ignition SUBARU FORESTER 2004 Service Repair Manual

FUJI HEAVY INDUSTRIES LTD. G8080GE4
2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
ENGINE SECTION 3
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(H4DOTC 2.5)
EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICE)EC(H4DOTC 2.5)
INTAKE (INDUCTION) IN(H4DOTC 2.5)
MECHANICAL ME(H4DOTC 2.5)
EXHAUST EX(H4DOTC 2.5)
COOLING CO(H4DOTC 2.5)
LUBRICATION LU(H4DOTC 2.5)
SPEED CONTROL SYSTEM SP(H4DOTC 2.5)
IGNITION IG(H4DOTC 2.5)
STARTING/CHARGING SYSTEM SC(H4DOTC 2.5)
ENGINE (DIAGNOSTIC) EN(H4DOTC 2.5)

FUJI HEAVY INDUSTRIES LTD. G8080GE4
2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
ENGINE SECTION 3
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(H4DOTC 2.5)
EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICE)EC(H4DOTC 2.5)
INTAKE (INDUCTION) IN(H4DOTC 2.5)
MECHANICAL ME(H4DOTC 2.5)
EXHAUST EX(H4DOTC 2.5)
COOLING CO(H4DOTC 2.5)
LUBRICATION LU(H4DOTC 2.5)
SPEED CONTROL SYSTEM SP(H4DOTC 2.5)
IGNITION IG(H4DOTC 2.5)
STARTING/CHARGING SYSTEM SC(H4DOTC 2.5)
ENGINE (DIAGNOSTIC) EN(H4DOTC 2.5)

FUJI HEAVY INDUSTRIES LTD. G8080GE4
2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
ENGINE SECTION 3
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(H4DOTC 2.5)
EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICE)EC(H4DOTC 2.5)
INTAKE (INDUCTION) IN(H4DOTC 2.5)
MECHANICAL ME(H4DOTC 2.5)
EXHAUST EX(H4DOTC 2.5)
COOLING CO(H4DOTC 2.5)
LUBRICATION LU(H4DOTC 2.5)
SPEED CONTROL SYSTEM SP(H4DOTC 2.5)
IGNITION IG(H4DOTC 2.5)
STARTING/CHARGING SYSTEM SC(H4DOTC 2.5)
ENGINE (DIAGNOSTIC) EN(H4DOTC 2.5)

FUJI HEAVY INDUSTRIES LTD. G8080GE4
2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
ENGINE SECTION 3
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(H4DOTC 2.5)
EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICE)EC(H4DOTC 2.5)
INTAKE (INDUCTION) IN(H4DOTC 2.5)
MECHANICAL ME(H4DOTC 2.5)
EXHAUST EX(H4DOTC 2.5)
COOLING CO(H4DOTC 2.5)
LUBRICATION LU(H4DOTC 2.5)
SPEED CONTROL SYSTEM SP(H4DOTC 2.5)
IGNITION IG(H4DOTC 2.5)
STARTING/CHARGING SYSTEM SC(H4DOTC 2.5)
ENGINE (DIAGNOSTIC) EN(H4DOTC 2.5)

IGNITION
IG(H4DOTC 2.5)
Page
1. General Description ....................................................................................2

IG(H4DOTC 2.5)-2
IGNITION
General Description
1. General Description
A: SPECIFICATION
Specifications for 2.5 L model are included in
IG(H4DOTC) section. eral Description.>

FUJI HEAVY INDUSTRIES LTD. G8080GE4
2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
ENGINE SECTION 3
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(H4DOTC 2.5)
EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICE)EC(H4DOTC 2.5)
INTAKE (INDUCTION) IN(H4DOTC 2.5)
MECHANICAL ME(H4DOTC 2.5)
EXHAUST EX(H4DOTC 2.5)
COOLING CO(H4DOTC 2.5)
LUBRICATION LU(H4DOTC 2.5)
SPEED CONTROL SYSTEM SP(H4DOTC 2.5)
IGNITION IG(H4DOTC 2.5)
STARTING/CHARGING SYSTEM SC(H4DOTC 2.5)
ENGINE (DIAGNOSTIC) EN(H4DOTC 2.5)

FUJI HEAVY INDUSTRIES LTD. G8080GE4
2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
ENGINE SECTION 3
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(H4DOTC 2.5)
EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICE)EC(H4DOTC 2.5)
INTAKE (INDUCTION) IN(H4DOTC 2.5)
MECHANICAL ME(H4DOTC 2.5)
EXHAUST EX(H4DOTC 2.5)
COOLING CO(H4DOTC 2.5)
LUBRICATION LU(H4DOTC 2.5)
SPEED CONTROL SYSTEM SP(H4DOTC 2.5)
IGNITION IG(H4DOTC 2.5)
STARTING/CHARGING SYSTEM SC(H4DOTC 2.5)
ENGINE (DIAGNOSTIC) EN(H4DOTC 2.5)

EN(H4DOTC 2.5)-2
ENGINE (DIAGNOSTIC)
Basic Diagnostics Procedure
1. Basic Diagnostics Procedure
A: PROCEDURE
1. ENGINE
Step Check Yes No
1 CHECK ENGINE START FAILURE.
1) Ask the customer when and how the trou-
ble occurred using the interview check list.
Check List for Interview.>
2) Start the engine.Does the engine start? Go to step 2.Inspection using
“Diagnostics for
Engine Start Fail-
ure”. EN(H4DOTC 2.5)-
54, Diagnostics for
Engine Starting
Fai lu r e.>
2 CHECK ILLUMINATION OF MALFUNCTION
INDICATOR LIGHT.Does malfunction indicator
light illuminate?Go to step 3.Inspection using
“General Diagnos-
tic Table”. EN(H4DOTC 2.5)-
258, General Diag-
nostic Table.>
3 CHECK INDICATION OF DTC ON DISPLAY.
1) Turn the ignition switch to OFF.
2) Connect the Subaru Select Monitor or the
OBD-II general scan tool to data link connec-
tor.
3) Turn the ignition switch to ON and the Sub-
aru Select Monitor or OBD-II general scan tool
switch to ON.
4) Read the DTC on the Subaru Select Moni-
tor or OBD-II general scan tool.Does the Subaru Select Moni-
tor or OBD-II general scan tool
indicate DTC?Record the DTC.
Repair the trouble
cause. EN(H4DOTC 2.5)-
65, List of Diag-
nostic Trouble
Code (DTC).> Go
to step 4.Repair the related
parts.
N
OTE:
If DTC is not shown
on display although
the malfunction in-
dicator light illumi-
nates, perform the
diagnostics for mal-
function indicator
light circuit or com-
bination meter.
EN(H4DOTC 2.5)-
45, Malfunction In-
dicator Light.>
4 PERFORM THE DIAGNOSIS.
1) Perform clear memory mode. EN(H4DOTC 2.5)-42, Clear Memory Mode.>
2) Perform the “INSPECTION MODE”. to EN(H4DOTC 2.5)-35, Inspection Mode.>Does the Subaru Select Moni-
tor or OBD-II general scan tool
indicate DTC?Check on “Diag-
nostic Chart with
Diagnostic Trou-
ble Code (DTC)”.
EN(H4DOTC 2.5)-
70, Diagnostic
Procedure with
Diagnostic Trou-
ble Code (DTC).>Finish the diagno-
sis.

EN(H4DOTC 2.5)-13
ENGINE (DIAGNOSTIC)
Electrical Component Location
 SOLENOID VALVE, ACTUATOR, EMISSION CONTROL SYSTEM PARTS AND IGNITION SYSTEM
PARTS
(1) Wastegate control solenoid valve (3) Ignition coil (5) Oil flow control solenoid valve
(4) Tumble generator valve actuator (2) Purge control solenoid valve (6) Injector
EN-00310 (1)EN-00311 (2)
EN-02411
(4)(4) (1)
(5)(5)(3)(6)(2)(3)(5)(6)