brake disc SUBARU FORESTER 2004 Service Repair 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-10
CRUISE CONTROL SYSTEM
Stop and Brake Switch
6. Stop and Brake Switch
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Disconnect the connector from stop and brake
switch, and then remove the switch. 54, REMOVAL, Stop Light Switch.>
B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
Measure the brake switch (A) and stop light switch
(B) resistance.
If NG, replace the stop and brake switch.
Switch Pedal Terminal No. Standard
BrakeReleased 1 and 4 Less than 1 Ω
Depressed 1 and 4 More than 1 MΩ
Stop lightReleased 2 and 3 More than 1 MΩ
Depressed 2 and 3 Less than 1 Ω
CC-00022
1234
(A)
(B)
3 2 14

CC(H4SO)-22
CRUISE CONTROL SYSTEM (DIAGNOSTIC)
Diagnostic Procedure with Symptom
Step Check Yes No
1 CHECK STOP LIGHT SWITCH AND BRAKE
SWITCH CIRCUIT.
1) Turn the ignition switch to OFF.
2) Disconnect the stop light switch and brake
switch harness connector.
3) Turn the ignition switch to ON.
4) Turn the cruise control main switch to ON.
5) Measure the voltage between harness con-
nector terminal and chassis ground.
Connector & terminal
(B65) No. 2 (+) — Chassis ground (
−): Is the voltage more than 10 V? Go to step 2. Check the fuse
No. 16 (in fuse &
relay box).
 Check the har-
ness for open or
short between
stop light/brake
switch and fuse &
relay box.
2 CHECK STOP LIGHT SWITCH AND BRAKE
SWITCH CIRCUIT.
Measure the voltage between harness connec-
tor terminal and chassis ground.
Connector & terminal
(B65) No. 4 (+) — Chassis ground (
−): Is the voltage more than 10 V? Go to step 3. Check the har-
ness for open or
short between
stop light/brake
switch and cruise
control module (AT
model).
 Check the clutch
switch and circuit
(MT model).
3 CHECK STOP LIGHT SWITCH AND BRAKE
SWITCH CIRCUIT.
1) Turn the cruise control main switch and
ignition switch to OFF.
2) Disconnect the cruise control module har-
ness connector.
3) Measure the resistance between cruise
control module harness connector terminal
and stop light switch and brake switch harness
connector terminal.
Connector & terminal
(B94) No. 20 — (B65) No. 3:
(B94) No. 16 — (B65) No. 1: Is the resistance less than 10
Ω?Go to step 4.Repair the har-
ness.
4 CHECK STOP LIGHT SWITCH AND BRAKE
SWITCH.
Remove and check the stop light switch and
brake switch. Switch.>Are the stop light switch and
brake switch are OK?Stop light switch
and brake switch
circuit are OK.Replace the stop
light switch and
brake switch.

CC(H4SO)-24
CRUISE CONTROL SYSTEM (DIAGNOSTIC)
Diagnostic Procedure with Symptom
Step Check Yes No
1 CHECK CLUTCH SWITCH CIRCUIT.
1) Turn the ignition switch to OFF.
2) Disconnect the clutch switch harness con-
nector.
3) Turn the ignition switch to ON.
4) Turn the cruise control main switch to ON.
5) Measure the voltage between harness con-
nector terminal and chassis ground.
Connector & terminal
(B107) No. 2 (+) — Chassis ground (
−):Is the voltage more than 10 V? Go to step 2.Check the harness
for open or short
between clutch
switch and cruise
control module.
2 CHECK CLUTCH SWITCH CIRCUIT.
1) Turn the cruise control main switch and
ignition switch OFF.
2) Disconnect the stop light switch and brake
switch harness connector.
3) Measure the resistance between clutch
switch harness connector terminal and stop
light switch and brake switch harness connec-
tor terminal.
Connector & terminal
(B107) No. 1 — (B65) No. 4:Is the resistance less than 10
Ω?Go to step 3.Repair the har-
ness.
3 CHECK CLUTCH SWITCH.
Remove and check the clutch switch. CC-11, Clutch Switch.>Is the clutch switch OK? Clutch switch cir-
cuit is OK.Replace the clutch
switch.

CC(H4DOTC 2.5)-19
CRUISE CONTROL SYSTEM (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
Step Check Yes No
1 CHECK STOP LIGHT SWITCH AND BRAKE
SWITCH CIRCUIT.
1) Turn the ignition switch to OFF.
2) Disconnect the stop light switch and brake
switch harness connector.
3) Turn the ignition switch to ON.
4) Measure the voltage between harness con-
nector terminal and chassis ground.
Connector & terminal
(B65) No. 2 (+) — Chassis ground (
−): Is the voltage more than 10 V? Go to step 2. Check the fuse
No. 16 (in fuse &
relay box).
 Check the har-
ness for open or
short between
stop light/brake
switch and fuse &
relay box.
2 CHECK STOP LIGHT SWITCH AND BRAKE
SWITCH CIRCUIT.
Measure the voltage between harness connec-
tor terminal and chassis ground.
Connector & terminal
(B65) No. 1 (+) — Chassis ground (
−): Is the voltage more than 10 V? Go to step 3. Check the fuse
No. 11 (in fuse &
relay box).
 Check the har-
ness for open or
short between
stop light/brake
switch and fuse &
relay box.
 Check the clutch
switch and circuit.
3 CHECK STOP LIGHT SWITCH AND BRAKE
SWITCH CIRCUIT.
1) Turn the ignition switch to OFF.
2) Disconnect the ECM harness connector.
3) Measure the resistance between ECM har-
ness connector terminal and stop light switch
and brake switch harness connector terminal.
Connector & terminal
(B136) No. 8 — (B65) No. 3:
(B136) No. 9 — (B65) No. 4: Is the resistance less than 10
Ω? Go to step 4.Repair the har-
ness.
4 CHECK STOP LIGHT SWITCH AND BRAKE
SWITCH.
Remove and check the stop light switch and
brake switch. Switch.>Are the stop light switch and
brake switch OK? Stop light switch
and brake switch
circuit are OK.Replace the stop
light switch and
brake switch.

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)

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.

RM-6
RECOMMENDED MATERIAL
Recommended Materials
8. ADHESIVES
Use the adhesives shown in the table below, or equivalent.
Grease MT main shaft FX 2200 clutch grease 000040901 —
Clutch master cylinder
push rodSlicolube G-40M 004404003 —
 Gear shift lever
 Select lever
 Clutch operating cyl-
inder
 Accelerator pedal
 Clutch pedal
 Brake pedal
 Hill holder
 Clutch bearing
 Clutch release lever
 Steering shaft bear-
ingSUNLIGHT2 003602010 —
Steering gearbox Valiant grease M-2 003608001 —
Disc brake Niglube RX-2 K0779GA102 —
 Drum brake
 Drum brake wheel
cylinderMolykote No. 7439 003602001 —
 Brake pad
Brake shoeMolykote AS-880N K0777YA010 —
Front axle AARi One luber C — —
Front axle AC HTBJ — —
Rear axle BJ Molylex No. 2 003601001 —
Rear axle EBJ NTG2218 — —
Rear axle DOJ VU-3A702 23223GA050 —
 Water pump
Door latch
Door strikerSlicolube G-30M 004404002 —
Adhesive Application point Recommended Item number Alternative
Adhesive Windshield and body Dow Automotive’s
Adhesive: Gurit-ESSEX
Betaseal 1502 or equivalent
Glass primer: Betawipe VP
04604 or Betawipe 5001
Paint surface primer: Betap-
rime 5402——
Soft vinyl Cemedine 540 — 3M’s EC-776 EC-847 or EC-1022
(Spray type)
Momentary sealant Cemedine 3000 — Armstrong’s Eastman 910
Inner rearview mirror
baseREPAIR KIT IN MR 65029FC000 — Grease Application point Recommended Item number Alternative

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