torque SUBARU FORESTER 2004 Service Repair Manual

EX(H4SO)-9
EXHAUST
Front Exhaust Pipe
8) Tighten the bolt which holds front and center ex-
haust pipe assembly to hanger bracket.
Tightening torque:
35 N
⋅m (3.6 kgf-m, 26.0 ft-lb)
9) Lower the vehicle.
10) Connect the rear oxygen sensor connector.
11) Connect the front oxygen (A/F) sensor connec-
tor.
12) Connect the battery ground cable to battery.
C: INSPECTION
1) Make sure there are no exhaust leaks from con-
nections and welds.
2) Make sure there are no holes or rusting.
EX-00038
EX-00030
EX-00029
FU-00009

EX(H4SO)-11
EXHAUST
Rear Exhaust Pipe
4. Rear Exhaust Pipe
A: REMOVAL
1) Separate the rear exhaust pipe from center ex-
haust pipe.
CAUTION:
Be careful, the exhaust pipe is hot.
2) Separate the rear exhaust pipe from muffler.
3) Apply a coat of SUBARU CRC to mating area of
the cushion rubbers in advance.
SUBARU CRC (Part No. 004301003)
4) Remove the rear exhaust pipe bracket from the
cushion rubber.
B: INSTALLATION
1) Apply a coat of SUBARU CRC to mating area of
the cushion rubbers in advance.
SUBARU CRC (Part No. 004301003)
2) Install the rear exhaust pipe bracket to cushion
rubber.
NOTE:
Replace the gaskets with new ones.
3) Install the rear exhaust pipe to muffler.
Tightening torque:
48 N
⋅m (4.9 kgf-m, 35.4 ft-lb)
4) Install the rear exhaust pipe to center exhaust
pipe.
Tightening torque:
18 N
⋅m (1.8 kgf-m, 13.0 ft-lb)
EX-00037
EX-00024
EX-00025
EX-00025
EX-00024
EX-00037

EX(H4SO)-13
EXHAUST
Muffler
5. Muffler
A: REMOVAL
1) Separate the muffler from rear exhaust pipe.
CAUTION:
Be careful, the exhaust pipe is hot.
2) Apply a coat of SUBARU CRC to mating area of
the cushion rubbers in advance.
SUBARU CRC (Part No. 004301003)
3) Remove the front, right and left cushion rubber,
and detach the muffler assembly.
B: INSTALLATION
Install in the reverse order of removal.
NOTE:
Replace the gasket with a new one.
Tightening torque:
48 N
⋅m (4.9 kgf-m, 35.4 ft-lb)
C: INSPECTION
1) Make sure there are no exhaust leaks from con-
nections and welds.
2) Make sure there are no holes or rusting.
3) Make sure the cushion rubber is not worn or
cracked.
EX-00024
EX-00026
EX-00024

CO(H4SO)-4
COOLING
General Description
B: COMPONENT
1. WATER PUMP
 NON-TURBO MODEL
(1) Water pump ASSY (5) GasketTightening torque: N⋅m (kgf-m, ft-lb)
(2) Gasket (6) Thermostat coverT1: First 12 (1.2, 8.7)
Second 12 (1.2, 8.7)
(3) Heater by-pass hose
(4) ThermostatT2: 6.5 (0.66, 4.8)
CO-00001
T2(2) (1)
(4)
T1
(3)
(5)
(6)
T1

CO(H4SO)-5
COOLING
General Description
 TURBO MODEL
(1) Thermostat cover (5) GasketTightening torque: N⋅m (kgf-m, ft-lb)
(2) Gasket (6) Heater by-pass hoseT1: First 12 (1.2, 8.7)
Second 12 (1.2, 8.7)
(3) Thermostat (7) Coolant filler tank by-pass hose
(4) Water pump ASSY (8) Water by-pass pipeT2: 6.5 (0.66, 4.8)
CO-00002
T2
(1)(3)
(6)(7)(8)
(4)
(2)
(5)
T2
T2
T1
T1

CO(H4SO)-6
COOLING
General Description
 MODEL WITH ATF WARMER
(1) Thermostat cover (5) GasketTightening torque: N⋅m (kgf-m, ft-lb)
(2) Gasket (6) Heater by-pass hoseT1: First 12 (1.2, 8.7)
Second 12 (1.2, 8.7)
(3) Thermostat (7) Coolant filler tank by-pass hose
(4) Water pump ASSY (8) Water by-pass pipeT2: 6.5 (0.66, 4.8)
CO-02006
(1)(3)
(6)(7)(8)
(4)
(2)
(5)
T2
T2
T1
T1

CO(H4SO)-7
COOLING
General Description
2. RADIATOR AND RADIATOR FAN
 NON-TURBO MODEL
(1) Radiator lower cushion (11) Radiator sub fan (21) Radiator outlet hose
(2) Radiator (12) Radiator sub fan motor (22) Radiator drain plug
(3) Radiator upper cushion (13) Radiator main fan (23) Radiator cap
(4) Radiator upper bracket (14) Radiator main fan motor
(5) Clamp (15) ATF hose clamp (AT model)Tightening torque: N
⋅m (kgf-m, ft-lb)
(6) Radiator inlet hose (16) ATF inlet hose A (AT model)T1: 4.4 (0.45, 3.3)
(7) Engine coolant reservoir tank cap (17) ATF outlet hose A (AT model)T2: 7.5 (0.76, 5.5)
(8) Overflow hose (18) ATF pipe (AT model)T3: 18 (1.8, 13.0)
(9) Engine coolant reservoir tank (19) ATF inlet hose B (AT model)T4: 3.4 (0.35, 2.5)
(10) Radiator sub fan shroud (20) ATF outlet hose B (AT model)T5: 4.9 (0.50, 3.6)
CO-00003
(9)
(1)(10)(8)
(2)
T3
T2
T2
T4
T4(14)
(20) (22)(3) (4)
(19)(16)
(18)(7)
(17)
(15) (15)
(15)
(15) (15) (15)(12)
(11)
(13)
T5
T1
T1
(5) (5)
(5)(6)
(21)
A
A
C
T3
B
B
C
(23)

CO(H4SO)-9
COOLING
General Description
(1) Radiator lower cushion (18) ATF pipe (AT model) (31) Oil cooler inlet hose B (MT model
with oil cooler)
(2) Radiator (19) ATF inlet hose B (AT model)
(3) Radiator upper cushion (20) ATF outlet hose B (AT model) (32) Oil cooler outlet hose B (MT
model with oil cooler)
(4) Radiator upper bracket (21) Radiator outlet hose
(5) Clamp (22) Radiator drain plug (33) Spacer (MT model with oil cooler)
(6) Radiator inlet hose (23) Engine coolant filler tank (34) Cushion (MT model with oil
cooler)
(7) Engine coolant reservoir tank cap (24) Engine coolant filler tank cap
(8) Over flow hose (25) Engine overflow hose (35) Setting washer (MT model with oil
cooler)
(9) Engine coolant reservoir tank (26) Radiator under cover (AT model)
(10) Radiator fan shroud (27) Engine air breather hose
(11) Radiator sub fan (28) Oil cooler inlet hose A (MT model
with oil cooler)Tightening torque: N
⋅m (kgf-m, ft-lb)
(12) Radiator sub fan motorT1: 4.4 (0.45, 3.3)
(13) Radiator main fan (29) Oil cooler outlet hose A (MT
model with oil cooler)T2: 7.5 (0.76, 5.5)
(14) Radiator main fan motorT3: 18 (1.8, 13.0)
(15) ATF hose clamp (AT model) (30) Oil cooler pipe (MT model with oil
cooler)T4: 3.4 (0.35, 2.5)
(16) ATF inlet hose A (AT model)T5: 4.9 (0.50, 3.6)
(17) ATF outlet hose A (AT model)

CO(H4SO)-10
COOLING
General Description
C: 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 in 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
sensors or units, be sure to disconnect the ground
cable from battery.

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