catalytic SUBARU FORESTER 2004 Service Repair Manual

RM-2
RECOMMENDED MATERIAL
Recommended Materials
1. Recommended Materials
A: RECOMMENDED MATERIALS
1. GENERAL
To insure the best performance, always use the
specified oil, gasoline, adhesive, sealant, etc. or a
substitute of equivalent quality.
2. FUEL
Always use a gasoline of the same or higher octane
value than specified in the owner’s manual. Ignor-
ing the specifications below will result in damage or
poor operation of the engine and fuel injection sys-
tem. Use the specified gasoline to correct perfor-
mance.
 Unleaded gasoline
Use unleaded gasoline and not leaded gasoline on
vehicles with catalytic converter installed to reduce
air pollution. Using leaded gasoline will damage the
catalytic converter.
*For Australia model.
 Leaded gasoline
On vehicles without catalytic converter, use leaded
gasoline with an octane value of 90 RON or higher.
Model Petrol RON
Non-turbo UnleadedMore than 95 RON
More than 90 RON
*
Turbo Unleaded More than 98 RON

EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICE)
EC(H4SO)
Page
1. General Description ....................................................................................2
2. Front Catalytic Converter ............................................................................3
3. Rear Catalytic Converter .............................................................................6
4. EGR Valve ..................................................................................................7
5. Canister .......................................................................................................8
6. Purge Control Solenoid Valve .....................................................................9
7. Two-way Valve ..........................................................................................10

EC(H4SO)-3
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICE)
Front Catalytic Converter
2. Front Catalytic Converter
A: REMOVAL
1) Set the vehicle on a lift.
2) Disconnect the ground cable from battery.
3) Disconnect the front oxygen (A/F) sensor con-
nector.
4) Disconnect the connector from rear oxygen sen-
sor connector.
5) Lift-up the vehicle.
6) Remove the under cover.7) Separate the center exhaust pipe from rear ex-
haust pipe.
CAUTION:
Be careful, the exhaust pipe is hot.
8) Remove the nuts which hold front exhaust pipe
onto cylinder heads.
9) Remove the front and center exhaust pipe from
hanger bracket.
CAUTION:
Be careful not to pull down the front exhaust
pipe and center exhaust pipe.
FU-00009
EX-00029
EX-00030
EX-00037
EC-00009
EX-00038

EC(H4SO)-4
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICE)
Front Catalytic Converter
10) Separate the front catalytic converter from front
exhaust pipe.
B: INSTALLATION
NOTE:
Replace gaskets with new ones.
1) Install the front catalytic converter to front ex-
haust pipe.
Tightening torque:
30 N
⋅m (3.1 kgf-m, 22.4 ft-lb)
2) Install the front and center exhaust pipe assem-
bly to the vehicle. And temporarily tighten the bolt
which installs center exhaust pipe to hanger brack-
et.3) Tighten the nuts which hold front exhaust pipe
onto cylinder heads.
Tightening torque:
30 N
⋅m (3.1 kgf-m, 22.4 ft-lb)
4) Tighten the bolts which install front and center
exhaust pipe to rear exhaust pipe.
Tightening torque:
18 N
⋅m (1.8 kgf-m, 13.0 ft-lb)
5) Tighten the bolt which holds front and center ex-
haust pipe assembly to hanger bracket.
Tightening torque:
35 N
⋅m (3.6 kgf-m, 26.0 ft-lb)
6) Install the under cover.
EC-00011
EC-00011
EX-00038
EC-00009
EX-00037
EX-00038

EC(H4SO)-5
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICE)
Front Catalytic Converter
7) Lower the vehicle.
8) Connect the front oxygen (A/F) sensor connec-
tor.
9) Connect the connector to rear oxygen sensor
connector.
10) Connect the battery ground cable to battery.
C: INSPECTION
1) Make sure there are no exhaust leaks from con-
nections and welds.
2) Make sure there are no holes or rusting.
EX-00029
EX-00030
FU-00009

EC(H4SO)-6
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICE)
Rear Catalytic Converter
3. Rear Catalytic Converter
A: REMOVAL
1. WITH OBD
The front and rear catalytic converter and center
exhaust pipe are integrated into one unit. There-
fore, the removal and installation procedures are
the same as the those for the front catalytic con-
verter. Catalytic Converter.>
2. WITHOUT OBD
Rear catalytic converter and rear exhaust pipe are
integrated into one unit. Refer to Rear Exhaust
Pipe for removal procedures. 11, REMOVAL, Rear Exhaust Pipe.>
B: INSTALLATION
1. WITH OBD
Install in the reverse order of removal.
2. WITHOUT OBD
Install in the reverse order of removal.
C: INSPECTION
1. WITH OBD
1) Make sure there are no exhaust leaks from con-
nections and welds.
2) Make sure there are no holes or rusting.
2. WITHOUT OBD
Inspect in the same procedures as the vehicle with
OBD.
(A) Front catalytic converter
(B) Rear catalytic converter
(A) Front exhaust pipe
(B) Rear catalytic converter
(C) Rear exhaust pipe
EC-00080
EC-00081
(A)
(B)(C)
(A) Front catalytic converter
(B) Rear catalytic converter
(A) Front exhaust pipe
(B) Rear catalytic converter
(C) Rear exhaust pipe
EC-00080
EC-00081
(A)
(B)(C)

EX(H4SO)-3
EXHAUST
General Description
(1) Front exhaust pipe upper cover
CTR(14) Muffler (28) Rear catalytic converter upper
cover
(15) Cushion rubber
(2) Front exhaust pipe lower cover
CTR(16) Rear exhaust pipe (29) Rear catalytic converter lower
cover
(17) Clamp
(3) Clamp (18) Center exhaust pipe upper cover (30) Rear catalytic converter
(4) Front exhaust pipe upper cover LH (19) Center exhaust pipe lower cover (31) Gasket
(5) Front exhaust pipe lower cover LH (20) Protector
(6) Front exhaust pipe (21) GasketTightening torque: N
⋅m (kgf-m, ft-lb)
(7) Front exhaust pipe lower cover RH (22) Front oxygen (A/F) sensorT1: 8 (0.8, 5.8)
(8) Front exhaust pipe upper cover
RH(23) Front catalytic converterT2: 13 (1.3, 9.4)
(24) Center exhaust pipeT3: 18 (1.8, 13.0)
(9) Gasket (25) Front catalytic converter lower
coverT4: 21 (2.1, 15.2)
(10) SpringT5: 30 (3.1, 22.4)
(11) Chamber (26) Front catalytic converter upper
coverT6: 35 (3.6, 26.0)
(12) GasketT7: 48 (4.9, 35.4)
(13) Self-locking nut (27) Rear oxygen sensor

EX(H4SO)-5
EXHAUST
General Description
(1) Front exhaust pipe upper cover
CTR(15) Rear exhaust upper cover (31) Front catalytic converter upper
cover
(16) Rear exhaust lower cover
(2) Front exhaust pipe lower cover
CTR(17) Rear catalytic lower converter
cover(32) Front oxygen (A/F) sensor
(33) Rear oxygen sensor
(3) Clamp (18) Clamp (34) Clamp
(4) Front exhaust pipe upper cover LH (19) Cushion rubber
(5) Front exhaust pipe lower cover LH (20) Rear exhaust pipeTightening torque: N
⋅m (kgf-m, ft-lb)
(6) Front exhaust pipe (21) GasketT1: 8 (0.8, 5.8)
(7) Front exhaust pipe lower cover RH (22) Self-locking nutT2: 13 (1.3, 9.4)
(8) Front exhaust pipe upper cover
RH(23) MufflerT3: 18 (1.8, 13.0)
(24) ProtectorT4: 21 (2.1, 15.2)
(9) Gasket (25) GasketT5: 30 (3.1, 22.4)
(10) Gasket (26) Front catalytic converterT6: 35 (3.6, 26.0)
(11) Spring (27) Center exhaust lower coverT7: 48 (4.9, 35.4)
(12) Chamber (28) Center exhaust upper cover
(13) Rear catalytic converter (29) Center exhaust pipe
(14) Rear catalytic converter upper
cover(30) Front catalytic converter lower
cover

EN(H4SO)-13
ENGINE (DIAGNOSTIC)
Electrical Component Location
EN-00162
(2)
(3) (1)
(4)
(1) Front oxygen (A/F) sensor (3) Front catalytic converter (4) Rear catalytic converter
(2) Rear oxygen sensor
EN-00014
(1)
EN-00163 (2)
EN-00016
(3)
EN-00164 (4)

EN(H4SO)-128
ENGINE (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
Step Check Yes No
1 CHECK ANY OTHER DTC ON DISPLAY.Is any other DTC displayed? Inspect the DTC
using “List of Diag-
nostic Trouble
Code (DTC)”.
EN(H4SO)-72, List
of Diagnostic Trou-
ble Code (DTC).>
N
OTE:
In this case, it is not
necessary to in-
spect DTC P0133.Go to step 2.
2 CHECK EXHAUST SYSTEM.
N
OTE:
Check the following items:
 Loose installation of front portion of exhaust
pipe onto cylinder heads
 Loose connection between front exhaust
pipe and front catalytic converter
 Damage of exhaust pipe resulting in a holeIs there a fault in exhaust sys-
tem?Repair exhaust
system.Replace the front
oxygen (A/F) sen-
sor. FU(H4SO)-40,
Front Oxygen (A/
F) Sensor.>