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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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.
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