Subaru 2004 Forester Manuale utente

FUJI HEAVY INDUSTRIES LTD. G8080GE3

2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX

ENGINE SECTION 2

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)

EMISSION CONTROL

(AUX. EMISSION CONTROL DEVICE) EC(H4DOTC)

INTAKE (INDUCTION) IN(H4DOTC)

MECHANICAL ME(H4DOTC)

EXHAUST EX(H4DOTC)

COOLING CO(H4DOTC)

LUBRICATION LU(H4DOTC)

SPEED CONTROL SYSTEM SP(H4DOTC)

IGNITION IG(H4DOTC)

STARTING/CHARGING SYSTEM SC(H4DOTC)

ENGINE (DIAGNOSTIC) EN(H4DOTC)

IGNITION

IG(H4DOTC)

Page

1. General Description ....................................................................................2

2. Spark Plug...................................................................................................5

3. Ignition Coil & Ignitor ASSY ........................................................................8

IG(H4DOTC)-2

IGNITION

General Description

1. General Description

A: SPECIFICATION

Item Designation

Ignition coil and ignitor

ASSY

Model FK0186

Ignition type Direct ignition

Manufacturer DIAMOND

Spark plug

Type and manufacturer 2.0 L model NGK: PFR6G

2.5 L model NGK: ILFR6B

Thread diameter, pitch, length mm 14, 1.25, 26.5

Spark gap mm (in) 0.7 — 0.8 (0.028 — 0.031)

Electrode 2.0 L model Platinum

2.5 L model Irigium

IG(H4DOTC)-3

IGNITION

General Description

B: COMPONENT

(1) Spark plug (2) Ignition coil & ignitor ASSY Tightening torque: N

⋅

m (kgf-m, ft-lb)

T1: 21 (2.1, 15.2)

T2: 16 (1.6, 11.7)

IG-00001

(1)

(2)

IG(H4DOTC)-4

IGNITION

General Description

C: CAUTION

• Wear working clothing, including a cap, protec-

tive goggles, and protective shoes during opera-

tion.

• Remove contamination including dirt and corro-

sion before removal, installation or disassembly.

• Keep the disassembled parts in order and pro-

tect them from dust or 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 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.

IG(H4DOTC)-5

IGNITION

Spark Plug

2. Spark Plug

A: REMOVAL

CAUTION:

All spark plugs installed on an engine, must be

of the same heat range. <Ref. to IG(H4DOTC)-2,

General Description.>

1. RH SIDE

1) Disconnect the ground cable from battery.

2) Remove the air cleaner lower case. <Ref. to

IN(H4DOTC)-7, REMOVAL, Air Cleaner.>

3) Disconnect the connector from ignition coil.

4) Remove the ignition coil.

5) Remove the spark plugs with the spark plug

sockets.

2. LH SIDE

1) Disconnect the battery cables, and then remove

the battery and battery carrier.

2) Disconnect the washer motor connector.

3) Disconnect the rear window glass washer hose

from washer motor, then plug connection with a

suitable cap.

4) Remove the two bolts which hold washer tank,

then take the tank away from working area.

FU-00009

FU-01307

IG-00003

IG-00004

FU-00009

IG-00005

IG-00006

IG(H4DOTC)-6

IGNITION

Spark Plug

5) Disconnect the connector from ignition coil.

6) Remove the ignition coil.

7) Remove the spark plugs with the spark plug

sockets.

B: INSTALLATION

1. RH SIDE

Install in the reverse order of removal.

Tightening torque (Spark plug):

21 N

⋅

m (2.1 kgf-m, 15.2 ft-lb)

Tightening torque (Ignition coil):

16 N

⋅

m (1.6 kgf-m, 11.7 ft-lb)

NOTE:

The above torque should be only applied to new

spark plugs without oil on their threads.

In case their threads are lubricated, the torque

should be reduced by approx. 1/3 of the specified

torque in order to avoid over-stressing.

2. LH SIDE

Install in the reverse order of removal.

Tightening torque (Spark plug):

21 N

⋅

m (2.1 kgf-m, 15.2 ft-lb)

Tightening torque (Ignition coil):

16 N

⋅

m (1.6 kgf-m, 11.7 ft-lb)

NOTE:

The above torque should be only applied to new

spark plugs without oil on their threads.

In case their threads are lubricated, the torque

should be reduced by approx. 1/3 of the specified

torque in order to avoid over-stressing.

C: INSPECTION

Check the electrodes and inner and ceramic insu-

lator of plugs, noting the type of deposits and the

degree of electrode erosion.

1) Normal:

Brown to grayish-tan deposits and slight electrode

wear indicates correct spark plug heat range.

FU-01308

IG-00008

IG-00009

(A) Electrode gap

(B) Carbon accumulation or wear

(D) Damage

(E) Damaged gasket

IG-00010

(A)

(B) (C)

(D)

(E)

IG-00011

IG(H4DOTC)-7

IGNITION

Spark Plug

2) Carbon fouled:

Dry fluffy carbon deposits on insulator and elec-

trode are mostly caused by slow speed driving in

city, weak ignition, too rich fuel mixture, dirty air

cleaner, etc.

It is advisable to replace with plugs having hotter

heat range.

3) Oil fouled:

Wet black deposits show excessive oil entrance

into combustion chamber through worn rings and

pistons or excessive clearance between valve

guides and stems. If the same condition remains

after repair, use a hotter plug.

4) Overheating:

White or light gray insulator with black or gray

brown spots and bluish burnt electrodes indicates

engine overheating. Moreover, the appearance re-

sults from incorrect ignition timing, loose spark

plugs, wrong selection of fuel, hotter range plug,

etc. It is advisable to replace with plugs having

colder heat range.

D: ADJUSTMENT

Clean the spark plugs with a wire brush. Clean and

remove the carbon or oxide deposits, but do not

wear ceramic insulator.

If deposits are too stubborn, replace the plugs.

After cleaning the spark plugs, correct the spark

plug gap using a gap gauge.

NOTE:

Do not use spark plug cleaners, because the spark

plugs are applied with platinum or irigium tips.

Spark plug gap: L

0.7 — 0.8 mm (0.028 — 0.031 in)

NOTE:

Replace with a new spark plug if this area (A) is

worn to “ball” shape.

IG-00012

IG-00013

IG-00014

IG-00015

L(A)

IG(H4DOTC)-8

IGNITION

Ignition Coil & Ignitor ASSY

3. Ignition Coil & Ignitor ASSY

A: REMOVAL

Direct ignition type has been adopted. Refer to the

“SparkPlug Removal” for removal procedure. <Ref.

to IG(H4DOTC)-5, REMOVAL, Spark Plug.>

B: INSTALLATION

Install in the reverse order of removal.

Tightening torque:

16 N

⋅

m (1.6 kgf-m, 11.7 ft-lb)

C: INSPECTION

Ignitor is integrated with the coil. Therefore resis-

tance cannot be measured.

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