Subaru 2001 Forester User manual

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, reassem-
bling, inspection and adjustment of com-
ponents and diagnostics for guidance 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 genu-
ine parts.
All information, illustration and specifica-
tions contained in this manual are based
on the latest product information avail-
able at the time of publication approval.
FUJI HEAVY INDUSTRIES LTD.
2001 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
ENGINE2 SECTION
G8050GE3

IGNITION
IG(DOHC TURBO)
Page
1. General Description.....................................................................................2
2. Spark Plug...................................................................................................4
3. Ignition Coil and Ignitor Assembly...............................................................8

1. General Description S181001
A: SPECIFICATIONS S181001E49
Item Designation
Ignition coil
and ignitor
assembly
Model FK0140
Manufacturer DIAMOND
Spark plug Type and manufacturer PFR6G .......... NGK Thread size mm 14, P = 1.25
Spark gap mm (in) 0.7 —0.8 (0.028 —0.031)
IG(DOHC TURBO)-2
GENERAL DESCRIPTION
Ignition

B: COMPONENT S181001A05
EN0853
(1) Spark plug
(2) Ignition coil and ignitor ASSY Tightening torque: N·m (kgf-m, ft-lb)
T1: 21 (2.1, 15)
T2: 16 (1.6, 11.7)
C: CAUTION S181001A03
쐌Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
쐌Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
쐌Keep the disassembled parts in order and pro-
tect them from dust or dirt.
쐌Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary
removal, installation, disassembly, and replace-
ment.
쐌Be careful not to burn your hands, because each
part on the vehicle is hot after running.
쐌Be sure to tighten fasteners including bolts and
nuts to the specified torque.
쐌Place shop jacks or safety stands at the speci-
fied points.
쐌Before disconnecting electrical connectors of
sensors or units, be sure to disconnect negative
terminal from battery.
IG(DOHC TURBO)-3
GENERAL DESCRIPTION Ignition

2. Spark Plug S181003
A: REMOVAL S181003A18
CAUTION:
All spark plugs installed on an engine, must be
of the same heat range.
Spark plug:
NGK: PFR6G
1. RH SIDE S181003A1801
1) Disconnect battery ground cable.
G6M0095
2) Remove air cleaner lower case. <Ref. to
IN(DOHC TURBO)-7, REMOVAL, Air Cleaner.>
3) Disconnect connector from ignition coil.
EN0854
4) Remove ignition coil.
EN0855
5) Remove spark plugs with the spark plug socket.
EN0856
2. LH SIDE S181003A1802
1) Disconnect battery cables, and then remove
battery and battery carrier.
G6M0095
2) Disconnect washer motor connector (A).
B6M0562D
3) Disconnect rear window glass washer hose
from washer motor, then plug connection with a
suitable cap.
IG(DOHC TURBO)-4
SPARK PLUG
Ignition

4) Remove the two bolts which hold the washer
tank, then take the tank away from the working
area.
B2M2023
5) Disconnect connector from ignition coil.
EN0857
6) Remove ignition coil.
EN0858
7) Remove spark plug with the spark plugs socket.
EN0859
B: INSTALLATION S181003A11
1. RH SIDE S181003A1101
1) Install in the reverse order of removal.
Tightening torque (Spark plug):
21 N·m (2.1 kgf-m, 15 ft-lb)
Tightening torque (Ignition coil):
16 N·m (1.63 kgf-m, 11.8 ft-lb)
CAUTION:
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 approximately 1/3 of the
specified torque in order to avoid over-stress-
ing.
2. LH SIDE S181003A1102
1) Install in the reverse order of removal.
Tightening torque (Spark plug):
21 N·m (2.1 kgf-m, 15 ft-lb)
Tightening torque (Ignition coil):
16 N·m (1.63 kgf-m, 11.8 ft-lb)
CAUTION:
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 approximately 1/3 of the
specified torque in order to avoid over-stress-
ing.
IG(DOHC TURBO)-5
SPARK PLUG Ignition

C: INSPECTION S181003A10
Check electrodes and inner and outer porcelain of
plugs, noting the type of deposits and the degree
of electrode erosion.
S6M0420A
(A) Electrode gap
(B) Carbon accumulation or wear
(C) Cracks
(D) Damage
(E) Damaged gasket
1) Normal
Brown to grayish-tan deposits and slight electrode
wear indicate correct spark plug heat range.
G6M0087
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.
G6M0088
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 same condition remains after
repair, use a hotter plug.
G6M0089
4) Overheating
White or light gray insulator with black or gray
brown spots and bluish burnt electrodes indicate
engine overheating. Moreover, the appearance
results 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.
G6M0090
IG(DOHC TURBO)-6
SPARK PLUG
Ignition

D: ADJUSTMENT S181003A01
Clean spark plugs in a sand blast type cleaner.
Avoid excessive blasting. Clean and remove car-
bon or oxide deposits, but do not wear away por-
celain.
If deposits are too stubborn, replace plugs.
After cleaning spark plugs, recondition firing sur-
face of electrodes with file. Then correct the spark
plug gap using a gap gauge.
Spark plug gap: L
0.7 —0.8 mm (0.028 —0.031 in)
S6M0412A
NOTE:
Replace with new spark plug if this area is worn to
“ball”shape.
IG(DOHC TURBO)-7
SPARK PLUG Ignition

3. Ignition Coil and Ignitor
Assembly S181015
A: REMOVAL S181015A18
Direct ignition type has been adopted. Refer to the
“Spark Plug Removal”for removal procedure.
<Ref. to IG(DOHC TURBO)-4, REMOVAL, Spark
Plug.>
B: INSTALLATION S181015A11
Install in the reverse order of removal.
Tightening torque:
16 N·m (1.63 kgf-m, 11.8 ft-lb)
C: INSPECTION S181015A10
Because ignition coil is a direct ignition type, the
resistance cannot be measured in a single unit. For
inspection procedure of ignition system, refer to
the following. <Ref. to EN(DOHC TURBO)-72,
IGNITION CONTROL SYSTEM, Diagnostics for
Engine Starting Failure.>
IG(DOHC TURBO)-8
IGNITION COIL AND IGNITOR ASSEMBLY
Ignition