Page 1585 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)
Page 1586 of 2870
Page 1587 of 2870
EXHAUST
EX(H4DOTC)
Page
1. General Description ....................................................................................2
2. Front Exhaust Pipe......................................................................................7
3. Center Exhaust Pipe ...................................................................................9
4. Joint Pipe ..................................................................................................13
5. Rear Exhaust Pipe ....................................................................................14
6. Muffler .......................................................................................................16
Page 1588 of 2870
EX(H4DOTC)-2
EXHAUST
General Description
1. General Description
A: COMPONENT
1. FRONT EXHAUST PIPE
EX-02006
T1
T5
T1
T3
T6
T3
T4
T3
T4
T2 T1
(1)
(3)
(6)
(7)
(10)(5)
(13)
(9) (17)
(12)(11) (14)(15)(19) (16)
(4)(2)
(18)
A
A
T1
T2(20)
(21)(22)
(7)
T3
(8)
Page 1589 of 2870

EX(H4DOTC)-3
EXHAUST
General Description
(1) Gasket (12) Exhaust manifold upper cover
(LH)Tightening torque: N·m (kgf-m, ft-lb)
(2) Exhaust manifold upper cover
(RH)T1: 19 (1.9, 13.7)
(13) Exhaust manifold lower cover (LH)T2: 7.5 (0.8, 5.5)
(3) Exhaust manifold (RH) (14) GasketT3: 35 (3.6, 26.0)
(4) Exhaust manifold lower cover
(RH)(15) Turbocharger joint pipeT4: 40 (4, 28.9)
(16) GasketT5:
INSTALLATION, Front Oxygen
(A/F) Sensor.> or
FU(H4DOTC 2.5)-37,
INSTALLATION, Front Oxygen
(A/F) Sensor.> (5) Front exhaust pipe upper cover (17) Front oxygen (A/F) sensor
(6) Front exhaust pipe upper insulator
(RH)(18) Exhaust temperature sensor
(19) Precatalytic converter
(7) Gasket (20) Front exhaust pipe upper insulator
(LH)
(8) Front exhaust pipeT6:
INSTALLATION, Exhaust
Temperature Sensor.> or
to FU(H4DOTC 2.5)-40,
INSTALLATION, Exhaust
Temperature Sensor.> (9) Front exhaust pipe lower insulator
(RH)(21) Front exhaust pipe lower insulator
(LH)
(10) Front exhaust pipe lower cover (22) Exhaust manifold (LH)
(11) Gasket
Page 1590 of 2870

EX(H4DOTC)-4
EXHAUST
General Description
2. CENTER AND REAR EXHAUST PIPE, AND MUFFLER
2.0 L model
(1) Gasket (13) Rear catalytic converter (25) Muffler cutter
(2) Front catalytic converter (14) Gasket (26) Center exhaust pipe (Rear)
(3) Center pipe upper cover (Front) (15) Rear exhaust pipe
(4) Center exhaust pipe (Front) (16) Lower rear exhaust pipe cover
(Front)Tightening torque: N·m (kgf-m, ft-lb)
(5) Center pipe lower cover (Front)T1: 13 (1.3, 9.6)
(6) Bracket (17) ChamberT2: 18 (1.8, 13.0)
(7) Gasket (18) CushionT3: 30 (3.1, 22.4)
(8) Center pipe upper cover (Rear) (19) SpringT4: 35 (3.6, 26.0)
(9) Center pipe lower cover (Rear) (20) BoltT5: 48 (4.9, 35.4)
(10) Upper rear catalytic converter
cover(21) Upper rear exhaust pipe cover
(Front)T6:
INSTALLATION, Rear Oxygen
Sensor.>
(11) Lower rear catalytic converter
cover(22) Gasket
(23) Muffler
(12) Rear oxygen sensor (24) Cushion rubber
EX-00040
T4
A
T1
T5
T6
T4
(25)
(19)(24)
(24) (20)
(18) (17)
(16)(23)
(22)
(21)
A
(14)
T3
T4
T4
T4
(1)
(2)
(6)
(3)
(5)
T2 (8)(10) (12)
(11) (13)
(9) (26)
(7)
T1
T1
(15)
(4)
Page 1591 of 2870
EX(H4DOTC)-5
EXHAUST
General Description
2.5 L model
(1) Gasket (12) GasketTightening torque: N·m (kgf-m, ft-lb)
(2) Front catalytic converter (13) Rear exhaust pipeT1: 13 (1.3, 9.6)
(3) Center pipe upper cover (14) ChamberT2: 18 (1.8, 13.0)
(4) Center exhaust pipe (15) Cushion rubberT3: 30 (3.1, 22.4)
(5) Center pipe lower cover (16) SpringT4: 35 (3.6, 26.0)
(6) Bracket (MT model) (17) BoltT5: 48 (4.9, 35.4)
(7) Bracket (AT model) (18) GasketT6:
INSTALLATION, Rear Oxygen
Sensor.> (8) Catalytic converter upper cover (19) Muffler
(9) Catalytic converter lower cover (20) Cushion rubber
(10) Rear oxygen sensor (21) Muffler cutter
(11) Rear catalytic converter
A
A
T5
T4
T3
T4
T4
T4
T4
T2
(21) (20)
(19)(18)
(15) (14)
(1)
(2)(3)
(5)
(6)(4)(11) (17)
(16)(8)
(12)
(10)
(13)
T1
T6
(7)
EX-02007
(9)
(20)
Page 1592 of 2870
EX(H4DOTC)-6
EXHAUST
General Description
B: 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 yourself, because each
part on 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.