boot SUBARU FORESTER 2004 Service Repair Manual

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-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

PM-4
PERIODIC MAINTENANCE SERVICE
Schedule
2. EXCEPT FOR EUROPE AREA
For periodic maintenance of over 50,000 km (30,000 miles) or 48 months, carry out inspections by referring
to the following tables. For a maintenance period gone beyond these tables, apply them repeatedly as a set
of 50,000 km (30,000 miles) or 48 months.
For periodic maintenance of over 100,000 km (60,000 miles) or 48 months, carry out inspections by referring
to the following tables. For a maintenance period gone beyond these tables, apply them repeatedly as a set
of 100,000 km (60,000 miles) or 48 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]
Months 12 24 36 48
Remarks ×1,000 km 5 12.5 25 37.5 50
×1,000 miles 3 7.5 15 22.5 30
1 Engine oil R R R R
2 Engine oil filter R R R R
Maintenance Interval
[Number of months or km (miles), whichever occurs first]
Months 12 24 36 48
Remarks ×1,000 km 1.6 25 50 75 100
×1,000 miles 1 15 30 45 60
3 Spark plugs For Turbo R
Others R R R R
4Drive belt(s) IIII
5 Camshaft drive belt R
6 Fuel line I I
7 Fuel filter R R
8 Air cleaner element I R I R
9 Cooling system I I
10 Coolant R R
11 Clutch system I I I I I
12 Hill-holder system I I I I I
13 Transmission oil R R
14 ATF R R
15 Front & rear differential oil R R
16 Brake line I I
17 Brake fluid R R
18 Disc brake pads & discs I I I I
19 Brake linings and drums I I
20 Parking brake I I I I
21 Suspension I I I I
22 Wheel bearing (I)
23 Axle boots & joints I I I I
24 Steering system (Power steering) I I I I

PM-5
PERIODIC MAINTENANCE SERVICE
Schedule
B: MAINTENANCE SCHEDULE 2
1. EUROPE AREA
Item EveryRepeat short
distance driveRepeat
rough/muddy
road driveExtremely
cold weather
areaSalt or other
corrosive
used or
coastal areaHigh humid-
ity or moun-
tain areaRepeat tow-
ing trailer
Engine oil Replace
more fre-
quentlyReplace
more fre-
quentlyReplace
more fre-
quently
Engine oil filter Replace
more fre-
quentlyReplace
more fre-
quentlyReplace
more fre-
quently
Fuel line 12 months
I 15,000 km
9,000 miles
Transmission oilReplace
more fre-
quently
AT FReplace
more fre-
quently
Front & rear dif-
ferential oilReplace
more fre-
quently
Brake line 12 months
I 15,000 km
9,000 miles
Brake fluid 12 months
R 15,000 km
9,000 miles
Brake pads 12 months
II I I 15,000 km
9,000 miles
Brake linings
and drums12 months
II I I 15,000 km
9,000 miles
Parking brake 12 months
II I I 15,000 km
9,000 miles
Suspension 12 months
III 15,000 km
9,000 miles
Axle boots &
joints12 months
II I I 15,000 km
9,000 miles
Steering system
(Power steering)12 months
III 15,000 km
9,000 miles

PM-6
PERIODIC MAINTENANCE SERVICE
Schedule
2. EXCEPT FOR EUROPE AREA
Item EveryRepeat short
distance driveRepeat
rough/muddy
road driveExtremely
cold weather
areaSalt or other
corrosive
used or
coastal areaHigh humid-
ity or moun-
tain areaRepeat tow-
ing trailer
Engine oil Replace
more fre-
quentlyReplace
more fre-
quentlyReplace
more fre-
quently
Engine oil filter Replace
more fre-
quentlyReplace
more fre-
quentlyReplace
more fre-
quently
Fuel line 6 months
I 12,500 km
7,500 miles
Transmission oilReplace
more fre-
quently
AT FReplace
more fre-
quently
Front & rear dif-
ferential oilReplace
more fre-
quently
Brake line 6 months
I 12,500 km
7,500 miles
Brake fluid 12 months
R 25,000 km
15,000 miles
Brake pads 6 months
II I I 12,500 km
7,500 miles
Brake linings
and drums6 months
II I I 12,500 km
7,500 miles
Parking brake 6 months
II I I 12,500 km
7,500 miles
Suspension 6 months
III 12,500 km
7,500 miles
Axle boots &
joints6 months
II I I 12,500 km
7,500 miles
Steering system
(Power steering)6 months
III 12,500 km
7,500 miles

PM-39
PERIODIC MAINTENANCE SERVICE
Axle Boots & Joints
24.Axle Boots & Joints
A: INSPECTION
1. FRONT AND REAR AXLE BOOTS
Inspect the front axle boots (A) and rear axle boots
(B) for deformation, damage or failure. If faulty, re-
place them with new ones. Drive Shaft.>
2. PROPELLER SHAFT
Inspect the propeller shaft for damage or failure. If
faulty, replace with a new one. peller Shaft.>
(A)
PM-00063
(B)
PM-00064

PM-41
PERIODIC MAINTENANCE SERVICE
Steering System (Power Steering)
26.Steering System (Power
Steering)
A: INSPECTION
1. STEERING WHEEL
1) Set the steering wheel in a straight-ahead posi-
tion, and check the wheel spokes to make sure
they are correctly set in their specified positions.
2) Lightly turn the steering wheel to the right and
left to determine the point where front wheels start
to move.
Measure the distance of the movement of steering
wheel at the outer periphery of wheel.
Steering wheel free play:
0 — 17 mm (0 — 0.67 in)
Move the steering wheel vertically toward the shaft
to ascertain if there is play in the direction.
Maximum permissible play:
0.5 mm (0.020 in)
3) Drive the vehicle and check the following items.
(1) Steering force:
The effort required for steering should be
smooth and even at all points, and should not
vary.
(2) Pull to one side:
Steering wheel should not be pulled to either
side while driving on a level surface.
(3) Wheel runout:
Steering wheel should not be runout.
(4) Return factor:
Steering wheel should return to its original posi-
tion after it has been turned and then released.
2. STEERING SHAFT JOINT
When the steering wheel free play is excessive,
disconnect the universal joint of steering shaft and
check it for any play and yawing torque (at the point
of the crossing direction). Also inspect for any dam-
age to sealing or worn serrations. If the joint is
loose, retighten the mounting bolts to the specified
torque.
Tightening torque:
24 N·m (2.4 kgf-m, 17.4 ft-lb)
3. GEARBOX
1) With wheels placed in the direction of straight
ahead, turn the steering wheel 90° in both the right
and left directions.
While the steering wheel is being rotated, check for
looseness in gearbox.
Tightening torque:
59 N·m (6.0 kgf-m, 43.4 ft-lb)
2) Check the boot for damage, cracks or deteriora-
tion.
3) With the vehicle on a level surface, quickly turn
the steering wheel to the right and left.
While the steering wheel is being rotated, check the
gear backlash. If any unusual noise is noticed, ad-
just the gear backlash in the following manner.
(1) Tighten the adjusting screw to 7.4 N·m (0.75
kgf-m, 5.4 ft-lb) and then loosen. Repeat this op-
eration twice.
(A) Steering wheel free play
PM-00065
(A)
SUBARUSRS AIRBAG
(A) Boot
(B) Gear box mounting bolt
PM-00066
PM-00067
(A)
(B)

PM-43
PERIODIC MAINTENANCE SERVICE
Steering System (Power Steering)
7. HOSES OF OIL PUMP FOR DAMAGES
Check the pressure hose and return hose of oil
pump for crack, swell or damage. Replace the hose
with a new one if necessary.
CAUTION:
Prevent the hoses from revolving and/or turn-
ing when installing hoses.
8. POWER STEERING PIPES FOR DAM-
AGE
Check the power steering pipes for corrosion and
damage.
Replace the pipes with a new one if necessary.
9. GEARBOX BOOTS
Inspect both sides of gearbox boots as follows, and
correct the defects if necessary.
1) (A) and (B) positions of gearbox boot are fitted
correspondingly in (A) and (C) grooves of gearbox
and the rod (C).
2) Clips are fitted outside of (A) and (B) positions of
boot.
3) Boot does not have crack and hole.
NOTE:
Rotate (B) the position of gearbox boot against
twist of it produced by adjustment of toe-in, etc.
Apply grease to the groove (C).
10.FITTING BOLTS AND NUTS
Inspect the fitting bolts and nuts of oil pump and
bracket for looseness, and retighten them if neces-
sary.
NOTE:
Inspect or retighten them when engine is cold.
PM-00071
PM-00090
(C)
(B)
(A)

CO(H4SO)-42
COOLING
Coolant Filler Tank
11.Coolant Filler Tank
A: REMOVAL
WARNING:
The radiator is pressurized. Wait until the en-
gine cools down before working on the radia-
tor.
1) Drain the coolant about 3.02 (3.2 US qt, 2.6 Imp
qt). GINE COOLANT, REPLACEMENT, Engine Cool-
ant.>
2) Remove the air cleaner upper cover and air in-
take boot. Cleaner.>
3) Remove the air cleaner element.
4) Disconnect the engine coolant hoses from cool-
ant filler tank.
5) Remove the bolts and nut which install coolant
filler tank.
6) Disconnect the engine coolant hose which con-
nects under side of coolant filler tank.
7) Remove the coolant filler tank.
B: INSTALLATION
1) Install in the reverse order of removal.
Tightening torque:
T1: 19 N
⋅m (1.9 kgf-m, 13.7 ft-lb)
T2: 21 N
⋅m (2.1 kgf-m, 15.2 ft-lb)
2) Fill engine coolant. ING OF ENGINE COOLANT, REPLACEMENT,
Engine Coolant.>
CO-00051
CO-00052
T2
T1
CO-00053

LU(H4SO)-16
LUBRICATION
Oil Pan and Strainer
5. Oil Pan and Strainer
A: REMOVAL
1) Set the vehicle on lift arms.
2) Remove the front wheels.
3) Disconnect the ground cable from battery.
4) Remove the air intake duct and air cleaner case.
(Non-turbo model)

Case.>
5) Disconnect the connector from mass air flow
sensor. (Turbo model)
6) Remove the air intake boot and air cleaner upper
cover. (Turbo model)
7) Remove the intercooler (Turbo model) IN(H4DOTC)-10, REMOVAL, Intercooler.>8) Remove the pitching stopper.
9) Remove the radiator upper brackets.
10) Support the engine with a lifting device and
wire ropes.
11) Lift-up the vehicle.
CAUTION:
When lifting up the vehicle, rise up the wire
rope together.
12) Remove the under cover.
FU-00009
LU-00026
LU-00070
ME-00213
LU-00027
LU-00028