SUBARU FORESTER 2004 Service Repair Manual

INTAKE (INDUCTION)
IN(H4SO)
Page
1. General Description ....................................................................................2
2. Air Cleaner Element ....................................................................................5
3. Air Cleaner Case .........................................................................................6
4. Air Intake Duct.............................................................................................7
5. Resonator Chamber ....................................................................................8

IN(H4SO)-2
INTAKE (INDUCTION)
General Description
1. General Description
A: COMPONENT
IN-00076
T2
T2
T4
T4T4T5
T3
(6)
(19)
(19)(18)
(18)
(15)(11)
(17)
(16)(9)(12)
(10) (10)
(10)
(13)
(14) (3)
(5)
(4)
T1
T1
(2)
(1)(2)
(1)
(8) (7)
(20)

IN(H4SO)-3
INTAKE (INDUCTION)
General Description
(1) Spacer (10) Clip (19) Spacer
(2) Bushing (11) Air cleaner element (20) Clip
(3) Resonator chamber (12) Air cleaner case B
(4) Cushion (13) Stay LH (MT model)Tightening torque: N
⋅m (kgf-m, ft-lb)
(5) Air intake duct A (14) Stay LH (AT model)T1: 33 (3.4, 24.6)
(6) Air intake duct B (15) Stay RHT2: 6.5 (0.66, 4.8)
(7) Bushing (16) Engine harness bracketT3: 7.5 (0.76, 5.5)
(8) Intake air temperature sensor (17) ClampT4: 16 (1.6, 11.6)
(9) Air cleaner case A (18) BushingT5: 3 (0.3, 2.2)

IN(H4SO)-4
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(H4SO)-5
INTAKE (INDUCTION)
Air Cleaner Element
2. Air Cleaner Element
A: REMOVAL
1) Remove the air intake duct from air cleaner
case.
2) Remove the bolt (A) which secures air cleaner
case to stay.
3) Remove the clip (B) above the air cleaner case.
4) Remove the air cleaner element.
B: INSTALLATION
Install in the reverse order of removal.
NOTE:
 Fasten with a clip after inserting the lower tab of
the case.
 Refer to “COMPONENT” for tightening torque.
<Ref. to IN(H4SO)-2, COMPONENT, General De-
scription.>
C: INSPECTION
Replace if excessively damaged or dirty.
IN-00039
(B)(B)(B)
(A)

IN(H4SO)-6
INTAKE (INDUCTION)
Air Cleaner Case
3. Air Cleaner Case
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Disconnect the connector (A) of intake air tem-
perature sensor.
3) Remove the bolt (B) which installs air cleaner
case to stay.
4) Disconnect the hoses and intake duct from air
cleaner case.
5) Loosen the clamp which connects air cleaner
case to throttle body.
6) Remove the air cleaner case.
B: INSTALLATION
Install in the reverse order of removal.
NOTE:
Refer to “COMPONENT” for tightening torque.
<Ref. to IN(H4SO)-2, COMPONENT, General De-
scription.>
C: INSPECTION
Inspect for cracks and loose connections.
FU-00009
IN-00040
(B)
(A)(B)
IN-00041

IN(H4SO)-7
INTAKE (INDUCTION)
Air Intake Duct
4. Air Intake Duct
A: REMOVAL
1) Remove the bolt (A) which installs air intake duct
A on the front side of body.
2) Remove the clip (B) which connects air intake
duct A to resonator chamber.
3) Remove the air intake duct A.
4) Remove the air intake duct B from resonator
chamber and air cleaner case.
B: INSTALLATION
Install in the reverse order of removal.
NOTE:
Refer to “COMPONENT” for tightening torque.
<Ref. to IN(H4SO)-2, COMPONENT, General De-
scription.>
C: INSPECTION
1) Inspect for cracks and loose connections.
2) Inspect that no foreign objects are mixed in the
air intake duct.
IN-00042
(A)(B)
IN-00043

IN(H4SO)-8
INTAKE (INDUCTION)
Resonator Chamber
5. Resonator Chamber
A: REMOVAL
1) Remove the air intake duct. <Ref. to IN(H4SO)-
7, REMOVAL, Air Intake Duct.>
2) Remove the resonator chamber.
B: INSTALLATION
Install in the reverse order of removal.
NOTE:
Refer to “COMPONENT” for tightening torque.
<Ref. to IN(H4SO)-2, COMPONENT, General De-
scription.>
C: INSPECTION
Inspect for cracks and loose connections.
IN-00044

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)

MECHANICAL
ME(H4SO)
Page
1. General Description ....................................................................................2
2. Compression .............................................................................................25
3. Idle Speed .................................................................................................26
4. Ignition Timing ...........................................................................................27
5. Intake Manifold Vacuum............................................................................28
6. Engine Oil Pressure ..................................................................................29
7. Fuel Pressure ............................................................................................30
8. Valve Clearance ........................................................................................31
9. Engine Assembly ......................................................................................34
10. Engine Mounting .......................................................................................41
11. Preparation for Overhaul ...........................................................................42
12. V-belt .........................................................................................................43
13. Crank Pulley ..............................................................................................45
14. Timing Belt Cover......................................................................................47
15. Timing Belt ................................................................................................48
16. Cam Sprocket ...........................................................................................53
17. Crank Sprocket .........................................................................................55
18. Valve Rocker Assembly ............................................................................56
19. Camshaft ...................................................................................................58
20. Cylinder Head ...........................................................................................62
21. Cylinder Block ...........................................................................................69
22. Engine Trouble in General ........................................................................91
23. Engine Noise .............................................................................................96