torque SUBARU FORESTER 2004 Service Repair Manual

FU(H4DOTC 2.5)-57
FUEL INJECTION (FUEL SYSTEM)
Fuel Filter
27.Fuel Filter
A: REMOVAL
WARNING:
 Place “NO FIRE” signs near the working area.
 Be careful not to spill fuel on the floor.
1) Release the fuel pressure.
FUEL PRESSURE, OPERATION, Fuel.>
2) Disconnect the fuel delivery hoses from fuel filter.
3) Remove the filter from holder.
B: INSTALLATION
CAUTION:
 If fuel hoses are damaged at the connecting
portion, replace it with a new one.
 If clamps are badly damaged, replace 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

FU(H4DOTC 2.5)-58
FUEL INJECTION (FUEL SYSTEM)
Fuel Cut Valve
28.Fuel Cut Valve
A: REMOVAL
WARNING:
 Place “NO FIRE” signs near the working area.
 Be careful not to spill fuel on the floor.
1) Remove the fuel tank.
Tank.>
2) Move the clip and disconnect the evaporation
hose from fuel cut valve.
3) Remove the bolts which install fuel cut valve.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
4.4 N·m (0.45 kgf-m, 3.3 ft-lb)
FU-00119
FU-00120

SP(H4DOTC 2.5)-2
SPEED CONTROL SYSTEM
General Description
1. General Description
A: SPECIFICATION
B: COMPONENT
Accelerator pedalFree play At pedal pad 0 — 4 mm (0 — 0.16 in)
Stroke At pedal pad 52 — 57 mm (2.05 — 2.24 in)
(1) Accelerator pedal bracket (4) Accelerator pedalTightening torque: N·m (kgf-m, ft-lb)
(2) Accelerator pedal ASSY (5) Spring pinT: 18 (1.8, 13.0)
(3) Accelerator pedal spring (6) Accelerator stopper
(6)
(1)
(2)
(5)(3)
(4)
SP-00002
T
T
T
T
T

SP(H4DOTC 2.5)-3
SPEED CONTROL SYSTEM
General Description
C: CAUTION
 Wear work clothing, including a cap, protective
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 and 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 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.

SP(H4DOTC 2.5)-4
SPEED CONTROL SYSTEM
Accelerator Pedal
2. Accelerator Pedal
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Disconnect the connector.
3) Remove the nuts which securing accelerator
pedal assembly.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
C: DISASSEMBLY
NOTE:
Accelerator pedal for 2.5 L model is a non-disas-
semble part.
SP-00011

EN(H4DOTC 2.5)-29
ENGINE (DIAGNOSTIC)
Subaru Select Monitor
NOTE:
For detailed operation procedure, refer to the “SUBARU SELECT MONITOR OPERATION MANUAL”.
Mass air flow sensor signal Air Flow Sensor Voltage V
AT/MT identification signal AT Vehicle ID Signal ON or OFF
ETC motor relay ETC Motor Relay ON or OFF
Clutch SW Clutch Switch ON or OFF
Stop Light SW Stop Light Switch ON or OFF
SET/COAST SW SET/COAST Switch ON or OFF
RESUME/ACCEL SW RESUME/ACCEL Switch ON or OFF
Brake SW Brake Switch ON or OFF
Main SW Main Switch ON or OFF
Ignition switch signal Ignition Switch ON or OFF
Test Mode Signal Test Mode Signal ON or OFF
Neutral position switch signal Neutral Position Switch ON or OFF
Air conditioning switch signal A/C Switch ON or OFF
Air conditioning signal A/C Compressor Signal ON or OFF
Radiator main fan relay signal Radiator Fan Relay #1 ON or OFF
Knocking signal Knocking Signal ON or OFF
Radiator sub fan relay signal Radiator Fan Relay #2 ON or OFF
Power steering switch signal P/S Switch ON or OFF
Rear oxygen sensor rich signalRear O
2 Rich Signal
ON or OFF
Starter switch signal Starter Switch ON or OFF
Idle switch signal Idle Switch Signal ON or OFF
Crankshaft position sensor signal Crankshaft Position Sig. ON or OFF
Camshaft position sensor signal Camshaft Position Sig. ON or OFF
Rear defogger switch signal Rear Defogger SW ON or OFF
Blower fan switch signal Blower Fan SW ON or OFF
Small light switch signal Light Switch ON or OFF
Handle switch signal Handle Switch —
Wiper switch signal Wiper Switch ON or OFF
A/C mid pressure switch signal A/C mid Pressure Switch ON or OFF
AT coordinate retard angle demand Retard Signal form AT ON or OFF
AT coordinate fuel cut demand Fuel Cut Signal from AT ON or OFF
AT coordinate permission signal Torque Permission Signal ON or OFF
UDC not torque down output Ban of Torque Down ON or OFF
UDC torque down demand Request Torque Down UDC ON or OFF
Tumble generated valve output signal TGV Output ON or OFF
Tumble generated valve drive signal TGV Drive OPEN or CLOSERemarks Display Unit of measure

EN(H4DOTC 2.5)-32
ENGINE (DIAGNOSTIC)
Subaru Select Monitor
7. LED OPERATION MODE FOR ENGINE
1) On the «Main Menu» display screen, select the {Each System Check} and press the [YES] key.
2) On the «System Selection Menu» display screen, select the {Engine} and press the [YES] key.
3) Press the [YES] key after the information of engine type was displayed.
4) On the «Engine Diagnosis» screen, select the {Current Data Display/Save}, and then press the [YES] key.
5) On the «Data Display» screen, select the {Data & LED Display} and press the [YES] key.
6) Using the scroll key, move the display screen up or down until the desired data is shown.
 A list of the support data is shown in the following table.
Description Display Message LED “ON” requirements
Ignition switch signal Ignition Switch ON or OFF When ignition switch is ON.
Test Mode Signal Test Mode Signal ON or OFF When test mode connector is connected.
Neutral position switch signal Neutral Position Switch ON or OFF When neutral position signal is entered.
Air conditioning switch signal A/C Switch ON or OFF When air conditioning switch is ON.
Air conditioning relay signal A/C Compressor Signal ON or OFF When air conditioning relay is in function.
Radiator main fan relay signal Radiator Fan Relay #1 ON or OFF When radiator main fan relay is in function.
Knocking signal Knocking Signal ON or OFF When knocking signal is input.
Radiator sub fan relay signal Radiator Fan Relay #2 ON or OFF When radiator sub fan relay is in function.
Rear oxygen sensor rich signalRear O
2 Rich Signal
ON or OFFWhen rear oxygen sensor mixture ratio is
rich.
Starter switch signal Starter Switch Signal ON or OFF When starter switch signal is entered.
Idle switch signal Idle Switch Signal ON or OFF When idle switch signal is entered.
Crankshaft position sensor signal Crankshaft Position Signal ON or OFFWhen crankshaft position sensor signal is
input.
Camshaft position sensor signal Camshaft Position Signal ON or OFFWhen camshaft position sensor signal is
entered.
Power steering switch signal P/S Switch ON or OFF When power steering switch is entered.
Rear defogger switch signal Rear Defogger Switch ON or OFF When rear defogger switch is ON.
Blower fan switch signal Blower Fan Switch ON or OFF When blower fan switch is ON.
Small light switch signal Light Switch ON or OFF When small light switch is ON.
Tumble generated valve actuator
signalTGV Output ON or OFF When TGV actuator signal is entered.
Tumble generated valve drive sig-
nalTGV DriveClose or
OpenWhen TGV moves and valve opens.
Handle switch signal Handle SWLow Input
or High
InputIlluminates in Low Input.
AT/MT identification terminal AT Vehicle ID Signal ON or OFF ON (AT model).
Wiper switch signal Wiper Switch ON or OFF When wiper switch is turned to ON.
A/C mid pressure switch signal A/C Mid Pressure Switch ON or OFFWhen A/C mid pressure switch is turned to
ON.
AT coordinate retard angle
demandRetard Signal from AT ON or OFF When AT retard angle signal is exists.
AT coordinate fuel cut demand Fuel Cut Signal from AT ON or OFFWhen AT coordinate fuel cut demand signal
is exists.
AT coordinate permission signal Torque Permission Signal ON or OFFWhen AT coordinate permission signal is
exists.
VDC not torque down out put Ban of Torque Down ON or OFFWhen VDC not torque down output signal is
exists.
VDC torque down demand Request Torque Down VDC ON or OFFWhen VDC torque down demand signal is
exists.
ETC motor relay signal ETC Motor Relay ON or OFFWhen electronic throttle control relay is in
function.
Clutch switch signal Clutch Switch ON or OFF When clutch switch is ON.
Stop switch signal Stop Light Switch ON or OFF When stop light switch is ON.

EN(H4DOTC 2.5)-258
ENGINE (DIAGNOSTIC)
General Diagnostic Table
19.General Diagnostic Table
A: INSPECTION
1. ENGINE
NOTE:
Malfunction of parts other than those listed is also possible. General.>
Symptom Problem parts
1. Engine stalls during idling.1) Electronic throttle control
2) Manifold absolute pressure sensor
3) Mass air flow and intake air temperature sensor
4) Ignition parts (*1)
5) Engine coolant temperature sensor (*2)
6) Crankshaft position sensor (*3)
7) Camshaft position sensor (*3)
8) Fuel injection parts (*4)
2. Rough idling1) Electronic throttle control
2) Manifold absolute pressure sensor
3) Mass air flow and intake air temperature sensor
4) Engine coolant temperature sensor (*2)
5) Ignition parts (*1)
6) Air intake system (*5)
7) Fuel injection parts (*4)
8) Crankshaft position sensor (*3)
9) Camshaft position sensor (*3)
10) Oxygen sensor
11) Fuel pump and fuel pump relay
3. Engine does not return to idle.1) Electronic throttle control
2) Engine coolant temperature sensor
3) Manifold absolute pressure sensor
4) Mass air flow sensor
4. Poor acceleration1) Manifold absolute pressure sensor
2) Mass air flow and intake air temperature sensor
3) Electronic throttle control
4) Fuel injection parts (*4)
5) Fuel pump and fuel pump relay
6) Engine coolant temperature sensor (*2)
7) Crankshaft position sensor (*3)
8) Camshaft position sensor (*3)
9) A/C switch and A/C cut relay
10) Engine torque control signal circuit
11) Ignition parts (*1)
5. Engine stalls or engine sags or hesitates at
acceleration.1) Manifold absolute pressure sensor
2) Mass air flow and intake air temperature sensor
3) Engine coolant temperature sensor (*2)
4) Crankshaft position sensor (*3)
5) Camshaft position sensor (*3)
6) Purge control solenoid valve
7) Fuel injection parts (*4)
8) Fuel pump and fuel pump relay
6. Surging1) Manifold absolute pressure sensor
2) Mass air flow and intake air temperature sensor
3) Engine coolant temperature sensor (*2)
4) Crankshaft position sensor (*3)
5) Camshaft position sensor (*3)
6) Fuel injection parts (*4)
7) Throttle position sensor
8) Fuel pump and fuel pump relay

CS-2
CONTROL SYSTEM
General Description
1. General Description
A: SPECIFICATION
Item Specification
Swing torque of rod against lever N (kgf, Ib) 3.7 (0.38, 0.83) or less

CS-3
CONTROL SYSTEM
General Description
B: COMPONENT
1. AT SELECT LEVER
 NON-TURBO MODEL
CS-00367
T3
T2
T3
T1
(10) (22)
(9) (8)
(7)(6) (5) (4) (2)
(3)
(1)(22)(12)
(13)
(15)
(16)
(21) (20) (19) (17)
(14)
(11)
(18)
(23)
(24)
(1) Bulb (11) Spacer (21) Adjusting nut A
(2) Detent arm (12) Grip (22) Clip
(3) Detent spring (13) Indicator cover (23) Tube
(4) Select lever ASSY (14) Blind (24) Cover
(5) Spring pin (15) Cushion
(6) Arm ASSY (16) Guide plateTightening torque: N·m (kgf-m, ft-lb)
(7) Bushing ASSY (17) Snap pinT1: 7.5 (0.76, 5.5)
(8) Base plate (18) WasherT2: 13 (1.3, 9.4)
(9) Grommet (19) Select cableT3: 18 (1.8, 13.0)
(10) Packing (20) Adjusting nut B