lock SUBARU FORESTER 2004 Service Repair Manual

PM-13
PERIODIC MAINTENANCE SERVICE
Timing Belt
7. Timing Belt
A: REPLACEMENT
1. NON-TURBO MODEL
1) Remove the radiator fan and air conditioner fan.
Fan Motor.> Fan and Fan Motor.>
2) Shield the radiator from any damage using card-
board and blanket.
3) Remove the V-belt cover.
4) Remove the V-belts. belt.>
5) Remove the air conditioning compressor V-belt
tensioner.
6) To lock the crankshaft, use ST. Remove the pul-
ley bolt.
ST 499977100 CRANK PULLEY WRENCH
7) Remove the crank pulley.
8) Remove the left side belt cover.
9) Remove the front timing belt cover.
10) Remove the timing belt guide. (MT model)11) Turn the crankshaft and align alignment marks
on crankshaft, and right and left cam sprockets with
notches of belt cover and cylinder block.
ST 499987500 CRANKSHAFT SOCKET
12) Remove the belt idler.
13) Remove the belt idler (No. 2).
14) Remove the timing belt.
15) Remove the automatic belt tension adjuster as-
sembly.
PM-00003
PM-00007
ST
PM-00008
(A) Notch
(B) Alignment mark
PM-00009
(B)
(B)
(B) (A)
PM-00010
PM-00011

PM-14
PERIODIC MAINTENANCE SERVICE
Timing Belt
16) Install in the reverse order of removal. ME(H4SO)-49, INSTALLATION, Timing Belt.>
2. TURBO MODEL
1) Remove the radiator fan and air conditioner fan.
Fan Motor.> Fan and Fan Motor.>
2) Protect the radiator with cardboard and blanket.
3) Remove the V-belts. belt.>
4) Remove the air conditioning compressor drive
belt tensioner.
5) To lock the crankshaft use ST. Remove the pul-
ley bolt.
ST 499977300 CRANK PULLEY WRENCH
6) Remove the crank pulley.
7) Remove the air conditioning compressor drive
belt tensioner.
8) Remove the belt cover (LH).
9) Remove the belt cover (RH).
10) Remove the front belt cover.11) Remove the timing belt guide. (MT model)
12) Turn the crankshaft and align alignment marks
on crankshaft, and right and left cam sprockets with
notches of belt cover and cylinder block. To turn the
crankshaft, use ST.
STPM-00093
PM-00008
ME-00727
ME-00728
ME-00729

PM-25
PERIODIC MAINTENANCE SERVICE
Hill-holder System
15.Hill-holder System
A: INSPECTION AND ADJUSTMENT
1) Confirm the stopping and starting performance
by activating the hill-holder on an uphill road of 3°
or higher inclination.
(1) When the vehicle does not stop;
Tighten the adjusting nut of PHV cable.
(2) When the vehicle does not start properly;
A; When the hill-holder is released later than en-
gagement of clutch (engine tends to stall): Loos-
en the adjusting nut gradually until smooth
starting is enabled.
B; When the hill-holder is released earlier than
engagement to clutch (vehicle slips down slight-
ly): Tighten the adjusting nut so that hill-holder is
released later than engagement of clutch (status
in A). Then make adjustment the same as in A.
CAUTION:
 Whenever turning the adjusting nut, hold the
inner cable with pliers to prevent it from turn-
ing.
 Replace the pressure hold valve (PHV) or
PHV cable with a new one, if they are defective
and/or damaged.
(A) Lock nut
(B) Adjusting nut
(C) Pressure hold valve
(C) (B)
(A)
PM-00077

PM-31
PERIODIC MAINTENANCE SERVICE
Brake Line
(4) If there is no free play between clevis pin
and clevis, turn the brake switch adjusting nut
until the clearance between stopper and screw
of brake switch becomes 0.3 mm (0.012 in).
3) Check the pedal stroke.
While the engine is idling, depress the brake pedal
with a 490 N (50 kgf, 110 lb) load and measure the
distance between brake pedal and steering wheel.
With the brake pedal released, measure the dis-
tance between pedal and steering wheel again.
The difference between the two measurements
must be less than specified value. If the distance is
more than specified value, there is possibility of air
inside the hydraulic unit.
Brake pedal reserve distance: A
For Australia model
105 mm (4.13 in)/ 490 N (50 kgf , 110 lb) or less
Except for Australia model
90 mm (3.54 in)/ 490 N (50 kgf , 110 lb) or less4) Check to see if air is in the hydraulic brake line
by the feel of pedal operation. If air appears to exist
in the line, bleed it from the system.
5) Check for even operation of all brakes, using a
brake tester or by driving the vehicle for a short dis-
tance on a straight road.
2. BRAKE SERVO SYSTEM
1) With the engine off, depress the brake pedal
several times applying the same pedal force: Make
sure the travel distance should not change.
2) With the brake pedal depressed, start the en-
gine: Make sure the pedal should move slightly to-
ward the floor.
3) With the brake pedal depressed, stop the engine
and keep the pedal depressed for 30 seconds:
Make sure the pedal height should not change.
4) Check valve is built into the vacuum hose. Dis-
connect the vacuum hose to inspect function of
check valve.
Blow air into the vacuum hose from its brake boost-
er side end: Air must flow out of engine side end of
hose. Next blow air into the hose from engine side:
Air should not to brake booster side.
Replace both check valve and vacuum hose if the
check valve is faulty. Engine side of vacuum hose
is indicated by marking “ENG” as shown in illustra-
tion.
5) Check the vacuum hose for cracks or other dam-
age.
CAUTION:
When installing the vacuum hose on the engine
and brake booster, do not use soapy water or
lubricating oil on their connections.
6) Check vacuum hose to make sure it is tight and
secure.
(A) Brake switch
(B) Adjusting nut
(C) 0.3 mm (0.012 in)
(D) Stopper
(E) Clevis pin
(F) Clevis
(G) Brake pedal free play
(H) Lock nut
(I) Brake booster operating rod
(J) Play at pin
(A) Steering wheel
(B) Toe board
PM-00041
(B)
(G) (H)
(I)
(J)(C)
(D)
(E)
(F)(A)
PM-00045(B)(A) = A
1
12
2
(A) Engine side
(B) Brake booster side
(C) ENG
PM-00046
(B)
(C) (A)

PM-35
PERIODIC MAINTENANCE SERVICE
Brake Linings and Drums
2) Check the disk rotor for wear, dents or other
damage. If the inside surface of disk rotor is
streaked, correct the surface with emery cloth
(#200 or more). If it is unevenly worn or tapered,
correct or replace it.
Brake drum inside diameter
Standard value: 170 mm (6.69 in)
Wear limit: 171 mm (6.73 in)
3) If the deformation or wear of back plate, shoe,
etc. is noticeable, replace them.
4) When the shoe return spring tension is exces-
sively weakened, replace it.B: ADJUSTMENT
1. REAR DRUM BRAKE
The main brake is adjusted automatically, and so
there is no need to adjust it.
2. PARKING BRAKE (REAR DISC BRAKE)
For rear disc brake, adjust the parking brake after
bleeding air.
1) Remove the rear cover (rubber) installed at back
plate.
2) Turn the adjuster toward arrow mark (upward)
until it is locked slightly, by using a flat tip screwdriv-
er as shown in illustration.
3) Turn back (downward) the adjuster 3 to 4 notch-
es.
4) Install the rear cover (rubber) at original position
correctly.
(A) Inside diameter
(B) Disk
PM-00055
(A) (B)
(A) Adjuster
(B) Rear cover (rubber)
(C) Back plate
PM-00056
(B)
(C) (A)

PM-37
PERIODIC MAINTENANCE SERVICE
Suspension
4. WHEEL ALIGNMENT OF FRONT SUS-
PENSION
1) Check the alignment of front suspension to en-
sure that following items conform to standard val-
ues.
 Toe-in
 Camber angle
 Caster angle
 Steering angle

2) When the caster angle does not conform to ref-
erence, visually inspect the following components
and replace deformed parts.
 Suspension components [Strut assembly, cross-
member, transverse link, etc.]
 Body parts to which suspensions are installed.
3) When the toe-in and camber are out of standard
value, adjust them so that they conform to respec-
tive service standard. WHEEL TOE-IN, INSPECTION, Wheel Align-
ment.> Wheel Alignment.>
4) When the right-and-left turning angles of tire are
out of standard, adjust to standard value. FS-10, STEERING ANGLE, INSPECTION, Wheel
Alignment.>
5. WHEEL ALIGNMENT OF REAR SUS-
PENSION
1) Check the alignment of rear suspension to en-
sure that following items are within standard val-
ues.
 Toe-in
 Camber angle
 Thrust angle

2) When the camber angle does not conform to ref-
erence, visually inspect parts listed below. If defor-
mation is observed, replace the damaged parts.
 Suspension components [Shock absorber, front
lateral links, rear lateral links, trailing link, etc.]
 Body parts to which suspensions are installed.
3) When the toe-in and thrust angle are out of stan-
dard value, adjust them so that they conform to re-
spective service standard. WHEEL TOE-IN, INSPECTION, Wheel Align-
ment.> SPECTION, Wheel Alignment.>
6. OIL LEAKAGE OF STRUT
Visually inspect the front strut and rear strut for oil
leakage as instructed. If oil leakage reaches under
spring seat lower portion, replace the front strut and
rear strut.
7. TIGHTNESS OF BOLTS AND NUTS
Check the bolts and nuts shown in the figure for
looseness. Retighten the bolts and nuts to speci-
fied torque. If the self-lock nuts and bolts are re-
moved, replace them with new ones.
Front suspension: tion.>
Rear suspension: tion.>
8. DAMAGE TO SUSPENSION PARTS
Check the following parts and the fastening portion
of the vehicle body for deformation or excessive
rusting which impairs the suspension. Remove the
contaminations on spring seat lower portion with
care because dirt, sand, etc. tend to accumulate on
it. If necessary, replace the damaged parts with
new ones. If minor rust formation, pitting, etc. are
noted, remove the rust and apply remedial anti-cor-
rosion measures.
 Front suspension
 Transverse link
 Crossmember
Strut
 Rear suspension
 Crossmember
 Lateral links
 Trailing link
Strut
 In the district where salt is sprayed to melt snow
on a road in winter, check suspension parts for
damage caused by rust every 12 months after
lapse of 60 months. Take rust prevention measure
as required.

PM-38
PERIODIC MAINTENANCE SERVICE
Wheel Bearing
23.Wheel Bearing
A: INSPECTION
1. FRONT WHEEL BEARING
NOTE:
Inspect the condition of front wheel bearing grease.
1) Lift-up the front of vehicle.
2) While holding the front wheel by hand, swing it in
and out to check bearing free play.
3) Loosen the wheel nuts and remove front wheel.
4) If bearing free play exists in step 2) above, at-
tach a dial gauge to the hub and measure axial dis-
placement in axial direction.
Service limit:
Straight-ahead position within 0.05 mm
(0.0020 in)
5) Remove the bolts and self-locking nuts, and ex-
tract transverse link from front crossmember.
6) Remove the AARi of front drive shaft from trans-
mission.
7) While supporting the front drive shaft horizontal-
ly with one hand, turn the hub with the other to
check for noise or binding.
If the hub is noisy or binds, disassemble the front
axle and check condition of oil seals, bearing, etc.
2. REAR WHEEL BEARING
1) Lift-up the rear of vehicle.
2) While holding the rear wheel by hand, swing it in
and out to check bearing free play.
3) Loosen the wheel nuts and remove rear wheel.
4) If the bearing free play exists in step 2) above,
attach a dial gauge to the hub assembly and mea-
sure axial displacement in axial direction.Service limit:
Straight-ahead position within 0.05 mm
(0.0020 in)
5) Remove the DOJ of rear drive shaft from rear dif-
ferential.
6) While supporting the rear drive shaft horizontally
with one hand, turn the hub assembly with the other
to check for noise or binding.
If the hub assembly is noisy or binds, disassemble
the rear axle and check condition of oil seals, bear-
ings, etc.
(A) Inner oil seal
(B) Snap ring
(C) Bearing
(D) Housing
(E) Outer oil seal
(F) Hub bolt
(G) Hub
PM-00061
(A)
(B)
(C)
(D)
(E)(G) (F)
(A) Inner oil seal
(B) Rear housing
(C) Bearing
(D) Snap ring
(E) Outer oil seal
(F) Tone wheel
(G) Hub bolt
(H) Hub
(I) Socket bolt
PM-00062
(A)
(B)
(C)
(D)
(E)(G)
(H)
( I ) (F)

PM-42
PERIODIC MAINTENANCE SERVICE
Steering System (Power Steering)
(2) Retighten the adjusting screw to 7.4 N·m
(0.75 kgf-m, 5.4 ft-lb) and back off 25°.
(3) Apply Liquid gasket to at least 1/3 of entire
perimeter of adjusting screw thread.
(4) Install the lock nut. While holding the adjust-
ing screw with a wrench, tighten the lock nut us-
ing ST.
ST 926230000 SPANNER
Tightening torque (Lock nut):
39 N·m (4.0 kgf-m, 29 ft-lb)
Hold the adjusting screw with a wrench to pre-
vent it from turning it, while tightening the lock
nut.
4. TIE-ROD
1) Check the tie-rod and tie-rod ends for bends,
scratches or other damage.
2) Check the connections of knuckle ball joints for
play, inspect for damage on dust seals, and check
free play of ball studs. If the castle nut is loose, re-
tighten it to the specified torque, then tighten further
up to 60° until the cotter pin hole is aligned.
Tightening torque:
27 N·m (2.75 kgf-m, 19.9 ft-lb)3) Check the lock nut on tie-rod end for tightness. If
it is loose, retighten it to the specified torque.
Tightening torque:
83 N·m (8.5 kgf-m, 61.5 ft-lb)
5. POWER STEERING FLUID LEVEL
NOTE:
 Check at power steering fluid temperature 20°C
(68°F); read the fluid level on the “COLD” side.
 Check at power steering fluid temperature 80°C
(176°F); read the fluid level on the “HOT” side.
1) Place the vehicle with engine stopped on a flat
and level surface.
2) Check the fluid level using the scale on the out-
side of reservoir tank (A). If the level is below “MIN”
(B), add fluid to bring it up to “MAX” (C).
NOTE:
If the fluid level is at “MAX” level or above, drain flu-
id to keep the level in specified range of indicator by
using a syringe or the like.
Recommended fluid:
Dexron III
Fluid capacity:
0.72 (0.7 US qt, 0.6 Imp qt)
6. POWER STEERING FLUID FOR LEAKS
Inspect the underside of oil pump and gearbox for
power steering system, hoses, piping and their
couplings for fluid leaks.
If fluid leaks are found, correct them by retightening
their fitting bolts (or nuts) and/or replacing their
parts.
CAUTION:
 Wipe the leakage fluid off after correcting flu-
id leaks, or a wrong diagnosis is taken later.
 Also pay attention to clearances between
hoses (or pipings) and other parts when in-
specting fluid leaks.
(A) Apply Liquid gasket to at least 1/3 of entire
perimeter
(A) Tie-rod end
(B) Knuckle arm
PM-00068
(A)
PM-00069
(A)
(B)
PM-00070
(A)
(C)
(B)

FU(H4SO)-26
FUEL INJECTION (FUEL SYSTEM)
Crankshaft Position Sensor
5. Crankshaft Position Sensor
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the bolt which install crankshaft position
sensor to the cylinder block.
3) Remove the crankshaft position sensor, and dis-
connect the connector from it.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
T: 6.4 N
⋅m (0.65 kgf-m, 4.7 ft-lb)
FU-00009
FU-00056
FU-00057
FU-00058
T

FU(H4SO)-28
FUEL INJECTION (FUEL SYSTEM)
Knock Sensor
7. Knock Sensor
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the air cleaner case. IN(H4SO)-6, REMOVAL, Air Cleaner Case.>
3) Disconnect the knock sensor connector.
4) Remove the knock sensor from the cylinder
block.
B: INSTALLATION
1) Install the knock sensor to the cylinder block.
Tightening torque:
24 N
⋅m (2.4 kgf-m, 17.4 ft-lb)
NOTE:
The extraction area of the knock sensor cord must
be positioned at a 60° angle relative to the engine
rear.
2) Connect the knock sensor connector.
3) Install the air cleaner case.
Case.>
4) Connect the battery ground cable to battery.
FU-00009
FU-00062
FU-00519
(A) Front side
FU-00413
(A)
60
FU-00062
FU-00009