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(SOHCw/oOBD)
Page
1. General Description.....................................................................................2
2. Spark Plug...................................................................................................5
3. Ignition Coil and Ignitor Assembly...............................................................9
4. Spark Plug Cord........................................................................................11

1. General Description S161001
A: SPECIFICATIONS S161001E49
Item Designation
Ignition coil and ignitor
assembly
Model CM12–100B
Manufacturer HITACHI
Primary coil resistance 0.7 Ω±10%
Secondary coil resistance 13.0 kΩ±20%
Insulation resistance between primary terminal
and case More than 10 MΩ
Spark plug
Type and manufacturer BKR6E* .......... NGK RC10YC4** .......... CHAMPION
BKR5E-11** .......... NGK (Alternate)
Thread size mm 14, P = 1.25
Spark gap mm (in) 0.7 —0.8 mm (0.028 —0.031 in)*
1.0 —1.1 mm (0.039 —0.043 in)**
*: Without catalytic converter
**: With catalytic converter
IG(SOHCw/oOBD)-2
GENERAL DESCRIPTION
Ignition

B: COMPONENT S161001A05
S6M0139B
(1) Spark plug
(2) Spark plug cord (#1, #3)
(3) Ignition coil and ignitor ASSY
(4) Spark plug cord (#2, #4) Tightening torque: N·m (kgf-m, ft-lb)
T1: 6.4 (0.65, 4.7)
T2: 21 (2.1, 15)
C: CAUTION S161001A03
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(SOHCw/oOBD)-3
GENERAL DESCRIPTION Ignition

D: PREPARATION TOOL S161001A17
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
S2M2137A
498307600 CHECK BOARD KIT Troubleshooting for engine electrical systems
(1) CHECK BOARD: 498307610
(2) CHECK BOARD ADAPTER: 498307620
IG(SOHCw/oOBD)-4
GENERAL DESCRIPTION
Ignition

2. Spark Plug S161003
A: REMOVAL S161003A18
CAUTION:
All spark plugs installed on an engine, must be
of the same heat range.
Spark plug:
With catalyst model: CHAMPION
RC10YC4
Without catalyst model: NGK BKR6E
1. RH SIDE S161003A1805
1) Disconnect battery ground cable.
G6M0095
2) Remove air intake duct and resonator chamber.
(1) Remove bolt which installs air intake duct
on the front side of body.
S6M0708
(2) Remove bolt which installs air intake duct
on body.
B6M1302
(3) Remove air intake duct as a unit.
B2M2012
(4) Remove resonator chamber.
B2M2306
3) Remove spark plug cords by pulling boot, not
cord itself.
S2M2135
4) Remove spark plugs with the spark plug socket.
B6M0923
IG(SOHCw/oOBD)-5
SPARK PLUG Ignition

2. LH SIDE S161003A1806
1) Disconnect battery ground cable.
G6M0095
2) Disconnect washer motor connector.
S2M0546
3) Disconnect rear window glass washer hose
from washer motor, then plug connection with a
suitable cap.
4) Remove the two bolts which hold the washer
tank, then take the tank away from the working
area.
B2M2023
5) Remove spark plugs cord by pulling boot, not
cord itself.
S2M2136
6) Remove spark plug with the spark plug socket.
B6M0926
B: INSTALLATION S161003A11
1. RH SIDE S161003A1105
Install in the reverse order of removal.
Tightening torque (Spark plug):
21 N·m (2.1 kgf-m, 15 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.
Tightening torque (Resonator chamber):
32 N·m (3.3 kgf-m, 24 ft-lb)
2. LH SIDE S161003A1106
Install in the reverse order of removal.
Tightening torque (Spark plug):
21 N·m (2.1 kgf-m, 15 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(SOHCw/oOBD)-6
SPARK PLUG
Ignition

C: INSPECTION S161003A10
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
D: CLEANING S161003E56
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.
IG(SOHCw/oOBD)-7
SPARK PLUG Ignition

E: ADJUSTMENT S161003A01
Correct it if the spark plug gap is measured with a
gap gauge, and it is necessary.
Spark plug gap: L
With catalyst:
1.0 —1.1 mm (0.039 —0.043 in)
Without catalyst:
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(SOHCw/oOBD)-8
SPARK PLUG
Ignition

3. Ignition Coil and Ignitor
Assembly S161015
A: REMOVAL S161015A18
1) Disconnect battery ground cable.
G6M0095
2) Disconnect spark plug cords from ignition coil
and ignitor assembly.
S6M0372
3) Disconnect connector from ignition coil and
ignitor assembly.
S6M0366
4) Remove ignition coil and ignitor assembly.
S6M0371
B: INSTALLATION S161015A11
Install in the reverse order of removal.
Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
CAUTION:
Be sure to connect wires to their proper posi-
tions. Failure to do so will damage unit.
S6M0371
IG(SOHCw/oOBD)-9
IGNITION COIL AND IGNITOR ASSEMBLY Ignition

C: INSPECTION S161015A10
Using oscilloscope and accurate tester, inspect the
following items, and replace if defective.
쐌Ignitor input signal
쐌Secondary coil resistance
쐌Poor contact in ignition coil and ignitor assembly
connector
1) Turn ignition switch to OFF.
2) Disconnect connector from ECM, then connect
ST. <Ref. to EN(SOHCw/oOBD)-23, HOW TO
CHECK I/O SIGNAL FOR ECM, Engine Control
Module (ECM) I/O Signal.>
ST 498307600 CHECK BOARD KIT
3) Turn ignition switch to ON.
4) Measure voltage between ignition coil and igni-
tion assembly and body.
Connector & terminal:
(A) No. 5 —Engine ground
(A) No. 12 —Engine ground
S6M0378A
Specified voltage: 3 —4V
B2M0224B
5) Turn ignition switch to OFF.
6) Disconnect connector from ignition coil and
ignitor assembly.
7) Remove spark plug cords.
8) Measure resistance between spark plug cord
contact portions to check secondary coil.
Terminals / Specified resistance:
(A) —(B) / 13.0 ±2.6 kΩ
(C) —(D) / 13.0 ±2.6 kΩ
CAUTION:
If the resistance is extremely low, this indicates
the presence of a ground short circuit.
B6M0810B
9) Check poor contact in ignition coil and ignitor
assembly connector.
IG(SOHCw/oOBD)-10
IGNITION COIL AND IGNITOR ASSEMBLY
Ignition

4. Spark Plug Cord S161014
A: INSPECTION S161014A10
Check for:
1) Damage to cords, deformation, burning or rust
formation of terminals
2) Resistance values of cords
Resistance value:
5.24 —12.23 kΩ
S6M0145
IG(SOHCw/oOBD)-11
SPARK PLUG CORD Ignition

IG(SOHCw/oOBD)-12
SPARK PLUG CORD
Ignition

MEMO:
IG(SOHCw/oOBD)-13
Ignition SPARK PLUG CORD

IG(SOHCw/oOBD)-14
Ignition SPARK PLUG CORD