Page 1025 of 2870
CO(H4SO)-42
COOLING
Coolant Filler Tank
11.Coolant Filler Tank
A: REMOVAL
WARNING:
The radiator is pressurized. Wait until the en-
gine cools down before working on the radia-
tor.
1) Drain the coolant about 3.02 (3.2 US qt, 2.6 Imp
qt).
GINE COOLANT, REPLACEMENT, Engine Cool-
ant.>
2) Remove the air cleaner upper cover and air in-
take boot.
Cleaner.>
3) Remove the air cleaner element.
4) Disconnect the engine coolant hoses from cool-
ant filler tank.
5) Remove the bolts and nut which install coolant
filler tank.
6) Disconnect the engine coolant hose which con-
nects under side of coolant filler tank.
7) Remove the coolant filler tank.
B: INSTALLATION
1) Install in the reverse order of removal.
Tightening torque:
T1: 19 N
⋅m (1.9 kgf-m, 13.7 ft-lb)
T2: 21 N
⋅m (2.1 kgf-m, 15.2 ft-lb)
2) Fill engine coolant.
ING OF ENGINE COOLANT, REPLACEMENT,
Engine Coolant.>
CO-00051
CO-00052
T2
T1
CO-00053
Page 1026 of 2870

CO(H4SO)-43
COOLING
Engine Cooling System Trouble in General
12.Engine Cooling System Trouble in General
A: INSPECTION
Trouble Possible cause Corrective action
Over-heatinga. Insufficient engine coolantReplenish the engine coolant, inspect for leakage, and
repair.
b. Loose timing belt Repair or replace the timing belt tensioner.
c. Oil on drive belt Replace.
d. Malfunction of thermostat Replace.
e. Malfunction of water pump Replace.
f. Clogged engine coolant passage Clean.
g. Improper ignition timingInspect and repair the ignition control system.
nostics Procedure.>
h. Clogged or leaking radiator Clean or repair, or replace.
i. Improper engine oil in engine coolant Replace the engine coolant.
j. Air/fuel mixture ratio too leanInspect and repair the fuel injection system.
nostics Procedure.>
k. Excessive back pressure in exhaust system Clean or replace.
l. Insufficient clearance between piston and cylinder Adjust or replace.
m. Slipping clutch Repair or replace.
n. Dragging brake Adjust.
o. Defective thermostat Replace.
p. Malfunction of radiator fanInspect the radiator fan relay, engine coolant tempera-
ture sensor or radiator motor and replace there.
Over-coolinga. Atmospheric temperature extremely low Partly cover the radiator front area.
b. Defective thermostat Replace.
Engine coolant
leaks.a. Loosened or damaged connecting units on hoses Repair or replace.
b. Leakage from water pump Replace.
c. Leakage from water pipe Repair or replace.
d. Leakage around cylinder head gasket Retighten the cylinder head bolts or replace gasket.
e. Damaged or cracked cylinder head and crankcase Repair or replace.
f. Damaged or cracked thermostat case Repair or replace.
g. Leakage from radiator Repair or replace.
Noisea. Defective drive belt Replace.
b. Defective radiator fan Replace.
c. Defective water pump bearing Replace the water pump.
d. Defective water pump mechanical seal Replace the water pump.
Page 1027 of 2870
CO(H4SO)-44
COOLING
Engine Cooling System Trouble in General
Page 1028 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 1029 of 2870

LUBRICATION
LU(H4SO)
Page
1. General Description ....................................................................................2
2. Oil Pressure System ...................................................................................8
3. Engine Oil..................................................................................................10
4. Oil Pump ...................................................................................................12
5. Oil Pan and Strainer ..................................................................................16
6. Oil Pressure Switch ...................................................................................20
7. Engine Oil Cooler ......................................................................................21
8. Engine Oil Filter.........................................................................................23
9. Engine Lubrication System Trouble in General.........................................24
Page 1030 of 2870

LU(H4SO)-2
LUBRICATION
General Description
1. General Description
A: SPECIFICATION
Lubrication methodForced lubrication
Oil pumpPump type Trochoid type
Number of teethInner rotor 9
Outer rotor 10
Outer rotor diameter×thicknessNon-turbo model 78×7 mm (3.07×0.28 in)
Turbo model 78×10 mm (3.07×0.39 in)
Tip clearance between inner and outer rotorStandard 0.04 — 0.14 mm (0.0016 — 0.0055 in)
Limit 0.18 mm (0.0071 in)
Side clearance between inner rotor and pump
caseStandard 0.02 — 0.07 mm (0.0008 — 0.0028 in)
Limit 0.12 mm (0.0047 in)
Case clearance between outer rotor and pump
caseStandard 0.10 — 0.175 mm (0.0039 — 0.0069 in)
Limit 0.20 mm (0.0079 in)
Capacity at
80°C (176°F)Non-turbo
model
600 rpmDischarge
pressure98 kPa (1.0 kg/cm
2, 14 psi)
Discharge
quantity3.22 (3.4 US qt, 2.8 Imp qt)/min.
5,000 rpmDischarge
pressure294 kPa (3.0 kg/cm
2, 43 psi)
Discharge
quantity32.62 (34.4 US qt, 28.7 Imp qt)/min.
Turbo model
600 rpmDischarge
pressure98 kPa (1.0 kg/cm
2, 14 psi)
Discharge
quantity4.62 (4.9 US qt, 4.0 Imp qt)/min.
5,000 rpmDischarge
pressure294 kPa (3.0 kg/cm
2, 43 psi)
Discharge
quantity47.02 (49.7 US qt, 41.4 Imp qt)/min.
Relief valve operation pressureNon-turbo model
490 kPa (5.0 kg/cm
2, 71 psi)
Turbo model
588 kPa (6.0 kg/cm
2, 85 psi)
Oil filterTy p eFull-flow filter type
Filtration areaNon-turbo
760 cm
2 (118 sq in)
Tu r b o
800 cm
2 (124 sq in)
By-pass valve opening pressureNon-turbo
157 kPa (1.60 kg/cm
2, 22.8 psi)
Tu r b o
160 kPa (1.63 kg/cm
2, 23.2 psi)
Outer diameter×widthNon-turbo 80×70 mm (3.15×2.76 in)
Tu r b o 6 8×65 mm (2.68×2.56 in)
Oil filter to engine thread size M 20×1.5
Oil pressure
switchType Immersed contact point type
Working voltage — wattage 12 V — 3.4 W or less
Warning light activation pressure
14.7 kPa (0.15 kg/cm
2, 2.1 psi)
Proof pressure
More than 981 kPa (10 kg/cm
2, 142 psi)
Oil capacity (at replacement) 4.02 (4.2 US qt, 3.5 Imp qt)
Page 1031 of 2870
LU(H4SO)-3
LUBRICATION
General Description
B: COMPONENT
1. NON-TURBO MODEL
(1) Plug (13) Oil pressure switch (25) Drain plug
(2) Gasket (14) Oil filler duct (26) Metal gasket
(3) Relief valve spring (15) O-ring (27) Gasket
(4) Relief valve (16) Oil filler cap
(5) Oil seal (17) O-ringTightening torque: N
⋅m (kgf-m, ft-lb)
(6) Oil pump case (18) Baffle plateT1: 5 (0.5, 3.6)
(7) Inner rotor (19) O-ringT2: 6.4 (0.65, 4.7)
(8) Outer rotor (20) Oil strainerT3: 10 (1.0, 7.2)
(9) Oil pump cover (21) Oil level gauge guideT4: 44 (4.5, 32.5)
(10) Oil filter (22) O-ringT5: 25 (2.5, 18.1)
(11) O-ring (23) Oil pan
(12) Oil pump ASSY (24) Oil level gauge
LU-02008
(12)
(11)
T5
T2
T1
T2
T2
T1
T1
T1
T3
T4
T2
(13)
(9)
(8)
(7)
(6)
(20) (19)
(27) (18)(17) (15)
(14) (16)
(24)
(23) (10)
(25)(26)
(5)
(4)
(3)(2)
(1)
(22)
(21)
T4
Page 1032 of 2870
LU(H4SO)-4
LUBRICATION
General Description
2. TURBO MODEL
(35)
(15)
(14)
T7
T2
T1
T2
T5T2
T9
T1
T1
T3
T8
T6
T4
T2
(29)
(9)
(8)
(7) (6)(30)
(12)
(22) (33)
(23)
(24) (32) (21) (16)
(25) (11)
(10)
(28)(27)
T4
(34)
(5)
(4)
(3)(2)
(1)
(31)
(13)
T1
T6
(20) (19) (18) (17)
LU-02005
(26)
(36)