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1. 10W 30 or 10W 40 5W 30 Recommend RM 00003 Manual transmission oil and rear differential RM 00004 RM 3 RECOMMENDED MATERIALS RECOMMENDED MATERIALS SAE viscosity No and applicable temperature SAE J300 Front differential AT RM 00005 4 FLUID Use the fluids specified in the table below Do not mix two different kinds or makes of fluid 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 DOT3 FMVSS No 116 DOT4 5 COOLANT Use genuine coolant to protect the engine Coolant Recommended Item number Alternative Coolant SUBARU coolant 000016218 None Water for dilution 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 Recommended Item number Alternative Air conditioner Refrigerant HFC134a None ZXL200PG None Compressor oil 7 GREASE Use the grease and supplementary lubricants shown in the table bel
2. emet A ERE NT 00010 9 TRAINING 10 GENERAL SCAN TOOL 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 IDENTIFICATION 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 MT gt Vehicle identification Ns Saudi Arabia plate Saudi Arabia model Built date plate Australia model Tire inflation pressure label Driver side Australia model Tire pressure label Driver side Except Australia model D plate Europe model ADR compliance plate Australia model Model number plate ID 00015 Transmission serial number ENGINE Engine serial number ID 00011 ID 00013 Transmission serial number ID 00012 ID 2 IDENTIFICATION IDENTIFICATION T type No Stamp location 10 00016 WY 22
3. tA R 92 N 82 3 g 3 B 1 1 2 00112 1 RHD model 2 LHD model Selector Gear Position Position 2nd 3rd D Yes Yes 3 Yes 2 Yes 1 39 HEATER amp VENTILATION Operate the heater and ventilation system to check for normal airflow outlet control air inlet control air flow capacity and heating performance 40 AIR CONDITIONER Operate the air conditioner Check that the A C compressor operates normally and enough cooling is provided 41 CRUISE CONTROL Operate the cruise control system Check that the system is activated and deactivated correctly PRE DELIVERY INSPECTION 42 ATF LEVEL Check that the ATF level is normal If insufficient check that no leaks are found Then add the neces sary amount of the specified ATF PM 00033 5 Level gauge HOT side Upper level B Lower level m oou COLD side Upper level Lower level Q 43 POWER STEERING FLUID LEVEL Check that the power steering fluid level is normal If insufficient check that no leaks are found Then add the necessary amount of the specified power steering fluid PM 00070 A Reservoir tank B MIN level C MAX level 44 FLUID LEAK CHECK Check the entire areas of the vehicle for any trace of coolant oil fluid leaks 45 WATER LEAK TEST Spray the vehicle with water and check tha
4. M B 00070 Unlock Lock PRE DELIVERY INSPECTION PRE DELIVERY INSPECTION 2 Close the driver s door completely and place the door lock knob A to the lock position Then pull in side door handles B to ensure that doors will not open For other doors place the door lock knob A to the lock positions and then pull the inside door handles to ensure that the doors will not open A 00004 Door lock knob B Inside door handle 3 Press the driver s side power door lock switch to lock side Check that all doors including rear gate are locked 4 Press the driver s side power door lock switch to unlock side Check that all doors including rear gate are unlocked 00107 6 CHECK DOUBLE LOCK OPERATION 1 Fully open all the windows 2 Remove the key 3 Lock all the doors using the key or transmitter 4 Verify that all the doors including rear gate are not unlocked when pressing power door lock switch to unlock side 5 Verify that the door is not opened when operat ing door lock knob to unlock position and pulling in ner remote Perform the same check for other doors 7 CHECK THE OPERATION OF CHILD SAFETY LOCKS 1 Set the child safety lock on both rear doors to the lock positions 2 Close the rear doors completely 3 Check that the lock levers of the rear doors are in the unlock positions
5. Model number plate sp x PEK FUJI HEAVY INDUSTRIES LTD HeBS c 15 5 4 3 elo o 4 option code 2 7 5 5 1 VIN 7751 REFI applied model SIG K 2 KY AA K 4 1 0 T 0 trim code engine type 21310 RyvavyH X Color code transmission type 0 C U 3 amp 4 10 00017 10 3 IDENTIFICATION IDENTIFICATION 2 MEANING OF V I N The meaning of the VIN is as follows Europe Australia and General Except GCC JF19G5LK43G002001 The starting and ending brackets are stop marks Meaning Details Manufacturer body area JF1 Passenger car FHI made JF2 MPV FHI made Car line S FORESTER Body type G Wagon Displacement 5 2 0L AWD 9 2 5L AWD Steering position K RHD Right hand drive L LHD Left hand drive Engine amp transmission R SOHC MPI 4 speed AT SOHC MPI Full time AWD 5 speed MT Dual range DOHC Turbo Full time AWD 5 speed MT DOHC Turbo 4 speed AT Full time AWD Single range Full time AWD Dual range AWD AT 2008MY 2004MY 3 4 5 3 4 5 2005MY G FHI Gunma Drive type Model year 11 G Factory location 12 t
6. Suspension components Front strut assembly and rear shock absorber assembly Parts connecting between suspension and body 4 When no components are deformed adjust the wheel arch height by replacing coil spring in the suspension which wheel arch height is out of stan dard Ref to FS 7 Wheel Alignment Ref to RS 9 Wheel Alignment PM 34 SUSPENSION PERIODIC MAINTENANCE SERVICES 4 WHEEL ALIGNMENT OF FRONT SUS PENSION 1 Check the alignment of front suspension to en sure that following items conform to standard val ues Toe in Camber angle Caster angle Steering angle Ref to FS 7 Wheel Alignment 2 When the caster angle does not conform to ref erence visually inspect the following components and replace deformed parts Suspension components Strut assembly cross member transverse link etc Body parts to which suspensions are installed 3 When the toe in and camber are out of standard value adjust them so that they conform to respec tive service standard 4 When the right and left turning angles of tire are out of standard adjust to standard value 5 WHEEL ALIGNMENT OF REAR SUS PENSION 1 Check the alignment of rear suspension to en sure that following items are within standard val ues Toe in Camber angle Thrust angle Ref to RS 9 Wheel Alignment 2 When the camber angle does not conform to ref erence visually inspect parts lis
7. N General Description nennen nennen nnn 2 S h d l NU RE EM 3 PNG ING OE MIS 6 8 Spark ute toe ond bau qe e 9 5 duds 10 Camshaft Drive Belt ern ete Lose par Pen gh er eerta Cet at domed 12 IUIS 15 Fuel Filles ede ERES E ueniet ro QE 16 Air Cleaner Element Ra 17 Cooling Taco Te 18 eerie 19 lee i a RH 21 Transmission Oil ees cies ora 22 Hill holder System p eo te etes e tcn persones 23 no sce E S suc ec ecard saa nA 24 Front amp Rear Differential 26 Brake Linie conet nate RO 28 FUG poem 30 Disc Brake Pads and 31 Brake Linings and erc dl 32 SUSDENSION dones epic onis roba 34 Wheel eo tee ae a RR da ea Tera tes 36 Axle Boots amp Joints 5
8. from 2003MY The manuals contain the latest information at the time of publication Changes in specifications methods etc may be made without notice FW 2 HOW TO USE THIS MANUALS HU Page 1 How to Use This Manuals cc ccccccecceececececeeeceeecseeeeeceueeeeeeneereeeneeeneeeness 2 HOW TO USE THIS MANUALS HOW TO USE THIS MANUALS 1 How to Use This Manuals A HOW TO USE THIS MANUALS 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 2 HOW TO USE THIS MANUALS HOW TO USE THIS MANUALS 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 Selective part Repla
9. 3 0 2 ss 4 9 7 D 1 6 2 3 4 4 6 1 4 PRECAUTION PRECAUTION PRECAUTION 1 Precaution A PRECAUTION Please clearly understand and adhere to the follow ing general precautions They must be strictly fol lowed to avoid minor or serious injury to the person doing the work or people in the area 1 ABS Handle the ABS as a total system Do not disas semble or attempt to repair individual parts Doing so could prevent the ABS system from operating when needed or cause it to operate incorrectly and result in injury 2 BRAKE FLUID If brake fluid gets in your eyes or on your skin do the following Wash out your eyes and seek immediate medical attention Wash your skin with soap and then rinse thor oughly with water 3 ELECTRIC FAN The electric fan may rotate without warning even when the engine is not on Do not place your hand cloth tools or other items near the fan at any time 4 ROAD TESTS Always conduct road tests in accordance with traf fic rules and regulations to avoid bodily injury and interrupting traffic 5 AIRBAG To prevent bodily injury from unexpected deploy ment of airbags and unnecessary maintenance fol low the instructions 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 at least 20 seconds to dis
10. Option code ECAJ Meaning Viscous Details Destination Main option of vehicle ID 6 RECOMMENDED MATERIALS RM Page 1 Recommended Materials 2 RECOMMENDED MATERIALS RECOMMENDED MATERIALS 1 Recommended Materials A RECOMMENDED MATERIALS 1 GENERAL To insure the best performance always use the specified oil gasoline adhesive sealant etc or that of equivalent quality 2 FUEL Always use a gasoline of the same or higher octane value than specified in the owner s manual Ignor ing the specifications below will result in damage or Lubricant Recommended poor operation of the engine and fuel injection sys tem Use the specified gasoline to correct perfor mance Unleaded gasoline Use unleaded gasoline and not leaded gasoline in stalled to reduce air pollution Using leaded gaso line will damage the catalytic converter 3 LUBRICANTS Use either the lubricants in the table below or equivalent lubricants See the table below to choose the correct SAE viscosity Alternative API Spec CCMC Spec ACEA Spec G4 or G5 A1 A2 or A3 API SH or SG SL or SJ Grade Energy conserving Engine oil RM 00001 RM 00002 Manual transmission oil Front differential AT Rear differential RM 2 RECOMMENDED MATERIALS RECOMMENDED MATERIALS SAE viscosity No and applicable temperature SAE J300 Engine oil
11. 4 145 4 145 4 300 4 300 4 300 4 300 Option Sport package base Aluminum wheel O O O O O O Front fog light mE O O O Cruise control High grade audio Sport steering Leather package base O O O O paa seat Leather 4 I Air conditioner Side airbag Sunroof Self leveling function Rr Cold area pack A Cold area pack B Cold area pack C Security system For the option codes refer to ID section Ref to ID 6 Option code SPC 7 SPECIFICATIONS 3 OPTION Option FORESTER Front kgf Ib Rear kgf Ib Total kgf Ib Sport package base 0 1 0 2 0 4 0 9 0 5 1 1 Aluminum wheel 6 5 14 3 6 5 14 3 13 0 28 6 7 3 16 1 7 3 16 1 Front fog light 3 Cruise control 8 High grade audio 2 7 Sport steering 0 7 Leather package base 0 0 Leather seat Leather door trim 9 2 Air conditioner 34 2 Side airbag Sunroof 36 8 Self leveling function Rr 8 7 0 Cold area pack A 0 7 Cold area pack B 0 9 Cold area pack C 0 9 Security system SPC 8 6 1 7 3 2
12. 5 Install one end of a vinyl tube onto the air bleeder and insert the other end of the tube into a container to collect the brake fluid PM 00048 NOTE Cover the bleeder with waste cloth when loosen ing it to prevent brake fluid from being splashed over surrounding parts During the bleeding operation keep the brake reservoir tank filled with brake fluid to eliminate en try of air The brake pedal operating must be very slow For convenience and safety two people should do the work The amount of brake fluid required is approx 500 m2 16 9 US fl oz 17 6 Imp fl oz for total brake 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 drains into container and then quickly tighten the screw 8 Repeat steps 6 and 7 above until there are no air bubbles in the drained brake fluid and new fluid flows through vinyl tube NOTE Add brake fluid as necessary while performing the air bleed operation in order to prevent the tank from running short of brake fluid 9 After completing the bleeding operation hold brake pedal depressed and tighten the screw and install bleeder cap Tightening torque 8 0 8 kgf m 5 8 ft lb 10 Bleed air from each wheel cylinder by following the previous 5 steps 11 Depress the brake pedal with a force of appr
13. 650 100 700 100 650 100 Maximum output kW PS rpm 92 125 5 600 130 177 5 600 115 156 5 600 Maximum torque N m kgf m ft Ib rpm 184 18 8 3 600 SPC 2 245 25 0 3 200 223 22 7 3 600 FORESTER C ELECTRICAL Model 2 0L Non turbo 2 0L Turbo SPECIFICATIONS 2 5L Non turbo Ignition timing at BTDC rpm idling speed 10 10 650 12 10 700 MT 10 10 650 15 10 650 Spark plug Type and manufacturer CHAMPION RC10YC4 Alternate CHAMPION RC8YC4 NGK PFR6G NGK BKR6E 11 DENSO K20PR U11 CHAMPION RC10YC4 Alternate CHAMPION RC8YC4 NGK BKR6E 11 DENSO K20PR U11 Generator 12V 90A Battery Type and capacity BHR MT 12 V 48 AH 55D23L AT 12 V 52 AH 65D23L For Australia model D TRANSMISSION Model 2 0L Non turbo 2 0L Turbo 12 V 27 AH 34B19L 12 V 48 AH 55D23L 2 5L Non turbo Transmission type 5MT 4AT 5MT 4AT 5MT 4AT Clutch type DSPD TCC DSPD TCC DSPD TCC Gear ratio 1st 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 3rd 1 448 1 000 1 366 1 000 1 448 1 000 4th 1 088 0 694 0 972 0 694 1 088 0 694 5th 0 871 0 738 0 780 Reverse 3 333 2 272 3 333 2 272 3 333 2 272 Dual range 1 447 1 196 Reduction 1st Type of gear Helical Helic
14. 9 Open and close all doors to see that there are no abnormal conditions 6 Operation check of double lock 10 Check that the double lock operates normally 7 Operation check of the child lock system 11 Check the child lock system operate normally 8 Check the rear gate for lock unlock and open close operations 12 Check if the rear gate can be unlocked normally from the emergency door 13 Open and close the rear gate to see that there are no abnormal condi tions 14 Operate the power door locking switch to check that the rear gate is locked and unlocked normally 9 Operation check of fuel lid opener lock release lever 15 Operate the fuel lid opener to check that the fuel lid is unlocked normally 10 Accessory check Check that the following accessories are provided Owner s manual Warranty booklet Service booklet Spare key Jack Tool set Spare tire 11 Operation check of hood lock release system 16 Operate the hood lock release lever to check that the hood opens nor mally 12 Battery 17 Check the battery for any abnormal conditions such as rust and trace of battery fluid leaks 13 Brake fluid 18 Check the fluid amount 14 Engine oil 19 Check the oil amount 15 Transmission fluid 20 Check the fluid amount 21 For AT check the front differential oil 16 AT front differential oil 22 Check the AT front d
15. 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 B grooves of gearbox and the rod C 2 Clips are fitted outside of A and B positions of boot 3 Boot does not have crack and hole NOTE Rotate B the position of gearbox boot against twist of it produced by adjustment of toe in etc Im PM 00090 10 FITTING BOLTS AND NUTS Inspect the fitting bolts and nuts of oil pump and bracket for looseness and retighten them if neces sary Inspect and or retighten them when engine is cold PM 41 PERIODIC MAINTENANCE SERVICES 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 lt Ref to AB 2 Basic Diagnostic Procedure gt 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 PM 00103 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 indicate a trouble code a fault is identified When the
16. Ib 1 035 1 035 1 035 1 035 1 035 1 035 2 280 2 280 2 280 2 280 2 280 2 280 Maximum permissi Total kgf Ib 1 880 1 880 1 880 1 880 1 880 1 880 ble weight M P W 4 140 4 140 4 140 4 140 4 140 4 140 Option Sport package base Aluminum wheel O O O O O O Front fog light Cruise control High grade audio Sport steering Leather package base Leather seat Leather E u __ __ door trim Air conditioner Side airbag Sunroof Self leveling function Rr Cold area pack A ae Z Cold area pack B Cold area pack C Security system SPC 5 FORESTER SPECIFICATIONS Option codex EC K4 Model 2 0L AWD 2 0XT 5MT 4AT 5MT 4AT Curb weight C W Front kgf Ib 790 810 815 835 1 740 1 785 1 795 1 840 Rear kgf Ib 620 620 630 630 1 365 1 365 1 390 1 390 Total kgf Ib 1 410 1 430 1 445 1 465 3 105 3 150 3 185 3 230 Maximum permissi Front kgf Ib 1 010 1 010 1 010 1 010 ble axle weight 2 225 2 225 2 225 2 225 M P A W Rear kgf lb 1 035 1 035 1 035 1 035 2 280 2 280 2 280 2 280 Maximum permissi Total kgf Ib 1 950 1 950 1 950 1 950 ble w
17. Lower level 17 COOLANT Check the coolant amount on the reservoir If the amount is insufficient check that no leaks are found Then add the necessary amount of coolant with the specified concentration 8 PRE DELIVERY INSPECTION 18 CLUTCH FLUID Check the clutch fluid amount If the amount is in sufficient check that no leaks are found Then add the necessary amount of the specified fluid zm Sits PM 00076 A Reservoir tank B MIN level C MAX level 19 WINDOW WASHER FLUID Check the window washer fluid amount If the amount is insufficient check that no leaks are found Then add the necessary amount of washer fluid commercially available 20 HOOD LATCH CHECK Retract the hood stay and close the hood Check that the hood is securely latched 21 KEYLESS ENTRY SYSTEM Check the keyless entry system operations as fol lows Fully open all the door windows Remove the key from the ignition switch and close all the doors including rear gate PRE DELIVERY INSPECTION Press the LOCK button on the transmitter once and check if all the doors are locked and the haz ard light flashes once 00108 DBO 00109 Press the UNLOCK button on the transmitter once and check if the all doors are unlocked and the hazard light flashes twice 00110 4 Oe 00111 Close all
18. Then pull the inside door han dles of the rear doors to ensure that the doors will not open 4 Next pull the outside door handles of the rear doors to ensure that the doors will open 00084 Unlock Lock Child safety lock 8 CHECK THE REAR GATE FOR LOCK UNLOCK AND OPEN CLOSE OPERA TIONS 1 Open and close the rear gate several times for smooth movement 2 Operate the rear gate lever to check that the rear gate is locked and unlocked normally 1 Remove the blind cover inside the rear gate 00006 PRE DELIVERY INSPECTION 2 Using a screwdriver check the rear gate is lock unlock 9 OPERATION CHECK OF FUEL LID OPENER LOCK RELEASE LEVER Operate the fuel lid opener and verify that the fuel lid opens normally Check that the filler cap is se curely closed 10 ACCESSORY CHECK Check that the following accessories are provided in the luggage compartment or cargo area Owner s manual Warranty booklet Service booklet Spare key Jack Tool set Spare tire A Jack handle 7 PRE DELIVERY INSPECTION 11 OPERATION CHECK OF HOOD LOCK RELEASE SYSTEM Operate the hood release knob and check that the hood is unlocked normally 00071 Operate the lever and check that the hood is opened normally Then support the
19. lt Ref to CO SOHC 34 Radiator Main Fan and Fan Motor gt lt Ref to CO SOHC 40 Radiator Sub Fan and Fan Motor gt 2 Protect the radiator with cardboard and blanket 3 Remove the V belts lt Ref to ME TURBO 44 V belt gt 4 Remove the air conditioning compressor drive belt tensioner 5 Remove the pulley bolt To lock the crankshaft use ST ST 499977300 CRANKSHAFT PULLEY WRENCH PM 00093 PERIODIC MAINTENANCE SERVICES 6 Remove the crankshaft pulley 7 Remove the air conditioning compressor drive belt tensioner 8 Remove the belt cover LH 9 Remove the belt cover RH 10 Remove the front belt cover 11 Turn the crankshaft and align alignment marks on crankshaft and right and left camshaft sprock ets with notches of belt cover and cylinder block To turn the crankshaft use ST ST 499987500 CRANKSHAFT SOCKET PM 00094 A Notch B Alignment mark 12 Remove the belt idler 13 Remove the timing belt PM 13 CAMSHAFT DRIVE BELT PERIODIC MAINTENANCE SERVICES 14 Remove the automatic belt tension adjuster as sembly PM 00096 15 Install in the reverse order of removal lt Ref to ME TURBO 48 Timing Belt Assembly gt CAUTION When installing the timing belt be sure to align all alignment marks on the belt with corre sponding marks on the sprockets If incorrectly installed interfe
20. 2 US qt 1 8 Imp qt of the undiluted solution of SUBARU coolant If a coolant concentration of 5096 is needed drain all the coolant and refill with the undiluted solution only 4 US qt Imp qt 2 PM 00026 Quantity of coolant to be drained Necessary concentration of coolant Concentration of coolant in vehicle cooling sys tem 9 20 CLUTCH SYSTEM PERIODIC MAINTENANCE SERVICES 13 Clutch System A INSPECTION AND ADJUSTMENT 1 Push the release lever to retract the push rod of the operating cylinder and check if the fluid level in the clutch reservoir tank rises or not NON TURBO MODEL PM 00075 A Release lever B Push rod C Operating cylinder TURBO MODEL PM 00101 A Release lever B Push rod C Operating cylinder 2 If the fluid level rises pedal free play is correct 3 If the fluid level does not rise or the push rod cannot be retracted adjust the clutch pedal lt Ref to CL 37 Clutch Pedal gt 4 Check the fluid level using the scale on the out side of the clutch master cylinder tank A If the lev el is below MIN B inspect 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 clutch reservoir tank Recommended clutch fluid FMVSS No 116 fresh DOT3 or DOT4 br
21. 34 Radiator Main Fan and Fan Motor gt lt Ref to CO SOHC 40 Radiator Sub Fan and Fan Motor gt 2 Sheild the radiator from any damage using card board and blanket 3 Remove the V belt cover NON TURBO MODEL re EX A Cu 2 E 7 SC 00096 4 Remove the V belts Ref to ME SOHC 41 V belt gt 5 Remove the air conditioning compressor drive belt tensioner 6 To lock the crankshaft use ST Remove the pul ley bolt ST 499977100 CRANKSHAFT PULLEY WRENCH PM 00007 7 Remove the crankshaft pulley 8 Remove the left side belt cover 9 Remove the front timing belt cover 10 Remove the timing belt guide MT vehicle only 11 Turn the crankshaft and align alignment marks on crankshaft and right and left camshaft sprock ets with notches of belt cover and cylinder block ST 499987500 CRANKSHAFT SOCKET PM 00009 A Notch B Alignment mark 12 Remove the belt idler PM 12 CAMSHAFT DRIVE BELT 13 Remove the belt idler No 2 PM 00010 14 Remove the timing belt 15 Remove the automatic belt tension adjuster as sembly PM 00011 16 Install in the reverse order of removal Ref to ME SOHC 47 INSTALLATION Timing Belt As sembly gt 2 TURBO MODEL 1 Remove the radiator fan and air conditioner fan
22. 847 or EC 1022 Spray type Momentary sealant Cemedine 3000 Armstrong s Eastman 910 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 Torque converter clutch case Three Bond 1215 004403007 Dow Corning s No 7038 Transmission Three Bond 1217B K0877YA020 Rear differential Three Bond 1324 004403042 Rear differential Three Bond 1105 004403010 Dow Corning s No 7038 Weatherstrip Starcalking B 33A 000018901 Butyl Rubber sealant Steering adjusting screw Three Bond 1102 004403006 SOHC cam cap Three Bond 1280B RM 5 K0877YA018 RECOMMENDED MATERIALS RECOMMENDED MATERIALS RM 6 PRE DELIVERY INSPECTION PI Page 1 gt Pre delivery InspectloFi cocci eerte 2 PRE DELIVERY INSPECTION PRE DELIVERY INSPECTION 1 Pre delivery Inspection A GENERAL The purposes of the pre delivery inspection PDI are as follows Remove the additional parts used for ensuring the vehicle quality during transportation and restore the vehicle to its normal state Check if the vehicle before delivery is in a normal state Check for any damage or missing parts that may have taken place during transportation or storage Make sure
23. Outer oil seal Hub bolt Hub p attach a dial gauge to the hub COMPL and mea sure axial displacement in axial direction Service limit Straight ahead position within 0 05 mm 0 0020 in 5 Remove the DOJ of rear drive shaft from rear dif ferential Ref to DS 37 Rear Drive Shaft 6 While supporting the rear drive shaft horizontally with one hand turn the hub COMPL with the other to check for noise or binding If the hub COMPL is noisy or binds disassemble the rear axle and check condition of oil seals bear ings etc gt o Inner oil seal Rear housing Bearing Snap ring Outer oil seal Tone wheel Hub bolt Hub Socket bolt PM 36 AXLE BOOTS amp JOINTS PERIODIC MAINTENANCE SERVICES 24 Axle Boots amp 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 lt Ref to DS 31 Front Drive Shaft gt lt Ref to DS 37 Rear Drive Shaft gt PM 00064 2 PROPELLER SHAFT Inspect the propeller shaft for damage or failure If faulty replace with a new one lt Ref to DS 14 Pro peller Shaft gt PM 37 PERIODIC MAINTENANCE SERVICES 25 Tire Rotation A INSPECTION TIRE ROTATION 1 Replace the tire if the tread depth is less than 1 6 mm 0 063 in or if wear indicators appear
24. across the tire tread 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 front and rear tires as illustrared in order to ensure uniform tire wear lt gt 00079 PM 00080 A New tread B Worn tread C Tread wear indicator PM 38 STEERING SYSTEM POWER STEERING PERIODIC MAINTENANCE SERVICES 26 Steering System Power Steering A INSPECTION 1 STEERING WHEEL 1 Set the steering wheel in a straight ahead posi tion and check the wheel spokes to make sure they are correctly set in their specified positions 2 Lightly turn the steering wheel to the right and left to determine the point where front wheels start to move Measure the distance of the movement of steering wheel at the outer periphery of wheel Steering wheel free play 0 17 mm 0 0 67 in PM 00065 A Steering wheel free play Move the steering wheel vertically toward the shaft to ascertain if there is play in the direction Maximum permissible play 0 5 mm 0 020 in 3 Drive the vehicle and check the following items during operation 1 Steering force The effort required for steering should be smooth and even at all points and should not vary 2 Pull to one side Steering wheel should not be pulled to either side while dri
25. airbag system is in good order no trouble codes are stored in the memory the warning light blinks on and off at 0 6 second intervals as long as the diagnosis terminal is connected to ground terminal 4 When the warning light indicates a trouble code check the airbag system in accordance with the trouble shooting procedure Ref to AB 2 Basic Diagnostic Procedure PM 42
26. ced ee eee reri 37 ER C FO RE Reed 38 Steering System Power 39 Supplemental Restraint 0 00001 42 GENERAL DESCRIPTION PERIODIC MAINTENANCE SERVICES 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 SCHEDULE PERIODIC MAINTENANCE SERVICES 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 Maintenance interval Number of months or km miles whichever occurs first Month 12 24 36 48 60 72 84 96 Remarks x 1 000 km 1 6 15 30 45 60 75 90 105 120 x 1 000 miles 1 9 19 28 38 47 56 66 75 Engine oil R R R R R R Engine oil filter R R R R R R X Spark plug For Turbo R Others Drive belt s Camshaft drive belt Fuel line Fuel filter Air cleaner element Cooling system Coolant Clutch system Hill holder system Transmission oil ATF Front amp rear differential Brake line Brake fluid Disk brake pads amp discs Brake linings amp drums Parking bra
27. doors and rear gate press the LOCK button of the transmitter Press the UNLOCK but ton of the transmitter and wait for 30 seconds Check that all doors and the rear gate are automat ically locked again PRE DELIVERY INSPECTION PRE DELIVERY INSPECTION 22 SEAT Check that each seat provides full functionality in sliding and reclining Check all available functions of the rear seat 23 SEAT BELT Pull out the seat belt and then release it Check that the belt webbing retracts smoothly 24 WHEEL ALIGNMENT Check the wheel alignments lt Ref to FS 7 Wheel Alignment gt and lt Ref to RS 9 Wheel Alignment gt 25 TEST MODE CONNECTORS Turn the ignition switch to ON and check that the check engine light starts blinking If the light blinks return the ignition key to LOCK and disconnect the test mode connector Then turn the ignition key to ON again If the check engine light blinks at that time in spite of the disconnected test mode connec tor carry out an engine diagnosis 1000 0000 0000 00076 A Test mode connector Green 26 STARTING CONDITION Start the engine and check that the engine starts smoothly If any battery voltage problems are found recharge or replace the battery If any ab normal noises are observed immediately stop the engine and check and repair the necessary compo nents 27 EXHAUST SYSTEM Listen to the exhaust noise to see if no abnormal
28. not matter if the oil to be added is a different brand from that in the en gine however use oil having the API classification and SAE viscosity No designated by SUBARU f vehicle is used in desert areas with very high temperatures or for other heavy duty applications the following viscosity oils may be used API classification SL SJ or SH 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 level Ref to PM 7 INSPECTION Engine Oil B INSPECTION 1 Park the vehicle on a level surface 2 Remove the oil level gauge and wipe it clean 3 Reinsert the level gauge all the way Be sure that the level gauge is correctly inserted and in the proper orientation 4 Remove it again and note the reading If the en gine oil level is below the L line add oil to bring the level up to the F line PM 00082 A Oillevel gauge Oil filler cap C Notch mark g Upper level Lower level Approx 1 0 1 1 Us qt 0 9 Imp qt E F 5 After turning off the engine wait few minutes for the oil to drain back into oil pan before checking the level 6 Just after driving or while the engine is warm en gine oil level may show in the range between the F line and the notch mark This is caused by ther mal expansion of the engine oil 7 To preve
29. 0055 Inside diameter B Disk 3 If the deformation or wear of back plate shoe etc is noticeable replace them 4 When the shoe return 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 disc brake adjust the parking brake after bleeding air 1 Remove the rear cover rubber installed at back plate 2 Turn the adjuster toward arrow mark upward until it is locked slightly by using a flat tip screwdriv er as shown in illustration A wal Eo p PM 00056 A Adjuster B Cover rubber C Back plate 3 Turn back downward the adjuster 3 to 4 notch es 4 Install the cover rubber at original position cor rectly PM 33 SUSPENSION PERIODIC MAINTENANCE SERVICES 22 Suspension 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 If relative movement B is observed between the brake disc cover A and end of transverse link D ball joint C may be excessively worn PM 00057 3 Next grasp the end of transverse link and move it up and down Relative movement A between the housing D and transverse link C boss indi cates ball join
30. 25 Thermostat Ref to CO SO 27 Radiator Ref to CO SOHC 33 Radi ator Cap 4 Check the electric fan operates using Subaru Select Monitor when the coolant temperature ex ceeds 95 C 203 F If not operate check the elec tric fan system Ref to CO SOHO 11 Radiator Fan System PM 18 COOLANT PERIODIC MAINTENANCE SERVICES 12 Coolant A REPLACEMENT 1 REPLACEMENT OF COOLANT WARNING The radiator is of the pressurized type Do not attempt to open the radiator cap immediately after the engine has been stopped 1 Lift up the vehicle 2 Remove the under cover 3 Place a container under drain pipe 4 Loosen and remove the drain cock to drain en gine coolant into container 527 00009 5 For quick draining open the radiator cap NOTE Be careful not to spill coolant on the floor 6 Drain the coolant from reservoir tank 7 Tighten the radiator drain cock securely after draining coolant 8 Remove the air bleeder valve cap of heater hose part RHD Non turbo model PM 00143 9 Remove the rubber cap of air bleeder pipe from the side of A C compressor and then install the viny hose Turbo model PM 00144 10 Slowly pour the coolant into radiator Pour the coolant up to air bleeder hole and then install the cap RHD Non turbo and Turbo model 11 Pour the coolant from radiator filler port to neck of f
31. 3 a 5 00003 NT 00004 NOTE NOTE e Jack up point KU it 2 4 pps ES TIAM J Sa TS I MG PN NT 00005 A Front B Rear NT 5 NOTE NOTE 6 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 SOBs NT 6 NOTE NOTE i LLL 45 45 A NT 00008 A Tie down range 7 TOWING Avoid towing vehicles except when the vehicle can not be driven Use a loader instead of towing When towing other vehicles to prevent excessive weight from damaging the hook or vehicle Do not tow other vehicles with a front towing hook Make sure the vehicle towing is heavier that the vehicle being towed NT 7 NOTE NOTE 8 FRONT HOOD STAY INSTALLATION At the check and general maintenance NT 00009 When wider hood opening is necessary Set stay into the hole of hood inner as shown in the figure below NOTE Before setting the hood in this position remove the windshield washer hose attaching clip from the hood
32. 7 Rear Disc Brake Assembly 5 Tighten the wheel nuts to secure disk rotor 6 Set a dial gauge at a point less than 10 mm 0 39 in from outer periphery of rotor and then measure the disk rotor runout Disc rotor runout limit Front 0 075 mm 0 0030 in Rear 0 070 mm 0 0028 in PM 00051 PM 31 BRAKE LININGS AND DRUMS PERIODIC MAINTENANCE SERVICES 21 Brake Linings and Drums A INSPECTION 1 REAR DRUM BRAKE 1 Remove the brake drum and check that there is no fluid leakage from wheel cylinder If there is fluid leakage from wheel cylinder inspect the wheel cylinder and then repair or replace it 2 Inspect the brake shoes for damage or deformi ties and check brake linings for wear NOTE Always replace both leading and trailing brake shoes for the right and left wheels at the same time When either the right and left brake assembly is replaced always replace the leading shoe and trail ing shoe of the other Thickness of lining except back metal Standard value 4 1 mm 0 161 in Service limit 1 5 mm 0 059 in PM 00052 A B C Rotational direction of drum Forward Wheel cylinder Upper shoe return spring Adjusting lever G Trailing shoe Lower shoe return spring Leading shoe 3 Check the brake drum for wear dents or other damage If the inside surface of brake drum is streaked cor rect the sur
33. ERING PERIODIC MAINTENANCE SERVICES 2 Retighten the adjusting screw to 7 4 N m 0 75 kgf m 5 4 ft lb and back off 25 3 Apply liquid packing to at least 1 3 of entire perimeter of adjusting screw thread alg A Apply liquid packing to at least 1 3 of entire perimeter PM 00068 4 Install the lock nut While holding the adjust ing screw with a wrench tighten the lock nut us ing ST ST 926230000 SPANNER Tightening torque Lock nut 39 4 0 kgf m 29 ft lb Hold the adjusting screw with a wrench to pre vent it from turning while tightening the lock nut 4 TIE ROD 1 Check the tie rod and tie rod ends for bends scratches or other damage PM 00069 A Tie rod end B Knuckle arm 2 Check the connections of knuckle ball joints for play inspect for damage on dust seals and check free play of ball studs If the castle nut is loose re tighten it to the specified torque then tighten further up to 60 until the cotter pin hole is aligned Tightening torque 27 N m 2 75 kgf m 19 9 ft Ib 3 Check the lock nut on tie rod end for tightness If it is loose retighten it to the specified torque Tightening torque 83 N m 8 5 kgf m 61 5 ft Ib 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 fl
34. PERATION Suba ru Select Monitor gt 2 Make sure the vehicle is level 3 After selecting all positions P R N D 3 2 1 set the select lever in P range Measure the ATF level with the engine idling for one or two minutes A B C B C COLD Lo Fo AT 00015 A ATF level gauge B Upper level C Lower level 4 Make sure that ATF level is above the center of upper and lower marks NOTE When the transmission is hot the level should be above the center of upper and lower marks and when it is cold the level should be found below the center of these two marks 5 If the ATF level is below the center between up per and lower marks add the recommended ATF until the ATF level is found above the center be tween upper and lower marks CAUTION Use care not to exceed the upper limit level Remember that the addition of ATF to the up per limit mark when the transmission is cold will result in overfilling of ATF causing a trans mission failure 6 Check ATF level after raising ATF temperature to 60 80 C 140 176 F by running the vehi cle or by idling the engine again 7 Check the ATF for leaks Check for leaks in the transmission If there are leaks it is necessary to repair or replace gasket oil seals plugs or other parts B REPLACEMENT 1 AUTOMATIC TRANSMISSION FLUID 1 Drain the ATF Automatic Transmission Fluid by removing drain plug aft
35. PT FOR 2 0L NON TURBO MODEL PM 00037 A Filler plug B Drain plug PM 26 FRONT amp REAR DIFFERENTIAL OIL PERIODIC MAINTENANCE SERVICES 2 0L NON TURBO MODEL PM 00102 A Filler plug B Drain plug Oil capacity 0 8 0 0 8 US qt 0 7 Imp qt NOTE Each oil manufacturer has its base oil and addi tives Thus do not mix two or more brands 5 Install the filler plug onto rear differential gear case firmly NOTE Apply fluid packing to the filler plug threads ex cept for 2 0 L Non turbo model Fluid packing Three Bond 1105 Part No 004403010 Use a new aluminum gasket for 2 0 L Non turbo model Tightening torque Except for 2 0 L Non turbo model 49 0 N m 5 0 kgf m 36 2 ft Ib 2 0 L Non turbo model 34 N m 3 5 kgf m 25 3 ft Ib PM 27 BRAKE LINE PERIODIC MAINTENANCE SERVICES 18 Brake Line A INSPECTION 1 BRAKE LINE 1 Check scratches swelling corrosion traces of fluid leakage on the brake hoses or pipe joints 2 Check the possibility of adjacent parts interfering with brake pipes hoses during driving and loose connections clamps 3 Check any trace of fluid leakage scratches etc on the master cylinder wheel cylinder and pres sure control valve NOTE When the brake fluid level in the reservoir tank is lower than the specified limit the brake fluid warn ing light on the combination meter will come on Vi
36. R PERIODIC MAINTENANCE SERVICES 9 Fuel Filter A REPLACEMENT For fuel filter replacement procedures refer to FU section lt Ref to FU SOHC 62 Fuel Filter gt B INSPECTION 1 If it 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 PM 16 AIR CLEANER ELEMENT 10 Air Cleaner Element A REPLACEMENT 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 3 FE CA Cy eu 2 7 IN 00039 5 Install in the reverse order of removal CAUTION Fasten with a clip after inserting the lower tab of the case PERIODIC MAINTENANCE SERVICES 2 TURBO MODEL 1 Remove the clip B above the air cleaner case 3 Install in the reverse order of removal CAUTION Align the protruding portion of air cleaner up per cover with holes of air cleaner lower case then secure upper cover to case PM 00100 PM 17 COOLING SYSTEM PERIODIC MAINTENANCE SERVICES 11 Cooling System A INSPECTION 1 Check the radiator for leakage filling it with cool ant and attach the radiator cap tester to filler neck Then apply a pres
37. SUBARU FORESTER 2003 Model Year PDF Service Manual CHASSIS SECTION Pub No G8070GE5 BODY SECTION Pub No G8070GE6 WIRING SYSTEM SECTION Pub No G8070GE7 2003 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 FUJI HEAVY INDUSTRIES LTD FOREWORD HOW TO USE THIS MANUALS SPECIFICATIONS PRECAUTION NOTE IDENTIFICATION ID RECOMMENDED MATERIALS RM PRE DELIVERY INSPECTION PERIODIC MAINTENANCE SERVICES G8070GE1 FOREWORD 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
38. URBO MODEL TURBO MODEL ulli x 4 1 JO gt E SC 00096 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 Remove the front side belt C 4 Install a new belt and tighten the slider bolt so as to obtain the specified belt tension 5 Tighten the lock bolt A PM 10 DRIVE BELT S 6 Tighten the slider bolt B Tightening torque Lock bolt 25 N m 2 5 kgf m 18 ft Ib Slider bolt 8 N m 0 8 kgf m 5 8 ft Ib 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 5 Install a new belt and tighten the slider bolt so as to obtain the specified belt tension 6 Tighten the lock nut A 7 Install the front side belt Ref to ME SOHC 42 REAR SIDE BELT INSTALLATION V belt gt Tightening torque 23 N m 2 3 kgf m 17 0 ft Ib PM 11 PERIODIC MAINTENANCE SERVICES CAMSHAFT DRIVE BELT PERIODIC MAINTENANCE SERVICES 7 Camshaft Drive Belt A REPLACEMENT 1 NON TURBO MODEL 1 Remove the radiator fan and air conditioner fan lt Ref to CO SOHC
39. VOADNAeAT AS Details Engine type EJ 4 cylinders Displacement 20 2 0L 25 2 5L Fuel feed system 1 D MPI SOHC A 5 L MPI Turbo Emission control Transmission W MT X AT Minor change U Initial Detailed specifications Used when ordering parts See the parts catalog for details ID 5 IDENTIFICATION IDENTIFICATION Transmission TY755XF3AA Meaning Details Transmission T Transmission Transmission type Y Full time AWD MT center differential Z Full time AWD AT MPT Classification 75 MT 1A AT Series 3 AT 5 MT Transmission specifica tions V Full time AWD 5 speed MT with viscous coupling center dif ferential single range X Full time AWD 5 speed MT Dual range with viscous cou pring center differential Z Full time AWD 4 speed AT with MPT Mounted body F 2 5L SOHC R 2 0L SOHC N 2 0L DOHC Turbo Minor change 3 Initial Detailed specifications Rear differential 1 VA1REK Meaning Used when ordering parts See the parts catalog for details Details For AWD V AWD Type A A type Hypoid gear diameter mm in 1 152 6 0 dia Installation position R Rear Reduction gear ratio E 4 111 F 4 444 Specification differ ences Rear differential 2 HP Reduction gear ratio Viscous Viscous
40. ake fluid CAUTION Prevent the clutch fluid from being splashed over vehicle body If the clutch fluid is splashed over vehicle body flush it and then wipe it up NOTE Avoid mixing different brakes of brake fluid to prevent degradation of the fluid Be careful not to allow dirt or dust to get into the reservoir tank EA Xi PM 00076 A Reservoir tank B MIN lever C MAX lever PM 21 TRANSMISSION OIL PERIODIC MAINTENANCE SERVICES 14 Transmission Oil A REPLACEMENT 1 MANUAL TRANSMISSION 1 Drain the gear oil by removing drain plug after al lowing the engine to cool for 3 to 4 hours NOTE Before starting work cool off the engine well f transmission gear oil adheres to the exhaust pipe wipe it off completely o PM 00029 2 Replace the gasket with new one and then tight en it to the specified torque Tightening torque 44 4 5 kgf m 32 5 ft Ib 3 Fill transmission gear oil through the oil level gauge hole up to the upper point of level gauge NOTE Each oil manufacturer has its base oil and addi tives Thus do not mix two or more brands Gear oil capacity Non turbo model 4 0 0 4 2 US qt 3 5 Imp qt Turbo model Without oil pump 3 5 0 3 7 US qt 3 1 Imp qt With oil pump 3 9 0 4 1 US qt 3 4 Imp qt PM 00030 A Oillevel gauge B Upper level C Lower level PM 22 HILL HOLDER SYSTEM 15 Hill holder Syste
41. al Helical gear Front reduction Gear ratio 1 000 1 000 1 000 drive Final Type of gear Hypoid Hypoid Hypoid Hypoid Hypoid Hypoid reduction Gear ratio 4 111 4 444 4 444 4 111 4 111 4 444 Reduction Transfer Type of gear Helical Helical Helical gear Rear reduction Gear ratio 1 081 drive 1 090 1 000 1 000 Final Type of gear Hypoid Hypoid Hypoid reduction Gear ratio 4111 4 111 4 444 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 Europe spec vehicle E STEERING Type Rack and Pinion 4 111 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 F SUSPENSION Front Macpherson strut type Independent Coil spring Rear Dual link type Independent Coil spring SPC 3 FORESTER SPECIFICATIONS G BRAKE Model 2 0L Non turbo 2 5L Non turbo 2 0L Turbo 2 5L Non turbox 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 RHD model H TIRE Rim size 15 6 16 x 61 5 Tire size 205 70 R15 95H 215 60 R16 95V P215 60 R16 94H Type Steel belted radi
42. al Tubeless I CAPACITY Model 2 0L Non turbo 2 0L Turbo 2 5L Non turbo 5MT 4AT 5MT 4AT 5MT 4AT Fuel tank Q US gal Imp gal 60 15 9 13 2 Engine oil Q US qt Imp qt When replacing Transmission gear oil Q US qt Imp qt 3 5 4 0 8 7 3 1 4 0 4 2 3 5 3 9 4 2 3 5 4 1 3 4 1 Automatic transmis Q US qt Imp qt 9 3 sion fluid 9 8 8 2 AT differential gear oil Q US qt Imp qt 1 2 1 3 1 1 Approx 4 0 4 2 3 5 Approx 4 5 4 8 4 0 Approx 4 0 4 2 3 5 AWD rear differential Q US qt Imp qt gear oil Power steering fluid Q US qt Imp qt 0 7 0 7 0 6 Engine coolant Q US qt Imp qt 7 3 7 7 6 4 2 0 8 0 8 0 6 1 With oil pump x2 MT vehicles with oil cooler included SPC 4 FORESTER SPECIFICATIONS J WEIGHT 1 LHD MODEL Option codex EC K4 KS Model 2 0L 2 5L AWD 2 0X 2 5X 5MT 4AT 5MT 4AT 5MT 4AT Curb weight C W Front kgf Ib 760 775 775 790 780 800 1 675 1 710 1 710 1 740 1 720 1 765 Rear kgf Ib 600 600 595 595 620 620 1 325 1 325 1 310 1 310 1 365 1 365 Total kgf Ib 1 360 1 375 1 370 1 385 1 400 1 420 3 000 3 035 3 020 3 050 3 085 3 130 Maximum permissi Front kgf Ib 1 010 1 010 1 010 1 010 1 010 1 010 ble axle weight 2 225 2 225 2 225 2 225 2 225 2 225 M P A W Rear kgf
43. al tool HU 4 HOW TO USE THIS MANUALS 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 4 5 kgf m 33 ft lb HU 5 HOW TO USE THIS MANUALS HOW TO USE THIS MANUALS HOW TO USE THIS MANUALS HU 6 SPECIFICATIONS SPECIFICATIONS FORESTER 1 Forester A DIMENSIONS Model 2 0L Non turbo 2 0L Turbo 2 5L Non 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 With sunroof B ENGINE Model 2 0L Non turbo 2 0L Turbo 2 5L Non turbo Engine type Horizontally opposed liquid cooled 4 cylinder 4 stroke gasoline engine Valve arrangement Overhead camshaft type Bore x Stroke mm in 92 x 75 3 62 x 2 95 99 5 x 79 3 92 x 3 11 Displacement cm cu in 1 994 121 67 2 457 149 94 Compression ratio 10 0 0 2 8 0 0 2 10 0 0 2 Firing order 3 2 4 Idle speed at Park Neutral position rpm
44. and steering wheel With the brake pedal released measure the dis tance between pedal and steering wheel again The difference between the two measurements must be less than specified value If the distance is more than specified there is possibility of air inside the hydraulic unit a _ n moo Brake pedal reserve distance A For Australia 105 mm 4 13 in 490 N 50 kgf 110 Ib or less Except for Australia 90 mm 3 54 in 490 N 50 kgf 110 Ib or less l k A A j 1 21 51 12 SS B Nu PM 00045 A Steering wheel B Toe board PERIODIC MAINTENANCE SERVICES 4 Check to see if air is in the hydraulic brake line by the feel of pedal operation If air appears to exist in the line bleed it from the system 5 Check for even operation of all brakes using a brake tester or by driving the vehicle for a short dis tance on a straight road 2 BRAKE SERVO SYSTEM 1 With the engine off depress the brake pedal several times applying 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 pedal depressed stop the engine and keep the pedal depressed for 30 seconds Make sure the pedal height should not change 4 Check valve is built into the vacuum hose Dis connect the vacuum hose to inspect function
45. ce Interval Number of months or km miles whichever occurs first Months 12 24 36 48 Remarks x 1 000 km 1 6 25 50 75 100 x 1 000 miles 1 15 30 45 Spark plugs For Turbo Others R R R Drive belt s Camshaft drive belt Fuel line Fuel filter Air cleaner element Cooling system Coolant Clutch system Hill holder system Transmission oil ATF Front amp rear differential oil Brake line Brake fluid Disc brake pads amp discs Brake linings and drums Parking brake Suspension Wheel bearing Axle boots amp joints Steering system Power steering o D D D D D D D D D D BD dD 2 2 Symbols used R Replace I Inspection I Recommended service for safe vehicle operation NOTE 1 When the vehicle is used in extremely dusty conditions the air cleaner element should be replaced more often 2 ATF filter is a maintenance free part ATF filter needs replacement when it is physically damaged or ATF leaked PM 4 SCHEDULE PERIODIC MAINTENANCE SERVICES B MAINTENANCE SCHEDULE 2 Repeat short distance drive Repeat rough muddy road drive Extremely cold weather area Salt or other corrosive used or coastal area High humid ity or moun tain area Repeat tow ing trailer Engine
46. cement part Sealing point um Should be lubricated with oil Should be lubricated with grease T1 T2 Tightening torque HU 00001 HU 3 HOW TO USE THIS MANUALS HOW TO USE THIS MANUALS 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 f many serviceable parts are included in one service procedure appropriate reference are provided for each part Example 15 Main Shaft Assembly for Sin 4 40 gle Range A REMOVAL B 1 Remove the manual transmission assembly from vehicie Ref to MT 33 REMOVAL Manual Transmission Assembly 11 Tighten the lock nuts to the specified torque us ing ST1 and ST2 NOTE D Secure the lock nuts in two Places affer tightening ST2 499987003 SOCKET WRENCH ST1 498937000 iB TRANSMISSION HOLDER 8 Tightening torque 118 12 0 kgf m 86 8 ft lb G m H HU 00002 A Component D Caution G Tightening torque B Process E Tool number of special tool H Illustration C Reference F Name of speci
47. charge electricity before beginning work Step 1 Turn the ignition switch OFF Step 2 Disconnect the ground cable from bat tery 6 AIRBAG DISPOSAL To prevent bodily injury from unexpected airbag deployment do not dispose airbag modules in the same way as other refuse Follow the special in structions for disposal in this manual Follow all government regulations concerning disposal of refuse 7 AIRBAG MODULE Adhere to the following when handing and storing the airbag module to prevent bodily injury from un expected deployment Do not hold the harnesses or connectors to carry module Do not face the bag in the direction that it opens towards yourself or other people Do not face the bag in the direction that it opens towards the floor or walls 8 AIRBAG SPECIAL TOOLS To prevent unexpected deployment only use spe cial tools 9 WINDOW Always wear safety glasses when working around any glass to prevent glass fragments from damag ing your eyes 10 WINDOW ADHESIVE Always use the specified urethane adhesive when attaching glass to prevent it from coming loose and falling resulting in accidents and injury PC 2 NOTE lg ierat eene een Fake NOTE NOTE 1 Note A NOTE This is information that can improve efficiency of maintenance and assure sound work 1 FASTENER NOTICE Fasteners are used to prevent parts from damage and dislocati
48. ck that the window washer system operates normally Wiper Power window operation check Dynamic Test with the Vehicle Running Step 0 Check that the wiper system operates normally 1 Check the power window for correct operations 6 Check that the radio system operates normally Check point 37 Brake test 1 Check that the foot brake operates normally 38 Parking brake 2 Check that the parking brake operates normally 39 AT shift control 3 Check the AT shift patterns are correct 40 Heater amp ventilation 4 Check that the heater amp ventilation system operates normally 41 Air conditioner 5 Check that the air conditioner operates normally 42 Speed control Checks after Dynamic Test Step 6 Check that the speed control operates normally Check point 43 ATF level 1 Check that the ATF level is normal 44 Power steering fluid level 2 Check that the power steering fluid level is normal 45 Fluid leak check 3 Check for fluid oil leaks 46 Water leak check 4 Spray the vehicle with water and check for water leaks 47 Appearance check 2 5 Remove the protective coating wrap guard if any 6 Check the body paints for damage and smears 7 Check the plated parts for damage and rust 4 PRE DELIVERY INSPECTION 1 APPEARANCE CHECK 1 If the vehicle is cover
49. ed with protective coating visually check the vehicle body for damage and dents 2 If there is no protective coating check the body paints for small areas of damage or stains and re pair as necessary 3 Check the window glass door glass and lights for any cracks or damage and repair or replace the parts as necessary 4 Check the plated parts such as the grilles and door knobs for damage or loss of gloss and repair or replace the parts as necessary 2 TIRE CHECK Check the tire outer faces for any damage Check the tire air pressure by referring to the fol lowing table Tire size Tire inflation pressure kPa kg cm psi Front Rear 200 2 0 29 190 1 9 28 200 2 0 29 190 1 9 28 205 70R15 215 60R16 3 FUSE INSTALLATION A vehicle just delivered has no fuse for the room lamp circuit to prevent battery discharge Attach a 15 A fuse A as shown in the figure 00001 5 PRE DELIVERY INSPECTION 4 CONNECTION OF AIR CONDITIONER HARNESS A vehicle just delivered has its air conditioner har ness disconnected to protect the air conditioner compressor Connect the harness as shown in the figure 00002 5 CHECK THE DOORS FOR LOCK UN LOCK AND OPEN CLOSE OPERATIONS 1 Using the key lock and unlock the door several times to check for normal operation Open and close the door several times for smooth movement EUN
50. eight M P W 4 295 4 295 4 295 4 295 Option Sport package base a Aluminum wheel Front fog light Cruise control O O High grade audio Sport steering Leather package base O O O O Leather seat Leather door trim Air conditioner O Side airbag O Sunroof O Self leveling function Rr Cold area pack A Cold area pack B Cold area pack C Security system For the option codes refer ID section Ref to 10 6 Option code SPC 6 FORESTER SPECIFICATIONS 2 RHD MODEL Option codex EK KA EK Model 2 0L 2 5L 2 0L AWD 2 0X 2 5X 2 0XT 5MT 4AT 5MT 4AT 5MT 4AT Curb weight C W Front kgf Ib 775 790 765 785 815 835 1 705 1 740 1 685 1 730 1 795 1 840 Rear kgf Ib 600 600 625 625 635 635 1 325 1 325 1 380 1 380 1 400 1 400 Total kgf Ib 1 375 1 390 1 390 1 410 1 450 1 470 3 030 3 065 3 065 3 110 3 195 3 240 Maximum permissi Front kgf Ib 1 010 1 010 1 010 1 010 1 010 1 010 ble axle weight 2 225 2 225 2 225 2 225 2 225 2 225 M P A W Rear kgf Ib 1 035 1 035 1 035 1 035 1 035 1 035 2 280 2 280 2 280 2 280 2 280 2 280 Maximum permissi Total kgf Ib 1 880 1 880 1 950 1 950 1 950 1 950 ble weight M P W
51. er allowing the engine to cool for 3 to 4 hours NOTE Before starting work cool off the engine well E PM 00032 A Front differential drain plug B ATF drain plug 2 Replace the gasket with a new one and then tighten the specified torque Tightening torque 25 2 55 kgf m 18 4 ft lb 3 Fill ATF up to the middle of the COLD side on level gauge by using the gauge hole Recommended fluid Dexron type automatic transmission fluid Fluid capacity Fill the same amount drained from ATF drain plug hole PM 24 ATF PERIODIC MAINTENANCE SERVICES 4 Check the ATF level lt Ref to PM 24 INSPEC TION ATF gt COLD Lo 209 O HOT 00033 Level gauge Hot side Upper level D Lower level Cold side Upper level Lower level 2 ATF FILTER NOTE ATF filter is a maintenance free part ATF filter needs replacement when it has physically dam aged or ATF leaked For the replacement procedures of the ATF filter lt Ref to AT 69 ATF Filter gt PM 25 FRONT amp REAR DIFFERENTIAL OIL PERIODIC MAINTENANCE SERVICES 17 Front amp Rear Differential Oil A REPLACEMENT 1 FRONT DIFFERENTIAL MANUAL TRANSMISSION For MT vehicle manual transmission oil works as differential oil to lubricate differential Refer to Transmission Oil Ref to PM 22 Transmission Oil gt 2 FRONT DIFFERENTIAL AUTOMATIC TRANSMISSION 1 Dra
52. face with emery 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 6 mm 9 079 in If deformation or wear of back plate shoe etc is noticeable replace the affected parts PM 00053 A Inside diameter 2 PARKING BRAKE REAR DISC BRAKE Inspect the brake linings and drums of both sides of the rear brake at the same time by removing brake drums 1 Inspect the brake shoes for damage or deforma tion and check brake linings for wear NOTE Always replace both primary and secondary brake shoes for the right and left wheels at the same time Brake lining thickness except back metal Standard value 3 2 mm 0 126 in Wear limit 1 5 mm 0 059 in PM 00054 A Forward B Brake shoe Primary side C Brake shoe Secondary side PM 32 BRAKE LININGS AND DRUMS PERIODIC MAINTENANCE SERVICES 2 Check the disk rotor for wear dents or other damage If the inside surface of disk rotor is streaked correct the surface with emery cloth 200 or more If it is unevenly worn or tapered correct or replace it Brake drum inside diameter Standard value 170 mm 6 69 in Wear limit 171 mm 6 73 in 0
53. hood with hood stay 00082 PRE DELIVERY INSPECTION PRE DELIVERY INSPECTION 12 BATTERY Check the battery terminals to make sure that no rust or corrosions due to fluid leaks are found Check that the battery caps are securely tightened 00012 B Upper level C Lower level 13 BRAKE FLUID Check the brake fluid amount If the amount is in sufficient carry out a brake line test to identify brake fluid leaks and check the brake operation Af ter that refill the brake fluid tank with the specified type of fluid 14 ENGINE OIL Check the engine oil amount If the amount is insuf ficient check that no leaks are found Then add the necessary amount of the specified engine oil LU 00105 Oil level gauge Engine oil filler cap Upper level Lower level Approx 1 0 1 1 US qt 0 9 Imp qt gt gt 15 TRANSMISSION FLUID Check the transmission fluid amount If the amount is insufficient check that no leaks are found Then add the necessary amount of the specified fluid PM 00030 A Oil level gauge B Upper level C Lower level 16 AT FRONT DIFFERENTIAL OIL Check the AT front differential oil amount If the amount is insufficient check that no leaks are found Then add the necessary amount of the specified AT front differential oil A Oil level gauge B Upper level C
54. ifferential oil amount 17 Coolant 23 Check the coolant amount 18 Clutch fluid 24 Check the clutch fluid amount 19 Window washer fluid 25 Check the window washer fluid amount 20 Hood latch check 26 Check that the hood is closed and latched securely 21 Keyless entry system 27 Check that the keyless entry system operates normally 22 Security system 28 Check that the security system operates normally 23 Seat 29 Check the seat surfaces for smears or dirt 30 Check the seat installation conditions and functionality 24 Seat belt 31 Check the seat belt installation conditions and functionality 25 Wheel alignment 32 Check that the wheel alignments are properly adjusted 3 PRE DELIVERY INSPECTION PRE DELIVERY INSPECTION Checks with the Engine Running Step Check point Test mode connectors 1 Test mode connectors Starting condition 2 Start the engine and check that the engine starts smoothly Exhaust system 3 Check that the exhaust noise is normal and no leaks are found Indicator light 4 Check that all the indicator lights operate normally Clock 5 Check that the clock operates normally Radio Cigarette lighter 7 Check that the cigarette lighter operates normally Lighting system 8 Check that the lighting systems operate normally Window washer 9 Che
55. iller then pour into reservoir tank up to FULL level Coolant capacity fill up to FULL level 2 0 L Non turbo AT model Approx 6 5 2 6 9 US qt 5 7 Imp qt 2 0 L Non turbo MT model Approx 6 6 2 7 0 US qt 5 8 Imp qt 2 0 L Turbo AT and MT with oil cooler model Approx 7 3 0 7 7 US qt 6 4 Imp qt 2 0 L Turbo MT without oil cooler model Approx 7 4 0 7 8 US qt 6 5 Imp qt 2 5 L AT model Approx 6 8 0 7 2 US qt 6 0 Imp qt 2 5 L MT model Approx 6 9 0 7 3 US qt 6 1 Imp qt NOTE The SUBARU Genuine Coolant containing anti freeze and anti rust agents is especially made for SUBARU engine which has an aluminum crank case Always use SUBARU Genuine Coolant since other coolant may cause corrosion 12 Securely install the radiator cap 13 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 purge the air trapped in cooling system 14 Stop the engine and wait until coolant temper ature lowers Then open the radiator cap to check coolant level and add coolant up to radiator filler neck Next add coolant into reservoir tank up to FULL level 15 After adding coolant securely install the radia tor and reservoir tank caps PM 19 COOLANT PERIODIC MAINTENANCE SERVICES 2 RELATIONSHIP OF SUBARU COOLANT CONCENTRATION AND FREEZING TEM PERATURE The concentration and safe operating temperature of the SUBARU coolant is sh
56. in the differential gear oil by removing drain plug after allowing the engine to cool for 3 to 4 hours NOTE Before starting work cool off the engine well f front differential gear oil adheres to the exhaust pipe wipe it off completely PM 00034 2 Replace the gasket with a new one and then tighten the drain plug to specified torque Tightening torque 44 N m 4 5 kgf m 32 5 ft Ib 3 Fill differential gear oil through the oil level gauge hole up to the upper point of level gauge NOTE 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 0 1 2 1 4 US qt 1 0 1 1 Imp qt PM 00035 A Oillevel gauge B Upper level C Lower level 3 REAR DIFFERENTIAL 1 Drain the oil by removing drain plug 2 Remove the filler plug for quick draining oil 3 Install the drain plug after draining oil NOTE Apply fluid packing to the drain plug threads ex cept for 2 0 L Non turbo model Fluid packing Three Bond 1105 Part No 004403010 Use a new aluminum gasket for 2 0 L Non turbo model Tightening torque Except for 2 0 L Non turbo model 49 0 N m 5 0 kgf m 36 2 ft Ib 2 0 L Non turbo model 34 N m 3 5 kgf m 25 3 ft Ib Tightening torque 4 After installing the drain plug onto rear differen tial gear case firmly fill oil up fully to the mouth of filler plug EXCE
57. ke Suspension Wheel bearing Axle boot amp joint Steering system J 2 0 d d 0 d d 3 Symbols used R Replace I Inspection I Recommended service for safe vehicle operation NOTE 1 When the vehicle is used in extremely dusty conditions the air cleaner element should be replaced more often 2 ATF filter is a maintenance free part ATF filter needs replacement when it is physically damaged or ATF leaked PM 3 SCHEDULE PERIODIC MAINTENANCE SERVICES 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 Maintenance Interval Number of months or km miles whichever occurs first Months 12 24 36 48 Remarks x 1 000 km 12 5 25 37 5 50 x 1 000 miles 7 5 15 22 5 30 Engine oil R R R R Engine oil filter R R R R For periodic maintenance of over 100 000 km 60 000 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 100 000 km 60 000 miles or 48 months Maintenan
58. m 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 A When the hill holder is released later than en gagement of 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 Tighten the adjusting nut so that hill holder is released later than engagement of clutch status in A Then make adjustment the same as in A NOTE Whenever turning the adjusting nut hold the in ner cable with pliers to prevent it from turning Replace the pressure hold valve PHV or PHV cable with a new one if they are defective and or damaged PM 00077 A Lock nut B Adjusting nut C Pressure hold valve PM 23 PERIODIC MAINTENANCE SERVICES PERIODIC MAINTENANCE SERVICES 16 ATF A INSPECTION CAUTION The level of ATF varies with fluid temperature Pay attention to the fluid temperature when checking ATF level 1 Raise the ATF temperature by driving a distance of 5 to 10 km 3 to 6 miles Otherwise idle the en gine to raise ATF temperature to 60 80 C 140 176 F on Subaru Select Monitor lt Ref to AT 18 READ CURRENT DATA O
59. ng torque 2 Remove six clips Nam 4 5 9 Oil drain plug LU 00007 Pd LU 00006 PM 6 ENGINE OIL PERIODIC MAINTENANCE SERVICES 7 Fill engine oil through the filler pipe up to center between upper level and lower level Make sure that the vehicle is placed level when checking oil level Use engine oil of proper quality and viscosity selected in accordance with the table in figure Recommended oil API classification SL or SJ or SH with the words Energy Con serving or Energy conserving II CCMC specification G4 or G5 ACEA specification A1 A2 or or New API mark displayed on the container If it is impossible to get SL or SJ or SH grade you may use SG grade Engine oil capacity Non turbo model Upper level Approx 4 0 2 4 2 US qt 3 5 Imp qt Lower level Approx 3 0 2 3 2 US qt 2 6 Imp qt Turbo model Upper level Approx 4 5 0 4 8 US qt 4 0 Imp qt Lower level Approx 3 5 0 3 7 US qt 3 1 Imp qt SAE A C 30 20 15 0 15 30 40 CF 22 4 5 32 59 86 104 10W 30 10W 40 5W 30 B PM 00088 A Visosity No and applicable temperature B Preferred The proper viscosity helps vehicle get good cold and hot starting by reducing viscous friction and thus increasing cranking speed NOTE When replenishing oil it does
60. noises are observed 28 INDICATOR LIGHT Check that all the indicator lights are off 29 CLOCK Check the clock for normal operations and enough accuracy 30 RADIO Check the radio for full functionality and normal noise level Also check the CD unit operations 31 CIGARETTE LIGHTER Check the cigarette lighter operations 32 LIGHTING SYSTEM Check the headlight operations Check the brake light operations Check the other lights for normal operations 33 WINDOW WASHER Check that the window washer system injects washer fluid to the specified area of windshield shown in the figure Front injection position A 350 mm 13 78 in B 150 mm 5 91 in C 275 mm 10 83 in D 600 mm 23 62 in WW 00107 1 Nozzle Rear injection position A 36 mm 1 42 in B 72 1 a ay 00081 1 Nozzle 34 WIPER Check the front and rear wipers for normal opera tions 10 PRE DELIVERY INSPECTION 35 POWER WINDOW OPERATION CHECK Manipulate the power window switches one by one to check that each of the power windows goes up and down with no abnormal noises 36 BRAKE TEST Check the foot brake for normal operations 37 PARKING BRAKE Check the parking brake for normal operations 38 AT SHIFT CONTROL Set the AT select lever to each gear position while checking that the demanded gear position is cor rectly attained A
61. nt overfilling the engine oil do not add oil above the F line when the engine is cold PM 7 ENGINE OIL FILTER PERIODIC MAINTENANCE SERVICES 4 Engine Oil Filter NOTE The filter element and filter case are permanently A REPLACEMENT joined therefore interior cleaning is not necessary 1 Remove six clips 8 Check the engine oil level Ref to PI 3 PDI PROCEDURE Pre delivery Inspection lt LU 00006 3 Remove the oil filter with ST ST 498547000 OIL FILTER WRENCH Non turbo model ST 18332AA000 OIL FILTER WRENCH Turbo model O A Engine oil filter PM 00141 4 Geta new oil filter and apply a thin coat of engine oil to the seal rubber 5 Install the oil filter by turning it by hand being careful not to damage the seal rubber 6 Tighten more approx 2 3 to 3 4 turn after the seal rubber contacts the cylinder block Do not tighten excessively or oil may leak 7 After installing the oil filter run the engine and make sure that no oil is leaking around seal rubber PM 8 SPARK PLUGS 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 N um N C pP f 00001 5 Set the new spark plug Recommended
62. o 17 002001 Serial number GCC countries Saudi Arabia etc JF19G93MX3J002001 The starting and ending brackets are stop marks Meaning Details Manufacturer body area JF1 Passenger car FHI made Car line S FORESTER Body type G Wagon Displacement 9 2 5L AWD Grade 3 2 5X Restraint M Manual belts dual airbag Check digit 0 9 amp X Model year 3 2003MY 4 2004MY 5 2005MY 11 Transmission type H Full time AWD 4 speed AT J Full time AWD 5 speed MT dual range 12 to 17 002001 Serial number 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 SG5AL1K Meaning Details Series S FORESTER Body type G Wagon Engine displacement Drive system Suspension system 5 2 0L AWD 9 2 5L AWD Minor change Initial Destination RHD Right hand drive LHD Left hand drive Grade 2 0X HUNTER Ver 2 0XT 2 5X Transmission fuel feed system The engine and transmission type are as follows Engine EJ201NWUAA Meaning SOHC MPI 4 speed AT SOHC MPI Full time AWD 5 speed MT Dual range DOHC Turbo Full time AWD 5 speed MT DOHC Turbo 4 speed AT
63. of check valve Blow air into the vacuum hose from its brake boost er side end Air must flow out of engine side end of hose Next blow air into the hose from engine side Air should not flow out of hose Replace both check valve and vacuum hose if the check valve is faulty Engine side of vacuum hose is indicated by marking ENG as shown A B 4 C 00046 Engine side B Brake booster side C ENG 5 Check the vacuum hose for cracks or other dam age NOTE When installing the vacuum hose on the engine and brake booster do not use soapy water or lubri cating oil on their connections 6 Check vacuum hose to make sure it is tight and secure PM 29 BRAKE FLUID PERIODIC MAINTENANCE SERVICES 19 Brake Fluid A REPLACEMENT 1 Either jack up the vehicle and place a safety stand under it or lift up the vehicle 2 Remove both front and rear wheels 3 Draw out the brake fluid from master cylinder with syringe 4 Refill the reservoir tank with recommended brake fluid Recommended brake fluid FMVSS 116 fresh DOTS3 or 4 brake fluid NOTE Avoid mixing different brands of brake fluid to prevent degrading the quality of the fluid Be careful not to allow dirt or dust to get into the reservoir tank Bleeding sequence 1 2 3 4 1 4 A 3 2 PM 00047 Front right Rear left Front left Rear right Secondary Primary
64. oil Replace more fre quently Replace more fre quently Replace more fre quently Engine oil filter Replace more fre quently Replace more fre quently Replace more fre quently Fuel line 6 months 12 500 km 7 500 miles Transmission oil Replace more fre quently Replace more fre quently Front amp rear dif ferential oil Replace more fre quently Brake line 6 months 12 500 km 7 500 miles Brake fluid 12 months 25 000 km 15 000 miles Brake pads 6 months 12 500 km 7 500 miles Brake linings and drums 6 months 12 500 km 7 500 miles Parking brake 6 months 12 500 km 7 500 miles Suspension 6 months 12 500 km 7 500 miles Axle boots amp joints 6 months 12 500 km 7 500 miles Steering system Power steering 6 months 12 500 km 7 500 miles PM 5 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 ac the engine oil Hare e A Oil drain plug LU 00007 PM 00074 5 Replace the drain plug gasket A Oillevel gauge 6 Tighten the engine oil drain plug after draining B Oil filler cap engine oil Tighteni
65. on due to looseness Fasteners must be tightened to the specified torque Do not apply paint lubricant rust retardant or oth er substances to the surface around bolts fasten ers etc Doing so will make it difficult to obtain the correct torque and result in looseness and other problems 2 STATIC ELECTRICITY DAMAGE Do not touch the ECM connectors logic boards and other such parts when there is a risk of static electricity Always use a static electricity prevention cord or touch grounded metal before conducting work 3 IGNITION OFF BATTERY When removing the battery cables always be sure to turn the ignition off to prevent electrical damage to the ECM from rush current 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 NT 2 NOTE NOTE 5 LIFTS AND JACKS When using a lift or jack ridged rack 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 Support Locations NT 00001 Pantograph jack NT 00002 NT
66. ow Item number Alternative 004301003 Recommended SUBARU CRC Grease Application point sensor Bolts etc Supplementary lubricants RM 4 Grease RECOMMENDED MATERIALS Application point Recommended RECOMMENDED MATERIALS Item number Alternative Grease MT main shaft FX 2200 clutch grease 000040901 Clutch master cylinder push rod Slicolube G 40M 004404003 Gear shift lever Select lever Clutch operating cyl inder Accelerator pedal Clutch pedal Brake pedal Hill holder Clutch bearing Clutch release lever Steering shaft bear ing SUNLIGHT2 003602010 Steering gear box Valiant grease M 2 003608001 Disc brake Niglube RX 2 K0779GA102 Drum brake Drum brake wheel cylinder Molykote No 7439 003602001 Brake pad Brake shoe Molykote AS 880N K0777YA010 Front axle AAR One luber C Front axle AC HTBJ Rear axle BJ Molylex No 2 003601001 Rear axle EBJ NTG2218 Rear axle DOJ VU 3A702 23223GA050 Water pump Door latch Door striker 8 ADHESIVES Use the adhesives shown in the table below or equivalent Slicolube G 30M 004404002 Adhesive Application point Recommended Item number Alternative Adhesive Windshield and body Essex Chemical Crop s Ure Sunstar 580 thane E Soft vinyl Cemedine 540 3M s EC 776 EC
67. own in the diagram Measuring the temperature and specific gravity of the coolant will provide this information Example If the coolant temperature is 25 C 77 F and its specific gravity is 1 054 the concentration is 35 point A the safe operating temperature is 14 C 7 F point B and the freezing temperature is 20 4 F point C 1 100 1 000 710 30 20 10 0 10 20 30 40 50 40 22 4 14 32 50 68 86 104 122 5 C F PM 00025 1 Coolant gravity 2 Safe operating temperature 3 Concentration of coolant 4 Freezing temperature 5 Coolant temperature 3 PROCEDURE TO ADJUST THE CON CENTRATION OF THE COOLANT To adjust the concentration of the coolant accord ing to temperature find the proper fluid concentra tion in the above diagram and replace the necessary amount of coolant with an undiluted so lution of SUBARU genuine coolant concentration 50 The amount of coolant that should be replaced can be determined using the diagram Example Assume that the coolant concentration must be in creased from 25 to 40 Find point A where the 25 line of coolant concentration intersects with the 40 curve of the necessary coolant concentra tion and read the scale on the vertical axis of the graph at height A The quantity of coolant to be drained is 2 1 0 2 2 US qt 1 8 Imp qt Drain 2 1 0 2 2 US qt 1 8 Imp qt of coolant from the cooling system and add 2 1 0 2
68. ox 294 N 30 kgf 66 Ib and hold it there for approx 20 seconds At this time check the pedal to see if it makes any unusual movement Visually inspect the bleeder screws and brake pipe joints to make sure that there is no fluid leakage 12 Install the wheels and drive the vehicle for a short distance between 2 to 3 km 1 to 2 miles to make sure that brakes are operating properly PM 30 DISC BRAKE PADS AND DISCS 20 Disc Brake Pads and Discs A INSPECTION 1 DISC BRAKE PAD AND DISC 1 Jack up the vehicle and support with rigid racks Then remove the wheels 2 Visually check the pad thickness through inspec tion hole of disc brake assembly Replace the pad if necessary NOTE When replacing a pad always replace the pads for both the right and left wheels at the same time Also replace the pad clips if they are twisted or worn PM 00049 A Inspection hole Pad thickness including back metal mm in Front Rear 17 0 67 14 0 55 7 5 0 295 6 5 0 256 Standard Service limit PM 00050 1 Thickness of pad 2 Back metal 3 Lining PERIODIC MAINTENANCE SERVICES 3 Check the disc rotor and correct or replace if itis damaged or worn Brake disc thickness mm in Front Rear 24 0 94 10 0 39 22 0 87 8 5 0 335 Standard Wear limit 4 Remove the caliper body Ref to BR 21 Front Disc Brake Assembly gt Ref to BR 2
69. rence between pistons and valves may occur B INSPECTION 1 SOHC MODEL 1 Remove the front timing belt cover and timing belt cover LH 2 While cranking the engine at least four rotations check the timing belt back surface for cracks or damage Replace the faulty timing belt as needed 3 Measure the timing belt width W If itis less than 27 mm 1 06 in check idlers tensioner water pump pulley and cam sprocket to determine idler alignment squareness Replace the worn timing belt PM 00016 4 Install the front timing belt cover and timing belt cover LH 2 DOHC MODEL 1 Remove the timing belt cover LH 2 While cranking the engine at least four rotations check the timing belt back surface for cracks or damage Replace the faulty timing belt as needed 3 Measure the timing belt width W If itis less than 30 mm 1 18 in check idlers tensioner water pump pulley and cam sprocket to determine idler alignment squareness Replace the worn timing belt 4 Install the timing belt cover LH PM 00097 PM 14 FUEL LINE PERIODIC MAINTENANCE SERVICES 8 Fuel Line A INSPECTION The fuel line is located mostly internally so check pipes areas near pipes and engine compartment piping for rust hose damage loose bands etc If faulty parts are found repair or replace them lt Ref to FU SOHC 65 Fuel Delivery Return and Evap oration Lines gt PM 15 FUEL FILTE
70. spark plug SOHC CHAMPION RC10YC4 Alternate NGK BKR6E 11 NGK BKR5E 11 Spark plug gap 1 0 1 1 mm 0 039 0 043 in DOHC turbo model NGK PFR6B 11 Spark plug gap 0 7 0 8 mm 0 028 0 031 in 6 Tighten the spark plug lightly with hand and then secure with a plug wrench to the specified torque Tightening torque 20 6 N m 2 10 kgf m 15 19 ft Ib NOTE Be sure to place the gasket between the cylinder head and spark plug f a torque wrench is not available tighten the spark plug until gasket contacts cylinder head then tighten further 1 4 to 1 2 turns PM 9 PERIODIC MAINTENANCE SERVICES DRIVE BELT S PERIODIC MAINTENANCE SERVICES 6 Drive Belt s A INSPECTION 1 Replace the belts if cracks fraying or wear is found 2 Check the drive belt tension and adjust it if nec essary by changing the generator installing position and or idler pulley installing position Ref to PM 10 REPLACEMENT Drive Belt s gt Belt tension A Replaced 7 9 mm 0 276 0 354 in Reused 9 0 10 0 mm 0 354 0 394 in B Replaced 7 5 8 5 mm 0 295 0 335 in Reused 9 0 10 0 mm 0 354 0 394 in 98 N 10 kg PM 00002 A Front side belt B Rear side belt C P Crankshaft pulley GEN Generator P S Power steering oil pump pulley A C Air conditioning compressor pulley Idler pulley B REPLACEMENT 1 V BELT COVER 1 Remove the V belt cover NON T
71. sually check the brake hose using a mirror where it is difficult to see for any damage BR 00095 1 Front brake hose 2 Front brake pipe BR 00096 1 Rear brake pipe 2 Brake hose 3 Clamp B CHECKING 1 SERVICE BRAKE 1 Check the free play of brake pedal with a force of less than 10 N 1 kgf 2 Ib Brake pedal free play 0 5 2 0 mm 0 02 0 08 in PM 00078 A Brake pedal free play 2 If the free play is out of specifications above ad just the brake pedal as follows 1 Be sure the engine is off No vacuum is ap plied to brake booster 2 There should be play between brake boost er clevis and pin at brake pedal installing por tion Depress brake pedal pad with a force of less than 10 N 1 kgf 2 Ib to a stroke of 0 5 to 2 0 mm 0 02 to 0 08 in 3 Depress the surface of brake pad by hand PM 28 BRAKE LINE 4 If there is no free play between clevis pin and clevis turn the brake switch adjusting nut until the clearance between stopper and screw of brake switch becomes 0 3 mm 0 012 in PM 00041 Brake switch Adjusting nut 0 3 mm 0 012 in Stopper Clevis pin Clevis Brake pedal free play Lock nut Brake booster operating rod Play at pin 3 Check the pedal stroke While the engine is idling depress the brake pedal with a 490 N 50 kgf 110 Ib load and measure the distance between brake pedal
72. sure of 157 kPa 1 6 kg cm 23 psi and check the following points Each portion of radiator for leakage Hose joints and other connections for leakage NOTE When attaching or detaching tester and when operating tester use special care not to deform ra diator filler neck NON TURBO MODEL When performing this check be sure to keep the engine stationary and fill the radiator with coolant Wipe off check points before applying pressure Use care not to spill coolant when detaching the tester from radiator 2 Check the radiator cap valve open pressure us ing radiator cap tester NOTE Rust or dirt on the cap may prevent the valve from functioning normally be sure to clean the cap be fore testing 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 maintained for this period Radiator cap valve open pressure Standard value 93 123 kPa 0 95 1 25 kg cm 14 18 psi Service limit 83 kPa 0 85 kg cm 12 psi PM 00023 00089 A Deformation B Deformation damage rust 3 Start the engine and then check it does not overheat or it is cooled excessively If it overheats or it is cooled excessively check the cooling sys tem Ref to CO SOHC 20 Water Pump gt Ref to CO SOHC
73. t B may be excessively worn PM 00058 4 If relative movement is observed in the immedi ately preceding two steps remove and inspect the ball joint If free play exceeds standard replace the ball joint lt Ref to FS 18 Front Ball Joint gt 5 Damage of dust seal Visually inspect the ball joint dust seal If it is dam aged remove the transverse link lt Ref to FS 16 Front Transverse Link gt And measure free play of ball joint lt Ref to FS 18 Front Ball Joint gt 1 When looseness exceeds standard value replace 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 wheel toe in is not at specified value ad just the toe in lt Ref to FS 7 Wheel Alignment gt PM 00059 A Dust seal 2 TRANSVERSE LINK S REAR BUSHING Check oil leaks at around liquid filled bushing If oil leaks replace the bushing PM 00060 A Rear bushing B Transverse link 3 WHEEL ARCH HEIGHT 1 Unload cargoes and set the vehicle in curb weight empty condition 2 Then check the wheel arch height of front and rear suspensions to ensure that they are within specified values Ref to FS 7 Wheel Alignment 3 When the wheel arch height is out of standard visually inspect the following components and re place deformed parts
74. t every 12 months after lapse of 60 months Take rust prevention measure as required PM 35 WHEEL BEARING PERIODIC MAINTENANCE SERVICES 23 Wheel Bearing A INSPECTION 1 FRONT WHEEL BEARING NOTE Inspect the condition of front wheel bearing grease 1 Jack up the front of vehicle 2 While holding the front wheel by hand swing it in and out to check bearing free play 3 Loosen the wheel nuts and remove front wheel 4 If bearing free play exists in step 2 above at tach a dial gauge to the hub and measure axial dis placement in axial direction Service limit Straight ahead position within 0 05 mm 0 0020 in 5 Remove the bolts and self locking nuts and ex tract transverse link from front crossmember 6 Remove the AAR of front drive shaft from trans mission lt Ref to DS 17 Front Axle gt 7 While supporting the front drive shaft horizontal ly with one hand turn the hub with the other to check for noise or binding If the hub is noisy or binds disassemble the front axle and check condition of oil seals bearing etc 27 PM 00061 A B C Inner oil seal Snapring Bearing Hausing G 2 REAR WHEEL BEARING 1 Jack up the rear of vehicle 2 While holding the rear wheel by hand swing it in and out to check bearing free play 3 Loosen the wheel nuts and remove rear wheel 4 If the bearing free play exists in step 2 above
75. t no wa ter enters the passenger compartment Before performing the water leakage test re move anything that may obstruct the operation or which must be kept dry PI 11 PRE DELIVERY INSPECTION PRE DELIVERY INSPECTION Close all windows completely and then close all doors tightly Close the hood before starting the test Connect a hose to a tap and spray water on the vehicle The rate of water discharge must be ap prox 20 25 0 5 3 6 6 US gal 4 4 5 5 Imp gal per minute When spraying water on areas adjacent to the floor and wheel house increase the pressure When di recting water on areas other than the floor portion and wheel house decrease the pressure But the force of water must be made strong occasionally by pressing the end of the hose NOTE Be sure to keep the hose at least 10 cm 3 9 in from the vehicle Check the following areas Front window and body framework mating por tion Door mating portions Glass mating portions Rear quarter window mating portions Rear window and body framework mating portion Around roof drips If any dampness in the compartment is discovered after the water has been applied carefully check all areas that may have possibly contributed to the leak 46 APPEARANCE CHECK 2 Check the vehicle body paints plated faces glass and lenses for any dirt or damage 12 PERIODIC MAINTENANCE SERVICES PM SEO ec IO PO PO
76. ted below If defor mation is observed replace the damaged parts e Suspension components Shock absorber link F link R link UPR arm R sub frame 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 standard 6 OIL LEAKAGE OF STRUT Visually inspect the front strut and rear strut for oil leakage as instructed Replace front strut and rear strut if oil leaks excessively 7 TIGHTNESS OF BOLTS AND NUTS Check the bolts and nuts shown in the figure for looseness Retighten the bolts and nuts to speci fied torque If the self lock nuts and bolts are re moved replace them with new ones Front suspension Ref to FS 2 General Descrip tion Rear suspension Ref to RS 2 General Descrip tion 8 DAMAGE TO SUSPENSION PARTS 1 Check the following parts and the fastening por tion of the vehicle body for deformation or exces sive rusting which impairs the suspension necessary replace the damaged parts with new ones If minor rust formation pitting etc are noted remove the rust and apply remedial anti corrosion measures Front suspension Transverse link Crossmember Strut Rear suspension Crossmember ateral links Trailing link Strut n the district where salt is sprayed to melt snow on a road in winter check suspension parts for damage caused by rus
77. to provide a complete vehicle to the customer Because of the above reasons all dealerships must always carry out the PDIs before delivering vehicle In addition all franchised shops and PDI centers must check the status of every vehicle received to identify who is responsible for any possible defects 2 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 If the protective coating has been removed visually check the body paints for small areas of damage or stains 2 Visually check the glass and light lenses for any damage and cracks or excessive gaps to the body sheet metal 3 Visually check the plated parts for any damage 2 Tire check 4 Check the tires for damage abnormal conditions and dents on the wheels 5 Check the tire air pressure 3 Fuse installation 6 If the vehicle is about to be delivered to the customer attach a room lamp fuse 4 Connection of air conditioner harness 7 If the vehicle is about to be delivered to the customer connect the air con ditioner harness 5 Check the doors for lock unlock and open close operations 8 Using the key check if the door can be locked and unlocked normally
78. uid level on the HOT side 1 Place the vehicle with engine OFF on a flat and level surface 2 Check the fluid level using the scale on the out side of reservoir tank A If the level is below MIN B add fluid to bring it up to MAX C PM 00070 NOTE If the fluid level is at MAX level or above drain fluid to keep the level in specified range of indicator by using a syringe or the like Recommended fluid Dexron Ill Fluid capacity 0 7 0 0 7 US qt 0 6 Imp qt 6 POWER STEERING FLUID FOR LEAKS Inspect the underside of oil pump and gearbox for power steering system hoses piping and their couplings for fluid leaks If fluid leaks are found correct them by retightening their fitting bolts or nuts and or replacing their parts NOTE Wipe the leakage fluid off after correcting fluid leaks or a wrong diagnosis is taken later Also pay attention to clearances between hoses or pipings and other parts when inspecting fluid leaks PM 40 STEERING SYSTEM POWER STEERING 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 PM 00071 8 POWER STEERING PIPES FOR DAM AGE Check the power steering pipes for corrosion and damage Replace the pipes with a new one if necessary 9
79. ving on a level surface 3 Wheel runout Steering wheel should not show any sign of runout 4 Return factor Steering wheel should return 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 it for any play and yawing torque at the point of the crossing direction Also inspect for any dam age to sealing or worn serrations If the joint is loose retighten the mounting bolts to the specified torque Tightening torque 24 N m 2 4 kgf m 17 4 ft Ib PM 00066 3 GEARBOX 1 With wheels placed on a level surface turn the steering wheel 90 in both the right and left direc tions While the wheel is being rotated reach under the vehicle and check for looseness in gearbox Tightening torque 59 N m 6 0 kgf m 43 4 ft Ib PM 00067 A Boot B Gear box mounting bolt 2 Check the boot for damage cracks or deteriora tion 3 With the vehicle on a level surface quickly turn the steering wheel to the right and left While the steering wheel is being rotated check the gear backlash If any unusual noise is noticed ad just the gear backlash in the following manner 1 Tighten the adjusting screw to 7 4 N m 0 75 kgf m 5 4 ft Ib and then loosen Repeat this op eration twice PM 39 STEERING SYSTEM POWER STE

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