Page 977 of 2870
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
Page 978 of 2870
EX(H4SO)-10
EXHAUST
Center Exhaust Pipe
3. Center Exhaust Pipe
A: REMOVAL
After removing the center and front exhaust pipes
as one unit, separate them. Refer to the procedure
for removing the front exhaust pipe.
EX(H4SO)-7, REMOVAL, Front Exhaust Pipe.>
B: INSTALLATION
Install the center exhaust pipe and front exhaust
pipe as one unit. Refer to the procedure for install-
ing the front exhaust pipe.
INSTALLATION, Front Exhaust Pipe.>
C: INSPECTION
1) Make sure there are no exhaust leaks from con-
nections and welds.
2) Make sure there are no holes or rusting.
Page 979 of 2870
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
Page 980 of 2870
EX(H4SO)-12
EXHAUST
Rear Exhaust Pipe
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.
Page 981 of 2870
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
Page 982 of 2870
EX(H4SO)-14
EXHAUST
Muffler
Page 983 of 2870

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)
Page 984 of 2870

COOLING
CO(H4SO)
Page
1. General Description ....................................................................................2
2. Radiator Fan System ................................................................................13
3. Engine Coolant..........................................................................................19
4. Water Pump ..............................................................................................21
5. Thermostat ................................................................................................26
6. Radiator.....................................................................................................28
7. Radiator Cap .............................................................................................34
8. Radiator Main Fan and Fan Motor ............................................................35
9. Radiator Sub Fan and Fan Motor..............................................................40
10. Reservoir Tank ..........................................................................................41
11. Coolant Filler Tank ....................................................................................42
12. Engine Cooling System Trouble in General ..............................................43