weight SUBARU FORESTER 2004 Service Repair Manual

AC-24
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
Electronic leak detector
An ELECTRONIC LEAK DETECTOR can be available at either a spe-
cialty tool supplier or an A/C equipment supplier.
Weight scale
A WEIGHT SCALE such as an electronic charging scale or a bath-
room scale with digital display will be needed, if a 13.6 kg (30 lb) refrig-
erant container is used. Illustration Tools and Equipment
AC-00019
AC-00020

AC-28
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
Refrigerant Charging Procedure
6) Leave it at least 5 to 10 minutes after closing the
valves on low-/high-pressure sides, and then check
the low-pressure gauge reading for any changes.
When the gauge reading changes, this is a sign of
leakage. Check the pipe or hose connector points,
and repair if necessary. Repeat the procedure from
1) after repairing the faulty part.
7) If there are no leaks, further evacuate the sys-
tem 20 to 30 minutes.
8) Close all valves and stop the vacuum pump.
9) Following the can tap operation manual instruc-
tions, install it to refrigerant can.
10) Disconnect the vacuum pump from center
hose, and connect the hose to tap valve.
11) When a 13.6 kg (30 lb) refrigerant container is
used, measure the refrigerant amount in use using
a weighting scale before connecting to center hose.
12) Open the valve on HFC-134a source.13) Loosen the center hose connection on manifold
gauge (if applicable, press a purge valve on mani-
fold gauge) only for a couple of seconds to allow
the air in the center hose to escape by the refriger-
ant.
14) Make sure that the high-pressure valve of man-
ifold gauge is closed, and then open the low-pres-
sure side valve only to charge the refrigerant.
CAUTION:
Do not open the high-pressure valve. Be sure to
open the low-pressure valve.
15) Close the low-pressure valve when the low-
pressure gauge reading reaches 200 kPa (1,500
mmHg, 59.1 inHg).
16) Using a leak tester, check the system for refrig-
erant leaks.
17) After confirming that there are no leaks with the
leak test, charge the required amount of refrigerant.
18) If the HFC-134a source is empty, close the low-
pressure valve and then close the valve on can tap
before replacing the empty source. Restart charg-
ing operation after replacing the HFC-134a source
with a new one and purging.
19) Close the low-pressure valve if the charge rate
of refrigerant becomes worse.
20) Confirm that both the low-/high-pressure
valves are closed. Start the engine with A/C switch
OFF.
21) Quickly repeat A/C switch ON-OFF cycles a
few times to prevent initial compressor damage.
(1) Tap valve
(2) To center manifold hose
(1) Refrigerant container (HFC-134a)
(2) Weighting scale
AC-00214
(1)
(2)
AC-00215
(1)
(2)
(1) Open
(2) Close
AC-00216
AC-00217
(1)
(2)

SPC-5
SPECIFICATION
Forester
J: WEIGHT
1. LHD MODEL
★: For the option codes, refer to ID section. Option code
★EC K4 KS
Model 2.0 L Non-turbo 2.5 L Non-turbo
Grade 2.0 X 2.5 X
Transmission 5MT 4AT 5MT 4AT 5MT 4AT
Curb weight (C.W.)Front kgf (lb)760
(1,675)775
(1,710)775
(1,710)790
(1,740)780
(1,720)800
(1,765)
Rear kgf (lb)600
(1,325)600
(1,325)595
(1,310)595
(1,310)620
(1,365)620
(1,365)
Total kgf (lb)1,360
(3,000)1,375
(3,035)1,370
(3,020)1,385
(3,050)1,400
(3,085)1,420
(3,130)
Maximum permissi-
ble axle weight
(M.P.A.W.)Front kgf (lb)1,010
(2,225)1,010
(2,225)1,010
(2,225)1,010
(2,225)1,010
(2,225)1,010
(2,225)
Rear kgf (lb)1,035
(2,280)1,035
(2,280)1,035
(2,280)1,035
(2,280)1,035
(2,280)1,035
(2,280)
Maximum permissi-
ble weight (M.P.W.)Total kgf (lb)1,880
(4,140)1,880
(4,140)1,880
(4,140)1,880
(4,140)1,880
(4,140)1,880
(4,140)
OptionSport package base — — — — — —
Aluminum wheel❍❍❍❍❍❍
Front fog light — — — —❍❍
Cruise control — — — —❍❍
High-grade audio — — — — — —
Sport steering — — — — — —
Leather package base — — — — — —
Leather seat, Leather
door trim——————
Navigation system ——————
Air conditioner — —❍❍❍❍
Side airbag — — — — — —
Sunroof — — — — — —
Self-leveling function Rr❍❍————
Cold area pack A — — — — — —
Cold area pack B — — — — — —
Cold area pack C — — — — — —
Cold area pack D❍❍————
Heated mirrors❍❍————
Security system — — — — — —

SPC-6
SPECIFICATION
Forester
★: For the option codes, refer to ID section. Option code
★EC K4
Model2.0 L Turbo
Grade2.0 XT
Transmission 5MT 4AT 5MT 4AT
Curb weight (C.W.)Front kgf (lb) 810 (1,785) 830 (1,830) 815 (1,795) 835 (1,840)
Rear kgf (lb) 620 (1,365) 620 (1,365) 630 (1,390) 630 (1,390)
Total kgf (lb) 1,430 (3,150) 1,450 (3,195) 1,445 (3,185) 1,465 (3,230)
Maximum permissible axle
weight (M.P.A.W.)Front kgf (lb) 1,010 (2,225) 1,010 (2,225) 1,010 (2,225) 1,010 (2,225)
Rear kgf (lb) 1,035 (2,280) 1,035 (2,280) 1,035 (2,280) 1,035 (2,280)
Maximum permissible
weight (M.P.W.)Total kgf (lb)1,950 (4,295) 1,950 (4,295) 1,950 (4,295) 1,950 (4,295)
OptionSport package base — — — —
Aluminum wheel — — — —
Front fog light❍❍❍❍
Cruise control❍❍—❍
High-grade audio — — — —
Sport steering — — — —
Leather package base❍❍❍❍
Leather seat, Leather door trim — — —❍
Navigation system — — — —
Air conditioner❍❍❍❍
Side airbag❍❍❍❍
Sunroof — —❍❍
Self-leveling function Rr❍❍——
Cold area pack A — — — —
Cold area pack B❍❍——
Cold area pack C — — — —
Cold area pack D — — — —
Heated mirrors❍❍——
Security system ————

SPC-7
SPECIFICATION
Forester
2. RHD MODEL
★: For the option codes, refer to ID section. Option code
★EK EK
Model 2.0 L Non-turbo 2.0 L Turbo
Grade 2.0 X 2.0 XT
Transmission 5MT 4AT 5MT 4AT
Curb weight (C.W.)Front kgf (lb) 775 (1,710) 790 (1,740) 815 (1,795) 835 (1,840)
Rear kgf (lb) 600 (1,325) 600 (1,325) 635 (1,400) 635 (1,400)
Total kgf (lb) 1,375 (3,035) 1,390 (3,065) 1,450 (3,195) 1,470 (3,240)
Maximum permissible axle
weight (M.P.A.W.)Front kgf (lb) 1,010 (2,225) 1,010 (2,225) 1,010 (2,225) 1,010 (2,225)
Rear kgf (lb) 1,035 (2,280) 1,035 (2,280) 1,035 (2,280) 1,035 (2,280)
Maximum permissible
weight (M.P.W.)Total kgf (lb)1,880 (4,145) 1,880 (4,145) 1,950 (4,300) 1,950 (4,300)
OptionSport package base ————
Aluminum wheel❍❍——
Front fog light — —❍❍
Cruise control — —❍❍
High-grade audio ————
Sport steering ————
Leather package base — —❍❍
Leather seat, Leather door trim — —❍❍
Navigation system ————
Air conditioner❍❍❍❍
Side airbag — —❍❍
Sunroof — —❍❍
Self-leveling function Rr❍❍❍❍
Cold area pack A❍❍——
Cold area pack B ————
Cold area pack C — —❍❍
Cold area pack D ————
Heated mirrors❍❍❍❍
Security system — —❍❍

SPC-8
SPECIFICATION
Forester
★: For the option codes, refer to ID section. Option code
★KA
Model 2.5 L Non-turbo 2.5 L Turbo
Grade 2.5 X 2.5 XS 2.5 XT
Transmission 5MT 4AT 5MT 4AT 5MT 4AT
Curb weight (C.W.)Front kgf (lb)765
(1,685)785
(1,730)760
(1,675)780
(1,720)815
(1,795)835
(1,840)
Rear kgf (lb)610
(1,345)610
(1,345)605
(1,335)605
(1,335)610
(1,345)610
(1,345)
Total kgf (lb)1,375
(3,030)1,395
(3,075)1,365
(3,010)1,385
(3,055)1,425
(3,140)1,445
(3,185)
Maximum permissi-
ble axle weight
(G.A.L.R.)Front kgf (lb)1,010
(2,225)1,010
(2,225)1,010
(2,225)1,010
(2,225)1,010
(2,225)1,010
(2,225)
Rear kgf (lb)1,035
(2,280)1,035
(2,280)1,035
(2,280)1,035
(2,280)1,035
(2,280)1,035
(2,280)
Maximum permissi-
ble weight (G.V.M.)Total kgf (lb)1,950
(4,300)1,950
(4,300)1,950
(4,300)1,950
(4,300)1,950
(4,300)1,950
(4,300)
OptionSport package base — — — — — —
Aluminum wheel — — — — — —
Front fog light — —❍❍❍❍
Cruise control❍❍❍❍❍❍
High-grade audio — — — — — —
Sport steering — — — —❍❍
Leather package base — — — —❍❍
Leather seat, Leather
door trim——————
Navigation system ——————
Air conditioner❍❍❍❍❍❍
Side airbag — — — — — —
Sunroof — — — — — —
Self-leveling function Rr — —❍❍❍❍
Cold area pack A — — — — — —
Cold area pack B — — — — — —
Cold area pack C — — — — — —
Cold area pack D — — — — — —
Heated mirrors — — — — — —
Security system — — — — — —

NT-3
NOTE
Note
7. LIFTS AND JACKS
When using a lift or jack to raise a vehicle, always follow instructions concerning jack-up points and weight
limits to prevent the vehicle from falling, which could result in injury. Be especially careful to make sure the
vehicle is balanced before raising it.
Be sure to set the wheel stoppers when jacking-up only the front or rear of the vehicle.
• Support Locations
 Pantograph jack
NT-00001
NT-00002

NT-7
NOTE
Note
 Chain direction at tie-down condition
 Chain pulling range at tie-down condition Vehicle sinking volume at tie-down condition
Measure the distance L between tire highest point
to arch highest point before tie-down and after tie-
down. Difference of measurement value (drop
height) shall be within 50 mm (1.97 in). Make sure
to fix the vehicle securely.
9. TOWING
Avoid towing vehicles except when the vehicle cannot be driven. For models with AWD or AT use a loader
instead of towing. When towing other vehicles, to prevent excessive weight from damaging the hook or ve-
hicle:
 Do not tow other vehicles with a front hook for tie-down.
 Make sure the vehicle towing is heavier that the vehicle being towed.
(A) Chain pulling range at tie-down condition
NT-00007
NT-00008
: (A)
NT-00082
L
L

PM-36
PERIODIC MAINTENANCE SERVICE
Suspension
22.Suspension
A: INSPECTION
1. SUSPENSION BALL JOINT
1) Jack-up the vehicle until front wheels are off
ground.
2) Grasp the bottom of tire and move it in and out.
If relative movement (B) is observed between the
brake disc cover (A) and end of transverse link (D),
ball joint (C) may be excessively worn.
3) Grasp the end of transverse link (C) and move it
up and down. Relative movement (A) between the
housing (D) and transverse link boss indicates ball
joint (B) may be excessively worn.
4) If relative movement is observed in the immedi-
ately preceding two steps, remove and inspect the
ball joint. If free play exceeds standard, replace the
ball joint.
5) Damage of dust seal
Visually inspect the ball joint dust seal. If it is dam-
aged, remove the transverse link. Front Transverse Link.> And measure free play of
ball joint.
(1) When looseness exceeds standard value,
replace the ball joint.
(2) If the dust seal is damaged, replace with the
new ball joint.
NOTE:
When the transverse link ball joint has been re-
moved or replaced, check the toe-in of front wheel. If the front wheel toe-in is not at specified value, ad-
just the toe-in.
2. TRANSVERSE LINK’S REAR BUSHING
Check oil leaks at around liquid-filled bushing. If oil
leaks, replace the bushing.
3. WHEEL ARCH HEIGHT
1) Unload cargoes and set the vehicle in curb
weight (empty) condition.
2) Then, check the wheel arch height of front and
rear suspensions to ensure that they are within
specified values.
3) When the wheel arch height is out of standard,
visually inspect the following components and re-
place deformed parts.
 Suspension components [Front strut assembly
and rear strut assembly]
 Parts connecting between suspension and body.
4) When no components are deformed, adjust the
wheel arch height by replacing coil spring in the
suspension which wheel arch height is out of stan-
dard. RS-8, Wheel Alignment.>
PM-00057
(A)
(B)
(C) (D)
PM-00058
(A)
(B) (C)(D)
(A) Dust seal
(A) Rear bushing
(B) Transverse link
PM-00059
(A)
PM-00060
(A)
(B)

ME(H4SO)-37
MECHANICAL
Engine Assembly
18) Remove the pitching stopper.
19) Disconnect the fuel delivery hose (A), return
hose (B) and evaporation hose (C).
CAUTION:
 Disconnect the hose with its end wrapped
with cloth to prevent fuel from splashing.
 Catch fuel from the hose into container.
20) Support the engine with a lifting device and
wire ropes.21) Support the transmission with a garage jack.
CAUTION:
Before moving the engine away from transmis-
sion, check to be sure no work has been over-
looked. Doing this is very important in order to
facilitate re-installation and because the trans-
mission lowers under its own weight.
22) Separation of the engine and transmission.
(1) Remove the starter. REMOVAL, Starter.>
(2) Remove the bolts which hold upper side of
transmission to engine.
23) Install the ST to torque converter clutch case.
(AT model)
ST 498277200 STOPPER SET
24) Remove the engine from vehicle.
(1) Slightly raise the engine.
(2) Raise the transmission with garage jack.
ME-00213
FU-00149
(A)
(B)
(C)
ME-00214
(A) Transmission
(B) Garage jack
ME-00215
(B)(A)
ME-00216
ST
ME-00217