suspension SUBARU FORESTER 2004 Service Repair Manual

LI-14
LIGHTING SYSTEM
Headlight Assembly
7) Remove the packing (A) from seal groove.
CAUTION:
Completely remove the packing not to leave
any chips behind.
D: ASSEMBLY
1) Cut the tip of packing (A) at an angle of 45°.
2) With the cut end facing upward, insert the pack-
ing (A) into groove around seal.
CAUTION:
 If the packing protrudes, slowly take it off the
groove.
 Do not stretch the packing. If the packing is
stretched, seal fails.
3) After making a round of the seal, cut its tip at an
angle of 45°, with its length 10 mm (0.39 in) longer
than the circumference of seal so that the tip over-
laps the other. Then, press it onto the seal, using a
screwdriver.4) Match the positions of the lens and headlight as-
sembly, and then insert the lens into headlight as-
sembly.
5) Secure the hook, and then install the clip and
screw.
6) Put the seal portion of headlight assembly into
the water and check that water does not enter in-
side the headlight.
CAUTION:
Be sure that water does not enter inside the
headlight through the bulb socket or ventilation
hole.
E: ADJUSTMENT
1. HEADLIGHT AIMING
CAUTION:
Turn off the light before adjusting headlight
aiming. If the light is necessary to check aim-
ing, do not turn on for more than two minutes.
NOTE:
Before checking the headlight aiming, be sure of
the following:
 The area around the headlight has not sustained
any accident, damage or other type of deformation.
 Vehicle is parked on a level surface.
 The inflation pressure of tires is correct.
 Vehicle’s fuel tank is fully charged.
1) Bounce the vehicle several times to normalize
the suspension.
2) Make certain that someone is seated in the driv-
er’s seat.
3) Turn the headlights on and then adjust the low
beam pattern by following positions on the screen.
NOTE:
 Set the headlight beam leveler switch to “0” posi-
tion.
 Adjust the vertical aim (A) first, then horizontal
aim (B).(A) Packing
(A) Packing
LI-00060
(A)
LI-00061
(A)
LI-00062
10mm
LI-00015
(A)
(B)

BS-13
BODY STRUCTURE
Datum Dimensions
2. SUSPENSION CROSSMEMBER
*1: Standard line
*2: Side sill
Unit: mm (in)
BS-00036
(54)
(54)
(65)
(65)
(54)
(66)(63)2
75(2.95)
150(5.91) 2547(100.28)
860(33.86)
840(33.07)
(62)
(65)
1 1
(66)
(66)
(63)
(63)
(62)
(62)
920(36.22)
206(8.11)139(5.47)205(8.07)

FUJI HEAVY INDUSTRIES LTD. G8080GE6
2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
CHASSIS SECTION
This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.
All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.FRONT SUSPENSION FS
REAR SUSPENSION RS
WHEEL AND TIRE SYSTEM WT
DIFFERENTIAL DI
TRANSFER CASE TC
DRIVE SHAFT SYSTEM DS
ABS ABS
ABS (DIAGNOSTIC) ABS
BRAKE BR
PARKING BRAKE PB
POWER ASSISTED SYSTEM
(POWER STEERING)PS

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)

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.

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