torque SUBARU FORESTER 2004 Service Repair Manual

ME(H4DOTC)-53
MECHANICAL
V-belt
2. REAR SIDE BELT
1) Install the belt, and tighten the slider bolt (B) so
as to obtain the specified belt tension. ME(H4DOTC)-53, INSPECTION, V-belt.>
2) Tighten the lock nut (A).
Tightening torque:
Lock nut (A);
22.6 N
⋅m (2.3 kgf-m, 16.6 ft-lb)
C: INSPECTION
1) Replace the belts, if cracks, fraying or wear is
found.
2) Check the drive belt tension and adjust it if nec-
essary by changing generator installing position
and/or idler pulley installing position.
Belt tension (With using belt tension gauge)
(A)
Replaced: 640 — 780 N (65 — 80 kgf, 144 —
175 lb)
Reused: 490 — 640 N (50 — 65 kgf, 110 — 144
lb)
(B)*
Replaced: 740 — 880 N (76 — 89 kgf, 167 —
197 lb)
Reused: 350 — 450 N (36 — 46 kgf, 78 — 101
lb)
*: With air conditioner
(A)
(B)
ME-00060
(A) Front side belt
(B) Rear side belt
C/P Crank pulley
GEN Generator
P/S Power steering oil pump pulley
A/C A/C compressor pulley
I/P Idler pulley
C/P P/SA/C
GEN
(A)
(B)
I/P
PM-00154

ME(H4DOTC)-55
MECHANICAL
Crank Pulley
13.Crank Pulley
A: REMOVAL
1) Remove the V-belt. REMOVAL, V-belt.>
2) Remove the crank pulley bolt. To lock the crank-
shaft, use ST.
ST 499977400 CRANK PULLEY WRENCH
(2.0 L model)
ST 499977100 CRANK PULLEY WRENCH
(2.5 L model)
3) Remove the crank pulley.
B: INSTALLATION
1. 2.0 L MODEL
1) Install the crank pulley.
2) Install the pulley bolt.
To lock the crankshaft, use ST.
ST 499977400 CRANK PULLEY WRENCH
(1) Clean the crank pulley thread using an air
gun.
(2) Apply engine oil to the crank pulley bolt seat
and thread.
(3) Tighten the bolts temporarily with tightening
torque of 44 N⋅m (4.5 kgf-m, 33 ft-lb).
(4) Tighten the crank pulley bolts.
Tightening torque:
127 N
⋅m (13 kgf-m, 94.0 ft-lb)
3) Confirm that the tightening angle of crank pulley
bolt is 45 degrees or more. If the tightening angle of
crank pulley bolt is less than 45 degrees, conduct
the following procedures.CAUTION:
If the tightening angle of crankshaft pulley bolt
is less than 45 degrees, the bolt should be dam-
aged. In this case, the bolt must be replaced.
(1) Replace the crankshaft pulley bolts and
clean them.
Crankshaft pulley bolt:
12369AA011
(2) Clean the crankshaft thread using an air
gun.
(3) Tighten the bolts temporarily with tightening
torque of 44 N⋅m (4.5 kgf-m, 33 ft-lb).
(4) Tighten the crankshaft pulley bolts keeping
them in an angle between 45 degrees and 60
degrees.
NOTE:
Conduct the tightening procedures by confirming
the turning angle of crankshaft pulley bolt referring
to the gauge indicated on timing belt cover.
4) Install the A/C belt tensioner.
5) Install the V-belt. STALLATION, V-belt.>
2. 2.5 L MODEL
1) Install the crank pulley.
2) Install the pulley bolt.
To lock the crankshaft, use ST.
ST 499977100 CRANK PULLEY WRENCH
(1) Clean the crank pulley thread using an air
gun.
(2) Apply engine oil to the crank pulley bolt seat
and thread.
(3) Tighten the bolts temporarily with tightening
torque of 44 N⋅m (4.5 kgf-m, 33 ft-lb).
(4) Tighten the crank pulley bolts.
ME-00227
STST
ME-00227
STST
ME-00061

ME(H4DOTC)-56
MECHANICAL
Crank Pulley
Tightening torque:
180 N
⋅m (18.3 kgf-m, 132.7 ft-lb)
3) Confirm that the tightening angle of crank pulley
bolt is 65 degrees or more. If the tightening angle of
crank pulley bolt is less than 65 degrees, conduct
the following procedures.
CAUTION:
If the tightening angle of crank pulley bolt is
less than 65 degrees, the bolt should be dam-
aged. In this case, the bolt must be replaced.
(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 degrees and 75 de-
grees.
NOTE:
Conduct the tightening procedures by confirming
the turning angle of crank pulley bolt referring to the
gauge indicated on timing belt cover.
4) Install the A/C belt tensioner.
5) Install the V-belt. STALLATION, V-belt.>
C: INSPECTION
1) Make sure the V-belt is not worn or otherwise
damaged.
2) Check the tension of the belt. ME(H4DOTC)-53, INSPECTION, V-belt.>
ME-00063ST
ME-00061

ME(H4DOTC)-57
MECHANICAL
Timing Belt Cover
14.Timing Belt Cover
A: REMOVAL
1) Remove the V-belt. REMOVAL, V-belt.>
2) Remove the crank pulley. 55, REMOVAL, Crank Pulley.>
3) Remove the timing belt cover (LH) (A).
4) Remove the timing belt cover (RH) (B).
5) Remove the front timing belt cover (C).
B: INSTALLATION
1) Install the front timing belt cover (C).
Tightening torque:
5 N
⋅m (0.5 kgf-m, 3.6 ft-lb)
2) Install the timing belt cover (RH) (B).
Tightening torque:
5 N
⋅m (0.5 kgf-m, 3.6 ft-lb)
3) Install the timing belt cover (LH) (A).
Tightening torque:
5 N
⋅m (0.5 kgf-m, 3.6 ft-lb)
4) Install the crank pulley. 55, INSTALLATION, Crank Pulley.>
5) Install the V-belt. STALLATION, V-belt.>
C: INSPECTION
Make sure the cover is not damaged.
ME-00064
(A)
(C) (B)
ME-00064
(A)
(C) (B)

ME(H4DOTC)-60
MECHANICAL
Timing Belt Assembly
 Do not release the press pressure until stopper
pin is completely inserted.
(1) Attach the automatic belt tension adjuster
assembly to the vertical pressing tool.
(2) Slowly move the adjuster rod down with a
pressure of 294 N (30 kgf, 66 lb) until the adjust-
er rod is aligned with the stopper pin hole in the
cylinder.
(3) With a 2 mm (0.08 in) dia. stopper pin or a 2
mm (0.08 in) (nominal) dia. hex bar wrench in-
serted into the stopper pin hole in the cylinder,
secure the adjuster rod.
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. 2.
Tightening torque:
39 N
⋅m (4.0 kgf-m, 28.9 ft-lb)
4) Install the belt idler.
Tightening torque:
39 N
⋅m (4.0 kgf-m, 28.9 ft-lb)
2. TIMING BELT
1) Preparation for installation of automatic belt ten-
sion adjuster assembly. AUTOMATIC BELT TENSION ADJUSTER AS-
SEMBLY AND BELT IDLER, INSTALLATION,
Timing Belt Assembly.>
2) Crankshaft and camshaft sprocket alignment.
(1) Align mark (A) on the crankshaft sprocket
with mark on the oil pump cover at cylinder
block.
ME-00077
ME-00078
ME-00079
ME-00075
ME-00080
(A)
ME-00081

ME(H4DOTC)-63
MECHANICAL
Timing Belt Assembly
Align the alignment mark on timing belt with marks on sprockets in alphabetical order shown in the figure.
While aligning marks, position the timing belt properly.
CAUTION:
 Disengagement of more than three timing belt teeth may result in interference between the valve
and piston.
 Ensure the belt’s rotating direction is correct.
4) Install the belt idlers.
Tightening torque:
39 N
⋅m (4.0 kgf-m, 28.9 ft-lb)
NOTE:
Make sure that the marks on the timing belt and
sprockets are aligned.
5) After ensuring that the marks on the timing belt
and sprockets are aligned, remove the stopper pin
from tensioner adjuster.
(1) Arrow mark (4) 54.5 tooth length (7) Install it in the end
(2) Timing belt (5) 51 tooth length
(3) 28 tooth length (6) 28 tooth length
ME-00089 (1) (2)
(5)
(6) (4)
(D)
(A)
(C) (B)
(E) (3)
RH-IN
RH-EXLH-EX LH-IN
(7)
ME-00090

ME(H4DOTC)-64
MECHANICAL
Timing Belt Assembly
6) Install the timing belt guide. (MT model)
(1) Temporarily tighten the bolts.
(2) Check and adjust the clearance between
timing belt and timing belt guide.
Clearance:
1.0
±0.5 mm (0.039±0.020 in)(3) Tighten the bolts.
Tightening torque:
10 N
⋅m (1.0 kgf-m, 7.2 ft-lb)
Tightening torque:
6.4 N
⋅m (0.7 kgf-m, 5.1 ft-lb)
Tightening torque:
6.4 N
⋅m (0.7 kgf-m, 5.1 ft-lb)
Tightening torque:
6.4 N
⋅m (0.7 kgf-m, 5.1 ft-lb)
ME-00091
ME-00730
ME-00731
ME-00732
ME-00095
ME-00727
ME-00728
ME-00729

ME(H4DOTC)-66
MECHANICAL
Cam Sprocket
16.Cam Sprocket
A: REMOVAL
1) Remove the V-belt. REMOVAL, V-belt.>
2) Remove the crank pulley. ME(H4DOTC)-55, REMOVAL, Crank Pulley.>
3) Remove the timing belt cover. ME(H4DOTC)-57, REMOVAL, Timing Belt Cover.>
4) Remove the timing belt assembly. ME(H4DOTC)-58, REMOVAL, Timing Belt Assem-
bly.>
5) Remove the camshaft position sensor. (2.0 L
model) Camshaft Position Sensor.>
6) Remove the cam sprockets. To lock the cam-
shaft, use ST.
ST 499207400 CAM SPROCKET WRENCH
ST 499977500 CAM SPROCKET WRENCH
B: INSTALLATION
1) Install the cam sprocket. To lock the camshaft,
use ST.
ST 499207400 CAM SPROCKET WRENCH
Tightening torque:
98 N
⋅m (10 kgf-m, 72.4 ft-lb)
ST 499977500 CAM SPROCKET WRENCH
Tightening torque:
Tighten to 29.5 N
⋅m (3.0 kgf-m, 21.8 ft-lb) of
torque, and then tighten further by 45
°
2) Install the camshaft position sensor. FU(H4DOTC)-31, INSTALLATION, Camshaft Po-
sition Sensor.>
3) Install the timing belt assembly. ME(H4DOTC)-60, INSTALLATION, Timing Belt
Assembly.>
4) Install the timing belt cover. ME(H4DOTC)-57, INSTALLATION, Timing Belt
Cover.>
5) Install the crank pulley. 55, INSTALLATION, Crank Pulley.>
6) Install the V-belt. STALLATION, V-belt.>
C: INSPECTION
1) Check the sprocket teeth for abnormal wear and
scratches.
2) Make sure there is no free play between sprock-
et and key.
3) Check the cam sprocket notch used for sensor
for damage and contamination of foreign matter.
ME-00709
ME-00710
ME-00709
ME-00710

ME(H4DOTC)-70
MECHANICAL
Camshaft
Liquid gasket:
Part No. 004403007
THREE BOND 1215 or equivalent
 2.0 L MODEL
 2.5 L MODEL
(2) Apply engine oil to cap bearing surface and
install the cap on camshaft as shown by identifi-
cation mark (A).
(3) Gradually tighten the camshaft cap and oil
control valve assembly in at least two stages in
alphabetical sequence shown in the figure, and
then tighten to specified torque.
Tightening torque:
T1: 10 N
⋅m (1.0 kgf-m, 7 ft-lb)
T2: 20 N
⋅m (2.0 kgf-m, 14.5 ft-lb) 2.0 L MODEL
 2.5 L MODEL
(4) Similarly, tighten cap on the exhaust side.
After tightening cap, ensure the camshaft ro-
tates only slightly while holding it at “base” circle.
Tightening torque:
T1: 10 N
⋅m (1.0 kgf-m, 7 ft-lb)
T2: 20 N
⋅m (2.0 kgf-m, 14.5 ft-lb)
 2.0 L MODEL
 2.5 L MODEL
ME-00715
ME-00773
ME-00112
L E
R E
R I
L I
(A)
(B)
(A)
(E)
(F) (D)(C)
T1
ME-00716
T2
ME-00774
(A)(E)
(F)(B)(D)
(C)T2
T1
ME-00717(B)
(A)
(E)
(F) (D)(C)
T2
T1
ME-00775
(A)(E)
(F)(B)(D)
(C)T2
T1

ME(H4DOTC)-71
MECHANICAL
Camshaft
3) Camshaft oil seal installation: Apply grease to
new oil seal lips and press onto front end of cam-
shaft by using ST1 and ST2.
NOTE:
Use a new oil seal.
ST1 499587600 OIL SEAL INSTALLER
ST2 499597200 OIL SEAL GUIDE
4) Rocker cover installation:
(1) Install the gasket on rocker cover. Install the
peripheral gasket and ignition coil gasket.
(2) Apply liquid gasket to four front open edges
of peripheral gasket.
Liquid gasket:
Part No. 004403007
THREE BOND 1215 or equivalent
 2.0 L MODEL 2.5 L MODEL
(3) Install the rocker cover on cylinder head.
Ensure the gasket is properly positioned during
installation.
(4) Tighten the rocker cover tightening bolt in al-
phabetical sequence shown in the figure, and
then tighten to specified torque.
Tightening torque:
6.4 N
⋅m (0.65 kgf-m, 4.7 ft-lb)
ME-00116
ST1
ST2
ME-00759
RH
LH
ME-00776
ME-00777
(E)
(F)(H)
(G)
(D),(L) (A),(I)(C),(K)
(B),(J)