coolant SUBARU FORESTER 2004 Service Owner's Manual
[x] Cancel search | Manufacturer: SUBARU, Model Year: 2004, Model line: FORESTER, Model: SUBARU FORESTER 2004Pages: 2870, PDF Size: 38.67 MB
Page 795 of 2870
FU(H4SO)-13
FUEL INJECTION (FUEL SYSTEM)
Throttle Body
2. Throttle Body
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the air cleaner case.
3) Disconnect the accelerator cable (A).
4) Disconnect the cruise control cable (B). (With
cruise control model)
5) Disconnect the connectors from idle air control
solenoid valve, throttle position sensor and mani-
fold absolute pressure sensor.
6) Disconnect the engine coolant hoses (A) from
the throttle body.7) Remove the bolts (B) which install throttle body
to the intake manifold.
B: INSTALLATION
1) Install in the reverse order of removal.
NOTE:
Replace the gasket with a new one.
Tightening torque:
THROTTLE BODY;
22 N
⋅m (2.2 kgf-m, 15.9 ft-lb)
2) Adjust the accelerator cable play.
(A) Throttle position sensor
(B) Manifold absolute pressure sensor
(C) Idle air control solenoid valve
FU-00009
FU-00251
(B)
(A)
FU-00378
(B)
(A)(C)
FU-00253
(B)
(B)
(A)(A)
Page 797 of 2870
FU(H4SO)-15
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
(7) Place the power steering pump on the right
side wheel apron.
8) Disconnect the spark plug cords from the spark
plugs.
9) Disconnect the PCV hose from the intake mani-
fold.
10) Disconnect the engine coolant hose (A) from
the throttle body.
11) Disconnect the brake booster hose.12) Remove the air cleaner case stay RH and en-
gine harness bracket, and disconnect the engine
harness connectors from the bulkhead harness
connectors.
13) Disconnect the connectors from the engine
coolant temperature sensor.
14) Disconnect the knock sensor connector.
15) Disconnect the connector from the crankshaft
position sensor.
FU-00021
FU-00141
FU-00361
(A)(A)
FU-00143
FU-00258
FU-00145
FU-00062
FU-00056
Page 799 of 2870
FU(H4SO)-17
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
2) Connect the fuel hoses.
3) Connect the EGR pipe to intake manifold.
Tightening torque:
34 N
⋅m (3.4 kgf-m, 24.6 ft-lb)
4) Connect the connector to the camshaft position
sensor.
5) Connect the connector to the oil pressure switch.6) Connect the connector to the crankshaft position
sensor.
7) Connect the knock sensor connector.
8) Connect the connectors to the engine coolant
temperature sensor.
9) Install the air cleaner case stay RH and engine
harness bracket, and connect the engine harness
connectors to the bulkhead connectors.
(A) Fuel delivery hose
(B) Fuel return hose
(C) Evaporation hose
(B) (A)
(C)
FU-00259
FU-00148
FU-00147
FU-00146
FU-00056
FU-00062
FU-00145
FU-00258
Page 800 of 2870
FU(H4SO)-18
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
10) Connect the brake booster hose.
11) Connect the engine coolant hose (A) to the
throttle body.
12) Connect the PCV hose to the intake manifold.
13) Connect the spark plug cords to the spark
plugs.
14) Install the power steering pump and reservoir
tank to bracket.
(1) Install the reservoir tank to bracket.(2) Connect the connector to the power steering
pump switch.
(3) Tighten the bolts which install power steer-
ing pump bracket.
Tightening torque:
22 N
⋅m (2.2 kgf-m, 15.9 ft-lb)
(4) Install the power steering pipes onto the
right side intake manifold protector.
(5) Install the front side V-belt.
FU-00143
FU-00361
(A)(A)
FU-00141
FU-00020
FU-00017
FU-00139
FU-00255
Page 807 of 2870
FU(H4SO)-25
FUEL INJECTION (FUEL SYSTEM)
Engine Coolant Temperature Sensor
4. Engine Coolant Temperature
Sensor
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the air intake duct and air cleaner as-
sembly.
3) Disconnect the connector from the engine cool-
ant temperature sensor.
4) Remove the engine coolant temperature sensor.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
18 N
⋅m (1.8 kgf-m, 13.0 ft-lb)
FU-00009
FU-00145
FU-00288
Page 884 of 2870
ME(H4SO)-15
MECHANICAL
General Description
C: CAUTION
Wear working clothing, including a cap, protec-
tive goggles and protective shoes during operation.
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 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 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 not to stain seats and windows
with coolant or oil. Place a cover over fenders, as
required, 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.
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
18231AA010 CAM SPROCKET
WRENCH Used for removing and installing cam
sprocket. (LH side)
Also the CAM SPROCKET WRENCH
(499207100) can be used.
24082AA230
(Newly adopted tool)CARTRIDGE Troubleshooting for electrical systems.
ST18231AA010
ST24082AA230
Page 909 of 2870
ME(H4SO)-40
MECHANICAL
Engine Assembly
11) Tighten the nuts which hold lower side of trans-
mission to engine.
Tightening torque:
50 N
⋅m (5.1 kgf-m, 36.9 ft-lb)
12) Tighten the nuts which install front cushion rub-
ber onto crossmember.
Tightening torque:
85 N
⋅m (8.7 kgf-m, 63 ft-lb)
NOTE:
Make sure the front cushion rubber mounting bolts
(A) and locator (B) are securely installed.
13) Install the front and center exhaust pipe.
Pipe.>
14) Connect the following hoses.
(1) Fuel delivery hose, return hose and evapo-
ration hose
(2) Heater inlet and outlet hoses
(3) Brake booster vacuum hose
15) Connect the following connectors.
(1) Engine ground cables
Tightening torque:
14 N
⋅m (1.4 kgf-m, 10.1 ft-lb)
(2) Engine harness connectors
(3) Generator connector and terminal
(4) A/C compressor connectors
(5) Power steering pressure switch
16) Connect the following cables.
(1) Accelerator cable
(2) Cruise control cable (With cruise control)
17) Adjust each connected cable.18) Install the air cleaner case stay.
Tightening torque:
16 N
⋅m (1.6 kgf-m, 11.6 ft-lb)
19) Install the A/C pressure hoses.
20) Install the radiator to vehicle.
21) Install the air intake duct and air cleaner case.
22) Install the under cover.
23) Install battery in the vehicle, and then connect
the cables.
24) Fill engine coolant.
25) Check the ATF level and correct if necessary.
(AT model)
26) Charge the A/C system with refrigerant.
cedure.>
27) Remove the front hood stay, and then close the
front hood.
28) Take off the vehicle from lift arms.
C: INSPECTION
1) Make sure the pipes and hoses are installed cor-
rectly.
2) Make sure the engine coolant and ATF are at
specified levels.
ME-00219
ME-00056
(A)
(A)(B)
(B)
Page 920 of 2870
ME(H4SO)-51
MECHANICAL
Timing Belt
5) After ensuring that the marks on timing belt and
cam sprockets are aligned, remove the stopper pin
from belt tension adjuster.
6) Install the timing belt guide. (MT model)
(1) Temporarily tighten the remaining bolts.
(2) Check and adjust the clearance between
timing belt and timing belt guide by using thick-
ness gauge.
Clearance:
1.0
±0.5 mm (0.039±0.020 in)(3) Tighten the remaining bolts.
Tightening torque:
10 N
⋅m (1.0 kgf-m, 7.2 ft-lb)
7) Install the belt cover.
8) Install the crank pulley.
9) Install the V-belt.
C: INSPECTION
1. TIMING BELT
1) Check the timing belt teeth for breaks, cracks,
and wear. If any fault is found, replace the belt.
2) Check the condition of back side of belt; if any
crack is found, replace the belt.
CAUTION:
Be careful not to let oil, grease or coolant
contact the belt. Remove quickly and thorough-
ly if this happens.
Do not bend the timing belt sharply.
In radial diameter: h
60 mm (2.36 in) or more
ME-00245
ME-00230
ME-00246
ME-00247
ME-00248
h
Page 984 of 2870
COOLING
CO(H4SO)
Page
1. General Description ....................................................................................2
2. Radiator Fan System ................................................................................13
3. Engine Coolant..........................................................................................19
4. Water Pump ..............................................................................................21
5. Thermostat ................................................................................................26
6. Radiator.....................................................................................................28
7. Radiator Cap .............................................................................................34
8. Radiator Main Fan and Fan Motor ............................................................35
9. Radiator Sub Fan and Fan Motor..............................................................40
10. Reservoir Tank ..........................................................................................41
11. Coolant Filler Tank ....................................................................................42
12. Engine Cooling System Trouble in General ..............................................43
Page 985 of 2870
CO(H4SO)-2
COOLING
General Description
1. General Description
A: SPECIFICATION
ModelNon-turbo Turbo
Cooling system Electric fan+Forced engine coolant circulation system
Total engine coolant capacity2(US qt, Imp qt)2.0L with ATF warmer:
Approx. 6.9 (7.29, 6.07)
2.0L AT:
Approx. 6.5 (6.87, 5.72)
2.0L MT:
Approx. 6.6 (6.98, 5.81)
2.5L AT:
Approx. 6.8 (7.19, 5.98)
2.5L MT:
Approx. 6.9 (7.29, 6.07)AT :
Approx. 7.3 (7.71, 6.42)
MT with oil cooler:
Approx. 7.3 (7.71, 6.42)
MT without oil cooler:
Approx. 7.4 (7.82, 6.51)
Water pumpType Centrifugal impeller type
Discharge perfor-
mance IDischarge 202 (5.3 US gal, 4.4 Imp gal)/min.
Pump speed — Discharge
pressure760 rpm — 2.9 kPa (0.3 mAq)
Engine coolant temperature 85°C (185°F)
Discharge perfor-
mance IIDischarge 1002 (26.4 US gal, 22.0 Imp gal)/min.
Pump speed — Discharge
pressure3,000 rpm — 49.0 kPa (5.0 mAq)
Engine coolant temperature 85°C (185°F)
Discharge perfor-
mance IIIDischarge 2002 (52.8 US gal, 44.0 Imp gal)/min.
Pump speed — Discharge
pressure6,000 rpm — 225.4 kPa (23.0 mAq)
Engine coolant temperature 85°C (185°F)
Impeller diameter 76 mm (2.99 in)
Number of impeller vanes 8
Pump pulley diameter 60 mm (2.36 in)
Clearance between
impeller and caseStandard 0.5 — 0.7 mm (0.020 — 0.028 in)
Limit 1.0 mm (0.039 in)
“Thrust” runout of impeller end 0.5 mm (0.020 in)
ThermostatType Wax pellet type
Starts to open 80 — 84°C (176 — 183°F) 76 — 80°C (169 — 176°F)
Fully opened 95°C (203°F) 91°C (196°F)
Valve lift 9.0 mm (0.354 in) or more
Valve bore 35 mm (1.38 in)
Radiator fanMotorMain fan 70 W2.0L AT (K4
★1) : 70 W
2.0L AT (EC, EK★1) :
120 W
2.0 L MT: 70 W
2.5 L: 120 W
Sub fan 70 W2.0L AT (K4
★1) : 70 W
2.0L AT (EC, EK★1) :
120 W
2.0 L MT: 70 W
2.5 L: 120 W
Fan diameter×Blade320 mm (11.81 in)×5 (main fan)
320 mm (11.81 in)×7 (sub fan)