Subaru 2004 Forester User manual

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)

IGNITION
IG(H4DOTC)
Page
1. General Description ....................................................................................2
2. Spark Plug...................................................................................................5
3. Ignition Coil & Ignitor ASSY ........................................................................8

IG(H4DOTC)-2
IGNITION
General Description
1. General Description
A: SPECIFICATION
Item Designation
Ignition coil and ignitor
ASSY
Model FK0186
Ignition type Direct ignition
Manufacturer DIAMOND
Spark plug
Type and manufacturer 2.0 L model NGK: PFR6G
2.5 L model NGK: ILFR6B
Thread diameter, pitch, length mm 14, 1.25, 26.5
Spark gap mm (in) 0.7 — 0.8 (0.028 — 0.031)
Electrode 2.0 L model Platinum
2.5 L model Irigium

IG(H4DOTC)-3
IGNITION
General Description
B: COMPONENT
(1) Spark plug (2) Ignition coil & ignitor ASSY Tightening torque: N ⋅ m (kgf-m, ft-lb)
T1: 21 (2.1, 15.2)
T2: 16 (1.6, 11.7)
IG-00001
(1)
T1
T2
T1
(1)
(2)
(2)
T2

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.

IG(H4DOTC)-5
IGNITION
Spark Plug
2. Spark Plug
A: REMOVAL
CAUTION:
All spark plugs installed on an engine, must be
of the same heat range. <Ref. to IG(H4DOTC)-2,
General Description.>
1. RH SIDE
1) Disconnect the ground cable from battery.
2) Remove the air cleaner lower case. <Ref. to
IN(H4DOTC)-7, REMOVAL, Air Cleaner.>
3) Disconnect the connector from ignition coil.
4) Remove the ignition coil.
5) Remove the spark plugs with the spark plug
sockets.
2. LH SIDE
1) Disconnect the battery cables, and then remove
the battery and battery carrier.
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 working area.
FU-00009
FU-01307
IG-00003
IG-00004
FU-00009
IG-00005
IG-00006

IG(H4DOTC)-6
IGNITION
Spark Plug
5) Disconnect the connector from ignition coil.
6) Remove the ignition coil.
7) Remove the spark plugs with the spark plug
sockets.
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)
Tightening torque (Ignition coil):
16 N
⋅ m (1.6 kgf-m, 11.7 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)
Tightening torque (Ignition coil):
16 N
⋅ m (1.6 kgf-m, 11.7 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.
FU-01308
IG-00008
IG-00009
(A) Electrode gap
(B) Carbon accumulation or wear
(C) Cracks
(D) Damage
(E) Damaged gasket
IG-00010
(A)
(B) (C)
(D)
(E)
IG-00011

IG(H4DOTC)-7
IGNITION
Spark Plug
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.
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: ADJUSTMENT
Clean the spark plugs with a wire brush. Clean and
remove the carbon or oxide deposits, but do not
wear ceramic insulator.
If deposits are too stubborn, replace the plugs.
After cleaning the spark plugs, correct the spark
plug gap using a gap gauge.
NOTE:
Do not use spark plug cleaners, because the spark
plugs are applied with platinum or irigium tips.
Spark plug gap: L
0.7 — 0.8 mm (0.028 — 0.031 in)
NOTE:
Replace with a new spark plug if this area (A) is
worn to “ball” shape.
IG-00012
IG-00013
IG-00014
IG-00015
L(A)

IG(H4DOTC)-8
IGNITION
Ignition Coil & Ignitor ASSY
3. Ignition Coil & Ignitor ASSY
A: REMOVAL
Direct ignition type has been adopted. Refer to the
“SparkPlug Removal” for removal procedure. <Ref.
to IG(H4DOTC)-5, REMOVAL, Spark Plug.>
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
16 N
⋅ m (1.6 kgf-m, 11.7 ft-lb)
C: INSPECTION
Ignitor is integrated with the coil. Therefore resis-
tance cannot be measured.