torque SUBARU FORESTER 2004 Service Repair Manual

ME(H4SO)-74
MECHANICAL
Cylinder Block
4) Tighten the 10 mm cylinder block connecting
bolts on LH side (A — D) in alphabetical sequence.
Tightening torque:
15 N
⋅m (1.5 kgf-m, 10.8 ft-lb)
5) Tighten the 10 mm cylinder block connecting
bolts on RH side (E — J) in alphabetical sequence.
Tightening torque:
15 N
⋅m (1.5 kgf-m, 10.8 ft-lb)
6) Further tighten the LH side bolts (A — D) to 90°
in alphabetical sequence.7) Further tighten the RH side bolts (E — J) to 90°
in alphabetical sequence.
8) Tighten the 8 mm and 6 mm cylinder block con-
necting bolts on LH side (A — H) in alphabetical se-
quence.
Tightening torque:
(A) — (G): 25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
(H): 6.4 N
⋅m (0.65 kgf-m, 4.7 ft-lb)
9) Install the rear oil seal using ST1 and ST2.
ST1 499597100 OIL SEAL GUIDE
ST2 499587200 OIL SEAL INSTALLER
10) Position the top ring gap at (A) or (B) in the fig-
ure.
11) Position the second ring gap at 180° on the re-
verse side for top ring gap.
 2.0 L model
ME-00398
(A)
(B)
(C) (D)
ME-00399
(E)(G)
(F)(I)
(J)
(H)
ME-00398
(A)
(B)
(C) (D)
(A) Rear oil seal
(B) Fly wheel attaching bolt
ME-00399
(E)(G)
(F)(I)
(J)
(H)
ME-00147
(B)(C)
(D)
(E)
(F)
(G)
(H)
(A)
ME-00148
ST1
ST2
(B)
(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)-78
MECHANICAL
Cylinder Block
(5) Apply liquid gasket around the service hole
plug.
Liquid gasket:
THREE BOND 1215 (Part No. 004403007) or
equivalent(6) Install the service hole plug and gasket.
NOTE:
Use a new gasket.
(7) Turn the cylinder block to face the #3 and #4
piston side upward. Using the same procedures
as used for #1 and #2 cylinders, install the pis-
tons and piston pins.
ME-00160
ME-00140
(1) Piston (5) Service hole plugTightening torque: N⋅m (kgf-m, ft-lb)
(2) Piston pin (6) Service hole coverT1: 6.4 (0.65, 4.7)
(3) Snap ring (7) O-ringT2: 70 (7.1, 51.4)
(4) Gasket
(1)(2)(3)
(1)
(2) (6)
(3)(7) (4) (5)
ME-00161
T2T1

ME(H4SO)-79
MECHANICAL
Cylinder Block
18) Install the water pipe.
19) Install the baffle plate.
Tightening torque:
6.4 N
⋅m (0.65 kgf-m, 4.7 ft-lb)
20) Install the oil strainer and O-ring.
Tightening torque:
10 N
⋅m (1.0 kgf-m, 7 ft-lb)
21) Install the oil strainer stay.
22) Apply liquid gasket to the matching surfaces,
and then install the oil pan.
Liquid gasket:
THREE BOND 1215 (Part No. 004403007) or
equivalent
Tightening torque:
6.4 N
⋅m (0.65 kgf-m, 4.7 ft-lb)
23) Apply liquid gasket to the matching surfaces,
and then install the oil separator cover.
Liquid gasket:
THREE BOND 1215 (Part No. 004403007) or
equivalentTightening torque:
6.4 N
⋅m (0.65 kgf-m, 4.7 ft-lb)
24) Install the flywheel or drive plate.
To lock the crankshaft, use ST.
ST 498497100 CRANKSHAFT STOPPER
Tightening torque:
72 N
⋅m (7.3 kgf-m, 52.8 ft-lb)
 MT model
 AT model
NOTE:
Using STs, remove the flywheel. (2.5 L MT model)
ST1 498497100 CRANKSHAFT STOPPER
ME-00300
ME-00162
ME-00163
NE-00297ST
ME-00298

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)-83
MECHANICAL
Cylinder Block
D: ASSEMBLY
1) Apply oil to the surfaces of the connecting rod
bearings.
2) Install the connecting rod bearings on connect-
ing rods and connecting rod caps.
3) Position each connecting rod with the marked
side facing forward, and then install them.
4) Install the connecting rod cap with connecting
rod nut.
Ensure the arrow on connecting rod cap faces the
front during installation.
CAUTION:
 Each connecting rod has its own mating cap.
Make sure that they are assembled correctly by
checking their matching number.
 When tightening the connecting rod nuts, ap-
ply oil on the threads.
5) Install the expander, lower rail and upper rail in
this order by hand. Then install the second ring and
top ring with a piston ring expander.
(1) Connecting rod bearing (5) Second ringTightening torque: N⋅m (kgf-m, ft-lb)
(2) Connecting rod (6) Top ringT: 45 (4.6, 33)
(3) Connecting rod cap (7) Snap ring
(4) Oil ring (8) Side mark
ME-00392
(2)
(4)
(5)
(6)
(1)
(1)
(7)(8) (3)T

EX(H4SO)-3
EXHAUST
General Description
(1) Front exhaust pipe upper cover
CTR(14) Muffler (28) Rear catalytic converter upper
cover
(15) Cushion rubber
(2) Front exhaust pipe lower cover
CTR(16) Rear exhaust pipe (29) Rear catalytic converter lower
cover
(17) Clamp
(3) Clamp (18) Center exhaust pipe upper cover (30) Rear catalytic converter
(4) Front exhaust pipe upper cover LH (19) Center exhaust pipe lower cover (31) Gasket
(5) Front exhaust pipe lower cover LH (20) Protector
(6) Front exhaust pipe (21) GasketTightening torque: N
⋅m (kgf-m, ft-lb)
(7) Front exhaust pipe lower cover RH (22) Front oxygen (A/F) sensorT1: 8 (0.8, 5.8)
(8) Front exhaust pipe upper cover
RH(23) Front catalytic converterT2: 13 (1.3, 9.4)
(24) Center exhaust pipeT3: 18 (1.8, 13.0)
(9) Gasket (25) Front catalytic converter lower
coverT4: 21 (2.1, 15.2)
(10) SpringT5: 30 (3.1, 22.4)
(11) Chamber (26) Front catalytic converter upper
coverT6: 35 (3.6, 26.0)
(12) GasketT7: 48 (4.9, 35.4)
(13) Self-locking nut (27) Rear oxygen sensor

EX(H4SO)-5
EXHAUST
General Description
(1) Front exhaust pipe upper cover
CTR(15) Rear exhaust upper cover (31) Front catalytic converter upper
cover
(16) Rear exhaust lower cover
(2) Front exhaust pipe lower cover
CTR(17) Rear catalytic lower converter
cover(32) Front oxygen (A/F) sensor
(33) Rear oxygen sensor
(3) Clamp (18) Clamp (34) Clamp
(4) Front exhaust pipe upper cover LH (19) Cushion rubber
(5) Front exhaust pipe lower cover LH (20) Rear exhaust pipeTightening torque: N
⋅m (kgf-m, ft-lb)
(6) Front exhaust pipe (21) GasketT1: 8 (0.8, 5.8)
(7) Front exhaust pipe lower cover RH (22) Self-locking nutT2: 13 (1.3, 9.4)
(8) Front exhaust pipe upper cover
RH(23) MufflerT3: 18 (1.8, 13.0)
(24) ProtectorT4: 21 (2.1, 15.2)
(9) Gasket (25) GasketT5: 30 (3.1, 22.4)
(10) Gasket (26) Front catalytic converterT6: 35 (3.6, 26.0)
(11) Spring (27) Center exhaust lower coverT7: 48 (4.9, 35.4)
(12) Chamber (28) Center exhaust upper cover
(13) Rear catalytic converter (29) Center exhaust pipe
(14) Rear catalytic converter upper
cover(30) Front catalytic converter lower
cover

EX(H4SO)-6
EXHAUST
General Description
B: CAUTION
 Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
 Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
 Keep the disassembled parts in order and pro-
tect them from dust or dirt.
 Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly, and replacement.
 Be careful not to burn your hands, because each
part on the vehicle is hot after running.
 Be sure to tighten fasteners including bolts and
nuts to the specified torque.
 Place shop jacks or rigid racks at the specified
points.
 Before disconnecting electrical connectors of
sensors or units, be sure to disconnect the ground
cable from battery.

EX(H4SO)-8
EXHAUST
Front Exhaust Pipe
9) Remove the front and center exhaust pipe as-
sembly from vehicle.
CAUTION:
 Be careful not to let the front and center ex-
haust pipe assembly fall off when removing as
it is quite heavy.
 After removing the front and center exhaust
pipe assembly, do not apply excessive pulling
force on the rear exhaust pipe.
10) Separate the front exhaust pipe from center ex-
haust pipe.
11) Remove the front oxygen (A/F) sensor and the
rear oxygen sensor. MOVAL, Front Oxygen (A/F) Sensor.> FU(H4SO)-42, REMOVAL, Rear Oxygen Sensor.>
B: INSTALLATION
1) Install the front oxygen (A/F) sensor and the rear
oxygen sensor. TION, Front Oxygen (A/F) Sensor.> FU(H4SO)-42, INSTALLATION, Rear Oxygen
Sensor.>
2) Install the front exhaust pipe to center exhaust
pipe.
NOTE:
Replace the gaskets with new ones.
Tightening torque:
30 N
⋅m (3.1 kgf-m, 22.4 ft-lb)
3) Install the front and center exhaust pipe assem-
bly to vehicle.4) Temporarily tighten the bolt which installs front
and center exhaust pipe assembly to hanger brack-
et.
5) Tighten the nuts which hold front exhaust pipe
onto cylinder heads.
Tightening torque:
30 N
⋅m (3.1 kgf-m, 22.4 ft-lb)
6) Install the under cover.
7) Tighten the bolts which install front and center
exhaust pipe assembly to rear exhaust pipe.
Tightening torque:
18 N
⋅m (1.8 kgf-m, 13.0 ft-lb)
EC-00011
EC-00011
EX-00038
EC-00009
EX-00037