for4 sec1 8 PDF

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Titre: 87B...BE_.book

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2004 FORESTER SERVICE MANUAL

QUICK REFERENCE INDEX

ENGINE SECTION 1

This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reassembling, inspection and adjustment of
components and diagnostics for guidance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.

FUEL INJECTION (FUEL SYSTEM)

FU(H4SO)

EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICE)

EC(H4SO)

INTAKE (INDUCTION)

IN(H4SO)

MECHANICAL

ME(H4SO)

EXHAUST

EX(H4SO)

COOLING

CO(H4SO)

LUBRICATION

LU(H4SO)

SPEED CONTROL SYSTEM

SP(H4SO)

IGNITION

IG(H4SO)

STARTING/CHARGING SYSTEM

SC(H4SO)

ENGINE (DIAGNOSTIC)

EN(H4SO)

All information, illustration and specifications contained in this manual are
based on the latest product information
available at the time of publication
approval.
FUJI HEAVY INDUSTRIES LTD.

G8080GE2

SPEED CONTROL SYSTEM

SP(H4SO)
1.
2.
3.

Page
General Description ....................................................................................2
Accelerator Pedal........................................................................................4
Accelerator Control Cable ...........................................................................9

General Description
SPEED CONTROL SYSTEM

1. General Description
A: SPECIFICATION
Accelerator pedal

Free play
Stroke

At pedal pad
At pedal pad

0 — 4 mm (0 — 0.16 in)
52 — 57 mm (2.05 — 2.24 in)

B: COMPONENT
1. LHD MODEL
(1)

(2)
(3)
(4)

T1
(5)

(13)
T2

(11)
(7)

(6)

(10)

(12)

(8)

(9)
SP-00021

(1)
(2)
(3)
(4)
(5)
(6)

Accelerator bracket
Stopper
Bushing
Clip
Accelerator spring
Accelerator pedal spring

(7)
(8)
(9)
(10)
(11)
(12)

Accelerator pedal lever
Spring pin
Accelerator pedal
Accelerator stopper
Accelerator plate
Clip

SP(H4SO)-2

(13)

Kick-down switch (AT model)

Tightening torque: N⋅m (kgf-m, ft-lb)
T1: 12 (1.2, 9.0)
T2: 18 (1.8, 13.0)

General Description
SPEED CONTROL SYSTEM

2. RHD MODEL

(1)

(3)

(2)

(11)

T1

(8)

T2
(9)
(7)
(4)

(6)
(5)

(10)

SP-00022

(1)
(2)
(3)
(4)
(5)

Accelerator bracket
Stopper
Accelerator pedal lever
Accelerator pedal spring
Accelerator pedal

(6)
(7)
(8)
(9)
(10)

Spring pin
Accelerator spring
Bushing
Clip
Accelerator stopper

C: CAUTION
• Wear work clothing, including a cap, protective
goggles, and protective shoes during operation.
• Remove contamination, including dirt and corrosion, before removal, installation or disassembly.
• Keep the disassembled parts in order and protect them from dust and dirt.
• Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary removal, installation, disassembly, and replacement.
• Be careful not to burn yourself, because each
part in the vehicle is hot after running.
• Be sure to tighten fasteners including bolts and
nuts to the specified torque.
• Place shop jacks or rigid racks at the specified
points.
• Before disconnecting electrical connectors of
sensors or units, be sure to disconnect the ground
cable from battery.

SP(H4SO)-3

(11)

Kick-down switch (AT model)

Tightening torque: N⋅m (kgf-m, ft-lb)
T1: 12 (1.2, 9.0)
T2: 18 (1.8, 13.0)

Accelerator Pedal
SPEED CONTROL SYSTEM

2. Accelerator Pedal

• RHD Non-turbo model

A: REMOVAL

(C)

(B)

1) Disconnect the ground cable from battery.
2) Remove the lock nut from accelerator cable
bracket.
3) Separate the accelerator cable from bracket.
4) Remove the accelerator cable end from throttle
cam.
NOTE:
Be careful not to kink the accelerator cable.
• Non-turbo model

(E)
(E)
(D)
(E)

(A)

(E)

SP-00005

• LHD Turbo model
(D)

(E)
(A)

(A)
(E)
(B)
(C)

(D)

(B) (C)

SP-00003

• Turbo model

(E)

(E)

SP-00023

• RHD Turbo model
(B)

(D)
(C)

(E)

(C)

(A)

(D)

(A)

(E)

(B)
SP-00004

SP-00006

(A)
(B)
(C)
(D)

Lock nut
Accelerator cable bracket
Accelerator cable
Throttle cam

5) Remove the clip inside engine compartment.
• LHD Non-turbo model
(A)
(E)

(A)
(B)
(C)
(D)
(E)

Toe board
Accelerator cable
To accelerator pedal
Brake booster
Clip

6) Remove the instrument panel lower cover from
instrument panel, and connector.
7) Disconnect the connector from kick-down
switch. (AT model)

(E) (D)

(C)
(E)
(B)
SP-00017

SP(H4SO)-4

Accelerator Pedal
SPEED CONTROL SYSTEM

8) Remove the accelerator pedal mounting bolt
from accelerator pedal bracket.
• LHD model

11) Disconnect the accelerator cable bushing from
accelerator pedal lever.

(A)

SP-00009
SP-00018

(A) Flat tip screwdriver

• RHD model

12) Disconnect the accelerator cable stopper (A)
from bracket.
(A)

SP-00007

9) Disconnect the grommet from toe board.
NOTE:
From the inside compartment, push the grommet
(A) into hole.

SP-00010

13) Separate the accelerator cable and accelerator
bracket.

B: INSTALLATION
Install in the reverse order of removal.

(A)

SP-00008

NOTE:
• If the cable clamp is damaged, replace it with a
new one.
• Never fail to cover the outer cable end with boot.
• Be careful not to kink the accelerator cable.
• For tightening torque, refer to “COMPONENT”.
<Ref. to SP(H4SO)-2, COMPONENT, General Description.>

10) Pull out the cable from toe board hole.

SP(H4SO)-5

Accelerator Pedal
SPEED CONTROL SYSTEM

C: DISASSEMBLY

• RHD model

1) Remove the clip, and then remove the accelerator pedal lever from accelerator bracket.
2) Pull out the spring pin, and then remove the accelerator pedal from accelerator pedal lever.
• LHD model

(A)

(B)

(G)

(J)

(A)
(B)
(C)
(C)

(D)

(D)

(E)

(E)

(J)

(F)

(G)

(H)
(F)

(I)
SP-00025

(A)
(B)
(C)
(D)
(E)
(F)
(G)
(H)
(I)
(J)

(H)
(I)
SP-00024

(A)
(B)
(C)
(D)
(E)
(F)
(G)
(H)
(I)
(J)

Accelerator bracket
Stopper
Bushing
Clip
Accelerator spring
Accelerator pedal spring
Accelerator pedal lever
Spring pin
Accelerator pedal
Kick-down switch (AT model)

Accelerator bracket
Stopper
Bushing
Clip
Accelerator spring
Accelerator pedal spring
Accelerator pedal lever
Spring pin
Accelerator pedal
Kick-down switch (AT model)

D: ASSEMBLY
Assemble in the reverse order of disassembly.
NOTE:
Clean and apply grease to the portions indicated in
the figure.
Grease:
SUNLIGHT No. 2 (Part No. 003602010)

SP(H4SO)-6

Accelerator Pedal
SPEED CONTROL SYSTEM

E: INSPECTION

F: ADJUSTMENT

1. ACCELERATOR PEDAL
Lightly move the pedal pad in lateral direction to ensure that pedal deflection is in specified range.
CAUTION:
If excessive deflection is noted, replace the
bushing and clip with new ones.
Deflection of accelerator pedal:
Service limit
±2.0 mm (±0.079 in) or less

1) Check the pedal stroke and free play by operating accelerator pedal by hand.
2) If it is not within specified value, adjust it by turning the nut connecting the accelerator cable to
throttle body.
Free play at pedal pad: L
0 — 4 mm (0 — 0.16 in)
Stroke at pedal pad: A
52 — 57 mm (2.05 — 2.24 in)

(B)

(A)
SP-00013

2. KICK-DOWN SWITCH
If the kick-down switch does not operate properly
(or if it does not stop at the specified position), replace with a new one.
Specified position: A
2.0 — 3.5 mm (0.079 — 0.098 in)

L

A
A

SP-00027

(A) Accelerator pedal
(B) Accelerator pedal bracket

SP-00026

Accelerator cable lock nut tightening torque:
12 N⋅m (1.2 kgf-m, 9 ft-lb)
3) Check to ensure the kick-down switch operates
at the specified value in relation to the stroke of the
accelerator pedal.
If it is not within specified value, adjust it by adjusting the position of kick-down switch.
CAUTION:
Be careful not to rotate the kick-down switch.
Kick-down switch stroke: L
47 — 49 mm (1.85 — 1.93 in)

SP(H4SO)-7

Accelerator Pedal
SPEED CONTROL SYSTEM

Kick-down switch tightening torque:
12 N⋅m (1.2 kgf-m, 9 ft-lb)

(A)

L
OFF
ON
SP-00028

(A) Kick down switch

SP(H4SO)-8

Accelerator Control Cable
SPEED CONTROL SYSTEM

3. Accelerator Control Cable
A: REMOVAL
1) Remove the accelerator pedal. <Ref. to
SP(H4SO)-4, REMOVAL, Accelerator Pedal.>
2) Separate the accelerator cable and accelerator
pedal.

B: INSTALLATION
1) Install in the reverse order of removal.
NOTE:
• If the cable clamp is damaged, replace it with a
new one.
• Never fail to cover the outer cable end with boot.
• Be careful not to kink the accelerator cable.
CAUTION:
Do not apply grease to except specified part.
2) Apply grease to engine side accelerator cable
end.
Grease:
Slicolube G-30M (Part No. 004404002)

(A)

(B)

SP-00042

(A) Accelerator cable end
(B) Throttle cam

3) Adjustment after pedal installation. <Ref. to
SP(H4SO)-7, ADJUSTMENT, Accelerator Pedal.>

C: INSPECTION
1) Make sure the inner cable is not twisted or worn.
2) Make sure the outer cable is not cracked.

SP(H4SO)-9

Accelerator Control Cable
SPEED CONTROL SYSTEM

SP(H4SO)-10