2004 SUBARU FORESTER transmission

ME(H4DOTC)-45
MECHANICAL
Engine Assembly
26) Support the transmission with a garage jack.
NOTE:
Before moving the engine away from transmission,
check to be sure no work has been overlooked. Do-
ing this is very important in order to facilitate re-in-
stallation and because transmission lowers under
its own weight.
27) Separation of the engine and transmission.
(1) Remove the starter. REMOVAL, Starter.>
(2) Install the ST to torque converter clutch
case. (AT model)
ST 498277200 STOPPER SET
(3) Remove the bolts which hold the right upper
side of transmission to engine.
28) Remove the engine from vehicle.
(1) Slightly raise the engine.
(2) Raise the transmission with garage jack.
(3) Move the engine horizontally until the main-
shaft is withdrawn from clutch cover.
(4) Slowly move the engine away from engine
compartment.NOTE:
Be careful not to damage adjacent parts or body
panels with crank pulley, oil pressure gauge, etc.
29) Remove the front cushion rubbers.
B: INSTALLATION
1) Install the clutch release fork and bearing onto
transmission. (MT model)
(1) Remove the release bearing from clutch
cover with flat type screw driver.
(2) Install the release bearing on transmission.
(3) Install the release fork into release bearing
tab.
ME-00048
ST
ME-00049
ME-00050
(A) Release fork
(B) Release bearing
ME-00051
ME-00052
(A)
(B)

ME(H4DOTC)-46
MECHANICAL
Engine Assembly
(4) Apply grease to the specified points.
 Spline FX2200
 Shaft SUNLIGHT 2
(5) Insert the release fork shaft into release fork.
CAUTION:
Make sure the cutout portion of release fork
shaft contacts spring pin.(6) Tighten the plug.
Tightening torque:
44 N
⋅m (4.5 kgf-m, 32.5 ft-lb)
2) Install the front cushion rubbers to engine.
Tightening torque:
35 N
⋅m (3.6 kgf-m, 25.8 ft-lb)
3) Install the engine onto transmission.
(1) Position the engine in engine compartment,
and then align it with the transmission.
NOTE:
Be careful not to damage the adjacent parts or
body panels with crank pulley, oil pressure gauge,
etc.
(2) Apply a small amount of grease to the
splines of mainshaft. (MT model)
4) Tighten the bolts which hold the right upper side
of transmission to engine.
Tightening torque:
50 N
⋅m (5.1 kgf-m, 36.9 ft-lb)
5) Remove the lifting device and wire ropes.
(A) Spline (FX2200)
(B) Shaft (SUNLIGHT 2)
(A) Release fork
(B) Release shaft
(C) Spring pin
ME-00053 (A)
(B)
ME-00054
(A)(B)
(C)ME-00055
ME-00050

ME(H4DOTC)-48
MECHANICAL
Engine Assembly
(3) Install the power steering pipe bracket on in-
take manifold RH.
(4) Connect the power steering switch connec-
tor.
(5) Install the front side V-belt, and adjust it.
INSTALLATION, V-belt.>
13) Lift-up the vehicle.
14) Tighten the nuts which hold the lower side of
transmission to engine.
Tightening torque:
50 N
⋅m (5.1 kgf-m, 36.9 ft-lb)
15) Tighten the nuts which install the front cushion
rubber onto crossmember.
Tightening torque:
85 N
⋅m (8.7 kgf-m, 62.7 ft-lb)NOTE:
Make sure the front cushion rubber mounting bolts
(A) and locator (B) are securely installed.
16) Install the ATF cooler pipe to frame. (AT model)
17) Install the center exhaust pipe.
Exhaust Pipe.>
18) Lower the vehicle.
19) Connect the following hoses:
(1) Fuel delivery hose, return hose and evapo-
ration hose
(2) Heater inlet and outlet hoses
(3) Brake booster vacuum hose
20) Connect the following connectors and termi-
nals:
(1) Engine ground terminal
(2) Engine harness connectors
(3) Generator connector and terminal
(4) A/C compressor connectors
21) Connect the following cables:
(1) Accelerator cable
(2) Clutch release spring
22) After connecting each cable, adjust them.
23) Install the air intake system.
(1) Install the intercooler. 11, INSTALLATION, Intercooler.>
(2) Install the air cleaner element and air clean-
er upper cover.
(3) Install the engine harness connector brack-
et.
(4) Install the filler hose to air cleaner case.
ME-00036
ME-00035
ME-00040
ME-00056
(A)
(A)(B)
(B)

EX(H4DOTC)-10
EXHAUST
Center Exhaust Pipe
15) Remove the clip by pulling out from the upper
side of crossmember.
 AT model
 MT model
16) Separate the center exhaust pipe from rear ex-
haust pipe.
17) Remove the bolt which holds center exhaust
pipe bracket to transmission.
18) Remove the intercooler bracket.19) Remove the bolt which holds center exhaust
pipe to hanger bracket.
CAUTION:
Be careful not to pull down the center exhaust
pipe.
20) Remove the center exhaust pipe.
B: INSTALLATION
NOTE:
Replace the gaskets with new ones.
1) Install the center exhaust pipe and temporarily
tighten the bolt which holds center exhaust pipe to
hanger bracket.
2) Temporarily tighten the bolt which holds center
pipe to transmission.
3) Connect the center exhaust pipe to turbocharg-
er.
Tightening torque:
35 N·m (3.6 kgf-m, 26.0 ft-lb)
FU-01311
FU-01312
EX-00042
EX-00014
EX-00043
EX-00016
EX-00012

EX(H4DOTC)-11
EXHAUST
Center Exhaust Pipe
4) Install the center exhaust pipe to rear exhaust
pipe.
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
5) Connect the connector to rear oxygen sensor.
6) Secure the clip on crossmember.
 AT model
 MT model7) Tighten the bolt which holds center exhaust pipe
bracket to transmission.
Tightening torque:
30 N·m (3.1 kgf-m, 22.4 ft-lb)
8) Tighten the bolt which holds center exhaust pipe
to hanger bracket.
Tightening torque:
35 N·m (3.6 kgf-m, 26.0 ft-lb)
9) Tighten the bolts which hold intercooler bracket.
Tightening torque:
35 N·m (3.6 kgf-m, 26.0 ft-lb)
10) Lower the vehicle.
11) Place the turbocharger lower cover, and tighten
the bolts which install upper side of lower cover.
Tightening torque:
7.4 N·m (0.75 kgf-m, 5.4 ft-lb)
EX-00042
FU-00081
FU-01311
FU-01312
EX-00014
EX-00043
EX-00011

ENGINE (DIAGNOSTIC)
EN(H4DOTC)
Page
1. Basic Diagnostics Procedure ......................................................................2
2. Check List for Interview ...............................................................................4
3. General Description ....................................................................................6
4. Electrical Component Location ...................................................................9
5. Engine Control Module (ECM) I/O Signal .................................................23
6. Engine Condition Data ..............................................................................27
7. Transmission Control Module (TCM) I/O Signal .......................................28
8. Data Link Connector .................................................................................29
9. OBD-II General Scan Tool ........................................................................30
10. Subaru Select Monitor...............................................................................33
11. Read Diagnostic Trouble Code (DTC) ......................................................39
12. Inspection Mode ........................................................................................40
13. Drive Cycle ................................................................................................45
14. Clear Memory Mode..................................................................................47
15. Compulsory Valve Operation Check Mode ...............................................48
16. Malfunction Indicator Light ........................................................................50
17. Diagnostics for Engine Starting Failure .....................................................59
18. List of Diagnostic Trouble Code (DTC) .....................................................74
19. Diagnostic Procedure with Diagnostic Trouble Code (DTC) .....................80
20. General Diagnostic Table........................................................................295

EN(H4DOTC)-3
ENGINE (DIAGNOSTIC)
Basic Diagnostics Procedure
2. AUTOMATIC TRANSMISSION
When the DTC about automatic transmission is
shown on display, carry out the following basic
check.After that, carry out the replacement or re-
pair work.
1) ATF level check Transmission Fluid.>
2) Differential gear oil level check Differential Gear Oil.>
3) ATF leak check Transmission Fluid.>
4) Differential gear oil leak check Differential Gear Oil.>
5) Stall Test
6) Line Pressure Test sure Test.>
7) Transfer Clutch Pressure Test Transfer Clutch Pressure Test.>
8) Time Lag Test
9) Road Test
10) Shift characteristics Clutch Pressure Test.>

EN(H4DOTC)-7
ENGINE (DIAGNOSTIC)
General Description
12) Observe the following cautions when installing
a radio in MFI equipped models.
CAUTION:
 The antenna must be kept as far apart as pos-
sible from the control unit. (The ECM is located
under the steering column, inside of the instru-
ment panel lower trim panel.)
 The antenna feeder must be placed as far
apart as possible from the ECM and MFI har-
ness.
 Carefully adjust the antenna for correct
matching.
 When mounting a large power type radio, pay
special attention to the three items above men-
tioned.
 Incorrect installation of the radio may affect
the operation of the ECM.
13) Before disconnecting the fuel hose, disconnect
the fuel pump connector and crank the engine for
more than five seconds to release pressure in the
fuel system.If engine starts during this operation,
run it until it stops.
14) Problems in the electronic-controlled automatic
transmission may be caused by failure of the en-
gine, the electronic control system, the transmis-
sion proper, or by a combination of these.These
three causes (engine, electronic control system,
transmission) must be distinguished clearly when
performing diagnostics.
15) Diagnostics should be conducted by rotating
with simple, easy operations and proceeding to
complicated, difficult operations.The most impor-
tant thing in diagnostics is to understand the cus-
tomer’s complaint, and distinguish between the
three causes.
16) On the model with ABS, when performing driv-
ing test in jacked-up or lifted-up position, some-
times the warning light may be lit, but this is not a
malfunction of the system.The reason for this is the
speed difference between the front and rear
wheels.After diagnosis of engine control system,
perform the ABS memory clearance procedure of
self-diagnosis function.
B: INSPECTION
Before performing diagnostics, check the following
items which might affect engine problems:
1. BATTERY
1) Measure battery voltage and specific gravity of
electrolyte.
Standard voltage: 12 V
Specific gravity: Above 1.2602) Check the condition of the main and other fuses,
and harnesses and connectors.Also check for
proper grounding.
2. ENGINE GROUND
Make sure the engine ground terminal is properly
connected to the engine.
C: NOTE
1. GENERAL DESCRIPTION
 On-board diagnosis (OBD) system detects and
indicates a fault in various inputs and outputs of the
complex electronic control.Malfunction indicator
light in the combination meter indicates occurrence
of a fault or trouble.
 Further, against such a failure or sensors as may
disable the drive, the fail-safe function is provided
to ensure the minimal driveability.
 The OBD system incorporated with the vehicles
within this engine family complies with Section
1968.1, California Code of Regulations (OBD-II
regulation).The OBD system monitors the compo-
nents and the system malfunction listed in Engine
Section which affects on emissions.
 When the system decides that a malfunction oc-
curs, malfunction indicator light illuminates.At the
same time of the malfunction indicator light illumi-
nation or blinking, the DTC and a freeze frame en-
gine conditions are stored into on-board computer.
 The OBD system stores freeze frame engine
condition data (engine load, engine coolant tem-
perature, fuel trim, engine speed and vehicle
speed, etc.) into on-board computer when it detects
a malfunction first.
 If the OBD system detects the various malfunc-
tions including the fault of fuel trim or misfire, the
OBD system first stores freeze frame engine condi-
tions about the fuel trim or misfire.
 When the malfunction does not occur again for
three consecutive driving cycles, malfunction indi-
cator light is turned off, but DTC remains at on-
board computer.
 The OBD-II system is capable of communication
with a general scan tool (OBD-II general scan tool)
formed by ISO 9141 CARB.
EN-00070