lock SUBARU FORESTER 2004 Service Repair Manual

ME(H4DOTC)-106
MECHANICAL
Cylinder Block
2.0 L MODEL
Standard diameter:
A: 92.005 — 92.015 mm (3.6222 — 3.6226 in)
B: 91.995 — 92.005 mm (3.6218 — 3.6222 in)
2.5 L MODEL
Standard diameter:
A: 99.505 — 99.515 mm (3.9175 — 3.9179 in)
B: 99.495 — 99.505 mm (3.9171 — 3.9175 in)
2) How to measure the inner diameter of each cyl-
inder:
Measure the inner diameter of each cylinder in both
the thrust and piston pin directions at the heights
shown in the figure, using a cylinder bore gauge.
NOTE:
Measurement should be performed at a tempera-
ture of 20°C (68°F).
Taper:
Standard
0.015 mm (0.0006 in)
Limit
0.050 mm (0.0020 in)Out-of-roundness:
Standard
0.010 mm (0.0004 in)
Limit
0.050 mm (0.0020 in)
3) When the piston is to be replaced due to general
or cylinder wear, determine a suitable sized piston
by measuring the piston clearance.
4) How to measure the outer diameter of each pis-
ton:
Measure the outer diameter of each piston at the
height shown in the figure. (Thrust direction)
NOTE:
Measurement should be performed at a tempera-
ture of 20°C (68°F).
(A) Main journal size mark
(B) Cylinder block (RH)-(LH) combination mark
(C) #1 cylinder bore size mark
(D) #2 cylinder bore size mark
(E) #3 cylinder bore size mark
(F) #4 cylinder bore size mark
ME-00170 #5
#4
#3
#2
#1(A)(B)
(F)
(D)
A BA B
5 45 4
(C) (E)
(A) Piston pin direction
(B) Thrust direction
H1: 10 mm (0.39 in)
H2: 45 mm (1.77 in)
H3: 80 mm (3.15 in)
H4: 115 mm (4.53 in)
ME-00171
(A)
(B)
H2 H1
H3
H4

ME(H4DOTC)-107
MECHANICAL
Cylinder Block
2.0 L MODEL
Piston grade point H:
40.0 mm (1.57 in)
Piston outer diameter:
Standard
A: 91.985 — 91.995 mm
(3.6214 — 3.6218 in)
B: 91.975 — 91.985 mm
(3.6211 — 3.6214 in)
0.25 mm (0.0098 in) oversize
92.225 — 92.235 mm
(3.6309 — 3.6313 in)
0.50 mm (0.0197 in) oversize
92.475 — 92.485 mm
(3.6407 — 3.6411 in)
2.5 L MODEL
Piston grade point H:
38.2 mm (1.50 in)
Piston outer diameter:
Standard
A: 99.505 — 99.515 mm
(3.9175 — 3.9179 in)
B: 99.495 — 99.505 mm
(3.9171 — 3.9175 in)
0.25 mm (0.0098 in) oversize
99.745 — 99.765 mm
(3.9270 — 3.9278 in)
0.50 mm (0.0197 in) oversize
99.995 — 100.015 mm
(3.9368 — 3.9376 in)
5) Calculate the clearance between cylinder and
piston.
NOTE:
Measurement should be performed at a tempera-
ture of 20°C (68°F).
Cylinder to piston clearance at 20
°C (68°F):
2.0 L MODEL
Standard
0.010 — 0.030 mm (0.0004 — 0.0012 in)
Limit
0.050 mm (0.0020 in)2.5 L MODEL
Standard
−0.010 — 0.010 mm (−0.0004 — 0.0004 in)
Limit
0.030 mm (0.0012 in)
6) Boring and honing:
(1) If the value of taper, out-of-roundness, or
cylinder-to-piston clearance measured exceeds
the specified limit or if there is any damage on
the cylinder wall, reboring it to use an oversize
piston.
CAUTION:
When any of the cylinders needs reboring, all
other cylinders must be bored at the same time,
and use oversize pistons. Do not perform bor-
ing on one cylinder only, nor use an oversize
piston for one cylinder only.
(2) If the cylinder inner diameter exceeds the
limit after boring and honing, replace the crank-
case.
NOTE:
Immediately after reboring, the cylinder diameter
may differ from its real diameter due to temperature
rise. Thus, pay attention to this when measuring
the cylinder diameter.
Limit of cylinder enlarging (boring):
0.5 mm (0.020 in)
3. PISTON AND PISTON PIN
1) Check the pistons and piston pins for damage,
cracks and wear, Replace if defective.
2) Check the piston ring grooves for wear and dam-
age, Replace if defective.
3) Measure the piston-to-cylinder clearance at
each cylinder. DER AND PISTON, INSPECTION, Cylinder
Block.> If any of the clearances is not within speci-
fication, replace the piston or bore the cylinder to
use an oversize piston.
ME-00172
H

ME(H4DOTC)-108
MECHANICAL
Cylinder Block
4) Make sure that the piston pin can be inserted
into the piston pin hole with a thumb at 20°C (68°F).
Replace if defective.
Standard clearance between piston pin and
hole in piston:
Standard
0.004 — 0.008 mm (0.0002 — 0.0003 in)
Limit
0.020 mm (0.0008 in)
5) Check the circlip installation groove on piston for
burr (A). If necessary, remove the burr from groove
so that the piston pin can lightly move.
6) Check the piston pin circlip for distortion, cracks
and wear.4. PISTON RING
1) If the piston ring is broken, damaged, or worn, or
if its tension is insufficient, or when the piston is re-
placed, replace the piston ring with a new one of
the same size as the piston.
NOTE:
 Marks are shown on the end of top and second
rings. When installing the rings to piston, face this
mark upward.
 Oil ring consists of upper rail, expander and low-
er rail. When installing on piston, be careful of each
rail’s direction.
ME-00173
ME-00174
ME-00175
(A)
(A) Upper rail
(B) Expander
(C) Lower rail
ME-00375(A)
(B)
(C)
(A)
(B)
(C)

ME(H4DOTC)-109
MECHANICAL
Cylinder Block
2) Squarely place the piston ring and oil ring in cyl-
inder, and then measure the piston ring gap with a
thickness gauge.
 2.0 L MODEL
 2.5 L MODEL
3) Measure the clearance between piston ring and
piston ring groove with a thickness gauge.
NOTE:
Before measuring the clearance, clean the piston
ring groove and piston ring.
5. CONNECTING ROD
1) Replace the connecting rod, if the large or small
end thrust surface is damaged.
2) Check for bend or twist using a connecting rod
aligner. Replace the connecting rod if the bend or
twist exceeds the limit.
Limit of bend or twist per 100 mm (3.94 in) in
length:
0.10 mm (0.0039 in)
Unit: mm (in)
Standard Limit
Piston
ring gapTop ring0.20 — 0.25
(0.0079 — 0.0098)1.0 (0.039)
Second
ring0.35 — 0.50
(0.0138 — 0.0197)1.0 (0.039)
Oil ring
rail0.20 — 0.50
(0.0079 — 0.0197)1.5 (0.059)
Unit: mm (in)
Standard Limit
Piston
ring gapTop ring0.20 — 0.25
(0.0079 — 0.0098)1.0 (0.039)
Second
ring0.37 — 0.52
(0.015 — 0.020)1.0 (0.039)
Oil ring
rail0.20 — 0.50
(0.0079 — 0.0197)1.5 (0.059)
Unit: mm (in)
Standard Limit
Clearance
between
piston ring
and piston
ring grooveTop ring0.040 — 0.080
(0.0016 — 0.0031)0.15 (0.0059)
Second
ring0.030 — 0.070
(0.0012 — 0.0028)0.15 (0.0059)
ME-00177
(A) Thickness gauge
(B) Connecting rod
ME-00178
(A)
(A) (B)
(B)
ME-00179

ME(H4DOTC)-110
MECHANICAL
Cylinder Block
3) Install the connecting rod fitted with bearing to
crankshaft, and then measure the side clearance
(thrust clearance). Replace the connecting rod if
the side clearance exceeds the specified limit.
Connecting rod side clearance:
Standard
0.070 — 0.330 mm (0.0028 — 0.0130 in)
Limit
0.40 mm (0.016 in)
4) Inspect the connecting rod bearing for scar,
peeling, seizure, melting, wear, etc.
5) Measure the oil clearance on individual connect-
ing rod bearings by means of plastigage. If any oil
clearance is not within specification, replace the
defective bearing with a new one of standard size
or undersize as necessary (See the table).
2.0 L MODEL
Connecting rod oil clearance:
Standard
0.020 — 0.046 mm (0.0008 — 0.0018 in)
Limit
0.050 mm (0.0020 in)2.5 L MODEL
Connecting rod oil clearance:
Standard
0.017 — 0.045 mm (0.0007 — 0.0018 in)
Limit
0.05 mm (0.0020 in)
6) Inspect the bushing at connecting rod small end,
and replace if worn or damaged. Also measure the
piston pin clearance at connecting rod small end.
Clearance between piston pin and bushing:
Standard
0 — 0.022 mm (0 — 0.0009 in)
Limit
0.030 mm (0.0012 in)
Unit: mm (in)
BearingBearing size
(Thickness at cen-
ter)Outer diameter of
crank pin
Standard1.486 — 1.498
(0.0585 — 0.0590)51.984 — 52.000
(2.0466 — 2.0472)
0.03
(0.0012)
undersize1.504 — 1.512
(0.0592 — 0.0595)51.954 — 51.970
(2.0454 — 2.0461)
0.05
(0.0020)
undersize1.514 — 1.522
(0.0596 — 0.0599)51.934 — 51.950
(2.0447 — 2.0453)
0.25
(0.0098)
undersize1.614 — 1.622
(0.0635 — 0.0639)51.734 — 51.750
(2.0368 — 2.0374)
ME-00180
Unit: mm (in)
BearingBearing size
(Thickness at cen-
ter)Outer diameter of
crank pin
Standard1.490 — 1.502
(0.0587 — 0.0591)51.984 — 52.000
(2.0466 — 2.0472)
0.03
(0.0012)
undersize1.504 — 1.512
(0.0592 — 0.0595)51.954 — 51.970
(2.0454 — 2.0461)
0.05
(0.0020)
undersize1.514 — 1.522
(0.0596 — 0.0599)51.934 — 51.950
(2.0447 — 2.0453)
0.25
(0.0098)
undersize1.614 — 1.622
(0.0635 — 0.0639)51.734 — 51.750
(2.0368 — 2.0374)
ME-00181
ME-00174

ME(H4DOTC)-111
MECHANICAL
Cylinder Block
7) Replacement procedure is as follows:
(1) Remove the bushing from connecting rod
with ST and press.
(2) Press the bushing with ST after applying oil
on the periphery of bushing.
ST 499037100 CONNECTING ROD BUSH-
ING REMOVER AND IN-
STALLER
(3) Make two 3 mm (0.12 in) holes in bushing.
Ream the inside of bushing.
(4) After the completion of reaming, clean the
bushing to remove chips.
6. CRANKSHAFT AND CRANKSHAFT
BEARING
1) Clean the crankshaft completely and check for
cracks by means of red lead check etc., and re-
place if defective.
2) Measure the crankshaft bend, and correct or re-
place if it exceeds the limit.
NOTE:
If a suitable V-block is not available, install the #1
and #5 crankshaft bearing on cylinder block, posi-
tion the crankshaft on these bearings and measure
the crankshaft bend using a dial gauge.
Crankshaft bend limit:
0.035 mm (0.0014 in)
3) Inspect the crank journal and crank pin for wear.
If they are not within the specifications, replace the
bearing with a suitable (undersize) one, and then
replace or recondition the crankshaft as necessary.
When grinding the crank journal or crank pin, finishthem to specified dimensions according to the un-
dersize bearing to be used.
Crank pin and crank journal:
Out-of-roundness
0.005 mm (0.0002 in) or less
Taper limit
0.07 mm (0.0028 in)
Grinding limit
0.250 mm (0.0098 in)
ME-00182
ST
ME-00183
ME-00184

ME(H4DOTC)-112
MECHANICAL
Cylinder Block
 2.0 L MODEL
O.D.: Outer Diameter
 2.5 L MODEL
O.D.: Outer DiameterUnit: mm (in)
Crank journal diameter
Crank pin diameter
#1, #3, #5 #2, #4
StandardJournal O.D.59.992 — 60.008
(2.3619 — 2.3625)59.992 — 60.008
(2.3619 — 2.3625)51.984 — 52.000
(2.0466 — 2.0472)
Bearing size
(Thickness at cen-
ter)1.998 — 2.011
(0.0787 — 0.0792)2.000 — 2.013
(0.0787 — 0.0793)1.486 — 1.498
(0.0585 — 0.0590)
0.03 (0.0012)
undersizeJournal O.D.59.962 — 59.978
(2.3607 — 2.3613)59.962 — 59.978
(2.3607 — 2.3613)51.954 — 51.970
(2.0454 — 2.0461)
Bearing size
(Thickness at cen-
ter)2.017 — 2.020
(0.0794 — 0.0795)2.019 — 2.022
(0.0795 — 0.0796)1.504 — 1.512
(0.0592 — 0.0595)
0.05 (0.0020)
undersizeJournal O.D.59.942 — 59.958
(2.3599 — 2.3605)59.942 — 59.958
(2.3599 — 2.3605)51.934 — 51.950
(2.0447 — 2.0453)
Bearing size
(Thickness at cen-
ter)2.027 — 2.030
(0.0798 — 0.0799)2.029 — 2.032
(0.0799 — 0.0800)1.514 — 1.522
(0.0596 — 0.0599)
0.25 (0.0098)
undersizeJournal O.D.59.742 — 59.758
(2.3520 — 2.3527)59.742 — 59.758
(2.3520 — 2.3527)51.734 — 51.750
(2.0368 — 2.0374)
Bearing size
(Thickness at cen-
ter)2.127 — 2.130
(0.0837 — 0.0839)2.129 — 2.132
(0.0838 — 0.0839)1.614 — 1.622
(0.0635 — 0.0639)
Unit: mm (in)
Crank journal diameter
Crank pin outer diameter
#1, #3, #5 #2, #4
StandardJournal O.D.59.992 — 60.008
(2.3619 — 2.3625)59.992 — 60.008
(2.3619 — 2.3625)51.984 — 52.000
(2.0466 — 2.0472)
Bearing size
(Thickness at cen-
ter)1.998 — 2.011
(0.0787 — 0.0792)2.000 — 2.013
(0.0787 — 0.0793)1.490 — 1.502
(0.0587 — 0.0591)
0.03 (0.0012)
undersizeJournal O.D.59.962 — 59.978
(2.3607 — 2.3613)59.962 — 59.978
(2.3607 — 2.3613)51.954 — 51.970
(2.0454 — 2.0461)
Bearing size
(Thickness at cen-
ter)2.017 — 2.020
(0.0794 — 0.0795)2.019 — 2.022
(0.0795 — 0.0796)1.504 — 1.512
(0.0592 — 0.0595)
0.05 (0.0020)
undersizeJournal O.D.59.942 — 59.958
(2.3599 — 2.3605)59.942 — 59.958
(2.3599 — 2.3605)51.934 — 51.950
(2.0447 — 2.0453)
Bearing size
(Thickness at cen-
ter)2.027 — 2.030
(0.0798 — 0.0799)2.029 — 2.032
(0.0799 — 0.0800)1.514 — 1.522
(0.0596 — 0.0599)
0.25 (0.0098)
undersizeJournal O.D.59.742 — 59.758
(2.3520 — 2.3527)59.742 — 59.758
(2.3520 — 2.3527)51.734 — 51.750
(2.0368 — 2.0374)
Bearing size
(Thickness at cen-
ter)2.127 — 2.130
(0.0837 — 0.0839)2.129 — 2.132
(0.0838 — 0.0839)1.614 — 1.622
(0.0635 — 0.0639)

ME(H4DOTC)-113
MECHANICAL
Cylinder Block
4) Measure the thrust clearance of crankshaft at
center bearing. If the clearance exceeds the limit,
replace the bearing.
Crankshaft thrust clearance:
Standard
0.030 — 0.115 mm (0.0012 — 0.0045 in)
Limit
0.25 mm (0.0098 in)
5) Inspect individual crankshaft bearings for signs
of flaking, seizure, melting and wear.6) Measure the oil clearance on each crankshaft
bearing by means of plastigage. If the measure-
ment is not within the specification, replace the de-
fective bearing with an undersize one, and replace
or recondition the crankshaft as necessary.
Crankshaft oil clearance:
Standard
0.010 — 0.030 mm (0.0004 — 0.0012 in)
Limit
0.040 mm (0.0016 in)
ME-00313

ME(H4DOTC)-115
MECHANICAL
Piston
22.Piston
A: REMOVAL AND INSTALLATION
For operations related to piston, refer to “20. Cylin-
der Block.” Cylinder Block.> STALLATION, Cylinder Block.>

ME(H4DOTC)-116
MECHANICAL
Connecting Rod
23.Connecting Rod
A: REMOVAL AND INSTALLATION
For operations related to connecting rod, refer to
“20. Cylinder Block.” REMOVAL, Cylinder Block.> ME(H4DOTC)-88, INSTALLATION, Cylinder
Block.>