Subaru 2004 FORESTER Service Manual
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Subaru 2004 FORESTER Service Manual

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2004 Model Year
PDF Service Manual
General Information SECTION (Pub.No.G8080GE1)
ENGINE SECTION 1 (Pub.No.G8080GE2)
ENGINE SECTION 2 (Pub.No.G8080GE3)
ENGINE SECTION 3 (Pub.No.G8080GE4)
TRANSMISSION SECTION (Pub.No.G8080GE5)
CHASSIS SECTION (Pub.No.G8080GE6)
BODY SECTION (Pub.No.G8080GE7)
WIRING SYSTEM SECTION (Pub.No.G8080GE8)

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  • Page 1 2004 Model Year PDF Service Manual GENERAL INFORMATION SECTION (Pub.No.G8080GE1) ENGINE SECTION 1 (Pub.No.G8080GE2) ENGINE SECTION 2 (Pub.No.G8080GE3) ENGINE SECTION 3 (Pub.No.G8080GE4) TRANSMISSION SECTION (Pub.No.G8080GE5) CHASSIS SECTION (Pub.No.G8080GE6) BODY SECTION (Pub.No.G8080GE7) WIRING SYSTEM SECTION (Pub.No.G8080GE8)
  • Page 3 2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX GENERAL INFORMATION SECTION FOREWORD HOW TO USE THIS MANUAL SPECIFICATION PRECAUTION This service manual has been prepared to provide SUBARU service personnel NOTE with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
  • Page 5 FOREWORD Page Foreword .....................2...
  • Page 6 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 7: How To Use This Manual

    HOW TO USE THIS MANUAL Page How to Use This Manual ................2...
  • Page 8 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 9 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 10 How to Use This Manual HOW TO USE THIS MANUAL 4. SPECIFICATION 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 11 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 12 How to Use This Manual HOW TO USE THIS MANUAL HU-6...
  • Page 13 SPECIFICATION Page Forester.......................2...
  • Page 14 Forester SPECIFICATION 1. Forester A: DIMENSIONS Model 2.0 L Non-turbo 2.0 L Turbo 2.5 L Non-turbo 2.5 L 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) 1,590 (62.6) Length mm (in)
  • Page 15 Forester SPECIFICATION C: ELECTRICAL Model 2.0 L Non-turbo 2.0 L Turbo 2.5 L Non-turbo 2.5 L Turbo MT: 10°±10°/650 Ignition timing at idling speed BTDC/rpm 10°±10°/650 12°±10°/700 17°±10°/700 AT: 15°±10°/650 CHAMPION: CHAMPION: RC10YC4 RC10YC4 Spark plug Type and manufacturer NGK: PFR6G NGK: ILFR6B Alternate Alternate...
  • Page 16 Forester SPECIFICATION F: SUSPENSION Front Macpherson strut type, Independent, Coil spring Rear Dual-link type, Independent, Coil spring G: BRAKE ★ Model 2.0 L Non-turbo, 2.5 L Non-turbo 2.0 L Turbo, 2.5 L Non-turbo , 2.5 L Non-turbo Service brake system Dual circuit hydraulic with vacuum suspended power unit Front Ventilated disc brake...
  • Page 17 Forester SPECIFICATION J: WEIGHT 1. LHD MODEL ★ Option code Model 2.0 L Non-turbo 2.5 L Non-turbo Grade 2.0 X 2.5 X Transmission Front kgf (lb) (1,675) (1,710) (1,710) (1,740) (1,720) (1,765) Curb weight (C.W.) Rear kgf (lb) (1,325) (1,325) (1,310) (1,310) (1,365)
  • Page 18 Forester SPECIFICATION ★ Option code Model 2.0 L Turbo Grade 2.0 XT Transmission Front kgf (lb) 810 (1,785) 830 (1,830) 815 (1,795) 835 (1,840) Curb weight (C.W.) Rear kgf (lb) 620 (1,365) 620 (1,365) 630 (1,390) 630 (1,390) Total kgf (lb) 1,430 (3,150) 1,450 (3,195) 1,445 (3,185)
  • Page 19 Forester SPECIFICATION 2. RHD MODEL ★ Option code Model 2.0 L Non-turbo 2.0 L Turbo Grade 2.0 X 2.0 XT Transmission Front kgf (lb) 775 (1,710) 790 (1,740) 815 (1,795) 835 (1,840) Curb weight (C.W.) Rear kgf (lb) 600 (1,325) 600 (1,325) 635 (1,400) 635 (1,400)
  • Page 20 Forester SPECIFICATION ★ Option code Model 2.5 L Non-turbo 2.5 L Turbo Grade 2.5 X 2.5 XS 2.5 XT Transmission Front kgf (lb) (1,685) (1,730) (1,675) (1,720) (1,795) (1,840) Curb weight (C.W.) Rear kgf (lb) (1,345) (1,345) (1,335) (1,335) (1,345) (1,345) 1,375 1,395...
  • Page 21 Forester SPECIFICATION 3. OPTION Option Front kgf (lb) Rear kgf (lb) Total kgf (lb) Sport package base 0.1 (0.2) 0.4 (0.9) 0.5 (1.1) −6.5 (−14.3) −6.5 (−14.3) −13.0 (−28.6) 15 IN Aluminum wheel −7.3 (−16.1) −7.3 (−16.1) −14.6 (−32.2) 16 IN −0.1 (−0.2) Front fog light 0.7 (1.5)
  • Page 22 Forester SPECIFICATION SPC-10...
  • Page 23 PRECAUTION Page Precaution ....................2...
  • Page 24 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- •...
  • Page 25 NOTE Page Note......................2...
  • Page 26 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 27 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 28 Note NOTE • Lift NT-00003 • Rigid rack NT-00004 NT-4...
  • Page 29 Note NOTE • Jack-up point NT-00005 Front Rear NT-5...
  • Page 30 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 tie-down Rear Hook for towing and tie-down NT-6...
  • Page 31 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 32 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 33 IDENTIFICATION Page Identification ....................2...
  • Page 34 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 Emission control label Vehicle identification number Saudi Arabia plate (Saudi Arabia model) Built date plate...
  • Page 35 Identification IDENTIFICATION VA-type Label location T-type Stamp location ID-00016 Model number plate FUJI HEAVY INDUSTRIES LTD. J F 1 S G 5 L K 4 3 G 0 0 2 0 0 S G 5 A L 1 K option code applied model E J 2 0 1 NWU A A trim code...
  • Page 36 Identification IDENTIFICATION 2. MEANING OF V.I.N. The meaning of the VIN is as follows: • Europe, Australia and General (Except GCC) ]JF1SG5LK44G002001[ The starting and ending brackets ( ][ ) are stop marks. Digits Code Meaning Details 1 to 3 Manufacturer body area JF1: Passengercar, FHI made JF2: MPV, FHI made Car line...
  • Page 37 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. SG5BL1K Digits Code...
  • Page 38 Identification IDENTIFICATION • Transmission TY755XF3AA Digits Code Meaning Details Transmission T: Transmission Transmission type Y: Full-time AWD MT center differential Z: Full-time AWD AT MPT 3 and 4 Classification 75: MT 1A: AT 1B: AT Series 3: AT 5: MT Transmission specifica- V: Full-time AWD 5-speed MT with viscous coupling center dif- tions...
  • Page 39 RECOMMENDED MATERIAL Page Recommended Materials ................2...
  • Page 40 Recommended Materials RECOMMENDED MATERIAL 1. Recommended Materials A: RECOMMENDED MATERIALS 1. GENERAL To insure the best performance, always use the specified oil, gasoline, adhesive, sealant, etc. or a substitute of equivalent quality. 2. FUEL Always use a gasoline of the same or higher octane value than specified in the owner’s manual.
  • Page 41 Recommended Materials RECOMMENDED MATERIAL 3. LUBRICANTS Use either the lubricants in the table below or equivalent lubricants. See the table below to choose the correct SAE viscosity. Recommended Lubricant Alternative API Spec. CCMC Spec. ACEA Spec. Engine oil SL or SJ Grade “Energy conserving” G4 or G5 A1, A2 or A3 SH or SG...
  • Page 42 Recommended Materials RECOMMENDED MATERIAL SAE viscosity No. and applicable temperature Engine oil Non-turbo model (˚C) –30 –20 –10 (˚F) –22 –4 10W-30 or 10W-40 5W-30 0W-20 Recommend RM-00032 Turbo model –30 –20 –10 (˚C) –4 (˚F) –22 10W-30 or 10W-40 5W-30 Recommend RM-00033 RM-4...
  • Page 43 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 44 Recommended Materials RECOMMENDED MATERIAL Grease Application point Recommended Item number Alternative Grease MT main shaft FX 2200 clutch grease 000040901 — Clutch master cylinder Slicolube G-40M 004404003 — push rod • Gear shift lever SUNLIGHT2 003602010 — • Select lever •...
  • Page 45 Recommended Materials RECOMMENDED MATERIAL 9. SEAL MATERIAL Use seal material shown in the table below, or equivalent. Seal material Application point Recommended Item number Alternative Seal material • Engine case Three Bond 1215B 004403007 Dow Corning’s No. 7038 • Torque converter clutch case •...
  • Page 46 Recommended Materials RECOMMENDED MATERIAL RM-8...
  • Page 47 PRE-DELIVERY INSPECTION Page Pre-delivery Inspection................2...
  • Page 48 • Make sure to deliver a complete vehicle to the customer. Because of the above reasons, all SUBARU distrib- utor service must always carry out the PDIs before delivering a vehicle. In addition, all SUBARU distributor service and PDI...
  • Page 49 Pre-delivery Inspection PRE-DELIVERY INSPECTION B: PDI PROCEDURE Follow the procedures shown in the table below. Static Checks Just After Vehicle Receipt Step Check point 1. Appearance check (1) If the vehicle is covered with protective coating, visually check the vehicle body for damage and dents.
  • Page 50 Pre-delivery Inspection PRE-DELIVERY INSPECTION Checks with the Engine Running Step Check point 26. Test mode connectors Test mode connectors 27. Starting condition Start the engine and check that the engine starts smoothly. 28. Exhaust system Check that the exhaust noise is normal and no leaks are found. 29.
  • Page 51 Pre-delivery Inspection PRE-DELIVERY INSPECTION 1. APPEARANCE CHECK 4. CONNECTION OF AIR CONDITIONER HARNESS 1) If the vehicle is covered with protective coating, visually check the vehicle body for damage and A vehicle just delivered has its air conditioner har- dents. ness disconnected to protect the air conditioner 2) If there is no protective coating, check the body compressor.
  • Page 52 Pre-delivery Inspection PRE-DELIVERY INSPECTION 2) Close the driver’s door completely, and place the 6. CHECK DOUBLE LOCK OPERATION. door lock knob (A) to the lock position. Then pull in- 1) Fully open all the windows. side door handles (B) to ensure that doors will not 2) Remove the key.
  • Page 53 Pre-delivery Inspection PRE-DELIVERY INSPECTION 8. CHECK THE REAR GATE FOR LOCK/ 10.ACCESSORY CHECK UNLOCK AND OPEN/CLOSE OPERA- Check that the following accessories are provided TIONS. in the luggage compartment or cargo area. • Owner’s manual 1) Open and close the rear gate several times for •...
  • Page 54 Pre-delivery Inspection PRE-DELIVERY INSPECTION 11.OPERATION CHECK OF HOOD LOCK 12.BATTERY RELEASE SYSTEM Check the battery terminals to make sure that no rust or corrosions due to fluid leaks are found. Operate the hood release knob and check that the Check that the battery caps are securely tightened. hood is unlocked normally.
  • Page 55 Pre-delivery Inspection PRE-DELIVERY INSPECTION 15.TRANSMISSION FLUID 18.CLUTCH FLUID Check the transmission fluid amount. If the amount Check the clutch fluid amount. If the amount is in- is insufficient, check that no leaks are found. Then, sufficient, check that no leaks are found. Then, add add the necessary amount of the specified fluid.
  • Page 56 Pre-delivery Inspection PRE-DELIVERY INSPECTION 21.KEYLESS ENTRY SYSTEM • Close all doors and rear gate, press the “LOCK” button of the keyless transmitter. Press the “UN- Check the keyless entry system operations as fol- LOCK” button of the keyless transmitter and wait lows: for 30 seconds.

  • Page 57: Parking Brake

    Pre-delivery Inspection PRE-DELIVERY INSPECTION 29.CLOCK Rear injection position: A: 35 mm (1.38 in) Check the clock for normal operations and enough ° B: 72 accuracy. 30.RADIO Check the radio for full functionality and normal noise level. Also check the CD unit operations. 31.FRONT ACCESSORY POWER SUPPLY SOCKET Check the front accessory power supply socket op-...
  • Page 58 Pre-delivery Inspection PRE-DELIVERY INSPECTION 6) Set the AT select lever to each gear position 42.POWER STEERING FLUID LEVEL while checking that the demanded gear position is Check that the power steering fluid level is normal. correctly attained. If insufficient, check that no leaks are found. Then add the necessary amount of the specified power steering fluid.
  • Page 59 Pre-delivery Inspection PRE-DELIVERY INSPECTION If any dampness in the compartment is discovered 4) Check each portion of the vehicle body and un- after the water has been applied, carefully check all derside components for the formation of rust. If rust areas that may have possibly contributed to the is discovered, remove it with #80 —...
  • Page 60 Pre-delivery Inspection PRE-DELIVERY INSPECTION PI-14...

  • Page 61: Table Of Contents

    PERIODIC MAINTENANCE SERVICE Page General Description ..................2 Schedule .....................3 Engine Oil....................7 Engine Oil Filter...................9 Spark Plugs....................10 V-belt......................11 Timing Belt ....................13 Fuel Line ....................17 Fuel Filter ....................18 Air Cleaner Element ..................19 Cooling System ..................20 Engine Coolant..................21 Clutch System ...................23 Transmission Gear Oil ................24 Hill-holder System ..................25 ATF ......................26 Front &...

  • Page 62: General Description

    General Description PERIODIC MAINTENANCE SERVICE 1. General Description A: GENERAL Be sure to perform periodic maintenance in order to maintain vehicle performance and find problems before they become serious. PM-2...
  • Page 63 Schedule PERIODIC MAINTENANCE SERVICE 2. Schedule A: MAINTENANCE SCHEDULE 1 1. FOR EUROPE AREA For periodic maintenance of over 120,000 km (75,000 miles) or 96 months, carry out inspection by referring to the following table. For a maintenance period gone beyond these tables, apply them repeatedly as a set of 120,000 km (75,000 miles) or 96 months.

  • Page 64: Table Of Contents

    Schedule PERIODIC MAINTENANCE SERVICE 2. EXCEPT FOR EUROPE AREA For periodic maintenance of over 50,000 km (30,000 miles) or 48 months, carry out inspections by referring to the following tables. For a maintenance period gone beyond these tables, apply them repeatedly as a set of 50,000 km (30,000 miles) or 48 months.
  • Page 65 Schedule PERIODIC MAINTENANCE SERVICE B: MAINTENANCE SCHEDULE 2 1. EUROPE AREA Salt or other Repeat Extremely High humid- Repeat short corrosive Repeat tow- Item Every rough/muddy cold weather ity or moun- distance drive used or ing trailer road drive area tain area coastal area Engine oil...
  • Page 66 Schedule PERIODIC MAINTENANCE SERVICE 2. EXCEPT FOR EUROPE AREA Salt or other Repeat Extremely High humid- Repeat short corrosive Repeat tow- Item Every rough/muddy cold weather ity or moun- distance drive used or ing trailer road drive area tain area coastal area Engine oil Replace...

  • Page 67: Engine Oil

    Engine Oil PERIODIC MAINTENANCE SERVICE 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 68 API classification and SAE viscosity No. designat- ed by SUBARU. NOTE: If the vehicle is used in areas with very high temper-...

  • Page 69: Engine Oil Filter

    Engine Oil Filter PERIODIC MAINTENANCE SERVICE 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) or 65 mm 1) Remove six clips securing service hole cover.

  • Page 70: Spark Plugs

    Spark Plugs PERIODIC MAINTENANCE SERVICE 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 71 V-belt PERIODIC MAINTENANCE SERVICE 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-11, REPLACEMENT, V-belt.>...
  • Page 72 V-belt PERIODIC MAINTENANCE SERVICE 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 73: Timing Belt

    Timing Belt PERIODIC MAINTENANCE SERVICE 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 74 Timing Belt PERIODIC MAINTENANCE SERVICE 16) Install in the reverse order of removal. <Ref. to 11) Remove the timing belt guide. (MT model) ME(H4SO)-49, INSTALLATION, Timing Belt.> 2. TURBO MODEL 1) Remove the radiator fan and air conditioner fan. <Ref. to CO(H4SO)-35, Radiator Main Fan and Fan Motor.>...
  • Page 75 Timing Belt PERIODIC MAINTENANCE SERVICE ST 499987500 CRANKSHAFT SOCKET 16) Install in the reverse order of removal. <Ref. to ME(H4DOTC)-58, 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 76 Timing Belt PERIODIC MAINTENANCE SERVICE 4) Install the timing belt cover (LH). PM-00097 PM-16...

  • Page 77: Fuel Line

    Fuel Line PERIODIC MAINTENANCE SERVICE 8. Fuel Line A: INSPECTION Check pipes and areas near pipes for rust, hose damage, loose bands, etc. If faulty parts are found, repair or replace them. <Ref. to FU(H4SO)-63, Fuel Delivery, Return and Evaporation Lines.> PM-17...

  • Page 78: Fuel Filter

    Fuel Filter PERIODIC MAINTENANCE SERVICE 9. Fuel Filter A: REPLACEMENT For fuel filter replacement procedures, refer to “FU” section. <Ref. to FU(H4SO)-60, Fuel Filter.> B: INSPECTION 1) If fuel filter is clogged, or if replacement interval has been reached, replace it. 2) If water is found in it, shake and expel the water from inlet port.

  • Page 79: Air Cleaner Element

    Air Cleaner Element PERIODIC MAINTENANCE SERVICE 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 80: Cooling System

    Thermostat.> <Ref. CO(H4SO)-28, Radiator.> <Ref. to CO(H4SO)-34, 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)-13, Radiator Fan System.>...

  • Page 81: Engine Coolant

    The SUBARU Genuine Coolant containing anti- A: REPLACEMENT freeze and anti-rust agents is especially made for SUBARU engine, which has an aluminum crank- 1. REPLACEMENT OF ENGINE COOLANT case. Always use SUBARU Genuine Coolant, since other coolant may cause corrosion.
  • Page 82 The concentration and safe operating temperature centration in the above diagram and replace the of the SUBARU Genuine Coolant is shown in the necessary amount of coolant with an undiluted so- diagram. Measuring the temperature and specific lution of SUBARU Genuine Coolant (concentration gravity of the coolant will provide this information.

  • Page 83: Clutch System

    Clutch System PERIODIC MAINTENANCE SERVICE 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 84: Transmission Gear Oil

    Transmission Gear Oil PERIODIC MAINTENANCE SERVICE 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 85: Hill-Holder System

    Hill-holder System PERIODIC MAINTENANCE SERVICE 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 86 NOTE: gine to raise ATF temperature to 70 — 80°C (158 Before starting work, cool off ATF well. — 176°F) on Subaru Select Monitor. <Ref. to 4AT(H4SO)-18, READ CURRENT DATA, OPERA- TION, Subaru Select Monitor.> 2) Make sure the vehicle is level.
  • Page 87 PERIODIC MAINTENANCE SERVICE 4) Check the ATF level. <Ref. to PM-26, INSPEC- TION, ATF.> PI-00105 (A) Level gauge (B) Check position when “HOT” (C) Upper level (D) Lower level (E) Check position when “COLD” 2. ATF FILTER NOTE: ATF filter is a maintenance free part. ATF filter needs replacement, when it has physically dam- aged or ATF leaked.
  • Page 88 Front & Rear Differential Oil PERIODIC MAINTENANCE SERVICE 17.Front & Rear Differential Oil Differential gear oil capacity: 1.1 — 1.32 (1.2 — 1.4 US qt, 1.0 — 1.1 Imp qt) A: REPLACEMENT 1. FRONT DIFFERENTIAL (MT MODEL) For MT model, manual transmission oil works as differential oil to lubricate differential.
  • Page 89 Front & Rear Differential Oil PERIODIC MAINTENANCE SERVICE 5) After installing the drain plug onto rear differen- 6) Install the filler plug or oil temperature switch tial gear case firmly, fill oil up fully to the mouth of onto rear differential gear case firmly. filler plug.
  • Page 90 Brake Line PERIODIC MAINTENANCE SERVICE 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 91 Brake Line PERIODIC MAINTENANCE SERVICE (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 92: Brake Fluid

    Brake Fluid PERIODIC MAINTENANCE SERVICE 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 93: Disc Brake Pads And Discs

    Disc Brake Pads and Discs PERIODIC MAINTENANCE SERVICE 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 94 Brake Linings and Drums PERIODIC MAINTENANCE SERVICE 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 95 Brake Linings and Drums PERIODIC MAINTENANCE SERVICE 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 96 Suspension PERIODIC MAINTENANCE SERVICE 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) Grasp the bottom of tire and move it in and out.
  • Page 97 Suspension PERIODIC MAINTENANCE SERVICE 4. WHEEL ALIGNMENT OF FRONT SUS- 6. OIL LEAKAGE OF STRUT PENSION Visually inspect the front strut and rear strut for oil leakage as instructed. If oil leakage reaches under 1) Check the alignment of front suspension to en- spring seat lower portion, replace the front strut and sure that following items conform to standard val- rear strut.

  • Page 98: Wheel Bearing

    Wheel Bearing PERIODIC MAINTENANCE SERVICE 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 99: Axle Boots & Joints

    Axle Boots & Joints PERIODIC MAINTENANCE SERVICE 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 100: Tire Rotation

    Tire Rotation PERIODIC MAINTENANCE SERVICE 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 101 Steering System (Power Steering) PERIODIC MAINTENANCE SERVICE 26.Steering System (Power 2. STEERING SHAFT JOINT Steering) 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 102 Steering System (Power Steering) PERIODIC MAINTENANCE SERVICE (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 103 Steering System (Power Steering) PERIODIC MAINTENANCE SERVICE 7. HOSES OF OIL PUMP FOR DAMAGES 10.FITTING BOLTS AND NUTS Check the pressure hose and return hose of oil Inspect the fitting bolts and nuts of oil pump and pump for crack, swell or damage. Replace the hose bracket for looseness, and retighten them if neces- with a new one if necessary.
  • Page 104 Steering System (Power Steering) PERIODIC MAINTENANCE SERVICE PM-44...

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