1999 SUBARU FORESTER Service Repair Manual

(3) Set a new bearing and closely install a fit
tool on the bearing outer race. Press the bear-
ing down into place with a hand press or vise.
A socket wrench can serve as the tool.
(4) Install front bearing retainer.
S6M0410A
(A) Bearing
(B) Socket wrench
(C) Front bracket
D: ASSEMBLY
Assemble in the reverse order of disassembly.
1) Pulling up brush
Before assembling, press the brush down into the
brush holder with your finger and secure in that
position by passing a [2 mm (0.08 in) dia. length 4
to 5 cm (1.6 to 2.0 in)] wire (A) through the hole
shown in the figure.
CAUTION:
Be sure to remove the wire after reassembly.
S6M0411A
2) Heat the bearing box in the rear bracket [50 to
60ÉC (122 to 140ÉF)] and press the rear bearing
into the rear bracket.
CAUTION:
Grease should not be applied for the rear bear-
ing. Remove oil completely if it is found on the
bearing box.
3) After reassembly, turn the pulley by hand to
check that the rotor turns smoothly.
3. Spark Plug
A: REMOVAL AND INSTALLATION
CAUTION:
All spark plugs installed on an engine, must be
of the same heat range.
Spark plug:
CHAMPION: RC10YC4
(Alternate)
CHAMPION: RC8YC4
NGK: BKR6E-11
NIPPONDENSO: K20PR-U11
1. #1 SPARK PLUG
1) Disconnect battery ground cable.
G6M0095
2) Remove air intake duct and resonator chamber.
(1) Remove bolt which installs air intake duct
on the front side of body.
S6M0708
(2) Remove bolt which installs air intake duct
on body.
B2M2284
16
6-1[W2D0]SERVICE PROCEDURE
3. Spark Plug

(3) Set a new bearing and closely install a fit
tool on the bearing outer race. Press the bear-
ing down into place with a hand press or vise.
A socket wrench can serve as the tool.
(4) Install front bearing retainer.
S6M0410A
(A) Bearing
(B) Socket wrench
(C) Front bracket
D: ASSEMBLY
Assemble in the reverse order of disassembly.
1) Pulling up brush
Before assembling, press the brush down into the
brush holder with your finger and secure in that
position by passing a [2 mm (0.08 in) dia. length 4
to 5 cm (1.6 to 2.0 in)] wire (A) through the hole
shown in the figure.
CAUTION:
Be sure to remove the wire after reassembly.
S6M0411A
2) Heat the bearing box in the rear bracket [50 to
60ÉC (122 to 140ÉF)] and press the rear bearing
into the rear bracket.
CAUTION:
Grease should not be applied for the rear bear-
ing. Remove oil completely if it is found on the
bearing box.
3) After reassembly, turn the pulley by hand to
check that the rotor turns smoothly.
3. Spark Plug
A: REMOVAL AND INSTALLATION
CAUTION:
All spark plugs installed on an engine, must be
of the same heat range.
Spark plug:
CHAMPION: RC10YC4
(Alternate)
CHAMPION: RC8YC4
NGK: BKR6E-11
NIPPONDENSO: K20PR-U11
1. #1 SPARK PLUG
1) Disconnect battery ground cable.
G6M0095
2) Remove air intake duct and resonator chamber.
(1) Remove bolt which installs air intake duct
on the front side of body.
S6M0708
(2) Remove bolt which installs air intake duct
on body.
B2M2284
16
6-1[W2D0]SERVICE PROCEDURE
3. Spark Plug

(3) Remove air intake duct as a unit.
B2M2012
(4) Remove resonator chamber.
B2M2306
3) Remove #1 spark plug cord by pulling boot, not
the cord itself.
B6M0922
4) Remove spark plug with the spark plug socket.
B6M0923
5) Install in the reverse order of removal.
Tightening torque (Spark plug):
20.6
±2.9 N´m (2.10±0.30 kg-m, 15.19±2.14
ft-lb)
Tightening torque (Resonator chamber):
32
±10 N´m (3.3±1.0 kg-m, 24±7 ft-lb)
B2M2306
CAUTION:
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 approximately 1/3 of the
specified torque in order to avoid over-stress-
ing.
2. #2 SPARK PLUG
1) Disconnect battery ground cable.
G6M0095
2) Remove #2 spark plug cord by pulling boot, not
cord itself.
B6M0927
17
[W3A2]6-1SERVICE PROCEDURE
3. Spark Plug

3) Remove spark plug with the spark plug socket.
B6M0924
4) Install in the reverse order of removal.
Tightening torque (Spark plug):
20.6
±2.9 N´m (2.10±0.30 kg-m, 15.19±2.14
ft-lb)
CAUTION:
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 approximately 1/3 of the
specified torque in order to avoid over-stress-
ing.
3. #3 SPARK PLUG
1) Disconnect battery ground cable.
G6M0095
2) Remove air intake duct and resonator chamber.
(1) Remove bolt which installs air intake duct
on the front side of body.
S6M0708
(2) Remove bolt which installs air intake duct
on body.
B2M2284
(3) Remove air intake duct as a unit.
B2M2012
(4) Remove resonator chamber.
B2M2306
3) Remove #3 spark plug cord by pulling boot, not
cord itself.
B6M0928
18
6-1[W3A3]SERVICE PROCEDURE
3. Spark Plug

4) Remove spark plug with the spark plug socket.
B6M0925
5) Install in the reverse order of removal.
Tightening torque (Spark plug):
20.6
±2.9 N´m (2.10±0.30 kg-m, 15.19±2.14
ft-lb)
Tightening torque (Resonator chamber):
32
±10 N´m (3.3±1.0 kg-m, 24±7 ft-lb)
B2M2306
CAUTION:
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 approximately 1/3 of the
specified torque in order to avoid over-stress-
ing.
4. #4 SPARK PLUG
1) Disconnect battery ground cable.
G6M0095
2) Disconnect washer motor connector.
S2M0546
3) Disconnect rear window glass washer hose
from washer motor, then plug connection with a
suitable cap.
4) Remove the two bolts which hold the washer
tank, then take the tank away from the working
area.
B2M2023
5) Remove #4 spark plug cord by pulling boot, not
cord itself.
B6M0929
6) Remove spark plug with the spark plug socket.
B6M0926
19
[W3A4]6-1SERVICE PROCEDURE
3. Spark Plug

7) Install in the reverse order of removal.
Tightening torque (Spark plug):
20.6
±2.9 N´m (2.10±0.30 kg-m, 15.19±2.14
ft-lb)
CAUTION:
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 approximately 1/3 of the
specified torque in order to avoid over-stress-
ing.
B: INSPECTION
Check electrodes and inner and outer porcelain of
plugs, noting the type of deposits and the degree
of electrode erosion.
S6M0420A
(A) Electrode gap
(B) Carbon accumulation or wear
(C) Cracks
(D) Damage
(E) Damaged gasket
1) Normal
Brown to grayish-tan deposits and slight electrode
wear indicate correct spark plug heat range.
G6M0087
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.
G6M0088
3) Oil fouled
Wet black deposits show excessive oil entrance
into combustion chamber through worn rings and
pistons or excessive clearance between valve
guides and stems. If same condition remains after
repair, use a hotter plug.
G6M0089
4) Overheating
White or light gray insulator with black or gray
brown spots and bluish burnt electrodes indicate
engine overheating. Moreover, the appearance
results from incorrect ignition timing, loose spark
plugs, wrong selection of fuel, hotter range plug,
etc. It is advisable to replace with plugs having
colder heat range.
G6M0090
20
6-1[W3B0]SERVICE PROCEDURE
3. Spark Plug

C: CLEANING AND REGAPPING
Clean spark plugs in a sand blast type cleaner.
Avoid excessive blasting. Clean and remove car-
bon or oxide deposits, but do not wear away por-
celain.
If deposits are too stubborn, discard plugs.
After cleaning spark plugs, recondition firing sur-
face of electrodes with file. Then correct the spark
plug gap using a gap gauge.
Spark plug gap: L
1.0 Ð 1.1 mm (0.039 Ð 0.043 in)
S6M0412A
NOTE:
Replace with new spark plug if this area is worn to
ªballº shape.
4. Ignition Coil and Ignitor
Assembly
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
G6M0095
2) Disconnect spark plug cords from ignition coil
and ignitor assembly.
3) Disconnect connector from ignition coil and
ignitor assembly.
B6M0932
4) Remove ignition coil and ignitor assembly.
B6M0930
5) Install in the reverse order of removal.
CAUTION:
Be sure to connect wires to their proper posi-
tions. Failure to do so will damage unit.
21
[W4A0]6-1SERVICE PROCEDURE
4. Ignition Coil and Ignitor Assembly

C: CLEANING AND REGAPPING
Clean spark plugs in a sand blast type cleaner.
Avoid excessive blasting. Clean and remove car-
bon or oxide deposits, but do not wear away por-
celain.
If deposits are too stubborn, discard plugs.
After cleaning spark plugs, recondition firing sur-
face of electrodes with file. Then correct the spark
plug gap using a gap gauge.
Spark plug gap: L
1.0 Ð 1.1 mm (0.039 Ð 0.043 in)
S6M0412A
NOTE:
Replace with new spark plug if this area is worn to
ªballº shape.
4. Ignition Coil and Ignitor
Assembly
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
G6M0095
2) Disconnect spark plug cords from ignition coil
and ignitor assembly.
3) Disconnect connector from ignition coil and
ignitor assembly.
B6M0932
4) Remove ignition coil and ignitor assembly.
B6M0930
5) Install in the reverse order of removal.
CAUTION:
Be sure to connect wires to their proper posi-
tions. Failure to do so will damage unit.
21
[W4A0]6-1SERVICE PROCEDURE
4. Ignition Coil and Ignitor Assembly