steering SUBARU FORESTER 2004 Service Owner's Manual

EI-42
EXTERIOR/INTERIOR TRIM
Instrument Panel Assembly
6) Loosen the four instrument panel installation bolts.
7) Remove the driver’s and passenger’s airbag mod-
ule. Module.> Airbag Module.>
8) Loosen the steering beam installation bolts.
9) Loosen the brake pedal installation bolts. to BR-50, REMOVAL, Brake Pedal.>
10) Remove two clips from the edge of instrument
panel assembly.
11) Remove the instrument panel assembly.
CAUTION:
Do not disconnect the connector by pulling har-
ness.
NOTE:
 If necessary, make matching marks for easy re-
assembly.
 When storing the removed instrument panel, place it
standing up on the floor.B: INSTALLATION
Install in the reverse order of removal.
CAUTION:
 Be careful not to snag the harness.
 Make sure to connect the harness connector.
NOTE:
When setting the instrument panel into position, push
the hook into grommet (A) on the body panel.
EI-00066
EI-00068
EI-00069
(A)
(A)(A)

CC-9
CRUISE CONTROL SYSTEM
Cruise Control Command Switch
5. Cruise Control Command
Switch
A: REMOVAL
WARNING:
Before servicing, be sure to read the notes in
the AB section for proper handling of the driv-
er’s airbag module. General Description.>
1) Set the front wheels in straight ahead position.
2) Turn the ignition switch to OFF.
3) Disconnect the ground cable from battery and
wait for at least 20 seconds before starting work.
4) Using the TORX
® BIT T30 (Tamper resistant type),
loosen the two TORX® bolts which secure driver’s air-
bag module.
5) Disconnect the airbag module connector on
back of airbag module.
6) Remove the horn switch from steering wheel as
shown.7) Disconnect the horn and cruise control com-
mand switch connector, then remove the cruise
control command switch.
B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
Measure the cruise control command switch resis-
tance.
If NG, replace the cruise control command switch.
(1)
TORX® BIT T30
CC-00018
(1)
CC-00019
Switch Position Terminal No. Standard
CANCELON 1 (+) and 2 (−) Less than 1 Ω
ON 1 (+) and 3 (−) Less than 1 Ω
SET/COASTOFF 1 and 2 More than 1 MΩ
ON 1 and 2 Less than 1 Ω
RESUME/
ACCELOFF 1 and 3 More than 1 MΩ
ON 1 and 3 Less than 1 Ω
CC-00020
CC-00038
1 2 3

CC(H4SO)-19
CRUISE CONTROL SYSTEM (DIAGNOSTIC)
Diagnostic Procedure with Symptom
E: CHECK CRUISE CONTROL COMMAND SWITCH
TROUBLE SYMPTOM:
Cruise control cannot be set. (Cancelled immediately.)
WIRING DIAGRAM:
CC-00040
B94F45B236S1F144
12345678910
11 12 13 14 15 16 17 18 19 20
412365
4
321
BATTERY
CRUISE CONTROL MODULECRUISE CONTROL
COMMAND SWITCH
STEERING
ROLL CONNECTORHORN HORN RELAY HORN SWITCH
RESUME/
ACCEL
SWITCHCANCEL
SWITCHSET/
COAST
SWITCH M/B No.6
B94
F37
B62F45
S1
321
910
B236
13
3 2
11
3245123
8910411 12 13 14 15 16567
F144
F37
RHD
RHD
LHD
LHD
RHD :
:LHD
: LHD MODEL
: RHD MODEL
LHD
RHDRHD LHD
RHD :
:LHD

FUJI HEAVY INDUSTRIES LTD. G8080GE6
2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
CHASSIS 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.FRONT SUSPENSION FS
REAR SUSPENSION RS
WHEEL AND TIRE SYSTEM WT
DIFFERENTIAL DI
TRANSFER CASE TC
DRIVE SHAFT SYSTEM DS
ABS ABS
ABS (DIAGNOSTIC) ABS
BRAKE BR
PARKING BRAKE PB
POWER ASSISTED SYSTEM
(POWER STEERING)PS

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. 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. 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. 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. 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 — — — — — —