engine SUBARU FORESTER 2004 Service Manual PDF

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.

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

ID-2
IDENTIFICATION
Identification
1. Identification
A: IDENTIFICATION
1. IDENTIFICATION NUMBER AND LABEL LOCATIONS
The VIN (Vehicle Identification Numbers) is used to classify the vehicle.
Positioning of the plate label for identification
ID-00015
Vehicle identification
number
Model number plate Emission control labelVacuum hose
piping label
ID plate (Europe model)
ADR compliance plate
(Australia model)Tire inflation pressure label
(Driver side) (Australia model)
Tire pressure label
(Driver side) (Except Australia model)
Saudi Arabia plate
(Saudi Arabia model)
Built date plate
(Australia model)
ID-00011Engine serial number
ENGINE
ID-00012
4ATTransmission serial number
ID-00013
Transmission serial number5MT

ID-3
IDENTIFICATION
Identification
ID-00016
VA-type
T-typeLabel
location
Stamp location
ID-00017
41JF1
SG
5L
SG 5 A L 1KK
43
EJ 201NWUAA
T
Y755
XF
3A
A G
00200
EC1
0
23
0
applied modeloption code
trim codeVIN
engine type
transmission typeColor code
FUJI HEAVY INDUSTRIES LTD.
Model number plate
AJ

ID-4
IDENTIFICATION
Identification
2. MEANING OF V.I.N.
The meaning of the VIN is as follows:
 Europe, Australia and General (Except GCC)
]JF1SG5LK44G002001[
The starting and ending brackets ( ][ ) are stop marks.
 GCC countries (Saudi Arabia, etc.)
]JF1SG93MX4J002001[
The starting and ending brackets ( ][ ) are stop marks.
Digits Code Meaning Details
1 to 3 JF1 Manufacturer body area JF1: Passengercar, FHI made
JF2: MPV, FHI made
4 S Car line S: FORESTER
5 G Body type G: Wagon
6 5 Displacement 5: 2.0L AWD
9: 2.5L AWD
7 L Steering position K: RHD (Right-hand drive)
L: LHD (Left-hand drive)
8 K Engine & transmission R: SOHC MPI 4-speed AT
K: SOHC MPI Full-time AWD 5-speed MT Dual range
D: DOHC Turbo Full-time AWD 5-speed MT
T: DOHC Turbo 4-speed D-AT
9 4 Drive type 3: Full-time AWD Single range
4: Full-time AWD Dual range
5: AWD AT
10 4 Model year 3: 2003MY
4: 2004MY
5: 2005MY
11 G Factory location G: FHI (Gunma)
12 to 17 002001 Serial number —
Digits Code Meaning Details
1 to 3 JF1 Manufacturer body area JF1: Passenger car, FHI made
4 S Car line S: FORESTER
5 G Body type G: Wagon
6 9 Displacement 9: 2.5L AWD
7 3 Grade 3: 2.5X
8 M Restraint M: Manual belts, dual airbag
9 X Check digit 0 — 9 & X
10 4 Model year 3: 2003MY
4: 2004MY
5: 2005MY
11 J Transmission type H: Full-time AWD 4-speed AT
J: Full-time AWD 5-speed MT dual range
12 to 17 002001 Serial number —

ID-5
IDENTIFICATION
Identification
3. MODEL NUMBER PLATE
The model number plate indicates: the applied model, the option code, the trim code, the engine type, the
transmission type, and the exterior color code. This information is helpful when placing orders for parts.
SG5BL1K
The engine and transmission type are as follows:
 Engine
EJ201NWTAA
Digits Code Meaning Details
1 S Series S: FORESTER
2 G Body type G: Wagon
3 5 Engine displacement
Drive system
Suspension system5: 2.0 L AWD
9: 2.5 L AWD
4 B Minor change B: 2004MY
5 L Destination K: RHD (Right-hand drive)
L: LHD (Left-hand drive)
6 1 Grade 1: 2.0X
3: HUNTER Ver
5: 2.0XT
7: 2.5X
B: 2.5XT
7 K Transmission, fuel feed
systemR: SOHC MPI 4-speed AT
K: SOHC MPI Full-time AWD 5-speed MT Dual range
D: DOHC Turbo Full-time AWD 5-speed MT
P: DOHC Turbo 4-speed AT
T: DOHC Turbo 4-speed D-AT
Digits Code Meaning Details
1 and 2 EJ Engine type EJ: 4 cylinders
3 and 4 20 Displacement 20: 2.0L
25: 2.5L
5 1 Fuel feed system 1: D-MPI SOHC-A
5: L-MPI Turbo
6 N Emission control M: Unleaded non-STEP-III
N: Unleaded STEP-III
7 W Transmission W: MT
Y: MT (Response to CO
2 emission control)
X: AT
V: AT (Response to CO
2 emission control)
8 T Minor change T: 2004MY
9 to 10 AA Detailed specifications Used when ordering parts. See the parts catalog for details.

RM-2
RECOMMENDED MATERIAL
Recommended Materials
1. Recommended Materials
A: RECOMMENDED MATERIALS
1. GENERAL
To insure the best performance, always use the
specified oil, gasoline, adhesive, sealant, etc. or a
substitute of equivalent quality.
2. FUEL
Always use a gasoline of the same or higher octane
value than specified in the owner’s manual. Ignor-
ing the specifications below will result in damage or
poor operation of the engine and fuel injection sys-
tem. Use the specified gasoline to correct perfor-
mance.
 Unleaded gasoline
Use unleaded gasoline and not leaded gasoline on
vehicles with catalytic converter installed to reduce
air pollution. Using leaded gasoline will damage the
catalytic converter.
*For Australia model.
 Leaded gasoline
On vehicles without catalytic converter, use leaded
gasoline with an octane value of 90 RON or higher.
Model Petrol RON
Non-turbo UnleadedMore than 95 RON
More than 90 RON
*
Turbo Unleaded More than 98 RON

RM-3
RECOMMENDED MATERIAL
Recommended Materials
3. LUBRICANTS
Use either the lubricants in the table below or equivalent lubricants. See the table below to choose the correct
SAE viscosity.
LubricantRecommended
Alternative
API Spec. CCMC Spec. ACEA Spec.
Engine oil SL or SJ Grade “Energy conserving” G4 or G5 A1, A2 or A3 SH or SG
Manual transmission oil GL-5 — — —
Front differential oil GL-5 — — —
Rear differential oil GL-5 — — —
SAE
0W-20
NE
E
RG
G
YCONSERVIN
APISERVICESL
RM-00006
RM-00001
SAE
5W-30
NE
E
RG
G
YCONSERVIN
APISERVICESL
AMERICANPETROLEUMINSTITUTE
FOR
GASOLINE
ENGINES
CERTIFEID
RM-00002

RM-4
RECOMMENDED MATERIAL
Recommended Materials
SAE viscosity No. and applicable temperature
Engine oil
Non-turbo model
Tu r b o m o d e l
RM-00032 (˚F) –22 –4 14 50 68 86 104 (˚C) –30 –20 –10 0 10 20 30 40
5W-30
32
10W-30 or 10W-40
0W-20 Recommend
RM-00033 (˚F)–22–4 14 50 68 86 104 (˚C)–30–20 –100
10 20 30 40
5W-30 Recommend
32
10W-30 or 10W-40

RM-5
RECOMMENDED MATERIAL
Recommended Materials
4. FLUID
Use the fluids specified in the table below. Do not mix two different kinds or makes of fluid.
5. COOLANT
Use genuine coolant to protect the engine.
6. REFRIGERANT
Standard air conditioners on Subaru vehicles use HFC134a refrigerant. Do not mix it with other refrigerants.
Also, do not use any air compressor oil except for ZXL200PG.
7. GREASE
Use the grease and supplementary lubricants shown in the table below.
SAE viscosity No. and applicable temperature SAE J300
Manual transmission oil, front differential oil and rear differential oil
Fluid Recommended Alternative Remarks
Automatic transmission fluid DEXRON III — —
Power steering fluid DEXRON III — —
Brake fluid FMVSS No. 116 DOT3 FMVSS No. 116 DOT4 —
Clutch fluid FMVSS No. 116 DOT3 FMVSS No. 116 DOT4 —
Coolant Recommended Item number Alternative
Coolant SUBARU coolant 000016218 None
Water for dilution Distilled water — Tap water (Soft water)
Air conditioner Recommended Item number Alternative
Refrigerant HFC134a — None
Compressor oil ZXL200PG — None
Grease Application point Recommended Item number Alternative
Supplementary lubricants  Oxygen sensor
 Bolts, etc.SUBARU CRC 004301003 —
RM-00004 (F)–22 –4 14 50 68 86 104 (C)–30 –20 –100
10 20 30 40
85W
75W-9080W90
32