SUBARU FORESTER 2004 Service Repair Manual

LU(H4SO)-3
LUBRICATION
General Description
B: COMPONENT
1. NON-TURBO MODEL
(1) Plug (13) Oil pressure switch (25) Drain plug
(2) Gasket (14) Oil filler duct (26) Metal gasket
(3) Relief valve spring (15) O-ring (27) Gasket
(4) Relief valve (16) Oil filler cap
(5) Oil seal (17) O-ringTightening torque: N
⋅m (kgf-m, ft-lb)
(6) Oil pump case (18) Baffle plateT1: 5 (0.5, 3.6)
(7) Inner rotor (19) O-ringT2: 6.4 (0.65, 4.7)
(8) Outer rotor (20) Oil strainerT3: 10 (1.0, 7.2)
(9) Oil pump cover (21) Oil level gauge guideT4: 44 (4.5, 32.5)
(10) Oil filter (22) O-ringT5: 25 (2.5, 18.1)
(11) O-ring (23) Oil pan
(12) Oil pump ASSY (24) Oil level gauge
LU-02008
(12)
(11)
T5
T2
T1
T2
T2
T1
T1
T1
T3
T4
T2
(13)
(9)
(8)
(7)
(6)
(20) (19)
(27) (18)(17) (15)
(14) (16)
(24)
(23) (10)
(25)(26)
(5)
(4)
(3)(2)
(1)
(22)
(21)
T4

LU(H4SO)-4
LUBRICATION
General Description
2. TURBO MODEL
(35)
(15)
(14)
T7
T2
T1
T2
T5T2
T9
T1
T1
T3
T8
T6
T4
T2
(29)
(9)
(8)
(7) (6)(30)
(12)
(22) (33)
(23)
(24) (32) (21) (16)
(25) (11)
(10)
(28)(27)
T4
(34)
(5)
(4)
(3)(2)
(1)
(31)
(13)
T1
T6
(20) (19) (18) (17)
LU-02005
(26)
(36)

LU(H4SO)-5
LUBRICATION
General Description
C: 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 yourself, because each
part in 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.
(1) Plug (16) Oil pressure switch (33) O-ring
(2) Gasket (17) Oil filler cap (34) Oil filter connector (model without
oil cooler)
(3) Relief valve spring (18) O-ring
(4) Relief valve (19) Oil filler duct (35) Plug (model without oil cooler)
(5) Oil seal (20) O-ring (36) O-ring
(6) Oil pump case (21) Rocker cover
(7) Inner rotor (22) Oil strainerTightening torque: N
⋅m (kgf-m, ft-lb)
(8) Outer rotor (23) GasketT1: 5 (0.5, 3.6)
(9) Oil pump cover (24) Oil level gauge guideT2: 6.4 (0.65, 4.7)
(10) Oil filter (25) Oil panT3: 10 (1.0, 7.0)
(11) Oil cooler connector (model with
oil cooler)(26) Oil level gaugeT4: 44 (4.5, 32.5)
(27) Metal gasketT5: 69 (7.0, 50.9)
(12) Water by-pass pipe (model with oil
cooler)(28) Drain plugT6: 6.4 (0.65, 4.7)
(29) O-ringT7: 25 (2.5, 18.1)
(13) Oil cooler (model with oil cooler) (30) Adapter (1)T8: 44 (4.5, 32.5)
(14) O-ring (31) Adapter (2)T9: 54 (5.5, 40)
(15) Oil pump ASSY (32) Baffle plate

LU(H4SO)-6
LUBRICATION
General Description
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
499977400
(2.0 L model)CRANK PULLEY
WRENCHUsed for stopping rotation of crank pulley when
loosening and tightening crankshaft pulley bolt.
499977100
(2.5 L model)CRANK PULLEY
WRENCHUsed for stopping rotation of crank pulley when
loosening and tightening crankshaft pulley bolt.
498547000 OIL FILTER
WRENCHUsed for removing and installing oil filter.
(Outer diameter: 80 mm (3.15 in))
18332AA000 OIL FILTER
WRENCHUsed for removing and installing oil filter.
(Outer diameter: 68 mm (2.68 in))
ST-499977400
ST-499977100
ST-498547000
ST18332AA000

LU(H4SO)-7
LUBRICATION
General Description
18332AA010 OIL FILTER
WRENCHUsed for removing and installing oil filter.
(Outer diameter: 65 mm (2.56 in))
499587100 OIL SEAL
INSTALLERUsed for installing oil pump oil seal. ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST18332AA010
ST-499587100

LU(H4SO)-8
LUBRICATION
Oil Pressure System
2. Oil Pressure System
A: WIRING DIAGRAM
LU-00102
E
i12
i10
i3
B38
B9
A3
B22
E3
14
E11
A:
B:
B:
i10
123456789101112131415161718192021222324252627282930219
32
1234 5610 11 12 13 14 15716
23 3019 20
22 26 27 28 29817
24 3118
25
i3B22
125678
131415169101112
34
17181920
**: 5
: 14
No.14SBF-4SBF-1
B72
14
B72i12
12345678910111213143412
TURBO MODEL NON-TURBO MODELBATTERY
IGNITION
SWITCH
COMBINATION
METER
OIL PRESSURE
WARNING LIGHT
OIL PRESSURE
SWITCH

LU(H4SO)-9
LUBRICATION
Oil Pressure System
B: INSPECTION
Step Check Yes No
1 CHECK COMBINATION METER.
1) Turn the ignition switch to ON. (engine
OFF)
2) Check other warning lights.Does the warning lights illumi-
nate?Go to step 2.Repair or replace
the combination
meter. <Ref. to IDI-
4, INSPECTION,
Combination
Meter System.>
2 CHECK HARNESS CONNECTOR BETWEEN
COMBINATION METER AND OIL PRES-
SURE SWITCH.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from oil pressure
switch.
3) Turn the ignition switch to ON.
4) Measure the voltage of harness between
the combination meter connector and chassis
ground.
Connector & terminal
(E11) No. 1 (+) — Chassis ground (
−):Is the voltage more than 10 V? Replace the oil
pressure switch.Go to step 3.
3 CHECK COMBINATION METER.
1) Turn the ignition switch to OFF.
2) Remove the combination meter.
3) Measure the resistance of combination
meter.
Te r m i n a l
No. B9 — No. A3:Is the resistance less than 10
Ω?Replace the har-
ness connector
between combina-
tion meter and oil
pressure switch.Repair or replace
the combination
meter and the oil
pressure switch
warning light bulb.

LU(H4SO)-10
LUBRICATION
Engine Oil
3. Engine Oil
A: INSPECTION
1) Park the vehicle on a level surface.
2) Remove the oil level gauge and wipe it clean.
3) Reinsert the level gauge all the way. Be sure that
the level gauge is correctly inserted and in the
proper orientation.
4) Remove it again and note the reading. If the en-
gine oil level is below the “L” line, add oil to bring
the level up to “F” line.
5) After turning off the engine, wait a few minutes
for the oil to drain back into the oil pan before
checking the level.
6) Just after driving or while the engine is warm, en-
gine oil level may show in the range between the
“F” line and notch mark. This is caused by thermal
expansion of the engine oil.
NOTE:
To prevent overfilling the engine oil, do not add oil
above the “F” line when the engine is cold.
B: REPLACEMENT
1) Open the engine oil filler cap for quick draining of
the engine oil.
2) Remove six clips.
3) Turn the service hole cover counterclockwise.
4) Drain the engine oil by loosening the engine oil
drain plug.
5) Replace the drain plug gasket.
(A) Oil level gauge
(B) Engine oil filler cap
(C) Upper level
(D) Lower level
(E) Approx. 1.02 (1.1 US qt, 0.9 Imp qt)
LU-00138
(A)(B)
(C)
(D) (E)
(A) Drain plug
(B) Oil filter
LU-00103
LU-00104
LU-00089
(B)
(A)

LU(H4SO)-11
LUBRICATION
Engine Oil
6) Tighten the engine oil drain plug after draining
engine oil.
Tightening torque:
44 N
⋅m (4.5 kgf-m, 32.5 ft-lb)
7) Install the service hole cover.
8) Fill engine oil through the filler pipe up to upper
point on level gauge. Make sure that the vehicle is
placed level when checking oil level. Use the en-
gine oil of proper quality and viscosity, selected in
accordance with the table in figure.
Recommended oil
API classification SL, SJ with the “Energy
Conserving” logo is printed, or SH (if you
cannot obtain the oil with SL, SJ or SH
grades, you may use SG, SF grades “ENER-
GY CONSERVING” oil.)
ACEA specification, A1, A2 or A3
CCMC specification, G4 or G5
New API certification mark (Star burst mark)
label is on the container.
Engine oil capacity:
Upper level
4.02 (4.2 US qt, 3.5 Imp qt)
Lower level
3.02 (3.2 US qt, 2.6 Imp qt)
 Non-turbo model Turbo model
The proper viscosity helps vehicle get good cold
and hot starting by reducing viscous friction and
thus increasing cranking speed.
CAUTION:
When replenishing oil, it does not matter if the
oil to be added is a different brand from that in
the engine; however, use oil having the API
classification and SAE viscosity No. designat-
ed by SUBARU.
NOTE:
If the vehicle is used in areas with very high tempera-
tures or for other heavy duty applications, the follow-
ing viscosity oils may be used: API classification: SL
or SJ or SH
SAE Viscosity No. : 30, 40, 10W-50, 20W-40, 20W-
50.
9) Close the engine oil filler cap.
10) Start the engine and warm it up for a time.
11) After the engine stops, recheck the oil level. If
necessary, add engine oil up to the upper level on
level gauge.
(A) Drain plug
(B) Oil filter
(1) SAE Viscosity No. and Applicable Temperature
(2) PREFERRED
LU-00089
(B)
(A)
LU-02006
40 30 15 0 -15 -20 -30 ( C)
104 86 59 32
10W-30,10W-40 5 -4 -22 ( F)
SAE (1)
5W-30,0W-20 (2)
(1) SAE Viscosity No. and Applicable Temperature
(2) PREFERRED
(A) Oil level gauge
(B) Engine oil filler cap
(C) Upper level
(D) Lower level
(E) Approx. 1.02 (1.1 US qt, 0.9 Imp qt)
LU-02007
40 30 15 0 -15 -20 -30 ( C)
104 86 59 32 5 -4 -22 ( F)
SAE (1)
10W-30,10W-40
5W-30 (2)
LU-00138
(A)(B)
(C)
(D) (E)

LU(H4SO)-12
LUBRICATION
Oil Pump
4. Oil Pump
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Lift-up the vehicle.
3) Remove the under cover.
4) Remove the bolts which install water pipe of oil
cooler to oil pump. (Turbo model)
5) Remove the water pipe and hoses between oil
cooler and water pump. (Turbo model)
6) Remove the radiator. <Ref. to CO(H4SO)-28,
REMOVAL, Radiator.>7) Remove the crankshaft position sensor.
8) Remove the V-belts.
<Ref. to ME(H4SO)-43, REMOVAL, V-belt.> <Ref.
to ME(H4DOTC)-52, REMOVAL, V-belt.>
9) Remove the rear side V-belt tensioner.
10) Remove the crankshaft pulley by using ST.
ST 499977400 CRANK PULLEY WRENCH
(2.0 L model)
ST 499977100 CRANK PULLEY WRENCH
(2.5 L model)
11) Remove the water pump. <Ref. to CO(H4SO)-
21, REMOVAL, Water Pump.>
FU-00009
LU-00137
LU-00010
LU-00046
LU-00011
LU-00012