replace disc SUBARU FORESTER 2004 Service Repair Manual

FU(H4DOTC)-37
FUEL INJECTION (FUEL SYSTEM)
Idle Air Control Solenoid Valve
12.Idle Air Control Solenoid
Valve
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Disconnect the connector from idle air control
solenoid valve.
3) Remove the idle air control solenoid valve from
throttle body.
4) Remove the gasket from throttle body.
B: INSTALLATION
Install in the reverse order of removal.
NOTE:
Replace the gasket with a new one.
Tightening torque:
2.8 N
⋅m (0.29 kgf-m, 2.1 ft-lb)
FU-00009
FU-00070
FU-00071
FU-00072
FU-00071

FU(H4DOTC)-67
FUEL INJECTION (FUEL SYSTEM)
Fuel Filter
30.Fuel Filter
A: REMOVAL
WARNING:
 Place “NO FIRE” signs near working area.
 Be careful not to spill fuel on floor.
1) Release the fuel pressure. FU(H4DOTC)-54, RELEASING OF FUEL PRES-
SURE, OPERATION, Fuel.>
2) Disconnect the fuel delivery hoses from fuel fil-
ter.
3) Remove the filter from holder.
B: INSTALLATION
CAUTION:
 If fuel hoses are damaged at connecting por-
tions, replace them with new ones.
 If clamps are badly damaged, replace them
with new ones.
1) Install in the reverse order of removal.
2) Tighten the hose clamp screws.
Tightening torque:
1.25 N
⋅m (0.13 kgf-m, 0.94 ft-lb)
C: INSPECTION
1) Check the inside of fuel filter for dirt and water
sediment.
2) If it is clogged, or if replacement interval has
been reached, replace it.
3) If water is found in it, shake and expel the water
from inlet port.
FU-00118
FU-00118

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.

IN(H4DOTC)-6
INTAKE (INDUCTION)
General Description
B: 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
sensor or units, be sure to disconnect the ground
cable from battery.

IN(H4DOTC)-7
INTAKE (INDUCTION)
Air Cleaner
2. Air Cleaner
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Disconnect the connector from mass air flow
sensor.
3) Loosen the clamp (A) which connects air intake
boot and intake duct.
4) Remove the clip (B) from air cleaner upper cover.
5) Remove the air cleaner upper cover.
6) Remove the air cleaner element.
7) Remove the air cleaner lower case.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
33 N
⋅m (3.4 kgf-m, 24.6 ft-lb)
NOTE:
Before installing the air cleaner upper cover, align
the holes with protruding portions of air cleaner
lower case, then secure the upper cover to lower
case.
C: INSPECTION
Replace if excessively damaged or dirty.
FU-00009
IN-00005
IN-00006
(B)
(A)
IN-00007
IN-00007
IN-00008

ME(H4DOTC)-22
MECHANICAL
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 in 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.
 All parts should be thoroughly cleaned, paying
special attention to the engine oil passages, pis-
tons and bearings.
 Rotating parts and sliding parts such as piston,
bearing and gear should be coated with oil prior to
assembly.
 Be careful not to let oil, grease or coolant contact
the timing belt, clutch disc and flywheel.
 All removed parts, if to be reused, should be re-
installed in the original positions and directions.
 Bolts, nuts and washers should be replaced with
new ones as required.
 Even if necessary inspections have been made
in advance, proceed with assembly work while
making rechecks.
 Remove or install the engine in an area where
chain hoists, lifting devices, etc. are available for
ready use.
 Be sure not to damage coated surfaces of body
panels with tools or stain seats and windows with
coolant or oil. Place a cover over fenders, as re-
quired, for protection.
 Prior to starting work, prepare the following:
Service tools, clean cloth, containers to catch cool-
ant and oil, wire ropes, chain hoist, transmission
jacks, etc.
 Lift-up or lower the vehicle when necessary.
Make sure to support the correct positions.

ME(H4DOTC)-36
MECHANICAL
Fuel Pressure
7. Fuel Pressure
A: INSPECTION
CAUTION:
Before removing the fuel pressure gauge, re-
lease the fuel pressure.
NOTE:
If out of specification, check or replace the pressure
regulator and pressure regulator vacuum hose.
1) Release the fuel pressure. FU(H4DOTC)-54, RELEASING OF FUEL PRES-
SURE, OPERATION, Fuel.>
2) Open the fuel filler flap lid, and then remove the
fuel filler cap.
3) Disconnect the fuel delivery hoses from fuel fil-
ter, and then connect the fuel pressure gauge.
4) Connect the connector of fuel pump relay.
5) Start the engine.6) Measure the fuel pressure while disconnecting
the pressure regulator vacuum hose from intake
manifold.
Fuel pressure:
Standard; 284 — 314 kPa (2.9 — 3.2 kgf/cm2,
41 — 46 psi)
7) After connecting the pressure regulator vacuum
hose, measure the fuel pressure.
Fuel pressure:
Standard; 230 — 260 kPa (2.35 — 2.65 kgf/
cm
2, 33 — 38 psi)
NOTE:
The fuel pressure gauge registers 10 to 20 kPa (0.1
to 0.2 kgf/cm
2, 1 to 3 psi) higher than standard val-
ues during high-altitude operations.
ME-00010
FU-00262
ME-00011
ME-00011

EX(H4DOTC)-6
EXHAUST
General Description
B: 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.

EX(H4DOTC)-7
EXHAUST
Front Exhaust Pipe
2. Front Exhaust Pipe
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the front oxygen (A/F) sensor. FU(H4DOTC)-45, REMOVAL, Front Oxygen (A/F)
Sensor.> or MOVAL, Front Oxygen (A/F) Sensor.>
3) Remove the under cover.
4) Remove the lower exhaust manifold cover.
5) Remove the nuts which hold front exhaust pipe
assembly to turbocharger joint pipe.
6) While holding the front exhaust pipe assembly
with one hand, remove the nuts which hold front ex-
haust pipe assembly to cylinder head exhaust port.7) Remove the front exhaust pipe assembly.
8) Remove the covers from exhaust manifold and
front exhaust pipe.
9) Separate the front exhaust pipe from exhaust
manifolds.
B: INSTALLATION
NOTE:
Replace the gaskets with new ones.
1) Assemble the front exhaust pipe and exhaust
manifolds.
Tightening torque:
35 N·m (3.6 kgf-m, 26.0 ft-lb)
2) Install the front exhaust pipe covers.
Tightening torque:
7.5 N·m (0.8 kgf-m, 5.5 ft-lb)
3) Install the exhaust manifold upper cover (RH).
Tightening torque:
19 N·m (1.9 kgf-m, 13.7 ft-lb)
FU-00009
EX-00246
EX-00004
EX-00005
EX-00245
EX-00245

EX(H4DOTC)-14
EXHAUST
Rear Exhaust Pipe
5. Rear Exhaust Pipe
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Lift-up the vehicle.
3) Separate the rear exhaust pipe from center ex-
haust pipe.
CAUTION:
Be careful, the exhaust pipe is hot.
4) Separate the rear exhaust pipe from muffler.
CAUTION:
Be careful not to pull down the rear exhaust
pipe.5) Separate the rear exhaust pipe from cushion
rubber, and then remove.
B: INSTALLATION
NOTE:
Replace the gasket and nuts with new ones.
1) Install the rear exhaust pipe to cushion rubber.
2) Install the rear exhaust pipe to muffler.
Tightening torque:
48 N·m (4.9 kgf-m, 35.4 ft-lb)
FU-00009
EX-00045
EX-00020
EX-00021
EX-00021
EX-00020