boot SUBARU FORESTER 2004 Service User Guide

LU(H4SO)-19
LUBRICATION
Oil Pan and Strainer
10) Remove the lifting device and steel cables.
11) Install the pitching stopper.
Tightening torque:
T1: 50 N
⋅m (5.1 kgf-m, 36.9 ft-lb)
T2: 58 N
⋅m (5.9 kgf-m, 42.8 ft-lb)
12) Install the radiator upper brackets.
13) Install the air intake duct and air cleaner case.
(Non-turbo model) LATION, Air Intake Duct.> INSTALLATION, Air Cleaner Case.>
14) Install the intercooler. (Turbo model) IN(H4DOTC)-11, INSTALLATION, Intercooler.>15) Install the air intake boot and air cleaner upper
cover. (Turbo model)
16) Connect the connector to mass air flow sensor.
(Turbo model)
17) Install the front wheels.
18) Connect the battery ground cable to battery.
19) Fill engine oil. TION, Engine Oil.>
C: INSPECTION
By visual check make sure the oil pan, oil strainer,
oil strainer stay and baffle plate are not damaged.
LU-00028
ME-00218T2T1
LU-00027
LU-00070
LU-00026
FU-00009

SP(H4SO)-5
SPEED CONTROL SYSTEM
Accelerator Pedal
8) Remove the accelerator pedal mounting bolt
from accelerator pedal bracket.
 LHD model
 RHD model
9) Disconnect the grommet from toe board.
NOTE:
From the inside compartment, push the grommet
(A) into hole.
10) Pull out the cable from toe board hole.11) Disconnect the accelerator cable bushing from
accelerator pedal lever.
12) Disconnect the accelerator cable stopper (A)
from bracket.
13) Separate the accelerator cable and accelerator
bracket.
B: INSTALLATION
Install in the reverse order of removal.
NOTE:
 If the cable clamp is damaged, replace it with a
new one.
 Never fail to cover the outer cable end with boot.
 Be careful not to kink the accelerator cable.
 For tightening torque, refer to “COMPONENT”.
scription.>
SP-00018
SP-00007
SP-00008
(A)
(A) Flat tip screwdriver
SP-00009
(A)
SP-00010
(A)

SP(H4SO)-9
SPEED CONTROL SYSTEM
Accelerator Control Cable
3. Accelerator Control Cable
A: REMOVAL
1) Remove the accelerator pedal. SP(H4SO)-4, REMOVAL, Accelerator Pedal.>
2) Separate the accelerator cable and accelerator
pedal.
B: INSTALLATION
1) Install in the reverse order of removal.
NOTE:
 If the cable clamp is damaged, replace it with a
new one.
 Never fail to cover the outer cable end with boot.
 Be careful not to kink the accelerator cable.
CAUTION:
Do not apply grease to except specified part.
2) Apply grease to engine side accelerator cable
end.
Grease:
Slicolube G-30M (Part No. 004404002)
3) Adjustment after pedal installation. SP(H4SO)-7, ADJUSTMENT, Accelerator Pedal.>
C: INSPECTION
1) Make sure the inner cable is not twisted or worn.
2) Make sure the outer cable is not cracked.
(A) Accelerator cable end
(B) Throttle cam
SP-00042
( A )
( B )

IG(H4SO)-5
IGNITION
Spark Plug
2. Spark Plug
A: REMOVAL
CAUTION:
All spark plugs installed on an engine, must be
of the same heat range.
1. RH SIDE
1) Disconnect the ground cable from battery.
2) Remove the air cleaner case. 8, REMOVAL, Resonator Chamber.>
3) Remove the spark plug cords by pulling boot, not
the cord itself.
4) Remove the spark plugs with spark plug sock-
ets.
2. LH SIDE
1) Disconnect the ground cable from battery.
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 the working area.
5) Remove the spark plugs cord by pulling boot, not
the cord itself.
Spark plug
CHAMPION: RC10YC4
NGK: BKR5E-11 (Alternate)
FU-00009
IG-00017
IG-00018
FU-00009
IG-00019
IG-00020
IG-00021

FU(H4DOTC)-14
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
3. Intake Manifold
A: REMOVAL
1) Release the fuel pressure. 54, RELEASING OF FUEL PRESSURE, OPERA-
TION, Fuel.>
2) Open the fuel filler flap lid and remove the fuel
filler cap.
3) Disconnect the ground cable from battery.
4) Lift-up the vehicle.
5) Remove the under cover.
6) Drain the coolant about 3.02 (3.2 US qt, 2.6 Imp
qt).
7) Remove the air cleaner upper cover and air in-
take boot. Cleaner.>
8) Remove the air cleaner element.
9) Remove the intercooler. 10, REMOVAL, Intercooler.>
10) Disconnect the accelerator cable.
11) Remove the coolant filler tank. CO(H4SO)-42, REMOVAL, Coolant Filler Tank.>
12) Remove the power steering pump.(1) Remove the front side V-belt. ME(H4DOTC)-52, REMOVAL, V-belt.>
(2) Disconnect the power steering switch con-
nector.
(3) Remove the bolts which secure the power
steering pipe brackets to intake manifold.
CAUTION:
Do not disconnect the power steering hose.
(4) Remove the bolts which secure the power
steering pump bracket.
(5) Remove the power steering tank from the
bracket by pulling it upward.
FU-00009
FU-00016
FU-00011
FU-00017
FU-00018
FU-00019
FU-00020

IN(H4DOTC)-2
INTAKE (INDUCTION)
General Description
1. General Description
A: COMPONENT
1. AIR CLEANER
(1) Mass air flow and intake air tem-
perature sensor(7) Air cleaner lower case (14) Cushion
(8) Cushion rubber
(2) Air cleaner upper cover (9) Air intake ductTightening torque: N
⋅m (kgf-m, ft-lb)
(3) Air cleaner element (10) Resonator chamber ASSYT1: 7.5 (0.76, 5.5)
(4) Spacer (11) Cushion rubberT2: 33 (3.4, 24.6)
(5) Bushing (12) ClampT3: 2.5 (0.25, 1.8)
(6) Clip (13) Air intake bootT4: 1.7 (0.17, 1.2)
(3)
(12)
(12) (13)
(6)
(6)(7)
(4)
(5) (8)
(14)
(11)
(10)T3
T3
T2
(9)
T1
T1
T1
T1
T4
(2)
(1)
IN-00001

IN(H4DOTC)-7
INTAKE (INDUCTION)
Air Cleaner
2. Air Cleaner
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Disconnect the connector from mass air flow
sensor.
3) Loosen the clamp (A) which connects air intake
boot and intake duct.
4) Remove the clip (B) from air cleaner upper cover.
5) Remove the air cleaner upper cover.
6) Remove the air cleaner element.
7) Remove the air cleaner lower case.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
33 N
⋅m (3.4 kgf-m, 24.6 ft-lb)
NOTE:
Before installing the air cleaner upper cover, align
the holes with protruding portions of air cleaner
lower case, then secure the upper cover to lower
case.
C: INSPECTION
Replace if excessively damaged or dirty.
FU-00009
IN-00005
IN-00006
(B)
(A)
IN-00007
IN-00007
IN-00008

FU(H4DOTC 2.5)-14
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
3. Intake Manifold
A: REMOVAL
1) Release the fuel pressure.
FUEL PRESSURE, OPERATION, Fuel.>
2) Open the fuel filler flap lid and remove the fuel
filler cap.
3) Disconnect the ground cable from battery.
4) Lift up the vehicle.
5) Remove the under cover.
6) Drain the engine coolant about 3.02 (3.2 US qt,
2.6 Imp qt).
7) Remove the air cleaner upper cover and air in-
take boot. Cleaner.>
8) Remove the air cleaner element.
9) Remove the intercooler. 10, REMOVAL, Intercooler.>
10) Remove the coolant filler tank. CO(H4SO)-42, REMOVAL, Coolant Filler Tank.>
11) Remove the power steering pump.
(1) Remove the front side V-belt. ME(H4DOTC)-52, REMOVAL, V-belt.>(2) Disconnect the power steering switch con-
nector.
(3) Remove the bolts which secure the power
steering pipe brackets to the intake manifold.
NOTE:
Do not disconnect the power steering hose.
(4) Remove the bolts which secure the power
steering pump bracket.
(5) Remove the reservoir tank from the bracket
by pulling it upward.
FU-00009
FU-00016
FU-00017
FU-00018
FU-00019
FU-00020

CS-5
CONTROL SYSTEM
General Description
2. MT GEAR SHIFT LEVER
(1) Gear shift knob (11) Bushing A (21) Boot & insulator ASSY
(2) Console boot (12) Spring pin (22) Front cover
(3) Plate ASSY (13) Cushion rubber (23) Clamp
(4) Gear shift lever (14) Bushing B
(5) Bushing (15) JointTightening torque: N·m (kgf-m, ft-lb)
(6) Bushing (16) RodT1: 7.5 (0.76, 5.5)
(7) Lock wire (17) BracketT2: 12 (1.2, 8.7)
(8) Boot (18) WasherT3: 18 (1.8, 13.0)
(9) Snap ring (19) Stay
(10) O-ring (20) Spacer
CS-00357
T2
(5) (5)
(5) (5)
(4)
(6)(3) (2)(1)
(18)(21)(23) (22)
(20)
(19)(17)T1
(14)
(13) (16)
(15)
(12) (12)
(11)
(10)
(10)
(9)(8)
(7)
T3
T3
T3
T3

CS-14
CONTROL SYSTEM
Select Cable
4) Install the snap pin to range select lever.
5) Shift the select lever to “N” range, then adjust the
select cable position. MENT, Select Cable.>
6) Install the heat shield cover. (If equipped)
7) Install the front and center exhaust pipe.
 Non-turbo model
haust Pipe.>
 Turbo model
Exhaust Pipe.>
C: INSPECTION
Check the removed cable and replace if damaged,
rusty, or defective.
1) Check for smooth operation of the cable.
2) Check the inner cable for damage and rust.
3) Check the outer cable for damage, bends, and
cracks.
4) Check the boot for damage, cracks, and deterio-
ration.
5) Shift the select lever from “P” range to “1” range.
You should be able to feel the detentes in each
range. If the detentes cannot be felt or the range
pointer is improperly aligned, adjust the cable.
D: ADJUSTMENT
1) Set the vehicle on a lift.
2) Shift the select lever to “N” range.
3) Lift-up the vehicle.
4) Remove the rear exhaust pipe and muffler.
5) Remove the heat shield cover. (If equipped)6) Loosen the adjusting nuts on each side.
7) Turn the adjusting nut B until it lightly touches
the bushing assembly.
8) While preventing the adjusting nut B from mov-
ing with a wrench, tighten the adjusting nut A.
Tightening torque:
7.5 N·m (0.76 kgf-m, 5.5 ft-lb)
(A) Range select lever
(B) Snap pin
(C) Select cable
(D) Clamp
(E) Washer
CS-00036
(C)(B) (A)
(E) (D)
(A) Adjusting nut A
(B) Adjusting nut B
(A) Front side
(B) Select lever
(C) Bushing ASSY
(D) Adjusting nut B
(E) Contact point
(F) Adjusting nut A
(A) Adjusting nut A
(B) Adjusting nut B
CS-00040
(A) (B)
CS-00041
(A)(B)
(C)
(D)
(E)(F)
CS-00042
(A)
(B)