engine SUBARU FORESTER 2004 Service Repair Manual
[x] Cancel search | Manufacturer: SUBARU, Model Year: 2004, Model line: FORESTER, Model: SUBARU FORESTER 2004Pages: 2870, PDF Size: 38.67 MB
Page 1551 of 2870
ME(H4DOTC)-91
MECHANICAL
Cylinder Block
19) 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.
(A) Front mark
ME-00722
(A)
ME-00158
ST1ST3
ME-00159
ME-00160
Page 1554 of 2870
ME(H4DOTC)-94
MECHANICAL
Cylinder Block
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.30) 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)
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.
31) Install the water by-pass pipe for heater.
32) 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)
(A) O-ring
ME-00165
(A)
ME-00312
(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
Page 1555 of 2870
ME(H4DOTC)-95
MECHANICAL
Cylinder Block
33) Install the oil filter using ST.
34) Install the water by-pass pipe between oil cool-
er and water pump.
35) Install the water pipe.
NOTE:
Always use a new O-ring.
36) Install the cylinder head assembly.
Assembly.>
37) Install the oil level gauge guide and tighten the
attaching bolt (LH side).
38) Install the rocker cover.
39) Install the crank sprocket.
et.>40) Install the cam sprocket.
et.>
41) Install the timing belt assembly.
Assembly.>
42) Install the timing belt cover.
Cover.>
43) Install the crank pulley.
44) Install the generator and A/C compressor
brackets on cylinder head.
45) Install the V-belt.
46) Install the intake manifold.
fold.>
2. 2.5 L MODEL
(1) Crankshaft bearing (3) Cylinder block (4) Rear oil seal
(2) Crankshaft
ME-00144
( 1 )
( 1 )
( 2 )
( 3 )
( 3 )
( 4 )
Page 1556 of 2870
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)
Page 1559 of 2870
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
Page 1560 of 2870
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
Page 1562 of 2870
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.
30) Install the 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
Page 1563 of 2870
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.
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.
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.
et.>
42) Install the cam sprocket.
et.>
43) Install the timing belt assembly.
Assembly.>
44) Install the timing belt cover.
Cover.>
45) Install the crank pulley.
46) Install the generator and A/C compressor
brackets on cylinder head.
47) Install the V-belt.
48) Install the intake manifold.
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
Page 1578 of 2870
ME(H4DOTC)-118
MECHANICAL
Engine Trouble in General
25.Engine Trouble in General
A: INSPECTION
NOTE:
“RANK” shown in the chart refers to the possibility of reason for the trouble in order (“Very often” to “Rarely”)
A — Very often
B — Sometimes
C — Rarely
TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK
1. Engine will not start.
1) Starter does not turn. Starter Defective battery-to-starter harness B
Defective starter switch C
Defective inhibitor switch or neutral switch C
Defective starter B
Battery Poor terminal connection A
Run-down battery A
Defective charging system B
Friction Seizure of crankshaft and connecting rod bearing C
Seized camshaft C
Seized or stuck piston and cylinder C
2) Initial combustion does
not occur. Starter Defective starter C
Engine control system
Fuel line Defective fuel pump and relay A
Lack of or insufficient fuel B
Belt Defective (deterioration, etc.) B
Defective timing B
Compression Incorrect valve clearance C
Loosened spark plugs or defective gasket C
Loosened cylinder head bolts or defective gasket C
Improper valve seating C
Defective valve stem C
Worn or broken valve spring B
Worn or stuck piston rings, cylinder and piston C
Incorrect valve timing B
Improper engine oil (low viscosity) B
3) Initial combustion occurs. Engine control system
Intake system Defective intake manifold gasket B
Defective throttle body gasket B
Fuel line Defective fuel pump and relay C
Clogged fuel line C
Lack of or insufficient fuel B
Belt Defective (deterioration, etc.) B
Defective timing B
Compression Incorrect valve clearance C
Loosened spark plugs or defective gasket C
Loosened cylinder head bolts or defective gasket C
Improper valve seating C
Defective valve stem C
Worn or broken valve spring B
Worn or stuck piston rings, cylinder and piston C
Incorrect valve timing B
Improper engine oil (low viscosity) B
Page 1579 of 2870
ME(H4DOTC)-119
MECHANICAL
Engine Trouble in General
4) Engine stalls after initial
combustion. Engine control system
Intake system Loosened or cracked intake duct B
Loosened or cracked PCV hose C
Loosened or cracked vacuum hose C
Defective intake manifold gasket B
Defective throttle body gasket B
Dirty air cleaner element C
Fuel line Clogged fuel line C
Lack of or insufficient fuel B
Belt Defective (deterioration, etc.) B
Defective timing B
Compression Incorrect valve clearance C
Loosened spark plugs or defective gasket C
Loosened cylinder head bolts or defective gasket C
Improper valve seating C
Defective valve stem C
Worn or broken valve spring B
Worn or stuck piston rings, cylinder and piston C
Incorrect valve timing B
Improper engine oil (low viscosity) B
2. Rough idle and engine
stallEngine control system
Intake system Loosened or cracked intake duct A
Loosened or cracked PCV hose A
Loosened or cracked vacuum hose A
Defective intake manifold gasket B
Defective throttle body gasket B
Defective PCV valve C
Loosened oil filler cap B
Dirty air cleaner element C
Fuel line Defective fuel pump and relay C
Clogged fuel line C
Lack of or insufficient fuel B
Belt Defective timing C
Compression Incorrect valve clearance B
Loosened spark plugs or defective gasket B
Loosened cylinder head bolts or defective gasket B
Improper valve seating B
Defective valve stem C
Worn or broken valve spring B
Worn or stuck piston rings, cylinder and piston B
Incorrect valve timing A
Improper engine oil (low viscosity) B
Lubrication system Incorrect oil pressure B
Defective rocker cover gasket C
Cooling system Overheating C
Others Malfunction of evaporative emission control system A
Stuck or damaged throttle valve B
Accelerator cable out of adjustment C TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK