cooling SUBARU FORESTER 2004 Service Manual PDF
[x] Cancel search | Manufacturer: SUBARU, Model Year: 2004, Model line: FORESTER, Model: SUBARU FORESTER 2004Pages: 2870, PDF Size: 38.67 MB
Page 1025 of 2870
CO(H4SO)-42
COOLING
Coolant Filler Tank
11.Coolant Filler Tank
A: REMOVAL
WARNING:
The radiator is pressurized. Wait until the en-
gine cools down before working on the radia-
tor.
1) Drain the coolant about 3.02 (3.2 US qt, 2.6 Imp
qt).
ant.>
2) Remove the air cleaner upper cover and air in-
take boot.
3) Remove the air cleaner element.
4) Disconnect the engine coolant hoses from cool-
ant filler tank.
5) Remove the bolts and nut which install coolant
filler tank.
6) Disconnect the engine coolant hose which con-
nects under side of coolant filler tank.
7) Remove the coolant filler tank.
B: INSTALLATION
1) Install in the reverse order of removal.
Tightening torque:
T1: 19 N
⋅m (1.9 kgf-m, 13.7 ft-lb)
T2: 21 N
⋅m (2.1 kgf-m, 15.2 ft-lb)
2) Fill engine coolant.
Engine Coolant.>
CO-00051
CO-00052
T2
T1
CO-00053
Page 1026 of 2870
CO(H4SO)-43
COOLING
Engine Cooling System Trouble in General
12.Engine Cooling System Trouble in General
A: INSPECTION
Trouble Possible cause Corrective action
Over-heatinga. Insufficient engine coolantReplenish the engine coolant, inspect for leakage, and
repair.
b. Loose timing belt Repair or replace the timing belt tensioner.
c. Oil on drive belt Replace.
d. Malfunction of thermostat Replace.
e. Malfunction of water pump Replace.
f. Clogged engine coolant passage Clean.
g. Improper ignition timingInspect and repair the ignition control system.
h. Clogged or leaking radiator Clean or repair, or replace.
i. Improper engine oil in engine coolant Replace the engine coolant.
j. Air/fuel mixture ratio too leanInspect and repair the fuel injection system.
k. Excessive back pressure in exhaust system Clean or replace.
l. Insufficient clearance between piston and cylinder Adjust or replace.
m. Slipping clutch Repair or replace.
n. Dragging brake Adjust.
o. Defective thermostat Replace.
p. Malfunction of radiator fanInspect the radiator fan relay, engine coolant tempera-
ture sensor or radiator motor and replace there.
Over-coolinga. Atmospheric temperature extremely low Partly cover the radiator front area.
b. Defective thermostat Replace.
Engine coolant
leaks.a. Loosened or damaged connecting units on hoses Repair or replace.
b. Leakage from water pump Replace.
c. Leakage from water pipe Repair or replace.
d. Leakage around cylinder head gasket Retighten the cylinder head bolts or replace gasket.
e. Damaged or cracked cylinder head and crankcase Repair or replace.
f. Damaged or cracked thermostat case Repair or replace.
g. Leakage from radiator Repair or replace.
Noisea. Defective drive belt Replace.
b. Defective radiator fan Replace.
c. Defective water pump bearing Replace the water pump.
d. Defective water pump mechanical seal Replace the water pump.
Page 1027 of 2870
CO(H4SO)-44
COOLING
Engine Cooling System Trouble in General
Page 1028 of 2870
FUJI HEAVY INDUSTRIES LTD. G8080GE2
2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
ENGINE SECTION 1
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(H4SO)
EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICE)EC(H4SO)
INTAKE (INDUCTION) IN(H4SO)
MECHANICAL ME(H4SO)
EXHAUST EX(H4SO)
COOLING CO(H4SO)
LUBRICATION LU(H4SO)
SPEED CONTROL SYSTEM SP(H4SO)
IGNITION IG(H4SO)
STARTING/CHARGING SYSTEM SC(H4SO)
ENGINE (DIAGNOSTIC) EN(H4SO)
Page 1053 of 2870
FUJI HEAVY INDUSTRIES LTD. G8080GE2
2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
ENGINE SECTION 1
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(H4SO)
EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICE)EC(H4SO)
INTAKE (INDUCTION) IN(H4SO)
MECHANICAL ME(H4SO)
EXHAUST EX(H4SO)
COOLING CO(H4SO)
LUBRICATION LU(H4SO)
SPEED CONTROL SYSTEM SP(H4SO)
IGNITION IG(H4SO)
STARTING/CHARGING SYSTEM SC(H4SO)
ENGINE (DIAGNOSTIC) EN(H4SO)
Page 1064 of 2870
FUJI HEAVY INDUSTRIES LTD. G8080GE2
2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
ENGINE SECTION 1
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(H4SO)
EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICE)EC(H4SO)
INTAKE (INDUCTION) IN(H4SO)
MECHANICAL ME(H4SO)
EXHAUST EX(H4SO)
COOLING CO(H4SO)
LUBRICATION LU(H4SO)
SPEED CONTROL SYSTEM SP(H4SO)
IGNITION IG(H4SO)
STARTING/CHARGING SYSTEM SC(H4SO)
ENGINE (DIAGNOSTIC) EN(H4SO)
Page 1075 of 2870
FUJI HEAVY INDUSTRIES LTD. G8080GE2
2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
ENGINE SECTION 1
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(H4SO)
EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICE)EC(H4SO)
INTAKE (INDUCTION) IN(H4SO)
MECHANICAL ME(H4SO)
EXHAUST EX(H4SO)
COOLING CO(H4SO)
LUBRICATION LU(H4SO)
SPEED CONTROL SYSTEM SP(H4SO)
IGNITION IG(H4SO)
STARTING/CHARGING SYSTEM SC(H4SO)
ENGINE (DIAGNOSTIC) EN(H4SO)
Page 1098 of 2870
FUJI HEAVY INDUSTRIES LTD. G8080GE2
2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
ENGINE SECTION 1
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(H4SO)
EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICE)EC(H4SO)
INTAKE (INDUCTION) IN(H4SO)
MECHANICAL ME(H4SO)
EXHAUST EX(H4SO)
COOLING CO(H4SO)
LUBRICATION LU(H4SO)
SPEED CONTROL SYSTEM SP(H4SO)
IGNITION IG(H4SO)
STARTING/CHARGING SYSTEM SC(H4SO)
ENGINE (DIAGNOSTIC) EN(H4SO)
Page 1140 of 2870
EN(H4SO)-42
ENGINE (DIAGNOSTIC)
Drive Cycle
13.Drive Cycle
A: OPERATION
There are three driving patterns on diagnosis. Fol-
lowing trouble can be diagnosed with driving spec-
ified patterns. After repair the following trouble, be
sure to check that the trouble is cleared correctly by
the driving specified patterns.
1. PREPARATION FOR DRIVE CYCLE
1) Check battery voltage is more than 12 V and fuel
remains half [20 — 402 (5.3 — 10.6 US gal, 4.4 —
8.8 Imp gal)].2) After clearing the memory, check for any remain-
ing unresolved trouble data.
3) Separate the test mode connector.
NOTE:
Be sure to perform the diagnosis after idling from
starting the cooled engine except when the engine
coolant temperature is specified.
Perform the diagnosis twice when the DTC is
marked with *. After the completion of first diagno-
sis, stop the engine and perform the second diag-
nosis on same condition.
2. DRIVE THE VEHICLE 20 MINUTES AT THE SPEED OF 80 KM/H (50 MPH), AND THEN IDLE
THE ENGINE 1 MINUTE.
3. 10 MINUTES IDLING
NOTE:
Drive the vehicle more than 4 km/h (6 MPH) before diagnosis.
DTC Item On condition
*P0030 HO2S Heater Control Circuit (Bank 1 Sensor 1) —
*P0111Intake Air Temperature Sensor Circuit Range/Per-
formance ProblemEngine coolant temperature at start is less than 30°C (86°F)
*P0125Insufficient coolant temperature for closed loop
fuel controlEngine coolant temperature at start is less than 20°C (68°F)
*P0130O
2 Sensor Circuit (Bank 1 Sensor 1)
—
*P0133O
2 Sensor Circuit Slow Response (Bank 1 Sensor
1)—
*P0420Catalyst System Efficiency Below Threshold
(Bank 1)—
P0459Evaporative Emission Control System Purge Con-
trol Valve Circuit High—
*P0461 Fuel Level Sensor Circuit Range/Performance —
*P0464 Fuel Level Sensor Circuit Intermittent —
*P1137O
2 Sensor Circuit (Bank 1 Sensor 1)
—
DTC Item On condition
*P0483 Cooling Fan Rationality Check —
*P0506 Idle Control System RPM Lower Than Expected —
*P0507 Idle Control System RPM Higher Than Expected —
Page 1172 of 2870
EN(H4SO)-74
ENGINE (DIAGNOSTIC)
List of Diagnostic Trouble Code (DTC)
P0420 Catalyst System Efficiency Below
Threshold (Bank 1)
Trouble Code (DTC).>
P0458 Evaporative Emission Control Sys-
tem Purge Control Valve Circuit Low
cedure with Diagnostic Trouble Code (DTC).>
P0459 Evaporative Emission Control Sys-
tem Purge Control Valve Circuit High
Procedure with Diagnostic Trouble Code (DTC).>
P0461 Fuel Level Sensor Circuit Range/Per-
formance
Code (DTC).>
P0462 Fuel Level Sensor Circuit Low Input
P0463 Fuel Level Sensor Circuit High Input
P0464 Fuel Level Sensor Circuit Intermittent
(DTC).>
P0483 Cooling Fan Rationality Check
P0502 Vehicle Speed Sensor Circuit Low
Input
P0503 Vehicle Speed Sensor Intermittent/
Erratic/High
P0506 Idle Control System RPM Lower
Than Expected
Code (DTC).>
P0507 Idle Control System RPM Higher
Than Expected
Code (DTC).>
P0512 Starter Request Circuit
P0513 Incorrect Immobilizer Key
P0519 Idle Control System Malfunction
(Fail-Safe)
(DTC).>
P0565 Cruise Control On Signal
P0604 Internal Control Module Random
Access Memory (RAM) Error
nostic Trouble Code (DTC).>
P0691 Cooling Fan 1 Control Circuit Low
P0692 Cooling Fan 1 Control Circuit High
P0703 Torque Converter/Brake Switch “B”
Circuit
(DTC).>
P0705 Transmission Range Sensor Circuit
(PRNDL Input)
P0710 Transmission Fluid Temperature
Sensor Circuit
P0716 Torque converter turbine speed sen-
sor