for4 sec1 2 .pdf



Nom original: for4_sec1_2.pdfTitre: 87B...BE_.bookAuteur: Kurosawa

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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, reassembling, inspection and adjustment of
components and diagnostics for guidance 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.

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)

All information, illustration and specifications contained in this manual are
based on the latest product information
available at the time of publication
approval.
FUJI HEAVY INDUSTRIES LTD.

G8080GE2

EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICE)

EC(H4SO)
1.
2.
3.
4.
5.
6.
7.

Page
General Description ....................................................................................2
Front Catalytic Converter ............................................................................3
Rear Catalytic Converter.............................................................................6
EGR Valve ..................................................................................................7
Canister.......................................................................................................8
Purge Control Solenoid Valve .....................................................................9
Two-way Valve..........................................................................................10

General Description
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICE)

1. General Description
A: CAUTION
• Wear working clothing, including a cap, protective goggles, and protective shoes during operation.
• Remove contamination including dirt and corrosion before removal, installation or disassembly.
• Keep the disassembled parts in order and protect them from dust or dirt.
• Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary removal, installation, disassembly, and replacement.
• Be careful not to burn yourself, because each
part on 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.

EC(H4SO)-2

Front Catalytic Converter
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICE)

2. Front Catalytic Converter

7) Separate the center exhaust pipe from rear exhaust pipe.

A: REMOVAL

CAUTION:
Be careful, the exhaust pipe is hot.

1) Set the vehicle on a lift.
2) Disconnect the ground cable from battery.

EX-00037

FU-00009

3) Disconnect the front oxygen (A/F) sensor connector.

8) Remove the nuts which hold front exhaust pipe
onto cylinder heads.

EC-00009

EX-00029

4) Disconnect the connector from rear oxygen sensor connector.

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.

EX-00030

5) Lift-up the vehicle.
6) Remove the under cover.

EX-00038

EC(H4SO)-3

Front Catalytic Converter
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICE)

10) Separate the front catalytic converter from front
exhaust pipe.

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)

EC-00011

B: INSTALLATION
NOTE:
Replace gaskets with new ones.
1) Install the front catalytic converter to front exhaust pipe.
Tightening torque:
30 N⋅m (3.1 kgf-m, 22.4 ft-lb)

EC-00009

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)

EX-00037
EC-00011

2) Install the front and center exhaust pipe assembly to the vehicle. And temporarily tighten the bolt
which installs center exhaust pipe to hanger bracket.

5) Tighten the bolt which holds front and center exhaust pipe assembly to hanger bracket.
Tightening torque:
35 N⋅m (3.6 kgf-m, 26.0 ft-lb)

EX-00038

EX-00038

6) Install the under cover.

EC(H4SO)-4

Front Catalytic Converter
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICE)

7) Lower the vehicle.
8) Connect the front oxygen (A/F) sensor connector.

EX-00029

9) Connect the connector to rear oxygen sensor
connector.

EX-00030

10) Connect the battery ground cable to battery.

FU-00009

C: INSPECTION
1) Make sure there are no exhaust leaks from connections and welds.
2) Make sure there are no holes or rusting.

EC(H4SO)-5

Rear Catalytic Converter
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICE)

3. Rear Catalytic Converter

B: INSTALLATION

A: REMOVAL

1. WITH OBD

1. WITH OBD

Install in the reverse order of removal.

The front and rear catalytic converter and center
exhaust pipe are integrated into one unit. Therefore, the removal and installation procedures are
the same as the those for the front catalytic converter. <Ref. to EC(H4SO)-3, REMOVAL, Front
Catalytic Converter.>

EC-00080

(A) Front catalytic converter
(B) Rear catalytic converter

2. WITHOUT OBD
EC-00080

Install in the reverse order of removal.

(A) Front catalytic converter
(B) Rear 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. <Ref. to EX(H4SO)11, REMOVAL, Rear Exhaust Pipe.>

(A)
(C)
(B)
EC-00081

(A) Front exhaust pipe
(B) Rear catalytic converter
(C) Rear exhaust pipe

C: INSPECTION

(A)
(C)

1. WITH OBD

(B)
EC-00081

(A) Front exhaust pipe
(B) Rear catalytic converter
(C) Rear exhaust pipe

1) Make sure there are no exhaust leaks from connections and welds.
2) Make sure there are no holes or rusting.

2. WITHOUT OBD
Inspect in the same procedures as the vehicle with
OBD.

EC(H4SO)-6

EGR Valve
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICE)

4. EGR Valve
A: PROCEDURE
For EGR valve removal and installation procedures, refer to FU section. <Ref. to FU(H4SO)-34,
EGR Valve.>

EC(H4SO)-7

Canister
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICE)

5. Canister
A: REMOVAL
1) Lift-up the vehicle.
2) Loosen the two clamps which hold two canister
hoses, and disconnect the three evaporation hoses
from canister.

EC-00012

3) Remove the canister from body.

EC-00013

B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
23 N⋅m (2.3 kgf-m, 17 ft-lb)

EC-00013

C: INSPECTION
Make sure the canister and canister hoses are not
cracked or loose.

EC(H4SO)-8

Purge Control Solenoid Valve
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICE)

6. Purge Control Solenoid Valve

B: INSTALLATION

A: REMOVAL

Install in the reverse order of removal.
Tightening torque:
19 N⋅m (1.9 kgf-m, 13.7 ft-lb)

1) Disconnect the ground cable from battery.

FU-00009

2) Disconnect the connector and hoses from purge
control solenoid valve, and then remove the purge
control solenoid valve.

EC-00014

NOTE:
Connect the evaporation hoses as shown in the figure.

A

B

EC-00014
EC-00015

(A) To fuel pipe
(B) To intake manifold

C: INSPECTION
Make sure hoses are not cracked or loose.

EC(H4SO)-9

Two-way Valve
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICE)

7. Two-way Valve
A: REMOVAL
1) Lift-up the vehicle.
2) Remove the canister from body. <Ref. to
EC(H4SO)-8, REMOVAL, Canister.>
3) Remove the two-way valve with bracket as a single unit from body.

EC-00016

4) Remove the two-way valve from bracket.

B: INSTALLATION
Install in the reverse order of removal.

C: INSPECTION
Make sure that the hoses are not cracked or loose.

EC(H4SO)-10


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