lock SUBARU FORESTER 2004 Service Repair Manual

ME(H4DOTC)-96
MECHANICAL
Cylinder Block
1) Remove oil in the mating surface of bearing and
cylinder block before installation. Apply a coat of
engine oil to crankshaft pins.
2) Install crankshaft bearings on the cylinder block,
apply a coat of engine oil to crankshaft bearings,
and position the crankshaft on #2 and #4 cylinder
block.
3) Apply liquid gasket to the mating surface of #1
and #3 cylinder block, and position it on #2 and #4
cylinder block.
Liquid gasket:
Part No. 004403007
THREE BOND 1215 or equivalent
NOTE:
Do not allow liquid gasket to jut into O-ring grooves,
oil passages, bearing grooves, etc.
4) Apply engine oil to washers and thread of bolts.
5) Tighten the 10 mm cylinder block connecting
bolts in alphabetical sequence shown in the figure.
(LH side)
Tightening torque:
10 N
⋅m (1.0 kgf-m, 7.2 ft-lb)6) Tighten the 10 mm cylinder block connecting
bolts in alphabetical sequence shown in the figure.
(RH side)
Tightening torque:
10 N
⋅m (1.0 kgf-m, 7.2 ft-lb)
7) Further tighten the LH side bolts (A — D) in al-
phabetical sequence.
Tightening torque:
(A), (C): 20 N
⋅m (2.0 kgf-m, 14.8 ft-lb)
(B), (D): 15 N
⋅m (1.5 kgf-m, 10.8 ft-lb)
8) Further tighten the RH side bolts (E — J) in al-
phabetical sequence.
ME-00145
ME-00779
(A)
(B)
(D)
(C)
ME-00780
(J)
(H)
(G)
(E)
(F)(I)
ME-00779
(A)
(B)
(D)
(C)

ME(H4DOTC)-97
MECHANICAL
Cylinder Block
Tightening torque:
(E), (F), (G), (I): 20 N
⋅m (2.0 kgf-m, 14.8 ft-lb)
(H), (J): 18 N
⋅m (1.8 kgf-m, 13.3 ft-lb)
9) Further tighten the LH side bolts (A — D) by 90°
in alphabetical sequence.
10) Further tighten the RH side bolts (E — J) by 90°
in alphabetical sequence.11) Tighten the 8 mm and 6 mm cylinder block con-
necting bolts in alphabetical sequence shown in the
figure.
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)
12) Install the rear oil seal using ST1 and ST2.
ST1 499597100 CRANKSHAFT OIL SEAL
GUIDE
ST2 499587200 CRANKSHAFT OIL SEAL IN-
STALLER
13) Position the top ring gap at (A) or (B) in the fig-
ure.
14) Position the second ring gap at 180° on the re-
verse side for the top ring gap.
ME-00780
(J)
(H)
(G)
(E)
(F)(I)
ME-00779
(A)
(B)
(D)
(C)
ME-00780
(J)
(H)
(G)
(E)
(F)(I)
(A) Rear oil seal
(B) Flywheel attaching bolt
ME-00147
(B)(C)
(D)
(E)
(F)
(G)
(H)
(A)
ME-00148
ST1
ST2
(B)
(A)
ME-00781
(A)(B) 180

ME(H4DOTC)-98
MECHANICAL
Cylinder Block
15) Position the upper rail gap at (C) in the figure.
16) Align upper rail spin stopper (D) with piston
side surface hole (E).
17) Position the expander gap at (F) in the figure.
18) Position the lower rail gap at (G) in the figure.
NOTE:
 Ensure ring gaps do not face the same direction.
 Ensure ring gaps are not within the piston skirt
area.
ME-00782
(D)
(C)
25
ME-00783
(E)(D)
ME-00784
(F)
25
ME-00785
35(G)

ME(H4DOTC)-99
MECHANICAL
Cylinder Block
19) Install the circlip.
Install the circlips in piston holes located opposite
of service holes in cylinder block, when positioning
all pistons in the corresponding cylinders.NOTE:
Use new circlips.
20) Installing the piston:
(1) Turn the cylinder block so that #1 and #2 cyl-
inders face 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 the pistons and
cylinders and insert pistons in their cylinders us-
ing ST2.
ST2 498747300 PISTON GUIDE
(A) Front side
ME-00154
#4 #3
#2 #1
(A)
(1) Piston (4) GasketTightening torque: N⋅m (kgf-m, ft-lb)
(2) Piston pin (5) Service hole plugT: 70 (7.1, 51.4)
(3) Circlip
ME-00155
(1) (1)
(2)
(2) (3)
(3) (4)
(4) (5)
(5)
T
ME-00157
ST2
ST1

ME(H4DOTC)-100
MECHANICAL
Cylinder Block
NOTE:
Piston front mark faces towards the front of the en-
gine.
21) Installing piston pin:
(1) Apply a coat of engine oil to ST3.
(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 insert piston pin into piston and connecting
rod through service hole.
(4) Using the needle nose plier, install the cir-
clip.
NOTE:
Use new circlips.(5) Apply liquid gasket around the service hole
plug.
Liquid gasket:
Part No. 004403007
THREE BOND 1215 or equivalent
(6) Install the service hole plug and gasket.
NOTE:
Use a new gasket.
(A) Front mark
ME-00786
(A)
ME-00158
ST1ST3
ME-00159
ME-00160
ME-00140

ME(H4DOTC)-101
MECHANICAL
Cylinder Block
(7) Turn the cylinder block so that #3 and #4 cyl-
inders face upward. Using the same procedures
as used for #1 and #2 cylinders, install the pis-
tons and piston pins.
22) Install the water pipe.
23) Install the baffle plate.
Tightening torque:
6.4 N
⋅m (0.65 kgf-m, 4.7 ft-lb)
24) Install the oil strainer and O-ring
Tightening torque:
10 N
⋅m (1.0 kgf-m, 7 ft-lb)
25) Install the oil strainer stay.
26) Apply liquid gasket to the matching surfaces,
and then install the oil pan.
Liquid gasket:
Part No. 004403007
THREE BOND 1215 or equivalentTightening torque:
5 N
⋅m (0.5 kgf-m, 3.6 ft-lb)
(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) Circlip (7) O-ringT2: 70 (7.1, 51.4)
(4) Gasket
(1)(2)(3)
(1)
(2) (6)
(3)(7) (4) (5)
ME-00161
T2T1
ME-00162

ME(H4DOTC)-102
MECHANICAL
Cylinder Block
27) Apply liquid gasket to the matching surfaces,
and then install the oil separator cover.
Liquid gasket:
Part No. 004403007
THREE BOND 1215 or equivalent
Tightening torque:
6.4 N
⋅m (0.65 kgf-m, 4.7 ft-lb)
28) Install the drive plate. (AT model)
To lock the crankshaft, use ST.
ST 498497100 CRANKSHAFT STOPPER
Tightening torque:
72 N
⋅m (7.3 kgf-m, 52.8 ft-lb)
29) Install the flywheel. TION, Flywheel.>
30) Install the clutch disc and cover. 16, INSTALLATION, Clutch Disc and Cover.>
31) 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:
Part No. 004403007
THREE BOND 1215 or equivalent
(3) Apply a coat of engine oil to the inside of the
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)
NOTE:
 Do not forget to install the O-ring and seal when
installing the oil pump.
 Align the flat surface of oil pump’s inner rotor with
crankshaft before installation.
32) 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)
ME-00163
ME-00136
ST
ME-00164
(A) O-ring
ME-00165
(A)
ME-00312

ME(H4DOTC)-103
MECHANICAL
Cylinder Block
NOTE:
 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.
33) Install the water by-pass pipe for heater.
34) Install the oil cooler.
Tightening torque:
T1: 45 N
⋅m (4.6 kgf-m, 33 ft-lb)
T2: 6.4 N
⋅m (0.65 kgf-m, 4.7 ft-lb)
T3: 54 N
⋅m (5.3 kgf-m, 39 ft-lb)
35) Install the oil filter using ST. LU(H4SO)-23, INSTALLATION, Engine Oil Filter.>
ST 498547000 OIL FILTER WRENCH36) Install the water by-pass pipe between oil cool-
er and water pump.
37) Install the water pipe.
CAUTION:
Always use a new O-ring.
38) Install the cylinder head assembly. ME(H4DOTC)-76, INSTALLATION, Cylinder Head
Assembly.>
39) Install the oil level gauge guide and tighten the
attaching bolt (LH side).
40) Install the rocker cover.
41) Install the crank sprocket. ME(H4DOTC)-68, INSTALLATION, Crank Sprock-
et.>
42) Install the cam sprocket. ME(H4DOTC)-67, INSTALLATION, Cam Sprock-
et.>
43) Install the timing belt assembly. ME(H4DOTC)-60, INSTALLATION, Timing Belt
Assembly.>
44) Install the timing belt cover. ME(H4DOTC)-57, INSTALLATION, Timing Belt
Cover.>
45) Install the crank pulley. 55, INSTALLATION, Crank Pulley.>
46) Install the generator and A/C compressor
brackets on cylinder head.
47) Install the V-belt. INSTALLATION, V-belt.>
48) Install the intake manifold. FU(H4DOTC 2.5)-17, INSTALLATION, Intake
Manifold.>
(A) Adapter (1)
(B) Adapter connector
(C) Adapter (2)
(D) Oil cooler
(E) Oil cooler connector
ME-00167
(B) (C) (D)(E)(F)
(A)
LU-00044
(A)
(B)
(C)
(D)
(E)
T1
T2
T3

ME(H4DOTC)-104
MECHANICAL
Cylinder Block
C: DISASSEMBLY
1) Remove the connecting rod cap.
2) Remove the connecting rod bearing.
NOTE:
Arrange the removed connecting rod, connecting
rod cap and bearing in order to prevent confusion.
3) Remove the piston rings using the piston ring ex-
pander.
4) Remove the oil ring by hand.
NOTE:
Arrange the removed piston rings in proper order to
prevent confusion.
5) Remove the circlip.
(1) Connecting rod cap (3) Top ring (5) Oil ring
(2) Connecting rod bearing (4) Second ring (6) Circlip
ME-00168
(2)
(2)
(6)(5)
(4)
(3) (1)

ME(H4DOTC)-105
MECHANICAL
Cylinder Block
D: ASSEMBLY
1) Apply oil to the surfaces of the connecting rod
bearings. Install the connecting rod bearings on
connecting rods and connecting rod caps.
2) Install the connecting rod on crankshaft.
NOTE:
Position each connecting rod with the side marked
facing forward.
3) Install the connecting rod cap with connecting
rod nut.
Ensure the arrow on connecting rod cap faces the
front during installation.
NOTE:
 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, apply
oil on the threads.
4) Install the oil ring spacer, upper rail and lower rail
in this order by hand. Then install the second ring
and top ring with a piston ring expander.E: INSPECTION
1. CYLINDER BLOCK
1) Visually check for cracks and damage. Especial-
ly, inspect the important parts by means of red lead
check.
2) Check the oil passages for clogging.
3) Inspect the crankcase surface that mates with
cylinder head for warping by using a straight edge,
and correct by grinding if necessary.
Warping limit:
0.05 mm (0.0020 in)
Grinding limit:
0.1 mm (0.004 in)
Standard height of cylinder block:
201.0 mm (7.91 in)
2. CYLINDER AND PISTON
1) The cylinder bore size is stamped on cylinder
block’s front upper surface.
NOTE:
 Measurement should be performed at a temper-
ature of 20°C (68°F).
 Standard sized pistons are classified into two
grades, “A” and “B”. These grades should be used
as a guide line in selecting a standard piston.
(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) Circlip
(4) Oil ring (8) Side mark
ME-00169
(2)
(4)
(5)
(6)
(1)
(1)
(7)(8) (3)T