2004 SUBARU FORESTER steering wheel

ME(H4DOTC)-43
MECHANICAL
Engine Assembly
(4) Remove the power steering pump from en-
gine.
(5) Remove the reservoir tank from bracket by
pulling it upward.
(6) Place the power steering pump on RH side
wheel apron.
14) Lift-up the vehicle.
15) Remove the ATF cooler pipe from frame. (AT
model)
16) Remove the center exhaust pipe. EX(H4DOTC)-9, REMOVAL, Center Exhaust
Pipe.>17) Remove the nuts which hold the lower side of
transmission to engine.
18) Remove the nuts which install the front cushion
rubber onto front crossmember.
19) Lower the vehicle.
20) Separate the clutch release fork from release
bearing. (MT model)
(1) Remove the clutch operating cylinder from
transmission.
(2) Remove the plug using a 10 mm hexagon
wrench.
ME-00037
ME-00038
ME-00039ME-00040
ME-00041
ME-00042

EX(H4DOTC)-12
EXHAUST
Center Exhaust Pipe
12) Place the turbocharger upper cover, and tight-
en the bolts which install upper side of upper cover.
Tightening torque:
7.4 N·m (0.75 kgf-m, 5.4 ft-lb)
13) Lift-up the vehicle.
14) Tighten the bolts which install under side of tur-
bocharger upper cover.
Tightening torque:
7.4 N·m (0.75 kgf-m, 5.4 ft-lb)
15) Install the universal joint. (RHD model)
(1) Align the bolt hole on long yoke side of uni-
versal joint with the cutout at serrated section of
shaft end, and insert the universal joint.
(2) Align the bolt hole on short yoke side of uni-
versal joint with the cutout at serrated section of
gearbox assembly. Lower the universal joint
completely.
(3) Temporarily tighten the bolt on short yoke
side. Raise the universal joint to make sure the
bolt is properly passing through the cutout at
serrated section.
(4) Tighten the bolt on long yoke side, then that
on the short yoke side.
Tightening torque:
24 N·m (2.4 kgf-m, 17.4 ft-lb)CAUTION:
 Make sure that the universal joint bolts are
tightened through notches in shaft serration.
 Excessively large tightening torque of uni-
versal joint bolts may lead to heavy steering
wheel operation.
Standard clearance between gearbox to DOJ:
Over 15 mm (0.59 in)
16) Install the under cover.
17) Lower the vehicle.
18) Install the intercooler bracket.
19) Install the intercooler.
cooler.>
20) Align the center of roll connector. (RHD model)
TION, Inspection Locations After a Collision.>
EX-00017
EX-00009
EX-00008
EX-00007

EN(H4DOTC)-7
ENGINE (DIAGNOSTIC)
General Description
12) Observe the following cautions when installing
a radio in MFI equipped models.
CAUTION:
 The antenna must be kept as far apart as pos-
sible from the control unit. (The ECM is located
under the steering column, inside of the instru-
ment panel lower trim panel.)
 The antenna feeder must be placed as far
apart as possible from the ECM and MFI har-
ness.
 Carefully adjust the antenna for correct
matching.
 When mounting a large power type radio, pay
special attention to the three items above men-
tioned.
 Incorrect installation of the radio may affect
the operation of the ECM.
13) Before disconnecting the fuel hose, disconnect
the fuel pump connector and crank the engine for
more than five seconds to release pressure in the
fuel system.If engine starts during this operation,
run it until it stops.
14) Problems in the electronic-controlled automatic
transmission may be caused by failure of the en-
gine, the electronic control system, the transmis-
sion proper, or by a combination of these.These
three causes (engine, electronic control system,
transmission) must be distinguished clearly when
performing diagnostics.
15) Diagnostics should be conducted by rotating
with simple, easy operations and proceeding to
complicated, difficult operations.The most impor-
tant thing in diagnostics is to understand the cus-
tomer’s complaint, and distinguish between the
three causes.
16) On the model with ABS, when performing driv-
ing test in jacked-up or lifted-up position, some-
times the warning light may be lit, but this is not a
malfunction of the system.The reason for this is the
speed difference between the front and rear
wheels.After diagnosis of engine control system,
perform the ABS memory clearance procedure of
self-diagnosis function.
B: INSPECTION
Before performing diagnostics, check the following
items which might affect engine problems:
1. BATTERY
1) Measure battery voltage and specific gravity of
electrolyte.
Standard voltage: 12 V
Specific gravity: Above 1.2602) Check the condition of the main and other fuses,
and harnesses and connectors.Also check for
proper grounding.
2. ENGINE GROUND
Make sure the engine ground terminal is properly
connected to the engine.
C: NOTE
1. GENERAL DESCRIPTION
 On-board diagnosis (OBD) system detects and
indicates a fault in various inputs and outputs of the
complex electronic control.Malfunction indicator
light in the combination meter indicates occurrence
of a fault or trouble.
 Further, against such a failure or sensors as may
disable the drive, the fail-safe function is provided
to ensure the minimal driveability.
 The OBD system incorporated with the vehicles
within this engine family complies with Section
1968.1, California Code of Regulations (OBD-II
regulation).The OBD system monitors the compo-
nents and the system malfunction listed in Engine
Section which affects on emissions.
 When the system decides that a malfunction oc-
curs, malfunction indicator light illuminates.At the
same time of the malfunction indicator light illumi-
nation or blinking, the DTC and a freeze frame en-
gine conditions are stored into on-board computer.
 The OBD system stores freeze frame engine
condition data (engine load, engine coolant tem-
perature, fuel trim, engine speed and vehicle
speed, etc.) into on-board computer when it detects
a malfunction first.
 If the OBD system detects the various malfunc-
tions including the fault of fuel trim or misfire, the
OBD system first stores freeze frame engine condi-
tions about the fuel trim or misfire.
 When the malfunction does not occur again for
three consecutive driving cycles, malfunction indi-
cator light is turned off, but DTC remains at on-
board computer.
 The OBD-II system is capable of communication
with a general scan tool (OBD-II general scan tool)
formed by ISO 9141 CARB.
EN-00070

FU(H4DOTC 2.5)-15
FUEL INJECTION (FUEL SYSTEM)
Intake Manifold
(6) Place the power steering pump on the right
side wheel apron.
12) Disconnect the emission hose from the PCV
valve.
13) Disconnect the engine coolant hoses from the
throttle body.
14) Disconnect the brake booster hose.15) Disconnect the pressure hose from the intake
duct.
16) Disconnect the engine harness connectors
from the bulkhead harness connectors.
17) Disconnect the connectors from the engine cool-
ant temperature sensor (A), oil pressure switch (B)
and crankshaft position sensor (C).
FU-00021
FU-00022
FU-01074
FU-00023
FU-00024
FU-00025
FU-00026
(A)
(B)
(C)
FU-00027

4AT-95
AUTOMATIC TRANSMISSION
Transfer Clutch
12) Install the transfer clutch assembly without
damaging seal ring.
E: INSPECTION
 Inspect the drive plate facing for wear and dam-
age.
 Inspect the snap ring for wear; return spring for
permanent distortion, breakage and deformation.
 Inspect the damage for D-ring.
 Measure the extension end play and adjust it to
within specifications. MENT, Transfer Clutch.>
1) Check clearance between snap ring and pres-
sure plate.
2) Before measuring clearance, place the same
thickness of shim on both sides to prevent pressure
plate from tilting.
3) If the clearance is out of specification, select a
suitable retaining plate and adjust it.
Standard value:
0.7 — 1.1 mm (0.028 — 0.043 in)
Service limit:
1.6 mm (0.063 in)4) Check that the tight corner braking does not oc-
cur when the vehicle is started with steering wheel
held at fully turned position. If tight corner braking
occurs, perform the following procedures.
(1) With the steering wheel held at fully turned
position, drive the vehicle in “D” range and with
vehicle speed at approx. 5 km/h (3 MPH) in both
clockwise and counterclockwise directions for
approx. ten times each, while repeating acceler-
ation and braking intermittently.
(2) If the tight corner braking still persists, drive
the vehicle again in a circle for several laps.
F: ADJUSTMENT
1) Measure distance “A” from end of extension
case and rear drive shaft with ST.
ST 398643600 GAUGE
2) Measure the distance “B” from the transmission
case end to reduction drive gear end surface with
ST1 and ST2.
ST1 398643600 GAUGE
ST2 499577000 GAUGE(A) Transfer clutch ASSY
(B) Extension case
Retaining plate
TOOL NUMBER Thickness mm (in)
31593AA151 3.3 (0.130)
31593AA161 3.7 (0.146)
31593AA171 4.1 (0.161)
31593AA181 4.5 (0.177)
AT-00125
(A)
(B)
AT-00142
AST
AT-01029
ST2ST1
B
AT-01030