Subaru 2004 Forester User manual

FUJI HEAVY INDUSTRIES LTD. G8080GE2
2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
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.
FUEL INJECTION (FUEL SYSTEM) FU(H4SO)
EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICE) EC(H4SO)
INTAKE (INDUCTION) IN(H4SO)
MECHANICAL ME(H4SO)
EXHAUST EX(H4SO)
COOLING CO(H4SO)
LUBRICATION LU(H4SO)
SPEED CONTROL SYSTEM SP(H4SO)
IGNITION IG(H4SO)
STARTING/CHARGING SYSTEM SC(H4SO)
ENGINE (DIAGNOSTIC) EN(H4SO)

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

EX(H4SO)-2
EXHAUST
General Description
1. General Description
A: COMPONENT
1. 2.0 L MODEL
EX-02010
T7
T2
T2
T3
T6
T5
T5
T2
T2
T2
(15)
(15)
(15)
(18)
(28)
(29)
(30)
(20)
(21)
(19)
(23)
(1)
(2)
(3)
(3)
(4)
(5)
(6)
(7)
(8)
(24)
(11)
(16)
(10)
(9)
(14)
(12)
(13)
T5 T2
(31)
(31)
T1
T6
T4
T4
(27)
(17)
(26)
(22)
(25)

EX(H4SO)-3
EXHAUST
General Description
(1) Front exhaust pipe upper cover
CTR
(14) Muffler (28) Rear catalytic converter upper
cover
(15) Cushion rubber
(2) Front exhaust pipe lower cover
CTR
(16) Rear exhaust pipe (29) Rear catalytic converter lower
cover
(17) Clamp
(3) Clamp (18) Center exhaust pipe upper cover (30) Rear catalytic converter
(4) Front exhaust pipe upper cover LH (19) Center exhaust pipe lower cover (31) Gasket
(5) Front exhaust pipe lower cover LH (20) Protector
(6) Front exhaust pipe (21) Gasket Tightening torque: N
⋅ m (kgf-m, ft-lb)
(7) Front exhaust pipe lower cover RH (22) Front oxygen (A/F) sensor T1: 8 (0.8, 5.8)
(8) Front exhaust pipe upper cover
RH
(23) Front catalytic converter T2: 13 (1.3, 9.4)
(24) Center exhaust pipe T3: 18 (1.8, 13.0)
(9) Gasket (25) Front catalytic converter lower
cover
T4: 21 (2.1, 15.2)
(10) Spring T5: 30 (3.1, 22.4)
(11) Chamber (26) Front catalytic converter upper
cover
T6: 35 (3.6, 26.0)
(12) Gasket T7: 48 (4.9, 35.4)
(13) Self-locking nut (27) Rear oxygen sensor

EX(H4SO)-4
EXHAUST
General Description
2. 2.5 L MODEL
EX-02011
T7
T1
T6 T2
T6
T3
T5
T5
T4
T4
T2
T2
T2
T6
(19)
(19)
(19)
(33)
(34)
(28)
(24)
(25)
(27)
(29)
(31)
(32)
(30)
(26)
(1)
(2)
(3)
(3)
(4)
(5)
(6)
(7)
(8)
(20)
(10)
(11)
(13)
(23)
(21)
(22)
(14)
T5 T2
(9)
(9)
(12)
(16)
(18)
(18)
(15)
(17)
(18)

EX(H4SO)-5
EXHAUST
General Description
(1) Front exhaust pipe upper cover
CTR
(15) Rear exhaust upper cover (31) Front catalytic converter upper
cover
(16) Rear exhaust lower cover
(2) Front exhaust pipe lower cover
CTR
(17) Rear catalytic lower converter
cover
(32) Front oxygen (A/F) sensor
(33) Rear oxygen sensor
(3) Clamp (18) Clamp (34) Clamp
(4) Front exhaust pipe upper cover LH (19) Cushion rubber
(5) Front exhaust pipe lower cover LH (20) Rear exhaust pipe Tightening torque: N
⋅ m (kgf-m, ft-lb)
(6) Front exhaust pipe (21) Gasket T1: 8 (0.8, 5.8)
(7) Front exhaust pipe lower cover RH (22) Self-locking nut T2: 13 (1.3, 9.4)
(8) Front exhaust pipe upper cover
RH
(23) Muffler T3: 18 (1.8, 13.0)
(24) Protector T4: 21 (2.1, 15.2)
(9) Gasket (25) Gasket T5: 30 (3.1, 22.4)
(10) Gasket (26) Front catalytic converter T6: 35 (3.6, 26.0)
(11) Spring (27) Center exhaust lower cover T7: 48 (4.9, 35.4)
(12) Chamber (28) Center exhaust upper cover
(13) Rear catalytic converter (29) Center exhaust pipe
(14) Rear catalytic converter upper
cover
(30) Front catalytic converter lower
cover

EX(H4SO)-6
EXHAUST
General Description
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.
• Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly, and replacement.
• Be careful not to burn your hands, because each
part on the vehicle is hot after running.
• Be sure to tighten fasteners including bolts and
nuts to the specified torque.
• Place shop jacks or rigid racks at the specified
points.
• Before disconnecting electrical connectors of
sensors or units, be sure to disconnect the ground
cable from battery.

EX(H4SO)-7
EXHAUST
Front Exhaust Pipe
2. Front Exhaust Pipe
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Disconnect the front oxygen (A/F) sensor con-
nector.
3) Disconnect the rear oxygen sensor connector.
4) Lift-up the vehicle.
5) Separate the front and center exhaust pipe as-
sembly from rear exhaust pipe.
CAUTION:
Be careful, the exhaust pipe is hot.
6) Remove the under cover.
7) Remove the nuts which hold front exhaust pipe
onto cylinder heads.
8) Remove the bolt which installs front and center
exhaust pipe assembly to hanger bracket.
FU-00009
EX-00029
EX-00030
EX-00037
EC-00009
EX-00038

EX(H4SO)-8
EXHAUST
Front Exhaust Pipe
9) Remove the front and center exhaust pipe as-
sembly from vehicle.
CAUTION:
• Be careful not to let the front and center ex-
haust pipe assembly fall off when removing as
it is quite heavy.
• After removing the front and center exhaust
pipe assembly, do not apply excessive pulling
force on the rear exhaust pipe.
10) Separate the front exhaust pipe from center ex-
haust pipe.
11) Remove the front oxygen (A/F) sensor and the
rear oxygen sensor. <Ref. to FU(H4SO)-40, RE-
MOVAL, Front Oxygen (A/F) Sensor.> <Ref. to
FU(H4SO)-42, REMOVAL, Rear Oxygen Sensor.>
B: INSTALLATION
1) Install the front oxygen (A/F) sensor and the rear
oxygen sensor. <Ref. to FU(H4SO)-40, INSTALLA-
TION, Front Oxygen (A/F) Sensor.> <Ref. to
FU(H4SO)-42, INSTALLATION, Rear Oxygen
Sensor.>
2) Install the front exhaust pipe to center exhaust
pipe.
NOTE:
Replace the gaskets with new ones.
Tightening torque:
30 N
⋅ m (3.1 kgf-m, 22.4 ft-lb)
3) Install the front and center exhaust pipe assem-
bly to vehicle.
4) Temporarily tighten the bolt which installs front
and center exhaust pipe assembly to hanger brack-
et.
5) Tighten the nuts which hold front exhaust pipe
onto cylinder heads.
Tightening torque:
30 N
⋅ m (3.1 kgf-m, 22.4 ft-lb)
6) Install the under cover.
7) Tighten the bolts which install front and center
exhaust pipe assembly to rear exhaust pipe.
Tightening torque:
18 N
⋅ m (1.8 kgf-m, 13.0 ft-lb)
EC-00011
EC-00011
EX-00038
EC-00009
EX-00037

EX(H4SO)-9
EXHAUST
Front Exhaust Pipe
8) Tighten the bolt which holds front and center ex-
haust pipe assembly to hanger bracket.
Tightening torque:
35 N
⋅ m (3.6 kgf-m, 26.0 ft-lb)
9) Lower the vehicle.
10) Connect the rear oxygen sensor connector.
11) Connect the front oxygen (A/F) sensor connec-
tor.
12) Connect the battery ground cable to battery.
C: INSPECTION
1) Make sure there are no exhaust leaks from con-
nections and welds.
2) Make sure there are no holes or rusting.
EX-00038
EX-00030
EX-00029
FU-00009

EX(H4SO)-10
EXHAUST
Center Exhaust Pipe
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. Refer to the procedure for install-
ing the front exhaust pipe. <Ref. to EX(H4SO)-8,
INSTALLATION, Front Exhaust Pipe.>
C: INSPECTION
1) Make sure there are no exhaust leaks from con-
nections and welds.
2) Make sure there are no holes or rusting.

EX(H4SO)-11
EXHAUST
Rear Exhaust Pipe
4. Rear Exhaust Pipe
A: REMOVAL
1) Separate the rear exhaust pipe from center ex-
haust pipe.
CAUTION:
Be careful, the exhaust pipe is hot.
2) Separate the rear exhaust pipe from muffler.
3) Apply a coat of SUBARU CRC to mating area of
the cushion rubbers in advance.
SUBARU CRC (Part No. 004301003)
4) Remove the rear exhaust pipe bracket from the
cushion rubber.
B: INSTALLATION
1) Apply a coat of SUBARU CRC to mating area of
the cushion rubbers in advance.
SUBARU CRC (Part No. 004301003)
2) Install the rear exhaust pipe bracket to cushion
rubber.
NOTE:
Replace the gaskets with new ones.
3) Install the rear exhaust pipe to muffler.
Tightening torque:
48 N
⋅ m (4.9 kgf-m, 35.4 ft-lb)
4) Install the rear exhaust pipe to center exhaust
pipe.
Tightening torque:
18 N
⋅ m (1.8 kgf-m, 13.0 ft-lb)
EX-00037
EX-00024
EX-00025
EX-00025
EX-00024
EX-00037

EX(H4SO)-12
EXHAUST
Rear Exhaust Pipe
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)-13
EXHAUST
Muffler
5. Muffler
A: REMOVAL
1) Separate the muffler from rear exhaust pipe.
CAUTION:
Be careful, the exhaust pipe is hot.
2) Apply a coat of SUBARU CRC to mating area of
the cushion rubbers in advance.
SUBARU CRC (Part No. 004301003)
3) Remove the front, right and left cushion rubber,
and detach the muffler assembly.
B: INSTALLATION
Install in the reverse order of removal.
NOTE:
Replace the gasket with a new one.
Tightening torque:
48 N
⋅ m (4.9 kgf-m, 35.4 ft-lb)
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-00024
EX-00026
EX-00024

EX(H4SO)-14
EXHAUST
Muffler