2004 SUBARU FORESTER sensor

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)

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.

EX(H4DOTC)-7
EXHAUST
Front Exhaust Pipe
2. Front Exhaust Pipe
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the front oxygen (A/F) sensor. FU(H4DOTC)-45, REMOVAL, Front Oxygen (A/F)
Sensor.> or MOVAL, Front Oxygen (A/F) Sensor.>
3) Remove the under cover.
4) Remove the lower exhaust manifold cover.
5) Remove the nuts which hold front exhaust pipe
assembly to turbocharger joint pipe.
6) While holding the front exhaust pipe assembly
with one hand, remove the nuts which hold front ex-
haust pipe assembly to cylinder head exhaust port.7) Remove the front exhaust pipe assembly.
8) Remove the covers from exhaust manifold and
front exhaust pipe.
9) Separate the front exhaust pipe from exhaust
manifolds.
B: INSTALLATION
NOTE:
Replace the gaskets with new ones.
1) Assemble the front exhaust pipe and exhaust
manifolds.
Tightening torque:
35 N·m (3.6 kgf-m, 26.0 ft-lb)
2) Install the front exhaust pipe covers.
Tightening torque:
7.5 N·m (0.8 kgf-m, 5.5 ft-lb)
3) Install the exhaust manifold upper cover (RH).
Tightening torque:
19 N·m (1.9 kgf-m, 13.7 ft-lb)
FU-00009
EX-00246
EX-00004
EX-00005
EX-00245
EX-00245

EX(H4DOTC)-8
EXHAUST
Front Exhaust Pipe
4) Install the front exhaust pipe assembly.
Tightening torque:
35 N·m (3.6 kgf-m, 26.0 ft-lb)
5) Connect the exhaust manifold (RH) to turbo-
charger joint pipe.
Tightening torque:
T1: 35 N·m (3.6 kgf-m, 26.0 ft-lb)
T2: 40 N·m (4.0 kgf-m, 28.9 ft-lb)
6) Install the exhaust manifold lower cover.
Tightening torque:
19 N·m (1.9 kgf-m, 13.7 ft-lb)
7) Install the front oxygen (A/F) sensor. FU(H4DOTC)-45, INSTALLATION, Front Oxygen
(A/F) Sensor.> or INSTALLATION, Front Oxygen (A/F) Sensor.>
8) Install the under cover.9) Connect the battery ground cable to battery.
EX-00070
T2
T1
EX-00071
T2
T2
EX-00246
FU-00009

EX(H4DOTC)-9
EXHAUST
Center Exhaust Pipe
3. Center Exhaust Pipe
A: REMOVAL
1) Set the vehicle on a lift.
2) Disconnect the ground cable from battery.
3) Remove the intercooler.
er.>
4) Remove the intercooler bracket.
5) Lift-up the vehicle.
6) Remove the under cover.
7) Remove the universal joint bolts and then re-
move the universal joint. (RHD model)
CAUTION:
Scribe alignment marks on the universal joint
so that it can be reassembled at the original
serration.
8) Remove the bolts which install lower side of tur-
bocharger upper cover.
CAUTION:
Be careful, the turbocharger and exhaust pipe
are hot.9) Lower the vehicle.
10) Remove the turbocharger upper cover.
11) Remove the bolts which install upper side of
turbocharger upper cover, and remove it.
12) Separate the center exhaust pipe from turbo-
charger.
13) Lift-up the vehicle.
14) Disconnect the connector from rear oxygen
sensor.
EX-00007
EX-00008
EX-00009
EX-00010
EX-00011
EX-00012
FU-00081

EX(H4DOTC)-11
EXHAUST
Center Exhaust Pipe
4) Install the center exhaust pipe to rear exhaust
pipe.
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
5) Connect the connector to rear oxygen sensor.
6) Secure the clip on crossmember.
 AT model
 MT model7) Tighten the bolt which holds center exhaust pipe
bracket to transmission.
Tightening torque:
30 N·m (3.1 kgf-m, 22.4 ft-lb)
8) Tighten the bolt which holds center exhaust pipe
to hanger bracket.
Tightening torque:
35 N·m (3.6 kgf-m, 26.0 ft-lb)
9) Tighten the bolts which hold intercooler bracket.
Tightening torque:
35 N·m (3.6 kgf-m, 26.0 ft-lb)
10) Lower the vehicle.
11) Place the turbocharger lower cover, and tighten
the bolts which install upper side of lower cover.
Tightening torque:
7.4 N·m (0.75 kgf-m, 5.4 ft-lb)
EX-00042
FU-00081
FU-01311
FU-01312
EX-00014
EX-00043
EX-00011

EX(H4DOTC)-13
EXHAUST
Joint Pipe
4. Joint Pipe
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Disconnect the exhaust temperature sensor
connector.
3) Remove the front oxygen (A/F) sensor. FU(H4DOTC)-45, REMOVAL, Front Oxygen (A/F)
Sensor.> or MOVAL, Front Oxygen (A/F) Sensor.>
4) Remove the under cover.
5) Remove the exhaust manifold lower cover (RH).6) Remove the nuts which hold front exhaust man-
ifold to joint pipe.
7) Remove the center exhaust pipe. EX(H4DOTC)-9, REMOVAL, Center Exhaust
Pipe.>
8) Remove the turbocharger.
er.>
9) Take off the joint pipe in the upward direction.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
T: 35 N·m (3.6 kgf-m, 26.0 ft-lb)
FU-00009
EX-00044
EX-00003
EX-00018
EX-00019
T

IG(H4DOTC)-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.