SUBARU FORESTER 2004 Service Repair Manual

SPC-2
SPECIFICATION
Forester
1. Forester
A: DIMENSIONS
★: With sunroof
B: ENGINE
Model 2.0 L Non-turbo 2.0 L Turbo 2.5 L Non-turbo 2.5 L Turbo
Overall length mm (in) 4,450 (175.2)
Overall width mm (in) 1,735 (68.3)
Overall height (at C.W.) mm (in) 1,590 (62.6) 1,585 (62.4) 1,590 (62.6)
CompartmentLength mm (in) 1,795 (70.7)
Width mm (in) 1,455 (57.3)
Height mm (in)
1,245 (49.0), 1,210 (47.6)
★
Wheelbase mm (in) 2,525 (99.4)
Tread Front mm (in) 1,495 (58.9)
Rear mm (in) 1,485 (58.5)
Minimum road clearance mm (in) 190 (7.5) 195 (7.7) 200 (7.9)
Model 2.0 L Non-turbo 2.0 L Turbo 2.5 L Non-turbo 2.5 L Turbo
Engine type Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine
Valve arrangement Overhead camshaft type
Bore×Stroke mm (in) 92×75 (3.62×2.95) 99.5×79 (3.92×3.11)
Displacement
cm
3 (cu in)1,994 (121.67) 2,457 (149.94)
Compression ratio 10.0±0.2 8.0±0.2 10.0±0.2 8.2±0.2
Firing order 1 — 3 — 2 — 4
Idle speed at Park or Neu-
tral positionrpm 650±100 700±100 650±100 700±100
Maximum output kW (PS)/rpm 92 (125)/5,600 130 (177)/5,600 115 (156)/5,600 155 (211)/5,600
Maximum torque N⋅m (kgf-m, ft-lb)/rpm184 (18.8, 41.4)/
3,600245 (25.0, 55.1)/
3,200223 (22.7, 50.1)/
3,600320 (32.6, 71.8)/
3,600

SPC-3
SPECIFICATION
Forester
C: ELECTRICAL
★: For Australia model
D: TRANSMISSION
5MT: 5 forward speeds with synchromesh and 1-reverse
4AT: Electronically controlled fully-automatic, 4-forward speeds and 1-reverse
DSPD: Dry Single Plate Diaphragm
TCC: Torque Converter Clutch
★: For Europe model
E: STEERING
Model 2.0 L Non-turbo 2.0 L Turbo 2.5 L Non-turbo 2.5 L Turbo
Ignition timing at idling speed BTDC/rpm 10°±10°/650 12°±10°/700MT: 10°±10°/650
AT : 1 5°±10°/65017°±10°/700
Spark plug Type and manufacturerCHAMPION:
RC10YC4
NGK: PFR6GCHAMPION:
RC10YC4
NGK: ILFR6B
Alternate
NGK: BKR5E-11Alternate
NGK: BKR5E-11
Generator12 V — 90 A
Battery Type and capacity (5HR)MT: 12 V — 48 AH (55D23L)
AT: 12 V — 52 AH (65D23L)12 V — 27 AH
(34B19L)
12 V — 48 AH
(55D23L)
★
MT: 12 V — 48
AH (55D23L)
AT: 12 V — 52
AH (65D23L)
Model 2.0 L Non-turbo 2.0 L Turbo 2.5 L Non-turbo 2.5 L Turbo
Transmission type 5MT 4AT 5MT 4AT 5MT 4AT 5MT 4AT
Clutch type DSPD TCC DSPD TCC DSPD TCC DSPD TCC
Gear ratio1st 3.454 2.785 3.454 2.785 3.454 2.785 3.454 2.785
2nd 2.062 1.545 1.947 1.545 2.062 1.545 1.947 1.545
3rd 1.448 1.000 1.366 1.000 1.448 1.000 1.366 1.000
4th 1.088 0.694 0.972 0.694 1.088 0.694 0.972 0.694
5th 0.871 — 0.738 — 0.780 — 0.738 —
Reverse 3.333 2.272 3.333 2.272 3.333 2.272 3.333 2.272
Dual range 1.447 — — — 1.196 — — —
Reduction
gear (Front)1st reduc-
tionType of gear — Helical — Helical — Helical — Helical
Gear ratio — 1.000 — 1.000 — 1.000 — 1.000
Final reduc-
tionType of gear Hypoid
Gear ratio 4.111 4.444 4.444 4.111 4.111 4.444 4.111 4.444
Reduction
gear (Rear)Transfer
reductionType of gear Helical — Helical — Helical — Helical —
Gear ratio 1.000 —1.081
★,
1.000— 1.000 — 1.000 —
Final reduc-
tionType of gear Hypoid
Gear ratio 4.111 4.4444.111
★,
4.4444.111 4.111 4.444 4.111 4.444
Ty p eRack and Pinion, Integral
Turns, lock to lock3.0
Minimum turning circle m (ft)Curb to curb 10.6 (34.8)
Wall to wall 11.4 (37.4)

SPC-4
SPECIFICATION
Forester
F: SUSPENSION
G: BRAKE
★: RHD model
H: TIRE
I: CAPACITY
★1: With oil pump★2: MT model with oil cooler Included★3: Model with ATF warmer Front Macpherson strut type, Independent, Coil spring
Rear Dual-link type, Independent, Coil spring
Model 2.0 L Non-turbo, 2.5 L Non-turbo
2.0 L Turbo, 2.5 L Non-turbo
★, 2.5 L Non-turbo
Service brake system Dual circuit hydraulic with vacuum suspended power unit
Front Ventilated disc brake
Rear Drum brake Disc brake
Parking brake Mechanical on rear brakes
Rim size 15×6J 16×6 1/2J
Tire size 205/70 R15 95H 215/60 R16 95V, P215/60 R16 94H
Type Steel belted radial, Tubeless
Model 2.0 L Non-turbo 2.0 L Turbo 2.5 L Non-turbo 2.5 L Turbo
Tr a n s m i s s i o n 5 M T 4 AT 5 M T 4 AT 5 M T 4 AT 5 M T 4 AT
Fuel tank2 (US gal, Imp gal) 60 (15.9, 13.2)
Engine oil
(When
replacing)2 (US qt, Imp qt) Approx. 4.0 (4.2, 3.5)
Tr a n s m i s -
sion gear oil2 (US qt, Imp qt)4.0
(4.2, 3.5)—3.5
(3.7, 3.1),
3.9
(4.1, 3.4)
★1
—4.0
(4.2, 3.5)—3.5
(3.7, 3.1)—
AT F2 (US qt, Imp qt) —8.4
(8.9, 7.4)—9.3
(9.8, 8.2)—9.3
(9.8, 8.2)—9.3
(9.8, 8.2)
Front differ-
ential gear
oil2 (US qt, Imp qt) —1.2
(1.3, 1.1)—1.2
(1.3, 1.1)—1.2
(1.3, 1.1)—1.2
(1.3, 1.1)
Rear differ-
ential gear
oil2 (US qt, Imp qt) 0.8 (0.8, 0.6)
Pow er
steering
fluid2 (US qt, Imp qt) 0.7 (0.7, 0.6)
Engine
coolant2 (US qt, Imp qt)6.6
(7.0, 5.8)6.5
(6.9, 5.7),
6.9
(7.3, 6.1)
★3
7.4
(7.8, 6.5)7.3
(7.7, 6.4)
★2
6.9
(7.3, 6.1)6.8
(7.2, 6.0)7.4
(7.8, 6.5)7.3
(7.7, 6.4)

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

SPC-6
SPECIFICATION
Forester
★: For the option codes, refer to ID section. <Ref. to ID-5, MODEL NUMBER PLATE, Identification.> Option code
★EC K4
Model2.0 L Turbo
Grade2.0 XT
Transmission 5MT 4AT 5MT 4AT
Curb weight (C.W.)Front kgf (lb) 810 (1,785) 830 (1,830) 815 (1,795) 835 (1,840)
Rear kgf (lb) 620 (1,365) 620 (1,365) 630 (1,390) 630 (1,390)
Total kgf (lb) 1,430 (3,150) 1,450 (3,195) 1,445 (3,185) 1,465 (3,230)
Maximum permissible axle
weight (M.P.A.W.)Front kgf (lb) 1,010 (2,225) 1,010 (2,225) 1,010 (2,225) 1,010 (2,225)
Rear kgf (lb) 1,035 (2,280) 1,035 (2,280) 1,035 (2,280) 1,035 (2,280)
Maximum permissible
weight (M.P.W.)Total kgf (lb)1,950 (4,295) 1,950 (4,295) 1,950 (4,295) 1,950 (4,295)
OptionSport package base — — — —
Aluminum wheel — — — —
Front fog light❍❍❍❍
Cruise control❍❍—❍
High-grade audio — — — —
Sport steering — — — —
Leather package base❍❍❍❍
Leather seat, Leather door trim — — —❍
Navigation system — — — —
Air conditioner❍❍❍❍
Side airbag❍❍❍❍
Sunroof — —❍❍
Self-leveling function Rr❍❍——
Cold area pack A — — — —
Cold area pack B❍❍——
Cold area pack C — — — —
Cold area pack D — — — —
Heated mirrors❍❍——
Security system ————

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

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

SPC-9
SPECIFICATION
Forester
3. OPTION
Option Front kgf (lb) Rear kgf (lb) Total kgf (lb)
Sport package base 0.1 (0.2) 0.4 (0.9) 0.5 (1.1)
Aluminum wheel15 IN−6.5 (−14.3)−6.5 (−14.3)−13.0 (−28.6)
16 IN−7.3 (−16.1)−7.3 (−16.1)−14.6 (−32.2)
Front fog light 0.7 (1.5)−0.1 (−0.2) 0.6 (1.3)
Cruise control 1.5 (3.3) 0.2 (0.5) 1.7 (3.8)
High-grade audio 0.8 (1.8) 0.4 (0.9) 1.2 (2.7)
Sport steering 0.2 (0.5) 0.1 (0.2) 0.3 (0.7)
Leather package base 0.0 (0.0) 0.0 (0.0) 0.0 (0.0)
Leather seat, Leather door trim 1.2 (2.6) 3.0 (6.6) 4.2 (9.2)
Navigation system−1.7 (−3.7)−0.8 (−1.8)−2.5 (−5.5)
Air conditioner 16.9 (37.3)−1.4 (−3.1) 15.5 (34.2)
Side airbag 2.0 (4.4) 2.4 (5.3) 4.4 (9.7)
Sunroof 3.5 (7.7) 13.2 (29.1) 16.7 (36.8)
Self-leveling function RrNon-turbo 0.1 (0.2) 3.0 (6.6) 3.1 (6.8)
Turbo 0.1 (0.2) 3.1 (6.8) 3.2 (7.0)
Cold area pack A 0.1 (0.2) 0.2 (0.5) 0.3 (0.7)
Cold area pack B 0.1 (0.2) 0.3 (0.7) 0.4 (0.9)
Cold area pack C 0.1 (0.2) 0.3 (0.7) 0.4 (0.9)
Cold area pack D 0.0 (0.0) 0.0 (0.0) 0.0 (0.0)
Heated mirrors 0.0 (0.0) 0.0 (0.0) 0.0 (0.0)
Security system 0.3 (0.7) 0.3 (0.7) 0.6 (1.4)

SPC-10
SPECIFICATION
Forester

PRECAUTION
PC
Page
1. Precaution ...................................................................................................2