Subaru 2004 Forester User manual

FUJI HEAVY INDUSTRIES LTD. G8080GE2

2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX

ENGINE SECTION 1

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(H4SO)

EMISSION CONTROL

(AUX. EMISSION CONTROL DEVICE) EC(H4SO)

INTAKE (INDUCTION) IN(H4SO)

MECHANICAL ME(H4SO)

EXHAUST EX(H4SO)

COOLING CO(H4SO)

LUBRICATION LU(H4SO)

SPEED CONTROL SYSTEM SP(H4SO)

IGNITION IG(H4SO)

STARTING/CHARGING SYSTEM SC(H4SO)

ENGINE (DIAGNOSTIC) EN(H4SO)

IGNITION

IG(H4SO)

Page

1. General Description ....................................................................................2

2. Spark Plug...................................................................................................5

3. Ignition Coil & Ignitor Assembly ..................................................................8

4. Spark Plug Cord..........................................................................................9

IG(H4SO)-2

IGNITION

General Description

1. General Description

A: SPECIFICATION

Item Designation

Ignition coil/igni-

tor assembly

Model FH0137

Manufacturer DIAMOND

Primary coil resistance 0.73 Ω±10%

Secondary coil resistance 12.8 kΩ±15%

Insulation resistance between primary terminal and

case More than 100 MΩ

Spark plug

Type and manufacturer CHAMPION: RC10YC4

NGK: BKR5E-11 (Alternate)

Thread size mm 14, P = 1.25

Spark plug gap mm (in) 1.0 — 1.1 (0.039 — 0.043)

IG(H4SO)-3

IGNITION

General Description

B: COMPONENT

(1) Spark plug (4) Spark plug cord (#2, #4) Tightening torque: N

⋅

m (kgf-m, ft-lb)

(2) Spark plug cord (#1, #3) T1: 21 (2.1, 15.2)

(3) Ignition coil & ignitor ASSY T2: 6.4 (0.65, 4.7)

IG-00042

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.

IG(H4SO)-5

IGNITION

Spark Plug

2. Spark Plug

A: REMOVAL

CAUTION:

All spark plugs installed on an engine, must be

of the same heat range.

1. RH SIDE

1) Disconnect the ground cable from battery.

2) Remove the air cleaner case. <Ref. to IN(H4SO)-

8, REMOVAL, Resonator Chamber.>

3) Remove the spark plug cords by pulling boot, not

the cord itself.

4) Remove the spark plugs with spark plug sock-

ets.

2. LH SIDE

1) Disconnect the ground cable from battery.

2) Disconnect the washer motor connector.

3) Disconnect the rear window glass washer hose

from washer motor, then plug connection with a

suitable cap.

4) Remove the two bolts which hold washer tank,

then take the tank away from the working area.

5) Remove the spark plugs cord by pulling boot, not

the cord itself.

Spark plug

CHAMPION: RC10YC4

NGK: BKR5E-11 (Alternate)

FU-00009

IG-00017

IG-00018

FU-00009

IG-00019

IG-00020

IG-00021

IG(H4SO)-6

IGNITION

Spark Plug

6) Remove the spark plugs with spark plug sock-

ets.

B: INSTALLATION

1. RH SIDE

Install in the reverse order of removal.

Tightening torque (Spark plug):

21 N

⋅

m (2.1 kgf-m, 15.2 ft-lb)

NOTE:

The above torque should be only applied to new

spark plugs without oil on their threads.

In case their threads are lubricated, the torque

should be reduced by approx. 1/3 of the specified

torque in order to avoid over-stressing.

2. LH SIDE

Install in the reverse order of removal.

Tightening torque (Spark plug):

21 N

⋅

m (2.1 kgf-m, 15.2 ft-lb)

NOTE:

The above torque should be only applied to new

spark plugs without oil on their threads.

In case their threads are lubricated, the torque

should be reduced by approx. 1/3 of the specified

torque in order to avoid over-stressing.

C: INSPECTION

Check the electrodes and inner and ceramic insu-

lator of plugs, noting the type of deposits and the

degree of electrode erosion.

1) Normal:

Brown to grayish-tan deposits and slight electrode

wear indicates correct spark plug heat range.

2) Carbon fouled:

Dry fluffy carbon deposits on insulator and elec-

trode are mostly caused by slow speed driving in

city, weak ignition, too rich fuel mixture, dirty air

cleaner, etc.

It is advisable to replace with plugs having hotter

heat range.

IG-00022

(A) Electrode gap

(B) Carbon accumulation or wear

(D) Damage

(E) Damaged gasket

IG-00023

(A)

(B) (C)

(D)

(E)

IG-00024

IG-00025

IG(H4SO)-7

IGNITION

Spark Plug

3) Oil fouled:

Wet black deposits show excessive oil entrance

into combustion chamber through worn rings and

pistons or excessive clearance between valve

guides and stems. If the same condition remains

after repair, use a hotter plug.

4) Overheating:

White or light gray insulator with black or gray

brown spots and bluish burnt electrodes indicates

engine overheating. Moreover, the appearance re-

sults from incorrect ignition timing, loose spark

plugs, wrong selection of fuel, hotter range plug,

etc. It is advisable to replace with plugs having

colder heat range.

D: CLEANING

Clean the spark plugs in a sand blast type cleaner.

Avoid excessive blasting. Clean and remove the

carbon or oxide deposits, but do not wear away ce-

ramic insulator.

If deposits are too stubborn, replace the spark

plugs.

E: ADJUSTMENT

Correct it if the spark plug gap is measured with a

gap gauge, and it is necessary.

Spark plug gap: L

1.0 — 1.1 mm (0.039 — 0.043 in)

NOTE:

Replace with a new spark plug if this area (A) is

worn to “ball” shape.

IG-00026

IG-00027

IG-00028

L(A)

IG(H4SO)-8

IGNITION

Ignition Coil & Ignitor Assembly

3. Ignition Coil & Ignitor Assem-

bly

A: REMOVAL

1) Disconnect the ground cable from battery.

2) Disconnect the spark plug cords from ignition

coil & ignitor assembly.

3) Disconnect the connector from ignition coil & ig-

nitor assembly.

4) Remove the ignition coil & ignitor assembly.

B: INSTALLATION

Install in the reverse order of removal.

Tightening torque:

6.4 N

⋅

m (0.65 kgf-m, 4.7 ft-lb)

C: INSPECTION

Using the accurate tester, inspect the secondary

coil resistance, and replace if defective.

CAUTION:

• If the resistance is extremely low, this indi-

cates the presence of a short-circuit.

• Ignitor is integrated in coil. Therefore, prima-

ry coil resistance can not be measured.

Specified resistance:

[Secondary side]

Between (A) and (B)

12.8 k

Ω±

15%

Between (C) and (D)

12.8 k

Ω±

15%

Insulation between primary terminal and case: 100

MΩor more.

FU-00009

IG-00043

IG-00044

IG-00045

(C)

(A)

(D)

(B)

IG(H4SO)-9

IGNITION

Spark Plug Cord

4. Spark Plug Cord

A: INSPECTION

Check for:

1) Damage to cords, deformation, burning or rust

formation of terminals

2) Resistance values of cords

Resistance value:

#1 cord: 5.6 — 10.6 k

Ω

#2 cord: 7.3 — 13.7 k

Ω

#3 cord: 5.9 — 11.1 k

Ω

#4 cord: 7.3 — 13.7 k

Ω

IG-00031

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