SUBARU FORESTER 2004 Service Repair Manual

EC(H4SO)-2
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICE)
General Description
1. General Description
A: 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.

EC(H4SO)-3
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICE)
Front Catalytic Converter
2. Front Catalytic Converter
A: REMOVAL
1) Set the vehicle on a lift.
2) Disconnect the ground cable from battery.
3) Disconnect the front oxygen (A/F) sensor con-
nector.
4) Disconnect the connector from rear oxygen sen-
sor connector.
5) Lift-up the vehicle.
6) Remove the under cover.7) Separate the center exhaust pipe from rear ex-
haust pipe.
CAUTION:
Be careful, the exhaust pipe is hot.
8) Remove the nuts which hold front exhaust pipe
onto cylinder heads.
9) Remove the front and center exhaust pipe from
hanger bracket.
CAUTION:
Be careful not to pull down the front exhaust
pipe and center exhaust pipe.
FU-00009
EX-00029
EX-00030
EX-00037
EC-00009
EX-00038

EC(H4SO)-4
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICE)
Front Catalytic Converter
10) Separate the front catalytic converter from front
exhaust pipe.
B: INSTALLATION
NOTE:
Replace gaskets with new ones.
1) Install the front catalytic converter to front ex-
haust pipe.
Tightening torque:
30 N
⋅m (3.1 kgf-m, 22.4 ft-lb)
2) Install the front and center exhaust pipe assem-
bly to the vehicle. And temporarily tighten the bolt
which installs center exhaust pipe to hanger brack-
et.3) Tighten the nuts which hold front exhaust pipe
onto cylinder heads.
Tightening torque:
30 N
⋅m (3.1 kgf-m, 22.4 ft-lb)
4) Tighten the bolts which install front and center
exhaust pipe to rear exhaust pipe.
Tightening torque:
18 N
⋅m (1.8 kgf-m, 13.0 ft-lb)
5) Tighten the bolt which holds front and center ex-
haust pipe assembly to hanger bracket.
Tightening torque:
35 N
⋅m (3.6 kgf-m, 26.0 ft-lb)
6) Install the under cover.
EC-00011
EC-00011
EX-00038
EC-00009
EX-00037
EX-00038

EC(H4SO)-5
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICE)
Front Catalytic Converter
7) Lower the vehicle.
8) Connect the front oxygen (A/F) sensor connec-
tor.
9) Connect the connector to rear oxygen sensor
connector.
10) Connect the battery ground cable to battery.
C: INSPECTION
1) Make sure there are no exhaust leaks from con-
nections and welds.
2) Make sure there are no holes or rusting.
EX-00029
EX-00030
FU-00009

EC(H4SO)-6
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICE)
Rear Catalytic Converter
3. Rear Catalytic Converter
A: REMOVAL
1. WITH OBD
The front and rear catalytic converter and center
exhaust pipe are integrated into one unit. There-
fore, the removal and installation procedures are
the same as the those for the front catalytic con-
verter. <Ref. to EC(H4SO)-3, REMOVAL, Front
Catalytic Converter.>
2. WITHOUT OBD
Rear catalytic converter and rear exhaust pipe are
integrated into one unit. Refer to Rear Exhaust
Pipe for removal procedures. <Ref. to EX(H4SO)-
11, REMOVAL, Rear Exhaust Pipe.>
B: INSTALLATION
1. WITH OBD
Install in the reverse order of removal.
2. WITHOUT OBD
Install in the reverse order of removal.
C: INSPECTION
1. WITH OBD
1) Make sure there are no exhaust leaks from con-
nections and welds.
2) Make sure there are no holes or rusting.
2. WITHOUT OBD
Inspect in the same procedures as the vehicle with
OBD.
(A) Front catalytic converter
(B) Rear catalytic converter
(A) Front exhaust pipe
(B) Rear catalytic converter
(C) Rear exhaust pipe
EC-00080
EC-00081
(A)
(B)(C)
(A) Front catalytic converter
(B) Rear catalytic converter
(A) Front exhaust pipe
(B) Rear catalytic converter
(C) Rear exhaust pipe
EC-00080
EC-00081
(A)
(B)(C)

EC(H4SO)-7
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICE)
EGR Valve
4. EGR Valve
A: PROCEDURE
For EGR valve removal and installation proce-
dures, refer to FU section. <Ref. to FU(H4SO)-34,
EGR Valve.>

EC(H4SO)-8
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICE)
Canister
5. Canister
A: REMOVAL
1) Lift-up the vehicle.
2) Loosen the two clamps which hold two canister
hoses, and disconnect the three evaporation hoses
from canister.
3) Remove the canister from body.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
23 N
⋅m (2.3 kgf-m, 17 ft-lb)
C: INSPECTION
Make sure the canister and canister hoses are not
cracked or loose.
EC-00012
EC-00013
EC-00013

EC(H4SO)-9
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICE)
Purge Control Solenoid Valve
6. Purge Control Solenoid Valve
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Disconnect the connector and hoses from purge
control solenoid valve, and then remove the purge
control solenoid valve.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
19 N
⋅m (1.9 kgf-m, 13.7 ft-lb)
NOTE:
Connect the evaporation hoses as shown in the fig-
ure.
C: INSPECTION
Make sure hoses are not cracked or loose.
FU-00009
EC-00014
(A) To fuel pipe
(B) To intake manifold
EC-00014
EC-00015
A
B

EC(H4SO)-10
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICE)
Two-way Valve
7. Two-way Valve
A: REMOVAL
1) Lift-up the vehicle.
2) Remove the canister from body. <Ref. to
EC(H4SO)-8, REMOVAL, Canister.>
3) Remove the two-way valve with bracket as a sin-
gle unit from body.
4) Remove the two-way valve from bracket.
B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
Make sure that the hoses are not cracked or loose.
EC-00016

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)