2004 SUBARU FORESTER sensor

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.

LU(H4SO)-5
LUBRICATION
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 yourself, 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.
(1) Plug (16) Oil pressure switch (33) O-ring
(2) Gasket (17) Oil filler cap (34) Oil filter connector (model without
oil cooler)
(3) Relief valve spring (18) O-ring
(4) Relief valve (19) Oil filler duct (35) Plug (model without oil cooler)
(5) Oil seal (20) O-ring (36) O-ring
(6) Oil pump case (21) Rocker cover
(7) Inner rotor (22) Oil strainerTightening torque: N
⋅m (kgf-m, ft-lb)
(8) Outer rotor (23) GasketT1: 5 (0.5, 3.6)
(9) Oil pump cover (24) Oil level gauge guideT2: 6.4 (0.65, 4.7)
(10) Oil filter (25) Oil panT3: 10 (1.0, 7.0)
(11) Oil cooler connector (model with
oil cooler)(26) Oil level gaugeT4: 44 (4.5, 32.5)
(27) Metal gasketT5: 69 (7.0, 50.9)
(12) Water by-pass pipe (model with oil
cooler)(28) Drain plugT6: 6.4 (0.65, 4.7)
(29) O-ringT7: 25 (2.5, 18.1)
(13) Oil cooler (model with oil cooler) (30) Adapter (1)T8: 44 (4.5, 32.5)
(14) O-ring (31) Adapter (2)T9: 54 (5.5, 40)
(15) Oil pump ASSY (32) Baffle plate

LU(H4SO)-12
LUBRICATION
Oil Pump
4. Oil Pump
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Lift-up the vehicle.
3) Remove the under cover.
4) Remove the bolts which install water pipe of oil
cooler to oil pump. (Turbo model)
5) Remove the water pipe and hoses between oil
cooler and water pump. (Turbo model)
6) Remove the radiator. REMOVAL, Radiator.>7) Remove the crankshaft position sensor.
8) Remove the V-belts.
to ME(H4DOTC)-52, REMOVAL, V-belt.>
9) Remove the rear side V-belt tensioner.
10) Remove the crankshaft pulley by using ST.
ST 499977400 CRANK PULLEY WRENCH
(2.0 L model)
ST 499977100 CRANK PULLEY WRENCH
(2.5 L model)
11) Remove the water pump. 21, REMOVAL, Water Pump.>
FU-00009
LU-00137
LU-00010
LU-00046
LU-00011
LU-00012

LU(H4SO)-16
LUBRICATION
Oil Pan and Strainer
5. Oil Pan and Strainer
A: REMOVAL
1) Set the vehicle on lift arms.
2) Remove the front wheels.
3) Disconnect the ground cable from battery.
4) Remove the air intake duct and air cleaner case.
(Non-turbo model)

Case.>
5) Disconnect the connector from mass air flow
sensor. (Turbo model)
6) Remove the air intake boot and air cleaner upper
cover. (Turbo model)
7) Remove the intercooler (Turbo model) IN(H4DOTC)-10, REMOVAL, Intercooler.>8) Remove the pitching stopper.
9) Remove the radiator upper brackets.
10) Support the engine with a lifting device and
wire ropes.
11) Lift-up the vehicle.
CAUTION:
When lifting up the vehicle, rise up the wire
rope together.
12) Remove the under cover.
FU-00009
LU-00026
LU-00070
ME-00213
LU-00027
LU-00028

LU(H4SO)-19
LUBRICATION
Oil Pan and Strainer
10) Remove the lifting device and steel cables.
11) Install the pitching stopper.
Tightening torque:
T1: 50 N
⋅m (5.1 kgf-m, 36.9 ft-lb)
T2: 58 N
⋅m (5.9 kgf-m, 42.8 ft-lb)
12) Install the radiator upper brackets.
13) Install the air intake duct and air cleaner case.
(Non-turbo model) LATION, Air Intake Duct.> INSTALLATION, Air Cleaner Case.>
14) Install the intercooler. (Turbo model) IN(H4DOTC)-11, INSTALLATION, Intercooler.>15) Install the air intake boot and air cleaner upper
cover. (Turbo model)
16) Connect the connector to mass air flow sensor.
(Turbo model)
17) Install the front wheels.
18) Connect the battery ground cable to battery.
19) Fill engine oil. TION, Engine Oil.>
C: INSPECTION
By visual check make sure the oil pan, oil strainer,
oil strainer stay and baffle plate are not damaged.
LU-00028
ME-00218T2T1
LU-00027
LU-00070
LU-00026
FU-00009

SP(H4SO)-3
SPEED CONTROL SYSTEM
General Description
2. RHD MODEL
C: CAUTION
 Wear work clothing, including a cap, protective
goggles, and protective shoes during operation.
 Remove contamination, including dirt and corro-
sion, before removal, installation or disassembly.
 Keep the disassembled parts in order and pro-
tect them from dust and 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 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.
(1) Accelerator bracket (6) Spring pin (11) Kick-down switch (AT model)
(2) Stopper (7) Accelerator spring
(3) Accelerator pedal lever (8) BushingTightening torque: N
⋅m (kgf-m, ft-lb)
(4) Accelerator pedal spring (9) ClipT1: 12 (1.2, 9.0)
(5) Accelerator pedal (10) Accelerator stopperT2: 18 (1.8, 13.0)
SP-00022
(1)
(2)(3)
(11)
(8)
(7) (9)
(6)(4)
(5)
(10)
T1
T2

IG(H4SO)-4
IGNITION
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 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.

SC(H4SO)-5
STARTING/CHARGING SYSTEM
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 yourself, 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.