torque SUBARU FORESTER 2004 Service Repair Manual
[x] Cancel search | Manufacturer: SUBARU, Model Year: 2004, Model line: FORESTER, Model: SUBARU FORESTER 2004Pages: 2870, PDF Size: 38.67 MB
Page 901 of 2870
ME(H4SO)-32
MECHANICAL
Valve Clearance
To set the #3, #2 and #4 cylinder pistons to their
top dead centers on compression stroke, turn the
crank pulley clockwise 90° at a time starting with ar-
row mark on cam sprocket (LH) facing up.
13) After inspection, install the related parts in the
reverse order of removal.
Tightening torque:
Resonator chamber;
33 N
⋅m (3.4 kgf-m, 25 ft-lb)
B: ADJUSTMENT
NOTE:
Adjustment of the valve clearance should be per-
formed while engine is cold.
1) Set the #1 cylinder piston to top dead center of
compression stroke by rotating crank pulley clock-
wise using socket wrench.
NOTE:
When arrow mark (A) on the cam sprocket (LH)
comes exactly to the top, #1 cylinder piston is
brought to the top dead center of compression
stroke.2) Adjust the #1 cylinder valve clearance.
(1) Loosen the valve rocker nut and screw.
(2) Place suitable thickness gauge.
(3) While noting the valve clearance, tighten the
valve rocker adjusting screw.
(4) When specified valve clearance is obtained,
tighten the valve rocker nut.
Tightening torque:
10 N
⋅m (1.0 kgf-m, 7.2 ft-lb)
CAUTION:
Insert the thickness gauge in as horizontally
as possible with respect to the valve stem end
face.
Adjust the exhaust valve clearances while
lifting up the vehicle.
Valve clearance:
Intake:
0.20
±0.04 mm (0.0079±0.0016 in)
Exhaust:
0.25
±0.04 mm (0.0098±0.0016 in)
3) Ensure the valve clearances are within specifi-
cations.
4) Turn the crankshaft two complete rotations until
#1 cylinder piston is again set to the top dead cen-
ter of compression stroke.
5) Ensure the valve clearances are within specifi-
cations. If necessary, readjust the valve clearanc-
es.
6) Similar to adjustment procedures used for #1
cylinder, adjust the #2, #3 and #4 cylinder valve
clearances.
ME-00202
#1
#2#3 #4
IN-00044
ME-00200
(A)
ME-00203
Page 905 of 2870
ME(H4SO)-36
MECHANICAL
Engine Assembly
(2) Loosen the lock bolt and slider bolt, and
then remove the front side V-belt.
AL, V-belt.>
(3) Remove the pipe with bracket.
(4) Remove the bolts which install power steer-
ing pump bracket.
(5) Remove the reservoir tank from bracket by
pulling it upward.
(6) Place the power steering pump on right side
wheel apron.14) Remove the front and center exhaust pipe.
15) Remove the nuts which hold lower side of
transmission to engine.
16) Remove the nuts which install front cushion
rubber onto front crossmember.
17) 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 torque con-
verter clutch to drive plate.
(4) Remove other bolts while rotating the en-
gine using socket wrench.
ME-00331
FU-00139
FU-00020
FU-00140ME-00210
ME-00211
ME-00212
Page 906 of 2870
ME(H4SO)-37
MECHANICAL
Engine Assembly
18) Remove the pitching stopper.
19) Disconnect the fuel delivery hose (A), return
hose (B) and evaporation hose (C).
CAUTION:
Disconnect the hose with its end wrapped
with cloth to prevent fuel from splashing.
Catch fuel from the hose into container.
20) Support the engine with a lifting device and
wire ropes.21) Support the transmission with a garage jack.
CAUTION:
Before moving the engine away from transmis-
sion, check to be sure no work has been over-
looked. Doing this is very important in order to
facilitate re-installation and because the trans-
mission lowers under its own weight.
22) Separation of the engine and transmission.
(1) Remove the starter.
(2) Remove the bolts which hold upper side of
transmission to engine.
23) Install the ST to torque converter clutch case.
(AT model)
ST 498277200 STOPPER SET
24) Remove the engine from vehicle.
(1) Slightly raise the engine.
(2) Raise the transmission with garage jack.
ME-00213
FU-00149
(A)
(B)
(C)
ME-00214
(A) Transmission
(B) Garage jack
ME-00215
(B)(A)
ME-00216
ST
ME-00217
Page 907 of 2870
ME(H4SO)-38
MECHANICAL
Engine Assembly
(3) Move the engine horizontally until main
shaft is withdrawn from clutch cover.
(4) Slowly move the engine away from engine
compartment.
NOTE:
Be careful not to damage the adjacent parts or
body panels with crank pulley, oil level gauge, etc.
25) Remove the front cushion rubbers.
B: INSTALLATION
1) Install the front cushion rubbers.
Tightening torque:
34 N
⋅m (3.5 kgf-m, 25.3 ft-lb)
2) Install the engine onto transmission.
(1) Position the engine in engine compartment
and align it with transmission.
NOTE:
Be careful not to damage the adjacent parts or
body panels with crank pulley, oil level gauge, etc.
(2) Apply a small amount of grease to the spline
of main shaft. (MT model)3) Tighten the bolts which hold upper side of trans-
mission to engine.
Tightening torque:
50 N
⋅m (5.1 kgf-m, 36.9 ft-lb)
4) Remove the lifting device and wire ropes.
5) Remove the garage jack.
6) 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)
7) 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
8) Install the starter.
9) Install the torque converter clutch onto drive
plate. (AT model)
ME-00214
ME-00214
ME-00216
ME-00214
ME-00218T2T1
Page 908 of 2870
ME(H4SO)-39
MECHANICAL
Engine Assembly
(1) Tighten the bolts which hold torque convert-
er clutch to drive plate.
(2) Tighten other bolts while rotating the engine
by using a socket wrench.
NOTE:
Be careful not to drop the bolts into torque convert-
er clutch housing.
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
(3) Plug up the service hole and prevent foreign
matters from getting in.
10) Install the power steering pump on bracket.
(1) Install the reservoir tank on bracket.
(2) Install the power steering pump on bracket,
and then tighten the bolts.
Tightening torque:
20.1 N
⋅m (2.05 kgf-m, 14.8 ft-lb)(3) Tighten the bolts which install power steer-
ing pump bracket, and then install the spark plug
cords.
(4) Connect the power steering switch connec-
tor.
(5) Install the front side V-belt, and adjust it.
(6) Install the resonator chamber.
Tightening torque:
33 N
⋅m (3.4 kgf-m, 24.6 ft-lb)
ME-00212
FU-00020
FU-00139
ME-00331
FU-00017
IN-00044
Page 909 of 2870
ME(H4SO)-40
MECHANICAL
Engine Assembly
11) Tighten the nuts which hold lower side of trans-
mission to engine.
Tightening torque:
50 N
⋅m (5.1 kgf-m, 36.9 ft-lb)
12) Tighten the nuts which install front cushion rub-
ber onto crossmember.
Tightening torque:
85 N
⋅m (8.7 kgf-m, 63 ft-lb)
NOTE:
Make sure the front cushion rubber mounting bolts
(A) and locator (B) are securely installed.
13) Install the front and center exhaust pipe.
Pipe.>
14) 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
15) Connect the following connectors.
(1) Engine ground cables
Tightening torque:
14 N
⋅m (1.4 kgf-m, 10.1 ft-lb)
(2) Engine harness connectors
(3) Generator connector and terminal
(4) A/C compressor connectors
(5) Power steering pressure switch
16) Connect the following cables.
(1) Accelerator cable
(2) Cruise control cable (With cruise control)
17) Adjust each connected cable.18) Install the air cleaner case stay.
Tightening torque:
16 N
⋅m (1.6 kgf-m, 11.6 ft-lb)
19) Install the A/C pressure hoses.
20) Install the radiator to vehicle.
21) Install the air intake duct and air cleaner case.
22) Install the under cover.
23) Install battery in the vehicle, and then connect
the cables.
24) Fill engine coolant.
25) Check the ATF level and correct if necessary.
(AT model)
26) Charge the A/C system with refrigerant.
cedure.>
27) Remove the front hood stay, and then close the
front hood.
28) Take off the vehicle from lift arms.
C: INSPECTION
1) Make sure the pipes and hoses are installed cor-
rectly.
2) Make sure the engine coolant and ATF are at
specified levels.
ME-00219
ME-00056
(A)
(A)(B)
(B)
Page 910 of 2870
ME(H4SO)-41
MECHANICAL
Engine Mounting
10.Engine Mounting
A: REMOVAL
1) Remove the engine assembly.
2) Remove the engine mounting from engine as-
sembly.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
Engine mounting:
34 N
⋅m (3.5 kgf-m, 25.3 ft-lb)
C: INSPECTION
Make sure there are no cracks or other damage.
Page 912 of 2870
ME(H4SO)-43
MECHANICAL
V-belt
12.V-belt
A: REMOVAL
1. FRONT SIDE BELT
NOTE:
Perform the following procedures 1) to 4) with the
engine installed to body.
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
1) Wipe off any oil or water on the belt and pulley.
2) Install the V-belt (C), and tighten the slider bolt
so as to obtain the specified belt tension
3) Tighten the lock bolt (A).
4) 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)
2. REAR SIDE BELT
1) Install the V-belt, and tighten the slider bolt (B)
so as to obtain the specified belt tension.
ME-00222
ME-00223
(B)
(C)
(A)
ME-00224
(A) (B)
ME-00225
ME-00223
(B)
(C)
(A)
Page 913 of 2870
ME(H4SO)-44
MECHANICAL
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 the generator installing position
or idler pulley installing position.
Belt tension
(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)
C/P Crank pulley
GEN Generator
P/S Power steering oil pump pulley
A/C Air conditioning compressor pulley
I/P Idler pulley
ME-00224
(A) (B)
ME-00226
(A) (B)(C)GEN
C/P
I/P A/C
P/S
Page 914 of 2870
ME(H4SO)-45
MECHANICAL
Crank Pulley
13.Crank Pulley
A: REMOVAL
1) Remove the V-belt.
2) Remove the crank pulley bolt. Use ST to lock the
crankshaft.
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.
Use ST to lock the crankshaft.
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 (13.0 kgf-m, 94.0 ft-lb)
3) Confirm that the tightening angle of crank pulley
bolt is 45° or more. If the tightening angle of crank
pulley bolt is less than 45°, conduct the following
procedures.(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 45° and 60°.
NOTE:
Conduct the tightening procedures by confirming
the turning angle of crank pulley bolt referring to the
gauge indicated on belt cover.
4) Install the A/C belt tensioner.
5) Install the A/C belt.
2. 2.5 L MODEL
1) Install the crank pulley.
2) Install the pulley bolt.
Use ST to lock the crankshaft.
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).
ME-00227
STST
ME-00227
STST
ME-00225
ME-00228