SUBARU FORESTER 2004 Service Repair Manual

IN(H4DOTC)-2
INTAKE (INDUCTION)
General Description
1. General Description
A: COMPONENT
1. AIR CLEANER
(1) Mass air flow and intake air tem-
perature sensor(7) Air cleaner lower case (14) Cushion
(8) Cushion rubber
(2) Air cleaner upper cover (9) Air intake ductTightening torque: N
⋅m (kgf-m, ft-lb)
(3) Air cleaner element (10) Resonator chamber ASSYT1: 7.5 (0.76, 5.5)
(4) Spacer (11) Cushion rubberT2: 33 (3.4, 24.6)
(5) Bushing (12) ClampT3: 2.5 (0.25, 1.8)
(6) Clip (13) Air intake bootT4: 1.7 (0.17, 1.2)
(3)
(12)
(12) (13)
(6)
(6)(7)
(4)
(5) (8)
(14)
(11)
(10)T3
T3
T2
(9)
T1
T1
T1
T1
T4
(2)
(1)
IN-00001

IN(H4DOTC)-3
INTAKE (INDUCTION)
General Description
2. INTAKE DUCT
(1) Clamp (5) Air by-pass hose CTightening torque: N⋅m (kgf-m, ft-lb)
(2) PCV hose ASSY (6) Intake ductT1: 19 (1.9, 13.7)
(3) Air by-pass hose A (7) ClampT2: 3 (0.3, 2.2)
(4) Air by-pass hose B
IN-00056
T1
(1) (3) (4)
(6) (5)
(2)
(7)
T2

IN(H4DOTC)-4
INTAKE (INDUCTION)
General Description
3. INTERCOOLER
(1) Intercooler (7) O-ringTightening torque: N⋅m (kgf-m, ft-lb)
(2) Intercooler bracket RH (8) ClampT1: 3 (0.3, 2.2)
(3) Intercooler bracket LH (9) Air by-pass hose AT2: 6.1 (0.62, 4.5)
(4) Clamp (10) Intercooler ductT3: 16 (1.6, 11.6)
(5) Air intake duct (11) Clamp
(6) Air by-pass valve (12) PCV pipe
IN-00248
T1
T2
T2T3
T3
(2)
(4) (12)
(5)
(4)
(10)(7)
(10)
(11)(11)(1)
(3)
(10)(11)
(6)(7)(8)(9)
T3
T3
(7)

IN(H4DOTC)-5
INTAKE (INDUCTION)
General Description
4. TURBOCHARGER
(1) Oil inlet pipe (7) GasketTightening torque: N⋅m (kgf-m, ft-lb)
(2) Metal gasket (8) Oil outlet pipeT1: 4.4 (0.45, 3.3)
(3) Turbocharger (9) ClipT2: 4.9 (0.50, 3.6)
(4) Water pipe (10) Oil outlet hoseT3: 29 (3.0, 21.7)
(5) Clamp (11) Turbocharger bracket RHT4: 33 (3.4, 24.6)
(6) Engine coolant hose (12) Turbocharger bracket LHT5: 16 (1.6, 11.6)
IN-00249
T5
T1(3)
(8)
(4) (5) (9)
(9)(6)
(12) (1)
(2)
(2)
(2)
(2)
(2)
(7)
(2)
(11)(10)
T4
T2
T3
T4
(2)

IN(H4DOTC)-6
INTAKE (INDUCTION)
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
sensor or units, be sure to disconnect the ground
cable from battery.

IN(H4DOTC)-7
INTAKE (INDUCTION)
Air Cleaner
2. Air Cleaner
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Disconnect the connector from mass air flow
sensor.
3) Loosen the clamp (A) which connects air intake
boot and intake duct.
4) Remove the clip (B) from air cleaner upper cover.
5) Remove the air cleaner upper cover.
6) Remove the air cleaner element.
7) Remove the air cleaner lower case.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
33 N
⋅m (3.4 kgf-m, 24.6 ft-lb)
NOTE:
Before installing the air cleaner upper cover, align
the holes with protruding portions of air cleaner
lower case, then secure the upper cover to lower
case.
C: INSPECTION
Replace if excessively damaged or dirty.
FU-00009
IN-00005
IN-00006
(B)
(A)
IN-00007
IN-00007
IN-00008

IN(H4DOTC)-8
INTAKE (INDUCTION)
Air Intake Duct
3. Air Intake Duct
A: REMOVAL
Remove the bolts which install air intake duct on
the front side of body.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
7.5 N
⋅m (0.76 kgf-m, 55 ft-lb)
C: INSPECTION
1) Inspect for cracks and loose connections.
2) Inspect that no foreign objects are mixed in the
air intake duct.
IN-00009
IN-00009

IN(H4DOTC)-9
INTAKE (INDUCTION)
Intake Duct
4. Intake Duct
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the intake manifold. <Ref. to
FU(H4DOTC)-14, REMOVAL, Intake Manifold.> or
<Ref. to FU(H4DOTC 2.5)-14, REMOVAL, Intake
Manifold.>
3) Remove the sensor, engine harness, and fuel
pipe attached to intake manifold. <Ref. to
FU(H4DOTC)-21, DISASSEMBLY, Intake Mani-
fold.> or <Ref. to FU(H4DOTC 2.5)-19, DISAS-
SEMBLY, Intake Manifold.>
4) Remove the intake duct from intake manifold.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
19 N
⋅m (1.9 kgf-m, 13.7 ft-lb)
FU-00009
IN-00250
IN-00250

IN(H4DOTC)-10
INTAKE (INDUCTION)
Intercooler
5. Intercooler
A: REMOVAL
1) Disconnect the PCV hose from PCV pipe.
2) Remove the PCV pipe from intercooler.
3) Disconnect the hose from air by-pass valve.4) Remove the bolts which secure intercooler to
bracket.
5) Loosen the clamp (A) which connects turbo-
charger and intercooler duct.
6) Loosen the clamp (B) which connects throttle
body and intercooler.
7) Disconnect the intercooler duct from turbocharg-
er.
8) Remove the intercooler from throttle body.
IN-00011
IN-00012
IN-00013
IN-00014
IN-00015
IN-00016
(A)(B)

IN(H4DOTC)-11
INTAKE (INDUCTION)
Intercooler
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
16 N
⋅m (1.6 kgf-m, 11.6 ft-lb)
C: DISASSEMBLY
1) Remove the air by-pass valve from intercooler.
2) Remove the intercooler ducts from intercooler.3) Separate the ducts.
D: ASSEMBLY
Assemble in the reverse order of disassembly.
NOTE:
Install the O-ring in proper position.
Tightening torque:
16 N
⋅m (1.6 kgf-m, 11.6 ft-lb)
IN-00014
IN-00015
IN-00017
IN-00018
IN-00027
IN-00017
IN-00018