Subaru 2004 Forester User manual

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)

FUJI HEAVY INDUSTRIES LTD. G8080GE1
2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
GENERAL INFORMATION
SECTION
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, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance 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.
All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.
FOREWORD FW
HOW TO USE THIS MANUAL HU
SPECIFICATION SPC
PRECAUTION PC
NOTE NT
IDENTIFICATION ID
RECOMMENDED MATERIAL RM
PRE-DELIVERY INSPECTION PI
PERIODIC MAINTENANCE SERVICE PM

FOREWORD
FW
Page
1. Foreword .....................................................................................................2

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.

HOW TO USE THIS MANUAL
HU
Page
1. How to Use This Manual .............................................................................2

HU-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. The specification, maintenance and other
information for the components are included, and
diagnosis information has also been added where
necessary.
2. INDEX
The first page has an index with tabs.

HU-3
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.
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
T5
T5
T8
T6
T6
T6
T11
T10
T1
T1
T3
T3
T3
T1
T9
T4
T5
T5 T3
T4
T3
T2
T4
T2
T1
T3
(20)
(21)
(23)
(22)
(10)
(24)
(25)
(26)
(35)
(34)
(27)
(14)
(28)
(29)
(31)
(32)
(37)
(30)
(33)
(36)
T3
T2
T1
:Selective part
:Replacement part
:Should be lubricated with grease.
:Should be lubricated with oil.
:Sealing point
:Tightening torque
....
,

HU-4
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.
• If many serviceable parts are included 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 of special tool
HU-00002
1) Remove the manual transmission assembly
from vehicie. <Ref. to MT-33, REMOVAL, Manual
Transmission Assembly.>
15.Main Shaft Assembly for Sin-
gle-Range
A: REMOVAL
11) Tighten the lock nuts to the specified torque us-
ing ST1 and ST2.
NOTE:
Secure the lock nuts in two Places affer tightening.
ST2 499987003 SOCKET WRENCH
ST1 498937000 TRANSMISSION HOLDER
(A)
(B)
(C)
(D)
(G)
(E) (F)
(H)
Tightening torque:
118 N m (12.0 kgf-m, 86.8 ft-lb)
ST1
ST2

HU-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.
Example:
Tightening torque:
44 N·m (4.5 kgf-m, 33 ft-lb)

HU-6
HOW TO USE THIS MANUAL
How to Use This Manual

SPECIFICATION
SPC
Page
1. Forester.......................................................................................................2

SPC-2
SPECIFICATION
Forester
1. Forester
A: DIMENSIONS
★: With sunroof
B: ENGINE
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)
Compartment
Length mm (in) 1,795 (70.7)
Width mm (in) 1,455 (57.3)
Height mm (in) 1,245 (49.0), 1,210 (47.6)★
Wheelbase mm (in) 2,525 (99.4)
Tread Front mm (in) 1,495 (58.9)
Rear mm (in) 1,485 (58.5)
Minimum road clearance mm (in) 190 (7.5) 195 (7.7) 200 (7.9)
Model 2.0 L Non-turbo 2.0 L Turbo 2.5 L Non-turbo 2.5 L Turbo
Engine type Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine
Valve arrangement Overhead camshaft type
Bore×Stroke mm (in) 92×75 (3.62×2.95) 99.5×79 (3.92×3.11)
Displacement cm3(cu in) 1,994 (121.67) 2,457 (149.94)
Compression ratio 10.0±0.2 8.0±0.2 10.0±0.2 8.2±0.2
Firing order 1 — 3 — 2 — 4
Idle speed at Park or Neu-
tral position rpm 650±100 700±100 650±100 700±100
Maximum output kW (PS)/rpm 92 (125)/5,600 130 (177)/5,600 115 (156)/5,600 155 (211)/5,600
Maximum torque N⋅m (kgf-m, ft-lb)/rpm 184 (18.8, 41.4)/
3,600
245 (25.0, 55.1)/
3,200
223 (22.7, 50.1)/
3,600
320 (32.6, 71.8)/
3,600

SPC-3
SPECIFICATION
Forester
C: ELECTRICAL
★: For Australia model
D: TRANSMISSION
5MT: 5 forward speeds with synchromesh and 1-reverse
4AT: Electronically controlled fully-automatic, 4-forward speeds and 1-reverse
DSPD: Dry Single Plate Diaphragm
TCC: Torque Converter Clutch
★: For Europe model
E: STEERING
Model 2.0 L Non-turbo 2.0 L Turbo 2.5 L Non-turbo 2.5 L Turbo
Ignition timing at idling speed BTDC/rpm 10°±10°/650 12°±10°/700 MT: 10°±10°/650
AT: 1 5 °±10°/650 17°±10°/700
Spark plug Type and manufacturer
CHAMPION:
RC10YC4 NGK: PFR6G
CHAMPION:
RC10YC4 NGK: ILFR6B
Alternate
NGK: BKR5E-11
Alternate
NGK: BKR5E-11
Generator 12 V — 90 A
Battery Type and capacity (5HR) MT: 12 V — 48 AH (55D23L)
AT: 12 V — 52 AH (65D23L)
12 V — 27 AH
(34B19L)
12 V — 48 AH
(55D23L)★
MT: 12 V — 48
AH (55D23L)
AT: 12 V — 52
AH (65D23L)
Model 2.0 L Non-turbo 2.0 L Turbo 2.5 L Non-turbo 2.5 L Turbo
Transmission type 5MT 4AT 5MT 4AT 5MT 4AT 5MT 4AT
Clutch type DSPD TCC DSPD TCC DSPD TCC DSPD TCC
Gear ratio
1st 3.454 2.785 3.454 2.785 3.454 2.785 3.454 2.785
2nd 2.062 1.545 1.947 1.545 2.062 1.545 1.947 1.545
3rd 1.448 1.000 1.366 1.000 1.448 1.000 1.366 1.000
4th 1.088 0.694 0.972 0.694 1.088 0.694 0.972 0.694
5th 0.871 — 0.738 — 0.780 — 0.738 —
Reverse 3.333 2.272 3.333 2.272 3.333 2.272 3.333 2.272
Dual range 1.447 — — — 1.196 — — —
Reduction
gear (Front)
1st reduc-
tion
Type of gear — Helical — Helical — Helical — Helical
Gear ratio — 1.000 — 1.000 — 1.000 — 1.000
Final reduc-
tion
Type of gear Hypoid
Gear ratio 4.111 4.444 4.444 4.111 4.111 4.444 4.111 4.444
Reduction
gear (Rear)
Transfer
reduction
Type of gear Helical — Helical — Helical — Helical —
Gear ratio 1.000 — 1.081★,
1.000 — 1.000 — 1.000 —
Final reduc-
tion
Type of gear Hypoid
Gear ratio 4.111 4.444 4.111★,
4.444 4.111 4.111 4.444 4.111 4.444
Ty p e Rack and Pinion, Integral
Turns, lock to lock 3.0
Minimum turning circle m (ft) Curb to curb 10.6 (34.8)
Wall to wall 11.4 (37.4)

SPC-4
SPECIFICATION
Forester
F: SUSPENSION
G: BRAKE
★: RHD model
H: TIRE
I: CAPACITY
★1: With oil pump
★2: MT model with oil cooler Included
★3: Model with ATF warmer
Front Macpherson strut type, Independent, Coil spring
Rear Dual-link type, Independent, Coil spring
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
Rear Drum brake Disc brake
Parking brake Mechanical on rear brakes
Rim size 15×6J 16×6 1/2J
Tire size 205/70 R15 95H 215/60 R16 95V, P215/60 R16 94H
Type Steel belted radial, Tubeless
Model 2.0 L Non-turbo 2.0 L Turbo 2.5 L Non-turbo 2.5 L Turbo
Tran s mis s io n 5M T 4 AT 5 MT 4AT 5M T 4 AT 5 M T 4AT
Fuel tank 2(US gal, Imp gal) 60 (15.9, 13.2)
Engine oil
(When
replacing)
2(US qt, Imp qt) Approx. 4.0 (4.2, 3.5)
Tr a n s m i s -
sion gear oil 2(US qt, Imp qt) 4.0 (4.2, 3.5) —
3.5
(3.7, 3.1),
3.9
(4.1, 3.4)
★1
—4.0
(4.2, 3.5) —3.5 (3.7, 3.1) —
ATF 2(US qt, Imp qt) — 8.4
(8.9, 7.4) —9.3
(9.8, 8.2) —9.3
(9.8, 8.2) —9.3
(9.8, 8.2)
Front differ-
ential gear
oil
2(US qt, Imp qt) — 1.2
(1.3, 1.1) —1.2 (1.3, 1.1) —1.2 (1.3, 1.1) —1.2 (1.3, 1.1)
Rear differ-
ential gear
oil
2(US qt, Imp qt) 0.8 (0.8, 0.6)
Power
steering
fluid
2(US qt, Imp qt) 0.7 (0.7, 0.6)
Engine
coolant 2(US qt, Imp qt) 6.6
(7.0, 5.8)
6.5
(6.9, 5.7),
6.9
(7.3, 6.1)
★3
7.4
(7.8, 6.5)
7.3
(7.7, 6.4)
★2
6.9
(7.3, 6.1)
6.8
(7.2, 6.0)
7.4
(7.8, 6.5)
7.3
(7.7, 6.4)

SPC-5
SPECIFICATION
Forester
J: WEIGHT
1. LHD MODEL
★: For the option codes, refer to ID section. <Ref. to ID-5, MODEL NUMBER PLATE, Identification.>
Option code★EC K4 KS
Model 2.0 L Non-turbo 2.5 L Non-turbo
Grade 2.0 X 2.5 X
Transmission 5MT 4AT 5MT 4AT 5MT 4AT
Curb weight (C.W.)
Front kgf (lb) 760
(1,675)
775
(1,710)
775
(1,710)
790
(1,740)
780
(1,720)
800
(1,765)
Rear kgf (lb) 600
(1,325)
600
(1,325)
595
(1,310)
595
(1,310)
620
(1,365)
620
(1,365)
Total kgf (lb) 1,360
(3,000)
1,375
(3,035)
1,370
(3,020)
1,385
(3,050)
1,400
(3,085)
1,420
(3,130)
Maximum permissi-
ble axle weight
(M.P.A.W.)
Front kgf (lb) 1,010
(2,225)
1,010
(2,225)
1,010
(2,225)
1,010
(2,225)
1,010
(2,225)
1,010
(2,225)
Rear kgf (lb) 1,035
(2,280)
1,035
(2,280)
1,035
(2,280)
1,035
(2,280)
1,035
(2,280)
1,035
(2,280)
Maximum permissi-
ble weight (M.P.W.) Total kgf (lb) 1,880
(4,140)
1,880
(4,140)
1,880
(4,140)
1,880
(4,140)
1,880
(4,140)
1,880
(4,140)
Option
Sport package base — — — — — —
Aluminum wheel ❍❍❍❍❍❍
Front fog light — — — — ❍❍
Cruise control — — — — ❍❍
High-grade audio — — — — — —
Sport steering — — — — — —
Leather package base — — — — — —
Leather seat, Leather
door trim ——————
Navigationsystem ——————
Air conditioner — — ❍❍❍❍
Side airbag — — — — — —
Sunroof — — — — — —
Self-leveling function Rr ❍❍————
Cold area pack A — — — — — —
Cold area pack B — — — — — —
Cold area pack C — — — — — —
Cold area pack D ❍❍————
Heated mirrors ❍❍————
Security system — — — — — —

SPC-6
SPECIFICATION
Forester
★: For the option codes, refer to ID section. <Ref. to ID-5, MODEL NUMBER PLATE, Identification.>
Option code★EC K4
Model 2.0 L Turbo
Grade 2.0 XT
Transmission 5MT 4AT 5MT 4AT
Curb weight (C.W.)
Front kgf (lb) 810 (1,785) 830 (1,830) 815 (1,795) 835 (1,840)
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) 1,465 (3,230)
Maximum permissible axle
weight (M.P.A.W.)
Front kgf (lb) 1,010 (2,225) 1,010 (2,225) 1,010 (2,225) 1,010 (2,225)
Rear kgf (lb) 1,035 (2,280) 1,035 (2,280) 1,035 (2,280) 1,035 (2,280)
Maximum permissible
weight (M.P.W.) Total kgf (lb) 1,950 (4,295) 1,950 (4,295) 1,950 (4,295) 1,950 (4,295)
Option
Sport package base — — — —
Aluminum wheel — — — —
Front fog light ❍❍❍❍
Cruise control ❍❍—❍
High-grade audio — — — —
Sport steering — — — —
Leather package base ❍❍❍❍
Leather seat, Leather door trim — — — ❍
Navigation system — — — —
Air conditioner ❍❍❍❍
Side airbag ❍❍❍❍
Sunroof — — ❍❍
Self-leveling function Rr ❍❍——
Cold area pack A — — — —
Cold area pack B ❍❍——
Cold area pack C — — — —
Cold area pack D — — — —
Heated mirrors ❍❍——
Securitysystem ————

SPC-7
SPECIFICATION
Forester
2. RHD MODEL
★: For the option codes, refer to ID section. <Ref. to ID-5, MODEL NUMBER PLATE, Identification.>
Option code★EK EK
Model 2.0 L Non-turbo 2.0 L Turbo
Grade 2.0 X 2.0 XT
Transmission 5MT 4AT 5MT 4AT
Curb weight (C.W.)
Front kgf (lb) 775 (1,710) 790 (1,740) 815 (1,795) 835 (1,840)
Rear kgf (lb) 600 (1,325) 600 (1,325) 635 (1,400) 635 (1,400)
Total kgf (lb) 1,375 (3,035) 1,390 (3,065) 1,450 (3,195) 1,470 (3,240)
Maximum permissible axle
weight (M.P.A.W.)
Front kgf (lb) 1,010 (2,225) 1,010 (2,225) 1,010 (2,225) 1,010 (2,225)
Rear kgf (lb) 1,035 (2,280) 1,035 (2,280) 1,035 (2,280) 1,035 (2,280)
Maximum permissible
weight (M.P.W.) Total kgf (lb) 1,880 (4,145) 1,880 (4,145) 1,950 (4,300) 1,950 (4,300)
Option
Sportpackagebase ————
Aluminum wheel ❍❍——
Front fog light — — ❍❍
Cruise control — — ❍❍
High-gradeaudio ————
Sportsteering ————
Leather package base — — ❍❍
Leather seat, Leather door trim — — ❍❍
Navigationsystem ————
Air conditioner ❍❍❍❍
Side airbag — — ❍❍
Sunroof — — ❍❍
Self-leveling function Rr ❍❍❍❍
Cold area pack A ❍❍——
ColdareapackB ————
Cold area pack C — — ❍❍
ColdareapackD ————
Heated mirrors ❍❍❍❍
Security system — — ❍❍

SPC-8
SPECIFICATION
Forester
★: For the option codes, refer to ID section. <Ref. to ID-5, MODEL NUMBER PLATE, Identification.>
Option code★KA
Model 2.5 L Non-turbo 2.5 L Turbo
Grade 2.5 X 2.5 XS 2.5 XT
Transmission 5MT 4AT 5MT 4AT 5MT 4AT
Curb weight (C.W.)
Front kgf (lb) 765
(1,685)
785
(1,730)
760
(1,675)
780
(1,720)
815
(1,795)
835
(1,840)
Rear kgf (lb) 610
(1,345)
610
(1,345)
605
(1,335)
605
(1,335)
610
(1,345)
610
(1,345)
Total kgf (lb) 1,375
(3,030)
1,395
(3,075)
1,365
(3,010)
1,385
(3,055)
1,425
(3,140)
1,445
(3,185)
Maximum permissi-
ble axle weight
(G.A.L.R.)
Front kgf (lb) 1,010
(2,225)
1,010
(2,225)
1,010
(2,225)
1,010
(2,225)
1,010
(2,225)
1,010
(2,225)
Rear kgf (lb) 1,035
(2,280)
1,035
(2,280)
1,035
(2,280)
1,035
(2,280)
1,035
(2,280)
1,035
(2,280)
Maximum permissi-
ble weight (G.V.M.) Total kgf (lb) 1,950 (4,300)
1,950
(4,300)
1,950
(4,300)
1,950
(4,300)
1,950
(4,300)
1,950
(4,300)
Option
Sport package base — — — — — —
Aluminum wheel — — — — — —
Front fog light — — ❍❍❍❍
Cruise control ❍❍❍❍❍❍
High-grade audio — — — — — —
Sport steering — — — — ❍❍
Leather package base — — — — ❍❍
Leather seat, Leather
door trim ——————
Navigationsystem ——————
Air conditioner ❍❍❍❍❍❍
Side airbag — — — — — —
Sunroof — — — — — —
Self-leveling function Rr — — ❍❍❍❍
Cold area pack A — — — — — —
Cold area pack B — — — — — —
Cold area pack C — — — — — —
Cold area pack D — — — — — —
Heated mirrors — — — — — —
Security system — — — — — —