2004 SUBARU FORESTER fuel

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)

MECHANICAL
ME(H4DOTC)
Page
1. General Description ....................................................................................2
2. Compression .............................................................................................31
3. Idle Speed .................................................................................................32
4. Ignition Timing ...........................................................................................33
5. Intake Manifold Vacuum............................................................................34
6. Engine Oil Pressure ..................................................................................35
7. Fuel Pressure ............................................................................................36
8. Valve Clearance ........................................................................................37
9. Engine Assembly ......................................................................................41
10. Engine Mounting .......................................................................................50
11. Preparation for Overhaul ...........................................................................51
12. V-belt .........................................................................................................52
13. Crank Pulley ..............................................................................................55
14. Timing Belt Cover......................................................................................57
15. Timing Belt Assembly................................................................................58
16. Cam Sprocket ...........................................................................................67
17. Crank Sprocket .........................................................................................68
18. Camshaft ...................................................................................................69
19. Cylinder Head Assembly ...........................................................................76
20. Cylinder Block ...........................................................................................84
21. Intake and Exhaust Valve .......................................................................115
22. Piston ......................................................................................................116
23. Connecting Rod ......................................................................................117
24. Crankshaft ...............................................................................................118
25. Engine Trouble in General ......................................................................119
26. Engine Noise ...........................................................................................124

ME(H4DOTC)-31
MECHANICAL
Compression
2. Compression
A: INSPECTION
CAUTION:
After warming-up, engine becomes very hot. Be
careful not to burn yourself during measure-
ment.
1) After warming-up the engine, turn the ignition
switch to OFF.
2) Make sure that the battery is fully charged.
3) Release the fuel pressure. FU(H4DOTC)-54, RELEASING OF FUEL PRES-
SURE, OPERATION, Fuel.>
4) Remove all the spark plugs. IG(H4DOTC)-5, REMOVAL, Spark Plug.>
5) Fully open the throttle valve.
6) Check the starter motor for satisfactory perfor-
mance and operation.
7) Hold the compression gauge tight against spark
plug hole.
NOTE:
When using a screw-in type compression gauge,
the screw (put into cylinder head spark plug hole)
should be less than 18 mm (0.71 in) long.
8) Crank the engine by means of starter motor, and
then read the maximum value on the gauge when
the pointer is steady.9) Perform at least two measurements per cylinder,
and make sure that the values are correct.
Compression (350 rpm and fully open throttle):
Standard
981 — 1,177 kPa (10 — 12 kgf/cm
2, 142 —
171 psi)
Limit
882 kPa (9.0 kgf/cm
2, 128 psi)
Difference between cylinders
Less than 49 kPa (0.5 kgf/cm
2, 7 psi)
ME-00007

ME(H4DOTC)-36
MECHANICAL
Fuel Pressure
7. Fuel Pressure
A: INSPECTION
CAUTION:
Before removing the fuel pressure gauge, re-
lease the fuel pressure.
NOTE:
If out of specification, check or replace the pressure
regulator and pressure regulator vacuum hose.
1) Release the fuel pressure. FU(H4DOTC)-54, RELEASING OF FUEL PRES-
SURE, OPERATION, Fuel.>
2) Open the fuel filler flap lid, and then remove the
fuel filler cap.
3) Disconnect the fuel delivery hoses from fuel fil-
ter, and then connect the fuel pressure gauge.
4) Connect the connector of fuel pump relay.
5) Start the engine.6) Measure the fuel pressure while disconnecting
the pressure regulator vacuum hose from intake
manifold.
Fuel pressure:
Standard; 284 — 314 kPa (2.9 — 3.2 kgf/cm2,
41 — 46 psi)
7) After connecting the pressure regulator vacuum
hose, measure the fuel pressure.
Fuel pressure:
Standard; 230 — 260 kPa (2.35 — 2.65 kgf/
cm
2, 33 — 38 psi)
NOTE:
The fuel pressure gauge registers 10 to 20 kPa (0.1
to 0.2 kgf/cm
2, 1 to 3 psi) higher than standard val-
ues during high-altitude operations.
ME-00010
FU-00262
ME-00011
ME-00011

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)

MECHANICAL
ME(H4DOTC)
Page
1. General Description ....................................................................................2
2. Compression .............................................................................................31
3. Idle Speed .................................................................................................32
4. Ignition Timing ...........................................................................................33
5. Intake Manifold Vacuum............................................................................34
6. Engine Oil Pressure ..................................................................................35
7. Fuel Pressure ............................................................................................36
8. Valve Clearance ........................................................................................37
9. Engine Assembly ......................................................................................41
10. Engine Mounting .......................................................................................50
11. Preparation for Overhaul ...........................................................................51
12. V-belt .........................................................................................................52
13. Crank Pulley ..............................................................................................55
14. Timing Belt Cover......................................................................................57
15. Timing Belt Assembly................................................................................58
16. Cam Sprocket ...........................................................................................67
17. Crank Sprocket .........................................................................................68
18. Camshaft ...................................................................................................69
19. Cylinder Head Assembly ...........................................................................76
20. Cylinder Block ...........................................................................................84
21. Intake and Exhaust Valve .......................................................................115
22. Piston ......................................................................................................116
23. Connecting Rod ......................................................................................117
24. Crankshaft ...............................................................................................118
25. Engine Trouble in General ......................................................................119
26. Engine Noise ...........................................................................................124

ME(H4DOTC)-41
MECHANICAL
Engine Assembly
9. Engine Assembly
A: REMOVAL
1) Set the vehicle on a lift.
2) Open the front hood fully, and then support with
the hood stay.
3) Collect the refrigerant from A/C system.

4) Release the fuel pressure.
(1) Disconnect the fuel pump relay connector.
(2) Start the engine, and run until stalls.
(3) After the engine stalls, crank it for 5 seconds
more.
(4) Turn the ignition switch to OFF.
5) Remove the filler cap.
6) Disconnect the ground cable from battery.
7) Remove the radiator from vehicle. CO(H4SO)-28, REMOVAL, Radiator.>
8) Remove the coolant filler tank. CO(H4SO)-42, REMOVAL, Coolant Filler Tank.>
9) Disconnect the A/C pressure hoses from A/C
compressor.10) Remove the intercooler. 10, REMOVAL, Intercooler.>
11) Disconnect the following connectors and cable.
(1) Engine harness connector
(2) Engine ground terminal
(3) Disconnect the right and left side engine
ground cables.
FU-00262
FU-00009
ME-00026
ME-00027
ME-00028
FU-00131
FU-00132

ME(H4DOTC)-44
MECHANICAL
Engine Assembly
(3) Screw the 6 mm dia. bolt into release fork
shaft, and remove it.
(4) Raise the release fork, and then unfasten
the release bearing tabs to free release fork.
NOTE:
Step (4) is required to prevent interference with en-
gine when removing the engine from transmission.
21) Separate the torque converter clutch from drive
plate. (AT model)
(1) Lower the vehicle.
(2) Remove the service hole plug.
(3) Remove the bolts which hold the torque
converter clutch to drive plate.
(4) Remove the other bolts while rotating the
engine using socket wrench.22) Remove the pitching stopper.
23) Disconnect the fuel delivery hose, return hose
and evaporation hose.
NOTE:
 Catch fuel from the hose into container.
 Disconnect the hose with its end wrapped with
cloth to prevent fuel from splashing.
24) Remove the fuel filter and bracket.
25) Support the engine with a lifting device and
wire ropes.
(A) Shaft
(B) Bolt
ME-00043 (B)(A)
ME-00044
MT-00069
ME-00045
ME-00046
ME-00047