SUBARU FORESTER 2004 Service Repair Manual

PI-8
PRE-DELIVERY INSPECTION
Pre-delivery Inspection
11.OPERATION CHECK OF HOOD LOCK
RELEASE SYSTEM
Operate the hood release knob and check that the
hood is unlocked normally.
Operate the lever (A) and check that the hood is
opened normally. Then support the hood with hood
stay.
12.BATTERY
Check the battery terminals to make sure that no
rust or corrosions due to fluid leaks are found.
Check that the battery caps are securely tightened.
13.BRAKE FLUID
Check the brake fluid amount. If the amount is in-
sufficient, carry out a brake line test to identify
brake fluid leaks and check the brake operation. Af-
ter that, refill the brake fluid tank with the specified
type of fluid.
14.ENGINE OIL
Check the engine oil amount. If the amount is insuf-
ficient, check that no leaks are found. Then, add
the necessary amount of the specified engine oil.
PI-00071
PI-00082
(A)
(A) Cap
(B) Upper level
(C) Lower level
(A) Engine oil level gauge
(B) Engine oil filler cap
(C) Notch mark
(D) Upper level
(E) Lower level
(F) Approx. 12 (1.1 US qt, 0.9 Imp qt)
PI-00012
(A)
(B)
(C)
PM-00181
(A)(B)
(D)
(E) (F)(C)

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)

PI-10
PRE-DELIVERY INSPECTION
Pre-delivery Inspection
21.KEYLESS ENTRY SYSTEM
Check the keyless entry system operations as fol-
lows:
 Fully open all the door windows.
 Remove the key from the ignition switch and
close all the doors including rear gate.
 Press the “LOCK” button on the keyless transmit-
ter once and check if all the doors are locked, and
the hazard light flashes once.
 Press the “UNLOCK” button on the keyless
transmitter once and check if the all doors are un-
locked, and the hazard light flashes twice. Close all doors and rear gate, press the “LOCK”
button of the keyless transmitter. Press the “UN-
LOCK” button of the keyless transmitter and wait
for 30 seconds. Check that all doors and the rear
gate are automatically locked again.
22.SEAT
Check that each seat provides full functionality in
sliding and reclining. Check all available functions
of the rear seat.
23.SEAT BELT
Pull out the seat belt and then release it. Check that
the belt webbing retracts smoothly.
24.WHEEL ALIGNMENT
Check the wheel alignments. Alignment.>
25.TEST MODE CONNECTORS
Turn the ignition switch to ON and check that the
malfunction indicator light starts blinking. If the light
blinks, return the ignition key to LOCK and discon-
nect the test mode connector. Then, turn the igni-
tion key to ON again. If the malfunction indicator
light blinks at that time in spite of the disconnected
test mode connector, carry out an engine diagno-
sis.
26.STARTING CONDITION
Start the engine and check that the engine starts
smoothly. If any battery voltage problems are
found, recharge or replace the battery. If any nois-
es are observed, immediately stop the engine and
check and repair the necessary components.
27.EXHAUST SYSTEM
Listen to the exhaust noise to see if no unusual
noises are heard.
28.INDICATOR LIGHT
Check that all the indicator lights are off.
PI-00108
PI-00109
PI-00110
PI-00111
(A) Test mode connector (Green)
PI-00076
(A)

PI-11
PRE-DELIVERY INSPECTION
Pre-delivery Inspection
29.CLOCK
Check the clock for normal operations and enough
accuracy.
30.RADIO
Check the radio for full functionality and normal
noise level. Also check the CD unit operations.
31.FRONT ACCESSORY POWER SUPPLY
SOCKET
Check the front accessory power supply socket op-
erations.
32.LIGHTING SYSTEM
 Check the headlight operations.
 Check the brake light operations.
 Check the other lights for normal operations.
33.WINDOW WASHER
Check that the window washer system injects
washer fluid to the specified area of windshield
shown in the figure.
Front injection position:
A: 350 mm (13.78 in)
B: 150 mm (5.91 in)
C: 275 mm (10.83 in)
D: 600 mm (23.62 in)Rear injection position:
A: 35 mm (1.38 in)
B: 72
°
34.WIPER
Check the front and rear wipers for normal opera-
tions.
35.POWER WINDOW OPERATION CHECK
Manipulate the power window switches one by one
to check that each of the power windows goes up
and down with no noises.
36.BRAKE TEST
Check the foot brake for normal operations.
37.PARKING BRAKE
Check the parking brake for normal operations.
38.AT SHIFT CONTROL
1) Turn the ignition switch to ON.
2) Check that the select lever can not be moved
from “P” range when brake pedal is not depressed.
3) Check that the select lever can be moved from
“P” range when brake pedal is depressed.
4) Select the select lever to except “P” range.
5) Check that the ignition key can not be removed
from ignition switch when ignition switch is turned
to OFF.
WW-00107
(A) (A)
(B) (B)
(C)
(D)
(1) Nozzle
PI-00081
(1)
A
B

PI-12
PRE-DELIVERY INSPECTION
Pre-delivery Inspection
6) Set the AT select lever to each gear position
while checking that the demanded gear position is
correctly attained.
39.HEATER & VENTILATION
Operate the heater and ventilation system to check
for normal airflow outlet control, air inlet control, air-
flow capacity, and heating performance.
40.AIR CONDITIONER
Operate the air conditioner. Check that the A/C
compressor operates normally and enough cooling
is provided.
41.ATF LEVEL
Check that the ATF level is normal. If insufficient,
check that no leaks are found. Then add the neces-
sary amount of the specified ATF.
42.POWER STEERING FLUID LEVEL
Check that the power steering fluid level is normal.
If insufficient, check that no leaks are found. Then
add the necessary amount of the specified power
steering fluid.
43.FLUID LEAK CHECK
Check the entire areas of the vehicle for any trace
of coolant/oil/fluid leaks.
44.WATER LEAK TEST
Spray the vehicle with water and check that no wa-
ter enters the passenger compartment.
 Before performing the water leakage test, re-
move anything that may obstruct the operation or
which must be kept dry.
 Close all windows completely, and then close all
doors tightly. Close the hood before starting the
test.
 Connect a hose to a tap, and spray water on the
vehicle. The rate of water discharge must be ap-
prox. 20 — 252 (5.3 — 6.6 US gal, 4.4 — 5.5 Imp
gal) per minute.
When spraying water on areas adjacent to the floor
and wheel house, increase the pressure. When di-
recting water on areas other than the floor portion
and wheel house, decrease the pressure. But the
force of water must be made strong occasionally by
pressing the end of the hose.
NOTE:
Be sure to keep the hose at least 10 cm (3.9 in)
from the vehicle.
Check the following areas:
 Front window and body framework mating por-
tion
 Door mating portions
 Glass mating portions
 Rear quarter window mating portions
 Rear window and body framework mating portion
 Around roof drips
(1) RHD model
(2) LHD model
Selector
Po si t io nGear Position
1st 2nd 3rd 4th
D OKOKOKOK
3 OKOKOK —
2OKOK——
1OK———
(A) Level gauge
(B) Check position when “HOT”
(C) Upper level
(D) Lower level
(E) Check position when “COLD”
PI-00112(1) (2)
P
R
N
D
3
2
1
PI-00105
COLD
LFHOT LF
(A)
(C)
(D)
(C)
(D)
(E)
(B)
(A) Reservoir tank
(B) MIN level
(C) MAX level
PM-00070
(A)
(C)
(B)

PI-13
PRE-DELIVERY INSPECTION
Pre-delivery Inspection
If any dampness in the compartment is discovered
after the water has been applied, carefully check all
areas that may have possibly contributed to the
leak.
45.APPEARANCE CHECK 2
1) When vehicle body is covered with protective
film (wrap guard), peel it off.
NOTE:
 Use of steam eases peeling off the wrap guard.
 When performing on the vehicles left for a long
time, or during low temperature period, sprinkle
some water heated to 50 — 60°C (122 — 140°F)
over the vehicle to raise its surface temperature be-
fore peeling off the wrap guard.
Do not use the water heated to over 60°C (140°F).
 If the adhesive remains on the coated surface,
rub the portion with a flannel rag, etc. soaked with a
coat of coating wax or a solvent, such as oil ben-
zene and IPA, and then wipe it off.
 Avoid adhesion of the solvent to resin or rubber
components. Do not use coating wax or a solvent
while the component surface temperature is high
due to hot weather, etc.
 If the coated surface is swollen out due to seams
or moisture, expose the vehicle to the sun light for a
few hours. Otherwise, heat the portion with seams
or moisture using a dryer, etc.
 Dispose of the peeled wrap guard as burnable in-
dustrial garbage.
2) Check the whole vehicle body for stains, flaking,
damage caused by transportation, rust, dirt, cracks,
or blistering.
NOTE:
 It is better to determine an inspection pattern in
order to avoid missing an area, since the total in-
spection area is wide.
 It is desirable not to make corrections to the body
paint unless absolutely needed. However, if any
corrections are required to remove scratches or
rust, the area to be corrected must be limited as
much as possible. Re-painting and spray painting
must be avoided whenever possible.
3) Carefully check each window glass for scratch-
es. Slight damage may be removed by polishing
with cerium oxide. (Half-fill a cup with cerium oxide,
and add warm water to it. Then agitate the content
until it turn to wax. Apply this wax to a soft cloth,
and polish the glass.)4) Check each portion of the vehicle body and un-
derside components for the formation of rust. If rust
is discovered, remove it with #80 — #180 emery
paper, and treat the surface with rust preventive.
After this treatment is completed, flush the portion
thoroughly, and prepare the surface for repair
painting.
5) Check each portion of the body and all of the
chrome parts for deformation or distortion. Also
check each lamp lens for cracks.

PI-14
PRE-DELIVERY INSPECTION
Pre-delivery Inspection

PERIODIC MAINTENANCE SERVICE
PM
Page
1. General Description ....................................................................................2
2. Schedule .....................................................................................................3
3. Engine Oil....................................................................................................7
4. Engine Oil Filter...........................................................................................9
5. Spark Plugs ...............................................................................................10
6. V-belt .........................................................................................................11
7. Timing Belt ................................................................................................13
8. Fuel Line ...................................................................................................17
9. Fuel Filter ..................................................................................................18
10. Air Cleaner Element ..................................................................................19
11. Cooling System .........................................................................................20
12. Engine Coolant..........................................................................................21
13. Clutch System ...........................................................................................23
14. Transmission Gear Oil ..............................................................................24
15. Hill-holder System .....................................................................................25
16. ATF ...........................................................................................................26
17. Front & Rear Differential Oil ......................................................................28
18. Brake Line .................................................................................................30
19. Brake Fluid ................................................................................................32
20. Disc Brake Pads and Discs .......................................................................33
21. Brake Linings and Drums ..........................................................................34
22. Suspension ...............................................................................................36
23. Wheel Bearing...........................................................................................38
24. Axle Boots & Joints ...................................................................................39
25. Tire Rotation..............................................................................................40
26. Steering System (Power Steering) ............................................................41

PM-2
PERIODIC MAINTENANCE SERVICE
General Description
1. General Description
A: GENERAL
Be sure to perform periodic maintenance in order to
maintain vehicle performance and find problems
before they become serious.

PM-3
PERIODIC MAINTENANCE SERVICE
Schedule
2. Schedule
A: MAINTENANCE SCHEDULE 1
1. FOR EUROPE AREA
For periodic maintenance of over 120,000 km (75,000 miles) or 96 months, carry out inspection by referring
to the following table. For a maintenance period gone beyond these tables, apply them repeatedly as a set
of 120,000 km (75,000 miles) or 96 months.
Symbols used:
R: Replace
I: Inspection
(I): Recommended service for safe vehicle operation.
N
OTE:
(1) When the vehicle is used in extremely dusty conditions, the air cleaner element should be replaced more often.
(2) ATF filter is a maintenance free part. ATF filter needs replacement, when it is physically damaged or ATF leaked.Maintenance interval
[Number of months or km (miles), whichever occurs first]
Month 1224364860728496
Remarks ×1,000 km 1.6 5 15 30 45 60 75 90 105 120
×1,000 miles 1 3 9 19 28 38 47 56 66 75
1Engine oil RRRRRRRR
2Engine oil filter RRRRRRRR
3 Spark plug For Turbo R
Others RRRR
4Drive belt(s) IIIIIIII
5Camshaft drive belt RRRR
6Fuel line IIII
7 Fuel filter R R
8 Air cleaner element I R I R I R I R
9Cooling system IIII
10Coolant RRRR
11Clutch system IIII
12Hill-holder system IIII
13 Transmission oil I R I R
14 ATF I R I R
15 Front & rear differential I R I R
16Brake line IIII
17Brake fluid RRRR
18Disk brake pads & discs IIIIIIII
19Brake linings & drums IIII
20Parking brake IIII
21Suspension IIII
22 Wheel bearing(I)
23Axle boot & joint IIIIIIII
24Steering system IIII