2004 SUBARU FORESTER engine

FU(H4DOTC)-44
FUEL INJECTION (FUEL SYSTEM)
Wastegate Control Solenoid Valve Assembly
16.Wastegate Control Solenoid
Valve Assembly
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Disconnect the connector from wastegate con-
trol solenoid valve assembly.
3) Disconnect the engine harness connector from
bracket.
4) Remove the bracket from body.
5) Disconnect the pressure hoses (C) from waste-
gate control solenoid valve assembly.6) Remove the wastegate control solenoid valve
assembly from bracket.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
6.5 N
⋅m (0.66 kgf-m, 4.8 ft-lb)
FU-00009
FU-02087
FU-00367
(C)
FU-00368
FU-00368

FU(H4DOTC)-45
FUEL INJECTION (FUEL SYSTEM)
Front Oxygen (A/F) Sensor
17.Front Oxygen (A/F) Sensor
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Disconnect the connector from front oxygen (A/
F) sensor.
3) Disconnect the engine harness fixed by clip (A)
from bracket (B).
4) Remove the front right side wheel.
5) Lift-up the vehicle.
6) Remove the service hole cover.7) Apply SUBARU CRC or its equivalent to the
threaded portion of front oxygen (A/F) sensor, and
leave it for 1 minute or more.
SUBARU CRC (Part No. 004301003)
8) Remove the front oxygen (A/F) sensor.
CAUTION:
When removing the oxygen (A/F) sensor, wait
until the exhaust pipe cools, otherwise it will
damage the exhaust pipe.
B: INSTALLATION
1) Before installing the front oxygen (A/F) sensor,
apply anti-seize compound only to the threaded
portion of front oxygen (A/F) sensor to make next
removal easier.
Anti-seize compound:
SS-30 JET LUBE
CAUTION:
Never apply anti-seize compound to the protec-
tor of front oxygen (A/F) sensor.
2) Install the front oxygen (A/F) sensor.
Tightening torque:
30 N
⋅m (3.1 kgf-m, 22.1 ft-lb)
FU-00009
FU-02088
FU-00078
(A)(B)
FU-00079
FU-00080
FU-00080

FU(H4DOTC)-46
FUEL INJECTION (FUEL SYSTEM)
Front Oxygen (A/F) Sensor
3) Install the service hole cover.
4) Lower the vehicle.
5) Install the front right side wheel.
6) Connect the engine harness with clip (A) to
bracket (B).
7) Connect the connector of front oxygen (A/F)
sensor.
8) Connect the battery ground cable to battery.
FU-00079
FU-00078
(A)(B)
FU-02088
FU-00009

FU(H4DOTC)-50
FUEL INJECTION (FUEL SYSTEM)
Engine Control Module (ECM)
20.Engine Control Module (ECM)
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the lower inner trim of passenger side.

3) Detach the floor mat of front passenger seat
side.
4) Remove the protect cover.
5) Remove the nuts (A) which hold the ECM to
bracket.
6) Remove the clip (B) from bracket.
7) Disconnect the ECM connectors and take out
the ECM.
B: INSTALLATION
Install in the reverse order of removal.
NOTE:
When replacing the ECM, be careful not to use the
wrong spec. ECM to avoid any damage to the fuel
injection system.
FU-00009
FU-00084
(A)
(A)
(B)
FU-00085

FU(H4DOTC)-54
FUEL INJECTION (FUEL SYSTEM)
Fuel
24.Fuel
A: OPERATION
1. RELEASING OF FUEL PRESSURE
WARNING:
 Place “NO FIRE” signs near working area.
 Be careful not to spill fuel on floor.
1) Disconnect the connector from fuel pump relay.
2) Start and run the engine until it stalls.
3) After the engine stalls, crank it for 5 more sec-
onds.
4) Turn the ignition switch to OFF.
2. DRAINING FUEL
WARNING:
 Place “NO FIRE” signs near working area.
 Be careful not to spill fuel on floor.
1) Set the vehicle on a lift.
2) Disconnect the ground cable from battery.
3) Open the fuel filler flap lid and remove the fuel
filler cap.
4) Lift-up the vehicle.5) Drain fuel from the fuel tank.
Set a container under vehicle and remove the drain
plug from fuel tank.
6) Tighten the fuel drain plug.
Tightening torque:
26 N
⋅m (2.7 kgf-m, 19.2 ft-lb)
FU-00262
FU-00009
FU-00089
FU-00089

FU(H4DOTC)-70
FUEL INJECTION (FUEL SYSTEM)
Fuel Delivery, Return and Evaporation Lines
33.Fuel Delivery, Return and Evaporation Lines
A: REMOVAL
1) Set the vehicle on a lift.
2) Release the fuel pressure. Fuel.>
3) Open the fuel filler flap lid and remove the fuel filler cap.
4) Remove the floor mat.
5) Remove the fuel delivery pipes and hoses, fuel return pipes and hoses, evaporation pipes and hoses.
6) In the engine compartment, detach the fuel de-
livery hoses (A), return hoses (B) and evaporation
hoses (C).
7) Lift-up the vehicle.8) Disconnect the two-way valve hose (A) from
two-way valve and disconnect the canister hose (B)
from canister.
FU-00122
(B) (A)
(C)
FU-00374
(A)(B)
FU-00091

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)

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)