SUBARU FORESTER 2004 Service Repair Manual

LU(H4SO)-13
LUBRICATION
Oil Pump
12) Remove the timing belt guide. (MT model)
13) Remove the crank sprocket.
14) Remove the bolts which install oil pump onto
cylinder block.
15) Remove the oil pump by using flat tip screw-
driver.
CAUTION:
Be careful not to scratch the mating surfaces of
cylinder block and oil pump.B: INSTALLATION
Install in the reverse order of removal.
Do the following:
1) Apply liquid gasket to the matching surfaces of
oil pump.
Liquid gasket:
Part No. 004403007
THREE BOND 1215 or equivalent
2) Replace the O-ring (A) with a new one.
3) Apply a coat of engine oil to the inside of oil seal.
4) Be careful not to scratch the oil seal when install-
ing oil pump on cylinder block.
5) Position the oil pump, aligning the notched area
with crankshaft, and push the oil pump straight.
CAUTION:
Make sure the oil seal lip is not folded.
6) Install the oil pump.
Tightening torque:
T: 6.4 N
⋅m (0.65 kgf-m, 4.7 ft-lb)
LU-00013
LU-00014
LU-00015
LU-00016
LU-00017
(A)
LU-00018
LU-00019
T
T

LU(H4SO)-14
LUBRICATION
Oil Pump
C: DISASSEMBLY
Remove the screws which secure oil pump cover
and disassemble oil pump. Inscribe alignment
marks on the inner and outer rotors so that they can
be replaced in their original positions during reas-
sembly.
CAUTION:
Before disassembling the oil pump, remove the
relief valve.
D: ASSEMBLY
1) Install the front oil seal by using ST.
ST 499587100 OIL SEAL INSTALLER
NOTE:
Use a new oil seal.
2) Apply a coat of engine oil to the inner and outer
rotors.
3) Install the inner and outer rotors in their original
positions.
4) Install the oil relief valve and relief valve spring
and plug.
NOTE:
Use a new gasket.
5) Install the oil pump cover.
Tightening torque:
T1: 5 N
⋅m (0.5 kgf-m, 3.6 ft-lb)
T2: 44 N
⋅m (4.5 kgf-m, 32.5 ft-lb)
(A) Oil seal
(B) Pump case
(C) Inner rotor
(D) Outer rotor
(E) Pump cover
(F) Relief valve
(G) Relief valve spring
(H) Plug
(I) Gasket
LU-00020
(E)
(D)
(C)
(B)
(A)
(F)
(G)(I)
(H)
LU-00021
ST
LU-00022
T1
T2

LU(H4SO)-15
LUBRICATION
Oil Pump
E: INSPECTION
1. TIP CLEARANCE
Measure the tip clearance of rotors. If clearance ex-
ceeds the limit, replace the rotors as a matched set.
Tip clearance:
Standard
0.04 — 0.14 mm (0.0016 — 0.0055 in)
Limit
0.18 mm (0.0071 in)
2. CASE CLEARANCE
Measure the clearance between the outer rotor and
oil pump rotor housing. If clearance exceeds the
limit, replace the rotor.
Case clearance:
Standard
0.10 — 0.175 mm (0.0039 — 0.0069 in)
Limit
0.20 mm (0.0079 in)
3. SIDE CLEARANCE
Measure the clearance between the oil pump inner
rotor and pump cover. If clearance exceeds the lim-
it, replace the rotor or pump body.
Side clearance:
Standard
0.02 — 0.07 mm (0.0008 — 0.0028 in)
Limit
0.12 mm (0.0047 in)
4. OIL RELIEF VALVE
Check the valve for fitting condition and damage,
and the relief valve spring for damage and deterio-
ration. Replace the parts if defective.
Relief valve spring:
Non-turbo model
Free length
72.8 mm (2.866 in)
Installed length
54.7 mm (2.154 in)
Load when installed
81.4 N (8.3 kgf, 18.3 lb)
Turbo model
Free length
73.7 mm (2.902 in)
Installed length
54.7 mm (2.154 in)
Load when installed
93.2 N (9.5 kgf, 20.9 lb)
5. OIL PUMP CASE
Check the oil pump case for worn shaft hole,
clogged oil passage, worn rotor chamber, cracks,
and other faults.
6. OIL SEAL
Check the oil seal lips for deformation, hardening,
wear, etc. and replace if defective.
LU-00023
LU-00024
LU-00025

LU(H4SO)-16
LUBRICATION
Oil Pan and Strainer
5. Oil Pan and Strainer
A: REMOVAL
1) Set the vehicle on lift arms.
2) Remove the front wheels.
3) Disconnect the ground cable from battery.
4) Remove the air intake duct and air cleaner case.
(Non-turbo model)

Case.>
5) Disconnect the connector from mass air flow
sensor. (Turbo model)
6) Remove the air intake boot and air cleaner upper
cover. (Turbo model)
7) Remove the intercooler (Turbo model) IN(H4DOTC)-10, REMOVAL, Intercooler.>8) Remove the pitching stopper.
9) Remove the radiator upper brackets.
10) Support the engine with a lifting device and
wire ropes.
11) Lift-up the vehicle.
CAUTION:
When lifting up the vehicle, rise up the wire
rope together.
12) Remove the under cover.
FU-00009
LU-00026
LU-00070
ME-00213
LU-00027
LU-00028

LU(H4SO)-17
LUBRICATION
Oil Pan and Strainer
13) Drain the engine oil.
Set a container under the vehicle, and remove the
drain plug from oil pan.
14) Remove the front and center exhaust pipes.
(Non-turbo model) AL, Front Exhaust Pipe.>
15) Remove the nuts which install front cushion
rubber onto front crossmember.
16) Remove the bolts which install oil pan on cylin-
der block while raising up engine.
17) Insert the oil pan cutter blade between the cyl-
inder block to oil pan clearance.
CAUTION:
Do not use a screwdriver or similar tool in place
of oil pan cutter.18) Remove the oil strainer.
19) Remove the baffle plate.
(A) Gasket
(B) Drain plug
LU-00029
(B)(A)
LU-00030
LU-00031
LU-00032
LU-00033

LU(H4SO)-18
LUBRICATION
Oil Pan and Strainer
B: INSTALLATION
CAUTION:
Before installing the oil pan, clean sealant from
oil pan and engine block.
1) Install the baffle plate.
Tightening torque:
6.4 N
⋅m (0.65 kgf-m, 4.7 ft-lb)
2) Install the oil strainer onto baffle plate.
NOTE:
Replace the O-ring with a new one.
Tightening torque:
10 N
⋅m (1.0 kgf-m, 7.2 ft-lb)
3) Apply liquid gasket to the mating surfaces and
install oil pan.
Liquid gasket:
Part No. 004403007
THREE BOND 1215 or equivalent4) Tighten the bolts which install the oil pan onto
engine block.
Tightening torque:
5 N
⋅m (0.5 kgf-m, 3.6 ft-lb)
5) Lower the engine onto front crossmember.
6) Tighten the nuts which install front cushion rub-
ber onto front crossmember.
Tightening torque:
69 N
⋅m (7.0 kgf-m, 50.9 ft-lb)
7) Install the front and center exhaust pipes. (Non-
Turbo model) TION, Front Exhaust Pipe.>
NOTE:
Always use new gaskets.
8) Install the under cover.
9) Lower the vehicle.
CAUTION:
When lowering the vehicle, lower the lifting de-
vice and wire rope together.
LU-00033
LU-00032
LU-00034
LU-00031
LU-00030
LU-00035

LU(H4SO)-19
LUBRICATION
Oil Pan and Strainer
10) Remove the lifting device and steel cables.
11) Install the pitching stopper.
Tightening torque:
T1: 50 N
⋅m (5.1 kgf-m, 36.9 ft-lb)
T2: 58 N
⋅m (5.9 kgf-m, 42.8 ft-lb)
12) Install the radiator upper brackets.
13) Install the air intake duct and air cleaner case.
(Non-turbo model) LATION, Air Intake Duct.> INSTALLATION, Air Cleaner Case.>
14) Install the intercooler. (Turbo model) IN(H4DOTC)-11, INSTALLATION, Intercooler.>15) Install the air intake boot and air cleaner upper
cover. (Turbo model)
16) Connect the connector to mass air flow sensor.
(Turbo model)
17) Install the front wheels.
18) Connect the battery ground cable to battery.
19) Fill engine oil. TION, Engine Oil.>
C: INSPECTION
By visual check make sure the oil pan, oil strainer,
oil strainer stay and baffle plate are not damaged.
LU-00028
ME-00218T2T1
LU-00027
LU-00070
LU-00026
FU-00009

LU(H4SO)-20
LUBRICATION
Oil Pressure Switch
6. Oil Pressure Switch
A: REMOVAL
1) Remove the generator from bracket. SC(H4SO)-15, REMOVAL, Generator.>
2) Disconnect the terminal from oil pressure switch.
3) Remove the oil pressure switch.
B: INSTALLATION
1) Apply liquid gasket to the oil pressure switch
threads.
Liquid gasket:
Part No. 004403007
THREE BOND 1324 or equivalent
2) Install the oil pressure switch onto engine block.
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
3) Connect the terminal of oil pressure switch.
4) Install the generator on bracket. SC(H4SO)-15, INSTALLATION, Generator.>
C: INSPECTION
Make sure oil does not leak or seep from where the
oil pressure switch is installed.
LU-00036
LU-00037
LU-00038
LU-00037
LU-00036

LU(H4SO)-21
LUBRICATION
Engine Oil Cooler
7. Engine Oil Cooler
A: REMOVAL
NOTE:
Engine oil cooler is equipped with turbo model only.
1) Lift-up the vehicle.
2) Remove the under cover.
3) Drain the engine oil. Set a container under the
vehicle, and remove the drain plug from oil pan.
4) Drain the engine coolant.
5) Remove the water by-pass pipe between oil
cooler and water pump.
6) Remove the engine oil filter. 23, REMOVAL, Engine Oil Filter.>
7) Remove the connector and remove oil cooler.8) Remove the adapters (1) and (2).
(A) Gasket
(B) Drain plug
LU-00039
(B)(A)
LU-00040
(A) Adapter (1)
(B) Adapter connector
(C) Adapter (2)
(D) Oil cooler
(E) Oil cooler connector
LU-00041
(A)
(B)
(C)
(D)
(E)

LU(H4SO)-22
LUBRICATION
Engine Oil Cooler
B: INSTALLATION
NOTE:
Engine oil cooler is equipped with turbo model only.
1) Install in the reverse order of removal.
2) Contact the knock pin (A) of adapter (1) to cylin-
der block rib (B) to install adapter (1).
3) Install the adapter (2).
4) Contact the engine oil cooler stopper (A) to
adapter (2) rib (B) to install engine oil cooler.
Tightening torque:
T1: 6.4 N
⋅m (0.7 kgf-m, 5.1 ft-lb)
T2: 44 N
⋅m (4.5 kgf-m, 33 ft-lb)
T3: 54 N
⋅m (5.5 kgf-m, 40 ft-lb)NOTE:
Always use a new O-ring.
C: INSPECTION
1) Check that the coolant passages are not
clogged using air blow method.
2) Check the mating surfaces of cylinder block, O-
ring groove and oil filter for damage.
LU-00042
(A)
(B)
LU-00043
(B)(A)
(A) Adapter (1)
(B) Adapter connector
(C) Adapter (2)
(D) Oil cooler
(E) Oil cooler connector
LU-00044
(A)
(B)
(C)
(D)
(E)
T1
T2
T3