SUBARU FORESTER 2004 Service Repair Manual

ME(H4DOTC)-121
MECHANICAL
Engine Trouble in General
5. Engine does not return to
idle.Engine control system A
Intake system Loosened or cracked vacuum hose A
Others Stuck or damaged throttle valve A
Accelerator cable out of adjustment (2.0 L model) B
6. Dieseling (Run-on) Engine control system A
Cooling system Overheating B
Others Malfunction of evaporative emission control system B
7. Afterburning in exhaust
systemEngine control system A
Intake system Loosened or cracked intake duct C
Loosened or cracked PCV hose C
Loosened or cracked vacuum hose B
Defective PCV valve B
Loosened oil filler cap C
Belt Defective timing B
Compression Incorrect valve clearance B
Loosened spark plugs or defective gasket C
Loosened cylinder head bolts or defective gasket C
Improper valve seating B
Defective valve stem C
Worn or broken valve spring C
Worn or stuck piston rings, cylinder and piston C
Incorrect valve timing A
Lubrication system Incorrect oil pressure C
Cooling system Over cooling C
Others Malfunction of evaporative emission control system C
8. Knocking Engine control system A
Intake system Loosened oil filler cap B
Belt Defective timing B
Compression Incorrect valve clearance C
Incorrect valve timing B
Cooling system Overheating A
9. Excessive engine oil con-
sumptionIntake system Loosened or cracked PCV hose A
Defective PCV valve B
Loosened oil filler cap C
Compression Defective valve stem A
Worn or stuck piston rings, cylinder and piston A
Lubrication system Loosened oil pump attaching bolts and defective gas-
ketB
Defective oil filter o-ring B
Defective crankshaft oil seal B
Defective rocker cover gasket B
Loosened oil drain plug or defective gasket B
Loosened oil pan fitting bolts or defective oil pan B TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK

ME(H4DOTC)-122
MECHANICAL
Engine Trouble in General
10. Excessive fuel consump-
tionEngine control system A
Intake system Dirty air cleaner element A
Belt Defective timing B
Compression Incorrect valve clearance B
Loosened spark plugs or defective gasket C
Loosened cylinder head bolts or defective gasket C
Improper valve seating B
Defective valve stem C
Worn or broken valve spring C
Worn or stuck piston rings, cylinder and piston B
Incorrect valve timing B
Lubrication system Incorrect oil pressure C
Cooling system Over cooling C
Others Accelerator cable out of adjustment (2.0 L model) B TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK

ME(H4DOTC)-123
MECHANICAL
Engine Noise
26.Engine Noise
A: INSPECTION
NOTE*:
When disconnecting the fuel injector connector, Malfunction Indicator Light illuminates and DTC is stored in
ECM memory.
Therefore, carry out the CLEAR MEMORY MODE Mode.> and INSPECTION MODE after con-
necting the fuel injector connector.
Type of sound Condition Possible cause
Regular clicking soundSound increases as engine
speed increases. Valve mechanism is defective.
 Incorrect valve clearance
 Worn valve rocker
 Worn camshaft
 Broken valve spring
Heavy and dull clankOil pressure is low. Worn crankshaft main bearing
 Worn connecting rod bearing (big end)
Oil pressure is normal. Loose flywheel mounting bolts
 Damaged engine mounting
High-pitched clank (Spark
knock)Sound is noticeable when
accelerating with an overload. Ignition timing advanced
 Accumulation of carbon inside combustion chamber
 Wrong heat range of spark plug
 Improper octane number of gasoline
Clank when engine speed is
medium (1,000 to 2,000 rpm).Sound is reduced when fuel
injector connector of noisy cyl-
inder is disconnected.
(NOTE*) Worn crankshaft main bearing
 Worn bearing at crankshaft end of connecting rod
Knocking sound when engine
is operating under idling speed
and engine is warmSound is reduced when fuel
injector connector of noisy cyl-
inder is disconnected.
(NOTE*) Worn cylinder liner and piston ring
 Broken or stuck piston ring
 Worn piston pin and hole at piston end of connecting rod
Sound is not reduced if each
fuel injector connector is dis-
connected in turn. (NOTE*) Unusually worn valve lifter
 Worn cam gear
 Worn camshaft journal bore in crankcase
Squeaky sound —  Insufficient generator lubrication
Rubbing sound —  Defective generator brush and rotor contact
Gear scream when starting
engine— Defective ignition starter switch
 Worn gear and starter pinion
Sound like polishing glass with
a dry cloth— Loose drive belt
 Defective water pump shaft
Hissing sound — Loss of compression
 Air leakage in air intake system, hoses, connections or mani-
folds
Timing belt noise — Loose timing belt
 Belt contacting case/adjacent part
Valve tappet noise —  Incorrect valve clearance

ME(H4DOTC)-124
MECHANICAL
Engine Noise

FUJI HEAVY INDUSTRIES LTD. G8080GE3
2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
ENGINE SECTION 2
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(H4DOTC)
EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICE)EC(H4DOTC)
INTAKE (INDUCTION) IN(H4DOTC)
MECHANICAL ME(H4DOTC)
EXHAUST EX(H4DOTC)
COOLING CO(H4DOTC)
LUBRICATION LU(H4DOTC)
SPEED CONTROL SYSTEM SP(H4DOTC)
IGNITION IG(H4DOTC)
STARTING/CHARGING SYSTEM SC(H4DOTC)
ENGINE (DIAGNOSTIC) EN(H4DOTC)

EXHAUST
EX(H4DOTC)
Page
1. General Description ....................................................................................2
2. Front Exhaust Pipe......................................................................................7
3. Center Exhaust Pipe ...................................................................................9
4. Joint Pipe ..................................................................................................13
5. Rear Exhaust Pipe ....................................................................................14
6. Muffler .......................................................................................................16

EX(H4DOTC)-2
EXHAUST
General Description
1. General Description
A: COMPONENT
1. FRONT EXHAUST PIPE
EX-02006
T1
T5
T1
T3
T6
T3
T4
T3
T4
T2 T1
(1)
(3)
(6)
(7)
(10)(5)
(13)
(9) (17)
(12)(11) (14)(15)(19) (16)
(4)(2)
(18)
A
A
T1
T2(20)
(21)(22)
(7)
T3
(8)

EX(H4DOTC)-3
EXHAUST
General Description
(1) Gasket (12) Exhaust manifold upper cover
(LH)Tightening torque: N·m (kgf-m, ft-lb)
(2) Exhaust manifold upper cover
(RH)T1: 19 (1.9, 13.7)
(13) Exhaust manifold lower cover (LH)T2: 7.5 (0.8, 5.5)
(3) Exhaust manifold (RH) (14) GasketT3: 35 (3.6, 26.0)
(4) Exhaust manifold lower cover
(RH)(15) Turbocharger joint pipeT4: 40 (4, 28.9)
(16) GasketT5: INSTALLATION, Front Oxygen
(A/F) Sensor.> or FU(H4DOTC 2.5)-37,
INSTALLATION, Front Oxygen
(A/F) Sensor.> (5) Front exhaust pipe upper cover (17) Front oxygen (A/F) sensor
(6) Front exhaust pipe upper insulator
(RH)(18) Exhaust temperature sensor
(19) Precatalytic converter
(7) Gasket (20) Front exhaust pipe upper insulator
(LH)
(8) Front exhaust pipeT6: INSTALLATION, Exhaust
Temperature Sensor.> or to FU(H4DOTC 2.5)-40,
INSTALLATION, Exhaust
Temperature Sensor.> (9) Front exhaust pipe lower insulator
(RH)(21) Front exhaust pipe lower insulator
(LH)
(10) Front exhaust pipe lower cover (22) Exhaust manifold (LH)
(11) Gasket

EX(H4DOTC)-4
EXHAUST
General Description
2. CENTER AND REAR EXHAUST PIPE, AND MUFFLER
 2.0 L model
(1) Gasket (13) Rear catalytic converter (25) Muffler cutter
(2) Front catalytic converter (14) Gasket (26) Center exhaust pipe (Rear)
(3) Center pipe upper cover (Front) (15) Rear exhaust pipe
(4) Center exhaust pipe (Front) (16) Lower rear exhaust pipe cover
(Front)Tightening torque: N·m (kgf-m, ft-lb)
(5) Center pipe lower cover (Front)T1: 13 (1.3, 9.6)
(6) Bracket (17) ChamberT2: 18 (1.8, 13.0)
(7) Gasket (18) CushionT3: 30 (3.1, 22.4)
(8) Center pipe upper cover (Rear) (19) SpringT4: 35 (3.6, 26.0)
(9) Center pipe lower cover (Rear) (20) BoltT5: 48 (4.9, 35.4)
(10) Upper rear catalytic converter
cover(21) Upper rear exhaust pipe cover
(Front)T6: INSTALLATION, Rear Oxygen
Sensor.>
(11) Lower rear catalytic converter
cover(22) Gasket
(23) Muffler
(12) Rear oxygen sensor (24) Cushion rubber
EX-00040
T4
A
T1
T5
T6
T4
(25)
(19)(24)
(24) (20)
(18) (17)
(16)(23)
(22)
(21)
A
(14)
T3
T4
T4
T4
(1)
(2)
(6)
(3)
(5)
T2 (8)(10) (12)
(11) (13)
(9) (26)
(7)
T1
T1
(15)
(4)