2004 SUBARU FORESTER check oil

PM-11
PERIODIC MAINTENANCE SERVICE
V-belt
6. V-belt
A: INSPECTION
1) Replace the belts, if cracks, fraying or wear is
found.
2) Check the V-belt tension and adjust it if neces-
sary by changing the generator installing position
or idler pulley installing position. REPLACEMENT, V-belt.>
Belt tension
(A)
replaced: 7.0 — 9.0 mm (0.276 — 0.354 in)
reused: 9.0 — 10.0 mm (0.354 — 0.394 in)
(B)
replaced: 7.5 — 8.5 mm (0.295 — 0.335 in)
reused: 9.0 — 10.0 mm (0.354 — 0.394 in)
B: REPLACEMENT
1. V-BELT COVER
1) Remove the V-belt cover.
 Non-turbo model Turbo model
2. FRONT SIDE BELT (DRIVING POWER
STEERING OIL PUMP AND GENERATOR)
NOTE:
Wipe off any oil or water on the belt and pulley.
1) Loosen the lock bolt (A).
2) Loosen the slider bolt (B).
3) Remove the front side belt (C).
4) Install a new belt, and tighten the slider bolt (B)
so as to obtain the specified belt tension.
5) Tighten the lock bolt (A).
6) Tighten the slider bolt (B).
Tightening torque:
Lock bolt
25 N·m (2.5 kgf-m, 18 ft-lb)
Slider bolt:
8 N·m (0.8 kgf-m, 5.8 ft-lb)
(A) Front side belt
(B) Rear side belt
C/P Crank pulley
GEN Generator
P/S Power steering oil pump pulley
A/C Air conditioning compressor pulley
I/P Idler pulley
C/P P/SA/C
GEN
(A)(B) 98 N (10 kg, 22 lb)
I/P
PM-00002
PM-00003
SC-00096
PM-00004
(B)
(C)
(A)

PM-21
PERIODIC MAINTENANCE SERVICE
Engine Coolant
12.Engine Coolant
A: REPLACEMENT
1. REPLACEMENT OF ENGINE COOLANT
WARNING:
The radiator is of the pressurized type. Do not
attempt to open the radiator cap immediately
after the engine has been stopped.
1) Lift-up the vehicle.
2) Remove the under cover.
3) Place a container under drain pipe.
4) Loosen and remove the drain cock to drain en-
gine coolant into container.
5) For quick draining, open the radiator cap.
CAUTION:
Be careful not to spill coolant on the floor.
6) Drain the coolant from reservoir tank.
7) Tighten the radiator drain cock securely after
draining coolant.
8) Slowly pour the engine coolant from radiator fill-
er port to neck of filler, then pour into reservoir tank
up to “FULL” level.
Coolant capacity (fill up to “FULL” level)
2.0 L Non-turbo AT model:
Approx. 6.52 (6.9 US qt, 5.7 Imp qt)
2.0 L Non-turbo MT model:
Approx. 6.62 (7.0 US qt, 5.8 Imp qt)
2.0 L Non-turbo model with ATF warmer:
Approx. 6.92 (7.3 US qt, 6.1 Imp qt)
2.0 L 2.5 L Turbo AT and MT with oil cooler
model:
Approx. 7.32 (7.7 US qt, 6.4 Imp qt)
2.0 L 2.5 L Turbo MT without oil cooler model:
Approx. 7.42 (7.8 US qt, 6.5 Imp qt)
2.5 L AT model:
Approx. 6.82 (7.2 US qt, 6.0 Imp qt)
2.5 L MT model:
Approx. 6.92 (7.3 US qt, 6.1 Imp qt)NOTE:
The SUBARU Genuine Coolant containing anti-
freeze and anti-rust agents is especially made for
SUBARU engine, which has an aluminum crank-
case. Always use SUBARU Genuine Coolant,
since other coolant may cause corrosion.
9) Securely install the radiator cap.
10) Run the engine for more than 5 minutes at
2,000 to 3,000 rpm. (Run the engine until radiator
becomes hot in order to purge the air trapped in
cooling system.)
11) Stop the engine and wait until coolant temper-
ature lowers. Then open the radiator cap to check
coolant level and add coolant up to radiator filler
neck. Next, add coolant into reservoir tank up to
“FULL” level.
12) After adding coolant, securely install the radia-
tor and reservoir tank caps.
CO-00009

PM-26
PERIODIC MAINTENANCE SERVICE
ATF
16.ATF
A: INSPECTION
CAUTION:
The level of ATF varies with fluid temperature.
Pay attention to the fluid 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 the engine idling for one or two minutes.
4) Make sure that ATF level is above the center of
upper and lower level.
NOTE:
When the transmission is hot, the level should be
above the center of upper and lower marks, and
when it is cold, the level should be found below the
center of these two marks.
5) If the ATF level is below the center between up-
per and lower marks, add the recommended ATF
until the ATF level is found above the center be-
tween upper and lower marks.
CAUTION:
 Use care not to exceed the upper limit level.
 Remember that the addition of ATF to the up-
per limit mark when the transmission is cold
will result in overfilling of ATF, causing a trans-
mission 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.7) Check the ATF for leaks.
Check for leaks in the transmission. If there are
leaks, it is necessary to repair or replace gasket, oil
seals, plugs or other parts.
B: REPLACEMENT
1. AUTOMATIC TRANSMISSION FLUID
1) Drain the ATF by removing drain plug.
NOTE:
Before starting work, cool off ATF well.
2) Replace the gasket with a new one, and then
tighten the specified torque.
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
3) Fill ATF up to the middle of the “COLD” side on
level gauge by using the gauge hole.
Recommended fluid:
Dexron III type automatic transmission fluid
Fluid capacity:
Fill the same amount drained from ATF drain
plug hole.
(A) Level gauge
(B) Check position when “HOT”
(C) Upper level
(D) Lower level
(E) Check position when “COLD”
PI-00105
COLD
LFHOT LF
(A)
(C)
(D)
(C)
(D)
(E)
(B)(A) Front differential drain plug
(B) ATF drain plug
PM-00032
(B)
(A)

PM-31
PERIODIC MAINTENANCE SERVICE
Brake Line
(4) If there is no free play between clevis pin
and clevis, turn the brake switch adjusting nut
until the clearance between stopper and screw
of brake switch becomes 0.3 mm (0.012 in).
3) Check the pedal stroke.
While the engine is idling, depress the brake pedal
with a 490 N (50 kgf, 110 lb) load and measure the
distance between brake pedal and steering wheel.
With the brake pedal released, measure the dis-
tance between pedal and steering wheel again.
The difference between the two measurements
must be less than specified value. If the distance is
more than specified value, there is possibility of air
inside the hydraulic unit.
Brake pedal reserve distance: A
For Australia model
105 mm (4.13 in)/ 490 N (50 kgf , 110 lb) or less
Except for Australia model
90 mm (3.54 in)/ 490 N (50 kgf , 110 lb) or less4) Check to see if air is in the hydraulic brake line
by the feel of pedal operation. If air appears to exist
in the line, bleed it from the system.
5) Check for even operation of all brakes, using a
brake tester or by driving the vehicle for a short dis-
tance on a straight road.
2. BRAKE SERVO SYSTEM
1) With the engine off, depress the brake pedal
several times applying the same pedal force: Make
sure the travel distance should not change.
2) With the brake pedal depressed, start the en-
gine: Make sure the pedal should move slightly to-
ward the floor.
3) With the brake pedal depressed, stop the engine
and keep the pedal depressed for 30 seconds:
Make sure the pedal height should not change.
4) Check valve is built into the vacuum hose. Dis-
connect the vacuum hose to inspect function of
check valve.
Blow air into the vacuum hose from its brake boost-
er side end: Air must flow out of engine side end of
hose. Next blow air into the hose from engine side:
Air should not to brake booster side.
Replace both check valve and vacuum hose if the
check valve is faulty. Engine side of vacuum hose
is indicated by marking “ENG” as shown in illustra-
tion.
5) Check the vacuum hose for cracks or other dam-
age.
CAUTION:
When installing the vacuum hose on the engine
and brake booster, do not use soapy water or
lubricating oil on their connections.
6) Check vacuum hose to make sure it is tight and
secure.
(A) Brake switch
(B) Adjusting nut
(C) 0.3 mm (0.012 in)
(D) Stopper
(E) Clevis pin
(F) Clevis
(G) Brake pedal free play
(H) Lock nut
(I) Brake booster operating rod
(J) Play at pin
(A) Steering wheel
(B) Toe board
PM-00041
(B)
(G) (H)
(I)
(J)(C)
(D)
(E)
(F)(A)
PM-00045(B)(A) = A
1
12
2
(A) Engine side
(B) Brake booster side
(C) ENG
PM-00046
(B)
(C) (A)

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)

PM-37
PERIODIC MAINTENANCE SERVICE
Suspension
4. WHEEL ALIGNMENT OF FRONT SUS-
PENSION
1) Check the alignment of front suspension to en-
sure that following items conform to standard val-
ues.
 Toe-in
 Camber angle
 Caster angle
 Steering angle

2) When the caster angle does not conform to ref-
erence, visually inspect the following components
and replace deformed parts.
 Suspension components [Strut assembly, cross-
member, transverse link, etc.]
 Body parts to which suspensions are installed.
3) When the toe-in and camber are out of standard
value, adjust them so that they conform to respec-
tive service standard. WHEEL TOE-IN, INSPECTION, Wheel Align-
ment.> Wheel Alignment.>
4) When the right-and-left turning angles of tire are
out of standard, adjust to standard value. FS-10, STEERING ANGLE, INSPECTION, Wheel
Alignment.>
5. WHEEL ALIGNMENT OF REAR SUS-
PENSION
1) Check the alignment of rear suspension to en-
sure that following items are within standard val-
ues.
 Toe-in
 Camber angle
 Thrust angle

2) When the camber angle does not conform to ref-
erence, visually inspect parts listed below. If defor-
mation is observed, replace the damaged parts.
 Suspension components [Shock absorber, front
lateral links, rear lateral links, trailing link, etc.]
 Body parts to which suspensions are installed.
3) When the toe-in and thrust angle are out of stan-
dard value, adjust them so that they conform to re-
spective service standard. WHEEL TOE-IN, INSPECTION, Wheel Align-
ment.> SPECTION, Wheel Alignment.>
6. OIL LEAKAGE OF STRUT
Visually inspect the front strut and rear strut for oil
leakage as instructed. If oil leakage reaches under
spring seat lower portion, replace the front strut and
rear strut.
7. TIGHTNESS OF BOLTS AND NUTS
Check the bolts and nuts shown in the figure for
looseness. Retighten the bolts and nuts to speci-
fied torque. If the self-lock nuts and bolts are re-
moved, replace them with new ones.
Front suspension: tion.>
Rear suspension: tion.>
8. DAMAGE TO SUSPENSION PARTS
Check the following parts and the fastening portion
of the vehicle body for deformation or excessive
rusting which impairs the suspension. Remove the
contaminations on spring seat lower portion with
care because dirt, sand, etc. tend to accumulate on
it. If necessary, replace the damaged parts with
new ones. If minor rust formation, pitting, etc. are
noted, remove the rust and apply remedial anti-cor-
rosion measures.
 Front suspension
 Transverse link
 Crossmember
Strut
 Rear suspension
 Crossmember
 Lateral links
 Trailing link
Strut
 In the district where salt is sprayed to melt snow
on a road in winter, check suspension parts for
damage caused by rust every 12 months after
lapse of 60 months. Take rust prevention measure
as required.

PM-38
PERIODIC MAINTENANCE SERVICE
Wheel Bearing
23.Wheel Bearing
A: INSPECTION
1. FRONT WHEEL BEARING
NOTE:
Inspect the condition of front wheel bearing grease.
1) Lift-up the front of vehicle.
2) While holding the front wheel by hand, swing it in
and out to check bearing free play.
3) Loosen the wheel nuts and remove front wheel.
4) If bearing free play exists in step 2) above, at-
tach a dial gauge to the hub and measure axial dis-
placement in axial direction.
Service limit:
Straight-ahead position within 0.05 mm
(0.0020 in)
5) Remove the bolts and self-locking nuts, and ex-
tract transverse link from front crossmember.
6) Remove the AARi of front drive shaft from trans-
mission.
7) While supporting the front drive shaft horizontal-
ly with one hand, turn the hub with the other to
check for noise or binding.
If the hub is noisy or binds, disassemble the front
axle and check condition of oil seals, bearing, etc.
2. REAR WHEEL BEARING
1) Lift-up the rear of vehicle.
2) While holding the rear wheel by hand, swing it in
and out to check bearing free play.
3) Loosen the wheel nuts and remove rear wheel.
4) If the bearing free play exists in step 2) above,
attach a dial gauge to the hub assembly and mea-
sure axial displacement in axial direction.Service limit:
Straight-ahead position within 0.05 mm
(0.0020 in)
5) Remove the DOJ of rear drive shaft from rear dif-
ferential.
6) While supporting the rear drive shaft horizontally
with one hand, turn the hub assembly with the other
to check for noise or binding.
If the hub assembly is noisy or binds, disassemble
the rear axle and check condition of oil seals, bear-
ings, etc.
(A) Inner oil seal
(B) Snap ring
(C) Bearing
(D) Housing
(E) Outer oil seal
(F) Hub bolt
(G) Hub
PM-00061
(A)
(B)
(C)
(D)
(E)(G) (F)
(A) Inner oil seal
(B) Rear housing
(C) Bearing
(D) Snap ring
(E) Outer oil seal
(F) Tone wheel
(G) Hub bolt
(H) Hub
(I) Socket bolt
PM-00062
(A)
(B)
(C)
(D)
(E)(G)
(H)
( I ) (F)

PM-42
PERIODIC MAINTENANCE SERVICE
Steering System (Power Steering)
(2) Retighten the adjusting screw to 7.4 N·m
(0.75 kgf-m, 5.4 ft-lb) and back off 25°.
(3) Apply Liquid gasket to at least 1/3 of entire
perimeter of adjusting screw thread.
(4) Install the lock nut. While holding the adjust-
ing screw with a wrench, tighten the lock nut us-
ing ST.
ST 926230000 SPANNER
Tightening torque (Lock nut):
39 N·m (4.0 kgf-m, 29 ft-lb)
Hold the adjusting screw with a wrench to pre-
vent it from turning it, while tightening the lock
nut.
4. TIE-ROD
1) Check the tie-rod and tie-rod ends for bends,
scratches or other damage.
2) Check the connections of knuckle ball joints for
play, inspect for damage on dust seals, and check
free play of ball studs. If the castle nut is loose, re-
tighten it to the specified torque, then tighten further
up to 60° until the cotter pin hole is aligned.
Tightening torque:
27 N·m (2.75 kgf-m, 19.9 ft-lb)3) Check the lock nut on tie-rod end for tightness. If
it is loose, retighten it to the specified torque.
Tightening torque:
83 N·m (8.5 kgf-m, 61.5 ft-lb)
5. POWER STEERING FLUID LEVEL
NOTE:
 Check at power steering fluid temperature 20°C
(68°F); read the fluid level on the “COLD” side.
 Check at power steering fluid temperature 80°C
(176°F); read the fluid level on the “HOT” side.
1) Place the vehicle with engine stopped on a flat
and level surface.
2) Check the fluid level using the scale on the out-
side of reservoir tank (A). If the level is below “MIN”
(B), add fluid to bring it up to “MAX” (C).
NOTE:
If the fluid level is at “MAX” level or above, drain flu-
id to keep the level in specified range of indicator by
using a syringe or the like.
Recommended fluid:
Dexron III
Fluid capacity:
0.72 (0.7 US qt, 0.6 Imp qt)
6. POWER STEERING FLUID FOR LEAKS
Inspect the underside of oil pump and gearbox for
power steering system, hoses, piping and their
couplings for fluid leaks.
If fluid leaks are found, correct them by retightening
their fitting bolts (or nuts) and/or replacing their
parts.
CAUTION:
 Wipe the leakage fluid off after correcting flu-
id leaks, or a wrong diagnosis is taken later.
 Also pay attention to clearances between
hoses (or pipings) and other parts when in-
specting fluid leaks.
(A) Apply Liquid gasket to at least 1/3 of entire
perimeter
(A) Tie-rod end
(B) Knuckle arm
PM-00068
(A)
PM-00069
(A)
(B)
PM-00070
(A)
(C)
(B)