SUBARU FORESTER 2004 Service Repair Manual

EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICE)
EC(H4DOTC)
Page
1. General Description ....................................................................................2
2. Front Catalytic Converter ............................................................................3
3. Rear Catalytic Converter .............................................................................4
4. Precatalytic Converter .................................................................................5
5. Canister .......................................................................................................6
6. Purge Control Solenoid Valve .....................................................................7
7. Two-way Valve ............................................................................................8

EC(H4DOTC)-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 your hands, 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(H4DOTC)-3
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICE)
Front Catalytic Converter
2. Front Catalytic Converter
A: REMOVAL
1) Remove the center exhaust pipe. EX(H4DOTC)-9, REMOVAL, Center Exhaust
Pipe.>
2) Separate the front catalytic converter from cen-
ter exhaust pipe. (2.0 L model)
 2.0 L model
 2.5 L model
B: INSTALLATION
NOTE:
Replace the gaskets with new ones.
Install in the reverse order of removal.
C: INSPECTION
1) Make sure there are no exhaust leaks from con-
nections and welds.
2) Make sure there are no holes or rusting.
(A) Front catalytic converter
(A) Front catalytic converter
(A)
EC-02010
EC-00001
(A)

EC(H4DOTC)-4
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICE)
Rear Catalytic Converter
3. Rear Catalytic Converter
A: REMOVAL
1. 2.0 L MODEL
1) Remove the center exhaust pipe. EX(H4DOTC)-9, REMOVAL, Center Exhaust
Pipe.>
2) Separate the rear catalytic converter from front
center exhaust pipe.
2. 2.5 L MODEL
Remove the rear exhaust pipe. EX(H4DOTC)-14, REMOVAL, Rear Exhaust
Pipe.>
B: INSTALLATION
NOTE:
Replace the gaskets with new ones.
Install in the reverse order of removal.
C: INSPECTION
1) Make sure there are no exhaust leaks from con-
nections and welds.
2) Make sure there are no holes or rusting.
(A) Rear catalytic converter
(A) Rear catalytic converter
(A)
EC-02011
(A)
EC-00002

EC(H4DOTC)-5
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICE)
Precatalytic Converter
4. Precatalytic Converter
A: REMOVAL
Precatalytic converter (A) is built in the joint pipe.
Refer to the removal of joint pipe for removal proce-
dure. Pipe.>
B: INSTALLATION
Refer to the installation of joint pipe for installation
procedure. TION, Joint Pipe.>
C: INSPECTION
1) Make sure there are no exhaust leaks from con-
nections and welds.
2) Make sure there are no holes or rusting.
(A)
EC-00077

EC(H4DOTC)-6
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-00003
EC-00004
EC-00004

EC(H4DOTC)-7
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.
3) Remove the bolt which installs the purge control
solenoid valve onto intake manifold.
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 the hoses are not cracked or loose.
FU-00009
EC-00005
EC-00005
(A) To intake manifold
(B) To purge valve
(A)
(B)
EC-02014

EC(H4DOTC)-8
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. EC(H4DOTC)-6, 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-00007

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)

INTAKE (INDUCTION)
IN(H4DOTC)
Page
1. General Description ....................................................................................2
2. Air Cleaner ..................................................................................................7
3. Air Intake Duct.............................................................................................8
4. Intake Duct ..................................................................................................9
5. Intercooler .................................................................................................10
6. Turbocharger.............................................................................................12
7. Air By-pass Valve ......................................................................................14
8. Resonator Chamber ..................................................................................15