stop start SUBARU FORESTER 2004 Service User Guide

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)

ME(H4SO)-26
MECHANICAL
Idle Speed
3. Idle Speed
A: INSPECTION
1) Before checking idle speed, check the following:
(1) Ensure the air cleaner element is free from
clogging, ignition timing is correct, spark plugs
are in good condition, and the hoses are con-
nected properly.
(2) Ensure the malfunction indicator light does
not illuminate.
2) Warm-up the engine.
3) Stop the engine, and then turn the ignition switch
to OFF.
4) When using the Subaru Select Monitor, refer to
the following. TOOL, PREPARATION TOOL, General Descrip-
tion.>
(1) Insert the cartridge to Subaru Select Moni-
tor.
(2) Connect the Subaru Select Monitor to data
link connector.
(3) Turn the ignition switch to ON, and Subaru
Select Monitor switch to ON.
(4) Select the {Each System Check} in Main
Menu.
(5) Select the {Engine Control System} in Se-
lection Menu.
(6) Select the {Current Data Display & Save} in
Engine Control System Diagnosis.
(7) Select the {Data Display} in Data Display
Menu.
(8) Start the engine, and then read the engine
idle speed.
5) When using the tachometer (Secondary pick-up
type).
(1) Attach the pick-up clip to No. 1 cylinder
spark plug cord.(2) Start the engine, and then read the engine
idle speed.
NOTE:
 When using the OBD-II general scan tool, care-
fully read its operation manual.
 This ignition system provides simultaneous igni-
tion for #1 and #2 plugs. It must be noted that some
tachometers may register twice that of actual en-
gine speed.
6) Check the idle speed when unloaded. (With
headlights, heater fan, rear defroster, radiator fan,
air conditioning, etc. OFF)
Idle speed [No load and gears in “N” or “P”
range]:
650
±100 rpm
7) Check the idle speed when loaded. (Turn the air
conditioning switch to “ON” and operate the com-
pressor for at least 1 minute before measurement.)
Idle speed [A/C “ON”, no load and gears in “N”
or “P” range]:
850
±100 rpm
NOTE:
Idle speed can not be adjusted manually, because
the idle speed is automatically adjusted.
If the specified idle speed can not be maintained,
refer to General On-board Diagnosis Table under
“Engine Control System”. Basic Diagnostics Procedure.>
ME-00325
ME-00193

ME(H4SO)-37
MECHANICAL
Engine Assembly
18) Remove the pitching stopper.
19) Disconnect the fuel delivery hose (A), return
hose (B) and evaporation hose (C).
CAUTION:
 Disconnect the hose with its end wrapped
with cloth to prevent fuel from splashing.
 Catch fuel from the hose into container.
20) Support the engine with a lifting device and
wire ropes.21) Support the transmission with a garage jack.
CAUTION:
Before moving the engine away from transmis-
sion, check to be sure no work has been over-
looked. Doing this is very important in order to
facilitate re-installation and because the trans-
mission lowers under its own weight.
22) Separation of the engine and transmission.
(1) Remove the starter. REMOVAL, Starter.>
(2) Remove the bolts which hold upper side of
transmission to engine.
23) Install the ST to torque converter clutch case.
(AT model)
ST 498277200 STOPPER SET
24) Remove the engine from vehicle.
(1) Slightly raise the engine.
(2) Raise the transmission with garage jack.
ME-00213
FU-00149
(A)
(B)
(C)
ME-00214
(A) Transmission
(B) Garage jack
ME-00215
(B)(A)
ME-00216
ST
ME-00217

ME(H4SO)-38
MECHANICAL
Engine Assembly
(3) Move the engine horizontally until main
shaft is withdrawn from clutch cover.
(4) Slowly move the engine away from engine
compartment.
NOTE:
Be careful not to damage the adjacent parts or
body panels with crank pulley, oil level gauge, etc.
25) Remove the front cushion rubbers.
B: INSTALLATION
1) Install the front cushion rubbers.
Tightening torque:
34 N
⋅m (3.5 kgf-m, 25.3 ft-lb)
2) Install the engine onto transmission.
(1) Position the engine in engine compartment
and align it with transmission.
NOTE:
Be careful not to damage the adjacent parts or
body panels with crank pulley, oil level gauge, etc.
(2) Apply a small amount of grease to the spline
of main shaft. (MT model)3) Tighten the bolts which hold upper side of trans-
mission to engine.
Tightening torque:
50 N
⋅m (5.1 kgf-m, 36.9 ft-lb)
4) Remove the lifting device and wire ropes.
5) Remove the garage jack.
6) Install the pitching stopper.
Tightening torque:
T1: 50 N
⋅m (5.1 kgf-m, 37 ft-lb)
T2: 58 N
⋅m (5.9 kgf-m, 43 ft-lb)
7) Remove the ST from torque converter clutch
case. (AT model)
NOTE:
Be careful not to drop the ST into torque converter
clutch case when removing ST.
ST 498277200 STOPPER SET
8) Install the starter. STALLATION, Starter.>
9) Install the torque converter clutch onto drive
plate. (AT model)
ME-00214
ME-00214
ME-00216
ME-00214
ME-00218T2T1

LU(H4SO)-11
LUBRICATION
Engine Oil
6) Tighten the engine oil drain plug after draining
engine oil.
Tightening torque:
44 N
⋅m (4.5 kgf-m, 32.5 ft-lb)
7) Install the service hole cover.
8) Fill engine oil through the filler pipe up to upper
point on level gauge. Make sure that the vehicle is
placed level when checking oil level. Use the en-
gine oil of proper quality and viscosity, selected in
accordance with the table in figure.
Recommended oil
API classification SL, SJ with the “Energy
Conserving” logo is printed, or SH (if you
cannot obtain the oil with SL, SJ or SH
grades, you may use SG, SF grades “ENER-
GY CONSERVING” oil.)
ACEA specification, A1, A2 or A3
CCMC specification, G4 or G5
New API certification mark (Star burst mark)
label is on the container.
Engine oil capacity:
Upper level
4.02 (4.2 US qt, 3.5 Imp qt)
Lower level
3.02 (3.2 US qt, 2.6 Imp qt)
 Non-turbo model Turbo model
The proper viscosity helps vehicle get good cold
and hot starting by reducing viscous friction and
thus increasing cranking speed.
CAUTION:
When replenishing oil, it does not matter if the
oil to be added is a different brand from that in
the engine; however, use oil having the API
classification and SAE viscosity No. designat-
ed by SUBARU.
NOTE:
If the vehicle is used in areas with very high tempera-
tures or for other heavy duty applications, the follow-
ing viscosity oils may be used: API classification: SL
or SJ or SH
SAE Viscosity No. : 30, 40, 10W-50, 20W-40, 20W-
50.
9) Close the engine oil filler cap.
10) Start the engine and warm it up for a time.
11) After the engine stops, recheck the oil level. If
necessary, add engine oil up to the upper level on
level gauge.
(A) Drain plug
(B) Oil filter
(1) SAE Viscosity No. and Applicable Temperature
(2) PREFERRED
LU-00089
(B)
(A)
LU-02006
40 30 15 0 -15 -20 -30 ( C)
104 86 59 32
10W-30,10W-40 5 -4 -22 ( F)
SAE (1)
5W-30,0W-20 (2)
(1) SAE Viscosity No. and Applicable Temperature
(2) PREFERRED
(A) Oil level gauge
(B) Engine oil filler cap
(C) Upper level
(D) Lower level
(E) Approx. 1.02 (1.1 US qt, 0.9 Imp qt)
LU-02007
40 30 15 0 -15 -20 -30 ( C)
104 86 59 32 5 -4 -22 ( F)
SAE (1)
10W-30,10W-40
5W-30 (2)
LU-00138
(A)(B)
(C)
(D) (E)

SC(H4SO)-3
STARTING/CHARGING SYSTEM
General Description
B: COMPONENT
1. STARTER
(1) Front bracket (7) Internal gear ASSY (13) Brush holder ASSY
(2) Sleeve bearing (8) Shaft ASSY (14) Sleeve bearing
(3) Lever set (9) Gear ASSY (15) Rear cover
(4) Magnet switch ASSY (10) Packing (16) Rear cover set
(5) Stopper set (11) Yoke ASSY
(6) Over running clutch (12) Armature
SC-00058
(14) (1)
(2)(3)(4)
(10)
(11)(12)
(13)(15)(16) (5)(6)(7)(8) (9)

SC(H4SO)-8
STARTING/CHARGING SYSTEM
Starter
7) Remove the plate.
8) Remove the shaft assembly and overrunning
clutch from front bracket as a unit.
NOTE:
Check the following points before removal.
 Lever direction
 Position of internal gear assembly
9) Remove the overrunning clutch from shaft as-
sembly as follows:
(1) Remove the stopper from ring by lightly tap-
ping the stopper with an appropriate tool (such
as a 14 mm (0.55 in) a fit socket wrench).(2) Remove the ring, stopper and clutch from
shaft.
(A) Plate
(A) Lever
(B) Shaft ASSY
(C) Overrunning clutch
(D) Internal gear ASSY
SC-00065
(A)
SC-00066
(A)
(D)
(C) (B)
(A) Socket wrench
(B) Ring
(C) Shaft
(D) Stopper
SC-00014

SC(H4SO)-9
STARTING/CHARGING SYSTEM
Starter
D: ASSEMBLY
NOTE:
Apply grease to the following parts before assem-
bly.
 Sleeve bearing
 Pinion shaft rotational portion
 Shaft spline portion
 Inside of reduction system
 Lever fulcrum/Clutch rotational portion
1) Install the overrunning clutch to shaft assembly.
2) Install the stopper to shaft assembly as follows.
(1) Insert the ring into the shaft groove by lightly
tapping it with an appropriate tool (such as a fit
socket wrench).
(2) Install the stopper to ring using a press.
3) Install the shaft assembly to front bracket while
taking care of the following points.
(1) Lever direction(2) Internal gear position
4) Install the plate.
5) Install the planetary gear.
6) Install packing A and B while taking care of in-
stalling positions.
7) Install the armature to yoke assembly.
(A) Ring
(B) Stopper
SC-00067
(B)(A)
SC-00068
(A)
(B)
SC-00069
(A) Plate
(A) Packing A
(B) Packing B
SC-00070
SC-00065
(A)
SC-00071
(A)
(B)

SC(H4SO)-13
STARTING/CHARGING SYSTEM
Starter
7. PINION GAP
1) Measure the pinion gap while the pinion is pulled
out as shown in the figure.
Pinion gap:
0.5 — 2.0 mm (0.020 — 0.079 in)
If the motor is running with the pinion forced end-
wise on shaft, disconnect the connector from termi-
nal M of switch assembly, and then connect
terminal M to ground terminal (−) of battery with a
lead wire. Next, gently push the pinion back with
your fingertips, and then measure the pinion gap.
2) If the pinion gap is outside specified range, re-
move or add number of adjustment washers used
on the mounting surface of switch assembly until
correct pinion gap is obtained.
8. PERFORMANCE TEST
The starter should be submitted to performance
tests whenever it has been overhauled, to assure
its satisfactory performance when installed on the
engine.
Three performance tests, no-load test, load test,
and lock test, are presented here; however, if the
load test and lock test cannot be performed, carry
out at least the no-load test.
For these performance tests, use the circuit shown
in figure.
1) No-load test
With switch on, adjust the variable resistance to ob-
tain 11 V, take the ammeter reading, and then mea-
sure the starter speed. Compare these values with
the specifications.
No-load test (Standard):
Voltage / Current
MT model
MAX. 11 V / 95 A
AT model
MAX. 11 V / 90 A
Rotating speed
MT model
2,500 rpm or more
AT model
2,000 rpm or more
2) Load test
Apply the specified braking torque to starter. The
condition is satisfactory if the current draw and
starter speed are within the specifications.
Load test (Standard):
Voltage / Load
MT model
7.5 V / 8.84 N (0.90 kgf, 1.99 lb)
AT model
7.7 V / 16.7 N (1.70 kgf, 3.75 lb)
(A) Pinion
(B) Pinion gap
(C) Stopper
SC-00027
(A) Variable resistance
(B) Starter body
(C) Magnetic switch
SC-00077
(A) (B)
(C)
12V +
AV
BS
M

EN(H4SO)-7
ENGINE (DIAGNOSTIC)
General Description
 The antenna feeder must be placed as far
apart as possible from the ECM and MFI har-
ness.
 Carefully adjust the antenna for correct
matching.
 When mounting a large power type radio, pay
special attention to the three items above men-
tioned.
 Incorrect installation of the radio may affect
the operation of the ECM.
13) Before disconnecting the fuel hose, disconnect
the fuel pump connector and crank the engine for
more than five seconds to release pressure in the
fuel system. If engine starts during this operation,
run it until it stops.
14) Problems in the electronic-controlled automatic
transmission may be caused by failure of the en-
gine, the electronic control system, the transmis-
sion proper, or by a combination of these. These
three causes must be distinguished clearly when
performing diagnostics.
15) Diagnostics should be conducted by rotating
with simple, easy operations and proceeding to
complicated, difficult operations. The most impor-
tant thing in diagnostics is to understand the cus-
tomer’s complaint, and distinguish between the
three causes.
16) In AT models, do not continue the stall for more
than five seconds. (from closed throttle, fully open
throttle to stall engine speed.)
17) On the model with ABS, when performing driv-
ing test in jacked-up or lifted-up position, some-
times the warning light may be lit, but this is not a
malfunction of the system. The reason for this is the
speed difference between the front and rear
wheels. After diagnosis of engine control system,
perform the ABS memory clearance procedure of
self-diagnosis function.
B: INSPECTION
Before performing diagnostics, check the following
items which might affect engine problems:
1. BATTERY
1) Measure battery voltage and specific gravity of
electrolyte.
Standard voltage: 12 V
Specific gravity: Above 1.260
2) Check the condition of the main and other fuses,
and harnesses and connectors. Also check for
proper grounding.
2. ENGINE GROUND
Make sure the engine grounding terminal is proper-
ly connected to the engine.
C: NOTE
1. GENERAL DESCRIPTION
 On-board diagnosis (OBD) system detects and
indicates a fault in various inputs and outputs of the
complex electronic control. Malfunction indicator
light in the combination meter indicates occurrence
of a fault or trouble.
 Further, against such a failure or sensors as may
disable the drive, the fail-safe function is provided
to ensure the minimal driveability.
 The OBD system incorporated with the vehicles
within this engine family complies with Section
1968.1, California Code of Regulations (OBD-II
regulation). The OBD system monitors the compo-
nents and the system malfunction listed in Engine
Section which affects on emissions.
 When the system decides that a malfunction oc-
curs, malfunction indicator light illuminates. At the
same time of the malfunction indicator light illumi-
nation or blinking, the DTC and a freeze frame en-
gine conditions are stored into on-board computer.
 The OBD system stores freeze frame engine
condition data (engine load, engine coolant tem-
perature, fuel trim, engine speed and vehicle
speed, etc.) into on-board computer when it detects
a malfunction first.
 If the OBD system detects the various malfunc-
tions including the fault of fuel trim or misfire, the
OBD system first stores freeze frame engine condi-
tions about the fuel trim or misfire.
 When the malfunction does not occur again for
three consecutive driving cycles, malfunction indi-
cator light is turned off, but DTC remains at on-
board computer.
 The OBD-II system is capable of communication
with a general scan tool (OBD-II general scan tool)
formed by ISO 9141 CARB.
EN-00153