SUBARU FORESTER 2004 Service Repair Manual

PC-2
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. RADIATOR FAN
The radiator 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 the
steps below and then wait at least 20 seconds to
discharge 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 all government
regulations concerning disposal of refuse.
7. AIRBAG MODULE
Adhere to the following when handling 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 recommended or alternative adhe-
sive when attaching glass to prevent it from coming
loose and falling, resulting in accidents and injury.

NOTE
NT
Page
1. Note.............................................................................................................2

NT-2
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 dislocation 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 control unit, connectors, logic
boards, and other such parts when there is a risk of
static electricity. Always use a static electricity pre-
vention cord or touch grounded metal before con-
ducting work.
3. BATTERY
When removing the battery cables, always be sure
to turn the ignition switch off to prevent electrical
damage to the control unit 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.
5. PROTECTING VEHICLE UNDER MAIN-
TENANCE
Make sure to attach the fender cover, seat covers,
etc. before work.
6. ENSURING SAFETY DURING WORK
When working in a group of two or more, perform
the work with calling each other to ensure mutual
safety.

NT-3
NOTE
Note
7. LIFTS AND JACKS
When using a lift or jack 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.
Be sure to set the wheel stoppers when jacking-up only the front or rear of the vehicle.
• Support Locations
 Pantograph jack
NT-00001
NT-00002

NT-4
NOTE
Note
 Lift
 Rigid rack
NT-00003
NT-00004

NT-5
NOTE
Note
 Jack-up point
(A) Front (B) Rear
NT-00005
(A)
(B)

NT-6
NOTE
Note
8. 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.
(A) Front (C) Hook for tie-down (D) Rear
(B) Hook for towing and tie-down
NT-00006
(B)
(C)(B)
(A)
(D)
(C)

NT-7
NOTE
Note
 Chain direction at tie-down condition
 Chain pulling range at tie-down condition Vehicle sinking volume at tie-down condition
Measure the distance L between tire highest point
to arch highest point before tie-down and after tie-
down. Difference of measurement value (drop
height) shall be within 50 mm (1.97 in). Make sure
to fix the vehicle securely.
9. TOWING
Avoid towing vehicles except when the vehicle cannot be driven. For models with AWD or AT use a loader
instead of towing. When towing other vehicles, to prevent excessive weight from damaging the hook or ve-
hicle:
 Do not tow other vehicles with a front hook for tie-down.
 Make sure the vehicle towing is heavier that the vehicle being towed.
(A) Chain pulling range at tie-down condition
NT-00007
NT-00008
: (A)
NT-00082
L
L

NT-8
NOTE
Note
10.FRONT HOOD STAY INSTALLATION
 At the check and general maintenance
 When wider hood opening is necessary
Set stay into the hole of hood inner as shown in the figure below.
NOTE:
Before setting the front hood in this position, remove the windshield washer hose attaching clip from the front
hood.
11.TRAINING
For information about training, contact a dealer or
agent.
12.GENERAL SCAN TOOL
Using general scan tools will greatly improve effi-
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-00009
NT-00010

IDENTIFICATION
ID
Page
1. Identification ................................................................................................2