ignition SUBARU FORESTER 2004 Service Repair Manual
[x] Cancel search | Manufacturer: SUBARU, Model Year: 2004, Model line: FORESTER, Model: SUBARU FORESTER 2004Pages: 2870, PDF Size: 38.67 MB
Page 897 of 2870
ME(H4SO)-28
MECHANICAL
Intake Manifold Vacuum
5. Intake Manifold Vacuum
A: INSPECTION
1) Warm-up the engine.
2) Disconnect the brake vacuum hose from intake
manifold, and then install the vacuum gauge.
3) Keep the engine at idle speed, and then read the
vacuum gauge indication.By observing the gauge needle movement, the in-
ternal condition of engine can be diagnosed as de-
scribed below.
Vacuum pressure (at idling, A/C “OFF”):
Less than
−60.0 kPa (−450 mmHg, −17.72 in-
Hg)
ME-00195
Diagnosis of engine condition by measurement of intake manifold vacuum
Vacuum gauge indication Possible engine condition
1. Needle is steady but lower than normal position. This ten-
dency becomes more evident as engine temperature rises.Air leakage around intake manifold gasket or disconnection or
damaged vacuum hose
2. When engine speed is reduced slowly from higher speed,
needle stops temporarily when it is lowering or becomes steady
above normal position.Exhaust pressure too high, or exhaust system clogged
3. Needle intermittently drops to position lower than normal
position.Leakage around cylinder
4. Needle drops suddenly and intermittently from normal posi-
tion.Sticky valves
5. When engine speed is gradually increased, needle begins to
vibrate rapidly at certain speed, and then vibration increases as
engine speed increases.Weak or broken valve springs
6. Needle vibrates above and below normal position in narrow
range.Defective ignition system
Page 922 of 2870
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)
Page 923 of 2870
MECHANICAL
ME(H4SO)
Page
1. General Description ....................................................................................2
2. Compression .............................................................................................25
3. Idle Speed .................................................................................................26
4. Ignition Timing ...........................................................................................27
5. Intake Manifold Vacuum............................................................................28
6. Engine Oil Pressure ..................................................................................29
7. Fuel Pressure ............................................................................................30
8. Valve Clearance ........................................................................................31
9. Engine Assembly ......................................................................................34
10. Engine Mounting .......................................................................................41
11. Preparation for Overhaul ...........................................................................42
12. V-belt .........................................................................................................43
13. Crank Pulley ..............................................................................................45
14. Timing Belt Cover......................................................................................47
15. Timing Belt ................................................................................................48
16. Cam Sprocket ...........................................................................................53
17. Crank Sprocket .........................................................................................55
18. Valve Rocker Assembly ............................................................................56
19. Camshaft ...................................................................................................58
20. Cylinder Head ...........................................................................................62
21. Cylinder Block ...........................................................................................69
22. Engine Trouble in General ........................................................................91
23. Engine Noise .............................................................................................96
Page 967 of 2870
ME(H4SO)-96
MECHANICAL
Engine Noise
23.Engine Noise
A: INSPECTION
NOTE*:
When disconnecting fuel injector connector, the malfunction indicator light illuminates and DTC is stored in ECM memory.
Therefore, carry out the clear memory mode
Regular clicking soundSound increases as engine
speed increases. Valve mechanism is defective.
Incorrect valve clearance
Worn valve rocker
Worn camshaft
Broken valve spring
Heavy and dull clankOil pressure is low. Worn crankshaft main bearing
Worn connecting rod bearing (big end)
Oil pressure is normal. Loose flywheel mounting bolts
Damaged engine mounting
High-pitched clank (Spark
knock)Sound is noticeable when
accelerating with an overload. Ignition timing advanced
Accumulation of carbon inside combustion chamber
Wrong spark plug
Improper gasoline
Clank when engine speed is
medium (1,000 to 2,000 rpm).Sound is reduced when fuel
injector connector of noisy cyl-
inder is disconnected.
(NOTE*) Worn crankshaft main bearing
Worn bearing at crankshaft end of connecting rod
Knocking sound when engine
is operating under idling speed
and engine is warmSound is reduced when fuel
injector connector of noisy cyl-
inder is disconnected.
(NOTE*) Worn cylinder liner and piston ring
Broken or stuck piston ring
Worn piston pin and hole at piston end of connecting rod
Sound is not reduced if each
fuel injector connector is dis-
connected in turn. (NOTE*) Unusually worn valve lifter
Worn cam gear
Worn camshaft journal bore in crankcase
Squeaky sound — Insufficient generator lubrication
Rubbing sound — Defective generator brush and rotor contact
Gear scream when starting
engine— Defective ignition starter switch
Worn gear and starter pinion
Sound like polishing glass with
a dry cloth— Loose drive belt
Defective water pump shaft
Hissing sound — Loss of compression
Air leakage in air intake system, hoses, connections or mani-
folds
Timing belt noise — Loose timing belt
Belt contacting case/adjacent part
Valve tappet noise — Incorrect valve clearance
Page 968 of 2870
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)
Page 983 of 2870
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)
Page 996 of 2870
CO(H4SO)-13
COOLING
Radiator Fan System
2. Radiator Fan System
A: WIRING DIAGRAM
CO-02003
B72 SBF-1
SBF-4
NO.17
NO.18
MAIN FAN MOTOR
(EXCEPT TURBO AT MODEL)
F17
2
1
ET
MAIN
FA N
RELAY-1
FA N
MODE
RELAY31
34
32
30
5
9
7
8
6 SUB
FA N
RELAY A/C RELAY HOLDER
28
25
3
4
27
29
RHD
RHD
RHD
RHDLHD
LHD
LHD
F2
B1001110F2
B100197
2
1
F27
B25
B24
A14
ECM
(NON- TURBO MODEL)B134 A:
A13
NA
F17
F16
21
LHD
RHD
F2(BLACK)
(BLACK) (GRAY)
(GRAY)F2
A/C RELAY HOLDER
F27
12
34
567891110
1312142120
2322243130
333234
1615171819
26252728293536
B:B135
A:
B134
1234567891011121314151617181920212223242526272829303132333435
: : ::
ET
TA
1234 5678910 11 12 13 14 15 16 17 18 19 2012345
678910
11 12 19 20 2113 14 15 16 17 18 22
B135 B:
ECM
(TURBO MODEL)
(BLUE)
(BLUE)
567 2 134
2910
1112131415252416
30
98171819202821222332312627333435
: TURBO MODELTB
: NON-TURBO
MODEL
NA: TURBO AT MODEL
TA
: EXCEPT TURBO
AT MODEL
ET
: KA TURBO MODEL AND
EC,EK TURBO AT MODEL : 30A 1*
1*
1*
: LHD MODEL : (GRAY) 2*
2*
SUB FAN MOTOR
(TURBO AT MODEL)
F16
1
2
MAIN FAN MOTOR
(TURBO AT MODEL)
F17
1
2
SUB FAN MOTOR
(EXCEPT TURBO AT MODEL)
F16
2
1
TA
ET
TA
TA
LHD
TA
ET
ET
TBNA
TB
12
F17
F16TA
:
TA
ET
:
ET
E
EXCEPT KA TURBO MODEL AND
EC,EK TURBO AT MODEL: 20A
IGNITION SWITCH
BATTERY
3412
B72
Page 997 of 2870
CO(H4SO)-14
COOLING
Radiator Fan System
B: INSPECTION
DETECTING CONDITION:
Engine coolant temperature is above 95°C (203°F).
Vehicle speed is below 19 km/h (12 MPH).
TROUBLE SYMPTOM:
Radiator main fan and sub fan does not rotate under the above conditions.
Step Check Yes No
1 CHECK OPERATION OF RADIATOR FAN.
1) Connect the test mode connector.
2) Turn the ignition switch to ON.
3) Using Subaru Select Monitor, check the
compulsory operation of radiator fan relay.
N
OTE:
With Subaru Select Monitor
When checking the compulsory operation of
radiator fan, the radiator main and sub fan
repeat the rotation in order of following: low
speed rotation → high speed rotation → off.
Subaru Select Monitor
Refer to Compulsory Valve Operation Check
Mode for detail procedures.
Check Mode.>Do the radiator main and sub
fan rotate at low speed?Go to step 2.Go to step 3.
2 CHECK OPERATION OF RADIATOR FAN.
1) Connect the test mode connector.
2) Turn the ignition switch to ON.
3) Using Subaru Select Monitor, check the
compulsory operation of radiator fan relay.
N
OTE:
With Subaru Select Monitor
When checking the compulsory operation of
radiator fan, the radiator main and sub fan
repeat the rotation in order of following: low
speed rotation → high speed rotation → off.
Subaru Select Monitor
Refer to Compulsory Valve Operation Check
Mode for detail procedures.
Check Mode.>Do the radiator main and sub
fan rotate at high speed?Radiator main fan
system is okay.Go to step 32.
3 CHECK POWER SUPPLY TO MAIN FAN RE-
LAY.
1) Turn the ignition switch to OFF.
2) Remove the fan relay 1 from A/C relay
holder.
3) Measure the voltage between main fan
relay terminal and chassis ground.
Connector & terminal
(F27) No. 31 (+) — Chassis ground (
−):Is the voltage more than 10 V? Go to step 4.Go to step 5.
4 CHECK POWER SUPPLY TO MAIN FAN RE-
LAY.
1) Turn the ignition switch to ON.
2) Measure the voltage between main fan
relay terminal and chassis ground.
Connector & terminal
(F27) No. 34 (+) — Chassis ground (
−):Is the voltage more than 10 V? Go to step 8.Go to step 7.
5 CHECK FUSE.
1) Remove the fuse from A/C relay holder.
2) Check the condition of fuse.Is the fuse blown out? Replace the fuse. Go to step 6.
Page 998 of 2870
CO(H4SO)-15
COOLING
Radiator Fan System
6 CHECK HARNESS OF FUSE TERMINAL
AND MAIN FAN RELAY TERMINAL.
1) Turn the ignition switch to OFF.
2) Measure the resistance between 20 A fuse
terminal and main fan relay terminal.
Te r m i n a l
No. 2 — No. 31:Is the resistance less than 1
Ω?Repair the power
supply line.Repair the open
harness.
7 CHECK FUSE.
1) Turn the ignition switch to OFF
2) Remove the fuse No. 18.
3) Check the condition of fuse.Is the fuse blown out? Replace the fuse. Repair the power
supply line.
8 CHECK MAIN FAN RELAY.
1) Turn the ignition switch to OFF.
2) Measure the resistance between main fan
relay terminals.
Te r m i n a l
No. 30 — No. 31:Is the resistance more than 1
MΩ?Go to step 9.Replace the main
fan relay.
9 CHECK MAIN FAN RELAY.
1) Connect the battery to main fan relay termi-
nals No. 32 and No. 34.
2) Measure the resistance between main fan
relay terminals.
Te r m i n a l
No. 30 — No. 31:Is the resistance less than 1
Ω?Go to step 10.Replace the main
fan relay.
10 CHECK HARNESS BETWEEN MAIN FAN
RELAY TERMINAL AND MAIN FAN MOTOR
CONNECTOR.
1) Disconnect the connector from main fan
motor.
2) Measure the resistance between main fan
relay terminal and main fan motor connector.
Connector & terminal
Turbo AT model
(F17) No. 1 — (F27) No. 30:
Except turbo AT model
(F17) No. 2 — (F27) No. 30:Is the resistance less than 1
Ω?Go to step 11.Repair the open
harness between
main fan relay ter-
minal and main fan
motor connector.
11 CHECK HARNESS BETWEEN MAIN FAN
MOTOR CONNECTOR AND FAN MODE RE-
LAY CONNECTOR.
1) Remove the fan mode relay from A/C relay
holder.
2) Measure the resistance between main fan
motor connector and fan mode relay connec-
tor.
Connector & terminal
Turbo AT model
(F17) No. 2 — (F27) No. 9:
Except turbo AT model
(F17) No. 1 — (F27) No. 9:Is the resistance less than 1
Ω?Go to step 12.Repair the open
harness between
main fan motor
connector and fan
mode relay con-
nector.
12 CHECK POOR CONTACT.
Check poor contact in main fan motor connec-
tor.Is there poor contact in main
fan motor connector?Repair poor con-
tact in main fan
motor connector.Go to step 13.
13 CHECK MAIN FAN MOTOR.
Connect the battery positive (+) terminal to ter-
minal No. 2 (except turbo AT model), No. 1
(turbo AT model), and ground (−) terminal to
terminal No. 1 (except turbo AT model), No. 2
(turbo AT model) of main fan motor.Does the main fan rotate? Go to step 14.Replace the main
fan motor with new
one. Step Check Yes No
Page 999 of 2870
CO(H4SO)-16
COOLING
Radiator Fan System
14 CHECK FAN MODE RELAY.
Measure the resistance of fan mode relay.
Te r m i n a l
No. 6 — No. 9:Is the resistance less than 1
Ω?Go to step 15.Replace the fan
mode relay.
15 CHECK RESISTANCE BETWEEN FAN
MODE RELAY TERMINAL AND SUB FAN
MOTOR CONNECTOR.
1) Disconnect the connector from sub fan
motor.
2) Measure the resistance between fan mode
relay terminal and sub fan motor connector.
Connector & terminal
Turbo AT model
(F16) No. 1 — (F27) No. 6:
Except turbo AT model
(F16) No. 2 — (F27) No. 6:Is the resistance less than 1
Ω?Go to step 16.Repair the open
harness between
fan mode relay ter-
minal and sub fan
motor connector.
16 CHECK SUB FAN MOTOR AND GROUND
CIRCUIT.
Measure the resistance between sub fan motor
connector and chassis ground.
Connector & terminal
Turbo AT model
(F16) No. 2 — Chassis ground:
Except turbo AT model
(F16) No. 1 — Chassis ground:Is the resistance less than 5
Ω?Go to step 17.Repair the open
harness between
sub fan motor con-
nector and chassis
ground.
17 CHECK POOR CONTACT.
Check poor contact in sub fan motor connec-
tor.Is there poor contact in sub fan
motor connector?Repair poor con-
tact in sub fan
motor connector.Go to step 18.
18 CHECK SUB FAN MOTOR.
Connect the battery positive (+) terminal to ter-
minal No. 2 (except turbo AT model), No. 1
(turbo AT model), and ground (−) terminal to
terminal No. 1 (except turbo AT model), No. 2
(turbo AT model) of sub fan motor.Does the sub fan rotate? Go to step 19.Replace the sub
fan motor with new
one.
19 CHECK HARNESS BETWEEN MAIN FAN
RELAY AND ECM.
1) Disconnect the connector from ECM.
2) Measure the resistance between fan relay 1
terminal and ECM connector.
Connector & terminal
Turbo model
(B135) No. 25 — (F27) No. 32:
Non-turbo model
(B134) No. 14 — (F27) No. 32:Is the resistance less than 1
Ω?Go to step 20.Repair the open
harness between
fan relay 1 terminal
and ECM.
20 CHECK POOR CONTACT.
Check poor contact in ECM connector.Is there poor contact in ECM
connector?Repair poor con-
tact in ECM con-
nector.Contact with SUB-
ARU dealers.
21 CHECK POWER SUPPLY TO SUB FAN RE-
LAY.
1) Turn the ignition switch to OFF.
2) Remove the sub fan relay from A/C relay
holder.
3) Measure the voltage between sub fan relay
terminal and chassis ground.
Connector & terminal
(F27) No. 28 (+) — Chassis ground (
−):Is the voltage more than 10 V? Go to step 22.Go to step 23. Step Check Yes No