ECU SUBARU FORESTER 2004 Service Repair Manual

EN(H4SO)-256
ENGINE (DIAGNOSTIC)
General Diagnostic Table
*1: Check ignition coil & ignitor ASSY and spark plug.
*2: Indicate the symptom occurring only in cold temperatures.
*3: Ensure the secure installation.
*4: Check fuel injector, fuel pressure regulator and fuel filter.
*5: Inspect air leak in air intake system.
*6: Adjust the accelerator cable.
2. AUTOMATIC TRANSMISSION
NOTE:
Check general diagnostics table with non-conformity symptom for automatic transmission. 4AT(H4SO)-2, Basic Diagnostic Procedure.>
6. Surging1) Intake manifold pressure sensor
2) Intake air temperature sensor
3) Manifold absolute pressure sensor
4) Engine coolant temperature sensor (*2)
5) Crankshaft position sensor (*3)
6) Camshaft position sensor (*3)
7) Fuel injection parts (*4)
8) Throttle position sensor
9) Fuel pump and fuel pump relay
7. Spark knock1) Intake manifold pressure sensor
2) Intake air temperature sensor
3) Manifold absolute pressure sensor
4) Engine coolant temperature sensor
5) Knock sensor
6) Fuel injection parts (*4)
7) Fuel pump and fuel pump relay
8. After burning in exhaust system1) Intake manifold pressure sensor
2) Intake air temperature sensor
3) Manifold absolute pressure sensor
4) Engine coolant temperature sensor (*2)
5) Fuel injection parts (*4)
6) Fuel pump and fuel pump relay Symptom Problem parts

FU(H4DOTC)-13
FUEL INJECTION (FUEL SYSTEM)
Throttle Body
2. Throttle Body
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the intercooler. 10, REMOVAL, Intercooler.>
3) Disconnect the connector from the throttle posi-
tion sensor (A) and idle air control solenoid valve
(B) and manifold absolute pressure sensor (C).
4) Disconnect the accelerator cable.
5) Disconnect the engine coolant hoses from throt-
tle body.6) Remove the bolts which secure the throttle body
to intake manifold.B: INSTALLATION
1) Install in the reverse order of removal.
NOTE:
Always use a new gasket.
Tightening torque:
22 N
⋅m (2.2 kgf-m, 16.2 ft-lb)
2) Adjust the accelerator cable play. SP(H4SO)-9, INSTALLATION, Accelerator Control
Cable.>
FU-00009
(A)(B)
(C)
FU-00010
FU-00011
FU-00012
FU-00013

FU(H4DOTC)-14
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
3. Intake Manifold
A: REMOVAL
1) Release the fuel pressure. 54, RELEASING OF FUEL PRESSURE, OPERA-
TION, Fuel.>
2) Open the fuel filler flap lid and remove the fuel
filler cap.
3) Disconnect the ground cable from battery.
4) Lift-up the vehicle.
5) Remove the under cover.
6) Drain the coolant about 3.02 (3.2 US qt, 2.6 Imp
qt).
7) Remove the air cleaner upper cover and air in-
take boot. Cleaner.>
8) Remove the air cleaner element.
9) Remove the intercooler. 10, REMOVAL, Intercooler.>
10) Disconnect the accelerator cable.
11) Remove the coolant filler tank. CO(H4SO)-42, REMOVAL, Coolant Filler Tank.>
12) Remove the power steering pump.(1) Remove the front side V-belt. ME(H4DOTC)-52, REMOVAL, V-belt.>
(2) Disconnect the power steering switch con-
nector.
(3) Remove the bolts which secure the power
steering pipe brackets to intake manifold.
CAUTION:
Do not disconnect the power steering hose.
(4) Remove the bolts which secure the power
steering pump bracket.
(5) Remove the power steering tank from the
bracket by pulling it upward.
FU-00009
FU-00016
FU-00011
FU-00017
FU-00018
FU-00019
FU-00020

FU(H4DOTC)-17
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
26) Disconnect the fuel delivery hose, return hose
and evaporation hose.
CAUTION:
 Do not spill fuel.
 Catch the fuel from hoses in a container or
cloth.
27) Remove the bolts which secure the intake man-
ifold to cylinder heads.
28) Disconnect the ground cable connector.
29) Remove the intake manifold.B: INSTALLATION
1) Install the intake manifold onto cylinder heads.
NOTE:
Always use new gaskets.
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.4 ft-lb)
2) Connect the ground cable.
3) Connect the fuel delivery hose, return hose and
evaporation hose.
FU-00032
FU-00033
FU-00131
FU-00132
FU-00033
FU-00131
FU-00132
FU-00032

FU(H4DOTC)-27
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
19) Install the throttle body to intake manifold.
NOTE:
Replace the gasket with a new one.
Tightening torque:
22 N
⋅m (2.2 kgf-m, 16.2 ft-lb)
20) Connect the connector to the throttle position
sensor (A), idle air control solenoid valve (B) and
manifold absolute pressure sensor (C).
21) Connect the engine harness with clip (D) to in-
take manifold.22) Install the engine ground cable to intake mani-
fold.
Tightening torque:
19 N
⋅m (1.9 kgf-m, 14.0 ft-lb)
23) Install the fuel pipe protector RH.
Tightening torque:
19 N
⋅m (1.9 kgf-m, 14.0 ft-lb)
NOTE:
Bolt (A) is tightened together with ground cable.
Tighten it securely.
FU-00013
FU-00038
(A)
(B) (C)
(D) (D)
FU-00036
FU-00037
FU-00522
(A)

FU(H4DOTC)-28
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
24) Install the fuel pipe protector LH.
NOTE:
Bolt (A) is tightened together with ground cable.
Tighten it securely.
Tightening torque:
19 N
⋅m (1.9 kgf-m, 14.0 ft-lb)
E: INSPECTION
Make sure the fuel pipe and fuel hoses are not
cracked and the connections are tightened firmly.
(A)
FU-00523

FU(H4DOTC)-40
FUEL INJECTION (FUEL SYSTEM)
Fuel Injector
B: INSTALLATION
1. RH SIDE
Install in the reverse order of removal.
NOTE:
Replace the O-ring and insulators with new ones.
Tightening torque:
19 N
⋅m (1.9 kgf-m, 14.0 ft-lb)
Tightening torque:
19 N
⋅m (1.9 kgf-m, 14.0 ft-lb)NOTE:
Bolt (A) is tightened together with ground cable.
Tighten it securely.
Tightening torque:
19 N
⋅m (1.9 kgf-m, 14.0 ft-lb)
2. LH SIDE
Install in the reverse order of removal.
NOTE:
Replace the O-ring and insulators with new ones.
Tightening torque:
5 N
⋅m (0.5 kgf-m, 3.7 ft-lb)
(A) O-ring
(B) Fuel injector
(C) Insulator
FU-00073
(A)
(C)
(C)(B)
FU-00046
FU-00619
(A) O-ring
(B) Fuel injector
(C) Insulator
FU-00522
(A)
FU-00073
(A)
(C)
(C)(B)
FU-00043

FU(H4DOTC)-41
FUEL INJECTION (FUEL SYSTEM)
Fuel Injector
Tightening torque:
19 N
⋅m (1.9 kgf-m, 14.0 ft-lb)
Tightening torque:
19 N
⋅m (1.9 kgf-m, 14.0 ft-lb)
NOTE:
Bolt (A) is tightened together with ground cable.
Tighten it securely.
Tightening torque:
19 N
⋅m (1.9 kgf-m, 14.0 ft-lb)
FU-00044
FU-00618
(A)
FU-00523

FU(H4DOTC)-56
FUEL INJECTION (FUEL SYSTEM)
Fuel Tank
B: INSTALLATION
1) Support the fuel tank with transmission jack and
push the fuel tank harness into access hole with
grommet.
2) Set the fuel tank and temporarily tighten the
bolts of fuel tank bands.
WARNING:
A helper is required to perform this work.
3) Connect the two-way valve hose (A) to two-way
valve and connect the canister hose (B) to canister.
4) Connect the fuel filler hose and air vent hose.5) Connect the fuel hoses, and secure them with
clips and quick connector. 71, INSTALLATION, Fuel Delivery, Return and
Evaporation Lines.>
6) Tighten the band mounting bolts.
Tightening torque:
33 N
⋅m (3.4 kgf-m, 24.3 ft-lb)
7) Install the rear crossmember. INSTALLATION, Rear Crossmember.>
8) Connect the connector (A) to the fuel tank cord,
and plug the service hole with grommet (B).
9) Set the rear seat and floor mat.
FU-00411
(A)(B)
FU-00091
FU-00092
FU-00093
FU-00411
(B)
(A)
FU-00090

FU(H4DOTC)-71
FUEL INJECTION (FUEL SYSTEM)
Fuel Delivery, Return and Evaporation Lines
9) Separate the quick connector on fuel delivery
line.
(1) Clean the pipe and connector, if they are
covered with dust.
(2) Hold the connector (A) and push retainer (B)
down.
(3) Pull out the connector (A) from retainer (B).
B: INSTALLATION
1) Connect the quick connector on fuel delivery
line.
NOTE:
 Replace the retainer with a new one.
 Make sure the connected portion is not damaged
or has dust. If necessary, clean the seal surface of
pipe.(1) Set the new retainer (B) to connector (A).
(2) Push the pipe into connector completely.
NOTE:
At this time, two clicking sounds are heard.
CAUTION:
 Pull the connector to ensure it is connected
securely.
 Ensure the two retainer pawls are engaged in
their mating positions in connector.
 Be sure to inspect the hoses and their con-
nections for any leakage of fuel.
(A) Connector
(B) Retainer
(C) Pipe
(A) Seal surface
(B) Pipe
FU-00124
(A)(B)
(C)
FU-00125
(A)
(B)
(A) Connector
(B) Retainer
(C) Pipe
(A) Connector
(B) Retainer
(C) Pipe
FU-00126
(C)
(A)
(B)
FU-00127
(A)
(B)
(C)