2004 SUBARU FORESTER gas type

EN(H4DOTC 2.5)-28
ENGINE (DIAGNOSTIC)
Subaru Select Monitor
4. READ CURRENT DATA FOR ENGINE. (NORMAL MODE)
1) On the «Main Menu» display screen, select the {Each System Check} and press the [YES] key.
2) On the «System Selection Menu» display screen, select the {Engine} and press the [YES] key.
3) Press the [YES] key after the information of engine type was displayed.
4) On the «Engine Diagnosis» screen, select the {Current Data Display/Save}, and then press the [YES] key.
5) On the «Data Display Menu» screen, select the {Data Display} and press the [YES] key.
6) Using the scroll key, move the display screen up or down until the desired data is shown.
 A list of the support data is shown in the following table.
Remarks Display Unit of measure
Battery voltage Battery Voltage V
Vehicle speed signal Vehicle Speed km/h or MPH
Engine speed signal Engine Speed rpm
Engine coolant temperature signal Coolant Temp.°C or °F
Ignition timing signal Ignition Timing deg
Throttle position signal Throttle Opening Angle %
Injection pulse width Fuel Injection #1 Pulse ms
Fuel pump duty control signal Fuel Pump Duty %
A/F sensor current A/F Sensor #1 Current mA
A/F sensor resistance A/F Sensor #1 ResistanceΩ
Front oxygen (A/F) sensor lambda value A/F Sensor #1 —
Rear oxygen sensor output signalRear O
2 Sensor
V
Short term fuel trim A/F Correction #1 %
Knock sensor compensation Knocking Correction deg
Atmospheric pressure signal Atmosphere Pressure mmHg, kPa, inHg or psi
Intake manifold relative pressure signal Mani. Relative Pressure mmHg, kPa, inHg or psi
Intake manifold absolute pressure signal Mani. Absolute Pressure mmHg, kPa, inHg or psi
A/F correction (short term fuel trim) by rear oxygen sensor A/F Correction #3 %
Long term whole fuel trim A/F Learning #1 %
Canister purge control solenoid valve duty ratio CPC Valve Duty Ratio %
Primary supercharged pressure control signal Primary Control %
Tumble generated valve position sensor signal (RH side) TGV Position Sensor R V
Tumble generated valve position sensor signal (LH side) TGV Position Sensor L V
Acceleration opening angle Accel Opening Angle %
VVT advance angle amount (R) VVT Adv. Amount R deg
VVT advance angle amount (L) VVT Adv. amount L deg
OCV duty R OCV Duty R %
OCV duty L OCV Duty L %
OCV current R OCV current R mA
OCV current L OCV Current L mA
Throttle motor duty Throttle Motor Duty %
Throttle power supply voltage Throttle Motor Voltage V
Sub throttle sensor voltage Sub-Throttle Sensor V
Main throttle sensor voltage Main-Throttle Sensor V
Sub acceleration sensor voltage Sub-Accelerator Sensor V
Main acceleration sensor voltage Main-Accelerator Sensor V
Memory vehicle speed Memorized Cruise Speed km/h
Alternate duty ratio ALT Duty %
Exhaust gas temperature signal Exhaust gas temperature°C
Estimated cumulative driving distance Odd Meter Km
Fuel level signal Fuel Level Voltage V
Intake air temperature signal Intake Air Temp.°C or °F
Mass air flow sensor signal Mass Air Flow g/s

4AT-30
AUTOMATIC TRANSMISSION
Automatic Transmission Fluid
2. Automatic Transmission Flu-
id
A: INSPECTION
NOTE:
The level of ATF varies with fluid temperature. Pay
attention to the ATF temperature when checking
ATF level.
1) Raise the ATF temperature by driving a distance
of 5 to 10 km (3 to 6 miles). Otherwise, idle the en-
gine to raise ATF temperature to 70 — 80°C (158
— 176°F) on Subaru Select Monitor. 4AT(H4SO)-18, READ CURRENT DATA, OPERA-
TION, Subaru Select Monitor.>
2) Make sure the vehicle is level.
3) After selecting all positions (P, R, N, D, 3, 2, 1),
set the select lever in “P” range. Measure the ATF
level with engine idling for one or two minutes.
4) Make sure that ATF level is above the center of
upper level and lower level at HOT side.
If the ATF level is below the lower level, check for
leaks in the transmission. If there are leaks, it is
necessary to repair or replace gasket, oil seals,
plugs or other parts.
5) If the ATF level is below the center between up-
per level and lower level, add the recommended
ATF until the fluid level is found above the center
between upper level and lower level marks.
CAUTION:
 Use care not to exceed the upper level.
 Remember that the addition of ATF to the up-
per limit mark when the transmission is cold
will overfilling of ATF, causing a transmission
failure.
6) Check ATF level after raising ATF temperature
to 70 — 80°C (158 — 176°F) by running the vehicle
or by idling the engine again.
B: REPLACEMENT
1) Lift-up the vehicle.2) Drain the ATF completely.
CAUTION:
Directly after the engine has been running, the
ATF is hot. Be careful not to burn yourself.
3) Replace the gasket with new one, and then tight-
en the drain plug (ATF).
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
4) Lower the vehicle.
5) Pour ATF from the ATF charge pipe.
Recommended fluid:
DEXRON III type automatic transmission flu-
id
Capacity:
Fill the same amount of ATF drained from
drain plug hole.
CAPACITY WHEN TRANSMISSION IS OVER-
HAULED:
2.0 L NON-TURBO MODEL
8.4 — 8.72 (8.9 — 9.2 US qt, 7.4 — 7.7 Imp
qt)
EXCEPT 2.0 L NON-TURBO MODEL
9.3 — 9.62 (9.8 — 10.1 US qt, 8.2 — 8.4 Imp
qt)
6) Check the level and leaks of ATF.
mission Fluid.>
(A) ATF level gauge
(B) Upper level
(C) Lower level
AT-00674
COLD
LFHOT LF
(C)
(C)
(B)
(B)
(A)(A) Oil pan
(B) Drain plug (ATF)
(C) Differential gear oil drain plug
AT-00016
(A) (B)
(C)

4AT-64
AUTOMATIC TRANSMISSION
Control Valve Body
7) Fill liquid gasket to holes except for bolt holes
(three) of transmission case.
Liquid gasket:
THREE BOND 1217B (Part No. K0877YA020)
8) Install the oil pan with equally tighten the bolts.
Tightening torque:
5 N
⋅m (0.5 kgf-m, 3.6 ft-lb)
9) Pour ATF from the ATF charge pipe.
Recommended fluid:
DEXRON III type automatic transmission flu-
id
Capacity:
Pour fluid as same amount as drained fluid
from drain plug hole.
10) Inspect the level of ATF.

2. TURBO MODEL
1) Check that the dust and other foreign matters
are not on control valve body.
2) Temporarily assemble the control valve body
and the ground cable to transmission, and install oil
cooler pipe.3) Equally tighten the bolts.
Tightening torque:
8 N
⋅m (0.8 kgf-m, 5.8 ft-lb)
4) Attach the magnet at the specified position of oil
pan.
5) Apply proper amount of liquid gasket to the en-
tire oil pan mating surface.
Liquid gasket:
THREE BOND 1217B (Part No. K0877YA020)
AT-02123
AT-00059
(A) Transmission ground
Bolt length mm (in)
(1) 35 (1.38)
(2) 30 (1.18)
AT-01718
(1)
(1)
(2)
(2)
(2)(2)
(2)
(2)(2)(2)(2)
(2)
(2)
(A)
AT-00057
AT-00051

4AT-65
AUTOMATIC TRANSMISSION
Control Valve Body
6) Fill liquid gasket to holes except for bolt holes
(three) of transmission case.
Liquid gasket:
THREE BOND 1217B (Part No. K0877YA020)
7) Install the oil pan with equally tighten the bolts.
Tightening torque:
5 N
⋅m (0.5 kgf-m, 3.6 ft-lb)
8) Pour ATF from the ATF charge pipe.
Recommended fluid:
DEXRON III type automatic transmission flu-
id
Capacity:
Pour fluid as same amount as drained fluid
from drain plug hole.
9) Bleed the air of control valve. Air Bleeding of Control Valve.>
10) Check the ATF level. matic Transmission Fluid.>
11) Execute the learning control promotion. to 4AT(H4DOTC)-17, FACILITATION OF LEARN-
ING CONTROL, OPERATION, Subaru Select
Monitor.>
C: DISASSEMBLY
Non-turbo model only
1) Remove the oil strainer from lower control valve
body.
NOTE:
While assembling, safekeeping the bolt to identify
bolt position, because the bolt length is different.
2) Remove the duty solenoids, solenoids and sen-
sor from lower control valve body.
NOTE:
While assembling, safekeeping the bolt to identify
bolt position, because the bolt length is different.
AT-01339
(A) Short bolts
(B) Middle bolt
(C) Long bolts
(A) Lock-up duty solenoid (Blue)
(B) Low clutch timing solenoid (Gray)
(C) Line pressure duty solenoid (Red)
(D) Shift solenoid 2 (Yellow)
(E) Shift solenoid 1 (Green)
(F) 2-4 brake timing solenoid (Black)
(G) 2-4 brake duty solenoid (Red)
AT-00065
A
ABAA
AC
ACC
AB
AC
CC
AT-02124
(E)
(F)(G)
(D)(C)
(B)(A)

CL-19
CLUTCH SYSTEM
Flywheel
3. Flywheel
A: REMOVAL
1) Remove the transmission assembly. 5MT-32, REMOVAL, Manual Transmission As-
sembly.>
2) Remove the clutch cover and clutch disc. to CL-16, REMOVAL, Clutch Disc and Cover.>
3) Using the ST, remove the flywheel.
ST 498497100 CRANKSHAFT STOPPER
B: INSTALLATION
1) Install the flywheel and ST.
ST 498497100 CRANKSHAFT STOPPER2) Tighten the flywheel attaching bolts to the spec-
ified torque.
NOTE:
Tighten the flywheel installing bolts gradually. Each
bolt should be tightened to the specified torque in a
crisscross fashion.
Tightening torque:
72 N
⋅m (7.3 kgf-m, 52.8 ft-lb)
3) Install the clutch disc and cover. INSTALLATION, Clutch Disc and Cover.>
4) Install the transmission assembly. 36, INSTALLATION, Manual Transmission Assem-
bly.>
C: INSPECTION
CAUTION:
Since this bearing is grease sealed and is of a
non-lubrication type, do not wash with gasoline
or any solvent.
1) Damage of facing and ring gear
If defective, replace the flywheel.
2) Smoothness of rotation
Rotate the ball bearing applying pressure in thrust
direction.
3) If noise or excessive play is noted, replace the
flywheel.
(A) Flywheel
CL-00019ST (A)
CL-00020ST
(A) Flywheel
(B) Ring gear
CL-00021
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
CL-00022
(B)
(A)

CL-22
CLUTCH SYSTEM
Release Bearing and Lever
4) Insert the release fork shaft into release fork.
NOTE:
Make sure the cutout portion of release fork shaft
contacts spring pin.
5) Tighten the plug.
Tightening torque:
44 N
⋅m (4.5 kgf-m, 32.5 ft-lb)
6) Move the release fork to ensure that release
bearing and release fork move smoothly.
7) Install the transmission assembly. 36, INSTALLATION, Manual Transmission Assem-
bly.>
C: INSPECTION
1. RELEASE BEARING
CAUTION:
Since this bearing is grease sealed and is of a
non-lubrication type, do not wash with gasoline
or any solvent when servicing the clutch.
1) Check the bearing for smooth movement by ap-
plying force in the radial direction.
Radial direction stroke:
1.6 mm (0.063 in)
2) Check the bearing for smooth rotation by apply-
ing pressure in the thrust direction.
3) Check wear and damage of the bearing case
surface contacting with lever.
(A) Release fork
(B) Release shaft
(C) Spring pin
CL-00030
(A) (B)
(C)
CL-00031
(A) Bearing case
(A) Bearing case
CL-00032
(A)
CL-00160
(A)