torque SUBARU FORESTER 2004 Service Repair Manual

CL-16
CLUTCH SYSTEM
Clutch Disc and Cover
2. Clutch Disc and Cover
A: REMOVAL
1) Remove the transmission assembly from vehicle
body. mission Assembly.>
2) Install the ST on flywheel.
ST 499747100 CRANKSHAFT STOPPER
3) Remove the clutch cover and clutch disc.
NOTE:
 Take care not to allow oil on the clutch disc fac-
ing.
 Do not disassemble either the clutch cover or
clutch disc.
B: INSTALLATION
1) Insert the ST into clutch disc and install them on
the flywheel by inserting the ST end into pilot bear-
ing.
NOTE:
When installing the clutch disc, be careful to its di-
rection.
ST 499747100 CLUTCH DISC GUIDE2) Position “0” marks on clutch cover and flywheel
120° apart, and then tighten the clutch cover instal-
lation bolts diagonally.
NOTE:
 “0” marks indicate the directions of residual un-
balance.
 Temporarily tighten the bolts by hand. Each bolt
should be tightened to the specified torque in a
crisscross fashion.
Tightening torque:
16 N
⋅m (1.6 kgf-m, 11.6 ft-lb)
3) Remove the ST.
ST 499747100 CLUTCH DISC GUIDE
4) Install the transmission assembly. 36, INSTALLATION, Manual Transmission Assem-
bly.>
(A) Clutch cover
(A) Flywheel side
CL-00011
(A)
ST
CL-00012
(A)
ST
(A) “0” marks
CL-00013 (A)ST(2)
(5)
(3)(1)
(6)
(4)

CL-19
CLUTCH SYSTEM
Flywheel
3. Flywheel
A: REMOVAL
1) Remove the transmission assembly. 5MT-32, REMOVAL, Manual Transmission As-
sembly.>
2) Remove the clutch cover and clutch disc. to CL-16, REMOVAL, Clutch Disc and Cover.>
3) Using the ST, remove the flywheel.
ST 498497100 CRANKSHAFT STOPPER
B: INSTALLATION
1) Install the flywheel and ST.
ST 498497100 CRANKSHAFT STOPPER2) Tighten the flywheel attaching bolts to the spec-
ified torque.
NOTE:
Tighten the flywheel installing bolts gradually. Each
bolt should be tightened to the specified torque in a
crisscross fashion.
Tightening torque:
72 N
⋅m (7.3 kgf-m, 52.8 ft-lb)
3) Install the clutch disc and cover. INSTALLATION, Clutch Disc and Cover.>
4) Install the transmission assembly. 36, INSTALLATION, Manual Transmission Assem-
bly.>
C: INSPECTION
CAUTION:
Since this bearing is grease sealed and is of a
non-lubrication type, do not wash with gasoline
or any solvent.
1) Damage of facing and ring gear
If defective, replace the flywheel.
2) Smoothness of rotation
Rotate the ball bearing applying pressure in thrust
direction.
3) If noise or excessive play is noted, replace the
flywheel.
(A) Flywheel
CL-00019ST (A)
CL-00020ST
(A) Flywheel
(B) Ring gear
CL-00021
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
CL-00022
(B)
(A)

CL-22
CLUTCH SYSTEM
Release Bearing and Lever
4) Insert the release fork shaft into release fork.
NOTE:
Make sure the cutout portion of release fork shaft
contacts spring pin.
5) Tighten the plug.
Tightening torque:
44 N
⋅m (4.5 kgf-m, 32.5 ft-lb)
6) Move the release fork to ensure that release
bearing and release fork move smoothly.
7) Install the transmission assembly. 36, INSTALLATION, Manual Transmission Assem-
bly.>
C: INSPECTION
1. RELEASE BEARING
CAUTION:
Since this bearing is grease sealed and is of a
non-lubrication type, do not wash with gasoline
or any solvent when servicing the clutch.
1) Check the bearing for smooth movement by ap-
plying force in the radial direction.
Radial direction stroke:
1.6 mm (0.063 in)
2) Check the bearing for smooth rotation by apply-
ing pressure in the thrust direction.
3) Check wear and damage of the bearing case
surface contacting with lever.
(A) Release fork
(B) Release shaft
(C) Spring pin
CL-00030
(A) (B)
(C)
CL-00031
(A) Bearing case
(A) Bearing case
CL-00032
(A)
CL-00160
(A)

CL-25
CLUTCH SYSTEM
Operating Cylinder
B: INSTALLATION
1) Apply grease (SUNLIGHT 2: Part No.
003602010) to the contact point of the release lever
and operating cylinder.
2) Install in the reverse order of removal.
Before installing the operating cylinder, apply
grease (SUNLIGHT 2: Part No. 003602010) to con-
tact point of the release lever and operating cylin-
der.
Tightening torque:
T1: 18 N
⋅m (1.8 kgf-m, 13.0 ft-lb)
T2: 37 N
⋅m (3.8 kgf-m, 27.5 ft-lb)
 NON-TURBO model
 TURBO modelNOTE:
 Be sure to install the clutch hose with the mark
side facing upward.
 Be careful not to twist the clutch hose during in-
stallation.
3) After bleeding air from the operating cylinder,
ensure that clutch operates properly.

C: INSPECTION
1) Check the operating cylinder for damage. If op-
erating cylinder is damaged, replace it.
2) Check the operating cylinder for fluid leakage or
damage on boot. If any leakage or damage is
found, replace the operating cylinder.
T2
CL-00039T2
T1
CL-00040
T2
T1
(A) Marking
(B) Clutch hose
(C) Operating cylinder
CL-00041
(A)
(B) (C)

CL-26
CLUTCH SYSTEM
Master Cylinder
6. Master Cylinder
A: REMOVAL
1) Thoroughly drain the brake fluid from reservoir
tank.
2) Remove the snap pin, clevis pin and separate
the push rod of master cylinder from clutch pedal.
3) Remove the air cleaner case and air intake duct
(Non-turbo model). AL, Air Cleaner Case.> MOVAL, Air Intake Duct.>
4) Remove the intercooler (Turbo model). IN(H4DOTC)-10, REMOVAL, Intercooler.>
5) Remove the clutch pipe from master cylinder.
6) Remove the master cylinder with reservoir tank.
CAUTION:
Be extremely careful not to spill brake fluid.
Brake fluid spilt on the vehicle body will harm
the paint surface; wipe it off quickly if spilt.
B: INSTALLATION
1) Install the master cylinder to body, and install the
clutch pipe to master cylinder.
NOTE:
Check that the pipe is routed properly.
Tightening torque:
T1: 15 N
⋅m (1.5 kgf-m, 10.8 ft-lb)
T2: 18 N
⋅m (1.8 kgf-m, 13.0 ft-lb)
2) Apply a coat of grease to the clevis pin.
3) Connect the push rod of master cylinder to
clutch pedal, and install the new clevis pin and
snap pin.
4) After bleeding air from the system, ensure that
clutch operates properly.

5) Install the air cleaner case and air intake duct
(Non-turbo model). LATION, Air Cleaner Case.> INSTALLATION, Air Intake Duct.>
6) Install the intercooler (Turbo model). IN(H4DOTC)-11, INSTALLATION, Intercooler.>
(A) Clevis pin
(B) Snap pin
(C) Push rod
(D) Push rod lock nut
CL-00042
(A)
(B)
(C)(D)
CL-00137
(A) Clevis pin
(B) Snap pin
(C) Push rod
CL-00163
T2T1
CL-00045
(A)
(B)
(C)

CL-28
CLUTCH SYSTEM
Master Cylinder
5) Move the cylinder boot backward.
6) Remove the stop ring.
CAUTION:
Be careful when removing the stop ring to pre-
vent the rod, washer, piston and return spring
from flying out.
7) Remove the air bleeder.
D: ASSEMBLY
1. EXCEPT RHD TURBO MODEL
1) Apply a coat of grease to the contacting surfaces
of the push rod and piston before installation.
Grease:
SILICONE GREASE G40M (Part No.
004404003)
2) To assemble the master cylinder, reverse the
sequence of disassembly procedure.
Tightening torque:
10 N
⋅m (1.0 kgf-m, 7 ft-lb)
2. RHD TURBO MODEL
1) Apply a coat of grease to the contacting surfaces
of the push rod and piston before installation.
Grease:
SILICONE GREASE G40M (Part No.
004404003)
2) Assemble in the reverse order of disassemble.
E: INSPECTION
If any damage, deformation, wear, swelling, rust or
other faults are found on the cylinder, piston, push
rod, fluid reservoir, return spring, gasket, cylinder
boot and hose replace the faulty part.
(A) Cylinder boot
(B) Master cylinder
CL-00048
(A)
(B)
CL-00054
(A) Master cylinder body
(B) Return spring
(C) Piston
(D) Stop ring
(E) Rod ASSY
(F) Clutch damper
(G) Cylinder boot
CL-00055
CL-00056
(B)
(C)
(D)
(E) (A)
(F)
(G)

CL-30
CLUTCH SYSTEM
Clutch Pipe and Hose
B: INSTALLATION
1. EXCEPT RHD TURBO MODEL
Install in the reverse order of removal.
Tightening torque:
T1: 15 N
⋅m (1.5 kgf-m, 10.8 ft-lb)
T2: 18 N
⋅m (1.8 kgf-m, 13.0 ft-lb)
T3: 25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
2. RHD TURBO MODEL
Install in the reverse order of removal.
Tightening torque:
T1: 7.5 N
⋅m (0.76 kgf-m, 5.53 ft-lb)
T2: 8 N
⋅m (0.8 kgf-m, 5.8 ft-lb)
T3: 15 N
⋅m (1.5 kgf-m, 10.8 ft-lb)
T4: 18 N
⋅m (1.8 kgf-m, 13.0 ft-lb)
T5: 25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
C: INSPECTION
Check the pipes and hoses for cracks, breakage, or
damage. Check the joints for fluid leakage. If any
cracks, breakage, damage, or leakage is found, re-
pair or replace the applicable pipe or hose.
(A) Clutch pipe (LHD model)
(B) Clip
(C) Clutch hose
(D) Clutch pipe (RHD model)
(D)
(B) (C)(A)
T1
T1
T2
T1
T3
CL-00125
(A) Clutch pipe
(B) Connector
(C) Clutch hose
(A)
(A) (A)
T3
T3T3
T3
T1
T3
T5
T5
(C)
T2
T4
(B)
CL-00061

CL-32
CLUTCH SYSTEM
Clutch Fluid Air Bleeding
9. Clutch Fluid Air Bleeding
A: PROCEDURE
1. NON-TURBO MODEL
NOTE:
Bleed air from the oil line with help of co-worker.
1) Remove the air cleaner case and air intake duct.
Case.> take Duct.>
2) Fit one end of a vinyl tube into the air bleeder of
operating cylinder and put the other end into a
brake fluid container.
3) Slowly depress the clutch pedal and keep it de-
pressed. Then open the air bleeder to discharge air
together with the fluid. Release the air bleeder for 1
or 2 seconds. Next, with the bleeder closed, slowly
release the clutch pedal.
4) Repeat these steps until there are no more air
bubbles in the vinyl tube.
CAUTION:
Cover the bleeder with waste cloth when loos-
ening it, to prevent brake fluid from being
splashed over surrounding parts.5) Tighten the air bleeder.
Tightening torque:
T: 8 N
⋅m (0.8 kgf-m, 5.8 ft-lb)
6) After depressing the clutch pedal, make sure
that there are no leaks evident in the entire system.
7) After bleeding air from the system, ensure that
clutch operates properly.
2. TURBO MODEL
NOTE:
Bleed air from the oil line with help of co-worker.
1) Remove the intercooler. 11, INSTALLATION, Intercooler.>
2) Fit one end of a vinyl tube into the air bleeder of
master cylinder and put the air bleeder of other end
into a brake fluid container. (RHD turbo model)
3) Slowly depress the clutch pedal and keep it de-
pressed. Then open the air bleeder to discharge air
together with the fluid. Release the air bleeder for 1
or 2 seconds. Next, with the bleeder closed, slowly
release the clutch pedal. (RHD turbo model)
4) Repeat these steps until there are no more air
bubbles in the vinyl tube.
CAUTION:
Cover the bleeder with waste cloth when loos-
ening to prevent brake fluid from being
splashed over surrounding parts.
(A) Clutch hose
(B) Air bleeder
(A) Operating cylinder
(B) Vinyl tube
CL-00063
(B)(A)
CL-00064
(B)
(A)
(A) Vinyl tube
CL-00065
T
(A)
CL-00066

CL-33
CLUTCH SYSTEM
Clutch Fluid Air Bleeding
5) Tighten the air bleeder. (RHD turbo model)
Tightening torque:
T: 8 N
⋅m (0.8 kgf-m, 5.8 ft-lb)
6) Remove the operating cylinder.
NOTE:
Do not remove the clutch hose.
7) Fix the piston with clamp to avoid the piston from
jumping out.
8) Fit one end of a vinyl tube into the air bleeder of
operating cylinder and put the other end into a
brake fluid container.9) Slowly depress the clutch pedal and keep it de-
pressed. Then open the air bleeder to discharge air
together with the fluid.
Release the air bleeder for 1 or 2 seconds. Next,
with the bleeder closed, slowly release the clutch
pedal.
NOTE:
Set the air breather screw part higher than tip of op-
erating cylinder when performing this procedure.
10) Repeat these steps until there are no more air
bubbles in the vinyl tube.
CAUTION:
Cover the bleeder with waste cloth when loos-
ening it, to prevent brake fluid from being
splashed over surrounding parts.
11) Tighten the air bleeder.
Tightening torque:
T: 8 N
⋅m (0.8 kgf-m, 5.8 ft-lb)
12) Install the operating cylinder.
Tightening torque:
T: 37 N
⋅m (3.8 kgf-m, 27.5 ft-lb)
13) After depressing the clutch pedal, make sure
that there are no leaks evident in the entire system.
14) After bleeding air from the system, ensure that
clutch operates properly.
15) Install the intercooler. 11, INSTALLATION, Intercooler.>
CL-00067
T
CL-00068
CL-00069
(A) Operating cylinder
(B) Vinyl tube
CL-00070
(B) (A)
CL-00068

CL-35
CLUTCH SYSTEM
Clutch Pedal
2. RHD MODEL
1) Disconnect the ground cable from battery.
2) Loosen the screws and clips, and then remove
the lower cover.
3) Disconnect the clutch switch connector. (Model
with cruise control system)
4) Remove the snap pin connecting clutch pedal
and clutch master cylinder rod, and then pull the
clevis pin out.
5) Remove the clutch master cylinder mounting
nut.
6) Remove the PHV adjusting nut and the lock nut.
(Model with hill holder)
7) Remove the cable clamp, and disconnect the
PHV cable from PHV. (Model with hill holder)CAUTION:
Carefully protect the boot and inner cable from
damage when disconnecting the PHV cable.
8) Remove the clutch pedal bracket.
B: INSTALLATION
1) Install the clutch pedal bracket.
Tightening torque:
18 N
⋅m (1.8 kgf-m, 13.0 ft-lb)
2) Install the clutch master cylinder mounting nut.
Tightening torque:
18 N
⋅m (1.8 kgf-m, 13.0 ft-lb)
3) Insert the new clevis pin to assist rod A, and then
install the snap pin.
NOTE:
Apply a coat of grease to the clevis pin.
4) Adjust the stroke amount of clutch pedal. to CL-37, ADJUSTMENT, Clutch Pedal.>
5) Adjust the hill holder (Model with hill holder).

6) Connect the clutch switch connector. (Model
with cruise control system)
7) Install the instrument panel lower cover.
(A) Master cylinder
(A) Adjusting nut
(B) Lock nut
(C) PHV
CL-00072
CL-00164
(A)
CL-00091
(C)(B) (A)
(A) PHV cable
(B) Clamp
(A) Clutch pedal bracket
(B) Clutch pedal
(B) (A)
CL-00092
( A )
( B )
CL-00126