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

(15)

(18)

(28)

(29)

(30)

(20)

(21)

(19)

(23)

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

(24)

(11)

(16)

(10)

(9)

(14)

(12)

(13)

T5 T2

(31)

(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

(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

T6 T2

(19)

(33)

(34)

(28)

(24)

(25)

(27)

(29)

(31)

(32)

(30)

(26)

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

(20)

(10)

(11)

(13)

(23)

(21)

(22)

(14)

T5 T2

(9)

(12)

(16)

(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

(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

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

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