light SUBARU FORESTER 2004 Service Repair Manual

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-41
PERIODIC MAINTENANCE SERVICE
Steering System (Power Steering)
26.Steering System (Power
Steering)
A: INSPECTION
1. STEERING WHEEL
1) Set the steering wheel in a straight-ahead posi-
tion, and check the wheel spokes to make sure
they are correctly set in their specified positions.
2) Lightly turn the steering wheel to the right and
left to determine the point where front wheels start
to move.
Measure the distance of the movement of steering
wheel at the outer periphery of wheel.
Steering wheel free play:
0 — 17 mm (0 — 0.67 in)
Move the steering wheel vertically toward the shaft
to ascertain if there is play in the direction.
Maximum permissible play:
0.5 mm (0.020 in)
3) Drive the vehicle and check the following items.
(1) Steering force:
The effort required for steering should be
smooth and even at all points, and should not
vary.
(2) Pull to one side:
Steering wheel should not be pulled to either
side while driving on a level surface.
(3) Wheel runout:
Steering wheel should not be runout.
(4) Return factor:
Steering wheel should return to its original posi-
tion after it has been turned and then released.
2. STEERING SHAFT JOINT
When the steering wheel free play is excessive,
disconnect the universal joint of steering shaft and
check it for any play and yawing torque (at the point
of the crossing direction). Also inspect for any dam-
age to sealing or worn serrations. If the joint is
loose, retighten the mounting bolts to the specified
torque.
Tightening torque:
24 N·m (2.4 kgf-m, 17.4 ft-lb)
3. GEARBOX
1) With wheels placed in the direction of straight
ahead, turn the steering wheel 90° in both the right
and left directions.
While the steering wheel is being rotated, check for
looseness in gearbox.
Tightening torque:
59 N·m (6.0 kgf-m, 43.4 ft-lb)
2) Check the boot for damage, cracks or deteriora-
tion.
3) With the vehicle on a level surface, quickly turn
the steering wheel to the right and left.
While the steering wheel is being rotated, check the
gear backlash. If any unusual noise is noticed, ad-
just the gear backlash in the following manner.
(1) Tighten the adjusting screw to 7.4 N·m (0.75
kgf-m, 5.4 ft-lb) and then loosen. Repeat this op-
eration twice.
(A) Steering wheel free play
PM-00065
(A)
SUBARUSRS AIRBAG
(A) Boot
(B) Gear box mounting bolt
PM-00066
PM-00067
(A)
(B)

ME(H4SO)-23
MECHANICAL
General Description
2. GENERAL TOOL
499817100 ENGINE STAND  Stand used for engine disassembly and
assembly.
 Used with ENGINE STAND ADAPTER RH
(498457000) & LH (498457100).
499977100 CRANK PULLEY
WRENCHUsed for stopping rotation of crank pulley when
loosening and tightening crank pulley bolts. (2.5
L model)
499977400 CRANK PULLEY
WRENCHUsed for stopping rotation of crank pulley when
loosening and tightening crank pulley bolts. (2.0
L model)
499987500 CRANKSHAFT
SOCKETUsed for rotating crankshaft.
TOOL NAME REMARKS
Compression gauge Used for measuring compression.
Tachometer (secondary pick-up type) Used for measuring idle speed.
Timing light Used for measuring ignition timing.ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-499817100
ST-499977100
ST-499977400
ST-499987500

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)-27
MECHANICAL
Ignition Timing
4. Ignition Timing
A: INSPECTION
CAUTION:
After warming-up, engine becomes very hot. Be
careful not to burn yourself during measure-
ment.
1) Warm-up the engine.
2) To check the ignition timing, connect a timing
light to #1 cylinder spark plug cord, and illuminate
the timing mark with timing light.
3) Start the engine at idle speed and check the ig-
nition timing.
Ignition timing [BTDC/rpm]:
10
°±10°/650
If the timing is not correct, check the ignition control
system. Procedure.>
ME-00194

ME(H4SO)-29
MECHANICAL
Engine Oil Pressure
6. Engine Oil Pressure
A: INSPECTION
1) Disconnect the ground cable from battery.
2) Remove the generator from bracket. SC(H4SO)-15, REMOVAL, Generator.>
3) Disconnect the connector from oil pressure
switch.
4) Remove the oil pressure switch from cylinder
block. sure Switch.>
5) Connect the oil pressure gauge hose to cylinder
block.
6) Connect the battery ground cable to battery.
7) Start the engine, and then measure the oil pres-
sure.
Oil pressure:
Standard:
88 kPa (0.9 kg/cm
2, 13 psi) or more at 800 rpm
294 kPa (3.0 kg/cm2, 43 psi) or more at 5,000
rpmCAUTION:
 If the oil pressure is out of specification,
check the oil pump, oil filter and lubrication
line. gine Lubrication System Trouble in General.>
 If the oil pressure warning light is turned ON
and oil pressure is in specification, replace the
oil pressure switch. SPECTION, Engine Lubrication System Trouble
in General.>
NOTE:
The specified data is based on an engine oil tem-
perature of 80°C (176°F).
8) After measuring the oil pressure, install the oil
pressure switch. LATION, Oil Pressure Switch.>
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
9) Install the generator and V-belt in the reverse or-
der of removal, and then adjust the V-belt deflec-
tion. belt.>
FU-00009
FU-00009
ME-00196

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)-65
MECHANICAL
Cylinder Head
(5) Compress the valve spring, and then fit the
valve spring retainer key.
(6) After installing, tap the valve spring retainers
lightly with plastic hammer for better seating.
E: INSPECTION
1. VALVE SPRING
1) Check the valve springs for damage, free length,
and tension. Replace the valve spring if it is not
within the standard value presented in the table.
2) To measure the squareness of valve spring,
stand the spring on a surface plate and measure its
deflection at the top using a try square.
2. INTAKE AND EXHAUST VALVE OIL
SEAL
In the following case, pinch and remove the oil seal
from valve using pliers, and then replace it with a
new one.
 When the lip is damaged.
 When the spring is out of the specified position. When readjusting the surfaces of intake valve
and valve sheet.
 When replacing the intake valve guide.
1) Place the cylinder head on ST1.
2) Using ST2, press-fit the oil seal.
CAUTION:
 Apply engine oil to oil seal before press-fit-
ting.
 When press-fitting oil seal, do not use ham-
mer or strike in.
 Differentiate between intake valve oil seal
and exhaust valve oil seal by noting their differ-
ence in color.
ST1 498267800 CYLINDER HEAD TABLE
ST2 498857100 VALVE OIL SEAL GUIDE
Color of rubber part:
Intake [Black]
Exhaust [Brown]
Color of spring part:
Intake [Silver]
Exhaust [Silver]
F: ADJUSTMENT
1. CYLINDER HEAD
1) Make sure that no crack or other damage exists.
In addition to visual inspection, inspect important
areas by means of red lead check.
Also make sure that gasket installing surface
shows no trace of gas and water leaks.
2) Place the cylinder head on ST.
ST 498267800 CYLINDER HEAD TABLE
3) Measure the warping of the cylinder head sur-
face that mates with crankcase using a straight
edge and thickness gauge.
If the warping exceeds the limit, regrind the surface
with a surface grinder.
Warping limit:
0.05 mm (0.0020 in)
Grinding limit:
0.1 mm (0.004 in)
Standard height of cylinder head:
97.5 mm (3.839 in)
(A) Retainer
(B) Valve spring
Free length 54.30 mm (2.1378 in)
Squareness 2.5°, 2.4 mm (0.094 in)
Tension/spring
height215 — 246 N
(21.9 — 25.1 kgf, 48.2 — 55.3 lb)/
45.0 mm (1.772 in)
527 — 582 N
(53.7 — 59.3 kgf, 118.1 — 130.8 lb)/
34.7 mm (1.366 in)
ME-00282
(B)(B)
(A)
ME-00283
ME-00284
ST1
ST2

ME(H4SO)-67
MECHANICAL
Cylinder Head
(2) Insert the ST2 into valve guide and press it
down to remove valve guide.
ST1 498267800 CYLINDER HEAD TABLE
ST2 499767200 VALVE GUIDE REMOVER
(3) Turn the cylinder head upside down and
place ST as shown in the figure.
Intake side:
ST 499767700 VALVE GUIDE ADJUSTER
Exhaust side:
ST 499767800 VALVE GUIDE ADJUSTER
(4) Before installing new oversize valve guide,
make sure that neither scratches nor damages
exist on the inside surface of valve guide holes
in cylinder head.
(5) Put new valve guide, coated with sufficient
oil, in the cylinder, and then insert the ST1 into
valve guide. Press in until the valve guide upper
end is flush with the upper surface of ST2.ST1 499767200 VALVE GUIDE REMOVER
Intake side:
ST2 499767700 VALVE GUIDE ADJUSTER
Exhaust side:
ST2 499767800 VALVE GUIDE ADJUSTER
(6) Check the valve guide protrusion.
Valve guide protrusion: L
Intake
20.0 — 20.5 mm (0.787 — 0.807 in)
Exhaust
16.5 — 17.0 mm (0.650 — 0.669 in)
(7) Ream the inside of valve guide with ST.
Gently rotate the reamer clockwise while press-
ing it lightly into valve guide, and return it also ro-
tating clockwise. After reaming, clean the valve
guide to remove chips.
CAUTION:
 Apply engine oil to the reamer when reaming.
 If the inner surface of the valve guide is torn,
the edge of the reamer should be slightly
ground with an oil stone.
 If the inner surface of the valve guide be-
comes lustrous and the reamer does not chips,
use a new reamer or remedy the reamer.
(A) Valve guide
ME-00290
ST2
ST1
(A)
ME-00291
ST
(A) Valve guide
ST2
ME-00292
ST1
ME-00293(A)L