torque SUBARU FORESTER 2004 Service Manual PDF

EB-18
EXTERIOR BODY PANEL
Rear Gate Panel
2. REAR GATE DAMPER STAY
1) Open the rear gate. Use a support to support the
rear gate.
NOTE:
After the rear gate damper stay is removed, the rear
gate cannot stay open. Supporting the rear gate with
a jack, remove the bolts.
CAUTION:
 Do not damage the piston rods and oil seals.
 Never disassemble the cylinders: They con-
tain gas.
2) Loosen the bolts to remove the rear gate damper
stay from rear gate.
B: INSTALLATION
1. REAR GATE PANEL
1) Install in the reverse order of removal.
2) Install the rear gate panel with uniform clearance
to the body.
3) Refer to COMPONENT of General Description for
tightening torque. EL, COMPONENT, General Description.>
NOTE:
After supporting the rear gate with a jack, start
working.
2. REAR GATE DAMPER STAY
1) Install the mounting bolt (A) to the rear gate pan-
el and body.
Tightening torque:
14 N·m (1.43 kgf-m, 10.3 ft-lb)
2) Firmly install the rear gate damper stay (B) to
mounting bolt (A).
3) Tighten the bolts at upper side of rear gate damp-
er stay.
Tightening torque:
7.5 N·m (0.76 kgf-m, 5.5 ft-lb)
EB-00021
EB-00024
(A)(B)
EB-00075

CC-5
CRUISE CONTROL SYSTEM
Actuator
2. Actuator
A: REMOVAL
CAUTION:
 Be careful not to apply excessive load to the
wire cable when adjusting and/or installing; oth-
erwise, the actuator may be deformed or dam-
aged.
 Do not bend the cable sharply with a radius
less than 100 mm (3.94 in); otherwise, cable
may bend permanently, resulting in poor per-
formance.
 When installing the cable, be careful not to
sharply bend or pinch the inner cable; other-
wise, the cable may break.
1) Disconnect the ground cable from battery.
2) Remove the clip bands from cruise control cable.
3) Loosen the nut which secures cruise control ca-
ble end to throttle cam, and then remove the cable
from throttle cam.
4) Remove the four actuator attaching bolts.
5) Remove the actuator while disconnecting the
connector.
 LHD model RHD model
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
ACTUATOR:
7.4 N
⋅m (0.75 kgf-m, 5.4 ft-lb)
Cable end nut:
12 N
⋅m (1.2 kgf-m, 8.7 ft-lb)
NOTE:
(A): Must be adjusted when the cable end outer is
fixed in place, so that gap between throttle cam and
lever is 0 — 1 mm (0 — 0.04 in), otherwise, inner
cable deflection (D) is 1 — 8 mm (0.039 — 0.315 in)
when the throttle cable is installed.
(Must be attached while the throttle cam is being
pulled by wire cable.)
(B): Must be coated evenly on the cam end inner
connection.
(C): Cover must be inserted securely, until tip of ca-
ble touches cover stopper.
CC-00009
CC-00010
CC-00070
CC-00037
(B)
(A) (D) (C)

HU-3
HOW TO USE THIS MANUAL
How to Use This Manual
3. COMPONENTS
Illustrations are listed for each component. The information necessary for repair work (tightening torque,
grease up points, etc.) is described on these illustrations. Information is described using symbol. To order the
parts, refer to parts catalogue.
Example:
HU-00001
(14)
(9)
(8)(7)(6)
(10)
(4)
(10)
(22)(11)
(19) (17) (15) (13)(12)
(18) (16) (1)(2)(3)
(4)(5)(6)
(7)
(8)
(11) (10)(9)
(12)
(13)
(19)(18)
(20)(17)
(16)(24)
(10)(25) (5)
(4)
(4)
(4)(3)
(3)
(3) (2) (1)
(21) (15)
(23)
T7
T2
T2
T2
T2
T2
T2
T4
T5
T5
T8
T6
T6
T6T11
T10
T1
T1
T3
T3
T3
T1
T9
T4
T5
T5T3
T4
T3T2
T4
T2
T1
T3
(20)
(21)
(23)
(22)
(10)
(24)(25)(26)(35)
(34)
(27)
(14)
(28)
(29)
(31)
(32)(37)(30)
(33)
(36)
T3
T2T1:Selective part
:Replacement part
:Should be lubricated with grease. :Should be lubricated with oil.:Sealing point
:Tightening torque .... ,

HU-4
HOW TO USE THIS MANUAL
How to Use This Manual
4. SPECIFICATION
If necessary, specifications are also included.
5. INSPECTION
Inspections are included to be carried out before and after maintenance.
6. MAINTENANCE
• Maintenance instructions for serviceable parts describes work area and detailed steps with illustration. It
also describes the use of special tool, tightening torque, cautions for each procedure.
 If many serviceable parts are included in one service procedure, appropriate reference are provided for
each part.
Example:
(A) Component (D) Caution (G) Tightening torque
(B) Process (E) Tool number of special tool (H) Illustration
(C) Reference (F) Name of special tool
HU-00002
1) Remove the manual transmission assembly
from vehicie. Transmission Assembly.>
15.Main Shaft Assembly for Sin-
gle-Range
A: REMOVAL
11) Tighten the lock nuts to the specified torque us-
ing ST1 and ST2.
NOTE:
Secure the lock nuts in two Places affer tightening.
ST2 499987003 SOCKET WRENCH
ST1 498937000 TRANSMISSION HOLDER
(A)
(B)
(C)
(D)
(G) (E) (F)
(H)
Tightening torque:
118 N m (12.0 kgf-m, 86.8 ft-lb)
ST1ST2

HU-5
HOW TO USE THIS MANUAL
How to Use This Manual
7. DIAGNOSIS
Tables showing a step-by-step process make it
easy to conduct diagnosis.
8. SI UNITS
Measurements in these manuals are according to
the SI units. Metric and yard/pound measurements
are also included.
Example:
Tightening torque:
44 N·m (4.5 kgf-m, 33 ft-lb)

SPC-2
SPECIFICATION
Forester
1. Forester
A: DIMENSIONS
★: With sunroof
B: ENGINE
Model 2.0 L Non-turbo 2.0 L Turbo 2.5 L Non-turbo 2.5 L Turbo
Overall length mm (in) 4,450 (175.2)
Overall width mm (in) 1,735 (68.3)
Overall height (at C.W.) mm (in) 1,590 (62.6) 1,585 (62.4) 1,590 (62.6)
CompartmentLength mm (in) 1,795 (70.7)
Width mm (in) 1,455 (57.3)
Height mm (in)
1,245 (49.0), 1,210 (47.6)
★
Wheelbase mm (in) 2,525 (99.4)
Tread Front mm (in) 1,495 (58.9)
Rear mm (in) 1,485 (58.5)
Minimum road clearance mm (in) 190 (7.5) 195 (7.7) 200 (7.9)
Model 2.0 L Non-turbo 2.0 L Turbo 2.5 L Non-turbo 2.5 L Turbo
Engine type Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine
Valve arrangement Overhead camshaft type
Bore×Stroke mm (in) 92×75 (3.62×2.95) 99.5×79 (3.92×3.11)
Displacement
cm
3 (cu in)1,994 (121.67) 2,457 (149.94)
Compression ratio 10.0±0.2 8.0±0.2 10.0±0.2 8.2±0.2
Firing order 1 — 3 — 2 — 4
Idle speed at Park or Neu-
tral positionrpm 650±100 700±100 650±100 700±100
Maximum output kW (PS)/rpm 92 (125)/5,600 130 (177)/5,600 115 (156)/5,600 155 (211)/5,600
Maximum torque N⋅m (kgf-m, ft-lb)/rpm184 (18.8, 41.4)/
3,600245 (25.0, 55.1)/
3,200223 (22.7, 50.1)/
3,600320 (32.6, 71.8)/
3,600

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)

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.

RM-7
RECOMMENDED MATERIAL
Recommended Materials
9. SEAL MATERIAL
Use seal material shown in the table below, or equivalent.
Seal material Application point Recommended Item number Alternative
Seal material  Engine case
 Torque converter
clutch case
 Transmission case
(5MT)Three Bond 1215B 004403007 Dow Corning’s No. 7038
Transmission Three Bond 1217B K0877YA020 —
Rear differential Three Bond 1324 004403042 —
Rear differential Three Bond 1105 004403010 Dow Corning’s No. 7038
Weather strip Starcalking B-33A 000018901 Butyl Rubber sealant
Steering adjusting screw Three Bond 1102 004403006 —
SOHC camshaft cap Three Bond 1280B K0877YA018 —

PM-7
PERIODIC MAINTENANCE SERVICE
Engine Oil
3. Engine Oil
A: REPLACEMENT
1) Open the engine oil filler cap for quick draining of
the engine oil.
2) Remove six clips securing service hole cover.
3) Turn the service hole cover counterclockwise.4) Drain the engine oil by loosening engine oil drain
plug.
5) Replace the drain plug gasket with a new one.
6) Tighten the engine oil drain plug after draining
engine oil.
Tightening torque:
44 N·m (4.5 kgf-m, 33 ft-lb)
(A) Oil level gauge
(B) Engine oil filler cap
PM-00155
(A)(B)
LU-00005
LU-00006
(A) Engine oil drain plug
(B) Engine oil filter
(A) Engine oil drain plug
(B) Engine oil filter
LU-00007
(B)
(A)
LU-00007
(B)
(A)