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 915 of 2870
ME(H4SO)-46
MECHANICAL
Crank Pulley
(4) Tighten the crank pulley bolts.
Tightening torque:
177 N
⋅m (18.0 kgf-m, 130.2 ft-lb)
3) Confirm that the tightening angle of crank pulley
bolt is 65° or more. If the tightening angle of crank
pulley bolt is less than 65°, 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 65° and 75°.
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.
C: INSPECTION
1) Make sure the V-belt is not worn or otherwise
damaged.
2) Check the tension of the belt.
STST
ME-00225
ME-00228
Page 916 of 2870
ME(H4SO)-47
MECHANICAL
Timing Belt Cover
14.Timing Belt Cover
A: REMOVAL
1) Remove the V-belt.
2) Remove the crank pulley.
3) Remove the belt cover (LH).
4) Remove the front belt cover.
B: INSTALLATION
1) Install the front belt cover.
Tightening torque:
5 N
⋅m (0.5 kgf-m, 3.6 ft-lb)
2) Install the belt cover (LH).
Tightening torque:
5 N
⋅m (0.5 kgf-m, 3.6 ft-lb)
3) Install the crank pulley.
4) Install the V-belt.
C: INSPECTION
Make sure the cover is not damaged.
(A) Timing belt cover (LH)
(B) Front timing belt cover
(A) Timing belt cover (LH)
(B) Front timing belt cover
ME-00229
(A)
(B)
ME-00229
(A)
(B)
Page 919 of 2870
ME(H4SO)-50
MECHANICAL
Timing Belt
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. 1).
Tightening torque:
39 N
⋅m (4.0 kgf-m, 28.9 ft-lb)
2. TIMING BELT
1) Preparation for the installation of automatic belt
tension adjuster assembly
SEMBLY AND BELT IDLER, INSTALLATION,
Timing Belt.>
2) Installation of timing belt
(1) Turn the cam sprocket No. 2 using ST1, and
then turn the cam sprocket No. 1 using ST2 so
that their alignment marks (A) come to top posi-
tions.
ST1 18231AA010 CAM SPROCKET WRENCH
NOTE:
Also the CAM SPROCKET WRENCH (499207100)
can be used.ST2 499207400 CAM SPROCKET WRENCH
(2) While aligning alignment marks (B) on the
timing belt with marks (A) on sprockets, position
the timing belt properly.
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 (No. 2).
Tightening torque:
39 N
⋅m (4.0 kgf-m, 28.9 ft-lb)
ME-00241
ME-00242
ME-00243
(A)
ME-00244
ME-00235
Page 920 of 2870
ME(H4SO)-51
MECHANICAL
Timing Belt
5) After ensuring that the marks on timing belt and
cam sprockets are aligned, remove the stopper pin
from belt tension adjuster.
6) Install the timing belt guide. (MT model)
(1) Temporarily tighten the remaining bolts.
(2) Check and adjust the clearance between
timing belt and timing belt guide by using thick-
ness gauge.
Clearance:
1.0
±0.5 mm (0.039±0.020 in)(3) Tighten the remaining bolts.
Tightening torque:
10 N
⋅m (1.0 kgf-m, 7.2 ft-lb)
7) Install the belt cover.
8) Install the crank pulley.
9) Install the V-belt.
C: INSPECTION
1. TIMING BELT
1) Check the timing belt teeth for breaks, cracks,
and wear. If any fault is found, replace the belt.
2) Check the condition of back side of belt; if any
crack is found, replace the belt.
CAUTION:
Be careful not to let oil, grease or coolant
contact the belt. Remove quickly and thorough-
ly if this happens.
Do not bend the timing belt sharply.
In radial diameter: h
60 mm (2.36 in) or more
ME-00245
ME-00230
ME-00246
ME-00247
ME-00248
h
Page 924 of 2870
ME(H4SO)-53
MECHANICAL
Cam Sprocket
16.Cam Sprocket
A: REMOVAL
1. REMOVAL
1) Remove the V-belt.
2) Remove the crank pulley.
3) Remove the belt cover.
4) Remove the timing belt assembly.
5) Remove the camshaft position sensor.
Sensor.>
6) Remove the cam sprocket No. 2. To lock the
camshaft, use ST.
ST 18231AA010 CAM SPROCKET WRENCH
NOTE:
Also the CAM SPROCKET WRENCH (499207100)
can be used.
7) Remove the cam sprocket No. 1. Use ST to lock
the camshaft.
ST 499207400 CAM SPROCKET WRENCH
B: INSTALLATION
1) Install the cam sprocket No. 1. To lock the cam-
shaft, use ST.
ST 499207400 CAM SPROCKET WRENCH
Tightening torque:
78 N
⋅m (8.0 kgf-m, 57.9 ft-lb)
NOTE:
Do not confuse the right and left side cam sprock-
ets during installation. The cam sprocket No. 2 is
identified by a projection used to monitor camshaft
position sensor.
2) Install the cam sprocket No. 2. Use ST to lock
camshaft.
ST 18231AA010 CAM SPROCKET WRENCH
NOTE:
Also the CAM SPROCKET WRENCH (499207100)
can be used.
Tightening torque:
78 N
⋅m (8.0 kgf-m, 57.9 ft-lb)
3) Install the camshaft position sensor.
Sensor.>
4) Install the timing belt assembly.
5) Install the belt cover.
6) Install the crank pulley.
7) Install the V-belt.
ME-00250
ST
ME-00251
ST
ME-00251
ST
ME-00250
ST
Page 927 of 2870
ME(H4SO)-56
MECHANICAL
Valve Rocker Assembly
18.Valve Rocker Assembly
A: REMOVAL
1) Remove the V-belt.
2) Remove the crank pulley.
3) Remove the belt cover.
4) Remove the timing belt assembly.
5) Remove the cam sprocket.
6) Disconnect the PCV hose and remove rocker
cover.
7) Removal of valve rocker assembly
(1) Remove the bolts (a) through (h) in alpha-
betical sequence.
NOTE:
Leave two or three threads of bolts (g and h) en-
gaged to retain the valve rocker assembly.
(2) Remove the valve rocker assembly.
B: INSTALLATION
1) Installation of valve rocker assembly
(1) Temporarily tighten the bolts (a) through (d)
equally as shown in the figure.
NOTE:
Do not allow the valve rocker assembly to gouge
knock pins.
(2) Tighten the bolts (e) through (h) to specified
torque.
(3) Tighten the bolts (a) through (d) to specified
torque.Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
2) Adjust the valve clearances.
3) Install the rocker cover and connect PCV hose.
4) Install the cam sprocket.
5) Install the timing belt assembly.
6) Install the belt cover.
7) Install the crank pulley.
8) Install the V-belt.
C: DISASSEMBLY
1) Remove the bolts which secure rocker shaft.
2) Extract the rocker shaft. Remove the valve rock-
er arms, springs and shaft supports from rocker
shaft.
NOTE:
Arrange all removed parts in order so that they can
be installed in their original positions.
3) Remove the nut and adjusting screw from valve
rocker.
ME-00253(a) (b)
(c)(d)
(e)(f)
(g) (h)
ME-00254
ME-00255
(a)
(b)(c)
(d)(e)
(f)(g)
(h)
Page 928 of 2870
ME(H4SO)-57
MECHANICAL
Valve Rocker Assembly
D: ASSEMBLY
1) Install the adjusting screw and nut to valve rock-
er.
2) Arrange the valve rocker arms, springs and shaft
supports in assembly order and insert valve rocker
shaft.
Tightening torque (Shaft supports installing
bolts):
5 N
⋅m (0.5 kgf-m, 3.6 ft-lb)
NOTE:
Valve rocker arms, rocker shaft and shaft supports
have identification marks. Ensure the parts with
same markings are properly assembled.
3) Install the valve rocker shaft securing bolts.
E: INSPECTION
1. VALVE ROCKER ARM AND ROCKER
SHAFT
1) Measure the inside diameter of valve rocker arm
and outside diameter of valve rocker shaft, and de-
termine the difference between the two (= oil clear-
ance).
Clearance between arm and shaft:
Standard
0.020 — 0.054 mm (0.0008 — 0.0021 in)
Limit
0.10 mm (0.0039 in)2) If oil clearance exceeds the limit, replace the
valve rocker arm or shaft, whichever shows greater
amount of wear.
Rocker arm inside diameter:
22.020 — 22.041 mm (0.8669 — 0.8678 in)
Rocker shaft diameter:
21.987 — 22.000 mm (0.8656 — 0.8661 in)
3) If cam or valve contact surface of valve rocker
arm is worn or dented excessively, replace the
valve rocker arm.
4) Check that the valve rocker arm roller rotates
smoothly. If not, replace the valve rocker arm.
ME-00256
ME-00257
Page 930 of 2870
ME(H4SO)-59
MECHANICAL
Camshaft
16) Remove the plug from rear side of camshaft.
CAUTION:
Do not remove the oil seal unless necessary.
Do not scratch the journal surface when re-
moving oil seal.
B: INSTALLATION
1) Apply a coat of engine oil to the camshaft jour-
nals, and then install the camshaft.
2) Install the camshaft cap.
(1) Apply liquid gasket on the around of cam-
shaft cap.
Liquid gasket:
THREE BOND 1280B (Part No. K0877YA018)
NOTE:
Apply a coat of 3 mm (0.12 in) dia (A). liquid gasket
along edge (B) of the camshaft cap (C) mating sur-
face.
(2) Temporarily tighten the bolts (g) through (j)
in alphabetical sequence.(3) Install the valve rocker assembly.
(4) Tighten the bolts (a) through (h) in alphabet-
ical sequence.
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
(5) Tighten the TORX bolts (i) through (n) in al-
phabetical sequence using ST.
ST 499497000 TORX PLUS
Tightening torque:
18 N
⋅m (1.8 kgf-m, 13.0 ft-lb)
ME-00264
ME-00265
(A)
(B)
(C)
ME-00266
(g)
(h)
(j) (i)
ME-00267
ME-00268
(a)
(b)(c)
(d)(e)
(f)(g)
(h)
ME-00269
(i)
(j)(m)
(n)(k)
(l)
Page 931 of 2870
ME(H4SO)-60
MECHANICAL
Camshaft
(6) Tighten the bolts (o) through (v) in alphabet-
ical sequence.
Tightening torque:
10 N
⋅m (1.0 kgf-m, 7.2 ft-lb)
(7) Tighten the bolts (w) through (x) in alphabet-
ical sequence.
Tightening torque:
10 N
⋅m (1.0 kgf-m, 7.2 ft-lb)
3) Apply a coat of grease to oil seal lips, and then
install the oil seal (A) on camshaft using ST1 and
ST2.
NOTE:
Use a new oil seal.
ST1 499597000 OIL SEAL GUIDE
ST2 499587500 OIL SEAL INSTALLER
4) Install the plug using ST.
ST 499587700 CAMSHAFT OIL SEAL IN-
STALLER
5) Adjust the valve clearance.
6) Install the rocker cover and connect PCV hose.7) Install the oil level gauge guide. (LH side only)
8) Install the camshaft position sensor support. (LH
side only)
9) Install the tensioner bracket.
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
10) Install the belt cover No. 2 (RH).
Tightening torque:
5 N
⋅m (0.5 kgf-m, 3.6 ft-lb)
11) Install the belt cover No. 2 (LH).
Tightening torque:
5 N
⋅m (0.5 kgf-m, 3.6 ft-lb)
12) Install the crank sprocket.
13) Install the cam sprocket.
14) Install the timing belt assembly.
15) Install the belt cover.
16) Install the crank pulley.
17) Install the V-belt.
ME-00270
(o)
(r)(q)
(v)(u)
(p)(s)
(t)
ME-00271
(x) (w)
ME-00272(A)
ST2
ST1
ME-00273
ME-00274
Page 937 of 2870
ME(H4SO)-66
MECHANICAL
Cylinder Head
NOTE:
Uneven torque for the cylinder head bolts can cause
warping. When reassembling, pay special attention
to the torque so as to tighten evenly.
2. VALVE SEAT
Inspect the intake and exhaust valve seats, and
then correct the contact surfaces with valve seat
cutter if they are defective or when valve guides are
replaced.
Valve seat width: W
Intake (A)
Standard 1.1 mm (0.043 in)
Limit 1.8 mm (0.071 in)
Exhaust (B)
Standard 1.5 mm (0.059 in)
Limit 2.2 mm (0.087 in)
3. VALVE GUIDE
1) Check the clearance between valve guide and
stem. The clearance can be checked by measuring
the outside diameter of valve stem and the inside
diameter of valve guide with outside and inside mi-
crometers respectively.
Clearance between the valve guide and valve
stem:
Standard
Intake 0.035 — 0.062 mm (0.0014 — 0.0024
in)
Exhaust 0.040 — 0.067 mm (0.0016 —
0.0026 in)
Limit
0.15 mm (0.0059 in)
2) If the clearance between valve guide and stem
exceeds the standard value, replace the valve
guide or valve itself whichever shows greater
amount of wear. See the following procedure for
valve guide replacement.
Valve guide inner diameter:
6.000 — 6.012 mm (0.2362 — 0.2367 in)
Valve stem outer diameters:
Intake
5.950 — 5.965 mm (0.2343 — 0.2348 in)
Exhaust
5.945 — 5.960 mm (0.2341 — 0.2346 in)
(1) Place the cylinder head on ST1 with the
combustion chamber upward so that valve
guides enter the holes in ST1.
(A) Straight edge
(B) Thickness gauge
ST(A)
(B)
ME-00285
WW
(A) (B)
ME-00397
ME-00287
(A) Valve guide
(A)
ME-00288
ME-00289
X Y