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Subaru 2004 FORESTER Service Manual
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Subaru 2004 FORESTER Service Manual

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2004 FORESTER SERVICE MANUAL

ENGINE SECTION 1

This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.
All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.
FUJI HEAVY INDUSTRIES LTD.
QUICK REFERENCE INDEX
FUEL INJECTION (FUEL SYSTEM)
EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICE)
INTAKE (INDUCTION)
MECHANICAL
EXHAUST
COOLING
LUBRICATION
SPEED CONTROL SYSTEM
IGNITION
STARTING/CHARGING SYSTEM
ENGINE (DIAGNOSTIC)
FU(H4SO)
EC(H4SO)
IN(H4SO)
ME(H4SO)
EX(H4SO)
CO(H4SO)
LU(H4SO)
SP(H4SO)
IG(H4SO)
SC(H4SO)
EN(H4SO)
G8080GE2

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Summary of Contents for Subaru 2004 FORESTER

  • Page 1: Engine Section

    2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 FUEL INJECTION (FUEL SYSTEM) FU(H4SO) EMISSION CONTROL EC(H4SO) (AUX. EMISSION CONTROL DEVICE) INTAKE (INDUCTION) IN(H4SO) MECHANICAL ME(H4SO) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO)

  • Page 2: Table Of Contents

    EXHAUST EX(H4SO) Page General Description ..................2 Front Exhaust Pipe..................7 Center Exhaust Pipe .................10 Rear Exhaust Pipe ..................11 Muffler .......................13...

  • Page 3: General Description

    General Description EXHAUST 1. General Description A: COMPONENT 1. 2.0 L MODEL (15) (14) (12) (13) (15) (11) (10) (16) (15) (27) (26) (17) (28) (22) (18) (25) (24) (23) (31) (30) (19) (29) (21) (20) (31) EX-02010 EX(H4SO)-2...
  • Page 4 General Description EXHAUST Front exhaust pipe upper cover (14) Muffler (28) Rear catalytic converter upper cover (15) Cushion rubber Front exhaust pipe lower cover (16) Rear exhaust pipe (29) Rear catalytic converter lower cover (17) Clamp Clamp (18) Center exhaust pipe upper cover (30) Rear catalytic converter Front exhaust pipe upper cover LH...
  • Page 5 General Description EXHAUST 2. 2.5 L MODEL (19) (23) (21) (22) (14) (15) (19) (18) (11) (18) (13) (20) (12) (18) (19) (10) (16) (33) (17) (31) (34) (28) (32) (30) (26) (29) (27) (25) (24) EX-02011 EX(H4SO)-4...
  • Page 6 General Description EXHAUST Front exhaust pipe upper cover (15) Rear exhaust upper cover (31) Front catalytic converter upper cover (16) Rear exhaust lower cover Front exhaust pipe lower cover (17) Rear catalytic lower converter (32) Front oxygen (A/F) sensor cover (33) Rear oxygen sensor Clamp...
  • Page 7 General Description EXHAUST B: 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.

  • Page 8: Front Exhaust Pipe

    Front Exhaust Pipe EXHAUST 2. Front Exhaust Pipe 4) Lift-up the vehicle. 5) Separate the front and center exhaust pipe as- A: REMOVAL sembly from rear exhaust pipe. 1) Disconnect the ground cable from battery. CAUTION: Be careful, the exhaust pipe is hot. FU-00009 2) Disconnect the front oxygen (A/F) sensor con- EX-00037...
  • Page 9 Front Exhaust Pipe EXHAUST 9) Remove the front and center exhaust pipe as- 4) Temporarily tighten the bolt which installs front sembly from vehicle. and center exhaust pipe assembly to hanger brack- CAUTION: • Be careful not to let the front and center ex- haust pipe assembly fall off when removing as it is quite heavy.
  • Page 10 Front Exhaust Pipe EXHAUST 8) Tighten the bolt which holds front and center ex- C: INSPECTION haust pipe assembly to hanger bracket. 1) Make sure there are no exhaust leaks from con- nections and welds. Tightening torque: ⋅ 2) Make sure there are no holes or rusting. 35 N m (3.6 kgf-m, 26.0 ft-lb) EX-00038...

  • Page 11: Center Exhaust Pipe

    Center Exhaust Pipe EXHAUST 3. Center Exhaust Pipe A: REMOVAL After removing the center and front exhaust pipes as one unit, separate them. Refer to the procedure for removing the front exhaust pipe. <Ref. to EX(H4SO)-7, REMOVAL, Front Exhaust Pipe.> B: INSTALLATION Install the center exhaust pipe and front exhaust pipe as one unit.

  • Page 12: Rear Exhaust Pipe

    Rear Exhaust Pipe EXHAUST 4. Rear Exhaust Pipe B: INSTALLATION 1) Apply a coat of SUBARU CRC to mating area of A: REMOVAL the cushion rubbers in advance. 1) Separate the rear exhaust pipe from center ex- SUBARU CRC (Part No. 004301003) haust pipe.
  • Page 13 Rear Exhaust Pipe EXHAUST C: INSPECTION 1) Make sure there are no exhaust leaks from con- nections and welds. 2) Make sure there are no holes or rusting. 3) Make sure the cushion rubber is not worn or cracked. EX(H4SO)-12...

  • Page 14: Muffler

    CAUTION: cracked. Be careful, the exhaust pipe is hot. EX-00024 2) Apply a coat of SUBARU CRC to mating area of the cushion rubbers in advance. SUBARU CRC (Part No. 004301003) EX-00026 3) Remove the front, right and left cushion rubber, and detach the muffler assembly.
  • Page 15 Muffler EXHAUST EX(H4SO)-14...