check transmission fluid SUBARU FORESTER 2004 Service Repair Manual

PI-3
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 (1) Check the tires for damage, abnormal conditions, and dents on the
wheels.
(2) Check the tire air pressure.
3. Fuse installation If the vehicle is about to be delivered to the customer, attach a room light
fuse.
4. Connection of air conditioner harness If the vehicle is about to be delivered to the customer, connect the air condi-
tioner harness.
5. Check the doors for lock/unlock and open/close
operations.(1) Using the key, check if the door can be locked and unlocked normally.
(2) Open and close all doors to see that there are no abnormal conditions.
6. Operation check of double lock Check that the double lock operates normally.
7. Operation check of the child safety lock system. Check the child safety lock system operates normally.
8. Check the rear gate for lock/unlock and open/
close operations.(1) Check if the rear gate can be unlocked normally from the emergency
door.
(2) Open and close the rear gate to see that there are no abnormal condi-
tions.
(3) 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
leverOperate 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 Operate the hood lock release lever to check that the hood opens normally.
12. Battery Check the battery for any abnormal conditions such as rust and trace of bat-
tery fluid leaks.
13. Brake fluid Check the fluid amount.
14. Engine oil Check the oil amount.
15. Transmission fluid (1) Check the fluid amount.
(2) For AT, check the front differential oil.
16. AT front differential oil Check the AT front differential oil amount.
17. Coolant Check the coolant amount.
18. Clutch fluid Check the clutch fluid amount.
19. Window washer fluid Check the window washer fluid amount.
20. Hood latch check Check that the hood is closed and latched securely.
21. Keyless entry system Check that the keyless entry system operates normally.
22. Security system Check that the security system operates normally.
23. Seat (1) Check the seat surfaces for smears or dirt.
(2) Check the seat installation conditions and functionality.
24. Seat belt Check the seat belt installation conditions and functionality.
25. Wheel alignment Check that the wheel alignments are properly adjusted.

PI-9
PRE-DELIVERY INSPECTION
Pre-delivery Inspection
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.
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.
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.
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.
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.
(A) Oil level gauge
(B) Upper level
(C) Lower level
(A) Oil level gauge
(B) Upper level
(C) Lower level
PM-00030
(B)
(C) (A)
PM-00035
(B)
(C)(A)
(A) Reservoir tank
(B) MIN level
(C) MAX level
PM-00076
(A)
(B) (C)

PM-26
PERIODIC MAINTENANCE SERVICE
ATF
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 70 — 80°C (158
— 176°F) on Subaru Select Monitor. <Ref. to
4AT(H4SO)-18, READ CURRENT DATA, OPERA-
TION, Subaru Select Monitor.>
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.
4) Make sure that ATF level is above the center of
upper and lower level.
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 70 — 80°C (158 — 176°F) by running the vehicle
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 by removing drain plug.
NOTE:
Before starting work, cool off ATF well.
2) Replace the gasket with a new one, and then
tighten the specified torque.
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
3) Fill ATF up to the middle of the “COLD” side on
level gauge by using the gauge hole.
Recommended fluid:
Dexron III type automatic transmission fluid
Fluid capacity:
Fill the same amount drained from ATF drain
plug hole.
(A) Level gauge
(B) Check position when “HOT”
(C) Upper level
(D) Lower level
(E) Check position when “COLD”
PI-00105
COLD
LFHOT LF
(A)
(C)
(D)
(C)
(D)
(E)
(B)(A) Front differential drain plug
(B) ATF drain plug
PM-00032
(B)
(A)

CO(H4SO)-31
COOLING
Radiator
4) Attach the power steering hose to radiator.
5) Connect the radiator inlet hose.
6) Install the reservoir tank.
Tightening torque:
4.9 N
⋅m (0.50 kgf-m, 3.6 ft-lb)
7) Connect the overflow hose.
8) Lift-up the vehicle.
9) Connect the ATF cooler hoses. (AT model)10) Connect the radiator outlet hose.
11) Connect the connectors to radiator main fan
motor (A) and sub fan motor (B).
12) Install the under cover.
13) Lower the vehicle.
14) Connect the battery ground cable to battery.
15) Fill engine coolant. <Ref. to CO(H4SO)-19,
FILLING OF ENGINE COOLANT, REPLACE-
MENT, Engine Coolant.>
16) Check the ATF level. <Ref. to 4AT-30, IN-
SPECTION, Automatic Transmission Fluid.>
CO-00037
CO-00035
CO-00015
CO-00034
CO-00076
CO-00013
(A)(B)
FU-00009

CO(H4SO)-33
COOLING
Radiator
12) Connect the oil cooler hose. (MT model with oil
cooler)
13) Connect the radiator outlet hose.
14) Connect the connectors to radiator main fan
motor (A) and sub fan motor (B).
15) Install the under cover.
16) Lower the vehicle.
17) Connect the battery ground cable to battery.
18) Fill engine coolant. <Ref. to CO(H4SO)-19,
FILLING OF ENGINE COOLANT, REPLACE-
MENT, Engine Coolant.>19) Check the ATF level. <Ref. to 4AT-30, IN-
SPECTION, Automatic Transmission Fluid.>
C: INSPECTION
1) Remove the radiator cap, top off radiator, and
then attach the tester (A) to radiator in place of cap.
 NON-TURBO MODEL
 TURBO MODEL
2) Apply a pressure of 157 kPa (1.6 kg/cm
2, 23 psi)
to the radiator to check if:
(1) Engine coolant leaks at/around radiator.
(2) Engine coolant leaks at/around hoses or
connections.
CAUTION:
 Inspection must be carried out at the side of
coolant filler tank, not at the side of radiator.
 Engine should be off.
 Wipe engine coolant from check points in ad-
vance.
 Be careful to prevent engine coolant from
spurting out when removing the tester.
 Be careful also not to deform the filler neck of
radiator when installing or removing tester.
CO-00034
CO-00030
CO-00013
(A)(B)
FU-00009
CO-00042
(A)
CO-00043
(A)

EN(H4SO)-3
ENGINE (DIAGNOSTIC)
Basic Diagnostics Procedure
2. AUTOMATIC TRANSMISSION
When the DTC about automatic transmission is
shown on display, carry out the following basic
check. After that, carry out the replacement or re-
pair work.
1) ATF level check <Ref. to 4AT-30, Automatic
Transmission Fluid.>
2) Differential gear oil level check <Ref. to 4AT-31,
Differential Gear Oil.>
3) ATF leak check <Ref. to 4AT-30, Automatic
Transmission Fluid.>
4) Differential gear oil level check <Ref. to 4AT-31,
Differential Gear Oil.>
5) Stall Test <Ref. to 4AT-33, Stall Test.>
6) Line Pressure Test <Ref. to 4AT-36, Line Pres-
sure Test.>
7) Transfer Clutch Pressure Test <Ref. to 4AT-38,
Transfer Clutch Pressure Test.>
8) Time Lag Test <Ref. to 4AT-35, Time Lag Test.>
9) Road Test <Ref. to 4AT-32, Road Test.>
10) Shift characteristics <Ref. to 4AT-38, Transfer
Clutch Pressure Test.>

EN(H4SO)-74
ENGINE (DIAGNOSTIC)
List of Diagnostic Trouble Code (DTC)
P0420 Catalyst System Efficiency Below
Threshold (Bank 1)<Ref. to EN(H4SO)-164, DTC P0420 CATALYST SYSTEM EFFICIENCY
BELOW THRESHOLD (BANK 1), Diagnostic Procedure with Diagnostic
Trouble Code (DTC).>
P0458 Evaporative Emission Control Sys-
tem Purge Control Valve Circuit Low<Ref. to EN(H4SO)-166, DTC P0458 EVAPORATIVE EMISSION CON-
TROL SYSTEM PURGE CONTROL VALVE CIRCUIT LOW, Diagnostic Pro-
cedure with Diagnostic Trouble Code (DTC).>
P0459 Evaporative Emission Control Sys-
tem Purge Control Valve Circuit High<Ref. to EN(H4SO)-169, DTC P0459 EVAPORATIVE EMISSION CON-
TROL SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH, Diagnostic
Procedure with Diagnostic Trouble Code (DTC).>
P0461 Fuel Level Sensor Circuit Range/Per-
formance<Ref. to EN(H4SO)-171, DTC P0461 FUEL LEVEL SENSOR CIRCUIT
RANGE/PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0462 Fuel Level Sensor Circuit Low Input <Ref. to EN(H4SO)-173, DTC P0462 FUEL LEVEL SENSOR CIRCUIT LOW
INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0463 Fuel Level Sensor Circuit High Input <Ref. to EN(H4SO)-176, DTC P0463 FUEL LEVEL SENSOR CIRCUIT
HIGH INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0464 Fuel Level Sensor Circuit Intermittent <Ref. to EN(H4SO)-179, DTC P0464 FUEL LEVEL SENSOR CIRCUIT
INTERMITTENT, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0483 Cooling Fan Rationality Check <Ref. to EN(H4SO)-181, DTC P0483 COOLING FAN RATIONALITY
CHECK, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0502 Vehicle Speed Sensor Circuit Low
Input<Ref. to EN(H4SO)-184, DTC P0502 VEHICLE SPEED SENSOR CIRCUIT
LOW INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0503 Vehicle Speed Sensor Intermittent/
Erratic/High<Ref. to EN(H4SO)-185, DTC P0503 VEHICLE SPEED SENSOR CIRCUIT
HIGH INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0506 Idle Control System RPM Lower
Than Expected<Ref. to EN(H4SO)-187, DTC P0506 IDLE CONTROL SYSTEM RPM
LOWER THAN EXPECTED, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0507 Idle Control System RPM Higher
Than Expected<Ref. to EN(H4SO)-189, DTC P0507 IDLE CONTROL SYSTEM RPM
HIGHER THAN EXPECTED, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0512 Starter Request Circuit <Ref. to EN(H4SO)-191, DTC P0512 STARTER REQUEST CIRCUIT, Diag-
nostic Procedure with Diagnostic Trouble Code (DTC).>
P0513 Incorrect Immobilizer Key <Ref. to IM-20, DTC P0513 INCORRECT IMMOBILIZER KEY, Diagnostics
Procedure with Diagnostic Trouble Code (DTC).>
P0519 Idle Control System Malfunction
(Fail-Safe)<Ref. to EN(H4SO)-194, DTC P0519 IDLE CONTROL SYSTEM MALFUNC-
TION (FAIL-SAFE), Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0565 Cruise Control On Signal <Ref. to EN(H4SO)-196, DTC P0565 CRUISE CONTROL ON SIGNAL,
Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0604 Internal Control Module Random
Access Memory (RAM) Error<Ref. to EN(H4SO)-198, DTC P0604 INTERNAL CONTROL MODULE
READ ACCESS MEMORY (RAM) ERROR, Diagnostic Procedure with Diag-
nostic Trouble Code (DTC).>
P0691 Cooling Fan 1 Control Circuit Low <Ref. to EN(H4SO)-200, DTC P0691 COOLING FAN 1 CONTROL CIRCUIT
LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0692 Cooling Fan 1 Control Circuit High <Ref. to EN(H4SO)-203, DTC P0692 COOLING FAN 1 CONTROL CIRCUIT
HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0703 Torque Converter/Brake Switch “B”
Circuit<Ref. to EN(H4SO)-206, DTC P0703 TORQUE CONVERTER/BRAKE
SWITCH “B” CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0705 Transmission Range Sensor Circuit
(PRNDL Input)<Ref. to 4AT(H4SO)-95, CHECK INHIBITOR SWITCH, Diagnostic Proce-
dure without Diagnostic Trouble Code (DTC).>
P0710 Transmission Fluid Temperature
Sensor Circuit<Ref. to 4AT(H4SO)-38, DTC 27 ATF TEMPERATURE SENSOR, Diagnos-
tic Procedure with Diagnostic Trouble Code (DTC).>
P0716 Torque converter turbine speed sen-
sor<Ref. to 4AT(H4SO)-49, DTC 36 TORQUE CONVERTER TURBINE SPEED
SENSOR, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> DTC Item NOTE

EN(H4DOTC)-3
ENGINE (DIAGNOSTIC)
Basic Diagnostics Procedure
2. AUTOMATIC TRANSMISSION
When the DTC about automatic transmission is
shown on display, carry out the following basic
check.After that, carry out the replacement or re-
pair work.
1) ATF level check <Ref. to 4AT-30, Automatic
Transmission Fluid.>
2) Differential gear oil level check <Ref. to 4AT-31,
Differential Gear Oil.>
3) ATF leak check <Ref. to 4AT-30, Automatic
Transmission Fluid.>
4) Differential gear oil leak check <Ref. to 4AT-31,
Differential Gear Oil.>
5) Stall Test <Ref. to 4AT-33, Stall Test.>
6) Line Pressure Test <Ref. to 4AT-36, Line Pres-
sure Test.>
7) Transfer Clutch Pressure Test <Ref. to 4AT-38,
Transfer Clutch Pressure Test.>
8) Time Lag Test <Ref. to 4AT-35, Time Lag Test.>
9) Road Test <Ref. to 4AT-32, Road Test.>
10) Shift characteristics <Ref. to 4AT-38, Transfer
Clutch Pressure Test.>

4AT-30
AUTOMATIC TRANSMISSION
Automatic Transmission Fluid
2. Automatic Transmission Flu-
id
A: INSPECTION
NOTE:
The level of ATF varies with fluid temperature. Pay
attention to the ATF 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 70 — 80°C (158
— 176°F) on Subaru Select Monitor. <Ref. to
4AT(H4SO)-18, READ CURRENT DATA, OPERA-
TION, Subaru Select Monitor.>
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 engine idling for one or two minutes.
4) Make sure that ATF level is above the center of
upper level and lower level at HOT side.
If the ATF level is below the lower level, check for
leaks in the transmission. If there are leaks, it is
necessary to repair or replace gasket, oil seals,
plugs or other parts.
5) If the ATF level is below the center between up-
per level and lower level, add the recommended
ATF until the fluid level is found above the center
between upper level and lower level marks.
CAUTION:
 Use care not to exceed the upper level.
 Remember that the addition of ATF to the up-
per limit mark when the transmission is cold
will overfilling of ATF, causing a transmission
failure.
6) Check ATF level after raising ATF temperature
to 70 — 80°C (158 — 176°F) by running the vehicle
or by idling the engine again.
B: REPLACEMENT
1) Lift-up the vehicle.2) Drain the ATF completely.
CAUTION:
Directly after the engine has been running, the
ATF is hot. Be careful not to burn yourself.
3) Replace the gasket with new one, and then tight-
en the drain plug (ATF).
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
4) Lower the vehicle.
5) Pour ATF from the ATF charge pipe.
Recommended fluid:
DEXRON III type automatic transmission flu-
id
Capacity:
Fill the same amount of ATF drained from
drain plug hole.
CAPACITY WHEN TRANSMISSION IS OVER-
HAULED:
2.0 L NON-TURBO MODEL
8.4 — 8.72 (8.9 — 9.2 US qt, 7.4 — 7.7 Imp
qt)
EXCEPT 2.0 L NON-TURBO MODEL
9.3 — 9.62 (9.8 — 10.1 US qt, 8.2 — 8.4 Imp
qt)
6) Check the level and leaks of ATF.
<Ref. to 4AT-30, INSPECTION, Automatic Trans-
mission Fluid.>
(A) ATF level gauge
(B) Upper level
(C) Lower level
AT-00674
COLD
LFHOT LF
(C)
(C)
(B)
(B)
(A)(A) Oil pan
(B) Drain plug (ATF)
(C) Differential gear oil drain plug
AT-00016
(A) (B)
(C)

4AT-35
AUTOMATIC TRANSMISSION
Time Lag Test
6. Time Lag Test
A: INSPECTION
NOTE:
If the select lever is shifted while the engine is
idling, there will be a certain time elapse or lag be-
fore the shock can be felt. This is used for checking
the condition of the low clutch, reverse clutch, low &
reverse brake and one-way clutch.
 Perform the test at normal operation fluid tem-
perature 70 — 80°C (158 — 176°F).
 Be sure to allow a one minute interval between
tests.
 Perform measurement for three times and take
the average value.
1) Fully apply the parking brake.
2) Start the engine.
Check the idling speed (A/C OFF).
3) Shift the select lever from “N” to “D” range.
Using a stop watch, measure the time it takes from
shifting the lever until the shock is felt.
Time lag: Less than 1.2 seconds
If “N” → “D” time lag is longer than specified:
 Line pressure too low
 Low clutch worn
 One-way clutch not operating properly
 D-ring worn
4) In the same manner, measure the time lag for
“N” → “R”.
Time lag: Less than 1.5 seconds
If “N” → “R” time lag is longer than specified:
 Line pressure too low
 Reverse clutch worn
 Low & reverse brake worn
 D-ring worn