Subaru Forester SG 2004 Manual Download Page 1

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FW-2

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.

Summary of Contents for Forester SG 2004

Page 1: ...anuals 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 s...

Page 2: ...CTURE Each section consists of SCT that are broken down into SC that are divided into sections for each com ponent The specification maintenance and other information for the components are included a...

Page 3: ...parts refer to parts catalogue Example HU 00001 14 9 8 7 6 10 4 10 22 11 19 17 15 13 12 18 16 1 2 3 4 5 6 7 8 11 10 9 12 13 19 18 20 17 16 24 10 25 5 4 4 4 3 3 3 2 1 21 15 23 T7 T2 T2 T2 T2 T2 T2 T4...

Page 4: ...ed in one service procedure appropriate reference are provided for each part Example A Component D Caution G Tightening torque B Process E Tool number of special tool H Illustration C Reference F Name...

Page 5: ...AGNOSIS 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 inclu...

Page 6: ...HU 6 HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL...

Page 7: ...g of the plate label for identification ID 00010 Bar cord label America spec vehicles only Tire inflation pressure label Vehicle identification number plate Vehicle identification number Model number...

Page 8: ...6 2 5L AWD 7 3 Grade 3 2 5X 5 2 5XS 9 2 5XT 8 6 Restraint 6 Manual belts dual airbag side airbag 9 X Check digit X or 0 9 10 4 Model year 4 2004MY 5 2005MY 6 2006MY 11 G Transmission type G Full time...

Page 9: ...bo MFI 4 speed AT Digits Code Meaning Details 1 and 2 EJ Engine type EJ 4 cylinders 3 and 4 25 Displacement 25 2 5L 5 1 Fuel feed system 1 D MFI SOHC A 5 MFI DOHC Turbo 6 B Exhaust regulations B US Fe...

Page 10: ...ION Rear differential T2 Option code U4QW Code Reduction gear ratio LSD T2 4 111 No JP 4 111 Viscous TP 4 444 No CF 4 444 Viscous Digits Code Meaning Details 1 to 2 U4 Destination U4 U S A CO Canada 3...

Page 11: ...ID 6 IDENTIFICATION IDENTIFICATION...

Page 12: ...uch parts when there is a risk of static electricity Always use a static electricity pre vention cord or touch grounded metal before con ducting work 3 BATTERY When removing the battery cables always...

Page 13: ...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 Be sure to set the wheel...

Page 14: ...NT 4 NOTE NOTE Lift Safety stand NT 00003 NT 00004...

Page 15: ...NT 5 NOTE NOTE Jack up point A Front B Rear NT 00005 A B...

Page 16: ...Tie downs are used when transporting vehicles and when using the chassis dynamo Attach tie downs only to the specified points on the vehicle A Front B Hook for towing and tie down C Hook for tie down...

Page 17: ...shall be within 50 mm 1 97 in Make sure to fix the vehicle securely 9 TOWING Avoid towing vehicles except when the vehicle cannot be driven For models with AWD or AT use a loader instead of towing Wh...

Page 18: ...nt hood in this position remove the windshield washer hose attaching clip from the front hood 11 TRAINING For information about training contact a dealer or agent 12 GENERAL SCAN TOOL Using general sc...

Page 19: ...cap tester Raise the pressure until the needle of gauge stops and see if the pressure can be retained for 5 to 6 seconds The radiator cap is normal if a pressure above the service limit value has been...

Page 20: ...ect or replace if it is damaged or worn 4 Remove the caliper body Ref to BR 18 Front Disc Brake Assembly Ref to BR 24 Rear Disc Brake Assembly 5 Tighten the wheel nuts to secure disk rotor 6 Set a dia...

Page 21: ...ll the oil filter by turning it by hand being careful not to damage the seal rubber Tighten the oil filter 80 mm 3 15 in in diameter by approx 2 3 3 4 rotation more after the seal rub ber of oil filte...

Page 22: ...er counterclockwise 4 Drain the engine oil by loosening engine oil drain plug 5 Replace the drain plug gasket with a new one 6 Tighten the engine oil drain plug after draining engine oil Tightening to...

Page 23: ...L or SJ ILSAC classification GF 3 SAE Viscosity No 30 40 10W 50 20W 40 20W 50 8 Close the engine oil filler cap 9 Start the engine and warm it up for a time 10 After the engine stops recheck the oil l...

Page 24: ...he oil level gauge hole up to the upper point of level gauge CAUTION Each oil manufacturer has its base oil and addi tives Thus do not mix two or more brands Differential gear oil capacity 1 1 1 3 2 1...

Page 25: ...T REAR DIFFERENTIAL OIL 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 Tighteni...

Page 26: ...clutch engine tends to stall Loos en the adjusting nut gradually until smooth starting is enabled B When the hill holder is released earlier than engagement to clutch vehicle slips down slight ly Tigh...

Page 27: ...5 75 82 5 90 97 5 105 112 5 120 Remarks 1 000 km 4 8 12 24 36 48 60 72 81 4 96 108 120 132 144 156 168 180 192 1 000 miles 3 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 Engine...

Page 28: ...000 km 15 000 miles Transmission oil 15 months R 24 000 km 15 000 miles ATF 15 months R 24 000 km 15 000 miles Front rear differ ential oil 15 months R 24 000 km 15 000 miles Brake line 15 months I I...

Page 29: ...Alternate NGK BKR5E 11 Alternate Turbo model NGK PFR6G Spark plug gap Non turbo model 1 0 1 1 mm 0 039 0 043 in Turbo model 0 7 0 8 mm 0 028 0 031 in 6 Tighten the spark plug lightly with hand and th...

Page 30: ...to its original posi tion after it has been turned and then released 2 STEERING SHAFT JOINT 1 When the steering wheel free play is excessive disconnect the universal joint of steering shaft and check...

Page 31: ...5 ft lb 5 POWER STEERING FLUID LEVEL NOTE Check at power steering fluid temperature 20 C 68 F read the fluid level on the COLD side Check at power steering fluid temperature 80 C 176 F read the fluid...

Page 32: ...if necessary 9 GEARBOX BOOTS Inspect both sides of gearbox boots as follows and correct the defects if necessary 1 A and B positions of gearbox boot are fitted correspondingly in A and C grooves of g...

Page 33: ...dentify the fault 2 Turn the ignition switch to ON and connect the airbag diagnosis terminal of the service connector located below lower cover to ground terminal 3 The warning light blinks to indicat...

Page 34: ...place the ball joint 2 If the dust seal is damaged replace with the new ball joint NOTE When the transverse link ball joint has been re moved or replaced check the toe in of front wheel If the front w...

Page 35: ...rear lateral links trailing link etc Body parts to which suspensions are installed 3 When the toe in and thrust angle are out of stan dard value adjust them so that they conform to re spective service...

Page 36: ...sioner 6 To lock the crankshaft use ST Remove the pul ley bolt ST 499977100 CRANK PULLEY WRENCH 7 Remove the crank pulley 8 Remove the left side belt cover 9 Remove the front timing belt cover 10 Remo...

Page 37: ...2 V belt 4 Remove the air conditioning compressor drive belt tensioner 5 To lock the crankshaft use ST Remove the pul ley bolt ST 499977300 CRANK PULLEY WRENCH 6 Remove the crank pulley 7 Remove the a...

Page 38: ...the timing belt back surface for cracks or damage Replace the faulty timing belt as needed 3 Measure the timing belt width W If it is less than 27 mm 1 06 in check idlers tensioner water pump pulley...

Page 39: ...PM 14 PERIODIC MAINTENANCE SERVICES TIMING BELT 4 Install the timing belt cover LH W PM 00097...

Page 40: ...s the tire tread CAUTION It is recommended that both right and left tires are replace as a set 2 Adjust the wheel alignment if abnormally uneven tire wear is found 3 Also rotate the tires between the...

Page 41: ...ex haust pipe wipe it off completely 2 Replace the gasket with new one and then tight en it to the specified torque Tightening torque 69 N m 7 0 kgf m 50 6 ft lb 3 Fill transmission gear oil through t...

Page 42: ...turbo model Turbo model 2 FRONT SIDE BELT DRIVING POWER STEERING OIL PUMP AND GENERATOR NOTE Wipe off any oil or water on the belt and pulley 1 Loosen the lock bolt A 2 Loosen the slider bolt B 3 Remo...

Page 43: ...ront side belt 2 Loosen the lock nut A 3 Loosen the slider bolt B 4 Remove the rear side belt 5 Install a new belt and tighten the slider bolt so as to obtain the specified belt tension 6 Tighten the...

Page 44: ...binds disassemble the front axle and check condition of oil seals bearing etc 2 REAR WHEEL BEARING 1 Lift up the rear of vehicle 2 While holding the rear wheel by hand swing it in and out to check be...

Page 45: ...r cleaner 2 TURBO MODEL 1 Remove the clip B above the air cleaner case 2 Remove the air cleaner B INSTALLATION 1 NON TURBO MODEL Install in the reverse order of removal CAUTION Fasten with a clip afte...

Page 46: ...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 Ref to DS 39 Rear Drive Shaft 2 PROPELLER SHAFT Inspect...

Page 47: ...ke system 6 Instruct your co worker to depress the brake pedal slowly two or three times and then hold it de pressed 7 Loosen the bleeder screw approx 1 4 turn until a small amount of brake fluid drai...

Page 48: ...sually check the brake hose using a mirror where it is difficult to see for any damage B CHECKING 1 SERVICE BRAKE 1 Check the free play of brake pedal with a force of less than 10 N 1 kgf 2 lb Brake p...

Page 49: ...the same pedal force Make sure the travel distance should not change 2 With the brake pedal depressed start the en gine Make sure the pedal should move slightly to ward the floor 3 With the brake ped...

Page 50: ...mery cloth 200 or more If it is unevenly worn tapered or the outside surface of brake drum is damaged correct or replace it Brake drum inner diameter Standard value 228 6 mm 9 000 in Service limit 230...

Page 51: ...spring tension is exces sively weakened replace it B ADJUSTMENT 1 REAR DRUM BRAKE The main brake is adjusted automatically and so there is no need to adjust it 2 PARKING BRAKE REAR DISC BRAKE For rear...

Page 52: ...ct the clutch master cylinder operating cylinder and hydraulic line for fluid leaks If fluid leaks are found repair or replace If fluid leaks are not found add clutch fluid to bring it up to MAX C of...

Page 53: ...ant since other coolant may cause corrosion 9 Securely install the radiator cap 10 Run the engine for more than 5 minutes at 2 000 to 3 000 rpm Run the engine until radiator becomes hot in order to pu...

Page 54: ...oncentration in tersects with the 40 curve of the necessary the engine coolant concentration and read the scale on the vertical axis of the graph at height A The quantity of the engine coolant to be d...

Page 55: ...or operation of the engine and fuel injection sys tem Use the specified gasoline to correct perfor mance 3 LUBRICANTS Use either the lubricants in the table below or equivalent lubricants See the tabl...

Page 56: ...nd applicable temperature SAE J300 Engine oil Manual transmission oil and rear differential oil RM 00003 F 22 4 14 50 68 86 104 C 30 20 10 0 10 20 30 40 5W 30 Recommend 32 10W 30 or 10W 40 RM 00004 F...

Page 57: ...ifferential AT Fluid Recommended Alternative Remarks Automatic transmission fluid DEXRON III Power steering fluid DEXRON III Brake fluid FMVSS No 116 DOT3 FMVSS No 116 DOT4 Clutch fluid FMVSS No 116 D...

Page 58: ...HT2 003602010 Steering gear box Valiant grease M 2 003608001 Disk brake Niglube RX 2 K0779GA102 Drum brake Drum brake wheel cylinder Molykote No 7439 003602001 Brake pad Brake shoe Molykote AS 880N K0...

Page 59: ...der block Torque converter clutch case Three Bond 1215 004403007 Dow Corning s No 7038 Transmission oil pan AT model Three Bond 1217B K0877YA020 Rear differential Three Bond 1324 004403042 Rear differ...

Page 60: ...n turbo 2 5L Turbo Engine type Horizontally opposed liquid cooled 4 cylinder 4 stroke gasoline engine Valve system Valve arrangement SOHC DOHC Valve quantity Intake2 Exhaust2 Bore Stroke mm in 99 5 79...

Page 61: ...r Helical Helical Gear ratio 1 000 1 000 Final reduction Type of gear Hypoid Gear ratio 4 111 4 444 Reduction gear Rear drive Transfer reduction Type of gear Helical Helical Gear ratio 1 000 1 000 Fin...

Page 62: ...l 2 5 L Non turbo Grade 2 5 X 2 5 XS Transmission 5MT 4AT 5MT 4AT 5MT 4AT 5MT 4AT Curb weight C W Front kg lb 780 1 720 800 1 765 780 1 720 800 1 765 780 1 720 800 1 765 785 1 725 805 1 770 Rear kg lb...

Page 63: ...15 640 1 415 Total kg lb 1 425 3 140 1 445 3 185 1 425 3 145 1 445 3 190 Gross axle weight G A W Front kg lb 930 2 050 930 2 050 930 2 050 930 2 050 Rear kg lb 1 000 2 200 1 000 2 200 1 000 2 200 1 00...

Page 64: ...477 3 250 1 475 3 250 1 490 3 285 1 480 3 260 1 500 3 300 1 480 3 260 1 500 3 300 Gross axle weight G A W Front kg lb 990 2 190 990 2 190 990 2 190 990 2 190 990 2 190 990 2 190 990 2 190 990 2 190 9...

Page 65: ...1 375 Total kg lb 1 400 3 090 1 420 3 135 1 405 3 095 1 425 3 140 1 405 3 095 1 425 3 140 Gross axle weight G A W Front kg lb 930 2 050 930 2 050 930 2 050 930 2 050 930 2 050 930 2 050 Rear kg lb 1 0...

Page 66: ...g lb 1 420 3 130 1 440 3 175 1 425 3 145 1 445 3 190 1 425 3 140 1 445 3 185 Gross axle weight G A W Front kg lb 930 2 050 930 2 050 930 2 050 930 2 050 930 2 050 930 2 050 Rear kg lb 1 000 2 200 1 00...

Page 67: ...020 2 250 1 020 2 250 1 020 2 250 1 020 2 250 1 020 2 250 1 020 2 250 1 020 2 250 1 020 2 250 1 020 2 250 Gross vehicle weight G V W kg lb 1 960 4 320 1 960 4 320 1 960 4 320 1 960 4 320 1 960 4 320 1...

Page 68: ...SPC 10 SPECIFICATIONS FORESTER...

Page 69: ...structions in this manual when performing maintenance on airbag components or nearby and airbag wiring harnesses or nearby To prevent unexpected deployment perform one of the steps below and then wait...

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