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Intake Induction (H4DOTC): Diagnosis Subaru Forester SJ

Mechanical 37 illustrations ~1656 words

INSPECTION

  1. Check that the air cleaner element has no deformation, cracks or other damages.
  2. Check the air cleaner element for excessive dirt.

Scheme 896

Scheme 896: REMOVAL
Scheme 896: REMOVAL

Scheme 897

Scheme 897
Scheme 897

Scheme 898

Scheme 898
Scheme 898

Scheme 899

Scheme 899
Scheme 899

Scheme 900

Scheme 900
Scheme 900
  1. Disconnect the ground cable from battery.
  2. Remove the air intake duct (rear). < Ref. to «REMOVAL»(ref-662121-S38398809152014101300000) , Air Intake Duct. >
  3. Remove the engine control module (ECM). < Ref. to «REMOVAL»(ref-662119-S30397921182014101300000) , Engine Control Module (ECM). >
  4. Remove the clips (2 places) which secure the front mud guard RH to the vehicle.
  5. Turn over the front mud guard RH, and loosen the clamp which secures the air intake boot to the air cleaner case (rear).
  6. Disconnect the connector (A) from the mass air flow and intake air temperature sensor, and remove the clip (B) from the air cleaner case (rear).
  7. Remove the air cleaner case (rear) and air cleaner element.
  8. Remove bolts (A) and nuts (B) which secure the air cleaner case (front) to the body and air cleaner case bracket, and remove the air cleaner case (front).
  9. Remove the air cleaner case bracket from the vehicle.

Check that the air cleaner case has no deformation, cracks or other damages.

Scheme 901

Scheme 901: REMOVAL
Scheme 901: REMOVAL

Scheme 902

Scheme 902
Scheme 902

Scheme 903

Scheme 903
Scheme 903
  1. Disconnect the ground cable from battery.
  2. Remove the air cleaner case. < Ref. to «REMOVAL»(ref-662121-S18634593152014101300000) , Air Cleaner Case. >
  3. Lift up the vehicle.
  4. Remove the under cover. < Ref. to «REMOVAL»(ref-662136-S19922819302014101300000) , Front Under Cover. >
  5. Remove the air intake boot from the intake duct No. 1.
  6. Lower the vehicle.
  7. Remove the nuts which secure the turbo duct to the vehicle, and remove the air intake boot from the upper side of the vehicle together with the turbo duct.
  8. Remove the duct bracket from the vehicle.

Check that the air intake boot and turbo duct have no cracks, damage or loose part.

Scheme 904

Scheme 904: REMOVAL
Scheme 904: REMOVAL

Scheme 905

Scheme 905
Scheme 905
  1. Remove the clip which secures air intake duct (rear), and remove the air intake duct (rear).
  2. Remove the clip (A) and four claws and then remove the air intake duct (front).
  1. Check that the air intake duct has no deformation, cracks or other damages.
  2. Inspect that no foreign objects are mixed in the air intake duct.

Scheme 906

Scheme 906: INTAKE DUCT NO. 1
Scheme 906: INTAKE DUCT NO. 1

Scheme 907

Scheme 907
Scheme 907

Scheme 908

Scheme 908
Scheme 908

Scheme 909

Scheme 909
Scheme 909

Scheme 910

Scheme 910
Scheme 910
  1. Disconnect the ground cable from battery.
  2. Remove the air intake duct (rear). < Ref. to «REMOVAL»(ref-662121-S38398809152014101300000) , Air Intake Duct. >
  3. Disconnect the vacuum hose from vacuum pipe.
  4. Lift up the vehicle.
  5. Remove the under cover. < Ref. to «REMOVAL»(ref-662136-S19922819302014101300000) , Front Under Cover. >
  6. Disconnect the connector from the wastegate control solenoid valve.
  7. Disconnect the PCV pipe (A) from the intake duct No. 1, and disconnect the vacuum control hose (B) from the wastegate control solenoid valve.
  8. Remove the air intake boot from the intake duct No. 1, and disengage the clip which secures the air by-pass valve to the intake duct No. 1.
  9. Remove the bolts which secure the intake duct No. 1 to the turbocharger, and remove the intake duct No. 1.

Scheme 911

Scheme 911: INTAKE DUCT NO. 2
Scheme 911: INTAKE DUCT NO. 2

Scheme 912

Scheme 912
Scheme 912

Scheme 913

Scheme 913
Scheme 913

Scheme 914

Scheme 914
Scheme 914

Scheme 915

Scheme 915
Scheme 915
  1. Remove the clip (A), lift the front of the collector cover in the direction of arrow, and then remove the collector cover.
  2. Disconnect the ground cable from battery.
  3. Remove the air intake duct (rear). < Ref. to «REMOVAL»(ref-662121-S38398809152014101300000) , Air Intake Duct. >
  4. Remove the intercooler. < Ref. to «REMOVAL»(ref-662121-S20295609002014101300000) , Intercooler. >
  5. Remove the radiator sub fan and fan motor assembly. < Ref. to «REMOVAL»(ref-662123-S22947873392014101300000) , Radiator Sub Fan and Fan Motor. >
  6. Lift up the vehicle.
  7. Remove the under cover. < Ref. to «REMOVAL»(ref-662136-S19922819302014101300000) , Front Under Cover. >
  8. Disconnect the PCV pipe (A) and vacuum hose (B) from the intake duct No. 1, and disconnect the vacuum hose (C) from the air by-pass valve.
  9. Disengage the clip which secures the air by-pass valve to the intake duct No. 1.
  10. Lower the vehicle.
  11. Remove the bolts which secure the intake duct No. 2 to the turbocharger.
  12. Pull out the air by-pass valve from the intake duct No. 1, and remove the intake duct No. 2 from the intake manifold.

Scheme 916

Scheme 916
Scheme 916

Scheme 917

Scheme 917
Scheme 917
  1. Remove the clip (A), lift the front of the collector cover in the direction of arrow, and then remove the collector cover.
  2. Disconnect the ground cable from battery.
  3. Remove the intercooler. < Ref. to «REMOVAL»(ref-662121-S20295609002014101300000) , Intercooler. >
  4. Remove the clip securing the brake booster vacuum hose to the intake manifold, and move the brake booster vacuum hose at the locations that do not interfere operation.
  5. Remove the intake duct No. 3 from the throttle body.
  1. Check that the intake duct has no deformation, cracks or other damages.
  2. Check the vacuum hose for cracks, damage or looseness.

Scheme 918

Scheme 918
Scheme 918

Scheme 919

Scheme 919
Scheme 919

Scheme 920

Scheme 920
Scheme 920

Scheme 921

Scheme 921
Scheme 921
  1. Remove the clip (A), lift the front of the collector cover in the direction of arrow, and then remove the collector cover.
  2. Disconnect the ground cable from battery.
  3. While pressing the section (A) shown in the figure, move the lock lever (B) in the direction of the arrow to disconnect the connectors from the ECM in numerical order as shown in the figure.
  4. Loosen the clamp (A) which holds the intake duct to intercooler.
  5. Remove the bolts which secure the intercooler to the intercooler stay, and remove the intercooler.
  6. Remove the brake booster vacuum hose from the clip (A).
  7. Remove the intercooler stay RH from the engine hanger stay, and remove the intercooler stay LH from the intake manifold.
  8. Remove the insulator and clamp from intake duct.

Scheme 922

Scheme 922
Scheme 922

Scheme 923

Scheme 923
Scheme 923

Scheme 924

Scheme 924
Scheme 924

Scheme 925

Scheme 925
Scheme 925

Scheme 926

Scheme 926
Scheme 926

Scheme 927

Scheme 927
Scheme 927
  1. Install the insulator and clamp to the intake duct. NOTE: Use a new insulator. Apply a thin coat of SUBARU PS fluid (K0515YA000) or liquid paraffin to the inner periphery of the insulator.
  2. Install the intercooler stay RH to the engine hanger stay. Tightening torque: 16 N.m (1.6 kgf-m, 11.8 ft-lb)
  3. Temporarily tighten the intercooler stay LH to the intake manifold.
  4. Install the brake booster vacuum hose to the clip (A).
  5. Insert the intercooler into the intake duct No. 2, and temporarily tighten the clamp which secures the intake duct No. 2 to the intercooler. NOTE: When inserting the intercooler into the intake duct No. 2, be careful that the insulator is not turned over.
  6. Insert the intercooler into the intake duct No. 3, and tighten the clamp which secures the intake duct to the intercooler. NOTE: When inserting the intercooler into the intake duct No. 3, be careful that the insulator is not turned over. Tightening torque: 3 N.m (0.3 kgf-m, 2.2 ft-lb)
  7. Install the bolts which secure the intercooler to the intercooler stay, and tighten the bolt which secures the intercooler stay LH to the intake manifold. Tightening torque: 16 N.m (1.6 kgf-m, 11.8 ft-lb)
  8. Move the lock lever in the direction of the arrow, and connect the connector to the ECM in numerical order as shown in the figure.
  9. Connect the battery ground terminal.
  10. Install the collector cover.

Check that the intercooler and intercooler stay have no deformation, cracks or other damages.

OTHER INSPECTIONS

  1. Check that the turbocharger and pipe have no deformation, cracks or other damages.
  2. Check that the hose has no cracks, damage or loose part.
  3. Check that there are no oil leakage or water leakage from the pipe attachment section.

Scheme 928

Scheme 928: REMOVAL
Scheme 928: REMOVAL

Scheme 929

Scheme 929
Scheme 929

Scheme 930

Scheme 930
Scheme 930
  1. Remove the air intake duct (rear). < Ref. to «REMOVAL»(ref-662121-S38398809152014101300000) , Air Intake Duct. >
  2. Disconnect the PCV hose assembly from the oil catch tank. NOTE: To disconnect the PCV hose assembly, fit the cut outs of the ST with the protrusions on the clamp as shown in the figure, squeeze the ST's handles together and unlock the clamp. ST 18353AA000 CLAMP PLIERS
  3. Lift up the vehicle.
  4. Remove the under cover. < Ref. to «REMOVAL»(ref-662136-S19922819302014101300000) , Front Under Cover. >
  5. Disconnect the turbocharger hose from the oil pipe, and drain the engine oil in the oil catch tank. NOTE: Prepare the container for draining of engine oil.
  6. Remove bolts which secure the oil catch tank to the turbocharger and exhaust stay, and remove the oil catch tank.

Scheme 931

Scheme 931
Scheme 931
  1. Install the oil catch tank to the turbocharger and exhaust stay. Set the oil catch tank to the turbocharger, and temporarily tighten the bolts which secure the oil catch tank to the turbocharger and exhaust stay. NOTE: Use a new gasket. Tighten the bolts which secure the oil catch tank to the turbocharger and exhaust stay in numerical order as shown in the figure. Tightening torque: T1: 6.4 N.m (0.7 kgf-m, 4.7 ft-lb) T2: 10.5 N.m (1.1 kgf-m, 7.7 ft-lb)
  2. Connect the turbocharger hose to the oil pipe.
  3. Install the under cover. < Ref. to «INSTALLATION»(ref-662136-S09037710362014101300000) , Front Under Cover. >
  4. Lower the vehicle.
  5. Connect the PCV hose assembly to the oil catch tank. NOTE: Use a new clamp. To connect the PCV hose assembly, fit the cut outs of the ST with the protrusions on the clamp as shown in the figure, squeeze the ST's handles together and lock the clamp. ST 18353AA000 CLAMP PLIERS
  6. Install the air intake duct (rear). < Ref. to «INSTALLATION»(ref-662121-S35607443062014101300000) , Air Intake Duct. >
  7. Check the engine oil level and replenish the engine oil if necessary. < Ref. to «INSPECTION»(ref-662113-S03739542742014101300000) , Engine Oil. >
  1. Check that the oil catch tank does not have deformation, cracks or damage.
  2. Check that the PCV hose and turbocharger hose have no cracks, damage or loose part.

Refer to "Scavenge Pump" for inspection procedure of scavenge pump. < Ref. to INSPECTION , Scavenge Pump. >

Scheme 932

Scheme 932: REMOVAL
Scheme 932: REMOVAL
  1. Remove the intake duct No. 1. < Ref. to «INTAKE DUCT NO. 1»(ref-662121-S27614790662014101300000) , REMOVAL, Intake Duct. >
  2. Disconnect the vacuum hose from the air by-pass valve, and remove the air by-pass valve from the intake duct No. 2.

Check that the vacuum hose and air by-pass pipe have no cracks, damage or loose part.

Check that the resonator chamber has no deformation, cracks or other damages.

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