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
(C) Cracks
(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-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