front brake SUBARU FORESTER 2004 Service Owner's Guide

EN(H4DOTC)-42
ENGINE (DIAGNOSTIC)
Inspection Mode
1. PREPARATION FOR THE INSPECTION
MODE
1) Check battery voltage is more than 12 V and fuel
remains half [20 to 402 (5.3 to 10.6 US gal, 4.4 to
8.8 Imp gal)].
2) Lift-up the vehicle using a garage jack and place
it on rigid racks or drive the vehicle onto free rollers.
WARNING:
 Before raising the vehicle, ensure parking
brakes are applied.
 Do not use a pantograph jack in place of a rig-
id rack.
 Secure a rope or wire to the front or rear tow-
ing hooks to prevent the lateral runout of front
wheels.
 Do not abruptly depress/release clutch pedal
or accelerator pedal during works even when
the engine is operating at low speeds since this
may cause vehicle to jump off free rollers.
 In order to prevent the vehicle from slipping
due to vibration, do not place any wooden
blocks or similar items between the rigid racks
and the vehicle.
 Since the rear wheels will also rotate, do not
place anything near them.Also, make sure that
nobody goes in front of the vehicle.
2. SUBARU SELECT MONITOR
1) After clearing the memory, check for any remain-
ing unresolved trouble data. <Ref. to
EN(H4DOTC)-47, Clear Memory Mode.>
2) Idle the engine.
3) Prepare the Subaru Select Monitor kit. <Ref. to
EN(H4DOTC)-8, PREPARATION TOOL, General
Description.>
4) Connect the diagnosis cable to Subaru Select
Monitor.
5) Insert the cartridge to Subaru Select Monitor.
<Ref. to EN(H4DOTC)-8, PREPARATION TOOL,
General Description.>
6) Connect the test mode connector (A) located at
the lower portion of instrument panel (on the driv-
er’s side).
(A) Rigid rack
(B) Free rollers
EN-00041
(A)
(B)
(A) Test mode connector
EN-00038
EN-00039
EN-00333
(A)

EN(H4DOTC)-43
ENGINE (DIAGNOSTIC)
Inspection Mode
7) Connect the Subaru Select Monitor to data link
connector.
(1) Connect the Subaru Select Monitor to data
link connector located in the lower portion of the
instrument panel (on the driver’s side).
(2) Connect the diagnosis cable to data link
connector.
CAUTION:
Do not connect the scan tools except for Suba-
ru Select Monitor and OBD-II general scan tool.
8) Turn the ignition switch to ON (engine OFF) and
Subaru Select Monitor switch to ON.
9) On the «Main Menu» display screen, select the
{Each System Check} and press the [YES] key.
10) On the «System Selection Menu» display
screen, select the {Engine} and press the [YES]
key.
11) Press the [YES] key after the information of en-
gine type was displayed.
12) On the «Engine Diagnosis» screen, select the
{D Check} and press the [YES] key.
13) When the “Perform D Check?” is shown on the
screen, press the [YES] key.14) Perform subsequent procedures as instructed
on the display screen.
 If trouble still remains in the memory, the corre-
sponding DTC appears on the display screen.
NOTE:
 For detailed operation procedure, refer to the
“SUBARU SELECT MONITOR OPERATION MAN-
UAL”.
 For details concerning DTCs, refer to the List of
Diagnostic Trouble Code (DTC).
<Ref. to EN(H4DOTC)-74, List of Diagnostic Trou-
ble Code (DTC).>
 Release the parking brake.
 The speed difference between front and rear
wheels may light either the ABS warning light, but
this indicates no malfunctions.When engine control
diagnosis is finished, perform the ABS memory
clearance procedure of self-diagnosis function.
3. OBD-II GENERAL SCAN TOOL
1) After performing the diagnostics and clearing the
memory, check for any remaining unresolved trou-
ble data. <Ref. to EN(H4DOTC)-47, Clear Memory
Mode.>
2) Idle the engine.
3) Connect the test mode connector (A) located at
the lower portion of instrument panel (on the driv-
er’s side).
4) Connect the OBD-II general scan tool to its data
link connector in the lower portion of the instrument
panel (on the driver’s side).
CAUTION:
Do not connect the scan tools except for Suba-
ru Select Monitor and OBD-II general scan tool.
(A) Power switch
EN-00334
EN-00040
(A)
EN-00333
(A)
EN-00334

EN(H4DOTC)-44
ENGINE (DIAGNOSTIC)
Inspection Mode
5) Start the engine.
NOTE:
 Ensure the select lever is placed in the “P” range
before starting.(AT model)
 Depress the clutch pedal when starting the en-
gine.(MT model)
6) Using the selector lever or shift lever, turn the “P”
range switch and the “N” range switch to ON.
7) Depress the brake pedal to turn the brake switch
ON.(AT model)
8) Keep the engine speed in the 2,500 — 3,000
rpm range for 40 seconds.
9) Place the select lever or shift lever in the “D”
range (AT model) or “1st” gear (MT model) and
drive the vehicle at 5 to 10 km/h (3 to 6 MPH).
NOTE:
 On AWD vehicles, release the parking brake.
 The speed difference between front and rear
wheels may light either the ABS warning light, but
this indicates no malfunctions.When engine control
diagnosis is finished, perform the ABS memory
clearance procedure of self-diagnosis function.
10) Using the OBD-II general scan tool, check
DTC(s) and record the result(s).
NOTE:
 For detailed operation procedures, refer to the
OBD-II General Scan Tool Operation Manual.
 For details concerning DTCs, refer to the List of
Diagnostic Trouble Code (DTC).
<Ref. to EN(H4DOTC)-74, List of Diagnostic Trou-
ble Code (DTC).>

EN(H4DOTC 2.5)-37
ENGINE (DIAGNOSTIC)
Inspection Mode
1. PREPARATION FOR THE INSPECTION
MODE
1) Check battery voltage is more than 12 V and fuel
remains half [20 — 402 (5.3 — 10.6 US gal, 4.4 —
8.8 Imp gal)].
2) Lift-up the vehicle using a garage jack and place
it on rigid racks or drive the vehicle onto free rollers.
WARNING:
 Before raising the vehicle, ensure parking
brakes are applied.
 Do not use a pantograph jack in place of a rig-
id rack.
 Secure a rope or wire to the front or rear tow-
ing hooks to prevent the lateral runout of front
wheels.
 Do not abruptly depress/release clutch pedal
or accelerator pedal during works even when
the engine is operating at low speeds since this
may cause vehicle to jump off free rollers.
 In order to prevent the vehicle from slipping
due to vibration, do not place any wooden
blocks or similar items between the rigid racks
and the vehicle.
 Since the rear wheels will also rotate, do not
place anything near them. Also, make sure that
nobody goes in front of the vehicle.
2. SUBARU SELECT MONITOR
1) Idle the engine.
2) Prepare the Subaru Select Monitor kit. <Ref. to
EN(H4DOTC 2.5)-7, PREPARATION TOOL, Gen-
eral Description.>
3) Connect the diagnosis cable to Subaru Select
Monitor.
Insert the cartridge to Subaru Select Monitor. <Ref.
to EN(H4DOTC 2.5)-7, PREPARATION TOOL,
General Description.>
4) Connect the test mode connector (A) located at
the lower portion of instrument panel (on the driv-
er’s side).
(A) Rigid rack
(B) Free rollers
EN-00041
(A)
(B)
(A) Test Mode Connector
EN-00038
EN-00039
EN-00333
(A)

EN(H4DOTC 2.5)-38
ENGINE (DIAGNOSTIC)
Inspection Mode
5) Connect the Subaru Select Monitor to data link
connector located in the lower portion of the instru-
ment panel (on the driver’s side).
CAUTION:
Do not connect the scan tools except for Suba-
ru Select Monitor and OBD-II general scan tool.
6) Turn the ignition switch to ON (engine OFF) and
Subaru Select Monitor switch to ON.
7) On the «Main Menu» display screen, select the
{Each System Check} and press the [YES] key.
8) On the «System Selection Menu» display screen,
select the {Engine} and press the [YES] key.
9) Press the [YES] key after the information of en-
gine type was displayed.
10) On the «Engine Diagnosis» screen, select the
{D Check} and press the [YES] key.
11) When the “Perform D Check?” is shown on the
screen, press the [YES] key.
12) Perform subsequent procedures as instructed
on the display screen.
 If trouble still remains in the memory, the corre-
sponding DTC appears on the display screen.
NOTE:
 For detailed operation procedure, refer to the “SUB-
ARU SELECT MONITOR OPERATION MANUAL”.
 For details concerning DTCs, refer to the List of
Diagnostic Trouble Code (DTC).
<Ref. to EN(H4DOTC 2.5)-65, List of Diagnostic
Trouble Code (DTC).>
 Release the parking brake. The speed difference between front and rear
wheels may light either the ABS warning light, but this
indicates no malfunctions. When engine control diag-
nosis is finished, perform the ABS memory clearance
procedure of self-diagnosis function. <Ref. to ABS-
23, Clear Memory Mode.>
3. OBD-II GENERAL SCAN TOOL
1) Idle the engine.
2) Connect the test mode connector (A) located at
the lower portion of instrument panel (on the driv-
er’s side).
3) Connect the OBD-II general scan tool to its data
link connector in the lower portion of the instrument
panel (on the driver’s side).
CAUTION:
Do not connect the scan tools except for Suba-
ru Select Monitor and OBD-II general scan tool.
4) Start the engine.
NOTE:
 Ensure the select lever is placed in the “P” range
before starting. (AT model)
 Depress the clutch pedal when starting the en-
gine. (MT model)
5) Using the select lever or shift lever, turn the “P”
position switch and the “N” position switch to ON.
6) Depress the brake pedal to turn the brake switch
ON. (AT model)
7) Keep the engine speed in the 2,500 — 3,000
rpm range for 40 seconds.
8) Place the select lever or shift lever in the “D”
range (AT model) or “1st” gear (MT model) and
drive the vehicle at 5 to 10 km/h (3 to 6 MPH).
(A) Power switch
EN-02353
EN-00040
(A)
EN-00333
(A)
EN-02353

EN(H4DOTC 2.5)-39
ENGINE (DIAGNOSTIC)
Inspection Mode
NOTE:
 On AWD vehicles, release the parking brake.
 The speed difference between front and rear
wheels may light either the ABS warning light, but
this indicates no malfunctions. When engine con-
trol diagnosis is finished, perform the ABS memory
clearance procedure of self-diagnosis function.
<Ref. to ABS-23, Clear Memory Mode.>
9) Using the OBD-II general scan tool, check
DTC(s) and record the result(s).
NOTE:
 For detailed operation procedures, refer to the
OBD-II General Scan Tool Operation Manual.
 For details concerning DTCs, refer to the List of
Diagnostic Trouble Code (DTC).
<Ref. to EN(H4DOTC 2.5)-65, List of Diagnostic
Trouble Code (DTC).>

4AT-2
AUTOMATIC TRANSMISSION
General Description
1. General Description
A: SPECIFICATION
1. TORQUE CONVERTER CLUTCH
2. OIL PUMP
3. TRANSMISSION CONTROL ELEMENT
4. TRANSMISSION GEAR RATIO5. PLANETARY GEAR AND PLATE
Model2.0 L
Non-
turbo2.5 L
Non-
turbo2.0 L
Tu r b o2.5 L
Tu r b o
Ty p eSymmetric, 3 element, single stage, 2 phase
torque converter
Stall torque
ratio2.0 —
2.21.9 —
2.11.85 —
2.152.05 —
2.35
Nominal
diameter246 mm (9.69 in)
Stall speed
(at sea level)2,000 —
2,500
rpm2,100 —
2,600
rpm2,600 —
3,300
rpm2,700 —
3,200
rpm
One-way
clutchSprague type one-way clutch
Type Pracoid constant-displacement pump
Driving method Driven by engine
Number of teethInner rotor 9
Outer rotor 10
Ty p e4-forward, 1-reverse, double-row plan-
etary gears
Multi-plate clutch 3 sets
Multi-plate brake 2 sets
One-way clutch
(sprague type)1 sets
Gear ratio
1st 2.785
2nd 1.545
3rd 1.000
4th 0.694
Rev 2.272
Model2.0 L Non-
turbo2.5 L Non-
turboTu r b o
Tooth num-
ber of front
sun gear33
Front pinion
number of
teeth21
Front inter-
nal gear
number of
teeth75
Tooth num-
ber of rear
sun gear42
Rear pinion
number of
teeth17
Tooth num-
ber of rear
internal gear75
Drive &
driven plate
number of
high clutch45
Drive &
driven plate
number of
low clutch467
Drive &
driven plate
number of
reverse
clutch2
Drive &
driven plate
number of 2-
4 brake34
Drive &
driven plate
number of
low &
reverse
brake467

4AT-9
AUTOMATIC TRANSMISSION
General Description
4. CONTROL VALVE AND HARNESS ROUTING
A Non-turbo model B Turbo model
(1) Stay (11) Accumulator piston (23) 2-4 brake duty solenoid
(2) Transmission harness ASSY (12) Accumulator spring (24) Line pressure duty solenoid
(3) O-ring (13) Side plate (25) Low clutch timing solenoid
(4) O-ring (14) Upper separate plate (26) Lock-up duty solenoid
(5) Torque converter turbine speed
sensor(15) Middle control valve body (27) Oil strainer
(16) Separate plate (28) Control valve ASSY
(6) O-ring (17) Fluid filter (29) Rear vehicle speed sensor (turbo
model)
(7) Front vehicle speed sensor (18) Fluid filter
(8) O-ring (19) Lower control valve body
(9) Rear vehicle speed sensor (non-
turbo model)(20) Shift solenoid 2Tightening torque: N
⋅m (kgf-m, ft-lb)
(21) Shift solenoid 1T1: 7 (0.7, 5.1)
(10) Upper control valve body (22) 2-4 brake timing solenoidT2: 8 (0.8, 5.8)
AT-01864
T1T2
T2
T2
T2
T2
T2
T2T2
T2
T1
(1)(2)
(3)(4)
(5)
(6)
(7)
(10)
(11)
(12)
(14)
(13)(15)
(16)
(17)
A(24)(19)
(18)
(20)
(21)
(22)
(23) (26) (25)
(27)
(28)
B
T1
(8)
(9)
T1
(8)
(29)

4AT-11
AUTOMATIC TRANSMISSION
General Description
6. PLANETARY GEAR AND 2-4 BRAKE
(1) Thrust needle bearing (10) Washer (19) Snap ring
(2) Front sun gear (11) Thrust needle bearing (20) 2-4 spring retainer
(3) Thrust needle bearing (12) Rear internal gear (21) 2-4 brake piston
(4) Snap ring (13) Washer (22) D-ring
(5) Front planetary carrier (14) Snap ring (23) D-ring
(6) Thrust needle bearing (15) Retaining plate (24) 2-4 brake piston retainer
(7) Rear sun gear (16) Drive plate (25) 2-4 brake seal
(8) Thrust needle bearing (17) Driven plate (26) Leaf spring
(9) Rear planetary carrier (18) Pressure rear plate
AT-00007
(1)(2)(3)(4)(5)
(6)
(14)
(15)
(16)(16)(16)(18)(17)
(20) (26)(17)
(7)
(8)
(9)(10)(11)
(12)(13)
(19)
(21)
(22)
(23)(25)
(24)

4AT-33
AUTOMATIC TRANSMISSION
Stall Test
5. Stall Test
A: INSPECTION
NOTE:
The stall test is of extreme importance in diagnos-
ing the condition of the automatic transmission and
the engine. It should be conducted to measure the
engine stall speeds in “R” and “2” ranges (when
HOLD switch is ON).
Purposes of the stall test:
 To check the operation of the automatic trans-
mission clutch.
 To check the operation of the torque converter
clutch.
 To check engine performance.
1) Check that the throttle valve opens fully.
2) Check that the engine oil level is correct.
3) Check that the coolant level is correct.
4) Check that the ATF level is correct.
5) Check that the differential gear oil level is cor-
rect.
6) Increase ATF temperature to 70 — 80°C (158 —
176°F) by idling the engine for approximately 30
minutes (with select lever set to “N” or “P”).
7) Place the wheel chocks at the front and rear of
all wheels and engage the parking brake.
8) Shift the manual linkage to ensure it operates
properly, then shift the select lever to the “2” range
and turn the HOLD switch to ON.
9) While forcibly depressing the foot brake pedal,
gradually depress the accelerator pedal until the
engine operates at full throttle.
10) When the engine speed is stabilized, record
that speed quickly and release the accelerator ped-
al.
11) Shift the select lever to “N” range, and cool
down the engine by idling it for more than one
minute.12) If the stall speed in “2” range (with HOLD switch
ON) is higher than specifications, low clutch slip-
ping and “2-4 brake slipping” may occur. To identify
it, conduct the same test as above in “R” range.
13) Perform the stall tests with the select lever in
the “D” range.
NOTE:
 Do not continue the stall test for more than five
seconds at a time (from closed throttle, fully open
throttle to stall speed reading). Failure to follow this
instruction causes the engine oil and ATF to deteri-
orate and the clutch and brake to be adversely af-
fected.
 Be sure to cool down the engine for at least one
minute after each stall test with the select lever set
in the “P” or “N” range and with the idle speed lower
than 1,200 rpm.
 If the stall speed is higher than the specified
range, attempt to finish the stall test in as short a
time as possible, in order to prevent the automatic
transmission from sustaining damage.
Stall speed (at sea level):
2.0 L NON-TURBO MODEL
2,000 — 2,500 rpm
2.0 L TURBO MODEL
2,600 — 3,300 rpm
2.5 L NON-TURBO MODEL
2,100 — 2,600 rpm
2.5 L TURBO MODEL
2,700 — 3,200 rpm
(A) Brake pedal
(B) Accelerator pedal
(A) (B)
P
R
N
D
3
2
1
AT-00449