Page 1449 of 2870
IN(H4DOTC)-10
INTAKE (INDUCTION)
Intercooler
5. Intercooler
A: REMOVAL
1) Disconnect the PCV hose from PCV pipe.
2) Remove the PCV pipe from intercooler.
3) Disconnect the hose from air by-pass valve.4) Remove the bolts which secure intercooler to
bracket.
5) Loosen the clamp (A) which connects turbo-
charger and intercooler duct.
6) Loosen the clamp (B) which connects throttle
body and intercooler.
7) Disconnect the intercooler duct from turbocharg-
er.
8) Remove the intercooler from throttle body.
IN-00011
IN-00012
IN-00013
IN-00014
IN-00015
IN-00016
(A)(B)
Page 1450 of 2870
IN(H4DOTC)-11
INTAKE (INDUCTION)
Intercooler
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
16 N
⋅m (1.6 kgf-m, 11.6 ft-lb)
C: DISASSEMBLY
1) Remove the air by-pass valve from intercooler.
2) Remove the intercooler ducts from intercooler.3) Separate the ducts.
D: ASSEMBLY
Assemble in the reverse order of disassembly.
NOTE:
Install the O-ring in proper position.
Tightening torque:
16 N
⋅m (1.6 kgf-m, 11.6 ft-lb)
IN-00014
IN-00015
IN-00017
IN-00018
IN-00027
IN-00017
IN-00018
Page 1451 of 2870
IN(H4DOTC)-12
INTAKE (INDUCTION)
Turbocharger
6. Turbocharger
A: REMOVAL
1) Set the vehicle on a lift.
2) Disconnect the ground cable from battery.
3) Remove the center exhaust pipe.
EX(H4DOTC)-9, REMOVAL, Center Exhaust
Pipe.>
4) Lower the vehicle.
5) Separate the turbocharger joint pipe from turbo-
charger.
6) Disconnect the engine coolant hose which is
connected to coolant filler tank.7) Loosen the clamp which secures turbocharger to
intake duct.
8) Remove the bolt which secures bracket of oil
pipe to turbocharger.
9) Remove the oil pipe from turbocharger.
10) Remove the turbocharger bracket.
11) Disconnect the oil outlet hose from pipe.
12) Take out the turbocharger from engine com-
partment.
FU-00009
IN-00019
IN-00020IN-00074
IN-00022
IN-00023
IN-00024
Page 1452 of 2870
IN(H4DOTC)-13
INTAKE (INDUCTION)
Turbocharger
B: INSTALLATION
1) Connect the oil outlet hose to outlet pipe.
2) Install the turbocharger to intake duct.
Tightening torque:
3 N
⋅m (0.3 kgf-m, 2.2 ft-lb)
3) Install the oil pipe to turbocharger.
Tightening torque:
16 N
⋅m (1.6 kgf-m, 11.6 ft-lb)
4) Install the joint pipe to turbocharger.
NOTE:
Replace the gasket with a new one.Tightening torque:
35 N
⋅m (3.6 kgf-m, 26.0 ft-lb)
5) Install the turbocharger bracket.
Tightening torque:
33 N
⋅m (3.4 kgf-m, 24.6 ft-lb)
6) Connect the engine coolant hose which is con-
nected to coolant filler tank.
7) Lift-up the vehicle.
8) Install the center exhaust pipe.
EX(H4DOTC)-10, INSTALLATION, Center Ex-
haust Pipe.>
IN-00024
IN-00074
IN-00022
IN-00019
IN-00023
IN-00020
Page 1453 of 2870
IN(H4DOTC)-14
INTAKE (INDUCTION)
Air By-pass Valve
7. Air By-pass Valve
A: REMOVAL
1) Disconnect the air by-pass hoses from air by-
pass valve.
2) Remove the air by-pass valve from intercooler.
B: INSTALLATION
Install in the reverse order of removal.
NOTE:
Install the O-ring in proper position.
Tightening torque:
16 N
⋅m (1.6 kgf-m, 11.6 ft-lb)
IN-00013
IN-00017
IN-00017
Page 1454 of 2870
IN(H4DOTC)-15
INTAKE (INDUCTION)
Resonator Chamber
8. Resonator Chamber
A: REMOVAL
1) Set the vehicle on a lift.
2) Remove the air intake duct.
IN(H4DOTC)-8, REMOVAL, Air Intake Duct.>
3) Remove the air cleaner lower case.
IN(H4DOTC)-7, REMOVAL, Air Cleaner.>
4) Remove the resonator chamber mounting bolt
on the right of engine compartment.
5) Remove the front right tire, and lift the vehicle.
6) Remove the front mudguard RH.
7) Remove the resonator chamber from the inside
front fender.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
7.5 N
⋅m (0.76 kgf-m, 5.5 ft-lb)
C: INSPECTION
Inspect for cracks and loose connections. Check
that no foreign objects are mixed in the resonator
chamber.
IN-00025
IN-00026
IN-00026
IN-00025
Page 1455 of 2870
IN(H4DOTC)-16
INTAKE (INDUCTION)
Resonator Chamber
Page 1456 of 2870

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)