Subaru Forester SG 2004 Manual
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Subaru Forester SG 2004 Manual

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FOREWORD
FOREWORD
1. Foreword
A: FOREWORD
These manuals are used when performing mainte-
nance, repair, or diagnosis of the Subaru FOREST-
ER.
Applied model: SG***** from 2004MY
The manuals contain the latest information at the
time of publication. Changes in specifications,
methods, etc. may be made without notice.
FW-2

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Summary of Contents for Subaru Forester SG 2004

  • Page 1 FOREWORD 1. Foreword A: FOREWORD These manuals are used when performing mainte- nance, repair, or diagnosis of the Subaru FOREST- Applied model: SG***** from 2004MY The manuals contain the latest information at the time of publication. Changes in specifications, methods, etc. may be made without notice.
  • Page 2 HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL 1. How to Use This Manual A: HOW TO USE THIS MANUAL 1. STRUCTURE Each section consists of SCT that are broken down into SC that are divided into sections for each com- ponent.

  • Page 3: How To Use This Manual

    HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL 3. COMPONENTS Illustrations are listed for each component. The information necessary for repair work (tightening torque, grease up points, etc.) is described on these illustrations. Information is described using symbol. To order the parts, refer to parts catalogue.

  • Page 4: Specifications

    HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL 4. SPECIFICATIONS If necessary, specifications are also included. 5. INSPECTION Inspections are included to be carried out before and after maintenance. 6. MAINTENANCE • Maintenance instructions for serviceable parts describes work area and detailed steps with illustration. It also describes the use of special tool, tightening torque, cautions for each procedure.
  • Page 5 HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL 7. DIAGNOSIS Tables showing a step-by-step process make it easy to conduct diagnosis. 8. SI UNITS Measurements in these manuals are according to the SI units. Metric and yard/pound measurements are also included.
  • Page 6 HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL HU-6...
  • Page 7 IDENTIFICATION IDENTIFICATION 1. Identification A: IDENTIFICATION 1. IDENTIFICATION NUMBER AND LABEL LOCATIONS The VIN (Vehicle Identification Numbers) is used to classify the vehicle. Positioning of the plate label for identification Vacuum hose piping label Vehicle identification number plate Emission control label Vehicle identification number Bar cord label...
  • Page 8 IDENTIFICATION IDENTIFICATION Model number plate FUJI HEAVY INDUSTRIES LTD. J F 1 S G 6 3 5 X 3 G 7 0 0 0 0 S G 9 A Y 7 J option code applied model E J 2 5 1 BWU A A trim code engine type 2 3 0...
  • Page 9 IDENTIFICATION IDENTIFICATION 3. MODEL NUMBER PLATE The model number plate indicates: the applied model, the option code, the trim code, the engine type, the transmission type, and the exterior color code. This information is helpful when placing orders for parts. SG9BY7J Digits Code...
  • Page 10 IDENTIFICATION IDENTIFICATION • Rear differential Code Reduction gear ratio 4.111 4.111 Viscous 4.444 4.444 Viscous • Option code U4QW Digits Code Meaning Details 1 to 2 Destination U4: U.S.A. CO: Canada 3 to 4 Main option of vehicle — ID-5...
  • Page 11 IDENTIFICATION IDENTIFICATION ID-6...
  • Page 12 4. SERVICE PARTS Use authentic service parts for maximum perfor- mance and maintenance, when conducting repairs. Subaru/FHI will not be responsible for poor perfor- mance resulting from the use of parts not specified by a genuine dealer. 5. PROTECTING VEHICLE UNDER MAIN-...
  • Page 13 NOTE NOTE 7. LIFTS AND JACKS When using a lift or jack to raise a vehicle, always follow instructions concerning jack-up points and weight limits to prevent the vehicle from falling, which could result in injury. Be especially careful to make sure the vehicle is balanced before raising it.
  • Page 14 NOTE NOTE • Lift NT-00003 • Safety stand NT-00004 NT-4...
  • Page 15 NOTE NOTE • Jack-up point NT-00005 Front Rear NT-5...
  • Page 16 NOTE NOTE 8. TIE-DOWNS Tie-downs are used when transporting vehicles and when using the chassis dynamo. Attach tie-downs only to the specified points on the vehicle. NT-00006 Front Hook for towing and tie-down Hook for tie-down Rear NT-6...
  • Page 17 NOTE NOTE • Chain direction at tie-down condition • Vehicle sinking volume at tie-down condition Measure the distance L between tire highest point to arch highest point before tie-down and after tie- down. Difference of measurement value (drop height) shall be within 50 mm (1.97 in). Make sure to fix the vehicle securely.
  • Page 18 For information about training, contact a dealer or Using general scan tools will greatly improve effi- agent. ciency of repairing engine electronic controls. The SUBARU Select Monitor can be used to diagnose the engine and also the ABS, the air conditioner, and other parts. NT-8...

  • Page 19: Cooling System

    Thermostat.> <Ref. CO(H4SO)-26, Radiator.> <Ref. to CO(H4SO)-32, Radiator Cap.> 4) Check the radiator fan operates using SUBARU Select Monitor, when the coolant temperature ex- ceeds 95°C (203°F). If not operate, check the radi- ator fan system. <Ref. to CO(H4SO)-11, Radiator Fan System.>...

  • Page 20: Disc Brake Pad And Disc

    DISC BRAKE PADS AND DISCS PERIODIC MAINTENANCE SERVICES 20.Disc Brake Pads and Discs 3) Check the disc rotor, and correct or replace if it is damaged or worn. A: INSPECTION Brake disc thickness mm (in) 1. DISC BRAKE PAD AND DISC Front Rear Standard...

  • Page 21: Engine Oil Filter

    ENGINE OIL FILTER PERIODIC MAINTENANCE SERVICES 4. Engine Oil Filter 6) Install the oil filter by turning it by hand, being careful not to damage the seal rubber. A: REPLACEMENT • Tighten the oil filter 80 mm (3.15 in) in diameter 1) Remove six clips securing service hole cover.

  • Page 22: Engine Oil

    ENGINE OIL PERIODIC MAINTENANCE SERVICES 3. Engine Oil 4) Drain the engine oil by loosening engine oil drain plug. A: REPLACEMENT 1) Open the engine oil filler cap for quick draining of the engine oil. LU-00007 (A) Engine oil drain plug (B) Engine oil filter PM-00155 5) Replace the drain plug gasket with a new one.
  • Page 23 “F” line when the engine is cold. gine; however, use oil having the API classification and SAE viscosity No. designated by SUBARU. • If vehicle is used in desert areas with very high temperatures or for other heavy duty applications,...

  • Page 24: Front & Rear Differential Oil

    FRONT & REAR DIFFERENTIAL OIL PERIODIC MAINTENANCE SERVICES 17.Front & Rear Differential Oil Differential gear oil capacity: 1.1 — 1.3 2 (1.2 — 1.4 US qt, 1.0 — 1.1 lmp qt) A: REPLACEMENT 1. FRONT DIFFERENTIAL (MT MODEL) For MT model, manual transmission oil works as differential oil to lubricate differential.
  • Page 25 FRONT & REAR DIFFERENTIAL OIL PERIODIC MAINTENANCE SERVICES 5) Install the filler plug onto rear differential gear case firmly. NOTE: Apply liquid gasket to the draining plug threads. Liquid gasket: Three Bond 1105 (Part No. 004403010) Tightening torque: 49.0 N·m (5.0 kgf-m, 36.2 ft-lb) PM-27...

  • Page 26: Hill-Holder System

    HILL-HOLDER SYSTEM PERIODIC MAINTENANCE SERVICES 15.Hill-holder System A: INSPECTION AND ADJUSTMENT 1) Confirm the stopping and starting performance by activating the hill-holder on an uphill road of 3° or higher inclination. (1) When the vehicle does not stop; Tighten the adjusting nut of PHV cable. (2) When the vehicle does not start properly;...
  • Page 27 SCHEDULE PERIODIC MAINTENANCE SERVICES 2. Schedule A: MAINTENANCE SCHEDULE 1 MAINTENANCE INTERVAL [Number of months or km (miles), whichever occurs first] Months 7.5 15 22.5 30 37.5 45 52.5 60 67.5 75 82.5 90 97.5 105 112.5 120 × 1,000 km 4.8 12 72 81.4 96 108 120 132 144 156 168 180 192 Remarks...
  • Page 28 SCHEDULE PERIODIC MAINTENANCE SERVICES B: MAINTENANCE SCHEDULE 2 Item Every Repeat short Repeat Extremely Salt or other High humidity Repeat tow- distance rough/muddy cold weather corrosive or mountain ing trailer drive road drive area used or area coastal area Engine oil 3.75 months 6,000 km 3,750 miles...

  • Page 29: Spark Plugs

    SPARK PLUGS PERIODIC MAINTENANCE SERVICES 5. Spark Plugs A: REPLACEMENT 1) Remove the intake duct and intake chamber. 2) Remove the washer tank and put it aside. 3) Disconnect the spark plug cord. 4) Remove the spark plug with a plug-wrench. PM-00001 5) Set the new spark plug.

  • Page 30: Steering System (Power Steering)

    STEERING SYSTEM (POWER STEERING) PERIODIC MAINTENANCE SERVICES 26.Steering System (Power 2. STEERING SHAFT JOINT Steering) 1) When the steering wheel free play is excessive, disconnect the universal joint of steering shaft and A: INSPECTION check it for any play and yawing torque (at the point of the crossing direction).

  • Page 31: Power Steering Fluid Level

    STEERING SYSTEM (POWER STEERING) PERIODIC MAINTENANCE SERVICES (2) Retighten the adjusting screw to 7.4 N·m 3) Check the lock nut on tie-rod end for tightness. If (0.75 kgf-m, 5.4 ft-lb) and back off 25°. it is loose, retighten it to the specified torque. (3) Apply Liquid gasket to at least 1/3 of entire Tightening torque: perimeter of adjusting screw thread.
  • Page 32 STEERING SYSTEM (POWER STEERING) PERIODIC MAINTENANCE SERVICES 7. HOSES OF OIL PUMP FOR DAMAGES Check the pressure hose and return hose of oil pump for crack, swell or damage. Replace the hose with a new one if necessary. NOTE: Prevent the hoses from revolving and/or turning when installing hoses.

  • Page 33: Supplemental Restraint System

    SUPPLEMENTAL RESTRAINT SYSTEM PERIODIC MAINTENANCE SERVICES 27.Supplemental Restraint System A: INSPECTION Check the airbag system in accordance with the result of the self-diagnosis. <Ref. to AB-2, Basic Diagnostic Procedure.> 1) Ensure that airbag connectors are connected. If not, properly connect. When the ignition switch is turned ON with the connector(s) disconnected, the airbag warning light blinks to identify the fault.
  • Page 34 SUSPENSION PERIODIC MAINTENANCE SERVICES 22.Suspension If the front wheel toe-in is not at specified value, ad- just the toe-in. <Ref. to FS-6, Wheel Alignment.> A: INSPECTION 1. SUSPENSION BALL JOINT 1) Jack-up the vehicle until front wheels are off ground. 2) Next, grasp the bottom of tire and move it in and out.
  • Page 35 SUSPENSION PERIODIC MAINTENANCE SERVICES 4. WHEEL ALIGNMENT OF FRONT SUS- 8. DAMAGE TO SUSPENSION PARTS PENSION Check the following parts and the fastening portion of the vehicle body for deformation or excessive 1) Check the alignment of front suspension to en- rusting which impairs the suspension.

  • Page 36: Timing Belt

    TIMING BELT PERIODIC MAINTENANCE SERVICES 7. Timing Belt 11) Turn the crankshaft and align alignment marks on crankshaft, and right and left cam sprockets with A: REPLACEMENT notches of belt cover and cylinder block. ST 499987500 CRANKSHAFT SOCKET 1. NON-TURBO MODEL 1) Remove the radiator fan and air conditioner fan.
  • Page 37 TIMING BELT PERIODIC MAINTENANCE SERVICES 16) Install in the reverse order of removal. <Ref. to 11) Remove the timing belt guide. (MT model) ME(H4SO)-47, INSTALLATION, Timing Belt As- sembly.> 2. TURBO MODEL 1) Remove the radiator fan and air conditioner fan. <Ref.
  • Page 38 TIMING BELT PERIODIC MAINTENANCE SERVICES ST 499987500 CRANKSHAFT SOCKET 16) Install in the reverse order of removal. <Ref. to ME(H4DOTC)-50, Timing Belt Assembly.> CAUTION: When installing the timing belt, be sure to align all alignment marks on the belt with corre- sponding marks on the sprockets.
  • Page 39 TIMING BELT PERIODIC MAINTENANCE SERVICES 4) Install the timing belt cover (LH). PM-00097 PM-14...

  • Page 40: Tire Rotation

    TIRE ROTATION PERIODIC MAINTENANCE SERVICES 25.Tire Rotation A: INSPECTION 1) Replace the tire if the tread depth is less than 1.6 mm (0.063 in) or if wear indicators appear across the tire tread. CAUTION: It is recommended that both right and left tires are replace as a set.

  • Page 41: Transmission Gear Oil

    TRANSMISSION GEAR OIL PERIODIC MAINTENANCE SERVICES 14.Transmission Gear Oil A: REPLACEMENT 1. MANUAL TRANSMISSION 1) Drain the gear oil by removing drain plug. CAUTION: • Before starting work, cool off the transmis- sion gear oil well. • If transmission gear oil adheres to the ex- haust pipe, wipe it off completely.
  • Page 42 V-BELT PERIODIC MAINTENANCE SERVICES 6. V-belt • Turbo model A: INSPECTION 1) Replace the belts, if cracks, fraying or wear is found. 2) Check the V-belt tension and adjust it if neces- sary by changing the generator installing position or idler pulley installing position. <Ref. to PM-9, RE- PLACEMENT, V-belt.>...
  • Page 43 V-BELT PERIODIC MAINTENANCE SERVICES 3. REAR SIDE BELT (DRIVING AIR CONDI- TIONER) NOTE: Wipe off any oil or water on the belt and pulley. 1) Remove the front side belt. 2) Loosen the lock nut (A). 3) Loosen the slider bolt (B). 4) Remove the rear side belt.

  • Page 44: Front Wheel Bearing

    WHEEL BEARING PERIODIC MAINTENANCE SERVICES 23.Wheel Bearing Service limit: Straight-ahead position within 0.05 mm A: INSPECTION (0.0020 in) 5) Remove the DOJ of rear drive shaft from rear dif- 1. FRONT WHEEL BEARING ferential. <Ref. to DS-39, Rear Drive Shaft.> NOTE: 6) While supporting the rear drive shaft horizontally Inspect the condition of front wheel bearing grease.

  • Page 45: Air Cleaner Element

    AIR CLEANER ELEMENT PERIODIC MAINTENANCE SERVICES 10.Air Cleaner Element 2) Remove the air cleaner. A: REMOVAL 1. NON-TURBO MODEL 1) Remove the air intake duct from air cleaner case. 2) Remove the bolt (A) which installs air cleaner case to stays. 3) Remove the clip (B) above the air cleaner case.

  • Page 46: Axle Boots & Joints

    AXLE BOOTS & JOINTS PERIODIC MAINTENANCE SERVICES 24.Axle Boots & Joints A: INSPECTION 1. FRONT AND REAR AXLE BOOTS Inspect the front axle boots (A) and rear axle boots (B) for deformation, damage or failure. If faulty, re- place them with new ones. <Ref. to DS-33, Front Drive Shaft.>...

  • Page 47: Brake Fluid

    BRAKE FLUID PERIODIC MAINTENANCE SERVICES 19.Brake Fluid • During the bleeding operation, keep the brake reservoir tank filled with brake fluid to A: REPLACEMENT eliminate entry of air. 1) Lift-up the vehicle. • The brake pedal operating must be very slow. 2) Remove both front and rear wheels.
  • Page 48 BRAKE LINE PERIODIC MAINTENANCE SERVICES 18.Brake Line B: CHECKING A: INSPECTION 1. SERVICE BRAKE 1) Check the free play of brake pedal with a force of 1. BRAKE LINE less than 10 N (1 kgf, 2 lb). 1) Check scratches, swelling, corrosion, traces of Brake pedal free play: fluid leakage on the brake hoses or pipe joints.

  • Page 49: Brake Line

    BRAKE LINE PERIODIC MAINTENANCE SERVICES (4) If there is no free play between clevis pin 4) Check to see if air is in the hydraulic brake line and clevis, turn the brake switch adjusting nut by the feel of pedal operation. If air appears to exist until the clearance between stopper and screw in the line, bleed it from the system.

  • Page 50: Brake Linings And Drums

    BRAKE LININGS AND DRUMS PERIODIC MAINTENANCE SERVICES 21.Brake Linings and Drums If deformation or wear of back plate, shoe, etc. is noticeable, replace the affected parts. A: INSPECTION 1. REAR DRUM BRAKE 1) Remove the brake drum, and check that there is no fluid leakage from wheel cylinder.
  • Page 51 BRAKE LININGS AND DRUMS PERIODIC MAINTENANCE SERVICES 2) Check the disk rotor for wear, dents or other B: ADJUSTMENT damage. If the inside surface of disk rotor is 1. REAR DRUM BRAKE streaked, correct the surface with emery cloth (#200 or more). If it is unevenly worn or tapered, The main brake is adjusted automatically, and so correct or replace it.

  • Page 52: Clutch System

    CLUTCH SYSTEM PERIODIC MAINTENANCE SERVICES 13.Clutch System CAUTION: • Prevent the clutch fluid from being splashed A: INSPECTION AND ADJUSTMENT over vehicle body. If the clutch fluid is splashed 1) Push the release lever to retract the push rod of over vehicle body, flush it, and then wipe it up.
  • Page 53 2) Remove the under cover. The concentration and safe operating temperature 3) Place a container under drain pipe. of the SUBARU Genuine Coolant is shown in the 4) Loosen and remove the drain cock to drain en- diagram. Measuring the temperature and specific gine coolant into container.
  • Page 54 SUBARU Genuine Coolant (concentration 50%). The amount of coolant that should be replaced can be determined using the diagram.

  • Page 55: Recommended Materials

    RECOMMENDED MATERIALS RECOMMENDED MATERIALS 1. Recommended Materials 2. FUEL Always use a gasoline of the same or higher octane A: RECOMMENDED MATERIALS value than specified in the owner’s manual. Ignor- ing the specifications below will result in damage or 1. GENERAL poor operation of the engine and fuel injection sys- To insure the best performance, always use the tem.
  • Page 56 RECOMMENDED MATERIALS RECOMMENDED MATERIALS SAE viscosity No. and applicable temperature SAE J300 Engine oil –20 –10 (˚C) –30 –22 –4 (˚F) 10W-30 or 10W-40 5W-30 Recommend RM-00003 Manual transmission oil and rear differential oil –30 –20 –10 (˚C) –22 –4 (˚F) 75W-90 RM-00004...

  • Page 57: Engine Coolant

    Distilled water — Tap water (Soft water) 6. REFRIGERANT Standard air conditioners on Subaru vehicles use HFC134a refrigerant. Do not mix it with other refrigerants. Also, do not use any air compressor oil except for ZXL200PG. Air conditioner Recommended Item number...
  • Page 58 Use the grease and supplementary lubricants shown in the table below. Grease Application point Recommended Item number Alternative Supplementary lubricants • O sensor SUBARU CRC 004301003 — • Bolts, etc. Grease MT main shaft FX2200 clutch grease 000040901 — Clutch master cylinder...

  • Page 59: Seal Material

    RECOMMENDED MATERIALS RECOMMENDED MATERIALS 9. SEAL MATERIAL Use seal material shown in the table below, or equivalent. Seal material Application point Recommended Item number Alternative Seal material • Cylinder block Three Bond 1215 004403007 Dow Corning’s No. 7038 • Torque converter clutch case Transmission oil pan Three Bond 1217B...
  • Page 60 FORESTER SPECIFICATIONS 1. Forester A: DIMENSIONS 2.5 L Model Non-turbo Turbo Overall length mm (in) 4,450 (175.2) Overall width mm (in) 1,735 (68.3) Overall height (at C.W.) mm (in) 1,590 (62.6) 1,585 (62.4) 1,012 (39.8) Front mm (in) 992 (39.0)*1 Head room 998 (39.3) Rear...
  • Page 61 FORESTER SPECIFICATIONS D: TRANSMISSION Model 2.5L Non-turbo 2.5L Turbo Transmission type Clutch type DSPD DSPD 3.454 3.027 3.454 2.785 2.062 1.619 1.947 1.545 1.448 1.000 1.366 1.000 Gear ratio 1.088 0.694 0.972 0.694 0.780 — 0.738 — Reverse 3.333 2.272 3.333 2.272 Type of gear...
  • Page 62 FORESTER SPECIFICATIONS I: CAPACITY 2.5L Non-turbo 2.5L Turbo Model 2 (US gal, Imp gal) Fuel tank 60 (15.9, 13.2) Engine oil 2 (US qt, Imp qt) Approx. 4.0 (4.2, 3.5) (When replaced) 2 (US qt, Imp qt) Transmission gear oil —...
  • Page 63 FORESTER SPECIFICATIONS Option code★1 U4OU U4NR 2.5 L Non-turbo Model 2.5 XS Front kg (lb) 785 (1,730) 805 (1,775) 785 (1,730) 805 (1,775) Curb weight (C.W.) Rear kg (lb) 640 (1,410) 640 (1,410) 640 (1,415) 640 (1,415) Total kg (lb) 1,425 (3,140) 1,445 (3,185) 1,425 (3,145)
  • Page 64 FORESTER SPECIFICATIONS Option code★1 U4NQ U4PV U4PU U4OU U4NR 2.5 L Turbo Model 2.5 XT Front kg (lb) (1,820) (1,860) (1,820) (1,860) (1,830) (1,865) (1,830) (1,870) (1,830) (1,870) Curb weight (C.W.) Rear kg (lb) (1,390) (1,395) (1,390) (1,390) (1,420) (1,420) (1,430) (1,430) (1,430)
  • Page 65 FORESTER SPECIFICATIONS 2. FOR CANADA MODEL Option code★1 COQW CONQ COPV 2.5 L Non-turbo Model 2.5 X 2.5 XS Front kg (lb) (1,720) (1,765) (1,720) (1,765) (1,720) (1,765) Curb weight (C.W.) Rear kg (lb) (1,370) (1,370) (1,375) (1,375) (1,375) (1,375) 1,400 1,420 1,405...
  • Page 66 FORESTER SPECIFICATIONS Option code★1 COPU CONR COOU 2.5 L Non-turbo Model 2.5 XS Front kg (lb) (1,725) (1,770) (1,730) (1,775) (1,730) (1,775) Curb weight (C.W.) Rear kg (lb) (1,405) (1,405) (1,415) (1,415) (1,410) (1,410) 1,420 1,440 1,425 1,445 1,425 1,445 Total kg (lb) (3,130)

  • Page 67: Optional Parts

    FORESTER SPECIFICATIONS Option code★1 CONQ COPV COPU CONR COOU 2.5 L Turbo Model 2.5 XT Front kg (lb) (1,820) (1,860) (1,820) (1,860) (1,830) (1,865) (1,830) (1,875) (1,830) (1,875) Curb weight (C.W.) Rear kg (lb) (1,390) (1,395) (1,390) (1,390) (1,410) (1,410) (1,420) (1,420) (1,420)
  • Page 68 FORESTER SPECIFICATIONS SPC-10...
  • Page 69 PRECAUTION PRECAUTION 1. Precaution 7. AIRBAG MODULE Adhere to the following when handling and storing A: PRECAUTION the airbag module to prevent bodily injury from un- Please clearly understand and adhere to the follow- expected deployment: ing general precautions. They must be strictly fol- •...

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