torque SUBARU FORESTER 2004 Service Repair Manual

IN(H4DOTC)-15
INTAKE (INDUCTION)
Resonator Chamber
8. Resonator Chamber
A: REMOVAL
1) Set the vehicle on a lift.
2) Remove the air intake duct. IN(H4DOTC)-8, REMOVAL, Air Intake Duct.>
3) Remove the air cleaner lower case. IN(H4DOTC)-7, REMOVAL, Air Cleaner.>
4) Remove the resonator chamber mounting bolt
on the right of engine compartment.
5) Remove the front right tire, and lift the vehicle.
6) Remove the front mudguard RH.
7) Remove the resonator chamber from the inside
front fender.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
7.5 N
⋅m (0.76 kgf-m, 5.5 ft-lb)
C: INSPECTION
Inspect for cracks and loose connections. Check
that no foreign objects are mixed in the resonator
chamber.
IN-00025
IN-00026
IN-00026
IN-00025

ME(H4DOTC)-10
MECHANICAL
General Description
B: COMPONENT
1. TIMING BELT
(1) Timing belt cover No. 2 (RH) (11) Exhaust cam sprocket (LH)Tightening torque: N⋅m (kgf-m, ft-lb)
(2) Timing belt guide (12) Timing beltT1: 5 (0.5, 3.6)
(3) Crank sprocket (13) Belt idler No. 2T2: 10 (1.0, 7)
(4) Timing belt cover No. 2 (LH) (14) Belt idlerT3: 25 (2.5, 18.1)
(5) Tensioner bracket (15) Timing belt cover (LH)T4: 39 (4.0, 28.9)
(6) Automatic belt tension adjuster
ASSY(16) Front belt coverT5: INSTALLATION, Cam
Sprocket.> (17) Timing belt cover (RH)
(7) Belt idler (18) Crank pulley (2.0 L model)
(8) Exhaust cam sprocket (RH) (19) Crank pulley (2.5 L model)T6: INSTALLATION, Crank Pulley.>
(9) Intake cam sprocket (RH)
(10) Intake cam sprocket (LH)T7: 6.4 (0.65, 4.7)
ME-02008
T5
T1T6(7)(6)
(10)
(19)(5)
(14)(2)
(3)
T2
(4)
(1)(2)
(2)
T7
T4
T3
T3
T4
T5
T4
T5T1
T7(11)
(15)
(17)
(2)
(9)
(8)
(13) (14) (12)
T1
T1
T7
T1
T1
T5
(16)
T6(18)

ME(H4DOTC)-12
MECHANICAL
General Description
(1) Rocker cover (RH) (15) Intake camshaft (LH) (29) Oil flow control solenoid valve
(2) Rocker cover gasket (RH) (16) Exhaust camshaft (LH) (30) Gasket
(3) Intake camshaft cap (Front RH) (17) Intake camshaft cap (Front LH) (31) Oil return cover
(4) Intake camshaft cap (Rear RH) (18) Intake camshaft cap (Rear LH)
(5) Intake camshaft (RH) (19) Exhaust camshaft cap (Front LH)Tightening torque: N
⋅m (kgf-m, ft-lb)
(6) Exhaust camshaft cap (Front RH) (20) Exhaust camshaft cap (Center
LH)T1: INSTALLATION, Cylinder Head
Assembly.> (7) Exhaust camshaft cap (Center
RH) (21) Exhaust camshaft cap (Rear LH)
(8) Exhaust camshaft cap (Rear RH) (22) Rocker cover gasket (LH)T2: 5 (0.5, 3.6)
(9) Exhaust camshaft (RH) (23) Rocker cover (LH)T3: 8 (0.8, 5.9)
(10) Cylinder head bolt (24) Oil filler capT4: 10 (1.0, 7)
(11) Oil seal (25) GasketT5: 6.4 (0.65, 4.7)
(12) Cylinder head (RH) (26) Oil filler ductT6: 20 (2.0, 14.5)
(13) Cylinder head gasket (27) O-ring
(14) Cylinder head (LH) (28) Stud bolt

ME(H4DOTC)-14
MECHANICAL
General Description
(1) Rocker cover (RH) (15) Cylinder head (LH) (29) Oil pipe (RH)
(2) Rocker cover gasket (RH) (16) Intake camshaft (LH) (30) Stud bolt
(3) Camshaft cap (Front RH) (17) Exhaust camshaft (LH)
(4) Intake camshaft cap (Rear RH) (18) Camshaft cap (Front LH)Tightening torque: N
⋅m (kgf-m, ft-lb)
(5) Intake camshaft (RH) (19) Intake camshaft cap (Rear LH)T1: INSTALLATION, CYLINDER
HEAD ASSEMBLY.> (6) Oil flow control solenoid valve (20) Exhaust camshaft cap (Rear LH)
(7) Exhaust camshaft cap (Rear RH) (21) Rocker cover gasket (LH)
(8) Gasket (22) Rocker cover (LH)T2: 8 (0.8, 5.9)
(9) Oil return cover (23) Oil filler capT3: 10 (1.0, 7.2)
(10) Exhaust camshaft (RH) (24) GasketT4: 6.4 (0.65, 4.7)
(11) Cylinder head bolt (25) Oil filler ductT5: 20 (2.0, 14.5)
(12) Oil seal (26) O-ringT6: 29 (3.0, 21.4)
(13) Cylinder head (RH) (27) Oil pipe (LH)
(14) Cylinder head gasket (28) Gasket

ME(H4DOTC)-17
MECHANICAL
General Description
(1) Oil pressure switch (15) AdapterTightening torque: N⋅m (kgf-m, ft-lb)
(2) Cylinder block (RH) (16) Oil coolerT1: 5 (0.5, 3.6)
(3) Service hole plug (17) Waster by-pass pipe T2: 6.4 (0.65, 4.7)
(4) Gasket (18) ConnectorT3: 10 (1.0, 7.2)
(5) Oil separator cover (19) Oil strainerT4: 25 (2.5, 18.1)
(6) Water by-pass pipe (20) GasketT5: INSTALLATION, CYLINDER
BLOCK.> (7) Oil pump (21) Oil pan
(8) Front oil seal (22) Drain plug
(9) Rear oil seal (23) Metal gasketT6: 70 (7.1, 50.6)
(10) O-ring (24) Oil level gauge guideT7: First 12 (1.2, 8.7)
Second 12 (1.2, 8.7)
(11) Service hole cover (25) Oil filter
(12) Cylinder block (LH) (26) GasketT8: 16 (1.6, 11.6)
(13) Water pump (27) Water pump hoseT9: 44 (4.5, 33)
(14) Baffle plate (28) PlugT10: 25 (2.5, 18.1)
T11: 54 (5.3, 39)
T12: 45 (4.6, 33)

ME(H4DOTC)-18
MECHANICAL
General Description
5. CRANKSHAFT AND PISTON
 2.0 L MODEL
(1) Flywheel (MT model) (9) Piston pin (17) Crankshaft bearing #1, #3
(2) Ball bearing (MT model) (10) Circlip (18) Crankshaft bearing #2, #4
(3) Reinforcement (AT model) (11) Connecting rod bolt (19) Crankshaft bearing #5
(4) Drive plate (AT model) (12) Connecting rod
(5) Top ring (13) Connecting rod bearingTightening torque: N
⋅m (kgf-m, ft-lb)
(6) Second ring (14) Connecting rod capT1: 45 (4.6, 33.3)
(7) Oil ring (15) CrankshaftT2: 72 (7.3, 52.8)
(8) Piston (16) Woodruff key
ME-00005
(10)(1)
(17)
(18)(18)(13) (12) (11)
(8)(10) (10)
(9)
(16)
(19)
(10)
(9) (11) (13)
(12) (8)
(14)
(13)(14) (13) (15)
(7)(6)(5)
(17)
T2
(2)
(4)
(3)
(5)
(6) (7)
T2
T1

ME(H4DOTC)-19
MECHANICAL
General Description
 2.5 L MODEL
(1) Flywheel (MT model) (9) Piston pin (17) Crankshaft bearing #1, #3
(2) Ball bearing (MT model) (10) Circlip (18) Crankshaft bearing #2, #4
(3) Reinforcement (AT model) (11) Connecting rod bolt (19) Crankshaft bearing #5
(4) Drive plate (AT model) (12) Connecting rod
(5) Top ring (13) Connecting rod bearingTightening torque: N
⋅m (kgf-m, ft-lb)
(6) Second ring (14) Connecting rod capT1: 52 (5.3, 38.4)
(7) Oil ring (15) CrankshaftT2: 72 (7.3, 52.8)
(8) Piston (16) Woodruff key
ME-00822
T1
(5)
(6)
(7)
(10)
(8)(10)
(12)
(13)
(13)
(16)(13)
(12)
(19)
(18)
(17)
(17)(18)(10)(10)
(7)
(6)
(5)
(9)(8) (13) (15)
(14)
(11) (14)(9)
T1(11)
(1)
T2
(2)(4)
(3)
T2

ME(H4DOTC)-20
MECHANICAL
General Description
6. ENGINE MOUNTING
 2.0 L MODEL
(1) Front cushion rubberTightening torque: N⋅m (kgf-m, ft-lb)
T1: 34 (3.5, 25.3)
T2: 85 (8.7, 62.7)
ME-00407
T1T1
T2
T2
( 1 )

ME(H4DOTC)-21
MECHANICAL
General Description
 2.5 L MODEL
(1) Heat shield cover (3) Front engine mounting bracketTightening torque: N⋅m (kgf-m, ft-lb)
(2) Front cushion rubber T1: 35 (3.6, 25.8)
T2: 42 (4.3, 30.9)
T3: 85 (8.7, 62.7)
ME-00706
(3)
T3
T1
(2)
(1)
(3)
(2)
T3
T1
T2
T2

ME(H4DOTC)-22
MECHANICAL
General Description
C: 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 yourself, because each
part in 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.
 All parts should be thoroughly cleaned, paying
special attention to the engine oil passages, pis-
tons and bearings.
 Rotating parts and sliding parts such as piston,
bearing and gear should be coated with oil prior to
assembly.
 Be careful not to let oil, grease or coolant contact
the timing belt, clutch disc and flywheel.
 All removed parts, if to be reused, should be re-
installed in the original positions and directions.
 Bolts, nuts and washers should be replaced with
new ones as required.
 Even if necessary inspections have been made
in advance, proceed with assembly work while
making rechecks.
 Remove or install the engine in an area where
chain hoists, lifting devices, etc. are available for
ready use.
 Be sure not to damage coated surfaces of body
panels with tools or stain seats and windows with
coolant or oil. Place a cover over fenders, as re-
quired, for protection.
 Prior to starting work, prepare the following:
Service tools, clean cloth, containers to catch cool-
ant and oil, wire ropes, chain hoist, transmission
jacks, etc.
 Lift-up or lower the vehicle when necessary.
Make sure to support the correct positions.