Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Subaru Forester 1999-2004 Approved Subaru Forester 1999-2000 ENGINE SECTION Engine MSA5T0122A27580

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MSA5T0122A27580


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                                    SERVICE PROCEDURE                                      [W7A1] 2-3
                                                                                        7. Cylinder Block


7. Cylinder Block                                        11) Remove flywheel (MT vehicles only) or drive
                                                         plate (AT vehicles only).
A: REMOVAL                                               Using ST, lock crankshaft.
                                                         ST 498497100 CRANKSHAFT STOPPER
1. RELATED PARTS
NOTE:
Before conducting this procedure drain engine oil
completely if applicable.
1) Remove intake manifold. 
2) Remove timing belt. 
3) Remove A/C compressor bracket. (With A/C
model)
4) Remove generator and A/C compressor with
their brackets.
                                                                                             S2M1818A
5) Remove cylinder head bolts in alphabetical
sequence shown in figure.
CAUTION:
Leave bolts (a) and (c) engaged by three or four
threads to prevent cylinder head from falling.




                                                                                             S2M1870A

                                                         12) Remove oil separator cover.
                                                         13) Remove water by-pass pipe for heater.
                                      B2M2628A
                                                         14) Remove water by-pass pipe between oil
                                                         cooler and water pump (AT vehicles only).
6) While tapping cylinder head with a plastic
hammer, separate it from cylinder block.
7) Remove bolts (a) and (b) to remove cylinder
head.




                                                                                              S2M0305

                                                         15) Remove water pump.

                                      B2M2628A

8) Remove cylinder head gasket.
CAUTION:
Do not scratch the mating surface of cylinder
head and cylinder block.
9) Similarly, remove right side cylinder head.
10) Remove clutch housing cover (MT vehicles
only).


                                                    39
2-3    [W7A1]                        SERVICE PROCEDURE
7. Cylinder Block


16) Remove oil pump from cylinder block.                   22) Remove oil cooler (AT vehicles only).
Use a flat-bladed screwdriver as shown in figure
when removing oil pump.
CAUTION:
Be careful not to scratch the mating surface of
cylinder block and oil pump.




                                        S2M1819

17) Removal of oil pan
   (1) Turn cylinder block with #2 and #4 piston
   sides facing upward.
   (2) Remove bolts which secure oil pan to cylin-
   der block.
                                                                                                 S2M0123C
   (3) Insert a oil pan cutter blade between cylin-
   der block-to-oil pan clearance and remove oil              (A)   Gasket
   pan.                                                       (B)   Oil cooler
CAUTION:                                                      (C)   Connector
Do not use a screwdriver or similar tool in
place of oil pan cutter.                                   23) Remove water pipe. 




                                        S2M1820                                                   B2M2638

18)   Remove oil strainer stay.
19)   Remove oil strainer.
20)   Remove baffle plate.
21)   Remove oil filter using ST.
ST    498187000 OIL FILTER WRENCH




                                       S2M1871A


                                                      40
                                 SERVICE PROCEDURE                                            [W7A2] 2-3
                                                                                           7. Cylinder Block


2. CYLINDER BLOCK




                                                                                                     S2M1590A


(1) Service hole plug            (3) Circlip                              (5) Service hole cover
(2) Gasket                       (4) Piston pin

1) Remove service hole cover and service hole          2) Rotate crankshaft to bring #1 and #2 pistons to
plugs using hexagon wrench [14 mm (0.55 in)].          bottom dead center position, then remove piston
                                                       circlip through service hole of #1 and #2 cylinders.




                                    B2M2620
                                                                                                   G2M0165




                                                  41
2-3    [W7A2]                     SERVICE PROCEDURE
7. Cylinder Block


3) Draw out piston pin from #1 and #2 pistons          4) Similarly remove piston pins from #3 and #4
using ST.                                              pistons.
ST 499097700 PISTON PIN REMOVER                        5) Remove bolts which connect cylinder block on
CAUTION:                                               the side of #2 and #4 cylinders.
Be careful not to confuse original combination         6) Back off bolts which connect cylinder block on
of piston, piston pin and cylinder.                    the side of #1 and #3 cylinders two or three turns.
                                                       7) Set up cylinder block so that #1 and #3 cylin-
                                                       ders are on the upper side, then remove cylinder
                                                       block connecting bolts.
                                                       8) Separate left-hand and right-hand cylinder
                                                       blocks.
                                                       CAUTION:
                                                       When separating cylinder block, do not allow
                                                       the connecting rod to fall and damage the cyl-
                                                       inder block.
                                    S2M1872A




                                                                                                 B2M2408A


(1) Cylinder block                (3) Crankshaft                         (5) Piston
(2) Rear oil seal                 (4) Crankshaft bearing

9) Remove rear oil seal.                               CAUTION:
10) Remove crankshaft together with connecting         Do not confuse combination of crankshaft
rod.                                                   bearings. Press bearing at the end opposite to
11) Remove crankshaft bearings from cylinder           locking lip.
block using hammer handle.




                                                  42
                                     SERVICE PROCEDURE                                         [W7C1] 2-3
                                                                                            7. Cylinder Block


12) Draw out each piston from cylinder block
using wooden bar or hammer handle.
CAUTION:
Do not confuse combination of piston and cyl-
inder.
B: DISASSEMBLY
1. CRANKSHAFT AND PISTON




                                                                                                     B2M1320I


(1) Connecting rod cap               (3) Top ring                            (5) Oil ring
(2) Connecting rod bearing           (4) Second ring                         (6) Circlip

1) Remove connecting rod cap.                               Warping limit:
2) Remove connecting rod bearing.                               0.05 mm (0.0020 in)
CAUTION:                                                    Grinding limit:
Arrange removed connecting rod, connecting                      0.1 mm (0.004 in)
rod cap and bearing in order to prevent confu-
sion.                                                       Standard height of cylinder block:
                                                                201.0 mm (7.91 in)
3) Remove piston rings using the piston ring
expander.
4) Remove the oil ring by hand.
CAUTION:
Arrange the removed piston rings in good
order to prevent confusion.
5) Remove circlip.

C: INSPECTION
1. CYLINDER BLOCK
1) Visually check for cracks and damage.
Especially, inspect important parts by means of red
lead check.
2) Check the oil passages for clogging.
3) Inspect crankcase surface that mates with cyl-
inder head for warping by using a straight edge,
and correct by grinding if necessary.

                                                       43
2-3    [W7C2]                            SERVICE PROCEDURE
7. Cylinder Block


2. CYLINDER AND PISTON                                     2) How to measure the inner diameter of each
                                                           cylinder
1) The cylinder bore size is stamped on the cylin-
                                                           Measure the inner diameter of each cylinder in
der block's front upper surface.
                                                           both the thrust and piston pin directions at the
CAUTION:                                                   heights shown in the figure, using a cylinder bore
Measurement should be performed at a tem-                  gauge.
perature 20



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