steering SUBARU FORESTER 2004 Service Workshop Manual

FU(H4SO)-15
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
(7) Place the power steering pump on the right
side wheel apron.
8) Disconnect the spark plug cords from the spark
plugs.
9) Disconnect the PCV hose from the intake mani-
fold.
10) Disconnect the engine coolant hose (A) from
the throttle body.
11) Disconnect the brake booster hose.12) Remove the air cleaner case stay RH and en-
gine harness bracket, and disconnect the engine
harness connectors from the bulkhead harness
connectors.
13) Disconnect the connectors from the engine
coolant temperature sensor.
14) Disconnect the knock sensor connector.
15) Disconnect the connector from the crankshaft
position sensor.
FU-00021
FU-00141
FU-00361
(A)(A)
FU-00143
FU-00258
FU-00145
FU-00062
FU-00056

FU(H4SO)-18
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
10) Connect the brake booster hose.
11) Connect the engine coolant hose (A) to the
throttle body.
12) Connect the PCV hose to the intake manifold.
13) Connect the spark plug cords to the spark
plugs.
14) Install the power steering pump and reservoir
tank to bracket.
(1) Install the reservoir tank to bracket.(2) Connect the connector to the power steering
pump switch.
(3) Tighten the bolts which install power steer-
ing pump bracket.
Tightening torque:
22 N
⋅m (2.2 kgf-m, 15.9 ft-lb)
(4) Install the power steering pipes onto the
right side intake manifold protector.
(5) Install the front side V-belt. ME(H4SO)-43, INSTALLATION, V-belt.>
FU-00143
FU-00361
(A)(A)
FU-00141
FU-00020
FU-00017
FU-00139
FU-00255

FU(H4SO)-35
FUEL INJECTION (FUEL SYSTEM)
Fuel Injector
13.Fuel Injector
A: REMOVAL
1. RH SIDE
1) Release the fuel pressure.
PRESSURE, OPERATION, Fuel.>
2) Open the fuel flap lid, and remove the fuel filler
cap.
3) Disconnect the ground cable from battery.
4) Remove the resonator chamber. IN(H4SO)-8, REMOVAL, Resonator Chamber.>
5) Remove the spark plug cords from the spark
plugs (#1 and #3 cylinders).6) Remove the power steering pump and reservoir
tank from the brackets.
(1) Remove the front side V-belt. ME(H4SO)-43, REMOVAL, V-belt.>
(2) Remove the bolts which hold the power
steering pipes onto the intake manifold protec-
tor.
(3) Remove the bolts which install the power
steering pump to the bracket.
(4) Disconnect the connector from the power
steering pump switch.
FU-00009
FU-00302
FU-00255
FU-00139
FU-00017

FU(H4SO)-36
FUEL INJECTION (FUEL SYSTEM)
Fuel Injector
(5) Remove the power steering tank from the
bracket by pulling it upwards.
(6) Place the power steering pump and reser-
voir tank on the right side wheel apron.
7) Remove the fuel pipe protector RH.
8) Disconnect the connector from fuel injector.9) Remove the bolts which holds the fuel injector
pipe to the intake manifold.
10) Remove the fuel injector from the intake mani-
fold.
(1) Remove the fuel injector securing clip.
(2) Remove the fuel injector while lifting up the
fuel injector pipe.
FU-00020
FU-00021
FU-00267
FU-00303
FU-00284
FU-00304
FU-00305
FU-00306

ME(H4SO)-35
MECHANICAL
Engine Assembly
(4) Engine harness connectors
(5) Generator connector, terminal and A/C
compressor connector
(6) Accelerator cable (A) and cruise control ca-
ble (B)(7) Pressure switch
12) Disconnect the following hoses.
(1) Brake booster vacuum hose
(2) Heater inlet and outlet hose
(3) Heater inlet and outlet hose (with ATF
warmer model)
13) Remove the power steering pump from brack-
et.
(1) Remove the resonator chamber.
(A) Generator connector and terminal
(B) A/C compressor connector
ME-00207
ME-00208
(A)
(B)
(B)(A)
ME-00328
FU-00017
ME-00329
ME-00330
ME-02009

ME(H4SO)-36
MECHANICAL
Engine Assembly
(2) Loosen the lock bolt and slider bolt, and
then remove the front side V-belt. ME(H4SO)-43, FRONT SIDE BELT, REMOV-
AL, V-belt.>
(3) Remove the pipe with bracket.
(4) Remove the bolts which install power steer-
ing pump bracket.
(5) Remove the reservoir tank from bracket by
pulling it upward.
(6) Place the power steering pump on right side
wheel apron.14) Remove the front and center exhaust pipe.
Pipe.>
15) Remove the nuts which hold lower side of
transmission to engine.
16) Remove the nuts which install front cushion
rubber onto front crossmember.
17) Separate the torque converter clutch from drive
plate. (AT model)
(1) Lower the vehicle.
(2) Remove the service hole plug.
(3) Remove the bolts which hold torque con-
verter clutch to drive plate.
(4) Remove other bolts while rotating the en-
gine using socket wrench.
ME-00331
FU-00139
FU-00020
FU-00140ME-00210
ME-00211
ME-00212

ME(H4SO)-39
MECHANICAL
Engine Assembly
(1) Tighten the bolts which hold torque convert-
er clutch to drive plate.
(2) Tighten other bolts while rotating the engine
by using a socket wrench.
NOTE:
Be careful not to drop the bolts into torque convert-
er clutch housing.
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
(3) Plug up the service hole and prevent foreign
matters from getting in.
10) Install the power steering pump on bracket.
(1) Install the reservoir tank on bracket.
(2) Install the power steering pump on bracket,
and then tighten the bolts.
Tightening torque:
20.1 N
⋅m (2.05 kgf-m, 14.8 ft-lb)(3) Tighten the bolts which install power steer-
ing pump bracket, and then install the spark plug
cords.
(4) Connect the power steering switch connec-
tor.
(5) Install the front side V-belt, and adjust it.
STALLATION, V-belt.>
(6) Install the resonator chamber.
Tightening torque:
33 N
⋅m (3.4 kgf-m, 24.6 ft-lb)
ME-00212
FU-00020
FU-00139
ME-00331
FU-00017
IN-00044

ME(H4SO)-40
MECHANICAL
Engine Assembly
11) Tighten the nuts which hold lower side of trans-
mission to engine.
Tightening torque:
50 N
⋅m (5.1 kgf-m, 36.9 ft-lb)
12) Tighten the nuts which install front cushion rub-
ber onto crossmember.
Tightening torque:
85 N
⋅m (8.7 kgf-m, 63 ft-lb)
NOTE:
Make sure the front cushion rubber mounting bolts
(A) and locator (B) are securely installed.
13) Install the front and center exhaust pipe. to EX(H4SO)-8, INSTALLATION, Front Exhaust
Pipe.>
14) Connect the following hoses.
(1) Fuel delivery hose, return hose and evapo-
ration hose
(2) Heater inlet and outlet hoses
(3) Brake booster vacuum hose
15) Connect the following connectors.
(1) Engine ground cables
Tightening torque:
14 N
⋅m (1.4 kgf-m, 10.1 ft-lb)
(2) Engine harness connectors
(3) Generator connector and terminal
(4) A/C compressor connectors
(5) Power steering pressure switch
16) Connect the following cables.
(1) Accelerator cable
(2) Cruise control cable (With cruise control)
17) Adjust each connected cable.18) Install the air cleaner case stay.
Tightening torque:
16 N
⋅m (1.6 kgf-m, 11.6 ft-lb)
19) Install the A/C pressure hoses. INSTALLATION, Hose and Tube.>
20) Install the radiator to vehicle. CO(H4SO)-30, INSTALLATION, Radiator.>
21) Install the air intake duct and air cleaner case.
Duct.> Cleaner Case.>
22) Install the under cover.
23) Install battery in the vehicle, and then connect
the cables.
24) Fill engine coolant.
COOLANT, REPLACEMENT, Engine Coolant.>
25) Check the ATF level and correct if necessary.
(AT model)
mission Fluid.>
26) Charge the A/C system with refrigerant. to AC-27, OPERATION, Refrigerant Charging Pro-
cedure.>
27) Remove the front hood stay, and then close the
front hood.
28) Take off the vehicle from lift arms.
C: INSPECTION
1) Make sure the pipes and hoses are installed cor-
rectly.
2) Make sure the engine coolant and ATF are at
specified levels.
ME-00219
ME-00056
(A)
(A)(B)
(B)

ME(H4SO)-44
MECHANICAL
V-belt
2) Tighten the lock nut (A).
Tightening torque:
Lock nut (A)
22.6 N
⋅m (2.3 kgf-m, 16.6 ft-lb)
C: INSPECTION
1) Replace the belts, if cracks, fraying or wear is
found.
2) Check the drive belt tension and adjust it if nec-
essary by changing the generator installing position
or idler pulley installing position.
Belt tension
(A)
replaced: 7 — 9 mm (0.276 — 0.354 in)
reused: 9 — 11 mm (0.354 — 0.433 in)
(B)
replaced: 7.5 — 8.5 mm (0.295 — 0.335 in)
reused: 9.0 — 10.0 mm (0.354 — 0.394 in)
C/P Crank pulley
GEN Generator
P/S Power steering oil pump pulley
A/C Air conditioning compressor pulley
I/P Idler pulley
ME-00224
(A) (B)
ME-00226
(A) (B)(C)GEN
C/P
I/P A/C
P/S

CO(H4SO)-29
COOLING
Radiator
14) Detach the power steering hose from clip on ra-
diator.
15) Lift the radiator up and away from the vehicle.
2. TURBO MODEL
WARNING:
The radiator is pressurized. Wait until the en-
gine cools down before working on the radia-
tor.
1) Set the vehicle on a lift.
2) Disconnect the ground cable from battery.
3) Lift-up the vehicle.
4) Remove the under cover.
5) Drain the engine coolant completely. CO(H4SO)-19, DRAINING OF ENGINE COOL-
ANT, REPLACEMENT, Engine Coolant.>
6) Disconnect the connectors of radiator main fan
motor (A) and sub fan motor (B).7) Disconnect the radiator outlet hose from thermo-
stat cover.
8) Disconnect the ATF cooler hose from ATF pipe.
(AT model) Plug the opennings in the hose and ra-
diator with caps in order to prevent ATF from leak-
ing.
9) Disconnect the oil cooler hose from oil cooler
pipe. (MT model with oil cooler)
Install the cap to prevent oil from leaking.
10) Lower the vehicle.
11) Remove the V-belt covers.
12) Disconnect the overflow hose.
CO-00037
FU-00009
CO-00013
(A)(B)
CO-00030
CO-00034
SC-00096