torque SUBARU FORESTER 2004 Service Repair Manual

SP(H4SO)-2
SPEED CONTROL SYSTEM
General Description
1. General Description
A: SPECIFICATION
B: COMPONENT
1. LHD MODEL
Accelerator pedalFree play At pedal pad 0 — 4 mm (0 — 0.16 in)
Stroke At pedal pad 52 — 57 mm (2.05 — 2.24 in)
(1) Accelerator bracket (7) Accelerator pedal lever (13) Kick-down switch (AT model)
(2) Stopper (8) Spring pin
(3) Bushing (9) Accelerator pedalTightening torque: N
⋅m (kgf-m, ft-lb)
(4) Clip (10) Accelerator stopperT1: 12 (1.2, 9.0)
(5) Accelerator spring (11) Accelerator plateT2: 18 (1.8, 13.0)
(6) Accelerator pedal spring (12) Clip
(8) (1)
(2)
(3)
(4)
(6)(13) (5)
(9) (10)(7)
(12) (11)
T2
T1
SP-00021

SP(H4SO)-3
SPEED CONTROL SYSTEM
General Description
2. RHD MODEL
C: CAUTION
 Wear work clothing, including a cap, protective
goggles, and protective shoes during operation.
 Remove contamination, including dirt and corro-
sion, before removal, installation or disassembly.
 Keep the disassembled parts in order and pro-
tect them from dust and dirt.
 Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly, and replacement.
 Be careful not to burn yourself, because each
part in the vehicle is hot after running.
 Be sure to tighten fasteners including bolts and
nuts to the specified torque.
 Place shop jacks or rigid racks at the specified
points.
 Before disconnecting electrical connectors of
sensors or units, be sure to disconnect the ground
cable from battery.
(1) Accelerator bracket (6) Spring pin (11) Kick-down switch (AT model)
(2) Stopper (7) Accelerator spring
(3) Accelerator pedal lever (8) BushingTightening torque: N
⋅m (kgf-m, ft-lb)
(4) Accelerator pedal spring (9) ClipT1: 12 (1.2, 9.0)
(5) Accelerator pedal (10) Accelerator stopperT2: 18 (1.8, 13.0)
SP-00022
(1)
(2)(3)
(11)
(8)
(7) (9)
(6)(4)
(5)
(10)
T1
T2

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)-7
SPEED CONTROL SYSTEM
Accelerator Pedal
E: INSPECTION
1. ACCELERATOR PEDAL
Lightly move the pedal pad in lateral direction to en-
sure that pedal deflection is in specified range.
CAUTION:
If excessive deflection is noted, replace the
bushing and clip with new ones.
Deflection of accelerator pedal:
Service limit
±2.0 mm (±0.079 in) or less
2. KICK-DOWN SWITCH
If the kick-down switch does not operate properly
(or if it does not stop at the specified position), re-
place with a new one.
Specified position: A
2.0 — 3.5 mm (0.079 — 0.098 in)
F: ADJUSTMENT
1) Check the pedal stroke and free play by operat-
ing accelerator pedal by hand.
2) If it is not within specified value, adjust it by turn-
ing the nut connecting the accelerator cable to
throttle body.
Free play at pedal pad: L
0 — 4 mm (0 — 0.16 in)
Stroke at pedal pad: A
52 — 57 mm (2.05 — 2.24 in)
Accelerator cable lock nut tightening torque:
12 N
⋅m (1.2 kgf-m, 9 ft-lb)
3) Check to ensure the kick-down switch operates
at the specified value in relation to the stroke of the
accelerator pedal.
If it is not within specified value, adjust it by adjust-
ing the position of kick-down switch.
CAUTION:
Be careful not to rotate the kick-down switch.
Kick-down switch stroke: L
47 — 49 mm (1.85 — 1.93 in)
SP-00013
SP-00026
A
(A) Accelerator pedal
(B) Accelerator pedal bracket
SP-00027
(A)
L
A (B)

SP(H4SO)-8
SPEED CONTROL SYSTEM
Accelerator Pedal
Kick-down switch tightening torque:
12 N
⋅m (1.2 kgf-m, 9 ft-lb)
(A) Kick down switch
SP-00028 (A)
L
OFF
ON

IG(H4SO)-3
IGNITION
General Description
B: COMPONENT
(1) Spark plug (4) Spark plug cord (#2, #4)Tightening torque: N⋅m (kgf-m, ft-lb)
(2) Spark plug cord (#1, #3)T1: 21 (2.1, 15.2)
(3) Ignition coil & ignitor ASSYT2: 6.4 (0.65, 4.7)
IG-00042

IG(H4SO)-4
IGNITION
General Description
C: CAUTION
 Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
 Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
 Keep the disassembled parts in order and pro-
tect them from dust or dirt.
 Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly, and replacement.
 Be careful not to burn yourself, because each
part on the vehicle is hot after running.
 Be sure to tighten fasteners including bolts and
nuts to the specified torque.
 Place shop jacks or rigid racks at the specified
points.
 Before disconnecting electrical connectors of
sensors or units, be sure to disconnect the ground
cable from battery.

IG(H4SO)-6
IGNITION
Spark Plug
6) Remove the spark plugs with spark plug sock-
ets.
B: INSTALLATION
1. RH SIDE
Install in the reverse order of removal.
Tightening torque (Spark plug):
21 N
⋅m (2.1 kgf-m, 15.2 ft-lb)
NOTE:
The above torque should be only applied to new
spark plugs without oil on their threads.
In case their threads are lubricated, the torque
should be reduced by approx. 1/3 of the specified
torque in order to avoid over-stressing.
2. LH SIDE
Install in the reverse order of removal.
Tightening torque (Spark plug):
21 N
⋅m (2.1 kgf-m, 15.2 ft-lb)
NOTE:
The above torque should be only applied to new
spark plugs without oil on their threads.
In case their threads are lubricated, the torque
should be reduced by approx. 1/3 of the specified
torque in order to avoid over-stressing.
C: INSPECTION
Check the electrodes and inner and ceramic insu-
lator of plugs, noting the type of deposits and the
degree of electrode erosion.
1) Normal:
Brown to grayish-tan deposits and slight electrode
wear indicates correct spark plug heat range.
2) Carbon fouled:
Dry fluffy carbon deposits on insulator and elec-
trode are mostly caused by slow speed driving in
city, weak ignition, too rich fuel mixture, dirty air
cleaner, etc.
It is advisable to replace with plugs having hotter
heat range.
IG-00022
(A) Electrode gap
(B) Carbon accumulation or wear
(C) Cracks
(D) Damage
(E) Damaged gasket
IG-00023
(A)
(B)
(C)
(D)
(E)
IG-00024
IG-00025

IG(H4SO)-8
IGNITION
Ignition Coil & Ignitor Assembly
3. Ignition Coil & Ignitor Assem-
bly
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Disconnect the spark plug cords from ignition
coil & ignitor assembly.
3) Disconnect the connector from ignition coil & ig-
nitor assembly.
4) Remove the ignition coil & ignitor assembly.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
6.4 N
⋅m (0.65 kgf-m, 4.7 ft-lb)
C: INSPECTION
Using the accurate tester, inspect the secondary
coil resistance, and replace if defective.
CAUTION:
 If the resistance is extremely low, this indi-
cates the presence of a short-circuit.
 Ignitor is integrated in coil. Therefore, prima-
ry coil resistance can not be measured.
Specified resistance:
[Secondary side]
Between (A) and (B)
12.8 k
Ω±15%
Between (C) and (D)
12.8 k
Ω±15%
Insulation between primary terminal and case: 100
MΩ or more.
FU-00009
IG-00043
IG-00044
IG-00044
IG-00045
(C)
(A)
(D)
(B)

SC(H4SO)-2
STARTING/CHARGING SYSTEM
General Description
1. General Description
A: SPECIFICATION
Item Designation
StarterType Reduction type
Vehicle type MT model AT model
Model M000T30471 M000T20171
Manufacturer Mitsubishi Electric
Voltage and output 12 V — 1.0 kW 12 V — 1.4 kW
Direction of rotation Counterclockwise (viewed from pinion gear side)
Number of pinion teeth 8 9
No-load charac-
teristicsVo l t a g e 1 1 V
Current 95 A or less 90 A or less
Rotating speed 2,500 rpm or more 2,000 rpm or more
Load character-
isticsVoltage 7.5 V 7.7 V
Current 300 A 400 A
Torque 8.84 N (0.90 kgf, 1.99 lb) or more 16.7 N (1.70 kgf, 3.75 lb) or more
Rotating speed 870 rpm or more 710 rpm or more
Lock character-
isticsVo l t a g e 4 V 3 . 5 V
Current 680 A or less 960 A or less
Torque 17 N (1.73 kgf, 12.5 lb) or more 31 N (3.16 kgf, 22.9 lb) or more
GeneratorTy p eRotating-field three-phase type, Voltage regulator built-in type, with load
response control system
ModelEC, EK model: A002TG0391
Other model: A002TB6991
Manufacturer Mitsubishi Electric
Voltage and output 12 V — 90 A
Polarity on ground side Negative
Rotating direction Clockwise (viewed from pulley side)
Armature connection 3-phase Y-type
Output currentEC, EK model1,500 rpm — 40 A or more
2,500 rpm — 74 A or more
5,000 rpm — 84 A or more
Other model1,500 rpm — 36 A or more
2,500 rpm — 65 A or more
5,000 rpm — 86 A or more
Regulated voltage 14.1 — 14.8 V [20°C (68°F)]