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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, reassembling, inspection and adjustment of
components and diagnostics for guidance 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.

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)

All information, illustration and specifications contained in this manual are
based on the latest product information
available at the time of publication
approval.
FUJI HEAVY INDUSTRIES LTD.

G8080GE2

EXHAUST

EX(H4SO)
1.
2.
3.
4.
5.

Page
General Description ....................................................................................2
Front Exhaust Pipe......................................................................................7
Center Exhaust Pipe .................................................................................10
Rear Exhaust Pipe ....................................................................................11
Muffler .......................................................................................................13

General Description
EXHAUST

1. General Description
A: COMPONENT
1. 2.0 L MODEL
(15)

(14)
(12)

(13)
T7

(15)

(11)

(10)

(16)
(9)
(15)

T1

T4
(27)
T6

T2

(26)

T2
(17)

(22)

(18)

T4
T2

(28)

(23)

(25)
(24)

T2

(8)
(3)
(31)

T3
(1)

(30)

(2)
(3)

T6
(19)

T2

(7)
T5

T2

(31)

(29)

(21)

(4)

(20)

T5

(6)
(5)
T5

EX-02010

EX(H4SO)-2

General Description
EXHAUST
(1)

Front exhaust pipe upper cover
CTR

(2)

Front exhaust pipe lower cover
CTR

(3)
(4)
(5)
(6)
(7)
(8)

Clamp
Front exhaust pipe upper cover LH
Front exhaust pipe lower cover LH
Front exhaust pipe
Front exhaust pipe lower cover RH
Front exhaust pipe upper cover
RH

(9)
(10)
(11)
(12)
(13)

Gasket
Spring
Chamber
Gasket
Self-locking nut

(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)

Muffler
Cushion rubber
Rear exhaust pipe
Clamp
Center exhaust pipe upper cover
Center exhaust pipe lower cover
Protector
Gasket
Front oxygen (A/F) sensor
Front catalytic converter
Center exhaust pipe
Front catalytic converter lower
cover

(26)

Front catalytic converter upper
cover

(27)

Rear oxygen sensor

EX(H4SO)-3

(28)

Rear catalytic converter upper
cover

(29)

Rear catalytic converter lower
cover

(30)
(31)

Rear catalytic converter
Gasket

Tightening torque: N⋅m (kgf-m, ft-lb)
T1: 8 (0.8, 5.8)
T2: 13 (1.3, 9.4)
T3: 18 (1.8, 13.0)
T4: 21 (2.1, 15.2)
T5: 30 (3.1, 22.4)
T6: 35 (3.6, 26.0)
T7: 48 (4.9, 35.4)

General Description
EXHAUST

2. 2.5 L MODEL
(19)

(23)
(21)

T6

(22)

(14)
T7

(15)

(19)

(18)
(11)
(18)
(13)

(20)
(12)
(18)

(10)

(19)

(16)
T1

T4
(33)

(17)

T2
T6
(31)
(34)
(28)

(32)
T4

(30)

T2

(26)
T2

(8)
(3)
(9)

T3
(1)

(29)

(2)
(3)

T6

(27)

T2
(25)

(4)
(7)
T5

T2

(9)

(24)

T5

(6)
(5)
T5

EX-02011

EX(H4SO)-4

General Description
EXHAUST
(1)

Front exhaust pipe upper cover
CTR

(2)

Front exhaust pipe lower cover
CTR

(3)
(4)
(5)
(6)
(7)
(8)

Clamp
Front exhaust pipe upper cover LH
Front exhaust pipe lower cover LH
Front exhaust pipe
Front exhaust pipe lower cover RH
Front exhaust pipe upper cover
RH

(9)
(10)
(11)
(12)
(13)
(14)

Gasket
Gasket
Spring
Chamber
Rear catalytic converter
Rear catalytic converter upper
cover

(15)
(16)
(17)

Rear exhaust upper cover
Rear exhaust lower cover
Rear catalytic lower converter
cover

(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)

Clamp
Cushion rubber
Rear exhaust pipe
Gasket
Self-locking nut
Muffler
Protector
Gasket
Front catalytic converter
Center exhaust lower cover
Center exhaust upper cover
Center exhaust pipe
Front catalytic converter lower
cover

EX(H4SO)-5

(31)

Front catalytic converter upper
cover

(32)
(33)
(34)

Front oxygen (A/F) sensor
Rear oxygen sensor
Clamp

Tightening torque: N⋅m (kgf-m, ft-lb)
T1: 8 (0.8, 5.8)
T2: 13 (1.3, 9.4)
T3: 18 (1.8, 13.0)
T4: 21 (2.1, 15.2)
T5: 30 (3.1, 22.4)
T6: 35 (3.6, 26.0)
T7: 48 (4.9, 35.4)

General Description
EXHAUST

B: CAUTION
• Wear working clothing, including a cap, protective goggles, and protective shoes during operation.
• Remove contamination including dirt and corrosion before removal, installation or disassembly.
• Keep the disassembled parts in order and protect them from dust or dirt.
• Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary removal, 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)-6

Front Exhaust Pipe
EXHAUST

2. Front Exhaust Pipe

4) Lift-up the vehicle.
5) Separate the front and center exhaust pipe assembly from rear exhaust pipe.

A: REMOVAL
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 connector.

EX-00037

6) Remove the under cover.
7) Remove the nuts which hold front exhaust pipe
onto cylinder heads.

EX-00029

3) Disconnect the rear oxygen sensor connector.
EC-00009

8) Remove the bolt which installs front and center
exhaust pipe assembly to hanger bracket.

EX-00030

EX-00038

EX(H4SO)-7

Front Exhaust Pipe
EXHAUST

9) Remove the front and center exhaust pipe assembly from vehicle.
CAUTION:
• Be careful not to let the front and center exhaust 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 exhaust pipe.

4) Temporarily tighten the bolt which installs front
and center exhaust pipe assembly to hanger bracket.

EX-00038

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)

EC-00011

11) Remove the front oxygen (A/F) sensor and the
rear oxygen sensor. <Ref. to FU(H4SO)-40, REMOVAL, 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, INSTALLATION, Front Oxygen (A/F) Sensor.> <Ref. to
FU(H4SO)-42, INSTALLATION, Rear Oxygen
Sensor.>
2) Install the front exhaust pipe to center exhaust
pipe.

EC-00009

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)

NOTE:
Replace the gaskets with new ones.
Tightening torque:
30 N⋅m (3.1 kgf-m, 22.4 ft-lb)

EX-00037

EC-00011

3) Install the front and center exhaust pipe assembly to vehicle.

EX(H4SO)-8

Front Exhaust Pipe
EXHAUST

8) Tighten the bolt which holds front and center exhaust pipe assembly to hanger bracket.
Tightening torque:
35 N⋅m (3.6 kgf-m, 26.0 ft-lb)

C: INSPECTION
1) Make sure there are no exhaust leaks from connections and welds.
2) Make sure there are no holes or rusting.

EX-00038

9) Lower the vehicle.
10) Connect the rear oxygen sensor connector.

EX-00030

11) Connect the front oxygen (A/F) sensor connector.

EX-00029

12) Connect the battery ground cable to battery.

FU-00009

EX(H4SO)-9

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. Refer to the procedure for installing the front exhaust pipe. <Ref. to EX(H4SO)-8,
INSTALLATION, Front Exhaust Pipe.>

C: INSPECTION
1) Make sure there are no exhaust leaks from connections and welds.
2) Make sure there are no holes or rusting.

EX(H4SO)-10

Rear Exhaust Pipe
EXHAUST

4. Rear Exhaust Pipe

B: INSTALLATION

A: REMOVAL

1) Apply a coat of SUBARU CRC to mating area of
the cushion rubbers in advance.

1) Separate the rear exhaust pipe from center exhaust pipe.
CAUTION:
Be careful, the exhaust pipe is hot.

SUBARU CRC (Part No. 004301003)
2) Install the rear exhaust pipe bracket to cushion
rubber.

EX-00025
EX-00037

2) Separate the rear exhaust pipe from muffler.

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)

EX-00024

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.

EX-00024

4) Install the rear exhaust pipe to center exhaust
pipe.
Tightening torque:
18 N⋅m (1.8 kgf-m, 13.0 ft-lb)

EX-00025

EX-00037

EX(H4SO)-11

Rear Exhaust Pipe
EXHAUST

C: INSPECTION
1) Make sure there are no exhaust leaks from connections 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

Muffler
EXHAUST

5. Muffler

C: INSPECTION

A: REMOVAL

1) Make sure there are no exhaust leaks from connections and welds.
2) Make sure there are no holes or rusting.
3) Make sure the cushion rubber is not worn or
cracked.

1) Separate the muffler from rear exhaust pipe.
CAUTION:
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.

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)

EX-00024

EX(H4SO)-13

Muffler
EXHAUST

EX(H4SO)-14