(2) Crankshaft
ME-00144
( 1 )
( 1 )
( 2 )
( 3 )
( 3 )
( 4 )
ME-00145

ME(H4SO)-76
MECHANICAL
Cylinder Block
 2.5 L model
CAUTION:
 Ensure ring gaps do not face the same direc-
tion.
 Ensure ring gaps are not within the piston
skirt area.
15) Install snap ring.
Install snap rings in the piston holes located oppo-
site service holes in cylinder block, when position-
ing all pistons in the corresponding cylinders.
NOTE:
Use new snap rings.
CAUTION:
Piston front mark faces towards the front of the
engine.
 2.0 L model 2.5 L model
(A) Front side
ME-00415
5SH
(G)
ME-00306
#4 #3
#2 #1
(A)
ME-00387
B0SH
(A) Front mark
ME-00404
5SH
(A)

ME(H4SO)-77
MECHANICAL
Cylinder Block
16) Installing piston
(1) Turn the cylinder block to face the #1 and #2
piston side upward.
(2) Using the ST1, turn the crankshaft so that
#1 and #2 connecting rods are set at bottom
dead center.
ST1 499987500 CRANKSHAFT SOCKET
(3) Apply a coat of engine oil to pistons and cyl-
inders, and then insert the pistons in their cylin-
ders using ST2.
ST2 398744300 PISTON GUIDE (2.0 L model)
ST2 498747300 PISTON GUIDE (2.5 L model)
17) Installing piston pin
(1) Apply a coat of engine oil to the ST3 before
insertion.
(2) Insert the ST3 into service hole to align pis-
ton pin hole with connecting rod small end.ST3 499017100 PISTON PIN GUIDE
(3) Apply a coat of engine oil to the piston pin,
and then insert the piston pin into piston and
connecting rod through service hole.
(4) Install the snap ring using needle nose plier.
NOTE:
Use new snap rings.
(1) Piston (4) GasketTightening torque: N⋅m (kgf-m, ft-lb)
(2) Piston pin (5) Service hole plugT: 70 (7.0, 50.6)
(3) Circlip
ME-00155
(1) (1)
(2)
(2) (3)
(3) (4)
(4) (5)
(5)
T
ME-00157
ST2
ST1
ME-00158
ST1ST3
ME-00159

ME(H4SO)-80
MECHANICAL
Cylinder Block
ST2 499057000 TORX PLUS
25) Install the housing cover.
26) Installation of oil pump
(1) Discard the front oil seal after removal. Re-
place with a new one using the ST.
ST 499587100 OIL SEAL INSTALLER
(2) Apply liquid gasket to the matching surface
of oil pump.
Liquid gasket:
THREE BOND 1215 (Part No. 004403007) or
equivalent(3) Apply a coat of engine oil to the inside of oil
seal.
(4) Install the oil pump on cylinder block. Be
careful not to damage the oil seal during instal-
lation.
Tightening torque:
6.4 N
⋅m (0.65 kgf-m, 4.7 ft-lb)
CAUTION:
 Be sure to install the O-ring and seal when in-
stalling oil pump.
 Align flat surface of oil pump’s inner rotor
with crankshaft before installation.
27) Install the water pump and gasket.
Tightening torque:
First; 12 N
⋅m (1.2 kgf-m, 8.7 ft-lb)
Second; 12 N
⋅m (1.2 kgf-m, 8.7 ft-lb)
CAUTION:
 Be sure to use a new gasket.
 When installing the water pump, tighten the
bolts in two stages in alphabetical sequence as
shown in the figure.
 Model without ATF warmer
(A) Flywheel
(A) O-ring
(A)
ME-00382
ST1ST2
ME-00164
ME-00165
(A)
ME-00312
ME-00333
(B)
(F) (D)(C)
(A)
(E)

ME(H4SO)-81
MECHANICAL
Cylinder Block
 Model with ATF warmer
28) Install the water by-pass pipe for heater.
29) Get a engine oil filter and apply a thin coat of
engine oil to the seal rubber.
30) Install the oil filter by turning it by hand, being
careful not to damage the seal rubber.
 Tighten the oil filter 80 mm (3.15 in) or 65 mm
(2.56 in) in diameter by approx. 2/3 — 3/4 rotation
more after the seal rubber of oil filter comes in con-
tact with cylinder block or oil cooler.
 Tighten the oil filter 68 mm (2.68 in) in diameter
by approx. 1 rotation more after the seal rubber of
oil filter comes in contact with cylinder block or oil
cooler.
CAUTION:
Do not tighten excessively, or oil may leak.
31) Tighten the cylinder head bolts.
(1) Apply a coat of engine oil to washers and
bolt threads.
(2) Tighten all bolts to 29 N⋅m (3.0 kgf-m, 22 ft-
lb) in alphabetical sequence.
Then tighten all bolts to 69 N⋅m (7.0 kgf-m, 51 ft-
lb) in alphabetical sequence.
(3) Back off all bolts by 180° in reverse order of
installation, and back them off again by 180°.
(4) Tighten all bolts to 42 N⋅m (3.9 kgf-m, 31 ft-
lb) in alphabetical sequence.
(5) Tighten all bolts by 80° — 90° in alphabeti-
cal sequence.
(6) Tighten all bolts by 40° — 45° in alphabeti-
cal sequence.
NOTE:
Do not tighten the bolts more than 45°.
(7) Further tighten bolts (a) and (b) by 40° —
45°.NOTE:
Ensure the total “re-tightening angle” in the [former
two steps], do not exceed 90°.
32) Install the oil level gauge guide and tighten the
attaching bolt (left side only).
33) Install the rocker cover.
34) Install the crank sprocket. 55, INSTALLATION, Crank Sprocket.>
35) Install the cam sprocket. 53, INSTALLATION, Cam Sprocket.>
36) Install the timing belt assembly. ME(H4SO)-49, INSTALLATION, Timing Belt.>
37) Install the belt cover. INSTALLATION, Timing Belt Cover.>
38) Install the crank pulley. INSTALLATION, Crank Pulley.>
39) Install the generator and A/C compressor
brackets on cylinder head.
40) Install the V-belt. STALLATION, V-belt.>
41) Install the intake manifold. 16, INSTALLATION, Intake Manifold.>
ME-02017
(B) (C) (D)(E)(F)
(A)
ME-00279
(c)
(b)(f)
(d) (a)
(e)

ME(H4SO)-91
MECHANICAL
Engine Trouble in General
22.Engine Trouble in General
A: INSPECTION
NOTE:
“RANK” shown in the chart refer to the possibility of reason for the trouble in order (“Very often” to “Rarely”)
A — Very often
B — Sometimes
C — Rarely
TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK
1. Engine will not start.
1) Starter does not turn. Starter Defective battery-to-starter harness B
Defective starter switch C
Defective inhibitor switch or neutral switch C
Defective starter B
Battery Poor terminal connection A
Run-down battery A
Defective charging system B
Friction Seizure of crankshaft and connecting rod bearing C
Seized camshaft C
Seized or stuck piston and cylinder C
2) Initial combustion does
not occur. Starter Defective starter C
Engine control system A
Fuel line Defective fuel pump and relay A
Lack of or insufficient fuel B
Belt Defective B
Defective timing B
Compression Incorrect valve clearance C
Loosened spark plugs or defective gasket C
Loosened cylinder head bolts or defective gasket C
Improper valve seating C
Defective valve stem C
Worn or broken valve spring B
Worn or stuck piston rings, cylinder and piston C
Incorrect valve timing B
Improper engine oil (low viscosity) B
3) Initial combustion occurs. Engine control system A
Intake system Defective intake manifold gasket B
Defective throttle body gasket B
Fuel line Defective fuel pump and relay C
Clogged fuel line C
Lack of or insufficient fuel B
Belt Defective B
Defective timing B
Compression Incorrect valve clearance C
Loosened spark plugs or defective gasket C
Loosened cylinder head bolts or defective gasket C
Improper valve seating C
Defective valve stem C
Worn or broken valve spring B
Worn or stuck piston rings, cylinder and piston C
Incorrect valve timing B
Improper engine oil (low viscosity) B

ME(H4SO)-92
MECHANICAL
Engine Trouble in General
4) Engine stalls after initial
combustion. Engine control system A
Intake system Loosened or cracked intake duct B
Loosened or cracked PCV hose C
Loosened or cracked vacuum hose C
Defective intake manifold gasket B
Defective throttle body gasket B
Dirty air cleaner element C
Fuel line Clogged fuel line C
Lack of or insufficient fuel B
Belt Defective B
Defective timing B
Compression Incorrect valve clearance C
Loosened spark plugs or defective gasket C
Loosened cylinder head bolts or defective gasket C
Improper valve seating C
Defective valve stem C
Worn or broken valve spring B
Worn or stuck piston rings, cylinder and piston C
Incorrect valve timing B
Improper engine oil (low viscosity) B
2. Rough idle and engine
stallEngine control system A
Intake system Loosened or cracked intake duct A
Loosened or cracked PCV hose A
Loosened or cracked vacuum hose A
Defective intake manifold gasket B
Defective throttle body gasket B
Defective PCV valve C
Loosened oil filler cap B
Dirty air cleaner element C
Fuel line Defective fuel pump and relay C
Clogged fuel line C
Lack of or insufficient fuel B
Belt Defective timing C
Compression Incorrect valve clearance B
Loosened spark plugs or defective gasket B
Loosened cylinder head bolts or defective gasket B
Improper valve seating B
Defective valve stem C
Worn or broken valve spring B
Worn or stuck piston rings, cylinder and piston B
Incorrect valve timing A
Improper engine oil (low viscosity) B
Lubrication system Incorrect oil pressure B
Defective rocker cover gasket C
Cooling system Overheating C
Others Malfunction of evaporative emission control system A
Stuck or damaged throttle valve B
Accelerator cable out of adjustment C TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK

ME(H4SO)-93
MECHANICAL
Engine Trouble in General
3. Low output, hesitation and
poor accelerationEngine control system A
Intake system Loosened or cracked intake duct A
Loosened or cracked PCV hose A
Loosened or cracked vacuum hose B
Defective intake manifold gasket B
Defective throttle body gasket B
Defective PCV valve B
Loosened oil filler cap B
Dirty air cleaner element A
Fuel line Defective fuel pump and relay B
Clogged fuel line B
Lack of or insufficient fuel C
Belt Defective timing B
Compression Incorrect valve clearance B
Loosened spark plugs or defective gasket B
Loosened cylinder head bolts or defective gasket B
Improper valve seating B
Defective valve stem C
Worn or broken valve spring B
Worn or stuck piston rings, cylinder and piston C
Incorrect valve timing A
Improper engine oil (low viscosity) B
Lubrication system Incorrect oil pressure B
Cooling system Overheating C
Over cooling C
Others Malfunction of evaporative emission control system A
4. Surging Engine control system A
Intake system Loosened or cracked intake duct A
Loosened or cracked PCV hose A
Loosened or cracked vacuum hose A
Defective intake manifold gasket B
Defective throttle body gasket B
Defective PCV valve B
Loosened oil filler cap B
Dirty air cleaner element B
Fuel line Defective fuel pump and relay B
Clogged fuel line B
Lack of or insufficient fuel C
Belt Defective timing B
Compression Incorrect valve clearance B
Loosened spark plugs or defective gasket C
Loosened cylinder head bolts or defective gasket C
Improper valve seating C
Defective valve stem C
Worn or broken valve spring C
Worn or stuck piston rings, cylinder and piston C
Incorrect valve timing A
Improper engine oil (low viscosity) B
Cooling system Overheating B
Others Malfunction of evaporative emission control system C TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK

ME(H4SO)-94
MECHANICAL
Engine Trouble in General
5. Engine does not return to
idle.Engine control system A
Intake system Loosened or cracked vacuum hose A
Others Stuck or damaged throttle valve A
Accelerator cable out of adjustment B
6. Dieseling (Run-on) Engine control system A
Cooling system Overheating B
Others Malfunction of evaporative emission control system B
7. After burning in exhaust
systemEngine control system A
Intake system Loosened or cracked intake duct C
Loosened or cracked PCV hose C
Loosened or cracked vacuum hose B
Defective PCV valve B
Loosened oil filler cap C
Belt Defective timing B
Compression Incorrect valve clearance B
Loosened spark plugs or defective gasket C
Loosened cylinder head bolts or defective gasket C
Improper valve seating B
Defective valve stem C
Worn or broken valve spring C
Worn or stuck piston rings, cylinder and piston C
Incorrect valve timing A
Lubrication system Incorrect oil pressure C
Cooling system Over cooling C
Others Malfunction of evaporative emission control system C
8. Knocking Engine control system A
Intake system Loosened oil filler cap B
Belt Defective timing B
Compression Incorrect valve clearance C
Incorrect valve timing B
Cooling system Overheating A
9. Excessive engine oil con-
sumptionIntake system Loosened or cracked PCV hose A
Defective PCV valve B
Loosened oil filler cap C
Compression Defective valve stem A
Worn or stuck piston rings, cylinder and piston A
Lubrication system Loosened oil pump attaching bolts and defective gas-
ketB
Defective oil filter seal B
Defective crankshaft oil seal B
Defective rocker cover gasket B
Loosened oil drain plug or defective gasket B
Loosened oil pan fitting bolts or defective oil pan B TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK

ME(H4SO)-95
MECHANICAL
Engine Trouble in General
10. Excessive fuel consump-
tionEngine control system A
Intake system Dirty air cleaner element A
Belt Defective timing B
Compression Incorrect valve clearance B
Loosened spark plugs or defective gasket C
Loosened cylinder head bolts or defective gasket C
Improper valve seating B
Defective valve stem C
Worn or broken valve spring C
Worn or stuck piston rings, cylinder and piston B
Incorrect valve timing B
Lubrication system Incorrect oil pressure C
Cooling system Over cooling C
Others Accelerator cable out of adjustment B TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK