lock SUBARU FORESTER 2004 Service Repair Manual

EX(H4SO)-5
EXHAUST
General Description
(1) Front exhaust pipe upper cover
CTR(15) Rear exhaust upper cover (31) Front catalytic converter upper
cover
(16) Rear exhaust lower cover
(2) Front exhaust pipe lower cover
CTR(17) Rear catalytic lower converter
cover(32) Front oxygen (A/F) sensor
(33) Rear oxygen sensor
(3) Clamp (18) Clamp (34) Clamp
(4) Front exhaust pipe upper cover LH (19) Cushion rubber
(5) Front exhaust pipe lower cover LH (20) Rear exhaust pipeTightening torque: N
⋅m (kgf-m, ft-lb)
(6) Front exhaust pipe (21) GasketT1: 8 (0.8, 5.8)
(7) Front exhaust pipe lower cover RH (22) Self-locking nutT2: 13 (1.3, 9.4)
(8) Front exhaust pipe upper cover
RH(23) MufflerT3: 18 (1.8, 13.0)
(24) ProtectorT4: 21 (2.1, 15.2)
(9) Gasket (25) GasketT5: 30 (3.1, 22.4)
(10) Gasket (26) Front catalytic converterT6: 35 (3.6, 26.0)
(11) Spring (27) Center exhaust lower coverT7: 48 (4.9, 35.4)
(12) Chamber (28) Center exhaust upper cover
(13) Rear catalytic converter (29) Center exhaust pipe
(14) Rear catalytic converter upper
cover(30) Front catalytic converter lower
cover

CO(H4SO)-23
COOLING
Water Pump
B: INSTALLATION
1. NON-TURBO MODEL
1) Install water pump onto cylinder block (LH).
NOTE:
 Replace the gasket with a new one.
 When installing the water pump, tighten bolts in
two stages in alphabetical sequence as shown in
the figure.
Tightening torque:
First:
12 N
⋅m (1.2 kgf-m, 8.7 ft-lb)
Second:
12 N
⋅m (1.2 kgf-m, 8.7 ft-lb)
 Model without ATF warmer
 Model with ATF warmer
2) Connect the hose to water pump.
3) Install the tensioner bracket.
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)4) Install the belt cover No. 2 (LH).
Tightening torque:
5 N
⋅m (0.5 kgf-m, 3.6 ft-lb)
5) Install the camshaft sprockets (LH) by using ST.
ST 18231AA010 CAM SPROCKET WRENCH
NOTE:
Also the CAM SPROCKET WRENCH (499207100)
can be used.
Tightening torque:
78 N
⋅m (8.0 kgf-m, 57.9 ft-lb)
6) Install the belt idler No. 2.
Tightening torque:
39 N
⋅m (4.0 kgf-m, 28.9 ft-lb)
7) Install the automatic belt tension adjuster which
tension rod is holded with pin. 49, AUTOMATIC BELT TENSION ADJUSTER AS-
SEMBLY AND BELT IDLER, INSTALLATION,
Timing Belt.>
8) Install the timing belt. TIMING BELT, INSTALLATION, Timing Belt.>
CO-00026
(E)
(D)
(B)
(C)(A) (F)
CO-02008
(B) (C) (D)(E)(F)
(A)
CO-00020
CO-00019
CO-00018
ST
CO-00017

CO(H4SO)-24
COOLING
Water Pump
9) Install the V-belts. STALLATION, V-belt.>
10) Install the radiator. STALLATION, Radiator.>
2. TURBO MODEL
1) Install the water pump onto cylinder block (LH).
NOTE:
 Replace the gasket with a new one.
 When installing the water pump, tighten bolts in
two stages in alphabetical sequence as shown in
the figure.
Tightening torque:
First:
12 N
⋅m (1.2 kgf-m, 8.7 ft-lb)
Second:
12 N
⋅m (1.2 kgf-m, 8.7 ft-lb)
2) Connect the hose to water pump.
3) Install the tensioner bracket.
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)4) Install the belt cover No. 2 (LH).
Tightening torque:
5 N
⋅m (0.5 kgf-m, 3.6 ft-lb)
5) Install the cam sprockets (LH) by using ST.
ST 499977500 CAM SPROCKET WRENCH
(Intake)
Tightening torque:
2.0 L model
98 N
⋅m (10.0 kgf-m, 72.4 ft-lb)
2.5 L model
29.5 N
⋅m (3.0 kgf-m, 21.8 ft-lb), and then
tighten 45
° furthermove
ST 499207400 CAM SPROCKET WRENCH
(Exhaust)
Tightening torque:
98 N
⋅m (10.0 kgf-m, 72.4 ft-lb)
6) Install the camshaft position sensor. (2.0 L mod-
el) Camshaft Position Sensor.>
7) Install the belt idler No. 2 (C).
8) Install the belt idler (B).
CO-00027
(B) (C) (D)(E)(F)
(A)
CO-00025
CO-00024
ME-00710
ME-00709

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)-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)-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)-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)-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

LU(H4SO)-23
LUBRICATION
Engine Oil Filter
8. Engine Oil Filter
A: REMOVAL
1) Remove six clips on the under cover.
2) Turn the service hole cover counterclockwise.
3) Remove the oil filter with ST.
ST 498547000 OIL FILTER WRENCH (Outer
diameter: 80 mm (3.15 in))
ST 18332AA000 OIL FILTER WRENCH (Outer
diameter: 68 mm (2.68 in))
ST 18332AA010 OIL FILTER WRENCH (Outer
diameter: 65 mm (2.56 in))
B: INSTALLATION
1) Wipe and clean the oil filter matching surface on
cylinder block and oil cooler.
2) Get a new oil filter and apply a thin coat of engine
oil to the seal rubber.
CAUTION:
Be careful not to use the oil filter 80 mm (3.15 in)
in diameter to turbo model.
3) Install the oil filter by turning it by hand, being
careful not to damage seal rubber.
 Tighten the oil filter 80 mm (3.15 in) or 65 mm
(2.56 in) in diameter by approx. 2/3 — 3/4 rotation
more after the seal rubber of oil filter comes in con-
tact with cylinder block or oil cooler.
 Tighten the oil filter 68 mm (2.68 in) in diameter
by approx. 1 rotation more after the seal rubber of
oil filter comes in contact with cylinder block or oil
cooler.
CAUTION:
Do not tighten excessively, or oil may leak.
C: INSPECTION
1) After installing the oil filter, run the engine and
make sure that no oil is leaking around seal rubber.
NOTE:
The filter element and filter case are permanently
jointed; therefore, interior cleaning is not neces-
sary.
2) Check the engine oil level. 10, INSPECTION, Engine Oil.>
(A) Oil filter
LU-00103
LU-00104
LU-00091
(A)