set clock SUBARU FORESTER 2004 Service Repair Manual

AC-4
HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC)
General Description
5. CONTROL SWITCHES
Start and warm-up the engine completely.
1) Inspection using switches
2) Compressor operation inspection
3) Inspection of illumination control
No. Point to check Switch operation Judgment standard
1 Fan speed control dial Turn the fan speed control dial clockwise.Fan speed changes 1st → 2nd → 3rd → 4th
as dial turn.
2AUTO switch1) Press the AUTO switch.
2) Turn the temperature control dial to the left
fully, and set maximum cool position. Outlet air temperature: COOL
 Fan speed: 4th
 Outlet opening: VENT
 Inlet opening: RECIRC
 Compressor: AUTO
3) Turn the temperature control dial to the right
slowly, and change the setting from maximum
cool position to maximum hot position gradually. Outlet air temperature: COOL → HOT
 Fan speed: AUTO
 Outlet opening: AUTO
 Inlet opening: AUTO
 Compressor: AUTO
4) Turn the temperature control dial to the right
fully, and set maximum hot position. Outlet air temperature: HOT
 Fan speed: 4th
 Outlet opening: HEAT
 Inlet opening: FRESH
 Compressor: AUTO
3 Defroster switch Press the defroster switch. Outlet air temperature: AUTO
 Fan speed: AUTO
 Outlet opening: DEF
 Inlet opening: FRESH
 Compressor: ON
4FRESH/RECIRC
switchPress the FRESH/RECIRC switch.Inlet opening switches RECIRC → FRESH or
FRESH → RECIRC each time pressing the
switch.
5 Mode control dial Press the mode control dial.Outlet opening switches VENT → BI-LEVEL
→ HEAT → DEF/HEAT each time dialing
clockwise.
No. Point to check Switch operation Judgment standard
1 Compressor1) A/C switch is turned to ON.
2) Turn the fan speed control clockwise.Compressor: ON
No. Point to check Switch operation Judgment standard
1 Illumination1) Turn the lighting switch to ON. Illumination comes on.
2) Press the OFF switch one second or more. Illumination dimming is cancelled.

ME(H4SO)-31
MECHANICAL
Valve Clearance
8. Valve Clearance
A: INSPECTION
NOTE:
Inspection and adjustment of the valve clearance
should be performed while engine is cold.
1) Set the vehicle on a lift.
2) Lift-up the vehicle.
3) Remove the under cover.
4) Lower the vehicle.
5) Disconnect the ground cable from battery.
6) Remove the belt cover (LH).
7) When inspecting the #1 and #3 cylinders:
(1) Disconnect the spark plug cords from spark
plugs RH side. REMOVAL, Spark Plug.>
(2) Disconnect the PCV hose from rocker cover
(RH).
(3) Remove the bolts, and then remove the
rocker cover (RH).
8) When inspecting the #2 and #4 cylinders:
(1) Disconnect the spark plug cords from spark
plugs (LH Side) REMOVAL, Spark Plug.>
(2) Disconnect the PCV hose from rocker cover
(LH).
(3) Remove the bolts, and then remove the
rocker cover (LH).
9) Set the #1 cylinder piston to top dead center of
compression stroke by rotating crank pulley clock-
wise using a socket wrench.NOTE:
When arrow mark (A) on the cam sprocket (LH)
comes exactly to the top, #1 cylinder piston is
brought to the top dead center of compression
stroke.
10) Measure the #1 cylinder valve clearance by us-
ing thickness gauge.
CAUTION:
 Insert the thickness gauge (A) in as horizon-
tal a direction as possible with respect to the
valve stem end face.
 Measure the exhaust valve clearances while
lifting-up the vehicle.
Valve clearance (Standard):
Intake;
0.20
±0.04 mm (0.0079±0.0016 in)
Exhaust;
0.25
±0.04 mm (0.0098±0.0016 in)
11) If necessary, adjust the valve clearance. to ME(H4SO)-32, ADJUSTMENT, Valve Clear-
ance.>
12) Similar to measurement procedures used for
#1 cylinder, measure the #2, #3 and #4 cylinder
valve clearances.
NOTE:
 Be sure to set the cylinder pistons to their re-
spective top dead centers on compression stroke
before measuring valve clearances.
FU-00009
ME-00199
ME-00200
(A)
ME-00201
(A)

ME(H4SO)-32
MECHANICAL
Valve Clearance
 To set the #3, #2 and #4 cylinder pistons to their
top dead centers on compression stroke, turn the
crank pulley clockwise 90° at a time starting with ar-
row mark on cam sprocket (LH) facing up.
13) After inspection, install the related parts in the
reverse order of removal.
Tightening torque:
Resonator chamber;
33 N
⋅m (3.4 kgf-m, 25 ft-lb)
B: ADJUSTMENT
NOTE:
Adjustment of the valve clearance should be per-
formed while engine is cold.
1) Set the #1 cylinder piston to top dead center of
compression stroke by rotating crank pulley clock-
wise using socket wrench.
NOTE:
When arrow mark (A) on the cam sprocket (LH)
comes exactly to the top, #1 cylinder piston is
brought to the top dead center of compression
stroke.2) Adjust the #1 cylinder valve clearance.
(1) Loosen the valve rocker nut and screw.
(2) Place suitable thickness gauge.
(3) While noting the valve clearance, tighten the
valve rocker adjusting screw.
(4) When specified valve clearance is obtained,
tighten the valve rocker nut.
Tightening torque:
10 N
⋅m (1.0 kgf-m, 7.2 ft-lb)
CAUTION:
 Insert the thickness gauge in as horizontally
as possible with respect to the valve stem end
face.
 Adjust the exhaust valve clearances while
lifting up the vehicle.
Valve clearance:
Intake:
0.20
±0.04 mm (0.0079±0.0016 in)
Exhaust:
0.25
±0.04 mm (0.0098±0.0016 in)
3) Ensure the valve clearances are within specifi-
cations.
4) Turn the crankshaft two complete rotations until
#1 cylinder piston is again set to the top dead cen-
ter of compression stroke.
5) Ensure the valve clearances are within specifi-
cations. If necessary, readjust the valve clearanc-
es.
6) Similar to adjustment procedures used for #1
cylinder, adjust the #2, #3 and #4 cylinder valve
clearances.
ME-00202
#1
#2#3 #4
IN-00044
ME-00200
(A)
ME-00203

ME(H4SO)-33
MECHANICAL
Valve Clearance
NOTE:
 Be sure to set the cylinder pistons to their re-
spective top dead centers on compression stroke
before adjusting valve clearances.
 To set the #3, #2 and #4 cylinder pistons to their
top dead centers of compression stroke, turn the
crank pulley clockwise 90° at a time starting with ar-
row mark on cam sprocket (LH) facing up.
ME-00202
#1
#2#3 #4

SC(H4SO)-12
STARTING/CHARGING SYSTEM
Starter
2. YOKE
Make sure the pole is set in position.
3. OVERRUNNING CLUTCH
Inspect the teeth of pinion for wear and damage.
Replace if it is damaged. Rotate the pinion in direc-
tion of rotation (counterclockwise). It should rotate
smoothly. But in opposite direction, it should be
locked.
CAUTION:
Do not clean the overrunning clutch with oil to
prevent grease from flowing out.
4. BRUSH AND BRUSH HOLDER
1) Brush length
Measure the brush length, and then replace if it ex-
ceeds the service limit.
Replace if abnormal wear or cracks are noticed.
Brush length:
Standard
12.3 mm (0.484 in)
Service limit
7.0 mm (0.276 in)
2) Brush movement
Be sure the brush moves smoothly inside brush
holder.
3) Brush spring force
Measure the brush spring force with a spring scale.
If it is less than the service limit, replace the brush
holder.
Brush spring force:
Standard
15.9 — 19.5 N (1.62 — 1.99 kgf, 3.57 — 4.38
lb) (when new)
Service limit
2.5 N (0.25 kgf, 0.56 lb)
5. SWITCH ASSEMBLY
Be sure there is continuity between the terminals S
and M, and between terminal S and ground. Use a
circuit tester (set in “ohm”).
Also check to be sure there is no continuity be-
tween terminal M and B.
Terminal / Specified resistance:
S — M / Less than 1
Ω
S — Ground / Less than 1 Ω
M — B / More than 1 MΩ
6. SWITCH ASSEMBLY OPERATION
1) Connect the terminal S of switch assembly to
positive terminal of battery with a lead wire, and
starter body to ground terminal of battery. The pin-
ion should be forced endwise on shaft.
CAUTION:
With the pinion forced endwise on shaft, starter
motor can sometimes rotate because current
flows, through pull-in coil, to motor. This is not
a problem.
2) Disconnect the connector from terminal M, and
then connect the positive terminal of battery and
terminal M using a lead wire and ground terminal to
starter body.
In this test set up, the pinion should return to its
original position even when it is pulled out with a
screwdriver.
(A) Service limit line
(B) Brush
SC-00102
(A)
(B)
(A) Terminal S
(B) Terminal M
SC-00075
B
M
S
SC-00076
(B) (A)

ME(H4DOTC)-38
MECHANICAL
Valve Clearance
(5) Move the washer tank upward.
(6) Disconnect the ignition coil connector.
(7) Remove the ignition coil.
(8) Place a suitable container under the vehicle.
(9) Disconnect the PCV hose from rocker cover
(LH).
(10)Remove the bolts, and then remove the
rocker cover (LH).
11) Turn the crankshaft pulley clockwise until arrow
mark on the camshaft sprocket is set to position
shown in the figure.
NOTE:
Turn the crankshaft using socket wrench.
12) Measure the #1 cylinder intake valve and #3
cylinder exhaust valve clearance by using thick-
ness gauge (A).
NOTE:
 Insert the thickness gauge in as horizontal a di-
rection as possible with respect to the shim.
 Measure the exhaust valve clearances while lift-
ing-up the vehicle.
Valve clearance:
Intake: 0.20
±0.02 mm (0.0079±0.0008 in)
Exhaust: 0.35
±0.02 mm (0.0138±0.0008 in)NOTE:
If the measured value is not within specification,
take notes of the value in order to adjust the valve
clearance later on.
13) If necessary, adjust the valve clearance. to ME(H4DOTC)-39, ADJUSTMENT, Valve Clear-
ance.>
14) Further turn the crankshaft pulley clockwise.
Using the same procedures described previously,
and then measure the valve clearances again.
(1) Set the arrow mark on camshaft sprocket to
position shown in the figure, and then measure
the #2 cylinder exhaust valve and #3 cylinder in-
take valve clearances.
(2) Set the arrow mark on camshaft sprocket to
position shown in the figure, and then measure
the #2 cylinder intake valve and #4 cylinder ex-
haust valve clearances.
ME-00017
ME-00733
ME-00019
(A)
ME-00734
ME-00735

ME(H4DOTC)-69
MECHANICAL
Camshaft
16) Remove the oil flow control solenoid valve as-
sembly, intake camshaft cap, and camshaft.
17) Loosen the exhaust camshaft cap bolts equal-
ly, a little at a time in alphabetical sequence shown
in the figure.
 2.0 L MODEL
 2.5 L MODEL
18) Remove the exhaust camshaft cap and cam-
shaft.
NOTE:
Arrange the camshaft caps in order so that they
can be installed in their original positions.
19) Similarly, remove the camshafts (RH) and re-
lated parts.B: INSTALLATION
1) Camshaft installation: Apply engine oil to cylin-
der head at camshaft bearing location before in-
stalling the camshaft. Install the camshaft so that
each valve is close to or in contact with “base circle”
of cam lobe.
NOTE:
 When the camshafts are positioned as shown in
the figure, camshafts need to be rotated at a mini-
mum to align with the timing belt during installation.
 Camshaft (RH) need not be rotated when set at
position shown in the figure. Intake camshaft (LH):
Rotate 80° clockwise. Exhaust camshaft (LH): Ro-
tate 45° counterclockwise.
2) Camshaft cap and oil flow control solenoid valve
assembly installation:
(1) Apply liquid gasket sparingly to cap mating
surface.
NOTE:
Do not apply liquid gasket excessively. Failure to
do so may cause excess packing to come out and
flow toward the oil seal, resulting in oil leaks.
ME-00714(B)
(A)
(E)
(F) (D)(C)
ME-00772
(A)(E)
(F)(B)(D)
(C)
A Cylinder head (LH)
B Cylinder head (RH)
(a) Intake camshaft
(b) Exhaust camshaft
ME-00111
1111
77.5 77.5
(a)
(b)
(a)(b)
A
B

4AT-140
AUTOMATIC TRANSMISSION
AT Main Case
19) Install the needle bearing, and then secure with
the snap ring.
20) Install the one-way clutch and one-way clutch
inner race, and then secure with the snap ring.
21) Set the one way clutch inner race to D clutch
drum. Make sure that the forward clutch is free in
the clockwise direction and locked in the counter
clockwise direction, as viewed from the front of the
vehicle.
3. 2-4 BRAKE
1) Install 2-4 brake piston to 2-4 brake piston re-
tainer.
4. ONE-WAY CLUTCH INNER RACE
1) Install the needle bearing to inner race using ST
and press.
ST 398497701 SEAT
2) Apply vaseline to the groove of inner race and
new seal ring.
3) Install two seal rings to one-way clutch inner
race.
5. ONE-WAY CLUTCH OUTER RACE
1) Install the needle bearing, and then secure with
the snap ring.
2) Install the one-way clutch and one-way clutch in-
ner race, and then secure with the snap ring.
(A) Needle bearing
(B) Snap ring
(A) Locked
(B) Free
(A) 2-4 brake piston
(B) 2-4 brake piston retainer
AT-00268
(B)(A)
AT-00282
(B) (A)
AT-00288
(A)(B)
(A) One-way clutch inner race
(B) Seal ring
(A) Needle bearing
(B) Snap ring
ST
AT-00299
AT-00298(B)(A)
AT-00268
(B)(A)

4AT-141
AUTOMATIC TRANSMISSION
AT Main Case
3) Set the one way clutch inner race to low clutch
drum. Make sure that the forward clutch is free in
the clockwise direction and locked in the counter
clockwise direction, as viewed from the front of the
vehicle.
E: INSPECTION
1. HIGH CLUTCH AND REVERSE CLUTCH
Check the following items:
 Drive plate facing for wear and damage
 Snap ring for wear, return spring for setting and
breakage, and snap ring retainer for deformation
 Lip seal and D-ring for damage
 Piston and drum check ball for operation
 Adjust total end play. JUSTMENT, Oil Pump Housing.>
2. PLANETARY GEAR AND LOW CLUTCH
Check the following items:
 Drive plate facing for wear and damage
 Snap ring for wear, return spring for setting and
breakage, and spring retainer for deformation
 Lip seal and D-ring for damage
 Piston check ball for operation
 Measure the total end play and adjust it within
specifications. Oil Pump Housing.>
3. 2-4 BRAKE
Check the following items:
 Drive plate facing for wear and damage
 Snap ring for wear and spring retainer for defor-
mation
 Lip seal and D-ring for damage
 Measure the total end play and adjust it within
specifications. Oil Pump Housing.>
4. ONE-WAY CLUTCH
 Make sure the snap ring is not worn and the seal
rings are not deformed.
 Measure the total end play and adjust it within
specifications. Oil Pump Housing.>
5. LOW AND REVERSE BRAKE
Check the following:
 Drive plate facing for wear and damage
 Snap ring for wear and spring retainer for defor-
mation
(A) Locked
(B) Free
AT-00282
(B) (A)

5MT-100
MANUAL TRANSMISSION AND DIFFERENTIAL
Front Differential Assembly
E: INSPECTION
Repair or replace the differential gear in the follow-
ing cases:
 The hypoid drive gear and drive pinion shaft
tooth surface are damaged, excessively worn, or
seized.
 The roller bearing on the drive pinion shaft has a
worn or damaged roller path.
 There is damage, wear, or seizure of the differ-
ential bevel pinion, differential bevel gear, washer,
pinion shaft, and straight pin.
 The differential case has worn or damaged slid-
ing surfaces.
1. DIFFERENTIAL BEVEL PINION GEAR
BACKLASH
Measure the backlash between differential bevel
gear and pinion. If it is not within specifications, in-
stall a suitable washer to adjust it.
NOTE:
Be sure the pinion gear tooth contacts adjacent
gear teeth during measurement.
ST1 498247001 MAGNET BASE
ST2 498247100 DIAL GAUGE
Standard backlash:
0.13 — 0.18 mm (0.0051 — 0.0071 in)
2. HYPOID GEAR BACKLASH
1) Set the ST1, ST2 and ST3. Insert the needle
through transmission oil drain plug hole so that the
needle comes in contact with the tooth surface at a
right angle.
ST1 498247001 MAGNET BASE
ST2 498247100 DIAL GAUGE
ST3 498255400 PLATE
2) Install the axle shaft (SUBARU Genuine Parts)
to both sides, move it clockwise and counter clock-
wise to contact tooth, and then read the value of
dial gauge runout.
Parts No. 38415AA100 AXEL SHAFT
Backlash:
0.13 — 0.18 mm (0.0051 — 0.0071 in)
3) If the backlash is outside specified range, adjust
it by turning the holder in right side case.
(A) Drive pinion shaft
(B) Hypoid driven gear
(C) Pinion shaft
(D) Straight pin
(E) Washer
(F) Differential bevel gear
(G) Differential bevel pinion
(H) Roller bearing
(I) Differential case
MT-00291
(A)
(B)(C)
(E)
(E)
(F)
(F)
(G)
(G)
(D)
(H) (I)
(H)MT-00285
ST1
ST2
MT-00293ST1
ST2ST3