Subaru Forester SG 2004 User manual

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.

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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.

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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
....
,

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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.
• 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

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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)

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HOW TO USE THIS MANUAL
HOW TO USE THIS MANUAL

ID-2
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
ID-00010
Bar cord label
(America spec. vehicles only)
Tire inflation
pressure label
Vehicle identification number plate
Vehicle identification
number
Model number plate
Emission control label
Vacuum hose
piping label
ID-00011
Engine serial number
ENGINE
ID-00012
4AT
Transmission serial number
ID-00013
Transmission serial number
5MT
ID-00014
Stamp location

ID-3
IDENTIFICATION
IDENTIFICATION
2. MEANING OF V.I.N.
The meaning of the VIN is as follows:
]JF1SG636X4G700001[
The starting and ending brackets ( ][ ) are stop marks.
Digits Code Meaning Details
1 to 3 JF1 Manufacturer body area JF1: Passenger car, FHI made
4 S Car line S: Forester
5 G Body type G: Wagon
6 6 Displacement 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 AWD 5-speed MT
H: Full-time AWD 4-speed AT
12 to 17 700001 Serial number —
ID-00006
41
JF1SG63
SG9AY7J
5X3
EJ251BWUAA
TY755VC3AA
G70000
E0
1
0
230
applied model option code
trim code
VIN
engine type
transmission type
Color code
FUJI HEAVY INDUSTRIES LTD.
Model number plate

ID-4
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
The engine and transmission type are as follows:
• Engine
EJ251BWTAA
• Transmission
TY755VC4AA
Digits Code Meaning Details
1 S Series S: Forester
2 G Body type G: Wagon
3 9 Engine displacement
Drive system
Suspension system
9: 2.5L AWD
4 B Model year B: 2004MY
5 Y Destination Y: U.S.A., Canada
6 7 Grade 7: 2.5X
8: 2.5XS
B: 2.5XT
7 J Transmission, fuel feed
system
J: SOHC MFI 5-speed MT
R: SOHC MFI 4-speed AT
D: DOHC Turbo MFI 5-speed MT
P: DOHC Turbo 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 Federal & California
7 W Transmission W: MT
X: AT
8 to 10 TAA Detailed specifications Used when ordering parts. See the parts catalog for details.
Digits Code Meaning Details
1 T Transmission T: Transmission
2 Y Transmission type Y: Full-time AWD MT center differential
Z: Full-time AWD AT MPT
3 and 4 75 Classification 75: MT
1A: AT
1B: AT (Turbo)
55 Series 3:AT
5: MT, AT (Turbo)
6 V Transmission specifica-
tions
V: Full-time AWD 5-speed MT with viscous coupling center dif-
ferential single range
Z: Full-time AWD 4-speed AT with MPT
L: Full-time AWD 4-speed AT with MPT (Turbo)
7 C Mounted body C: US 2.5L SOHC
H: 2.5L DOHC Turbo
8 to 10 4AA Detailed specifications Used when ordering parts. See the parts catalog for details.

ID-5
IDENTIFICATION
IDENTIFICATION
• 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 to 4 QW Main option of vehicle —